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SEBM036303

MACHINE MODEL

SERIAL NUMBER

PC130-7

70001 and up

This shop manual may contain attachiments and optional equipment that are not available in your
area. Please consult your local Komatsu distributor for those items you may require.
Materials and specifications are subject to change without notice.
PC130-7 mounts the SAA4D95LE-3 engine.
For details of the engine, see the 95-3 Series Engine Shop Manual.

2004
All Rights Reserved
Printed in Japan 10-04(02)

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CONTENTS
No. of page

01

GENERAL ................................................................................................................01-1

10

STRUCTURE AND FUNCTION .................................................................10-1

20

TESTING AND ADJUSTING .......................................................................20-1

30

DISASSEMBLY AND ASSEMBLY ..........................................................30-1

40

MAINTENANCE STANDARD......................................................................40-1

90

OTHERS ....................................................................................................................90-1

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00-2-3
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SAFETY

SAFETY NOTICE

SAFETY
SAFETY NOTICE
IMPORTANT SAFETY NOTICE
Proper service and repair is extremely important for safe machine operation. The service and
repair techniques recommended by Komatsu and described in this manual are both effective
and safe. Some of these techniques require the use of tools specially designed by Komatsu for
the specific purpose.
To prevent injury to workers, the symbol k is used to mark safety precautions in this manual.
The cautions accompanying these symbols should always be followed carefully. If any dangerous situation arises or may possibly arise, first consider safety, and take the necessary actions
to deal with the situation.

GENERAL PRECAUTIONS
Mistakes in operation are extremely dangerous.
Read the Operation and Maintenance Manual carefully BEFORE operating the machine.
1. Before carrying out any greasing or repairs, read
all the precautions given on the decals which are
fixed to the machine.
2. When carrying out any operation, always
wear safety shoes and helmet. Do not wear
loose work clothes, or clothes with buttons
missing.

Always wear safety glasses when hitting


parts with a hammer.
Always wear safety glasses when grinding
parts with a grinder, etc.

3. If welding repairs are needed, always have a


trained, experienced welder carry out the work.
When carrying out welding work, always wear
welding gloves, apron, hand shield, cap and
other clothes suited for welding work.
4. When carrying out any operation with two or
more workers, always agree on the operating
procedure before starting. Always inform your
fellow workers before starting any step of the
operation. Before starting work, hang UNDER
REPAIR signs on the controls in the operator's
compartment.
5. Keep all tools in good condition and learn the
correct way to use them.

6. Decide a place in the repair workshop to keep


tools and removed parts. Always keep the tools
and parts in their correct places. Always keep
the work area clean and make sure that there is
no dirt or oil on the floor. Smoke only in the areas
provided for smoking. Never smoke while working.
PREPARATIONS FOR WORK
7. Before adding oil or making any repairs, park the
machine on hard, level ground, and block the
wheels or tracks to prevent the machine from
moving.
8. Before starting work, lower blade, ripper, bucket
or any other work equipment to the ground. If
this is not possible, insert the safety pin or use
blocks to prevent the work equipment from falling. In addition, be sure to lock all the control
levers and hang warning signs on them.
9. When disassembling or assembling, support the
machine with blocks, jacks or stands before
starting work.
10.Remove all mud and oil from the steps or other
places used to get on and off the machine.
Always use the handrails, ladders or steps when
getting on or off the machine. Never jump on or
off the machine. If it is impossible to use the
handrails, ladders or steps, use a stand to provide safe footing.

00-3

SAFETY

PRECAUTIONS DURING WORK


11.When removing the oil filler cap, drain plug or
hydraulic pressure measuring plugs, loosen
them slowly to prevent the oil from spurting out.
Before disconnecting or removing components
of the oil, water or air circuits, first remove the
pressure completely from the circuit.
12.The water and oil in the circuits are hot when the
engine is stopped, so be careful not to get
burned.
Wait for the oil and water to cool before carrying out any work on the oil or water circuits.
13.Before starting work, remove the leads from the
battery. Always remove the lead from the negative () terminal first.
14.When raising heavy components, use a hoist or
crane.
Check that the wire rope, chains and hooks are
free from damage.
Always use lifting equipment which has ample
capacity.
Install the lifting equipment at the correct places.
Use a hoist or crane and operate slowly to prevent the component from hitting any other part.
Do not work with any part still raised by the hoist
or crane.
15.When removing covers which are under internal
pressure or under pressure from a spring,
always leave two bolts in position on opposite
sides. Slowly release the pressure, then slowly
loosen the bolts to remove.
16.When removing components, be careful not to
break or damage the wiring. Damaged wiring
may cause electrical fires.
17.When removing piping, stop the fuel or oil from
spilling out. If any fuel or oil drips onto the floor,
wipe it up immediately. Fuel or oil on the floor
can cause you to slip, or can even start fires.
18.As a general rule, do not use gasoline to wash
parts. In particular, use only the minimum of
gasoline when washing electrical parts.

00-4

SAFETY NOTICE

19.Be sure to assemble all parts again in their original places.


Replace any damaged parts with new parts.
When installing hoses and wires, be sure
that they will not be damaged by contact
with other parts when the machine is being
operated.
20.When installing high pressure hoses, make sure
that they are not twisted. Damaged tubes are
dangerous, so be extremely careful when installing tubes for high pressure circuits. Also, check
that connecting parts are correctly installed.
21.When assembling or installing parts, always use
the specified tightening torques. When installing
protective parts such as guards, or parts which
vibrate violently or rotate at high speed, be particularly careful to check that they are installed
correctly.
22.When aligning two holes, never insert your fingers or hand. Be careful not to get your fingers
caught in a hole.
23.When measuring hydraulic pressure, check that
the measuring tool is correctly assembled before
taking any measurements.
24.Take care when removing or installing the tracks
of track-type machines.
When removing the track, the track separates
suddenly, so never let anyone stand at either
end of the track.

FOREWORD

GENERAL

FOREWORD
GENERAL

This shop manual has been prepared as an aid to improve the quality of repairs by giving the serviceman an
accurate understanding of the product and by showing him the correct way to perform repairs and make judgements. Make sure you understand the contents of this manual and use it to full effect at every opportunity.

This shop manual mainly contains the necessary technical information for operations performed in a service
workshop. For ease of understanding, the manual is divided into the following chapters; these chapters are further divided into the each main group of components.

STRUCTURE AND FUNCTION


This section explains the structure and function of each component. It serves not only to give an understanding of the structure, but also serves as reference material for troubleshooting.
In addition, this section may contain hydraulic circuit diagrams, electric circuit diagrams, and maintenance standards.
TESTING AND ADJUSTING
This section explains checks to be made before and after performing repairs, as well as adjustments to
be made at completion of the checks and repairs.
Troubleshooting charts correlating "Problems" with "Causes" are also included in this section.
DISASSEMBLY AND ASSEMBLY
This section explains the procedures for removing, installing, disassembling and assembling each component, as well as precautions for them.
MAINTENANCE STANDARD
This section gives the judgment standards for inspection of disassembled parts.
The contents of this section may be described in STRUCTURE AND FUNCTION.
OTHERS
This section mainly gives hydraulic circuit diagrams and electric circuit diagrams.
In addition, this section may give the specifications of attachments and options together.

NOTICE
The specifications contained in this shop manual are subject to change at any time and without any
advance notice. Use the specifications given in the book with the latest date.

00-5

FOREWORD

HOW TO READ THE SHOP MANUAL

HOW TO READ THE SHOP MANUAL

REVISED EDITION MARK

VOLUMES
Shop manuals are issued as a guide to carrying out
repairs. They are divided as follows:

When a manual is revised, an edition mark


((1)(2)(3)....) is recorded on the bottom of the pages.

Chassis volume: Issued for every machine model


Engine volume: Issued for each engine series
Each issued as one
Electrical volume:
Attachments volume: volume to cover all
models

REVISIONS

These various volumes are designed to avoid duplicating the same information. Therefore, to deal with
all repairs for any model , it is necessary that chassis, engine, electrical and attachment volumes be
available.
DISTRIBUTION AND UPDATING
Any additions, amendments or other changes will be
sent to KOMATSU distributors. Get the most up-todate information before you start any work.

FILING METHOD
1. See the page number on the bottom of the page.
File the pages in correct order.
2. Following examples show how to read the page
number.
Example 1 (Chassis volume):
10 - 3
Item number (10. Structure and
Function)
Consecutive page number for each
item.
Example 2 (Engine volume):
12 - 5
Unit number (1. Engine)
Item number (2. Testing and Adjusting)
Consecutive page number for each
item.
3. Additional pages: Additional pages are indicated
by a hyphen (-) and number after the page
number. File as in the example.
Example:
12-203
10-4
12-203-1
10-4-1
Added pages
12-203-2
10-4-2
12-204
10-5

00-6

Revised pages are shown in the LIST OF REVISED


PAGES next to the CONTENTS page.

SYMBOLS
So that the shop manual can be of ample practical
use, important safety and quality portions are
marked with the following symbols.

Symbol

Item

Remarks

Safety

Special safety precautions


are necessary when performing the work.

Caution

Special technical precautions or other precautions


for preserving standards
are necessary when performing the work.

Weight

Weight of parts of systems. Caution necessary


when selecting hoisting
wire, or when working posture is important, etc.

Tightening
torque

Places that require special


attention for the tightening
torque during assembly.

Coat

Places to be coated with


adhesives and lubricants,
etc.

Oil, water

Places where oil, water or


fuel must be added, and
the capacity.

Drain

Places where oil or water


must be drained, and
quantity to be drained.

3
2

FOREWORD

HOISTING INSTRUCTIONS

HOISTING INSTRUCTIONS
HOISTING
k Heavy parts (25 kg or more) must be lifted
with a hoist, etc. In the DISASSEMBLY
AND ASSEMBLY section, every part
weighing 25 kg or more is indicated clearly
with the symbol 4

If a part cannot be smoothly removed from the


machine by hoisting, the following checks
should be made:
1) Check for removal of all bolts fastening the
part to the relative parts.
2) Check for existence of another part causing
interference with the part to be removed.

WIRE ROPES
1) Use adequate ropes depending on the
weight of parts to be hoisted, referring to
the table below:
Wire ropes
(Standard "Z" or "S" twist ropes
without galvanizing)
Rope diameter

Allowable load

mm

kN

tons

10
11.5
12.5
14
16
18
20
22.4
30
40
50
60

9.8
13.7
15.7
21.6
27.5
35.3
43.1
54.9
98.1
176.5
274.6
392.2

1.0
1.4
1.6
2.2
2.8
3.6
4.4
5.6
10.0
18.0
28.0
40.0

Slinging near the edge of the hook may cause


the rope to slip off the hook during hoisting, and
a serious accident can result. Hooks have maximum strength at the middle portion.

100%

88%

79%

71%

41%
SAD00479

3) Do not sling a heavy load with one rope alone,


but sling with two or more ropes symmetrically
wound onto the load.
k Slinging with one rope may cause turning
of the load during hoisting, untwisting of
the rope, or slipping of the rope from its
original winding position on the load, which
can result in a dangerous accident.

4) Do not sling a heavy load with ropes forming a


wide hanging angle from the hook.
When hoisting a load with two or more ropes,
the force subjected to each rope will increase
with the hanging angles. The table below
shows the variation of allowable load kN {kg}
when hoisting is made with two ropes, each of
which is allowed to sling up to 9.8 kN {1000 kg}
vertically, at various hanging angles.
When two ropes sling a load vertically, up to
19.6 kN {2000 kg} of total weight can be suspended. This weight becomes 9.8 kN {1000 kg}
when two ropes make a 120 hanging angle.
On the other hand, two ropes are subjected to
an excessive force as large as 39.2 kN {4000
kg} if they sling a 19.6 kN {2000 kg} load at a
lifting angle of 150.

The allowable load value is estimated to be onesixth or one-seventh of the breaking strength of
the rope used.

2) Sling wire ropes from the middle portion of the


hook.

00-7

FOREWORD

METHOD OF DISASSEMBLING, CONNECTING PUSH-PULL TYPE COUPLER

METHOD OF DISASSEMBLING, CONNECTING PUSH-PULL TYPE COUPLER


k Before carrying out the following work, release
the residual pressure from the hydraulic tank.
For details, see TESTING AND ADJUSTING,
Releasing residual pressure from hydraulic
tank.

k Even if the residual pressure is released from


the hydraulic tank, some hydraulic oil flows out
when the hose is disconnected. Accordingly,
prepare an oil receiving container.
Disconnection
1) Release the residual pressure from the hydraulic tank. For details, see TESTING AND
ADJUSTING, Releasing residual pressure from
hydraulic tank.
2) Hold adapter (1) and push hose joint (2) into
mating adapter (3). (See Fig. 1)
The adapter can be pushed in about 3.5
mm.
Do not hold rubber cap portion (4).
3) After hose joint (2) is pushed into adapter (3),
press rubber cap portion (4) against (3) until it
clicks. (See Fig. 2)
4) Hold hose adapter (1) or hose (5) and pull it out.
(See Fig. 3)
Since some hydraulic oil flows out, prepare
an oil receiving container.
Connection
1) Hold hose adapter (1) or hose (5) and insert it in
mating adapter (3), aligning them with each
other. (See Fig. 4)
Do not hold rubber cap portion (4).
2) After inserting the hose in the mating adapter
perfectly, pull it back to check its connecting
condition. (See Fig. 5)
When the hose is pulled back, the rubber
cap portion moves toward the hose about
3.5 mm. This does not indicate abnormality,
however.

00-8

Type 1

FOREWORD

METHOD OF DISASSEMBLING, CONNECTING PUSH-PULL TYPE COUPLER

Type 3

1) Hold the mouthpiece of the tightening portion


and push body (2) in straight until sliding prevention ring (1) contacts contact surface a of
the hexagonal portion at the male end.

1) Hold the mouthpiece of the tightening portion


and push body (2) in straight until sliding prevention ring (1) contacts contact surface a of
the hexagonal portion at the male end.

2) Hold in the condition in Step 1), and turn


lever (4) to the right (clockwise).

2) Hold in the condition in Step 1), and push


until cover (3) contacts contact surface a of
the hexagonal portion at the male end.

3) Hold in the condition in Steps 1) and 2), and


pull out whole body (2) to disconnect it.

3) Hold in the condition in Steps 1) and 2), and


pull out whole body (2) to disconnect it.

Disassembly

Type 2

Hold the mouthpiece of the tightening portion


and push body (2) in straight until sliding prevention ring (1) contacts contact surface a of
the hexagonal portion at the male end to connect it.

Connection

Hold the mouthpiece of the tightening portion


and push body (2) in straight until sliding prevention ring (1) contacts contact surface a of
the hexagonal portion at the male end to connect it.

00-9

FOREWORD

COATING MATERIALS

COATING MATERIALS

The recommended coating materials such as adhesives, gasket sealants and greases used for disassembly
and assembly are listed below.
For coating materials not listed below, use the equivalent of products shown in this list.
Category

Komatsu code

Part No.

Q'ty

Container

Main applications, featuresr

LT-1A

790-129-9030

150 g

Tube

Used to prevent rubber gaskets, rubber cushions, and cock plug from
coming out.

LT-1B

790-129-9050

20 g
(2 pcs.)

Polyethylene
container

Used in places requiring an immediately effective, strong adhesive.


Used for plastics (except polyethylene, polyprophylene, tetrafluoroethlene and vinyl chloride), rubber,
metal and non-metal.

LT-2

09940-00030

50 g

Polyethylene
container

Features: Resistance to heat and


chemicals
Used for anti-loosening and sealant
purpose for bolts and plugs.

LT-3

790-129-9060
(Set of adhesive
and hardening
agent)

Adhesive:
1 kg
Hardening
agent:
500 g

Can

LT-4

790-129-9040

250 g

Polyethylene
container

Holtz
MH 705

790-126-9120

75 g

Tube

Used as heat-resisting sealant for repairing engine.

50 g

Polyethylene
container

Quick hardening type adhesive


Cure time: within 5 sec. to 3 min.
Used mainly for adhesion of metals,
rubbers, plastics and woods.

Adhesives

Three bond
1735

790-129-9140

Used as adhesive or sealant for metal, glass and plastic.

Aron-alpha
201

790-129-9130

2g

Polyethylene
container

Quick hardening type adhesive


Quick cure type (max. strength after
30 minutes)
Used mainly for adhesion of rubbers,
plastics and metals.

Loctite
648-50

79A-129-9110

50 cc

Polyethylene
container

Resistance to heat, chemicals


Used at joint portions subject to high
temperatures.

LG-1

790-129-9010

200 g

Tube

Used as adhesive or sealant for gaskets and packing of power train case,
etc.

LG-5

790-129-9080

1 kg

Can

Used as sealant for various threads,


pipe joints, flanges.
Used as sealant for tapered plugs,
elbows, nipples of hydraulic piping.

Tube

Features: Silicon based, resistance


to heat, cold
Used as sealant for flange surface,
tread.
Used as sealant for oil pan, final
drive case, etc.

LG-6

790-129-9020

200 g

Gasket
sealant
LG-7

790-129-9070

1g

Tube

Features: Silicon based, quick hardening type


Used as sealant for flywheel housing, intake manifold, oil an, thermostat housing, etc.

Three bond
1211

790-129-9090

100 g

Tube

Used as heat-resisting sealant for repairing engine.

Tube

Features: Silicone type, heat resistant, vibration resistant, and impact


resistant sealing material
Used as sealing material for transfer
case

Three bond
1207B

00-10

Used as sealant for machined holes.

419-15-18131

100 g

FOREWORD

Molybdenum
disulphide
lubricant

Grease

Primer

Adhesive

Caulking
material

Komatsu code

Part No.

Q'ty

Container

Main applications, featuresr

LM-G

09940-00051

60 g

Can

Used as lubricant for sliding portion


(to prevent from squeaking).

Tube

Used to prevent seizure or scuffling


of the thread when press fitting or
shrink fitting.
Used as lubricant for linkage, bearings, etc.

LM-P

09940-00040

G2-LI

SYG2-400LI
SYG2-350LI
SYG2-400LI-A
SYG2-160LI
SYGA-160CNLI

G2-CA

SYG2-400CA
SYG2-350CA
SYG2-400CA-A
SYG2-160CA
SYGA-160CNCA

200 g

General purpose type


Various

Various

Various

Various

Used for normal temperature, light


load bearing at places in contact
with water or steam.

Used for heavy load portion

Molybdenum
disulphide
grease
LM-G (G2-M)

SYG2-400M
SYG2-400M-A
SYGA-16CNM

Hyper White
Grease G2-T
G0-T (*)
*: For use in cold
district

SYG2-400T-A
SYG2-16CNT
SYG0-400T-A (*)
SYG0-16CNT (*)

400 g
16 kg

Seizure resistance and heat resistance higher than molybdenum diBellows type
sulfide grease
Can
Since this grease is white, it does
not stand out against machine
body.

Biogrease G2B
G2-BT (*)
*: For high
temperature
and large load

SYG2-400B
SYGA-16CNB
SYG2-400BT (*)
SYGA-16CNBT (*)

400 g
16 kg

Bellows type
Can

SUNSTAR
PAINT PRIMER
580 SUPER

20 ml

Glass
container

SUNSTAR
GLASS PRIMER
580 SUPER

20 ml

Glass
container

400 g 10 Bellows type


400 g 20 Bellows type
16 kg
Can

417-926-3910

SUNSTAR
PENGUINE
SEAL 580
SUPER "S" or
"W"

320 ml

Polyethylene
container

Sika Japan,
Sikaflex 256HV

20Y-54-39850

310 ml

Polyethylene
container

SUNSTAR
PENGUINE
SEAL No. 2505

417-926-3920

320 ml

Polyethylene
container

SEKISUI
SILICONE
SEALANT

20Y-54-55130

333 ml

Polyethylene
container

Since this grease is decomposed


by bacteria in short period, it has
less effects on microorganisms,
animals, and plants.
Used as primer for cab side
(Using limit: 4 months)
Used as primer for glass side
(Using limit: 4 months)
Adhesive for cab glass

Category

COATING MATERIALS

"S" is used for high-temperature season (April - October)


and "W" for low-temperature
season (November - April) as
adhesive for glass.
(Using limit: 4 months)
Used as adhesive for glass.
(Using limit: 6 months)
Used to seal joints of glass
parts.
(Using limit: 4 months)
Used to seal front window.
(Using limit: 6 months)

00-11

FOREWORD

STANDARD TIGHTENING TORQUE

STANDARD TIGHTENING TORQUE


STANDARD TIGHTENING TORQUE TABLE (WHEN USING TORQUE WRENCH)
In the case of metric nuts and bolts for which there is no special instruction, tighten to the torque given in
the table below.
Tightening torque
Thread diameter
of bolt

Width across
flats

mm

mm

Nm

kgm

6
8
10
12
14

10
13
17
19
22

11.8 14.7
27 34
59 74
98 123
153 190

1.2 1.5
2.8 3.5
6 7.5
10 12.5
15.5 19.5

16
18
20
22
24

24
27
30
32
36

235 285
320 400
455 565
610 765
785 980

23.5 29.5
33 41
46.5 58
62.5 78
80 100

27
30
33
36
39

41
46
50
55
60

1150 1440
1520 1910
1960 2450
2450 3040
2890 3630

118 147
155 195
200 250
250 310
295 370

Thread diameter
of bolt

Width across
flats

mm

mm

Nm

kgm

6
8
10
12

10
13
14
27

5.9 9.8
13.7 23.5
34.3 46.1
74.5 90.2

0.6 1.0
1.4 2.4
3.5 4.7
7.6 9.2

Tightening torque

Sealing surface

TABLE OF TIGHTENING TORQUES FOR FLARED NUTS


In the case of flared nuts for which there is no
special instruction, tighten to the torque given in
the table below.

SAD00483

Thread diameter

Width across flat

mm

mm

Nm

kgm

14
18
22
24
30
33
36
42

19
24
27
32
36
41
46
55

24.5 4.9
49 19.6
78.5 19.6
137.3 29.4
176.5 29.4
196.1 49
245.2 49
294.2 49

2.5 0.5
52
82
14 3
18 3
20 5
25 5
30 5

00-12

Tightening torque

FOREWORD

STANDARD TIGHTENING TORQUE

TABLE OF TIGHTENING TORQUES FOR SPLIT FLANGE BOLTS


In the case of split flange bolts for which there is no special instruction, tighten to the torque given in the
table below.

Thread diameter

Width across flat

Tightening torque

mm

mm

Nm

kgm

10
12
16

14
17
22

59 74
98 123
235 285

6 7.5
10 12.5
23.5 29.5

TABLE OF TIGHTENING TORQUES FOR O-RING BOSS PIPING JOINTS


Unless there are special instructions, tighten the O-ring boss piping joints to the torque below.

Thread diameter

Width across flat

mm

mm

14
20
24
33
42

Varies depending
on type of
connector.

Tightening torque (Nm {kgm})

Norminal No.

02
03, 04
05, 06
10, 12
14

Range
35 63
84 132
128 186
363 480
746 1010

{3.5 6.5}
{8.5 13.5}
{13.0 19.0}
{37.0 49.0}
{76.0 103}

Target
44 {4.5}
103 {10.5}
157 {16.0}
422 {43.0}
883 {90.0}

TABLE OF TIGHTENING TORQUES FOR O-RING BOSS PLUGS


Unless there are special instructions, tighten the O-ring boss plugs to the torque below.

Thread diameter

Width across flat

mm

mm

08
10
12
14
16
18
20
24
30
33
36
42
52

14
17
19
22
24
27
30
32
32

36

Tightening torque (Nm {kgm})

Norminal No.

08
10
12
14
16
18
20
24
30
33
36
42
52

Range
5.88 8.82
9.8 12.74
14.7 19.6
19.6 24.5
24.5 34.3
34.3 44.1
44.1 53.9
58.8 78.4
93.1 122.5
107.8 147.0
127.4 176.4
181.3 240.1
274.4 367.5

{0.6 0.9}
{1.0 1.3}
{1.5 2.0}
{2.0 2.5}
{2.5 3.5}
{3.5 4.5}
{4.5 5.5}
{6.0 8.0}
{9.5 12.5}
{11.0 15.0}
{13.0 18.0}
{18.5 24.5}
{28.0 37.5}

Target
7.35 {0.75}
11.27 {1.15}
17.64 {1.8}
22.54 {2.3}
29.4 {3.0}
39.2 {4.0}
49.0 {5.0}
68.6 {7.0}
107.8 {11.0}
124.4 {13.0}
151.9 {15.5}
210.7 {21.5}
323.4 {33.0}

00-13

FOREWORD

STANDARD TIGHTENING TORQUE

TIGHTENING TORQUE FOR 102 ENGINE SERIES


1) BOLT AND NUTS
Use these torques for bolts and nuts (unit: mm) of Cummins Engine.
Thread diameter

Tightening torque

mm

Nm

kgm

10 0 2
24 0 4
43 0 6
77 0 12

6
8
10
12

1.02 0 0.20
2.45 0 0.41
4.38 0 0.61
7.85 0 1.22

2) EYE JOINTS
Use these torques for eye joints (unit: mm) of Cummins Engine.
Thread diameter

Tightening torque

mm

Nm

kgm

802
10 0 2
12 0 2
24 0 4
36 0 5

6
8
10
12
14

0.81 0 0.20
1.02 0 0.20
1.22 0 0.20
2.45 0 0.41
3.67 0 0.51

3) TAPERED SCREWS
Use these torques for tapered screws (unit: inch) of Cummins Engine.
Thread diameter

Tightening torque

inch

Nm

kgm

301
802
12 0 2
15 0 2
24 0 4
36 0 5
60 0 9

1 / 16
1/8
1/4
3/8
1/2
3/4
1

0.31 0 0.10
0.81 0 0.20
1.22 0 0.20
1.53 0 0.41
2.45 0 0.41
3.67 0 0.51
6.12 0 0.92

TIGHTENING TORQUE TABLE FOR HOSES (TAPER SEAL TYPE AND FACE SEAL TYPE)
Tighten the hoses (taper seal type and face seal type) to the following torque, unless otherwise specified.
Apply the following torque when the threads are coated (wet) with engine oil.
Tightening torque (Nm {kgm})
Nominal size Width across
of hose
flats

Taper seal
type

Face seal type

Nominal thread
Thread size size
Root diameter
- Threads per
(mm)
inch, Thread series (mm) (Reference)

Range

Target

19

34 - 63 {3.5 - 6.5}

44 {4.5}

14

9
- 18UNF
16

14.3

22

54 - 93 {5.5 - 9.5}

74 {4.5}

11
- 16UN
16

17.5

24

59 - 98 {6.0 - 10.0}

78 {8.0}

18

04

27

84 - 132 {8.5 - 13.5}

103 {10.5}

22

13
- 16UN
16

20.7

05

32

128 - 186 {13.0 - 19.0}

157 {16.0}

24

1 - 14UNS

25.4

06

36

177 - 245 {18.0 - 25.0}

216 {22.0}

30

3
1 - 12UNF
16

30.3

(10)

41

177 - 245 {18.0 - 25.0}

216 {22.0}

33

(12)

46

197 - 294 {20.0 - 30.0}

245 {25.0}

36

(14)

55

246 - 343 {25.0 - 35.0}

294 {30.0}

42

02

03

00-14

FOREWORD

ELECTRIC WIRE CODE

ELECTRIC WIRE CODE


In the wiring diagrams, various colors and symbols are employed to indicate the thickness of wires.
This wire code table will help you understand WIRING DIAGRAMS.
Example: 5WB indicates a cable having a nominal number 5 and white coating with black stripe.

CLASSIFICATION BY THICKNESS
Copper wire
Cable O.D.
(mm)

Current
rating
(A)

Applicable circuit

0.88

2.4

12

Starting, lighting, signal


etc.

0.32

2.09

3.1

20

Lighting, signal etc.

65

0.32

5.23

4.6

37

Charging and signal

15

84

0.45

13.36

7.0

59

Starting (Glow plug)

40

85

0.80

42.73

11.4

135

Starting

60

127

0.80

63.84

13.6

178

Starting

100

217

0.80

109.1

17.6

230

Starting

Norminal
number

Number of
strands

Dia. of
strands
(mm2)

Cross
section
(mm2)

0.85

11

0.32

26

CLASSIFICATION BY COLOR AND CODE


Circuits
Priority
Classification

Primary

Charging

Ground

Starting

Lighting

Instrument

Signal

Other

Code

Color

White

Black

Black

Red

Yellow

Green

Blue

Code

WR

BW

RW

YR

GW

LW

2
Color White & Red

Code

WB

White & Black Red & White Rellow & Red Green & White Blue & White
BY

RB

YB

GR

LR

Auxiliary

Color White & Black

Code

WL

Black & Yellow Red & Black Yellow & Black Green & Red Blue & Yellow
BR

Color White & Blue

Code

Color White & Green

Code

Color

WG

RY

Black & Red Red & Yellow


RG

YG

GY

LY

Yellow &
Green

Green &
Yellow

Blue & Yellow

YL

GB

LB

5
Red & Green Yellow & Blue Green & Black Blue & Black
RL

YW

GL

6
Red & Blue Yellow & White Green & Blue

n
n

00-15

FOREWORD

CONVERSION TABLE

CONVERSION TABLE
METHOD OF USING THE CONVERSION TABLE
The Conversion Table in this section is provided to enable simple conversion of figures. For details of the
method of using the Conversion Table, see the example given below.

EXAMPLE
Method of using the Conversion Table to convert from millimeters to inches
1. Convert 55 mm into inches.
(1) Locate the number 50 in the vertical column at the left side, take this as A, then draw a horizontal line
from A.
(2) Locate the number 5 in the row across the top, take this as B, then draw a perpendicular line down
from B.
(3) Take the point where the two lines cross as C. This point C gives the value when converting from millimeters to inches. Therefore, 55 mm = 2.165 inches.
2. Convert 550 mm into inches.
(1) The number 550 does not appear in the table, so divide by 10 (move the decimal point one place to the
left) to convert it to 55 mm.
(2) Carry out the same procedure as above to convert 55 mm to 2.165 inches.
(3) The original value (550 mm) was divided by 10, so multiply 2.165 inches by 10 (move the decimal point
one place to the right) to return to the original value. This gives 550 mm = 21.65 inches.
B
Millimeters to inches
1 mm = 0.03937 in

00-16

0
10
20
30
40

0
0.394
0.787
1.181
1.575

0.039
0.433
0.827
1.220
1.614

0.079
0.472
0.866
1.260
1.654

0.118
0.512
0.906
1.299
1.693

0.157
0.551
0.945
1.339
1.732

50
60
70
80
90

1.969
2.362
2.756
3.150
3.543

2.008
2.402
2.795
3.189
3.583

2.047
2.441
2.835
3.228
3.622

2.087
2.480
2.874
3.268
3.661

2.126
2.520
2.913
3.307
3.701

5
0.197
0.591
0.984
1.378
1.772
C
2.165
2.559
2.953
3.346
3.740

0.236
0.630
1.024
1.417
1.811

0.276
0.669
1.063
1.457
1.850

0.315
0.709
1.102
1.496
1.890

0.354
0.748
1.142
1.536
1.929

2.205
2.598
2.992
3.386
3.780

2.244
2.638
3.032
3.425
3.819

2.283
2.677
3.071
3.465
3.858

2.323
2.717
3.110
3.504
3.898

FOREWORD

CONVERSION TABLE

Millimeters to Inches
1 mm = 0.03937 in

0.039

0.079

0.118

0.157

0.197

0.236

0.276

0.315

0.354

10

0.394

0.433

0.472

0.512

0.551

0.591

0.630

0.669

0.709

0.748

20

0.787

0.827

0.866

0.906

0.945

0.984

1.024

1.063

1.102

1.142

30

1.181

1.220

1.260

1.299

1.339

1.378

1.417

1.457

1.496

1.536

40

1.575

1.614

1.654

1.693

1.732

1.772

1.811

1.850

1.890

1.929

50

1.969

2.008

2.047

2.087

2.126

2.165

2.205

2.244

2.283

2.323

60

2.362

2.402

2.441

2.480

2.520

2.559

2.598

2.638

2.677

2.717

70

2.756

2.795

2.835

2.874

2.913

2.953

2.992

3.032

3.071

3.110

80

3.150

3.189

3.228

3.268

3.307

3.346

3.386

3.425

3.465

3.504

90

3.543

3.583

3.622

3.661

3.701

3.740

3.780

3.819

3.858

3.898

Kilogram to Pound
1 kg = 2.2046 lb

0
0

2.20

4.41

6.61

8.82

11.02

13.23

15.43

17.64

19.84

10

22.05

24.25

26.46

28.66

30.86

33.07

35.27

37.48

39.68

41.89

20

44.09

46.30

48.50

50.71

51.91

55.12

57.32

59.53

61.73

63.93

30

66.14

68.34

70.55

72.75

74.96

77.16

79.37

81.57

83.78

85.98

40

88.18

90.39

92.59

94.80

97.00

99.21

101.41

103.62

105.82

108.03

50

110.23

112.44

114.64

116.85

119.05

121.25

123.46

125.66

127.87

130.07

60

132.28

134.48

136.69

138.89

141.10

143.30

145.51

147.71

149.91

152.12

70

154.32

156.53

158.73

160.94

163.14

165.35

167.55

169.76

171.96

174.17

80

176.37

178.57

180.78

182.98

185.19

187.39

189.60

191.80

194.01

196.21

90

198.42

200.62

202.83

205.03

207.24

209.44

211.64

213.85

216.05

218.26

00-17

FOREWORD

CONVERSION TABLE

Liter to U.S. Gallon


1l = 0.2642 U.S. Gal

0.264

0.528

0.793

1.057

1.321

1.585

1.849

2.113

2.378

10

2.642

2.906

3.170

3.434

3.698

3.963

4.227

4.491

4.755

5.019

20

5.283

5.548

5.812

6.076

6.340

6.604

6.869

7.133

7.397

7.661

30

7.925

8.189

8.454

8.718

8.982

9.246

9.510

9.774

10.039

10.303

40

10.567

10.831

11.095

11.359

11.624

11.888

12.152

12.416

12.680

12.944

50

13.209

13.473

13.737

14.001

14.265

14.529

14.795

15.058

15.322

15.586

60

15.850

16.115

16.379

16.643

16.907

17.171

17.435

17.700

17.964

18.228

70

18.492

18.756

19.020

19.285

19.549

19.813

20.077

20.341

20.605

20.870

80

21.134

21.398

21.662

21.926

22.190

22.455

22.719

22.983

23.247

23.511

90

23.775

24.040

24.304

24.568

24.832

25.096

25.361

25.625

25.889

26.153

Liter to U.K. Gallon


1l = 0.21997 U.K. Gal

0.220

0.440

0.660

0.880

1.100

1.320

1.540

1.760

1.980

10

2.200

2.420

2.640

2.860

3.080

3.300

3.520

3.740

3.950

4.179

20

4.399

4.619

4.839

5.059

5.279

5.499

5.719

5.939

6.159

6.379

30

6.599

6.819

7.039

7.259

7.479

7.969

7.919

8.139

8.359

8.579

40

8.799

9.019

9.239

9.459

9.679

9.899

10.119

10.339

10.559

10.778

50

10.998

11.281

11.438

11.658

11.878

12.098

12.318

12.528

12.758

12.978

60

13.198

13.418

13.638

13.858

14.078

14.298

14.518

14.738

14.958

15.178

70

15.398

15.618

15.838

16.058

16.278

16.498

16.718

16.938

17.158

17.378

80

17.598

17.818

18.037

18.257

18.477

18.697

18.917

19.137

19.357

19.577

90

19.797

20.017

20.237

20.457

20.677

20.897

21.117

21.337

21.557

21.777

00-18

FOREWORD

CONVERSION TABLE

kgm to ft. lb
1 kgm = 7.233 ft. lb

7.2

14.5

21.7

28.9

36.2

43.4

50.6

57.9

65.1

10

72.3

79.6

86.8

94.0

101.3

108.5

115.7

123.0

130.2

137.4

20

144.7

151.9

159.1

166.4

173.6

180.8

188.1

195.3

202.5

209.8

30

217.0

224.2

231.5

238.7

245.9

253.2

260.4

267.6

274.9

282.1

40

289.3

296.6

303.8

311.0

318.3

325.5

332.7

340.0

347.2

354.4

50

361.7

368.9

376.1

383.4

390.6

397.8

405.1

412.3

419.5

426.8

60

434.0

441.2

448.5

455.7

462.9

470.2

477.4

484.6

491.8

499.1

70

506.3

513.5

520.8

528.0

535.2

542.5

549.7

556.9

564.2

571.4

80

578.6

585.9

593.1

600.3

607.6

614.8

622.0

629.3

636.5

643.7

90

651.0

658.2

665.4

672.7

679.9

687.1

694.4

701.6

708.8

716.1

100

723.3

730.5

737.8

745.0

752.2

759.5

766.7

773.9

781.2

788.4

110

795.6

802.9

810.1

817.3

824.6

831.8

839.0

846.3

853.5

860.7

120

868.0

875.2

882.4

889.7

896.9

904.1

911.4

918.6

925.8

933.1

130

940.3

947.5

954.8

962.0

969.2

976.5

983.7

990.9

998.2

1005.4

140

1012.6

1019.9

1027.1

1034.3

1041.5

1048.8

1056.0

1063.2

1070.5

1077.7

150

1084.9

1092.2

1099.4

1106.6

1113.9

1121.1

1128.3

1135.6

1142.8

1150.0

160

1157.3

1164.5

1171.7

1179.0

1186.2

1193.4

1200.7

1207.9

1215.1

1222.4

170

1129.6

1236.8

1244.1

1251.3

1258.5

1265.8

1273.0

1280.1

1287.5

1294.7

180

1301.9

1309.2

1316.4

1323.6

1330.9

1338.1

1345.3

1352.6

1359.8

1367.0

190

1374.3

1381.5

1388.7

1396.0

1403.2

1410.4

1417.7

1424.9

1432.1

1439.4

00-19

FOREWORD

CONVERSION TABLE

kg/cm2 to lb/in2
1kg/cm2 = 14.2233 lb/in2

14.2

28.4

42.7

56.9

71.1

85.3

99.6

113.8

128.0

10

142.2

156.5

170.7

184.9

199.1

213.4

227.6

241.8

256.0

270.2

20

284.5

298.7

312.9

327.1

341.4

355.6

369.8

384.0

398.3

412.5

30

426.7

440.9

455.1

469.4

483.6

497.8

512.0

526.3

540.5

554.7

40

568.9

583.2

597.4

611.6

625.8

640.1

654.3

668.5

682.7

696.9

50

711.2

725.4

739.6

753.8

768.1

782.3

796.5

810.7

825.0

839.2

60

853.4

867.6

881.8

896.1

910.3

924.5

938.7

953.0

967.2

981.4

70

995.6

1010

1024

1038

1053

1067

1081

1095

1109

1124

80

1138

1152

1166

1181

1195

1209

1223

1237

1252

1266

90

1280

1294

1309

1323

1337

1351

1365

1380

1394

1408

100

1422

1437

1451

1465

1479

1493

1508

1522

1536

1550

110

1565

1579

1593

1607

1621

1636

1650

1664

1678

1693

120

1707

1721

1735

1749

1764

1778

1792

1806

1821

1835

130

1849

1863

1877

1892

1906

1920

1934

1949

1963

1977

140

1991

2005

2020

2034

2048

2062

2077

2091

2105

2119

150

2134

2148

2162

2176

2190

2205

2219

2233

2247

2262

160

2276

2290

2304

2318

2333

2347

2361

2375

2389

2404

170

2418

2432

2446

2460

2475

2489

2503

2518

2532

2546

180

2560

2574

2589

2603

2617

2631

2646

2660

2674

2688

190

2702

2717

2731

2745

2759

2773

2788

2802

2816

2830

200

2845

2859

2873

2887

2901

2916

2930

2944

2958

2973

210

2987

3001

3015

3030

3044

3058

3072

3086

3101

3115

220

3129

3143

3158

3172

3186

3200

3214

3229

3243

3257

230

3271

3286

3300

3314

3328

3343

3357

3371

3385

3399

240

3414

3428

3442

3456

3470

3485

3499

3513

3527

3542

00-20

FOREWORD

CONVERSION TABLE

Temperature
Fahrenheit-Centigrade Conversion ; a simple way to convert a Fahrenheit temperature reading into a Centigrade temperature reading or vice versa is to enter the accompanying table in the center or boldface column of figures.
These figures refer to the temperature in either Fahrenheit or Centigrade degrees.
If it is desired to convert from Fahrenheit to Centigrade degrees, consider the center column as a table of
Fahrenheit temperatures and read the corresponding Centigrade temperature in the column at the left.
If it is desired to convert from Centigrade to Fahrenheit degrees, consider the center column as a table of
Centigrade values, and read the corresponding Fahrenheit temperature on the right.
1C = 33.8F

40.4
37.2
34.4
31.7
28.9

40
35
30
25
20

40.0
31.0
22.0
13.0
4.0

11.7
11.1
10.6
10.0
9.4

11
12
13
14
15

51.8
53.6
55.4
57.2
59.0

7.8
8.3
8.9
9.4
10.0

46
47
48
49
50

114.8
116.6
118.4
120.2
122.0

27.2
27.8
28.3
28.9
29.4

81
82
83
84
85

117.8
179.6
181.4
183.2
185.0

28.3
27.8
27.2
26.7
26.1

19
18
17
16
15

2.2
0.4
1.4
3.2
5.0

8.9
8.3
7.8
7.2
6.7

16
17
18
19
20

60.8
62.6
64.4
66.2
68.0

10.6
11.1
11.7
12.2
12.8

51
52
53
54
55

123.8
125.6
127.4
129.2
131.0

30.0
30.6
31.1
31.7
32.2

86
87
88
89
90

186.8
188.6
190.4
192.2
194.0

25.6
25.0
24.4
23.9
23.3

14
13
12
11
10

6.8
8.6
10.4
12.2
14.0

6.1
5.6
5.0
4.4
3.9

21
22
23
24
25

69.8
71.6
73.4
75.2
77.0

13.3
13.9
14.4
15.0
15.6

56
57
58
59
0

132.8
134.6
136.4
138.2
140.0

32.8
33.3
33.9
34.4
35.0

91
92
93
94
95

195.8
197.6
199.4
201.2
203.0

22.8
22.2
21.7
21.1
20.6

9
8
7
6
5

15.8
17.6
19.4
21.2
23.0

3.3
2.8
2.2
1.7
1.1

26
27
28
29
30

78.8
80.6
82.4
84.2
86.0

16.1
16.7
17.2
17.8
18.3

61
62
63
64
65

141.8
143.6
145.4
147.2
149.0

35.6
36.1
36.7
37.2
37.8

96
97
98
99
100

204.8
206.6
208.4
210.2
212.0

20.0
19.4
18.9
18.3
17.8

4
3
2
1
0

24.8
26.6
28.4
30.2
32.0

0.6
0
0.6
1.1
1.7

31
32
33
34
35

87.8
89.6
91.4
93.2
95.0

18.9
19.4
20.0
20.6
21.1

66
67
68
69
70

150.8
152.6
154.4
156.2
158.0

40.6
43.3
46.1
48.9
51.7

105
110
115
120
125

221.0
230.0
239.0
248.0
257.0

17.2
16.7
16.1
15.6
15.0

1
2
3
4
5

33.8
35.6
37.4
39.2
41.0

2.2
2.8
3.3
3.9
4.4

36
37
38
39
40

96.8
98.6
100.4
102.2
104.0

21.7
22.2
22.8
23.3
23.9

71
72
73
74
75

159.8
161.6
163.4
165.2
167.0

54.4
57.2
60.0
62.7
65.6

130
135
140
145
150

266.0
275.0
284.0
293.0
302.0

14.4
13.9
13.3
12.8
12.2

6
7
8
9
10

42.8
44.6
46.4
48.2
50.0

5.0
5.6
6.1
6.7
7.2

41
42
43
44
45

105.8
107.6
109.4
111.2
113.0

24.4
25.0
25.6
26.1
26.7

76
77
78
79
80

168.8
170.6
172.4
174.2
176.0

68.3
71.1
73.9
76.7
79.4

155
160
165
170
175

311.0
320.0
329.0
338.0
347.0

00-21

FOREWORD

UNITS

UNITS
In this manual, the measuring units are indicated with Internatinal System of units (SI).
As for reference, conventionally used Gravitational System of units are indicated in parentheses {
Example:
N {kg}
Nm {kgm}
MPa {kg/cm2}
kPa {mmH2O}
kPa {mmHg}
kW/rpm {HP/rpm}
g/kWh {g/HPh}

00-22

}.

01 GENERAL

GENERAL ASSEMBLY DRAWING ........................................... 01-2


SPECIFICATIONS ..................................................................... 01-4
WEIGHT TABLE ........................................................................ 01-7
LIST OF LUBRICANTS AND WATER ....................................... 01-9

PC130-7

01-1

GENERAL

GENERAL ASSEMBLY DRAWING

GENERAL ASSEMBLY DRAWING


SPECIFICATION DIMENSIONAL DRAWING

PC130-7
Item

Unit
2.5 m arm, 500 mm shoe

3.0 m arm, 700 mm shoe

Overall length

mm

7,595

7,485

Overall height

mm

2,810

3,170

Overall width

mm

2,490

2,490

Shoe width

mm

500

700

Cab height

mm

2,810

2,810

Trail swing radius

mm

2,190

2,190

Crawler overall length

mm

3,610

3,610

Distance between tambler center

mm

2,880

2,880

01-2

PC130-7

GENERAL

GENERAL ASSEMBLY DRAWING

WORKING RANGE DRAWING

PC130-7
Working range (mm)
2.5 m arm

3.0 m arm

Maximum digging radius

8,290

8,785

Maximum digging depth

5,520

6,015

Maximum digging height

8,610

8,790

Maximum vertical wall digging depth

4,940

5,360

Maximum dumping height

6,170

6,535

Minimum swing radius of work equipment

2,450

2,610

Maximum reach at ground level

8,170

8,665

PC130-7

01-3

GENERAL

SPECIFICATIONS

SPECIFICATIONS
PC130-7
Machine model
2.5 m arm, 500 mm shoe

Dimension

Bucket capacity (SAE)

0.5

0.5

Operating weight

kg

12,200

13,050

Max. digging depth

mm

5,520

6,015

Max. vertical wall depth

mm

4,940

5,360

Max. digging reach

mm

8,290

8,785

Max. reach st ground level

mm

8,170

8,665

Max. digging height

mm

8,610

8,970

Max. dumping height

mm

6,170

6,535

kN {kg}

93.2 {9,500}

93.2 {9,500}

Swing speed

rpm

11.0

11.0

Swing max. slope angle

deg.

20

20

Travel speed (Hi/Lo)

km/h

2.7/5.5

2.7/5.5

Gradeability

deg.

35

35

Ground pressure

{kg/cm2}

38 {0.39}

29 {0.30}

Max. digging force (bucket)

mm

7,595

7,485

Overall width

mm

2,490

2,690

Overall height (for transport)

mm

2,810

3,170

Overall height to top of cab

mm

2,730

2,730

Ground clearance of counterweight

mm

855

855

Min. ground clearance

mm

400

400

Tail swing radius

mm

2,190

2,190

Min. swing radius of work euipment

mm

2,450

2,610

Height of work equipment at min.


swing radius

mm

6,455

6,455

Length of track

mm

3,610

3,610

Distance between tumbler center

mm

2,880

2,880

Track gauge

mm

1,990

1,990

Overall height of machine cab

mm

1,885

1,885

Model

SAA4D95LE-3

Type

4-cycle, water-cooled, in-line, vertical,


direct injection, with turbochatger, after cooler
mm

4 95 x 115

l {cc}

3.260 {3,260}

Rated horsepower

kW/rpm{HP/rpm}

66.2/2,200 {88.7/2,200}

Max. torpue

Nm/rpm{kgm/rpm}

353/1,500 {36.0/1,500}

High idling speed

rpm

2,400

Low idling speed

rpm

1,100

g/kWh{g/HPh}

224 {165}

Performance

Piston displacement
Engine

kPa

Overall length (for transport)

No. of cylinders-bore x stroke

Min. fuel consumption ratio

01-4
(3)

70001 and up
m3

Working ranges

Performance

Serial No.

3.0 m arm, 700 mm shoe

PC130-7

GENERAL

SPECIFICATIONS

PC130-7
Machine model
2.5 m arm, 500 mm shoe
Serial No.

70001 and up
24V, 3.0 kw

Alternator

24V, 25A

Battery

12V, 64 Ah x 2

Radiator type

Aluminum wave (4-line)

Carrier roller

1 on each side

Track roller

7 on each side

Track shoe (iron shoe)

Asembly-type triple grouster, 43 on each side

Hydraulic pump

(road liner)
Type x no.

Hydraulic motor Control


valve

Type x no.

Road liner, 43 on each side


Variable displacement piston type x 1

Discharge
Set pressure (at operation)

l /min

226 (at 2,200rpm)

MPa {kg/cm2}

31.9 {325}

(at traveling)

34.8 {355}
7-spool type x 1

Control method

Hydraulic type

Travel motor

Variable displacement piston type


(with brake valve, holding brake) x 2

Swing motor

Fixed displacement piston type


(with safety valve, holding brake) x 1

Hydraulic tank

Box-shaped, open

Hydraulic filter

Tank return side

Hydraulic cooler

Air cooled

PC130-7

Boom cylinder

Work equipment cylinder

Type

Reciprocating piston tipe

Reciprocating piston tipe

Cylinder inner diameter

mm

105

105

Piston rod diameter

mm

70

70

Stroke

mm

990

990

Max. length betwiin pins

mm

2,490

2,490

Min. length betwiin pins

mm

1,500

1,500

Reciprocating piston tipe

Reciprocating piston tipe

Type
Arm cylinder

Undercarriage

Engine

Starting motor

Hydraulic system

3.0 m arm, 700 mm shoe

Cylinder inner diameter

mm

115

115

Piston rod diameter

mm

75

75

Stroke

mm

1,175

1,175

Max. length betwiin pins

mm

2,877

2,877

Min. length betwiin pins

mm

1,702

1,702

01-5

GENERAL

SPECIFICATIONS

PC130-7
Machine model
2.5 m arm, 500 mm shoe

01-6

70001 and up

Type
Bucket cylinder

Work equipment cylinder

Hydraulic system

Serial No.

3.0 m arm, 700 mm shoe

Reciprocating piston tipe

Reciprocating piston tipe

Cylinder inner diameter

mm

95

95

Piston rod diameter

mm

65

65

Stroke

mm

885

885

Max. length betwiin pins

mm

2,263

2,263

Min. length betwiin pins

mm

1,378

1,378

PC130-7

GENERAL

WEIGHT TABLE

WEIGHT TABLE

k This weight table is a guide for use when transporting or handling component.
Unit: kg
Machine model

PC130-7

Serial No.

70001 and up

Engine assembly (excl. water, oil)

449

Engine (excl. water, oil)

345

Engine mount

19.6

PTO

4.1

Hydraulic pump

80

Radiator, oil cooler assembly

83

Revolving frame

1,110

Operator's cab

279

Operator's seat

35

Fuel tank (excl. fuel)

101

Hydraulic tank (excl. hydraulic oil)

89

Control valve

116

Self pressure reducing valve

4.8

Counterweight

2,455

Swing motor (with brake valve)

26

Swing circle

155

Swing machinery

72.2

Center swivel joint

28.6

Track frame assembly

2,260

Track frame

1,280

Idler assembly

79 x 2

Recoil spring assembly

69.5 x 2

Carrier roller

16.5 x 2

Track roller

21 x 14

Travel motor, final drive assembly

144 x 2

Sprocket

33.7 x 2

Track shoe assembly


Triple grouser shoe (500mm)

725 x 2

Triple grouser shoe (600mm)

815 x 2

Triple grouser shoe (700mm)

905 x 2

City pad shoe (500mm)

720 x 2

Road liner (500mm)

780 x 2

PC130-7

01-7

GENERAL

WEIGHT TABLE

Unit: kg
Machine model

PC130-7

Serial No.

70001 and up

Boom assembly

1,088

Arm assembly

392.4

Bucket link assembly

92.7

Bucket assembly

369

Boom cylinder assembly

92.7

Arm cylinder assembly

135

Bucket cylinder assembly

82.6

01-8

PC130-7

GENERAL

LIST OF LUBRICANTS AND WATER

LIST OF LUBRICANTS AND WATER

RESERVOIR

KIND OF
-22
FLUID
-30

AMBIENT TEMPERATURE
-4
-20

14
-10

32
0

50
10

68
20

CAPACITY ( )
86
30

104F
40C

Specified

Refill

17.5

16

0.75

0.75

2.5

2.5

2.5

2.5

0.090 --0.105

0.090 --0.105

0.075 --0.085

0.075 --0.085

0.068 --0.076

0.068 --0.076

140

90

SAE 30
SAE 10W

Engine oil pan

SAE 10W-30
SAE 15W-40
PTO case
Swing machinery case
Final drive case (each)

SAE 30
Engine oil

Idler (each)
Track roller (each)

SAE 30

Carrier roller (each)


SAE 10W
SAE 10W-30

Hydraulic system

SAE 15W-40
Hydraulic oil

Fuel tank

HD46-HM (a)
ASTM D975 No.2

Diesel fuel

240

ASTM D975 No. 1


Cooling system

PC130-7

Coolant

Add antifreeze

18.2

01-9

10 STRUCTURE AND FUNCTION

PTO ...........................................................................10- 2
COOLING SYSTEM ..................................................10- 3
POWER TRAIN .........................................................10- 5
SWING CIRCLE ........................................................10- 6
SWING MACHINERY................................................10- 7
TRACK FRAME.........................................................10- 8
IDLER CUSHION ......................................................10- 9
HYDRAULIC COMPONENT LAYOUT ......................10- 10
VALVE CONTROL.....................................................10- 12
HYDRAULIC TANK AND FILTER..............................10- 14
HYDRAULIC PUMP (PISTON PUMP) ......................10- 15
CONTROL VALVE.....................................................10- 36
SUCTION SAFETY VALVE .......................................10- 46
CLSS .........................................................................10- 47
SELF PRESSURE REDUCING VALVE ....................10- 79
CENTER SWIVEL JOINT..........................................10- 86
TRAVEL MOTOR (FINAL DRIVE).............................10- 87
SWING MOTOR ........................................................10- 96
SOLENOID VALVE....................................................10-102
PPC ACCUMULATOR...............................................10-104
PPC VALVE ...............................................................10-105
WORK EQUIPMENT .................................................10-116
AIR CONDITIONER PIPING .....................................10-117
ENGINE CONTROL ..................................................10-118
ELECTRIC CONTROL SYSTEM ..............................10-123
MONITOR SYSTEM..................................................10-150

PC130-7

10-1

STRUCTURE AND FUNCTION

PTO

PTO

1.
2.
3.
4.

Coupling
Shaft
Cage
Hydraulic pump

10-2

5. Level plug
6. Oil filler plug
7. Breather

PC130-7

STRUCTURE AND FUNCTION

COOLING SYSTEM

COOLING SYSTEM

PC130-7

10-3

STRUCTURE AND FUNCTION

1.
2.
3.
4.
5.
6.
7.
8.

COOLING SYSTEM

9.
10.
11.
12.
13.
14.
15.
16.

Reservoir tank
Shroud
Oil cooler
Fan
Radiator
Fan guard
Oil cooler
Radiator cap

Charge air inlet hose


Radiator inlet hose
Charge air outlet hose
Oil cooler outlet
Drain valve
Radiator outlet hose
Air condenser
Oil cooler inlet

SPECIFICATION
Radiator

Oil cooler

Charge air cooler

Aluminium wave
(4-line)

CF40

Aluminium wave

(mm)

3.5/2

3.5/2

4.0/2

(m2)

25.58

11.60

9.54

Pressure valve cracking pressure


(kPa {kg/cm2})

49.0 14.7
{0.5 0.15}

Vacuum valve cracking pressure


(kPa {kg/cm2})

-4.9 0
{-0.05 0}

Core type
Fin pitch
Total heat dissipation surface

10-4
(3)

PC130-7

STRUCTURE AND FUNCTION

POWER TRAIN

POWER TRAIN

1.
2.
3.
4.
5.
6.
7.

Idler
Control valve
Self pressure reducing valve
Travel motor
Hydraulic pump
Engine
2-stage relief solenoid valve

PC130-7

8.
9.
10.
11.
12.
13.
14.

Swing hold brake solenoid valve


2-speed travel changeover solenoid valve
PPC lock solenoid valve
Swing motor
Center swivel joint
Swing machinery
Swing circle

10-5

STRUCTURE AND FUNCTION

SWING CIRCLE

SWING CIRCLE

1. Outer race
2. Ball
3. Inner race
a. Inner race soft zone "S" position
b. Outer race soft zone "S" position

10-6

SPECIFICATIONS
Reduction ratio:

90
11

= 8.182

Amount of grease: 6.5 l (Grease: G2-LI)

PC130-7

STRUCTURE AND FUNCTION

SWING MACHINERY

SWING MACHINERY

1.
2.
3.
4.
5.
6.
7.
8.
9.

Swing pinion (No. of teeth: 11)


Case
No. 2 sun gear (No. of teeth: 17)
No. 2 planetary carrier (No. of teeth: 17)
Ring gear (No. of teeth: 61)
No. 1 planetary carrier (No. of teeth: 17)
No. 1 sun gear (No. of teeth: 14)
Oil level gauge/ oil filler port
Swing motor

PC130-7

10.
11.
12.
13.

No. 1 planetary gear (No. of teeth: 24)


No. 2 planetary gear (No. of teeth: 22)
Drain plug
Swing circle

SPECIFICATION
+ 61
Reduction ratio: 1414
x

17 + 61
17

= 24.58

10-7

STRUCTURE AND FUNCTION

TRACK FRAME

TRACK FRAME

1.
2.
3.
4.

Idler
Track frame
Carrier roller
Travel motor

10-8

5.
6.
7.
8.

Sprocket
Track roller
Idler cushion
Track shoe

PC130-7

STRUCTURE AND FUNCTION

IDLER CUSHION

IDLER CUSHION

1.
2.
3.
4.
5.
6.
7.
8.
9.
10.

Idler
Support
Yoke
Cylinder
Recoil spring
U-packing
Pilot
Nut
Valve
Grease fitting

PC130-7

SPECIFICATION
Grease : G2-LI
Amount of filled grease : 140 ml

10-9

STRUCTURE AND FUNCTION

HYDRAULIC COMPONENT LAYOUT

HYDRAULIC COMPONENT LAYOUT

1.
2.
3.
4.
5.
6.
7.
8.
9.
10.

11.
12.
13.
14.

Bucket cylinder
Arm cylinder
Boom cylinder
Hydraulic tank
Swing motor
Hydraulic pump
Oil cooler
L.H. travel motor
Control valve
4-spool solenoid valve
PPC lock
2-speed travel speed selection
Swing holding brake
2-stage relief
L.H. PPC valve
R.H. PPC valve
Travel PPC valve
Center swivel joint

10-10

PC130-7

STRUCTURE AND FUNCTION

PC130-7

HYDRAULIC COMPONENT LAYOUT

10-11

STRUCTURE AND FUNCTION

VALVE CONTROL

VALVE CONTROL

10-12

PC130-7

STRUCTURE AND FUNCTION

VALVE CONTROL

1. R.H. work equipment PPC valve


2. R.H. work equipment control lever
(for boom and bucket operation)
3. Main pump
4. Control valve
5. 4-spool solenoid valve
6. L.H. work equipment control lever
(for arm, swing operation)
7. L.H. work equipment PPC valve
8. Safety lock lever
9. L.H. travel pedal
10. R.H. travel pedal
11. L.H. travel lever
12. R.H. travel lever
13. Travel PPC valve
14. Attachment PPC valve
(Attachment installable machine)
15. Attachment pedal
(Attachment installable machine)
Lever and Pedal Positions
(A) HOLD
(B) Boom LOWER
(C) Boom RAISE
(D) Bucket CURL
(E) Bucket DUMP
(F) HOLD
(G) Arm OUT
(H) Arm IN
(J) Swing LEFT
(K) Swing RIGHT
(L) L.H. travel FORWARD
(M) L.H. travel REVERSE
(N) R.H. travel FORWARD
(P) R.H. travel REVERSE
(Q) PPC FREE
(R) PPC LOCK

PC130-7

10-13

STRUCTURE AND FUNCTION

HYDRAULIC TANK AND FILTER

HYDRAULIC TANK AND FILTER

1.
2.
3.
4.
5.
6.
7.
8.
9.
10.

Hydraulic tank
Drain plug
Oil filler cap
Pressure valve
Vacuum valve
Sight gauge
Suction strainer
Filter element
Bypass strainer
Bypass valve

10-14

SPECIFICATION
Tank capacity : 130 l
Hydraulic oil amount in tank : 90 l
Pressure valve cracking pressure :
16.7 6.9 kPa {0.17 0.07 kg/cm2}
Vacuum valve cracking pressure :
-0.49 0 kPa {-0.005 0 kg/cm2}
Bypass valve set pressure :
103 29.4 kPa {1.05 0.2 kg/cm2}

PC130-7

STRUCTURE AND FUNCTION

HYDRAULIC PUMP

HYDRAULIC PUMP (PISTON PUMP)


MAIN PUMP
Type : HPV95 (for 105cc/rev.)

1.
2.
3.
4.
5.
6.

Main pump
LS valve
PC valve
Fixed choke valve
PC-EPC valve (for PC mode selection)
LS-EPC valve (for LS set selection)

PC130-7

IM
: PC mode change current
PA
: Main pump delivery
PB
: Main pump pressure input
PS
: Main pump absorption
PD1 : Case drain
PLS : Control valve LS pressure inlet
PEPC : EPC valve basic pressure inlet

10-15

STRUCTURE AND FUNCTION

1.
2.
3.
4.
5.
6.
7.

Shaft
Cradle
Case
Rocker cam
Shoe
Piston
Cylinder block

10-16

HYDRAULIC PUMP

8.
9.
10.
11.
12.
13.

Valve plate
End cap
Spring
Servo last chance filter
Servo piston
Slider

PC130-7

STRUCTURE AND FUNCTION

HYDRAULIC PUMP

FUNCTION
This pump converts engine rotation and torque
transmitted to the pump shaft into hydraulic
energy and discharges pressurized oil according
to load.
This pump can change delivery when the swash
plate angle is changed.

STRUCTURE
Cylinder block (7) is supported to shaft (1) with
spline a, and shaft (1) is supported with the front
and rear bearings.
Shoe (5) is punched to the tip of piston (6) with a
concave ball so that piston (6) and shoe (5) form
a spherical bearing.
Shoe (5) is always pressed to plane A of rocker
cam (4) and slides in a circle.
Rocker cam (4) leads highly pressurized oil
together with cylindrical plane B with cradle (2)
fixed to the case, forms a static pressure bearing
and slides.
Piston (6) moves in the axial direction relatively
in each cylinder of cylinder block (7).
Cylinder block (7) rotates relatively while sealing
pressurized oil against valve plate (8), and the
plane is designed to balance the oil pressure
properly.
Oil in each cylinder of cylinder block (7) is
absorbed and discharged through valve plate
(8).
PC130-7

10-17
(3)

STRUCTURE AND FUNCTION

HYDRAULIC PUMP

OPERATION
1. Pump Operation
Shaft (1) rotates together with cylinder block (7),
and shoe (5) slides on plate A. When rocker
arm (4) moves along cylindrical plane B, the
inclination
to centerline X of rocker cam (4)
and the axial direction of cylinder block (7)
changes. Inclination
is called "swash plate
angle."

When the swash plate angle of center line X of


rocker cam (4) is
to the axial direction of cylinder block (7), plane A works like the cam against
shoe (5).
Therefore, piston (6) slides inside cylinder block
(7), and the capacities E and F of cylinder block
(7) come to change differently. Then, the pump
absorbs and discharges the difference E-F.
When the capacity in E chamber contracts as
cylinder block (7) rotates, the pump discharges
oil during the process. On the other hand, when
the capacity in F chamber increases, the pump
absorbs oil during the process. (The figure
shows the end of the absorbing process in
Chamber F and the end of the discharging process in Chamber E.
When the centerline X of rocker cam (4) comes
to the axial direction of cylinder block (7) (when
the swash plate angle is 0), the difference
between capacities E and F in cylinder block (7)
comes to 0. And the pump comes to stop
absorbing or discharging oil, i.e., the pump
stops. (However, the swash plate angle never
comes to 0 practically.)
In other words, swash plate angle
and the
pump delivery are in the proportional relations.

10-18
(3)

PC130-7

STRUCTURE AND FUNCTION

HYDRAULIC PUMP

2. Delivery Control
When swash plate angle
increases, the difference between capacities E and F becomes
larger and delivery Q increases. Servo piston
(12) changes the swash plate angle .
The servo piston moves in the direction of
straight reciprocation according to signal pressures of the PC and LS valves. This straight
motion is transmitted to rocker arm (4) through
slider (13), and rocker cam (4), which is supported with the cylindrical plane to cradle (2),
slides in the direction of rotation.

Servo piston's (12) area receiving the pressure is


different on the right and left sides, and the discharge (self) pressure PP from the main pump is
always led to the pressure chamber of the small
diameter piston.
The output pressure Pen of the LS valve is led to
the pressure chamber of the large diameter piston.
Motions of the servo piston are controlled
according to the relations between the small
diameter piston pressure PP and the large diameter piston pressure Pen and the rate of area
receiving pressure of the small diameter piston
to that of the large diameter piston.

PC130-7

10-19
(3)

STRUCTURE AND FUNCTION

HYDRAULIC PUMP

LS AND PC VALVE
LS valve

1.
2.
3.
4.
5.
6.
7.
8.
9.
10.

Sleeve
Piston
Spool
Seat
Plug
Spring
Sleeve
Nut
O-ring
Nut

PA : Pump pressure inlet


PB : Pump pressure inlet
PDP : Drain
PLP : Control pressure outlet
PLS : Over load pressure inlet
PPL : Control pressure intle
PSIG : LS mode switching pressure inlet

PC Valve

1.
2.
3.
4.
5.
6.
7.
8.
9.

Piston
Spring
Seat
Spring
Seat
Spool
Piston
Sleeve
Lock nut

10-20

10. Plug
11. Lock nut
PA
PA2
PD
PM
PPL

: Pump discharge pressure inlet


: Pump discharge pressure inlet
: Drain pressure outlet
: PC mode switching pressure inlet
: PC valve signal pressure outlet

PC130-7

STRUCTURE AND FUNCTION

HYDRAULIC PUMP

FIXED THROTTLE VALVE

1. Plug
2. Plug
PA
: Drain pressure outlet
POUT : Control pressure outlet
PIN : LS valve signal pressure inlet

PC130-7

10-21

STRUCTURE AND FUNCTION

HYDRAULIC PUMP

FUNCTION
1. LS Valve
The LS valve detects loads and controls delivery.
This valve controls main pump delivery Q with
differential pressure PLS (PP PLS) [that is
called LS Differential Pressure] between the
main pump pressure PP and control valve outlet
pressure PLS.
This valve is applied with main pump pressure
PP, pressure PLS that is obtained from the control valve output [that is called LS Pressure] and
pressure PSIG from the LS-EPC valve [that is
called LS Selection Pressure].
The relations of differential pressure PLS (=
PP PLS) between main pump pressure PP and
LS pressure PLS with delivery Q vary with the
LS selection current ISIG of the LS-EPC valve as
shown in the right figure.
As ISIG changes from 0 to 1A, the spring set
force changes accordingly, and the selector point
for pump discharge amount changes from 0.64
to 2.1 MPa {6.5 to 21.5 kg/cm2} at the standard
median.
2. PC Valve
When pump discharge pressure PP rises, the
control valve spool stroke will increase and the
opening area will enlarge. So, the PC valve controls pump delivery Q so that delivery Q does not
increase above a certain level depending on discharge pressure PP.
The valve also controls the pump absorbing
hydraulic horsepower to approximately equal
horsepower so that the pump absorbing horsepower does not exceed the engine horsepower.
This means that, when a load to the actuator
increases during operation and pump discharge
pressure PP rises, this valve will reduce pump
delivery Q, or when pump discharge pressure
PP drops, this valve will increase delivery Q.
In this case, the relations between pump discharge pressure PP and pump delivery Q
change as shown in the right figure since the current value given to the PC-EPC valve solenoid is
regarded as a parameter.
However, some PC valves have the function to
sense actual engine speeds in the heavy-duty
operation mode and to reduce pump delivery
and recover speed when the speed reduces due
to increase of load.
In other words, when an increase of load
reduces engine speed below the set value, the
command current from the controller to the PCEPC valve solenoid will increase as engine
speed reduces and will reduce the pump swash
plate angle.

10-22
(3)

PC130-7

STRUCTURE AND FUNCTION

HYDRAULIC PUMP

OPERATION

1. LS Valve
1) When the control valve is at the center
value position
The LS valve is a 3-way selector valve, and
the pressure PLS (LS pressure) from the
control valve inlet is being led to spring
chamber B and pump discharge pressure PP
is being led to the H port of sleeve (8).
Spool (6) position is determined depending
on the force of LS pressure PLS + the force
of spring (4) Z and force of the pump discharge pressure (self-pressure) PP.

PC130-7

10-23
(3)

STRUCTURE AND FUNCTION

Before the engine starts, servo piston (12) is


pressed to the right side. (See the right figure.)
If the control lever is at the "center value"
position when the engine starts, LS pressure
PLS will be 0 MPa (0 kg/cm2). (The LS valve
interconnects to the drain circuit through the
control valve spool.)
At the time, spool (6) is pressed to the left
side and C port is connected to D port. The
pump discharge pressure enters from K port
to the piston large diameter side and from J
port to the piston small diameter side respectively. So, the area difference of servo piston (12) minimizes the swash plate angle.

10-24
(3)

HYDRAULIC PUMP

PC130-7

STRUCTURE AND FUNCTION

2) Operation in direction for maximum pump


delivery
When the LS differential pressure
PLS
between pump discharge pressure PP and
LS pressure PLS reduces (when the control
valve is large and discharge pressure PP
drops, for example), the combined force of
LS pressure PLS and spring (4) pushes
spool (6) to the right side.
When spool (6) moves, port D is connected
to port E to bring the PC valve in line. At the
time, the PC valve is connected to the drain
port, and circuit D K is applied with drain
pressure PT. (The operation of the PC valve
will be explained later.)

PC130-7

HYDRAULIC PUMP

Therefore, pressure on the piston large


diameter side of servo piston (12) comes to
drain pressure PT, and since the pump discharge pressure PP is applied to port J on
the small diameter side, servo piston (12) is
pushed to the right side and the swash plate
is moved to the delivery increasing direction.
When port G is applied with the output pressure of the EPC valve for the LS valve, piston (7) is pushed to the left side.
This is effective to reduce spring (4) set
force, and the differential pressure between
oil pressure PP when ports D and E of spool
(6) are connected and PP changes.

10-25
(3)

STRUCTURE AND FUNCTION

3) Operation in direction for minimum pump


delivery
The following explains movement of servo
piston (12) to the left side (in the direction for
minimum pump delivery). When LS differential pressure PLS increases (when the control valve opening area becomes small and
pump discharge pressure PP increases, for
example), the force of discharge pressure
PP pushes the spool (6) to the left side.
As spool (6) moves, pump discharge pressure PP flows from port C to port D and
comes from port K to the piston large diameter side.

10-26
(3)

HYDRAULIC PUMP

Though pump discharge pressure PP comes


to port J of the piston small diameter side,
servo piston (12) is pushed to the left side
due to the area difference between the piston large diameter side and the piston small
diameter side of servo piston (12) and the
swash plate is moved in the delivery reducing direction.
When port G is applied with the LS selection
pressure, it is effective to reduce spring (4)
set force.

PC130-7

STRUCTURE AND FUNCTION

4) When the servo piston balances


The area receiving pressure on the piston
large diameter side is supposed to be A1,
the one on the small diameter side is supposed to be A0 and pressure flowing to the
piston large diameter side is supposed to be
PEN.
When pump discharge pressure PP of the
LS valve balances with the combined force
of LS pressure PLS and spring (4) force Z
and the relations of A0 x PP = A1 x PEN are
satisfied, servo piston (12) stops at the position and the swash plate is held at the intermediate position (stops where the opening
from port D to port E of spool (6) is almost
equal to the one from port C to port D).

PC130-7

HYDRAULIC PUMP

At the time, the relations of areas receiving


pressure on both ends of servo piston (12)
are A0 : A1 = 1 : 1.75, and the ones of pressures applied on the piston both ends at the
balancing time are PP : PEN = 1.75 : 1
approximately.
Spring (4) force has been adjusted so that
the balance stop position of spool (6) is
determined when PP PLS = 2.21 MPa
{22.5 kg/cm 2 } is satisfied at the standard
center.
When port G is applied with PSIG (EPC
valve output pressure for LS valve of 0 2.9
MPa {10 30 kg/cm 2 }), however, the balance stop position changes proportionally to
the PSIG pressure in the range of PP PLS
from 2.1 to 0.6 MPa {21.5 to 6.5 kg/cm2}.

10-27
(3)

STRUCTURE AND FUNCTION

2. PC Valve
(1) When the pump controller is normal, the
load to the actuator is small and the pump
discharge pressure PP is low
1) Function of PC-EPC Valve Solenoid
(1)
The pump controller provides a command current to PC-EPC valve solenoid
(1). This command current actuates the
PC-EPC valve and outputs a signal pressure. When receiving the signal pressure, the PC valve changes the force
given to piston (2).
Spool (3) stops where the force to piston
(2) balances with the combined force of
spring setting force of springs (4) and (6)
on the opposite side and the force given
to spool (3) by the pump discharge pressure PP.

10-28
(3)

HYDRAULIC PUMP

And pressure output from the PC valve


(the pressure at C port) varies with the
spool position.
The value of command current X is
determined depending on type of work
(lever control), selection of working
mode, set point of engine speed and
actual speed.

PC130-7

STRUCTURE AND FUNCTION

2) Function of Spring
The loads to springs (4) and (6) of the PC
valve are determined depending on
swash plate position.
As servo piston (9) moves, piston (7)
connected to slider (8) moves to the right
or the left.
When piston (7) moves to the left, spring
(6) will be contracted. If the piston
moves further to the left, the spring will
be brought to seat (5) and be fixed there.
Thereafter, spring (4) will only move.
This means that the spring load changes
as piston (7) extends or contracts springs
(4) and (6).

PC130-7

HYDRAULIC PUMP

Also, since the pressing force of piston


(2) changes as the command current
input to the PC-EPC valve solenoid (1)
changes, the load to springs (4) and (6)
changes depending on the value of the
command current.
The C port of the PC valve is connected
to the E port of the LS valve. The self
pressure PP is provided to A port, the
small diameter side of servo piston (9)
and B port.

10-29
(3)

STRUCTURE AND FUNCTION

10-30
(3)

HYDRAULIC PUMP

When the pump discharge pressure PP


is small, the spool is located at a position
in the left direction. At the time, C port is
connected to D port, and pressure to the
LS valve becomes drain pressure PT. If
E port of the LS valve is connected to G
port at the time, the pressure from J port
to the large diameter side of the piston
will become drain pressure PT. And the
servo piston will moves to the right side.
Then, the pump delivery will increase.
Also, as servo piston (9) operates, slider
(8) moves piston (7) to the right side, and
the spring force becomes weak because
springs (4) and (6) expand. As the
spring force becomes weak, spool (3)
moves to the right side to disconnect C
port from D port. Then, the pump discharge pressure ports B and C are connected.
As a result, pressure at the C port rises
and pressure on the large diameter side
of the piston rises as well, and servo piston (9) stops moving to the right side.
This means that the stop position of
servo piston (9) (= pump delivery) is
determined where the pressing force
caused pressure PP to spool (3), the
pressing force of the PC-EPC valve solenoid and the forces of the springs (4) and
(6) balance with each other.

PC130-7

STRUCTURE AND FUNCTION

(2) When the pump controller is normal, the


load to actuator is large and the pump
discharge pressure PP is high
When the load is large and the pump discharge pressure is high, the force pushing
spool (3) to the left side increases and spool
(3) comes to the position shown in the above
figure.
Then, the pressure flowing from C port to the
LS valve becomes about 3/5 of the pump discharge pressure PP because the pressure
from A port partly flows from C port to D port
through the LS valve as shown in the above
figure.

PC130-7

HYDRAULIC PUMP

When E port of the LS valve is connected to


G port, this pressure is led from J port to the
large diameter side of the servo piston (9)
and the servo piston comes to stop.
When the pump discharge pressure PP
increase and spool (3) moves further to the
left side, discharge pressure PP will flow to C
port so as to minimize the pump delivery.

10-31
(3)

STRUCTURE AND FUNCTION

When servo piston (9) moves to the left side,


piston (7) will move to the left.
Then, springs (4) and (6) will be compressed
and will push spool (3) back. If piston (7)
moves further to the left, ports C and D will
open wide.
As a result, the pressure at port C (= J) will
drop, and servo piston (9) will move to the
left and will stop.
At the time, servo piston (9) is located further
to the left than where it is when pump discharge pressure PP is low.

The positional relations between pump discharge pressure PP and servo piston (9) are
shown by a broken line because springs (4)
and (6) are 2-stage ones. And the relations
between discharge pressure PP and pump
delivery Q are as shown in the right figure.

Also, when the command current X to the


PC-EPC valve solenoid increases, the relations between the pump discharge pressure
PP and the pump delivery Q will move in parallel in relation to the pushing force of the
PC-EPC valve solenoid. Therefore, the force
of the PC-EPC valve solenoid (1) will be
added to the leftward pressing force of the
discharge pressure PP to the spool (3), and
the relations between PP and Q will move
from
to
as X increases.

10-32
(3)

HYDRAULIC PUMP

PC130-7

STRUCTURE AND FUNCTION

3) When the pump controller is out of order


and the PC redundant switch is set to ON
1) In case of light load to main pump
When the pump controller is out of order,
set the PC redundant switch to ON to
change the circuit to the resistor side. In
this case, since the current is too large
when power is directly taken from the
battery, the resistor is connected to control the current to the PC-EPC valve solenoid.
At the time, the current becomes constant and piston (2) pressing force
becomes constant as well.

PC130-7

HYDRAULIC PUMP

When the pump discharge pressure is


low, the combined force of the force of
PC-EPC valve solenoid (1) and discharge pressure PP is smaller than the
spring set force. So, spool (3) balances
at a position in the left side.
At the time, C port has the same pressure as the drain pressure at D port, and
the drain pressure PT is led to the large
diameter side of servo piston (9) through
the LS valve.
Then, servo piston (9)
moves in the diction where delivery
increases because the pressure on the
small diameter side of the piston is large.

10-33
(3)

STRUCTURE AND FUNCTION

HYDRAULIC PUMP

2) In case of heavy load to main pump


When the PC redundant switch is set to
ON just like in the previous paragraph, a
constant command current is sent to PCEPC valve solenoid (1). So, piston (2)
pushes spool (3) with a constant force.
When pump discharge pressure PP
rises, the spool will moves further to the
left side than when the main pump is
lightly loaded and will balance at the
position shown in the above figure.
In this case, since the pressure from A
port is led to C port, servo piston (9) will
move to the left side (small delivery) and
will stop at a position further to the left
than when the pump is lightly loaded.

10-34
(3)

PC130-7

STRUCTURE AND FUNCTION

PC130-7

HYDRAULIC PUMP

This means that the current, which is


sent to the PC-EPC valve solenoid
through the resistor when the PC redundant switch is set to On, determines the
curve between pump discharge pressure
PP and delivery Q as shown in the figure.
When the PC redundant switch is set to
ON, curve
is further to the left than
curve
drawn when the pump controller is normal.

10-35
(3)

STRUCTURE AND FUNCTION

CONTROL VALVE

CONTROL VALVE
OUTLINE
The following are 3 types of control valves.
6-spool valve (without service valve)
7-spool valve (with service valve)
8-spool valve (with 2 service valve)
a Each service valve is a single add-on type, so it
is possible to add or remove the extra valve at
any time.
External apperance and cross sections shown are
for the 7 spool valve only.
AA

: Pressure sensor port


(pressure sensor is intalled)
A1 : To swing motor MB
A2 : To L.H. travel motor A
A3 : To R.H. travel motor A
A4 : To boom cylinder bottom
A5 : To arm cylinder head
A6 : To bucket cylinder head
A7 : To attachment 1
B1 : To swing motor MA
B2 : To L.H. travel motor B
B3 : To R.H. travel motor B
B4 : To boom cylinder head
B5 : To arm cylinder bottom
B6 : To bucket cylinder bottom
B7 : To attachment 1
BP : From boom RAISE PPC/EPC valve
LS : To pump LS valve
PA1 : From swing L.H. PPC/EPC valve
PA2 : From L.H. travel forward PPC valve
PA3 : From R.H. travel reverse PPC valve
PA4 : From boom RAISE PPC/EPC valve
PA5 : From arm OUT PPC/EPC valve
PA6 : From bucket DUMP PPC/EPC valve
PA7 : From service 1 PPC valve
PB1 : From swing R.H. PPC/EPC valve
PB2 : From L.H. travel reverse PPC valve
PB3 : From R.H. travel forward PPC valve
PB4 : From boom LOWER PPC/EPC valve
PB5 : From arm IN PPC/EPC valve
PB6 : From bucket CURL PPC/EPC valve
PB7 : From service 1 PPC valve
P
: From main pump
PP : To main pump
PX : From 2-stage relief solenoid valve
SA : From swing stroke control solenoid valve
SB : From swing stroke control solenoid valve
TS1 : To tank
TS2 : To tank
TB : To tank
TC : To oil cooler
TSW : To swing motor

10-36
(3)

1. Swing bleed valve


2. Travel junction valve
3. Arm rcheck valve
4. Cover
5. Service valve
6. Bucket valve
7. Arm valve
8. Boom valve
9. R.H. travel valve
10. L.H. travel valve
11. Swing valve
12. PT port block
13. Boom lock valve

PC130-7

STRUCTURE AND FUNCTION

CONTROL VALVE

7 spool valve
(6 spool valve + service valve)

PC130-7

10-37
(3)

STRUCTURE AND FUNCTION

CONTROL VALVE

CROSS-SECTIONAL DRAWING
a Cross-sectional drawing shows 7-spool valve (6-spool + service valve).
(1/8)

1.
2.
3.
4.
5.
6.
7.

Safety-suction valve
Suction valve (L.H. travel A)
Suction valve (R.H. travel A)
Suction valve (Boom bottom)
Suction valve (Arm head)
Suction valve (Bucket head)
Safety-suction valve mount (service A)

10-38
(3)

8 Safety-suction valve mount (service B)


9. Suction valve (Bucket bottom)
10. Suction valve (Arm bottom)
11. Suction valve (Boom head)
12. Suction valve (R.H. travel B)
13. Suction valve (L.H. travel B)
14. Lift check valve

PC130-7

STRUCTURE AND FUNCTION

CONTROL VALVE

(2/8)

1.
2.
3.
4.
5.
6.
7.
8.

Main relief valve


Spool (swing)
Spool (L.H. travel)
Spool (R.H. ravel)
Spool (boom)
Spool (arm)
Spool (bucket)
Spool (service)

PC130-7

10-39

STRUCTURE AND FUNCTION

CONTROL VALVE

(3/8)

1.
2.
3.
4.
5.
6.
7.
8.

Pressure compensation valve F (swing)


Pressure compensation valve F (L.H. travel)
Pressure compensation valve F (R.H. travel)
Pressure compensation valve F (boom)
Pressure compensation valve F (arm)
Pressure compensation valve F (bucket)
Pressure compensation valve F (service)
Unload valve

10-40
(3)

9.
10.
11.
12.
13.
14.
15.

Pressure compensation valve R (service)


Pressure compensation valve R (bucket)
Pressure compensation valve R (arm)
Pressure compensation valve R (boom)
Pressure compensation valve R (R.H. travel)
Pressure compensation valve R (L.H. travel)
Pressure compensation valve R (swing)

a The above F and R means the following valves :


F : Flow control valve
R : Pressure reducing valve

PC130-7

STRUCTURE AND FUNCTION

CONTROL VALVE

(4/8)

1.
2.
3.
4.
5.
6.

LS pressure detection plug


LS bypass plug
Pump pressure detection plug
Check valve (bucket head)
Check valve (arm head)
LS selection valve

PC130-7

10-41
(3)

STRUCTURE AND FUNCTION

CONTROL VALVE

(5/8)

1.
2.
3.
4.
5.
6.

Main relief valve


Cooler bypass valve
Lift check valve
LS selection valve
Spool (swing)
Pressure compensation valve R

10-42
(3)

7. Swing bleed valve


8. Pressure compensation valve F
F : Flow control valve
R : Pressure reducing valve

PC130-7

STRUCTURE AND FUNCTION

CONTROL VALVE

(6/8)

1.
2.
3.
4.
5.
6.
7.

Suction valve (A)


Suction valve (B)
Spool (L.H. travel)
Pressure compensation valve R
Travel junction valve
Pressure compensation valve F
Suction valve (A)

PC130-7

8.
9.
10.
11.

Suction valve (B)


Spool (R.H. travel)
Pressure compensation valve R
Pressure compensation valve F

F : Flow control valve


R : Pressure reducing valve

10-43

STRUCTURE AND FUNCTION

CONTROL VALVE

(7/8)

1.
2.
3.
4.
5.
6.
7.
8.

Suction valve (A)


Boom lock valve
Suction valve (B)
Spool
Pressure compensation valve R
Pressure compensation valve F
Suction valve (A)
Suction valve (B)

10-44
(3)

9.
10.
11.
12.

Spool
Pressure compensation valve R
Arm regemeration valve
Pressure compensation valve F

F : Flow control valve


R : Pressure reducing valve

PC130-7

STRUCTURE AND FUNCTION

CONTROL VALVE

(8/8)

1.
2.
3.
4.
5.
6.
7.
8.

Suction valve (A)


Suction valve (B)
Spool
Pressure compensation valve R
Pressure compensation valve F
Safty-suction valve mount (A)
Safty-suction valve mount (B)
Spool

PC130-7

9.
10.
11.
12.

Pressure compensation valve R


Pressure compensation valve F
Pressure relief plug
Unload valve

F : Flow control valve


R : Pressure reducing valve

10-45
(3)

STRUCTURE AND FUNCTION

SUCTION SAFETY VALVE

SUCTION SAFETY VALVE


(SAFETY VALVE WITH SUCTION FOR SERVICE PORT)
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.

Suction valve
Main valve
Piston
Piston spring
Poppet
Poppet spring
Suction valve
Sleeve
Adjustment screw
Lock nut

SPECIFICATION
Part No. (Reference)

Set pressure

Use

709-70-74600

24.5 MPa {250 kg/cm2}


(at the time of 5l/min.)

For crusher

709-70-74700

17.2 MPa {175 kg/cm2}


(at the time of 5l/min.)

10-46

PC130-7

STRUCTURE AND FUNCTION

CLSS

CLSS
OUTLINE OF CLSS
Features
CLSS stands for Closed Center Load Sensing System and is featured as follows :
Fine controllability without affect of load
Controllability that allows digging even in the fine
control mode.
Ease of compound operation in which the flow
distribution performance depends on spool
opening area during compound operation.
Saving of energy by variable pump control

PC130-7

Configuration
The CLSS consists of a variable displacement
piston pump, a control valve and actuators.
The pump body consists of a main pump, a PC
valve and an LS valve.

10-47

STRUCTURE AND FUNCTION

CLSS

Basic principle
1. Control of pump swash plate angle
The pump swash plate angle (pump delivery) is
controlled so that the LS differential pressure
PLS, which is the difference between the pump
discharge pressure PP and the LS pressure PLS
(actuator load pressure) at the control valve outlet, becomes constant.
(LS differential pressure PLS = Pump pressure
PP - LS pressure PLS)

When the LS differential pressure PLS reduces


below the set pressure of the LS valve (when the
actuator load pressure is high), the pump swash
plate angle will move in the direction of maximum. When the set pressure is raised (when the
actuator load pressure is low), the pump swash
plate angle will move in the direction of minimum.
a For the detail of the operation, see the paragraph
of "Hydraulic Pump."

10-48

PC130-7

STRUCTURE AND FUNCTION

CLSS

2. Pressure compensation control


A valve (pressure compensation valve) is
mounted on the outlet side of the control valve.
In case of compound operation of the actuator
with this valve, the differential pressure
P
between the spool upstream (inlet) and the
downstream (outlet) of each valve becomes constant irrespective of load (pressure). So, the flow
from the pump is distributed (compensated) in
proportion to the opening areas S1 and S2 of
each valve being operated.

PC130-7

10-49

STRUCTURE AND FUNCTION

CLSS

EACH FUNCTION AND OPERATION OF EACH VALVE


Hydraulic circuit diagram and valve names

10-50
(3)

PC130-7

STRUCTURE AND FUNCTION

CLSS

1. Unload valve
Set pressure : 3.38 MPa {34.5 kg/cm2}
2. Safety-suction valve
Set pressure : 35.8 MPa {365 kg/cm2}
3. Pressure compensation valve
4. Suction valve
5. Main relief valve
Set pressure : normal: 31.9 MPa {325 kg/cm2}
High pressure : 34.8 MPa {355 kg/cm2}
6. Lift check valve
7. Cooler bypass valve
8. LS selection valve
9. Swing bleeding valve
10. Travel junction valve
11. Arm regeneration valve
12. Boom lock valve

PC130-7

10-51
(3)

STRUCTURE AND FUNCTION

CLSS

UNLOAD VALVE
1. When the control valve is neutral
FUNCTION
When the control valve is neutral, the delivery Q
equivalent to the pump minimum swash plate
angle is released to the tank circuit. At the time,
pump discharge pressure PP is set to 2.45 MPa
{25.0kg/cm2} with spring (3) inside the vale. (The
LS pressure PLS is 0 MPa {0kg/cm2}.)

OPERATION
Pump discharge pressure PP is applied to the
left end face of spool (4) and LS pressure PLS is
applied to the right end face.
Since the LS pressure PLS is 0 when the control
valve is neutral, pump discharge pressure PP is
only applied and is set with the lead to spring (3).
When pump discharge pressure PP rises to
spring (3) load (2.45 MPa {25.0 kg/cm2}), spool
(4) will move toward the right side and pump circuit PP will interconnect to tank circuit T through
the drill hole.
Therefore, pump discharge pressure PP is set to
2.45 MPa {25.0 kg/cm2}.

