PC240-6K S Eebm000505 PDF

EEBMOO0505 SOW IM LAINNO AIL KOMATSU PC210, 210LC-ck PC240, 240LC, PC240NLC-ck MACHINE MODEL SERIAL NUMBER PC210, 210LC-6K K30001 and up PC240, 240LC, 240NLC-6K 30001 and up This shop manual may contain attachments and optional equipment that are not available in your area. Please consult your local Komatsu distributor for those items you may require. Materials and specifications are subject to change without notice. PC210, 210LC-6 mount the S6D102L-1 engine; PC240, 240LC-6 mount the SA6D102L-1 engine. For details of the engine, see the 102 Service Engine Shop Manual. ©1997 MOMATSU All Rights Reserved Printed in Belgium 02-97‘The affected pages are indicated by the use of the following marks. It is requested that necessary ac- Merk | indication Action required tions be taken to these pages according to the table below. Page to be newly added ane [Page to be replaced | Replace (_ ) [Page tobe deleted | Discard Pages having no marks are those previously revised or made addons. LIST OF REVISED PAGES wa Pace eT wane Page Tl wan rage Th] man Pape 770] wan page Tat © 004 ® 10-13 fo} 10-48 oO 10-82 @ 10-115 © vo uO oO ros} one © 2 021 © 10-45, @ 10-50 oO 10-84 oO wn7 © 0-2-2 ® 10-16 oO 10-51 oO 10-85, oO 10-118 @ © 023 © 10-17 oO 10-52 o 10-86 @Q 18119 @ 00-3 10418 fo} 10-53 ® 10-87 o 10-120 @ vo 0 wo oO wont os io} 1080 oe 0 foi 0 toe ne oe oO wows o7 woe} wor oO wom toe ioe 10880 oe 8 ious 0 009 10-25 oO 10-59 oO 10-93 ® 10-126 OD coro oO oo wo 0 won? oo wor 8 or ios om 0 0012 10-28 @ 10-62 oO 10-96 oO 10-129 00-13 10-29 oO 10-63, @® 10-97 ® 10-130 © 00-14 10-30 oO 10-64 oO 10-98 oO 10-131 @ wos sr | ees 8 mo woe cos be 6 08 8 om ois @ oo sO eer 8 wor wore ne we 3 joi 0 ious sO we 3 wom 0 wore tos ioe} om foie foie1 @ we 8 woe won 0 ions 0 o1ee @ 10-3, oO 10-39 oO 10-72 oO 10-106 = @ 10-1363 @ 104 @ 10-40 fo 10-73 oO 10107 © 10-136-4 @ sO io tom 0 iow ones 10-6 oO 10-42 ® 10-76 OQ 10109 @ 10-1366 @ 10-7 oO 10-43 ® 10-77 ® 10-110 @ 10-138 sO tou on 0 foi 0 owe 0 sO ios om O wore © iouo 10-10 oO 10-46 @O 10-80 ® 10113 © 10-141 fo} 10-12 ® 10-47 Oo 10-61 ® 10-114 @ 10142 @ 00-2-1Mark Page Foreon| Mat Page iugol| Mark Page TM! mark Pago TIMES! wark Page Time of 1143 @ 2019 20-69 2osa8 zo-te tore @ 20-14 20-70 20-128 20-182 co) © 2015 2071 2os27 20-188 (oan © 20-16 zor 20-128 20-108 (10-148) © 2017 20-73 20-120 20-185, 10-149 2018 2074 20-190 20-108 10-180 © 2020 2075 20-31 20-187 10181 2021 2076 20-132 20-188, 1012 © 2022 2078 204138 20-189 10153 © 2023 2079 20134 20-190 10158 2024 2080 20-135 20-101 10-155 2025 2081 20-136 20-192 10-158 2028 2082 20197 20-183 10157 2027 2089 20-138 20-196 10-158 20.28 20-84 20-139 20-195 1189 © 2029 20.85 2-140 zows tote 20-0 20.88 zoe ow wis © 2031 20.87 20-42 20-198 wie 202 20-88 2osa3 20.199 118s © 2003 20-89 2014s tore 20-94 20-00 20-48, 20201 118s © 2095 2001 20-46 20202 1016 © 2036 20-82 2oca7 20208, 10167 © 2087 2093 20-48 20.204 1018 2038 2094 20-49 20.205 10-168 2030 2095 20150 20206, 10170 20.40 2098 20st 20207 171 2041 2007 20153 20.208 1017 20.42 2098 20154 20209 10.173 © 2043 2090 20455, 20210 10178 20.48 20-100 20-156 zo2ti 10175 20.45 20:01 20187 20212 10.178 20.48 zo-102 204158, 20213 10.177 2047 20-108 201859 20216 10.178 20.48 20-104 20-160 20215 10.179 20-49 20-105 zoe 20216 10-180 © 2080 20-108 2oss2 20217 worse 2051 20007 204183, 20-218 118s 2053 20-108 20-68 20219 10-188 20-54 20-100 20-165 20-200 2055 20-110 204186 20-221 2058 2011 20467 20222 201 2087 zone 20-168 20-205 22 20.58 20-113 20-169 2022 208 2059 20-18 2070 20225 204 200 20-16 zor 20205, 205 2081 20-116 zoare * 227 © 206 2062 20118 20.173 20208 207 20-63 2-119 2oara 20220 ns @ 2064 20-120 2075 2021 209 2065, 20-121 20.176 20282 20-10 20-66 20-122 zea? 20283 zon 2067 20-123 20-78 20235, 202 2068 20-124 20-180 20236 00-2-2Mark Page [ircon| Mark Page (yrgcl| Mark Page T¢Ol Mak Page TIME! wark Page Timeot 202007 3027 30-82 oO 20-298 3028 30-89 ow 0 20-299 2029 20-04 21 O 20-240 30.90 20-85 «2 © 20281 3031 20-86 42 ® 20242 m0 2087 4022 20.248 90.33 30-88 4023 2024 3034 2089 4024 20245 w025 20-90 4025 20.246 3096 2001 4028 20247 3037 30-92 4027 20248 2098 2009 4028 20-240 2099 3084 doz 20-250 2040 30-95 40:30 20251 aot 20-06 4031 20-252 9042 3097 4032 20-259 3043 30-08 4033 20254 20-44 20-09 404 20255 2045 230-100 4035 ® 20.256 2046 30-101 40-96 20-257 30-47 30-102 40-37 @ 20258 2048 20103 4038 20.250 209 so-108 402 «@ 20-260 20-50 30108 faa) 20261 2st 20-106 40st 20-262 20-82 3007 20263 3053 30-108 3054 20-109 90-55 30-110 4 30-56 sont 02 2057 sone 203 2058 oo-119 204 2089 0-114 205. 3060 0-115 206 2061 0-116 27 2062 30-117 8 2009 209 20-64 20-10 3065 404 won 20-86 402 w0-12 2067 403 20-19 20-68 404 woe 20-89 405 18 30-70 406 2047 oo-72 407 20418 90-73 408 a9 2074 09 3020 30-75 40-10 2021 2076 wont 2022 2077 40-12 3023 3078 40-19 3028 2079 404 2025 30-80 40-18 3026 3081 4018 00-2-3a)20506 10 STRUCTURE AND FUNCTION Engine related parts nn 10-2 Radiator « oil cooler « aftercooler wo 10-3. Powertrain nnn eee 0) Final dfive sesnmnnnnnnnnnnnnnnnnn 102 5) Swing circle 10 6 Swing machindery smn W028 Track frame recoil spring 10- 9 Hydraulic piping drawing sno W001 Hydraulic circuit diagram 10- 12 Hydraulic tank. 10-14 Hydraulic PUMP wnnnnnnmnnnnnnnne 10° 15 Control valve... 40- 38 ciss 10- 47 SWING MOF ensmnmnesennnnnnnnnsnnn 10° 92 Center swivel joint so snes 10> 96 Travel motor... 40-105 Work equipment « swing PPC valve 10-108 Travel PPC valve se 0-110 Service PPC valve osnnneesnnnee WANG Safety lock valve 10-117 PPC accumulator 10-117 PPC shuttle « travel junction Valve nnn 10-118, EPC * solenoid ValVE wnrnnnnnnnennnnnees 10425, Hydraulic cylinder 10-130 Additional ft for breaker 10-131 Overload warning device svnnnees 10-432 Hose burst protection valve snnnees 10-136, 2nd Boom Holding valve sow 10-136-3 Work equipment... 10-136-6 Electrical control system 10-138 Electrical wiring diagram 10-143 Engine control SySteM w.rnnnnnnnnnnne 10-149) Electronic control system 10-154 Machine monitor system on 10179, 10-1STRUCTURE AND FUNCTION ENGINE RELATED PARTS ENGINE RELATED PARTS Be cc ce 1. Drive plate OUTLINE . Torsion spring + The damper assembly is a wet type. . Stopper pin Oil capacity: 0.752 2 3 4, Friction plate 5. Damper assembly 6. Air cleaner 7. Intake connector & Muffler 9. Rear engine mount }0. Front engine mount 10-2 @STRUCTURE AND FUNCTION 2ND BOOM HOLDING VALVE pooe Port T (to tank) Port Pi (from boom LOWER PPC valve) Port Cy (to boom cylinder bottom) Port V (from boom control valve) osena 2ND BOOM HOLDING VALVE . Safety-suction valve Pilot spring . Pilot spool Poppet spring Poppet 10-136-3STRUCTURE AND FUNCTION 2ND BOOM HOLDING VALVE Operation 1) 2) At boom EXTEND When the second boom is extended, the main pressure from the control valve pushes poppet (6) up in the direction of the arrow. Because of this, the main pressure from the control valve passes through the valve and flows to the bottom end of the boom adjust cylinder. f Seat FF een a Tren # exten OF Premen, Boom pedal at NEUTRAL When the second boom is raised and the control lever is returned to NEUTRAL, the circuit for the holding pressure at the bottom end of the boom adjust cylinder is closed by poppet (6) and at the same time, the oil flowing into poppet (5) through orfice a of poppet (5) is closed by pilot spool (3). Asa result, the second boom is held in position. concros econo Contras valve 10-136-4 @STRUCTURE AND FUNCTION 2ND BOOM HOLDING VALVE 3) Atboom RETRACT When teh second boom is retracted, the pilot pressure from the PPC valve pushes pilot spool (3) and the pressurised oil in chamber b inside the poppet is drained, ‘When the pressure at port Cy rises because of the pressurised oil from the bottem end of the adjust cylinder, the difference in pressure between the oil surrounding the lower end of poppet (5) and the oil in chamber b allows the poppet tot rise allowing to flow from port Cy to port V which then flows to the control valve. If anny abnormal pressure is generated in the circuit at the bottom end of the boom adjust cylinder, safaty valve (1) is actuated contro! Seas! secona 10-136-5 ®STRUCTURE AND FUNCTION 2ND BOOM HOLDING VALVE 208608129 Arm Bucket cylinder . Arm cylinder Boom Boom cylinder Bucket Parons 10-136-6EEBM000502 DIOP 1M WANINAOANILy KOMATSU PC210,210LC-6k PC240 240LC, PC240NLC-6K MACHINE MODEL SERIAL NUMBER PC210, 210LC-6K K30001 and up PC240, 240LC, 240NLC-6K 30001 and up + This shop manual may contain attachments and optional equipment that are not available in your area. Please consult your local Komatsu distributor for those items you may require. Materials and specifications are subject to change without notice. PC210, 210LC-6 mount the $6D102L-1 engine; PC240, 240LC-6 mount the SA6D102L-1 engine. For details of the engine, see the 102 Service Engine Shop Manual, © 1995 KOMATSU All Rights Reserved. Printed in Belgium 10-95.05002.SP01 00-110 20 30 40 00-2 CONTENTS No. of page STRUCTURE AND FUNCTION weve 10-1 TESTING AND ADJUSTING... DISASSEMBLY AND ASSEMBLY MAINTENANCE STANDARD..............c:ss:scssessesssssssesesseeneeees 40-1 2050620506 ‘The affected pages are indicated by the use of the following marks. It is requested that necessary actions must be taken to these pages according to the list oe Indication eeecae below. © | Page to be newly added | Add # | Page 0 be replaced Replace (1 | Page to be deleted Discard Pages having no marks are not revised at this time LIST OF REVISED PAGES. Mork Pages Revo” Tarark Pages ReViiON | ntark Pages PESO | ear Pages FEB | Mark Pages Revlon © 00-1 @ 10-23 @ 10-64 @® 10-105 @ © 10-143 @® 00. 2 wa oO 10-65 1-106 O | + wm @ © 00-21 @ 10-25 @ 10-66 10-107 @ (10-146) @ © 00-22 @ 10-26 @ 10-67 © 10-108 @ (10-147) @ © 0-23 @ 10-27 @ 10-68 @D 10-109 @® (10-148) @ 00- 3 10-28 @ 10-69 D 10-110 OD 10-149 © 00- 4 10-29 OD 10-70 @ 0-111 @ 10-150 O 00- 5 10-30 @ 0-71 @ 10-112, @ 10-151 © 00. 6 031 wn @ 10.113 © 1182 00-7 10-32 oO 10-73 OD 10-114 D 10-153 @ 00-8 033 074 @ 10-115 10-154 00-8 1038 @ 0-76 018 10-185 00-10 1035 077 0117 10-155 © 00-11 1036 10-78 OD 10-118 OD 10-157 @ 00-12 10-38 10-79 OD 10-119 10-158 @ 00-13 1033 10-80 OD 10-120 OD 10-159 © oo-t4 1040 wer o w121 10-160 00-15 10-41 ® 10-82 © 10-122, D 10-161 @® 00-16 02 © wes © 10-123 toi 00-17 10-43 10-84 © 10-124 OD 10-168 OD +01 @ wu 085 © 0-125 @ tose 02 O 45 wo8 0-126 10185 03 @ 1048 © wa 0127 @ 10-188 04 O 47 we @ 10-128 10.167 05 © 1048 © 10-89 OD 10-129 OD 10-168 10-6 fo} 10-49 @ 10-90 © 10-130 © 10-169 OD 07 © |e 00 © war © | o wim @ 0.170 08 @ 1031 © we © | o wim @ win 10-9 oO 10-52 @ 10-93 © © 10133 @ 10-172, 10-10 @ 10-63 ® 10-94 ® o 10134 @ 10-173 wn @ 1054 @ ws © | o 15 @ wim 02 O 055 © wos © | o 16 @ 10.175 0-14 O 1056 10-97 © © 10-1361 @ 10-176 OD 10-15 oO 10-57 @ 10-98 © o 10-1362 @ 10-177 © 10.18 1058 wo © | o w1363 @ 104178 10-17 oO 10-59 fo} 10-100 ® 10-138 @ 10-179 ® 0-18 OD 10-60 @ 10-101 © 10-139 @ 10-180 © 10-19 oO 10-61 @ 10-102 @® 10-140 @ 10-181 © 10-20 ®Q 10-62 ® 10-103 @ 10-141 O 10-182 O 10-22, 10-63 @ 10-104 10-142, 10-183 00-2-1Mark Pages FOC” | mark Pages REWsiOn | mark ages Fevition | rar Pages ROMSIO" | mare Pages Revision 10-184 20- 64 20-110 20-167 20-225 10-185 © 20- 85 20.111 20-168 20-226 10-188 O 20- 56 20-112 20-169 20-227 20- 87 20-113 20-170 20.228 20-1 20- 58 20-114 204171 20-229 20. 2 20. 59 20-115 20-172 20.231 20-3 20- 60 20-116 20-173 20-232 20- 4 20- 61 20-118 20-174 20-233 20-5 20- 62 20-19 20-175 20-238 20- 6 20- 63 20-120 20-176 20-236 20-7 20-64 @ 204121 20-17 20-237 20- 8 20-65 20-122 20-178 20-238 20- 9 20-66 20-123 20-180 20-239 20- 10 20-67 @ 20-124 20-181 20-240 20-11 20- 68 20-125 20-182 20-241 20- 12 20- 69 20-126 20-183 20-242 20.13 20: 70 20-127 20-184 20-243 20. 14 20-71 20-128 20-185 20-244 20-15 20-72 20-129 20-186 20-245, 20-16 20-73 20-130 20-187 20-246 20-17 20-74 20-131 20-188 20.287 20-18 20-75 20-132 20-189 20-248 20-19 20-76 20-133 20-190 20-249 20- 20 20-77 20-134 20-191 20-280 20-21 20-78 20-135 20-192 20-251 20- 22 20-79 20-136 20-193 20.252 20- 23 20- 80 20-137 20-194 20.253 20- 24 20- a2 20-138 20-195 20.254 20- 28 20- €8 20-138 20-196 20.255 20- 26 20- 84 20-140 20-197 20-256 20-27 20- 86 20-141 20-198 20-257 20- 28 20- 86 20-142 20-199 20-258 20- 29 20- 87 20-143 20-201 20-259 20- 30 20- 88 20-144 20-202 20-260 20- 32 20- 89 20-145 20-203 20.261 20- 33 20- 90 20-48 20-204 20-262 20- 34 20-91 20-47 20-205 20-263 20-35 20- 92 20-48 20-208 20- 36 20- 93 20-149 20-208, 304 20-37 20- 94 20-150 20-209 30-2 20-38, 20- 95 20-151 20-210 30-3 20-39 20- 96 20-153 20211 30-4 20- 40 20. 97 20-154 20-212 30-5 20-41 20- 98 20-155 20-213 30-6 20-42 20- 99 20-156 20-214 30-7 20- 43 20-100 20-157 20-215 30 8 20- 44 20-101 20-158 20-216 30-9 20- 45 20-102 20-159 20.217 30-10 20- 46 20-103 20-160 20.218 30-11 20-47 20-104 20-161 20219 30-12 20- 48 20-108 20-162 20-220 30-13 20- 49 20-108 20-163 20-221 30-14 20- 60 20-107 20-164 20-222 30-16 20- 51 20-108 20185, 20-223 30-17 20. 53 20-109 20-168 20-224 30-18 00-2-2 2050620506 Mark Pages Revlon | hark Pages ROMO | ark Pages FEMSOM | ark pages REVIOM | mark Pages Reiton 30-19 30-75 OD 40-12 30-20 30-76 40-13 30-21 30-7 40-14 30-22 30- 78 40-15 30-23 30-79 40-17 oO 30-24 30- 80 40-18 30-25 30- 81 40-19 30-26 30- 82 40-20 @ 30-27 30- 83 40-21 30-28 30- 84 40-22 30-29 30- 85, 40-23 30-20 30. 86 40.24 30-31 30- 87 40-25 30-32 30- 88 40.28 30-33 30- 89 4027 30-34 30- 90 40-28 30-35 30-91 40-29 30-36 30: 92 40-30 20.37 30. 99 aoa 30-38 30- 94 40-32 30-39 30- 95, 40-34 30-40 30- 96 40-35 30-41 30- 97 40-36 30-42 30- 98 40.37 30-43 30- 99 40-38 30-44 30-100 40-39 30-45 30-101 40-40 30-46 30-102 40-41 30-47 30-103 3048 30-104 3049 30-108 30-50 30-106 30-51 30-107 30-52 30-108 30-53 30-109 30-54 30-110 30-55 30.117 30-56 30-112 30-57 30-113 30-58 30118 30-59 30-115, 30-60 30-116 30-61 30-117 30-62 30-63 4 30-64 40- 2 30-65 40- 3 30-668 wo 4 30-67 40- 5 30-68 00. 6 30-69 @ 40- 7 30-70 40- 8 30-72 “0 9 30-73 oO 40- 10 30-74 @ 40-11 00-2-3k20506 10 STRUCTURE AND FUNCTION Engine related parts Radiator « oll cooler + aftercooler. 3 Power train .. 4 Final drive .. 5 Swing CifCle «von 6 Swing machinery 10-7 Track frame + recoil spring... 10-8 Track shoe Hydraulic piping drawing .. Hydraulic circuit diagram .. Hydraulic tank. Hydraulic pump Control valve .. CLSS.... Swing motor... Center swivel joint Travel motor Valve control... Work equipment « swing PPC valve .. Travel PPC valve Service PPC valve ... Safety lock valve .... PPC accumulator... PPC shuttle + travel junction valve EPC + solenoid valve Hydraulic cylinder Additional filter for breaker... Overload warning device .. Hose burst protection valve . Work equipment: Electrical control system Electrical wiring diagram Engine control system Electronic control system .. Machine monitor system 10-1 ®STRUCTURE AND FUNCTION ENGINE RELATED PARTS ENGINE RELATED PARTS 20506 on 88 ce DD |. Drive plate OUTLINE Torsion spring + The damper assembly is a wet type. . Stopper pin Oil capacity: 0.758 . Friction plate . Damper assembly . Air cleaner . Intake connector Muffler . Rear engine mount . Front engine mount Seerogsens 10-2k20506 STRUCTURE AND FUNCTION 2). Pressure compensation ciss A valve (pressure compensation valve) is installed to the outlet port side of the control valve to balance the load. When there is compound operation of the actuators, this valve acts to make pressure difference AP constant for the upstream flow (inlet port) and downstream flow (outlet port) of the spool of each valve. In this way, the flow of oil from the pump is divided in proportion to area of opening $1 and $2 of each valve. Load oe Actuator Load w g ft oe R [Pressure Pressure ese et »| TS Lf le ” WU um LT 202F06081 10-49 ©STRUCTURE AND FUNCTION OPERATION FOR EACH FUNCTION OF CLSS Hydraulic cirouit diagram for system fee 10-50 2050620506 STRUCTURE AND FUNCTION ADDITIONAL FILTER FOR BREAKER ADDITIONAL FILTER FOR BREAKER * FOR MACHINE EQUIPPED WITH BREAKER 20505096 1. Head cover SPECIFICATIONS 2. Element Rated pressure : 6.86 MPa (70 kg/cm?) 3. Case Flow :107¢/min 4. Drain plug Relief valve cracking pressure: 0.34 + 0.049 MPa 5. Valve (3.5 £ 0.5 kg/om’) 6. Spring Filter mesh size: 6 um 7. Spring set plug Filtering area: 3160 em? 10-131 ®‘STRUCTURE AND FUNCTION OVERLOAD WARNING DEVICE 1 OUTLINE Buzzer Oil pressure switch / /- Boom control 7 “ / 800m eylindor aaa ae FUNCTION + This device is installed to warn the operator when the machine is close to tipping over when it lifts an excessive weight while being used as a crane. STRUCTURE + When an excessive weight is lifted, the oil pressure goes up at the bottom side of the boom cylinders. When this happens, the pressure switch senses the rising pressure, turns the pressure switch on, and lights the monitor lamp to warm the operator. When the monitor lamp lights, immediately lower the weight to the ground or bring the arm closer in to the operator to prevent the machine from tipping over. 10-132 OVERLOAD WARNING DEVICE FO20E346C20506 STRUCTURE AND FUNCTION OVERLOAD WARNING DEVICE Control panel Overload warning pilot lamp (Monitor, 10-133STRUCTURE AND FUNCTION OPERATION + Hose (2) directs the oil pressure from the bottom side of the boom cylinders to pressure switch (3). When the boom is in the lowest position + When boom (5) is in the lowest po: tion, lever (4) takes position A in Fig. 1 and the pressure to activate its switch (closed and open) becomes 60 kg/cm*. . When the boom is in the highest position + When the boom is in the highest posi tion, lever (4) takes position B in Fig. 1 and the pressure to activate the switch becomes 360 kg/cm, When the boom is in an arbitrary position + When the boom is in a position any- where between the lowest and the highest points, the operating pressure of switch (3) will be somewhere between 60 kg/cm? and 360 kg/cm’, based on the boom position: For instance, when the boom is in a certain position between the lowest and the highest points, lever (4) takes a position which corresponds to that boom posi tion. OVERLOAD WARNING DEVICE If lever (4) is in the position to make the operating pressure of the pressure switch 10 kg/cm? (which is the same pressure as the bottom side of the boom cylinder), the pressure switch will turn on when excessive weight is lifted by the boom and the oil pressure of the bottom of the boom cylinders exceeds 150 kgfor. When the machine is performing any kind of operation other than lifting loads, fasten the pressure switch lever (4) with the bolt (6) to prolong the life at the pressure switch. k2050620506 ‘STRUCTURE AND FUNCTION OVERLOAD WARNING DEVICE 3. ADJUSTING PRESSURE OF THE OIL PRESSURE SWITCH + Screw D: Pressure range adjustment screw To make an adjustment so that the oil pressure switch acts normally when checking the operation of the overload warning device. Turning to the left makes the pressure range wider. + Screw E: Zero point adjustment screw Turning to the right one complete turn raises the pressure by 57 kg/cm’. Each complete turn to the left lowers the pressure by 57 kg/ cm? a 1. Body AiWren an adjustments required, contact 2, Bouldon tube your Komatsu distributor and have 3. Eocontie make the adjustment. 4, Microswitch 5. é 1 Lever and roller Adjustment screw (E) Adjustment screw (D) 0206361 10-135 ©STRUCTURE AND FUNCTION HOSE BURST PROTECTION VALVE (BOOM) HOSE BURST PROTECTION VALVE (BOOM) High pressure from 1) @D contrel valve w'por At signal ipod —_ Overond cation signal yp YZ, TEA < ‘ ao Ly vy 3 1. Body 2. Spool 3. Relief valve 4, Check valve pone 210-1008 FUNCTION This valve prevents sudden uncontrolled lowering of the boom, when lifting, due to the burst of a hose in the boom cylinder line. In such a condition this valve will hold the load until operator lowers the boom in a controlled way using the normal wrist control. 10-136 2050620506 STRUCTURE AND FUNCTION When hose burst occurs (Operation to lower safety) The sudden loss of pressure at port V will cause check valve (4) to re-seat and so the valve is locked. + The boom can be lowered in a controlled way by operating the wrist control in the normal way. HOSE BURST PROTECTION VALVE (BOOM) V port Ec To tank cylinder [| Be0m control |L_L contot ever i 10-136-1 ®STRUCTURE AND FUNCTION HOSE BURST PROTECTION VALVE (BOOM) OPERATION BOOM RAISE During boom raising the pilot signal from wrist control operates control valve spool to direct high pressure oil to port V of hose burst valve. + This pressure lifts check valve (4) from seat & high pressure oil flows in the bottom of the cylinder raising the boom. V port ED To tank aon Boom control L\ control lever BOOM LOWER During boom lowering the pilot signal re- == verses the front through the control valve spool. High pressure oil flows to the head side of the cylinder. Oil in the bottom side of the cylinder flows through the port Cy of the valve but cannot flow past the check valve. The pilot signal also opens the spool (2) of the hose burst valve and allows oil to flow back to tank. Tpont ep To tank p | 10-136-2 20506k20506 STRUCTURE AND FUNCTION WORK EQUIPMENT WORK EQUIPMENT easeNe 2osroei2a Arm Bucket cylinder Arm cylinder Boom Boom cylinder Bucket 10-136-3 ®EEBM000501 EOP IMUAINTO ANIL KOMATSU PC210,210LC-6k PC240, 240LC, PC240NLC-6K MACHINE MODEL SERIAL NUMBER PC210, 210LC-6K K30001 and up PC240, 240LC, 240NLC-6K K30001 and up This shop manual may contain attachments and optional equipment that are not available in your area. Please consult your local Komatsu distributor for those items you may require. Materials and specifications are subject to change without notice. + PC210, 210LC-6 mount the S6D102L-1 en; PC240, 240LC-6 mount the SA6D102L-1 1 For details of the engine, see the 102 Service Engine Shop Manual, © 1995 KOMATSU Al Rights Reserved Printed in Belgium 05-95.05002.SP01 00-110 20 30 40 00-2 CONTENTS No. of page STRUCTURE AND FUNCTION.. 10-1 TESTING AND ADJUSTING DISASSEMBLY AND ASSEMBLY . MAINTENANCE STANDARD................04 2050620506 ‘The affected pages are indicated by the use of the following marks. It is requested that necessary actions ‘must be taken to these pages according to thelist below. Mark Indication ‘Action required © | Page to be newly added add © | Page tobe reptaced Replace (1 | Page to be deleted Discard Pages having no marks are not revised at this time. 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Track frame + recoil spring Track shoe : Hydraulic piping drawing .. Hydraulic circuit diagram Hydraulic tank. Hydraulic pump Control valve 2 3 4 5 6 7 8 9 n 2 4 6 38 a7 cis... ‘Swing motor... 0- 92 Center swivel j -10- 95 Travel motor 10- 96 Valve control... ‘Work equipment + swing PPC valve ... Travel PPC valve Service PPC valve Safety lock valve PPC accumulator PPC shuttle « travel junction valve EPC - solenoid valve... Hydraulic cylinder Additional filter for breaker... Overload warning device Work equipment. Electrical wiring diagram Electrical control system ... Engine control system Electronic control system Machine monitor system.. 10-105 10-106 1. 10-110 10-114 10-117 10-117 10-118 . 10-125 10-130 10-131 10-132 10-136 - 10-138, 10-145 10-149 - 10-154 10-179STRUCTURE AND FUNCTION ENGINE RELATED PARTS ENGINE RELATED PARTS BB cc DD 1. Drive plate OUTLINE 2. Torsion spring + The damper assembly is a wet type. 3. Stopper pin Oil capacity: 0.75¢ 4. Friction plate 5. Damper assembly 6. Air cleaner 7. Intake connector & Muffler 9. Rear engine mount 10. Front engine mount 10-2 2050620506 STRUCTURE AND FUNCTION RADIATOR «+ OIL COOLER + 1 2 3 4 PEN OMReNe AFTERCOOLER 5 6 Reservoir tank il cooler Radiator Fan Radiator inlet hose Radiator outlet hose Radiator cap Net Shroud RADIATOR - COOLER + AFTERCOOLER SPECIFICATIONS Radiator: CWX-4 Oil cooler: SF-3 10-3STRUCTURE AND FUNCTION POWER TRAIN POWER TRAIN 1. Idler 2. Center swivel joint 3. Control valve 4, Final drive 5. Travel motor 6. Hydraulic pump 10-4 ® 7. Engine 8, Travel speed solenoid vaive ‘9. Swing brake solenoid valve 10. Swing motor 11. Swing machinery 12. Swing circle 20506k20506 STRUCTURE AND FUNCTION FINAL DRIVE 3 rT) Fr] 12 FINAL DRIVE |. Level plug . Drain plug . No. 2 sun gear (No. of teeth: 12) . No. 1 sun gear (No. of teeth: 21) . No. 1 platetary carrier . Cover . No. 2 planetary carrier . Sprocket . Floating seal ). Travel motor |. Hub . No. 2 planetary gear (No. of teeth: 36) . Ring gear (No. of teeth: 84) . No. 1 planetary gear (No. of teeth: 31) ‘SPECIFICATIONS. Reduction ratio: — CE) x CS) + 1 = 39.000 20sca06012 10-5STRUCTURE AND FUNCTION SWING CIRCLE 1. Swing circle inner race (No. of teeth: 110) 2. Ball 3. Swing circle outer race a. Inner race soft zone position b. Outer race soft zone S position 10-6 2oscaosor SPECIFICATIONS Reduction ratio: 110 . 7.333 Amount of grease: 21¢ (G2-LI) SWING CIRCLE k2050620506 STRUCTURE AND FUNCTION SWING MACHINERY " 12 13 }—4 15 16 7 20sFosooe ‘SWING MACHINERY 1. Swing pinion (No. of teeth: 15) 2. Cover 3. Case 4. No, 2 of planetary carrier 5. No. 2 sun gear (No. of teeth: 15) 6. No. 2 ring gear (No. of teeth: 72) 7. Case 8. No. 1 ring gear (No. of teeth: 72) 9. No. 1 sun gear (No. of teeth: 21) 10. Swing motor I level gauge 12. Cover 13. No. 1 planetary gear (No. of teeth: 25) 14, No. 1 planetary carrier 15. Coupling 16. No. 2 planetary gear (No. of teeth: 28) 17. Drain plug SPECIFICATIONS Reduction ratio: 21472 ,, 15472 21 15 5.686 10-7‘STRUCTURE AND FUNCTION TRACK FRAME - RECOIL SPRING ‘* The diagram shows the PC210-6K. ‘TRACK FRAME + RECOIL SPRING Idler Track frame Carrier roller Final drive Track roller Track shoe Center guard Recoil spring Front guard PON OMPONS 10-8 ® 205cA06015| The dimensions and number of track rollers may differ according to the model, but the. basic structure is the same. No. of track rollers Model PC210-6K PC210LC-6K PC240-6K PC240LC-6K PC240NLC-6K No. of rollers (each side) 7 9 8 10 9 2050620506 STRUCTURE AND FUNCTION ‘TRACK SHOE TRACK SHOE ‘STANDARD SHOE Item Model! pczi0-6k_| PC2t0LC-6k | PC240-6K_| PC240LC-6K |PC240NLC-6K Shoe width (triple shoe) | 600mm | 700mm | 600mm | 700mm | 600mm Link pitch 190 mm 1gomm_ | 190mm | 190mm | 190mm No. of rollers (each side) 45 49 47 51 49 ‘SELECTION OF TRACK SHOE + Select the most suitable track shoe from the following table. PCHIO-GK POZTOLC-OK PozaoeK PCROLESK PORONLC-OK Mots! [Epeareaton] SES [Seciteton, GBR [Specticnion] GE [Soectcwion] SE% [Soectenion] SH standord | su" [ a | Oem | a | Same | | mm | a | RP Tw Option mam [ 8 | Mme |e | am | oe | Ome | Aw | Om | 8 Option me | c | Mmm | c = — | mr [ ic | Mme [ic ‘Option a = = = — | ar |e Option — [-- - e a e - Option =| = J-|] = [-7 - [-[ - [- Option -~| - [-[ = [-[T - [-T = [=STRUCTURE AND FUNCTION TRACK SHOE Precautions when using Travel in Lo speed when traveling on rough ground obstacles such as large boulders and fallen trees. Cannot be used on rough ground where there are large obstacles such as boulders and fallen trees. Travel in Hi speed only on flat ground, and when i impossible to avoid traveling obstacles, lower the travel speed to approx. half of Lo speed. Category Use ‘a | Rocky ground, normal river soil B | Normal soil, soft land | Extremely soft ground {swampy ground) Use only for ground where “A" and “B” sink and are impossible to use. Cannot be used on rough ground where there are large obstacles such as boulders and fallen trees. Travel in Hi speed only on flat ground, and when it is impossible to avoid traveling over obstacles, lower the travel speed to approx. half of Lo speed. * Categories “B" and “C” are wide shoes, so there are restrictions on their use. There- fore, before using, check the restrictions and consider carefully the conditions of use before recommending a suitable shoe width. * When selecting the shoe width, select the narrowest shoe possible within the range that will give no problem with flotation and ground pressure. Ifa wider shoe than necessary is used, there if ;cessary, give the customer guidance in their use. 10-10 will be a large load on the shoe, and this may lead to bending of the shoe, cracking of the links, breakage of the pins, loosening of the shoe bolts, or other problems. 20506STRUCTURE AND FUNCTION HYDRAULIC TANK HYDRAULIC TANK Hydraulic tank Bypass valve Oil fitter cap Sight gauge Hydraulic oil level sensor Suction strainer Filter element NOOPOND 10-14 7 Pce10-Kost SPECIFICATIONS Tank capacity: 2300 Amount of oil inside tank: 166 Pressure valve Relief cracking pressure: 0.017 + 0.004 MPa (0.17 + 0.04 kg/cm’) Suction cracking pressure: 0 ~ 0.0005 MPa (0 - 0.005 kg/cm’) Bypass valve set pressure: 0.103 + 0.02 MPa (1.05 + 0.2 kg/cm’) 2050620506 STRUCTURE AND FUNCTION HYDRAULIC PUMP Pump drain port PDF Front delivery port PAF Rear delivery port PAR Control pump suction port PGS Control pump delivery port PGA Front LS pressure port PLSF ar LS pressure port PLSR control EPC pressure port PSIGR i, Main pump suction port PS j. LS control EPC pressure port PSIGF e@seacge PRaeNe HYDRAULIC PUMP |. Front main pump . Rear main pump Control relief valve Rear TVC-LS valve 3. Front TVC+LS valve Control pump 10-15STRUCTURE AND FUNCTION 1. MAIN PUMP (HPV95+95) Pump drain port PDF Front delivery port PAF Rear delivery port PAR Front control pressure PENF Rear delivery pressure port PAR Front delivery pressure port PAZF Rear delivery pressure port PAIR Rear control pressure port PENR Suction port PS Front delivery pressure port PAIF vrpesseege 10-16 oO HYDRAULIC PUMP 208F 05006 20506,20506 STRUCTURE AND FUNCTION HYDRAULIC PUMP OPERATION 1. Operation of pump 1) Cylinder block (7) rotates together with shaft (1), and shoe (5) slides on flat sur- \ face A. \ When this happens, rocker cam (4) moves along cylindrical surface B, so angle « between center line X of rocker = cam (4) and the axial direction of cylin- 7 der block (7) changes. (Angle «is called the swash plate angle.) 2) Center line X of rocker cam (4) mai tains swash plate angle « in relation to the axial direction of cylinder block (7), 8 205F06009 and flat surface A moves as a cam in relation to shoe (5). In this way, piston (6) slides on the inside of cylinder block (7), so a difference between volume E and Fis created inside cylinder block (7). The suction and discharge is carried out by this difference F-E. In other words, when cylinder block (7) rotates and the volume of chamber E becomes smaller, the oil is discharged during that stroke. On the other hand, the volume of chamber F becomes larger, and as the volume becomes big- ger, the oil is sucked in, 3) If center line X of rocker cam (4) is in 205F06010 line with the axial direction of cylinder block (7) (swash plate angle = 0), the ifference between volumes E’ and F” inside cylinder block (7) becomes 0, so ‘the pump does not carry out any suction or discharge of oil. (In actual fact, the swash plate angle never becomes 0) _208F06011 10-17, ®STRUCTURE AND FUNCTION 2. Control of discharge amount + If swash plate angle a becomes larger, the difference in volumes E and F becomes larger and discharge volume Q increases. + Swash plate angle o: is changed by servo piston (12), + Servo piston (12) moves in a reciprocal movement (c+) according to the command from the TVC*LS vaive. + This straight line movement is transmitted through rod (13) to rocker cam (4), and rocker cam (4), which is supported by the cylindrical surface to cradle (2), moves in a swing- ing movement on the cylindrical surface in (Cdirection) 10-18 HYDRAULIC PUMP 205F06012 With servo piston (12), the area receiving the pressure is different on the left and right, so main pump discharge pressure (self-pressure) PP is always connected to the chamber receiving the pressure on the small diameter piston side (the self-pressure is brought in). Output pressure PEN of the LS valve is brought to the chamber receiving the pressure at the large diameter piston end. The relationship in the size of self-pressure PP and the pressure at the small diameter piston end, and the ratio between the area receiving the pressure of the small diameter piston and the large diameter piston controls the movement of servo piston (12). 2050620506 STRUCTURE AND FUNCTION HYDRAULIC PUMP 20806007 7. Cylinder block 8. Valve plate 9. End cap 10. Rear shaft 11. Rear case 6. Piston 12. Servo piston 10-19 ®STRUCTURE AND FUNCTION HYDRAULIC PUMP oS = é Ey Ee) ae Sarees la a Spline A 2 Spline 20506008 FUNCTION + The engine rotation and torque transmitted to the pump shaft is converted into hydraulic energy, and pressurized oil is discharged according to the load. + It is possible to change the delivery amount by changing the swash plate angle. ‘STRUCTURE + Cylinder block (7) is supported to shaft (1) by a spline, and shaft (1) is supported by the front and rear bearings. + The tip of piston (6) is a concave ball, and shoe (5) is caulked to it to form one unit. Piston (6) and shoe (5) form a spherical bearing. + Rocker cam (4) has flat surface A, and shoe (5) is always pressed against this surface while sliding in a circular movement. + Rocker cam (4) brings high pressure oil at cylindrical surface B with cradle (2), which is secured to the case, and forms a static pressure bearing when it slides. 10-20 ® Piston (6) carries out relative movement in the axial direction inside each cylinder chamber of cylinder block (7). The cylinder block seals the pressure oil to valve plate (8) and carries out relative rotation. This surface is designed so that the oil pressure balance is maintained at a suitable level. The oil inside each cylinder chamber of cyl- Inder block (7) is sucked in and discharged through valve plate (8). K20506STRUCTURE AND FUNCTION 2. TVC+LS VALVE HYDRAULIC PUMP. a. Port PA2 (Pump delivery pressure inlet port) b, Port PEN (TVC:LS valve signal pressure outlet port) ¢, Port PA1 (Pump delivery pressure inlet port) 10-22 |. Port PLS (Control valve LS pressure inlet port) Port PSIG (LS control EPC valve pressure inlet port) 2050620506 ‘STRUCTURE AND FUNCTION HYDRAULIC PUMP LS VALVE ‘TVC VALVE 1. Locknut 8. Solenoid 2. Plug 9. Piston 3. Spring 10. 4. Spool 1 5. Sleeve 2 6. Piston 8. 7. Plug 14. 15. Valve body 10-23STRUCTURE AND FUNCTION FUNCTION 1 LS VALVE The LS valve detects the load and controls the discharge amount. This valve controls main pump discharge amount Q according to tial pressure 4 PLS (= PP - PLS) (the difference between main pump pressure PP and control valve outlet port pressure PLS) (called the LS differential pressure). Main pump pressure PP, pressure PLS (called the LS pressure) coming from the control valve output, and pressure PSIG (called the LS selection pressure) from the proportional solenoid valve enter this valve. The relationship between discharge amount Q and differential pressure A PLS, (the difference between main pump pressure PP and LS. pressure PLS) (= PP - PLS) changes as shown in the diagram on the right according to LS selector pressure PSIG. When PSIG changes between 0 and 2.94 MPa (0 and 30 kg/cm*), the spool load changes according to this, and the selector point for the pump discharge amount changes at the rated central value between 0.64 and 2.11 MPa (6.5 and 21.5 kg/cm’). ‘TVC VALVE When the pump discharge pressure PP1 (self- pressure) and PP2 (other pump pressure) are high, the TVC valve controls the pump so that no more oil than the constant flow (in accordance with the discharge pressure) flows even if the stroke of the control valve becomes larger. In this way it carries out ‘equal horsepower control so that the horsepower absorbed by the pump does not ex- ceed the engine horsepower. In other words, if the load during the operation becomes larger and the pump discharge pressure rises, it reduces the discharge amount from the pump; and if the pump discharge pressure drops, it increases the discharge amount from the pump. The relationship between the average of the front and rear pump discharge pressures (PP1 + PP2)/2 and pump discharge amount Q is shown on the right, with the current given to the TVC valve solenoid shown as a pa- rameter. However, in the heavy-duty operation mode, there are cases where it is given the function of sensing the actual speed of the engine, and if the speed drops because 10-24 o HYDRAULIC PUMP. PSIG ~ 2.96 MPa (20 kglem*) PSIG = 0 MPa (0 kglem) Pump discharge amount @ DEES) 217 BTS) MPa glee) LS differential pressure PLS 18a 4A 7a Pump discharge amount Q Pump discharge pressure PP z05F06018 of an increase in the load, it reduces the pump discharge amount to allow the speed to recover. In other words, when the load increases and the engine drops below the set value, the command to the TVC valve solenoid from: the controller increases according to the drop in the engine speed to reduce the pump swash plate angle, k2050620506 STRUCTURE AND FUNCTION HYDRAULIC PUMP OPERATION eae a a PSIG : : ; Li ; ry CTT if =p = 44 a) ‘Small ciameter end 8 (Direction of minimum dischergel + The LS valve is a three-way selector valve, with pressure PLS (LS pressure) from the outlet port of the control valve brought to spring chamber “% charge pressure of plug (6). The "and main pump brought to chamber *j e of this LS pressure PLS + force F of spring (3) and the main pump pressure (self- pressure) PP determines the position of spool (4). However, the size of the output pressure PSIG (the LS selection pressure) of the EPC valve for the LS valve entering port "e" also changes the position of spool (4). (The set pressure of the spring changes.) + Before the engine is started, servo piston (1) is pushed to the right by spring (7) installed to rod (2). (See the fiagram on the right) + When the engine is started and the control lever is at the neutral position, LS pressure PLS is 0 MPa (0 kg/cm’). (It is interconnected with the drain circuit through the contro! valve spool.) Large diameter end 205F06019 -208F06020 At this point, spool! (4) is pushed to the left, and port “d” and port “e” are connected. Pump pressure PP enters the large diameter end of the piston from port “h”, and the same pump pressure PP also enters the small diameter end of the piston, so the swash plate is moved to the minimum angle by the difference in area of piston (1). 10-25STRUCTURE AND FUNCTION 2) Operation in maximum discharge amount HYDRAULIC PUMP. TWe valve (from outlet port of (from LS controt ai control valve) EPC valve) PLS PSIG = PP iS 4 » e tal 7 a f éild cq 20506 [ol tT yz malt diameter end ff \y Large diameter end (Direction of maximum discharge) + When the difference between main pump + pressure PP and LS pressure PLS, in other words, LS differential pressure APLS, be- ‘comes smaller (for example, when the area of opening of the control valve becomes larger and pump pressure PP drops), spool (4) is pushed to the right by the combined force of LS pressure PLS and the force of spring (3). . + When spool (4) moves, port “b” and port “¢" are joined and connected to the TVC valve. When this happens, the TVC valve is Connected to the drain port, so circuit “e” - “h" becomes drain pressure PT. (The operation of the TVC valve is explained later.) 10-26 @ 205F06021 For this reason, the pressure at the large piston diameter end of servo piston (1) be- ‘comes drain pressure PT, and pump pressure PP enters the small diameter end, so ‘servo piston (1) is pushed to the right. There- fore, rod (2) moves to the right and moves the swash plate in the direction to make the discharge amount larger. If the output pressure PSIG of the EPC valve for the LS valve enters port “e”, this pressure creates a force to move piston (5) to the left. If piston (5) is pushed to the left, it acts to make the set pressure of spring (3) ‘weaker, and the difference between PLS and PP changes when ports “b” and “e” of spool (4) are connected.20506 STRUCTURE AND FUNCTION HYDRAULIC PUMP 3) Operation in minimum direction for pump discharge amount trom outlet port of from LS control control valve) EPC valve! Te valve 9 ‘Small diameter end Lerge diameter end {Direction of minimum discharge) The following explains the situation if servo piston (1) moves to the left {the discharge amount becomes smaller). When LS differential pressure A PLS becomes larger (for example, when the area of opening of the control valve becomes smaller and pump pressure PP rises), pump pressure PP pushes spool (4) to the left. When spool (4) moves, main pump pressure PP flows from port "d" to port "e", and from port “h', it enters the large piston diameter end. 20806022 ‘Main pump pressure PP also enters the small piston diameter end, but because of the dif ference in area between the large piston di ameter end of servo piston (1) and the small piston diameter end, servo piston (1) is pushed to the left. As a result, rod (2) moves in the direction to make the swash plate angle smaller. IFLS selection pressure PSIG enters port "e", it acts to make the set pressure of spring (3) weaker. 10-27STRUCTURE AND FUNCTION 4) When servo piston balanced (from outer port of control valve) EPC valve) ee Psi HYDRAULIC PUMP (from LS control TVC vaive [ Orr Pon eee |e oe | Area receiving pressure At PEN EA wea [UY si 2 + Let us take the area receiving the pressure at the large piston diameter end as At, the area receiving the pressure at the small diameter end as AQ, and the pressure flowing into the large piston diameter end as PEN. If the main pump pressure PP of the LS valve and the combined force of force F of spring (3) and LS pressure PLS are balanced, and the relationship is AO x PP = A1 x PEN, servo piston (1) will stop in that position, and the swash plate will be kept at an intermediate position. (It will stop at a position where the ‘opening of the throttle from port "b" to port “c" and from port “d to port “c” of spool (4) is approximately the same. At this point, the pressure of port “e" is approx. 1/2 pump pressure PP.) 10-28 Largo diameter ond 20sF06023 At this point, the relationship between the area receiving the pressure at both ends of piston (1) is AO:A1 = 1:2, so the pressure applied to both ends of the piston when it is balanced becomes PP:PEN # 2:1. The posi- jon where spool (4) is balanced and stopped is the standard center, and the force of spring (3) is adjusted so that it is determined when PP — PLS = 2.11 MPa (21.5 kg/cm’), However, if PSIG (the output pressure of 0 - 2.94 MPa {0 - 30 kg/cm’) of the EPC valve of the LS valve) is applied to port “e*, the balance stop position will change in proportion to pressure PSIG between PP - PLS = 2.11 ~ 0.64 MPa (21.5 - 6.5 kg/cm’). k2050620506 STRUCTURE AND FUNCTION ‘TVC VALVE When pump controller is normal HYDRAULIC PUMP PPI PP2 MH i PT iS valve . a : - | ’ 1 So co 6 5 0 347 10 21 Ty all dametes endl 8 Of Ul Lage ciomete ona eoseeacen irction of maximum dschrga eM) Pump controler TVC prolix Ee a * Other pump pressure t atry [I This is the pressure of 2ase06024 on the pump at the oppo- When the load on the actuator is small and pump pressures PP1 and PP2 are low + Movement of solenoid (1) ‘Command current X from the pump controller flows to solenoid (1). This command current changes the internal force pushing solenoid push pin (11). On the opposite side to the force pushing this solenoid push pin (11) is the spring set pressure of springs (3) and (4) and pump Pressure PP1 and other pump (see *) pressure PP2. Piston (2) stops at a position where the combined force pushing piston (2) is balanced, and the pressure (pressure of port “¢") output from the TVC valve changes according to this position. sites end. For the Front pump, it is the Rear pump pressure. For the Rear pump, it is the Front pump pressure. The size of command current X is determined by the nature of the operation (lever operation), the selection of the working mode, and the set value and actual value for the engine speed. 10-29STRUCTURE AND FUNCTION (2) Movement of spring + The spring load springs (3) and (4) in the TVC valve is determined by the swash plate position + When servo piston (9) moves, cam (7), which is connected to rod (8), also moves. When this happens, lever (6) is rotated by the angle of cam (7), and piston (5) moves to the right and left. + If piston (5) moves to the right, spring (3) is compressed, and if it moves further to the right, spring (4) contacts seat (10), so both spring (3) and spring (4) function. In other words, the spring load is changed by piston () extending or contracting springs (3) and @. + lf command current X input to solenoid (1) ‘changes further, the force pushing solenoid push pin (11) changes, and the spring load of springs (3) and (4) also changes according to the value of the solenoid command current. + Port “c" of the TVC valve is connected to port “e” of the LS valve (see 1. LS valve). Self pressure PP1 enters port “b” and the small piston diameter end of servo piston (9), and the other pump pressure enters port ta", + When pump pressures PP1 and PP2 are ‘small, piston (2) is on the right. At this point, port “c” and port “d" are connected, and the pressure entering the LS valve becomes drain pressure PT. If port “h” and port “e” of the LS valve are connected (see 1. LS valve), the pressure entering the large piston diameter end from port “f” becomes drain pressure PT, and servo piston (9) moves to the right. In this way, the pump discharge amount moves in the direction of increase. 