Shop Manual Pc1100lc-6

SEBM014206
1
PC1100-6
PC1100SP-6
PC1100LC-6
MACHINE MODEL SERIAL NUMBER
PC1100-6 10001 and up

PC1100SP-6 10001 and up
PC1100LC-6 10001 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.
• PC1100-6 mount the SAA6D170-2 engine.

For details of the engine, see the 6D170-2 Series Engine Shop Manual.
© 2001 1
All Rights Reserved
00-1
Printed in Japan 03-01(01) 6
CONTENTS
No. of page
01 GENERAL ........................................................................ 01-1
10 STRUCTURE AND FUNCTION ...................................... 10-1
20 TESTING AND ADJUSTING .......................................... 20-1
30 DISASSEMBLY AND ASSEMBLY ................................. 30-1
40 MAINTENANCE STANDARD ......................................... 40-1
90 OTHERS........................................................................... 90-1
00-2 PC1100-6
2
LIST OF REVISED PAGES
The affected pages are indicated by the use of the

following marks. It is requested that necessary actions Mark Indication Action required
be taken to these pages according to the table below.
fi Page to be newly added Add
‡ Page to be replaced Replace
( ) Page to be deleted Discard
Pages having no marks are those previously revised

or made additions.
LIST OF REVISED PAGE
Time of Time of Time of Time of Time of

Mark Page Mark Page Mark Page Mark Page Mark Page
revision revision revision revision revision
o 00- 1 6 01- 1 10-13 10-43 10-74

00- 2 2 01- 2 4 10-14 10-44 10-75
o 00- 2-1 6 01- 3 4 10-15 10-45 10-76
o 00- 2-2 6 01- 3-1 4 10-16 10-46 10-77
o 00- 2-3 6 01- 4 1 10-17 10-47 10-78
o 00- 2-4 6 01- 5 10-18 10-48 10-79
o 00- 2-5 6 01- 5-1 4 10-19 10-49 10-80
00- 3 01- 5-2 4 10-20 10-50 10-82
00- 4 01- 6 4 10-21 10-51 10-83
00- 5 01- 7 10-22 10-52 10-84
00- 6 01- 7-1 4 10-23 4 10-53 10-86
00- 7 01- 7-2 4 10-24 10-54 10-87
00- 8 01- 8 10-26 10-55 10-88
00- 9 01- 9 10-27 10-57 10-89
o 00-10 10-28 10-58 10-90
o 00-11 10-29 10-59 10-91
00-12 10- 1 10-30 10-60 10-92
00-13 10- 2 10-31 10-61 10-93
00-14 10- 3 10-33 10-62 10-94
00-15 10- 4 10-34 10-64 10-95
00-16 10- 5 10-35 10-65 10-96
00-17 10- 6 10-36 10-66 10-97
00-18 10- 7 1 10-37 10-67 10-98
00-19 10- 8 10-38 10-68 10-99
00-20 10- 9 10-39 10-69 10-100
00-21 10-10 10-40 10-70 10-101
00-22 10-11 10-41 10-72 10-102
10-12 10-42 10-73 10-104
PC1100-6 00-2-1
6

10-105 10-151 20-10-6 4 20-121 1 20-214 3

10-106 10-152 20-10-7 4 20-122 1 20-215 3
10-107 10-153 20-10-8 4 20-123 1 20-216 3
10-108 10-154 20-10-9 4 20-124 1 20-217 3
10-109 10-155 20-11 1 20-125 1 20-218 3
10-110 10-156 20-12 1 20-126 1 20-219 3
10-111 10-157 20-13 1 20-127 1 20-220 3
10-112 10-158 20-14 1 20-128 1 20-221 3
10-113 10-159 20-15 1 20-129 1 20-222 3
10-114 10-160 20-16 1 20-130 1 20-223 3
10-115 10-161 20-17 1 20-131 1 20-224 3
10-116 10-162 20-18 1 20-132 1 20-225 3
10-117 10-164 20-19 1 20-133 1 20-226 3
10-118 10-165 20-20 1 20-134 1 20-227 3
10-119 10-166 20-21 1 20-135 1 20-228 3
10-120 10-167 20-22 1 20-136 1 20-229 3
10-121 4 10-168 20-23 1 20-137 1 20-230 3
10-126 10-169 20-24 1 20-138 1 20-231 3
10-127 10-170 20-25 1 20-139 1 20-232 3
10-128 10-171 20-140 1 20-233 3
10-129 10-172 20-101 1 20-141 1 20-234 3
10-130 10-173 20-102 1 20-142 1 20-235 4
10-131 10-174 20-103 1 20-143 1 20-236 3
10-132 20-104 1 20-144 1 20-237 3
10-133 20-105 1 20-145 1 20-238 3
10-134 20- 1 4 20-106 1 20-146 1 20-239 3
10-135 20- 2 1 20-107 1 20-147 1 20-240 3
10-137 20- 3 4 20-108 1 20-241 4
10-138 20- 4 1 20-109 1 20-201 3 20-242 3
10-139 20- 5 1 20-110 1 20-202 3 20-243 3
10-140 20- 6 1 20-111 1 20-203 3 20-244 3
10-141 20- 7 1 20-112 1 20-204 3 20-245 3
10-142 20- 8 1 20-113 1 20-205 3 20-246 3
10-143 20- 9 1 20-114 1 20-206 3 20-248 3
10-144 20-10 1 20-115 1 20-207 3 20-249 3
10-146 20-10-1 4 o 20-116 6 20-208 3 20-250 3
10-147 20-10-2 4 20-117 1 20-209 3 20-251 3
10-148 20-10-3 4 20-118 1 20-210 3 20-252 3
10-149 20-10-4 4 20-119 1 20-211 3 20-253 3
10-150 20-10-5 4 20-120 1 20-212 3
00-2-2 PC1100-6
6

20-301 3 20-380 3 20-421 3 20-489 3 20-570 3

20-302 3 20-381 3 20-422 3 20-490 3 20-571 3
20-303 3 20-382 3 20-491 3 20-572 3
20-304 3 20-383 3 20-451 3 20-492 3 20-573 3
20-305 3 20-384 3 20-452 3 20-493 3 20-574 3
20-306 3 20-385 3 20-453 3 20-494 3 20-575 3
20-307 3 20-386 3 20-454 3 20-576 3
20-308 3 20-388 3 20-455 3 20-501 3 20-577 3
20-309 3 20-389 3 20-456 3 20-502 3 20-578 3
20-310 3 20-390 3 20-457 3 20-503 3 20-579 3
20-391 3 20-458 3 20-504 3 20-580 3
20-351 4 20-392 3 20-459 3 20-505 3 20-581 3
20-352 3 20-393 3 20-460 3 20-506 3 20-582 3
20-353 4 20-394 3 20-461 3 20-507 3 20-583 3
20-354 3 20-395 3 20-462 3 20-508 3
20-355 3 20-396 3 20-463 3 20-509 3 20-601 3
20-356 3 20-397 3 20-465 3 20-510 3 20-602 3
20-357 3 20-398 3 20-466 3 20-511 3 20-603 3
20-358 4 20-399 4 20-467 3 20-512 3 20-604 3
20-359 4 20-468 3 20-513 3 20-605 3
20-360 3 20-401 3 20-469 3 20-514 3 20-606 3
20-361 3 20-402 3 20-470 3 20-607 3
20-362 3 20-403 3 20-471 3 20-551 3 20-608 3
20-363 3 20-404 3 20-472 3 20-552 3 20-609 3
20-364 3 20-405 3 20-473 3 20-553 3 20-610 3
20-365 4 20-406 3 20-474 3 20-554 3 20-611 3
20-366 3 20-407 3 20-475 3 20-555 3 20-612 3
20-367 3 20-408 3 20-476 3 20-556 3 20-613 3
20-368 3 20-409 3 20-477 3 20-557 3 20-614 3
20-369 3 20-410 3 20-478 3 20-558 3 20-615 3
20-370 3 20-411 3 20-479 3 20-560 3 20-616 3
20-371 3 20-412 3 20-480 3 20-561 3 20-617 3
20-372 3 20-413 3 20-481 3 20-562 3 20-618 3
20-373 3 20-414 3 20-482 3 20-563 3 20-619 3
20-374 3 20-415 3 20-483 3 20-564 3 20-620 3
20-375 3 20-416 3 20-484 3 20-565 3 20-621 3
20-376 3 20-417 3 20-485 3 20-566 3 20-622 3
20-377 3 20-418 3 20-486 3 20-567 3 20-623 3
20-378 3 20-419 3 20-487 3 20-568 3 20-624 3
20-379 3 20-420 3 20-488 3 20-569 3 20-625 3
PC1100-6 00-2-3
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20-626 3 30-18 2 30-58 2 30-98 2 30-103-35 5

20-627 3 30-19 2 30-59 2 30-99 2 30-103-36 5
20-628 3 30-20 2 30-60 2 30-100 2 30-103-37 5
20-629 3 30-21 2 30-61 2 30-101 2 30-103-38 5
20-630 3 30-22 2 o 30-62 6 30-102 2 30-103-39 5
20-631 3 30-23 2 30-63 2 30-103 2 30-103-40 5
20-632 3 30-24 2 30-64 2 30-103-1 5 30-103-41 5
20-633 3 30-25 2 30-65 2 30-103-2 5 30-103-42 5
20-634 3 30-26 2 30-66 2 30-103-3 5 30-103-43 5
20-635 3 30-27 2 30-67 2 30-103-4 5 30-103-44 5
20-636 3 30-28 2 30-68 2 30-103-5 5 30-103-45 5
20-637 3 30-29 2 30-69 2 30-103-6 5 30-103-46 5
20-638 3 30-30 2 30-70 2 30-103-7 5 30-103-47 5
20-639 3 30-31 2 30-71 2 30-103-8 5 30-103-48 5
20-640 3 30-32 2 30-72 2 30-103-9 5 30-103-49 5
20-641 3 30-33 2 30-73 2 30-103-10 5 30-103-50 5
20-642 3 30-34 2 30-74 2 30-103-11 5 30-103-51 5
20-643 3 30-35 2 30-75 2 30-103-12 5 30-104 2
20-644 3 30-36 2 30-76 2 30-103-13 5 30-105 2
30-37 2 30-77 2 30-103-14 5 30-106 2
30-38 2 30-78 2 30-103-15 5 30-107 2
30- 1 4 30-39 2 30-79 2 30-103-16 5 30-108 2
30- 2 5 30-40 2 30-80 2 30-103-17 5 30-109 2
30- 3 2 30-41 2 30-81 2 30-103-18 5 30-110 2
30- 4 2 30-42 2 30-82 2 30-103-19 5 30-111 2
30- 5 2 30-43 2 30-83 2 30-103-20 5 30-112 2
30- 6 2 30-44 2 30-84 2 30-103-21 5 30-113 2
30- 7 2 30-45 2 30-85 2 30-103-22 5 30-114 2
30- 8 2 30-46 2 30-86 2 30-103-23 5 30-115 2
30- 9 5 30-47 2 30-87 2 30-103-24 5 30-116 2
30-10 5 30-48 2 30-88 2 30-103-25 5 30-117 2
30-11 5 30-49 2 30-89 2 30-103-26 5 30-118 2
30-11-1 5 30-50 2 30-90 2 30-103-27 5 30-119 2
30-11-2 5 30-51 2 30-91 2 30-103-28 5 30-120 2
30-12 2 30-52 2 30-92 2 30-103-29 5 30-121 2
30-13 2 30-53 2 30-93 2 30-103-30 5 30-122 2
30-14 2 30-54 2 30-94 2 30-103-31 5 30-123 2
30-15 2 30-55 2 30-95 2 30-103-32 5 30-124 2
30-16 2 30-56 2 30-96 2 30-103-33 5 30-125 2
30-17 2 30-57 2 30-97 2 30-103-34 5 30-126 2
00-2-4 PC1100-6
6

30-127 2 30-150-1 4 40-25

30-128 2 30-150-2 4 40-26
30-129 2 30-151 2 40-27
30-130 2 30-152 2 40-28
30-131 2 30-153 2 40-29
30-132 2 30-154 2 40-30
30-133 2 30-155 2 40-31
30-134 2 30-156 2 40-32
30-135 4 30-157 2 40-33
30-136 4 30-158 2 40-34
30-136-1 4 30-159 2 40-35
30-136-2 4 30-160 2 40-36
30-137 4 30-161 2 40-37
30-138 4 30-162 2 40-38
30-138-1 4 30-163 2 40-39
30-138-2 4 30-164 2 40-40 4
30-139 4 30-165 2 40-41 1
30-140 4 40-41-1 4
30-140-1 4 40-42 4
30-140-2 4 40- 1 4 40-43 1
30-140-3 4 40- 2 40-43-1 4
30-140-4 4 40- 3 40-43-2 4
30-141 4 40- 4 40-44
30-142 4 40- 6 40-45
30-142-1 4 40- 7 40-46
30-142-2 4 40- 8 40-47
30-143 4 40- 9
30-144 4 40-10
30-144-1 4 40-12 90- 1 4
30-144-2 4 40-13 90- 3
30-145 4 40-14 90- 3-2 4
30-146 4 40-15 90- 5
30-146-1 4 40-16 90- 7
30-146-2 4 40-17 90- 9
30-146-3 4 40-18 90-11
30-146-4 4 40-19 90-13 4
30-147 2 40-20 90-15 4
30-148 2 40-21 90-17 4
30-149 4 40-22 1 90-19 4
30-150 4 40-24
PC1100-6 00-2-5
6
SAFETY SAFETY NOTICE
SAFETY
SAFETY NOTICE
IMPORTANT SAFETY NOTICE
Proper service and repair is extremely important for safe machine operation. The
service and repair techniques recommended by Komatsu and described in this manual
are both effective and safe. Some of these techniques require the use of tools specially
designed by Komatsu for the specific purpose.
To prevent injury to workers, the symbol ¤ is used to mark safety precautions in this
manual. The cautions accompanying these symbols should always be followed care-
fully. If any dangerous situation arises or may possibly arise, first consider safety, and
take the necessary actions to deal with the situation.
GENERAL PRECAUTIONS 6. Decide a place in the repair workshop to

keep tools and removed parts. Always keep
Mistakes in operation are extremely dangerous. the tools and parts in their correct places.
Read the Operation and Maintenance Manual Always keep the work area clean and make
carefully BEFORE operating the machine. sure that there is no dirt or oil on the floor.
1. Before carrying out any greasing or repairs, Smoke only in the areas provided for smok-
read all the precautions given on the decals ing. Never smoke while working.
which are fixed to the machine.
2. When carrying out any operation, always PREPARATIONS FOR WORK
wear safety shoes and helmet. Do not wear
loose work clothes, or clothes with buttons 7. Before adding oil or making any repairs,
missing. park the machine on hard, level ground, and
• Always wear safety glasses when hitting block the wheels or tracks to prevent the
parts with a hammer. machine from moving.
• Always wear safety glasses when grind- 8. Before starting work, lower blade, ripper,
ing parts with a grinder, etc.
bucket or any other work equipment to the
3. If welding repairs are needed, always have a ground. If this is not possible, insert the
trained, experienced welder carry out the safety pin or use blocks to prevent the work
work. When carrying out welding work, al- equipment from falling. In addition, be sure
ways wear welding gloves, apron, hand to lock all the control levers and hang warn-
shield, cap and other clothes suited for welding signs on them.
ing work.
9. When disassembling or assembling, support
4. When carrying out any operation with two the machine with blocks, jacks or stands
or more workers, always agree on the oper- before starting work.
ating procedure before starting. Always in-
10. Remove all mud and oil from the steps or
form your fellow workers before starting any
other places used to get on and off the ma-
step of the operation. Before starting work,
chine. Always use the handrails, ladders or
hang UNDER REPAIR signs on the controls
steps when getting on or off the machine.
in the operator's compartment.
Never jump on or off the machine. If it is
5. Keep all tools in good condition and learn impossible to use the handrails, ladders or
the correct way to use them. steps, use a stand to provide safe footing.
00-3
SAFETY SAFETY NOTICE
PRECAUTIONS DURING WORK 19. Be sure to assemble all parts again in their
original places.
11. When removing the oil filler cap, drain plug Replace any damaged parts with new parts.
or hydraulic pressure measuring plugs, • When installing hoses and wires, be sure
loosen them slowly to prevent the oil from that they will not be damaged by contact
spurting out. with other parts when the machine is be-
Before disconnecting or removing compo- ing operated.
nents of the oil, water or air circuits, first 20. When installing high pressure hoses, make
remove the pressure completely from the
sure that they are not twisted. Damaged
circuit. tubes are dangerous, so be extremely care-
12. The water and oil in the circuits are hot ful when installing tubes for high pressure
when the engine is stopped, so be careful circuits. Also, check that connecting parts
not to get burned. are correctly installed.
Wait for the oil and water to cool before
21. When assembling or installing parts, always
carrying out any work on the oil or water
use the specified tightening torques. When
circuits.
installing protective parts such as guards,
13. Before starting work, remove the leads from or parts which vibrate violently or rotate at
the battery. Always remove the lead from high speed, be particularly careful to check
the negative (–) terminal first. that they are installed correctly.
14. When raising heavy components, use a hoist 22. When aligning two holes, never insert your
or crane. fingers or hand. Be careful not to get your
Check that the wire rope, chains and hooks fingers caught in a hole.
are free from damage.
23. When measuring hydraulic pressure, check
Always use lifting equipment which has that the measuring tool is correctly assem-
ample capacity.
bled before taking any measurements.
Install the lifting equipment at the correct
places. Use a hoist or crane and operate
24. Take care when removing or installing the
slowly to prevent the component from hit- tracks of track-type machines.
ting any other part. Do not work with any
When removing the track, the track sepa-
part still raised by the hoist or crane. rates suddenly, so never let anyone stand at
15. When removing covers which are under in- either end of the track.
ternal pressure or under pressure from a
spring, always leave two bolts in position
on opposite sides. Slowly release the pres-
sure, then slowly loosen the bolts to remove.
16. When removing components, be careful not
to break or damage the wiring. Damaged
wiring may cause electrical fires.
17. When removing piping, stop the fuel or oil
from spilling out. If any fuel or oil drips onto
the floor, wipe it up immediately. Fuel or oil
on the floor can cause you to slip, or can
even start fires.
18. As a general rule, do not use gasoline to
wash parts. In particular, use only the mini-
mum of gasoline when washing electrical
parts.
00-4
F O R EW OR D GENERAL
F O R EWOR D
GENERAL
This shop manual has been prepared as an aid to improve the quality of repairs by giving the
serviceman an accurate understanding of the product and by showing him the correct way to perform
repairs and make judgements. Make sure you understand the contents of this manual and use it to full
effect at every opportunity.
This shop manual mainly contains the necessary technical information for operations performed in a
service workshop. For ease of understanding, the manual is divided into the following chapters; these
chapters are further divided into the each main group of components.
STRUCTURE AND FUNCTION

This section explains the structure and function of each component. It serves not only to give
an understanding of the structure, but also serves as reference material for troubleshooting.
TESTING AND ADJUSTING

This section explains checks to be made before and after performing repairs, as well as
adjustments to be made at completion of the checks and repairs.
Troubleshooting charts correlating "Problems" to "Causes" are also included in this section.
DISASSEMBLY AND ASSEMBLY

This section explains the order to be followed when removing, installing, disassembling or
assembling each component, as well as precautions to be taken for these operations.
MAINTENANCE STANDARD
This section gives the judgement standards when inspecting disassembled parts.
NOTICE
The specifications contained in this shop manual are subject to change at any
time and without any advance notice. Use the specifications given in the book
with the latest date.
00-5
F O R EW OR D HOW TO READ THE SHOP MANUAL
HOW TO READ THE SHOP MANUAL

VOLUMES REVISED EDITION MARK
Shop manuals are issued as a guide to carrying When a manual is revised, an edition mark
out repairs. They are divided as follows: (123....) is recorded on the bottom of the
Chassis volume: Issued for every machine model pages.
Engine volume: Issued for each engine series
Electrical volume:
Attachments volume: } Each issued as one
volume to cover all
models
REVISIONS
Revised pages are shown in the LIST OF RE-
These various volumes are designed to avoid VISED PAGES next to the CONTENTS page.
duplicating the same information. Therefore, to
deal with all repairs for any model , it is neces-
sary that chassis, engine, electrical and attach-
SYMBOLS
ment volumes be available.
So that the shop manual can be of ample prac-
DISTRIBUTION AND UPDATING tical use, important safety and quality portions
are marked with the following symbols.
Any additions, amendments or other changes
will be sent to KOMATSU distributors. Get the
most up-to-date information before you start any
work.
FILING METHOD
1. See the page number on the bottom of the Symbol Item Remarks
page. File the pages in correct order.
2. Following examples show how to read the Special safety precautions are
page number. ¤ Safety necessary when performing
the work.
Example 1 (Chassis volume):
Special technical precautions
10 - 3
or other precautions for pre-
Item number (10. Structure

fl Caution serving standards are neces-
sary when performing the
and Function) work.
Consecutive page number for
Weight of parts of systems.
each item. Caution necessary when se-
Example 2 (Engine volume):

4 Weight lecting hoisting wire, or when
working posture is important,
etc.
12 - 5
Tightening Places that require special at-
Unit number (1. Engine) 3 tention for the tightening
torque torque during assembly.
Item number (2. Testing and
Adjusting) Places to be coated with ad-
Consecutive page number for 2 Coat
hesives and lubricants, etc.
each item.
Places where oil, water or fuel
5 Oil, water must be added, and the ca-
3. Additional pages: Additional pages are indi- pacity.
cated by a hyphen (-) and number after the
Places where oil or water
page number. File as in the example. 6 Drain must be drained, and quan-
Example: tity to be drained.
10-4 12-203
10-4-1 12-203-1
Added pages
10-4-2 12-203-2
10-5 12-204
00-6
F O R EW OR D HOISTING INSTRUCTIONS
HOISTING INSTRUCTIONS
HOISTING
Slinging near the edge of the hook may
 Heavy parts (25 kg or more) must be cause the rope to slip off the hook during
lifted with a hoist, etc. In the DISAS- hoisting, and a serious accident can re-
SEMBLY AND ASSEMBLY section, sult. Hooks have maximum strength at
every part weighing 25 kg or more is the middle portion.
indicated clearly with the symbol 4
• If a part cannot be smoothly removed from

the machine by hoisting, the following checks
should be made:
1) Check for removal of all bolts fastening 100% 88% 79% 71% 41%
the part to the relative parts. SAD00479
2) Check for existence of another part caus- 3) Do not sling a heavy load with one rope
ing interference with the part to be re- alone, but sling with two or more ropes
moved. symmetrically wound onto the load.
¤ Slinging with one rope may cause
turning of the load during hoisting,
WIRE ROPES untwisting of the rope, or slipping of
the rope from its original winding
1) Use adequate ropes depending on the
position on the load, which can re-
weight of parts to be hoisted, referring to
sult in a dangerous accident.
the table below:
Wire ropes 4) Do not sling a heavy load with ropes form-
(Standard "Z" or "S" twist ropes ing a wide hanging angle from the hook.
without galvanizing) When hoisting a load with two or more
ropes, the force subjected to each rope
Rope diameter Allowable load will increase with the hanging angles. The
table below shows the variation of allow-
mm kN tons
able load kN {kg} when hoisting is made
10 9.8 1.0 with two ropes, each of which is allowed
11.2 13.7 1.4 to sling up to 9.8 kN {1000 kg} vertically,
at various hanging angles.
12.5 15.7 1.6
When two ropes sling a load vertically, up
14 21.6 2.2 to 19.6 kN {2000 kg} of total weight can be
16 27.5 2.8 suspended. This weight becomes 9.8 kN
18 35.3 3.6 {1000 kg} when two ropes make a 120°
20 43.1 4.4 hanging angle. On the other hand, two
ropes are subjected to an excessive force
22.4 54.9 5.6
as large as 39.2 kN {4000 kg} if they sling
30 98.1 10.0
a 19.6 kN {2000 kg} load at a lifting angle
40 176.5 18.0 of 150°.
50 274.6 28.0 °
60 392.2 40.0
fl The allowable load value is estimated to

be one-sixth or one-seventh of the break-
ing strength of the rope used.
2) Sling wire ropes from the middle portion

of the hook.
00-7
F O R EW OR D METHOD OF DISASSEMBLING, CONNECTING PUSH-PULL TYPE COUPLER
METHOD OF DISASSEMBLING, CONNECTING PUSH-PULL TYPE COUPLER

fl There are 2 types of push-pull type coupler. The method of disassembling and connecting is differ-
ent, so see the table below when disassembling and connecting the coupler.
Type 1 Type 2
1) Hold the mouthpiece of the tightening por- 1) Hold the mouthpiece of the tightening por-
tion and push body (2) in straight until slid- tion and push body (2) in straight until slid-
ing prevention ring (1) contacts contact sur- ing prevention ring (1) contacts contact sur-
face a of the hexagonal portion at the male face a of the hexagonal portion at the male
end. end.
2) Hold in the condition in Step 1), and push 2) Hold in the condition in Step 1), and turn
until cover (3) contacts contact surface a of lever (4) to the right (clockwise).
the hexagonal portion at the male end.
Disassembly
3) Hold in the condition in Steps 1) and 2), and 3) Hold in the condition in Steps 1) and 2), and
pull out whole body (2) to disconnect it. pull out whole body (2) to disconnect it.
00-8
F O R EW OR D METHOD OF DISASSEMBLING, CONNECTING PUSH-PULL TYPE COUPLER
Type 1 Type 2
• Hold the mouthpiece of the tightening por- • Hold the mouthpiece of the tightening por-
tion and push body (2) in straight until slid- tion and push body (2) in straight until slid-
ing prevention ring (1) contacts contact sur- ing prevention ring (1) contacts contact sur-
face a of the hexagonal portion at the male face a of the hexagonal portion at the male
end to connect it. end to connect it.
Connection
00-9
F O R EW OR D COATING MATERIALS
COATING MATERIALS
fl The recommended coating materials such as adhesives, gasket sealants and greases used for
disassembly and assembly are listed below.
fl For coating materials not listed below, use the equivalent of products shown in this list.
Category Komatsu code Part No. Q'ty Container Main applications, features
• Used to prevent rubber gaskets, rubber

LT–1A 790–129–9030 150 g Tube cushions, and cock plug from coming out.
• Used in places requiring an immediately
effective, strong adhesive. Used for plas-
790–129–9050 20 g Polyethylene
LT–1B tics (except polyethylene, polyprophylene,
(2 pes.) container
tetrafluoroethlene and vinyl chloride), rub-
ber, metal and non-metal.
• Features: Resistance to heat and chemi-

Polyethylene cals
LT–2 09940–00030 50 g
container • Used for anti-loosening and sealant pur-
pose for bolts and plugs.
790–129–9060 Adhesive: • Used as adhesive or sealant for metal, glass

(Set of adhe- 1 kg and plastic.
LT–3 sive and Hardening Can
hardening agent:
agent) 500 g
Adhesives
Polyethylene • Used as sealant for machined holes.
LT–4 790–129–9040 250 g
container
Holtz • Used as heat-resisting sealant for repair-
790–126–9120 75 g Tube
MH 705 ing engine.
• Quick hardening type adhesive

Three bond Polyethylene • Cure time: within 5 sec. to 3 min.
790–129–9140 50 g
1735 container • Used mainly for adhesion of metals, rub-
bers, plastics and woods.
• Quick hardening type adhesive

• Quick cure type (max. strength after 30 min-
Aron-alpha Polyethylene
790–129–9130 2g utes)
201 container
• Used mainly for adhesion of rubbers, plas-
tics and metals.
• Features: Resistance to heat, chemicals

Loctite Polyethylene • Used at joint portions subject to high tem-
648-50 79A–129–9110 50 cc
container peratures.
• Used as adhesive or sealant for gaskets

LG-1 790–129–9010 200 g Tube
and packing of power train case, etc.
• Used as sealant for various threads, pipe

Polyethylene joints, flanges.
LG-5 790–129–9080 1 kg
container • Used as sealant for tapered plugs, elbows,
Gasket nipples of hydraulic piping.
sealant
• Features: Silicon based, resistance to heat,
cold
LG-6 790–129-9020 200 g Tube • Used as sealant for flange surface, tread.
• Used as sealant for oil pan, final drive case,
etc.
00-10
F O R EW OR D COATING MATERIALS
Category Komatsu code Part No. Q'ty Container Main applications, features
• Features: Silicon based, quick hardening

type
LG-7 790-129-9070 1 kg Tube • Used as sealant for flywheel housing, in-
Gasket take manifold, oil an, thermostat housing,
sealant etc.
Three bond • Used as heat-resisting sealant for repairing

790–129–9090 100 g Tube engine.
1211
• Used as lubricant for sliding portion (to pre-

Molybde- LM-G 09940-00051 60 g Can vent from squeaking).
num
disulphide • Used to prevent seizure or scuffling of the
lubricant LM-P 09940-00040 200 g Tube thread when press fitting or shrink fitting.
• Used as lubricant for linkage, bearings, etc.
SYG2-400LI • General purpose type

SYG2-350LI
G2-LI SYG2-400LI-A Various Various
SYG2-160LI
SYGA-160CNLI
• Used for normal temperature, light load

SYG2-400CA bearing at places in contact with water or
Grease SYG2-350CA steam.
G2-CA SYG2-400CA-A Various Various
SYG2-160CA
SYGA-160CNCA
Molybdenum 400 g • Used for places with heavy load

disulphide SYG2-400M (10 per Belows type
lubricant case)
00-11
F O R EW OR D STANDARD TIGHTENING TORQUE
STANDARD TIGHTENING TORQUE
STANDARD TIGHTENING TORQUE TABLE (WHEN USING TORQUE WRENCH)

fl In the case of metric nuts and bolts for which there is no special instruction, tighten to the torque
given in the table below.
Thread diameter Width

of bolt across flats
mm mm Nm kgm
6 10 13.2 ± 1.4 1.35 ± 0.15
8 13 31 ± 3 3.2 ± 0.3
10 17 66 ± 7 6.7 ± 0.7
12 19 113 ± 10 11.5 ± 1
14 22 177 ± 19 18 ± 2
16 24 279 ± 30 28.5 ± 3
18 27 382 ± 39 39 ± 4
20 30 549 ± 59 56 ± 6
22 32 745 ± 83 76 ± 8.5
24 36 927 ± 103 94.5 ± 10.5
27 41 1320 ± 140 135 ± 15
30 46 1720 ± 190 175 ± 20
33 50 2210 ± 240 225 ± 25
36 55 2750 ± 290 280 ± 30
39 60 3290 ± 340 335 ± 35
Thread diameter Width

of bolt across flats
mm mm Nm kgm
6 10 7.85 ± 1.95 0.8 ± 0.2
8 13 18.6 ± 4.9 1.9 ± 0.5
10 14 40.2 ± 5.9 4.1 ± 0.6
12 27 82.35 ± 7.85 8.4 ± 0.8
Sealing surface
TABLE OF TIGHTENING TORQUES FOR FLARED NUTS

fl In the case of flared nuts for which there is no special
instruction, tighten to the torque given in the table below.
SAD00483
Thread diameter Width across flat Tightening torque

mm mm Nm kgm
14 19 24.5 ± 4.9 2.5 ± 0.5
18 24 49 ± 19.6 5±2
22 27 78.5 ± 19.6 8±2
24 32 137.3 ± 29.4 14 ± 3
30 36 176.5 ± 29.4 18 ± 3
33 41 196.1 ± 49 20 ± 5
36 46 245.2 ± 49 25 ± 5
42 55 294.2 ± 49 30 ± 5
00-12
TABLE OF TIGHTENING TORQUES FOR SPLIT FLANGE BOLTS

fl In the case of split flange bolts for which there is no special instruction, tighten to the torque

mm mm Nm kgm
10 14 65.7 ± 6.8 6.7 ± 0.7
12 17 112 ± 9.8 11.5 ± 1
16 22 279 ± 29 28.5 ± 3
TABLE OF TIGHTENING TORQUES FOR O-RING BOSS PIPING JOINTS

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

Nominal No.
mm mm Nm kgm
02 14 34.3 ± 4.9 3.5 ± 0.5
03, 04 20 Varies depending on 93.1 ± 9.8 9.5 ± 1
05, 06 24 type of connector. 142.1 ± 19.6 14.5 ± 2
10, 12 33 421.4 ± 58.8 43 ± 6
14 42 877.1 ± 132.3 89.5 ± 13.5
TABLE OF TIGHTENING TORQUES FOR O-RING BOSS PLUGS

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

Nominal No.
mm mm Nm kgm
08 8 14 7.35 ± 1.47 0.75 ± 0.15
10 10 17 11.27 ± 1.47 1.15 ± 0.15
12 12 19 17.64 ± 1.96 1.8 ± 0.2
14 14 22 22.54 ± 1.96 2.3 ± 0.2
16 16 24 29.4 ± 4.9 3 ± 0.5
18 18 27 39.2 ± 4.9 4 ± 0.5
20 20 30 49 ± 4.9 5 ± 0.5
24 24 32 68.6 ± 9.8 7± 1
30 30 32 107.8 ± 14.7 11 ± 1.5
33 33 — 127.4 ± 19.6 13 ± 2
36 36 36 151.9 ± 24.5 15.5 ± 2.5
42 42 — 210.7 ± 29.4 21.5 ± 3
52 52 — 323.4 ± 44.1 33 ± 4.5
00-13
TIGHTENING TORQUE FOR 102 ENGINE SERIIES (BOLT AND NUTS)

Use these torques for bolts and nuts (unit: mm) of Cummins Engine.
Thread diameter Tightening torque

mm Nm kgm
6 10 ± 2 1.02 ± 0.20
8 24 ± 4 2.45 ± 0.41
10 43 ± 6 4.38 ± 0.61
12 77 ± 12 7.85 ± 1.22
TIGHTENING TORQUE FOR 102 ENGINE SERIIES (EYE JOINTS)

Use these torques for eye joints (unit: mm) of Cummins Engine.

mm Nm kgm
6 8 ± 2 0.81 ± 0.20
8 10 ± 2 1.02 ± 0.20
10 12 ± 2 1.22 ± 0.20
12 24 ± 4 2.45 ± 0.41
14 36 ± 5 3.67 ± 0.51
TIGHTENING TORQUE FOR 102 ENGINE SERIIES (TAPERED SCREWS)

Use these torques for tapered screws (unit: inch) of Cummins Engine.

inch Nm kgm
1 / 16 3 ± 1 0.31 ± 0.10
1/8 8 ± 2 0.81 ± 0.20
1/4 12 ± 2 1.22 ± 0.20
3/8 15 ± 2 1.53 ± 0.41
1/2 24 ± 4 2.45 ± 0.41
3/4 36 ± 5 3.67 ± 0.51
1 60 ± 9 6.12 ± 0.92
00-14
F O R EW OR D ELECTRIC WIRE CODE
ELECTRIC WIRE CODE

In the wiring diagrams, various colors and symbols are employed to indicate the thickness of wires.
This wire code table will help you understand WIRING DIAGRAMS.
Example: 5WB indicates a cable having a nominal number 5 and white coating with black stripe.
CLASSIFICATION BY THICKNESS
Copper wire
Nominal Cable O.D. Current rating
number Number of Dia. of strands Cross section (mm) (A) Applicable circuit
strands (mm) (mm2)
0.85 11 0.32 0.88 2.4 12 Starting, lighting, signal etc.
2 26 0.32 2.09 3.1 20 Lighting, signal etc.
5 65 0.32 5.23 4.6 37 Charging and signal
15 84 0.45 13.36 7.0 59 Starting (Glow plug)
40 85 0.80 42.73 11.4 135 Starting
60 127 0.80 63.84 13.6 178 Starting
100 217 0.80 109.1 17.6 230 Starting
CLASSIFICATION BY COLOR AND CODE
Circuits
Prior- Charging Ground Starting Lighting Instrument Signal Other
ity Classi-
fication
Pri- Code W B B R Y G L
1 mary
Color White Black Black Red Yellow Green Blue
Code WR — BW RW YR GW LW
2
Color White & Red — Black & White Red & White Yellow & Red Green & White Blue & White
Code WB — BY RB YB GR LR
3
Color White & Black — Black & Yellow Red & Black Yellow & Black Green & Red Blue & Red
Auxi- Code WL — BR RY YG GY LY
4 liary
Color White & Blue — Black & Red Red & Yellow Yellow & Green Green & Yellow Blue & Yellow
Code WG — — RG YL GB LB
5
Color White & Green — — Red & Green Yellow & Blue Green & Black Blue & Black
Code — — — RL YW GL —
6
Color — — — Red & Blue Yellow & White Green & Blue —
00-15
F O R EW OR D CONVERSION TABLE
CONVERSION TABLE
METHOD OF USING THE CONVERSION TABLE

The Conversion Table in this section is provided to enable simple conversion of figures. For
details of the method of using the Conversion Table, see the example given below.
EXAMPLE
• Method of using the Conversion Table to convert from millimeters to inches
1. Convert 55 mm into inches.
(1) Locate the number 50 in the vertical column at the left side, take this as A, then draw a horizontal
line from A.
(2) Locate the number 5 in the row across the top, take this as B, then draw a perpendicular line
down from B.
(3) Take the point where the two lines cross as C. This point C gives the value when converting
from millimeters to inches. Therefore, 55 mm = 2.165 inches.
2. Convert 550 mm into inches.

(1) The number 550 does not appear in the table, so divide by 10 (move the decimal point one place
to the left) to convert it to 55 mm.
(2) Carry out the same procedure as above to convert 55 mm to 2.165 inches.
(3) The original value (550 mm) was divided by 10, so multiply 2.165 inches by 10 (move the decimal
point one place to the right) to return to the original value. This gives 550 mm = 21.65 inches.
B
Millimeters to inches
..........................................
1 mm = 0.03937 in
0 1 2 3 4 5 6 7 8 9
0 0 0.039 0.079 0.118 0.157 0.197 0.236 0.276 0.315 0.354

10 0.394 0.433 0.472 0.512 0.551 0.591 0.630 0.669 0.709 0.748
20 0.787 0.827 0.866 0.906 0.945 0.984 1.024 1.063 1.102 1.142
30 1.181 1.220 1.260 1.299 1.339 1.378 1.417 1.457 1.496 1.536
40 1.575 1.614 1.654 1.693 1.732 1.772 1.811 1.850 1.890 1.929
C
50 1.969 2.008 2.047 2.087 2.126 2.165 2.205 2.244 2.283 2.323
A ...........................................................................................
60 2.362 2.402 2.441 2.480 2.520 2.559 2.598 2.638 2.677 2.717
70 2.756 2.795 2.835 2.874 2.913 2.953 2.992 3.032 3.071 3.110
80 3.150 3.189 3.228 3.268 3.307 3.346 3.386 3.425 3.465 3.504
90 3.543 3.583 3.622 3.661 3.701 3.740 3.780 3.819 3.858 3.898
00-16
Millimeters to Inches
1 mm = 0.03937 in
0 1 2 3 4 5 6 7 8 9
0 0 0.039 0.079 0.118 0.157 0.197 0.236 0.276 0.315 0.354

10 0.394 0.433 0.472 0.512 0.551 0.591 0.630 0.669 0.709 0.748
20 0.787 0.827 0.866 0.906 0.945 0.984 1.024 1.063 1.102 1.142
30 1.181 1.220 1.260 1.299 1.339 1.378 1.417 1.457 1.496 1.536
40 1.575 1.614 1.654 1.693 1.732 1.772 1.811 1.850 1.890 1.929
50 1.969 2.008 2.047 2.087 2.126 2.165 2.205 2.244 2.283 2.323
60 2.362 2.402 2.441 2.480 2.520 2.559 2.598 2.638 2.677 2.717
70 2.756 2.795 2.835 2.874 2.913 2.953 2.992 3.032 3.071 3.110
80 3.150 3.189 3.228 3.268 3.307 3.346 3.386 3.425 3.465 3.504
90 3.543 3.583 3.622 3.661 3.701 3.740 3.780 3.819 3.858 3.898
Kilogram to Pound
1 kg = 2.2046 lb
0 1 2 3 4 5 6 7 8 9
0 0 2.20 4.41 6.61 8.82 11.02 13.23 15.43 17.64 19.84

10 22.05 24.25 26.46 28.66 30.86 33.07 35.27 37.48 39.68 41.89
20 44.09 46.30 48.50 50.71 51.91 55.12 57.32 59.53 61.73 63.93
30 66.14 68.34 70.55 72.75 74.96 77.16 79.37 81.57 83.78 85.98
40 88.18 90.39 92.59 94.80 97.00 99.21 101.41 103.62 105.82 108.03
50 110.23 112.44 114.64 116.85 119.05 121.25 123.46 125.66 127.87 130.07
60 132.28 134.48 136.69 138.89 141.10 143.30 145.51 147.71 149.91 152.12
70 154.32 156.53 158.73 160.94 163.14 165.35 167.55 169.76 171.96 174.17
80 176.37 178.57 180.78 182.98 185.19 187.39 189.60 191.80 194.01 196.21
90 198.42 200.62 202.83 205.03 207.24 209.44 211.64 213.85 216.05 218.26
00-17
Liter to U.S. Gallon

1¶ = 0.2642 U.S. Gal
0 1 2 3 4 5 6 7 8 9
0 0 0.264 0.528 0.793 1.057 1.321 1.585 1.849 2.113 2.378

10 2.642 2.906 3.170 3.434 3.698 3.963 4.227 4.491 4.755 5.019
20 5.283 5.548 5.812 6.076 6.340 6.604 6.869 7.133 7.397 7.661
30 7.925 8.189 8.454 8.718 8.982 9.246 9.510 9.774 10.039 10.303
40 10.567 10.831 11.095 11.359 11.624 11.888 12.152 12.416 12.680 12.944
50 13.209 13.473 13.737 14.001 14.265 14.529 14.795 15.058 15.322 15.586
60 15.850 16.115 16.379 16.643 16.907 17.171 17.435 17.700 17.964 18.228
70 18.492 18.756 19.020 19.285 19.549 19.813 20.077 20.341 20.605 20.870
80 21.134 21.398 21.662 21.926 22.190 22.455 22.719 22.983 23.247 23.511
90 23.775 24.040 24.304 24.568 24.832 25.096 25.361 25.625 25.889 26.153
Liter to U.K. Gallon

1¶ = 0.21997 U.K. Gal
0 1 2 3 4 5 6 7 8 9
0 0 0.220 0.440 0.660 0.880 1.100 1.320 1.540 1.760 1.980

10 2.200 2.420 2.640 2.860 3.080 3.300 3.520 3.740 3.950 4.179
20 4.399 4.619 4.839 5.059 5.279 5.499 5.719 5.939 6.159 6.379
30 6.599 6.819 7.039 7.259 7.479 7.969 7.919 8.139 8.359 8.579
40 8.799 9.019 9.239 9.459 9.679 9.899 10.119 10.339 10.559 10.778
50 10.998 11.281 11.438 11.658 11.878 12.098 12.318 12.528 12.758 12.978
60 13.198 13.418 13.638 13.858 14.078 14.298 14.518 14.738 14.958 15.178
70 15.398 15.618 15.838 16.058 16.278 16.498 16.718 16.938 17.158 17.378
80 17.598 17.818 18.037 18.257 18.477 18.697 18.917 19.137 19.357 19.577
90 19.797 20.017 20.237 20.457 20.677 20.897 21.117 21.337 21.557 21.777
00-18
kgm to ft. lb
1 kgm = 7.233 ft. lb
0 1 2 3 4 5 6 7 8 9
0 0 7.2 14.5 21.7 28.9 36.2 43.4 50.6 57.9 65.1

10 72.3 79.6 86.8 94.0 101.3 108.5 115.7 123.0 130.2 137.4
20 144.7 151.9 159.1 166.4 173.6 180.8 188.1 195.3 202.5 209.8
30 217.0 224.2 231.5 238.7 245.9 253.2 260.4 267.6 274.9 282.1
40 289.3 296.6 303.8 311.0 318.3 325.5 332.7 340.0 347.2 354.4
50 361.7 368.9 376.1 383.4 390.6 397.8 405.1 412.3 419.5 426.8
60 434.0 441.2 448.5 455.7 462.9 470.2 477.4 484.6 491.8 499.1
70 506.3 513.5 520.8 528.0 535.2 542.5 549.7 556.9 564.2 571.4
80 578.6 585.9 593.1 600.3 607.6 614.8 622.0 629.3 636.5 643.7
90 651.0 658.2 665.4 672.7 679.9 687.1 694.4 701.6 708.8 716.1
100 723.3 730.5 737.8 745.0 752.2 759.5 766.7 773.9 781.2 788.4
110 795.6 802.9 810.1 817.3 824.6 831.8 839.0 846.3 853.5 860.7
120 868.0 875.2 882.4 889.7 896.9 904.1 911.4 918.6 925.8 933.1
130 940.3 947.5 954.8 962.0 969.2 976.5 983.7 990.9 998.2 1005.4
140 1012.6 1019.9 1027.1 1034.3 1041.5 1048.8 1056.0 1063.2 1070.5 1077.7
150 1084.9 1092.2 1099.4 1106.6 1113.9 1121.1 1128.3 1135.6 1142.8 1150.0
160 1157.3 1164.5 1171.7 1179.0 1186.2 1193.4 1200.7 1207.9 1215.1 1222.4
170 1129.6 1236.8 1244.1 1251.3 1258.5 1265.8 1273.0 1280.1 1287.5 1294.7
180 1301.9 1309.2 1316.4 1323.6 1330.9 1338.1 1345.3 1352.6 1359.8 1367.0
190 1374.3 1381.5 1388.7 1396.0 1403.2 1410.4 1417.7 1424.9 1432.1 1439.4
00-19
kg/cm2 to lb/in2
1kg/cm2 = 14.2233 lb/in2
0 1 2 3 4 5 6 7 8 9
0 0 14.2 28.4 42.7 56.9 71.1 85.3 99.6 113.8 128.0

10 142.2 156.5 170.7 184.9 199.1 213.4 227.6 241.8 256.0 270.2
20 284.5 298.7 312.9 327.1 341.4 355.6 369.8 384.0 398.3 412.5
30 426.7 440.9 455.1 469.4 483.6 497.8 512.0 526.3 540.5 554.7
40 568.9 583.2 597.4 611.6 625.8 640.1 654.3 668.5 682.7 696.9
50 711.2 725.4 739.6 753.8 768.1 782.3 796.5 810.7 825.0 839.2
60 853.4 867.6 881.8 896.1 910.3 924.5 938.7 953.0 967.2 981.4
70 995.6 1010 1024 1038 1053 1067 1081 1095 1109 1124
80 1138 1152 1166 1181 1195 1209 1223 1237 1252 1266
90 1280 1294 1309 1323 1337 1351 1365 1380 1394 1408
100 1422 1437 1451 1465 1479 1493 1508 1522 1536 1550
110 1565 1579 1593 1607 1621 1636 1650 1664 1678 1693
120 1707 1721 1735 1749 1764 1778 1792 1806 1821 1835
130 1849 1863 1877 1892 1906 1920 1934 1949 1963 1977
140 1991 2005 2020 2034 2048 2062 2077 2091 2105 2119
150 2134 2148 2162 2176 2190 2205 2219 2233 2247 2262
160 2276 2290 2304 2318 2333 2347 2361 2375 2389 2404
170 2418 2432 2446 2460 2475 2489 2503 2518 2532 2546
180 2560 2574 2589 2603 2617 2631 2646 2660 2674 2688
190 2702 2717 2731 2745 2759 2773 2788 2802 2816 2830
200 2845 2859 2873 2887 2901 2916 2930 2944 2958 2973
210 2987 3001 3015 3030 3044 3058 3072 3086 3101 3115
220 3129 3143 3158 3172 3186 3200 3214 3229 3243 3257
230 3271 3286 3300 3314 3328 3343 3357 3371 3385 3399
240 3414 3428 3442 3456 3470 3485 3499 3513 3527 3542
00-20
Temperature
Fahrenheit-Centigrade Conversion ; a simple way to convert a Fahrenheit temperature reading into a Centigrade tempera-
ture reading or vice versa is to enter the accompanying table in the center or boldface column of figures.
These figures refer to the temperature in either Fahrenheit or Centigrade degrees.
If it is desired to convert from Fahrenheit to Centigrade degrees, consider the center column as a table of Fahrenheit
temperatures and read the corresponding Centigrade temperature in the column at the left.
If it is desired to convert from Centigrade to Fahrenheit degrees, consider the center column as a table of Centigrade values,
and read the corresponding Fahrenheit temperature on the right.
1°C = 33.8°F
°C °F °C °F °C °F °C °F
–40.4 –40 –40.0 –11.7 11 51.8 7.8 46 114.8 27.2 81 117.8

–37.2 –35 –31.0 –11.1 12 53.6 8.3 47 116.6 27.8 82 179.6
–34.4 –30 –22.0 –10.6 13 55.4 8.9 48 118.4 28.3 83 181.4
–31.7 –25 –13.0 –10.0 14 57.2 9.4 49 120.2 28.9 84 183.2
–28.9 –20 –4.0 –9.4 15 59.0 10.0 50 122.0 29.4 85 185.0
–28.3 –19 –2.2 –8.9 16 60.8 10.6 51 123.8 30.0 86 186.8

–27.8 –18 –0.4 –8.3 17 62.6 11.1 52 125.6 30.6 87 188.6
–27.2 –17 1.4 –7.8 18 64.4 11.7 53 127.4 31.1 88 190.4
–26.7 –16 3.2 –7.2 19 66.2 12.2 54 129.2 31.7 89 192.2
–26.1 –15 5.0 –6.7 20 68.0 12.8 55 131.0 32.2 90 194.0
–25.6 –14 6.8 –6.1 21 69.8 13.3 56 132.8 32.8 91 195.8

–25.0 –13 8.6 –5.6 22 71.6 13.9 57 134.6 33.3 92 197.6
–24.4 –12 10.4 –5.0 23 73.4 14.4 58 136.4 33.9 93 199.4
–23.9 –11 12.2 –4.4 24 75.2 15.0 59 138.2 34.4 94 201.2
–23.3 –10 14.0 –3.9 25 77.0 15.6 60 140.0 35.0 95 203.0
–22.8 –9 15.8 –3.3 26 78.8 16.1 61 141.8 35.6 96 204.8

–22.2 –8 17.6 –2.8 27 80.6 16.7 62 143.6 36.1 97 206.6
–21.7 –7 19.4 –2.2 28 82.4 17.2 63 145.4 36.7 98 208.4
–21.1 –6 21.2 –1.7 29 84.2 17.8 64 147.2 37.2 99 210.2
–20.6 –5 23.0 –1.1 30 86.0 18.3 65 149.0 37.8 100 212.0
–20.0 –4 24.8 –0.6 31 87.8 18.9 66 150.8 40.6 105 221.0

–19.4 –3 26.6 0 32 89.6 19.4 67 152.6 43.3 110 230.0
–18.9 –2 28.4 0.6 33 91.4 20.0 68 154.4 46.1 115 239.0
–18.3 –1 30.2 1.1 34 93.2 20.6 69 156.2 48.9 120 248.0
–17.8 0 32.0 1.7 35 95.0 21.1 70 158.0 51.7 125 257.0
–17.2 1 33.8 2.2 36 96.8 21.7 71 159.8 54.4 130 266.0

–16.7 2 35.6 2.8 37 98.6 22.2 72 161.6 57.2 135 275.0
–16.1 3 37.4 3.3 38 100.4 22.8 73 163.4 60.0 140 284.0
–15.6 4 39.2 3.9 39 102.2 23.3 74 165.2 62.7 145 293.0
–15.0 5 41.0 4.4 40 104.0 23.9 75 167.0 65.6 150 302.0
–14.4 6 42.8 5.0 41 105.8 24.4 76 168.8 68.3 155 311.0

–13.9 7 44.6 5.6 42 107.6 25.0 77 170.6 71.1 160 320.0
–13.3 8 46.4 6.1 43 109.4 25.6 78 172.4 73.9 165 329.0
–12.8 9 48.2 6.7 44 111.2 26.1 79 174.2 76.7 170 338.0
–12.2 10 50.0 7.2 45 113.0 26.7 80 176.0 79.4 175 347.0
00-21
F O R EW OR D UNITS
UNITS
In this manual, the measuring units are indicated with Internatinal System of units (SI).
As for reference, conventionally used Gravitational System of units are indicated in parentheses { }.
Example:
N {kg}
Nm {kgm}
MPa {kg/cm2}
kPa {mmH2O}
kPa {mmHg}
kw/rpm {HP/rpm}
g/kwh {g/HPh}
00-22
01 GENERAL
Specification drawings .................................. 01-2

Specifications ................................................. 01-4
Weight table .................................................. 01-6
Fuel, coolant and lubricants ........................ 01-8
PC1100-6 01-1
GENERAL SPECIFICATION DRAWINGS
SPECIFICATION DRAWINGS
PC1 100-6 BACKHOE
PC1 IOOLC-6 BACKHOE Unit: mm
7965
t- -I
141
13
12
11
10
15350
SUP05351
+ The figures in ( ) show the value for the PCIIOOLC-6.
01-2 PC1 100-6

0
PC1 lOOSP-6 BACKHOE

Unit: mm
3470
2990,_ I / 2245
I 1-i
SUP05352
PC1 100-6
PC1 100-6 LOADING SHOVEL
6320 _ 4810
I (~=4870)
6425 -I
6760
l-
SWPO6318
01-3-l PCllOO-6
0
GENERAL SPECIFICATIONS
SPECIFICATIONS
BACK HOE
Machine model PC1100-6 PC1100SP-6 PC1100LC-6

Serial Number 10001 and up 10001 and up 10001 and up
Bucket capacity m3 5.0 6.5 5.0
Weight of machine kg 103,000 104,000 109,800

Max. digging depth mm 9,350 7,900 9,350
Working ranges
Max. vertical wall depth mm 7,610 5,025 7,610
Max. digging reach mm 15,350 14,070 15,350

Max. reach at ground level mm 15,000 13,670 15,000
Max. digging height mm 13,400 13,000 13,400

Performance
Max. dumping height mm 8,680 8,450 8,680

Max. digging force kN {kg} 478.6 {48,800} 525,6 {53,600} 478.6 {48,800}
Swing speed rpm 5.8 5.8 5.8
Swing max. slope angle deg. 12 12 12

Travel speed km/h Lo: 2.1 Hi: 3.2 Lo: 2.1 Hi: 3.2 Lo: 2.7 Hi: 3.2
Gradeability deg. 35 35 35
Ground pressure
kPa {kg/cm2} 132 {1.35} 133 {1.36} 84 {0.86}
[standard double grouser shoe width] [700 mm] [700 mm] [1,000 mm]
Overall length mm 16,020 14,790 16,020
Overall width mm 5,475 5,475 5,625

Overall width of track (when extended) mm 4,965 4,965 5,265
Overall height mm 6,040 6,265 6,040
Overall height to top of machine mm 4,880 4,880 4,880

Ground clearance of upper structure mm 1,790 1,790 1,790
Dimensions
Min. ground clearance mm 990 990 990
Tail swing radius mm 4,870 4,870 4,870

Min. swing radius of work equipment mm 7,965 6,415 7,965
Height of work equipment at min. swing radius mm 11,390 11,020 11,390
Length of track on ground mm 4,995 4,995 5,970

Track gauge (when extended) mm 3,900 3,900 3,900
Height of machine cab mm 3,925 3,925 3,925
01-4 PC1100-6
1

Model SAA6D170-2
Type 4-cycle, water-cooled, in-line, vertical, direct injection,
with turbocharger and aftercooler (air cooled)
No. of cylinders – bore x stroke mm 6 – 170 x 170

Piston displacement ¬ {cc} 23.15 {23,150}
Flywheel horsepower kW/rpm {HP/rpm} 611/1,800 {620/1,800}
Performance
Engine
Max. torque Nm/rpm {kgm/rpm} 2,756/1,300 {281/1,300}

Max. speed at no load rpm 2,000
Min. speed at no load rpm 730
Min. fuel consumption g/kWh {g/HPh} 209 {156}
Starting motor 24V, 7.5 kW x 2
Alternator 24V, 50A
Battery 12V, 170 Ah x 2
Radiator core type CWX-4
Carrier roller 3 on each side
carriage
Under-
Track roller 8 on each side

Track shoe Assembly-type double Assembly-type double
grouser, 48 on each side grouser, 55 on each side
Type Variable displacement piston type:
Hydraulic
HPV160+160, HPV95+95 x 2; gear type SAR100+020+010

pump
Delivery ¬/min Piston type: 494+494+600, gear type: 158+33+16

Set pressure MPa {kg/cm2} Piston type: 31.4 {320}, gear type: 2.9 {30}
Control
Type x No. 4-spool type x 2, + 5-spool type x 1

valve
Control method Hydraulic

Travel motor Piston type (with brake valve, shaft brake):
Hydraulic
x 2 (MSF340VP)
motor
Hydraulic system
Swing motor Piston type (with safety valve, shaft brake):

x 2 (KMF160AB-2)
ª1, ª2 Arm ª1, ª2 Bucket

ª1 Boom
STD STD SP version
Hydraulic cylinder
Cylinder type Double-acting piston Double-acting piston

Inside diameter of cylinder mm 225 250 160 160
Outside diameter of piston rod mm 160 170 110 110
Stroke mm 2,390 2,435 1,825 1,950
Max. distance between pins mm 5,839 3,620 2,535 2,660
Min. distance between pins mm 3,449 6,055 4,360 4,610
Hydraulic tank Box-shaped, with breather
Hydraulic filter Tank return side
Hydraulic cooler Air cooled (J4)
ª1: Head side with cushion ª2: Bottom side with cushion
PC1100-6 01-5
LOADING SHOVEL
Machine model PC1 100-6 loading shovel

-
Serial Number 10001 and up
Bucket capacity m3 6.5

- _.-.
I
Weight of machine kg 108,000
I
_--
Max. digging depth mm 3,650
Max. vertical wall depth mm -
Max. digging reach mm 11,400
Max. reach at ground level mm 11,020
Max. digging height mm 12,400
Max. dumping height mm 8,790
Max. digging force kN {kg1 608.0 {62,000}
Swing speed rpm 5.8
Swing max. slope angle deg. 12
Travel speed km/h Lo: 2.1 Hi: 3.2
Gradeability deg. 35
Ground pressure
Pa {kg/cm 135 I1.38)
[standard double grouser shoe width] [700 mm]
Overall length mm 11,130
Overall width mm 5,475
Overall width of track (when extended) mm 4,965
Overall height mm 5,910
Overall height to top of machine mm 4,880
Ground clearance of upper structure mm 1,790
Min. ground clearance mm 980
Tail swing radius mm 4,870
Min. swing radius of work equipment mm 6,760
Height of work equipment at min. swing radius mm 8,500
Length of track on ground mm 4,935
Track gauge (when extended) mm 3,900
Height of machine cab mm 3,925
01-5-l PC1 100-6

0
Serial Number f 10001 and up
Model SAAGDI 70-Z
Type 4-cycle, water-cooled, in-line, vertical, direct injection,

with turbocharger and aftercooler (air cooled)
No. of cylinders - bore x stroke mm 6 - 170 x 170
Piston displacement Q {cc) 23.15 (23,150)
Flywheel horsepower kW/rpm IHP/rpm: 456/l ,800 I61 l/l ,800)

$
c Max. torque Vmlrpm {kgmlrpm 2,770/l ,300 {283/l ,300)
i Max. speed at no load rpm 2,000
5 Min. speed at no load rpm 730
a. Min. fuel consumption g/kWh QU-IPhI 205 (153)
Starting motor 24V, 7.5 kW x 2
Alternator 24V, 50A
Battery 12V 170 Ah x 2
Radiator core type cwx-4
Carrier roller 3 on each side
Track roller 8 on each side
Track shoe Assembly-type double grouser,

48 on each side
-.
Type Variable displacement piston type:
0
3Q HPV160t160,HPV95t95x 2; gear type SAR100t020t010
FE
;z Delivery Q/min Piston type: 494+494+600, gear type: 158+33+16
Set pressure MPa {kg/cm? Piston type: 31.4 13201, gear type: 2.9 {301
0, Type x No. 4-spool type x 2, + 5-spool type x 1
E1
O?
,, Control method Hydraulic
Travel motor Piston type (with brake valve, shaft brake):

0
5g x 2 (MSF340VP)
!!z
FE Swing motor Piston type (with safety valve, shaft brake):
x 2 (KMF160AB-2)
% Boom % Arm Bucket Bottom dump

-
Cylinder type Double acting piston
Inside diameter of cylinder mm 225 140
Outside diameter of piston rod mm 160 90
Stroke mm 1,960 435
Max. distance between pins mm 5,120 1,485
Min. distance between pins mm 3,160 1,050
Hydraulic tank Box-shaped, with breather
Hydraulic filter In tank return side
_l Hydraulic
%I: Head side with

cooler
cushion ~2: Bottom side with cushion

Air cooled (J4)
PC1 100-6 01-5-2

0
GENERAL WEIGHT TABLE
WEIGHT TABLE
g This weight table is a guide for use when transporting or handling components
BACKHOE Unit: kg
Machine model PC1 100-6 PC1 IOOSP-6 PC1 1OOLC-6
Engine assembly 3,839.5 3,839.5 3,839.5
Engine 2,814 2,814 2,814
PTO (incl. lubricating piping) 505 505 505
No. 1 pump 157 157 157
No. 2 pump 148 148 148
No. 3 pump 191 191 191
Control pump (for control, PTO lubrication 24.5 24.5 24.5
and aftercooler fan drive)
Radiator assembly 239 239 239
Oil cooler assembly 321 321 321
Hydraulic tank (excl. hydraulic oil) 776 776 776
Revolving frame (incl. left and right decks) 9,660 9,660 9,660
Operator’s cab 370 370 370
Swing machinery 532 x 2 532 x 2 532 x 2
Swing motor assembly 126 x 2 126 x 2 126 x 2
Travel motor assembly 145x2 145 x 2 145 x 2
L.H. 5-spool control valve 260 260 260
R.H. 4-spool control valve 253 253 253
Swing 4-spool control valve 240 240 240
Center swivel joint 69 69 69
Counterweight (excl. mounting bolts) 17,400 17,400 17,400

-
Track frame assembly 27,478 27,478 29,854
l Center frame 6,600 6,600 6,600
l Track frame 4,342 x 2 4,342 x 2 5,150 x 2
l Carrier roller 80 x 6 80 x 6 80 x 6
l Track roller 190 x 16 190 x 16 190 x 20
l Idler cushion assembly 1,000 x 2 1,000 x 2 1,000 x 2
l Idler 788 x 2 788 x 2 788 x 2
l Final drive assembly 1,869 x 2 1,869 x 2 1,869 x 2
l Swing circle assembly 2,165 2,165 2,165
01-6 PC1 100-6

0
Unit: kg
Track shoe assembly

• Standard shoe (700 mm) 10,630 10,630 —
• Wide shoe (1,000 mm) 12,940 12,940 14,820
• Wide shoe (1,200 mm) — — 16,350

Boom assembly (excl. piping) 10,265 10,110 10,265
Arm assembly (excl. piping) 3,520 3,915 3,520
Bucket assembly (excl. piping) 4,579 5,591 4,579

Boom cylinder assembly 1,174 x 2 1,174 x 2 1,174 x 2
Arm cylinder assembly 1,538 1,538 1,538
Bucket cylinder assembly 442 x 2 459 x 2 442 x 2

Boom foot pin 71.4 x 2 71.4 x 2 71.4 x 2
Boom cylinder foot pin 43.8 x 2 43.8 x 2 43.8 x 2

Boom cylinder top pin 43.2 x 2 43.2 x 2 43.2 x 2
Boom-arm connecting pin 168.6 168.6 168.6
Arm cylinder foot pin 92.9 101.3 92.9

Arm cylinder top pin 97.9 97.9 97.9
Link-arm connecting pin 103 103 103
Link-bucket connecting pin 110.4 110.4 110.4

Bucket cylinder top pin 37.9 37.9 37.9
Bucket cylinder foot pin 37.9 37.9 37.9
Arm-bucket connecting pin 120.4 120.4 120.4

Link assembly 817 878 817
Link connecting pin 103 103 103
PC1100-6 01-7
LOADING SHOVEL Unit: kg
Engine assembly 3,839
Engine 2,814
PTO (incl. lubricating piping) 505
No. 1 pump 157
No. 2 pump 148
No. 3 pump 191
Control pump (for control, PTO lubrication 24.5
and aftercooler fan drive)
Radiator assembly 239
Oil cooler assembly 321
Hydraulic tank (excl. hydraulic oil) 776
Revolving frame (incl. left and right decks) 9,660
Operator’s cab 370
Swing machinery 532 x 2
Swing motor assembly 126 x 2
Travel motor assembly 145 x 2
L.H. 5-spool control valve 260
R.H. 4-spool control valve 253
Swing 4-spool control valve 240
Center swivel joint 69
Counterweight (excl. mounting bolts) 17,400
Track frame assembly 27,478
Center frame 6,600
Track frame 4,342 x 2
Carrier roller 80 x 6
Track roller 190 x 16
Idler cushion assembly 1,000 x 2
Idler 788 x 2
Final drive assembly 1,869 x 2
Swing circle assembly 2,165
01-7-l PC1 100-6

0
Unit: kg
Track shoe assembly
l Standard shoe (700 mm) 10,630
l Wide shoe (1,000 mm) 12,940
Boom assembly (excl. piping) 6,150
Arm assembly (excl. piping) 5,020
Bucket assembly (excl. piping) 8,650
Boom cylinder assembly 1,073 x 2
Arm cylinder assembly 602 x 2
Bucket cylinder assembly 730 x 2
Bottom dump cylinder 147 x2
Boom foot pin 71.4 x 2
Boom cylinder foot pin 43.8 x 2
Boom cylinder top pin 43.2 x 2
Boom-arm connecting pin 81 x2
Arm cylinder foot pin 24 x 2
Arm cylinder top pin 24 x 2
Link-arm connecting pin 54 x 2
Link-bucket connecting pin 46 x 2
Bucket cylinder top pin 54 x 2
Bucket cylinder foot pin 50 x 2
Arm-bucket connecting pin 68 x 2
Link assembly 652
Link connecting pin -
PC1 100-6 01-7-2

0
GENERAL FUEL, COOLANT AND LUBRICANTS
FUEL, COOLANT AND LUBRICANTS

AMBIENT TEMPERATURE CAPACITY (¬)
KIND OF
RESERVOIR –22 –4 14 32 50 68 86 104°F
FLUID Specified Refill
–30 –20 –10 0 10 20 30 40°C
SAE 30
SAE 10W
Engine oil pan 55 51
SAE 10W-30
SAE 15W-40
SAE 30
PTO case Engine 13.5 13.5
oil SAE 10W
Swing machinery case (each side) 21.5 21.5

SAE 30
Final drive case (each side) 22 22
Hydraulic system SAE 10W 800 440
Idler (1 each) 0.75 – 0.83 0.75 – 0.83

Gear
Track roller (1 each) oil GO 140B 0.80 – 0.85 0.80 – 0.85
Carrier roller (1 each) 0.45 – 0.50 0.45 – 0.50
ASTM D975 No. 2

Fuel tank Diesel 880 —
fuel ASTM D975A No.1
Cooling system Coolant Add antifreeze 140 —
01-8 PC1100-6
GENERAL FUEL, COOLANT AND LUBRICANTS
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 oil in

Fuel sulphur content
engine oil pan
0.5 to 1.0% 1/2 of regular interval
Above 1.0% 1/4 of regular interval
(2) When starting the engine in an atmospheric

temperature of lower than 0°C, be sure to
use engine oil of SAE10W, SAE10W-30 and
SAE15W-40, even though an atmospheric
temperature goes up to 10°C more or less in
the day time.
(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 (SAE10W-30, 15W-
40), but be sure to add single grade oil that
matches the temperature in the table on the
left.
(5) We recommend Komatsu genuine oil which
has been specifically formulated and ap-
proved for use in engine and hydraulic work
equipment applications.
ASTM: American Society of Testing and Material

SAE: Society of Automotive Engineers
API: American Petroleum Institute
Specified capacity: Total amount of oil includ-

ing oil for components and
oil in piping.
Refill capacity: Amount of oil needed to refill
system during normal inspection
and maintenance.
PC1100-6 01-9
10 STRUCTURE AND FUNCTION
PTO ................................................................ 10- 2 Return oil filter ........................................... 10- 69

PTO lubrication system ............................... 10- 3 Drain oil filter ............................................. 10- 70
Radiator, oil cooler, aftercooler .................. 10- 4 L.H. 5-spool control valve ......................... 10- 72
Power train ................................................... 10- 6 R.H. 4-spool control valve ......................... 10- 74
Swing machinery ......................................... 10- 8 Swing. 4-spool control valve .................... 10- 76
Swing circle .................................................. 10- 9 Straight-travel valve .................................. 10- 78
Final drive ..................................................... 10-10 Boom lower regeneration valve ............... 10- 82
Track frame ................................................... 10-11 Swing motor ............................................... 10- 86
Track shoe .................................................... 10-12 Center swivel joint ..................................... 10- 88
Air piping diagram ....................................... 10-13 Travel motor ............................................... 10- 89
Air circuit diagram ....................................... 10-14 PPC control relief valve ............................. 10- 99
Air governor ................................................. 10-15 Safety lock valve ........................................ 10-100
Air tank .......................................................... 10-15 Accumulator ............................................... 10-101
Safety valve .................................................. 10-16 Valve control .............................................. 10-102
Horn valve .................................................... 10-16 Work equipment, swing PPC valve .......... 10-104
Grease pump ................................................ 10-17 Travel PPC valve ........................................ 10-108
Hydraulic piping drawing ............................ 10-18 Solenoid valve ............................................ 10-112
Hydraulic circuit diagram ............................ 10-23 Work equipment ........................................ 10-114
Hydraulic tank .............................................. 10-24 Air conditioner ........................................... 10-115
Hydraulic pump ............................................ 10-26 Actual electric wiring diagram ................. 10-116
NO. 1 pump .................................................. 10-27 Electric circuit diagram .............................. 10-120
NO. 2 pump .................................................. 10-51 Engine control ............................................ 10-126
NO. 3 pump .................................................. 10-57 Machine control system ............................ 10-137
Line oil filter ................................................. 10-67 Machine monitor system .......................... 10-168
Pilot oil filter ................................................. 10-68
PC1100-6 10-1
STRUCTURE AND FUNCTION PTO
PTO
1. Driven gear (No. of teeth: 49) Specifications

2. PTO case Lubricating oil : 13.5 ¬
3. Drive gear (No. of teeth: 56) Reduction ratio: SAR100+020+010 shaft = 1
4. Main shaft
5. Hub HPV160+160 shaft = 49 = 0.875
56
6. Connection plate 42
HPV95+95 shaft = = 0.750
7. Driven gear (No. of teeth: 42) 56
8. Breather
A. Center of HPV160+160 shaft

B. Center of crankshaft (SAR100+020+010)
C. Center of HPV95+95 shaft
D. Center of HPV95+95 shaft
10-2 PC1100-6
STRUCTURE AND FUNCTION PTO LUBRICATION SYSTEM
PTO LUBRICATION SYSTEM

Hydraulic circuit diagram
Hydraulic piping diagram
1. PTO case Outline

2. Divider block The PTO uses the control and PTO lubricating,
3. Lubricating pipe aftercooler fan drive pump (4). The lubricating
4. Control, PTO lubricating, aftercooler fan drive oil inside PTO case (1) passes through oil filter
pump (SAR100+020+010) (5), is sent to top divider block (2), and is then
5. Oil filter divided to various parts of the PTO to lubricate
and cool the gears.
PC1100-6 10-3
STRUCTURE AND FUNCTION RADIATOR, OIL COOLER, AFTERCOOLER
RADIATOR, OIL COOLER, AFTERCOOLER
10-4 PC1100-6
STRUCTURE AND FUNCTION RADIATOR, OIL COOLER, AFTERCOOLER
1. Aftercooler Specifications
2. Reservoir tank 1. Fan
3. Aftercooler fan Outside diameter: 1,320 mm
4. Fan guard No. of vanes: 6
5. Fan pulley Rotating speed: Standard 1,078 rpm
6. Radiator inlet tube (At rated engine speed of
7. Fan 1,800 rpm)
8. Radiator upper tank 2. Radiator
9. Oil cooler Core type: CWX-4
10. Radiator lower tank Fin pitch: 5 mm
11. Radiator outlet tube Cracking pressure for pressure valve:
49 ± 9.8 kPa
{0.5 ± 0.1 kg/cm2}
Cracking pressure for vacuum valve:
0 – 4.9 kPa
{0 – 0.05 kg/cm2}
3. Oil cooler
Core type: J4
Fin pitch: 3 mm
4. Aftercooler fan
Outside diameter: 620 mm
No. of vanes: 8
Rotating speed: Standard 1,430 rpm
(At rated engine speed of
1,800 rpm)
PC1100-6 10-5
STRUCTURE AND FUNCTION POWER TRAIN
POWER TRAIN
10-6 PC1100-6
STRUCTURE AND FUNCTION POWER TRAIN
1. Idler 9. PTO 15. Swing brake solenoid valve

2. Center swivel joint 10. No. 3 pump (HPV160+160) 16. Travel speed solenoid valve
3. Swing motor (KMF160AB-2) 11. No. 1 pump (HPV95+95) 17. Swing machinery
4. L.H. 5-spool control valve 12. No. 2 pump (HPV95+95) 18. Swing circle
5. R.H. 4-spool control valve 13. Control, PTO lubricating,
6. Final drive, sprocket aftercooler fan drive pump A. Swing 4-spool control valve
7. Travel motor (MSF340VP) (SAR100+020+010) B. Swing brake solenoid valve
8. Engine (SAA6D170-2) 14. Swing 4-spool control valve
PC1100-6 10-7
1
STRUCTURE AND FUNCTION SWING MACHINERY
SWING MACHINERY
1. Swing pinion (No. of teeth: 13)

2. Cover
3. Case
4. Coupling
5. No. 2 planet gear (No. of teeth: 35)
6. Ring gear (No. of teeth: 92)
8. Cover
9. Swing motor
10. Dipstick
11. No. 1 sun gear (No. of teeth: 19)
12. No. 1 planetary carrier
15. Drain plug
Specification
Reduction ratio: 19 + 92 x 19 + 92
19 19
= 34.130
10-8 PC1100-6
STRUCTURE AND FUNCTION SWING CIRCLE
SWING CIRCLE
1. Swing circle inner race (No. of teeth: 132) Specifications

2. Ball Reduction ratio: 183 =10.153
3. Swing circle outer race 13
Amount of grease: 65 ¬ (G2-LI)
a. Inner race soft zone “S” position
b. Outer race soft zone “plug” position
PC1100-6 10-9
STRUCTURE AND FUNCTION FINAL DRIVE
FINAL DRIVE
1. Level plug
2. Drain plug
3. Cover
6. Drive gear (No. of teeth: 19)
9. Hub
10. Sprocket
11. Floating seal
12. Case
13. Coupling
15. Travel motor
16. Idler gear (No. of teeth: 27)
17. No. 1 ring gear (No. of teeth: 68)
19. Driven gear (No. of teeth: 69)
20. No. 2 ring gear (No. of teeth: 63)
Specifications
13 + 68 19 + 69
Reduction ratio: – ( )×( )
13 19
63
× ( 13 ) = –139.852
10-10 PC1100-6
STRUCTURE AND FUNCTION TRACK FRAME
TRACK FRAME
fl The diagram shows the PC1100-6.
1. Idler • The dimensions and number of track rollers

2. Track frame may differ according to the model, but the
3. Carrier roller basic structure is the same.
4. Center frame
5. Final drive • No. of track rollers
6. Track roller
7. Track shoe Model No. of rollers (each side)
8. Idler cushion
PC1100-6
9. Front guard 8
PC1100SP-6
PC1100LC-6 10
PC1100-6 10-11
STRUCTURE AND FUNCTION TRACK SHOE
TRACK SHOE
Standard shoe
Model PC1100-6 PC11000SP-6 PC1100LC-6
Item
Shoe width
(double shoe) 700 mm 700 mm 1000 mm
Link pitch 280 mm 280 mm 280 mm

No. of shoes
(each side) 48 48 55
Selection of track shoe

• Select the most suitable track shoe from the following table
PC1100-6 PC1100SP-6 PC1100LC-6
Specifications Cate- Cate- Cate-
gory Specifications gory Specifications gory
Standard 700 mm double A 700 mm double A 1000 mm double A
Option 1000 mm double B 1000 mm double B 1200 mm double B
Category Use Precautions when using

Rocky ground • Travel in Lo speed when traveling on rough ground with obstacles
A normal river soil such as large boulders and fallen trees.
• Cannot be used on rough ground where there are large obstacles
Normal soil, such as boulders and fallen trees.
B soft land • Travel in Hi speed only on flat ground; when it is impossible 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 impossible
to use.
Extremely soft • Cannot be used on rough ground where there are large obstacles
C ground (swampy such as boulders and fallen trees.
ground) • Travel in Hi speed only on flat ground; when it is impossible to
avoid traveling over obstacles, lower the travel speed to approx.
half of Lo speed.
D Paved surface • The shoes are flat, so they have low gradeability.
• The shoes are made of rubber, so be careful when traveling on
E Paved surface rough ground.
fl Categories "B" and "C" are wide shoes, so fl When selecting the shoe width, select the
there are restrictions on their use. There- narrowest shoe possible within the range
fore, before using, check the restrictions are that will give no problem with flotation and
consider carefully the conditions of use be- ground pressure.
fore recommending a suitable shoe width. If If a wider shoe than necessary is used, there
necessary, give the customer guidance in will be a large load on the shoe, and this
their use. may lead to bending of the shoe, cracking of
the links, breakage of the pins, falling out of
the pins, loosening of the shoe bolts, or other
problems.
10-12 PC1100-6
STRUCTURE AND FUNCTION AIR PIPING DIAGRAM
AIR PIPING DIAGRAM
1. Grease gun Outline

2. Grease reel This machine uses pressurized air to operate
3. Grease pump the air horn and automatic greasing system.
4. Air governor The pressurized air is supplied by air compres-
5. Air compressor sor (5) installed to the engine and is stored in
6. Safety valve air tank (7).
7. Air tank When the pressure in the air tank reaches 0.82
8. Horn valve MPa {8.4 kg/cm2}, the air compressor is unloaded;
9. Air horn when the tank pressure drops below 0.72 MPa
{7.3 kg/cm2}, the air compressor again starts to
supply pressurized air.
PC1100-6 10-13
STRUCTURE AND FUNCTION AIR CIRCUIT DIAGRAM
AIR CIRCUIT DIAGRAM
1. Air compressor (capacity: 102 ¬/600 rpm)

2. Unloader valve
3. Air governor (cut-out pressure: 0.82 +0.03 +0.35 2
–0.005 MPa {8.4 –0.05 kg/cm })
+0.03 +0.35 2
(cut-in pressure: 0.72 –0.005 MPa {6.0 –0.05 kg/cm })
4. Check valve
5. Air tank
6. Safety valve (set pressure: 0.95 –0 –0
–0.05 MPa {9.7 –0.5 kg/cm })
2
7. Battery
8. Horn switch
9. Horn valve
10. Air horn
11. Grease pump
12. Grease reel
13. Grease gun
10-14 PC1100-6
AIR GOVERNOR
STRUCTURE AND FUNCTION AIR TANK
AIR GOVERNOR
Function 1. Bubble seat

• Port A is connected to the air tank and port 2. Diaphragm
B is connected to the unloader valve of the 3. Body
air compressor. The air governor maintains 4. Sleeve
the air pressure inside the air tank within 5. Adjustment screw
the specified range. If the pressure exceeds 6. Spring
the specified pressure, it stops the operation 7. Cover
of the air compressor to prevent the air pres-
sure from rising any higher. A : From air tank
B : To unload valve
Specifications
• Cut-out pressure: 0.82 +0.03
–0.005 MPa
{8.4 +0.35 2
–0.05 kg/cm })
+0.03
• Cut-in pressure: 0.72 –0.005 MPa
{7.3 +0.35 2
–0.05 kg/cm })
AIR TANK
Specifications
• Capacity: 15 ¬
PC1100-6 10-15
SAFETY VALVE
STRUCTURE AND FUNCTION HORN VALVE
SAFETY VALVE
1. Cover
2. Sleeve
3. Spring
4. Pin
5. Cap
6. Valve
7. Nipple
–0 –0
Set pressure: 0.95 –0.05 MPa {9.7–0.5 kg/cm2})
Function
• The safety valve is installed to the air tank,
and if any pressure above the set pressure
is generated in the air circuit, it acts to re-
lease the compressed air inside the air tank
to the atmosphere in order to maintain the
safety of the air circuit.
HORN VALVE
1. Spring
2. Magnet
3. Wire
4. Wire
5. Coil
6. Cover
7. Piston
8. Body
A : From air tank

B : To horn
10-16 PC1100-6
STRUCTURE AND FUNCTION GREASE PUMP
GREASE PUMP
1. Silencer Function
2. Valve • The pump is divided into air chamber (4)
3. Cover and grease chamber (6). As the amount of
4. Air chamber grease in grease chamber (6) goes down,
5. Follow plate follow plate (5) is pulled down to push down
6. Grease chamber the grease stuck to the edge of grease cham-
7. Grease tank ber (6).
A : Air inlet port

B : Grease outlet port
PC1100-6 10-17
STRUCTURE AND FUNCTION HYDRAULIC PIPING DRAWING
HYDRAULIC PIPING DRAWING

BACK HOE
(1/2)
10-18 PC1100-6
PC1100-6 10-19
(2/2)
10-20 PC1100-6
PC1100-6 10-21
1. Bucket cylinder
2. Arm cylinder
3. Boom cylinder
4. Swing motor
5. Aftercooler fan drive motor
6. Line oil filter (for R.H. 4-spool control valve)
7. Oil cooler
8. Line oil filter (for L.H. 5-spool control valve)
9. Line oil filter (for swing 4-spool control valve)
10. Return oil filter
11. L.H. travel motor
12. Drain oil filter
13. Hydraulic tank
14. Center swivel joint
15. Boom LOWER regeneration valve
16. R.H. 4-spool control valve
17. L.H. 5-spool control valve
18. Swing holding brake solenoid valve
19. Travel speed selector solenoid valve
20. Swing holding brake solenoid valve
21. Straight-travel solenoid valve
22. —
23. Machine push-up solenoid valve
24. Accumulator
25. Pilot oil filter
26. No. 3 pump
27. Control, PTO lubrication, aftercooler fan drive
pump
28. No. 2 pump
29. Oil filter
30. No. 1 pump
31. Swing 4-spool control valve
32. Pilot relief valve
33. PPC control relief valve
34. CO cancel solenoid valve
35. Heavy lift solenoid valve
36. Swing priority selector solenoid valve
37. Boom shockless control solenoid valve (LOWER)
38. Boom shockless control solenoid valve (RAISE)
39. L.H. PPC valve
40. Travel PPC valve
41. R.H. PPC valve
10-22 PC1100-6
STRUCTURE AND FUNCTION HYDRAULIC CIRCUIT DIAGRAM
HYDRAULIC CIRCUIT DIAGRAM

BACKHOE
See page 90-3.
LOADING SHOVEL
See page 90-3-2.
PCllOO-6 1O-23
0
STRUCTURE AND FUNCTION HYDRAULIC TANK
HYDRAULIC TANK
1. Hydraulic tank Specifications

2. Strainer Tank capacity: 1,146 ¬
3. Oil filler cap Amount of oil inside tank: 664 ¬ (at H level)
4. Pressure valve
5. Safety valve Pressure valve
6. Return filter Relief cracking pressure: 38.3 ± 14.7 kPa
7. Drain filter {0.39 ± 0.15 kg/cm2}
8. Sight guage Suction cracking pressure: 0 – 4.51 kPa
9. Hydraulic oil temperature gauge {0 – 0.046 kg/cm2}
10. Suction strainer
11. Drain valve
10-24 PC1100-6
STRUCTURE AND FUNCTION HYDRAULIC PUMP
HYDRAULIC PUMP
1. No. 3 pump (HPV160+160) Outline

2. Control pump assembly (SAR100+020+010) The hydraulic pumps consist of three variable
2A. For PPC valve control (SAR100) displacement swash plate type piston pumps
2B. For aftercooler fan drive motor (SAR020) and a control pump. The piston pumps have the
2C. For PTO lubrication (SAR010) valves shown in the table below, and the con-
3. No. 2 pump (HPV95+95) trol pump is used for the PPC valve control,
4. No. 1 pump (HPV95+95) aftercooler fan drive, and PTO lubrication.
Pump No.1 (HPV95+95) No.2 (HPV95+95) No.3 (HPV160+160)
(type)
Valve Front Rear Front Rear Front Rear
TVC — — — — —
CO — — —
NC — — —
Servo
10-26 PC1100-6
STRUCTURE AND FUNCTION NO. 1 PUMP
NO. 1 PUMP
HPV95+95
1. Front pump P3 : Swing pump pressure IN port Pd : Jet sensor downstream

2. Front servo valve PA1 : Discharge port pressure IN port
3. Front CO, NC valve PA2 : Discharge port Ps : Suction port
4. Rear servo valve Pd11 : Drain port Pt : Jet sensor upstream pressure
5. Rear CO, NC valve Pd21 : Drain port IN port
6. TVC valve Pc : CO selector pilot port Psv : Servo basic pressure IN port
7. Rear pump
PC1100-6 10-27
1. No. 1 main pump
Pac : Servo actuator port

Psv : Servo basic pressure IN port
10-28 PC1100-6
1. Front shaft 8. Front end cap 15. Rear case

2. Front cradle 9. Coupling 16. Rocker cam
3. Front case 10. Impeller 17. Rear cradle
4. Rocker cam 11. Rear end cap 18. Rear shaft
5. Piston 12. Valve plate 19. Servo piston
6. Cylinder block 13. Cylinder block
7. Valve plate 14. Piston
PC1100-6 10-29
2. No. 1 pump front servo assembly
1. CO, NC valve Pc : CO selector pilot port

2. Servo valve Pd : Jet sensor downstream pressure IN port
Pt : Jet sensor upstream pressure IN port
PA1 : Main pump pressure IN port Pdr : Servo valve drain OUT port
Pe1 : TVC valve output pressure detection port Psv : Servo basic pressure IN port
Pe2 : TVC valve output pressure front, rear in- Pecn : CO, NC valve output pressure OUT port
terconnection port
10-30 PC1100-6
No. 1 pump front servo valve
PA2(IN) : Main pump pressure IN port Pdr(OUT) : Servo valve drain OUT port
PA2(OUT) : Main pump pressure OUT port Psv1 : Servo basic pressure IN port
Pac : Servo actuator port Pecn : CO, NC valve output pressure IN port
Pdr : CO, NC valve drain port
PC1100-6 10-31
3. No. 1 pump rear servo assembly
1. TVC valve Pd : Jet sensor downstream pressure IN port

2. CO, NC valve Pe : TVC valve output pressure front, rear inter-
3. Connector connection port
4. Servo valve Pt : Jet sensor upstream pressure IN port
PA2 : Main pump pressure IN port Psv : Servo basic pressure IN port
Pc : CO selector pilot port
PC1100-6 10-33
No. 1 pump rear servo valve
PA1(IN) : Main pump pressure IN port Pdr : CO, NC valve drain port
PA1(OUT) : Main pump pressure OUT port Pdr(OUT) : Servo valve drain OUT port
PA2(IN) : Main pump pressure IN port Psv1 : Servo basic pressure IN port
PA2(OUT) : Main pump pressure OUT port Psv2 : Servo basic pressure OUT port
10-34 PC1100-6
1. Plug 7. Spring 13. Plug

2. Locknut 8. Plug 14. Spring
3. Control piston 9. Cover 15. Piston
4. Pin 10. Locknut 16. Sleeve
5. Arm 11. Locknut 17. Cover
6. Valve body 12. Cover 18. Locknut
Function
Discharge amounts Q1 and Q2 of main pumps
PA1 and PA2 are controlled individually by the
respective servo valves. The relationship be-
tween pump discharge amount Q and input sig-
nal Pecn to the servo valve is as shown in the
graph on the right. Q varies in proportion to
Pecn.
PC1100-6 10-35
Operation
1) Operation in direction of increase of pump discharge amount (max. angle)
• The control pump pressure Psv is taken to drain chamber e. As a result, servo piston
port a. chamber f is also interconnected with cham-
Signal pressure Pecn from the NC valve is ber e through port g and port d.
taken from port b to chamber c. At the same time, port a is interconnected
• When signal pressure Pecn rises, control pis- with port h, so the oil flows through port i to
ton (8) is pushed to the left by the hydraulic servo piston chamber j, pushes servo piston
pressure in chamber c, and stops at a point (19) to the left, increases the swash plate
where it balances the pressure of springs (4) angle in the main piston pump and increases
and (4A). the pump discharge amount.
At the same time, arm (6) uses servo piston • When servo piston (19) moves, arm (6) ro-
(19) as a fulcrum and sways to the left in the tates clockwise with its center at pin (7).
same way as control piston (8). This moves Guide spool (13) is moved to the right and
guide spool (13) to the left. closes port a, port d and port h, so the dis-
• When guide spool (13) moves, port a and charge increases by an amount that matches
port d are closed and port d is connected to signal pressure Pecn.
10-36 PC1100-6
2) Operation in direction of decrease of pump discharge amount (min. angle)
• When signal pressure Pecn goes down, con- At the same time, port a is interconnected
trol piston (8) moves to the right and stops with port d, so the oil flows through port g
at a point where the hydraulic pressure in to servo piston chamber f, pushes servo pis-
chamber c balances the pressure of springs ton (19) to the right, decreases the swash
(4) and (4A). plate angle in the main piston pump and
At the same time, arm (6) uses servo piston decreases the pump discharge amount.
(19) as a fulcrum and sways to the right in • When servo piston (19) moves, arm (6) ro-
the same way as control piston (8). This tates counterclockwise with its center at pin
moves guide spool (13) to the right. (7). Guide spool (13) is moved to the left and
• When guide spool (13) moves, port a and closes port a, port d and port h, so the dis-
port h are closed and port h is connected to charge decreases by an amount that matches
drain chamber e. As a result, servo piston signal pressure Pecn.
chamber j is also interconnected with cham-
ber e through port i and port h.
PC1100-6 10-37
4. TVC valve
PA1 : Main pump pressure IN port

PA2 : Main pump pressure IN port 1. Spring 6. Piston
PA3 : Swing pump pressure IN port 2. Spool 7. Body
Pd : TVC valve drain OUT port 3. Piston 8. Solenoid
Pe : TVC valve output pressure OUT port 4. Piston 9. Sleeve
Psv : Servo basic pressure IN port 5. Sleeve 10. Piston
10-38 PC1100-6
OPERATION AND FUNCTION OF TVC VALVE

1) When command current value from controller is small in DH and H mode
Function Operation
• When the power mode is at DH mode or H • The command current sent from the con-
mode, the pump discharge amount is controller actuates solenoid push pin (9) and
trolled to the optimum amount by the com- spool (2) moves. When this happens, the
mand current sent from the controller in ac- piston stops at a point where it balances the
cordance with the variation in the engine total of the force of spring (1), the force of
speed. push pin (9), and the force of
• In G mode or when the pump prolix switch TVC output pressure Pe acting on piston (3).
is ON, the pump discharge amount is con- The command current at this point is small,
trolled according to the pump discharge pres- so spool (2) is balanced at the bottom.
sure (load) by hydraulic sensing which fol- As a result, port a and port b are almost
lows a constant pump absorption torque. completely open, so the pressure oil from
the control pump is almost all output as TVC
fl For details, see MACHINE CONTROL SYS- output pressure Pe.
TEM. In this way, the pump discharge amount be-
comes the maximum.
PC1100-6 10-39
2) When command current value from controller is large in DH and H mode
Operation
• The command current sent from the con-
troller actuates solenoid push pin (9) and
spool (2) moves. When this happens, the
piston stops at a point where it balances the
force of spring (1). The command current at
this point is large, so spool (2) is balanced at
the top.
As a result, the flow of oil from the control
pump at port a and port b is throttled. At the
same time, the area of the opening at port b
and port c (drain port) becomes larger.
In this way, TVC output pressure Pe goes
down, and the pump discharge amount de-
creases.
10-40 PC1100-6
3) When pump load is small in G mode (pump prolix switch ON)
• When G mode is selected (pump prolix • Main pump discharge pressures PA1 and
switch ON) solenoid push pin (9) is pushed PA2 are low, so spool (2) is pushed down
up, increases the set pressure of spring (1), fully by spring (1). As a result, control pump
and this condition is maintained. discharge pressure Psv and TVC valve out-
• As a result, the pump absorption torque be- put pressure Pe are equal.
comes constant, so TVC output pressure Pe At this point, TVC valve output pressure Pe
(= pump discharge amount) is controlled by becomes the maximum, and the main pump
the pump discharge pressure. discharge amount is also the maximum.
PC1100-6 10-41
4) When pump load is large in G mode (pump prolix switch ON)
• When main pump discharge pressure PA1

(or PA2) increases, spool (2) is moved up by
piston (4) or piston (6). As a result, the flow
of oil from port a to port b is throttled by the
notch in the spool. At the same time, the
area of the opening at port b and port c
(drain port) becomes larger. In this way, TVC
output pressure Pe goes down, and the
pump discharge amount decreases.
10-42 PC1100-6
5. No. 1 pump front CO, NC valve
PA1I : Main pump pressure IN port Pd : Jet sensor downstream pressure IN port
Pe1 : TVC valve output pressure front, rear Pt : Jet sensor upstream pressure IN port
interconnection port Pdr2 : Servo valve drain OUT port
Pe2 : TVC valve output pressure detection port Pecn : CO, NC valve output pressure OUT port
PC1100-6 10-43
6. No. 1 pump rear CO, NC valve
PA1I :Main pump pressure IN port Pd : Jet sensor downstream pressure IN port
PA1o :Main pump pressure OUT port Pt : Jet sensor upstream pressure IN port
PA2I :Main pump pressure IN port Pdr1 : Servo valve drain IN port
PA2o :Main pump pressure OUT port Pdr2 : Servo valve drain OUT port
Pe1 : TVC valve output pressure front, rear in- Psv1 : Servo basic pressure IN port
terconnection port Psv2 : Servo basic pressure OUT port
Pe2 : TVC valve output pressure IN port Pecn : CO, NC valve output pressure OUT port
10-44 PC1100-6
CO valve NC valve
1. Plug 7. Plug
2. Piston 8. Sleeve
3. Spring 9. Piston
4. Spool 10. Spool
5. Piston 11. Spring
6. Plug 12. Plug
PC1100-6 10-45
FUNCTION AND OPERATION OF CO VALVE

1) When main pump discharge pressure is lower than relief pressure
Function Operation
• When the load becomes large during opera- • Spool (4) is being pushed down fully by
tions and the main pump discharge pres- spring (3).
sure rises to a point close to relief pressure, As a result, port a and port b are fully open
the cut-off function of the CO valve acts to and TVC valve output pressure Pe and CO
reduce the pump discharge in order to re- valve output pressure Pec are equal.
duce relief loss. In this way, CO valve output pressure Pec
• At the same time, it has a cut-off cancel becomes the maximum and the main pump
function actuated by the pilot pressure from discharge amount also becomes the maxi-
the heavy-lift solenoid valve. mum.
• The CO valve is controlled by balancing the
spring with the total of main pump discharge
pressure PA and CO valve output pressure
Pec.
10-46 PC1100-6
2) When main pump discharge pressure becomes close to relief pressure
• If the load increases and main pump dis-

charge pressure PA comes close to the relief
pressure, main pump discharge pressure PA
pushes piston (5). At the same time, CO valve
output pressure Pec pushes piston (5), and
spool (4) moves up.
As a result, the flow of oil from port a to
port b is throttled by the notch in the spool,
and the area of the opening at port b and
port c (drain port) becomes larger.
In this way, CO valve output pressure Pec
goes down, and the pump discharge amount
becomes the minimum.
PC1100-6 10-47
3) When cut-off function is canceled by heavy-lift solenoid valve
• When the heavy-lift solenoid valve is excited

and is switched, pilot pressure Pc is sent to
the port, and piston (2) is pushed down fully.
For this reason, seat (6) contacts seat (7)
and spool (4) is locked.
As a result, main pump discharge pressure
PA goes up, but even when it reaches the
relief pressure, spool (4) is not actuated, so
CO valve output pressure Pec remains at the
maximum.
10-48 PC1100-6
FUNCTION AND OPERATION OF NC VALVE

1) When control valve is at neutral
Function Operation
• The NC valve controls the main pump dis- • When control valve is at neutral, jet sensor
charge amount according to the amount that differential pressure (Pt – Pd) becomes the
the control valve spool is operated. This flow maximum, and the force of jet sensor out-
control function reduces the neutral loss and put pressure Pt pushing piston (10) becomes
fine control loss. larger than the total of the force of spring
• The NC valve is controlled by balancing the (12) and the force of jet sensor output pres-
total of the jet sensor output pressure Pt sure Pd pushing the bottom of spool (11).
and the NC valve output pressure Pecn with As a result, spool (11) is pushed down, so
the total of the force of NC valve spring (12) the flow to port c and port b is throttled, and
and the jet sensor output pressure Pd. the area of the opening of port b and port a
• The jet sensor picks up the flow of oil re- (drain port) becomes larger. In this way, NC
turning to the tank through the control valve valve output pressure Pecn becomes the
and takes them as Pt and Pd of the NC valve. minimum, and the main pump discharge
amount also becomes the minimum.
PC1100-6 10-49
2) When control lever is operated
• When the control valve is moved, the jet

sensor differential pressure (Pt – Pd) goes
down in accordance with the movement of
the control valve. Spool (11) is pushed up,
and the area of the opening of port c and
port b becomes larger.
In this way, NC valve output pressure Pecn
becomes larger and the discharge amount
from the main pump increases. In other
words, the pump discharge amount in-
creases according to the amount the control
lever is operated.
10-50 PC1100-6
NO. 2 PUMP
HPV95+95
1. Front pump PA1 : Discharge port Pt : Jet sensor upstream

3. Rear servo valve Pd : Jet sensor downstream Psv : Servo basic pressure IN
4. Rear pump pressure IN port port
Pd11 : Drain port Pecn : CO, NC valve output
Pd21 : Drain port pressure IN port
Ps : Suction port
PC1100-6 10-51
1. No. 2 main pump

10-52 PC1100-6
1. Front shaft 8. Front end cap 15. Rear case

2. Front cradle 9. Coupling 16. Rocker cam
3. Front case 10. Impeller 17. Rear cradle
PC1100-6 10-53
2. No. 2 pump front servo
1. Servo valve PA1 : Main pump pressure IN port

PA2 : Main pump pressure IN port
Pdr : Servo valve drain OUT port
Pecn : CO, NC valve output pressure IN port
10-54 PC1100-6
3. No. 2 pump rear servo
1. Servo valve PA1 : Main pump output pressure OUT port

PA2 : Main pump output pressure IN port
Pecn : CO, NC valve output pressure IN port
PC1100-6 10-55
NO. 3 PUMP
HPV160+160
1. Front pump PA1 : Discharge port Pe : TVC valve output

3. Front CO, NC valve Pd11 : Drain port Ps : Suction port
4. Rear servo valve Pd21 : Drain port Pt : Jet sensor upstream
5. Rear pump Pc : CO selector pilot port pressure IN port
Pd : Jet sensor downstream Psv : Servo basic pressure
pressure IN port IN port
PC1100-6 10-57
1. No. 3 main pump
PA1 : Pump discharge port Psv1A : Servo piston output port

PA2 : Pump discharge port Psv1B : Servo valve output port
Psv1 : Servo valve basic pressure port Psv2A : Servo piston output port
Psv2 : Servo valve basic pressure port Psv2B : Servo valve output port
10-58 PC1100-6
1. Front shaft 8. Front end cap 15. Rocker cam

2. Front cradle 9. Impeller 16. Rear case
3. Front case 10. Coupling 17. Rear cradle
PC1100-6 10-59
2. No. 3 pump front servo assembly
1. CO, NC valve Pc : CO selector pilot port

2. Servo valve Pd : Jet sensor downstream pressure IN port
Pt : Jet sensor upstream pressure IN port
Pe1 : TVC valve output pressure IN port Psv : Servo basic pressure IN port
Pe2 : TVC valve output pressure front, rear in- Pecn : CO, NC valve output pressure OUT port
terconnection port
10-60 PC1100-6
No. 3 pump front servo valve
PA2(IN) : Main pump pressure IN port Pdr(OUT) : Servo valve drain OUT port
PA2(OUT) : Main pump pressure OUT port Psv1 : Servo basic pressure IN port
Pdr(IN) : CO, NC valve drain Pdr IN port
PC1100-6 10-61
3. No. 3 pump rear servo
1. Servo valve PA1 : Main pump output pressure P1 IN port

PA2 : Main pump output pressure P2 IN port
10-62 PC1100-6
4. No. 3 pump CO, NC valve
PA1I : Main pump pressure IN port Pd : Jet sensor downstream pressure IN port
Pe1 : TVC valve output pressure IN port Pt : Jet sensor upstream pressure IN port
Pe2 : TVC valve output pressure detection port Pdr2 : Servo valve drain OUT port
Pc : CO selector pilot port Pecn : CO, NC valve output pressure OUT port
10-64 PC1100-6
CO valve NC valve
1. Plug 8. Plug
2. Piston 9. Sleeve
3. Spool 10. Piston
4. Spring 11. Spool
5. Piston 12. Spring
6. Plate 13. Plug
7. Plug
PC1100-6 10-65
Function and operation of CO valve for No. 3 pump:

fl Structurally, the CO valve for the No. 3 pump does not function.
• Structurally, the CO valve for the No. 3 pump

is set so that it does not function. As a re-
sult, when main pump discharge pressure
PA rises and reaches the relief pressure,
spool (4) is not actuated and CO valve out-
put pressure Pec always remains at the maxi-
mum.
10-66 PC1100-6
STRUCTURE AND FUNCTION LINE OIL FILTER
LINE OIL FILTER
1. Element Outline
2. Case There are three line oil filters installed to the
3. Cover discharge side of the main pump. They protect
the circuit and equipment by removing all dirt
A : From main pump and dust from the oil.
B : To control valve
PC1100-6 10-67
STRUCTURE AND FUNCTION PILOT OIL FILTER
PILOT OIL FILTER
1. Relief valve Outline

