Shop Manual VEBM720100

PW148-8
MACHINE MODEL SERIAL NUMBER
PW148-8 H50051 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.

• PW148-8 mount the SAA4D107E-1 engine.

• For details of the engine, see the 107 Series Engine Shop Manual.

© 2010
All Rights Reserved
Printed in Europe 2010-06
PW140-7 VEBM410101
CONTENTS
No. of page

00 FOREWORD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00-1

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

10 STRUCTURE, FUNCTION AND MAINTENANCE

STANDARD. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-1

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

20 TESTING AND ADJUSTING. . . . . . . . . . . . . . . . . . . . . . 20-101

20 TESTING AND ADJUSTING

Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-221

20 TESTING AND ADJUSTING

Troubleshooting when failure code is indicated . . . . 20-301

20 TESTING AND ADJUSTING

Troubleshooting of electrical system (E-Mode) . . . . . 20-521

20 TESTING AND ADJUSTING

Troubleshooting of electrical system
(Error Checking of items without Monitor codes) . . . 20-601

20 TESTING AND ADJUSTING

Troubleshooting of hydraulic and mechanical system
(H-Mode) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-711

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

90 OTHER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-1

PW148-8 VEBM720100 TOC-1

 Blank for technical reason

TOC-2 PW148-8 VEBM720100

 00 FOREWORD
Safety
Important safety notice
Proper service and repair is extremely important for
the safe operation of your machine. The service and
repair techniques recommended and described in
this manual are both effective and safe methods of
operation. Some of these operations require the use
of tools specially designed for the purpose.
To prevent injury to workers, the symbol is used
to mark safety precautions in this manual. The cau-
tions accompanying these symbols should always be
followed carefully. If any dangerous situation arises
or may possibly arise, first consider safety, and take
the necessary actions to deal with the situation.
General precautions
Mistakes in operation are extremely dangerous.
Read the OPERATION & MAINTENANCE MANUAL
carefully BEFORE operating the machine.
1. Before carrying out any greasing or repairs, read
all the precautions given on the decals which are
fixed to the machine.
2. When carrying out any operation, always wear
safety shoes and helmet. Do not wear loose
work clothes, or clothes with buttons missing.
• Always wear safety glasses when hitting
parts with a hammer.
• Always wear safety glasses when grinding
parts with a grinder, etc.
3. If welding repairs are needed, always have a
trained, experienced welder carry out the work.
When carrying out welding work, always wear
welding gloves, apron, glasses, cap and other
clothes suited for welding work.
4. When carrying out any operation with two or
more workers, always agree on the operating
procedure before starting. Always inform your
fellow workers before starting any step of the op-
eration. Before starting work, hang UNDER RE-
PAIR signs on the controls in the operator's
compartment.
PW140-7 VEBM720100
5. Keep all tools in good condition and learn the
correct way to use them.
6. Decide a place in the repair workshop to keep
tools and removed parts. Always keep the tools
and parts in their correct places. Always keep the
work area clean and make sure that there is no
dirt or oil on the floor. Smoke only in the areas
provided for smoking. Never smoke while work-
ing.
Preparations for work
1. Before adding oil or making repairs, park the ma-
chine on hard, level ground, and block the
wheels or tracks to prevent the machine from
moving.
2. Before starting work, lower blade, ripper, bucket
or any other work equipment to the ground. If this
is not possible, insert the safety pin or use blocks
to prevent the work equipment from falling. In ad-
dition, be sure to lock all the control levers and
hang warning signs on them.
3. When disassembling or assembling, support the
machine with blocks, jacks or stands before
starting work.
4. Remove all mud and oil from the steps or other
places used to get on and off the machine. Al-
ways use the handrails, ladders or steps when
getting on or off the machine. Never jump on or
off the machine. If it is impossible to use the
handrails, ladders or steps, use a stand to pro-
vide safe footing.
00-1
Safety FOREWORD

Precautions during work
1. When removing the oil filler cap, drain plug or hy-
draulic pressure measuring plugs, loosen them
slowly to prevent the oil from spurting out. Before
disconnecting or removing components of the oil,
water or air circuits, first remove the pressure
completely from the circuit.
2. The water and oil in the circuits are hot when the
engine is stopped, so be careful not to get
burned. Wait for the oil and water to cool before
carrying out any work on the oil or water circuits.
3. Before starting work, remove the leads from the
battery. ALWAYS remove the lead from the nega-
tive (-) terminal first.
4. When raising heavy components, use a hoist or
crane. Check that the wire rope, chains and
hooks are free from damage. Always use lifting
equipment which has ample capacity. Install the
lifting equipment at the correct places. Use a
hoist or crane and operate slowly to prevent the
component from hitting any other part. Do not
work with any part still raised by the hoist or
crane.
10. When installing high pressure hoses, make sure
that they are not twisted. Damaged tubes are
dangerous, so be extremely careful when install-
ing tubes for high pressure circuits. Also check
that connecting parts are correctly installed.
11. When assembling or installing parts, always use
the specified tightening torques. When installing
protective parts such as guards, or parts which
vibrate violently or rotate at high speed, be par-
ticularly careful to check that they are installed
correctly.
12. When aligning two holes, never insert your fin-
gers or hand. Be careful not to get your fingers
caught in a hole.
13. When measuring hydraulic pressure, check that
the measuring tool is correctly assembled before
taking any measurements.
14. Take care when removing or installing the tracks
of track-type machines. When removing the
track, the track separates suddenly, so never let
anyone stand at either end of the track.

5. When removing covers which are under internal

pressure or under pressure from a spring, always
leave two bolts in position on opposite sides.
Slowly release the pressure, then slowly loosen
the bolts to remove.

6. When removing components, be careful not to

break or damage the wiring, Damaged wiring
may cause electrical fires.

7. When removing piping, stop the fuel or oil from

spilling out. If any fuel or oil drips on to the floor,
wipe it up immediately. Fuel or oil on the floor
can cause you to slip, or can even start fires.

8. As a general rule, do not use gasoline to wash

parts. In particular, use only the minimum of
gasoline when washing electrical parts.

9. Be sure to assemble all parts again in their origi-

nal places. Replace any damaged part with new
parts.

• When installing hoses and wires, be sure

that they will not be damaged by contact with
other parts when the machine is being oper-
ated.

00-2 PW140-7 VEBM720100

FOREWORD General

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

This shop manual mainly contains the necessary technical infor-

mation for operations performed in a service workshop. For
ease of understanding, the manual is divided into the following
sections. These sections are further divided into each main
group of components.

General
This section lists the general machine dimensions, performance
specifications, component weights, and fuel, coolant and lubri-
cant specification charts.

Structure and function

This section explains the structure and function of each compo-
nent. It serves not only to give an understanding of the structure,
but also serves as reference material for troubleshooting.

Testing, adjusting and troubleshooting

This section explains checks to be made before and after per-
forming repairs, as well as adjustments to be made at comple-
tion of the checks and repairs. Troubleshooting charts
correlating “Problems” to “Causes” are also included in this sec-
tion.

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 dis-
assembled parts.

NOTE
The specifications contained in this shop manual are subject to
change at any time and without any advance notice. Contact your
distributor for the latest information.

PW148-8 VEBM720100 00-3

How to read the shop manual FOREWORD

How to read the shop manual

Volumes Revised edition mark
Shop manuals are issued as a guide to carrying out When a manual is revised, an edition mark (c d
repairs. They are divided as follows: e…) is recorded on the bottom of the pages.
• Chassis volume:
Issued for every machine model Revisions
• Engine volume: Revised pages are shown at the LIST OF REVISED
Issued for each engine series PAGES between the title page and SAFETY page.
• Electrical volume:
Each issued as one to cover all models
Symbols
• Attachment volume:
Each issued as one to cover all models So that the shop manual can be of ample practical
use, important safety and quality portions are marked
These various volumes are designed to avoid dupli- with the following symbols:
cation of information. Therefore to deal with all re-
pairs for any model, it is necessary that chassis, Symbol Item Remarks
engine, electrical and attachment be available.


Special safety precautions are
Safety necessary when performing the
work.
Distribution and updating


Special technical precautions or
Any additions, amendments or other changes will be other precautions for preserving
sent to your distributors. Get the most up-to-date in- Caution
standards are necessary when
formation before you start any work. performing the work.

Weight of parts or systems. Cau-

4 tion necessary when selecting
Weight
Filing method hoisting wire or when working
posture is important, etc.
1. See the page number on the bottom of the page. Places that require special atten-
Tightening
File the pages in correct order. 3 torque
tion for tightening torque during
assembly.
2. Following examples show how to read the page
number. Places to be coated with adhe-
2 Coat
sives and lubricants etc.
Example 1 (Chassis volume):

10 - 3 Places where oil, water or fuel

5 Oil, water
must be added, and the capacity.
Item number
(10. Structure and Function)
Places where oil or water must be
6 Drain drained, and quantity to be
Consecutive page number for drained.
each item

3. Additional pages: Additional pages are indicated

by a point (.) and number after the page number.
File as in the example.

