SEBMO21K0502 SO IM TAINAN Ls KOMATSU PC150-5 MACHINE MODEL SERIAL No. PC150-5 6001 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. © PC150-5 mount the S6D95L-1 engine: For details of the engine, see the 95 Series Engine Shop Manual. Printed in Japan 00-1 (07-9102}00711CONTENTS 10 STRUCTURE AND FUNCTION ........... 20 TESTING AND ADJUSTING .............. 30 DISASSEMBLY AND ASSEMBLY 40 MAINTENANCE STANDARD ............ 00-2 No. of page ee 10-1 021K05021K05 The affected pages are indicated by the use of the flowing marks rs requested nat necesery aeons M@% | __noation ‘|: Acton equred be taken to these pages according tothe table below es @ | Pace tobe replaces Replace (1 | Pagetovedeieed | iscara Pages having no marks are those previously revised or made additions LIST OF REVISED PAGES Mark Pane Revsor]oon age Reveer|an Pogo Fereo| mark Poae TorS2M] waa page Revigon © 01 @ 10.22 10.63 10-100 20-28 00-2 10.23 10.66 10-101 20-24 «021 @ 10-24 10-65 10-102 © 2025 @ © 022 @ 10.28 10.66 10-103 20-26 © 023 @ 10.26 10.67 10-108 20-27 00-3 10.27 10.68 10-105 20-28 00-4 10.28 10-70 10-108 20:29 00-5 10.28 10.71 10.107 20-30 00-6, 10.30 10.72 10-108 20-31 00-7 10.31 10.73 10-109 20-92 00-8 10.22 10-74 10-110 20-33 00-9 10.33 2 107 @ 10-111 20-94 00-10 10-34 |e 107% @ 10-112 20-35 0-12 10-35 21077 @ 10-113 20-36 00-13 10.36 e107 @ 10.114 20:37 2 014 @ 10.38 2 107 @ 10-118 20-38 10.39 * 108 @ «203 @ 10-4 10.40 2 1081 @ 20-1 20.40 10.2 10-42 © 10811 @ | © 22 @ 20-41 103 10-48 © 10812 @ | « 23 @ 20-42 104 10-44 6 10813 @ |e 204 2B 20-43 105 10-45 10-82 |” 205 2 204 @ fo oc ia ie aoe Bec 10-7 10.47 10-84 | 20-7 20-46 108 10-48 10-85 20.8 20-87 109 10-49 10-86 20.9 20.48 10.10 | 10-80 10-87 20-10 20-49 10-11 10-51 10-88 20-11 | 20-80 10-13 10-52 10-89 20-12 | 2081 10-14 10:58 10-90 20-13 | 20-82 10-14-1 10-54 10.91 20-14 20-53 1014-2 10-55 10-92 20-15 20-54 10-16 10-56 10-93 20-16 20-55 10.16 10-57 10-98 20-17 20-56 10.17 | 10-88 | 10-95 20-18 20-57 1018 10-59 10:96 20-19 20-58 10-19 10-60 10.97 20-20 20-59 10:20 | 10-61 10.98 20-21 20-60 10.21 10.62 10.98 20-22 20-61 00-2-1Mark Pave Revs" Man Page ROMBOM] mark Page FOBT Mare Page REMEOM Maw Page Revion 20.62 © 20120 ® | © 20178 @ 306.2 © 30-45-14 © 20-63 20-121 20-177 30-7 30-45-15 © 20-64 20-122 © 20178 @ 30-8 30-46 20-65 20-123 20-179 309 © 30-47 20-66 20-128 20-180 3091 @ 30-48 20-67 20-126 20-181 30-10 30-49 20-68 20-127 © 20-182 @ 30-11 30-49-1 © 20-70 20-128 20-183 30-12 30-492 © 20-71 © 20128 @ 20-184 30-14 30-493 © 20-73, 20-130 20-185 30-15 3049-4 20-74 20-131 20-186 30-16 30-495 © 20-75 20-132 20-187 30-17 30-496 © 20-76 20-133, 20-188 30.18 3048-7 20-7 20-134 20-189 30-19 30-498 20-78 20-135 20-191 30.20 30-50 20-79 © 20136 @ 20-192 30-21 30.51 20-80 20-137 20-193 30-22 30-52 20-81 20-138 © 20-194 @ 30-23 30.53, 20-82 | 20-139 © 20-195 ® 30.24 30-54 20-83 20-140 20-196 30-25 30-55, 20-84 | 20-141 © 20137 @ 30-26 30-56 20-85 20-142 © 20-198 @ 30-27 30-57 20-86 20-143, © 20199 @ 30-28 30-58, 20-87 20-144 © 20200 @ 30-29 30.69 20-88 20-148, 20-201 30-30 30-60 20-89 20-146 20-202 30-31 30-61 20-90 20-147 20-203 30-32 30-62 20-91 | 20-148 © 20-204 @ 30-33 } 30-63 20-92 20-149 © 20-208 ® 30-34 30-64 20-93 | © 20150 @ | © 20206 @ 30-35 30-65 20-94 | © 20151 @ 20-207 30-36 | 3066 @ 20-95, © 20.152 @ | @ 20-208 @ 30-37 30-67 @ 20-97 20-153 20-208 30-38 30-67-1 @ © 2098 @ 20-154 © 20210 @ 30-39 | 30672 © 20-99 20-155 20-211 30-40 | 30673 © 20-100 20-156 20-212 30-41 | 30674 © 20-101 20-187 20-213, 30-42 | 30675 © 20-102 20-158 20-214 30-43 30-676 © © 20103 @ 20-159 20-215 30-44 30-67.7 @ 20-104 © 20160 @ | © 20216 @ 30-45, 30-678 O 20-106 20-161 20-217 30-45-1 © 30-679 © 20-107 20-162 20.218 30-45-2 © 30-67-10 © 20-108 20-163 20-219 30-45-3 © 30-67-11 © © 20-110 © 20-164 @ 20-220 30-454 30-67-12 © 20-111 © 20-16 © 20-221 30-455 © 30-67-13 O © 20112 @ 20-166 30-456 © 30-67-14 © 20-113, 20-187 301 @ 30-45-7 © 30-67-18 D 20-114 20-168 302 © 30-45-8 © 30-67-16 © 20-115 © 20170 @ 30-3 30-45-9 © 30-67-17 © 20-116 20-171 30-4 30-45-10 © 30.68, 20-117 20-172 30-5 30-45-11 © 30-69 20-118 20-173 30-6 30-45-12 © 30-70 20-119 20-174 3061 @ 30-46-13 © 30-71 00-2-2 @ 021K05,Mark Page RVSION| work Page Rewison umber Revision] number Rewsion| number Mark Page Mack Page Merk Page Rewiion 021K05 T 30-72 40-22 30-73 | 40-23 30-74 | 40-24 30-75 40-25 30-76 40.26 30-77 40-27 30-78 40-28 30-79 40.29 30-80 40-30 30-81 40-31 30-82 30-83 30-84 | 30-85 30-86 30-87 30-88 30-89 | 30-90 30-91 30:92 30-93 30-94 30-95 30-96 30:97 30-98 30-99 30-100 30-101 30-102 30-103 30-104 30-105 40-1 40-2 40.3 40-4 40-5 40:6 40-8 | 40-9 40-10 40-11 40-12 40-13 40-14 40-15 40-17 40-18 40-19 40-21 00-2-3A IMPORTANT SAFETY NOTICE Proper service and repair is extremely important for the safe operation of your machine. The service and repair techniques recommended by Komatsu and described in this manual are both effective and safe methods of operation. Some of these operations re- quire the use of tools specially designed by Komatsu for the purpose To prevent injury to workers, the symbols & and “AX” are used to mark safety pre- cautions 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. A SAFETY GENERAL PRECAUTIONS Mistakes in operation are extremely dangerous. Read the Operation and Maintenance Manual carefully BEFORE operating the machine. 1. Before carrying out any greasing or repairs, read all the precautions given on the decals which are fixed to the machine. 2.When carrying out any operation, always wear safety shoes and helmet. Do not wear loose work clothes, or clothes with buttons missing. ‘« Always wear safety glasses when hitting parts with a hammer. « Always wear safety glasses when grinding parts with a grinder, ete. 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 op- erating 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 alll tools in good condition and learn the correct way to use them. 6.Decide a place in the repair workshop to keep tools and removed parts. Always keep the tools and parts in their correct places. Always keep the work area clean and make sure that there is no dirt or oil on the floor. Smoke only in the areas provided for smoking. Never smoke while working PREPARATIONS FOR WORK 7.Before adding oil or making any repairs, park the machine on hard, level ground, and block the wheels or tracks to prevent the machine from moving 8 Before starting work, lower blade, ripper, bucket or any other work equipment to the ground. if this is not possible, insert the safety pin or use blocks to prevent the work equipment from falling. In addition, be sure to lock all the control levers and hang warning signs on them. 9.When disassembling or assembling, sup- port the machine with blocks, jacks or stands before starting work 10. Remove all mud and oil from the steps or other places used to get on and off the machine. Always use the handrails, ladders. or steps when getting on or off the machine. Never jump on or off the machine. If it is impossible to use the handrails, ladders or steps, use a stand to provide safe footing, 00-3PRECAUTIONS DURING WORK 111. 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 compo- nents 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 car- rying 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 hit- ting any other part. Do not work with any part still raised by the hoist or crane. 15. When removing covers which are under in- ternal 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 on to 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 mini- mum of gasoline when washing electrical parts. 00-4 19.Be sure to assemble all parts again in their original places. Replace any damaged parts with new parts. When installing hoses and wires, be sure that they will not be damaged by contact with other parts when the ma- chine is being operated. 20.When installing high pressure hoses, make sure that they are not twisted. Damaged tubes are dangerous, so be extremely care- ful when installing tubes for high pressure circuits. Also, check that connecting parts are correctly installed. 21. When assembling or installing parts, always use the specified tightening torques. When installing protective parts such as guards, or parts which vibrate violently or rotate at high speed, be particularly careful to check that they are installed correctly, 22. When aligning two holes, never insert your fingers or hand. Be careful not to get your fingers caught in a hole 23.When measuring hydraulic pressure, check that the measuring tool is correctly assem- bled before taking any measurements. 24. 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: 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 chapters for each main group of components; these chapters are further divided into the following sections. 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 inspécting disassembled parts. NOTICE The specifications contained in this shop manual are subject to change at any time and without any advance notice. Contact your KOMATSU distributor for the latest information. 00-5HOW TO READ THE SHOP MANUAL HOW TO READ THE SHOP MANUAL VOLUMES Shop manuals are issued as a guide to carry- ing out repairs. They are divided as follows: Chassis volume: Issued for every machine model Issued for each engine series Each issued as fone volume to | cover all models Engine volume: Electrical volume Attachments volume These various volumes are designed to avoid duplicating the same information. Therefore to deal with all repairs for any model, it is neces- sary that chassis, engine, electrical and attach- ment volumes are ready. DISTRIBUTION AND UPDATING Any additions, amendments or other changes will be sent to KOMATSU distributers. 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 shows how to read the page number. Example 1 (Chassis volume): 10-3 7 Item number (10. Structure and Function) Consecutive page number for each item, Example 2 (Engine volume): 12-410 U Unit number (1. Engine) Item number (2. Testing and Adjusting) Group No. (4. Fuel system) '— Consecutive page No. (Page 10 of Group 4) 3. Additional pages: Additional pages are in- dicated by a hyphen (-) and number after the Page number. File as in the example. Example: 10-4 12-203 10-4-1 12-203-1 10-4.2 +—Added pages 19°903-2 10-5 12-204 00-6 REVISED EDITION MARK (DOG When a manual is revised, an edition mark is recorded on the bottom outside corner of the pages. REVISIONS Revised pages are shown at the LIST OF REVISED PAGES on the between the title page and SAFETY page. SYMBOLS So that the shop manual can be of ample practical use, important places for safety and quality are marked with the following symbols. Symbol | tem Remarks Special safety precautions aro A necessary when performing the work Safety Extra special safety precautions “pr are necessary when performing * the work because it s under internal pressure, Special technical precautions or other precautions for | Caution | preserving standards are necessary when performing the work Weight of parts or systems ‘Caution necessary when Weight | selecting hoisting wire, or when working posture is important, ete. Places that require special San |,Tahten, [attention forthe tightening ‘46 torque during assembly. Places tobe coated with ee Coat | adhesives and lubricants etc. © Places where ol water or fel Wer |i, water] must be added, andthe [capacity Places where oil or water must Drain | be drained, and quantity to be drainedHOISTING INSTRUCTIONS HOISTING INSTRUCTIONS Ay Heavy parts (25 kg or more) must be lifted with a hoist etc. In the Disassembly and Assembly section, every part weigh- ing 26 kg or more is indicated clearly with the symbol ~., > 1.If 2 part cannot be smoothly removed from the machine by hoisting, the following checks should be made: + Check for removal of all bolts fastening the part to the relative parts. * Check for existence of another part causing interference with the part to be removed. 2. Wire ropes 1) Use adequate ropes depending on the weight of parts to be hoisted, referring to the table below: Wire ropes (Standard “2” or “S” twist ropes without galvanizing) Rope diameter (mm | Allowable load (tons) 10 ] 10 112 | 14 125 16 14 22 16 | 28 18 | 36 20 | 44 224 56 30 100 40 18.0 50 280 60 40.0 Slinging near the edge of the hook may cause the rope to slip off the hook during hoisting, and a serious accident can result. Hooks have maximum strength at the middle portion, b6G¢6¢ ui 00% 79% 1% 3)Do not sling a heavy load with one rope alone, but sling with two or more ropes symmetrically wound on to 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 ina dangerous accident 4)Do not sling a heavy load with ropes forming @ 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 suspended. 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 @ 2000 kg load at a lifting angle of 150° AA rm A The allowable load value is estimated to be one-sixth or one-seventh of the breaking strength of the rope used. 2) Sling wire ropes from the middle portion of the hook. ae > 50085 00-7STANDARD TIGHTENING TORQUE STANDARD TIGHTENING TORQUE 1, STANDARD TIGHTENING TORQUE OF BOLTS AND NUTS The following charts give the standard tightening torques of bolts and nuts. Exceptions are given in sections of “Disassembly and Assembly”. Thread diameter Width of bolt across flat (mm) (mm) kgm Nm 6 10 1,350.15 13.2414 8 13 3.2+03 31.4429 10 7 6720.7 65.7468 12 19 11.5+1.0 112498 14 22 18.0+20 177419 16 24 28.523 27929 18 27 3944 383+39 20 30 56+6 | 549-458, 22 32 76=8 74578 24 36 94.5+10 927+98 27 a1 135415 1320+ 140 30 46 17520 1720+ 190 33 50 22525 | 2210+ 240 36 55 280+30 | 2750+290 39 60 335435 3280+340 This torque table does not apply to the bolts with which nylon packings or other non- ferrous metal washers are to be used, or which require tightening to otherwise specified torque. + Nm (newton meter): 1Nm = 0.1 kgm 2. TIGHTENING TORQUE OF SPLIT FLANGE BOLTS Use these torques for split flange bolts. Thread diameter Width Tightening torque of bolt, across flats (mm) (mm) kgm Nm 10 14 67+07 | 65.7+68 12 W7 11.541 112+98 16 22 28.543 279229 00-8STANDARD TIGHTENING TORQUE Use these torques for nut pat of flared me Thread diameter Width across flats Tightening torque COATING MATERIALS The recommended coating materials prescribed in Komatsu Shop Manuals are listed below. Nomenclature | Komatsu code ‘pplcations Tra Used to apply rubber pads, rubber gaskets, and cork plugs ne Tae to apply resin, wubb, metalic and aa non-metallic parts whens fast, strong seal is needed. Adhesives ur" Preventing bolts, aus and plugs from loosening and leaking ail Provides an airtight, electrically nsulating seal ie Used for aluminum surfaces. 