10-30 @ HYDRAULIC PUMP As servo piston (9) moves further, piston (5) is moved to the left by rod (8), cam (7), and lever (6). Springs (3) and (4) expand and the spring force becomes weaker. When the spring force becomes weake, piston (2) ‘moves to the left, so the connection between port “e” and port “d” is cut, and the pump discharge pressure is connected to port “b”. As a result, the pressure at port “c” rises, and the pressure at the large piston diameter end also rises, so the movement of piston (9) to the right is stopped. In other words, the stop position for piston (9) (= pump discharge amount) is deceded at the point where the force of springs (3) and (4) and the pushing force from the solenoid and the pushing force created by pressure PP1 and PP2 acting on piston (2) are in balance. 2050620506 STRUCTURE AND FUNCTION PPI PP2, HYDRAULIC PUMP 1s vave co 6 5 pf [4a fo 2 TF KN Ismail diameter endl 3 pert re ws —P b, When load on actuator is small and pump discharge pressure is high + When the load is large and pump discharge pressures PP1 and PP2 are high, the force pushing piston (2) to the left becomes larger and piston (2) moves to the position shown in the diagram above. + When this happens, as shown in the die- ‘gram above, part of the pressurized oil form Port "b" flows out to port "d” and the pressurized oil flowing from port “c" to the LS valve becomes approximately half of main pump pressure PP1. When port "h' and port "e" of the LS valve are connected (see 1. LS valve), the pressure from port “f" enters the large piston diameter end of servo piston (9), and servo piston (9) stops. ff main pump pressures PP1 and PP2 increase further and piston (2) moves further to the left, main pump pressure PP1 flows to port "e" and acts to make the discharge amount the minimum. When piston (9) moves to the left, piston (5) is moved to the right by cam (7) and lever (6). For this reason, springs (3) and (4) are ‘compressed and push back piston (2). Be- cause of this force, piston (2) cuts off the connection from port “b" to port “e', and port “e' and port “d* are connected. As a result, the pressure at port "c" (= "") drops, and piston (9) stops moving to the left. The position in which piston (9) stops when this happens is further to the left than the position when pump pressures PP1 and PP2 are low. 10-31 ®STRUCTURE AND FUNCTION HYDRAULIC PUMP. + The relation of pump pressures PP1 + PP2 and the position of servo piston (9) forms a bent line because of the double-spring effect of springs (3) and (4). The relationship between pump pressures PP1 + PP2 and pump discharge amount Q is shown in the figure on the right. + if command voltage x sent to solenoid (1) increase further, the relationship between pump pressures PP1 and PP2, and pump discharge amount Q is proportional to the pushing force of the solenoid and moves in parallel. In other words, if the pushing force of solenoid (1) is added to the force pushing to the left because of the pump pressure applied to the piston (2), the relationship between PP and Q moves from A to B in accordance with the increase in x 10-32 PP1+PP2 ‘208F06027 B be large) 20srosoze 2050620506 STRUCTURE AND FUNCTION HYDRAULIC PUMP 2) When pump controller is abnormal and TVC prolix switch is ON 6 $0347] [fo 2a small diameter ena] 9 Bon 8 Ff (Direction of maximum discharged fH Battery _205F06029 esisor ‘a, When load on main pump is light + If there is a failure in the pump controller, turn TVC prolix switch ON to switch to the resistor side. In this case, the power source is taken directly from the battery. But if the current is used as itis, itis too large, so use the resistor to control the current flowing to solenoid (1), + When this is done, the current becomes constant, so the force pushing solenoid push pin (11) is also constant. + If main pump pressures PP1 and PP2 are low, the combined force of the pump_pres- sure and the force of solenoid (1) is weaker than the spring set force, so piston (2) is balanced at a position to the right. Large diameter end Pump controller TVC prox OFF switen ‘At this point, port “e" is connected to the drain pressure of port "d", and the large piston diameter end of servo piston (9) also becomes the drain pressure PT through the LS valve. When this happens, the pressure at the small piston diameter end is large, so servo piston (9) moves in the direction to make the discharge amount larger. 10-33STRUCTURE AND FUNCTION PPt PP2) mM eT Swale | » ‘ 1 5 os Fart 43 fo 201 (Deecton of minimum sscharse) Pump conolr TVG poli Ore witch ip ea fon Taito esto b. When main pump load is heavy Q\ + In the same way as in the previous item, when the TVC prolix switch is ON, the command current X sent to solenoid (1) becomes constant. For this reason, the force of solenoid push pin (11) pushing piston (2) is constant. + If main pump pressures PP1 and PP2 increase, piston (2) moves further to the left than when the main pump load is light, and is balanced at a position towards the left. + Inthis case, the pressure from port “b” flows to port “e”, so servo piston (9) moves to the left (to make the discharge amount smaller) by the same mechanism as explained in Item 2.1)-b. In other words, even when the TVC prolix switch is ON, the curve for the pump pressure P and discharge amount Q is determined es shown in the diagram for the 10-34 ® HYDRAULIC PUMP. zosrosozs _-A (when controlier is ormal, x email value of the current sent to the solenoid through the resistor. The curve when the TVC prolix switch is ON is curve B, which is to the left of curve A for when the pump controller is normal. 2050620506 STRUCTURE AND FUNCTION 3. CONTROL PUMP (BAR-016) HYDRAULIC PUMP. Ga oO a Ks b cr 2osrocora 1. Body ‘SPECIFICATIONS 2. Driven gear Type: BAR- 016 3. Housing Theoretical delivery: 16.0 cc/rev 4. Drive gear Max. delivery pressure: 3.23 MPa (33 kg/cm?) 5. Relief valve 6. Filter a. Suction port b. Delivery port 10-35‘STRUCTURE AND FUNCTION RELIEF VALVE \ 2 y \ 5 8 \ \ | ~ oo = Sous: ee FUNCTION ‘The relief valve is assembled in the body of the control pump, and when the PPC valve is at neutral, the oil sent from the pump is relieved through this valve. (It sets the maximum. pressure in the circuit during operations.) OPERATION + Chamber A is the pump circuit and chamber Cis the drain circuit. The oil passes through the orifice in the main valve and fills chamber B. +f any abnormal pressure is generated, and the differential p ressure [n/4(D2 - d2) x pressure of chamber A] created by the difference in the area of “d” and diameter D reaches the pressure set by the main valve spring, the main valve opens, and the oil in chamber A is released to chamber C. This suppresses the rise in the pressure in chamber A. 10-36 rn HYDRAULIC PUMP Adjustment screw Locknut Sleeve valve spring Pilot piston Main valve oaPeNe Set pressure: 3.33 MPa (34 kg/cm®) (at 33 g/min) oaiKris2 20506STRUCTURE AND FUNCTION CONTROL VALVE CONTROL VALVE 9-SPOOL VALVE (STANDARD + 3 SERVICE VALVE) 8 uu + @), ee f/f VV \ VA pb pd ff pf ph 99 pj pl pn PP pr 10-38 k2050620506 STRUCTURE AND FUNCTION 6-spool valve Cover 1 Cover 2 Pump merge-divider valve ‘Arm counterbalance valve No. 1 Service valve No. 2 Service valve No. 3 Service valve PASM ERONa Port PP1 (from rear main pump) Port PP2 (from front main pump) Port A6 (to arm cylinder head) Port BG (to arm cylinder bottom) Port AB (to LH. travel motor) Port B5 (to LH. travel motor) Port Aé (to swing motor) Port B4 (to swing motor) Port A3 {to boom cylinder bottom) Port B3 (to boom cylinder head) Port A2 (to RH, travel motor) Port B2 (to R.H. travel motor) Port A1 (to bucket cylinder head) Port B1 (to bucket cylinder bottom) Port A-1 (to attachment) Port B-1 (to attachment) Port A-2 (to attachment) Port B-2 (to attachment) Port A-3 (to attachment) Port B-3 (to attachment) Port T (to tank) Port T1 (to travel junction valve) Port T2 (to travel junction valve) Port T3 (to travel junction valve) Port Té (to travel junction valve) pose one prepopgrarcse xgser CONTROL VALVE OUTLINE This control valve consists of the 6-spool valve (an integrated composition) and 3 service valves. The pump merge-divider valve and arm counterbalance valve are installed to this. Each vaive forms one unit with the connection bolt, and the passages are internally connected, so the structure is compact and is very easy to service. This control valve consists of one spool for one item of the work equipment, so it has @ simple structure. . Port PLS1 (to rear pump control) Port PLS2 (to front pump control) 9. Port TS (to tank) Port PS (from solenoid valve) |. Port BP (from solenoid valve) . Port PX (from solenoid valve) . Port P12 (from arm PPC/EPC valve) Port P11 (from arm PPC/EPC valve) . Port P10 (from L.H. travel PPC valve) . Port P9 (from LH. travel PPC valve) . Port PB (from swing PPC/EPC valve) f. Port P7 (from swing PPC/EPC valve) . Port P6 (from boom PPC/EPC valve) . Port PS (from boom PPC/EPC valve) Port P4 (from R.H. travel PPC valve) . Port P3 (from R.H. travel PPC valve) . Port P2 (from bucket PPC/EPC valve) |. Port P1 (from bucket PPC/EPC valve) pm Port P-2 (from service PPC valve) pn. . Port P-4 (from service PPC valve) Pp. Pa. po. pr. ff. 99. hh. kk. Port P-1 (from service PPC valve) Port P-3 (from service PPC valve) Port P-6 (from service PPC valve) Port P-5 (from service PPC valve) Port SA (pressure sensor mount port) Port SB (pressure sensor mount port) Port BP3 (from travel PPC) Port BP2 (from arm PPC) 10-39 @STRUCTURE AND FUNCTION MAIN STRUCTURE KK 4 1. Spool (arm) 2. Spool (LH. travel) 3. Spool (swing) 4. Spool (boom) 5, Spool (RH. travel) 6. Spool (bucket) 7. Spool (service 1) 8. Spool (service 2) 10-40 CONTROL VALVE 13 ew ot in 10. nN. 12. 13. 14. 15. . Spool (service 3) Spool return spring Main unload « LS relief valve Main relief valve (bucket end group) ‘Sub-unload valve (bucket end group) Main relief valve (arm end group) Sub-unload valve (arm end group) 2050620506 STRUCTURE AND FUNCTION CONTROL VALVE Mem, |. LS shuttle valve LS select valve 1 2 3. Pump merge-divider valve (for main) 4, Return spring 5. Pump merge-divider valve (for LS) 6. Return spring 7. LS bypass valve 10-41STRUCTURE AND FUNCTION Pressure compensation valve Safety-suction valve Check valve for arm regeneration circuit ‘Arm counterbalance vaive Suction valve Check valve for boom regeneration cir ogrens 10-42 CONTROL VALVE 2050620506 STRUCTURE AND FUNCTION CONTROL VALVE 6-SPOOL VALVE (STANDARD) For details of the names of the ports and the main structure, see 9-SPOOL VALVE. 10-43 ®oSTRUCTURE AND FUNCTION CONTROL VALVE 7-SPOOL VALVE (STANDARD + 1 SERVICE VALVE) For details of the names of the ports and the main structure, see 9-SPOOL VALVE. 1 i q 10-44 2050620506 STRUCTURE AND FUNCTION CONTROL VALVE 8-SPOOL VALVE (STANDARD + 2 SERVICE VALVE) For details of the names of the ports and the main structure, see 9-SPOOL VALVE. f VL \\N pb pd pf ff 4 99 PNpiPe pm PP y x / bb. 10-45‘STRUCTURE AND FUNCTION SAFETY-SUCTION VALVE FOR SERVICE VALVE CONTROL VALVE |. Suction valve 1 2. 3. 4. 5. Poppet 6. Poppet spring 7 8. 9. 0. f = p . Suction valve spring i = b , Sleeve Y ry . Adjustment screw ; 10. Locknut osro6ose Part No. Set Pressure Use 709-70-74600 24.5 MPa (250 kglem) at & &/min For crusher (Okada) 10-46 @ 2050620506 STRUCTURE AND FUNCTION cLSS OUTLINE OF CLSS cuss Contr valve 1] rv vatve ' ' ' ' ' ' ' ' 1 ' ' T ' t t 1 u Ls valve b}-—— A t 1 i 1 1 1 L Iservo pistor} Features v 2) 3) 4) CLSS stands for Closed center Load Sens- ing System, and has the following features. Fine control not influenced by load Control enabling digging even with fine control Ease of compound operation ensured by flow divider function using area of opening of spool during compound operations. Energy saving using variable pump control 20sr06o39 Structure The CLSS consists of a main pump (2 pumps), control valve, and actuators for the work equipment. ‘The main pump body consists of the pump itself, the TVC valve and LS valve. 10-47STRUCTURE AND FUNCTION cuss BASIC PRINCIPLE 1) Control of pump swash plate angle The pump swash plate angle (pump discharge amount) is controlled so that LS differential pressure APLS is constant. LS differential pressure APLS, which is the differential pressure between pump discharge pressure PP and LS pressure PLS (actuator load pressure) at the outlet port of the control valve (LS differential pressure APLS = Pump discharge pressure PP — LS pressure PLS) + IFLS differential pressure APLS becomes lower than the set differential pressure of the LS valve, the pump swash plate angle becomes greater, and if it becomes higher, the pump swash plate angle becomes smaller. Actuator Max. ° ee : a 4 3 in é Pump passoge—~ | 1! Ls passage 202rosoeo Max 1 ‘ I Servo ' paon ty 4 ans tt 4 " 1S valve i \ ad] Dirt err sant Diterenil pressure U1 Smal tow) IVC valve oy ‘small caren Ty tarae current Gio 2o2r060s9 10-48 2050620506 STRUCTURE AND FUNCTION 2 Pressure compensation ciss A valve (pressure compensatin valve) is installed to the outlet port side of the control valve to balance the load. ‘When there is compound operation of the actuators, this valve acts to make pressure difference AP constant for the upstream flow (inlet port) and downstream flow (outlet port) of the spool of each valve. In this way, the flow of oil from the pump is divided in proportion to area of opening S1 and $2 of each valve. Load w ‘Actuator ‘Actuator Pressure compensa. Pressure compensa tion waive oP 20206061 10-49STRUCTURE AND FUNCTION OPERATION FOR EACH FUNCTION OF CLSS. Hydraulic circuit diagram for system 10-50 ® k2050620506 STRUCTURE AND FUNCTION 1. Main unload valve 2. LS relief valve 3A. Main relief valve (group at bucket end) 3B. Main relief valve (group at arm end) 4A. Sub-unload valve (group at bucket end) 48. Sub-unload valve (group at arm end) 5, Bucket spool 6. Pressure compensation valve 7. Safety-suction valve 8, LS shuttle valve 9. RH. travel spool 10. Suction valve 11. Boom spool 12. Check vaive (for boom regeneration circuit) 13. Swing spool 14. LH. travel spool 15, Arm spool 16. Arm counterbalance valve 17. Check valve (for arm regeneration circuit) 18. LS select valve 19. Pump merge-divider valve To bucket cylinder To RH. travel motor To boom cylinder To swing motor To LH. travel motor To arm cylinder To travel junction valve To travel junction valve ZOMMOOwD> ciss 10-51 @oSTRUCTURE AND FUNCTION ciss SYSTEM DIAGRAM * This shows actuator (6A) and the stroke end relief in the merge mode. 1A Main pump 18. Main pump 2A. Main relief valve (for power max.) 2B. Main relief valve (for power max.) 3A. Sub unload valve 3B. Sub unload valve 4. Pump merge-divider valve 5A. Control valve 5B. Control valve 10-52 ® 6A. Actuator 6B. Actuator 7A. Check valve 7B. Check valve 8, Pump passage 9. LS circuit 10. Tank passage 11. Valve 12. Spring 2osFoso43 13, Piston 14. Clearance filter 15. Poppet 16. Spring 17. Piston 18. Piston 19. Piston 20. LS bypass valve 2050620506 STRUCTURE AND FUNCTION cuss 1. Main unload valve + LS relief valve 1), When main unload valve is actuated \ 10 . i > 1 a 18 as o AL /, “f L \ 15 da ds PXY PAR PAF 2osFosota Function Operation + When all the control valves are at neutral, the oil discharged when the pump is at the minimum swash plate angle is drained. When this happens, the pump pressure becomes a pressure that matches the set load of spring (12) inside the vaive (P1 pressure): The LS pressure is drained from LS bypass valve (20), so LS pressure = tank pressure = 0 MPa (0 kg/cm’). + When operated (for operations in the discharge range for the minimum swash plate angle), the discharge pressure of the oil discharged with the pump at the minimum swash plate angle is LS pressure + P1 pressure. In other words, the LS control differential pressure (APLS) of the oil discharged at the minimum swash plate angle is the P1 pressure. The pressure in pump passage (8) is received by area di at the end face of the valve and area d2 at the end face of piston (13). The pressure in LS circuit (9) is drained to the tank from LS bypass vaive (20), so LS pressure 0 MPa (0 kg/cm?) There is no way for the pressurized oil discharged by the pump to escape, so the pre: sure in pump passage (8) rises. This pressure acts on surface differential portion At between area d1 at the end face of the vale and area d2 at the end face of piston (13), and this is received by force F1 of spring (12) (condition: d1 > d2). Therefore, if passage pressure P1 x area difference Al > spring force F1, the valve is pushed to the right, and the pressurized oil flows from the valve to tank passage (10). The LS differential pressure (pump discharge pressure ~ LS circuit pressure) is greater than the pump LS control pressure at the time of the unload operation, so a signal is sent to move the pump swash plate in the direction of the minimum angle. 10-53 ®STRUCTURE AND FUNCTION cLss 2) At LS relief (standard mode relief, cut-off control) 20 0 D zi zi = — 16 a aon ns | : im t \ ‘ A d@ Bg m4 6 ds f5 da dS XY 7m” 78 PAR PAF ose0e04s Function + When the control valve is actuated, the maximum pressure in LS circut (9) is controlled to the specified pressure (the specified maximum pressure for the pump circuit). That is, the cut-off control is carried out. Operation (1) When the control vale is operated, the LS pressure passes through throttle $1 of spool (GA) and is sent to LS circuit (9). This LS Pressure goes from clearance filter (14) through orifice B to spring chamber (12). Part also goes through orifices C and D, and the poppet end portion d3, and is sent to end portion d4 of piston (17). Piston (19) acts as a stopper for piston (17). Therefore, the LS pressure is applied to area difference ‘A2 between area d3 at the end of the poppet and area dé at the end of the piston, and this is received by force F2 of spring (16) (condition: d3 > d4). (2) When LS pressure rises, and the condition becomes LS pressure x area difference A2 > force F2 of spring (16), the poppet moves to the right and seat E opens. As a result the 10-54 o pressurized oil in LS circuit (9) passes through the notched groove in the outside circumference of poppet (15) and flows to tank passage (10). * Clearance filter (14) is set to diameter clearance < orifice diameter, and prevents the entry of dirt which might block the orifice. Pump circuit pressure (3) When the pressurized oil in LS circuit (9) flows to tank passage (10) in operation (2) above, the pressure difference from the Pump passage becomes greater because of the pressure loss in the LS circuit. (4) When the pressure difference becomes P1 Pressure as explained in item 1) "When main unload valve is actuated", the valve moves to the right, and the pressurized oil discharged from the pump flows to tank passage (10). In this way, the maximum pressur of the pump passage is controlled. (5) When this unload operation is carried out, pump discharged pressure - LS circuit pressure is greater than the pump LS control pressure, so a signal is sent to set the pump swash plate to the minimum angle. 2050620506 STRUCTURE AND FUNCTION 3) When power max. function is actuated PAR PAF When the pilot pressure is applied to port PX1, piston (18) and piston (18) move to the left, and poppet (15) and piston (17) are brought into close contact, so poppet (15) cannot move and the LS control pressure rises. ciss 2osF 06045 10-55 oOSTRUCTURE AND FUNCTION 2. Sub-unload valve Function + When the pump flow is divided and the control vaive group on one side is actuated (with the remaining control valve group at neutral), the sub-unload vaive drains the pump flow to the group that is at neutral. Operation + The pressure in pump passage (1) is received at the end portion of valve (4). The control valve is at neutral, so the pressure of LS circuit (2) is 0 MPa (0 kg/cm?) + The pressurized oil in pump passage (1) is. stopped by valve (4) and cannot escape, so the pressure rises, When this pressure becomes larger than the force of spring (5), valve (4) moves to the left, ports B and C are interconnected, and the pump pressure flows to tank passage (3). In addition, the pressurized oil in LS circuit (2) passes from orifice A through port C and is drained to tank passage (3). Therefore, in this operation, LS pressure = tank pressure. + In this unload operation, pump discharge pressure ~ LS circuit pressure is greater than the pump LS control pressure, so a signal is sent to set the pump swash plate to the minimum angle. 10-56 @ ciss 208F06047 2osFo604e 20506k20506 STRUCTURE AND FUNCTION ciss 3. Introduction of LS pressure * The diagram shows the condition for arm IN. Upstream pressure of pressure compensation valve {for spoot meters downstream) A D 6 => 3 1 2osFoe049 1. Main pump Function 2. Main spool + The upstream pressure (= spool meter-in 3. Pressure compensation valve downstream pressure) of pressure compen- 4. Valve sation valve (3) is introduced and goes to 5. Ball valve shuttle valve (7) as the LS pressure. When 6. LS shuttle valve this happens, it is connected to port B of the actuator through valve (4), and LS pressure ;ctuator load pressure. Introduction hole a inside the spool has a small diameter, so it also acts as a throttle. Operation + When spool (2) is operated, the pump pressure passes through introduction hole a, enters port C, and is taken to the LS circuit. ‘When the purnp pressure rises and reaches the load pressure of port B, ball valve (5) opens. 10-57 @‘STRUCTURE AND FUNCTION 4. LS bypass valve ciss Main pump Main spool Pressure compensation valve LS shuttle valve LS bypass valve LS circuit 10-58 20506050 Function + The residual pressure in LS circuit (6) is released from orifices a and b. + This reduces the speed of the rise in the LS pressure, and prevents any sudden change in the oil pressure. Furthermore, a pressure loss is generated by the circuit resistance between LS shuttle valve (4) and throttle ‘of main spool (2) according to the bypass flow from LS bypass vale (5), As a result, the effective LS differential pressure drops, and the dynamic stability of the actuator is increased. k2050620506 STRUCTURE AND FUNCTION 5. Pressure compensation valve 3 2 4 —— eE—fo 5—— Ty ciss oaeeNe Main pump Valve Shuttle valve Piston Spring LS shuttle valve 208F060s1 Function 1) During independent operation and at max mum load pressure (during compound operations, when load pressure is higher than other work equipment) + The pressure compensation valve acts as @ load check valve. Operation + If the pump pressure (LS pressure) is lower than the load pressure at port C, shuttle valve (3) inside pressure compensation valve piston (4) moves to interconnect spring chamber E and port C. From this condition, the force of spring (5) acts to move piston (4) and valve (2) in the direction of closing. 10-59STRUCTURE AND FUNCTION ciss 6 8 ; Upocoom pres of posure ee oorrerescrn booood5 - 1 2) When receiving compensation (during compound operations, when load pressure is lower than other work equipment) + The pressure compensation valve is closed by the LS pressure of port D, and the spool meter-in downstream pressure of port B becomes the same as the maximum pressur of the other work equipment. The spool meter-in upstream pressure of port Ais the pump pressure, so spool meter-in differential pressure (upstream pressure (pressure of port A) - downstream pressure (pressure of port B)) becomes the same for all spools that are being operated. There- fore, the pump flow is divided in proportion to the area of the meter-in opening. 10-60 Operation + Spring chamber E's interconnected with port D. Piston (4) and valve (2) are actuated by the LS circuit pressure from the other work equipment at port F in the direction of closing (to the right). In other words, the valve upstream pressure of port B (= spool meter- in downstream pressure) is controlled by the LS pressure. 2050620506 STRUCTURE AND FUNCTION cuss 6. Shuttle valve inside pressure compensation valve => L), 20sF06053 4. Main pump Funetion 2. Valve When holding pressure at port A > LS pressure 3. Shuttle valve inside pressure in spring chamber B compensation valve + Shuttle valve (3) is pushed to the right by 4. Piston the pressure of port A, and the circuit be- ‘tween ports A and C is shut off. In this condition, the holding pressure at port A is taken to spring chamber B, and pushes piston (4) to the left to prevent piston (4) and valve (2) from separating. 10-61STRUCTURE AND FUNCTION + TMi For travel, swing Travel: No holding pressure is generated at port, Ain the travel circuit, so a pressure compensation valve without a shuttle valve is used. ‘Swing: The holding pressure at the swing port is low, $0 a pressure compensation valve without a shuttle vaive is used. Reference: When there is no shuttle valve + If there is no shuttle valve, piston (4) and valve (2) will separate. In this condition, if another actuator is operated, the piston acts as an accumulator, so there is a time lag. 10-62 ® ciss 2osros0se LS pressure Time lag 20805055, Time Holding pressure 20sFos056 2050620506 STRUCTURE AND FUNCTION cuss Shuttle valve Al From LS eireuit | To actuator Spool meter-in downstream pressure 20506067 Surface area ratio of pressure compensation valve The condition of the flow division changes according to the ratio of the area of portion At and portion AZ of the pressure compensation valve. Area ratio = A2/A1 + When area ratio = 1: Spool meter-in downstream pressure = Max. load pressure, and oil flow is divided in proportion to area of opening of spool. + When ratio is more than 1: Spool meter-in downstream pressure > Max. load pressure, and oil flow is divided in a proportion less than area of opening of spool. + When ratio is less than 1 ‘Spool meter-in downstream pressure < Max. load pressure, and oil flow is divided in a proportion more than area of opening of spool. 10-63 oOSTRUCTURE AND FUNCTION cLss 7. Boom regeneration circuit -—- © nase Lowel > ab ah 1 aosrososs 1 2. Main spool 3A. Pressure compensation valve 3B. Pressure compensation valve 4A, Safety-suction valve 4B. Suction valve 5. Check valve 6. LS shuttle valve 7. Drain circuit 8. Regeneration circuit 10-64 Function 1) Cylinder head pressure < cylinder bottom pressure (free fall, etc.) + A return flow circuit is provided from the ‘cylinder bottom to the cylinder head so that when the boom is lowered, the return flow can be used to increase the flow of oil from the pump to the cylinder bottom. Operation + When the cylinder head pressure < cylinder bottom pressure, part of the pressurized oil from the cylinder bottom passes through the Notch in spool (2), goes through port B, and enters drain circuit (7). The rest of the oil goes from port C, enters regeneration circuit (8), opens check valve (6), and passes through ports G and D to flow back to the cylinder head, 2050620506 STRUCTURE AND FUNCTION ciss > RAISE LOWER © 208F06059 2) Cylinder head pressure > Cylinder bottom pressure (digging operations, etc.) + Check valve (5) in regeneration circuit (8) acts to shut off the flow from the cylinder head to the cylinder bottom. 10-65STRUCTURE AND FUNCTION 8, Arm regeneration circuit ciss Main pump Main spool . Pressure compensation valve . Pressure compensation valve . Safety valve 3. Safety valve Arm counterbalance valve Piston Spool Check valve . LS shuttle valve . Drain circuit |. Regeneration circuit BSBSya SSeeroge 10-66 205F06060 Function 1) Cylinder head pressure > cylinder bottom pressure + A return flow circuit is provided from the cylinder head to the cylinder bottom so that when the arm is moved in, the flow of oil to the cylinder becomes the pump discharge amount + the return flow, and this increases the cylinder speed. Operation + When the cylinder head pressure > cylinder bottom pressure, the pressurized oil from the cylinder head passes through the notch in spool (2), enters port € and opens check valve (8), then passes through ports D and E 10 flow back to the cylinder bottom. 2050620606 STRUCTURE AND FUNCTION ciss 2) When load is large + During arm IN operations, if the load increases and the cylinder bottom pressure exceeds 16.6 MPa (170 kg/cm*), counterbalance valve (5) is actuated to increase the meter-out opening at the cylinder head. This reduces the pressure loss between the cylinder head and the hydraulic tank, and ensures the digging force. Operation + The cylinder bottom pressure enters port F and pushes piston (6) to the left. Spool (7) ‘moves fully to the left and interconnects port € of regeneration circuit (11) and tank drain circuit (10). As a result, the pressure loss in the drain circuit is reduced. 20506063, 3) Cylinder bottom pressure > Cylinder head pressure + When the cylinder bottom pressure > cylinder head pressure, check valve (8) is closed by the cylinder bottom pressure and prevents any oil flowing back from the cylinder bottom to the head end. 10-67STRUCTURE AND FUNCTION 9. Arm counterbalance valve Check valve Regeneration Tank drain circuit uit ome eNe 10-68 From eylinder head ciss From eylinder bottom 4 208F06062 Operation During arm IN operations, if the actuating pressure at the arm cylinder bottom rises, the pressure at port A also rises. When the force received by piston (1) from the pressure at port A becomes greater than the force of spring (3), piston (1) moves to the left. Spool (2) is pushed by piston (1) and also moves to the left, so ports B and C are inter- ‘connected. When this happens, the pressurized oil from the cylinder head passes through ports B and C, and flows directly to drain circuit (6). (The pressure loss is removed when draining.) ‘When this happens, check valve (4) is closed by the pressure at port A, so it shuts off regeneration circuit (5), and prevents the oil from flowing back from the cylinder bottom to the head end. 2050620506 STRUCTURE AND FUNCTION ciss 10. Spool stroke modulation (1) Boom raise modulation rf =< Boom raise — PPC pressure Spool iston : Spool stroke a AL ._ Boom raise reres oF ae <2 PPC pressure i Sti: Spool stroke St2: Piston stroke Boom and arm simultaneous operation Function Operation ‘When boom RAISE and arm DIG are operated © 1.. When no arm operation. simultaneously, good simultaneous operation is When boom raises, spool (1) goes to left achieved by restriction of boom spool max. (@) by stroke Sto to touch piston (2) stroke. 2. When arm digs (1) Arm DIG PPC pressure goes to LH. of piston (2) from Port A, and pushes piston (2) to right ( =»). (2) When boom raises, spool (1) goes to left (4=), but’spool max. stroke is restricted to Stt because piston (2) moves by Stz. 10-69 @STRUCTURE AND FUNCTION ciss (3) Arm dig modulation | Monee JF 3 z / No travel operation pressure sa 3 A sem PPC pressure > Arm and travel simultsneous operation Function Operation When machine goes up high slope and arm digs, 1. With no travel operation flow to arm cylinder is restricted by limitation of When arm digs, spool (1) goes to R.H. (=) arm spool stroke to avoid pressure drop of by stroke Sto to touch piston (2). pump. F pump flow goes to LH. travel motor 2. With travel operation through travel junction valve. (1) Travel PPC pressure goes to R.H. of piston (2) from port A, and pushes piston (2) to left. (2) When arm digs, spool (1) goes to right (#), but spool max. stroke is restricted to Sti because piston (2) moves by Stz. 10-70 2050620506 ‘STRUCTURE AND FUNCTION ciss Pee refaure s ve PL lr from erm dig U7 P, PPC valve 2 Function In simultaneous operation of boom and arm, such as finishing, arm spool speed is delayed to prevent sudden speed change of arm and ma: chine operates smoothly. 8. Movement of arm timing valve a pressure Operation When arm digs and boom raises simultaneously, spool is delayed because PPC circuit is reduce by arm timing vaive and pressure which forces spool (1) is reduced. 2 pressure + t Time of delay Ye During simul Function Reduce arm PPC pressure to M/V for simultane: ‘ous operation of arm dig and boom up. Operation 1. Simple operation of arm dig PPC pressure goes to P1 port and pushes spool (1) to right against spring (2) and P1 port through P2 port via B. taneous operation 2. Simultaneous operation of arm dig and boom up {i) When boom raises, PPC pressure goes to P3 port and pushes spool (1) to left. When levers are fully stroked towards arm dig and boom raise simultaneously, spool (1) is pushed to left by force according to following formula. P1 pressure < P2 pressure + spring force (P1 pressure = P2 pressure) Then B is.intercepted and PPC pressure of arm dig goes to P2 port from P1 port via orifice A. iy 10-71 oOSTRUCTURE AND FUNCTION 11. Pump merge-divider valve Ps rors To control valve Main spool Spring LS spool Spring LS circuit (bucket end) LS circuit (arm end) LS circuit (arm end) LS circuit (bucket end) PaO PEN Function + This acts to merge or divide (send to its own control valve group) oil flows P1 and P2 of pressurized oil discharged from the two pumps. + Atthe same time, it also carries out merging ividing of the LS circuit pressure. ciss P2 Pt 205F06063 Operation v When merging pump flow (when pressure PS is OFF) Pilot pressure PS is OFF, so main spool (1) is pushed to the left by spring (2), and ports E and F are interconnected. Therefore, pressurized oil P1 and P2 discharged from the two pumps is merged at ports E and F, and is sent to the control valve that demands the oil. In the same way, LS spool (3) is also pushed to the left by spring (4), so the ports are connected as follows. Connected ports: A < D, B <> C Therefore, the LS pressure supplied from the spools of each control valve to LS circuits (6), (6), (7), and (8) is all sent to the pressure compensation valve and other valves. 2050620506 STRUCTURE AND FUNCTION cLss 5 A 8 D 7 5 =aNE z EEL ~ — 8 I Ps TON, »> E F 2 To bucket control vaive end To arm contol valve end P2 Pt 205F0s064 2) When dividing pump flow (when pilot pressure PS is ON) + When pilot pressure PS is ON, main spool (1) is moved to the right by the PS pressure, and ports E and F are disconnected. Therefore, the pressurized oil discharged from each pump is sent to its own control valve group. Pressure P1: To bucket, RH. travel, boom group Pressure P2: To swing, LH. travel, arm group + Inthe same way, LS spool (3) is also moved to the right by the PS pressure, and the prots are connected as follows. Connected ports: B © D, others are not connected. Therefore, LS circuits (5), (6), (7) and (8) are all sent to their own control valve group, 10-73 ®‘STRUCTURE AND FUNCTION ciss 12. LS select valve * The diagram shows the situation when the swing and left travel are operated at the same time. (BP pressure ON) Valve Spring Piston Piston ‘Swing spool LH. travel spool ‘Arm spool LH. shuttle valve LS circuit OorOnEENe 205F0s06s Function + This valve is used to increase the ease of operating the work equipment. It prevents high pressure from being generated when the swing is operated, It also prevents the high LS pressure from the swing circuit from flowing into any other LS circuit when the BP ‘swing is operated together with the work ‘OFF 4 equipment. Operation 1), When pilot pressure BP is OFF Pilot pressure BP is OFF, so piston (3) is To LS shuttle vake Pushed to the left by spring (2). if the swing is then operated, swing LS pressure P1 2osFo60ss passes through swing spool (6) and enters port A. It pushes valve (1) to the left and 4 3 2 el ‘connects ports A and B. Therefore, swing LS | / a pressure P1 flows to LS shutttle valve (8). 2) When pilot pressure BP is ON + When pilot pressure BP is ON, piston (3) is moved to the right against spring (2) by the > >) aad BP pressure. It pushes valve (1) to the right BP and closes the circuit between ports A and "O's B. As a result, swing LS pressure P1 stops flowing to LS shuttle valve (8), and even if swing LS pressure P1 rises to a high pressure, it does not influence any other LS cir- To LS shuttle valve cuit. 20806067 10-74 ® 2050620506 STRUCTURE AND FUNCTION Operation 1) When the arm and boom are operated multaneously, the swash plate angle for both pumps becomes the maximum. When this happens, the load pressure at the boom RAISE side is higher than at the arm side, so the LS pressure passes through ports E and F of boom spool (8), enters LS shuttle valve (22) and is sent to the LS circuit. This LS pressure is transmitted to port G of arm pressure compensation valve (17), and acts to increase the set pressure of the pressure compensation valve. Because of this, the pressure between port H or arm spool (11) and port I or pressure compensation valve (17) rises, and spool meter-in LS differential pressure (pump pressure - LS pressure APLS) becomes the same as that at the boom end. 2) Because of the above operation, the oil flow is divided in proportion to the size of the opening area of boom spool (8) and the ‘opening area of arm spool (11). Meter-in LS differential pressure APLS during boom RAISE + arm IN is APLS < boom LS control pressure, so the main pump swash plate angle is set to maximum. ciss 10-91STRUCTURE AND FUNCTION SWING MOTOR SWING MOTOR Port S Port MB (from control valve) Port MA (from control valve) Port T (to tank) Port B (from swing brake solenoid valve) paege 10-92 rrosesois SPECIFICATIONS ttem —~M¢e!) pc2to-6k | Pc240-6K Type KMF90AB-2 Taporeticst 87.8 cclrev Safety valve Bah NP Set pressure (280 kglen) Rated speed | 2,298 rpm | 2,403 rpm Brake releasing 737 MPa, pressure eigen k2050620508 STRUCTURE AND FUNCTION SWING MOTOR . Brake spring . Drive shaft Cover Case Disc Plate Brake piston End cover Piston penemeeno 10. 1 2. 13. 4. 15 Faoscso16 Cylinder Valve plate Air bleed plug Center shaft Center spring . Safety valve 16. "7. Check valve Check valve spring 10-93STRUCTURE AND FUNCTION ‘SWING HOLDING BRAKE OPERATION 1) When swing brake solenoid valve is deactivated When the swing brake solenoid valve is deactivated, the pressurized oil from the control pump is shut off and port B is connected to the tank circuit. Because of this, brake piston (7) is pushed down in the direction of the arrow by brake spring (1), so disc (5) and plate (6) are pushed together and the brake is applied. 2) When swing brake solenoid valve is excited When the swing solenoid valve is excited, the valve is switched, and the pressurized il from the control pump enters port B and flows to brake chamber "a". The pressurized oil entering chamber “a” ‘overcomes the force of brake spring (1), and brake piston (7) is pushed up in the direction of the arrow. Because of this, disc (5) and plate (6) separate, and the brake is released. 10-94 SWING MOTOR [fab i | | | ‘Swing brake solenoid vaive 20808050 ‘Swing brake solenoid valve 208F05051 2050620506 STRUCTURE AND FUNCTION CENTER SWIVEL JOINT CENTER SWIVEL JOINT 4-PORT SWIVEL —=( ene SOs e2 a—l z 1. Cover Al. From control valve port B2 2. Body A2.To R.H. travel motor port PB z0sFo0076 3. Slipper seal B1. From control valve port BS 4. O-ring B2. To LH. travel motor port PA 5. Shaft C1. From control valve port AZ C2. To RH. travel motor port PA D1. From control valve port AS D2. To LH. travel motor port PB E1. From travel speed solenoid valve E2, To LH. and R.H. travel motors port P Ti. To tank 12. From LH. and R.H. travel motors port T 10-95 ®STRUCTURE AND FUNCTION TRAVEL MOTOR TRAVEL MOTOR Port PB (from contro! valve) Port PA (from control valve) Port T (to tank) Port P (from travel speed solenoid valve) pogo 10-96 ‘TRAVEL MOTOR aostooore SPECIFICATIONS tem Model | pc210-6k | PC240-6K Type HMV160ADT-2 Rayoguen [Mie_[r0s core]ne corev "Y _|Mex. 160.8 colrev Set pressure eats, Rated Min. ity] 1-834 rpm | 1,780 rpm ’ can Max ty] 1.004 rpm | 1,048 rpm Brake releasi 78 MPs pressure "9 seer Travel speed iff aaa 1 . scune eae Skat’ 2050620506 STRUCTURE AND FUNCTION exomrens Output shaft Motor case Ball Rocker cam Piston Cylinder Valve plate End cover Regulator valve . Spring |. Brake spring . Brake piston . Plate . Disc . Regulator piston Spring TRAVEL MOTOR 17. 19. 20. 22, 20806079 . Check valve spring }. Check valve 1. Counterbalance valve . Spool return spring . Safety valve . Slow return valve 10-97‘STRUCTURE AND FUNCTION OPERATION OF MOTOR 1) Motor swash plate angle (capacity) at maximum TRAVEL MOTOR valve (deactivated) 15 mW © + The solenoid valve is deactivated, so the pilot pressure oil from the control pump does not flow to port P. For this reason, regulator valve (9) is pushed to the right in the direction of the arrow by spring (10). + Because of pushes check valve (22), and the main pressure oil from the control valve going to end cover (8) is shut off by regulator valve (9). + Fulcrum ‘a" of rocker cam (4) is eccentric to point of force "b" of the combined force of the propulsion force of cylinder (6), so the combined force of the piston propulsion force acts as a moment to angle rocker cam (4) in the direction of the maximum swash plate angle. 10-98 ® + Atthe same time, the pressurized 2 ‘Travel contra! ‘20sF6080 lator piston (15) passes through orifice "e" in regulator valve (9) and is drained to the motor case. + As a result, rocker cam (4) moves in the maximum swash plate angle direction, the motor capacity becomes maximum. k20506k20506 STRUCTURE AND FUNCTION TRAVEL MOTOR 2) Motor swash plate angle (capacity) at minimum ‘Travel speed solenoid valve (excites) + |r ‘Travel control valve 20806081 + When the solenoid valve is excited, the pilot pressure oil from the control pump flows to port P, and pushes regulator valve (9) to the left in the direction of the arrow. + Because of this, the main pressure oil from the control valve passes through passage “d” in regulator valve (9), enters regulator piston (15) at the bottom, and pushes regulator piston (15) to the right in the direction of the arrow. + As a result, rocker cam (4) moves in the minimum swash plate angle direction, the motor capacity becomes minimum. 10-99‘STRUCTURE AND FUNCTION OPERATION OF PARKING BRAKE 1) When starting to travel When the travel lever is operated, the pressurized oil from the pump actuates counterbalance valve spool (19}, opens the circuit to the parking brake, and flows into chamber A of brake piston (12). If overcomes the force of spring (11), and pushes piston (12) to the right in the direction of the arrow. ‘When this happens, the force pushing plate (13) and disc (14) together is lost, so plate (13) and disc (14) separate and the brake is released. 2) When stopping travel When the travel lever is placed in neutral, counterbalance valve spool (19) returns to the neutral position and the circuit to the parking brake is closed. The pressurized oil in chamber A of brake piston (12) is drained to the case from the orifice in the brake piston, and brake piston (12) is pushed to the left in the direction of the arrow by spring (11). As a result, plate (13) and disc (14) are pushed together, and the brake is applied. A time delay is provided by having the pressurized oil pass through a throttle in slow return valve (22) when the brake piston returns, and this ensures that the bake still effective after the machine stops. 