Example:
10-4
10-4.1
Added Pages
10-4.2
10-5

00-4 PW148-8 VEBM720100

FOREWORD Hoisting instructions

Hoisting instructions
Hoisting

Heavy parts (25kg or more) must be lift-

ed with a hoist, etc. In the DISASSEM-
BLY AND ASSEMBLY section, every
part weigthing 25 kg or more is indicat- 4 100% 88% 79% 71% 41%
ed clearly with the symbol: SAD00479

5. Do not sling a heavy load with one rope alone,

If a part cannot be smoothly removed from the ma- but sling with two or more ropes symmetrically
chine by hoisting, the following checks should be wound on to the load
made:

1. Check for removal of all bolts fastening the part

to the relative parts. Slinging with one rope may cause turning of the
load during hoisting, untwisting of the rope, or
2. Check for existence of another part causing in- slipping of the rope from its original winding po-
terface with the part to be removed. sition on the load, which can result in a danger-
ous accident
Wire Ropes
3. Use adequate ropes depending on the weight of 6. Do not sling a heavy load with ropes forming a
parts to be hoisted, referring to the table below: wide hanging angle from the hook. When hoist-
ing a load with two or more ropes, the force sub-
Wire ropes jected to each rope will increase with the hanging
(Standard “Z” or “S” twist ropes without galvanizing) angles. The table below shows the variation of
Rope diameter Allowable load allowable load (kg) when hoisting is made with
mm kN tons two ropes, each of which is allowed to sling up to
10 9.8 1.0 1000 kg vertically, at various hanging angles.
When two ropes sling a load vertically, up to
11.2 13.7 1.4
2000 kg of total weight can be suspended. This
12.5 15.7 1.6
weight becomes 1000 kg when two ropes make
14 21.6 2.2 a 120° hanging angle. On the other hand, two
16 27.5 2.8 ropes are subject to an excessive force as large
18 35.3 3.6 as 4000 kg if they sling a 2000 kg load at a lifting
20 43.1 4.4 angle of 150°.
22.4 54.9 5.6
30 98.1 10.0
40 176.5 18.0
50 274.6 28.0
60 392.2 40.0

The allowable load value is estimated to be 1/6

or 1/7 of the breaking strength of the rope used.

4. Sling wire ropes from the middle portion of the

hook. Slinging near the edge of the hook may
cause the rope to slip off the hook during hoist-
ing, and a serious accident can result. Hooks
have maximum strength at the middle portion

PW148-8 VEBM720100 00-5

Coating materials FOREWORD

Coating materials
The recommended coating materials prescribed in the shop
manuals are listed below.

Category Code Part No. Quantity Container Main applications, features

• Used to prevent rubber gaskets, rubber cush-

LT-1A 790-129-9030 150 g Tube
ions and cork plugs from coming out

• Used in places requiring an immediately effec-

tive, strong adhesive.
20 g Polyethylene
LT-1B 790-129-9050 • Used for plastics (except polyethylene, polypro-
(2 pes.) container
pylene, tetrafluoroethylene, and vinyl chloride),
rubber, metal and non-metal.

• Features: Resistance to heat, chemicals

Polyethylene
LT-2 09940-00030 50 g • Used for anti-loosening and sealant purposes
container
for bolts and plugs.

Adhesive:
790-129-9060
1 kg
(Set of adhesive • Used as adhesive or sealant for metal, glass or
LT-3 Hardening Can
and hardening plastic.
agent:
agent)
500 g
Adhesives

Polyethylene
LT-4 790-129-9040 250 g • Used as sealant for machined holes.
container

Holtz • Used as heat-resisting sealant for repairing en-

790-126-9120 75 g Tube
MH 705 gine.

• Quick hardening type adhesive.

Three
Polyethylene • Cure time: within 5 sec. to 3 min.
bond 179-129-9140 50 g
container • Used mainly for adhesion of metals, rubbers,
1735
plastics and woods.

• Quick hardening type adhesive.

Aron- • Quick cure type (max. strength after 30 min-
Polyethylene
alpha 790-129-9130 2g utes).
container
201 • Used mainly for adhesion of rubbers, plastics
and metals.

• Features: Resistance to heat, chemicals

Loctite Polyethylene
79A-129-9110 50 cc • Used at joint portions subject to high tempera-
648-50 container
ture.

• Used as adhesive or sealant for gaskets and

LG-1 790-129-9010 200 g Tube
packing of power train case, etc.

• Features: Resistance to heat

sealant
Gasket

• Used as sealant for flange surfaces and bolts at

high temperature locations; used to prevent sei-
LG-3 790-129-9070 1 kg Can zure.
• Used as sealant for heat resistant gasket for at
high temperature locations such as engine pre-
combustion chamber, exhaust pipe.

00-6 PW148-8 VEBM720100

FOREWORD Coating materials

Category Code Part No. Quantity Container Main applications, features

• Features: Resistance to water, oil

• Used as sealant for flange surface, thread.
• Also possible to use as sealant for flanges with
LG-4 790-129-9020 200 g Tube
large clearance.
• Used as sealant for mating surfaces of final
drive case, transmission case.

• Used as sealant for various threads, pipe joints,

Polyethylene flanges.
LG-5 790-129-9080 1 kg
container • Used as sealant for tapered plugs, elbows, nip-
sealant
Gasket

ples of hydraulic piping.

• Features: Silicon based, resistant to heat, cold.

LG-6 09940-00011 250 g Tube • Used as sealant for flange surface, thread.
• Used as sealant for oil pan, final drive case, etc.

• Features: Silicon based, quick hardening type.

LG-7 09920-00150 150 g Tube • Used as sealant for flywheel housing, intake
manifold, oil pan, thermostat housing, etc.

Three
• Used as heat-resisting sealant for repairing en-
bond 790-129-9090 100 g Tube
gines.
1211

• Used as lubricant for sliding parts (to prevent

Molybdenum

LM-G 09940-00051 60 g Can

disulphide

squeaking).
lubricant

• Used to prevent seizure or scuffing of the thread

LM-P 09940-00040 200 g Tube when press fitting or shrink fitting.
• Used as lubricant for linkage, bearings, etc.

SYG2-400LI
SYG2-350LI
G2-LI SYG2-400LI-A Various Various • General purpose type
SYG2-160LI
SYGA160CNLI

SYG2-400CA
SYG2-350CA
• Used for normal temperature, light load bearing
G2-CA SYG2-400CA-A Various Various
Grease

at places in contact with water or steam.

SYG2-160CA
SYG2-160CNCA
disulphide lubricant
Molybdenum

400 g
SYG2-400M Belows type • Used for places with heavy load.
(10 per case)

PW148-8 VEBM720100 00-7

Standard tightening torque FOREWORD

Standard tightening torque

Standard tightening torque of bolts and

nuts
The following charts give the standard tightening torques of bolts
and nuts. Exceptions are given in DISASSEMBLY AND ASSEM-
BLY.

Thread diameter of bolt Width across flats

mm mm Nm kgm

6 10 13.2 ± 1.4 1.35 ± 0.15

8 13 31.4 ± 2.9 3.20 ± 0.3

10 17 65.7 ± 6.8 6.70 ± 0.7

12 19 112 ± 9.8 11.5 ± 1.0

14 22 177 ± 19 18 ± 2.0

16 24 279 ± 29 28.5 ± 3

18 27 383 ± 39 39 ± 4

20 30 549 ± 58 56 ± 6

22 32 745 ± 78 76 ± 8

24 36 927 ± 98 94.5 ± 10

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 3280 ± 340 335 ± 35

Thread diameter of bolt Width 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

00-8 PW148-8 VEBM720100

FOREWORD Standard tightening torque

Tightening torque of hose nuts

Use these torques for hose nuts.

Thread diameter Width across flat Tightening torque

Nominal No.
mm mm Nm kgm
02 14 19 24.5 ± 4.9 2.5 ± 0.5
03 18 24 49 ± 19.6 5±2
04 22 27 78.5 ± 19.6 8±2
05 24 32 137.3 ± 29.4 14 ± 3
06 30 36 176.5 ± 29.4 18 ± 3
10 33 41 196.1 ± 49 20 ± 5
12 36 46 245.2 ± 49 25 ± 5
14 42 55 294.2 ± 49 30 ± 5

Tightening torque of split flange bolts

Use these torques for split flange bolts.

Thread diameter Width across flat Tightening 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

Tightening torques for hoses (taper seal

type and face seal type)
• Unless there are special instructions, tighten the hoses (ta-
per the hoses (taper seal type and face seal type) to the
torque below.

• Apply the following torque when the threads are coated

(wet) with engine oil.