0 coat plugs (plate shaped, bow! shaped] and holes, and oe mating portion of shat. Let Used with gaskets and packings to increase sealing effect. Hoat-resistant gasket for precombuation chambers a oe ce ‘and exhaust piping. caeeee an Used by itself on mounting surfaces on the final drve and Wanemission cases. (Thickness after tightening’ 0.07 — 0.08 mm) 1s-6 Silicon base type used in combination with LG-1 and LG-4 Fas a shorter curing time than LG-6, ands easier 10 peel off ‘Antifition compound Applied to bearings and taper shafts to facilitate press-fitting and to {Cabricant including ime : ero acaeee prevent sticking, burning or rusting Grease “Tpplied to bearings siding parts and oll seals for lubrication, rast (Cithium greased feat prevention and factitation of assembling work. Veseline _ Used for protecting battery electrode terminals from corrosion, _L. *LT-2ii also called LOCTITE in the shop manuals, 00-9ELECTRIC WIRE CODE aay In the wiring diagrams, various colors and symbols are employed to indicate the thickness of wires. ELECTRIC WIRE CODE This wire code table will help you understand WIRING DIAGRAMS. Example: 5WB indicates a cable having a nominal numiber 5 and white coating with black stripe CLASSIFICATION BY THICKNESS 60 127 oa | 63.84 13.6 178 Starting CLASSIFICATION BY COLOR AND CODE o asd | carton Ground Starting Lighting Instrument Signal ‘other mer | Color White Black Black Red ‘Yellow ; [coir] writesnea | _— | eck a white | Rede wnte | Volowa ed | Geena White| Blac & White 2 ‘awe-| Color] Whites Biack | — | Black & Yellow | Rede Black | Yellow & Black | Green&Red | Blue & Red tary Coae We BR RY YG. GY Y ‘ Coior| Wrietsive | — | Beck&Aea | Rede Vetow | Velow& Groen Gwen & Yelow| Blue &Velow . Color | White & Gree = = Red & Green | Yellow & Blue | (Green & Black) | (Blue & Black) . Color = - Red& Blue | Yellow & White | (Green & Blue) 00-10WEIGHT TABLE Ay Tris weight tobi is a guide for use when transporting or handling components. Unit: kg Machine Model PC150-5 Serial Numbers 6001 and up Engine assembly (excluding water and oil) 440 PTO. 27 Radiator and oil cooler assembly 508 Revolving frame 1,330 Operator's cab 238 Operator's seat 317 Fuel tank (excluding fuel) 112 Hydraulic tank (excluding oil) 98 Counterwieght 2,760 Hydraulic pump assembly 160 LH. 6-spool control valve 44.5 RH. 5-spool control valve 40 ‘Swing circle assembly 223.4 ‘Swing machinery assembly 137.4 Swing motor 50 Center swivel joint 35.2 Track frame assembly 3,335 + Track frame 1,833 + Idler 140 x2 + Idler cushion 103.3 x 2 + Carrier roller 2x2 + Track roller 37x14 + Travel motor and final drive assembly 269 x2 + Sprocket 418 x2 00-12 021K05021K05 Unit: kg Machine Model PC150-5 Serial Numbers 6001 and up Track shoe assembly + Triple shoe (500 mm) 2,150 + Wide triple-shoe (600 mm) 2,380 + Wide triple-shoe (700 mm) 2,610 + Swamp-shoe (720 mm) 2,840 Boom assembly 1,085 ‘Arm assembly 500 Link assembly 151.1 Bucket assembly 476 Boom cylinder assebly 126.8 x2 ‘Arm cylinder assembly 182.7 Bucket cylinder assembly 105.5 00-13LIST OF LUBRICANT AND WATER noe ‘AMBIENT TEMPERATURE CAPACITY (L) Lerctiscid ie 4 8 so 7 a Bot es Specified | Refi Gln el sen Ew Engine ol pan pane tow 19 | 178 a EE (nae | PTO caso j os | oe Swing machine | case ” GE) 1s | as Final crive case / (each) Engine oil | | 4 4 4 Hanae She 10 Ci ann Hycrauiceystom — «| as EL Idler (each) | 007-008) — ‘Track roler (each) Tes a ose] — Carr roller (each) | 028-025) — ana | | Ful ta ees wt P| | wo | [aE AST he 7 T Coating. systom water | Add antieeze | 18 = ASTM: American Society of Testing and Material SAE: Society of Automotive Engineers API American Petroleum Institute ‘% ASTM D975 No.1 ‘Specified capacity: Total amount of oil including oil for components and oil in piping. Refill capacity: Amount of oil needed to refill system during normal inspection and maintenance NoTE: (1) When fuel sulphur content is less than 0.5%, change oil in the oil pan every periodic main- tenance hours described in this manual. Change oil according to the following table if fuel sulphur content is above 0.5%. ‘Change interval of oi engine oil pan Fuel sulphur content (05 t0 1.0% ‘Above 1.0% 1/2 of regular interval 174 of regular interval (2) When starting the engine in an atmospheric temperature of lower than O°C, be sure to use engine oil of SAE1OW, SAE10W-30 and SAE15W-40 even though an atmospheric ‘temperature goes up to 10°C more or less in the day time, 00-14 @ (3) Use API classification CD as engine oil and if API classification CC, reduce the engine oil change interval to half. (4) There is no problem if single grade oil is mixed with multigrade oil (SAETOW-30, 15W-40), but be sure to add single grade oil that matches the temperature in the table on the left. (8) We recommend Komatsu genuine oil which has been specifically formulated and approved for use. in engine and hydraulic work equipment applications. 021K0s021K05 10 STRUCTURE AND FUNCTION Power train ... -10- 2 Final drive 10. 3 Swing circle 10-4 ‘Swing machinery 210 5 Track frame 10-6 Idler 10 7 Idler cushion. 10-7 Carrier roller 10- 8 Track roller . 10. 8 Track shoe ......s.e0 secre 10-9 Hydraulic piping ceceeeeeseeee 10° 11 Hydraulic circuit diagram + 10- 13 Hydraulic tank : 10-14 OLSS (Open center Load Sensing System) 2 10-14-1 Hydraulic pump . 10-15 LH. 6-spoo! control vaive RH. 5-spool control valve ‘Swing motor... Center swivel joint Travel motor Valve control. PPC valve 10. 54 Accumulator -10- 58 Safety lock valve . -10- 58 Solenoid valve ... -10- 59 Shuttle valve ....... 10- 63 Boom holding valve = 10- 64 Hydraulic cylinder ........2..006 10- 67 Electrical wiring diagram = 10- 70 Electrical circuit diagram Engine control system PEMC system . EMACC (Electronic Monitor and Control Console) ... - 10-109 10-1POWER TRAIN 10-2 Noosens Idler Centor swivel joint R.H. 5-spool control valve Travel speed solenoid valve ‘Swing brake solenoid valve Final drive Travel motor 202F05511 8. Hydraulic pump 9. Engine 10. RH. 6-spool control valve 11. Swing motor 12. Swing machinery 13. Swing circle 021K05021K05 FINAL DRIVE 1, Level plug 2. Drain plug 3, No. 1 sun gear (21 teeth) 4. No. 2 sun gear (9 teeth) 5. No. 2 Planet carrier 6. Cover 7. No. 1 planet carrier 8, Retainer (78 teeth) 9. Sprocket 10. Floating seal 11. Travel motor 12. Hub 13. No. 1 planetary gear (29 teeth) 14, Ring gear (81 teeth) 15. No. 2 planetary gear (36 teeth) ‘SPECIFICATION Reduction ratio: 9, 81421 a 2 202FO5605 10-3SWING CIRCLE 1 b. 10-4 ‘Swing circle outer race Ball bearing Swing circle inner race (94 teeth) Inner race soft zoné Outer race soft zone SPECIFICATIONS Reduction ratio: $4 — 6.714 Grease volume: 9.51 (Grease G2-LI) 20205608 021K05021K05, SWING MACHINERY Section A~A 1. Swing pinion (14 teeth) 2. Case 3. Planet carrier 4. Ring gear (76 teeth) 5. Bearing holder 6. Drive gear (20 teeth) 7. Cover 8. Swing motor 9. Driven gear (65 teeth) and sun gear (14 teeth) 10. Planetary gear (31 teeth) 11, Drain plug 12. Level gauge SPECIFICATION Reduction ratio 8 (1. 78 14 )= 20893 20 Section Cc 202F05607 10-5TRACK FRAME 10-6 1, Idler 2. Track frame 3. Carrier roller 4, Travel motor 5. Sprocket 6. Track shoe 7. Idler cushion 8. Track roller 20205609 021KO81 2 3 4 5 = 4 6. — d 8 5 202F05013 IDLER CUSHION ~ 202F08611 Lubricating plug Support Idler Floating seal Idler shaft Bushing Front support (cylinder) Recoil spring ‘Wear ring Packing Rear support Lubricator Drain plug COIAMEeno SPECIFICATIONS Grease volume: 330 cc (G2-LI) 10-7CARRIER ROLLER Shaft Collar Floating seal Roller Ring Cover Lubricating plug Neesene 205F05014 Lubricating plug Collar Floating seal Roller . Bushing Shaft 2@aRens =| J 2082452 021K05,TRACK SHOE O “y O 1 2 3 8 ete eI oe ‘SA \ g 10 208F05015 1. Link 6. Master bushing ‘SPECIFICATIONS (Standard shoe) 2. Shoe 7. Master dust seal ‘Shoe width: 500 mm triple-shoe 3. Regular pin 8. Master pin Link pitch: 190 mm 4. Regular bushing 9. Shoe nut Number of shoe: 82 5. Regular dust seal 10. Shoe bolt 10-9SELECTION OF TRACK SHOE © Select the most suitable track shoe from the following table. Specifications Category 500 mm triple shoe A 600 mm triple shoe fo 700 mm triple shoe c 720 mm swamp shoe | cc Category Use Precautions when using ‘A [Rocky ground, normal | = Travel in Lo speed when traveling on rough ground with river soil obstacles such es large boulders and fallen trees. Cannot be used on rough ground where there are large obsta- cles such as boulders and fallen trees. B | Normal soil, soft land | . Travel in Hi speed only on flat ground, and when it is impos- sible to avoid traveling over obstacles, lower the travel speed to approx. half of Lo speed. * Use only for ground where “A” and “B” sink and are impos: sible to use, = Cannot be used on rough ground where there are large obsta- Ce | trometvisar ee cles such as boulders and fallen trees. (swampy ground) * Travel in Hi speed only on flat ground, and when it is impos- sible to avoid traveling over obstacles, lower the travel speed to approx. half of Lo speed. 021K05 % Categories “B" and “C” are wide shoes, so there are restrictions on their use. Therefore, before using, check the restrictions and consider carefully the conditions of use before recommending a suitable shoe width. If necessary, give the customer guidance in their use. %* When selecting the shoe width, select the narrowest shoe possible within the range that will give no problem with flotation and ground pressure. Hf a wider shoe than necessary is used, there 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. 10-10021K05 HYDRAULIC PIPING F21K05001 Bucket cylinder Arm oylinder Hydraulic tank ‘Swing brake solenoid vaive Straight-travel solenoid valve Travel speed solenoid valve CO cancel solenoid valve R.H. 5-spoo! controt valve Hydraulic pump 10. LH. 6-spoo! control valve 11. Oil cooler 12. PPC shuttle valve 13. Arm half flow solenoid valve 14. LH. travel motor 15. Pump oil pressure sensor 16, Accumulator 17. RH. travel motor 18. LH. PPC valve 19. Safety tock valve 20. Swing motor 21. RH. PPC valve 22. Center swivel joint 23. Boom holding valve 24. Boom cylinder © PNonsens 10-11021KO5, HYDRAULIC CIRCUIT DIAGRAM F21K08002 10-13HYDRAULIC TANK Drain plug Cap Pressure valve Safety valve Return oil filter Hydraulic tank Sight gauge Suction strainer eyomsens 10-14 Section A-A Section BB 20205614 SPECIFICATIONS * Tank capacity: 190 © Oil amount: 135 1 © Pressure valve Relief set pressure: 0,39 + 0.15 kg/cm? ‘Suction set pressure: 0 — 0,046 kg/cm? * Safety vaive set pressure: 1.05 + 0.20 kg/cm? 021K05021K05 OLSS (Open center Load Sensing System) Motor vinder 1 I et et LH. 6-spoo! spool Control come Valve Vawve Rear Engine Front pump M pump Servo Servo valve valve NC valve NC valve CO viave CO wtave We viave Controller §-—{1] Ea 7 OLSS (Open center Load Sensing System) is an energy-saved system to reduce the fuel con sumption by means of controlling the swash plate angle (delivery) of the variable- displacement swash-plate type piston pump. Therefore this system acts to reduce the hydraulic loss during operation, to increase the fine control and to control the pump delivery. Charging pump F21K05051-K 10-14-11 EFFECTIVE USE OF ENGINE HORSEPOWER In H mode, the set speed of the engine and the actual speed of the engine are always detected. As a result, even if the load changes during operation, the discharge amount (swash plate angle) or the pump is controlled so that the load on the engine {engine speed) is always maintained con- stant, thus ensuring effective use of the ‘engine horsepower. (Engine speed, oil pressure sensing control) CUT-OFF CONTROL © The cut-off control is a function to reduce relief loss during operations. If the load increases, the discharge pressure of the main pump is increased; if the load comes close to the relief pressure, the discharge volume is decreased, © This function is carried out with the CO valve. For details of the operation of the CO valve, see HYDRAULIC PUMP. FLOW CONTROL PNC (pump neutral control) '* When the control levers are at neutral, the pump discharge volume is kept to the minimum to reduce the wasteful flow of oil when the control valve is at neutral PFC (pump fine control) '* When the lever is operated, the necessary flow is ordered to the pump based on the flow command that corresponds with the lever travel. This reduces the wasteful flow of oil that occurs during fine control * At the same time, by increasing the pump discharge pressure to the optimum value according to the lever travel, the fine control performance is improved. © This function is carried out with the NC valve and jet sensor. For details of the operation of the NC valve, and jet sensor see HYDRAULIC PUMP. 10-14-2 Mai ery pressure P Pump discharge pressure (kg/cm in pump delivery H.0.G.0,LO+L rot Pump delivery volume 202F05113, Note) HO Heavy-duty operation mode, G0 General operation mode. F.O. Finishing operation moda, LO. Lifting operation mode Los when there sno cutot!| Pump discharge volume (I/min.) | cutott Pump discharge volume (Q) 20205006 20205149 021K05021K0s HYDRAULIC PUMP a. CO cancel pressure Psor IN port b. Jet sensor output pressure Pt IN port ©. CO cancel pressure Psor IN port d. Jet sensor output pressure Pr IN port e. Jet sensor output pressure Pa IN port f. Jet sensor output pressure Pd IN port PN ORsoNne 202F05617 TVC valve Front CO*NC valve Front servo valve Rear CO*NC valve Rear servo valve Charging pump and relief valve Rear main pump Front main pump. 10-151, FRONT MAIN PUMP AND REAR MAIN PUMP (HPVO71+071) a. Suction PS port b. Front main pump discharge Prt port c. Rear main pump discharge Pr2 port d. Serove valve output pressure Pcs port e. Rear main pump discharge Pr2 port 4. Front main pump discharge Prt port 10-16 Borccose 202F05618A Charging pump pressure Pc1 port Servo valve output pressure Pcta port Servo valve output pressure Pcts port Charging pump pressure Pc2 port Rear main pump discharge Pr2 port Front main pump discharge Prt port Servo valve output pressure Pc2s port 021K05021K05: 1. Front drive shaft 2. Front cradle 3. Front pump case 4. Front rocker cam 5. Front piston 6. Front cylinder ‘Section B—B ay Section A—A 7. Front valve plate 8. End cap 9. Coupling 10. Rear valve seat 11. Rear cylinder 12, Rear piston Section C—c 202F0s619, 13, Rear rocker cam 14, Rear pump case 15, Rear cradle 16. Rear drive shaft 17. Servo piston 10-172. SERVO VALVE & The drawing shows the servo valve for front main pump. é Section B — B ° Section —D SectionE —E Section F—F Section —G 202F08022 a. Servo actuator port 4. Front main pump output pressure Prt IN port b. Servo actuator port h. CO, NC valve drain Par IN port c. Servo actuator port i, CO, NC valve output pressure IN port d. NC valve output pressure Pi pick-up port j. Charging pump pressure PPo OUT port ¢. Servo valve drain Pdr OUT port k. Rear main pump output pressure Pee OUT {Rear main pump output pressure Pr2 IN port port |. Front main pump output pressure Per OUT port 10-18 021K05021K05, ——tL \ | \ \ | \ \ 9 18 W 16 1 are 13 12 1. Lock nut 8.Pin 15. Guide spool 2. Cover 9. Control piston 16. Spring 4. Spring 11, Plug 18. Cover 5. Body 12. Lock nut 19, Lock nut 6. Spring 13. Cover cha 14. Sleeve FUNCTION * Discharge volumes Q1 and Qz of main pumps Ppt and Pr2 are controlled individually by their ‘own servo valve. The relationship between pump discharge bolume Q and input signal Pi sent to the servo valve is as showon in the graph on the right Q changes in proportion to Pi ° é Pump del (cc/rev) CONC valve output pressure Pikg/em®) 202F05024 10-19OPERATION 1) Operation for increasing pump discharges (rocker cam angle changes to the large) Woe mh gg Pi 1 : NC valve IVC valve| * Charging pump pressure Pe is sent to port a. Signal pressure Pi from the NC valve is sent from port b to chamber c. ‘* As signal pressure Pi rises, the pressure in chamber C pushes control piston (9) to the left in the direction of the arrow. The piston stops in @ position where it is balanced with the force of springs (4) and (6). At the same time, arm (7) uses servo piston (20) as a fulcrum, moves to the left in the same way as control piston (9), and while fluctuating, moves guide spool (15) to the left 10-20 20205025 ‘* The movement of guide spool (15) closes port a and port d, and connects port d with drain chamber e. As a result, servo piston chamber fis also connected to chamber e through port g and port d. At the same time, port a and port h are connected, and the flow passes through port ‘0 