10-100 TRAVEL MOTOR 2o8F06082 [See ve acto 20506003, 2050620506 STRUCTURE AND FUNCTION OPERATION OF BRAKE VALVE 7 The brake valve consists of a check valve, counterbalance valve, and safety valve in a circuit as shown in the diagram on the right. (Fig. 1) The function and operation of each component is as given below. ince valve, check valve When traveling downhill, the weight of the machine makes it try to travel faster than the speed of the motor. As a result, if the machine travels with the engine at low speed, the motor will rotate without load and the machine will run away, which is extremely dangerous. To prevent this, these valves act to make the machine travel according to the engine speed (pump discharge amount) peration when pressure oil is supplied When the travel lever is operated, the pressurized oil from the control valve is supplied to port PA. It pushes open check valve (18A) and flows from motor inlet port MA to motor outlet port MB. However, the motor outlet port is closed by check valve (18B) and spool (19), so the pressure at the supply side rises. (Fig. 2) The pressurized oil at the supply side flows from orifice E1 in spool (19) and orifice E2 in the piston to chamber $1. When the pressure in chamber $1 goes above the spool switching pressure, spool (19) is pushed to the right in the direction of the arrow. As a result, port MB and PB are connected, the outlet port side of the motor is opened, and the motor starts to rotate. (Fig. 3) ‘TRAVEL MOTOR Check valve Safety valve! ae 2osrocoee [Trove ontot Pal Pe 18h H 188 e Us sit} wal MB E2 20sF0s0es (Fig. 2) 18h 5 sid 2 ig. 3) 20506086, 10-101STRUCTURE AND FUNCTION Operation of brake when traveling downhill If the machine tries to run away when traveling downhill, the motor will turn under 1no load, so the pressure at the motor inlet port will drop, and the pressure in chamber $1 through orifices E1 and E2 will also drop. When the pressure in chamber $1 drops below the spool switching pressure, spool (19) is returned to the left in the direction of the arrow by spring (20), and outlet port MB is throttled. As a result, the pressure at the outlet port side rises, resistance is generated to the rotation of the motor, and this prevents the machine from running away. In other words, the spool moves to a position where the pressure at outlet port MB balances the pressure at the inlet port and the force generated by the weight of the Machine. It throttles the outlet port circuit and controls the travel speed according to the amount of oil discharged from the pump. (Fig. 4) 2) Safety valve (2-way operation, 2-stage set safety valve) Function + When travel is stopped (or when traveling downhill, the circuits at the inlet and outlet ports of the motor are closed by the counterbalance valve, but the motor is rotated by inertia, so the pressure at the outlet port of the motor will become abnormally high and damage the motor or piping. The safety valve acts to release this abnormal pressure and send it to the inlet port side of the motor to prevent damage to the equipment. Operation in both directions 1) When pressure in chamber MB has become high (when rotating clockwise) + When the travel is stopped (or when traveling downhill), chamber MB in the outlet port circuit is closed by the check valve of the counterbalance valve, but the pressure at the outlet port rises because of inertia. (Fig. 5) + If the pressure goes above the set pressure, the force produced by the difference in area between D1 and D2 [r/4(D1? - D2") x pressure] overcomes the force of the spring and moves the poppet to the left, so the oil flows to chamber MA in the circuit on the opposite side. (Fig. 6) 10-102 ® ‘TRAVEL MOTOR ig. 9 20806087 ig.) 20506088, p2 Dt i; aio: a Poppet ig. 6) 205F06089 2050620506 STRUCTURE AND FUNCTION 2) When pressure in chamber MA has become high (when rotating counterclockwise) + When the travel is stopped (or when traveling downhill), chamber MA in the outlet port circuit is closed by the check valve of the counterbalance valve, but the pressure at the outlet port rises because of inertia. (Fig. 7) + Ifthe pressure goes above the set pressure, the force produced by the difference in area between D1 and D3 [n/4 (D3? - D1?) x pressure] overcomes the force of the spring and moves the poppet to the left, so the oil flows to chamber MB in the circuit on the opposite side. (Fig. 8) Operation of mechani sure 1) When starting travel (high pressure setting) When the travel lever is operated, the pre: surized oil from the pump actuates counter balance valve spool (19), and opens the pi lot circuit to the safety valve. The oll passes from chamber G to passage H and flows into chamber J, pushes the piston to the right in the direction of the arrow, and com- presses the spring to make the set load larger. Because of this, the set pressure of the safety valve is switched to the high pressure setting, and a large drawbar pull is made available. for varying set pres- TRAVEL MOTOR OO ig.) 208F06090 poppet aie ‘205F06091 Piston Spring / Mi = Ce MB fl J H G = | 4 ‘Travel control 19 (Fig. 9) 208F00082 10-103 @STRUCTURE AND FUNCTION 2) When stopping travel (low pressure setting) When the travel lever is placed at neutral, the pressure in chamber PA drops and counterbalance valve spool (19) returns to the neutral position. While the counterbalance valve spool is returning to the neutral position, the pressurized oil in chamber J passes through passage H, and escapes to chamber PA from chamber G. The piston moves to the left in the direction of the arrow, and the set load becomes smaller. Because of this, the set pressure of the safety valve is ‘switched to the low pressure setting in order to relieve the shock when reducing speed. [Set pressure of safety vaive] ‘When starting, wee aera When stopping High pressure setting | Low pressure setting ‘37.73 MPa (385 kglem’) | 27.44 MPa (280 kg/cm’) 10-104 o TRAVEL MOTOR Piston Spring LL MB ‘Travel control valve Fg. 10) 20805093 2050620506 STRUCTURE AND FUNCTION VALVE CONTROL C210, 210LC-6K PC240, 240LC, 240NLC-6K 1. Travel PPC valve 10. 2. Service PPC valve 11 3. Service pedal 12. 4. LH. travel lever 1B. ravel lever 4. |. PPC valve RH. work equipment 15. lever 16. 8. LS control EPC valve 17. 9. Hydraulic pump 18. Control valve PPC shuttle valve Accumulator Solenoid valve LH. work equipment lever Safety lock valve LH. PPC valve Safety lock lever Timing valve @8006600 Boom LOWER Bucket DUMP Bucket CURL Neutral Arm IN Arm OUT @SG8260 VALVE CONTROL ‘Swing RIGHT ‘Swing LEFT Neutral Travel REVERSE Travel FORWARD Lock FREE 10-105STRUCTURE AND FUNCTION WORK EQUIPMENT - SWING PPC VALVE WORK EQUIPMENT - SWING PPC VALVE PC210, 210LC-6K C240, 240LC, 240NLC-6K ol TT 20uF02032 a. Port P (from control pump) b. Port T {to tank) ¢. Port P2 (L.H.: Arm IN / R.H.: Boom RAISE) d. Port P4 (LH. Swing LEFT / R.H.: Bucket DUMP) fe. Port Pt (LH. Arm OUT / R.H.: Boom LOWER) Port P3 (L.H.: Swing RIGHT / R.H.: Bucket CURL) 10-106 2050620506 STRUCTURE AND FUNCTION WORK EQUIPMENT - SWING PPC VALVE — 1 i a lof hf Oo a 1— [ae O 10 a—a = be ' ml ¢ > i > 20uF02083 1. Spool 7. Joi 2. Metering spring 8. Plate 3. Centering spring 9. Retainer 4. Piston 10. Body 5. Disc 11. Filter 6. Nut (for connecting lever) 10-107STRUCTURE AND FUNCTION OPERATION 1) At neutral Ports A and B of the control vaive and ports Pr 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 — fine control) When piston (4) starts to be pushed by disc (6), 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 control_pump passes through fine contro! hole “f* and goes from port Pt 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 Pt. When this happens, spool (1) moves up or down so that the force of metering spring (2) is balanced with the pressure at port Pt. 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) 10-108 ® WORK EQUIPMENT + SWING PPC VALVE Fig.) \ 5 4 4 cS oO to tT ® 1— Mer ASM convotvane M38)! orroroes (Fig.2) 2050620506 STRUCTURE AND FUNCTION 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 Pt is released. H the pressure at port Pt 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 Pt recovers to a pressure that corresponds to the lever position. When the spool of the control valve returns, oil in drain chamber D flows in from fine control hole "fin 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 Pr. Therefore, the pilot pressure oil from the control 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) WORK EQUIPMENT - SWING PPC VALVE Control valve (Fig.3) Control valve rorro1087 (Fig.4) 10-109STRUCTURE AND FUNCTION ‘TRAVEL PPC VALVE TRAVEL PPC VALVE Port P (from control pump) Port T (to tank) Port P1 (LH. travel REVERSE) Port Ps (R.H. travel REVERSE) Port P2 (LH. travel FORWARD} Port P4 (R.H. travel FORWARD) se aooe 10-110 oO 2050620506 STRUCTURE AND FUNCTION TRAVEL PPC VALVE ce 208F06108 1. Piston 5. Valve 2. Plate 6. Metering spring 3. Collar 7. Centering spring 4. Body 8. Bolt 10-111STRUCTURE AND FUNCTION OPERATION 1. At neutral Ports A and B of the control valve and ports P1 and P2 of the PPC vaive are connected to drain chamber D through fine contro! hole "fin spool (1). (Fig. 1) 2. Fine control (neutral — fine contro!) When piston (4) starts to be pushed by disc (6), 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. At almost the same time, it is connected to pump pressure chamber PP, and the pilot pressure of the control pump is sent from port A through fine control hole “f* to port P1. When the pressure at port P1 rises, spool (1) is pushed back. Fine control hole "fis shut off from pump pressure chamber Pr. At almost the same time, it is connected to drain chamber D, so the pressure at port P1 escapes. As a result, spool (1) moves up and down until the force of metering spool (2) is balanced with the pressure of port Pt. The relationship of the positions of spoo! (1) and body (10) (fine control hole “fis in the middle between drain hole D and pump pressure chamber Pr) does not change until retainer (9) contacts spool! (1) Therefore, metering spring (2) is compressed in proportion to the travel of the control lever, so the pressure at port Pt also rises in proportion to the travel of the control lever. In this way, the spool of the control valve moves to a position where the pressure of chamber A (same as pressure at port Pt) and the force of the return spring of the control valve spool are balanced. (Fig. 2) 10-112 ® TRAVEL PPC VALVE AM Control vaive pe 1 i jane 4 a A 4%. ru . a LJ t i sjees : 7 1 db (the a a eM conor ve 2H) 2050620506 STRUCTURE AND FUNCTION 3. 4) Fine contro! (control lever returned) When disc (6) starts to be returned, spool (1) is pushed up by the force of centering spring (3) and the pressure at port P1. Because of this, fine control hole “f” is connected to drain chamber D, and the pressurized oil at port Pt is released. If the pressure at port P1 drops too much, spool (1) is pushed up by metering spring {2), so fine control hole “f" is shut off from drain chamber D. At almost the same time, it is connected to pump pressure chamber PP, so the pressure at port Pt supplies the pump pressure until the pressure recovers to a pressure equivalent to the position of the lever. When the control valve returns, oil in drain chamber D fiows in from fine control hole “" of the valve on the side that is not moving. It passes through port P2 and goes to chamber B to charge the oil. (Fig. 3) At full stroke Disc (5) pushes down piston (4), and retainer (8) pushes down spool (1). Fine control hole “f" is shut off from drain chamber D, and is connected to pump pressure chamber PP. Therefore, the pilot pressure oil from the control pump passes through fine control hole “f” and flows to chamber A from port P1 to push the control valve spool. The return oil from chamber B passes from port P2 through fine control hole “f” and flows to drain chamber D. (Fig. 4) ‘TRAVEL PPC VALVE ig. 3) 227701096 ig. 4 22F01097 10-113STRUCTURE AND FUNCTION SERVICE PPC VALVE ‘SERVICE PPC VALVE . Pin Cam . Ball Piston Cover Sleeve . Centering spring . Metering spring Spool . Body Seernogrena Port T (to tank) Port P (from control pump) Port A (to service valve P1) Port B (to service valve P2) pegs 10-114 2050620506 STRUCTURE AND FUNCTION OPERATION At neutr + The pressurized oil from the control pump ‘enters from port P and is blocked by spool (9). + Port A and B of the control valve and port “a" and “b” of the PPC valve are connected to drain port T through fine contro! hole X of spool (9). When operated + When cam (2) is moved, metering spring (8) is pushed by ball (3), piston (4), and sleeve (6), and spool (9) is also pushed down by this + As a result, fine control hole X is shut off from the drain circuit. At almost the same time, fine control portion ¥ is connected with port “a”, and the pressurized oil from port P flows from port “a” to port A of the control valve. ‘SERVICE PPC VALVE Pce10-K003 10-115 ®‘STRUCTURE AND FUNCTION + When the pressure at port “a” becomes higher, spoo! (9) is pushed back by the force acting on the end of the spool. When fine control portion ¥ closes, fine control hole X is connected to the drain circuit at almost the same time. + Asa result, spool (9) moves up and down to balance the force at_port “a” and the force at metering spring (8). + Therefore, metering spring (8) is compressed in proportion to the amount the control lever is moved. The spring force becomes larger, so the pressure at port “a” also i creases in proportion to the amount the control lever is operated. + In this way, the control valve spool moves to a position where the pressure of port A {the same as the pressure at port “a”) is balanced with the force of the return spring of the control valve spool. 10-116 SERVICE PPC VALVE © Control valve P210-Ko0s 2050620506 STRUCTURE AND FUNCTION SAFETY LOCK VALVE Fzoscso18 PPC ACCUMULATOR ‘SAFETY LOCK VALVE PPC ACCUMULATOR Lever Body Seat Ball End cap Gas plug Shell 1 2 3. Poppet 4. 5 6 Holder . Bladder Oil port SPECIFICATIONS Gas capacity: 400 cc 10-117 oO‘STRUCTURE AND FUNCTION PPC SHUTTLE - TRAVEL JUNCTION VALVE PPC SHUTTLE + TRAVEL JUNCTION VALVE @ 2 [9 te 6-6 G A, ! ‘| . , Lt, er wo = os a 1. PPC shuttle valve OUTLINE (2. Travel junction valve + The PPC shuttle valve and travel junction valve form a combined structure. 10-118 ® 2050620506 STRUCTURE AND FUNCTION PPC SHUTTLE VALVE PPC SHUTTLE + TRAVEL JUNCTION VALVE FUNCTION This sends the PPC valve output pressure or EPC valve output pressure to the control valve and travel junction valve. It is provided with a mount port for the pressure switch for detect- ing the pilot pressure. 10-119STRUCTURE AND FUNCTION Port P11 (from swing PPC valve) Port P21 (from swing PPC valve) Port P31 (from bucket PPC valve) Port P41 (from bucket PPC valve) Port PB1 (from boom PPC valve) Port P61 (from arm PPC/EPC valve) Port PLS (to LS select valve) Port P71 (from arm PPC/EPC valve) Port P81 (from boom PPC/EPC valve) Port PA1 (from R.H. travel PPC valve) Port PB1 (from LH. travel PPC valve) Port PC1 (from LH. travel PPC valve) Port P91 (from R.H. travel PPC valve) Port P12 [to control valve (swing)] Port P22 [to control valve (swing) Port P32 [to control valve (bucket)] Port P42 [to control valve (bucket)] Port P52 [to control valve (boom)] Port P62 [to control valve (arm)] Port P72 [to control valve (arm)] Port P82 [to control valve (boom)] Port PAZ [to control vaive (R.H. travel)] w. Port PB2 [to control valve (L.H. travel)] x. Port PC2 [to control valve (L.H. travel)] y. Port P92 [to control valve (R.H. travel)] 21, Port PR (to travel junction valve) 22, Port PF (to travel junction valve) aa. Port A1 (mount port for swing oil pressure switch) ba, Port AB (mount port for bucket DUMP oil pressure switch) bb. Port A2 (mount port for bucket CURL oil pressure switch) ca, Port A4 (mount port for arm OUT oil pressure switch) cb. Port A3 (mount port for arm IN pressure switch) da. Port AS (mount port for boom RAISE pressure switch) db. Port A7 (mount port for boom LOWER oil pressure switch) ee. Port AG (mount port for travel oil pressure switch) grRT seme eoge To tank Boom contro! fi vatve Tpor =D To tank 2050620506 STRUCTURE AND FUNCTION ENGINE CONTROL SYSTEM Battery relay Battery Starting switch Fuel control dial Governor motor Starting motor Engine throttle controller Fuel injection pump PxET REND Ful ENGINE CONTROL SYSTEM INCTION The engine can be stated and stopped simply by using the starting switch. A dial type engine control is used to control the engine speed. The engine throttle controller receives the control signal from the fuel control dial, sends a drive signal to the governor motor, and controls the angle of the governor lever in the fuel injection pump. At the same time, the engine throttle controller also receives signals from other controllers to control the engine speed. 10-149 ®STRUCTURE AND FUNCTION 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 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 contrat The fuel control dial sends a signal to the engine throttle controller according to the position of the dial. The engine throttle 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 controller, so that it can observe the operation of the governor motor. Stopping engine When the starting switch is placed at the OFF position, the shut off valve is closed so the supply of fuel to the engine is shut off and the engine stops. 10-150 ENGINE CONTROL SYSTEM ‘Power source fl on satpe ivenisagnateonior Fusteontat Ln [opine Erin yet cont one (Throne gnah|eonater 2050620506 ‘STRUCTURE AND FUNCTION ENGINE CONTROL SYSTEM 2, COMPONENTS OF SYSTEM 1) FUEL CONTROL DIAL a HIGH Front of machine 61 “ee A-A * we FUNCTION + The fuel control dial is installed at the bottom of the monitor panel. A potentiometer is installed under the knob, and when the knob is turned, it rotates the potentiometer shaft. When the shaft rotates, the resistance of the variable resistor inside the potentiometer changes, and the desired throttle signal is sent to the engine throttle controller. The shaded area in the graph on the right is the abnormality detection area and the engine speed is set at low idling. 1. Knob 2. Dial 3. Spring 4. Ball 5. Potentiometer 6. Connector Composition of cireut Wy 109 : 5 Lo 00.251 Characteristics of throttle voltage 46.75 5 Voltage 10-151 ®STRUCTURE AND FUNCTION 2) GOVERNOR MOTOR ENGINE CONTROL SYSTEM FUNCTION + The motor is rotated and the governor lever of the fuel injection pump is controlled by the drive signal from the engine throttle controller. + Astepping motor is used for the motor which provides the motive power. In addition, a potentiometer for giving feedback is installed to allow observation of the operation of the motor. + The rotation of the motor is transmitted to the potentiometer through a gear. 10-152 oO i 8 1. Potentiometer [ | 2) Cover A | 3. Shaft 4. Dust seal 8. Bearing 3 8. Motor 7. Gear 8. Connector - — Y Aa a aosrosiae OPERATION Motor stationary + Both A phase and B phase of the motor are continuous, and a holding torque is generated in the motor. Motor rotating + A pulse current is applied to the A phase and B phase from the engine throttle controller to give synchronous rotation with the pulse, 2050620506 STRUCTURE AND FUNCTION 3) ENGINE THROTTLE CONTROLLER ENGINE CONTROL SYSTEM Input and output signals zosrosias CN-E01 No.| Name of signal input/output No.| Name of signal Inputioutput 1 [Controller power source (24V) = 12 |Gno Input 2 | Controller power source (24V) = 13 | Battery relay drive Output 3 | Network circuit -) = 14 | Network circuit (pump +) = 4 | Auto deceleration Input 15 | Network circuit (monitor +) = 5 |Potentiometer power source (5V)|__ — 16 | Potentiometer GND = 6 | Starting switch ON signal Input 17 | signat ©” “Or Potentiometer Input 7 | Fuet contro! dial Input 18 | Model selection 2 Input Model selection 1 Input 18 | Model selection 4 Input 9 | Model selection 3 Input 20 | Governor motor drive A (+) Output 10 | Governor motor drive A (+) Output 21 | Governor motor drive B (+) Output 11 | Governor motor drive B (+) Output 10-153STRUCTURE AND FUNCTION ELECTRONIC CONTROL SYSTEM CONTROL FUNCTION ELECTRONIC CONTROL SYSTEM Pump & engine mutual control function 2 Pump and valve control function 3 Power maximizing function 3 ‘Swift slow-down function 4 Electronic control system Auto-deceleration function 5 Engine automatic warming-up, overheat prevention function 6 ‘Swing priority function 1 ‘Swing control system 8 Travel control function * For details of the self-diagnostic function, see TROUBLESHOOTING. 10-154 Self-diagnostic function 2050620506 STRUCTURE AND FUNCTION ELECTRONIC CONTROL SYSTEM 1) Control method in each mode Heavy-duty operation (H/O) mode + Matching point in heavy-duty operation + When the load on the pump rises and the mode: . . pressure rises, the engine speed goes down. 96% partial output_point When this happens, the pump discharge Model amount is reduced, and the engine speed is Mode ha Pc24o controlled so that it becomes near the 96% partial output point. If the reverse happens controlled so that the pump discharge amount is increased until the engine speed becomes near the 96% partial output point. By repeating this control, the engine can always be used at near the 96% partial output point. General operation (G/O), finishing operation (F/O), breaker operation (B/O) mode A i i + Matching point in general operation, finish- + When the load on the pump rises and the ir yn, and breaker operation modes: pressure rises, the engine speed goes down. 80% partial output point. When this happens, mutual control of the engine and pump is used to control the system so that the pump absorption torque follows the equal horsepower curve of the en- }————— gine, and the engine speed is lowered while eon keeping the torque constant. soe emicy, [81 KW (108 HP)| 96 kW (128 HP) In this way, the engine is used in a range breaker operstion | er | eco which provides good fuel efficiency. Pc240 10-157 @OSTRUCTURE AND FUNCTION Lifting operation (L/O) mode Engine torque T Engine horsepower HP speed N + Matching point in lifting operation mod 60% partial output poi Model aaa Poat0 P20 Titing operation | B7 RW (76 HPT [76 RW (102 HPT ey 71306 him | soo bon Power maximizing mode 3 i Engine speed N ELECTRONIC CONTROL SYSTEM Pump discharge pressure P Pump discharge ammount Q + When the lifting operation mode is selected, the engine speed is automatically lowered to the partial position. In this condition, control is carried out in the same way as for the general operation, finishing operation, and breaker operation modes to match the load on the pump. In this way, the fuel consumption is reduced and the fine control ability is improved, Pump discharge pressure P Engine speed N + Matching point in power max. mode: Reted output point Moae ——W0%!|—pc210 C240 199 KW (133 HP)|IT7 KW (168 HP) poner 72,200 rpm _| 2,300 rpm 10-158 Engine speed N Pump discharge amount @ 208F06 151 205F061s2 When the pump load increases, the engine speed drops. When this happens, the pump discharge is reduced to prevent the engine speed from going down and to ensure that the engine is used at near the rated output point. 2050620506 STRUCTURE AND FUNCTION 2) Pump control function when traveling Engine torque T Engine speed N 208F06153 + When the machine travels in the heavy-duty operation (H/O) mode, the engine speed rises, and the pump is controlled in the ‘same way as when in the power maximizing mode. + When the machine travels in any mode other than the heavy-duty operation (H/O) mode, the working mode and engine speed are kept as they are, and the pump absorption torque is increased. 3) Control function when TVC prolix switch is ON PON (Prox) IN: OFF (Normalt + Even if any abnormality should occur in the controller or sensors, the TVC prolix switch can be turned ON to provide an absorption torque more or less equivalent to the general operation (G/O) mode, thereby allowing the machine to maintain is functions. Pump discharge pressure P ELECTRONIC CONTROL SYSTEM Pump discharge amount O 208F06187 Engine torque T Engine speed N Pump discharge pressure P Pump discharge amount Q 20806186. Pump discharge pressure P Pump discharge amount @ In this case, it is designed to allow a constant current to flow from the battery to the TVC valve, so oil pressure sensing is carried out only by the TVC valve, 10-159STRUCTURE AND FUNCTION ELECTRONIC CONTROL SYSTEM 2. PUMP AND VALVE CONTROL FUNCTION eet 1h zlg/Elal# faa 3/8) z)a}3) a i 3/2 Eis a He aE < | | = | | i I i FUNCTION + The following two functions are available to provide the optimum matching under vari- ‘ous working conditions: a 2-stage relief function which increases the digging power, and a fine control mode function which improves ‘the ease of fine control. 10-160 2050620506 STRUCTURE AND FUNCTION 1)_LS control function + The switching point (LS set differential pressure) for the pump discharge amount inside ‘the LS valve is changed by changing the ‘output pressure from the LS control EPC valve to the LS valve according to the engine speed and operating condition of the actuator. + Because of this, the timing for starting the discharge amount from the pump can be optimized, to give excellent ease of compound operation and fine control. 2) Cut-off function For details of the operation, see CLSS. 3) 2-stage relief function + The relief pressure for normal operation is 31.85 MPa (325 kgicm*), but when the 2- stage relief function is actuated, the relief pressure rises to approx. 34.79 MPa (355 kg/ om’). Because of this, the hydraulic pressure is increased by one stage. + Actuating con tion jons for 2-stage relief func- + In lifting operation (V/O) a MS dot finetge| S55 kaemn are actuated ELECTRONIC CONTROL SYSTEM EPC pressure at 2.94 MPa (30 kam) (OMS (0 glee) Pump discharge amount Q LS set citferential pressure 20sF06160 10-161STRUCTURE AND FUNCTION 4) Fine control mode function + When the finishing operation (F/O) mode is selected from the working mode, the pump LS valve is controlled, and the pump discharge amount is reduced to improve the ease of fine control and the precision when finishing. + Relationship between working mode and pump discharge amount (for independent operation) ELECTRONIC CONTROL SYSTEM % ‘Actuator Boom Arm Bucket | Swing | Breaker Mode RAISE |LOWER| IN | OUT Heavy-duty operation (H/O) es 100 too | 100 | 50 | 5 | — General operation (G/O) Finishing operation (F/0) [100 <505] 50 | 100 | 40 (60) | 40 (60) | — Lifting operation (L/O) 50 so | so | a | a | — Breaket operation (8/0) 100 too | 100 | 50 | 50 | 60 The figures in (_) are for the PC210. The figures in < > are for when arm IN is operated. * In each working mode, the full flow of the pump at the set engine speed is taken as 100%. +t 10-162 k2050620506 STRUCTURE AND FUNCTION ELECTRONIC CONTROL SYSTEM 3. POWER MAXIMIZING. SWIFT SLOW-DOWN FUNCTION Control valve | 2tage ait solenoid valve oe Main pump i) Governor Fuel injection motor a ia : Cy Engine switeh speed [IS vate 1S valve Control pump L Potentiometersignall Engine throne see controller Network signal) | Pump controls Monitor panel 208F08169 FUNCTION + This function provides an increase in the digging power for a certain time or switches the working mode to the lifting operation (L/ ) and reduces the speed. It is operated using the LH. knob switch to momentarily match the operating conditions. * The power max. function and swift slow- down function are operated with the same switch. Only one of these functions can be selected at any time; they cannot both be operated together. 10-163STRUCTURE AND FUNCTION 1) Power maximi 9 function + During digging operations, when that extra bit of digging power is needed (for example, when digging up boulders), the LH. knob ‘switch can be pressed to raise the hydraulic pressure by approx.10 % and increase the digging force. + If the LH. knob switch is pressed ON when the working mode is at H/O or G/O, each function is automatically set as follows. 3S Wortng | Engine, Faxaatn made’ | pumprcontol ‘ime Heavy | Matching at | Actuated | Automat duty” | rated output | (31.8 | cally poration | point $49 MPa) | Cantoled tap 5" | Shores 585 kaler’| Soe 2). Swift slow-down function + During normal operations, if it is de d to carry out lifting operations or finishing operations for 2 moment, the working mode can be switched to lifting operation (L/O) mode by operating the LH. knob switch. + If the LH. knob switch is pressed ON when the working mode is at H/O or G/O, each function is autor: & lly set as follows. Working mode ‘Actuating ume Ling operation ‘While switch Is kept pressed, 10-164 ELECTRONIC CONTROL SYSTEM 2050620506 STRUCTURE AND FUNCTION 4 Monitor pane! Ful AUTO-DECELERATION FUNCTION Engine Governor motor Fue injection pum ‘Main pump Fuel control dial ELECTRONIC CONTROL SYSTEM LH, work equipment lever Boom RR puctet e Control pump CURL RAISE uM =, Soupmens Arm CO (cowe swing LeFr our W ago ||| Travel lever ax re] r [LH travel Engine throttle INCTION If all the contro! levers are at neutral when waiting for work or waiting for a dump truck, the engine speed is automatically reduced to a midrange speed to reduce fuel consumption and noise. If any lever is operated, the engine speed returns immediately to the set speed. Pump controller 10-165STRUCTURE AND FUNCTION OPERATION Control levers at neutral If the engine is running at above the deceleration actuation speed (approx. 1400 rpm), and all the control levers are returned to neutral, the engine speed drops immediately to approx. 100 rpm below the set speed to the No. 1 deceleration position. If another 4 seconds passes, the engine speed is reduced to the No. 2 deceleration position (approx. 1400 rpm}, and is kept at that speed until a lever is operated. ‘Speed (rpm) 100 No. 1 deceleration at? No. 2 deceleration (1,400) ELECTRONIC CONTROL SYSTEM When control lever is operated + If any control lever is operated when the engine speed is at No. 2 deceleration, the engine speed will immediately rise to the speed set by the fuel control dial. Levers at neutral 10-166 4 Less than 2 Less than 1 Time (eee) Lever operated 2osrosi6s. 2050620506 STRUCTURE AND FUNCTION 5. Ful ELECTRONIC CONTROL SYSTEM AUTOMATIC WARMING-UP AND ENGINE OVERHEAT PREVENTION. FUNCTION (Coolant temperature signal) Engine (Network signa INCTION If the coolant temperature is low, this automatically raises the engine speed to warm up the engine after it is started. (Automatic ‘warming-up function) In addition, if the coolant temperature rises too high during operations, it reduces the load of the pump to prevent overheating. (Engine overheat prevention function) )Coolant temperature ‘Main pump Monitor panel fh Re \ © a ion zg i Pump controler 208F06166 10-167STRUCTURE AND FUNCTION 1) Engine automatic warming-up function + After the engine is started, if the engine coot- ant temperature is low, the engine speed is ‘automatically raised to warm up the engine, ELECTRONIC CONTROL SYSTEM Conditions for actuation (both are necessary) ‘Actuation Coolant temperature: Less than 30°C Engine speed: Less than 1,400 rpm => Engine speed: 1,400 rpm Conditions for cancellation (any one) Coolant temperature: 30°C or above Cancellation Automatic : —i ‘Automatic warming-up time: ‘10 minutes or more Engine speed: As desired Fugl control dial: Held at more than Manual | 70% of full speed for more than 3 seconds. 10-168 2050620506 STRUCTURE AND FUNCTION ELECTRONIC CONTROL SYSTEM 2) Engine overheat prevention function + This function protects the engine by lowering the pump load and engine speeed to prevent overheating when the engine coolant temperature has risen too far. + This system is actuated in two stages. The first stage is when the water temperature is between 102°C and 105°C, and the second stage is when the water temperature is 105°C and above. Normal operation (coolant tempertature below 102°C) Coolant temperature: — J Selon sae {Coolant temperature Seuge" Green range) Normal operation ‘1st stage (Coolant temperature between 102°C and 105°C) ‘aan onion Fanon Fone Cancel oon Winimane_[ rene [Pome | | [Eason wreegars ea stage Coolant temperature Cys > jow 102°C jelow 102°C and 105% Mode kept as itis, eral ishing, | Mode op 2 ~ When the above condition 8 | (Cootan trperaire Breaker’ ut reduced pt te yen roe 2 | Gauge: Red range — is 5 ro the condition before the iting kept ae fUncton wae actuated {automatic reset ration 2nd stage (Coolant temperature 105°C and above) ‘Actuation condition ‘Actuation, remedy Cancel condition Working mode In any mode Coolant temperature: 8] Coolant temperature: Below 102°C | 1@C'and'above Engine speed Low idling Fuel gona dg 2 | (Cootans temperature Monitor caution lamp | Lights up low ialing position * [frise: Red one Caution buzzer ‘Sounds i Wien tie ati conciiona) ‘are met, the system returns. {fo the condition before the ‘overheat prevention {ncon ves actuated imanval reset 10-169STRUCTURE AND FUNCTION ELECTRONIC CONTROL SYSTEM 6. SWING PRIORITY FUNCTION + There is a SWING ACCEL switch on the monitor panel for the boom/swing priority selection mode. This switch can be turned ON or ‘OFF to change the matching of the boom RAISE and swing operations, The oil flow is divided and sent to the swing to match the swing angle to allow compound ‘operations to be carried out easily. Boom/swing priority selection mode OFF: ‘90° swing and loading of dump truck Boom/swing priority selection mode ON: 180° swing and loading of dump truck sro 205F06167 ‘Swing priory ° 90 180 ‘swing angle (+) praroatas) + The change in the matching between the When boom/swing priority selection mode is OFF boom RAISE and swing is carried out by changing the signal to the pump merge-divider valve. Lo Boom RAISE and swing are parallel 20sFos6t gl When boom/swing priority selection mode is ON ix ae marge ever ave wf FT (scare [ cow The boom RAISE and swing use separate pumps, so swing is independent 10-170 2050620506 STRUCTURE AND FUNCTION ELECTRONIC CONTROL SYSTEM 7. SWING CONTROL FUNCTION Work equipment lever PPC val Shute vane 4 i ! Gil pressure ewiteh Cont valve Swing brake Pump margeT— solonia valve ay Ff Jowett 3) ‘ON rome sch VJ (Swing lock switch signal) oN OFF] (Drive si (Swing lever signal) Pump controller Swing motor Monitor pane! OFF Control pump ‘Main pump FUNCTION + The system is provided with a swing lock and swing holding brake function. 10-171STRUCTURE AND FUNCTION 1). Swing lock, swing holding brake function + The swing lock (manual) can be locked at any desired position, and the swing holding brake (automatic) is interconnected with the swing, so it prevents any hydraulic drift after the swing is stopped. ¥ Operation of swing lock prolix switch if any abnormality should occur in the controller, and the swing holding brake is not actuated normally and the swing cannot be operated, the swing lock prolix switch can be operated to cancel the swing lock and allow the swing to be operated. * Even when the swing lock prolix switch is turned ON, the swing lock switch stays ON and the swing brake is not canceled ‘* When the swing brake is canceled, the swing has only a hydraulic brake operated by the safety valve, so if the swing is stopped on a slope, there may be hydraulic drift. 2) Hydraulic oil quick warm-up function when swing lock switch is ON + When the swing lock switch is turned ON, the relief pressure rises from 31.85 MPa (325 kg/cm?) to 34.79 MPa (355 kg/cm’). If the work equipment is relieved in this condition, the hydraulic oil temperature will rise more quickly and the warming-up time can be reduced. 10-172 ® ELECTRONIC CONTROL SYSTEM Task] Ter S| ae [rovaion Operation Whon swing Ioyr i placed at metal syebrans eros Shor apron soe wee ort | oFF Suing levers oprats, bake Cechaaed and ong con be Sperted realy Swing oaks actuated nd swing | nisl ston wing | Even when swing iver ON | ON | jock” | operated, swing lock is not SEncted nd sang does hot Sarg ek] OW Tw controler] — OFF han protien [ON sbnerielontoter normal Swingtok | on | om | on | oF win swing |-swing | swing | S48, Suing tock” tock | ioce [hela Sta | Canceled | sppiog | B98 2050620506 STRUCTURE AND FUNCTION ELECTRONIC CONTROL SYSTEM 8. TRAVEL CONTROL FUNCTION - Travel motor Trovl over f ! 3M vet LH. RH. 1 HH Hiunetion| { \ ee \ a eI ! Regu mm) Oe ! EA ae ' ’ i 4 sane] Lf | cu preeue! — wich t Toon rae . - ET fSemeierc onl Thm Controt pump |__t Fuel contro! ‘Main pump t Gal ' Mi M } ' ce i a Ea ag ‘ iz t i {rave lever sional -4 & (Pressure sensor aie ine Pump controller [peste srs Engine throttle Throttle signal) Monitor panel 208F08179 FUNCTION + When traveling, the pump control is carried out, and the travel speed can be selected manually or automatically to give a travel performance that suits the nature of the work of the jobsite. 10-173STRUCTURE AND FUNCTION 1) Pump control function when traveling + Ifthe travel is operated in any working mode other than the heavy-duty operation (H/O) mode, this increases the pump absorption torque while keeping the working mode and engine speed as they are. * For details, see PUMP & ENGINE MUTUAL CONTROL SYSTEM. 2) Travel speed selection function i) Manual selection using travel speed switch H the travel speed switch is set to Lo, Mi, or Hi, the pump controller controls the pump flow and motor volume at each speed range as follows to switch the travel speed. Automatic selection according to engine speed I the engine speed is reduced to below 1400 rpm by the fuel control dial: + If the machine is traveling in Lo, it will Not shift even if Mi or Hi are selected. + Ifthe machine is traveling in Mi, it will not shift even if Hi is selected. + If the machine is traveling in Hi, it will automatically shift to iii) Automatic selection according to pump discharge pressure If the machine is traveling with the travel speed switch at Hi, and the load increases, such as when traveling up a steep hill, if the travel pressure continues at 33.32 MPa (340 kglom?) for more than 0.5 sec. the motor volume is automatically switched and the travel speed changes to Mi, (The travel speed switch stays at Hi.) The machine continues to travel in Mi, and when the load is reduced, such as when the machine travels again on fiat ground or goes downhill, and the travel pressure stays at 17.64 MPa (180 kg/erm*) or less for more than 0.5 sec, the motor volume is automatically switched and the travel speed returns to Hi 10-174 ‘Travel speed ELECTRONIC CONTROL SYSTEM Trove] ta] Mew sith | wow Spee) | rang soa | gh Sond Pure fow ag 5 wo | cor [wx | mn | Min raw! spca| P0|Pa0| PCO] Pao [rca rezIO fire) 32 | 34 | 45 | 45 | 56 | 55 Te 180) ‘Travel pressure (MPa (kglem) 33.32 (340) 2osros206 k20506k20506 STRUCTURE AND FUNCTION ELECTRONIC CONTROL SYSTEM 9. _COMPONENTS OF SYSTEM 1) ENGINE SPEED SENSOR 1 2 3 4 \ 5 0.7516 E LJ Composition of circuit 206F00176 1. Wire FUNCTION 2. Magnet + The engine speed sensor is installed to the 3. Terminal ring gear portion of the engine flywheel. it 4. Housing counts electrically the number of gear teeth 5. Connector that pass in front of the sensor, and sends the results to the pump controller. + This detection is carried out by a magnet, and an electric current is generated every time the gear tooth passes in front of the magnet. 2) PPC OIL PRESSURE SWITCH 1. Plug 3 2. Switch / 3. Connector tt SPECIFICATIONS | Composition of points: N.O. points Actuation (ON) pressure: 0.49 + 0.1 MPa (5.0 + 1.0 kglem’) Reset (OFF) pressure: 0.29 + 0.05 MPa (3.0 + 0.5 kg/cm’) FUNCTION + There are 8 switches installed to the PPC shuttle valve. The operating condition of each : [27 f) actuator is detected from the PPC pressure, 2/ and this is sent to the pump controller. a Composition of ecult 10-175‘STRUCTURE AND FUNCTION ELECTRONIC CONTROL SYSTEM 3) PUMP PRESSURE SENSOR 1. Plug 2. Sensor 3. Connector FA Composition of circuit FUNCTION + This sensor is installed to the inlet port ci —- cuit of the control valve. It converts the pump discharge pressure to a voltage and sends this to the controller. ell sph OPERATION (stnnias stot + When the pressurized oil entering from the pressure introduction portion pressurizes the oa diaphragm of the pressure detection portion, the diaphragm deflects and changes sf 1 shape. | | ‘A gauge layer is installed to the face oppo- 7 site the diaphragm, and the resistance of the gauge layer converts the deflection of the diaphragm into an output voltage and 3 t sends it to the amp (voltage amplifier. | + The voltage is further amplified by the am- 2 plifier and is sent to the pump controller. + Relationship between P (kg/cm?) and output voltage (V) V = 0.008 x P + 1.0 | * 1 kg/om? = 0.098 MPa | 0100200 30000505 Pressure P(kg/cm!) Sensor output voltage 20sF0s161 10-176 k2050620506 STRUCTURE AND FUNCTION 4) PUMP CONTROLLER on-co2 en-003 en-col Input and output signals cx-cot ELECTRONIC CONTROL SYSTEM 208F06176 cn-coz cn-cos Ne Teneotrins [rewousa] [Re Tenectnps —[wentama) [he saver + [ao S 1 Soon ech woot | [A | Paenre neon S10) Tem 2 [eno S 2 [ Boom LOWER son Trout | [22 | Pressure seeor 25) = 2 [ts eet sleois ‘uo | [a | Teva eve Tepe | [22 | Prenuresenorsower2ev | — [Pomp mage avidersoois | Opa | | «| Soom RAISE swish Two | [2 S = = S = | Aen each Tepe | | 25 | Amo eclertion a | revel apne sles asa | [6 | Am out owen tnout | [a5 | Sreos ser Tea 7 | ecomel €FC -) ‘onpe | | 7 | eos cunt ewer Tope | [27 | nemon stout moniord [| — © [pero ‘usu | [6 | Bien OUP ower Tosa | [20 | Montor cre eine pera oupe | [| swine wn ee eo = 1 | Contoter power sous 267 | — 11] Medel steaion S| Tosa] fae = = 2 [1S pee ater Gasae | [72] Swirg oc etic vent | [i = : “u_[ aoe rot stra fousue | [ve tops] [at | Speeder eee 1 [eS coral BPE owe | [os Inout | [38 [Neon aut = ne [vere own | [os veo | [ae = = a [veae cese | [a = = 10-177STRUCTURE AND FUNCTION 5) TVC PROLIX RESISTOR 1. Resistor 2. Connector SPECIFICATION Resistance; 302 6) FUEL CONTROL DIAL, GOVERNOR MOTOR, ENGINE THROTTLE CONTROLLER * See ENGINE CONTROL SYSTEM. 7) MONITOR PANEL * See MONITORING SYSTEM. 8) TVC VALVE * See HYDRAULIC PUMP. 10-178 Ful 9) ELECTRONIC CONTROL SYSTEM 208F06178 INCTION This resistor acts to allow a suitable current to flow to the TVC solenoid when the TVC prolix switch is ON. No current flows when the TVC prolix switch is OFF. LS CONTROL EPC VALVE LS SELECT SOLENOID VALVE PUMP MERGE-DIVIDER SOLENOID VALVE 2-STAGE RELIEF SOLENOID VALVE TRAVEL SPEED SOLENOID VALVE SWING BRAKE SOLENOID VALVE * See EPC. SOLENOID VALVE. 2050620506 STRUCTURE AND FUNCTION MACHINE MONITOR SYSTEM Monitor panel Sensor signal sensors 5 source Battery FUNCTION + The machine monitor system uses the network circuits between the controllers and sensors installed to all parts of the machine to observe the condition of the machine. It processes this information, and displays it fon a panel to inform the operator of the condition of the machine. + The content of the information displayed on the machine can broadly be divided as follows. 1, Monitor portion This gives an alarm if any abnormality ‘occurs in the machine. 2. Gauge portion This always displays the coolant temperature and fuel level. 3. Time display 1) This normally displays the time. 2) If this is set to the machine data monitoring mode, internal data from each controller, including the monitor panel itself, are displayed. Buzzer signal MACHINE MONITOR SYSTEM Controllers 2osrosz49 3) Ifitis set to the trouble data memory mode, the trouble data for each controller, including the monitor panel itself, are displayed. 4) It displays that the system has been set to the governor motor adjustment mode and automatic vibration offset adjustment mode. 5) In emergencies, it displays abnormalities in any controller. * For details of the content of the display and the method of operation, see TROUBLESHOOTING. The monitor panel has various built-in mode selector switches, and also functions as the control panel for the electronic control system. 10-179STRUCTURE AND FUNCTION 1. MONITOR PANEL C210, 210LC-6K PC240,240LC, 240NLC-6K = OUTLINE + The monitor panel consists of the time display, monitor display, and mode selector switches. + Ithas a built-in CPU (Central Processing Unit), and processes, displays, and outputs the data from the sensors and controllers. + The time display and monitor display panels use a liquid crystal display (LCD). The mode switches are flat sheet switches. 10-180 MACHINE MONITOR SYSTEM on-Po on-Pov zosrosaso Input and output signals cnres [Lennon TS] 1 [Wontersomrsoom] =| [+ [Peotone [met 2 Jeno ower suco| ——] [2 [Ovens wo 2 [vm atieat [hoa | [2 [Sein mame To 1 Joeitesion mp] [Yao von [sania rich on [ser] [6 [wot ion 3 | wer [rete Tena] | |Reeor nie | et [Sars ino] [2 [sa tout | oor veo) [ro [eumer cae | tot [ono =] [te eoet tenses ie 73 Jae Daa] [isomer wer owt 1s |ePer Tot | [76 [engine seed | tt te [toss aon [roe] [oe] Ene wo 17 |e rire | ee 2050620506 STRUCTURE AND FUNCTION MONITOR DISPLAY ‘d 8s TIME & EG GE COOUNNNOOLODDD, 7 MACHINE MONITOR SYSTEM |. Clock Coolant temperature gauge . Fuel level gauge . Engine oil level caution lamp . Hydraulic oil level caution lamp . Preheating pilot lamp 1 2 2. 4 5. 6. 7 8. 9. 10, Engine oil pressure caution lamp 1. 12. 13. 14. 46. . Swing holding brake pilot lamp a . Battery charge caution lamp 5 . Air cleaner clogging caution lamp Coolant level caution lamp Fuel level caution lamp Coolant temperature caution lamp Overload caution (when lifting) ums 8 7 8 Low PPC pressure e of display 20806251 Symbol | Display item Display range | When engine is stopped | When engine is running Flashes and buzzer KE} | coolant tevel Below low level__| Flashes when abnormal | Eres ang Pune, Below 1,500 rpm: pelo O05 MPa | Lights up when normal oO | pans ‘Above 506 rpms | (oes out when ongine | Sneek abormal below 0.15 MPa | Starts) (1.5 kolo") DB | Azcieaner el aon ; meee en clogged OFF lashes when abnormal Lights up when normal Charge level Mien charging is | (goes out when engine defective Flashes when abnormal starts) WB) |eocine ottevet | soow ow iver | Fnehes when abnormal | OFF i] [reraute ot | suowtowinvet | Fishes when atnonmat | OFF von pong in| Light up when swing lock swith is ON, fashes Lights up for 30 seconds when soning atch i t Proheatng | During rabeating | HEAT Manatee esta a a reheating is completed 10-181 ®STRUCTURE AND FUNCTION MACHINE MONITOR SYSTEM ‘Symbol lay item Display range | When engine is stopped | When engine is running TILE 105 Flashes when’ above 102°C, flashes and buzzer ray] apenenel sounds when above 105°C eceeenlh Fuel evel Fas when below lowe level quem Fite overioad caution | when machine is close to tipping or near hydraulic unit yi «tif | Low PPC pressure | When pilot contol pressure is low * When the starting switch is turned ON, the buzzer sounds for 1 second, all the monitor display lamps light up for 3 seconds, and after this, all lamps except “Engine oil pressure" and "Charge level” go out. The "Engine oil pressure" and "Charge level" go out when the engine is started. 