10-52
(3)

1.
2.
3.
4.

Unload valve
Sleeve
Spring
Spool

PLS : LS circuit (pressure)


PP : Pump circuit (pressure)
T
: Tank circuit

PC130-7

STRUCTURE AND FUNCTION

CLSS

When the differential pressure between discharge pressure PP and LS pressure PLS
comes to spring (3) load (2.45 MPa {25.0 kg/
cm2}), the unload valve will open and LS differential pressure PLS will come to 2.45 MPa
{25.0 kg/cm2}.

2. When the control valve is in the fine control


mode
FUNCTION
When the control valve is in the fine control
mode and the requested flow of the actuator is
less than the pump minimum swash plate angle,
pump discharge pressure PP is set to LS pressure PLS + 2.45 MPa {25.0 kg/cm2}.

OPERATION
When the control valve is operated in the fine
control mode, LS pressure PLS will occur and
will be applied to the right end face of spool (4).
At the time differential pressure between LS
pressure PLS and pump discharge pressure PP
increases because the opening area of the control valve spool is small.
When the differential pressure between pump
discharge pressure PP and LS pressure PLS
comes to spring (3) load (2.45 MPa {25.0 kg/
cm2}), spool (4) will move to the right side and
pump circuit PP will interconnect to tank circuit T.
This means that pump discharge pressure PP is
set to the spring force (2.45 MPa {25.0 kg/cm2} +
LS pressure PLS, and LS differential pressure
PLS comes to 2.45 MPa {25.0 kg/cm2}.

PC130-7

1.
2.
3.
4.

Unload valve
Sleeve
Spring
Spool

PLS : LS circuit (pressure)


PP : Pump circuit (pressure)
T
: Tank circuit

10-53
(3)

STRUCTURE AND FUNCTION

CLSS

3. When the control valve is operated


FUNCTION
If the required flow of the actuator increases over
the pump minimum swash plate angle when the
control valve is operated, the flow to tank circuit
T will be interrupted and pump delivery Q will be
completely flown to the actuator circuit.

OPERATION
When the control valve is operated with large
stroke, LS pressure PLS will occur and will be
applied to the right end face of spool (4). At the
time, the opening areas of the control valve
spool is large and the difference between LS
pressure PLS and pump discharge pressure PP
is small.
So, the differential pressure between pump discharge pressure PP and LS pressure PLS does
not reach spring (3) load (2.45 MPa {25.0 kg/
cm2}) and spring (3) pushes spool (4) to the left
side.
Then, pump circuit PP and tank circuit T are
interrupted, and pump delivery Q is completely
flown to the actuator circuit.

10-54
(3)

1.
2.
3.
4.

Unload valve
Sleeve
Spring
Spool

PLS : LS circuit (pressure)


PP : Pump circuit (pressure)
T
: Tank circuit

PC130-7

STRUCTURE AND FUNCTION

CLSS

LEADING OF LS PRESSURE
FUNCTION
The LS pressure is load pressure to the actuator
on the outlet side of the control valve.
In case of a work equipment valve, pressure
reducing valve (3) of the pressure compensation
valve reduces pump discharge pressure PP to
the same level as actuator circuit pressure A and
leads the pressure to LS circuit PLS.

Also, orifice C is mounted on piston (5) halfway


from pump circuit PP to pressure reducing valve
(3), and the orifice has the damper function.
The travel valves leads actuator circuit pressure
A directly to LS circuit PLS.

1. Work equipment valve (boom, arm, bucket, swing)

OPERATION
When spool (1) is operated, pump discharge
pressure PP will be led to actuator circuit A
through bridge passage b from flow control valve
(2) and spool notch a.
Since pressure reducing valve (3) moves to the
right at the same time, pump discharge pressure
PP led from orifice c is reduced due to pressure
loss at notch d and is led to LS circuit PLS and to
spring chamber PLS1.
At the time, LS circuit PLS is connected to tank
circuit T from LS bypass plug (4).

PC130-7

Both end face areas of pressure reducing valve


(3) are the same (SA = SLS), and actuator circuit
pressure PA (= A) is applied to the SA side and
reduced pump discharge pressure PP is applied
to the SLS side on the opposite side.
Therefore, pressure reducing valve (3) balances
at the position where actuator circuit pressure
PA becomes equal to the pressure of spring
chamber PLS1. The pump discharge pressure
PP reduced at notch d comes to actuator circuit
pressure A and is led to the LS circuit PLS.

10-55
(3)

STRUCTURE AND FUNCTION

CLSS

2. Travel valve

OPERATION
When spool (1) is operated, the pump discharge
pressure PP will be led to actuator circuit A
through bridge passage b from flow control valve
(2) and spool notch a.
At the same time, the actuator circuit pressure
PA moves pressure reducing valve (3) to the
right side, and notches c and d interconnect to
the travel junction circuit e and LS circuit PLS
respectively.
So, actuator circuit pressure PA (= A) is led from
notch c to LS circuit PLS through notch d.
a The travel circuit is different from the work equipment circuit, actuator circuit pressure PA is
directly led to the LS circuit PLS.

10-56
(3)

PC130-7

STRUCTURE AND FUNCTION

CLSS

LS BYPASS PLUG
FUNCTION
This plug released residual pressure of the LS
pressure PLS.
This plug slows the rising speed of the LS pressure PLS, causes pressure losses at the spool
and the throttle of the shuttle valve by the discarded throttled flow and reduces the effective
LS differential pressure for higher safety.

OPERATION
Pressurized oil in the LS circuit PLS flows from
clearance filter a in the space between LS
bypass plug (1) and the valve body to tank circuit
T through orifice b.

PC130-7

1. LS bypass plug
PLS : LS circuit (pressure)
T
: Tank circuit (pressure)

10-57
(3)

STRUCTURE AND FUNCTION

CLSS

PRESSURE COMPENSATION VALVE


FUNCTION
When the load pressure becomes lower than
another actuator and the flow is going to
increase during a compound operation, this
valve compensates the load pressure. (At the
time, the load pressure of another actuator under
compound operation (the upper side) is higher
than that of the actuator on this side (the lower
side).

10-58

PC130-7

STRUCTURE AND FUNCTION

CLSS

OPERATION
When the load pressure of another actuator side
(the upper side) rises during a compound operation, the flow in actuator circuit A on this side (the
lower side) is apt to increase.
In this case, LS pressure PLS of another actuator is applied to spring chamber PLS1 and
pushes pressure reducing valve (1) and flow
control valve (2) to the left side.
Flow control valve (2) throttles the opening area
between pump circuit PP and spool upstream
PPA and causes a pressure loss between PP
and PPA.
Flow control valve (2) and pressure reducing
valve (1) balance each other where the pressure
difference between PA applied to both end faces
of pressure reducing valve (1) and PLS becomes
the same as the pressure loss between PP
before and after the flow control valve and PPA.
So, the pressure differences between upstream
pressures PPA and downstream pressures PA of
both spools under compound operation become
the same, and the pump flow is distributed in
proportion to the opening area of each spool
notch a.

PC130-7

10-59
(3)

STRUCTURE AND FUNCTION

CLSS

AREA RATIO OF PRESSURE COMPENSATION VALVE


FUNCTION
The pressure compensation valve slightly adjust the ratio (S2/S1) of area S1 on the left side of flow control
valve (2) and area S2 on the right side of pressure reducing valve (1) to suite the characteristics of each
actuator and determines the compensation characteristics.
S1 : Area of flow control valve (2) - area of piston (3)
S2 : Area of pressure reducing valve (1) - area of piston (3)

Area ratio (S1:S2) and compensation characteristics


When the ratio is 1.00 : The expression [Pump (discharge) pressure PP - Spool notch upstream pressure
PPB]
[LS circuit pressure PLS - Actuator circuit pressure PA (= A)] can be held,
and the flow is distributed as per the spool opening area ratio.
When the ratio is more than 1.00 : The expression PP - PPB > PLS - PA (= A) can be held, and the flow is
distributed less than the spool opening area ratio.
When the ratio is less than 1.00 : The expression PP - PPB < PLS - PA (= A) can be held, and the flow is
distributed more than the spool opening area ratio.

10-60
(3)

PC130-7

STRUCTURE AND FUNCTION

BOOM HOLDING VALVE


FUNCTION
When the boom lever is not being operated, the oil at the boom bottom leaks from spool (1) and prevents
hydraulic drift of the boom.

OPERATION
1) At boom RAISE
When the control lever is operated to boom
RAISE, the main pressure from the control
valve pushes poppet (5) up.
As a result, the main pressure oil from the
control valve passes through the inside of
the valve and flows to the boom cylinder bottom.

PC130-7

10-60-1
(3)

STRUCTURE AND FUNCTION

CLSS

2) At boom HOLD
When the control lever has been operated
to boom RAISE and is then returned to the
HOLD position, the holding pressure at the
boom cylinder bottom end is closed by poppet (5). At the same time, the oil flowing
inside poppet (5) from orifice a in poppet (5)
is closed by pilot spool (3).
In this way, the boom is held in position.

10-60-2
(3)

PC130-7

STRUCTURE AND FUNCTION

CLSS

3) At boom LOWER
When the control lever is operated to boom
LOWER, pilot pressure P1 from the PPC
valve pushes pilot spool (3) and the pressure
oil in chamber b inside the poppet is drained.
The oil pressure at port Ab increases
because of the pressure oil from the boom
cylinder bottom, but the oil pressure in chamber b is lowered by orifice a.
If the pressure in chamber b becomes lower
than the pressure at port Aa, poppet (5)
opens and the pressure oil from port Ab
flows to port Aa and goes to the control
valve.

PC130-7

10-60-3
(3)

STRUCTURE AND FUNCTION

CLSS

BOOM REGENERATION CIRCUIT


FUNCTION
1) When the boom is being lowered, if bottom pressure A of cylinder (1) is higher than head pressure B,
and the boom is lowered under its own weight, this sends the return oil flow at the bottom end to the
head end to increase the cylinder speed by that amount.

OPERATION
If the boom is lowered under its own weight,
pressure A at the bottom end of boom cylinder
(1) becomes higher than pressure B at the head
end.
When this happens, part of the return oil at the
bottom end passes through regeneration passage a of boom spool (1), pushes check valve
(3) open, and flows to the head end.
As a result, the boom lowering speed is
increased.

10-60-4
(3)

PC130-7

STRUCTURE AND FUNCTION

CLSS

2) When lowering the boom, if head pressure B of cylinder (1) is greater than bottom pressure A, and the
work equipment is in the load process, check valve (3) closes and shuts off the circuit between the head
and bottom ends.

OPERATION
When the boom is lowered, if the work equipment is in the load process, pressure B at the
head end of cylinder (1) becomes higher than
pressure A at the bottom end.
When this happens, check valve (3) is closed by
spring (4) and pressure B at the head end, so
the circuit between the head circuit and bottom
circuit is shut off.

PC130-7

10-60-5
(3)

STRUCTURE AND FUNCTION

CLSS

ARM REGENERATION CIRCUIT


1. At arm in and own weight fall
FUNCTION
When the arm falls due to its own weight
because head pressure A in arm cylinder (1) is
higher than bottom pressure B during arm digging, this circuit brings the return flow on the
head side to the bottom side to increase the cylinder speed.

OPERATION
When the arm falls for digging due to its own
weight, the head side pressure A in arm cylinder
(1) will rise above bottom side pressure B.
At the time, part of the return flow on the head
side passes through regeneration passage a of
arm spool (2), pushes check valve (3) to open it
and flows to the bottom side.
This increases the arm digging speed.

PC130-7

1. Arm cylinder
2. Arm spool
3. Check valve
A : Head circuit (pressure)
B : Bottom circuit (pressure)
PP : Pump circuit (pressure)

10-61
(3)

STRUCTURE AND FUNCTION

CLSS

2. At arm in process
FUNCTION
When bottom pressure B of cylinder (1) rises
above head pressure A and the arm enters the
digging process, check valve (3) will be closed
and the circuits on the head side and the bottom
side will be interrupted.

OPERATION
When the arm is in the digging process, the bottom side pressure B of arm cylinder (1) will rise,
close check valve (3) and interrupt the circuits on
the head side and the bottom side.

10-62
(3)

1. Arm cylinder
2. Arm spool
3. Check valve
A : Head circuit (pressure)
B : Bottom circuit (pressure)
PP : Pump circuit (pressure)

PC130-7

STRUCTURE AND FUNCTION

CLSS

TRAVEL JUNCTION VALVE


(L.H. and R.H. travel junction circuit)
1. When traveling straight

10-64

PC130-7

STRUCTURE AND FUNCTION

CLSS

FUNCTION
When the L.H. and R.H. travel spool is operated
to compensate flow errors in the L.H. and R.H.
travel circuits during straight travel, the junction
circuit will open.
Then, the flows to the L.H. and R.H. travel
motors will become the same during the straight
travel, and travel deviation will decrease.
At the time of steering, load pressure difference
brings back the pressure reducing valve of the
travel valve inside the steering and closes the
spool notch opening of the travel junction valve
to close the junction circuit for steering.
OPERATION
When the L.H. and R.H. travel spool (1) is operated, the pump delivery will flow from the pump
circuit PP to A through the actuator circuit PA.
When traveling straight, the actuator circuit PA
will be equalized and the L.H. and R.H. pressure
reducing valves (2) will be pressed the same
stroke to the right. Then, the notch a and the
junction circuit will open.
The L.H. travel forward oil pressure P1 and the
R.H. travel forward oil pressure P2 are led to the
spring chamber on the both end of the travel
junction valve spool (4) through the respective
shuttle valves (5). So, P1 = P2, and the spool is
at the neutral position, and the notch d is open.
Then, the L.H. and R.H. travel actuator circuits
are interconnected with the junction circuit.
When any difference occurs in the flows to the
L.H and R.H. travel motors, this valve will compensate them and will reduce occurrence of
travel deviations.

PC130-7

10-65
(3)

STRUCTURE AND FUNCTION

CLSS

2. When operating travel steering

10-66

PC130-7

STRUCTURE AND FUNCTION

CLSS

OPERATION
When the L.H. travel spool (L.H. 1) is returned to
the neutral side from the straight traveling state
and the steering is operated, there will occur any
difference in the load pressures in the L.H. and
R.H. travel actuator circuits PA (R.H. A > L.H. A).
The LS pressure PLS will become the same as
the R.H. A on the higher load pressure side.
Therefore, the flow control valve on the L.H.
travel side is pressed to the left side with the LS
pressure PLS, i.e., the load pressure on the R.H.
travel side, and the notch a closes to interrupt
the L.H. and R.H. travel circuits. Also, since the
pressures in the spring chambers on the both
ends of the travel junction valve spool (4)
become different and P1 becomes higher than
P2, the spool (4) moves to the P1 side and the
notch d closes. Then, the steering can be operated.
The damper is provided to relax the transition
characteristics of the junction circuit at the time
of abrupt operation.

PC130-7

10-67

STRUCTURE AND FUNCTION

CLSS

TRAVEL LS BYPASS CIRCUIT


1. At normal operation

10-68

PC130-7

STRUCTURE AND FUNCTION

CLSS

FUNCTION
When an actuator is operated during travel, this
circuit will increase the discarded throttled flow of
the LS circuit PLS, loosen the pressure compensation accuracy of the travel circuit and limits
reduction of the travel speed to small extent.
The bypass circuit is closed in case of independent travel or independent operation of an actuator.
OPERATION
When boom spool (1) is operated, the LS circuit
PLS will come to the same pressure as the boom
circuit pressure A1.
At the same time, the LS circuit pressure PLS is
led to the spring chamber PLS1 of pressure
reducing valve (2) of the travel valve.
Since the travel spool is not operated, the travel
actuator circuit PA is closed and check valve (4)
inside flow control valve (3) is also closed.
Therefore, the travel LS bypass circuit is closed
in case of independent operation of the boom.

PC130-7

10-69
(3)

STRUCTURE AND FUNCTION

CLSS

2. At operation of travel + other actuator

10-70

PC130-7

STRUCTURE AND FUNCTION

CLSS

OPERATION
When boom spool (1) is operated, the LS circuit
PLS will come to the same pressure as the boom
circuit pressure A1.
Since the actuator circuit pressure is generally
higher at boom RAISE than during travel (A1 >
A2), the pressure in spring chamber PLS1 of
flow control valve (3) on the travel side is higher
than the travel circuit pressure PA.
So, the pressure reducing valve (2) moves to the
left side, and the LS pressure of spring chamber
PLS1 pushes check valve (4) from orifice a to
open it and flows to the travel circuit PA through
passages b and c.
Therefore, when LS circuit pressure PLS, which
has been as high as boom circuit pressure A1,
flows to travel circuit A2, the pressure will drop.

PC130-7

10-71
(3)

STRUCTURE AND FUNCTION

CLSS

3. At simultaneous operation of boom + swing


FUNCTION
When the boom is raised at the time of swinging,
the swing pool stroke will be controlled and the
flow to the boom will be distributed more to raise
the boom more.
1) When the boom is not raised

OPERATION
Since the SA and SB ports are interconnected to
the drain and no force is given to piston (2), the
stroke of spool (1) is not controlled. So, spool
(1) comes to cases (4) and (5) and the stroke
increases by ST1. This increases the filtering oil
flow.

10-72
(3)

1.
2.
3.
4.
5.

Spool (swing)
Piston
Plug
Case
Case

ST1 : Spool stroke

PC130-7

STRUCTURE AND FUNCTION

CLSS

2) At simultaneous operation of boom RAISE

OPERATION
When the boom RAISE PPC pressure is led to
piston (2) as the stroke control pilot pressure PS
through SA and SB ports, piston (2) will be
pressed in the inner direction.
At the time, the maximum stroke of spool (1) will
shorten (by ST0) due to control of piston (2).
Boom RAISE OFF ST1 > Boom RAISE ON ST0
The spool (1) stroke is controlled and shortens.
If the boom is raised at the time of swing (hoist
swing), notch a opening area will decrease. So,
the flow distribution to the boom will increase
and the boom will rise higher at the time of hoist
swing.

PC130-7

10-73
(3)

STRUCTURE AND FUNCTION

CLSS

SWING BLEED VALVE


FUNCTION
For swing operation, a bleed valve is provided to
the pressure reducing valve to raise the LS pressure slowly and to smooth the swing operation.
1. Swing at neutral position

OPERATION
Since notch a of pressure reducing valve (1) and
the LS circuit are closed and the bleed-off circuit
and LS circuit are also closed, the LS pressure
PLS is not affected by operation of other work
equipment.
The pump discharge pressure PP is also interrupted from the bleed-off circuit with piston (2)
and is not affected.
Notch b of bleed spool (3) and the bleed-off circuit are interconnected each other.

10-74
(3)

PC130-7

STRUCTURE AND FUNCTION

CLSS

2. At swing fine control

OPERATION
The pressure reducing valve moves in the right
direction, and notch a and the LS circuit interconnect each other. Also, pump circuit PP, bleed-off
circuit and LS circuit interconnect each other
through piston (2).
Bleed spool (3) moves in the left direction in proportion to raise of the swing PPC pressure PA.
But notch b throttles and interconnect to the
bleed-off circuit in the fine control region and
determines the intermediate pressure before
pump discharge pressure PP is reduced and
applied to LS pressure PLS.
Therefore, the intermediate pressure is set lower
than the pump discharge pressure PP and rises
as bleed spool (3) moves . So, the LS pressure
PLS rises slowly.

PC130-7

10-75
(3)

STRUCTURE AND FUNCTION

CLSS

3. At full swing operation

OPERATION
When the swing PPC pressure PA comes to the
maximum, notch b of bleed spool (3) interrupt
the bleed-off circuit. The intermediate pressure
becomes equal to the pump discharge pressure
PP, and the LS pressure PLS becomes equal to
the actuator circuit pressure.

10-76
(3)

PC130-7

STRUCTURE AND FUNCTION

CLSS

LS SELECT VALVE
FUNCTION
At the time of simultaneous operation of swing +
boom RAISE, this valve prevents high swing LS
pressure from entering the LS circuit PLS and
also prevents the boom RAISE speed from
reducing by securing the pump flow at the time of
swing drive.
1. During normal operation

OPERATION
The pilot pressure is not generally applied to pilot
port BP except for boom RAISE operation.
In this state, the pump discharge pressure PP
pushes valve (1) to open it and is led to pressure
reducing valve (4) of the swing valve. At the
time of swing operation, there occurs the LS
pressure PLS suitable for the load pressure, and
the pressure is led to the pump LS valve.

PC130-7

10-77
(3)

STRUCTURE AND FUNCTION

CLSS

2. At simultaneous operation of swing + boom RAISE

OPERATION
At the simultaneous operation of swing + boom
RAISE, the signal pressure of the PPC circuit is
led to pilot port BP.
When this pilot pressure BP is applied to piston
(2) and reaches a pressure that is stronger than
spring (3), piston (2) will be pushed to the left
side, valve (1) will close and the pump discharge
pressure PP will not come to flow to pressure
reducing valve (4) of the swing valve.
Then, the swing pressure does not cause LS
pressure PLS, but the LS pressure PLS cause
the boom RAISE pressure is led to the pump LS
valve, and the pump delivery is controlled with
the boom RAISE LS pressure.
The pilot pressure BP depends on the control
lever stroke.

10-78
(3)

PC130-7

STRUCTURE AND FUNCTION

SELF PRESSURE REDUCING VALVE

SELF PRESSURE REDUCING VALVE

P1 : From pump
PR : Supply to solenoid valve, PPC valve and EPC valve.
T : To hydraulic tank

PC130-7

10-79

STRUCTURE AND FUNCTION

1.
2.
3.
4.
5.
6.

Control valve block


Valve (sequence valve)
Spring
Screw
Poppet
Spring (pressure reducing valve pilot)

10-80

SELF PRESSURE REDUCING VALVE

7.
8.
9.
10.
11.

Spring (pressure reducing valve main)


Valve (pressure reducing valve)
Spring (safety valve)
Ball
Filter

PC130-7

STRUCTURE AND FUNCTION

SELF PRESSURE REDUCING VALVE

FUNCTION
The self pressure reducing valves reduces the
discharge pressure of the main pump and supplies it to the solenoid valve, the PPC valve, etc.
as the control pressure.

PC130-7

10-81

STRUCTURE AND FUNCTION

SELF PRESSURE REDUCING VALVE

1. At engine stop (total low pressure)

OPERATION
Spring (6) pushes poppet (5) to the seat, and the
circuit between ports PR and T is closed.
Spring (7) pushes valve (8) to the left side, and
the circuit between ports P1 and PR is open.
Spring (3) pushes valve (2) to the left side, and
the circuit between ports P1 and P2 is closed.

10-82
(3)

PC130-7

STRUCTURE AND FUNCTION

SELF PRESSURE REDUCING VALVE

2. At neutral and reduction of load pressure P2


(at own weight fall in boom LOWER and arm
IN)
Note : When load pressure P2 is lower than output
pressure PR of the self pressure reducing
valve.

OPERATION
Spring (3) and the PR pressure (0 MPa {0 kg/
cm2} at the time of engine stop) pushes valve (2)
in direction to close the circuit between ports P1
and P2. When the hydraulic oil enters P1 port,
the expression (P1 pressure
Spring (7) force +
( d area x PR pressure)) holds, and the self
pressure reducing valve will adjust the openings
of ports P1 and P2 so that the P1 pressure can
be maintained higher than the PR pressure.
When the PR pressure rises above the set pressure, poppet (5) will open and the hydraulic oil
flows through the route from PR port, hole a in
spool (8), poppet (5) opening to tank port T.

PC130-7

Therefore, there will occur a differential pressure


around hold a in spool (8) and the spool will
move in the direction to close port P1 and the PR
opening. Then, the P1 pressure is reduced and
adjusted to a certain pressure (set pressure) with
the opening and is supplied as the PR pressure.

10-83
(3)

STRUCTURE AND FUNCTION

SELF PRESSURE REDUCING VALVE

3. At raise of load pressure P2

OPERATION
When the load pressure P2 rises due to digging
or other operations, the pump delivery will
increase and P1 pressure will rise.
Then, the expression (P1 pressure > Spring (7)
force + ( d area x PR pressure)) will hold, and
valve (2) will move to the right side till the stroke
end. As a result, the opening between ports P1
and P2 will increase, the passage resistance will
become smaller to reduce engine loss horsepower.
When the PR pressure rises above the set pressure, poppet (5) will open and hydraulic oil will
flow through the route from the PR port, hole a in
spool (8), poppet (5) opening to tank port T.

10-84
(3)

Therefore, there will occur a differential pressure


around hold a in spool (8) and the spool will
move in the direction to close port P1 and PR
opening. Then, the P1 pressure is reduced and
adjusted to a certain pressure (set pressure) with
the opening and is supplied as the PR pressure.

PC130-7

STRUCTURE AND FUNCTION

SELF PRESSURE REDUCING VALVE

4. At occurrence of abnormal high pressure

OPERATION
When PR pressure of the self pressure reducing
valve rises abnormally high, ball (10) will separate from the seat against spring (9) force to flow
hydraulic oil to the output ports PR o T so as to
reduce the PR pressure. Then, the equipment
(PPC valve, solenoid valve, etc.), to which the oil
pressure is supplied, is protected from the abnormal high pressure.

PC130-7

10-85
(3)

STRUCTURE AND FUNCTION

CENTER SWIVEL JOINT

CENTER SWIVEL JOINT

1.
2.
3.
4.
5.

Cover
Body
Slipper seal
O-ring
Shaft

10-86

A1 :
A2 :
B1 :
B2 :
C1 :
C2 :
D1 :
D2 :
E1 :
E2 :
DR1 :
DR2 :

From control valve (R.H. travel Forward)


To R.H. travel motor B
From control valve (L.H. travel Forward)
To L.H. travel motor A
From control valve (R.H. travel Reverse)
To R.H. travel motor A
From control valve (L.H. travel Reverse)
To L.H. travel motor B
2-stage travel selection solenoid valve
To L.H./R.H. travel motor D
To hydraulic tank
From L.H. travel motor C1 and R.H. travel
motor C2

PC130-7

STRUCTURE AND FUNCTION

TRAVEL MOTOR

TRAVEL MOTOR (FINAL DRIVE)

A : From control valve (L.H./R.H. travel)


B : From control valve (L.H./R.H. travel)
C1 : To hydraulic tank (L.H. travel motor)
Plug (R.H. travel motor)
C2 : Plug (L.H. travel motor)
To hydraulic tank (R.H. travel motor)
D : From travel 2nd speed selector solenoid valve

PC130-7

10-87

STRUCTURE AND FUNCTION

1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.

Plug
Check valve spring
Check valve
Return spring
Counterbalance valve
Safety valve
Safety valve spring
End cover
Regulator valve
Spring
Brake piston
Cylinder
Spring
Swash plate
Pivot
Crankshaft
RV gear A

10-88

TRAVEL MOTOR

18.
19.
20.
21.
22.
23.
24.
25.
26.
27.
28.
29.
30.
31.
32.
33.
34.

RV gear B
Cover
Driven gear
Drive gear
Drain plug
Hub
Regulator piston
Spindle
Piston
Floating seal
Plate
Disc
Valve plate
Spring
Piston
Plug
Check valve

PC130-7

STRUCTURE AND FUNCTION

TRAVEL MOTOR

SPECIFICATION
Type
Theoretical delivery
(cm3/rev{cc/rev})
Rated speed (rpm)

GM18VL3
Hi

33.2 {33.2}

Lo

52.7 {52.7}

Hi

3,562

Lo

2,291

Brake releasing pressure


(MPa{kg/cm2})

0.68
{6.94}

Hi-Lo switching pressure


(MPa{kg/cm2})

2.94
{30}

Final drive reduction ratio

66

OUTLINE
Travel speed selection

Swash plate (14) has 2 faces (x, y) behind it, and


is supported by pivot (15).
When pressure of comtrol chamber a rises, it
pushes regulator piston (24), then swash plate
angle becomes minimum, then travel speed
goes high.

PC130-7

10-89
(3)

STRUCTURE AND FUNCTION

TRAVEL MOTOR

OPERATION
Operation of motor
At slow speed (the motor swash plate angle is maximized.)

Since the travel 2nd speed selector solenoid


valve is demagnetized, pressurized oil from the
main pump does not flow to the D port.
Therefore, spring (10) has pressed regulator
valve (9) to the left side.
So, regulator valve (9) stops the main pressurized oil led from the control valve to the end
cover by pushing check valve (34).
The pressurized oil in the control chamber drains
in the motor case through passage b of regulator
valve (9).
Then, the main pressurized oil from cylinder c
chamber pushes swash plate (14) in the direction to maximize the swash plate angle and the
motor capacity is increased to the maximum for
slow speed travel.

10-90
(3)

PC130-7

STRUCTURE AND FUNCTION

TRAVEL MOTOR

At high speed (the motor swash plate angle is minimized.)

When the travel 2nd speed selector solenoid


valve is energized, pilot pressure from the main
pump will flow in D port and push regulator valve
(9) in the right direction.
Therefore, the main pressurized oil from the control valve passes through passage b of regulator
valve (9), flows in control chamber a and pushed
regulator piston (24) in the left direction.
Then, swash plate (14) is pressed in the direction to minimize the swash plate angle, and the
motor capacity is minimized for high speed
travel.

PC130-7

10-91
(3)

STRUCTURE AND FUNCTION

TRAVEL MOTOR

Operation of brake valve


The brake valve consists of check valves (3a)
and (3b), counterbalance valve (5) and safety
valve (6), and the circuit configuration is as per
the right figure.
Functions and operations of these components
are as follows :

Counterbalance valve, check valve


Function
When traveling down a slope, the own weight
falling force will make the machine travel faster
than the motor rotation. So, traveling with
reduced engine speed is very dangerous
because the motor idles and runs away.
These valves let the machine travel at a speed
appropriate for the engine speed (pump delivery)
to prevent this danger.
Operation at oil supply
When the travel lever is operated, pressurized oil
from the control valve will be supplied to the PA
port, push and open check valve (3a) and flow
from MA port on the motor inlet side to MB port
on the motor outlet side.
Since the motor outlet circuit is closed with check
valve (3b) and counterbalance valve (5), however, the supply-side pressure will rise.

10-92
(3)

PC130-7

STRUCTURE AND FUNCTION

TRAVEL MOTOR

The pressurized oil on the supply side flows in


the S1 chamber from orifice E1 of counterbalance valve (5). When the pressure in S1 chamber rises above the switching pressure of the
counterbalance valve, counterbalance valve (5)
will be pressed in the right direction.
So, the circuit between outlet side MB port and
PB port will open, the motor outlet circuit will
open, and the motor will start rotating.

Brake operation at traveling downhill


If the machine is going to run away when traveling downhill, the motor will idle to reduce oil pressure on the motor inlet side and the pressure in
S1 chamber through orifice E1.
When the pressure in S1 chamber drops below
the switching pressure of the counterbalance
valve, counterbalance valve (5) will be returned
in the left direction with return spring (4), and outlet side MB port will be throttled.
Then, pressure on the outlet side will rise and
rotation resistance will occur to the motor to prevent the machine from running away.
This means that counterbalance valve (5) moves
to a position where the machine own weight and
inlet side pressure balance with the pressure at
outlet side MB port, and the outlet circuit is throttled to control speed to the pump delivery.

PC130-7

10-93
(3)

STRUCTURE AND FUNCTION

TRAVEL MOTOR

Safety valve
Function
When stopping a travel (or traveling downhill),
counterbalance valve (5) will close the inlet and
outlet circuits of the motor.
Since the motor
keeps rotating by inertia, however, pressure on
the outlet side of the motor will rise abnormally
and the motor and pipes may be damaged.
Then, safety valve leads the abnormally high
pressure to the inlet side of the motor to prevent
equipment from being damaged.
Operation
When the pressurized oil being supplied from PA
port is stopped flowing at the time of travel stop,
return spring (4) will return counterbalance valve
(5) from the right side to the left side (neutral
position).
Though counterbalance valve (5) closes a chamber on the outlet side circuit, the inertia lets the
motor rotate and the pressure in a chamber
rises.
The highly pressurized oil in a chamber passes
through throttle b of safety valve (6a) and enters
in d chamber from c chamber. The pressurized
oil entered in d chamber moves piston (32) to the
left side. Meantime, safety valve (6a) is pushed
to open by the pressurized oil in a chamber, and
the pressurized oil in a chamber flows in f chamber through e port. Therefore, the pressurized
oil in a chamber flows in f chamber at a comparatively slow speed to control the pressure in a
chamber and also to prevent cavitation in f
chamber at the same time.
When piston (32) reaches the stroke end, the
pressures in d and c chambers will rise, safety
valve (6a) will be closed again and the pressure
in a chamber will rise further.
Then, safety valve (6b) will open and the pressurized oil in the a chamber will flow in f chamber
from g chamber. The pressure in a chamber
can be controlled in two stage as mentioned
above, and the hydraulic motor can be smoothly
braked to stop.

10-94
(3)

PC130-7

STRUCTURE AND FUNCTION

TRAVEL MOTOR

Operation of parking brake


When operating travel
When the travel lever is operated, pressurized oil
from the pump will work on counterbalance valve
(5), open circuit a to the parking brake and flow
in b chamber of brake piston (11).
The pressure in b chamber overcomes spring
(31) and pushed brake piston (11) in the left
direction.
This will eliminate the press force to plate (28)
and disc (29), and plate (28) and disc (29) will
separate, and the brake force will be released.

When positioning travel neutral


When the travel lever is brought to the neutral
position, counterbalance valve (5) will return to
the neutral position and circuit a to the parking
brake will be closed.
The pressurized oil in b chamber of brake piston
(11) will be drained in the case, and spring (31)
will push the brake piston in the right direction.
Therefore, plate (28) and disc (19) will be
pushed to each other, and the brake will come to
work.

PC130-7

10-95
(3)

STRUCTURE AND FUNCTION

SWING MOTOR

SWING MOTOR
TYPE : KMF40ABE-3

B
S
T
MA
MB

:
:
:
:
:

From swing brake solenoid valve


From control valve
To tank
From control valve
From control valve

10-96

SPECIFICATION
Type : KMF40ABE-3
Theoretical delivery : 40.2 cc/rev
Safety valve set pressure : 27.5 MPa {280 kg/cm2}
Rated speed : 2,413 rpm
Brake releasing pressure :1.77 MPa{18.0 kg/cm2}

PC130-7

STRUCTURE AND FUNCTION

1.
2.
3.
4.
5.
6.
7.
8.
9.
10.

Drive shaft
Spacer
Case
Disc
Plate
Brake ring
Brake piston
Housing
Reverse prevention valve
Center spring

PC130-7

SWING MOTOR

11.
12.
13.
14.
15.
16.
17.
18.
19.
20.

Cylinder
Valve plate
Piston
Center shaft
Safety valve
Check valve
Check valve spring
Shuttle valve
Shuttle valve spring
Brake spring

10-97

STRUCTURE AND FUNCTION

SWING MOTOR

SWING BRAKE
1. When solenoid valve is demagnetized
Operation
When the solenoid valve of the swing brake is
demagnetized, pressurized oil from the control
pump will be interrupted and the B port will be
connected to the tank circuit.
Then, brake piston (7) will be pressed downward
with brake spring (8) and will push disc (4) and
plate (5) to work the brake.

2. When solenoid valve is energized


Operation
When the solenoid valve of the swing brake is
energized, the valve will be changed over and
pressurized oil from the control pump will enter
the B port and will flow in to the brake chamber
A.
Pressurized oil in the A chamber will push brake
spring (8) and brake piston (7) will move upward.
Then, disc (4) and plate (5) will separate to
release the brake.

10-98
(3)

PC130-7

STRUCTURE AND FUNCTION

SWING MOTOR

REVERSE PREVENTION VALVE

1.
2.
3.
4.
5.
6.
7.

Valve body
Spool (MA side)
Spring (MA side)
Plug (MA side)
Spool (MB side)
Spring (MB side)
Plug (MB side)

MA : Port
MB : Port
T1 : Port
T2 : Port

PC130-7

10-99

STRUCTURE AND FUNCTION

SWING MOTOR

Effect explanation drawing

10-100

PC130-7

STRUCTURE AND FUNCTION

SWING MOTOR

FUNCTION
This function is used for reducing swing back
generated on a swing body that can result from
factors such as inertia of the swing body, backlash and rigidity of the machinery system and
compressibility of hydraulic oil.
This function helps preventing loose loads at the
end of swing or cutting lead time (better positioning performance allows you to proceed to the
next operation within a shorter time).

1. When MB port pressure is generated


Operation
MB pressure is conducted to d room via the cutout. Utilizing difference of space (D1>D2), the
pressure compresses spring (6) and drives spool
(5) leftward to interconnect MB o e.
Since MA pressure at this time is lower than the
pressure set on spring (3), spool (2) is not moved
and pressurized oil remains closed. Thus, the
braking force is maintained.

2. When the motor is once stopped


Operation
The motor is reverse rotated by charging pressure generated on the MB port (1st reverse rotation).
At this time, reversing pressure is generated on
the MA port. MA pressure conducted to a room
interconnects MA o b by compressing spring (3)
and driving spool (2) rightward.
The pressure is then conducted through drilled
hole on spool (5) to interconnect b o f. Reversing pressure on the MA port is bypassed to the T
port to disable the 2nd reverse rotation.

PC130-7

10-101
(3)

STRUCTURE AND FUNCTION

SOLENOID VALVE

SOLENOID VALVE
FOR PPC LOCK, 2ND TRAVEL SPEED SELECT, SWING HOLD BRAKE AND 2-STAGE
RELIEF SOLENOID VALVE.

1.
2.
3.
4.

PPC lock solenoid valve


2nd travel speed select solenoid valve
Swing hold brake solenoid valve
2-stage relief solenoid valve

Solenoid valve
5. Push pin
6. Coil
7. Gauge
8. Spool
9. Block
10. Spring

A1 : To PPC valve
A2 : To 2-stage relief valve
A3 : To swing hold brake
A4 : To 2nd travel speed select valve
ACC : To accumulator
P1 : From self-pressure reducing valve
T
: To hydraulic oil tank

Check valve
11. Plug
12. Spring
13. Plunger

10-102

PC130-7

STRUCTURE AND FUNCTION

SOLENOID VALVE

OPERATION
When solenoid is "demagnetized"
Coil (6) remains demagnetized as long as signal
current to it is stopped..
Thus, spool (8) is pushed leftward by spring (10).
Since ports P to A are closed by this spool, flow
of pilot oil pressure to the actuator is blocked. At
the same time, oil from the actuator is lead from
A port to T port, then drained to the hydraulic oil
tank.

When solenoid is "magnetized"


Coil (6) is magnetized by signal current conducted to it.
Thus, spool (8) is pushed rightward by push pin
(5).
As the result, pilot oil pressure is conducted from
P port through cage (7) and A port up the actuator.
At the same time, T port is closed, thereby blocking flow of oil to the hydraulic oil tank.

PC130-7

10-103
(3)

STRUCTURE AND FUNCTION

PPC ACCUMULATOR

PPC ACCUMULATOR
1.
2.
3.
4.
5.
6.

Gas plug
Shell
Poppet
Holder
Bladder
Oil port

SPECIFICATIONS
Gas used : Nitrogen gas
Gas capacity : 0.3 l
Charged gas pressure :
1.18 MPa (12 kg/cm2) at 80C
Maximum operating pressure :
6.86 MPa (70 kg/cm2)

10-104

PC130-7

STRUCTURE AND FUNCTION

PPC VALVE

PPC VALVE
FOR SWING, WORK EQUIPMENT

P : From main pump


P1 : Left : Arm OUT/Right : Boom LOWER
P2 : Left : Arm IN/Right : Boom RAISE

PC130-7

P3 : Left : Swing RIGHT/Right : Bucket CURL


P4 : Left : Swing LEFT/Right : Bucket DUMP
T : To tank

10-105

STRUCTURE AND FUNCTION

1.
2.
3.
4.
5.

Spool
Metering spring
Centering spring
Piston
Disk

10-106

PPC VALVE

6.
7.
8.
9.
10.

Nut (for linking the lever)


Joint
Plate
Retainer
Body

PC130-7

STRUCTURE AND FUNCTION

PPC VALVE

OPERATION
1) At neutral
Ports A and B of the control valve and ports P1
and P2 of the PPC valve are connected to drain
chamber D through fine control hole f in spool
(1). (Fig. 1)

2) During fine control (neutral o fine control)


When piston (4) starts to be pushed by disc (5),
retainer (9) is pushed; spool (1) is also pushed
by metering spring (2), and moves down.
When this happens, fine control hole f is shut off
from drain chamber D, and at almost the same
time, it is connected to pump pressure chamber
PP, so pilot pressure oil from the main pump
passes through fine control hole f and goes from
port P1 to port A.
When the pressure at port P1 becomes higher,
spool (1) is pushed back and fine control hole f is
shut off from pump pressure chamber PP. At
almost the same time, it is connected to drain
chamber D to release the pressure at port P1.
When this happens, spool (1) moves up or down
so that force of metering spring (2) is balanced
with the pressure at port P1. The relationship 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 of movement of the
control lever, so the pressure at port P1 also
rises in proportion to the travel of the control
lever. In this way, the control valve spool moves
to a position where the pressure in chamber A
(the same as the pressure at port P1) and the
force of the control valve spool return spring are
balanced. (Fig. 2)

PC130-7

10-107

STRUCTURE AND FUNCTION

PPC VALVE

3) During fine control (when control lever is


returned)
When disc (5) starts to be returned, spool (1) is
pushed up by the force of centering spring (3)
and the pressure at port P1.
When this happens, fine control hole f is connected to drain chamber D and the pressure oil
at port P1 is released.
If the pressure at port P1 drops too far, spool (1)
is pushed down by metering spring (2), and fine
control hole f is shut off from drain chamber D. At
almost the same time, it is connected to pump
pressure chamber PP, and the pump pressure is
supplied until the pressure at port P1 recovers to
a pressure that corresponds to the lever position.
When the spool of the control valve returns, oil in
drain chamber D flows fine control hole f' in the
valve on the side that is not working. The oil
passes through port P2 and enters chamber B to
fill the chamber with oil. (Fig. 3)

4) At full stroke
When disc (5) pushes down piston (4), and
retainer (9) pushes down spool (1), fine control
hole f is shut off from drain chamber D, and is
connected with pump pressure chamber PP.
Therefore, the pilot pressure oil from the main
pump passes through fine control hole f and
flows to chamber A from port P1, and pushes the
control valve spool.
The oil returning from chamber B passes from
port P2 through fine control hole f' and flows to
drain chamber D. (Fig. 4)

10-108

PC130-7

STRUCTURE AND FUNCTION

PPC VALVE

FOR TRAVEL

P
T
P1
P2

: From main pump


: To tank
: L.H reverse
: L.H forward

PC130-7

P3 : R.H reverse
P4 : R.H forward
P5 : Travel signal

10-109

STRUCTURE AND FUNCTION

1.
2.
3.
4.

Plate
Body
Piston
Collar

10-110

PPC VALVE

5.
6.
7.
8.

Metering spring
Centering spring
Valve
Pin

PC130-7

STRUCTURE AND FUNCTION

PPC VALVE

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

2. In the fine control mode


(neutral o fine control)
As piston (4) is pushed by disk (5), retainer (9) ia
also pushed. At the same time, spool (1) is also
pushed down via the metering spring (2).
By this move, connection of the fine control hole
f is switched from drain room D to the pump
pressure room PP, and pilot pressurized oil for
the main pump is conducted from P1 port to A
port.
As P1 port pressure increases, spool (1) is
pushed back. By this move, connection of the
fine control hole f is switched from pump pressure room PP to drain room D, thereby relieving
P1 port pressure.
As the result, spool (1) moves up and down so
that force of metering spring (2) and P1 port
pressure may be balanced.
Positional relationship between spool (1) and
body (10) (fine control hole f is situated at mid
point between drain room D and pump pressure
room PP) remains unchanged until retainer (9) is
contacted against spool (1).
Metering spring (2) is, therefore, compressed in
proportion to strokes of the operation lever.
Thus, the P1 port pressure, too, also increases
in proportion to strokes of the operation lever.
As the result, the operation valve spool moves to
the position where pressure of A room (the same
as P1 port pressure) is balanced against force of
the operation valve spool return spring.

PC130-7

10-111
(3)

STRUCTURE AND FUNCTION

PPC VALVE

3. In the fine control mode (when operation


lever is shifted back to its original position)
As disk (5) starts returning, spool (1) is pushed
up by force of centering spring (3) and P1 port
pressure.
By this move, the fine control hole f is connected
to drain room D and relieves pressurized oil of
P1 port to it.
If P1 port pressure goes excessively low, spool
(1) is pushed down by metering spring (2) and
passage between the fine control hole f and
drain room D is shut down. And, almost at the
same time, the hole is connected to pump pressure room PP and starts supplying pressure to
the pump. This supply continues until P1 port
pressure is recovered to the level equivalent to
the lever position.
When the operation valve spool returns, oil in
drain room D flows in through the fine control
hole f' on the not moving side valve. Oil is then
conducted via P2 port to room B to fill it up.

4. In the full stroke mode


When disk (5) pushes down piston (4) and
retainer (9) pushes down spool (1), connection of
the fine control hole f is switched from drain
room D to pump pressure room PP.
Thus, pilot pressurized oil from the control pump
passes through the fine control hole f and conducted to A room via P1 port to push the operation valve spool.
Return oil from B room is conducted from P2 port
to drain room D via the fine control hole f'.

10-112
(3)

PC130-7

STRUCTURE AND FUNCTION

PPC VALVE

FOR SERVICE

1.
2.
3.
4.
5.
6.
7.
8.
9.

Spool
Metering spring
Centering spring
Piston
Lever
Plate
Retainer
Body
Filter

PC130-7

P
T
P1
P

: From self pressure reducing valve


: To tank
: To blade or service valve
: To blade or service valve

10-113

STRUCTURE AND FUNCTION

PPC VALVE

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

2. In the fine control mode


(Neutral o fine control)
As piston (4) is pushed by disk (5), retainer (7) is
also pushed. At the same time, spool (1) is also
pushed down via metering spring (2).
By this move, connection of the fine control hole
f is switched from drain room D to pump pressure room PP, and pilot pressurized oil for the
control pump is conducted from P1 port to A
port.
As P1 port pressure increases, spool (1) is
pushed back. By this move, connection of the
fine control hole f is switched from pump pressure room PP to drain room D, thereby relieving
P1 port pressure.
As the result, spool (1) moves up and down so
that force of metering spring (2) and P1 port
pressure may be balanced.
Positional relationship between spool (1) and
body (8) (fine control hole f is situated at mid
point between drain room D and pump pressure
room PP) remains unchanged until retainer (7) is
contacted against spool (1).
Metering spring (2) is, therefore, compressed in
proportion to strokes of the operation lever.
Thus, the P1 port pressure, also increases in
proportion to strokes of the operation lever.
As the result, the operation valve spool moves to
the position where pressure of A room (the same
as P1 port pressure) is balanced against force of
the operation valve spool return spring.

10-114
(3)

PC130-7

STRUCTURE AND FUNCTION

PPC VALVE

3. In the fine control mode (when the operation


lever is shifted back to its original position)
As lever (5) starts returning, spool (1) is pushed
up by force of centering spring (3) and P1 port
pressure. By this move, the fine control hole f is
connected to drain room D and relieves pressurized oil of P1 port to it.
If P1 port pressure goes excessively low, spool
(1) is pushed down by metering spring (2) and
passage between the fine control hole f and
drain room D is shut down. And, almost at the
same time, the hole is connected to pump pressure room PP and starts supplying pressure to
the pump. This supply continues until the P1
port pressure is recovered to the level equivalent
to the lever position.
When the operation valve spool returns, oil in
drain room D flows in through the fine control
hole f' on the not moving side valve. Oil is then
conducted via P2 port to the room B to fill it up.

4. In the full stroke mode


When disk (5) pushes down piston (4) and
retainer (7) pushes down spool (1), connection of
the fine control hole f is switched from drain
room D to pump pressure room PP.
Thus, pilot pressurized oil from the control pump
passes through the fine control hole f and conducted to A room via P1 port to push the operation valve spool.
Return oil from B room is conducted from P2 port
to drain room D via the fine control hole f'.

PC130-7

10-115
(3)

STRUCTURE AND FUNCTION

WORK EQUIPMENT

WORK EQUIPMENT

1.
2.
3.
4.
5.
6.
7.

Bucket
Link
Bucket cylinder
Arm
Arm cylinder
Boom
Boom cylinder

10-116

PC130-7

STRUCTURE AND FUNCTION

AIR CONDITIONER PIPING

AIR CONDITIONER PIPING

A:
B:
C:
D:

Hot air/cold air spurting port


Internal air circulation port
External air inlet
Refrigerant checking port

1.
2.
3.
4.

Hot water inport piping


Air conditioner compressor
Condenser
Refrigerant piping

PC130-7

5.
6.
7.
8.

Receiver tank
Hot water return piping
Air conditioner unit
Duct

10-117

STRUCTURE AND FUNCTION

ENGINE CONTROL

ENGINE CONTROL

1.
2.
3.
4.
5.
6.
7.
8.
9.

Starting switch
Fuel control dial
Governor motor
Starting motor
Linkage
Battery relay
Battery
Engine throttle and pump controller
Fuel injection pump

10-118
(3)

OUTLINE
The engine can be started and stopped with only
starting switch (1).
The engine throttle and pump controller (8) reveives the signal of fuel control dial (2) and transmits the drive signal to governor motor (3) to
control the governor lever angle of fuel injection
pump (9) and control the engine speed.

PC130-7

STRUCTURE AND FUNCTION

ENGINE CONTROL

1. OPERATION OF SYSTEM
Starting engine
When the starting switch is turned to the START
position, the starting signal flows to the starting
motor, and the starting motor turns to start the
engine.
When this happens, the engine throttle and
pump controller 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 engine
throttle and pump controller according to the
position of the dial. The engine throttle and pump
controller calculates the angle of the governor
motor according to this signal, and sends a signal to drive 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 engine throttle and
pump controller, so that it can observe the operation of the governor motor.

Stopping engine
When the starting switch is turned to the STOP
position, the engine throttle and pump controller
drives the governor motor so that the governor
lever is set to the NO INJECTION position.
When this happens, to maintain the electric
power in the system until the engine stops completely, the engine throttle and pump controller
itself drives the battery relay.

PC130-7

10-119

STRUCTURE AND FUNCTION

ENGINE CONTROL

2. COMPONENT
Fuel control dial
1.
2.
3.
4.
5.
6.

Knob
Dial
Spring
Ball
Potentiometer
Connector

FUNCTION
The fuel control dial is installed under the monitor
panel, and a potentiometer is installed under the
knob. The potentiometer shaft is turned by turning the knob.
As the potentiometer shaft is turned, the resistance of the variable resistor in the potentiometer
changes and a throttle signal is sent to the
engine throttle and pump controller.
The hatched area in the graph shown at right is
the abnormality detection area.

10-120

PC130-7

STRUCTURE AND FUNCTION

ENGINE CONTROL

GOVERNOR MOTOR

1.
2.
3.
4.
5.
6.
7.
8.

Potentiometer
Cover
Shaft
Dust seal
Bearing
Motor
Gear
Connector

OPERATION
While motor is stopped
Electric power is applied to both phases A and B
of the motor.
While motor is running
The engine throttle and pump controller supplies
a pulse current to phases A and B, and the motor
revolves, synchronizing to the pulse.

FUNCTION
The motor is turned according to the drive signal
from the engine throttle and pump controller to
control the governor lever of the fuel injection
pump.
This motor used as the motive power source is a
stepping motor.
A potentiometer for feedback is installed to monitor the operation of the motor.
Revolution of the motor is transmitted through
the gear to the potentiometer.
PC130-7

10-121

STRUCTURE AND FUNCTION

ELECTRIC CONTROL SYSTEM

ELECTRIC CONTROL SYSTEM


CONTROL FUNCTION

1
Engine/Pump composite control function

2
Pump/Valve control function

3
One-touch power maximizing function

4
Auto-deceleration function

5
Electric control system

Auto-warm-up/Overheat prevention function

6
Swing control function

7
Travel control function

8
ATT flow control, circuit selector function (if equipped)

Self-diagnosis function

10-122

PC130-7

STRUCTURE AND FUNCTION

ELECTRIC CONTROL SYSTEM

MACHINE CONTROL SYSTEM DIAGRAM

10-124
(3)

PC130-7

STRUCTURE AND FUNCTION

PC130-7

ELECTRIC CONTROL SYSTEM

10-125

STRUCTURE AND FUNCTION

ELECTRIC CONTROL SYSTEM

1. ENGINE AND PUMP CONTROL FUNCTION

10-126

PC130-7

STRUCTURE AND FUNCTION

ELECTRIC CONTROL SYSTEM

FUNCTION
This function is for selecting any of the four working modes "A," "B", "E" and "L" with the working
mode selector switch on the monitor panel. The
controller can select optimum engine torques or
pump absorption torques for works to be
expected.

The controller detects the engine governor


speed set with the fuel control dial depending on
the pump absorption torque set in each mode
and detects actual engine speeds. Then, the
controller controls all torques at each output
point of the engine so that the pump can absorb
them.

When an engine speed was lowered, the controller prevents the engine from stopping by throttling the pump absorption toque.

PC130-7

10-127
(3)

STRUCTURE AND FUNCTION

1. CONTROL METHOD IN EACH MODE


Mode A
Matching point in Mode A
When a load to the pump increases and the
pressure rises and the engine speed lowers.
At the time, the controller reduces the pump
delivery so that the speed lowers to the speed at
the full output point or so. If the pressure drops
on the contrary, the controller increases the
pump delivery so that the speed comes to the
speed at the full output point or so.
The controller repeats these controls so that the
engine can always be used at speeds at the full
output point or so.

10-128

ELECTRIC CONTROL SYSTEM

A Travel (A1)

66.2 kW/2,200 rpm


{88.7 HP/2,200 rpm}

A Work (A2)

65.5 kW/2,200 rpm


{87.8 HP/2,200 rpm}

PC130-7

STRUCTURE AND FUNCTION

ELECTRIC CONTROL SYSTEM

Mode E / Mode B / Mode L


Mode
Partial output point

Model

90%

90%

56%

PC130-7

Mode E

58.8 kW/2,000 rpm {78.9 HP/2,000 rpm}

Mode B

58.8 kW/2,000 rpm {78.9 HP/2,000 rpm}

Mode L

36.8 kW/1,500 rpm {70 HP/1,500 rtpm}

At this time, the controller keeps the pump


absorption torque along the constant horsepower curve and lower the engine speed by
the composite control of the engine and
pump.
By this method, the engine is used in the low
fuel consumption area.

PC130-7

10-129

STRUCTURE AND FUNCTION

ELECTRIC CONTROL SYSTEM

2. FUNCTION TO CONTROL PUMP DURING


TRAVEL
If the machine travels in mode work A, B, E, or L,
the working mode does not change, but the
pump absorption torque and engine speed rise
to travel A mode.

3. PUMP DRIVE IN AN EMERGENCY


Even if controllers and sensors get out of order,
the emergency pump drive switch (S) will enable
to maintain functions of the machine with absorption torques quite similar to those in the Mode E.
In this case, a constant current flows from the
battery to the PC-EPC valve, and the valve
detects the oil pressure only.
(1) Normal
(2) Emergency
a The emergency pump drive switch (S) is of the
alternative type. If the machine is operated after
the switch is set to "Emergency (2)" even though
the machine is normal, the user code "E02" will
be shown on the display.

10-130

PC130-7

STRUCTURE AND FUNCTION

ELECTRIC CONTROL SYSTEM

2. PUMP/VALVE CONTROL FUNCTION

FUNCTION
The machine is matched to various types of work
properly with the 2-stage relief function to
increase the digging force, etc.

PC130-7

10-131

STRUCTURE AND FUNCTION

ELECTRIC CONTROL SYSTEM

1) Cut-off function
When the cut-off function is turned on, the
PC-EPC current is increased to near the
maximum value.
By this operation, the flow rate in the relief
state is lowered to reduce fuel consumption.
Operating condition for turning on cut-off
function.

Condition
The average value of the front and rear pressure sensors is above 27.9 MPa {285 kg/cm2}
and the one-touch power maximizing function is
not turned on

The cut-off function does not work, however,


while the machine is traveling in mode A, the
lock switch is turned on.
2) 2-stage relief function
The relief pressure in the normal work is 31.9
MPa {325 kg/cm2}. If the 2-stage relief function is turned on, however, the relief pressure
rises to about 34.8 MPa {355 kg/cm2}.
By this operation, the hydraulic force is
increased further.
Operating condition for turning on 2-stage
relief function

Condition
Relief pressure
During travel
When swing lock switch is
31.9 MPa
turned on
{325 kg/cm2}
When one-touch power maxi
mizing function is turned on
34.8 MPa
When L mode is operated
{355 kg/cm2}

10-132

PC130-7

STRUCTURE AND FUNCTION

ELECTRIC CONTROL SYSTEM

3. ONE-TOUCH POWER MAXIMIZING FUNCTION

FUNCTION
Power can be increased for about 8.5 sec. by
operating the left knob switch.

PC130-7

10-133

STRUCTURE AND FUNCTION

ELECTRIC CONTROL SYSTEM

1) One-touch power maximizing function


When the operator needs more digging force
to dig up a large rock, etc., if the left knob
switch is pressed, the hydraulic force is
increased about 9% to increase the digging
force.
If the left knob switch is turned on in working
mode "A" or "E", each function is set automatically as shown below.

Software cut-off function


Working
mode

Engine/Pump
control

A, E

Matching at rated
output point

10-134

2-stage relief function


31.9 MPa {325 kg/cm2}

34.8 MPa {355 kg/cm2}

Operation time
Automatically
Cancel
reset at 8.5 sec

PC130-7

STRUCTURE AND FUNCTION

ELECTRIC CONTROL SYSTEM

4. AUTO-DECELERATION FUNCTION

FUNCTION
If the all control levers are set in NEUTRAL while
waiting for a dump truck or work, the engine
speed is lowered to the medium level automatically to reduce the fuel consumption and noise.
If any lever is operated, the engine speed rises
to the set level instantly.

PC130-7

10-135

STRUCTURE AND FUNCTION

ELECTRIC CONTROL SYSTEM

OPERATION
When control levers are set in neutral
If all the control levers are set in NEUTRAL while
the engine speed is above the decelerator operation level (about 1,400 rpm), the engine speed
lowers instantly to the first deceleration level
about 100 rpm lower than the set speed.
If 4 more seconds pass, the engine speed lowers
to the second deceleration level (about 1,400
rpm) and keeps at that level until any lever is
operated again.
When any control lever is operated
If any control lever is operated while the engine
speed is kept at the second deceleration level,
the engine speed rises instantly to the level set
with the fuel control dial.

10-136

PC130-7

STRUCTURE AND FUNCTION

ELECTRIC CONTROL SYSTEM

5. AUTO-WARM-UP/OVERHEAT PREVENTION FUNCTION

FUNCTION
After the engine is started, if the engine coolant
temperature is low, the engine speed is raised
automatically to warm up the engine. If the
engine coolant temperature rises too high during
work, the pump load is reduced to prevent overheating.

PC130-7

10-137
(3)

STRUCTURE AND FUNCTION

ELECTRIC CONTROL SYSTEM

1) Auto-warm-up function
After the engine is started, if the engine coolant water temperature is low, the engine
speed is raised automatically to warm up the
engine.
Operating condition (All)

Operated

Coolant temperature: Below 30C.


Engine speed: Max. 1,200 rpm

Engine speed: Max. 1,200 rpm

Resetting condition (Any one)


Auto
Manual

Coolant temperature: Above 30C


Auto-warm-up operation time: Min. 10 minutes

Reset

Engine speed: Any level

Fuel control dial: Kept at 70% of full level for 3 sec. or


longer

Operating condition

Operation/Remedy

Resetting condition
Coolant and oil temperature:
Below 105?C

Coolant and oil temperature: Above


105C

Operating condition
Coolant and oil temperature: Above
102C

10-138
(3)

Work mode: Mode A, E,


OR B
Engine speed: Keep as is.
Monitor alarm lamp: Lights up.
Lower pump discharge.

Work mode: Mode A


Engine speed: Keep as is.
Lower pump discharge.

Under above condition, controller is set to condition before


operation of function. (Manual
reset)

Coolant and oil temperature:


Below 102C
Under above condition, controller is set to condition before
operation of function. (Automatic reset)
Resetting condition

Operation/Remedy
Work mode: Travel
Engine speed: Keep as is.
Lower travel speed.

Fuel control dial: Return to low


idle position once.

Resetting condition

Operation/Remedy

Operating condition

Coolant and oil temperature: Above 95C

Operation/Remedy

Operating condition

Coolant and oil temperature: Above 98C

Work mode: Any mode


Engine speed: Low idle
Monitor alarm lamp: Lights up
Alarm buzzer: Sounds

Coolant and oil temperature:


Below 98C
Under above condition, controller is set to condition before
operation of function. (Automatic reset)
Resetting condition

Coolant and oil temperature:


Below 95C
Under above condition, controller is set to condition before
operation of function. (Automatic reset)

PC130-7

STRUCTURE AND FUNCTION

ELECTRIC CONTROL SYSTEM

6. SWING CONTROL FUNCTION

1.
2.
3.
4.
5.
6.
7.
8.
9.
10.

Battery
Battery relay
Fusible link
Starting switch
Fuse box
Controller
Swing holding brake release switch
Swing lock switch
Monitor panel
Swing holding brake solenoid valve

Input/Output Signals
a. Controller power supply
b. Solenoid power supply
c. Monitor panel power supply
d. S-NET signal

PC130-7

11.
12.
13.
14.
15.
16.
17.
18.

PPC lock solenoid valve


Swing motor
L.H. work equipment PPC valve
Arm IN PPC oil pressure switch
Swing PPC oil pressure switch
Engine
Hydraulic pump
Control valve
18a. Self pressure reducing valve
18b. Main relief valve

e. Solenoid valve drive signal


f. Swing PPC oil pressure switch signal
g. Arm IN PPC oil pressure switch signal

10-139

STRUCTURE AND FUNCTION

FUNCTION
Swing lock and swing holding brake
The swing lock (manual type) is for locking swing
at optional positions. The swing holding brake
(automatic type) interlocks with swing and prevents hydraulic drift from occurring after stop of
swing.
a When the swing lock is released, only the
hydraulic brake with the safety valve is effective
for swing. So, note that, when a swing stops on
a slope, a hydraulic drift may occur sometimes.
a Even during arm IN operation, release the swing
holding brake.

ELECTRIC CONTROL SYSTEM

Swing
lock
switch

OFF

ON

Release of swing holding brake


If the controller gets out of order and no swing is
possible because the swing holding brake does
not work normally, use the swing holding brake
release switch (S), and the swing holding brake
will be released and swing will become possible.
(1) Normal
(2) Release
a Even if the swing holding brake release switch is
set to "ON," the swing holding brake is not be
released while the swing lock switch is set to
"ON."

Swing
lock
monitor

Function

Operation

The lamp Swing


goes
holding
OUT.
brake

When the swing control lever is set to


NEUTRAL, the swing
holding brake works 4
sec. later.
When the swing control lever or the arm IN
lever is operated, the
swing holding brake is
released and free
swing becomes possible.

The lamp Swing


turns ON. lock

The swing holding brake


works, and the swing is
locked.
Even if the swing control lever is operated,
the swing holding brake
cannot be released,
and no swing is possible.

Swing
ON
holding
(when the controller
brake reis out of order)
lease switch
Swing lock
switch

Swing brake

OFF
(when the controller
is in order)

ON

OFF

ON

OFF

The
swing
lock
works.

The
swing
lock is
released.

The
swing
lock
works.

The
swing
holding
brake
works.

Input/Output signal time chart

10-140

PC130-7

STRUCTURE AND FUNCTION

ELECTRIC CONTROL SYSTEM

7. TRAVEL CONTROL FUNCTION

1.
2.
3.
4.
5.
6.
7.
8.
9.

Battery
Battery relay
Fusible link
Starting switch
Fuse box
Controller
Monitor panel
Travel speed selector solenoid valve
L.H. travel motor

Input/Output signals
a. Controller power supply
b. Solenoid power supply
c. Monitor panel power supply
d. S-NET signal

PC130-7

10.
11.
12.
13.
14.
15.

R.H. travel motor


Engine speed sensor
Pump pressure sensor
Engine
Hydraulic pump
Control valve
15a. Self pressure reducing valve
15b. Main relief valve

e. Solenoid valve drive signal


f. Engine speed signal
g. Pump pressure signal

10-141

STRUCTURE AND FUNCTION

FUNCTION
Travel Speed Selection
1. Travel Speed "Manual" Change
When the travel speed selector switch is set
to LOW or HIGH, the motor capacity
changes and travel speeds can be selected.

ELECTRIC CONTROL SYSTEM

Travel speed
selector switch

LOW
(low speed)

HIGH
(high speed)

Motor capacity
(cc/rev)

52.7

33.2

Travel speed
(km/h)

2.7

5.5

Maximum

Minimum

Travel motor swash plate


angle

2. "Automatic"change of travel speed


1) Automatic selection corresponding to engine
speed
If engine speed drops to 1,500 rpm or
less when travel speed selector switch is
in HIGH and travel speed is HIGH, travel
speed changes to LOW automatically.
If engine speed becomes 1,700 rpm or
less when travel speed selector switch is
in HIGH and travel speed is LOW, travel
speed changes to HIGH automatically.
a If travel speed selector switch is in LOW,
travel speed is not changed automatically.
2) Automatic selection corresponding to discharge pressure of pump
If travel pressure of 30.4MPa {310 kg/
cm2} or higher continues for 0.2 seconds
or more when travel speed selector
switch is in HIGH, travel speed changes
to LOW automatically.
If travel pressure of 16.7MPa {170 kg/
cm2} or lower continues for 0.2 seconds
or more when travel speed selector
switch is in HIGH, travel speed changes
to HIGH automatically.
a If travel speed selector switch is in LOW,
travel speed is not changed automatically.

10-142
(3)

PC130-7

STRUCTURE AND FUNCTION

ELECTRIC CONTROL SYSTEM

8. PPC LOCK FUNCTION

1.
2.
3.
4.
5.
6.
7.
8.
9.

Battery
Battery relay
Fusible link
Starting switch
Fuse box
Controller
Safety lock lever
PPC lock switch
PPC lock solenoid valve

10.
11.
12.
13.
14.
15.
16.

Left work equipment PPC valve


Right work equipment PPC valve
Traveling PPC valve
Blade PPC valve (Blade specification)
Engine
Hydraulic pump
Operation valve
16a. Self pressure reducing valve
16b. Man relief valve

Input/Output signals
a. Power supply of controller
b. Power supply of solenoids
c. Solenoid valve driving signals

Function
PPC lock switch works with safety lock lever.
Setting safety lock lever to "Lock", PPC lock
switch turns to "OFF".
Turning PPC lock switch to "OFF" shuts off current to PPC lock solenoid valve, making operation lever on the work equipment disabled.

PC130-7

10-143

STRUCTURE AND FUNCTION

ELECTRIC CONTROL SYSTEM

SELF DIAGNOSIS FUNCTION


1. Error code display/Alarm functions
Controller always watches electronic devices
which constitutes the system, including controller itself, each potentiometer which issues
input signals, each solenoid valve which
receives output signals, and EPC valves, to
check for they normal operation.
If an abnormality occurred in any of these
devices, the controller diagnoses it and display the results on display (1) of monitor
panel as a "USER CODE" or "SERVICE
CODE", sounding alarm buzzer at the same
time to notify the abnormality to operator.
a Refer to the "TROUBLESHOOTING" section as for the details of display and measures to be taken.
2. Error code memory function
Controller takes in memory the error code
diagnosed about an abnormality which
occurred in advanced system.
a Refer to the "TESTING AND ADJUSTING"
section as for the details of display and how
to reset.

10-144

PC130-7

STRUCTURE AND FUNCTION

ELECTRIC CONTROL SYSTEM

SYSTEM COMPONENTS
ENGINE SPEED SENSOR

FUNCTION
The engine speed sensor is installed on the ring
gear of the engine flywheel. It electrically counts
number of gear teeth that pass its front side and
sends the counting to the controller.

1.
2.
3.
4.
5.

Magnet
Terminal
Case
Boots
Connector

Remarks : Number of ring gear teeth is 127.

For the count, a magnet is used which generates


current every time a gear tooth passes its front
side.

PC130-7

10-145

STRUCTURE AND FUNCTION

ELECTRIC CONTROL SYSTEM

PPC HYDRAULIC SWITCH

SPECIFICATION
Contact structre : Normally opened
Operating (ON) pressure :
490 98.1 kPa {5.0 1.0 kg/cm2}
Resetting (OFF) pressure :
294 49.0 kPa {3.0 0.5 kg/cm2}

1. Plug
2. Switch
3. Connector

FUNCTION
8 switches installed to junction block sense operating condetion of each actuator, and send it to
controller.
1 switch installed to travel PPC valve sense
travel operating condition, and send it to controller.

10-146

PC130-7

STRUCTURE AND FUNCTION

ELECTRIC CONTROL SYSTEM

CONTROLLER

PC130-7

10-147

STRUCTURE AND FUNCTION

ELECTRIC CONTROL SYSTEM

Input/output signals
CN-1

CN-2

Pin
No.

Signal name

Input/
output

Pin
No.

CN-3
Signal name

Input/
output

Pin
No.

Output

Control power supply

Input
Input

Signal name

NC

Input

NC

NC

Input

Swing prolix switch

Input

Solenoid power supply

NC

Input

NC

Input

SOL_COM

Input/
output

Signal GND

232C_RxD

Input

Battery relay drive

Output

NC

Input

NC

Input

Motor drive a (+)

Output

NC

Input

Over load caution enable


switch

Input

LS_EPC

Output

Overload pressure sensor

Input

NC

Output

Pump pressure sensor

Input

NC

Output

Input

NC

10

Signal GND

11

Knob switch

Input

12

NC

Input

13

Feed back signal

Input

14

NC

Input

15

NC

Input

16

SENS_PWR

17

Start switch (C)

Input

18

NC

Input

19

Fuel dial

Input

20

NC

Input

21

Analog GND

Output

Machine select 4

NC

Output

NC

Output

POT_PWR

23

Start switch (Acc)

Output
Input

24

NC

Input

Input

10

NC

Input

11

NC

Output

12

CAN shield

13

Machine select 5

14

232C_TxD

15

NC

Input
Output
Input

16

NC

Input

17

Machine select 3

Input

18

NC

Output

19

NC

Output

20

NC

Input

22

10-148

21

S_NET

22

CANO_L

23

CAN1_L

Input/
Output
Input/
Output
Input/
Output

Bucket curl switch

Input

10

Boom ralse switch

Input

11

Control power supply

Input

12

Solenoid power supply

Input

13

SOL_COM

14

Key signal

Input

15

Motor drive a (-)

Output

16

PC-EPC

Output

17

NC

Output

18

Heater relay solenoid

Output

19

Bucket dump switch

Input

20

Boom lower switch

Input

21

GND

22

Solenoid power supply

23

SOL_COM

24

Key signal

25

Motor drive b (+)

Output

Input

Input

24

Flash memory write enable


signal

Input

26

NC

Output

25

NC

Input

27

Travel speed solenoid

Output

26

NC

Input

28

2-stage rellef solenoid

Output

27

Machine select 2

Input

29

Swing switch

Input

28

NC

Input

30

Arm curl switch

Input

29

Puls GND

31

GND

30

NC

Input

32

GND

31

GND (S_NET GND)

33

GND

32

CAN0_H

34

NC

33

CAN1_H

Input/
Output
Input/
Output

35

Motor drive b (-)

Output

36

NC

Output

37

Swing brake solenoid

Output

38

NC

Output

34

GND (232C GND)

35

Service switch

36

NC

Input

37

Machine select 1

Input

38

Swing lock switch

Input

39

Puls GND

40

Eng. speed

39

Travel switch

Input

40

Arm dump switch

Input

Input

PC130-7

STRUCTURE AND FUNCTION

ELECTRIC CONTROL SYSTEM

PUMP PRESSURE SENSOR

1. Plug
2. Sensor
3. Connector

FUNCTION
Mounted on the inlet circuit of control valve, this
sensor changes discharging pressure of pump
into voltage, and send it to automatic travel
speed change controller.

Monitor panel
a Refer to the section describing the "Monitor System".
PC valve
LS valve
PC-EPC valve
a Refer to the section describing the "Hydraulic
Pump (Piston pump)".
LS-EPC valve
a Refer to the section describing the "Hydraulic
Pump (Piston pump)".
PPC lock solenoid valve
2nd speed select solenoid valve
Swing hold brake solenoid valve
2-stage relief solenoid valve
a Refer to the section describing the "Solenoid
Valve".

PC130-7

10-149

STRUCTURE AND FUNCTION

MONITOR SYSTEM

MONITOR SYSTEM

1.
2.
3.
4.
5.

Monitor panel
Battery
Controller
Sensors and switches
Wiper motor, window washer motor

Description
The monitor system monitors conditions of the
machine with sensors mounted on its each section, processes promptly the information
obtained, and displays it on panel to let operator
know the conditions of the machine.

Input/Output signals
a. Power supply
b. Switch signal
c. Caution signal
d. Sensor/switch signal
e. Sensor/switch signal
f. Output for driving

10-150

PC130-7

STRUCTURE AND FUNCTION

MONITOR SYSTEM

MONITOR PANEL

OUTLINE
The monitor panel has the functions to display a
monitor, gauge, service meter and electric system. It has also an alarm buzzer built in.
A CPU (Central Processing Unit) mounted inside
processes, displays and outputs information.

Input/Output signals
AMP070-12P [CN-P01]
Pin No.
1
2
3
4
5
6
7
8
9
10
11
12

PC130-7

Signal name
Starting switch (battery)
Starting switch (battery)
Window washer motor output
Starting switch (C-terminal)
Wiper W-contact
GND
GND
VB + (24V)
Wiper motor (+)
Wiper motor ()
Alarm buzzer ON signal
Wiper P-contact

The monitor's switch section consists of three flat


type sheet switches. Pressing any of these
switches changes the conditions of the machine,
which are shown by LEDs located above the
switches turned ON.
The monitor does not give correct display if any
of the monitor panel unit, controller, or the wiring
between monitor-panel and controller is in abnormal condition.

AMP040-20P [CN-P02]
I/O signal
Input
Input
Output
Input
Input

Input
Output
Output
Input
Input

Pin No.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20

Signal name
Engine coolant temperature
Fuel level
Radiator coolant level
NC
Air cleaner clogging
NC
Engine oil pressure
Engine oil level
S-NET signal
S-NET signal
Battery charge level
Hydraulic oil level
GND (analog signal)
NC
Pull-up window limit switch
Alarm buzzer cancel
Swing lock
Preheating
Lamp switch
GND (S-NET)

I/O signal
Input
Input
Input
Input
Input
Input
Input
Input
Input/Output
Input/Output
Input
Input

Input
Input
Input
Input
Input

10-151

STRUCTURE AND FUNCTION

MONITOR SYSTEM

METER DISPLAY

No.
1

Display
category

Display item

Service meter

[*1]
2 Display
3a Gauge
3b Caution

Coolant
temperature

4a Gauge
4b Caution

Fuel level

Pilot

[*2]
7

8
9
10
Caution
11

12

Display method

Time counting while engine is in operation (alternator is generating) (Always lit even if starting switch is OFF)
Count time during engine operates.
Alphanumerics in 2 Displays 2 digit alphanumerics (user code or
digits
service code) if electric control system is in abnormal condition.
See picture above All the segments of the corresponding level and
lower are turned ON.
Specified tempera- (Level 8 (102C or higher):Monitor lamp blinks.
ture (102C) or
Level 9: Monitor lamp blinks and alarm buzzer
higher
sounds.)
See picture above All the segments of the corresponding level and
lower are turned on. (Level 1 (42 l or less):
Specified level
Monitor lamp blinks.)
(42 l) or lower

Display Remarks
color

0 99999.9 h

Blue

LCD

Red

LED

Blue

LCD

Red

LED

Turned on for about 30 seconds after starting


switch was turned to "HEAT". It blinks (for about
10 seconds) after preheating was over to notify
it to operator, and then it is turned off.
Turned on when the swing lock function is acWhen swing-lock is
tive.
Swing lock
in operation
Blinks when swing holding brake release
Green
switch was turn on.
Turned ON when specified oil maintenance
periods (125h, 250, and 500h) elapsed. (Also,
When
specified
oilOil
elapsed time and telephone No. of your dealmaintenance
perimaintenance
er are shown on service meter.)
ods elapsed
Not turned on if no oil maintenance period
has been specified.
Engine oil level Max. low level
Charge in fault
Battery charge (charge voltage <
level
battery voltage)
Turned ON when starting switch was turned on;
Air cleaner
turned off after engine started running.
At
clogging
clogging
In normal condition : turned OFF
Red
In abnormal condition : turned ON
Lower
than
the
Engine oil
(As
for
engine
oil
pressure,
charge
and
over
specified pressure
pressure
49 kPa {0.5 kg/cm2} load alarm buzzer sounds if the pressure became abnormal when engine was running.)
Min. specified presOver load
sure 16.7 MPa {170
kg/cm2}
Preheating

Display area

During preheating

Lamp

[*1] As for display and operation, refer to the "Self Diagnosis Function" section.
[*2] As for display and operation, refer to the "Troubleshooting" chapter.

10-152

PC130-7

STRUCTURE AND FUNCTION

MONITOR SYSTEM

MONITOR SWITCH

No.

Name

Function

Operation

Used to select a travel speed from two of them.


"Lo" is lit: Travel in low speed.
1 Travel speed selector switch "Hi" is lit: Travel in high speed.
Lo
Hi
<The speed is locked at Lo when arm crane is used.>
Activates the function to reduce fuel consumption.
Turned ON: The function is active.
ON
OFF
2 Auto-deceleration switch
Turned OFF: The function is not active.
(Lit)
<The function is made inactive when arm crane is
used.>
Activates wiper of front glass.
"ON" is lit: Wiper works continuously.
OFF
INT
ON
3 Wiper switch
"INT" is lit: Wiper works intermittently.
(Not lit)
(Intermittent) (Continuous)
Not lit: Wiper is not working.
[When wiper is not working]
ON : Washer fluid is sprayed
and wiper works continuously.
OFF : Wiper works twice and
stops after the switch was
released.
[When wiper is working intermit4 Windshield washer switch
Sprays washer fluid onto front glass.
tently]
ON : Washer fluid is sprayed
and wiper works continuously.
OFF : Wiper works twice and returns to intermittent operation after the switch was
released.
Sets the movement and force of the working
equipment.
"A" is lit: A mode (for heavy duty work)
* Operation mode selector
A
E
L
B
5 switch
"E" is lit: E mode (for fuel economical operation)
"L" is lit: L mode (for fine control work)
"B" is lit: B mode (for breaker work)

You can change the default settings which become active when starting switch is turned on. Refer to the
"TROUBLESHOOTING" chapter.
a Signs written in bold fonts in the "Operation" column above represent the positions switches default to when
starting switched is turned on.

PC130-7

10-153
(3)

STRUCTURE AND FUNCTION

MONITOR SYSTEM

SENSORS

Signal from a sensor is directly entered to the


panel.
There are two types of sensors, contact type and
resistance type.
One end of a contact type sensor is connected to
the ground on the machine body.
Display class
Caution
Gauge

Sensor type
Engine oil pressure
Coolant temperature
Fuel level
Hydraulic oil temperature

Sensing approach
Contact
Resistance
Resistance
Resistance

When normal
OFF (open)

When failed
ON (closed)

ENGINE OIL PRESSURE SENSOR

1. Plug
2. Contact ring
3. Contact

4. Diaphragm
5. Spring
6. Terminal

COOLANT TEMPERATURE SENSOR


HYDRAULIC OIL TEMPERATURE SENSOR

1. Connector
2. Plug
3. Thermistor

10-154

PC130-7

STRUCTURE AND FUNCTION

MONITOR SYSTEM

FUEL LEVEL SENSOR

1.
2.
3.
4.

Float
Connector
Cover
Variable resisto

PC130-7

10-155

20 TESTING AND ADJUSTING


STANDARD VALUE TABLE FOR ENGINE.......... 20- 2
STANDARD VALUE TABLE FOR CHASSIS........ 20- 3
TESTING AND ADJUSTING................................ 20-101
TROUBLESHOOTING ......................................... 20-201

Note the following when making judgements using the standard value tables for testing, adjusting, or troubleshooting.
1. The standard value for a new machine given in the table is the value used when shipping the machine from
the factory and is given for reference. It is used as a guideline for judging the progress of wear after the
machine has been operated, and as a reference value when carrying out repairs.
2. The service limit value given in the tables is the estimated value for the shipped machine based on the
results of various tests. It is used for reference together with the state of repair and the history of operation
to judge if there is a failure.
3. These standard values are not the standards used in dealing with claims.
When carrying out testing, adjusting, or troubleshooting, park the machine on level ground, inset the safety
pins, and use blocks to prevent the machine from moving.
When carrying out work together with other workers, always use signals and do not let unauthorized people
near the machine.
When checking the 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.
Be careful not to get caught in the fan, fan belt or other rotating parts.

PC130-7

20-1
(1)

TESTING AND ADJUSTING

STANDARD VALUE TABLE FOR ENGINE

STANDARD VALUE TABLE FOR ENGINE

Item

Model name

PC130-7

Engine

SAA4D95LE-3

Measurement condition

Unit

Standard value

Permissible value

2,350 100

2,350 100

1,100 50

1,100 50

2,200

Max. 4.5

Max. 6.5

Max. 1.0

Max. 2.0

0.35

0.50

MPa
{kg/cm2}
(rpm)

Min. 2.9
{Min. 30}
(320 360)

2.0
{20}
(320 360)

kPa
{mmH2O}

Max. 0.49
{Max. 50}

0.98
{100}

0.34 0.59
{3.5 6.0}

0.25
{2.5}

0.29 0.54
{3.0 5.5}

0.21
{2.1}

Min. 0.1
{Min. 1.0}
Min. 0.08
{Min. 0.8}

0.07
{0.7}
0.07
{0.7}

90 110

120

6 0.75

6 0.75

High idling
Engine speed

Low idling

rpm

Rated speed
During sharp acceleration
Exhaust gas color
During high idling
Valve clearance
(Cooled)
Compression pressure

Blow-by pressure

Bosch
index

Intake valve
mm
Exhaust valve
Oil temperature: 40 60 C
(Engine speed)
Coolant temperature:
Within operating range
At rated output
Coolant temperature:
Within operating range
At high idling (SAE30)

Oil pressure

At high idling (SAE10W)

MPa
{kg/cm2}

At low idling (SAE30)


At high idling (SAE10W)
Oil temperature

Through speed range (In oil pan)

Fuel injection timing

Before top dead center (BTDC)

Fan belt tension

Deflection under finger pressure of


58.8 N {6 kg}

mm

6 10

6 10

Air conditioner compressor belt tension

Deflection under finger pressure of


58.8 N {6 kg}

mm

6 10

6 10

20-2
(1)

PC130-7

TESTING AND ADJUSTING

STANDARD VALUE TABLE FOR CHASSIS

STANDARD VALUE TABLE FOR CHASSIS


Model name
Category

Item

Unit

Standard value

Permissible value

rpm

2,120 100

2,120 100

rpm

2,180 100

2,180 100

rpm

1,400 100

1,400 100

8.0 0.5

8.0 0.5

9.5 0.5

9.5 0.5

8.0 0.5

8.0 0.5

Bucket control valve

8.0 0.5

8.0 0.5

Swing control valve

8.0 0.5

8.0 0.5

Travel control valve

8.0 0.5

8.0 0.5

85 10

85 10

85 10

85 10

85 10

85 10

Swing control lever

85 10

85 10

Travel control lever

112 15

112 15

Play of control lever

10 15

10 15

15.7 3.9
{1.6 0.4}
15.7 3.9
{1.6 0.4}

Max. 24.5
{Max. 2.5}
Max. 24.5
{Max. 2.5}

12.7 2.9
{1.3 0.3}

Max. 21.6
{Max. 2.2}

12.7 2.9
{1.3 0.3}

Max. 21.6
{Max. 2.2}

Travel control lever

24.5 5.9
{2.5 0.6}

Max. 39.2
{Max. 4.0}

Travel control pedal

80.4 20.1
{8.2 2.0}

Max. 107.9
{Max. 11}

Engine speed

Pump relief

Pump relief + Onetouch power maximizing

During auto-deceleration

Control valve spool stroke

Boom control valve

Control lever stroke

Measurement condition
Engine coolant temperature:
Within operating range
Hydraulic oil temperature: 45 55 C
Engine speed: High idling
Working mode: A
Arm OUT relief
Engine coolant temperature:
Within operating range
Hydraulic oil temperature: 45 55 C
Engine speed: High idling
Arm OUT relief + One-touch power
maximizing switch ON
Engine speed: High idling
Auto-decelerator switch: ON
All control levers in neutral
Engine: Stopped
IN

Arm control valve


OUT
mm

Boom control lever

Operating effort of control lever

PC130-7

Arm control lever

Engine: Stopped
Center of lever grip
Read max. value to stroke end
(Exclude play in neutral position).

Bucket control lever


mm

Boom control lever


Arm control lever
Bucket control lever
Swing control lever

PC130-7

Hydraulic oil temperature:


Within operating range
Engine speed: High idling
Center of lever grip
Tip of pedal
Read max. value to stroke end

N
{kg}

20-3
(1)

TESTING AND ADJUSTING

STANDARD VALUE TABLE FOR CHASSIS

Model name
Category

Item

Unload pressure

Boom relief pressure

Oil pressure

Arm relief pressure

Bucket relief pressure

PC130-7

Measurement condition

Unit

Standard value

Permissible value

MPa
{kg/cm2}

2.9 0.5
{30 5}

2.9 0.5
{30 5}

At normal
relief

31.9 + 2.0
0
{325 + 20
0 }

33.3 36.8
{340 375}

At power
max.

34.8 1.0
{355 10}
31.9 + 2.0
0
{325 + 20
0 }
34.8 1.0
{355 10}
31.9 + 2.0
0
{325 + 20
0 }

36.3 39.2
{370 400}
33.3 36.8
{340 375}
36.3 39.2
{370 400}
33.3 36.8
{340 375}

34.8 1.0
{355 10}

36.3 39.2
{370 400}

28.9 1.5
{295 15}
34.8 1.0
{355 10}

28.9 32.9
{295 335}
36.3 39.2
{370 400}

3.23 0.2
{33 2}

2.84 3.43
{29 35}

2.7 + 1.0
0.7
{28 + 107 }

2.7 + 1.0
0.7
{28 + 107 }

2.2 0.1
{22.5 1}

2.2 0.1
{22.5 1}

Hydraulic oil temperature: 45 55 C


Engine speed: High idling
Working mode: A
Pump outlet pressure when all levers
are in neutral
Hydraulic oil temperature: 45 55 C
Engine speed:
High idling
Working mode: A
Pump outlet pressure
when measured circuit is
relieved

At normal
relief
At power
max.
At normal
relief

MPa
{kg/cm2}

At power
max.

Swing relief pressure


Travel relief pressure

Control circuit basic


pressure

LS differential pressure

20-4
(1)

Hydraulic oil temperature: 45 55 C


Engine speed: High idling
MPa
Outlet pressure of self-reducing pres{kg/cm2}
sure valve when all levers are in neutral
Hydraulic oil temperature: When all
45 55 C levers are
Engine speed: High idling in neutral
MPa
Working mode: A
{kg/cm2}
When
Pump pressure - LS prestravel syssure
tem runs
idle at Hi

PC130-7

TESTING AND ADJUSTING

STANDARD VALUE TABLE FOR CHASSIS

Model name
Category

Item

Overrun of swing

PC130-7

Measurement condition

Hydraulic oil temperature: 45 55 C


Engine speed: High idling
Working mode: A
Quantity of overrun of swing circle
when it stops after 1 turn
( ): Qty of overrun of periphery of
swing circle

Unit

Standard value

Permissible value

deg
(mm)

75 10
{730 100}

Max. 90
(Max. 870)

2.9 0.3

Max. 3.5

4.0 0.4

Max. 8.5

sec

28.6 4.8

28.6 5.8

mm

90

Hydraulic oil temperature:


45 55 C
Engine speed: High idling
180
Working mode: A
Time taken to swing 90 and
180 after starting

sec

Swing

Time taken to start


swinging

Time taken to swing


Hydraulic oil temperature: 45 55 C
Engine speed: High idling
Working mode: A
Time taken to swing 5 turns after
swinging 1 turn

Hydraulic drift of swing


Hydraulic oil temperature: 45 55 C
Engine: Stopped
Set upper structure at 90 to machine
body on slope of 15.
Make match marks on inner race and
outer race of swing circle.
Measure deviation of match marks in
15 minutes.

PC130-7

20-5
(1)

TESTING AND ADJUSTING

STANDARD VALUE TABLE FOR CHASSIS

Model name

Swing

Category

Item

Leakage from swing


motor

PC130-7

Measurement condition

Unit

Standard value

Permissible value

l/min

Max. 3

Max. 6

46.1 9.2

46.1 9.2

Hi

21.9 2.2

23.1 3.0

Lo

27.6 5.1

27.6 7.1

Hi

13.2 1.2

13.2 1.7

Max. 200

Max. 220

Hydraulic oil temperature: 45 55 C


Engine speed: High idling
Swing lock switch: LOCK
Measure leakage for 1 minutes while
swing circuit is relieved.

Lo

Travel speed (Idle run)

sec
Hydraulic oil temperature:
45 55 C
Engine speed: High idling
Working mode: A
Measure time taken to rotate
track shoe 5 turns after 1 turn.

Travel

Travel speed
(Actual travel)

Travel deviation

20-6
(1)

Hydraulic oil temperature:


45 55 C
Engine speed: High idling
Working mode: A
Hard and level place
Measure time taken to travel 20
m after running up 10 m.