servo piston chamber j to push servo piston (20) to the left in the direction of the arrow. The rocker cam angle of the main piston pump becomes larger, and the pump discharge volume increases. ‘© Because of the movement of servo piston (20), arm (7) rotates clockwise around pin (8), ‘moves guide spool (15) to the right, and closes port a, port d, and port h, so the discharge volume increases only by an amount corres- ponding to signal pressure Pi 021K05021K05 2) Operation for decreasing pump discharges (rocker cam angle changes to the small) oe b 46 9 = SEE = zy \ a Nae Wg cH aI Pe 1 =] [ H s ay Pi aa : ef] [Nc valve : r Hee. ® . a CO valve T He. TVC valve rapes M ‘© When signal pressure Pi drops, control piston (8) moves to the right in the direction of the arrow to a point where the hydraulic pressure of chamber c is in balance with the force of springs (4) and (6) At the same time, arm (7) uses servo piston (20) as a fulerum, moves to the right in the same way as control piston (9), and while fluctuating, moves guide spool (15) to the right ‘* The movement of guide spool (15) closes port a and port h, and connects port h with drain chamber e. Asa result, servo piston chamber jis also connected to chamber e through port i and port h 202F05026 At the same time, port a and port d are connected, and the flow passes through port g to servo piston chamber f to push servo piston (20) to the right in the direction of the arrow. The rocker cam angle of the main piston pump becomes smaller, and the pump discharge volume decreases Because of the movement of servo piston (20), arm (7) rotates counterclockwise around pin (8), moves guide spool (15) to the left, and closes port a, port d, and port h, so the discharge volume decreases only by an amount corresponding to signal pressure Pi 10-213. TVC VALVE eeapge w EF | + ORY ie f o 3 EF Section A— A OPO ° B J 8. !o oo ° Section — C SectionD —D SectionE —E Section F—F Charging pump pressure PPo IN port 1. Spring 5. Sleeve Front main pump output pressure Prt IN port 2. Spool 6. Piston Rear main pump output pressure Pe2 IN port 3. Piston 7. Body TVC valve drin Par OUT port 4. Piston 8. Solenoid TVC valve output pressure Pt OUT port 10-22 202F05027 021K08021K05 FUNCTION AND OPERATION 1) When command current from pump controller is small (when pump controller is normal) Pi Ne | co. valve | valve —! Servo valve Servo piston Desaute GT Treeae Discharge eencialy (Control valve Fl FUNCTION ‘© When the pump controller is normal, the main pump discharge volume can be controlled as desired over a wide range according to the command current from the pump controller to carry out the power mode function. * When the pump controller is abnormal, hydraulic sensing is carried out to control the main pump discharge volume according to the load (pump discharge pressure) to carry out the constant torque control function (prolix function) For details, see PEMC SYSTEM. TVC valve “TFVE prolix switch Resistor 202F05028 OPERATION © Because of the command current sent from the controller, solenoid push pin (9) moves, and piston (2) also moves. It stops at a point where the sum of the force of spring (1) and the force of push pin (9) and the force of TVC output pressure Ptz acting on piston (3) is in balance. When this happens, the command current is small, so piston (2) balances at the bottom. As a result, port a and port b are almost completely open, and almost all the pressur- ized oil from the charging pump is output as. TVC output pressure Pt2. Because of this, the pump discharge volume is maximum. 10-232) When command current from pump controller Servo valve Servo piston Decrease =— T-Tincrease Discharge eam mT cee of M f * Because of the command current sent from the controller, solenoid push pin (9) moves, and the piston (2) also moves it stops at the point where it is balanced with the force of spring (1). When this happens, the command current is large, so piston (2) is balanced at the top. As a result, the flow of oil sent from the charging pump is throttled at port a and port b, and the area of the opening at port b and port ¢ (drain port) becomes larger because of this, TVC valve output pressure Ptz drops and the pump discharge volume is reduced 10-24 large (when pump controller is normal) TVC valve onlg °F FVE protix switch Resistor 20205029 021K05021K05 3) Main pump under light load (pump controller abnormal and TVC prolix switch ON) TVc valve my Nc |co valve | valve Servo valve Servo piston DecreoselGI = Trerease Diechorge (Conival valve (Gontral valve. Pump ontrotler o on TVG prolix switch Resistor 202F05030 '* Main pump discharge pressures Prt and Pr2 are low, so spool (2) is pushed down by spring (1), As a result, charging pump discharge pressure Pc and TVC valve output pressure Ptz are equal. When this happens, TVC valve output pres- sure Pt2 is maximum and the main pump discharge volume is also maximum. 10-254) Main pump under heavy load (pump controller abnormal and TVC prolix switch ON) TVC valve Pil uc valve co ‘Servo valve Servo piston Decrease =~ UpTincrease Discharge (Contra |, Control valve: valve TVE prolix switch Resistor 20205031 ‘* When main pump discharge pressure Prt (or Pr2) increases, spool (2) is moved up by piston (4) or piston (6). As a result, the flow at port and port b is throttled by the notch in the spool, and the area of the opening at port band port ¢ (drain port) becomes larger. Because of this, TVC valve output pressure Ptz drops and the main pump discharge volume is reduced 10-26 021K05021K05, 4. CO*NC VALVE + The drawing shows the CO, Charging pump pressure Pro OUT port Main pump output pressure Pet (Pr2) OUT port Main pump output pressure Pre (Pp1) OUT port TVC valve output pressure Ptz IN port TVC valve drain Par port CO cancel pressure Psof (Psor) IN port TVC valve output pressure Pt2 F-R connection port Jet sensor output pressure Pd IN port Jet sensor output pressure Pt IN port Section A—A CO VALVE NC 1. Plug 7. 2. Piston 8. 3. Spring 9. 4, Spool 10, 5. Piston "1 6. Plug 12 4 (_): For rear servo valve VALVE Plug Sleeve Piston Spool Spring Plug NC valve for the front main pump. 202F05032, 10-27FUNCTION AND OPERATION OF CO VALVE 1) When main pump discharge pressure is below relief pressure Servo valve Servo piston Decrease I= increase Discharge (Control FUNCTION If the load increases during operation, and the main pump discharge pressure increases, when it becomes nearly the relief pressure, the CO valve carries out the cut-off function to reduce the discharge amount of the pump and reduce the relief loss. © At the same time, the pilot pressure of the CO function cancel solenoid vaive also has the function of canceling the cut-off. ‘* The CO valve is controlled by balancing the spring with the sum of main pump discharge pressure Pr and CO valve output pressure Peo. 10-28 0 valve ei} | \ 20205033 OPERATION ® Spool (4) is pushed down by spring (3) As a result, port a and port b are completely open, and TVC valve output pressure Pt2 are equal Because of this, CO valve output pressure Poo becomes maximum, and the discharge volume of the main pump is also maximum, 021K08021K05 2) When the main pump discharge pressure is higher than the main relief pressure = Servo piston Decrease Up increase Discharge Can Can} fae ae a * When main pump discharge pressure Pr comes close to the relief pressure owing to an increase in the load, piston (5) is pushed by main pump discharge pressure Pp and at the same time piston (5) is pushed by CO vaive output pressure Peo. When the force of spring (3) is overcome by the pressing force of the pistons, spool (4) moves upward. As a result, the spool land restricts the oil flow from port a to port b and at the same time the opening area of port b and port ¢ (drain port) are made larger Because of this, CO valve output pressure Pco becomes down, and the discharge volume of the main pump is also minimum. CO valve 0 cancel solenoid val = Deoer vated a 202F05034 10-293) When cut-off function is canceled by CO cancel solenoid valve CO cancel solenoid valve 2 = exeatf! [A J Pil no r re Sa : Lome co te} Discharge | Contr |_{Contralh valve valve 202F05035 * When the CO cance! solenoid valve is switched, pilot pressure is taken to port Pso and piston (2) is pushed down As a result, the setting of spring (3) becomes larger, so even when main pump discharge pressure Pp rises and reaches the relief pressure, spool (4) is not actuated and CO valve output pressure Pco remains at the 10-30 021K05,021K05 FUNCTION AND OPERATION OF NC VALVE 1) Control valve at neutral ; Control valve | servo valve Servo piston Discharge FUNCTION * The NC valve controls the main pump discharge volume according to the amount ‘of operation of the control valve spool, and carries out the function of controlling the oil flow to reduce the neutral loss and fine control loss. ‘* The NC valve is controlled by balancing the sum of jet sensor output pressure Pt and NC valve output pressure Pi with the sum of the force of NC valve spring (12) and jet sensor output pressure Pd. * The jet sensor detects the flow of return oil passing through the control vaive and returning to the tank, and takes it as NC valve Pt and Pd 202F05036 OPERATION © The differential pressure (Pt—Pd) of the jet sensor reaches the maximum and jet sensor output pressure Pt acting on piston (10) becomes greater than the sum of the force of spring (12) and jet sensor output presure Pd acting on the lower end of spool (11). As a result, spool (11) is pushed downward, causing a restriction of the oil flow between. port ¢ and port b and in turn opening port b and port a (drain port), Output pressure Pt of the NC valve is then reduced to the minimum and the main pump discharge is also reduced to the minimum with the swash plate angle minimized through the operation of the servo valve. 10-312) When the control valve is operated co | comets NC valve l a ee ? | ——n [— By | 8 Peo! co [rye [Pe vaive | valve | servo valve Servo piston Decrease Inara Discharge 202F05037 © With the jet sensor differential pressure (Pt— Pd) reduced according to the operation of the control valve, spool (11) is pushed upward, fully opening port ¢ and port b. Because of this, the NC valve output pressure Pi increases. And the main pump discharge is also increased. That is to say, the pump discharge increases as the stroke of the lever increases, 10-32 021K05021K05 5. CHARGING PUMP (BAR25) AND RELIEF VALVE ‘Section B—B 1 2 3. 4. 5. 6. Body Drive gear Driven gear Cover Relief vaive Filter © Suction Section A—A 202F05620 ‘SPECIFICATIONS Theoretical delivery: 25 cc/rev. Operating pressure: 30 kg/cm? 10-33L.H. 6-SPOOL CONTROL VALVE wrol Pa3 port (From LH. PPC valve) Pas port (From LH. PPC valve) 1 port (From front main pump) A3 port (To swing motor MB port) ‘AS port (To arm cylinder bottom side) As port (To LH. travel motor PB port) NGB port (To front main pump NC valve} NCA port (To front main pump NC valve) T port (To tank) B6 port (To LH. travel motor PA port) rrsesrpacge 10-34 202F05621 Bs port (To arm cylinder head side) B3 port (To swing motor MA port) B2 port (To boom cylinder bottom side} a2 port (From R.H. PPC valve) Ps port (From L.H. PPC valve) Pas port (From swing brake solenoid valve) Pas port (From L.H. PPC valve) Ts port (To tank) P2 port (From straight-travel valve) pr avpeosgrx 021K05021K05, Nogsens Main relief valve Spool (service) ‘Spool (boom-Hi) Spool (swing) ‘Spool (arm-Lo) Spool (LH. travel) Jet sensor relief valve ‘Section D—D 10. " 12 13. 14. d Section J—J 202F05622 Spool return spring Safety-suction valve Suction valve Check valve Check valve spring Spool (swing priority) Jet sensor orifice 10-35,‘SWING PRIORITY VALVE FUNCTION © When operating the swing and arm at the same time, most of the oil flows to the arm, which has less load. The flow of oil to the swing circuit is reduced so the arm speed is faster than the swing speed. This makes combined operations difficult, © To prevent this, the swing priority valve is Switched to restrict the flow of pressure oil to the arm-Lo control valve. This restricts the arm speed and makes it easier to operate the arm and swing at the same time. OPERATION When swing is at neutral * When the swing is at neutral, no pilot pressure oil flows from the solenoid valve ‘The swing priority valve is not actuated, so the pressurized oil from the front main pump. passes through port P1 and flows to the arm. Lo control valve. When swing is operated * When the swing is operated, spool (13) of the swing priority valve is pushed to the left by the pilot pressure from the solenoid valve Because of this, the pressurized oil flowing from front main pump to the arm Lo control valve is throttled by the swing priority valve and the arm speed is controlled, so the simultaneous operation performance is improved 10-36 ‘Swing brake} solenoid valve df 20205041 202F05042 021K05R.H. 5-SPOOL CONTROL VALVE Ts port Pas port (From LH. PPC valve) Pad port (From R.H. PPC valve) Pas port (From R.H. PPC valve) T port (to tank) As port (To arm cylinder bottom side} ‘A4 port (To boom cylinder bottom side) A port (To bucket cylinder bottom side) A2 port (From front main pump) A1 port (To R.H. travel motor PB port) Px port (From rear main pump) B1 port (To RH. travel motor PA port) rrvosesgascs 10-38 a. °. P. qa s. 1 u v. x 202F05623, Bz port (To LH. travel control valve) B3 port (To bucket cylinder head side) B4 port (To boom cylinder head side) Bs port (To arm cylinder head side) NCB port (To rear main pump NC valve) NCA port (To rear main pump NC valve) Pas port (From LH. PPC valve) Pas port (From R.H. PPC valve) Pa port (From RH. PPC valve) Paz port (From Straight-travel solenoid valve) Po port P2 port 021K05,021K05, NOgReNns Section AA Jet sensor relief valve ‘Spool (arm-Hi} Spool {boom-Lo) Spool (bucket) Spool (R.H. travel) Main relief valve Spool return spring on 10. 12. 13. 14. ‘Section HH FE Section J—J 202F05624 Suction valve Safety-suction valve Safety valve Check valve Check valve spring Spool (Straight-travel) Jet sensor orifice 10-39STRAIGHT-TRAVEL VALVE FUNCTION '* While operating the swing, boom, arm, or bucket when traveling, the pressure oil flowing to the RH. and LH. travel circuit branches into the swing, boom, arm, or bucket circuit. Since the supply of pressure oil ina branched travel circuit is less than that in the circuit before the branch, the motor naturally slows down, resulting in a turn. © When the straight-travel valve is switched over to establish continuity between the R.H. and LH. travel circuits, this undesired turning is prevented by equalizing the supply of pressure oil to the R.H. and L.H. travel motors 50 that they rotate at the same speed. OPERATION When traveling only * Since no pilot pressure oil flows the solenoid valve, so the straight-travel valve is not operated, © Therefore, the circuit between port PR (R.H. travel circuit) and port PL (LH. travel circuit) remains closed and both circuits remain independent. During simultaneous operation © While operating the work equipment or swing when traveling, spool (13) is pushed to the right in the direction of the arrow by the pilot pressure from the straight-travel_ solenoid valve. * Because of this, port PR and port PL then become connected to each other and an equal amount of pressure oil is supplied to the R.H. and L.H. travel motors, allowing both motors to rotate at the same speed The machine travels thus in a straight line 10-40 Straight. Solenoid mr Pawan LN. travel 202F05046 021K05,SWING MOTOR a. S port b. MB port (From LH, 6-spool control valve) c. MA port (From LH. 6-spool control valve) d. B port (From swing brake solenoid valve) @. T port (To tank) 10-42 SPECIFICATIONS Type: Theoretical delivery Safety valve set pressure Rated speed: Brake releasing pressure 202F05625, KMF9OAB-2 87.8 cc/rev 230 *§ ka/om? 1.087 rpm Max. 14 kg/cm? 021K05021K05: Section B—B 202F05626 1. Brake spring 10. Cylinder 2. Drive shaft 11. Valve plate 3. Cover 12. Air bleeding plug 4. Housing 13. Center shaft 5. Dise 14. Center spring 6. Plate 15. Safety valve 7. Brake piston 16. Check valve 8. End cover 17. Check valve spring 9. Piston 10-43‘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 charging 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 valveis excited When the swing brake solenoid valve is excited, the valve is switched, and the pressurized oil from the charging 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. 