Tightening torque Nm {kgm} Taper seal Face seal

Nominal Nominal No. -
Width Thread
No. of Number of
across flat Range Target Thread size (mm) diameter (mm)
hose threads, type of
(Referenced)
thread
34 - 54 {3.5 - 5.5} - 9/16 - 18UN 14.3
02 19 44 {4.5}
34 - 63 {3.5 - 6.5} 14 - -
22 54 - 93 {5.5 - 9.5} 74 {7.5} - 11/16 - 16UN 17.5
03
24 59 - 98 {6.0 - 10.0} 78 {8.0} 18 - -
04 27 84 - 132 {8.5 - 13.5} 103 {10.5} 22 13/16 - 16UN 20.6
05 32 128 - 186 {13.0 - 19.0} 157 {16.0} 24 1 - 14UNS 25.4
06 36 177 - 245 {18.0 - 25.0} 216 {22.0} 30 1 - 3/16 - 12UN 30.2
(10) 41 177 - 245 {18.0 - 25.0} 216 {22.0} 33 - -
(12) 46 197 - 294 {20.0 - 30.0} 245 {25.0} 36 - -
(14) 55 246 - 343 {25.0 - 35.0} 294 {30.0} 42 - -

PW148-8 VEBM720100 00-9

Standard tightening torque FOREWORD

Tightening torque for 107 engine series

(bolts and nuts)
• Unless there are special instructions, tighten the metric bolts
and nuts of the 107 engine series to the torque below.

Thread diameter Tightening torque

mm Nm kgm Nm kgm

6 10 ± 2 1.02 ± 0.20 8±2 0.81 ± 0.20

8 24 ± 4 2.45 ± 0.41 10 ± 2 1.02 ± 0.20

10 43 ± 6 4.38 ± 0.61 12 ± 2 1.22 ± 0.20

12 77 ± 12 7.85 ± 1.22 24 ± 2 2.45 ± 0.41

14 - - 36 ± 5 3.67 ± 0.51

Tightening torque for 107 engine series

(eye joints)
Use these torque values for eye joints (unit: mm).

Thread diameter Tightening torque

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 107 engine series

(tapered screws)
Use these torque values for tapered screws (unit: inch).

Thread diameter Tightening torque

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

00-10 PW148-8 VEBM720100

FOREWORD Electric wire code

Electric wire code

In the wiring diagrams, various colors and symbols are em-
ployed to indicate the thickness of wires. This wire code table
will help you understand WIRING DIAGRAMS.

EXAMPLE:
05WB indicates a cable having a nominal number 05 and white
coating with black stripe.

Classification by thickness
Copper wire
Nominal Cable O.D. Current
Number of Dia. Of Cross sec- Applicable circuit
number (mm) rating (A)
strands strand (mm) tion (mm)

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

Prior- Circuits
Charging Ground Starting Lighting Instrument Signal Other
ity Classification

Code W B B R Y G L
Primary

1
Color White Black Black Red Yellow Green Blue

Code WR — BW RW YR GW LW
2 White & Black & Red & Yellow & Green & Blue &
Color —
Red White White Red White White

Code WB — BY RB YB GR LR
3 White & Black & Yel- Yellow & Green &
Color — Red & Black Blue & Red
Black low Black Red

Code WL — BR RY YG GY LY
Auxiliary

4 White & Red & Yel- Yellow & Green & Blue & Yel-
Color — Black & Red
Blue low Green Yellow low

Code WG — — RG YL GB LB
5 White & Red & Yellow & Green & Blue &
Color — —
Green Green Blue Black Black

Code — — — RL YW GL —
6 Yellow & Green &
Color — — — Red & Blue —
White Blue

PW148-8 VEBM720100 00-11

Conversion tables FOREWORD

Conversion tables

Method of using the conversion table

The Conversion Table in this section is provided to enable sim-
ple 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 mil-

limeters to inches.

1. Convert 55 mm into inches.

a. Locate the number 50 in the vertical column at the left

side, take this as (1), then draw a horizontal line from
(1).

b. Locate the number 5 in the row across the top, take this
as (2), then draw a perpendicular line down from (2).

★ Take the point where the two lines cross as (3). This
point (3) gives the value when converting from millime-
ters to inches. Therefore, 55 millimeters = 2.165 inches.

2. Convert 550 mm into inches.

a. The number 550 does not appear in the table, so divide

by 10 (move the decimal one place to the left) to convert
it to 55 mm.

b. Carry out the same procedure as above to convert 55

mm to 2.165 inches.

c. The original value (550 mm) was divided by 10, so multi-

ply 2.165 inches by 10 (move the decimal one place to
the right) to return to the original value. This gives 550
mm = 21.65 inches.

(2)
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
(3)
50 1.969 2.008 2.047 2.087 2.126 2.165 2.205 2.244 2.283 2.323
(1)
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

00-12 PW148-8 VEBM720100

FOREWORD Conversion tables

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

PW148-8 VEBM720100 00-13

Conversion tables FOREWORD

Litre to U.S. Gallon 1 L = 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

Litre to U.K. Gallon 1 L = 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 7.699 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

00-14 PW148-8 VEBM720100

FOREWORD Conversion tables

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 1352.63 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

PW148-8 VEBM720100 00-15

Conversion tables FOREWORD

kg/cm2 to lb/in2 1 kg/cm2 = 14.2233lb/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 19324 1949 1963 1977
140 1991 2005 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

00-16 PW148-8 VEBM720100

FOREWORD Conversion tables

Temperature
Fahrenheit Centigrade Conversion; a simple way to convert a
Fahrenheit temperature reading into a Centigrade temperature
reading or vise 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, con-
sider the center column as a table of Fahrenheit temperatures
and read the corresponding Centigrade temperature in the col-
umn at the left. If it is desired to convert from Centigrade to Fahr-
enheit degrees, consider the center column as a table of
Centigrade values, and read the corresponding Fahrenheit tem-
perature on the right.

°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

PW148-8 VEBM720100 00-17

Units FOREWORD

Units
In this manual, the measuring units are indicated with Interna-
tional 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}

00-18 PW148-8 VEBM720100

 01 GENERAL
Specification dimension drawings . . . . . . . . 01-2
Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01-2
Working ranges . . . . . . . . . . . . . . . . . . . . . . . . 01-4
Working range: 1 piece boom . . . . . . . . . . . . . . 01-4
Working range: 2 piece boom . . . . . . . . . . . . . . 01-5
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . 01-7
Weight table. . . . . . . . . . . . . . . . . . . . . . . . . . . 01-9
1 piece boom. . . . . . . . . . . . . . . . . . . . . . . . . . 01-10
2 piece boom. . . . . . . . . . . . . . . . . . . . . . . . . . .01-11
Fuel, coolant and lubricants . . . . . . . . . . . . 01-12

PW148-8 VEBM720100 01-1

Specification dimension drawings GENERAL

Specification dimension drawings

Dimensions

A
C
E

B
D

A
I C
E

B
H
D
L
J
F K
G

Description PW148-8

One-piece boom Two-piece boom

A Overall length (Driving position)
B Overall height (Driving position)
See next page
C Overall length (Transport position)
D Overall height (Transport position)
E Radius of upper structure 1,850 mm
F Front and rear track 1,914 mm
G Overall width 2,550 mm
H Overall height of cabin 3,173 mm
I Overall width of upper structure 2,490 mm
J Ground clearance 341 mm
K Wheel base 2,500 mm
L Height bottom edge counterweight 1,242 mm

01-2 PW148-8 VEBM720100

GENERAL Specification dimension drawings

One-piece boom Two-piece boom

Arm Drive position Transport position Drive position Transport position
A (mm) B (mm) C (mm) D (mm) A (mm) B (mm) C (mm) D (mm)
2.1m 7,116 3,677 7,369 2,846 5,545 3,907 7,690 3,155
2.5m 7,120 3,677 7,374 2,944 5,545 3,907 7,690 3,155
3.0m 7,160 3,677 7,392 3,221 5,545 3,901 7,690 3,155

PW148-8 VEBM720100 01-3

Working ranges GENERAL

Working ranges

Working range: 1 piece boom

Arm length mm 2100 2500 3000

A Max. digging height 7,980 8,270 8,703

B Max. dumping height 5,731 6,020 6,447

C Max. digging depth 4,462 4,860 5,362

D’ Max. digging reach GL 7,740 8,140 8,640

D Max. digging reach 7,907 8,320 8,807

A

D’

01-4 PW148-8 VEBM720100

GENERAL Working ranges

Working range: 2 piece boom

Arm length mm 2100 2500 3000

A Max. digging height 9,228 9,518 9,951

B Max. dumping height 6,844 7,133 7,562

C Max. digging depth 5,091 5,489 5,991

D’ Max. digging reach GL 8,100 8,500 9,000

D Max. digging reach 8,268 8,671 9,168

A

E’