2. Case The pilot oil filter is installed to the discharge
3. Element side of the control pump and protects the PPC
4. Center bolt valve and other pilot pressure equipment.
10-68 PC1100-6
STRUCTURE AND FUNCTION RETURN OIL FILTER
RETURN OIL FILTER
1. Cover Outline
2. Spring There are two return oil filters installed to the
3. Bypass valve rear face of the hydraulic tank. They remove the
4. Bypass valve spring dirt and dust in the return oil.
5. Element
6. Housing Specifications
• Bypass valve set pressure:
A : From control valve 0.10 ± 0.02 MPa {1.05 ± 0.2 kg/cm2}
B : To hydraulic tank
PC1100-6 10-69
STRUCTURE AND FUNCTION DRAIN OIL FILTER
DRAIN OIL FILTER
1. Bracket Outline
2. Safety valve The drain oil filters are installed between the
3. Cartridge hydraulic tank and the travel motor, swing mo-
4. Filter tor, and aftercooler fan drive motor. They re-
move the dirt and dust in the oil from each
motor drain port.
Specifications
• Safety valve set pressure:
0.10 MPa {1.05 kg/cm2}
10-70 PC1100-6
STRUCTURE AND FUNCTION L.H. 5-SPOOL CONTROL VALVE
L.H. 5-SPOOL CONTROL VALVE
A1 : Plug P : From No. 1, No. 2 main pump PB3 : From L.H. PPC valve
A2 : To boom cylinder P1 : To R.H. 4-spool control valve P2 PB4 : From R.H. PPC valve
A3 : To arm cylinder T : To hydraulic tank PB5 : From L.H. travel PPC
A4 : To bucket cylinder PA1 : Plug valve
A5 : To L.H. travel motor P2 PA2 : From R.H. PPC valve PP : 2-stage main relief
B1 : Plug PA3 : From L.H. PPC valve solenoid valve
B2 : Plug PA4 : From R.H. PPC valve NCA : To NC valve at rear
B3 : To arm cylinder PA5 : From L.H. travel PPC valve of No. 1 main pump
B4 : To bucket cylinder PB1 : Plug NCB : To NC valve at rear
B5 : To L.H. travel motor P1 PB2 : From R.H. PPC valve of No. 1 main pump
10-72 PC1100-6
STRUCTURE AND FUNCTION L.H. 5-SPOOL CONTROL VALVE
1. Main relief valve 6. Spool (boom Hi) 11. Throttle valve

2. Spool return spring 7. Spool (bottom) 12. Check valve with orifice
3. Spool (L.H. travel) 8. Jet sensor orifice 13. Check valve spring
4. Spool (bucket Hi) 9. Jet sensor relief valve 14. Suction-safety valve
5. Spool (arm Lo) 10. Valve body 15. Suction valve
PC1100-6 10-73
STRUCTURE AND FUNCTION R.H. 4-SPOOL CONTROL VALVE
R.H. 4-SPOOL CONTROL VALVE
A1 : To R.H. travel motor P1 P2 : To L.H. 5-spool control PB4 : From L.H. PPC valve
A2 : To boom cylinder valve P1 PP : From control pump
A3 : To bucket cylinder T : To hydraulic tank PR : From 2-stage main
A4 : To arm cylinder PA1 : From R.H. travel PPC valve relief solenoid valve
B1 : To R.H. travel motor P2 PA2 : From R.H. PPC valve PS : From 2-stage safety
B2 : To boom cylinder PA3 : From R.H. PPC valve solenoid valve
B3 : To bucket cylinder PA4 : From L.H. travel PPC valve PT : To hydraulic tank
B4 : To arm cylinder PB1 : From R.H. travel PPC valve NCA : To NC valve at front
P : From No. 1, No. 2 main pump PB2 : From R.H. PPC valve of No. 1 main pump
P1 : From No. 1, No. 2 main pump PB3 : From R.H. PPC valve NCB : To NC valve at front
of No. 1 main pump
10-74 PC1100-6
STRUCTURE AND FUNCTION R.H. 4-SPOOL CONTROL VALVE
1. Main relief valve 6. Spool return spring 11. Check valve spring
2. Spool (R.H. travel) 7. Valve body 12. Straight-travel valve
3. Spool (boom Lo) 8. Jet sensor orifice 13. Suction valve
4. Spool (bucket Lo) 9. Jet sensor relief valve 14. Suction-safety valve
5. Spool (arm Hi) 10. Check valve 15. Suction-safety valve
PC1100-6 10-75
STRUCTURE AND FUNCTION SWING 4-SPOOL CONTROL VALVE
SWING 4-SPOOL CONTROL VALVE
A1 : To boom cylinder P : From No. 3 main pump PB3 : From R.H. PPC valve
A2 : To swing motor MB T : To hydraulic tank PB4 : From L.H. PPC valve
A3 : To bucket cylinder PA1 : From control pump PR : From 2-stage main relief
A4 : To arm cylinder PA2 : From L.H. PPC valve solenoid valve
B1 : Plug PA3 : From L.H. PPC valve NCA : To NC valve at front of
B2 : To swing motor MA PA4 : From L.H. PPC valve No. 3 main pump
B3 : Plug PB1 : From L.H. PPC valve NCB : To NC valve at front of
B4 : To arm cylinder PB2 : From L.H. PPC valve No. 3 main pump
10-76 PC1100-6
STRUCTURE AND FUNCTION SWING 4-SPOOL CONTROL VALVE
1. Main relief valve 6. Spool return spring 11. Piston

2. Spool (for swing) 7. Valve body 12. Check valve spring
3. Spool (for boom plus) 8. Jet sensor orifice 13. Check valve
4. Spool (for bucket plus) 9. Jet sensor relief valve 14. Safety valve with suction
5. Spool (for arm plus) 10. Check valve with orifice
PC1100-6 10-77
STRUCTURE AND FUNCTION STRAIGHT-TRAVEL VALVE
STRAIGHT-TRAVEL VALVE
P : From pump at front of No. 1 main pump Outline

P1 : From pump at rear of No. 1 main pump • The straight-travel valve is installed to the
P2 : To L.H. travel spool of L.H. 5-spool R.H. 4- spool control valve. It acts to prevent
control valve any deviation in the direction of travel if the
P3 : To bucket, boom spool boom, arm, or bucket are operated when
P4 : To arm spool the machine is traveling.
PP : From control pump
PT : To hydraulic tank
10-78 PC1100-6
1. Orifice
2. Check valve
3. Spring
4. Spool return spring
5. Body
6. Spool
7. Cover
PC1100-6 10-79
Function
• When the travel is operated at the same time
as the boom, arm, or bucket, the pressure
oil flowing to the left and right travel circuits
is divided and sent to the boom, arm, or
bucket circuit. If the oil in one travel circuit
is divided off, the amount of oil supplied to
the travel motor will be less than in the travel
circuit which is not divided, so the drop in
the supply of oil to the travel motor will
cause the machine to deviate.
• To prevent this, the straight-travel valve is
switched to interconnect the left and right
travel circuits. This ensures that the amount
of oil supplied to the left and right travel
motors is equal, so the left and right travel
motors both rotate at the same speed, and
this prevents any travel deviation.
Operation
When travel is operated independently (straight-
travel solenoid valve de-energized)
• The straight-travel solenoid valve is de-en-
ergized, so no pilot pressure flows, and spool
(6) remains pushed to the left.
• Because of this, port P2 (left travel circuit)
and port P1 (right travel circuit) are not in-
terconnected, and each circuit remains inde-
pendent.
When travel and work equipment are operated

at same time (straight-travel solenoid valve ex-
cited)
• The straight-travel solenoid valve is excited,
so the pilot pressure flows and spool (6) is
pushed to the right.
• Because of this, port P2 and port P1 are
interconnected, so the amount of oil sup-
plied to the left and right travel motors is
the same. As a result, the left and right travel
motors both rotate at the same speed, so
there is no travel deviation.
10-80 PC1100-6
STRUCTURE AND FUNCTION BOOM LOWER REGENERATION VALVE
BOOM LOWER REGENERATION VALVE
T : To tank
PB : From boom cylinder bottom
PM : From boom cylinder head
Pi : From boom LOWER PPC valve
10-82 PC1100-6
1. Body
2. Spool
3. Check valve
4. Spring
5. Spring (small)
6. Spring (large)
PC1100-6 10-83
Function
• When the boom is lowered, some of the oil
drained from the bottom end of the boom
cylinder is circulated to the cylinder head to
increase the lowering speed of the boom.
Operation
1. When control lever (1) is operated to the
LOWER position, PPC pressure flows and
boom Lo spool (2) moves to the LOWER
position. At the same time, regeneration
valve spool (3) is moved by the PPC pres-
sure from port Pi. As a result, the head and
bottom ends of boom cylinder (4) are inter-
connected through ports PB and PM.
2. When this happens, the oil from the cylinder
bottom passes through the control valve and
returns to tank (5). Some of the oil enters
port PB of the regeneration valve and flows
from port PM to the cylinder head to in-
crease the lowering speed of the boom.
3. The boom cylinder has a large volume, and
during compound operations, the oil flow
from the pump to the cylinder head is insuf-
ficient, so this action prevents any vacuum
from forming inside the circuit.
10-84 PC1100-6
STRUCTURE AND FUNCTION SWING MOTOR
SWING MOTOR
KMF160AB-2
1. Swing motor Specifications

2. Swing holding brake Model: KMF160AB-2
Theoretical discharge: 160.7 cc/rev
B : From swing holding brake solenoid valve Rated speed: 1830 rpm
S : From tank Brake release pressure:
T1 : To tank 1.8 ± 0.4 MPa {18.4 ± 4 kg/cm2}
T2 : From cooling piping port S
MA : From swing control valve port B1
MB : From Swing control valve port A1
10-86 PC1100-6
STRUCTURE AND FUNCTION SWING MOTOR
1. SWING MOTOR
1. Housing
2. Brake spring (Belleville spring)
3. Brake piston
4. Plate
5. Disc
6. Brake case
7. Output shaft
8. Cylinder block
9. Piston
10. Valve plate
11. Center shaft
2. SAFETY VALVE
1. Safety valve Specifications

2. Housing Safety valve set pressure:
3. Check valve 27 MPa {275 kg/cm2} (at 300 ¬/min)
4. Check valve spring Cracking pressure:
Min. 19.6 MPa {200 kg/cm2} (at 5 ¬/min)
Check valve set pressure: 0.03 MPa {0.3 kg/cm2}
PC1100-6 10-87
STRUCTURE AND FUNCTION CENTER SWIVEL JOINT
CENTER SWIVEL JOINT
1. Cover A1 : From L.H. travel control valve port B5

2. Body A2 : To L.H. travel motor port P1
3. Slipper seal B1 : From L.H. travel control valve port A5
4. Oil seal B2 : To L.H. travel motor port P2
5. Shaft C1 : From R.H. travel control valve port B1
C2 : To R.H. travel motor port P2
D1 : From R.H. travel control valve port A1
D2 : To R.H. travel motor port P1
P1 : From travel speed selector solenoid valve
P2 : To L.H., R.H. travel speed selector valve
T1 : To hydraulic tank
T2 : From L.H. and R.H. travel motor port Dr
10-88 PC1100-6
STRUCTURE AND FUNCTION TRAVEL MOTOR
TRAVEL MOTOR
MSF-340VP
1. Travel selector valve Specifications

2. Motor Model : MSF-340VP
3. Travel brake valve Theoretical delivery : 1st 337.2 cc/rev
: 2nd 228.6 cc/rev
Rated pressure : 34.3 MPa {350 kg/cm2}
P1 : From control valve Rated speed : 1st 1,465 rpm
P2 : From control valve (at 494 ¬/min.)
PI : From travel speed solenoid valve : 2nd 2,161 rpm
T : To hydraulic tank (at 494 ¬/min.)
Brake release pressure : 1.7 MPa {17 kg/cm2}
PC1100-6 10-89
1. Travel motor, travel speed selector valve, parking brake
1. Travel speed selector valve

1a. Spool
1b. Spring
2. Relief valve
2a. Shockless piston
2b. Poppet
10-90 PC1100-6
3. Rear cover 10. Piston assembly 17. Plate

4. Collar 11. Case 18. Brake piston
5. Valve plate 12. Shaft 19. Spring
6. Cylinder block assembly 13. Steel ball
7. Piston assembly 14. Rocker cam
8. Holder 15. Preload spring
9. Retainer 16. Disc
PC1100-6 10-91
1-1 Motor
• There are 9 pistons (7) assembled in cylin-

der block (6). The end face of the cylinder
block has a spherical surface and is in con-
tact with valve plate (5), which has two half-
moon shaped ports (divider valve for high/
low speed selector).
• The fixed surface (contact surface with the

motor case) forming the non-sliding surface
of rocker cam (13) has two faces. The high/
low speed volume selection for this motor is
carried out by fixing each face to provide
large capacity (low speed) or small capacity
(high speed).
The angling operation of rocker cam (14) is
carried out by actuating control piston (10)
with the self-pressure through the speed se-
lector valve when the motor is being driven,
and this angles the rocker cam.
There are two control pistons each for the
high/low pressure divider ports of valve plate
(5), and these provide propulsion force to
the rocker cam.
10-92 PC1100-6
1-2 Speed selector valve

Operation
1) At low speed (pilot pressure PI = 0)
• When pilot pressure PI from the control (1a) and is drained into the motor case. There
pump is 0, spool (1a) of travel speed selec- is no angle propulsion force acting on rocker
tor valve (1) is not switched. cam (14), so the low-speed surface is kept in
In this condition, the oil from the chamber a static condition.
of control piston (10) passes through spool
PC1100-6 10-93
2) At high speed (automatic 2nd)
• When the pilot signal is ON, pilot pressure When this happens, the main oil pres-
PI from the control pump acts on travel speed sure (M1, M2) passes through spool (1a)
selector valve (1) and the capacity is auto- and goes to the control piston chamber.
matically changed by the drive pressure of Rocker cam (14) overcomes moment Mx
the travel motor. with hydraulic force from propulsion
force Fc of control piston (10). It rotates
Balance of force for travel speed selector and holds the moment balance at the
valve high speed surface and is held in posi-
F1 [Force pushing spool (1a) to right (high- tion (Mx < Fc, L).
speed side)] = A (area of spool (1a) re- ii) When operating the steering or traveling
ceiving pressure) x PI uphill, if the motor drive pressure is high,
F2 [Force pushing spool (1a) to left (low- and it goes above the set pressure, the
speed side)] = A (area of spool (1a) re- condition becomes F1 < F2, and spool
ceiving pressure) x PH (motor drive pres- (1a) is pushed to the left.
sure) + force of spring (1b) When this happens, the main oil pres-
sure (M1, M2) passes through spool (1a)
i) When traveling on level ground, if the and is drained to the motor case. This
travel motor drive pressure is low, the creates the low-speed condition in the
condition becomes F1 > F2, and spool same way as when PI = 0.
(1a) is pushed to the right.
10-94 PC1100-6
1-3 Parking brake
The parking brake is a hydraulic release, wet

type, multiple disc negative brake. The re-
lease pressure employs a self-pressure re-
lease method using the travel motor drive
pressure through the oil passage in the coun-
terbalance valve spool of the travel brake
valve.
When the machine is traveling, the drive

pressure is sent to port P of the parking
brake circuit, acts on the piston in the brake
cylinder chamber, overcomes the force of
the spring and releases the brake.
When the machine is parked or stopped, the
counterbalance valve spool returns to neu-
tral, and the oil in the cylinder chamber is
released to the tank through the counterbal-
ance valve spool, so the brake is applied by
the force of the spring to mechanically lock
the motor shaft and hold the machine in
position.
When parking brake is ON

When the travel lever is placed in neutral,
the counterbalance valve spool returns to
the neutral position and parking brake cir-
cuit P is closed.
The pressurized oil in chamber e of the brake
piston passes through the counterbalance
valve spool, is drained to the tank, and brake
piston (18) is pushed fully to the left by force
Fs of spring (19), and the brake is applied.
When parking brake is OFF

When the travel lever is operated, the pres-
surized oil from the pump actuates the coun-
terbalance valve spool, opens the circuit to
the parking brake, and flows into chamber e
of brake piston (18). It overcomes the force
of spring (19), and pushes brake piston (18)
to the right.
When this happens, the force pushing plate
(17) and disc (16) together is lost, so the
plate and disc separate and the brake is re-
leased.
PC1100-6 10-95
1-4 Relief valve
1. Shockless piston
2. Poppet
a. Poppet orifice
b. Relief housing orifice
c. Piston stroke
Function
In addition to the pressure control function, this
relief valve has a shockless function (2-stage
pressure increase function). This acts to reduce
the shock generated at the beginning when the
speed is reduced (when the machine is stopped).
Operation
1) When relief valve starts to be actuated (1st
stage)
The area receiving the pressure which lifts
poppet (2) becomes area S1 of the poppet
seat.
For this reason, it has a much larger pres-
sure-receiving area than the pressure-receiv-
ing area when it is set (S1 – S2), so the relief
actuating pressure becomes a low pressure
of approx. 15.7 MPa {160 kg/cm2}.
This condition is maintained until the move-
ment of shockless piston (1) is completed
(approx. 0.25 sec).
2) When movement of shockless piston is com-

pleted (2nd stage)
The pressure in the relief valve spring cham-
ber rises, the pressure on both sides of pop-
pet (2) becomes the same, and it becomes
the specified set pressure.
fl Set pressure and amount of adjustment

Amount of adjustment for one turn:
Approx. 7.8 MPa {80 kg/cm2}
10-96 PC1100-6
2. Travel brake valve
Function 1. Cap assembly

• The brake valve consists of counterbalance 2. Return spring
valve (3) and check valve (5). 3. Counterbalance valve
• The counterbalance valve acts to prevent the 4. Body
piston motor from stopping or overrunning. 5. Check valve
• When traveling downhill, the weight of the 6. Check valve spring
machine makes it try to travel at a speed a. Orifice
faster than the rotation of the motor.
For this reason, if the machine is traveling
with the engine running at low speed, the Specification
motor will rotate under no load or may run Safety valve set pressure: 34 Mpa {350 kg/cm2}
away, which is extremely dangerous. Counterbalance switching pressure:
To prevent this, this valve controls the 1.0 ± 0.1 MPa {10 ± 1 kg/cm2}
amount of oil on the return side in order to Check valve switching pressure:
keep the valve pressure constant, and makes 0.02 ± 0.01 MPa {0.2 ± 0.1 kg/cm2}
it possible to carry out travel operations
which match the oil delivery from the mo-
tor.
PC1100-6 10-97
Operation when oil is supplied

• When the travel lever is operated, the pres-
surized oil from the control valve is supplied
to port P1. It pushes open check valve (5a)
and flows from motor inlet port M1 to mo-
tor outlet port M2.
However, the motor outlet port is closed by
check valve (5b) and spool (3), so the pres-
sure at the supply side rises.
• The pressurized oil at the supply side flows

from orifice a in spool (3) to chamber A.
When the pressure in chamber A goes above
the spool switching pressure, spool (3) is
pushed to the left.
As a result, port M2 and port P2 are con-
nected, the outlet port side of the motor is
opened, and the motor starts to rotate.
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
A through orifice a will also drop.
When the pressure in chamber A drops be-
low the spool switching pressure, spool (3)
is returned to the right by spring (2), and
outlet port M2 is throttled.
As a result, the pressure at the outlet port
side rises, resistance is generated to the ro-
tation of the motor, and this prevents the
machine from running away.
In other words, spool (3) moves to a posi-
tion where the pressure at outlet port M2
balances the pressure at the inlet port and
the force generated by the weight of the
machine. It throttles the outlet port circuit
and controls the travel speed according to
the amount of oil discharged from the pump.
10-98 PC1100-6
STRUCTURE AND FUNCTION PPC CONTROL RELIEF VALVE
PPC CONTROL RELIEF VALVE
1. Relief valve A: From PPC valve Specifications

2. Valve body B: From solenoid valve Set pressure: 3.1 +0.3 +3 2
+0 MPa {32 +0 kg/cm }
3. Check valve spring C: From pilot valve (at 182 ¬/min)
4. Check valve D: To PPC valve
E: To accumulator
F : To solenoid valve
P: From control pump
T: To tank
PC1100-6 10-99
STRUCTURE AND FUNCTION SAFETY LOCK VALVE
SAFETY LOCK VALVE
1. Lever
2. End cap
3. Ball
4. Seat
5. Body
Outline
• The safety lock valve is installed between
the PPC valve and the control relief valve in
the PPC circuit. If the work equipment safety
lever is set to the LOCK position, the safety
lock valve is interconnected with the work
equipment safety lever, so it is actuated. It
stops the oil in the PPC circuit and makes it
impossible to operate the work equipment.
10-100 PC1100-6
STRUCTURE AND FUNCTION ACCUMULATOR
ACCUMULATOR
For PPC valve
1. Gas plug
2. Shell
3. Poppet
4. Holder
5. Bladder
6. Oil port
Specifications
Type of gas : Nitrogen gas
Gas volume : 500 cc
Max. actuating pressure: 3.1 MPa {32 kg/cm2}
Min. actuating pressure : 1.2 MPa {12 kg/cm2}
Function
• The accumulator is installed between the PPC
control pump and the PPC valve. Even if the
engine is stopped with the work equipment
raised, pilot oil pressure is sent to the main
control valve by the pressure of the nitrogen
gas compressed inside the accumulator, so
it is possible to lower the work equipment
under its own weight.
Operation
• After the engine stops, when the PPC valve
is at neutral, chamber A inside the bladder
is compressed by the oil pressure in cham-
ber B.
• If the PPC valve is operated, the oil pressure
in chamber B becomes less than 2.9 MPa
{30 kg/cm2}, so the bladder expands under
the pressure of the nitrogen gas in chamber
A. The oil entering chamber B is sent as the
pilot pressure to actuate the main control
valve.
PC1100-6 10-101
STRUCTURE AND FUNCTION VALVE CONTROL
VALVE CONTROL
1. R.H. 4-spool control valve Lever positions

2. L.H. 5-spool control valve 1 HOLD 9 Swing right
3. Accumulator 2 Boom RAISE 0 Swing left
4. Swing 4-spool control valve 3 Boom LOWER A Neutral
5. Safety lock valve 4 Bucket DUMP B Travel REVERSE
6. Safety lock lever 5 Bucket CURL C Travel FORWARD
7. Left PPC valve 6 HOLD D LOCK
8. Left work equipment lever 7 Arm IN E FREE
9. Travel PPC valve 8 Arm OUT
10. L.H. travel lever
11. R.H. travel lever
12. Right PPC valve
13. Right work equipment lever
10-102 PC1100-6
STRUCTURE AND FUNCTION WORK EQUIPMENT, SWING PPC VALVE
WORK EQUIPMENT, SWING PPC VALVE
P : From control pump P2 : Left: Swing left, Right: Bucket CURL

T : To hydraulic tank P3 : Left: Arm OUT, Right: Boom LOWER
P1 : Left: Swing right, Right: Bucket DUMP P4 : Left: Arm IN, Right: Boom RAISE
10-104 PC1100-6
1. Spool 6. Nut (for connecting lever)

2. Metering spring 7. Joint
3. Centering spring 8. Plate
4. Piston 9. Retainer
5. Disc 10. Body
PC1100-6 10-105
Operation
1) At neutral
Ports A and B of the control valve and ports
P1, P2, P3, and P4 of the PPC valve are con-
nected to drain chamber D at the bottom.
(Fig. 1)
2) Fine control (neutral → fine control)

When piston (4) starts to be pushed by disc
(5), retainer (9) is pushed. Spool (1) is also
pushed by metering spring (2) and moves
down.
When this happens, port P1 is shut off from
drain chamber D. At almost the same time,
it is connected to pump pressure chamber
PP, and the pilot pressure of the control
pump is sent from port P1 to port A.
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 al-
most the same time, it is connected to drain
chamber D, so the pressure at port P1 es-
capes.
As a result, spool (1) moves up and down
until the force of metering spool (2) is bal-
anced with the pressure of port P1.
The relationship of the positions of spool (1)
and body (10) does not change until retainer
(9) contacts spool (1).
Therefore, metering spring (2) is compressed
in proportion to the travel of the control le-
ver, so the pressure at port P1 also rises in
proportion to the travel of the control lever.
In this way, the spool of the control valve
moves to a position where the pressure of
chamber A (same as pressure at port P1)
and the force of the return spring of the
control valve spool are balanced. (Fig. 2)
10-106 PC1100-6
3) Fine control (control lever returned)

When disc (5) starts to be returned, spool (1)
is pushed up by the force of centering spring
(3) and the pressure at port P1.
Because of this, port P1 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 port P1 is shut off from drain cham-
ber D. At almost the same time, it is con-
nected 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 returns, oil in drain
chamber D flows in from the valve on the
side that is not moving. It passes through
port P2 and goes to chamber B to charge
the oil. (Fig. 3)
4) At full stroke
When disc (5) pushes down piston (4), and
retainer (9) pushes down spool (1), port P1
is shut off from drain chamber D, and is
connected to pump pressure chamber PP.
Therefore, the pilot pressure oil from the
control pump flows to chamber A from port
P1 to push the control valve spool.
The return oil from chamber B passes from
port P2 and flows to drain chamber D. (Fig.
4)
PC1100-6 10-107
STRUCTURE AND FUNCTION TRAVEL PPC VALVE
TRAVEL PPC VALVE
P : From control pump

T : To hydraulic tank
P1 : L.H. travel FORWARD
P2 : L.H. travel REVERSE
P3 : R.H. travel FORWARD
P4 : L.H. travel REVERSE
10-108 PC1100-6
1. Piston 5. Valve
2. Plate 6. Metering spring
3. Collar 7. Centering spring
4. Body 8. Bolt
PC1100-6 10-109
Operation
1) At neutral
Ports A and B of the control valve and ports
P1 and P2 of the PPC valve are connected to D
drain chamber D through fine control hole f
in spool (1). (Fig. 1)
f
T
P
P1 P2
A Control valve B
(Fig. 1)
SBP00281
2) Fine control (neutral → fine control)

When piston (4) starts to be pushed by disc
(5), retainer (9) is pushed. Spool (1) is also
pushed by metering spring (2) and moves
down. 5
When this happens, fine control hole f is 4
shut off from drain chamber D. At almost D
9
the same time, it is connected to pump pres-
sure chamber PP, and the pilot pressure of 2
the control pump is sent from port A through f T
fine control hole f to port P1.
When the pressure at port P1 rises, spool (1) P
is pushed back. Fine control hole f is shut
off from pump pressure chamber PP. At al- 1
most the same time, it is connected to drain PP
chamber D, so the pressure at port P1 es- P1 P2
10
capes.
As a result, spool (1) moves up and down
A Control valve B
until the force of metering spool (2) is bal-
anced with the pressure of port P1. (Fig. 2)
The relationship of the positions of spool (1)
and body (10) (fine control hole f is in the SBP00282
middle between drain hole D and pump pres-
sure chamber PP) does not change until re-
tainer (9) contacts spool (1).
Therefore, metering spring (2) is compressed
in proportion to the travel of the control le-
ver, so the pressure at port P1 also rises in
proportion to the travel of the control lever.
In this way, the spool of the control valve
moves to a position where the pressure of
chamber A (same as pressure at port P1)
and the force of the return spring of the
control valve spool are balanced. (Fig. 2)
10-110 PC1100-6
3) Fine control (control lever returned)

When disc (5) starts to be returned, spool (1)
is pushed up by the force of centering spring
(3) and the pressure at port P1. 5
Because of this, fine control hole f is con-
nected to drain chamber D, and the pressu-
rized oil at port P1 is released. 3 D
If the pressure at port P1 drops too much, 2
spool (1) is pushed down by metering spring
(2), so fine control hole f is shut off from f T
drain chamber D. At almost the same time, P
it is connected to pump pressure chamber f'
PP, so the pressure at port P1 supplies the
1
pump pressure until the pressure recovers
PP
to a pressure equivalent to the position of
P1 P2
the lever.
When the control valve returns, oil in drain
chamber D flows in from fine control hole f’ A B
Control valve
of the valve on the side that is not moving.
It passes through port P2 and goes to cham- (Fig. 3)
ber B to charge the oil. (Fig. 3)
SBP00283
4) At full stroke
Disc (5) pushes down piston (4), and retainer
(9) pushes down spool (1). Fine control hole
f is shut off from drain chamber D, and is 5
connected to pump pressure chamber PP.
4
Therefore, the pilot pressure oil from the D
control pump passes through fine control 9
hole f and flows to chamber A from port P1
to push the control valve spool. f T
The return oil from chamber B passes from
port P2 through fine control hole f’ and flows P
f'
to drain chamber D. (Fig. 4)
1
PP
P1 P2
A Control valve B
(Fig. 4)
SBP00284
PC1100-6 10-111
STRUCTURE AND FUNCTION SOLENOID VALVES
SOLENOID VALVES
• Solenoid valve A: Swing holding brake, travel speed selector
• Solenoid valve B: Straight travel, machine push-up
• Solenoid valve C: CO cancel, heavy lift, swing priority selector
Solenoid valve A
1. Front swing solenoid valve Outline
2. Travel speed selector solenoid valve There are three solenoid valves installed. They
3. Rear swing solenoid valve respectively control the hydraulic equipment
Solenoid valve B listed in the table below.
1. Straight-travel solenoid valve Connected
2. — port
A1 A2 A3
3. Machine push-up solenoid valve Solenoid
valve
Solenoid valve C A
1. CO cancel solenoid valve Front swing L.H., R.H. Rear swing
(Center of motor travel motor motor
2. Heavy lift solenoid valve chassis)
3. Swing priority selector solenoid valve Straight- Safety valve
B travel valve at boom
(Center of of R.H. 4- — head end of
A1 : See table on right chassis) spool control R.H. 4-spool
A2 : See table on right valve control valve
A3 : See table on right C CO valve of R.H. 4-spool Swing 4-
(Rear of control valve, spool control
P : From control pump hydraulic
No. 1, 3
L.H. 5-spool
T : To hydraulic tank pump valve
tank) control valve
10-112 PC1100-6
STRUCTURE AND FUNCTION SOLENOID VALVES
1. Connector
2. Variable iron core
3. Coil
4. Push pin
5. Spring
6. Spool
7. Body
Operation
When solenoid is deenergized
• No signal current flows from the controller,
so coil (3) is deenergized.
• Because of this, spool (6) is pushed fully to
the left by spring (5).
• As a result, port P is closed, so pressure oil
from the control pump does not flow to the
actuator.
At the same time, the oil from the actuator
flows from port A to port T and is drained to
the tank.
When solenoid is energized

• When the signal current flows from the con-
troller to coil (3), coil (3) is energized.
• Because of this, spool (6) is pushed to the
right by push pin (4).
• As a result, pressure oil from the control
pump flows from port P to port A, and then
flows to the actuator.
At the same time, port T is closed, so the oil
does not flow to the tank.
PC1100-6 10-113
STRUCTURE AND FUNCTION WORK EQUIPMENT
WORK EQUIPMENT
BACK HOE
1. Arm
2. Bucket cylinder
3. Arm cylinder
4. Boom
5. Boom cylinder
6. Bucket
10-114 PC1100-6
STRUCTURE AND FUNCTION AIR CONDITIONER
AIR CONDITIONER
AIR CONDITIONER PIPING
STD CAB SPECIFICATION
1. Duct A : Fresh air

2. Condenser B : Recirculated air
3. Air conditioner compressor C : Hot air/cold air
4. Hot water return piping
5. Hot water pickup piping
6. Refrigerant piping
7. Receiver tank
8. Air conditioner unit
PC1100-6 10-115
STRUCTURE AND FUNCTION ACTUAL ELECTRIC WIRING DIAGRAM
ACTUAL ELECTRIC WIRING DIAGRAM

BACK HOE (1/2)
10-116 PC1100-6
PC1100-6 10-117
(2/2)
10-118 PC1100-6
PC1100-6 10-119
STRUCTURE AND FUNCTION ELECTRICAL CIRCUIT DIAGRAM
1. Boom working lamp 45. Air cleaner clogging sensor

2. Battery 46. Starting motor
3. Battery relay 47. No. 1 engine speed sensor
4. Fusible link 48. No. 2 engine speed sensor
5. APS controller 49. TVC solenoid valve
6. Fuel level sensor 50. Engine oil pressure switch
7. Room lamp (low temperature)
8. Horn valve 51. Engine oil pressure switch
9. Swing holding brake solenoid valve (high temperature)
10. Travel speed selector solenoid valve 52. Engine oil level sensor
11. Swing holding brake solenoid valve 53. Fuel injection pump
12. Straight-travel solenoid valve (with electronic governor)
14. Machine push-up solenoid valve 54. APS nozzle & glow plug
15. CO cancel solenoid valve 55. Relay for swing holding brake
16. Heavy lift solenoid valve 56. Relay for boom shockless
17. Swing priority solenoid valve 57. Relay for boom light
18. Hydraulic tank level sensor 58. Alarm buzzer
19. Hydraulic oil temperature sensor (high 59. Relay for head light
temperature) 60. Starting switch
20. Step light 61. Horn switch
21. Boom shockless (LOWER) solenoid valve 62. Fuel control dial
22. Washer tank 63. Cigar lighter
23. Boom shockless (RAISE) solenoid valve 64. Radio
24. Air conditioner unit 65. Air conditioner controller
25. Flash light 66. APS actuation switch
26. Wiper motor 67. Pump controller
27. Cab front lamp 68. R.H. speaker
28. R.H. working lamp 69. Engine controller
29. Swing R.H. PPC oil pressure switch 70. Governor cut relay
30. Swing L.H. PPC oil pressure switch 71. Horn valve relay
31. Arm IN PPC oil pressure switch 72. APS controller relay
32. Arm OUT PPC oil pressure switch 73. Connector for connecting electronic
33. Bucket CURL PPC oil pressure switch governor checker
34. Bucket DUMP PPC oil pressure switch 74. L.H. speaker
35. Boom RAISE PPC oil pressure switch 75. Step light timer
36. Boom LOWER PPC oil pressure switch 76. Step light switch
37. L.H. travel REVERSE PPC oil pressure 77. Pump prolix resistor
switch 78. Wiper washer relay box
38. L.H. travel FORWARD PPC oil pressure 79. Monitor panel
switch 80. Swing prolix switch
39. R.H. travel REVERSE PPC oil pressure 81. Pump prolix switch
switch 82. Fuse box
40. R.H. travel FORWARD PPC oil pressure 83. Swing lock switch
switch 84. Wiper washer switch
41. Air conditioner compressor 85. Light switch
electromagnetic clutch 86. Alarm buzzer cancel switch
42. Alternator 87. Heater switch
43. Engine water temperature sensor 88. Machine push-up switch
44. APS water temperature sensor 89. Boom shockless switch
10-120 PC1100-6
STRUCTURE AND FUNCTION ELECTRICAL CIRCUIT DIAGRAM
ELECTRICAL CIRCUIT DIAGRAM

BACKHOE
(l/4) ....................................... See page 90- 5.
(214) ....................................... See page 90- 7.
(3/4) ....................................... See page 90- 9.
(4/4) ....................................... See page 90-I 1.
LOADING SHOVEL
(l/4) ....................................... See page 90-13.
WI) ....................................... See page 90-15.
(3/4) ....................................... See page 90-17.
(4/4) ....................................... See page 90-19.
PC1100-6 10-121
0
STRUCTURE AND FUNCTION ENGINE CONTROL
ENGINE CONTROL
1. Battery Outline
2. Battery relay • The engine can be started and stopped sim-
3. Starting switch ply by using starting switch (3).
4. Fuel control dial • With the dial type engine controller, the con-
5. Fuel injection pump with electronic governor trol signal from fuel control dial (4) is re-
6. Starting motor ceived by engine controller (7). A drive sig-
7. Engine controller nal is sent to fuel injection pump (5) with
8. Pump controller electronic governor, and the rack position is
controlled to control the engine speed.
10-126 PC1100-6
1. Operation of system
Starting engine
• When the starting switch is turned to the
START position, the starting signal flows to
the starting motor, so the starting motor ro-
tates and starts the engine.
When this happens, the engine controller
confirms the signal voltage from the fuel
control dial and sets the engine speed to the
set speed.
PC1100-6 10-127
Engine speed control

• The fuel control dial sends a signal voltage
that matches the angle position to the en-
gine controller.
The engine controller calculates the engine
speed to match that signal voltage and con-
trols the electronic governor so that the en-
gine runs at that speed.
10-128 PC1100-6
Stopping engine
• When the starting switch is set to the STOP
position and the power source (ACC termi-
nal) of the engine controller goes OFF, the
engine controller cuts the drive signal to the
electronic governor and stops the engine.
PC1100-6 10-129
2. Function
• 3-mode selector type engine output control
function
The engine controller receives the DH, H and
G mode switch signals from the monitor
through the network signal and controls the
engine output according to each mode.
(For details of the engine output control func-
tion for each mode, see the section on the
machine control system.)
• Auto-deceleration function
The pump controller receives the auto-de-
celeration switch from the monitor panel
through the network signal. The pump con-
troller outputs the deceleration actuation/can-
cel commands to the engine controller ac-
cording to the signals from the travel and
work equipment control lever oil pressure
switches.
(For details of the auto-deceleration function
for each mode, see the section on the ma-
chine control system.)
• Automatic engine warming-up, overheat pre-

vention function
The pump controller receives the signal from
the engine water temperature sensor. The
pump controller then sends the engine speed
commands to the engine controller when
carrying out automatic warming up of the
engine and prevention of overheating.
(For details of the engine automatic warm-
ing-up function for each mode, see the sec-
tion on the machine control system.)
• Error display function

The engine controller itself has a self-diag-
nostic display function, but it has the func-
tion of displaying on the monitor the overall
errors (user code, service code) for the pump
controller, monitor, and the machine over-
all.
Note: The error code displayed on the moni-

tor and the error code displayed by
the engine controller itself are not the
same.
10-130 PC1100-6
3. Components of system
Fuel control dial
1. Knob
2. Dial
3. Spring
4. Ball
5. Potentiometer
6. Connector
Function
• The fuel control dial is installed at the bot-
tom of the monitor panel. A potentiometer
is installed under the knob, and when the
knob is turned, it rotates the potentiometer
shaft.
When the shaft rotates, the resistance of the
variable resistor inside the potentiometer
changes, and the desired throttle signal is
sent to the engine throttle and pump con-
troller.
• The hatched area in the graph on the right is
the abnormality detection area and the en-
gine speed is set at low idling.
PC1100-6 10-131
FUEL INJECTION PUMP WITH ELECTRONIC GOVERNOR

STRUCTURAL DIAGRAM
1. Delivery valve Function

2. Plunger barrel • With control of the fuel injection amount,
3. Plunger the governor actuation hydraulic pressure is
4. Hydraulic piston adjusted by the hydraulic control valve ac-
5. Hydraulic control valve (adjusting fuel cording to the command from the engine
injection amount) controller. It then acts on the piston at the
6. Hydraulic control valve (adjusting fuel rear of the rack and moves the control rack
injection timing) to adjust the fuel injection amount.
7. Gear pump • The fuel injection timing is adjusted by
As seen from rear Left: Oil changing the length of the plunger of the
( Right: Fuel ) fuel injection pump.
8. Center bearing The plunger is divided into two parts, and it
9. Camshaft is possible to change the free stroke by send-
10. Roller ing electronically controlled hydraulic pres-
11. Tappet sure between the two parts to change the
12. Pump housing length.
13. Tappet guide • The governor solenoid and prestroke sole-
14. Spring nut noid are proportional solenoids, and change
the input current from the controller to a
propulsion force. This propulsion force is
used to control the spool of the hydraulic
control valve (the valve for the governor and
the valve for adjusting the fuel injection tim-
ing) to change the hydraulic pressure.
10-132 PC1100-6
HYDRAULIC CIRCUIT
PLUNGER BARREL VARIABLE PRESTROKE STRUCTURE
1. Hydraulic pump A : From engine main gallery

2. Relief valve B : To engine oil pan
Set pressure: 1.5 MPa {15 kg/cm2}
3. Filter
4. Solenoid valve for controlling rack position
5. Hydraulic cylinder for controlling rack
position
6. Solenoid valve for controlling prestroke
7. Hydraulic cylinder for controller prestroke
8. Filter
9. Fuel injection pump assembly with
electronic governor
PC1100-6 10-133
Engine throttle, pump controller
10-134 PC1100-6
Input and output signals
PC1100-6 10-135
STRUCTURE AND FUNCTION MACHINE CONTROL SYSTEM
MACHINE CONTROL SYSTEM

CONTROL FUNCTIONS
1 OFF (Cancel)
Auto deceleration function
ON
2 3-mode selector type engine torque control function
3-mode selector type pump torque control
Electronic OLSS function
Cut-off control
Flow control
3 OFF
Heavy-lift function
ON
4 OFF (Digging improvement mode)
2-stage boom pushing force
selector function
ON (Machine push-up mode)
(Machine push-up)
5
Swing control function
Machine
6
control
Engine automatic warming up,
system
overheat prevention function
7 Travel pressure
rise function
Travel speed selector
function Lo (Low speed) fixed
Travel speed
selector function
Hi (High speed) →
← Lo (low speed)
automatic gear shift
8 ON
Boom shockless control
function
Cancel
9
Straight-travel function
10
Swing priority function
11
Boom assurance function
PC1100-6 10-137
MACHINE CONTROL SYSTEM DIAGRAM
10-138 PC1100-6
PC1100-6 10-139
1. Auto deceleration function
Function
• If all the control levers are at neutral when
waiting for work or waiting for a dump truck,
the engine speed is automatically reduced
to a midrange speed to reduce fuel consump-
tion and noise.
• If any lever is operated, the engine speed
returns immediately to the set speed.
10-140 PC1100-6
Operation
Control levers at neutral When control lever is operated
• If the engine is running at above the decel- • If any control lever is operated when the
eration actuation speed (approx. 1300 rpm), engine speed is at No. 2 deceleration, the
and all the control levers are returned to engine speed will immediately rise to the
neutral, the engine speed drops immediately speed set by the fuel control dial.
to approx. 100 rpm below the set speed to
the No. 1 deceleration position.
• If another 4 seconds passes, the engine
speed is reduced to the No. 2 deceleration
position (approx. 1300 rpm), and is kept at
that speed until a lever is operated.
PC1100-6 10-141
2. Electronic OLSS function

Pump control system
• Interconnected control of all pumps is car-

ried out by one TVC valve.
• DH mode: Total horsepower control by en-
gine speed sensing
H mode: Total horsepower control by en-
gine speed sensing
G Mode: Constant torque control
• Prolix circuit: Absorption torque equivalent
to G mode
10-142 PC1100-6
1) Control method in each mode

DH, H mode
• Matching point in DH, H mode: Rated output

point
Model
PC1100-6
Mode
DH 456 kW/1,800 rpm {611 HP/1,800 rpm}
H 419 kW/1,730 rpm {562 HP/1,730 rpm}
• When the load on the pump rises and the

pressure rises, the engine speed goes down.
When this happens, the pump discharge
amount is reduced, and the engine speed is
controlled so that it becomes close to the
rated speed.
If the reverse happens and the pressure goes
down, the system is controlled so that the
pump discharge amount is increased until
the engine speed reaches close to the rated
speed.
By repeating this control, the engine can al-
ways be used at near the rated output point.
• Compared with the DH mode, which pro-
vides the maximum output, the H mode low-
ers the engine output to provide matching
at a point which gives better fuel consump-
tion efficiency than the DH mode.
PC1100-6 10-143
G mode
• Matching point
Mode G Model
Mode PC1100-6
Partial output point 78% 355 kW/1,740 rpm

G {476 HP/1,740 rpm}
• When the pump load increases and the pres-

sure rises, the engine speed drops.
When this happens, combined control of the
engine and pump carries out controls so that
the engine speed goes down while the pump
absorption torque is maintained constant
along the equal horsepower curve of the
engine.
• Compared with the H mode, the high idling
engine speed is lowered, so the engine can
be used in a good fuel consumption range.
2) Cut-off function
• If the load during operation increases and
the pump discharge pressure rises to near
the relief pressure, the main pump cut-off
valve is actuated to reduce the relief loss.
10-144 PC1100-6
3. Heavy lift function
10-146 PC1100-6
Outline
• This function increases the boom lifting
power by approx. 10%.
• It can be actuated only when the boom
RAISE is being actuated independently. If
the arm IN or bucket CURL are operated at
the same time, the heavy-lift function is au-
tomatically canceled.
Operation
Lever operation
Heavy-lift Heavy-lift Main relief Boom
switch Boom Arm IN or solenoid valve set CO valve lifting
RAISE bucket CURL valve pressure force
De- 31.4 MPa

OFF Operated — Actuated Normal
energized {320 kg/cm2}
34.3 MPa
Neutral Excited {350 kg/cm2} Canceled 10% up
ON Operated
If the arm IN or bucket CURL are operated dur-
Operated ing boom RAISE operations, this function is au- Normal
tomatically canceled, and the condition becomes
the same as when the switch is turned OFF.
fl Heavy-lift solenoid valve

For details of the structure and function, see SOLENOID VALVE.
fl CO valve
For details of the structure and function, see NO. 1 PUMP.
fl Main relief valve
For details of the structure and function, see L.H. 5-SPOOL VALVE.
PC1100-6 10-147
4. 2-stage boom pushing force selector

function
10-148 PC1100-6
Outline
• This function switches the pushing force of
the boom. It is aimed to provide both in-
creased digging efficiency by reducing the
digging resistance of the boom, and in-
creased ease of operation by increasing the
thrusting force for excavation, digging square
holes, carrying out twist turns, or escaping
from soft ground.
Operation
• This function acts to change the set pressure of the safety valve at the boom cylinder end of the
R.H. 4-spool control valve boom Lo in 2 ways: to low pressure (14.7 MPa {150 kg/cm2) and high
pressure (33.3 MPa {340 kg/cm2}.
Machine Machine
Mode Safety valve Effect
push-up push-up
set pressure
switch solenoid valve
By reducing the boom pushing force, it is

Boom made easier for the boom to escape auto-
pushing 14.7 MPa
Excited matically in the RAISE direction and to re-
force (low {150 kg/cm2} duce the number of times that the boom is
mode) operated. At the same time it also makes
the digging operation smoother.
Boom By increasing the thrust force for boom

33.3 MPa LOWER, the ease of operation is improved
pushing De-energized for excavation, digging square holes, carry-
force (high {340 kg/cm2} ing out twist turns, or escaping from soft
mode) ground.
fl Machine push-up solenoid valve

For details of the structure and function, see SOLENOID VALVE.
fl Boom safety valve
For details of the structure and function, see R.H. 4-SPOOL VALVE.
PC1100-6 10-149
5. Swing control function
Function
• The system is provided with a swing lock
and swing holding brake function.
10-150 PC1100-6
1) Swing lock, swing holding brake function

• The swing lock (manual) can be locked at fl Swing brake solenoid valve
any desired position, and the swing lock and For details of the structure and function, see
swing holding brake (automatic) are inter- SOLENOID ASSEMBLY.
connected with the swing, so they prevent fl Swing motor
any hydraulic drift after the swing is stopped. For details of the structure and function, see
SWING MOTOR.
Actuation
Swing lock Swing lock Swing brake
Mode switch lamp solenoid valve Actuation
When swing and work equipment levers are placed at

neutral, swing brake is applied after approx. 5 sec;
when any swing or work equipment lever is operated,
brake is canceled and swing can be operated freely
Swing See diagram

holding OFF OFF on right
brake
Swing lock is actuated and swing is held in position.

Swing
ON ON De-energized Even when swing lever is operated, swing lock is not
brake canceled and swing does not move.
2) Operation of swing lock prolix switch

• If any abnormality should occur in the con-
Swing
troller, and the swing holding brake is not lock
ON OFF
(when controller (when controller
actuated normally and the swing cannot be prolix is abnormal) is normal)
operated, the swing lock prolix switch can switch
be operated to cancel the swing lock and Swing
allow the swing to be operated. lock ON OFF ON OFF
switch
fl Even when the swing lock prolix switch is
turned ON, the swing lock switch stays ON Swing hold-
Swing Swing lock Swing lock Swing lock
ing brake
and the swing brake is not canceled. brake applied canceled applied
applied
fl When the swing brake is canceled, the swing
has only a hydraulic brake operated by the
safety valve, so if the swing is stopped on a
slope, there may be hydraulic drift.
3) Hydraulic oil quick warm-up function when

swing lock switch is ON
• When the swing lock switch is turned ON,
the pump cut-off is canceled. If the work
equipment is relieved in this condition, the
hydraulic oil temperature will rise more
quickly and the warming-up time can be re-
duced.
PC1100-6 10-151
6. Automatic warming-up and engine overheat

prevention function
Function
• If the water temperature is low, this auto-
matically raises the engine speed to warm
up the engine after it is started. In addition,
if the water temperature rises too high dur-
ing operations, it automatically lowers en-
gine speed to low idling, and reduces the
load of the pump to prevent overheating.
10-152 PC1100-6
1) Engine automatic warming-up function

• After the engine is started, if the engine cool-
ant temperature is low, the engine speed is
automatically raised to warm up the engine.
Conditions for actuation (both are necessary) Actuation
Coolant temperature: Less than 30°C Engine speed: 1200 rpm

Engine speed: Less than 1200 rpm
Conditions for cancellation (any one) Cancellation

Coolant temperature: 30*C or above
Auto-
matic Automatic warming-up time: 10 minutes or more Engine speed: As desired
Fuel control dial: Held at more than 70% of
Manual full throttle for more than 3 seconds
2) Engine overheat prevention function

• This function protects the engine by lower-
ing the pump load and engine speed to pre-
vent overheating when the engine coolant
temperature has risen too high.
• This system is actuated at 105°C and above.
Actuation condition Actuation, remedy
Water temperature: Working mode : In any mode

105°C and above Engine speed : Low idling
(Water temperature gauge: Monitor warning lamp : Lights up
Red range) Alarm buzzer : Sounds
Cancel condition
Water temperature: Below 105°C

Fuel control dial : Return temporarily
to low idling position
• When the above conditions are met, the

system returns to the condition before
the overheat prevention function was
actuated (manual reset).
PC1100-6 10-153
7. Travel speed selector function

1) Travel pressure rise function
10-154 PC1100-6
Outline
• To maintain the drawbar pull when traveling,
the cut-off is canceled and the main relief
pressure is raised from 31.4 MPa {320 kg/
cm2} to 34.3 MPa {350 kg/cm2}.
Operation
Pressure increase Main relief valve Cut-off cancel

CO valve
solenoid valve set pressure solenoid valve
34.3 MPa
When traveling Energized Energized Canceled
{350 kg/cm2}
31.4 MPa
When not traveling Deenergized Deenergized Actuated
{320 kg/cm2}
PC1100-6 10-155
2) Travel speed selector function
The travel pressure (self pressure) changes the

swash plate angle of the travel motor and auto-
matically shifts the speed range.
• When traveling at high speed with the travel
speed switch at Hi, if the travel pressure
goes above 28.4 MPa {290 kg/cm2}, such as
when starting to travel uphill, the self pres-
sure shifts to low speed travel. If the ma-
chine continues to travel at low speed and
then comes again to a flat area, when the
travel pressure drops below 28.4 MPa {290
kg/cm2}, the speed is switched back to high
speed travel.
Travel speed Travel speed Travel motor

Travel speed Remarks
switch solenoid valve swash plate angle
Low speed Suitable for traveling on rough

Lo Deenergized Max.
(max 2.1 km/h) ground or traveling downhill
Max. Low speed (2.1 km/h) Suitable for moving

Hi Energized ↕ ↔ high speed (3.2 km/h) long distances
Min
10-156 PC1100-6
8. Boom shockless control function

This function improves safety by preventing spillage of the load from the bucket and by reducing
the shock when the boom is stopped, thereby reducing operator fatigue.
Actuation
Boom shockless Cancel solenoid Boom shockless
Remarks
switch valve control
ON
De-energized ON Suitable for normal operations
(Contacts open)
OFF Suitable for compacting or

Excited Canceled
(Contacts closed) skeleton work
• If the boom is raised, the pilot pressure from the PPC valve is generated in line A. When this
happens, the pressure in line A passes through check valve (2) and pushes the spool of the main
valve in the direction of the arrow. The pilot oil at the left end of the spool passes through line B
and the PPC valve, and returns to the tank. However, when this happens, check valve (4) is being
pushed open by the pressure in line A, so it also allows the oil to pass in the opposite direction.
For this reason, the boom can be raised without any delay in response.
• In this condition, if the boom RAISE operation is stopped, the spool of the main valve moves in the
opposite direction to the arrow and drains the oil from line A. However, the action of check valve
(2) means that the oil must pass through orifice (1). As a result, the spool returns slowly to the
neutral position to prevent any shock.
PC1100-6 10-157
9. Straight-travel function
10-158 PC1100-6
Outline
• When the travel is operated at the same time • To prevent this, the straight-travel valve is
as the boom, arm, or bucket, the pressure switched to interconnect the left and right
oil flowing to the left and right travel circuits travel circuits. This ensures that the amount
is divided and sent to the boom, arm, or of oil supplied to the left and right travel
bucket circuit. motors is equal, so the left and right travel
If the oil in one travel circuit is divided off, motors both rotate at the same speed, and
the amount of oil supplied to the travel mo- this prevents any travel deviation.
tor will be less than in the travel circuit which
is not divided, so the drop in the supply of
oil to the travel motor will cause the ma-
chine to deviate.
Operation
Work equipment
Left and right Straight-travel Straight-travel
control lever, Remarks
travel levers solenoid valve valve
swing lever
Left and right travel motor

Neutral De-energize Not actuated
circuits independent
Operation
Left and right travel motor
Operated Excited Actuated
circuits actuated
PC1100-6 10-159
10. Swing priority function

• There is a swing priority mode switch on
the monitor panel. By turning this switch
ON/OFF it is possible to change the match-
ing of the boom RAISE and swing. This di-
vides the flow to provide a swing speed
which matches the swing angle, thereby ena-
bling the operator to carry out compound
operations easily.
Swing priority mode OFF:
90° swing and load dump truck
Swing priority mode ON:
180° swing and load dump truck
Number of
Swing priority
Solenoid boom riase
selector valve
control valve
Swing priority
OFF
mode OFF OFF 3
(de-energized)
(standard)
Swing priority
ON
mode ON ON 2
(excited)
(swing priority)
10-160 PC1100-6
Operation
When swing priority mode is OFF:
Boom RAISE is driven by 3 control valves (R.H. 4-spool control valve, L.H. 5-spool control valve,
and swing 4-spool control valve).
When swing priority mode is ON:
Swing priority solenoid valve is driven and swing 4-spool control valve is locked. As a result, boom
RAISE is driven by 2 control valves (R.H. 4-spool control valve and L.H. 5-spool control valve). (The
swing and boom RAISE control valves become independent.)
PC1100-6 10-161
11. Swing assurance function

• If the swing is operated at the same time as the arm or bucket, the throttle valve in the arm or
bucket circuit acts to ensure the flow of oil to the swing to ensure good performance during
combined operations.
Operation
• There is a throttle valve in the arm circuit of the swing 4-spool control valve, and when the swing
PPC pressure goes above 1.5 MPa {15 kg/cm2} (when the control lever is operated approx. half
way), the swing assurance selector valve is actuated and the swing drive pressure locks the pilot
check valve of the bucket throttle valve in the swing 4-spool control valve.
• When this condition occurs, the oil in the swing 4-spool control valve forms a parallel circuit, so
the flow of oil to the arm and bucket is throttled by the throttle valve and the drive pressure for the
swing rises. In this way, the drive for the swing is ensured.
10-162 PC1100-6
12. Components of system

1) Pump controller
10-164 PC1100-6
Input and output signals
PC1100-6 10-165
2) Engine speed sensor
1. Wire Function
2. Magnet • The engine speed sensor is installed to the
3. Terminal ring gear portion of the engine flywheel. It
4. Housing counts electrically the number of gear teeth
5. Connector that pass in front of the sensor, and sends
the results to the engine throttle and pump
controller.
• This detection is carried out by a magnet,
and an electric current is generated every
time the gear tooth passes in front of the
magnet.
3) PPC hydraulic pressure switch
1. Plug
2. Switch
3. Connector
Specifications
Composition of points: N.O. points
Actuation (ON) pressure:
0.5 ± 0.1 MPa (5.0 ± 1.0 kg/cm2)
Reset (OFF) pressure:
0.3 ± 0.05 MPa (3.0 ± 0.5 kg/cm2)
Function
• There are 8 switches installed
to the PPC shuttle valve. The
operating condition of each ac-
tuator is detected from the PPC
pressure, and this is sent to the
engine throttle and pump con-
troller.
10-166 PC1100-6
4) TVC prolix resistor
1 2
SBP00370
1. Resistor
2. Connector
Specification Function
Resistance: 20 Ω • This resistor acts to allow a suitable current
to flow to the TVC solenoid when the TVC
prolix switch is ON.
• No current flows when the TVC prolix switch
is OFF.
5) Fuel control dial, electronic governor

fl See ENGINE CONTROL.
6) Monitor panel
fl See MACHINE MONITOR SYSTEM.
7) TVC valve
fl See HYDRAULIC PUMP.
PC1100-6 10-167
STRUCTURE AND FUNCTION MACHINE MONITOR SYSTEM
MACHINE MONITOR SYSTEM
Function
• The machine monitor system uses the sen- • The monitor panel also has various built-in
sors installed to all parts of the machine to mode selector switches, and functions as the
observe the condition of the machine. It proc- control panel for the machine control sys-
esses this information swiftly, and displays tem.
it on a panel to inform the operator of the
condition of the machine.
• The content of the information displayed on
the machine can broadly be divided as fol-
lows.
1. Monitor portion
This gives an alarm if any abnormality oc-
curs in the machine.
2. Gauge portion
This always displays the condition of the
machine (coolant temperature, fuel level).
10-168 PC1100-6
1. Monitor panel
Outline
• The monitor panel consists of the switches Input and output signals
for the monitor display functions, mode se- CN-P01 CN-P02
lector, and electrical components. Pin No. Name of signal Pin No. Name of signal
• It has a built-in CPU (Central Processing Unit), 1 NC 1 GND
2 NC 2 Washer output
and processes, displays, and outputs the in- 3 NC 3 Wiper signal
formation. 4 N/W signal 4 Wiper SW (ON)
• The monitor display panel uses a liquid crys- 5 Swing lock 5 Wiper SW (WASHER)
6 Buzzer stop 6 NC
tal display (LCD). The mode switches are flat 7 Buzzer output 7 NC
sheet switches. 8 Lamp 8 +VB
9 Key ON signal 9 GND
10 Acc signal 10 Washer output
11 N/W signal 11 NC
12 NC 12 Wiper SW (INT)
13 NC 13 NC
14 N/W GND 14 +VB
15 NC 15 NC
16 NC 16 NC
17 NC
18 Preheating
19 Start signal
20 NC
PC1100-6 10-169
MONITOR DISPLAY
1. Clock
2. Service meter
3. Fuel level gauge
4. Fuel level caution lamp
5. Engine oil level caution lamp
6. Hydraulic oil level caution lamp
7. Preheating pilot lamp
8. Swing holding brake pilot lamp
9. Oil maintenance pilot lamp
10. Battery charge caution lamp
11. Air cleaner clogging caution lamp
12. Hydraulic oil temperature caution lamp
13. Engine oil pressure caution lamp
14. Coolant level caution lamp
15. Coolant temperature caution lamp
16. Coolant temperature gauge
10-170 PC1100-6
Content of display
Symbol Display item Display range When engine is stopped When engine is running
Flashes and buzzer

Coolant level Below low level Flashes when abnormal
sounds when abnormal
SAP00519
Below 1500 rpm:

below 0.05 MPa
Lights up when normal
Engine oil {0.5 kg/cm2} Flashes and buzzer sounds
(goes out when engine
pressure Above 1500 rpm: starts) when abnormal
SAP00520
above 0.15 MPa
{1.5 kg/cm2}
Air cleaner
When clogged OFF Flashes when abnormal
clogging
SAP00521
Lights up when normal

When charging is
Charge level (goes out when engine Flashes when abnormal
defective
SAP00522 starts)
Engine oil level Below low level Flashes when abnormal OFF
SAP00523
Hydraulic oil level Below low level Flashes when abnormal OFF
SAP00524
Parking When swing is Lights up when swing lock switch is ON, flashes
(Swing lock) locked when swing lock prolix switch is ON
SAT00098
Oil maintenance See next page. OIL MAINTENANCE FUNCTION

SAP02732
When glow plug is preheating: ON; when glow plug

When APS is has completed preheating: OFF; when engine coolant
Preheating temperature is above set temperature: Flashes (2 times/
actuated
SAP00526 3 seconds), then goes OFF
Coolant Flashes when above 102°C, flashes and

temperature buzzer sounds when above 105°C
SAP00527
Fuel level Flashes when below low level

SAP00528
Hydraulic oil Above specified Flashes and buzzer sounds

OFF
temperature level when abnormal
SAD01484
PC1100-6 10-171
OIL MAINTENANCE FUNCTION
1. Function, operation
The oil maintenance function uses LED lamps
on the monitor panel to inform the operator
at a fixed interval after the engine oil is
changed that the oil change interval has been
reached.
At the same time, it also functions to display
the service contact telephone number on the
liquid crystal display.
1) Confirmation of elapsed time
Normally, no display is given until the
elapsed time reaches the point B on the
right diagram after reset. However, if
the buzzer cancel switch is pressed and
the key is turned to the ON position (with
the buzzer cancel switch hold for 2.5 sec-
onds), the elapsed time is displayed on
the service meter display.
2) Oil change display
When the elapsed time has reached or
passed the point B on the right diagram,
the service meter display gives the
elapsed time and the LED flashes when
the key is turned ON.
2. Setting change interval

1) The change interval can be set by using
the interval setting mode. The time that
can be set are [125 h], [250 h], [500 h],
[no setting], and [demo mode]. The de-
fault setting is [no setting].
2) To enter the change interval setting
mode, keep the time switch and active
mode switch (swing priority switch)
pressed simultaneously for 2.5 seconds.
3) If the buzzer cancel switch is pressed in
the change interval setting mode, the
time display will change from […] →
[125] → [250] → [500] → [ d] ([…] indi-
cates [no setting] and [ d] indicates
[demo mode]).
4) To save the change interval time, set the
monitor panel display to the desired time
(mode), then keep the time switch and
active mode switch (swing priority
switch) pressed simultaneously for 2.5
seconds.
10-172 PC1100-6
3. Display timing, content

1) Oil change display
After all the lamps light up, the elapsed
time is displayed for 10 seconds. For the
next 10 seconds, the telephone number
is displayed.
However, if no telephone number has
been input, the elapsed time is displayed
for 20 seconds after all the lamps light
up.
2) Elapsed time confirmation
After all the lamps light up, the elapsed
time is displayed for 10 seconds.
4. Elapsed time reset

1) During the oil change interval display and
the elapsed time display, for 10 seconds
after all lamps light up (during the
elapsed time display), if the buzzer can-
cel switch is pressed and held for 3 sec-
onds, the elapsed time is reset. When
the elapsed time is reset, the elapsed
time shows [0h] for 1 second.
2) When the set time is changed, the
elapsed time is reset to 0h.
5. Demo mode
1) The set time in the demo mode is 250h
and the elapsed time is set to 240h. When
the key is turned ON, the oil change dis-
play is given. However, the elapsed time
does not increase.
It is also possible to carry out the reset
operation during this display.
In the demo mode, after the key is turned
ON three times, the interval setting is
automatically set to [no setting] from the
4th time. In addition, the elapsed time is
reset to 0h and the elapsed time count
starts.
PC1100-6 10-173
SWITCHES
1. Working mode switch

2. Auto deceleration switch
3. Swing priority mode switch
4. Travel speed switch
5. Knob button switch (Heavy lift)
• There are three mode selector switches on Switch actuation table

the switch panel. Each time any of these
Item Actuation
switches is pressed, the condition of the
machine will change. The LEDs on the switch Working mode DH ↔ H ↔ G
panel light up to indicate the condition of
Heavy lift button OFF ↔ ON
the machine.
Auto decel ON ↔ OFF
Travel speed Hi ↔ Lo
Swing priority OFF ↔ ON
fl The bold letters indicate the default position

of the switch when the starting switch is
turned ON.
10-174 PC1100-6
20 TESTING AND ADJUSTING
Standard value table

Standard value table for engine related parts.. ............................................................................ 20- 2
Standard value table for chassis related parts ............................................................................. 20- 3
Standard value table for electrical parts. ...................................................................................... 20- 11
Testing and adjusting ........................................................................................................................... 7r-l- In,

..L” I” I
Troubleshooting ...................................................................................................................................... 20-201
Note the following when making judgements using the standard value tables for testing, adjusting, or
troubleshooting.
The standard value for a new machine given in the table is the value used when shipping the machine from
the factory and is given for reference. It is used as a guideline for judging the progress of wear after the
machine has been operated, and as a reference value when carrying out repairs.
The service limit value given in the tables is the estimated value for the shipped machine based on the results
of various tests. It is used for reference together with the state of repair and the history of operation to judge
if there is a failure.
These standard values are not the standards used in dealing with claims.
a When carrying out testing, adjusting, or troubleshooting, park the machine on level ground, insert the
safety pins, and use blocks to prevent the machine from moving.
a When carrying out work together with other workers, always use signals and do not let unauthorized people
near the machine.
a When checking the water level, always wait for the water to cool down. If the radiator cap is removed when
the water is still hot, the water will spurt out and cause burns.
a Be careful not to get caught in the fan, fan belt or other rotating parts.
PC1 100-6 20-l

0
TESTING AND ADJUSTING STANDARD VALUE TABLE FOR ENGINE RELATED PARTS
STANDARD VALUE TABLE FOR ENGINE RELATED PARTS
Machine model PC1 100-6
Engine SAAGDI 70-2
Item Measurement condition Unit Standard value Permissible value

I I
High idling 2,000 + 50 2,000 + 50
Engine speed Low idling rpm 730 f 25 730 ? 25
Rated speed 1,800 -
intake air pressure At rated output Min. 120 {900} Min. 96 {720}
All speed range

Exhaust gas pressure Max. 620 Max. 670
(intake air temp.: 20°C) “’
I I
At sudden acceleration Bosch Max. 4.5 Max. 5.5
Exhaust gas color
index
At high idling Max. 1.0 Max. 2.0
(normal temperature)
Valve clearance Intake valve 0.4 -
mm
Exhaust valve 1.0 -
Oil temperature:
40 - 60°C I I
Compression pressure
(Engine speed: Min. 2.9 130) Min. 2.1 {21}
(SAE30 oil)
(Coqlant temperature:
wrthrn operatmg range) kPa
Blow-by pressure
Max. 3.9 (400) Max. 7.9 (8001
(SAE30 oil) ImmHzO}
At rated output
(Coolant temperature:
Min. 80°C)
At high idling (SAE30) MPa 0.39 - 0.54 (4.0 - 5.5} Min. 0.21 (2.1}
Oil pressure (kg/cm*}
At low idling (SAEBO) Min. 0.12 il.21 0.07 (0.71
At high idling (SAEIOW) 0.34 - 0.49 (3.0 - 5.01 Min. 0.18 (1.8)
At low idling (SAEIOW) I I Min. 0.1 (I.01 Min. 0.07 (0.7}
All speed range

Oil temperature “C 80- 110 Max. 120
(inside oil pan)
Fuel injection timing B. T. D. C. 19 + 0.5 19 Y?0.5
Deflection when pressed

Alternator belt tension with finger force of 10 - 15 -
approx. 58.8 N 16 kg1
mm
Deflection when pressed
Air conditioner com-
with finger force of -
pressor belt tension 10 * 15
approx. 58.8 N (6 kg)
20-2 PC1 100-6

0
TESTING AND ADJUSTING STANDARD VALUE TABLE FOR CHASSIS RELATED PARTS
STANDARD VALUE TABLE FOR CHASSIS RELATED PARTS

BACKHOE
Applicable model
T PC1 100-6
CatI
e- Standard value Ser;igl$mit
Item Measurement conditions Unit
W ‘Y ‘or new machine
. Engine at full throttle

. Hydraulic oil temperature:
All pumps at relief 1,850 T 100 1,850 + 100
45 - 55°C
. Engine oil pressure:
_ Within operating range
. Engine water temperature:
All pumps at relief
Within operating range rpm
. In D.H mode 1,800 + 100 1,800 + 100
, hea& lift ON
. Boom RAISE relief
Engine speed when

auto-deceleration is 1,300 f 100
. All control levers at neutral
actuated
I
I I
a b a b
g 1 Bottom dump / ’ Engine stopped
12 r 0.5 12 + 0.5 12 + 0.5 12 + 0.5
16 + 0.5 16 2 0.5 16 + 0.5 16 + 0.5
BVPO3101
mm
16 + 0.5 16 + 0.5 16 k 0.5 16 + 0.5
?z
5 Boom Plus I
16 2 0.5 16 + 0.5 16 f 0.5 16 _+0.5
85% 10 852 10
852 10 852 10
852 10 85+ 10
mm
852 10 852 10
N + Forward.
Travel control lever 115 + 15 115 f 15
Reverse(both sides]
Work equipment.
Max. 10 Max. 10
swinq, travel
PC1 100-6 20-3

0
Applicable model PC1100-6
Cate- Item Measurement conditions Standard value

Unit for Service limit
gory new machine value
Operating effort of control levers
Boom control lever · Engine stopped 15.7 ± 4.9 {1.6 ± 0.5} 15.7 ± 4.9 {1.6 ± 0.5}
· Oil temperature: 45 – 55°C
Arm control lever · Fit push-pull scale to center of 15.7 ± 4.9 {1.6 ± 0.5} 15.7 ± 4.9 {1.6 ± 0.5}
control lever knob
Bucket control lever · Measure max. value to end of N {kg} 12.7 ± 3.9 {1.3 ± 0.4} 12.7 ± 3.9 {1.3 ± 0.4}
travel
Swing control lever 12.7 ± 3.9 {1.3 ± 0.4} 12.7 ± 3.9 {1.3 ± 0.4}
Travel control lever 24.5 ± 5.9 {2.5 ± 0.6} 24.5 ± 5.9 {2.5 ± 0.6}
· Engine at full Heavy lift + 1.0 + 10 + 1.0 + 10

31.4 {320 – 15 } 31.4 {320 – 25 }
RAISE
OFF – 1.5 – 2.5

throttle
Heavy lift + 1.0 + 10 + 1.0 + 10
· Oil tempera- ON 33.3 – 1.5 {340 – 15} 33.3 – 2.5 {340 – 25}
Boom ture:
Machine
LOWER
45 – 55°C push-up OFF 18.6 ± 1.9 {190 ± 20} 18.6 ± 1.9 {190 ± 20}
· In D.H mode Machine + 1.0 + 10 + 1.0 + 10
· Relieve only 31.4 – 1.5 {320 – 15 } 31.4 – 2.5 {320 – 25 }
push-up ON
circuit being + 1.0 + 10 + 1.0 + 10
Arm measured 31.4 – 1.5 {320 – 15 } 31.4 – 2.5 {320 – 25 }
+ 1.0 + 10 + 1.0 + 10
Bucket 31.4 – 1.5 {320 – 15 } 31.4 – 2.5 {320 – 25 }
+ 1.0 + 10 + 1.0 + 10
Travel 34.3 – 1.5 {350 – 15 } 34.3 – 2.5 {350 – 25 }
+ 1.0 + 10 + 1.0 + 10
Swing 30.4 – 1.9 {310 – 20 } 30.4 – 2.9 {310 – 30 }
· Engine at full throttle

+ 0.4 +3.5 + 0.4 +3.5
Hydraulic pressure
Control · Oil temperature: 45 – 55°C 3.1 0 {32 0 } 3.1 0 {32 0 }

· All control levers at neutral
MPa
· Engine at All control {kg/
levers at neutral 2.3 ± 0.3 {23 ± 3} Min. 1.8 {18}
full throttle cm2}
TVC valve output · Oil temperature:
Boom RAISE
Heavy lift
pressure 45 – 55°C OFF 1.13 ± 0.2 {11.5 ± 2} 1.08 ± 0.2 {11 ± 2}
relief
· In D.H mode
Heavy lift
ON 1.03 ± 0.2 {10.5 ± 2} 0.98 ± 0.2 {10 ± 2}
· Engine at All control

levers at neutral Max. 0.25 {2.6} Max. 0.4 {4.1}
No.1 pump full throttle
No.2 pump · Oil temperature: Travel under no
CO·NC 45 – 55°C Min. 1.7 {17} Min. 1.7 {17}
valve load
output · In D.H mode
All control Max. 0.68 {6.9} Max. 0.82 {8.4}
pressure levers at neutral
No.3 pump
Swing under no Min. 1.7 {17} Min. 1.7 {17}
load
Left 5-spool · Engine at All control 1.8 ± 0.2 {18 ± 2} Min. 1.5 {15}
Jet control valve full throttle levers at neutral
sensor Right 4-spool · Oil temperature: Travel under no
differen- control valve 45 – 55°C Max. 0.2 {2} Max. 0.2 {2}
load
tial · In D.H mode
output All control
Swing 4- levers at neutral 1.8 ± 0.2 {18 ± 2} Min. 1.5 {15}
pressure spool control
valve Swing under no Max. 0.2 {2} Max. 0.2 {2}
load
20-4 PC1100-6
1

PPC valve output · Hydraulic oil temperature: + 0.6
2.9 – 0.2 {30 +– 5.5
1.5} 2.9 + 0.6
– 0.2 {30 +– 5.5
1.5}
pressure 45 – 55°C
· Control lever full stroke
Hydraulic pressure

· Hydraulic oil temperature:
Solenoid valve
45 – 55°C MPa 2.9 ± 0.6 {30 ± 5.5} 2.9 ± 0.6 {30 ± 5.5}
output pressure · Operate only solenoid being {kg/
measured cm2}
45 – 55°C
Drop in hydraulic · Difference between relief
pressure with engine at full Max. 2.0 {20} Max. 2.9 {30}
pressure
throttle and relief pressure with
engine at low idling
· Work equipment posture
Overrun when · Engine at full throttle deg. Max. 60 Max. 80

· Hydraulic oil temperature: (Max. 1,275) (Max.1,700)
stopping swing 45 – 55°C (mm)
· In D.H mode
· Bucket: No load
· Stop after swinging one turn and
measure distance that swing circle
moves
Value in ( ) shows distance at
outside circumference of swing circle
90° 4.7 ± 0.5 Max. 5.7

Swing
Time taken to
start swing · Engine at full throttle
45 – 55°C
· In D.H mode 180° 7.6 ± 0.8 Max. 9.2
· Bucket: No load
· Time taken to swing 90° and
180° from starting position sec
Time taken to swing 52 ± 2.6 Max. 59

45 – 55°C
· In D.H mode
· Bucket: No load
· Swing one turn, then measure
time taken to swing next 5 turns
PC1100-6 20-5
1

Hydraulic drift of deg. 0 0

swing (mm) (0) (0)
Swing
· Engine stopped
45 – 55°C
· Set machine on 15° slope, and set
upper structure at 90° to the side.
· Make match marks on swing circle
outer race and track frame.
· Measure distance that match
marks move apart after 5 minutes.

Leakage from swing · Hydraulic oil temperature: ¬ /min Max. 14 Max. 28
motor 45 – 55°C
· Relieve swing circuit.

Low speed
95 – 117 95 – 117
Travel speed (1) sec

High speed
45 – 55°C
· In D.H mode 65 – 80 65 – 80
· Raise track on one side at a
time, rotate one turn, then
measure time taken for next 5
Travel
turns with no load.

Low speed
29 – 37 29 – 37
Travel speed (2) sec

High speed

45 – 55°C
· In D.H mode 20 – 25 20 – 25
· Run up for at least 10 m, and
measure time taken to travel
next 20 m on flat ground.
20-6 PC1100-6
1


45 – 55°C
· In D.H mode
Travel deviation · Use a hard horizontal surface. mm Max. 200 Max. 220
· Run up for at least 10 m, and
measure deviation (χ) when
traveling next 20 m on flat
ground.
20m
10m BKP00107
Travel
· Work equipment
posture
Hydraulic drift of · Engine stopped

mm 0 0
travel · Hydraulic oil temperature:
45 – 55°C
· Stop machine on 12° slope with
sprocket at uphill end of ma-
chine.
· Do not place the work equip-
ment on the ground.
· Measure the distance the
machine moves in 5 minutes.
Leakage of travel
motor ¬ /min Max. 20 Max. 40

45 – 55°C
· Lock shoes and relieve travel
circuit.
PC1100-6 20-7
1

Total work
equipment
hydraulic drift at Max. 1,200 Max. 1,800
[ tip of bucket
teeth ] (Max. 650) (Max. 1,000)
Hydraulic drift of work equipment
Boom cylinder · Place in above posture and

(amount of measure extension or retraction of Max. 50 Max. 75
retraction of each cylinder and downward (Max. 30) (Max. 45)
cylinder)
movement at tip of bucket teeth.
· Engine stopped
· Hydraulic oil temperature: mm
45 – 55°C
· Horizontal, flat ground
Arm cylinder · All control levers at neutral
(amount of · Buket: Rated load or full load of Max. 160 Max. 240
extension of soil (Max. 70) (Max. 105)
cylinder) STD, LC specification:
75.9 kN {7,740 kg}
SP specification:
Work equipment
100.6 kN {10,260 kg}

· Start measuring immediately after
Bucket cylinder setting.
(amount of · Measure hydraulic drift every 5 Max. 95 Max. 145
retraction of minutes, and judge from results (Max. 45) (Max. 70)
cylinder) for 15 minutes.
· Figures in ( ) are value when
bucket is not loaded.
· Work equipment posture STD, LC SP STD, LC SP

specification specification specification specification
RAISE
Work equipment speed
Boom 6.2 ± 0.7 6.6 ± 0.7 Max. 7.6 Max. 8.0

Bucket teeth in
[ ]
contact with
ground
↔
· Hydraulic oil temperature: sec

Cylinder fully 45 – 55°C
extended · In D.H mode
· Bucket: No load
LOWER
4.0 ± 0.4 4.4 ± 0.4 Max. 4.8 Max. 5.2
20-8 PC1100-6
1

STD, LC SP STD, LC SP
· Work equipment posture specification specification specification specification
IN
5.0 ± 0.5 5.0 ± 0.5 Max. 6.0 Max. 6.0
Arm
Cylinder fully
[ retracted
] sec
↔
Fully extended
OUT
Work equipment speed
· Hydraulic oil temperature: 4.0 ± 0.4 4.0 ± 0.4 Max. 4.8 Max. 4.8
45 – 55°C
· In D.H mode
· Bucket: No load

CURL
3.3 ± 0.4 3.5 ± 0.4 Max. 4.1 Max. 4.3
Bucket
[ ]
Cylinder fully
retracted
Work equipment
sec
↔
Fully extended
DUMP

· Hydraulic oil temperature: 3.1 ± 0.4 3.3 ± 0.4 Max. 3.9 Max. 4.1
45 – 55°C
· In D.H mode
· Bucket: No load

Time lag
Boom sec Max. 3 Max. 5

· Engine at low idling
45 – 55°C
· Retract arm and bucket cylinder
fully, then lower boom from max.
RAISE point and measure time
taken from point where bucket
contacts ground to point where
chassis rises from ground.
PC1100-6 20-9
1

Arm sec Max. 3 Max. 5

45 – 55°C
· Set top surface of boom horizon-
tal, retract bucket cylinder fully,
then extend arm cylinder and
measure time taken for arm to
start moving again after stopping
at bottom.
Time lag
Work equipment
Bucket sec Max. 3 Max. 5

45 – 55°C
· Set top surface of boom horizon-
tal, retract arm cylinder fully,
then extend bucket cylinder and
measure time taken for bucket to
start moving again after stopping
at bottom.
Internal oil leakage
Cylinders · Engine at full throttle Max. 7 Max. 28

45 – 55°C cc/min
· Relieve only circuit being
Center swivel measured. Max. 10 Max. 100
joint
20-10 PC1100-6
1
LOADING SHOVEL
Applicable model PC1 100-6 loading shovel

-
Catt Standard value
Item Measurement conditions Unit ‘or new machine
gor

All pumps at relief 1.850 + 100 1.850 f 100
45 - 55°C
. Engine oil pressure:
Within operating range
. Engine water temperature:
All pumps at relief
Within operating range rm
+ 1,800 2 100 1,800 2 100
. In D.H mode
heavy lift ON
. Boom RAISE relief
Engine speed when

auto-deceleration is 1,300 * 100
. All control levers at neutral
actuated
a b a b
. Engine stopped
12 + 0.5 12 + 0.5 12 + 0.5 12 2 0.5
i 16 f 0.5 16 + 0.5 16 + 0.5 16 t 0.5
BVP03101
mm
16 2 0.5 16 f 0.5 16 2 0.5 16 t 0.5
16 + 0.5 16 f 0.5 16 t 0.5 16 2 0.5
. Engine N+
Boom control lever 852 10 85~ 10
RAISE. LOWER
stopped
. Center of N-4 852 10 85* 10
Arm control lever IN .OUT
lever knob
. Read max. N+
Bucket control lever 85% 10 852 10
value to end CURL. DUMP
mm
of travel N + Left .
Swing control lever 852 10 85e 10
Right swing
N -+ Forward.
Travel control lever 115 + 15 115 f 15
Reverse(bothsides
Control lever Work equipment.
Max. 10 Max. 10
play amount swing, travel
PC1 100-6 20-10-l

0
Standard value Ser;$ztdmit

Item Measurement conditions Unit for new machine
Boom control lever Engine stopped 15.7 + 4.9 11.6 + 0.5) 15.7 -c 4.9 Il.6 + 0.51
Oil temperature: 45 - 55°C
Arm control lever Fit push-pull scale to center of 15.7 2 4.9 (1.6 f 0.51 15.7 + 4.9 (1.6? 0.5)
control lever knob
Bucket control lever Measure max. value to end of N (kg1 12.7 -c 3.9 (1.3 r 0.41 12.7 + 3.9 11.3 + 0.4)
travel
Swing control lever 12.7 + 3.9 (1.3 + 0.4) 12.7 + 3.9 11.3 + 0.41
Travel control lever 24.5 2 5.9 (2.5 + 0.6) 24.5 + 5.9 (2.5 rt 0.61
. Engine at full 31.4 -,I~

t10 1320 _&
110 31.4 110
_2’5 I320 ‘;;I
throttle
. Oil tempera- t10 5 1340 -151
33.3 -, +I0 33.3 -2.5
110 (340 ‘:;I
Boom ture:
chine
45 - 55°C 18.6 + 1.9 (190 I? 20) 18.6 f 1.9 I190 + 201
,h-up OFF _.
. In D.H mode
. Relieve only 31.4 -,I~
+lO (320 -,&
t10 31.4 ‘;; 1320 :;;I
circuit being
Arm 31.4 -,
t10 5 1320 _J
cl0 31.4 ‘;I; 1320 :;;I
measured
Bucket 31.4 I;:; (320 ‘$1 _2:5 (320 _&

31.4 t10 110
_
OPEN 28.9 +o.; I295 +;, 28.9 1;:; (295 ‘:o)
Bottom dump _---
CLOSE 31.4 ‘;:; (320 ‘;;, 31.4 ‘;:; (320 -‘;;I
Travel 34.3 -,
110 a 1350 -151
t10 34.3 :::; I350 ‘:;I
MPa
Swing (kg/ 30.4 110 +lO
_I:9 (310 -201 30.4 ‘:.; (310 ::;,
cm21
Engine at full throttle

Control Oil temperature: 45 - 55°C 3.1 + ;,” (32 +3d5) 3.1 +;.’ (32 +i5}
All control levers at neutral
. Engine at All control

2.3 2 0.3 (23 t 31 Min. 1.8 {I81
fulithrottle levers at neutral
TVC valve output
1.13? 0.2 (11.5 f 2) 1.08 + 0.2 (11 ? 2)
pressure
1.03 f 0.2 (IO.5 + 21 0.98 + 0.2 {IO + 21
. Engine at All control

levers at neutral Max. 0.25 (2.6) Max. 0.4 (4.1)
No.1 pump full throttle
No.2 pump . Oil temperature: Travel under no
CO.NC Min. 1.7 117) Min. 1.7 117)
45 - 55°C load
valve
. In D.H mode
output All control
Max. 0.68 (6.9) Max. 0.82 18.4)
pressure levers at neutral
No.3 pump
Swing under no
Min. 1.7 {17) Min. 1.7 (17)
load
20-10-2 PC 1100-6
0
Applicable model
T PC1 100-6 loading shovel
Standard value
Item Measurement conditions Unit for new machine
Left 5-spool . Engine at All control
control valve levers at neutral 1.8 f 0.2 iI8 + 2) Min. 1.5 (151
Jet full throttle
sensor Right 4-spool oil tHllpWatUK?: Travel Under no
differen- control valve 45 - 55°C load Max. 0.2 (2) Max. 0.2 (2)
tial . In D.H mode
output All control
Swing 4- levers at neutral 1.8 + 0.2 {I8 2 21 Min. 1.5 1151
pressure spool control
valve Swing under no
load Max. 0.2 121 Max. 0.2 (21

PPC valve output . Hydraulic oil temperature: +55
2.9 : ::; (30 - 1:s)
pressure 45 - 55°C MPa
. Control lever full stroke {kg/
cm21
Hydraulic oil temperature:
Solenoid valve
45 - 55°C 2.9 t 0.6 {30 2 5.51 2.9 + 0.6 (30 + 5.51
output pressure Operate only solenoid being
measured

45 - 55°C
Drop in hydraulic . Difference between relief
Max. 2.0 1201 Max. 2.9 I301
pressure pressure with engine at full
throttle and relief pressure with
engine at low idling
Work equipment posture
Overrun when deg. Max. 60 Max. 80

stopping swing . Engine at full throttle (Max. 1,275) (Max. 1,700)
. 141;~5;li~ oil temperature: mm)
0
In D.H mode
Bucket: No load
Stop after swinging one turn and
measure distance that swing circle
moves
Value in ( ) shows distance at
outside circumference of swing circle
-
. Work equipment posture
90’ 4.7 c 0.5 Max. 5.7
Time taken to -
TWP01783 set
start swing
45 - 55°C
In D.H mode 180’ 7.6 2 0.8 Max. 9.2
Bucket: No load
Time taken to swing 90” and
180” from starting position
-
PC1 100-6 20- 1o-3

0
Applicable model
T- PC1 100-6 loading shovel
Catc Standard value

gor Item Measurement conditions Jnit
or new machine
Work equipment Posture
0.7 2$
rime taken to swing
//////////////~‘T’w~~, G8/2 set 52 f 2.6 Max. 59
45 - 55°C
. In D.H mode
. Bucket: No load
Swing one turn, then measure
time taken to swing next 5 turns
_
.-P
3
0-J
Hydraulic drift of deg. 0 0

swing mml (0) (0)
Engine stopped
45 - 55°C
Set machine on 15” slope, and set
upper structure at 90” to the side.
Make match marks on swing circle
outer race and track frame.
Measure distance that match
marks move apart after 5 minutes.

Leakage from swing . Hydraulic oil temperature:
45 - 55°C 4!/mir Max. 14 Max. 28
motor
. Relieve swing circuit.
95- 117 95- 117
Travel speed ( 1) TWP01786 set

45 - 55°C
65 - 80 65 - 80
. In D.H mode
Raise track on one side at a ,
time, rotate one turn, then
measure time taken for next 5
turns with no load.
-
20-10-4 PC1 100-6

0
-
Applicable model T PC1 100-6 loading shovel
Cats Standard value

gor Item Measurement conditions Unit For new machine
29 - 37 29 - 37
Travel speed (2)

TWP01787 set
45 - 55°C
20 - 25 20 - 25
In D.H mode
Run up for at least 10 m, and
measure time taken to travel
next 20 m on flat ground.

"A
TWPOi788
45 - 55°C
Travel deviation
In D.H mode mm Max. 200 Max. 220
Use a hard horizontal surface.
Run up for at least 10 m, and
measure deviation (X) when
traveling next 20 m on flat ground.
20m
I- -I
1 10m _i
BKP00107
Hydraulic drift of mm 0
travel
Hydraulic &i temperature:
45 - 55°C
Stop machine on 12” slope with
sprocket at uphill end of machine.
. Do not place the work equip-
ment on the ground.
. Measure the distance the
machine moves in 5 minutes.
PC1 100-6 20- 1o-5

0
Applicable model
Standard value
For new machine
t
stage of travel e/mir Max. 20 Max. 40

or Lock Pin
TWP01790

45 - 55°C
Lock shoes and relieve travel
circuit.
Total work
equipment Max. 1,400 Max. 2,100
hydraulic drift at (Max. 760) (Max. 1,200)
tip of bucket
teeth
TWP01791
Boom cylinder
(amount of Place in above posture and
-
retraction of measure extension or retraction
cylinder) of each cylinder and downward
movement at tip of bucket teeth.
Engine stopped
Hydraulic oil temperature: mm
45 - 55°C
Horizontal, flat ground
Arm cylinder All control levers at neutral
(amount of Buket: Rated load or full load - -
extension of
of soil
cylinder)
114.7 kN {I 1,700 kg)
Start measuring immediately
after setting.
. Measure hydraulic drift every 5
minutes, and judge from results
for 15 minutes.
Bucket cylinder . Figures in ( ) are value when
(amount of -
bucket is not loaded.
retraction of
cylinder)
20-10-6 PCllOO-6
0
Cate
Applicable model
r PC1 100-6 loading
Standard value
shovel
Ser;i.cEimit
Item Measurement conditions Jnit or new machine
gorj
6.9 + 0.7 8.3

Boom
Bucket teeth in
contact with
ground set
TWP01792
T
Cylinder fully
extended Hydraulic oil temperature:
4.8 f 0.5 5.8
45 - 55°C
In D.H mode
. Bucket: No load
-
4.0 t 0.5 Max. 5.0
1
Arm
Cylinder fully
u I
retracted
c 0) set
$ ‘//////I///////////
TWP01793
-
Fully extended Engine at full throttle
Hydraulic oil temperature: 3.1 + 0.4 Max. 3.9
45 - 55°C
In D.H mode
Bucket: No load

fl
3.5 t 0.4 Max. 4.3
1
Bucket
Cylinder fully
retracted
set
z
-
Fully extended Enaine at full throttleTWP0’7g4
. Hydraulic oil temperature: 3.0 2 0.4 Max. 3.8
45 - 55°C
. In D.H mode
. Bucket: No load
2.0 2 0.3 Max. 2.6

Bottom dump
I
Cylinder fully
retracted
set
z TWP01795
Fully extended
2.3 T 0.3 Max. 2.9
45 - 55°C
PC1 100-6 20-10-7

0
Applicable model
Standard value Ser;ic;;mit

or new machine
Boom TWPOl796 set Max. 3 Max. 5

Engine at low idling
45 - 55°C
Retract arm and bucket cylinder
fully, then lower boom from
max. RAISE point and measure
time taken from point where
bucket contacts ground to point
where chassis rises from
ground.
_-
I
c- 2$
‘/W////////////////
Arm
TWP01797
set Max. 3 Max. 5

45 - 55°C
Set top surface of boom hori-
zontal, retract bucket cylinder
fully, then extend arm cylinder
and measure time taken for arm
to start moving again after
stopping at bottom.
Bucket TWP01798 set Max. 3 Max. 5

45 - 55°C
Set top surface of boom hori-
zontal, retract arm cylinder fully,
then extend bucket cylinder and
measure time taken for bucket
to start moving again after
stopping at bottom.
20-10-8 PC1 100-6

0
r
L
Standard value
Item Measurement conditions Unit f‘or new machine
TWP01799
Bottom dump set Max. 3 Max. 5
Time taken for bottom dump to
move again when operated from
max. bottom open position to
close position and stopped
temporarily.
45 - 55°C

Cylinders 45 - 55°C Max. 5 Max. 20
. Hydraulic oil pressure:
31.4 + 1.0 MPa I320 + 10 kg/cm21 :c/mir l-
Center swivel
Max. 10 Max. 100
joint
PC1 100-6 zo- 1o-9

0
TESTING AND ADJUSTING STANDARD VALUE TABLE FOR ELECTRICAL PARTS
STANDARD VALUE TABLE FOR ELECTRICAL PARTS
Sys- Name of Connector Inspection Measurement

Judgment table
tem component No. method conditions
If the condition is as shown in the table 1) Turn starting
below, it is normal. switch OFF.
resistance
Measure
2) Disconnect
Between (1) – (3) 4 – 6 kΩ E06 connector.
Fuel control dial E06 (male)
Between (1) – (2) 0.25 – 7 kΩ
Between (2) – (3) 0.25 – 7 kΩ

resistance
Measure

E21 (male) 2) Disconnect
Between (1) – (2) 500 – 1,000 Ω E21 connector.
Between (1) (2) – chassis Min. 1 MΩ
No. 1 engine
speed sensor
If the condition is as shown in the table 1) Start engine.
Measure
below, it is normal. 2) Insert T-

voltage
E21 adapter.
Between (1) – (2) 0.5 – 3.0 V fl Measure with
the tester in
the AC range.

resistance
Measure

2) Disconnect
E07 (male) Between (1) – (2) 500 – 1,000 Ω E07 connector.
Engine controller system
Between (1) (2) – chassis Min. 1 MΩ

No. 2 engine
speed sensor
Measure

voltage
E07 adapter.
Between (1) – (2) 0.5 – 3.0 V fl Measure with
the tester in
the AC range.

Visual
check
Kerosene mode M36

selector switch N36 Gasoline mode Disconnect
connector Kerosene mode Connect

Measure
Electronical governor fuel injection pump
below, it is normal.
voltage
switch ON.
Rack position E22 2) Insert T-
sensor Between (1) – (2) 4.5 – 5.4 V adapter.
Between (3) – (2) 0.1 – 4.5 V

resistance
Measure
2) Disconnect
Governor E19 E32 E19, E32
control E19 (male)
E32 (male) Between (1) – (2) Between (1) – (2) 10 – 21 Ω connector.
solenoid
Between (1) (2) Between (1) (2)
– chassis – chassis Min. 1 MΩ

resistance
Measure
Variable pre- below, it is normal. switch OFF.

stroke control E20 (male) 2) Disconnect E20
Between (1) – (2) 10 – 21 Ω connector.
solenoid
Between (1)(2) – chassis Min. 1 MΩ
PC1100-6 20-11
1

Judgment table
Measure
voltage
Main power below, it is normal. switch ON.
source E12 2) Insert T-
Between (9)(17) – (8)(16) 20 – 30 V adapter.
Measure
voltage
Backup power below, it is normal. switch OFF.
source E12 2) Insert T-
Between (7) – (8)(16) 20 – 30 V adapter.
Measure

voltage
Solenoid below, it is normal. switch ON.

power source E13 2) Insert T-
Between (1) – (21) 20 – 30 V adapter.

below, it is normal. switch ON.
2) Insert T-
Between E14(6) – E14(16)
Measure
adapter.
voltage
(sensor power source) 4.75 – 5.25 V

Fuel control E14
dial E15 Fuel dial 4.0 – 4.75 V
Between at min.
E15(11) – E14(16)
Fuel dial
Engine controller
(Input signal) 0.25 – 1.0 V

at max.

Measure

voltage
No. 1 engine adapter.

speed sensor E14 Between (2) – (14) 0.5 – 3.0 V fl Measure with
the tester in
the AC range.

Measure

voltage
No. 2 engine adapter.

speed sensor E14 Between (3) – (14) 0.5 – 3.0 V fl Measure with
the tester in
the AC range.

Kerosene below, it is normal. switch ON.
Measure
voltage
mode 2) Insert T-
selector E12 Selector switch 20 – 30 V adapter.
E17 Between released
switch E17(2) –
E12(8)(16) Selector switch
connected Max. 1 V

Measure

voltage
Rack position E13 2) Insert T-

sensor E14 Between E13(16) – (21) 4.5 – 5.4 V adapter.
Between E14(7) – (14) 0.1 – 4.5 V
20-12 PC1100-6
1

Judgment table
Measure
voltage
Governor cut 2) Insert T-
relay signal E12 When normal 20 – 30 V
Between adapter.
(4) – (13) When abnormal Max. 1 V

Measure
voltage
2) Insert T-
Connector E14 Between adapter.
Check 0 E14(1) – E14(14) 20 – 30 V
check signal E17
Check 1 Between Max. 1 V
E17(1) – E14(14)
Engine controller
If the condition is as shown in the table 1) Engine full

below, it is normal. throttle.
2) Insert T-
Measure
voltage
Auto- Lever operated Max. 1 V adapter.

deceleration E12 Between
E17(12) – fl Operate the
signal E17 lever slightly
E12(8)(6) All levers at 20 – 30 V
neutral (just enough to
turn the PPC
switch ON).
Measure

voltage
Starting
switch E12 below, it is normal. switch START.
start signal E17 2) Insert T-
Between E17(18) – E12(8)(6) 20 – 30 V adapter.

2) Insert T-
Measure
voltage
APS actuate E12 When APS adapter.

signal Between stopped Max. 1 V
E18 E18(4) – fl See the Note
E12(8)(6) When APS for actuation of
20 – 30 V the APS.
operated

Continuity

2) Disconnect
APS switch M91 (male) Between OFF No continuity M91 connec-
(2) – (3) Continuity tor.
ON

APS controller system

resistance
Measure
APS water 2) Disconnect

temperature P19 (male) Between Less than 20°C Max. 0.5 Ω P19 connector.
sensor terminal
and body Min. 20°C Min. 1 MΩ

resistance
Measure

Glow plug P13 (male) 2) Disconnect
No. 1 glow Between (1) – body P13 connector.
0.8 – 1.3 Ω
No. 2 glow Between (4) – body
resistance
Measure

APS nozzle below, it is normal. switch OFF.
— 2) Disconnect
Between nozzle terminal 1.5 – 2.5 Ω connector.
PC1100-6 20-13
1

Judgment table
Measure
voltage
Power source E25 below, it is normal. switch ON.
voltage E26 2) Insert T-
Between E25(1) – E26(1) 20 – 30 V adapter.

Measure
voltage
APS water 2) Insert T-
temperature E26 Less than 20°C Max. 1 V adapter.
Between
sensor (2) – (1)
Min. 20°C 7 – 10 V

Measure
voltage
2) Insert T-
Glow plug 1 E25 When APS adapter.
E26 Between stopped Max. 1 V
E25(2) –
E26(1) When APS 4 – 12 V
operated

APS controller system

Measure
voltage
APS controller
2) Insert T-
Glow plug 2 E25 When APS adapter.
Between stopped Max. 1 V
E26
E25(3) –
E26(1) When APS 4 – 12 V
operated

Measure
voltage
2) Insert T-
E25 When APS adapter.
APS nozzle Between stopped Max. 1 V
E26 E25(4) –
E26(1) When APS 0.4 – 5 V
operated

Measure
voltage
Starting switch below, it is normal. switch START.

START signal E26 2) Insert T-
Between (3) – (1) 10 – 24 V adapter.

2) Insert T-
When APS adapter.
Max. 1 V
Measure
voltage
Preheating Between stopped

monitor lamp E26 (4) – (1) When APS 12 – 20 V
signal operated (Note)
Note: After the starting switch is turned ON,
the voltage is held for 12 seconds, and
then goes down to less than 1 V.
20-14 PC1100-6
1

Judgment table
Continuity
2) Disconnect
X05 When FREE When LOCK X05 connector.
Swing lock switch
(female) Between (1) – (2) No continuity Continuity
Between (3) – (4) Continuity No continuity

Continuity
2) Disconnect
Swing prolix SW01 When OFF When ON harness.
switch (main body)
Between (1) – (3) No continuity Continuity

2) Disconnect C05
When OFF When ON connector.
Continuity

Pump prolix
C05 (male)
Pump controller system
switch Between (4) – (2) Continuity No continuity

resistance
Measure

Pump prolix below, it is normal. switch OFF.
resistor C06 (male) 2) Disconnect
Between (1) – (2) 19 – 21 Ω C06 connector.
Boom RAISE S02 (male) If the condition is as shown in the table 1) Start the
below, it is normal. engine.
Boom LOWER S04 (male) (or check with
Between Lever at neutral Min. 1 MΩ the accumula-
Arm IN S05 (male)
(1) – (2) tor charged)
Lever operated Max. 1 Ω 2) Disconnect the
Arm OUT S03 (male)
connector to
PPC pressure switch

Bucket CURL S06 (male) be checked.
resistance
Bucket DUMP S07 (male)

Measure
Left swing S10 (male)

Right swing S08 (male)
L.H. travel S12 (male)
FORWARD
L.H. travel S13 (male)
REVERSE
R.H. travel S01 (male)
FORWARD
R.H. travel S11 (male)
REVERSE
PC1100-6 20-15
1

Judgment table
resistance
Measure
Model selection C09 2) Disconnect C09
Between Between Between Between connector.
connector (female) (1) – (8) (2) – (8) (3) – (8) (4) – (8)
Continuity No continuity No continuity No continuity

resistance
Measure

TVC solenoid C13 (male) 2) Disconnect C13
Between (1) – (2) 10 – 22 Ω connector.

resistance
Measure

Swing priority 2) Disconnect V01
solenoid V01 (male) Between (1) – (2) 20 – 60 Ω connector.

resistance
Measure

2-stage relief V02 (male) 2) Disconnect V02
solenoid Between (1) – (2) 20 – 60 Ω connector.

resistance
Measure

Straight travel V03 (male) 2) Disconnect
solenoid Between (1) – (2) 20 – 60 Ω connector.

resistance
Measure
Swing holding below, it is normal. switch OFF.