10-182 k2050620506 ‘STRUCTURE AND FUNCTION ‘SWITCHES 1 HO GO FO 10 6D — 2 Oo 0 0 06 GD AK Xo 4% 2 & — "—~2 1 *1G5% 6 6 8/3 —"@D @& + The switch portion consists of five mode selection switches, and the condition of the machine changes each time that any switch pressed. The LED above the switch lights up to display the present condition of the machine. MACHINE MONITOR SYSTEM Working mode switch ‘Auto-deceleration switch Boom/swing p riority mode switch 4, Travel speed switch 5. Power max/Swift slow-down switch oe _ zosroses2 ‘Switch actuation table ‘Symbol | _ Item Action’ AAR [BERENS 10 6 670 «£10 « UO + 810 + kos 4. [Si%fon | rowen ur — sees Down & [bea (ON <> OFF reaver o =| Hie Mi es bo swins me [see OFF & ON * The bold letters indicate the default position of the switch when the starting switch is turned ON. 10-183STRUCTURE AND FUNCTION MACHINE MONITOR SYSTEM 2. SENSORS + The signals from the sensors are input directly to the monitor panel. The contact type sensors are always connected at one end to the chassis GND. Name of sensor | Type of sensor | When normal | When abnormal Coolant level Contact type ON (close) OFF (open) Engine oil level | Contact type | ON (close) OFF (open) eygieulc oll | Contact type | ON (close) | OFF (open) aol Contact type | OFF (open) | ON (clos Coolant =. Coolant ure | Resistance type = = Fuel level Resistance type = = ‘ir cl ead Contact type | ON (close) | OFF (open) 1) COOLANT LEVEL SENSOR ‘Sub tank Float Sensor Connector 2osrosies: 10-184 20506STRUCTURE AND FUNCTION MACHINE MONITOR SYSTEM 2) ENGINE OIL LEVEL SENSOR 3) HYDRAULIC OIL LEVEL SENSOR 1 2 1. Connector \ [ 3. Float S 4. Switch Mh \ — . 3 4) ENGINE OIL PRESSURE SENSOR (COMMON FOR BOTH Lo AND Hi) 1. Plug 2. Contact ring 3. Contact 6. Terminal Actuation (ON) pressure Lo: 0.05 + 0.02 MPa (0.5 + 0.2 kg/cm’) or less Hi: 0.15 + 0.02 MP3 (1.5 + 0.2 kg/cm) or less Composition of circuit 20sr0si69 10-185STRUCTURE AND FUNCTION MACHINE MONITOR SYSTEM 5) COOLANT TEMPERATURE SENSOR 1 2 3 Connector Plug Thermistor ere (=) 6) FUEL LEVEL SENSOR Float Connector Cover Variable resistor PeNe 20506253, Actuation (OFF) pressure: 7.47 + 0.49 kPa (-762 + 50 mmH;0) Composition of circuit 20sF06254 2050620506 ‘TROUBLESHOOTING CHECKS BEFORE TROUBLESHOOTING CHECKS BEFORE TROUBLESHOOTING tem are | __Remedy Check fuel level > | ‘Add fuel ie teeter tear cron . ener Bek rau oe - re B | aces rt ot sie - een Bs creck ing machinery oe - nae 2 | 6. chock engine ol level (Level of olin el pan - ‘oi © 7. check cooting water evel - Add water - Check condition of dust indicator - Clean or replace ee — Si oe eee - ones Sioa soesrne seer : oat ee - ropot Pe Wc - “an SS ay ra Pr - ane By ee eee - — F | checks for getting wet onto wiring Disconnect a ocean ine . ee |. Ghee tent ge oe 278-286 replace Noearhan toca is opated ; Replece 20-63TROUBLESHOOTING CONNECTOR TYPES AND MOUNTING LOCATIONS CONNECTOR TYPES AND MOUNTING LOCATIONS psetr | type | SF] tetiea component | Mt) leer | type | SP] let component | Att A01 | KES1 | 2 | Window washer circuit | J5 E11 | RING | 1 |Heater relay A2 ‘103 | KEST | 2 |LSsolect solenoid circuit] as || Hor |S _| 16 intermediate connector | R9,G9 fave | Kesi | 2 |Pume.merge-svder sole: ae || Ho2 |S | 16 [Intermediate connector | — ‘A05 | KEST | 2 [ning brake solenoid creat | — | | N02 | $__| 16 | Intermediate connector ‘A06 | KES1 | 2 |Patage rele solenoid creat | — || HO4 | S$ _| 16 Intermediate connector ‘A07 | KES1 | 2 |Travel peed solenoid creat | — || HOS | M_ | 6 |Intermediate connector ‘A08 | KES1 | 2 [Heater circuit Ta] [Hoe | t_ | 2_ [intermediate connector ‘A09 | KES1 | 2 |Lower wiper circuit — | Ho7 | s _| 12 [intermediate connector ‘ait | KES1 | 2 [Alarm buzzer circuit | me || H0@ | M_| & |Intermediate connector ‘A13 | KEST | 2 [Starter relay circuit a7 | |_H09_|_M_| 2 [Intermediate connector A14 | KES1 | 2 | Battery relay drive circuit | | — Kor = 1_|Aircon switch ‘Ate | KES1 | 2 [Fuel shut off circuit =] [koe |x [4 [Aircon pressure switch | 15 ‘a7 | KESt | 2 [Starter ciruit wr | [Moz |x | 2 [Safety relay ci cor | mic | 17 [Pump controlier os | [Mos | M_ | 4 |Heater switch PS 02 | 040 | 20 [Pump controller = Mos | KES1 | 2 {Right front light &5 cos | 040 | 16 [Pump controller ae] [mos | Kest | 2 [Working lamp (boom) | D6 cor TX] 2 [Rear pump Te vawe Pro | |_MI0 | M_| 1 [Intermediate connector | FS: cos | S| 10 [IVC prolix switch we] Mtr [| 2 |Fusibte tink 5 cos M 2 |TVC prolix resistor PS M2 | Kest | 4 |Heater ‘Ha co7 x 3. |Rear pump pressure sensor | 19 M13 | AMP | 8 | Speaker RO cos | X | 3 [Front pump preseure sensor | — || MM | L | 2 |Fusible link 5 cog | S$ | 8 |Model selection connector | Q6 M16 | - | 1 [Horn (high sound) Fa cio | x | 2 |iScontol PC sowncidvave| ra] |_M17 | - | 1 |Hern tow sound) — cis | x | 2 [Front pump Tvcvaive | uo || MIS | M | 4 [Wiper wosher switch | 08 £01 | Mic | 21 [Engine throttle controlier| pe || M20 | ~ | — (Cigarette lighter NB E04 | x | 3 [Governor potentiometer | | | M23 |_M_| 2 |Hom swith RH. knob ewich | H4,F7] £05 |X | 4 [Governor motor Te] [M26 | ame | 11 [Air conditioner Ha 0s | M | 2 [Fuel control dial Tana] {M28 | KesO | 2 [Window washer motor | Js £07 | x | 2 [Engine speed sensor wae [Smee | 1 | Electromagnetic citch for] Ha Eos | SWP | 14 [Intermediate connector M35 x 4 | Condenser for air conditioner | 15 E10 | -_| 1 [Fuel shut off mss | M_ | 3 |Light switch 08 + The Address column in the table above shows the address in the connector arrangement drawing (2-dimensional drawing). * This table includes connectors that are not shown in the drawing. 20-64 ® 20506HOB HO3 HO7 Hoo M13 HO2 i 8 el 5 x 5 / R11 COS R10 Ros ROS W10 4 4 3 2 i EB = &‘TROUBLESHOOTING CONNECTION TABLE FOR CONNECTOR PIN NUMBERS CONNECTION TABLE FOR CONNECTOR PIN NUMBERS ‘The terms male and female refer to the pins, while the terms male housing and female housing refer to the mating portion of the housing, pins Male (female housing) Female (male housing) 1 } \ / \ f ry 4 = fot + 14 ere 2 2 1 a \_ / MAC f : i ial [= ? \ 3 a 1 Cel er oe | 4 1 “ foo 5 13 G i 2 4 4 2 | peewee 20-68 2050620506 DISASSEMBLY AND ASSEMBLY REMOVAL OF CONTROL VALVE ASSEMBLY Ay Aur the engine at low idling, operate the cylinder to the end of its stroke without relieving the circuit, lower the work equipment to the ground, then stop the engine. For details, see TESTING AND ADJUSTING, Releasing pressure in hydraulic circuit. After stopping the engine, do as follows. ‘© Loosen the oil filler cap slowly to release the pressure inside the tank. ‘© Operate the control levers. + Operate the control levers several times to release the pressure in the accumulator. © Start the engine and run at low idling for approx. 5 seconds, then stop the operation and operate the control levers. + Repeat the above operation several times to release the remaining pressure completely 1. Open engine hood, and remove divider covers (1), then disconnect intake connector. 2. Disconnect hoses (2), (3), and (4), remove 2 connec tors (6) from holder, then disconnect. % Remove the hose mounting elbow from the valve body. 3. Remove block (6). 4, Disconnect hoses (7) and (8), and block (9). + When disconnecting block (9}, loosen the mount ing bolts of the block tube flange first. 5. Disconnect tubes (10), (11), and (12), and hoses (13), (14), and (15). + Disconnect 6 tubes and 7 hoses. % With hoses (15) there is another hose under each of the hoses. CONTROL VALVEDISASSEMBLY AND ASSEMBLY 6. Disconnect hoses (16) and (17). 7. Sling control valve assembly (18), then remove ‘mounting bolts, and lift off control valve assembly. (Ce) Control valve assembly: 170 kg INSTALLATION OF CONTROL VALVE ASSEMBLY © Carry out installation in the reverse order to removal. ‘© Refiling with oil (hydraulic tank) % Add oil through the oil filler to the specified level. Run the engine to circulate the oil through the system. Then check the oil level again, © Bleeding air + Bleed the air from the circuit between the valve and the hydraulic cylinder. For details, see ‘TESTING AND ADJUSTING, Bleeding air. 30-68 CONTROL VALVE 2050620506 DISASSEMBLY AND ASSEMBLY REMOVAL OF CONTROL VALVE ASSEMBLY + T-spool control valve (1 service valve) Ay felease the remaining pressure in the hydraulic circuit. For details, see TESTING AND ADJUST- ING, Releasing pressure in hydraulic circuit. 4. Open engine hood and chassis bodywork cover, remove divider cover (1), then disconnect intake ‘connector (2) 2. Disconnect hoses (3), (4), and (5), and remove 2 ‘connectors (6) from clip, then disconnect. + Remove the hose mounting elbow from the valve body. 3. Remove block (7). 4. Disconnect hoses (8) and block (9). ‘* When disconnecting block (9), loosen the mounting bolts of the flange for the tubes at the bottom first. 5. Disconnect hose (10), and remove tube (11) and block (12) 6 Disconnect hoses (13) and (14), and remove tubes (15) and (16) CONTROL VALVE nD) ool) 30-69 @DISASSEMBLY AND ASSEMBLY 7. Remove tubes (17), (18), and (19), and disconnect hoses (20) and (21). 8 Disconnect hoses (22), (23), and (24) mounted to [7 =) CG. * @ ga7\ a] bottom of valve. 9. Lift off control valve assembly (25). Control valve assembly: 185 kg INSTALLATION OF CONTROL VALVE ASSEMBLY * T-spoo! control valve (1 service valve) © Carry out installation in the reverse order to removal ‘© Refiling with oil (hydraulic tank) %* Add oil through the oil filler to the specified level. Run the engine to circulate the oil through the system, Then check the oil level again. % Bleed the air from the circuit between the valve and the hydraulic cylinder. For details, see ‘TESTING AND ADJUSTING, Bleeding air. 30-70 CONTROL VALVE 20866615] 2050620506 DISASSEMBLY AND ASSEMBLY CONTROL VALVE From front of machine 16 17 18 19 20 21 2 My 1 oe ra RR, Right side of machine Left side of machine Front of machine 5 a From rear of machine 26 24 24 25 30 26 27 28 ai 7 12 8 b From top of machine. ara 4 1 pe a 30-73DISASSEMBLY AND ASSEMBLY ASSEMBLY OF CONTROL VALVE ASSEMBLY + Before assembling, coat the sliding surface with engine oil. 1. RiHitravel control valve, L.H. travel control valve 1) Assemble spool assembly (53) to valve body. 2) Assemble retainer (56) and spring (55) to spool, then fit O-ring to case (54) and install. Gare) Case mounting bolt: 30.9 3.4 Nm (2.9 + 0.5 kgm) 3) Assemble retainer (52) and spring (61) to spool, then fit O-ring to case (60) and instal ==) Case mounting bolt: 30.9 & 3.4 Nm (2.9 0.5 kgm) 2. Swing control valve 1) Assemble spool assembly (49) to valve body. 2) Assemble retainer (44) and spring (42)t 0 ‘spool, then fit O-ring to case (41) and install. Gz) Case mounting bol 30.9 + 3.4 Nm (29+ 0.5 kgm) 3) Assemble retainer (48), and spring (46) to ‘spool, then fit O-ring to case (48) and install w=) Case mounting bolt: 30.9 4 3.4 Nm (2.94 0.5 kgm) 3. Arm control valve, boom control valve, bucket control valve 1) Assemble spool assembly (40) to valve body. 2) Assemble retainer (44), and spring (42) to spool, then fit O-ring to case (61) and install == Case mounting bolt: 30.9 + 3.4 Nm (2.9 £ 0.5 kgrn) 3) Assemble retainer (38) and spring (38) to spool, then fit O-ring to case (37) and install. >=) Case mounting bolt: 30.9 = 3.4 Nm (2.9 + 0.5 kgm) 4. Covers 1) Fit O-ring to cover (36) and install 2). Fit O-ring to cover (35) and install. ==) Mounting bolt: 166.7 © 9.8Nm(17 + tkgm) Tighten the mounting bolts in the order shown in the diagram. 5. LS shuttle valve, pump merge-divider valve, counterbalance valve 1). Assemble valve (60) and spring (59) to valve body, and install arm counterbalance valve Go. ==) Mounting bolt: 66.2 + 7.4 Nm (6.8 + 0.8 kgm) + Tighten the mounting bolts in the order shown in the diagram. 2) Assemble valve (58) and spring (67) to valve body, and install pump mergedivider valve (33). SEE] Mounting bott: 166.3 + 9.4 Nm (17 +1 kgm) 30-74 ® ‘Tighten the mounting bolts in the order shown in the diagram. 3) Install LS shuttle valves (32) and (31). G3=) Mounting bolt: 66.2 + 7.4 Nm (6.8 + 0.8 kgm) LS select valve Install LS select valve(30). Gu LS select valve: 127.5 £19.6 Nm (13 2 kgm) Pressure compensation valves + Check marks made on each pressure compensation valve when disassembling, and install in correct position. 1) Before installing pressure compensation valves below, install check valves (28) and (22). 2). Fit O-rings, then install arm IN pressure com- Pensation valve (28], LH. travel FORWARD pressure compensation valve (27), left swing pressure compensation valve (26) boom LOWER pressure compensation valve (25), RH. travel FORWARD pressure compensation valve (24), and bucket CURL pressure compensation valve (23). 3) Fit O-rings, then install arm OUT pressure compensation valve (21), LH. travel REVERSE pressure compensation valve (20), right swing press (18), boom RAISE pressure compensation valve (18), F.H. travel REVERSE pressure compensation valve (17), and bucket DUMP pressure compensation valve (16) == Pressure compensation valve: 2255 + 19.6 Nm (23: 2 kgm) Unload valves, safety-suction valves, suction valves 1) Fit O-rings and install suction valves (18), (14), (13), and (12). GE) Suction valve: 147.1. 9.8 Nm (15 + 1 kgm) 2) Fit O-ring and installs afety-suction valves (11, (10), (9), (8), (7), and (6). GHz] Safety-suction vaive: 147.1 + 9.8. Nm (15 + 1 kom) 3) Fit O-ring and install unload valves (6) and (4). x=) Unload valve: 98.1 + 9.8 Nm (10 + 1 kgm) ‘Main reliefvalve, mair unload - LS relief valve 1). Fit O-ring and install main unload + LS reliet valve (3) GE) Main unload « LS relief valv 85.9 + 7.4 Nm (8.8 + 0.8 kgm) 2). Fit O-fing and install main relief valve (1. m=) Main relief vaive: 53.9 + 4.9 Nm (6.5 + 0.5 kam) 2050620506 DISASSEMBLY AND ASSEMBLY CONTROL VALVE From front of machine 18 17 18 19 20 21 22 ——_‘Le#t side of machine Right side of machine 5 From tear of machine 26 3B 7 gm 5 30 2 TO 6 Front of machine From top of machine "A. tftDISASSEMBLY AND ASSEMBLY DISASSEMBLY OF PUMP MERGE-DIVIDER VALVE ASSEMBLY PUMP MERGE-DIVIDER VALVE if 0 G l capa l 1. Remove plug (2) from valve body (1), then remove spring (3) and spoo! (4). Remove plate (5) 3. Remove plug (6), then remove spring (7) and spool @) Remove plug (9). * After disassembling, if there is any abnormality in body (1) or spools (4) or (8), replace the whole pump merge-divider valve assembly. ASSEMBLY OF PUMP MERGE-DIVIDER VALVE ASSEMBLY ‘* Before assembling, coat the sliding surface with engine oil 1. Fit O-ring to plug (9) and install to valve body (1) SBD Plug (9): 38.7 + 6.4.Nm (4.0 + 0.6 kar) 2. Assemble spool (8) and spring (7), then fit O-ring to plug (6) and instal GE) Plug (6): 98.7 + 5.4 Nm (4.0 + 0.6 kgm) 3, Fit O-ring to plate (5) and install to valve body. 4. Assemble spool (4) and spring (3), then fit O-ring to plug (2) and install, SED Plug (2): 152.3 + 24.8 Nm (15.5 + 25 kam) 30-76 @O 2osrossi8 2050620506 MAINTENANCE STANDARD CONTROL VALVE CONTROL VALVE ‘Figure shows 9-spool control valve (with 3 service valve). 9-spool control valve includes 6-spool, 7-spool and 8-spool control valves. re = OTD Don Gun 1047-988 5m 10672 981im (ne tim (rs tign) Bt / stands © / = ie / elt aS a Se 2 ‘ a \ ‘ ) J | 30.92 3.4Nm oan Ee EE de 2 em GMEG02+74Nm Gu 6622 74NM Go 9224 Nm {6.75 + 0.75 kgm) (6.75 + 0.75 kgm) / fbeo3btgm) J yt / wm 662274Nm Ga) 1887 298m (es 075 K9m) (irs tam WAAAAR, Stott Ee 40-17MAINTENANCE STANDARD. CONTROL VALVE Viti pd s/s / FREI 98.05 = 9.75 Nm (102 Tom) 232755 298 Nm (1721 kgm) Gu 755 +98Nm (1721 kgm) LAVA nN —— 3 Unit: mm No. Check item Criteria Remedy Standard size Repair limit Free length| Installed | installed | Free | Installed 1] Spool return spring x0.D. | length | load | tength | toad 416.5 N 3932 | Sonng if 542x348] 612 : = 2 | spring if any (42.5 kg) (34ko)_| damages or : WaOAN seen cetozmatons 2| Spool return spring seoxas] siz | BAAN | — | B84N | are found i x sexon | _ | 3146N 3] Spo! return spring sasxos] 52 | es 40-18 2050620506 MAINTENANCE STANDARD CONTROL VALVE an 4 %6,0529.750 titan 1 2 ‘ERD 85.8527.35Nm eae aim 3.924 0 dm 3.924.900 K-K (5,540. 5kgm) (5.5+0.5kgm) wet Unit mm No, Check item Criteria Remedy Standard se Rapa int Free length] Instaod | instaled | Free | Installed 1] Main untoad spring TODe | “ong | toad” | tongth | "toad reorn |_| 2087N ed a (26.6 kg) {21.3 kg) tot spin x wizn |_| son 2| Ls ralit spring maxv2| we | aSt2N Eales Spang any 3| Valve spring 23.2% 7.2 19 A12N - 33.3N damages or 8 aa Geigy | damages or ore ound. — . sesn |_| 2960N 4] Rot spring orxes| 26a | geen 2380.8 . wean |_| orn 5| Unioad spring sexta} 26 | (AN A Check valve spring 5 x .E 103.9 N - 44 N 7 aan ee 195 (10.6 kg) (0.45 kg) 40-19MAINTENANCE STANDARD CONTROL VALVE Gm IA =98Nm GE] 30232796Nm a= 29232 196Nim (824 kgm) 2am (ao 22 gm) a 1477 298Nm (152 1 kgm) / an ui 298Nm Gm 232 196Nm. GHEITS9BNm — Ga] 3232 196Nm [sete (40'= 2 kam) (521 hom) (4022 4gm) Gu 3923196 Gm W711 298Nm Gory 962.32 196Nm (40 = 2 kgm) (1521 49m) (402 kam) 7 1079-1471 Nem (11-18 kgm) 3 \ HE 2923 2 19.6NNm GR WA298Nm. Gus) 3923 196Nm (60 2 kom) (152 tkgm) (40 2kgm) 40-20 20506EEBM000500 DOW IM LAVIN ANIL KOMATSU PC210,210LC-6k PC240, 240LC. PC240NLC-6K MACHINE MODEL SERIAL NUMBER PC210, 210LC-6K K30001 and up PC240, 240LC, 240NLC-6K 30001 and up + This shop manual may contain attachments and optional equipment that are not available in your area. Please consult your local Komatsu distributor for those items you may require. Materials and specifications are subject to change without notice. + PC210, 210LC-6 mount the S6D102L-1 engine; PC240, 240LC-6 mount the SA6D102L-1 engine. For details of the engine, see the 102 Service Engine Shop Manual. © 1995 MOMATSU ‘Al Rights Reserved Printed in Belgium 04-95.04001.SP01 00-110 20 30 40 00-2 CONTENTS No. of page STRUCTURE AND FUNCTION... 280 10-1 TESTING AND ADJUSTING DISASSEMBLY AND ASSEMBLY MAINTENANCE STANDARD... 20506‘SAFETY SAFETY SAFETY NOTICE ‘SAFETY NOTICE IMPORTANT SAFETY NOTICE Komatsu for the specific purpose. 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 To prevent injury to workers, the symbol), 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 grind- ing 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, glasses, 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 ke 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 smok- ing. 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 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. 00-3SAFETY 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 19. 20. 21. 22. 23, 24, SAFETY NOTICE 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. 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. ‘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. When aligning two holes, never insert your fingers or hand. Be careful not to get your fingers caught in a hole. When measuring hydraulic pressure, check that the measuring tool is correctly assembled before taking any measurements. Take care when removing or installing the tracks of track-type machines. When removing the track, the track sepa- rates 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. 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" to “Causes” are also included in this section. DISASSEMBLY AND ASSEMBLY This section explains the order to be followed when removing, installing, disassembling or assembling each component, as well as precautions to be taken for these operations. MAINTENANCE STANDARD This section gives the judgement standards when inspecting disassembled parts. 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. 00-5FOREWORD HOW TO READ THE SHOP MANUAL VOLUMES ‘Shop manuals are issued as a guide to carrying out repairs. They are divided as follows: Chassis volume: Issued for every machine model Engine volume: Issued for each engine series Each issued as one volume to cover all models 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. Electrical volume: Attachments volum: DISTRIBUTION AND UPDATING Any additions, amendments or other changes will be sent to KOMATSU distributors. Get the most up-to-date information before you start any work. FILING METHOD 1. See the page number on the bottom of the page. File the pages in correct order. 2. Following examples show how to read the page number. Example 1 (Chassis volume): 10-3 tem 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: 10-4 12-208 10-41 12-2031 10-4.2!— Added pages —{_13.03-2 105 12-204 00-6 HOW TO READ THE SHOP MANUAL REVISED EDITION MARK When a manual is re (O@®. pages. ed, an edition mark ) is recorded on the bottom of the REVISIONS Revised pages are shown in the LIST OF RE- VISED PAGES next to the CONTENTS page. SYMBOLS So that the shop manual can be of ample prac- tical use, important safety and quality portions are marked with the following symbols. ‘Symbol A item Remarks Special safety precautions are necessary when performing the work. Safety Special technical precautions or other precautions for pre- serving standards are necessary when performing the work, Caution | Weight of parts of systems. Caution necessary when selecting hoisting wire, or when working posture is important, ete. Weight Places that require special at- tention for the tightening torque during assembly. [Tightening torque Places to be coated with ad- Cost | hesives and lubricants, ete. Places where oil, water or fuel must be added, and the capacity. Oil, water Places where oil or water must be drained, and quan- tity to be drained. iad an DrainFOREWORD HOISTING INSTRUCTIONS HOISTING Ay Heavy parts (25 kg or more) must be ifted with a hoist, etc. In the DISAS- SEMBLY AND ASSEMBLY section, every part weighing 25 kg or more is indicated clearly with the symbol 2, + 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 belo Wire ropes (Standard *Z" or "S* twist ropes without galvanizing) Rope diameter (mm) | Allowable load (tons) 10 10 n2 14 125 16 “ 22 16 28 18 36 20 44 22.4 56 30 10.0 40 18.0 50 28.0 60 40.0 HOISTING INSTRUCTIONS 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% 3) Do not sling a heavy load with one rope alone, but sling with two or more ropes symmetrically wound onto the load. B Singing 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 form- ing 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 (kg) when hoisting is made with ‘two ropes, each of which is allowed to sling up to 1000 kg vertically, at various hanging angles. When two ropes sling a load vertically, up to 2000 kg of total weight can be sus- pended. This weight becomes 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 4000 kg if they sling a 2000 kg load at a lifting angle of 150°. * The allowable load value is estimated to be one-sixth or one-seventh of the break- ing strength of the rope used. 2) Sling wire ropes from the middle portion of the hook. : B 2009} a z Ling antec) sane 00-7FOREWORI COATING MATERIALS The recommended coating materials prescribed in Komatsu Shop Manuals are listed below. COATING MATERIALS Category [Komatsu code| PartNo _O'y_| Container Main applications, features - 7 Ted preven rubber gaskets, rubber Susans, eae tot 0 | 1809 ws and cork plugs from coming out a Used in paces requiring an immediatly offs 7 e-onso | 229 | Plastic |" tive, strong adhesive. Used for Paste fexcapt 18 Teo | oa) container polyethylene, polypropylene, tetrafluoroethylene, tnd vinyl chord) rubber, metal, and non metal Masia] Features: Resistance ro heat, chemicals tr-2 | ove4o-o00g0 | soe | fase 1° Usedorantloosoning and sealant purposes for Adtesive _ bois and plug rao [om Used 0 ednete 0 solat Tor meal la, BTS (Set of eee 17-3 and hardenging|tercening | Can jeoere ‘500 9 cra [roorae-o1| 2509 | PERG, [> Used a alan or maciad alee Foaiuren Fosisiance to feat chomieas (Loete648-50)|794-129.9110/ so.ee | — |" Used at Joint portions subject to high tempere- ture Used as adhesive oF sealant Tor Gankate ad [ter [reo-tzs-so10 | 2000 | Tube |° yead,gs Ganesie or Sealant | Features Resistance fo heat Used as sealant for flange surfaces and bots a ts |roorascom| amg | can | Mh ember ceo edt prevent od as sealant for heat resistant gasket fr high | temperature latins such 0 engine precombusion chamber, exhous pipe - Features! Rositance 10 water, Used as sealant for Mange surface, thread ube |* Aso possible to use as Sealant for langes with Gasket sealant| ioe aoe aol Tube large clearance * Used as sealant for mating surfaces of final dive cose, transmission case Used a5 sealant or various Treads ip es | Prost |" lange 1e5 790-128-9080 | 1K3 | container |+ Used as sealant for tapered plugs, elbows, nip- bles of hydraulic piping Features Sicon based resistance T Rea, cod uc-s | ovsto-ocorr | 250g | tube |* Used sealant or tangesurace thread Used as seslont forall po, fina dive cao, et. Features Sicon based, auck hardening type tc-7 | osezo-oors0 | 150g | Tube |+ Used e soar or fywhae! housing, intake men S| MY | foto pan, thermostat housing. ete. ust preven Used 23 lubricant for sing parts Wo prevent tion lubricant|___ — 9940-00051 | 60.9 can squeaking) aa ° Molybdenum ‘Used to provent size or sing oT re Wea Gisutphigetw:| — — | oss4n-ono4o | 200g | Tube |’ when press ting or shrink ting bricont Used as lbriant fr linkage, bearings, et. VG-3600 General purpose type YG Lubimgeen| —c2-ut | S¥G~0LhA | varius | various |Svecteou SYGA-160CNU '$5G2-4008 sed for sarmal Temperature, Wahi Tod bearing SYG2- 0c at laces In contact with water or steam Gikiemgeme| —2-ca | SyG2at0CA-A| Verious | Various SvG2-160CA SYGA-18CNCA Nolyoaenare aed Yor places wit Tavy Tama sulphide = S¥G2-400M | 1008, Bellows type ” sree 00-8FOREWORD STANDARD TIGHTENING TORQUE STANDARD TIGHTENING TORQUE STANDARD TIGHTENING TORQUES OF BOLTS AND NUTS The following charts give the standard tightening torques of bolts and nuts. Exceptions are given in section of DISASSEMBLY AND ASSEMBLY. 1. Kgm = 9.806 Nm Thread diameter Width of bolt across flats mm mm kgm [ Nm 6 10 1.3520.15 13.2214 8 13 3.2203 31.4229 10 | 7 67207 65.7268 2 19 11.5210 112298 4 2 18.0220 177219 16 | 24 28.523 27929 18 a 3924 383239 20 30 5626 549258 2 2 76:8 745278 Py 36 94.5210 927298 2 a 135215 1320140 30 “6 17520 1720190 33 50 225225 2210240 36 55 28030 2750 +290 39 60 335235 3280340 * This torque table does not apply to the bolts with which nylon packings or other nonferrous metal washers are to be used, or which require tightening to otherwise specified torque.FOREWORD STANDARD TIGHTENING TORQUE TIGHTENING TORQUE OF SPLIT FLANGE BOLTS Use these torques for split flange bolts. rest Ba | across fats Tightening torque mm mm ‘kam Nm 10 “4 67207 65.7268 2 "7 11521 112498 16 2 20523 27929 TIGHTENING TORQUE FOR FLARED NUTS: Use these torques for flared part of nut. Tad sinter [Wid across fate Tightening traue mm mm kam Nm 14 19 2.5205 | 24.5249 18 2 522 492196 2 u 822 7852196 24 32 1423 137.3229.4 30, 36 1823 176.5+29.4 33, 4a 2025 196.1249 36 46 2525 245.2249 42 55 3025 (294.2449 00-10FOREWORD ELECTRIC WIRE CODE ELECTRIC WIRE CODE In the wiring diagrams, various colors and symbols are employed to indicate the thickness of wit 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 Iuimbor | Nambe; of i ofataraelorogs sagion] “imm) [UNIAN | Appleabe cut oss | om 032 oe 2a 12 __| Starting, lighting, signal et. 2 26 ose | 209 3a 20 | Lighting, signal etc. 5 6 032 528 48 37 | Charging and signal 15 | os 13.38 70 50 | staring (Glow plug) 0 | 080 an | in 135 starting 60 127 080 we | 136 v7e__|_ staring 10 217 ogo | 109.1 176 230 | Starting CLASSIFICATION BY COLOR AND CODE Grea Prior eigen | Charging | Ground | Staring | Lighting | Instrument | signal | Other ication pi [Code] W 8 8 R Y 6 L 1 [Pa Color] white | Black | Black Red Yelow | Green Blue 2 code] WR = Bw FW YR cw w color] White & Red | — [Black & White| Red & White | Yellow & Red [Green & White Blue & White 3 Code] WB = By FB YB cA un Color| White & Black] — [Black & Yelow | Red & Black Yellow & Blac Green & Red | Blue & Red aus Code] WL. = BR RY Ys ey v 4 |ilery = Color] White & Blue] _— _| Black & Red |Red & Yellow feliow & Greenforeen & Yelow|Blue & Yellow '. Code] WG = = RG we cB B Color] White & Green] — —___ | Red & Green [Yellow & Biue [Green & Black] Biue & Black 6 Code] — = = AL w Gt = color] — = =| Redaive frotow awnite|Green & Blue] — 00-11FOREWORD 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 mi 1. Convert 55 mm into inches. (1) Locate the number 50 line from @). (2) Locate the number 5 in the row across the top, take this as @, then draw a perpendicular line down from ®. (3) Take the point where the two lines cross as ©. This point © gives the value when converting from millimeters to inches. Therefore, 55 mm = 2.165 inches. eters to inches the vertical column at the left side, take this as @), then draw a horizontal 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. Millimeters to inches 1. mm = 0.03937 in 0 1 2 3 4 7 8 9 0 | 0 | 0.039} 0.079 | 0.118 | 0.157 10 | 0.394 | 0.433 | 0.472 | 0.512 | 0.551 20 | 0.787 | 0.827 | 0.866 | 0.906 | 0.945 30 | 1.181| 1.220] 1.260 | 1.299 | 1.339 40 | 1.575 | 1.614| 1.654 | 1.693 | 1.732 0.276 | 0.315 | 0.354 0.663 | 0.709 | 0.748 1.063 | 1.102 | 1.142 1.457 | 1.496 | 1.536 1.850 | 1.890 | 1.929 2.244 | 2.283 | 2.323 2.638 | 2.677 | 2.717 3.032 | 3.071 | 3.110 3.425 | 3.465 | 3.504 3.819 | 3.858 | 3.898 '2:362"7"'2.402 "2.447 |"2.480'] "3.520 2.756 | 2.795 | 2.835 | 2.874 | 2.913 3.150 | 3.189 | 3.228 | 3.268 | 3.307 3.543 | 3.583 | 3.622 | 3.661| 3.701 00-12FOREWORD CONVERSION TABLE Millimeters to Inches ‘mm = 0.03937 in of 1]2]s3if4)s5i]e6f]74{s 4s o | o | 0039 | 0079 | 0.118 | 0.187 | 0.197 | 0.236 | 0.276 | 0.315 | 0.354 to | 0.394 | 0.438 | 0.472 | 0.512 | 0.551 | 0.591 | 0.630 | 0.669 | 0.709 | 0.748 20 | 0.787 | 0.827 | 0.66 | 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 | 1575 | 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 | 2.263 | 2.223 60 — | 2.362 | 2.402 | 2.441 | 2.480 | 2.520 | 2.559 | 2.508 | 2.698 | 2.677 | 2.717 70 | 2.756 | 2.795 | 2835 | 2874 | 2913 | 2953 | 2.992 | 2.032 | 3071 | 3.110 20 | 3.150 3.228 | 3.268 | 3307 | 3.346 | 206 | 3.425 | 3.465 | 3504 90 | 3543 | 3503 | 3622 | 3.661 | 3701 | 2.740 | 3.700 | aero | 3958 | 2.008 Kilogram to Pound ‘kg = 2.2066 Ib T ] ° 1 2 3 4 5 6 7 8 9 ° ° 220 441| 661) 8a2| 1102] 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] 5953] 61.73) 63.93 30 66.14 | 68.34] 70.55] 72.75| 74.96] 77.16| 79.37] 8157| 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, 80 | 110.23 | 112.44 | 114.64 | 116.85 | 119.08 | 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 1198.42 | 200.62 | 202.83 | 205.03 | 207.24 | 209.44 | 211.64 | 213.85 | 216.08 | 218.26 1 00-13FOREWORD CONVERSION TABLE Liter to U.S. Gallon 1 = 0.2642 US. Gal ° 1 2 3 4 5 6 7 a | 9 o ° 0.264 | 0.528 | 0.793 | 1.057 | 1.321 | 1.585 | 1.849 | 2113 | 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 80 | 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 | 19.286 | 19.549 | 19.813 | 20.077 | 20.341 | 20.608 | 20.870 80 | 21.134 | 21.398 | 21.662 | 21.926 | 22.190 | 22.455 | 22.719 | 22.988 | 23.247 | 23.511 90 23.778 | 24.040 | 24.304 | 24.568 | 24.832 | 25.096 | 25.361 |25#25 25.889 | 26.153 1 1 Liter to U.K. Gallon .21997 U.K. Gal T 0 1 2 3 4 5 6 7 8 9 0 o 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] 3520] 3740) 3.950) 4.179 20 4399 | 4.619 | 4.839] 5.059 | 5.279 | 5.499] 5.719| 5.939) 6.159 | 6.379 30 6599 | 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 | 19.367 | 19.577 90 19.797 | 20.017 | 20.237 | 20.487 | 20.677 | 20.897 | 21.117 | 21.337 | 21.567 | 21.777 00-14FOREWORD CONVERSION TABLE kgm to ft. Ib 1 kgm = 7.233 ft. 1b 0 1 2 3 4 5 6 7 8 9 o ° 72| 145| 217] 289] 362] 434] so6| 579] 65.1 10 723| 796| 968| 940| 101.3| 1085) 115.7 | 1230 | 190.2 | 197.4 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 | 2532 | 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 | 4195 | 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 | 5135 | 520.8 | 5280 | 535.2 | 5425 | 549.7 | 5869 | 5642 | 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 | 7233 | 7305 | 737.8 | 7450 | 752.2 | 759.5) 766.7 | 7739 | 781.2 | 7884 110 795.6 | 802.9 | 810.1 | 817.3 | 824.6 | 831.8 | 839.0 | 846.3 | 853.5 | 860.7 120 | 968.0 | 875.2 | 9824 2969 | 9041 | 911.4 | 9186 | 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. | 1138.6 | 1142.8 | 1150.0 160 | 1157.3 | 11645 | 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 | 1348.3 | 1352.6 | 1359.8 | 1967.0 190 1374.3 | 1381.5 | 1388.7 | 1396.0 | 1403.2 | 1410.4 | 1417.7 | 1424.9 | 1432.1 | 1439.4FOREWORD CONVERSION TABLE kg/em? to Ib/in o 1 2 3 4 5 6 7 8 9 ° o | 12} 284] 427| seo! 711| 953] 996| 1138) 1280 10 1422| 1565 | 170.7 | 1849 | 199.1] 213.4 | 227.6 | 2418 | 2560 | 270.2 20 2845 | 298.7 | 3129 | 327.1 | 341.4| 3556 | 3698 | 3840 | 3983 4125 30 426.7 | 440.9 455.1 | 469.4 | 483.6 | 497.8 | 512.0 | 5263| 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 | 7538 | 768.1 | 7823) 7965 | 810.7 | 825.0 | 939.2 60 853.4 | 967.6 | 981.8 | 996.1 | 910.3) 9245 | 938.7 | 953.0 | 9672 | 981.4 70 995.6 | 1010 | 1024 | 1038 | 1053 | 1067 | 1081 | 1095 | 1109 | 1124 80 |1138 | 1152 | 1166 | 11 [1195 | 1209 | 1228 | 1237 | 1262 | 1266 90 1280 | 1294 | 1309 | 1323 | 1337 | 1351 | 1365 | 1380 | 1394 | 1408 yoo | 1422 | 1437 | 1451 | 1465 | 1479 | 1493 | 1508 | 1522 | 1536 | 1550 110 | 1565 | 1579 | 1593 | 1607 | 1621 | 1636 | 1650 | 1664 | 1678 | 1693 zo | 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 | 2592 | 2546 eo | 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 | 2044 | 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 |3288 | 3300 | 3314 | 3328 | 3343 | 3357 | 3371 | 3385 | 3399 240 | 3414 | 3428 | 3442 | 3456 | 3470 | 3485 | 3499 | 3513 | 3527 | 3542FOREWORD CONVERSION TABLE Temperature Fahrenheit-Contigrade Conversion ; a simple way to convert a Fahrenheit temperature reading into a Centigrade temperature reading or vice versa isto 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 Contigrade degrees, consider the conter column as a table of Fahrenheit ‘temperatures and read the corresponding Centigrade temperature in the column at the loft. If itis desired to convert from Centigrade to Fahrenheit degrees, consider the center column as @ table of Centigrade values, and read the corresponding Fahrenheit temperature on the right, 33.8°F °c of | ec ce | ec F c °F T 40.4 | 40 | 40.0 | 117 | 11 518 78 | 46 | 1148 | 27.2 | 81 1178 -372 | -35 | -310 | -111 | 12 | 536 | 93} 47 | 1166 | 278 | @2 | 1796 -344 | -30 | -220 | -106 | 13 | 554] a9] 43 | 1186 | 203 | 93 | 1814 -317 | -25 | -130 | -100 | 14 | 572 | 94] 49 | 1202 | 209 | e¢ | 1032 -289 | -20 | -40 | -94| 15 | 590] 100] 50 | 1220 | 204 | 85 | 188.0 23 | -19 | -22| -89| 16 | 608 | 106 | 81 | 1238 | 300 | a6 | 1858 -78|-18 | -04| -83 | 17 | 626] 111 | 52 | 1256 | 306 | 87 | 1086 272 | -17 14 | -78 | 18 | 664 | a7 | 53 | 1274] 311 | 88 | 1904 -26.7 | -16 32 | 72| 1 | 662] 122) 54 | 1292 | a7 | a9 | 1922 -26.1 | 15 50 | -7| 2 | 630 | 128) 55 | 1310 | 322 | 90 | 1940 25.6 | 14 es | -01| 21 | se | 133) 56 | 1328 | s28 | 91 | 1958 -25.0 | -13 ac | -s6| 2 | m6] 139) 57 | 1346 | 333 | 92 | 1976 -244 | -12 | 104 | 50 | 23 | 734 | 144 | 58 | 1364 | 339 | 93 | 199.4 -239 | -11 | 122 | 44 | 26 | 752] 150 | 59 | 1382 | 344] 94 | 2012 -233 | -10 | wo} -39| 2 | 770 | 156 | 60 | 1400 | 350 | 95 | 2030 28 | -9 18 | -33 | 26 7s | 161] 61 | 1418 | 356 | 96 | 2048 222) 8 76 | -28 | 27 806 | 167 | 62 143.6 | 36.1 | 97 206.6 217 | -7 | 194 | -22| 28 | s24 | 72] 63 | 1454 | 367 | 98 | 2084 ara | 6 | 22] -7 | 29 | saz | we] 66 | 1472 | 372 | 99 | 2102 206 | -5 | 230] -11 | 30 | g60 | 123] 65 | 1490 | 378 | 100 | 2120 200 | -4 | 28 | -o6 | 31 | s78| 129 | 66 | 1508 | 406 | 105 | 221.0 -194 | -3 | 26] 0 | 32 | 96] 194] 67 | 1526 | 433 | 110 | 2300 -199 | 2 | 24] 06 | 33 | 914 | 200 | 68 | 1544 | 461 | 115 | 2390 ~183 | -1 | 302] 11] 34 | 932 | 206 | 63 | 1562 | 489 | 120 | 2480 -78 | 0 | 320] 17 | 35 | 950] 211 | 70 | 1580 | 517 | 125 | 2570 -72| 1 | 338 | 22] 36 | 968 | 217] 71 | 1598 | 544 | 130 | 2660 167 2 | 356 28 | 37 g9a6 | 222 | 72 | 1616 | 572 | 135 | 2750 161 | 3 | 374 | 33 | 38 | 1004 | 228 | 73 | 1634 | 600 | 140 | 2840 156 | 4 | 392] 39 | 39 | 1022 | 233 | 74 | 1052 | 627 | 145 | 2930 150 | 5 | 410 | 44 | 40 | 1080] 239} 75 | 1670 | 656 | 150 | 3020 144 | 6 | 428 | 50] 41 | 1058] 244] 76 | 1688 | 683 | 155 | 311.0 -139 | 7 | 46 | 56 | 42 | 076 | 250 | 77 | 1706 | 71.1 | 160 | 3200 133 | 8 | 464 | 61 | 43 | 1094] 256 | 78 | 1724 | 739 | 165 | 3200 128 | 9 | 42 | 67) 44 | 1112} 261 | 79 | 1742 | 767 | 170 | 3380 122 | 10 | 800 | 72] 4 | 1130 | 267 | 80 | 1760 | 704 | 175 | 347.0 00-172020506 20 TESTING AND ADJUSTING 20-2 20-13 Table of judgement standard value. ‘Standard value table for electrical part ‘Checking and adjusting belt tension for air conditioner compressor see 20-22 Adjusting engine speed sensor.. w= 20-28 Testing and adjusting governor motor lever stroke 20-24 Testing clearance of swing circle bearing ...... 20-26 Testing and adjusting track shoe tension Testing and adjusting hydraulic pressure in work equipment, swing, travel circuit... 20-28 Testing and adjusting TVC valve output pressure (servo piston input pressure)... 20-32 Testing and adjusting LS valve output pressure (servo piston input pressure) and LS differenti Testing and adjusting control pump circuit oil pressure. : sve 20-27 20-34 20-37 Testing EPC valve, solenoid valve output pressur Measuring PPC valve output pressure and testing PPC shuttle valve Adjusting work equipment + swing PPC valve Adjusting travel lever .. Testing travel deviation : Testing locations causing hydraulic drift of work equipment. 20-39 20-41 20-43 20-44 20-45 20-46 ‘Measuring oil leakage 20-48 Releasing remaining pressure in hydraulic circuit. 20-49 Bleeding air ‘TROUBLESHOOTING Aiviven carrying out testing, adjusting, or troubleshooting, park the machine on level ground and use the safety pins and blocks to prevent the machine from moving. Aidt carrying out work together with other workers, always use signals and donot let unauthorized people ‘near the machine. Ai Wnen checking the water level, sways wat forthe water to ool down, H the radiator cap is removed when the water is tll hot, the water wil spurt out and cause burns Ai50 careful not to get caught inthe fan, fan belt, o other rotating parts 20-1TESTING AND ADJUSTING TABLE OF JUDGEMENT STANDARD VALUE © FOR ENGINE TABLE OF JUDGEMENT STANDARD VALUE Machine model Pc210-6K. Po2so-sk Engine seDt02L, ‘sasD1021, — Measurement conditions | unt | Stenders | Permissible | Standard | Permissibie | value ‘value value Value | Working rom | 2,130 + 60 - 2,300 = 60 a | High iting | Traveling | cpm | 2,390260| — - 2,490 + 60 - Engine speed Low iating rom | 1,066 + 66 : 1086 + 66 - Working | pm | 1.950 - 2,100 - Rated speed |— — Traveling | rom | 2,200 - 2,300 - 2050620506 ‘TESTING AND ADJUSTING © FOR CHASSIS ‘+ The standard values and permissible values shown in this table are all values for H/O (heavy-duty operation) TABLE OF JUDGEMENT STANDARD VALUE mode. Machine mode! C210, 240-6K Cate tem Measurement conditions Unit ‘Standard value, | Permissible value sory | = Engine at high idling | | + Hydraulic oil temperature: Pato bet) eeaie) ecaae} Jorma |. 45 55°C z ‘+ Coolant temperature: = ‘hin operating range 2380 100 | 23502100 | ~ - & | At2-pumo +_2:pump reli Arm rat 2 | rotet £ Arm rele ‘om £ Atsrmlg|* fenal ver operated in sa 2200 + 100 | 2.300. 100 | 2200. 100 | 200+ 100 «Engine at high ting Speed when auto. | Fue control cl at MAX 7 deceleration is operated |+ Control lever at neutral 1400s 120 1400 « 120 Boom contol valve e[-[e fetal | Arm contra valve & | suctet conve vave . | mm 3 oss0sless05| - |oss0s/95+05 ® | swing control valve | ‘Travel control valve sere Center of tever knob Max. 84 Boom control fever + Read max. value to end of 7628 | Min. 68 tev! : & | arm control le + Engine stopped | Max. 84 g |" - + Excluding neutral play 1628 Min. 68 z & | eucret comrot iver 7828 | Mores 8 = Max. 84 3 | swing conto! ver 7x8 mntae : Max. 125 E | travel conto ever M5201 Min, 108 Play of contol lever Max. 10 Max. 15 | + Engine at high idling 17.7239 Max. 24.5 Boom control lever |7 OiMtemperature: 45> 55°C | (18204) (Max. 2.5) i * GheontTever knob to | 177539 Max. 245 ‘Arm control lever measure (18 + 0.4) (Max. 2.5) + Mesure mox. value to end ase __|_meo.— a oavel Max. 218 cket control lever » ei a) | wax 26 Swing conto! lever 4 5 +04) (Max. 22) 245259 1 Max. 292 Travel conteol lover (25 0.6) (Max. 4.0) 7482 186 Max. 1078 Pedal (76 = 1.9) (Max. 11) 20-3TESTING AND ADJUSTING TABLE OF JUDGEMENT STANDARD VALUE Machine mode Pcato, 240-8K Cate- tem Measurement conditions. Unit ‘Standard value Permissible value oy Hyena a Tampa Boom ee 45 - 55°C 31.85 + 0.98 33.81 (ex 345) + tt pressure wi engi is 290 Ma 30 (Me to Bt high ing aleve ony ‘am ses hctneonrees we 1 Batten are when Mn “5% dr 228 (onan | Bucket eer mo con wed (oos=%5 win. 33.81 (Min 3 rere +, Pump outlet por pressure 147 [og5 415 Max 3087 (Max.315 swing “RE ova eae reor 3% (205°%5 Max 3087, (Max 28) Petes fo elo one ; Hi 1 oom 18) | Moa228 Man 30 § [ree 2u70%}% (578) | ME I i | “08 [8 Won 355 (on 38 © | contr pum psf 2909 (a0 ee is rot pump jones] 29e'0% (20°a) | Min ese (Min: 20 iets oF rampaatore: [pact \s atterentat pressure |. eee Regt |rouonpener 21620006 2221) | 218 0088 2 = nis [tae ae conto ever Sena + Engin at ig Ena Normal Tye yavecutpet | yd o |, [ormon Biaton input prssure) | MPSS: Ipanpjvon + IRHIO mode |"*F[Power || leis as 20-4 2050620506 TESTING AND ADJUSTING TABLE OF JUDGEMENT STANDARD VALUE Mochine mode pczi0, 240-6 Cate-) tem Measurement conditions Unit. ‘Standard value Permissible value ee Wort enpman Won och pezio | pczao | porta | peat me Swing bate enle ea, | ta 100 | Moe30 | max 20 | moe 160 an « Ent ih ng + FORRES Planar: 55° | 1 rts Subse tat a | Seg rea Se moves Werk equipment Max ech et 80" 31203 a0 ee a2) Max. 3.8. Tie tate oat crew ce | ray : rosso | Engine at high idling 180" | Hydraulic oll temperature: 45 ~ 55°C | 48206 | 46205 | Max. 64 | Man. 55 at ce Finest, awin 90" ae 180" om sting sean _ > ‘Wor gpm Wx ach T ; | Time taken owing — wwe. | 24222 |2402.28] Max 0 | sox 20 + Engine thigh ing ee | 1 SOUS SPlrpelaure: 8-56 | eae | ae Sete and maar te | drat of ening zosteeee | mm ‘ o LARUE pert: 560 | Lee eae tas Seager | See ye sere cite oer ee eee te match mare move | apart after 5 minutes Leatape rom swing |= SoG sapere 8-550 |, ‘motor + Swing lock switch ON erin. Max. 5 Max. 10 20-5TESTING AND ADJUSTING ‘TABLE OF JUDGEMENT STANDARD VALUE ‘Machine mode! C210, 240-6K cate tem ‘Measurement conditions Unit | Standard valve | Permissible value sory pcz10 | pcz4o | Pc210 | | sto. | sro: | sto: | 5 soz? | e227 | ae te: te tc sto: Fi jaa5 45s Travel speed (1 | wa | sa e + Engine at high idling 255-49 1 Hiydiouie oi temperature: + in WO mode eosee sto: | sto, | sto: | sto 1 Ralee task on one side at atime, | Hi zisz2| 22 [ss-3is| 2733 f fotste one tun, tan measure tne tee) Me” |e) Me {ata for nent’ rns with 0 oud go2s | av=25 | 275-35 | 225-36 bo 225238 210235| 20-28 | 20-28 “Travel speed (2) 7 .| mi | soc. [160228 160225) 145-21| 145-21 ‘208F06708 | 8 Engine at high iting 8 rule ol tomperature: ‘ye i 55 x : + In HO mode z 2 Runup'iorst least 10 m, ana | wi | raver] w92t | 12-18 | 12-15 ‘measure time taken to travel next 20m on fat ground, 208F06704 + Engine at high fling { Hydraulis oll temperature: & 55°C | { Run'up for at least 10 m, and measure oviation when traveling next 20 mon fist ground, ‘Travel deviation ++ Use 9 hard horizontal surface. mm ‘Max. 200, 300 20m | 10m + Mossure dimension x z9sr2aca 20-6TESTING AND ADJUSTING ‘TABLE OF JUDGEMENT STANDARD VALUE Machine model PO2t0, 240-6 Cate- tem Measurement Unit | Standard value [Permissible value gory conditions | Hydraulic drift of | * Engine stopped mm Oo 0 travel + Hysraute ol temperate 45-65°C + Stop machine on 12" slope with ‘sprocko facing straight up the slope. ‘+ Measure the distance the machine _ moves in 5 minutes, Leakage of travel motor Lexie | Zim 136 272 zosrosroe | + Engine at high iting ‘+ Hydraulic oll temperature: 43-550 | + Lock shoas and relieve travel | cieut Total work | Posture for measurement equipment (rydraulic dit attip of Max. 600 Max.900 bucket teeth) =| Boom z scaidno ta 8) cylinder fee ae 5 (amount of ee Max. 18 Max.27 % | F)retraction of EB |g evtinder) 3 iE + Plann ahve pote ee nm — < measure extension o¢roaction of [5] Amoylinder | cach cylinder downward movement & | g|(amountot | atipol bucket tet Z| extension ot | + Bucket: Rated toad Max. 160 Max. 240 3 cylinder) | + Horizoota, fat ground 2 + Lovers at neutral + Engine stopped Bucket * Hoi aterperatie: oylinder + Start measuring immediately ater (amount ot |" Settng retraction of | + Measure hydraulic drift every 5 Max. 35 Max. 53 eylinder) minutes, an judge fom rests for ‘Sminuies 20-7TESTING AND ADJUSTING ‘TABLE OF JUDGEMENT STANDARD VALUE ‘Appicable model Poet, 240-6K Cate is Measurement Unit | Standard value] Pormissibe value oy ~S a Poato | poeso | Pozi | Poaso Bucket teeth in Q contact with = 35404 | 3.7404 | Max43 | Max.43 ground : ‘otros I eri G| | 29203 | o2203| wera | vera . ‘Hycaule of tempoetre 24z03 Max. 28 Oyindor aly | Ee g oxi ln HIO mode 3B] Arm | Cylinder fully z 3.6404 | 3.8404 | Max4.5 | Max. 4,7 8 reraced z al dea | 7P9!n@ at ih iting 5 29+03| 31403 | Max.37 | Max.39 | Fully exten + Hydraulic ol temperature: 3 ous sintoO mode Bucket : Gylinder fu Zz em “ a F] | sszos| s7s06| noxae | manas E ! Torn |) z Fully extended | + Engine at high ialine g I u See 2 26403 | 27403 | Max.28 | Max.29 2 45 - 55°C a sin FiO rode 208F007 Max. 1.0 Max.12 oom | tower doom and measure tie taton for pint wher bck ol trate gud top where 2 shessi tan fom gourd : ‘adapter to the connector flange Ifthe condition is a8 shown in the table below, [3) Turn starting § itis normal button OFF i 2: |e | disconneet 5 5 ‘connector POS, 3 g ‘TRaise | max. | |2)Drain ol, then 2 | yaraute ot roo imate) | f remove sensor. 