10-44 M “a Carano Sing brake 205F 05050 Charging ‘Swing Brake soenoid 205F 05081 021Kos,021K05 CENTER SWIVEL JOINT oReNne Cover Body Slipper seal Oil seal Shaft AL Br. B2 cn C2, View 2 From R.H. 5-spool control valve B1 port . To R.H. travel motor Pa port From L.H. 6-spool control valve B6 port To LH, travel motor PA port From R.H. 5-spool control valve A1 port To RH. travel motor PB port Di Da. 1 E2, t Te. 202F05627 From LH. 6-spool control valve As port From L.H. 6-spool control valve Pe port From travel speed solenoid valve To LH. and R.H. travel motor P port To tank From L.H. and R.H. travel motor T port 10-45TRAVEL MOTOR PB port (From travel control valve) PA port (From travel control valve) P port (From travel speed solenoid valve) T port (To tank) 10-46 202F05628 SPECIFICATIONS Type: HMV110ADT Theoretical delivery: Min. 62 ce/rev Max. 110 ce/rev Rated pressure: 325 kg/cm? Rated speed Min. 1,530 rpm Max. 920 rpm Brake releasing pressure: Max. 12.8 + 16 kg/cm? Hi-Lo switching pressure: 8 +4 kg/cm? 021K05:021K08 SEN OMEeNo Output shaft Motor case Regulator piston Cradle Rocker cam Piston Cylinder Valve plate End cover 10. u 12 13. 14, 16. 16. 17. 18. Regulator valve Spring Brake spring Brake piston Plate Dise Regulator piston Spring Check valve spring 19. 20. 21 22 23, 24, 25, 26. 202F05629 Check valve Counterbalance valve ‘Spool return spring Safety vaive Check vaive Air bleeder Check vaive Check valve spring 10-47MOTOR OPERATION 1) At Lo speed (motor rocker cam angle at maximum) YY | 1 _o | Travel control ri 12 TP No valve [rt Travel speed solenoid valve of. GE 205F050598 ‘© The solenoid valve is deactivated, so the pilot. © At the same time, the pressurized oil at pressure oil from the charging pump does not, regulator piston (16) at the bottom passes flow to port P. through orifice b in regulator valve (10) and For this reason, regulator valve (10) is pushed is drained to the motor case. to the upside in the direction of the arrow As a result, rocker cam (5) moves in the by spring (11). maximum rocker cam angle direction, the © Because of this it pushes check valve (19), motor capacity becomes maximum, and the and the main pressure oil from the control system is set to Lo speed. valve to end cover (9) passes through passage a in regulator valve (10), enters regulator piston (3) at the top, and pushes regulator piston (3) to the right in the direction of the arrow. 10-48 021K05021K05 2) At Hi speed (motor rocker cam angle at minimum) Travel speed solenoid valu \ R19 Travel control valve rae ‘© The solenoid valve is excited, so the pilot pressure oil from the charging pump flows to port P, and pushes regulator valve (10) is pushed to the bottom in the direction of the arrow. * Because of this, the main pressure oil from the control vaive passes through passage ¢ in regulator vaive (10), enters regulator piston (16) at the bottom, and pushes regulator piston (16) to the left in the direction of the arrow. 205FO5060A * At the same time, the pressurized oil at regulator piston (3) at the top passes through orifice d in regulator vaive (10) and is drained to the motor case. ® As a result, rocker cam (5) moves in the minimum rocker cam angle direction, the motor capacity becomes minimum, and the system is set to Hi speed. 10-49PARKING BRAKE OPERATION 1) When starting to travel When the travel lever is operated, the pressurized oil from the pump actuates counterbalance valve spool (20), and pushes open check valve (25), the circuit to the parking brake is opened. And the oil flows into chamber a of brake piston (13), over- comes the force of spring (12), and pushes piston (13) to the right in the direction of the arrow, When this happens, the force pushing plate (14) and disc (15) together is lost, so plate (14) and disc (15) separate and the brake is released. 2) When stopping travel When the travel lever is placed in neutral, counterbalance valve spool (20) returns to the neutral position and the circuit to the parking brake is closed. The pressurized oil in chamber a of brake piston (13) is drained to the case from the orifice in the brake piston, and brake piston (13) is pushed to the left in the direction of the arrow by spring (12) As a result, plate (14) and disc (15) are pushed together, and the brake is applied 10-50 Pras control rset 202F05518A Fffcgueteontral Pivaive KZ 202F05519 021KO5021K0s BRAKE VALVE * 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 compo: nent is as given below. 1) Counterbalance valve, check valve Function '* When traveling down a slope, 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 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 volume), Operation when pressure 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 (19 a)and flows from motor inlet port MA to motor outlet port MB. However, the motor outlet port is closed by check valve (19 b) and spoo! (20), so the pressure at the supply side rises. (Fig. 2) © The pressurized oil at the supply side flows from orifice E1 in spool (20) to chamber S1, and when the pressure in chamber $1 goes above the spool switching pressure, spool! (20) is pushed to the right in the direction of the arrow. As a result, port MB and port PB are connected, the outlet port side of the motor is opened, and the motor starts to rotate. (Fig 3) Control valve 205F05063A 13h 205FO50648 1] Ft s.-S MA to (Fig. 2) canrorvane | Pal pa je 4 / ste Fg 3) 208FO5085A 10-51Operation of brake when traveling downhill * If the machine tries to run away when traveling downhill, the motor will turn under no load, so the pressure at the motor inlet port will drop, and the pressure in chamber $1 through orifice E1 will also drop. When the pressure in chambar S1 drops below the spool switching pressure, spool (20) is returned to the left in the direction of the arrow by spring (21), 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 running away, In other words, the spool is moved 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 speed according to the discharge volume of the pump. (Fig.4) 2) Safety valve Function ‘* When travel is stopped (or when traveling downhill, the circuit at the inlet and outlet ports of the motor are closed by the coun- terbalance valve, but the motor is rotated by inertia, so the pressure at the oultet port of the motor will become abnormally hight and damage the motor or piping. The safety valve acts to release this abnormal pressure and sent it to the inlet port side of the motor to prevent damage to the equipment. Operation © When stopping travel (or when traveling downhill), chamber E in the outlet port circuit is closed by the check valve of the counter balance 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 [1r/4(D; —D:) x pressure] overcomes the force of the spring and moves the poppet to the right, so the oil flow to chamber F in the circuit on the opposite side. (Fig. 6) 10-52 Control valve 1% pal lee 3% N (Fig. 4) 208050660 (Fig. 5) 2osr2044 (Fig. 6) 20sr2045 021K05021K05: VALVE CONTROL 1. RH. PPC valve 2. R.H. work equipment control lever 3. RH. 5-spool control valve 4, Hydraulic pump 5. LH. 6-spool control valve 6. Accumulator 7. Shuttle valve F21KO5010 8. Arm half flow solenoid valve 9. LH. PPC valve 10. Safety lock valve 11. LH. work equipment control lever 12. LH. travel control lever 13. RH. travel control lever 10-53PPC VALVE P port (From charging pump) T port (To tank) P2 port (L.H.: arm in/R.H.: boom raise) P4 port (L.H.: R.H. swing/R.H.: bucket dump) Pt port (LH.: arm out/R.H.: boom lower) P3 port (LH.: LH. swing/R.H.: bucket cur!) seaege 10-54 202FO5066A FUNCTION ‘© The PPC valve supplies pressure oil from the charging pump to the side face of the spool of each control valve according to the amount of travel of the control lever. This pressure oil actuates the spool 021K05,021K05 1, Spool 2. Metering spring 3. Centering spring 4. Damper piston 5. Damper spring 6 Piston SectionD —D 202F06067 7. Disk 8. Lever 9. Joint 10. Plate 11. Collar 12. Body 10-55OPERATION 1) Control lever at neutral Ports Pt and P2 of the PPC valves in circuits A and B of the control valve are connected to drain chamber D through fine control hole f in spool (1). (Fig. 1) 2) Control lever operated slightly (fine con- trol) When piston (6) starts to be pushed by disc (7), retainer (13) is pushed. Spool! (1) is also pushed by 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 valve is sent through fine control hole f to port P1. When the pressure at port P1 rises, spool (1) is pushed back Fine control hole f is shut off from pump. pressure chamber Pp. At almost the same time it is connected to drain chamber D, so the pressure at port P1 escapes to drain chamber D. Spool (1) moves up and down until the force of metering spring (2) is balanced with the pressure of port P1 The relationship of the positions of spool (1) and body (12) {fine contro! hole f is in the middle between drain hole D and pump pressure chamber Pp) does not change until damper piston (4) contacts piston (6). Therefore, metering spring 2) is compressed in proportion to the travel of the control lever, 30 the pressure at port P1 also rises in proportion to the travel of the contro! lever. The spoot of the control vaive moves to a position where the pressure of port A (same as pressure at port Pt and the force fo the return spring of the control vaive balanced. (Fig. 2) 10-56 Control valve (Fig.1) Control valve (Fig.2) 202F05068 20205069 021Kos021K05 3) During fine control (control lever returned) When disc (7) starts to be returned, spool (1) is pushed up by the force of centering spring (3) and the pressure at port Ps Because of this, fine control hole f is connected to drain chamber D, and the pressurized oil at port P1 is released. If the pressure at port P1 drops too much, spool (1) is pushed down 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 P1 supplies the pump pressure until the pressure recovers to a pressure equivalent to the position of the lever When the control valve spool returns, oil in drain chamber D from fine control hole f* of the valve on the side that is not moving folws through port P2 and goes to chamber B, so the oil is is charged. (Fig. 3) 4) At full stroke Disc (7) pushes down piston (6), but damper piston (4) also follows this and 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 charging 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. With damper piston (4) that was following piston (6), the pressurized oil in the spring chamber flows out from orifice a, and damper piston (4) and spool (1) are pushed back by the force of metering spring (2) and the hydraulic pressure at port Pt The time lag when the lever is suddenly operated is prevented by damper piston (4). (During fine control, damper piston (4) does not follow piston (6), so the fine control performance is maintained.) (Fig. 4) (Fig.3) 20205070 (Fig.4) 202F05071 10-57ACCUMULATOR Gas plug Shell Poppet Holder Bladder Oil port PR RENs SPECIFICATIONS Gas capacity: 300 ce 20205072 SAFETY LOCK VALVE Lever Body Seat Ball End cap gReNe Froscso18 10-58 021K0s:021K05 SOLENOID VALVE FOR CO CANCEL, TRAVEL SPEED, STRAIGHT-TRAVEL AND SWING BRAKE Ta port Pr port (To safety lock valve) At port (To front and rear CO valve) Tr port Az port (To LH. and RH. travel motor) Tz port As port (To straight-travel valve) Ta port ‘As port (To swing priority valve and swing motor) P2 port (From charging pump) oRONS 20205074 Block CO cancel solenoid valve Travel speed solenoid valve Straight-travel solenoid valve ‘Swing brake solenoid valve 10-59Section A—A OPERATION Solenoid deactivated * No signal current flows from the controller, so solenoid is deactivated. Because of this, port A is closed, and the pressurized oil from the charging pump does not flow to the actuator. ‘At the same time, the oil from the actuator flows from port B to port C and is drained to the tank Solenoid excited © When the signal current flows from the controller, solenoid (3) is excited. Because of this, the pressurized oil from the charging pump passes from port A through, the inside of spool, flows to port B and then. flows to the actuator. At the same time, port C is closed, so the oil does not flow to the tank, 10-60 202F05075, A = Desexivated 1 2 3. 4 5. 6 7 Connector Plunger Coil Push pin Spool Spring Block F21K05052-K F21K05053-K 021K05021K05, FOR ARM HALF FLOW 202F05631 P1 port (From arm PPC valve P3 port) 1. Arm half flow solenoid valve T3 port . $1 port (To arm-Hi control valve) Tt port T2 port 10-61Connector Plunger Coil Spring Spool Body Plug Negsens 20205079 OPERATION Solenoid deactivated * No signal current flows from the controller, so coil is deactivated, Because of this, port P and port S are interconnected, and the pressurized oil from the PPC valve flows to the control valve. By] Control valve Fg F21KO5054-K. Solenoid excited * When the signal current flows from the controller, coil is excited. Because of this, port P is closed, and the pressurized oil from the PPC valve does not, Control valve > s flow to the control valve, = At the same time, port $ and port T are interconnected, so the pressurized oil from the control valve is drained the tank. P| T PPC. valve F21KO5055-K 10-62 021K05SHUTTLE VALVE FOR OIL PRESSURE SENSOR 1. Cover 2. Ball 3. Body 4. Pressure sensor a. Pi port (From front main pump) b. Pz port (From rear main pump) Section A—A 202F05082 021K05 FOR WORK EQUIPMENT AND SWING OIL PRESSURE SWITCH Plug Body Ball Bt port (Swing oil pressure switch installed hole) Ps port (RH. swing) Ps port (LH. swing) Pr port (Arm in) Pe port (Arm out) Ps port (Bucket curl) B2 port (Work equipment oil pressure switch installed hole) 1. P3 port (Bucket dump) i. P2 port (Boom raise) | i. Pr port (Boom lower) 202F05083, a wne © 10-63BOOM HOLDING VALVE Section 8—B LA 24 eo \e T port (To tank) Pi port (To boom PPC valve) Cy port (To boom cylinder bottom side) |. V port (From boom control valve) a b. cS 4. 10-64 open Section AA 20205632 Safety-suction valve Pilot spring Pilot spool Poppet spring Poppet 021K05,021K05, OPERATION 1) Atboom RAISE When the boom is raised, the main pressure from the control valve pushes up poppet (5) in the direction of the arrow. Because of this, the main pressure oil from the control valve passes through the valve and flows to the bottom end of the boom oylinder. 2) Boom lever at NEUTRAL When the boom is raised and the contro! lever is returned to NEUTRAL, the circuit for the holding pressure at the bottom end of the boom cylinder is closed by poppet (5), and at the same time, the circuit for the oil flowing into poppet (5) through orifice a of poppet (5) is closed by pilot spoo! (3). As a result, the boom is held in position. 