V04 (male) 2) Disconnect
brake solenoid V11 (male) Between (1) – (2) 20 – 60 Ω
(F) (R) V04, V11
Between (1)(2) – chassis Min. 1 MΩ connector.

resistance
Measure

Travel speed 2) Disconnect V06

resistance
Measure

CO cancel V07 (male) 2) Disconnect
solenoid Between (1) – (2) 20 – 60 Ω V07connector.
Measure

voltage
Pump controller
Main below, it is normal. switch ON.

power source C01 2) Insert T-
Measure

voltage
Solenoid below, it is normal. switch ON.

power source C02 2) Insert T-
20-16 PC1100-6
1

Judgment table
Measure
voltage
2) Insert T-
Swing lock C16 Swing lock adapter.
Between switch at FREE 20 – 30 V
switch C17 C17(16) –
C16(3)(4) Swing lock Max. 1 V
switch at LOCK

Measure
voltage
Swing prolix 2) Insert T-

C16 Swing prolix adapter.
switch Between switch at OFF 20 – 30 V
C17
C17(8) –
C16(3)(4) Swing prolix Max. 1 V
switch at ON

Measure
2) Insert T-
voltage
No.2 engine adapter.
C16 Between (2) – (1) 0.5 – 3.0 V fl Measure with
speed sensor
the tester in
the AC range.
1) Start engine.
Boom RAISE Between C17(2) – C16(3)(4) 2) Insert T-
Boom LOWER Between C17(10) – C16(3)(4) adapter.
Arm IN Between C17(3) – C16(3)(4)

Pump controller
Arm OUT Between C17(11) – C16(3)(4)

Bucket CURL Between C16(11) – C16(3)(4)
Measure voltage
Bucket DUMP Between C16(12) – C16(3)(4)

L.H. swing Between C17(7) – C16(3)(4)
PPC pressure C16
switch C17 R.H. swing Between C16(5) – C16(3)(4)
L.H. travel Between C16(6) – C16(3)(4)
R.H. travel Between C16(13) – C16(3)(4)
If the condition is as shown in the table

Control levers at neutral Levers operated
20 – 30 V Max. 1 V

Mode Between C17(5) Max. 2) Insert T-
selection 1 – C16(3)(4) 1V adapter.
Measure
voltage
Model C16
selection Mode Between C17(13)
C17 selection 2 – C16(3)(4) 20 – 30 V
connector
Mode Between C17(6)
selection 3 – C16(3)(4) 20 – 30 V
Mode Between C17(14)
selection 4 – C16(3)(4) 20 – 30 V

Measure
voltage

TVC solenoid C02 2) Insert T-
Between (18) – (11)(21) 0–1V adapter.
3) Fuel dial at
MAX.
PC1100-6 20-17
1

Judgment table
below, it is normal. 2) Insert T-adapter.
Measure
voltage
Swing priority fl Operate the
solenoid C01 Between Swing priority switch ON
+ swing lever operated 20 – 30 V
lever slightly
(5) – (just enough to
(6)(12) All control levers at turn the PPC
neutral Max. 1 V
switch ON).

Measure
voltage
2-stage relief fl Operate the

solenoid C01 Between Travel lever operated 20 – 30 V lever slightly
neutral Max. 1 V
switch ON).

Measure
voltage
Straight travel fl Operate the

C01 Work equipment + L.H. and lever slightly
solenoid Between R.H. travel levers operated 20 – 30 V
Max. 1 V
neutral switch ON).

Pump controller

Measure
voltage
Swing holding fl Operate the

C01 Work equipment or
brake solenoid Between swing lever operated 20 – 30 V lever slightly
5 sec after all control turn the PPC
(6)(12) levers are placed at neutral Max. 1 V
switch ON).
Measure
voltage
Travel speed fl Operate the

C01 Travel speed switch Hi +
solenoid Between travel lever operated 20 – 30 V lever slightly
neutral Max. 1 V
switch ON).
Measure
voltage
CO cancel fl Operate the

solenoid C01 Between Travel lever operated 20 – 30 V lever slightly
neutral Max. 1 V
switch ON).

Measure
voltage
Auto- fl Operate the

deceleration C01 Auto-deceleration switch ON
Between + all control levers at neutral 20 – 30 V lever slightly
signal (4) – (just enough to
(6)(12) Auto-deceleration turn the PPC
switch at OFF Max. 1 V
switch ON).
Continuity
Machine push-up system

Machine push-up M38 No 2) Disconnect
switch Between When switch is ON continuity M38 connec-
(female) tor.
(1) – (2)
When switch is OFF Continuity

resistance
Measure

Machine push-up 2) Disconnect V05
20-18 PC1100-6
1

Judgment table
Continuity
Boom shockless M33 No 2) Disconnect
solenoid (female) Between When switch is ON continuity M33 connec-
(1) – (3) tor.
When switch is OFF Continuity
Boom shockless system
resistance If the condition is as shown in the table 1) Turn starting

Measure

Boom RAISE 2) Disconnect V09
V09 (male) Between (1) – (2) 20 – 60 Ω connector.
shockless solenoid

resistance
switch OFF.
Measure
Boom LOWER 2) Disconnect V10
shockless solenoid V10 (male) Between (1) – (2) 20 – 60 Ω connector.
PC1100-6 20-19
1

Judgment table
resistance
Measure
Coolant 2) Disconnect P07
temperature P07 (male) Normal temperature Approx.
Between (25°C) 37– 50 kΩ connector.
sensor 3) Remove
(1) – (2) Approx.
100°C 3.5 – 4.0 kΩ senosr.
resistance If the condition is as shown in the table 1) Turn starting

Measure
Position of float upper Approx. 2) Disconnect P06

Fuel level sensor P06 (male) Between connector.
limit Max. 12 Ω
(1) – 3) Remove
body Position of float lower Approx.
limit 85 – 110Ω senosr.

switch OFF.
resistance
Measure
Coolant level P08 (male) 2) Disconnect

Above LOW water level P08, P20
sensor P20 (male) Between in sub tank Max. 1 Ω
connector.
(1) – (2) Below LOW water level
in sub tank Min.1 MΩ
If the condition is as shown in the table 1) Install oil

below, it is normal. pressure
measuring
Oil pressure switch for low pressure gauge.
2) Disconnect
Between Oil pressure above 0.07 MPa
Min.1 MΩ sensor harness.
resistance
{above 0.7 kg/cm2}

Measure
terminal 3) Start engine.

Monitor panel system
Engine oil – body Oil pressure below 0.03 MPa

Max. 1 Ω fl It is also possi-
pressure switch — {below 0.3 kg/cm2} ble to remove
the sensor and
Oil pressure switch for high pressure check as an
Oil pressure above 0.17 MPa individual part.
Between {above 1.7 kg/cm2} Min.1 MΩ fl The switch at the
terminal flywheel end is
– body Oil pressure below 0.13 MPa
{below 1.3 kg/cm2} Max. 1 Ω the low-pressure
switch.

resistance
below, it is normal. 2) Disconnect

Measure
Air cleaner P11 (male) P11, P12

clogging sensor P12 (female) Air cleaner normal Max. 1 Ω connector.
Between
P11 – P12
Air cleaner clogged Min.1 MΩ

below, it is normal. (at mid-range
resistance
Measure
speed or
Alternator R terminal Between R terminal – chassis 27.5 – 29.5 V above)
fl If the battery is old, or after starting in
cold areas, the voltage may not rise for
some time.

resistance

Measure
Engine oil level Position of float upper 2) Disconnect P05

P05 (male) Max. 1 Ω connector.
sensor Between limit
(1) – body Position of float lower
3) Remove
limit Min.1 MΩ sensor.

resistance

Measure
Hydraulic oil level Position of float upper 2) Disconnect P09

sensor P09 (male) Max. 1 Ω connector.
Between limit
(1) – body Position of float lower
3) Remove
limit Min.1 MΩ sensor.
20-20 PC1100-6
1

Judgment table
resistance
Measure
Hydraulic oil 2) Disconnect P10
temperature P10 (male) Normal temperature Approx.
Between (25°C) 37– 50 kΩ connector.
sensor 3) Remove
(1) – (2) Approx.
100°C 3.5– 4.0 kΩ senosr.
If the condition is as shown in the table 1) Insert a

below, it is normal. dummy
resistance with
Position of Display level resistance (kΩ) the starting
Confirmation of display · measure resistance
gauge display (controller input resistance) switch OFF, or

Starting switch Starting switch measure the
ON OFF resistance of
the sensor.
All OFF – 0.646 2) Check the
Right
side
display with
9 0.575 – 0.342 the starting
Coolant switch ON.
8 3.156 – 3.708
➝
temperature C03
sensor (female) 7 3.422 – 3.900
[ ]
Engine water Between
position
Display
temperature (1) – (16) 6 3.600 – 4.349

gauge
5 4.015 – 5.122
4 4.728 – 6.816
3 6.294 – 10.744
2 9.946 – 36.535
side
Left
Pump controller
1 33.725 –
flLevels 8 and 9 flash
If the condition is as shown in the table 1) Insert a

below, it is normal. dummy
resistance with
Position of Display level resistance (kΩ) the starting
Confirmation of display · measure resistance
gauge display (controller input resistance) switch OFF, or

Starting switch Starting switch measure the
ON OFF resistance of
the sensor.
All OFF – 13.82 2) Check the
Right
side
display with
9 11.71 – 21.25 the starting
switch ON.
8 18.90 – 28.45
➝
C03
Fuel level (female)
sensor Between 7 25.82 – 31.85
position
Fuel level (2) – (16)

[ ]
Display
gauge 6 29.18 – 39.91
5 37.00 – 44.60
4 41.77 – 55.14
➝
3 50.42 – 77.07
2 72.98 – 691.50
side
Left
1 63.800 –
flLevel 1 flashes
PC1100-6 20-21
1

Judgment table
Measure
voltage
Coolant level Above LOW water level 2) Insert T-
sensor C16 Between in sub tank Max. 1 V adapter.
(8) – (3)(4) Below LOW water level
in sub tank 20 – 30 V
If the condition is as shown in the table 1) Install oil

below, it is normal. pressure
measuring
Oil pressure switch for low pressure gauge.
Oil pressure above 0.07 MPa 2) Insert T-
Between 20 – 30 V
Measure
{above 0.7 kg/cm2} adapter.

voltage
Engine oil (15) – (3)(4) Oil pressure below 0.03 MPa 3) Start engine.
pressure C16 {below 0.3 kg/cm2} Max. 1 V
switch
Oil pressure switch for high pressure
Oil pressure above 0.17 MPa
Between {above 1.7 kg/cm2} 20 – 30 V
(7) – (3)(4) Oil pressure below 0.13 MPa
{below 1.3 kg/cm2}
Max. 1 V


Measure
voltage
Air cleaner adapter.

Pump controller
clogging C16 Air cleaner normal Max.1 V

sensor Between
(17) – (3)(4)
Air cleaner clogged 20 – 30 V
If the condition is as shown in the table 1) Insert T-

below, it is normal. adapter.
Measure
voltage
Alternator C03 Stop engine Max.1 V

Between
(12) – (16)
Start engine 20 – 30 V

Measure
voltage
Engine oil Position of float upper 2) Insert T-

C16 Max. 1 V adapter.
level sensor Between limit
(16) – (3)(4) Position of float lower
3) Remove
limit 20 – 30 V sensor.

Measure
voltage
Hydraulic oil Position of float upper 2) Insert T-

C16 Max. 1 V adapter.
level sensor Between limit
(9) – (3)(4) Position of float lower
3) Remove
limit 20 – 30 V sensor.
Measure

voltage
Starting
switch ON below, it is normal. switch ON.
C03 2) Insert T-
signal Between (8) – (16) 20 – 30 V adapter.
20-22 PC1100-6
1

Judgment table
Pump controller

below, it is normal. switch START.
Measure
voltage
Starting switch 2) Insert T-
START signal C03 Between (8) – (16) 20 – 30 V adapter.

Continuity
Buzzer cancel 2) Disconnect
P03 connector.
switch (female) Between Free No continuity
(1) – (2)
Push Continuity

2) Disconnect
Between Between Between
Switch
(1) – (2) (1) – (2) (1) – (4) M18 connec-
tor.
WASH II No Continuity Continuity
Continuity
continuity
Wiper · washer M18 No No
INT Continuity
(female)
switch continuity continuity

No No No
OFF continuity continuity continuity
ON Continuity No No
continuity continuity
WASH I Continuity Continuity No

continuity
1) Turn starting
Measure
If the condition is as shown in the table

voltage

Power source P02 2) Insert T-

2) Insert T-
ON signal adapter.
Between Wiper switch OFF 20 – 30 V

(4) – (1)(9)
Wiper switch ON Max. 1 V
Monitor panel
Wiper · washer INT signal

switch P02
Measure
(12) – (1)(9)
voltage
Wiper switch INT Max. 1 V
WASH signal

(5) – (1)(9)
Wiper switch WASH Max. 1 V

Buzzer cancel P01 When buzzer cancel 2) Insert T-
switch Between 20 – 30 V adapter.
P02 P01(6) –
switch is released
P02(1)(9) When buzzer cancel
switch is pushed Max. 1 V
PC1100-6 20-23
1

Judgment table
Measure
voltage
2) Insert T-
Swing lock P01 Swing lock adapter.
Between switch at OFF 20 – 30 V
switch P02 P01(5) –
P02(1)(9) Swing lock Max. 1 V
switch at ON

Measure
voltage
2) Insert T-
Light switch P01 Light switch Max. 1 V adapter.
Between at OFF
P02 P01(8) –
P02(1)(9) Light switch 20 – 30 V
at ON
Measure

voltage
Monitor panel
Starting below, it is normal. switch ON.

switch ON P01
P02 2) Insert T-
signal Between P01(9) – P02(1)(9) 20 – 30 V adapter.
Measure

voltage
Starting P01 below, it is normal. switch ON.

switch ACC 2) Insert T-
signal P02
Between P01(10) – P02(1)(9) 20 – 30 V adapter.
Measure

voltage
Starting below, it is normal. switch ON.

switch START P01
P02 2) Insert T-
signal Between P01(19) – P02(1)(9) 20 – 30 V adapter.

Measure
2) Insert T-
voltage
APS
preheating P01 Preheating Max. 1 V adapter.
Between stopped
signal P02 P01(18) –
P02(1)(9) Preheating 20 – 30 V
operated
20-24 PC1100-6
1

Judgment table
Continuity
2) Disconnect L03
Step light When released No connector.
switch L03 (male) Between continuity
(1) – (2)
When pressed Continuity

Measure
voltage

Power source T21 2) Insert T-
voltage Between (2) – (1) 20 – 30 V adapter.
Step light system

Measure
2) Insert T-
voltage
Step light switch

Step light timer
Input signal T21 Max. 1 V adapter.

Between released
(3) – (1) Step light switch 20 – 30 V
pressed

2) Insert T-
Step light switch adapter.
Measure
Max. 1 V
voltage
Between released
Output signal T21 (4) – (1) Step light switch 20 – 30 V
pressed (Note)
Note: After the switch is pressed, the volt-
age is held for 60 seconds, and then
goes down to less than 1 V.
PC1100-6 20-25
1
Tools for testing, adjusting, and troubleshooting ............................................................................. 20-102

Measuring engine speed ....................................................................................................................... 20-103
Measuring air supply pressure (Boost pressure) ............................................................................... 20-104
Measuring exhaust temperature ........................................................................................................... 20-105
Measuring exhaust color ...................................................................................................................... 20-106
Adjusting valve clearance ..................................................................................................................... 20-107
Measuring compression pressure ........................................................................................................ 20-108
Measuring blow-by pressure ................................................................................................................ 20-109
Testing and adjusting fuel injection timing ........................................................................................ 20-110
Measuring engine oil pressure ............................................................................................................ 20-111
Testing and adjusting fan belt tension ............................................................................................... 20-112
Testing and adjusting alternator belt tension .................................................................................... 20-112
Testing and adjusting belt tension for air conditioner compressor ................................................ 20-113
Adjusting engine speed sensor ............................................................................................................ 20-113
Testing clearance of swing circle bearing .......................................................................................... 20-114
Measuring wear of sprocket ................................................................................................................. 20-115
Testing and adjusting track shoe tension ........................................................................................... 20-116
Testing and adjusting hydraulic pressure in work equipment, swing, travel circuit ..................... 20-117
Testing and adjusting control pump circuit oil pressure .................................................................. 20-122
Testing and adjusting piston pump control pressure ....................................................................... 20-123
Measuring servo piston stroke ............................................................................................................. 20-131
Measuring PPC valve output pressure and testing PPC shuttle valve ............................................ 20-132
Testing solenoid valve output pressure .............................................................................................. 20-136
Adjusting work equipment, swing PPC valve .................................................................................... 20-138
Testing travel deviation ......................................................................................................................... 20-139
Testing locations causing hydraulic drift of work equipment .......................................................... 20-140
Measuring oil leakage ........................................................................................................................... 20-141
Bleeding air ............................................................................................................................................ 20-145
Releasing remaining pressure in hydraulic circuit ............................................................................ 20-147
PC1100-6 20-101
1
TESTING AND ADJUSTING TOOLS FOR TESTING, ADJUSTING, AND TROUBLESHOOTING
TOOLS FOR TESTING, ADJUSTING, AND TROUBLESHOOTING
Check or measurement item Symbol Part No. Part Name Remarks

Digital display
Engine speed A 799-203-8001 Multi-tachometer L : 60 – 2,000 rpm
H : 60 – 19,999 rpm
Air supply pressure –101 – 199.9 kPa

B 799-201-2202 Boost gauge kit
(boost pressure) {–760 – 1,500 mmHg}
Coolant, oil and exhaust
temperature C 799-101-1502 Digital temperature gauge –99.9 – 1,299°C
1 799-201-9000 Handy Smoke Checker Discoloration 0 – 70%

Exhaust color D (with standard color)
Commercially (Discoloration x 1/10 = Bosh index)
2 available Smoke meter
795-125-1390 For intake : 0.4 mm
Valve clearance E Feeler gauge For exhaust : 1.0 mm
795-502-1205 Compression gauge 0 – 6.9 MPa {0 – 70 kg/cm2}
Compression pressure F
• 795-502-1350 • Adapter For 170 engine series
Blow-by pressure G 799-201-1504 Blow-by checker 0 – 4.9 MPa {0 – 500 mmH2O}
Fuel injection time H 795-471-1200 Gauge assembly
Pressure gauge:
799-101-5002 Hydraulic tester 2.5, 5.9, 39.2, 58.8 MPa
{25, 60, 400, 600 kg/cm2}
Pressure gauge:
1 790-261-1203 Digital hydraulic tester 58.8 MPa {600 kg/cm2}
Oil pressure J 799-101-5220 Nipple
10 x 1.25
07002-11023 O-ring
2 799-401-2320 Hydraulic gauge 0.98 MPa {10 kg/cm2)
3 799-401-2701 Differential pressure gauge 0 – 49 MPa {0 – 500 kg/cm2}
Measuring wear of sprocket K 796-827-1120 Wear gauge
79A-264-0021 Push-pull scale 0 – 294N {0 – 30 kg}

Operating effort L
79A-264-0091 Push-pull scale 0 – 490N {0 – 50 kg}
Stroke, hydraulic drift Commercially
M available Scale
Work equipment speed Commercially
N available Stop watch
Servo piston stroke P 566-98-41120 Disc gauge
Measuring voltage and
resistance values Q 79A-264-0211 Tester
Troubleshooting of 799-601-8000 T-adapter assembly

wiring harnesses and R
sensors 799-601-7360 Adapter For relay (5 Pin)
20-102 PC1100-6
1
TESTING AND ADJUSTING MEASURING ENGINE SPEED
MEASURING ENGINE SPEED

¤ When removing or installing the measuring
equipment, be careful not to touch any high
temperature parts.
fl Measure the engine speed under the following
conditions.
• Coolant temperature: Within operating range
• Hydraulic oil temperature : 45 – 55°C
1. Remove the cap.
2. Install pick-up q of multi-tachometer A, then

connect it to multi-tachometer A.
3. Start the engine, and measure the engine speed

when it is set to the conditions for measuring.
1) Measuring low idling and high idling speeds:
i) Set the working mode switch to DH
mode.
ii) Turn the auto-deceleration switch OFF.
fl When measuring at high idling only.
iii) Measure the engine speed with the fuel
control dial set to low idling (MIN) or
high idling (MAX).
2) Measuring auto-deceleration speed:
i) Turn the auto-deceleration switch ON.
ii) Set the fuel control dial to high idling.
iii) Measure the engine speed with all the
levers at neutral.
3) Measuring speed at all-pump relief:
i) Set the working mode to the DH mode.
ii) Turn the heavy-lift switch OFF.
iii) Set the fuel control dial to high idling.
iv) Measure the speed with arm IN circuit
relieved.
4) Measuring speed at all-pump relief + heavy
lift ON:
i) Set the working mode to the DH mode.
ii) Turn the heavy-lift switch ON.
iii) Set the fuel control dial to high idling.
iv) Measure the speed with boom RAISE cir-
cuit relieved.
PC1100-6 20-103
1
TESTING AND ADJUSTING MEASURING AIR SUPPLY PRESSURE (BOOST PRESSURE)
MEASURING AIR SUPPLY

PRESSURE (BOOST PRESSURE)
¤ When removing or installing the measuring
equipment or when carrying out the measure-
ments, be careful not to touch any high tem-
perature parts.
fl Measure the air supply pressure under the fol-
lowing conditions.
1. Remove air supply pressure measurement plug

(1) (PT 1/8).
2. Fit nipple q of oil pressure gauge J1, and con-

nect to boost gauge B.
3. Run the engine at a mid-range speed or above,

and bleed the oil from inside the hose.
fl Insert the connection of the pressure gauge
and hose about half way, and repeatedly
open the self-seal portion of the hose to
bleed the oil.
fl If Pm kit (A) is available, use the air bleed
coupling (790-261-1130) inside the kit.
fl The gauge does not work if there is any oil
inside the hose, so always be sure to bleed
all the oil.
4. Set the working mode switch to the DH mode

and turn the heavy-lift switch ON.
5. Run the engine at full throttle, and measure the

air supply pressure when the boom RAISE cir-
cuit is relieved.
20-104 PC1100-6
1
TESTING AND ADJUSTING MEASURING EXHAUST TEMPERATURE
MEASURING EXHAUST TEM-

PERATURE
fl Wait for the temperature of the exhaust mani-
fold to go down before removing or installing
the temperature sensor.
fl Measure the exhaust temperature under the fol-
lowing conditions.
1. Remove exhaust temperature measurement plug

(1).
2. Install sensor q of digital temperature gauge C,

then connect to digital temperature gauge C.
fl Clamp the wiring harness of the tempera-
ture gauge so that it does not touch any
high temperature part during the measure-
ment.
3. Run the engine at full throttle and measure the

maximum temperature during operation.
PC1100-6 20-105
1
TESTING AND ADJUSTING MEASURING EXHAUST COLOR
MEASURING EXHAUST COLOR

• When measuring in the field where there is no
air or electric power supply, use Handy Smoke
Checker D1; when recording formal data, use
Smoke Meter D2.
fl Raise the coolant temperature to the operat-
ing range before measuring.
¤ Be careful not to touch any hot parts when re-
moving or installing the measuring tools.
1. Measuring with Handy Smoke Checker D1

1) Install filter paper to Handy Smoke Checker
D1.
2) Insert the exhaust gas suction port into the
exhaust pipe, accelerate the engine suddenly,
and operate the handle of Handy Smoke
Checker D1 at the same time to collect the
exhaust gas on the filter paper.
3) Remove the filter paper and compare it with
the scale supplied to judge the condition.
2. Measuring with Smoke Meter D2

1) Insert the probe q of Smoke Meter D2 into
the outlet port of the exhaust pipe, and
tighten the clip to secure it to the exhaust
pipe.
2) Connect the air hose and the socket of the
probe hose and accelerator switch to Smoke
Meter D2.
fl Keep the pressure of the air supply be-
low 1.5 MPa {15 kg/cm2}.
3) Connect the power cord to the AC socket.
fl When connecting the cord, check that
the power switch of Smoke Meter D2 is
OFF.
4) Loosen the cap nut of the suction pump,
and fit the filter paper.
fl Fit the filter paper securely so that the
exhaust gas cannot leak.
5) Turn the power switch of Smoke Meter D2
ON.
6) Accelerate the engine suddenly, and depress
the accelerator pedal of Smoke Meter D2 at
the same time to collect the exhaust gas
color on the filter.
7) Place the filter paper used to catch the ex-
haust gas color on top of at least 10 sheets
of unused filter paper inside the filter paper
holder, and read the value shown.
20-106 PC1100-6
1
TESTING AND ADJUSTING ADJUSTING VALVE CLEARANCE
ADJUSTING VALVE
CLEARANCE
1. Remove the cylinder head cover.
fl For details, see DISASSEMBLY AND ASSEM-
BLY, REMOVAL OF CYLINDER HEAD ASSEM-
BLY.
2. Crank the engine to rotate the crankshaft in the

normal direction. Align “1.6TOP” line (2) on the
crankshaft pulley with pointer (1), and set the
No. 1 cylinder to the compression top dead
center position. When rotating, check the move-
ment of the valves.
fl Carry out the cranking with the barring de-
vice of the flywheel housing.
fl At the compression top dead center, the
rocker arms for both the intake and exhaust
move.
If the rocker arms do not move, the cylinder
is not at compression top dead center, so
rotate the crankshaft one more turn and align
the lines again.
3. When No. 1 cylinder is at compression top dead

center, adjust the valves marked ● in the valve
arrangement chart. Next, rotate the crankshaft
one turn (360°) in the normal direction and ad-
just the valve clearance of the remaining valves
marked fi.
4. To adjust the valve clearance, loosen locknut

(6), then insert feeler gauge E between rocker
arm (3) and crosshead (4), and turn adjustment
screw (5) until the clearance is a sliding fit. Then
tighten locknut (6) to hold the adjustment screw
in position.
3 Locknut : 57.8 – 77.4 Nm {5.9 – 7.9 kgm}
fl After adjusting No. 1 cylinder at compression

top dead center, it is also possible to turn the
crankshaft 120˚ each time and adjust the valve
clearance of each cylinder according to the fir-
ing order.
• Firing order : 1-5-3-6-2-4
fl After tightening the locknut, check the valve

clearance again.
PC1100-6 20-107
1
TESTING AND ADJUSTING MEASURING COMPRESSION PRESSURE
MEASURING COMPRESSION
PRESSURE
¤ When measuring the compression pressure, be
extremely careful not to touch the exhaust mani-
fold or muffler, or to get your clothes caught in
the fan, fan belt or other rotating parts.
1. Adjust the valve clearance.

For details, see ADJUSTING VALVE CLEAR-
ANCE.
2. Warm up the engine to make the oil tempera-

ture 40 – 60°C.
3. Remove nozzle holder assembly (1) from the

cylinder to be measured.
BLY, REMOVAL OF NOZZLE HOLDER AS-
SEMBLY.
4. Set multi-tachometer A in position.

fl See MEASURING ENGINE SPEED.
5. Install adapter q of compression gauge F, then

connect to compression gauge F.
6. Disconnect fuel injection pump connectors E19

(2) and E32 (3).
fl Always turn the starting switch OFF before
disconnecting or connecting the connectors.
7. Crank the engine with the starting motor and

measure the compression pressure.
fl Measure the compression pressure at the
point where the pressure gauge indicator
remains steady.
fl When measuring the compression pressure,
measure the engine speed to confirm that it
is within the specified range.
20-108 PC1100-6
1
TESTING AND ADJUSTING MEASURING BLOW-BY PRESSURE
MEASURING BLOW-BY
PRESSURE
fl Measure the blow-by pressure under the follow-
ing conditions.
• Hydraulic oil temperature: 45 – 55°C
1. Install the nozzle q of blow-by checker G to

blow-by hose (1).
2. Connect nozzle q to blow-by checker G.
3. Set the working mode switch to DH mode.
4. Run the engine at full throttle and measure the

blow-by pressure with the arm IN circuit relieved.
fl Measure the blow-by pressure at the point
where the gauge indicator remains steady.
PC1100-6 20-109
1
TESTING AND ADJUSTING TESTING AND ADJUSTING FUEL INJECTION TIMING

FUEL INJECTION TIMING
1. Remove No. 1 cylinder nozzle holder assembly
(1).
BLY, REMOVAL OF NOZZLE HOLDER AS-
SEMBLY.
2. Remove the coupling cover of the fuel injection
pump.
3. Crank the engine to rotate the crankshaft in the
normal direction and align “1.6TOP” line (3) with
pointer (2) to set the No. 1 cylinder to compres-
sion top dead center.
fl Carry out cranking with the barring device
on the flywheel housing.
fl At compression top dead center, line “a” on
the coupling is near line “b” on the fuel
injection pump.
If the lines are not near each other, the cyl-
inder is not at compression top dead center,
so rotate one more turn and align the lines
again.
4. Set so that the tip of gauge assembly H con-
tacts the head of the piston.
5. At near the top dead center, rotate the crank-
shaft in the normal direction and in the reverse
direction to set the top dead center accurately
with the scale of the dial gauge.
fl Set the scale on the dial gauge to 0 when
the piston is at top dead center.
6. Rotate the crankshaft in the reverse direction
from the top dead center position until the scale
on the dial gauge is approx. 10 mm.
7. Rotate the crankshaft again in the normal direc-
tion until the scale on the dial gauge shows
stroke “c” to align the fuel injection timing.
+ 0.31
fl Stroke c: 5.89 – 0.30 mm (BTDC 19 ± 0.5°)
fl Always rotate the crankshaft in the normal
direction to align the position. If stroke “c”
is passed, carry out the operation again from
Step 6.
8. When doing this, check that line “a” on the
coupling is aligned with line “b” on the fuel
injection pump body.
fl If the lines are not aligned, loosen 2 mount-
ing bolts (4) in the oblong holes in the cou-
pling, rotate the coupling to align the lines,
then tighten the mounting bolts.
3 Nut: 147 – 166 Nm {15 – 17 kgm}
fl After completion of adjustment, rotate the crank-
shaft in the normal direction and check again
that when it passes the compression top dead
center, the error on the dial gauge display is
+ 0.31
000
– 0.30 mm.
If the error is not within the specified range,
carry out the adjustment again from Step 5.
20-110 PC1100-6
1
TESTING AND ADJUSTING MEASURING ENGINE OIL PRESSURE
MEASURING ENGINE OIL

PRESSURE
fl Measure the engine oil pressure under the fol-
lowing conditions.
1. Remove engine oil high-pressure switch (1) (PT1/

8).
2. Install the nipple q of oil pressure gauge J1

and connect to oil pressure gauge J2 (0.98 MPa
{10 kg/cm2}).
3. Start the engine, and measure the oil pressure

with the engine at low idling and at high idling.
PC1100-6 20-111
1
TESTING AND ADJUSTING FAN BELT TENSION
TESTING AND ADJUSTING TESTING AND ADJUSTING ALTERNATOR BELT TENSION

FAN BELT TENSION
fl An auto-tensioner is used to keep the fan belt
tension constant regardless of the elongation of
the V-belt, so there is no need to adjust the belt
tension until the belt is replaced.
However, if the belt slips or if the belt has been
replaced, adjust the belt tension as follows.
1. Loosen stopper bolt (1), then assemble 3 belts.
2. Tighten stopper bolt (1) until it contacts tension

bracket (2), then tighten a further 2 turns.
3. Secure with locknut (3).

3 Locknut: 245 – 308.7 Nm {25 – 31.5 kgm}

ALTERNATOR BELT TENSION
Testing
• Measure deflection a of the belt when pressed
with a force of approx. 58.8 Nm {approx. 6 kg}
at a point midway between the water pump pul-
ley and the alternator pulley.
• Belt deflection a: 10 – 15 mm
Adjusting
fl If the deflection of the belt is not normal, adjust
as follows.
1. Loosen mounting bolt (1) and locknut (2).
2. Turn adjustment nut (3) and move alternator

assembly (4) to adjust the belt tension.
3. Tighten locknut (2) and mounting bolt (1).
20-112 PC1100-6
1
TESTING AND ADJUSTING BELT TENSION FOR AIR CONDITIONER COMPRESSOR
TESTING AND ADJUSTING ADJUSTING ENGINE SPEED SENSOR

BELT TENSION FOR AIR
CONDITIONER COMPRESSOR
Testing
• Measure deflection a of the belt when it is
pressed with a force of approx. 58.8 N {6 kg} at
a point midway between the drive pulley and
the compressor pulley.
• Deflection a of belt: 10 – 15 mm
Adjusting
fl If the belt tension is not correct, adjust as fol-
lows.
1. Loosen 4 mounting bolts (1) and locknut (2).
2. Turn adjustment nut (3) and move compressor

assembly (4) together with the bracket to adjust
the tension of the belt.
3. Tighten locknut (2) and 4 mounting bolts (1).
ADJUSTING ENGINE SPEED

SENSOR
fl Adjust both No. 1 engine speed sensor (1) and
No. 2 engine speed sensor (2) in the same way.
1. Screw in until the tip of sensor (3) contacts gear

(4).
fl Be careful not to let the tip of the sensor be
scratched or to let any iron particles stick to
the sensor tip.
2 Tip of sensor thread:
Gasket sealant (LG-6)
2. When sensor (3) contacts gear (4), turn back 1 ±

1/6 turns to make clearance a.
• Clearance a: 1.5 ± 0.25 mm
3. Tighten locknut (5).
fl Be particularly careful when handling the sen-

sor wiring to ensure that no excessive force is
brought to bear on the wiring.
PC1100-6 20-113
1
TESTING AND ADJUSTING TESTING CLEARANCE OF SWING CIRCLE BEARING
TESTING CLEARANCE OF
SWING CIRCLE BEARING
fl Measure the clearance of the swing circle bear-
ing as follows when it is mounted on the ma-
chine.
¤ When carrying out the measurement, do not
put your hand or feet under the undercarriage.
1. Fix a dial gauge to the outer race (or inner race)

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

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

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

fl The value on the dial gauge is the clearance
of the swing circle bearing.
6. Return to the condition in Step 2, and check that

the dial gauge has returned to the zero point.
fl If it has not returned to the zero point, re-
peat Steps 2 to 5.
20-114 PC1100-6
1
TESTING AND ADJUSTING MEASURING WEAR OF SPROCKET
MEASURING WEAR OF SPROCKET
1. Align wear gauge K with the portion of the

sprocket not meshed with the track shoe.
fl Align with the datum line, then align the
wave shape of the sprocket with the wave
shape of the wear gauge.
2. Judge the wear of the sprocket.

fl If the sprocket wave pattern is above the
wear limit line, it is possible to use the
sprocket as it is.
fl If the sprocket wave pattern has reached the
wear limit line, replace the sprocket with a
new part.
PC1100-6 20-115
1
TESTING AND ADJUSTING TESTING AND ADJUSTING TRACK SHOE TENSION

TRACK SHOE TENSION
Testing
1. Using the boom and arm, jack up the track on
the side to be measured.
2. Measure clearance a between the track roller

tread and top surface of the track link.
• Measurement position: 4th track roller from
sprocket.
• Standard clearance a : 310 – 360 mm
Adjusting
fl If the track shoe tension is not within the stand-
ard value, adjust as follows.
1. If the track tension is too high:
Loosen plug (1) gradually, and release the
grease.
¤ There is danger that the plug may fly out
under the high internal pressure of the
grease, so never loosen plug (1) more than
1 turn.
fl If the grease does not come out easily, move
the machine backwards or forwards slowly.
2. If the track tension is too low:

Pump in grease through grease fitting (2).
fl If the grease cannot be pumped in easily,
move the machine backwards and forwards
slowly.
20-116 PC1100-6
1
6
TESTING AND ADJUSTING HYDRAULIC PRESSURE IN WORK
TESTING AND ADJUSTING EQUIPMENT, SWING, TRAVEL CIRCUIT

HYDRAULIC PRESSURE IN
WORK EQUIPMENT, SWING,
TRAVEL CIRCUIT
Measuring
fl Oil temperature when measuring: 45 – 55˚C
¤ Lower the work equipment to the ground and
stop the engine. Operate the control levers sev-
eral times to release the remaining pressure in
the hydraulic piping. Then loosen the oil filler
cap slowly to release the pressure inside the
hydraulic tank.
fl The relief pressure of the boom LOWER circuit
can be measured only for the front pump cir-
cuit.
fl The relief pressure of the bucket DUMP circuit
cannot be measured for the No. 3 pump circuit.
1. Measuring front pump (No. 1 F + No. 2 F) circuit

pressure
1) Connect oil pressure gauge J1 (58.8 MPa
{600 kg/cm2}) to quick coupler (1) or (2) for
the circuit to be measured.
• (1): No. 1 front pump
• (2): No. 2 front pump
2) Set the working mode switch to the DH
mode.
3) Run the engine at full throttle and measure
the pressure under each of the following con-
ditions.
4) Measuring main relief pressure when heavy
lift is OFF (normal):
i) Turn the heavy-lift switch OFF.
ii) Measure the oil pressure when the ac-
tuator to be measured is relieved.
lift is ON (raised pressure):
i) Turn the heavy-lift switch ON.
ii) Measure the oil pressure with the circuit
relieved at boom RAISE.
6) Measuring boom LOWER relief pressure
when machine push-up is OFF (normal):
i) Turn the machine push-up switch OFF.
relieved at boom LOWER.
fl Under these conditions, the set pressure
of the safety valve for the boom LOWER
circuit is lower than the main relief pres-
sure, so the value measured will be the
relief pressure of the safety valve.
PC1100-6 20-117
1
7) Measuring boom LOWER relief pressure

when machine push-up is ON (raised pres-
sure):
i) Turn the machine push-up switch ON.
relieved at boom LOWER.
fl Under these conditions, the set pressure
of the safety valve for the boom LOWER
circuit is higher than the main relief pres-
sure, so the value measured will be the
relief pressure of the safety valve.
fl Condition of actuatorswhen measuring
• For the work equipment, operate each
cylinder to the end of its stroke.
¤ For the travel circuit, put block q be-
tween the sprocket and frame to lock
the track, and relieve each side at a time.
2. Measuring rear pump (No. 1 R + No. 2 R) circuit

pressure
• (3): No. 1 rear pump
• (4): No. 2 rear pump
mode.
the pressure under each of the following con-
ditions.
20-118 PC1100-6
1
fl Condition of actuators when measuring

¤ For the travel circuit, put block q be-
tween the sprocket and frame to lock
the track, and relieve each side at a time.
3. Measuring No. 3 pump circuit pressure

• (5): Front pump
• (6): Rear pump
mode.
the pressure under each of the following
conditions.
fl Under these conditions, the set pressure of
the safety valve for the swing circuit is lower
than the main relief pressure, so the value
measured will be the relief pressure of the
safety valve.
• For the swing, turn the swing lock switch
ON to lock the swing.
PC1100-6 20-119
1
Adjusting
fl Adjust only the swing motor safety valve. Never
adjust any other safety valve.
1. Adjusting R.H. 4-spool valve main relief valve

fl If the relief pressure of the front pump cir-
cuit is not correct, adjust the main relief valve
of the R.H. 4-spool valve as follows.
1) Disconnect hose (7).
2) Loosen locknut (8) so that elbow (9) can
move.
3) Adjusting high-pressure setting
Loosen locknut (10), then turn holder (11) to
adjust.
fl Turn the holder to adjust as follows.
To INCREASE pressure, turn CLOCK-
WISE.
To DECREASE pressure, turn
COUNTERCLOCKWISE.
fl Amount of adjustment for one turn of
holder:
3 Locknut: 78 – 93 Nm {8 – 9.5 kgm}
fl When the high-pressure setting is
changed, the low-pressure setting will
also change, so adjust the low-pressure
setting also.
4) Adjusting low-pressure setting
Loosen locknut (12), then turn holder (13) to
adjust.
fl Turn the holder to adjust as follows.
To INCREASE pressure, turn CLOCK-
WISE.
To DECREASE pressure, turn
COUNTERCLOCKWISE.
holder:
3 Locknut: 93 – 123 Nm {9.5 – 12.5 kgm}
fl After completion of adjustment, repeat
the procedure in above to check the set
pressure again.
2. Adjusting L.H. 5-spool valve main relief valve

fl If the relief pressure of the rear pump circuit
is not correct, adjust the main relief valve of
the L.H. 5-spool valve as follows.
fl Adjust in the same way as for the R.H. 4-
spool valve.
20-120 PC1100-6
1
3. Adjusting swing 4-spool valve main relief valve

fl If the relief pressure of the No. 3 pump cir-
cuit is not correct, adjust the main relief valve
of the swing 4-spool valve as follows.
spool valve.
4. Adjusting swing motor safety valve

fl If the relief pressure of the swing motor is
not correct, adjust the safety valve of the
swing motor as follows.
1) Loosen locknut (14), then turn adjustment
screw (15) to adjust.
fl Turn the adjustment screw to adjust as
follows.
• To INCREASE pressure, turn CLOCK-
WISE.
• To DECREASE pressure, turn
COUNTERCLOCKWISE.
adjustment screw:
Approx. 4.7 MPa {47.9 kg/cm2}
3 Locknut: 147 – 196 Nm {15 – 20 kgm}
pressure again.
PC1100-6 20-121
1
TESTING AND ADJUSTING CONTROL
TESTING AND ADJUSTING PUMP CIRCUIT OIL PRESSURE

CONTROL PUMP CIRCUIT OIL
PRESSURE
Measuring
fl Oil temperature when measuring: 45 – 55°C
1. Install oil pressure gauge J1 (5.9 MPa {60 kg/
cm2}) to quick coupler (1).
2. Start the engine run the engine at full throttle,

and measure the oil pressure with all the con-
trol levers at neutral.
Adjusting
fl If the relief pressure of the control circuit is not
correct, adjust the control relief valve as fol-
lows.
1. Remove cap (2).
2. Loosen locknut (3) and turn adjustment screw

(4) to adjust.
fl Turn the adjustment screw as follows.
• To INCREASE pressure, turn CLOCKWISE
COUNTERCLOCKWISE
fl Amount of adjustment for one turn of ad-
justment screw:
3 Locknut: 9.8 Nm {1 kgm}
fl After completion of adjustment, repeat the
procedure in above to check the set pres-
sure again.
20-122 PC1100-6
1
TESTING AND ADJUSTING TESTING AND ADJUSTING PISTON PUMP CONTROL PRESSURE

PISTON PUMP CONTROL
PRESSURE
Measuring
1. TVC valve output pressure

fl The TVC valve output pressure varies with
the discharge pressure of each valve, so al-
ways check that the oil pressure of the work
equipment, swing, and travel circuits is nor-
mal before measuring.
fl The TVC valve output pressure uses the con-
trol circuit pressure as the basic pressure,
so always check that the oil pressure of the
control circuit is normal before measuring.
1) Remove oil pressure measurement plug (1)
(Thread dia.=10mm, Pitch=1.25mm) of the
No. 3 front pump.
2) Install nipple q of oil pressure gauge J1,
then connect oil pressure gauge J1 (5.9 MPa
{60 kg/cm2}).
3) Set the working mode switch to DH mode.
4) Run the engine at full throttle, and measure
the pressure under the following conditions.
5) Measuring with all control levers at neutral:
Set all the control levers to neutral and meas-
ure the output pressure.
6) Measuring with circuit relieved at heavy-lift
OFF + boom RAISE
ii) Measure the output pressure with the
circuit relieved at boom RAISE.
7) Measuring with circuit relieved at heavy-lift
ON + boom RAISE
ii) Measure the output pressure with the
circuit relieved at boom RAISE.
2. Measuring output pressure of No. 1 and No. 2

pump CO and NC valves
1) Remove oil pressure measurement plugs (2)
and (3) (Thread dia.=10mm, Pitch=1.25mm)
of the No. 2 pump.
• (2): For front pump circuit
• (3): For rear pump circuit
PC1100-6 20-123
1
2) Fit nipple q of oil pressure gauge J1, then

connect oil pressure gauge J1 (5.9 MPa {60
kg/cm2}).
conditions.
4) Measuring when work equipment control le-
vers are at neutral:
i) Set the working mode switch to the DH
mode.
ii) Measure the output pressure when all
control levers area at neutral.
5) Measuring when track is rotating under no
load:
mode.
ii) Using the boom and arm, jack up the
track on the side to be measured.
iii) Measure the output pressure when the
track is rotating under no load.
fl The output pressure of the CO, NC valve
differs according to the jet sensor output
differential pressure, so if the CO, NC valve
output pressure is not normal, always meas-
ure the jet sensor output differential pres-
sure.
3. Measuring No. 3 pump CO, NC valve output

pressure
1) Remove oil pressure measurement plug (4)
(Thread dia.=10mm, Pitch=1.25mm).
2) Fit nipple q of oil pressure gauge J1, then
connect oil pressure gauge J1 (5.9 MPa {60
kg/cm2}).
conditions.
20-124 PC1100-6
1
4) Measuring when work equipment control le-

vers are at neutral:
mode.
ii) Measure the output pressure when all
control levers area at neutral.
5) Measuring when upper structure is swing-
ing under no load:
mode.
ii) Measure the output pressure when the
upper structure is swinging under no
load.
fl The output pressure of the CO, NC valve
differs according to the jet sensor output
pressure differential pressure, so if the CO,
NC valve output pressure is not normal, al-
ways measure the jet sensor output differ-
ential pressure.
4. Measuring R.H. 4-spool valve and L.H. 5-spool

valve jet sensor output differential pressure
¤ Loosen the oil filler cap slowly to release
the pressure inside the hydraulic tank.
1) Remove high-pressure oil pressure measure-
ment plug (5) (PT1/8) and low-pressure oil
pressure measurement plug (6) (PT1/8).
PC1100-6 20-125
1
2) Fit nipple e of oil pressure gauge J1, then

connect differential gauge J3 or oil pressure
gauge J1 (5.9 MPa {60 kg/cm2}).
mode.
4) Start the engine, then using the boom and

arm, jack up the track on the side to be
measured.
the output differential pressure when all le-
vers are at neutral and when the track is
rotating under no load.
5. Measuring swing 4-spool valve jet sensor out-

put differential pressure
¤ Loosen the oil filler cap slowly to release the
pressure inside the hydraulic tank.
1) Remove high-pressure oil pressure measure-
ment plug (7) (PT1/8) and low-pressure oil
pressure measurement plug (8) (PT1/8).
20-126 PC1100-6
1
2) Install nipple e of oil pressure gauge J1,

then connect to differential gauge J3 or oil
pressure gauge J1 (58.8 MPa {600 kg/cm2}).
fl When using oil pressure gauge J1 (58.8
MPa {600 kg/cm2}), exchange with a 0.98
MPa {10 kg/cm2} unit gauge to measure
the high pressure and low pressure.
3) Set the working mode switch to DH mode.
the output differential pressure with all the
control levers at neutral and with the swing
operated under no load.
Adjusting
1. Adjusting TVC valve
fl If the TVC valve output pressure is not cor-
rect, adjust the TVC valve of the No. 1 pump
as follows.
1) Loosen locknut (9).
2) Turn adjustment screw (10) to adjust.
follows.
WISE.
COUNTERCLOCKWISE.
adjustment screw:
3 Locknut: 5.9 – 9.8 Nm {0.6 – 1.0 kgm}
pressure again.
PC1100-6 20-127
1
2. Adjusting No. 1 and No. 2 pump CO and NC

valves
fl If the CO, NC valve output pressure is not
correct, adjust the CO, NC valve of the No. 1
pump as follows.
1) Adjusting CO valve
i) Loosen locknut (11).
ii) Turn adjustment screw (12) to adjust.
fl Turn the adjustment screw to adjust
as follows.
• To INCREASE pressure, turn
CLOCKWISE.
COUNTERCLOCKWISE.
fl Amount of adjustment for one turn
of adjustment screw:
3 Locknut:
5.9 – 9.8 Nm {0.6 – 1.0 kgm}
fl After completion of adjustment, re-
peat the procedure in above to check
the set pressure again.
2) Adjusting NC valve
i) Loosen locknut (13).
ii) Turn adjustment screw (14) to adjust.
fl Turn the adjustment screw to adjust
as follows.
• To INCREASE pressure, turn
CLOCKWISE.
COUNTERCLOCKWISE.
fl Amount of adjustment for one turn
of adjustment screw:
3 Locknut:
5.9 – 9.8 Nm {0.6 – 1.0 kgm}
20-128 PC1100-6
1
3. Adjusting No. 3 pump CO and NC valves

fl If the CO, NC valve output pressure is not
correct, adjust the CO, NC valve as follows.
1) Adjusting CO valve
fl Adjust in the same way as for the No. 1
and No. 2 pump CO and NC valves
2) Adjusting NC valve
fl Adjust in the same way as for the No. 1
and No. 2 pump CO and NC valves
4. Adjusting R.H. 4-spool valve and L.H. 5-spool

valve jet sensor
fl If the output differential pressure of the jet
sensor is not correct, adjust the jet sensor
relief valve as follows.
1) Loosen locknut (15).

2) Turn adjustment screw (16) to adjust.
follows.
WISE.
COUNTERCLOCKWISE.
adjustment screw:
3 Locknut: 59 – 78 Nm {6 – 8 kgm}
PC1100-6 20-129
1
5. Adjusting swing 4-spool valve jet sensor

fl If the jet sensor output differential pressure
is not correct, adjust the jet sensor relief
valve as follows.
spool valve and L.H. 5-spool valve jet sen-
sor.
20-130 PC1100-6
1
TESTING AND ADJUSTING MEASURING SERVO PISTON STROKE
MEASURING SERVO PISTON

STROKE
fl When judging the condition of the servo valve,
measure the stroke of the servo valve as fol-
lows.
1. Measurement tools to prepare

1) Prepare new servo piston cover (1).
fl The same part is used for the No. 1 pump
and No. 2 pump.
2) Machine a PT1/4 tap hole in the center of cap
(1).
3) Install disk gauge P in cap (1).
2. Measuring stroke
1) Remove the cap at the servo piston spring
chamber end, then install the measuring tool.
fl Install the tool for measuring the cap O-
ring.
2) Stop the engine, push in the rod of the meas-
urement tool fully, and measure dimension
a1 of the rod.
3) Start the engine and use the work equip-
ment to jack up the track shoe from the
ground on the side to be measured.
4) Run the engine at full throttle, rotate the
track under no load, and measure dimen-
sion a2 of the rod.
5) Calculate stroke b of the servo piston from
dimensions a1 and a2.
fl Standard stroke b of servo piston
• No. 1 pump, No. 2 pump: 9.37 mm
• No. 3 pump: 12.2 mm
3. Pass/Fail judgment
fl If the servo piston stroke is not correct, be-
fore judging the condition, remove the servo
valve, servo piston cap, and spring, then
move the servo piston by hand and check
that it moves smoothly.
1) If servo piston stroke is correct:
The servo valve is normal.
2) If servo piston stroke is not correct:
• If the servo piston moves smoothly:
The servo valve is defective.
• If the servo piston does not move
smoothly: The servo valve is normal.
PC1100-6 20-131
1
MEASURING PPC VALVE OUTPUT PRESSURE AND
TESTING AND ADJUSTING TESTING PPC SHUTTLE VALVE
MEASURING PPC VALVE OUT-

PUT PRESSURE AND TESTING
PPC SHUTTLE VALVE
1. Measuring PPC valve output pressure

1) Disconnect hose (1) of the circuit to be meas-
ured.
fl See the diagram on the next page for
details of the hose to disconnect.
2) Install adapter q and nipple w of oil pres-

sure gauge J1, then connect oil pressure
3) Run the engine at full throttle, operate the

control lever of the circuit to be measured,
and measure the oil pressure.
fl Measure with the lever operated fully.
• For the work equipment, operate
each cylinder to the end of its stroke.
• For the swing, turn the swing lock
switch ON to lock the swing.
¤ For the travel circuit, put block e
between the sprocket and frame to
lock the track.
20-132 PC1100-6
1
2. Measuring swing PPC shuttle valve

1) Disconnect hose (2).
2) Install adapter q and nipple w of oil pres-

sure gauge J1, then connect oil pressure
3) Run the engine at full throttle, swing the

upper structure to the left and right, and
measure the oil pressure in each direction.
fl If the oil pressure is correct for both the
left and right swing, the shuttle valve is
normal.
fl If the oil pressure is not correct for ei-
ther the left or right swing, the shuttle
valve ball is probably stuck.
PC1100-6 20-133
1
20-134 PC1100-6
1
PC1100-6 20-135
1
TESTING AND ADJUSTING TESTING SOLENOID VALVE OUTPUT PRESSURE
TESTING SOLENOID VALVE

OUTPUT PRESSURE
¤ Loosen the oil filler cap slowly to release the
1. Disconnect outlet hose (9) of the solenoid valve

(1) – (8) to be measured
• (1): Straight-travel solenoid valve
• (2): Machine push-up solenoid valve
• (3): Swing holding brake R solenoid valve

• (4): Travel speed solenoid valve
• (5): Swing holding brake F solenoid valve
• (6): CO cancel solenoid valve

• (7): 2-stage relief solenoid valve
• (8): Swing priority solenoid valve
2. Install adapter q and nipple w of oil pressure

gauge J1, then connect oil pressure gauge J1
(5.9 MPa {60 kg/cm2}).
20-136 PC1100-6
1
TESTING AND ADJUSTING TESTING SOLENOID VALVE OUTPUT PRESSURE
3. Start the engine and measure the output pres-

sure when set or operated to the conditions in
the table below.
fl When operating the work equipment, swing,
or travel levers, operate slightly (enough for
the PPC pressure switch to be turned ON).
Table
Condition of Oil pressure
No. Solenoid Measurement conditions solenoid (MPa {kg/cm2}) Operating condition
Flow from front pump circuit
All levers at neutral OFF 0 and rear pump circuit divided
Straight
1 travel Flow from front pump circuit
Swing or work equipment and travel 2.9 ± 0.6
control lever operated simultaneously ON {30 ± 5.5} and rear pump circuit merged
When machine push-up switch is at Boom LOWER safety valve
high-pressure setting OFF 0 at high-pressure setting
Machine
2 push-up When machine push-up switch is at 2.9 ± 0.6 Boom LOWER safety valve
low-pressure setting ON {30 ± 5.5} at low-pressure setting
5 sec after all work equipment and Swing holding brake
Swing swing levers are returned to neutral OFF 0 applied
3 holding
brake R Swing or work equipment lever 2.9 ± 0.6 Swing holding brake
operated ON {30 ± 5.5} canceled
Travel motor swash plate
Travel speed switch at Lo OFF 0 angle at MAX
Travel
4 speed Travel speed switch at Hi and travel 2.9 ± 0.6 Travel motor swash plate
lever operated ON {30 ± 5.5} angle at MIN
5 sec after all work equipment and Swing holding brake
Swing swing levers are returned to neutral OFF 0 applied
5 holding
brake F Swing or work equipment lever 2.9 ± 0.6 Swing holding brake
operated ON {30 ± 5.5} canceled
Working mode switch at H or G OFF 0 Pump CO function actuated

CO
6 cancel 2.9 ± 0.6 Pump CO function
Working mode switch at DH ON {30 ± 5.5} canceled
Main relief valve at low-
2-stage When heavy-lift switch is OFF OFF 0 pressure setting
7 main
relief When heavy-lift switch is ON and boom 2.9 ± 0.6 Main relief valve at high-
RAISE is operated independently ON {30 ± 5.5} pressure setting
Swing priority switch OFF OFF 0 Boom Plus spool actuated

Swing
8 priority 2.9 ± 0.6
Swing priority switch ON ON {30 ± 5.5} Boom Plus spool stopped
PC1100-6 20-137
1
TESTING AND ADJUSTING ADJUSTING WORK EQUIPMENT, SWING PPC VALVE
ADJUSTING WORK EQUIP-

MENT, SWING PPC VALVE
fl If there is excessive play at the tip of the work
equipment or swing lever, adjust at the PPC
valve end as follows.
• Standard lever play a: 0.5 – 3 mm at point 200
mm from rotating center of lever (forward and
reverse, and left and right)
1. Remove boot (1).
2. Loosen locknut (2), then turn disc (3) to adjust

the play of the lever.
fl When doing this, do not move the piston.
3. Secure disc (3) in position, then tighten locknut

(2) to the specified torque.
3 Locknut :
98.07 – 127.49 Nm {10 – 13 kgm}
4. Install boot (1).
20-138 PC1100-6
1
TESTING AND ADJUSTING TESTING TRAVEL DEVIATION
TESTING TRAVEL DEVIATION

fl When traveling on level ground.
1. Set the machine in the travel posture.
fl For the travel posture, extend the bucket and
arm cylinder rods fully, and hold the boom
angle at 45˚.
2. Operate with the engine at full throttle, run up

for 10 m, then measure the deviation over the
next 20 m.
fl Install the oil pressure gauge and measure
the pump discharge pressure at the same
time.
PC1100-6 20-139
1
TESTING LOCATIONS CAUSING HYDRAULIC
TESTING AND ADJUSTING DRIFT OF WORK EQUIPMENT
TESTING LOCATIONS
CAUSING HYDRAULIC DRIFT
OF WORK EQUIPMENT
fl If there is any hydraulic drift in the work equip-
ment (cylinders), check as follows to determine
if the cause is in the cylinder packing or in the
control valve.
1. Checking boom and bucket cylinders
1) Set in the same posture as when measuring
hydraulic drift, and stop the engine.
2) Operate the boom control lever to RAISE or
the bucket control lever to CURL.
• If the lowering speed increases, the pack-
ing is defective.
• If there is no change, the boom lock valve
(boom) or the control valve (bucket) is
defective.
fl If the pressure in the accumulator has
dropped, run the engine for approx. 10
seconds to charge the accumulator again
before operating.
2. Checking arm cylinder
1) Stop the arm cylinder at a point approx. 100
mm before the end of the IN stroke, then
stop the engine.
2) Operate the control lever to arm IN.
• If the lowering speed increases, the pack-
ing is defective.
• If there is no change, the control valve is
defective.
fl If the pressure in the accumulator has
dropped, run the engine for approx. 10
seconds to charge the accumulator again
before operating.
[Reference]If the cause of the hydraulic drift is in
the packing, and the above operation is
carried out, the downward movement be-
comes faster for the following reasons.
1) If the work equipment is set to the above
posture (holding pressure applied to the bot-
tom end), the oil at the bottom end leaks to
the head end. However, the volume at the
head end is smaller than the volume at the
bottom end by the volume of the rod, so the
internal pressure at the head end increases
because of the oil flowing in from the bot-
tom end.
2) When the internal pressure at the head end
increases, the pressure at the bottom end
also rises in proportion to this. The balance
is maintained at a certain pressure (this dif-
fers according to the amount of leakage) by
repeating this procedure.
3) When the pressure is balanced, the down-
ward movement becomes slower. If the le-
ver is then operated according to the proce-
dure given above, the circuit at the head
end is opened to the drain circuit (the bot-
tom end is closed by the check valve), so
the oil at the head end flows to the drain
circuit and the downward movement be-
comes faster.
20-140 PC1100-6
1
TESTING AND ADJUSTING MEASURING OIL LEAKAGE
MEASURING OIL LEAKAGE

fl Oil temperature when measuring: 45 – 55˚C
1. Work equipment cylinder
1) Fully extend the rod of the cylinder to be
measured, then stop the engine.
2) Disconnect piping (1) at the head end, then
block the piping at the chassis end with a
blind plug.
¤ Be careful not to disconnect the piping
at the bottom end.
3) Start the engine and apply the relief pres-
sure to the bottom end of the cylinder with
the engine at full throttle.
• Boom cylinder: RAISE
• Arm cylinder: IN
• Bucket cylinder: CURL
4) Continue this condition for 30 seconds, then
measure the oil leakage for the next one
minute.
PC1100-6 20-141
1
2. Swing motor
¤ Loosen the hydraulic tank oil filler cap slowly
to release the pressure inside the tank.
1) Disconnect drain hose (2) from the swing
motor, then install a blind plug at the tank
end.
2) Turn the swing lock switch LOCK.
3) Start the engine and operate the swing re-
lief with the engine at full throttle.
minute.
fl After measuring, swing 180° and measure
again.
3. Travel motor
¤ Loosen the hydraulic tank oil filler cap slowly
to release the pressure inside the tank.
1) Disconnect drain hose (3) from the travel
motor, then fit a blind plug at the hose end.
2) Fit block q between the sprocket and frame
to lock the track.
3) Start the engine and operate the travel relief
with the engine at full throttle.
¤ When measuring the oil leakage from
the travel motor, mistaken operation of
the control lever may lead to a serious
accident, so always use signals and check
carefully when carrying out this opera-
tion.
minute.
fl When measuring, move the motor slightly
(to change the position between the valve
plate and cylinder, and between the piston
and cylinder), and measure several times.
20-142 PC1100-6
1
4. Center swivel joint

Table (inspection port and measurement port)
Swivel joint Direction of rotation Swivel joint
inspection port of travel motor measurement port
A L.H. FORWARD T·B
B L.H. REVERSE A·P
C R.H. FORWARD P·D
D R.H. REVERSE T·C
P Speed selection B·C
1) Put block q between the sprocket and frame

to lock the rotation of the travel motor where
the port is to be inspected, and stop the
engine.
¤ Loosen the hydraulic tank oil filler cap
slowly to release the pressure inside the
tank.
2) Disconnect the hoses at the botom of the
swivel joint for the measurement port at both
sides of the port to be inspected, and fit
blind plugs in the hoses.
fl When measuring at port T, disconnect
and block the hoses at the top of the
swivel joint to prevent the oil from the
other circuits from flowing in. At the bot-
tom, disconnect the hoses, and do not
block them. Catch the oil in an oil pan.
as follows.
i) Ports A, B, C, D
Relieve the travel motor slowly in the
direction of rotation for the port to be
inspected.
¤ If the lever is operated mistakenly, it
may lead to serious injury or dam-
age, so be sure to confirm signals
and signs carefully.
ii) Port P
Set the travel speed switch to Hi.
4) Continue for one minute, then measure the
oil leakage for the next one minute.
PC1100-6 20-143
1
20-144 PC1100-6
1
TESTING AND ADJUSTING BLEEDING AIR
BLEEDING AIR
1. Bleeding air from hydraulic pumps
fl If the hydraulic pump or related piping has
been removed and installed again, bleed the
air from the hydraulic pumps as follows.
1) Loosen air bleed plugs (1), (2), and (3) 4
turns.
2) Loosen the oil filler cap of the hydraulic tank
and leave for approx. 10 minutes.
fl The time needed differs according to the
amount of oil remaining inside the pump
case.
3) When oil comes out of air bleed plugs (1)
and (2), tighten air bleed plugs (1) and (2).
4) Start the engine and run at low idling.
fl Set the safety lock lever to the LOCK
position to prevent the work equipment
from moving.
5) When no more cloudy white oil comes out
from air bleed plug (3), tighten air bleed
plug (3).
2. Bleeding air from swing motor

fl If the travel motor, center swivel joint, or
related piping has been removed and in-
stalled again, bleed the air from the hydrau-
lic pumps as follows.
1) Loosen air bleed plug (4).
2) Start the engine and use the boom and arm
to jack up the track shoe from the ground
on the side where the air is to be bled.
3) Run the engine at low idling and rotate the
track under no load.
4) When oil comes out from air bleed plug (4),
tighten air bleed plug (4).
PC1100-6 20-145
1
TESTING AND ADJUSTING BLEEDING AIR
3. Bleeding air from swing motor

fl When the swing motor has been removed
or installed again, or when the related pip-
ing has been disconnected or connected, do
as follows to bleed the air from the swing
motor.
1) Run the engine at low idling, then start and
stop the swing several times.
fl This operation will bleed the air inside
the swing motor automatically.
4. Bleeding air from hydraulic cylinders

fl When the hydraulic cylinders have been re-
moved or installed again, or when the re-
lated piping has been disconnected or con-
nected, do as follows to bleed the air from
the hydraulic cylinders.
1) Start the engine and run at idling for approx.
5 minutes.
2) Run the engine at low idling, then raise and
lower the boom 4 – 5 times in succession.
fl Operate the piston rod to a point approx.
100 mm before the end of its stroke. Do
not relieve the circuit under any circum-
stances.
3) Keep the engine running at low idling, oper-
ate the cylinder slowly (take at least 10 sec-
onds) from a point approx. 100 mm before
the end of the stroke, extend the cylinder to
the end of its stroke to relieve the circuit,
and hold in the relief position for 3 minutes.
4) Run the engine at high idling, operate the
cylinder slowly (take at least 10 seconds) from
a point approx. 100 mm before the end of
the stroke, extend the cylinder to the end of
its stroke to relieve the circuit, and hold in
the relief position for 1 minute.
20-146 PC1100-6
1
TESTING AND ADJUSTING RELEASING REMAINING PRESSURE IN HYDRAULIC CIRCUIT
RELEASING REMAINING
PRESSURE IN
HYDRAULIC CIRCUIT
fl If the piping between the hydraulic cylinder and
the control valve is to be disconnected, release
the remaining pressure from the circuit as fol-
lows.
The travel circuit is an open circuit, so there is
no remaining pressure. It is enough to remove
the oil filler cap.
1. Loosen the oil filler cap slowly to release the

pressure inside the tank.
2. Operate the control levers.

fl When the levers are operated 2 – 3 times,
the pressure stored in the accumulator is
removed.
3. Start the engine, run at low idling for approx. 5

minutes, then stop the engine and operate the
control levers.
fl Repeat the above operation 2 – 3 times to
release all the remaining pressure.
PC1100-6 20-147
1
TROUBLESHOOTING
Points to remember when troubleshooting ........................................................................................ 20-202

Sequence of events in troubleshooting .............................................................................................. 20-203
Points to remember when carrying out maintenance ....................................................................... 20-204
Checks before troubleshooting ............................................................................................................ 20-212
Connector types and mounting locations ........................................................................................... 20-214
Connection table for connector pin numbers .................................................................................... 20-220
Explanation of functions of control mechanism for electrical system ............................................ 20-231
Display method and special functions of monitor panel .................................................................. 20-232
Details of troubleshooting and troubleshooting procedure ............................................................. 20-248
Method of using judgement table ....................................................................................................... 20-250
Method of using troubleshooting charts ............................................................................................ 20-252
Troubleshooting of communication abnormality system (N mode) ............................................... 20-301
Troubleshooting of engine controller & APS controller system (E mode) ..................................... 20-351
Troubleshooting of engine system (S mode) ..................................................................................... 20-401
Troubleshooting of pump controller system (C mode) ..................................................................... 20-451
Troubleshooting of pump controller input signal system (F mode) ............................................... 20-501
Troubleshooting of hydraulic, mechanical system (H mode) ........................................................... 20-551
Troubleshooting of machine monitor system (M mode) .................................................................. 20-601
PC1100-6 20-201
3
TROUBLESHOOTING POINTS TO REMEMBER WHEN TROUBLESHOOTING
POINTS TO REMEMBER WHEN TROUBLESHOOTING

¤ Stop the machine in a level place, and check that the safety pin, blocks, and parking brake are securely fitted.
¤ When carrying out the operation with two or more workers, keep strictly to the agreed signals, and do not
allow any unauthorized person to come near.
¤ If the radiator cap is removed when the engine is hot, hot water may spurt out and cause burns, so wait for
the engine to cool down before starting troubleshooting.
¤ Be extremely careful not to touch any hot parts or to get caught in any rotating parts.
¤ When disconnecting wiring, always disconnect the negative (–) terminal of the battery first.
¤ When removing the plug or cap from a location which is under pressure from oil, water, or air, always release
the internal pressure first. When installing measuring equipment, be sure to connect it properly.
The aim of troubleshooting is to pinpoint the basic cause of the failure, to carry out repairs swiftly, and to
prevent reoccurrence of the failure.
When carrying out troubleshooting, and important point is of course to understand the structure and function.
However, a short cut to effective troubleshooting is to ask the operator various questions to form some idea
of possible causes of the failure that would produce the reported symptoms.
1. When carrying out troubleshooting, do not hurry 4) Check the stroke of the control valve spool.
to disassemble the components. 5) Other maintenance items can be checked ex-
If components are disassembled immediately any ternally, so check any item that is considered
failure occurs: to be necessary.
• Parts that have no connection with the fail- 4. Confirming failure
ure or other unnecessary parts will be disas- • Confirm the extent of the failure yourself,
sembled. and judge whether to handle it as a real fail-
• It will become impossible to find the cause ure or as a problem with the method of op-
of the failure. eration, etc.
It will also cause a waste of manhours, parts, or fl When operating the machine to reenact
oil or grease, and at the same time, will also lose the troubleshooting symptoms, do not
the confidence of the user or operator. carry out any investigation or measure-
For this reason, when carrying out troubleshoot- ment that may make the problem worse.
ing, it is necessary to carry out thorough prior 5. Troubleshooting
investigation and to carry out troubleshooting in • Use the results of the investigation and in-
accordance with the fixed procedure. spection in Items 2 – 4 to narrow down the
2. Points to ask user or operator causes of failure, then use the troubleshoot-
1) Have any other problems occurred apart from ing flowchart to locate the position of the
the problem that has been reported? failure exactly.
2) Was there anything strange about the ma- fl The basic procedure for troubleshooting
chine before the failure occurred? is as follows.
3) Did the failure occur suddenly, or were there 1) Start from the simple points.
problems with the machine condition before 2) Start from the most likely points.
this? 3) Investigate other related parts or in-
4) Under what conditions did the failure occur? formation.
5) Had any repairs been carried out before the 6. Measures to remove root cause of failure
failure? • Even if the failure is repaired, if the root cause
When were these repairs carried out? of the failure is not repaired, the same failure
6) Has the same kind of failure occurred be- will occur again.
fore? To prevent this, always investigate why the
3. Check before troubleshooting problem occurred. Then, remove the root
1) Check the oil level cause.
2) Check for any external leakage of oil from
the piping or hydraulic equipment.
3) Check the travel of the control levers.
20-202 PC1100-6
3
TROUBLESHOOTING SEQUENCE OF EVENTS IN TROUBLESHOOTING
SEQUENCE OF EVENTS IN TROUBLESHOOTING
Office, shop Jobsite
Step 1
Examination, confirmation of symptoms
1) When a request for repairs is received, first

ask the following points.
• Name of customer
• Type, serial number of machine
• Details of jobsite, etc.
2) Ask questions to gain an outline of the prob-
lem.
• Condition of failure
• Work being carried out at the time of the
failure
• Operating environment
• Past history, details of maintenance, etc.
Step 2
Determining probable location of cause
1) Look at the troubleshooting section of the

shop manual to find locations of possible
causes.
Step 3
Preparation of troubleshooting tools
1) Look at the table of troubleshooting tools in

the shop manual and prepare the necessary Step 7
tools. • Pinpoint locations of failure (carry out
• T-adapter troubleshooting)
• Hydraulic pressure gauge kit, etc. • Decide action to take
2) Look in the parts book and prepare the nec-
essary replacement parts. 1) Before starting troubleshooting, locate and
repair simple failures.
• Check before starting items
• Other check items
2) See the Troubleshooting Section of the shop
manual, select a troubleshooting flowchart
that matches the symptoms, and carry out
troubleshooting.
Step 6
Re-enacting failure
• Drive and operate the machine to confirm

the condition and judge if there is really a
failure.
Step 4 Step 5
Go to jobsite Ask operator questions to confirm details of
failure.
• Was there anything strange about the ma-

chine before the failure occurred?
• Did the failure occur suddenly?
• Had any repairs been carried out before the
failure?
PC1100-6 20-203
3
TROUBLESHOOTING POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE
POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE

To maintain the performance of the machine over a long period, and to prevent failures or other
troubles before they occur, correct operation, maintenance and inspection, troubleshooting, and re-
pairs must be carried out. This section deals particularly with correct repair procedures for mechatronics
and is aimed at improving the quality of repairs. For this purpose, it gives sections on “Handling
electric equipment” and “Handling hydraulic equipment” (particularly gear oil and hydraulic oil).
1. POINTS TO REMEMBER WHEN HANDLING

ELECTRIC EQUIPMENT
1) Handling wiring harnesses and connectors

Wiring harnesses consist of wiring connecting
one component to another component, connec-
tors used for connecting and disconnecting one
wire from another wire, and protectors or tubes
used for protecting the wiring.
Compared with other electrical components fit-
ted in boxes or cases, wiring harnesses are more
likely to be affected by the direct effects of rain,
water, heat, or vibration. Furthermore, during
inspection and repair operations, they are fre-
quently removed and installed again, so they
are likely to suffer deformation or damage. For
this reason, it is necessary to be extremely care-
ful when handling wiring harnesses.
Main failures occurring in wiring harness

1 Defective contact of connectors (defective
contact between male and female)
Problems with defective contact are likely to
occur because the male connector is not
properly inserted into the female connector,
or because one or both of the connectors is
deformed or the position is not correctly
aligned, or because there is corrosion or
oxidization of the contact surfaces.
2 Defective crimping or soldering of connec-

tors
The pins of the male and female connectors
are in contact at the crimped terminal or
soldered portion, but if there is excessive
force brought to bear on the wiring, the plat-
ing at the joint will peel and cause improper
connection or breakage.
20-204 PC1100-6
3
3 Disconnections in wiring
If the wiring is held and the connectors are
pulled apart, or components are lifted with a
crane with the wiring still connected, or a
heavy object hits the wiring, the crimping of
the connector may separate, or the solder-
ing may be damaged, or the wiring may be
broken.
4 High-pressure water entering connector

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

If oil or grease are stuck to the connector
and an oil film is formed on the mating sur-
face between the male and female pins, the
oil will not let the electricity pass, so there
will be defective contact.
If there is oil or grease stuck to the connec-
tor, wipe it off with a dry cloth or blow it dry
with compressed air and spray it with a con-
tact restorer.
fl When wiping the mating portion of the
connector, be careful not to use exces-
sive force or deform the pins.
fl If there is oil or water in the compressed
air, the contacts will become even dirtier,
so remove the oil and water from the
compressed air completely before clean-
ing with compressed air.
PC1100-6 20-205
3
2) Removing, installing, and drying connectors and

wiring harnesses
‡ Disconnecting connectors
1 Hold the connectors when disconnecting.
When disconnecting the connectors, hold the
connectors and not the wires. For connec-
tors held by a screw, loosen the screw fully,
then hold the male and female connectors
in each hand and pull apart. For connectors
which have a lock stopper, press down the
stopper with your thumb and pull the con-
nectors apart.
fl Never pull with one hand.
2 When removing from clips

When removing a connector from a clip, pull
the connector in a parallel direction to the
clip.
fl If the connector is twisted up and down
or to the left or right, the housing may
break.
3 Action to take after removing connectors

After removing any connector, cover it with
a vinyl bag to prevent any dust, dirt, oil, or
water from getting in the connector portion.
fl If the machine is left disassembled for a
long time, it is particularly easy for im-
proper contact to occur, so always cover
the connector.
20-206 PC1100-6
3
‡ Connecting connectors
1 Check the connector visually.
1) Check that there is no oil, dirt, or water
stuck to the connector pins (mating por-
tion).
2) Check that there is no deformation, de-
fective contact, corrosion, or damage to
the connector pins.
3) Check that there is no damage or break-
age to the outside of the connector.
fl If there is any oil, water, or dirt stuck to
the connector, wipe it off with a dry cloth.
If any water has got inside the connec-
tor, warm the inside of the wiring with a
dryer, but be careful not to make it too
hot as this will cause short circuits.
fl If there is any damage or breakage, re-
place the connector.
2 Fix the connector securely.

Align the position of the connector correctly,
then insert it securely.
For connectors with lock stopper, push in
the connector until the stopper clicks into
position.
3 Correct any protrusion of the boot and any

misalignment of the wiring harness
For connectors fitted with boots, correct any
protrusion of the boot. In addition, if the
wiring harness is misaligned, or the clamp
is out of position, adjust it to its correct po-
sition.
fl If the connector cannot be corrected eas-
ily, remove the clamp and adjust the
position.
4 If the connector clamp has been removed,

be sure to return it to its original position.
Check also that there are no loose clamps.
PC1100-6 20-207
3
‡ Drying wiring harness

If there is any oil or dirt on the wiring harness,
wipe it off with a dry cloth. Avoid washing it in
water or using steam. If the connector must be
washed in water, do not use high-pressure wa-
ter or steam directly on the wiring harness.
If water gets directly on the connector, do as

follows.
1 Disconnect the connector and wipe off the
water with a dry cloth.
fl If the connector is blown dry with com-
pressed air, there is the risk that oil in
the air may cause defective contact, so
remove all oil and water from the com-
pressed air before blowing with air.
2 Dry the inside of the connector with a dryer.

If water gets inside the connector, use a dryer
to dry the connector.
fl Hot air from the dryer can be used, but
regulate the time that the hot air is used
in order not to make the connector or
related parts too hot, as this will cause
deformation or damage to the connec-
tor.
3 Carry out a continuity test on the connector.

After drying, leave the wiring harness dis-
connected and carry out a continuity test to
check for any short circuits between pins
caused by water.
fl After completely drying the connector,
blow it with contact restorer and reas-
semble.
20-208 PC1100-6
3
3) Handling control box

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

box.
4 Cover the control connectors with tape or a
vinyl bag.
Never touch the connector contacts with your
hand.
5 During rainy weather, do not leave the con-
trol box in a place where it is exposed to
rain.
6 Do not place the control box on oil, water,

or soil, or in any hot place, even for a short
time.
(Place it on a suitable dry stand).
7 Precautions when carrying out arc welding
When carrying out arc welding on the body,
disconnect all wiring harness connectors con-
nected to the control box. Fit an arc welding
ground close to the welding point.
2. Points to remember when troubleshooting electric circuits

1) Always turn the power OFF before disconnecting or connect connectors.
2) Before carrying out troubleshooting, check that all the related connectors are properly inserted.
fl Disconnect and connect the related connectors several times to check.
3) Always connect any disconnected connectors before going on to the next step.
fl If the power is turned ON with the connectors still disconnected, unnecessary abnormality
displays will be generated.
4) When carrying out troubleshooting of circuits (measuring the voltage, resistance, continuity, or
current), move the related wiring and connectors several times and check that there is no
change in the reading of the tester.
fl If there is any change, there is probably defective contact in that circuit.
PC1100-6 20-209
3
3. POINTS TO REMEMBER WHEN HANDLING

HYDRAULIC EQUIPMENT
With the increase in pressure and precision of hy-

draulic equipment, the most common cause of fail-
ure is dirt (foreign material) in the hydraulic circuit.
When adding hydraulic oil, or when disassembling
or assembling hydraulic equipment, it is necessary
to be particularly careful.
1) Be careful of the operating environment.

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

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

operations.
Be careful not to let any dirt or dust get in when
refilling with hydraulic oil. Always keep the oil
filler and the area around it clean, and also use
clean pumps and oil containers. If an oil clean-
ing device is used, it is possible to filter out the
dirt that has collected during storage, so this is
an even more effective method.
20-210 PC1100-6
3
5) Change hydraulic oil when the temperature is

high.
When hydraulic oil or other oil is warm, it flows
easily. In addition, the sludge can also be drained
out easily from the circuit together with the oil,
so it is best to change the oil when it is still
warm. When changing the oil, as much as pos-
sible of the old hydraulic oil must be drained
out. (Drain the oil from the hydraulic tank; also
drain the oil from the filter and from the drain
plug in the circuit.) If any old oil is left, the
contaminants and sludge in it will mix with the
new oil and will shorten the life of the hydraulic
oil.
6) Flushing operations
After disassembling and assembling the equip-
ment, or changing the oil, use flushing oil to
remove the contaminants, sludge, and old oil
from the hydraulic circuit.
Normally, flushing is carried out twice: primary
flushing is carried out with flushing oil, and sec-
ondary flushing is carried out with the specified
hydraulic oil.
7) Cleaning operations
After repairing the hydraulic equipment (pump,
control valve, etc.) or when running the ma-
chine, carry out oil cleaning to remove the sludge
or contaminants in the hydraulic oil circuit.
The oil cleaning equipment is used to remove
the ultrafine (about 3µ) particles that the filter
built into the hydraulic equipment cannot re-
move, so it is an extremely effective device.
PC1100-6 20-211
3
TROUBLESHOOTING CHECKS BEFORE TROUBLESHOOTING
CHECKS BEFORE TROUBLESHOOTING
Item Judgement Action

value
1. Check fuel level, type of fuel — Add fuel
2. Check for impurities in fuel — Clean, drain
Lubricating oil, coolant
3. Check hydraulic oil level — Add oil

4. Check hydraulic strainer — Clean, drain
5. Check swing machinery oil level — Add oil
6. Check engine oil level (oil pan oil level), type of oil — Add oil
7. Check coolant level — Add water
8. Check dust indicator for clogging — Clean or replace
9. Check hydraulic filter — Replace
equipment
1. Check for looseness, corrosion of battery terminal, wiring — Tighten or replace

Electrical
2. Check for looseness, corrosion of alternator terminal, wiring — Tighten or replace

3. Check for looseness, corrosion of starting motor terminal, wiring — Tighten or replace
mechanical
equipment
Hydraulic,
1. Check for abnormal noise, smell — Repair

2. Check for oil leakage — Repair
3. Carry out air bleeding — Bleed air
1. Check battery voltage (engine stopped) 20 – 30V Replace

2. Check battery electrolyte level — Add or replace
Electrics, electrical equipment
3. Check for discolored, burnt, exposed wiring — Replace

4. Check for missing wiring clamps, hanging wiring — Repair
5. Check for water leaking on wiring (be particularly careful attention — Disconnect
to water leaking on connectors or terminals) connector and dry
6. Check for blown, corroded fuses — Replace
7. Check alternator voltage (engine running at 1/2 throttle or above) After running Replace
for several
minutes:
27.5 – 29.5V
8. Check operating sound of battery (when switch is turned ON/OFF) — Replace
20-212 PC1100-6
3
TROUBLESHOOTING CONNECTOR TYPES AND MOUNTING LOCATIONS
CONNECTOR TYPES AND MOUNTING LOCATIONS

Con- No. Add- Con- No. Add-
nector Type of Mounting location nector Type of Mounting location
ress ress
No. pins No. pins
C01 MIC 13 Pump controller R4 E26 SWP 6 APS controller C2
C02 MIC 21 Pump controller R8 E27 S 16 Intermediate connector M7
C03 AMP040 20 Pump controller R4 E28 S 16 Intermediate connector M8
C05 S 10 Pump prolix switch Q2 E32 X 3 Governor control solenoid valve U2
C06 M 2 Pump prolix resistor Q3 F01 X 2 Travel alarm L7
C09 S 8 Model selection connector R7 F10 M 4 Flasher timer M8
C13 X 2 TVC valve V1 H12 S 16 Intermediate connector M5
C16 MIC 17 Pump controller R8 H13 S 16 Intermediate connector M6
C17 AMP040 16 Pump controller R6 H14 M 6 Intermediate connector M5
CH1 S 16 Electronic governor checker connector Q9 H15 L 2 Intermediate connector M5
D01 KES1 2 Diode (for washer motor) — L03 M 2 Step light switch R7
D03 KES1 2 Diode (for heater unit circuit) — M2 X 2 Starting motor X5
D03 KES1 2 Diode (for V02 solenoid) — M06 M 3 Heater switch N3
D04 KES1 2 Diode (for V03 solenoid) — M07 M 2 Light switch N2
D05 KES1 2 Diode (for V04, V11 solenoid) — M08 1-pin 1 Boom working lamp A6
connector
1-pin
D06 KES1 2 Diode (for V05 solenoid) — M09 connector 1 Boom working lamp A5
D07 KES1 2 Diode (for V06 solenoid) — M10 M 1 Intermediate connector E7
D09 KES1 2 Diode (for V01 solenoid) — M11 L 2 Fusible link D7
D11 KES1 2 Diode (for alarm buzzer) — M12 KES1 3 Heater unit R8
D14 KES1 2 Diode (for battery relay circuit) — M13 KES0 2 Right speaker M5
D18 KES1 2 Diode (for V07 solenoid) — M14 L 2 Fusible link C7
1-pin
D20 KES1 2 Diode (for V09, V10 solenoid) — M16 connector 1 Horn valve H9
1-pin
D22 KES1 2 Diode (for travel alarm circuit) — M17 connector 1 Horn valve H9
D23 KES1 2 Diode (for travel alarm circuit) — M18 M 4 Wiper washer switch N2
1-pin
D26 KES1 2 Diode (for swing prolix circuit) — M20 connector 1 Cigar lighter N3
D28 KES1 2 Diode (for automatic greasing circuit) — M21 PA 9 Radio N4
E06 M 3 Fuel control dial N3 M23 M 2 Horn switch R6
E07 X 2 No. 2 engine speed sensor X5 M26 M 6 Air conditioner unit G1
E08 SWP 14 Intermediate connector V1 M28 KES0 2 Window washer motor I2
E12 MIC 17 Engine controller R8 M33 AMP250 3 Boom shockless motor M4
E13 MIC 21 Engine controller P9 M34 X 1 Magnetic clutch for air conditioner compressor S3
E14 AMP040 20 Engine controller O9 M36 M 1 Kerosene mode selector switch R8
E15 AMP040 16 Engine controller N9 M38 M 2 Machine push-up switch M3
1-pin
E16 AMP040 12 Engine controller O9 M39 connector 1 Option power source M8
E17 AMP040 20 Engine controller P9 M42 M 1 Right working lamp B3
E18 AMP040 16 Engine controller O9 M44 M 4 Intermediate connector M5
E19 X 2 Governor control solenoid valve T3 M45 M 3 Network pass connector R1
E20 X 3 Prestroke control solenoid valve T2 M62 X 2 Intermediate connector R7
E21 X 2 No. 1 engine speed sensor X5 M66 1-pin 1 Auto greasing pilot lamp O1
connector
1-pin
E22 X 4 Rack sensor S3 M67 connector 1 Auto greasing pilot lamp O1
1-pin
E23 SWP 16 Intermediate connector V1 M69 connector 1 Option power source connector M8
1-pin
E25 X 4 APS controller C2 M70 connector 1 Service power source connector O1
20-214 PC1100-6
3
TROUBLESHOOTING CONNECTOR TYPES AND MOUNTING LOCATIONS
Con- No. Add- Con- No. Add-

nector Type of Mounting location nector Type of Mounting location
ress ress
No. pins No. pins
M71 1-pin 1 Room lamp F8
connector R24 Shinagawa 5 Governor cut relay Q9
M72 M 3 Intermediate connector M8 S01 X 2 R.H. travel FORWARD PPC pressure switch J1
M73 KES0 2 Left speaker N9 S02 X 2 Boom RAISE PPC pressure switch K2
M74 X 2 Intermediate connector D7 S03 X 2 Arm OUT PPC pressure switch L2
M75 M 1 Step light G9 S04 X 2 Boom LOWER PPC pressure switch K1
M76 M 1 Cab front lamp D7 S05 X 2 Arm IN PPC pressure switch L2
M77 M 1 Cab front lamp E7 S06 X 2 Bucket CURL PPC pressure switch K2
M79 M 8 Intermediate connector M5 S07 X 2 Bucket DUMP PPC pressure switch K2
M80 M 1 Intermediate connector G1 S08 X 2 Swing right PPC pressure switch L2
M81 M 2 Intermediate connector M8 S09 X 2 Service PPC pressure switch I2
M82 M 1 Flash light E1 S10 X 2 Swing left PPC pressure switch L2
M90 X 2 Starting motor U2 S11 X 2 R.H. travel REVERSE PPC pressure switch J1
M91 KES1 4 APS switch N4 S12 X 2 L.H. travel FORWARD PPC pressure switch J1
1-pin
M93 connector 1 Service power source connector O2 S13 X 2 L.H. travel REVERSE PPC pressure switch J1
M94 M 4 Intermediate connector R5 SW01 — 4 Swing prolix switch R2
M95 KES0 2 Window washer motor I2 T02 — 1 Revolving frame ground connection —
M96 M 6 Intermediate connector Q1 T05 — 1 Pump controller ground connection R4
1-pin
M97 connector 1 Room lamp G9 T06 — 1 Cab front lamp D7
M99 X 3 Intermediate connector G8 T07 — 1 Step light H9
P01 AMP040 20 Monitor panel O2 T08 — 1 Cab front lamp E7
P02 AMP040 16 Monitor panel O2 T20 M 8 Flash timer N9
P03 M 2 Buzzer cancel switch N3 T21 M 6 Step light timer O9
P04 M 2 Alarm buzzer O2 V01 X 2 Swing priority solenoid valve L7
P05 X 1 Engine oil level sensor U2 V02 X 2 2-stage relief solenoid valve K8
P06 X 1 Fuel level sensor E8 V03 X 2 Straight-travel solenoid valve J9
P07 X 2 Coolant temperature sensor W7 V04 X 2 Swing holding brake solenoid valve J9
P08 X 2 Coolant level sensor F8 V05 X 2 Machine push-up solenoid valve J8
P09 X 1 Hydraulic oil level sensor I2 V06 X 2 Travel speed solenoid valve I9
P10 X 2 Hydraulic oil temperature sensor J3 V07 X 2 CO cancel solenoid valve K8
P11 1-pin 1 Air cleaner clogging sensor X7 V09 X 2 Boom RAISE shockless solenoid valve G1
connector
P12 1-pin 1 Air cleaner clogging sensor X6
connector V10 X 2 Boom LOWER shockless solenoid valve H1
P13 X 4 APS nozzle & glow plug W7 V11 X 2 Swing holding brake solenoid valve I9
1-pin
P19 connector 1 APS water temperature sensor V8 W08 AMP070 18 Wiper, washer relay box Q3
P20 X 2 Coolant level sensor G9 W21 M 4 Wiper motor E1
R04 Shinagawa 5 Room light relay Q2 X01 MIC 21 Intermediate connector N5
R05 Shinagawa 5 Head light relay Q3 X05 M 4 Swing lock switch N2
R15 Shinagawa 5 Boom shockless relay Q2 X07 MIC 17 Intermediate connector N4
R16 Shinagawa 5 Flash relay N9
R17 Shinagawa 5 Step light relay M9
R18 Shinagawa 5 Horn valve relay P9
R20 Shinagawa 5 Swing holding brake relay O2
R23 Shinagawa 5 APS controller relay P9
PC1100-6 20-215
3
TROUBLESHOOTING CONNECTOR ARRANGEMENT DIAGRAM
CONNECTOR ARRANGEMENT DIAGRAM
20-216 PC1100-6
3
PC1100-6 20-217
3
20-218 PC1100-6
3
PC1100-6 20-219
3
TROUBLESHOOTING CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS

fl The terms male and female refer to the pins, while the terms male housing and female housing
refer to the mating portion of the housing.
No. X type connector

of
pins Male (female housing) Female (male housing)
1
1
2
2
TEW00221 TEW00222
1 3 3 1
2 2
TEW00223 TEW00224
1 3
3 1
2 4 4 2
TEW00225 TEW00226
20-220 PC1100-6
3
No. SWP type connector

of
1 4 4 1
3 6
TEW00235 6 3 BLP00033
1 5 5 1
4 8
8 4
TEW00237 TEW00238
4 1
1 4
8 5
12 5 8
12 9 9 12
BLP00034 BLP00035
1 4 8 11 11 8 4 1
14
3 7 10 14
14 10 7 3
TEW00239 TEW00240
4 1 4
1
8 5
5 8
16
12 9 9 12
16 13
BLP00036 13 16 BLP00037
PC1100-6 20-221
3
No. M type connector

of
2 2
1 BLP00038 1 BLP00039
2 3 3 2
1 1
TEW00243 TEW00244
1 3 3 1
2 4 4 2
TEW00245 TEW00246
1 4 4 1
3 6 6 3 TEW00248
TEW00247
4 1 4
1
8 5
BLP00040 5 8 BLP00041
20-222 PC1100-6
3
No. S type connector

of
1 5 5 1
4 8 TEW00249
8 4 TEW00250
6 1
1 6
10
5 10
TEW00251 10 5 BLP00042
12
(White)
16
(White)
PC1100-6 20-223
3
No. S type connector

of
10
(Blue)
1 6 6 1
12
(Blue)
5 12
BLP00043 12 5 TEW00254
1 8 8 1
16
(Blue)
7 16 BLP00044 16 7 TEW00256
20-224 PC1100-6
3
No. MIC connector

of
3 3 1
1
4 5 5 4
BLP00045 BLP00046
1 5 5 1
6 9 9 6
9
BLP00047 BLP00048
1 7 7 1
13 13 8
8
13
BLP00049 BLP00050
1 9 9 1
10 17 17 10
17
BLP00051 BLP00052
1 11
11 1
12 21
21 12
21
TEW00260
TEW00259
PC1100-6 20-225
3
No. AMP040 type connector

of
4 8
8 4
1 5
5 1 BLP00054
BLP00053
6 12 12 6
12
1 7
BLP00055 7 1 BLP00056
8 16
16 8
16
9 1
1 9
BLP00057 TEW00232
10 20
20 10
20
11 1
1 11 TEW00234
BLP00058
20-226 PC1100-6
3
No. AMP070 type connector

of
1 7 7 1
6 14 14 BLP00060
BLP00059 6
1 9 9 1
12
8 18
BLP00061 18 8 BLP00062
PC1100-6 20-227
3
No. L type type connector

of
1 1
2
2 2
TEW00257 TEW00258
20-228 PC1100-6
3
No. Automobile connector

of
2
2
1 1
BLP00063 BLP00064
3 1 1 3
4 6
6 4 BLP00069 BLP00070
4 1 1 4
5 8
8 5 BLP00071 BLP00072
PC1100-6 20-229
3
No. Relay connector

of
2 5 2 1
1 3 6 5 6 3
BLP00073 BLP00074
6 4 3 6 5
4 3 1 2
5 2 1
BLP00075 BLP00076
20-230 PC1100-6
3
TROUBLESHOOTING EXPLANATION OF CONTROL MECHANISM FOR ELECTRICAL SYSTEM
EXPLANATION OF CONTROL MECHANISM FOR ELECTRICAL

SYSTEM
1. Explanation of machine control functions
The control mechanism for the electrical system consists of the monitor panel and governor and
pump controller. The monitor panel and the governor and pump controller input the signals that
are necessary, and together with the signals selected by the monitor panel, the governor and
pump controller outputs or inputs the necessary signals and control the pump absorption torque
and engine output.
PC1100-6 20-231
3
TROUBLESHOOTING DISPLAY METHOD AND SPECIAL FUNCTIONS OF MONITOR PANEL
DISPLAY METHOD AND SPECIAL FUNCTIONS OF MONITOR

PANEL
1. Troubleshooting function of lamps, gauges, buzzer
When the starting switch is turned on, all the lamps and gauges light up for approx. 3 seconds,
and the buzzer sounds for approx. 1 second. During this time, the monitor itself carries out self
diagnosis, and after it has finished, it gives the normal display (if any lamp does not light up
during the visual check, the lamp bulb is blown).
2. User code display function

All the abnormality data for the engine controller and pump controller are transmitted to the
monitor panel.
Of the abnormality data, items with a high emergency level are displayed as a user code automati-
cally on the time display of the monitor panel to advise the operator of the action to take.
User code display
Example: When user code [E02] is displayed
Table of user codes

User code Abnormal system User code Abnormal system
E02 TVC system E11 Engine control system
E03 Swing holding brake system E12 Engine speed sensor system
E0E Network system E13 Governor cut relay system
E10 Engine emergency stop system E14 Fuel control dial system
20-232 PC1100-6
3
2. User code display function

All the abnormality data for the engine controller and pump controller are transmitted to the
monitor panel.
These abnormality data, regardless of whether they are necessary to display as a user code or not,
are all stored inside the monitor panel as service codes.
When the following operations are carried out, the service codes are displayed on the monitor
panel time display and the elapsed time data (time on the service meter) are displayed on the
service meter display panel.
Method of displaying and deleting service codes
1. To switch to the service code display mode, keep the Time switch + L.H. travel speed switch
pressed for at least 2.5 seconds.
Example 1: When the display shows that [E213] occurred 6 hours before
Example 2: When [E213] occurred 6 hours before and the display shows that the abnormality is still
continuing (the letter “E” appears at the head of the code)
PC1100-6 20-233
3
Method of displaying and deleting service codes
Example 3: When the service code is not recorded
2. To go on to the next service code display, press the Time switch + Working mode right switch.
3. To go back to the previous service code display, press the Time switch + Working mode left
switch.
4. To finish using the service code display mode, keep the Time switch + L.H. travel speed switch
5. To delete the service codes from memory, keep the Time switch pressed and turn the starting
switch OFF. Then turn the starting switch ON again and keep the Time switch pressed for at
least 5 seconds.
Table of service codes

Service code Abnormal system User code
E101 Abnormality in error history data —
E102 Abnormality in clock data —
E103 Short circuit with power source, short circuit in buzzer output system —
E104 Abnormality in air cleaner clogging sensor detected —
E106 Abnormality in engine oil high-pressure sensor detected —
E108 Engine water temperature over 105°C detected —
E113 Short circuit in wiper drive system —
E114 Short circuit in window washer drive system —
E117 S-NET communications error with engine controller E0E
E118 S-NET communications error with pump controller E0E
E201 Short circuit in CO cancel solenoid system —
E202 Short circuit in straight-travel solenoid system —
E203 Short circuit in swing holding brake solenoid relay system E03
E204 Short circuit in 2-stage relief solenoid system —
E205 Short circuit in swing priority solenoid system —
E206 Short circuit in travel speed solenoid system —
E211 Disconnection in CO cancel solenoid system —
20-234 PC1100-6
3
Service code Abnormal system User code
I E212 1 .
Drsconnection in straight-travel solenoid system I - I
E213 Disconnection in swing holding brake solenoid relay system E03
E214 Disconnection in 2-stage relief solenoid system
I E215 1 Drsconnection in swing priority solenoid system I - I

I E216 1 Drsconnection
. in travel speed solenoid system I - I
I E217 Error in pump controller model selection input I - I
E218 S-NET response overtime error with pump controller
E227 Abnormality in No. 2 engine speed sensor system (pump controller) -
E228 Abnormality in auto-deceleration output system -
I E232 Short circuit in TVC solenoid system I E02 I

I E233 1 Drsconnection
. in TVC solenoid system I E02 I
E313 Error in automatic greasing controller -
E501 Abnormality in engine controller power source system El0
I E502 ~~ I----Abnormality in engine controller I El0 I

I E503 / .
Mrstaken connection of engine controller connector I - I
E504 Engine overrun abnormality -
E505 Abnormality in fuel control dial system El4
E507 Abnormality in engine controller S-NET -
Abnormality in governor servo
E534 Abnormality in machine selection input to engine controller El1
E535 Abnormality in engine controller backup power source system -
E536 Abnormality in engine controller switch power source system -
E537 Abnormality in engine controller solenoid power source system El0
% If service codes E513 and E514 occur at the same time, user code El0 is displayed.
PC1 100-6 20-235

0
3. Monitoring code display function

The input signals from the sensors to each component and the output signals to drive the solenoid
can be checked in real time with the monitoring code.
When the following operations are carried out, the monitoring codes are displayed on the monitor
panel time display and the monitoring data are displayed on the service meter display panel.
Method of displaying monitoring codes
1. To set to the machine data monitoring mode, keep the Time switch + Heavy lift switch pressed
for at least 2.5 seconds.
Example 1: When a numeric display monitoring code (engine speed: 2050 rpm) is displayed
Example 2: When a bit pattern display monitoring code (S-NET component connection condition)
is displayed
20-236 PC1100-6
3
Method of displaying monitoring codes
2. To go on to the next monitoring code display, press the Time switch + Working mode right
switch.
3. To go back to the previous monitoring code display, press the Time switch + Working mode left
switch.
4. To finish using the monitoring code display mode, keep the Time switch + Heavy lift switch
Table of monitoring codes

fl For details of the (6 bit) in the Unit column, see the bit pattern chart.
Code No. Item Unit Name of component
01 Monitor panel model code — Monitor panel
02 Pump controller model code — Pump controller
03 Engine controller model code — Engine controller
08 S-NET component connection condition (6 bit) Monitor panel
10 Engine speed 10 rpm Pump controller
11 (Spare) Pump controller
13 TVC output current 10 mA Pump controller
14 (Spare) — Pump controller
16 No. 2 throttle command 10 rpm Pump controller
20 Pump controller switch input condition (1) (6 bit) Pump controller
21 Pump controller switch input condition (2) (6 bit) Pump controller
22 Pump controller switch condition signal (3) (6 bit) Pump controller
23 Pump controller solenoid drive condition (6 bit) Pump controller
24 Pump controller chassis warning sensor input condition (1) (6 bit) Pump controller
25 Pump controller chassis warning sensor input condition (2) (6 bit) Pump controller
26 Pump controller input/output condition (6 bit) Pump controller
32 Battery voltage (VBB voltage) 100 mV Pump controller
36 Pump controller input condition (6 bit) Pump controller
40 Engine speed 10 rpm Pump controller
41 Coolant temperature sensor input voltage 10 mV Pump controller
42 Fuel level sensor input voltage 10 mV Pump controller
PC1100-6 20-237
3
Code No. Item Unit Name of component