5 | level sonsor 2 | 4 Insor | 3 ‘T-adapter into £ é sensor. S 2 thower | agin. 1 Moe 2 4 | Whe condition is as shown in the table below, | 1) Stan engine & | kis normal 2} Bisconnect eit Pu PI eridemaier | % 7 Fatma | 8 Air cleaner normal Continuity pirates 5 ‘Air cleaner clogged No continuity ‘connector st i Sensor ond to 2 measure. 20-21CHECKING AND ADJUSTING BELT TENSION TESTING AND ADJUSTING FOR AIR CONDITIONER COMPRESSOR CHECKING AND ADJUSTING BELT TENSION FOR AIR CONDITIONER COMPRESSOR CHECKING 1. Remove belt guard ©. 2. Press compressor drive belt midway between fan pulley and compressor pulley. The belt should normally deflect by about 15-18 mm (0.60-0.70 inch) when pressed with the finger (with a force of approx. 6kg (13 1b). ADJUSTING 1. Loosen two nuts and bolts ©. 2. tighten belt to tightness criteria. Tighten lower bolt to hold in position. 3. Tighten upper bolt. 4. Check each pulley for damage, wear of the V-groove and wear of the V-belt. In particular, be sure to check the V-belt is not touching the bottom of the V-groove. 5. Replace belt if it has streched, leaving no allowance for adjustment, or if there is a cut or crack on belt. 6. Refit belt guard. 7. When the new belt is set, readjust it after operating for one hour. 20-22 2050820506 TESTING AND ADJUSTING ADJUSTING ENGINE SPEED SENSOR ‘Screw in until the tip of sensor (1) contacts gear (2). | When gear (2) contacts sensor (1), turn back one turn. Tighten locknut (3) Be particularly careful when securing the sensor wiring to ensure that no excessive force is brought to bear on the wiring. Be careful not to let the tip of the sensor be scratched or to let any iron particles stick to the sensor tip. sono ADJUSTING ENGINE SPEED SENSOR 202F06298 |_| cee 2osrosz22 20-23TESTING AND ADJUSTING TESTING AND ADJUSTING GOVERNOR MOTOR LEVER STROKE TESTING AND ADJUSTING GOVERNOR MOTOR LEVER STROKE TESTING ‘Use the governor motor adjustment mode. 1. In the time mode display, keep the time switch + travel speed RH. switch + working mode RLH. switch pressed for 2.5 seconds. 2. In this condition, check the governor lever and spring rod. 3. After checking, repeat the procedure in Step 1) to finish the governor motor adjustment mode. ADJUSTING 1. Turn the starting switch OFF, then remove the nut and disconnect joint (1) from governor lever (4). 2. Repeat the procedure in Step 1-1) above to set to the governor motor adjustment mode. 3. Set governor lever (4) to a position where it contacts the full speed stopper (5) of the injection pump, then adjust the length of spring assembly (2) and rod (3), and connect joint (1) with the nut, ‘4. From the above position, turn joint (1) back 4 turns, and secure in position with locknut (6). * Caution When the spring assembly is removed and the starting switch is at the OFF position, if the governor motor lever is moved suddenly, the governor motor ill generate electricity, and this may cause a failure in the engine throttle controller, Engine governor lever Low idle stop 4 Full speed stop (6) Front face of evlinder block F20 Full speed View "A" tate 20-24 2050620506 TESTING AND ADJUSTING TESTING AND ADJUSTING GOVERNOR MOTOR LEVER STROKE 5. Confirm engine speeds are within tolerance according to: No load engine speeds Condition | Fuel aiat | Pc210_| _PC24o Tow idle 71086 = 66 | 1,065 = 65 Auto warm up | Min. | 1.200260 | 1,200 + 60 ‘Auto decel Max. | 1.400260 | 1,400 + 60 Lo. Max. | 1710260 | 1,800 = 60 6.0, FO. Max. | 2.050260 | 2,120 = 60 Ho. Max. | 2,132.60 | 2,200 + 60 Travel * Max._| 2,390 260 | 2,490 = 60 To check travel condition, ensure H.0. working mode is selected then move travel le F so that ‘auto decel is cancel but machine does not move. 20-25TESTING AND ADJUSTING TESTING CLEARANCE OF SWING CIRCLE BEARING Method of testing cl mounted on machine 1. Fix a magnet-type dial gauge to the outer circle (or inner circle) of the swing circle, and put the tip of the probe in contact with the inner circle (or outer circle. Set the dial gauge at the front or rear. ince of swing circle bearing when 2. Extend the work equipment to the maximum reach, and set the tip of the bucket to the same height as the bottom of the revolving frame. When this is done, the upper structure will tit for- ‘ward, so the front will go down and the rear will rise. 3. Set the dial gauge to the zero point. 4 Set the arm more or less at right angles to the ground surface, then lower the boom until the front of the machine comes off the ground. When this is done, the upper structure will tilt back, 0 the front will rise and the rear will go down. 5. Read the value on the dial gauge at this point. The value on the dial gauge is the clearance of the swing circle bearing. By Wire n carrying out the measurement, do not put your hand or feet under the undercarriage. 6. Return to the condition in Step 2, and check that the dial gauge has returned to the zero point. If it has not returned to the zero point, repeat Steps 2 to 5. 20-26 TESTING CLEARANCE OF SWING CIRCLE BEARING Oaer oe ae art tse Tack ame D) [Fir tome Dial a yD! on r2onosaos TTT 7 r20s0s906 | 8 i al 7 20805907 20506k20506 TESTING AND ADJUSTING TESTING AND ADJUSTING TRACK SHOE TENSION TESTING AND ADJUSTING TRACK SHOE TENSION -— TESTING 1. Raise the track frame using the arm and boom, and measure the clearance between the bottom of the track frame and the top of the track shoe, Clearance: 303 + 20 mm Measurement position Track frame C210: ‘4th track roller from the sprocket. PC2IOLC : Sth track roller from the sprocket. C240: Midway between the 4th and 5th track roller from the sprocket. PC240LC _: Midway between the Sth and 6th track roller from the sprocket. PC240NLC: Sth track roller from the sprocket. ADJUSTING i + If the track shoe tension is not within the standard value, adjust as follows. | 1. When the tension is too high: Loosen plug (1) gradually, and release the grease. | There is danger that the plug may fly out under A the high internal pressure of the grease, so never loosen plug (1) more than 1 turn. 4 Ifthe grease does not come out easily, move the machine backwards or forwards slowly. “Track shoe 2. If track is too loose: Pump in grease through grease fitting (2). If the grease cannot be pumped in easily, move the machine backwards and forwards slowly. 20-27TESTING AND ADJUSTING HYDRAULIC PRESSURE TESTING AND ADJUSTING IN WORK EQUIPMENT, SWING, TRAVEL CIRCUIT TESTING AND ADJUSTING HYDRAULIC PRESSURE IN WORK EQUIPMENT, SWING, TRAVEL CIRCUIT MEASURING % Hydraulic oll temperature when measuring: 45 — 55C Bi Lower the work equipment to the ground and stop the engine. Loosen the ol filer cap slowly to release the pressure inside the hycraulc tank ‘Then put the safety lock lever in the LOCK posi tion. Remove pressure pick-up plug (1) of 2) (Thread dia=t0mm, Pitche! 25mm) fom the circuit to be measured, then intall ll pressure gauge C:(52.8 MPa (600 kglem) @ Measuring main unload pressure Unload pressure when front and rear pump flows ‘are merged Measure the oil pressure in H/O mode with the engine at high idling and the control levers at neutral © Measuring sub-unioad pressure % The unload pressure in the circuit which is not under load when the front and rear pump flows are divided. 1. Set to HIO mode + boom/swing priority selection mode ON. 2. Measure the pressure in the pump circuit on the opposite side when the arm or bucket circuit is relieved. Arm relief: load on front pump, rear pump un- loaded. Bucket relief : load on rear pump, front pump un- loaded, ¢ Measuring pump relief pressure 1. When LS relief valve is actuated When hydraulic pressure is 31.9 MPa (325 ka/ em’) 1) Measure the pressure when each actuator ‘except the travel actuator is relieved in H/O mode with the engine at high idling, ‘Note that the set pressure of the safety valve for the swing motor and head end of the boom is lower than the LS relief pressure, so the value measured will be the relief pressure of the safety valve. If the swing lock switch is ON, the pressure will rise, s0 always keep the lock switch OFF when measuring. 20-28 Table 1 Combination of pumps and actuators controlled when flow from front and rear pumps is divided Pump Controlled actuator ¢ Arm cylinder Front pump ¢ Swing motor # ¢ LH. travel motor Boom eyoder# near pump |e Bunk eyincer |S pa oevet moor The set pressure of the safety valve at the head fend and the swing motor is lower than the set pressure of the main relief valve. 2050620506 TESTING AND ADJUSTING HYDRAULIC PRESSURE TESTING AND ADJUSTING IN WORK EQUIPMENT, SWING, TRAVEL CIRCUIT 2. When pressure rises to 34.8 MPa (356 kg/cm’) * Main relief valve actuated 1) When travel is operated Measure the hydraulic pressure when the travel is relieved on each side separately in H/O mode with the engine at high idling. ‘To relieve the travel circuit, put block @ Under the track shoe grouser, or put block © between the sprocket and frame to lock the track. 2) When power max. function is actuated When measuring the oil pressure in G/O or H/O mode with the engine at high idling and zoreorn16|| the power max. function actuated, relieve one of the boom, arm, or bucket circuits, and measure the oil pressure. ADJUSTING 1. LS relief valve 1) Loosen nut (1) s0 that elbow (2) can move. 2) Loosen locknut (3), then turn holder (4) to adjust, % Turn the holder to adjust as follows. ¢ To INCREASE pressure, turn CLOCKWISE, © To DECREASE pressure, turn COUN- ‘TERCLOCKWISE. 4 205F06320 2. Main relief valve @ Loosen locknut (1), then turn adjustment screw (2) to adjust. + Turn the adjustment screw to adjust as follows To INCREASE pressure, turn CLOCKWISE. To DECREASE pressure, turn COUN- TERCLOCKWISE. % Amount of adjustment for one turn of adjustment screw: 12.6 MPa (128 ka/om?) 2osross2!‘TESTING AND ADJUSTING HYDRAULIC PRESSURE TESTING AND ADJUSTING IN WORK EQUIPMENT, SWING, TRAVEL CIRCUIT 3. Swing motor safety valve ¢ Loosen locknut (1), then turn adjustment screw (2) to adjust % Turn the adjustment screw to adjust as follows. ‘© To INCREASE pressure, turn CLOCKWISE, @ To DECREASE pressure, turn COUN. TERCLOCKWISE. 20-30 20506‘TESTING AND ADJUSTING TVC VALVE OUTPUT TESTING AND ADJUSTING PRESSURE (SERVO PISTON INPUT PRESSURE) TESTING AND ADJUSTING TVC VALVE OUTPUT PRESSURE (SERVO PISTON INPUT PRESSURE) (MEASURING Hydraulic oil temperature when measuring: 45 ~ 55°C @ Measure the oll pressure when the circuit is relieved in the power max. mode. 1) Remove pressure measurement plugs (1), (2) (3), ‘and (4) (Thread dia.=10 mm, Pitch=1.5 mm), and install oil pressure gauge Cs. Install a 39.2 MPa (400 kg/cm’) gauge to the servo valve end, and a 58.8 MPa (600 kg/cm’) gauge to the pump outlet port end. 2). Set the swing lock switch ON. 3) Set the working mode to H/O mode. 4) Run the engine at high idling, turn the L. H. knob switch ON, and measure the oil pressure when the arm IN circuit is relieved ‘Check that the servo piston input pressure is 12 of the pump discharge pressure. [Referencel If there is any abnormality in the LS valve or servo piston, the servo piston input pressure will be almost the same or 0 of the pump discharge pressure. 2050620506 TESTING AND ADJUSTING ADJUSTING * If the load becomes larger, the engine speed will drop. Or if the engine speed remains normal, the work equipment speed will drop. In such cases, if the pump discharge pressure and LS differential pressure are normal, adjust the TVC valve as follows. There are two sets, so adjust both the front and rear to the same angle. Loosen locknut (3), and if the speed is slow, turn screw (4) to the left; if the engine speed drops, turn the screw to the right. ‘If the screw is turned to the left, the pump absorption torque will be increased, and if it is turned to the right, the pump absorption torque will be reduced. There is also a connection with the angle, so see Note below. % The adjustment range for the screw is a mai mum of 90° to both the left and right. After completing the adjustment, tighten the locknut. Gw=I Locknut : 29.4 = 4.9 Nm (3.0 + 0.5 kgm) Note: The screw is an eccentric cam, so if it is turned from position @ in the graph, the stroke of the servo piston will move as shown in the graph. If it is turned one full turn, it will return to the original Position, but the screw will become looser, so there will be play in the screw. Therefore, turn the screw @ maximum of 90° to the left and right from the position @ set when the machine was shipped. TESTING AND ADJUSTING TVG VALVE OUTPUT PRESSURE (SERVO PISTON INPUT PRESSURE) Punch mark showing ‘eccentric postion 4 a Hi | BEE postion when BE | rome 5 : ‘ fe : Postion when lt iad | ? 90 180. 320 Position of screw when shipped ‘eccentric position 7202708961 20-33TESTING AND ADJUSTING LS VALVE OUTPUT PRESSURE (SERVO TESTING AND ADJUSTING _PISTON INPUT PRESSURE) AND LS DIFFERENTIAL PRESSURE TESTING AND ADJUSTING LS VALVE OUTPUT PRESSURE (SERVO PISTON INPUT PRESSURE) AND LS DIFFERENTIAL PRESSURE Hydraulic oil temperature when measuring: 45 ~ 55°C MEASURING 1 Measuring LS valve output pressure (servo piston input pressure) 1) Remove pressure measurement plugs (1), (2) (3), and (4) (Thread dia.= 10 mm, Pitch=1.5 mm), and install oil pressure gauge Cr. Install a 39.2 MPa (400 kg/cm*) gauge to the servo valve end, and a 58.8 MPa (600 kg/cm’) gauge to the pump outlet port end. ‘© Oil pressure when travel is rotating under no load on one side ') Set the working mode to H/O mode, and set, the travel speed switch to Hi. ii) Use the work equipment to raise the track ‘assembly on one side. iii). Measure the oil pressure with the engine at high idling and the travel lever operated to the end of its stroke to rotate the track under no load, Run the engine at high idling, operate the travel lever to the end of its stroke, and measure the oil pressure when the working mode and travel speed are switched as shown in Table 1. Table 1 [Servo Pump Working | Travel | pressure {Piston inlet mode | lever | (MPa. [Port pres- | Remarks (kgiom2y [sure (MPa kg/cm’) | About i372 = 099/372 = 068 10 mode | Neural /272,2 089 [872 069] Some About 262 = 196] 441 «098 WO mode) fur |g Say) Hs tr) (2, 2050620506 TESTING AND ADJUSTING TESTING AND ADJUSTING LS VALVE OUTPUT PRESSURE (SERVO 2. Measuring LS differential pressure 1) Measuring with a differential pressure gauge a Remove oil pressure measurement plugs (5) and (6) (Thread dia.=10mm, Pitch=1.5mm), and install differential pressure gauge Cs Set to the conditions in Table 2 and measure the LS differential pressure. Tabie2 Dieronia Working [Fuel control Working |Fuel contr | Operation [pressure Rigetgen Covers ot | 296 + 098 Eolas) rae neutral (30 + 10) Travel peed: Hi | Travel veut | a 46 201 Wo mode] MAX [under no toad | 2282 | tower fly | operated 2) Measuring with oil pressure gauge % The maximum differential pressure is 294 iip iio vw MPa (30 kg/cm’), so measure with the same gauge. Remove oil pressure measurement plugs (5) and (6) (thread dia.=10mm, pitch=1.5mm), and install the plug inside hydraulic tester Cr Install oil pressure gauge Cs (58.8 MPa (600 kglem*)) to the measurement plug for the pump discharge pressure. Use a gauge with a scale in units of 0.98 MPa (10 kg/cm). (If no 58.8 MPa (600 kg/cm") pressure gauge is available, a 39.2 MPa (400 kg/ em*) pressure gauge can be used.) ‘Set to the conditions in Table 2 and measure the pump discharge pressure. % Stand directly in front of the indicator and be sure to read it correctly. Remove oil pressure gauge Gs, then install to the LS pressure measurement plug, Set to the conditions in Table 2 and measure the LS pressure. %* Stand directly in front of the indicator and be sure to read it correctly. © Pump discharge pressure ~ LS pressure = Differential pressure PISTON INPUT PRESSURE) AND LS DIFFERENTIAL PRESSURE. 205F06328| Difrential pressure none / Vi / | 20-35TESTING AND ADJUSTING ‘TESTING AND ADJUSTING LS VALVE OUTPUT PRESSURE (SERVO ADJUSTING 1 Adjusting LS valve When the differential pressure is measured under the conditions above, and the results show that the differential pressure is not within the standard value, adjust as follows. 1) Loosen locknut (7) and turn screw (8) to adjust the differential pressure. ‘Turn the screw to adjust the differential pressure as follows. ¢ To INCREASE pressure, turn CLOCKWISE @ To DECREASE pressure, turn COUN. TERCLOCKWISE 2) After adjusting, tighten locknut (7) FRED Locknut : 29.4 + 4.9 Nm (3.0 + 0.5 kgm) Note: Always measure the differential pressure while adjusting, 20-36 ET] PISTON INPUT PRESSURE) AND LS DIFFERENTIAL PRESSURE mo MN O 3 8k20506 TESTING AND ADJUSTING TESTING AND ADJUSTING CONTROL PUMP CIRCUIT OIL PRESSURE TESTING AND ADJUSTING CONTROL PUMP CIRCUIT OIL PRESSURE MEASURING + Hydraulic oll temperature when measuring: 45 ~ 55°C 1. Remove pressure pick-up plug (1) (Thread dia.=10mm, Pitch=1.25mm), and install oil pressure gauge C1 (5.88 MPa (60 kgicm:) 2. Start the engine and measure with the engine at high idling. ‘When testing for internal leakage of the equipment in the control circuit, use the parts given below to shut off the circuit for the following sections when measuring the relief pressure. No Section of hydraulic | Component that circuit shut off can be checked 1.| Control pump outlet port | Control pump Solenoid valve inlet port | Solenoid valve Travel PPC valve inlet port | Travel PPC valve 4. | BAH. PPC valve inlet pon | RH. PPC valve 5 | LH. PPC valve inlet port | LH. PPC valve + tems No.2 and below can be checked if the equip- ‘ment in the previous number is normal. Use the following parts to shut off the circuit. © For elbow Sleeve nut : 07221-20210, 07221 ~ 20315 07221 - 20422 Plug (07222 - 00210, 07222-00315 07222 - 00414 © For hose Plug 07376 ~ 60210, 07376 ~ 50315 07376 - 50422 Solanoid valve TT» #® onto! pump sto Travel PPC AH. PPC LH. PPC valve valve (valve Or : Q fol} Safety lock valve Accumulator \ V osFoeaaa| 20sro6s34 20-37TESTING AND ADJUSTING TESTING AND ADJUSTING CONTROL PUMP CIRCUIT OIL PRESSURE ADJUSTING 1. Loosen locknut (2) and turn adjustment screw (3) to adjust. % Turn the adjustment screw as follows. @ To INCREASE pressure, turn CLOCKWISE To DECREASE pressure, turn COUN TERCLOCKWISE %* Amount of adjustment for one turn of adjustment screw: 0.53 MPa (5.4 kglcm). ED Locknut : 63.7 + 9.8 Nm (6.5 = 1.0 kam) + After completion of adjustment, repeat the procedure in Item 1 to check the set pressure again. 20-38 20srosaa5 | 2050620506 TESTING AND ADJUSTING TESTING EPC VALVE, SOLENOID VALVE OUTPUT PRESSURE TESTING EPC VALVE, SOLENOID VALVE OUTPUT PRESSURE MEASURING | %* Hydraulic oil temperature when measuring: 45 ~ 55°C 1. Measuring output pressure of LS control EPC valve 1). Disconnect output hose (1) of the LS control EPC valve, then use adapter C2 in the oil pressure ‘gauge kit to install oll pressure gauge Cr (5.88 MPa (60 kg/cm). 2) Measure the output pressure under the conditions in Table 1. Table 1 Operation and | Engine | Output JiReference] speed | pressure |Current working mode | (pm) Pa emi] (A) Ail control levers Pee Min. 1500| 2.94 (30) | 900 » 30 H/O mode or G/O mode | | Travel ercuit at Travel circuit at |yjin 2000] 0 (0) ° work equipment lever is operated | ‘Monitoring code 10 or 40 for engine speed Monitoring code 15 for LS control EPC current 20-39TESTING AND ADJUSTING TESTING EPC VALVE, SOLENOID VALVE OUTPUT PRESSURE Measuring output pressure of ONIOFF solenoid valve 1) Disconnect outlet hose (2) of the solenoid valve, then use adapter Cs in the oil pressure gauge kit to instal oil pressure gauge Cs (5.88 MPa (60 ka/ om?) | 2) Measure the output pressure under the condi- | tions in Table 2. | ao } Table 2 lame of satin. condition of | Oil pres. Name of Measurement contions Overaine | Conaonot | SUPT | Remons teheno% condition | solenoid | jet Min. 276 guiza | Seingerwovkeaupmen: iver ooraed | ratecacoee | on | hn 1 | brake Solenoie | Al evers except wavel at neutral rake | Gisee after returning to neutral) actuated | OFF | oto Travel speed switch at Hi or Mi | tor swash Engine spaod 1500rph or above Travel speed Hi | ON | -MIB-274 | Diste'angie Travel Travel lever operated (Min. 28) | at minimum 2 | doeed — nn 010016 | Travel speed switch a Lo or engine vel epee | jotor sw Speed 1800 rom or below eel cee 0 | plate ance ‘Detage | Sting lock switeh ON + work — Min. 2.78 | a 2rgpe | StuhQneet eed | Pressure oN | Un 2 solenoid | Aur levers at neutral [ Normal pressure | __OFF o Suing ok stn OF, compound ron ow | Min-27% | vies ony or us. operation of swin divided (Min. 28} | compound opera- 4] 'Secq_ | Serave ov erm OUT or boom RAISE compound ope Selonoid travel arm ur. Aver at neural sarge | ore a _| boom fase Lever at neutral, or boom, arm, bucket | Flow from front | Pump | operated independently rcteecieeaoad | aaa © | ts pump merge ‘merge mmerge-dvier 5 | aiviger | valve actuated | Sole | Trav or swing operated independently | front and rear on | Min. 274 | at same time | fered, | on | i The basic pressure of the LS select solenoid valve is supplied from the PPC shuttle valve.Therefore, the | cI oil pressure is not supplied unless one of the travel, or arm OUT or boom RAISE % Operation of solenoid valve ON: Continuous (oil pressure generated) | OFF: Not continuous (oil pressure: 0) operated. 20sro6930 20-40 2050620506 ‘TESTING AND ADJUSTING MEASURING PPC VALVE OUTPUT PRESSURE AND TESTING PPC SHUTTLE VALVE %* Hydraulic oil temperature when measuring: 45 - 55°C 1 Measuring PPC valve output pressure 1) Disconnect the hose of the circuit to be measured (see next pagel. 2) Install adapter Gs between the hose and elbow. 3) Install oil pressure gauge Cs (5.88 MPa (60 kg/ cm?) to adapter Cs. 4) Run the engine at high idling, operate the control lever of the circuit to be measured, and measure the oil pressure Checking PPC shuttle valve I the output pressure at the control valve end is low, check for leakage of oil from the PPC shuttle valve as, follows. 1) Disconnect the hose between the PPC valve and the shuttle block at the block end. 2) Install an adapter for measuring the oil pressure to the tip of the hose, then install blind plugs to the tip and shuttle block end. 3) Operate the contro! lever and measure the out- ut pressure. ‘If the output pressure becomes normal, there is leakage from the PPC shuttle valve; if there is no change, the PPC vaive is defective. Checking defective operation of PPC shuttle valve 1) Remove the oil pressure switch, fit adapter Cs, then install oil pressure gauge Cr (5.88 MPa (60, kg/om?). 2) Operate the applicable lever. no oil pressure is generated or if oil pressure is generated when another lever is operated, the operation of the PPC shuttle valve is defective. MEASURING PPC VALVE OUTPUT PRESSURE AND TESTING PPC SHUTTLE VALVE PPC. 8 Bling plug zo2r0ss66, 20-41MEASURING PPC VALVE OUTPUT PRESSURE TESTING AND ADJUSTING AND TESTING PPC SHUTTLE VALVE Oil pressure switch location di ‘Shuttle block seen from rear of machine . ‘swing Bucket DUMP. (ses) ‘sory Bucket CURL Gg ts G ‘Aron (05) | Boom LOWER ‘soa ‘Aen OUT Travel ‘03, (sow < oo Boom RAISE mA (soz) zo2r0ss67 © Circuit diagram Ting valve k20506 na FT} P07 evento Gwen foe] a0] Otte © [5 far| swe fm] (= pon "2OsFOes07 1. Swing PPC shuttle valve 5, Travel PPC shuttle valve 2. PPC shuttle valve for LS select 6. PPC shuttle valve for R.H. travel FORWARD, LH. 3, PPC shuttle valve for arm OUT, Loom RAISE travel REVERSE 4, PPC shuttle valve for LH. travel FORWARD, R.H. travel REVERSE 20-4220506 TESTING AND ADJUSTING ADJUSTING WORK EQUIPMENT * SWING PPC VALVE If there is excessive play in the work equipment or swing lever, adjust as follows. Lower the work equipment to the ground and stop the engine. Loosen the oil filler cap slowly to release the pressure inside the hydraulic tank. Then set the safety lock lever to the LOCK position. Remove the PPC valve. Remove boot (1). 3. Loosen locknut (2), then screw in disc (3) until it con: tacts the 4 heads of piston (4). When doing this, do not move the piston. 4. Secure disc (3) in position, then tighten locknut (2) to the specified torque =D Locknut : 107.8 = 9.8 Nm (11 = 1 kgm) Install boot (1). ‘With the above adjustment, the clearance between disc (3) and piston (4) becomes 0. ADJUSTING WORK EQUIPMENT - SWING PPC VALVE 2orro1129 20-43TESTING AND ADJUSTING ADJUSTING TRAVEL LEVER 1 install lever (1) to the PPC valve. ion, move left and right travel levers (3) forward and backward, and check that the levers are fitted securely in the stopper (bolt head) of the PPC valve. Check also that cover (3) is not contacting portion®). % fit is contacting, adjust with the PPC mounting bolt or cover mounting bolt. ADJUSTING TRAVEL LEVER 20-44 202F08372 k2050620506 TESTING AND ADJUSTING TESTING TRAVEL DEVIATION When traveling on level ground. Set the machine in the travel posture. + For the travel posture, extend the bucket and arm. cylinder rods fully, and hold the boom angle at 45 ‘Travel for 10 m, then measure the deviation when traveling for the next 20 m. + Set to H/O mode and measure with the engine at + high idling, Install the hydraulic pressure gauge and measure the pump discharge pressure at the same time. Make @ mark Lay out a string 20m point Mack Measure the amount of dimension a at this point TESTING TRAVEL DEVIATION 205F06708 Do not stop; continue to travel forthe whole distance Fun up for 10 m Nake a mark at the 10 m midway point ‘Mark 10 m midway point_? ‘Mako 2 mark ‘Mark 20265258 20-45TESTING LOCATIONS CAUSING HYDRAULIC TESTING AND ADJUSTING DRIFT OF WORK EQUIPMENT TESTING LOCATIONS CAUSING HYDRAULIC DRIFT OF WORK EQUIPMENT ‘Boom, bucket checking posture tf here fs any hydrate dit in the work equipment (eyinders), check ae follows to determine the cause isvm the cylinder packing or inthe contol valve 4. Chocking fr defective cylinder packing 4) "Checking boom and bucket eyinders 1) "Set the some posture ae when meesuring hvdroulis dit and stop the engine, fez: 1.208 i Operate the boom contol lever to RAISE oF the bucket conta ever to CURL ifthe towering speed increases, the pack forces ing is detective there is no change, the boom holding Valve boom or the contol valve (bucket) is detective 2) Checking arm evinder 1) "Operate the arm evlindor to move the arm in fut, then stop the ongne, iy Operate the conte Tove to ar IN ofthe lowering speed incense, the pack ing ie detective. | @ If there is no change, the control valve is | | defective. | | se itthe prossur in the accumulator hos dropped, run the engine for approx. 1 sosrosses seconds to charge the accumulator again before operating, tReterenel I tho couse of the hyoulc dit isin the pactng, and the above operation is Carried out, the downward movement becomes faster forthe fllowing rea 1) tfthe work equipment i et othe above posture {holding prestute applied tothe bottom en, the tilt the ottom end leaks to the heod end. How” ver the volume atthe heed ends smater thon the volume a the bottom end by the volume of the rod, so the internal pressure at the head end inereses because ofthe el flowing in rom the botom end 2) When the internal pressure ot the head end in- treaaes the pressure at he bottom end also ies in proportion to thia-Thebelene s meintaned at 2 corein pressure (his alfers according to the mount of leakage) by repeating tis procedure, 2) When the pressure is belenead, the downward movement becomes slower, Ifthe lever Is then perted according tothe procedure given above the creuit tthe heed end fa opened tothe ain Ghoul the bottom ead fs lowed by the check Calva, #0 the ell at tho Read ond flowe to the train circuit and the downward movement be: comes fst 20-46 2050620506 TESTING AND ADJUSTING 2. Checking PPC valve Ifthe hydraulic drift differs when the safety lock lever is in the LOCK or FREE position, (engine running),the PPC valve is defective. TESTING LOCATIONS CAUSING HYDRAULIC DRIFT OF WORK EQUIPMENT 20-47TESTING AND ADJUSTING MEASURING OIL LEAKAGE MEASURING OIL LEAKAGE + Hydraulic oil temperature when measuring: 45 = §5°© ||| -—$__$__________ 1, Work equipment cylinder Posture for measuring boom eyinder + Ifthe hydraulic drift of the work equipment is outside the standard value, measure the leakage inside the cylinder as follows, and judge if the cause of the hydraulic drift isin the cylinder or in the control valve If the leakage is within the standard value, the problem is in the control valve. Ifthe leakage is greater than the standard value, the problem is in the cylinder. 1). Fully extend the rod of the cylinder to be measured, then stop the engine. 2}. Disconnect piping (1) at the head end, then biock | ping at the chassis end with a blind plug. Be careful not to disconnect the piping at the bottom end, 3) Start the engine and apply the relief pressure to the bottom end of the cylinder with the engine at high idling, 4) Continue this condition for 30 seconds, then measure the oil leakage for the next one minute. | End of stroke Rolie! pressure __ Bucket cylinder L __ 20206375) 20-48 2050620506 TESTING AND ADJUSTING ‘Swing motor 1). Disconnect drain hose (1) from the swing motor, then fit a blind plug at the tank end. 2) Set the swing lock switch ON. 3) Start the engine and operate the swing relief with the engine at high idling. 4) Continue this condition for 30 seconds, then measure the oil leakage for the next one minute. + After measuring, swing 180° and measure again. Travel motor 1 Disconnect drain hose (2) from the travel motor, then fia blind plug atthe hose end 2) Fit block @ under the track shoe grouser, or fit block @ between the sprocket and frame to lock the track 3). Start the engine and operate the travel relief with the engine at high idling Bi When measuring the oil leakage from the travel moter, mistaken operation ofthe control lover may lead to @ serious accident, 20 always use signals and check when carrying out this operation. 4) Continue this condition for 30 seconds, then meas- ue the oil leakage forthe next one minute 4% When measuring, move the motor slightly (to change the position between the valve plate and cylinder, and piston and cylinder), end messure several mes. RELEASING REMAINING PRESSURE IN HYDRAULIC cl IRCUIT If the piping between the hydraulic cylinder and the control valve is disconnected, release the remaining pressure from the circuit as follows. ‘The travel circuit is an open circuit, so there is no remaining pressure. It is enough to remove the oil filler cap. Loosen the oil filler cap slowly to release the pressure inside the tank. Operate the control levers, When the levers are operated 2 ~ 3 times, the pressure stored in the accumulator is removed. Start the engine, run at low idling for approx. 5 minutes, then stop the engine and operate the control levers. ‘Repeat the above operation 2~3 times to release all the remaining pressure. RELEASING REMAINING PRESSURE IN HYDRAULIC CIRCUIT 20101116 20-49TESTING AND ADJUSTING BLEEDING AIR BLEEDING AIR Order for operations and procedure for bleeding ai a Air bleeding procedure 1 2 ‘ 5 6 7 | a Blessing | | edi air be Bleeding | stax | Bleeding | air trom St ogg pen EP engine Swin operations| valve an Nature of work pump ene | evlinder | motor " Control | | | valve 1 | ‘* Replace hydraulic ol. ostot osteo to lo Clean stainer | f Sten|” Se ‘© Replace return fiter : element ic) cS ‘© Replace, repair pump | 0 @ Remove suction piping < S ‘© Replace, repair contvol_| F 5 valve | S 9 Replace cylinder ° Oo Remove eylinder piping 2 ® Replace swing motor © Remove swing motor o ———> 0 ———4 0 piping | © Replace travel motor, | | swivel on a @ Remove travel motor, © ~ ° swivel piping @ Replace EPC valve oO oO ! Note 1: Bleed the air from the swing and travel motors only when the oil inside the motor case has been drained. 1. Bleeding v 2) 3) 4 5) 6 from pump Loosen air bleed plug (1), and check that oil oozes. out from the plug. When oil oozes out, tighten plug(1). Sw) Plug : 17.15 = 2.45 Nm (1.75 = 0.25 kgm) Hf no oil oozes out from the air bleed plug: Leave plug (1) loosened and remove hose (2) and elbow (3), Pour in oil through the elbow mount hole until oll o02es out from plug (1). Fit elbow (3) and install hose (2) Tighten air bleed plug (1) Ge Plug: 17.15 = 2.45 Nm (1.75 = 0.25 kgm) Precautions when starting the engine After completing the above procedure and starting the engine, run the engine at low idling for 10 minutes. If the coolant temperature is low and automatic warming-up is carried out, cancel it by using the fuel control dial after starting the engine. 20-50 20506k20506 TESTING AND ADJUSTING BLEEDING AIR air from hydraulic cylinders 1) Start the engine and run at idling for approx. § minutes. 2) Run the engine at low idling, then raise and lower the boom 4 ~ § times in succession, * Operate the piston rod to approx. 100 mm before the end of its stroke. Do not relieve the circuit under any circumstances. 3) Run the engine at high idling and repeat Step 2. After that, run the engine at low idling, and operate the piston rod to the end of its stroke to relieve the circuit 4) Repeat Steps 2) and 3) to bleed the air from the arm and bucket cylinders. ‘* When the cylinder has been replaced, bleed the air before connecting the piston rod. Be particularly careful not to operate the cylinder to the end of its stroke when the piston rod has been connected to the LOWER end of the boom cylinder, Bleeding air from swing motor 1) Run the engine at low idling, loosen air bleed plug (1), and check that oi! oozes out. + If no oil oozes out from the air bleed plug: 2) Stop the engine, and pour oil into the motor case from plug (1). 3) Tighten air bleed plug (1). GEE) Plug : 1666 = 19.6 Nm (17 +2 kgm) Bleeding air from travel motor Run the engine at low idling, loosen air bleed plug (2), and when oil oozes out, tighten the plug again. 20-5120506 TROUBLESHOOTING Points to remember when troubleshooting .. Sequence of events in troubleshootin, Precautions when carrying out maintenance Checks before troubleshooting. Connector types and mounting locations .. Connection table for connector pin number: Explanation of control mecha 1m for electrical system. Display method and special functions of monitor panel Method of using judgement table... Method of using troubleshooting charts. Details of troubleshooting and troubleshooting procedure .. Troubleshooting of engine throttle controller system (E mode) .. Troubleshooting of engine (S mode) Troubleshooting of pump controller system (C mode) .. Troubleshooting of pump controller input signal system (F mode) .. Troubleshooting of hydraulic and mechanical system (H mode) Troubleshooting of machine monitor system (M mode). 20-53‘TROUBLESHOOTING POINTS TO REMEMBER WHEN TROUBLESHOOTING POINTS TO REMEMBER WHEN TROUBLESHOOTING A 3:0p the machine in a level place, and check that the safety pin, blocks, and parking brake are securely fitted. Aivinen carrying out the operation with two or more workers, kagp strictly tothe agreed signal, and do not ‘allow any unauthorized person to come n atte raciatr cap is removed wien the engine is hot hot water may spurt out and cause buns, so walt for the engine to coo! down betor staring troubleshooting. Bice extremely careful not to touch any hot parts orto get caught in any rotating parts Aivinen disconnecting wising, always disconnect the negative (terminal ofthe batery fis. Ai Wren removing the plug or cap from a location which is under pressure from oll, water Fa 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 swit Prevent reoccurrence of the failure. ly, and to When carrying out troubleshooting, and important point is of course to understand the structure and function. 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. + [twill become impossible to find the cause of the failure. It will also cause a waste of manhours, parts, or il 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. 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 mé chine 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? Check before troubleshooting 1) Check the oil level 2) Check for any external leakage of oll from the piping or hydraulic equipment. 3) Check the travel of the control levers. 20-54 a short cut to effective troubleshooting is to ask the operator various questions to form some idea le causes of the failure that would produce the reported symptoms. 4) Check the stroke of the control valve spool. 5) Other maintenance items can be checked ex- ternally, so check any item that is considered to be necessary. 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. When operating the machine to reenact the troubleshooting symptoms, do not carry out any investigation or measure- ‘ment that may make the problem worse. 5. Troubleshooting + Use the results of the investigation and 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. ‘The basic procedure for troubl is as follows. 1) Start from the simple points. 2) Start from the most likely points. 3) Investigate other related parts or information, shooting 6. Measures to remove root cause of failure + Even ifthe 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. 20506k20506 ‘TROUBLESHOOTING ‘SEQUENCE OF EVENTS IN TROUBLESHOOTING SEQUENCE OF EVENTS IN TROUBLESHOOTING |____ ree ste N sem, HES) soba + Conon oft 2 Tadapte Step 4 Ce Type sell numberof mochine S_Datls of jbste, ete 2) Ask questions te galt an outline ofthe prob- ita being cri ou at the ime of he (op 1 Look atthe troubleshooting ssction of te shop manual t find locations of posible 11 Look atthe tebe of troubleshooting tal in the shop manual and prepare the nocetsary| Hydra pressure gouge Kt, 2) Lookin the parts book and prepare the nee 8 ‘sr epi oboe 2 Check before staring tems Other check heme 2 ‘See the Troubleshooting Section of he shop manual, elect # voubleshooting fwshart that matches the symptoms, end cary out troubleshooting Mors Y DD ===] 5S + Was thre anting strange about the me 4 O_O" : rue? a 1 fadonrmpersbeoncoredoutbaorehe DY S| a fate? 20-55‘TROUBLESHOOTING PRECAUTIONS WHEN CARRYING OUT MAINTENANCE PRECAUTIONS WHEN CARRYING OUT MAINTENANCE To maintain the performance of the machine over a long period, and to prevent failures or other troubles before they occur, correct operation, maintenance and inspection, troubleshooting, and repairs must be carried out. This section deals particularly with correct repair proce- dures for mechatronics and is aimed at improv- ing the quality of repairs. For this purpose, it gives sections on “Handling electric equipment” and “Handling hydraulic equipment” (particlularly hydraulic oil. 1. PRECAUTIONS WHEN HANDLING ELEC- TRIC 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 pro- tector 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 suf- fer 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) Improper insertion 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. Tew 20-56 20506k20506 ‘TROUBLESHOOTING (2) Defective compression or soldering of connectors The pins of the male and female connectors are in contact at the compressed terminal or soldered portion, but there is excessive force on the wiring, and the plating peels to cause improper correc- tion or breakage. (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 compression of the connector may be lost, or the soldering may be damaged, or the wiring may be broken. (4) High pressure water entering connector The connector is disigned 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. The connector is designed to prevent water from entering, but at the same e, if the water does enter, it is difficult for it to be drained. Therefore, if water should get into the connector, the pins will be short-circuited by the water, so if any water gets in, immediately dry the connector or take other appropriate action before passing electricity through it. (5) Oil or dirt stuck to connector If oll or grease are stuck to the connector and an oil film is formed on the mating surface between the male and female pins, the oil will not let the electricity pass, so there will be defective contact. If there is oil or grease or dirt stuck to the connector, wipe it off with a dry cloth or blow dry with air, and spray it with contact restorer. * When wiping the mating portion of the connector, be careful not to use excessive force or deform the pi If there is water or oil in the air, it will increase the contamination of the points, so clean with air from which all the water and oil has been removed, PRECAUTIONS WHEN CARRYING OUT MAINTENANCE 20-57‘TROUBLESHOOTING 2) Removi 19, installing, and drying connectors and wiring harnesses Disconnecting connectors a (2) 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. Action to take after removing connectors After removing any connector, cover it with a vinyl bag to prevent any dust, dirt, oil, or water from getting in the connector portion. Connecting connectors a Check the connector visually. a. Check that there is no oil, dirt, or water stuck to the connector pins {mating portion). b. Check that there is no deformation, defective contact, corrosion, or damage to the connector pins. ¢. Check that there is no damage or breakage to the outside of the connector. Hf 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. %* If there is any damage or breakage, replace the connector. 20-58 PRECAUTIONS WHEN CARRYING OUT MAINTENANCE Press tight when removing tockstopper~ 0. ‘rewoorse 20506k20506 ‘TROUBLESHOOTING PRECAUTIONS WHEN CARRYING OUT MAINTENANCE (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 or the boot. In addition, if the wiring harness is misaligned, or the clamp is out of position, adjust it to its correct position. * When blowing with dry air, there is danger that the oil in the air may cause improper contact, so clean with air from which all the water and oil has been removed. Drying wiring harness If there is any oil or dirt on the wiring harness, wipe it off with a dry cloth. Avoid washing it in water or using steam. If the connector must be washed in water, do not use high pressure water or steam directly on the wiring harness. If water gets directly on the connector, do as follows. (1) Disconnect the connector and wipe off the water with a dry cloth. If the connector is blown dry with air, there is the risk that oil in the air may cause defective contact, so avoid blowing with air. side of the connector with a If water gets inside the connector, use a dryer to dry the connector. * Hot air from the dryer can be used, but be careful not to make the connector or related parts too hot, as this will cause deformation or damage to the connector. -— remotesTROUBLESHOOTING PRECAUTIONS WHEN CARRYING OUT MAINTENANCE (3) Carry out a continuity test on the con- rector. After drying, leave the wiring harness disconnected and carry out a continuity test to check for any short circuits between pins caused by water = * After completely drying the connec tor, blow it with contact restorer and reassemble. ptr ‘ewor208 3) Handling control box (1) The control box contains a microcom- puter 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 contro! connectors with tape or a vinyl bag. (6) During rainy weather, do not leave the control box in a place where it is ex- posed 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 are welding ground close to the welding point. > ‘ewomes 20-60 2050620506 TROUBLESHOOTING 2. POINTS TO REMEMBER WHEN HAN- DLING 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. Avoid adding hydraulic oil 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 maintenance of hydraulic equipment should be carried out in a specially prepared dustproot 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 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 contain- ers. If an oil cleaning device is used, it is Possible to filter out the dirt that has col- lected during storage, so this is an even more effective method. or dust get in during PRECAUTIONS WHEN CARRYING OUT MAINTENANCE ‘emo 20-61‘TROUBLESHOOTING PRECAUTIONS 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. (Do not drai the oll from the hydraulic tank; also drai the oll 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 twici mary flushing is carried out with flushing oil, and secondary flushing is carried out with the specified hydraulic oi n After repairing the hydraulic equipment (pump, control valve, etc.) or when running the machine, carry out oil cleaning to remove the sludge or contaminants in the hydraulic oil circuit The oll cleaning equi move the ultrafine (about 3p) particles that the filter built into the hydraulic equipment cannot remove, so it is an extremely effective device. 