Hydraulic oil temperature: 45 55 C


Engine speed: High idling
Working mode: A
Travel speed: Lo
Hard and level place
Measure travel deviation in travel of
20 m after running up 10 m.

mm

PC130-7

TESTING AND ADJUSTING

STANDARD VALUE TABLE FOR CHASSIS

Model name
Category

Item

PC130-7

Measurement condition

Unit

Standard value

Permissible value

mm

l/min

Max. 5

Max. 10

Whole work
equipment
(Hydraulic drift of tooth tip)

Max. 460

Max. 700

Boom cylinder
(Retraction of cylinder)

Max. 10

Max. 12

Max. 80

Max. 90

Max. 22

Max. 40

3.7 0.4

Max. 4.3

2.6 0.5

Max. 3.2

Travel

Hydraulic drift of travel

Hydraulic drift of work equipment


Work equipment speed

Work equipment

Leakage from travel


motor

PC130-7

Hydraulic oil temperature: 45 55 C


Engine: Stopped
Stop machine on slope of 12 degrees
with sprocket on upper side.
Measure hydraulic drift of travel in 5
minutes.
Hydraulic oil temperature: 45 55 C
Engine speed: High idling
Lock sprocket.
Measure leakage for 1 minutes while
travel circuit is relieved.

Hydraulic oil temperature: 45 55 C


Level and flat place
Bucket: Full of dirt and sand or filled
Arm cylinder
with rated load (1,080 kg)
(Extension of cylinder) Level boom top, retract arm cylinder
fully, and extract bucket cylinder fully.
Engine: Stopped
Work equipment control lever: Neutral
Bucket cylinder
Start measuring hydraulic drift just
(Retraction of cylinder) after setting machine and measure
every 5 minutes for 15 minutes.

mm

RAISE

Boom speed

Hydraulic oil temperature:


45 55 C
Engine speed: High idling
Working mode: A
LOWER
Measure time taken to move
bucket between RAISE stroke
end and ground touch point of
bucket.

sec

20-7
(1)

TESTING AND ADJUSTING

STANDARD VALUE TABLE FOR CHASSIS

Model name
Category

Item

PC130-7

Measurement condition

Unit

CURL

Work equipment

Work equipment speed

Arm speed

(1)

Hydraulic oil temperature:


45 55 C
Engine speed: High idling
Working mode: A
DUMP
Measure time taken to move
bucket between DUMP stroke
end and CURL stroke end

Boom time lag

Permissible value

3.2 0.4

Max. 4.4

3.1 0.3

Max. 3.7

2.9 0.3

Max. 3.7

2.3 0.2

Max. 2.9

Max. 3.0

Max. 4.0

sec

CURL

Bucket speed

Time lag

20-8

Hydraulic oil temperature:


45 55 C
Engine speed: High idling
Working mode: A
DUMP
Measure time taken to move
arm between OUT stroke end
and IN stroke end (between
starting points of cushion).

Standard value

sec

sec
Hydraulic oil temperature: 45 55 C
Engine speed: Low idling
Working mode: A
Lower boom from RAISE stroke end
and measure time taken to start raising front of machine after bucket
touches ground.

PC130-7

TESTING AND ADJUSTING

STANDARD VALUE TABLE FOR CHASSIS

Model name
Category

Item

Measurement condition

Unit

Standard value

Permissible value

sec

Max. 2.0

Max. 3.0

sec

Max. 2.0

Max. 3.0

Max. 3.5

Max. 15

Max. 10

Max. 50

Max. 500

Max. 500

Hydraulic oil temperature: 45 55 C


Engine speed: Low idling
Working mode: A
Move IN arm from OUT stroke end
and measure time taken to start moving arm again after it is stopped.
For measuring posture, see WORK
EQUIPMENT 6.

Time lag

Work equipment

Arm time lag

PC130-7

Bucket time lag

Compound operation performance

Oil leakage

Hydraulic oil temperature: 45 55 C


Engine speed: Low idling
Working mode: A
Curl bucket from DUMP stroke end
and measure time taken to start moving bucket again after it is stopped.
For measuring posture, see WORK
EQUIPMENT 7.
Hydraulic oil temperature: 45 55 C
Engine speed: High idling
Relieve cylinder to be measured or
Center swivel joint travel circuit and measure leakage in
1 minute.
Cylinder

Travel deviation in
compound operation
of work equipment and
travel

PC130-7

cc/min

Hydraulic oil temperature: 45 55 C


Engine speed: High idling
Working mode: A
Travel speed: Lo
Hard and level place
Measure travel deviation in travel of
20 m after running up 10 m.
mm

20-9
(1)

TESTING AND ADJUSTING

STANDARD VALUE TABLE FOR CHASSIS

Model name
Category

PC flow control
characteristics

Measurement condition

Hydraulic oil temperature: 45 55 C


Engine: High idling
Working mode: A
Time taken to swing
Bucket: Filled with rated load
90 in compound oper- Hard and level place
ation of raising boom
Set arm vertically and lower back of
and starting swinging
bucket to ground.
Raise boom and start swinging simultaneously from above posture and
measure time taken to pass 90 point.

Pump
performance

Item

Hydraulic pump
capacity

20-10
(1)

See graph.

PC130-7
Unit

Standard value

Permissible value

sec

4.0
(Reference value)

l/min

See graph.

PC130-7

TESTING AND ADJUSTING

STANDARD VALUE TABLE FOR CHASSIS

Model name
Category

Item

PC130-7

Measurement condition

Unit

Standard value

Permissible value

Pump performance

Hydraulic pump performance

PC-EPC current: 400 mA


Pump speed: 2,000 rpm
Check point

Test pump discharge


pressure
(MPa{kg/cm2})

Standard discharge
(l/min)

Lower limit of
discharge
(l/min)

Any point

Q
(See graph)

Q
(See graph)

a Avoid measuring near a broken point of the graph, since the error becomes large at that point.
a When measuring without removing the pump from the machine, if the engine speed cannot be set to the specified speed with the fuel control dial, calculate the pump discharge pressure at the specified speed from the
engine speed and pump discharge at the time of measurement.

PC130-7

20-11
(1)

TESTING AND ADJUSTING


TOOLS FOR TESTING, ADJUSTING, AND TROUBLESHOOTING ......................................................... 20-102
TESTING AND ADJUSTING ENGINE SPEED .......................................................................................... 20-104
MEASURING EXHAUST GAS COLOR ..................................................................................................... 20-105
ADJUSTING VALVE CLEARANCE ........................................................................................................... 20-107
MEASURING COMPRESSION PRESSURE ............................................................................................. 20-109
MEASURING BLOW-BY PRESSURE ....................................................................................................... 20-110
MEASURING ENGINE OIL PRESSURE ................................................................................................... 20-111
TESTING AND ADJUSTING FOR FUEL INJECTION TIMING ................................................................ 20-112
ADJUSTING ENGINE SPEED SENSOR .................................................................................................. 20-116
TESTING AND ADJUSTING FAN BELT TENSION .................................................................................. 20-117
TESTING AND ADJUSTING AIR CONDITIONER COMPRESSOR BELT TENSION .............................. 20-118
MEASURING CLEARANCE OF SWING CIRCLE BEARING .................................................................... 20-119
TESTING AND ADJUSTING TRACK SHOE TENSION ............................................................................ 20-120
TESTING AND ADJUSTING OIL PRESSURE IN WORK EQUIPMENT, SWING, AND TRAVEL CIRCUITS....... 20-122
MEASURING CONTROL CIRCUIT BASIC PRESSURE ........................................................................... 20-125
TESTING AND ADJUSTING OIL PRESSURE IN PUMP PC CONTROL CIRCUIT .................................. 20-126
TESTING AND ADJUSTING OIL PRESSURE IN PUMP LS CONTROL CIRCUIT .................................. 20-129
MEASURING SOLENOID VALVE OUTPUT PRESSURE ......................................................................... 20-133
MEASURING PPC VALVE OUTPUT PRESSURE .................................................................................... 20-135
ADJUSTING PLAY OF WORK EQUIPMENT AND SWING PPC VALVES ............................................... 20-136
TESTING PARTS WHICH CAUSE HYDRAULIC DRIFT OF WORK EQUIPMENT .................................. 20-137
MEASURING OIL LEAKAGE ..................................................................................................................... 20-139
RELEASING RESIDUAL PRESSURE IN HYDRAULIC CIRCUIT ............................................................. 20-142
BLEEDING AIR FROM EACH PART ......................................................................................................... 20-143
TESTING PROCEDURE FOR DIODE ...................................................................................................... 20-146
SPECIAL FUNCTIONS OF MONITOR PANEL ......................................................................................... 20-147
PREPARATION WORK FOR TROUBLESHOOTING FOR ELECTRIC SYSTEM .................................... 20-166
PM-CLINIC SERVICE ................................................................................................................................. 20-167

PC130-7

20-101
(1)

TOOLS FOR TESTING, ADJUSTING, AND TROUBLESHOOTING

TESTING AND ADJUSTING

Testing and adjusting item

Measuring exhaust gas


color

Part No.

Part name

Q'ty

Symbol

TOOLS FOR TESTING, ADJUSTING, AND TROUBLESHOOTING


Remarks

1 799-203-9000

Handy smoke
checker

Commercially
2 available

Smoke meter

Pollution level: 0 70% (With standard


color)
(Pollution level x 1/10 C Bosch index)

Commercially
available

Feeler gauge

(Air intake side: 0.35 mm, Exhaust side:


0.50 mm)

795-502-1205

Compression gauge

0 6.9MPa {0 70kg/cm2}

795-502-1370

Adapter

6204-11-3880

Gasket

799-201-1504

Blow-by checker

799-101-5002

Hydraulic tester

Pressure gauge: 2.5,5.9,39.2,58.8MPa


{25,60,400,600kg/cm2}

790-261-1203

Digital hydraulic
tester

Pressure gauge: 58.8MPa {600kg/cm2}

E 2 799-401-2320

Hydraulic tester

Pressure gauge: 0.98MPa {10kg/cm2}

Adapter

Size: 06

799-101-5220

Nipple

07002-11023

O-ring

Spring pusher

Adjusting valve clearance

Measuring compression
pressure

For 95E-3 engine

Measuring blow-by pressure

Measuring engine oil pressure

3 799-401-3500
4

Size: 10 x 1.25mm

1 795-102-2103
Measuring fuel injection
timing

For delivery valve method

Measuring clearance of
swing circle bearing

2 Commercially
available

Dial gauge

Commercially
available

Dial gauge

799-101-5002

Hydraulic tester

790-261-1203

Digital hydraulic
tester

799-101-5220

Nipple

07002-11023

O-ring

799-101-5002

Hydraulic tester

790-261-1203

Digital hydraulic
tester

799-101-5230

Nipple

07002-11423

O-ring

799-101-5002

Hydraulic tester

790-261-1203

Digital hydraulic
tester

799-101-5230

Nipple

07002-11423

O-ring

Testing and adjusting oil


pressure in work equipH
ment, swing, and travel circuits

* Same as E1

* Same as E4

1
Measuring control circuit
basic pressure

* Same as E1

Size: 14 x 1.5mm

1
Testing and adjusting oil
pressure in pump PC control circuit

* Same as H (Only quantity is different)

20-102
(1)

PC130-7

Part name

Q'ty

Testing and adjusting item

TOOLS FOR TESTING, ADJUSTING, AND TROUBLESHOOTING

Symbol

TESTING AND ADJUSTING

799-101-5002

Hydraulic tester

790-261-1203

Digital hydraulic
tester

799-101-5230

Nipple

07002-11423

O-ring

Differential pressure
gauge

799-101-5002

Hydraulic tester

790-261-1203

Digital hydraulic
tester

Adapter

799-101-5002

Hydraulic tester

790-261-1203

Digital hydraulic
tester

Adapter

Part No.

1
Testing and adjusting oil
pressure in pump LS control circuit

1
M

2 799-401-3100

Measuring PPC valve output pressure

* Same as H (Only quantity is different)

3 799-401-2701

Measuring solenoid valve


output pressure

Remarks

1
N

2 799-401-3100

* Same as E1

Size: 03

* Same as E1

* Same as M2

Measuring oil leakage

Commercially
available

Measuring cylinder

Measuring water temperature and oil temperature

799-101-1502

Digital thermometer

-99.9 1,299C

Measuring operating effort


and pressing force

79A-264-0021 Push-pull scale

0 294N {0 30kg}

79A-264-0091 Push-pull scale

0 490N {0 50kg}

Measuring stroke and


hydraulic drift

Commercially
available

Scale

Measuring work equipment


speed

Commercially
available

Stopwatch

Measuring voltage and


resistance

Commercially
available

Circuit tester

a For the model names and part Nos. of the T-adapters and boxes used for troubleshooting for the monitor
panel, controllers, sensors, actuators, and wiring harnesses, see TROUBLESHOOTING, Layout of connectors and electric circuit diagram of each system.

PC130-7

20-103
(1)

TESTING AND ADJUSTING

TESTING AND ADJUSTING


ENGINE SPEED
MEASURING
1. Preparation work
1) Turn the starting switch ON and set the monitor panel in the "Monitoring function [02]" to
prepare for measurement of the engine
speed.
a For the operating method, see "Special
functions of monitor panel".
Monitoring code: 010 (Engine speed)
a The engine speed is displayed in rpm.
2) Warm up the engine to the following operating condition.
Engine coolant temperature: Within operating range
Hydraulic oil temperature: 45 55C
a Measure the engine speed with the working mode switch in the A-mode position.

TESTING AND ADJUSTING ENGINE SPEED

4. Measuring pump relief and one-touch power


maximizing speed
1) Set the fuel control dial in the high idling
(MAX) position.
2) Relieve the arm circuit by moving the arm IN,
keeping pressing the one-touch power maximizing switch, and measure the engine
speed.
a The one-touch power maximizing function is reset automatically in about 8.5
seconds even if the switch is kept held.
Accordingly, measure the engine speed
in that period.
5. Measuring auto-deceleration speed
1) Start the engine and set the fuel control dial
in the high idling position (MAX).
2) Set the work equipment control, swing control, and travel levers in neutral and measure
the engine speed.
a The engine speed lowers to a certain
level about 5 seconds after all the levers
are set in neutral. This level is the autodeceleration speed.
ADJUSTING
Adjusting governor spring
a If the high idling speed is out of the standard
range or the engine speed is unstable (the
engine hunts), adjust the governor spring with
"Governor adjustment function [03]" of the monitor panel.
a For the adjustment procedure, see SPECIAL
FUNCTIONS OF MONITOR PANEL.

1. Measuring low idling speed


1) Set the fuel control dial in the low idling (MIN)
position.
2) Set the work equipment control, swing control, and travel levers in neutral and measure
the engine speed.
2. Measuring high idling speed
1) Turn the auto-decelerator switch OFF.
2) Set the fuel control dial in the high idling
(MAX) position.
3) Set the work equipment control, swing control, and travel levers in neutral and measure
the engine speed.
3. Measuring pump relief speed
1) Set the fuel control dial in the high idling
(MAX) position.
2) Relieve the arm circuit by moving the arm IN
and measure the engine speed.

20-104
(1)

PC130-7

TESTING AND ADJUSTING

MEASURING EXHAUST GAS COLOR

MEASURING EXHAUST GAS


COLOR
a Measuring instruments for exhaust gas color
Symbol
A

Part No.

2. Measuring with smoke meter A2


1) Insert probe [1] of smoke meter A2 in the
outlet of exhaust pipe (1) and fix it to the
exhaust pipe with a clip.

Part name

799-201-9000

Handy Smoke Checker

Commercially
available

Smoke Meter

k When installing and removing the measuring


instruments, take care not to touch a hot part.
a If an air source and an electric power source are
not available in the field, use handy smoke
checker A1. When recording official data, use
smoke meter A2.
1. Measuring with handy smoke checker A1
1) Stick a sheet of filter paper to smoke checker
A1.
2) Insert the exhaust gas intake pipe in exhaust
pipe (1).
3) Run the engine.
4) Accelerate the engine suddenly or run it at
high idling and operate the handle of smoke
checker A1 so that the filter paper will absorb
the exhaust gas.

2) Connect the probe hose, receptacle of the


accelerator switch, and air hose to smoke
meter A2.
a Limit the supplied air pressure to 1.5
MPa {15 kg/cm2}.
3) Connect the power cable to a receptacle of
AC 100 V.
a Before connecting the cable, check that
the power switch of the smoke meter is
turned OFF.
4) Loosen the cap nut of the suction pump and
fit the filter paper.
a Fit the filter paper securely so that the
exhaust gas will not leak.
5) Turn on the power switch of smoke meter
A2.

5) Remove the filter paper and compare it with


the attached scale.
6) After finishing measurement, remove the
measuring instrument and return the
removed parts.
6) Start the engine and heighten the engine
coolant temperature to the operating range.

PC130-7

20-105
(1)

TESTING AND ADJUSTING

MEASURING EXHAUST GAS COLOR

7) Accelerate the engine suddenly or run it at


high idling and press the accelerator pedal of
smoke meter A2 and collect the exhaust gas
into the filter paper.
8) Place the contaminated filter paper on the
clean filter paper (at least 10 sheets) in the
filter paper holder and read the indicated
value.
9) After finishing measurement, remove the
measuring instrument and return the
removed parts.

20-106
(1)

PC130-7

TESTING AND ADJUSTING

ADJUSTING VALVE CLEARANCE

ADJUSTING VALVE
CLEARANCE
a Adjusting instrument for valve clearance
Symbol

Part No.

Commercially
available

4. While the No. 1 cylinder is at the compression


top dead center, adjust the valve clearances
marked with q in the valve arrangement drawing
according to the following procedure.

Part name
Feeler gauger

1. Open the engine hood and remove all cylinder


head covers (1).

2. Remove the engine undercover (on the radiator


side).
3. Rotate the crankshaft forward to bring the
stamped "1.4TOP" line (a) of the crank pulley to
pointer (2) and set the No. 1 cylinder to the compression top dead center.
a Crank the crankshaft with the crank pulley
mounting bolt.
a There are 2 stamped "1.4TOP" lines on the
crank pulley. Use the one at the diagonal
position of "2.3TOP".
a When the No. 1 cylinder is at the compression top dead center, the rocker arm of the
No. 1 cylinder can be moved by the valve
clearance with the hand. If the rocker arm
cannot be moved, the No. 1 cylinder is not at
the compression top dead center. In this
case, rotate the crankshaft one more turn.

1) Insert feeler gauge B in clearance (b)


between rocker arm (3) and valve stem (4)
and adjust the clearance with adjustment
screw (5).
a With the feeler gauge inserted, turn the
adjustment screw to a degree that you
can move the filler gauge lightly.
2) Secure adjustment screw (5) and tighten
locknut (6).
3 Locknut: 39.2 49 Nm {4 5 kgm}
a After tightening the locknut, check the
valve clearance again.
a After adjusting all of the valves marked
with q, go to the next procedure.

5. Rotate the crankshaft forward to bring the


stamped "1.4TOP" line (a) of the crank pulley to
pointer (2) and set the No. 4 cylinder to the compression top dead center.

PC130-7

20-107
(1)

TESTING AND ADJUSTING

ADJUSTING VALVE CLEARANCE

6. While the No. 4 cylinder is at the compression


top dead center, adjust the valve clearances
marked with Q in the valve arrangement drawing.
a Adjust the valve clearance according to step
4 above.
7. After finishing adjustment, return the removed
parts.

3 Cylinder head cover mounting bolt:


7.84 9.8 Nm {0.8 1.0 kgm}

20-108
(1)

PC130-7

TESTING AND ADJUSTING

MEASURING COMPRESSION PRESSURE

MEASURING COMPRESSION
PRESSURE
a Measuring instruments for compression pressure
Symbol
C

Part No.

Part name

795-502-1205

Compression gauge

795-502-1370

Adapter

6204-11-3880

Gasket

a When measuring the compression pressure,


take care not to burn yourself on the exhaust
manifold, muffler, etc. or get caught in a rotating
part.
6. Remove governor spring (2).
1. Adjust the valve clearance.
a See Adjusting valve clearance.

7. Put governor lever (3) of the fuel injection pump


to the STOP side stopper and fix it.

2. Warm up the engine until the engine oil temperature is 40 60C.


3. Prepare for measuring the engine speed.
a See Testing and adjusting engine speed.
4. Open the engine hood and remove nozzle holder
(1) of the cylinder to measure the compression
pressure.

8. Crank the engine with the starting motor and


measure the compression pressure.
a Read the compression gauge when its
pointer is stabilized.
a When measuring the compression pressure,
measure the engine speed, too, and check
that it is in the measurement condition range.

5. Install adapter [1] of compression gauge C to the


mounting part of the nozzle holder and connect
gauge [2].
a Install the gasket to the end of the adapter.
a Secure the adapter with the clamping holder
and mounting bolt for the nozzle holder.
3 Mounting bolt: 39.2 49 Nm {4 5 kgm}

PC130-7

9. After finishing measurement, remove the measuring instruments and return the removed parts.
a Check that the fulcrum of the clamping
holder for the nozzle holder is seated on the
cylinder head, and then tighten the mounting
bolt.
3 Mounting bolt: 39.2 49 Nm {4 5 kgm}

20-109
(1)

MEASURING BLOW-BY PRESSURE

TESTING AND ADJUSTING

MEASURING BLOW-BY
PRESSURE
a Measuring instruments for blow-by pressure
Symbol

Part No.

799-201-1504

5. Run the engine at high idling and measure the


blow-by pressure.
Working mode: A
Work equipment, swing, and travel circuit:
Relieve the travel circuit.

Part name
Blow-by checker

1. Remove the engine undercover (on the flywheel


side).
2. Install nozzle [1] of blow-by checker C to the end
of blow-by hose (1) and connect it to gauge [2].

6. After finishing measurement, remove the measuring instruments and return the removed parts.

3. Start the engine and lock the travel mechanism.

k Put pin [3] between the sprocket and track


frame to lock the travel mechanism
securely.

4. Start the engine and warm it up to the operating


range.
Engine coolant temperature: Within operating range
Hydraulic oil temperature: 45 55C

20-110
(1)

PC130-7

TESTING AND ADJUSTING

MEASURING ENGINE OIL PRESSURE

MEASURING ENGINE OIL


PRESSURE

5. Measure the oil pressure during low idling and


high idling.

a Measuring instruments for engine oil pressure


Symbol
1
E

2
3
4

Part No.

Part name

799-101-5002

Hydraulic tester

790-261-1203

Digital hydraulic tester

799-401-2320

Hydraulic tester

799-401-3500

Adapter (Size: 06)

799-101-5220

Nipple (10 x 1.25 mm)

07002-11023

O-ring

1. Open the pump room cover and disconnect outlet hose (1) of the engine oil filter.

6. After finishing measurement, remove the measuring instruments and return the removed parts.

2. Install adapter E3 and connect the disconnected


hose again.
3. Install nipple E4 and connect it to hydraulic tester
E2.

4. Start the engine and heighten the engine coolant


temperature to the operating range.

PC130-7

20-111
(1)

TESTING AND ADJUSTING FOR FUEL INJECTION TIMING

TESTING AND ADJUSTING

TESTING AND ADJUSTING


FOR FUEL INJECTION TIMING
a Testing and adjusting instruments for fuel injection timing (for delivery valve method)
Symbol
F

Part No.

Part name

795-102-2103

Spring pusher

Commercially
available

Dial gauge

TESTING AND ADJUSTING BY MATCH MARK


METHOD
a After removing and installing the fuel injection
pump without repairing it or when only checking
the injection timing, test and adjust the injection
timing according to the following procedure.
TESTING
1. Open the engine hood and remove all cylinder
head covers (1).

4. Remove cover (3) of the fuel injection pump


drive shaft.
5. Insert pin [1] in the mounting bolt hole of the front
cover (on the outside of the engine) to check the
fuel injection timing.
a Use a pin 4.0 4.5 mm in diameter and
about 80 mm in length.
a If the pin enters smoothly to inside of the
drive gear of the fuel injection pump, the fuel
injection timing is normal. In this case, return
the removed parts.
a If the pin touches the drive gear of the fuel
pump, the fuel injection timing is abnormal.
In this case, adjust the fuel injection timing.

2. Remove the engine undercover (on the radiator


side).
3. Rotate the crankshaft forward to bring the
stamped "1.4TOP" line (a) of the crank pulley to
pointer (2) and set the No. 1 cylinder to the compression top dead center.
a Crank the crankshaft with the crank pulley
mounting bolt.
a There are 2 stamped "1.4TOP" lines on the
crank pulley. Use the one at the diagonal
position of "2.3TOP".
a When the No. 1 cylinder is at the compression top dead center, the rocker arm of the
No. 1 cylinder can be moved by the valve
clearance with the hand. If the rocker arm
cannot be moved, the No. 1 cylinder is not at
the compression top dead center. In this
case, rotate the crankshaft one more turn.

20-112
(1)

ADJUSTING
a If the fuel injection timing is abnormal, adjust it
according to the following procedure.
1. Remove the fuel pump, holder, and drive gear
together.
a See DISASSEMBLY AND ASSEMBLY,
Removal, installation of fuel pump assembly.

PC130-7

TESTING AND ADJUSTING

TESTING AND ADJUSTING FOR FUEL INJECTION TIMING

2. Remove bolt (3) and fix drive gear (4) to holder


(5) with fixing bolt [2].
a As fixing bolt [2], use a bolt 6 mm in thread
diameter and 35 mm in length.
a Pass the fixing bolt through the screw hole of
bolt (3) and tighten it into the screw hole of
the drive gear, and the fuel injection pump is
fixed in the fuel injection timing.

ADJUSTING BY DELIVERY VALVE METHOD


a After repairing or replacing the fuel injection
pump or timing gear, adjust the injection timing
according to the following procedure.
ADJUSTING
a Apply the delivery valve method to only adjustment of the injection timing.
1. Open the engine hood and remove all cylinder
head covers (1).

3. Install the fuel injection pump, holder, and drive


gear together.
a See DISASSEMBLY AND ASSEMBLY,
Removal, installation of fuel pump assembly.
a After installing the fuel injection pump temporarily, check the fuel injection timing according to the above described procedure.
4. After finishing adjustment, remove the measuring tools and return the removed parts.
k Be sure to remove pin [1] and fixing bolt [2].
3 Cylinder head cover mounting bolt:
7.84 9.8 Nm {0.8 1.0 kgm}

PC130-7

2. Remove the engine undercover (on the radiator


side).
3. Rotate the crankshaft forward to bring the
stamped "1.4TOP" line (a) of the crank pulley to
pointer (2) and set the No. 1 cylinder to the compression top dead center.
a Crank the crankshaft with the crank pulley
mounting bolt.
a There are 2 stamped "1.4TOP" lines on the
crank pulley. Use the one at the diagonal
position of "2.3TOP".
a When the No. 1 cylinder is at the compression top dead center, the rocker arm of the
No. 1 cylinder can be moved by the valve
clearance with the hand. If the rocker arm
cannot be moved, the No. 1 cylinder is not at
the compression top dead center. In this
case, rotate the crankshaft one more turn.

20-113
(1)

TESTING AND ADJUSTING

TESTING AND ADJUSTING FOR FUEL INJECTION TIMING

4. Remove snap ring (6) of the rocker arm shaft on


the No. 1 cylinder side, and then remove rocker
arm (7) of the No. 1 air intake valve.
a Remove the valve stem cap, too.

8. Install dial gauge F2 on the valve stem of No. 1


air intake valve (11) and set it to the 0 point.
a Since the No. 1 cylinder is at the compression top dead center, set this point as the 0
point.
9. Rotate the crankshaft about 45 in reverse.

5. Using spring pusher F1, remove valve cotter (8)


of the No. 1 air intake valve.
6. Loosen spring pusher F1 and remove seat (9)
and spring (10).

7. While No. 1 air intake valve (11) is in contact with


the top of piston (12), turn the valve stem with
the hand to press No. 1 air intake valve (11)
against the piston.
a Since the piston stroke will be measured at
the valve stem top, check that the valve bottom is in contact with the piston top securely.

20-114
(1)

10. Rotate the crankshaft forward slowly so that dial


gauge F2 will indicate fuel injection timing dimension (a).
a When adjusting the crankshaft to fuel injection timing dimension (a), be sure to rotate it
forward so that the adjustment will not be
affected by the backlash of the drive gear. (If
the crankshaft passes the adjustment dimension, return it sufficiently, and then adjust it
again forward.)
a Fuel injection timing dimension (a) and fuel
injection timing
Fuel injection timing
dimension (a)
Fuel injection timing
(Reference)

mm

0.42 0.08
6 0.75

11. Disconnect all of connected fuel injection tubes


(12), if there are any.

PC130-7

TESTING AND ADJUSTING

TESTING AND ADJUSTING FOR FUEL INJECTION TIMING

12. Remove delivery valve holder (14) for the No. 1


cylinder of fuel pump (13), delivery valve (15),
and spring (16), and then install delivery valve
holder (14) again.

13. Remove governor spring (17), and then put the


governor lever (18) of the fuel injection pump to
the stopper on the FULL side and fix it.

16. Tighten 4 mounting nuts (19) of fuel injection


pump (13) securely and alternately.

17. After finishing adjustment, remove the adjusting


tools and return the removed parts.
a Replace the O-ring and copper gasket of the
delivery valve with new ones.
k Tighten the delivery valve securely in 3
times. (If it is not tightened sufficiently, the
gasket may be broken.)
3 Delivery valve holder:
39.2 44.1 Nm {4 4.5 kgm}
3 Fuel injection tube sleeve nut:
19.6 24.5 Nm {2 2.5 kgm}

14. Remove the fixing bracket and lubrication tube of


fuel injection pump (13), loosen 4 mounting nuts
(19), and lean the fuel injection pump outward
fully.
a Loosen the mounting nuts to a degree that
the fuel injection pump can be moved in and
out within the range of the oblong hole (Do
not loosen them so much that the fuel injection pump will have play).

3 Cylinder head cover mounting bolt:


7.84 9.8 Nm {0.8 1.0 kgm}
a After finishing adjustment, if the stamped
lines of the fuel injection pump and holder
are not at the same position or there is not a
stamped line on the fuel injection pump,
stamp a new line to show that the fuel injection timing has been adjusted.

15. Operating priming pump (20) of fuel injection


pump 13, move the injection pump gradually
toward the cylinder block and stop when the fuel
stops flowing out of No. 1 delivery valve holder
(14), and then tighten the mounting nuts temporarily.
a The position where fuel stops flowing out of
the No. 1 delivery valve holder is the position
to start fuel injection in the No. 1 cylinder
(fuel injection timing).

PC130-7

20-115
(1)

TESTING AND ADJUSTING

ADJUSTING ENGINE SPEED


SENSOR
a If the engine speed sensor has been removed
and installed or its signal contains an error,
adjust it according to the following procedure.
a Remove engine speed sensor (1) before adjusting it and check that its tip is free from steel chips
(The engine speed sensor is installed to the right
side of the flywheel housing).

ADJUSTING ENGINE SPEED SENSOR

4. After finishing adjustment, check that the monitor


panel displays the engine speed normally in the
"Monitoring mode".
a For the operating method, see "Special functions of monitor panel".
Monitoring code: 010 (Engine speed)

1. Screw in sensor (1) until its tip touches the tooth


tip of flywheel ring gear (2).
2 Threads: Gasket sealant (LG-6)

2. Return sensor (1) by the specified angle.


a Returning angle of sensor: 1 1/6 turn
a After this adjustment, clearance (a) between
the sensor tip and gear tooth tip is 1.25
1.75 mm.
2 Nut: 49 68.6 Nm {5 7 kgm}

3. Fixing sensor (1), tighten nut (3).

20-116
(1)

PC130-7

TESTING AND ADJUSTING

TESTING AND ADJUSTING FAN BELT TENSION

TESTING AND ADJUSTING


FAN BELT TENSION

ADJUSTING
a If the deflection of the belt is abnormal, adjust it
according to the following procedure.

TESTING
1. Open the engine hood and remove the belt cover
from above the alternator.

1. Loosen alternator mounting bolts (1) and (2).

2. Press the intermediate point of the belt between


the fan pulley and alternator pulley with a finger
and measure deflection (a) of the belt.
Force to press belt: Approx. 58.8 N {6 kg}
Deflection (a): 6 10 mm

2. Adjust the belt tension by moving alternator (5)


with adjustment bolt (4).
a Turn the adjusting belt to left, the belt tension
tight.
3. Tighten locknut (3) and mounting bolts (2) and
(1).
a Check breakage of the pulleys, wear of the
V-grooves, and contact of the belts and Vgrooves.
a If a belt is lengthened to the adjustment limit,
cut, or cracked, replace it with new one.

4. After finishing adjustment, return the covers.


a If a V-belt is replaced, adjust its tension again
after 1 operating hour.

PC130-7

20-117
(1)

TESTING AND ADJUSTING

TESTING AND ADJUSTING


AIR CONDITIONER
COMPRESSOR BELT
TENSION
TESTING
1. Open the engine hood and remove the belt cover
from above the air conditioner compressor.
2. Press the intermediate point of the belt between
the fan pulley and alternator pulley with a finger
and measure deflection "a" of the belt.
Force to press belt: Approx. 58.8 N {6 kg}
Deflection (a): 6 10 mm

TESTING AND ADJUSTING AIR CONDITIONER


COMPRESSOR BELT TENSION

ADJUSTING
a If the deflection of the belt is abnormal, adjust it
according to the following procedure.
1. Loosen compressor bracket mounting bolts (1)
and (2).
2. Adjust the belt tension by moving compressor (3)
and bracket (4) together.
a Use a bar, etc. to move the bracket (Do not
push the compressor directly with a bar, etc.)
3. Tighten mounting bolts (2) and (1).
a Check breakage of the pulleys, wear of the
V-grooves, and contact of the belts and Vgrooves.
a If a belt is lengthened to the adjustment limit,
cut, or cracked, replace it with new one.

4. After finishing adjustment, return the covers.


a If a V-belt is replaced, adjust its tension again
after 1 operating hour.

20-118
(1)

PC130-7

TESTING AND ADJUSTING

MEASURING CLEARANCE OF SWING CIRCLE BEARING

MEASURING CLEARANCE OF
SWING CIRCLE BEARING
a Measuring instrument for clearance of swing circle bearing
Symbol

Part No.

Commercially
available

Part name
Dial gauge

a When measuring the clearance of the swing circle bearing on the actual machine, observe the
following procedure.
k While measuring, do not put your hands or foot
under the undercarriage.
1. Fix dial gauge G to outer race (1) or inner race
(2) of the swing circle and apply the probe to the
end face of inner race (2) or outer race (1) on the
opposite side.
a Set dial gauge G on the front or at rear side
of the machine

4. Set the arm at almost a right angle to the ground


and lower the boom until the track shoe at the
front side of the machine is floated.
a At this time, the front end of the upper structure rises and the rear end lowers.
5. Under this condition, read dial gauge G.
a Dial gauge G indicates the clearance of the
bearing.

2. Set the work equipment in the maximum reach


posture and set the bucket tip to the height of the
revolving frame bottom.
a At this time, the front end of the upper structure lowers and the rear end rises.

6. Return the machine to the posture of step 2 and


check that dial gauge G indicates 0 again.
a If dial gauge G does not indicate 0, repeat
steps 3 5.

3. Set the dial gauge G to the 0 point.

7. After finishing measurement, remove the measuring instruments and return the removed parts.

PC130-7

20-119
(1)

TESTING AND ADJUSTING

TESTING AND ADJUSTING


TRACK SHOE TENSION
TESTING
1. Running the engine at low idling, move the
machine forward by the length of track on ground
and stop slowly.
2. Place straight bar [1] on the track shoe between
the idler and the 1st carrier roller.
a As straight bar [1], use an L-shape steel, etc.
which will be deflected less.
3. Measure maximum clearance (a) between
straight bar [1] and track shoe.
Standard maximum clearance (a):
10 30 mm

TESTING AND ADJUSTING TRACK SHOE TENSION

ADJUSTING
a If the track shoe tension is out of the standard
range, adjust it according to the following procedure.
1. When tension is too high
1) Loosen valve (1) gradually to discharge the
grease.

k Since the valve may jump out because


of the high-pressure grease in it, do not
loosen it more than 1 turn.
a If the grease is not discharged well, drive
the machine forward and in reverse
slowly.
2) Tighten valve (1).
3 Valve: 58.8 88.2 Nm {6 9 kgm}
3) After finishing adjustment, check again that
the track shoe tension is normal according to
the above described procedure.

2. When tension is low


1) Add grease through valve (2).
a If the track shoe is not tensed well, drive
the machine forward and in reverse
slowly.
2) After finishing adjustment, check again that
the track shoe tension is normal according to
the above described procedure.

20-120
(1)

PC130-7

TESTING AND ADJUSTING

TESTING AND ADJUSTING TRACK SHOE TENSION

a You may supply grease until distance (b)


between the idler guide and track frame end
is 0 mm. If the tension is still low, the pin and
bushing are worn excessively. In this case,
turn over or replace the pin and bushing.

PC130-7

20-121
(1)

TESTING AND ADJUSTING

TESTING AND ADJUSTING OIL PRESSURE IN WORK EQUIPMENT,


SWING, AND TRAVEL CIRCUITS

TESTING AND ADJUSTING


OIL PRESSURE IN WORK
EQUIPMENT, SWING, AND
TRAVEL CIRCUITS
a Testing and adjusting instruments for oil pressure
in work equipment, swing, and travel circuits
Symbol
1
H
2

Part No.

Part name

799-101-5002

Hydraulic tester

790-261-1203

Digital hydraulic tester

799-101-5220

Nipple (10 x 1.25 mm)

07002-11023

O-ring

a The oil pressure in work equipment, swing, and


travel circuits (pump discharge pressure) can be
checked with monitoring function [02] of the
monitor panel.
Monitoring code: 011, 012 (Pump discharge
pressure)
a The pump discharge pressure is displayed in 1
kg/cm2.

2) Install nipple H2 and connect it to oil pressure gauge [1] of hydraulic tester H1.
a Use the oil pressure gauges of 58.8 MPa
{600 kg/cm2}.

3) Run the engine and heighten the hydraulic


oil temperature to 45 55C.

MEASURING
1. Preparation work

k Lower the work equipment to the ground


and stop the engine. Operate the control
levers several times to release the residual
pressure in the piping, and then loosen the
oil filler cap of the hydraulic tank slowly to
release the internal pressure of the hydraulic tank.
1) Remove the top cover of the control valve,
and then remove pump pressure pickup plug
(1) from the top of the control valve.

20-122
(1)

2. Measuring unload pressure


1) Start the engine.
2) Run the engine at high idling and set all the
control levers in neutral and measure the oil
pressure.
a The pressure measured when the unload
valve is unloaded is indicated.

PC130-7

TESTING AND ADJUSTING

TESTING AND ADJUSTING OIL PRESSURE IN WORK EQUIPMENT,


SWING, AND TRAVEL CIRCUITS

3. Measuring work equipment circuit relief pressure


1) Start the engine and move the cylinder to be
measured to the stroke end.
2) Run the engine at high idling and relieve the
cylinder and measure the oil pressure.
a The pressure measured when the main relief
valve is relieved is indicated.
a If the one-touch power maximizing switch is
released, the main relief valve is relieved at
low pressure. If the former is pressed, the
latter is relieved at high pressure.
a If the swing lock switch is set in the LOCK
position, the 2-stage relief solenoid valve is
turned ON and the main relief valve is
relieved at high pressure. Accordingly, keep
the swing lock switch turned OFF.

ADJUSTING
a The unload valve cannot be adjusted.
1. Adjusting main relief pressure (High pressure setting side)
a If the high relief pressure of the work equipment circuit and travel circuit is abnormal,
adjust the high pressure setting side of main
relief valve (2) according to the following procedure.
a The high relief pressure is the pressure
applied when the 2-stage relief solenoid
valve is turned ON and the pilot pressure is
applied to the selector port.

4. Measuring swing circuit relief pressure


1) Start the engine and set the swing lock
switch in the LOCK position.
2) Run the engine at high idling and relieve the
swing circuit and measure the oil pressure.
a The pressure measured when the swing
motor safety valve is relieved is indicated.
a The swing motor relief pressure is lower than
the main relief pressure.
5. Measuring travel circuit relief pressure
1) Start the engine and lock the travel mechanism.
k Set pin [2] between the sprocket and
track frame to lock the travel mechanism securely.

1) Disconnect pilot hose (3).


2) Fixing holder (4), loosen locknut (5).
3) Turn holder (4) to adjust the pressure.
a If the holder is
turned to the right, the pressure
rises.
turned to the left, the pressure lowers.
a Quantity of adjustment per turn of holder:
Approx. 12.6 MPa {Approx. 128 kg/cm2}
4) Fixing holder (4), tighten locknut (5).
3 Locknut: 39.2 49 Nm {4 5 kgm}

2) Run the engine at high idling and relieve the


travel circuit and measure the oil pressure.
a The pressure measured when the main relief
valve is relieved is indicated. The travel circuit is always relieved at high pressure.
5) Connect pilot hose (3).

PC130-7

20-123
(1)

TESTING AND ADJUSTING

TESTING AND ADJUSTING OIL PRESSURE IN WORK EQUIPMENT,


SWING, AND TRAVEL CIRCUITS

6) After finishing adjustment, check again that the


pressure is normal according to the above
described measurement procedure.
a If the high pressure setting side is adjusted,
the low pressure setting side changes.
Accordingly, adjust the low pressure setting
side, too.
2. Adjusting main relief pressure (Low pressure
setting side)
a If the low relief pressure of the work equipment circuit is abnormal or the high pressure
setting was adjusted, adjust the low pressure
setting side of main relief valve (2) according
to the following procedure.
a The low relief pressure is the pressure
applied when the 2-stage relief solenoid
valve is turned OFF and the pilot pressure is
not applied to the selector port.
1) Disconnect pilot hose (3).
2) Fixing holder (6), loosen locknut (7).
3) Turn holder (6) to adjust the pressure.
a If the holder is
turned to the right, the pressure
rises.
turned to the left, the pressure lowers.
a Quantity of adjustment per turn of holder:
Approx. 12.6 MPa {Approx. 128 kg/cm2}
4) Fixing holder (6), tighten locknut (7).
3 Locknut:
53.9 63.7 Nm {5.5 6.5 kgm}

5) Connect pilot hose (3).


6) After finishing adjustment, check again that
the pressure is normal according to the
above described measurement procedure.

20-124
(1)

3. Adjusting swing relief pressure


a If the relief pressure of the swing circuit is
abnormal, adjust swing motor safety valve
(8) according to the following procedure.

1) Fixing adjustment screw (9), loosen locknut


(10).
2) Turn adjustment screw (9) to adjust the pressure.
a If the adjustment screw is
turned to the right, the pressure
rises.
turned to the left, the pressure lowers.
a Quantity of adjustment per turn of adjustment screw: Approx. 14 MPa {Approx.
143 kg/cm2}
3) Fixing adjustment screw (9), tighten locknut
(10).
3 Locknut:
53.9 73.5 Nm {5.5 7.5 kgm}

4) After finishing adjustment, check again that


the pressure is normal according to the
above described measurement procedure.

PC130-7

TESTING AND ADJUSTING

MEASURING CONTROL CIRCUIT BASIC PRESSURE

MEASURING CONTROL
CIRCUIT BASIC PRESSURE
a Measuring instruments for control circuit basic
pressure
Symbol
1
J
2

Part No.

4. Run the engine at high idling and set all the control levers in neutral and measure the oil pressure.

Part name

799-101-5002

Hydraulic tester

790-261-1203

Digital hydraulic tester

799-101-5230

Nipple (10 x 1.25 mm)

07002-11423

O-ring

k Lower the work equipment to the ground and


stop the engine. Operate the control levers
several times to release the residual pressure
in the piping, and then loosen the oil filler cap of
the hydraulic tank slowly to release the internal
pressure of the hydraulic tank.
1. Open the pump room cover and remove control
circuit basic pressure pickup plug (1) under the
hydraulic pump.

5. After finishing measurement, remove the measuring instruments and return the removed parts.
a Do not adjust the relief valve for the control circuit basic pressure is not adjustable.

2. Install nipple J2 and connect it to oil pressure


gauge [1] of hydraulic tester J1.
a Use the oil pressure gauges of 5.9 MPa {60
kg/cm2}.

3. Run the engine and heighten the hydraulic oil


temperature to 45 55C.

PC130-7

20-125
(1)

TESTING AND ADJUSTING OIL PRESSURE


IN PUMP PC CONTROL CIRCUIT

TESTING AND ADJUSTING

TESTING AND ADJUSTING


OIL PRESSURE IN PUMP PC
CONTROL CIRCUIT

(2): PC valve output pressure pickup plug (at


top of hydraulic pump)

a Testing and adjusting instruments for oil pressure


in pump PC control circuit
Symbol
1
K
2

Part No.

Part name

799-101-5002

Hydraulic tester

790-261-1203

Digital hydraulic tester

799-101-5220

Nipple (10 x 1.25 mm)

07002-11023

O-ring

MEASURING
Measuring PC valve output pressure (servo piston inlet pressure)
a Before measuring the PC valve output pressure
(servo piston inlet pressure), check that the oil
pressure in the work equipment, swing, and
travel circuits and the basic pressure in the control circuit are normal.
a Measure the PC valve output pressure (servo
piston inlet pressure) and pump discharge pressure simultaneously and compare them.

3. Install nipple K2 and connect it to oil pressure


gauge [1] of hydraulic tester K1.
a Use the oil pressure gauge of 58.8 MPa {600
kg/cm2}.
The drawing shows the pump discharge
pressure side.

k Lower the work equipment to the ground and


stop the engine. Operate the control levers
several times to release the residual pressure
in the piping, and then loosen the oil filler cap of
the hydraulic tank slowly to release the internal
pressure of the hydraulic tank.
1. Remove the top cover of the control valve and
open the pump room cover.
2. Remove oil pressure pickup plugs (1) and (2).
(1): Pump discharge pressure pickup plug (at
top of control valve)

The drawing shows the PC valve output


pressure side.

4. Run the engine and heighten the hydraulic oil


temperature to 45 55C.

20-126
(1)

PC130-7

TESTING AND ADJUSTING OIL PRESSURE


IN PUMP PC CONTROL CIRCUIT

TESTING AND ADJUSTING

ADJUSTING
Adjusting PC valve
a If either of the following phenomena occurs and
the PC valve seems to be defective, adjust PC
valve (3) according to the procedure shown
below.
As the working load increases, the engine
speed lowers remarkably.
The engine speed is normal but the work
equipment speed is low.
a The figure shows the hydraulic pump seen from
the front side of the machine.

5. While running the engine at high idling, measure


the pump discharge pressure and PC valve output pressure (servo piston inlet pressure) simultaneously.
Working mode: A
Swing lock switch: LOCK (2-stage relief
valve is turned ON and relief pressure is set
high)
Work equipment, swing, and travel circuits:
Relieve arm circuit by moving arm IN.
a Method of judgment:
If the pump discharge pressure and PC valve
output pressure (servo piston output pressure) are in the following ratio, they are normal.
Measured oil pressure

Ratio of oil pressure

Pump discharge pressure

PC valve output pressure


(Servo piston inlet
pressure)

Approx. 3/5

a If the PC valve or the servo piston is abnormal, the PC valve output pressure (servo piston inlet pressure) is "the same as the pump
discharge pressure" or "almost 0".
6. After finishing measurement, remove the measuring instruments and return the removed parts.

1. Loosen hose fixing (4).


2. Fixing sleeve (5), loosen locknut (6).
3. Turn sleeve (5) to the right or left to adjust the
pump absorption torque.
a If the sleeve is
turned to the right, the pump absorption
torque increases.
turned to the left, the pump absorption
torque decreases.
a Limit the turning angle of the sleeve to the
following range.
Right turning: Max. 1 turn (360)
Left turning: Max. 1/2 turn (180)
a Change of servo piston stroke per turn of
sleeve: 1.5 mm
3 Locknut: 88 113 Nm {9 11.5 kgm}

4. Fixing sleeve (5), tighten locknut (6).

PC130-7

20-127
(1)

TESTING AND ADJUSTING

TESTING AND ADJUSTING OIL PRESSURE


IN PUMP PC CONTROL CIRCUIT

5. Tighten hose fixing nut (4).

6. After finishing adjustment, check that the pressure is normal according to the above described
procedure.

20-128
(1)

PC130-7

TESTING AND ADJUSTING OIL PRESSURE


IN PUMP LS CONTROL CIRCUIT

TESTING AND ADJUSTING

TESTING AND ADJUSTING


OIL PRESSURE IN PUMP LS
CONTROL CIRCUIT

(2): LS valve output pressure pickup


plug (at top of hydraulic pump)

a Testing and adjusting instruments for oil pressure


in pump LS control circuit
Symbol
1
L

2
3

Part No.

Part name

799-101-5002

Hydraulic tester

790-261-1203

Digital hydraulic tester

799-101-5220

Nipple (10 x 1.25 mm)

07002-11023

O-ring

799-400-2701

Differential pressure gauge

MEASURING
1. Measuring LS valve output pressure (servo
piston inlet pressure)
a Before measuring the LS valve output pressure (servo piston inlet pressure), check that
the oil pressure in the work equipment,
swing, and travel circuits and the basic pressure in the control circuit are normal.
a Measure the LS valve output pressure (servo
piston inlet pressure) and pump discharge
pressure simultaneously and compare them.
k Lower the work equipment to the ground
and stop the engine. Operate the control
levers several times to release the residual
pressure in the piping, and then loosen the
oil filler cap of the hydraulic tank slowly to
release the internal pressure of the hydraulic tank.
1) Remove the top cover of the control valve
and open the pump room cover.
2) Remove oil pressure pickup plugs (1) and
(2).
(1): Pump discharge pressure pickup
plug (at top of control valve)

PC130-7

3) Install nipple L2 and connect it to oil pressure


gauge [1] of hydraulic tester L1.
a Use the oil pressure gauge of 58.8 MPa
{600 kg/cm2}.
The drawing shows the pump discharge
pressure side.

The drawing shows the LS valve output


pressure side.

20-129
(1)

TESTING AND ADJUSTING OIL PRESSURE


IN PUMP LS CONTROL CIRCUIT

TESTING AND ADJUSTING

4) Run the engine and heighten the hydraulic


oil temperature to 45 55C, and then push
up the track shoe on either side with the work
equipment.

6) After finishing measurement, remove the


measuring instruments and return the
removed parts.
5) While running the engine at high idling, measure the pump discharge pressure and LS
valve output pressure (servo piston inlet
pressure) simultaneously.
Working mode: A
Travel speed switch: Hi
Work equipment, swing, and travel circuits:
Set all levers in neutral and run track
shoe on one side idle.
k Checking the safety around the
machine, run the track shoe pushed up
idle.
a Method of judgment:
If the pump discharge pressure and LS
valve output pressure (servo piston output pressure) are in the following ratio,
they are normal.

2. Measuring LS differential pressure


a Measure the pump discharge pressure and
LS pressure (actuator load pressure) simultaneously and calculate the difference
between them.
1) Remove the top cover of the control valve
and remove oil pressure pickup plugs (1) and
(3).
(1): Pump discharge pressure pickup
plug
(3): LS pressure pickup plug

Pump
LS valve
discharge output Ratio of oil presTravel lever pressure pressure
sure
MPa {kg/cm2}
Neutral

2.90.5
{305}

2.90.5
{305}

Almost same
pressure
(1:1)

Full (Idle
running)

7.82.0
{8020}

4.41.0
{4510}

Almost 3/5
(1:0.6)

20-130
(1)

PC130-7

TESTING AND ADJUSTING

2) Install nipple L2 and connect it to the oil


pressure gauge of hydraulic tester L1.
a When using differential pressure gauge:
Connect the pump discharge pressure to
the high pressure side (back side) and
connect the LS pressure to the low pressure side (lower side).
Since the differential pressure gauge
needs a 12-V power source, connect it to
a battery.
a When using oil pressure gauge:
Use the oil pressure gauge of 58.8 MPa
{600 kg/cm2}.
Since the differential pressure is about
2.9 MPa {30 kg/cm2} at maximum, measure it by installing the same gauge to
the pickup plugs alternately.

TESTING AND ADJUSTING OIL PRESSURE


IN PUMP LS CONTROL CIRCUIT

4) While running the engine at high idling, measure the pump discharge pressure and LS
valve output pressure (servo piston inlet
pressure) simultaneously.
Working mode: A
Travel speed switch: Hi
Work equipment, swing, and travel circuits:
Set all levers in neutral and run track
shoe on one side idle.
k Checking the safety around the
machine, run the track shoe pushed up
idle.
a Calculation of LS differential pressure
(when oil pressure gauge is used):
LS differential pressure = Pump discharge pressure - LS pressure
a If the LS differential pressure is as follows, it is normal.
Travel lever

LS differential pressure

Neutral

LS differential pressure
in neutral
(See standard values
table)

Specified LS differential
pressure
Full (Idle running)
(See standard values
table)

3) Run the engine and heighten the hydraulic


oil temperature to 45 55C, and then push
up the track shoe on either side with the work
equipment.

5) After finishing measurement, remove the


measuring instruments and return the
removed parts.

PC130-7

20-131
(1)

TESTING AND ADJUSTING

ADJUSTING
Adjusting LS valve
a If the LS differential pressure is abnormal, adjust
LS valve (4) according to the procedure shown
below.
a The figure shows the hydraulic pump seen from
the front side of the machine.

TESTING AND ADJUSTING OIL PRESSURE


IN PUMP LS CONTROL CIRCUIT

6. After finishing adjustment, check that the pressure is normal according to the above described
procedure.

1. Loosen hose sleeve nut (4).


2. Fixing plug (5), loosen locknut (6).
3. Turn plug (5) to adjust the differential pressure.
a If the plug is
turned to the right, the differential pressure rises.
turned to the left, the differential pressure
lowers.
a Quantity of adjustment (LS differential pressure) per turn of plug:
1,304 kPa {13.3 kg/cm2}
a Tighten the hose sleeve nut (4) temporarily
and turn the plug, while checking the LS differential pressure.
3 Locknut: 98 122.5 Nm {10 12.5 kgm}

4. Fixing plug (5), tighten locknut (6).

5. Tighten hose sleeve nut (4).

20-132
(1)

PC130-7

TESTING AND ADJUSTING

MEASURING SOLENOID VALVE OUTPUT PRESSURE

MEASURING SOLENOID
VALVE OUTPUT PRESSURE
a Measuring instruments for solenoid valve output
pressure
Symbol
M

Part No.

1
2

a Use the oil pressure gauges of 5.9 MPa {60


kg/cm2}.
a The figure shows the measuring instruments
connected to the outlet hose of the 2-stage
relief solenoid valve.

Part name

799-101-5002

Hydraulic tester

790-261-1203

Digital hydraulic tester

799-401-3100

Adapter (Size 02)

a Before measuring the solenoid valve output


pressure, check that the basic pressure in the
control circuit is normal.

k Lower the work equipment to the ground and


stop the engine. Operate the control levers
several times to release the residual pressure
in the piping, and then loosen the oil filler cap of
the hydraulic tank slowly to release the internal
pressure of the hydraulic tank.

4. Run the engine and heighten the hydraulic oil


temperature to 45 55C.

1. Remove the undercover of the control valve and


disconnect outlet hoses (1) (4) of the solenoid
valves to be measured.
No.
1

Solenoid valve to be measured


2-stage relief solenoid valve

Swing holding brake solenoid valve

Travel speed solenoid valve

PPC pressure lock solenoid valve

a Since outlet hose (4) of the PPC pressure


lock solenoid valve has a quick coupler,
measure the output pressure on the PPC
valve side.

2. Install adapter M2 and connect the disconnected


hose again.

5. Run the engine at high idling, operate the control


levers and switches to turn the solenoid valve
ON or OFF, and measure the oil pressure.
a For the conditions for turning the solenoid
valve ON and OFF, see the operations table
of each solenoid valve.
a The operating condition of the solenoid valve
can be also checked with the monitoring
function [02] of the monitor panel (excluding
the PPC pressure lock solenoid valve).
a If the output pressure is as follows, the solenoid valve is normal.
Solenoid valve

Output pressure

OFF
(Deenergized)

0 MPa {0kg/cm2}

ON (Energized)

Almost same as control basic


pressure
(See standard values table)

3. Install nipple [1] of hydraulic tester M1 and connect it to hydraulic gauge [2].

PC130-7

20-133
(1)

MEASURING SOLENOID VALVE OUTPUT PRESSURE

TESTING AND ADJUSTING

6. After finishing measurement, remove the measuring instruments and return the removed parts.
Operation table of 2-stage relief solenoid valve
Operation

Operating condition
One-touch power maximizing switch: ON (8.5-sec timer)
Tr avel signal

ON

Swing lock switch


Other than above condition

OFF

Operation table of swing holding brake solenoid valve


Operation

Operating condition
Work equipment, swing, and travel signals

Any one is turned ON

ON

Swing holding brake release switch: RELEASE (Upper) position


Other than above condition

OFF

Operation table of travel speed brake solenoid valve


Operating condition

Operation

Travel speed switch: Lo


Auto shift function operates during run at Hi

Engine speed: Below 1,500 rpm


Pump pressure: Above 30.4 MPa {310 kg/cm2}

OFF

Overheat prevention function operates during run


Hydraulic oil temperature: Above 95C
at Hi
Other than above condition

ON

Operation table of PPC pressure lock solenoid valve


Operating condition
Safety lock lever

20-134
(1)

Operation

LOCK position

OFF

FREE position

ON

PC130-7

TESTING AND ADJUSTING

MEASURING PPC VALVE OUTPUT PRESSURE

MEASURING PPC VALVE


OUTPUT PRESSURE
a Measuring instruments for PPC valve output
pressure
Symbol

Part No.

Part name

799-101-5002

Hydraulic tester

790-261-1203

Digital hydraulic tester

a Before measuring the PPC valve output pressure, check that the basic pressure in the control
circuit is normal.

k Lower the work equipment to the ground and


stop the engine. Operate the control levers
several times to release the residual pressure
in the piping, and then loosen the oil filler cap of
the hydraulic tank slowly to release the internal
pressure of the hydraulic tank.

a Since PPC oil pressure switches (10) and


(11) are installed in the battery room, open
the battery room cover.

1. Disconnect PPC oil pressure switches (1) (4)


of the circuit to be measured.
No. Circuit to be measured No. Circuit to be measured
1

Boom RAISE (S06)

Swing RIGHT (S07)

Boom LOWER (S02)

Swing LEFT (S03)

Arm IN (S04)

Travel (S30)

Arm OUT (S04)

1ATT on front side


10 (S10)

Bucket CURL (S08)

1ATT on rear side


11 (S11)

Bucket DUMP (S01)

a Since PPC oil pressure switches (1) (8) are


installed in the battery room, open the battery room cover.

a Since PPC oil pressure switch (9) is installed


on the under side of the floor frame, remove
the cab undercover (on the front side).

PC130-7

2. Install nipple [1] of hydraulic tester N and connect it to oil pressure gauge [2].
a Use the oil pressure gauges of 5.9 MPa {60
kg/cm2}.
a The figure shows the measuring instruments
installed to the mounting part of the swing
LEFT PPC pressure switch.

3. Run the engine and heighten the hydraulic oil


temperature to 45 55C.

20-135
(1)

TESTING AND ADJUSTING

MEASURING SOLENOID VALVE OUTPUT PRESSURE,


ADJUSTING PLAY OF WORK EQUIPMENT AND SWING PPC VALVES

ADJUSTING PLAY OF WORK


EQUIPMENT AND SWING PPC
VALVES
a If the work equipment and swing levers have
large play, adjust them according to the following
procedure.
1. Remove the work equipment and swing PPC
valve assembly.
2. Remove bellows (1).

4. Run the engine at high idling and measure the oil


pressure while the control lever or pedal of the
measured circuit is in neutral and while it is operated to the stroke end.
a If the PPC valve output pressure is as follows, the solenoid valve is normal.
Lever/Pedal

Output pressure

In neutral

0 MPa {0kg/cm2}

Operated to
stroke end

Almost same as control basic


pressure (See standard values
table)

3. Loosen locknut (2) and tighten disc (3) until it


touches the heads of 4 pistons (4).
a Do not move the piston at this time.
4. Fix disc (3) and tighten locknut (2) to the specified torque.
3 Locknut: 69 88 Nm {7 9 kgm}

5. Install bellows (1).


6. Install the work equipment and swing PPC valve
assembly.

5. After finishing measurement, remove the measuring instruments and return the removed parts.

20-136
(1)

PC130-7

TESTING AND ADJUSTING

TESTING PARTS WHICH CAUSE HYDRAULIC DRIFT OF


WORK EQUIPMENT

TESTING PARTS WHICH


CAUSE HYDRAULIC DRIFT OF
WORK EQUIPMENT
a If the work equipment (cylinder) drifts hydraulically, check to see if the cause is on the cylinder
packing side or control valve side or hydraulic
drift prevention valve side (if equipped) according to the following procedure.
1. Testing boom cylinder and bucket cylinder
1) Set the machine in the position of measuring
hydraulic drift and stop the engine.
a Fill the bucket with a rated load or with
dirt and sand.

2) When testing the boom cylinder, set the


boom control lever in the RAISE position.
When testing the bucket cylinder, set the
bucket control lever in the CURL position.
If the lowering speed is increased at this
time, the cylinder packing is defective.
If the lowering speed does not change at
this time, the control valve or hydraulic
drift prevention valve (if equipped) is
defective.
a Operate the control lever while the starting switch is in the ON position.
a If the pressure in the accumulator is lost,
run the engine for about 10 seconds to
heighten the pressure in the accumulator.
2. Testing arm cylinder
1) Stop the arm cylinder about 100 mm before
the IN stroke end and stop the engine.

PC130-7

2) Operate the arm control lever in the IN position.


If the lowering speed is increased at this
time, the cylinder packing is defective.
If the lowering speed does not change at
this time, the control valve is defective.
a Operate the control lever while the starting switch is in the ON position.
a If the pressure in the accumulator is lost,
run the engine for about 10 seconds to
heighten the pressure in the accumulator.

[Reference]
Reason why the lowering speed is increased by
the above operation when the cylinder packing is
the cause of the hydraulic drift:
1) If the machine is set in the above position (where
the holding pressure is applied to the bottom
side), the oil leaks from the bottom side to the
head side. Since the volume on the head side is
less than that on the bottom side by the volume
of the rod, the pressure in the head side is
increased by the oil flowing in from the bottom
side.
2) As the pressure in the head side is increased, it
is balanced at a certain level (which depends on
the leakage), and then the lowering speed is lowered.
3) If the circuit on the head side is opened to the
drain circuit by the above operation of the lever
(the bottom side is closed by the check valve at
this time), the oil on the head side flows in the
drain circuit. As a result, the pressure is unbalanced and the lowering speed is increased.

20-137
(1)

TESTING AND ADJUSTING

TESTING PARTS WHICH CAUSE HYDRAULIC DRIFT OF


WORK EQUIPMENT

3. Testing PPC valve


While the pressure in the accumulator is high,
set the safety lock lever in the LOCK/FREE position and measure the lowering distance.
a Operate the control lever while the starting
switch is in the ON position.
a If the pressure in the accumulator is lost, run
the engine for about 10 seconds to heighten
the pressure in the accumulator.
a If there is a difference in the lowering distance between the LOCK position and FREE
position, the PPC valve is defective (it has an
internal defect).

20-138
(1)

PC130-7

TESTING AND ADJUSTING

MEASURING OIL LEAKAGE

MEASURING OIL LEAKAGE


a Measuring instruments fro oil leakage
Symbol

Part No.

Commercially
available

Part name
Measuring cylinder

1. Measuring oil leakage from boom cylinder


1) Run the engine and heighten the engine oil
temperature to 45 55C, and then move
the boom cylinder to the RAISE stroke end.

k Release the residual pressure in the


piping on the boom cylinder head side.
For details, see RELEASING RESIDUAL PRESSURE IN HYDRAULIC CIRCUIT (Operate the lever in the boom
RAISE direction only, however).
2) Disconnect hose (1) on the cylinder head
side and block the hose side with a plate.

2. Measuring oil leakage from arm cylinder


1) Run the engine and raise the engine oil temperature to 45 55C, and then move the
arm cylinder to the IN stroke end.
k Release the residual pressure in the
piping on the arm cylinder head side.
For details, see RELEASING RESIDUAL PRESSURE IN HYDRAULIC CIRCUIT (Operate the lever in the arm IN
direction only, however).
2) Disconnect hose (2) on the cylinder head
side and block the hose side with a plate.

k Take care not to disconnect the hose on


the cylinder bottom side.
a Use the following part to block the hose
side.
07376-50522 (Plug No. 05)

k Take care not to disconnect the hose on


the cylinder bottom side.
a Use the following part to block the hose
side.
07376-50422 (Plug No. 04)

3) Run the engine at high idling and relieve the


arm circuit by moving the arm IN.
k Take care not to "move the arm OUT".
4) Measure the oil leakage for 1 minute after 30
seconds since relieving is started.
5) After finishing measurement, return the
removed parts.
3) Run the engine at high idling and relieve the
boom circuit by raising the boom.

k Take care not to "lower the boom".


4) Measure the oil leakage for 1 minute after 30
seconds since relieving is started.
5) After finishing measurement, return the
removed parts.

PC130-7

20-139
(1)

TESTING AND ADJUSTING

3. Measuring oil leakage from bucket cylinder


1) Run the engine and raise the engine oil temperature to 45 55C, and then move the
bucket cylinder to the CURL stroke end and
stop the engine.

k Release the residual pressure in the


piping on the bucket cylinder head side.
For details, see RELEASING RESIDUAL PRESSURE IN HYDRAULIC CIRCUIT (Operate the lever in the arm
CURL direction only, however).
2) Disconnect hose (3) on the cylinder head
side and block the hose side with a plate.

MEASURING OIL LEAKAGE

4. Measuring oil leakage from swing motor


1) Run the engine and raise the engine oil temperature to 45 55C.
2) Disconnect drain hose (4) and block the
hose side with a plug.
a Use the following part to block the hose
side.
07376-50522 (Plug No. 05)

k Take care not to disconnect the hose on


the cylinder bottom side.
a Use the following part to block the hose
side.
07376-50422 (Plug No. 04)

3) Turn the swing lock switch ON.


4) Run the engine at high idling and relieve the
swing circuit by swinging.
a Measure the oil leakage for 1 minute
after 30 seconds since relieving is
started.
a After measuring 1 time, swing 180, and
then measure again.
5) After finishing measurement, return the
removed parts.
3) Run the engine at high idling and relieve the
bucket circuit by curling the bucket.

k Take care not to "dump the bucket".


4) Measure the oil leakage for 1 minute after 30
seconds since relieving is started.
5) After finishing measurement, return the
removed parts.

20-140
(1)

PC130-7

TESTING AND ADJUSTING

MEASURING OIL LEAKAGE

5. Measuring oil leakage from travel motor


1) Run the engine and raise the engine oil temperature to 45 55C, and then remove the
travel motor cover.
2) Run the engine and lock the travel system.
k Put pin [1] between the sprocket and
track frame to lock the travel system
securely.

3) Disconnect drain hose (5) of the travel motor


and block the hose side with a plug.
a Use the following part to block the hose
side.
07376-50422 (Plug No. 04)

4) Run the engine at high idling, relieve the


travel circuit, and measure the oil leakage.

k Wrong operation of the lever can cause


an accident. Accordingly, make signs
and checks securely.
a Measure the oil leakage for 1 minute
after 30 seconds since r elieving is
started.
a Measure several times, moving the
motor a little (changing the position of the
valve plate and cylinder and that of the
cylinder and piston) each time.
5) After finishing measurement, return the
removed parts.

PC130-7

20-141
(1)

TESTING AND ADJUSTING

RELEASING RESIDUAL PRESSURE IN HYDRAULIC CIRCUIT

RELEASING RESIDUAL
PRESSURE IN HYDRAULIC
CIRCUIT
1. Releasing residual pressure in hydraulic tank

k Since the hydraulic tank is enclosed and


pressurized, release the residual pressure
in it when removing a hose or a plug connected to it.
1) Lower the work equipment to the ground in a
stable position and stop the engine.
2) Loosen oil filler cap (1) of the hydraulic tank
gradually to release the air in the tank.
a If you open the pump room cover, you
can loosen the oil filler cap from the right
side of the machine.

4) Repeat steps 2) and 3) above 2 3 times,


and the residual pressure in the piping is
released completely.
3. Releasing residual pressure in swing motor
circuit
a The residual pressure in the swing motor circuit can be released by performing the operation for RELEASING RESIDUAL
PRESSURE IN HYDRAULIC CYLINDER
CIRCUIT (Operate the lever in the swing
direction only, however).
4. Releasing residual pressure in travel motor
circuit
a Since the control valve spool of the travel
motor circuit is open, the pressure in this circuit can be released by performing RELEASING RESIDUAL PRESSURE IN
HYDRAULIC TANK.

2. Releasing residual pressure in hydraulic cylinder circuit

k When disconnecting a pipe between a


hydraulic cylinder and the control valve,
release the residual pressure in the piping
according to the following procedure.
1) Release the residual pressure in the hydraulic tank.
For details, see RELEASING
RESIDUAL PRESSURE IN HYDRAULIC
TANK.
a Keep the oil filler cap of the hydraulic
tank removed.
2) Turn the starting switch ON and set the
safety lock lever in the FREE position, and
then operate the work equipment control
levers on both sides forward, backward, to
the right, and to the left.
a The control valve is operated by the
pressure in the accumulator. The pressure in the accumulator is used up, however, after the control valve is operated 2
3 times.
3) Run the engine at low idling for 10 seconds
to heighten the pressure in the accumulator.

20-142
(1)

PC130-7

TESTING AND ADJUSTING

BLEEDING AIR FROM EACH PART

BLEEDING AIR FROM EACH PART


Air bleeding procedure
Air bleeding item

Contents of work
Replacing hydraulic oil
Cleaning strainer

Bleeding air
from
hydraulic
pump

Starting
engine

Bleeding air Bleeding air


Bleeding air
from swing from travel
from cylinder
motor
motor

(See note)

(See note)

6
Checking oil
level and
starting
operation

Replacing return filter element


Replacing and repairing hydraulic
pump
Removing suction piping

Replacing and repairing control valve


Removing control valve piping

Replacing and repairing cylinder


Removing cylinder piping

Replacing and repairing swing motor


Removing swing motor piping

Replacing and repairing travel motor


Removing travel motor piping

Replacing and repairing swivel joint


Removing swivel joint piping

q
q

q
q

Note: Bleed air from the swing motor and travel motor only when the oil in the motor cases is drained.
1. Bleeding air from hydraulic pump
1) Open the pump room cover, loosen bleeder
(1), and check that oil flows out.
2) If the oil does not flow out, disconnect drain
hose (2) and fill the pump case with oil
through the drain port.
a Fix the drain hose adapter to a place
higher than the oil level in the hydraulic
tank.
a Fill the pump case with oil until oil containing no bubbles flows out of the
bleeder.
3) After oil containing no bubbles flows out of
bleeder (1), tighten the bleeder.
3 Air bleeder:
7.8 9.8 Nm {0.8 1.0 kgm}
a If the drain hose has been disconnected,
connect it after tightening the bleeder.

PC130-7

2. Starting engine
When running the engine after performing step
1, keep its speed at low idling for 10 minutes.
a If the engine coolant temperature is low and
the automatic warm-up operation is started,
stop the engine temporarily and reset the
automatic warm-up operation with the fuel
control dial (Set the starting switch in the ON
position and hold the fuel control dial in the
MAX position for 3 seconds, and the automatic warm-up operation is reset).

20-143
(1)

TESTING AND ADJUSTING

BLEEDING AIR FROM EACH PART

3. Bleeding air from cylinder


a If a cylinder was replaced, bleed air from it
before connecting the work equipment. In
particular, the boom cylinder does not move
to the lowering stroke end, if it is installed to
the work equipment.
1) Run the engine at low idling for about 5 minutes.
2) Running the engine at low idling, raise and
lower the boom 4 5 times.
a Stop the piston rod about 100 mm before
each stroke end. Do not relieve the oil.
3) Running the engine at high idling, perform
step 2).
4) Running the engine at low idling, move the
piston rod to the stroke end and relieve the
oil.
5) Bleed air from the arm cylinder and bucket
cylinder according to steps 2) 4).

5. Bleeding air from travel motor


1) Remove the travel motor cover and run the
engine at low idling.
2) Loosen drain hose (4) and check that oil
oozes out, and then tighten the drain hose.

4. Bleeding air from swing motor


1) Run the engine at low idling.
2) Loosen air bleeding plug (3) and check that
the oil oozes out, and then tighten the air
bleeding plug.

3) Running the engine at low idling and using


the work equipment, raise the track shoe on
either side.

3 Air bleeding plug:


25.5 34.3 Nm {2.5 3.5 kgm}
3) If the oil does not oozes out, remove air
bleeding plug (3) and fill the pump case with
oil.

4) Running the engine at low idling, run the


raised track shoe idle slowly for about 2 minutes.
a Run the track shoe forward and in
reverse as evenly as possible.
a Run the track shoe on the opposite side
idle similarly.
4) Run the engine at low idling and swing slowly
2 turns or more in each direction.

20-144
(1)

PC130-7

TESTING AND ADJUSTING

BLEEDING AIR FROM EACH PART

6. Checking oil level and starting work


1) Run the engine, retract the arm cylinder and
bucket cylinder to the stroke ends, lower the
work equipment to the ground, and stop the
engine.

2) Check the oil level by sight gauge (5) on the


side of the hydraulic tank.
a If the oil level is between lines H and L, it
is normal.
a If the oil level is below line L, add new oil.

PC130-7

20-145
(1)

TESTING AND ADJUSTING

TESTING PROCEDURE FOR DIODE

TESTING PROCEDURE FOR


DIODE
a Test an assembled-type diode (18-pin) or a diode
(2-pin) according to the following procedure.
a The conductive direction of an assembled-type
diode is shown in the following figure.

a The conductive direction of a diode is marked on


its surface.

2. When using an analog circuit tester


1) Set the circuit tester in the resistance range.
2) Apply the test pins as shown below and
check movement of the pointer.
i) Apply the red (+) test pin to the anode (P)
side of the diode and the black (-) test pin
to the cathode (N) side.
ii) Apply the red (+) test pin to the cathode
(N) side of the diode and the black (-) test
pin to the anode (P) side.
3) Judge the condition of the diode from movement of the pointer.
The pointer does not move in i) above
but moves in ii): Normal (Moving angle
(Resistance) depends on the type and
measurement range of the circuit tester,
however)
The pointer moves in both i) and ii):
Defective (Internal short circuit)
The pointer does not move in either of i)
and ii): Defective (Internal disconnection)

1. When using a digital circuit tester


1) Set the circuit tester in the diode range and
check the indicated value.
a If an ordinary tester is used, the voltage
of the battery in itself is indicated.
2) Apply the red (+) test pin to the anode (P)
side of the diode and the black (-) test pin to
the cathode (N) side and read the indicated
value.
3) Judge the condition of the diode from the
indicated value.
The indicated value does not change:
There is not continuity (Defective).
The indicated value changes: There is
continuity (Normal) (Note).
Note) In the case of a silicon diode, the circuit tester indicates a value of 460
600.

20-146
(1)

PC130-7

TESTING AND ADJUSTING

SPECIAL FUNCTIONS OF MONITOR PANEL

SPECIAL FUNCTIONS OF MONITOR PANEL

Section to display special functions


1. Display section
2. Service meter section

PC130-7

Section to operate special function 1


(Basic operation)
3. Caution buzzer stop switch
4. Auto-decelerator switch
5. Setting switch (Black switch)
6. Travel speed shifting switch

Section to operate special function 2


(Selecting operation and special
operation)
7. Working mode selector switch (UP)
8. Working mode selector switch
(DOWN)
9. Swing lock switch

20-147
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TESTING AND ADJUSTING

SPECIAL FUNCTIONS OF MONITOR PANEL

Ordinary functions and special functions of monitor panel


The monitor panel has the ordinary functions and special functions and displays various pieces of information
on display section (1) and service meter section (2).
Some items are displayed automatically according to the internal setting of the monitor panel and the others are
displayed by operating switches.
1. Ordinary functions: Operator menu
The items in this menu are displayed normally or displayed automatically when a trouble occurs.
2. Special functions: Service menu
The items in this menu are not displayed normally. Each serviceman can display them by operating special
switches. These functions are used for special setting, testing, adjusting, or troubleshooting.
Flow of each function

Function of displaying service meter

O <Automatic>
2

Function of displaying user code

Special functions (Service menu)

<Operation of switch> O

Ordinary functions (Operator menu)


3

Function of displaying error code [01]

Monitoring function [02]

Function of adjusting governor [03]

Function of selecting maintenance period [04]

Function of selecting default working mode [05]

Special function of monitoring replacement of engine oil

a Each number in [ ] is a code No. displayed in the service meter section when the menu is selected.

20-148
(3)

PC130-7

TESTING AND ADJUSTING

Display of operator menu


a Only outline of the operator menu is described in
this section. For details of each menu, see
O P E R AT I O N M A N U A L o r t h e v o l u m e o f
STRUCTURE AND OPERATION.
1. Function of displaying service meter
While the machine is used normally, the monitor
panel displays the following information.

Display section (1): Nothing is displayed

Service meter section (2): Service meter

SPECIAL FUNCTIONS OF MONITOR PANEL

2. Function of displaying user code


If the machine has any trouble, the corresponding user code is displayed automatically in display section (1) and the caution buzzer is turned
ON to urge the operator to take a proper remedy,
depending on the degree of the trouble.
a Service meter section (2) continues displaying the service meter.
a For displayed user codes and the remedies
shown to the operator, see "User codes and
remedies shown to operator".
a Each user code simply shows occurrence of
a trouble to the operator. To find out the
cause of the trouble, a serviceman must
check the error code with the "Function of
displaying error code [01]" in the service
menu.

<Reference>
A user code is displayed only when a serious trouble
occurs.
Even if a user code is not displayed, a trouble may
have occurred. If you feel any abnormality, be sure
to check for an error code with the "Function of displaying error code [01]" in the service menu.

PC130-7

20-149
(1)

SPECIAL FUNCTIONS OF MONITOR PANEL

TESTING AND ADJUSTING

a User codes and remedies shown to operator


User
code

Error mode

Remedy (shown to operator)

Caution
buzzer

Error in pump control system

If the emergency pump drive switch is set in the upper position, the machine can operate normally. Have the machine
inspected immediately, however.

E03

Error in swing brake system

Set the swing holding brake release switch in the upper position to release the brake. Apply the swing brake manually
with the swing lock switch, if necessary. The brake may not
be released, depending on the cause of the failure. In any
case, have the machine inspected immediately.

E05

Error in governor system

Have the machine inspected immediately.

E02

20-150
(1)

PC130-7

TESTING AND ADJUSTING

Operation and display of service menu


How to select service menu
a When using the general functions in the service
menu, perform the following switch operation to
change the screen of the monitor panel.
3.
4.
5.
6.

Function of displaying error code [01]


Monitoring function [02]
Function of adjusting governor [03]
Function of selecting maintenance period
[04]
7. Function of selecting default working
mode [05]
1) Operating switches
Holding caution buzzer stop switch (3), hold auto
decelerator switch (4) for 2.5 seconds.

SPECIAL FUNCTIONS OF MONITOR PANEL

3) Selecting menu
Holding caution buzzer stop switch (3), operate
working mode selector switches (7) and (8) to
select a menu you will use.
UP switch (7): Menu No. increases.
DOWN switch (8): Menu No. decreases.
Menu
No.

Service menu
(Excluding special functions)

01

Function of displaying error code

02

Monitoring function

03

Function of adjusting governor

04

Function of selecting maintenance


period

05

Function of selecting default working


mode

4) Executing menu
Select a menu you will use and press set switch
(5), and the menu is executed.

2) Displaying display section and service meter


section
If the switches are operated as shown above, the
first menu No. [01] (Monitoring function) is displayed in service meter section (2).
a Nothing is displayed in display section (1).

5) Finishing service menu


Holding caution buzzer stop switch (3), hold auto
decelerator switch (4) for 2.5 seconds (similarly
to the selecting operation).
a The service menu is finished and the ordinary screen appears.
a The service menu can be also finished by
turning the starting switch OFF while the service menu is selected. (In this case, the ordinary screen appears when the starting
switch is turned ON again.)
a To use the special functions in the service menu,
you must operate the switches differently from
the above. See details of each menu.
8. Function of adjusting service meter
9. Special function of monitoring replacement of engine oil

PC130-7

20-151
(1)

TESTING AND ADJUSTING

SPECIAL FUNCTIONS OF MONITOR PANEL

3. Function of displaying error code [01]


With this function, you can check the error code
of a trouble which is occurring at present or has
occurred in the past.

1) Selecting and executing function


i) Select menu No. [01] in the menu selection mode.
ii) Press set switch (5) to execute this function.
2) Information displayed in display section and
service meter section 1 (When error code is
recorded)
If an error code is recorded, the following
information is displayed in display section (1)
and service meter section (2).
(a): Error code
(b): Service meter reading increased after
trouble occurred
(c): Mark [E] to indicate that trouble is occurring at present
a Mark [E] to indicate that a trouble is
occurring at present indicates that the
error code is being detected now. It is
not displayed if the trouble has been
repaired or the error code is not
detected.
a For the error codes which the monitor
panel and governor and pump controller
can detect, see the "Error codes table".

20-152
(1)

3) Information displayed in display section and


service meter section 2 (When error code is
not recorded)
If an error code is not recorded, display section (1) and service meter section (2) display
as shown below.

4) Number of recorded error codes and display


order of them
This function can record up to 20 error
codes, which are displayed in order from the
latest one.
a If a new trouble occurs while 20 error
codes are recorded, the oldest error
code is deleted and the error code of the
new trouble is recorded.

PC130-7

TESTING AND ADJUSTING

SPECIAL FUNCTIONS OF MONITOR PANEL

5) Change of displayed error codes


Holding caution buzzer stop switch (3), operate working mode selector switches (7) and
(8) to change the displayed error codes.
UP switch (7): Next error code appears.
DOWN switch (8): Previous error code
appears.
6) How to delete error code
i) Holding caution buzzer stop switch (3),
turn the starting switch OFF and keep
holding caution buzzer stop switch (3).
ii) Under the above condition, turn the starting switch ON again and hold caution
buzzer stop switch (3) for 5 seconds.
a An error code having the mark [E] cannot
be deleted.

PC130-7

20-153
(1)

SPECIAL FUNCTIONS OF MONITOR PANEL

TESTING AND ADJUSTING

Error codes table


User code

Error code

104

Clogging of air cleaner

108

Overheating of engine coolant

112

Short circuit in wiper motor drive forward system

113

Short circuit in wiper motor drive reverse system

114

Short circuit in windshield washer drive system

115

Trouble in operation of windshield wiper

116

Trouble in storage of windshield wiper

E03

203

Short circuit in swing holding brake solenoid

205

Short circuit in 2-stage relief solenoid

206

Short circuit travel speed shifting solenoid

E03

213

Disconnection in swing holding brake solenoid

215

Disconnection in 2-stage relief solenoid

216

Disconnection travel speed shifting solenoid

217

Abnormality in input model code

218

Disconnection in S-NET signal line

222

Short circuit in LS-EPC solenoid

223

Disconnection in LS-EPC solenoid

224

Abnormality in pump pressure sensor

226

Abnormality in pressure sensor power supply

227

Abnormality in engine speed sensor

E02

232

Short circuit in PC-EPC solenoid

E02

233

Disconnection in PC-EPC solenoid

251

Abnormality in overload pressure sensor

301

Engine low idling speed out of standard range

302

Engine high idling speed out of standard range

306

Abnormality in governor potentiometer

E05

308

Abnormality in fuel control dial

315

Short circuit in battery relay output line

316

Step-out of governor motor

E05

317

Disconnection in phases A and B of governor motor

E05

318

Short circuit in phases A and B of governor motor

20-154
(1)

Trouble

PC130-7

TESTING AND ADJUSTING

SPECIAL FUNCTIONS OF MONITOR PANEL

4. Monitoring function [02]


With this function, you can monitor the revolution
speed, oil pressure, current, voltage, input condition, output condition, etc. in real time by the signals from the sensors, switches, and solenoids
installed to various parts of the machine.

1) Selecting and executing function


i) Select menu No. [02] in the menu selection mode.
ii) Press set switch (5) to execute this function.

3) Information displayed in display section and


service meter section 1 (When numeral code
is displayed)
If a numeral monitoring code is selected, the
following information is displayed in display
section (1) and service meter section (2).
(a): Monitoring code
(b): Monitoring information (Value is displayed)

2) Selecting and executing monitoring code


Holding caution buzzer stop switch (3), operate working mode selector switches (7) and
(8) to select a monitoring code displayed in
service meter section (1).
UP switch (7): Code No. increases.
DOWN switch (8): Code No. decreases.
a This function displays monitoring code
[001] and its information first.
a For the items and code Nos. which you
can monitor, see the "Monitoring codes
table".

PC130-7

20-155
(1)

TESTING AND ADJUSTING

SPECIAL FUNCTIONS OF MONITOR PANEL

4) Information displayed in display section and


service meter section 2 (When 6-bit code is
displayed)
If a 6-bit monitoring code is selected, the following information is displayed in display
section (1) and service meter section (2).
(a): Monitoring code
(b): Monitoring information (6 pieces of information are displayed in bits)
a In the 6-bit display mode, only the top
and bottom of the 7-segment mark are
used to display. "Solid black" indicates
the ON state, and "white on black background" indicates the OFF state.
a For the No. of each bit, see the "Monitoring codes table" and the drawing
attached to it.

20-156
(1)

PC130-7

TESTING AND ADJUSTING

SPECIAL FUNCTIONS OF MONITOR PANEL

Monitoring codes table


Code

Monitoring item

Unit

001

Monitor panel model code

Numeral

002

Governor and pump controller model code (Pump side)

Numeral

003

Governor and pump controller model code (Engine throttle side)

Numeral

008

Connecting condition of network

Numeral

010

Engine speed

10rpm

011

Pump discharge pressure

kg/cm2

012

Pump discharge pressure

kg/cm2

013

PC-EPC solenoid output current

10mA

015

LS-EPC solenoid output current

10mA

016

2nd throttle speed

10rpm

018

(Unused)

019

(Unused)

020

021

022

023

PC130-7

Swing oil pressure switch (ON)

(6bit)

Travel oil pressure switch (ON)

(6bit)

Boom LOWER oil pressure switch (ON)

(6bit)

Boom RAISE oil pressure switch (ON)

(6bit)

Arm IN oil pressure switch (ON)

(6bit)

Arm OUT oil pressure switch (ON)

(6bit)

Bucket CURL oil pressure switch (ON)

(6bit)

Bucket DUMP oil pressure switch (ON)

(6bit)

(Unused)

(6bit)

Service oil pressure switch (ON)

(6bit)

(Unused)

(6bit)

(Unused)

(6bit)

(Unused)

(6bit)

(Unused)

(6bit)

One-touch power maximizing switch (ON)

(6bit)

Swing holding brake release switch (RELEASE)

(6bit)

Swing lock switch (LOCK)

(6bit)

(Unused)

(6bit)

(Unused)

(6bit)

(Unused)

(6bit)

Swing holding brake solenoid (ON)

(6bit)

(Unused)

(6bit)

2nd relief solenoid (ON)

(6bit)

Travel speed shifting solenoid (ON)

(6bit)

Remarks

Input condition of switch 1

Input condition of switch 2

Input condition of switch 3

Drive condition of solenoid valve

20-157
(1)

SPECIAL FUNCTIONS OF MONITOR PANEL

TESTING AND ADJUSTING

Code
024

027

Monitoring item
(Unused)

Input condition of model


selection signal

Unit

Model selection 1 (Connected to ground)

(6bit)

Model selection 2 (Connected to ground)

(6bit)

Model selection 3 (Connected to ground)

(6bit)

Model selection 4 (Connected to ground)

(6bit)

Model selection 5 (Connected to ground)

(6bit)

(Unused)

(6bit)

030

Fuel control dial input voltage

10mV

031

Governor potentiometer input voltage

10mV

032

Controller power source voltage

100mV

033

Governor motor phase A output current

10mA

034

Governor motor phase B output current

10mA

035

Battery relay BR output voltage

100mV

036

037

(Unused)

(6bit)

(Unused)

(6bit)

(Unused)

(6bit)

(Unused)

(6bit)

Starting switch signal C (START)

(6bit)

(Unused)

(6bit)

Battery relay (DRIVEN)

(6bit)

(Unused)

(6bit)

(Unused)

(6bit)

(Unused)

(6bit)

(Unused)

(6bit)

(Unused)

(6bit)

Input condition of signal

Output condition of signal

041

Engine coolant sensor input voltage

10mV

042

Fuel level sensor input voltage

10mV

043

Alternator input voltage

10mV

044

(Unused)

045

Starting switch signal ACC (ON)

(6bit)

Starting switch signal C (START)

(6bit)

Starting switch signal R1 (HEAT)

(6bit)

Lamp switch (ON)

(6bit)

(Unused)

(6bit)

(Unused)

(6bit)

Input condition 4 of switch

20-158
(1)

Remarks

PC130-7

TESTING AND ADJUSTING

SPECIAL FUNCTIONS OF MONITOR PANEL

Code

046

049

Monitoring item

Unit

Air cleaner clogging switch (OPEN)

(6bit)

(Unused)

(6bit)

Engine oil pressure switch (OPEN)

(6bit)

Engine oil level switch (OPEN)

(6bit)

(Unused)

(6bit)

Alternator (Normal generation)

(6bit)

Swing lock switch (LOCK)

(6bit)

Caution buzzer stop switch (ON)

(6bit)

Windows limit switch (ON)

(6bit)

Wiper contact W (ON)

(6bit)

Wiper contact P (ON)

(6bit)

(Unused)

(6bit)

Input condition of sensor

Input condition 5 of switch

200

Monitor panel program version

Numeral

201

Governor and pump controller program version

Numeral

Display of numeral code

PC130-7

Remarks

Display of 6bit

20-159
(1)

TESTING AND ADJUSTING

5. Function of adjusting governor [03]


This function is used to adjust the governor lever
stroke after the governor actuator, fuel injection
pump, or governor spring is removed and
installed or replaced, or when the high idling
speed is low or engine speed is not stabilized.

1) Selecting and executing function


i) Select menu No. [03] in the menu selection mode.
ii) Press set switch (5) to execute this function.
2) Condition of governor motor
If this function is executed, all the governor
control functions are cancelled, and then the
operating angle of the governor actuator follows up only the operation signal of the fuel
control dial.
a While this function is executed, [GOV] is
displayed in display section (1) and
[gSET] is displayed in service meter section (2).