205F05091 208F05092 10-653) Boom LOWER When the boom is lowered, the pilot pres- sure from the PPC valve pushes pilot spool (3) and the pressurized oil in chamber b inside the poppet is drained. When the pressure at port Cy rises because of the pressurized oil from the bottom end of the boom cylinder, the pressure of the pressurized oil in chamber b is lowered be- cause of orifice a. If the pressure in chamber b drops below the pressure at port V, poppet (5) opens, the pressurized oil flows from port Cy to Port V, and then flows to the control valve. If any abnormal pressure is generated in the circuit at the bottom end of the boom cylin- der, safety valve (1) is actuated. 10-66 205F05093, 021K05,021K05, HYDRAULIC CYLINDER 1. BOOM CYLINDER 202F05633 202F05634 3. BUCKET CYLINDER 202FO5635, 10-671. Rod side bushing 8. Head side tube 15. Bottom side bushing 2. Piston rod 9. Casting ring 16. Bottom side cushion plunger 3. Cylinder head 10. Piston ring 17. Ball 4, Rod packing 11. Wear ring 18, Head side cushion plunger 5. Buffer ring 12. Piston 6. Wear ring 13, Piston nut 7. Cylinder 14. Bottom side tube ‘SPECIFICATIONS Unit: mm. — —_Sylinder Boom Arm. Bucket Rod outside diameter 78 85 70 Cylinder inside diameter 110 120 100 Stroke 1.170 1,352 1,023 Maximum length 2.805 3,285 2,500 Minimum length 1,635 1,933 1.477 Piston nut width across flats 75 85 75 10-68 021K05ELECTRICAL WIRING DIAGRAM ©Ervomsena= 10-70 Monitor panel ‘Swing lock switch Horn switch Starting switch Fuel control dial Cigarette lighter Buzzer Service meter ‘Swing lock prolix switch 10. 12. 13. 14. 15. 16 17. 18, TVC prolix switch Pump controller Engine throttle controller Resistor Wiper relay Heater Lo relay Heater Hi relay Light relay Fuse box F21KO5011 021K05021K05 F21K05012 19. 20, 21 22 23, 24, 25, 26 27 28. 29. 30. 31 32 33, 34, 35, 36 37, 38. 39. 40, at 42 43, 44, 45. 46. 47. Working lamp Head lamp Fuel level sensor ‘Swing brake solenoid valve Straight travel solenoid valve Travel speed solenoid valve CO cancel solenoid valve TVC valve Engine speed sensor Room lamp Engine oil pressure sensor Governor motor Heater relay Starting motor Alternator Goolant temperature sensor Coolant level sensor Battery relay Battery Engine oil level sensor ‘Arm half flow solenoid valve Work equipement oil pressure swtich ‘Swing oil pressure switch Pump oil pressure sensor Heater ‘Wiper motor LH. travel fimit switch R.H. travel limit siwtch Horn 202F05638 10-71ELECTRICAL CIRCUIT DIAGRAM | | en-l Bove code thor depieyod on me ‘acting or troubleshooting CConnetor type Number of pins Jc) Connector No. (This numbers aaplaved on the machine and in troubleshooting 021K05021K05 ALPHABETICAL INDEX NO PARTS NAME ‘ADDRESS RO: PARTS NAME ‘ADDRESS + | Aero Ne or 8. 2 | Antenna a8 ee M7 3 | Am hal Wow solenoid vane Ng. 88, Mz. | Battery Ka 70, Ma: 3 | Batery relay fa 7 Ma | Sumer a 7a CN-VS: Ma. 7 cabin a CO cancel solenoid valve Ma. | Cigar iahier oo Compressor power source 2 Op eN-ci 7 Coolant evel sensor oh fo | cw-co 7 Coolant MS Tp ence i: Cocer power source cd 12 owca e Engine ts 13 | once 8 Engine ground Na Ta | cNc7. ca Engin ol evel sensor Lt 1 | cNoF co Engine oil pressure senaar co 18 NOT) ce Engine speed sensor Na iL ew.015 Me '83 “Engine throttle eotrallor HS ia | ev.0i7 MS ‘34 Flor frame [a 18 | cwv.02 ‘M7 5 | Fuol contra di aa 20_| v0 38 ‘86 | Fuel level sensor ts 2 v0 6 7 | Fuse box 5 22 | owv.05: MT 88, Ke 23 | cwv.06. co 39 th 2a ew0T ca '90 Governor moior M7 25 | -cw.08 co 31 | Head amp. 1s 25} CNet Ha ‘92 | Hoater 38 a7 | vez te ‘93 | Heater Hireioy ca 2a nes Fa ‘94 | Heater Lo: oT 29 ewes Me. 95 | reat relay ae 30 ees Me. 961 Horn 17 3 ewes 3a 97 | Horn swieh 3 aE LONE? Me. 96 Intake air heater Na 33 CMO a 99 Lamp relay ce 34 oer ra 100" Mentor pana? Aa 35 | CMa 8, TO1 "Monitor switch connecting tae us 36 | exw 39) [oz Wotwr m7 37 LEN Me 3 103” Potentonaier We 36 | CNMI Ag 104 Pump controler G7 39 CN We 6 105 Pump of pressure ewiich J 0 CNS KT. 108 Pump TVC prolx switch Fo ait enna ae 107 Rado 9, axons ‘aT 08 Resistor 38 aa uM AB oa Revolving Tame: Fe ‘aa | CNM. Da 110 Room amp. ca a5 | cuMSt ws HITT Service 1 mit eter co 5 CN MB 2 TIE) Service Zim switch 18 a, CNT i TI3_Servien meter ra a8 | cue i 114 Speaker 39 49 MO a 115 | Staring maior iz 50] CNT a 116 Staring switch 35 51 | cN-PId 35 TIT Swraight-ravel solenoid valve NB 52 | cNP2 ad 118 Swing brake solenoid valve 7 bss Pepa cH 118 Swng tek pole switeh ED) [ae Tews: a 120" Swing tock switch 7 55 | CNP ts 121 Swing ol pressure swith 3 [Beer 6 122Travol ima sateh cH ip [sr [ens ro 123" Travel limit awteh RH) 8 [se ena o7 124 Travel speed solenoid vale NT [ae fen-re or 125 TVC vaive *3 0 cn-Fa a 1261 Vane oo 31 | wR a 127” Window washor 7 ez | NST we 128.” Window washer switch 7 oa ON STO) He 1287 Wiper motor ae ee ewstT Ha 130°" Wiper motor relay o7, 5 [ews B “131 | Work equipment oll pressure switch 2, 6 | NSE: ia 132) Werking emo isENGINE CONTROL SYSTEM Starting switch Fuel control dial Governor motor Starting motor Battery relay Battery Engine throttle controller Fuel injection pump evo EeNa 10-74 20205642 OUTLINE © The engine can be started and stopped simply by using the starting switch © The enigne speed can be controlled using @ dial control system for the fuel control © The engine throttle controller also controls the engine speed at the same time using signals from the pump controller. % For detail, see PEMC SYSTEM. 021K05021K05 GOVERNOR MOTOR LINKAGE fee ——__ws__. Naf PENS es F21Kos201 Governor lever Loose spring Yoke Governor motor 10-75 ®1, OPERATION OF SYSTEM Starting engine ‘When the starting switch is turned to the START position, the start signal flows to the starting motor, and the starting motor turns to start the engine When this happens, the engine throttle con troller checks the signal voltage from the fuel control dial and sets th engine speed to the set speed Engine speed control The fuel control dial sends a signal valtage 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 valtage, and drives the governor motor so that it is set to that position. When this happens, it detects the operating angle of the governor motor using a potenti- ometer and observes the governor motor. Stopping engine When the engine throttle controller detects that the starting switch is at the STOP position, it drives the governor motor to set it to the no injection position, and stops the engine When this happens, to maintain the electric power in the system until the engine stops completely, the engine throttle controller itself drives the battery relay. 10-76 ® Fuel cotta dat EAST. a Re a r te [ 202F05098 Starting Seen 8 ae 202F05099 021K0s021KO5, 2. COMPONENT EQUIPMENT OF SYSTEM 1) ENGINE THROTTLE CONTROLLER 1. Self-diagnostic LEDs 202F05100 10-77, @Control function of controller * The engine throttie controller receives the input signals shown in the diagram on the right, processes these internally and sends output signals to the pump controller, governor motor, and battery relay. 1) Engine speed set function using fuel control dial An output signal that matches input valtage @ corresponding to the position of the fuel control dial is sent so that the governor motor is set to turning angle b. Turning angle b is fed back to the controller by the potentiometer signal, and the oper- ation of the governor motor is always observed. 2) Engine speed control by No.2 throttle nal from pump controller The pump controller controls the engine speed directly using the No.2 throttle signal in order to carry out the PEMC system. The engine throttle controller controls the engine using the lower signal (higher voltage) of the throttle signal from the fuel contro! dial and the No.2 throttle signal from the pump controller. Example: Even if the fuel control dial is set to the MAX. position, if [finishing opeation mode and S. model]is selected for the working mode and power mode, the engine speed will automat- ically be set to partial speed. For details, see PEMC SYSTEM. 10-78 @ (input sana) {Output signal (ie went sa | +| — feasts] [Orwe sana Governor motor turning angle (engine speed) Fuel control dial position (degree) Hiidling ® Losidling rd | | operating range 20205101 Engine throttle controller output characteristics ‘Fuel control dial output voltage (V} Fuel control dial output characteristics “Governor mator 202F05102 021K05,021K05, 3) Auto-deceleration function using auto- deceleration signal from pump controller When the pump controller detects that all levers are at neutral, it sends the auto: deceleration signal to the engine throttle controller. When this signal is received, the engine throttle controller reduces the engine speed to the deceleration position. For details, see PEMC SYSTEM. 4) Automatic warming-up function using warming-up signal from monitor Alter the engine is started, if the engine water temperature is low, the monitor sends the warming-up signal to the engine throttle controller When this signal is received, the engine throttle controller raises the engine speed to carry out warming-up. % For details, see PEMC SYSTEM 5) Engine stop function using starting switch signal When the starting switch is turning OFF, the engine throttle controller detects this, and drives the battery relay to maintain the electric power. At the same time, it drives the governor motor to pull back the fuel injection pump lever to the STOP position. 6) Self-diagnostic function Three LEDs (red, green, red) light up and go out to indicate that the machine is normal, or to indicate the location of any failure when, any abnormality occurs. * For details, see the TROUBLESHOOTING. Starting switch 2% lore Operation of governor motor stor Battery relay |__ont_ ona drive signal lore 25c00 4 F21K05056-K Voltage between connector CN-E1 (13) — (12) (Battery relay drive signal) Signal Voltage (V) ON-1 20—30 ON-2 18—28 OFF 15 — -30Internal structure of controller * The inside of the controller consists of the input circuit, microcomputer, and drive [ | ¢ circuit shown in the diagram on the right, = $ ——]™"] ~ 5 -| | 8 and these have the various functions ¢— | 8 2 ett 2 described below. sey tes tey2] os 1) Input circuits ga F] fe] |é e These receive the signals from the fuel ata I control dial (throttle signal), pump controller | — (No.2 throttle signal, auto-deceleration 202F06106 signal), monitor (warming-up signal), and starting switch (start signal}, and send them to the microcomputer, In this portion, the noise in the signals is removed and the wave pattern of the signal is regulated. In addition, it makes the power source (approx. 5V) for the governor motor poten tiometer and fuel control dial 2) Microcomputer The angle of the governor motor is calculated from the input signals sent from the input circuits, and the pulse signal to drive the governor motor is sent to the drive circuit 3) Drive circuit The pulse signal sent from the microcom- puter is used to switch the direction of the current flowing to the governor motor to retate the motor clockwise or counter: clockwise. 3 86 o 021K05021KO5 2) FUEL CONTROL DIAL Max, Machine foward FUNCTION © This is installed under the monitor panel. A potentiometer is installed under the knob, and when the knob is turned, it rotates the potentiometer shaft. This ratation changes the resistance of the variable resistor inside the potentiometer, and sends the desired throttle signal to the engine throttle controller. The shaded area in the graph on the right shows the abnormal detection area, and the engine speed is set to low idling © There are detents at ten places on the knob of the fuel control dial, but the knob can be set at any desired position. Knob Dial Spring Ball Potentiometer Connector eanwns Composition of circuit, angle (%) Di eee Voltage (V) teens “Throttle voltage characteristics 202F05108 10-81 ®3) GOVERNOR MOTOR 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. * A stepping motor is used for the motor which provides the motive power. In addition, a potentiometer to give feed-back is installed to allow observation of the operation of the motor. The rotation of the motor is transimitted to the potentiometer through a gear. 10-81-1 D @ 6 1. Potentiometer H 2. Cover | 3. Shaft / 4. Dust seal / 5. Bearing / 6. Motor 7 7. Gear 8 Connector Bock 23) \sgiVstes] Composition of circuit 202F08107 OPERATION Motor stationary * Current is passing through both the A-phase coil and B-phase coil of the motor. Motor rotating * Apulse current is applied to the A phase and B phase by the engine throttle controller to give synchronous rotation with the pulse. 021K05021K05, OUTLINE OF OPERATION OF STEPPING MoTOR Fig. 1 shows a diagram of the stepping motor expanded in the direction of the circumference. It shows the relative positions of the teeth of the rotor and stator, and the condition corres- ponds to current drive pattern 1 in Table 1 If the motor is changed from this condition into current drive pattern 2, the relative positions of the stator and rotor will become as shown by the dotted line in Fig. 1 (the stator is fixed, 50 the rotor moves to the left) When switched in the pattern 2+ 3-4 4 1 ..., the rotor also moves to the left in the same way. If the current drive pattern is changed 4 = 32-414... the rotor moves to the right. Fig 1. Expanded diagram of stepping motor Rotor (permanent magnet) A phase 8B phase Frososcee Table 1 Current drive pattern | Pattern 1 Pattern 2 Pattern 3 Pattern 4 i 7 | Acphase current Hf 4 “i B-phase current 10-81-2 ®4) LOOSE SPRING Yoke Pipe Spring Spring Rod oP RONe 10-81-3 @® 202F05930 021K05PEMC SYSTEM CONTROL FUNCTION Working mode solection function Pump & Engine Maal conor (PERC system Power set selection function Flow control {PNC, PFC) function Cut-off (CO) function Pump control system Cut-off cancel function Half flow function ‘Auto-deceleration system PEMC system Engine sutomatie warning up, overheat prevention system fo ‘warming-up function Overheat prevention function ‘Swing control system Swing lek neon H- Sng hang brake uncon wig priority fneon Travel control system {Pump control function when traveling) Automatic Hi-Lo travel speed shifting function ‘Straight-travel function Self-diagnostic function 202F0S108 PEMC system: Pump and Engine Mutual Control System © The PEMC system is a system of total control to give a high level of both power and fuel economy by controlling both the pump and engine. 