PW148-8 VEBM720100 01-5

Working ranges GENERAL

Blank for technical reason

01-6 PW148-8 VEBM720100

GENERAL Specifications

Specifications
Machine model PW148-8

Serial Number H50051 and up

Bucket capacity m³ 0.55m³

Operating weight kg 14,390*

2.1
Max. digging force
2.5 kN {kg} 93.0 {9,483}
(using power max. function)
3.0

Swing speed rpm 11.0

Performance

Swing max. slope angle deg. 17.0

Cr: 2.5
Travel speed km/h Lo: 8.5Hi: 35
(Germany:20)

deg. 35
Gradeability
kPa {kg cm²} 36.3 {0.37}

Standard Tyre Width mm 10.00 - 20

* Weight will vary depending on specification

PW148-8 VEBM720100 01-7

Specifications GENERAL

Machine model PW148-8

Serial Number H50051 and up

Model SAA4D107E-1
Type 4-cycle, water-cooled, in-line, vertical, direct injection,
with turbo charger
No. of cylinders - bore x stroke mm 4 - 107 x 124
Piston displacement l {cc} 4.5 {4500}

Flywheel horsepower kW/rpm 79.6/2200

Performance
Engine

Max. torque Nm/rpm 464/1500

Max. speed at no load rpm 2,320
Min. speed at no load rpm 1,050

Starting motor 24V, 4.5 kW

Alternator 24V, 60 A
Battery 12V, 120 Ah x 2

Radiator core type Triple Cooler

Hydraulic

Type x No. HPV95 (112), variable displacement

pump

Delivery l/min 274 x 1

Set pressure MPa (kg/cm²) Piston type: 37.2 {380}

1 Piece Boom 7-spool + 1 service spool type x 1 Hydraulic

Control
valve

Type x No.
Control method 2 Piece Boom 8-spool + 1 service spool type x 1 Hydraulic

Travel motor A6VM100 HAXT/63W-VZB380A-SK, Piston type

Hydraulic
motor

(with counter balance valve): x 1

Swing motor MSF85P, Piston type
(with safety valve, holding brake): x 1

Type Boom Arm Bucket

Double acting Double acting Double acting

1 Piece Boom

piston piston piston

Hydraulic system

105 115 95
Inside diameter of cylinder mm
Diameter of piston rod mm 70 75 65
902 1,159 885
Stroke mm
2,390 2,861 2,263
Hydraulic cylinder

Max. distance between pins mm

Min. distance between pins mm 1,488 1,702 1,378

Type Adjust Boom Arm Bucket

Double L.H R.H

Double acting Double acting
acting Double acting piston piston
2 Pice Boom

piston piston

140 105 115 95

Inside diameter of cylinder mm
75 70 75 65
Diameter of piston rod mm
555 902 1,159 885
Stroke mm
1,680 2,402 2,861 2,263
Max. distance between pins mm
1,125 1,500 1,702 1,378
Min. distance between pins mm

Hydraulic tank Closed box type

Hydraulic filter Tank return side

Hydraulic cooler CF40-1 (Air cooled)

01-8 PW148-8 VEBM720100

GENERAL Weight table

Weight table

This weight table is for use when handling components or

when transporting the machine.

Unit: kg

Machine model PW148-8

Serial Number H50051 and up

Engine assembly 478

• Engine 390
• Damper 1.5
• Hydraulic pump 86.5

Radiator oil cooler assembly 105

Hydraulic tank, filter assembly (excluding hydraulic oil) 145

Fuel tank (excluding fuel) 120

Revolving frame 1,190

Operator’s cab 290

Mechanical 38
Operator’s seat
Air Suspension 42

Counterweight 2,580

Swing machinery 100

Control valve 160

Travel motor 75

Center swivel joint 95

PW148-8 VEBM720100 01-9

Weight table GENERAL

1 piece boom
Unit: kg

Machine model PW148-8

Serial Number H50051 and up

Boom assembly 798

2.1 m 284
Arm assembly
2.5 m 317
(with no piping)
3.0 m 437

Bucket assembly 900

Boom cylinders 115.9 x 2

S/V 138.4
Arm cylinder
S/V less 136.4

Bucket cylinder 94

Boom foot pin 21.3

Boom cylinder pins 7.4 x 2 and 19.55

Arm cylinder pins 6.1 and 6.5

Boom/Arm pivot pin 12

Bucket linkage and pins 120.15

01-10 PW148-8 VEBM720100

GENERAL Weight table

2 piece boom
Unit: kg

Machine model PW148-8

Serial Number H50051 and up

1st Boom 400

Boom assembly
2nd Boom 475

2.1 m 284

Arm assembly 2.5 m 317

3.0 m 437

Bucket assembly 900

Boom cylinders 118 x 2

Adjust cylinder 123.7

S/V 138.4
Arm cylinder
S/V less 136.4

Bucket cylinder 94

Boom foot pin 21.3

Boom cylinder pins 7.4 x 2 and 19.55

Adjust cylinder pins 10.15 and 13

Arm cylinder pins 6.1 and 6.5

Boom/Arm pivot pin 12

Bucket Linkage and pins 120.15

PW148-8 VEBM720100 01-11

Fuel, coolant and lubricants GENERAL

Fuel, coolant and lubricants

Ambient temperature CAPACITY
Reservoir Kind of fluid Type of oil
Min. Max Specified Refill

-30° C 30° C Komatsu EOS0W30

-25° C 40° C Komatsu EOS5W40

Engine oil
Engine oil pan -20° C 40° C Komatsu EO10W30DH 19.1 litre 17.1 litre

-15° C 50° C Komatsu EO15W40DH

0° C 40° C Komatsu EO30DH

Swing machinery case Engine oil -20° C 40° C SAE 30 2.5 litre 2.5 litre

Bio-oil -20° C 30° C Panolin HLP synth 46

Hydr-oil -20° C 50° C Komatsu H046-HM

Hydraulic system -25° C 40° C Komatsu EOS5W40 164 litre 123 litre

Engine oil -20° C 40° C Komatsu EO10W30DH

-15° C 40° C Komatsu EO15W40DH

-10° C 40° C ASTM D975 No. 2

Fuel tank Diesel fuel -30° C -10° C ASTM D975 No 1 275 litre 275 litre
(for winter use)

Cooling system Supercoolant -30° C 50° C AF-NAC 16 litre 16 litre

Front Fuchs Titan UTTO 10.5 litre 10.5 litre

Axles
Rear ZF 20W-40 9.5 litre 9.5 litre
-30° C 40° C BP Tractran 8 20W-30
Transmission + clutch Multi oil BP Terrac Super 4.85 litre 4.85 litre
Transmission S

Front Fuchs Titan UTTO 2.5 litre 2.5 litre

Hubs -20° C 40° C
Rear ZF 20W-40 2.0 litre 2.0 litre

Remark
• We recommend Komatsu genuine oil which has been spe-
cifically formulated and approved for use in engine and hy-
draulic work equipment applications.

• Only use high quality oils which meet internationally recog-

nized specifications.