43 Alternator (charge) input voltage 100 mV Pump controller
44 Hydraulic oil temperature sensor input voltage 10 mV Pump controller
47 Monitor panel output condition (1) (6 bit) Monitor panel
48 Monitor panel input condition (1) (6 bit) Monitor panel
49 Monitor panel input condition (2) (6 bit) Monitor panel
4A Monitor panel input condition (3) (6 bit) Monitor panel
4C Monitor panel output condition (2) (6 bit) Monitor panel
50 Engine speed (No. 1 speed sensor) 10 rpm Engine controller
51 Engine speed (No. 2 speed sensor) 10 rpm Engine controller
52 Fuel control dial input voltage 10 mV Engine controller
53 Rack sensor input voltage 10 mV Engine controller
54 Governor solenoid output current 10 mA Engine controller
55 Prestroke solenoid output current 10 mA Engine controller
56 (Spare) Engine controller
60 Engine controller input condition (6 bit) Engine controller
61 Engine controller output condition (6 bit) Engine controller
C0 Monitor panel program version — Monitor panel
C1 Pump controller program version — Pump controller
C2 Engine controller program version — Engine controller
20-238 PC1100-6
3
Bit pattern display (bit for applicable No. lights up)
Code Content Bit Details (condition when lighted up)

1 Pump controller connected
2 Governor controller connected
3 Engine controller connected
08 Connection of S-NET components
4 Engine controller connected
5
6
1 Right swing PPC pressure switch ON
2 R.H. travel PPC pressure switch ON
Input condition of pump controller 3 Boom LOWER PPC pressure switch ON
20
PPC pressure switches 4 Boom RAISE PPC pressure switch ON
5 Arm IN PPC pressure switch ON
6 Arm OUT PPC pressure switch ON
1 Bucket CURL PPC pressure switch ON
2 Bucket DUMP PPC pressure switch ON
Input condition of pump controller
3 Swing lock switch ON
21 PPC pressure switches and other
4 Service PPC pressure switch ON
switches
5 L.H. travel PPC pressure switch ON
6 Swing prolix switch ON
1 Model selection 1 GND connected
22 Pump controller model selection
5
6
PC1100-6 20-239
3
Code Content Bit Details (condition when lighted up)

1 CO cancel solenoid ON
2 Straight-travel solenoid ON
Drive condition of pump controller 3 Swing holding brake solenoid ON
23
solenoid 4 2-stage relief solenoid ON
5 Swing priority solenoid ON
6 Travel speed solenoid ON
1 Engine low-pressure hydraulic sensor OPEN (above specified pressure)
2 Engine high-pressure hydraulic sensor OPEN (above specified pressure)
Input condition (1) of pump con- 3 Coolant level sensor OPEN (below low level)
24
troller monitor alarm sensors 4 Engine oil level sensor OPEN (below low level)
5 Hydraulic oil level sensor OPEN (below low level)
6 Air cleaner clogging sensor OPEN (clogging detected)
1
2 Overload sensor OPEN
Input condition (2) of pump con- 3
25
troller monitor alarm sensors 4
5 Auto greasing controller abnormal
6
1
2
Input/output condition of pump 3 Auto-deceleration signal output
26
controller 4
5 Left swing PPC pressure switch ON
6
1
2
3
36 Input condition of pump controller
4
5 Starting switch ON
6
1
2 Alarm buzzer OFF
Output condition (1) of monitor 3 Wiper motor drive (R) OFF
47
panel 4 Wiper motor drive (L) OFF
5 Window washer drive ON
6
20-240 PC1100-6
3
Zode Content
Input condition (I) of monitor

48
panel
Input condition (2) of monitor

49
panel
Input condition (3) of monitor

4A
panel
Input condition (4) of monitor @ Wiper motor reverse relay output OFF or set voltage abnormal
4c
panel @ Washer motor drive output OFF or set voltage abnormal
0
0 Kerosene mode signal input
@ Auto-deceleration signal input
input condition of engine control- 0

60
ler @ APS actuation signal input
0 Starting switch terminal C ON
8
(Q Governor cut relay output ON
0
Output condition of engine con- @ Machine selection on 55°C specification
61
troller 0
PC1 100-6 20-241

0
4. Function for setting working mode default

The working mode on the monitor panel is set so that the H mode normally lights up when the
starting switch is turned ON.
If the function for setting the default is used as follows, it is possible to change the setting so that
the system starts with the working mode desired by the operator.
Method of setting default
1. To change to the default setting mode, keep the Time switch + Working mode right switch
fl When the system enters the default setting mode, the working mode LED flashes.
2. To change the default set mode, press the Working mode left switch or Working mode right
switch to light up the LED of the desired working mode.
3. To finish using the default setting mode, keep the the Time switch + Working mode right switch
20-242 PC1100-6
3
5. Displaying and setting oil maintenance function

On machines equipped with the oil maintenance function, the “Change engine oil” LED lights up
from a point 10 hours before the time set for the oil change and stays lighted up until the system
is reset. The elapsed time is displayed on the service meter and the telephone number is displayed
on the time display and service meter display. (It is displayed for 20 seconds after the starting
switch is turned ON.)
With the oil maintenance function, it is possible to set, change, or cancel the display, or set,
change, or cancel the telephone number.
Oil maintenance function display
Example: Oil change interval setting: 250 h, time elapsed since last oil change: 245 h, telephone
number: 0123456789 are displayed
fl Nothing is displayed until the elapsed time enters the period of 10 hours before the change
interval.
(If you want to see the elapsed time when there is no display, keep the buzzer stop switch
pressed and turn the starting switch ON. The elapsed time will be displayed for 10 seconds.)
fl The telephone number display is not shown if the telephone has not been set.
fl If the telephone number is set, when the starting switch is turned ON, the elapsed time is
displayed for 10 seconds at the top and the telephone number for 10 seconds at the bottom,
then the display returns to the normal display.
fl If the telephone number is not set, when the starting switch is turned ON, the elapsed time is
displayed for 20 seconds (top), then the display returns to the normal display.
PC1100-6 20-243
3
Setting interval and resetting elapsed time
1. Setting interval
1) Keep the Time switch + Swing priority mode switch pressed for at least 2.5 seconds.
2) Press the Buzzer stop switch and select the interval.
Example: Interval: When selecting 250 h
fl Interval display
– – – h: Default mode (oil maintenance function not set)
125h: Interval is set for every 125 hours
dh: Demo mode is set
fl Set the interval according to the Operation and Maintenance Manual.
3) Keep the Time switch + Swing priority mode switch pressed for at least 2.5 seconds to
complete the setting of the interval.
3. Resetting elapsed time after changing oil

Press the Buzzer stop switch and keep it depressed for 3 seconds while the elapsed time and
telephone number are being displayed (for 20 seconds) on the monitor panel. The elapsed time
will be reset and the display will show “Elapsed time: 0h” for 1 second.
20-244 PC1100-6
3
Setting interval and resetting elapsed time
ª Demo mode
If the demo mode is used, a demonstration of the oil maintenance function can be carried out
when the machine is delivered.
The following functions can be carried out in the demo mode
1 Elapsed time display (note: this is for demonstration purpose only, so the elapsed time is
fixed at 240h)
2 Telephone number display (note: the telephone number must be set individually)
3 Resetting elapsed time
fl After setting to the demo mode, turn the starting switch ON again to start the demonstra-
tion.
Note: If the starting switch is turned ON four times, the demo mode is canceled and the
system automatically switches the default mode.
(If you want to continue the demonstration, it is necessary to set to the demo mode again.)
PC1100-6 20-245
3
Setting, changing telephone number
1. To change to the telephone number setting mode, keep the Time switch + Auto-deceleration
fl The 2 digits on the left will flash and the other 8 digits will light up.
2. To select the 2-digit block to be changed (the number can be set or changed when the 2-digit
block is flashing)
1) To move the flashing to the right, press the Time switch + Working mode right switch.
2) To move the flashing to the left, press the Time switch + Working mode left switch.
3. To set or change the number (to set or change the left or right digits in the flashing 2-digit block)
1) To set or change the number in the left digits, press the Time switch + Travel speed left
switch.
2) To set or change the number in the right digits, press the Time switch + Travel speed right
switch.
fl The available numbers are 0 – 9 and blank.
If the number is set as a blank, that digit will not light up when the telephone number is
displayed.
fl To stop the telephone number display, set all the numbers to 0.
4. To finish using the telephone number setting mode, keep the Time switch + Auto-deceleration
switch pressed for at least 2.5 seconds.
20-246 PC1100-6
3
TROUBLESHOOTING ORDER OF TROUBLESHOOTING WHEN CARRYING OUT TROUBLESHOOTING
ORDER OF TROUBLESHOOTING WHEN CARRYING OUT

TROUBLESHOOTING
If any abnormality occurs on the machine, use the flow chart below to judge which system has the
problem, go to the judgement table for the engine controller, APS controller, and engine system, and
the judgement table for the pump controller and hydraulic (mechanical) system, and then proceed to
the troubleshooting mode.
E02 is displayed
Go to troubleshooting for
C, F, H mode
E03 is displayed
E0E is displayed N mode
E10 is displayed
YES
E11 is displayed
E12 is displayed E, S mode
E13 is displayed
1 E14 is displayed
Is user code
displayed on
monitor panel?
E1fifi is displayed M mode
YES Go to troubleshooting for

E2fifi is displayed C, F, H mode
E5fifi is displayed E, S mode
2
Is service code
displayed on
NO monitor panel?
• Turn starting Engine Go to troubleshooting for

3 E, S mode
switch ON. Is abnormality in
• Set to service engine, Go to troubleshooting for
code display NO machine, or Machine C, F, H mode
mode. monitor panel?
• Judge from type Go to troubleshooting for
Monitor panel
of problem that M mode
has occurred.
20-248 PC1100-6
3
N mode
fl After checking the service code, go directly to N mode.
E, S mode
fl Go to the judgement table for the engine controller, APS controller, and engine system in trouble-
shooting for E mode, check the type of problem, service code, and APS controller LED display to
determine the problem system, then go to troubleshooting for E mode or S mode as appropriate.
C, F, H mode
fl Go to the judgement table for the pump controller, and hydraulic (mechanical) system in trouble-
shooting for C mode, check the type of problem, service code, monitoring code display, and
solenoid valve input voltage to determine the problem system, then go to troubleshooting for C
mode, F mode, or H mode as appropriate.
M mode
fl After checking the service code, go directly to M mode.
PC1100-6 20-249
3
TROUBLESHOOTING METHOD OF USING JUDGEMENT TABLE
METHOD OF USING JUDGEMENT TABLE

1. Judgement table for engine controller and engine
This judgement table is a tool to determine if the problem with the machine is caused by an
abnormality in the electrical system or by an abnormality in the engine. The symptoms are then
used to decide which troubleshooting table (E-fifi, S-fifi) matches the symptoms.
<Method of using judgement table>
1) Locate the problem that has occurred in the failure mode column and go to the right across the
judgement table.
2) If there is a ‡ mark or ■ mark, check the service code or APS controller LED display given at
the top of the column.
3) If the display is normal: Go further to the right across the judgement table, and if all the ‡
marks or ■ marks are normal, go to the troubleshooting code at
the right side of the table.
If the display is not normal: Go to the troubleshooting code at the bottom of the judgement
table.
JUDGEMENT TABLE FOR ENGINE CONTROLLER, APS CONTROLLER, AND ENGINE RELATED PARTS
Checking service code
Checking preheating pilot lamp display and APS controller LED display
Checking service code Checking monitoring code
User code
Abnormality detected in engine high-pressure oil pressure sensor

Abnormality in rack sensor power source system
Abnormality in controller switch power source system

Abnormality in controller solenoid power source system
Abnormality in No. 1 engine speed sensor system

Service code Abnormality in No. 2 engine speed sensor system
Abnormality in controller power source system
Engine water temperature over 105°C detected

Abnormality in controller backup power source system
Monitoring code
Disconnection in prestroke solenoid system
Disconnection in governor cut relay system

Disconnection in governor solenoid system
Short circuit in prestroke solenoid system
Short circuit in governor cut relay system

Short circuit in governor solenoid system
Abnormality in rack sensor signal system
[ The “E” mark is omitted from

the service code ] Abnormality fuel control dial system
Rack position sensor input voltage

Governor solenoid output voltage
Mistaken connection of connector
Prestroke solenoid output voltage
Troubleshooting code
Fuel control dial input voltage

Abnormality in controller
No. 1 engine speed

No. 2 engine speed
Engine overrun
Failure mode User code E10 E11 E12 E13 E14 — — 50 51 52 53 54 55

Service code 501 502 521 522 531 537 508 511 515 516 513 514 525 526 505 503 504 535 536 106 108 — — — — — —
Starting performance is poor (starting always takes time) ‡ ‡ ‡ ■ fi fi S-1
Engine does not turn E-20
Engine does
not start
Engine turns but no exhaust smoke comes out ‡ ‡ ‡ ‡ ‡ ‡ ‡ ‡ ■
S-2
Exhaust smoke comes out, but engine does not start ■ fi
Engine does not pick up smoothly (follow-up is poor) ‡ ‡ ‡ fi fi fi fi S-3
Engine stops during operations ‡ ‡ ‡ ‡ ‡ ‡ ‡ ‡ ‡ S-4
Engine does not rotate smoothly (hunting) ‡ ‡ ‡ fi fi fi S-5
Engine lacks output or lacks power ‡ ‡ ‡ ‡ ‡ fi fi fi fi fi S-6
Exhaust gas is black (incomplete combustion) ‡ ‡ ‡ ‡ fi S-7
Oil consumption is excessive or exhaust gas is blue S-8
Oil becomes contaminated quickly S-9
Fuel consumption is excessive ‡ ‡ ‡ fi S-10
Oil is in cooling water, or water spurts back, or water level goes down S-11
Oil pressure caution lamp lights up M-13
Oil level rises (water, fuel mixed with oil) S-13
Water temperature becomes too high (overheating) M-13
Abnormal noise is made S-15
Vibration is excessive S-16
Automatic warming-up function does not work or is not canceled ‡ fi fi fi M-18
Engine does not stop ‡ E-21
Troubleshooting code E-1 E-2 E-3 E-4 E-5 E-6 E-7 E-8 E-9 E-10 E-11 E-12 E-13 E-14 E-15 E-16 E-17 E-18 E-19 S-12 S-14 E-22 — — — — — —
‡: Check the service code display. If there is no display, go to the right; if there is a display, go to the
bottom.
■: Check the preheating pilot lamp display and APS controller LED display. If the voltage is normal, go
to the right; if the voltage is abnormal, go to the bottom. (For details of the APS display, see the
next page.)
fi: Monitoring code to use as reference when proceeding with troubleshooting (if necessary, check the
display).
<Example of use>
1) Failure mode “Starting performance is poor (starting always takes time)” has occurred.
2) Check the display of the service codes [E511], [E515], [E516], and the APS controller LED.
3) If there is a display: Carry out troubleshooting for troubleshooting codes E-8, E-9, E-10, or E-22.
If there is no display: Carry out troubleshooting for troubleshooting code S-1.
20-250 PC1100-6
3
TROUBLESHOOTING METHOD OF USING JUDGEMENT TABLE
2. Judgement table for pump controller and hydraulic (mechanical) system

This judgement table is a tool to determine if the problem with the machine is caused by an
abnormality in the electrical system or by an abnormality in the hydraulic or mechanical system.
The symptoms are then used to decide which troubleshooting table (C-fifi, F-fifi, H-fifi) matches
the symptoms.
<Method of using judgement table>
1) Locate the problem that has occurred in the failure mode column and go to the right across
the judgement table.
2) If there is a ‡ mark, ◆ mark, or ■ mark, check the solenoid valve input voltage, service code,
or monitoring code given at the top of the column.
3) If the display is normal: Go further to the right across the judgement table, and if all the ‡
marks, ◆ marks, or ■ marks are normal, go to the troubleshoot-
ing code at the right side of the table.
If the display is not normal: Go to the troubleshooting code at the bottom of the judgement
table.
JUDGEMENT TABLE FOR PUMP CONTROLLER AND HYDRAULIC (MECHANICAL) RELATED PARTS
Checking solenoid
Troubleshooting code for hydraulic, mechanical system

Checking service code inlet port voltage Checking monitoring code Monitoring code for reference during troubleshooting
Disconnection in CO cancel solenoid system
Short circuit in CO cancel solenoid system
Disconnection in 2-stage relief solenoid system
Disconnection in swing priority solenoid system
PPC pressure switch Solenoid drive condition

Disconnection in straight-travel solenoid system
Short circuit in TVC solenoid system
Short circuit in swing holding brake solenoid system

Disconnection in swing holding brake solenoid system
Abnormality in auto-deceleration output system

Disconnection in TVC solenoid system
User code
Disconnection in travel speed solenoid system

Short circuit in swing priority solenoid system
Pump controller model selection

Short circuit in straight-travel solenoid system
Short circuit in 2-stage relief solenoid system
Auto-deceleration signal output

Short circuit in travel speed solenoid system
Swing holding brake solenoid

Service code
Pump controller model code

Model selection input error
Monitoring code
Machine push-up solenoid
Boom shockless solenoid
Swing priority solenoid

Straight-travel solenoid
Bucket DUMP (service)
2-stage relief solenoid
Travel speed solenoid

The “E” mark is omitted
[ ]
CO cancel solenoid
TVC output current
Swing lock switch
from the service code
Boom LOWER
Engine speed
Bucket CURL
Boom RAISE
Right swing
R.H. travel
Left swing
L.H. travel
Arm OUT
Arm IN
Failure mode
Connectors
Connectors
Connector
User code LED E02 E03 — — — — — — — — 20 21 26 21 22 23 26

V04, V11
V09, V10
V05
02 10 13 12
Service code OFF 232 233 203 213 201 211 202 212 204 214 205 215 206 216 217 227 228 1 2 3 4 5 6 1 2 5 5 3 34 1 2 3 4 5 6 3
‡ ‡ ‡ ‡ fi fi fi fi
All work equipment,
Speeds of all work equipment, swing, travel are slow or lack power H-1
swing, travel
There is excessive drop in engine speed, or engine stalls ‡ ‡ ‡ ‡ ‡ fi fi fi fi H-2

No work equipment, travel, swing move H-3
Abnormal noise generated (around pump) H-4
Auto-deceleration does not work ‡ ‡ ■ ■ ■ ■ ■ ■ ■ ■ ■ fi –
In normal mode ‡ ‡ fi
Boom is slow or lacks power With heavy lift ON ‡ ‡ ‡ ‡ ■ fi fi H-5
With machine push-up ON ◆
Work equipment
Arm is slow or lacks power H-6

Bucket is slow or lacks power H-7
Boom does not move H-8
Arm does not move H-9
Bucket does not move H-10
Excessive hydraulic drift H-11
Boom
Excessive time lag H-12
Arm, bucket
Boom shockless function does not work or cannot be canceled H-13
Machine deviates naturally Deviates in same direction in FORWARD and REVERSE ◆
H-14
to one side when traveling Deviates in opposite direction in FORWARD and REVERSE
Travel system
Deviation is excessive Only at full stroke

H-15
when starting Both during fine control operations and at full stroke
Deviation is excessive during compound operations ‡ ‡ ■ ■ ■ ■ ■ ■ ■ ■ ■ fi H-16
Travel speed is slow or lacks power ‡ ‡ ‡ ‡ fi fi H-17
Both directions (FORWARD and REVERSE)
Does not travel (one side only) H-18
One direction only (either FORWARD or REVERSE)
Travel speed does not switch ‡ ‡ ■ ■ fi H-19
Both left and right ‡ ‡ ◆ ■ ■ ■ ■ ■ ■ ■ ■ ■ fi
Does not swing H-20
One direction only
Both left and right
Swing acceleration is poor or lacks power H-21
One direction only
Swing system
During compound operations with bucket, swing speed is slow or acceleration is poor H-22
During compound operations with boom when swing priority is ON, swing speed is slow or acceleration is poor ‡ ‡ fi H-23
Both left and right
Excessive overrun when stopping swing H-24
One direction only
Both left and right ‡ ‡ fi
Excessive shock when stopping swing H-25
One direction only
Both left and right
Excessive abnormal noise when stopping swing H-26
One direction only ‡ ‡
Excessive hydraulic drift of swing fi H-27
Troubleshooting code of pump controller system C-1 C-2 C-3 C-4 C-5 C-6 C-7 C-8 C-9 C-10 C-11 C-12 C-13 C-14 C-15 C-16 C-17 C-18 C-19 C-20 C-21 – – – – – – – – – – – – – – – – – – – – – –
Troubleshooting code of pump controller input signal system – – – – – – – – – – – – – – – – – – – – – F-1 F-2 F-3 F-4 F-5 F-6 F-7 F-8 F-9 F-10 F-11 – – – – – – – – – – –
‡: Check the service code display. If there is no display, go to the right; if there
– is a display, go to the bottom.
■: Measure the voltage at the solenoid inlet port. If the voltage is normal, go to the right; if the voltage is abnormal, go to the bottom.
◆: Check the monitoring code display. If the display is normal, go to the right; if the display is abnormal, go to the bottom.
fi: Monitoring code to use as reference when proceeding with troubleshooting (if necessary, check the display).
<Example of use>
1) Failure mode “Speeds of all work equipment, swing, travel are slow or lack power” has
occurred.
2) Check the display of the service codes [E232], [E233], [E217], and [E227].
3) If there is a display: Carry out troubleshooting for troubleshooting codes C-2, C-3, C-16, or C-17.
If there is no display: Carry out troubleshooting for troubleshooting code H-1.
PC1100-6 20-251
3
TROUBLESHOOTING METHOD OF USING TROUBLESHOOTING CHARTS
METHOD OF USING TROUBLESHOOTING CHARTS

1. Category of troubleshooting code number
Troubleshooting Code No. Component

N-fifi Troubleshooting of network system
E-fifi Troubleshooting of engine controller & APS controller system
S-fifi Troubleshooting of engine
C-fifi Troubleshooting of pump controller
F-fifi Troubleshooting of pump controller input signal system
H-fifi Troubleshooting of hydraulic, mechanical system
M-fifi Troubleshooting of monitor panel system
2. Method of using troubleshooting table for each troubleshooting mode

1) Troubleshooting code number and problem (See Example 1)
The title of the troubleshooting chart gives the troubleshooting code, service code, and failure
mode (problem with the machine).
2) Distinguishing conditions (See Example 2)
Even with the same failure mode (problem), the method of troubleshooting may differ accord-
ing to the model, component, or problem. In such cases, the failure mode (problem) is further
divided into sections marked with small letters (for example, a)), so go to the appropriate
section to carry out troubleshooting.
If the troubleshooting table is not divided into sections, start troubleshooting from the first
check item in the failure mode.
3) Method of following troubleshooting chart (See Example 3)
• Check or measure the item inside , and according to the answer follow either the YES
line or the NO line to go to the next . (Note: The number written at the top right corner
of the is an index number; it does not indicate the order to follow.)
• Following the YES or NO lines according to the results of the check or measurement will
lead finally to the Cause column. Check the cause and take the action given in the Remedy
column on the right.
• Below the there are the methods for inspection or measurement, and the judgement
values. If the judgement values below the are correct or the answer to the question
inside the is YES, follow the YES line; if the judgement value is not correct, or the
answer to the question is NO, follow the NO line.
• Below the is given the preparatory work needed for inspection and measurement, and
the judgement values. If this preparatory work is neglected, or the method of operation or
handling is mistaken, there is danger that it may cause mistaken judgement, or the equip-
ment may be damaged. Therefore, before starting inspection or measurement, always read
the instructions carefully, and start the work in order from Item 1).
4) General precautions (See Example 4)
When carrying out troubleshooting for the failure mode (problem), precautions that apply to all
items are given at the top of the page and marked with fl.
The precautions marked fl are not given in the , but must always be followed when
carrying out the check inside the .
5) Troubleshooting tools
When carrying out the troubleshooting, prepare the necessary troubleshooting tools. For de-
tails, see TOOLS FOR TESTING, ADJUSTING, AND TROUBLESHOOTING.
6) Installation position, pin number
A diagram or chart is given for the connector type, installation position, and connector pin
number connection. When carrying out troubleshooting, see this chart for details of the con-
nector pin number and location for inspection and measurement of the wiring connector
number appearing in the troubleshooting flow chart for each failure mode (problem).
20-252 PC1100-6
3
<Example>
1 M-11 When starting switch is turned on and engine is started, basic check items flash
4 fl Before carrying out troubleshooting, check that all the related connectors are properly
inserted.
fl Always connect any disconnected connectors before going on the next step.
fl Check both the alternator system and the engine oil pressure system.
2 a) Alternator system
Cause Remedy
3 YES Defective pump Replace

Does monitoring controller
YES code [43] show a
2 value of more
Is voltage than 100?
Defective monitor panel Replace
YES between C03 • Run engine at NO
(12) and chassis mid-range speed Defective contact,
1
ground normal? or above. disconnection, or short
Is voltage between circuit with ground in Repair or
alternator terminal • Run engine at
mid-range speed NO wiring harness between replace
R and chassis
or above. C03 (female) (12) and
ground normal?
• 20 – 30 V alternator terminal R
• Run engine at
mid-range speed Defective alternator Replace
or above. NO
• 20 – 30 V
M-11 Related electric circuit diagram
PC1100-6 20-253
3
TROUBLESHOOTING OF
COMMUNICATION ABNORMALITY SYSTEM
(N MODE)
Action taken by controller when abnormality occurs and problems on machine ..........................20-302
Electrical circuit diagram of N Mode system ......................................................................................20-304
N-1 [E117, 118 occur at same time] Monitor panel communication abnormality ....................20-305
N-2 [E117, 218 occur at same time] Engine controller communication abnormality ............... 20-307
N-3 [E118, 507 occur at same time] Pump controller communication abnormality .................20-309
PC1100-6 20-301
3
ACTION TAKEN BY CONTROLLER WHEN ABNORMALITY
TROUBLESHOOTING OCCURS AND PROBLEMS ON MACHINE

OCCURS AND PROBLEMS ON MACHINE
User Service
Abnormal system Nature of abnormality
code code
• When problem occurs at same time as E118
1. Disconnection, defective contact of monitor panel S-
NET
2. Wiring harness of monitor panel S-NET short circuiting
with chassis ground
S-NET communication
3. Defective monitor panel
E117 error with engine
controller • When problem occurs at same time as E218
1. Disconnection, defective contact in wiring harness of
engine controller S-NET
2. Wiring harness of engine controller S-NET short
E0E circuiting with chassis ground
3. Defective engine controller
• When problem occurs at same time as E117: Same as

E117 above
S-NET communication • When problem occurs at same time as E507
error with pump 1. Disconnection, defective contact in wiring harness of
E118
controller pump controller S-NET
2. Wiring harness of pump controller S-NET short
circuiting with chassis ground
3. Defective pump controller

— E218 Pump controller S-NET
response overtime error E117 above

Abnormality in engine E118 above
— E507
controller S-NET system
20-302 PC1100-6
3
Condition when normal Action by controller when Problem that appears on machine
(voltage, current, resistance) abnormality is detected when there is abnormality
1. Working mode becomes G 1. Operation is carried out in G Mode.
Mode. 2. Lacks power or speed is slow.
2. Displays user code E0E on
monitor panel.

2. Displays user code E0E on
monitor panel.


PC1100-6 20-303
3
TROUBLESHOOTING ELECTRICAL CIRCUIT DIAGRAM OF N MODE SYSTEM
ELECTRICAL CIRCUIT DIAGRAM OF N MODE SYSTEM
20-304 PC1100-6
3
TROUBLESHOOTING N-1
N-1 [E117, E118 occur at same time] Monitor panel communication

abnormality
fl This troubleshooting is carried out when there is still an abnormality, so when disconnecting the
connector and inserting the T-adapter, or when removing the T-adapter and returning the connec-
tor to its original position, if the service code E is not displayed, the problem has been removed.
fl If the starting switch was turned off after the abnormality occurred, turn the starting switch on and
check that the service code displays E. (If it is not displayed, the problem has been removed.)
fl Before carrying out troubleshooting, check that all the related connectors are properly inserted.
Cause Remedy
YES
Has been reset
4 YES
1 Is resistance between
YES P01 (female) (4) (11)
Is monitoring
and (12), or between Short circuit in wiring
code [02], [03] 3 (4) (11) and chassis harness at side where
display normal? When E16 and C17 normal? Repair or
resistance is not normal,
YES are disconnected, do
NO replace
• Disconnect P01, or short circuit with
• Disconnect P01 bits (1), (2), (3), and
C17, and E16. ground connection
(4) light up in
and connect • Turn starting switch OFF.
monitoring code [08]?
again. • Min. 1 MΩ. Defective pump
• Turn starting 2 • Turn starting controller, engine Replace
switch ON. Do bits (1), (2), (3), switch ON. NO controller
• See Table 1. and (4) light up in • See Table 2.
NO monitoring code
Defective controller at
[08]? YES
5 side where bit does not Replace
Is voltage between E16 light up in Item 2
• Turn starting
(female) (6)(12) and
switch ON.
chassis, and between
• See Table 2. NO C17 (female) (4) (12) 6 YES
and chassis normal? Is resistance between
• Disconnect E16 P01(4) and C17 (female)
and C17. (4), and between P01
NO (female) (11) and E16 Defective contact or
• Turn starting
(female) (12) normal? disconnection in wiring Repair or
switch ON.
• Disconnect P01, NO harness at side where replace
• Min. 7.5 V
E16 and C17. resistance is not normal
• Turn starting
switch OFF.
• Max. 1Ω.
Table 1
Monitoring code Display
02 Pump controller model code
03 Engine controller model code
fl If the controllers are not connected to the network, “– – –” is displayed. If the correct alphanumerics
are not displayed or another model is displayed, the model selection signal of the controllers is
abnormal.
PC1100-6 20-305
3
TROUBLESHOOTING N-1
Table 2
08 Network connection condition
• Bits light up when network is connected (12: Pump controller, 34: Engine controller)
fl Checks for disconnection in the network system can be carried out with this monitoring code.
The display does not change when there is a short circuit with the ground. (The normal display is
given.)
N-1 Related electrical circuit diagram
20-306 PC1100-6
3
TROUBLESHOOTING N-2
N-2 [E117, E218 occur at same time] Engine controller communication

abnormality
fl This troubleshooting is carried out when there is still an abnormality, so when disconnecting
the connector and inserting the T-adapter, or when removing the T-adapter and returning the
connector to its original position, if the service code E is no displayed, the problem has been
removed.
Cause Remedy
YES
Has been reset
4 YES
1 Is resistance between Defective monitor panel Replace
YES E16 (female) (6) (12)
Is monitoring and (10), or between Short circuit in wiring
code [03] display 3 (6) (12) and chassis harness at side where
normal? normal? Repair or
When E16 is resistance is not normal,
YES disconnected, do bits NO replace
• Disconnect P01, or short circuit with
• Disconnect E16 (3) and (4) light up in C17, and E16. ground connection
and M94 and monitoring code [08]? • Turn starting switch OFF.
connect again. • Min. 1 MΩ. Defective engine
• Turn starting 2 • Turn starting Replace
switch ON. NO controller
switch ON. Do bits (3) and (4)
• See Table 1. light up in • See Table 2.
NO monitoring code
[08]? YES Defective engine
5 Replace
controller
• Turn starting Is voltage between
switch ON. E16 (female) (6)(12)
• See Table 2. and chassis
NO 6 YES Defective monitor panel
normal?
Is resistance between and pump controller Replace
• Disconnect E16. E16 (female) (6) – C17
• Turn starting (female) (12), E16
NO (female) (12) – P01 Defective contact or
switch ON. disconnection in wiring
(female) (11) normal? Repair or
• Min. 7.5 V harness at side where
• Disconnect P01, NO replace
E16, and C17. resistance is not normal
• Turn starting
switch OFF.
• Max. 1Ω
Table 1
03 Engine controller model code
abnormal.
PC1100-6 20-307
3
TROUBLESHOOTING N-2
Table 2
• Bits light up when network is connected (34: Engine controller)

given.)
20-308 PC1100-6
3
TROUBLESHOOTING N-3
N-3 [E118, E507 occur at same time] Pump controller communication

abnormality
fl This troubleshooting is carried out when there is still an abnormality, so when disconnecting
the connector and inserting the T-adapter, or when removing the T-adapter and returning the
connector to its original position, if the service code E is not displayed, the problem has been
removed.
Cause Remedy
YES
Has been reset
4 YES
1 Defective monitor panel Replace
Is resistance
Is monitoring YES between C17
code [02] display 3 (female) (4) (12) and
chassis normal? Short circuit in wiring Repair or
normal? When C17 is
harness at side where replace
YES disconnected, do bits • Disconnect P01, NO resistance is not normal
• Disconnect C17 (1) and (2) light up in C17, and E16.
and connect monitoring code [08]? • Turn starting switch OFF.
again. • Turn starting • Min. 1 MΩ. Defective pump
• Turn starting 2 Replace
switch ON. NO controller
switch ON. Do bits (1) and (2)
• See Table 2.
• See Table 1. light up in
NO monitoring code
[08]? YES Defective pump
5 Replace
• Turn starting controller
Is voltage between
switch ON.
C17 (female) (4)(12)
• See Table 2.
NO and chassis 6 YES Defective monitor panel
normal? Replace
Is resistance between and pump controller
• Disconnect C17. C17 (female) (4) – P01
• Turn starting (female) (4), C17
NO (female) (12) – E16 Defective contact or
(female) (6) normal? Repair or
• Min. 7.5 V harness at side where
• Disconnect P01, NO replace
E16, and C17. resistance is not normal
• Turn starting
switch OFF.
• Max. 1Ω
Table 1
abnormal.
PC1100-6 20-309
3
TROUBLESHOOTING N-3
Table 2
• Bits light up when network is connected (12: Pump controller)

given.)
20-310 PC1100-6
3
TROUBLESHOOTING OF ENGINE CONTROLLER
& APS CONTROLLER SYSTEM
(E MODE)
Judgement table for engine controller, APS controller, and engine related parts.. ........... _.......... .20-352
Points to remember when carrying out troubleshooting of engine controller system.. .............. ..20-35 5
Action taken by controller when abnormality occurs and problems on machine.. ....................... .20-356
Electrical circuit diagram of E mode system ...................................................................................... .20-364
E- 1 IE5011 Abnormality in engine controller power supply system is displayed ............ ..20-36 8
E- 2 IE5021 Abnormality in engine controller is displayed ..................................................... 20-369
E- 3 IE5211 Disconnection in governor control solenoid system is displayed ..................... 20-370
E- 4 IE5221 Short circuit in governor control solenoid system is displayed ........................ 20-371
E- 5 [E5311 Abnormality in governor servo is displayed.. ...................................................... 20-372
E- 6 1E5371 Abnormality in controller solenoid power supply system is displayed ......... ..20-37 3
E- 7 IE5081 Abnormality in rack sensor power supply system is displayed ....................... .20-374
E- 8 [E51 11 Abnormality in rack sensor signal system is displayed .................................... .20-375
E- 9 [E5151 Disconnection in prestroke control solenoid system is displayed .................... 20-376
E-10 IE5161 Short circuit in prestroke solenoid control system is displayed ...................... .20-377
E-II [E5131 Abnormality in engine speed sensor (I) system is displayed ........................... 20-378
E-12 LE5141 Abnormality in engine speed sensor (2) system is displayed .......................... .20-379
E-13 IE5251 Disconnection in governor cut relay system is displayed.. ............................... .20-380
E-14 [E5261 Short circuit in governor cut relay system is displayed ..................................... 20-381
E-15 IE5051 Abnormality in fuel control dial voltage is displayed ........................................ .20-382
E-16 [E5031 Mistaken connection of connector is displayed.. ................................................. 20-383
E-17 IE5041 Engine overrun is displayed.. ................................................................................ .20-384
E-18 [E5351 Abnormality in engine controller backup power supply system is displayed....20-38 5
E-19 [E5361 Abnormality in controller power supply system is displayed ............................. 20-386
E-20 Engine does not start.. ....................................................................................................... .20-388
E-21 Engine does not stop ......................................................................................................... .20-391
E-22 Defective actuation of APS ................................................................................................. 20-392
E-23 IE5341 Abnormality in machine selection input to engine controller is displayed.. .. ..20-39 9
PC 1100-6 20-351
0
JUDGEMENT TABLE FOR ENGINE CONTROLLER, APS
TROUBLESHOOTING CONTROLLER, APS CONTROLLER, AND ENGINE RELATED PARTS
JUDGEMENT TABLE FOR ENGINE CONTROLLER, APS CON-

TROLLER, AND ENGINE RELATED PARTS
User code
Abnormality in rack sensor power source system

Abnormality in controller solenoid power source system
Service code

Monitoring code
Disconnection in prestroke solenoid system

Disconnection in governor solenoid system
Short circuit in prestroke solenoid system

Short circuit in governor solenoid system
Abnormality in rack sensor signal system

[ The “E” mark is omitted from
the service code ]

Abnormality in controller
Failure mode User code E10 E11
Service code 501 502 521 522 531 537 508 511 515 516
Starting performance is poor (starting always takes time) ‡ ‡ ‡
Engine does not turn
Engine does
not start
Engine turns but no exhaust smoke comes out ‡ ‡ ‡ ‡ ‡ ‡
Exhaust smoke comes out, but engine does not start
Engine does not pick up smoothly (follow-up is poor) ‡ ‡ ‡
Engine stops during operations ‡ ‡ ‡ ‡ ‡ ‡
Engine does not rotate smoothly (hunting) ‡ ‡ ‡
Engine lacks output or lacks power ‡ ‡ ‡ ‡ ‡
Exhaust gas is black (incomplete combustion) ‡
Oil consumption is excessive or exhaust gas is blue
Oil becomes contaminated quickly
Fuel consumption is excessive ‡ ‡ ‡
Oil is in cooling water, or water spurts back, or water level goes down
Oil pressure caution lamp lights up
Oil level rises (water, fuel mixed with oil)
Water temperature becomes too high (overheating)
Abnormal noise is made
Vibration is excessive
Automatic warming-up function does not work or is not canceled ‡
Engine does not stop ‡
Troubleshooting code E-1 E-2 E-3 E-4 E-5 E-6 E-7 E-8 E-9 E-10
‡: Check the service code display. If there is no display, go to the right; if there is a display, go to the
bottom.
■: Check the preheating pilot lamp display and APS controller LED display. If the voltage is normal, go
to the right; if the voltage is abnormal, go to the bottom. (For details of the APS display, see the
next page.)
fi: Monitoring code to use as reference when proceeding with troubleshooting (if necessary, check the
display).
20-352 PC1100-6
3

T Checking monitoring code 1
k
TY
2
zi %
i.! 2
m
.- & 2 9
u s 2
3 : a
2
a
F 5 5 5
L1 0 0
8 P .E 0 n
5 E z 0
z WI
5 F
0 al
>
C iz
.- 5 H i
m o?
E k5 s
E 5 s E 2
b N
f Ti P t;
2
% 2 L? -c3 a
El2 El3 Tl ii 52 54 55
+k
- - -
5131514 525 526 io5 I03 504 535 536 iO6 IOE
-- -- -
0
-
+ - * - - - - - -
- -
s-2
0
- I I - - -
I I
T
- -0 0
- - - -0 s-3
I I
G-
- - - -
s-4
s- 0 -
0
-
s-5
5-
- 0
- 0
- 0 - -
0 S-6
0
- - - - 0
- - -
s-7
- - - - - - S-8
t - - - - - - -
s-9
- - - - - - -
0 S-IO
S-II
- - - - - - -
M-13
- - - - - - -
s-13
-
- - M-13
- - - - - - -
s-15
S-16
- - - -
-
7 0
- - 0 - - -
- - - E-21
i-11 1E-12 i-131E-14 -15
-
_
- - -- - -
PC1 100-6 20-353

0
PREHEATING PILOT LAMP DISPLAY AND APS CONTROLLER LED DISPLAY
Preheating pilot lamp display

fl When the starting switch is turned ON, the preheating pilot lamp display changes as follows
according to whether the condition is normal or abnormal.
Starting switch Preheating Water temperature APS switch

ON APS switch ON completed Engine starts switch OFF OFF
Water
When normal
ON OFF Flashes
temperature OFF (for 12 sec) (1 time/sec) OFF
below 20°C
Water
temperature OFF Flashes (1 time/sec)
above 20°C
When OFF
OFF ON
abnormal
ª The APS water temperature sensor is switched ON when the water temperature is below 20°C and
is switched OFF when the water temperature goes above 20°C.
APS controller LED display

fl The APS controller carries out self-diagnosis of disconnections and short circuits with the ground
in glow plug 1 system, glow plug 2 system, and the nozzle system. It gives the following LED
displays according to whether the system is normal or abnormal.
fl If any short circuit or disconnection occurs in the power source system, all the LEDs go out.
fl There is no self-diagnosis for the APS water temperature sensor system (because it is an ON/OFF
switch).
When When
LED No. LED color Type of abnormality normal abnormal
1 Red Short circuit with ground in glow plug 1 system fi (OFF) ‡ (ON)
2 Green Disconnection in glow plug 1 system ‡ (ON) fi (OFF)
3 Red Short circuit with ground in glow plug 2 system fi (OFF) ‡ (ON)
4 Green Disconnection in glow plug 2 system ‡ (ON) fi (OFF)
5 Red Short circuit with ground in nozzle system fi (OFF) ‡ (ON)
6 Green Disconnection in nozzle system ‡ (ON) fi (OFF)
20-354 PC1100-6
3
POINTS TO REMEMBER WHEN CARRYING OUT
TROUBLESHOOTING TROUBLESHOOTING OF GOVERNOR, PUMP CONTROLLER SYSTEM
POINTS TO REMEMBER WHEN CARRYING OUT TROUBLE-

SHOOTING OF ENGINE CONTROLLER SYSTEM
1. Points to remember if abnormality returns to normal by itself:
If the connector is disconnected and the T-adapter is inserted, or if the T-adapter is removed and
the connector is returned to its original position when carrying out troubleshooting of the failure,
and the service code is no longer displayed, or if the monitor display returns to normal, the
abnormality has probably returned to normal.
However, there is a high probability that the same problem will occur again, so it is desirable to
follow up this problem carefully.
2. Handling service code memory retention function:

1) When displaying the abnormality code in memory and carrying out troubleshooting, note
down the content of the display, then erase the display. After trying to re-enact the problem,
carry out troubleshooting according to the failure code that is displayed.
(There are cases where mistaken operation or abnormalities that occur when the connector is
disconnected are recorded by the memory retention function. Erasing the data in this way
saves any wasted work.)
2) After completing troubleshooting, always erase the service code from memory again.
PC1100-6 20-355
3

User Service
code code
Abnormality in engine 1. E535 and E536 occur at same time
E501 controller power supply
system
Abnormality in engine 1. Defective engine controller

E502
controller
1. Disconnection, defective contact inside governor control

solenoid
2. Disconnection, defective contact in wiring harness between
controller E13 (7) and governor control solenoid E19 (1)
(No. 1 (+) side)
3. Disconnection, defective contact in wiring harness between
Disconnection in gover- controller E13 (4) and governor control solenoid E32 (1)
E521 nor control solenoid (No. 2 (+) side)
system 4. Disconnection, defective contact, short circuit with ground
in wiring harness between controller E13 (17) and gover-
nor control solenoid E19 (2) (No. 1 (–) side)
5. Disconnection, defective contact, short circuit with ground
nor control solenoid E32 (2) (No. 2 (–) side)
E10
1. Short circuit, short circuit with ground inside governor
control solenoid
2. Short circuit with ground, short circuit with power source
nor control solenoid E19 (1) (No. 1 (+) side)
3. Short circuit with ground, short circuit with power source
E522 Short circuit in governor
nor control solenoid E32 (1) (No. 2 (+) side)
control solenoid system
4. Short circuit with power source in wiring harness be-
tween controller E13 (17) and governor control solenoid
E19 (2) (No. 1 (–) side)
tween controller E13 (15) and governor control solenoid
E32 (2) (No. 2 (–) side)
1. Defective governor control solenoid system or rack sen-

sor system
(Governor command value and rack sensor signal do not
match)
E531 Abnormality in governor 2. Abnormality in solenoid power source system
servo 3. Defective engine controller
20-356 PC1100-6
3
1. Stops engine. 1. Stops engine during operation.
• Same as E535 and E536 2. Displays user code E10 on 2. Cannot start engine.
monitor panel.

2. Displays user code E10 on 2. Cannot start engine.
monitor panel.
1. Sets output to governor 1. Stops engine during operation.

control solenoid to 0 (stops 2. Cannot start engine.
engine)
2. Displays user code E10 on
monitor panel.
fl If the abnormality is re-
stored by the vibration of
• Solenoid resistance value: 10 – 21 Ω the machine, it resets au-
tomatically. (However, the
service code display does
not go out.)
1. Sets output to governor 1. Stops engine during operation.

control solenoid to 0 (stops 2. Cannot start engine.
engine)
monitor panel.
• Solenoid resistance value: 10 – 21 Ω the machine, it resets au-
not go out.)

2. Displays user code E10 on 2. Cannot start engine.
monitor panel.
the machine, it resets au-
not go out.)
PC1100-6 20-357
3
User Service
code code
1. Disconnection, defective contact inside governor cut re-
lay
2. Disconnection, defective contact in wiring harness be-
Abnormality in control- tween starting switch terminal ACC and governor cut re-
El0 E537 ler solenoid power lay R24 (3)
supply system 3. Disconnection, defective contact, short circuit with ground
in wiring harness between controller El3 (I) and rack
sensor R24 (6)
Defect inside rack sensor

Disconnection, defective contact, short circuit with ground
in wiring harness between controller El3 (16) and rack
Abnormality in rack sen- sensor E22 (1)
E508
sor power source system Disconnection, defective contact in wiring harness be-
tween rack sensor E22 (2) and chassis ground
Defective engine controller
1. Defect inside rack sensor

Abnormality in rack sensor E22 (3) (f+) side)
E511
sensor signal system 3. Disconnection, defective contact, short circuit with ground
sensor E22 (4) ((-1 side)
Disconnection, defective contact inside prestroke control

solenoid
Disconnection, defective contact in wiring harness be-
Disconnection in tween controller El3 (9) and prestroke control solenoid
El1
E515 prestroke control sole- E20 (1) ((+) side)
noid system Disconnection, defective contact, short circuit with ground
in wiring harness between controller El3 (19) and
prestroke control solenoid E20 (2) ((-1 side)
Disconnection, defective contact inside prestroke control

solenoid
Short circuit with ground, short circuit with power source
Disconnection in in wiring harness between controller El3 (9) and prestroke
E516 prestroke control sole- control solenoid E20 (I) (I+) side)
noid system Short circuit with power source in wiring harness be-
tween controller El3 (19) and prestroke control solenoid
E20 (2) ((4 side)
Abnormality in machine 1. Disconnection or short circuit with chassis ground in wir-

E534 selection input to engine ing harness attached with connector E09.
controller 2. Abnormality in engine controller
20-358 PC1 100-6

0
2. Displays user code El0 on 2. Cannot start engine.
monitor panel.
* If the abnormality is re-
* Voltage between El2 (1) and stored by the vibration of
chassis: 20 - 30 V the machine, it resets au-
not go out.)
1. Operates with open control 1. Feels that there is lack of power.

with output restricted to 80%. 2. Engine does not pick up smoothly.
2. Displays user code El1 on 3. Starting performance is poor.
monitor panel.
* Voltage between El3 (I) and Sr If the abnormality is re-
chassis: 4.6 - 5.4 V stored by the vibration of
not go out.)
1. Operates with open control 1. Feels that there is lack of power.

with output restricted to 80%. 2. Engine does not pick up smoothly.
2. Displays user code El1 on 3. Starting performance is poor.
. Voltage between El4 (7) and monitor panel.
chassis: 0.1 - 4.5 V t If the abnormality is re-
- Voltage between El4 (17) and stored by the vibration of
chassis: 0.1 - 4.5 V the machine, it resets au-
not go out.)
Sets output to prestroke 1. Feels that there is lack of power.

control solenoid to 0. 2. Engine does not pick up smoothly.
Operates with output re- 3. Large amount of black smoke is
stricted to 80%. included in exhaust.
Displays user code El1 on 4. Starting performance is poor.
monitor panel.
Solenoid resistance value: 10 - 21 LZ
If the abnormality is re-
l

not go out.)
Sets output to prestroke 1. Feels that there is lack of power.
control solenoid to 0. 2. Engine does not pick up smoothly.
Operates with output re- 3. Large amount of black smoke is
stricted to 80%. included in exhaust.
Displays user code El1 on 4. Starting performance is poor.
monitor panel.
Solenoid resistance value: 10 - 21 I1
If the abnormality is re-
l

not go out.)
Connector El8 (female) Displays user code El1 on Engine lacks power.
Specification monitor panel.
Pin (14) 1 Pin (15)
PC1 100-6 20-359

0
User Service
code code
1. Defect inside No. 1 engine speed sensor or defective
adjustment
in wiring harness between controller E14 (2) and No. 1
Abnormality in engine engine speed sensor E21 (1)
E513
speed sensor (1) system 3. Defective contact, disconnection in wiring harness be-
tween No. 1 engine speed sensor E21 (2) and chassis
ground
E12
1. Defect inside No. 2 engine speed sensor or defective
adjustment
in wiring harness between controller E14 (3) and No. 2
Abnormality in engine engine speed sensor E07 (1)
E514 speed sensor (2) system 3. Defective contact, disconnection in wiring harness be-
tween No. 2 engine speed sensor E07 (2) and chassis
ground
1. Disconnection, defective contact inside governor cut re-

lay
in wiring harness between starting switch terminal ACC
Disconnection in gover- and governor cut relay R24 (1)
E525
nor cut relay system 3. Disconnection, defective contact, short circuit with ground
nor cut relay R24 (2)
E13
1. Short circuit inside governor cut relay
tween controller E12 (4) and governor cut relay R24 (2)
Short circuit in governor
E526 cut relay system
1. Disconnection, defective contact, short circuit in wiring

harness inside fuel control dial
in wiring harness between controller E14 (6) and fuel
control dial E06 (1) ((+) side)
Abnormality in fuel 3. Disconnection, defective contact in wiring harness be-
E14 E505 control dial system tween controller E14 (16) and fuel control dial E06 (3)
((–) side)
in wiring harness between controller E15 (11) and fuel
control dial E06 (2) (signal side)
20-360 PC1100-6
3
1. Operates with normal con- 1. Feels that there is lack of power.
trol. 2. Engine does not pick up smoothly.
2. Displays user code E12 on 3. Engine stops during operation and
monitor panel. cannot be started again.
• Sensor resistance value: fl If the abnormality is re-
500 – 1000 Ω stored by the vibration of
not go out.)
1. Operates with normal con- 1. Feels that there is lack of power.

trol. 2. Engine does not pick up smoothly.
2. Displays user code E12 on 3. Engine stops during operation and
monitor panel. cannot be started again.
• Sensor resistance value: fl If the abnormality is re-
500 – 1000 Ω stored by the vibration of
not go out.)
1. Operates with normal con-

trol.
monitor panel.
• Relay resistance value: 200 – 900 Ω fl If the abnormality is re-
not go out.)

trol.
monitor panel.
• Relay resistance value: 200 – 900 Ω
not go out.)
1. Operates at throttle posi- 1. Engine speed does not rise to high

tion before abnormality oc- idling.
curred. 2. Lacks acceleration.
• Voltage (power source) between E14 monitor panel.
(6) and (16): 4.6 – 5.4 V fl If the abnormality is re-
• Voltage (signal) between E15 (11) stored by the vibration of
and E14 (16): 0.7 – 4.3 V the machine, it resets au-
not go out.)
PC1100-6 20-361
3
User Service
code code
in wiring harness between controller E17 (1) and chassis
ground
— E503 Mistaken connection of
connector 2. Defective engine controller
1. Engine speed has gone above operating range.
— E504 Engine overrun
1. Backup power source voltage has dropped below 17V.

in wiring harness between fuse box No. 14 and controller
Abnormality in engine
E12 (7)
— E535 controller backup power
supply system 3. Disconnection, defective contact in wiring harness be-
tween controller E12 (8)(16) and chassis ground
1. Switch power source voltage has dropped below 17V.

in wiring harness between starting switch terminal ACC
Abnormality in control- and controller E12 (9)(17)
— E536 ler power supply system 3. Disconnection, defective contact in wiring harness be-
tween controller E12 (8)(16) and chassis ground
20-362 PC1100-6
3
1. Stops engine.
• Resistance between E17 (1) and stored by the vibration of
chassis: Max. 1 Ω the machine, it resets au-
not go out.)
1. Stops fuel injection imme- 1. Engine speed does not follow fuel
diately when overrun oc- control dial position.
curs (when speed drops to
1500 rpm, operates with
normal control).
not go out.)

trol.
• Voltage between E12 (7) and (8)(16): stored by the vibration of
20 – 30 V the machine, it resets au-
not go out.)

trol.
• Voltage between E12 (9)(17) and stored by the vibration of
(8)(16): 20 – 30 V the machine, it resets au-
not go out.)
PC1100-6 20-363
3
TROUBLESHOOTING ELECTRICAL CIRCUIT DIAGRAM OF E MODE SYSTEM
ELECTRICAL CIRCUIT DIAGRAM OF E MODE SYSTEM

ENGINE CONTROLLER SYSTEM
20-364 PC1100-6
3
-
-
--
I&------__--------_____-_____-_----i
1 f-
I -
‘&----- I
7
r
J
_ L
:
_ x
_ _
t+
J
TWPOIBOI
PCl lOO-6 20-365

0
APS CONTROLLER & ENGINE STARTING SYSTEM
20-366 PC1100-6
3
PC1100-6 20-367
3
TROUBLESHOOTING E-1
E-1 [E501] Abnormality in engine controller power source system is

displayed
connector and inserting the T-adapter, or when removing the T-adapter and returning the con-
nector to its original position, if the service code “E” is not displayed, the problem has been
removed.
check that the service code displays “E”. (If it is not displayed, the problem has been removed.)
Cause Remedy
2 YES Defective engine

Replace
Is voltage between controller
YES E12 (9)(17) and
1 chassis ground
normal?
Is voltage Go to E-19 —
between E12 (7) • Turn starting NO
and chassis switch ON.
ground normal? • 20 – 30 V
• Turn starting Go to E-18 —
switch OFF. NO
• 20 – 30 V
E-1 Related electrical circuit diagram
20-368 PC1100-6
3
TROUBLESHOOTING E-2
E-2 [E502] Abnormality in engine controller is displayed
tor to its original position, if the service code “E” is not displayed, the problem has been
removed.
Cause Remedy

Replace
E12 (9)(17) and
chassis ground
normal?
Go to E-19 —
• Turn starting NO
switch ON.
• 20 – 30 V
PC1100-6 20-369
3
TROUBLESHOOTING E-3
E-3 [E521] Disconnection in governor control solenoid system is displayed
removed.
Cause Remedy
YES Defective engine

Replace
3 controller
Is resistance Disconnection, defective
YES between E13 contact, short circuit Repair or
(female) (4) and 4 YES with ground in wiring harness replace
between E13 (female) (15) and
(15) normal? Is voltage E32 (female) (2)
2 • Turn starting between E32 (1)
Defective contact or
switch OFF. NO and chassis Repair or
Is resistance ground normal? disconnection in wiring
YES between E13 • Disconnect E13.
harness between E13 (female) replace
• 10 – 21 Ω • Turn starting NO (4) and E32 (female) (1)
(female) (7) and
(17) normal? switch ON.
• 20 – 30 V Disconnection, defective
• Turn starting contact, short circuit Repair or
1 switch OFF. 5 YES
with ground in wiring harness replace
Is resistance • Disconnect E13. Is voltage between E13 (female) (17) and
between E19, E32 • 10 – 21 Ω between E19 (1) E19 (female) (2)
(male) (1) and (2) NO and chassis Defective contact or
normal? ground normal?
disconnection in wiring Repair or
• Turn starting • Turn starting NO harness between E13 (female) replace
switch OFF. switch ON. (7) and E19 (female) (1)
• Disconnect E19 • 20 – 30 V
and E32. Defective governor
Replace
• 10 – 21 Ω NO control solenoid
20-370 PC1100-6
3
TROUBLESHOOTING E-4
E-4 [E522] Short circuit in governor control solenoid system is displayed
removed.
Cause Remedy

Replace
3 controller
Is resistance between
Short circuit with power
YES E13 (female) (4) –
(15), (4)(15) – chassis source in wiring harness Repair or
ground as shown in 4 YES
between E13 (female) replace
Table 1? When E32 is disconnected,
(15) and E32 (female) (2)
is resistance and voltage
2 • Turn starting between E13 (female) (4) Short circuit with ground,
Is resistance between switch OFF. NO and chassis ground as short circuit with power
YES E13 (female) (7) – • Disconnect E13. shown in Table 2? Repair or
source in wiring harness
(17), (7)(17) – chassis • Disconnect E13 replace
NO between E13 (female) (4)
ground as shown in and E32.
Table 1?
and E32 (female) (1)
• Turn starting
• Turn starting switch OFF. Short circuit with power
1 5 YES source in wiring harness Repair or
switch OFF.
Is resistance When E32 is disconnected, between E13 (female) replace
• Disconnect E13.
between E19, E32 is resistance and voltage (17) and E19 (female) (2)
(male) (1) – (2),(1)(2) between E13 (female) (7)
– chassis ground as NO and chassis ground as Short circuit with ground,
shown in Table 1? shown in Table 2? short circuit with power Repair or
• Turn starting • Disconnect E13 NO source in wiring harness replace
switch OFF. and E19. between E13 (female) (7)
• Turn starting and E19 (female) (1)
• Disconnect E19 switch OFF.
and E32. Defective governor
Replace
NO control solenoid
Table 1
E19 (male) E32 (male) E13 (female) E13 (female) Resistance
Between Between Between Between 10 – 21 Ω
(1) and (2) (1) and (2) (7) and (17) (4) and (15)
Between Between Between Between
Min. 1 MΩ
(1)(2) and chassis (1)(2) and chassis (7)(17) and chassis (4)(15) and chassis
Table 2
E13 (female) E13 (female) Resistance Voltage
Between Between
(7) and chassis (4) and chassis Min. 1 MΩ Max. 1 V
PC1100-6 20-371
3
TROUBLESHOOTING E-5
E-5 [E531] Abnormality in governor servo is displayed
tor to its original position, if the service code “E” is not displayed, the problem has been removed.
Cause Remedy
2 YES Defective fuel injection

Replace
pump
When fuel injection
YES pump is repaired or
1 replaced, does
display go off?
Is voltage between Defective engine
Replace
E13 (female) (1) • Turn starting NO controller
and chassis switch ON.
ground normal?
• Turn starting Go to E-6 —

switch ON. NO
• 20 – 30 V
20-372 PC1100-6
3
TROUBLESHOOTING E-6
E-6 [E537] Abnormality in controller solenoid power supply system is

displayed
removed.
fl Check that the engine can be cranked (if the engine cannot be cranked, carry out troubleshooting
E-20 first).
Cause Remedy

controller Replace
Is voltage
YES between E13 (1) Defective contact,
2 and chassis disconnection, short circuit
ground normal? with ground in wiring harness
Repair or
Is voltage replace
YES between R24 (3) between E13 (female) (1) and
and chassis R24 (female) (6)
switch ON.
1 ground normal? • 20 – 30 V. Defective contact or
Is resistance
between R24 • Turn starting disconnection in wiring Repair or
(female) (3) – (5), (3) switch ON. NO harness between R24 (female) replace
– (6) as shown in • 20 – 30 V. (3) and X07 (female) (11)
Table ?
• Turn starting Defective governor
switch OFF. Replace
NO control solenoid
• Disconnect R24.
Table
R24 (male) Resistance
Between Min. 1 MΩ
(3) and (5)
Between
Max. 1 Ω
(3) and (6)
PC1100-6 20-373
3
TROUBLESHOOTING E-7
E-7 [E508] Abnormality in rack sensor power source system is

displayed
removed.
Cause Remedy

Replace
2 controller
Is resistance between Defective contact or
YES E13 (female) (16) and disconnection in wiring
chassis ground 3 YES harness between E22 Repair or
normal? (female) (2) and chassis replace
1 Is voltage
between E22 (1) ground
• Turn starting
Is resistance
switch OFF. NO and chassis Defective contact,
between E22 ground normal?
• Disconnect E13. disconnection, short circuit Repair or
(male) (1) and (2)
• Min. 500 kΩ. • Turn starting NO with ground in wiring harness replace
normal ?
switch ON. between E13 (female) (16) and
• Turn starting • 4.6 – 5.4 V. E22 (female) (1)
switch OFF.
• Disconnect E22. Defective rack sensor Replace
• Min. 500 kΩ. NO
20-374 PC1100-6
3
TROUBLESHOOTING E-8
E-8 [E511] Abnormality in rack sensor signal system is displayed
removed.
fl If service code [E508] is displayed at the same time, carry out troubleshooting E-7 first.
Cause Remedy

controller Replace
Is voltage
YES between E14 (17)
Defective contact,
2 and chassis disconnection, short circuit
Is voltage ground normal? with ground in wiring harness
Repair or
YES between E14 (7) between E22 (female) (4) and replace
and chassis switch ON. E14 (female) (17)
1 ground normal? • 0.1 – 4.5 V.
Is resistance Defective contact,
• Turn starting disconnection, short circuit Repair or
between E22
switch ON. NO with ground in wiring harness replace
(male) (3) – (2),
• 0.1 – 4.5 V. between E22 (female) (3) and
(4) – (2) normal ?
E14 (female) (7)
• Turn starting
switch OFF. Defective rack senosr Replace
• Disconnect E22. NO
• 50 kΩ – 1 MΩ
PC1100-6 20-375
3
TROUBLESHOOTING E-9
E-9 [E515] Disconnection in prestroke control solenoid system is

displayed
removed.
Cause Remedy

Replace
2 controller
Is resistance
YES between E13 Defective contact or
3 YES disconnection in wiring Repair or
(female) (9) and
harness between E13 replace
(19) normal ? Is voltage
1 (female) (19) and E20 (2)
• Turn starting between E20 (1)
Is resistance Defective contact,
switch OFF. NO and chassis
between E20 ground normal? disconnection, short circuit
• Disconnect E13. Repair or
(male) (1) and (2) with ground in wiring harness
• 10 – 21 Ω. • Turn starting NO between E13 (female) (9) and
replace
normal ?
switch ON. E20 (female) (1)
• Turn starting • 20 – 30 V.
switch OFF. Defective prestroke
• Disconnect E20. Replace
NO control solenoid
• 10 – 21 Ω.
E-9 Related electric circuital diagram
20-376 PC1100-6
3
TROUBLESHOOTING E-10
E-10 [E516] Short circuit in prestroke control solenoid system is

displayed
removed.
Cause Remedy

Replace
2 controller
YES E13 (female) (9) -– Short circuit with power
(19), (9)(19) – chassis source in wiring harness
3 YES Repair or
ground as shown in between E13 (female)
Table 1? When E20 is disconnected, replace
1 is resistance and voltage (19) and E20 (female) (2)
Is resistance • Turn starting
between E13 (female) (9) Short circuit with
between E20(male) switch OFF. NO and chassis ground as
(1) – (2), (1)(2) – • Disconnect E13. ground, short circuit with Repair or
shown in Table 2?
chassis ground as power source in wiring
• Disconnect E13 NO replace
shown in Table 1? harness between E13
and E20. (female) (9) and E20
• Turn starting • Turn starting
switch ON. (female) (1)
switch OFF.
• Disconnect E20. Defective prestroke
NO Replace
control solenoid
Table 1
E20 (male) E13 (female) Resistance
Between Between
(1) and (2) (9) and (19) 10 – 21 Ω
Between Between Min. 1 MΩ
(1)(2) and chassis (9)(19) and chassis
Table 2
E13 (female) Resistance Voltage
Between
Min. 1 MΩ Max. 1 V
(9) and chassis
PC1100-6 20-377
3
E-11 [E513] Abnormality in engine speed sensor (1) system is

displayed
removed.
Cause Remedy
YES Defective engine Replace

controller
2
Is voltage
YES between E14 (3)
YES Defective adjustment of
and chassis Adjust
3 speed sensor
ground normal?
When speed sensor Defective contact,
• Start engine. is adjusted, does
1 • 0.5 – 3.0 V. disconnection, short circuit
NO voltage in Item 2 4 YES with ground in wiring harness Repair or
Is resistance become normal? replace
Is resistance between between E14 (female) (3) and
between E07 E07 (female) (2) and E21 (female) (1)
(male) (1) and (2) chassis ground
NO Defective contact or
normal ? normal?
• Turn starting • Turn starting NO harness between E07 replace
switch OFF. switch OFF. (female) (2) and chassis
• Disconnect E07. • Disconnect E07. ground
• 500 – 1,000 kΩ. • Max. 1 Ω. Defective engine speed
Replace
NO sensor (1)
20-378 PC1100-6
3
E-12 [E514] Abnormality in engine speed sensor (2) system is

displayed
removed.
Cause Remedy
YES Defective engine Replace

2 controller
Is voltage
YES between E14 (3)
YES Defective adjustment of
and chassis Adjust
ground normal?
3 speed sensor
When speed sensor Defective contact,
• Start engine. is adjusted, does
1 • 0.5 – 3.0 V. disconnection, short circuit
NO voltage in Item 2 4 YES Repair or
with ground in wiring harness
Is resistance become normal? replace
Is resistance between between E14 (female) (3) and
between E07 E07 (female) (1)
E07 (female) (2) and
(male) (1) and (2)
NO chassis ground
normal ? normal?
• Turn starting • Turn starting NO harness between E07 replace
switch OFF. switch OFF. (female) (2) and chassis
• Disconnect E07. • Disconnect E07. ground
• 500 – 1,000 kΩ. • Max. 1 Ω.
Defective engine speed
NO Replace
sensor (2)
PC1100-6 20-379
3
E-13 [E525] Disconnection in governor cut relay system is displayed
removed.
fl If service code [E501] is displayed at the same time, carry out troubleshooting E-1 first.
Cause Remedy

Replace
2 controller
Is voltage Defective contact or
YES between E12 (4) disconnection in wiring
and chassis 3 YES harness between E12 Repair or
ground normal? (female) (4) and R24 replace
Is voltage
1
• Turn starting between R24 (1) (female) (2)
Is resistance switch ON. NO and chassis Defective contact,
between R24 • 20 – 30 V. ground normal?
(male) (1) and (2) disconnection, short circuit Repair or
normal ? • Turn starting NO with ground in wiring harness replace
switch ON. between X07 (female) (11)
• Turn starting • 20 – 30 V. and R24 (female) (1)
switch OFF.
Defective rgovernor cut
• Disconnect R24. Replace
NO replay
• 200 – 900 Ω.
20-380 PC1100-6
3
E-14 [E526] Short circuit in governor cut relay system is displayed
removed.
Cause Remedy

When R24 is Replace
controller
YES disconnected, is voltage
between E12 (female)
1 (4) and chassis ground
Is resistance normal? source in wiring harness Repair or
between • Disconnect E12 between E12 (female) (4) replace
NO
R24(male) (1) and and R24. and R24 (female) (2)
(2) normal? • Turn starting
switch ON.
• Turn starting • Max. 1 V Defective governor cut
Replace
switch OFF. NO replay
• Disconnect R24.
• 200 – 900 Ω.
PC1100-6 20-381
3
E-15 [E505] Abnormality in fuel control dial voltage is displayed
removed.
fl Before carrying out troubleshooting, check that all the related
connectors are properly inserted.
fl Always connect any disconnected connectors before going Cause Remedy
on the next step.

Replace
2 controller
Is voltage Defective contact or

YES between E15 (11) disconnection in wiring
and chassis
YES Repair or
harness between E15
ground normal? 3 replace
(female) (11) and E06
Is voltage (female) (2)
• Turn starting
between E06 (2)
switch ON.
• 0.7 – 4.3 V NO and chassis 4 YES
Defective fuel control dial Replace
ground normal? When E06 is
disconnected, is
1 • Turn starting resistance between E15 Short circuit with ground
switch ON. NO (female) (11) and
in wiring harness
Is voltage chassis ground normal? Repair or
• 0.7 – 4.3 V between E15 (female)
between E14 (6) replace
• Turn starting switch NO
and (16) normal? OFF. (11) and E06 (female) (2)
• Disconnect E15 and E16.
• Min. 1 MΩ Defective contact or
• Turn starting 6 YES disconnection in wiring
switch ON. Repair or
Is resistance harness between E14 replace
• 4.6 – 5.4 V (female) (16) and E06
YES between E06
(male) (1) and (3) (female) (3)
5 normal?
Defective fuel control dial Replace
Is voltage • Turn starting NO
between E06 (1) switch OFF.
NO and chassis • Disconnect E06.
disconnection in wiring
ground normal? • 4 – 6 kΩ YES Repair or
harness between E14
• Turn starting 7 (female) (6) and E06
replace
switch ON. Is voltage (female) (1)
• 4.6 – 5.4 V between E14 (6)
NO and chassis 8 YES Defective engine
ground normal? Replace
When E06 is controller
disconnected, is
• Turn starting resistance between E14
switch ON. NO (female) (6) and chassis Short circuit with ground
• 4.6 – 5.4 V ground normal? in wiring harness E14 Repair or
• Turn starting NO (female) (6) and E06 replace
switch OFF. (female) (1)
• Disconnect E15
and E06.
E-15 Related electrical circuit diagram • Min. 1 MΩ
20-382 PC1100-6
3
E-16 [E503] Mistaken connection of connector is displayed
tor to its original position, if the service code “E” is not displayed, the problem has been removed.
Cause Remedy
1 YES Defective engine Replace

Is resistance controller
between E17 (1)
and chassis Defective contact or
ground normal ? disconnection in wiring
Repair or
harness between E17
• Turn starting NO replace
(female) (1) and chassis
switch OFF. ground
• Disconnect E17.
• Max. 1 Ω.
PC1100-6 20-383
3
E-17 [504] Engine overrun is displayed
Cause Remedy
Act according
4 YES Other abnormality has
to displayed
occurred at same time
service codes
YES Is other service
code displayed at
3
same time?
Defective fuel injection Replace
YES Is adjustment of • Turn starting NO pump
engine speed
2 sensor normal? switch ON.
Is resistance
• See TESTING Defective adjustment of
YES between E07 Adjust
(male) (1) and (2) AND NO speed sensor
1 normal? ADJUSTING.
Is resistance
• Turn starting Defective No. 2 engine
between E21 Replace
switch OFF. speed sensor
(male) (1) and NO
• Disconnect E07.
(2) normal?
• 500 – 1000 Ω
• Turn starting Defective No. 1 engine
switch OFF. Replace
NO speed sensor
• Disconnect E21.
• 500 – 1000 Ω
20-384 PC1100-6
3
E-18 [E535] Abnormality in engine controller backup power supply

system is displayed
removed.
fl Check that the engine can be cranked (if the engine cannot be cranked, carry out troubleshooting
E-20 first).
fl Check that fuse 14 is not blown (if it is blown, check for a short circuit with the ground in the
related circuits for fuse 14).
Cause Remedy

Replace
YES between E12 (8)
1 (16) and chassis disconnection in wiring
Is voltage ground normal ? harness between E12 Repair or
between E12 (7) • Turn starting NO (female) (8)(16) and replace
and chassis switch OFF. chassis ground
ground normal? • Disconnect E12. Defective contact,
• Turn starting • Max. 1 Ω. disconnection, short Repair or
switch OFF. NO circuit with ground in replace
• 20 – 30 V. wiring harness between
fuse 14 and E12
(female) (7)
PC1100-6 20-385
3
E-19 [E536] Abnormality in controller power supply system is

displayed
removed.
Cause Remedy

Replace
YES between E12
(female) (8)(16) and
chassis ground
1 harness between E12 Repair or
normal ?
(female) (8) (16) and replace
Is voltage • Turn starting NO chassis ground
between E12 (9) switch OFF.
(17) and chassis • Disconnect E12. Defective contact,
ground normal? • Max. 1 Ω. disconnection, short circuit
3 YES Repair or
with ground in wiring
• Turn starting Is voltage between replace
harness between starting
switch ON. starting switch
terminal ACC and
switch terminal ACC and
• 20 – 30 V. NO E12 (female) (9) (17)
chassis ground
normal?
Defective starting switch Replace
switch ON.
• 20 – 30 V.
20-386 PC1100-6
3
E-20 Engine does not start
fl Check that fuse 14 is not blown (if it is blown, check for a short circuit with the ground in the
related circuits for fuse 14).
fl Check that the wiring harness between battery relay terminal B – battery (+) – battery (–) – chassis
is connected securely.
4 YES
Is voltage between
YES starting motor
terminal B and
chassis ground
normal?
switch ON.
3 • 20 – 30 V
Is there sound of YES
YES starting motor 6
pinion engaging? Is voltage between
YES starting motor
terminal R and
• Starting switch 7 YES
chassis ground
ON ´↔ START normal? Is voltage between
5 • Turn starting alternator terminal
Is voltage between switch ON. NO R and chassis
starting motor • Max. 1 V ground normal?
terminal S and NO
• Disconnect wiring.
NO chassis ground
• Turn starting switch ON.
2 normal?
• Max. 1 V
• Turn starting 8 YES
YES Is sound heard switch to START. Is resistance
from battery • 20 – 30 V
relay? between starting
switch terminal B
NO and terminal C
• Starting switch normal?
OFF ´↔ ON NO
• Turn starting
switch to START.
• Disconnect X07. • Max. 1 Ω
10 YES
Is resistance
YES between batery
relay terminal E and
chassis ground
1 9 normal?
Is voltage between • Turn starting NO
Is voltage and batery relay switch OFF.
specific gravity of terminal BR and • Max. 1 Ω
battery normal? NO chassis ground YES
normal?
11
• Turn starting • Turn starting
Is voltage between
switch OFF. switch ON. starting switch
• Voltage: Min. 24V • 20 – 30 V terminal BR and
• Specific gravity: NO chassis ground
12 YES
Min. 1.26 normal? Is resistance
between starting
• Turn starting switch terminal B
switch ON. NO and terminal BR
• 20 – 30 V normal?
switch to START.
• Disconnect X07.
• Max. 1 Ω
NO
20-388 PC1100-6
3
Cause Remedy
Defective starting motor Replace
replace
motor terminal B and
battery relay terminal M
Defective starting motor Replace

between starting motor Repair or
terminal R and D14 replace
(female) (2), or short circuit
of diode D14
Defective alternator Replace
replace
switch terminal C and
starting motor terminal S
Defective battery relay Replace
harness between battery
replace
relay terminal E and
chassis ground
replace
switch terminal BR and
battery relay terminal BR
replace
switch terminal B and
battery relay terminal B
Insufficient battery Charge or

capacity replace
PC1100-6 20-389
3
20-390 PC1100-6
3
E-21 Engine does not stop
Cause Remedy

Replace
1 controller
Is voltage
between E12 (9) Short circuit with power
(17) and chassis 2 YES source in wiring harness Repair or
ground normal? Is resistance between E12 (female) (9) replace
between starting (17) and starting switch
• Turn starting switch terminal B terminal ACC
switch OFF. NO and terminal ACC
• Max. 1 V. normal?
switch OFF.
• Disconnect X07.
• Min. 1 MΩ
PC1100-6 20-391
3
E-23 [534] Abnormality in machine selection input to engine controller

is displayed
* Before carrying out troubleshooting, check that all the related connectors are properly inserted.
* Always connect any connectors before going on the next step.
Cause Remedy
Ir Carry out troubleshooting with the starting switch OFF.

Replace
controller
~~~
Short circuit with chassis
ground in wiring harness Repair or
between E09 and engine replace
NO
resistance between controller
El8 (female) (141,(151
and chassis ground? Replace
1BothresistancebetweenI I controller
El8 Ifemale)1141
and
chassisground.and
resistancebetweenEl8
(femaleI(15)andchassis Disconnection in wiring
groundare1Rorless. Repair or
harness between E09
NO replace
and engine controller
Normal condition
Connector El8 (female)

Specification
Pin (14) Pin (15)
Standard Disconnected Disconnected

55°C Connected with Connected with
specification chassis ground chassis ground

Enstne controller
I 1
El8 (04016)
/---
55” Specification Standard
TWPOI802
PC1 100-6 20-399

0
Cause Remedy
Defective APS
Replace
controller
harness between E26 Repair or
(female) (1) and chassis replace
ground
Defective APS
Replace
controller relay
Defective contact,
disconnection, short circuit Repair or
with ground in wiring harness
replace
between R23 (female) (5) and
E25 (female) (1)
Defective contact,
disconnection, short circuit
with ground in wiring Repair or
harness between starting replace
switch terminal ACC and
R23 (female) (5)
harness between R23 Repair or
ground
harness between M91 Repair or
(female) (2) and R23 replace
(female) (1)
Defective APS switch Replace
harness between fuse 2 replace
and M91 (female) (3)
PC1100-6 20-393
3
b) Preheating pilot lamp flashes when water temperature is below 20°C when APS switch is ON
(controller LEDs all give normal display)
Preheating pilot lamp lights up when water temperature is above 20°C when APS switch is ON
(controller LEDs all give normal display)
fl Carry out troubleshooting with the APS switch ON.
fl Check the engine water temperature.
Cause Remedy
2 YES
Defective APS controller Replace
Is resistance
YES between E26
(female) (2) and Defective contact,
1 chassis ground disconnection, short
Is resistance normal ? circuit with ground in Repair or
between P19 • Turn starting NO wiring harness between replace
(male) and chassis switch OFF. E26 (female) (2) and P19
ground normal ? • Disconnect E26. (female)
• Turn starting • Same as Item 1.
Defective APS water
Replace
switch OFF. NO temperature sensor
• Disconnect P19.
• Water
temperature
below 20°C:
Max. 1 Ω
• Water
temperature
above 20°C:
Min. 1 MΩ
c) Nozzle does not inject fuel when starting switch is turned to START after completion of
preheating when APS switch is ON (controller LEDs all give normal display)
fl Carry out troubleshooting of start signal (terminal C) system.
fl Check that the injection nozzle stop valve is open.
Cause Remedy
YES
1
Is voltage
between E26 (3) Defective contact or
and chassis 2 YES disconnection in wiring
Repair or
ground normal? Is voltage between
harness between E26
replace
starting switch (female) (3) and starting
• Turn starting terminal C and switch terminal C
switch to NO chassis ground
START. normal?
• 20 – 30 V Defective starting switch Replace
switch ON.
• 20 – 30 V
20-394 PC1100-6
3
d) Controller LED 1 (short circuit in glow plug 1 system) gives abnormal display
Cause Remedy
2 YES
Is resistance
YES between E25
(female) (2) and
1 chassis ground Short circuit with ground
Is resistance normal? in wiring harness Repair or
between glow plug between E25 (female) (2) replace
1 terminal and
switch OFF. and glow plug 1 terminal
chassis ground
normal? • Disconnect E25.
• Turn starting • 0.8 – 1.3 Ω
Defective glow plug 1 Replace
switch OFF. NO
• Disconnect plug
terminal.
• 0.8 – 1.3 Ω
e) Controller LED 2 (disconnection in glow plug 1 system) gives abnormal display
Cause Remedy
2 YES
Is resistance
YES between E25
(female) (2) and
1 Short circuit with ground
chassis ground
1 terminal and • Turn starting NO
and glow plug 1 terminal
chassis ground switch OFF.
switch OFF. NO
• Disconnect plug
terminal.
• 0.8 – 1.3 Ω
PC1100-6 20-395
3
f) Controller LED 3 (short circuit in glow plug 2 system) gives abnormal display
Cause Remedy
2 YES Defective APS controller Replace

Is resistance
YES between E25
(female) (3) and
chassis ground
2 terminal and and glow plug 2 terminal
switch OFF. NO
• Disconnect plug
2.
• 0.8 – 1.3 Ω
g) Controller LED 4 (disconnection in glow plug 2 system) gives abnormal display
Cause Remedy
2 YES
Is resistance
YES between E25
(female) (3) and
2 terminal and • Turn starting NO
and glow plug 2 terminal
switch OFF. NO
• Disconnect plug
terminal.
• 0.8 – 1.3 Ω
20-396 PC1100-6
3
k) Preheating pilot lamp lights up when APS switch is OFF

fl Carry out troubleshooting with the APS switch OFF.
Cause Remedy
YES Defective APS controller

Replace
relay
1
When relay R23 is
interchanged with Short circuit with power
another relay, does YES source in wiring harness Repair or
condition become 2 between E25 (female) (1) replace
normal? and R23 (female) (3)
Is voltage
• Turn starting between R23 (1) Short circuit with power
switch ON. 3 YES
NO and chassis source in wiring harness Repair or
ground normal? Is resistance between R23 (female) (1) replace
• Turn starting between M91 and M91 (female) (2)
switch ON. NO (male) (2) and (3)
• Max. 1 V normal?
Defective APS switch Replace
switch OFF.
• Disconnect M91.
• Max. 1 MΩ
PC1100-6 20-397
3
20-398 PC1100-6
3
E-23 [534] Abnormality in machine selection input to engine controller

is displayed
* Before carrying out troubleshooting, check that all the related connectors are properly inserted.
* Always connect any connectors before going on the next step.
Cause Remedy
Ir Carry out troubleshooting with the starting switch OFF.

Replace
controller
~~~
Short circuit with chassis
ground in wiring harness Repair or
between E09 and engine replace
NO
resistance between controller
El8 (female) (141,(151
and chassis ground? Replace
1BothresistancebetweenI I controller
El8 Ifemale)1141
and
chassisground.and
resistancebetweenEl8
(femaleI(15)andchassis Disconnection in wiring
groundare1Rorless. Repair or
harness between E09
NO replace
and engine controller
Normal condition
Connector El8 (female)

Specification
Pin (14) Pin (15)
Standard Disconnected Disconnected

55°C Connected with Connected with
specification chassis ground chassis ground

Enstne controller
I 1
El8 (04016)
/---
55” Specification Standard
TWPOI802
PC1 100-6 20-399

0
TROUBLESHOOTING OF ENGINE SYSTEM
(S MODE)
Method of using troubleshooting charts .............................................................................................20-402

S- 1 Starting performance is poor (starting always takes time) ..................................................20-406
S- 2 Engine does not start ................................................................................................................20-407
a) Engine turns but no exhaust smoke comes out (fuel is not being injected) ............... 20-407
b) Exhaust smoke comes out, but engine does not start (fuel is being injected) ...........20-408
S- 3 Engine does not pick up smoothly (follow-up is poor) .........................................................20-409
S- 4 Engine stops during operations ...............................................................................................20-410
S- 5 Engine does not rotate smoothly (hunting)............................................................................20-411
S- 6 Engine lacks output (no power) ...............................................................................................20-412
S- 7 Exhaust smoke is black (incomplete combustion) .................................................................20-413
S- 8 Oil consumption is excessive (or exhaust smoke is blue) ....................................................20-414
S- 9 Oil becomes contaminated quickly ..........................................................................................20-415
S-10 Fuel consumption is excessive ................................................................................................20-416
S-11 Oil is in cooling water, or water spurts back, or water level goes down ........................... 20-417
S-12 Oil pressure caution lamp lights up (drop in oil pressure) ..................................................20-418
S-13 Oil level rises ..............................................................................................................................20-419
S-14 Water temperature becomes too high (overheating) ............................................................20-420
S-15 Abnormal noise is made ...........................................................................................................20-421
S-16 Vibration is excessive ................................................................................................................20-422
PC1100-6 20-401
3
METHOD OF USING TROUBLESHOOTING CHARTS
This troubleshooting chart is divided into three sec-

tions: questions, check items, and troubleshooting.
The questions and check items are used to pinpoint
high probability causes that can be located from the
failure symptoms or simple inspeciton without us-
ing troubleshooting tools.
Next, troubleshooting tools or direct inspection are
used to check the high probability causes to make
final confirmation.
[Questions]
Sections A + B in the chart on the right corre-
sponds to the items where answers can be ob-
tained from the user. The items in B are items
that can be obtained from the user, depending
on the user’s level.
[Check items]
The serviceman carries out simple inspection to
narrow down the causes. The items under C in
Causes
the chart on the right correspond to this.
The serviceman narrows down the causes from
information A that he has obtained from the
user and the results of C that he has obtained
from his own inspection.
[Troubleshooting]
Troubleshooting is carried out in the order of
probability, starting with the causes that have (1) (2) (3)
been marked as having the highest probability
from information gained from [Questions] and
[Check items].
(a)
Questions
A (b)
(c)
(d)
(e)
B
Check items
i
shooting
Trouble-
ii
iii
20-402 PC1100-6
3
The basic method of using the troubleshooting chart

is as follows.
Items listed for [Questions] and [Check items] that
have a relationship with the Cause items are marked
with o, and of these, causes that have a particularly
high probability are marked with T.
Check each of the [Questions] and [Check items] in
turn, and mark the o or T in the chart for items
where the problem appeared. The vertical column
(Causes) that has the highest number of points is
the most probable cause, so start troubleshooting
for that item to make final confirmation of the cause.
ª1. For [Confirm recent repair history] in the Causes
[Questions] Section, ask the user, and mark
the Cause column with #to use as refer-
n)
ence for locating the cause of the failure.
ctio
However, do not use this when making cal-
inje
culations to narrow down the causes.
sive
#
e
ª2. Use the in the Cause column as reference
renc
xces
zle
noz
for [Degree of use (Operated for long pe-
ent
erfe
p (e
r
g
inde
riod)] in the [Questions] section. As a rule,
lem
tion
imin
, int
pum
do not use it when calculating the points for
er e
c
, cyl
rger
inje
on t
ion
locating the cause, but it can be included if
lean
ring
cha
ecti
zed
ject
necessary to determine the order for trou-
air c
urbo
, sei
ston
r inj
e in
bleshooting.
rope
ged
ged
ctiv
n pi
ed t
Clog
Clog
Defe
Wor
Seiz
ª1 Confirm recent repair history Imp
ª2 Degree of use Operatred for long period
PC1100-6 20-403
3
• Example of troubleshooting when exhaust gas is black

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

General causes why exhaust gas is black Causes
• Insufficient intake of air
• Improper condition of fuel injection
d)
d
ion)
eize
hea
• Excessive injection of fuel
ject
er s
and
e in
lung
seat
rger
essiv
ck, p
elem rence
cha
lve
n tim nozzle
(exc
o
, va
p (ra
ent
terfe
turb
er
alve
ing
r
ed m ce
n
mp
uffle
pum
lind
ctio
r, in
een
ran
u
of v
y
p
rope ized inje
clea
w
arge
n pis cleaner
g, c
ion
rope jection
t
ctio
tact
e
ject
air b
in
alve
logg
Clog urboch
r inje
n
Legend
e in
ton
e co
, se
e in
air
e of
: Possible causes (judging from Questions and check items)
d, c
r
ectiv
ged
ged
ctiv
ctiv
ed t
: Most probable causes (judging from Questions and Check items)
she
kag
: Possible causes due to length of use (used for a long period)
Clog
D efe
Defe
W or
Seiz
Deff
Imp
Imp
Cru
Lea
: Items to confirm the cause.
Confirm recent repair history
Degree of use Operated for long period
Suddenly became black
Questions
Color of exhaust gas Gradually became black

Blue under light load
Engine oil must be added more frequently
Suddenly
Power was lost
Gradually
Non-specified fuel has been used
Noise of interference is heard from around turbocharger
Dust indicator is red
Blow-by gas is excessive
Engine pickup is poor and combustion is irregular
When exhaust manifold is touched immediately after
Check items
starting engine, temperature of some cylinders is low

Match marks on fuel injection pump are out of alignment
Seal on injection pump has come off
Clanging sound is heard from around cylinder head
Exhaust noise is abnormal
Muffler is crushed
Leakage of air between turbocharger and head, loose clamp
When turbocharger is rotated by hand, it is found to be heavy

When air cleaner is inspected directly, it is found to be clogged
When compression pressure is measured, it is found to be low
Speed of some cylinders does not change when operating
Troubleshooting
on reduced cylinders
When check is made using delivery method, injection timing

is found to be incorrect
Injection pump test shows that injection amount is incorrect
When valve clearance is checked directly it is found to be
outside standard value
When muffler is removed, exhaust gas color returns to normal
When control rack is pushed, it is found to be heavy or does
not return
Replace
Replace
Replace
Replace
Replace
Replace
Adjust
Adjust
Adjust
Repair
Clean
Remedy
20-404 PC1100-6
3
Five causes
Step 1
Clarify the relationship between the three
symptoms in the [Questions] and [Check items]
section and the five Cause items in the vertical
column.
Three symptoms
Step 2
Add up the total of and marks where the
horizontal lines for the three symptoms and the
vertical columns for the causes intersect.
(1) Clogged air cleaner element:
(2) Air leakage between turbocharger
and head:
(3) Clogged, seized injection nozzle:
(4) Defective contact of valve, valve seat:
(5) Worn piston ring, cylinder:
Step 3
The calculation in Step 2 show that the closest
relationship is with [Clogged air cleaner
element]. Follow this column down to the
troubleshooting area and carry out the
troubleshooting item marked . The Remedy is
given as [Clean], so carry out cleaning, and the
exhaust gas color should return to normal.
PC1100-6 20-405
3
TROUBLESHOOTING S-1
S-1 Starting performance is poor (starting always takes time)

General causes why exhaust smoke comes out but
engine takes time to start
• Defective electrical system
• Insufficient supply of fuel
• Improper selection of fuel
(At ambient temperature of 10˚C or below, use
ASTM D975 No. 1)
fl Battery charging rate Causes
Charging rate
Ambient tem-
100% 90% 80% 75% 70%
ck)
p rflow v alve
alve
perature
20°C 1.28 1.26 1.24 1.23 1.22
Defe d gove ool val r breath l piping ger stu
fv
iner
p ov relie
0°C 1.29 1.27 1.25 1.24 1.23
stra
at
ft
n
–10°C 1.30 1.28 1.26 1.25 1.24
gov or oi n pum l pump

Seiz rnor spl tank a ir in fu ack, plu
Clogged go l inject overnor ear sha

Defective A l filter, elemen alve se
Defe tive ope rnor oil e stuck er hole
e
iner ipe
p
Lea tive fue ection ozzle ttery

pum
• The specific gravity should exceed the value
oi
r oil pply
(r
e
t
ner lve, v
Clogctive fu ation of pump g

r inj ion n ted ba
for the charging rate of 70% in the above table.
Defective re S devic riming
Gov ged fue gging, pump

Clogged air ntact o linder
stra
Clog e, clo injectio ming
erno l su
• In cold areas the specific gravity must ex-
f va
io
a
Defective al ulator e
n
a
g
r
v
ceed the value for the charging rate of 75%
i
p
y
i
t
Imp ctive in deterio
Defective or ernator
Clogctive co ring, c
in the above table.
ged vern
a
rope ject
l e
e
g
c
Legend
r
t
l
Defe piston
fue
: Most probable causes (judging from Questions and Check items) d
kag
g e
e
n
e
c
c
Defe
Defe
Wor

Degree of use of machine Operated for long period
Gradually became worse
Ease of starting
Starts when warm
Questions
Takes time to start again after warming up

Preheating pilot lamp does not light up
Replacement of filters has not been carried out according to Operation Manual
Dust indicator lamp is red
Non-specified fuel is being used
Battery charge lamp is ON
Starting motor cranks engine slowly
Engine does not pick up smoothly, and combustion is irregular
Check items
Counter marks on fuel injection pump are out of alignment

Mud is stuck to fuel tank cap
When engine is cranked with starting motor,
1) Little fuel comes out even when fuel injection pump sleeve nut is loosened
2) No fuel comes out even when fuel filter air bleed plug is loosened
Leakage from fuel piping
There is hunting from engine (rotation is irregular)
When air cleaner element is inspected directly, it is found to be clogged
When fuel filter, strainer are inspected directly, they are found to be clogged
When priming pump strainer is inspected directly, it is found to be clogged
Glow plug mount does not become warm
Is voltage 26 – 30V between alternator terminal Yes
Troubleshooting
B and terminal E with engine at low idling? No

Either specific gravity of electrolyte or voltage of battery is low
Speed does not change when operation of certain cylinders is stopped
When check is made using delivery method, injection timing is found to be incorrect
When control rack is pushed, it does not return
(when rack stopper bolt at rear of pump is removed and rack
piston is pushed with clean screwdriver, rack does not move)
When fuel cap is inspected directly, it is found to be clogged
Inspect governor oil pump directly
Inspect governor spool valve directly
When governor oil supply pipe is inspected directly, it is found to be clogged
When governor oil strainer is inspected directly, it is found to be clogged
When overflow valve is inspected, it is found that valve is stiff or open
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Adjust
Adjust
Clean
Clean
Clean
Clean
Clean
Remedy
20-406 PC1100-6
3
TROUBLESHOOTING S-2
S-2 Engine does not start

a) Engine turns but no exhaust smoke comes
out (fuel is not being injected)
General causes why engine turns but no ex-

haust smoke comes out
• Supply of fuel impossible
• Supply of fuel is extremely small
• Improper selection of fuel (particularly in win-
ter)
Standards for use of fuel

Ambient temprature Causes
Type of fluid –22 –4 14 32 50 68 86 104°F
ve
d)
–30 –20 –10 0 10 20 30 40°C
f val
. )
seize
c
ft, et
y
(rack haft, ke
relie
ASTM D975 No.2
ger
, sha
ft
ump
plun
Clog or spoo of gove ear, sha

Diesel fuel
hole
es
ipe
e
oil p
ASTM D975 No.1
er
n (g
,
driv
ly p
train
her
iner
pisto
rnor
air b ng
k
mp
ump r
erno il supp
reat
ump
stuc
e
mp
stra
s
pipi
n
,
n pu
mp
i
stra
il pu
ion p
lve
r oil
uel
u
o
p
ctio
d
ng p
l va
lter,
or o
ged vernor
ng f
use
ed, b el inject
feed
rope el tank
ation
inje
el fi
Lack d primi
Defe govern
Clog d, leaki
fuel
ken
actu
gov
Legend
go
fuel
Clog fuel
u
fu
fu
o
f
r
r
ctive
ctive
ged
ged
ged
ern
ken
ge
of
ge
ed
Clog
Clog
Clog
Defe
Seiz
Gov
Imp
Seiz
Bro

Exhaust smoke suddenly stops coming out (when starting again)
Replacement of filters has not been carried out according
Questions
to Operation Manual
When fuel tank is inspected, it is found to be empty
There is leakage from fuel piping
When fuel filter is drained, fuel does not come out
1) Injection pump coupling does not turn
2) No fuel comes out even when fuel filter air bleed
Check items
plug is loosened
3) No fuel spurts out even when injection pipe sleeve
nut is loosened
Rust and water are found when fuel tank is drained
Inspect fuel injection pump directly

Control pump does not move
Inspect feed pump directly
Troubleshooting
Inspect governor spool valve directly
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Clean
Clean
Clean
Clean
Remedy
Add
PC1100-6 20-407
3
TROUBLESHOOTING S-2
b) Exhaust smoke comes out, but engine does

not start (Fuel is being injected)
General causes why exhaust smoke comes out

but engine does not start
• Lack of rotating force due to defective elec-
trical system Causes
er st etc.)
u ck)
,
ck, p cker lever
• Improper selection of fuel and oil
hole ray
p
lung
, ro
stem
ve s
on r tion pum em (valve
ery
air b defecti
el sy
aine er
igh
her
p ( ra
batt
n
ent
iner
ilter inder li
oo h
injec valve syst
n fu
r
reat
elem
zle,
Clog e, clogg iorated
stra
oil t
air i
, str
noz
ice
cyl
ump
amic
d
ine
ing,
ane
dev
eter
use
ing,
ion
tank
n dyn
eng
p
Defe d air cle
Clog d inject
APS
Clog d fuel f
Visc er fuel
feed
fuel
fuel
Legend
e or
broke
y of
t
e
s
ctive
ged
ged
ctiv
ctiv
n pi
osit
rop
tive,
ge
ge
kag
ge
Clog
Clog
Defe
Wor
Defe
Defec
Imp
Lea
Suddenly failed to start
When engine is cranked, abnormal noise is heard from around head
Questions

to Operation Manual
Rust is found when fuel tank is drained
Preheating pilot lamp does not light up
Starting motor cranks engine slowly
1) Little fuel comes out even when fuel injection pump
sleeve nut is loosened
Check items
2) Little fuel comes out even when fuel filter air bleed
plug is loosened
When fuel filter is drained, no fuel comes out
Remove head cover and inspect directly

When control rack is pushed, it is found to be heavy, or does not return
Troubleshooting
When feed pump strainer is inspected directly, it is found to be clogged
Glow plug mount does not become warm
Either specific gravity of electrolyte or voltage of battery is low
When feed pump is operated, operation is too light or too heavy
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Clean
Clean
Clean
Clean
Clean
Remedy
20-408 PC1100-6
3
TROUBLESHOOTING S-3
S-3 Engine does not pick up smoothly (follow-up is poor)

General causes why engine does not pick up smoothly
• Improper fuel used
• Defective fuel injection pump Causes
seat
spra
lve
hole
tive
ranc erence
d va
efec
her
e an
ilter lement
er
g
e, d
pum ainer
terf
ntac el pipin
king r breat
der
rain
valv
n
ozzl
cylin
p st
i
, str
re
,
p
ai
clea
t of
n
pum
fu
ane
g
ion
ed t n ring,
ank
r
cha
lve
Clog d air cle
Defe d inject
eed
Clog d fuel f
Clog d fuel t
feed
Legend
urbo
, lea
r va
e co
sto
f
rope
ged
ged
ctiv
ctiv
n pi
ge
ge
ge
ge
Clog
Clog
Clog
Defe
Wor
Seiz
Imp
Replacement of filters has not been carried out according to
Operation Manual
Questions

Engine pick-up suddenly became poor
Color of exhaust gas
Black
Check items
High idling speed under no load is normal, but speed

suddenly drops when load is applied

When feed pump strainer is inspected directly, it is found to be clogged
Troubleshooting

Inspect feed pump
When valve clearance is checked directly, it is found to be
Replace
Replace
Replace
Replace
Correct
Correct
Adjust
Clean
Clean
Clean
Clean
Remedy
PC1100-6 20-409
3
TROUBLESHOOTING S-4
S-4 Engine stops during operations

General causes why engine stops during opera-
tions
• Seized parts inside engie
• Overheating
fl If there is overheating and the engine
stops, carry out troubleshooting for over-
heating.
• Failure in machine
fl If the engine stops because of a failure in
the machine, carry out troubleshooting
for the machine.
Causes
ve
.)
d)
, etc
f val
relie t
seize
r oil pply il pump r, shaf

, key
ever
nger
ker l
haft
a
Bro en pum d gear ystem (v aring d
p ge
o
men
, plu
Bro en, seiz ic valve shaft b cting r
Defe en, seiz achine pump er hole

, roc
ve s
iner ipe
ged govern of gove oil pum
quip
er
(rack
alve
p
o
r
n
d
e
e
rnor
i
g
h
Clogged, le d gear mp stra
Bro n dynam d cran n, conn
Clog of fuel njectio iliary e

mp
Clogen, seiz ing pu trainer
Fail tive fue l tank a l pipin

on m injectio breat
Defe ed fue ng fu haft
stra
Lack en fuel p or au train
r
erno l su
n pu
n o
s
r
r
gov or oi
n
k
e
s
,
Brok en, seiz d pisto
ove
i
ter,
n
ed g
o
l
i
i
t
i
f
a
im
k
e
e
e
l
actu
i
a
Legend
l
e
Bro en, seiz
r
u
p
f
ctive
d
d
d
e
e
e
ure
g
g
g
c
e
k
k
k
k
k
Clog
k
k
Clog
Clog
Bro
Bro
Bro
Abnormal noise was heard and
Condition engine stopped suddenly
when engine Engine overheated and stopped
Questions
stopped Engine stopped slowly

There was hunting and engine stopped
Fuel level caution lamp is lighted up
to Operation Manual
Engine runs, but when work equipment control lever is
operated, engine stops
Check items
Does not turn at all

Carry out troubleshooting for machine.
Try to turn by Turns in opposite direction

hand using Moves amount of backlash
barring tool Shaft does not turn
Metal particles are found when oil is drained
Remove oil pan and inspect directly
Troubleshooting
When gear train is inspected, it does not turn

Turns when pump auxiliary equipment is removed
Inspect feed pump directly
Control rack does not move
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Clean
Clean
Clean
Clean
Clean
—
Remedy
Add
20-410 PC1100-6
3
TROUBLESHOOTING S-5
S-5 Engine does not rotate smoothly (hunting)

General causes why engine does not rotate
smoothly
• Air in fuel system
• Defective governor mechanism
Causes
e
mp
, pip
nozzle
ool)
ing pu
er
hole
rack
n filt
filter
id, sp
p and
d prim
rnor
er
e
ther
trol
leno
rain
inlet
scre
d pum
nk an
ove
er
con
o
brea
o lo
p st
s
ump
ump
rain
fuel ta
(
of g
n fee
rnor
n of
pum
is to
r, st
oil p
oil p
r
etwee
i
tween
gove
ion
a
ratio
tank
filte
eed
ing
erat
rnor
rnor
cuit b
uit be
g of
prim
e
g sp
fuel
fuel
gove
gove
e op
e op
in cir
slidin
in circ
Legend
el
of fu
idlin
ed, air
ged
ged
ged
ctiv
ctiv
ed, air
ged
ged
ctive
Clog
Clog
Clog
Defe
Defe
Lack
Low
Clog
Clog
Clogg
Clogg
Defe

Occurs at a certain speed range
Occurs at low idling
Questions
Condition of hunting
Occurs even when speed is raised
Occurs on slopes
Replacement of filters has not been carried out according to Operation Manual
Rust is found when fuel tank is drained
When priming pump is operated,
Check items
1) No response, light, return is quick

2) No response, light, return is normal
Engine speed sometimes rises too far
Engine is sometimes difficult to stop
Movement of governor lever (solenoid plunger) is stiff