10-82 021K05,TOTAL SYSTEM DIAGRAM Travel motor Swing motor | Camm Ff sina srry e{ swine fa 021KO5 : { rust cna al) {| foro] | Enso trate we senul | | conte cep [ee he T 202F05643 10-831. PUMP AND ENGINE MUTUAL CONTROL SYSTEM (WORKING MODE SELECTION AND POWER SET SELECTION) Cantrar Engine H be fe signal) Travel control lever (Potentiometer signal anal © OUTLINE ‘© The changes in the engine speed caused by the pump load are detected by the engine speed sensor and fuel control dial output signal. The pump controller calculates these signals, and sends the results to the TVC valve as a signal to control the pump discharge volume. In this way, it can always give the ‘optimum matching of the engine torque and pump absorption torque. Engine torque Lot. 6.0,F.0 / Lots 5 “wos 5 non ¢ g z i 4] Engine speed N 202F05111 Note) H.0: Heavy-duty operation mode, F.O: Finishir G.0: General operation mode, 10-84 +) |(Soeed sina) Engine throttle |_(hretif signa | Jcontroller TRe7 indie sonatT Fuel control dial Engine horsepower on Low, Boi Lois operation mode, LO: Lifting operation mode Pump {Switch signat) 202F05110 '® The combination of the 4-level working mode and 3-level power set makes it possible to choose a pump absorption torque correspond- ing to the nature of the work, so it is possible to use the engine more effectively while also reducing fuel consumption. © Normally, the combination of the working mode and power set takes the working mode as the basic mode, and the power set is automatically set according to the selection of the working mode. Main pump delivery Goro, Hors. \HosL| ON Pump delivery pressure P Pump delivery volume Q 202F05113 Engine speed N 202F05112, 021K05:021K05 CONTROL OF H MODE When using H.0 mode and H mode ‘© Working mode: H.0 © Power set H © CO function Cancel © Pump absorption horsepower: At rated output point PC150-5 98.6 HP/2,000 rpm © When the pump controller receives the power set [H] signal from the monitor, it sends out an electric command for the H mode output setting to the engine throttle controller. The engine throttle controller receives this and uses the governor motor to set the engine governor lever to the FULL position. © If the pump load becomes too high and the engine speed drops, the engine speed sensing reduces the pump discharge amount, and momentarily resets the engine speed to the rated point. In this way, the engine torque and pump absorption torque are always matched at the rated point, and the engine horsepower can be used to the maximum. The CO (cut-off) function controls the pump discharge volume when the hydraulic pres- sure is being relieved to provide effect in reducing power loss. However, when the heavy-duty operation mode is being used, the CO function is canceled; when there is heavy load the pump discharge volume is increased to increase the speed and give emphasis to production and increase in power. When using G.O, F.O or L.O mode and H mode © Working mode: G.0, F.0 or L.O ‘© Power set: H © CO function: Actuated * Pump absorption horsepower: At rated output point ‘© The control is basically the same as for [H.O} and [H] mode When the CO function is actuated and the pressure is near the relief pressure, itreduces the pump discharge volume, thereby reducing hydraulic loss. Engine torque Engine torque T Engine speed N 20205114 ‘* Engine horsepower & a 3 2] Engine speed N 202F08118 ‘© Main pump delivery (H.O mode) \ Pump delivery volume Q 202F08116 ‘© Pump delivery (G.0, F.0 or LO mode) a | e Pump delivery volume Q o9¢95437 10-85CONTROL OF S MODE When using H.0 and S mode © Working mode: H.0 © Power set: s © CO function: Cancel ‘© Pump absorption horsepower: At 80% partial output point PC150-5 80.9 HP/1,850 rpm © When the pump controller receives the working mode [H.O] and power set [S] signal from the monitor, it sends our an electric command for the $ mode output setting to the engine throttle controller. The engine throttle controller receives this and uses the governor motor to set the governor lever to the FULL position. © When there is no load, and a load starts to be applied, the engine torque and horsepower move from@)to@®). (Fig. 1, 2) When this happens, the pump output also moves from@to®). (Fig. 3) ‘* When the load becomes larger, the engine torque and horsepower move from © to© along the constant horsepower curve towards the most efficient fuel consumption point (Figs. 1. 2) When this happens, the bydraulic pump is fixed around the maximum swash plate angle, so the discharge pressure is increased, and the pump absorption torque is also increased. (Fig. 4) The pump output for ©) and © is on the constant horsepower and there is no differ fence, but when the machine is in static balance, ® and ®are distinguished on the pump discharge curve as shown in the diagram. (Fig. 3) © If the load is further increased, the engine torque and horsepower are fixed at © (Fig. 1, 2), and as the pump discharge pressure increases, the pump swash plate angle is throttled back, (Fig. 4) As a result, the pump output pressure moves from@to@. (Fig. 3) * The CO function is canceled. 10-86 * Engine torque (Fig. 1) Engine torque T Engine speed N ‘¢ Engine horsepower (Fig. 2) Engine horsepower HP Engine speed N © Main pump delivery (Fig. 3) Pump delivery pressure P Pump delivery volume O ‘* Pump rocker cam angle (Fig. 4) Pump swash plate angle (deg.) 202F05118, 202F05119 202F05120-1 202F05121-1 021K05021KO5, When using G.O, F.O or L.O and S mode * Working mode: G.0, F.0 or L.O © Power set: s © CO function: Actuated ‘© Pump absorption horsepower: At 80% partial output point PCI50-5 80.9 HP/1,700 rpm © When the pump controller receives the working mode [G.0] (or [F.O}[L.O}) and power set [S] signal from the monitor, it sends out an electric command for the S mode output setting to the engine throttle controller. The engine throttle controller receives this and uses the governor motor to set the governor lever to the partial position. © The engine speed is different, but the control is basically the same as for (H.] and [S] mode. * The CO function is actuated, and when it reaches near the relief pressure, the pump discharge amount is reduced to reduce hydraulic loss. * Engine torque Engine torque T Engine speed N * Engine horsepower Engine horsepower HP Engine speed N 20205123, ‘¢ Main pump delilvery @ Pump delivery prossure P Pump delivery volume Q 202F05124-1 ‘* Pump rocker cam angle Pump swash plate angle (deg.) 202F05125-2 10-87CONTROL OF L MODE When using H.0 and L mode © Working mode: H.0 © Power set: L © COfunction: Cancel © Pump absorption horsepower: At 65% partial output point PC150-5 ~ 64.1 HP/1,850 rpm © When the pump controller receives the working mode (}.0] and power set (L] signal from the monitor, it sends out an electric command for the L mode output setting to the engine throttle controller. The engine throttle controller receives this and uses the governor motor to set the governor lever to the FULL position. ‘* The pump absorption horsepower and engine speed are different, but the control is basically the same as for [H.O] and [S] mode. 10-88 # Engine torque Engine torque T Engine speed N ** Engine horsepower Engine horsepower HP Engine speed N ‘* Main pump delilvery very pressure P © Pump Pump delivery pressure P Pump delivery volume Q rocker cam angle Pump swash plate angle (deg.) 202F05126 202F08127 202F05128-1 202F05129-1 021K05,021K05, When using G.0 or F.0 mode and L mode © Working mode: —G.O or F.0 © Power set L © CO function: Actuated ‘© Pump absorption horsepower: At 65% partial output point PC150-5 64.1 HP/1,600 rpm When the pump controller receives the working mode [G.0} (or [F.01) and power set [L] signal from the monitor, it sends out an electric command for the L mode output setting to the engine throttle controller. The engine throttle controller receives this and uses the governor motor to set the governor lever to the partial position. ‘* The pump absorption horsepower and engine speed are different, but the control is basically the same as for [G.0] (or [F.O}, [L.O}) and [S} mode. '* Engine torque Engine torque T Engine speed N 202F05130 ‘* Engine horsepower Engine horsepower HP Engine speed N 20205131 '* Main pump delilvery Pump delivery pressure P Pump delivery volume Q 202F05132-1 '* Pump rocker cam angle Pump swash plate angle (deg.) 202F05133-1 10-89When using L.O mode and L mode Working mode: L.O Power set: fl, CO function: Actuated Pump absorption horsepower: ‘At 50% partial output point PC150-5 49.3 HP/1,500 rpm When the pump controller receives the working mode [L.O] and power set [L] signal from the monitor, it sends out an electric command for the L mode output setting to the engine throttle controller. ‘The engine throttle controller receives this and uses the governor motor to set the governor lever to the partial position The pump absorption horsepower and engine speed are different, but the control is basically the same as for [G.0] or ((F.0}, [L.O) and [H] mode. The area around the matching point is a highly efficient area for engine fuel consumption, 50 the fuel reduction effect is extremely large. At the same time, by throttling the pump output, it is possible to obtain a high level of fine contro! performance to match fine control operation. 10-90 Engine torque Engine torque T Engine speed N 202F05134 * Engine horsepower Engine horsepower HP Engine speed N 20205135 jain pump delilvery z very pressure P E| aL Pump delivery volume Q. 20205136 021K05021K05, Control function when operating travel ‘© When the travel is operated, even if any working mode or power set is selected, the working mode and engine speed will stay as they are, and only the power set is switched to the equivalent of H mode (Pump control by engine speed sensing) to increase the pump absorption torque. CONTROL FUNCTION WHEN TVC PROLIX SWITCH IS ON © If any abnormality occurs in the controller or sensors, a constant current flows from the battery to the TVC valve to so that the function, can be maintained through a pump absorption torque more or less equivalent to S mode. In this condition, only hydraulic sensing using the TVC valve is used. * Engine torque Engine torque T r Engine speed N 20205138 '* Main pump delilvery Pump delivery pressure P Pump delivery volume Q 20205139-1 ‘* Main pump delilvery Pump delivery pressure P Pump delivery volume Q. 20205140 10-91‘SELECTION OF MODE ‘Automatic setting 2s Selected mode function 8} Level of achievement 32 ano | co | Halffiow = rower eet decel. function | mod inction Hq 1. Full power used by engine speed sensing on 2. Power increased by cancellation of cut-ott 98.6 HP/2,000 rpm . s ° SL —>_ onvorr | 2%, | OFF 180.9 HP/1,850 rpm (cancel) [J | i : eae levers rave 64.1 HP/1,850 rpm H 1, Fuel consumption improved by partial use }— on/oFF | of engine power 98.6 HP/2,000 rpm s ° en ; a on oFF 80.9 HP/1,700 rpm ic 64.1 HP/1,600 rpm | ON/OFF (actuated) | (cancel) L ae gine speed M Pomp dave volume 4 98.6 HP/2,000 rpm 80.9 HP/1,700 rpm if (84.1. HP/1,600 rpm | ON/OFF ON/OFF ON ON actuated) | (actuated) Ease of operation improved by half flow mode function H s L 98.6 HP/2,000 rpm 80.9 HP/1,700 rpm T ON/OFF ON/OFF 49.3 HP/1,500 rpm on OFF {actuated) | (cancel) Increase of fine control range Improvement in efficiency by lowering engine speed Pomp davery volume O The thick lines mark the modes and functions that are automatically selected according to selection of the working mode. * When the starting switch is turned ON, working mode [G.0] and the default modes and functions are automatically set. 10-92 021K05021K05, 2. PUMP CONTROL SYSTEM = EE] THE il im T ara Hl Shute se eS» ——————————w 5} valve! | i fe iH hh i i iF 1 u u Se I u i Teh = He [intraver] |] EL Arm-Hi [hens | u ef amo fete EL Boomio fa | 11 {Swing pron Ebi | 1) Swing fa sear | 1 | Boom-Hi Fa RH travel 1 HL Service ! i 1 i " i " i i! | i u 1 i \ SESS ‘SSeted vane TP | (Div sana (swich sana Pum Controller | Cre signa 202F05648 OUTLINE © By controlling the main pump discharge volume accoring to the stroke of the control lever, it is possible to reduce the neutral loss and fine control loss. © The cut-off function and half flow mode function that is automatically set by the working mode provides excellent reduction of relief loss and fine control performance. 10-931) FLOW CONTROL FUNCTION PNC (Pump Neutral Control) ‘© When the control levers are at neutral, the pump discharge volume is controlled to the minimum to reduce the wasted oil flow that occurs when the contro! valve is at neutral PFC (Pump Fine Control) © When the lever is operated, the contro! for the necessary oil flow is sent to the pump based on the flow command cor- Lever stroke L responding to the stroke of the lever. In 2oor0s14a this way, the wasted oil flow that occurs during fine control is reduced. * Atthe same time, by increasing the pump discharge volume by a suitable amount to correspond to the stroke of the lever, the fine control performance is improved. % For detail, see HYDRAULIC PUMP. Pump delivery volume Q 2) CUT-OFF (CO) FUNCTION * When the load increases during opera- tions and the main pump discharge pressure rises, it reduces the pump discharge volume when the pressure is near the relief pressure, and acts to reduce relief loss. + For detail, see HYDRAULIC PUMP. 3) CUT-OFF CANCEL FUNCTION © When the load increases during opera- tions and the main pump discharge pressure rises, the pump discharge volume is not cut-off even when the pressure is near the relief pressure. This ensures the flow of oil and prevents any drop in speed + For detail, see HYDRAULIC PUMP. * Actuation and cancelation of the cut-off function is automatically determined by the position of the working mode switch and swing lock switch. * Operation of switches and cut-off function When the engine speed is lower than approx. 1400 rpm, the CO cancel function does not work Pump delivery pressure P Pump delivery volume Q 202F05149) Not cut off Pump delivery pressure P Working mode switch [Bning tock witch HO] Go | FO | LO | on | oFF Pump delivery volume Q Pection [Cancel [Actuated] Actuated [Actuated] Cancel [Actuated 202F05150 10-94 021K05021K05 %* Quick warming up of hydraulic oil when 9 lock switch is ON When the swing lock switch is turned ON, the CO function is canceled. In this condition, if the work equipment is relieved, the hydraulic oil temperature can be raised quickly to reduce the time taken for warming up. 4) HALF FLOW MODE FUNCTION If F.0 mode is selected with the working mode switch, the operation of the control valve at the Arm Hi (IN) side is stopped, and the pumps for the work equipment are separated. As a result, there is no influence from the load on the other pump when carrying out digging or leveling operations. This provides improvement in fine control and finishing accuracy. © Relationship between working mode and pump discharge volume (during inde- pendent operation) oI ‘Actuator] Boom am], Travel . Bucket | Swing Working mode—_[Raise [tower] w [our ta] aa 10 mode 200 | 100 | 200 | 200 | 100 | 100 | 100 | 100 6.0 mode F.0 mode 100 a 200 | 100 [E24 200} 100 | 100 | 100 | 100 LO mode 200 % The portion for 100%. fone pump is taken as 10-953. AUTO-DECELERATION SYSTEM. Engine Fuel contro dial Governor ° iL i I (evoke CTheote signal) [arm [Heer] Engine throttle controler Shuttle valve Travel control lever [Work equipment lever (Auto-deceleration (Swing lever signal (Travel laver signal) OUTLINE * This is a fully electronic control type, and when all the work equipment, swing and travel levers are at neutral, and the pump controller receives the signal, it sends a ‘command to the engine throttle controller. When this is received, the engine throttle controller drives the governor motor to reduce the engine speed, there by reducing fuel consumption and noise, 10-96 Pump conteaiier |g (Syttch sional Fal 202F05151-1 Fuel contet ait seting ram ao g E 1 not oc z (averneuran Time o0250 ~~ Lever Sperationy see 20205152 021K05021K05, OPERATION When auto-deceleration switch ON 1. If the fuel contro! dial is set at 2 position higher that 1500 rpm, and all control levers are at neutral, the pump controler receives the neutral signal and sends the auto- deceleration signal to the engine throttle controller, When the engine throttle controller receives the signal, it sends the drive signal to the governor motor to drive the governor motor and pull back the injection pump governor lever to the No.1 deceleration position. It holds it at this position for approximately 4 seconds, When this happens, the engine speed is lowered by about 100 rpm from the dial setting 2. After the levers have been at neutral for more than 4 seconds, the drive signal is again sent from the engine throttle controller to the governor motor, and the governor lever is pulled back and held in the No.2 deceleration position The engine speed in this position is approx 1400 rpm. 3. In the deceleration condition, if any control lever is operated, the pump controller receives the signal and cancels the auto- deceleration signal sent to the engine throttle controller. When this happens, the engine throttle controller sends a drive signal to the governor motor to return the governor lever to its original setting. When auto-deceleration switch is OFF ‘© The engine speed can be set as desired using the fuel control dial, and even if all the levers are at neutral, the engine speed is not reduced, Ft cone at 7 Se oe Th fjem, [sera I tae Ee sesame] m ace] got ae Oa Pred fas foes val aw FE | 2 “ Sakis" ul Lema sa feng [ 202F05185-1 10-974. ENGINE AUTOMATIC WARMING-UP AND OVERHEAT PREVENTION FUNCTION Engine Eee Governor (Coolant temperature signal} Monitor BT OB panel Fuelcontoldial @| 2 Hi s| 3 Rays we 2) | 2! a) qi 2 ‘| a - | u 2 | EL ef engine throttie bw Ey _.