01-12 PW148-8 VEBM720100

 10 STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD
Engine related parts . . . . . . . . . . . . . . . . . . . . . . . . . 10-2
Radiator, oil cooler, aftercooler and fuel cooler . . 10-3
Power train . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-4
Swing circle. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-6
Swing machinery & motor . . . . . . . . . . . . . . . . . . . . 10-7
Operation of swing lock . . . . . . . . . . . . . . . . . . . . . . . 10-9
Relief valve portion . . . . . . . . . . . . . . . . . . . . . . . . . . 10-10
Undercarriage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-12
Transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-14
Quick coupler control valve. . . . . . . . . . . . . . . . . . 10-17
ATT EPC valve assembly . . . . . . . . . . . . . . . . . . . . 10-19
Travel motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-20
Operation of travel motor . . . . . . . . . . . . . . . . . . . . . 10-22
Clutch control circuit . . . . . . . . . . . . . . . . . . . . . . . 10-24
Axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-26
Suspension lock cylinder . . . . . . . . . . . . . . . . . . . 10-30
Braking system . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-32
Brake/steer pump . . . . . . . . . . . . . . . . . . . . . . . . . . 10-34
Priority valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-35
Power brake valve . . . . . . . . . . . . . . . . . . . . . . . . . 10-36
Accumulator for brake valve . . . . . . . . . . . . . . . . . 10-38
Steering system . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-39
Steering column . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-40
Orbitrol valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-41
Hydraulic equipment layout drawings . . . . . . . . . 10-42
Hydraulic circuit diagram. . . . . . . . . . . . . . . . . . . . 10-44
Hydraulic tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-45
Hydraulic pump. . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-47
LS valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-52
PC valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-53
LS(PC)-EPC valve . . . . . . . . . . . . . . . . . . . . . . . . . . 10-67
Pilot pressure control (PPC) system . . . . . . . . . . 10-70
Control valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-72
CLSS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-83
Outline of CLSS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-83
Basic Principle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-84
Operation for each function and valve . . . . . . . . . . . 10-86
1. Unload valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-88
2. Introduction of LS pressure. . . . . . . . . . . . . . . . . . 10-91
3. LS bypass plug . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-92
4. Pressure compensation valve. . . . . . . . . . . . . . . . 10-94
5. Area ratio of pressure compensation valve . . . . . 10-96
6. Boom regeneration circuit. . . . . . . . . . . . . . . . . . . 10-98
7. Arm regeneration circuit . . . . . . . . . . . . . . . . . . . 10-100
8. Swing bleeding valve . . . . . . . . . . . . . . . . . . . . . 10-102
9. Variable type pressure compensation valve
(for service). . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-103
10.LS select valve. . . . . . . . . . . . . . . . . . . . . . . . . . 10-104
Centre swivel joint . . . . . . . . . . . . . . . . . . . . . . . . 10-105
Travel PPC pedal . . . . . . . . . . . . . . . . . . . . . . . . . 10-106
Work equipment – Swing PPC valve. . . . . . . . . . 10-108
Solenoid valve block . . . . . . . . . . . . . . . . . . . . . . 10-112
ON / OFF Solenoid valves (3 way valve) . . . . . . . . 10-114
Attachment PPC valve . . . . . . . . . . . . . . . . . . . . . . 10-120
PW148-8 VEBM720100
Boom safety valve . . . . . . . . . . . . . . . . . . . . . . . . . 10-124
Hydraulic cylinder . . . . . . . . . . . . . . . . . . . . . . . . . 10-126
Boom cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-126
Arm cylinder. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-126
Bucket cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-126
Adjust cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-127
Outrigger cylinder . . . . . . . . . . . . . . . . . . . . . . . . . 10-128
Dozer cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-130
Work equipment. . . . . . . . . . . . . . . . . . . . . . . . . . . 10-132
Work equipment. . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-133
1.Dimension of arm . . . . . . . . . . . . . . . . . . . . . . . . . 10-134
2.Dimension of bucket . . . . . . . . . . . . . . . . . . . . . . . 10-136
Air conditioner . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-138
Air conditioner piping . . . . . . . . . . . . . . . . . . . . . . . . 10-138
Electrical wiring diagramm . . . . . . . . . . . . . . . . . . 10-139
Electrical system . . . . . . . . . . . . . . . . . . . . . . . . . . 10-140
Engine control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-140
Electrical control system . . . . . . . . . . . . . . . . . . . 10-147
Machine control system diagram . . . . . . . . . . . . . . . 10-148
Machine monitor system. . . . . . . . . . . . . . . . . . . . 10-170
Monitor panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-171
Monitor control, display portion . . . . . . . . . . . . . . . . 10-174
Monitor gauge displays . . . . . . . . . . . . . . . . . . . . . . 10-178
Keypad layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-183
Overload warning device . . . . . . . . . . . . . . . . . . . 10-186
Outline . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-186
Sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-187
Coolant temperature sensor . . . . . . . . . . . . . . . . . . 10-188
Oil pressure switch . . . . . . . . . . . . . . . . . . . . . . . . . 10-188
Rotation sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-189
Boost pressure and temperature sensor . . . . . . . . . 10-189
WIF (Water-In-Fuel detection) sensor . . . . . . . . . . . 10-190
Engine oil level sensor. . . . . . . . . . . . . . . . . . . . . . . 10-190
Coolant level sensor . . . . . . . . . . . . . . . . . . . . . . . . 10-191
Coolant temperature sensor . . . . . . . . . . . . . . . . . . 10-192
Fuel level sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-192
Air cleaner clogging sensor . . . . . . . . . . . . . . . . . . . 10-193
Overload Caution sensor . . . . . . . . . . . . . . . . . . . . . 10-193
Swing proximity sensor . . . . . . . . . . . . . . . . . . . . . . 10-194
Travel PPC sensor. . . . . . . . . . . . . . . . . . . . . . . . . . 10-194
PPC pressure sensor. . . . . . . . . . . . . . . . . . . . . . . . 10-194
Park brake pressure sensor. . . . . . . . . . . . . . . . . . . 10-195
1st attachment circuit hydraulic performance
(main valve bypassed) . . . . . . . . . . . . . . . . . . . . . 10-196
Travel system. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-197
Travel circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-197
Operational and control features . . . . . . . . . . . . . . . 10-212
Steering system . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-217
Operating principles. . . . . . . . . . . . . . . . . . . . . . . . . 10-217
Service brake and suspension system . . . . . . . . 10-230
Braking system . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-230
KOMTRAX terminal system . . . . . . . . . . . . . . . . . 10-235
10-1
Engine related parts STRUCTURE AND FUNCTION, MAINTENANCE STANDARD

Engine related parts

8 7 6 3 5 4

1. Oil fill cap 5. Oil catcher tube

2. Muffler 6. Brake/Steer pump
3. Rear engine mount 7. Front engine mount
4. Breather hose 8. Fan

Outline
• The damper assembly is a dry type.

10-2 PW148-8 VEBM720100

STRUCTURE AND FUNCTION, MAINTENANCE STANDARD Radiator, oil cooler, aftercooler and fuel cooler

Radiator, oil cooler, aftercooler and fuel cooler

1 2 3 4 5

1. Radiator Cap
2. Shroud
3. After Cooler
4. Radiator
5. Oil Cooler
6. Condenser assy
7. Fuel Coler

PW148-8 VEBM720100 10-3

Power train STRUCTURE AND FUNCTION, MAINTENANCE STANDARD

Power train

7 6 3

5
18

4
14

10 8 9

13 2 7

11 1

12

15 16 17

10-4 PW148-8 VEBM720100

STRUCTURE AND FUNCTION, MAINTENANCE STANDARD Power train

1. Centre swivel joint

2. Hydraulic tank
3. Main pump
4. Engine
5. Gear pump
6. PPC solenoid valve inc.
Clutch control sol
Travel direction sol
7. Main control valve
8. Priority valve
9. Clutch control accumulator
10. Accumulators
11. Power brake valve
12. Swing circle
13. Swing motor / machinery
14. Rear axle
15. Propshaft
16. Travel motor
17. Transmission
18. Front axle

PW148-8 VEBM720100 10-5

Swing circle STRUCTURE AND FUNCTION, MAINTENANCE STANDARD

Swing circle

245 - 308.9Nm
(25 - 31kgm)

245 - 308.9Nm
(25 - 31kgm)

1 Swing circle inner race (No. of teeth: 99)

2 Ball
3 Swing circle outer race
a Inner race soft zone S position
b Outer race soft zone S position

Amount of grease: 6.5 litres

No Check item Criteria Remedy

Axial clearance of bearing Standard clearance Clearance limit

4 Replace
(when mounted on chassis) 0.5-1.6 3.2

Specifications
99
Reduction ratio: = 8.182
11

10-6 PW148-8 VEBM720100

STRUCTURE AND FUNCTION, MAINTENANCE STANDARD Swing machinery & motor

Swing machinery & motor

1. Swing machinery
2. Swing motor
3. Swing pinion
4. Dipstick

PW148-8 VEBM720100 10-7

Swing machinery & motor STRUCTURE AND FUNCTION, MAINTENANCE STANDARD

1. Swing pinion (No. of teeth: 11)

2. Case
3. No. 2 sun gear (No. of teeth: 17)
4. No. 2 planetary carrier (No. of teeth 17)
5. Ring gear (No of teeth: 61)
6. No. 1 planetary carrier (No of teeth: 14)
7. No. 1 sun gear (No. of teeth: 14)
8. Oil level gauge / oil filler port
9. Swing motor
10. No. 1 planetary gear (No. of teeth: 24)
11. No. 2 planetary gear (No. of teeth: 22)
12. Drain plug
13. Swing circle

Specification
14 + 61 17 + 61
Reduction ratio: X = 24.58
14 17

10-8 PW148-8 VEBM720100

STRUCTURE AND FUNCTION, MAINTENANCE STANDARD Swing machinery & motor

Operation of swing lock

1. When swing lock solenoid valve is deactivated
When the swing lock solenoid valve is deactivated, the pres-
surized oil from the gear pump is shut off and port B is con-
nected to the tank circuit.
Gear pump
As a result, brake piston (7) is pushed down by brake spring
(1), discs (5) and plates (6) are pushed together, and the
brake is applied.

AA

2. When swing lock solenoid valve is excited

When the swing lock solenoid valve is excited, the valve is
switched and the pressure oil from the gear pump enters
port B and flows to brake chamber a.
Gear pump
The pressure oil entering chamber a overcomes brake
spring (1) and pushes brake piston (7) up. As a result, discs
(5) and plates (6) are separated and the brake is released.