Movement of spool valve is stiff
Troubleshooting

When governor oil screen filter is inspected, it is found to be clogged
When governor oil inlet filter, oil supply pipe are inspected, they are found to be clogged
Replace
Correct
Correct
Adjust
Adjust
Adjust
Adjust
Clean
Clean
Clean
Clean
Remedy
Add
PC1100-6 20-411
3
TROUBLESHOOTING S-6
S-6 Engine lacks output (no power)

Measure the engine speed and judge if the cause is
in the engine or on the machine.
General causes why engine lacks output
• Insufficient supply of fuel Causes
• Improper fuel used
oid
(if non-specified fuel is used, output drops)
pray
seat
olen
• Lack of output due to overheating
ol, s
ve s
lve
fl If there is overheating and insufficient output,
Clog ve cont earance lunger
hole
nce
d va
ecti
spo
carry out troubleshooting for overheating.
er
fere
her
train
e an
rope injectio zle, def
p
t
air b ng
roke
men
er
mp
reat
filte linder
nter
i
Seiz d inject pump s
Defe d fuel t fuel pip

rain
valv
rest
n pu
r ele
er, i
noz
r, st
y
le p
f
c
o
ane
n pi ocharg
,
ion
ank
cl
act
ring
ng
ing
riab
lve
Seiz d air cle
Clog d primi
leak
fuel
ton
Legend
r va
e va
urb
uel
,
ged
ged
ctiv
ed t
ed f
ge
ge
ge
ge
cti
Clog
Clog
Clog
Defe
Clog
Wor
Imp
Suddenly
Power was lost
Gradually
Questions

to Operation Manual
Black
High idling speed under no load is normal, but speed
Check items
suddenly drops when load is applied

High idling speed of engine is low

Troubleshooting
When valve clearance is checked directly, it is found to be outside standard value
When priming pump is operated, operation is too light or too heavy
Inspect sliding of spool valve, solenoid at variable prestroke end
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Adjust
Clean
Clean
Clean
Clean
Remedy
20-412 PC1100-6
3
TROUBLESHOOTING S-7
S-7 Exhaust smoke is black

(incomplete combustion)
General causes why exhaust smoke is black
Causes
ead
olen ed)
oid
iz
nd h
er se
e at
e an arger a
s
lung
ol, s
lve
ck, p
e
d va
ston aner ele ferenc
spo
zzle
h
boc
r a
t
rope jection ion no
roke
(
men
ntac een tur
ump
rope ized in nder
r
clea ng
betw fler
e
Wor d air cle er, inte
Defe e fuel in of valv

ranc
rest
timi
on p
muf
ject
cyli
le p
arg
jecti
,
ged
t
ring
riab
lve
Clog turboch
Defe e of air
clog
Legend
r va
e va
e co
, se
r in
,
ged
ctiv
ctiv
n pi
ctiv
ge
she
kag
ed
Clog
Defe
Seiz
Imp
Imp
Cru
Lea
Suddenly became black
Color of exhaust gas Gradually became black
Questions

Suddenly
Power was lost
Gradually
Check items

Exhaust noise is abnormal
Muffler is crushed
Leakage of air between turbocharger and head, loose clamp

Troubleshooting

When check is made using delivery method, injection
timing is found to be incorrect
When valve clearance is checked directly it is found to be
When muffler is removed, exhaust color returns to normal
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Adjust
Adjust
Clean
Remedy
PC1100-6 20-413
3
TROUBLESHOOTING S-8
S-8 Oil consumption is excessive (or exhaust smoke is blue)

fl To prevent leakage of oil in the cylinders, do
not run the engine at idling for more than 20
minutes continuously. (Both low and high
idling)
General causes why oil consumption is exces-

sive
• Abnormal combustion of oil
• External leakage of oil
• Wear of lubrication system
Causes
t blo e end
end
wer
al
ead
bin
n se
take urface
m o lter or o hose
t tur
oler
m
er h
yste
oil a , broke
e fro her or b r liner
il co
al a
al a
lind
s
her
s
seal
an o g
d
n se
n se
r cy
lu
dde
reat
de
e)
p
m o iping
eal,
guid
cylin
Wor
Wor
m in
n
drai
ar s
oil p
l fi
p
ing
muc (stem,
n fro
gine
ng,
r
l
l
n re
oole
i
i
i
o
on r
Clog iston ri
t
m
m
brea
ed i
h en
r
roke
arge
Legend
oil c
e fro
e fro
e fro
lve
pist
k
c
n va
ged
n, b
och
t su
np
kag
kag
ken
kag
kag
ken
Wor
Wor
Wor

Turb
Too
Dus
Bro
Lea
Lea
Lea
Lea
Bro

Questions
Oil consumption suddenly increased

Engine oil becomes contaminated quickly
Exhaust smoke is blue under light load
Excessive
Amount of blow-by gas
None
Area around engine is dirty with oil
There is oil in engine cooling water
Check items
When exhaust pipe is removed, inside is found to be dirty with oil

When turbocharger air supply pipe is removed, inside is
found to be dirty with oil
Oil is accumulated inside flywheel housing
Oil level is above H mark on oil level gauge
Clamps for intake system are loose

When breather element is inspected, it is found to be
clogged with dirty oil
Troubleshooting
There is external leakage of oil from engine

Pressure-tightness test of oil cooler shows there is leakage
Excessive play of turbocharger shaft
Inspect rear seal directly
When intake manifold is removed, dust is found inside
When intake manifold is removed, inside is found to be dirty with oil
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Correct
Correct
Correct
Correct
Correct
Correct
Clean
Remedy
20-414 PC1100-6
3
TROUBLESHOOTING S-9
S-9 Oil becomes contaminated quickly

General causes why oil becomes contaminated
quickly
• Intake of exhaust gas due to internal wear
• Clogging of lubrication passage
• Incomplete combustion
• Improper oil used
• Operation under excessive load
• Too long between oil changed
Causes
nd
ine e
turb
e
e
n pip
r tub
rger
d
drai
athe
, bre r
adde
safe urbocha
brea , cylinde
ide
k
blac
ger
e
u
valv
ust s gine oil
g
char
oler
alve
tt
ther
e is
g
n va filter
y
Defe e seal a
Clog ston rin
t
il co
o
Legend
mok
v
h en
turb
lve,
oil

o
ctive
muc
ged
ged
ged
ged
: Most probable causes (judging from Questions and Check items) ctiv
n pi
Exha
Clog
Clog
Clog
Defe
Wor
Wor
: Items to confirm the cause. Too

Questions

Non-specified oil is being used
Black
Excessive
Carry out troubleshooting for "Exhaust smoke is black".
Amount of blow-by gas

None
Check items
When oil filter is inspected, metal particles are found

When exhaust pipe is removed, inside is found to be dirty with oil
Engine oil temperature rises quickly

When breather element is inspected directly, hose is found to
be broken or clogged with dirty oil
Troubleshooting
When oil filter is inspected directly, it is found to be clogged

When oil cooler is inspected directly, it is found to be clogged
Turbocharger drain tube is clogged
Excessive play of turbocharger shaft
When safety valve is directly inspected, spring is found to be
catching or broken
Replace
Replace
Replace
Replace
Replace
Correct
Clean
Clean
Clean
Remedy
PC1100-6 20-415
3
TROUBLESHOOTING S-10
S-10 Fuel consumption is excessive

General causes why fuel consumption is exces-
sive
• Leakage of fuel
Causes
ter
ger
)
id
ction
el fil
leno
plun
e inje
r
g, fu
ove
l, so
ng
cessiv
pray
ump
c
pipin
spoo
timi
ead
er s
p (ex
oke
de h
fuel
n
ion
o
hold
n pum
restr
i
from
t
ject
insi
e c
ble p
j
jectio
zzle
el in
el in
fuel
age
varia
e no
Legend
fuel in
e fu
e fu
leak
e of
ctiv
ctiv
ctiv
ctive
rnal
kag
ctive
Defe
Defe
Defe
Exte
Defe
Lea
Defe
Questions
More than for other machines

Condition of fuel of same model
consumption Gradually increased
Suddenly increased
Black
Exhaust smoke color
White
There is irregular combustion
Check items

There is external leakage of fuel from engine
Engine oil level rises and smells of diesel fuel
Engine low idling speed is high
Injection pump measurement shows that injection amount is excessive

Troubleshooting

When check is made using delivery method, injection
timing is found to be incorrect
Replace
Replace
Replace
Correct
Correct
Adjust
Adjust
Remedy
20-416 PC1100-6
3
S-11 Oil is in cooling water, or water spurts back, or water level goes down
General causes why oil is in cooling water
• Internal leakage in lubrication system
• Internal leakage in cooling system
Causes
ther)
pittin
t
aske
brea
k
d by
bloc
er
-ring
ad g
gged
oole
f lin
ause
der
l (clo
e
re, O
les c
oil c
d, h
cylin
sion
p sea
g, ho
r co
hea
ain
otru
ks in
r pum
O-rin
oole
er tr
der
p r
cylin
Legend
crac
pow
wate
oil c
liner
ent

ffici
aged
aged
rnal
ken
ken
ken

Insu
Dam
Inte
Dam
Bro
Bro
Bro

Questions

Suddenly increased
Oil level
Gradually increased
Hard water is being used as cooling water
Check items
(or corrosion resistor valve is closed)

Engine oil level has risen, oil is cloudy white
Excessive air bubbles inside radiator, spurts back

Troubleshooting
Pressure-tightness test of cylinder head shows there is leakage

Remove cylinder head and inspect directly
When water pump is inspected, it is found to be abnormal
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Remedy
PC1100-6 20-417
3
S-12 Oil pressure caution lamp lights up (drop in oil pressure)

General causes why oil pressure caution lamp lights up
• Leakage, clogging, wear of lubricating system
• Defective oil pressure control
• Improper oil used (improper viscosity)
• Deterioration of oil due to overheating
fl Standards for engine oil selection
Ambient temperature
Type of fulid Causes

–22 –4 14 32 50 68 86 104°F
–30 –20 –10 0 10 20 30 40°C
SAE 30
n
il pa
pan
g
SAE 10W
ipin
Engine oil
de o
i l
r
lic p
o
nso
ng
e
SAE 10W-30
insi
d
razi
alve
r
drau
e se
nso
insi
l
pe b
urna
pipe
tor v
el se
ssur
an
d hy
pipe
SAE 15W-40
mp
r
oil p
n pi
oole
g, jo
ilter
il
n
gula
l pre
l lev
she
l pu
in o
o
ion
i
o
suct
oil c
oil f
Legend
il in
arin
, cru
e re
suct
suct
e oi
e oi
e oi
uel
of o
n be
ged
ged
ged
ctiv
ctiv
ctiv
ctiv
er, f
king
ken
ken
Clog
Clog
Defe
Defe
Defe
Defe
Clog
Lack
Wor
Wat
Bro
Bro
Lea
Questions
to Operation Manual
Oil pressure caution lamp lights up
Lights up at low idling

Condition when oil pressure Lights up at low, high idling
caution lamp lights up Occurs on slopes
Sometimes lights up
Leaking, crushed hydraulic piping (external)
Check items
Oil level caution lamp lights up

When oil level in oil pan is checked, it is found to be low
Metal particles are stuck to oil filter element
Oil is cloudy white or smells of diesel fuel
Carry out troubleshooting for "Oil level rises".
When oil filter is inspected directly, it is found to be clogged

Troubleshooting
Oil pump rotation is heavy, or there is play

There is catching of relief valve, spring or valve guide is broken
Oil level caution lamp goes out when oil level sensor is replaced
When oil pressure is measured, it is found to be within standard value
Remove oil cooler and inspect directly
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Correct
Clean
Remedy
—
Add
20-418 PC1100-6
3
S-13 Oil level rises

fl If there is oil in the cooling water, carry out
troubleshooting for “Oil is in cooling water”
also.
General causes why oil level rises
• Water in oil
• Fuel in oil (diluted, and smells of diesel fuel)
• Entry of oil from other component
Causes
ge ty ap
eal
ber)
c
pe)
ive s
ng
ing
nt
hole stion cham
pitti
pme
osta jection p r retain
fect
(flan
e by
i
, de
equ
ombu
ump
lde
mad
l fro p auxili e
g prec
ary
ac
e ho
ve
surf
lder ing
d re reather
n, d ter pum t (includin
cylin , holes
slee
k
bloc
-r
ozzl
ring t
eal
a
Broke ve nozz core, O
t se
l in
mn
ar s
gaske
b
der
m
e fue
p
f pu
e ho
head
r O-
ler
insid
erm
al o
l
age
Defe e of fue
Defe oil coo
Clog nder head,
line
side
Legend
e se
e th
part
wa
m
d
a
ks in
age
ctiv
ctiv
ged
ctive
n cyli
ken
kag
cti
Dam
Defe
Defe
Crac
Wor
Bro
Lea

Questions

There is oil in radiator cooling water
Exhaust smoke is white
When engine is first started, drops of water come from muffler
When radiator cap is left open and engine is run at idling,
abnormal number of bubbles appear, or water spurts back
Water pump breather hole is clogged with mud
Check items
When water pump breather hole is cleaned, water comes out

Oil level goes down in PTO
Oil level goes down in hydraulic tank
Engine oil smells of diesel fuel
Fuel must be added more frequently

Troubleshooting
Remove water pump and inspect directly

Inspect rear seal directly
When pump auxiliary equipment is removed,
seal is found to be damaged
Remove nozzle holder and inspect directly
Remove fuel injection pump and inspect directly
Thermostat seat valve contact is defective
Remove oil pan and check directly
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Correct
Remedy
PC1100-6 20-419
3
S-14 Water temperature becomes too high (overheating)

General causes why water temperature becomes too
high
• Lack of cooling air (deformation, damage of fan)
• Drop in heat dissipation efficiency
• Defective cooling circulation system Causes
itting
)
pen
g e
by p
lley
gau
ot o
ns
n pu
ade
es n
ture
or fi
les m
sket
oole
rn fa
t (do
alve
pera
diat
k
d ga
core
g, ho
bloc
ater
oil c
, wo
re v
osta
d ra
tem
ump
a
ng w
O-rin
ator
der
essu
ping
ken
e
she
erm
ater
er p
d, h
cylin
, bro
radi
, cru
liner
ooli
Legend
slip
e pr
e th
ew
hea
wat
of c
ged
ged
ged
aged
ctiv
ctiv
ctiv
ked
belt
ken
ken
Defe
Clog
Defe
Defe
Clog
Clog
Crac
Lack
Dam
Fan
Bro
Bro

Suddenly overheated
Condition of overheating
Always tends to overheat
Questions
Rises quickly
Water temperature gauge
Does not go down from red range
Radiator water level caution lamp lights up
Fan belt whines under sudden load
Cloudy white oil is floating on cooling water
Cooling water flows out from overflow hose
Excessive air bubbles inside radiator, water spurts back
Engine oil level has risen, oil is cloudy white
Check items
Radiator shroud, inside of underguard are clogged with dirt or mud

When light bulb is held behind radiator, no light passes through
Water is leaking because of cracks in hose or loose clamps
When belt tension is inspected, it is found to be loose
Temperature difference between top and bottom radiator tanks is excessive

Temperature difference between top and bottom radiator tanks is slight
When water filler port is inspected, core is found to be clogged
When function test is carried out on thermostat, it does
Troubleshooting
not open even at cracking temperature

When water temperature is measured, it is found to be room temperature
When oil cooler is inspected directly, it is found to be clogged
When measurement is made with radiator cap tester, set
pressure is found to be low
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Correct
Remedy
Add
20-420 PC1100-6
3
S-15 Abnormal noise is made

fl Judge if the noise is an internal noise or an
external noise.
General causes why abnormal noise is made

• Abnormality due to defective parts
• Abnormal combustion
• Air sucked in from intake system
Causes
g
ipin
ad
etc.)
men interfer ive injec d)
)
omp osition)
tion
s e iz e
d he
g
r
or p
e c l e slippin
shin ference er line
ver,
r an
e
betw cklash rocker le
ger
ress
ranc
fp
d
ump ck, plun
out o
e
e,
cylin
harg
a
enc
ess
Defo e fuel in ion pum zzle
oard
alve
(exc
ft be ioner c
rboc
rger n ring,
(ra
valv
no
m (v
ng b
p
er
n tu
g
n
arin
, int
g
t of
e
o
it
ividi
o
t
a
belt
i
ond
on p
urbo of pist
e sys
e
ject
in b
e
ler (d
air c
d bu
d in
jecti
rope an, fan
valv
ject
r tra
cha
sha
just
muff
r
n
Seiz ve wea
Defe d, seize
Defe e of air
Clog , seize
amic
Seiz e from
a
i
rank
r ad
r ge
fuel
Legend
df
side
n
rme
y
rope
ctive
ed c
ed t
sing
en d
ct in
essi
ctiv
ge
kag
kag
Defe
Brok
Imp
Imp
Mis
Exc
Lea
Lea
Questions
Gradually occurred
Condition of abnormal nois
Suddenly occurred
Black
Metal particles are found in oil filter
Engine pickup is poor and combustion is abnormal
Check items

Seal on fuel injection pump has come off
Abnormal noise is loud when accelerating engine
Leakage of air between turbocharger and head
Vibrating noise is heard from around muffler

Remove gear cover and inspect directly
Troubleshooting

Fan is deformed, belt is loose
When valve clearance is checked, it is found to be outside standard value
Remove cylinder head cover and inspect directly
When muffler is removed, abnormal noise disappears
Check for leakage from air conditioner compressor piping
Remove oil pan and inspect
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Correct
Adjust
Adjust
Remedy
PC1100-6 20-421
3
S-16 Vibration is excessive

fl If there is abnormal noise together with the
vibration, carry out troubleshooting for “Ab-
normal noise is made”.
General causes why vibration is excessive
• Defective parts (abnormal wear, breakage)
• Improper alignment
• Abnormal combustion
Causes
tc.)
er)
tion)
O
ver, e
n
amp
d PT
shio
injec
ring
ker le
ft (d
n cu
e an
ssive
bea
e, roc
roke
sha
ngin
hing
sh
e
ain
lv
c
per
n
p (ex
m (va
lts, b
ortio
l
utpu
en e
k
bus
d, m
zzle
dam
bac
pum
syste
o
lot p
n no
twe
nt b
am
de o
g ro
ain
ion
tion
valve
er, c
t be
mou
ar tr
rt pi
ctio
ctin
insi
brat
injec
ic
n
lanc
inje
Legend
ppo
r ge
ynam
nne
gine
nme
part
e vi
fuel
: Possible causes (judging from Questions and check items) n ba
n co
n su
rope
ged
tive d
e en
ctiv
ctive
alig
ken
Clog
Defe
Loos
Wor
Wor
Wor
Defec
Imp
Defe
Mis
Bro
Questions
Suddenly increased
Condition of vibration
Gradually increased
Metal particles are found in oil filter
Oil pressure is low at low idling
Check items
Vibration occurs at mid-range speed

Vibration follows engine speed
Exhaust smoke is black
Seal on fuel injection pump has come off

Remove side cover and inspect directly
Check directly for wear, play in support pilot portion
Troubleshooting
When engine mount bolts are inspected directly, loose

bolts are found; check for broken cushion
Inspect inside of output shaft (damper) directly
Radial, face runout are found to be outside range
Remove front cover and inspect directly
Remove vibration damper and inspect directly
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Adjust
Remedy
20-422 PC1100-6
3
TROUBLESHOOTING OF PUMP
CONTROLLER SYSTEM
(C MODE)
Judgement table for pump controller and hydraulic (mechanical) related parts ........................... 20-452
Points to remember when carrying out troubleshooting of pump controller system ...................20-455
Action taken by controller when abnormality occurs and problems on machine ..........................20-456
Electrical circuit diagram for C mode system .....................................................................................20-462
C- 1 Abnormality in controller power source (controller LED is OFF) ...........................................20-465
C- 2 [E232] Short circuit in TVC solenoid system is displayed ......................................................20-466
C- 3 [E233] Disconnection in TVC solenoid system is displayed ...................................................20-468
C- 4 [E203] Short circuit in swing holding brake solenoid relay system is displayed ................ 20-470
C- 5 [E213] Disconnection in swing holding brake solenoid relay system is displayed .............20-472
C- 6 [E201] Short circuit in CO cancel solenoid system is displayed ............................................20-474
C- 7 [E211] Disconnection in CO cancel solenoid system is displayed .........................................20-475
C- 8 [E202] Short circuit in straight-travel solenoid system is displayed ......................................20-476
C- 9 [E212] Disconnection in straight-travel solenoid system is displayed .................................. 20-477
C-10 [E204] Short circuit in 2-stage relief solenoid system is displayed .......................................20-478
C-11 [E214] Disconnection in 2-stage relief solenoid system is displayed ....................................20-479
C-12 [E205] Short circuit in swing priority solenoid system is displayed .....................................20-480
C-13 [E215] Disconnection in swing priority solenoid system is displayed .................................. 20-481
C-14 [E206] Short circuit in travel speed solenoid system is displayed ........................................20-482
C-15 [E216] Disconnection in travel speed solenoid system is displayed .....................................20-483
C-16 [E217] Model selection input error is displayed .......................................................................20-484
C-17 [E227] Abnormality in engine speed sensor (2) system is displayed ....................................20-486
C-18 [E228] Abnormality in auto-deceleration output system is displayed ...................................20-487
C-19 Abnormality in swing holding brake system is displayed (no service code is displayed) .... 20-488
C-20 Abnormality in machine push-up solenoid system (no service code is displayed) ............20-489
C-21 Abnormality in boom shockless solenoid system (no service code is displayed) ............... 20-492
PC1100-6 20-451
3
JUDGEMENT TABLE FOR FOR PUMP CONTROLLER
TROUBLESHOOTING AND HYDRAULIC (MECHANICAL) RELATED PARTS
JUDGEMENT TABLE FOR PUMP CONTROLLER AND

HYDRAULIC (MECHANICAL) RELATED PARTS
Disconnection in CO cancel solenoid system

Short circuit in CO cancel solenoid system
Disconnection in 2-stage relief solenoid system
Disconnection in swing priority solenoid system

Disconnection in straight-travel solenoid system
Short circuit in TVC solenoid system
Short circuit in swing holding brake solenoid system

Disconnection in swing holding brake solenoid system
Disconnection in TVC solenoid system
User code
Disconnection in travel speed solenoid system

Short circuit in swing priority solenoid system
Short circuit in straight-travel solenoid system
Short circuit in 2-stage relief solenoid system
Short circuit in travel speed solenoid system

Service code
Model selection input error

Monitoring code
The “E” mark is omitted

[ from the service code ]
Failure mode User code LED E02 E03 — — — — — — —

Service code OFF 232 233 203 213 201 211 202 212 204 214 205 215 206 216 217 227
‡ ‡ ‡ ‡
All work equipment,
Speeds of all work equipment, swing, travel are slow or lack power
swing, travel
There is excessive drop in engine speed, or engine stalls ‡ ‡ ‡ ‡ ‡

No work equipment, travel, swing move
Abnormal noise generated (around pump)
Auto-deceleration does not work ‡
In normal mode ‡ ‡
Boom is slow or lacks power With heavy lift ON ‡ ‡ ‡ ‡
With machine push-up ON
Work equipment
Arm is slow or lacks power

Bucket is slow or lacks power
Boom does not move
Arm does not move
Bucket does not move
Excessive hydraulic drift
Boom
Excessive time lag
Arm, bucket
Boom shockless function does not work or cannot be canceled
Machine deviates naturally Deviates in same direction in FORWARD and REVERSE
to one side when traveling Deviates in opposite direction in FORWARD and REVERSE
Travel system
Deviation is excessive Only at full stroke

when starting Both during fine control operations and at full stroke
Deviation is excessive during compound operations ‡ ‡
Travel speed is slow or lacks power ‡ ‡ ‡ ‡
Both directions (FORWARD and REVERSE)
Does not travel (one side only)
One direction only (either FORWARD or REVERSE)
Travel speed does not switch ‡ ‡
Both left and right ‡ ‡
Does not swing
One direction only
Both left and right
Swing acceleration is poor or lacks power
One direction only
Swing system
During compound operations with bucket, swing speed is slow or acceleration is poor
During compound operations with boom when swing priority is ON, swing speed is slow or acceleration is poor ‡ ‡
Both left and right
Excessive overrun when stopping swing
One direction only
Both left and right ‡ ‡
Excessive shock when stopping swing
One direction only
Both left and right
Excessive abnormal noise when stopping swing
One direction only ‡ ‡
Excessive hydraulic drift of swing
Troubleshooting code of pump controller system C-1 C-2 C-3 C-4 C-5 C-6 C-7 C-8 C-9 C-10 C-11 C-12 C-13 C-14 C-15 C-16 C-17
Troubleshooting code of pump controller input signal system – – – – – – – – – – – – – – – – –
‡: Check the service code display. If there is no display, go to the right; if there
– is a display, go to the bottom.
■: Measure the voltage at the solenoid inlet port. If the voltage is normal, go to the right; if the voltage is abnormal, go to the bottom.
◆: Check the monitoring code display. If the display is normal, go to the right; if the display is abnormal, go to the bottom.
fi: Monitoring code to use as reference when proceeding with troubleshooting (if necessary, check the display).
20-452 PC1100-6
3
Checking solenoid
Troubleshooting code for hydraulic, mechanical system

inlet port voltage Checking monitoring code Monitoring code for reference during troubleshooting
PPC pressure switch Solenoid drive condition
Abnormality in auto-deceleration output system
Auto-deceleration signal output


Pump controller model code
Machine push-up solenoid
Boom shockless solenoid
Swing priority solenoid

Straight-travel solenoid
Bucket DUMP (service)
Travel speed solenoid

CO cancel solenoid
TVC output current
Swing lock switch
Boom LOWER
Engine speed
Bucket CURL
Boom RAISE
Right swing
R.H. travel
Left swing
L.H. travel
Arm OUT
Arm IN
Connectors
Connectors
Connector
— 20 21 26 21 22 23 26
V04, V11
V09, V10
V05
02 10 13 12
228 1 2 3 4 5 6 1 2 5 5 3 34 1 2 3 4 5 6 3
fi fi fi fi H-1
fi fi fi fi H-2
H-3
H-4
‡ ■ ■ ■ ■ ■ ■ ■ ■ ■ fi –
fi
■ fi fi H-5
◆
H-6
H-7
H-8
H-9
H-10
H-11
H-12
◆ H-13
H-14
H-15
■ ■ ■ ■ ■ ■ ■ ■ ■ fi H-16
fi fi H-17
H-18
■ ■ fi H-19
◆ ■ ■ ■ ■ ■ ■ ■ ■ ■ fi
H-20
H-21
H-22
fi H-23
H-24
fi
H-25
H-26
fi H-27
C-18 C-19 C-20 C-21 – – – – – – – – – – – – – – – – – – – – – –
– – – – F-1 F-2 F-3 F-4 F-5 F-6 F-7 F-8 F-9 F-10 F-11 – – – – – – – – – – –
PC1100-6 20-453
3
Method of measuring solenoid inlet voltage

fl The pump controller observes the circuit between swing holding brake relay R20 and swing
holding brake solenoid V04, V11 (secondary side) of the swing holding brake solenoid circuit, the
circuit for machine push-up solenoid V05, and the circuit for boom shockless solenoids V09 and
V10. Even if a short circuit or disconnection occurs in these circuits, no service code is displayed.
For this reason, measure the solenoid inlet voltage as follows to judge if the problem is in the
electrical system or in the hydraulic or mechanical system.
1. Measuring swing holding brake solenoid inlet voltage

1) Insert T-adapters into swing holding brake solenoids V04 and V11.
2) Start the engine and turn the swing lock switch ON.
3) If the voltage between V04 and V11 pins (1) and (2) is as shown in the table below, the
condition is normal.
Between V04, V11 Swing lever operated 20 – 30 V

(1) – (2) 5 sec after returning all levers to Neutral Max. 1 V
2. Measuring machine push-up solenoid inlet voltage

1) Insert a T-adapter into machine push-up solenoid V05.
2) Turn the starting switch ON.
3) If the voltage between V05 pins (1) and (2) is as shown in the table below, the condition is
normal.
Between V05 Machine push-up switch OFF 20 – 30 V

(1) – (2) Machine push-up switch ON Max. 1 V
3. Measuring boom shockless solenoid inlet voltage

1) Insert T-adapters into boom shockless solenoid V09 and V10.
2) Turn the starting switch ON.
3) If the voltage between V09 and V10 pins (1) and (2) is as shown in the table below, the
condition is normal.
Between V09, V10 Boom shockless switch OFF 20 – 30 V

(1) – (2) Boom shockless switch ON Max. 1 V
20-454 PC1100-6
3
TROUBLESHOOTING TROUBLESHOOTING OF PUMP CONTROLLER SYSTEM

TROUBLESHOOTING OF PUMP CONTROLLER SYSTEM
1. Points to remember if abnormality returns to normal by itself:
If the connector is disconnected and the T-adapter is inserted, or if the T-adapter is removed and
the connector is returned to its original position when carrying out troubleshooting of the failure,
and the service code is no longer displayed, or if the monitor display returns to normal, the
abnormality has probably returned to normal.
However, there is a high probability that the same problem will occur again, so it is desirable to
follow up this problem carefully.
2. Handling service code memory retention function:

1) When displaying the abnormality code in memory and carrying out troubleshooting, note
down the content of the display, then erase the display. After trying to re-enact the problem,
carry out troubleshooting according to the service code that is displayed.
(There are cases where mistaken operation or abnormalities that occur when the connector is
disconnected are recorded by the memory retention function. Erasing the data in this way
saves any wasted work.)
2) After completing troubleshooting, always erase the service code from memory again.
PC1100-6 20-455
3

User Service
code code
1. Short circuit with ground, short circuit inside TVC solenoid
2. Short circuit with power source, short circuit with ground in wiring
harness between controller C02 (8) and TVC solenoid C13 (1) ((+)
E232 Short circuit in TVC side)
solenoid system 3. Short circuit with power source in wiring harness between control-
ler C02 (18) and TVC solenoid C13 (2) ((–) side)
1. Disconnection, defective contact inside TVC solenoid

2. Disconnection, defective contact in wiring harness between con-
E02 troller C02 (8) and TVC solenoid C13 (1) ((+) side)
3. Disconnection, defective contact, short circuit with ground in wir-
ing harness between controller C02 (18) and TVC solenoid C13 (2)
Disconnection in ((–) side)
E233 TVC solenoid 4. Defective pump controller
system
1. Short circuit with ground, short circuit inside swing holding brake
relay
2. Short circuit with ground in wiring harness between controller C01
Short circuit in (3) and relay R20 (1) ((+) side)
E203 swing holding brake 3. Defective pump controller
solenoid relay
system
E03
1. Disconnection, defective contact inside swing holding brake relay
2. Disconnection, defective contact, short circuit with power source in
wiring harness between controller C01 (3) and relay R20 (1) ((+)
Disconnection in side)
E213 swing holding brake 3. Disconnection, defective contact in wiring harness between relay
solenoid relay R20 (2) and chassis ground ((–) side)
system 4. Defective pump controller
1. Short circuit with ground, short circuit inside CO cancel solenoid

Short circuit in CO (8) and solenoid V07 (2) ((+) side)
— E201 cancel solenoid 3. Defective pump controller
system
20-456 PC1100-6
3
Condition when normal Action by controller when abnor- Problem that appears on machine
(voltage, current, resistance) mality is detected when there is abnormality
1. Makes output to TVC solenoid 0. 1. No current flows to the TVC so-
2. Displays user code E02 on monitor lenoid. Therefore, when the TVC
panel. valve output pressure goes
· Resistance of solenoid: fl If the abnormality is restored by the down and the load is large, there
10 – 22 Ω vibration of the machine, it resets the is a big drop in the engine speed
power source to restore to the proper which may result in the engine
condition. (However, the service code stalling.
display does not go out.)
1. The current stops flowing to the TVC 1. In the case of Action 1, it is the
solenoid, so no particular action is same as E232.
taken. 2. In the case of Action 2, the cur-
2. If there is a short circuit with the rent (min. 1 A) continues to flow
· Resistance of solenoid: ground at the (–) end, the current (min. to the TVC solenoid, so the out-
10 – 22 Ω 1 A) continues to flow to the TVC so- put of the TVC valve increases
· Current: 1000 mA lenoid. and the overall speed becomes
(DH mode, auto-decelera- 3. It displays user code E02 on the moni- slower.
tion ON, fuel control dial tor panel.
at MAX., all levers at fl If the abnormality is restored by the
neutral) vibration of the machine, it resets the
power source to restore to the proper
condition. (However, the service code
· Resistance of relay: 1. Makes output to relay 0. 1. When the swing is operated, the
200 – 400 Ω 2. It displays user code E03 on the moni- swing holding brake is not re-
fl When the swing holding tor panel. leased, so the upper structure
brake system is seen from fl If the abnormality is restored by the does not swing.
the controller, the relay is vibration of the machine, it resets the
the primary circuit and the power source to restore to the proper
solenoid is the secondary condition. (However, the service code
circuit, so observe the re- display does not go out.)
lay circuit of the primary
circuit.
· Resistance of relay: 1. The current stops flowing to the relay, 1. When the swing is operated, the
200 – 400 Ω so no particular action is taken. swing holding brake is not re-
fl When the swing holding 2. It displays user code E03 on the moni- leased, so the upper structure
brake system is seen from tor panel. does not swing.
the controller, the relay is fl If the abnormality is restored by the 2. If there is a short circuit with
the primary circuit and the vibration of the machine, it resets the the power source, the solenoid
solenoid is the secondary power source to restore to the proper remains actuated.
circuit, so observe the re- condition. (However, the service code
lay circuit of the primary display does not go out.)
circuit.
1. Makes output to solenoid 0. 1. If load becomes large in heavy

fl If the abnormality is restored by the lift mode, boom RAISE speed
vibration of the machine, it resets the becomes low.
· Resistance of solenoid: power source to restore to the proper 2. In heavy lift mode, lifting force
20 – 60 Ω condition. (However, the service code of boom is weak.
display does not go out.) 3. When traveling uphill in Low
speed, the travel speed becomes
slow.
PC1100-6 20-457
3
User Service
code code
1. Short circuit with ground, short circuit inside straight- travel sole-
Short circuit in noid
— E202 straight-travel 2. Short circuit with ground in wiring harness between controller C01
solenoid system (2) and solenoid V03 (2) ((+) side)
1. Short circuit with ground, short circuit inside heavy lift solenoid
Short circuit in 2. Short circuit with ground in wiring harness between controller C01
— E204 2-stage relief (10) and solenoid V02 (2) ((+) side)
solenoid system 3. Defective pump controller
1. Short circuit with ground, short circuit inside swing priority sole-
Short circuit in noid
— E205 swing priority 2. Short circuit with ground in wiring harness between controller C01
solenoid system (5) and solenoid V01 (2) ((+) side)
1. Short circuit with ground, short circuit inside travel speed solenoid
Short circuit in
— E206 (9) and solenoid V06 (2) ((+) side)
travel speed
solenoid system
1. Disconnection, defective contact inside CO cancel solenoid

wiring harness between controller C01 (8) and solenoid V07 (2) ((+)
side)
Disconnection in CO 3. Disconnection, defective contact in wiring harness between sole-
— E211 cancel solenoid noid V07 (1) and chassis ground ((–) side)
system 4. Defective pump controller
1. Disconnection, defective contact inside travel straight solenoid

Disconnection in wiring harness between controller C01 (2) and solenoid V03 (2) ((+)
— E212 travel straight side)
solenoid system 3. Disconnection, defective contact in wiring harness between sole-
noid V03 (1) and chassis ground ((–) side)
1. Disconnection, defective contact inside heavy lift solenoid

Disconnection in wiring harness between controller C01 (10) and solenoid V02 (2)
— E214 2-stage relief ((+) side)
noid V02 (1) and chassis ground ((–) side)
20-458 PC1100-6
3
1. Makes output to solenoid 0. 1. When travel is operated at same
fl If the abnormality is restored by the time as work equipment or
· Resistance of solenoid: vibration of the machine, it resets the swing, travel deviation occurs.
20 – 60 Ω power source to restore to the proper
1. Makes output to solenoid 0. 1. In heavy lift mode, lifting force

fl If the abnormality is restored by the of boom is weak.
· Resistance of solenoid: vibration of the machine, it resets the 2. Drawbar pull is weak.
1. Makes output to solenoid 0. 1. When swing + boom RAISE is

fl If the abnormality is restored by the operated at same time in boom
· Resistance of solenoid: vibration of the machine, it resets the priority mode, boom rises too
20 – 60 Ω power source to restore to the proper far.
1. Makes output to solenoid 0. 1. Travel speed does not switch to

fl If the abnormality is restored by the Hi.
· Resistance of solenoid: vibration of the machine, it resets the
1. The current stops flowing to the sole- 1. In heavy lift mode, boom RAISE
noid, so no particular action is taken. speed becomes slower when
fl If the abnormality is restored by the load becomes larger.
vibration of the machine, it resets the 2. In heavy lift mode, lifting force
· Resistance of solenoid: power source to restore to the proper of boom is weak.
20 – 60 Ω condition. (However, the service code 3. Travel speed becomes slow
display does not go out.) when traveling uphill in Low
travel speed range.
4. When there is short circuit with
power source, solenoid remains
actuated.
1. The current stops flowing to the sole- 1. When travel is operated at same
noid, so no particular action is taken. time as work equipment or
· Resistance of solenoid: fl If the abnormality is restored by the swing, travel deviation occurs.
20 – 60 Ω vibration of the machine, it resets the 2. When there is short circuit with
power source to restore to the proper power source, solenoid remains
condition. (However, the service code actuated.
1. The current stops flowing to the sole- 1. In heavy lift mode, lifting force
noid, so no particular action is taken. of boom is weak.
· Resistance of solenoid: fl If the abnormality is restored by the 2. Drawbar pull is weak.
20 – 60 Ω vibration of the machine, it resets the 3. When there is short circuit with
power source to restore to the proper power source, solenoid remains
condition. (However, the service code actuated.
PC1100-6 20-459
3
User Service
code code
1. Disconnection, defective contact inside swing priority solenoid
— E215 swing priority side)
noid V01 (1) and chassis ground (–) side)
1. Disconnection, defective contact inside travel speed solenoid

— E208 travel speed side)
noid V06 (1) and chassis ground (–) side)
1. Disconnection, defective contact, short circuit with ground in model

selection wiring harness (C17(5)(6)(13)(14))
— E216 Model selection 2. Defective pump controller
input error
1. Disconnection, defective contact, short circuit with ground inside

engine speed sensor
Abnormality in 2. Disconnection, defective contact, short circuit with ground in wiring
— E227 engine speed harness between controller C16 (2) and controller E07 (1) (SIG
sensor (2) system side) or between C16 (1) and E07 (2) ((–) side)
1. Disconnection, defective contact, short circuit with ground in wiring

Abnormality in harness between pump controller C01 (4) and engine controller
— E228 auto-deceleration E17 (12)
output system 2. Defective pump controller
Abnormality in auto
— E313 greasing controller
system
20-460 PC1100-6
3
1. The current stops flowing to the sole- 1. When swing + boom RAISE is
noid, so no particular action is taken. operated at same time in boom
fl If the abnormality is restored by the priority mode, boom rises too
· Resistance of solenoid: vibration of the machine, it resets the far.
20 – 60 Ω power source to restore to the proper 2. When there is short circuit with
condition. (However, the service code power source, solenoid remains
display does not go out.) actuated.
1. The current stops flowing to the sole- 1. Travel speed does not switch to
noid, so no particular action is taken. Hi.
fl If the abnormality is restored by the 2. When there is short circuit with
· Resistance of solenoid: vibration of the machine, it resets the power source, solenoid remains
20 – 60 Ω power source to restore to the proper actuated.
· Between C17 (female) (5) Detects abnormality in input 1. Speed is slow for all work equip-
and chassis: Max. 1 Ω 1. Retains data when starting switch is ment, swing, and travel, or en-
· Between C17 (female) ON gine stalls.
(6),(13),(14) and chassis: 2. Functions as PC1100 when non-set 2. Work equipment, swing, travel
Min. 1 MΩ conditions are input speeds are all slow, or lacks
power.
· Resistance of sensor: 1. Operates in equivalent to G Mode. 1. Operates in equivalent to G

500 – 1000 Ω Mode, so speed is slightly
· Voltage of sensor: slower.
0.5 – 3.0 V
(Engine started, AC range)
1. Functions with signal from network 1. No abnormality appears.

· Resistance between C01 (S-NET) circuit. (However, if an abnormality oc-
(female) (4) and E17 (fe- curs at the same time in the net-
male) (12): Max. 1 Ω work, the auto-deceleration can-
not be actuated.)
PC1100-6 20-461
3
TROUBLESHOOTING ELECTRICAL CIRCUIT DIAGRAM FOR C MODE SYSTEM
ELECTRICAL CIRCUIT DIAGRAM FOR C MODE SYSTEM
20-462 PC1100-6
3
TROUBLESHOOTING ELECTRICAL CIRCUIT DIAGRAM FOR C MODE SYSTEM
PC1100-6 20-463
3
TROUBLESHOOTING C-1
C-1 Abnormality in controller power source system (controller LED is

OFF)
fl Check that fuse 1 is not blown. (If it is blown, check for a short circuit with the ground in the related
circuits for fuse 1.)
fl When the starting motor starts normally. (If the engine does not start, carry out E-20 first.)
fl Always connect any disconnected connectors before going on to the next step.
Cause Remedy
2 YES Defective pump

controller Replace
YES C02 (female) (11)(21) Defective contact or
and chassis ground disconnection in wiring
1 normal? Repair or
harness between C02
• Turn starting (female) (11)(21) and replace
Is voltage between NO
C01 (7)(13) and switch OFF. chassis ground
chassis ground • Disconnect C02. Defective contact, or
normal? • Max. 1 Ω 3 YES disconnection in wiring Repair or
• Turn starting harness between fuse 1 replace
Is voltage
outlet and C01 (female)
switch ON. between fuse 1 (7)(13)
• 20 – 30V NO outlet and
chassis normal? Defective contact, or
• Turn starting NO harness between battery replace
switch ON. relay terminal M and
• 20 – 30V fuse 1 inlet
C-1 Related electrical circuit diagram
PC1100-6 20-465
3
TROUBLESHOOTING C-2
C-2 [E232] Short circuit in TVC solenoid system is displayed

tor to its original position, if an E service code is not displayed, the problem has been removed.
fl If the starting switch is turned OFF after an abnormality occurs, turn the starting switch ON and
check if an E service code is displayed. (If it is not displayed, the problem has been removed.)
fl Carry out troubleshooting with the TVC prolix switch OFF.
Cause Remedy
YES Defective pump

Replace
3 controller
When C13 is
YES disconnected, is
voltage between
C02 (female) (18)
4 YES
Go to A
and chassis normal? Is resistance
• Disconnect C02 between C05
and C13. NO (male) (2) and (4)
2 • Turn starting normal? Defective TVC prolix Replace
When C13 is disconnected, switch ON. switch
is resistance and voltage • Turn starting NO
YES • Max. 1 V
between C02 (female) (8) switch OFF.
and chassis ground as • Disconnect C05. Short circuit with ground
shown in Table 2? • Max. 1 Ω or short circuit with power
6 YES Repair or
• Disconnect C02 When C05 is disconnected, replace
between C05 (female)(3)
and C13. YES is resistance and voltage
and C13 (female) (1)
1 • Turn starting between C02 (female) (8)
5 and chassis ground as Short circuit with ground
Is resistance switch ON. Is resistance shown in Table 2? or short circuit with power Repair or
between C13 (male) between C05 (male)
(1) and (2), (1) and (1) and (3), (1)(3) and
• Disconnect C02 NO source in wiring harness replace
and C05. between C02 (female)(8)
chassis ground as NO chassis ground as
shown in Table 1? • Turn starting and C05 (male) (1)
shown in Table 3?
• Turn starting • Turn starting switch ON. Defective TVC prolix
Replace
switch OFF. switch OFF. NO switch
• Disconnect C13. • Disconnect C05.
Defective TVC solenoid
(internal short circuit Replace
NO with ground)

1 YES source in wiring harness Repair or
When C05 is between C05 (female)(4) replace
disconnected, is and C13 (female)(2)
A voltage between C02 Short circuit with power
(female) (18) and
chassis normal1? Repair or
between C02
• Disconnect C02 NO replace
(female)(18) and C05
and C05. (female)(2)
• Turn starting
switch ON.
• Max. 1 V
Table 1 Table 2
Between C13 (male) (1) – (2) 10 – 22 Ω Resistance Voltage
Between C13 (male) (1) – chassis Min. 1 MΩ Between C02 (female) (8) – chassis Min. 1 MΩ Max. 1 V
Table 3
Between C05 (male) (1) – (3) Max. 1 Ω
Between C05 (male) (1)(3) – chassis Min. 1 MΩ
20-466 PC1100-6
3
TROUBLESHOOTING C-2
PC1100-6 20-467
3
TROUBLESHOOTING C-3
C-3 [E233] Disconnection in TVC solenoid system is displayed

fl Carry out troubleshooting with the TVC prolix switch OFF.
Cause Remedy
YES Defective pump

Replace
3 controller
Is voltage
YES between C02 (18)
and chassis 4 YES
ground normal? Is resistance Go to A
between C05 (male)
• Turn starting (2) and (4), (2)(4)
switch ON. NO and chassis as
2 • 0.8 – 1.0 V. Defective TVC prolix
shown in Table 2? Replace
Is voltage between • Turn starting NO switch
YES C13 (female) (1)
switch OFF.
and chassis Defective contact or
• Disconnect C05.
ground normal? disconnection in wiring
6 YES harness between C05 Repair or
• Disconnect C13. Is voltage between (female) (3) and C13 replace
• Turn starting YES C05 (female) (1) and (female) (1)
1 switch ON. 5 chassis ground
• 20 – 30 V normal ? Defective contact or
Is resistance Repair or
Is resistance disconnection in wiring
between C13 (male)
between C05 • Disconnect C05. NO harness between C02 replace
(1) and (2), (2) and
chassis ground as NO (male) (1) and (3) • Turn starting (female) (8) and C05
shown in Table 1? normal? switch ON. (male) (1)
• Turn starting • Turn starting • 20 – 30 V Defective TVC prolix
switch OFF. Replace
switch OFF. NO switch
• Disconnect C13. • Disconnect C05
• Max. 1 Ω
Defective TVC solenoid
(internal disconnection Replace
NO or defective contact)
Disconnection, defective
contact, short circuit with
7 YES ground in wiring harness Repair or
Is voltage between C05 (female) (4) replace
between C05 (4) and C13 (female) (2)
A
and chassis
ground normal? Disconnection, defective
contact, short circuit with Repair or
• Turn starting NO ground in wiring harness replace
switch ON. between C02 (female)
• 0.8 – 1.0 V (18) and C05 (male) (2)
Table 1 Table 2
Between C13 (male) (1) – (2) 10 – 22 Ω Between C05 (male) (2) – (4) Max. 1 Ω
Between C13 (male) (2) – chassis Min. 1 MΩ Between C05 (male) (2)(4) – chassis Min. 1 MΩ
20-468 PC1100-6
3
TROUBLESHOOTING C-3
PC1100-6 20-469
3
TROUBLESHOOTING C-4
C-4 [E203] Short circuit in swing holding brake solenoid relay system
is displayed
fl When carrying out troubleshooting, always turn the swing lock switch and the swing prolix switch
OFF.
Cause Remedy
YES Defective pump Replace

controller
2
Short circuit with ground
Is voltage
4 YES in wiring harness Repair or
YES between R20 (1) between X05 (male) (4)
Is resistance replace
and chassis between X05 and R20 (female) (1)
ground normal? YES
(female) (3) and
3 chassis ground
• Start engine. Is resistance in wiring harness between Repair or
1 normal?
• Operate swing between X05 C01 (female) (3) and X05 replace
Interchange relay lever. • Turn starting NO
(female) (3)(4) and (male) (3) or between X05
R20 with other • 20 – 30 V NO chassis ground switch OFF. (male) (3) and SW1 (1)
relay. Is [E203] normal? • Disconnect X05.
displayed? • Min. 1 MΩ Defective swing lock
• Turn starting switch (internal short Replace
• Start engine. switch OFF. NO circuit with ground)
• Operate swing • Disconnect X05.
lever. • Min. 1 MΩ Defective swing holding
brake relay (internal
Replace
NO short circuit or short
circuit with ground)
20-470 PC1100-6
3
TROUBLESHOOTING C-4
PC1100-6 20-471
3
TROUBLESHOOTING C-5
C-5 [E213] Disconnection in swing holding brake solenoid relay system

is displayed
fl When carrying out troubleshooting, always turn the swing lock prolix switch OFF.
a) When [E213] is displayed with swing lock switch OFF

Cause Remedy
fl Carry out troubleshooting with the swing lock switch OFF.

controller Replace
Is resistance
YES between R20
(female) (2) and Defective contact or
chassis ground disconnection in wiring
normal? harness between R20 Repair or
• Turn starting NO (female) (2) and chassis replace
2 ground
Is voltage switch OFF.
• Disconnect R20. Disconnection, defective
YES between R20 (1)
and chassis • Min. 1 MΩ 5 YES contact, short circuit with Repair or
power source in wiring
ground normal? harness between X05 (male)
replace
YES Is there continuity (4) and R20 (female) (1)
• Start engine. between X05
1 4 (male) (3) and (4)? Defective swing lock
• Operate swing
When C01 is switch (internal
Interchange relay lever. disconnected, is Replace
R20 with other • 20 – 30 V voltage between X05
• Disconnect X05. NO disconnection or
• Turn starting switch defective contact)
relay. Is [E213] NO (male) (3) and chassis
OFF.
ground norma? Disconnection, defective
displayed? • Turn swing lock contact, short circuit with
• Disconnect C01 switch OFF. Repair or
• Turn starting power source in wiring
and X05. NO harness between C01 replace
switch ON.
• Turn starting (female) (3) – D26 – X05
switch ON. (male) (3)
• Max. 1 V Defective swing holding
brake relay (internal Replace
NO
disconnection or
defective contact)
b) When [E213] is displayed with swing lock switch at LOCK Cause Remedy
fl Carry out troubleshooting with the swing lock switch at LOCK.
YES Defective pump

Replace
controller
1 Defective contact or
Is resistance between disconnection in wiring Repair or
3 YES harness between C17
C17 (female) (16) and replace
chassis ground Is resistance (female) (16) and X05
normal? YES between X05 (male) (male) (1)
2 (2) and chassis
• Turn starting ground normal? Defective contact or
Is there continuity disconnection in wiring Repair or
switch OFF.
between X05 • Turn starting NO harness between X05 replace
• Disconnect C17.
• Max. 1 Ω NO (female) (1) and switch OFF. (male) (2) and chassis
(2)? • Disconnect X05. ground
• Turn starting • Max. 1 Ω Defective swing lock
switch (internal Replace
switch OFF. NO
• Disconnect X05. disconnection or
defective contact)
20-472 PC1100-6
3
TROUBLESHOOTING C-5
PC1100-6 20-473
3
TROUBLESHOOTING C-6
C-6 [E201] Short circuit in CO cancel solenoid system is displayed

Cause Remedy

Replace
Is residence controller
YES between C01
(female) (8) and
Is resistance between normal? in wiring harness Repair or
YES V07 (male) (1) and • Turn starting NO between C01 (female) (8) replace
(2), (2) and chassis as switch OFF. and V07 (female) (2)
1 shown in table? • Disconnect C01.
Interchange V07 • 20 – 60 Ω
• Turn starting
with other
switch OFF. NO
solenoid. Is [E201]
• Disconnect V07.
dislayed?
Defective CO cancel
• Start engine. solenoid (internal short Replace
• Turn heavy lift circuit or short circuit
switch ON.
NO
with ground)
• Operate boom
RAISE.
Table
Between V07 (male) (1) – (2) 20 – 60 Ω
Between V07 (male) (2) – chassis Min. 1 MΩ
20-474 PC1100-6
3
TROUBLESHOOTING C-7
C-7 [E211] Disconnection in CO cancel solenoid system is displayed

Cause Remedy

controller Replace
Is voltage between
and chassis Short circuit with power
3 ground normal? source in wiring harness Repair or
Is resistance • Disconnect C01. between C01 (female) (8) replace
NO
YES between C01 • Turn starting and V07 (female) (2)
switch OFF.
chassis ground
normal? • Max. 1 V 5 YES disconnection in wiring Repair or
harness between C01
2 • Turn starting Is resistance
replace
between V07 (female) (8) and V07
Is resistance switch OFF. (female) (2)
(female) (1) and
YES between V07 • Disconnect C01. NO chassis ground
(male) (1) and (2) • 20 – 60 Ω normal? disconnection in wiring Repair or
normal? • Turn starting NO harness between V07 replace
1
• Turn starting switch OFF. (female) (1) and chassis
Interchange V07 ground
switch OFF. • Disconnect V07.
with other
• Disconnect V07. • Max. 1 Ω
solenoid. Is
• 20 – 60 Ω NO
[E211] displayed?
• Turn starting Defective CO cancel
switch ON. solenoid (internal
• Turn heavy lift disconnection or Replace
switch OFF. NO
defective contact)
PC1100-6 20-475
3
TROUBLESHOOTING C-8
C-8 [E202] Short circuit in straight-travel solenoid system is displayed

Cause Remedy

Replace
YES between C01
(female) (2) and
YES between V03 (male) between C01 (female) (2) replace
(1) and (2), (2) and
switch OFF. and V03 (female) (2)
1 chassis as shown in
table? • Disconnect C01.
with other • Turn starting
solenoid. Is switch OFF. NO
[E202] displayed? • Disconnect V03.
Defective straight-travel
• Start engine. solenoid (internal short
• Operate left and Replace
NO circuit or short circuit
right travel with ground)
levers and work
equipment at
same time.
Table
Between V02 (male) (1) – (2) 20 – 60 Ω
20-476 PC1100-6
3
TROUBLESHOOTING C-9
C-9 [E212] Disconnection in straight-travel solenoid system is displayed

Cause Remedy

Replace
YES C01 (male) (2) and
chassis ground Short circuit with power
3 normal? source in wiring harness
Repair or
Is resistance between C01 (female) (2)
• Disconnect C01. NO replace
between C01 and V03 (female) (2)
YES • Turn starting
switch ON.
chassis ground
normal?
• Max. 1 V 5 YES disconnection in wiring Repair or
harness between C01
2 • Turn starting Is resistance
(female) (2) and V03 replace
Is resistance between V03
(female) (1) and
YES between V03 • Disconnect C01. NO chassis ground
(male) (1) and (2) • 20 – 60 Ω normal? Repair or
1
Interchange V03 • Disconnect V03. ground
switch OFF.
with other • Max. 1 Ω
• Disconnect V03.
solenoid. Is
• 20 – 60 Ω NO
[E212] displayed?
• Turn starting Defective straight-travel
disconnection or Replace
NO
defective contact)
PC1100-6 20-477
3
TROUBLESHOOTING C-10
C-10 [E204] Short circuit in 2-stage relief solenoid system is displayed

Cause Remedy

controller Replace
Is resistance
YES between C01
(female) (10) and
YES between V02 (male) between C01 (female) replace
(1) and (2), (2) and (10) and V02 (female) (2)
chassis as shown in switch OFF.
1
Defective 2-stage relief
• Turn heavy lift Replace
switch ON. with ground)
• Operate boom
RAISE.
Table
Between V02 (male) (1) – (2) 20 – 60 Ω
20-478 PC1100-6
3
C-11 [E214] Disconnection in 2-stage relief solenoid system is displayed

Cause Remedy

controller
Is voltage between
ground normal? source in wiring harness
3 Repair or
between C01 (female)
Is resistance • Disconnect C01. NO (10) and V02 (female) (2) replace
YES between C01
• Turn starting
chassis ground
switch ON.
normal? • Max. 1 V 5 YES Repair or
harness between C01
2 • Turn starting Is resistance (female) (10) and V02 replace
between V02 (female) (2)
Is resistance switch OFF.
(female) (1) and
YES between V02 • Disconnect C01. NO chassis ground Defective contact or
1
switch OFF.
• Disconnect V02.
solenoid. Is
• 20 – 60 Ω NO
[E214] displayed?
• Turn starting
Defective 2-stage relief
switch ON.
solenoid (internal
NO
defective contact)
PC1100-6 20-479
3
C-12 [E205] Short circuit in swing priority solenoid system is displayed

Cause Remedy

Replace
YES between C01
(female) (5) and
(1) and (2), (2) and
Defective swing priority
• Turn swing Replace
priority mode with ground)
switch ON.
• Operate swing.
Table
Between V01 (male) (1) – (2) 20 – 60 Ω
20-480 PC1100-6
3
C-13 [E215] Disconnection in swing priority solenoid system is

displayed
Cause Remedy

ground normal? source in wiring harness
3 Repair or
between C01 (female) (5)
Is resistance • Disconnect C01. NO and V01 (female) (2) replace
between C01
YES • Turn starting
chassis ground
switch ON.
harness between C01
between V01 (female) (2)
Is resistance switch OFF.
(female) (1) and
1 (female) (1) and chassis
• Turn starting switch OFF.
switch OFF.
• Disconnect V01.
solenoid. Is
• 20 – 60 Ω NO
[E215] displayed?
• Turn starting
Defective swing priority
switch ON.
solenoid (internal
NO
defective contact)
PC1100-6 20-481
3
C-14 [E206] Short circuit in travel speed solenoid system is displayed

Cause Remedy

Replace
YES between C01
(female) (9) and
(1) and (2), (2) and
Defective travel speed
• Set travel speed Replace
switch to Hi. with ground)
• Operate travel
lever.
Table
Between V06 (male) (1) – (2) 20 – 60 Ω
20-482 PC1100-6
3
C-15 [E216] Disconnection in travel speed solenoid system is displayed

Cause Remedy

controller
Is voltage between
3 ground normal? source in wiring harness
Repair or
between C01 (female) (9)
Is resistance • Disconnect C01. NO and V06 (female) (2) replace
YES between C01 • Turn starting
switch ON.
chassis ground disconnection in wiring
harness between C01
between V06
Is resistance switch OFF. (female) (2)
(female) (1) and
1
switch OFF.
• Disconnect V06.
solenoid. Is
• 20 – 60 Ω NO
[E216] displayed?
• Turn starting Defective travel speed
NO
defective contact)
PC1100-6 20-483
3
C-16 [E217] Model selection input error is displayed

Cause Remedy
YES Defective pump

controller Replace
1
Is display for
monitoring codes
YES
[02][22] as shown
in Table 1? 2 Defective contact,
Is voltage between disconnection, short
• Turn starting C17 (5)(6)(13)(14) circuit with ground, or
switch ON. and chassis ground short circuit in wiring
NO as shown in Table
3 YES Repair or
Is resistance harness in circuit where replace
2? voltage is defective in
between C09
• Turn starting (female) (8) and Item 2.
switch ON NO (1)(2)(3)(4) as shown Defective model
in Table 3? selection connector Replace
• Turn starting NO (internal disconnection,
switch OFF. defective contact, short
• Disconnect C09. circuit)

22 input condition
Table 2
C17 Between (5) – chassis Between (6) – chassis Between (13) – chassis Between (14) – chassis
Voltage Max. 1 V 20 – 30 V 20 – 30 V 20 – 30 V
Table 3
C09 (female) Between (8) – (1) Between (8) – (2) Between (8) – (3) Between (8) – (3)
Resistance Max. 1 Ω Min. 1 MΩ Max. 1 Ω Min. 1 MΩ
20-484 PC1100-6
3
PC1100-6 20-485
3
C-17 [E227] Abnormality in engine speed sensor (2) system is

displayed
Cause Remedy

controller Replace
Is resistance
YES between C16
2 chassis ground disconnection in wiring
Is resistance normal? harness between C16 Repair or
YES between C16 • Turn starting NO (female) (1) and chassis replace
(female) (2) and
switch OFF. ground
1 chassis ground as
Is resistance shown in table? • Disconnect C16. Disconnection, defective
between E07 (male) • Turn starting • Max. 1 Ω contact, short circuit with Repair or
(1) and (2), (1)(2) switch OFF. NO ground in wiring harness replace
and chassis ground • Disconnect C16. between C16 (female) (2)
as shown in table? • 500 – 1000 Ω and E07 (female) (1)
• Turn starting Defective engine speed
switch OFF. sensor (2) (internal Replace
NO
• Disconnect E07. disconnection, defective
contact, short circuit)
Table
E07 (male) Resistance
Between (1) – (2) 500 – 1000 Ω
20-486 PC1100-6
3
C-18 [E228] Abnormality in auto-deceleration output system is

displayed
Cause Remedy
YES Defective pump Replace

controller
1
Is voltage 3 YES Defective engine
between C01 (4) controller Replace
Is resistance
and chassis between C01
YES
ground normal? (female) (4) and E17 Defective contact or
2 (female) (12)
• Turn starting disconnection in wiring
Is resistance normal?
switch ON. harness between C01 Repair or
between C01
(female) (4) and
• Turn starting NO (female) (4) and E17 replace
• Turn auto-
NO chassis ground switch OFF. (female) (12)
deceleration
normal? • Disconnect C01 and E17.
switch OFF. Short circuit with ground
• Max. 1 Ω
• Min. 5 V • Turn starting in wiring harness Replace
switch OFF. NO between C01 (female) (4)
• Disconnect C01 and E17 (female) (12)
and E17.
• Min. 1 MΩ
PC1100-6 20-487
3
TROUBLESHOOTING C19
C-19 Abnormality in swing holding brake system (no service code is

displayed)
fl Even if an abnormality occurs in the swing holding brake system, the service code is not displayed
on the monitor panel.
a) When swing holding brake is not actuated (short circuit)
Cause Remedy
YES Defective swing holding

brake relay (internal Replace
1
short circuit or short
Interchange R20
with other relay. Short circuit with power
Does condition 2 YES source in wiring harness
Repair or
become normal? Interchange swing
between R20 (female) (5)
replace
holding brake solenoid – V04 (female) (2) and
• Start engine. with other solenoid. V11 (female) (2)
NO Does condition become
Defective swing holding
normal? Repair or
brake solenoid (spool
• Start engine. NO stuck) replace
b) When swing holding brake cannot be released (disconnection)

Cause Remedy
Defective swing holding

YES brake relay (internal
Replace
disconnection or defective
contact)
Interchange R20 disconnection in wiring
4 YES harness between R20 Repair or
YES with other relay. Is resistance (female) (5) – V04 (female) replace
Does condition
become normal? YES between V04 and (2) or V11 (female) (2)
V11 (female) (1) and
3 chassis ground
• Start engine. disconnection in wiring Repair or
1 Is voltage normal?
harness between V04 replace
Is resistance between R20 (3) • Turn starting switch NO (female) (1) or V11 (female)
between V04 and OFF.
NO and chassis • Disconnect V04 and
(1) – chassis ground
V11 (male) (1) – (2), ground normal?
(2) – chassis ground V11. Disconnection, defective
as shown in table? • Turn starting • Max. 1 Ω contact, short circuit with Repair or
• Turn starting switch ON. NO ground in wiring harness replace
switch OFF. • 20 – 30 V between fuse 2 outlet and
R20 (female) (3)
• Disconnect V04
and V11. Defective swing holding
Repair or
brake solenoid (internal
NO disconnection, defective replace
contact, internal short circuit,
or short circuit with ground)
Table
Between V04, V11 (male) (1) – (2) 20 – 60 Ω
Between V04, V11 (male) (2) – chassis ground Min. 1 MΩ
20-488 PC1100-6
3
TROUBLESHOOTING C19
PC1100-6 20-489
3
C-20 Abnormality in machine push-up solenoid system (no service

code is displayed)
fl Even if an abnormality occurs in the machine push-up solenoid system, the service code is not
displayed on the monitor panel.
a) When machine push-up switch is set to low-pressure setting, system does not switch to low-
pressure setting (disconnection)
fl Carry out troubleshooting with the machine push-up switch at the low-pressure setting position.
Cause Remedy
YES Repair or
harness between V05
ground
2
Is voltage
4 YES contact, short circuit with Repair or
YES between V05 (2) ground in wiring harness replace
and chassis Is resistance between M38 (male) (1) and
ground normal? YES
between M38 (1) V05 (female) (2)
3 and (2) normal?
• Disconnect V05. Defective machine push-
1 Is voltage Repair or
• Turn starting
Is resistance switch ON. between M38 (2) • Turn starting switch NO up switch replace
and chassis OFF.
between V05 • 20 – 30 V NO
ground normal? • Disconnect M38. Disconnection, defective
(male) (1) and (2) • Set to low pressure.
normal? contact, short circuit with
• Disconnect M38. • Max. 1 Ω Repair or
ground in wiring harness
• Turn starting • Turn starting NO replace
between fuse 2 and M38
switch OFF. switch ON. (male) (2)
• Disconnect V05. • 20 – 30 V
Defective machine push-
• 20 – 60 Ω up switch (internal Replace
NO disconnection, defective
contact, or short circuit
with ground)
b) When machine push-up switch is set to high-pressure setting, system does not switch to high-
pressure setting (short circuit)
fl Carry out troubleshooting with the machine push-up switch at the high-pressure setting position.
Cause Remedy

1 YES source in wiring harness Repair or
Is resistance between M38 (male) (1) replace
between M38 and V05 (female) (2)
(female) (1) and
Defective machine push-
(2) normal?
up switch (internal short Replace
• Turn starting NO circuit)
switch OFF.
• Disconnect M38.
• Set to high
pressure.
• Min. 1 MΩ
20-490 PC1100-6
3
PC1100-6 20-491
3
C-21 Abnormality in boom shockless solenoid system (no service code

is displayed)
fl Even if an abnormality occurs in the boom shockless solenoid system, the service code is not
displayed on the monitor panel.
a) When boom shockless switch is turned OFF, shockless mode is not canceled (disconnection)
fl Carry out troubleshooting with the boom shockless switch OFF.
YES
2 YES
Interchange R15
YES with other relay.
Does condition
become normal? YES
• Start engine.
3 6
Is voltage
Is voltage between
V09, V10 (2) and YES between R15 (1)
and chassis
NO chassis ground ground normal?
normal?
• Turn starting
• Disconnect V09 5 switch ON.
1 and V10. Is resistance • 20 – 30 V
• Turn starting
Is resistance
switch ON.
YES between R15 NO
(female) (2) and
between V09,
• 20 – 30 V chassis ground
V10 (male) (1) normal?
and (2) normal? 4 • Turn starting
• Turn starting Is voltage switch OFF.
switch OFF. between R15 (3) • Disconnect R15.
• Disconnect V09 NO and chassis • Max. 1 Ω
and V10. ground normal?
NO
• 20 – 60 Ω • Turn starting
switch ON.
• 20 – 30 V
NO
NO
20-492 PC1100-6
3
Cause Remedy
Defective boom
shockless relay (internal
defective contact)
Repair or
harness between V09
(female) (1) and V10 (female) replace
(1) – chassis ground
harness between R15 replace
(female) (5) – V09 (female)
(2) and V10 (female) (2)
8 YES contact, short circuit with Repair or
Is resistance ground in wiring harness replace
between M33 (female) (3)
YES between M33 and R15 (female) (1)
7 (female) (1) and
Defective boom shockless
Is voltage between
(3) normal? switch (internal
disconnection or defective
Replace
M33 (female) (1) • Turn starting NO
and chassis switch OFF. contact)
ground normal? • Disconnect M33. Disconnection, defective
• Turn boom shockless switch OFF. contact, short circuit with
• Disconnect M33. • Max. 1 Ω ground in wiring harness Repair or
• Turn starting NO between fuse 2 outlet and replace
switch ON. M33 (female) (1)
• 20 – 30 V Defective contact or
harness between R15 Repair or
ground
contact, short circuit with Repair or
ground in wiring harness replace
between fuse 2 outlet and
R15 (female) (3)
Defective boom shockless
solenoid at side where Replace
resistance is defective
(internal disconnection or
defective contact)
PC1100-6 20-493
3
b) When boom shockless switch is turned ON, shockless mode is not actuated (short circuit)
fl Carry out troubleshooting with the boom shockless switch ON.
Cause Remedy
Defective boom
YES shockless relay (internal Replace
1 short circuit)
Interchange R15 Short ciruit with power
with other relay. source in wiring harness
YES between R15 (female) (5) Repair or
Does condition
become normal? 2 – V09 (female) (2) or V10 replace
Is voltage (female) (2)
• Start engine. between R15 (1) Short ciruit with power
NO and chassis 3 YES source in wiring harness Repair or
ground normal? between M33 (female)
(3) and R15 (female) (1)
• Turn starting between M33 (1)
switch ON. NO and (3) normal?
Defective boom
• Max.1 V
shockless switch Replace
• Turn starting NO (internal short circuit)
switch OFF.
• Disconnect M33.
• Min. 1 MΩ
20-494 PC1100-6
3
TROUBLESHOOTING OF PUMP CONTROLLER
INPUT SIGNAL SYSTEM
(F MODE)
Electrical circuit diagram of F mode ....................................................................................................20-502

F- 1 [Bit pattern 20-(1)] (Swing to right oil pressure switch) does not light up ........................... 20-504
F- 2 [Bit pattern 20-(2)] (R.H. travel oil pressure switch) does not light up .................................20-505
F- 3 [Bit pattern 20-(3)] (Boom LOWER oil pressure switch) does not light up ........................... 20-506
F- 4 [Bit pattern 20-(4)] (Boom RAISE oil pressure switch) does not light up .............................20-507
F- 5 [Bit pattern 20-(5)] (Arm IN oil pressure switch) does not light up .......................................20-508
F- 6 [Bit pattern 20-(6)] (Arm OUT oil pressure switch) does not light up ...................................20-509
F- 7 [Bit pattern 21-(1)] (Bucket CURL oil pressure switch) does not light up .............................20-510
F- 8 [Bit pattern 21-(2)] (Bucket DUMP oil pressure switch) does not light up ............................ 20-511
F- 9 [Bit pattern 21-(5)] (L.H. travel oil pressure switch) does not light up .................................. 20-512
F-10 [Bit pattern 26-(5)] (Swing to left oil pressure switch) does not light up .............................20-513
F-11 [Bit pattern 21-(3)] (Swing lock switch) does not light up ......................................................20-514
PC1100-6 20-501
3
TROUBLESHOOTING ELECTRICAL CIRCUIT DIAGRAM OF F MODE
ELECTRICAL CIRCUIT DIAGRAM OF F MODE
20-502 PC1100-6
3
TROUBLESHOOTING ELECTRICAL CIRCUIT DIAGRAM OF F MODE
PC1100-6 20-503
3
TROUBLESHOOTING F-1
F-1 [Bit pattern 20-(1)] (Swing to right oil pressure switch) does not
light up
tor to its original position, if the monitoring mode display returns to normal, the problem has
been removed.
¤ When operating the swing with the engine started, set the swing lock switch to LOCK.
(When operating the swing with the engine stopped, charge the accumulator first.)
Cause Remedy
Defective pump
YES controller Replace
1
Is voltage Repair or
3 YES ground in wiring harness
between C16 (5) replace
and chassis and S08 (female) (2)
ground normal? YES between S08
(female) (1) and
chassis ground
• Start engine. Is resistance between disconnection in wiring Repair or
normal?
• Swing lever at S08 (male) (1) and (2) harness between S08 replace
neutral: 20 – 30V normal, and is circuit (female) (1) and chassis
NO insulated from switch OFF.
• Swing lever ground
chassis? • Disconnect S08.
operated to right:
• Max. 1 Ω Defective right swing
Max. 1 V • Disconnect S08. Replace
• Start engine. pressure switch (internal
NO
• Swing lever at disconnection, defective
neutral: Min. 1 MΩ contact, short circuit)
• Swing lever
operated to right:
Max. 1 Ω
F-1 Related electrical circuit diagram
20-504 PC1100-6
3
TROUBLESHOOTING F-2
F-2 [Bit pattern 20-(2)] (R.H. travel oil pressure switch) does not light
up
been removed.
¤ When operating the travel with the engine started, check that the area around the machine is safe.
(When operating the travel with the engine stopped, charge the accumulator first.)
Cause Remedy
Defective pump
YES Replace
controller
1 contact, short circuit with
Is voltage 3 YES ground in wiring harness Repair or
between C16 (13) between C16 (female) (13) – replace
Is resistance S01 (female) (2) or S11
and chassis between S01, S11
ground normal? YES (female) (2)
(female) (1) and
2 chassis ground
• Start engine. Is resistance between disconnection in wiring
normal? Repair or
• R.H. travel lever S01, S11 (male) (1) harness between S01
at neutral: and (2) normal, and (female) (1) or S11 (female)
20 – 30V NO is circuit insulated switch OFF. (1) – chassis ground
• R.H. travel lever from chassis? • Disconnect S01 and S11. Defective R.H. travel
operated: • Disconnect S01 • Max. 1 Ω FORWARD pressure switch
and S11. or R.H. travel REVERSE Replace
Max. 1 V NO
disconnection, defective
• R.H. travel lever at
neutral: Min. 1 MΩ
• R.H. travel lever
operated: Max. 1 Ω
PC1100-6 20-505
3
TROUBLESHOOTING F-3
F-3 [Bit pattern 20-(3)] (Boom LOWER oil pressure switch) does not
light up
been removed.
¤ When operating the work equipment with the engine started, check that the area around the
machine is safe and move the work equipment only slightly.
(When operating the boom LOWER with the engine stopped, charge the accumulator first.)
Cause Remedy
YES Defective pump

controller Replace
1 Disconnection, defective
Is voltage Repair or
3 YES ground in wiring harness
between C16 (10) between C16 (female) (10) replace
Is resistance
and chassis between S04 and S04 (female) (2)
ground normal? YES
(female) (1) and
2 chassis ground Defective contact or
normal? Repair or
• Boom lever at S04 (male) (1) and (2) harness between S04
neutral: 20 – 30V normal, and is circuit
switch OFF. (female) (1) and chassis
• Boom lever NO insulated from ground
operated to chassis? • Disconnect S04.
LOWER: Max. 1 V • Disconnect S04 . • Max. 1 Ω Defective boom LOWER
pressure switch (internal Replace
• Start engine. NO
• Boom lever at
• Boom lever
operated to
LOWER: Max. 1 Ω
20-506 PC1100-6
3
TROUBLESHOOTING F-4
F-4 [Bit pattern 20-(4)] (Boom RAISE oil pressure switch) does not
light up
been removed.
(When operating the boom RAISE with the engine stopped, charge the accumulator first.)
Cause Remedy
YES Defective pump

controller Replace
Is voltage 3 YES ground in wiring harness Repair or
between C17 (2) Is resistance between C16 (female) (2) replace
ground normal? YES
(female) (1) and
• Start engine. Is resistance between normal? disconnection in wiring Repair or
• Boom lever at S02 (male) (1) and (2)
• Turn starting NO harness between S02 replace
• Boom lever NO insulated from switch OFF.
• Disconnect S02. ground
operated to chassis?
RAISE: Max. 1 V • Disconnect S02 . • Max. 1 Ω Defective boom RAISE
• Start engine. pressure switch (internal Replace
NO
• Boom lever at disconnection, defective
• Boom lever
operated to RAISE:
Max. 1 Ω
PC1100-6 20-507
3
TROUBLESHOOTING F-5
F-5 [Bit pattern 20-(5)] (Arm IN oil pressure switch) does not light up
been removed.
¤When operating the work equipment with the engine started, check that the area around the
Cause Remedy
YES Defective pump

controller Replace
Is voltage 3 YES Repair or
ground in wiring harness
ground normal? YES
(female) (1) and
• Arm lever at S05 (male) (1) and (2) harness between S05
• Arm lever NO insulated from switch OFF.
ground
operated to IN: chassis? • Disconnect S05.
Max. 1 V • Disconnect S05 . • Max. 1 Ω Defective arm IN pressure
switch (internal Replace
• Arm lever at disconnection, defective
• Arm lever
operated to IN:
Max. 1 Ω
20-508 PC1100-6
3
TROUBLESHOOTING F-6
F-6 [Bit pattern 20-(6)] (Arm OUT oil pressure switch) does not light
up
been removed.
Cause Remedy
YES Defective pump

controller Replace
Is voltage contact, short circuit with
and chassis between S03
ground normal? YES and S03 (female) (2)
(female) (1) and
• Arm lever at S03 (male) (1) and (2)
NO switch OFF. (female) (1) and chassis
• Arm lever insulated from
operated to OUT: chassis?
Max. 1 V • Disconnect S03 . • Max. 1 Ω Defective arm OUT
• Arm lever at disconnection, defective
• Arm lever
operated to OUT:
Max. 1 Ω
PC1100-6 20-509
3
TROUBLESHOOTING F-7
F-7 [Bit pattern 21-(1)] (Bucket CURL oil pressure switch) does not
light up
been removed.
Cause Remedy
YES Defective pump

controller Replace
ground normal? YES and S06 (female) (2)
(female) (1) and
• Bucket lever at S06 (male) (1) and (2)
NO insulated from switch OFF. (female) (1) and chassis
• Bucket lever
CURL: Max. 1 V • Disconnect S06 . • Max. 1 Ω Defective bucket CURL
• Bucket lever at disconnection, defective
• Bucket lever
operated to CURL:
Max. 1 Ω
20-510 PC1100-6
3
TROUBLESHOOTING F-8
F-8 [Bit pattern 21-(2)] (Bucket DUMP oil pressure switch) does not
light up
been removed.
fl If service PPC pressure switch is equipped, check the circuit at the same time.
Cause Remedy
YES Defective pump

controller Replace
between C16 (12)
Is resistance between C16 (female) (12) replace
YES and S06 (female) (2)
ground normal? (female) (1) and
• Bucket lever at S07 (male) (1) and (2)
• Bucket lever NO insulated from switch OFF.
DUMP: Max. 1 V • Disconnect S07 . • Max. 1 Ω Defective bucket DUMP
pressure switch (internal
Replace
• Bucket lever at disconnection, defective
neutral:Min. 1 MΩ contact, short circuit)
• Bucket lever
operated to
DUMP: Max. 1 Ω
PC1100-6 20-511
3
TROUBLESHOOTING F-9
F-9 [Bit pattern 21-(5)] (L.H. travel oil pressure switch) does not light
up
been removed.
¤When operating the travel with the engine started, check that the area around the machine is safe.
Cause Remedy
YES Defective pump

controller Replace
1 contact, short circuit with
Is voltage ground in wiring harness
3 YES between C16 (female) (6) – Repair or
between C16 (6) Is resistance replace
S12 (female) (2) or S13
and chassis between S12,S13
YES (female) (2)
ground normal? (female) (1) and
chassis ground
normal? harness between S12 Repair or
• L.H. travel lever S12, S13 (male) (1)
• Turn starting NO (female) (1) or S13 (female) replace
at neutral: and (2) normal, and
20 – 30V NO is circuit insulated switch OFF. (1) and chassis ground
• L.H. travel lever from chassis? • Disconnect S12 and S13. Defective L.H. travel
operated to IN: • Disconnect S12 • Max. 1 Ω FORWARD pressure switch
or L.H. travel REVERSE Replace
Max. 1 V and S13. NO
• L.H. travel lever
at neutral:
Min. 1 MΩ
• L.H. travel lever
operated :
Max. 1 Ω
20-512 PC1100-6
3
TROUBLESHOOTING F-10
F-10 [Bit pattern 26-(5)] (Swing to left oil pressure switch) does not
light up
been removed.
¤ When operating the swing with the engine started, set the swing lock switch to LOCK.
Cause Remedy
YES Defective pump

controller Replace
Is voltage 3 YES ground in wiring harness
between C17 (7) Repair or
and chassis and S10 (female) (2) replace
YES between S10
ground normal? (female) (1) and Defective contact or
2 chassis ground
normal?
harness between S10 Repair or
• Swing lever at S10 (male) (1) and (2)
• Turn starting NO (female) (1) and chassis replace
NO insulated from switch OFF. ground
• Swing lever
chassis? • Disconnect S10.
operated to left: Defective left swing
• Disconnect S10 . • Max. 1 Ω
Max. 1 V pressure switch (internal Replace
• Start engine. NO disconnection, defective
• Swing lever at contact, short circuit)
neutral:
Min. 1 MΩ
• Swing lever
operated to left:
Max. 1 Ω
PC1100-6 20-513
3
TROUBLESHOOTING F-11
F-11 [Bit pattern 21-(3)] (Swing lock switch) does not light up
been removed.
fl Check that the swing lock lamp display on the monitor panel is normal.
(If the swing lock lamp does not light up, carry out troubleshooting for M-fifi first.)
Cause Remedy
YES Defective pump

controller Replace
Is voltage ground in wiring harness
3 YES Repair or
between C17 (16) between C17 (female) (16)
and chassis and X05 (male) (2)
ground normal? YES between X05
(male) (2) and Defective contact or
2 chassis ground
• Turn starting Is resistance between disconnection in wiring
normal? Repair or
switch ON. X05 (female) (1) and harness between X05
• Swing lock (2) normal, and is
• Turn starting NO (male) (1) and chassis replace
switch ON: NO circuit insulated from switch OFF. ground
Max. 1V chassis? • Disconnect X05
• Turn starting • Max. 1 Ω Defective swing lock
• Swing lock
switch OFF switch (internal Replace
switch OFF: NO
• Disconnect X05. disconnection, defective
20 – 30 V
• Swing lock contact, short circuit)
switch ON:
Max. 1 Ω
• Swing lock
switch OFF:
Min. 1 MΩ
20-514 PC1100-6
3
TROUBLESHOOTING OF HYDRAULIC,
MECHANICAL SYSTEM
(H MODE)
Table of failure modes and causes ......................................................................................................20-552

Before carrying out troubleshooting of hydraulic system (H Mode) ................................................20-554
H- 1 Speeds of all work equipment, swing, travel are slow or lack power .................................. 20-560
H- 2 There is excessive drop in engine speed, or engine stalls .....................................................20-562
H- 3 No work equipment, travel, swing move ..................................................................................20-564
H- 4 Abnormal noise generated (from around pump) .....................................................................20-565
H- 5 Boom is slow or lacks power .....................................................................................................20-566
H- 6 Arm is slow or lacks power ........................................................................................................20-568
H- 7 Bucket is slow or lacks power ....................................................................................................20-568
H- 8 Boom does not move ..................................................................................................................20-569
H- 9 Arm does not move .....................................................................................................................20-569
H-10 Bucket does not move .................................................................................................................20-569
H-11 Excessive hydraulic drift .............................................................................................................20-570
H-12 Excessive time lag .......................................................................................................................20-570
H-13 Boom shockless function is not actuated or cannot be canceled ..........................................20-571
H-14 Machine deviates naturally to one side during travel operations .........................................20-572
H-15 Deviation is excessive when starting ........................................................................................20-574
H-16 Travel deviation is excessive during compound operations ..................................................20-575
H-17 Travel speed is slow or lacks power .........................................................................................20-575
H-18 Travel does not move (one side only) ......................................................................................20-576
H-19 Travel speed does not switch .....................................................................................................20-577
H-20 Does not swing ............................................................................................................................20-578
H-21 Swing speed is slow or swing acceleration is poor ................................................................20-579
H-22 In compound operations with bucket, swing speed is
slow or swing acceleration is poor .....................................................................................20-580
H-23 In compound operations with boom when boom priority is ON,
swing speed is slow or swing acceleration is poor ..........................................................20-580
H-24 Excessive overrun when stopping swing ..................................................................................20-581
H-25 Excessive shock when stopping swing .....................................................................................20-582
H-26 Excessive abnormal noise when stopping swing ....................................................................20-583
H-27 Excessive hydraulic drift of swing .............................................................................................20-583
PC1100-6 20-551
3
TROUBLESHOOTING TABLE OF FAILURE MODES AND CAUSES
TABLE OF FAILURE MODES AND CAUSES

Hydraulic pump Control valve
Parts causing failure
Swing compensation valve

Hydraulic oil tank strainer
Straight-travel valve
Safety-suction valve
Main relief valve
Jet sensor valve

CO · NC valve
Suction valve
Servo valve
TVC valve
Spool
Pump
Valve
Failure mode
‡
All work equipment,
Speeds of all work equipment, swing, travel are slow or lack power
swing, travel
There is excessive drop in engine speed, or engine stalls ‡ ‡

No work equipment, travel, swing move
Abnormal noise generated (from around pump) ‡ ‡
In normal mode ‡ ‡ ‡
Boom is slow or lacks power With heavy lift ON ‡
With machine push-up ON ‡
Work equipment system
Arm is slow or lacks power ‡ ‡ ‡

Bucket is slow or lacks power ‡ ‡ ‡
Boom does not move ‡
Arm does not move ‡
Bucket does not move ‡
Excessive hydraulic drift ‡ ‡ ‡
Boom ‡
Excessive time lag
Arm, bucket ‡
Boom shockless function does not work or cannot be canceled
Machine deviates naturally Deviates in same direction in FORWARD and REVERSE ‡ ‡ ‡ ‡ ‡ ‡ ‡
to one side when traveling Deviates in opposite direction in FORWARD and REVERSE ‡
Only at full stroke ‡ ‡
Travel system
Deviation is excessive
when starting Both during fine control operations and at full stroke ‡ ‡ ‡
Deviation is excessive during compound operations ‡
Travel speed is slow or lacks power
Does not travel Both directions (FORWARD and REVERSE)
(one side only) One direction only (either FORWARD or REVERSE) ‡ ‡
Travel speed does not switch
Both left and right
Does not swing
One direction only ‡
Both left and right
Swing speed is slow or swing acceleration is poor
During compound operations with bucket, swing speed is slow or acceleration is poor ‡
Swing system
During compound operations with boom when swing priority is ON, swing speed is slow or acceleration is poor
Both left and right
Excessive overrun when stopping swing
Both left and right
Excessive shock when stopping swing
One direction only
Both left and right
Excessive abnormal noise when stopping swing
One direction only
Excessive hydraulic drift of swing
20-552 PC1100-6
3
‡
‡
Jet sensor orifice
‡
Boom LOWER regeneration valve
‡
‡
‡
‡ ‡
Hydraulic cylinder
PC1100-6
‡
‡
‡
Center swivel joint
‡
‡
‡
‡
Swing motor proper, internal leakage
‡
Safety valve
‡ ‡
‡ ‡
‡ ‡
‡ ‡
Suction valve
‡
‡
‡
‡
Swing motor
Swing holding brake

TROUBLESHOOTING
‡
Back pressure compensation valve
‡
‡
‡
Travel motor proper, internal leakage
‡
Counterbalance valve
‡
Safety valve
‡
Speed selector servo valve
Travel motor
‡
Parking brake
Pump
pump
Control
‡ ‡
‡ ‡
Relief valve
‡
‡
‡
‡
‡
‡
‡
‡
‡
‡
‡
‡
PPC valve
‡
Boom shockless valve
Swing PPC shuttle valve
‡ ‡
Swing compensation pilot valve
CO cancel
‡ ‡
2-stage relief
‡ ‡
‡
Machine push-up
‡
Boom shockless
‡
Straight-travel
‡
Travel speed
Solenoid valve
‡
‡
‡
‡
Swing holding brake
‡
Swing priority
‡
PTO
‡
‡
‡
‡
Swing machinery
‡
‡
Final drive
‡
‡
Engine
Troubleshooting code
H-9
H-8
H-7
H-6
H-5
H-4
H-3
H-2
H-1
H-27
H-26
H-25
H-24
H-23
H-22
H-21
H-20
H-19
H-18
H-17
H-16
H-15
H-14
H-13
H-12
H-11
H-10
3
TABLE OF FAILURE MODES AND CAUSES
20-553
BEFORE CARRYING OUT TROUBLESHOOTING
TROUBLESHOOTING OF HYDRAULIC SYSTEM (H MODE)
BEFORE CARRYING OUT TROUBLESHOOTING OF HYDRAULIC

SYSTEM (H MODE)
20-554 PC1100-6
3
1. Actuation and combination of hydraulic 2. Judgement procedure if work equipment is

pumps slow and there is travel deviation to the
• Three tandem pumps (total of 6 pumps) left:
are used in the work equipment, travel, • The cause is probably one of the follow-
and swing circuits: No. 1 pump ing:
(HPV95+95), No. 2 pump (HPV95+95), and 1) Defective main relief of L.H. 5-spool
No. 3 pump (HPV160+160) control valve
• The oil from the No. 1 front pump and 2) Defective jet sensor of L.H. 5-spool
No. 2 front pump merges and flows to control valve
the R.H. 4-spool valve; the oil from the 3) Defective CO · NC valve of No. 1 rear
No. 1 rear pump and No. 2 rear pump pump
merges and flows to the L.H. 5-spool 4) Defective servo valve of No. 1 rear
valve; and the oil from the No. 3 front pump
rear pump and No. 3 rear pump merges 5) Defective No. 1 rear pump
and flows to the swing 4-spool valve. 6) Defective servo valve of No. 2 rear
• The TVC control for the No. 1 pump, No. pump
2 pump, and No. 3 pump is all carried 7) Defective No. 2 rear pump
out in the same way by the TVC valve • If the problem occurs, measure the fol-
installed to the No. 1 rear lowing to judge if the related part is de-
• The CO · NC control for the No. 1 front fective.
pump and No. 2 front pump is carried 1) Measure relief pressure to judge
out in the same way by the CO · NC valve main relief valve
installed to the No. 1 front pump and by 2) Measure differential pressure to
the jet sensor installed to the R.H. 4-spool judge jet sensor
control 3) Measure output pressure to judge
• The CO · NC control for the No. 1 rear CO · NC valve
pump and No. 2 rear pump is carried out • As mentioned above, the oil flow in the
in the same way by the CO · NC valve No. 1 pump and No. 2 pump merges, so
installed to the No. 1 rear pump and by to judge if the problem is in the No. 1
the jet sensor installed to the L.H. 5-spool pump servo valve and pump proper or
control in the No. 2 pump servo valve and pump
• The CO · NC control for the No. 3 front proper, interchange the outlet port hoses
rear pump and No. 3 rear pump is car- of the No. 2 pump between the front
ried out in the same way by the CO · NC and rear. It is then possible to judge as
valve installed to the front pump and by follows which pump is defective.
the jet sensor installed to the swing 4- 1) If deviation is to left (no change), No.
spool valve. 1 rear pump is defective
2) If deviation is to right (opposite di-
rection), No. 2 rear pump is defec-
tive
3) If the travel speed becomes slow, the
jet sensor is defective or the CO · NC
valve is defective (if the left and right
relief pressures are normal).
• Next, to judge if the problem is in the
servo valve or the pump proper, remove
the servo valve and test the individual
part, or judge from the stroke of the servo
piston.
fl For the actual procedure for judgement,
follow the “Troubleshooting chart for
judgement when work equipment is slow
and there is travel deviation to the left”.
PC1100-6 20-555
3
3. Judgement procedure if work equipment is

slow and there is travel deviation to the
right:
fl For this problem, use the explanation
given “2. Judgement procedure if work
equipment is slow and there is travel
deviation to the left”, but replace as fol-
lows.
Use R.H. 4-spool control valve instead of
L.H. 5-spool control valve; and use front
pump instead of rear pump.
For all other points, the judgement pro-
cedure is the same.
4. Judgement procedure if work equipment is

slow and swing is also slow (but travel
speed is normal):
• The cause is probably one of the follow-
ing:
1) Defective main relief valve of swing
4-spool control valve
2) Defective jet sensor of swing 4-spool
control valve
3) Defective CO · NC valve of No. 3 pump
4) Defective servo valve of No. 3 front
pump
5) Defective No. 3 front pump
6) Defective servo valve of No. 3 rear
pump
7) Defective No. 3 rear pump
• If the problem occurs, measure the fol-
lowing to judge if the related part is de-
fective.
1) Measure relief pressure to judge
main relief valve
2) Measure differential pressure to
judge jet sensor
3) Measure output pressure to judge
CO · NC valve
• To judge if the problem is in the servo
valve or the pump proper of the No. 3
front pump, or in the servo valve or the
pump proper of the No. 3 rear pump,
remove the servo valve and test the in-
dividual part, or judge from the stroke of
the servo piston.
fl It is impossible to judge if the problem
is in the front pump or the rear pump
while the pumps are mounted on the
machine, so remove the No. 3 pump as-
sembly and test individually.
20-556 PC1100-6
3
Troubleshooting chart for judgement when work

equipment is slow and there is travel deviation
to the left
fl Use this troubleshooting chart to judge if Causes

the location of the problem is in the No. 1 a b c d e f g h i j k l m n
L.H. 5- R.H. 4-
pump system or in the No. 2 pump system. No. 1 pump No. 2 pump spool spool
control control
1. To judge if the servo valve is defective or valve valve
not, remove the servo valve and carry out a Front Rear Front Rear
test on the individual part, or measure the pump pump pump pump
servo piston stroke.

fl Carry out the individual test on the servo
piston at the specified repair shop.
Defective main relief valve
Defective main relief valve

2. If there is a big drop in speed and it seems
Defective CO · NC valve
Defective CO · NC valve
Defective servo valve

that there is an abnormality in the pump,
Defective jet sensor
Defective jet sensor

check the line filter also.
Defective pump
Defective pump
Defective pump
Defective pump
3. If there is only a small drop in speed and the
problem is not corrected by adjusting the
equipment, check the line filter also.
Remedy A A A A A A
No. Troubleshooting X X X X X X X X X X X X X X
1 There is travel deviation to left, and work equipment speed is slow ‡ ‡ ‡ ‡ ‡ ‡ ‡
‡
Travel deviates to left
2 Travel relief pressure of rear pump is low

3 Item 2 is normal, and when No. 2 pump Machine deviates to left (no change) ‡ ‡
4 outlet hoses are interchanged Machine deviates to right (opposite direction) ‡ ‡
5 between front and rear Left and right travel speeds both become slow ‡ ‡
6 In Item 3, No. 1 rear servo valve is normal ‡
7 In Item 4, No. 2 rear servo valve is normal ‡
8 In Item 5, jet sensor differential pressure of L.H. 5-spool control valve is defective ‡
9 Item 6 is normal, but No. 1 rear NC valve output pressure is defective ‡
10 There is travel deviation to right, and work equipment speed is slow ‡ ‡ ‡ ‡ ‡ ‡ ‡
Travel deviates to right
11 Travel relief pressure of front pump is low ‡

12 Item 11 is normal, and when No. 2 pump Machine deviates to right (no change) ‡ ‡
13 outlet hoses are interchanged Machine deviates to left (opposite direction) ‡ ‡
14 between front and rear Left and right travel speeds both become slow ‡ ‡
15 In Item 12, No. 1 front servo valve is normal ‡
16 In Item 13, No. 2 front servo valve is normal ‡
17 In Item 14, jet sensor differential pressure of R.H. 4-spool control valve is defective ‡
18 Item 15 is normal, but No. 1 rear NC valve output pressure is defective ‡
fl Start troubleshooting from the top, and judge that the item with the most ‡ marks is the cause of the failure.
fl Remedy A: Adjust X: Repair or replace
PC1100-6 20-557
3
Interchange method of No. 2 pump outlet hoses between front and rear
Hyrdraulic circuit after interchanging hoses
20-558 PC1100-6
3
TROUBLESHOOTING H-1
H-1 Speeds of all work equipment, swing, travel are slow or lack
power
fl Measure the speeds of the work equipment, travel, and swing, and confirm that they are all slow
(or lack power).
fl Check that no abnormal noise is being generated from the hydraulic pump before carrying out
troubleshooting.
fl Carry out all troubleshooting in the DH mode.
Cause Remedy
YES
See H-14 —
1 YES Defective engine See S Mode

3
Is there travel
deviation? YES Is output
pressure of TVC
4 YES Defective adjustment of Adjust
valve normal?
Does output TVC valve
• Max. 220 mm/
• See Table. pressure become
20 m 2
• Engine at high • Engine at high NO normal when TVC
valve is adjusted?
idling Is control pump idling Defective TVC valve Repair or
relief pressure • See Table. NO replace
NO normal? • Engine at high
idling
• 3.1 +0.4 MPa Internal leakage in
0 YES
equipment in control See Note
{32 +3.5
0
kg/cm2} 5
• Engine at high system
Is control relief
idling pressure normal
when 1 – 5 in
NO diagram are
6 YES Defective adjustment of
Adjust
blocked? Does relief pressure control relief valve
• 3.1 +0.4
MPa
0
become normal
when control relief
{32 +3.5
kg/cm2}
0 NO
valve is adjusted?
• Engine at high
Go to A
idling • 3.1 +0.4 MPa NO
0
{32 +3.5
0
kg/cm2}
• Engine at high
7 YES idling Repair or
Defective control pump
replace
Are metal
A particles found
inside pilot filte?
Defective control relief Repair or
NO valve replace
Table
Measurement conditions TVC valve output pressure
All control levers at neutral Min. 1.8 MPa {Min. 18 kg/cm2}
Heavy lift OFF + boom RAISE relief 1.08 ± 0.2 MPa {11 ± 2 kg/cm2}
Heavy lift ON + boom RAISE relief 0.98 ± 0.2 MPa {10 ± 2 kg/cm2}
Note: Block 1, 4, 6 – C in diagram individually, measure the control relief pressure, decide which
equipment is defective, then repair or replace.
20-560 PC1100-6
3
TROUBLESHOOTING H-1
PC1100-6 20-561
3
TROUBLESHOOTING H-2
H-2 There is excessive drop in engine speed, or engine stalls

YES
2
• Output pressure
Is CO · NC valve becomes normal.
YES output pressure • Condition does not
of No. 1 pump become normal.
normal?
• See Table 2
• Engine at high
idling 3
Does output • Output pressure
pressure become becomes normal.
• Condition also
NO normal when CO
valve is adjusted? becomes normal
• See Table 2
• Engine at high
idling
1
• Output pressure
Is output does not become
pressure of TVC normal.
valve normal? • Condition does not
become normal.
• See Table 1
• Engine at high
idling
• Output pressure
becomes normal.
• Condition does not
become normal.
4
Do output pressure • Output pressure
and condition becomes normal.
become normal • Condition also
NO when TVC valve is becomes normal
adjusted?
• See Table 1
• Engine at high
idling
• Output pressure
does not become
normal.
• Condition does not
become normal.
Table 1
Measurement conditions TVC valve output pressure
All control levers at neutral Min. 1.8 MPa {Min. 18 kg/cm2}
Heavy lift OFF + boom RAISE relief 1.08 ± 0.2 MPa {11 ± 2 kg/cm2}
20-562 PC1100-6
3
TROUBLESHOOTING H-2
Cause Remedy
Defective engine See S Mode
Defective adjustment of
Adjust
CO · NC valv
Defective CO · NC valve Repair or

replace
Defective adjustment of Adjust

TVC valve
Defective TVC valve Repair or

replace
Table 2
Measurement conditions CO · NC valve output pressure
Heavy lift OFF + boom RAISE relief 1.10 +0.20 +2.0 2

–0.58 MPa {11 –5.9 kg/cm }
PC1100-6 20-563
3
TROUBLESHOOTING H-3
H-3 No work equipment, travel, swing move

fl Check that the safety lock valve linkage is normal.
Cause Remedy
Internal leakage in
YES
equipment in control See Note
3 system
Is control relief
YES pressure normal
when 1 – 5 in
diagram are 4 YES Repair or
Defective control pump
blocked? replace
2 Are metal
Does oil come out • 3.1 +0.4
0 MPa particles found
YES when control pump {32 +3.5
0
kg/cm2} NO inside pilot filter?
pressure • Engine at high Defective control relief Repair or
measurement plug idling NO valve replace
1 is removed?
Does oil come out • Crank engine
when main pump with barring
pressure Repair or
device at Defective PTO
measurement plug NO replace
flywheel portion.
is removed?
• Crank engine
with barring Repair or
device at Defective PTO
NO replace
flywheel portion.
Note: Block 1, 4, 6 – C in diagram individually, measure the control relief pressure, decide which
equipment is defective, then repair or replace.
20-564 PC1100-6
3
TROUBLESHOOTING H-4
H-4 Abnormal noise generated (from around pump)
Cause Remedy
YES Clogged hydraulic tank

Clean
strainer
2
YES Is strainer
clogged? YES Tighten
Loose piping clamp
3
Is problem removed
when piping
1 between tank and 4 YES Defective hydraulic Repair or
NO
pump is tightened? pump replace
Is oil level in Are metal wear
hydraulic tank particles found in
normal? NO drained hydraulic Inspect again
oil? Operate for a short time
(depending on
and watch for any
NO change in symptoms changes in
symptoms)
Lack of oil Add oil

NO
PC1100-6 20-565
3
TROUBLESHOOTING H-5
H-5 Boom is slow or lacks power

fl Check that the arm, bucket, travel, and swing speeds are normal, and that there is no deviation
when traveling.
a) In normal mode, boom is slow or lacks power.

fl “Normal mode” means the following conditions: Heavy lift OFF, swing priority OFF, machine
push-up OFF.
Cause Remedy
4 YES Defective boom LOWER Repair or

regeneration valve replace
Does control
YES valve spool move
3 smoothly?
Is swing priority Defective operation of Repair or
YES solenoid valve NO control valve spool replace
outlet pressure
2 normal?
Defective operation of
Is output • See Table. Repair or
YES swing priority solenoid
pressure of PPC • Engine at high NO replace
valve
valve normal? idling
1 • 2.9 +0.6
–0.2 MPa Repair or
{30 +5.5 kg/cm2} Defective PPC valve
–1.5
NO replace
Is hydraulic drift • Engine at high
of boom cylinder idling
normal?
YES Defective hydraulic Repair or
• At rated load: 5 cylinder seal replace
Max. 75 mm/ Does speed of
15 minutes downward
• At no load: movement become
NO faster when boom 6 YES Defective control valve
Max. 45 mm/ Does hydraulic drift safety-suction valve Replace
lever is operated?
15 minutes become normal when
• Engine stopped • See TESTING safety-suction valve is
AND NO interchanged with other
ADJUSTING safety-suction valve?
Defective control valve Replace
• It is also possible • For standard NO
to measure values, see Item 1.
leakage from • See Note
cylinder.
• Max. 28 cc/min
• Engine at high
idling
Table
Measurement conditions Solenoid valve outlet pressure
Swing priority switch OFF 0 MPa {0 kg/cm2}
Swing priority switch ON 2.9 ± 0.6 MPa {30 ± 5.5 kg/cm2}
Note: The set pressure for the boom safety-suction valve is different from the set pressure for the arm
and bucket safety-suction valves, so interchange the valves temporarily for the purpose of
testing. A hose is installed at the head end, so fit a blind plug when disconnecting, and be sure
to replace the valves in their original positions after completion of the troubleshooting.
20-566 PC1100-6
3
TROUBLESHOOTING H-5
b) When heavy lift is ON, boom RAISE speed is slow or lacks power
Cause Remedy
Defective control valve