20-62 2050620506 ‘TROUBLESHOOTING CHECKS BEFORE TROUBLESHOOTING CHECKS BEFORE TROUBLESHOOTING hem ecasnen Remedy Check fuel level : Add fuel sg | 2 Check for diet or water in fuel ; Clean, drain 3 | 8. check hydraulic ol ove : Adi oi 3 Check hydraulic oil strainer - Clean, drain 3 | 5. chk swing machinery ove - so 2 | 6. check engine oil level (Level of olin oi! pam) : Aad oi EB | 2. cheek cooting water tevel : Add water A Check condition of dust indicator - Clean or replace Check hydraulic oi iter Replace “= £ | 1 Check for loose or coroded batory terminals : Tighten or replace 5 £2 Check or loose or corroded aerator terminals : Tighten or replce #3 | 3. check for loose or corroded straight motor terminals : Tighten or replace 1g| 1 Check or abnormal nose or smal : Repair E| 2. check fr oil leakage : Repair 8] 5, Bleed air from system - Bleed air CCheck battery voltage (engine stopped) 20-30 Replace CCheck level of battery electro - Add or replace a | % Check for discolored, burnt, or bare wiring : Replace © | 4. check for missing wiring clamps, hanging wires - Repeir © | checks for getting wet onto wing | pisconnect 3 (check carefully getting wet at connectors - | connector and 3 | and terminals | dry connection 3B | 6. check for broken or corroded fuses : | Replace {engine Fanning at osGe half throttle) 278-296 Replace {seven Starting Switch Roth ON'%0 OFF) - Replace 20-63TROUBLESHOOTING CONNECTOR TYPES AND MOUNTING LOCATIONS CONNECTOR TYPES AND MOUNTING LOCATIONS Ce ne ; Con. No. Pager | Te [Gh | test component | ost | type |'a| ea component ‘ot | KES1 | 2 | Window washer circuit E11 | RING | 1 [Heater relay ‘A0s | KES1 | 2 [LS select solenoid circuit 101 | S| 16 [intermediate connector aoe | xesi | 2 [Pump merge-divder sole Hoz |S _| 16 [intermediate connector ‘A05 | KES1 | 2. [Swing brake solenoid cect ea |S | ‘A06 | KES1 | 2 |2stage relief solenoid creut Hol S| ‘A07 | KEST | 2 | Travel speed solenoid ckeut eed EIS ‘ave | KES1 | 2 [Heater circuit Hos |__| 2 [intermediate connector ‘A09 | KES1 | 2 [Lower wiper circuit Ho7 |__| 12 [Intermediate connector ‘ait | Kest | 2 [Alarm buzzer circuit Hos | M_| 6 Intermediate connector ‘Ara | KES1 | 2 |Sterter relay cirouit Hoa | M_ | 2 [intermediate connector At | KES1 | 2. [Battery relay drive circuit kor | - [1 ‘Ate | KES1 | 2 [Fuel shut off circuit ES ‘At7 | KES1 | 2. [Starter circuit woz | X_| 2 [Safety relay cor | MIC | 17 [Pump controtier Moe | _M_ | 4 [Heater switch co2 | 040 | 20 [Pump controller Mos | KeS1 | 2 [Right front light cos | 040 | 16 [Pump controller mos | Kest | 2 | Working lamp (boom) cos | x | 2 [Rear pump TVC valve mio | M_[ 1 [Intermediate connector | cos |S _| 10 | TVC prolix switch mit | t| 2 [Fusible tink cos | M_| 2 |TVC prolix resistor Miz | kest | 4 [Heater co7 | x _| 3 [Rear pump pressure sensor Mis | AMP | 8 |Speaker - cos | x | s [Front pump pressure sensor ia |b | 2 | Fusible tink cos |S | 8 [Model selection connector te | - | 1. [Horn (high sound) cro | x | 2 [tS control EPC solenoid valve Mi7_|_-__[ 1. [Horn (low sound) c13 | x | 2 [Front pump TVC valve is | M_| 4 |Wiper, washer switch £01 | mic | 21 [Engine throttle controller M20 | - | — |Cigarette lighter E04 3_|Governor potentiometer M23 | M_| 2 |Horn switch, RH. knob switch e05 | x | 4 |Governor motor M26 11 [Air conditioner E08 2 [Fuel control dial M26 2. [Window washer motor £07 | _X | 2 [Engine speed sensor M34 1 |Fitcopan ther somprearer Eos | SWP | 14 |Intermadicta connector M35, 4 [Condenser for air condtionar ci | — | 1 [Fuel shut off | Figo Tom] 2 [tio ewten %* The Address column in the table above shows the address in the connector arrangement drawing {2-dimensional drawing). * This table includes connectors that are not shown in the drawing. 20-64 2050620506 HoB Ho3 Ho7 Hog M13 HO2 20-67‘TROUBLESHOOTING CONNECTION TABLE FOR CONNECTOR PIN NUMBERS CONNECTION TABLE FOR CONNECTOR PIN NUMBERS The terms male and female refer to the pins, while the terms male housing and female housing refer to the mating portion of the housing. X type connector No. of pins Male (female housing) Female (male housing) ‘| 205F08309 | 20805910 1 | Tat T \ 2 208F08311 20sr0s912 3 | 1 a \ 4 2 4 2osrosais 20-68 2050620506 ‘TROUBLESHOOTING CONNECTION TABLE FOR CONNECTOR PIN NUMBERS M type connector tao pins Male {female housing) Female (male housing) | ir, ] E _ | Hi] Eg 2 2 a =e Rm | @ ss [xh iz s 1 1 2 3 \ = : iF 3 ry t~«~dS — 1 3 1 \ / Si = fl Et EI / 4 2 20-69‘TROUBLESHOOTING CONNECTION TABLE FOR CONNECTOR PIN NUMBERS Ww wpe connector No.of pins Male (female housing) Female (male housing) 4 1 \ / 8 | a 1 = | 6 3 Sree — 20-70 20506k20506 TROUBLESHOOTING CONNECTION TABLE FOR CONNECTOR PIN NUMBERS S type connector No. of pins Male (female housing) Female (male housing) 208F08927 10 9 a aa eT 208F08390 16 LL gaa 20-71‘TROUBLESHOOTING CONNECTION TABLE FOR CONNECTOR PIN NUMBERS ‘AMPO40 type connector No. of pins Male (female housing) Female (male housing) 16 20505295 205F05296 m0 / / ipsa - | IBS 20 |eaes le Le no zosrosa98 20-72 2050620506 ‘TROUBLESHOOTING CONNECTION TABLE FOR CONNECTOR PIN NUMBERS ‘AMPO70 type connector No. of ins Male (female housing) Female (male housing) 4 | bi 18 20sFo6s66 205F06367 20-73‘TROUBLESHOOTING CONNECTION TABLE FOR CONNECTOR PIN NUMBERS ‘AMP250 type connector No. of ; pins Male (female housing) Female (male housing) 2 2 1 3 a a 20-74 a § 820506 ‘TROUBLESHOOTING CONNECTION TABLE FOR CONNECTOR PIN NUMBERS No. of pins ‘SWP type connector Male (female housing) Female (male housing) 4 wo i 56103087 | 56103086 20-75‘TROUBLESHOOTING CONNECTION TABLE FOR CONNECTOR PIN NUMBERS MIC connector No. of pins Male (female housing) Female (male housing) v arene ra2rass 1 " | salesalelescle pefjecal| Jessie | 2 a 1 | v42F418 teres 20-76 2050620506 ‘TROUBLESHOOTING CONNECTION TABLE FOR CONNECTOR PIN NUMBERS No. of pins. Relay connector — s | | Simple cones Wo. of pins Male (male housing) Female (female housing) ' a 9 woot ES hing connector 1 —LO 20-77‘TROUBLESHOOTING CONNECTION TABLE FOR CONNECTOR PIN NUMBERS Ltype connector No. of pins Male (female housing) Female (male housing) 2 a 2oTr01149 201801150 PA type connector No. of ; pins Male (female housing) | Female (male housing) -fr7- elo ols 9 {0 tn oF elo a)+ | 20806970 | 205F08971 20-78 2050620506 ‘TROUBLESHOOTING CONNECTION TABLE FOR CONNECTOR PIN NUMBERS No. of pins ‘Automobile connector (KESO) Male (female housing) Female (male housing) 20-79‘TROUBLESHOOTING CONNECTION TABLE FOR CONNECTOR PIN NUMBERS ‘Automobile connector (KES1) No.of pins Female (female housing) Male (male housing) a 2 _ eI anaeaa 4206280 | | I 1 BSS — 3 | ——— x 3 ¥ 2 429F951 anarasz 1, 2 2 1 4 z 4 4 ‘3 420689 a29F998 20-80 k20506‘TROUBLESHOOTING EXPLANATION OF CONTROL MECHANISM FOR ELECTRICAL SYSTEM EXPLANATION OF CONTROL MECHANISM FOR ELECTRICAL SYSTEM 1. Explanation of machine control functions ‘The control mechanism for the electrical system consists of the monitor panel, together with the signals selected by the monitor panel, the controllers output or input the necessary signals and control the pump absorption torque and engine output. Monitor panel sonore FB] newsmucret of) pig serescee_of TT FW ; Ses “ Feat control Fe) 208F06375 2. Explanation of networking functions With this system, a networking method has been adopted for the first time for the transmission and reception of data between the controllers. With the conventional system, the necessary data is transmitted and received through an independent signal line between each controller. With the new method, this system has been replaced by two dedicated networking wires; in this new system, all the data that is needed is transmitted and received between the controllers by using these networking wires. 20-82 k20506k20506 ‘TROUBLESHOOTING DISPLAY METHOD AND SPECIAL FUNCTIONS OF MONITOR PANEL DISPLAY METHOD AND SPECIAL FUNCTIONS OF MONITOR PANEL 1 Display on machine monitor When the starting switch is turned ON, all the monitor gauge lamps light up for approx. 3 seconds, and the buzzer sounds for approx. 1 second. During this time, the monitor itself carries out self diagnosis, and after it has finished, it gives the normal display. Recording of service codes and user code display function 1) Allthe abnormality data for the engine throttle controller and pump controller is received by the monitor panel. When the monitor panel receives this data, it records the abnormality deta, and at the same time, depending on the nature of the abnormality, it displays the user code on the time display panel to advise the operator of the action to take. However, in cases of abnormalities which are not urgent and do not require the user code to be displayed, only the content of the abnormality is recorded, and no display 2) Type of user cod 02 | Pump TVC system E03 | Swing holding brake system E05 | Governor motor system ind system % For details of the service codes included in the user code, see ACTION TAKEN BY THE CONTROLLER. WHEN AN ABNORMALITY OCCURS, THE SYMPTOMS ON THE MACHINE’or JUDGEMENT TABLE. 3) Displaying user code If it becomes necessary to display the user code, the time displayed panel is automatically switched to advise the operator to take the necessary action, ‘© Actual display i) Example: Disconnection in the swing brake solenoid system E]:(BTST eaux —— Flashes L___— component code Blank 20-83‘TROUBLESHOOTING DISPLAY METHOD AND SPECIAL FUNCTIONS OF MONITOR PANEL 4) Display of service code ‘The monitor panel records both service codes which are included in the user code, and service codes which are not included. This data can be displayed on the time display as follows. + For details of the service codes that are not included in the user code, see ACTION TAKEN BY CONTROL- LER WHEN ABNORMALITY OCCURS AND PROBLEMS ON MACHINE. ‘Time ewiteh Working mode switen LH. travel “SS Seed Sah Front of monitor panel fan of monitor panel 1) Method of displaying service code Operation T Display 1. To set tothe service code display | 1. Time display goes out mode, (On the display panel, the service code and number of hours Keep the time switch + LH. travel | (service meter hours) since the occurrence of the abnormality speed switch pressed for 2.5 see: | are displayed in turn ones. Example of display When E2: 12 occurs 12 hours ago (service meter) Note: It is possible to call it up at | 1) Display of service code 2). Elapsed time the following times. (service meter display) 1) Inthe time display mode (normal mode) OTe): —O 207 2) Inthe user code mode 3) In the machine data monitor: | 55% LL eum SI ing mode - Servi code tapeed 4) In the time adjustment mode time aa L____. component cose 20-84 20506‘TROUBLESHOOTING DISPLAY METHOD AND SPECIAL FUNCTIONS OF MONITOR PANEL Operation Display 2. To go to the next service code | 3) If any abnormality exists at this ime, the E mark is display, displayed Press the time switch + RH. work: : ing mode sw 7 18 mode switch FIAT 3. To go back to the previous service code display, there is an abnormality, oF the controler is Bross the time switch + LH. working carn ot Sn move owt 4. To finish with the service code | 4)_‘If there is no service code in memory mode, Use the same procedure as in item —=T—]2[—]—]—] is ciaptayen. 1 5. To erase the memory, Keep the time switch pressed, turn the starting switch from OFF to ON, and keep the time switch pressed for § seconds. 3. Machine data monitoring mode function ‘The input signals from the monitor panel and controller sensors and the output signals to drive the solenoid can be checked by displaying them on the time display. Time swite function switch Front of monitor pane! Rear of monitor pa 20sr08s78 20-85‘TROUBLESHOOTING DISPLAY METHOD AND SPECIAL FUNCTIONS OF MONITOR PANEL 1) Method of displaying monitoring mode Operation Display 1. To set to the monitoring mode, do | 1. Goes off the time display, and display as follows. as follows. 2. Example of display Keep the time switch + lever switch | 1) When pump controller engine speed is monitored function switch pressed for 2.5 seconds. 1S 5] Note: This is possible atthe follow: | ing times. 3rd digit is forthe tens, 1) During the time display mode lank his display means 2050 (normal mode) | "om, 2) During the user code mode 3) During the time adjustment mode 4) During the service code mode 2) When front TVC output current is displayed Le Monitoring code {Engine speed) 2. To go to the next monitoring code | display, a ma co Press the time switch + R.H. work- | =! et iy ing mode switch. ] — a The Sd digit is forthe tons, 3. To go back to the previous moni- shank fo this inlay mnene 180 mA toring code display, Press the time switch + LH. working Le tortorng code mode switch (Front TV output curent 4, Bit pattern display ® @ @ 1) Set to the bit patern display code 9 @ D Monitoring code zosrosaez 5. To finish with the machine data | 3. Example of bit pattern display monitoring mode, use the same | 1). For code 08 (connection of S-NET components) procedure as in item 1 If the display is set to code 08, the applicable bits light uP 2). For code 20 (input condition of pump controler oil pressure switch) Set to code 20, and operate the lever of the system to be splayed | Wen'ne switch is rumad ON, ihe applicable bits ght up. 20-86 2050620506 ‘TROUBLESHOOTING DISPLAY METHOD AND SPECIAL FUNCTIONS OF MONITOR PANEL 2}. Tale of chine data mankoing codes For cata of te inte Uni cole, see the Bit peter chr we im tom Nam of component ot | Monitor panel model code =| Monto panel 02 | Pump eonllar model ode =| Pump conto oa | Engine throttle conor model code [engin eonie conan co | SET condton pir 3 | Monitor pane! 10 [ Enoine epood Trp _| Pomp convoter [a Front pump discharge pressure input kg/cm? | Pump controller el leseree see pees iat? Por contr +2 | Font TVC eurent op toma [Pomp controller & | (uveER Gx) eS : 5 ® 4. Governor motor adjustment mode This is used when adjusting the linkage between the governor motor and the injection pump. For details of the procedure, see TESTING AND ADJUSTING. 20-90 2050620506 ‘TROUBLESHOOTING DISPLAY METHOD AND SPECIAL FUNCTIONS OF MONITOR PANEL 5. Time adjustment mode To adjust the time, do as follows. ‘Operation Display ] 1. To set tothe time adjustment | 1. The time display flashes mode, Keep the time switch depressed . for 25 seconds. Cine] |—— sane 2. Use the LH. working mode switch 3. Use the R.H. working mode = Hour switch to advance the minute. Flashes 4. To return to the time display mode use the same procedure as in Step 1 20-91‘TROUBLESHOOTING METHOD OF USING JUDGEMENT TABLE METHOD OF USING JUDGEMENT TABLE This judgement table is @ tool to determine if the problem with the machine is caused by an abnormality in the electrical system or by an abnormality in the hydraulic or mechanical system. The symptoms are then used to decide which troubleshooting table (E-0, $-00, F-00, H-00, K-00, M-00) matches the symptoms. ‘The judgement table is designed so that it is easy to determine from the user code and service code which troubleshooting table to go to. + The abnormality display (caution) given by the monitor panel leads directly to troubleshooting of the machine monitor (M-O0). (See troubleshooting of the machine monitor system) 1. When using judgement table for engine throttle controller and engine related parts ‘© Ifa service code is displayed on the monitor panel, go to the troubleshooting code at the bottom of the judgement table (E-00). (Ae mark is put at the places where the failure mode and service code match.) Ifa problem has appeared but no service code is displayed on the monitor panel, go to the point where the failure mode matches the troubleshooting code on the right of the judgement table (E-00 or S-00). Failure mode “Engine does not start”. Procedure: Check if the service code is being displayed on the monitor panel. i f | Py lt 7 sce Tt er] eaterfeatestest —t-t-t = fe SS Te ber fea aie ea| FI | (Judgement) 1) Ifa service code is being displayed on the monitor panel: {go to troubleshooting E-OO for the engine throttle controller system. 2) If no service code is displayed on the monitor panel, and the engine does not start © Check that starting motor rotates [[_ Starting motor rotates .. Goto troubleshooting S-2 of mechanical system Starting motor does not rotate ... Go to troubleshooting E-11 of electrical system 20-92 2 8 820506 ‘TROUBLESHOOTING METHOD OF USING JUDGEMENT TABLE 2. When using judgement table for pump controller and hydraulic related parts ¢ Ifa service code is displayed on the monitor panel, go to the troubleshooting code at the bottom of the judgement table (C-00). (Ae mark is put at the places where the failure mode and service code match.) ‘¢ Ifa problem has appeared but no service code is displayed on the monitor panel, go to the point where the failure mode matches the input signal, and check the display for the input signal (the display at the place with a mark). ‘© If itis displayed normally, go to the troubleshooting code on the right of the judgement table (H-OO). ‘¢ Ifthe input signal is not displayed on the monitor panel, go to the troubleshooting code at the bottom of the judgement table (F-O0). Failure mode “Auto-deceleration does not work". Procedure: Check if the service cade is being displayed on the monitor panel. (Judgement) 1). Ifa service code is being displayed on the monitor panel: 90 to troubleshooting C-00 for the pump controller system. 2). If no service code is displayed on the monitor panel, and the auto-deceleration does not work: ‘© Check pump controller input signal [— There is a signal... Go to troubleshooting H-5 of mechanical-system L__ There is no signal ... Go to troubleshooting F-00 of electrical system (F mode for applicable system) 20-93‘TROUBLESHOOTING METHOD OF USING TROUBLESHOOTING CHARTS: METHOD OF USING TROUBLESHOOTING CHARTS. 1 Category of troubleshooting code number cee Component Service code E00 Troubleshooting of electrical system for engine throttle controller £3: 00 $00 Troubleshooting of engine related parts = C00) ‘Troubleshooting of electrical system for pump controller [__£2:00 F-00 ‘Troubleshooting of input signal system for pump controller [ : H-00 Troubleshooting of hydraulic, mechanical system for pump controller = __ K-00) Troubleshooting of electrical system for vaive controller (HYPER GX) | 4: OO ‘M00 Troubleshooting of machine monitor system Et: 00 Method of using troubleshooting table for each troubleshooting mode 2) 3) 4 5) Troubleshooting code number and problem The title of the troubleshooting chart gives the troubleshooting code, service code, and failure mode (problem with the machine). (See Example (1)) Distinguishing conditions Even with the same failure mode (problem), the method of troubleshooting may differ according to the model, component, or problem. In such cases, the failure mode (problem) is further divided into sections marked with small letters (for example, a)), 50 go to the appropriate section to carry out troubleshooting, If the troubleshooting table is not divided into sections, start troubleshooting from the first check item in the failure mode. (See Example (2)) Method of following troubleshooting chart © Check or measure the item inside CH and according to the answer follow either the YES line or the NO line to go to the next [——]. (Note: The number written atthe top right corner of the [____] is an index number; it does not indicate the order to follow.) ‘© Following the VES or NO lines according to the results of the check or measurement will lead finally to the Cause column. Check the cause and take the action given in the Remedy column on the rightSee Example (3)) © Below the [_____] there are the methods for inspection or measurement, and the judgement values. I the judgement values below the [_____] are correet or the answer to the question inside the [____] is YES, follow the YES line; if the judgement value is not correct, or the answer to the question i& NO, follow the NO line. © Below the [_____] is given the preparatory work needed for inspection and measurement, and the judgement values. If this preparatory work is neglected, or the method of operation or handling is mistaken, there is danger that it may cause mistaken judgement, or the equipment may be damaged. Therefore, before starting inspection or measurement, always read the instructions carefully, and start the work in order from item 1). General precautions, ‘When carrying out troubleshooting for the failure mode (problem, precautions that apply to all items are given at the top of the page and marked with *. (See Example (4) ‘The precautions marked % are not given in the , but must always be followed when carrying ut the check inside the Troubleshooting tools When carrying out the troubleshooting, prepare the necessary troubleshooting tools. For details, see TOOLS FOR TESTING, ADJUSTING, AND TROUBLESHOOTING, 20-94 2050620506 TROUBLESHOOTING METHOD OF USING TROUBLESHOOTING CHARTS 6). Installation position, pin number A diagram or chart is given for the connector type, installation position, and connector pin number connection. When carrying out troubleshooting, see this chart for details of the connector pin number and location for inspection and measurement of the wiring connector number appearing in the troubleshooting flow chart for each failure mode (problem) (1) M-7 When starting switch is turned ON (engine stopped), check item flashes (4) & Before carrying out troubleshooting, check that all the related connectors are properly inserted. * Always connect any disconnected connectors before going % Check that the coolant is at the specified level before carrying out troubleshooting 12) [BJ esetne ovat tases Divided into sections a) b) | ©] lengine oit tevel flashes } fon the next step, and b) ° cae fens pes. Defective coolant level - sar ec) f Sm ioe Basa o> : ea nacre 3 vs Deteive monitor pare! | Resa ree ° POR tween PO1 (female) mas (07) anc (3) as Defective contact, or dis- Clean idetective “Tuna rowninaior Tumse | Seca eomectonntng nes ste tamer | comes oa NO bemenn anon i resin female} (2) and ‘connect short connector to PO8 (female) #03 (111 — POX female) (10) thos poo? |] «Rint sch OF Turn staring sien [_* Disconnect FOX. oe 0 eet Se i + Bicones P SemeenFv amet = epace = ears ound Table Shon conocer | Conta eennectd [Vos Daconneced | Ws 20-95TROUBLESHOOTING _DETAILS OF TROUBLESHOOTING AND TROUBLESHOOTING PROCEDURE DETAILS OF TROUBLESHOOTING AND TROUBLESHOOTING PROCEDURE If any abnormality should occur, it is necessary to go to the correct troubleshooting chart in accordance with the judgement table for that type of failure (engine throttle controller, pump controller, valve controller). For details of the troubleshooting and troubleshooting procedure, refer to this flow chart. When carrying out troubleshooting, ask the operator as much as possible about the condition of the machine, and check the following items before starting. (1) Condition of controller connection (check with monitoring code 02 - 04) (2), Blown fuses (monitoring code 32) (3) Battery voltage (monitoring code 32) (4) Electricity generation (charge input) voltage (monitoring code 43) The procedure for carrying out check items No. 3 and No. 4 in the flow chart below is given on the following pages. 02 Pump TVC system YE £02 (Swing ldng bake systom) Goto No.2 £26 (Governarmotor sytem) 1 Cary ot roublshocing for Yyesy £200105255 fr mp contort C pose) ———— amar ese 1s tere user £200 19 £200 for engine tote controle ystem € mode} ——— cat out oubleshooting for oss dato : on agin rote sont ese ate tI Paty Pana 8 YES carry out troubleshooting for a ogee (8 mode) sects 2 YES Marines 5, || Code deploy Issarice serra" bey Cary out woubleshooing fr Scived on is role in cage sate mode En nbfectazed vel 3 “Soto NOswnesytom erode, EET) panel T{svstem or 4 chart for Seton? ‘wheres no Ope 7 4 | foveem? ‘service code “Opa = Spiny on otek sere fete” || Sar fedpoment eile, ‘dusting ot |_!2 Carry out troubleshooting for veslamre sensing ot Lr fas mechonia syst rot [ge rom modes ecocte |] Sette sea. , |B || Bee Ee so does 7 “Ghckuane | Saespend rmontor || “montomng? | Sropunder ponerswiten || mode. |_heavyload? Camry ot vouesoaing nofosout |] “eataier NO System fF mod. sayy |] SEBS -Fimpéonoter ores so “ig sonrte pastor ot | shore tx nex poe monmat Hine disoay nt give, ne montana NO ontolere detective, 20-96 20506k20506 TROUBLESHOOTING __DETAILS OF TROUBLESHOOTING AND TROUBLESHOOTING PROCEDURE * NOTE If there is no abnormality display in the networking system transmitted in S-NET, it can be taken that the output, signal from the monitor panel has been transmitted. However, even if there is no abnormality display, if the operation is defect e, use the following procedure when checking directly, If any abnormality occurs in the S-NET system, the system is automatically switched to the following default mode, so be careful when carrying out troubleshooting, * Default mode 1 2 When networking cannot be carried out for the monitor and engine throttle controller + pump controller ‘Set mode Pump controller Engine throttle controller 1 | Working mode G/O mode HO mode 2_| Throttle signal FULL FULL 3 | Auto-deceleration ‘ON (deceleration mode) ON (deceleration mode) 4 | Coolant temperature signal OFF = | 5 | Priority mode OFF = 6 | Power max. mode (ON (power max. possible) 7_| Travel speed 10 I _- @ | Automatic warming-up __ [ON (automatic warming-up mode) When networking cannot be carried out for the monitor and engine throttle controller Only throttle signal is recognized as FULL; normal control is carried out for others. ‘* Procedure for checking monitor panel output signal + For details of operating the monitoring mode, see MONITOR PANEL DISPLAY AND SPECIAL FUNCTIONS. Connection condition of components 1). Set to the monitoring mode and display monitoring code 08. 2). The time display (bits) will ight up to display the components that are connected, * © Pump controller, @ engine throttle controller, @ valve controller will light up. Checking working mode signal (check No. 2 throttle signal at the same time) 11. Set to the monitoring mode and display monitoring code 40. 2) Switch the working mode as shown in Table 1 and check that the engine speed changes. vom) peel! {The figures in hare tho rated speed Wortig move] Open” a vo _(MetCenipment | Ao ase am) | Apo 2 a Travel | Approx. 2,420 (2,200) Approx. 2,520 (2,300) Vion eaipment [Aron 23801900) | Approx 22002000) eoro He Teva fevron 21001 1 | Aaron 24001 — 9 Wik canon | Arpox 170000) | Approx 1780 (5m “0 Travel Approx. 1,750( - } Approx. 1,750( - ) 20-97TROUBLESHOOTING _ DETAILS OF TROUBLESHOOTING AND TROUBLESHOOTING PROCEDURE 3. Checking travel speed selection signal 1) Set to the monitoring mode and display monitoring code 23. 2) Change the travel speed switch to Mi or Hi, run the engine at 1500 rpm or above, and operate the control lever. Check that bit @ lights up when this is done, 4. Checking boomiswing priority selection mode signal (swing boost 2 for HYPER GX) ‘If the travel oil pressure switch signal is not input to the controller, the flow from the front and rear pumps will remain divided. 1) Turn the boom/swing priority switch to ON (swing boost 2 for HYPER GX) 2) Set to the monitoring mode and display monitoring code 23. 3) Check that bit @ lights up when the boom, arm, bucket, and swing are operated independently or together. Check the operating condition of the pump merge-divider solenoid valve ‘¢ Checking input signal of engine throttle controller, pump controller, valve controller (HYPER GX) Check the input signal for each controller as follows. Pump controller Checking input signal 1) Check oil pressure switch i) Set to the monitoring mode and display monitoring codes 20 and 21 ji) Operate each work equipment lever, and check how the bit pattern lights up. + For details of the bit pattern chart, see MONITOR PANEL DISPLAY AND SPECIAL FUNCTIONS. 2) Check engine speed sensor (check engine speed) ji) Set to the monitoring mode and display monitoring code 10. ) Use the fuel control dial to change the speed, and measure the engine speed when this is done. 3} Check pump pressure sensor }) Set to the monitoring mode and display monitoring codes 11 and 12. %* Code 11 is for the front pump, and code 12 is for the rear pump. ii) Refer to Table 2 and measure the hydraulic pressure at the front and rear pumps. Table 2. Pump merge-divided flow logic and pumps actuated by control levers Boom/swing priority selection mode OFF] _beafe/Syng Prony selection Basically flow is merged a la Front pump Rear pump Front pump Rear pump LH. travel ° : ‘Swing e Arm ° ° - Boom © @ Bucket e ° Ru. travel < a ‘When the travel is operated independently divided flow, travel + compound operations becomes the merged flow. 20-98 2050620506 TROUBLESHOOTING __DETAILS OF TROUBLESHOOTING AND TROUBLESHOOTING PROCEDURE 4) 5) Check kerosene mode input signal i) Set to the monitoring mode, and display monitoring code 22. ii) Connect the CN-M36 connector and check that bit ©) lights up. Check LH. knob switch input signal ’) Set to the monitoring mode, and display monitoring code 22. ii) Push the LH. knob switch ON and check that bit © lights up. 2. Check output signals v 2) 3 4) Check LS contro! EPC solenoid output current i) Set to the monitoring mode, and display monitoring code 18. ii) Run the engine at high idling with all the levers at neutral and in the G/O or H/O mode, and measure the current. % All levers at neutral: 900 = 80 mA Engine at high idling, travel speed Hi, travel lever operated: 0 A Check No. 2 throttle signal i) Set to the monitoring mode, and display monitoring code 16. ii) Use the procedure in item 2 for checking the monitor panel output signal, and measure the engine speed. Check ON <> OFF solenoid condition i) Set to the monitoring mode, and display monitoring code 23. ii) Refer to Table 3 and check that the applicable bit lights up. Table 3. Types of solenoid and conditions for actuation Name of solenoid ‘Actuation condition Bit that lights up. elect ‘Swing + travel lever operated ® ‘Swing brake ‘Swing operated oO Pump merge-divider | Lj mode @ Zstage relief Travel lever operated 6 ‘Travel speed switch: Hi Travel speed Fuel control dial at midway position or above © Travel lever operated Check TVC solenoid output current i) Set to the monitoring mode, and display monitoring codes 13 and 14. © Code 13 is for the front pump, and code 14 is for the rear pump. ii) With the starting switch kept at the ON position and in the GO mode, measure the current when the fuel control dial is turned to the MAX position. PC200 510 = 80 mA, PC220 410 + 80 mA, 20-99TROUBLESHOOTING __ DETAILS OF TROUBLESHOOTING AND TROUBLESHOOTING PROCEDURE ‘¢ Engine throttle controller 1. Check input signal 1) Check fuel control dial input voltage i) Set to the monitoring mode, and display monitoring code 30. ii) Measure the voltage when the fuel control dial is turned from low idling to high idling. * Voltage: 0.25 - 4.75 V 2) Check governor potentiometer voltage i) Set to the monitoring mode, and display monitoring code 31 ii) Measure the potentiometer voltage when the fuel control dial is turned from low idling to high idling, * Voltage: 05 ~ 45V Check output signal 1) Check governor motor drive current i) Set to the monitoring mode, and display monitoring codes 33 and 34. ‘* Code 33 is the A phase (direction for increasing engine speed), and code 34 is the B phase (direction for reducing engine speed) ii) Measure the governor motor drive current when the fuel control dial is turned in the acceleration direction and deceleration direction. + Current: 700 = 70 mA 2) Measure battery relay drive voltage i) Set to the monitoring mode, and display monitoring code 35. ii) Measure the battery relay drive voltage when the starting switch is turned from ON to OFF. iii) Set to the monitoring mode, and display monitoring code 37 iv) Check that bit © lights up when the starting switch is turned from ON to OFF. (Min. 4 seconds - Max. 7 seconds) 20-100 2050620506 Engine throttle controller system circuit diagram Action taken by controller when abnormality occurs and problems on machine Judgement table for engine throttle controller and engine related parts TROUBLESHOOTING OF ENGINE THROTTLE CONTROLLER SYSTEM (E MODE) to remember when carryi 1g out troubleshooting of engine throttle controller system ....20-102 Troubleshooting flow charts for each failure mode £-10 [3:16] Abnormality (step-out) in governor motor system is displayed .. E-11 Engine does not start. E-12_ Engine speed is irregular E-13 Lack of output (engine high idling speed E-14 Engine does not stop. E-15 Defective operation of battery relay system (engine does not stop) 1 Abnormality in engine throttle controller power source system (engine speed stays at low idling) 2. [3:08] Abnormality in fuel contro! dial input value is displayed 3. [E3:17] Abnormality (disconnection) in governor motor drive system is displayed w.r20-108 4. [€3:18] Abnormality (short circuit) in governor motor drive system is displayed 5 [€3:01] Abnormality in network reception system is displayed 6 7 8 9 [€3:05] Abnormality in model code is displayed [E3:06] Abnormality in governor potentiometer system is displayed [E3:07] Abnormality in pump controller throttle system is displayed .. [3:15] Abnormality (short circuit) in battery relay output system is displayed a) Idling speed is irregular .. b) There is hunting... too low) . 20-101POINTS TO REMEMBER WHEN CARRVING OUT TROUBLE- TROUBLESHOOTING ‘SHOOTING OF ENGINE THROTTLE CONTROLLER SYSTEM POINTS TO REMEMBER WHEN CARRYING OUT TROUBLESHOOTING OF ENGINE THROTTLE CONTROLLER SYSTEM 1. Points to remember when there is abnormality which is not displayed by user code ‘The engine is controlled by an engine throttle controller. ‘The problems that may occur with this system include the following. Idling speed is too high (too low) High idling speed is too low Auto-deceleration speed is too high (too low) Engine speed for automatic warming-up operation is too high (too low) There is hunting 6. Engine does not stop If any abnormality occurs, and the abnormality is displayed on the time display portion of the monitor panel, use the troubleshooting table to determine the appropriate troubleshooting flow chart from E1 to E10 However, if there is any abnormality in the machine and no abnormality display is given, it is necessary to determine whether the problem is in the mechanical system or in the electrical system. Ifthe linkage between the governor motor and the injection pump is not properly adjusted, problems 1 to 6 listed above may occur. Therefore, if there is no abnormality display, but one of problems 1 to 6 above has occurred, carry out troubleshooting as follows. 2 ves ance agurent of governor mato inkge iiaage bare See TESTING AND ACLUSTING vos Yes|Breenmieeiese, | 1 Vth ee ease, || Meee {G0 to troubleshooting E-12~ E15 of eestrical system Recto pomp “With starting se arate So ‘ON, operate fu parolees peawe || contol dil and brmencerstnaswes || Working mode Cr a {Goto troubleshooting $1 -$-16 of engine system “engine dows nol sap, push {ovelnor lever to STO® postion End check engine tope Disconnect the linkage as explained above, or check the adjustment and go to the troubleshooting flow chart for the mechanical system or electrical system. ‘For details of the procedure for adjusting the linkage, see TESTING AND ADJUSTING. 2. Points to remember if abnormality returns to normal by itself In the following cases, there is a high probability that the same problem will occur again, so it is desirable to follow up this problem carefully. 1) If any abnormality returns to normal by itself, 2) If the connector is disconnected and the T-adapter is inserted, or if the T-adapter is removed and the connector is returned to its original position when carrying out troubleshooting of the failure, and the service code is no longer displayed, or if the monitor display returns to normal After completing troubleshooting, always erase the user code from memory. Service code memory retention function When displaying the service code in memory and carrying out troubleshooting, note down the content of the display, then erase the display. After trying to re-enact the problem, carry out troubleshooting according to the service code that is displayed (There are cases where mistaken operation or abnormalities that occur when the connector is disconnected are recorded by the memory retention function. Erasing the data in this way saves any wasted work.) 20-102 2050620506 TROUBLESHOOTING Ea E-1 Abnormality in engine throttle controller power source system (engine speed stays at low idling) % This troubleshooting is carried out when there is still an abnormality, so when disconnecting the connector and inserting the T-adapter, or when removing the T-adapter and returning the connector to its original position, if the service code is not displayed, the problem has been removed. con = we Detective engin throtie | Replace Yesleoverenctia H Defective contact, or dis normal? 3 yes eornecton nating harass | Repair or 's voltage between PSor tni = £01 Yemale 6) /normal? «Tur starting switch ke Le a + Tun starting switch | 4 YES | connection in wiring harness | Repair or 'NO| and GND normal? Detective contact, or dis- i HATO vette J} QO AG EO1(MIC21) Fuse +HO6(L2) ay “026101 hy S @ BI E {n 1 202cK06501 20-107‘TROUBLESHOOTING E2 £-2 [E3:08] Abnormality in fuel control | input value is displayed + This troubleshooting is carried out when there is still an abnormality, so when disconnecting the connector and inserting the T-adapter, or when removing the T-adapter and returning the connector to its original position, if the service code is not displayed, the problem has been removed. + Before carrying out troubleshooting, check that all the related connectors are properly inserted. + Always connect any disconnected connectors before going on the next step. Cause Remedy conmceccet ES Detecive engine rote | Replace YES) fete 116, or L] 1[ [semeeneasrn aed apps Detective wiring harnessin |p is resistance be syst mith dotective eed fever ede aie) [| -turn sting NO fastance a tea) ao) uteh OF Sowntn tote? | | « Biconnac £0. “Tum Sarina eecive vel contol diat | Replace Gate OFF NO Vameaaca fo fen + Baconnec 08 Note: If 3:06 also occurs at the same time, check the wiring harness below. + Wiring harness between E01 (female) (6) ~ H02 (1) ~ E04 (female) (1) short circuiting with ground, or contact with other wiring harness Table 1 E01female? E06{mate) Resistance valve -m ma 025-7K2 | 7-08) 21a 025 - 7k. (8) : 2-3K0 : -@ [Between each pin - and cassis, E-2 Related electric circuit diagram Engine throttle controller XOT(MICI7) E06 (M3) forte o 1 eons som | g B Fe g le) omen |G T T covernor owe S 5 +HO2 (S16) £04 (X3) 20-108 8 g20506 ‘TROUBLESHOOTING E3 E-3 [E3:17] Abnormality (disconnection) in governor motor drive system is displayed This troubleshooting is carried out when there is still an abnormality, 20 when disconnecting the connector and inserting the T-adapter, or when removing the T-adapter and returning the connector to Its original position, if the service code is not displayed, the problem has been removed. During operation, if tere is 1) 2 simultaneous disconnection in A phase and B phase: © the engine wil run at low idling @ the engine will not stop 2) a disconnection in either A phase or 8 phase: the engine speed will remain the same as before the abnormality occurred + Ifthe problem occurs when the engine is stopped, 1) the engine can be started, bu it stays in low idling, or 2) twill not stop ater i is started. By Step the engine (push the governor lever of the fuel injection pump to the NO INJECTION positon) before checking 4 Before carrying out troubleshooting, check tha all the related connectors are propery inserted. % Always connect any disconnected connectors before going on the next step cause Remedy 2 YES Detective engine torte | Replace Ege pem eontatier, EM femal or between 1 1 {lesen ands . Ts vestancabatwasn) | [25 shown in Tole Defective wisinghacnessin | pecar or rem witn detective ep raise betesen 1 =Tumstacing NO Fessonce reploce [chp andenssns[] _ sich OFF. SEsnewnin Tabi? | | Disconnect 0% “Turn staning a i swteh OFF efetve governor mator | Replace + Biconneneos, NO Table 1 £06 (male) Eo1(femae) Resistance value | [ae (10) ~ (20) 25-70 a ann 25-70 7-6) (ao - Min, Ma 4) (19) - 2) Min, MO Between pins | Between pins mereray | oan co en Min, Ma and chassis and chassis E-3 Related electric circuit diagram E01 (MIC21) H02(S16) E05 (X4) — 2} ac @ 7 Wan Eases 5 30 £3] AC-) L$ 3 S B(-) (8) 4 oeckoss03 20-109‘TROUBLESHOOTING Es E-4 [E3:18] Abnormality (short circuit) in governor motor drive system is displayed + This troubleshooting is carried out when there is still an abnormality, so when disconnecting the connector land inserting the T-adapter, or when removing the T-adapter and returning the connector to its original position, ifthe service code is not displayed, the problem has been removed. + Ifthe abnormality occurs during operation, because of the force of the spring, 4) the engine will run at low idling, or 2) the engine will not stop + Ifthe problem occurs when the engine is stopped, 1) the engine can be started, but it stays in low idling, or 2) it will not stop after itis started. A Stop the engine push the governor lever of the fuel injection pump to the NO INJECTION position) before checking + Before carrying out troubleshooting, check that all the related connectors are properly inserted. + Always connect any disconnected connectors before going on the next step. cause remedy epee Defective engine throttle Replace rege eo ronoher YES i San Teron pgm] | essen ae Detective wiring names in Veep or ectencitte || stunsanpa NO aasans epee candace |] | swich OF S2kEeeis abe’ | |» Disconnect €or “Turn sa Sten OFF + Blsconnec E06. fective governor motor | Replace Table + 05 imate) | E01 Gemale) | _ Resistance valve i i -e@) (10) - (20) 25-70 ow av-@n 25-70 =a) 0-0) Min. a, = (0-20 Min. a. Setween pina | Between pine aaa | cannaaen | Min we nd chasis | and chess E-4 Related electric circuit diagram E01 (MIC21) HO2(S16) E05 (X4) Governor 2 motor =z A(+) 1 E| 3c) 39 23) AC) 8) a £8] B(-) ) 2oecko6sos 20-110 2050620506 ‘TROUBLESHOOTING ES E-5 [E3:01] Abnormality in network reception system is displayed + This troubleshooting is carried out when the and inserting the T-adapter, or when removing the T-adapter and returning the connector to its origi Position, if the service code is not displayed, the problem has been removed. + If the starting switch is turned ON when there is a disconnection in the wiring harness between the monitor panel and the controller, or the positive end (+) of the network wiring harness or the inside of the controller are short circuited, the controller cannot carry out networking, so the monitor panel does not display any ‘abnormality Before carrying out troubleshooting, check that all the related connectors are properly inserted ‘* Always connect any disconnected connectors before going on the next step. is still an abnormality, so when disconnecting the connector ! ‘When E3:01 is displayed independently cause Remedy Detective conte oc matin ‘Ofengine trotle controler | Repair eonractar€08 Disaorest€08 esenntr han Dette engine tratie | Replace oes serves code controller etsy gout? “Tum arng sch ee ts comnection of 4 YES! [Defective pump controler | Replace + Disconnect connec. L Sun ave! tor nen connect NO] Sepaycd? YES] ¢otaoe tatween ‘Sinetor apa cess ‘+ Turn starting switch 3 [1 95) normal? on “Torn gariog Deteivecomact or |pepiror ps ov Does LED ot pum Bcomnecion network |ReRai coast No) Sona lpg “Tun saringoweh i - oN NO hen When £2:18 and E3:01 are displayed simultaneously cause feedy Yes Detection cemaing |. 1 P02 er * Dianne POP onset tan fame nan, Posie song atacmert Lrg o eran ode feminghereesinconae™ | display go out? 2 with ground mre Preah Is thre comity Tansee? L] between Po2’ BERGE xo] etl 6 ang 2 VES Dacomect, NO Tchr === contoter wich hasbeen | Replece sonet carseat onnocted wasecive Sensing” “gwich OFFS ny between FY Side Bethan, $e service ‘C03, and E01. 20d GND? eee oo Detective mentor panet | Repisce femesaoma — *Tunstag Contater ten «Shake wing shectng for ‘names around contraler cons stron cesting or cont + Connect 902 ast " 20-111‘TROUBLESHOOTING ES Monitoring display (Time display portion) ngeOO@ YeQO@ © fgpomiesreten ‘@ Sone ar E-5 Related electric circuit diagram c03 (04016) P02 (04016) Network eeu Pump controller B01 (M1C21) tomers") @ Monitor fey | @ * Check for the LED display for the engine throttle con: troller and pump controller from the direction of the ‘arrow as shown in the diagram on the right. Note 1: Push the operator's seat down to the front, then remove the two rear covers to check. Note 2: The LED display for the pump controller is di cult to see, $0 use a mirror. 