AA

PW148-8 VEBM720100 10-9

Swing machinery & motor STRUCTURE AND FUNCTION, MAINTENANCE STANDARD

Relief valve portion

1. Outline
The relief portion consists of check valves (2) and (3), shut-
tle valves (4) and (5), and relief valve (1).

2. Function
When the swing is stopped, the outlet port circuit of the mo-
tor from the control valve is closed, but the motor continues
to rotate under inertia, so the pressure at the output side of
the motor becomes abnormally high, and this may damage
the motor.

To prevent this, the abnormally high pressure oil is relieved

to port S from the outlet port of the motor (high-pressure
side) to prevent any damage.

Operation

1. When starting swing.

When the swing control lever is operated to swing right, the
pressure oil from the pump passes through the control valve
and is supplied to port MA. As a result, the pressure at port
MA rises, the starting torque is generated in the motor, and
the motor starts to rotate. The oil from the outlet port of the
motor passes from port MA through the control valve and re-
turns to the tank. (Fig. 1)

2. When stopping swing.

When the swing control lever is returned to neutral, the sup-
ply of pressure oil from the pump to port MA is stopped. With
the oil from the outlet port of the motor, the return circuit to
the tank is closed by the control valve, so the pressure at
port MB rises. As a result, rotation resistance is generated in
the motor, so the braking effect starts.

If the pressure at port MB becomes higher than the pressure

at port MA, it pushes shuttle valve A (4) and chamber C be-
comes the same pressure as port MB. The oil pressure rises
further until it reaches the set pressure of relief valve (1). As
a result, a high braking torque acts on the motor and stops
the motor. (Fig.2)

When relief valve (1) is being actuated, the relief oil and oil
from port S passes through check valve B (3) and is sup-
plied to port MA. This prevents cavitation at port MA.

10-10 PW148-8 VEBM720100

STRUCTURE AND FUNCTION, MAINTENANCE STANDARD Swing machinery & motor

Blank for technical reason

PW148-8 VEBM720100 10-11

Undercarriage STRUCTURE AND FUNCTION, MAINTENANCE STANDARD

Undercarriage

14

13 3

12

11 9

10-12 PW148-8 VEBM720100

STRUCTURE AND FUNCTION, MAINTENANCE STANDARD Undercarriage

6
8

4
5

10

1. Undercarriage
2. Step
3. Wheel Chock
4. Front Oscillating Steering Axle
5. Rear Axle
6. Propshaft
7. Travel motor
8. Transmission
9. Double Wheel Assy
10. Steering Cylinder
11. Suspension Lock Cylinders
12. Swivel Joint
13. Slew Ring
14 Axle Oscillation pin

PW148-8 VEBM720100 10-13

Transmission STRUCTURE AND FUNCTION, MAINTENANCE STANDARD

Transmission

Q 4

Engaged
3
P

Disengaged

1. Transmission disengagement pin (for towing)

2. Oil filler plug
3. Oil drain plug
4. Breather

Specifications
Type Single motor two speed automatic power shift

Small clutch (High gear) 1.32: 1

Gear ratio
Large clutch (Low gear) 4.93: 1

Pressure required to disengage clutches (Large & Small) 58 +/- 7 bar.

Output shaft DIN 120 (8stud) fixing.

Oil capacity 4.85 litres.

Oil change interval 1000 hours

10-14 PW148-8 VEBM720100

STRUCTURE AND FUNCTION, MAINTENANCE STANDARD Transmission

Function
Pressure applied in port P will disengage the small clutch, low
speed will be selected. Pressure applied in port Q will disengage
the large clutch, high speed will be selected. No pressure in port
P and Q will engage both small and large clutches. When both
clutches are engaged this locks the input shaft of the transmis-
sion to the housing locking the transmission, this is used for the
park brake condition.

Steering pump

Park brake switch Park brake solenoid valve

Controller Transmission clutch solenoid valve

Swivel joint

P Q

Power shift Transmission

Travel motor

Small clutch

Large clutch

Hi = sun + planets locked together, planetary drive = (1.32: 1)

Lo = sun drives planets annulus is held, planet carrier is the out-

put = (4.93: 1)

PW148-8 VEBM720100 10-15

Transmission STRUCTURE AND FUNCTION, MAINTENANCE STANDARD

9
8

10 7

5
13

4
14

11

12
3

1. Sleeve
2. Small clutch pack (high gear)
3. Large clutch pack (low gear)
4. Ball Bearing
5. Bearing
6. Epicyclic Gearbox
7. Spur Gear
8. Roller Bearing
9. Spur Gear
10. Coupling
11. Bearing
12. Flange
13. Pin
14. Casing

10-16 PW148-8 VEBM720100

STRUCTURE AND FUNCTION, MAINTENANCE STANDARD Quick coupler control valve

Quick coupler control valve

Port T
Port A

2b

Port P
Port B

2a

1. Pressure switch S30

2a. Pressure reducing valve at port P
2b. Pressure reducing valve at port B
3. Lock solenoid valve V16

Specification
Standard pressure setting: 40 bar
Adjustable pressure range: 10-360 bar
Max. operation pressure: 380 bar

Operation
The quick coupler valve is directly connected to the
pump pressure port on the control valve.

If the solenoid valve is de-energized, pump pressure

is applied to port (B) to keep the quick coupler cylin-
der in the locked position.

The pressure switch (S30) is connected to the pump

controller to activate the buzzer in case the lock cyl-
inder pressure is below 25 bar.

Lock and un-lock pressures can be adjusted individu-

ally, now.

PW148-8 VEBM720100 10-17

Quick coupler control valve STRUCTURE AND FUNCTION, MAINTENANCE STANDARD

Shematic

P T

T1
2a

40 bar

V16

40 bar

2b

B2

A B B1

P From control valve pump pressure port

T To tank
T1 Blind plugged
A To quick coupler cylinder – unlock direction
B To quick coupler cylinder – lock and hold direction
B1 Blind plugged
B2 To pressure switch S30 (Open at 25 bar)

10-18 PW148-8 VEBM720100

STRUCTURE AND FUNCTION, MAINTENANCE STANDARD ATT EPC valve assembly

ATT EPC valve assembly

11 11
8 16 4 6 10 7 17 9 5

12 14 1 15 13
2 3

1. Valve Manifold
2. Port "P"
3. Port "T"
4. 1 Att EPC Valve
5. 1 Att EPC Valve
6. To Main Valve Port PA8
7. To Main Valve Port PB8
8. 1 Att EPC Valve Connector V24
9. 1 Att EPC Valve Connector V23
10. Blanking Plug
11. Mounting Bolts
12. 2 Att EPC Valve
13. 2 Att EPC Valve
14. To Main Valve Port PA9
15. To Main Valve Port PB9
16. 2 Att EPC Valve Connector V26
17. 2 Att EPC Valve Connector V25

PW148-8 VEBM720100 10-19

Travel motor STRUCTURE AND FUNCTION, MAINTENANCE STANDARD

Travel motor
A6VM100 HAXT/63W-VAB380A-SK

A Service port
B Service port
G1 Port for synchronous control of a number of units and for remote control pressure
X Pilot pressure port
T1 Case drain port
T2 Case drain port
U Flushing port
S Boosting
MA:MB Gauge ports (one either side)
Gext Brake release port - external
M1 Gauge port control pressure

Specifications

Type 100cc unit

Min displacement setting 35cc/rev
Brake relief valve setting 420 bar
Counterbalance valve pressure setting 7 bar

10-20 PW148-8 VEBM720100

STRUCTURE AND FUNCTION, MAINTENANCE STANDARD Travel motor

Function
The travel motor is a device for driving the transmission by con-
verting the hydraulic power into mechanical torque.
Oil is delivered via the main valve to ports A/B and this flow ro-
tates a rotary group which is connected to the motor output
splines which are positioned to the transmission input.

Travel Motor

3 1

1. Counterbalance valve
2. Motor
3. Relief valve

PW148-8 VEBM720100 10-21

Travel motor STRUCTURE AND FUNCTION, MAINTENANCE STANDARD

Operation of travel motor

1. During normal travel

1 2
5 4 6

1. Travel motor
2. Transmission and clutch
3. Drive shafts
4. Main control valve
5. Main pump
6. Swivel joint

• Oil is supplied to the travel motor from the control valve by

the travel spool. When the spool is opened the machine ac- 100
Max Angle
Displacement

celerates from the stationary the pressure at the travel motor

rises to maximum. This high pressure is used to set the dis-
(cc/rev)

placement of the travel motor to maximum to give maximum

torque.

• As the machine speed increases, so pressure required to 35

move the machine will reduce. This reducing pressure is Min Angle
used to reduce the displacement of the travel motor to allow
275 305 380
increasing speed. The travel motor changes from maximum Pressure (kg/cm²)
displacement to preset minimum. Displacement changes
according to the diagram.