SPECIAL FUNCTIONS OF MONITOR PANEL

3) Adjusting governor lever stroke


a The turning direction of the governor
spring described below is the direction
when the governor actuator is seen from
the fuel injection pump side.
i) Keep the fuel control dial in the MAX
position.
ii) Loosen locknut (2) on the governor actuator side of governor spring (1).
iii) Turn governor spring (1) clockwise to
reduce its installed length (a) and return
governor lever (3) of the fuel injection
pump to a position where it does not
touch the full stopper.
iv) Turn governor spring (1) counterclockwise to increase its installed length (a)
and stop it when governor lever (3) of the
fuel injection pump touches the full stopper.
Standard installed length (a) (Reference): 262 mm
v) Turn governor spring (1) counterclockwise further by 2.5 turns to compress the
spring in governor spring (1).
a Since the inside spring is compressed, only the outer cylinder of
governor spring (1) moves toward
the fuel injection pump by about 3.1
mm (the installed length does not
change).
vi) Fixing governor spring (1), tighten locknut (2) on the governor actuator side.
a Before fixing the locknut, check that
the water drain hole of the governor
spring is directed down. If the water
drain hole is not directed down,
loosen locknut (4) on the fuel injection pump side and turn the whole
governor spring to adjust (Take care
not to change the adjustment dimension of the governor spring).
3 Locknut:
11.8 19.6 Nm {1.2 2.0 kgm}

20-160
(1)

PC130-7

TESTING AND ADJUSTING

SPECIAL FUNCTIONS OF MONITOR PANEL

vii) Return the fuel control dial to the MIN


position, and then turn it again slowly
toward the MAX position. At this time,
check that governor spring is compressed by about 3.1 mm after governor
lever (3) reaches the full stopper.

PC130-7

20-161
(1)

TESTING AND ADJUSTING

SPECIAL FUNCTIONS OF MONITOR PANEL

6. Function of selecting maintenance period


[04]
With this function, you can adjust the maintenance period of the engine oil for the function of
the engine oil replacement monitor.

3) Settling maintenance period


The display or maintenance period becomes
effective when it is selected. Accordingly,
perform the ordinary finishing operation.
1) Selecting and executing function
i) Select menu No. [04] in the menu selection mode.
ii) Press set switch (5) to execute this function.
2) Selecting maintenance period
The current display mode or maintenance
period is displayed in service meter section
(2). Press set switch (5) to select a maintenance period.
a Nothing is displayed in display section
(1).
a Each time the set switch is pressed, the
display mode or maintenance period
changes in the following order.
Display
0

20-162
(1)

Display mode/Maintenance period


Reset maintenance function

125

125-hour interval

250

250-hour interval

500

500-hour interval

<Special functions of engine oil replacement monitor>


a For the method of displaying the engine oil
replacement monitor, method of checking the
elapsed time after replacement of engine oil,
method of clearing the elapsed time, and method
of displaying demonstration mode, see "9. Special functions of engine oil replacement monitor".

Demonstration mode

PC130-7

TESTING AND ADJUSTING

7. Function of selecting default working mode


[05]
With this function, you can freely select the working mode which is set automatically when the
starting switch is turned ON (When the machine
is delivered, mode A is set).

SPECIAL FUNCTIONS OF MONITOR PANEL

3) Settling default working mode


Press set switch (5) to settle the selected
working mode.

1) Selecting and executing function


i) Select menu No. [05] in the menu selection mode.
ii) Press set switch (5) to execute this function.
2) Selecting default working mode
The currently set working mode is displayed
in service meter section (2). Press working
mode selector switches (7) and (8) to select
a working mode.
UP switch (7): Next mode is displayed.
DOWN switch (8): Previous mode is displayed.
a Nothing is displayed in display section
(1).
a The working mode changes in the following order.
AoEoB
a Mode L cannot be set as the default.

PC130-7

20-163
(1)

TESTING AND ADJUSTING

SPECIAL FUNCTIONS OF MONITOR PANEL

8. Special functions of engine oil replacement


monitor
1) Ordinary display of engine oil replacement
monitor
If the rest of time before the set engine oil
replacement time is 10 hours or shorter,
engine oil replacement monitor (10) lights up
and display the elapsed time in service meter
section for 20 seconds each time the starting
switch is turned ON.

4) Function of demonstration mode


If the demonstration mode is selected, you
can perform demonstration of the oil maintenance function when teaching the operation
to a customer.
The functions and display of the demonstration mode are as follows.

2) Checking elapsed time


To check the elapsed time while engine oil
replacement monitor (10) is OFF, turn the
starting switch OFF and press set switch (5)
and then turn the starting switch ON and
keep holding set switch (5).

1. The internally set interval is recognized


as 250 hours and the elapsed time is recognized as 240 hours.
2. When the starting switch is turned ON
after the demonstration mode is set, the
ordinary display is repeated up to 3 times
(number of the times of turning the starting switch ON).
3. After the demonstration is finished, resetting of maintenance setting [0] is recognized.
a When the demonstration is repeated 3
times, resetting of maintenance setting is
recognized. If setting is necessary at this
time, see "Function of selecting maintenance period".

3) Clearing elapsed time


To clear the elapsed time after replacing the
engine oil, hold set switch (5) for 3 seconds
while the elapsed time is displayed.
a If the above operation is performed, the
elapsed time in the monitor panel is set
to 0 hour.

20-164
(3)

PC130-7

TESTING AND ADJUSTING

PREPARATION WORK FOR TROUBLESHOOTING FOR


ELECTRIC SYSTEM

PREPARATION WORK FOR


TROUBLESHOOTING FOR
ELECTRIC SYSTEM

2. Governor and pump controller


a The governor and pump controller is installed
in the cover at the rear of the operator's seat.
1) Remove the 3 mounting bolts and cover (3).

a When carrying out troubleshooting for an electric


circuit related to the monitor panel and governor
and pump controller, expose the related connectors according to the following procedure.
1. Monitor panel
1) Remove cover (1)
a The cover is fixed with 2 clips at the top
and bottom. Just pull it up to remove it.
a If the daylight sensor of the air conditioner is installed, disconnect connector
P15 on the back side of the cover.
2) Insert or connect testing T-adapters in or to
connectors C01, C02, and C03 of governor
and pump controller (4).
a Since the connectors are secured with
screws, loosen those screws before disconnecting.
a When connecting the connectors again,
tighten their screws to the specified
torque.
3 Screw: 2.82 Nm {0.288 kgm}

2) Remove the 3 mounting screws, and then


remove monitor panel (2) from the mount.
a Take care not to drop the mounting
screws into the console.
3) Insert or connect testing T-adapters in or to
connectors P01 and P02 of the monitor
panel.
a Connector P70 clamped near the above
connectors is not used.

PC130-7

20-165
(3)

Pm-Clinic Service
Model

Serial No.

Service meter

PC130-7

Boom
Arm
Bucket

User's name

Date of inspection

Inspector

Main parts

Specifications
Attachments

Shoe width

Standard
Standard
Standard

(
(
(

)
)
)

1 att.
Blade
2-piece boom

(
(

)
)

500 mm
600 mm
700 mm

Check of oil and coolant levels


When necessary
Damper case oil
Machinery case oil

Radiator coolant
Engine oil
Hydraulic oil
Max. range of engine coolant temperature

(Top)

Max. range of hydraulic oil temperature

(Bottom)

Final drive case oil


(
)

Ambient temperature

Altitude
m
Operator's opinion

Visual inspection result

Error code history

Memo

PC130-7

20-167
(2)

TESTING AND ADJUSTING

PM-CLINIC SERVICE

Items related to engine

20-168
(1)

PC130-7

TESTING AND ADJUSTING

PM-CLINIC SERVICE

Items related to hydraulic equipment

PC130-7

20-169
(1)

20-170

(1)

PC130-7

Full (MAX)

Low (MIN)

Low (MIN)

Full (MAX)

Full (MAX)

Full (MAX)

Working
mode

ON

OFF

OFF

OFF

OFF

OFF

OFF

Auto
decelerator

OFF

ON

ON

OFF

OFF

OFF

OFF

One-touch power
max. switch

Condition

Serial No.

Full (MAX)

Full (MAX)

Full (MAX)

Full (MAX)

Full (MAX)

Full (MAX)

Full (MAX)

Working
mode

Boom top on level, no load

Boom top on level, no load

Boom top on level, no load

Boom top on level, no load

Max. reach, no load

Position of work equipment

Push up track shoe 1 side by 1

Max. reach

Engine speed

Blow-by pressure

Engine speed

Engine oil pressure

Engine speed

Engine oil pressure

Engine speed

Measured item

Travel (5 turns)

Swing (5 turns)

Hi

Lo

Bucket CURL

Arm IN (*1)

Arm IN (*1)

Arm IN (*1)

Arm OUT (*1)

Boom RAISE (*1)

Measured item

Left

Right

19.7 24.1

19.7 24.1

36.9 55.3

36.9 55.3

Right
Left

23.8 33.4

23.8 33.4

2.6 3.2

3.7 5.1

3.0 3.8

2.8 3.6

2.8 3.4

3.3 4.1

Standard value for


new machine

Left

Right

sec

Unit

1,300 1,500

0.98 {100}

2,080 2,280

0.15 {1.5}

1,050 1,150

0.25 {2.5}

2,250 2,450

Service limit
value

20.1 26.1

20.1 26.1

36.9 55.3

36.9 55.3

22.8 34.4

22.8 34.4

Max. 3.7

Max. 5.4

Max. 4.6

Max. 4.4

Max. 3.7

Max. 4.3

Service limit
value

Standard value

1,300 1,500

Max. 0.49{Max. 50}

kPa{mmH2O}
rpm

2,080 2,280

Min. 0.18{Min. 1.8}

1,050 1,150

rpm

MPa{kg/cm }

0.340.54{3.55.5}

MPa{kg/cm2}
rpm

2,250 2,450

Standard value for


new machine

Standard value

Date of inspection

rpm

Unit

User's name

Hydraulic oil temperature: 45 55 C

All levers in neutral

Arm DUMP relief

Arm DUMP relief

All levers in neutral

All levers in neutral

All levers in neutral

All levers in neutral

Operation of work
equipment

Service meter

Arm top and boom foot on level, no load

*1: Until cylinder cushion starts working

Full (MAX)

Fuel control
dial

No.

Condition

2. Work equipment, switch, and travel speed

Full (MAX)

Fuel control
dial

No.

1. Engine

Model

Measured
value

Measured
value

Judgmen

Good/Bad

Good/Bad

Good/Bad

Judgment

Inspector

PC130-7

20-171

(1)

Full (MAX)

Full (MAX)

Full (MAX)

Full (MAX)

Full (MAX)

Full (MAX)

Full (MAX)

Full (MAX)

Fuel control Working


dial
mode

No.

Condition

OFF

OFF

OFF

OFF

OFF

OFF

OFF

OFF

OFF

OFF

OFF

OFF

OFF

ON

OFF

OFF

Lowering distance of bucket


tip (in 15 min)

Measured item

Swing relief pressure


(Motor safety valve)

Swing lock
(Switch: LOCK)

60kg/cm2

(4)

Right front

PC control pressure
(PC valve)

Left rear
(1):(3)=1:0.5

{370400kg/cm2}

36.339.2MPa

Left

{21.523.5kg/cm2}

2.12.3MPa

{2138kg/cm2}

1.963.7MPa

{370400kg/cm2}

36.339.2MPa

{343378kg/cm2}

33.337.0MPa

{2935kg/cm2}

2.843.43MPa

Point
(Service limit
value)

Good/Bad

Judgment

28.932.9MPa

Servo inlet Control basic


pressure
pressure

600kg/cm2

(3)

Measured
value

{295335kg/cm2}

LS pressure

600kg/cm2

600kg/cm2
Pump
pressure

(2)

Max. 700

(1)

Max. 460

Service limit
value

Standard value
Standard value
for new machine

{kg/cm2}

MPa

Unit

mm

Unit

Right

LS differential pressure
(LS valve: Operated)

LS differential pressure
(LS valve: Neutral)

Pump relief pressure (Main


relief valve: High pressure)

Pump relief pressure (Main


relief valve: Low pressure)

Control basic pressure


(Self-reducing pressure valve)

Travel relief pressure Right rear


Travel lock
(Main relief valve)
(With sprocket fixed)
(Motor safety valve) Left front

Swing lock
(Switch: LOCK)

Idle travel
(With shoe raised)

All levers in neutral

Arm DUMP relief

Arm DUMP relief

All levers in neutral

Measured item
(Tested part)

Hydraulic oil temperature: 45 55 C

Arm top and boom foot on level,


rated load on bucket

Position of work equipment

Condition

Hydraulic oil temperature: 45 55 C

Auto
One-touch power Operation of work
decelerator
max. switch
equipment

Working
mode

Engine stopped

Fuel control
dial

4. Oil pressure

No.

3. Hydraulic drift of work equipment

TROUBLESHOOTING
POINTS TO REMEMBER WHEN TROUBLESHOOTING ......................................................................... 20-202
SEQUENCE OF EVENTS IN TROUBLESHOOTING ................................................................................ 20-203
POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE ...................................................... 20-204
INSPECTION BEFORE TROUBLESHOOTING ........................................................................................ 20-212
CLASSIFICATION OF AND PROCEDURES FOR TROUBLESHOOTING ............................................... 20-213
CONNECTOR ARRANGEMENT DRAWING AND ELECTRIC CIRCUIT DIAGRAM OF EACH SYSTEM ....... 20-217
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS .................................................................... 20-234
T-BRANCH BOX AND T-BRANCH TABLE ............................................................................................... 20-257

PC130-7

20-201
(1)

TROUBLESHOOTING

POINTS TO REMEMBER WHEN TROUBLESHOOTING

POINTS TO REMEMBER WHEN TROUBLESHOOTING


k Stop the machine in a level place, and check that the safety pin, blocks, and parking brake are securely fitted.
k When carrying out the operation with two or more workers, keep strictly to the agreed signals, and do not

allow any unauthorized person to come near.

k If the radiator cap is removed when the engine is hot, hot water may spurt out and cause burns, so wait for

the engine to cool down before starting troubleshooting.

k Be extremely careful not to touch any hot parts or to get caught in any rotating parts.

k When disconnecting wiring, always disconnect the negative () terminal of the battery first.

k When removing the plug or cap from a location which is under pressure from oil, water, or air, always release

the internal pressure first. When installing measuring equipment, be sure to connect it properly.
The aim of troubleshooting is to pinpoint the basic cause of the failure, to carry out repairs swiftly, and to
prevent reoccurrence of the failure.
When carrying out troubleshooting, and important point is of course to understand the structure and function.
However, a short cut to effective troubleshooting is to ask the operator various questions to form some idea
of possible causes of the failure that would produce the reported symptoms.
1. When carrying out troubleshooting, do not hurry
to disassemble the components.
If components are disassembled immediately
any failure occurs:
Parts that have no connection with the failure
or other unnecessary parts will be disassembled.
It will become impossible to find the cause of
the failure.
It will also cause a waste of manhours, parts, or
oil or grease, and at the same time, will also lose
the confidence of the user or operator.
For this reason, when carrying out troubleshooting, it is necessary to carry out thorough prior
investigation and to carry out troubleshooting in
accordance with the fixed procedure.
2. Points to ask user or operator
1) Have any other problems occurred apart
from the problem that has been reported?
2) Was there anything strange about the
machine before the failure occurred?
3) Did the failure occur suddenly, or were there
problems with the machine condition before
this?
4) Under what conditions did the failure occur?
5) Had any repairs been carried out before the
failure?
When were these repairs carried out?
6) Has the same kind of failure occurred
before?
3. Check before troubleshooting
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.

20-202
(1)

5) Other maintenance items can be checked


externally, so check any item that is considered to be necessary.
4. Confirming failure
Confirm the extent of the failure yourself, and
judge whether to handle it as a real failure or
as a problem with the method of operation,
etc.
a When operating the machine to reenact
the troubleshooting symptoms, do not
carry out any investigation or measurement that may make the problem worse.
5. Troubleshooting
Use the results of the investigation and inspection in Items 2 4 to narrow down the
causes of failure, then use the troubleshooting flowchart to locate the position of the failure exactly.
a The basic procedure for troubleshooting
is as follows.
1) Start from the simple points.
2) Start from the most likely points.
3) Investigate other related parts or
information.
6. Measures to remove root cause of failure
Even if the failure is repaired, if the root
cause of the failure is not repaired, the same
failure will occur again.
To prevent this, always investigate why the
problem occurred. Then, remove the root
cause.

PC130-7

TROUBLESHOOTING

SEQUENCE OF EVENTS IN TROUBLESHOOTING

SEQUENCE OF EVENTS IN TROUBLESHOOTING

PC130-7

20-203
(1)

TROUBLESHOOTING

POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE

POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE


To maintain the performance of the machine over a long period, and to prevent failures or other troubles before
they occur, correct operation, maintenance and inspection, troubleshooting, and repairs must be carried out.
This section deals particularly with correct repair procedures for mechatronics and is aimed at improving the
quality of repairs. For this purpose, it gives sections on Handling electric equipment and Handling hydraulic
equipment (particularly gear oil and hydraulic oil).
1. Points to remember when handling electric
equipment
1) Handling wiring harnesses and connectors
Wiring harnesses consist of wiring connecting
one component to another component, connectors used for connecting and disconnecting one
wire from another wire, and protectors or tubes
used for protecting the wiring.
Compared with other electrical components 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 inspection and repair operations, they are
frequently removed and installed again, so they
are likely to suffer deformation or damage. For
this reason, it is necessary to be extremely careful when handling wiring harnesses.
Main failures occurring in wiring harness
1) Defective contact of connectors (defective
contact between male and female)
Problems with defective contact are likely to
occur because the male connector is not
properly inserted into the female connector,
or because one or both of the connectors is
deformed or the position is not correctly
aligned, or because there is corrosion or
oxidization of the contact surfaces.

2) Defective crimping or soldering of connectors


The pins of the male and female connectors
are in contact at the crimped terminal or soldered portion, but if there is excessive force
brought to bear on the wiring, the plating at
the joint will peel and cause improper connection or breakage.

20-204
(1)

PC130-7

TROUBLESHOOTING

POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE

3) Disconnections in wiring
If the wiring is held and the connectors are
pulled apart, or components are lifted with a
crane with the wiring still connected, or a
heavy object hits the wiring, the crimping of
the connector may separate, or the 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 connector, water may enter the connector, depending on the direction of the
water jet.
As already said, the connector is designed
to prevent water from entering, but at the
same time, if water does enter, it is difficult
for it to be drained. Therefore, if water
should get into the connector, the pins will
be short-circuited by the water, so if any
water gets in, immediately dry the connector
or take other appropriate action before
passing electricity through it.
5) Oil or dirt stuck to connector
If oil or grease are stuck to the connector
and an oil film is formed on the mating 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 stuck to the connector, wipe it off with a dry cloth or blow it dry
with compressed air and spray it with a contact restorer.
a When wiping the mating portion of the
connector, be careful not to use excessive force or deform the pins.
a If there is oil or water in the compressed
air, the contacts will become even dirtier,
so remove the oil and water from the
compressed air completely before
cleaning with compressed air.

PC130-7

20-205
(1)

TROUBLESHOOTING

POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE

2) Removing, installing, and drying connectors


and wiring harnesses

Disconnecting connectors
1) Hold the connectors when disconnecting.
When disconnecting the connectors, hold
the connectors and not the wires. For connectors held by a screw, loosen the screw
fully, then hold the male and female connectors in each hand and pull apart. For connectors which have a lock stopper, press
down the stopper with your thumb and pull
the connectors apart.
a Never pull with one hand.
2) When removing from clips
When removing a connector from a clip, pull
the connector in a parallel direction to the
clip.
a If the connector is twisted up and down
or to the left or right, the housing may
break.

3) 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.
a If the machine is left disassembled for a
long time, it is particularly easy for improper contact to occur, so always cover
the connector.

20-206
(1)

PC130-7

TROUBLESHOOTING

POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE

Connecting connectors
1) Check the connector visually.
1) Check that there is no oil, dirt, or water
stuck to the connector pins (mating portion).
2) Check that there is no deformation,
defective contact, corrosion, or damage
to the connector pins.
3) Check that there is no damage or breakage to the outside of the connector.
a If there is any oil, water, or dirt stuck to
the connector, wipe it off with a dry cloth.
If any water has got inside the connector, warm the inside of the wiring with a
dryer, but be careful not to make it too
hot as this will cause short circuits.
a If there is any damage or breakage, replace the connector.
2) Fix the connector securely.
Align the position of the connector correctly,
then insert it securely.
For connectors with lock stopper, push in
the connector until the stopper clicks into
position.
3) Correct any protrusion of the boot and any
misalignment of the wiring harness
For connectors fitted with boots, correct any
protrusion of the boot. In addition, if the wiring harness is misaligned, or the clamp is
out of position, adjust it to its correct position.
a If the connector cannot be corrected
easily, remove the clamp and adjust the
position.
4) If the connector clamp has been removed,
be sure to return it to its original position.
Check also that there are no loose clamps.

Connecting connectors (DT type connector)


Since the DT 8-pole and 12-pole DT type connectors have 2 latches respectively, push them
in until they click 2 times.
1. Male connector, 2. Female connector
Normal locking state (Horizontal): a, b, d
Incomplete locking state (Diagonal): c

PC130-7

20-207
(1)

TROUBLESHOOTING

POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE

Drying wiring harness


If there is any oil or dirt on the wiring harness,
wipe it off with a dry cloth. Avoid washing it in
water or using steam. If the connector must be
washed in water, do not use high-pressure
water or steam directly on the wiring harness.
If water gets directly on the connector, do as follows.
1) Disconnect the connector and wipe off the
water with a dry cloth.
a If the connector is blown dry with compressed air, there is the risk that oil in the
air may cause defective contact, so remove all oil and water from the compressed air before blowing with air.
2) Dry the inside of the connector with a dryer.
If water gets inside the connector, use a
dryer to dry the connector.
a Hot air from the dryer can be used, but
regulate the time that the hot air is used
in order not to make the connector or related parts too hot, as this will cause deformation or damage to the connector.

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.
a After completely drying the connector,
blow it with contact restorer and reassemble.

20-208
(1)

PC130-7

TROUBLESHOOTING

POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE

3) Handling control box


1) The control box contains a microcomputer
and electronic control circuits. These control
all of the electronic circuits on the machine,
so be extremely careful when handling the
control box.
2) Do not open the cover of the control box
unless necessary.

3) Do not place objects on top of the control


box.
4) Cover the control connectors with tape or a
vinyl bag.
Never touch the connector contacts with
your hand.
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 on a suitable dry stand).
7) Precautions when carrying out arc welding
When carrying out arc welding on the body,
disconnect all wiring harness connectors
connected to the control box. Fit an arc
welding ground close to the welding point.

2. Points to remember when troubleshooting electric circuits


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

PC130-7

20-209
(1)

TROUBLESHOOTING

POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE

3. Points to remember when handling hydraulic


equipment
With the increase in pressure and precision of
hydraulic equipment, the most common cause of
failure is dirt (foreign material) in the hydraulic circuit. When adding hydraulic oil, or when disassembling or assembling hydraulic equipment, it is
necessary to be particularly careful.
1) Be careful of the operating environment.
Avoid adding hydraulic oil, replacing filters, or
repairing the machine in rain or high winds, or
places where there is a lot of dust.
2) Disassembly and maintenance work in the
field
If disassembly or maintenance work is carried
out on hydraulic equipment in the field, there is
danger of dust entering the equipment. It is also
difficult to confirm the performance after repairs,
so it is desirable to use unit exchange. Disassembly and main-tenance of hydraulic equipment should be carried out in a specially
prepared dustproof workshop, and the performance should be confirmed with special test
equipment.
3) Sealing openings
After any piping or equipment is removed, the
openings should be sealed with caps, tapes, or
vinyl bags to prevent any dirt or dust from 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 area around it clean, and also use
clean pumps and oil containers. If an oil cleaning device is used, it is possible to filter out the
dirt that has collected during storage, so this is
an even more effective method.

20-210
(1)

PC130-7

TROUBLESHOOTING

POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE

5) Change hydraulic oil when the temperature


is high.
When hydraulic oil or other oil is warm, it flows
easily. In addition, the sludge can also be
drained out easily from the circuit together with
the oil, so it is best to change the oil when it is
still warm. When changing the oil, as much as
possible of the old hydraulic oil must be drained
out. (Drain the oil from the hydraulic tank; also
drain the oil from the filter and from the drain
plug in the circuit.) If any old oil is left, the contaminants 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 contaminants, 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,
c o n tr o l v a lv e , e t c .) o r wh e n r u n ni n g t he
machine, carry out oil cleaning to remove the
sludge or contaminants in the hydraulic oil circuit.
The oil cleaning equipment is used to remove
the ultrafine (about 3) particles that the filter
built into the hydraulic equipment cannot
remove, so it is an extremely effective device.

PC130-7

20-211
(1)

TROUBLESHOOTING

INSPECTION BEFORE TROUBLESHOOTING

INSPECTION BEFORE TROUBLESHOOTING

1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.

Hydraulic and
Electrical
mechanical
equipment
equipment

Lubricating oil/Coolant

Item
Check of level and type of fuel
Check of fuel for foreign matter
Check of fuel filter cartridge for clogging
Check of level and type of oil in engine oil pan
Check of engine oil filter for clogging
Check of coolant level
Check of air cleaner for clogging
Check of level and type of hydraulic oil
Check of hydraulic oil strainer for clogging
Check of hydraulic oil filter for clogging
Check of level and type of swing machinery oil
Check of level and type of final drive oil

Add fuel
Clean or drain
Replace
Add oil
Replace
Add coolant
Clean or replace
Add oil
Clean or drain
Replace
Add oil
Add oil

1. Check of battery terminal wires for looseness and corrosion


2. Check of alternator terminal wires for looseness and corrosion
3. Check of starting motor terminal wires for looseness and corrosion

Retighten or replace
Retighten or replace
Retighten or replace

1. Check for abnormal sound and smell


2. Check for oil leakage
3. Air bleeding operation

Repair
Repair
Bleed air

Electrical parts

3.
4.
5.
6.
7.

8.

(1)

Remedy

1. Check of battery voltage (with engine stopped)


2. Check of electrolyte level

20-212

Criterion

20 30V

Charge or replace
Add distilled water
or replace electrolyte
Check of wires for discoloration, burn, and removal of covers

Replace
Check of wires for removal of clamps and looseness

Repair
Check of wires for wetting with water (Particularly check connectors and

Disconnect and dry


terminals for wetting)
connectors
Check of fuses for breakage and corrosion

Replace
Check of alternator voltage (with engine at medium or higher speed)
Must be 27.5 - Replace
29.5 V after
operation of
several minutes.
Check of operating sound of battery relay (when starting switch is

Replace
turned OFF and ON)

PC130-7

TROUBLESHOOTING

CLASSIFICATION OF AND PROCEDURES FOR TROUBLESHOOTING

CLASSIFICATION OF AND PROCEDURES FOR


TROUBLESHOOTING
Classification of troubleshooting
Mode
Code display

Contents
Troubleshooting when error code is displayed

E-mode

Troubleshooting for electric system

H-mode

Troubleshooting for hydraulic and mechanical system

S-mode

Troubleshooting for engine unit

Procedure for troubleshooting


If a phenomenon looking like a trouble occurs in the machine, select a proper troubleshooting No. according to
the following procedure, and then go to the corresponding troubleshooting section.
1. Procedure for troubleshooting to be taken when user code is displayed on monitor panel:
If a user code is displayed on the monitor panel, display the error code by using the error code display function of the monitor panel.
Carry out the troubleshooting for the corresponding "Code display" according to the displayed error code.
2. Procedure for troubleshooting when electrical system error code or mechanical system error code
is recorded in error history:
If a user code is not displayed on the monitor panel, check the error code with the error code display function of the monitor panel.
If the error code is recorded, carry out troubleshooting for the corresponding "Code display" according to
the displayed error code.
a If error codes are recorded, delete all of them and reproduce them, and then see if the trouble is still detected.
a If an error code is still output, the mark of "E" is displayed at the left end of the lower line.
3. Procedure for troubleshooting to be taken when user code is not displayed and error history is not
recorded:
If a user code is not displayed in the monitor panel and an error code is not recorded, a trouble that the
machine cannot find out by itself may have occurred in the electrical system or hydraulic and mechanical
system.
In this case, check the phenomenon looking like a trouble again and select the same phenomenon from the
table of "Phenomena looking like troubles and troubleshooting Nos.", and then carry out troubleshooting
related to that phenomenon in the "E mode", "H mode", or "S mode".

PC130-7

20-213
(1)

TROUBLESHOOTING

CLASSIFICATION OF AND PROCEDURES FOR TROUBLESHOOTING

Phenomena looking like troubles and troubleshooting Nos.


Troubleshooting
No.

Phenomenon looking like trouble

Code
display

E-mode

H-mode

S-mode

Phenomena related to user code or error code


1

User codes are displayed on monitor panel

If error code display function is checked, error codes are displayed

According to displayed
code

Phenomena related to engine


3

Engine does not start easily (It always takes time to start)

S-1

Engine does not crank

Engine cranks but exhaust smoke


does not come out
(Fuel is not injected)

S-2 b)

Exhaust smoke comes out but engine


does not start (Fuel is injected)

S-2 c)

Engine speed does not rise sharply (Follow-up performance is low)

Engine stops during operation

E-2

S-4

Engine rotation is abnormal (Engine hunts)

E-3

S-5

10

Output is insufficient (Power is low)

S-6

11

Exhaust gas color is bad (Incomplete combustion)

S-7

12

Oil is consumed much (or exhaust gas color is bad)

S-8

13

Oil becomes dirty quickly

S-9

14

Fuel is consumed much

S-10

15

Coolant contains oil (or it blows back or reduces)

S-11

16

Engine oil pressure caution lamp lights up (Oil pressure lowers)

S-12

17

Oil level rises (Water or fuel is mixed in oil)

S-13

18

Water temperature rises too high (Overheating)

S-14

19

Abnormal sound comes out

S-15

20

Vibration is excessive

S-16

21

Engine does not stop

E-4

22

Auto-decelerator does not operate

E-5

23

Automatic warm-up system does not operate

E-6

24

Preheater does not operate

E-7

Engine does not start

E-1

S-2 a)

S-3

H-5

Phenomena related to work equipment, swing, and travel


25

Speed or power of whole work equipment, travel, and swing is low

H-1

S-6

26

Engine speed lowers extremely or engine stalls

H-2

S-4

27

Work equipment, travel, and swing systems do not work

28

Abnormal sound comes out from around hydraulic pump

H-4

29

Fine control performance or response is low

H-6

20-214
(1)

E-8

H-3

PC130-7

TROUBLESHOOTING

CLASSIFICATION OF AND PROCEDURES FOR TROUBLESHOOTING

Troubleshooting
No.

Phenomenon looking like trouble

Code
display

E-mode

H-mode

S-mode

Phenomena related to work equipment


30

Speed or power of boom is low

H-7

31

Speed or power of arm is low

H-8

32

Speed or power of bucket is low

H-9

33

Work equipment does not move singly

H-10

34

Hydraulic drift of work equipment is large

H-11

35

Time lag of work equipment is large

H-12

36

One-touch power maximizing function does not work

E-9

H-13

Phenomena related to compound operation


37

In compound operation of work equipment, speed of part loaded


more is low

H-14

38

When machine swings and raises boom simultaneously, boom rising


speed is low

H-15

39

When machine operates work equipment or swings and travels


simultaneously, travel speed lowers largely

H-16

Phenomena related to travel


40

Machine deviates during travel

H-17

41

Travel speed is low

H-18

42

Machine is not steered well or steering power is low

H-19

43

Travel speed does not change

H-20

44

Travel motor does not work (only 1 side)

H-21

45

Travel alarm does not sound or does not stop sounding

E-33

Phenomena related to swing


46

Upper structure does not swing

H-22

47

Swing acceleration or swing speed is low

H-23

48

Upper structure overruns remarkably when it stops swinging

H-24

49

Large shock is made when upper structure stops swinging

H-25

50

Large sound is made when upper structure stops swinging

H-26

51

Hydraulic drift of swing is large

H-27

Phenomena related to monitor panel (Operator menu: Ordinary screen)


52

No items are displayed on monitor panel

E-10

53

7-segment LED's of monitor panel display partially

E-11

54

Monitor lamp of monitor panel is different from mounted model

E-12

55

When starting switch is turned ON, basic check items light up or


flash

E-13

56

While engine is running, caution items flash

E-14

57

While engine is running, emergency stop items flash

E-15

58

Engine coolant thermometer does not display normally

E-16

59

Fuel level gauge does not display normally

E-17

60

Swing lock monitor does not display normally

E-18

PC130-7

20-215
(1)

TROUBLESHOOTING

CLASSIFICATION OF AND PROCEDURES FOR TROUBLESHOOTING

Troubleshooting
No.

Phenomenon looking like trouble

Code
display

E-mode

61

When monitor switches are operated, display by lamps does not


change

E-19

62

Windshield wiper or windshield washer does not operate

E-20

63

Lower wiper does not operate

E-21

64

Caution buzzer cannot be stopped

E-22

H-mode

S-mode

Phenomena related to monitor panel (Service menu: Special function screen)


65

Monitoring function does not display "Boom RAISE" normally

E-23

66

Monitoring function does not display "Boom LOWER" normally

E-24

67

Monitoring function does not display "Arm IN" normally

E-25

68

Monitoring function does not display "Arm OUT" normally

E-26

69

Monitoring function does not display "Bucket CURL" normally

E-27

70

Monitoring function does not display "Bucket DUMP" normally

E-28

71

Monitoring function does not display "Swing" normally

E-29

72

Monitoring function does not display "Travel" normally

E-30

73

Monitoring function does not display "Service" normally

E-31

Other phenomena
74

Air conditioner does not operate (Troubleshooting for air conditioner


system)

20-216
(1)

E-32

PC130-7

CONNECTOR ARRANGEMENT DRAWING AND ELECTRIC


CIRCUIT DIAGRAM OF EACH SYSTEM

TROUBLESHOOTING

CONNECTOR ARRANGEMENT DRAWING AND ELECTRIC


CIRCUIT DIAGRAM OF EACH SYSTEM
Connectors list

Connector
No
A01
A02
A03
A04
A05
A06
A07
A09
A10
A11
A12
A13
A14
A15
A16
A20
A21
A22
A23
A25
A26
A27
A29
A31
A33
A34
A35
A41
A42
A43
A44
A50
A50
A51
A60
A61
A70
A71K
A80
A95
A96
A97
A98
A99

PC130-7

Type
X
X
DT
SWP
SWP
SWP
SWP
SWP
Terminal
Terminal
Terminal
Terminal
Terminal
Terminal
Terminal
Terminal
Terminal
Terminal
Terminal
Terminal
Terminal
X
Terminal
D
X
L
M
090-II
X
X
One-pin
connector
X
KES0
D
X
D
D
D

D
D
D
D
SWP

a The address of each connector roughly shows the place of the connector in
the connectors stereogram and the circuit diagram of each system.
No. of
pins

Name of device

Stereogram
S-1
T-1
N-3
N-1
T-1
N-1
S-1
N-2
I-1
I-2
I-2
I-2
L-1
J-2
J-2
L-2
L-2
K-2
K-3
K-1
K-1
L-1
K-2
L-7
L-5
L-3
L-3
G-1
G-9
I-9

4
4
12
6
14
14
16
8
1
1
1
1
1
1
1
1
1
1
1
1
1
2
1
2
2
2
2
1
1
2

Intermediate connector
Intermediate connector
Intermediate connector
Intermediate connector
Intermediate connector
Intermediate connector
Intermediate connector
Intermediate connector
Revolving frame ground
Revolving frame ground
Revolving frame ground
Revolving frame ground
Revolving frame ground
Revolving frame ground
Revolving frame ground
Battery relay (Terminal E)
Battery relay (Terminal BR)
Battery relay (Terminal M)
Battery relay (Terminal B)
Heater relay (Coil)
Heater relay (Contact)
Starting motor safety relay (Terminals S, R)
Starting motor safety relay (Terminals C)
Air cleaner clogging switch
Radiator coolant level sensor
Fusible link (65A)
Fusible link (30A)
Horn
Intermediate connector
Travel alarm (If equipped)

Working lamp (Right front)

D-9

2
2
3
1
2
3
2
4
2
2
2
2
8

Intermediate connector
Windshield washer motor (Tank)
Pump oil pressure sensor
Fuel level sensor
Hydraulic oil temperature sensor
Overload alarm pressure sensor (If equipped)
Fuel priming pump (If equipped)
Spare connector
Spare connector
Spare connector
Spare connector
Spare connector
Intermediate connector

E-9
E-9
I-9
G-9
K-9
G-9
G-1
R-1
K-8
K-8
L-8
L-8
N-2

Address
MGcircuit circuit
H-7
I-8
H-7
I-8
H-6
I-6
H-6
H-6
H-4
I-1
I-1
I-1
I-1
I-1
I-1
I-1
J-3
J-2
J-2
J-2
K-3
K-3
K-3
K-3
K-5
K-5
K-7
K-7

I-7
G-1

G-1
H-1

Pcircuit
H-8
H-7
H-7
H-7
H-6
H-5
H-5
H-5
I-1

I-1
J-1
J-1

J-4
J-3
K-4
K-3
K-7
K-7
K-5
L-5

L-3
L-3

G-2
K-5
H-1

K-6
K-6
K-5
K-6
A-70

H-3

H-4

20-217
(1)

CONNECTOR ARRANGEMENT DRAWING AND ELECTRIC


CIRCUIT DIAGRAM OF EACH SYSTEM

TROUBLESHOOTING

Connector
No

Type

No. of
pins

C01
C02
C03
C09
D01
D02
D03
E01
E02
E03
E04
E05
E06
E06
E08
E10
E11
E12
F02A
F02B
FB1
H07
H08
H09
H10
H11
H12
H15
J01
J02
J03
J04
J05
J06
J07
J08
J09
J10
K19
K30
K31
M07
M09
M13
M19
M21
M22
M23
M26
M27
M29

DRC
DRC
DRC
S
SWP
SWP
SWP
Terminal
Terminal
D
D
D
M
X
X
D
D
X
SWP
DT

M
M
S
S
S
S
090
J
J
J
J
J
J
J
J
J
J
M
DT
DT
M
M

PA
090
090
SWP

040

24
40
40
8
8
8
8
1
1
2
2
2
3
1
2
3
4
2
2
2

2
8
8
16
16
12
20
20
20
20
20
20
20
20
20
20
20
2
3
3
3
1
2
2
9
6
8
12
16
20

20-218
(1)

Name of device
Governor and pump controller
Governor and pump controller
Governor and pump controller
Model selection connector
Concentrated diode
Concentrated diode
Concentrated diode
Electrical intake air heater
Engine oil pressure switch
Engine oil level switch
Engine speed sensor
Engine coolant temperature sensor
Fuel control dial
Air conditioner compressor magnetic clutch
Intermediate connector
Governor potentiometer
Governor motor
Alternator [35-A alternator specification]
Intermediate connector
Rotary lamp (If equipped)
Fuse box
Intermediate connector
Intermediate connector
Intermediate connector
Intermediate connector
Intermediate connector
Intermediate connector
Intermediate connector
Junction connector (Black)
Junction connector (Black)
Junction connector (Green)
Junction connector (Green)
Junction connector (Pink)
Junction connector (Orange)
Junction connector (Orange)
Junction connector (Pink)
Junction connector (Pink)
Junction connector (Orange)
Pump resistor (For driving pump in emergency)
CAN terminal resistance
CAN terminal resistance
Light switch
Working lamp (Boom front)
Speaker (Right)
Cigarette lighter
Radio (If equipped)
Right lever knob switch
Left lever knob switch
Intermediate connector
Air conditioner unit
Air conditioner control panel

Stereogram
U-9
V-9
W-9
U-9
W-9
W-8
W-3
J-9
K-8
K-8
H-9
K-8
O-8
J-8
L-7
J-9
J-8
J-2
AA-9
AA-9
U-2
Y-5
W-6
W-6
S-9
S-9
S-9
N-7
T-9
V-3
V-3
V-3
V-3
W-3
W-4
W-4
W-3
W-3
W-3
W-7
N-4
P-8
F-9
AC-8
N-3
U-2
N-7
T-1
W-4
W-5
U-2

Address
MGcircuit circuit
A-4
A-8
A-3
A-7
A-3
A-4
C-8
A-8
D-1
A-8
D-1
L-3
L-7
L-4
K-6

Pcircuit
A-8
A-7
A-4
G-8

K-9
K-5
F-1
K-4

K-2

I-1
K-6
K-6
L-2

J-9

B-1

D-3

I-9
I-9
I-8

B-9

J-8
J-8
C-7
C-6
C-5
C-3
C-9
C-9
D-9
D-9
E-9
E-9
F-9

E-9
E-9

C-3
C-9
D-9
D-9
E-9
E-9

F-9

E-9

D-9
D-9

F-9
G-9

E-9
G-8

A-3
A-4
B-1
G-1

C-1
L-8

B-8

PC130-7

CONNECTOR ARRANGEMENT DRAWING AND ELECTRIC


CIRCUIT DIAGRAM OF EACH SYSTEM

TROUBLESHOOTING

Connector
No

Type

No. of
pins

M30
M31
M31B
M32
M32B
M33
M33
M40
M40A
M40B
M41
M42
M43
M45
M46
M50
M51
M71
M72
M73
M91
M92
P01
P02
P03
P05
P06
P15
P17
P70
R10
R11
R13
R16
R17
R18
R20
R22
R30
R31
S01
S02
S03
S04
S05
S06
S07
S08
S09
S10
S11

M
M
M
M
M
SWP
SWP
SWP
SWP
SWP
X
M
D
090
AMP
AMP
M
M

M
KES0
070
040
M
M
M
Y050

040
R
R
R
R
R
R
R
R
R
R
X
X
X
X
X
X
X
X
X
X
X

16
2
2
2
2
2
8
2
2
2
2
1
1
12
4
8
8
2
4
2
1
4
12
20
2
2
2
2
2
16
5
5
5
5
5
5
5
5
5
5
2
2
2
2
2
2
2
2
2
2
2

PC130-7

Name of device
Air conditioner control panel
Optional power supply (2)
Heated seat (If equipped)
Optional power supply (1)
Heated seat (If equipped)
Heated seat switch (If equipped)
Air conditioner unit
Headlamp (Left)
Intermediate connector
Rear lamp (If equipped)
Headlamp (Right)
Intermediate connector
Working lamp (Rear) (If equipped)
Network bus connector
RS232C junction connector
Radio cassette (If equipped)
Radio cassette (If equipped)
Room lamp
DC/DC converter
Speaker (Left)
Working lamp (Left front) (If equipped)
Lower wiper motor
Monitor panel
Monitor panel
Caution buzzer stop switch
Rotary lamp switch (If equipped)
Lower wiper switch
Air conditioner daylight sensor (If equipped)
Air conditioner high/low pressure switch
Monitor panel
Light relay (1)
Starting motor cutout relay (PPC lock)
Starting motor cutout relay (Personal code)
Light relay (2)
12-V selector relay
Lower wiper relay
Spare connector
Spare connector
Air conditioner blower relay
Air conditioner compressor relay
Bucket CURL pressure switch
Boom LOWER oil pressure switch
Swing LEFT oil pressure switch
Arm IN pressure switch
Bucket DUMP oil pressure switch
Boom RAISE oil pressure switch
Swing RIGHT oil pressure switch
Arm OUT oil pressure switch
Intermediate connector
Service 1 (Front) oil pressure switch (If equipped)
Service 1 (Rear) oil pressure switch (If equipped)

Stereogram
U-2
W-6
U-2
Y-5
V-2
W-2
W-6
Z-8
AA-8
AC-8
Y-7
I-9
I-9
W-8
V-9
AD-8
AD-8
Z-8
W-7
AD-7
H-1
H-1
N-6
N-5
P-9
W-2
W-1
N-6
N-4
N-5
O-8
P-8
Q-9
T-9
W-4
T-9
T-9
U-9
W-6
W-5
L-6
L-4
L-7
L-5
L-6
L-4
L-6
L-5
L-3
L-3
K-3

Address
MGcircuit circuit

Pcircuit

K-8
K-8
K-8
K-7
H-2
H-1
B-9

H-8
H-8
A-7
A-6
B-1

L-9
L-9

A-9

F-1

A-5
D-1
D-1
D-1
E-1

L-9
B-9

E-1
C-9
C-9

K-4
K-4
K-3
K-4
K-3
K-5
K-3
K-4
H-3
G-2
G-2

20-219
(1)

CONNECTOR ARRANGEMENT DRAWING AND ELECTRIC


CIRCUIT DIAGRAM OF EACH SYSTEM

TROUBLESHOOTING

Connector
No

Type

No. of
pins

S14
S21
S21
S22
S22
S25
S30
S31
SC
T05
T06
T06A
T11
T13
T91
T92
V01
V04
V05
V06
V21
V22
V30
W03
W04
X05

M
Terminal
X
Terminal
X
090
X
X
Terminal
Terminal
Terminal
M
Terminal
D
D
D
D
D
D
D
D
D
X
X
M
M

3
6
2
6
2
16
2
2
1
1
1
1
1
1
1
1
2
2
2
2
2
2
2
2
6
4

20-220
(1)

Name of device
Safety lock switch
Emergency pump drive switch
Service 2 (Front) oil pressure switch (If equipped)
Swing holding brake release switch
Service 2 (Rear) oil pressure switch (If equipped)
Intermediate connector
Travel oil pressure switch
Spare connector
Starting motor (Terminal C)
Floor frame ground
Radio body ground
Intermediate connector
Cab ground
Intermediate connector
Intermediate connector
Intermediate connector
PPC lock solenoid valve
Travel speed shifting solenoid valve
Swing holding brake solenoid valve
2-stage relief solenoid
PC-EPC solenoid valve
LS-EPC solenoid valve
Spare connector
Window rear limit switch
Wiper motor
Swing lock switch

Stereogram
T-1
R-9
K-3
R-9
K-3
Q-9
O-1
P-1
J-8
V-2
U-2
T-2
AD-3
K-8
K-8
K-8
J-2
J-2
J-3
K-3
K-9
K-9
N-2
AB-9
Y-3
Q-9

Address
MGcircuit circuit
K-9

K-4
K-4
K-4

Pcircuit
F-8
E-2
G-1
F-2
G-1
E-3
A-1
A-1

I-2
I-2
I-1
K-8
K-7
K-7
K-7
K-9
K-8
A-1

K-8
A-9
C-1

C-2

PC130-7

TROUBLESHOOTING

CONNECTOR ARRANGEMENT DRAWING AND ELECTRIC


CIRCUIT DIAGRAM OF EACH SYSTEM

STEREOGRAM OF CONNECTORS

20-222
(1)

PC130-7

TROUBLESHOOTING

PC130-7

CONNECTOR ARRANGEMENT DRAWING AND ELECTRIC


CIRCUIT DIAGRAM OF EACH SYSTEM

20-223
(1)

TROUBLESHOOTING

20-224
(1)

CONNECTOR ARRANGEMENT DRAWING AND ELECTRIC


CIRCUIT DIAGRAM OF EACH SYSTEM

PC130-7

TROUBLESHOOTING

PC130-7

CONNECTOR ARRANGEMENT DRAWING AND ELECTRIC


CIRCUIT DIAGRAM OF EACH SYSTEM

20-225
(1)

TROUBLESHOOTING

20-226
(1)

CONNECTOR ARRANGEMENT DRAWING AND ELECTRIC


CIRCUIT DIAGRAM OF EACH SYSTEM

PC130-7

TROUBLESHOOTING

CONNECTOR ARRANGEMENT DRAWING AND ELECTRIC


CIRCUIT DIAGRAM OF EACH SYSTEM

CIRCUIT DIAGRAM OF MONITOR PANEL SYSTEM (M-CIRCUIT)

20-228
(1)

PC130-7

TROUBLESHOOTING

CONNECTOR ARRANGEMENT DRAWING AND ELECTRIC


CIRCUIT DIAGRAM OF EACH SYSTEM

a This circuit diagram is made by excerpting the monitor panel system, engine preheating/starting/charging
system, lower wiper system, and light system from the general electric circuit diagram.

PC130-7

20-229
(3)

TROUBLESHOOTING

CONNECTOR ARRANGEMENT DRAWING AND ELECTRIC


CIRCUIT DIAGRAM OF EACH SYSTEM

CIRCUIT DIAGRAM OF ENGINE THROTTLE CONTROL SYSTEM OF GOVERNOR AND


PUMP CONTROLLER (G-CIRCUIT)

20-230
(1)

PC130-7

TROUBLESHOOTING

CONNECTOR ARRANGEMENT DRAWING AND ELECTRIC


CIRCUIT DIAGRAM OF EACH SYSTEM

a This circuit diagram is made by excerpting the governor and pump controller system (engine throttle/power
supply/model selection/communication system) from the general electric circuit diagram.

PC130-7

20-231
(1)

TROUBLESHOOTING

CONNECTOR ARRANGEMENT DRAWING AND ELECTRIC


CIRCUIT DIAGRAM OF EACH SYSTEM

CIRCUIT DIAGRAM OF PUMP CONTROL SYSTEM OF GOVERNOR AND PUMP CONTROLLER (P-CIRCUIT)

20-232
(1)

PC130-7

TROUBLESHOOTING

CONNECTOR ARRANGEMENT DRAWING AND ELECTRIC


CIRCUIT DIAGRAM OF EACH SYSTEM

a This circuit diagram is made by excerpting the governor and pump controller system (pump control), PPC
lock system, and travel alarm system from the general electric circuit diagram.

PC130-7

20-233
(1)

TROUBLESHOOTING

CONNECTION TABLE FOR CONNECTOR PIN NUMBERS

CONNECTION TABLE FOR CONNECTOR PIN NUMBERS


a The terms male and female refer to the pins, while the terms male housing and female housing refer to the
mating portion of the housing.

X type connector

No.of
pins

Male (female housing)

Female (male housing)

T-adapter
Part No.

Part No.: 08055-00181

Part No.: 08055-00191

799-601-7010

799-601-7020

Part No.: 08055-00282

Part No.: 08055-00292

799-601-7030

Part No.: 08055-00381

Part No.: 08055-00391

799-601-7040

Part No.: 08055-00481

Part No.: 08055-00491

Terminal part No.: 79A-222-3370


Electric wire size: 0.85
Grommet: Black
Qty: 20

Terminal part No.: 79A-222-3390


Electric wire size: 0.85
Grommet: Black
Qty : 20

Terminal part No.: 79A-222-3380


Electric wire size: 2.0
Grommet: Red
Qty: 20

Terminal part No.: 79A-222-3410


Electric wire size: 2.0
Grommet: Red
Qty: 20

20-234
(1)

PC130-7

TROUBLESHOOTING

No.of
pins

CONNECTION TABLE FOR CONNECTOR PIN NUMBERS

SWP type connector


Male (female housing)

Female (male housing)

799-601-7050

Part No.: 08055-10681

Part No.: 08055-10691

799-601-7060

Part No.: 08055-10881

Part No.: 08055-10891

12

799-601-7310

Part No.: 08055-11281

Part No.: 08055-11291

14

799-601-7070

Part No.: 08055-11481

PC130-7

T-adapter
Part No.

Part No.: 08055-11491

20-235
(1)

TROUBLESHOOTING

CONNECTION TABLE FOR CONNECTOR PIN NUMBERS

SWP type connector

No. of
pins

Male (female housing)

Female (male housing)

16

T-adapter
Part No.

799-601-7320

Part No.: 08055-11681

Part No.: 08055-11691

Terminal part No.:


Electric wire size: 0.85
Grommet: Black
Qty: 20

Terminal part No.:


Electric wire size: 0.85
Grommet: Black
Qty: 20

Terminal part No.:


Electric wire size: 1.25
Grommet: Red
Qty: 20

Terminal part No.:


Electric wire size: 1.25
Grommet: Red
Qty: 20

20-236
(1)

PC130-7

TROUBLESHOOTING

CONNECTION TABLE FOR CONNECTOR PIN NUMBERS

M type connector

No.of
pins

Male (female housing)

Female (male housing)

T-adapter Part
No.

Part No.: 08056-00171

Part No.: 08056-00181

799-601-7080

799-601-7090

Part No.: 08056-00271

Part No.: 08056-00281

799-601-7110

Part No.: 08056-00371

Part No.: 08056-00381

799-601-7120

Part No.: 08056-00471

Part No.: 08056-00481

799-601-7130

Part No.: 08056-00671

Part No.: 08056-00681

799-601-7340

Part No.: 08056-00871

PC130-7

Part No.: 08056-00881

20-237
(1)

TROUBLESHOOTING

No.of
pins

CONNECTION TABLE FOR CONNECTOR PIN NUMBERS

S type connector
Male (female housing)

Female (male housing)

799-601-7140

Part No.: 08056-10871

Part No.: 08056-10881

10
(White)

799-601-7150

Part No.: 08056-11071

Part No.: 08056-11081

12
(White)

799-601-7350

Part No.: 08056-11271

Part No.: 08056-11281

16
(White)

799-601-7330

Part No.: 08056-11671

20-238
(1)

T-adapter
Part No.

Part No.: 08056-11681

PC130-7

TROUBLESHOOTING

No.of
pins

CONNECTION TABLE FOR CONNECTOR PIN NUMBERS

S type connector
Male (female housing)

Female (male housing)

10
(Blue)

12
(Blue)

799-601-7160

Part No.: 08056-11272

Part No.: 08056-11282

16
(Blue)

799-601-7170

Part No.: 08056-11672

PC130-7

T-adapter
Part No.

Part No.: 08056-11682

20-239
(1)

TROUBLESHOOTING

CONNECTION TABLE FOR CONNECTOR PIN NUMBERS

MIC type connector

No.of
pins

Male (female housing)

Female (male housing)

T-adapter Part
No.

Body part No.: 79A-222-2640 (Qty: 5)

Body part No.: 79A-222-2630 (Qty: 5)

11

Body part No.: 79A-222-2680 (Qty: 5)

Body part No.: 79A-222-2670 (Qty: 5)

799-601-2710

Body part No.: 79A-222-2620 (Qty: 5)

Body part No.: 79A-222-2610 (Qty: 5)

799-601-2950

Body part No.: 79A-222-2660 (Qty: 5)

Body part No.: 79A-222-2650 (Qty: 5)

13

799-601-2720

Body part No.: 79A-222-2710 (Qty: 2)

20-240
(1)

Body part No.: 79A-222-2690 (Qty: 2)

PC130-7

TROUBLESHOOTING

No.of
pins

CONNECTION TABLE FOR CONNECTOR PIN NUMBERS

MIC type connector


Male (female housing)

Female (male housing)

17

799-601-2730

Body part No.: 79A-222-2730 (Qty: 2)

Body part No.: 79A-222-2720 (Qty: 2)

21

PC130-7

T-adapter Part
No.

799-601-2740

Body part No.: 79A-222-2750 (Qty: 2)

Body part No.: 79A-222-2740 (Qty: 2)

Terminal part No.: 79A-222-2770


(Qty: 50)

Terminal part No.: 79A-222-2760


(Qty: 50)

20-241
(1)

TROUBLESHOOTING

No.of
pins

CONNECTION TABLE FOR CONNECTOR PIN NUMBERS

AMP040 type connector


Male (female housing)

Female (male housing)

T-adapter Part
No.

799-601-7180

Housing part No.: 79A-222-3430 (Qty: 5)

12

799-601-7190

Housing part No.: 79A-222-3440 (Qty: 5)

16

799-601-7210

Housing part No.: 79A-222-3450 (Qty: 5)

20

799-601-7220

Housing part No.: 79A-222-3460 (Qty: 5)

a Terminal part No.: 79A-222-3470 (No relation with number of pins)

20-242
(1)

PC130-7

TROUBLESHOOTING

No.of
pins

CONNECTION TABLE FOR CONNECTOR PIN NUMBERS

AMP070 type connector


Male (female housing)

Female (male housing)

10

799-601-7510

Part No.: 08195-10210

12

799-601-7520

Part No.: 08195-12210

14

799-601-7530

Part No.: 08195-14210

18

799-601-7540

Part No.: 08195-18210

20

799-601-7550

PC130-7

T-adapter Part
No.

Part No.: 08195-20210

20-243
(1)

TROUBLESHOOTING

No.of
pins

CONNECTION TABLE FOR CONNECTOR PIN NUMBERS

L type connector
Male (female housing)

Female (male housing)

No.of
pins

Connector for PA
Male (female housing)

Female (male housing)

Bendix MS connector
Male (female housing)

Female (male housing)

10

(1)

T-adapter Part
No.

799-601-3460

20-244

T-adapter Part
No.

No.of
pins

T-adapter Part
No.

PC130-7

TROUBLESHOOTING

CONNECTION TABLE FOR CONNECTOR PIN NUMBERS

KES 1 (Automobile) connector

No.of
pins

Male (female housing)

Female (male housing)

T-adapter Part
No.

Part No.: 08027-10210 (Natural color)


08027-10220 (Black)

Part No.: 08027-10260 (Natural color)


08027-10270 (Black)

Part No.:08027-10310

Part No.:08027-10360

Part No.: 08027-10410 (Natural color)


08027-10420 (Black)

Part No.: 08027-10460 (Natural color)


08027-10470 (Black)

Part No.: 08027-10610 (Natural color)


08027-10620 (Black)

PC130-7

Part No.: 08027-10660 (Natural color)


08027-10670 (Black)

20-245
(1)

TROUBLESHOOTING

CONNECTION TABLE FOR CONNECTOR PIN NUMBERS

KES 1 (Automobile) connector

No.of
pins

Male (female housing)

Female (male housing)

Part No.: 08027-10810 (Natural color)


08027-10820 (Black)

No.of
pins

Part No.: 08027-10860 (Natural color)


08027-10870 (Black)

Connector for relay (Socket type)


Male (female housing)

Female (male housing)

799-601-7370

20-246

T-adapter Part
No.

799-601-7360

(1)

T-adapter Part
No.

PC130-7

TROUBLESHOOTING

No.of
pins

CONNECTION TABLE FOR CONNECTOR PIN NUMBERS

F type connector
Male (female housing)

Female (male housing)

PC130-7

T-adapter
Part No.

20-247
(1)

TROUBLESHOOTING

CONNECTION TABLE FOR CONNECTOR PIN NUMBERS

[The pin No. is also marked on the connector (electric wire insertion end)]
HD30 Series connector

Type
(shell
size
code)

Body (plug)

Body (receptacle)

Pin (male terminal)

Pin (female termial)

T-adapter
Part No.

799-601-9210

18-8
(1)

Part No.: 08191-11201, 08191-11202,


08191-11205, 08191-11206
Pin (female terminal)

Part No.: 08191-14101, 08191-14102,


08191-14105, 08191-14106
Pin (male termial)

799-601-9210

Part No.: 08191-12201, 08191-12202,


08191-12205, 08191-12206
Pin (male terminal)

Part No.: 08191-13101, 08191-13102,


08191-13105, 08191-13106
Pin (female termial)

799-601-9220

Part No.: 08191-21201, 08191-12202,


08191-21205, 08191-12206
18-14
(2)
Pin (female terminal)

Part No.: 08191-24101, 08191-24102,


08191-24105, 08191-24106
Pin (male termial)

799-601-9220

Part No.: 08191-22201, 08191-22202,


08191-22205, 08191-22206

20-248
(1)

Part No.: 08191-23101, 08191-23102,


08191-23105, 08191-23106

PC130-7

TROUBLESHOOTING

CONNECTION TABLE FOR CONNECTOR PIN NUMBERS

[The pin No. is also marked on the connector (electric wire insertion end)]
Type
(shell
size
code)

HD30 Series connector


Body (plug)

Body (receptacle)

Pin (male terminal)

Pin (female termial)

T-adapter
Part No.

799-601-9230

18-20
(3)

Part No.:08191-31201, 08191-31202

Part No.:08191-34101, 08191-34102

Pin (female terminal)

Pin (male termial)

799-601-9230

Part No.:08191-32201, 08191-32202

Part No.:08191-33101, 08191-33102

Pin (male terminal)

Pin (female termial)

799-601-9240

18-21
(4)

Part No.:08191-41201, 08191-42202

Part No.:08191-44101, 08191-44102

Pin (female terminal)

Pin (male termial)

799-601-9240

Part No.:08191-42201, 08191-42202

PC130-7

Part No.:08191-43101, 08191-43102

20-249
(1)

TROUBLESHOOTING

CONNECTION TABLE FOR CONNECTOR PIN NUMBERS

[The pin No. is also marked on the connector (electric wire insertion end)]
HD30 Series connector

Type
(shell
size
code)

Body (plug)

Body (receptacle)

Pin (male terminal)

Pin (female termial)

T-adapter
Part No.

799-601-9250

24-9
(5)

Part No.:08191-51201, 08191-51202

Part No.:08191-54101, 08191-54102

Pin (female terminal)

Pin (male termial)

799-601-9250

Part No.:08191-52201, 08191-52202

Part No.:08191-53101, 08191-53102

Pin (male terminal)

Pin (female termial)

799-601-9260

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


08191-61205, 08191-62206
24-16
(6)
Pin (female terminal)

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


08191-64105, 08191-64106
Pin (male termial)

799-601-9260

Part No.: 08191-62201, 08191-62202,


08191-62205, 08191-62206

20-250
(1)

Part No.: 08191-63101, 08191-63102,


08191-63105, 08191-63106

PC130-7

TROUBLESHOOTING

CONNECTION TABLE FOR CONNECTOR PIN NUMBERS

[The pin No. is also marked on the connector (electric wire insertion end)]
HD30 Series connector

Type
(shell
size
code)

Body (plug)

Body (receptacle)

Pin (male terminal)

Pin (female termial)

T-adapter
Part No.

799-601-9270

24-21
(7)

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


08191-71205, 08191-71206
Pin (female terminal)

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


08191-74105, 08191-74106
Pin (male termial)

799-601-9270

Part No.: 08191-72201, 08191-72202,


08191-72205, 08191-72206
Pin (male terminal)

Part No.: 08191-73101, 08191-73102,


08191-73105, 08191-73106
Pin (female termial)

799-601-9280

Part No.: 08191-81201, 08191-81202


08191-81203, 08191-81204
08191-81205, 08191-80206
24-22
(8)
Pin (female terminal)

Part No.: 08191-84101,


08191-84103,
08191-84105,

08191-84102
08191-84104
08191-84106

Pin (male termial)

799-601-9280

Part No.: 08191-82201,


08191-82203,
08191-82205,

PC130-7

08191-82202
08191-82204
08191-82206

Part No.: 08191-83101,


08191-83103,
08191-83105,

08191-83102
08191-83104
08191-83106

20-251
(1)

TROUBLESHOOTING

CONNECTION TABLE FOR CONNECTOR PIN NUMBERS

[The pin No. is also marked on the connector (electric wire insertion end)]
HD30 Series connector

Type
(shell
size
code)

Body (plug)

Body (receptacle)

Pin (male termial)

Pin (female terminal)

T-adapter
Part No.

799-601-9290

24-31
(9)

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


08191-91205, 08191-91206
Pin (female terminal)

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


08191-94105, 08191-94106
Pin (male termial)

799-601-9290

Part No.: 08191-92203, 08191-92204,


08191-92205, 08191-92206

20-252
(1)

Part No.: 08191-93103, 08191-93104,


08191-93105, 08191-93106

PC130-7

TROUBLESHOOTING

CONNECTION TABLE FOR CONNECTOR PIN NUMBERS

[The pin No. is also marked on the connector (electric wire insertion end)]
DT Series connector

No.of
pins

Body (plug)

Body (receptacle)

T-adapter
Part No.

799-601-9020

Part No.: 08192-12200 (normal type)


08192-22200 (fine wire type)

Part No.: 08192-12100 (normal type)


08192-22100 (fine wire type)

799-601-9030

Part No.: 08192-13200 (normal type)


08192-23200 (fine wire type)

Part No.: 08192-13100 (normal type)


08192-23100 (fine wire type)

799-601-9040

Part No.: 08192-14200 (normal type)


08192-24200 (fine wire type)

Part No.: 08192-14100 (normal type)


08192-24100 (fine wire type)

799-601-9050

Part No.: 08192-16200 (normal type)


08192-26200 (fine wire type)

PC130-7

Part No.: 08192-16100 (normal type)


08192-26100 (fine wire type)

20-253
(1)

TROUBLESHOOTING

CONNECTION TABLE FOR CONNECTOR PIN NUMBERS

[The pin No. is also marked on the connector (electric wire insertion end)]
DT Series connector

No.of
pins

Body (plug)

Body (receptacle)

8GR:
8B:
8G:
8BR:

Part No.: 08192-1820


08192-2820

(normal type) Part No.: 08192-1810


(fine wire type)
08192-2810

799-601-9060
799-601-9070
799-601-9080
799-601-9090

(normal type)
(fine wire type)

12GR:
12B:
12G:
12BR:

12

Part No.: 08192-1920


08192-2920

20-254
(1)

T-adapter Part No.

(normal type) Part No.: 08192-1910


(fine wire type)
08192-2910

799-601-9110
799-601-9120
799-601-9130
799-601-9140

(normal type)
(fine wire type)

PC130-7

TROUBLESHOOTING

CONNECTION TABLE FOR CONNECTOR PIN NUMBERS

[The pin No. is also marked on the connector (electric wire insertion end)]
DTM Series connector

No.of
pins

Body (plug)

Body (receptacle)

T-adapter Part
No.

799-601-9010

Part No.: 08192-02200

Part No.: 08192-02100

[The pin No. is also marked on the connector (electric wire insertion end)]
DTHD Series connector

No.of
pins

Body (plug)

Body (receptacle)

T-adapter Part
No.

Part No.: 08192-31200 (Contact size#12) Part No.: 08192-31100 (Contact size#12)
08192-41200 (Contact size #8)
08192-41100 (Contact size #8)
08192-51200 (Contact size #4)
08192-51100 (Contact size #4)

PC130-7

20-255
(1)

TROUBLESHOOTING

CONNECTION TABLE FOR CONNECTOR PIN NUMBERS

[The pin No. is also marked on the connector (electric wire insertion end)]
No.of
pins

DRC26 Series connector


Body (plug)

Body (receptacle)

24

799-601-9360

Part No.: 7821-93-3110

40
(A)

799-601-9350

Part No.: 7821-93-3120

40
(B)

799-601-9350

20-256
(1)

T-adapter Part
No.

Part No.: 7821-93-3130

PC130-7

TROUBLESHOOTING

T-BRANCH BOX AND T-BRANCH TABLE

T-BRANCH BOX AND T-BRANCH TABLE

799-601-2600
799-601-3100
799-601-3200
799-601-3300
799-601-3360
799-601-3370
799-601-3380
799-601-3410
799-601-3420
799-601-3430
799-601-3440
799-601-3450
799-601-3460
799-601-3510
799-601-3520
799-601-3530
799-601-2910
799-601-3470
799-601-2710
799-601-2720
799-601-2730
799-601-2740
799-601-2950
799-601-2750
799-601-2760
799-601-2770
799-601-2780
799-601-2790
799-601-2810
799-601-2820
799-601-2830
799-601-2840
799-601-2850
799-601-7010
799-601-7020
799-601-7030
799-601-7040
799-601-7050
799-601-7060
799-601-7310
799-601-7070
799-601-7320
799-601-7080
799-601-7090
799-601-7110
799-601-7120
799-601-7130
799-601-7340

PC130-7

Measurement box
Measurement box
Measurement box
Measurement box
Plate
Plate
Plate
BENDIX (MS)
BENDIX (MS)
BENDIX (MS)
BENDIX (MS)
BENDIX (MS)
BENDIX (MS)
BENDIX (MS)
BENDIX (MS)
BENDIX (MS)
BENDIX (MS)
Case
MIC
MIC
MIC
MIC
MIC
ECONO
ECONO
ECONO
ECONO
ECONO
DLI
DLI
DLI
Additional cable
Case
X
X
X
X
SWP
SWP
SWP
SWP
SWP
M
M
M
M
M
M

799-601-9300

799-601-9200

799-601-9100

799-601-9000

799-601-8000

799-601-7500

799-601-7400

799-601-7100

799-601-7000

799-601-6500

799-601-6000

799-601-5500

799-601-3000

799-601-2900

799-601-2800

Connector type or
No. of pins
part name

799-601-2700

Part No.

799-601-2500

a The vertical column shows part number of T-Branch Box or T-Branch, and horizontal column shows part
number of Harness Checker Ass'y.

Econo-21P
MS-37P
MS-37P
Econo-24P
For MS box
For MS box
For MS box
24P
24P
17P
17P
5P
10P
5P
14P
19P
14P
5P
13P
17P
21P
9P
2P
3P
4P
8P
12P
8P
12P
16P

1P
2P
3P
4P
6P
8P
12P
14P
16P
1P
2P
3P
4P
6P
8P

20-257
(1)

799-601-7140
799-601-7150
799-601-7160
799-601-7170
799-601-7330
799-601-7350
799-601-7180
799-601-7190
799-601-7210
799-601-7220
799-601-7230
799-601-7240
799-601-7270
799-601-7510
799-601-7520
799-601-7530
799-601-7540
799-601-7550
799-601-7360
799-601-7370
799-601-7380
799-601-9010
799-601-9020
799-601-9030
799-601-9040
799-601-9050
799-601-9060
799-601-9070
799-601-9080
799-601-9090
799-601-9110
799-601-9120
799-601-9130
799-601-9140
799-601-9210
799-601-9220
799-601-9230
799-601-9240
799-601-9250
799-601-9260
799-601-9270
799-601-9280
799-601-9290
799-601-9310
799-601-9320
799-601-9330
799-601-9340
799-601-9350
799-601-9360
799-601-9410

S
S
S
S
S
S
AMP040
AMP040
AMP040
AMP040
Short connector
Case
Case
070
070
070
070
070
Relay connector
Relay connector
JFC connector
DTM
DT
DT
DT
DT
DT
DT
DT
DT
DT
DT
DT
DT
HD30
HD30
HD30
HD30
HD24
HD30
HD30
HD30
HD30
Plate
Measurement box
Case
Case
DRC
DRC
For NE, G sensor
For fuel, boost
799-601-9420
press.
799-601-9430 PVC socket

20-258
(1)

799-601-9300

799-601-9200

799-601-9100

799-601-9000

799-601-8000

799-601-7500

799-601-7400

799-601-7100

799-601-7000

799-601-6500

799-601-6000

799-601-5500

799-601-3000

799-601-2900

799-601-2800

Connector type or
No. of pins
part name

799-601-2700

Part No.

T-BRANCH BOX AND T-BRANCH TABLE

799-601-2500

TROUBLESHOOTING

8P
10P-White
12P-Blue
16P-Blue
16P-White
12P-White
8P
12P
16P
20P
X-2

10P
12P
14P
18P
20P
5P
6P
2P
2P
2P
3P
4P
6P
8P-Gray
8P-Black
8P-Green
8P-Brown
12P-Gray
12P-Black
12P-Green
12P-Brown
18-8
18-14
18-20
18-21
24-9
24-16
24-21
24-23
24-31
For HD30
For DT, HD

40P
24P
2P
3P
2P

PC130-7

TROUBLESHOOTING
WHEN ERROR CODE IS DISPLAYED
(DISPLAY OF ERROR CODE)
BEFORE CARRYING OUT TROUBLESHOOTING WHEN CODE IS DISPLAYED .................................. 20-302
INFORMATION IN TROUBLESHOOTING TABLE .................................................................................... 20-307
Error code [104] (Clogging of air cleaner) .................................................................................................. 20-310
Error code [108] (Overheating of engine coolant) .......................................................................................20-311
Error code [112] (Short circuit in wiper motor drive forward system) ......................................................... 20-312
Error code [113] (Short circuit in wiper motor drive reverse system) ......................................................... 20-314
Error code [114] (Short circuit in windshield washer drive system) ............................................................ 20-316
Error code [115] (Trouble in operation of windshield wiper) ....................................................................... 20-318
Error code [116] (Trouble in storage of windshield wiper) .......................................................................... 20-320
Error code [203] (Short circuit in swing holding brake solenoid) ................................................................ 20-322
Error code [205] (Short circuit in 2-stage relief solenoid) ........................................................................... 20-324
Error code [206] (Short circuit in travel speed shifting solenoid) ................................................................ 20-326
Error code [213] (Disconnection in swing holding brake solenoid) ............................................................ 20-328
Error code [215] (Disconnection in 2-stage relief solenoid) ....................................................................... 20-330
Error code [216] (Disconnection in travel speed shifting solenoid) ............................................................ 20-332
Error code [217] (Abnormality in input model code) ................................................................................... 20-334
Error code [218] (Disconnection in S-NET signal line) ............................................................................... 20-336
Error code [222] (Short circuit in LS-EPC solenoid) ................................................................................... 20-338
Error code [223] (Disconnection in LS-EPC solenoid) ............................................................................... 20-339
Error code [224] (Abnormality in pump pressure sensor) .......................................................................... 20-340
Error code [226] (Abnormality in pressure sensor power supply) .............................................................. 20-342
Error code [227] (Abnormality in engine speed sensor) ............................................................................. 20-344
Error code [232] (Short circuit in PC-EPC solenoid) .................................................................................. 20-346
Error code [233] (Disconnection in PC-EPC solenoid) .............................................................................. 20-348
Error code [251] (Abnormality in overload pressure sensor) ..................................................................... 20-350
Error code [301] (Engine low idling speed out of standard range) ............................................................. 20-352
Error code [302] (Engine high idling speed out of standard range) ............................................................ 20-352
Error code [306] (Abnormality in governor potentiometer) ......................................................................... 20-354
Error code [308] (Abnormality in fuel control dial) ...................................................................................... 20-356
Error code [315] (Short circuit in battery relay output line) ......................................................................... 20-358
Error code [316] (Step-out of governor motor) ........................................................................................... 20-360
Error code [317] (Disconnection in phases A and B of governor motor) .................................................... 20-362
Error code [318] (Short circuit in phases A and B of governor motor) ....................................................... 20-364

PC130-7

20-301
(1)

Error
code

218

315

(1)

20-302
217

203

205

206

213

215

216

104

108

112

q
q

113

q
q

114

115

q
q

116

q
q

316

317

318

222

q
q

223

q
q

226

224

227

232

233

251

301

302

306

308

q
q

Defective travel speed shifting solenoid

Defective 2-stage relief solenoid valve

Defective swing holding brake solenoid

Defective LS-EPC solenoid

Defective PC-EPC solenoid

Clogging of air cleaner

Overheating of engine

Defective fuel control of engine

Defective adjustment of governor lever

Defective mechanical system of engine

Defective air cleaner clogging switch

Defective engine coolant temperature sensor

Defective engine speed sensor


(including adjustment)

Defective governor potentiometer

Defective governor motor

Defective fuel control dial

Defective emergency pump drive switch

Defective swing lock switch

Defective windshield washer motor

Defective wiper motor

Defective sensor power supply (5 V)

Defective governor and pump controller

Defective monitor panel

Defective fuse or fusible link

Defective battery relay

TROUBLESHOOTING
BEFORE CARRYING OUT TROUBLESHOOTING WHEN CODE IS DISPLAYED

BEFORE CARRYING OUT TROUBLESHOOTING WHEN CODE IS


DISPLAYED

Error codes and possible causes of them


Possible causes

q
q

q
q

q
q

q
q

q
q

PC130-7

PC130-7
q

q
q
q

q
Short circuit with power source in wiring harness

Grounding fault in wiring harness

Disconnection in wiring harness

Defective assembled-type diode

Overload pressure sensor

Pump pressure sensor

TROUBLESHOOTING

q
q

q
q

q
q

BEFORE CARRYING OUT TROUBLESHOOTING WHEN CODE IS DISPLAYED

Possible causes

q
q

q
q

q
q

q
q

20-303

(1)

TROUBLESHOOTING

BEFORE CARRYING OUT TROUBLESHOOTING WHEN CODE IS DISPLAYED

Connection table of fuse box


a This connection table shows the devices to which each power supply of the fuse box (FB1) supplies power
(A switch power supply is a device which supplies power while the starting switch is at the ON position and
a constant power supply is a device which supplies power while the starting switch is at the OFF position).
a When carrying out troubleshooting related to the electrical system, you should check the fuse box and fusible link to see if the power is supplied normally.
Type of power
supply

Fuse No.

Fuse capacity

Destination of power
Governor and pump controller (Controller power supply)

10A

PC-EPC solenoid (Emergency pump drive switch circuit)


Swing holding brake solenoid (Swing holding brake release
switch circuit)

20A

10A

Governor and pump controller (Solenoid power supply)


PPC oil pressure lock solenoid
Starting motor cutout relay (For PPC lock)
Cigarette lighter

10A
Windshield washer motor

Switch power supply


(Fusible link: A34)

10A

Horn

10A

Lower wiper motor [If equipped]

10A

Rotary lamp [If equipped], DC/DC converter [If equipped]

10A

Working lamp (Boom and right front)


Working lamp (Left front and rear) [If equipped]
9

10A

One-touch power maximizing switch circuit

10

10A

Fuel priming pump [If equipped]

11

20A

Air conditioner unit

12

20A

Starting motor cutout relay (For personal code)


Monitor panel (Switch power supply)
Light relay 1
13

20A

Light relay 2
Panel night light signal circuit

14

10A

15

10A

Heated seat [If equipped]


Heated seat [If equipped]
Travel alarm [If equipped]

Constant power
supply (Fusible link:
A35)

20-304
(3)

16

10A

Radio back up (Constant power supply)

17

20A

Monitor panel (Constant power supply)

18

10A

Starting switch

19

10A

Room lamp

20

10A

(Spare)

PC130-7

TROUBLESHOOTING

BEFORE CARRYING OUT TROUBLESHOOTING WHEN CODE IS DISPLAYED

Troubles which occur when controller power supply of governor and pump controller
is defective
a The controller power supply (FB1-1) of the governor and pump controller drives the controller system.
a Accordingly, if the controller power supply is turned off, the controller cannot control the governor motor and
battery relay and the following troubles occur.
1) The engine can be started but cannot be stopped.
2) The engine speed cannot be controlled with the fuel control dial.
a If the above problems occur, check the related fuse (FB1-1) and "green LED" of the governor and pump
controller to see if the power is supplied normally.
Lighting: The controller power is supplied (There is not an error and the power supply is normal).
Flashing: The controller power is supplied (There is an error).
Put out: The controller power is not supplied.
a Green LED of governor and pump controller (GREEN)

PC130-7

20-305
(1)

TROUBLESHOOTING

BEFORE CARRYING OUT TROUBLESHOOTING WHEN CODE IS DISPLAYED

Troubles which occur when solenoid power supply of governor and pump controller is
defective
a The solenoid power supply (FB1-2) of the governor and pump controller is used by the controller to drive the
solenoids and relays.
a Accordingly, if the solenoid power supply is turned off, when the controller outputs the power to the solenoids or relays, the power is not supplied to any of the solenoids and relays and all or some of the following
error codes are displayed simultaneously.
[E213]: Disconnection in swing holding brake solenoid
[E215]: Disconnection in 2-stage relief solenoid
[E216]: Disconnection in travel speed shifting solenoid
[E222]: Disconnection in LS-EPC solenoid
[E223]: Disconnection in PC-EPC solenoid
a If the above problems occur, check the related fuse (FB1-2) and inlet voltage of the governor and pump controller.
1) Disconnect connector C03 of the controller and connect a T-adapter to the wiring harness side.
2) Turn the starting switch ON.
3) Measure the voltage between each of pins (2) and (12) and each of pins (31), (32), and (33).
Pins (2) and (3) are the power supply pins and pins (31), (32), and (33) are the ground pins.
Pins (2) and (3) are the power supply and pins (31), (32), and (33) are the chassis ground.
If the voltage is 20 30 V, it is normal.
a Power supply connector (C03) of governor and pump controller

20-306
(1)

PC130-7

INFORMATION IN TROUBLESHOOTING TABLE

TROUBLESHOOTING

INFORMATION IN TROUBLESHOOTING TABLE


a The following information is summarized in the troubleshooting table and the related electrical circuit diagram. Before carrying out troubleshooting, understand that information fully.
User code
Error code
Display on panel Display on panel

Trouble

Trouble indicated by error code

Contents of
Condition at the time when the monitor panel or controller detects the trouble
trouble
Action of monitor
The action taken by the monitor panel or controller to protect the system or devices when the monitor
panel or
panel or controller detects the trouble
controller
Problem that
appears on
machine
Related
information

The problem that appears on the machine as a result of the action taken by the monitor panel or controller (shown above)
Information related to the detected trouble or troubleshooting
Cause

Standard value in normal state/Remarks on troubleshooting


<Contents of description>
Standard value in normal state to judge possible causes
Remarks on judgment

2
Possible causes
and standard
value in normal
state

PC130-7

<Troubles in wiring harness>


Disconnection
Connector is connected imperfectly or harness is broken.
Grounding fault
Harness which is not connected to chassis ground circuit is in contact with chassis ground circuit.
Short circuit with power source
Harness which is not connected to power source (24-V) circuit is in
contact with power source (24-V) circuit.
Possible causes of trouble
(Given numbers are refer- <Precautions for troubleshooting>
ence numbers, which do not 1) Method of indicating connector No. and handling of T-adapter
Insert or connect T-adapter as explained below for troubleshooting,
indicate priority)
unless otherwise specified.
If connector No. has no marks of "male" and "female", disconnect
connector and insert T-adapters in both male side and female
side.
If connector No. has marks of "male" and "female", disconnect
connector and connect T-adapter to only male side or female
side.
2) Entry order of pin Nos. and handling of circuit tester leads
Connect positive (+) lead and negative (-) lead of circuit tester as
explained below for troubleshooting, unless otherwise specified.
Connect positive (+) lead to pin No. or harness entered on front
side.
Connect negative (-) lead to pin No. or harness entered on rear

20-307
(1)

TROUBLESHOOTING

INFORMATION IN TROUBLESHOOTING TABLE

Related circuit diagram

This is a circuit diagram of the part related to troubleshooting.


Connector No.: Shows the "Type-Number of pin" and "Color".
Branching/Merging point: Shows that there is a branching/merging point in the electric circuit to be
checked.
Arrow ( ): Roughly shows the location on the machine.

20-308
(1)

PC130-7

[104]

TROUBLESHOOTING

Error code [104] (Clogging of air cleaner)


User code

Contents of
trouble
Action of
monitor panel
Problem that
appears on
machine
Related
information

Error code

Trouble
Clogging of air cleaner(Monitor panel system)
104
The signal circuit of the air cleaner clogging switch is opened (disconnected from the chassis ground)
while the engine is running.
None in particular.
If the machine is operated as it is, the engine may be damaged.
If the air cleaner clogging monitor of the monitor panel flashes while the engine is running, this error
code is recorded.
The input state (ON/OFF) from the air cleaner clogging switch can be checked with the monitoring function. (Code: 046, Right of upper line)
Cause
Clogging of air cleaner
1
(When system is normal)
Defective air cleaner clog2 ging switch (Internal disconnection)

Possible causes
and standard
value in normal
state

Standard value in normal state/Remarks on troubleshooting


Check the air cleaner. If it is clogged, clean or replace it.
aPrepare with starting switch OFF, then start engine and carry out troubleshooting.
A31 (male)
Between (1) and (2)

Air cleaner
When normal

Resistance
Max.1 z

When clogged
Min.1 Mz
aPrepare with starting switch OFF, then carry out troubleshooting without turning starting switch.
Disconnection in wiring
harness (Disconnection in Wiring harness between P02 (female) (5) and
Resistance Max.1 z
3
wiring harness or defective A31 (female) (1)
contact in connector)
Wiring harness between P11 (female) (2) and
Resistance Max.1 z
chassis ground (A15)
aPrepare with starting switch OFF, then start engine and carry out troubleshooting.
4 Defective monitor panel

P02
Between (5) and
chassis ground

Air cleaner
When normal

Voltage
Max. 1 V

When clogged

20 30 V

Circuit diagram related to air cleaner clogging switch

20-310
(1)

PC130-7

[108]

TROUBLESHOOTING

Error code [108] (Overheating of engine coolant)


User code

Contents of
trouble
Action of
monitor panel
Problem that
appears on
machine
Related
information

Error code

Trouble
Overheating of engine coolant (Monitor panel system)
108
The signal circuit of the engine coolant temperature sensor inputs 99 o or higher temperature while the
engine is running.
None in particular.
If the machine is operated as it is, the engine may be seized.
If the engine coolant temperature monitor of the monitor panel flashes while the engine is running, this
error code is recorded.
The input state (ON/OFF) from the engine coolant temperature sensor can be checked with the monitoring function. (Code: 041, by 10 mV)
Cause
Overheating of engine
1
(When system is normal)

Defective engine coolant


2 temperature sensor (Internal short circuit)
Possible causes
and standard
value in normal
state

Short circuit with chassis


ground in wiring harness
3
(Contact with ground circuit)

Standard value in normal state/Remarks on troubleshooting


The engine may have overheated. Find the cause and check the
engine for damage, and then repair.
aPrepare with starting switch OFF, then carry out troubleshooting without turning starting switch.
E05 (male)

Engine coolant
temperature

Resistance

Between (1) and (2)


3.5k 90 kz
10 100 C
Between (2) and
Min. 1 Mz
chassis ground
aPrepare with starting switch OFF, then carry out troubleshooting without turning starting switch.
Between P02 (female) (1) E05 (female) (2)
wiring harness and chassis ground

Resistance Min. 1 Mz

aPrepare with starting switch OFF, then carry out troubleshooting without turning starting switch.
4 Defective monitor panel

P02

Engine coolant
temperature

Between (1) and (13)


Between (1) and
chassis ground

Resistance
3.5k 90 kz

10 100 C

Min. 1 Mz

Circuit diagram related to engine coolant temperature sensor

PC130-7

20-311
(1)

[112]

TROUBLESHOOTING

Error code [112] (Short circuit in wiper motor drive forward system)
User code

Error code

Contents of
trouble
Action of
monitor panel

112

Problem that
appears on
machine
Related
information

Trouble

When the signal is output to the wiper motor drive forward circuit, an abnormal current flows.
Turns the output to the wiper motor drive forward circuit OFF.
Windshield wiper stops.

Cause
Defective wiper motor
1 (Internal short circuit or
grounding fault)
Possible causes
and standard
value in normal
state

Short circuit in wiper motor drive forward system


(Monitor panel system)

Short circuit with chassis


ground in wiring harness
2
(Contact with ground circuit)

3 Defective monitor panel

Standard value in normal state/Remarks on troubleshooting


aPrepare with starting switch OFF, then carry out troubleshooting without turning starting switch.
W04 (male)
Continuity/Resistance
Between (3) and (1)
Between (3) and chassis ground

aPrepare with starting switch OFF, then carry out troubleshooting without turning starting switch.
Between P01 (female) (9) W03 (female) (3)
wiring harness and chassis ground

(1)

Resistance Min. 1 Mz

aPrepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting.
P01
Wiper switch
Resistance
Between (9) and
chassis ground

20-312

There is continuity
Min. 1 Mz

OFF

Max. 3 V

ON

Max. 3 V 20 30 V
(Constant period)

PC130-7

TROUBLESHOOTING

[112]

Circuit diagram related to wiper motor

PC130-7

20-313
(1)

[113]

TROUBLESHOOTING

Error code [113] (Short circuit in wiper motor drive reverse system)
User code

Error code

Contents of
trouble
Action of
monitor panel

113

Problem that
appears on
machine
Related
information

Trouble

When the signal is output to the wiper motor drive reverse circuit, an abnormal current flows.
Turns the output to the wiper motor drive reverse circuit OFF.
Windshield wiper stops.

Cause
Defective wiper motor
1 (Internal short circuit or
grounding fault)
Possible causes
and standard
value in normal
state

Short circuit in wiper motor drive reverse system


(Monitor panel system)

Short circuit with chassis


ground in wiring harness
2
(Contact with ground circuit)

3 Defective monitor panel

Standard value in normal state/Remarks on troubleshooting


aPrepare with starting switch OFF, then carry out troubleshooting without turning starting switch.
W04 (male)
Continuity/Resistance
Between (1) and (3)
Between (1) and chassis ground

aPrepare with starting switch OFF, then carry out troubleshooting without turning starting switch.
Between P01 (female) (10) W03 (female) (1)
wiring harness and chassis ground

(1)

Resistance Min. 1 Mz

aPrepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting.
P01
Wiper switch
Resistance
Between (10) and
chassis ground

20-314

There is continuity
Min. 1 Mz

OFF

Max. 3 V

ON

Max. 3 V 20 30 V
(Constant period)

PC130-7

TROUBLESHOOTING

[113]

Circuit diagram related to wiper motor

PC130-7

20-315
(1)

[114]

TROUBLESHOOTING

Error code [114] (Short circuit in windshield washer drive system)


User code

Contents of
trouble
Action of
monitor panel
Problem that
appears on
machine
Related
information

Error code

Short circuit in windshield washer drive system


Trouble
(Monitor panel system)
114
When the windshield washer drive circuit is connected to the ground circuit (the output is turned ON),
an abnormal current flows.
Turns the ground output of the windshield washer motor circuit OFF.
The windshield washer stops.