2 YES Repair or
main relief valve (high-
Is 2-stage relief replace
pressure side)
YES solenoid valve
1 outlet pressure
normal? Defective operation of
Is CO cancel Repair or
solenoid valve • See Table. NO replace
valve
outlet pressure • Engine at high
normal? idling
• See Table. Defective operation of Repair or
• Engine at high NO CO cancel solenoid valve replace
idling
Table
Heavy lift switch OFF 0 MPa {0 kg/cm2}
Heavy lift switch ON + boom RAISE 2.9 ± 0.6 MPa {30 ± 5.5 kg/cm2}
c) When machine push-up is ON, boom LOWER speed is slow or lacks power
Cause Remedy

1 YES boom LOWER safety- Repair or
Is machine push- suction valve (high- replace
up solenoid valve pressure side)
outlet pressure
Repair or
machine push-up
• See Table. NO solenoid valve replace
• Engine at high
idling
Table
Machine push-up switch OFF 2.9 ± 0.6 MPa {30 ± 5.5 kg/cm2}
Machine push-up switch ON 0 MPa {0 kg/cm2}
PC1100-6 20-567
3
TROUBLESHOOTING H-6, H-7
H-6 Arm is slow or lacks power

fl Check that the boom, bucket, travel, and swing speeds are normal.
Cause Remedy
2 YES Defective operation of Repair or

control valve spool replace
Is output
YES
pressure of PPC
valve normal?
1 Defective PPC valve Repair or
• 2.9 +0.6
–0.2 MPa NO replace
Is hydraulic drift {30 +5.5 kg/cm2}
–1.5
of arm cylinder • Engine at high
normal? idling YES Defective hydraulic Repair or
3 cylinder seal replace
• At rated load: Does speed of
Max.240 mm/ downward
15 minutes movement become
• At no load: NO faster when arm 4 YES Defective control valve
lever is operated? Does hydraulic drift safety-suction valve Replace
Max.105 mm/
• See TESTING
safety-suction valve is
• Engine stopped AND NO interchanged with other
• It is also possible Defective control valve Replace
• For standard NO
leakage from • Interchange with
cylinder. safety-suction
• Max. 28 cc/min valve for bucket
• Engine at high
idling
H-7 Bucket is slow or lacks power

fl Check that the boom, bucket, travel, and swing speeds are normal.
Cause Remedy

Is output
YES pressure of PPC
valve normal?
1 Defective PPC valve Repair or
• 2.9 +0.6
Is hydraulic drift
{30 +5.5
–1.5
kg/cm2}
of bucket
• Engine at high
cylinder normal?
idling YES Defective hydraulic Repair or
• At rated load: Does speed of
Max.145 mm/ downward
15 minutes movement become
• At no load: NO faster when bucket 4 YES Defective control valve
Max.70 mm/ lever is operated? Does hydraulic drift safety-suction valve Replace
• See TESTING
safety-suction valve is
• Engine stopped AND NO interchanged with other
• It is also possible Defective control valve Replace
• For standard NO
to measure
values, see Item 1.
leakage from
• Interchange with
cylinder.
safety-suction
• Max. 28 cc/min
valve for arm
• Engine at high
idling
20-568 PC1100-6
3
TROUBLESHOOTING H-8, H-9, H-10
H-8 Boom does not move

fl Check that the arm, bucket, travel, and swing move normally.
Cause Remedy

Is output
pressure of PPC
valve normal?
Defective PPC valve Repair or
• 2.9 +0.6
{30 +5.5
–1.5
kg/cm2}
• Engine at high
idling
H-9 Arm does not move

fl Check that the boom, bucket, travel, and swing move normally.
Cause Remedy

Is output
pressure of PPC
valve normal?
• 2.9 +0.6
{30 +5.5
–1.5
kg/cm2}
• Engine at high
idling
H-10 Bucket does not move

fl Check that the boom, arm, travel, and swing move normally.
Cause Remedy

Is output
pressure of PPC
valve normal?
Repair or
Defective PPC valve
• 2.9 +0.6 NO replace
–0.2 MPa
{30 +5.5
–1.5
kg/cm2}
• Engine at high
idling
PC1100-6 20-569
3
H-11 Excessive hydraulic drift

Cause Remedy
YES Defective hydraulic Repair or

Does speed of
downward
movement become Defective operation of
faster when lever is
2 YES
Does condition become
control valve safety- Replace
operated? suction valve
normal when safety-
• See TESTING suction valve is
AND NO interchanged with other Defective control valve,
ADJUSTING. safety-suction valve? defective oil tightness of Replace
• It is also possible • For standard NO spool
leakage of • See Note
cylinder.
• Max. 28 cc/min
• Engine at high
idling
Note: The set pressure for the boom safety-suction valve is different from the set pressure for the arm
and bucket safety-suction valves, so interchange the valves temporarily for the purpose of
testing. A hose is installed at the head end, so fit a blind plug when disconnecting, and be sure
to replace the valves in their original positions after completion of the troubleshooting.
The set pressure of the safety-suction valves for the arm and bucket is the same.
H-12 Excessive time lag

a) Boom
Cause Remedy
1 YES
Does spool and
check valve of
suction valve
boom regeneration
valve move
smoothly? Defective operation of Repair or
NO boom regeneration valve replace
b) Arm, bucket
Cause Remedy
suction valve
20-570 PC1100-6
3
TROUBLESHOOTING H-13
H-13 Boom shockless function is not actuated or cannot be canceled
Cause Remedy

Is operation of boom shockless valve replace
boom shockless
solenoid valve
Repair or
boom shockless solenoid
NO replace
• See Note valve
Note: Remove the solenoid valve as an individual part from the block, then connect the connector.
Turn the starting switch ON, then turn the boom shockless switch ON-OFF. If the spool moves,
it is normal.
PC1100-6 20-571
3
H-14 Machine deviates naturally to one side during travel operations

fl Check that the travel speed is normal.
a) Direction of deviation is same in FORWARD and REVERSE
YES
YES
4
1 Are metal
Was it possible to YES particles found in YES
locate abnormality oil drained from 6
in troubleshooting final drive? Does direction of deviation
chart? YES change when left and right
hoses between swivel joint
• Carry out 3 5 and travel motor are
troubleshooting interchanged?
Is amount of oil Is leakage from
with
YES drained from swivel joint
troubleshooting NO
travel motor NO normal?
chart in BEFORE
normal?
CARRYING OUT
TROUBLESHOOT- 2 • Max. 40 ¬/min • Max.100 cc/min
ING OF • Engine at high • Engine at high
HYDRAULIC Is output idling idling NO
SYSTEM. pressure of PPC
NO valve normal?
• 2.9 +0.6
–0.2 MPa NO
{30 +5.5
–1.5
kg/cm2}
• Engine at high
idling
NO
b) Direction of deviation is different in FORWARD and REVERSE
Cause Remedy
YES Repair or
Dfective swivel joint seal
replace
1
Is deviation as 3 YES Defective operation of Repair or
shown in 1, 2, control valve spool replace
5, 6 in diagram
YES Is output
on right? pressure of PPC
2
valve normal?
Repair or
Is relief pressure Defective PPC valve
• 2.9 +0.6
at travel relief
NO normal? {30 +5.5
–1.5
kg/cm2}
• Engine at high
• 34.3 +1.0 idling Drop in set pressure of
–2.5 MPa Replace
{35 +10 kg/cm2} NO travel motor safety valve
–25
• Engine at high
idling
20-572 PC1100-6
3
Cause Remedy
Follow
See Cause column in instructions in
troubleshooting chart troubleshooting
chart
Repair or
Defective final drive
replace
7 YES Defective operation of

Replace
control valve spool
Does control
valve spool move
smoothly?
Repair or
NO replace
Defective travel motor Repair or

replace
Defective swivel joint Repair or

seal replace
Internal leakage in travel Repair or

motor replace

replace
Fig.: Location of defective swivel joint seal and direction of travel deviation
PC1100-6 20-573
3
H-15 Deviation is excessive when starting

fl Check that there is no deviation during normal travel.
a) Deviation when starting occurs only when control lever is operated fully
Cause Remedy
YES Defective operation of Repair or

pump servo valve replace
1
Does direction of
deviation change when 3 YES Defective operation of Repair or
No. 2 pump outlet Does direction of deviation control valve spool replace
hoses are interchanged YES change when left and right
between front and rear? hoses between control
2 valve and swivel joint are
Does direction of deviation interchanged? Defective swivel joint Repair or
change when left and right seal replace
hoses between swivel joint
NO
NO and travel motor are
interchanged?
Defective travel motor Repair or

NO replace
b) Deviation when starting occurs both when control lever is

operated a small amount and when it is operated fully Cause Remedy
YES Defective operation of Repair or

2 pump servo valve replace
Is output pressure
YES of CO · NC valve
normal on fast 3 YES Defective adjustment of
side? Does output
Adjust
CO · NC valve
pressure become
• See Table normal when
1
• Engine at high NO CO · NC valve is
Is differential idling adjusted? Repair or
pressure of jet Defective CO · NC valve
• See Table NO replace
sensor normal on
• Engine at high
fast side?
idling
• See Table. Defective adjustment of
YES
• Engine at high control valve jet sensor Adjust
4
idling relief valve
Does differential
pressure become
normal when jet
NO sensor relief valve is
5 YES Defective control valve Repair or
adjusted? Does differential jet sensor relief valve replace
pressure become
• See Table normal when relief
• Engine at high NO valves are interchanged
idling on opposite sides? Defective control valve Repair or
• See Table NO jet sensor orifice replace
• Engine at high
idling
Table
Measurement conditions Jet sensor differential pressure CO · NC valve output pressure
All control levers at neutral Min. 1.5 MPa {Min. 15 kg/cm2} Max. 0.4 MPa {Max. 4.1 kg/cm2}
Travel levers operated fully (track rotating under no load) Max. 0.2 MPa {Max. 2 kg/cm2} Min. 1.7 MPa {Min. 17 kg/cm2}
20-574 PC1100-6
3
H-16 Travel deviation is excessive during compound operations

fl Check that there is no travel deviation during independent operation.
Cause Remedy
Defective operation of Repair or

1 YES
control valve straight- replace
Is output pressure travel valve
of straight-travel
solenoid valve
Repair or
straight-travel solenoid
• See Table. NO replace
valve
• Engine at high
idling
Table
All control levers at neutral 0 MPa {0 kg/cm2}
Work equipment, swing + left and right travel levers operated 2.9 ± 0.6 MPa {30 ± 5.5 kg/cm2}
H-17 Travel speed is slow or lacks power

fl Check that there is no travel deviation.
Cause Remedy

1 YES
2-stage relief solenoid replace
Is output valve
pressure of CO
cancel solenoid
valve normal? Defective operation of Repair or
• See Table. NO CO cancel solenoid valve replace
• Engine at high
idling
Table
Travel levers at neutral 0 MPa {0 kg/cm2}
Travel levers operated 2.9 ± 0.6 MPa {30 ± 5.5 kg/cm2}
PC1100-6 20-575
3
H-18 Travel does not move (one side only)

a) Does not move in either direction (FORWARD and REVERSE)
Cause Remedy
1 YES Defective final drive Repair or

Are metal replace
particles found in
oil drained from Defective operation of
final drive? travel motor parking Repair or
NO brake or defective travel replace
motor
b) Does not move in one direction (FORWARD or REVERSE)
Cause Remedy

YES
travel motor replace
2 counterbalance valve
YES Is travel relief

YES Defective travel motor
pressure normal? Replace
3 safety valve
Does relief pressure
• 34.3 +1.0
–2.5 MPa become normal
1 {35 +10 kg/cm2} when safety valve is 4 YES Defective operation of
–25 NO Repair or
• Engine at high interchanged? control valve suction
Is output Does relief pressure replace
idling valve
pressure of PPC • 34.3 +1.0
–2.5 MPa
become normal
valve normal? {350 +10 kg/cm2} NO when safety valve is
–25
interchanged? Defective operation of Repair or
• Engine at high
• 2.9 +0.6
–0.2 MPa idling • 34.3 +1.0
–2.5 MPa NO control valve spool replace
{30 +5.5
–1.5
kg/cm2} {350 +10 kg/cm2}
–25
• Engine at high • Engine at high
idling idling
NO replace
20-576 PC1100-6
3
H-19 Travel speed does not switch

fl Check that travel speed is normal in Hi or Lo.
fl If the engine speed is 1400 rpm or below, and the travel actuation pressure is 28.4 MPa {290 kg/
cm2} or more, the speed is automatically fixed in Lo.
Cause Remedy

Is output pressure travel motor servo valve replace
of travel speed
solenoid valve
normal? Defective operation of Repair or
travel speed solenoid
NO replace
• See Table. valve
• Engine at high
idling
Table
Travel speed switch at Lo 0 MPa {0 kg/cm2}
Travel operated with travel speed switch at Hi 2.9 ± 0.6 MPa {30 ± 5.5 kg/cm2}
PC1100-6 20-577
3
H-20 Does not swing

fl Check that the work equipment and travel are normal.
fl Carry out all troubleshooting in the DH mode with the swing lock switch OFF.
a) Does not swing in either direction (left and right)
Cause Remedy
2 YES Defective swing Repair or

Are any metal machinery replace
YES particles found in
1 oil drained from
swing machinery? Defective swing holding
Is output pressure Repair or
of swing holding NO brake or swing motor replace
brake solenoid
valve normal?
• See Table. Repair or
swing holding brake
• Engine at high NO replace
solenoid valve
idling
Table
5 sec after returning swing lever to Neutral 0 MPa {0 kg/cm2}
Swing lever operated 2.9 ± 0.6 MPa {30 ± 5.5 kg/cm2}
b) Does not swing in one direction (either left or right)
Cause Remedy
YES Defective swing motor Repair or

2 safety valve replace
Is problem reversed
YES when left and right
safety valves are 3 YES Defective swing motor Repair or
interchanged? suction valve
Is problem reversed replace
1
• Check front and when left and right
Is output rear individually. NO suction valves are
interchanged?
pressure of PPC Defective operation of Repair or
valve normal? • Check front and NO control valve spool replace
rear individually.
• 2.9 +0.6
–0.2 MPa
{30 +5.5 kg/cm2}
–1.5 Repair or
• Engine at high Defective PPC valve
NO replace
idling
20-578 PC1100-6
3
H-21 Swing speed is slow or swing acceleration is poor

fl Check that the work equipment and travel are normal.
a) Swing speed is slow in both directions (left and right)
Cause Remedy

Are any metal machinery replace
YES particles found in
1 oil drained from
Is leakage of oil Repair or
NO brake or swing motor replace
from motor
normal?
• Max. 28 ¬/min. Oil leakage from swing Repair or

• Engine at high NO motor replace
idling
b) Swing speed is slow in one direction (either left or right)
Cause Remedy

2 safety valve replace
Is problem reversed
YES when left and right
safety valves are 3 YES Defective swing motor Repair or
interchanged? suction valve replace
1 Is problem reversed
suction valves are
Is output rear individually. NO
interchanged?
pressure of PPC • See Note. Defective operation of Repair or
valve normal? NO control valve spool replace
• Check front and
rear individually.
• 2.9 +0.6
–0.2 MPa • See Note.
{30 +5.5
–1.5
kg/cm2}
• Engine at high
NO replace
idling
Note: Instead of checking the problem, it is possible to measure the swing relief pressure.
Swing relief pressure: 30.4 +1.0 +10 2
–2.9 MPa {310 –30 kg/cm }
PC1100-6 20-579
3
H-22 In compound operations with bucket, swing speed is slow or

swing acceleration is poor
Cause Remedy

2 YES
control valve swing replace
Does swing compensation valve
YES compensation
1 pilot valve spool
move smoothly? Defective operation of
Is output pressure Repair or
swing compensation
of swing PPC NO replace
pilot valve
shuttle valve
normal?
Defective swing PPC Repair or
• 2.9 +0.6
–0.2 MPa
NO shuttle valve replace
{30 +5.5
–1.5
kg/cm2}
• Engine at high
idling
• Operate swing.
H-23 In compound operations with boom when swing priority is ON,

swing speed is slow or swing acceleration is poor
Cause Remedy

swing priority solenoid replace
valve
20-580 PC1100-6
3
H-24 Excessive overrun when stopping swing

a) Both directions (left and right)
Cause Remedy
Internal leakage of swing Repair or

motor replace
b) One direction only (either left or right)
Cause Remedy
YES Repair or
Defective PPC valve
replace
1
Is problem reversed
when left and right
PPC hoses are
interchanged? 2 safety valve replace
Is problem reversed
when left and right
NO safety valves are 3 YES Defective swing motor Repair or
interchanged? suction valve replace
Is problem reversed
rear individually. NO suction valves are
interchanged?
• See Note. Defective operation of Repair or
• Check front and NO control valve spool replace
rear individually.
• See Note.
Note: Instead of checking the problem, it is possible to measure the swing relief pressure.
Swing relief pressure: 30.4 +1.0 +10 2
–2.9 MPa {310 –30 kg/cm }
PC1100-6 20-581
3
H-25 Excessive shock when stopping swing

a) Shock excessive in both directions (left and right)
Cause Remedy

machinery replace
Are metal particles
YES found in oil
1 drained from
Is outlet pressure Repair or
of swing holding NO brake or swing motor replace
brake solenoid
valve normal?
• See Table. Repair or
swing holding brake
• Engine at high NO replace
solenoid valve
idling
Table
b) Shock excessive in one direction only (either left or right)
Cause Remedy
Defective swing motor Repair or

safety valve replace
20-582 PC1100-6
3
H-26 Excessive abnormal noise when stopping swing

a) Abnormal noise in both directions (left and right)
Cause Remedy

Is foreign material
machinery replace
found in oil
drained from
swing machinery? Defective back pressure Repair or
NO compensation valve replace
b) Abnormal noise in one direction only (either left or right)
Cause Remedy

swing motor safety valve replace
Is problem reversed
when left and right
safety valves are
interchanged? Defective swing motor Repair or
• Check front and NO suction valve replace
rear individually.
H-27 Excessive hydraulic drift of swing

Cause Remedy
1 YES Defective swing holding Repair or

Is output pressure brake replace
of swing holding
brake solenoid
valve normal? Defective operation of Repair or
swing holding brake replace
• See Table. NO solenoid valve
• Engine at high
idling
Table
PC1100-6 20-583
3
TROUBLESHOOTING OF MACHINE
MONITOR SYSTEM
(M MODE)
Action taken by monitor panel when abnormality occurs and problems on machine ..................20-602
Electrical circuit diagram for M mode system ....................................................................................20-606
M- 1 [E101] Abnormality in error data is displayed
[E102] Abnormality in clock data is displayed .........................................................................20-608
M- 2 [E103] Short circuit in buzzer output system is displayed ......................................................20-609
M- 3 [E104] Air cleaner clogging detected is displayed ...................................................................20-610
M- 4 [E106] Drop in engine oil Hi pressure detected is displayed .................................................20-610
M- 5 [E108] Engine water temperature 105° detected is displayed ................................................20-611
M- 6 When starting switch is turned on, none of lamps on monitor panel
light up for 3 seconds .................................................................................................................20-612
M- 7 When starting switch is turned on, monitor panel lamps all stay lighted up
and do not go out ........................................................................................................................20-614
M- 8 When starting switch is turned on, items lighted up on monitor panel
are different from machine .........................................................................................................20-614
M- 9 When starting switch is turned on (engine stopped), basic check items flash ....................20-615
M-10 When starting switch is turned on (engine stopped),
preheating monitor display is not normal ................................................................................20-618
M-11 When engine is started, basic check items flash .....................................................................20-619
caution items, emergency stop items flash ..............................................................................20-621
M-13 When engine is started, caution items, emergency stop items flash
(but there is no abnormality in any item) .................................................................................20-623
M-14 When starting switch is turned on (engine stopped), buzzer does not sound for 1 second
Caution item flashes but buzzer does not sound ....................................................................20-628
M-15 No abnormality is displayed on monitor but buzzer sounds .................................................20-628
M-16 Night lighting on monitor panel does not light up .................................................................20-629
M-17 Engine water temperature gauge does not rise .......................................................................20-630
M-18 Engine water temperature gauge does not give any display
(gauge does not even display 1st level) ...................................................................................20-630
M-19 Fuel level gauge always displays FULL ....................................................................................20-631
M-20 Fuel level gauge does not give any display (gauge does not even display 1st level) ........ 20-631
M-21 Swing lock switch is turned ON, but swing lock monitor does not light up .......................20-632
M-22 Swing prolix switch is turned ON (prolix), but swing lock monitor does not flash ............20-633
M-23 Service meter does not advance while engine is running .....................................................20-634
M-24 When starting switch is at OFF and time switch is pressed,
service meter does not give display ..........................................................................................20-634
M-25 Defective fuel level sensor system ............................................................................................20-635
M-26 Defective engine water temperature sensor system and
defective hydraulic oil temperature sensor system .................................................................20-636
M-27 Defective engine oil level sensor system and defective
hydraulic oil level sensor system ...............................................................................................20-637
M-28 Defective radiator water level sensor system ..........................................................................20-638
M-29 Defective operation of wiper (including cases where [E113] is displayed) ..........................20-639
M-30 Defective operation of window washer
(including cases where service code [E114] is displayed) ......................................................20-642
PC1100-6 20-601
3
ACTION TAKEN BY MONITOR PANEL WHEN ABNORMALITY

User Service
code code
1. Abnormality in internal memory
—
Abnormality in error 2. Excess voltage (more than 36 V) has occurred
E101
data 3. Low voltage (less than 12 V) has occurred
4. Defective connection of connector
1. Abnormality in internal clock function

Abnormality in clock 2. Excess voltage (more than 36 V) has occurred
— E102
data 3. Low voltage (less than 12 V) has occurred
4. Defective connection of connector
1. Short circuit inside buzzer

Short circuit in 2. Short circuit with power source in wiring harness between monitor
— E103 buzzer output P01 (7) and alarm buzzer P04 (2)
system 3. Defective monitor panel
fl If there is a disconnection, E103 is also displayed.
1. Air cleaner clogging sensor has detected clogging

Air cleaner clogging
— E104
detected
1. Engine oil pressure Hi sensor has detected drop in oil pressure
Drop in engine oil

— E106
pressure Hi detected
1. Engine water temperature gauge has detected water temperature

of 105°C
Engine water
— E108 temperature 105°C
detected

2. Defective wiper, washer relay box
Disconnection, short
— 3. Defective contact or disconnection in wiring harness between moni-
E113 circuit in wiper drive
tor panel P02 (3) and wiper, washer relay box W08 (2)
system
4. Short circuit with ground in wiring harness between monitor panel
P02 (3) – wiper, washer relay box W08 (2)
20-602 PC1100-6
3
1. Service code cannot be cleared.
· Turn the starting switch
2. Time becomes [00:00].
OFF. Then keep the time
switch pressed, turn the
starting switch ON again,
and keep the time switch
1. Service code cannot be cleared.
pressed for a further 5 sec-
2. Time becomes [00:00].
onds to reset. (If the sys-
. 3. Clock does not advance.
tem is reset, it is normal)
1. Buzzer does not sound.

· Voltage between P01 (7)
– chassis ground
Buzzer ON: Max. 1 V
Buzzer OFF: 20 – 30 V
· Resistance between P11 1. If abnormality detection contin-

(male) – P12 (female): ues, air cleaner clogging caution
Max. 1Ω (engine running) lamp flashes and buzzer sounds.
· Resistance between 1. If abnormality detection contin-

sensor terminal and ues, engine oil pressure caution
chassis: lamp flashes and buzzer sounds.
Min. 1 MΩ (engine at
mid-range speed or
above)
1. If abnormality detection contin-

ues, engine water temperature
· Resistance between P07 caution lamp flashes and buzzer
(1) – (2): sounds.
Min. 3.156 kΩ 2. If abnormality detection contin-
(engine running) ues, overheat prevention func-
tion is actuated, and engine
speed is reduced to low idling.
1. Wiper does not work.

2. Wiper does not stop.
· Resistance between P02
(3) – W08 (2): Max. 1 Ω
PC1100-6 20-603
3
User Service
code code
2. Defective wiper, washer relay box
Disconnection, short
3. Defective contact or disconnection in wiring harness between moni-
— E114 circuit in washer
tor panel P02 (2)(10) and wiper, washer relay box W08 (15)
drive system
4. Short circuit with ground in wiring harness between monitor panel
P02 (2)(10) – wiper, washer relay box W08 (15)
20-604 PC1100-6
3
1. Washer does not work.
2. Washer does not stop.
· Resistance between P02
(2)(10) – W08 (15):
Max. 1 Ω
PC1100-6 20-605
3
TROUBLESHOOTING ELECTRICAL CIRCUIT DIAGRAM FOR M MODE SYSTEM
ELECTRICAL CIRCUIT DIAGRAM FOR M MODE SYSTEM
20-606 PC1100-6
3
TROUBLESHOOTING ELECTRICAL CIRCUIT DIAGRAM FOR M MODE SYSTEM
PC1100-6 20-607
3
TROUBLESHOOTING M-1
M-1 [E101] Abnormality in error data is displayed or

[E102] Abnormality in clock data is displayed
fl This is not an abnormality. It occurs during troubleshooting when disconnecting and connecting
connector P02 (for the monitor panel electrical system), fuse 13, connector H14, connector M11,
battery relay terminal B, or the battery terminal. This action temporarily shuts off the monitor
panel power source circuit, so a service code is displayed.
fl Check that fuse 13 is not blown. (If it is blown, check for a short circuit with the ground in the
related circuits for fuse 13.)
Cause Remedy
YES
2
Is voltage between Disconnection, defective
YES P02 (8)(14) and contact, short circuit with
chassis ground 3 YES ground in wiring harness Repair or
normal? Is voltage between fuse 13 outlet replace
1
• Turn starting between fuse 13 and P02 (female) (8)(14)
Does service code
display appear
switch OFF. NO inlet and chassis Disconnection, defective
• 20 – 30 V ground normal? Repair or
again after system contact, short circuit with
has been reset? • Turn starting NO ground in wiring harness replace
switch OFF. between battery terminal
• Reset. For details, • 20 – 30 V B and fuse 13
see Note.
• After resetting Normal —
system, carry out NO
normal
operations for a
short time and
watch the
condition.
Note:
Resetting operation: Turn the starting switch OFF. Then keep the time switch depressed, turn the
starting switch ON again, and keep the time switch depressed for 5 seconds to
reset the system.
M-1 Related electrical circuit diagram
20-608 PC1100-6
3
TROUBLESHOOTING M-2
M-2 [E103] Short circuit in buzzer output system is displayed

check if an E service code is displayed. (If it is not displayed, the system has been reset.)
Cause Remedy
2 YES Defective monitor panel Replace

When P01 is
YES disconnected,
1 does buzzer Short circuit with ground
stop? in wiring harness Repair or
Is resistance
between P04 (male) • Turn starting NO between P01 (female) (7) replace
(2) – chassis ground switch ON. and P04 (female) (2)
normal?
• Turn starting Replace

Defective alarm buzzer
switch OFF. NO
• Disconnect P04.
• Min. 1 MΩ
PC1100-6 20-609
3
TROUBLESHOOTING M-3, M-4
M-3 [E104] Air cleaner clogging detected is displayed
Cause Remedy
YES
See M-13 f) —
1
Is air cleaner
clogging caution
lamp on monitor 2 YES
panel flashing?
Is [E] displayed at
head of service
NO code?
Defective air cleaner
—
NO (See Note)
Note: The monitor panel display has returned to normal, but the air cleaner clogging sensor has
detected symptoms of clogging in the past, so clean the air cleaner properly. For details, see the
Operation and Maintenance Manual.
M-4 [E106] Drop in engine oil Hi pressure detected is displayed
Cause Remedy
YES See M-11 b) —

1
Is engine oil
pressure caution
lamp on monitor 2 YES Defective monitor panel Replace
flashing?
Is [E] displayed at
head of service
NO code?
Failure in engine system
(See Note) —
NO
Note: The monitor panel display has returned to normal, but the engine oil pressure Hi sensor has
detected symptoms of a drop in the oil pressure in the past, so carry out troubleshooting of the
engine to remove the problem.
20-610 PC1100-6
3
TROUBLESHOOTING M-5
M-5 [E108] Engine water temperature 105°C detected is displayed
Cause Remedy
YES See M-13 d) —

1
Does engine water
temperature gauge on
monitor panel display
red range and is 2 YES
caution lamp flashing?
Is [E] displayed at
head of service
NO code?
Failure in engine system
—
NO (See Note)
Note: The monitor panel display has returned to normal, but the engine water temperature sensor has
detected symptoms of the engine water temperature reaching 105°C in the past, so carry out
troubleshooting of the engine to remove the problem.
PC1100-6 20-611
3
TROUBLESHOOTING M-6
M-6 When starting switch is turned on, none of lamps on monitor

panel light up for 3 seconds
fl Check that fuses 10 and 13 are not blown. (If they are blown, check for a short circuit with the
ground in the related circuits for fuses 10 and 13.)
fl Check that the engine starts properly. (If it does not start, carry out Troubleshooting E-20 first.)
a) None of lamps on monitor panel light up
Cause Remedy
YES Defective monitor panel Replace

2
Is voltage between Disconnection, defective
YES P01 (9) and contact, short circuit with
chassis ground 3 YES ground in wiring harness Repair or
normal? Is voltage between fuse 10 outlet and replace
between fuse 10 P01 (female) (9)
1 • Turn starting
Is voltage
switch ON. NO inlet and chassis contact, short circuit with
• 20 – 30 V ground normal? Repair or
between P02 ground in wiring harness
• Turn starting NO between battery relay
replace
(8)(14) – chassis
ground normal? switch ON. terminal M and fuse 10 inlet
• 20 – 30 V Disconnection, defective
• Turn starting 4 YES contact, short circuit with Repair or
switch ON. ground in wiring harness replace
Is resistance
• 20 – 30 V between fuse 13 outlet and
between P02 P02 (female) (8)(14)
NO (1)(9) and chassis
ground normal? Defective contact or
• Turn starting NO harness between P02 replace
switch OFF. (female) (1)(9) and chassis
• Disconnect P02. ground
• Max. 1 Ω
b) Some of lamps on monitor panel do not light up

Cause Remedy
20-612 PC1100-6
3
TROUBLESHOOTING M-6
PC1100-6 20-613
3
M-7 When starting switch is turned on, monitor panel lamps all stay
lighted up and do not go out
Cause Remedy
M-8 When starting switch is turned on, items lighted up on monitor

panel are different from machine
fl Immediately after replacing the monitor panel, turn the starting switch OFF, then turn it ON again
and check.
Cause Remedy
1 YES Defective monitor panel Replace

Is display of
monitoring code
[01] normal?
Go to troubleshooting
—
NO for C mode (See C-16)
• Turn starting
switch ON.
• See Table.
Table
01 Monitor panel model selection code
20-614 PC1100-6
3
TROUBLESHOOTING M-9
M-9 When starting switch is turned ON (engine stopped), basic check

items flash
a) (radiator water level) flashes

SAP00519
Cause Remedy
fl Check that the radiator water level is at the specified
level before carrying out troubleshooting.
YES Defective radiator water

level sensor system —
(see M-28)

1 Replace
controller
Does display go out Is bit (3) of
YES
when short monitoring code
connector is 3 [24] lighted up?
connected to P08, Is resistance
P20 (female)? YES between C16 • Turn starting NO
(female) (8) and
• Disconnect P08 switch ON.
chassis ground as Defective contact, or
and P20. shown in table?
• Turn starting 2 disconnection in wiring
• Turn starting harness between C16 Repair or
switch ON. Is resistance
switch OFF. NO (female) (8) and P20 replace
• Check P08 and between P20 (2)
• Disconnect C16 (female) (1)
P20 individually. NO and chassis
ground normal? and P20. Defective contact, or
5 YES disconnection in wiring
Repair or
• Turn starting Is resistance harness between P20
replace
switch OFF. between P08 (female) (2) and P08
• Disconnect P20. (female) (2) and (female) (1)
• Max. 1 Ω NO chassis ground Defective contact or
normal? disconnection in wiring Repair or
• Turn starting NO harness between P08 replace
switch OFF. (female) (2) and chassis
• Disconnect P08. ground
• Max. 1 Ω
Table
Connection between P20 (female) (1) and chassis Resistance
Connected Max. 1 Ω
Disconnected Min. 1 MΩ
M-9 a) Related electrical circuit diagram
PC1100-6 20-615
3
TROUBLESHOOTING M-9
b) (engine oil level) flashes

SAP00523
fl Check that the engine oil is at the specified level before carrying out troubleshooting.
Cause Remedy
Defective engine oil level

YES
sensor system —
(see M-27)
1
Does display go out 3 YES Defective pump Replace
when P05 (female)
(1) is connected to
controller
Is bit (4) of
chassis ground? YES
monitoring code
2 [24] lighted up?
• Disconnect P05. Is resistance
• Turn starting between C16 Defective monitor panel Replace
switch ON. (female) (16) and • Turn starting NO
NO chassis ground switch ON.
normal?
Defective contact, or
• Turn starting Repair or
harness between C16
switch OFF. NO replace
(female) (16) and P05
• Disconnect C16, (female) (1)
P05.
Table
M-9 b) Related electrical circuit diagram
20-616 PC1100-6
3
TROUBLESHOOTING M-9
c) (hydraulic oil level) flashes

SAP00524
fl Check that the hydraulic oil is at the specified level before carrying out troubleshooting.
Cause Remedy
Defective engine oil level

YES sensor system —
(see M-27)
1
Does display go out 3 YES Defective pump
when P09 (female)
controller Replace
(1) is connected to Is bit (5) of
chassis ground? YES monitoring code
2 [24] lighted up?
• Disconnect P09. Is resistance
• Turn starting between C16 Defective monitor panel Replace
switch ON. (female) (9) and • Turn starting NO
NO chassis ground switch ON.
normal?
harness between C16
• Disconnect C16, (female) (1)
P09.
Table
M-9 c) Related electrical circuit diagram
PC1100-6 20-617
3
TROUBLESHOOTING M-10

(preheating monitor) display is not normal SAP00526
a) When APS switch is turned ON, lamp does not light up

(APS is actuated)
Cause Remedy
YES Replace
Defective monitor panel
1
Is voltage 3 YES
between P01 (18) Defective APS controller Replace
Is voltage
and chassis
ground normal?
YES between E26 (4)
2 and chassis Defective contact or
• Turn starting When E26 is ground normal? disconnection in wiring
Repair or
switch ON. disconnected, is harness between P01
• Turn APS switch resistance between P01 (female) (18) and E26
NO (female) (18) and switch ON. (female) (4)
ON.
chassis ground normal? • Turn APS switch ON. Short circuit with ground
• 20 – 30 V
• Turn starting • 20 – 30 V in wiring harness Repair or
switch OFF. NO between P01 (female) replace
• Disconnect P01 (18) and E26 (female) (4)
and E26.
• Min. 1 MΩ
b) When APS switch is turned OFF, lamp lights up

(APS is not actuated) Cause Remedy

1
Is voltage
between P01 (18)
and chassis 2 YES
ground normal? When E26 is
disconnected, is
• Turn starting voltage between
switch ON. NO P01 (18) and chassis Short circuit with ground
• Turn APS switch ground normal? in wiring harness Repair or
OFF. • Turn starting NO between P01 (female) replace
• Max.1 V switch OFF. (18) and E26 (female) (4)
• Disconnect P01
and E26.
• Max.1 V
20-618 PC1100-6
3
M-11 When engine is started, basic check items flash

a) Alternator system
Cause Remedy

2 value of more
YES between C03 • Run engine at NO
(12) and chassis mid-range speed Defective contact,
1
ground normal? or above. disconnection, or short
Is voltage between circuit with ground in Repair or
alternator terminal • Run engine at
mid-range speed NO wiring harness between replace
R and chassis
or above. C03 (female) (12) and
ground normal?
• 20 – 30 V alternator terminal R
• Run engine at
mid-range speed Defective alternator Replace
or above. NO
• 20 – 30 V
PC1100-6 20-619
3
b) Engine oil pressure system
fl Check that the engine oil pressure is normal before carrying out troubleshooting.
Cause Remedy
Low-pressure sensor
YES Defective engine oil

pressure low-pressure Replace
sensor
1
When engine is running
at low idling and wiring 3 YES Defective pump
Replace
harness of oil pressure controller
sensor is removed, Is bit (1) of
YES
does display go out? monitoring code
2 [24] lighted up?
• Engine at low Is resistance
idling between C16 Defective monitor panel Replace
• Disconnect low- (female) (15) and • Engine at low NO
pressure sensor NO chassis ground idling
wiring harness. normal?
in wiring harness
between C16 (female)
(15) and low-pressure
• Disconnect low- sensor
pressure sensor
wiring harness
and C16.
• Min. 1 MΩ
Cause Remedy
High-pressure sensor
Defective engine oil

YES
pressure high-pressure Replace
sensor
1
When engine is running
at high idling and wiring 3 YES Defective pump
Replace
harness of oil pressure controller
sensor is removed, Is bit (2) of
YES
does display go out? monitoring code
2 [24] lighted up?
• Engine at high Is resistance
idling between C16
• Disconnect high- (female) (7) and
pressure sensor NO chassis ground switch ON.
wiring harness. normal?
in wiring harness Repair or
• Turn starting between C16 (female) (7)
and high-pressure
• Disconnect high- sensor
pressure sensor
wiring harness
and C16.
• Min. 1 MΩ
20-620 PC1100-6
3
M-12 When starting switch is turned on (engine stopped), caution

items, emergency stop items flash
a) Alternator system
Cause Remedy

2 value of more
YES between C03 • Turn starting NO
(12) and chassis switch ON.
1 Short circuit with power
normal?
Is voltage between source in wiring harness Repair or
alternator terminal • Turn starting between C03
switch ON NO replace
R and chassis (female)(12) and
normal? • Max. 1 V alternator terminal R
• Disconnect
wiring harness. Defective alternator Replace
switch ON.
• Max. 1 V
PC1100-6 20-621
3
b) Engine oil pressure sensor system
Cause Remedy
Low-pressure sensor

controller
Is bit (1) of
YES
monitoring code
2 [24] lighted up?
Is resistance
(female) (15) and
1 chassis ground switch ON.
normal?
Is there continuity disconnection in wiring
between low- • Turn starting Repair or
harness between C16
pressure sensor switch OFF NO replace
(female) (15) and low-
terminal and • Disconnect C16.
chassis ground?
pressure sensor
• Max. 1 Ω
• Turn starting Defective engine oil
switch OFF. pressure low-pressure Replace
• Remove low- NO sensor
pressure sensor
wiring harness.
Cause Remedy
High-pressure sensor

controller
Is bit (2) of
YES monitoring code
2 [24] lighted up?
Is resistance
(female) (7) and
chassis ground switch ON.
1 Defective contact, or
Is there continuity normal?
between high- • Turn starting Repair or
harness between C16
pressure sensor switch OFF NO replace
(female) (7) and high-
terminal and • Disconnect C16.
chassis ground? pressure sensor
• Max. 1 Ω
• Turn starting Defective engine oil
switch OFF. pressure high-pressure Replace
• Remove high- NO sensor
pressure sensor
wiring harness.
20-622 PC1100-6
3
M-13 When engine is started, caution items, emergency stop items

flash (but there is no abnormality in any item)
a) (engine oil pressure) flashes

SAP00520
Cause Remedy
See M-11 b) —
b) (radiator water level) flashes

SAP00519
fl Check that the radiator water level is normal before carrying out troubleshooting.
Cause Remedy
See M-9 a) —
c) (battery charge) flashes

SAP00522
Cause Remedy
See M-11 a) —
PC1100-6 20-623
3
d) (engine water temperature) flashes

SAP00527
fl Check that the engine water temperature is normal before carrying out troubleshooting.
Cause Remedy
Defective engine water

YES
temperature sensor —
2 system (see M-26)
When P07 is
YES disconnected, does
only level 1 (left
end) of gauge Replace
display light up? Is resistance controller
1 between C03
• Run engine at Short circuit with ground in
(female) (1) – (16),
Is engine water mid-range or NO wiring harness between C03
(1)(16) – chassis
temperature in above. ground normal?
(female) (1) and P07 (female) Repair or
red range? (1), or short circuit in wiring replace
• Turn starting NO harness between C03
switch OFF. (female) (16) and P07
• Run engine at • Disconnect C03 and P07. (female) (2)
mid-range or • Min. 1 MΩ
above. Defective monitor panel Replace
NO
M-13 d) Related electrical circuit diagram
20-624 PC1100-6
3
e) (fuel level) flashes

SAP00528
fl Check that there is ample fuel before carrying out troubleshooting.
Cause Remedy
Defective fuel level

YES
sensor system (see —
2 M-25)
When P06 (female)(1) is
YES connected to chassis
ground, do all lamps to
level 14 (right end) of 3 YES Defective pump
Replace
Is voltage
gauge display light up? controller
1
• Disconnect P06. between C03 (2)
Is fuel gauge in • Turn starting NO and chassis disconnection in wiring
switch ON ground normal? Repair or
red range? harness between C03 replace
• Disconnect C03. NO (female) (2) and P06
• Turn starting (female) (1)
• Start engine. switch ON
• Max. 1 V
NO
M-13 e) Related electrical circuit diagram
PC1100-6 20-625
3
f) (air cleaner clogging) flashes

SAP00521
fl Check that the air cleaner is not clogged before carrying out troubleshooting.
Cause Remedy
YES Defective air cleaner

clogging switch Replace
1 4 YES Defective pump

controller Replace
When P11 (female) Is bit (6) of
is connected to
YES monitoring code
P12 (male), does 3 [24] lighted up?
display go out? Is resistance
YES between C16 NO
• Disconnect P11 (female) (17) and
and P12. 2 chassis ground as Defective contact or
• Start engine. shown in table? disconnection in wiring
Is resistance Repair or
• Turn starting harness between C16
between P12 replace
switch OFF. NO (female) (17) and P11
NO (male) and chassis • Disconnect C16,
ground normal? (female)
P11, and P12
• Turn starting Defective contact or Repair or
switch OFF. disconnection in wiring
NO replace
• Disconnect P12. harness between P12
• Max. 1 Ω (male) and chassis
ground
Table
Connection between P11 (female) and P12 (male) Resistance
M-13 f) Related electrical circuit diagram
20-626 PC1100-6
3
g) (hydraulic oil temperature) flashes

SAD01484
fl Check that the hydraulic oil temperature is normal before carrying out troubleshooting.
Cause Remedy
Defective hydraulic oil

YES
system (See M-26)
1
When P10 is 3 YES Defective pump
disconnected, controller Replace
does display go Does monitoring
out?
2 value of more
• Start engine. Is resistance than 21?
between C03
(female) (11) – (16), • Turn starting NO
NO switch ON Short circuit with ground
(11)(16) – chassis
in wiring harness between
ground normal?
C03 (female) (11) and P10
• Turn starting (female) (1), or short circuit
Repair or
switch OFF. NO in wiring harness between replace
• Disconnect C16 C03 (female) (16) and P10
and P10. (female) (2)
• Min. 1 MΩ
M-13 g) Related electrical circuit diagram
PC1100-6 20-627
3
M-14 When starting switch is turned on (engine stopped), buzzer does

not sound for 1 second
Caution item flashes but buzzer does not sound
fl Of the caution items, the buzzer will not sound even if there is an abnormality in the battery charge
or fuel level.
fl Before carrying out troubleshooting, check that all Cause Remedy
the related connectors are properly inserted.
fl Always connect any disconnected connectors before
going on to the next step.
YES
2
When P01 (female)
YES (7) and chassis Defective contact or
ground are
connected, does 3 YES disconnection in wiring Repair or
buzzer sound? Is voltage harness between fuse 13 replace
1 and P04 (female) (1)
• Disconnect P01. between P04 (1)
Is resistance • Turn starting NO and chassis Defective contact or
between P04 switch ON ground normal? disconnection in wiring Repair or
(male) (1) and (2) harness between P01 replace
normal? • Turn starting NO
switch ON (female) and P04
• Turn starting • 20 – 30 V (female) (1)
switch OFF.
• Disconnect P04. Defective alarm buzzer Replace
• 200 – 300 Ω NO
M-15 No abnormality is displayed on monitor but buzzer sounds

fl When the buzzer sounds continuously. (If the buzzer sounds intermittently, carry out troubleshoot-
ing M-14.)
fl Before carrying out troubleshooting, check that all
Cause Remedy
the related connectors are properly inserted.
2 YES
YES When P01 is
disconnected,
does buzzer stop?
Is resistance in wiring harness Repair or
between P04 between P01 (female) (7) replace
(male)(2) and • Turn starting NO
switch ON and P04 (female) (2)
chassis ground
normal?
• Turn starting Defective alarm buzzer Replace
switch OFF. NO
• Disconnect P04.
• Min. 1 MΩ
M-14, 15 Related electrical circuit diagram
20-628 PC1100-6
3
M-16 Night lighting on monitor panel does not light up

fl Check that the head lamps and working lamps light up normally before carrying out troubleshoot-
ing.
Cause Remedy
YES Blown bulb or defective

Replace
contact of bulb
1
Is bulb blown or
is there defective YES
contact? 2
• Remove bulb. Does bit (3) of

• Check visually monitoring code
3 YES
for blown bulb. NO [49] go out?
Is voltage
• Turn starting between P01 (8)
switch ON NO and chassis
ground norma? disconnection in wiring
• Turn light switch Repair or
harness between P01
ON. • Turn starting NO replace
(female) (8) and M07
switch ON (male) (1)
• Turn light switch
ON.
• 20 – 30 V
PC1100-6 20-629
3
M-17 Engine water temperature gauge does not rise

fl If the engine water temperature actually does not rise, check the engine system.
the related connectors are properly inserted. Cause Remedy
YES
system (see M-26)
1
When short connector is 3 YES
connected to P07 (female), Defective monitor panel Replace
Does monitoring
do level lamps on gauge go
up in turn and then all
lamps go out? value of more
2 than 500? Defective pump
• Disconnect P07. Replace
• Turn starting When short connector NO controller
• Turn starting
is connected to P07
switch ON. switch ON
(female), is resistance Defective contact, or
NO between C03 (female) disconnection in wiring
(1) and (16) normal? 4 YES Repair or
harness between C03
• Turn starting Is voltage (female) (16) and P07 replace
switch OFF between P07 (1) (female) (2)
• Disconnect C03 NO and chassis
and P07. ground normal? Defective contact or
• Max. 1 Ω NO replace
• Turn starting harness between C03
switch ON (female) (1) and P07
• 20 – 30 V (female) (1)
M-18 Engine water temperature gauge does not give any display
(gauge does not even display 1st level)
YES
system (see M- 26)
1
When P07 is
disconnected, does 3 YES Defective pump
controller Replace
engine water Does monitoring
temperature gauge YES code [41] show a
display appear? 2 value of more
• Turn starting Is resistance than 500?
switch ON. between C03 Defective monitor panel Replace
(female) (1) and • Turn starting NO
NO chassis ground switch ON
normal? Short circuit with ground
• Disconnect C03 . in wiring harness Repair or
• Turn starting NO between C03 (female) (1) replace
switch OFF. and P07 (female) (1)
• Min. 1 MΩ
20-630 PC1100-6
3
M-19 Fuel level gauge always displays FULL

YES Defective fuel level

sensor system (see M-25) —
1
When P06 is
disconnected, do level 3 YES Defective pump
Replace
lamps on gauge go Does monitoring controller
down in turn and then YES code [42] show a
all lamps go out? value of more
2
• Turn starting Is resistance than 40?
switch ON. between C03 Defective monitor panel Replace
(female) (2) and • Turn starting NO
NO chassis ground switch ON
normal? Short circuit with ground
• Disconnect C03 in wiring harness Repair or
and P06. NO between C03 (female) (2) replace
• Turn starting and P06 (female) (1)
switch OFF.
• Min. 1 MΩ
M-20 Fuel level gauge does not give any display (gauge does not even
display 1st level)
YES Defective fuel level
sensor system (see M-25) —
1
When P06 (female)(1)
is connected to 3 YES Defective pump
Replace
chassis ground, does Does monitoring controller
display appear on YES code [42] show a
gauge? value of more
2
• Turn starting When P06 (female)(1) is than 400?
switch ON. connected to chassis Defective monitor panel Replace
ground, is resistance • Turn starting NO
NO between C03 (female) switch ON
(2) and chassis normal?
• Disconnect C03. Repair or
harness between C03
• Max. 1 Ω
PC1100-6 20-631
3
M-21 Swing lock switch is turned ON, but (swing lock monitor)
does not light up SAT00098
fl Check that the swing lock switch is actually being actuated before carrying out troubleshooting.
Cause Remedy
1 YES
Is voltage between
P01 (female) (5) and
chassis ground as Defective contact or
shown in table? disconnection in wiring
Repair or
harness between P01
(female) (5) and X05
switch ON (male) (1)
Table
Swing lock switch ON Max. 1 V
Swing lock switch OFF 20 – 30 V
20-632 PC1100-6
3
M-22 Swing prolix switch is turned ON (prolix), but (swing

lock monitor) does not flash SAT00098
fl Check that the swing prolix function is actually being actuated before carrying out troubleshooting.
Cause Remedy
2 YES
Is bit (6) of
YES
monitoring code
1 [21] lighted up?
Is voltage between Defective pump Replace
C17 (8) and • Turn starting NO controller
chassis ground as switch ON
shown in table ? Defective contact or
• Turn starting disconnection in wiring Repair or
switch ON NO harness between C17 replace
(female) (8) and SW1 (4)
Table
Swing prolix switch ON Max. 1 V
Swing prolix switch OFF 20 – 30 V
PC1100-6 20-633
3
M-23 Service meter does not advance while engine is running
Cause Remedy
YES —
See M-11 a)
1
Does battery
charge caution
lamp flash? 2 YES
Does monitoring
• Run engine at code [43] show a
mid-range or NO value of more
above. than 100? Defective pump Replace
• Run engine at NO controller
mid-range or
above.
M-24 When starting switch is at OFF and time switch is pressed,

service meter does not give display
Cause Remedy
1 YES
When starting
switch is ON, is
panel display
normal? —
See M-6
switch ON
20-634 PC1100-6
3
M-25 Defective fuel level sensor system

fl If it is judged from all the troubleshooting that the fuel level sensor is defective, check the sensor
as an individual part as follows.
fl Remove the fuel level sensor when carrying out the troubleshooting.
Cause Remedy
3 YES Interference with sensor Install

inside tank (See Note 2) correctly
Is there any large
YES
crack, chip, or
2 damage to float? Clean or
Defective contact of
replace
YES Does arm move NO connector
connector
smoothly?
1 Defective sensor (See Replace

When float is moved up Note 2) sensor
and down, is resistance
NO
between connector (1)
and flange as shown in
table? 4 YES Disconnection in wiring Replace
Check wiring harness (See Note 3) sensor
harness visually.
NO Is it broken?
Defective sensor Replace
NO sensor
Table
Top (FULL) stopper position Approx. 12 Ω or below
Bottom (EMPTY) stopper position Approx. 85 – 110 Ω
Note 1: Difference between fuel level and gauge display

For gauge display position 9 (FULL), the amount of fuel is 78 – 100%; and for display position
1 (EMPTY) it is below 14.5%.
If the chassis is at an angle, the displayed amount of fuel will be different from the actual
amount. Therefore, when checking, stop the machine at a horizontal place and wait for at
least 2 minutes before checking the gauge. (The display is given a time delay so that the
gauge can deal with sudden changes in the fuel level.)
Note 2: There is the possibility of defective installation or interference with the sensor inside the tank,
so be careful when installing.
Note 3: Check for vibration at the connector mount. If there is excessive vibration, take the appropri-
ate action.
PC1100-6 20-635
3
M-26 Defective engine water temperature sensor system and defective

hydraulic oil temperature sensor system
fl If it is judged from all the troubleshooting that the engine water temperature sensor is defective,
check the sensor as an individual part as follows.
fl Remove the engine oil temperature sensor or hydraulic oil temperature sensor when carrying out
troubleshooting.
Cause Remedy
YES Defective contact of Clean or repair

1 connector (See Note 1) connector
Is resistance
between connector
(1) and (2) as shown 2 YES Disconnection in wiring Replace
in table?
harness visually.
NO Is it broken?
Replace
Defective sensor
NO sensor
Table
Normal temperature (25°C) Approx. 37 – 50 Ω
100°C Approx. 3.5 – 4.0 Ω
BKP00291
Note 1: If the problem occurs again, the connector (female) at the chassis end is probably defective,
so check the connector and wiring harness at the chassis end.
ate action.
20-636 PC1100-6
3
M-27 Defective engine oil level sensor system and defective hydraulic
oil level sensor system
fl If it is judged from all the troubleshooting that the engine oil level sensor or hydraulic oil level
sensor is defective, check the sensor as an individual part as follows.
fl Remove the engine oil level sensor or hydraulic oil level sensor when carrying out troubleshoot-
ing.
Cause Remedy
YES Defective movement of

float due to dirt Clean
2
Is any foreign
YES material (dirt)
stuck to moving 3 YES Resonance of mount
part of float? Repair
Is there any large (See Note 4)
1 crack, chip, or
When float is moved up NO damage to float?
and down, is resistance Defective contact of Clean or repair
between connector (1) NO connector (See Note 2) connector
and flange as shown in
table?
4 YES Disconnection in wiring Replace

harness (See Note 3) sensor
Check wiring
harness visually.
NO Is it broken?
NO sensor
Table
Top (FULL) stopper position Max. 1 Ω
Bottom (EMPTY) stopper position Min. 1 MΩ
Note 1: Variations in oil level

The oil level may change according to the angle of the machine, the engine speed, or the
temperature of the oil, so check the oil level with the machine at a horizontal place.
ate action.
Note 4: Defective installation is a possible cause, so be careful when installing.
If the problem occurs again, check for any vibration of the mount, and if there is excessive
vibration, take the appropriate action.
PC1100-6 20-637
3
M-28 Defective radiator water level sensor system

fl If it is judged from all the troubleshooting that the radiator water level sensor is defective, check
the sensor as an individual part as follows.
fl Remove the radiator water level sensor when carrying out troubleshooting.
Cause Remedy
YES Defective movement of

float due to dirt Clean
2
Is any foreign
YES material (dirt)
stuck to moving 3 YES Resonance of mount
part of float? (See Note 4) Repair
Is there any large
1 crack, chip, or
When float is moved up NO damage to float?
and down, is resistance Defective contact of Clean or repair
between connector (1) NO connector (See Note 2) connector
and (2) as shown in
table?
4 YES Disconnection in wiring Replace

harness visually.
NO Is it broken?
NO sensor
Table
Top (FULL) stopper position Max. 1 Ω
Bottom (EMPTY) stopper position Min. 1 MΩ
Note 1: Variations in radiator sub tank water level

The sub tank water level may change according to the angle of the machine, or the swaying
of the machine, so check the water level with the machine at a horizontal place.
ate action.
Note 4: Defective installation is a possible cause, so be careful when installing.
If the problem occurs again, check for any vibration of the mount, and if there is excessive
vibration, take the appropriate action.
20-638 PC1100-6
3
M-29 Defective operation of wiper (including cases where [E113] is

displayed)
a) Wiper does not work when wiper, washer switch is at ON or INT
Cause Remedy
3 YES Replace or
harness between W08
YES between W08 (female) (3)
2 (male) (2) and (4)
Is voltage between normal? Defective wiper, washer
Repair
YES W08 (female) (4) • Turn starting NO relay box
and chassis switch OFF. Defective contact,
ground normal? • Disconnect W08. disconnection, or short
• Turn starting • 25.6 – 31.4 Ω circuit with ground in Replace or
switch ON. NO wiring harness between replace
• 20 – 30 V fuse 7 and W08 (female)
(4)
6 YES
1 Defective wiper motor Repair
Is resistance
YES between W21
Is service code (female) (2) and Defective contact or
[E113] displayed? chassis ground disconnection in wiring
5 normal?
harness between W21 Replace or
Is voltage • Turn starting replace
• Turn starting NO (female) (2) and chassis
YES between W21 (1) switch OFF. ground
switch ON. and chassis • Disconnect W21.
ground normal? • Max. 1 Ω 7 YES
• Turn starting Go to A
Is resistance
4 switch ON. between W08
• Turn wiper (female) (8) and Defective contact or
Is voltage NO chassis ground
switch to ON or disconnection in wiring
between P02 (3) normal? Replace or
INT. harness between W08
NO and chassis • 20 – 30 V
• Turn starting switch NO replace
ground normal? OFF. (female) (8) and chassis
• Disconnect W08. ground
• Turn starting • Max. 1 Ω
switch ON. 8 YES
• Turn wiper Defective monitor panel Repair
Is resistance
switch to ON or between M18 (male)
INT. Defective contact or
NO (1) and chassis
• Max. 1 V ground normal? disconnection in wiring
Replace or
harness between M18
(male) (1) and chassis
switch OFF. ground
• Disconnect M18.
9 YES • Max. 1 Ω Defective wiper, washer
When resistance between
Repair
relay box
W08 (female) (1) and W21
A (female) (1) is normal, and Defective contact,
is it properly insulated from disconnection, or short
chassis? circuit with ground in Replace or
• Turn starting NO wiring harness between replace
switch OFF. W08 (female) (1) and
• Disconnect W08 W21 (female) (1)
and W21.
• Max. 1 Ω
PC1100-6 20-639
3
b) Wiper does not work when wiper, washer switch is

Cause Remedy
at one position (ON or INT)
YES
2
Is voltage between
At ON P02 (female) (4)
and chassis
3 YES Repair or
ground normal? harness between P02
Is resistance (female) (4) and M18 replace
• Turn starting between M18 (male) (2)
1
Does wiper not • Turn wiper (2) normal? Defective wiper, washer
switch ON. Replace
work at ON or at • Turn starting switch NO switch
INT? • Max. 1 V ON.
• Turn wiper switch ON.
• Max. 1 Ω
YES
4
Is voltage between
P02 (female) (12)
At INT and chassis 5 YES
ground normal? harness between P02 Repair or
Is resistance (female) (12) and M18 replace
• Turn starting between M18 (male) (4)
• Turn wiper (4) normal? Defective wiper, washer
Replace
switch to INT. • Turn starting NO switch
• Max. 1 V switch ON.
• Turn wiper switch to INT.
• Max. 1 Ω
c) Wiper is actuated when wiper, washer switch is OFF Cause Remedy

When P02 is between W08 (female) replace
YES disconnected, is (2) and P02 (female) (3)
resistance between
W08 (female) (2) and
chassis ground normal? Defective wiper, washer
Replace
• Turn starting NO relay box
switch OFF.
1 • Disconnect P02
and W08. YES
• Min. 1 MΩ Defective wiper motor Replace
Is service code 4
[E113] displayed? Is voltage
YES between W21 (1) Short circuit with power
and chassis 5 YES source in wiring harness Repair or
ground normal? Is resistance between W08 (female) replace
• Turn starting between W08 (1) and W21 (female) (1)
3 switch ON. NO (male) (1) and (4)
Is voltage • Max. 1 V normal? Defective wiper, washer
between P02 (3) relay box Replace
NO and chassis switch OFF.
ground normal? • Disconnect W08.
• Min. 1 MΩ
• Turn starting YES
switch ON. Defective monitor panel Replace
6
• Turn wiper Is voltage between
P02 (4) and chassis
• 20 – 30 V ground, between in wiring harness
NO (12) and chassis 7 YES between M18 (male) (2) Repair or
ground normal? Is resistance and P02 (female) (4) or replace
• Turn starting between M18 between M18 (male) (4)
switch ON. NO (female) (1) – (2), and P02 (female) (12)
• Turn wiper (1) – (4) normal?
Defective wiper, washer Replace
switch OFF. • Turn starting NO switch
• 20 – 30 V switch OFF.
• Turn wiper
switch OFF.
• Min. 1 MΩ
20-640 PC1100-6
3
PC1100-6 20-641
3
M-30 Defective operation of window washer (including cases where

service code [E114] is displayed)
fl Check that the wiper works properly before carrying out troubleshooting. (If the wiper also does
not work, carry out Troubleshooting M-29 first.)
a) Window washer does not work when wiper, washer switch is at WASH I at WASH II
Cause Remedy
2 YES
harness between W08 Repair or
Is resistance (female) (15) and P02 replace
YES between W08 (female) (2)(10)
(male) (4) and
(15) normal? Defective wiper, washer Replace
switch OFF.
• Disconnect W08.
1 • 25.6 – 31.4 Ω 5 YES
Defective wiper motor Replace
Is voltage between
Is service code YES M28, M95 (female) Defective contact,
[E114] displayed? (2) and chassis disconnection, or short
4 ground normal? circuit with ground in Repair or
Is resistance • Disconnect M28 and NO wiring harness between replace
YES between M28, M95 M95. fuse 7 – M28, M95
(female) (1) and • Turn starting switch (female) (2)
chassis ground ON.
normal? • 20 – 30 V 6 YES Defective wiper, washer
Replace
3 • Disconnect M28 Is resistance relay box
between W08
Is voltage between and M95.
(female) (12) – M28, Defective contact or
P02 (2)(10) and • Turn starting NO M95 (female) (1)
NO chassis ground normal?
normal? • Turn wiper harness between M28, Repair or
• Turn starting switch NO
switch WASH I, OFF. M95 (female) (1) – W08 replace
• Turn starting • Disconnect W08, (female) (8)
II.
switch OFF. M28, and M95.
• Turn wiper • Max. 1 Ω
switch to WASH Defective monitor panel Replace
NO
I, II
• Max. 1 V
20-642 PC1100-6
3
b) Washer is actuated when wiper, washer switch is OFF
Cause Remedy

When P02 is between W08 (female) replace
disconnected, is (15) and P02 (female)
YES
resistance between (2)(10)
W08 (female) (15) and
chassis ground normal? Defective wiper, washer
Replace
switch OFF.
1 • Disconnect P02
and W08. YES
Defective wiper motor Replace
Is service code • Min. 1 MΩ 4
[E114] displayed? Is resistance
YES between M29, M95 Short circuit with ground
(female) (1) – in wiring harness
5 YES Repair or
chassis ground between W08 (female)
normal? Is resistance replace
(12) – M28, M95 (female)
• Disconnect M29 between W08 (1)
3 and M95. NO (male) (12) and
Is voltage between • Turn starting (8) normal? Defective wiper, washer
P02 (2)(10) and switch ON. relay box Replace
NO chassis ground • Turn wiper switch OFF.
normal? switch OFF. • Disconnect W08.
• Min. 1 MΩ
• Turn starting • Min. 1 MΩ
switch ON. 6
• Turn wiper
Is voltage
between P02 (5)
• 20 – 30 V
NO and chassis 7 YES in wiring harness Repair or
ground normal? Is resistance between M18 (male) (3) replace
between M18 and P02 (female) (5)
• Turn starting
• Turn wiper (3) normal?
Defective wiper, washer
switch OFF. Replace
• Turn starting NO switch
• 20 – 30 V switch OFF.
• Turn wiper
switch OFF.
• Min. 1 MΩ
PC1100-6 20-643
3
20-644 PC1100-6
3
30 DISASSEMBLY AND ASSEMBLY
METHOD OF USING MANUAL.. ............... 30- 3 FUEL TANK ASSEMBLY
PRECAUTIONS WHEN CARRYING OUT OP- Removal and Installation .................... 30-53
ERATION ............................................... 30- 5 FINAL DRIVE ASSEMBLY
SPECIAL TOOL LIST .................................. 30- 7 Removal and Installation .................... 30-54
SKETCHES OF SPECIAL TOOLS ............... 30-12 Disassembly ......................................... 30-55
STARTING MOTOR ASSEMBLY Assembly .............................................. 30-59
Removal and Installation .................... 30-19 REVOLVING FRAME ASSEMBLY
ALTERNATOR ASSEMBLY Removal and Installation .................... 30-67
Removal and Installation .................... 30-20 SWING MACHINERY ASSEMBLY
NOZZLE HOLDER ASSEMBLY Removal and Installation .................... 30-68
Removal and Installation .................... 30-21 Disassembly ......................................... 30-69
ENGINE OIL COOLER ASSEMBLY Assembly .............................................. 30-73
Removal and Installation .................... 30-22 SWING CIRCLE ASSEMBLY
FUEL INJECTION PUMP ASSEMBLY Removal and Installation .................... 30-78
Removal ................................................ 30-23 TRACK SHOE ASSEMBLY
Installation ............................................ 30-24 Removal ................................................ 30-79
WATER PUMP ASSEMBLY Installation ............................................ 30-80
Removal and Installation .................... 30-25 SPROCKET
TURBOCHARGER ASSEMBLY Removal and Installation.. .................. 30-81
Removal and Installation .................... 30-26 IDLER ASSEMBLY
THERMOSTAT ASSEMBLY Removal and Installation.. .................. 30-82
AIR COMPRESSOR ASSEMBLY Assembly .............................................. 30-85
Removal and Installation .................... 30-28 IDLER ADJUSTMENT CYLINDER
ENGINE FRONT SEAL ASSEMBLY
Removal and Installation .................... 30-29 Disassembly and Assembly ............... 30-87
ENGINE REAR SEAL RECOIL SPRING ASSEMBLY
Removal and Installation .................... 30-31 Removal and Installation .................... 30-88
CYLINDER HEAD ASSEMBLY Disassembly ......................................... 30-90
Removal ................................................ 30-33 Assembly .............................................. 30-91
Installation ............................................ 30-37 CARRIER ROLLER ASSEMBLY
AFTERCOOLER Removal and Installation .................... 30-92
RADIATOR, HYDRAULIC COOLER Assembly.. ............................................ 30-94
ASSEMBLY TRACK ROLLER ASSEMBLY
Removal ................................................ 30-40 Removal and Installation .................... 30-95
Installation ............................................ 30-41 Disassembly ......................................... 30-96
HYDRAULIC COOLER ASSEMBLY Assembly .............................................. 30-97
Removal and Installation .................... 30-42 HYDRAULIC TANK ASSEMBLY
ENGINE, PTO, HYDRAULIC PUMP Removal ................................................ 30-99
ASSEMBLY Installation .......................................... 30-100
Removal ................................................ 30-43 TVC VALVE ASSEMBLY
Installation ............................................ 30-46 Removal and Installation .................. 30-101
PTO ASSEMBLY SERVO VALVE ASSEMBLY
Removal ................................................ 30-47 Removal and Installation .................. 30-102
Installation ............................................ 30-48 HYDRAULIC PUMP ASSEMBLY
Disassembly ......................................... 30-49 Removal and Installation .................. 30-103
Assembly.. ............................................ 30-51
PC1 100-6 30-l

@
NO. 1, 2 PUMP (HPV95+95) BUCKET ASSEMBLY
Disassembly ................................. 30-103- 1 BACKHOE
Assembly ....................................... 30-103-11 Removal .............................................. 30-141
NO. 3 PUMP (HPV160+160) Installation .......................................... 30-142
Disassembly .................................. 30-103-27 LOADING SHOVEL
Assembly ....................................... 30-103-37 Removal ........................................... 30-142-1
MAIN PUMP INPUT SHAFT OIL SEAL Installation ....................................... 30-142-1
Removal and Installation .................. 30-104 ARM ASSEMBLY
MAIN RELIEF VALVE ASSEMBLY BACKHOE
Removal and Installation .................. 30-105 Removal .............................................. 30-143
Disassembly and Assembly ............. 30-106 Installation .......................................... 30-144
PILOT RELIEF VALVE ASSEMBLY LOADING SHOVEL
Removal and Installation .................. 30-107 Removal ........................................... 30-144-1
5-SPOOL CONTROL VALVE ASSEMBLY Installation ....................................... 30-144-1
Removal .............................................. 30-108 BOOM ASSEMBLY
Installation .......................................... 30-109 BACKHOE
4-SPOOL CONTROL VALVE ASSEMBLY Removal .............................................. 30-145
Removal .............................................. 30-110 Installation .......................................... 30-146
Installation .......................................... 30-111 LOADING SHOVEL
CONTROL VALVE ASSEMBLY Removal ........................................... 30-146-1
Disassembly ....................................... 30-114 Installation ....................................... 30-146-3
Assembly ............................................ 30-115 BUCKET, ARM ASSEMBLY
SWING MOTOR ASSEMBLY Removal .............................................. 30-147
Removal and Installation .................. 30-125 Installation .......................................... 30-148
CENTER SWIVEL JOINT ASSEMBLY WORK EQUIPMENT ASSEMBLY
Removal and Installation .................. 30-126 BACKHOE
Disassembly and Assembly ............. 30-127 Removal .............................................. 30-149
TRAVEL MOTOR ASSEMBLY Installation .......................................... 30-150
Removal and Installation .................. 30-128 LOADING SHOVEL
WORK EQUIPMENT PPC VALVE Removal ........................................... 30-150-1
ASSEMBLY Installation ....................................... 30-150-2
Removal and Installation .................. 30-129 CAB ASSEMBLY
Disassembly ....................................... 30-130 Removal .............................................. 30-151
Assembly ............................................ 30-131 Installation .......................................... 30-152
TRAVEL PPC VALVE ASSEMBLY COUNTERWEIGHT ASSEMBLY
Removal and Installation .................. 30-132 Removal and Installation .................. 30-153
Disassembly ....................................... 30-133 RECEIVER TANK ASSEMBLY
Assembly ............................................ 30-134 Removal and Installation .................. 30-154
BUCKET CYLINDER ASSEMBLY AIR CONDITIONER CONDENSER
BACKHOE ASSEMBLY
Removal .............................................. 30-135 Removal and Installation .................. 30-155
Installation .......................................... 30-136 AIR CONDITIONER COMPRESSOR
LOADING SHOVEL ASSEMBLY
Removal ........................................... 30-136-1 Removal and Installation .................. 30-156
Installation ....................................... 30-136-2 AIR CONDITIONER UNIT ASSEMBLY
ARM CYLINDER ASSEMBLY Removal .............................................. 30-157
BACKHOE Installation .......................................... 30-158
Removal .............................................. 30-137 SOLENOID VALVE ASSEMBLY
Installation .......................................... 30-138 Removal and Installation .................. 30-159
LOADING SHOVEL GOVERNOR CONTROLLER ASSEMBLY
Installation ....................................... 30-138-2 MONITOR PANEL ASSEMBLY
BOOM CYLINDER ASSEMBLY Removal and Installation .................. 30-161
BACKHOE PUMP CONTROLLER ASSEMBLY
Removal .............................................. 30-139 Removal and Installation .................. 30-162
Installation .......................................... 30-140 BOOM ROCK PREVENTION VALVE
LOADING SHOVEL ASSEMBLY
Installation ....................................... 30-140-2 ACCUMULATOR ASSEMBLY
BOTTOM DUMP CYLINDER ASSEMBLY Removal and Installation .................. 30-164
LOADING SHOVEL BOOM LOWER REGENERATION VALVE
Removal ........................................... 30-140-3 ASSEMBLY
Installation ....................................... 30-140-4 Removal and Installation .................. 30-165
30-2 PC1100-6
5
DISASSEMBLY AND ASSEMBLY METHOD OF USING MANUAL
METHOD OF USING MANUAL

1. When removing or installing unit assemblies
1 When removing or installing a unit assembly, the order of work and techniques used are given
for the removal operation; the order of work for the installation operation is not given.
2 Any special techniques applying only to the installation procedure are marked 1, and the
same mark is placed after the relevant step in the removal procedure to indicate which step in
the installation procedure it applies to.
(Example)
REMOVAL OF o o o o ASSEMBLY ............ Title of operation
 ...................................................................... Precautions related to safety when carrying out
the operation
1. X X X X (1) ..................................................... Step in operation
fl .................................................................. Technique or important point to remember
when removing XXXX (1).
2. # # # # (2): ............................................... 1 Indicates that a technique is listed for use
during installation
3. l l l l assembly (3)
6 ............................................................ Quantity of oil or water drained
INSTALLATION OF o o o o ASSEMBLY ....Title of operation

• Carry out installation in the reverse order to removal.
1 ............................................................. Technique used during installation
fl .................................................................. Technique or important point to remember when
installing # # # # (2).
• Adding water, oil ................................. Step in operation
fl ............................................................ Point to remember when adding water or oil
-......................................................... Quantity when filling with oil and water
2. General precautions when carrying out installation or removal (disassembly or assembly) of units
are given together as PRECAUTIONS WHEN CARRYING OUT OPERATION, so be sure to follow
these precautions when carrying out the operation.
3. Listing of special tools

1 For details of the description, part number, and quantity of any tools (A1, etc.) that appear in
the operation procedure, see the SPECIAL TOOLS LIST given in this manual.
PC1100-6 30-3
2
DISASSEMBLY AND ASSEMBLY METHOD OF USING MANUAL
4. General tightening torque table (when using torque wrench)

fl In the case of metric nuts and bolts for which there is no special instruction, tighten to the torque
Thread diameter Width across flats

SAD00481 SAD00482
mm mm kgm Nm
6 10 1.35 ± 0.15 13.2 ± 1.4
8 13 3.2 ± 0.3 31.4 ± 2.9
10 17 6.7 ± 0.7 65.7 ± 6.8
12 19 11.5 ± 1.0 112 ± 9.8
14 22 18.0 ± 2.0 177 ± 19
16 24 28.5 ± 3 279 ± 29
18 27 39 ± 4 383 ± 39
20 30 56 ± 6 549 ± 58
22 32 76 ± 8 745 ± 78
24 36 94.5 ± 10 927 ± 98
27 41 135 ± 15 1320 ± 140
30 46 175 ± 20 1720 ± 190
33 50 225 ± 25 2210 ± 240
36 55 280 ± 30 2750 ± 290
39 60 335 ± 35 3280 ± 340
Seal surface
SAD00483
5. Table of tightening torques for flared nuts
fl In the case of flared nuts for which there is no special instruction, tighten to the torque given in the
table below.
Thread diameter Width across flats Tightening torque
mm mm kgm Nm
14 19 2.5 ± 0.5 24.5 ± 4.9
18 24 5±2 49 ± 19.6
22 27 8±2 78.5 ± 19.6
24 32 14 ± 3 137.3 ± 29.4
30 36 18 ± 3 176.5 ± 29.4
33 41 20 ± 5 196.1 ± 49
36 46 25 ± 5 245.2 ± 49
42 55 30 ± 5 294.2 ± 49
6. Table of tightening torques for split flange bolts

fl In the case of split flange bolts for which there is no special instruction, tighten to the torque given
in the table below.
Thread diameter Width across flats Tightening torque
mm mm kgm Nm
10 14 6.7 ± 0.7 65.7 ± 6.8
12 17 11.5 ± 1 112 ± 9.8
16 22 28.5 ± 3 279 ± 29
30-4 PC1100-6
2
DISASSEMBLY AND ASSEMBLY PRECAUTIONS WHEN CARRYING OUT OPERATION
PRECAUTIONS WHEN CARRYING OUT OPERATION

[When carrying out removal or installation (disassembly or assembly) of units, be sure to follow the
general precautions given below when carrying out the operation.]
1. Precautions when carrying out removal work
• If the coolant contains antifreeze, dispose of it correctly.
• After disconnecting hoses or tubes, cover them or fit blind plugs to prevent dirt or dust from
entering.
• When draining oil, prepare a container of adequate size to catch the oil.
• Confirm the match marks showing the installation position, and make match marks in the neces-
sary places before removal to prevent any mistake when assembling.
• To prevent any excessive force from being applied to the wiring, always hold the connectors when
disconnecting the connectors. Do not pull the wires.
• Fit wires and hoses with tags to show their installation position to prevent any mistake when
installing.
• Check the number and thickness of the shims, and keep in a safe place.
• When raising components, be sure to use lifting equipment of ample strength.
• When using forcing screws to remove any components, tighten the forcing screws uniformly in
turn.
• Before removing any unit, clean the surrounding area and fit a cover to prevent any dust or dirt
from entering after removal.
fl Precautions when handling piping during disassembly
Fit the following blind plugs into the piping after disconnecting it during disassembly operations.
1) Hoses and tubes using sleeve nuts
Nominal Plug (nut end) Sleeve nut (elbow end) Use the two items below as a set
number
02 07376-50210 07221-20210 (Nut), 07222-00210 (Plug)
03 07376-50315 07221-20315 (Nut), 07222-00312 (Plug)
04 07376-50422 07221-20422 (Nut), 07222-00414 (Plug)
05 07376-50522 07221-20522 (Nut), 07222-00515 (Plug)
06 07376-50628 07221-20628 (Nut), 07222-00616 (Plug)
10 07376-51034 07221-21034 (Nut), 07222-01018 (Plug)
12 07376-51234 07221-21234 (Nut), 07222-01219 (Plug)
2) Split flange type hoses and tubes

Nominal
Flange (hose end) Sleeve head (tube end) Split flange
number
04 07379-00400 07378-10400 07371-30400
05 07379-00500 07378-10500 07371-30500
3) If the part is not under hydraulic pressure, the following corks can be used.
Nominal Dimensions
Part Number
number D d L
06 07049-00608 6 5 8
08 07049-00811 8 6.5 11
10 07049-01012 10 8.5 12
12 07049-01215 12 10 15 Taper 1/8
øD
ød
14 07049-01418 14 11.5 18
16 07049-01620 16 13.5 20
18 07049-01822 18 15 22
20 07049-02025 20 17 25
L
22 07049-02228 22 18.5 28
24 07049-02430 24 20 30
DEW00401
27 07049-02734 27 22.5 34
PC1100-6 30-5
2
DISASSEMBLY AND ASSEMBLY PRECAUTIONS WHEN CARRYING OUT OPERATION
2. Precautions when carrying out installation work

• Tighten all bolts and nuts (sleeve nuts) to the specified (KES) torque.
• Install the hoses without twisting or interference.
• Replace all gaskets, O-rings, cotter pins, and lock plates with new parts.
• Bend the cotter pins and lock plates securely.
• When coating with adhesive, clean the part and remove all oil and grease, then coat the threaded
portion with 2 – 3 drops of adhesive.
• When coating with gasket sealant, clean the surface and remove all oil and grease, check that there
is no dirt or damage, then coat uniformly with gasket sealant.
• Clean all parts, and correct any damage, dents, burrs, or rust.
• Coat rotating parts and sliding parts with engine oil.
• When press fitting parts, coat the surface with anti-friction compound (LM-P).
• After fitting snap rings, check that the snap ring is fitted securely in the ring groove.
• When connecting wiring connectors, clean the connector to remove all oil, dirt, or water, then
connect securely.
• When using eyebolts, check that there is no deformation or deterioration, screw them in fully, and
align the direction of the hook.
• When tightening split flanges, tighten uniformly in turn to prevent excessive tightening on one
side.
fl When operating the hydraulic cylinders for the first time after reassembling cylinders, pumps and
other hydraulic equipment removed for repair, always bleed the air as follows:
1. Start the engine and run at low idling.
2. Operate the work equipment control lever to operate the hydraulic cylinder 4 – 5 times,
stopping the cylinder 100 mm from the end of its stroke.
3. Next, operate the hydraulic cylinder 3 – 4 times to the end of its stroke.
4. After doing this, run the engine at normal speed.
fl When using the machine for the first time after repair or long storage, follow the same
procedure.
3. Precautions when completing the operation

• If the coolant has been drained, tighten the drain valve, and add water to the specified level. Run
the engine to circulate the water through the system. Then check the water level again.
• If the hydraulic equipment has been removed and installed again, add engine oil to the specified
level. Run the engine to circulate the oil through the system. Then check the oil level again.
• If the piping or hydraulic equipment have been removed, always bleed the air from the system
after reassembling the parts.
fl For details, see TESTING AND ADJUSTING, Bleeding air.
• Add the specified amount of grease (molybdenum disulphide grease) to the work equipment parts.
30-6 PC1100-6
2
DISASSEMBLY AND ASSEMBLY SPECIAL TOOL LIST
SPECIAL TOOL LIST

fl Tools with part number 79o T- ooo- oooo can not be supplied (they are items to be locally
manufactured).
fl Necessity: à : Cannot be substituted, should always be prepared (used).
Ý Extremely useful if available, can be substituted with commercially available part.
fl New/remodel: N: Tools with new part numbers, newly developed for this model.
fl R: Tools with upgraded part numbers, remodeled from items already available for
other models.
fl Blank: Tools already available for other models, can be used without any modification.
fl Tools marked 9 in the Sketch column are tools introduced in special sketches (See SKETCHES OF
SPECIAL TOOLS).
New/ Nature of work,
Component Symbol Part No. Part Name Necessity Q’ty remodel Sketch remarks
1 790-331-1110 Wrench à 1 Removal,
installation of
2 790-471-1001 Lifting tool à 1 cylinder head
795-902-1430 Push tool à 1 Press fitting of front
3 seal
01050-32235 Bolt à 3
795-902-1410 Sleeve à 1 Press fitting of front

4 sleeve
• Disassembly, 01050-32240 Bolt à 3
assembly of A
engine 795-902-1440 Push tool à 1 Press fitting of rear
5 seal
01050-32050 Bolt à 4
795-902-1420 Sleeve à 1
Press fitting of rear
6 795-902-1450 Bolt à 2 sleeve
01582-02016 Nut à 2
Removal, installation of
7 795T-871-1110 Adapter à 2 N 9 injection pump
790-701-5401 Push tool kit à 1
790-101-5541 • Plate 1 Press fitting of oil

1 seal
790-101-5421 • Grip 1
• Disassembly,
assembly of 01010-51240 • Bolt 1
swing F Press fitting of main
2 796T-826-1110 Plate à 1 N 9 bearing
machinery
Press fitting of sub
3 796T-826-1130 Push tool à 1 N 9 bearing
Press fitting of pinion
4 796T-826-1120 Push tool à 1 N 9 shaft
5 790-331-1110 Wrench à 1 Angle tightening
1 796-627-1200 Wrench assembly à 1 round nut
796T-827-1130 Spacer à 1 N 9
Pulling out of No. 1
2 01017-52450 Bolt à 1 carrier pin holder
01580-12419 Nut à 1
• Disassembly,
assembly of Pulling out of No. 1
J 3 790-201-2820 Spacer o 1 carrier pin
final drive
790-101-5401 Push tool kit (C) o 1
Press fitting of No. 1
• 790-101-5491 Push tool carrier gear bearing
4 outer race
• 790-101-5421 Grip 1
• 01010-51240 Bolt 1
PC1100-6 30-7
2

790-101-5001 Push tool kit o 1 Press fitting of needle
bearing
790-101-5151 • Plate 1 No. 2 carrier
5 790-101-5061 • Plate 1 No. 3 carrier
790-101-5021 • Grip 1
01010-50816 • Bolt 1
Press fitting of outer
6 796-627-1030 Push tool à 1 race
790-101-2300 Push-puller 1 Measurement depth
of hub bearing
• Disassembly, • 790-101-2310 • Block 1 inner race
assembly of J
final drive • 790-101-2350 • Leg 2
• 790-101-2360 • Plate 2
7 • 02215-11622 • Nut 2
791-181-1010 Adapter à 2
796T-627-1340 Push tool à 1 N 9

Puller
790-101-2102 (290 kN {30 ton}) à 1
790-101-1102 Hydraulic pump à 1

Installation of floating
8 796-627-1050 Installer à 1 seal
9 796-660-1560 Guide bolt à 2 travel motor
791-685-8501 Compressor à 1 Disassembly,
assembly of recoil
791-635-3160 Extension à 1 spring
796T-830-1110 Plate à 1 N 9
• Disassembly,
assembly of M 1 796T-830-1120 Spacer à 1 N 9
recoil spring
01010-61640 Bolt à 2
Cylinder
790-101-1600 (690 kN {70 ton}) à 1
790-101-1102 Hydraulic pump à 1
790-101-5401 Push tool kit (C) à 1 Press fitting of

carrier roller bearing
• 790-101-5441 • Plate 1 outer race
1
• 790-101-5421 • Grip 1
• 01010-51240 • Bolt 1
• Disassembly, Press fitting of carrier roller
assembly of 2 796T-830-1130 Push tool à 1 N 9 bearing inner race
L
carrier roller, 3 796T-830-1140 Adapter à 2 N 9 Press fitting of shaft
track roller, and roller
idler 4 796-570-1020 Installer à 1 Installation of carrier
roller floating seal
790-101-5401 Push tool kit (C) à 1
5 • 790-101-5521 • Plate 1
• 790-101-5421 • Grip 1
30-8 PC1100-6
2

5 • 01010-51240 • Bolt 1
Installation of track
6 790-434-1620 Installer 1 roller floating seal
790-401-1700 Lifting tool 1 Removal, installation
of track roller
790-401-1761 Adapter 1 assembly
7
790-401-1540 Shackle 2
790-401-1770 T-bolt 2
• Disassembly,
790-101-5401 Push tool lit 1
assembly of L
carrier roller, • 790-101-5541 • Plate 1
track roller, Press fitting of idler
8
idler • 790-101-5421 • Grip 1 bushing
• 01010-51240 • Bolt 1
Installation of idler
9 796-675-1510 Installer 1 floating seal
791-601-1000 Oil pump 1
10 791-646-8002 Oil lubricator 1 Filling with oil and

checking seal
790-701-3000 Seal checker 1
Unit repair stand
790-501-5000 (for 100V)
o 1 Disassembly,
Unit repair stand
790-501-5200 assembly of pump
(for 220V, 240V)
assembly
790-901-2110 Bracket o 1
1
790-901-1331 Plate o 1 For front pump
790-345-1020
or Plate o 1 For rear pump
790-345-1040
790-201-3330 Bolt 1
792-422-1120 Washer 1 Disassembly,

assembly of
2 01643-32460 Washer 1
• Disassembly, cylinder block
assembly of 01643-31845 Washer 1 assembly
hydraulic pump P
assembly 01580-01815 Nut 1
HPV95+95
790-201-2180 Plate 1
Removal of roller
3 790-201-2740 Spacer 1
bearing
790-201-2840 Spacer 1
796-720-2210 Screwdriver 1
Disassembly,
796-730-2120 Screwdriver 1 assembly of
4 impeller, and
796-720-2220 Socket 1 disassembly,
assembly of cradle
795-630-1803 Torque wrench 1
5 796-867-1200 Gauge 1 For minimum Adjustment of

servo piston
6 796-767-1100 Gauge 1 For maximum swash plate angle
PC1100-6 30-9
2
5

790-201-2160 Plate 1
7 Press fitting of roller
790-201-2730 Spacer 1 bearing
790-201-2190 Plate 1 Press fitting of shaft

8
790-201-2740 Spacer 1 assembly
• Disassembly,
assembly of 790-101-5001 Push tool kit 1
hydraulic pump P
assembly 790-101-5151 • Plate 1 Press fitting of oil
HPV95+95 9
790-101-5021 • Grip 1 seal
01010-50816 • Bolt 1
01435-01225 Bolt 1 Inspection of shaft

10
Commercially available Torque wrench 1 rotating torque
Unit repair stand
790-501-5000 (for 100V)
Unit repair stand
o 1 Disassembly,
790-501-5200 (for 220V, 240V) assembly of pump
assembly
1 790-901-2110 Bracket o 1
790-345-1010 Plate o 1 For front pump
790-345-1040 Plate o 1 For rear pump
796-720-2120 Screwdriver 1 Disassembly,

assembly of
2 796-720-2220 Socket 1 impeller, and
disassembly,
795-630-1803 Torque wrench 1 assembly of cradle
790-201-3610 Bolt 1
796-465-1110 Washer 1
Disassembly,
3 01643-33080 Washer 1 assembly of
cylinder block
01643-32016 Washer 1 assembly
• Disassembly, 01582-02016 Nut 1
assembly of
hydraulic pump Q 790-201-2220 Plate 1
assembly
Removal of roller
HPV160+160 4 790-201-2750 Spacer 1
bearing
790-201-2850 Spacer 1
5 796-660-1900 Gauge 1 For minimum Adjustment of

servo piston
6 796-867-1100 Gauge 1 For maximum swash plate angle
790-201-2190 Plate 1
7 Press fitting of roller
790-201-2740 Spacer 1 bearing
790-201-2240 Plate 1
8 Press fitting of shaft
790-201-2750 Spacer 1 assembly
791-222-1310 Plate 1
Press fitting of oil
9 790-101-5221 Grip 1
seal
01010-51225 Bolt 1
01435-01225 Bolt 1 Inspection of shaft

10
Commercially available Torque wrench 1 rotating torque
30-10 PC1100-6
2
5

796-832-1110 Remover & Installer 1 N
• 791-685-9510 • Frame 1
• 791-685-9520 • Frame 1
• 791-685-9530 • Rod 1
• 791-685-9540 • Rod 1
• 791-685-9550 • Nut 3
• 791-685-9560 • Bolt 4
• 791-126-0150 • Adapter 1
• 791-680-5520 • Guide 1
• 791-632-1150 • Pusher 1 Pulling out and

insertion of master
• 791-632-1140 • Adapter 1 pin
• Disassembly, • 791-832-1110 • Adapter 1 N

assembly of R 1
track • 790-434-1610 • Grip 1
• 01010-51440 • Bolt 2
• 791-685-9620 • Extension 1
• 791-632-1160 • Guide 1
• 791-680-5543 • Adapter 1
• 791-680-5551 • Guide 1
• 796-832-1120 • Adapter 1 N
• 791-632-1170 • Guide 1
• 791-680-9630 • Adapter 1
Cylinder
790-101-4300 (1,500 kN {150 ton})
1
Puller
790-101-4200 (290 kN {30 ton})
1
• 790-101-1102 Hydraulic pump 1

1 796-770-1301 Oil stopper 1 pump
790-101-5001 Push tool kit (A) 1
• 790-101-5151 • Plate 1 Replacement of input

2 shaft seal of No. 1, 2
• Removal, • 790-101-5021 • Grip 1 pump
installation of
hydraulic pump • 01010-50816 • Bolt 1
and replacement S
790-101-5201 Push tool kit (B) 1
of pump input
shaft oil seal 790-101-5221 • Grip 1 Replacement of input
3 shaft seal of No. 3
01010-51225 • Bolt 1 pump
791-222-1310 Plate 1
PC1100-6 30-11
2
5

1 790-502-1003 Repair stand o 1 Disassembly, assembly
of hydraulic cylinder
790-201-1702 Push tool kit (C) 1 Press fitting of coil
bushing
2 • 790-201-1861 • Push tool 1
(Bucket cylinder)
• 790-201-5021 • Grip 1
• 01010-50816 • Bolt 1
3 790-201-1910 Push tool 1 (Arm cylinder)
4 790-863-1110 Push tool 1 (Boom cylinder)
• 790-101-5421 Grip 1 Boom & arm

3,4 cylinder
• 01010-51240 Bolt 1
790-201-1500 Push tool kit 1 Press fitting of dust

seal
• 790-201-1670 • Plate 1 (Bucket cylinder)
• Disassembly, 5
• 790-101-5021 • Grip 1
assembly of U
hydraulic • 01010-50816 • Bolt 1
cylinder
6 792-715-1400 Push tool 1 (Boom & arm cylinder)
7 790-201-1920 Push tool 1
• 790-101-5421 • Grip 1
6,7
• 01010-51240 • Bolt 1
8 790-720-1000 Expander 1
Installation of piston
796-720-1680 Ring 1 ring
9 (Bucket cylinder)
07281-01589 Clamp 1
796-720-1710 Ring 1 (Arm cylinder)
10
07281-02709 Clamp 1
796-702-1720 Ring 1 (Boom cylinder)

11
07281-02429 Clamp 1
796T-870-1130 Sleeve 1 N 9 Pulling out of boom

foot pin
796T-870-1140 Sleeve 1 N 9
790-445-4130 Screw 1
• Disassembly,
assembly of V 1 01643-32780 Washer 1
work equipment
02215-11622 Nut 1
Puller
790-101-4200 1
(290 kN {30 ton})
790-101-1102 Hydraulic pump 1
30-11-1 PC1100-6
5

790-445-4120 Sleeve 1 Pulling out of boom
cylinder head pin
790-445-4140 Sleeve 1 and bottom pin
• 02215-11622 Nut 1
2
• 01643-32780 Washer 1
• 790-101-4200 Puller 1
(290 kN {30 ton})
796T-870-1120 Sleeve 1 N 9 Pulling out of boom

top pin
796-870-1110 Adapter 1 N
796-900-1230 Screw 1
• Disassembly, 3 01643-33080 Washer 1
assembly of V
work equipment 01582-03024 Nut 1
790-101-4000 Puller 1
(500 kN {50 ton})
796T-870-1150 Sleeve 1 N 9 Pulling out of arm

cylinder head pin
790-438-1110 Screw 1 and bottom pin
796-775-1110 Adapter 1
4 791-112-1180 Nut 1
790-101-2540 Washer 1
• @790-101-2102 Puller 1
(290 kN {30 ton})
799-703-1200 Service tool kit 1 Charging with new
freon gas
• Charging air 799-703-1100 Vacuum pump 1
conditioner with X 1
gas 799-703-1110 Vacuum pump (220 V) 1 799-703-1120 (240 V)
799-703-1400 Gas leak tester 1
PC1100-6 30-11-2
5
DISASSEMBLY AND ASSEMBLY SKETCHES OF SPECIAL TOOLS
SKETCHES OF SPECIAL TOOLS

Note: Komatsu cannot accept any responsibility for special tools
manufactured according to these sketches.
A7 – Adapter
F2 – Plate
30-12 PC1100-6
2
F3 – Push tool
F4 – Push tool
PC1100-6 30-13
2
J2 – Spacer
J7 – Push tool
30-14 PC1100-6
2
M1 – Plate
M1 – Spacer
PC1100-6 30-15
2
L2 – Push tool
L3 – Adapter
30-16 PC1100-6
2
V1 – Sleeve
V1 – Sleeve
PC1100-6 30-17
2
V3 – Sleeve
V4 – Sleeve
30-18 PC1100-6
2
DISASSEMBLY AND ASSEMBLY STARTING MOTOR
REMOVAL OF STARTING
MOTOR ASSEMBLY
 Disconnect the cable from the negative (–)
terminal of the battery.
A. Removal of R.H. starting motor assembly

1. Open cover (1) and use a ladder to enter into
side face of engine.
2. Disconnect wiring connector (2) (M2).
3. Disconnect terminal B wiring (3) (tightened
together with 3 wires).
4. Remove mounting bolt (4), then remove starting
motor assembly (5).
B.Removal of L.H. starting motor assembly

1. Open doors (1).
3. Disconnect terminal B wiring (3) (tightened
together with 3 wires).
4. Remove mounting bolt (4), then remove starting
motor assembly (5).
INSTALLATION OF STARTING
MOTOR ASSEMBLY
• Carry out installation in the reverse order to
removal.
PC1100-6 30-19
2
DISASSEMBLY AND ASSEMBLY ALTERNATOR
REMOVAL OF ALTERNATOR
ASSEMBLY
2. Disconnect wiring (2) (terminals B and R).
3. Loosen lock bolt (3).
4. Loosen locknuts (4) and lock bolt (5), and remove
fan belt (6) from pulley. 1
5. Remove lock bolts (3) and (5), then remove
alternator assembly (7).
INSTALLATION OF
ALTERNATOR ASSEMBLY
removal.
1
fl Adjust the fan belt tension.
For details, see TESTING AND ADJUSTING,
Adjusting fan belt tension.
30-20 PC1100-6
2
DISASSEMBLY AND ASSEMBLY NOZZLE HOLDER
REMOVAL OF NOZZLE
HOLDER ASSEMBLY
1. Open engine hood.
2. Remove fuel injection tubes (1). 1
3. Remove spill tube (2). 2
4. Remove connection (3).
5. Remove head cover (4). 3

fl Remove nozzle seal (5) from the head cover.
6. Remove 2 holder bolts (6), then remove nozzle

assembly (7). 4
INSTALLATION OF NOZZLE
HOLDER ASSEMBLY
removal.
1
3 Fuel injection tube:
22.7 ± 3.0 Nm {2.3 ± 0.3 kgm}
2
3 Spill tube: 15.8 ± 2.0 Nm {1.0 ± 0.2 kgm}
3
3 Head cover:
32.5 ± 3.0 Nm {3.3 ± 0.3 kgm}
4
3 Holder bolt:
27.5 ± 3.0 Nm {2.8 ± 0.3 kgm}
PC1100-6 30-21
2
DISASSEMBLY AND ASSEMBLY ENGINE OIL COOLER
REMOVAL OF ENGINE OIL

COOLER ASSEMBLY
1. Drain coolant.
2. Remove engine hood (1).
4 Engine hood assembly: 60 kg
3. Remove adiabatic plates (2), (3), and (4).
4. Remove brackets (5) together with oil cooler

mounting bolts.
5. Disconnect wiring harness clamp (6).
6. Remove water pipe (7).
7. Remove turbocharger drain tube (8).
8. Remove 26 mounting bolts (9), then remove oil

cooler assembly (10).
9. Remove core (12) from cover (11).
INSTALLATION OF ENGINE OIL

COOLER ASSEMBLY
removal.
• Refilling with water

Add water to the mouth of the radiator filler
port. Tighten the cap and run the engine to
circulate the water through the system. Then
check the water level in the reserve tank.
(Check if the water level goes up or down.)
30-22 PC1100-6
2
DISASSEMBLY AND ASSEMBLY FUEL INJECTION PUMP
REMOVAL OF FUEL INJECTION

PUMP ASSEMBLY
1. Close fuel valve.
3. Open engine side doors (2).
4. Remove cover (3), and disconnect wiring

connectors for injection pump.
fl Connectors for governor control solenoid:
E19, E32
fl Connector for variable prestroke control
solenoid: E20
fl Connector for rack sensor: E22
5. Disconnect hose (5) between hand priming pump

and feed pump.
6. Disconnect hose (6) between feed pump and
fuel filter.
7. Disconnect hose (7) between fuel injection pump
and fuel filter.
8. Disconnect hose (8) between fuel injection pump
and fuel tank.
9. Remove inlet tube (9) for fuel injection pump
lubrication.
10. Disconnect fuel injection tubes (10). 1

11. Remove U-bolt (11), then remove bracket (12).
12. Disconnect outlet tube (13) for fuel injection
pump lubrication.
13. Remove cover (14).
PC1100-6 30-23
2
DISASSEMBLY AND ASSEMBLY FUEL INJECTION PUMP
14. Loosen coupling bolts (15).
15. Remove 4 mounting bolts (16), then remove fuel

injection pump assembly (17).
4 Fuel injection pump assembly: 45 kg
INSTALLATION OF FUEL
INJECTION PUMP ASSEMBLY
removal.
1
3 Fuel injection tube:
23.66 ± 0.98 Nm {2.4 ± 0.1 kgm}
fl Adjust the fuel injection timing.

Testing and adjusting fuel injection timing.
fl Bleed the air from the fuel system.
30-24 PC1100-6
2
DISASSEMBLY AND ASSEMBLY WATER PUMP
REMOVAL OF WATER PUMP

ASSEMBLY
1. Drain coolant.

3. Remove 4 mounting bolts (2).
4. Remove bracket (3). 1
5. Remove connector tube (4) between oil cooler

and water pump.
fl Move the alternator wiring towards the
engine.
6. Remove mounting bolt (5) of water bypass pipe.
7. Remove 4 mounting bolts (6), then remove water

pump assembly (7).
fl Pull out the water bypass pipe while
removing the water pump assembly down
to the rear.
INSTALLATION OF WATER
PUMP ASSEMBLY
removal.
1
fl Tighten the bracket mounting bolts in turn
at the top and bottom.

PC1100-6 30-25
2
DISASSEMBLY AND ASSEMBLY TURBOCHARGER
REMOVAL OF
TURBOCHARGER ASSEMBLY
1. Open engine hood (1).
2. Disconnect bracket (2).
3. Remove 4 joint tube mounting bolts (3), and

disconnect joint tube (6) from air cleaner
assembly (4).
4. Remove lock bracket, and pull out joint tube (6)

from turbocharger.
5. Remove adiabatic plate (7).

fl Disconnect the exhaust temperature sensor
connector.
6. Disconnect turbocharger lubrication oil outlet

tube (8).
7. Disconnect clamp (9).
8. Remove clamps (10) (2 places), and pull out tube

(11) between aftercooler and turbocharger from
turbocharger.
9. Disconnect turbocharger lubrication oil inlet hose

(12).
10. Remove 4 mounting bolts, then remove

turbocharger assembly (13). 1
INSTALLATION OF
TURBOCHARGER ASSEMBLY
removal.
1
3 Turbocharger assembly mounting bolt:
67.0 ± 7.9 Nm {6.8 ± 0.8 kgm}
30-26 PC1100-6
2
DISASSEMBLY AND ASSEMBLY THERMOSTAT
REMOVAL OF THERMOSTAT
ASSEMBLY
1. Drain coolant.
3. Remove hose (2) between radiator and

thermostat.
4. Remove aeration tube (3).
5. Disconnect tension pulley lubrication grease

tubes (4) and (5).
6. Remove pin (7), and move water pipe (8) towards

rear of engine, then disconnect from cover (6).
7. Remove mounting bolts, then remove cover (6).
8. Remove thermostats (10) and seals (11) from

thermostat housing (9).
INSTALLATION OF
THERMOSTAT ASSEMBLY
removal.