| conteoter (Warming-up Signal) (Coolant temp.102°C signal) —— [Coolant temp. 107°C signal) (Working modé’signal) (Power set signal) Pump controller ave Sine Nevaive] [Ne vane] cove} [50 vane —; fic van xe sana OUTLINE * After the engine is started, this raises the engine speed automatically to warm up the engine. (Automatic warming-up function) In addition, to protect the engine, ifthe coolant temperature rises too high, it lowers the pump load and engine speed to prevent overheating of the engine. (Overheat prevention function) 10-98 20205156 021K05,021KO5, 1) AUTOMATIC WARMING-UP FUNCTION © Actuation table Conditions Action Coolant temperature: Less than 30°C g | Fuel contro! dial: Below set speed 5 [Set speed: 1,200 rpm] 2 | * If all the above conditions are satisfied, Engine speed: 1,200 rpm 2 ‘the automatic warming-up function is actuated. Coolant temperature: Above 30°C 7 | Fuel contro! dial: Held above 70% of high idling 3 for more than 3 sec. c Z £ | Warming up time: At least 10 minutes Se & | * If any of the above conditions is applicable, the ‘automatic warming-up function is canceled. 2) OVERHEAT PREVENTION FUNCTION © Actuation table Conditions Action Power set: Selected mode ‘Action mode 2 | H.0 and H,S mode H.0 and L mode 2 | cootant temperature: 102°— 107°C || TO. and HS mode _ endl meee § | (Coolant temperature gauge: Red range) || G.O and HS mode | G.L and L mode Bl2 F.0 and L mode F Load HSmode | LOand Lmode | Engine speed: Set speed for action mode 2 Power set L mode (same as No. 1 & | Coolant temperature: Above 107°C setting) © | (Coolant temperature gauge: Red range) | Engine speed: Low idling 8 Warning lamp, buzzer: ON £ | Coolant temperature: Under 102°C € | (Coolant temperature gauge: Green Power set: Default mode - range) —_| Engine speed: Default mode speed BE | * automatic reset & | | When coolant temperatures less than | power set: & | Z| Wher . fault mode O 1g | 202°, return fuel control dial to10W | Engine speed: Fuel control dial set speed 4 eens (as desired) 3 | * Manual reset 10-995. SWING CONTROL SYSTEM ‘Swing motor Work equipment control lever Seong ot a ute a wake” a= ! Sue 4 Bae ‘spool contro! it 4 =e a ‘Armio soni vae [La Leap] wang priority hb swing A [swing tock fed afew | tofworr ] Suing oe | | ee | Pump controller (Swing lock swith signal) ‘Drive signal {Swing iver saa (Swing lock switeh signal) Bee OUTLINE The swing is controlled comprehensively both when stopping and when operating the swing, by the swing lock, swing holding brake, and swing priority functions. 10-100 2020515; 021K05,021K05 y 2) SWING LOCK AND AUTOMATIC SWING HOLDING BRAKE SYSTEM The swing lock (manual) and swing holding brake (automatic) are employed to lock the swing in the desired position and to prevent hydraulic drift after stopping the swing. ‘Swing lock proiix switch function When the pump controller is abnormal and the swing holding brake function does not work normally, the swing lock prolix switch cancels the swing brake and operates the swing. * 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 ona slope, there may be hydraulic drift SWING PRIORITY FUNCTION When the swing and arm are operated together, a large amount of pressurized oil flows to the arm circuit where the load is ‘small, At the same time, the pressurized oil flowing to the swing circuit is reduced, so the arm speed increases in relation to the ‘swing speed, and simultaneous operation performance becomes poor. To prevent this, the pilot pressure of the swing brake solenoid valve switches the ‘swing priority valve. The flow of pressurized oil to the arm Lo control valve is then throttled to improve the simultaneous operation performance. % For details of the operation, see RH, 5: SPOOL CONTROL VALVE * Relationship between swing lock lamp and the brake Lock lamp] ‘Actuation ‘The swing brake is applied approx. 4 seconds after the) swing control lever is placed at neutral. When the swing contro lever is operated, the swing| brake is released and the upper structure can swing OFF (switch OFF) {Swing holding brake applied) free — : re The upper structure is held in place by the swing ON (switch On) | Brake, and even if the con earaisee trol lever is operated, the ei swing brake is not can- celed, so the upper struc- ture does not swing, Actuation table (OFF (when controler ‘Srormal ‘Swing lock [ ON (when controller rin ent Swing tock Ton on] or Swing [Swing oct wing ioc Swing oct Swing hace send [Paha Pawten | Sceeuest Seceaics 3) QUICK WARMING UP OF HYDRAULIC OIL, WHEN SWING LOCK SWITCH IS ON * For details, see PUMP CONTROL SYSTEM. 10-1016. TRAVEL CONTROL SYSTEM Travel motor ul i Change Loe LH. 6-spo0! camiot valve control valve Travel control lever ‘Straight-travel ‘solenoid valve feeb vena Dy M Fuel control dial Hi & Lo (Throttle signal) Engine throttle controller Pump controller solenoid vive OUTLINE * This increases the pump absorption torque and drawbar pull when traveling. © The travel performance is improved by switching the travel speed manually or automatically, ‘© The straight-travel function acts to prevent any deviation in travel during simultaneous operations. 10-102 3 \| = | e | é + | {Ox son) ‘Dive sal Tevet over sora 021K05021K05 y 2) PUMP CONTROL FUNCTION WHEN TRAVELING When traveling, the following functions are actuated. © If any of the working mode and power set are selected, the working mode and engine speed stay as they are and the power set only is switched to the equi- valent of H mode % For details, see ENGINE AND PUMP MUTUAL CONTROL SYSTEM. TRAVEL SPEED SWITCHING FUNCTION The switching of the travel speed can be carried out manually or automatically, and has the following functions. i) When the travel speed switch is switched, the solenoid valve is switched. The action of the pilot pressure then changes the motor swash plate angle and changes the travel speed ii) If the speed setting of the fuel control dial is set to less than approx. 1400 rpm: * When traveling in Lo, even if it is ‘switched to Hi, the transmission is not shifted ‘* When traveling in Hi, the transmis: sion automatically shifted to Lo iii) Automatic switching between Hi and Lo according to pump discharge pressure ‘© When traveling with the travel speed switch at Hi, if the machine travels up a slope and the pressure in the travel circuit goes above 290 kg/cm? for more than 0.5 second, the solenoid valve is deactivated (closed) and the travel speed is switched to Lo. If the machine continues to travel at Lo (with the travel speed switch still at Hi) and it comes again to flat ground or travels circuit drops below 190 kg/ em? for more than 0.5 second, the solenoid is excited (opened) and the speed is switched again to high speed High speed travel |——=[ Uphill siope (Travel speed switch (Travel pressure continues atHi) at more than 200 kg/cm? | for more than 0.5 second) 1 Low speed travel Flat surface, downhill slope. (Fravel pressure continues (Travel speed switch at less than 190 kg/cm? for gt Hi) ‘more than 0.6 second) 10-1033) STRAIGHT TRAVEL FUNCTION If the work equipment or swing are operated at the same time as the travel, some of the pressurized oil flowing to the left and right travel circuits will flow to the work equip- ment or swing circuit. This will create a difference in the amount of oil supplied to the left and right travel motors, and will cause the machine to deviate. To prevent this, when there is simultaneous operation, the straight-travel valve is switched by the pilot pressure of the straight-travel solenoid valve, the left and right travel circuits are interconnected, and the amount of oil flowing to the left and right travel motors is made the same to prevent any travel deviation. For details of the operation, see LH. 6- SPOOL CONTROL VALVE 10-104 021K05021K05 7. SYSTEM COMPONENT EQUIPMENT 1) PUMP CONTROLLER 1 Self-diagnostic display window 202F05160 10-1052) ENGINE SPEED SENSOR Magnet Terminal Case Boot Connector oReNe 3) ENGINE THROTTLE CONTROLLER, FUEL CONTROL DIAL AND GOVERNOR MOTOR %* For details, see ENGINE CONTROL SYSTEM, 4) MONITOR PANEL % For details, see EMACC. 5) TVC VALVE % For details, see HYDRAULIC PUMP. 6) SWING BRAKE SOLENOID VALVE STRAIGHT-TRAVEL SOLENOID VALVE TRAVEL SPEED SOLENOID VALVE CO CANCEL SOLENOID VALVE ARM HALF FLOW SOLENOID VALVE * For details, see SOLENOID VALVE ASSEMBLY. 10-106 —— ] 1516 0.7518 Composition of circuit 202F05161A FUNCTION © The engine speed sensor is installed to the ring gear of the engine flywheel, and acts to count electrically the number of gear teeth that pass in front of the sensor. This detection is carried out magnetically, and the sensor contains a magnet and detection coil 021K05,021K05, 7) PUMP PRESSURE SENSOR 1 2 4 Composition of circuit OUTLINE ‘© The pump discharge pressure is converted to a voltage, and the signal is sent to the pump. controller. FUNCTION © The voltage output is proportional to the pressure, 1 ‘Sensor output voltage V (V} Toa 200 300 06 Oil pressure {kg/em*) 202F05163, © Relationship between output voltage V (v) and pressure P (kg/cm?) V = 0.008 xP + 1.0 7\ Amplifier Cord Connector Flange Detect module of oil pressure Introduction pipe of oil pressure OOROns ono [Pe ma 20 ‘Output (1-8) 202F05162A OPERATION ‘To amplitier_!solation seam 7 Gauge seam Diaohraae (Staines) tf 6 4 ot ress 202F05164 ‘* When the pressurized oil entering from pressure introduction pipe (6) is pressurized by the diaphragm of pressure sensor module (5), the diaphragm shape changes. A bridge is formed on the opposite face of this diaphragm by a strain gauge, and the deflection of the diaphragm is converted from a resistance value of the strain gauge to the bridge output voltage and is sent tothe voltage amplifier (amp). © The voltage is further amplified by the amplifier, and is output to the controller. 10-1078) WORK EQUIPMENT OIL PRESSURE SWITCH AND SWING OIL PRESSURE SWITCH 1. Plug 2. Diaphragm 3. Guide pin 4. Pin cf] eo @—f) ees 6 = o Composition of circuit 202FO5864 SPECIFICATIONS 5. Movable contacts Actuation pressure: 5.0 + 1.0 kg/cm? 6. Connector Reset pressure: 3.0 + 0.5 kg/cm? 9) TRAVEL LIMIT SWITCH 10-108 fe Oa Connector a Composition of circuit Return spring Roller Shaft Dust seal Seal Micro switch Noonona 202F05166 021KO5,021K05 EMACC (Electronic Monitor and Control Console) ‘Monitor panel Sensor signal —> Power Sensor Battery © The electronic monitor and contro! console (EMACC) observes the condition of the machine through the sensors installed to various parts of the machine, and processes this information quickly. The system informs. the operator of the condition of the machine by displaying the condition on the panel The content of the panel displays can be broadly divided into the following, 1. Monitor portion that gives warnings when any abnormalities occurs in the machine. 2. The gauge portion (coolant temperature, fuel level) that always informs the con- dition of the machine. =§=9 Engine throttle controller Electrical parts Warming-up signal Pump controller Buzzer signal L - ‘Switeh signal Coolant temp. Signal Buzzer 202F08167 ® Various modes selector switches are built into the monitor panel, and it acts as the control portion of the machine control system, 10-1091, MONITOR PANEL usp pupa OUTLINE ‘© The monitor panel has the switch functions for the electrical parts, mode selection, and monitor display functions. It has a built-in CPU (Central Processing Unit), and processes the data and outputs the display. The monitor display uses a liquid crystal display (LCD). The switches are flat sheet switches. 10-110 202F05168, 021K05,021K05 MONITOR Coolant temperature gauge Engine oil level caution lamp Coolant level lamp Coolant temperature caution lamp Coolant level caution lamp Engine oil pressure caution lamp Fuel level caution lamp Charge level caution lamp Engine preheat pilot lamp 10. Fuel level gauge PeOronEens 202F05169 oT ara Bimbo item Gonaton fr dpi Description - Tadicates when placing The art zw] © | coolant ieve Below fow level teh to ON betorennarting the gse| = crate. cd on Pe ss It tis normal, the lamp go off. BE | D | Ensineoitievet emcee Itt am abnormal'ty the lamp flash. s Engine oil pressure | 0.5 kg/cm? max. 2 & Coolant evel Below iow ve | gs Indicates while the engine is ning 2 = nd the starting site ist to ON. z Coolant temperature | 107°C min iti is normal, the lamp goes off é It itis an abnormality, the lamp | flashed and the buzzer sounds. Zz Charge level When charging system fal. danc 2 a ea _ 3 | | Fuerte Below low level Appropriate place (one place 5 | © [emmmnnenane Appront 3 5 2 A zeae 8 fy 2 F aozssn | [ When the starting switch is turned to 7 HEAT position, this plot highs for 5 When preheating 30 seconds, then flashes (for 10 3 Seconds) to indicate the preheating = | istishe 10-111SWITCH mo Go FO OO eee works wooe [73 ‘on Heater fan switch Power mode selection switch Working mode selection switch Buzzer cancel switch Traveling speed switch Lamp switch Auto-deceleration switch Wiper switch ‘Swing lock lamp ORV OT EeNH 202F05172, © The switches consists of four mode selector switches and four electrical component switches; every time the switch is pressed, the condition of the machine changes. The present condition is displayed by the lighting up of the LED above the switch. 10-112 Item Action Working mode | G.0> HO > LO-F.0 Power set | S+H>L “Auto decel ON + OFF Travel speed Lo>H “Fans | COFF>Lo>Hi “Winer «| COFF>Lo>Hi “Lamp OFF >1>2 Buzzer cancel | OFF>ON % The bold letters indicate the default values when the staring switch is turned ON. 021K05021K05, 2. SENSOR © The signals from the sensors are input directly to the monitor panel One of the contact points of the sensors with contacts is always connected to the chassis GND epaneen Type of sensor Sensing type Normal Abnormal CHECK Coolant level Contact t ON (cl F CHECK nt le ype (close) | OFF (open) GROUP Engine oil level Contact type ON (close) __| OFF (open) CAUTION Engine oil pressure Contact type OFF (open) _| ON (close) Coolant temperature _| Resistance type = = GAUGE GROUP} = Fuel level Resistance type = = 1) COOLANT LEVEL SENSOR _-! 