Possible causes
and standard
value in normal
state

Cause

Standard value in normal state/Remarks on troubleshooting

Defective washer motor


(Internal short circuit)

aPrepare with starting switch OFF, then carry out troubleshooting without turning starting switch.
A50 (male)
Resistance

Short circuit with power


2 source in wiring harness
(Contact with 24-V circuit)

3 Defective monitor panel

20-316
(1)

Between (1) and (2)


5 20 z
aPrepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting.
Between P01 (female) (3) A50 (female) (2) or
D02 (female) (8) wiring harness and chassis
Voltage
Max. 1 V
ground
aPrepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting.
Windshield washer
P01
Voltage
switch
OFF
20 30 V
Between (3) and
chassis ground
ON
Max. 1 V

PC130-7

TROUBLESHOOTING

[114]

Circuit diagram related to windshield washer motor

PC130-7

20-317
(1)

[115]

TROUBLESHOOTING

Error code [115] (Trouble in operation of windshield wiper)


User code

Error code

Contents of
trouble
Action of
monitor panel

115

Problem that
appears on
machine
Related
information

Trouble

Trouble in operation of windshield wiper (Monitor panel system)

When the wiper operates, the W-signals of both ends of the operating range are not input.
Turns the operation signal to the wiper motor OFF.
The windshield wiper does not operate.
The input state (ON/OFF) from the W-signals of the wiper operating range can be checked with the
monitoring function. (Code: 049, Center of lower line)
Cause

Defective wiper motor


(Internal disconnection)

Standard value in normal state/Remarks on troubleshooting


aPrepare with starting switch OFF, then carry out troubleshooting without turning starting switch.
W04 (male)
Wiper blade
Resistance

Top of operating range


Max. 1 z
Other than top of
Min. 1 Mz
operating range
aPrepare with starting switch OFF, then carry out troubleshooting without turning starting switch.
Disconnection in wiring
harness (Disconnection in Wiring harness between P01 (female) (5) and
Resistance Max. 1 z
2
wiring harness or defective W04 (female) (6)
contact in connector)
Wiring harness between W04 (female) (5) and
Resistance Max. 1 z
chassis ground (A11, A12)
Between (6) and (5)

Possible causes
and standard
value in normal
state

aPrepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting.
3 Defective monitor panel

P01
Between (5) and
chassis ground

20-318
(1)

Wiper blade
Top of operating range

Voltage
Max. 1 V

Other than top of


operating range

20 30 V

PC130-7

TROUBLESHOOTING

[115]

Circuit diagram related to wiper motor

PC130-7

20-319
(1)

[116]

TROUBLESHOOTING

Error code [116] (Trouble in storage of windshield wiper)


User code

Error code

Contents of
trouble
Action of
monitor panel

116

Problem that
appears on
machine
Related
information

Trouble

When the wiper stored, the P-signals of the storage range is not input.
Turns the storage signal to the wiper motor OFF.
The wiper is not stored.
The input state (ON/OFF) from the P-signals of the wiper operating range can be checked with the monitoring function. (Code: 049, Left of upper line)
Cause

Possible causes
and standard
value in normal
state

Trouble in storage of windshield wiper (Monitor panel system)

Defective wiper motor


(Internal disconnection)

Standard value in normal state/Remarks on troubleshooting


aPrepare with starting switch OFF, then carry out troubleshooting without turning starting switch.
W04 (male)
Wiper blade
Resistance
Between (4) and (5)

(1)

Max. 1 z
Min. 1 Mz

aPrepare with starting switch OFF, then carry out troubleshooting without turning starting switch.

Disconnection in wiring
harness (Disconnection in Wiring harness between P01 (female) (12) and
Resistance Max. 1 z
2
wiring harness or defective W04 (female) (4)
contact in connector)
Wiring harness between W04 (female) (5) and
Resistance Max. 1 z
chassis ground (A11, A12)
aPrepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting.
P01
Wiper blade
Voltage
3 Defective monitor panel
Between (12) and
chassis ground

20-320

Storage range
Operating range

Storage range
Operating range

Max. 1 V
20 30 V

PC130-7

TROUBLESHOOTING

[116]

Circuit diagram related to wiper motor

PC130-7

20-321
(1)

[203]

TROUBLESHOOTING

Error code [203] (Short circuit in swing holding brake solenoid)


User code

Error code

E03
Contents of
trouble

203

Action of
controller
Problem that
appears on
machine
Related
information

Trouble

When the signal is output to the swing holding brake solenoid circuit, an abnormal current flows.
Turns the output to the swing holding brake solenoid circuit OFF.
Even if the cause of the failure disappears, the system does not reset itself until the starting switch is
turned OFF.
The machine cannot swing (The swing holding brake is not released).
The operation state (ON/OFF) of the swing holding brake solenoid can be checked with the monitoring
function. (Code: 023, Center of upper line)
If the solenoid and wiring harness are normal, the machine can swing by setting the swing holding brake
release switch in the FREE position. (The swing holding brake does not operate when the machine
stops swinging, however.)
Cause
Defective swing holding
1 brake solenoid (Internal
short circuit)

Possible causes
and standard
value in normal
state

Short circuit in swing holding brake solenoid


(Governor and pump controller system)

Short circuit with chassis


ground in wiring harness
2
(Contact with ground circuit)

Defective governor and


pump controller

Standard value in normal state/Remarks on troubleshooting


aPrepare with starting switch OFF, then carry out troubleshooting without turning starting switch.
V05 (male)
Between (1) and (2)

Between (2) and chassis ground


Min. 1 Mz
aPrepare with starting switch OFF, then carry out troubleshooting without turning starting switch.
Between C03 (female) (37) D01 J02 X05
Resistance Min. 1 Mz
V05 (female) (1) or S25 (female) (8) wiring
harness and chassis ground
aPrepare with starting switch OFF, then start engine and carry out troubleshooting.
Left work equipment
C03
Voltage
control lever
Between (37) and
chassis ground

20-322
(1)

Resistance
20 60 z

Neutral position
Swing position

Max. 1 V
20 30 V

PC130-7

TROUBLESHOOTING

[203]

Circuit diagram related to swing holding brake solenoid

PC130-7

20-323
(1)

[205]

TROUBLESHOOTING

Error code [205] (Short circuit in 2-stage relief solenoid)


User code

Error code

Contents of
trouble

205

Action of
controller
Problem that
appears on
machine
Related
information

Trouble

When the signal is output to the 2-stage relief solenoid circuit, an abnormal current flows.
Turns the output to the 2-stage relief solenoid circuit OFF.
Even if the cause of the failure disappears, the system does not reset itself until the starting switch is
turned OFF.
The one-touch power maximizing function does not work (The main relief valve is not set to high pressure).
The operation state (ON/OFF) of the 2-stage relief solenoid can be checked with the monitoring function. (Code: 023, Left of upper line)
Cause
Defective 2-stage relief
1 solenoid (Internal short circuit)

Possible causes
and standard
value in normal
state

Short circuit in 2-stage relief solenoid


(Governor and pump controller system)

Short circuit with chassis


ground in wiring harness
2
(Contact with ground circuit)

Standard value in normal state/Remarks on troubleshooting


aPrepare with starting switch OFF, then carry out troubleshooting without turning starting switch.
V06 (male)
Between (1) and (2)

Between (2) and chassis ground


Min. 1 Mz
aPrepare with starting switch OFF, then carry out troubleshooting without turning starting switch.
Between C03 (female) (28) V06 (female) (1)
Resistance Min. 1 Mz
wiring harness and chassis ground
aPrepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting.

Defective governor and


pump controller

C03
Between (37) and
chassis ground

20-324
(1)

Resistance
20 60 z

One-touch power maximizing switch


Released
Kept pressed

Voltage
Max. 1 V
20 30 V
(With 8.5-sec timer)

PC130-7

TROUBLESHOOTING

[205]

Circuit diagram related to 2-stage relief solenoid

PC130-7

20-325
(1)

[206]

TROUBLESHOOTING

Error code [206] (Short circuit in travel speed shifting solenoid)


User code

Error code

Contents of
trouble

206

Action of
controller
Problem that
appears on
machine
Related
information

Trouble

When the signal is output to the travel speed shifting solenoid circuit, an abnormal current flows.
Turns the output to the travel speed shifting solenoid circuit OFF.
Even if the cause of the failure disappears, the system does not reset itself until the starting switch is
turned OFF.
The travel speed is not set to HI (The swash plate angle of the travel motor is not set to the minimum).
The operation state (ON/OFF) of the travel speed shifting solenoid can be checked with the monitoring
function. (Code: 023, Left of lower line)
Cause
Defective travel speed
1 shifting solenoid (Internal
short circuit)

Possible causes
and standard
value in normal
state

Short circuit travel speed shifting solenoid


(Governor and pump controller system)

Short circuit with chassis


ground in wiring harness
2
(Contact with ground circuit)

Standard value in normal state/Remarks on troubleshooting


aPrepare with starting switch OFF, then carry out troubleshooting without turning starting switch.
V04 (male)
Between (1) and (2)

Resistance
20 60 z

Between (2) and chassis ground


Min. 1 Mz
aPrepare with starting switch OFF, then carry out troubleshooting without turning starting switch.
Between C03 (female) (27) V04 (female) (1)
Resistance Min. 1 Mz
wiring harness and chassis ground
aPrepare with starting switch OFF, then start engine and carry out troubleshooting.

20-326
(1)

Defective governor and


pump controller

C03

Travel speed switch


and travel lever

Voltage

Between (27) and


chassis ground

Lo + Neutral
Hi + Travel position

Max. 1 V
20 30 V

PC130-7

TROUBLESHOOTING

[206]

Circuit diagram related to travel speed shifting solenoid

PC130-7

20-327
(1)

[213]

TROUBLESHOOTING

Error code [213] (Disconnection in swing holding brake solenoid)


User code

Error code

E03
Contents of
trouble
Action of
controller

213

Problem that
appears on
machine

Related
information

Trouble

Disconnection in swing holding brake solenoid


(Governor and pump controller system)

When the signal is output to the swing holding brake solenoid circuit, no current flows.
None in particular (Since no current flows, the solenoid does not operate).
If the cause of the failure disappears, the system resets itself.
The machine cannot swing (The swing holding brake is not released).
The operation state (ON/OFF) of the swing holding brake solenoid can be checked with the monitoring
function. (Code: 023, Center of upper line)
If the solenoid and wiring harness are normal, the machine can swing by setting the swing holding brake
release switch in the FREE position. (The swing holding brake does not operate when the machine
stops swinging, however.)
During troubleshooting, keep the swing lock switch in the OFF position and the swing holding brake release switch in the RELEASE position.
Since the controller detects disconnection while the solenoid output is turned ON, be sure to turn the
solenoid output ON when checking for reproduction of the failure after repair. (For the method of turning the solenoid output ON and OFF, see troubleshooting for error code [203].)
Cause
Defective swing holding
1 brake solenoid (Internal
disconnection)

Defective swing lock switch


(Internal disconnection)

Standard value in normal state/Remarks on troubleshooting


aPrepare with starting switch OFF, then carry out troubleshooting without turning starting switch.
V05 (male)
Resistance
Between (1) and (2)
20 60 z
aPrepare with starting switch OFF, then carry out troubleshooting without turning starting switch.
X05 (female)
Between (3) and (4)

Possible causes
and standard
value in normal
state

harness (Disconnection in Wiring harness between D01 (female) (3) and


wiring harness or defective J02 and X05 (male) (3)
contact in connector)
Wiring harness between X05 (male) (4) and
V05 (female) (1)

Short circuit with power


5 source in wiring harness
(Contact with 24-V circuit)

(1)

Resistance
Max. 1 z

ON
Min. 1 Mz
aPrepare with starting switch OFF, then carry out troubleshooting withDefective assembled-type
out turning starting switch.
3 diode D01 (Internal disconD01 (male)
Digital circuit tester
Continuity
nection)
Between (7) and (3)
Diode mode
There is continuity
aPrepare with starting switch OFF, then carry out troubleshooting without turning starting switch.
Wiring harness between C03 (female) (37) and
Resistance Max. 1 z
D01 (female) (7)
Disconnection in wiring
4

20-328

Swing lock switch


OFF

Defective governor and


pump controller

Resistance

Max. 1 z

Resistance

Max. 1 z

Wiring harness between C03 (female) (3), (13),


Resistance Max. 1 z
(23) and V05 (female) (2)
aPrepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting.
Between C03 (female) (37) D01 (female) (7)
Voltage
Max. 1 V
wiring harness and chassis ground
aPrepare with starting switch OFF, then carry out troubleshooting without turning starting switch.
C03 (female)
Disconnect D01 and
Between (37) and (3), connect (3) and (7) on
female side.
(13), (23)

Resistance
20 60 z

PC130-7

TROUBLESHOOTING

[213]

Circuit diagram related to swing holding brake solenoid

PC130-7

20-329
(1)

[215]

TROUBLESHOOTING

Error code [215] (Disconnection in 2-stage relief solenoid)


User code

Error code

Contents of
trouble
Action of
controller

215

Trouble

Disconnection in 2-stage relief solenoid


(Governor and pump controller system)

When the signal is output to the 2-stage relief solenoid circuit, no current flows.
None in particular (Since no current flows, the solenoid does not operate).
If the cause of the failure disappears, the system resets itself.

Problem that
appears on
machine

The one-touch power maximizing function does not work (The main relief valve is not set to high pressure).

Related
information

The operation state (ON/OFF) of the 2-stage relief solenoid can be checked with the monitoring function. (Code: 023, Left of upper line)
Since the controller detects disconnection while the solenoid output is turned ON, be sure to turn the
solenoid output ON when checking for reproduction of the failure after repair. (For the method of turning the solenoid output ON and OFF, see troubleshooting for error code [205].)
Cause

Possible causes
and standard
value in normal
state

Standard value in normal state/Remarks on troubleshooting

aPrepare with starting switch OFF, then carry out troubleshooting withDefective 2-stage relief
out turning starting switch.
1 solenoid (Internal short cirV06 (male)
Resistance
cuit)
Between (1) and (2)
20 60 z
aPrepare with starting switch OFF, then carry out troubleshooting without turning starting switch.
Disconnection in wiring
harness (Disconnection in Wiring harness between C03 (female) (28) and
Resistance Max. 1 z
2
wiring harness or defective V06 (female) (1)
contact in connector)
Wiring harness between C03 (female) (3), (13),
Resistance Max. 1 z
(23) and V06 (female) (2)
Short circuit with power
3 source in wiring harness
(Contact with 24-V circuit)

Defective governor and


4
pump controller

aPrepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting.
Between C03 (female) (28) V06 (female) (1)
wiring harness and chassis ground

(1)

Max. 1 V

aPrepare with starting switch OFF, then carry out troubleshooting without turning starting switch.
C03 (female)
Resistance
Between (37) and (3), (13), (23)

20-330

Voltage

20 60 z

PC130-7

TROUBLESHOOTING

[215]

Circuit diagram related to 2-stage relief solenoid

PC130-7

20-331
(1)

[216]

TROUBLESHOOTING

Error code [216] (Disconnection in travel speed shifting solenoid)


User code

Error code

Contents of
trouble

216

Action of
controller

Trouble

Disconnection in travel speed shifting solenoid


(Governor and pump controller system)

When the signal is output to the travel speed shifting solenoid circuit, no current flows.
None in particular (Since no current flows, the solenoid does not operate).
If the cause of the failure disappears, the system resets itself.

Problem that
appears on
machine

The travel speed is not set to HI (The swash plate angle of the travel motor is not set to the minimum).

Related
information

The operation state (ON/OFF) of the travel speed shifting solenoid can be checked with the monitoring
function. (Code: 023, Left of lower line)
Since the controller detects disconnection while the solenoid output is turned ON, be sure to turn the
solenoid output ON when checking for reproduction of the failure after repair. (For the method of turning the solenoid output ON and OFF, see troubleshooting for error code [206].)
Cause
Defective travel speed
1 shifting solenoid (Internal
disconnection)

Possible causes
and standard
value in normal
state

Standard value in normal state/Remarks on troubleshooting


aPrepare with starting switch OFF, then carry out troubleshooting without turning starting switch.
V04 (male)
Resistance
Between (1) and (2)
20 60 z
aPrepare with starting switch OFF, then carry out troubleshooting without turning starting switch.

Disconnection in wiring
harness (Disconnection in Wiring harness between C03 (female) (27) and
Resistance
2
wiring harness or defective V04 (female) (1)
contact in connector)
Wiring harness between C03 (female) (3), (13),
Resistance
(23) and V04 (female) (2)
Short circuit with power
3 source in wiring harness
(Contact with 24-V circuit)

Defective governor and


pump controller

(1)

Max. 1 z

aPrepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting.
Between C03 (female) (27) V04 (female) (1)
Voltage
Max. 1 V
wiring harness and chassis ground
aPrepare with starting switch OFF, then carry out troubleshooting without turning starting switch.
C03 (female)
Resistance
Between (27) and (3), (13), (23)

20-332

Max. 1 z

20 60 z

PC130-7

TROUBLESHOOTING

[216]

Circuit diagram related to travel speed shifting solenoid

PC130-7

20-333
(1)

[217]

TROUBLESHOOTING

Error code [217] (Abnormality in input model code)


User code

Error code

Contents of
trouble

217

Action of
controller
Problem that
appears on
machine
Related
information

Trouble

Abnormality in input model code


(Governor and pump controller system)

A model code signal for a model which is not registered in the controller is input.
Uses the default model (PC200-7) for control.
Even if the cause of the failure disappears, the system does not reset itself until the starting switch is
turned OFF.
The engine does not output sufficient power or may stall.
The model name (number) recognized by the controller can be checked with the monitoring function.
(Code: 002, 003)
The input state (ON/OFF) of the model selection signal can be checked with the monitoring function.
(Code: 027, Other than left of lower line)
Cause

Standard value in normal state/Remarks on troubleshooting

aPrepare with starting switch OFF, then carry out troubleshooting without turning starting switch.
Defective model selection
C09 (female)
Resistance
1 connector (Internal disconnection or short circuit)
Between (1), (2) and (8)
Max. 1 z
Between (3), (4), (7) and (8)
Min. 1 Mz
aPrepare with starting switch OFF, then carry out troubleshooting without turning starting switch.
Disconnection in wiring
harness (Disconnection in
2
wiring harness or defective
contact in connector)
Possible causes
and standard
value in normal
state
Short circuit with chassis
ground in wiring harness
3
(Contact with ground circuit)

Wiring harness between C02 (female) (37) and


Resistance
C09 (male) (1)

Wiring harness between C02 (female) (27) and


Resistance Max. 1 z
C09 (male) (2)
Wiring harness between C09 (female) (8) and
Resistance Max. 1 z
chassis ground (A13)
aPrepare with starting switch OFF, then carry out troubleshooting without turning starting switch.
Between C02 (female) (17) C09 (male) (3)
Resistance Min. 1 Mz
wiring harness and chassis ground
Between C02 (female) (7) C09 (male) (4) wirResistance Min. 1 Mz
ing harness and chassis ground
Between C02 (female) (13) C09 (male) (7)
wiring harness and chassis ground

20-334
(1)

Defective governor and


pump controller

Max. 1 z

Resistance Min. 1 Mz

aPrepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting.
C02 (female)
Voltage
Between (7), (13), (17) and
chassis ground

20 20 V

Between (27), (37), and chassis


ground

Max. 1 V

PC130-7

TROUBLESHOOTING

[217]

Circuit diagram related to model selection connector

PC130-7

20-335
(1)

[218]

TROUBLESHOOTING

Error code [218] (Disconnection in S-NET signal line)


User code

Contents of
trouble

Error code

Action of
controller

Problem that
appears on
machine

Related
information

Disconnection in S-NET signal line


Trouble
(Governor and pump controller system)
218
A trouble has occurred in the S-NET communication between the monitor panel and controller (It has
been repaired when this error code is displayed).
Uses the following default items for control until the trouble is repaired.
1) Working mode: E
2) Travel speed: Lo
3) Auto-decelerator: ON
Even if the cause of the failure disappears, the system does not reset itself until the starting switch is
turned OFF.
The working mode cannot be changed (The working mode displayed in the monitor panel changes
normally).
The travel speed cannot be changed (The travel speed displayed in the monitor panel changes
normally).
The auto-decelerator cannot be reset (The auto-decelerator displayed in the monitor panel is reset
normally.)
This error code is displayed to notify the operator that a trouble has occurred when the S-NET communication between the monitor panel and governor and pump controller becomes normal.
The system is normal when the error code is displayed. Check the related devices and circuits and
remove the cause of the trouble, however, to prevent reoccurrence of the trouble.
Cause

Possible causes
and standard
value in normal
state

Standard value in normal state/Remarks on troubleshooting

aPrepare with starting switch OFF, then carry out troubleshooting without turning starting switch.
Disconnection in wiring
harness (Disconnection in Wiring harness between P02 (female) (9), (10)
Resistance Max. 1 z
1
wiring harness or defective and C02 (female) (21).
contact in connector)
Wiring harness between P02 (female) (20) and
Resistance Max. 1 z
C02 (female) (31)
aPrepare with starting switch OFF, then carry out troubleshooting withShort circuit with chassis
out turning starting switch.
ground in wiring harness
2
(Contact with ground cirBetween P02 (female) (9), (10) C02 (female)
Resistance Min. 1 Mz
cuit)
(21) wiring harness and chassis ground
Short circuit with power
3 source in wiring harness
(Contact with 24-V circuit)

4 Defective monitor panel

Defective governor and


pump controller

aPrepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting.
Between P02 (female) (9), (10) C02 (female)
Voltage
Max. 1 V
(21) wiring harness and chassis ground
aPrepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting.
P02
Voltage
Between (9), (10) and (20)
69V
aPrepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting.
C02
Voltage
Between (21) and (31)

20-336
(1)

69V

PC130-7

TROUBLESHOOTING

[218]

Circuit diagram related to S-NET

PC130-7

20-337
(1)

[222]

TROUBLESHOOTING

Error code [222] (Short circuit in LS-EPC solenoid)


User code

Error code

Contents of
trouble

222

Action of
controller
Problem that
appears on
machine
Related
information

Trouble

Short circuit in LS-EPC solenoid


(Governor and pump controller system)

An abnormal current flows in the LS-EPC solenoid circuit


Reduces the output to the LS-EPC solenoid circuit 0.
Even if the cause of the failure disappears, the system does not reset itself until the starting switch is
turned OFF.
The travel speed is fast at Lo. Amount of flow is large at model B. (The set pressure of the LS valve
cannot be controlled)
The output state (current) to the LS-EPC solenoid can be checked with the monitoring function.
(Code: 015, by 10 mA)
Cause

Standard value in normal state/Remarks on troubleshooting


aPrepare with starting switch OFF, then carry out troubleshooting without turning starting switch.

Possible causes
and standard
value in normal
state

Defective LS-EPC solenoid (Internal short circuit)

Short circuit with chassis


ground in wiring harness
2
(Contact with ground circuit)

V22 (male)
Between (1) and (2)

Resistance
7 14 z

Between (1) and chassis ground


Min. 1 Mz
aPrepare with starting switch OFF, then carry out troubleshooting without turning starting switch.
Between C03 (female) (6) V22 (female) (1)
Resistance Min. 1 Mz
wiring harness and chassis ground
aPrepare with starting switch OFF, then carry out troubleshooting without turning starting switch.

Defective governor and


pump controller

C03
Between (6) and (3), (13), (23)

Resistance
7 14 z

Between (6) and chassis ground

Min. 1 Mz

Circuit diagram related to LS-EPC solenoid

20-338
(1)

PC130-7

[223]

TROUBLESHOOTING

Error code [223] (Disconnection in LS-EPC solenoid)


User code

Error code

Contents of
trouble
Action of
controller

223

Problem that
appears on
machine
Related
information

Trouble

Disconnection in LS-EPC solenoid


(Governor and pump controller system)

No current flows in the LS-EPC solenoid circuit


None in particular (Since no current flows, the solenoid does not operate).
If the cause of the failure disappears, the system resets itself.
The travel speed is fast at Lo. Amount of flow is large at model B. (The set pressure of the LS valve
cannot be controlled)
The output state (current) to the LS-EPC solenoid can be checked with the monitoring function.
(Code: 015, by 10 mA)
Cause

Possible causes
and standard
value in normal
state

Defective LS-EPC solenoid (Internal short circuit)

Standard value in normal state/Remarks on troubleshooting


aPrepare with starting switch OFF, then carry out troubleshooting without turning starting switch.
V22 (male)
Resistance

Between (1) and (2)


7 14 z
aPrepare with starting switch OFF, then carry out troubleshooting without turning starting switch.
Disconnection in wiring
harness (Disconnection in Wiring harness between C03 (female) (6) and
Resistance Max. 1 z
2
wiring harness or defective V22 (female) (1)
contact in connector)
Wiring harness between C03 (female) (3), (13),
Resistance Max. 1 z
(23), and V22 (female) (2)
Short circuit with power
3 source in wiring harness
(Contact with 24-V circuit)

Defective governor and


4
pump controller

aPrepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting.
Between C03 (female) (6) V22 (female) (1)
wiring harness and chassis ground

Voltage

Max. 1 V

aPrepare with starting switch OFF, then carry out troubleshooting without turning starting switch.
C03
Resistance
Between (6) and (3), (13), (23)

7 14 z

Circuit diagram related to LS-EPC solenoid

PC130-7

20-339
(1)

[224]

TROUBLESHOOTING

Error code [224] (Abnormality in pump pressure sensor)


User code

Error code

Contents of
trouble
Action of
controller

224

Problem that
appears on
machine
Related
information

Trouble

Abnormality in pump pressure sensor


(Governor and pump controller system)

The signal voltage from the pump pressure sensor is below 0.3 V or above 4.72 V.
Sets the pump pressure to 0 MPa {0 kg/cm2} for control.
If the cause of the failure disappears, the system resets itself.
The travel speed does not change automatically (The travel load pressure cannot be sensed).
Cut-off function dose not work (The work equipment pressure can not be detected.)
If the 5-V circuit (B) and ground circuit (A) of the pressure sensor are connected inversely, the pressure
sensor will be broken. Accordingly, take extreme care when checking.
The input state (ON/OFF) from the pump pressure sensor can be checked with the monitoring function.
(Code: 011, 012, by 1 kg/cm2)
Cause
Defective sensor power
1
supply

Standard value in normal state/Remarks on troubleshooting


If error code [226] is displayed, carry out troubleshooting for it first.
aPrepare with starting switch OFF, then hold starting switch ON or start
engine and carry out troubleshooting.

Defective pump pressure


2 sensor (Internal defect)

A51
Between (B) and (A)

Power supply

Voltage
4.5 5.5 V

Between (C) and (A)


Signal
0.5 4.5 V
The pressure sensor voltage is measured with the wiring harness connected. Accordingly, if the voltage is abnormal, check the wiring harness and controller, too, for another cause of the trouble, and then
judge.
aPrepare with starting switch OFF, then carry out troubleshooting without turning starting switch.

Possible causes
and standard
value in normal
state

Disconnection in wiring
harness (Disconnection in
3
wiring harness or defective
contact in connector)

Short circuit with chassis


ground in wiring harness
4
(Contact with ground circuit)

Short circuit with power


5 source in wiring harness
(Contact with 24-V circuit)

20-340
(1)

Defective governor and


pump controller

Wiring harness between C01 (female) (22) and


Resistance
J07 and A51 (female) (B)

Max. 1 z

Wiring harness between C01 (female) (10) and


Resistance Max. 1 z
A51 (female) (A)
Wiring harness between C01 (female) (8) and
Resistance Max. 1 z
A51 (female) (C)
aPrepare with starting switch OFF, then carry out troubleshooting without turning starting switch.
Between C01 (female) (8) A51 (female) (C)
Resistance Min. 1 Mz
wiring harness and chassis ground
aPrepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting.
Between C01 (female) (22) J07 A51
(female) (B) wiring harness and chassis ground

Voltage

Max. 1 V

Between C01 (female) (8) A51 (female) (C)


Voltage
Max. 1 V
wiring harness and chassis ground
aPrepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting.
C01
Voltage
Between (22) and (10)
Between (8) and (10)

Power supply
Signal

4.5 5.5 V
0.5 4.5 V

PC130-7

TROUBLESHOOTING

[224]

Circuit diagram related to pump pressure sensor

PC130-7

20-341
(1)

[226]

TROUBLESHOOTING

Error code [226] (Abnormality in pressure sensor power supply)


User code

Error code

Contents of
trouble

226

Action of
controller
Problem that
appears on
machine
Related
information

Trouble

An abnormal current flows in the power supply (5 V) circuit of the pressure sensor or potentiometer.
Turns the output to the power supply (5 V) circuit OFF.
Even if the cause of the failure disappears, the system does not reset itself until the starting switch is
turned OFF.
The signals of the pressure sensor and potentiometer are not input normally.
The error codes of abnormality in the pressure sensor and abnormality in the potentiometer are displayed simultaneously.

Cause

Defective pressure sensor


1 or potentiometer (Internal
short circuit)

Possible causes
and standard
value in normal
state

Abnormality in pressure sensor power supply


(Governor and pump controller system)

Short circuit with chassis


ground in wiring harness
2
(Contact with ground circuit)

Standard value in normal state/Remarks on troubleshooting


aDisconnect connector with starting switch OFF, then turn starting
switch ON and carry out troubleshooting.
Fuel control dial
Connector E06
Disconnect the devices
Governor
Connector E10
at right in order. If the
potentiometer
error code disappears
Pump pressure
when a device is disConnector A51
sensor
connected, that device
Overload pressure
has a defect in it.
Connector A70
sensor (If installed)
aPrepare with starting switch OFF, then carry out troubleshooting without turning starting switch.
Between C01 (female) (22) J07 E06
(female) (1) wiring harness and chassis ground Resistance Min. 1 Mz
[Fuel control dial system]
Between C01 (female) (22) J07 E10
(female) (A) wiring harness and chassis ground Resistance Min. 1 Mz
[Governor potentiometer system]
Between C01 (female) (22) J07 A51
(female) (B) wiring harness and chassis ground Resistance Min. 1 Mz
[Pump pressure sensor system]
Between C01 (female) (22) J07 A70
(female) (B) wiring harness and chassis ground Resistance Min. 1 Mz
[Overload pressure sensor system: If installed]

Defective governor and


3
pump controller

20-342
(1)

aPrepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting.
C01
Between (22) and (10)

Voltage
4.5 5.5 V

PC130-7

TROUBLESHOOTING

[226]

Circuit diagram related to sensor power supply

PC130-7

20-343
(1)

[227]

TROUBLESHOOTING

Error code [227] (Abnormality in engine speed sensor)


User code

Error code

Contents of
trouble
Action of
controller

227

Problem that
appears on
machine
Related
information

Trouble

Normal pulse signals are not input to the signal circuit of the engine speed sensor.
Controls as if in the E-mode.
If the cause of the failure disappears, the system resets itself.
The output power is a little low (The engine speed cannot be sensed).
The input state (ON/OFF) from the engine speed sensor can be checked with the monitoring function.
(Code: 010, by 10 rpm)
Cause
Defective engine speed
1 sensor (Internal short circuit or disconnection)

Possible causes
and standard
value in normal
state

Abnormality in engine speed sensor


(Governor and pump controller system)

Defective adjustment of
engine speed sensor

Standard value in normal state/Remarks on troubleshooting


aPrepare with starting switch OFF, then carry out troubleshooting without turning starting switch.
E04 (male)
Resistance
Between (1) and (2)
Between (1) and chassis ground

500 1,000 z
Min. 1 Mz

See TESTING AND ADJUSTING, Adjusting engine speed sensor.


aPrepare with starting switch OFF, then carry out troubleshooting without turning starting switch.

Disconnection in wiring
harness (Disconnection in Wiring harness between C01 (female) (40) and
Resistance Max. 1 z
3
wiring harness or defective E04 (female) (1)
contact in connector)
Wiring harness between C01 (female) (29),
Resistance Max. 1 z
(39) and E04 (female) (2)
aPrepare with starting switch OFF, then turn starting switch ON and carShort circuit with power
ry out troubleshooting.
4 source in wiring harness
Between
C01 (female) (40) E04 (female) (1)
(Contact with 24-V circuit)
Voltage
Max. 1 V
wiring harness and chassis ground
aPrepare with starting switch OFF, then carry out troubleshooting without turning starting switch.
5

20-344
(1)

Defective governor and


pump controller

C02
Between (40) and (29), (39)

Resistance
500 1,000 z

Between (40) and chassis ground

Min. 1 Mz

PC130-7

TROUBLESHOOTING

[227]

Circuit diagram related to engine speed sensor

PC130-7

20-345
(1)

[232]

TROUBLESHOOTING

Error code [232] (Short circuit in PC-EPC solenoid)


User code

Error code

E02
Contents of
trouble

232

Action of
controller
Problem that
appears on
machine
Related
information

Trouble

Short circuit in PC-EPC solenoid


(Governor and pump controller system)

An abnormal current flows in the PC-EPC solenoid circuit.


Turns the output to the LS-EPC solenoid circuit OFF.
Even if the cause of the failure disappears, the system does not reset itself until the starting switch is
turned OFF.
If the pump load increases, the engine speed lowers largely and the engine may stall (The pump absorption torque cannot be controlled).
The output state (current) to the PC-EPC solenoid can be checked with the monitoring function.
(Code: 013, by 10 mA)
Cause

Standard value in normal state/Remarks on troubleshooting


aPrepare with starting switch OFF, then carry out troubleshooting without turning starting switch.

Possible causes
and standard
value in normal
state

Defective PC-EPC solenoid


(Internal short circuit)

V21 (male)
Between (1) and (2)

Resistance
7 14 z

Between (1) and chassis ground


Min. 1 Mz
aPrepare with starting switch OFF, then carry out troubleshooting without turning starting switch.
Emergency pump drive
Defective emergency pump
S25 (male)
Resistance
switch
2 drive switch (Internal short
circuit or disconnection)
Between (3) and (4)
Min. 1 Mz
Normal
Between (3) and
Min. 1 Mz
chassis ground
aPrepare with starting switch OFF, then carry out troubleshooting without turning starting switch.
Short circuit with chassis
ground in wiring harness
Between C03 (female) (16) S25 (female) (3)
Resistance Min. 1 Mz
3
(Contact with ground cirwiring harness and chassis ground
cuit)
Between S25 (female) (2) V21 (female) (1)
Resistance Min. 1 Mz
wiring harness and chassis ground
aPrepare with starting switch OFF, then carry out troubleshooting without turning starting switch.
4

20-346
(1)

Defective governor and


pump controller

C03 (female)
Between (16) and (3), (13), (23)

Resistance
7 14 z

Between (16) and chassis ground

Min. 1 Mz

PC130-7

TROUBLESHOOTING

[232]

Circuit diagram related to PC-EPC solenoid

PC130-7

20-347
(1)

[233]

TROUBLESHOOTING

Error code [233] (Disconnection in PC-EPC solenoid)


User code

Error code

E02
Contents of
trouble
Action of
controller

233

Problem that
appears on
machine
Related
information

Trouble

Disconnection in PC-EPC solenoid


(Governor and pump controller system)

No current flows in the PC-EPC solenoid circuit.


None in particular (Since no current flows, the solenoid does not operate).
If the cause of the failure disappears, the system resets itself.
If the pump load increases, the engine speed lowers largely and the engine may stall (The pump absorption torque cannot be controlled).
The output state (current) to the PC-EPC solenoid can be checked with the monitoring function.
(Code: 013, by 10 mA)
Cause

Standard value in normal state/Remarks on troubleshooting

aPrepare with starting switch OFF, then carry out troubleshooting without turning starting switch.
Defective PC-EPC solenoid
1
(Internal short circuit)
V21 (male)
Resistance
Between (1) and (2)
7 14 z
aPrepare with starting switch OFF, then carry out troubleshooting without turning starting switch.
Emergency pump drive
S25 (male)
Resistance
Defective emergency pump
switch
2 drive switch (Internal short
Normal
Max. 1 z
circuit or disconnection)
Between (2) and (3)
Emergency
Min. 1 Mz
Normal
Max. 1 z
Between (5) and (6)
Emergency
Min. 1 Mz
aPrepare with starting switch OFF, then carry out troubleshooting without turning starting switch.
Possible causes
and standard
value in normal
state

Disconnection in wiring
harness (Disconnection in
3
wiring harness or defective
contact in connector)

Short circuit with power


4 source in wiring harness
(Contact with 24-V circuit)

20-348
(1)

Defective governor and


pump controller

Wiring harness between C03 (female) (16) and


Resistance
S25 (female) (3)

Max. 1 z

Wiring harness between S25 (female) (2) and


V21 (female) (1)

Max. 1 z

Resistance

Wiring harness between C03 (female) (3), (13),


Resistance Max. 1 z
(23) and S25 (female) (6)
Wiring harness between S25 (female) (5) and
Resistance Max. 1 z
V21 (female) (2)
aPrepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting.
Between C03 (female) (16) S25 (female) (3)
Voltage
Max. 1 V
wiring harness and chassis ground
Between S25 (female) (2) V21 (female) (1)
wiring harness and chassis ground

Voltage

Max. 1 V

aPrepare with starting switch OFF, then carry out troubleshooting without turning starting switch.
C03 (female)
Between (16) and (3), (13),
and (23)

Resistance
7 14 z

PC130-7

TROUBLESHOOTING

[233]

Circuit diagram related to PC-EPC solenoid

PC130-7

20-349
(1)

[251]

TROUBLESHOOTING

Error code [251] (Abnormality in overload pressure sensor)


User code

Error code

Contents of
trouble
Action of
controller

251

Problem that
appears on
machine
Related
information

Trouble

Abnormality in overload pressure sensor


(Governor and pump controller system)

The signal voltage from the overload pressure sensor is below 0.3 V or above 4.72 V.
Sets the boom cylinder bottom pressure to 0 MPa {0 kg/cm2} for control.
If the cause of the failure disappears, the system resets itself.
The overload caution function does not operate (The load pressure on the boom cylinder bottom side
cannot be sensed).
aIf the 5-V circuit (B) and ground circuit (A) of the pressure sensor are connected inversely, the pressure
sensor will be broken. Accordingly, take extreme care when checking.
Cause
Defective sensor power
1
supply system

Standard value in normal state/Remarks on troubleshooting


If error code [226] is displayed, carry out troubleshooting for it first.
aPrepare with starting switch OFF, then hold starting switch ON or start
engine and carry out troubleshooting.
A70
Voltage

Defective overload pres2 sure sensor (Internal


defect)

Possible causes
and standard
value in normal
state

Between (B) and (A)


Between (C) and (A)

Power supply
Signal

4.5 5.5V
0.5 4.5V

The pressure sensor voltage is measured with the wiring harness connected. Accordingly, if the voltage is abnormal, check the wiring harness and controller, too, for another cause of the trouble, and then
judge.
aPrepare with starting switch OFF, then carry out troubleshooting without turning starting switch.
Wiring harness between C01 (female) (22) and
Resistance Max. 1 z
J07 and A70 (female) (B)

Disconnection in wiring
harness (Disconnection in
3
wiring harness or defective Wiring harness between C01 (female) (10) and
Resistance
contact in connector)
A70 (female) (A)
Wiring harness between C01 (female) (7) and
A70 (female) (C)
Short circuit with chassis
ground in wiring harness
4
(Contact with ground circuit)

Short circuit with power


5 source in wiring harness
(Contact with 24-V circuit)

Resistance

Max. 1 z
Max. 1 z

aPrepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting.
Between C01 (female) (7) - A70 (female) (C)
Resistance Min. 1 Mz
wiring harness and chassis ground
aPrepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting.
Between C01 (female) (22) J07 A70
Voltage
Max. 1 V
(female) (B) wiring harness and chassis ground
Between C01 (female) (7) A70 (female) (C)
wiring harness and chassis ground

Voltage

Max. 1 V

aPrepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting.
6

Defective governor and


pump controller

C01
Between (22) and (10)
Between (7) and (10)

20-350
(1)

Power supply

Voltage
4.5 5.5 V

Signal

0.5 4.5 V

PC130-7

TROUBLESHOOTING

[251]

Circuit diagram related to overload pressure sensor

PC130-7

20-351
(1)

[301], [302]

TROUBLESHOOTING

Error code [301] (Engine low idling speed out of standard range)
User code

Error code

Contents of
trouble
Action of
controller

301

Problem that
appears on
machine
Related
information

Trouble

Engine speed below 500 rpm is sensed for continuous 10 seconds while the engine is running.
None in particular.
If the cause of the failure disappears, the system resets itself.
If the machine is operated as it is, the engine may be damaged.
The input state (rpm) from the engine speed sensor can be checked with the monitoring function.
(Code: 010, by 10 rpm)
Cause

Possible causes
and standard
value in normal
state

Engine low idling speed out of standard range


(Governor and pump controller system)

Standard value in normal state/Remarks on troubleshooting

Check for external and internal factors that have lowered the engine low
Abnormality in mechanical
1
idling speed, and then carry out troubleshooting for the mechanical syssystem of engine
tem of the engine.
2

Defective governor and


pump controller

Troubleshooting cannot be carried out since the defect is in the governor and pump controller. (If there is not any visible trouble in the
machine, the controller may be used as it is.)

Error code [302] (Engine high idling speed out of standard range)
User code

Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information

Error code
302

20-352
(1)

Engine high idling speed out of standard range


(Governor and pump controller system)

Engine speed above 2,600 rpm is sensed for continuous 10 seconds while the engine is running.
None in particular.
If the cause of the failure disappears, the system resets itself.
If the machine is operated as it is, the engine may be damaged.
The input state (rpm) from the engine speed sensor can be checked with the monitoring function.
(Code: 010, by 10 rpm)
Cause

Possible causes
and standard
value in normal
state

Trouble

Standard value in normal state/Remarks on troubleshooting

Check for external and internal factors that have heightened the engine
Abnormality in mechanical
1
high idling speed, and then carry out troubleshooting for the mechanical
system of engine
system of the engine.
Troubleshooting cannot be carried out since the defect is in the goverDefective governor and
2
nor and pump controller. (If there is not any visible trouble in the
pump controller
machine, the controller may be used as it is.)

PC130-7

[306]

TROUBLESHOOTING

Error code [306] (Abnormality in governor potentiometer)


User code

Error code

Contents of
trouble

306

Action of
controller

Problem that
appears on
machine
Related
information

Trouble

Abnormality in governor potentiometer


(Governor and pump controller system)

The signal voltage from the governor potentiometer is below 0.4 V or above 4.6 V.
Calculates the motor position from the voltage just before occurrence of the trouble and uses it for control.
Even if the cause of the failure disappears, the system does not reset itself until the starting switch is
turned OFF.

The high idling speed is not obtained (it is a little low).


The low idling speed is not obtained (it is a little high).
The auto-decelerator or automatic warm-up system does not operate.
The engine stalls.
The engine does not stop.
The input state (voltage) from the governor potentiometer can be checked with the monitoring function.
(Code: 031, by 10 mV)
Cause

Defective sensor power


1
supply system

Standard value in normal state/Remarks on troubleshooting


If error code [226] is displayed, carry out troubleshooting for it first.
aPrepare with starting switch OFF, then carry out troubleshooting without turning starting switch.

Possible causes
and standard
value in normal
state

Defective governor potentiometer (Internal defect)

E10 (male)
Between (A) and (C)

Resistance
4.0 6.0 z

Between (B) and (A)


Between (B) and (C)

0.25 5.0 z
0.25 5.0 z

aPrepare with starting switch OFF, then carry out troubleshooting without turning starting switch.
Wiring harness between C01 (female) (22) and
Disconnection in wiring
Resistance Max. 1 z
harness (Disconnection in J07 and E10 (female) (A)
3
wiring harness or defective Wiring harness between C01 (female) (21) and
Resistance Max. 1 z
contact in connector)
E10 (female) (C)
Wiring harness between C01 (female) (13) and
Resistance Max. 1 z
E10 (female) (B)
Short circuit with chassis
ground in wiring harness
4
(Contact with ground circuit)

Short circuit with power


5 source in wiring harness
(Contact with 24-V circuit)

Defective governor and


pump controller

aPrepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting.
Between C01 (female) (13) E10 (female) (B)
wiring harness and chassis ground

aPrepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting.
Between C01 (female) (22) J07 E10
Voltage
Max. 1 V
(female) (A) wiring harness and chassis ground
Between C01 (female) (13) E10 (female) (B)
Voltage
Max. 1 V
wiring harness and chassis ground
aPrepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting.
C01
Between (22) and (21)
Between (13) and (21)

20-354
(1)

Resistance Min. 1 Mz

Power supply

Voltage
4.5 5.5 V

Signal

0.5 4.5 V

PC130-7

TROUBLESHOOTING

[306]

Circuit diagram related to governor motor and potentiometer

PC130-7

20-355
(1)

[308]

TROUBLESHOOTING

Error code [308] (Abnormality in fuel control dial)


User code

Error code

E05
Contents of
trouble

308

Action of
controller
Problem that
appears on
machine
Related
information

Trouble

Abnormality in fuel control dial


(Governor and pump controller system)

The signal voltage from the fuel control dial is below 0.23 V or above 4.77 V.
Calculates the fuel control dial position from the voltage just before occurrence of the trouble and uses
it for control.
If the cause of the failure disappears, the system resets itself.
If the output was set in the full mode before occurrence of the failure, it is not set in the partial mode.
If the output was set in the partial mode before occurrence of the failure, it is not set in the full mode.
The engine hunts.
The high idling speed is not obtained and the output is insufficient.
The input state (voltage) from the fuel control dial can be checked with the monitoring function.
(Code: 030, by 10 mV)
Cause
Defective sensor power
1
supply system

Standard value in normal state/Remarks on troubleshooting


If error code [226] is displayed, carry out troubleshooting for it first.
aPrepare with starting switch OFF, then carry out troubleshooting without turning starting switch.

Defective fuel control dial


(Internal defect)

E06 (male)
Between (A) and (C)

Resistance
4.0 6.0 z

Between (B) and (A)


Between (B) and (C)

0.25 5.0 z
0.25 5.0 z

aPrepare with starting switch OFF, then carry out troubleshooting without turning starting switch.

Possible causes
and standard
value in normal
state

Disconnection in wiring
harness (Disconnection in
3
wiring harness or defective
contact in connector)

Short circuit with chassis


ground in wiring harness
4
(Contact with ground circuit)

Short circuit with power


5 source in wiring harness
(Contact with 24-V circuit)

20-356
(1)

Defective governor and


pump controller

Wiring harness between C01 (female) (22) and


Resistance
J07 and E06 (female) (1)

Max. 1 z

Wiring harness between C01 (female) (21) and


Resistance Max. 1 z
E06 (female) (3)
Wiring harness between C01 (female) (19) and
Resistance Max. 1 z
E06 (female) (2)
aPrepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting.
Between C01 (female) (19) E06 (female) (2)
Resistance Min. 1 Mz
wiring harness and chassis ground
aPrepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting.
Between C01 (female) (22) J07 E06
(female) (1) wiring harness and chassis ground

Voltage

Max. 1 V

Between C01 (female) (19) E06 (female) (2)


Voltage
Max. 1 V
wiring harness and chassis ground
aPrepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting.
C01
Voltage
Between (22) and (21)
Between (19) and (21)

Power supply
Signal

4.5 5.5 V
0.5 4.5 V

PC130-7

TROUBLESHOOTING

[308]

Circuit diagram related to fuel control dial

PC130-7

20-357
(1)

[315]

TROUBLESHOOTING

Error code [315] (Short circuit in battery relay output line)


User code

Error code

Contents of
trouble

315

Action of
controller
Problem that
appears on
machine
Related
information

Trouble

Abnormality in battery relay output


(Governor and pump controller system)

When the signal is output to the battery relay drive circuit, an abnormal current flows.
Turns off the output to the battery relay drive circuit OFF.
Even if the cause of the failure disappears, the system does not reset itself until the starting switch is
turned OFF.
The engine does not stop (The controller power supply cannot be maintained until the engine stops).
The operation state (ON/OFF) of the battery relay can be checked with the monitoring function.
(Code: 037, Right of upper line)
Cause

Standard value in normal state/Remarks on troubleshooting


aPrepare with starting switch OFF, then carry out troubleshooting without turning starting switch.

Possible causes
and standard
value in normal
state

Short circuit with chassis


ground in wiring harness
2
(Contact with ground circuit)

20-358
(1)

Defective battery relay


(Internal short circuit)

Defective governor and


pump controller

Battery relay (unit)


Between A21 (BR) and A20 (E)

Resistance
Approx. 100 z

Between A21 (BR) and


chassis ground

Min. 1 Mz

aPrepare with starting switch OFF, then carry out troubleshooting without turning starting switch.
Between C03 (female) (4) D01 J01 A21
Resistance Min. 1 Mz
(BR) wiring harness and chassis ground
aPrepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting.
C03
Starting switch
Voltage
Between (4) and
chassis ground

ON o OFF

20 30 V
(For 4 7sec)

PC130-7

TROUBLESHOOTING

[315]

Circuit diagram related to battery relay

PC130-7

20-359
(1)

[316]

TROUBLESHOOTING

Error code [316] (Step-out of governor motor)


User code

Error code

Contents of
trouble

316

Action of
controller
Problem that
appears on
machine
Related
information

Trouble

The input signal from the governor potentiometer is much different from the set value in the controller.
Repeats the control operation (steps out).
Even if the cause of the failure disappears, the system does not reset itself until the starting switch is
turned OFF.
The engine speed cannot be controlled.
The engine hunts.
The engine does not stop.

Cause

Possible causes
and standard
value in normal
state

(1)

Standard value in normal state/Remarks on troubleshooting

Defective fuel control dial


system

Defective governor potentiIf error code [306] is displayed, carry out troubleshooting for it first.
ometer system

Defective governor motor


system (Disconnection)
Defective governor motor
4
system (Short circuit)
Defective adjustment of
5
governor lever
Defective fuel control sys6
tem of engine
3

20-360

Step-out of governor motor


(Governor and pump controller system)

Defective governor and


pump controller

If error code [308] is displayed, carry out troubleshooting for it first.

If error code [317] is displayed, carry out troubleshooting for it first.


If error code [318] is displayed, carry out troubleshooting for it first.
See TESTING AND ADJUSTING, Special functions of monitor panel
See Shop Manual for 95-3 Series engine.
Troubleshooting cannot be carried out since the defect is in the controller (If none of causes 1 6 is the cause of the trouble, the controller is
defective).

PC130-7

[317]

TROUBLESHOOTING

Error code [317] (Disconnection in phases A and B of governor motor)


User code

Error code

E05
Contents of
trouble
Action of
controller

317

Problem that
appears on
machine
Related
information

Trouble

Disconnection in phases A and B of governor motor


(Governor and pump controller system)

When the signal is output to the governor motor, no current flows.


None in particular.
If the cause of the failure disappears, the system resets itself.

The engine speed is set to low idling.


The engine hunts.
The engine does not stop.
The governor motor steps out.
The operation state (current) of the governor motor can be checked with the monitoring function.
(Code: 033 - Phase A, 034 - Phase B, by 10 mA)
Cause

Standard value in normal state/Remarks on troubleshooting


aPrepare with starting switch OFF, then carry out troubleshooting without turning starting switch.

Possible causes
and standard
value in normal
state

(1)

E11 (male)
Between (1) and (2)

Resistance
2.5 7.5 z

Between (3) and (4)


2.5 7.5 z
aPrepare with starting switch OFF, then carry out troubleshooting without turning starting switch.
Wiring harness between C03 (female) (5) and
Resistance Max. 1 z
E11 (female) (1)

Disconnection in wiring
harness (Disconnection in Wiring harness between C03 (female) (15) and
Resistance
2
wiring harness or defective E11 (female) (2)
contact in connector)
Wiring harness between C03 (female) (25) and
Resistance
E11 (female) (3)

20-362

Defective governor motor


(Internal disconnection)

Defective governor and


pump controller

Max. 1 z
Max. 1 z

Wiring harness between C03 (female) (35) and


Resistance Max. 1 z
E11 (female) (4)
aPrepare with starting switch OFF, then carry out troubleshooting without turning starting switch.
C03 (female)
Resistance
Between (5) and (15)
Between (25) and (35)

2.5 7.5 z
2.5 7.5 z

PC130-7

TROUBLESHOOTING

[317]

Circuit diagram related to governor motor and potentiometer

PC130-7

20-363
(1)

[318]

TROUBLESHOOTING

Error code [318] (Short circuit in phases A and B of governor motor)


User code

Error code

E05
Contents of
trouble
Action of
controller

318

Problem that
appears on
machine
Related
information

Trouble

Short circuit in phases A and B of governor motor


(Governor and pump controller system)

When the signal is output to the governor motor, an abnormal current flows.
None in particular.
If the cause of the failure disappears, the system resets itself.

The engine speed cannot be controlled.


The engine speed is set to low idling.
The engine hunts.
The engine does not stop.
The operation state (current) of the governor motor can be checked with the monitoring function.
(Code: 033 - Phase A, 034 - Phase B, by 10 mA)
Cause

Standard value in normal state/Remarks on troubleshooting


aPrepare with starting switch OFF, then carry out troubleshooting without turning starting switch.

Defective governor motor


1
(Internal disconnection)

Possible causes
and standard
value in normal
state

Short circuit with chassis


ground in wiring harness
2
(Contact with ground circuit)

E11 (male)
Between (1) and (2)

Resistance
2.5 7.5 z

Between (3) and (4)


Between (1) and chassis ground

2.5 7.5 z
Min. 1 Mz

Between (3) and chassis ground


Min. 1 Mz
aPrepare with starting switch OFF, then carry out troubleshooting without turning starting switch.
Between C03 (female) (5) E11 (female) (1)
Resistance Min. 1 Mz
wiring harness and chassis ground
Between C03 (female) (15) E11 (female) (2)
wiring harness and chassis ground

Resistance Min. 1 Mz

Between C03 (female) (25) E11 (female) (3)


wiring harness and chassis ground

Resistance Min. 1 Mz

Between C03 (female) (35) E11 (female) (4)


Resistance Min. 1 Mz
wiring harness and chassis ground
aPrepare with starting switch OFF, then carry out troubleshooting without turning starting switch.
C03 (female)
Resistance
Defective governor and
3
pump controller

20-364
(1)

Between (5) and (15)


Between (25) and (35)

2.5 7.5 z
2.5 7.5 z

Between (5) and chassis ground


Between (15) and chassis ground

Min. 1 Mz
Min. 1 Mz

Between (25) and chassis ground


Between (35) and chassis ground

Min. 1 Mz
Min. 1 Mz

PC130-7

TROUBLESHOOTING

[318]

Circuit diagram related to governor motor and potentiometer

PC130-7

20-365
(1)

TROUBLESHOOTING FOR ELECTRICAL SYSTEM


(E-MODE)
BEFORE CARRYING OUT TROUBLESHOOTING WHEN CODE IS DISPLAYED................................... 20-402
INFORMATION IN TROUBLESHOOTING TABLE ..................................................................................... 20-403
E- 1 Engine does not start......................................................................................................................... 20-404
E- 2 Engine stops during operation........................................................................................................... 20-408
E- 3 Engine speed is unstable or engine hunts......................................................................................... 20-410
E- 4 Engine does not stop......................................................................................................................... 20-412
E- 5 Auto-decelerator does not operate .................................................................................................... 20-414
E- 6 Automatic warm-up system does not operate ................................................................................... 20-415
E- 7 Preheater does not operate............................................................................................................... 20-416
E- 8 Work equipment, swing, and travel system do not operate ............................................................... 20-418
E- 9 One-touch power maximizing system does not operate.................................................................... 20-420
E-10 No items of monitor panel light up ..................................................................................................... 20-421
E-11 7-segment LED's of monitor panel does not light up partially............................................................ 20-422
E-12 Monitor lamp of monitor panel is different from mounted model........................................................ 20-422
E-13 When starting switch is turned ON, basic check items light up or flash ............................................ 20-423
E-14 While engine is running, caution items flash ..................................................................................... 20-424
E-15 While engine is running, emergency stop items flash ....................................................................... 20-428
E-16 Engine coolant thermometer is abnormal.......................................................................................... 20-430
E-17 Fuel level gauge is abnormal............................................................................................................. 20-431
E-18 Swing lock monitor is abnormal......................................................................................................... 20-432
E-19 When monitor switch is operated, display by lamp does not change ................................................ 20-434
E-20 Windshield wiper and windshield washer do not operate.................................................................. 20-436
E-21 Lower windshield wiper does not operate ......................................................................................... 20-440
E-22 Caution buzzer does not stop............................................................................................................ 20-442
E-23 Monitoring function does not display "Boom RAISE" normally .......................................................... 20-444
E-24 Monitoring function does not display "Boom LOWER" normally ....................................................... 20-446
E-25 Monitoring function does not display "Arm IN" normally .................................................................... 20-448
E-26 Monitoring function does not display "Arm OUT" normally ................................................................ 20-450
E-27 Monitoring function does not display "Bucket CURL" normally ......................................................... 20-452
E-28 Monitoring function does not display "Bucket DUMP" normally ........................................................ 20-454
E-29 Monitoring function does not display "Swing" normally ..................................................................... 20-456
E-30 Monitoring function does not display "Travel" normally ..................................................................... 20-458
E-31 Monitoring function does not display "service" normally.................................................................... 20-460
E-32 Troubleshooting of air conditioner ..................................................................................................... 20-464
E-33 Travel alarm does not sound or does not stop sounding................................................................... 20-475

PC130-7

20-401
(1)

TROUBLESHOOTING

BEFORE CARRYING OUT TROUBLESHOOTING WHEN CODE IS DISPLAYED

BEFORE CARRYING OUT TROUBLESHOOTING WHEN CODE IS


DISPLAYED
Connection table of fuse box

a This connection table shows the devices to which each power supply of the fuse box (FB1) supplies power
(A switch power supply is a device which supplies power while the starting switch is at the ON position and
a constant power supply is a device which supplies power while the starting switch is at the OFF position).
a When carrying out troubleshooting related to the electrical system, you should check the fuse box and fusible link to see if the power is supplied normally.
Type of power
supply

Fuse No.

Fuse capacity

Destination of power
Governor and pump controller (Controller power supply)

10A

PC-EPC solenoid (Emergency pump drive switch circuit)


Swing holding brake solenoid
(Swing holding brake release switch circuit)

Switch power supply


(Fusible link: A34)

20A

10A

Governor and pump controller (Solenoid power supply)


PPC oil pressure lock solenoid
Starting motor cutout relay (For PPC lock)
Cigarette lighter

10A
Windshield washer motor

Switch power supply


(Fusible link: A34)

10A

Horn

10A

Lower wiper motor [If equipped]

10A

Rotary lamp [If equipped]

10A

Working lamp (Boom and right front)


Working lamp (Left front and rear) [If equipped]
9

10A

One-touch power maximizing switch circuit

10

10A

Fuel priming pump [If equipped]

11

20A

Air conditioner unit

12

20A

Starting motor cutout relay (For personal code)


Monitor panel (Switch power supply)
Light relay 1
Switch power supply
(Fusible link: A34)

13

20A

Light relay 2
Panel night light signal circuit

14

10A

15

10A

Heated seat [If equipped]


Heated seat [If equipped]
Travel alarm [If equipped]

Constant power
supply
(Fusible link: A35)

20-402
(1)

16

10A

DC/DC converter (Power supply to 12-V devices)

17

20A

Monitor panel (Constant power supply)

18

10A

Starting switch

19

10A

Room lamp

20

10A

(Spare)

PC130-7

INFORMATION IN TROUBLESHOOTING TABLE

TROUBLESHOOTING

INFORMATION IN TROUBLESHOOTING TABLE


a The following information is summarized in the troubleshooting table and the related electrical circuit diagram. Before carrying out troubleshooting, understand that information fully.
Trouble
Related
information

Trouble which occurred in the machine


Information related to the detected trouble or troubleshooting
Cause

<Contents of description)
Standard value in normal state to judge possible causes
Remarks on judgment

<Troubles in wiring harness>


Disconnection
Connector is connected imperfectly or wiring harness is broken.
Grounding fault
Wiring harness which is not connected to chassis ground circuit is in
contact with chassis ground circuit.
Short circuit with power source
Wiring harness which is not connected to power source (24-V) circuit
is in contact with power source (24-V) circuit.

2
Possible causes
and standard
value in normal
state

Standard value in normal state/Remarks on troubleshooting

Possible causes of trouble


(Given numbers are
reference numbers, which
do not indicate priority)
3

<Precautions for troubleshooting>


1) Method of indicating connector No. and handling of T-adapter
Insert or connect T-adapter as explained below for troubleshooting, unless otherrwise specified.
If connector No. has no marks of "male" and "female", disconnect
connector and insert T-adapters in both male side and female
side.
If connector No. has marks of "male" and "female", disconnect
connector and connect T-adapter to only male side or female
side.
2) Entry order of pin Nos. and handling of circuit tester leads
Connect positive (+) lead and negative (-) lead of circuit tester as
explained below for troubleshooting, unless otherwise specified.
Connect positive (+) lead to pin No. or harness entered on front
side.
Connect negative (-) lead to pin No. or harness entered on rear
side.

Related circuit diagram

This is a circuit diagram of the part related to troubleshooting.


Connector No.: Shows the "Type-Number of pin" and "Color".
Branching/Merging point: Shows that there is a branching/merging point in the electric circuit to be
checked.
Arrow ( ): Roughly shows the location on the machine.

PC130-7

20-403
(1)

E-1

TROUBLESHOOTING

E-1 Engine does not start


Trouble
Related
information

Engine does not start


The engine starting circuit is equipped with the start lock function of safety lock lever type.
Cause

Possible causes
and standard
value in normal
state

20-404
(1)

Standard value in normal state/Remarks on troubleshooting


Battery voltage
Electrolyte specific gravity
Low charge level of battery
Min. 24 V
Min. 1.26
If the fuse is broken, the circuit probably has a grounding fault, etc.
(See Cause 10.)
Defective fuse No. 3 or 18
If the fuse is not broken and the monitor panel does not light up, check
the power supply circuit between the battery and fuse box, too.
aPrepare with starting switch OFF, then carry out troubleshooting without turning starting switch.
Defective starting switch
H15 (male)
Starting switch
Resistance
(Internal disconnection)
OFF
Min. 1 Mz
Between (1) and (4)
START
Max. 1 z
aPrepare with starting switch OFF, then carry out troubleshooting without turning starting switch.
Defective safety lock switch
S14 (female)
Safety lock lever
Resistance
(Internal disconnection)
Free
Min. 1 Mz
Between (1) and (3)
Lock
Max. 1 z
aPrepare with starting switch OFF, then carry out troubleshooting without turning starting switch.
Defective starting motor
R11 (female), R12
Resistance
cutout relay R11 or R13
(Internal disconnection or
Between (1) and (2)
100 500 z
short circuit)
Between (3) and (5)
Min. 1 Mz
Between (3) and (6)
Max. 1 z
aPrepare with starting switch OFF (Disconnect only terminal C), then
turn starting switch to START position and carry out troubleshooting.
Starting
Voltage/Resistance
Relay terminal, A27
switch
Between B and
Power
20 30 V
chassis ground
supply
Between E and
GND
Max. 1 z
chassis ground
Defective starting motor
safety relay
Between A27 (2) and
GeneraSTART
Max. 1 V
(Internal defect)
chassis ground
tion signal
Between A27 (1) and
Starting
20 30 V
chassis ground
input
Between C and
Starting
20 30 V
chassis ground
output
If the power supply, GND, generation signal, and starting input are normal and the starting output is not normal, the starting motor safety relay
is defective.
aPrepare with starting switch OFF, then turn starting switch to START
position and carry out troubleshooting.
Starting
Voltage
Starting motor
switch
Defective starting motor
Between B and
Power
20 30 V
(Internal defect)
chassis ground
supply
START
Starting
Between C and
20 30 V
chassis ground
output
If the power supply and starting signal are normal and the starting motor
does not rotate, the starting motor is defective.

PC130-7

E-1

TROUBLESHOOTING

Cause

Defective alternator
(Internal defect)

Standard value in normal state/Remarks on troubleshooting


aPrepare with starting switch OFF, then turn starting switch to ON or
START position and carry out troubleshooting.
E12 (male)
Between (1) and chassis ground

Resistance
Max. 1 V

aPrepare with starting switch OFF, then carry out troubleshooting without turning starting switch.
Wiring harness between FB1-18 outlet and H15
Resistance Max. 1 z
(female) (1)
Wiring harness between H15 (female) (4) and
Resistance Max. 1 z
J01 and R11 (female) (5)
Wiring harness between R11 (female) (3) and
Resistance Max. 1 z
A27 (female) (1)

Disconnection in wiring
harness
Wiring harness between starting safety relay C
9 (Disconnection in wiring
and starting motor C
harness or defective
Wiring harness between FB1-3 outlet and S14
contact in connector)
(male) (1)

Resistance

Max. 1 z

Resistance

Max. 1 z

Wiring harness between S14 (male) (3) and


Resistance Max. 1 z
R11 (female) (1)
Wiring harness between R11 (female) (2) and
Resistance Max. 1 z
R13 (female) (6)
Wiring harness between R13 (female) (3) and
Resistance Max. 1 z
J04 and chassis ground (A10)
aPrepare with starting switch OFF, then carry out troubleshooting without turning starting switch.

Possible causes
and standard
value in normal
state

Between FB1-18 outlet H15 (female) (1) wiring harness and chassis ground

Resistance

Min. 1 Mz

Between H15 (female) (4) J01 R11 (female)


(5) or P01 (female) (4) or C01 (female) (17) or
Resistance Min. 1 Mz
other related circuit wiring harness and chassis
Short circuit with chassis ground
ground in wiring harness Between R11 (female) (3) A27 (female) (1)
Resistance Min. 1 Mz
10
wiring harness and chassis ground
(Contact with ground
Between starting safety relay C starting motor
circuit)
Resistance Min. 1 Mz
C wiring harness and chassis ground
Between FB1-3 outlet S14 (male) (1) wiring
harness and chassis ground

Resistance

Min. 1 Mz

Between S14 (male) (3) R11 (female) (1) wirResistance Min. 1 Mz


ing harness and chassis ground

Short circuit with power


11 source in wiring harness
(Contact with 24-V circuit)

PC130-7

Between P02 (female) (14) J05 R13


Resistance Min. 1 Mz
(female) (2) wiring harness and chassis ground
aPrepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting.
Between A27 (female) (2) E08 (male) (1) or
J02 or D01 (female) (6) or P02 (female) (11) or
Voltage
Max. 1 V
other related circuit wiring harness and chassis
ground

20-405
(1)

TROUBLESHOOTING

E-1

Circuit diagram related to engine preheating, starting, charging, and stopping functions

20-406
(1)

PC130-7

E-2

TROUBLESHOOTING

E-2 Engine stops during operation


Trouble
Related
information

Engine stops during operation.


The input state (Voltage) from the governor potentiometer can be checked with the monitoring function.
(Code: 031, by 10 mV)
Cause

Defective governor
1 potentiometer
(Internal defect)

Possible causes
and standard
value in normal
state

Disconnection in wiring
harness
2 (Disconnection in wiring
harness or defective contact in connector)
Short circuit with chassis
ground in wiring harness
3
(Contact with ground
circuit)

Standard value in normal state/Remarks on troubleshooting


aPrepare with starting switch OFF, then carry out troubleshooting without turning starting switch.
E10 (male)
Resistance
4.0 6.0 z
0.25 5.0 z

Between (A) and (C)


Between (B) and (A)

Between (B) and (C)


0.25 5.0 z
aPrepare with starting switch OFF, then carry out troubleshooting without turning starting switch.
Wiring harness between C01 (female) (13) and
Resistance
E10 (female) (B)

Max. 1 z

aPrepare with starting switch OFF, then carry out troubleshooting without turning starting switch.
Between C01 (female) (13) E10 (female) (B)
Resistance Min. 1 Mz
wiring harness and chassis ground
aPrepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting.

Defective governor and


pump controller

C01
Between (22) and (21)
Between (13) and (21)

20-408
(1)

Power supply

Voltage
4.5 5.5 V

Signal

0.5 4.5 V

PC130-7

E-2

TROUBLESHOOTING

Circuit diagram related to governor motor and potentiometer

BWP13362

PC130-7

20-409
(1)

E-3

TROUBLESHOOTING

E-3 Engine speed is unstable or engine hunts


Trouble

Related
information

(1) Low idling speed is unstable.


(2) Engine hunts.
(3) High idling speed is low.
Since the governor and pump controller normally performs the following controls, the set opening angle
of the fuel control dial does not always conform accurately to the control angle of the governor motor.
1) Governor control by selecting working mode
2) Governor control by setting automatic decelerating function
3) Governor control according to operating condition of control lever
4) Governor control by automatic warm-up function in cold state
5) Governor control by turbocharger protecting function when engine is started
Accordingly, when checking the operation of the fuel control dial and governor motor, be sure to select
GOVERNOR ADJUSTMENT FUNCTION [03]. (Since the governor control function does not operate
in this mode, the set opening angle of the fuel control dial always conforms to the control angle of the
governor motor.)
The engine speed can be checked with the monitoring function.
(Code: 010, by 10 rpm)
Cause

Defective governor
1 potentiometer
(Internal defect)

Normal display

130
003
If the monitoring display is abnormal, carry out troubleshooting for error
code [217].

Malfunction of governor
motor

aTurn starting switch ON or start engine and carry out troubleshooting.


When the following operation is performed, if the governor motor lever
moves smoothly, the governor motor is normal.
Operate the fuel control dial between low idling and high idling.
Stop the engine by turning the starting switch OFF.

Defective fuel control


system of engine

See the Shop Manual for 95-3 Seriese, Engine.

Short circuit with chassis


ground in wiring harness
6
(Contact with ground
circuit)

(1)

Item
Governor and pump
controller model code

See TESTING AND ADJUSTING, Special functions of monitor panel.

Disconnection in wiring
harness
5 (Disconnection in wiring
harness or defective contact in connector)

20-410

Monitoring code
002

Defective adjustment of
governor lever

Possible causes
and standard
value in normal
state

Standard value in normal state/Remarks on troubleshooting


aTurn starting switch ON and carry out troubleshooting (monitoring).

Defective governor and


pump controller

aPrepare with starting switch OFF, then carry out troubleshooting without turning starting switch.
Wiring harness between C01 (female) (23) and
Resistance
J07 and H15 (female) (5)

Max. 1 z

aPrepare with starting switch OFF, then carry out troubleshooting without turning starting switch.
Between C01 (female) (23) J07 H15
Resistance Min. 1 z
(female) (5) or other related circuit wiring harness and chassis ground
Troubleshooting cannot be carried out since the defect is in the governor and pump controller (If none of causes 1 6 is the cause of the trouble, the governor and pump controller is defective).

PC130-7

TROUBLESHOOTING

E-3

Circuit diagram related to engine preheating, starting, charging, and stopping functions

PC130-7

20-411
(1)

E-4

TROUBLESHOOTING

E-4 Engine does not stop


Trouble
Related
information

Engine does not stop.


The governor and pump controller holds the battery relay for 4 seconds at shortest and 7 seconds at
longest to secure the drive power for the governor motor after the starting switch is turned to the OFF
position until the engine stops.
The drive state (ON/OFF) of the battery relay can be checked with the monitoring function.
(Code: 037, Right of upper line)
Cause

Defective battery relay


(Internal defect)

Defective assembled-type
2 diode D01
(Internal disconnection)
Possible causes
and standard
value in normal
state

Disconnection in wiring
harness
3 (Disconnection in wiring
harness or defective
contact in connector)

Standard value in normal state/Remarks on troubleshooting


aPrepare with starting switch OFF, then carry out troubleshooting without turning starting switch.
When the starting switch is operated as follows, if the battery relay contacts make operating sounds, the battery relay is normal.
Starting switch OFF o ON o OFF
aPrepare with starting switch OFF, then carry out troubleshooting without turning starting switch.
D01 (male)
Digital circuit tester
Continuity
Between (5) and (1)
Diode mode
There is continuity
aPrepare with starting switch OFF, then carry out troubleshooting without turning starting switch.
Wiring harness between C03 (female) (4) and
Resistance Max. 1 z
D01 (female) (5)
Wiring harness between D01 (female) (1) and
Resistance Max. 1 z
J01 and A21 (BR)
Wiring harness between A20 (E) and chassis
ground (A14)

20-412
(1)

Defective governor and


pump controller

Resistance

Max. 1 z

aPrepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting.
C03
Between (4) and
chassis ground

Starting switch
ON o OFF

Voltage
20 30 V
(4 7 sec)

PC130-7

TROUBLESHOOTING

E-4

Circuit diagram related to engine preheating, starting, charging, and stopping functions

PC130-7

20-413
(1)

E-5

TROUBLESHOOTING

E-5 Auto-decelerator does not operate


Trouble
Related
information

Auto-decelerator does not operate.


Since the auto-decelerator is set to 1,400 rpm, it does not operate if the fuel control dial is not set above
this level.
Check the display on the monitor panel while the engine is running.
Cause

1 Defective boom RAISE


signal

Defective boom LOWER


2 signal

3 Defective arm IN signal

4 Defective arm OUT signal

Possible causes
and standard
value in normal
state

5 Defective bucket CURL


signal

Defective bucket DUMP


6 signal

7 Defective swing signal

8 Defective travel signal

9 Defective attachment
signal

10 Defective governor and


pump controller

20-414
(1)

Standard value in normal state/Remarks on troubleshooting


When lever is
Monitoring code
operated: ON
6-bit display
(Center of lower line)
When
lever is in
020
neutral: OFF
If the display on the monitor panel is abnormal, carry out troubleshooting
for E-23.
When lever is
Monitoring code
operated: ON
6-bit display
(Center of upper line)
When lever is in
020
neutral: OFF
If the display on the monitor panel is abnormal, carry out troubleshooting
for E-24.
When lever is
Monitoring code
operated: ON
6-bit display
(Left of upper line)
When
lever is in
020
neutral: OFF
If the display on the monitor panel is abnormal, carry out troubleshooting
for E-25.
When lever is
Monitoring code
operated: ON
6-bit display
(Left of lower line)
When lever is in
020
neutral: OFF
If the display on the monitor panel is abnormal, carry out troubleshooting
for E-26.
When lever is
Monitoring code
operated: ON
6-bit display
(Right of upper line)
When
lever is in
021
neutral: OFF
If the display on the monitor panel is abnormal, carry out troubleshooting
for E-27.
When lever is
Monitoring code
operated: ON
6-bit display
(Right of lower line)
When lever is in
021
neutral: OFF
If the display on the monitor panel is abnormal, carry out troubleshooting
for E-28.
When lever is
Monitoring code
operated: ON
6-bit display
(Right of upper line)
When
lever is in
020
neutral: OFF
If the display on the monitor panel is abnormal, carry out troubleshooting
for E-29.
When lever is
Monitoring code
operated: ON
6-bit display
(Right of lower line)
When lever is in
020
neutral: OFF
If the display on the monitor panel is abnormal, carry out troubleshooting
for E-30.
When lever is
Monitoring code
operated: ON
6-bit display
(Center of lower line)
When
lever is in
021
neutral: OFF
IIf the display on the monitor panel is abnormal, carry out troubleshooting for E-31.
Troubleshooting cannot be carried out since the defect is in the governor and pump controller (If none of causes 1 9 is the cause of the trouble, the governor and pump controller is defective).

PC130-7

E-6

TROUBLESHOOTING

E-6 Automatic warm-up system does not operate


Trouble
Related
information

Automatic warm-up system does not operate.


When the engine coolant temperature is below 30C, the automatic warm-up system raises the engine
speed to 1,200 rpm.
If the fuel control dial is opened more than 70% for 3 seconds when the starting switch is turned ON or
after the engine is started, the automatic warm-up system is turned OFF.
Cause

Standard value in normal state/Remarks on troubleshooting


aTurn starting switch ON and carry out troubleshooting (monitoring).
Monitoring code
Item
Normal display

Possible causes
and standard
value in normal
state

041

Engine coolant
temperature sensor
voltage (Unit: 10 mV)

Approx. 480 440


(Coolant temperature:
0 30 C)

If the display on the monitor panel is abnormal, carry out troubleshooting


for E-16.
2

PC130-7

Defective engine coolant


temperature sensor system

Defective governor and


pump controller

Troubleshooting cannot be carried out since the defect is in the governor and pump controller (If none of the above causes is the cause of the
trouble, the governor and pump controller is defective).

20-415
(1)

E-7

TROUBLESHOOTING

E-7 Preheater does not operate


Trouble
Related
information

(1) When the starting switch is set in the HEAT position, the preheating monitor does not light up.
The preheater monitor lights up when the starting switch is turned to the HEAT position and starts flashing about 30 seconds after to notify the operator of completion of preheating (It stops flashing about 10
seconds after).
The input state (ON/OFF) of the preheating signal can be checked with the monitoring function.
(Code: 045, Center of upper line)
Cause
1 Defective starting switch

Possible causes
and standard
value in normal
state

Disconnection in wiring
harness
2 (Disconnection in wiring
harness or defective
contact in connector)

Trouble

Wiring harness between P02 (female) (18) and


Resistance
J02 (male) (7)

P02
Between (17) and
chassis ground

Starting switch
OFF

Voltage
Max. 1 V

HEAT

20 30 V

(2) When the starting switch is turned to the HEAT position, the heater unit does not become hot.
If the engine is started while the temperature is low (the coolant temperature is below 30C), the governor and pump controller drives the heater relay automatically to preheat the engine.
Cause

1 Defective starting switch

Standard value in normal state/Remarks on troubleshooting


aPrepare with starting switch OFF.
H15 (male)
Between (1) and (3)

Starting switch
OFF

Resistance
Min. 1 Mz
Max. 1 z

HEAT
aPrepare with starting switch OFF.

Possible causes
and standard
value in normal
state

Defective heater relay


2
(Internal disconnection)

Defective electrical intake


3 air heater
(Internal disconnection)
Disconnection in wiring
harness
4 (Disconnection in wiring
harness or defective
contact in connector)

Heater relay
Between A25 and
chassis ground
Between contact
terminals

Starting switch

Continuity/Resistance

OFF

There is continuity

HEAT

Max. 1 z

aPrepare with starting switch OFF, then carry out troubleshooting without turning starting switch.
Electrical intake air heater
Between E01 and chassis ground

(1)

Continuity
There is continuity

aPrepare with starting switch OFF, then carry out troubleshooting without turning starting switch.
Wiring harness between H15 (female) (3) and
J02 and A25
Wiring harness between A22 and heater relay
Wiring harness between A26 and E01

20-416

Max. 1 z

aPrepare with starting switch OFF.


3 Defective monitor panel

Related
information

Standard value in normal state/Remarks on troubleshooting


If the engine is not preheated (the heater unit does not become hot),
carry out troubleshooting for trouble (2).
aPrepare with starting switch OFF, then carry out troubleshooting without turning starting switch.

Resistance

Max. 1 z

Resistance

Max. 1 z

Resistance

Max. 1 z

PC130-7

TROUBLESHOOTING

E-7

Circuit diagram related to engine preheating, starting, charging, and stopping functions

PC130-7

20-417
(1)

E-8

TROUBLESHOOTING

E-8 Work equipment, swing, and travel system do not operate


Trouble

Work equipment, swing, and travel system do not operate

Related
information
Cause
1 Defective fuse No. 3

Defective safety lock switch


(Internal disconnection)

Defective PPC lock


solenoid
3
(Internal disconnection or
short circuit)

Possible causes
and standard
value in normal
state

Defective assembled-type
4 diode D01
(Internal short circuit)

Disconnection in wiring
harness
5 (Disconnection in wiring
harness or defective
contact in connector)

Short circuit with chassis


ground in wiring harness
6
(Contact with ground
circuit)

20-418
(1)

Standard value in normal state/Remarks on troubleshooting


If the fuse is broken, the circuit probably has a grounding fault, etc.
(See cause 6.)
aPrepare with starting switch OFF.
S14 (female)
Between (1) and (2)

Safety lock lever


Lock

Free
aPrepare with starting switch OFF.
V01 (male)
Between (1) and (2)

Resistance
Min. 1 Mz
Max. 1 z
Resistance
20 60 z

Between (1) and chassis ground


Min. 1 Mz
aPrepare with starting switch OFF, then carry out troubleshooting without turning starting switch.
D01 (male)
Resistance (Continuity)
Between (4) and (8)
Min. 1 Mz (No continuity)
aPrepare with starting switch OFF, then carry out troubleshooting without turning starting switch.
Wiring harness between FB1-3 outlet and S14
Resistance Max. 1 z
(male) (1)
Wiring harness between S14 (male) (2) and
J02 and V01 (female) (1)

Resistance

Max. 1 z

Wiring harness between V01 (female) (2) and


chassis ground

Resistance

Max. 1 z

aPrepare with starting switch OFF, then carry out troubleshooting without turning starting switch.
Between FB1-3 outlet S14 (male) (1) wiring
Resistance Min. 1 Mz
harness and chassis ground
Between S14 (male) (2) J02 V01 (female)
Resistance Min. 1 Mz
(1) or D01 (female) (4) wiring harness and
chassis ground

PC130-7

TROUBLESHOOTING

E-8

Circuit diagram related to PPC lock solenoid

PC130-7

20-419
(1)

E-9

TROUBLESHOOTING

E-9 One-touch power maximizing system does not operate


Trouble
Related
information

One-touch power maximizing system does not operate.


The input state (ON/OFF) from the one-touch power maximizing switch (left knob switch) can be
checked with the monitoring function. (Code: 022, Center of upper line)
Cause

Possible causes
and standard
value in normal
state

Standard value in normal state/Remarks on troubleshooting

If the fuse is broken, the circuit probably has a grounding fault, etc.
1 Defective fuse No. 9
(See cause 4.)
aPrepare with starting switch OFF, then carry out troubleshooting without turning starting switch.
Defective one-touch power
One-touch power
M23 (male)
Resistance
2 maximizing switch
maximizing switch
(Internal disconnection)
Released
Min. 1 Mz
Between (1) and (4)
Pressed
Max. 1 z
aPrepare with starting switch OFF, then carry out troubleshooting withDisconnection in wiring
out turning starting switch.
harness
Wiring harness between FB1-9 outlet and M23
Resistance Max. 1 z
3 (Disconnection in wiring
(female) (1)
harness or defective
Wiring harness between M23 (female) (4) and
contact in connector)
Resistance Max. 1 z
C01 (female) (1)
Short circuit with chassis
ground in wiring harness
4
(Contact with ground
circuit)

Defective governor and


pump controller

aPrepare with starting switch OFF, then carry out troubleshooting without turning starting switch.
Between FB1-9 outlet M23 (female) (1) wiring
Resistance Min. 1 Mz
harness and chassis ground
Between M23 (female) (4) C01 (female) (1)
Resistance Min. 1 Mz
wiring harness and chassis ground
aPrepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting.
C01

One-touch power
maximizing switch

Voltage

Between (11) and


chassis ground

Released
Pressed

Max. 1 V
20 30 V

Circuit diagram related to one-touch power maximizing switch

20-420
(1)

PC130-7

E-10

TROUBLESHOOTING

E-10 No items of monitor panel light up


Trouble

No items of monitor panel light up.

When the starting switch is turned ON, no items of monitor


panel light up.

Related
information
Cause
1 Defective fuse No.12

Possible causes
and standard
value in normal
state

Disconnection in wiring
harness
2 (Disconnection in wir
ing harness or defective
contact in connector)
Short circuit with chassis
ground in wiring harness
3
(Contact with ground
circuit)

Standard value in normal state/Remarks on troubleshooting


If the fuse is broken, the circuit probably has a grounding fault, etc.
(See cause 3.)
aPrepare with starting switch OFF, then carry out troubleshooting without turning starting switch.
Wiring harness between FB1-12 outlet and J07
Resistance Max. 1 z
and P01 (female) (1), (2)
Wiring harness between P01 (female) (6), (7)
Resistance Max. 1 z
and chassis ground (A11)
aPrepare with starting switch OFF, then carry out troubleshooting without turning starting switch.
Between FB1-12 outlet J07 P01 (female)
Resistance Min. 1 Mz
(1), (2) wiring harness and chassis ground
aPrepare with starting switch OFF.
P01 (female)
Starting switch

4 Defective monitor panel

Voltage/Resistance

Between (1), (2) and


chassis ground

ON

20 30 V

Between (6), (7) and


chassis ground

OFF

Max. 1 z

Circuit diagram related to monitor panel power supply

PC130-7

20-421
(1)

E-11, E-12

TROUBLESHOOTING

E-11 7-segment LED's of monitor panel does not light up partially


Trouble

7-segment LED's of monitor panel does When the starting switch is turned ON, 7-segment LED's of
not light up partially.
monitor panel does not light up partially.

Related
information
Possible causes
and standard
value in normal
state

Cause
1 Defective monitor panel

Standard value in normal state/Remarks on troubleshooting


Troubleshooting cannot be carried out since the defect is in the monitor
panel (The LCD that does not light up may be defective).

E-12 Monitor lamp of monitor panel is different from mounted model


Trouble

Monitor lamp of monitor panel is different When the starting switch is turned ON, the monitor panel
from mounted model
which lights up totally is different from the mounted model.

Related
information
Cause

Standard value in normal state/Remarks on troubleshooting


aTurn starting switch ON and carry out troubleshooting (monitoring).
Monitoring code
Item
Normal display

Possible causes
and standard
value in normal
state

Defective model code


signal

2 Defective monitor panel

20-422
(1)

Monitor panel
130
model code
If the display on the monitor panel is abnormal, carry out troubleshooting
for error code [217].
Troubleshooting cannot be carried out since the defect is in the monitor
panel (If none of the above causes is the cause of the trouble, the monitor panel is defective).
001

PC130-7

E-13

TROUBLESHOOTING

E-13 When starting switch is turned ON, basic check items light up or flash
Trouble
Related
information

(1) Engine oil level monitor flashes.


When the starting switch is turned ON, if the engine oil level monitor detects lowering of the engine oil
level, it flashes.
The input state (ON/OFF) from the engine oil level switch can be checked with the monitoring function.
(Code: 046, Center of lower line)
Cause
1

Low engine oil level


(When system is normal)

Defective engine oil level


2 switch
(Internal disconnection)
Possible causes
and standard
value in normal
state

Standard value in normal state/Remarks on troubleshooting


Check the engine oil level. If it is low, add new oil.
aPrepare with starting switch OFF, then carry out troubleshooting without turning starting switch.
E03 (male)
Engine oil level
Resistance
Between (1) and
chassis ground

When normal
When low

Max. 1 z
Min. 1 Mz

aPrepare with starting switch OFF, then carry out troubleshooting without turning starting switch.

Disconnection in wiring
harness
3 (Disconnection in wiring
harness or defective
contact in connector)

Wiring harness between P02 (female) (8) and


E03 (female) (1)

4 Defective monitor panel

aPrepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting.
P02
Engine oil level
Voltage
Between (8) and
chassis ground

When normal
When low

Resistance

Max. 1 z

Max. 1 V
20 30 V

Circuit diagram related to engine oil level switch

Trouble
Related
information

Possible causes
and standard
value in normal
state

PC130-7

(2) Engine oil replacement monitor lights up.


When the starting switch iResistances turned ON near the engine oil replacement period, the engine oil
replacement monitor lights. (Set up Machine only)
Cause
Engine oil replacement
1 period
(When system is normal)
2 Defective monitor panel

Standard value in normal state/Remarks on troubleshooting


It is near the engine oil replacement period. Check the elapsed time
and replace the oil.
If the time before the set engine oil replacement period is longer than 10
hours, the monitor panel is defective (Troubleshooting cannot be carried
out since the defect is in the monitor panel).

20-423
(1)

E-14

TROUBLESHOOTING

E-14 While engine is running, caution items flash


Trouble
Related
information

(1) Battery charge level monitor flashes.


While the engine is running, if the battery charge level monitor detects lowering of the charge voltage,
it flashes.
The generation state (Voltage) of the alternator and the input state (ON/OFF) of the generation signal
can be checked with the monitoring function.
(Code: 043, by 10 mV, left of lower line)
Cause

Possible causes
and standard
value in normal
state

Defective alternator
(Defective charge)

Disconnection in wiring
harness
2 (Disconnection in wiring
harness or defective
contact in connector)
Short circuit with chassis
ground in wiring harness
3
(Contact with ground
circuit)

4 Defective monitor panel

Standard value in normal state/Remarks on troubleshooting


aPrepare with starting switch OFF, then start engine and carry out troubleshooting.
E08 (female)
Engine speed
Voltage
Between (1) and
Above medium
20 30 V
chassis ground
(half) speed
aPrepare with starting switch OFF, then carry out troubleshooting without turning starting switch.
Wiring harness between P02 (female) (11) and
Resistance
J02 and E08 (male) (1)

aPrepare with starting switch OFF, then carry out troubleshooting without turning starting switch.
Between P02 (female) (11) J02 E08 (male)
(1) or A27 (female) (2) or D01 J01 D01
Resistance Min. 1 Mz
(female) (1) or H15 (female) (2) or A21 (BR)
wiring harness and chassis ground
aPrepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting.
E08 (female)
Engine speed
Voltage
Between (1) and
chassis ground

20-424
(1)

Max. 1 z

Above medium
(half) speed

20 30 V

PC130-7

E-14

TROUBLESHOOTING

Circuit diagram related to engine preheating, starting, charging, and stopping functions

PC130-7

20-425
(1)

E-14

TROUBLESHOOTING

Trouble
Related
information

Possible causes
and standard
value in normal
state

20-426
(1)

(2) Fuel level monitor flashes.


While the engine is running, if the fuel level monitor detects lowering of the fuel level (Fuel level gauge:
Red range), it flashes.
Cause
Low fuel level
1
(When system is normal)
2 Defective monitor panel

Standard value in normal state/Remarks on troubleshooting


Check the fuel level gauge. If the fuel level is low, add fuel.
If the monitor flashes while the fuel level gauge is not in the red range
(level 1), the monitor panel is defective (Troubleshooting cannot be carried out since the defect is in the monitor panel).

PC130-7

E-14

TROUBLESHOOTING

Trouble
Related
information

(3) Air cleaner clogging monitor flashes.


While the engine is running, if the air cleaner clogging monitor detects clogging of the air cleaner, it
flashes.
The input state (ON/OFF) from the air cleaner clogging switch can be checked with the monitoring function. (Code: 046, Right of upper line)
Cause
1

Clogging of air cleaner


(When system is normal)

Defective air cleaner


2 clogging switch
(Internal disconnection)
Possible causes
and standard
value in normal
state

Disconnection in wiring
harness
3 (Disconnection in wiring
harness or defective
contact in connector)

4 Defective monitor panel

Standard value in normal state/Remarks on troubleshooting


Check the air cleaner. If it is clogged, clean or replace it.
aPrepare with starting switch OFF, then start engine and carry out troubleshooting.
A31 (male)
Air cleaner
Resistance
Between (1) and (2)

When normal
When clogged

Max. 1 z
Min. 1 Mz

a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch.
Wiring harness between P02 (female) (5) and
Resistance Max. 1 z
A31 (female) (1)
Wiring harness between P11 (female) (2) and
Resistance Max. 1 z
chassis ground (A15)
aPrepare with starting switch OFF, then start engine and carry out troubleshooting.
P02
Air cleaner
Voltage
Between (5) and
chassis ground

When normal
When clogged

Max. 1 V
20 30 V

Circuit diagram related to air cleaner clogging switch

PC130-7

20-427
(1)

E-15

TROUBLESHOOTING

E-15 While engine is running, emergency stop items flash


Trouble
Related
information

(1) Engine coolant temperature monitor flashes.