10-22 PW148-8 VEBM720100

STRUCTURE AND FUNCTION, MAINTENANCE STANDARD Travel motor

2. Control speed downhill

At high speed when the machine is travelling downhill, ma-
chine speed must be limited to prevent overspeed of travel
motor, transmission and axles. In the downhill condition the
machine weight is driving the machine and pressure at the
travel motor inlet becomes low. This low pressure is used to
close the counterbalance valve.

This allows the counterbalance valve springs to centralise

the spool. The travel motor will rotate because it is driven
from the wheels and so oil in the travel motor is circulated at
high pressure through the brake valves. This oil circulated at
high pressure through the brake valves slows the machine
speed down.

3 4

2 1

1. Counterbalance valve
2. Relief valve
3. Swivel joint
4. Main control valve

PW148-8 VEBM720100 10-23

Clutch control circuit STRUCTURE AND FUNCTION, MAINTENANCE STANDARD

Clutch control circuit

Gear pump
on Engine

Park brake switch Park brake solenoid valve

Controller Transmission clutch solenoid valve

Swivel joint

P Q

Power shift Transmission

Travel motor

Small clutch

Large clutch

10-24 PW148-8 VEBM720100

STRUCTURE AND FUNCTION, MAINTENANCE STANDARD Clutch control circuit

Function
The clutches maintain the drive between the travel motor and
the transmission low or high sped. The low and high gear are
combined within the same clutch pack and gear selection is pro-
vided by the Hi/Lo speed transmission clutch solenoid.

A clutch is disengaged by applying pressure to that particular

clutch piston and the system does not allow pressure to be ap-
plied to both clutch pistons at the same time.

1. Pressure applied to transmission port ’P’ dis-engages the

high speed clutch pack meaning the low speed clutch pack
is engaged - low speed has been selected.

2. Pressure applied to transmission port ’Q’ dis-engages the

low speed clutch pack meaning the high speed clutch pack
is engaged - high speed has been selected.

3. When there is no pressure applied to port ’Q’ and port ’P’,

both low speed and high speed clutches are engaged mean-
ing the parking brake has been applied.

PW148-8 VEBM720100 10-25

Axle STRUCTURE AND FUNCTION, MAINTENANCE STANDARD

Axle

Outline
• Each axle consists of an axle housing supporting the chas-
sis weight, a differential set in the axle housing, a final drive,
and a brake provided at each end.

• A trunnion-type axle shaft with a king pin at the final drive

end is used to enable the direction of the machine to be
changed.

Front Axle

5 5

2 1 2
4

6 3 7 6

1. Steer cylinder 3. Axle housing 5. Brake line input 7. Oil level plug
2. Track control arms 4. Drive shaft input 6. Wheel hub

Front Axle Oil Capacity

PW148: 11.5 Litres

Front Hub Oil Capacity

PW148: 2.5 Litres

10-26 PW148-8 VEBM720100

STRUCTURE AND FUNCTION, MAINTENANCE STANDARD Axle

2 3 4 5 7 6 27, 28 29
10 11 24 23 25 26
1

13
12 30
14 38
15 37 35
21 22 16 36
17
34
20 19 18 33 32

31

1. Planetary holder 20. Screw

2. O-ring 21. Axle body long steering
3. Seal ring 22. Air valve
4. Screw 23. Screw
5. Pin 24. Shim ring
6. Disk/Washer 25. O-ring
7. Bushing 26. Roller bearing
8. Lip seal 27. Protection cap
9. Bushing 28. Nipple
10. Pressure pad 29. Bevel gear
11. Axle body short steering 30. Shim ring
12. O-ring 31. Planetary holder
13. Disk/Washer 32. Flange
14. Bushing 33. Lip seal
15. Seal ring 34. Roller bearing
16. Ring 35. Shim ring
17. Parallel pin 36. Bushing
18. Pin 37. Shim ring
19. Security dowel 38. Roller bearing

PW148-8 VEBM720100 10-27

Axle STRUCTURE AND FUNCTION, MAINTENANCE STANDARD

Rear axle

3 3

4 1 4
2

1. Axle housing
2. Drive shaft input
3. Brake line input
4. Wheel hub
5 Oil level plug

Rear Axle Oil Capacity

PW148 Axle: 9.5 Litres

Rear Hub Oil Capacity

PW148: 2 Litres

10-28 PW148-8 VEBM720100

STRUCTURE AND FUNCTION, MAINTENANCE STANDARD Axle

13 15 17 19 34 23
1 2 3 4 5 12 14 16 18 20 21 22 24

33

32 31 29 27 25
30 28 26

11 10 9 8 7 6

1. Screw 18. Hub

2. O-ring 19. O-ring
3. Roller Bearing 20. Plug
4. Beval Gear 21. Circlip
5. Roller Bearing 22. Hollow Wheel
6. Nut 23. Gear Pinion
7. Flange 24. Planetary Holder
8. Lip Seal 25. Screw Plug
9. Roller Bearing 26. Screw
10. Bushing 27. Disk/Washer
11. Roller Bearing 28. Brake
12. Shaft 29. Bushing
13. Adjusting Ring 30. Cylinder Head Screw
14. Tube Fitting 31. Circlip
15. Roller Bearing 32. Gasket
16. Sleeve 33. Seal Ring
17. Roller Bearing 34. Brake Disc

• When the service brake is applied, braking is carried out in

pairs to diagonally opposite wheels, the braking is after the
final gear reduction giving improved axle lock.

PW148-8 VEBM720100 10-29

Suspension lock cylinder STRUCTURE AND FUNCTION, MAINTENANCE STANDARD

Suspension lock cylinder

1. Wiper
2. Plunger
3. Cylinder housing
4. Check valve cartridge

Specifications
Piston Diameter 85mm

Stroke 170mm

Operating pressure 40 MPa (408 kg/cm2)

Pilot Pressure Min. 3.0 MPa (30.6 kg/cm2)

Pilot Pressure Max. 5.0 MPa (51 kg/cm2)

Structure and function

Plunger cylinder with inbuilt check valve.
The check valve is designed as a leak free ball seat valve which
is released by a control spool.

The control conduit is connected to both axle lock cylinders, the

pilot pressure piloting the check valve in the cylinder head is al-
so preloading the cylinders during pendulum motion therefore
only one conduit to the cylinders is necessary.

10-30 PW148-8 VEBM720100

STRUCTURE AND FUNCTION, MAINTENANCE STANDARD Suspension lock cylinder

Circuit

Purpose
The undercarriage of wheeled hydraulic excavators has one of
the two driven axles oscillating mounted. This makes it possible
to fully utilize the excavators rimpull in rough terrain - all of the
wheels being constantly in contract with the ground. A suspen-
sion cylinder is fitted on each side of the undercarriage to block
the axle during digging or lifting work.
Blocking the axle increases the excavators stability.
The oscillating axle (3) is mounted on axle mount pin (2) in the
middle of the excavator. The two cylinders (1) which are full of
hydraulic oil are connected through pipelines to the suspension
lock solenoid valve (4).
When the excavator is being moved on the jobsite, the suspen-
sion lock solenoid valve should be engernised so that the hy-
draulic oil in the cylinder can be returned to tank as the axle is
oscillating up and down. Before commencing excavating opera-
tions, the oscillation lock solenoid valve should be de-energised
to pressurise the oil in the cylinders. This will lock the axle in the
position it is in.

6
5 7

8
9
1

1. Cylinder 4. Oscillation lock solenoid valve 7. Swivel joint

2. Axle mount pin 5. PPC pressure reducing valve 8. PPC operated check valve
3. Oscillating axle 6. Hydraulic tank 9. Accumulator

Axle oscillation
Axle oscillation: 7°
Minimum turning radius PW148: 6.8m.

PW148-8 VEBM720100 10-31

Braking system STRUCTURE AND FUNCTION, MAINTENANCE STANDARD

Braking system

7 6 5

LS SIGNAL FEED TO
FROM STEER
STEER VALVE SYSTEM
13
1
R R2 R1
F
2 4

8
E
3 N
10
T´1
LS
EF CF
T1 9
))((

)(
P

B T´2

T2

FEED TO
PILOT
SYSTEM
R3

TO BACK PRESSURE
VALVE OM MAIN CV

X1 X
FEED FROM N
PILOT
SYSTEM

12 14

15 15

17

16
15 15

10-32 PW148-8 VEBM720100

STRUCTURE AND FUNCTION, MAINTENANCE STANDARD Braking system

1. Hydraulic oil filter

2. Gear pump
3. Priority valve
4. Brake control valve
5. Accumulator - service brake (0.75 l.)
6. Accumulator - service brake (0.75 l.)
7. Accumulator - parking brake (0.75 l.)
8. Pressure switch - stop light (5 ±0.5 bar)
9. Pressure switch (suspension lock) - (40 ± 5 bar)
10. Pressure switch - accumulator (70 ± 8 bar)
11. Hi / Lo solenoid valve
12. Pressure switch (parking brake) - (40 ± 1 bar) < less than activates
13. Brake pedal
14. Swivel joint
15. Service brake cylinder
16. Small (high speed) clutch
17. Large (low speed) clutch

Structure and function

The brake system is fully hydraulic. Hydraulic oil is supplied at
high pressure by gear pump to a priority valve giving priority to
the steering circuit first and secondly to the braking circuit when
the steering is not being used in the steering circuit. When brak-
ing oil is sent to the brake valve which provides braking pressure
to two separate braking circuits (service brakes). In the event of
failure of the power supply, the accumulators provide brake
pressure to allow the machine to be safely stopped.