PC1100-6 30-27
2
DISASSEMBLY AND ASSEMBLY AIR COMPRESSOR
REMOVAL OF AIR
COMPRESSOR ASSEMBLY
1. Drain engine cooling water to level of thermostat

housing.
2. Open engine room door.
3. Remove suction tube (1).
4. Remove tube (2) going to air tank.
5. Remove tube (3) going to air governor.
6. Remove lubrication tube (4).
7. Disconnect tube (5) coming from thermostat

housing.
8. Disconnect tube (6) going to engine oil cooler.
9. Remove mounting bolts, then remove air

compressor assembly (7).
INSTALLATION OF AIR
COMPRESSOR ASSEMBLY
removal.
30-28 PC1100-6
2
DISASSEMBLY AND ASSEMBLY ENGINE FRONT SEAL
REMOVAL OF ENGINE FRONT

SEAL
1. Remove radiator guard assembly.
For details, see REMOVAL OF RADIATOR,
HYDRAULIC COOLER ASSEMBLY.
2. Remove crankshaft pulley and damper (1).1
3. Remove front seal (2). 2
INSTALLATION OF ENGINE
FRONT SEAL
removal.
1
fl Align the dowel pin when installing the
crankshaft pulley.
fl Tighten the mounting bolts in the order
shown in the diagram on the right.
3 Crankshaft pulley mounting bolt:
1st step: 73.5 ± 19.6 Nm {7.5 ± 2 kgm}
2nd step: 245 ± 19.6 Nm {25 ± 2 kgm}
3rd step: 637 ± 19.6 Nm {65 ± 2 kgm}
2
• Procedure for assembling standard seal
fl Fill the lip portion with approx. 5 cc of lithium
grease (G2-LI).
fl Press fit front seal (2) to front cover (3).
fl After press fitting, check mounting dimension
“a”.
Front seal mounting dimension “a”:
66 mm (standard)
PC1100-6 30-29
2
DISASSEMBLY AND ASSEMBLY ENGINE FRONT SEAL
• Procedure for assembling front seal with sleeve

(for maintenance)
1) Using tool A4, guide bolt 1, and nut 2,
press fit sleeve (4) to crankshaft (5).
fl Tighten 3 nuts 2 uniformly.
fl Press fit until tool A4 contacts the end
face of the crankshaft.
fl After press fitting, check that mounting
dimension “b” of the sleeve is the
specified dimension.
Sleeve mounting dimension “b”:
68 ± 0.1 mm
2) Press fit front seal (6) to front cover (3).

fl Fill the lip portion with approx. 5 cc of
lithium grease (G2-LI).
fl After press fitting, check mounting
dimension “c”.
Front seal mounting dimension “c”:
66 mm (standard)
30-30 PC1100-6
2
DISASSEMBLY AND ASSEMBLY ENGINE REAR SEAL
REMOVAL OF ENGINE REAR

SEAL
1. Remove damper assembly.
For details, see REMOVAL OF DAMPER ASSEMBLY.
2. Remove 1 mounting bolt of flywheel (1), and

install guide bolt 1.
3. Using eyebolts 2, sling flywheel (1), then

remove remaining mounting bolts. 1
4. Move flywheel (1) out to front and lift off.

 The flywheel pilot is shallow and it may come
off suddenly, so be careful not to get your
fingers caught. 2
4 Flywheel: 75 kg
5. Remove rear seal (2).
INSTALLATION OF ENGINE
REAR SEAL
removal.
1
fl Coat the thread and seat surface of the
flywheel mounting bolts with anti-friction
compound (LM-P).
fl Secure the flywheel and housing with
stopper 3, then tighten the mounting bolts.
fl Tighten the flywheel mounting bolts in the
order shown in the diagram on the right.
3 Flywheel mounting bolt
1st step: 98 ± 19.6 Nm {10 ± 2 kgm}
2nd step: 294 ± 19.6 Nm {30 ± 2 kgm}
3rd step: 539 ± 19.6 Nm {55 ± 2 kgm}
PC1100-6 30-31
2
DISASSEMBLY AND ASSEMBLY ENGINE REAR SEAL
fl After installing the flywheel, use dial gauge

4 to measure the radial and face runout of
the flywheel.
• Face runout: Max. 0.15 mm
• Radial runout: Max. 0.20 mm
2
• Procedure for assembling standard seal
fl Press fit the rear seal until it contacts the
flywheel housing.
• Procedure for assembling rear seal with sleeve

(for maintenance)
1) Using tool A5, guide bolts 5, and nuts 6,
press fit sleeve (3) to crankshaft (4).
fl Tighten 2 nuts 6 uniformly.
fl Press fit until tool A5 contacts the
crankshaft.
fl After press fitting, check that mounting
dimension “a” of sleeve is the specified
dimension.
Sleeve mounting dimension “a”:
27 ± 1 mm
2) Press fit rear seal (5) until it contacts flywheel

housing (6).
30-32 PC1100-6
2
DISASSEMBLY AND ASSEMBLY CYLINDER HEAD
REMOVAL OF CYLINDER HEAD

ASSEMBLY
1. Open engine side doors (1).

2. Remove engine hoods (2).
3. Drain coolant.
4. Disconnect clamp (3) of turbocharger lubrication

oil inlet hose.
5. Remove U-bolt (4), then remove tube (5) between
aftercooler and turbocharger.
6. Remove bracket (6).
7. Disconnect tube (7) between aftercooler and
intake manifold.
8. Disconnect muffler end (8) and air cleaner end
(9) of Komaclone tube.
fl Remove it after removing the fuel injection
tube.
9. Disconnect turbocharger lubrication inlet hose
(10).
10. Disconnect wiring connector (11) (P13) for auto

priming.
11. Disconnect hose (12) for auto priming.
12. Disconnect hoses (13), and remove fuel filter
assembly (14).
13. Remove fuel injection tubes (15). 1
14. Remove inlet and outlet tubes (16) of corrosion

resistor.
15. Remove corrosion resistor assembly (17).
16. Disconnect fuel return hoses (18) and (19), then
remove bracket (20).
17. Disconnect hose (21) between compressor and
intake manifold.
PC1100-6 30-33
2
18. Remove mounting bolts, then lift off intake

manifold assembly (22). 2
4 Intake manifold assembly: 30 kg
19. Disconnect water temperature sensor wiring

connector (23) (P7).
20. Disconnect water temperature sensor wiring (24)
at connector end.
21. Remove ground connection wiring (25).

23. Remove exhaust temperature sensor (27), then
remove adiabatic plate (28).
25. Disconnect air cleaner clogging switch wiring

connectors (30) (P11, 12).
26. Remove air cleaner mounting bracket (31), then
remove air cleaner assembly (32).
27. Remove bracket (33), then remove joint tube
(34).
28. Disconnect heater hose (35).
29. Disconnect exhaust temperature sensor wiring
clamp (36).
30. Disconnect water temperature sensor wiring
connector (37) (P19).
30-34 PC1100-6
2
33. Lift off muffler assembly (40).

4 Muffler assembly: 90 kg
34. Disconnect turbocharger lubrication outlet tube

(41).
35. Lift off turbocharger and exhaust manifold

assembly (42). 3
4 Turbocharger, exhaust manifold assembly:
60 kg

37. Remove spill hose (44) and eye joint (45).
38. Remove cylinder head cover (46). 4
PC1100-6 30-35
2
39. Remove rocker arm assembly (47). 5

fl Loosen the locknut and turn the adjustment
screw back 2 – 3 turns.
40. Remove crosshead (48) and pushrod (49). 6
41. Remove holder (50), then remove nozzle holder

assembly (51). 7
42. Remove pin (52), and use a bar to move water

manifold (53).
43. Remove mounting bolts, then remove rocker arm

housing (54). 8
44. Using eyebolts 1, remove cylinder head

assembly (55). 9
4 Cylinder head assembly: 40 kg
30-36 PC1100-6
2
INSTALLATION OF CYLINDER
HEAD ASSEMBLY
removal.
1
3 Fuel injection tube sleeve nut:
23.66 ± 0.98 Nm {2.4 ± 0.1 kgm}
2
3 Intake manifold assembly mounting bolt:
66.15 ± 7.35 Nm {6.75 ± 0.75 kgm}
3
3 Turbocharger, exhaust manifold assembly
mounting bolt:
110.25 ± 12.25 Nm {11.25 ± 1.25 kgm}
4
3 Cylinder head cover mounting bolt :
31.85 ± 2.45 Nm {3.25 ± 0.25 kgm}
5
fl Clean the oil holes of the mounting bolts
before installing.
fl Check that the ball of the adjustment screw
is fitted properly into the socket of the push
rod.
fl Adjust the valve clearance.
Testing and adjusting valve clearance.
3 Rocker arm assembly mounting bolt :
98 ± 4.9 Nm {10 ± 0.5 kgm}
3 Locknut : 67.62 ± 9.8 Nm {6.9 ± 1 kgm}
6
fl Adjust the crosshead as follows.
1) Loosen the locknut and turn back the
adjustment screw.
2) Press down lightly on the top of the
crosshead and screw in the adjustment
screw.
PC1100-6 30-37
2
3) When the adjustment screw contacts the

valve stem, tighten it a further 20°.
4) Tighten the locknut to hold the
adjustment screw in position.
3 Locknut:
58.8 ± 5.88 Nm {6 ± 0.6 kgm}
7
fl Assemble so that the nozzle holder counter
marks are facing the front of the engine.
3 Holder mounting bolt:
27.5 ± 3.0 Nm {2.8 ± 0.3 kgm}
8
3 Rocker arm housing mounting bolt:
98 ± 4.9 Nm {10 ± 0.5 kgm}
9
fl Check that there is no dirt or dust on the
cylinder head mounting surface or inside the
cylinder.
fl Check that the grommet does not come out
when installing the gasket.
fl Tighten the cylinder head mounting bolts in
the order shown in the diagram on the right.
2 Mounting bolt:
Anti-friction compound (LM-P)
3 Cylinder head mounting bolt
1st step: 98 ± 9.8 Nm {10 ± 1 kgm}
2nd step: 186.2 ± 4.9 Nm {19 ± 0.5 kgm}
3rd step: Make marks with paint on the
bolt and head, then tighten bolt
a further 60° +15°0.
fl After tightening, make one punch mark on
the bolt head to indicate the number of times
it has been tightened.
If any bolt already has five punch marks, do
not reuse it. Replace it with a new bolt.

Add water to the specified level, and run the
engine to circulate the water through the system.
Then check the water level again.
30-38 PC1100-6
2
DISASSEMBLY AND ASSEMBLY AFTERCOOLER
REMOVAL OF AFTERCOOLER
ASSEMBLY
2. Remove handrail (2).
3. Remove step (3).

fl Remove the guard at the front of the
aftercooler.
4. Disconnect aftercooler outlet hose (4).
5. Disconnect aftercooler inlet hose (5).
6. Disconnect outlet hose (6) of aftercooler cooling

fan motor.
7. Disconnect inlet hose (7) of aftercooler cooling

fan motor.
8. Disconnect lubrication grease tube (8) of

aftercooler cooling fan motor.
9. Remove mounting bolts, then lift off aftercooler

assembly (9).
4 Aftercooler assembly: 1,060 kg
fl Sling the aftercooler before removing the
mounting bolts.
INSTALLATION OF
AFTERCOOLER ASSEMBLY
removal.
PC1100-6 30-39
2
DISASSEMBLY AND ASSEMBLY RADIATOR, HYDRAULIC COOLER
REMOVAL OF RADIATOR,
HYDRAULIC COOLER
ASSEMBLY
 Lower the work equipment completely to the
ground and stop the engine. Then loosen the oil
filler cap slowly to release the pressure inside
the hydraulic tank.
1. Drain coolant.
2. Remove radiator mask (1).
3. Remove radiator guards (2).
4. Remove condenser (3).
fl Remove the condenser, then let it hang at
the front face.
5. Disconnect radiator bottom hose (4).

6. Disconnect aeration hose (5).
7. Disconnect make-up line hose (6).

10. Disconnect radiator upper hose (9).

11. Disconnect lubrication grease tubes (10) (after-
cooler motor), (11) (tension pulley), and (12) (fan
pulley).
12. Disconnect hose (13) between reserve tank and
radiator.
14. Remove tube (15) between aftercooler and
turbocharger.
16. Remove guard (17).
17. Disconnect oil cooler inlet hose (18).
18. Remove clamp (19).

19. Loosen locknut (20), and return adjustment bolt
(21) fully to bracket.
20. Insert bar of approx. 50 cm in portion a, pull to
outside and hold in position while removing fan
belt (22).
30-40 PC1100-6
2
DISASSEMBLY AND ASSEMBLY RADIATOR, HYDRAULIC COOLER
21. Disconnect oil cooler outlet hose (23).

fl The oil inside the cooler will flow out when
the hose is disconnected, so prepare an oil
pan or other container to catch the oil.
6 Oil inside cooler: 30 ¬
22. Remove left and right cushions (24).

23. Remove mounting bolts (25), then lift off radiator
and hydraulic cooler assembly (26).
fl Sling the radiator and oil cooler assembly
before removing the mounting bolts.
4 Radiator, hydraulic cooler assembly:

560 kg
INSTALLATION OF RADIATOR,
HYDRAULIC COOLER
ASSEMBLY
removal.

• Refilling with oil

Add oil to the hydraulic tank to the specified
level. Run the engine to circulate the oil through
the system. Then check the oil level again.
• Adjust the fan belt tension.

Adjusting fan belt tension.
PC1100-6 30-41
2
DISASSEMBLY AND ASSEMBLY HYDRAULIC COOLER
REMOVAL OF HYDRAULIC
COOLER ASSEMBLY
the hydraulic tank.
1. Remove radiator mask (1).
2. Remove radiator guards (2).
3. Remove condenser (3).

fl Remove the condenser, then let it hang at
the front face.
4. Disconnect hydraulic oil inlet hose (4).
5. Disconnect hydraulic oil outlet hose (5).

fl The oil inside the cooler will flow out when
the hose is disconnected, so prepare an oil
pan or other container to catch the oil.
6 Oil inside cooler: 28 ¬
6. Remove mounting bolts, then lift off hydraulic

cooler assembly (6).
4 Hydraulic cooler assembly: 221 kg
fl Sling the hydraulic cooler assembly before

removing the mounting bolts.
INSTALLATION OF HYDRAULIC
COOLER ASSEMBLY
removal.

30-42 PC1100-6
2
DISASSEMBLY AND ASSEMBLY ENGINE, PTO, HYDRAULIC PUMP
REMOVAL OF ENGINE, PTO,

HYDRAULIC PUMP ASSEMBLY
the hydraulic tank.
1. Drain coolant.
6 Coolant: Approx. 160 ¬
2. Drain hydraulic oil.

6 Hydraulic oil: Approx. 650 ¬
3. Remove engine side doors (1).

4. Remove engine hoods (2).
5. Remove counterweight assembly.
For details, see REMOVAL OF COUNTERWEIGHT
ASSEMBLY.
6. Remove brackets (3) and (4).

7. Remove bracket (5) and support (6).
8. Remove frames (7).
9. Remove tube (8) between aftercooler and

turbocharger.
10. Remove tube (9) between aftercooler and intake
manifold.
12. Disconnect radiator upper hose (11).
13. Disconnect air compressor wiring connector (12)

(M34).
15. Loosen belt tension adjustment bolt (14).
fl Loosen the lock bolt.
fl Loosen the adjustment bolt and remove the
drive belt.
16. Remove 4 mounting bolts (15), then lower air
conditioner compressor assembly (16) to outside
of frame.
17. Disconnect air compressor unload tube (17).
18. Disconnect fuel return hose (18).
PC1100-6 30-43
2
19. Remove hose clamp bracket (19).

20. Disconnect hose (20) between fuel tank and
strainer.
21. Disconnect fuel return hose (21).
22. Disconnect hose (22) between air compressor
and air tank.
23. Disconnect air hose clamp (23).
24. Disconnect water hose clamp (24).

25. Disconnect lubrication grease hose (25).
26. Remove fan belt (26).
fl For details, see REMOVAL OF RADIATOR,
OIL COOLER ASSEMBLY.
27. Disconnect heater return hose (27).
28. Remove heater hose clamp (28).

29. Remove ground connection wiring (29).
30. Disconnect wiring connectors (30), (31), and (32)
(E08).
31. Disconnect cable (33) from starting motor.
32. Disconnect heater outlet hose (34).
33. Disconnect heater hose clamp (35).
34. Disconnect hose (36) between hydraulic tank and

filter.
35. Disconnect hose (37) between No. 1 pump and
filter.
36. Disconnect hose (38) between PPC pump and
filter.
37. Remove pilot filter assembly (39).
38. Disconnect PTO filter (40), and remove bracket
(41) from PTO housing.
39. Install lifting jig 1 to PTO housing.
30-44 PC1100-6
2
40. Disconnect No. 3 pump suction tube (42), No. 2

pump suction tube (43), and No. 1 pump suction
tube (44).
41. Disconnect pilot pump suction hoses (45).
42. Disconnect No. 3 pump discharge hose (46).
43. Disconnect hose (47) between pilot pump and
pilot filter.
44. Disconnect hoses (48) between pilot pump and
aftercooler fan motor.
45. Disconnect No. 2 pump discharge hoses (49).

46. Disconnect No. 1 pump discharge hose (50).
47. Disconnect hoses (51) between pilot filter and
No. 1 pump.
48. Disconnect hose (52) between control valve and
No. 1 pump.
49. Remove hose clamp (53), then disconnect hose
between block and No. 1 pump.
50. Remove mount (54), then lift off engine, PTO,

and hydraulic pump assembly (55). 1
4 Engine, PTO, hydraulic pump assembly:
Approx. 4,500 kg
fl While lifting off the engine, PTO, and
hydraulic pump assembly, check that all the
piping and wiring has been removed.
PC1100-6 30-45
2
INSTALLATION OF ENGINE,
PTO, HYDRAULIC PUMP
ASSEMBLY
removal.
1
3 Mount bolt :
823.7 – 1,029.7 Nm {84 – 105 kgm}

Add oil to the specified level. Run the engine to
circulate the oil through the system. Then check
the oil level again.

• Bleeding air
Bleed the air from the main pump.
Bleeding air from main pump.
• Adjusting drive belt tension.

Adjust the air conditioner compressor drive belt
and fan belt.
Adjusting belt tension.
30-46 PC1100-6
2
DISASSEMBLY AND ASSEMBLY PTO
REMOVAL OF PTO ASSEMBLY

1. Remove engine hood, side cover, frame, and
underguard.
For details, see REMOVAL OF ENGINE, PTO,
HYDRAULIC PUMP ASSEMBLY.

ASSEMBLY.
3. Remove air cleaner (1) together with bracket.

fl Disconnect the Komaclone tube.
pilot filter and hose (3) between No. 1 pump
and pilot filter, remove pilot filter (4), then move
towards engine.
5. Disconnect hose (5) coming from pilot pump,
remove PTO lubrication oil filter (6), then remove
bracket (7).
fl Disconnect the hose coming from the PTO
lubrication oil block.
6. Disconnect hose (8) coming from block.
7. Disconnect hoses (9) coming from control valve.
10. Disconnect hose (12) going to pilot filter.
11. Disconnect suction tubes (13) and (14) and hose

of each pump.
12. Disconnect PTO suction hose (17), then remove
filter (17a).
13. Disconnect hose (18) coming from PPC pump.
14. Disconnect connection hoses (19) and (20)
between pumps.
aftercooler cooling fan motor.
17. Disconnect branch hoses (23) and (24).
18. Disconnect hose (25) between PPC pump and
No. 1 pump.
19. Disconnect hose (26) going to PTO lubrication
oil block.
20. Disconnect branch hose (27).
PC1100-6 30-47
2
21. Remove mounting bolts of No. 1 pump (28),

pilot pump (29), No. 2 pump (30), and No. 3
pump (31), then lift off.
4 No. 1 pump assembly: Approx. 200 kg
No. 2 pump assembly: Approx. 150 kg
No. 3 pump assembly: Approx. 140 kg
Pilot pump assembly: Approx. 90 kg
22. Disconnect bracket (32) from PTO.
23. Remove drain plug (33) and drain lubrication
oil.
6 Lubrication oil : 13.5 ¬
24. Disconnect hose (34) between flywheel housing

and PTO.
25. Remove mounting bolts of left and right mounts
(35).
26. Set supports 1 under flywheel housing (36) on
left and right, and adjust height with jack.
fl The part is high, so be extremely careful.
27. Disconnect PTO lubrication oil tubes (37).
28. Remove 22 mounting bolts (38), then lift off PTO
assembly (39). 1
4 PTO assembly: 440 kg
29. Remove shaft (40).
30. Remove bolts (41), then remove hub (42). 2
31. Remove bolts (43), then remove plate (44). 3
INSTALLATION OF PTO
ASSEMBLY
removal.
1
3 Mounting bolt:
98 – 123 Nm {10 – 12.5 kgm}
2
3 Mounting bolt:
245 – 309 Nm {25 – 31.5 kgm}
3
3 Mounting bolt:
98 – 123 Nm {10 – 12.5 kgm}
30-48 PC1100-6
2
DISASSEMBLY OF PTO
ASSEMBLY
1. Front cover
1) Remove mounting bolts (1), then remove
front cover (2) using forcing screws 1.
fl Use a bar to adjust in the up-down
direction to reduce the load on the
forcing screw, and when a clearance is
made, insert wooden sheets.
2) Remove snap ring (3) from cover (2), then

remove bearing (4).
2. Gear assembly
1) Remove 2 gears (6) (for No. 1, 2 pump drive).
2) Remove gear (7) (for No. 3 pump drive).
fl If the gear assembly will not come out,

remove nipple (8), then use a puller to
remove the gear assembly.
PC1100-6 30-49
2
3. Removal of bearing
Using puller 2, remove bearing from each gear.
4. Rear cover
1) Remove snap ring (9) from rear cover (5).
2) Using push tool 3, pull out gear (10).
3) Remove snap ring (11) from rear cover (5),

then remove bearing (12).
fl After pulling out gear (10), turn over rear
cover (5).
30-50 PC1100-6
2
ASSEMBLY OF PTO
ASSEMBLY
1. Rear cover
1) Press fit bearing (12) to rear cover (5), then
install snap ring (11).
fl Coat the rolling surface with grease.
2 Bearing: Lubrication oil (G2-LI)
2) Using push tool 4, press fit gear (10).
3) After press fitting gear (10), install snap ring

(9).
2. Press fitting bearing

1) Using tool 5, press fit bearing to gear (6)
for No. 1, 2 pump drive.
PC1100-6 30-51
2
2) Using tool 5, press fit bearing to gear (7)

for No. 3 pump drive.
3. Gear assembly
1) Install nipples (8).
2) Press fit 2 gears (6) to rear cover (5).
3) Press fit gear (7) to rear cover.
fl Before press-fitting, coat the rolling
surface of the bearing with grease.
fl Put wooden sheet 6 in contact with the
gear, and tap lightly with a hammer to
press fit.
4. Front cover
1) After coating front cover (2) and bearing (4)
with grease, press fit, then install snap ring
(3).
2) Set guide bolts 7 (2 places) to rear cover

(5), then align front cover (2), and lower
slowly.
fl Coat the mating surface of the rear cover
with gasket sealant.
2 Mating surface of cover:
3) Tighten mounting bolts (1) in turn on
diagonally opposite sides.
3 Mounting bolt:
98 – 123 Nm {10 – 12.5 kgm}
30-52 PC1100-6
2
DISASSEMBLY AND ASSEMBLY FUEL TANK
REMOVAL OF FUEL TANK

ASSEMBLY
1. Drain fuel.
6 Fuel tank: 1,000 ¬
2. Remove handrails (1).
3. Remove steps (2) and (3).
4. Disconnect fuel level sensor wiring connector

(4) (P06).
5. Disconnect fuel injection pump return hose (5).
6. Disconnect injector return hose (6).
7. Disconnect hose (7) between fuel tank and

strainer.
8. Remove mounting bolts, then lift off fuel tank

assembly (8).
4 Fuel tank assembly: 740 kg
INSTALLATION OF FUEL TANK

ASSEMBLY
removal.
PC1100-6 30-53
2
DISASSEMBLY AND ASSEMBLY FINAL DRIVE
REMOVAL OF FINAL DRIVE

ASSEMBLY
 Loosen the oil filler cap slowly to release the
1. Remove track shoe assembly.

For details, see REMOVAL OF TRACK SHOE
ASSEMBLY.
2. Remove covers (1) and (2).
3. Disconnect hose (3) for travel speed selector

valve.
4. Disconnect drain hose (4).
6. Remove sprocket (6).
4 Sprocket assembly: 195 kg
7. Sling final drive assembly (7), then remove

mounting bolts and lift off final drive assembly.
1
4 Final drive assembly: 1,530 kg
INSTALLATION OF FINAL
DRIVE ASSEMBLY
removal.
1
2 Mounting bolt : Thread tightener (LT-2)
3 Mounting bolt:
882 – 1,030 Nm {90 – 105 kgm}
• Bleeding air
fl Bleed the air from the travel motor.
Bleeding air.
30-54 PC1100-6
2
DISASSEMBLY OF FINAL
DRIVE ASSEMBLY
1. Draining oil
Remove drain plug and drain oil from final drive
case.
6 Final drive case : Approx. 21 ¬
2. Put travel motor at bottom and set on block

(height approx. 350 mm).
3. Cover
Using forcing screws and eyebolts 1, remove
cover (1).
4. No. 3 carrier assembly

1) Remove thrust washer (50).
2) Using eyebolts 2, remove No. 3 carrier
assembly (2).
3) Disassemble No. 3 carrier assembly as

follows.
i) Remove mounting bolts (3).
ii) Using tool J2, remove holder (4).
iii) Turn over carrier assembly (2) and set to

press, then using tool J3, pull out pin (5)
and remove gear assembly (6).
PC1100-6 30-55
2
iv) Remove bearing (7) and spacer (8) from

gear assembly (6).
fl If the parts are to be used again,
make counter marks to prevent any
change in the combination with the
outer race.
v) Remove outer race (9) from gear
assembly (6).
5. No. 3 sun gear

1) Remove thrust washer (11) from No. 3 sun
gear (10).
2) Remove No. 3 sun gear (10).
6. No. 3 ring gear

Using eyebolts 3, remove No. 3 ring gear (12).
7. Hub assembly
1) Remove lock plate (13).
2) Using tool J4, remove nut (14).
30-56 PC1100-6
2
3) Using eyebolts 4, remove hub assembly (15)

together with bearing (16) from shaft (41).
4) Remove bearing (16) from hub (49).
5) Remove floating seal (17a) from hub (49).

fl If the seal is to be used again, be careful
not to damage the contact surface, and
keep in a safe place.
6) Remove outer races (18).
8. Spacer
Remove spacer (19) from shaft (41).

assembly (20).
follows.
i) Knock pin (21) into shaft (22).
ii) Push shaft (22) from pin side to remove.
fl Remove the pin from the shaft.
iii) Pull out gear (23) from carrier (27), then

remove thrust washer (24) and bearing
(25).
iv) Remove thrust assembly (26) from carrier
(27).
PC1100-6 30-57
2
10. No. 2 sun gear

Remove No. 2 sun gear (28).
11. No. 2 ring gear

Remove No. 2 ring gear (30).
12. Spacer
Remove spacer (31).

assembly (32).
follows.
i) Knock pin (33) into shaft (34).
ii) Pull out shaft (34) towards pin end.
fl Remove the pin from the shaft.
iii) Pull out gear (35) from carrier (36), then

remove thrust washer (37) and bearing
(38).
14. No. 1 ring gear

Remove No. 1 ring gear (39).
15. No. 1 sun gear

Remove No. 1 sun gear (40).
fl Note: If the travel motor is removed, the
gear will fall off when it is put in the posture
for disassembly.
16. Thrust washer

Remove thrust washer (48) from travel motor.
17. Floating seal

Remove floating seal (17b) from shaft (41).
fl If the seal is to be used again, be careful not
to damage the contact surface, and keep in
a safe place.
30-58 PC1100-6
2
ASSEMBLY OF FINAL DRIVE

ASSEMBLY
fl 1) Clean all parts, check for dirt or damage,
and correct all dents and burrs.
2) Coat the bearings and surfaces of all parts
with engine oil before installing.
1. Thrust washer
1) Set shaft assembly on block (height: approx.
350 mm).
2) Install thrust washer (48) of travel motor.
2. No. 1 sun gear

Install No. 1 sun gear (40).
3. No. 1 ring gear

Install No. 1 ring gear (39).
fl Set with the side with the cut outside
circumference facing the motor.
4. Spacer
Install spacer (31).

1) Assemble No. 1 carrier assembly as follows.
fl There are the remains of the caulking
when the pin is inserted at the end face
of hole h at the side of the carrier, so
remove the caulked metal from the inside
diameter of the hole before starting to
assemble.
i) Assemble bearing (38) to gear (35), put
thrust washers (37) in contact at both
sides, then set to carrier (36).
PC1100-6 30-59
2
ii) Align position of pin holes of carrier and

shaft, then tap with a plastic hammer to
install shaft (34).
fl When installing the shaft, rotate the
planetary gear, and be careful not to
damage the thrust washer.
iii) Install pin (33).
fl Check that the pin groove and
protruding part of the pin are not
fatigued. If the pin is defective,
replace it with a new part.
fl When assembling the pin again,
avoid the position previously used
for caulking.
fl After inserting the pin, caulk the pin
portion (marked by arrows) of the
carrier.
fl After assembling the carrier
assembly, check that gear (35) rotates
smoothly.
2) Using eyebolts 6, install No. 1 carrier
assembly (32).
6. No. 2 sun gear

1) Press fit button (29) to No. 2 sun gear (28).
2) Install No. 2 sun gear (28).
7. No. 2 ring gear

Install No. 2 ring gear (30).

i) Press fit thrust washer (44) to plate (43).
ii) Press fit thrust assembly (26) to carrier
(27).
30-60 PC1100-6
2
fl There are the remains of the caulking

when the pin is inserted at the end face
of hole h at the side of the carrier, so
remove the caulked metal from the inside
diameter of the hole before starting to
assemble.
iii) Assemble bearing (25) to gear (23), put
thrust washers (24) in contact at both
sides, then set to carrier (27).
iv) Align position of pin holes of carrier and
shaft, then tap with a plastic hammer to
install shaft (22).
gear, and be careful not to damage
the thrust washer.
v) Install pin (21).
fl Check that the pin groove and
protruding part of the pin are not
fatigued. If the pin is defective,
replace it with a new part.
fl When assembling the pin again,
avoid the position previously used
for caulking.
portion (marked by arrows) of the
carrier. (See Step 5-1)-iii).)
fl After assembling the carrier assembly,
check that gear (23) rotates smoothly.
assembly (20).
9. Spacer
Align protruding portion with protruding portion
of shaft (41), and install spacer (19).
fl Set the spacer with the shallow protruding
part facing the motor.
10. Hub assembly

1) Floating seal at shaft end
Using tool J8, install floating seal (17b) to
shaft (41).
fl Remove all oil and grease from the O-
ring and O-ring contact surface, and dry
the parts before installing the floating
seal.
PC1100-6 30-61
2
fl After installing the floating seal, check

that the angle of the floating seal is
within 1 mm.
fl After installing the floating seal, coat the
sliding surface thinly with engine oil.
2) Inside bearing
Shrink fit bearing (16) to shaft (41), or use
tool J3 to install.
fl When using tool J7, see the drawing on the

right.
3) Outer race at hub end

Expand fit outer race (18) to hub (49), or use
tool J6 to install.
fl When using tool J6, see the drawing on
the right.
4) Floating seal at hub end

Using tool J8, install floating seal (17a) to
hub (49).
fl For precautions and details of the tool,
see Step 10-1).
fl When turning over the hub, the floating
seal will be at the bottom, so install it
temporarily with several of bolts 8.
5) Installation of hub assembly
Using eyebolts 4, install hub assembly (15)
to shaft (41).
30-62 PC1100-6
2
6
6) Outside bearing
Install bearing (16).
7) Install nut as follows.

i) Set tool J7 in position.
ii) Push bearing inner race portion with
specified force.
fl Pushing force:
34.3 – 38.2 kN {3.5 – 3.9 ton}
iii) Rotate hub assembly 2 – 3 times to settle
bearing.
iv) Measure dimension a in the condition

above.
v) Measure thickness b of nut (14) as an

individual part.
vi) Calculate a – b = c.
vii) Using tool J1, tighten nut (14) to a point
where dimension c = +0.15
–0.05 mm.
PC1100-6 30-63
2
8) Install lock plate (13).

Install the lock plate as shown in the diagram
on the right.
2 Thread of mounting bolt :
Thread tightener (LT-2)
3 Mounting bolt:
59 – 74 Nm {6 – 7.5 kgm}
11. No. 3 ring gear

1) Install O-ring to shaft end.
2) Using eyebolts 3, install No. 3 ring gear
(12).
fl Align the bolt holes.
fl Install the ring gear with the machined
outside circumference facing up (out-
side).

i) Using tool J4, press fit outer race (9) to
gear (46).
ii) Assemble bearing (7) and spacer (8) to

gear (46), and set to carrier (47).
fl Align the carrier and bearing and
spacer holes accurately.
30-64 PC1100-6
2
iii) Expand fit shaft (5) or press fit with a

press.
fl Do not move the gear until the tip of
shaft (5) enters the carrier. Be
particularly careful with the spacer.
fl When press fitting the shaft, be
careful of the angle of the shaft, and
press fit so that there is no clearance
between the pin and end face m of
the bearing.
fl After press fitting the pin, check that
the gear rotates smoothly.
iv) Assemble holder (4) to shaft (5).
v) Tighten bolt (3).

2 Bolt: Thread tightener (LT-2)
3 Bolt:
931 – 1,030 Nm {90 – 105 kgm}
vi) Install thrust washer (50).

assembly (2).
fl Align the low portion (4 places) of spacer
(19) and shaft (41) with the carrier
assembly holder.
fl Align the bolt holes also.
13. No. 3 sun gear

1) Install thrust washer (11) to No. 3 sun gear
(10).
2) Install No. 3 sun gear (10).
fl Be careful not to get your fingers caught.
PC1100-6 30-65
2
14. Cover
Using eyebolts 1, install cover (1).
2 Mounting surface: Gasket sealant (LG-6)
2 Bolt: Thread tightener (LT-2)
3 Bolt: 982 – 1,030 Nm {90 – 105 kgm}
30-66 PC1100-6
2
DISASSEMBLY AND ASSEMBLY REVOLVING FRAME
REMOVAL OF REVOLVING
FRAME ASSEMBLY
ASSEMBLY.
2. Remove work equipment assembly.

For details, see REMOVAL OF WORK EQUIPMENT
ASSEMBLY.
3. Disconnect hose (1) coming from filter.

4. Disconnect hoses (2) and (3) coming from swing
motor.
5. Disconnect hoses (4) coming from 5-spool
control valve.
control valve.
7. Disconnect hose (6) coming from travel speed
selector solenoid valve.
8. Disconnect stopper link (7).
9. Leave 4 mounting bolts (8) at front and rear,
and remove remaining mounting bolts. 1
10. Lift off revolving frame assembly (9).
4 Revolving frame assembly:

Approx. 20,300 kg
INSTALLATION OF REVOLVING
FRAME ASSEMBLY
removal.
fl Remove the mounting bolts of the swing motor,

raise the swing gear enough for it to be free,
then set on a block.
1
2 Mounting bolt: Thread tightener (LT-2)
3 Mounting bolt:
1,960 – 2,450 Nm {200 – 250 kgm}
PC1100-6 30-67
2
DISASSEMBLY AND ASSEMBLY SWING MACHINERY
REMOVAL OF SWING
MACHINERY ASSEMBLY
the hydraulic tank.
fl Center of chassis
1. Disconnect hoses (1), (2), (3), and (4) coming
from control valve.
2. Disconnect hoses (5) and (6) going to swing
motor at front of chassis.
4. Disconnect swing brake release hose (8).
fl Front of chassis
motor at center of chassis.
4. Disconnect hose (13) going to boom LOWER
regeneration valve.
6. Remove mounting bolts (15), then lift off swing

motor assembly (16).
4 Swing motor assembly: 81 kg
7. Remove mounting bolts, then lift off swing

machinery assembly (17). 1
4 Swing machinery assembly: 532 kg
INSTALLATION OF SWING
MACHINERY ASSEMBLY
removal.
1
3 Mounting bolt :
824 – 1,030 Nm {84 – 105 kgm}

30-68 PC1100-6
2
DISASSEMBLY OF SWING
MACHINERY ASSEMBLY
1. Draining oil
Loosen drain plug and drain oil from swing 1
machinery case.
6 Swing machinery case: Approx. 21.5 ¬
2. Cover
Remove mounting bolts, then lift off cover (1).
CEP00205

2) Remove No. 1 sun gear (3). 3 2
CEP00206
3) Remove No. 1 carrier assembly (4).

4
CEP00207
4. Disassemble No. 1 carrier assembly as follows.

1) Push in pin (5) and knock out shaft (6) from
carrier (7). 7
5 10
fl After removing the shaft, remove pin (5).
2) Remove thrust washer (8), gear (9), bearing 8
(10), and thrust washer (11).
9 11 6
CEP00208
PC1100-6 30-69
2
5. Ring gear
Lift off ring gear (12).
12
CEP00209
6. No. 1 sun gear

1) Remove thrust washer (13) and collar (14). 14 13
2) Remove No. 1 sun gear (15).
15
CEP00210

16
CEP00211

Lift off No. 2 carrier assembly (17). 17
CEP00212
30-70 PC1100-6
2
8. Disassemble No. 2 carrier assembly as follows.

1) Push in pin (18), and knock out shaft (19)
from carrier (17). 19 22 17
fl After removing the shaft, remove pin 20
(18).
2) Remove thrust washer (20), gear (21), bearing
21
(22), and thrust washer (23).
23
18
CEP00213
9. Pinion shaft assembly

1) Remove bolt (24), then remove holder (25). 24
2) Remove gear (26). 26

25
CEP00214
3) Turn over case and pinion assembly, then

remove mounting bolts (28) of cover
assembly (27).
27
28
CEP00215
4) Turn over case and pinion assembly (29),

and set on press stand, then using push tool
F4, remove pinion shaft assembly (30) with
press.
fl Set a wooden block under the press, and
be careful not to damage the pinion shaft
assembly when removing it.
PC1100-6 30-71
2
10. Disassemble pinion shaft assembly as follows.

1) Using push tool 1, remove cover assembly
(27) and bearing (31) from shaft (32). 33
2) Remove oil seal (33) from cover (27).
27
31
32
27
CEP00218 CEP00219
11. Bearing
Using push tool, remove bearing (34) from case 35 34
(35).
CEP00220
30-72 PC1100-6
2
ASSEMBLY OF SWING
MACHINERY ASSEMBLY
fl Clean all parts, and check for dirt or damage.
Coat the sliding surfaces of all parts with engine
oil before installing.
1. Bearing
Using push tool F2, press fit bearing (31) to case
(35).
2. Cover assembly
1) Using push tool F1, press fit oil seal (33) to
cover (27).
2 Outside circumference of oil seal:
fl Be careful not to let the gasket sealant
(LG-6) get on the oil seal lip when press
fitting.
2) Fit cover assembly (27) to case (35), and

tighten mounting bolts (28). 27 28
2 Cover mounting surface:
35
2 Lip of oil seal: Grease (G2-LI)
fl Be careful not to let the gasket sealant
(LG-6) get on the oil seal lip when press
fitting.
CEP00223
3. Case assembly
1) Set case assembly (35) to shaft (32), then
using push tool 2, press fit bearing inner
race portion.
fl When setting the case assembly to the
shaft, be extremely careful not to damage
the oil seal.
PC1100-6 30-73
2
2) Bearing
Using tool F3, press fit bearing (34).
fl Push the bearing inner race and outer
race at the same time when press fitting.
Do not push only the inner race when
press fitting.
fl After press fitting the bearing, check that
the case rotates smoothly.
3) Gear, holder
Assemble gear (26), then fit holder (25) and 24
tighten bolt (24).
2 Mounting bolt: 26
Thread tightener (LT-2) 25
3 Mounting bolt:
343 – 427 Nm {35 – 43.5 kgm}
CEP00214
4. Assemble No. 2 carrier assembly as follows.

fl There are the remains of the caulking when 22 17
the pin is inserted at the end face of hole h
20
at the side of the carrier, so remove the
caulked metal from the inside diameter of
the hole before starting to assemble. 21
1) Assemble bearing (22) to gear (21), fit top
and bottom thrust washers (23) and (20) and
set gear assembly to carrier (17). 23
h
CEP00226
2) Align position of pin holes of shaft and

carrier, then tap with a plastic hammer to 21 19
install shaft (19).
3) Insert pin (18).
portion of the carrier.
fl After assembling the carrier assembly, check
that gear (21) rotates smoothly.
18
CEP00227
30-74 PC1100-6
2

Raise No. 2 carrier assembly (17) and install. 17
CEP00212
6. No. 2 sun gear

1) Assemble thrust washer (16). 16
CEP00211
2) Install No. 2 sun gear (15) to No. 2 carrier,

then install collar (14) and thrust washer (13). 14 13
15
CEP00210
7. Ring gear
Raise ring gear (12) and install.
fl Align with the drain hole and assemble.
2 Mating surface of ring gear and case:
12
CEP00209
PC1100-6 30-75
2
8. Assemble No. 1 carrier assembly as follows.

fl There are the remains of the caulking when
the pin is inserted at the end face of hole h h 10 7
at the side of the carrier, so remove the
caulked metal from the inside diameter of 8
the hole before starting to assemble.
1) Assemble bearing (10) to gear (9), fit top
and bottom thrust washers (8) and (11) and
set gear assembly to carrier (7).
9 11
CEP00228
2) Align position of pin holes of shaft and

carrier, then tap with a plastic hammer to
install shaft (6). 5
3) Insert pin (5).
portion of the carrier.
fl After assembling the carrier assembly, check
that gear (9) rotates smoothly. 9 6
CEP00229

Install No. 1 carrier assembly (4).
4
CEP00207
10. No. 1 sun gear

1) Assemble No.1 sun gear (3) to carrier
assembly. 3 2
2) Install thrust washer (2).
CEP00206
30-76 PC1100-6
2
11. Cover
Install cover (1).
2 Cover mounting surface:
Gasket sealant (LG-6) 1
3 Mounting bolt:
1st pass: 98 Nm {10 kgm}
2nd pass: 120 ± 5°
CEP00205
12. Refilling with oil

Tighten drain plug and add oil through oil filler.
5 Swing machinery case: Approx. 21.5 ¬
PC1100-6 30-77
2
DISASSEMBLY AND ASSEMBLY SWING CIRCLE
REMOVAL OF SWING CIRCLE

ASSEMBLY
1. Remove revolving frame assembly.
For details, see REMOVAL OF REVOLVING FRAME
ASSEMBLY.
2. Remove grease tubes (1).
3. Remove mounting bolts (2). 1
4. Pass a round bar through revolving frame

mounting bolt holes, then fit wire and lift off
swing circle assembly (3). 2
4 Swing circle assembly: 2,169 kg
5. Remove seal (4).
INSTALLATION OF SWING
CIRCLE ASSEMBLY
removal.
1
3 Mounting bolt:
1,960 – 2,450 Nm {200 – 250 kgm}
2
2 Mounting surface of swing circle:
Gasket sealant (LG- 6)
fl Amount of grease (G2-LI) to fill oil bath:
Approx. 75 ¬
fl Coat the inner teeth with grease (G2-LI).
fl Set the soft zone S mark on the inner race
facing the left side of the machine, then
install.
30-78 PC1100-6
2
DISASSEMBLY AND ASSEMBLY TRACK SHOE
REMOVAL OF TRACK SHOE

ASSEMBLY
1. Positioning master pin
fl Move the track so that the master pin is
midway between the idler and the carrier
roller. The track shoe is opened to the rear,
so be sure that there is enough space to lay
it out.
2. Loosen track shoe tension. 1

 Never loosen lubricator (1) more than one
turn.
fl If the track tension is not relieved even when
the lubricator is loosened, move the machine
backwards and forwards.
3. Using tool R1, pull out master pin.
4. Fit block or hydraulic jack 1 (100 kN {10 t})

under shoe at idler end, then remove guide pin
2. 2
5. Raise tip of track shoe with crane, and move

machine slowly to rear to open track shoe
assembly (3).
PC1100-6 30-79
2
DISASSEMBLY AND ASSEMBLY TRACK SHOE
INSTALLATION OF TRACK
SHOE ASSEMBLY
removal.
1
fl Adjust the track shoe tension.
Adjusting track shoe tension.
3 Lubricator:
73.5 ± 14.7 Nm {7.5 ± 1.5 kgm}
2
fl Assemble spacer (4) and washer (5) to the
link, connect to the bottom link, then install
the guide pin.
30-80 PC1100-6
2
DISASSEMBLY AND ASSEMBLY SPROCKET
REMOVAL OF SPROCKET
ASSEMBLY.
2. Swing work equipment 90°, push up chassis with

work equipment, set block 1 on top of track
shoe, then lower chassis slowly.
ground.
3. Remove mounting bolts (1), and lift off sprocket

(2). 1
4 Sprocket: 194 kg
INSTALLATION OF SPROCKET
removal.
1
3 Mounting bolt:
824 – 1,030 Nm {84 – 105 kgm}
PC1100-6 30-81
2
DISASSEMBLY AND ASSEMBLY IDLER
REMOVAL OF IDLER
ASSEMBLY
ASSEMBLY.
2. Remove idler assembly (1).

fl Pull out the idler assembly, then lift off the
idler and adjustment cylinder.
4 Idler assembly: 1,000 kg
INSTALLATION OF IDLER
ASSEMBLY
removal.
30-82 PC1100-6
2
DISASSEMBLY OF IDLER
ASSEMBLY
1. Remove plug and drain oil.
6 Idler: Approx. 750 – 830 cc
2. Set idler assembly (1) on block 1, remove bolt

and nut (2), then remove support (3).
3. Remove O-ring (4).

4. Remove plate (5), then remove dowel pin (6)
from plate.
5. Remove floating seal (7).
6. Turn over idler assembly, remove bolt and nut

(8), then remove support (9).
7. Remove O-ring (10).

8. Remove plate (11), then remove dowel pin (12)
from plate.
9. Remove floating seal (7).
PC1100-6 30-83
2
10. Remove shaft (13) from idler.
11. Remove bushings (14) and (15) from idler.
12. Remove floating seal (7) from supports (3) and

(9).
30-84 PC1100-6
2
ASSEMBLY OF IDLER
ASSEMBLY
fl Clean all parts, and check for dirt or damage.
1. Using tool L2, assemble floating seals (7) to
supports (3) and (9).
fl Check that the angle of the seal is less than
1 mm.
2. Using tool L1, press fit bushings (14) and (15) to

idler (1).
• Press-fitting force:
114 – 200 kN {11.6 – 20.4 t}
3. Using tool L2, assemble floating seal (7) to idler

(1).
1 mm.
4. Install shaft (13) to idler assembly (1).

fl Assemble the shaft so that the UP mark at
the end face of the shaft is at the top.
fl Assemble so that the oil filler plug is facing
the right side of the machine
PC1100-6 30-85
2
5. Assemble plate (5) to idler (1).

6. Install dowel pin (6) to plate (5).
7. Fit O-ring (4) to shaft (13).
8. Assemble plate (11) to idler (1).

9. Assemble dowel pin (12) to plate (11).
10. Fit O-ring (10) to shaft (13).
11. Assemble support (9) to shaft (13).

fl Align the dowel pin with the hole at the
support end.
12. Install bolt and nut (8), and secure support (9).
13. Turn over idler, and assemble support (3) to

shaft (13).
fl Align the dowel pin with the hole at the
support end.
14. Install bolt and nut (2), and secure support (3).
15. Using tool J3, add oil to specified level, then
tighten plug.
5 Idler: 750 – 830 cc (GO140)

3 Plug: 274.4 – 367.5 Nm {28 – 37.5 kgm}
30-86 PC1100-6
2
DISASSEMBLY AND ASSEMBLY IDLER ADJUSTMENT CYLINDER
DISASSEMBLY OF IDLER
ADJUSTMENT CYLINDER
ASSEMBLY
1. Remove plunger assembly (1).
2. Remove snap ring (3), then remove packing (4),

backup ring (5), and wear ring (6) from plunger
(2).
3. Remove dust seal (7).
ASSEMBLY OF IDLER
ADJUSTMENT CYLINDER
ASSEMBLY
1. Install wear ring (6) to plunger (2).
2. Assemble backup ring (5) and packing (4) to

plunger (2), then install snap ring (3).
3. Fill inside with grease (G2-LI), then assemble

plunger assembly (1) to piston.
4. Install dust seal (7).
PC1100-6 30-87
2
DISASSEMBLY AND ASSEMBLY RECOIL SPRING
REMOVAL OF RECOIL SPRING

ASSEMBLY
fl The coil portion of the recoil spring assembly is
hooked on the rib inside the track frame, so
prepare a special tool for disassembly.

ASSEMBLY.
2. Remove idler assembly.

For details, see REMOVAL OF IDLER ASSEMBLY.
3. Recoil spring assembly

1) Remove No. 2 and No. 3 track roller
assemblies.
For details, see REMOVAL OF TRACK ROLLER
ASSEMBLY.
2) After removing track roller assembly, install
tool 1.
fl When making tool 1, see Fig. 1.
fl Lower the track frame on top of the track
shoe.
3) Using eyebolts (Thread dia. = 16 mm, Pitch

= 2.0 mm), pull out recoil spring assembly
(1) and lift off.
4 Recoil spring assembly: 1,000 kg
INSTALLATION OF RECOIL
SPRING ASSEMBLY
removal.
fl To check that the spring is securely fitted

inside the track frame, look through the side
hole on the inside (at the 5th track roller
from the front).
30-88 PC1100-6
2
Fig. 1 (for tool 1)
PC1100-6 30-89
2
DISASSEMBLY OF RECOIL
SPRING ASSEMBLY
1. Set recoil spring assembly (1) to tool M1.
 The recoil spring is under a large installed
load, so be sure to set the tool properly.
Failure to do this is dangerous.
fl Installed load of spring: 578 kN {58,957 kg}
2. Apply hydraulic pressure slowly to compress

spring, then remove lock plate, and remove nut
(2).
3. Release hydraulic pressure gradually to relieve

tension of spring, then remove recoil spring
assembly (1) from tool M1.
4. Remove rear pilot (4) and rod (5) from spring

(3).
30-90 PC1100-6
2
ASSEMBLY OF RECOIL SPRING

ASSEMBLY
1. Install tool M1 to tip of rod (5).
fl Tool M1 is to prevent damage to the thread
when inserting the rear pilot.
2. Install rod (5) to spring (3).

Assemble rear pilot (4), and set to tool M1.
 The recoil spring is under a large installed
load, so be sure to set the parts properly.
Failure to do this is dangerous.
3. Apply hydraulic pressure slowly to compress

spring so that installed length of spring is
standard dimension.
fl Installed length “a” of spring: 1,280 mm
4. Fit nut (2) and secure with lock plate.
5. Release hydraulic pressure gradually to relieve

tension of spring, then remove recoil spring
assembly (1) from tool M1.
PC1100-6 30-91
2
DISASSEMBLY AND ASSEMBLY CARRIER ROLLER
REMOVAL OF CARRIER
ROLLER ASSEMBLY
1. Loosen track shoe slightly.
Adjusting track shoe tension.
2. Using hydraulic jack 1, push up track shoe.
3. Remove 4 mounting bolts (1).

4. Lift off carrier roller assembly (2).
fl Pull the carrier roller assembly to the outside
to a point where it does not fall.
4 Carrier roller assembly: 80 kg
INSTALLATION OF CARRIER
ROLLER ASSEMBLY
removal.
30-92 PC1100-6
2
DISASSEMBLY OF CARRIER
ROLLER ASSEMBLY
6 Carrier roller assembly:

Approx. 450 – 500 cc
2. Set carrier roller assembly (1) on press stand.

fl When support (2), shaft (3), and roller (4)
come away from roller (4), they will fall, so
set something to catch them under the roller.
3. Push with press, and remove support (2), shaft

(3), and roller (4) as one unit.
fl Remove floating seal (5) from support (2).
4. Remove shaft (3) and bearing (6) as one unit

from support (2).
5. Remove roller (4) and floating seal (5) (on top of

support (2)) as one unit.
6. Remove floating seal (5) from support (2).
7. Remove bearing (6) from support (2).
8. Remove floating seal (5) from roller (4).
9. Using tool L2, remove bearing (6) from shaft (3).
10. Remove bearing outer race (7) from support (2).
11. Using tool 1 , remove bushing (8) from support

(2).
PC1100-6 30-93
2
ASSEMBLY OF CARRIER
ROLLER ASSEMBLY
1. Using tool 1, press fit bushing (8) to support
(2).
fl Press fit so that the protrusion is the same
on the left and right.
2. Using tool L1, press fit bearing outer race (7) to
support (2).
3. Using tool L2, press fit bearing (6) to shaft (3).

fl Push in approx. 80 mm from the end face of
the shaft.
4. Install bearing (6) to shaft (3), install bushing (8)
to support (2), then press fit shaft (3) to support
(2).
fl Check that the inner race of the bearing is in
contact with bushing (8).
5. Using tool L4, install floating seal (5) to roller

(4).
1 mm.
fl Wash the O-ring and O-ring contact surface,
remove all oil and grease, then dry
thoroughly.
6. Assemble floating seal (5) to roller (4), then set
roller (4) on tool L3.
7. Assemble floating seal (5) to support (2), then
press fit support (2) and shaft (3) as one unit to
roller (4).
fl Make sure that there is no dirt stuck to the
seal surface.
8. Press fit bearing (6) to shaft (3).

9. Install floating seal (5) to support (2).
10. Assemble floating seal (5) to roller (4), then press
fit roller (4) to shaft (3).
fl Press fit roller (4) to the end face of the
shaft, then use tool L3 to press fit finally.
fl Ensure that the press-fitting force for the
shaft and each roller is at least 230 kN {23
tons}.
11. After assembling carrier roller assembly (1), fill
with oil.
5 Lubricating oil: 450 – 500 cc (GO140)

12. After filling carrier roller assembly with oil,
tighten plug.
3 Plug: 157 – 255 Nm {16 – 26 kgm}
30-94 PC1100-6
2
DISASSEMBLY AND ASSEMBLY TRACK ROLLER
REMOVAL OF TRACK ROLLER

ASSEMBLY
1. Loosen track shoe tension.
ASSEMBLY.
2. Remove track roller guards (1) and (2).
4 Track roller guard: 170 kg
3. Using work equipment, push up track frame on

side which is to be removed.
 After jacking up the chassis, set a block on
the track shoe.
4. Using tool L7, remove track roller assembly (2).

1
4 Track roller assembly (S flange): 140 kg
INSTALLATION OF TRACK
ROLLER ASSEMBLY
removal.
1
3 Roller mounting bolt:
137.2 ± 98 Nm {140 ± 10 kgm}
PC1100-6 30-95
2
DISASSEMBLY OF TRACK
ROLLER ASSEMBLY
fl Rotate the shaft while draining the oil.
6 Track roller: Approx. 800 – 850 cc
2. Remove pin (1), then remove collar (2).

3
3. Remove floating seal (3) from collar (2) and roller
3
(4).
1
2 CEP00085 CEP00086
4. Pull out roller (4) from shaft (5).

fl It is filled with 800 – 850 cc. of oil, so drain
the oil at this point or lay a cloth to prevent 5
the area from becoming dirty. 6
4 4
CEP00087 CEP00088
5. Remove floating seal (6) on opposite side from

roller (4) and collar (8).
9, 10
6. Remove pin (7), then remove collar (8) from
5
shaft (5).
6
7. Remove bushings (9) and (10) from roller (4).
4
7 CEP00089 CEP00090
30-96 PC1100-6
2
ASSEMBLY OF TRACK ROLLER

ASSEMBLY
1. Using tool 1, press fit bushings (9) and (10) to
roller (4).
2. Assemble collar (8) to shaft (5), and install pin

(7).
3. Using tool L6, install floating seal (6) to shaft

(5).
fl When assembling the floating seal, clean the
contact surface of O-ring (6c) and floating
seal (6a), remove all grease and oil, and dry
it. Make sure that no dirt or dust sticks to
the contact surface of the floating seal.
fl After inserting the floating seal, check that Remove all oil and Protrusion of seal
the angle of the seal is less than 1 mm. grease from
hatched portion.
5∼7mm
CEP00093 CEP00094
4. Using tool L6, install floating seals (6) and (3) to

roller (4).
fl For details of the precautions when installing
floating seals (6b) and (6d), and (3b) and
5
(3d), see the precautions marked fl for Step
3.
5. Assemble shaft (5) to roller (4). 4
CEP00096
6. Turn over roller (4) and shaft (5) assembly.
7. Using tool L6, install floating seal (3) to collar

(2). 4
fl For details of the precautions when installing
floating seals (3a) and (3c), see the
precautions marked fl for Step 3.
5
CEP00097
PC1100-6 30-97
2
8. Assemble collar (2) to shaft (5), and install pin

(1). 1
2
5
CEP00099
9. Using tool L10, apply standard pressure to roller

oil filler port, and check for leakage of air from
seal.
fl Standard pressure: 0.1 MPa (1 kg/cm2)
fl Method of checking
The standard pressure shall be maintained
for 10 seconds and the indicator of the gauge
shall not go down.
10. Using tool L10, fill track roller assembly with oil,
then tighten plug (11). L10
5 Track roller oil: 800 – 850 cc (EO30-CD)

3 Plug: 17 – 37 Nm {1.7 – 3.8 kgm}
To oil pump
To vacuum tank
CEP00201
11
CEP00202
30-98 PC1100-6
2
DISASSEMBLY AND ASSEMBLY HYDRAULIC TANK
TANK ASSEMBLY
 Swing the frame and set the position of the
hydraulic tank between the left and right tracks.
the hydraulic tank.
1. Drain oil from hydraulic tank.
6 Hydraulic tank: 650 ¬
2. Disconnect wiring connectors (1) (from top:

V7=CO cancel, V1=swing priority selector,
V2=main 2-stage relief valve).
3. Disconnect hose (2) coming from oil cooler.

4. Disconnect hose (3) coming from main pump
CO valve.
5. Disconnect hoses (4) and (5) coming from control
valve main relief.
6. Disconnect hose (6) coming from 4-spool control
valve (boom RAISE).
7. Disconnect wiring connector (7) (P1=hydraulic

oil high temperature sensor).
8. Disconnect tube (8) going to hydraulic tank.
9. Disconnect motor drain hose (9).
10. Disconnect pump drain hose (10).
11. Disconnect tube (11) coming from pilot pump.
12. Disconnect hose (12) coming from accumulator.
13. Disconnect clamps (13) and (14).

14. Disconnect wiring connector (15) (P09=oil level
sensor).
PC1100-6 30-99
2
DISASSEMBLY AND ASSEMBLY HYDRAULIC TANK
16. Remove filter assembly (17) from hydraulic tank,

and disconnect together with hose (18) from
hydraulic tank.
17. Disconnect hose (19) coming from 5-spool
control valve.
18. Disconnect hoses (20) going to oil cooler.

control valve.
20. Disconnect hydraulic tank bottom suction tube

(21).
21. Lift off hydraulic tank assembly (22). 1
4 Hydraulic tank assembly: 780 kg
TANK ASSEMBLY
removal.
1
3 Hydraulic tank mounting bolt:
490 – 608 Nm {50 – 62 kgm}
• Refilling with oil (hydraulic tank)

Run the engine to circulate the oil through the
system. Then check the oil level again.
• Bleeding air
Bleed the air.
Bleeding air.
30-100 PC1100-6
2
DISASSEMBLY AND ASSEMBLY TVC VALVE
REMOVAL OF TVC VALVE

ASSEMBLY
1. Open door of pump room.
2. Disconnect TVC valve wiring connector (1) (C13).
3. Disconnect hose (2) coming from swing pump

inlet.
4. Remove mounting bolts, then remove TVC valve

assembly (3). 1
INSTALLATION OF TVC VALVE

ASSEMBLY
removal.
1
3 Mounting bolt:
31.4 ± 2.9 Nm {3.2 ± 0.3 kgm}
PC1100-6 30-101
2
DISASSEMBLY AND ASSEMBLY SERVO VALVE
REMOVAL OF SERVO VALVE

ASSEMBLY
1. Remove external parts around hydraulic pump.
2. Disconnect discharge hoses (2) of No. 3 pump
(1).
3. Disconnect discharge hoses (4) of No. 1 pump
(3).
4. Disconnect jet sensor (upstream) hose (5).
5. Disconnect jet sensor (downstream) hose (6).
6. Disconnect TVC valve output pressure inlet hose
(7).
7. Disconnect hose (8) for C/O selector pilot.
fl Disconnect the C/O selector pilot hose and
the jet sensor (upstream and downstream
pressure) hose from the CO.NC valve of the
front pump of the No. 1 pump.
fl Disconnect the C/O selector pilot hose and
the jet sensor (upstream and downstream
pressure) hose from the CO.NC valve of the
rear pump of the No. 1 pump.
fl Disconnect the hose between the swing
pump inlet and the TVC valve.
8. Disconnect hose (9) between front and rear of
No. 3 pump servo valve. 1
9. Disconnect TVC valve wiring connector (10)
(C13).
10. Disconnect tube (11) between outside pumps
from front pump of No. 1 pump. 2
11. Remove servo valves (12), (13), (14), and (15)
together with CO.NC valve. 3
12. Disconnect CO + NC valve output pressure hoses
at front (16) and at rear (17).
13. Remove servo valves (18) and (19). 4
INSTALLATION OF SERVO
VALVE ASSEMBLY
removal.
1
3 Hose mounting bolt:
19.6 – 29.4 Nm {2 – 3 kgm}
2
3 Tube mounting bolt:
15.7 – 19.6 Nm {1.6 – 2 kgm}
34
3 Mounting bolt:
27 – 34 Nm {2.8 – 3.5 kgm}
30-102 PC1100-6
2
DISASSEMBLY AND ASSEMBLY HYDRAULIC PUMP
PUMP ASSEMBLY
the hydraulic tank.
1. Remove external parts around hydraulic pump.

2. Disconnect piping and wiring.
For details, see REMOVAL OF ENGINE, PTO,
HYDRAULIC PUMP ASSEMBLY.
3. Remove hydraulic tank strainer, and using tool
S, stop oil.
4. When not using tool S, drain hydraulic oil.
5. Remove No. 3 pump assembly (1).

4 No. 3 pump assembly: Approx. 200 kg

4 No. 1 pump assembly: 156 kg

4 No. 2 pump assembly: 146 kg
8. Remove pilot pump (4).

4 Pilot pump: Approx. 90 kg
PUMP ASSEMBLY
removal.

Add oil through the oil filler to the specified
• Bleeding air
Bleed the air from all parts.
Bleeding air.
PC1100-6 30-103
2
DISASSEMBLY OF HYDRAULIC
PUMP ASSEMBLY
HPV95+95
fl The diagrams all show the No. 1 pump.

With the No. 1 pump and No. 2 pump, the only
differences are the shape of the servo valve, the
position of port T and port P, and the direction
of the servo piston.
The procedure is basically the same.
1. Hydraulic pump assembly

Set hydraulic pump assembly (1) to tool P1.
2. Servo valve assembly

1) Remove tube (2).
fl Not installed to the No. 2 pump.
2) Remove front servo valve assembly (3).
fl With the No. 1 pump and No. 2 pump,
only the shape is different.
3) Remove rear servo valve assembly (4).
3. Rear pump assembly [1]

Remove 4 mounting nuts, then remove rear
pump assembly (5).
4. Front end cap assembly

1) Remove 2 mounting bolts and 4 nuts, then
remove front end cap assembly (6).
30-103-1 PC1100-6
5
2) Disassemble front end cap assembly as fol-

lows.
i) Remove valve plate (7) from end cap (8).
fl The valve plate and cylinder block
may be tightly fitted, so be careful
when removing.
ii) Remove ring (9).
iii) Remove needle bearing (10).

fl Push with a press from the notched
portion on the inside of the end cap
when removing the bearing.
iv) Remove flange (11).

v) Remove 4 studs (12) and 4 studs (13).
5. Front cylinder block, piston assembly

1) Remove front cylinder block and piston as-
sembly (14).
fl The piston is fitted tightly to the rocker
cam, so check that the cylinder block and
piston come off together as one unit.
PC1100-6 30-103-2
5
2) Disassemble front cylinder block and piston

assembly as follows.
i) Remove piston assembly (15) from cyl-
inder block assembly (16).
fl Remove the piston and shoe retainer
as one unit.
ii) Remove retainer guide (17).
iii) Remove 3 pins (18).
iv) Remove 9 pistons (19) from shoe retainer

(20).
v) Set tool P2 to cylinder block assembly

and compress spring.
vi) Remove snap ring (21) from cylinder
block (22).
vii) Remove tool P2.
viii)Remove seat (23), spring (24), and seat
(25).
6. Front cradle, shaft, rocker cam assembly

1) Remove 12 mounting bolts (75).
30-103-3 PC1100-6
5
2) Using guide bolt 1, remove front cradle,

shaft, and rocker cam assembly (26).
fl Be careful not to let the rocker cam sepa-
rate from the cradle.
3) Remove joint from mating surface of pump
case and cradle.
4) Disassemble front cradle, shaft, and rocker

cam assembly as follows.
i) Remove slider (27) and rocker cam (28)
from cradle and shaft assembly (29).
ii) Hold cradle and shaft assembly (29) in a

vice.
iii) Remove housing (30).
fl If it is difficult to remove, use a forc-
ing screw.
fl Shims are installed, so check the
number and thickness of the shims,
and keep in a safe place.
iv) Remove oil seal (31) from housing (30).
PC1100-6 30-103-4
5
v) Using press, remove shaft assembly (32)

from cradle (33).
vi) Remove snap ring (34) and washer (35)

from shaft (36).
fl The washer is a selected part, so
check the thickness.
vii) Using tool P3 and press, remove roller
bearing (37).
7. Front servo piston

1) Remove cap (38).
fl Loosen the mounting bolts uniformly
until the spring tension is released.
fl Shims are installed, so check the num-
ber and thickness of the shims, and keep
in a safe place.
2) Remove spring (39).
3) Remove cap (40).

fl If it is difficult to remove, use a forcing
screw.
in a safe place.
4) Remove front servo piston (41).
30-103-5 PC1100-6
5
8. Front pump case

1) Remove plug (42).
2) Remove front pump case (43) from tool P1.

Install rear pump assembly (5) to tool P1.
10. Impeller assembly

impeller assembly (45).
2) Disassemble impeller assembly as follows.

i) Remove shims (46).
fl Check the number and thickness of
the shims, and keep in a safe place.
ii) Remove 2 plates (47).
iii) Using tool P4, remove 4 mounting bolts,
then remove impeller (48) from coupling
(49).
PC1100-6 30-103-6
5
11. Rear end cap assembly

1) Remove 4 mounting bolts, then remove rear
end cap assembly (50).
2) Disassemble rear end cap assembly as fol-

lows.
i) Remove valve plate (51) from end cap
(52).
when removing.

12. Rear cylinder block, piston assembly

1) Remove rear cylinder block and piston as-
sembly (55).
2) Disassemble rear cylinder block and piston
fl For details, see 5. Front cylinder block,
piston assembly.
30-103-7 PC1100-6
5
13. Rear cradle, shaft, rocker cam assembly

2) Using guide bolt 1, remove rear cradle,

case and cradle.
4) Disassemble rear cradle, shaft, and rocker


vice.
iii) Remove cover (61).
ing screw.
PC1100-6 30-103-8
5
iv) Using press, remove shaft assembly (62)

from cradle (63).
v) Remove snap ring (64) and washer (65)

from shaft (66).
vi) Using tool P3 and press, remove roller
bearing (67).
vii) Using tool P4, remove mounting bolts,

then remove stopper (68) from cradle
(63).
14. Rear servo piston

1) Remove cap (69).
in a safe place.
30-103-9 PC1100-6
5
3) Remove cap (71).

screw.
in a safe place.
4) Remove rear servo piston (72).
15. Rear pump case

Remove plug (73).
PC1100-6 30-103-10
5
ASSEMBLY OF HYDRAULIC
PUMP ASSEMBLY
HPV95+95
fl Clean all parts, remove all burrs, check for dirt

or damage, and be particularly sure to clean the
drill hole oil passage.
fl Coat the rotating and sliding surfaces of all parts
with engine oil (EO-10CD) before assembling.
fl Always check the contact of the following parts
before assembling. For details, see CHECKING
CONTACT BETWEEN PARTS.
1) Cradle and rocker cam
2) Cylinder block and valve plate
3) Valve plate and end cap
fl The diagrams all show the No. 1 pump.
With the No. 1 pump and No. 2 pump, the only
differences are the shape of the servo valve, the
position of port T and port P, and the direction
of the servo piston.
The procedure is basically the same.
1. Rear pump case [1]

Set rear pump case (74) to working stand.

1) Insert rear servo piston (72) in pump case
(74).
fl When the slider groove is set facing the
bottom of the case, insert the servo pis-
ton so that the part receiving the servo
valve lever faces the mounting surface
of the servo valve.
2) Adjust minimum swash plate angle (MIN) of
servo piston as follows.
fl The minimum swash plate angle is at
the end where no spring is installed.
the position of adjustment is the oppo-
site (left and right).
i) Using tool P5, secure servo piston.
fl As shown in the diagram on the right,
fit the pin portion of tool P5 securely
into the part receiving the lever of
servo piston (74), and check that the
servo piston is held in position.
30-103-11 PC1100-6
5
ii) Measure protrusion dimension a of cap

(71).
iii) Measure inset dimension b from end face
of pump case (74) to end face of servo
piston (72).
iv) Calculate shim thickness c.
• c = (a – b) ± 0.05 mm
• Shim thickness:
0.1 mm, 0.2 mm, 0.5 mm
3) Adjust maximum swash plate angle (MAX)

of servo piston as follows.
fl The maximum swash plate angle is at
the end where the spring is installed.
the position of adjustment is the oppo-
site (left and right).
i) Using tool P6, secure servo piston.

fit the pin portion of tool P6 securely
ii) Measure protrusion dimension d of cap

(69).
iii) Measure inset dimension e from end face
piston (72).
iv) Calculate shim thickness f.
• f = (d – e) ± 0.05 mm
• Shim thickness:
0.1 mm, 0.2 mm, 0.5 mm
PC1100-6 30-103-12
5
4) Install selected shims, then fit O-ring and

install cap (71).
3 Mounting bolt:
59 – 74 Nm {6 – 7.5 kgm}
5) Install spring (70).

install cap (69).
3 Mounting bolt:
59 – 74 Nm {6 – 7.5 kgm}

1) Install rear pump case (74) to tool P1.
2) Fit O-ring and install plug (73).
3 Plug: 58.8 – 78.4 Nm {6.0 – 8.0 kgm}

1) Assemble rear cradle, shaft, and rocker cam
i) Using tool P7 and press, press fit roller
bearing (67) to shaft (66).
2 Press-fitting surface of bearing:
Grease (G2-LI)
fl The bearing is a split type, so be
careful to install facing in the correct
direction.
30-103-13 PC1100-6
5
ii) Select washer thickness as follows.

Select each thickness of washer (65) and
assemble temporarily. Measure dimension
g from top surface of washer to top end of
snap ring groove. Then select washer so
that dimension is within range below.
• g = 1.45 to 1.60 mm
• Washer thickness:
2.8 mm, 2.9 mm, 3.0 mm, 3.1 mm
iii) Fit selected washer (64), and install snap

ring (65).
iv) Fit stopper (68) to cradle (63), then using

tool P4, tighten mounting bolts.
2 Mounting bolt: Loctite #648
3 Mounting bolt:
13.2 ± 1.5 Nm {1.35 ± 0.15 kgm}
v) Using tool P8 and press, press fit shaft

assembly (62) to cradle (63).
Grease (G2-LI)
PC1100-6 30-103-14
5
2) Select shim thickness as follows.

i) Measure protrusion dimension h of cover
(61).
ii) Measure inset dimension i from end face
of cradle (63) to top face of outer race of
bearing (67).
iii) Calculate shim thickness j.
• j = h – i + (0.05 to 0.15) mm
• Shim thickness: 0.1 mm, 0.2 mm

assembly further as follows.
i) Install selected shim, then fit O-ring and
assemble cover (61) to cradle and shaft
assembly (60) temporarily.
fl Tighten the mounting bolts fully af-
ter installing the impeller assembly.
ii) Install rocker cam (59) to cradle and shaft

assembly (60).
fl Check that the sliding portion is fit-
ted tightly.
iii) Install slider (58).
fl Install so that the angled surface
faces the rocker cam.
4) Install joint to mating surface of pump case

and cradle.
fl Install the joint so that the hole with the
small diameter is facing the cradle.
5) Using guide bolt 1, fit O-ring and insert
rear cradle, shaft, and rocker cam assembly
(57) in pump case.
2 Mating surface:
Gasket sealant (LG-7 or LG-5)
30-103-15 PC1100-6
5
6) Tighten 12 mounting bolts (56).

3 Mounting bolt:
98 – 122.2 Nm {10 – 12.5 kgm}
fl After installing, check that the rocker cam
is fitted securely in the cradle.

1) Assemble rear cylinder block and piston as-
sembly as follows.
i) Assemble seat (25), spring (24), and seat
(23) to cylinder block (22).
fl Assemble so that the chamfered in-
side diameter of the seat is facing the
cylinder block.
ii) Set tool P2 to cylinder block (24) and com-
press spring.
iii) Install snap ring (21) and remove tool P2.
iv) Assemble 9 pistons (19) to shoe retainer

(20).
v) Install 3 pins (18) to cylinder block as-

sembly (16).
vi) Install retainer guide (17).
vii) Assemble piston assembly (15) to cylin-
der block assembly (16).
PC1100-6 30-103-16
5

sembly (55).
fl Check that the spline of the cylinder block
and shaft is meshed and that the sliding
portion of the rocker cam and piston
shoe is tightly fitted.

1) Assemble rear end cap assembly as follows.
i) Using press, press fit needle bearing (54)
to end cap (52).
ii) Install ring (53) to end cap (52).

fl Install the ring so that the hole with
the small diameter is facing the end
cap.
iii) Install valve plate (51).
fl Align the pin groove at the valve
plate end and the pin at the end cap
end, and check that the valve plate
and end cap are tightly fitted.
2) Fit O-ring and install end cap assembly (50).

2 Mating surface:
3 Mounting bolt:
59 – 74 Nm {6 – 7.5 kgm}
30-103-17 PC1100-6
5
1) Assemble impeller assembly as follows.
i) Install impeller (48) to coupling (49), then
using tool P4, tighten mounting bolts.
3 Mounting bolt:
4.4 – 5.4 Nm {0.45 – 0.55 kgm}
ii) Install 2 plates (47) to groove of cou-
pling.
2) Prevent rear shaft from rotating as follows.

i) Remove cover (61).
ii) Use guide bolt 2 and hexagonal wrench
3 to prevent rear shaft from rotating.

i) Assemble each thickness of shims (46)
temporarily, then fit impeller assembly
(45) and tighten mounting bolts (44) tem-
porarily.
• Shim thickness: 0.10 mm, 0.15 mm,
0.20 mm, 0.50 mm
ii) Measure protrusion dimension k from
mounting surface of end cap (52) to tip
of impeller assembly (45).
iii) Select shim so that protrusion dimen-
sion k is within range below.
• k = 8.66 ± 0.1 mm
4) Install selected shims (46), then install im-
peller assembly (45) and tighten mounting
bolts (44).
fl Check that there is no interference be-
tween the impeller and rear end cap.
3 Mounting bolt:
59 – 74 Nm {6 – 7.5 kgm}
PC1100-6 30-103-18
5
5) Remove hexagonal wrench 3 and guide bolt

2 used to prevent shaft from rotating.
6) Install shims and install cover (61).
3 Mounting bolt:
27.5 – 34.5 Nm {2.8 – 3.5 kgm}

Remove rear pump assembly (5) from tool P1.
9. Front pump case

1) Set front pump case (43) to tool P1.
2) Fit O-rings and install plug (42).
3 Plug: 58.8 – 78.4 Nm {6.0 – 8.0 kgm}

1) Insert front servo piston (41) in front pump
case.
of the servo valve.
2) Adjust minimum swash plate angle (MIN)
and maximum swash plate angle (MAX) of
fl For details, see 2. Rear servo piston.
fl With the front pump and rear pump, the
position of adjustment is the opposite
(left and right).
3) Insert selected shim, then fit O-ring and in-
stall cap (40).
3 Mounting bolt:
59 – 74 Nm {6 – 7.5 kgm}
30-103-19 PC1100-6
5

5) Insert selected shim, then fit O-ring and in-
stall cap (38).
3 Mounting bolt:
59 – 74 Nm {6 – 7.5 kgm}

1) Assemble front cradle, shaft, and rocker cam
i) Using tool P7 and press, press fit roller
Grease (G2-LI)
direction.
fl For details, see 4. Rear cradle, shaft,
rocker cam assembly.
ring (34).
iv) Using tool P8 and press, press fit shaft
Grease (G2-LI)
v) Select shim thickness as follows.
vi) Using tool P9, press fit oil seal (31) to

housing (30).
PC1100-6 30-103-20
5
vii) Install selected shim, then fit O-ring and

install housing (30) to cradle and shaft
assembly (29).
3 Mounting bolt:
27.5 – 34.5 Nm {2.8 – 3.5 kgm}
viii)Install rocker cam (28) to cradle and shaft

assembly (29).
ted tightly.
ix) Install slider (27).
2) Install joint to front cradle, shaft, and rocker

cam assembly.
front cradle, shaft, and rocker cam assembly
(26) in pump case.
2 Mating surface:

3 Mounting bolt:
98 – 122.2 Nm {10 – 12.5 kgm}
30-103-21 PC1100-6
5

1) Assemble front cylinder block and piston
fl For details, see 5. Rear cylinder block,
piston assembly.
2) Assemble cylinder block and piston assem-
bly (14) to pump case.

1) Assemble front end cap assembly as fol-
lows.
to end cap (8).
ii) Install 4 studs (13) and 4 studs (12).

3 Stud: 118 – 147 Nm {12 – 15 kgm}
iii) Fit O-ring and install flange (11).
3 Mounting bolt:
27.4 – 34.3 Nm {2.8 – 3.5 kgm}
iv) Install ring (9) to end cap (8).

cap.
v) Install valve plate (7).
PC1100-6 30-103-22
5
2) Fit O-ring, install front end cap assembly (6).

2 Mating surface:
3 Mounting nut:
235 ± 20 Nm {24 ± 2 kgm}
Mounting bolt:
59 – 74 Nm {6 – 7.5 kgm}

Fit O-ring and install rear pump assembly (5).
2 Mating surface:
fl If a gap is formed at the mating surface of
the end cap, there is probably improper ad-
justment of the rear pump impeller shim, so
carry out the adjustment again.
3 Mounting nut: 235 ± 20 Nm {24 ± 2 kgm}
15. Inspection of shaft rotating torque

Using tool P10, measure rotating torque of in-
put shaft.
fl Rotate shaft at a constant speed (3 – 5 sec/1
turn) and measure the rotating torque.
• Rotating torque:
Max. 49.0 Nm {max. 5.0 kgm}
(Torque variation range:
fl If the rotating torque is not normal, disas-
semble again and look for the cause.

1) Fit O-ring and install rear servo valve as-
sembly (4).
2 Mating surface:
fl When inserting the arm of the servo
valve into the servo piston, be careful
not to cause any gouging.
30-103-23 PC1100-6
5
fl Gradually tighten the mounting bolts on

opposite sides in turn in the order shown
in the diagram.
3 Mounting bolt:
27.5 – 34.3 Nm {2.8 – 3.5 kgm}
2) Fit O-ring and install front servo valve as-
sembly (3).
2 Mating surface:
in the diagram.
3 Mounting bolt:
27.5 – 34.3 Nm {2.8 – 3.5 kgm}
3) Fit O-ring and install tube (2).
3 Eyebolt:
15.7 – 19.6 Nm {1.6 – 2.0 kgm}
fl Not installed to the No. 2 pump.
PC1100-6 30-103-24
5
CHECKING CONTACT BETWEEN PARTS

fl If either part of the following pairs of sliding
parts has been repaired or replaced with a re-
pair part (new part), check the contact as fol-
lows.
There is no need for this check if both parts of
the pair have been repaired or replaced with a
repair part (new part).
1. Cradle and rocker cam

1) Remove all oil and grease from the parts to
be checked.
fl Do not wipe with a cloth.
2) Paint the cradle with inspection paint, then
put the rocker cam on top.
fl Coat thinly with paint.
fl Assemble in the direction shown in the
diagram on the right.
3) Push the rocker cam with a force of 39.2 –
49.0 N {4 – 5 kg}, and move it from the
position where it contacts the stopper to the
maximum swash plate angle. Repeat this
process 2 or 3 times.
4) Remove the rocker cam, transfer the contact
surface to a tape, and check the contact sur-
face.
fl The standard for the contact is as given
below.
(1) Within 32 – 44 mm of center (center
portion): Contact of more than 90%
(2) Range from center portion (32 – 44
mm) to 60 mm: Contact of 50% –
90%
(3) Not within width of 60 mm (outside):
Contact of less than 50%
• (It is not permitted to have contact
only at the outside and no contact at
the center.)
fl If the contact is defective and lapping is
carried out, it must always be carried
out for both parts together.
30-103-25 PC1100-6
5
2. Cylinder block and valve plate

1) Make a centering tool for the cylinder block
and valve plate.
fl The tool can be made from plastic,
bakelite or any other soft material.
be checked.
3) Paint the cylinder block with inspection paint,
then put the tool and valve plate on top.
4) Push the valve plate with a force of 39.2 –
49.0 N {4 – 5 kg} against the cylinder block,
turn the valve plate 90°, then turn it back to
the original position. Repeat this process 2
or 3 times.
5) Remove the valve plate, transfer the contact
face.
below.
(1) Seal portion (range of φ 90.5 mm): Con-
tact of more than 80% and no break
around whole circumference
(2) Land portion (range of φ 90.5 mm – φ
112 mm): Contact of more than 60% and
no break around whole circumference
3. Valve plate and end cap

be checked.
2) Paint the end cap with inspection paint, then
put the valve plate on top.
49.0 N {4 – 5 kg} against the end cap, turn
the valve plate 90°, then turn it back to the
original position. Repeat this process 2 or 3
times.
face.
fl The contact of the mating surface of the
valve plate and end cap must cover at
least 80% without any variation.
fl If the contact is defective, use a surface
plate and correct by lapping.
PC1100-6 30-103-26
5
DISASSEMBLY OF HYDRAULIC
PUMP ASSEMBLY
HPV160+160
1. Hydraulic pump assembly

Set hydraulic pump assembly (1) to tool Q1.

1) Remove hose (2).
2) Remove front servo valve assembly (3).
3) Remove rear servo valve assembly (4).
3. Rear pump [1]

pump assembly (5).
impeller assembly (7).
30-103-27 PC1100-6
5
2) Disassemble impeller assembly as follows.

i) Remove shims (8).
fl Check the number and thickness of
the shims, and keep in a safe place.
ii) Remove 2 plates (9).
iii) Using tool Q2, remove 7 mounting bolts,
then remove impeller (10) from coupling
(11).

1) Remove 7 mounting bolts, then remove front
case and end cap.
3) Disassemble front end cap assembly as fol-

lows.
(14).
when removing.

PC1100-6 30-103-28
5

1) Remove front cylinder block and piston as-
sembly (17).
2) Disassemble front cylinder block and piston

i) Remove piston assembly (18) from cyl-
inder block assembly (19).
fl Remove the piston and shoe retainer
as one unit.
ii) Remove retainer guide (20).
iii) Remove 3 pins (21).
iv) Remove 9 pistons (22) from shoe retainer

(23).
v) Set tool Q3 to cylinder block assembly

vi) Remove snap ring (24) from cylinder
block (25).
vii) Remove tool Q3.
viii)Remove seat (26), spring (27), and seat
(28).
30-103-29 PC1100-6
5

2) Using guide bolt 1, remove front cradle,

case and cradle.
4) Disassemble front cradle, shaft, and rocker


vice.
iii) Remove housing (33).
ing screw.
PC1100-6 30-103-30
5
iv) Remove oil seal (34) from housing (33).
v) Using press, remove shaft assembly (35)

from cradle (36).
vi) Remove snap ring (37) and washer (38)

from shaft (39).
vii) Using tool Q4 and press, remove roller
bearing (40).
viii)Using tool Q2, remove mounting bolts,

(36).
30-103-31 PC1100-6
5

1) Remove cap (42).
in a safe place.
3) Remove cap (44).

screw.
in a safe place.
4) Remove front servo piston (45).
9. Front pump case

1) Remove plug (46) and plug (47).
2) Remove front pump case (48) from tool Q1.

Install rear pump assembly (5) to tool Q1.
PC1100-6 30-103-32
5

case and end cap.
3) Disassemble rear end cap assembly as fol-

lows.
(51).
when removing.

iv) Remove flange (55).

v) Remove 4 studs (56).
30-103-33 PC1100-6
5

1) Remove rear cylinder block and piston as-
sembly (57).
2) Disassemble rear cylinder block and piston
fl For details, see 6. Front cylinder block,
piston assembly.

2) Using guide bolt 1, remove rear cradle,

case and cradle.
4) Disassemble rear cradle, shaft, and rocker

PC1100-6 30-103-34
5

vice.
iii) Remove cover (63).
ing screw.
iv) Using press, remove shaft assembly (64)

from cradle (65).
v) Remove mounting bolts (65), then re-

move plate (66) from shaft (67).
vi) Using tool Q4 and press, remove roller
bearing (68).
vii) Using tool Q2, remove mounting bolts,

(65).
30-103-35 PC1100-6
5

1) Remove cap (70).
in a safe place.
3) Remove cap (72).

screw.
in a safe place.
4) Remove rear servo piston (73).
15. Rear pump case

Remove plug (74).
PC1100-6 30-103-36
5
ASSEMBLY OF HYDRAULIC
PUMP ASSEMBLY
HPV160+160
fl Clean all parts, remove all burrs, check for dirt

or damage, and be particularly sure to clean the
drill hole oil passage.
fl Coat the rotating and sliding surfaces of all parts
with engine oil (EO-10CD) before assembling.
fl Always check the contact of the following parts
before assembling. For details, see CHECKING
CONTACT BETWEEN PARTS.

Set rear pump case (75) to working stand.

1) Insert rear servo piston (73) in rear pump
case (75).
of the servo valve.
2) Adjust minimum swash plate angle (MIN) of
fl The minimum swash plate angle is at
the end where no spring is installed.
i) Using tool Q5, secure servo piston.

fit the pin portion of tool Q5 securely
30-103-37 PC1100-6
5
ii) Measure protrusion dimension a of cap

(72).
iii) Measure inset dimension b from end face
piston (73).
iv) Calculate shim thickness c.
• c = (a – b) ± 0.05 mm
• Shim thickness:
0.1 mm, 0.2 mm, 0.5 mm
3) Adjust maximum swash plate angle (MAX)

fl The maximum swash plate angle is at
the end where the spring is installed.
i) Using tool Q6, secure servo piston.

fit the pin portion of tool Q6 securely
ii) Measure protrusion dimension d of cap

(70).
iii) Measure inset dimension e from end face
piston (73).
iv) Calculate shim thickness f.
• f = (d – e) ± 0.05 mm
• Shim thickness:
0.1 mm, 0.2 mm, 0.5 mm
PC1100-6 30-103-38
5

install cap (72).
3 Mounting bolt:
66 ± 6.9 Nm {6.7 ± 0.7 kgm}

install cap (70).
3 Mounting bolt:
66 ± 6.9 Nm {6.7 ± 0.7 kgm}

1) Install rear pump case (75) to tool Q1.
2) Fit O-ring and install plug (74).
3 Plug: 69 ± 9.8 Nm {7 ± 1 kgm}

i) Using tool Q7 and press, press fit roller
Grease (G2-LI)
direction.
ii) Fit washer (66) and tighten mounting
bolts (65).
3 Mounting bolt:
113 ± 9.8 Nm {11.5 ± 1 kgm}
30-103-39 PC1100-6
5
iii) Fit stopper (69) to cradle (65), then using

tool Q2, tighten mounting bolts.
3 Mounting bolt:
13.2 ± 1.5 Nm {1.35 ± 0.15 kgm}
v) Using tool Q8 and press, press fit shaft

Grease (G2-LI)

i) Measure protrusion dimension g of cover
(63).
ii) Measure inset dimension h from end face
of cradle (65) to top face of outer race of
roller bearing (68).
iii) Calculate shim thickness i.
• i = (g – h) ± 0.05 mm
• Shim thickness:
0.10 mm, 0.15 mm, 0.5 mm

assembly further as follows.
i) Install selected shim, then fit O-ring and
assemble cover (63) to cradle and shaft
assembly (62) temporarily.
3 Mounting bolt:
31.4 ± 2.94 Nm {3.2 ± 0.3 kgm}
PC1100-6 30-103-40
5
ii) Install rocker cam (61) to cradle and shaft

assembly (62).
ted tightly.
iii) Install slider (60).
4) Install joint to rear cradle, shaft, and rocker

cam assembly.
rear cradle, shaft, and rocker cam assembly
(59) in pump case.
2 Mating surface:

3 Mounting bolt:
176 ± 20 Nm {18 ± 2 kgm}

sembly as follows.
i) Assemble seat (28), spring (27), and seat
(26) to cylinder block (25).
fl Assemble so that the chamfered in-
side diameter of the seat is facing
the cylinder block.
ii) Set tool Q3 to cylinder block assembly
iii) Install snap ring (24) and remove tool
Q3.
30-103-41 PC1100-6
5
iv) Assemble 9 pistons (22) to shoe retainer

(23).
v) Install 3 pins (21) to cylinder block as-

sembly (19).
vi) Install retainer guide (20).
vii) Assemble piston assembly (18) to cylin-
der block assembly (19).

sembly (57).

1) Assemble rear end cap assembly as follows.
to end cap (51).
PC1100-6 30-103-42
5
ii) Install 4 studs (56).

iii) Fit O-ring and install flange (55).
3 Mounting bolt:
66 ± 6.9 Nm {6.7 ± 0.7 kgm}
iv) Install ring (53) to end cap (51).

cap.
v) Install valve plate (50).
2) Install joint to rear end cap assembly.
large diameter is facing the end cap.
3) Fit O-ring and install rear end cap assembly

(49).
2 Mating surface:
3 Mounting bolt (small):
54 ± 6.9 Nm {5.5 ± 0.7 kgm}
3 Mounting bolt (large):
470 ± 39 Nm {48 ± 4 kgm}

Remove rear pump assembly (5) from tool Q1.
30-103-43 PC1100-6
5
8. Front pump case

1) Set front pump case (48) to tool Q1.
2) Fit O-rings and install plug (47) and plug
(46).
3 Plug: 69 ± 9.8 Nm {7 ± 1 kgm}

1) Insert front servo piston (45) in front pump
case.
fl When the slider groove is set facing
the bottom of the case, insert the servo
piston so that the part receiving the
servo valve lever faces the mounting
surface of the servo valve.
2) Adjust minimum swash plate angle (MIN)
and maximum swash plate angle (MAX)
fl For details, see 2. Rear servo piston.
fl With the front pump and rear pump,
the position of adjustment is the op-
posite (left and right).
3) Insert selected shim, then fit O-ring and
install cap (44).
3 Mounting bolt:
66 ± 6.9 Nm {6.7 ± 0.7 kgm}
5) Insert selected shim, then fit O-ring and
install cap (42).
3 Mounting bolt:
66 ± 6.9 Nm {6.7 ± 0.7 kgm}

1) Assemble front cradle, shaft, and rocker
i) Using tool Q7 and press, press fit roller
Grease (G2-LI)
careful to install facing in the cor-
rect direction.
PC1100-6 30-103-44
5

Select each thickness of washer (38) and
assemble temporarily. Measure dimension
j from top surface of washer to top end of
snap ring groove. Then select washer so
that dimension is within range below.
• j = 1.45 to 1.60 mm
• Washer thickness :
3.0 mm, 3.1 mm, 3.2 mm

ring (37).
iv) Fit stopper (41) to cradle (36), then using

tool Q2, tighten mounting bolts.
3 Mounting bolt:
13.2 ± 1.5 Nm {1.35 ± 0.15 kgm}
v) Using tool Q8 and press, press fit shaft

Grease (G2-LI)
vi) Select shim thickness as follows.
30-103-45 PC1100-6
5
vii) Using tool Q9, press fit oil seal (34) to

housing (33).
viii)Install selected shim, then fit O-ring and

install housing (33) to cradle and shaft
assembly (32).
3 Mounting bolt:
31.4 ± 2.9 Nm {3.2 ± 0.3 kgm}
ix) Install rocker cam (31) to cradle and shaft

assembly (32).
ted tightly.
x) Install slider (30).
2) Install joint to front cradle, shaft, and rocker

cam assembly.
front cradle, shaft, and rocker cam assembly
(29) in pump case.
2 Mating surface:
PC1100-6 30-103-46
5

3 Mounting bolt:
176 ± 19.6 Nm {18 ± 2 kgm}

1) Assemble front cylinder block and piston
fl For details, see 5. Rear cylinder block,
piston assembly.
2) Assemble cylinder block and piston assem-
bly (17).

1) Assemble front end cap assembly as fol-
lows.
to end cap (14).
ii) Install ring (15) to end cap (14).

cap.
iii) Install valve plate (13).
30-103-47 PC1100-6
5
2) Install joint to front end cap assembly.

large diameter is facing the end cap.
3) Fit O-ring and install front end cap assembly
(12).
2 Mating surface:
3 Mounting bolt:
54 ± 6.9 Nm {5.5 ± 0.7 kgm}

1) Assemble impeller assembly as follows.
i) Install impeller (10) to coupling (11), then
using tool Q2, tighten mounting bolts.
3 Mounting bolt:
13.2 ±1.5 Nm {1.345 ± 0.15 kgm}
ii) Install 2 plates (9) to coupling groove.

i) Assemble each thickness of shims (8)
temporarily, then fit impeller assembly
(7) and tighten mounting bolts (6) tem-
porarily.
• Shim thickness: 0.10 mm, 0.15 mm,
0.20 mm, 0.50 mm
ii) Measure protrusion dimension k from
mounting surface of rear end cap (14) to
tip of impeller assembly (7).
iii) Select shim so that protrusion dimen-
sion k is within range below.
• k = 15.75 ± 0.1 mm
3) Install selected shims (9), then install impel-
ler assembly (7) and tighten mounting bolts
(6).
fl Check that there is no interference be-
tween the impeller and rear end cap.
3 Mounting bolt:
98 – 123 Nm {10.0 – 12.5 kgm}
PC1100-6 30-103-48
5

Fit O-ring and install rear pump assembly (5).
2 Mating surface:
fl If a gap is formed at the mating surface of
the end cap, there is probably improper ad-
justment of the rear pump impeller shim, so
carry out the adjustment again.
3 Mounting nut: 470 ± 39 Nm {48 ± 4 kgm}
15. Inspection of shaft rotating torque

Using tool Q10, measure rotating torque of in-
put shaft.
fl Rotate shaft at a constant speed (3 – 5 sec/1
turn) and measure the rotating torque.
• Rotating torque:
(Torque variation range:
fl If the rotating torque is not normal, disas-
semble again and look for the cause.

1) Fit O-ring and install rear servo valve as-
sembly (4).
2 Mating surface:
in the diagram.
3 Mounting bolt:
27.5 – 34.3 Nm {2.8 – 3.5 kgm}
2) Fit O-ring and install front servo valve as-
sembly (3).
2 Mating surface:
in the diagram.
3 Mounting bolt:
27.5 – 34.3 Nm {2.8 – 3.5 kgm}
3) Fit O-ring and install tube (2).
3 Sleeve nut: 19.6 – 29.4 Nm {2 – 3 kgm}
30-103-49 PC1100-6
5
CHECKING CONTACT BETWEEN PARTS

fl If either part of the following pairs of sliding
parts has been repaired or replaced with a re-
pair part (new part), check the contact as fol-
lows.
There is no need for this check if both parts of
the pair have been repaired or replaced with a
repair part (new part).
1. Cradle and rocker cam

be checked.
2) Paint the cradle with inspection paint, then
put the rocker cam on top.
fl Assemble in the direction shown in the
3) Push the rocker cam with a force of 39.2 –
49.0 N {4 – 5 kg}, and move it from the
position where it contacts the stopper to the
maximum swash plate angle. Repeat this
process 2 or 3 times.
4) Remove the rocker cam, transfer the contact
face.
below.
(1) Within 36 – 50 mm of center (center
portion): Contact of more than 90%
(2) Range from center portion (36 – 50
mm) to 67 mm: Contact of 50% –
90%
(3) Not within width of 67 mm (outside):
Contact of less than 50%
• (It is not permitted to have contact
only at the outside and no contact at
the center.)
fl If the contact is defective and lapping is
carried out, it must always be carried
out for both parts together.
PC1100-6 30-103-50
5
2. Cylinder block and valve plate

1) Make a centering tool for the cylinder block
and valve plate.
fl The tool can be made from plastic,
bakelite or any other soft material.
2 Remove all oil and grease from the parts to
be checked.
3) Paint the cylinder block with inspection paint,
then put the tool and valve plate on top.
49.0 N {4 – 5 kg} against the cylinder block,
turn the valve plate 90°, then turn it back to
the original position. Repeat this process 2
or 3 times.
face.
below.
(1) Seal portion (range of φ 101.5 mm):
Contact of more than 80% and no
break around whole circumference
(2) Land portion (range of φ 101.5 mm – φ
128 mm):
Contact of more than 60% and no
break around whole circumference
3. Valve plate and end cap

be checked.
2) Paint the end cap with inspection paint, then
put the valve plate on top.
49.0 N {4 – 5 kg} against the end cap, turn
the valve plate 90°, then turn it back to the
original position. Repeat this process 2 or 3
times.
face.
fl The contact of the mating surface of the
valve plate and end cap must cover at
least 80% without any variation.
fl If the contact is defective, use a surface
plate and correct by lapping.
30-103-51 PC1100-6
5
DISASSEMBLY AND ASSEMBLY MAIN PUMP INPUT SHAFT OIL SEAL
REMOVAL OF MAIN PUMP

INPUT SHAFT OIL SEAL
,
1. Remove main pump assembly.
For details, see REMOVAL OF MAIN PUMP
ASSEMBLY.

fl Be careful not to lose shims (2) and (3).
3. Remove oil seal (4) from cover (1). 1
INSTALLATION OF MAIN
PUMP INPUT SHAFT OIL SEAL
removal.
1
2 Coat the outside circumference of the oil
seal with grease (G2-LI) thinly, then press
fit.
fl Using tool 1, press fit oil seal (4).
30-104 PC1100-6
2
DISASSEMBLY AND ASSEMBLY MAIN RELIEF VALVE
REMOVAL OF MAIN RELIEF

VALVE ASSEMBLY
the hydraulic tank.
1. Disconnect hoses (1) (coming from solenoid for

2-stage main relief valve) from 4-spool control
valve and 5-spool control valve main relief valve.
fl 4-spool control valve x 2, 5-spool control
valve x 1
2. Remove main relief valve (2). 12
INSTALLATION OF MAIN
RELIEF VALVE ASSEMBLY
removal.
1
3 Main relief valve:
321 ± 46.6 Nm {32.8 ± 4.8 kgm}
2
fl Check the relief pressure.
Measuring oil pressure in work equipment,
swing, and travel circuits.
PC1100-6 30-105
2
DISASSEMBLY AND ASSEMBLY MAIN RELIEF VALVE
DISASSEMBLY OF MAIN
1. Remove sleeve assembly (1) from sleeve (2).
2. Remove springs (3) and (4), pistons (5) and (6),

and sleeve (7).
3. Disassembly of sleeve assembly

fl Do not disassemble except when replacing
parts. When disassembling, measure the
protrusion dimensions of sleeves (9) and (12).
fl Loosen locknut (8), and remove sleeve (9)
and piston (10).
fl Loosen locknut (11), and remove sleeve (12),
spring (13), and piston (14) from sleeve (15).
ASSEMBLY OF MAIN RELIEF

VALVE ASSEMBLY
1. Assembly of sleeve assembly
fl Set sleeves (12) and (9) to the protrusion
dimensions measured before disassembly,
then assemble. After installing the control
valve, adjust the relief pressure.
For details, see TESTING AND ADJUSTING,.
1) Assemble piston (14) and spring (13) to
sleeve (15), screw in sleeve (12), then tighten
locknut (11).
3 Locknut:
107.8 ± 14.7 Nm {11 ± 1.5 kgm}
2) Assemble piston (10) and sleeve (9) to sleeve
(12), then tighten locknut (8).
3 Locknut:
85.75 ± 7.35 Nm {8.75 ± 0.75 kgm}
2. Assemble sleeve (7), pistons (6) and (5), and

springs (4) and (3) to sleeve (2).
3. Install sleeve assembly (1).

3 Sleeve: 186.2 ± 9.8 Nm {19 ± 1 kgm}
30-106 PC1100-6
2
DISASSEMBLY AND ASSEMBLY PILOT RELIEF VALVE
REMOVAL OF PILOT RELIEF

VALVE ASSEMBLY
1. Disconnect hose (1) coming from electro-

magnetic valve.
2. Disconnect hose (2) coming from pilot filter.
3. Disconnect drain tube (3).