If the engine coolant temperature monitor detects a rise of engine coolant temperature (Coolant thermometer: Red range), it flashes.
Cause

Possible causes
and standard
value in normal
state

20-428
(1)

Standard value in normal state/Remarks on troubleshooting

Engine overheating
1
(When system is normal)

Check the engine coolant thermometer. If the engine coolant temperature is high, run the engine at low idling to cool it down.

2 Defective monitor panel

If the monitor flashes while the engine coolant thermometer is not in the
red range (level 8, 9), the monitor panel is defective (Troubleshooting
cannot be carried out since the defect is in the monitor panel).

PC130-7

E-15

TROUBLESHOOTING

Trouble
Related
information

(2) Engine oil pressure monitor flashes.


If the engine oil pressure monitor detects lowering of the engine oil pressure, it flashes.
The input state (ON/OFF) from the engine oil pressure switch can be checked with the monitoring function. (Code: 046, Center of upper line)
Cause
Lowering of engine oil
1 pressure
(When system is normal)
Defective engine oil
2 pressure switch
(Internal short circuit)

Possible causes
and standard
value in normal
state

Short circuit with chassis


ground in wiring harness
3
(Contact with ground
circuit)

4 Defective monitor panel

Standard value in normal state/Remarks on troubleshooting


Check the engine oil pressure. If it is low, repair the troubled parts.
aPrepare with starting switch OFF, then hold starting switch OFF and
start engine and carry out troubleshooting.
E02
Engine
Resistance
Between terminal and
chassis ground

When stopped
When operated

Max. 1 z
Min. 1 Mz

aPrepare with starting switch OFF, then carry out troubleshooting without turning starting switch.
Between P02 (female) (7) E02 wiring harness
Resistance Max. 1 z
and chassis ground
aPrepare with starting switch OFF, then hold starting switch ON and
start engine and carry out troubleshooting.
P02
Engine
Voltage
Between (7) and
chassis ground

When stopped
(Starting switch ON)

Max. 1 V

When operated

20 30 V

Circuit diagram related to engine oil pressure switch

PC130-7

20-429
(2)

E-16

TROUBLESHOOTING

E-16 Engine coolant thermometer is abnormal


Trouble

(1) While engine coolant temperature is rising normally, thermometer does not rise from white range (C).
(2) While engine coolant temperature is stabilized normally, thermometer rises to red range (H).

Related
information

The input state (ON/OFF) from the engine coolant temperature sensor can be checked with the monitoring function. (Code: 041, by 10 mV)
Cause

Defective engine coolant


temperature sensor
1
(Internal disconnection or
short circuit)

Possible causes
and standard
value in normal
state

Disconnection in wiring
harness
2 (Disconnection in wiring
harness or defective
contact in connector)
Short circuit with chassis
ground in wiring harness
3
(Contact with ground
circuit)
Short circuit with power
4 source in wiring harness
(Contact with 24-V circuit)

5 Defective monitor panel

Standard value in normal state/Remarks on troubleshooting


aPrepare with starting switch OFF, then carry out troubleshooting without turning starting switch.
Engine coolant
E05 (male)
Resistance
temperature
Between (1) and (2)
3.5 k 90 kz
10 100 C
Between (2) and
Min. 1 Mz
chassis ground
aPrepare with starting switch OFF, then carry out troubleshooting without turning starting switch.
Wiring harness between P02 (female) (1) and
Resistance Max. 1 z
E05 (female) (2)
Wiring harness between P02 (female) (13) and
Resistance
E05 (female) (1)

Max. 1 z

aPrepare with starting switch OFF, then carry out troubleshooting without turning starting switch.
Between P02 (female) (1) E05 (female) (2)
Resistance Min. 1 Mz
wiring harness and chassis ground
aPrepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting.
Between P02 (female) (1) E05 (female) (2)
Voltage
Max. 1 V
wiring harness and chassis ground
aPrepare with starting switch OFF, then carry out troubleshooting without turning starting switch.
P02

Engine coolant
temperature

Between (1) and (13)


Between (1) and
chassis ground

10 100 C

Resistance
3.5 k 90 kz
Min. 1 Mz

Circuit diagram related to engine coolant temperature sensor

20-430
(1)

PC130-7

E-17

TROUBLESHOOTING

E-17 Fuel level gauge is abnormal


Trouble
Related
information

(1) While fuel level is high, gauge does not rise from red range (E).
(2) While fuel level is low, gauge does not lower from green range (F).
The input state (ON/OFF) from the fuel level sensor can be checked with the monitoring function.
(Code: 042, by 10 mV)
Cause

Standard value in normal state/Remarks on troubleshooting


aPrepare with starting switch OFF, then carry out troubleshooting without turning starting switch.
Defective fuel level sensor
A60 (male)
Fuel level
Resistance
1 (Internal disconnection or
short circuit)
FULL
(Upper
limit)
Approx.
12 z
Between (1) and
chassis ground

Possible causes
and standard
value in normal
state

Disconnection in wiring
harness
2 (Disconnection in wiring
harness or defective
contact in connector)
Short circuit with chassis
ground in wiring harness
3
(Contact with ground
circuit)
Short circuit with power
4 source in wiring harness
(Contact with 24-V circuit)

EMPTY (Lower limit)

85 120 z

aPrepare with starting switch OFF, then carry out troubleshooting without turning starting switch.
Wiring harness between P02 (female) (2) and
A60 (female) (1)

Resistance

Max. 1 z

aPrepare with starting switch OFF, then carry out troubleshooting without turning starting switch.
Between P02 (female) (2) A60 (female) (1)
Resistance Min. 1 Mz
wiring harness and chassis ground
aPrepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting.
Between P02 (female) (2) A60 (female) (1)
wiring harness and chassis ground

Voltage

Max. 1 V

aPrepare with starting switch OFF, then carry out troubleshooting without turning starting switch.
6 Defective monitor panel

P02
Between (2) and
chassis ground

Fuel level
FULL (Upper limit)

Resistance
Approx. 12 z

EMPTY (Lower limit)

85 120 z

Circuit diagram related to fuel level sensor

PC130-7

20-431
(1)

E-18

TROUBLESHOOTING

E-18 Swing lock monitor is abnormal


Trouble
Related
information

(1) When swing lock switch is set in LOCK position, swing lock monitor does not light up.
(2) When swing lock switch is set in OFF position, swing lock monitor does not go off.
If the swing holding brake release switch is set in the RELEASE position, the swing lock monitor flashes.
The input state (ON/OFF) from the swing lock switch can be checked with the monitoring function.
(Code: 022, Left of upper line, 049, Right of upper line)
Cause
Defective swing lock switch
1 (Internal disconnection or
short circuit)

Disconnection in wiring
harness
2 (Disconnection in wiring
harness or defective
contact in connector)
Possible causes
and standard
value in normal
state

Short circuit with chassis


ground in wiring harness
3
(Contact with ground
circuit)

Short circuit with power


4 source in wiring harness
(Contact with 24-V circuit)

5 Defective monitor panel

Standard value in normal state/Remarks on troubleshooting


aPrepare with starting switch OFF, then carry out troubleshooting without turning starting switch.
X05 (female)
Swing lock switch
Resistance
Between (1) and (2)

(1)

Min. 1 Mz
Max. 1 z

aPrepare with starting switch OFF, then carry out troubleshooting without turning starting switch.
Wiring harness between P02 (female) (17) and
Resistance
J02 and X05 (male) (1)

Max. 1 z

Wiring harness between X05 (male) (2) and


Resistance Max. 1 z
J05 and chassis ground (A13)
aPrepare with starting switch OFF, then carry out troubleshooting without turning starting switch.
Between P02 (female) (17) J02 X05 (male)
Resistance Min. 1 Mz
(1) or C02 (female) (38) wiring harness and
chassis ground
aPrepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting.
Between P02 (female) (17) J02 X05 (male)
(1) or C02 (female) (38) wiring harness and
Voltage
Max. 1 V
chassis ground
aPrepare with starting switch OFF, then carry out troubleshooting without turning starting switch.
P02
Swing lock switch
Voltage
Between (17) and
chassis ground

20-432

OFF
LOCK

OFF
LOCK

20 30 V
Max. 1 V

PC130-7

TROUBLESHOOTING

E-18

Circuit diagram related to swing lock switch

PC130-7

20-433
(1)

E-19

TROUBLESHOOTING

E-19 When monitor switch is operated, display by lamp does not change
Trouble
Related
information
Possible causes
and standard
value in normal
state

20-434
(1)

When monitor switch is operated, display by lamp does not change.

Cause
1 Defective monitor panel

Standard value in normal state/Remarks on troubleshooting


Troubleshooting cannot be carried out since the defect is in the monitor
panel.

PC130-7

E-20

TROUBLESHOOTING

E-20 Windshield wiper and windshield washer do not operate


Trouble
Related
information

(1) Windshield wiper does not operate.


The input state (ON/OFF) from the window rear limit switch can be checked with the monitoring function.
(Code: 049, Center of upper line)
Cause

Standard value in normal state/Remarks on troubleshooting

aPrepare with starting switch OFF, then carry out troubleshooting withDefective window rear limit
out turning starting switch.
switch
W03 (male)
Front window
Resistance
1
(Internal disconnection or
When installed to front
Min. 1 Mz
short circuit)
Between (1) and (2)
When stored in rear
Max. 1 z
aPrepare with starting switch OFF, then carry out troubleshooting without turning starting switch.
Defective wiper motor
2
(Internal disconnection)
W04 (female)
Continuity

Possible causes
and standard
value in normal
state

Disconnection in wiring
harness
3 (Disconnection in wiring
harness or defective
contact in connector)
Short circuit with chassis
ground in wiring harness
4
(Contact with ground
circuit)
Defective monitor panel
(Window rear limit switch
system)

5
Defective monitor panel
(Wiper motor system)

20-436
(1)

Between (3) and (1)


There is continuity
aPrepare with starting switch OFF, then carry out troubleshooting without turning starting switch.
Wiring harness between P01 (female) (9) and
W04 (male) (3)

Resistance

Max. 1 z

Wiring harness between P01 (female) (10) and


Resistance
W04 (male) (1)

Max. 1 z

aPrepare with starting switch OFF, then carry out troubleshooting without turning starting switch.
Between P02 (female) (15) W03 (female) (1)
Resistance Min. 1 Mz
wiring harness and chassis ground
aPrepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting.
P02
Front window
Voltage
Between (15) and
chassis ground

When installed to front


When stored in rear

20 30 V
Max. 1 V

aPrepare with starting switch OFF, then carry out troubleshooting without turning starting switch.
P01
Wiper switch
Voltage
Between (9) and
chassis ground
Between (10) and
chassis ground

OFF

Max. 1 V

ON

Max. 1 V 20 30 V
(Constant period)

PC130-7

TROUBLESHOOTING

E-20

Circuit diagram related to wiper motor and window rear limit switch

PC130-7

20-437
(1)

E-20

TROUBLESHOOTING

Trouble

(2) Windshield washer does not operate.

Related
information
Cause
1 Defective fuse No. 4

Defective washer motor


2 (Internal disconnection or
short circuit)

Possible causes
and standard
value in normal
state

Disconnection in wiring
harness
3 (Disconnection in wiring
harness or defective
contact in connector)

Short circuit with chassis


ground in wiring harness
4
(Contact with ground
circuit)

Standard value in normal state/Remarks on troubleshooting


If the fuse is broken, the circuit probably has a grounding fault, etc.
(See cause 4.)
aPrepare with starting switch OFF, then carry out troubleshooting without turning starting switch.
A50 (male)
Between (1) and (2)

Resistance
5 20 z

Between (1) and chassis ground


Min. 1 Mz
aPrepare with starting switch OFF, then carry out troubleshooting without turning starting switch.
Wiring harness between FB1 4 and J03 and
J06 and A50 (female) (1)

Resistance

Max. 1 z

Wiring harness between A50 (female) (2) and


J04 and P01 (female) (3)

Resistance

Max. 1 z

aPrepare with starting switch OFF, then carry out troubleshooting without turning starting switch.
Between FB1-4 J03 J06 A50 (female) (1)
or D02 (female) (4) wiring harness and chassis Resistance Min. 1 Mz
ground
Between A50 (female) (2) J04 P01 (female)
Resistance Min. 1 Mz
(3) or D02 (female) (8) wiring harness and
chassis ground
aPrepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting.

5 Defective monitor panel

P01
Between (3) and
chassis ground

20-438
(1)

Windshield washer
switch
When OFF

20 30 V

When ON

Max. 1 V

Voltage

PC130-7

TROUBLESHOOTING

E-20

Circuit diagram related to windshield washer motor

PC130-7

20-439
(1)

E-21

TROUBLESHOOTING

E-21 Lower windshield wiper does not operate


Trouble

Lower windshield wiper does not operate.

Related
information
Cause
1 Defective fuse No. 6

Defective lower wiper


2 switch
(Internal disconnection)

Standard value in normal state/Remarks on troubleshooting


If the fuse is broken, the circuit probably has a grounding fault, etc.
(See cause 6.)
aPrepare with starting switch OFF, then carry out troubleshooting without turning starting switch.
P06 (female)
Lower wiper switch
Resistance
Between (1) and (2)

When OFF
When ON

Min. 1 Mz
Max. 1 z

aPrepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting.
M92 (female)
Between (1) and
chassis ground
Defective lower wiper
3 motor
(Internal disconnection)

Possible causes
and standard
value in normal
state

20 30 V
Max. 1 z
ON
20 30 V

aPrepare with starting switch OFF, then carry out troubleshooting without turning starting switch.

Short circuit with chassis


ground in wiring harness
6
(Contact with ground
circuit)

(1)

Between (3) and


chassis ground

Resistance

Between (4) and


Max. 1 V
chassis ground
If the voltage and resistance are normal and the lower windshield wiper
does not operate, the lower wiper motor is defective.
aReplace relay while starting switch is OFF, then turn starting switch ON
and carry out troubleshooting.
Defective lower wiper relay
4
(Internal disconnection)
When the right lower wiper relay is replaced with another
R18
one, if the condition becomes normal, the relay is defective.

Disconnection in wiring
harness
5 (Disconnection in wiring
harness or defective
contact in connector)

20-440

Between (2) and


chassis ground

Lower wiper switch

Wiring harness between FB1-6 outlet and J10


and M92 (female) (3) or R18 (female) (5) or
P06 (male) (1)

Resistance

Max. 1 z

Wiring harness between R18 (female) (1) and


P06 (male) (2)

Resistance

Max. 1 z

Wiring harness between M92 (female) (2), D03


(female) (5), R18 (female) (2) and J09 and
Resistance
chassis ground (T05)

Max. 1 z

Wiring harness between R18 (female) (3) and


D03 (female) (1) or M92 (female) (1)

Resistance

Max. 1 z

Wiring harness between R18 (female) (6) and


M92 (female) (6)

Resistance

Max. 1 z

aPrepare with starting switch OFF, then carry out troubleshooting without turning starting switch.
Between FB1-6 outlet J10 M92 (female) (3)
or R18 (female) (5) or P06 (male) (1) wiring har- Resistance Min. 1 Mz
ness and chassis ground
Between R18 (female) (1) P06 (male) (2) wirResistance Min. 1 Mz
ing harness and chassis ground
Between R18 (female) (3) D03 (female) (1) or
Resistance Min. 1 Mz
M92 (female) (1) wiring harness and chassis
ground
Between R18 (female) (6) M92 (female) (6)
Resistance Min. 1 Mz
wiring harness and chassis ground

PC130-7

TROUBLESHOOTING

E-21

Circuit diagram related to lower windshield wiper

PC130-7

20-441
(1)

E-22

TROUBLESHOOTING

E-22 Caution buzzer does not stop


Trouble
Related
information

Caution buzzer does not stop.


The input state (ON/OFF) from the caution buzzer stop switch can be checked with the monitoring function. (Code: 045, Right of upper line)
Cause

Standard value in normal state/Remarks on troubleshooting


aPrepare with starting switch OFF, then carry out troubleshooting without turning starting switch.

Defective caution buzzer


1 stop switch
(Internal disconnection)

Possible causes
and standard
value in normal
state

Disconnection in wiring
harness
2 (Disconnection in wiring
harness or defective
contact in connector)
Short circuit with power
3 source in wiring harness
(Contact with 24-V circuit)

P03 (female)

Caution buzzer
stop switch

Resistance

Between (1) and (2)

Released
Pressed

Min. 1 Mz
Max. 1 z

aPrepare with starting switch OFF, then carry out troubleshooting without turning starting switch.
Wiring harness between P02 (female) (16) and
Resistance Max. 1 z
P03 (male) (1)
Wiring harness between P03 (male) (2) and
Resistance Max. 1 z
J05 and chassis ground (A13)
aPrepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting.
Between P02 (female) (16) P03 (male) (1)
wiring harness and chassis ground

Voltage

Max. 1 V

aPrepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting.
5 Defective monitor panel

P02
Between (16) and
chassis ground

20-442
(1)

Caution buzzer
stop switch
Released

20 30 V

Pressed

Max. 1 V

Voltage

PC130-7

TROUBLESHOOTING

E-22

Circuit diagram related to caution buzzer stop switch

PC130-7

20-443
(1)

E-23

TROUBLESHOOTING

E-23 Monitoring function does not display "Boom RAISE" normally


Trouble
Related
information

Monitoring function does not display The monitoring function (special function) of the monitor
"Boom RAISE" normally.
panel does not display "Boom RAISE" normally.
6-bit position of boom RAISE oil pressure switch (Code: 020, Center of lower line)
Cause
Defective boom RAISE oil
pressure switch
1
(Internal disconnection or
short circuit)

Possible causes
and standard
value in normal
state

Disconnection in wiring
harness
2 (Disconnection in wiring
harness or defective
contact in connector)
Short circuit with chassis
ground in wiring harness
3
(Contact with ground
circuit)
Short circuit with power
4 source in wiring harness
(Contact with 24-V circuit)

Standard value in normal state/Remarks on troubleshooting


aPrepare with starting switch OFF, then start engine and carry out troubleshooting.
Right work equipment
S06 (male)
Resistance
control lever
Between (1) and (2)

Neutral position
Boom RAISE position

Min. 1 Mz
Max. 1 z

aPrepare with starting switch OFF, then carry out troubleshooting without turning starting switch.
Wiring harness between C03 (female) (10) and
Resistance
S06 (female) (1)

Max. 1 z

Wiring harness between S06 (female) (2) and


Resistance Max. 1 z
chassis ground (A16)
aPrepare with starting switch OFF, then carry out troubleshooting without turning starting switch.
Between C03 (female) (10) S06 (female) (1)
Resistance Min. 1 Mz
wiring harness and chassis ground
aPrepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting.
Between C03 (female) (10) S06 (female) (1)
wiring harness and chassis ground

Voltage

Max. 1 V

aPrepare with starting switch OFF, then start engine and carry out troubleshooting.
5

Defective governor and


pump controller

C03
Between (10) and
chassis ground

20-444
(1)

Right work equipment


control lever
Neutral position

20 30 V

Boom RAISE position

Max. 1 V

Voltage

PC130-7

TROUBLESHOOTING

E-23

Circuit diagram related to boom RAISE oil pressure switch

PC130-7

20-445
(1)

E-24

TROUBLESHOOTING

E-24 Monitoring function does not display "Boom LOWER" normally


Trouble
Related
information

Monitoring function does not display The monitoring function (special function) of the monitor
"Boom LOWER" normally.
panel does not display "Boom LOWER" normally.
6-bit position of boom LOWER oil pressure switch (Code: 020, Center of upper line)
Cause

Standard value in normal state/Remarks on troubleshooting


aPrepare with starting switch OFF, then start engine and carry out troubleshooting.
Defective boom LOWER oil
Right work equipment
pressure switch
S02 (male)
Resistance
1
control lever
(Internal disconnection or
short circuit)
Neutral position
Min. 1 Mz
Between (1) and (2)
Boom LOWER position
Max. 1 z

Possible causes
and standard
value in normal
state

Disconnection in wiring
harness
2 (Disconnection in wiring
harness or defective
contact in connector)
Short circuit with chassis
ground in wiring harness
3
(Contact with ground
circuit)
Short circuit with power
4 source in wiring harness
(Contact with 24-V circuit)

aPrepare with starting switch OFF, then carry out troubleshooting without turning starting switch.
Wiring harness between C03 (female) (20) and
Resistance
S02 (female) (1)

Max. 1 z

Wiring harness between S02 (female) (2) and


Resistance Max. 1 z
chassis ground (A16)
aPrepare with starting switch OFF, then carry out troubleshooting without turning starting switch.
Between C03 (female) (20) S02 (female) (1)
Resistance Min. 1 Mz
wiring harness and chassis ground
aPrepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting.
Between C03 (female) (20) S02 (female) (1)
wiring harness and chassis ground

Voltage

Max. 1 V

aPrepare with starting switch OFF, then start engine and carry out troubleshooting.
5

Defective governor and


pump controller

C03
Between (10) and
chassis ground

20-446
(1)

Right work equipment


control lever
Neutral position

20 30 V

Boom LOWER position

Max. 1 V

Voltage

PC130-7

TROUBLESHOOTING

E-24

Circuit diagram related to boom LOWER oil pressure switch

PC130-7

20-447
(1)

E-25

TROUBLESHOOTING

E-25 Monitoring function does not display "Arm IN" normally


Trouble
Related
information

Monitoring function does not display "Arm The monitoring function (special function) of the monitor
IN" normally.
panel does not display "Arm IN" normally.
6-bit position of arm IN oil pressure switch (Code: 020, Left of upper line)
Cause
Defective arm IN oil
pressure switch
1
(Internal disconnection or
short circuit)

Possible causes
and standard
value in normal
state

Disconnection in wiring
harness
2 (Disconnection in wiring
harness or defective
contact in connector)
Short circuit with chassis
ground in wiring harness
3
(Contact with ground
circuit)
Short circuit with power
4 source in wiring harness
(Contact with 24-V circuit)

Standard value in normal state/Remarks on troubleshooting


aPrepare with starting switch OFF, then start engine and carry out troubleshooting.
Left work equipment
S04 (male)
Resistance
control lever
Between (1) and (2)

Neutral position
Arm IN position

Min. 1 Mz
Max. 1 z

aPrepare with starting switch OFF, then carry out troubleshooting without turning starting switch.
Wiring harness between C03 (female) (30) and
Resistance
S04 (female) (1)

Max. 1 z

Wiring harness between S04 (female) (2) and


Resistance Max. 1 z
chassis ground (A16)
aPrepare with starting switch OFF, then carry out troubleshooting without turning starting switch.
Between C03 (female) (30) S04 (female) (1)
Resistance Min. 1 Mz
wiring harness and chassis ground
aPrepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting.
Between C03 (female) (30) S04 (female) (1)
wiring harness and chassis ground

Voltage

Max. 1 V

aPrepare with starting switch OFF, then start engine and carry out troubleshooting.
5

Defective governor and


pump controller

C03
Between (30) and
chassis ground

20-448
(1)

Left work equipment


control lever
Neutral position

20 30 V

Arm IN position

Max. 1 V

Voltage

PC130-7

TROUBLESHOOTING

E-25

Circuit diagram related to arm IN oil pressure switch

PC130-7

20-449
(1)

E-26

TROUBLESHOOTING

E-26 Monitoring function does not display "Arm OUT" normally


Trouble
Related
information

Monitoring function does not display "Arm The monitoring function (special function) of the monitor
OUT" normally.
panel does not display "Arm OUT" normally.
6-bit position of arm OUT oil pressure switch (Code: 020, Left of lower line)
Cause
Defective arm OUT oil
pressure switch
1
(Internal disconnection or
short circuit)

Possible causes
and standard
value in normal
state

Disconnection in wiring
harness
2 (Disconnection in wiring
harness or defective
contact in connector)
Short circuit with chassis
ground in wiring harness
3
(Contact with ground
circuit)
Short circuit with power
4 source in wiring harness
(Contact with 24-V circuit)

Standard value in normal state/Remarks on troubleshooting


aPrepare with starting switch OFF, then start engine and carry out troubleshooting.
Left work equipment
S08 (male)
Resistance
control lever
Between (1) and (2)

Neutral position
Arm OUT position

Min. 1 Mz
Max. 1 z

aPrepare with starting switch OFF, then carry out troubleshooting without turning starting switch.
Wiring harness between C03 (female) (40) and
Resistance
S08 (female) (1)

Max. 1 z

Wiring harness between S08 (female) (2) and


Resistance Max. 1 z
chassis ground (A16)
aPrepare with starting switch OFF, then carry out troubleshooting without turning starting switch.
Between C03 (female) (40) S08 (female) (1)
Resistance Min. 1 Mz
wiring harness and chassis ground
aPrepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting.
Between C03 (female) (40) S08 (female) (1)
wiring harness and chassis ground

Voltage

Max. 1 V

aPrepare with starting switch OFF, then start engine and carry out troubleshooting.
5

Defective governor and


pump controller

C03
Between (40) and
chassis ground

20-450
(1)

Left work equipment


control lever
Neutral position

20 30 V

Arm OUT position

Max. 1 V

Voltage

PC130-7

TROUBLESHOOTING

E-26

Circuit diagram related to arm OUT oil pressure switch

PC130-7

20-451
(1)

E-27

TROUBLESHOOTING

E-27 Monitoring function does not display "Bucket CURL" normally


Trouble
Related
information

Monitoring function does not display The monitoring function (special function) of the monitor
"Bucket CURL" normally.
panel does not display "Bucket CURL" normally.
6-bit position of bucket CURL oil pressure switch (Code: 021, Right of upper line)
Cause

Standard value in normal state/Remarks on troubleshooting


aPrepare with starting switch OFF, then start engine and carry out troubleshooting.
Defective bucket CURL oil
Right work equipment
pressure switch
S01 (male)
Resistance
1
control lever
(Internal disconnection or
short circuit)
Neutral position
Min. 1 Mz
Between (1) and (2)
Bucket CURL position
Max. 1 z

Possible causes
and standard
value in normal
state

Disconnection in wiring
harness
2 (Disconnection in wiring
harness or defective
contact in connector)
Short circuit with chassis
ground in wiring harness
3
(Contact with ground
circuit)
Short circuit with power
4 source in wiring harness
(Contact with 24-V circuit)

aPrepare with starting switch OFF, then carry out troubleshooting without turning starting switch.
Wiring harness between C03 (female) (9) and
S01 (female) (1)

Resistance

Max. 1 z

Wiring harness between S01 (female) (2) and


Resistance Max. 1 z
chassis ground (A16)
aPrepare with starting switch OFF, then carry out troubleshooting without turning starting switch.
Between C03 (female) (9) S01 (female) (1)
Resistance Min. 1 Mz
wiring harness and chassis ground
aPrepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting.
Between C03 (female) (9) S01 (female) (1)
wiring harness and chassis ground

Voltage

Max. 1 V

aPrepare with starting switch OFF, then start engine and carry out troubleshooting.
5

Defective governor and


pump controller

C03
Between (9) and
chassis ground

20-452
(1)

Right work equipment


control lever
Neutral position

20 30 V

Bucket CURL position

Max. 1 V

Voltage

PC130-7

TROUBLESHOOTING

E-27

Circuit diagram related to bucket CURL oil pressure switch

PC130-7

20-453
(1)

E-28

TROUBLESHOOTING

E-28 Monitoring function does not display "Bucket DUMP" normally


Trouble
Related
information

Monitoring function does not display The monitoring function (special function) of the monitor
"Bucket DUMP" normally.
panel does not display "Bucket DUMP" normally.
6-bit position of bucket DUMP oil pressure switch (Code: 021, Right of lower line)
Cause

Standard value in normal state/Remarks on troubleshooting


aPrepare with starting switch OFF, then start engine and carry out troubleshooting.
Defective bucket DUMP oil
Right work equipment
pressure switch
S05 (male)
Resistance
1
control lever
(Internal disconnection or
short circuit)
Neutral position
Min. 1 Mz
Between (1) and (2)
Bucket DUMP position
Max. 1 z

Possible causes
and standard
value in normal
state

Disconnection in wiring
harness
2 (Disconnection in wiring
harness or defective
contact in connector)
Short circuit with chassis
ground in wiring harness
3
(Contact with ground
circuit)
Short circuit with power
4 source in wiring harness
(Contact with 24-V circuit)

aPrepare with starting switch OFF, then carry out troubleshooting without turning starting switch.
Wiring harness between C03 (female) (19) and
Resistance
S05 (female) (1)

Max. 1 z

Wiring harness between S05 (female) (2) and


Resistance Max. 1 z
chassis ground (A16)
aPrepare with starting switch OFF, then carry out troubleshooting without turning starting switch.
Between C03 (female) (19) S05 (female) (1)
Resistance Min. 1 Mz
wiring harness and chassis ground
aPrepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting.
Between C03 (female) (19) S05 (female) (1)
wiring harness and chassis ground

Voltage

Max. 1 V

aPrepare with starting switch OFF, then start engine and carry out troubleshooting.
5

Defective governor and


pump controller

C03
Between (19) and
chassis ground

20-454
(1)

Right work equipment


control lever
Neutral position

20 30 V

Bucket DUMP position

Max. 1 V

Voltage

PC130-7

TROUBLESHOOTING

E-28

Circuit diagram related to bucket DUMP oil pressure switch

PC130-7

20-455
(1)

E-29

TROUBLESHOOTING

E-29 Monitoring function does not display "Swing" normally


Trouble
Related
information

Monitoring function does not display The monitoring function (special function) of the monitor
"Swing" normally.
panel does not display "Swing" normally.
6-bit position of swing oil pressure switch (Code: 0201, Right of upper line)
Cause
Defective swing LEFT oil
pressure switch
1
(Internal disconnection or
short circuit)

Defective swing RIGHT oil


pressure switch
2
(Internal disconnection or
short circuit)

Possible causes
and standard
value in normal
state

Disconnection in wiring
harness
3 Disconnection in wiring
harness or defective
contact in connector)

Short circuit with chassis


ground in wiring harness
4
(Contact with ground
ircuit)

Short circuit with power


5 source in wiring harness
(Contact with 24-V circuit)

Standard value in normal state/Remarks on troubleshooting


aPrepare with starting switch OFF, then start engine and carry out troubleshooting.
Left work equipment
S03 (male)
Resistance
control lever
Between (1) and (2)

Neutral position
Swing LEFT position

Min. 1 Mz
Max. 1 z

aPrepare with starting switch OFF, then start engine and carry out troubleshooting.
S07 (male)

Left work equipment


control lever

Resistance

Between (1) and (2)

Neutral position
Swing RIGHT position

Min. 1 Mz
Max. 1 z

aPrepare with starting switch OFF, then carry out troubleshooting without turning starting switch.
Wiring harness between C03 (female) (29) and
Resistance Max. 1 z
S03 (female) (1) or S07 (female) (1)
Wiring harness between S03 (female) (2) and
Resistance Max. 1 z
chassis ground (A16)
Wiring harness between S07 (female) (2) and
Resistance Max. 1 z
chassis ground (A16)
aPrepare with starting switch OFF, then carry out troubleshooting without turning starting switch.
Between C03 (female) (29) S03 (female) (1)
or S07 (female) (1) wiring harness and chassis Resistance Min. 1 Mz
ground
aPrepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting.
Between C03 (female) (29) S03 (female) (1)
or S07 (female) (1) wiring harness and chassis
ground

Voltage

Max. 1 V

aPrepare with starting switch OFF, then start engine and carry out troubleshooting.
6

20-456
(1)

Defective governor and


pump controller

C03

Left work equipment


control lever

Between (29) and


chassis ground

Neutral position
Swing LEFT or RIGHT
position

Voltage
20 30 V
Max. 1 V

PC130-7

TROUBLESHOOTING

E-29

Circuit diagram related to swing LEFT oil pressure switch and RIGHT oil pressure switch

PC130-7

20-457
(1)

E-30

TROUBLESHOOTING

E-30 Monitoring function does not display "Travel" normally


Trouble
Related
information

Monitoring function does not display The monitoring function (special function) of the monitor
"Travel" normally.
panel does not display "Travel" normally.
6-bit position of travel oil pressure switch (Code: 020, Right of lower line)
Cause
Defective travel oil pressure switch
1
(Internal disconnection or
short circuit)

Disconnection in wiring
harness
2 (Disconnection in wiring
harness or defective
contact in connector)
Possible causes
and standard
value in normal
state

Short circuit with chassis


ground in wiring harness
3
(Contact with ground
circuit)
Short circuit with power
4 source in wiring harness
(Contact with 24-V circuit)

20-458
(1)

Defective governor and


pump controller

Standard value in normal state/Remarks on troubleshooting


aPrepare with starting switch OFF, then start engine and carry out troubleshooting.
S30 (male)
Travel lever
Resistance
Between (1) and (2)

Neutral position
Forward or reverse
operation

Min. 1 Mz
Max. 1 z

aPrepare with starting switch OFF, then carry out troubleshooting without turning starting switch.
Wiring harness between C03 (female) (39) and
Resistance
S30 (female) (1)

Max. 1 z

Wiring harness between S30 (female) (1) and


Resistance Max. 1 z
chassis ground (A13)
aPrepare with starting switch OFF, then carry out troubleshooting without turning starting switch.
Between C03 (female) (39) J01 S30
Resistance Min. 1 Mz
(female) (1) and A43 (female) (2) wiring harness and chassis ground
aPrepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting.
Between C03 (female) (39) J01 S30
Voltage
Max. 1 V
(female) (1) wiring harness and chassis ground
aPrepare with starting switch OFF, then start engine and carry out troubleshooting.
C03
Between (39) and
chassis ground

Travel lever
Neutral position

Voltage
20 30 V

Forward or reverse
operation

Max. 1 V

PC130-7

TROUBLESHOOTING

E-30

Circuit diagram related to travel oil pressure switch and travel alarm

PC130-7

20-459
(1)

E-31

TROUBLESHOOTING

E-31 Monitoring function does not display "service" normally


When 1 attachment is installed
Trouble
Related
information

Monitoring function does not display


"Service" normally.

6-bit position of service oil pressure switch (Code: 0201, Center of lower line)
Cause
Defective service 1 (front)
oil pressure switch
1
(Internal disconnection or
short circuit)

Defective service 1 (rear)


oil pressure switch
2
(Internal disconnection or
short circuit)

Possible causes
and standard
value in normal
state

The monitoring function (special function) of the monitor


panel does not display "Service" normally.

Disconnection in wiring
harness
3 (Disconnection in wiring
harness or defective
contact in connector)

Short circuit with chassis


ground in wiring harness
4
(Contact with ground
circuit)

Short circuit with power


5 source in wiring harness
(Contact with 24-V circuit)

Standard value in normal state/Remarks on troubleshooting


aPrepare with starting switch OFF, then start engine and carry out troubleshooting.
S10 (male)
Between (1) and (2)

Service pedal 1
Neutral position

Resistance
Min. 1 Mz

Front position
Max. 1 z
aPrepare with starting switch OFF, then start engine and carry out troubleshooting.
S11 (male)
Service pedal 1
Resistance
Between (1) and (2)

Neutral position
Rear position

Min. 1 Mz
Max. 1 z

aPrepare with starting switch OFF, then carry out troubleshooting without turning starting switch.
Wiring harness between C02 (female) (35) and
Resistance Max. 1 z
S10 (female) (1) or S11 (female) (1)
Wiring harness between S10 (female) (2) and
Resistance Max. 1 z
chassis ground (A16)
Wiring harness between S11 (female) (2) and
Resistance Max. 1 z
chassis ground (A16)
aPrepare with starting switch OFF, then carry out troubleshooting without turning starting switch.
Between C02 (female) (35) S10 (female) (1)
or S11 (female) (1) wiring harness and chassis Resistance Min. 1 Mz
ground
aPrepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting.
Between C02 (female) (35) S10 (female) (1)
or S11 (female) (1) wiring harness and chassis
ground

Voltage

Max. 1 V

aPrepare with starting switch OFF, then start engine and carry out troubleshooting.
6

20-460
(1)

Defective governor and


pump controller

C02
Between (35) and
chassis ground

Service pedal 1
Neutral position

Voltage
20 30 V

Front or rear position

Max. 1 V

PC130-7

TROUBLESHOOTING

E-31

Circuit diagram related to service 1 oil pressure switches (front and rear)

PC130-7

20-461
(1)

E-31

TROUBLESHOOTING

When 2 attachments are installed


Trouble
Related
information

Monitoring function does not display


"Service" normally.

6-bit position of service oil pressure switch (Code: 0201, Center of lower line)
Cause
Defective service 1 (front)
oil pressure switch
1
(Internal disconnection or
short circuit)

Defective service 1 (rear)


oil pressure switch
2
(Internal disconnection or
short circuit)

Defective service 2 (front)


oil pressure switch
3
(Internal disconnection or
short circuit)

Defective service 2 (rear)


oil pressure switch
4
(Internal disconnection or
short circuit)

Possible causes
and standard
value in normal
state

Disconnection in wiring
harness
5 (Disconnection in wiring
harness or defective
contact in connector)

Short circuit with chassis


ground in wiring harness
6
(Contact with ground
circuit)

Short circuit with power


7 source in wiring harness
(Contact with 24-V circuit)

20-462
(1)

The monitoring function (special function) of the monitor


panel does not display "Service" normally.

Defective governor and


pump controller

Standard value in normal state/Remarks on troubleshooting


aPrepare with starting switch OFF, then start engine and carry out troubleshooting.
S10 (male)
Between (1) and (2)

Service pedal 1
Neutral position

Resistance
Min. 1 Mz

Front position
Max. 1 z
aPrepare with starting switch OFF, then start engine and carry out troubleshooting.
S11 (male)
Service pedal 1
Resistance
Between (1) and (2)

Neutral position
Rear position

Min. 1 Mz
Max. 1 z

aPrepare with starting switch OFF, then start engine and carry out troubleshooting.
Resistance
S21 (male)
Service pedal 2
Between (1) and (2)

Neutral position
Front position

Min. 1 Mz
Max. 1 z

aPrepare with starting switch OFF, then start engine and carry out troubleshooting.
S22 (male)
Between (1) and (2)

Service pedal 2
Neutral position

Resistance
Min. 1 Mz

Rear position
Max. 1 z
aPrepare with starting switch OFF, then carry out troubleshooting without turning starting switch.
Wiring harness between C02 (female) (35) and
Resistance Max. 1 z
S10 (female) (1) or S11 (female) (1) or S21
(female) (1) or S22 (female) (1)
Wiring harness between S10 (female) (2) and
Resistance Max. 1 z
chassis ground (A16)
Wiring harness between S11 (female) (2) and
Resistance Max. 1 z
chassis ground (A16)
Wiring harness between S21 (female) (2) and
chassis ground (A16)

Resistance

Max. 1 z

Wiring harness between S22 (female) (2) and


chassis ground (A16)

Resistance

Max. 1 z

aPrepare with starting switch OFF, then carry out troubleshooting without turning starting switch.
Between C02 (female) (35) S10 (female) (1)
or S11 (female) (1) or S21 (female) (1) or S22 Resistance Min. 1 Mz
(female) (1) wiring harness and chassis ground
aPrepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting.
Between C02 (female) (35) S10 (female) (1)
or S11 (female) (1) or S21 (female) (1) or S22
Voltage
Max. 1 V
(female) (1) wiring harness and chassis ground
aPrepare with starting switch OFF, then start engine and carry out troubleshooting.
C02
Service pedals 1 and 2
Voltage
Between (35) and
chassis ground

Neutral position
Front or rear position

20 30 V
Max. 1 V

PC130-7

TROUBLESHOOTING

E-31

Circuit diagram related to service 1 oil pressure switches (front and rear) and service 2 oil pressure
switches (front and rear)

PC130-7

20-463
(1)

E-32

TROUBLESHOOTING

E-32 Troubleshooting of air conditioner


Troubleshooting procedure for air conditioner system
a The control panel of the air conditioner constantly monitors the sensors and other devices in the system.
When it detects any abnormality, it displays "Self-diagnosis notice" on the display monitor by operating
switches specially.
a If you feel any abnormality in the air conditioner system, check the "Self-diagnosis notice" first according to
the procedure for "Troubleshooting by self-diagnosis notice", and then;
If the "Self-diagnosis notice" is displayed, continue the "Troubleshooting by self-diagnosis notice".
If the "Self-diagnosis notice" is not displayed, carry out the "Troubleshooting by trouble".

Troubleshooting by self-diagnosis notice


a Check the "Self-diagnosis notice" on the control
panel according to the following procedure.

How to display "Self-diagnosis notice"


1) Turn the starting switch ON.
2) Press OFF switch (1) and check that anything is not displayed on display monitor (2).
3) Hold the UP switch ( ) and DOWN switch
( ) of temperature setting switch (3) simultaneously for 3 seconds.
4) Check the "Self-diagnosis notice" displayed
on display monitor (2).

How to select "Self-diagnosis notice"


If multiple "Self-diagnosis notices" are recorded,
press the UP switch ( ) or DOWN switch ( ) of
temperature setting switch (3) to select another
notice.

Self-diagnosis notice

Trouble mode

E--

No trouble

E11

Disconnection in internal air sensor

How to delete "Self-diagnosis notice"


When reproducing the "Self-diagnosis notices"
or after removing the cause of a trouble, press
the switches on both sides of EXTERNAL/
INTERNAL air changeover switch (4) simultaneously for 3 seconds, and all the "Self-diagnosis notices" are deleted.

E12

Short circuit in internal air sensor

E15

Disconnection in water temperature sensor

E16

Short circuit in water temperature


sensor

E18

Short circuit in daylight sensor

Finishing display of "Self-diagnosis notice"


To finish display of the "Self-diagnosis notice",
press OFF switch (1) or turn the starting switch
OFF.

E43

Abnormality in air outlet damper

E44

Abnormality in air mix damper

E45

Abnormality in internal and external air damper

20-464
(1)

PC130-7

E-32

TROUBLESHOOTING

Self-diagnosis
notice
E11
Contents of
trouble
Action of
controller

Trouble

Disconnection in internal air sensor

Disconnection in the internal air sensor is detected.


Fixes the internal air temperature for control.
If the following condition is satisfied, the trouble is reset.
<Completion of removal of cause> + <Deletion of self-diagnosis notice> +
<Turning starting switch OFF and ON> + <Starting air conditioner>

Related
information
Cause
Defective internal air
1 sensor
(Internal disconnection)
Possible causes
and standard
value in normal
state

Disconnection in wiring
harness
2 (Disconnection in wiring
harness or defective
contact in connector)

Self-diagnosis
notice
E12
Contents of
trouble
Action of
controller

Defective air conditioner


system

Trouble

Standard value in normal state/Remarks on troubleshooting


aPrepare with starting switch OFF, then carry out troubleshooting without turning starting switch.
TH1 (male)
Between (1) and (2)

Resistance
300 z 430 kz

aPrepare with starting switch OFF, then carry out troubleshooting without turning starting switch.
Wiring harness between M30 (female) (12) and
Resistance
TH1 (female) (2)

Max. 1 z

Wiring harness between M29 (female) (11) and


Resistance Max. 1 z
TH1 (female) (1)
If neither of causes 1 and 2 is the cause of the trouble, the air conditioner system may be defective. See Shop Manual for Chassis Components, Troubleshooting for air conditioner.

Short circuit in internal air sensor

Short circuit in the internal air sensor is detected.


Fixes the internal air temperature for control.
If the following condition is satisfied, the trouble is reset.
<Completion of removal of cause> + <Deletion of self-diagnosis notice> +
<Turning starting switch OFF and ON> + <Starting air conditioner>

Related
information
Cause
Defective internal air
1 sensor
(Internal short circuit)
Possible causes
and standard
value in normal
state

Disconnection in wiring
harness
2 (Disconnection in wiring
harness or defective
contact in connector)

PC130-7

Defective air conditioner


system

Standard value in normal state/Remarks on troubleshooting


aPrepare with starting switch OFF, then carry out troubleshooting without turning starting switch.
Resistance
TH1 (male)
Between (1) and (2)
300 z 430 kz
aPrepare with starting switch OFF, then carry out troubleshooting without turning starting switch.
Wiring harness between M30 (female) (12) and
Resistance
TH1 (female) (2)

Max. 1 z

Wiring harness between M29 (female) (11) and


Resistance
TH1 (female) (1)

Max. 1 z

If neither of causes 1 and 2 is the cause of the trouble, the air conditioner system may be defective. See Shop Manual for Chassis Components, Troubleshooting for air conditioner.

20-465
(1)

E-32

TROUBLESHOOTING

Self-diagnosis
notice
E15
Contents of
trouble
Action of
controller

Trouble

Disconnection in water temperature sensor

Disconnection in the water temperature sensor is detected.


Ignores the warm-up control and fixes the water temperature at 60 C for control.
If the following condition is satisfied, the trouble is reset.
<Completion of removal of cause> + <Deletion of self-diagnosis notice> +
<Turning starting switch OFF and ON> + <Starting air conditioner>

Related
information
Cause
Defective water
1 temperature sensor
(Internal disconnection)
Possible causes
and standard
value in normal
state

Disconnection in wiring
harness
2 (Disconnection in wiring
harness or defective
contact in connector)

Self-diagnosis
notice
E16
Contents of
trouble
Action of
controller

Defective air conditioner


system

Trouble

Standard value in normal state/Remarks on troubleshooting


aPrepare with starting switch OFF, then carry out troubleshooting without turning starting switch.
THw (male)
Between (1) and (2)

Resistance
95 z 455 kz

aPrepare with starting switch OFF, then carry out troubleshooting without turning starting switch.
Wiring harness between M30 (female) (14) and
Resistance Max. 1 z
THw (female) (2)
Wiring harness between M29 (female) (11) and
Resistance Max. 1 z
THw (female) (1)
If neither of causes 1 and 2 is the cause of the trouble, the air conditioner system may be defective. See Shop Manual for Chassis Components, Troubleshooting for air conditioner.

Short circuit in water temperature sensor

Short circuit in the water temperature sensor is detected.


Ignores the warm-up control and fixes the water temperature at 60 C for control.
If the following condition is satisfied, the trouble is reset.
<Completion of removal of cause> + <Deletion of self-diagnosis notice> +
<Turning starting switch OFF and ON> + <Starting air conditioner>

Related
information
Cause
Defective water tempera1 ture sensor
(Internal short circuit)
Possible causes
and standard
value in normal
state

Disconnection in wiring
harness
2 (Disconnection in wiring
harness or defective
contact in connector)

20-466
(1)

Defective air conditioner


system

Standard value in normal state/Remarks on troubleshooting


aPrepare with starting switch OFF, then carry out troubleshooting without turning starting switch.
Resistance
THw (male)
Between (1) and (2)
95 z 455 kz
aPrepare with starting switch OFF, then carry out troubleshooting without turning starting switch.
Wiring harness between M30 (female) (14) and
Resistance
THw (female) (2)

Max. 1 z

Wiring harness between M29 (female) (11) and


Resistance
THw (female) (1)

Max. 1 z

If neither of causes 1 and 2 is the cause of the trouble, the air conditioner system may be defective. See Shop Manual for Chassis Components, Troubleshooting for air conditioner.

PC130-7

E-32

TROUBLESHOOTING

Self-diagnosis
notice
E18
Contents of
trouble
Action of
controller

Trouble

Short circuit in daylight sensor

Short circuit in the daylight sensor is detected.


Assumes that the daylight sensor is not installed for control.
If the following condition is satisfied, the trouble is reset.
<Completion of removal of cause> + <Deletion of self-diagnosis notice> +
<Turning starting switch OFF and ON> + <Starting air conditioner>

Related
information
Cause
Defective daylight sensor
1
(Internal short circuit)
Possible causes
and standard
value in normal
state

Disconnection in wiring
harness
2 (Disconnection in wiring
harness or defective
contact in connector)

Self-diagnosis
notice
E43
Contents of
trouble
Action of
controller

Defective air conditioner


system

Trouble

Standard value in normal state/Remarks on troubleshooting


The daylight sensor may be defective. Check it directly.
aPrepare with starting switch OFF, then carry out troubleshooting without turning starting switch.
Wiring harness between M30 (female) (16) and
Resistance Max. 1 z
P15 (female) (2)
Wiring harness between M30 (female) (3) and
Resistance Max. 1 z
P15 (female) (1)
If neither of causes 1 and 2 is the cause of the trouble, the air conditioner system may be defective. See Shop Manual for Chassis Components, Troubleshooting for air conditioner.

Abnormality in air outlet damper

Abnormality in the air outlet servomotor system is detected.


Stops the servomotor.
If the following condition is satisfied, the trouble is reset.
<Completion of removal of cause> + <Deletion of self-diagnosis notice> +
<Turning starting switch OFF and ON> + <Starting air conditioner>

Related
information

aDo not connect the power cables to the motor terminals directly to drive the motor. Doing so can damage the motor output shaft and break the motor coils.

Possible causes
and standard
value in normal
state

Cause
Standard value in normal state/Remarks on troubleshooting
Defective air outlet
1
The air outlet servomotor may be defective. Check it directly.
servomotor (Internal defect)
aPrepare with starting switch OFF, then carry out troubleshooting without
turning starting switch.
Wiring harness between Mv1 (female) (1) and
Resistance Max. 1 z
M30 (female) (3)
Disconnection in wiring
Wiring harness between Mv1 (female) (3) and
Resistance Max. 1 z
harness
M29 (female) (11)
2 (Disconnection in wiring
Wiring harness between Mv1 (female) (5) and
harness or defective
Resistance Max. 1 z
M30 (female) (9)
contact in connector)
Wiring harness between Mv1 (female) (6) and
Resistance Max. 1 z
M29 (female) (8)
Wiring harness between Mv1 (female) (7) and
Resistance Max. 1 z
M29 (female) (9)
If neither of causes 1 and 2 is the cause of the trouble, the air conditioner
Defective air conditioner
3
system may be defective. See Shop Manual for Chassis Components,
system
Troubleshooting for air conditioner.

PC130-7

20-467
(1)

E-32

TROUBLESHOOTING

Self-diagnosis
notice
E44
Contents of
trouble
Action of
controller
Related
information

Trouble

Abnormality in air mix damper

Abnormality in the air mix servomotor system is detected.


Stops the air mix servomotor.
If the following condition is satisfied, the trouble is reset.
<Completion of removal of cause> + <Deletion of self-diagnosis notice> +
<Turning starting switch OFF and ON> + <Starting air conditioner>
aDo not connect the power cables to the motor terminals directly to drive the motor. Doing so can damage the motor output shaft and break the motor coils.
Cause
Defective air mix
1 servomotor
(Internal defect)

Possible causes
and standard
value in normal
state

(1)

The air mix servomotor may be defective. Check it directly.


aPrepare with starting switch OFF, then carry out troubleshooting without
turning starting switch.
Wiring harness between MAM (female) (1) and
Resistance Max. 1 z
M29 (female) (11)

Disconnection in wiring
harness
2 (Disconnection in wiring
harness or defective
contact in connector)

20-468

Standard value in normal state/Remarks on troubleshooting

Defective air conditioner


system

Wiring harness between MAM (female) (3) and


M30 (female) (3)

Resistance

Max. 1 z

Wiring harness between MAM (female) (5) and


M30 (female) (2)

Resistance

Max. 1 z

Wiring harness between MAM (female) (6) and


Resistance Max. 1 z
M29 (female) (4)
Wiring harness between MAM (female) (7) and
Resistance Max. 1 z
M29 (female) (5)
If neither of causes 1 and 2 is the cause of the trouble, the air conditioner
system may be defective. See Shop Manual for Chassis Components,
Troubleshooting for air conditioner.

PC130-7

E-32

TROUBLESHOOTING

Self-diagnosis
notice
E45
Contents of
trouble
Action of
controller
Related
information

Trouble

Abnormality in air mix damper

Abnormality in the internal and external air servomotor is detected.


Stops the internal and external air servomotor.
If the following condition is satisfied, the trouble is reset.
<Completion of removal of cause> + <Deletion of self-diagnosis notice> +
<Turning starting switch OFF and ON> + <Starting air conditioner>
aDo not connect the power cables to the motor terminals directly to drive the motor. Doing so can damage the motor output shaft and break the motor coils.
Cause
Defective internal and
1 external air servomotor
(Internal defect)
2 Defective fuse (in unit)

Possible causes
and standard
value in normal
state

Disconnection in wiring
harness
3 (Disconnection in wiring
harness or defective
contact in connector)

PC130-7

Defective air conditioner


system

Standard value in normal state/Remarks on troubleshooting


The internal and external air servomotor may be defective. Check it
directly.
If the fuse (in the unit) is broken, the circuit probably has a grounding
fault, etc. Check the related circuits.
aPrepare with starting switch OFF, then carry out troubleshooting without
turning starting switch.
Wiring harness between MRF (female) (1) and
M29 (female) (6)

Resistance

Max. 1 z

Wiring harness between MRF (female) (3) and


M29 (female) (7)

Resistance

Max. 1 z

Wiring harness between MRF (female) (7) and


Resistance Max. 1 z
fuse in unit and M33 (male) (3)
If neither of causes 1 and 2 is the cause of the trouble, the air conditioner
system may be defective. See Shop Manual for Chassis Components,
Troubleshooting for air conditioner.

20-469
(1)

TROUBLESHOOTING

E-32

Circuit diagram related to air conditioner

20-470
(1)

PC130-7

E-32

TROUBLESHOOTING

Troubleshooting by trouble
Trouble
Related
information

(1) Air conditioner does not operate at all.

Cause
1 Defective fuse No. 11

Disconnection in wiring
harness
2 (Disconnection in wiring
harness or defective
contact in connector)

Standard value in normal state/Remarks on troubleshooting


If the fuse is broken, the circuit probably has a grounding fault, etc.
(See cause 3.)
aPrepare with starting switch OFF, then carry out troubleshooting without turning starting switch.
Wiring harness between FB1-11 outlet and M33
Resistance Max. 1 z
(female) (3)
Wiring harness between M27 (female) (14) and
Resistance Max. 1 z
M30 (female) (6)
Wiring harness between M33 (female) (2) and
Resistance Max. 1 z
chassis ground (A13)
Wiring harness between M29 (female) (12) and
Resistance
chassis ground (A13)

Possible causes
and standard
value in normal
state

Short circuit with chassis


ground in wiring harness
3
(Contact with ground
circuit)

Defective air conditioner


unit

Max. 1 z

aPrepare with starting switch OFF, then carry out troubleshooting without turning starting switch.
Between FB1-11 outlet M33 (female) (3) wirResistance Min. 1 Mz
ing harness and chassis ground
Between M27 (female) (14) M30 (female) (6)
Resistance Min. 1 Mz
wiring harness and chassis ground
aPrepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting.
M33
Voltage
Between (2) and (3)
20 30 V
If the above voltage is normal and the air conditioner unit does not operate, the air conditioner unit is defective.
aPrepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting.

5 Defective control panel

M30, M29
Between M30 (6) and M29 (12)

Voltage
20 30 V

If the above voltage is normal and the control panel does not operate,
the control panel is defective.

PC130-7

20-471
(1)

E-32

TROUBLESHOOTING

Trouble

(2) Air does not come out (Air flow is insufficient).

Related
information
Cause
1 Defective fuse (in unit)

Defective blower relay


(coil side)

Defective blower relay


(contact side)

Defective power transistor


(Internal defect)

Standard value in normal state/Remarks on troubleshooting


If the fuse (in the unit) is broken, the circuit probably has a grounding
fault, etc. Check the related circuits.
aPrepare with starting switch OFF, then carry out troubleshooting without turning starting switch.
R30 (male)
Between (1) and (3)

Resistance
140 340 z

aPrepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting.
R30
Fan switch
Voltage
Between (4) and
chassis ground

ON (Operation)
position

20 30 V

aPrepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting.
Fan switch
If air flow changes as fan switch is
Operate between Low and Medium operated, power transistor is normal.
and High.
aPrepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting.

5
Possible causes
and standard
value in normal
state

Defective blower motor


(Internal defect)

MB (female)

Fan switch
Voltage
ON (Operation)
Between (1) and (2)
20 30 V
position
If the above voltage is normal and the blower motor does not rotate, the
blower motor is defective.
aPrepare with starting switch OFF, then carry out troubleshooting without turning starting switch.

Disconnection in wiring
harness
6 (Disconnection in wiring
harness or defective
contact in connector)

Wiring harness between FB1-11 outlet and fuse


in unit and R30 (female) (3) or R31 (female) (1) Resistance
or M30 (female) (6)

Max. 1 z

Wiring harness between M29 (female) (3) and


R30 (female) (1)

Resistance

Max. 1 z

Wiring harness between M29 (female) (12) and


Resistance
chassis ground (A13)

Max. 1 z

Wiring harness between MB (female) (1) and


R30 (female) (4)
Wiring harness between MB (female) (2) and
PTR (female) (3)
Wiring harness between PTR (female) (1) and
chassis ground (A13)
Wiring harness between PTR (female) (2) and
M30 (female) (7)

Resistance

Max. 1 z

Resistance

Max. 1 z

Resistance

Max. 1 z

Resistance

Max. 1 z

Resistance

Max. 1 z

Wiring harness between PTR (female) (4) and


M30 (female) (8)
7

20-472
(1)

Defective air conditioner


system

If none of causes 1 6 is the cause of the trouble, the air conditioner


system may be defective. See Shop Manual for Chassis Components,
Troubleshooting for air conditioner.

PC130-7

E-32

TROUBLESHOOTING

Trouble

(3) Air is not cooled (Cooling performance is insufficient).

Related
information
Cause
1 Defective fuse (in unit)

Standard value in normal state/Remarks on troubleshooting


If the fuse (in the unit) is broken, the circuit probably has a grounding
fault, etc. Check the related circuits.

aPrepare with starting switch OFF, then carry out troubleshooting without turning starting switch.
Defective compressor relay
2
(coil side)
R31 (male)
Resistance
Between (1) and (2)
140 340 z
aPrepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. (Set temperature: Max. cooling)
Defective compressor relay
3
R31
Fan switch
Voltage
(contact side)
Between (4) and
ON (Operation)
20 30 V
chassis ground
position
4

Defective thermostat
(Internal defect)

Defective high/low
5 pressure switch
(Internal disconnection)
Possible causes
and standard
value in normal
state

Defective compressor
(Internal defect)
Defective compressor
7
(Internal defect)
6

aPrepare with starting switch OFF, then carry out troubleshooting without turning starting switch.
P17 (male)
Resistance
Between (1) and (2)

Max. 1 z

The compressor clutch may be defective. Check it directly.


The compressor may be defective. Check it directly.
aPrepare with starting switch OFF, then carry out troubleshooting without turning starting switch.

Disconnection in wiring
harness
8 (Disconnection in wiring
harness or defective
contact in connector)

PC130-7

The thermostat may be defective. Check it directly.

Defective air conditioner


system

Wiring harness between M30 (female) (4) and


P17 (female) (1)

Resistance

Max. 1 z

Wiring harness between P17 (female) (2) and


J04 and chassis ground (A12)

Resistance

Max. 1 z

Wiring harness between FB1-11 outlet and R31


(female) (2) or fuse in unit and R31 (female) (1) Resistance
or M30 (female) (6)

Max. 1 z

Wiring harness between ST1 (female) (1) and


R31 (female) (3)

Max. 1 z

Resistance

Wiring harness between M29 (female) (2) and


Resistance Max. 1 z
ST1 (female) (2)
Wiring harness between M29 (female) (12) and
Resistance Max. 1 z
chassis ground (A13)
Wiring harness between R31 (female) (4) and
Resistance Max. 1 z
E06 (female) (1)
If none of causes 1 8 is the cause of the trouble, the air conditioner
system may be defective. See Shop Manual for Chassis Components,
Troubleshooting for air conditioner.

20-473
(1)

TROUBLESHOOTING

E-32

Circuit diagram related to air conditioner

20-474
(1)

PC130-7

E-33

TROUBLESHOOTING

E-33 Travel alarm does not sound or does not stop sounding
When travel alarm is installed
Trouble

(1) Alarm does not sound while machine is traveling.


(2) Alarm sounds while machine is stopped.

Related
information
Cause
1 Defective fuse No. 15

2 Defective travel signal

Possible causes
and standard
value in normal
state

PC130-7

Standard value in normal state/Remarks on troubleshooting


If the fuse is broken, the circuit probably has a grounding fault, etc.
(See cause 4.)
aStart engine and carry out troubleshooting (Travel lever).
When lever is
Monitoring code
operated: ON
6-bit display
(Right of lower line)
When lever is in
020
neutral: OFF
aPrepare with starting switch OFF, then carry out troubleshooting without turning starting switch.

Disconnection in wiring
harness
3 (Disconnection in wiring
harness or defective
contact in connector)

Wiring harness between FB1-15 outlet and J03


Resistance
and A43 (female) (1)

Max. 1 z

Wiring harness between A43 (female) (2) and


J01 (male) (19)

Max. 1 z

Short circuit with chassis


ground in wiring harness
4
(Contact with ground
circuit)

aPrepare with starting switch OFF, then carry out troubleshooting without turning starting switch.
Between FB1-15 outlet J03 A43 (female)
Resistance Min. 1 Mz
(1) or other related circuit wiring harness and
chassis ground

5 Defective travel alarm

Troubleshooting cannot be carried out since the defect is in the travel


alarm (If none of the above causes 1 4 is the cause of the trouble, the
travel alarm is defective).

Resistance

20-475
(1)

TROUBLESHOOTING

E-33

Circuit diagram related to travel oil pressure switch and travel alarm

20-476
(1)

PC130-7

TROUBLESHOOTING FOR HYDRAULIC AND


MECHANICAL SYSTEM
(H-MODE)
INFORMATION IN TROUBLESHOOTING TABLE .................................................................................... 20-502
HYDRAULIC AND MECHANICAL SYSTEM DIAGRAM ............................................................................ 20-504
H- 1 Speed or power of whole work equipment, swing, and travel is low ................................................ 20-506
H- 2 Engine speed lowers extremely or engine stalls .............................................................................. 20-507
H- 3 Work equipment, swing, and travel systems do not work ................................................................ 20-508
H- 4 Abnormal sound comes out from around hydraulic pump ................................................................ 20-508
H- 5 Auto-decelerator does not operate ................................................................................................... 20-509
H- 6 Fine control performance or response is low ................................................................................... 20-509
H- 7 Speed or power of boom is low ........................................................................................................ 20-510
H- 8 Speed or power of arm is low ........................................................................................................... 20-511
H- 9 Speed or power of bucket is low ...................................................................................................... 20-512
H-10 Work equipment does not move singly ............................................................................................ 20-513
H-11 Hydraulic drift of work equipment is large ........................................................................................ 20-514
H-12 Time lag of work equipment is large ................................................................................................ 20-515
H-13 One-touch power maximizing function does not work ...................................................................... 20-515
H-14 In compound operation of work equipment, speed of part loaded more is low ................................ 20-516
H-15 When machine swings and raises boom simultaneously, boom rising speed is low ........................ 20-516
H-16 When machine operates work equipment or swings and travels simultaneously,
travel speed lowers largely .............................................................................................................. 20-516
H-17 Machine deviates during travel ........................................................................................................ 20-517
H-18 Travel speed is low ......................................................................................................................... 20-518
H-19 Machine is not steered well or steering power is low ....................................................................... 20-519
H-20 Travel speed does not change ......................................................................................................... 20-519
H-21 Travel motor does not work (only one side) ..................................................................................... 20-520
H-22 Upper structure does not swing ....................................................................................................... 20-521
H-23 Swing acceleration or swing speed is low ........................................................................................ 20-522
H-24 Upper structure overruns remarkably when it stops swinging .......................................................... 20-523
H-25 Large shock is made when upper structure stops swinging ............................................................. 20-524
H-26 Large sound is made when upper structure stops swinging ............................................................ 20-524
H-27 Hydraulic drift of swing is large ........................................................................................................ 20-525

PC130-7

20-501
(1)

INFORMATION IN TROUBLESHOOTING TABLE

TROUBLESHOOTING

INFORMATION IN TROUBLESHOOTING TABLE


a The following information is summarized in the troubleshooting table. Before carrying out troubleshooting,
understand that information fully.
Trouble
Related
information

Trouble which occurred in the machine


Information related to the detected trouble or troubleshooting
Cause

Standard value in normal state/Remarks on troubleshooting

Possible causes
and standard
value in normal
state

2
Possible causes of trouble
<Contents of description>
(Given numbers are refer Standard value in normal state to judge possible causes
ence numbers, which do not
Remarks on judgment
indicate priority)
3

20-502
(1)

PC130-7

TROUBLESHOOTING

HYDRAULIC AND MECHANICAL SYSTEM DIAGRAM

HYDRAULIC AND MECHANICAL SYSTEM DIAGRAM

20-504
(1)

PC130-7

TROUBLESHOOTING

HYDRAULIC AND MECHANICAL SYSTEM DIAGRAM

a This system diagram is a rough general hydraulic circuit diagram made as reference material for troubleshooting of the hydraulic and mechanical systems.

PC130-7

20-505
(1)

H-1

TROUBLESHOOTING

H-1 Speed or power of whole work equipment, swing, and travel is low
Trouble
Related
information

Speed or power of whole work equipment, swing, and travel is low.


Carry out the troubleshooting in working mode A.
Cause

1 Defective unload valve

Standard value in normal state/Remarks on troubleshooting


aPrepare with engine stopped, then run engine at high idling and carry
out troubleshooting.
Control levers
Unload pressure
All levers in neutral

2.4 3.4 MPa


{25 35 kg/cm2}

aPrepare with engine stopped, then run engine at high idling and carry
out troubleshooting
Defective adjustment or
2 malfunction of main relief
valve

Control levers
Arm-IN circuit relieved

Main relief pressure


33.6 37.0 MPa
{343 378 kg/cm2}

If the oil pressure does not become normal after adjustment, the main
relief valve may have a malfunction or a defect in it. Check the main
relief valve directly.
aPrepare with engine stopped, then run engine at high idling and carry
out troubleshooting

Possible causes
and standard
value in normal
state

Defective self-reducing
pressure valve

Defective adjustment or
malfunction of PC valve

Control levers

Control circuit basic pressure


2.84 3.43 MPa
All levers in neutral
{29 35 kg/cm2}
aPrepare with engine stopped, then run engine at high idling and carry
out troubleshooting
Measured pump
Measurement
Oil pressure ratio
discharge pressure
conditions
Pump discharge
pressure
PC valve output
pressure

Swing lock switch:


LOCK
Arm-IN circuit relieved

1
0.6 (3/5)

If the oil pressure does not become normal after adjustment, the PC
valve may have a malfunction or a defect in it. Check the PC valve
directly.
aPrepare with engine stopped, then run engine at high idling and carry
out troubleshooting
Measured pump
discharge pressure
5

Defective adjustment or
malfunction of LS valve

Pump discharge
pressure
LS valve output
pressure

Oil pressure ratio


Either track shoe
All levers in neutral
driven idle (Full stroke)
1
Almost same pressure
0.6 (3/5)

If the oil pressure does not become normal after adjustment, the LS
valve may have a malfunction or a defect in it. Check the LS valve
directly.
6 Malfunction of servo piston The servo piston may have a malfunction. Check it directly.
If none of above causes is the cause of the trouble, the cause may be
7 Defective piston pump
lowering performance, malfunction, or internal defect of the piston
pump.

20-506
(1)

PC130-7

H-2

TROUBLESHOOTING

H-2 Engine speed lowers extremely or engine stalls


Trouble
Related
information

Engine speed lowers extremely or engine stalls.


Carry out the troubleshooting in working mode A.
Cause

Defective adjustment or
1 malfunction of main relief
valve

Standard value in normal state/Remarks on troubleshooting


aPrepare with engine stopped, then run engine at high idling and carry
out troubleshooting.
Control levers
Main relief pressure
33.6 37.0 MPa
{343 378 kg/cm2}

Arm-IN circuit relieved

If the oil pressure does not become normal after adjustment, the main
relief valve may have a malfunction or a defect in it. Check the main
relief valve directly.
aPrepare with engine stopped, then run engine at high idling and carry
out troubleshooting.
Measured oil pressure
2

Defective adjustment or
malfunction of PC valve

Defective adjustment or
malfunction of LS valve

Possible causes
and standard
value in normal
state

Clogging of orifice or filter


in serve devices
5 Malfunction servo piston
4

PC130-7

Measurement
conditions

Oil pressure ratio

Pump discharge
1
Swing lock switch:
pressure
LOCK
PC valve output
Arm-IN circuit relieved
0.6 (3/5)
pressure
If the oil pressure does not become normal after adjustment, the PC
valve may have a malfunction or a defect in it. Check the PC valve
directly.
aPrepare with engine stopped, then run engine at high idling and carry
out troubleshooting.
Oil pressure ratio
Measured oil pressure
Either track shoe
All levers in neutral
driven idle (Full stroke)
Pump discharge
1
pressure
Almost same pressure
LS valve output
0.6 (3/5)
pressure
If the oil pressure does not become normal after adjustment, the LS
valve may have a malfunction or a defect in it. Check the LS valve
directly.
The orifices or filters in the pump servo devices may be clogged. Check
them directly.
The servo piston may have a malfunction. Check it directly.

20-507
(1)

H-3, H-4

TROUBLESHOOTING

H-3 Work equipment, swing, and travel systems do not work


Trouble
Related
information

Work equipment, swing, and travel systems do not work.


Carry out the troubleshooting in working mode A.
Cause

Standard value in normal state/Remarks on troubleshooting


aPrepare with engine stopped, then run engine at high idling and carry
out troubleshooting.
Safety lock lever
Solenoid valve output pressure

Possible causes
and standard
value in normal
state

Malfunction of PPC lock


solenoid valve

Malfunction of self-reducing pressure valve

LOCK

0 MPa
{0 kg/cm2}

FREE

2.84 3.43 MPa


{29 35 kg/cm2}

aPrepare with engine stopped, then run engine at high idling and carry
out troubleshooting.
Control levers
Control circuit basic pressure
All levers in neutral

2.84 3.43 MPa


{29 35 kg/cm2}

The piston pump may have a malfunction or has an internal defect.


Check it by the following method.
3 Malfunction of piston pump
Remove the pump discharge pressure pickup plug and crank the engine. If the oil flows out at this time, the piston pump is normal.
The pump shaft may not rotate because of an defect in the damper.
4 Defective damper
Check the damper directly.

H-4 Abnormal sound comes out from around hydraulic pump


Trouble
Related
information

Abnormal sound comes out from around hydraulic pump.


Carry out the troubleshooting in working mode A.
Cause
Lowering of hydraulic oil
1
level

Possible causes
and standard
value in normal
state

20-508
(1)

2 Defective hydraulic oil


Clogging of hydraulic tank
3
cap
Clogging of hydraulic tank
4
strainer
5 Defective piston pump

Standard value in normal state/Remarks on troubleshooting


Check it directly.
Hydraulic oil may contain air. Check hydraulic oil directly.
Negative pressure may be applied to the hydraulic tank because of clogging of the hydraulic tank cap. Check the cap directly.
Negative pressure may be applied to the suction circuit because of clogging of the hydraulic tank strainer. Check the strainer directly.
The piston pump may have a defect in it. Check it directly.

PC130-7

H-5, H-6

TROUBLESHOOTING

H-5 Auto-decelerator does not operate


Trouble
Related
information

Auto-decelerator does not operate.


Apply this troubleshooting if the auto-decelerator does not operate when the travel lever is operated.
(The shuttle valve (in the PPC valve) is installed between the PPC valve and oil pressure switch of only
in the travel circuit.)
Carry out the troubleshooting in working mode A.
Cause

Possible causes
and standard
value in normal
state

Malfunction of travel PPC


valve (shuttle valve)

Standard value in normal state/Remarks on troubleshooting


aPrepare with engine stopped, then run engine at high idling and carry
out troubleshooting.
Travel lever
PPC valve output pressure
Neutral position
Travel position

0 MPa
{0 kg/cm2}
2.84 3.43 MPa
{29 35 kg/cm2}

H-6 Fine control performance or response is low


Trouble
Related
information

Fine control performance or response is low.


Carry out the troubleshooting in working mode A.
Cause
Clogging of LS circuit
1
orifice

Standard value in normal state/Remarks on troubleshooting


The LS circuit may be clogged. Check it directly.
aPrepare with engine stopped, then run engine at high idling and carry
out troubleshooting.

Possible causes
and standard
value in normal
state

Measured oil pressure


2

Defective adjustment or
malfunction LS valve

3 Defective servo piston

PC130-7

Pump discharge
pressure
LS valve output
pressure

Oil pressure ratio


Either track shoe
All levers in neutral
driven idle (Full stroke)
1
Almost same pressure
0.6 (3/5)

If the oil pressure does not become normal after adjustment, the LS
valve may have a malfunction or a defect in it. Check the LS valve
directly.
The servo piston may have a malfunction. Check it directly.

20-509
(1)

H-7

TROUBLESHOOTING

H-7 Speed or power of boom is low


Trouble
Related
information

Speed or power of boom is low.


Carry out the troubleshooting in working mode A.
Cause

Standard value in normal state/Remarks on troubleshooting


aPrepare with engine stopped, then run engine at high idling and carry
out troubleshooting.
Right work equipment control lever
PPC valve output pressure

Malfunction of right PPC


valve (boom circuit)

Malfunction of boom control valve (spool)


Malfunction of boom con3 trol valve (pressure compensation valve)
2

Possible causes
and standard
value in normal
state

Neutral position

0 MPa
{0 kg/cm2}

Boom RAISE position


Boom LOWER position

2.84 3.43 MPa


{29 35 kg/cm2}

The spool of the boom control valve may have a malfunction. Check it
directly.
The pressure compensation valve of the boom control valve may have a
malfunction. Check it directly.

Malfunction of boom con4 trol valve (regeneration


valve)

The regeneration valve of the boom control valve may have a malfunction or a defective seal. Check it directly.

Malfunction or defective
5 seal of boom control valve
(suction valve)

The suction valve of the boom control valve may have a malfunction or a
defective seal. Check it directly.

Malfunction or defective
6 seal of centralized safetysuction valve
7

Malfunction of boom cylinder (lock valve)

Malfunction of boom cylinder (cylinder unit)

The centralized safety-suction valve may have a malfunction or a defective seal. Check it directly.
(A trouble of the centralized safety-suction valve have bad effects on the
arm and bucket.)
The lock valve of the boom cylinder may have a malfunction. Check it
directly.
aPrepare with engine stopped, then run engine at high idling and carry
out troubleshooting.
Boom cylinder
Leakage from cylinder
Relieved in RAISE position

20-510
(1)

15 cc/min

PC130-7

H-8

TROUBLESHOOTING

H-8 Speed or power of arm is low


Trouble
Related
information

Speed or power of arm is low.


Carry out the troubleshooting in working mode A.
Cause

Standard value in normal state/Remarks on troubleshooting


aPrepare with engine stopped, then run engine at high idling and carry
out troubleshooting.
Left work equipment control lever
PPC valve output pressure

Malfunction of left PPC


valve (boom circuit)

Neutral position
Arm IN position
Arm OUT position

Malfunction of arm control


valve (spool)
Malfunction of arm control
3 valve (pressure compensation valve)
Malfunction or defective
4 seal of arm control valve
(suction valve)
2

Possible causes
and standard
value in normal
state

0 MPa
{0 kg/cm2}
2.84 3.43 MPa
{29 35 kg/cm2}

The spool of the arm control valve may have a malfunction. Check it
directly.
The pressure compensation valve of the arm control valve may have a
malfunction. Check it directly.
The suction valve of the arm control valve may have a malfunction or a
defective seal. Check it directly.

The centralized safety-suction valve may have a malfunction or a defective seal. Check it directly.
(A trouble of the centralized safety-suction valve have bad effects on the
boom and bucket.)
aPrepare with engine stopped, then run engine at high idling and carry
out troubleshooting.
Malfunction of arm cylinder
6
(cylinder unit)
Arm cylinder
Leakage from cylinder
Relieved in IN position
15 cc/min
Malfunction or defective
5 seal of centralized safetysuction valve

PC130-7

20-511
(1)

H-9

TROUBLESHOOTING

H-9 Speed or power of bucket is low


Trouble
Related
information

Speed or power of bucket is low.


Carry out the troubleshooting in working mode A.
Cause

Standard value in normal state/Remarks on troubleshooting


aPrepare with engine stopped, then run engine at high idling and carry
out troubleshooting.
Right work equipment control lever
PPC valve output pressure

Malfunction of right PPC


valve (bucket circuit)

Neutral position
Bucket CURL position
Bucket DUMP position

Malfunction of bucket control valve (spool)


Malfunction of bucket con3 trol valve (pressure compensation valve)
Malfunction or defective
4 seal of bucket control valve
(suction valve)
2

Possible causes
and standard
value in normal
state

0 MPa
{0 kg/cm2}
2.84 3.43 MPa
{29 35 kg/cm2}

The spool of the bucket control valve may have a malfunction. Check it
directly.
The pressure compensation valve of the bucket control valve may have
a malfunction. Check it directly.
The suction valve of the bucket control valve may have a malfunction or
a defective seal. Check it directly.

The centralized safety-suction valve may have a malfunction or a defective seal. Check it directly.
(A trouble of the centralized safety-suction valve have bad effects on the
boom and arm.)
aPrepare with engine stopped, then run engine at high idling and carry
out troubleshooting.
Malfunction of bucket cylin6
der (cylinder unit)
Bucket cylinder
Leakage from cylinder
Relieved in CURL position
15 cc/min
Malfunction or defective
5 seal of centralized safetysuction valve

20-512
(1)

PC130-7

H-10

TROUBLESHOOTING

H-10 Work equipment does not move singly

Trouble
Related
information

(1) Boom does not move singly.


(2) Arm does not move singly.
(3) Bucket does not move singly.
Carry out the troubleshooting in working mode A.
Cause

Possible causes
and standard
value in normal
state

1 Malfunction of PPC valve

Standard value in normal state/Remarks on troubleshooting


aPrepare with engine stopped, then run engine at high idling and carry
out troubleshooting.
Work equipment control lever
PPC valve output pressure
Neutral
Operated

PC130-7

0 MPa
{0 kg/cm2}
2.84 3.43 MPa
{29 35 kg/cm2}

Malfunction of control valve


The spool of the control valve may have a malfunction. Check it directly.
(spool)

20-513
(1)

H-11

TROUBLESHOOTING

H-11 Hydraulic drift of work equipment is large


Trouble
Related
information

Possible causes
and standard
value in normal
state

Trouble
Related
information

(1) Hydraulic drift of boom is large.


Carry out the troubleshooting in working mode A.

Cause

Standard value in normal state/Remarks on troubleshooting

Defective boom cylinder


(cylinder unit)

aPrepare with engine stopped, then run engine at high idling and carry
out troubleshooting.
Boom cylinder
Leakage from cylinder

Relieved in RAISE position


15 cc/min
Defective seal of boom cyl- The seal of the lock valve of the boom cylinder may be defective. Check
2
inder (lock valve)
it directly.

(2) Hydraulic drift of arm is large.


Carry out the troubleshooting in working mode A.
Cause

Standard value in normal state/Remarks on troubleshooting

aPrepare with engine stopped, then run engine at high idling and carry
out troubleshooting.
Defective arm cylinder (cyl1
inder unit)
Arm cylinder
Leakage from cylinder
Possible causes
and standard
value in normal
state

Defective seal of arm con2


trol lever (spool)
Defective seal of arm con3
trol lever (suction valve)
4

Trouble
Related
information

Defective seal of centralized safety-suction valve

(3) Hydraulic drift of bucket is large.


Carry out the troubleshooting in working mode A.
Cause
Defective bucket cylinder
1
(cylinder unit)

Possible causes
and standard
value in normal
state

20-514
(1)

Relieved in IN position
15 cc/min
The seal of the arm control valve spool may be defective. Check it
directly.
The seal of the suction valve of the arm control valve may be defective.
Check it directly.
The seal of the centralized safety-suction valve of the control valve may
defective. Check it directly.
(A trouble of the centralized safety-suction valve have bad effects on
bucket.)

Defective seal of bucket


control valve (spool)

Standard value in normal state/Remarks on troubleshooting


aPrepare with engine stopped, then run engine at high idling and carry
out troubleshooting.
Bucket cylinder
Relieved in CURL position

Leakage from cylinder


15 cc/min

The seal of the bucket control valve spool may be defective. Check it
directly.

Defective seal of bucket


3 control valve (suction
valve)

The seal of the suction valve of the bucket control valve may be defective. Check it directly.

Defective seal of central4


ized safety-suction valve

The seal of the centralized safety-suction valve of the control valve may
defective. Check it directly.
(A trouble of the centralized safety-suction valve have bad effects on
arm.)

PC130-7

H-12, H-13

TROUBLESHOOTING

H-12 Time lag of work equipment is large


Trouble
Related
information

Time lag of work equipment is large.


Carry out the troubleshooting in working mode A.
Cause

Possible causes
and standard
value in normal
state

Standard value in normal state/Remarks on troubleshooting

Malfunction of control valve


The regeneration valve of the control valve may have a malfunction.
1 (regeneration valve) [Only
Check it directly.
boom]
2

Malfunction of control valve The suction valve of the control valve may have a malfunction. Check it
(Suction valve)
directly.

H-13 One-touch power maximizing function does not work


Trouble
Related
information

One-touch power maximizing function does not work.


Carry out installation in the reverse order to removal.
Cause

Possible causes
and standard
value in normal
state

Standard value in normal state/Remarks on troubleshooting


aPrepare with engine stopped, then run engine at high idling and carry
out troubleshooting.
Swing lock switch
Solenoid valve output pressure

Malfunction of 2-stage
relief solenoid valve

OFF
LOCK

PC130-7

Malfunction of main relief


valve

0 MPa
{0 kg/cm2}
2.84 3.43 MPa
{29 35 kg/cm2}

The main relief valve of the control valve may have a malfunction.
Check it directly.

20-515
(1)

H-14, H-15, H-16

TROUBLESHOOTING

H-14 In compound operation of work equipment, speed of part loaded more is low
Trouble
Related
information

In compound operation of work equipment, speed of part loaded more is low.


Carry out the troubleshooting in working mode A.
Cause

Possible causes
and standard
value in normal
state

Malfunction of pressure
1 compensation valve on
less load side

Standard value in normal state/Remarks on troubleshooting


The pressure compensation valve of the control valve on the less load
side may have a malfunction. Check it directly.
Larger
Less load
Compound operation
load side
side
Boom RAISE + Arm IN
Boom
Arm
Boom RAISE + Arm OUT
Boom RAISE + Bucket CURL

Arm
Boom

Boom
Bucket

Arm OUT + Bucket CURL


Boom LOWER + Arm OUT

Arm
Arm

Bucket
Boom

H-15 When machine swings and raises boom simultaneously, boom rising speed is
low
Trouble
Related
information
Possible causes
and standard
value in normal
state

When machine swings and raises boom simultaneously, boom rising speed is low.
Carry out the troubleshooting in working mode A.

Cause

Standard value in normal state/Remarks on troubleshooting

Malfunction of defective
seal of LS selector valve

The LS selector valve of the control valve may have a malfunction or a


defective seal. Check it directly.

H-16 When machine operates work equipment or swings and travels simultaneously,
travel speed lowers largely
Trouble
Related
information

Possible causes
and standard
value in normal
state

20-516
(1)

When machine operates work equipment or swings and travels simultaneously, travel speed lowers
largely.
Carry out the troubleshooting in working mode A.
Cause
Malfunction of work equip1 ment control valve (pressure compensation valve)
Malfunction of swing con2 trol valve (pressure compensation valve)
Malfunction of travel control
3 valve (pressure compensation valve)

Standard value in normal state/Remarks on troubleshooting


The pressure compensation valve of the work equipment control valve
may have a malfunction. Check it directly.
The pressure compensation valve of the swing control valve may have a
malfunction. Check it directly.
The pressure compensation valve of the travel control valve may have a
malfunction. Check it directly.

PC130-7

H-17

TROUBLESHOOTING

H-17 Machine deviates during travel


Trouble
Related
information

Machine deviates during travel.


Carry out the troubleshooting in working mode A.
Cause

Malfunction of self-reducing pressure valve

Standard value in normal state/Remarks on troubleshooting


aPrepare with engine stopped, then run engine at high idling and carry
out troubleshooting.
Control levers
Control circuit basic pressure
All levers in neutral

2.84 3.43 MPa


{29 35 kg/cm2}

aPrepare with engine stopped, then run engine at high idling and carry
out troubleshooting.
Travel lever
PPC valve output pressure
2
Possible causes
and standard
value in normal
state

Malfunction of travel PPC


valve

2.84 3.43 MPa


{29 35 kg/cm2}

Max. 0.4 MPa


{Max. 4 kg/cm2}
Malfunction of travel junc- The travel junction valve of the control valve may have a malfunction.
3
tion valve
Check it directly.
Malfunction of travel control The spool of the travel control valve may have a malfunction. Check it
4
valve (spool)
directly.
Difference between right and left of
above

Defective seal of center


swivel joint

6 Defective travel motor

7 Defective final drive

PC130-7

FORWARD or REVERSE position

The seal of the center swivel joint may be defective. Check it directly.
aPrepare with engine stopped, then run engine at high idling and carry
out troubleshooting.
Travel lever
Leakage from travel motor

Relieved in TRAVEL position


Max. 10 l/min

The final drive may have a defect in it. Check it directly. (It may be
checked by abnormal sound, abnormal heating, metal chips in drain oil,
etc.)

20-517
(1)

H-18

TROUBLESHOOTING

H-18 Travel speed is low


Trouble
Related
information

Travel speed is low.


Carry out the troubleshooting in working mode A.
Cause

Malfunction of self-reducing pressure valve

Standard value in normal state/Remarks on troubleshooting


aPrepare with engine stopped, then run engine at high idling and carry
out troubleshooting.
Control levers
Control circuit basic pressure
All levers in neutral

2.84 3.43 MPa


{29 35 kg/cm2}

aPrepare with engine stopped, then run engine at high idling and carry
out troubleshooting.
Travel lever
PPC valve output pressure
2

Malfunction of travel PPC


valve

FORWARD or REVERSE position

2.84 3.43 MPa


{29 35 kg/cm2}

Max. 0.4 MPa


{Max. 4 kg/cm2}
aPrepare with engine stopped, then run engine at high idling and carry
out troubleshooting.
Control levers
Main relief pressure
Difference between right and left of
above

Possible causes
and standard
value in normal
state

4
5
6
7

Malfunction of main relief


valve

(1)

36.3 39.2 MPa


{370 400 kg/cm2}

If the oil pressure does not become normal after adjustment, the main
relief valve may have a malfunction or a defect in it. Check the main
relief valve directly.
Malfunction of travel control The spool of the travel control valve may have a malfunction. Check it
valve (spool)
directly.
Malfunction of travel control
The pressure compensation valve of the travel control valve may have a
valve (pressure compensamalfunction. Check it directly.
tion valve)
Malfunction of travel control The suction valve of the travel control valve may have a malfunction.
valve (suction valve)
Check it directly.
Defective seal of center
The seal of the center swivel joint may be defective. Check it directly.
swivel joint
aPrepare with engine stopped, then run engine at high idling and carry
out troubleshooting.
Defective travel motor
Travel lever
Leakage from travel motor
Relieved in TRAVEL position
Max. 10 l/min

9 Defective final drive

20-518

Relieved in TRAVEL position

The final drive may have a defect in it. Check it directly. (It may be
checked by abnormal sound, abnormal heating, metal chips in drain oil,
etc.)

PC130-7

H-19, H-20

TROUBLESHOOTING

H-19 Machine is not steered well or steering power is low


Trouble
Related
information

Machine is not steered well or steering power is low.


Carry out the troubleshooting in working mode A.
Cause

Standard value in normal state/Remarks on troubleshooting


aPrepare with engine stopped, then run engine at high idling and carry
out troubleshooting.
Travel lever
PPC valve output pressure

Malfunction of travel PPC


valve

0 MPa
{0 kg/cm2}

Neutral position
FORWARD or REVERSE position

Possible causes
and standard
value in normal
state

2
3
4
5
6

Malfunction of travel junction valve


Malfunction of travel control
valve (spool)
Malfunction of travel control
valve (pressure compensation valve)
Malfunction of travel control
valve (suction valve)
Malfunction of travel motor
(safety-suction valve)

2.84 3.43 MPa


{29 35 kg/cm2}

The travel junction valve of the control valve may have a malfunction.
Check it directly.
The spool of the travel control valve may have a malfunction. Check it
directly.
The pressure compensation valve of the travel control valve may have a
malfunction. Check it directly.
The suction valve of the travel control valve may have a malfunction.
Check it directly.
The safety-suction valve of the travel motor may have a malfunction.
Check it directly.

H-20 Travel speed does not change


Trouble
Related
information

Travel speed does not change.


Carry out the troubleshooting in working mode A.
Cause

Standard value in normal state/Remarks on troubleshooting


aPrepare with engine stopped, then run engine at high idling and carry
out troubleshooting.

Possible causes
and standard
value in normal
state

PC130-7

Malfunction of travel speed


shifting solenoid valve

Travel speed switch

Travel lever

Lo position

Neutral position

Hi position

FORWARD or
REVERSE position

Solenoid valve output


pressure
0 MPa
{0 kg/cm2}
2.84 3.43 MPa
{29 35 kg/cm2}

Malfunction of travel motor The speed shifting section of the travel motor may have a malfunction.
(speed shifting section)
Check it directly.

20-519
(1)

H-21

TROUBLESHOOTING

H-21 Travel motor does not work (only one side)


Trouble
Related
information

Travel motor does not work (only one side).


Carry out the troubleshooting in working mode A.
Cause
Defective seal of travel
1 control valve
(suction valve)
2

Possible causes
and standard
value in normal
state

(1)

The seal of the suction valve of the travel control valve may be defective. Check it directly.

Malfunction of travel motor The counterbalance valve of the travel motor may have a malfunction.
(counterbalance valve)
Check it directly.

Malfunction of travel motor The safety-suction valve of the travel motor may have a malfunction.
(safety-suction valve)
Check it directly.
aPrepare with engine stopped, then run engine at high idling and carry
out troubleshooting.
4 Defective travel motor
Travel lever
Leakage from travel motor
3

5 Defective final drive

20-520

Standard value in normal state/Remarks on troubleshooting

Relieved in TRAVEL position


Max. 10 l/min
The final drive may have a defect in it. Check it directly. (It may be
checked by abnormal sound, abnormal heating, metal chips in drain oil,
etc.)

PC130-7

H-22

TROUBLESHOOTING

H-22 Upper structure does not swing


Trouble
Related
information

(1) Upper structure does not swing in either direction.