20-112 Engine throttle ler zozckoesos Engine throtte controler —~ Pump controler = 27 Minor zosrossee 2050620506 ‘TROUBLESHOOTING £6 £-6 [E3:05] Abnormality in model code is displayed This troubleshooting is carried out when there is still an abnormality, so when disconnecting the connector ‘and inserting the T-adapter, or when removing the T-adapter and returning the connector to its or position, if the service code is not displayed, the problem has been removed. + Before carrying out troubleshooting, check that all the related connectors are properly inserted. ‘* Always connect any disconnected connectors before going on the next step. Cause Remedy ne Detective engine wvowte | Replace SSpcode depoy 28] Sunn abe 2 ES oo “Turnsiering fyi. and H -Siormontaing NO] SNBagstown 9 Common orthoreven, | Restor ‘code 03 and 36. a shor ciruit with ground, or | replace “Tumsagng NO Gaconnectonn sppliable. en OFF sig horness = Baconnecr 01 on ‘Table 1 Monitoring aisplay (Time display portion! OFF Table? Resistance value f —T Condon of engine tvonle [Engine trotle convaler] {Applicable wiring 7 controller input model code harness Peato pez | Berwoon E01 female) 932208 anenien Minima | Max 1a ud.cuu | [Between E01 tema] yan var | win a aan Ha) and GN. z S Beiween £01 female) | haa va ni g3°220 eee | Moa . [Betwoen £01 lomaie oH L ween E01 ifemale)| yan ange | Min. 1 £6 Related electric circuit diagram E01(MIC21) CO9(SB) Model selection connector Saetion 1 p ct Mode! action 2 5 Gg g Mo o estion 3 Modo flection & GND g g Pczi0 Pozo 2oscaassa1 20-113‘TROUBLESHOOTING E-7_ [E3:06] Abnormality in governor potentiometer system i displayed % This troubleshooting is carried out when there is still an abnormality, so when disconnecting the connector and inserting the T-adapter, or when removing the T-adapter and returning the connector to its original position, if the service code is not displayed, problem has been removed. + Before carrying out troubleshooting, check that all the related connectors are properly inserted. + Always connect any disconnected connectors before going on the next step. couse Remedy 2 YES —— Detective engine ratte | Replace tacrpnoteet eontaie YES] fen BGI 1 | etait shown fnne Detective wiring harness in Is esstance System with dlectwe | Repel between E06 nale)|| = Turnstaning NO resistance place Mee= shes [| ewten OFF fhownin Table 1? || «Disconnect €01 “Torn soning et Repl ae elective governor motor | Replace Dlscomeetéos, NO Note: If £3:08 also occurs at the same time, check the wiring harness below. Wiring harness between £07 female) (5) X07 (6)-£06 femele) (1) short circuiting with ground, orcontect with other wiring homoss g 8 for ens) | Otiwoto) | ester ve n=) ee eas —7 eo 8 2a : oe om ‘and chassis = _Min 1a, E-7 Related electric circuit diagram x07 (MICI7) E06 (M3) B01 (MIC21) € T Throttle signal Feu ‘control gal ow ‘Throttle power ‘source (+) L a Feedback signal Governor | Throttie power potentiometer E ftource 4 S S +HO2 (516) E04 (X3) zozc06s02 20-11420506 ‘TROUBLESHOOTING E-8, E-9 E-8 [E3:07] Abnormality in pump controller throttle system is displayed Start troubleshooting from £6 [E305] or C-8 [€2:171 E-9 [E3:15] Abnormality (short circi displayed battery relay output system is + This troubleshooting is caried out when there is still an abnormality, so when disconnecting the connector and inserting the T-adapter, or when removing the T-adapter and returning the connector to ite original position, if the service code isnot displayed, the problem hes been removed. B S00 the engine (push the govenor lever ofthe fue injection pump to the NO INJECTION postion) % Before carrying out troubleshooting, check that al the related connectors are properly inserted % Always connect any disconnected connectors before going on the next step. Note: This only occurs when the engine is stopped and the stating switch is turned OFF. Cove Remedy ee Detective engine throtte | Replace EDT ema 1 ane ecatromar YES] cerry moat [| — Detective batoryrolay | Replace [female 13) an batery relay BR: Max 1 + Benwosn wing harass and thase Min, 7 MA Ie resistance be wveen £01 female) [ishong cnosoe ormal? ‘Tom starting ewiteh OFF 11 Contact betweon oer Wiring harese and wiring Thopron toon ~ |_* Disconnect Banana botery relay BR. Rat oetweay 2) np or “pnores NO Seterrmayer |" + Bheonnect or 2 ina ight connected E-9 Related electric circuit diagram XOT(MICIT) Fase 14 [—o~_o— Starting switch Engine throm contoller E01 (MICP1) Battery relay starting switch 02 (S16) JON’ signat Battery relay drive pis 2ozcKossa5: 20-115‘TROUBLESHOOTING E10 E-10 [E: 6] Abnormality (step-out) in governor motor system is played + This troubleshooting is carried out when there is still an abnormality, so when disconnecting the connector ‘and inserting the T-adapter, or when removing the T-adapter and returning the connector to its original position, if the service code is not displayed, the problem has been removed. + If any other service code {E3:01] ~ [€3:18] has occurred at the same time, start troubleshooting from that code. ‘Check that fuse 2 is normal. ‘Read the precautions given in TESTING AND ADJUSTING, “Adjusting stroke of governor motor lever” before carrying out the troubleshooting. Before carrying out troubleshooting, check that all the related connectors are properly inserted. Always connect any disconnected connectors before going on the next step. couse Remedy YES. 60 to applicable - troubleshooting code ; etc eon ote |ropace £305 7 oasis an sO [Operate fuel control} Sloyedr vyes| ob a RN ohatpeetin 4 7% 7 Serelon rma FS] ppetecivoiniage | |Acustor patron va 2| Thea rian) | [Behn ncn pup res Tynaring swe [ons es a reves sien Isssuamenot [| femme a Finkage norms seoyeraton OF Detecve governor motor | Replace xo “Serle Omens NO o i Beetle g “Dome “Tonacee | Sutera’, “Tnage st gover pong semen noes tne Een ND tne stent [ada or erator ets wee ron est nose. | ADJUSTING) 20-116 20506‘TROUBLESHOOTING E-11 Engine does not start When starting motor does not rotate. Check that fuse 14 is not blown before starting troubleshooting, Before carrying out troubleshooting, check that all the related connectors are properly inserted. Always connect any disconnected connectors before going on the next step. 4 YES i ytagepawoen ‘Yes staring motor" [| Fins | [Soe Twasagee (NO ves! Tosa H sme, Fe? 5 YES “ungengg, | [avons omen etch Stak | Sneha sopenes 1 “Tungieg — NO oe er 2 Bashy yes [ire ring s YES) switch is tumed Is there continuity EF sara ves] Senet” ee Sta 8 irs ey “Turn tating SS ae bs rexiance of ie " i FS! oning seh oh Ly Seer aon | sees 1 Seroconinuy || -Boweeppanna ves{sumezcctrng’ [| “Seteebeaatb switch terminal B tery relay BR: Max. he isyotoge ana 5 [| Sasae «Behe Ato ines acai 1 Ma See Search ary Sata tay ly tensa tevotape ct || -Tugnsorinonwien| “ens eattte + Min, 26 NO] termina B normal? [] + Remove terminal 8. NO Beit reir M138 E-11 Related electric circuit diagram gix2) EBSWP14) —HOBISI6) T xorimici7) Starting motor tb a Battery a) r Starting switch HOS1NB) Fuso le Battery relay Mw He 1516) a joa 20-118 2050620506 ‘TROUBLESHOOTING cause Remedy Defecive string motor Defective contact of wiring Rarnoss between battery) ate) relay 8 batry relay Mt starting motor te eat crc Bay Defectve contac, or ais Jeonnecton wiring hanes Serwean earing ste ter final C= x07)" HO — EEC te sacra Detective staring switch {between terminate 8 and ©) Defective battery lay Defective contact of wiring harness batween battery iy arminal E ane revhang ame one Defecive contac. ot ‘Ssconnecson in vring Rarness between str ort ermine B= De ozs) = eatery relay ermal BR Defecive staring swith etween 8 and Bi Defective contact, rai: eonnecton wing harness Between baer terminal Ratt Hos 6) KO T= starting etch terminal 8 incuting fuse ink! Lac of battery capacity Replace Repair or replace Repair or repioce Replace Replace Repae or etace Repair or replace Roptoce Repair or charge or 20-119‘TROUBLESHOOTING E-12 Engine speed E42 irregular Before carrying out troubleshooting, check that all the related connectors are properly inserted Always connect any disconnected connectors before going on the next step. a) Idling speed is irregular YER £201 dplayes? [who inage oe ‘es|weon governor mete snd icon pom by ecsoa does cont im become noma? * Bee TESTING AND ~Tygnsrng sen Sane N 3 Tmeniaae = starsignal 7 YES. ing porn S| Is voltage between NO dager stops nat Yer ecto a | 1 tot Potentometer 8 [] fem sna? Is engine tote onto model oda aeshown in bie" “Turn saring| witch ON, + Sotto monitoring foae 0 “Turn sang etch ES 5 voltage bemween on YER cot iV andi8, Formal an tab? “During operation, NO 2 ual controldiat_§ Be ain tzvotage amen || “ALLY Sy off] sem 25H NO Aton ai coer NO Engine throttle controller inodel soa | n3°3nn Poato 03°200 P24 03:220 | 20-120 20506k20506 ‘TROUBLESHOOTING E42 cause Remedy seoes - Detecive adjustment of | Adjust fntage —_ontrctive iniccion pump | See Smee Defective governor motor | Repioce Detective contacto wiring Rarnese between staring’ | Repaitor fswen ace x07 11101 [replace imal (or detective starting stich seee7 - seee2 ———_—. $f = E-12 Related electric circuit diagram Governor potentiometer Staring switch XO7(MICIT) Fuse 1 €}—p ca Engine throtle controler E01 (MIC21) xO7(MICI7) E06 (M3) Starting switch ON'signal € Fuel contol Twrotte sonst |@ 5 e 3 @ g GND T Feedback signl rote pow touree Oh S S HOa(516) £0a(x3) zoeckoss07 20-121‘TROUBLESHOOTING E-12 ves 4 aa 2 YEs| Bes ree a ‘YES! £3101 aisplayea? H ern or see TETNSAO Seine Teen ‘witch ON 3 Teton aa ves ad Deen sal 7 eretaeees | ofits ai Se ee vote betwen 1 — YES|Eonand Go) “Tam sare oteniamater_6,{ fromel snd sabe? Senso Fore font rn a ssvtape onamn | | = Ardowioaian tele veslgpeine [RSE Ky gant midway | yt conotdiat_s | [mel snd svi! vn cancel “Tonga ree Tres “Aon is volagebeneen “Sons Eotiand 16) cath agckv te coe NO] ormetandstabier [] *At Maing, “Rowing ce -avhih ito aay" xoy NO No T Engine thro controller rw | 93° 200 row | Q3220 20-122 2050620506 TROUBLESHOOTING E12 cause Remedy fw s = $ret scrsinerict | acne tog Detecive injection pump | see Smose sunsignal__8 YES Detecve governor motor | Replace Igvotagebenween ory ana aay serma and ble? Deecve conte of wing Farmers betwen Sy ch ace "xor tno | Regaicor “During operation NO ‘0 SSov itematel hor detective staring sich see crs it? Or rte orcs E-12 Related electric circuit diagram Starting switch) XO7(MICI7) Fuse 14 (cca) Engine throtie controler EorMicat) — xo7(Mic17) E06«M3) arog ewe] Fue! control dil 7 | b HoBTSI6) E0dcx3) Governor & potentiometer IG 1G co3oao-16) T se 20-123‘TROUBLESHOOTING £13 E-13 Lack of output (engine high idling speed is too low) 4 Bofore carrying out troubleshooting, check that al the related connectors are properly inserted 4% Always connect any disconnected connectors before going on the next step ves ves 2 YES] 1, £3901 displayed? Tone Soo 3 i Does neon ( Rect a poe" re votage tewzen Yes contend Ger 4 Se ee 1 alto = At low idling: inoue ves| voto ween || Aneae™ | corm Is engine throttle ? NO. soci toe normal and stable? ecmecern Table 1? 4 | Tatiow idling: Tees || Ue g pose moarmermeet Lf ASa aioe NO 8 Satta monitring NO|Sndiestion pump g se nat 1 ves Noses nes ESTRGAND NO Seeing XO ratie 1 Tenens ate contr | | Enns recede | n3°ann row | 37200 rw | O32ec8 20-12420506 TROUBLESHOOTING E43 Couse Remedy SeoEs = “J potective injection pump | ee § mode Startsignal___9 YES vss voltage between NES corte) ane a) Decseaton signal 8 []pormal ana stable? Is votage between EDs tana 2 normal ane sabe? During oparaton. NO Een TA deceleration an VN When caveat NO av Defective governor motor Detective contac f wiring osmess between starting Sytem ACEO? (171201 Teme) (6, o detective staring smth See c-15 seoe7 seat? Detective agjustment of povernor mato nage 1 S mode Seoes Suing Sch” XO7(MIC17) Fone S i Engine tote controler eormicar) —xorcici7) | eosanay wozTSie) — coaTeg contonen rte p> mene poe | | Hee c03(080-16) buo | @ (stSeraon| Pump controer ovens? Replace Repair or replace aust 20-125‘TROUBLESHOOTING E-14 Engine does not stop BSi0P the engine {push the fuel control lever ofthe fuel injection pump to the NO INJECTION position) before checking. 4% Before carrying out troubleshooting, check that al he related connectors are properly inserted % Always connect any disconnected connectors before going on the next step. 4% Read the precautions given in TESTING AND ADJUSTING, “Adjusting stroke of governor motor lever” before carrying out the troubleshooting, ves 2 7 yes YES| ever Contec STOP stopper and top tar posiion? Tye sane ovich 3 Potntiomer 8 YES noe Tenia nen startin ‘hes dae ves sich OF Sat time tage between No| pematiani dow Satay ivesigal § YESH Hh and) wa When so ermal? LL ch OF does no See TESTING AND YES togeoen iL] “whensnaineie NO cre mode! PONTING Sutsignal_4 || Pifoonin sown] | Pere 29-330 ade sa shown in Fwhen sri 1 pene: 28-327 Tae frwtchis OF ie || -20-30¥ ota between “Tugn wing och NO] E118) ana a ow ermal? oo Max WV No No Tobie 1 Engine throttle controller model code Pcz10 03:200 raw | Q30ee0 Table 2 \eotage rom taring (Abproe 21 (€016) = i rt (E01) CF Note: When the starting switch is ON, the controller end is OFF, but a voltage of approx. 20 ~ 30V is always flowing from starting switch BR, so if the voltage is measured at E01 (13), there is a voltage of 20 ~ 30V. 20-126 2050620506 TROUBLESHOOTING E14 cause Remedy Defective injection pump | See S mode Detective adustment of Tinkage J tect governor motor seee7 ef tective engine trot eontater Contact with 24V wiring mess of wiing harness $f rrr atari ten ac exon) = €0\ femae\ 6 or getetve starting ston omer E-14 Related electric circuit diagram Adjust Repisce ease Governor potentiometer Battery relay TOE SEL MeL 2 Starting switch Nite) € ‘HO2(S16) wow Ql g East S Gg HO2(S16) a( { E zozckuss0s: 20-127‘TROUBLESHOOTING E45 E-15 Defective operation of battery relay system (engine does not stop) Note: This only occurs when the engine is stopped and the starting switch is turned OFF. B 3:0 the engine (push the governor lever ofthe fuel injection pump to the NO INJECTION position) before checking % Before carrying out troubleshooting, check that all the related connectors are properly inserted. % Always connect any disconnected connectors before going on the next step. Coure Remedy Is 3:5 displayed Detective engine throwle | Replace Falay dive signal 2 onto: “Pap omrna oven || iy of pn oH toting de 35 St ——— Detective bateryreley | Replace “Turn staring smtch L] Boy lo wil ee arta eve Be and ont bata 1 Disconecton inti 205307 sesh Se EET oxo (emote (ayeH02(@)~ | Repaio Between 01 NO Srey ay an - EERIE EB anctatey vey ark 10 | ieee 1 fetien tg halo sin aa ttn ey OF 1 Diet Bas atey lay 2 Table 1 Sonor core) ot 3 an ay eae) OFF Mn soe Note: When the starting switch is ON, the controller end is OFF, but a voltage of approx. 20 - 30V is always flowing from starting switch BR, so if the voltage is measured at E01 (13), there is a voltage of 20 ~ 30V. E-15 Related electric cit XOTIMICIT) Fuse uit diagram ys stating ‘switch io sor cet Batty relay se no2isi6) son I o sy) Engine tote conroler Far 13. 20-128 k2050620506 Method of using troubleshooting chart. 1 S-2 TROUBLESHOOTING OF ENGINE (S MODE) Starting performance is poor (Starting always takes time) Engine does not start. ® Engine does not turn. 5 © Engine turns but no exhaust gas comes out (Fuel is not being ® Exhaust gas comes out but engine does not start (Fuel is being injected) Engine does not pick up smoothly (Follow-up is poor) Engine stops during operations Engine does not rotate smoothly . Engine lacks output (no power) : Exhaust gas is black (incomplete combustion) . Oil consumption is excessive (or exhaust gas Oil becomes contaminated quickly . Fuel consumption is excessive .. Oil is in cooling water, or water spurts back, or water level goes down Oil pressure lamp lights up (drop in oil pressure) Oil level rises ‘Water temperature becomes too high (overheating) Abnormal noise is made .. Vibration is excessive 20-129‘TROUBLESHOOTING METHOD OF USING TROUBLESHOOTING CHART METHOD OF USING TROUBLESHOOTING CHART 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 inspection without using troubleshooting tools. Next, troubleshooting tools or direct inspection ‘are used to check the high probability causes to make final confirmation [Questions} Sections ® + ® in the chart on the right corre: sponds to the items where answers can be ‘obtained from the user. The items in ® are items that can be obtained from the -user, ‘depending on the user's level. [Check items} The serviceman carries out simple inspection 0 narrow down the causes. The items under © in the chart on the right correspond to this. ‘The serviceman narrows down the causes from information ® that he has obtained from the user and the results of © that he has obtained in frafen 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}. t a = als oH = ie 5 ° (ah o 4 eh o ells | a 3 7 ° af ° 20-130 2050620506 ‘TROUBLESHOOTING METHOD OF USING TROUBLESHOOTING CHART ‘The basic method of using the troubleshooting chart is as follows. Items listed for [Questions] and [Check items] that have a relationship with the Cause items are marked with O, and of these, ‘causes that have a high probability are marked with ©. Check each of the (Questions) and (Check items] in turn, and marked the O or © in the chart for items where the problem ‘appeared. The vertical column (Causes) that has the highest umber of points is the most probable cause, so start troublesh- ‘oting for that item to make final confirmation of the cause. 381, For (Confirm recent repair history) in the [Ques tions] Section, ask the user, and mark the Cause column with a to use as reference for locating the cause of the failure. However, do not use this when making calculations to narrow down the Lox2. Use the 4 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 deter- ‘mine the order for troubleshooting, "FT | Confirm recent repair history ‘#2 [Degree of use Operated for long period 20-131‘TROUBLESHOOTING METHOD OF USING TROUBLESHOOTING CHART 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 weak- ef], 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. Dever ose i [rswoa ci 20-132 20506k20506 ‘TROUBLESHOOTING METHOD OF USING TROUBLESHOOTING CHART Five causes 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 © marks where the hori zontal lines for the three symptoms and the vertical columns for the causes intersect. (1) Clogged air cleaner element: 00 (2) Air leakage between turbocharger and head: 00 (3) Clogged, seized injection nozzle: ° (4) Defective contact of valve, valve seat: O (5) Worn piston ring, cylinder: ° Step 3 The calculations in Step 2 show that the deepest 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 20-133TROUBLESHOOTING S-1 Starting performance is poor (Starting always takes time) Check that there is no abnormality display for the engine throttle controller on the monitor panel General causes why starting performance is poor + Defective electrical system + Insufficient supply of fuel + Insufficient intake of air + Improper selection of fuel (At ambient temperature of ~ 10°C or below, use ‘ASTM D975 No. 1,and ~ 10°C or above,use ASTM. D975 No.2 diesel fuel.) +» Charging rate of battery. Ampicy —O0"9'] soon | vox | oom | v5% | 708 250 Tae [ae [im [ie ae oe yas [sar [as [ze | 1a T0e a0 o28 [196 [125 [ae ‘ei graviy shoud be forthe charging ie oF TON or more In cold weather the space gravity must be forthe charging at ofa aaa 75% nthe above ee i eT ‘ a monet tet Ht [etna SS sfofe { | aes a SO iS ~ Taaaae tor mc Ter sang tom eng San EGET tate: a When or ener nowt Toon wb Sed + 4 Wes ei i re oe minced ree ere ana 1 nes 6 ~ SV bese aerator wmasiaand [Var = I ier pee vty of sera ape Tay aon = ‘When Ge oko TN ay Sn 20-134 2050620506 ‘TROUBLESHOOTING $-2 Engine does not start @ Engine does not turn General causes why engine does not turn + Internal parts of engine seized + Hfinternal parts of the engine are seized, carry out troubleshooting for “Engine stops during operations”. + Failure in power train + Defective electrical system [enter cea rapar OY 3 [Drees orore [ata trong pv 4 | Condit of nar whan saving | Horn does nat ound & | swtonie tured ON [[Forrsound evel Rotting seeds sow Wen staring ste [Mates erate roe [| | rea to START, on Soon dserosoe 90m |) | moves out. but [Mates rating noise and 5 | oes not em 2 [hen saving swien ie tred fo START, pinion dows not move out o ¢) [Diten suring switch tured © ON, tei 90cicking sound & [peers rmination ‘When Bate teste Baar Sacro ound be ow peat gravy of aecvavs voage o bata Bow i For he folowing condone 11=# tun he saving wav OFF, | = éonect he cord and cary out woubleshooting at ON : . 1) When eins 8 and trina of stating swt are connected, | gine nar : 37 When erin and wma Cot waring mar oe conse | g | _ocine H |S Wher wemnar@ ana wrminal Cot ey ra = | a vienna ot ale ah ond Tomi’ Ba ring maar |B 2 | ae need ensng sre 3 37 There no 26Vvotugebetwsen terminal band wminaiEot | Danae ely fF han sing gare napecied dec oot wrasse Toundiobe | & chones rama — ili ais S2 20-135TROUBLESHOOTING @ Engine turns but no exhaust. * (Fuel is not bei jected) Check that there is no abnormality display for the engine throttle controller system on the monitor panel. General causes why engine turns but no exhaust gas ‘comes out Supply of fuel impossible Supply of fuel is extremely small Improper selection of fuel (particularly in winter) Standards for use of fuel — ‘Ambient temperature =20 10 010205 ASI Bate No Diesel tet, Tov uestons Check items Contes resem ory Degree of se [Deri roa ero | Exhaust gas suddenly (when arng gan) ope coming out | feplcement of ites as not een cariad aut acording to operation “There onkoge For al pS ‘When tartng sich turned ON linkage does noi move ‘Wen engine cranked with staring mot, 11 injection pump coupling does not rote 21 No fue comes out evan when fl filer air Bled plop oosened fe] © 5 No ue spurs out even when nection pipe sleeve rut i loosened ust and water are ound when fuels drained Troubleshooting Teck npcton pomp Srey When contol act is pushed, Ts found tobe hea oF don rok ‘When fl iter, sainer ar inspected Gres they ae found Be logged ‘When feed pump sirsne is napected ret, Ws found to Be logged Wine Inspecied avec Te found tbe clogged [Revco 20-136 2050620506 ‘TROUBLESHOOTING ® Exhaust gas comes out but engine does not General causes why exhaust gas comes out but engine does not start + Lack of rotating force due to defective electri- + Insufficient supply of fuel + Improper selection of fuel start cal system Insufficient intake of air Tone recent repa ROT Dears of we [Seer orion sea Sudenly filed Hart ‘Winen engine cranked, sbnoena nie a fam wound head [2 Engine ol mst be added more Feauenty EL Resusevna tetera 3 g Replacement of fiters has noi been carried out according to operation Ts one dom tree eee | cies 4 | ome ‘is aioe oe Ta an Soe SRT = Winn ota ei Saale te ao eo TS han sotpnian pane nad elando be = [Wario sna pean hy bye sd 3 [Rimparscreniapatans deep nile tobe sgt 8 [Heater mount does not become warm T nther specifi gravity of electrolyte or volage of Battery i low Tastee he as ase a Spots Gnaestsnnge ropa ed es lp ad a A EO a Jeneol £8] 2 2\elé 20-137‘TROUBLESHOOTING $3 S-3 Engine does not pick up smoothly (Follow-up is poor) ‘Check that there is no abnormality display for the ‘engine throttle controller system on the monitor panel. General causes why engine does not pick up smoothly + Insufficient intake of air + Insufficient supply of fuel + Improper condition of fuel injection + Use of improper fuel Coase Tan oa TE AO ere of oe Dperied rong pened [a fa |= = = Heinen estore eoanp ene [TY 2 | Novsnein oetar bonus sfelels g 3. [Ene of unt be added mor rear = g 4: [Rote td entrar ele 8 Nowe of rierenc sear Tom aad WrRecar B Engr crup sudan esr poor 3 2} fete cur ot enaan on Be nde Tad = * Biack oe e oc ° aging snd hear For wand nae hea / ‘Mud is stuck to fuel tank cap 2 Tere elon fon na z | fot ing sped uncer vod 8 nora Ba aerd Baa oe > S| when load is applied S {| Tessin tom eine ratn eo otal 2: [ten etsor mantles oocned media star Haina ware slo seers of ace rind slow Glow yoo ace = ‘When ay Sarat Ripased Gracy, Ws nto be onped TS ‘Wer i, tier arenas recy. heya ourdinbe Ty cogae When ood pany po CRS Greet Rood woe comma] | Le «| Somat some eynders does rot canes when opting on end y F | evinces 4) [ten env paki indo be ae or dove nt om . 4) [ten cnoressor messi is messed i found Below . 2 2 [ine arbocrpe brome by hind ound beter = ‘Wher ave cerancee ead drei, ound ob ie . sander valve hen el xp pase Gch, Ws eon be Coed . Wen eed puns operated operation InN orto her < sal elelelel alae wre) $) 3) 8] 8/213) 2) 5) 21214] Sle sielel2|els)s 20-13820506 TROUBLESHOOTING -4 Engine stops during operations + Check that the display for the fuel level on the monitor panel indicates that there is still fuel left. General causes why engine stops during operations Seized parts inside engine Insufficient supply of fuel ‘Overheating + If there is overheating and insufficient output, carry out troubleshooting for overheating, Failure in power train * If the engine stops because of a failure in the power train, carry out troubleshooting for the chassis. Coe Canon Ca Topo RT Dees ose per oon prod rans ovo nie was hor and engine stops suddeniy ole ° ele Condon wnen engine Engine ovrhed and sessed [SO I g | some Engine sped slow 2 There wa hnng on rae 5 é sonpes Tsien of Wr fas von carid of Boo : No tected ethan od stele ‘Wher eed pups opera Ta vo eobonse oH heavy oe Td wack ol nk = . ee z § | trtotumbynand ing bar Terns orp rac c 5 | cn wet Hoes onount of bach é i Shaf doesnot 3 etl aris oe ound wha ole ded = 3 i rare ater ner oo : Remove head cover and check drecty . 4 a [berger an ineecie dows norm = 2 3 [ition esd pomp retraced Sec, Ws ound i 3 . a E | tote coonee i Check ond pony Srey . ‘When cool ct puted soon be Dono 2 does not return | ° & Tales HAAG 218|3|- 20-139‘TROUBLESHOOTING S-5 Engine does not rotate smoothly % Check that there is no abnormality display for engine throttle controller system on the monitor panel. General causes why engine does not rotate smoothly (hunting) in fuel system + Defective govenor mechanism + Defective electrically controlled throttle machanism (electrically controlled throttle type) + If there is no hunting when the electrically controlled throttle rod is disconnected, carry out troubleshooting for the electical system, aa ST Soper oa [Seamed oso Ceara hat oe A eee ny i rane amanaa Ra nae sl oS ots tania nes ete ier od pon od . 11)_No response, light. return is quick 1 ett § | _2 No response, ght return normal @ § Lpeseetioerines tare 2 [Somstimes atic to sop engine 6 eat scien png a sone atte Tn pone Rar nod TT a Be ae ihr can po ee Fora toad DoT adjusted ° [in cone ae pnd a ots toro TT | [ent eet dec ud be ped = = 3 | When teed pump prefiteris inspected directy, itis found to be = | coos Pees ere : Ter i FO and Ba a a oe clogged s i iil i lnemesy] & | | alg a|3|z él? 20-140 2050620506 ‘TROUBLESHOOTING 56 S-6 Engine lacks output (no power) Check that there is no abnormality display for the engine throttle controller system on the ous | monitor panel. General causes why engine lacks output + Improper condition of fuel injection + Use of improper fuel {if non-specified fuel is used, output drops) + Lack of output due to overheating + If there is overheating and insufficient ‘output, carry out troubleshooting for overheating Con aan PE nse one Opened reg aroa [| [a [ato = Side t Power was lost a Ss . Grady a, [eletets 3 [Eat at ated nr tay 3 4 [ Roloc fier has ot ban caried Gu ocoring Top S| manual ° ° ° Noro ied Tat at ben ed a[ele Ait lane cogging op Taha 2 Color of exhaust gas eck 21s tive oer a Tie of erased For cand wrbarorger 2 Blow 8 oxen Enso kup spoor and crbusion aa 5 3 oe 4g | HP ing speed unr no ed normal but speed ade ope > E | when toad is apoied =?) 3. | Wren exiaut mentale oie Tneday afer ing oooh slo J | romper of some exer iow 2 Tere ning fom engin fouason a Wego ote ofa aging sound eer rom eound eying = Tigh ing seed of na ow 3 @ [eatage rom ei peng z ‘When a Senet shaped Gea, his ood oe sopoed——[ ‘When rabche ge rotted by hank found fo be basvy . Wher compresion pres ree nred, ound wb = : ‘Wher tel tr reir are pected rect ay re ound 7 tobe clogoes J [Rinne ong onamre mentary coed = | eet ta in teers sia nos Y 2 [hn conor ake pated Wi Todo be hen odo aterm Che [wen vaive clearance is checked directly, itis found to be use standard vale | u ‘When vrs led FULL potion Wont nt conic Sopp . ‘When fed Bu etd, operation 00 ight or we Neo Wher el ep i nopecied ety found be coped pores] 3181 8/8] S188 ie 31318 /8|2/2)2 1212 20-141‘TROUBLESHOOTING s7 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 Contr ap ROT Doses ose Dpertd oroog ered | [a fam = Sudeniy Beare Back 3 «| Colr ot exaust gas Graal become bic =e 2 z eur gt oad 3 [rae oan sand re Fearon = 8 Tvamuce Say = o o Geadaly ate ote Nan apetid fa ha bean ie 3 ‘oe ference ished und Bear = Ar eesner cogging frp Hots up z Tiowby esl ncetve z Ein to poor ad Gbunion WUT z z ole ‘When extavt mess euced medal afi Hara om [temperature of some eyinder slow ° [ith mares on fn neon pomp a oa oT Sane [easton ection pup hos come of & | earcing sound herd om around Ger Fed Exh rie ner 3 2 = ur cued 2 Lage oar bers wabochargr on hod bea Gan 2 Win hae Fed by Ran 1 Tod we ae = When a ener nepeciea recy, ti fond to be cogped . ‘When eeeenionprestreemeenred i found be fw . . Speed of oe cndes does ot change when peaing on Seed 2 | cvindors ° 3 | Wen chek ede sng dover mated econ Wana Toon ¥ | tobe nearest [5 [econ pump et awa mat cian soar cree = | When valve clearance is checked directiy itis found to be outside en ular removed ec gar ane ROT . When cont ack used tis fourd tbe beay or dvs nara i remeoy| £ 20-142 s7 2050620506 ‘TROUBLESHOOTING SB -8 Oil consumption is excessive (or exhaust gas is blue) * Do not run the engine at idling for more than 20 minutes continuously. (Both low and high ing) General causes why oil consumption is excessive * Abnormal combustion of oil + External leakage of oil ‘Wear of lubrication system om Tonto rsant rear OY { Deoree of use [Boers er ona paved = safe = (i consumpson suddeiy nareated o Engine of must be added mare heavenly ott Engine a becomes contorted aucty otto Exhaust gos Bue uncer ight faa t | Arormaly exsastve T ai 7 Amount of blow-by 938 {res around engine ary wih oT There on engine cooling water When exhaust pipe i removed, inside fund tbe Gy wih oF i T 3S Inside of wrboeherger take pipe ody with oF Co (ilovln elute or TOROFLOW tanemiaion damper chamber ieee T Clamps for inate syst ae loose z 5 3 8 Wien anna pa a Rem Roto —— TOTS TT ‘When rene rent sree oud be cond 7 1 There eal sage ool For eae elelele | pressareighesr st a coer shows here wee = Seer iy of urtncero a ele 4 [enor er sen areny = Wen inate rentad reared a ond ae . ‘Wher nate antes eove. ee oud To be ty wi = A 3 ii é 20-143‘TROUBLESHOOTING $-9 Oil becomes contaminated quickly General causes why oil becomes contaminated auickly * Intake of exhaust gas due to internal wear Clogging of lubrication passage + Improper combustion Use of improper oil + Operation under excessive load Coase an oan Toa RE [Deve oteoe [opernesotona pores [= = = 3 [ eeone ots be nears ey [ [iewapeced tua hon teen ued a ta dered | > ot of onan oo fet / ack = cmnornomy ane Aenean ene mG 5 aatiercovtn une sins om avon when a pres oe © [[ivver ot veri inapecied, mew! partces are found o|_Iefe 2 ian eras ee emved side found be ety wi 3 Sogn otenpertre ree Qty r : ‘When oSERN WanuT W Haan Ns Turd wbaTow = : ‘her Bote set npeced dec, 1s undo be ood | Py z | wir oi ones te braton i 4 [ithe ol te iinspaced dros Ws ound wb cogaed 2 : 4 [Wen ol cooler inspected directly, is found tobe clogged ot 3 3 [amen bbe Ome [aces py of wrboharger sat acl 2 Wrst oe ar ete eRe G ale ere i i 20-144 20506k20506 ‘TROUBLESHOOTING $10 S-10 Fuel consumption is excessive General causes why fuel consumption is exces- + Leakage of fuel + Improper condition of fuel injection + Excessive injection of fuel Deore owen Specie or ora ard ale = : ‘More then for or machine oT | conten ot et consamson tem et sts ° Suen neared ate om se o Esau ge color cs - Sra onhipeton pan has cone of - Tere agus eombusten t [When eohaun mania e wched moneda ter waning enone | || 5 | tapers of sme ctindr ito ° 4 [itch ron ijestin ump i mained 5. Thesis exeal linge offi fom ergine Ergineollovel res and vl of dese fue a Engine tw ing sped = gh c [instant Rane Ba eon ano a OTT z Soeed of some ringers dos sa chong when operating onreaued | |g | svingere [tren const cris use onion oder atroaem | [6 Finer checks made using devery metho. retin ting ound : 2 [emove neat cover ond chek resi emove fend pump od ect dec When engine speed erased low tng speed Todo ba Nh Remedy] = | 3 20-145‘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 Degree of use ‘porated fr ong parod Sesaeniy mereoned a] Gradvaly neveased Excessive sr Dubbo inate radiator, pure baat Hysauie ol oraue converter vansmission ole Guy whe ‘Wren hydra ol tora converter wansisson ols rained Frasnre igh Wat oa cooler thaws tere waa Pressure tighiness tex of elinder head shows thee i eatage Remove eyiner head and check dey choot pone Renice = Renice revise] @ 20-146 1 2050620506 ‘TROUBLESHOOTING S12 S-12 Oil pressure lamp lights up (drop in oil pressure) If engine oil level lamp on monitor panel is not lighted up. Ifoil pressure sensor is normal (see item for M mode). General causes why oil pressure lamp lights up + Leakage,clogging,wear of lubricating system + Defective oil pressure control + Use of improper oil {improper viscosity) + Deterioration of oil due to overheating ‘Standards for engine oil selection ‘Seieeon fa SAE numba secon Type of ot to ambient ampere 20 =10 0 10 20a SAE SRE iow Ensine ol = ED SAE Tawa) Tani ca en TY Degree of use [oveied torlona peroa [a [a = «| Retscent of firs fas nt nen ced ou scene 8 | operation manual 4 [caton amo hina a ST en-specfied fuel has been used ste Taito wo ing z a | condition when ot resre Thu tow nih ze PTete | Seetmes os ve efoto [There clogging, leakage from hydraulic piping (externalh © 2 et prices refund when of dra 2 [ht pre ae stock o terse 2 3 © Toitis cloudy white or smells of diesel of [ [itn arb aero’ Grays ond ob RE oo [remove tp and thot arecty oo 4 [otpome rotons ny, are By 1 2 4 [Ther xcting oa, ogo abe Fo t [sate ie trotan Wine of prewar enred sound be wi ander abe |remeoy} 2 i 20-147‘TROUBLESHOOTING $-13 Oil level rises + If there is oil in the cooling water, carry out troubleshooting for “Oil is in cooling water’ ‘Water in oil (cloudy white) + Fuel in oil (diluted, and smelis of diesel fuel) + Entry of oil from other component Toni rant Tapa TY Degree of ae ‘Sperated Te Tog pared “Tre ain radar cooing water ‘When engines fst saried drops of wale come Wom mater Tove radiator cap open, When engine eran ting, an abnor umber of aubbles appear, or water spurts back ‘Water pump breather hoe Goaged wih mud Oilevl goss down in damper chariber ———<—= ‘ilove goes down i hydra nk Engine oF sats of dase fel Fosl added more reauerty Pressure hires est of eying Read shows thre i leakage ‘When compression pressure measured, Femove water pump and check dvecty When pump is removed sal ound to be Broken “roubieshooting Remove incton pump and eneckdreiy [Remove of pan and eneck roe I on Repice repiace epic Repai| 20-148 $-13 2050620506 ‘TROUBLESHOOTING S14 ‘S-14 Water temperature becomes too high (overheating) If coolant level lamp on monitor panel is not lighted up. If coolant temperature gauge on monitor panel is normal (see M mode). General causes why water temperature becomes too high + Lack of cooling water (deformation, damage of fan) + Drop in heat dissipation efficiency + Defective in cooling circulation system + Rise in oil temperature of power train + Carry out troubleshooting for chassis. Tent sar apa OT Dagre of se T[oaratd fre ped Condon of overhang ae ses avy te parsers pee oes rot go down FO > ted ange Toa bo whines onder sodden ond = send ie i fowting on oni wate Cosing weer flows ot rom overiow ww S / Engine lee sre, oe coud wie 7 [Peso rood msde of ondergurd oe coged wah arto mod = = 22 [Wen tht ba is ei behing radio, no ight parses ough 3 [Wer is ating beens of eck in hoe or lore carpe a ] Tenparaure Berens betwen op od atom adatoms] T “Temperature afarene beeen top and Doar radar ks Y [hen water for por apected fe core ound be one . | [Resieemrertret ete se temectenmmtmn TT] 2. [Wen water temperature x meanired, Wis und io beomal = [Wren otcootrisapeced direct, hi found webs cogged | . ‘When meureent is made with aint cop tent, pen078 T at found. be ow | ‘Wher compres presare i mesai6d We ound 1 bow Remove of pan and eck dre t Falale ? feneo #121818 i 7 20-149‘TROUBLESHOOTING S-15 Abnormal noise is made + Judge if the noise is an internal noise or an external noise. General causes why abnormal noise is made ‘Abnormality due to defective parts Abnormal combustion noise + Air sucked in from intake system ‘Dears of ue Oe fr tng period ‘Suddeniy occured Ovetons Engin ol must be added more teaver i ecceeae oe under igh od Engine piskip i poor and combuebon i rege When exhaust manifolds touched mnmedately afar Haring engine ature of some cylinders is ow injection ump has come off ‘Abnormal noe ie oud when accelerating engine ‘heck items ‘Clanging sound iheard for around eyinder heed Leakage ofa Between turbocharger and head, lose Sar When wrubocharger rotated by Ts found 16 be heavy Femove ger cover and check avecty ‘Speed of some eyingers does not change when Operating o> reduced evinders When contol ack pushed, Ws found io be heavy or does nat earn Injection pump test shows hat injection amount I heareet Fan i deformed, or bat i oore ‘Troubleshooting ‘Wihen valve clearance i checked dred i found o be outs jemove cvinder head cove and check Gecy epee ‘aioe epa 20-150 $15 2050620506 ‘TROUBLESHOOTING S-16 Vibration is exces: 4 If there is abnormal noise together with the vibration, carry out troubleshooting for “Abnor- ‘mal noise is made" General causes why vibration is excessive + Defective parts (abnormal wear, breakage) + Improper alignment + Abnormal combustion S168 Conf reson repa ASOT Depree of use Operated or ong pared [= Sedseniy increased Conaiton of weration Gradual reared Metal pores are found in ter Metal pater are found when os drained Oi pressure is ow atiow ling Vibration occurs at miange apsed Vibration olow engine sored Esnaust ga ie lock Check items ol Seal on injection sunp has come of Tamove ol pan and sherk 76a [Check drcty for worn suppor piot lay [Check dracty for lovee engine mounting ol, broken cso Check ite of output shat Semper arecy When radia unout, outise standars “Troubleshooting Tun are measured they are Yoond Toba Remove head cover and check det ejection pump eet sow hat injection amount neore Renee Renee Recice 20-15120506 TROUBLESHOOTING OF PUMP CONTROLLER SYSTEM (C MODE) Points to remember when troubleshooting pump controller system ‘Action taken by controller when abnormality occurs and problems on machine wnnnnenm Judgement table for pump controller and hydraulic related parts... Pump controller system circuit diagram Troubleshooting flow charts for each failure mode ¢- 1 Abnormality in pump controller power source system (swing brake is not canceled, etc.) se C- 2. {€2:32] Short circuit in front pump TVC solenoid system is displayed 1E2:36] Short circuit in rear pump TVC solenoid system is displayed .. C- 3. [E2:33] Disconnection in front pump TVC solenoid system is displayed 1E2:37) Disconnection in rear pump TVC solenoid system is displayed... C- 4 [€2:03] Short circuit in swing brake solenoid system is displayed €- 5 [E2:13] Disconnection in swing brake solenoid system is displayed C6 [E2:02] Short circuit in LS select solenoid system is displayed {E2:04) Short circuit in pump merge-divider solenoid system is displayed [2:05] Short circui solenoid system is displayed [€2:06] Short circuit in travel speed solenoid system is displayed - 7 [E2:12] Disconnection in LS select solenoid system is displayed [€2:14] Disconnection in pump merge-divider solenoid system is displayed [€2:15} Disconnection in 2-stage relief solenoid system is displayed [€2:16] Disconnection in travel speed solenoid system is displayed ..... C- 8 [E2:17] Model selection input error is displayed C- 9 [E2:18] Network response overtime error is displayed €-10. {£2:22] Short circuit in LS control EPC solenoid system is displayed €-11 [€2:23] Disconnection in LS control EPC solenoid system is displayed C-12_[E2:24] Abnormality in front pump pressure sensor system is displayed [E2:25] Abnormality in rear pump pressure sensor system is displayed C13. [E2:26] Abnormality in pump pressure sensor power source system is displayed C-14_ [E2:27] Abnormality in engine speed sensor system is displayed C-15_ [E2:28] Abnormality in auto-deceleration output system is displayed 20-153POINTS TO REMEMBER WHEN TROUBLE- ‘TROUBLESHOOTING SHOOTING PUMP CONTROLLER SYSTEM POINTS TO REMEMBER WHEN TROUBLESHOOTING PUMP CONTROLLER SYSTEM 1. Points to remember if abnormality returns to normal by itself In the following cases, there is a high probability that the same problem will occur again, so it is desirable to follow up this problem carefully 1) If any abnormality returns to normal by itself, or 2) If the connector is disconnected and the T-adapter is inserted, or if the T-adapter is removed and the connector is returned to its original position when carrying out troubleshooting of the failure, and the service code is no longer displayed, or if the monitor display returns to normal. 3) After completing troubleshooting, always erase the user code from memory. 2. Service code memory retention function When displaying the service code in memory and carrying out troubleshooting, note down the content of the display, then erase the display. After trying to re-enact the problem, carry out troubleshooting according to the service code that is displayed. (There are cases where mistaken operation or abnormalities that occur when the connector is disconnected are recorded by the memory retention function. Erasing the data in this way saves any wasted work.) 20-154 20506k20506 TROUBLESHOOTING c1 C-1 Abnormality (si pump controller power source system g brake is not canceled, etc.) % This troubleshooting is carried out when there is still an abnormality, so when ‘and inserting the T-adapter, or when removing the T-adapter and returning the connector to its original position, if the service code is not displayed, the problem has been removed. Check that fuses 1 and 14 are not blown. Before carrying out troubleshooting, check that all the related connectors are properly inserted. Always connect any disconnected connectors before going on the next step. When the starting motor rotates correctly.(If the starting motor also does not rotate, go to E-11.) tt Cause Remedy Detective pump controler | Replace Ie voltage between gotcha Detective contac, or ais- fia normal? 2 YES. ing hamess | Repair or beween use andCht | replace eee fiemate) rt “a0 oe tad GND “Tumstacing NO smut Detect ori. swe Jeonnecton mwiting harness | agi, Serwsen use 1=HBs 2) | Repairor roy 0 fata Git batieryrley “um staning switch termina oN C-1 Related electric circuit diagram ‘Pump controll M14(L2) oo \@od po w08(t2) — G ; pe Aig Banery ry ni 1 XOT(MICIT) use aol Battery ie HO2 (S16) 7 cxsce (TD j ae 5 BRE 20-161‘TROUBLESHOOTING c2 C-2 [2:32] Short circt [E2:36] Short circt in front pump TVC solenoid system is displayed in rear pump TVC solenoid system is displayed + This troubleshooting is carried out when there is still an abnormality, so when disconnecting the connector and inserting the T-adapter, or when removing the T-adapter and returning the connector to its original position, if the service code is not displayed, the problem has been removed. ‘Ifthe starting switch is turned OFF after an abnormality occurs, turn the starting switch ON and check if £2:32 or £2:36 are displayed.