2 3. Sensor 3 rene Ei 7 4 Composition of circuit (ta) 202F05173 10-1132) ENGINE OIL LEVEL SENSOR Connector Bracket Float Switch BON ‘Composition of circuit 202051748 3) ENGINE OIL PRESSURE SENSOR Plug Contact ring Contact Diaphragm Spring Terminal OahOna Composition of circuit 20205175 1. Connector 2. Plug 3. Thermister =f) Composition of eieuit 20205176-1 10-114 021K05021K0s 5) FUEL LEVEL SENSOR PON Composition of circuit Section A— A, 2020817 Float Connector Cover Variable resistance 10-11520 TESTING AND ADJUSTING 021K05 Table of judgement standard value . +11 20-2 Standard value table for electrical system = 20-14 Tools for testing, adjusting, and troubleshooting 20-25 20-26 20-27 20-28 20-29 20-30 Adjusting valve clearance . Measuring compression pressure Testing and adjusting fuel injection timing Adjusting travel of governor motor lever Adjusting engine speed sensor .. Adjusting travel limit switch 20-30 Inspection of swing circle bearing clearance = 20-31 Testing and adjusting hydraulic pressure in work equipment, swing, travel circuit... 20-32 Testing and adjusting charging pump pressure . 20-34 Testing and adjusting main pump control pressure . 20-36 Measuring stroke of servo piston . 20-43 Testing and adjusting travel deviation 20-44 Measuring output pressure of PPC valve 20-46 Adjusting PPC valve . 20-47 Testing PPC shuttle valve - : 20-48 Measuring solenoid valve outlet port pressure . 20-49 Testing locations causing hydraulic drift of work equipment 20-50 Bleeding air 20-52 Releasing remaining pressure in hydraulic circuit 20-54 Troubleshooting 20-55 .2212"2 performing inspection, adjustment or fauitfinding, aprk the machine on level ground and check the safety pin and chock. By Wien performing joint work, make appropriate signals and allow only authorized personnel near the machine. Ay When checking the water level, allow the engine to cool down before removing the radiator ‘cap to prevent the risk of being scalded by hot water which may spurt out if the engine is hot. Take great care to avoid getting caught in rotating parts such as the fan, etc. 20-1TABLE OF JUDGEMENT STANDARD VALUE © FOR ENGINE Po180.8 sebast1 }__ ‘Standard | Permissible tom Measurement conditions | unit | Stender a. rom | 2200488) — Engine seed tom | ooo280 | = j om | 20007? | Atsudden aceteraion | BEM Tyas 55 78 Extoust gas color | Boer | maxto | 20 Valve clearance mm | 025 - (rormal temperature) mm | 80 Compression presure Oi temperature: 40-60°C | gem? | Min. 30 a ae so0n) tom) | 320" 360) | 1320 ~ 3601 (Coolant temperatre Biowoy presure ens |mmijo] 75 150 {ooiet temperature: taemt | 38-70 | 27 Om presure At tow iting $AE30) | aglem? | mint. | 07 Atlowiding GAEIOM talon? | Minos | OF 0 temperature eed a ve | eo-n0 | 120 Fue injetion timing of oer | weer Detection when pesed | 0 tension terran) swith finger foes ot pene 20-2 021K05021K05: © FOR CHASSIS %* The standard values and permissible values shown in this table are all values for H.O (heavy-duty operation) and H mode. Machine model P1806 — Classi Item Measurement conditions | Unit | Standard value | Permissible valve Hydraulic oi emperature 45—55°C Att: pumpreliet + Gaolant temperature Within operating 3 +1 pum clot: Buckar ae? Min 1.900 Min. 1.900, 3 lao 2 pump relat em relat & | ar2pump et sieHOmode, the co functions | rem £ ance Spved when aurodece!. | Fuel control dial at MAX. : 7 eraton ie acuated Controller a noel asc 200 1400 + 200 a a Boom-Lo conto! valve t ja8:08 [7108 | 7205 708 | 7:08 Boomti contol value = |s0s|s-05 | - jos |o.0s Aro contro va a l4s:05 | 7-08 | 7208 [48:05 | 7105 | 7:05 g * ff é esata a | arm contra vaive fs oo 9:05 | 9:05 9:05 | 9:05 | pucker contro! vaive | 102F 2002 | Sing contol valve eB lss:05 | 1105 | 7205 [4905 | 7205 |7:05 ‘Travel control valve | i | ae Center of ever knob eno on | Peomeons Red max. value 0 end of travel Min 88 Engine stopped i - _ | Arm control lever Except for neutral play 65:10 nenlee 2 5 Jt control over m 2 ere | Buster contol m 65:10 eae 2] , ms Mex 75 | Swing contol ever 65210 Mex. 78 © | travel contol over no:t5 110018 = pf Play of travel lever 10:5 | 10:5 Boom contol ewer |" Ens thigh ing 22103 J} axa ot eempereture: 45-56°C B 2 | Fie push-pull sale 10 ante of § | arm contro ever control lever Knob to measure | a0 Mx.26 2 Measure max. value to end of travel dt - $ | evcker contol tver 18103 Mex. 26 g 4 kg |__| £ | swing contro ever 22:03 Max. 3.4 2 Lever 22108 | Trove contro! ever 601506) co 65:18) “HF Forward Ri Reverce 20-3 @Machine model per80-5 7 item “Meesurement conditions Unit | Standard value | Permissible value + Oil temperature: 45 — 55°C 325415 Rais) | 9752 Boom + Relief pressure with engine at high idling £15 (Lower eeoxse tony le {Ralove ontycircult to be measured), ieaereieeceteeea ese oe oe hoa ttcse + vam rae aia Spat eS ae ___| 21. 800m naise:2 pump retet 500m Cowen Pelocreter t sucet #2, Aloe trnRee sono 30815 ee | ns. BO ncaS4 co tunctonis - Sing 25015 250425 a 380 tOlone sie) | 330 20 (one de BEES 1OWoNS | HEE Doone, charging pump we] Maes + Oil temperature: ~ TEE | conto tv at nual | -Enpicesrnch | eres ; MOS nat ode | pump ret § | ve vate ouput presse i ine oa i peessurel | . Max. 20 = | Pi+Ps _160—170 aad Mine { poo Bee = ++ Oil temperature: [ Te ESE: | control lover at neutral { co vave nt sooaea te] | ox 60 ox 60 (Ret | co-ncvaneouinn | “wheat po | Travel vera ul ek "tng ee | [cowie nc, win 175 Min 175 | Pup eet eo vale aust | | Resa at meco | Mmeo | { Ssused | Cowra | sSlgememae; 8 — sro neural | Engng hang atas esas iter ~oiltempertue 45 — 55°C Lever at ond | “Enanet g ang Shem | es tet ve Max Mow thay dethage aces des) | ® 20-4 0 021K08021K05, Machine made Pesos eee om Maasurement conditions Unie ‘Standord value Permissible value Working auament Naw ach Swing Swing brake angle ey Engine at high iting 70979823 Hydraulic ol! temperature: 45 — 55°C ‘Stop after swinging one turn and measure distance that swing Circle mover (oy, Distance of movement on outside ecumference of Des. (om Max. 80 (tax. 830) Max. 90 (tax: 1020) wing Wark equipment Max reach 7 Noload yaraulie oil tperature: 45 35°C H.0 and Hi mode 180" Time taken from starting postion to swing 90° and 180" 2et0a Mox.94 ‘Time taken to swing Workequioment Max. reach posture No toma ve Engine at high cling aoaranz3 Hiydraute of temperature: 45-55 110 end H made ‘Swing one turn, and measure time taken to swing next 5 euros 25225 2538 Hysraulie drift of ye ge 8 Bucket: Rated load (90 kg) Max reach mm Engine stopped Hydrauo a temperature esse ‘Set machine on 15° slope, and set Uppor structure at 138° to the side. Make match marks on swing ere Suter race and track rame, Measore cietanoe that match marks ave apart afer 5 minutes Lnakage from swig Hyaraulie oi temperature: ‘45 55°C 2imin ‘Swing ick switch ON Foleve swing citeuit 20-5Chasif- Machine mode! Pcrs0.5 Measurement conditions Unie Standard valve Permissible valve Trwel 20-6 ‘Travel speed (1) SE Engine at high ising Hydraulie of temporatur 45-55 Fae track on onesie ‘then measure time takon tor nont 6 turn Mx. 45 Max.30 ‘Travel speed (2) at |. | aret} 2rase Engine at high ialing Hydraulle ol temperature: a5 55°C HO and Hi mode # Fun up for at Inet 10°, ‘and measur time taken to ‘wavel next 20 mon fat sroun l s317} 13188 Travel devition Engin at high iting Hydeaulie oi temperature: 5-55 Flun up for ot eats 10m, anc ‘measure deviation when trevel- Ing next 20 m on flat ground. ++ Urea bard horizontal surface 20m f + 10m + Measure dimension x ‘Mex, 200 Max, 220, 021K05,021K05, Mechine mods pe1s05 asi itm Memarement conditions Unit | standard vate Persil ave sya at ot om 7 5 Engine sapped Hye ot tmparture Bosc Stow machine on 12° stope wrth sprocket facing sat Measure the dance the 3 trachine moves Sint. Leakage of ra ten dinin + Eogine a gh ing + Hyer et omperaure ose + Lock shoes and clio trave Work eipment poate Tox! work eau snort aro Giartoot Max. 400 ox. 600 bck tet | acomeytingee — E | tomounor = | retraction of Max 14 Max. 21 g |B] olin fac in above posture and Pls Irom extrion or ection B] EL dotnet aa donner a en Bis Srowenent at ipo eke teeth alt Bucher Rated food 5 | S| amovinier | ‘Honsorat i ground 3 , S| mmm ot Users arreuvet ms Max 165 3 | extention of Engine stopped aa S| Sincer yeu ot temperture 2 Bosse | Str maaringimesitety : ster sang Heme nvaulc dit for ach axcaceinde | Soe die Nom a rawacton of or Nemo Max. 28 Max. 42 Sine 20-7Mechine mode Peis08 — tam Masnarement conditions Unie | sear vatee Boom 4 Bock thin 2 Mon 99 contact with xz. |é round : t evlinae uty nea high ting 5 xed educa wmmmace: | asso Moc 31 etre g HO and mode E | am 1 2 37404 Mon 45 2 | Gvincer ay } bly EE RAE = E | tatyertended | engine ani iting | 3 treme oftemomrare: | 3 aoi03 Max. 38 2 asec _ Ho ond Hi mode — os sucker ae = ser08 Max a4 5 i ly 8 z ereeal Notond 5 Site se — 2 g + aoorna2s z fully extendes Engine at high iin g 3 pues eon coer asec Wd and H mde ~ Pa | 800m “a Tosranne ox. Mex. Lome bucket t ground and fori frm pound Ena: Low ing bya O tmperoture g asec E a} \4\ 1 a ) am WE orn Mae. 2 Mon. “Amount of te whan arm stops tora moran Engine: Cow ing Hydaule ol tmperaure sss 20-8 021K05021K05 Machine model PC150.5 See] am 7 fee , : es g an 3 fee ceca & _ 45 — 58°C. E |} joine 10 0 i z 20m i = : 8 & Hydraulic oil temperature: 3 se ere valve set presure \ M4 “ eee (30kg/em*} an 3 8. & lée ~ a 4 7 = = an 20-9Classi ‘ation | Discharge volume of main piston pump (H mode) 180) Upper iit ¥ 100 é 3 ° 105 Pump rated speed: 2,000 rpm PE tigre Pum discharge pressure = °F agyemy F21K05057-K | pischarge pressure | Oiecharge pressure =a se ‘of other pump: wwerage Pressure | discharge amount | standard value | coeckpon | tude ae ee | | Speeame | garcea eh | Meera | ate desire P, PePe see graph ‘See graph | oan mw * z See ar {Lower limit) when measuring, + When measuring with the ‘%& Bring discharge pressure P, and P; for the pump as close as possible to the average pressure ‘The error is greatest around the area where the graph bends, so avoid measuring at these points. bump mounted on the machine, if it is not possible to set the engine to the specified speed with the fuel control dial, use the engine speed and pump discharge amount ‘a8 a base to calculate the pump discharge amount at the specified speed. 20-10 021K05,021K05 “Tarek | Discharge volume of main piston pump (S mode) Lover tt | 8 — g ‘Actual discharge of pump fone pum) (17min) | : th i = 4 Pump discharge pressure F21K0s058« Pump rated speed: 1,900 rpm Discharge oresur | iscaraeoessre Standard velvefor | _ Judgement vere pressure cree poim | Motes pune | “See pam | SSdhogeamoust | sara ‘coe ‘taverns rem | OST ‘Stim ‘As desired a ete See graph See raph z crncitay | Bring discharge pressure P, and P; for the pump as close as possible to the average pressure when measuring, ‘The error is greatest around the area where the graph bends, so avoid measuring at these points. + When measuring with the pump mounted on the machine, if it is not possible to set the engine to the specified speed with the fuel control dial, use the engine speed and pump discharge amount as a base to calculate the pump discharge amount at the specified speed. 20-11Caton | Discharge volume of main piston pump (L mode) 021K05 | : g = aod i | oe z a 5 | gx 3 0 7 26 30 we F21K05059-K Pump rated speed: 1,700 rpm - Dagege mee] oes me] Aan paces Jammauets | cares { | * Bring discharge pressure P, and P, for the pump as close as possible to the average pressure when measuring. The error is greatest around the area where the graph bends, so avoid measuring at these points. | When measuring with the pump mounted on the machine, if it is not possible to set the engine to the specified speed with the fuel contro! dial, use the engine speed and pump discharge amount as a base to calculate the pump discharge amount at the specified speed 20-12021K05, TABLE OF SPEEDS FOR S,L MODES + The values in this table are reference values for the speed of the work equipment, swing, and travel when switching from H.0 and H mode to other modes Ci tem Moesuroment conditions unit | rcts0-s “+ Measure full stroke for each IS 22ns|é 0 sna] \-0 anal | evliner (for boom ony, measure | ay FE 4 800m time taken to lower tothe ground) | 2 (Bucket teeth in «Set the machine on a flat horizontal, © A024 0% |55= 1 |esmctwin "| sree aa oarol | ground syoylinder | = Noosd in bucket ——— Gitvastended) |“ Engie at high ition § 30x laos lazs | * Hydra oll temperature 2 asf od? aa le 45 - 55°C g { » |2 + When measuring boom: arm, |? bucket eines aly reacted | ASS BE am When measuring arm: top surface |Z | see. {*"Gs|7*¥q°° as] | & |tortnaertuiy | of boom horizontal bucket, | E | |tetecendceteay | evince uty tact t BE leer + When measuring uekat: top |g rex bos jas 3 surface of boom horizontal 3 04!" oa} 04) | | ‘vind fully retract us z ss oes feos jucket la 04) a8] (Cylinder fully o 1 | retracted < uly 1 | extended $ nox |2e+ os 3 ao oa) | 3 No lad in beket ] Swing one turn, then messure time | g akon to owing nxt two urn h2s 2 ‘Time taken to swing ° sane a 7 15} | Engine at high idl ] 1 + Hiyorati of temperature: bo = \4, sess ee Travel seed + Raise track on onesie at time, - rotate one trn, tn measure tie haa ‘taken to rotate the next two turns. | Hi PEreetE 2 ~ Amount of deviation when traveling 20m ar shown below 3 + Use a hard norzota surtac, 20m Travel deviation th men | Max. 200 -+Meaaure dimension x 20-13STANDARD VALUE TABLE FOR ELECTRICAL SYSTEM % Note 1: (Male) and (Female) in the Connector No. column indicates the mating at the terminal (pin). (For details, see CONNECTION TABLE FOR CONNECTORS). 2: The figure in(_) in the Judgement table column indicates the pin number. ee Masarament Sz] component | Comer, fon Sedge abe “ metro conditions 1F he condition sa shown in he 1) Tum starting table blow, fs normal switch OFF = 2) Disconnect Berwoen 1) — (2) connertr Fuel control il 5 Wat) — Bomeen (21) Berween (1? — I if he condition as shown in he 1) Turn starting sp | taptebeton: ite noemat suitor OFF & Berweon (1) — (2) 025-70 Powntionerer | eae | E or a 5 Berween (2) — (3 025— 10 3 i Beween (1) — (I 40K 3 Whe condition shown in he 1 Turn starting E fable tno, sisal switch OFF e |é Berween (1) ~ (2 4-00 2) Daconnnce =z ]° Between (3) — (4) 4-90 3 Motor 5 (mole) ‘ Bemeen (1) () No continuity 5 (1) chase No continuity 8 (3) — chassis No continuity By | time condition ia shown inthe 1) Tarn starting é B | tanto, normat switch ON, | poner source S eae | 2) sere come : Bemween (3) (12) 20-20v Tacaper. 3 i Beween ai—tia | z0-av | : 1) Turn staring z . swith ON. : s Beeon (18) | 2 tree 5 | Fuel conta aa 8 (omer sures) 478 — 525 Tasoper. | crmowe sone) & Beween (6) ~ (18) aaa z & 3 (owing i eZ Between (6) — Va) er . ig ng) - = 1 the condition i shown inthe 1 Tum surtog table boom, tis normal seh ON leer TTR 2) sere Berween(5)— (16) oo Sovernor 3 Lowiaing | 27-31 Poteniomeer £ i ish iaing | 08 —09v Beween (6) — (16) 475—525v 20-14 021K05,021K05, ‘Wessurement Component Sudan tae —— Thats conden Warshaw inthe 1) Turn saring | No.2 hone tae belo i's hore : sae ON sianal aemeen (8)— 119) | 025—a76v | | 2! inert ai aot 1 the condition is a shown in 1) Turn starting | trerasircnion, st nora sock ON meee Pe | cena a av] | 2 eee fede : ntwsin | When warmingup [wax ty | | 2 weer 3 (211012) | when cancstea | 8 — 12 z senna | Bee : ‘e,_| Ifthe condition i a: shown in the 1) Turn starting | B | tab beton.ieterormat ch ON Auto-desaaton eee ail 2) Inert _| [as : erwan [When oecnorating [ Max ay | | 2! Mme : 2 || on™ coca | g When caneeg | @— 12 5 2 7 i 1 he conten & a shown in 1 Tare warting 2 E | tnetabiebeiow, i normal mich ON g 8 5 2) Insert x Govenor motor Bi eayeen = 14) 28-6av Tedeoter ie 3 ewe (€)— 18 28 63v i i 08) 3 ie 1 he condition a shown in he 1 Tor sarin | tate tem es norma es 5 Fa ———— | 2» inet q Between 15) — 02) zo | aotr Battery relay Ky — vt} oT | aU peste 3 | “Cities tne string ten OW OFF ote tenes OV. "t hecondiion nos shown inthe 1) Far sarin table blow: normal es _ on Model sleton 2 % 2) set | [ eerweon(i7) chassis | Continuity Taesotr 20-15