Carry out the troubleshooting in working mode A.
Cause

Standard value in normal state/Remarks on troubleshooting


aPrepare with engine stopped, then run engine at high idling and carry
out troubleshooting.
Right work equipment control lever
Solenoid valve output pressure

Malfunction of swing holding brake solenoid valve

0 MPa
{0 kg/cm2}

Neutral position

2.84 3.43 MPa

SWING position

{29 35 kg/cm2}

Malfunction of swing motor The parking brake of the swing motor may have a malfunction. Check it
(parking brake)
directly.
aPrepare with engine stopped, then run engine at high idling and carry
out troubleshooting.
Left work equipment
Malfunction of swing motor
Swing lock switch
Swing relief pressure
3
control lever
(safety valve)
2

Possible causes
and standard
value in normal
state

LOCK

Defective swing motor


(motor unit)

Relieved in SWING
position

28.9 32.9 MPa


{295 335 kg/cm2}

aPrepare with engine stopped, then run engine at high idling and carry
out troubleshooting.
Left work equipment
Swing lock switch
Swing relief pressure
control lever
Relieved in SWING
LOCK
Max. 6 l/min
position

The swing machinery may have a defect in it. Check it directly. (It may
5 Defective swing machinery be checked by abnormal sound, abnormal heating, metal chips in drain
oil, etc.)

Trouble
Related
information

(2) Upper structure swings only in 1 direction.


Carry out the troubleshooting in working mode A.
Cause

Standard value in normal state/Remarks on troubleshooting


aPrepare with engine stopped, then run engine at high idling and carry
out troubleshooting.
Right work equipment control lever

Possible causes
and standard
value in normal
state

PC130-7

Malfunction of swing PPC


1
valve

Neutral position
SWING position

PPC valve output pressure


0 MPa
{0 kg/cm2}
2.84 3.43 MPa
{29 35 kg/cm2}

Malfunction of swing control valve (spool)

The spool of the swing control valve may have a malfunction. Check it
directly.

Defective seal of swing


motor (suction valve)

The seal of the suction valve of the swing motor may be defective.
Check it directly.

20-521
(1)

H-23

TROUBLESHOOTING

H-23 Swing acceleration or swing speed is low


Trouble
Related
information

(1) Swing acceleration or swing speed is low in both directions.


Carry out the troubleshooting in working mode A.
Cause
Malfunction of swing con1 trol valve (pressure compensation valve)
2

Standard value in normal state/Remarks on troubleshooting


The pressure compensation valve of the swing control valve may have a
malfunction. Check it directly.

Malfunction of swing bleed The swing bleed valve of the control valve may have a malfunction.
valve
Check it directly.

Malfunction of swing motor The parking brake of the swing motor may have a malfunction. Check it
(parking brake)
directly.
aPrepare with engine stopped, then run engine at high idling and carry
out troubleshooting.
Left work equipment
Malfunction of swing motor
Swing lock switch
Swing relief pressure
4
control lever
(safety valve)
3

Possible causes
and standard
value in normal
state

LOCK position

Relieved in SWING
position

28.9 32.9 MPa


{295 335 kg/cm2}

aPrepare with engine stopped, then run engine at high idling and carry
out troubleshooting.
Left work equipment
Leakage from swing
control lever
motor
Relieved in SWING
LOCK position
Max. 6 l/min
position
The swing machinery may have a defect in it. Check it directly. (It may
6 Defective swing machinery be checked by abnormal sound, abnormal heating, metal chips in drain
oil, etc.)

Trouble
Related
information

Defective swing motor


(motor unit)

(2) Swing acceleration or swing speed is low in only 1 direction.


Carry out the troubleshooting in working mode A.
Cause

1
Possible causes
and standard
value in normal
state

20-522
(1)

Swing lock switch

Malfunction of swing PPC


valve

Standard value in normal state/Remarks on troubleshooting


aPrepare with engine stopped, then run engine at high idling and carry
out troubleshooting.
Right work equipment control lever
PPC valve output pressure
In NEUTRAL position
In SWING position

0 MPa
{0 kg/cm2}
2.84 3.43 MPa
{29 35 kg/cm2}

Clogging of swing PPC


slow return valve

The swing PPC slow return valve may be clogged. Check it directly.

Malfunction of swing control valve (spool)

The spool of the swing control valve may have a malfunction. Check it
directly (including the stroke limiting mechanism).

Defective seal of swing


motor (suction valve)

The seal of the suction valve of the swing motor may be defective.
Check it directly.

PC130-7

H-24

TROUBLESHOOTING

H-24 Upper structure overruns remarkably when it stops swinging


Trouble
Related
information

(1) Upper structure overruns remarkably when it stops swinging in both directions.
Carry out the troubleshooting in working mode A.
Cause

Possible causes
and standard
value in normal
state

LOCK position

Trouble

Defective swing motor


(motor unit)

{295 335 kg/cm2}

Swing lock switch

Left work equipment


control lever

Leakage from swing


motor

LOCK position

Relieved in SWING
position

Max. 6 l/min

(2) Upper structure overruns remarkably when it stops swinging in only 1 direction.
Carry out the troubleshooting in working mode A.
Cause

1
Possible causes
and standard
value in normal
state

PC130-7

28.9 32.9 MPa

Relieved in SWING
position

aPrepare with engine stopped, then run engine at high idling and carry
out troubleshooting.
2

Related
information

Standard value in normal state/Remarks on troubleshooting

aPrepare with engine stopped, then run engine at high idling and carry
out troubleshooting.
Left work equipment
Malfunction of swing motor
Swing lock switch
Swing relief pressure
1
control lever
(safety valve)

Malfunction of swing PPC


valve

Standard value in normal state/Remarks on troubleshooting


aPrepare with engine stopped, then run engine at high idling and carry
out troubleshooting.
Right work equipment control lever
PPC valve output pressure
In NEUTRAL position
In SWING position

0 MPa
{0 kg/cm2}
2.84 3.43 MPa
{29 35 kg/cm2}

Clogging of swing PPC


slow return valve

The swing PPC slow return valve may be clogged. Check it directly.

Malfunction of swing control valve (spool)

The spool of the swing control valve may have a malfunction. Check it
directly.

Defective seal of swing


motor (suction valve)

The seal of the suction valve of the swing motor may be defective.
Check it directly.

20-523
(1)

H-25, H-26

TROUBLESHOOTING

H-25 Large shock is made when upper structure stops swinging


Trouble
Related
information

Large shock is made when upper structure stops swinging.


Carry out the troubleshooting in working mode A.
Cause

Standard value in normal state/Remarks on troubleshooting


aPrepare with engine stopped, then run engine at high idling and carry
out troubleshooting.
Right work equipment control lever
PPC valve output pressure

Possible causes
and standard
value in normal
state

Malfunction of swing PPC


valve

In NEUTRAL position
In SWING position

Malfunction of swing PPC


slow return valve
Malfunction of swing motor
3
(shockless valve)
2

0 MPa
{0 kg/cm2}
2.84 3.43 MPa
{29 35 kg/cm2}

The swing PPC slow return valve may have a malfunction. Check it
directly.
The shockless valve of the swing motor may have a malfunction. Check
it directly.

H-26 Large sound is made when upper structure stops swinging


Trouble
Related
information

Large sound is made when upper structure stops swinging.


Carry out the troubleshooting in working mode A.
Cause
Malfunction of back-pres1
sure check valve

Possible causes
and standard
value in normal
state

20-524
(1)

Standard value in normal state/Remarks on troubleshooting


The back-pressure check valve may have a malfunction. Check it
directly.

The swing motor (safety valves) may have a malfunction. Check it


Malfunction of swing motor
directly. (It may be checked by exchanging both valves and seeing the
(safety valve)
change of phenomenon.)
The swing motor (suction valves) may have a malfunction. Check it
Malfunction of swing motor
3
directly. (It may be checked by exchanging both valves and seeing the
(suction valve)
change of phenomenon.)
The swing machinery may have a defect in it. Check it directly. (It may
4 Defective swing machinery be checked by abnormal sound, abnormal heating, metal chips in drain
oil, etc.)
2

PC130-7

H-27

TROUBLESHOOTING

H-27 Hydraulic drift of swing is large


Trouble
Related
information

(1) When swing holding brake is applied


When the swing lock switch is in the LOCK position or when the swing holding brake release switch is
in the normal position, the swing holding brake operates and the upper structure is fixed with the disc
brake.
Carry out the troubleshooting in working mode A.
Cause

Possible causes
and standard
value in normal
state

Malfunction of swing holding brake solenoid valve

Related
information

PC130-7

0 MPa
{0 kg/cm2}
2.84 3.43 MPa
{29 35 kg/cm2}

The parking brake of the swing motor may have a malfunction or a


defect in it. Check it directly.

(2) When swing holding brake is released


When the swing holding brake release switch is in the RELEASE position, the swing brake is released
and the upper structure is secured by only hydraulic pressure.
Carry out the troubleshooting in working mode A.
Cause

Possible causes
and standard
value in normal
state

In NEUTRAL position
In SWING position

Malfunction or internal
2 defect of swing motor
(parking brake)

Trouble

Standard value in normal state/Remarks on troubleshooting


aPrepare with engine stopped, then run engine at high idling and carry
out troubleshooting.
Right work equipment control lever
Solenoid valve output pressure

Standard value in normal state/Remarks on troubleshooting

Defective seal of swing


control valve (spool)

The seal of the spool of the swing control valve may be defective.
Check it directly.

Defective seal of swing


The seal of the safety valve of the swing control valve may be defective.
control valve (safety valve) Check it directly.

Defective seal of swing


3 control valve (suction
valve)

The seal of the suction valve of the swing control valve may be defective. Check it directly.

Defective seal of swing


4 control valve (shockless
valve)

The seal of the shockless valve of the swing control valve may be defective. Check it directly.

20-525
(1)

TROUBLESHOOTING OF ENGINE
(S-MODE)

Method of using troubleshooting charts ...................................................................................................... 20-602


S-1 Starting performance is poor (Starting always takes time)................................................................ 20-606
S-2 Engine does not start ........................................................................................................................ 20-608
(1) Engine does not turn ................................................................................................................ 20-608
(2) Engine turns but no exhaust smoke comes out (Fuel is not being injected)............................. 20-609
(3) Exhaust smoke comes out but engine does not start (Fuel is being injected).......................... 20-610
S-3 Engine does not pick-up smoothly (Follow-up is poor) ......................................................................20-611
S-4 Engine stops during operations ........................................................................................................ 20-612
S-5 Engine does not rotate smoothly (Hunting)....................................................................................... 20-613
S-6 Engine lacks output (or lacks power) ................................................................................................ 20-614
S-7 Exhaust smoke is black (Incomplete combustion) ............................................................................ 20-615
S-8 Oil consumption is excessive (or exhaust smoke is blue) ................................................................ 20-616
S-9 Oil becomes contaminated quickly ................................................................................................... 20-617
S-10 Fuel consumption is excessive ......................................................................................................... 20-618
S-11 Oil is in cooling water, or water spurts back, or water level goes down ............................................ 20-619
S-12 Oil pressure caution lamp lights up (Drop in oil pressure) ................................................................ 20-620
S-13 Oil level rises (Water, fuel in oil)........................................................................................................ 20-621
S-14 Water temperature becomes too high (Overheating)........................................................................ 20-622
S-15 Abnormal noise is made ................................................................................................................... 20-623
S-16 Vibration is excessive ....................................................................................................................... 20-624

PC130-7

20-601
(1)

TROUBLESHOOTING

METHOD OF USING TROUBLESHOOTING CHARTS

METHOD OF USING TROUBLESHOOTING CHARTS


This troubleshooting chart is divided into three sections: questions, check items, and troubleshooting. The questions and check items are used to
pinpoint high probability causes that can be located
from the failure symptoms or simple inspeciton without using troubleshooting tools.
Next, troubleshooting tools or direct inspection are
used to check the high probability causes to make
final confirmation.
[Questions]
Sections (A) + (B) in the chart on the right corresponds to the items where answers can be
obtained from the user. The items in (B) are
items that can be obtained from the user,
depending on the user's level.
[Check items]
The serviceman carries out simple inspection to
narrow down the causes. The items under (C) in
the chart on the right correspond to this.
The serviceman narrows down the causes from
information (A) that he has obtained from the
user and the results of (C) that he has obtained
from his own inspection.
[Troubleshooting]
Troubleshooting is carried out in the order of
probability, starting with the causes that have
been marked as having the highest probability
from information gained from [Questions] and
[Check items].

20-602
(1)

PC130-7

METHOD OF USING TROUBLESHOOTING CHARTS

TROUBLESHOOTING

PC130-7

*1

Confirm recent repair history

*2

Degree of use

Defective injection pump (excessive injection)

Improper injection timing

Clogged, seized injection nozzle

Worn piston ring, cylinder

Clogged air cleaner element

*1. For [Confirm recent repair history] in the


[Questions] Section, ask the user, and mark
the Cause column with E to use as reference for locating the cause of the failure.
However, do not use this when making calculations to narrow down the causes.
*2. Use the E in the Cause column as reference for [Degree of use (Operated for long
period)] in the [Questions] section as reference. As a rule, do not use it when calculating the points for locating the cause, but it
can be included if necessary to determine
the order for troubleshooting.

Seized turbocherger, interference

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 Q, and of these, causes that have a high probability are marked with w.
Check each of the [Questions] and [Check items] in
turn, and marked the Q or w 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 confirmation of the cause.

Operated for long period

20-603
(1)

METHOD OF USING TROUBLESHOOTING CHARTS

TROUBLESHOOTING

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 exhaust gas is black
Insufficient intake of air
Improper condition of fuel injection
Excessive injection of fuel

Legend
: Possible causes (judging from Questions and Check items)
: Most probable causes (judging from Questions and Check items)
: Possible causes due to length of use (used for a long period)
: Items to confirm the cause.

20-604
(1)

PC130-7

TROUBLESHOOTING

METHOD OF USING TROUBLESHOOTING CHARTS

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

Step 2
Add up the total of
and
marked where the
horizontal limes for the three symptoms and the vertical
columns for the causes intersect.
(1) Clogged air cleaner element:
(2) Air leakage between turbocharger
and cyl. head:
(3) Clogged, seized injection nozzle:
(4) Defective contact of valve, valve seat:
(5) Worn piston ring, cylinder:

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 .
The Remedy is given as [Clean], so carry out cleaning,
and the exhaust gas color should return to normal.

PC130-7

20-605
(1)

S-1

TROUBLESHOOTING

S-1 Starting performance is poor


(Starting always takes time)
General causes why exhaust smoke comes out but engine takes time to start
Defective electrical system
Insufficient supply of fuel
Insufficient intake of air
Improper selection of fuel
(At ambient temperature of 10C or below,
ASTM D975 No. 2 diesel fuel is used)

1.22

1.24

1.23

0C

1.30

1.28

1.26

1.25

1.24

The specific gravity should exceed the value for the charging
rate of 70% in the above table.
In cold areas the specific gravity must exceed the value for the
charging rate of 75% in the above table.

Electrical intake air heater

1.23

1.25

Clogged feed pump gauze filter

1.24

1.27

Replace

1.26

1.29

Clean

1.28

0C

Clogged air cleaner element

20C

Clogged fuel filter, strainer

70 %

Clean

75 %

Worn piston ring, cylinder

80 %

Defective contact of valve, valve seat

90 %

Correct

Charging rate
100 %
Ambient
temperature

Replace

a Battery charging rate and gravity

Clean

Causes

Confirm recent repair history


Degree of use of machine

Questions

Ease of starting

Operated for long period


Gradually became worse
Starts when warm

Indicator lamp does not light up


Engine oil must be added more frequently
Replacement of filters has not been carried out according to operation Manual
Non-specified fuel has being used
Dust indicator lamp is red
Battery charge lamp is ON
Starting motor cranks engine slowly
When exhaust manifold is touched immediately after starting engine,
temperature of some cylinders is low
Engine does not pick up smoothly, and combustion is irregular

Check items

Blow-by gas is excessive


Timing lock on fuel injection pump does not match
Mud is stuck to fuel tank cap
When engine is cranked with starting motor,
1) Little fuel comes out even when injection pump piping sleeve nut is loosened
2) Little fuel comes out even when fuel filter air bleed plug is loosened
Leakage from fuel piping
There is hunting from engine (rotation is irregular)

When compression pressure is measured, it is found to be low


When air cleaner element is inspected directly, it is found to be clogged

Troubleshooting

When fuel filter, strainer are inspected directly, they are found to be clogged
When feed pump strainer is inspected directly, it is found to be clogged
Heater mount does not become warm
Is voltage 2630V between alternator terminal B and terminal E
with engine at low idling?

Yes
No

Either specific gravity of electrolyte or voltage of battery is low


Speed does not change when operation of certain cylinders is stopped
When control rack is pushed, it is found to be heavy or does not return
(check after removing fuel injection pump)
When fuel tank cap is inspected directly, it is found to be clogged
Remedy

Use a test stand when adjusting.

20-606
(1)

PC130-7

PC130-7
Leakage, clogging, air in fuel piping
Clogged air breather hole in fuel tank
Defective feed pump
Defective boost compensator cancel

Clean

Replace

Replace

Adjust

Correct

Defetive injection timing

Replace

Defetive injection pump (rack, plunger stuck)

Defective injection nozzle

Replace

Replace

Defective alternator
Defective or deteriorated battery

Replace

Defective regulator

Replace

TROUBLESHOOTING
S-1

Causes

20-607

(1)

S-2

TROUBLESHOOTING

S-2 Engine does not start


(1) Engine does not turn
General causes why engine does not turn

Causes

Internal parts of engine seized

Defective or deteriorated battery

Defective starting motor

Broken ring gear

Defective safety relay or safety switch

Defective battery relay

Defective battery terminal connection

Defective fuel cut solenoid

Defective starting switch

Replace

Replace

Replace

Replace

Replace

Replace

Replace

Defective wiring of starting circuit

Defective electrical system


Failure in power train

Questions

Replace

a If internal parts of the engine are seized, carry


out troubleshooting for Engine stops during
operations.

Confirm recent repair history


Degree of use of machine

Operated for long period

Condition of horn when


starting switch is turned ON

Horn sounds
Horn volume is low
Speed of rotation is low

When starting switch is


turned to START, pinion
moves out, but

Makes grating noise


Soon disengages pinion again

Check items

Makes rattling noise and does not turn


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 starting switch is turned ON, linkage is not actuated

Specific gravity of electrolyte, voltage of battery is low

Troubleshooting

For the following conditions 1) - 5), turn the starting switch


OFF, connect the cord, and carry out troubleshooting
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 connected,
engine starts
3) When terminal B and terminal C of safety relay are connected,
engine starts
4) When terminal of safety switch and terminal B of starting motor are
connected, engine starts
5) There is no 24V between battery relay terminal b and terminal E
When ring gear is inspected directly, tooth surface is found to be
chipped

Troubleshooting of defective wiring in starting circuit

When battery is checked, battery electrolyte is found to be low

Cannot be moved by hand even when linkage of fuel cut solenoid is


disconnected
Remedy

20-608
(1)

PC130-7

S-2

TROUBLESHOOTING

(2) Engine turns but no exhaust smoke comes out


(Fuel is not being injected)
General causes why engine turns but no exhaust smoke
comes out
Causes

Clogged fuel filter, strainer

Clogged feed pump strainer

Insufficient fuel in tank

Clogged, leaking fuel piping

Clogged air breather hole in fuel tank

Defective fuel cut solenoid

Improper fuel used

Replace

Replace

Replace

Replace

Replace

Replace

Questions

ASTM D975 No.1

Seized, broken feed pump piston

ASTM D975 No.2


Diesel fuel

Replace

AMBIENT TEMPRATURE
14
32
50
68F
-10
0
10
20C

Defective injection pump (rack, plunger seized)

-4
-20

Replace

KIND OF
FLUID

Broken injection pump drive shaft, key

a Standards for use of fuel

Replace

Supply of fuel impossible


Supply of fuel is extremely small
Improper selection of fuel (particularly in winter)

Replace

Confirm recent repair history


Degree of use of machine

Operated for long period

Exhaust smoke suddenly stops coming out (when starting again)


Replacement of filters has not been carried out according to Operation
Manual
Fuel tank is found to be empty
There is leakage from fuel piping

Check items

Mud is stuck to fuel tank cap


When starting switch is turned ON, linkage is not actuated
When fuel filter is drained, fuel does not come out
When engine is cranked with starting motor,
1) No fuel comes out even when fuel filter air bleed plug is
loosened
2) No fuel spurts out even when injection pump piping sleeve nut is
loosened
Rust and water are found when fuel tank is drained
Inspect injection pump directly

Troubleshooting

When control rack is pushed, it is found to be heavy, or does


not return
Inspect feed pump directly
When fuel filter, strainer are inspected directly, they are found to be
clogged
When feed pump strainer is inspected directly, it is found
to be clogged
When fuel cap is inspected directly, it is found to be clogged
Cannot be moved by hand even when linkage of fuel cut
solenoid is disconnected
Remedy

PC130-7

20-609
(1)

S-2

TROUBLESHOOTING

(3) Exhaust smoke comes out but engine does not


start (Fuel is being injected)
General causes why exhaust smoke comes out but
engine not start

Clogged air breather hole in fuel tank cap

Clean

Clean

Improper fuel used

Leakage, clogging, air in fuel system

Clogged injection nozzle, defective spray

Correct

Defective electrical intake air heater

Defective or deteriorated battery

Replace

Clean

Correct

Clogged feed pump strainer

Clogged air cleaner element

Clean

Worn piston ring, cylinder liner

Clogged fuel filter, strainer

Clean

Defective injection pump (rack, plunger stuck)

Replace

Replace

Defective, broken valve system (valve, rocker lever, etc.)

Lack of rotating force due to defective electrical


system
Insufficient supply of fuel
Insufficient intake of air
Improper selection of fuel and oil

Replace

Causes

Confirm recent repair history

Questions

Degree of use of machine

Operated for long period

Suddenly failed to start


When engine is cranked, abnormal noise is heard from
around cylinder head
Engine oil must be added more frequently
Non-specified fuel is being used
Replacement of filters has not been carried out according to
Operation Manual
Rust and water are found when fuel tank is drained
Dust indicator lamp is red
Indicator lamp does not light up
Starting motor cranks engine slowly
Mud is stuck to fuel tank cap

Check items

When fuel lever is placed at FULL position, it does not contact stopper
When engine is cranked with starting motor,
1) Little fuel comes out even when injection pump piping
sleeve nut is loosened
2) No fuel comes out even when fuel filter air bleed plug is
loosened
There is leakage from fuel piping
When exhaust manifold is touched immediately after starting
engine, temperature of some cylinders is low
When fuel filter is drained, no fuel comes out
Remove head cover and check directly

Troubleshooting

When control rack is pushed, it is found to be heavy, or


does not return
When compression pressure is measured, it is found to be low
When fuel filter, strainer are inspected directly, they are
found to be clogged
When feed pump strainer is inspected directly, it is found to
be clogged
When air cleaner element is inspected directly, it is found to be clogged
Heater mount does not become warm
Either specific gravity of electrolyte or voltage of battery is low
When feed pump is operated, there is no response, or
operation is too heavy
Speed does not change when operation of certain cylinders is stopped
When fuel tank cap is inspected directly, it is found to be clogged

Remedy

20-610
(1)

PC130-7

S-3

TROUBLESHOOTING

S-3 Engine does not pick-up smoothly


(Follow-up is poor)
General causes why engine does not pick up smoothly
Insufficient intake of air
Insufficient supply of fuel
Improper condition of fuel injction
Improper fuel used

Defective contact of valve and valve seat


Replace

Replace

Clogged, leaking fuel piping

Seized turbocharger, interference

Replace

Correct

Worn piston ring, cylinder liner

Replace

Improper valve clearance

Seized injection pump plunger

Correct

Clogged air breather hole in fuel tank cap

Clogged injection nozzle, defective spray

Clean

Clean

Clogged feed pump strainer

Clean

Adjust

Clogged air cleaner element

Clogged fuel filter, strainer

Clean

Causes

Confirm recent repair history

Questions

Degree of use of machine

Operated for long period

Replacement of filters has not been carried out according to


Operation Manual
Non-specified fuel is being used
Engine oil must be added more frequently
Engine pick-up suddenly became poor
Rust and water are found when fuel tank is drained
Dust indicator lamp is red
Noise of interference is heard from around turbocharger
Blue under light load
Color of exhaust gas

Black

Check items

Clanging sound is heard from around cylinder head


Mud is stuck to fuel tank cap
There is leakage from fuel piping
High idling speed under no load is normal, but speed
suddenly drops when load is applied
There is hunting from engine (rotation is irregular)
When exhaust manifold is touched immediately after starting
engine, temperature of some cylinders is low
Blow-by gas is excessive
When air cleaner element is inspected directly, it is found to
be clogged

Troubleshooting

When fuel filter, strainer are inspected directly, they are


found to be clogged
When feed pump strainer is inspected directly, it is found to be
clogged
Speed does not change when operation of certain cylinders
is stopped
When control rack is pushed, it is found to be heavy, or does not return
When compression pressure is measured, it is found to be low
When turbocharger is rotated by hand, it is found to be heavy
When valve clearance is checked directly, it is found to be
outside standard value
When fuel tank cap is inspected directly, it is found to be clogged
When feed pump is operated, operation is too light or too heavy

Remedy

PC130-7

20-611
(1)

S-4

TROUBLESHOOTING

S-4 Engine stops during operations

Clogged air breather hole in fuel tank

Defective injection pump (rack, plunger stuck)

Clean

Replace

Failure in power train

Broken, seized feed pump piston

Clogged, leaking fuel piping


Correct

Replace

Replace

Clogged fuel filter, strainer

Clogged feed pump strainer

Clean

Insufficient fuel in tank

Broken pump auxiliary equipment

Replace

Clean

Broken, seized gear train

Replace

Broken fuel pump drive shaft, key

Broken dynamic valve system (valve, rocker lever, etc.)

Replace

Add

Broken, seized piston, connecting rod

Broken, seized crankshaft bearing

Replace

Causes

Replace

General causes why engine stops during operations


Seized parts inside engine
Insufficient supply of fuel
Overheating
a If there is overheating and the engine stops,
carry out troubleshooting for overheating.
Failure in power train
a If the engine stops because of a failure in the
power train, carry out troubleshooting for the
chassis.

Confirm recent repair history


Degree of use of machine

Operated for long period

Questions

Abnormal noise was heard and


engine stopped suddenly
Condition when engine
stopped

Engine overheated and stopped


Engine stopped slowly
There was hunting and engine stopped

Replacement of filters has not been carried out according


to Operation Manual
Non-specified fuel is being used
Fuel level lamp lights up
Fuel tank is found to be empty
When feed pump is operated, operation is too light or too heavy

Check items

Mud is stuck to fuel tank cap


Engine rotates, but stops when power train is operated
Does not turn at all
When it is attempted to
turn by hand using
barring tool

Turns in opposite direction


Moves amount of backlash
Shaft does not turn

Rust and water are found when fuel tank is drained


Troubleshooting of chassis

Metal particles are found when oil is drained


Remove oil pan and inspect directly

Troubleshooting

Remove head cover and inspect directly


When gear train is inspected, it does not turn
Rotates when pump auxiliary equipment is removed
When fuel filter, strainer are inspected directly, they are
found to be clogged
When feed pump strainer is inspected directly, it is found to
be clogged
Inspect feed pump directly
When control rack is pushed, it is found to be heavy, or
does not return
Remedy

20-612
(1)

PC130-7

S-5

TROUBLESHOOTING

S-5 Engine does not rotate smoothly


(Hunting)
General causes why engine does not rotate smoothly
Air in fuel system
Defective governor mechanism
Defective electric governor mechanism
(engine with electric governor)

Clogged fuel filter, strainer

Clogged, air in circuit between fuel tank and feed pump

Clogged, air in circuit between feed pump and nozzle

Clogged air breather hole in fuel tank

Clean

Correct

Correct

Clean

Insufficient fuel in tank

Clogged feed pump strainer

Clean

Low idling speed is too low

Adjust

Add

Defective adjustment of governor

Defective operation of control rack

Adjust

Defective operation of governor

a If hunting stops when electric governor rod is


disconnected, carry out troubleshooting for
the chassis.

Adjust

Causes

Adjust

Confirm recent repair history

Questions

Degree of use of machine

Operated for long period


Occurs at a certain speed range

Condition of hunting

Occurs at low idling


Occurs even when speed is raised
Occurs on slopes

Replacement of filters has not been carried out according


to Operation Manual
Fuel tank is found to be empty
Rust, water are found when fuel tank is drained

Check items

Leakage from fuel piping


When feed pump is operated,
1) No response, light, return is quick
2) No response, light, return is normal
Engine speed sometimes rises too far
Engine is sometimes difficult to stop
Seal on injection pump has come off

Troubleshooting

When governor lever is moved it is found to be stiff


When injection pump is tested, governor is found to be
improperly adjusted
When control rack is pushed, it is found to be heavy, or
does not return
When fuel tank cap is inspected directly, it is found to be clogged
When feed pump strainer is inspected directly, it is
found to be clogged
When fuel filter, strainer are inspected directly, they are
found to be clogged
Remedy

PC130-7

20-613
(1)

S-6

TROUBLESHOOTING

S-6 Engine lacks output


(or lacks power)
General causes why engine lacks output

Clogged, leaking fuel piping

Clogged air breather hole in fuel tank

Defective boost compensator diaphragm

Correct

Clean

Replace

Defective westgate diaphragm

Defective contact of valve and valve seat

Bent fuel lever linkage, defective adjustment


Adjust

Improper valve clearance

Adjust

Replace

Clogged injection nozzle, defective spray

Seized injection pump plunger

Replace

Clogged feed pump strainer

Clean

Correct

Worn piston ring, cylinder

Clogged fuel filter, strainer

Seized turbocharger, interference

Clean

Clogged air cleaner element

a If there is overheating and lack of output, carry


out troubleshooting for overheating.

Replace

Insufficient intake of air


Insufficient supply of fuel
Improper condition of fuel injection
Improper fuel used
(if non-specified fuel is used, output drops)
Lack of output due to overtaking

Clean

Replace

Causes

Confirm recent repair history


Degree of use of machine

Questions

Power was lost

Operated for long period


Suddenly
Gradually

Engine oil must be added more frequently


Replacement of filters has not been carried out according
to Operation Manual
Non-specified fuel is being used
Dust indicator lamp is red
Black
Color of exhaust gas
Blue under light load
Noise of interference is heard from around turbocharger
Blow-by gas is excessive

Check items

Engine pickup is poor and combustion is irregular


High idling speed under no load is normal, but speed
suddenly drops when load is applied
When exhaust manifold is touched immediately after starting
engine, temperature of some cylinders is low
There is hunting from engine (rotation is irregular)
Clanging sound is heard from around cylinder head
High idling speed of engine is low
Leakage from fuel piping
When air cleaner element is inspected directly, it is found to be
clogged
When turbocharger is rotated by hand, it is found to be heavy

Troubleshooting

When compression pressure is measured, it is found to be low


When fuel filter, strainer are inspected directly, they are
found to be clogged
When feed pump strainer is inspected directly, it is found to be
clogged
Speed does not change when operation of certain cylinders
is stopped
When control rack is pushed, it is found to be heavy, or
does not return
When valve clearance is checked directly, it is found to be
outside standard value
When lever is placed at FULL position, it does not contact stopper
When feed pump is operated, operation is too light or too heavy

Remedy

20-614
(1)

Replace

When fuel tank cap is inspected directly, it is found to be clogged

PC130-7

S-7

TROUBLESHOOTING

S-7 Exhaust smoke is black


(Incomplete combustion)
General causes why exhaust smoke is black
Insufficient intake of air
Improper condition of fuel injection
Excessive injection of fuel

Improper valve clearance

Crushed, clogged muffler

Leakage of air between turbocharger and head

Defective contact of valve and valve seat

Defective injection pump (rack, plunger seized)

Replace

Correct

Replace

Replace

Adjust

Adjust

Improper injection timing

Defective injection pump (excessive injection)

Adjust

Worn piston ring, cylinder

Clogged injection nozzle, defective spray

Replace

Clean

Replace

Seized turbocharger, interference

Clogged air cleaner element

Replace

Causes

Confirm recent repair history


Degree of use of machine

Operated for long period

Questions

Suddenly became black


Color of exhaust gas

Gradually became black


Blue under light load

Engine oil must be added more frequently


Power was lost

Suddenly
Gradually

Non-specified fuel is being used


Noise of interference is heard from around turbocharger
Dust indicator lamp is red
Blow-by gas is excessive

Check items

Engine pickup is poor and combustion is irregular


When exhaust manifold is touched immediately after
starting engine, temperature of some cylinders is low
Timing lock on fuel injection pump does not match
Seal on injection pump has come off
Clanging sound is heard from around cylinder head
Exhaust noise is abnormal
Muffler is crushed
Leakage of air between turbocharger and head, loose clamp
When turbocharger is rotated by hand, it is found to be heavy
When air cleaner element is inspected directly, it is found to be
clogged

Troubleshooting

When compression pressure is measured, it is found to be low


Speed does not change when operation of certain cylinders
is stopped
When check 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 it is found to be
outside standard value
When muffler is removed, exhaust color returns to normal
When control rack is pushed, it is found to be heavy, or
does not return
Remedy

PC130-7

20-615
(1)

S-8

TROUBLESHOOTING

S-8 Oil consumption is excessive


(or exhaust smoke is blue)
a Do not run the engine at idling for more than 20
minutes continuously. (Both low and high idling)

Worn, broken rear seal, seal surface

Dust sucked in from intake system

Worn valve (stem, guide), broken seal

Correct

Correct

Correct

Turbocharger
Worn seal at turbine end

Worn seal at blower end


Replace

Broken oil cooler

Replace

Leakage from oil drain plug

Correct

Replace

Leakage from oil filter or oil cooler

Leakage from oil piping

Clogged breather or breather hose

Clean

Correct

Worn piston ring, cylinder (liner less engine)

Correct

Broken piston ring

Replace

Abnormal combustion of oil


External leakage of oil
Wear of lubrication system

Replace

Leakage from oil pan or cylinder head

Causes

General causes why oil consumption is excessive

Confirm recent repair history


Degree of use of machine

Operated for long period

Questions

Oil consumption suddenly increased


Engine oil must be added more frequently
Engine oil becomes contaminated quickly
Exhaust smoke is blue under light load
Amount of blow-by gas

Excessive
None

Check items

Area around engine is dirty with oil


There is oil in engine cooling water
When exhaust pipe is removed, inside is found to be dirty with oil
When turbocharger air supply pipe is removed, inside is
found to be dirty with oil
Oil level in clutch or TORQFLOW transmission damper
chamber rises
Clamps for intake system are loose

Troubleshooting

When compression pressure is measured, it is found to be low


When breather element is inspected, it is found to be
clogged with dirty oil
There is external leakage of oil from engine
Pressure-tightness test of oil cooler shows there is leakage
Excessive play of turbocharger shaft
Inspect rear seal directly
When intake manifold is removed, dust is found inside

Remedy

20-616
(1)

Correct

When intake manifold is removed, inside is found to be


dirty with oil

PC130-7

S-9

TROUBLESHOOTING

S-9 Oil becomes contaminated quickly


General causes why oil becomes contaminated quickly
Entry of exhaust gas due to internal wear
Clogging of lubrication passage
Improper fuel
Improper oil used
Operation under excessive load

Clogged turbocharger oil drain tube

Defective seal at turbocharger turbine end

Clean

Replace

Exhaust smoke is black

Worn valve, valve guide

Clogged oil cooler

Clean

Replace

Replace

Clogged breather, breather hose

Clogged oil filter

Clean

Worn piston ring, cylinder liner

Causes

Replace

Questions

Confirm recent repair history


Degree of use of machine

Operated for long period

Engine oil must be added more frequently


Non-specified oil is being used
Color of exhaust gas

Blue under light load


Black
Carry out troubleshooting for Exhaust smoke is black.

Check items

Excessive
Amount of blow-by gas

None

When oil filter is inspected, metal particles are found


When exhaust pipe is removed, inside is found to be dirty
with oil
Engine oil temperature rises quickly

Troubleshooting

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
When oil cooler is inspected directly, it is found to be clogged
Turbocharger oil drain tube is clogged
Excessive play of turbocharger shaft
When safety valve is directly inspected, spring is found to
be catching or broken
Remedy

PC130-7

20-617
(1)

S-10

TROUBLESHOOTING

S-10 Fuel consumption is excessive


General causes why fuel consumption is excessive
Leakage of fuel
Improper condition of fuel injection
Excessive injection of fuel

Leakage of fuel inside head cover

Defective adjustment of fuel control linkage

Adjust

External leakage from fuel piping, fuel filter

Correct

Defective oil seal inside feed pump (piston)

Defective fuel injection timing

Adjust

Correct

Defective injection pump plunger

Replace

Correct

Defective injection pump (excessive injection)

Defective nozzle holder spray

Replace

Causes

Adjust

Questions

Confirm recent repair history


Degree of use of machine
Condition of fuel
consumption

Operated for long period


More than for other machines of same
model
Gradually increased
Suddenly increased
Black

Exhaust smoke color

White

Seal on injection pump has come off

Check items

There is irregular combustion


When exhaust manifold is touched immediately after starting engine,
temperature of some cylinders is low
Match mark on injection pump is misaligned
There is external leakage of fuel from engine
Engine oil level rises and smells of diesel fuel
Engine low idling and high idling speeds are high
Injection pump measurement shows that injection amount is excessive

Troubleshooting

Speed does not change when operation of certain cylinders is stopped


When control rack is pushed, it is found to be heavy, or does not return
When check is made using delivery method, injection timing is found
to be incorrect
Remove head cover and inspect directly
Remove feed pump and inspect directly
When engine speed is measured, low idling and high idling speeds
are found to be high
Remedy

20-618
(1)

PC130-7

S-11

TROUBLESHOOTING

S-11 Oil is in cooling water, or water spurts


back, or water level goes down
General causes why oil is in cooling water
Internal leakage in lubrication system
Internal leakage in cooling system

Broken cylinder head, head gasket

Broken power train oil cooler

Holes caused by pitting

Internal cracks in cylinder block

Replace

Replace

Replace

Broken oil cooler core, O-ring

Replace

Causes

Replace

Questions

Confirm recent repair history


Degree of use of machine
Oil level

Operated for long period


Suddenly increased
Gradually increased

Hard water is being used as cooling water

Troubleshooting

Check items

Engine oil level has risen, oil is cloudy white


Excessive air bubbles inside radiator, spurts back
Hydraulic oil, transmission oil is cloudy white
When hydraulic oil, transmission oil is drained, water is
found
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

Remedy

PC130-7

20-619
(1)

S-12

TROUBLESHOOTING

S-12 Oil pressure caution lamp lights up


(Drop in oil pressure)
General causes why oil pressure lamp lights up

Leakage, clogging, wear of lubricating system


Defective oil pressure control
Improper oil used (improper viscosity)
Deterioration of oil due to overheating

Causes

Defective relief valve

Leaking, crushed hydraulic piping

Defective oil pressure sensor

Defective oil level sensor

Adjust

Correct

Replace

Replace

Lack of oil in oil pan

Defective regulator valve

Adjust

Defective oil pump

Add

Broken suction pipe brazing

SAE15W-40CD

Replace

Clogged oil filter

SAE10W-30CD

Correct

SAE10WCD
Engine oil

Worn bearing, journal

SAE30CD

Clogged strainer inside oil pan

40C
Clogged oil pipe inside oil pan

-30

Selection of SAE No. according to


ambient temperature
-20
-10
0
10
20
30

Clean

Type of oil

Water, fuel in oil

a Standards for engine oil selection

Questions

Confirm recent repair history


Degree of use of machine

Operated for long period

Replacement of filters has not been carried out according to


Operation Manual
Non-specified oil is being used
Caution lamp lights up
Lights up at low idling
Condition when oil
pressure lamp lights up

Lights up at low, high idling


Lights up on slopes

Check items

Sometimes lights up
There is crushing, leakage from hydraulic piping (external)
Oil level sensor lamp lights up
When oil level in oil pan is inspected, it is found to be low
Metal particles are found when oil is drained
Metal particles are stuck to oil filter element

Carry out troubleshooting


for Oil level rises.

Oil is cloudy white or smells of diesel oil

Remove oil pan and inspect directly


Oil pump rotation is heavy, there is play
There is catching of relief valve or regulator valve, spring or
valve guide is broken
When oil level sensor is replaced, oil level sensor lamp goes out

20-620
(1)

Clean

Remedy

Clean

When oil pressure is measured, it is found to be within


standard value
Clean

Troubleshooting

When oil filter is inspected, it is found to be clogged

PC130-7

S-13

TROUBLESHOOTING

S-13 Oil level rises (Water, fuel in oil)


a If there is oil in the cooling water, carry out troubleshooting for Oil is in cooling water.
General causes why oil level rises

Leakage of fuel from piping inside head cover

Defective thermostat

Holes made by pitting

Cracks inside cylinder block

Correct

Replace

Replace

Defective pump auxiliary equipment seal

Replace

Defective part inside injection pump

Worn, damaged rear seal surface

Correct

Replace

Broken cylinder head, head gasket

Replace

Correct

Broken oil cooler core, O-ring

Defective nozzle holder sleeve

Replace

Water in oil (milky white)


Fuel in oil (diluted, and smells of diesel fuel)
Entry of oil from other component

Replace

Causes

Questions

Confirm recent repair history


Degree of use of machine

Operated for long period

There is oil in radiator cooling water


Fuel must be added more frequently
Exhaust smoke is white

Check items

When engine is first started, drops of water come from


muffler
Leave radiator cap open. When engine is run at idling,
an abnormal number of bubbles appear, or water spurts back
Oil level goes down in clutch, TORQFLOW transmission,
or damper chamber
Oil level goes down in hydraulic tank
Engine oil smells of diesel fuel
Water temperature is low
Pressure-tightness test of oil cooler shows there is leakage

Troubleshooting

Pressure-tightness test of cylinder head shows there is leakage


When compression pressure is measured, it is found to be low
Inspect rear seal directly
When pump auxiliary equipment is removed, seal is found to
be damaged
Remove head cover and inspect directly
Remove injection pump and inspect directly
Defective contact with thermostat seal valve
Remove oil pan and check directly

Remedy

PC130-7

20-621
(1)

S-14

TROUBLESHOOTING

S-14 Water temperature becomes too high


(Overheating)
General causes why water temperature becomes too
high
Lack of cooling air (deformation, damage of fan)
Drop in heat dissipation efficiency
Defective cooling circulation system
Rise in oil temperature in power train

Broken cylinder head, head gasket

Holes made by pitting

Replace

Replace

Replace

Rise in torque converter oil temperature

Clogged, broken oil cooler

Defective pressure valve

Replace

Lack of cooling water

Defective water temperature gauge

Replace

Fan belt slipping, worn fan pulley

Clogged radiator core

Defective thermostat (does not open)

Replace

Correct

Correct

Broken water pump

Clogged, crushed radiator fins

Replace

a Carry out troubleshooting for chassis.

Correct

Causes

Add

Confirm recent repair history

Questions

Degree of use of machine


Condition of overheating

Operated for long period


Suddenly overheated
Always tends to overheat

Water temperature
gauge

Rises quickly
Does not go down from red range

Radiator water level sensor lights up


Fan belt whines under sudden load
Cloudy white oil is floating on cooling water
Cooling water flows out from overflow hose

Check items

Excessive air bubbles inside radiator, water spurts back


Engine oil level has risen, oil is cloudy white
There is play when fan pulley is rotated
Radiator shroud, inside of underguard are clogged with dirt or mud
When light bulb is held behind radiator, no light passes through
Water is leaking because of cracks in hose or loose clamps
When belt tension is inspected, it is found to be loose
Power train oil temperature enters red range faster than
engine water temperature

Carry out troubleshooting for chassis.

Temperature difference between top and bottom radiator tanks


is excessive

Troubleshooting

Temperature difference between top and bottom radiator tanks


is slight
When water filler port is inspected, core is found to be clogged
When function test is carried out on thermostat, it does not
open even at cracking temperature
When water temperature is measured, it is found to be normal
When oil cooler is inspected directly, it is found to be clogged
When measurement is made with radiator cap tester, set
pressure is found to be low
When compression pressure is measured, it is found to be low
Remove oil pan and inspect directly

Remedy

20-622
(1)

PC130-7

S-15

TROUBLESHOOTING

S-15 Abnormal noise is made


a Judge if the noise is an internal noise or an external
noise.
General causes why abnormal noise is made

Defective injection pump (excessive injection)

Deformed fan, fan belt interference

Defective adjustment of valve clearance

Broken dynamic valve system (valve, rocker lever, etc.)

Improper gear train backlash

Leakage of air between turbocharger and cylinder head

Defect inside muffler (dividing board out of position)

Replace

Correct

Replace

Replace

Replace

Correct

Correct

Defective injection pump (rack, plunger seized)

Replace

Replace

Missing, seized bushing

Clogged, seized injection nozzle

Replace

Excessive wear of piston ring, cylinder (liner less engine)

Seized turbocharger, interference

Replace

Abnormality due to defective parts


Abnormal combustion
Air sucked in from intake system

Replace

Causes

Questions

Confirm recent repair history


Degree of use of machine

Operated for long period

Condition of abnormal
noise

Gradually occurred
Suddenly occurred

Non-specified fuel is being used


Engine oil must be added more frequently
Color of exhaust gas

Blue under light load


Black

Metal particles are found in oil filter


Blow-by gas is excessive

Check items

Noise of interference is heard from around turbocharger


Engine pickup is poor and combustion is abnormal
When exhaust manifold is touched immediately after starting
engine, temperature of some cylinders is low
Seal on injection pump has come off
Abnormal noise is loud when accelerating engine
Clanging sound is heard from around cylinder head
Leakage of air between turbocharger and cylinder head, loose clamp
Vibrating noise is heard from around muffler
When compression pressure is measured, it is found to be low
When turbocharger is rotated by hand, it is found to be heavy

Troubleshooting

Remove gear cover and inspect directly


Speed does not change when operation of certain cylinders is
stopped
When control rack is pushed, it is found to be heavy, or does
not return
Injection pump test shows that injection amount is incorrect
Fan is deformed, belt is loose
When valve clearance is checked, it is found to be outside
standard value
Remove cylinder head cover and inspect directly
When muffler is removed, abnormal noise disappears

Remedy

PC130-7

20-623
(1)

S-16

TROUBLESHOOTING

S-16 Vibration is excessive


a If there is abnormal noise together with the vibration, carry out troubleshooting also for Abnormal
noise is made.
General causes why vibration is excessive

Improper gear train backlash

Defective dynamic valve system (valve, rocker lever, etc. stuck)

Defective injection pump (excessive fuel injection)

Correct

Replace

Adjust

Broken part inside output shaft (damper)

Center of engine and power train misaligned

Correct

Replace

Replace

Worn cam bushing

Loose engine mounting bolts, broken cushion

Replace

Worn connecting rod, main bearing

Defective parts (abnormal wear, breakage)


Improper alignment
Abnormal combustion

Replace

Causes

Questions

Confirm recent repair history


Degree of use of machine
Condition of vibration

Operated for long period


Suddenly increased
Gradually increased

Non-specified oil is being used


Metal particles are found in oil filter
Metal particles are found when oil is drained

Check items

Oil pressure is low at low idling


Vibration occurs at mid-range speed
Vibration follows engine speed
Exhaust smoke is black
Seal on injection pump has come off
Remove oil pan and inspect directly

Troubleshooting

Remove side cover and inspect directly


Inspect directly for loose engine mounting bolts, broken cushion
Inspect inside of output shaft (damper) directly
When face runout and radial runout are inspected, they are
found to be incorrect
Remove front cover and inspect directly
Remove head cover and inspect directly
Injection pump test shows that injection amount is incorrect

Remedy

20-624
(1)

PC130-7

30 DISASSEMBLY AND ASSEMBLY

HOW TO READ THIS MANUAL ................................................................................................................ 30- 2


PRECAUTIONS WHEN PERFORMING OPERATION .............................................................................. 30- 4
SPECIAL TOOL LIST ................................................................................................................................. 30- 6
SKETCH OF SPECIAL TOOL ................................................................................................................... 30- 9
REMOVAL AND INSTALLATION OF FUEL INJECTION PUMP ASSEMBLY .......................................... 30- 10
REMOVAL AND INSTALLATION OF CYLINDER HEAD ASSEMBLY....................................................... 30- 13
REMOVAL AND INSTALLATION OF RADIATOR ASSEMBLY ................................................................ 30- 18
REMOVAL AND INSTALLATION OF AFTERCOOLER ASSEMBLY ........................................................ 30- 19
REMOVAL AND INSTALLATION OF HYDRAULIC OIL COOLER ASSEMBLY ....................................... 30- 21
REMOVAL AND INSTALLATION OF ENGINE AND HYDRAULIC PUMP ASSEMBLY ........................... 30- 23
EXPANSION AND INSTALLATION OF TRACK SHOE ASSEMBLY ........................................................ 30- 28
REMOVAL AND INSTALLATION OF SPROCKET .................................................................................... 30- 30
REMOVAL AND INSTALLATION OF FINAL DRIVE ASSEMBLY ............................................................. 30- 31
DISASSEMBLY AND ASSEMBLY OF IDLER ASSEMBLY ....................................................................... 30- 32
DISASSEMBLY AND ASSEMBLY OF RECOIL SPRING........................................................................... 30- 35
DISASSEMBLY AND ASSEMBLY OF TRACK ROLLER ASSEMBLY ...................................................... 30- 39
DISASSEMBLY AND ASSEMBLY OF CARRIER ROLLER ASSEMBLY .................................................. 30- 40
REMOVAL AND INSTALLATION OF SWING MOTOR AND SWING MACHINERY ASSEMBLY ............. 30- 41
DISASSEMBLY AND ASSEMBLY OF SWING MOTOR AND SWING MACHINERY ASSEMBLY .......... 30- 42
REMOVAL AND INSTALLATION OF CENTER SWIVEL JOINT................................................................ 30- 48
DISASSEMBLY AND ASSEMBLY OF CENTER SWIVEL JOINT ASSEMBLY ......................................... 30- 50
REMOVAL AND INSTALLATION OF WORK EQUIPMENT ASSEMBLY ................................................... 30- 51
REMOVAL AND INSTALLATION OF REVOLVING FRAME ..................................................................... 30- 54
REMOVAL AND INSTALLATION OF SWING CIRCLE ASSEMBLY ......................................................... 30- 56
REMOVAL AND INSTALLATION OF HYDRAULIC TANK ASSEMBLY .................................................... 30- 57
REMOVAL AND INSTALLATION OF CONTROL VALVE ASSEMBLY ..................................................... 30- 60
DISASSEMBLY AND ASSEMBLY OF CONTROL VALVE ASSEMBLY ................................................... 30- 63
REMOVAL AND INSTALLATION OF HYDRAULIC PUMP ASSEMBLY ................................................... 30- 65
REMOVAL AND INSTALLATION OF HYDRAULIC PUMP INPUT SHAFT OIL SEAL .............................. 30- 68
DISASSEMBLY AND ASSEMBLY OF HYDRAULIC CYLINDER ASSEMBLY ......................................... 30- 69
REMOVAL AND INSTALLATION OF COUNTERWEIGHT ASSEMBLY ................................................... 30- 75
REMOVAL AND INSTALLATION OF AIR CONDITIONER UNIT ASSEMBLY ......................................... 30- 76
REMOVAL AND INSTALLATION OF OPERATOR'S CAB ........................................................................ 30- 79
REMOVAL AND INSTALLATION OF OPERATOR'S CAB GLASS (STUCK GLASS) .............................. 30- 83
REMOVAL AND INSTALLATION OF FRONT WINDOW ASSEMBLY ...................................................... 30- 94
REMOVAL AND INSTALLATION OF MONITOR PANEL ASSEMBLY ..................................................... 30-101
REMOVAL AND INSTALLATION OF CONTROLLER ASSEMBLY .......................................................... 30-102

PC130-7

30-1
(2)

DISASSEMBLY AND ASSEMBLY

HOW TO READ THIS MANUAL

HOW TO READ THIS MANUAL


REMOVAL AND INSTALLATION OF ASSEMBLIES
SPECIAL TOOLS

INSTALLATION OF PARTS

Special tools that are deemed necessary for


removal or installation of parts are listed.
List of the special tools contains the following
kind of information
1) Necessity
t: Special tools which cannot be substituted, should always be used.
q: Speciall tools which are very useful if
available, can be substituted with commercially available tools.

2) Distinction of new and existing special tools.


N: Tools with new part numbers, newly
developed for this model.
R: Tools with upgraded part numbers,
remodeled from already available tools
for other models.
Blank: Tools already available for other models,
used without any modification.
3) Circle mark (Q) in sketch column.
A circle mark means that a sketch of the special tool is presented in the section of
Sketches for Special Tools.
a Part No. of special tools starting with 79*T
means that they are locally made parts and as
such not interchangeable with those made by
Komatsu in Japan e.g. 79*T------.

Except where otherwise instructed, install parts


is the reverse order of removal.
Instructions and precautions for installing part
are shown with [*1] mark in the INSTALLATION
Section, identifying which step the instructions
are intended for.
Marks shown in the INSTALLATION Section
stand for the following.
k
a

This mark indicates safety-related precautions, which must be followed when


doing the work.
This marks gives guidance or precautions when doing the procedure.

2 This mark stands for a specific coating


agent to be used.
3 This mark indicates the specified torque.
5

This mark indicates an amount of oil or


water to be added.

SKETCHES OF SPECIAL TOOLS

Various special tools are illustrated for the convenience of local manufacture.

REMOVAL OF PARTS

The REMOVAL Section contains procedures,


precautions and the amount of oil or water to be
drained.
Various symbols used in the REMOVAL Section
are explained and listed below.
k
a
[*1]

This mark indicates safety-related precautions, which must be followed when


doing the work.
This mark gives guidance or precautions
when doing the procedure.
This mark shows that there are instructions or precautions for installing parts.

6 This mark shows oil or water be drained.

4 This mark shows the weight of a part or a


device.

30-2
(2)

PC130-7

DISASSEMBLY AND ASSEMBLY

HOW TO READ THIS MANUAL

DISASSEMBLY AND ASSEMBLY OF ASSEMBLIES


SPECIAL TOOLS

Special tools which are deemed necessary for


disassembly and assembly are listed in this section.
List of the special tools contains the following
kind of information.
1) Necessity
t: Special tools which cannot be substituted, should always be used.
q: Speciall tools which are very useful if
available, can be substituted with commercially available tools.
2) Distinction of new and existing special tools.
N: Tools with new part numbers, newly
developed for this model.
R: Tools with upgraded part numbers,
remodeled from already available tools
for other models.
Blank: Tools already available for other models,
used without any modification.
3) Circle mark (Q) in sketch column.
A circle mark means that a sketch of the special tool is presented in the section of
Sketches for Special Tools.
4) Part No. of special tools starting with 79*T
means that they are locally made parts and
as such not interchangeable with those
made by Komatsu in Japan e.g. 79*T-----.

ASSEMBLY

Section titled ASSEMBLY contain procedures,


precautions and the know-how for the work, as
well as the amount of oil or water to be added.
Various symbols used in the ASSEMBLY Section
are explained and listed below.
k
a

This mark indicates safety-related precautions, which must be followed when


doing the work.
This marks gives guidance or precautions when doing the procedure.

2 This mark stands for a specific coating


agent to be used.
3 This mark indicates the specified torque.
5

This mark indicates an amount of oil or


water to be added.

SKETCHES OF SPECIAL TOOLS


1) Vartious special tools are illustrated for the
convenience of local manufacture.

DISASSEMBLY

The DISASSEMBLY Section contains procedures, precautions and the amount of oil or water
to be drained.
Various symbols used in the DISASSEMBLY
Section are explained and listed below.
k
a

This mark indicates safety-related precautions which must be followed when doing
the work.
This mark gives guidance or precautions
when doing the procedure.

6 This mark shows oil or water to be


drained.

PC130-7

30-3
(2)

DISASSEMBLY AND ASSEMBLY

PRECAUTIONS WHEN PERFORMING OPERATION

PRECAUTIONS WHEN PERFORMING OPERATION


Be sure to follow the general precautions given below when performing removal or installation (disassmbly or
assembly) of units.
1. Precautions when performing removal work
If the engine coolant water contains antifreeze, dispose of it correctly.
After disconnecting hoses or tubes, cover them or install blind plugs to prevent dirt or dust from entering.
When draining oil, prepare a container of adequate size to catch the oil.
Confirm the match marks showing the installation position, and make match marks in the necessary
places before removal to prevent any mistake when assembling.
To avoid loosening any wire contacts, do not pull on the wires. In-order to prevent excessive force to the
wiring, hold onto the connectors when disconnecting them.
Fasten tags to wires and hoses to identify and show their installation position and help to prevent any
mistakes when re-installing.
Count and check the number and thickness of the shims, and keep them in a safe place.
When raising or lifting components, be sure to use proper lifting equipment of ample strength and safety.
When using forcing screws to remove any components, tighten the forcing screws uniformly in turn.
Before removing any unit, clean the surrounding area and install a cover to prevent any dust or dirt from
entering after removal.
a Precautions when handling piping during disassembling
Fit the following blind plugs into the piping after disconnecting it during disassembly operations.
A.

Face seal type hoses and tubes


Nominal
number
02
03
04
05
06

B.

Plug (nut end)

Nut (elbow end)

07376-70210
07376-70315
07376-70422
07376-70522
07376-70628

02789-00210
02789-00315
02789-00422
02789-00522
02789-00628

Split flange type hoses and tubes


Nominal
number
04
05

Flange (hose end)

Sleeve head (tube end)

Split flange

07379-00400
07379-00500

07378-10400
07378-10500

07371-30400
07371-30500

C. If the part is not under hydraulic pressure, the following corks can be used.

30-4
(2)

Nominal
number

Part Number

06
08
10
12
14
16
18
20
22
24
27

07049-00608
07049-00811
07049-01012
07049-01215
07049-01418
07049-01620
07049-01822
07049-02025
07049-02228
07049-02430
07049-02734

Dimensions
D
d
L
6
5
8
8
6.5
11
10
8.5
12
12
10
15
14 11.5 18
16 13.5 20
18
15
22
20
17
25
22 18.5 28
24
20
30
27 22.5 34

PC130-7

DISASSEMBLY AND ASSEMBLY

PRECAUTIONS WHEN PERFORMING OPERATION

2. Precautions when carrying out installation work


Tighten all bolts and nuts (sleeve nuts) to the specified (KES) torque.
Install the hoses without twisting or interference.
Replace all gaskets, O-rings, cotter pins, and lock plates with new parts.
Bend the cotter pins or lock plate securely.
When coating with adhesive, clean the part and remove all oil and grease, then coat the threaded portion with tow or three drops of adhesive.
When coating with gasket sealant, clean the surface and remove all oil and grease, check that there is
no dirt or damage, then coat uniformly with gasket sealant.
Clean all parts, and correct any damage, dents, burrs, or rust.
Coat rotating parts and sliding parts with engine oil.
When press fitting parts, coat the surface with anti-friction compound (LM-P).
After installing snap rings, check that the snap ring is installed securely in the ring groove.
When connecting wiring connectors, clean the connector to remove all oil, dirt, or water, then connect
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 tightening on one side.
a 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 it at low idle.
2. Operate the work equipment control lever to operate the hydraulic cylinders, 4 5 times, stopping the
cylinder 100 mm from the end of their stroke.
3. Next, operate the hydraulic cylinder 3 4 times to the end of its stroke.
4. After doing this, run the engine at normal speed.
a When using the machine for the first time after repair or long storage, follow the same procedure.
3. Precautions when completing the operations
If the engine coolant water has been drained, tighten the drain valve, and add coolant water to the specified level. Run the engine to circulate the coolant water through the system. Then check the coolant
water level again.
If the hydraulic equipment has been removed and installed again, add engine oil to the specified level.
Run the engine to circulate the oil through the system. Then check the oil level again.
If the piping or hydraulic equipment have been removed for repair, Bleed the air from the system after
reassembling the parts.
a For details, see TESTING AND ADJUSTING, Bleeding air.
Add the specified amount of grease (molybdenum disulphide grease) to the work equipment parts.

PC130-7

30-5
(2)

DISASSEMBLY AND ASSEMBLY

SPECIAL TOOL LIST

SPECIAL TOOL LIST

Wrench

790-101-2501

Push puller

790-101-2510

Block

790-101-2520

Screw

791-112-1180

Nut

790-101-2540

Washer

790-101-2630

Leg

790-101-2570

Plate

790-101-2560

Nut

790-101-2650

Adapter

796-460-1210

Oil stopper

790-101-2501

Push puller KIT

790-101-2510

Block

790-101-2550

Leg

790-101-2560

Nut

790-101-2570

Plate

790-101-3101

Bearing puller

790-101-4200

Puller

796T-426-1140

Push tool

790-201-2680

Plate

1 790-201-2850

Spacer

2 790-201-2750

Spacer

Symbol

Removal and installation


of cylinder head assembly

Disassembly and assembly of center swivel joint


assembly

Removal and installation


of engine and hydraulic
pump assembly
Removal and installation
of hydraulic pump assembly

Disassembly and assembly of swing machinery


assembly

Part No.

Part Name

30-6
(2)

Sketch

Qty

790-331-1110

Work item

New/
Remodel

Necessity

a Tools with part number 79 Tcannot be supplied (they must be locally manufactured).
a Necessity:
t...........Cannot be substituted, should always be installed (used)
q...........Extremely useful if available, can be substituted with commercially available part.
a New/Remodel:N ...........Tools with new part numbers, newly developed for this model.
:R ...........Tools with upgraded part numbers, remodeled from items already available for other
models.
:Blank.....Tools already available for other models, used without any modification
a Tools marked
in the Sketch column are tools introduced in the sketches of the special tools (See
SKETCHES OF SPECIAL TOOLS).
Contents of work
Tightening of cylinder head
bolt

Disassembly of center swivel


joint assembly

Stopping of oil

Removal of bearing

Q
Press fitting of oil seal

Press fitting of bearing inner


race

PC130-7

DISASSEMBLY AND ASSEMBLY

4
Disassembly and assembly of swing machinery
assembly

Press fitting of bearing outer


race

Plate

For main bearing

790-101-5441

Plate

For sub bearing

790-101-5421

Grip

01010-51240

Bolt

790-201-2850

Spacer

790-201-2650

Plate

790-502-1003

Cylinder repair
stand

790-102-4300

Wrench assembly

790-102-4310

Pin

790-720-1000

Expander

796-720-1660

Ring
(For boom and arm)
Clamp
(For boom and arm)

Part Name

790-101-5401

Push tool KIT

790-101-5461

07281-01159
4

Disassembly and assembly of hydraulic cylinder


assembly

Ring (For bucket)

07281-01029

Clamp (For bucket)

790-201-1702

Push tool KIT

790-101-5021

Grip

01010-50816

Bolt

Disassembly and assembly of


hydraulic cylinder assembly
Removal and installation of
piston

Installation of piston ring

790-201-1811
790-201-1821
790-201-1791

Push tool
(For boom)
Push tool
(For arm)
Push tool
(For bucket)

Press fitting of cylinder head


bushing

1
1

790-201-1500

Push tool KIT

790-201-5021

Grip

01010-50818

Bolt

790-201-1620

Plate (For boom)

790-201-1630

Plate (For arm)

790-201-1610

Plate (For bucket)

791-600-2001
or
791-685-8006

Compressor

790-201-2780

Spacer

PC130-7

Contents of work

Removal of 2-piece collar

796-720-1650

Disassembly and assembly of recoil spring assembly

Sketch

Part No.

New/
Remodel

Qty

Symbol

Necessity

Work item

SPECIAL TOOL LIST

Installation of dust seal

Disassembly and assembly


of recoil spring assembly

30-7
(2)

DISASSEMBLY AND ASSEMBLY

Extension

790-101-1300

Cylinder

790-101-1102

Pump

790-201-1500

Push tool KIT

790-201-1590

Plate

790-101-5021

Grip

790-101-5021

Grip

01010-50816

Bolt

791-675-1510

Installer

790-434-1650

Installer

791-601-1000

Oil pump

Filling with oil

790-434-1660

Installer

Installation of floating seal

791-601-1000

Oil pump

Filling with oil

791-616-1040
or
791-620-7000

Remover and
installer

790-105-1100

Cylinder

790-101-1102

Pump

791-463-1141

Push tool

790-201-2740

Spacer

799-703-1200

Service KIT

799-703-1100

799-703-1120

Vacuum pump
(For 100 V)
Vacuum pump
(For 220 V)
Vacuum pump
(For 240 V)

799-703-1401

Gas leak detector

799-703-1300

Adapter (When
vacuum pump for
refrigerant R12 is
used)

792-785-1100

Remover

790-101-4000

Puller

790-101-1102

Pump

793-498-1210

Lifter (Suction cup)

20Y-54-13180

Adapter

Disassembly and assembly of recoil spring assembly

Disassembly and assembly of idler assembly

Disassembly and assembly of carrier roller assembly

Development and installation of track shoe assembly

Removal and installation


of hydraulic pump input
shaft oil seal

799-703-1110
Removal and installation
of air conditioner unit
assembly

Removal and installation


of work equipment assembly

Removal and installation


of operator's cab glass
(stuck glass)

30-8
(2)

Part Name

Contents of work

Disassembly and assembly


of recoil spring assembly

Disassembly and assembly of track roller assembly

Part No.

Sketch

Qty

791-635-3160

Symbol

New/
Remodel

Necessity

Work item

SPECIAL TOOL LIST

Installation of dust seal

Installation of floating seal

Removal and press fitting of


master pin

Press fitting of oil seal

Filling with air conditioner


refrigerant (gas)

Removal of boom foot pin

Fixing of window glass

PC130-7

DISASSEMBLY AND ASSEMBLY

SKETCH OF SPECIAL TOOL

SKETCH OF SPECIAL TOOL


NOTE: Komatsu cannot accept any responsibility for special tools manufactured according to these sketches.

F2 Push tool

PC130-7

30-9
(2)

DISASSEMBLY AND ASSEMBLY

REMOVAL AND INSTALLATION


OF FUEL INJECTION PUMP
ASSEMBLY

FUEL INJECTION PUMP

4. Disconnect connector E05 (6) and remove clamp


(7).
5. Loosen bolts (8) and (9) and remove air conditioner compressor belt (10).
[*1]

REMOVAL

k Disconnect the cable from the negative () terminal of the battery.


1. Remove hood assembly (1).

4 Hood assembly: 30 kg

6. Remove bolts (8) and (9) and spacer (11).


Remove air conditioner compressor and bracket
assembly (12) and move them toward the counterweight.
a Do not separate the piping.

7. Remove heater hose (13).


2. Remove covers (2) (4).

8. Disconnect fuel hoses (14) and (15).


a Plug the hoses to prevent the fuel from leaking.
9. Remove fuel filter and bracket assembly (16).

3. Remove fan guard (5).

30-10
(2)

PC130-7

DISASSEMBLY AND ASSEMBLY

FUEL INJECTION PUMP

15. Remove lubrication tube (23).

10. Disconnect hose (17).


11. Remove tube (18).
12. Remove governor spring mounting nut (19).

16. Check that the fuel injection timing is normal.


For details, see TESTING AND ADJUSTING,
Testing and adjusting fuel injection timing, Testing and adjusting by match mark method.
[*3]
13. Remove 4 fuel tubes (20).

[*2]
17. Remove 5 mounting bolts (24), (25), and (26),
rear mounting bracket, and fuel injection pump
assembly (27).
[*3]
a Remove the above parts together with holder
(28).
a After removing the above parts, remove bolt
(29) and fix drive gear (30) to holder (28) with
fixing bolt [1] to prevent a change of the fuel
injection timing.
a As fixing bolt [1], use a bolt 6 mm in diameter
and at least 35 mm in length.

14. Disconnect fuel hoses (21) and (22).


a Plug the hoses to prevent the fuel from leaking.

PC130-7

30-11
(2)

DISASSEMBLY AND ASSEMBLY

FUEL INJECTION PUMP

INSTALLATION

Bleeding Air

Carry out installation in the reverse order to


removal.

[*1]

[*2]

[*3]

Adjust the tension of the air conditioner compressor belt. For details, see TESTING AND
ADJUSTING, Testing and adjusting tension
of air conditioner compressor belt.

3 Fuel tube sleeve nut:


19.6 24.5 Nm {2 2.5 kgm}
k After installing the fuel injection pump assembly, remove fuel injection timing adjustment pin
(See TESTING AND ADJUSTING, Testing
and adjusting fuel injection timing) and fixing
bolt [1] without fail.

Bleed air from the fuel piping according to the following procedure.

1. Fill the fuel tank with fuel (up to the maximum rising position of the float).
2. Loosen eyebolt (31).
3. Remove cap (32). Loosen the feed pump knob
and move it up and down to let fuel flow out of
the mounting part of eyebolt (23) until bubbles do
not come out any more.
4. Tighten eyebolt (31).

5. Start the engine and check that fuel does not


leak from the fuel system.
a Adjust the governor lever stroke. For details, see
TESTING AND ADJUSTING, Special functions
of monitor panel, 5. Governor adjusting mechanism 03.

30-12
(2)

PC130-7

DISASSEMBLY AND ASSEMBLY

CYLINDER HEAD

REMOVAL AND INSTALLATION


OF CYLINDER HEAD
ASSEMBLY

4. Remove bracket (6) and covers (7) and (8).

Wrench

REMOVAL

Sketch

790-331-1110

New/Remodel

Part name

Q'ty

Part No.

Necessity

Symbol

SPECIAL TOOL

t 1

k Disconnect the cable from the negative () terminal of the battery.

5. Remove fan guard (9) and hose (10).

[*1]

1. Remove hood assembly (1).

4 Hood assembly: 30 kg

6. Remove fan guard (11).


7. Disconnect connector E05 (12) and remove
clamp (13).

2. Drain the coolant.

6 Coolant: 13.4 l

3. Remove covers (2) (5).

PC130-7

8. Loosen bolts (14) and (15) and remove air conditioner compressor belt (16).
[*2]
9. Remove bolts (14) and (15) and spacer (17).
Remove air conditioner compressor and bracket
assembly (18) and move them toward the counterweight.
a Do not separate the piping.

30-13
(2)

DISASSEMBLY AND ASSEMBLY

CYLINDER HEAD

10. Remove heater hose (19).


11. Remove fuel filter and bracket assembly (20)
and move it to a place where it will not be an
obstacle.

14. Remove air conditioner compressor bracket (26).


a Remove the connector on the underside
from the clamp.
15. Remove heat insulation plate (27).
16. Remove clamp (28).

[*4]

12. Remove hoses (21) and (22), tube (23), and terminal (24).
17. Remove cover (28a).

13. Remove fuel tube (25).

[*3]
18. Remove muffler drain tube (29).
a The muffler drain tube is fixed by the hydraulic pump assembly mounting bolts.

30-14
(2)

PC130-7

DISASSEMBLY AND ASSEMBLY

CYLINDER HEAD

25. Remove cooling fan (41).

19. Remove muffler and bracket assembly (30).

26. Remove hoses (42) and (43) and water pump


assembly (44).
[*9]

20. Remove air intake hose (31) and air intake connector (32) from the turbocharger.
[*5]
21. Remove exhaust outlet (33).

[*6]

27. Remove tube (45).

22. Remove cylinder head cover (34).

[*7]

28. Remove the 2 mounting bolts on the turbocharger side of tube (46) and the clamp mounting bolt.
29. Remove exhaust manifold and turbocharger
assembly (47).
[*10]

23. Remove alternator mounting bolts (35) and (36).


24. Loosen locknut (37), move alternator (39) with
adjustment nut (38), and remove fan belt (40).
[*8]

PC130-7

30-15
(2)

DISASSEMBLY AND ASSEMBLY

30. Loosen locknut (48), and then loosen adjustment


screw (49) by 2 3 turns.
[*11]
a Perform this work at all of the 8 places.
31. Remove 5 mounting bolts (50), 3 mounting nuts
(51), and rocker arm and shaft assembly (52).
[*12]

CYLINDER HEAD

INSTALLATION

Carry out installation in the reverse order to


removal.

[*1]

3 Hose clamp:
10.5 0.5 Nm {107 5 kgcm}

32. Remove 8 push rods (53).


[*2]
33. Remove the (17) mounting bolts and lift off cylinder head and air intake manifold assembly (54).
[*13]
4 Cylinder head and air intake manifold
assembly: 40 kg

a Adjust the belt tension. For details, see


TESTING AND ADJUSTING, Testing and
adjusting air conditioner compressor belt tension.

[*3]

3 Fuel tube sleeve nut:


19.6 24.5 Nm {2 2.5 kgm}

[*4]

3 Clamp mounting bolt:


1st time: 39.2 49 Nm {4 5 kgm}
2nd time: 68.6 122.5 Nm {7 12.5 kgm}

[*5]

3 Clamp of air intake hose (31):


8.8 0.5 Nm {0.9 0.05 kgm}

[*6]

3 Mounting nut:
27 34 Nm {2.8 3.5 kgm}

[*7]

3 Mounting bolt:
7.84 9.8 Nm {0.8 1.0 kgm}

[*8]

[*9]

a Adjust the belt tension. For details, see


TESTING AND ADJUSTING, Testing and
adjusting fan belt tension.
3 Hose clamp:
8.8 0.5 Nm {0.9 0.05 kgm}

[*10]

3 Mounting bolt:
34.3 53.9 Nm {3.5 5.5 kgm}
a If the turbocharger assembly was removed
from the exhaust manifold, tighten its nuts to
the following torque.
3 Mounting nut:
27 34 Nm {2.8 3.5 kgm}

30-16
(2)

PC130-7

DISASSEMBLY AND ASSEMBLY

CYLINDER HEAD

[*11]
a Adjust the valve clearance. For details, see
TESTING AND ADJUSTING, Adjusting valve
clearance.
[*12]

3 Mounting bolt and nut:


19.6 29.4 Nm {2 3 kgm}

[*13]
a Tighten all of the cylinder head mounting
bolts according to the following procedure.
a Numbers (1) (4) in the figure denote the following.
(1): Exhaust side (2): Intake side
(3): Front
(4): Rear
1) Clean the screw holes on the cylinder
block side.
2) Apply molybdenum disulfide grease (LMP) to the threads and end of each bolt
and the bottom of each cylinder head
hole.
3) Rotate the bolts with the hand in the
numeric order shown in the figure until
each of them catch 2 3 threads of the
screw hole of the cylinder head.
4) Tighten the bolts to the torque of 68.6
9.8 Nm {7 1 kgm} in the numeric order
shown in the figure.
5) Tighten the bolts to the torque of 107.8
4.9 Nm {11 0.5 kgm} in the numeric
order shown in the figure.
+ 30
6) Using tool A, tighten the bolts by 90 0
in the numeric order shown in the figure.
(Angle tightening)
a When not using tool A, make marks
with paint on the bolt heads and cylinder head, and then tighten the bolts
so that the mark of each of them will
be at the above angle to the mark of
the cylinder head.

7) After tightening each bolt, make a punch


mark on it.
a If there are 5 punch marks on a bolt,
do not use that bolt any more but
replace it.
a If the air intake manifold was removed,
apply a string of gasket sealant (LG-7)
1 mm in diameter to the rim of each air
intake port as shown in the following
figure.

a If the nozzle holder was removed,


tighten it to the following torque.

3 Mounting bolt:
39.2 49 Nm {4 5 kgm}

Refilling with coolant


Add coolant through the coolant filler to
the specified level. Run the engine to circulate the coolant through the system.
Then, check the coolant level again.
5 Coolant: 13.4 l

PC130-7

Bleeding air
Bleed air from the fuel circuit. For details,
see Removal and installation of fuel injection pump assembly.

30-17
(2)

DISASSEMBLY AND ASSEMBLY

RADIATOR

REMOVAL AND INSTALLATION


OF RADIATOR ASSEMBLY
REMOVAL
1. Remove the undercover and drain the coolant.
6 Coolant: 13.4 l

2. Disconnect hoses (1) and (2) and remove plate


(3).
[*1]

6. Remove the 2 mounting bolts and lift off radiator


assembly (9).
a You can remove the radiator assembly with
your hands.
a Take care not to damage the radiator core.
4 Radiator assembly: 8 kg

3. Remove hood assembly (4).

4 Hood assembly: 30 kg

INSTALLATION

[*1]
4. Disconnect hoses (5) and (6).

[*2]

Carry out installation in the reverse order to


removal.
a Tighten the clamp of hose (1) with the bolt
right down.
3 Clamp of hose (2):
8.8 0.5 Nm {0.9 0.05 kgm}

5. Remove plates (7) and (8).


[*2]

3 Clamp of hose (5):


8.8 0.5 Nm {0.9 0.05 kgm}

Refilling with coolant


a Add coolant through the coolant filler to the specified level. Run the engine to circulate the coolant through the system. Then, check the coolant
level again.
5 Coolant: 13.4 l

30-18
(2)

PC130-7

DISASSEMBLY AND ASSEMBLY

AFTERCOOLER

REMOVAL AND INSTALLATION


OF AFTERCOOLER
ASSEMBLY

3. Remove the 3 mounting bolts of connector (3).


4. Loosen the 4 mounting nuts of clips (4).

[*2]

REMOVAL
1. Remove hood assembly (1).

4 Hood assembly: 30 kg

2. Disconnect hose (2).

[*1]

5. Remove the undercover and disconnect hose


(5).
[*3]
6. Remove the mounting bolts of plate (6) and
move the plate toward the rear of the machine.

PC130-7

30-19
(2)

DISASSEMBLY AND ASSEMBLY

7. Disconnect hose (7).

AFTERCOOLER

[*4]

8. Remove plates (8) and (9).

INSTALLATION

Carry out installation in the reverse order to


removal.

[*1]

3 Hose clamp:
8.8 0.5 Nm {0.9 0.05 kgm}

[*2]

3 Mounting nut:
10.8 26.5 Nm {1.1 2.7 kgm}

[*3]

9. Remove the 2 mounting bolts and lift off aftercooler assembly (10).
a You can remove the aftercooler assembly
with your hands.
a Take care not to damage the aftercooler
core.
4 Aftercooler assembly: 7 kg

30-20
(2)

a Tighten the hose clamp with the bolt right


down.
3 Hose clamp:
10.5 0.5 Nm {107 5 kgcm}

[*4]

3 Hose clamp:
10.5 0.5 Nm {107 5 kgcm}

PC130-7

DISASSEMBLY AND ASSEMBLY

REMOVAL AND INSTALLATION


OF HYDRAULIC OIL COOLER
ASSEMBLY

HYDRAULIC OIL COOLER

4. Remove 4 nuts (5).

REMOVAL
1. Remove hood assembly (1).

4 Hood assembly: 30 kg

5. Remove 2 bolts (6), 2 nuts (7), and 2 bolts (8)


and (9).

2. Remove plates (2) and (3).

6. Remove tube mounting bolts (10) under the


hydraulic oil cooler.

3. Loosen plug (4) of the pipe on the side of the


hydraulic oil cooler and drain the hydraulic oil
from the hydraulic oil cooler and piping.
a Before draining the oil, open the hydraulic
tank cap to release the pressure in the tank.

PC130-7

30-21
(2)

DISASSEMBLY AND ASSEMBLY

7. Lift off hydraulic oil cooler assembly (11).


a Take care not to damage the hydraulic oil
cooler core.
a You can remove the hydraulic oil cooler
assembly with your hands.
4 Hydraulic oil cooler assembly: 6 kg

30-22
(2)

HYDRAULIC OIL COOLER

INSTALLATION

Carry out installation in the reverse order to


removal.

Refilling with oil


a 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.

PC130-7

DISASSEMBLY AND ASSEMBLY

ENGINE AND HYDRAULIC PUMP

REMOVAL AND INSTALLATION


OF ENGINE AND HYDRAULIC
PUMP ASSEMBLY

4. Remove hood assembly (1).

4 Hood assembly: 30 kg

Oil stopper

Sketch

796-460-1210

New/Remodel

Part name

Q'ty

Part No.

Necessity

Symbol

SPECIAL TOOL

t 1

REMOVAL

k Disconnect the cable from the negative () terminal of the battery.

5. Remove covers (2) (5).

k Lower the work equipment to the ground and


stop the engine. Then, loosen the hydraulic oil
filler cap slowly to release the internal pressure
of the hydraulic tank.
a Put tags to the disconnected hoses to prevent a
mistake in re-connecting them.
1. Drain the coolant.
6 Coolant: 13.4 l

2. Remove the hydraulic tank strainer. Using tool


D, stop the oil.
a When not using tool D, remove the drain plug
and drain the oil from the hydraulic tank. [*1]
6 Hydraulic tank: 90 l

6. Remove bracket (6) and covers (7), (8), and (8a).

3. Close the fuel stop valve.

PC130-7

30-23
(2)

DISASSEMBLY AND ASSEMBLY

ENGINE AND HYDRAULIC PUMP

7. Remove fan guard (9) and hose (10).

[*2]

8. Disconnect hose (10a).

[*3]

9. Remove fan guard (11).

13. Disconnect wiring harness connectors E11 (19)


and E10 (20) from the left rear of the engine and
remove the wiring harness clamp.

14. Disconnect terminal (21) and remove the wiring


harness clamp.

10. Disconnect connector E05 (12) and remove


clamp (13).
11. Loosen bolts (14) and (15) and remove air conditioner compressor belt (16).
[*4]
12. Remove bolts (14) and (15) and spacer (17).
Remove air conditioner compressor and bracket
assembly (18) and move them toward the counterweight.
a Do not separate the piping.

15. Disconnect hose (22) from the engine and


remove the clamp above the engine and clamp
(23).
16. Remove clamp (24).
17. Disconnect terminal (25) from the starting motor.

30-24
(2)

PC130-7

DISASSEMBLY AND ASSEMBLY

18. Remove hose clamps (26) and (27) from the left
front of the engine.

ENGINE AND HYDRAULIC PUMP

23. Disconnect wiring harness connectors E08 (37)


and T92 (38) from the revolving frame at the right
lower part of the engine and remove clamp (39).

19. Disconnect the ground wire from the left front


engine mount bracket.

24. Remove cooling fan (40).


20. Disconnect hoses (28), (29), and (30).
a Put plugs to stop the fuel.
21. Remove the 2 mounting bolts of connector (31)
and disconnect hose (32) from the engine. [*5]

25. Remove cover (40a) and frame (40b).

22. Remove clamp (33) from the left lower part of the
engine and disconnect wiring harness connectors E03 (34), T91 (35), and T13 (36).

PC130-7

30-25
(2)

DISASSEMBLY AND ASSEMBLY

26. Disconnect hoses (41) (45).

ENGINE AND HYDRAULIC PUMP

32. Disconnect wiring harness connector E04 (56)


from the right rear of the engine.

27. Remove clamp (46).


33. Remove 4 engine mounting bolts (57).

28. Disconnect wiring harness connectors A61 (47),


V22 (48), and V21 (49) and remove clamps (50)
and (51).
29. Remove bracket (52).
30. Remove the mounting bolt of connector (53).
a Prepare a pan to receive the oil.

[*6]

34. Lift off engine and hydraulic pump assembly


(58).
a Check that all the wires and pipes are disconnected.

4 Engine and hydraulic pump assembly:


470 kg

31. Remove 2 bolts (54) and move engine oil filter


and bracket assembly (55) toward the engine.

30-26
(2)

PC130-7

DISASSEMBLY AND ASSEMBLY

INSTALLATION

[*1]

Carry out installation in the reverse order to


removal.
3 Hydraulic tank drain plug:
58.6 78.5 Nm {5.97 8.0 kgm}
(Target: 68.6 Nm {7 kgm})

[*2]

3 Hose clamp:
10.5 0.5 Nm {107 5 kgcm}

[*3]

3 Hose clamp:
8.8 0.5 Nm {0.9 0.05 kgm}

[*4]

ENGINE AND HYDRAULIC PUMP

Refilling with oil (Hydraulic tank)


a 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.
5 Hydraulic tank: 90 l

Bleeding air
a Bleed air. For details, see TESTING AND
ADJUSTING, Bleeding air from each part.

a Install the air conditioner compressor belt.


For details, see TESTING AND ADJUSTING,
Testing and adjusting air conditioner compressor belt.

[*5]

3 Hose clamp:
8.8 0.5 Nm {0.9 0.05 kgm}

[*6]

3 Engine mount mounting bolt:


245 309 Nm {25 31.5 kgm}
(Target: 279.6 Nm {28.5 kgm})
a If the engine mount bracket was removed
from the engine, tighten it to the following
torque.
3 Mount bracket mounting bolt on front side
of engine:
58.9 73.6 Nm {6.0 7.5 kgm}
(Target: 65.7 Nm {6.7 kgm})

3 Mount bracket mounting bolt on rear side


of engine:
98.1 122.6 Nm {10.0 12.5 kgm}
(Target: 112.8 Nm {11.5 kgm})

Refilling with coolant


a Add coolant through the coolant filler to the specified level. Run the engine to circulate the coolant through the system. Then, check the coolant
level again.
5 Coolant: 13.4 l

PC130-7

30-27
(2)

DISASSEMBLY AND ASSEMBLY

TRACK SHOE

EXPANSION AND
INSTALLATION OF TRACK
SHOE ASSEMBLY

3. Using tool M, pull out master pin (2).

[*2]

Remover and
installer

790-101-1300

Cylinder

790-101-1102

Pump

Part name

Sketch

Q'ty

791-616-1040
or
791-620-7000

Part No.

New/Remodel

Necessity

Symbol

SPECIAL TOOLS

4. Remove tool M and move the machine forward


so that temporary pin [1] will be in front of the
idler, then set block [2].

EXPANSION
1. Stop the machine so that the master pin will be
between the idler and carrier roller and the track
shoe can be expanded in the forward and backward directions.

5. Pull out temporary pin [1] and remove the dust


seal. Move the machine in reverse to expand
track shoe (3).
[*3]

2. Lower the work equipment to the ground and


loosen lubricator (1) to slacken the track shoe.
[*1]
k Since the internal pressure of the adjustment cylinder is very high, do not loosen
the lubricator more than 1 turn. If the
grease does not come out sufficiently, move
the machine forward and in reverse.

30-28
(2)

PC130-7

DISASSEMBLY AND ASSEMBLY

TRACK SHOE

INSTALLATION

[*1]

[*2]

[*3]

Carry out installation in the reverse order to


removal.
a Adjust the tension of the track shoe. For
detail, see TESTING AND ADJUSTING,
Inspection and adjustment of track shoe tension.
a Using tool M, press fit the master pin so that
its projection a will be as follows.
Dimension a: 5.5 2 mm

a When fitting the dust seal, apply grease (G2LI) to its contact face against the bushing.
a Install the track shoe assembly as shown in
the following figure. (The arrow indicates the
front of the machine.)

PC130-7

30-29
(2)

DISASSEMBLY AND ASSEMBLY

REMOVAL AND INSTALLATION


OF SPROCKET

SPROCKET

INSTALLATION

Carry out installation in the reverse order to


removal.

[*1]

2 Threads of sprocket mounting bolt:


Adhesive (LT-2)
3 Sprocket mounting bolt:
323.6 362.8 Nm {33 37 kgm}

REMOVAL
1. Expand the track shoe assembly. For details,
see EXPANSION OF TRACK SHOE ASSEMBLY.
2. Swing the work equipment by 90 and push up
the machine with it, and then set blocks [1]
between the track frame and track shoe.
3. Remove the 15 mounting bolts and lift off
sprocket (1).
[*1]
a Pass a bar, etc. through a bolt hole of the
sprocket to sling.
4 Sprocket: 40 kg

30-30
(2)

PC130-7

DISASSEMBLY AND ASSEMBLY

REMOVAL AND INSTALLATION


OF FINAL DRIVE ASSEMBLY
REMOVAL
1. Remove the sprocket, refer to the removing
sprocket section in this manual.

FINAL DRIVE

4. Remove the 20 mounting bolts from final drive


assembly (6) and lift if off to remove.
[*1]
a Be careful. Do not damage the face of the fitting seal at the base of the hose.
a When lifting off the final drive assembly, do
not use a tapped hole for lifting the cover.
4 Final drive assembly: 150kg

k Lower the work equipment to the ground for


safety. Stop the engine and loosen the oil filler
cap on the hydraulic tank to release pressure
inside.
2. Remove cover (1).

INSTALLATION

Install in reverse order to removal.

[*1]

3 Final drive assembly mounting bolt:


245.2 308.9 Nm {25 31.5 kgm}

Reflling hydraulic oil


Refill hydraulic oil through the oil filler port to the
specified level, and left the oil circulate in the
hydraulic system by starting the engine.
Then check the oil level again.

3. Disconnect four travel motor hoses (2), (3), (4)


and (5).

AJS01012.jpg

PC130-7

Bleeding air
a Bleed air. For details, see TESTING AND
ADJUSTING, Bleeding air from each part.

30-31
(2)

DISASSEMBLY AND ASSEMBLY

IDLER

DISASSEMBLY AND
ASSEMBLY OF IDLER
ASSEMBLY

4. Remove floating seal (6) on the opposite side


from idler (4) and shaft (5) and support (7)
assembly.

L 1 791-675-1510

Installer

Sketch

New/Remodel

Part name

Q'ty

Part No.

Necessity

Symbol

SPECIAL TOOL

DISASSEMBLY
5. Remove dowel pin (8), and then remove support
(7) from shaft (5).
6. Remove bushings (9) and (10) from idler (4).

1. Remove dowel pin (1) and support (2).


2. Remove floating seal (3) from support (2) and
idler (4).
3. Remove idler (4) from shaft (5) and support (7)
assembly.
a About 90 cc of oil is in these parts. Drain it at
this time or spread cloths to absorb it.

30-32
(2)

PC130-7

DISASSEMBLY AND ASSEMBLY

ASSEMBLY
1. Press fit bushings (9) and (10) to idler (4).

2. Fit the O-ring and install support (7) to shaft (5)


with dowel pin (8).

IDLER

4. Install shaft (5) and support (7) assembly to idler


(4).

5. Fill the space between shaft (5) and idler (4) with
90 cc of oil.
5 Idler: 90 cc (EO-30CD)

3. Using tool L1, install floating seal (6) to idler (4)


and shaft (5) and support (7) assembly.

a Thoroughly degrease and dry the O-ring and


the contact surfaces of the floating seal
before installing. Take care that the contact
surfaces of the floating seal will be free from
dirt.
a After installing the floating seal, check that its
slant is less than 1 mm.