4. Disconnect hose (4) coming from pilot valve.
5. Disconnect hoses (5) and (6) going to electro-
magnetic valve.
6. Disconnect tube (7) going to safety valve.
7. Disconnect hose (8) going to relay joint.
8. Remove pilot relief valve assembly (9). 1
INSTALLATION OF PILOT
removal.
1
3 Mounting bolt: 78.5 Nm {8 kgm}
PC1100-6 30-107
2
DISASSEMBLY AND ASSEMBLY 5-SPOOL CONTROL VALVE
REMOVAL OF 5-SPOOL
CONTROL VALVE ASSEMBLY
(NO. 1)
the hydraulic tank.
 Release the remaining pressure inside the
hydraulic circuit.
Releasing remaining pressure from hydraulic
circuit.
fl After disconnecting the PPC hoses, make counter

marks to distinguish the mounting positions.
fl After disconnecting the hoses and tubes, fit blind
plugs.
1. Disconnect wiring connector (1).

2. Disconnect tube (2) coming from line filter.
4. Remove clamp (5), then disconnect tube (6)

coming from main pump.
5. Disconnect R.H. PPC hoses (7) (L.H. travel), (8)
(bucket Hi), (9) (arm Lo), and (10) (boom Hi).
6. Disconnect hoses (11) going to 4-spool main
relief valve and hose between 2-stage main relief
solenoid valve and main relief valve.
7. Disconnect L.H. PPC hoses (12) (boom Hi), (13)

(arm Lo), (14) (bucket Hi), and (15) (L.H. travel).
8. Disconnect tube (16) for boom (RAISE) control.

9. Disconnect tube (17) for arm (OUT) control.
10. Disconnect tube (18) for bucket (CURL) control.
11. Disconnect tube (19) for arm (IN) control.
12. Disconnect tube (20) for bucket (DUMP) control.
13. Disconnect tube (21) for L.H. travel (FORWARD)
control.
14. Disconnect tube (22) for L.H. travel (REVERSE)
control.
15. Disconnect hose (23) going to filter.
fl Disconnect 2 hoses between the bottom of
the control valve and the main pump.
16. Remove mounting bolts and lift off 5-spool
control valve assembly (24). 1
4 5-spool control valve assembly: 260 kg
30-108 PC1100-6
2
INSTALLATION OF 5-SPOOL
(NO. 1)
removal.
1
fl Check the hydraulic pressure and speed of
the work equipment, travel, and swing
circuits. For details, see TESTING AND
ADJUSTING.
• Aligning position when installing valve.

1) Install jig bolts 1 and 2 as shown in
the diagram on the right.
2) Install tube 3 (normal piping).
3) Replace jig bolts with normal bolts.

level. Run the engine to circulate the oil
through the system. Then check the oil level
again.
PC1100-6 30-109
2
REMOVAL OF 4-SPOOL
(NO. 2)
the hydraulic tank.
hydraulic circuit.
circuit.
plugs.
1. Disconnect wiring connector (1).
2. Disconnect tube (2) coming from main pump.
4. Disconnect hose (5) between main relief valve
and solenoid valve of 2-stage safety valve.
5. Disconnect drain hose (straight travel valve) (6).

6. Disconnect R.H. PPC hoses (7) (R.H. travel), (8)
(boom Lo), (9) (bucket Lo), and (10) (arm Hi).
7. Disconnect hose (11) from solenoid valve of 2-
stage safety valve.
8. Disconnect hose (12) from straight travel valve
solenoid.
9. Disconnect L.H. PPC hoses (13) (R.H. travel), (14)
(boom Lo), (15) (bucket Lo), and (16) (arm Hi).
10. Disconnect tube (17) from line filter.

11. Disconnect tube (18) going to 5-spool control
valve (L.H. travel).
12. Disconnect tube (19) for R.H. travel (FORWARD)
control.
13. Disconnect tube (20) for R.H. travel (REVERSE)
control.
14. Disconnect tube (21) for boom (LOWER) control.
15. Disconnect tube (22) for boom (RAISE) control.
16. Disconnect tube (23) for bucket (CURL) control.
17. Disconnect tube (24) for bucket (DUMP) control.
18. Disconnect tube (25) for arm (IN) control.
19. Disconnect tube (26) for arm (OUT) control.
20. Remove step (27).
fl Disconnect 2 hoses between the bottom of
the control valve and the main pump.
21. Remove mounting bolts and lift off 4-spool
control valve assembly (28). 1
30-110 PC1100-6
2
(NO. 2)
removal.
1
fl Check the hydraulic pressure and speed of
the work equipment, travel, and swing
circuits. For details, see TESTING AND
ADJUSTING.
• Aligning position when installing valve.

1) Install jig bolts 1 and 2 as shown in
the diagram on the right.
2) Install tube 3 (normal piping).
3) Replace jig bolts with normal bolts.

again.
PC1100-6 30-111
2
REMOVAL OF 4-SPOOL
(NO. 3)
the hydraulic tank.
hydraulic circuit.
circuit.

plugs.
1. Disconnect tubes (1) going to No. 1, 2 control

valves.
2. Disconnect return line tubes (2).
3. Disconnect tube (3) for arm control.
4. Disconnect tube (4) for bucket control.
5. Disconnect tube (5) for arm control.
6. Disconnect tube (6) for bucket control.
7. Disconnect tube (7) for swing control.
8. Disconnect tube (8) for boom control.
9. Disconnect hose (9) from hydraulic pump.
10. Disconnect hose (10) from hydraulic valve.
11. Disconnect PPC hoses (arm control (11), bucket

control (12), swing control (13), boom control
(14)).
12. Disconnect PPC hoses (arm control (15), (bucket
control (16), swing control (17), boom control
(18)).
13. Disconnect inlet hose (19) of main 2-stage relief
solenoid valve.
14. Disconnect hoses (20) and (21) coming from No.

3 pump.
15. Remove 4-spool control valve (No. 3) assembly
(22).
30-112 PC1100-6
2
(NO. 3)
removal.

• Bleeding air
Bleed the air from the circuit between the valve
and hydraulic pressure cylinder.
Bleeding air.
PC1100-6 30-113
2
DISASSEMBLY AND ASSEMBLY CONTROL VALVE
DISASSEMBLY OF CONTROL
VALVE ASSEMBLY (NO. 1)
1. Remove bolt (2) from valve body (1), then
remove case (3).
2. Remove O-ring (4) from case (3).
3. Remove spring (5), tube (6), and retainer (9) from
bottom control valve mount, then pull out spool
(10).
4. Remove tube (7) and retainer (9) from boom Hi
control valve mount.
5. Remove springs (5) and (8), and retainer (9) from
boom Hi control valve mount, then pull out spool
(11).
6. Remove springs (5) and (8), and retainer (9) from
arm Lo, bucket Hi, and L.H. travel control valve
mount.
7. Pull out arm Lo spool (12), bucket Hi spool (13),
and L.H. travel spool (14).
8. Remove 2 suction valves (15).

9. Remove 5 suction-safety valves (16).
10. Remove main relief valve (17).
11. Remove plug (18), then remove (19) (O-ring,
backup ring, and O-ring).
12. Remove orifice (20).
13. Remove jet sensor relief valve (21).
14. Remove plug (22), then remove O-ring (23) from
plug.
15. Remove plug (24), then remove backup ring and
O-ring from plug.
16. Remove bolts (25), remove plate (26), then

remove O-ring (27), spring (28), and check valve
(29).
17. Remove plug (30), then remove backup ring (31)
and O- ring (32).
18. Remove nut (35), then remove sleeve (36).
19. Remove spring (33) and check valve (34) from
sleeve (36).
20. Remove backup ring (37) and O-ring (38) from
sleeve (36).
30-114 PC1100-6
2
ASSEMBLY OF CONTROL
1. Fit backup ring (37) and O-ring (38) to sleeve
(36), then assemble to valve body (1).
2 Sleeve: Thread tightener (Seal end 242)
3 Sleeve: 177 – 216 Nm {18 – 22 kgm}
2. Assemble nut (35) to sleeve (36).

3 Nut: 177 – 216 Nm {18 – 22 kgm}
3. Assemble check valve (34) and spring (33) to

sleeve (36).
4. Fit backup ring (31) and O-ring (32) to plug (30),

then assemble to sleeve (36).
3 Plug: 29.4 – 39.2 Nm {3 – 4 kgm}
5. Insert check valve (29) in valve body (1), then

assemble spring (28).
6. Fit O-ring to plate (26) and tighten to valve body

(1) with bolt.
3 Mounting bolt: 78.5 – 98 Nm {8 – 10 kgm}
7. Fit backup ring and O-ring to plug (24), then

assemble to valve body (1).
2 Plug: Thread tightener (Loctite No. 638)
3 Plug:
117.7 – 161.8 Nm {12.0 – 16.5 kgm}
8. Fit O-ring (23) to plug (22), then assemble to

valve body (1).
3 Plug: 58.8 – 78.5 Nm {6 – 8 kgm}
9. Assemble jet sensor relief valve (21) to valve

body (1).
3 Jet sensor relief valve:
177 – 196 Nm {18 – 20 kgm}
10. Assemble orifice (20) to valve body (1).

3 Orifice: 127 – 177 Nm {13 – 18 kgm}
11. Fit O-ring, backup ring, and O-ring (19) to plug

(18), then assemble to valve body (1).
12. Assemble main relief valve (17) to valve body

(1).
275 – 368 Nm {28 – 37.5 kgm}
PC1100-6 30-115
2
13. Assemble suction-safety valve (16) to valve body

(1).
3 Suction-safety valve:
216 – 235 Nm {22 – 24 kgm}
14. Assemble suction valve (15) to valve body (1).

3 Suction valve:
294 – 314 Nm {30 – 32 kgm}
15. Assemble spools (10) (bottom), (11) (boom Hi),

(12) (arm Lo), (13) (bucket Hi), and (14) (L.H.
travel) to valve body (1).
fl Coat the spool with engine oil.
fl Be careful not to mistake the location and
direction of the spool.
16. Assemble retainer (9), tube (6), and spring (5) to

bottom control valve mount.
17. Fit O-ring (4) to case (3) and tighten to valve

body (1) with bolt (2).
18. Assemble retainer (9) and tube (7) to boom Hi

control valve mount.

20. Assemble retainer (9) and springs (8) and (5) to

spool (12) (boom Lo control valve mount), spool
(13) (bucket Hi control valve mount), and spool
(14) (L.H. travel control valve mount).

30-116 PC1100-6
2
1. Remove mounting bolts (2) and (3) from valve
body (1), then remove straight travel valve (4).
2. Remove O-rings (5) and (6) from straight travel

valve (4).
3. Remove spring (7) and check valve (8) from each

port of valve body (1).
4. Remove seat (9), spring (10), and check valve

(11) from valve body (1).
5. Remove mounting bolts (12) from each control

valve mount, then remove case (13).
6. Remove O-ring (14) from each case (13).
7. Remove springs (15) and (16) from each control

valve mount, then remove retainer (17).
8. Pull out spool (18) for R.H. travel, spool (19) for
boom Lo, spool (20) for bucket Lo, and spool
(21) for arm Hi from valve body.
9. Remove 2 suction valves (22).
10. Remove suction-safety valves (23) and (24) (1

each) and 4 suction-safety valves (25).
14. Remove plug (29).
15. Remove backup ring and O-ring (30) from plug

(29).
PC1100-6 30-117
2
17. Disassembly of straight travel valve assembly

cover (33).
3) Remove backup ring and O-ring (35) from
plug (34).
4) Loosen nut (46) and remove sleeve (47).
5) Remove plug (44), spring (48), and check
valve (49) from sleeve (47).
6) Remove backup ring and O-ring (45) and
(50) from plug (44) and sleeve (47).
flange (38) and O-ring (40).
8) Remove spring (41) and spool (42).
9) Remove plug and O-ring (43) from spool (42).
ASSEMBLY OF CONTROL
1. Assembly of straight travel valve
1) Fit O-ring and plug (43), assemble to spool
(42), then insert together with spring (41) in
valve body (4).
2) Fit O-ring to flanges (38) and (39), and tighten
with mounting bolts (37) from left and right.
2 Flange: Liquid sealant (Seal end 242)
3) Fit backup ring and O-ring (50) to sleeve
(47), then assemble to valve body.
2 Sleeve: Liquid sealant (Seal end 242)
3 Sleeve: 177 – 216 Nm {18 – 22 kgm}
4) Tighten nut (46) in sleeve (47).
3 Nut: 177 – 216 Nm {18 – 22 kgm}
5) Fit backup ring and O-ring (45) to plug (44).
6) Insert check valve (49) and spring (48) in
sleeve (47), then assemble plug (44).
3 Plug: 29.4 – 39.2 Nm {3 – 4 kgm}
30-118 PC1100-6
2
7) Fit backup ring and O-rings (35) and (36) to

plug (34), then insert in valve body (4).
8) Install cover (32), then install bolt (51).
2 Cover: Liquid sealant (Seal end 242)
3 Bolt: 27.5 – 34.3 Nm {2.8 – 3.5 kgm}
9) Put cover (33) on valve body, fit washer to
bolt (32), then insert into valve body (4).
2. Fit O-ring to plug (31) and install.

3 Plug: 58.8 – 78.5 Nm {6 – 8 kgm}
3. Fit backup ring and O-ring (30) to plug (29) and

install.
3 Plug: 118 – 162 Nm {12 – 16.5 kgm}
4. Install main relief valve (28).

275 – 368 Nm {28 – 37.5 kgm}
5. Install jet sensor relief valve (27).

177 – 196 Nm {18 – 20 kgm}
6. Install orifice (26).

3 Orifice: 127 – 177 Nm {13 – 18 kgm}
7. Install suction-safety valves (23), (24), and (25).

216 – 235 Nm {22 – 24 kgm}
8. Install suction-safety valve (22).

294 – 314 Nm {30 – 32 kgm}
9. Insert spools (18) (R.H. travel), (19) (boom Lo),

(20) (bucket Lo), and (21) (arm Hi) in valve body
(1).
fl Coat the spool with engine oil, then insert.
10. Assemble retainer (17) and springs (15) and (16).
11. Fit O-ring (14) to case (13), and tighten with bolt
(12).
PC1100-6 30-119
2
12. Insert check valve (8) and spring (7) in valve

body (1).
13. Insert check valve (11), spring (10), and seat (9)
in valve body (1).
14. Fit O-rings (5) and (6) to straight travel valve (4),
and set to valve body (1).
15. Fit washers to mounting bolts (2) and (3) and

tighten.
fl Tighten in the order shown in the diagram
on the right.
3 Mounting bolt (2) x 12:
78.5 – 98.1 Nm {8 – 10 kgm}
157 – 177 Nm {16 – 18 kgm}
30-120 PC1100-6
2
1. Remove mounting bolts (2) and (3) from valve
body (1), then remove swing priority valve (4).
2. Remove O-rings (5) and (6) from swing priority
valve (4).
3. Remove spring (7) and check valve (8) from each

port of valve body (1).
4. Remove spring (9), seat (10), and check valve
(11) from valve body (1).
5. Remove spring (12) and check valve (13) from
valve body (1).
6. Remove mounting bolts (14) from each control

valve mount on left side (main relief valve mount
side), then remove case (15).
7. Remove O-ring (16) from each case (15).
8. Remove bolt (14) from each control valve mount
(Boom Plus), then remove case (15), tube (20),
and retainer (19).
9. Pull out spool (22) for Boom Plus.
10. Remove bolt (14), then remove case (15), springs
(17) and (18), and retainer (19).
11. Pull out swing spool (23).
12. Remove bolt (14), then remove case (15), tube
(21), and retainer (19).
13. Pull out spool (24) for Bucket Plus.
14. Remove bolt (14), then remove case (15), springs
(17) and (18), and retainer (19).
15. Pull out spool (25) for Arm Plus.
16. Remove O-ring (16) from each case.
17. Remove 6 plugs (26) from valve body (1).

18. Remove O-ring (27) and backup ring and O-ring
(28) from plug (26).
19. Remove 2 suction-safety valves (29).
24. Remove backup ring and O-ring (34) from plug
(33).
PC1100-6 30-121
2
26. Disassembly of swing priority valve assembly

cover (37).
2) Remove O-ring (38) from cover (37).
4) Remove backup ring, O-ring (40), and O-ring
(41) from plug (39).
5) Loosen nut (42), and remove sleeve (43).
6) Remove plug (44), spring (45), and check
valve (46) from sleeve (43).
7) Remove backup ring and O-rings (47) and
(58) from plug (44) and sleeve (43).
flange (50) and O-ring (51).
ASSEMBLY OF CONTROL
1. Assembly of swing priority valve
1) Fit washer to bolt (49), then install O-ring
(51) and flange (50) to valve body (4).
2) Fit backup ring and O-ring (48) to sleeve
(43), and assemble to valve body.
2 Sleeve: Liquid sealant (Seal end 242)
3 Sleeve: 177 – 216 Nm {18 – 22 kgm}
3) Tighten nut (42) to sleeve (47).
3 Nut: 177 – 216 Nm {18 – 22 kgm}
4) Fit backup ring and O-ring (47) to plug (44).
5) Insert check valve (46) and spring (45) in
sleeve (43), then assemble plug (44).
3 Plug: 29.4 – 39.2 Nm {3 – 4 kgm}
6) Fit backup ring and O-ring (40) and O-ring
(41) to plug (39), then insert in valve body
(4).
7) Fit O-ring, then set cover (37) together with
bolt (36) to valve body (4).
30-122 PC1100-6
2
2. Fit O-ring to plug (35) and install.

3 Plug: 58.8 – 78.5 Nm {6 – 8 kgm}
3. Fit backup ring and O-ring (34) to plug (33) and

install.
3 Plug: 118 – 162 Nm {12 – 16.5 kgm}
4. Install main relief valve (32).

275 – 368 Nm {28 – 37.5 kgm}
5. Install jet sensor relief valve (31).

177 – 196 Nm {18 – 20 kgm}
6. Install orifice (30).
3 Orifice: 127 – 177 Nm {13 – 18 kgm}
7. Install suction-safety valve (29).

216 – 235 Nm {22 – 24 kgm}
8. Fit O-ring (27) and backup ring and O-ring (28)

to plug (26), then install.
3 Plug: 177 – 196 Nm {18 – 20 kgm}
9. Insert spools (22) (Boom Plus), (23) (swing), (24)

(Bucket Plus), and (25) (Arm Plus) in valve body
(1).
fl Coat the spool with engine oil, then insert.
10. Assemble retainer (19) and spring (20).
11. Fit O-ring (16) to case (15), and tighten with bolt
(14).
13. Fit O-ring to case (17) and tighten with bolt (14).
14. Assemble retainer (19) and tube (21).
15. Fit O-ring to case (15) and tighten with bolt (14).
17. Fit O-ring (16) to case (15) and tighten with bolt
(14).
18. Assemble main relief valve in same way.
PC1100-6 30-123
2
19. Insert check valve (8) and spring (7) in valve

body (1).
20. Fit spring (9) to check valve (11) and seat (10),
then set to valve body (1).
21. Set check valve (13) and spring (12) to valve
body.
22. Fit O-rings (5) and (6) to swing priority valve
assembly (4), then set to valve body assembly
(1).
23. Fit washers to bolts (2) and (3), then tighten.

fl Tighten in the order shown in the diagram
on the right.
78.5 – 98.1 Nm {8 – 10 kgm}
157 – 177 Nm {16 – 18 kgm}
30-124 PC1100-6
2
DISASSEMBLY AND ASSEMBLY SWING MOTOR
REMOVAL OF SWING MOTOR

ASSEMBLY
 Lower the work equipment to the ground and
stop the engine. Then loosen the oil filler cap
hydraulic tank.
fl Center of chassis
1. Disconnect hoses (1), (2), (3), and (4) coming
from control valve.
2. Disconnect hoses (5) and (6) going to swing
motor at front of chassis.
fl Front of chassis
motor at center of chassis.
4. Disconnect hose (13) going to boom LOWER
regeneration valve.
6. Remove mounting bolts (15), then lift off swing

motor assembly (16).
4 Swing motor assembly: 130 kg
INSTALLATION OF SWIVEL
MOTOR ASSEMBLY
removal.

PC1100-6 30-125
2
DISASSEMBLY AND ASSEMBLY CENTER SWIVEL JOINT
REMOVAL OF CENTER SWIVEL

JOINT ASSEMBLY
hydraulic tank.
1. Disconnect piping and wiring crossing at top of
center swivel joint.
2. Disconnect hose (1) between swivel joint bottom
– L.H. and R.H. travel motors.
3. Disconnect travel speed selector hose (2)
between swivel joint bottom and L.H. and R.H.
travel motors.
4. Disconnect tubes (3) and (4) between swivel joint
bottom and L.H. travel motor.
fl Remove the clamps.
5. Disconnect tubes (5) and (6) between swivel joint
bottom and R.H. travel motor.
fl Disconnect the clamps.
6. Disconnect hoses (7) and (8) between 4-spool
control valve and swivel joint.
7. Disconnect hose (9) between travel speed
selector solenoid valve and swivel joint.
8. Pull out pin and remove stopper link (10).
9. Disconnect hoses (11) and (12) between 5-spool
control valve and swivel joint.
10. Disconnect hose (13) going to filter.
11. Disconnect inside and outside swing motor drain
hoses (14) and (15).
12. Lift off center swivel joint assembly (16).
4 Center swivel joint assembly: 70 kg
INSTALLATION OF CENTER
SWIVEL JOINT ASSEMBLY
removal.
fl Add oil to replace the oil that leaked out during
the removal operation.
30-126 PC1100-6
2
DISASSEMBLY AND ASSEMBLY CENTER SWIVEL JOINT
DISASSEMBLY OF CENTER
1. Remove cover (1). 1
2. Remove snap ring (2).

2
3. Using puller 1, pull out swivel rotor (4) and 3
ring (3) from swivel shaft (5).
4. Remove O-ring (6) and slipper seal (7) from

swivel rotor. 4
ASSEMBLY OF CENTER
5
1. Assemble slipper seal (7) and O-ring (6) to swivel
rotor.
CEP00381
2. Set swivel shaft (5) on block, and using push
tool 2, tap swivel rotor (4) with a plastic
hammer, and install.
2 Contact surface of rotor, slipper seal:
Grease (G2–LI)
fl When installing the rotor, be extremely
careful not to damage the lips of the slipper
seal and the O-ring.
3. Install ring (3) and secure with snap ring (2).
4. Fit O-ring and install cover (1).

3 Mounting bolt:
66.15 ± 7.35 Nm {6.75 ± 0.75 kgm}
CEP00382
PC1100-6 30-127
2
DISASSEMBLY AND ASSEMBLY TRAVEL MOTOR
REMOVAL OF TRAVEL MOTOR

ASSEMBLY
 Swing the work equipment 90°, then lower it
completely to the ground and stop the engine.
1. Remove covers (1) and (2).
2. Disconnect travel speed selector hose (3).
5. Remove mounting bolts on diagonally opposite

sides, set guide bolts 1 in position, then lift off
travel motor assembly (6).
fl Set guide bolts 1 in position, sling the travel
motor, then remove the mounting bolts, and
use forcing screws to pull out the motor
assembly.
4 Travel motor assembly: 60 kg
INSTALLATION OF TRAVEL
MOTOR ASSEMBLY
removal.
fl Be sure to install the thrust rings and O-rings.
30-128 PC1100-6
2
DISASSEMBLY AND ASSEMBLY WORK EQUIPMENT PPC VALVE
REMOVAL OF WORK
EQUIPMENT PPC VALVE
ASSEMBLY
the hydraulic tank.
1. Remove boots (1), then disconnect levers (2)

from PPC valve.
fl On the right side, disconnect horn wiring
connector (M23).
fl Remove the boots together with the levers.
2. Remove case covers (3).
3. Disconnect 6 hoses (4).

fl The hoses are distinguished by different
colored marks, but if oil gets on the marks,
the color may change.
4. Remove mounting bolts (5), then remove PPC

valve assembly (6). 1
INSTALLATION OF WORK
EQUIPMENT PPC VALVE
ASSEMBLY
removal.
1
fl If there is excessive play in the control levers,
adjust the PPC valve.
Adjusting PPC valve.
PC1100-6 30-129
2
DISASSEMBLY OF WORK
EQUIPMENT PPC VALVE
ASSEMBLY
1. Remove nut (1), then remove disc (2) and boot
(3).
2. Remove bolts, then remove plate (5).

fl Do not remove joint (4) unless it is to be
replaced.
3. Remove seal (6) and collar (7).
4. Pull out piston (8), then remove retainer (9),

springs (10) and (11), and shim (12).
fl Spring (10) consists of two each of two types of
springs with different installed loads, so check
the mounting position (oil pressure port) and
mark with tags to prevent mistakes when
installing.
5. Pull out valve (13) from body (14).
30-130 PC1100-6
2
ASSEMBLY OF WORK
EQUIPMENT PPC VALVE
ASSEMBLY
1. Assemble valve (13) to body (14).
2. Assemble shim (12) and spring (11) to valve

(13).
fl When assembling spring (11), set the end
with the small coil diameter (inside diameter)
at shim (12) end.
3. Assemble spring (10), retainer (9), and piston

(8).
fl The number of loops in the coil for spring
(10) is different for each of the hydraulic
ports below, so be careful when installing.
Position of port Free length of spring (mm)

P1, P2 38.71
P3, P4 42.48
fl The position of each port is marked on the

bottom of the valve body.
2 Piston: Grease (G2-LI)
fl When assembling piston (8), coat the outside
of the piston and the inside of the hole in
the body with grease.
4. Fit O-ring to collar (7) and assemble in body

(14), then install seal (6).
5. Install plate (5).

3 Mounting bolt:
13.23 ± 1.47 Nm {1.35 ± 0.15 kgm}
6. Install joint (4).

2 Rocking portion of joint: Grease (G2-LI)
2 Female thread of body:
Thread tightener (LT-2)
fl Coat two places on the female thread with

one drop each of Loctite as shown in the 5∼7mm
3 Joint: 44.1 ± 4.9 Nm {4.5 ± 0.5 kgm}
fl Keep strictly to the tightening torque for the
joint.
7. Assemble boot (3) and disc (2), and tighten with

nut (1).
3 Nut: 112.7 ± 14.7 Nm {11.5 ± 1.5 kgm}
fl After assembling the disc, adjust the height
of the disc. CEP00425
Adjusting PPC valve.
PC1100-6 30-131
2
DISASSEMBLY AND ASSEMBLY TRAVEL PPC VALVE
REMOVAL OF TRAVEL PPC

VALVE ASSEMBLY
the hydraulic tank.
1. Remove cover under travel PPC valve.

2. Remove floor mat.
3. Remove pedals (1) and levers.
4. Remove cover (3). 1
5. Remove covers (4), then remove springs (5).
6. Disconnect left and right FORWARD hoses (6).
2
7. Disconnect left and right REVERSE hoses (7).
8. Disconnect drain hose (8). 3
9. Disconnect hose (9) coming from pilot pump.
10. Remove mounting bolts, then remove travel PPC
valve assembly (10).
INSTALLATION OF TRAVEL
PPC VALVE ASSEMBLY
CEP00427
removal.
1 4
3 Cover mounting bolt:
19.6 ± 1.9 Nm {2.0 ± 0.2 kgm}
2
3 Hose mount joint bolt
(width across flats: 30mm):
39.2 ± 4.9 Nm {4.0 ± 0.5 kgm}
3 Hose mount joint bolt
(width across flats: 22mm):
29.4 ± 4.9 Nm {3.0 ± 0.5 kgm} 5 CEP00428
30-132 PC1100-6
2
DISASSEMBLY OF TRAVEL PPC

VALVE ASSEMBLY
1. Remove screws (1), then remove levers (2).
2. Remove mounting bolts (3), then remove case

and shaft assembly (4).
3. Remove 4 mounting bolts (5), then remove plate

and damper assembly (6).
fl Check the thickness and mounting position
of washer (7).
4. Remove mounting bolts (8), then remove damper

assembly (9) from plate (10).
5. Remove seal (11) and collar (12).
6. Pull out piston (13), then remove retainer (14),

springs (15) and (16), and shim (17).
fl Check the number and thickness of shim (17)
for each mounting position, and keep in sets
in a safe place.
7. Remove valve (18) from body (19).
8. Disassembly of case, shaft assembly

1) Knock pin (20) into shaft, and remove shaft
(21).
2) Remove lever (22).
3) Pull out pin (20) from shaft (21).
PC1100-6 30-133
2
ASSEMBLY OF TRAVEL PPC

VALVE ASSEMBLY
1. Assemble valve (18) in body (19).
2. Assemble shim (17) and spring (16) to valve
(18).
fl Check the number and thickness of shim (17)
for each mounting position, and assemble
in the same position as before disassembly.
Standard thickness of shim: 0.3 mm
fl The top and bottom of spring (16) are not
symmetrical, so set the small coil diameter
(inside diameter) at the shim end when
assembling.
3. Assemble spring (15), retainer (14), and piston
(13).
2 Outside circumference of piston, hole in
body: Grease (G2-LI)
4. Fit O-ring to collar (12) and assemble in body
(19), then install seal (11).
5. Install damper assembly (9) to plate (10) and
tighten mounting bolts (8).
3 Mounting bolt:
4.41 ± 0.49 Nm (0.45 ± 0.05 kgm)
6. Install plate and damper assembly (6), and
tighten mounting bolts (8).
fl Temporarily assemble a standard washer (1.6
mm) for washer (7).
After the completion of assembly, measure
the difference in the angle when the left and
right levers are operated fully. If the
difference in angle is greater than 0.7°,
change the thickness of washer (7) to make
the difference less than 0.7°.
• Thickness of washer: 1.0, 1.3, 1.6 mm
fl If the thickness of the washer is reduced
by 0.3 mm, the angle when the lever is
fully operated will be increased by 0.39°.
3 Mounting bolt:
30.87 ± 3.43 Nm (3.15 ± 0.35 kgm)
7. Install case and shaft assembly (4) and tighten
mounting bolts (3).
2 Rocking portion of shaft, connection of
lever and piston: Grease (G2-LI)
3 Mounting bolt:
27.93 ± 3.43 Nm (2.85 ± 0.35 kgm)
8. Install levers (2) and tighten screws (1).
2 Rocking portion of lever pin and plate:
Grease (G2-LI)
3 Screw: 8.82 ± 0.98 Nm (0.9 ± 0.1 kgm)
30-134 PC1100-6
2
DISASSEMBLY AND ASSEMBLY BUCKET CYLINDER
BACKHOE
REMOVAL OF BUCKET
CYLINDER ASSEMBLY I
g Set mounting pin (I) and link (2) at the bucket

.
cylinder rod end to a posrtron where there is no
interference, then set the back face of the bucket
on a block.
g Stop the engine, then operate the bucket con-
trol lever to release the remaining pressure in
the hydraulic circuit.
CWPO5937
1. Remove stopper, then remove rod pin (I) from

link (2).x-,
IXK
After removing the pin, start the engine,
retract the piston rod, then tie the piston rod
with wire to prevent it from coming out.
Extend the arm and set block @ between
the cylinder and the arm.
The bucket and link are still installed, so be
careful when extending the arm.
There are shims installed, so check the
number and thickness, and keep in a safe
place.
2. Disconnect 2 left and right cylinder bottom

grease hoses (3).
3. Disconnect right cylinder bottom hose (4) and

head hose (5).
4. Disconnect left cylinder bottom hose (6) and

head hose (7).
* If there is remaining pressure in the hydrau-
lic circuit, the oil may spurt out, so check
while disconnecting.
t Fit blind plugs in the hoses after disconnect-
ing them.
5. Sling right bucket cylinder assembly (8) and re- CWPO5939
move lock plate (9), then remove pin (IO). m

+ Pull out pin (IO) to a position where the
right cylinder comes off.
* There are shims installed, so check the
place.
6. Lift off right bucket cylinder assembly (8).
7. Remove the cylinder assembly on the left side

in the same way.
elkg Bucket cylinder assembly: 700 kg
PC1 100-6 30- 135

0
BACKHOE
INSTALLATION OF BUCKET
CYLINDER ASSEMBLY
. Carry out installation in the reverse order to

removal.
& Inside surface of bushing when assembling

pin: Anti-friction compound (LM-PI
& Grease after assembling pin: CWPO6016
Grease (LM-G)
a When aligning the position of the pin hole,
never insert your fingers in the pin hole.
Sr Adjust with shims so that clearance a be-
tween link (2) and the end face of the head
of cylinder (8) is 2 - 3 mm.
. Shim thickness: 0.8 mm (STD)
1.0 mm (SP)
a
Inside surface of bushing when assembling
pin: Anti-friction compound ILM-PI
Grease after assembling pin:
Grease (LM-G)
a When aligning the position of the pin hole, CWPO6019

Ir Adjust with shims so that clearance b be-
tween the end face and the bottom of cylin-
der (8) and bracket (9) is 2 - 3 mm.
l Shim thickness: 0.8 mm (STD)
1.0 mm (SP)
. Bleeding air
Ir Bleed the air.
Bleeding air.
. Refilling with oil (hydraulic tank)

* Add oil through the oil filler to the specified
again.
30-l 36 PC1 100-6

0
LOADING SHOVEL
REMOVAL OF BUCKET
CYLINDER ASSEMBLY
a Extend the arm cylinder fully, set the bottom of

the bucket horizontal, lower the work equipment
completely to the ground and stop the engine.
Operate the control levers several times to re-
lease the remaining pressure in the hydraulic
piping.
g Loosen the oil filler cap slowly to release the 3 DEP00540

* Fit blind plugs in the hoses after disconnecting

them, to prevent dirt or dust from entering.
1. Sling bucket cylinder assembly, and remove 3

mounting bolts, then using forcing screws
(Thread dia. = 24 mm, Pitch = 3.0 mm), remove
pin (1). m
g When the pin is removed, links (2) and (3)
will drop, so sling the links before removing
/
the pin. 7
kg
IL”7 Pin: 54 kg
\ Q
DWP00835
2. Start engine and retract piston rod fully.
g Tie the rod with wire to prevent it from com-
ing out.
a After stopping the engine, release the pres-
sure inside the piping.
Releasing pressure in PPC circuit.
3. Disconnect hose (5).
4. Sling piston rod end and bottom end, and re-

move plate, then using forcing screws (Thread
dia. = 24 mm, Pitch = 3.0 mm), pull out pin (6).
m
* Pull out the pin to a position where the cyl-
inder bottom can be disconnected.
&I kg Pin: 50 kg
5. Raise bucket cylinder assembly (7) carefully and

remove.
&I kg Bucket cylinder assembly: 730 kg
PC1 100-6 30-136-l

0
LOADING SHOVEL
CYLINDER ASSEMBLY

removal.
A When aligning the mounting position of the

pin, do not insert your fingers in the pin
hole.

hole.
t Bleed the air from the work equipment circuit.

Bleeding air from hydraulic cylinder.
. Refilling with oil

* Add oil to the specified level, and run the
engine to circulate the oil through the sys-
tem. Then check the oil level again.
30-136-2 PC1 100-6

0
DISASSEMBLY AND ASSEMBLY ARM CYLINDER
BACKHOE
REMOVAL OF ARM CYLINDER

ASSEMBLY
a Retract the arm cylinder fully and set block @

under the tip of the arm.
a Stop the engine and operate the control levers
to release the remaining pressure in each cylin-
der.
1. Disconnect piston rod grease hose (I).
2. Remove lock plate, then remove piston rod pin

(2). a
* Set block @ between the arm cylinder and
the boom.
3. Disconnect 2 bottom hoses (3).
4. Disconnect head hose (4).

* After disconnecting the hoses, fit blind plugs
to prevent the entry of dirt or dust.
I
5. Disconnect bottom grease hose (5).
5
6. Remove lock plate, then remove pin (6). a
* Sling arm cylinder assembly (7).
place.
7. Lift off arm cylinder assembly (7).
Arm cylinder assembly: 610 kg
PC 1100-6
INSTALLATION OF ARM
CYLINDER ASSEMBLY
removal.
& inside surface of bushing when assembling

& Grease after assembling pin:
Grease (LM-G)
&When aligning the position of the pin hole,
6 Inside surface of bushing when assembling

pin: Anti-friction compound (LM-P)
Grease (LM-G)
g When aligning the position of the pin hole,
* Adjust with shims (9) so that clearance a
between the end face of the bottom of cylin-
der (7) and bracket (8) is 2 - 3 mm.
. Shim thickness: 0.8 mm
. Bleeding air
* Bleed the air.
Bleeding air.

again.
30-138 PC1 100-6

0
LOADING SHOVEL
REMOVAL OF ARM CYLINDER

ASSEMBLY
g Retract boom cylinder fully, and extend arm cyl-

inder, then set the bottom of the bucket hori-
zontal, lower the work equipment completely to
the ground and stop the engine. Operate the
control levers several times to release the re- \
maining pressure in the hydraulic piping.
A Loosen the oil filler cap slowly to release the 3E

1. Disconnect grease hose (I) at piston rod end.
2. Sling arm cylinder assembly, and remove plate,

then using forcing screws (Thread dia. = 24 mm,
Pitch = 3.0 mm), pull out pin (2). a
* Pull out the pin to a position where the pis-
ton rob can be disconnected.
&I kg Pin: 24 kg
DWPflOf337

g Tie the rod with wire to prevent it from com-
ing out.
g After stopping the engine, release the pres-
4. Disconnect hose (3).
5. Sling piston rod end and bottom end, and re-

move plate, then using forcing screws (Thread
dia. = 24 mm, Pitch = 3.0 mm), pull out pin (4).
m DWPOOB38
* Pull out the pin to a position where the cyl-

inder bottom can be disconnected.
& kg Pin: 24 kg
6. Lift off arm cylinder assembly (5) carefully.
&I kg Arm cylinder assembly: 602 kg
PC 1 100-6 30-138-l
0
LOADING SHOVEL
INSTALLATION OF ARM
CYLINDER ASSEMBLY
removal.
a When aligning the mounting position of the pin,

do not insert your fingers in the pin hole.
a When aligning the mounting position of the pin,

do not insert your fingers in the pin hole.
* Bleed the air from the work equipment circuit.


Ir Add oil to the specified level, and run the
30-138-2 PC1 100-6

0
DISASSEMBLY AND ASSEMBLY BOOM CYLINDER
BACKHOE
REMOVAL OF BOOM
CYLINDER ASSEMBLY
a Extend the arm and bucket cylinder rods fully,

lower the work equipment completely to the
ground, and put the safety lock lever in the LOCK
position.
A Stop the engine and operate the control levers
to release the remaining pressure in the hydrau-
lic circuit.
-=-- CWPO5940
1. Disconnect grease hose (I).
2. Remove lock plate, then remove pin (2). m

* Sling the boom cylinder assembly.
3. Retract rod (3).
4. Lower boom cylinder slowly, and insert wedge

@ between cylinder bottom and revolving frame.
* Insert so that the cylinder is horizontal.
5. Disconnect head hose (4).
6. Disconnect bottom hose (5). e _= - d---h -=cwPo5941
7. Sling boom cylinder assembly (7) and remove

lock plate, then remove pin (7). a
* Use forcing screws when removing.
&I kg Boom cylinder assembly: 1,049 kg
CWPO5942
PC1 100-6 30- 139

0
INSTALLATION OF BOOM
CYLINDER ASSEMBLY

removal.

a Grease after assembling pin:
Grease (LM-G)
A When aligning the position of the pin hole,
I I \

Grease (LM-G)
Adjust with shims (9) so that clearance a
between the end face of the bottom of boom
cylinder (7) and bracket (81 is less than 1
mm.
. Shim thickness: 1.0, 1.5 mm
. Bleeding air
* Bleed the air.
Bleeding air.

again.
30- 140 PC1 100-6

0
LOADING SHOVEL
REMOVAL OF BOOM
CYLINDER ASSEMBLY
g Extend the arm and bucket fully, lower the work

equipment completely to the ground and stop
the engine. Operate the control levers several
times to release the remaining pressure in the
hydraulic piping.
g Loosen the oil filler cap slowly to release the


2. Remove plate (2).
3. Sling boom cylinder assembly, then using forc-

ing screws (Thread dia. = 24 mm, Pitch = 3.0
mm), pull out pin (31, and disconnect piston rod
from boom. m

a Tie the rod with wire to prevent it from com-
ing out.
5. Lower boom cylinder assembly onto stand, then

disconnect hose (4).
6. Sling boom cylinder assembly, and remove plate,

Pitch = 3.0 mm), pull out foot pin (5). m
DEP00549
7. Remove boom cylinder assembly (6).
& kg Boom cylinder assembly: 1,073 kg
DWPOO842
PC1 100-6
LOADING SHOVEL
CYLINDER ASSEMBLY
l Carry out installation in the reverse order to

removal.
a When aligning the mounting position of the

hole.
g When aligning the mounting position of the

hole.
* Adjust with shims so that the clearance
at the cylinder bottom end is between 2
and 3 mm.


30-140-2 PC1 100-6

0
DISASSEMBLY AND ASSEMBLY BOTTOM DUMP CYLINDER
LOADING SHOVEL
REMOVAL OF BOTTOM DUMP

CYLINDER ASSEMBLY
a Set the bottom of the bucket horizontal, and

retract the rod to a position where the rod con-
netting pin of the bottom dump cylinder can be
removed. Then fit a block under the bucket, lower
the work equipment completely to the ground
and stop the engine.
* Fit blind plugs in the hoses after disconnecting DEP00552
1. Remove cover (I).
2. Sling bottom dump cylinder assembly, and re-

move lock plate, then using forcing screws
(Thread dia. = 12 mm, Pitch = 1.75 mm), pull out
pin (2). m

Releasing pressure in PPC circuit. DFPOO663
4. Remove hose (3).
5. Remove 3 mounting bolts, then using forcing

screws (Thread dia. = 12 mm, Pitch = 1.75 mm),
pull out pin (4). a
6. Lift off bottom dump cylinder assembly (5).
&I kg Bottom dump cylinder assembly: 147 kg
PC1 100-6 30- 140-3

@
DISASSEMBLY AND ASSEMBLY BOTTOM DUMP CYLINDER
LOADING SHOVEL
INSTALLATION OF BOTTOM
DUMP CYLINDER ASSEMBLY

removal.
-a When aligning the mounting position of the

hole.

hole.


30- 140-4 PC1 100-6

0
DISASSEMBLY AND ASSEMBLY BUCKET
BACKHOE
REMOVAL OF BUCKET
ASSEMBLY
a Set the back face of the bucket facing down,

lower the work equipment completely to the
ground, and set the safety lock lever to the LOCK
position.
1. Remove 3 link pin lock bolts (2) of bucket (I),

then remove stopper (3).
2. Remove link pin (4). a

* Use forcing screws when removing.
* If it is difficult to remove the pin, raise the
bucket and move it backward and forward
to find a position where it is easier to re-
move the pin.
* If the bucket is not in contact with the ground,
set a block under the back face of the bucket.
* After removing the pin, retract the bucket
cylinder and lift up link (5).
3. Remove 3 lock bolts (6) of connecting pin be-
tween arm and bucket, then remove stopper (7).
4. Loosen 4 cover lock bolts (8).

5. Remove connecting pin (9) between arm and
bucket. a
j, Use forcing screws when removing.
Ir If it is difficult to remove the pin, move the
arm up and down a small amount to find a
position where it is easier to remove the
pin.
6. Remove 4 cover lock bolts (8) and cover (IO)
from bucket (I), then remove shim (I I), bushing
(12), and O-ring (13).
place.
7. Start engine, then raise work equipment to dis-
connect arm (14) from bucket.
&I kg Bucket assembly: 4,600 kg
PC1 100-6 30-141

0
BACKHOE
ASSEMBLY

removal.
a Inside surface of bushing when assembling

Grease (LM-G)

6 Grease after assembling pin:
Grease (LM-G)
* insert the O-ring at the end face of the bucket
boss securely.
* Adjustment of bucket clearance
I) Measure clearance @ between arm (14)
and bushing (12).
* Put the edge of the arm boss and
the edge of the bucket boss in con-
tact, and measure clearance 0.
2) After removing the shims, take out shims
equal to clearance 0, and fit the remain-
ing shims.
* Shim thickness: 0.5, 1.0 mm
* If clearance @ is smaller than the
thickness of one shim, do not carry
out any adjustment.
3) Tighten bolt (8) and bolt (6).
30-l 42 PC1 100-6

0
LOADING SHOVEL
REMOVAL OF BUCKET
ASSEMBLY
A Set the bottom of the bucket horizontal, lower

and stop the engine. Operate the control levers
several times to release the remaining pressure
in the hydraulic piping.
g Loosen the oil filler cap slowly to release the

Fit blind plugs in the hoses after disconnecting

1. Disconnect bottom dump cylinder hose (I).
2. Sling bucket cylinder assembly, and remove 3

mounting bolts, then using forcing screws
(Thread dia. = 24 mm, Pitch = 3.0 mm), pull out
pins (2) and (3).
* Remove the pins on the other side in the
same way.
a When the pins are removed, link (4) will drop,

so sling the links before removing the pin.
4. Lift off bucket assembly (6).
el kg Bucket assembly: 9,350 kg
PC1 100-6 30-142-l

0
LOADING SHOVEL
ASSEMBLY
* Install the hoses without twisting or interference.
1. Raise bucket assembly (61, set bottom of bucket

horizontal and lower bucket to ground.
2. Start engine and operate control levers, then

align arm and bucket pin mounting hole.
g Before starting the engine, check that there

is a blind plug in the bottom cylinder piping.

pin, never put your fingers in the pin hole.
3. Knock in pin (5), and tighten 3 mounting bolts.

* Install the pin on the other side in the same
way.
4. Raise link (4), and align mounting pin hole of

bucket, then knock in pins (3) and (2).

pin, never put your fingers in the pin hole.
5. Fit O-ring and connect bottom cylinder hose (I).
+ Bleed the air from the work equipment circuit.

Bleeding air and releasing pressure. After com-
pletion of bleeding the air, add oil to the hy-
draulic tank to the specified level.
30-142-2 PC1 100-6

0
DISASSEMBLY AND ASSEMBLY ARM
BACKHOE
REMOVAL OF ARM ASSEMBLY
1. Remove bucket assembly.

For details, see REMOVAL OF BUCKET ASSEM-
BLY.
* Secure the bucket link to the arm.
3. Disconnect 4 bucket cylinder hoses (2).

* Disconnect at the tip of the boom.
4. Sling arm cylinder assembly (3) and remove pin

(4). m
* Set block 0 between the arm cylinder and
the boom.
5. Sling arm assembly (6) and remove pin (5). m

+ If it is difficult to remove the pin, operate the
swing to move the boom slightly to the left
and right, and knock out the pin at a point
where the forcing screw becomes lighter.
6. Lift off arm assembly (6).

CWPO5944
&I kg Arm assembly: 4,000 kg
PC1 100-6 30- 143

0
BACKHOE
INSTALLATION OF ARM
ASSEMBLY

removal.

Grease (LM-G)

Grease (LM-G)
* Adjust with shims so that clearance a be-
tween the end face of the bottom of arm (6)
and boom (7) is less than 1 mm.
. Shim thickness: 1.0 mm CWPO
. Bleeding air
* Bleed the air.
Bleeding air.

again.
30- 144 PC1 100-6

0
LOADING SHOVEL
REMOVAL OF ARM ASSEMBLY
1. Remove bucket assembly. (Leave bucket, arm,

and link at cylinder end)
For details, see REMOVAL OF BUCKET ASSEM-
BLY.
2. Start engine, operate boom and set work equip-

ment so that bucket cylinder is perpendicular.
3. Disconnect grease tube hose (I).

Ir Sling arm cylinder assembly from boom end.
4. Remove 3 mounting bolts, then using forcing

screws (Thread dia. = 24 mm, Pitch = 3.0 mm),
pull out pin (2).
Ir Pull out the other pin in the same way, and
tie the link to the arm so that it does not
move.
5. Disconnect left and right bottom cylinder hoses

(3).
6. Remove cover (4), and disconnect wiring (5) and

cable (6) of potentiometer.
7. Remove 3 mounting bolts (7), the remove

potentiometer (8) together with bracket (9).
8. Sling arm assembly, remove 3 mounting bolts,

Pitch = 3.0 mm), pull out pin (IO).
+ Pull out the other pin in the same way, and
pull out the pins to a point where the arm
can be disconnected from the boom.
&I kg Pin: 81 kg
9. Lift off arm assembly (II). F20903202A
&I kg Arm assembly: 5,150 kg
PC1 100-6
LOADING SHOVEL
v
INSTALLATION OF ARM
ASSEMBLY
1. Raise arm assembly (II), set in mounting posi-

tion on boom, then align pin hole.

pin, never put your fingers in the pin holes.
2. Knock in pin (IO), and tighten 3 mounting bolts.
3. Fit bracket (9) and potentiometer (8) to arm as

one unit, and tighten 3 mounting bolts (7).
4. Connect wiring (5) and cable (6) of potentiometer,

and install cover (4).
5. Fit O-rings and connect left and right bottom

cylinder hoses (3).
6. Start engine, set arm cylinder piston rod mount

in position, knock in mounting pin (2), then lock
with 3 lock bolts.
+ When the engine is started and the piston
rod is extended, the piston rod on the oppo-
site side is also extended.
7. Install arm cylinder assembly on opposite side

in the same way.
Ir Set bucket assembly in mounting position.
8. Install grease tube hose (I).
9. Start engine, and set work equipment so that

bucket cylinder and arm are perpendicular.

10. Install bucket assembly.

For details see INSTALLATION OF BUCKET AS-
SEMBLY.
30-144-2 PC1 100-6

0
DISASSEMBLY AND ASSEMBLY BOOM
BACKHOE
REMOVAL OF BOOM
ASSEMBLY
1. Remove bucket and arm assembly.

For details, see REMOVAL OF BUCKET, ARM
ASSEMBLY.
2. Set tip of boom on support 0) and stop engine,

then operate boom control lever to release any
remaining pressure in boom cylinder.
CWPO5946
3. Sling boom cylinder (I) and remove pin (2). m

It Lower the boom cylinder slowly and insert a
wedge between the cylinder bottom and the
frame.
4. Disconnect 7 hoses (3) for bucket and arm.
5. Disconnect wiring connector (4) for working

lamp.
CWPO5947 CWPO5948
6. Sling boom assembly (7).
7. Remove lock plate (5), then remove boom foot

pins (6). jw
Ir Use forcing screws.
1 CWPO5949
8. Lift off boom assembly (7) slowly.

* Boom assembly (7) will rock when the crane
is operated, so fit rope @ to the tip of the
boom and apply tension to control the boom
and prevent it from rocking.
elkg Boom assembly: 9,000 kg
PC1 100-6
BACKHOE
ASSEMBLY

removal.

Grease (LM-G)

Grease (LM-G)
* Adjust with shims (9) so that clearance a
between the end face of the foot of boom
(7) and bracket (8) is less than 1 mm.
. Shim thickness: 1.0, 1.5 mm CWPO5951
. Bleeding air
* Bleed the air.
Bleeding air.

again.
30-146 PC1 100-6

0
LOADING SHOVEL
REMOVAL OF BOOM
ASSEMBLY
Special tools
1. Remove arm assembly.

For details, see REMOVAL OF ARM ASSEMBLY.
2. Disconnect bucket cylinder hose (I).
3. Sling bucket cylinder assembly (2), remove plate,

pull out pin (3), then remove bucket cylinder
assembly.
&I kg Pin: 50 kg
fh kg Bucket cylinder assembly: 730 kg
t Remove the other bucket cylinder in the

same way.
4. Sling arm cylinder assembly (4) at boom end

with lever block, and hold in position.
5. Sling boom (5).
6. Sling boom cylinder (6), and disconnect grease

hose (7).
7. Remove lock plate, pull out mounting pin (81,

then lower boom cylinder.
* Insert a block between the case at the boom
cylinder bottom end and the revolving frame
end, and support the boom cylinder. (Be-
cause there is grease fitting)
* Disconnect the other boom cylinder from the
boom in the same way.
8. Set stand (1) at tip of boom, and support boom.
9. Sling work equipment hoses (9). and disconnect

hoses at boom end.
* Oil may spurt out when the hose is discon-
nected, so loosen the hose flange slowly
when disconnecting.
10. Disconnect front lamp wiring.
11. Remove cover (IO), and disconnect wiring (11)

and cable (12) of potentiometer.
PC1 100-6 30-146-l

0
12. Remove 3 mounting bolts (13), then remove

potentiometer assembly (14) together with
bracket (I 5).
13. Sling boom, and pull out left and right boom
mounting pins (16).
Ir Use tool A to pull out boom mounting pin
(16).
A kg Boom mounting pin: 71 kg
+ Check the number and thickness of the shims

on both the left and right, and keep in a safe
place.
14. Raise arm cylinder and boom assembly (17) and

lower onto stand (2).
&l kg Boom assembly and arm cylinder

assembly: 8,100 kg (including pin, piping)
15. Support arm cylinder assembly (18) with hy-

draulic jack, and remove arm cylinder assembly
from boom.
30-146-2 PC1 100-6

0
LOADING SHOVEL
ASSEMBLY
1. Raise boom (17), and set on stand @ temperarily.
2. Using hydraulic jack, or lever block from boom

end, install arm cylinder assembly (18) to boom.
3. Raise boom (17), and align with mounting posi-

tion of left and right boom foot pins.

boom foot pin, never put your fingers in the
pin holes.
4. Assemble shims, knock in left and right boom

foot pins (16), then lock with plate.
5. Fit bracket (15) and potentiometer (14) to boom

as one unit, and tighten 3 mounting bolts (13).
w
F20903202A
PC1 100-6 30-146-3

0
6. Connect wiring (II) and cable (12) of

potentiometer, and install cover (IO).
7. Connect front lamp wiring.
8. Sling work equipment hoses (91, fit O-rings and

connect hose to tube at boom end.
9. Sling boom and arm cylinder assembly, and con-

nect boom cylinder assembly (6) to boom (5).
* To align the boom cylinder shaft and pin
mounts and the pin holes at the boom end,
move the boom and boom cylinder up and
down.
10. Knock pin (8), and lock with lock plate.

* Install the opposite side in the same way.
11. Connect boom cylinder and boom grease hose (7).
12. Sling bucket cylinder assembly (2), align with

boom mounting position, then knock in mount-
ing pin (3), and lock with plate.
* Install the opposite side in the same way.
13. Fit O-ring and connect bucket cylinder hose (I)

to bucket cylinder end.
14. Install arm assembly.

For details, see INSTALLATION OF ARM ASSEM-
BLY.
30-146-4 PC1 100-6

0
DISASSEMBLY AND ASSEMBLY BUCKET, ARM
REMOVAL OF BUCKET, ARM

ASSEMBLY
Backhoe specification
1. Disconnect grease hose (1).
2. Disconnect 4 bucket cylinder hoses (2).

fl Disconnect at the tip of the boom.
3. Sling arm cylinder assembly (3) and remove pin

(4). 1
fl Set block 1 between the arm cylinder and
the boom.
4. Raise bucket and arm assembly (6) a little and

remove pin (5). 2
fl If it is difficult to remove the pin, operate the
swing to move the boom slightly to the left
and right, and knock out the pin at a point
where the forcing screw becomes lighter.
5. Drive machine in reverse and separate bucket

and arm assembly (6) from boom.
6. Set support under arm and lower bucket and

arm assembly (6) slowly.
4 Bucket, arm assembly: 8,500 kg
PC1100-6 30-147
2
DISASSEMBLY AND ASSEMBLY BUCKET, ARM
INSTALLATION OF BUCKET,
ARM ASSEMBLY
Backhoe specification
removal.
1
Grease (LM-G)
 When aligning the position of the pin hole,
2
Grease (LM-G)
 When aligning the position of the pin hole,
fl Adjust with shims so that clearance a
between the end face of the bottom of arm
(7) and boom (8) is less than 1 mm.
• Shim thickness: 1.0 mm
• Bleeding air
fl Bleed the air.
Bleeding air.

fl Add oil through the oil filler to the specified
again.
30-148 PC1100-6
2
DISASSEMBLY AND ASSEMBLY WORK EQUIPMENT
BACKHOE
REMOVAL OF WORK
EQUIPMENT ASSEMBLY
1. Sling boom cylinder (I) and remove pin (2). a

* Lower the boom cylinder slowly and insert a
wedge between the cylinder bottom and the
frame.
2. Disconnect 7 bucket and arm hoses (3).
CWPO594i CWPO5948
3. Disconnect wiring connector (4) for working

lamp.
4. Sling work equipment assembly (7).
5. Remove lock plate (5), then remove boom foot

pins (6). m
* Use forcing screws.
6. Start engine and drive machine slowly in re-

verse.
7. Set support under boom foot, then operate crane

and lower work equipment sl’owly.
Work equipment assembly: 18,000 kg
CWPO5952
PC1 100-6 30- 149

0
BACKHOE
EQUIPMENT ASSEMBLY
removal.

Grease (LM-G)

Grease (LM-G)
* Adjust with shims (IO) so that clearance a
between the end face of the foot of boom
(8) and bracket (9) is less than 1 mm.
. Shim thickness: 1.0, 1.5 mm
-4- CWPO5953
. Bleeding air
Sr Bleed the air.
Bleeding air.

again.
30-150 PC1 100-6

0
LOADING SHOVEL
REMOVAL OF WORK
EQUIPMENT ASSEMBLY
Special tools
g Retract the boom cylinder fully, extend arm cyl-

inder, and set bottom of bucket horizontal. Lower
and stop the engine. Operate the control levers
several times to release the remaining pressure
in the hydraulic piping. Then loosen the oil filler
cap slowly to release the pressure inside the
hydraulic tank.
* Release the pressure inside the piping.

Bleeding air and releasing pressure.
1. Disconnect boom cylinder from boom.

For details, see REMOVAL OF BOOM CYLINDER
ASSEMBLY.
2. Disconnect bottom cylinder hose (I 1, bucket cyl-

inder hose (2) and arm cylinder hose (3).
* Oil may spurt out when the hose is discon-
nected, so loosen the hose flange slowly
when disconnecting.
g Fit blind plugs securely in the piping at the

chassis end so that oil does not spurt out
when the engine is started.
3. Disconnect front lamp wiring.
4. Remove potentiometer assembly.

For details, see REMOVAL OF BOOM ASSEM-
BLY.
5. Set the bottom of the bucket horizontal, lower

the bucket completely to the ground, and sling
boom assembly (4).
6. Pull out left and right boom foot pins (5), and
disconnect work equipment assembly (6) from
chassis.
For details, see REMOVAL OF BOOM ASSEM-
BLY.
Sr Check the number and thickness of the
2lNP01477
shims, and keep in a safe place.
PC1 100-6 30- 150- 1

0
7. Start engine, move machine in reverse slowly,

operate crane, and lower boom foot.
a Check that the boom foot is completely dis-

connected from the chassis before driving
the machine in reverse.
& kg Work equipment assembly: 25,100 kg
EQUIPMENT ASSEMBLY
1. Set the bottom of the bucket horizontal, lower

the bucket completely to the ground, and sling
boom assembly (4).
* Adjust the height that the boom assembly is
raised to align the boom foot with the height
of the mounting position on the chassis.
2. Move machine forward slowly, and align mount-

ing position of boom foot pin and revolving
frame. Assemble shim, then install boom foot
pin (51, and lock with plate.
g When aligning the mounting positions of the

revolving frame and boom foot pin, never
put your fingers in the pin holes.
3. Install potentiometer assembly.

For details, see INSTALLATION OF BOOM AS-
SEMBLY.
4. Connect front lamp wiring.
5. Fit O-rings and connect arm cylinder hose (31,

bucket cylinder hose (2). and bottom cylinder
hose (1).
6. Connect boom cylinder to boom.

For details, see INSTALLATION OF BOOM CYL-
INDER ASSEMBLY.
* Bleed the air from the work equipment cir-
cuit.
Bleeding air and releasing pressure.
After bleeding the air completely, add oil
through the oil filler to fill the hydraulic tank
to the specified level.
30- 150-2 PC1 100-6

0
DISASSEMBLY AND ASSEMBLY CAB
REMOVAL OF CAB ASSEMBLY

1. Remove floor mat.

2. Remove covers (1), (2), and (3).
3. Disconnect window washer hoses (4).

4. Disconnect wiper motor wiring connector (5)
(W21).
5. Remove base mounting bolts (6) and (7).
6. Remove plate (8).

8. Open door (10), and disconnect speaker wiring
connector (M13).
PC1100-6 30-151
2
DISASSEMBLY AND ASSEMBLY CAB
10. Remove base mounting bolts (12) and (13).
11. Remove wiring clamp (14) installed to cab.

fl Disconnect wiring connector (M72) for cab
head lamp and wiring connectors (M71, 97)
for room lamp.
12. Remove mounting bolts (15), then lift off cab

assembly (16).
fl When raising the cab assembly, check that
all the wiring and connectors have been
disconnected, then lift off slowly.
4 Cab assembly: 300 kg
INSTALLATION OF CAB
ASSEMBLY
removal.
30-152 PC1100-6
2
DISASSEMBLY AND ASSEMBLY COUNTERWEIGHT
REMOVAL OF
COUNTERWEIGHT ASSEMBLY
1. Sling counterweight assembly (1).
2. Remove mounting bolts (2). 1
3. Lift off counterweight assembly (1).
4 Counterweight assembly: 17,500 kg
INSTALLATION OF
COUNTERWEIGHT ASSEMBLY
removal.
1
3 Counterweight mounting bolt:
3,822 ± 392 Nm {390 ± 40 kgm}
PC1100-6 30-153
2
DISASSEMBLY AND ASSEMBLY RECEIVER TANK
REMOVAL OF RECEIVER TANK

ASSEMBLY
 Set tool X1 to the gas charging plug of the air
conditioner compressor and collect the air
conditioner gas (R134a).
1. Open door at rear of cab.

2. Disconnect hose (1) coming from air conditioner
condenser.
3. Disconnect hose (2) going to air conditioner unit.
4. Remove U-bolt (3), then remove receiver tank
assembly (4). 1
INSTALLATION OF RECEIVER
TANK ASSEMBLY
removal.
1
fl Be careful not to let dirt, dust, or water get
inside the hoses of the air conditioner circuit
when installing the hoses.
fl Check that there are O-rings at the
connections of the air conditioner hoses
when installing.
fl Check that the O-rings are not damaged or
deteriorated, then connect the hoses.
• Charging with air conditioner gas

Using tool X1, charge the air conditioner circuit
with air conditioner gas (R134a).
30-154 PC1100-6
2
DISASSEMBLY AND ASSEMBLY AIR CONDITIONER CONDENSER
REMOVAL OF AIR
CONDITIONER CONDENSER
ASSEMBLY
1. Open radiator mask.

2. Disconnect hose (1) coming from air conditioner
compressor.
3. Disconnect hose (2) going to receiver tank.
4. Remove 4 mounting bolts (3), then remove air
conditioner condenser assembly (4). 1
INSTALLATION OF AIR
CONDITIONER CONDENSER
ASSEMBLY
removal.
1
fl Be careful not to let dirt, dust, or water get
inside the hoses of the air conditioner circuit
when installing the hoses.
fl Check that there are O-rings at the
connections of the air conditioner hoses
when installing.

Using tool X1, charge the air conditioner circuit
with air conditioner gas (R134a).
PC1100-6 30-155
2
DISASSEMBLY AND ASSEMBLY AIR CONDITIONER COMPRESSOR
REMOVAL OF AIR
ASSEMBLY
1. Loosen lock bolt (1) of air conditioner compressor

mounting bracket.
3. Disconnect hoses (3). 1
fl Fit blind plugs in the hoses after
disconnecting.
5. Loosen locknut (5).
6. Loosen adjustment bolt (6) and remove drive
belt. 2
7. Remove mounting bolt (7), then remove air
conditioner compressor assembly (8).
INSTALLATION OF AIR
ASSEMBLY
removal.
1
2
fl Adjust the belt tension.
Testing and adjusting tension of air
conditioner compressor drive belt.

fl Using tool X1, charge the air conditioner
circuit with air conditioner gas (R134a).
30-156 PC1100-6
2
DISASSEMBLY AND ASSEMBLY AIR CONDITIONER UNIT
REMOVAL OF AIR
CONDITIONER UNIT
ASSEMBLY 1
 Disconnect the cable from the negative (–) 2

1. Close valve of heater hose (outlet).

fl It is installed to the engine water manifold.
CEP00105
2. Slide operator’s seat fully forward.
3. Remove plate (1), then remove cover (2).
4. Disconnect speaker wiring connector (3) (M13),

then disconnect cover (4).
fl Lift up the cover slightly before disconnecting
the speaker wiring connector.
5. Remove bellows hose (5).
6. Remove ducts (6) and (7).
PC1100-6 30-157
2
DISASSEMBLY AND ASSEMBLY AIR CONDITIONER UNIT
7. Disconnect governor controller wiring connectors

(8).
fl Connectors (E12, 13, 14, 15, 16, 17, 18)
8. Remove governor controller (9).
9. Remove relays (10), (11), and (12).
fl Relays (R18, 23, 24)
10. Disconnect wiring harness clamps (13) and (14)
from cover.
11. Disconnect wiring connector (15) (M26) for air

conditioner unit.
12. Tie wiring harnesses (16) together and move
towards cab.
14. Disconnect heater hoses (18) and (19).
fl Fit blind plugs in the hoses.
15. Disconnect refrigerant hoses (20) and (21).
fl The clamp is weak, so always hold with one
wrench while using the other to turn.
16. Disconnect wiring connectors (22), (23), (24), and

(25).
17. Disconnect 4 relays (26).
18. Remove filter (27).
19. Remove mounting bolts, then remove air
conditioner unit (28).
INSTALLATION OF AIR
CONDITIONER UNIT
ASSEMBLY
removal.

fl Add water through water filler to the
specified level.
Run the engine to circulate the water through
the system. Then check the water level again.

fl Using tool X1, charge the air conditioner
circuit with air conditioner gas (R134a).
30-158 PC1100-6
2
DISASSEMBLY AND ASSEMBLY SOLENOID VALVE
REMOVAL OF SOLENOID
VALVE ASSEMBLY
1. Boom rock prevention valve

1) Open door at rear of cab.
2) Disconnect wiring connectors (1) (V9, 10).
3) Remove nuts (2), then remove solenoids (3).
fl V9, V10: Boom rock prevention solenoid
valve
2. Swing priority valve, main 2-stage relief valve,

CO cancel valve
1) Open door at side of hydraulic tank.
2) Disconnect wiring connectors (1) (V1, 2, 7).
fl V1: Swing priority valve
V2: Main 2-stage relief valve
V3: CO cancel valve
3. Straight travel valve, swing lock valve, boom

head 2-stage safety valve, travel speed selector
valve, swing lock valve
1) Remove step at center of chassis.
2) Disconnect wiring connectors (1) (V3, 4, 5, 6,
11).
fl V3: Straight travel valve
V4: Swing lock valve
V5: Boom head 2-stage safety valve
V6: Travel speed selector valve
V11: Swing lock valve
INSTALLATION OF SOLENOID
VALVE ASSEMBLY
removal.
fl Be careful not to let dirt get stuck to the coil
insertion portion.
PC1100-6 30-159
2
DISASSEMBLY AND ASSEMBLY GOVERNOR CONTROLLER
REMOVAL OF GOVERNOR
CONTROLLER ASSEMBLY
1. Open air conditioner unit covers (1).
2. Disconnect wiring connectors (2) (E12, 13, 14,

15, 16, 17, 18).
3. Remove 4 mounting bolts (3), then remove

governor controller assembly (4).
INSTALLATION OF GOVERNOR
CONTROLLER ASSEMBLY
removal.
30-160 PC1100-6
2
DISASSEMBLY AND ASSEMBLY MONITOR PANEL
REMOVAL OF MONITOR
PANEL ASSEMBLY
1. Remove 4 screws (1), then disconnect monitor

panel assembly (2) from bracket.
2. Disconnect wiring connectors (3) (P01, 02), and

remove monitor panel assembly (2). 1
INSTALLATION OF MONITOR
PANEL ASSEMBLY
• Carry out installation in the reverse order to 3
removal.
1 2
• Check the mode setting and display function.
For details, see TESTING, ADJUSTING, AND
TROUBLESHOOTING.
CEP00437
PC1100-6 30-161
2
DISASSEMBLY AND ASSEMBLY PUMP CONTROLLER
REMOVAL OF PUMP
CONTROLLER ASSEMBLY
1
2
1. Slide operator’s seat fully forward.
2. Remove plate (1), then remove left cover (2).
3. Disconnect hose (3) and speaker wiring

connector (M13), then remove right cover (4).
fl Lift up the cover slightly before disconnecting
CEP00105
the speaker wiring connector.
4. Remove 5 connectors (5) (C01, 02, 03, 16, 17).
5. Remove pump controller assembly (6). 1
CEP00106
INSTALLATION OF PUMP
CONTROLLER ASSEMBLY 6

removal.
1
5
• Check the performance of the work equipment,
travel, and swing. For details, see TESTING AND
ADJUSTING. CEP00435
30-162 PC1100-6
2
DISASSEMBLY AND ASSEMBLY BOOM ROCK PREVENTION VALVE
REMOVAL OF BOOM ROCK

PREVENTION VALVE
ASSEMBLY
 Release the remaining pressure from the PPC
circuit.
1. Open door (1) at rear of cab.
2. Disconnect solenoid wiring connectors (2) (V9,

10).
3. Disconnect 4 hoses (3) and (4) between solenoid

valve and rock prevention valve.
fl Disconnect the hose between the rock
prevention valve and the right PPC valve
and the hose between the rock prevention
valve and the relay joint.
4. Remove mounting bolts, then remove rock

prevention valve assembly (5).
ROCK PREVENTION VALVE
ASSEMBLY
removal.
• Bleeding air.
Bleed the air fromx the PPC piping circuit.
Bleeding air.
PC1100-6 30-163
2
DISASSEMBLY AND ASSEMBLY ACCUMULATOR
REMOVAL OF ACCUMULATOR
ASSEMBLY
 Release the remaining pressure from the PPC
circuit.
1. Remove step (1).
2. Disconnect hose (2) coming from pilot relief

valve.
3. Remove mounting bolts, then remove

accumulator assembly (3).
INSTALLATION OF
ACCUMULATOR ASSEMBLY
removal.
• Bleeding air.
Bleed the air from the PPC piping circuit.
Bleeding air.
30-164 PC1100-6
2
DISASSEMBLY AND ASSEMBLY BOOM LOWER REGENERATION VALVE
REMOVAL OF BOOM LOWER

REGENERATION VALVE
ASSEMBLY
hydraulic tank.
 Release the remaining pressure from the
hydraulic circuit. For details, see TESTING AND
ADJUSTING, Releasing remaining pressure from
hydraulic circuit.
1. Disconnect tube (1) coming from boom control

block.
2. Disconnect hose (2) coming from front swing

machinery.
3. Disconnect hose (3) coming from control valve,

then remove mounting bolts, and remove boom
LOWER regeneration valve (4).
LOWER REGENERATION
VALVE ASSEMBLY
removal.
• Bleeding air.
Bleed the air from the boom LOWER regeneration
valve.
Bleeding air.
PC1100-6 30-165
2
40 MAINTENANCE STANDARD
Engine mount.. ............................................. 40- 2

PTO ............................................................... 40- 3
Swing circle ................................................. 40- 4
Swing machinery ........................................ 40- 6
Final drive .................................................... 40- 8
Track frame.. ................................................ 40-10
Idler.. ............................................................. 40-12
Carrier roller ................................................ 40-14
Track roller ................................................... 40-15
Track shoe ................................................... 40-16
Hydraulic pump.. ......................................... 40-20
Control, PTO lubricating,
aftercooler fan drive pump ................. 40-22
L.H. 5-spool control valve .......................... 40-24
R.H. 4spool control valve.. ........................ 40-26
Swing 4-spool control valve ...................... 40-28
Staight-travel valve ..................................... 40-31
Boon lower regeneration valve ................. 40-32
Swing motor.. .............................................. 40-33
Travel motor.. .............................................. 40-34
Center swivel joint ...................................... 40-36
PPC control relief valve .............................. 40-37
Work equipment l swing PPC valve.. ....... 40-38
Travel PPC valve ......................................... 40-39
Hydraulic cylinder
For backhoe.. .......................................... 40-40
For loading shovel ............................. 40-41-I
Work equipment
For backhoe ............................................ 40-42
For loading shovel ............................. 40-43-I
Dimensions of work equipment.. .............. 40-44
PC1 100-6 40- 1

0
MAINTENANCE STANDARD ENGINE MOUNT
ENGINE MOUNT
Unit: mm
No. Check item Criteria Remedy
Standard size Repair limit

Free height of front mount
1
rubber 141 —
Replace
Free height of rear mount
2 141 —
rubber
40-2 PC1100-6
MAINTENANCE STANDARD PTO
PTO
Unit: mm
Standard clearance Clearance limit

Backlash between drive
1 gear and driven shaft
(for HPV160+160) 0.07 – 0.18 —

2 gear and driven gear 0.273 – 0.374 —
(for SAR100+020+010) Adjust
Backlash between
3 drive gear and driven gear 0.2 – 0.74 —

4 gear and driven shaft 0.07 – 0.18 —
(for HPV95+95)
PC1100-6 40-3
MAINTENANCE STANDARD SWING CIRCLE
SWING CIRCLE
Unit: mm
Standard clearance Repair limit

Clearance of bearing in
1 axial direction (when Replace
mounted on machine) 0.5 – 2 4
40-4 PC1100-6
MAINTENANCE STANDARD SWING MACHINERY
SWING MACHINERY
40-6 PC1100-6
MAINTENANCE STANDARD SWING MACHINERY
Unit: mm

Backlash between swing
1 motor shaft and No. 1 sun
gear 0.19 – 0.29 —
Backlash between No. 1 sun

2 gear and No. 1 planet gear 0.19 – 0.56 0.90
Backlash between No. 1

3 planet gear and ring gear 0.24 – 0.70 0.90

4 planet gear and coupling 0.06 – 0.24 —

5 planet carrier and No. 2 0.40 – 0.71 1.10
sun gear Replace
6 gear and No. 2 planet gear 0.19 – 0.56 1.00

7 planet gear and ring gear 0.24 – 0.70 1.10
Backlash between coupling

8 and swing pinion 0.08 – 0.25 —
Backlash between swing

9 pinion and swing circle 0 – 1.13 2.00
Clearance between plate

10 and coupling 0.06 – 0.86 —

Repair hard
Wear of swing pinion oil chrome plating
11 seal contact surface 0
150 –0.100 — or replace
PC1100-6 40-7
MAINTENANCE STANDARD FINAL DRIVE
FINAL DRIVE
40-8 PC1100-6
MAINTENANCE STANDARD FINAL DRIVE
Unit: mm

1 planetary carrier and case 0.08 – 0.27 —
Backlash between drive gear

2 and No. 1 planetary carrier 0.21 – 0.57 —

3 sun gear and No. 1 0.24 – 0.71 —
planetary carrier
4 sun gear and No. 2 0.23 – 0.68 —
planet gear
5 planetary carrier and No. 2 0.28 – 0.87 —
ring gear
6 Backlash between coupling 0.38 – 0.72 — Replace

and drive gear

7 ring gear and case 0.08 – 0.26 —

8 sun gear and travel motor 0.07 – 0.18 —
coupling
9 gear and idler gear 0.15 – 0.53 —
Backlash between No.1

10 ring gear and idler gear 0.19 – 0.62 —
Backlash between driven

11 gear and No. 1 planet gear 0.19 – 0.62 —
12 Wear of sprocket tooth shape Repair limit: 6

Rebuild or
13 Sprocket tooth width replace
114 108
PC1100-6 40-9
MAINTENANCE STANDARD TRACK FRAME
TRACK FRAME
Unit: mm
Standard size Tolerance Repair limit

Rebuild or
Top-to-bottom width of Track frame 200 200±2 205 replace
1
idler guide
Idler support 195 195±1.2 185 Replace
Track frame 395 395±2 405 Rebuild or

Left-to-right width of idler replace
2 guide
+1.4
Idler support 391 391 –0.8 383

Replace
Free length Installation Installation Installation
Free length
3 Recoil spring x O.D. length load load
578.2 kN 460.9 kN
1,508 x 351 1,280 —
{58,957 kg} {47,000 kg}
40-10 PC1100-6
PC1100-6 40-11
MAINTENANCE STANDARD IOLER
IDLER
40-12 PC1100-6
MAINTENANCE STANDARD IDLER
Unit: mm

Outside diameter of
1
protruding part 962 —
Outside diameter of tread

2 920 908 Rebuild or
surface
replace
3 Depth of tread 21 —
4 Overall width 290 —
5 Width of tread 77 —
Tolerance
Standard Standard Clearance
Clearance between shaft size Shaft Hole clearance limit
6 and bushing
–0.080 +0.313 0.353 – Replace
125 –0.120 +0.273 0.433 1.5 bushing
Tolerance
Standard Standard Interference
Interference between idler size Shaft Hole interference limit
7 and bushing
135 +0.096 –0.098 0.140 – —
+0.042 –0.148 0.244
PC1100-6 40-13
MAINTENANCE STANDARD CARRIER ROLLER
CARRIER ROLLER
Unit: mm

1 Outside diameter of flange
220 —
2 Outside diameter of tread 205 185
4 Thickness of tread 67.6 —
5 Width of foange 17 — Replace
Tolerance
Standard Standard Interference
Interference between size Shaft Hole interference limit
6 bearing and roller
+0.039 0 0.020 –
125 +0.020 –0.015 0.040 —
Interference between +0.390 –0.059 0.020 –

7 bearing and shaft 70 +0.020 –0.015 0.054 —
Standard size Clearance limit

Play of roller in axial
8
direction 0 – 0.110 0.3
40-14 PC1100-6
MAINTENANCE STANDARD TRACK ROLLER
TRACK ROLLER
Unit: mm

1 Outside diameter of flange
320 —
Outside diameter of tread

2 surface 275 263
3 Thickness of tread 77.5 —

Rebuile or
replace
4 Overall width 370 —
5 Inside width 136 —
7 Width of flange 35 —
Standard Tolerance Standard Clearance

size Shaft Hole clearance limit
Clearance between shaft
8 and bushing
110 –0.120 +0.360 0.380 – 1.5
–0.207 +0.260 0.567 Replace
bushing
Standard Tolerance Standard Interference
size Shaft Hole interference limit
9 Interference between roller
and bushing
129 +0.087 +0.020 0.017 – —
+0.037 –0.015 0.102
PC1100-6 40-15
MAINTENANCE STANDARD TRACK SHOE
TRACK SHOE
fl P portion shows the link of bushing press fitting end.
40-16 PC1100-6
Unit: mm

1 Link pitch
280.3 283.3
When turned Reverse or

Standard size replace
Normal load Impact load
2 Bushing outside diameter
98.5 93.5 —
Repair or
3 Link height replace
181 168
Thickness of link metal

4 (bushing press-fitting portion) 56
5 256.6
Replace
6 Shoe bolt pitch 183
7 79.5
8 Inside width 135
9 Link Overall width 86.1 Repair or

replace
10 Tread width 75
11 Protrusion of pin 4.5
12 Protrusion of regular bushing 8.7
13 Overall length of pin 324.4

Adjust or
replace
14 Overall length of bushing 225.6
15 Thickness of bushing metal 18.8
16 Thickness of spacer 10.93
17 Bushing 215 – 304 kN {22 – 31 ton}

Press-fitting
18 force Regular pin 637 – 745 kN {65 – 76 ton} —
ª
19 Master 235 – 294 kN {24 – 30 ton}
ª : Dry type track link
PC1100-6 40-17
Unit: mm
Tightening torque Additional tightening

(Nm {kgm}) angle (deg.)
a. Regular link
1,372±137 {140±14} 150±10
Shoe bolt Retighten
Tightening torque Additional tightening Lower limit torque
20 (Nm {kgm}) angle (deg.) (Nm {kgm})
b. Master link
— — —
No. of shoes (each side) 48 —
Standard Tolerance Standard

size Shaft Hole interference
Interference between
21 bushing and link
98 +0.622 +0.087 0.435 – 0.622
+0.522 0
Interference between +0.426 –0.126
22 60 0.452 – 0.626
regular pin and link +0.326 –0.200
Clearance between size Shaft Hole clearance
23
regular pin and bushing
–0.174 +0.666 Adjust or
60.5 0.340 – 0.740 replace
–0.074 +0.166
ª size interference
Interference between Shaft Hole
24
master pin and link +0.228 –0.126
60 0.324 – 0.428
+0.198 –0.200
ª Clearance between size Shaft Hole clearance
25 master pin and bushing
60.5 –0.51 +0.666 0.676 – 1.276
–0.61 +0.166
ª : Dry type track link
40-18 PC1100-6
DOUBLE SHOE
Unit: mm

1 Height
50 25
2 Height 50 25
3 Thickness 25
Rebuild or
39 replace
4
Length at bottom
5 —
6 30
Length at top
7 30
PC1100-6 40-19
MAINTENANCE STANDARD HYDRAULIC PUMP
HYDRAULIC PUMP
HPV95 + 95 (No.1 main pump)
40-20 PC1100-6
MAINTENANCE STANDARD HYDRAULIC PUMP
PC1100-6 40-21
MAINTENANCE STANDARD CONTROL, PTO LUBRICATING, AFTERCOOLER FAN DRIVE PUMP
CONTROL, PTO LUBRICATING, AFTERCOOLER FAN DRIVE PUMP

SAR100+020+010
Unit: mm
Type Standard clearance Clearance limit
Clearance SAR100 0.10 – 0.15 0.19

1 between gear
case and side SAR020 0.10 – 0.15 0.19
plate
SAR010 0.10 – 0.15 0.19
SAR100 0.06 – 0.149 0.20

Clearance
Replace
between bearing
2 inner diameter SAR020 0.06 – 0.144 0.20
and gear shaft
outer diameter SAR010 0.06 – 0.144 0.20
Standard size Tolerance Repair limit

3 0
14 –0.5 —
Pin insertion depth
0
4 10 –0.5 —
Spline shaft rotating
5 torque 10.9 – 21.6 Nm {1.1 – 2.2 kgm}
Rotating speed Delivery pressure Standard delivery amount Delivery amount limit
(rpm) (MPa {kg/cm2}) (¬/min) (¬/min)
Delivery SAR100 2,500 2.9 {30} 15.1 138 —
Oil: EO10-CD
—
(Oil temp.:
45 – 50°C ) SAR020 2,500 6.9 {70} 18 16
SAR010 2,500 2.9 {30} 23 20
40-22 PC1100-6
1
MAINTENANCE STANDARD L.H. 5-SPOOL CONTROL VALVE
L.H. 5-SPOOL CONTROL VALVE
40-24 PC1100-6
MAINTENANCE STANDARD L.H. 5-SPOOL CONTROL VALVE
Unit: mm

Main relief valve, main Free length
1 valve spring x O.D. length load load
394.2 N 315.2 N
34.7 x 10.4 32.5 —
{40.2 kg} {32.2 kg}
Jet sensor relief valve, 30 N 24.3 N

2 34.5 x 10.8 29.4 —
pilot poppet spring {3.1 kg} {2.5 kg}
Jet sensor relief valve, 49 N 39.2 N Replace

3 37.4 x 11.4 33 — spring if
main valve spring {5.0 kg} {4.0 kg}
damaged or
431 N 345 N deformed
4 Spool return spring 69.9 x 57 63 —
{44 kg} {35.2 kg}
0N 0N
5 Spool return spring 75 x 37 74.5 —
{0 kg} {0 kg}
1N 0.78 N
6 Throttle valve spring 31.8 x 7.6 26.5 —
{0.1 kg} {0.08 kg}
18.8 N 15.1 N
7 Check valve spring 78.2 x 26.6 52 —
{1.92 kg} {1.54 kg}
PC1100-6 40-25
MAINTENANCE STANDARD R.H. 4-SPOOL CONTROL VALVE
R.H. 4-SPOOL CONTROL VALVE
40-26 PC1100-6
MAINTENANCE STANDARD R.H. 4-SPOOL CONTROL VALVE
Unit: mm

394.2 N 315.2 N
34.7 x 10.4 32.5 —
{40.2 kg} {32.2 kg}

2 34.5 x 10.8 29.4 —
Replace
3 37.4 x 11.4 33 — spring if
main valve spring {5.0 kg} {4.0 kg} damaged or
deformed
431 N 345 N
4 Spool return spring 69.9 x 57 63 —
{44 kg} {35.2 kg}
0N 0N
{0 kg} {0 kg}
18.8 N 15.1 N
{1.92 kg} {1.54 kg}
18.8 N 15.1 N
7 Check valve spring 53.6 x 31 39 —
{1.92 kg} {1.54 kg}
PC1100-6 40-27
MAINTENANCE STANDARD SWING 4-SPOOL CONTROL VALVE
SWING 4-SPOOL CONTROL VALVE

(1/2)
40-28 PC1100-6
(2/2)
PC1100-6 40-29
Unit: mm

394.2 N 315.2 N
34.7 x 10.4 32.5 —
{40.2 kg} {32.2 kg}

2 34.5 x 10.8 29.4 —

3 37.4 x 11.4 33 —
main valve spring {5.0 kg} {4.0 kg}
431 N 345 N Replace

4 Spool return spring 69.9 x 57 63 — spring if
{44 kg} {35.2 kg}
damaged or
0N 0N deformed
{0 kg} {0 kg}
1N 0.78 N
6 Throttle valve spring 31.8 x 7.6 26.5 —
{0.1 kg} {0.08 kg}
18.8 N 15.1 N
{1.92 kg} {1.54 kg}
18.8 N 15.1 N
8 Check valve spring 65.3 x 14 46 —
{1.92 kg} {1.54 kg}
18.8 N 15.1 N
9 Check valve spring 41.3 x 35.5 25.5 —
{1.92 kg} {1.54 kg}
40-30 PC1100-6
MAINTENANCE STANDARD STRAIGHT-TRAVEL VALVE
STRAIGHT-TRAVEL VALVE
Unit: mm

Free length
1 Spool return spring x O.D. length load load Replace
156.9 N spring if
117.5 x 27.9 68 — — damaged or
{16 kg} deformed
0.98 N
2 Throttle valve spring 31.8 x 7.6 26.5 — —
{0.1 kg}
PC1100-6 40-31
MAINTENANCE STANDARD BOOM LOWER REGENERATION VALVE
BOOM LOWER REGENERATION VALVE
Unit: mm

Free length
1 Spring (check valve) x O.D. length load load
29.4 N 23.5 N Replace
83.5 x 25.5 22 — spring if
{3 kg} {2.4 kg}
damaged or
206.4 N 165.1 N deformed
2 Spool return spring (large) 49.4 x 25.7 47 —
{21.1 kg} {16.9 kg}
58.5 N 46.8 N
3 Spool return spring (small) 41.1 x 9.6 35 —
{6 kg} {4.8 kg}
40-32 PC1100-6
MAINTENANCE STANDARD SWING MOTOR
SWING MOTOR
KMF160AB-2
Unit: mm

Free length Installation Installation Installation Replace
Free length spring if
1 Check valve spring x O.D. length load load
damaged or
66.5 x 25.6 45 —
{0.71 kg} {0.57 kg}
PC1100-6 40-33
MAINTENANCE STANDARD TRAVEL MOTOR
TRAVEL MOTOR
MSF-340VP
TRAVEL MOTOR, SPEED CHANGE VALVE, RELIEF VALVE
40-34 PC1100-6
MAINTENANCE STANDARD TRAVEL MOTOR
TRAVEL BRAKE VALVE
PC1100-6 40-35
MAINTENANCE STANDARD CENTER SWIVEL JOINT
CENTER SWIVEL JOINT
Unit: mm
Standard size Standard clearance Clearance limit

Clearance between rotor
1 and shaft Replace
110 0.056 – 0.105 0.111
40-36 PC1100-6
MAINTENANCE STANDARD PPC CONTROL RELIEF VALVE
PPC CONTROL RELIEF VALVE
Unit: mm

Free length
1 Check valve spring x O.D. length load load Replace
6.9 N 3.9 N
56 x 21.4 37 —
{0.7 kg} {0.4 kg}
PC1100-6 40-37
MAINTENANCE STANDARD WORK EQUIPMENT • SWING PPC VALVE
WORK EQUIPMENT • SWING PPC VALVE
Unit: mm

Free length
1 Centering spring x O.D. length load load
(for P3, P4)
17.6 N 13.7 N Replace
42.48 x 15.5 34 — spring if
{1.8 kg} {1.4 kg}
damaged or
2 Metering spring 26.7 x 8.14 24.9 —
{1.69 kg} {1.35 kg}
Centering spring 9.8 N 7.8 N

3 38.71 x 15.5 34 —
(for P1, P2) {1 kg} {0.8 kg}
40-38 PC1100-6
MAINTENANCE STANDARD TRAVEL PPC VALVE
TRAVEL PPC VALVE
Unit: mm

Free length
1 Metering spring x O.D. length load load Replace
16.7 N 13.7 N spring if
26.7 x 8.14 24.9 — damaged or
{1.7 kg} {1.4 kg} deformed
108 N 86.3 N
2 Centering spring 48.1 x 15.5 32.5 —
{11 kg} {8.8 kg}
PC1100-6 40-39
MAINTENANCE STANDARD HYDRAULIC CYLINDER
HYDRAULIC CYLINDER
For backhoe
Boom
m 1667*196Nm
(170*25koml
SUPOSI 51
Arm
Bucket
40-40 PCllOO-6
0
Unit: mm
Name of Standard Tolerance Standard Clearance

cylinder size Shaft Hole clearance limit
Boom 160 –0.043 +0.256 0.082 – 0.662

Clearance bet- –0.106 +0.039 0.362 Replace
1 ween piston rod bushing
and bushing –0.043 +0.255 0.081 –
Arm 170 –0.106 +0.038 0.361 0.661
Bucket 110 –0.036 +0.261 0.083 – 0.651

–0.090 +0.047 0.351
+0.025
Boom 140 — +0.370 — 1.0
Clearance bet-
ween piston rod Arm +0.025
2 160 — +0.370 — 1.0
support shaft
and bushing
Bucket 100 — +0.457 — 1.0
+0.370
Replace pin,
bushing
Boom 140 — +0.025 — 1.0
Clearance bet- +0.370
ween cylinder
3 bottom support Arm 160 — +0.245 — 1.0
shaft and +0.145
bushing
Bucket 100 — +0.475 — 1.0
+0.370
PC1100-6 40-41
1
MAINTENANCE STANDARD HYDRAULIC CYLINDER
For loading shovel
Boom: 170*25kPm s= Bohn:28+3h

Arm:91*14hm Arm: 6.8*0.7ksm
Backet: 130*20ksm Backet:l8*2kPm
Bottom dump:38*5.5kam Bottom dump:6.8*0.7kom
SWPO6319
Unit: mm
NCb.
T Check item
T Criteria Remedy
Name of
cylinder
Boom
Clearance
1 Replace
between piston Arm
bushing
rod and bushing
Bucket
Bottom
dump
Boom
Clearance Arm
between piston
2 rod support shaft
and bushing Bucket
Bottom
dump
- Replace pin,
bushing
Boom
Clearance Arm
between cylinder
3 bottom support
and bushing Bucket
Bottom
dump
40-41-l PCllOO-6
0
MAINTENANCE STANDARD WORK EQUIPMENT
WORK EQUIPMENT
For backhoe
A-A
D-D F-F
E-E
u
IU
G-G J-J
-4-J
40-42 PC1 100-6

0
Unit: mm
Tolerance
Clearance between bushing size Shaft Hole clearance limit
1 and mounting pin of boom
and revolving frame 160 –0.043 +0.436 0.393 – 1.5
–0.106 +0.350 0.542
Clearance between bushing –0.043 +0.172 0.128 –
2 and mounting pin of boom 160 –0.106 +0.085 0.278 1.5
and arm
3 and mounting pin of arm 140 –0.106 +0.321 0.510 1.5 Replace
and link
Clearance between bushing
4 and mounting pin of arm 140 –0.043 +0.397 0.355 – 1.5
and bucket –0.106 +0.312 0.503
5 and mounting pin of link 140 –0.106 +0.312 0.503 1.5
and link
6 and mounting pin of link 140 –0.043 +0.404 0.364 – 1.5
and bucket –0.106 +0.321 0.510
7 Bucket clearance 0.5 – 1.0 Adjust

shims
PC1100-6 40-43
For loading shovel
A-A 0-B
D-D E-E F-F G-G
II IO I3 12 I5 I4 16 I1
H-H J-J K-K
I8 20, /II
M-M N-N P-P SWPO6320
40-43-l PCllOO-6
0
Unit: mm
-
No Check item Criteria Remedy
-
Tolerance
Clearance between bushing size Shaft Hole clearance limit
1 and mounting pin of boom
and revolving frame -0.043 +0.436 0.393 -
160 +0.350 0.542 1.5
-0.106
Clearance between hole on

-0.043 +0.172 0.128 -
2 boss and mounting pin of 160 +0.085 0.278 1.5
boom and revolvino frame -0.106
Clearance between hole on boss

and mounting pin of boom -0.043 +O.lOO 0.043 -
3 140 0 0.206 1.5
cvlinder and revolvina frame -0.106

boss and mounting pin of -0.036 +O.lOO 0.036 -
4 115 0 0.190 1.5
boom and arm cvlinder -0.090
~-
-0.043 +O.lOO 0.043 -
6 boss and mounting pin of 140 0 0.206 1.5
-0.106
boom and boom cylinder
boss and mountina oin of -0.043 +O.lOO 0.043 -
6 130 0 0.206 1.5
boom and bucket :\jlinder -0.106
Clearance between boom

-0.043 +0.439 0.396 -
7 side bushing and mount- 160 io.353 0.545 1.5
ing pin of boom and arm -0.106
Clearance between arm

side bushing and mount- -0.043 +0.439 0.396 -
8 160 +0.353 0.545 1.5
ing pin of boom and arm -0.106

-0.036 +O.lOO 0.036 -
-0.090
arm cvlinder and arm
and mounting pin of -0.043 +0.396 0.353 -
10 130 +0.310 0.502 1.5
bucket cylinder and link -0.106
Clearance between hole on Replace

-0.043 +0.063 0.043 -
-0.106
bucket cylinder and link
and mounting pin of arm -0.043 +0.404 0.364 -
12 130 +0.321 0.510 1.5
and link -0.106

-0.043 +0.063 0.043 -
-0.106
arm and link
and mounting pin of link -0.043 +0.404 0.364 -
14 130 +0.321 0.510 1.5
and bucket -0.106

-0.043 +0.404 0.364 -
15 boss and mounting pin of 130 +0.321 0.510 1.5
-0.106
link and bucket
Clearance between arm
16 160 +0.353 0.545 1.5
ing pin of arm and bucket -0.106
Clearance between bucket

17 160 +0.353 0.545 1.5
ing pin of arm and bucket -0.106

18 90 0 0.190 1.5
bottom dump cylinder and -0.090
front bucket
19 90 0 0.190 1.5
bottom dump cylinder and -0.090
rear bucket
-0.036 +0.364 0.324 -
20 and mounting pin of front 115 +0.288 0.454 1.5
-0.090
bucket and rear bucket
boss and mountina oin of -0.036 +O.lOO 0.036 -
21 115 0 0.190 1.5
front bucket and re& ‘bucket -0.090
- i
PC1 100-6 40-43-Z

0
MAINTENANCE STANDARD DIMENSIONS OF WORK EQUIPMENT
DIMENSIONS OF WORK EQUIPMENT

1. ARM
40-44 PC1100-6
Unit: mm
Model
PC1100-6 PC1100SP-6 PC1100LC-6
with 3.4 m with 4.5 m with 3.4 m with 3.4 m with 4.5 m
No. heavy-duty arm heavy-duty arm heavy-duty arm arm arm
1 160 160 160 160 160
2 120 120 120 120 120
3 636 636 636 636 636
4 160 160 160 160 160
5 489 550 496 489 550
6 635 635 635 635 635
7 1,348 1,326 1,348 1,348 1,326
8 3,340 4,455 3,340 3,340 4,455
9 4,108 4,087 4,274 4,108 4,087
10 610 610 590 610 610
11 1,223 1,223 1,290 1,223 1,223
12 977 977 1,028 977 977
13 840 840 915 840 840
14 2,650 2,650 2,630 2,600 2,600
15 140 140 140 140 140
16 636 636 636 636 636
17 140 140 140 140 140

Arm as individual
part 637 637 637 637 637
18
When press-
fitting bushing 653 653 653 653 653
Min. 2,535 2,535 2,660 2,535 2,535

19
Max. 4,360 4,360 4,610 4,360 4,360
20 20 0 20 20 0
PC1100-6 40-45
2. BUCKET
40-46 PC1100-6
Unit: mm
Model
PC1100-6 PC1100SP-6 PC1100LC-6
No. 4.0 m3 bucket 5.0 m3 bucket 5.6 m3 bucket 4.0 m3 bucket 5.0 m3 bucket
1 837 837 911 837 837
2 76 76 82 76 76
3 95° 95° 95° 95° 95°
4 840 840 915 840 840
5 2,576 (2,618) 2,576 (2,618) 2,601 (2,638) 2,576 (2,618) 2,576 (2,618)
6 353 (403) 353 (403) 389 (443) 353 (403) 353 (403)
a φ 170 φ 170 φ 170 φ 170 φ 170

7
b φ 170 φ 170 φ 170 φ 170 φ 170
8 637.5 637.5 637.5 637.5 637.5
9 100 100 100 100 100
10 100 100 100 100 100
11 φ 280 φ 280 φ 280 φ 280 φ 280
12 φ 310 φ 310 φ 310 φ 310 φ 310
13 70.6 70.6 84.6 70.6 70.6
14 126.5 126.5 128 126.5 126.5
15 174 174 174 174 174
16 160 160 160 160 160
17 679.5 679.5 679.5 679.5 679.5
18 83 83 83 83 83
fl The figures in ( ) show the value for the long life tooth.
PC1100-6 40-47
90 OTHERS
Hydraulic circuit diagram

For backhoe .............................................................................................. 90-3
For loading shovel ............................................................................... 90-3-2
Electrical circuit diagram
For backhoe (l/4) .................................................................................. .90- 5
(2/4) .................................................................................. 90- 7
(3/4) .................................................................................. go- 9
(4/4) ................................................................................. .90-l 1
For loading shovel (l/4) ........................................................................ 90-13
(2/4). ....................................................................... 90-15
(3/4) ....................................................................... .90-17
(4/4) ........................................................................ 90-19
PC1 100-6 90-l

0
HYDRAULIC CIRCUIT DIAGRAM
PC1100-6
90-3
ELECTRICAL CIRCUIT DIAGRAM (1/4)
PC1100-6
90-5
PC1100-6
90-7
PC1100-6
90-9
PC1100-6
90-11

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Shop Manual Pc1100lc-6

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SEBM014206

PC1100-6 10001 and up

• PC1100-6 mount the SAA6D170-2 engine.

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

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

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

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

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

The affected pages are indicated by the use of the

‡ Page to be replaced Replace

( ) Page to be deleted Discard

Pages having no marks are those previously revised

LIST OF REVISED PAGE

Time of Time of Time of Time of Time of

o 00- 1 6 01- 1 10-13 10-43 10-74

Time of Time of Time of Time of Time of

10-105 10-151 20-10-6 4 20-121 1 20-214 3

Time of Time of Time of Time of Time of

20-301 3 20-380 3 20-421 3 20-489 3 20-570 3

Time of Time of Time of Time of Time of

20-626 3 30-18 2 30-58 2 30-98 2 30-103-35 5

Time of Time of Time of Time of Time of

30-127 2 30-150-1 4 40-25

IMPORTANT SAFETY NOTICE

GENERAL PRECAUTIONS 6. Decide a place in the repair workshop to

STRUCTURE AND FUNCTION

TESTING AND ADJUSTING

DISASSEMBLY AND ASSEMBLY

HOW TO READ THE SHOP MANUAL

Item number (10. Structure

Example 2 (Engine volume):

• If a part cannot be smoothly removed from

ﬂ The allowable load value is estimated to

2) Sling wire ropes from the middle portion

METHOD OF DISASSEMBLING, CONNECTING PUSH-PULL TYPE COUPLER

• Used to prevent rubber gaskets, rubber

• Features: Resistance to heat and chemi-

790–129–9060 Adhesive: • Used as adhesive or sealant for metal, glass

• Quick hardening type adhesive

• Quick hardening type adhesive

• Features: Resistance to heat, chemicals

• Used as adhesive or sealant for gaskets

• Used as sealant for various threads, pipe

• Features: Silicon based, quick hardening

Three bond • Used as heat-resisting sealant for repairing

• Used as lubricant for sliding portion (to pre-

SYG2-400LI • General purpose type

• Used for normal temperature, light load

Molybdenum 400 g • Used for places with heavy load

STANDARD TIGHTENING TORQUE

STANDARD TIGHTENING TORQUE TABLE (WHEN USING TORQUE WRENCH)

Thread diameter Width

Thread diameter Width

TABLE OF TIGHTENING TORQUES FOR FLARED NUTS

Thread diameter Width across flat Tightening torque

TABLE OF TIGHTENING TORQUES FOR SPLIT FLANGE BOLTS

Thread diameter Width across flat Tightening torque

TABLE OF TIGHTENING TORQUES FOR O-RING BOSS PIPING JOINTS

Thread diameter Width across flat Tightening torque

TABLE OF TIGHTENING TORQUES FOR O-RING BOSS PLUGS

Thread diameter Width across flat Tightening torque

TIGHTENING TORQUE FOR 102 ENGINE SERIIES (BOLT AND NUTS)

Thread diameter Tightening torque

TIGHTENING TORQUE FOR 102 ENGINE SERIIES (EYE JOINTS)