(if they are not displayed, the problem has been removed.) ‘Always turn the TVC prolix switch OFF. Before carrying out troubleshooting, check that all the related connectors are properly inserted, Always connect any disconnected connectors before going on the next step. see cause Remedy 3 YES Ta reaiatance Detective pump contatier | Repisce betwen each pin FFA fortesblesnosting H inthe table? hownal? Teresita, Berean each pia YES fortroubeshosting 1 [| Fintneabie’® = cota “Turn staring een NO OFF roma? + Disconnect Co Interchange wing tethoter VC “Typ starting etch olenoa te 1” OFF Spplcabe service [] Disconnect C04 or rode cepayes?” (Cr hichever appicabe *Itarchange wiring Tur storing swigh Applicable TVC solenoitis | Replace ON span NO detect Ayla oe of wight ‘os btween CO tema i) 5 YES Rice orwimegramare > Ny, rear berweont fle ea Rapaior ves] seme ech pin €6s'fatel (pump We | fe rublerestna nso th power ar eaeuneee ore wig ras between each pin Detective TUC pralx switeh, | Repair or A= lortovblesnooting «Sun stating aatcn NO ‘or opplicable one of wring [replace inthe tablet harness between TVC poli te + Disonnet Co. th O08 re) Tu sang Purp TV steno) o 25 oe annaowieh rae (i pm TV + Brzonnect 16 lr net Applicable one of wiring | Repair or hates between C13 replace {frmale (2srd C05 erste) (a) pump TVC solenoid, or wiring hamess between coe female (2) and 025 erate (tf pomp TVC Solenoid) in contact with Power source wiring harness 20-162 k2050820506 TROUBLESHOOTING c2 Tablet Sens ode Massaron cation Service code_| Troubleshooting 2 Troubleshooting 3 Troubleshooting 4 reat Between C12 imal) (and) | Benween Ct emaa (6 and@) | Between COs eae) Gana a) | 10-780 £2:52 [Between C13 imal) and | Between CDi emale) 6) and | Between COS female) (an vee C13 ale and [Baoan Go fone and Brower CB Goma 904 | yn yn Between C04 Grail and GY | Benween Gi oma (7 and | Bowser Gis ema) ana | —To-zem otwaer GB4 mala) @) and [Between CDi erate) and | Between COE (female (9) and ee [oer tweed eee eee | eee Min ta Trobueshooting 5 Between COS imal (=) = 1, (81=@)O=) tenia | €-2 Related electric circuit diagram VC prox switch Tz] ra aT s [ope oR ‘OFF Protx resistor ve wae Fuse cot (Mici7) 205CA05503| 20-163TROUBLESHOOTING c 3. [E2:33] Disconnection in front pump TVC solenoid system is displayed [E2:37] Disconnection in rear pump TVC solenoid system is displayed + This troubleshooting is carried out when there is still an abnormality, so when disconnecting the connector and inserting the T-adapter, or when removing the T-adapter and returning the connector to its original position, if the service code is not displayed, the problem has been removed. + If there is a disconnection in the solenoid or wiring harness, no current flows to the solenoid, If the No. 2 pin of the solenoid is short circuiting with the ground, the current (approx. 1 A) continues to flow to the solenoid. I the starting switch is turned OFF after an abnormality occurs, turn the starting switch ON and check if €2:33 or £2:37 are displayed.(if they are not displayed, the problem has been removed.) Always turn the TVC prolix switch OFF. Before carrying out troubleshooting, check that all the related connectors are properly inserted. ‘Always connect any disconnected connectors before going on the next step. Check that fuse 1 is normal, * ee Cause Remedy 3 YES Teresita Defective pump contoier | Replace Saar on YS eee Samat vyes| fate sth in | ma cowa yemaesiakhH “Tumgenro NO af feimeesean | arch re, finance || tun sacra nia pase Seresesevce |] -Bisereecotor wucctaacet” |) “erste Sica “Tagaiiee weak renee eco | Replace + Interchange wiring. NO ina Rear Serene acne Sol Sin, Secret cree Teng eit ves Ropar feet aizmulgea |renace s Sener, ference ens eiieetee iat eos veh i Repeats YE or roublesnootng Bod Basta ope) Sintherabe tera Tunas a| “bee - Beconnet| é Reger is restonce ° NO sizonmcion naptcaueonest | replace ten sath pn seesate Nee ren ae ferroiesnosing Series nT inte bie parca norma ese ~Turn sai ensuites, ath OF Estes Seesaw Bicone cn. sored I ecient” BiSiangwen pean 20-164 2050620506 TROUBLESHOOTING Table 1 Service code ‘Measurement location | \Resietance value Service code _| Troubleshoating 2 Troubleshooting 3 Troubleshooting & I Between C13 tm Berweon COT (emote (16) and (| Between COS \emale) Grandia) | 10-220 f2:22 | Bowoen C13 im Beewoon CO femal) and [Banween C5 emai 4 ond | an vagy : Between O08 tr Bewweon Got lemele) 7 and 9) | Between COB femele) Gandia | _W-22a 2:37 [Betwaen Os im Between Oi onal) (6) and Bowoun 605 Female) 1390 | yin yy Trobuleshooting & Between COS (mole) (1) = (i 2) — (8), 6) ~~ (9) Max 1 C3 Related electric circuit diagram VC prox itch T[27s]afs SPs popes a OFF, c13 cay f08 (s16) cot (MIci7) 2050806503 20-165‘TROUBLESHOOTING ca C-4 [E2:03] Short circuit in swing brake solenoid system is displayed ‘This troubleshooting is carried out when there is still an abnormality, so when disconnecting the connector and inserting the T-adapter, or when removing the T-adapter and returning the connector to its original position, if the service cod: layed, the problem has been removed. ‘4 Ifthe starting switch is turned OFF after an abnormality occurs, start the engine, operate the swing, and check if 2:03 is displayed.(if itis not displayed, the problem has been removed.) Before carrying out troubleshooting, check that all the related connectors are properly inserted. ‘Always connect any disconnected connectors before going on the next step. ‘* Always turn the swing lock prolix switch OFF, then turn the swing lock switch OFF before checking. cause Remedy 3 YES Detective pump contoier | Replace Teressiance be : a ves} tween COT female) YEltoon-aa ea H 2 chasis sown a in Tabie ‘YES between Ot mate] | = Turn staring NO ew (hand 29¢ eh OFF 1[| sewn in Tabie 12 |]. = Bisconnet cor “Turenig lock Interchange wing || “Torn wang switch OF ih the cwich OFF NO Selena ise203 [] . SuNOrE fopayed? Biscomect vou “Turse ue OF Detective swing brake | Replace sittechange wiring, NO escaye swing ss “Tusa such ON Sin Contact of power source 5 YES frnngheraes wits ving | Repair or Te owarca benead Farnese batweon x05." | reac, ves abt | Fem Sistema ie tl 2a eel Contet of power source fering heres with wring | Repair or is restance Pewee 5, “Turn staning NO Fares trees X08 [eee a ewer X05 4, 1 + Tum stating female) and Veta) 2) oral? = Bissonnect X05 ana ve {Resstance value Min. Ma “Tur seaing - Detective swing lock switch | Replace sich OFF No cae cana ER + Dasonnect X05, {Betuoon 4) and + Contact of power source | Repair or Waring heres wih wi ice ay came Between (103111) Between {1} and (2) | Betwoen 20-600 Between) and | Between (13) ne tain. mo 20-166 2050620506 TROUBLESHOOTING 4 C-4 Related electric circuit diagram ‘Swing lock prot switch ‘Seng lock switeh [23 apse Ow OFF OW. OFF x6 x1 Pump controler c1 No) a Ha Fuse 2o5caoesoa 20-167‘TROUBLESHOOTING cs C-5 [E2:13] Disconnection in swing brake solenoid system is displayed + This troubleshooting is carried out when there is still an abnormality, so when disconnecting the connector and inserting the T-adapter, or when removing the T-adapter and returning the connector to its original position, if the service code is not displayed, the problem has been removed. If there is a disconnection in the solenoid or wiring harness, the solenoid is not actuated. If the No. 2 pin of the solenoid is short circuiting with the ground, the solenoid continues to be actuated. + If the starting switch is turned OFF after an abnormality occurs, start the engine, operate the swing lever slightly (not enough to move the swing), and check if E2:13 is displayed. (fit is not displayed, the problem has been removed.) 4 Always turn the swing lock prolix switch OFF, then turn the swing lock switch OFF before checking. 4 Before carrying out troubleshooting, check that all the related connectors are propery inserted Always connect any disconnected connectors before going on the next step. Check that fuse 1 is normal. couse tenet ied [Defective pump controller | Replace ves eset (| ceases — YES] between VO4 ‘sLever at neutral; = NO Gown 1f]cies «fost pct Mae 3 with other aurteh OFF NO. Set Detacne aig tate | rgae Tanai Sorte farear oe a ep o pa VO (mate) (21 and Disconnection in wiring krescne ee aM T Seti | Bel” amet [| tunsaane — 50 Bregaseraaree |r a male} (4) and (3) witch OFF Goong oreo wh cal Bite ano, eaa rrergedvder a vB a | voacxe rr Travel speed tage rit 5 Ly tolenad oie S(_# | voEtxa) S aos P (|| zaenat © 2) Fuse n ea , : voe(x2) ‘AO? 20806505, 20-171‘TROUBLESHOOTING c7 €-7 [E2:12] Disconnection in LS select solenoid system [E2:14] Disconnection in pump merge- displayed [E2:15] Disconnection in 2-stage relief solenoid system is displayed [E2:16] Disconnection in travel speed solenoid system is displayed displayed ider solenoid system + This troubleshooting is carried out when there is still an abnormality, so when disconnecting the connector and inserting the T-adapter, or when removing the T-adapter and returning the connector to its original position, if the service code is not displayed, the problem has been removed. If there is a disconnection in the solenoid or wiring harness, the solenoid is not actuated. If the No. 2 pin of the solenoid is short circuiting with the ground, the solenoid continues to be actuated. % Ifthe starting switch is turned OFF after an abnormality occurs, turn the starting switch ON, operate according ‘to Condition 2 in Table 1, and check if any service code is displayed.{lf it is not displayed, the problem has been removed.) * Before carrying out troubleshooting, check that all the related connectors are properly inserted, Always connect any disconnected connectors before going on the next step. 4 Check that fuse 1 is normal * Cause Remedy 3 Tyas Eanes ech pin for pfroubleshoosings Fe coro inthetabie! Ts esatance formal? s| between soch pin VES ortroubieshooting | * Turn Sarina 1f]zinihenabe TT] awehON ay oral When OFF 20° 30 = -Dprat according to Condon wich OFF one of llowing stenods is Becomes’ NO eetecive Connector VO. VOB, VO, ESD 1s selet solenoid roe, wricnever is. E214 Pumpmerge-cvider Ta aia Sppteste folenoa i wt ex erlace «interchange wing. NO Murmstaning e216 wich ON spin - Shei mang s ves re Detective pump controler | Replace ys temereoge Sipiayad? A aves [pisos “Tumstaring NO Petomen soc pin ueh Disconnection in aphabie Heeeeerestns}) «Gow ving armecs between COT inthe be steording to male oy 1c" Norormai Senden ET eB or antcals | Rep or teiinghernesebewroen | relace “Tunsaang NO Soenois 21-604 (3 (0, -Bazonnest cor eFort) shoneroting th ground 20-172 K2050620506 TROUBLESHOOTING a Tables Measuroment cation Service ‘Troubleshooting 3 Condition 2 code ‘Troubleshooting 2 [——]_ Troubleshooting 4 Talon bam Fas Condtion + _ | ote Fun sang sich o START Yo san ; | luz ow sone ROSS fo coa me eae V2 sewer ct dona aon fa toon, teeth sooming pot zz inane” [20 - aoa tance toma [Condon 2 iene scien rode OFF. an ope boon ene | Sting overt sow! tena Juin x mare sahty RAISE poston eu do +" eoreee lee oe Th leoshaon smaeh iin foo eo] | tween Vos {eteen CO erate +E wmen —|ttinand (a 21a [imac fap ao.a tance tema When OFF whan [Hog Set waking mode switche UO mode | (1) and (2) jetween cov Sie ode oerffemaeh a [in 1m atc Jie ecween vs lwnen ow: same [ase lop eal eee stan ct savas [conden 2 stan I i a czas lia” (20-00 re coe ir OF Sing ct Been Co ven swingleckswien on | c ich ore Renae) fun. 1m sa cho lemserifa, [20 - eo] s eal ae serween cot emai) [Condition 2 irene Set travel speed switch to Mi inte), [22-806 @apsctases [nen OFF. evel [Benen co arn ton contra ao WO [1h ane (2h levers at neutral amalel 6) Ain. 1 MO| Operate travel lever slightly Note: We sible 2 accumulator is charge ie por ‘sey out the same operation with ing bwiteh st ON. C-7 Related electric circuit diagram Pump co4 controler (MIC17) iss | @ 5 feeder aT p CBG | vo2(x2) traeisoee | : Ao2 irerpedider CB Hi voaixa VB 02 LS select ‘solenoid valve ‘A04 Teal spend 2-stage relief Ip p solenoid valve re ¥ | vo5cx2y 1 fo | AOS see - Hoa B ¥ vo6(x2) (516) AO? 2oscaoes0s 20-173TROUBLESHOOTING ca 8 [E2:17] Model selection input error is displayed + This troubleshooting is carried out when there is still an abnormality, so when disconnecting the connector and inserting the T-adapter, or when removing the T-adapter and returning the connector to its original position, if the service code is not displayed, the problem has been removed. 4 Ifthe starting switch is turned OFF after an abnormality occurs, turn the starting switch ON and check if £2:17 is displayed. (If it is not displayed, the problem has been removed.) 4 Before carrying out troubleshooting, check that all the related connectors are properly inserted, ‘Always connect any disconnected connectors before going on the next step. Cause Famed i Dstcive pmpconrotar | Replace is montorng rece sepeyot |] mp cotter as Shownin tape P| | —— 2, XES stoner 02 “Tun statiog LU female 13) (8), Bae itoring NO 21,108 SAD Defeiva mad ston Seyepanoina [soon intabe ssurege,eegacoman- Le “Turn staring NO Sore ereatinappieabe " |"°222 Puen ore fring hrmess -Besonnen cn “Tobie 1 Monitoring mode display (Time display portion) Table 2_ Resistance valve OFF DEON ppicabie wiring Condition of pomp | Pump contratier mogel | | harness pez eee centile input cose, Between Ob? Wemale) I aaeann | hema min ma | Max. 10 Pca10 Between C02 female ima | Ge.eBd | | erence: vam ma | 10 Between cO2 (female Tae fas 220] gasaeg | fame | ee ae — GEL CCU | | eesween coz tomoiet | yin _ cee {0 and GND van C8 Related electric circuit di co2(040-20) cog(sa) 3 | iccton 1 eo aq & | mode! 2 8 | selection ? > g q 2 | mocet 5 ® & | tection Mosel selection 4 CO1(MICIT) q q GND Q 7 GND Pc2i0 Pc24o 20-174 2050620506 ‘TROUBLESHOOTING ce C-9 [E2:18] Network response overtime error is displayed This troubleshooting is carried out when there is still an abnormality, so when disconnecting the connector and inserting the T-adapter, or when removing the T-adapter and returning the connector to its original position, if the monitor code display returns to normal, the problem has been removed. + If the starting switch is turned ON when there is a disconnection in the wiring harness between the monitor panel and the controller, or the positive end (+) of the network wiring harness or the inside of the controller are short circuited, the controller cannot carry out networking, so the monitor panel does not display any abnormality % Before carrying out troubleshooting, check that all the related connectors are properly inserted. % Always connect any disconnected connectors before going on the next step. When E2:18 is displayed independently Cause Remedy Detective contac or matin Se ia, apo ae 1 Ticonrac connector CO, he] cannes gal. Detective pump conor | Replace Bor sere code sapay 90 01 Tum stating wen Ie connection of + Bissornec engine rote 4 YES oetctve engine tale | Repace omer then NOfeoeali ves isvotage tetween || [20% ce eee LS velentoernsr tl Bh ormal? Stinsiating “Torn sang Bets contact. or switch ON, gwtch ONS Does LED ot JBaconnection network | Rega o Sexegonnaina [Jeretiene 1] “Tamsarra SO] wing hamene NO setae oe Torn saci = - wen ON NO bens When £2:18 and E3:01 are displayed simuttaneously couse Remedy pos —________|tmontorponelconnesor_|epeor 1 ES resloce Taconnec connector P2, he Gannect it again, YES Festive send of nero | papsicor Soon sere cde 7 ring harness in coma |e splay 90 out th grou “Tun staring shore continuity Euan [orca 3. YES Ysconnect__ NO] female (7, 0 a ease inn SO [ABP A consatr wich nebo | Rene onrectoragnin, = Turnataring __ Lfoneat time steve nse penis ojesinay tomes EwtchOWand + Bconeet era Soe serves G03, ond Et snd a Deteive montor panei | Reace cose. + Staic wiring “Turn song NO reresgwnd "bch contr when State wiring haness around controler checking for hen chactlg for continuity, contin. Connect Fost 20-175‘TROUBLESHOOTING ‘Monitoring code display (Time display portion) | agpeOO@ } UeODO@ 13 | @ ‘mew. throttle connected! 03 (04016) Monto sae P02 (04016) B01 (MIC21) two Newore cron a |B carn | C ioovm |B % Check for the LED display for the engine throttle controller and pump controller from the direction of the arrow as shown in the diagram on the right. Note 1: Push the operator's seat down to the front, then remove the two rear covers to check. Note 2: The LED display for the pump controller is difficult to see, so use a mirror. 20-176 zozckussos Engine hon contr Pump controller 2050620506 TROUBLESHOOTING C10 C-10 [E2:22] Short circuit in LS control EPC solenoid system is displayed + This troubleshooting is carried out when there is still an abnormality, so when disconnecting the connector and inserting the T-adapter, or when removing the T-adapter and returning the connector to its original position, if the service code is not displayed, the problem has been removed. + If the starting switch is turned OFF after an abnormality occurs, turn the starting switch ON and check if €2:22 is displayed. (If it is not displayed, the problem has been removed.) + Before carrying out troubleshooting, check that all the related connectors are properly inserted. Always connect any disconnected connectors before going on the next step. couse Remedy 2 YES =a Detective controler Replace YES|ffomater 7. 1 Teena Cora of omer cue resins shown in Table 12 fring harness withing | pepir or Kacetes ao arose between cov" [Renate trea, H “gamnaus NO igri an 8m |" cehns ae + Bisconnect ct. “Tumsteging — [________1petsive ts control PC | Replace Etch OFF +Bkconneacta, NO Penal Tobie 1 (10 male (C01 (female) | Resistance value Betweon (1) and 2) | Between (15) and (7)] 7-4. Between (2) and | Between (7) nd chassis. chassis, MinnaMa | €-10 Related electric circuit dia Pump controtier cox (micet) HOI 10 (x2) Ls-EPC(+)) © C LS-EPO(— ©\+—-2 Erevan 2ozcx06810 20-177‘TROUBLESHOOTING cu C-11 [E2:23] Disconnection LS control EPC solenoid system is displayed + This troubleshooting is carried out when there is still an abnormality, so when disconnecting the connector and inserting the T-adapter, or when removing the T-adapter and returning the connector to its original position, if the service code is not displayed, the problem has been removed. + Ifthe starting switch is turned OFF after an abnormality occurs, turn the starting switch ON and check if £2:23 is displayed. (If it is not displayed, the problem has been removed.) + Before carrying out troubleshooting, check that all the related connectors are properly inserted. Always connect any disconnected connectors before going on the next step. coe Remedy ae 2 YES [Defective controller Replace Ferran NEB femal (i) Disconnection in wicing chassis harness between COT is resistance: —_. orale (18) sed To oo Repair or petween CAD, 4] *Zunstatiog NO. emalel tT and C16 erate) a Beets | BRS cor, ithe retina wah Tunsene Defective is contoierc | Replace ‘switch OFF. * Disconnect cra, NO solenoid Tablet 10 ima) Cov emale) | _ Resistance value Beoeen (1) and 2) | Between (16) and (n}] 7-142 Between (2) and | Botwoun (7) and : chassis. chassis, Min 1 Ma 6-11 Related electric circuit diagram Pump controlar CO (MIC21) HO. C10 (x2) Ls-EPo(+) € 0 LS-EPC(-)/] gy 2 frevane 2ozcxaes10 20-178 20506TROUBLESHOOTING C12 C-12 [E2:24] Abnormality in front pump pressure sensor system is displayed [E2:25] Abnormality in rear pump pressure sensor system is displayed ‘This troubleshooting is carried out when there is still an abnormality, so when disconnecting the connector ‘and inserting the T-adapter, or when removing the T-adapter and returning the connector to its original position, if the service code is not displayed, the problem has been removed. Ifthe starting switch is turned OFF after an abnormality occurs, turn the starting switch ON, start the engine, land check if any service code is displayed. (If it is not displayed, the problem has been removed.) ‘Before carrying out troubleshooting, check that all the related connectors are properly inserted. % Always connect any disconnected connectors before going on the next step. cause feedy yes = a Defective pump controller | Replace ; sh pin ‘YESH for troubleshooting [ [Disconnection in wiring noma terol) (et) - cos 2 female) (3) (Front), berween | Repalt or evolagebeween | | *Turnstarting NO C03 (female) (2) - Hor (13)- | "°F! veda || “pare Eb Veal) ean oe Fettatings [| -Beomerem short ere wah proung normal? 4 pes. |Applicable pressure sensor | Replace Sete Run engine at high | vohage between vf ee exch pin for + Repeat am rebel 0 5 yes irchange ina itketae eee with other ossure rma eresisonce Defectre pump conroler Repl sensor appt etree sth pin iaconacton nw cable service code Turn starting for troubleshooting FY hamness between C03 Setoyect TSN? nol a Fama ee aor 0 ‘+ lnterchange normal 2) E08 Moma Oo Renal or ees Ta (Fan eas female!) race sing vy 9 NOP Tifov (aa) 05) C07 (female) Tur Sting pee i, or shor circu with Wek ON Bain ~ Bones co, 2 -Rinengee't on coe bi Renate . - spa presi senor |Roice ‘Measurement location, — ] e228 | Een SST aocaene exams [rman Seer COTS tone | Seer COTTE 20-180 2050620506 TROUBLESHOOTING €-12 Related electric circuit diagram Pump controller CO03( 040-16) HO1(S16) Coa(x3) pressure (Ri pressure Sensor f) F pump pressure| 2avir) () pressure IRigewwe | Gf pump pressur 205CA08507 20-181TROUBLESHOOTING C-13 [E2:26] Abnormality in pump pressure sensor power source system displayed + This troubleshooting is carried out when there is still an abnormality, so when disconnecting the connector and inserting the T-adapter, or when removing the T-adapter and returning the connector to its original position, if the service code is not displayed, the problem has been removed. + Ifthe starting switch is turned OFF after an abnormality occurs, turn the starting switch ON and check if E2:26 is displayed. (It is not displayed, the problem has been removed.) % Before carrying out troubleshooting, check that all the related connectors are properly inserted. * Always connect any disconnected connectors before going on the next step. cause Remedy — Defective rear pump: Replace 1 pressure ssnse" I: vote between oral 2 possucesnaor "> /enlere “ea ie vokage between “Deh ON? NO TSormalt 3 Yes Detective pump convotr |eriece re feest oo. H “Turing nO|staaecn pt Disconnection in win teh Sede const ae Haims NO emreigecn | "Rim tng sich OF -Bironnet ca, Gin-eas €-13 Related electric circuit diagram Pump controller CO3(040-16) HO1(S16) COB8(x3) * pressure ur \q D R prossure ont pump ‘sensor (-) a pressure sensor 2avi+) co7(x3) {> F pressure Rear pum sensorsig | G 2 pressure sensor eworss_ | 9 20-182 205cA06507 2050620506 ‘TROUBLESHOOTING cu C-14 [E2:27] Abnormality in engine speed sensor system is displayed This troubleshooting is carried out when there is still an abnormality, so when disconnecting the connector ‘and inserting the T-adapter, or when removing the T-adapter and returning the connector to its original position, if the service code is not displayed, the problem has been removed. % Ifthe starting switch is turned OFF after an abnormality occurs, turn the starting switch ON and check if €2:27 is displayed. (If it is not displayed, the problem has been removed.) Before carrying out troubleshooting, check that all the related connectors are properly inserted. Always connect any disconnected connectors before going on the next step. caute Remedy aS Deteve pump convoter | Repice YES] Beton 603 4 \ismmat Dacannectionn wirng isreastance Raraebeween 8S? [Repair tatoos £07 “sa0—toopa NO mat Wr e)-€07 2 |repace fdatice, [eee orshont reat wah grou rormal? wich OFF » Bazonnet 2 eee Defective engine speed | Replace i sensor - Batonnect E07 6-14 Related electric circuit diagram Monitor pane Poe «o4016)| GX Pump controler 603 (04016) HOS (S16) EOBISWP14) EOT(X2) speed sensor gine ones) 8 f a ssn) 3 ome ty 2ozoKoest1 20-183TROUBLESHOOTING C15 C-15 [E2:28] Abnormality in auto-deceleration output system is displayed ‘This troubleshooting is carried out when there is still an abnormality, so when disconnecting the connector and inserting the T-adapter, or when removing the T-adapter and returning the connector to its ori position, if the service code is not displayed, the problem has been removed. ‘When the auto-deceleration switch is ON. + If the starting switch is turned OFF after an abnormality occurs, start the engine, operate the control lever (neutral + operated) with the auto-deceleration ON, and check if E2:28 is displayed. (If itis not displayed, the problem has been removed.) + Before carrying out troubleshooting, check that all the related connectors are properly inserted, * Always connect any disconnected connectors before going on the next step. cause Remedy YES Detective pump controler | Replace i wotage between oss Sra chosis ss shownin Tale Then COR Snconnacte, is otage between 1 No] EortiFand ta “Torn sarin wehON Detective engine htt | Replace jpormal? [controller ar = || Turn starting pane Ca tle Disconnection in wiring fwiten ONY NO} Gland hast Fares beween 603 | pep tfemste) (5) and EO1 female) | Repair +Tum starting NO 14), oF short cireuit with replace ate a ietece rie aia taen Corl Operation (5) and chassis ON, levers at neutral cae OFF, levers at neutral onw como Taine vane] mot fora | aa | earnest a 203 (04016) E01 (MIce1) auto-deceleration | ©} 1) [auto-decetertion output {> \cno g zozcKoes12 20-184 2050620506 TROUBLESHOOTING OF PUMP CONTROLLER INPUT SIGNAL SYSTEM (F MODE) When the monitoring mode is checked, if the following input signals are not light up, carry out troubleshooting for that item. Troubleshooting flow charts for each failure mode F. 1 Bit pattern 20-(1) Swing oil pressure switch does not light up .. F 2. Bit pattern 20-12) Travel oil pressure switch does not light up .. F. 3. Bit pattern 20-(3) Boom LOWER oil pressure switch does not light up. F. 4 Bit pattern 20-(4) Boom RAISE oil pressure switch does not ight up . F. 5. Bit pattern 20-(5) Arm IN oil pressure switch does not light up.. F- 6 Bit pattern 20-(6) Arm OUT oil pressure switch does not light up.. F- 7. Bit pattern 21-(1) Bucket CURL oil pressure switch does not light up F- 8 Bit pattern 21-(2) Bucket DUMP oil pressure switch does not light up. F- 9. Bit pattern 21-(3) Swing lock switch does not light up... 20-194 F-10 Engine speed is not displayed in monitoring code 10 (abnormality in engine speed sensor system). 20-195 F-12_ Bit pattern 22-(6) LH. knob switch does not light up .. 20-196 20-185‘TROUBLESHOOTING Fa F-1 Bit pattern 20-(1) Swing oil pressure switch does not light up This troubleshooting is carried out when ther is still an abnormality, so when disconnecting the connector and inserting the T-adapter, or when removing the T-adapter and returning the connector to ts original postion lf the monitoring code cleplay returns to normal, the problem has been removed. 4 Before carrying out troubleshooting check that all the related connectors are propery inserted % Always connect any disconnected connectors before going on the next step. A. Tum the swing lock switeh ON before operating the swing lever. $I there is no display when the lever is operated on one side, tho PPC shuttle valve is defective. ps [Defective pump controller | Replace 1 tn cnn Is voltage between 3 YES disconnection in wiring [Repair or carpe ESR Seamer [teats Lever a neural traulstes om Detective contact short nr insulated from (C02: Max. 1.0. female) (2) ~ HO4 (7) CO2 Ma tv chassis? Between wiring harness and chassis: Min. 1M | {female} (1} + Star engine, = Disconnect S08 and 2 + Swing Lever tive swing oil pressure | Replace 2 cf Hiovenece | g Ee aan 1a TE cnston oreo z a mane ttem't onthe ow chars F-1 Related electric circuit diagram Pump contro co2(04020) ‘ oe SE) BOB CK?) cing ol pressure swith Swing swcn \ @ 2 Fe) rT 20-18620506 ‘TROUBLESHOOTING F-2. Bit pattern 20-(2) Travel oil pressure switch does not light up ‘This troubleshooting is carried out when there is still an abnormality, so when disconnecting th land inserting the T-adapter, or when removing the T-adapter and retur position, if the monitoring code display returns to normal, the problem has been removed. Bi Beiore operating the travel lever, check thatthe surrounding area is safe, * 1 is votege berween coz Ghandchassis 3 YES connector ing the connector to its original Before carrying out troubleshooting, check that all the related connectors are properly inserted. Always connect any disconnected connectors before going on the next step. Hf there is no display when the travel lever is operated on one side, the PPC shuttle vaive is defective. cause Remedy Defective pump controlar Detective contact siesonnection ning Tamara er] farnose betwean SOT tiemale) i and chasse Detective contact. shor ercut with ground, or YES} Coa tiematel aC [[eesenrer| gene olaugtin =") “Bae ee oe chassis? + Between wir “Travelieve {Dieconnact $0 and oa, operated: Max... NO + Laver st neu Mins Sta engine, = Dissonnee $01 ‘tis iso possible to ite short connector and jue the condtion inthis cata, check votage etwoan COZ 3) Shathe chases in em Ton the flow eter itis 20~ 30 ‘Goto YES: sifiietess than WV: Gotono F-2 Related electric circuit diagram harness and chassis: Min, 1M disconnection wing farnaas between 02 femato) (3) Ho8 (1) - $01 Hema) 2) Detezive wave ol pressure eran Hite conan doesnt tren the sth ‘eplacad, go 10H, ‘Travel oil pressure switch &) Pump contiller $01(x2) 02104020) oa sie D> Travel [ | awh I \ Replace Repair or replace Repair or replace Replace 20-187‘TROUBLESHOOTING F3 F-3 pattern 20-(3) Boom LOWER pressure switch does not light up + This troubleshooting is caried out when there is still an abnormality, so when disconnecting the connector and inserting the T-adpter, or when removing the T-adapter and returning the connector to Its original position, if the monitoring code display returns to normal, the problem has been removed. By Wer: measuring with the engine running, make sure thatthe work equipment does not move when the lever is operated 4 Before carrying out troubleshooting, check that all the related connectors are properly inserted 4% Always connect any disconnected connectors before going on the next step. % When measuring with the engine stopped, charge the accumulator before starting Cause Remedy Yes, Detective pump controler | Replace 1 3 ves Detain ec oF evotnge moron eect — |rapicor eaeipean eae eae me, fest ‘ves|osttmate °™ U + Lever at neutral: 2 | Vineutted fom Detective contact, short 3 pans eee | Lo inscand's” raptor Boetowen [|Site St | "Speeensanaee NO Sscnmeacniy [tice Hoes Nofieaictiom' 1] Sete rng names and chasis win cn [femal i) "HO coz Benge Beta 258 an ial ~erom IDWER LOWER Detective boom LOWER ot | Replace -Pentnesea NO Tine conaton dos not Mi tet o normal ever ‘shen the seh fe Topisced, goto #8. + Sar engin, “Disconnect Soe, ‘tis also possible ofita short connector andjudge the contion. Inti cae, check the voltage between COZ (2 andthe chassis in tem Ton the fow ener iets 20-90 Goto res. =ifitis toss than 1 Gotono F-3 Related electric circuit diagram Pump controller c02(04020) Hoa $04(x2) — oarsz6) Boom LOWER ail pressure switen owen \ ch o fs) re 2oscaoest3 20-188 20506k20506 ‘TROUBLESHOOTING F4 F-4 Bit pattern 20-(4) Boom RAISE oil pressure switch does not light up 4+ This troubleshooting is caried out whan there is stl an abnormality, so when disconnecting the connector tnd inserting the T-adapter, or when removing the T-adapter and returning the connector to Ks original position It the monitoring code display returns to normal, the problem has been removed. A. When measuring withthe engine running, make sure thet the work equipment does not move when the lever is operated. 4 Bofore carrying out troubleshooting, check that ll the related connectors are properly inserted 4% Always connest any disconnected connector before going on the next step. 4% When measuring withthe engine stopped, charge the accumulator before stating cause Remedy Detective pump controller |Repace 1 Defective contact, or Ie votage between 3 YES eronnecon nating Sraenasts Ra Smess between Si formals x3 tema 9 nd ifmae} (tan chasse ‘YES| Cte femal) a, 2 [sera an ie cut Detective contact, short ee ante sera | eee | Ui SL Ia Boke _[fsseinriaza]| Ste seemed, | semiase UC al| “Save nee BEAT Nolan TY ee ing hares and ens inc | femal 1” HOO ne Breen Semmens Sena. sa eet uses free in ‘Serene SEEEen soe ‘tis also possible to ita short connect and judge the condition, In this case, check the voltage betwoon CBZ} and the chassis nem ‘Ton the iow ena ita 20-900" Goro ves, Hitless than 1 Gotono F-4 Related electric circuit diagram Pump controller co2(o4o16) = Hoa(s16) S02 x2) rc ‘Boom RAISE oil pressure switch ls) 20-189‘TROUBLESHOOTING F5 pattern 20-(5) Arm IN oil pressure switch does not light up 4+ This troubleshooting is carried out when there is still an abnormality, so when disconnecting the connector fapter, or when removing the T-adapter and returning the connector to its original position if the monitoring code display returne to normal, the problem hes been removed Ai When measuring with the engine running, make sure thatthe work equipment does not move when the lever is operated 4 Before carrying out troubleshooting, check that all the related connectors are properly inserted. + Always connect any disconnected connectors before going on the next step. When measuring with the engine stopped, charge the accumulator before starting couse Temedy ves ostecivepumpconrater | Relace 1 Osective conc, or is voto betwean 3 ves econ ioaing | Repsicor isseugor teres || RE ferertetweni6” | somal | nla anche Lover at nevtrah 2 || ted wore Detective contact, short aa Pemereereneent| | Ese Geeta a |aepoor “Howes SStecet EG | aenercoapa 50 scree |S tae Sit ares baraen Eien 80 ts «Breet ng hamase and chasis mi. ma | eal = HOH -co2 {Bioonl GH2 and 3 am opoee Lo ectve A ot voice fee ares |e Pe *Teureenomnel gre Suen Sheri Feploced. go 0H. ig slso possible tof shor connector an judge te conation Inti cage coast oop between CO8 1) an he hase ‘te 20 30 Goto YES. sf tess tan 1: Goto F-5 Related electric circuit diagram Pump controler co2!04a20) 5081x2) acm T T a . 2oscaaest3 20-190 k2050620506 TROUBLESHOOTING F-6 Bit pattern 20-(6) Arm OUT oil pressure switch does not light up + This troubleshooting is carried out when there is still an abnormality, so when disconnecting the connector ‘and inserting the T-adapter, or when removing the T-adapter and returning the connector to its original posi n, if the monitoring code display returns to normal, the problem has been removed. ‘When measuring with the engine running, make sure that the work equipment does not move when the lever, is operated. * Before carrying out troubleshooting, check that all the related connectors are properly inserted. Always connect any disconnected connectors before going on the next step. %* When measuring with the engine stopped, charge the accumulator before starting, cauee ene i= Detect puma sonar | Replace 1 3 ves one contact or i: votag between jeconnecion nising | Repsiror Ese} nd cnses Esa fremcterwem S00" roa norma? fea and fae) and chasis yes|enarema) i)" 2 [romain ie “Laver at nut ated fo Detective contac short ean [eseastance ptwoen] | Lena creutwih ground, or | Repair or Boar Sastre | NO fésconetaninverng [ropa bu remot na wees ms ‘areas berween $05 SE NOh etd om SEMEN 10 sees anche Min, 1 a emai (2H C02 «Str engine. cow {Ducane CO on $83 (mal) ieee eee Deteive armour ot | Ropace Mota NO ‘tis also possible to Ft a short connector and judge the condition, In this cage, check te voltage betwoen CBZ () andthe chasis nem ‘on the oem. ithe 20-30 Goto ves, Hits less than 1: GoteNo Pump controller pressure ston ‘Fivtheconation doesnot return normal even winen the sate Feploced goto Hs. co2(04020) —Hoarsi6) $0312) Arm QUT ol pressure switch C—) ee | 20-191TROUBLESHOOTING Fy F-7 Bit pattern 21-(1) Bucket CURL oil pressure switch does not light up This troubleshooting is carried out when there is still an abnormality, so when disconnecting the connector and inserting the T-adapter, or when removing the T-adapter and returning the connector to its original Position, if the monitoring code display returns to normal, the problem has been removed. Bi When measuring with the engine running, make sure that the work equipment does not move when the lever is operated. Before carrying out troubleshooting, check that all the related connectors are properly inserted. % Always connect any disconnected connectors before going on the next step. * When measuring with the engine stopped, charge the accumulator before starting, coun temas hs [Defective pump controller | Replace 1 coon or | yong bowen Becta og noir carina, =a Sree ik? | ss ves Sena meh TS has + Lever at neutral: 2 | | nested rors Defective contact, short Be Ppeerrereren || en tenga dapat or “Bek || ssienurpsar | Musa ——I semen 5 ‘operated: Formal sna iscreut 4 * Between CP harness between SOB RN NOVlead tom |. Seeetving hares andchssic Mn. 1a | fre “POH coe + Star engine, — Be sheet Be erate} 7} _ et ss Mint Pine cond doesnot Beton feo iaseoee {Diconnee S06, ‘tis also possible oft a short connector and iudge the canton. Inti cage, check the voltage between CD? (7) andthe chassis n tem ‘onthe flow ena Tia 209 Goto ves. Hts less than 1 Goteno F-7 Related electric circuit diagram Pump controllr coz(04020) — Haacsi6) S061 x2) Bucket rp 20-192 T cons P { —>) ‘when the switch fs replaced goto HS. Bucket CURL i pressure switen 20506k20506 ‘TROUBLESHOOTING F-8 Bit pattern 21-(2) Bucket DUMP oil pressure switch does not light up ‘This troubleshooting is carried out when there is still an abnormality, so when disconnecting the connector and inserting the T-adapter, or when removing the T-adapter and returning the connector to its original position, the monitoring code display returns to normal, the problem has been removed. A Wren measuring with the engine running, make sure tht the work equipment does not move wien the lever is operated. Before carrying out troubleshooting, check that all the related connectors are properly inserted. % Always connect any disconnected connectors before going on the next step. ‘When measuring with the engine stopped, charge the accumulator before starting, 1 is wotage benweon EoeiBh and chasse “Levert naval sav" + Bucket OUMP operate Mac tv + Start engine FB Rel nea ites eens cacmici?) fotage between O28} andthe cassis nam ome Tomy pes ‘Detective pump controller | Replace re Emmis) f iconnetaninwira |RSS en ican ves{eeierses* || is eh reuited wor Detective contact, short perce) [os Beecsrmestet Naver se eH] beeen cazpnd 5S seccoctenaaspe |r Nolen | | Se naa anni. ff ge 2 [chassis jisconnect CO2 and S07. | formate) 162 feerce 39 80 Pectenaanoone es | seo Ss Reerteeea nae SN, ea Feplaced, goto HS. 807(x2) Bucket DUMP Bucket DUMP oll pressure switch switch 20-193‘TROUBLESHOOTING Fg F-9 Bit pattern 21-(3) Swing lock switch does not light up * This troubleshooting is carried out when there is still an abnormality, so when disconnecting the connector ‘the T-adapter, or when removing the T-adapter and returning the connector to its original the monitoring code display returns to normal, the problem has been removed. + Ifthe panel display is normal, go to M-22 When panel swing lock lamp does not light up. ‘* Before cartying out troubleshooting, check that all the related connectors are properly inserted. * Always connect any disconnected connectors before going on the next step. cause Remedy YES, Detective pump contotr | Replace levotage between Detective suing look ston eee ne 2 YES cheatin ground 9 cing 12} normal? ee Irarness between CO hace + Tun starting ih harness between CO2 Repair or + Bisconneet co2 F-9 Related electric circuit diagram woutss6) cormict7) GND . ‘Swing lock switch GND q mont 6] 19 coe ‘ticasy| S196 srg) 3 st 1S 219IO0) p02t9c016} é Or a lz 20-194 2050620506 ‘TROUBLESHOOTING F10 F-10 Engine speed is not displayed in monitoring code 10 (abnormality in engine speed sensor system) Before carrying out troubleshooting, check that all the related connectors are properly inserted. Always connect any disconnected connactars before going on the next step. case fomedy 1 Detective austment of | Adjust. svoie speed sansor Does contin vyes|sconenermal | ten engine peed sensor is adjusted? 4S [Defective pump controller | Replace 1 | reefs H [Wien resistance Le [normal? neg i tae lective erin se = isto " Nesmursae NO Senor 9 "easement ‘Siectiest™ = getrena, sere cote asst 2% tte fective cata ot Soren. — Betar'2y sisconnecion in wing 00 1000 2 3 ves fig Zy fernembeweenta | apsicor sutch OFFS esos between Wate 121 £08 191110), | replace + Disconnect cos. | Enfiale “2. ii tta) or between POS NO}is circuit insulated fonmateh (144 (16 src Detective engine spese | epace + Between (1) and NO sensor eee * 8" oa + Beoen ion chaos Tin + Tomo witch OFF + Bicones E07 F-10 Related electric circuit diagram Pump controler 0304016) 403(816) E08’ SwP14) fesse +l @ a engine spood fee - 4—p Fensor po2(aaor6) lense sar ~ 20-195‘TROUBLESHOOTING FA F-12 Bit pattern 22-(6) LH. knob switch does not light up This troubleshooting is carried out when there is still an abnormality, so when disconnecting the connector and inserting the T-adapter, or when removing the T-adapter and returning the connector to its original position, if the monitoring code display returns to normal, the problem has been removed. ‘Set the working mode to G/O or H/O and the power max, swift slow-down switch to the power max. position. When fuse 5 is not blown. Before carrying out troubleshooting, check that all the related connectors are properly inserted. Always connect any disconnected connectors before going on the next step. eet Es Defective pump controller | Replace ee == ae aereset tng lama al ves estas teh Mz3 21-22 2) Se oe [ae eeeereeeeeeea | ee NO] terminal normal? ON: Mas. 10, nr Siaring ewich Haconnection inwiing, | pepsi wiring F-12 Related lactic circuit diagram 0204020) M23(M2) M22(M2) HO1(S16) dt fe Hoacst6) il¢—; ea 20-19620506 TROUBLESHOOTING PUMP MERGE-DIVIDER LOGIC PUMP MERGE-DIVIDER LOGIC otegory Flow divided Flow merged Flow divided Flow merged Boomiswing priority selection mode OFF ‘Boom/swing priority selection mode ON MPa 40 kaler) hem OUT « service and ‘rant or rear pump pressure more than 19.6MPa (200 kglerm) Mode rov-dividerstenoia ore [PUMP Merge-dvider [Pump merge-divder Pump mergecivdersolnois ON. | Pump merge vier slonoia OFF | Pune mare Pune merge uo |+At operations * [in raver On independent npound operation Piscean stim [eer Saaenwmapemion [inet 4 [caren om [inependont open of ig ‘rave isompoond operon : co | tava independent -Ei2$o independent operation ot | operation o boom, ‘rng Cmpoundopsaon ah | om, bude loperatons.. 8 and with wavet | Operations except operations A. 8 JOFF and owing tock swtchOFE | snd Cwit wavel OFF and swing lock] compound operation ‘a ‘switch OFF of each of these A Arm Int “Compound operation with 7 travel Swing r boom LOWER -Swing + arm iN -Swing + bucket CURL “Swing arm OUT -Swing + bucket DUMP “Sming + hoom RAISE independent ope | Fo swing + service “nen 3 Ari» Bucket CURL independent ope 2 ‘wen contin is am g Arm OUT + bucket DUMP independert operation of |, = B | and ront ar rear pump 2 pressure more than 3.92 Arm IN » bucket CURL xcept operations A B,C ‘ath pressure less than 17 Ma (150 kgfemor more than 245 MPs (250 kgiem' (except #) Arm OUT + bucket DUMP ‘and pressure less than 5.92 Ma Oxgiem' Ae OUT + service and pressure less than + Independent operation of travel “Independent operation of swing b| HO _|soperations 8 and C with travel (OFF and ewing lock switch OFF For nvER Gx $9.6 MPa 200KgIer’) ¢ | Boom prarty2 moeo + boom] Ail othere RAISE sem GUT ‘With travel ON Except operation D with swing tock OFF: ‘seporsted for other operations sselecr | Seperated for swing + travel, boom RAISE, arm OUT (solenoid ON), not | "Separated for swing With swing look OFF: travel (solenoid ON). not soparated for ather operations (solenoid Fel + The pressure of the front or rear pumps is as follows: When pressure rises: 24.6 MPa (250 kg/m, (For details, see Fig. 1) ‘When pressure goes down: 14.7 MPa (150 kg/em*) on| oFF| Var (360) 248 50 Pressure (MPatkgiem?) Fig. 205Fosze8 20-201‘TROUBLESHOOTING Ha H-1 Speeds of all work equipment, swing, travel are slow or lack power % Carry out troubleshooting with the swing priority mode OFF and in the H/O mode. ‘+ Check that no abnormal noise is being generated from the main pump before carrying out troubleshooting, (if there is any abnormal noise, carry out troubleshooting for H-4.) ves 5 [Does condition vis|Beconenerma: {| sen Nave e 8 ves — [Does condition «| sperms — |S AND NO} assembly is ‘yes input pressure of ADJUSTING. replaced? Sens pen | approx. 1/2 of main [] NO seers 4g | sSeebnow 1 Wes Boos contin Peso nora soupet prezue YES) cits contol EPC nomenssne he sora semis tetoed ~Ditrbaionat__ NO Le Sevo tS eae Se piton pomp. ‘aig al Ander YES main ump sat - pressure normal? [} NO “aids one Bas Tiga Erase ooh 8 ‘ain ray | sate, ([Peaneien Rion Leer er Iecontaigunp || “awrchOFe. "Nolen YES: Scan pesere ecet soon [eres I Foes conan waigs tons ||Pecore soa: Es! age nolwnon so eae 7 Check and Engine wg NO| ive pias? a ‘eo Siero Revie TSO, NO eine “ig oe glen SESE iN rn OF Ergo Bah Buse eee Pum fig aekeiteh OFF NO ‘Measuring servo piston inlet port pressure Measure the input pressure to the large diameter end of the servo piston when the pressure rises and the arm is relieved.(Approx.17.64 MPa(Approx. 180 kg/em’)) Basically, the pressure at the large diameter end is approx. 1/2 of the small diameter end. For details, see TESTING AND ADJUSTING} 20-202 20506

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