PC130-7

30-33
(2)

DISASSEMBLY AND ASSEMBLY

6. Using tool L1, install floating seal (3) to idler (4)


and support (2).
a For the precautions for installing the floating
seal, see step 3.

30-34
(2)

IDLER

7. Fit the O-ring and install support (2) with dowel


pin (1).

PC130-7

DISASSEMBLY AND ASSEMBLY

RECOIL SPRING

DISASSEMBLY AND
ASSEMBLY OF RECOIL
SPRING

DISASSEMBLY
1. Remove lock plate (1), seat (2), and valve (3).
2. Piston assembly
Remove piston assembly (5) from recoil spring
assembly (4).

Compressor

790-201-2780

Spacer

791-635-3160

Extension

790-101-1300

Cylinder

790-101-1102

Pump

790-201-1500

Push tool kit

Part name

790-201-1590

Plate

790-101-5021

Grip

01010-50816

Bolt

Sketch

791-600-2001
or
791-685-8006

Part No.

New/Remodel

Q'ty

Necessity

Symbol

SPECIAL TOOLS

PC130-7

30-35
(2)

DISASSEMBLY AND ASSEMBLY

RECOIL SPRING

3. Disassembly of recoil spring assembly


1) Set tool J1 to recoil spring assembly (4).

k Since the installed load of the spring is


heavy and dangerous, set the spring
securely.
a Installed load of spring:
84,340 N {8,600 kg}

2) Apply hydraulic pressure gradually to compress the spring, and then remove nut (6).
a Compress the spring until the nut is loosened.
a Release the hydraulic pressure gradually
to lower the spring tension perfectly.
a Free length of spring: 501.4 mm
3) Remove pilot (8), cylinder (9), and dust seal
(10) from spring (7).
4. Disassembly of piston assembly
1) Remove wear ring (12) from piston (11).
2) Remove snap ring (13) and U-packing (14).

30-36
(2)

PC130-7

DISASSEMBLY AND ASSEMBLY

RECOIL SPRING

ASSEMBLY

1. Assembly of piston assembly


1) Install U-packing (14) to piston (11) and
secure it with snap ring (13).
2) Install wear ring (12).
2. Assembly of recoil spring assembly
1) Using tool J2, install dust seal (10) to cylinder (9).

3) Apply hydraulic pressure gradually to compress the spring and tighten nut (6) the
installed length of the spring is a.
a Installed length a of spring: 390 mm

2) Install cylinder (9) and pilot (8) to spring (7),


and then set them to tool J1.
2 Sliding parts of cylinder:
Grease (G2-LI)

PC130-7

30-37
(2)

DISASSEMBLY AND ASSEMBLY

RECOIL SPRING

4) Remove recoil spring assembly (1) from tool


D1.
3. Piston assembly
Install piston assembly (5) to recoil spring
assembly (4).
2 Sliding parts of piston: Grease (G2-LI)

2 Wear ring: Grease (G2-LI)


a Install the piston assembly so that the valve
wil l b e i ns ta ll ed o n th e o utsi de of the
machine.
a Pour at least 120 cc of grease (G2-LI) in the
cylinder and bleed air, and then check that
grease comes out of the grease hole.

30-38
(2)

PC130-7

DISASSEMBLY AND ASSEMBLY

TRACK ROLLER

DISASSEMBLY AND
ASSEMBLY OF TRACK
ROLLER ASSEMBLY

Installer

4 791-601-1000

Oil pump

Part name

Sketch

2 790-434-1650

Part No.

New/Remodel

Q'ty

Necessity

Symbol

SPECIAL TOOLS

DISASSEMBLY
a Referring to the following drawing, disassemble
the track roller assembly.

ASSEMBLY
a Referring to the following drawing, assemble the
track roller assembly.
a In this section, only precautions for assembling
the track roller assembly are explained. For
items which are not explained below, see the
assembly procedure for the idler assembly.

a Using tool L4, fill the track roller assembly with


oil, and then tighten plug (11).
5 Track roller: 75 85 cc (EO30-CD)

a Tighten the mounting bolts of the track roller


assembly to the following torque.
2 Mounting bolt: Adhesive (LT-2)

3 Mounting bolt:
245.2 308.9 Nm {25 31.5 kgm}

a Using tool L2, install the floating seals.


a Thoroughly degrease and dry the O-ring and
contact surfaces of the floating seals (5) and (6)
(hatched parts) before installing. Take care that
the contact surfaces of the floating seal will be
free from dirt.
a After installing the floating seal, check that its
slant is less than 1 mm and its projection a is 5
7 mm.

PC130-7

30-39
(2)

DISASSEMBLY AND ASSEMBLY

CARRIER ROLLER

DISASSEMBLY AND
ASSEMBLY OF CARRIER
ROLLER ASSEMBLY

790-434-1660

Installer

791-601-1000

Oil pump

Part name

Sketch

Part No.

New/Remodel

Q'ty

Necessity

Symbol

SPECIAL TOOLS

DISASSEMBLY
a Referring to the following drawing, disassemble
the carrier roller assembly.

ASSEMBLY
a Referring to the following drawing, assemble the
carrier roller assembly.
a In this section, only precautions for assembling
the carrier roller assembly are explained. For
items which are not explained below, see the
assembly procedure for the idler assembly and
track roller assembly.

a Using tool L3, install the floating seals.


a Thoroughly degrease and dry the O-rings and
contact surfaces of the floating seals (6) and (7)
(hatched parts) before installing. Take care that
the contact surfaces of the floating seal will be
free from dirt.
a After installing each floating seal, check that its
slant is less than 1 mm.
a Using tool L4, fill the carrier roller assembly with
oil, and then tighten plug (8).

5 Carrier roller: 68 76 cc (EO30-CD)

30-40
(2)

PC130-7

DISASSEMBLY AND ASSEMBLY

SWING MOTOR AND SWING MACHINERY

REMOVAL AND INSTALLATION


OF SWING MOTOR AND
SWING MACHINERY
ASSEMBLY
REMOVAL

k Release the residual pressure in the hydraulic


circuit.
For details, see TESTING AND
ADJUSTING, Releasing residual pressure in
hydraulic circuit.
k Lower the work equipment to the ground in a
stable posture and set the lock lever in the
LOCK position.
1. Disconnect hoses (1) (5).
2. Remove 14 mounting bolts (6).

INSTALLATION

Carry out installation in the reverse order to


removal.

[*1]

3 Mounting bolt:
245 308.7 Nm {25 31.5 kgm}

Refilling with oil (Hydraulic tank)


a Add oil through the oil filler to the specified level.
Run the engine to circulate the oil through the
system. Then, check the oil level again.
Bleeding air
a Bleed air from the circuit. For details, see TESTING AND ADJUSTING, Bleeding air from each
part.

[*1]

3. Using forcing screw [1], lift off swing motor and


swing machinery assembly (7).
a Take care that the assembly will not interfere
with the hoses, etc. around it.

4 Swing motor and swing machinery assembly: 110 kg

PC130-7

30-41
(2)

DISASSEMBLY AND ASSEMBLY

SWING MOTOR AND SWING MACHINERY

790-101-2501

Push puller kit

1
1

790-101-2550 Leg

1 790-101-2560 Nut

790-101-2570 Plate

790-101-3101

Bearing puller

790-101-4200

Puller

796T-426-1140 Push tool

790-201-2680

Plate

Spacer

Spacer

Push tool kit

F 1 790-201-2850
3
2 790-201-2750
790-101-5401

Plate
790-101-5461 (For main bearing)
4
790-101-5441 Plate
(For sub bearing)

1
1

01010-51240

Bolt

790-201-2850

Spacer

790-201-2650

Plate

DISASSEMBLY
1. Draining oil
Loosen drain plug and drain oil from swing
machinery.
6 Swing machinery case : Approx. 2.5 l

30-42
(2)

3. No. 1 carrier, No. 2 sun gear assembly


1) Remove No. 1 sun gear (2).
2) Remove No. 1 carrier and No. 2 sun gear
assembly (3).

790-101-5421 Grip

Sketch

790-101-2510 Block

New/Remodel

Part name

4 Swing motor assembly : 30 kg

Q'ty

Part No.

2. Swing motor
Remove swing motor assembly (1).

Necessity

Symbol

DISASSEMBLY AND
ASSEMBLY OF SWING
MOTOR AND SWING
MACHINERY ASSEMBLY

3) Disassemble No. 1 carrier and No. 2 sun


gear assembly (3) as follows.
i) Remove snap ring (4), then remove
thrust washer (5), gear (6), bearing (7),
and thrust washer (8).

PC130-7

DISASSEMBLY AND ASSEMBLY

ii) Knock in pin (9) and knock out shaft (10).


a After removing the shaft, remove pin
(9).
iii) Remove snap ring (11), then remove No.
2 sun gear (12) from carrier (13).

SWING MOTOR AND SWING MACHINERY

3) Disassemble No. 2 carrier assembly as follows.


i) Push in pin (17), and knock out shaft (18)
from carrier (19).
a After removing the shaft, remove pin
(17).
ii) Remove thrust washer (20), gear (21),
bearing (22), and thrust washer (23).

4. Ring gear
Remove ring gear (14).
5. No. 2 carrier assembly
1) Remove spacer (15).
2) Remove No. 2 carrier assembly (16).

PC130-7

6. Retainer, collar
1) Remove retainer (24).
2) Set shaft and case assembly to press, push
split collar (25) with push tool F5, and press
fit bearing (26).
a Operate the press slowly, and press fit
the bearing to a position where it is possible to remove the split collar.
3) Remove split collar (25).

30-43
(2)

DISASSEMBLY AND ASSEMBLY

7. Shaft assembly
1) Set block [2] to shaft and case assembly
(27), then using push tool [3], remove shaft
assembly (28) with press .
2) Remove bearing (26).

SWING MOTOR AND SWING MACHINERY

2) Using puller [5], remove bearing outer races


(34) and (35) from case (33).

3) Using push tool F1, remove bearing (29) and


collar (30) from shaft (31).

8. Oil seal, bearing outer race


1) Remove oil seal (32) from case (33).

30-44
(2)

PC130-7

DISASSEMBLY AND ASSEMBLY

ASSEMBLY
a Clean all parts, and check for dirt or damage.
Coat the sliding surfaces of all parts with engine
oil before installing.
1. Bearing outer races
Using push tool F4, press fit outer races (34) and
(35) to case (33).

SWING MOTOR AND SWING MACHINERY

4) Using push tool F3-2, press fit bearing (26) to


a position where it is possible to insert split
collar.
a Press-fitting force : 11.8 kN {1,200 kg}
a Rotate the case and gradually press fit
the bearing.

5) Install split collars (25).


2. Shaft assembly
1) Fit O-ring to inside of collar (30) and install to
shaft (31).
2) Using push tool F3-1, press fit bearing (29)
with press.

6) Screw bolt (Thread dia.=12mm, Pitch=1.75mm)


into case, then using push- pull scale [8], measure tangential force in direction of rotation.
a Tangential force : Max. 176.5 N {18 kg}
a The tangential force is the maximum force
when starting rotation.

3) Set case assembly (36) to shaft assembly


(28).

PC130-7

30-45
(2)

DISASSEMBLY AND ASSEMBLY

SWING MOTOR AND SWING MACHINERY

3. Oil seal
Using push tool F2, press fit oil seal (32).
a Replace the oil seal with a new part.

iii) Align position of pin holes of shaft and


carrier, then tap with plastic hammer to
install shaft (18).
a When installing the shaft, rotate the
planetary gear, and be careful not to
damage the thrust washers.
iv) Insert pin (17).
a After inserting the pin, caulk the pin
portion of the carrier.

2 Lip of oil seal : Grease (G2-LI)

2 Periphery of oil seal:


Gasket sealant (LG-6)
a Take care that the gasket sealant will not
stick to the oil seal lip and shaft.

4. Retainer
Install retainer (24).

5. No. 2 carrier assembly


1) Assemble No. 2 carrier assembly as follows.
i) Assemble bearing (22) to gear (21).
ii) Fit top and bottom thrust washers (20)
and (23), then set gear assembly to carrier (19).

30-46
(2)

2) Install No. 2 carrier assembly (16) to shaft


and case assembly.
3) Install spacer (15).

6. Ring gear
Assemble O-ring (37) to shaft and case assembly, and install ring gear (14).

PC130-7

DISASSEMBLY AND ASSEMBLY

7. No. 1 carrier, No. 2 sun gear assembly


1) Assemble No. 1 carrier and No. 2 sun gear
assembly as follows.
i) Assemble No. 1 carrier (13) to No. 2 sun
gear (12), and install snap ring (11).
ii) Align position of pin holes of shaft and
carrier, then tap with a plastic hammer to
install shaft (10).
iii) Insert pin (9).
a After inserting the pin, caulk the pin
portion of the carrier .
a Check that the stepped difference a
between the shaft and carrier is less
than 0.2 mm.

SWING MOTOR AND SWING MACHINERY

2) Install No. 1 carrier and No. 2 sun gear


assembly (3).
3) Install No. 1 sun gear (2).

8. Swing motor assembly


Install swing motor assembly (1).

3 Mounting bolt :
110.3 12.3 Nm {11.25 1.25 kgm}

iv) Assemble thrust washer (8), bearing (7),


gear (6), and thrust washer (5), then
install snap ring (4).

9. Refilling with oil


Tighten the drain plug and add engine oil through
oil filler.
5 Swing machinery case : Approx. 2.5 l

PC130-7

30-47
(2)

DISASSEMBLY AND ASSEMBLY

REMOVAL AND INSTALLATION


OF CENTER SWIVEL JOINT

CENTER SWIVEL JOINT

4. Disconnect hoses (11) (17).

REMOVAL

k Release the residual pressure in the hydraulic circuit. For details, see TESTING AND ADJUSTING, Releasing residual pressure in hydraulic
circuit.
a Put tags to the disconnected hoses to prevent a
mistake in re-connecting them.
1. Remove pin (1) and move bar (2).
2. Disconnect hoses (3) (10).

5. Remove elbow (18).


6. Sling the center swivel joint assembly temporarily.
7. Remove 4 mounting bolts (19).

8. Lift off center swivel joint assembly (20).

4 Center swivel joint assembly: 35 kg

3. Remove undercovers (10a) and (10b).

30-48
(2)

PC130-7

DISASSEMBLY AND ASSEMBLY

CENTER SWIVEL JOINT

INSTALLATION

Carry out installation in the reverse order to


removal.

Refilling with oil (Hydraulic tank)


a Add oil through the oil filler to the specified level.
Run the engine to circulate the oil through the
system. Then, check the oil level again.
Bleeding air
a Bleed air from the circuit. For details, see TESTING AND ADJUSTING, Bleeding air from each
part.

PC130-7

30-49
(2)

DISASSEMBLY AND ASSEMBLY

CENTER SWIVEL JOINT

790-101-2501

Push puller

790-101-2510 Block

790-101-2520 Screw

791-112-1180 Nut

790-101-2540 Washer

790-101-2630 Leg

790-101-2570 Plate

790-101-2560 Nut

790-101-2650 Adapter

4. Remove O-ring (6) and slipper seal (7) from the


swivel rotor.

Sketch

New/Remodel

Part name

Q'ty

Part No.

Necessity

Symbol

DISASSEMBLY AND
ASSEMBLY OF CENTER
SWIVEL JOINT ASSEMBLY

DISASSEMBLY

ASSEMBLY
1. Fit slipper seal (7) and O-ring (6) to the swivel
rotor.
2. Set swivel shaft (5) to a block. Using the push
tool, hit swivel rotor (4) lightly with a plastic hammer to install the swivel shaft.

2 Contact surfaces of rotor and shaft:


Grease (G2-LI)
a When installing the rotor, take care extremely
not to damage the slipper seal and O-ring.

3. Install ring (3) and secure it with snap ring (2).


3 Mounting bolt:
31.3 2.9 Nm {3.2 0.3 kgm}

4. Fit the O-ring and install cover (1).

1. Remove cover (1).


2. Remove snap ring (2).
3. Using tool C, pull swivel rotor (4) and ring (3) out
of swivel shaft (5).

30-50
(2)

PC130-7

DISASSEMBLY AND ASSEMBLY

WORK EQUIPMENT

REMOVAL AND INSTALLATION


OF WORK EQUIPMENT
ASSEMBLY

792-785-1100
R

Remover

Puller
790-101-4000 (490 kN {50t} long) t
Pump
790-101-1102
t
(294 kN {30t})

Sketch

New/Remodel

Part name

Q'ty

Part No.

Necessity

Symbol

SPECIAL TOOLS

1
1

REMOVAL

k Except the arm and bucket fully. Lower the


work equipment to the ground and set the lock
lever to the lock position.
k Release the residual pressure in the hydraulic
circuit. For details, see TESTING AND
ADJUSTING, Release of residual pressure from
hydraulic circuit.
1. Disconnect grease hose (1).

4. Start the engine and retract the piston rod.


a Fasten the piston rod with wire so that it will
not slip out and lower the cylinder onto a
stand, or place a support under the bottom of
the cylinder to support it. In the latter case,
remove the grease fitting on the bottom side
first.
a Remove the bottom cylinder on the other
side in the same manner.
5. Disconnect hoses (6) to (9).
a Put tags to the disconnected hoses and
tubes to prevent a mistake in re-connecting
them.
a Put an oil stopper plug to each hose connecting part and bind the hose with ropes, etc. so
that it will not be an obstacle to the work.
6. Disconnect wiring harness connector A42 (10).

2. Sling boom cylinder assembly (2), and remove


lock bolt (3).
3. Remove plate (4), then remove head pin (5). [*1]
a There are shims installed, so check the number and thickness, and keep them in a safe
plate.

PC130-7

30-51
(2)

DISASSEMBLY AND ASSEMBLY

7. Sling the work equipment assembly and remove


plate (11) and foot pin (12).
[*2]

WORK EQUIPMENT

INSTALLATION

[*1]

Carry out installation in the reverse order to


removal.
a Tighten the locknut so that clearance a
between the plate and nut will be 0.5 1.5
mm.

When removing with tool R


Remove plate (11). Using tool R, remove
foot pin (12).
a Check the quantity and positions of the
inserted shims.
2 Greasing inside of bushing before assembling pin:
Molybdenum disulfide grease (LM-P)

2 Greasing after assembling pin:


Molybdenum disulfide grease (LM-P)

k When aligning the pin holes, never insert


your finger in the pin holes.
a Adjust clearance a between cylinder rod (14)
and plate (4) to below 1.0 mm with a shim.
Standard shim thickness: 1.0 mm

8. Lift off work equipment assembly (13).

4 Work equipment assembly: 2,700 kg

[*2]

2 Greasing inside of bushing before assembling pin:


Molybdenum disulfide grease (LM-P)

2 Greasing after assembling pin:


Molybdenum disulfide grease (LM-P)

30-52
(2)

PC130-7

DISASSEMBLY AND ASSEMBLY

WORK EQUIPMENT

k When aligning the position of the pin hole,


never insert your fingers into the pin hole.
a Adjust clearance a between boom (15) and
frame (16) with shim so that it will be less
than 0.5 mm.
Thickness of standard shims:
0.5, 1.0, and 2.0 mm.

Refilling with oil (Hydraulic tank)


a Add oil through the oil filler to the specified level.
Run the engine to circulate the oil through the
system. Then, check the oil level again.
Bleeding air
a Bleed air. For details, see TESTING AND
ADJUSTING, Bleeding air from each part.

PC130-7

30-53
(2)

DISASSEMBLY AND ASSEMBLY

REVOLVING FRAME

REMOVAL AND INSTALLATION


OF REVOLVING FRAME
REMOVAL
1. Remove the work equipment assembly. For
details, see Removal and installation of work
equipment assembly.
2. Remove the counterweight assembly.
For
details, see Removal and installation of counterweight assembly.
3. Disconnect hoses (1) (11)
a Put tags to the disconnected hoses to prevent a mistake in re-connecting them.

7. Remove pin (16) from the center swivel joint and


move bar (17).

4. Remove block (12).


8. Disconnect hoses (18) (21).
a Put tags to the disconnected hoses to prevent a mistake in re-connecting them.

5. Sling boom cylinder assembly (13) temporarily.

6. Remove plate (14) and pin (15), and then lift off
boom cylinder assembly (13).
[*1]
a Remove opposite boom cylinder assembly
as same procedure.
4 Boom cylinder assembly: 100 kg

9. Sling the revolving frame assembly temporarily.


a If the revolving frame assembly interferes
with the sling, move or remove the sling.
10. Remove the 34 mounting bolts and lift off revolving frame assembly (22).
[*2]

30-54
(2)

PC130-7

DISASSEMBLY AND ASSEMBLY

a Leaving 2 3 mounting bolts at the front and


rear parts, adjust the balance of the revolving
frame in each direction with lever blocks, etc.
Then, remove those mounting bolts.

k When removing the revolving frame assembly, take care that it will not interfere with the
center swivel joint.

REVOLVING FRAME

INSTALLATION

[*1]

4 Revolving frame assembly: 2,800 kg

[*2]

Carry out installation in the reverse order to


removal.
a Adjust clearance a between boom cylinder
(13) and frame (23) to below 1 mm with
shims.
Set shim thickness: 1.0, 2.0 mm

2 Mating face of swing circle:


Gasket sealant (LG-1)
2 Mounting bolt threads of revolving frame:
Adhesive (LT-2)

3 Mounting bolt of revolving frame:


245 308.9 Nm {25 31.5 kgm}
Target: 279.3 Nm {28.5 kgm}
Refilling with oil (Hydraulic tank)
a Add oil through the oil filler to the specified level.
Run the engine to circulate the oil through the
system. Then, check the oil level again.
Bleeding air
a Bleed air. For details, see TESTING AND
ADJUSTING, Bleeding air from each part.

PC130-7

30-55
(2)

DISASSEMBLY AND ASSEMBLY

SWING CIRCLE

REMOVAL AND INSTALLATION


OF SWING CIRCLE ASSEMBLY

INSTALLATION

Carry out installation in the reverse order to


removal.

[*1]

2 Mounting bolt threads of swing circle:


Adhesive (LT-2)

REMOVAL
1. Remove the revolving frame assembly. For
details, see Removal and installation of revolving
frame assembly.
2. Remove 38 mounting bolts (1).

3 Mounting bolt of swing circle:


245 308.9 Nm {25 31.5 kgm}
Target: 279.3 Nm {28.5 kgm}

[*1]

[*2]

a Set soft zone a (marked with S) of the inner


race on the side of the machine (outer race
soft zone b). (The arrow indicates the front
of the machine.)

2 Quantity of grease for circle:


Grease (G2-LI), 9.1 l

3. Lift off swing circle assembly (2).

4 Swing circle assembly: 160 kg

30-56
(2)

[*2]

PC130-7

DISASSEMBLY AND ASSEMBLY

HYDRAULIC TANK

REMOVAL AND INSTALLATION


OF HYDRAULIC TANK
ASSEMBLY
REMOVAL
1. Drain the oil from the hydraulic tank.
6 Hydraulic tank: 90 l

[*1]

2. Remove hood assembly (1).

4 Hood assembly: 30 kg
6. Remove frames (11) (13).

3. Remove covers (2) and (3).


7. Disconnect hoses (14) (21).
a Put tags to the disconnected hoses to prevent a mistake in re-connecting them.

4. Remove covers (4) (7).

5. Remove covers (8) (10).

PC130-7

30-57
(2)

DISASSEMBLY AND ASSEMBLY

HYDRAULIC TANK

8. Remove clamps (22) and (23).

15. Remove the 4 mounting bolts and hydraulic tank


assembly (31).
[*3]
4 Hydraulic tank assembly: 100 kg

9. Remove clamp (24).


10. Remove water separator and bracket assembly
(25) and move it toward the engine.

11. Disconnect hose (26).


12. Disconnect wiring harness connector A61 (27)
and remove clamp (28).
13. Remove the mounting bolt of connector (29) and
disconnect hose (30).
[*2]

14. Sling the hydraulic tank assembly temporarily.

30-58
(2)

PC130-7

DISASSEMBLY AND ASSEMBLY

HYDRAULIC TANK

INSTALLATION

[*1]

[*2]

Carry out installation in the reverse order to


removal.
3 Hydraulic tank drain plug:
58.8 78.5 Nm {6 8 kgm}
Target: 68.6 Nm {7 kgm}
a When tightening the hose clamp screws, set
them 180 apart from each other laterally (in
the horizontal direction).
3 Hose clamp: 90 5 Nm {8.8 0.5 kgm}

[*3]

2 Mounting bolt: Adhesive (LT-2)

3 Mounting bolt:
245 309 Nm {25.0 31.5 kgm}
Refilling with oil (Hydraulic tank)
a 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.
5 Hydraulic tank: 90 l

Bleeding air
a Bleed air. For details, see TESTING AND
ADJUSTING, Bleeding air from each part.

PC130-7

30-59
(2)

DISASSEMBLY AND ASSEMBLY

CONTROL VALVE

REMOVAL AND INSTALLATION


OF CONTROL VALVE
ASSEMBLY
REMOVAL

k Lower the work equipment to the ground and


stop the engine. Then, loosen the hydraulic oil
filler cap slowly to release the internal pressure
of the hydraulic tank.
k Set the lock lever in the LOCK position.
a Put tags to the disconnected hoses to prevent a
mistake in re-connecting them.
The control valve described below is a 7-spool
valve (6-spool valve + service valve) to which no
attachments are connected.
1. Open the engine hood and remove cover (1).

2. Disconnect the following hoses in front of the


control valve.

(1): Attachment 1

(2): Attachment 1

(3): Bucket cylinder (Head side)

(4): Bucket cylinder (Bottom side)

(5): Arm cylinder (Head side)

(6): Arm cylinder (Bottom side)

(7): Hydraulic tank

(8): Boom cylinder (Bottom side)

(9): Boom cylinder (Head side)


(10): Right travel motor
(11): Right travel motor
(12): Left travel motor
(13): Left travel motor
(14): Swing motor
(15): Swing motor
(16): Hydraulic tank

30-60
(2)

PC130-7

DISASSEMBLY AND ASSEMBLY

3. Disconnect the following hoses and wiring connectors on the left side of the control valve.
(17): Service 1 PPC valve
(18): Bucket CURL PPC/EPC valve
(Hose band: White)
(19): Arm IN PPC/EPC valve
(Hose band: Blue)
(20): Boom RAISE PPC/EPC valve
(Hose band: Brown)
(21): Right travel FORWARD PPC valve
(Hose band: Green)
(22): Left travel REVERSE PPC valve
(23): Swing RIGHT PPC valve
(24): Swing motor
(25): Oil cooler

PC130-7

CONTROL VALVE

4. Disconnect the following hoses and wiring connectors on the right side of the control valve.
(26): Pump pressure sensor connector A51
(27): Service 1 PPC valve
(28): Bucket DUMP PPC/EPC valve
(Hose band: Black)
(29): Arm OUT PPC/EPC valve
(Hose band: Yellow)
(30): Boom RAISE PPC/EPC valve
(Hose band: Green)
(31): Right travel REVERSE PPC valve
(Hose band: Blue)
(32): Left travel FORWARD PPC valve
(Hose band: Red)
(33): Swing LEFT PPC/EPC valve
(Hose band: Red)
(34): Hydraulic tank
(35): 2-stage relief solenoid valve

30-61
(2)

DISASSEMBLY AND ASSEMBLY

5. Disconnect the following hoses at the rear of the


control valve.
(36): LS valve
(37): Hydraulic pump
(38): Swing holding brake solenoid valve
(39): Swing holding brake solenoid valve
(40): Boom RAISE PPC/EPC valve
(41): Hydraulic pump

CONTROL VALVE

INSTALLATION

Carry out installation in the reverse order to


removal.

Refilling with oil (Hydraulic tank)


a Add oil through the oil filler to the specified level.
Run the engine to circulate the oil through the
system. Then, check the oil level again.
Bleeding air
a Bleed air. For details, see TESTING AND
ADJUSTING, Bleeding air from each part.

6. Remove the 4 mounting bolts and lift off control


valve assembly (42).
4 Control valve assembly: 120 kg

30-62
(2)

PC130-7

DISASSEMBLY AND ASSEMBLY

CONTROL VALVE

DISASSEMBLY AND
ASSEMBLY OF CONTROL
VALVE ASSEMBLY
a In this section, only the precautions for assembling the control valve assembly are described.
a For the tightening torque of the control valve
parts which are not shown in the following sectional view and explanation, see STRUCTURE
AND OPERATION, MAINTENANCE STANDARD, "Hydraulic equipment", "Control valve".

ASSEMBLY

a When tightening bolt (1) and plug (2) shown in


the figure, apply a drop (approx. 0.02 g) of LOCTITE (No. 638) to their threads.
a Apply LOCTITE to plug (2) as shown in the figure
at right.
Dimension a = 2 3 mm

3 Bolt (1): 11.8 14.7 Nm {1.2 1.5 kgm}


3 Plug (2): 14.7 19.6 Nm {1.5 2 kgm}

PC130-7

30-63
(2)

DISASSEMBLY AND ASSEMBLY

CONTROL VALVE

a Tighten the 4 combination nuts on the top of the


control valve in the following numerical order in 3
times.
a The arrow in the figure indicates the front of the
machine.
3 Combination nut:
1st time: 58.8 68.8 Nm {6 7 kgm}
2nd time: 78.5 88.3 Nm {8 9 kgm}
3rd time: 98.1 113 Nm {10 11.5 kgm}

30-64
(2)

PC130-7

DISASSEMBLY AND ASSEMBLY

HYDRAULIC PUMP

REMOVAL AND INSTALLATION


OF HYDRAULIC PUMP
ASSEMBLY

Oil stopper

Sketch

796-460-1210

New/Remodel

Part name

Q'ty

Part No.

Necessity

Symbol

SPECIAL TOOLS

REMOVAL

k Disconnect the cable from the negative () terminal of the battery.


k Lower the work equipment to the ground and
stop the engine. Then, loosen the hydraulic oil
filler cap slowly to release the internal pressure
of the hydraulic tank.
a Put tags to the disconnected hoses to prevent a
mistake in re-connecting them.

4. Remove covers (2) (4) and frame (5).


5. Remove bracket (6) and cover (7).
6. Remove clamp (8).

[*2]

1. Remove the hydraulic tank strainer. Using tool


D, stop oil from flowing out.
a When not using tool D, remove the drain plug
and drain oil from the hydraulic tank.
[*1]
6 Hydraulic tank: 90 l

2. Drain oil from the damper case.


6 Damper case: 0.75 l

3. Remove hood assembly (1).

4 Hood assembly: 30 kg

PC130-7

30-65
(2)

DISASSEMBLY AND ASSEMBLY

7. Remove muffler drain tube (9).


a The muffler drain tube is fixed with the
mounting bolts of the hydraulic pump assembly.

HYDRAULIC PUMP

13. Sling the hydraulic pump assembly temporarily.


14. Remove governor motor bracket mounting bolts
(22) and (23) and fix the bracket to the engine
with ropes.

8. Remove muffler and bracket assembly (10).

15. Lift off hydraulic pump assembly (24).


9. Disconnect hoses (11) (15).

4 Hydraulic pump assembly: 85 kg

[*3]

10. Remove clamp (16).

11. Disconnect wiring harness connectors A61 (17),


V22 (18), and V21 (19) and remove clamp (20).
12. Remove the mounting bolt of connector (21).
a Prepare a pan to receive the oil.

30-66
(2)

PC130-7

DISASSEMBLY AND ASSEMBLY

HYDRAULIC PUMP

INSTALLATION

Carry out installation in the reverse order to


removal.

[*1]

3 Hydraulic tank drain plug:


58.5 78.5 Nm {5.97 8.0 kgm}
(Target: 68.6 Nm {7 kgm})

[*2]

3 Clamp mounting bolt:


1st time: 39.2 49 Nm {4 5 kgm}
2nd time: 68.6 122.5 Nm {7 12.5 kgm}

[*3]

2 Hydraulic pump shaft spline:


Molybdenum disulfide grease (LM-G)
2 Mating face of hydraulic pump case:
Gasket sealant (LG-6)

Refilling with oil (Damper case)


a Add oil through the oil filler to the specified level.
5 Damper case: 0.75 l

Refilling with oil (Hydraulic tank)


a 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.
5 Hydraulic tank: 90l

Bleeding air
a Bleed air. For details, see TESTING AND
ADJUSTING, Bleeding air from each part.

PC130-7

30-67
(2)

DISASSEMBLY AND ASSEMBLY

HYDRAULIC PUMP INPUT SHAFT OIL SEAL

[*1]

Necessity

Q'ty

791-463-1141

Push tool

790-201-2740

Spacer

Part No.

Part name

Sketch

SPECIAL TOOLS
New/Remodel

INSTALLATION

Symbol

REMOVAL AND INSTALLATION


OF HYDRAULIC PUMP INPUT
SHAFT OIL SEAL

Carry out installation in the reverse order to


removal.
a Using tool N, press fit oil seal (3).

2 Lip and periphery of oil seal:


Grease (G2-LI)
a Apply grease thinly to the periphery of the oil
seal.

REMOVAL
1. Remove the hydraulic pump assembly. For
details, see REMOVAL AND INSTALLATION OF
HYDRAULIC PUMP ASSEMBLY.
2. Remove snap ring (1) and spacer (2).
3. Pry off oil seal (3) with a screwdriver, etc.
[*1]
a Take extreme care not to damage the shaft.

30-68
(2)

PC130-7

DISASSEMBLY AND ASSEMBLY

HYDRAULIC CYLINDER

DISASSEMBLY AND
ASSEMBLY OF HYDRAULIC
CYLINDER ASSEMBLY

Cylinder repair stand t

790-102-4300

Wrench assembly t

790-102-4310

Pin

Expander

3 790-720-1000
796-720-1660
4 07281-01159

Part name

Ring
(for boom and
q
bucket)
Clamp
(for boom and
q
bucket)
q

07281-01029

Clamp (for bucket) q

790-201-1702

Push tool kit

790-101-5021 Grip

01010-50816

1
1

790-201-1821 Push tool (for arm)

790-201-1791 Push tool


(for bucket)

790-201-1500

Ring (for bucket)

5 790-201-1811 Push tool


(for boom)

Push tool kit

790-201-5021 Grip

01010-50818

Bolt

4) Set piston rod assembly (2) to tool H1.

796-720-1650

Bolt

Sketch

Q'ty

1 790-502-1003

Part No.

New/Remodel

Necessity

Symbol

SPECIAL TOOLS

790-201-1620 Plate (for boom)

790-201-1630 Plate (for arm)

790-201-1610 Plate (for bucket)

5) Remove piston assembly lock screw (3).


a If the screw is so caulked that you cannot
remove it, tighten it temporarily and cut
the threads on it, and then remove it.

DISASSEMBLY
a The following explanation is common to the
boom, arm, and bucket cylinders, unless otherwise specified.
1. Piston rod assembly
1) Remove the piping from the cylinder assembly.
2) Remove the mounting bolts and cylinder
head assembly (1).
3) Pull out piston rod assembly (2).
a Put a container under the cylinder to
receive oil.

PC130-7

30-69
(2)

DISASSEMBLY AND ASSEMBLY

6) Using tool H2, remove piston assembly (4).

7) Remove plunger (5) and collar (6).


a Perform this work for only the boom and
arm cylinders.
8) Remove cylinder head assembly (7).

HYDRAULIC CYLINDER

2. Disassembly of piston assembly


1) Remove rings (11), wear rings (12), and piston ring (13).
2) Remove the O-ring and backup rings (14).

3. Disassembly of cylinder head assembly


1) Remove the O-ring and backup ring (15).
2) Remove snap ring (16) and dust seal (17).
3) Remove rod packing (18), buffer ring (19),
and bushing (20).

9) Remove cap (8), 11 balls (9), and plunger


(10).
a Take care not to lose the balls.
a Perform this work for only the arm cylinder.

30-70
(2)

PC130-7

DISASSEMBLY AND ASSEMBLY

ASSEMBLY

HYDRAULIC CYLINDER

2) Using tool H4, install piston ring (13).

a The following explanation is common to the


boom, arm, and bucket cylinders, unless otherwise specified.
a Take care not to damage the packings, dust
seals, O-rings, etc.
a Clean the all parts. After installing them, cover
the piping ports and pin holes to prevent dirt from
entering.
a Do not insert each backup ring forcibly, but warm
it in water at 50 60 C and then insert it.
1. Assembly of cylinder head assembly
1) Using tool H5, press fit bushing (20).
2) Install buffer ring (19) and rod packing (18).
3) Using tool H6, install dust seal (17) and
secure it with snap ring (16).
4) Install backup ring (15) and O-ring.

3) Install backup rings (14) and O-ring.


4) Install wear rings (12).
5) Install rings (11).
a Do not increase the closed gap of the
ring too much.
2 Ring groove: Grease (G2-LI)

3. Piston rod assembly


1) Set piston rod assembly (2) to tool H1.

2. Assembly of piston assembly


1) Set piston ring (13) to tool H3 and turn the
handle 8 10 times to expand the piston
ring.

PC130-7

30-71
(2)

DISASSEMBLY AND ASSEMBLY

2) Install cylinder head assembly (7).


3) Fit the O-ring and backup ring to collar (6),
and then install them.
a Perform this work for only the boom and
arm cylinders.
4) Install plunger (5).
a Perform this work for only the boom and
arm cylinders.

HYDRAULIC CYLINDER

6) Tighten piston assembly (4). Then, using


tool H2, tighten piston assembly (4) until the
screw holes are aligned.
a Remove the burrs from the threads with
a file.

7) Tighten screw (3).

5) Set plunger (10) to the piston rod. Install 11


balls (9) and secure them with cap (8).
a After installing the plunger, check that it
has a little play at its end.
a Perform this work for only the arm cylinder.

2 Threads of screw:
Adhesive (LOCTITE No. 262)
3 Screw:

58.9 73.6 Nm {6 7.5 kgm}


8) Caulk threaded part a by 4 places with a
punch.

When reusing the rod and piston assembly, assemble them according to the following procedure.
a Clean the parts thoroughly and remove
metal chips, dirt, etc.

30-72
(2)

PC130-7

DISASSEMBLY AND ASSEMBLY

HYDRAULIC CYLINDER

When replacing either or both of the rod and piston assembly (2), assemble the new parts
according to the following procedure.
a Make a mark of the cushion plug position on the
end of the rod having the bottom cushion. (Perform this work for only the arm cylinder.)
9) Using tool H2, tighten piston assembly (4)
until it reaches end b of the rod.
3 Piston assembly:
294 29.4 Nm {30 3.0 kgm}
a After tightening the piston, check that
plunger (5) has some play.
a Perform this work for only the boom and
arm cylinders.

10) Make a screw hole to install screw (3).


a Apply a drill to the V-groove of the
threaded parts of piston (4) and rod (2)
and make a hole.
a When making a hole on the cylinder having the bottom cushion, make it around
the cushion plug. (Perform this work for
only the arm cylinder.)
Dimensions of screw hole (mm)
Tap drill
diameter

Tap drill hole


depth

Tap to be
used

Tapping
depth

10.3

27

12 x 1.75

20

12) Tighten screw (3).

2 Threads of screw:
Adhesive (LOCTITE No. 262)
3 Screw:

58.9 73.6 Nm {6 7.5 kgm}


13) Caulk the threaded part by 4 places with a
punch.

14) Install piston rod assembly (2).


a Set the abutment joint of the ring at a
side and insert the piston rod, aligning it
with the cylinder tube.
a After inserting the piston rod, check that
the ring is not broken or removed, and
then insert to the end.

11) After making the hole, remove all metal chips


and dirt.

PC130-7

30-73
(2)

DISASSEMBLY AND ASSEMBLY

HYDRAULIC CYLINDER

15) Tighten the mounting bolts of cylinder head


assembly (1).
3 Mounting bolt:
Arm cylinder:
270 39.0 Nm {27.5 4.0 kgm}
Boom/Bucket cylinder:
172 24.5 Nm {17.5 2.5 kgm}

16) Install the piping.


a Tighten the bolts to install the piping
band to the cylinder to the following
torque.
3 27.4 6.9 Nm {2.8 0.7 kgm}

30-74
(2)

PC130-7

DISASSEMBLY AND ASSEMBLY

COUNTERWEIGHT

REMOVAL AND INSTALLATION


OF COUNTERWEIGHT
ASSEMBLY

INSTALLATION

REMOVAL

[*1]

1. Sling the counterweight assembly temporarily.


2. Remove 4 mounting bolts (1).

4 Counterweight assembly: 2,500 kg

PC130-7

2 Threads of mounting bolt:


Adhesive (LT-2)
3 Mounting bolt:
1,177 1,470 Nm {120 150 kgm}
Target: 1,324 Nm {135 kgm}

[*1]

[*2]

3. Lift off counterweight assembly (2).

Carry out installation in the reverse order to


removal.

a Adjust the clearance between the counterweight and revolving frame and the clearance between the counterweight and outside
door to 10 5 mm on right and left sides.

[*2]

30-75
(2)

DISASSEMBLY AND ASSEMBLY

AIR CONDITIONER UNIT

REMOVAL AND INSTALLATION


OF AIR CONDITIONER UNIT
ASSEMBLY

a When removing box (2), disconnect hoses (4)


and (5).

799-703-1120

Vacuum pump
(100 V)
Vacuum pump
(220 V)
Vacuum pump
(240 V)

799-703-1401

Gas leak detector

799-703-1300

Adapter (When
vacuum pump for
refrigerant R12 is
used)

799-703-1200
799-703-1100
799-703-1110
Q

Part name

Sketch

Q'ty

Service tool kit

Part No.

New/Remodel

Necessity

Symbol

SPECIAL TOOLS

a When removing box (3), disconnect wiring harness connector M79 (6).

REMOVAL

k Disconnect the cable from the negative () terminal of the battery.


1. Drain the coolant.

6 Coolant: 13.4 l
5. Remove cover (7).

2. Discharge the refrigerant (gas) from the air conditioner circuit.


[*1]
3. Remove the operator's seat.
4. Remove cover (1) and boxes (2) and (3).

30-76
(2)

PC130-7

DISASSEMBLY AND ASSEMBLY

6. Remove covers (8) (10).

AIR CONDITIONER UNIT

9. Disconnect wiring harness connectors M33 (15)


and M27 (16) and remove them from the
bracket.
a Remove the mounting bolts of bracket (17),
and then hold the clip on the back side of the
bracket and remove the connectors.

7. Disconnect ducts (11) and (12) from the air conditioner unit.

10. Remove duct (18).


11. Disconnect hoses (19) and (20) and remove air
conditioner unit assembly (21).
[*2]
a When removing the air conditioner unit
assembly, disconnect the 2 hoses from its
lower side.

8. Remove ducts (13) and (14).

PC130-7

30-77
(2)

DISASSEMBLY AND ASSEMBLY

AIR CONDITIONER UNIT

INSTALLATION

Carry out installation in the reverse order to


removal.

a When installing the hoses of the air conditioner


circuit, take care that dirt, dust, water, etc. will not
enter them.
a When installing each air conditioner hose, check
that the O-ring is fitted to it.
a Check each O-ring for flaw and deterioration.
[*1]
Charging with air conditioner refrigerant
a Using tool Q, charge the air conditioner circuit with air conditioner refrigerant (R134a).
[*2]

a When connecting each refrigerant pipe,


apply compressor oil (ND-OIL8) to its
threads and use a double spanner to tighten
it.

3 Hose threads M16 x 1.5 (Width across


flats: 19):
12 15 Nm {1.2 1.5 kgm}
Hose threads M22 x 1.5 (Width across
flats: 24):
20 25 Nm {2.0 2.5 kgm}
Hose threads M24 x 1.5 (Width across
flats: 27):
30 35 Nm {3.0 3.5 kgm}
M6 bolt of receiver (Width across flats:
10):
4 7 Nm {0.4 0.7 kgm}
M6 bolt of compressor pipe (Width
across flats: 10):
8 12 Nm {0.8 1.2 kgm}

30-78
(2)

PC130-7

DISASSEMBLY AND ASSEMBLY

REMOVAL AND INSTALLATION


OF OPERATOR'S CAB

OPERATOR'S CAB

5. Remove cover (5) and boxes (6) and (7).

REMOVAL

k Disconnect the cable from the negative () terminal of the battery.


1. Remove floor mat (1).

a When removing box (6), disconnect hoses


(8) and (9).

2. Remove the operator's seat assembly.


3. Remove the monitor panel assembly. For details,
see Removal and installation of monitor panel
assembly.
4. Remove covers (3) and (4).
a When removing cover (3), disconnect wiring
harness connector M19 on its back side.

PC130-7

a When removing box (7), disconnect wiring


harness connector M79 (10).

30-79
(2)

DISASSEMBLY AND ASSEMBLY

OPERATOR'S CAB

6. Remove cover (11).

10. Remove ducts (17) and (18).

7. Remove covers (12) (14).

11. Return the right lever stand removed in step 9.


12. Disconnect wiring harness connectors M71 (19),
H10 (20), H11 (21), and H12 (22).

8. Disconnect wiring harness connector W04 (15).


9. Remove the 4 mounting bolts of right lever stand
(16) and move the lever stand to the left side in
the operator's cab.

30-80
(2)

13. Remove duct (23).

PC130-7

DISASSEMBLY AND ASSEMBLY

14. Remove bracket (24) and duct (25).

15. Disconnect wiring harness connectors M72 (26),


H08 (27), H09 (28), and M31 (29).

OPERATOR'S CAB

18. Remove cover (32) under the front of the operator's cab.

19. Disconnect windshield washer hose (33).

16. Remove bracket (30) and move it toward the air


conditioner unit.

20. Sling operator's cab assembly temporarily.

17. Remove the 5 mounting bolts of controller bracket


(31) and move the bracket toward the air conditioner unit.

PC130-7

21. Remove 5 mounting bolts (34) and 4 mounting


nuts (35).
a Check the bolt length.

30-81
(2)

DISASSEMBLY AND ASSEMBLY

22. Lift off operator's cab assembly (36).

4 Operator's cab assembly: 280 kg

30-82
(2)

OPERATOR'S CAB

INSTALLATION

Carry out installation in the reverse order to


removal.

PC130-7

DISASSEMBLY AND ASSEMBLY

OPERATOR'S CAB GLASS

REMOVAL AND INSTALLATION OF OPERATOR'S CAB GLASS


(STUCK GLASS)

Among the panes of window glass on the 4 sides


of the operator's cab, 4 panes (1) (4) are stuck.
In this section, the procedure for replacing the
stuck glass is explained.
When replacing front window glass (4), remove
front window assembly (5). (It is impossible to
replace only the front window glass while the
front window assembly is installed to the operator's cab.)
For the procedure for replacing the front window
assembly, see REMOVAL AND INSTALLATION
OF FRONT WINDOW ASSEMBLY.

PC130-7

(1) :
(2) :
(3) :
(4) :
(5) :

Right side window glass


Left side rear window glass
Door lower window glass
Front window glass
Front window assembly
(Front window glass + Front frame)
(6) : Both-sided adhesive tape
(16): Center trim seal

30-83
(2)

DISASSEMBLY AND ASSEMBLY

OPERATOR'S CAB GLASS

793-498-1210

Lifter (Suction cup) t

20Y-54-13180

Adapter

Part name

Sketch

Part No.

New/Remodel

Q'ty

(The figure shows the operator's cab of a


wheel loader.)
Necessity

Symbol

SPECIAL TOOLS

REMOVAL
*

Remove the window glass to be replaced


according to the following procedure.

1. Using seal cutter [1], cut the adhesive between


broken window glass (7) and operator's cab
(metal sheet) (8).

a If the window glass is broken finely, it may be


removed with knife [4] and a screwdriver.
a Widening the cut with a screwdriver, cut the
adhesive and both-sided adhesive tape with
knife [4].
(The figure shows the operator's cab of a
wheel loader.)

a If a seal cutter is not available, make holes


on the adhesive and both-sided adhesive
tape with a drill and pass a fine wire (piano
wire, etc.) [2] through the holes. Grip the
both ends of the wire with priors [3], etc. (or
hold them by winding them onto something)
and move the wire to the right and left to cut
the adhesive and both-sided adhesive tape.
Since the wire may be broken by the frictional heat, apply lubricant to it.

30-84
(2)

2. Remove the window glass.

PC130-7

DISASSEMBLY AND ASSEMBLY

INSTALLATION
1. Using a knife and scraper [5], remove the
remaining adhesive and both-sided adhesive
tape from the metal sheets (glass sticking surfaces) of the operator's cab.
a Remove the adhesive and both-sided adhesive tape to a degree that they will not affect
adhesion of the new adhesive. Take care not
to scratch the painted surfaces. (If the
painted surfaces are scratched, adhesion will
be lowered.)

OPERATOR'S CAB GLASS

(The figure shows the operator's cab of a wheel


loader.)

(The figure shows the operator's cab of a


wheel loader.)

2. Remove oil, dust, dirt, etc. from the sticking surfaces of cab (8) and window glass (9) with white
gasoline.
a If the sticking surfaces are not cleaned well,
the glass may not be stuck perfectly.
a Clean the all black part on the back side of
the window glass.
a After cleaning the sticking surfaces, leave
them for at least 5 minutes to dry.

PC130-7

3. Apply primer (10).


a The using limit of primer (10) is 4 months
after the date of manufacture. Do not use
primer (10) after this limit.
a Use the primer within 2 hours after unpacking it.
a Even if the primer is packed again just after it
is unpacked, use it within 24 hours after it is
unpacked for the first time. (Discard the
primer 24 hours after it is packed.)
1) Stir the primers for paint and glass sufficiently before using them.
a If the primer has been stored in a refrigerator, leave it at the room temperature
for at least half a day before stirring it. (If
the primer is unpacked just after taken
out of the refrigerator, water will be condensed. Accordingly, leave the primer at
the room temperature for a sufficient
time.)
2) When reusing primer brush (11), wash it in
white gasoline.
a After washing the brush, check it again
for dirt and foreign matter.
a Prepare respective brushes for the paint
primer glass primer.

30-85
(2)

DISASSEMBLY AND ASSEMBLY

3) Evenly apply paint primer to the surfaces to


stick both-sided adhesive tapes and the surfaces out of those surfaces on operator's cab
(8) which will be coated with the adhesive.

2 Paint primer:
SUNSTAR PAINT PRIMER 580
SUPER or equivalent
a Do not apply the primer more than 2
times. (If it is applied more than 2 times,
its performance will be lowered.)

OPERATOR'S CAB GLASS

a In addition to the above parts, apply the


primer to right side window glass (1) and
door lower window glass (3).

Range to apply primer additionally for right


side window glass (1): (b)

Range to apply primer additionally for door


lower window glass (3): (c)
a After applying the primer, leave it for at least
5 minutes (within 8 hours) to dry.

a Parts to be coated with primer: Apply the


primer all over dimension (a).
Dimension to apply primer (a): 25 mm

a Never apply wrong primer. If the glass primer


is applied by mistake, wipe it off with white
gasoline.

30-86
(2)

PC130-7

DISASSEMBLY AND ASSEMBLY

4) Evenly apply glass primer to the sticking surfaces of window glass (9).
2 Glass primer:
SUNSTAR GLASS PRIMER 580
SUPER or equivalent
a Do not apply the primer more than 2
times. (If it is applied more than 2 times,
its performance will be lowered.)

a Parts to be coated with primer: Apply the


primer to the sticking surfaces of window
glass (9) and all over dimension (d)
which will be on both-sided adhesive
tape (6) and operator's cab (8).
a Do not apply the primer to the boarder
about 5 mm wide between the black part
and transparent part of the glass.
a After applying the primer, leave it for at
least 5 minutes (within 8 hours) to dry.
a Never apply wrong primer. If the glass
primer is applied by mistake, wipe it off
with white gasoline.

PC130-7

OPERATOR'S CAB GLASS

4. Stick both-sided adhesive tape (6) along the


inside edge of the glass sticking section.
a Do not remove the release tape of the bothsided adhesive tape on the glass sticking
side before sticking the glass.
a When sticking the both-sided adhesive tape,
do not touch the cleaned surface as long as
possible.
a Take that the both-sided adhesive tape will
not float at each corner of the window frame.

a When sticking both-sided adhesive tape (6)


around a frame, do not lap its finishing end
over the starting end but make clearance e of
about 5 mm between them.
1) Stick both-sided adhesive tape (6) for right
side window glass (1) as shown in the figure.

30-87
(2)

DISASSEMBLY AND ASSEMBLY

a Stick both-sided adhesive tape (6a) additionally for right side window glass (1).
Positions to stick additional both-sided
adhesive tape for right side window
glass:
(f) : 50 mm
(g) : 90 mm
(h) : 250 mm

2) Stick both-sided adhesive tape (6) for left


side rear window glass (2) as shown in the
figure.

30-88
(2)

OPERATOR'S CAB GLASS

3) Stick both-sided adhesive tape (6) for door


lower window glass (3) as shown in the figure.

a Stick both-sided adhesive tape (6b) additionally for door lower window glass (3).
a Positions to stick additional both-sided
adhesive tape for door lower window
glass:
(j) : 110 mm
(k) : 90 mm
(m) : 200 mm

PC130-7

DISASSEMBLY AND ASSEMBLY

4) Stick both-sided adhesive tape (6) for front


window glass (4) as shown in the figure.

a Stick both-sided adhesive tape (6c) of


the lower side of the front window glass
along the outside edge of the lower line,
differently from other both-sided adhesive tapes (6). (If it is stuck along the
inside, it will be seen through the transparent part of the glass.)

PC130-7

OPERATOR'S CAB GLASS

5. Position the new window glass.


1) Check the clearance between the window
glass and the operator's cab on the right, left,
upper, and lower sides, and then adjust it
evenly.
2) Stick tapes [6] between window glass (9) and
operator's cab (8) and draw positioning line
n.
a Stick tapes [6] to the right, left, and lower
parts of the right side window glass, left
side rear window glass, and door lower
window glass for accurate positioning.
3) Cut the tape between window glass (9) and
operator's cab (8) with a knife, and then
remove the window glass.
a Do not remove the tapes left on the window glass and operator's cab before
installing the window glass.

30-89
(2)

DISASSEMBLY AND ASSEMBLY

a When positioning front window glass (4),


set its horizontal position to the frame
width and set its vertical position so that
height difference (p) between it and the
frame top will be 3 mm.

6. Apply adhesive.
a Use either of the 2 types of the adhesive.

a
a
a
a
1)

2 Adhesive (Summer):
SUNSTAR PENGUINE SEAL 580
SUPER "S"
2 Adhesive (Winter):
SUNSTAR PENGUINE SEAL 580
SUPER "W"
The using limit of the adhesive is 4 months
after the date of manufacture. Do not use the
adhesive after this limit.
Keep the adhesive in a dark place where the
temperature is below 25C.
Never heat the adhesive higher than 30C.
When reusing the adhesive, remove the all
hardened part from the nozzle tip.
Break aluminum seal (13) of the outlet of
adhesive cartridge (12) and install the nozzle.

30-90
(2)

OPERATOR'S CAB GLASS

2) Cut the tip of the adhesive nozzle (14) so


that dimensions (q) and (r) will be as follows.
Dimension (q): 10 mm
Dimension (r): 15 mm

3) Set adhesive cartridge (12) to caulking gun


[7].
a An electric caulking gun is more efficient.

4) Remove the release tape of the both-sided


adhesive tape on the glass side.

PC130-7

DISASSEMBLY AND ASSEMBLY

5) Apply adhesive (15) to the outside of bothsided adhesive tape (6) of the operator's cab.

OPERATOR'S CAB GLASS

a Apply adhesive (15) additionally for additional both-sided adhesive tape (6a) of
the right side window glass and additional both-sided adhesive tape (6b) of
door lower window glass.

a Apply adhesive (15) to dimensions (s)


and (t) of both-sided adhesive tape (6) of
operator's cab (8).
Dimension (s): 10 mm
Dimension (t): 15 mm
a Apply adhesive (15) higher than bothsided adhesive tape (6).
a Apply the adhesive evenly.

AJF00822

PC130-7

30-91
(2)

DISASSEMBLY AND ASSEMBLY

7. Install the window glass.


1) Install window glass (9), matching it to the
lines of the positioning tapes drawn in step 5.
a Since the window glass cannot be
removed and stuck again, stick it very
carefully.
a Stick the glass within 5 minutes after
applying the adhesive.
2) After sticking window glass (9), press all
around it until it is stuck to the both-sided
adhesive tape.
a Press the corners of the window glass
firmly.

OPERATOR'S CAB GLASS

a After installing front window glass (4), fill


the clearances between it and center trim
seal (16) with caulking material in range
(s) to dimensions (t) and (u).
After applying the primer to glass (4) of
section A A, apply adhesive as caulking material.
Caulking dimension (t): 2 mm
Caulking dimension (u): 5 mm
a When caulking, mask the glass side and
form the adhesive with a rubber spatula
as shown in the figure.
a Wipe off projected adhesive.
2 Glass primer:
SUNSTAR GLASS PRIMER 580
SUPER
2 Adhesive:
SUNSTAR PENGUINE SEAL 580
SUPER "S" or "W"

a You can perform this work efficiently by


pulling window glass (9) from inside of
the operator's cab with suction cup X1.

30-92
(2)

PC130-7

DISASSEMBLY AND ASSEMBLY

8. Fix the window glass.


1) After installing right window glass (1) to the
operator's cab, insert stopper rubbers X2 to 2
places (v) at the bottom of the glass to fix the
glass.

OPERATOR'S CAB GLASS

9. After installing the window glass, remove the


primer and adhesive from the operator's cab and
window glass.
a Using white gasoline, wipe off the adhesive
before it is dried up.
a When cleaning the glass, do not give an
impact to it.
10. Protect the stuck window glass.
1) Keep the stopper rubbers, styrene foam
blocks, and rubber bands installed for 10
hours (at temperature of 20C and humidity
of 60%).
2) After removing the stopper rubbers, styrene
foam blocks, and rubber bands, wait at least
14 hours, at least 24 hours in total, before
operating the machine actually.

2) Using styrene foam blocks [9] and rubber


bands [10], fix the window glass and bothsided adhesive tape to fit them completely.

PC130-7

30-93
(2)

DISASSEMBLY AND ASSEMBLY

REMOVAL AND INSTALLATION


OF FRONT WINDOW
ASSEMBLY

k Lower the work equipment to the ground and


stop the engine.

To replace the front window glass, the front window assembly must be removed from the operator's cab. The procedure for removing and
installing the front window assembly (front frame
and front window glass) is explained below.

FRONT WINDOW

5. Release the rear locks.


6. Lower the front window assembly carefully a little. Put out rollers (8) and (9) under the both
sides of the front window through the portion
from which the corner blocks were removed in
step 3 (the portion where the rail is open) and
hold them.
7. Remove rollers (8) and (9) under the both sides
of the front window.

REMOVAL
1. Raise the front window assembly to the ceiling
and fix it with the rear locks (on both sides).
2. Remove left corner blocks (1) and (2) and right
corner block (3).
[*1]
3. Remove left striker bolt (4), right striker bolt (5),
left corner block bracket, and right corner block
bracket (7).
[*2]
4. Install left striker bolt (4) to the operator's cab
again and tighten it lightly.
a This bolt will be used to hang the pull-up
assist cable in step 8.

30-94
(2)

PC130-7

DISASSEMBLY AND ASSEMBLY

8. Remove left lower pin (10).


[*3]
a If left lower pin (10) is removed, plate (12) at
the end of pull-up assist cable (11) comes
off.
a Hang plate (12) on the left striker bolt.

FRONT WINDOW

9. Put out the bottom of front window assembly (13)


through the rail opening portion and lower it
gradually.

k The return load of 58.8 N {6 kg} is applied


to the rear of the operator's cab. Accordingly, take care when removing left lower
pin (10) to disconnect pull-up assist cable
(11).

10. Lower front window assembly (13) completely.


a Do not let the front window assembly touch
the monitor.

PC130-7

30-95
(2)

DISASSEMBLY AND ASSEMBLY

11. Twist front window assembly (13) to the right and


left to remove both upper rollers (14) and (15)
from the rails, and then remove front window
assembly (13).

FRONT WINDOW

INSTALLATION

Carry out installation in the reverse order to


removal.

[*1] [*2]
Adjust opening and closing of the front window
assembly according to the following procedure.
1. Open and close the front window to check that it
does not interfere with the rails and the rollers
are not hitch.
2. If there is any problem in opening or closing of
the front window, loosen the mounting bolts of
roller adjustment brackets (16) and (17) and
adjust the condition of the front window, and then
tighten the mounting bolts again.
3 Mounting bolt: 98 Nm {1.0 kgm}

30-96
(2)

PC130-7

DISASSEMBLY AND ASSEMBLY

FRONT WINDOW

3. Raise the front window assembly and fix it with


the rear locks (on both sides).
a Check that the locks in the rear of the operator's cab are applied securely.
4. Install right corner block (3) and fix right corner
block bracket (7) with right striker bolt (5).
a Tighten the striker bolt securely after adjusting it in step 6.
a Install the right corner block so that there will
be no level difference at part (a).
a Install the right corner block so that level difference (b) between the rail and right corner
block (3) at part PF will be 0 1.0 mm.
Check that the right corner block is not projected from the rail at the rolling surface of
the roller.
a Secure roller clearance (c) at part PJ.

PC130-7

30-97
(2)

DISASSEMBLY AND ASSEMBLY

5. Install left corner blocks (1) and (2) and secure


left corner bracket (6) with left striker bolt (4).
a Tighten the striker bolt securely after adjusting it in step 6.
a Install the left corner blocks so that there will
be no level difference at 2 part (d).
a Secure roller clearance (e).

30-98
(2)

FRONT WINDOW

6. Adjust the striker bolts according to the following


procedure (Adjust the "CLOSE" positions of the
front window assembly locks).
1) Tighten left striker bolt (4) and right striker
bolt (5) at roughly right positions so that front
window glass (18) will be fitted to cab-side
trim seal (19).

PC130-7

DISASSEMBLY AND ASSEMBLY

FRONT WINDOW

2) Open and close the front window assembly


and check the working condition of both
locks (20) and (21).
i) If both locks do not work normally, move
the striker bolts toward the rear of the
cab and tighten them again.
ii) After moving the striker bolts, check the
fitness of the front window glass and cabside trim seal which was checked in step
1).
iii) Repeat the work in i) and ii) until the fitness of the front window and the working
condition of both locks (20) and (21) are
acceptable, and then tighten the striker
bolts.

7. After adjusting the striker bolts, splash water


heavily over the front window glass and check
that the water does not leak into the cab.
8. Adjust the "opening" lock of the front window
assembly.
1) After adjusting the "closing" lock of the front
window in step 6, raise the front window
assembly to the ceiling.
2) Set the right and left front window assembly
locks at the rear of the operator's cab to the
"OPEN" positions, and then check the following items.
Check that right and left locks (20) and
(21) are closed normally.
Check that right and left locks (20) and
(21) are inserted in parallel in right and
left striker plates (22).
Check that right and left rubber stoppers
(24) are in contact with the front window
assembly and their deflection allowance
is 1.5 3.0 mm.
3) After checking the above items, if necessary,
adjust them by moving right and left striker
plates (22) at the rear of the operator's cab.

PC130-7

9. Adjust the front window stoppers.


1) After adjusting "closing" lock of the front window assembly in step 8, check the contact of
both front window stoppers (23).
2) If both stoppers (23) do not contact normally,
adjust and fix them at places where they contact normally.

30-99
(2)

DISASSEMBLY AND ASSEMBLY

FRONT WINDOW

10. Check the latching effort of the front window


assembly.
1) After finishing steps 6 8, check that latching
efforts of both locks (20) and (21) are even.
a Check the latching efforts on both "closing" side (in the front of the operator's
cab) and "opening" side (in the rear of
the operator's cab).

[*3]

3 Left lower pin:


27 34 Nm {2.75 3.47 kgm}

2 Mounting bolt: Adhesive (LT-2)

30-100
(2)

PC130-7

DISASSEMBLY AND ASSEMBLY

REMOVAL AND INSTALLATION


OF MONITOR PANEL
ASSEMBLY

MONITOR PANEL

3. Disconnect wiring harness connectors P01 (3)


and P02 (4) and remove monitor panel assembly
(5).

REMOVAL

k Disconnect the cable from the negative () terminal of the battery.


1. Remove cover (1).
a When removing the cover, disconnect wiring
harness connector P15 on its back side.

INSTALLATION

Carry out installation in the reverse order to


removal.

2. Remove 3 mounting bolts (2).

a Take care not to drop the mounting bolts in


the cover or duct.

PC130-7

30-101
(2)

DISASSEMBLY AND ASSEMBLY

REMOVAL AND INSTALLATION


OF CONTROLLER ASSEMBLY

CONTROLLER

INSTALLATION

Carry out installation in the reverse order to


removal.

REMOVAL

k Disconnect the cable from the negative () terminal of the battery.


1. Remove cover (1).

2. Disconnect wiring harness connectors C01 (2),


C02 (3), and C03 (4).
3. Loosen the 2 lower mounting bolts and remove
the 2 upper mounting bolts, and then pull up and
remove controller assembly (5).
a Take care extremely not to give a shock of
falling, etc. to the controller assembly.

30-102
(2)

PC130-7

40 MAINTENANCE STANDARD

SWING MACHINERY .............................................................. 40- 2


SWING CIRCLE ...................................................................... 40- 4
TRACK FRAME, IDLER CUSHION......................................... 40- 5
IDLER ...................................................................................... 40- 6
CARRIER ROLLER ................................................................. 40- 7
TRACK ROLLER ..................................................................... 40- 8
SPROCKET ............................................................................. 40- 9
TRACK SHOE ......................................................................... 40-10
HYDRAULIC PUMP................................................................. 40-14
CONTROL VALVE ................................................................... 40-15
SUCTION SAFETY VALVE ..................................................... 40-24
SELF PRESSURE REDUCTION VALVE ................................ 40-25
TRAVEL MOTOR..................................................................... 40-26
SWING MOTOR ...................................................................... 40-27
SOLENOID VALVE .................................................................. 40-28
CENTER SWIVEL JOINT ........................................................ 40-29
PPC VALVE ............................................................................. 40-30
HYDRAULIC CYLINDER......................................................... 40-34
WORK EQUIPMENT ............................................................... 40-36
DIMENSION OF WORK EQUIPMENT.................................... 40-38

PC130-7

40-1

MAINTENANCE STANDARD

SWING MACHINERY

SWING MACHINERY

40-2

PC130-7

MAINTENANCE STANDARD

SWING MACHINERY

Unit: mm
No.

Check item

Criteria

Remedy

Standard clearance

Clearance limit

Backlash between swing motor


shaft and No.1 sun gear.

0.07 0.18

0.4

Backlash between No.1 sun gear


and No.1 planetary gear.

0.13 0.31

0.6

Backlash between No.1 planetary


gear and ring gear.

0.15 0.34

0.7

Backlash between No.1 planetary


carrier and No.2
sun gear.

0.14 0.34

0.7

Backlash between No.2 sun gear


and No.2 planetary gear.

0.13 0.31

0.6

Backlash between No.2 planetary


gear and ring gear.

0.15 0.34

0.7

Backlash between No.2 planetary


carrier and swing pinion.

0.08 0.19

0.4

Backlash between swing pinion


and swing circle.

0.13 1.16

2.3

Standard size

Repair limit

Wear of swing pinion surface contacting with oil seal.

144.8

PC130-7

Replace

145 - 0.1000

Apply hardchrome plating


recondition, or
replace

40-3

MAINTENANCE STANDARD

SWING CIRCLE

SWING CIRCLE

Unit: mm
No.

40-4

Check item

Axial clearance of bearing

Criteria

Remedy

Standard clearance

Clearance limit

0.10 0.25

0.9

Replace

PC130-7

MAINTENANCE STANDARD

TRACK FRAME, IDLER CUSHION

TRACK FRAME, IDLER CUSHION

Unit: mm
No.

Check item

Idler guide top and


bottom width

Idler guide left and


right width

Criteria
Standard size

Clearance limit

Track frame

84

89

Idler support

82

77

Rebuild or
replace

Track frame

185

193

Rebuild

Idler support

183

175

Rebuild or
replace

Standard size
3

Recoil spring

PC130-7

Remedy

Rebuild

Repair limit

Free length

Installed
length

Installed
load

Free length

Installed
load

502

390

84.3 kN
{8,600 kg}

490

75.0 kN
{7,650 kg}

Replace

40-5

MAINTENANCE STANDARD

IDLER

IDLER

Unit: mm
No.

Check item

Criteria

Remedy

Standard size

Repair limit

527

Outer diameter of tread

489

477

Depth of protruding portion

19

25

Width of protruding portion

52

42

Total width

115

107

Width of tread

31.5

36.5

Outer diameter of protruding


portion

Clearance between idler shaft and


bushing

Interference between idler


and bushing

Standard
size

Shaft

Hole

Standard
clearance

Clearance
limit

54

0.250
0.280

+ 0.074
0

0.250
0.354

1.5

Standard
size
61

Side clearance of idler


(on one side)

10

Tread wall thickness


(at center of tread)

40-6

Tolerance

Rebuild or
replace

Tolerance
Shaft

Hole

+ 0.117
+ 0.087

+ 0.030
0

Standard in- Interference


terference
Replace
limit
0.057
0.117

Standard clearance

Clearance limit

0.18 0.38

1.5

Standard size

Repair limit

15

Rebuild or
replace

PC130-7

MAINTENANCE STANDARD

CARRIER ROLLER

CARRIER ROLLER

Unit: mm
No.

Check item

Outer diameter of tread

Width of tread

Clearance between shaft and


bushing

Criteria
Standard size

Repair limit

116

106

123

Standard
size
40

Interference between collar and


bushing

Play on carrier roller in


axial direction

Tread wall thickness


(at 10 mm away from end face roller)

PC130-7

Remedy

Tolerance
Shaft

Hole

Standard
clearance

+ 0.055
0.035

+ 0.261
+ 0.200

-0.145
0.226

Tolerance

Standard
size

Shaft

Hole

47

+ 0.061
0.036

+ 0.025
0

Rebuild or
replace

Clearance
limit

Replace

Standard in- Interference


terference
limit
0.011
0.061

Standard size

Repair limit

0.363 0.537

1.5

17.7

12.7

Rebuild or
replace

40-7

MAINTENANCE STANDARD

TRACK ROLLER

TRACK ROLLER

Unit: mm
No.

Check item

Criteria

Diameter of flange
(outside)

Remedy

Standard size

Repair limit

158

Outer diameter of tread

130

120

Flange width

26.5

Total width

176

Width of tread

35

Clearance between shaft and


bushing

Interference between roller and


bushing

Track roller side clearance


(on one side)

Tread wall thickness


(at center of width)

40-8

Rebuild or
replace

Standard
size

Shaft

Hole

Standard
clearance

Clearance
limit

48

0.250
0.350

+ 0.186
0.025

0.225
0.536

1.5

Standard
size
55

Tolerance

Rebuild or
replace

Tolerance
Shaft

Hole

+ 0.190
+ 0.110

+ 0.093
+ 0.063

Standard in- Interference


terference
Replace
limit
0.017
0.127

Standard clearance

Clearance limit

0.160 0.345

1.5

Standard size

Repair limit

37.5

32.5

Rebuild or
replace

PC130-7

MAINTENANCE STANDARD

SPROCKET

SPROCKET

Unit: mm
No.

Check item

Criteria

Remedy

Standard size

Tolerance

Repair limit

547.4

+ 1.0
2.0

535

Wear on addendum diameter

607

595

Wear on addendum width

27

22

Wear on tooth bottom width

42

1.5

39

Tooth bottom wall thickness

111.7

+ 0.465
1.160

105.5

Wear on tooth bottom diameter

PC130-7

Rebuild or
replace

40-9

MAINTENANCE STANDARD

TRACK SHOE

TRACK SHOE
TRIPLE SHOE, ROAD LINER, CITY PAD SHOE

1 Triple shoe and city pad shoe


2 Road liner
a P portion shows the link of bushing press fitting end.

40-10

PC130-7

MAINTENANCE STANDARD

TRACK SHOE

Unit: mm
No.

Check item

Criteria

Link pitch

Standard size

Repair limit

175.25

178.25

Bushing outside diameter


46.3

Link height

Thickness of link metal


(bushing pressfitting portion)

Turn of replace

When turned

Standard size
2

Remedy

Normal road

Impact road

42.3

Standard size

Repair limit

86

81

24

19

Rebuild or
replace

102.4
Replace

Shoe bolt pitch

86.4

57

8
9

Inside diameter
Link

10

52.4

Overall width

35

Tread width

30.1

11

Protrusion of pin

5.5

12

Protrusion of regular bushing

3.75

13

Overall length of pin

173

14

Overall length of bushing

86.7

15

Thickness of bushing metal

16

Thickness of spacer

17
18

Press fitting
force

*19

Rebuild or
replace

Adjust of
replace

Standard size

Repair limit

7.8

3.8

Bushing

39.2 137.2 kN {4 14 ton}

Regular pin

78.4 186.3 kN {8 19 ton}

Master pin

39.2 98.1 kN {4 10 ton}

a The items marked * are for dry type track.


PC130-7

40-11

MAINTENANCE STANDARD

TRACK SHOE

Unit: mm
No.

Check item

Criteria

Remedy

Tightening torque (Nm {kgm}) Additional tightening angle (deg)


a. Regular link
Shoe bolt
20
b. Master link

Triple shoe
City pad shoe

196 20
{20 2}

90 10

Road liner

147 10
{15 1}

50 5

Tightening torque
(Nm {kgm})

Additional tightening
angle (deg)

Lower limit torque


(Nm {kgm})

No. of shoe (each side)

21

22

23

Interference between bushing


and link

Interference between regular


pin and link

Clearance between regular


pin and bushing

43
Standard size

*24

*25

Height of
grouser

Standard
interference

46

+ 0.387
+ 0.347

+ 0.062
0

0.285 0.387

30

+ 0.150
0

0.198
0.250

0.198 0.400

Standard size

Standard size

Standard size
30

26

Tolerance
Hole

30

Clearance between master


pin and bushing

Shaft

30

Interference between master


pin and link

Retighten

a. Road liner

Tolerance

Standard
clearance

Shaft

Hole

+ 0.150
0

0.830
0.330

0.180 0.830 Adjust or


replace

Tolerance
Shaft

Hole

Standard
interference

+ 0.020
0.020

0.198
0.250

0.178 0.270

Tolerance

Standard
interference

Shaft

Hole

0.200
0.300

+ 0.630
+ 0.230

0.430 0.930

Standard size

Repair limit

58

21

Replace

a The items marked * are for dry type track.

40-12

PC130-7

MAINTENANCE STANDARD

TRACK SHOE

RIPLE SHOE, CITY PAD SHOE

Unit: mm
No.

Check item

Height of grouser

Overall height of shoe

Thickness

4
5

Criteria
Standard size

Repair limit

20

10

29.5

19.5
9.5
14

Length of grouser top

PC130-7

Remedy

Repair by
build-up
welding or
replace

13
15

40-13

MAINTENANCE STANDARD

HYDRAULIC PUMP

HYDRAULIC PUMP

40-14

PC130-7

MAINTENANCE STANDARD

CONTROL VALVE

CONTROL VALVE
(1/9)

PC130-7

40-15
(3)

MAINTENANCE STANDARD

CONTROL VALVE

(2/9)

Unit: mm
No.

Check item

Criteria
Standard size

Suction valve spring

Remedy
Repair limit

Free length
x O.D.

Installed
length

Installed
load

Free length

Installed
load

46.8 x 7.50

40.6

5.500.40N
{0.560.04kg}

4.40 N
{0.45 kg}

Suction valve spring

16.0 x 16.0

12.0

5.70 N
{0.58 kg}

4.50 N
{0.46 kg}

Piston spring

20.0 x 7.0

14.0

1.20 N
{0.12 kg}

0.98 N
{0.10 kg}

40-16
(3)

Replace spring
if any damages
or deformations
are found

PC130-7

MAINTENANCE STANDARD

CONTROL VALVE

(3/9)

Unit: mm
No.

Check item

Criteria
Standard size

Spool return spring

Remedy
Repair limit

Free length
x O.D.

Installed
length

Installed
load

Free length

Installed
load

45.0

53.5 N
{5.46 kg}

Spool return spring

45.0

55.9 N
{5.70 kg}

Spool return spring

41.0

92.2 N
{9.4 kg}

PC130-7

Replace spring
if any damages
or deformations
are found

40-17

MAINTENANCE STANDARD

CONTROL VALVE

(4/9)

Unit: mm
No.

Check item

Criteria
Standard size

Flow control valve spring

Remedy
Repair limit

Free length
x O.D.

Installed
length

Installed
load

Free length

Installed
load

23.5

29.4 N
{3 kg}

Pressure reduction valve spring

27.5 x 14.2

18.0

17.70.98N
{1.800.10kg}

13.7 N
{1.40 kg}

Pressure reduction valve spring

28.2 x 14.5

26.0

29.42.94N
{3.00.30kg}

23.5 N
{2.40 kg}

Pressure reduction valve spring

32.5 x 14.2

23

17.6 N
{1.8 kg}

14.1 N
{1.44 kg}

40-18
(3)

Replace spring
if any damages
or deformations
are found

PC130-7

MAINTENANCE STANDARD

CONTROL VALVE

(5/9)

Unit: mm
No.

Check item

Criteria
Standard size

Check valve spring

PC130-7

Remedy
Repair limit

Free length
x O.D.

Installed
length

Installed
load

Free length

Installed
load

41.5 x 8.50

31.5

5.88 N
{0.60 kg}

4.71 N
{0.48 kg}

Replace spring
if any damages
or deformations
are found

40-19
(3)

MAINTENANCE STANDARD

CONTROL VALVE

(6/9)

Unit: mm
No.

Check item

Criteria
Standard size

Lift check valve spring


Cooler bypass valve spring

Remedy
Repair limit

Free length
x O.D.

Installed
length

Installed
load

Free length

Installed
load

72.7 x 20.6

42.5

1354.90N
{13.80.50kg}

113 N
{11.5 kg}

Lift check valve spring

72.7 x 20.6

42.5

67.7 N
{6.9 kg}

Bleed spool return spring

23.3 x 12.5

23.0

3.920.98N
{0.400.10kg}

2.94 N
{0.30 kg}

40-20
(3)

Replace spring
if any damages
or deformations
are found

PC130-7

MAINTENANCE STANDARD

CONTROL VALVE

(7/9)

Unit: mm
No.

Check item

Criteria
Standard size

Travel junction spool

PC130-7

Remedy
Repair limit

Free length
x O.D.

Installed
length

Installed
load

Free length

Installed
load

17.7 x 8.20

13.0

13.70.10N
{1.400.10kg}

10.1 N
{1.10 kg}

Replace spring
if any damages
or deformations
are found

40-21

MAINTENANCE STANDARD

CONTROL VALVE

(8/9)

Unit: mm
No.

Check item

Criteria
Standard size

Check valve spring

40-22
(3)

Remedy
Repair limit

Free length
x O.D.

Installed
length

Installed
load

Free length

Installed
load

41.5 x 8.50

31.5

5.88 N
{0.60 kg}

4.71 N
{0.48 kg}

Replace spring
if any damages
or deformations
are found

PC130-7

MAINTENANCE STANDARD

CONTROL VALVE

(9/9)

PC130-7

40-23
(3)

MAINTENANCE STANDARD

SUCTION SAFETY VALVE

SUCTION SAFETY VALVE


FOR SERVICE VALVE

Unit: mm
No.

Check item

Criteria
Standard size

Suction valve spring

Piston spring

40-24

Remedy
Repair limit

Free length
x O.D.

Installed
length

Installed
load

Free length

Installed
load

16.3 x 21.3

9.50

2.06 N
{0.21 kg}

1.57 N
{0.16 kg}

20.0 x 7.0

14.0

2.06 N
{0.21 kg}

1.57 N
{0.16 kg}

Replace spring
if any damages
or deformations
are found

PC130-7

MAINTENANCE STANDARD

SELF PRESSURE REDUCTION VALVE

SELF PRESSURE REDUCTION VALVE

Unit: mm
No.

Check item

Criteria
Standard size

Spring
(pressure reduction main)

Remedy
Repair limit

Free length
x O.D.

Installed
length

Installed
load

Free length

Installed
load

19.2 x 7.20

16.1

19.6 N
{2.0 kg}

17.7 N
{1.80 kg}

Spring
(pressure reduction valve pilot)

16.5 x 7.20

12.7

20.6 N
{2.10 kg}

18.6 N
{1.90 kg}

Spring

71.0 x 18.0

59.0

200 N
{20.4 kg}

186 N
{19.0 kg}

Spring (safety valve)

16.1 x 7.80

13.4

61.7 N
{6.30 kg}

58.8 N
{6.0 kg}

PC130-7

Replace spring
if any damages
or deformations
are found

40-25

MAINTENANCE STANDARD

TRAVEL MOTOR

TRAVEL MOTOR
GM18VL-3

40-26

PC130-7

MAINTENANCE STANDARD

SWING MOTOR

SWING MOTOR
KMF40ABE-3

Unit: mm
No.

Check item

Criteria
Standard size

Check valve spring

Shuttle valve spring

PC130-7

Remedy
Repair limit

Free length
x O.D.

Installed
length

Installed
load

Free length

Installed
load

33.0 x 13.8

23.0

1.28 N
{0.13 kg}

0.98 N
{0.10 kg}

16.4 x 8.90

11.5

13.7 N
{1.40 kg}

10.8 N
{1.10 kg}

Replace spring
if any damages
or deformations
are found

40-27

MAINTENANCE STANDARD

SOLENOID VALVE

SOLENOID VALVE
FOR PPC LOCK, 2ND TRAVEL SPEED SELECTOR, SWING AND PARK BRAKE, AND 2STAGE RELIEF SOLENOID VALVE

40-28

PC130-7

MAINTENANCE STANDARD

CENTER SWIVEL JOINT

CENTER SWIVEL JOINT

Unit: mm
No.

Check item
Clearance between rotor and
shaft

PC130-7

Criteria

Remedy

Standard size

Standard clearance

Clearance limit

80

0.056 0.105

0.111

Replace

40-29

MAINTENANCE STANDARD

PPC VALVE

PPC VALVE
FOR SWING, WORK EQUIPMENT

Unit: mm
No.

Check item

Criteria
Standard size

Centering spring
(for P3 and P4 ports)

Remedy
Repair limit

Free length
x O.D.

Installed
length

Installed
load

Free length

Installed
load

44.45 x 15.5

34.0

29.4 N
{3.0 kg}

23.5 N
{2.40 kg}

Centering spring
(for P1 and P2 ports)

47.93 x 15.5

34.0

39.2 N
{4.0 kg}

31.4 N
{3.20 kg}

Metering spring

26.53 x 8.15

34.0

16.7 N
{1.70 kg}

13.7 N
{1.40 kg}

40-30

Replace spring
if any damages
or deformations
are found

PC130-7

MAINTENANCE STANDARD

PPC VALVE

FOR TRAVEL

Unit: mm
No.

Check item

Criteria
Standard size

Metering spring

Centering spring

PC130-7

Remedy
Repair limit

Free length
x O.D.

Installed
length

Installed
load

Free length

Installed
load

6.5 x 8.15

24.9

16.7 N
{1.70 kg}

13.7 N
{1.40 kg}

48.1 x 15.5

32.5

108 N
{11.0 kg}

86.3 N
{8.80 kg}

Replace spring
if any damages
or deformations
are found

40-31

MAINTENANCE STANDARD

PPC VALVE

FOR SERVICE

Unit: mm
No.

Check item

Criteria
Standard size

Centering spring

Metering spring

40-32

Remedy
Repair limit

Free length
x O.D.

Installed
length

Installed
load

Free length

Installed
load

42.4 x 15.5

28.4

207.8 N
{21.2 kg}

167 N
{17.0 kg}

2.7 x 8.10

22.0

16.7 N
{1.70 kg}

13.3 N
{1.36 kg}

Replace spring
if any damages
or deformations
are found

PC130-7

MAINTENANCE STANDARD

HYDRAULIC CYLINDER

HYDRAULIC CYLINDER
BOOM CYLINDER

ARM CYLINDER

BUCKET CYLINDER

40-34

PC130-7

MAINTENANCE STANDARD

HYDRAULIC CYLINDER

Unit: mm
No.

Check item
Cylinder

Clearance between
piston rod and
bushing

Clearance between
piston rod support
shaft and bushing

Cylinder piston
tightening torque

Cylinder piston lock


screw tightening
torque

PC130-7

Tolerance
Shaft
Hole

Standard
clearance

Clearance
limit

70

0.030
0.076

+ 0.259
+ 0.063

0.093
0.335

0.435

Arm

75

0.030
0.076

+ 0.279
+ 0.065

0.095
0.355

0.455

Bucket

65

0.030
0.076

+ 0.250
+ 0.055

0.085
0.326

0.426

Boom

70

0.030
0.100

+ 0.190
+ 0.070

0.100
0.290

1.0

Arm

70

0.030
0.100

+ 0.190
+ 0.070

0.100
0.290

1.0

Bucket

65

0.030
0.080

+ 0.170
+ 0.070

0.100
0.250

1.0

Boom

70

0.030
0.100

+ 0.190
+ 0.070

0.100
0.290

1.0

70

0.030
0.100

+ 0.190
+ 0.070

0.100
0.290

1.0

65

0.030
0.080

+ 0.170
+ 0.070

0.100
0.250

1.0

Clearance between
cylinder bottom support shaft and bush- Arm
ing
Bucket

Cylinder head
tightening torque

Standard
size

Remedy

Boom

Boom
4

Criteria

Arm

Replace
bushing

172 24.5 Nm {17.5 2.5 kgm}


270 39 Nm {27.5 4.0 kgm}

Bucket

172 24.5 Nm {17.5 2.5 kgm}

Boom

294 29.4 Nm {30.0 3.0 kgm}

Arm

294 29.4 Nm {30.0 3.0 kgm}

Bucket

294 29.4 Nm {30.0 3.0 kgm}

Boom

66.2 7.4 Nm {6.75 0.75 kgm}

Arm

66.2 7.4 Nm {6.75 0.75 kgm}

Bucket

30.9 3.4 Nm {3.15 0.35 kgm}

Re-tightening

40-35

MAINTENANCE STANDARD

WORK EQUIPMENT

WORK EQUIPMENT

40-36

PC130-7

MAINTENANCE STANDARD

WORK EQUIPMENT

Unit: mm
No.

Check item

Clearance between connecting


pin and bushing of revolving
frame and boom.

Criteria
Tolerance

Remedy

Standard
size

Shaft

Hole

Standard
clearance

Clearance
limit

70

0.030
0.100

+ 0.130
+ 0.065

0.095
0.230

0.8

Clearance between connecting


pin and bushing of boom and
arm.

70

0.030
0.100

+ 0.141
+ 0.074

0.104
0.241

0.8

Clearance between connecting


pin and bushing of arm and link.

60

0.030
0.080

+ 0.129
+ 0.074

0.104
0.209

0.8

60

0.030
0.080

+ 0.135
+ 0.074

0.104
0.215

0.8

65

0.030
0.080

+ 0.133
+ 0.074

0.104
0.213

0.8

Clearance between connecting


pin and bushing of arm and bucket.
Clearance between connecting
pin and bushing of link and
bucket.

Replace

Clearance between connecting


pin and bushing of link and link.

60

0.030
0.080

+ 0.130
+ 0.074

0.104
0.210

0.8

Clearance between the blade and


track frame mounting pin and
bushing

70

0.030
0.100

+ 0.198
+ 0.124

0.154
0.298

1.5

PC130-7

40-37

MAINTENANCE STANDARD

DIMENSION OF WORK EQUIPMENT

DIMENSION OF WORK EQUIPMENT


ARM

40-38

PC130-7

MAINTENANCE STANDARD

DIMENSION OF WORK EQUIPMENT

Unit: mm
No.

Measuring position

Tolerance

Standard size
70

Shaft

Hole

0.030
0.100

+ 0.100
0

81.5

+ 1.0
0

Cylinder head side

80

1.2

Boom side

226

+ 0.5
0

Arm side

226

0.2
0.7

Arm side
2

3
0.030
0.100

+ 0.100
0

70

264

2.0

213.5

1.0

640.6

0.5

2,491

2,101.9

1.5

10

290.4

0.5

11

493

0.2

12

422

0.5

13

374.9

14

1,175.1

15

60

0.030
0.080

+ 0.200
0

Link side

259

0
0.1

Bucket side

261

1.0

16

17

60

0.030
0.080

+ 0.200
0

Arm side

226

0
0.5

Bucket side

274

Min.

1,378

Max.

2,263

18

19

PC130-7

40-39

MAINTENANCE STANDARD

DIMENSION OF WORK EQUIPMENT

BUCKET

40-40

PC130-7

MAINTENANCE STANDARD

DIMENSION OF WORK EQUIPMENT

Unit: mm
No.

Measuring position

Standard size

Tolerance

371.3

0.5

51.6

0.5

97.9

374.9

1241.6

190.2

60

+ 0.2
0

10

64

11

80

12

261

1.0

13

50

14

85

15

380

+ 1.0
0

16

18

17

110

18

130

19

132

20

108

21

274

22

51

23

34

24

104.2

25

119.6

26

74

27

65

PC130-7

+ 0.25
0

40-41

90 OTHERS

HYDRAULIC CIRCUIT DIAGRAM........................................................... 90- 3


ELECTRICAL CIRCUIT DIAGRAM (1/4) ................................................ 90- 5
ELECTRICAL CIRCUIT DIAGRAM (2/4) ................................................. 90- 7
ELECTRICAL CIRCUIT DIAGRAM (3/4) ................................................. 90- 9
ELECTRICAL CIRCUIT DIAGRAM (4/4) ..................................................90-11

PC130-7

90-1
(3)

HYDRAULIC CIRCUIT DIAGRAM

PC130-7

90-3
(3)

ELECTRICAL CIRCUIT DIAGRAM (1/4)

PC130-7

90-5
(3)

ELECTRICAL CIRCUIT DIAGRAM (2/4)

PC130-7

90-7
(3)

ELECTRICAL CIRCUIT DIAGRAM (3/4)

PC130-7

90-9
(3)

ELECTRICAL CIRCUIT DIAGRAM (4/4)

PC130-7

90-11
(3)