A parking brake is provided which is operated by selecting park

brake switch in cab. This de-energises both high and low gear
signals and locks the transmission gears.

If there is no pressure the parking brake will activate.

PW148-8 VEBM720100 10-33

Brake/steer pump STRUCTURE AND FUNCTION, MAINTENANCE STANDARD

Brake/steer pump

5 3 4

1 2

1. Delivery port (outlet)

2. Suction port (inlet)
3. Washer
4. Nut
5. Pump assembly

Specifications
Type Gear pump

Rated speed 2500 RPM

Displacement 19cc/REV

Rated pressure 250 bar

Max. input shaft torque 250Nm

Rotation Anti-clockwise*
5
* Rotation direction when viewed on shaft.
5

Function
The brake/steer pumps function is to produce the necessary oil
flow/pressure to operate the brake, steering and pilot pressure
control circuits.

The pump is directly driven off the engine ancillary Power Take
Off (P.T.O.)

10-34 PW148-8 VEBM720100

STRUCTURE AND FUNCTION, MAINTENANCE STANDARD Priority valve

Priority valve

LS

EF CF

P Pressure port (from pump)

EF Output port to brake system
CF Output port to steering system
LS Load sensing port from steering valve

Specification
Priority valve control spring pressure: 7 bar

Function
When the steering wheel is turned, the oil flow is distributed in
such a way that the oil flow necessary for steering is led to the
steering unit through the CF connection.
The remaining oil flow is available for use of the brake valve,
through the EF connection.
The distribution is controlled by the LS signal from the steering
unit; so that the oil flow to the steering unit is always determined
by the actual steering rate.
Steering takes priority

PW148-8 VEBM720100 10-35

Power brake valve STRUCTURE AND FUNCTION, MAINTENANCE STANDARD

Power brake valve

A T1’T2’
1
X

3 View A 1
2
5
6 7

R2 N X1
8
R1 F R3

9 R
P B
4

T1
N’ T2

1. Brake system support pedal F Accumulator pressure switch P Feed from priority valve
with hook
R Accumulator B Return
2. Brake module (charging valve stabiliser) N Tank
3. Accumulator charging valve R1 Accumulator (service brake) N’ Tank (plugged)
4. 3 ways complete solenoid valve R2 Accumulator (service brake) R3 Plugged
5. Pedal rubber T1’ Service brake pressure switch (Accumulator on italian
machine)
6. Latch pedal T2’ Service brake pressure switch
7. Latch pedal fixing screw T2 Service brake
8. Latch pin T1 Service brake
9. Latch pin stirrup X Parking brake
X1 Parking brake pressure switch

10-36 PW148-8 VEBM720100

STRUCTURE AND FUNCTION, MAINTENANCE STANDARD Power brake valve

Specifications
(cut in) = 120 +/- 5 bar
Accumulator charge pressure
(cut out) = 155 +0/-2 bar

Service brake pressure 63 bar

Park brake pressure 58 +/- 7 bar

Function
The main function of the power brake valve is to gradually re-
duce the machines travelling speed when the pedal is slowly de-
pressed. The higher the force applied to depress the pedal, the
greater the deceleration of the machine, until the machine is
eventually in a stationary position.

An alternative function of the power brake valve is the digging

brake application, if the machine is to be used for digging, the
power brake valve should be fully depressed until the pedal is
locked and the latching hook is secured on its location pin. This
will prevent the machine from "Travelling" when it is being used
for digging.

PW148-8 VEBM720100 10-37

Accumulator for brake valve STRUCTURE AND FUNCTION, MAINTENANCE STANDARD

Accumulator for brake valve

Specifications
1. Nominal capacity 0.75L
2. Max. working pressure 210 bar
3. Max. p dynamic 175 bar
4. Working temperature - 30° to 125°C
5. Diaphragm NBR
6. Fluid Mineral oil
7. Body Forged steel
8. Surface finish Rust preventative coating
9. Pre-charge gas Nitrogen
10. Pre-charge pressure 50 bar

Structure ans function

• The accumulators are installed below the operators cab ac-
cessible from the under covers.

• Installed into the brake circuit the accumulators provide

pressure to the brakes in the event of a power failure ensur-
ing the machine is stopped safely.

NOTE
Accumulator A is only installed on italian specification machines.

10-38 PW148-8 VEBM720100

STRUCTURE AND FUNCTION, MAINTENANCE STANDARD Steering system

Steering system

3
2

6
1

1. Hydraulic filter
2. Brake/steer pump
3. Priority valve
4. Steering valve
5. Steering cylinder
6. Steering wheel

Structure and function

• The steering is fully hydraulic. The oil sent by the brake/
steer pump (2) mounted on the PTO at the front of the en-
gine, flows via the priority valve (3) to the steering valve (4).
From here it is passed through swivel joint to steering cylin-
der (5). the steering cylinder then extends or retracts to
move the tie-rod and steer the machine

• In the event of a failure of the hydraulic system the machine

can be steered by emergency steering. The steering valve
acts as a pump to send oil to the steering cylinder.

PW148-8 VEBM720100 10-39

Steering column STRUCTURE AND FUNCTION, MAINTENANCE STANDARD

Steering column

1. Steering wheel
2. Steering column
3. Pedal
4. Hose connections
5. Orbitrol valve
6. Mounting bracket

10-40 PW148-8 VEBM720100

STRUCTURE AND FUNCTION, MAINTENANCE STANDARD Orbitrol valve

Orbitrol valve

240 ~ 250 240 ~ 250

bar bar

70 cc/rev

100 cc/rev 190 ~ 195

bar

Specifications
P Pressure port (from priority valve)
Nominal displacement (normal operation) 170cc/rev
T Tank port
Nominal displacement (emergency operation) 70cc/rev
L Left turn port
Relief valve setting 190+5/-0 bar
R Right turn port

LS Load sensing port (to priority valve)

Structure and function
• The steering is fully hydraulic, the oil sent by the brake/steer
pump on the front of the engine flows via the priority valve to
the orbitrol valve, and finally to the steering cylinder which
controls, extends or retracts the tie rod on the axle to steer
the machine.

• In the event of failure of the power supply the machine can

be steered by ‘Emergency steering’, the steering valve acts
as a pump to send oil to the steering cylinders.

PW148-8 VEBM720100 10-41

Hydraulic equipment layout drawings STRUCTURE AND FUNCTION, MAINTENANCE STANDARD

Hydraulic equipment layout drawings

5 6 7 8

10
2 11

3 1 12

1. L.H PPC valve 12. Brake accumulators

2. RH PPC valve 13. Suspension cylinder
3. 2nd boom adjust pedal 14. Safety lock lever
4. Front axle 15. Hydraulic tank
5. Swivel joint 16. Combination cooler
6. Swing motor 17. Travel motor
7. Control valve 18. Arm cylinder
8. Hydraulic filter 19. 2nd boom adjust cylinder
9 Main pump 20. 1st boom cylinder
10 Rear axle 21. Bucket cylinder
11 Transmission

10-42 PW148-8 VEBM720100

STRUCTURE AND FUNCTION, MAINTENANCE STANDARD Hydraulic equipment layout drawings

15

16

14

13

17

18

19

21

20

PW148-8 VEBM720100 10-43

Hydraulic circuit diagram STRUCTURE AND FUNCTION, MAINTENANCE STANDARD

Hydraulic circuit diagram

(Please refer to Section 90)

10-44 PW148-8 VEBM720100

STRUCTURE AND FUNCTION, MAINTENANCE STANDARD Hydraulic tank

Hydraulic tank

7
6
5

1 4

1. Sight gauge
2. Oil filler cap
3. Hydraulic tank
4. Suction strainer
5. Filter element
6. Strainer
7. Bypass valve

PW148-8 VEBM720100 10-45

Hydraulic tank STRUCTURE AND FUNCTION, MAINTENANCE STANDARD

Specifications
Tank 166 Litres

Amount of oil inside tank 120 Litres

Pressure valve

16.7 +/-6.9 kPa

Relief cracking pressure
{0.17 +/-0.07 kg/cm2}

0 - 0.49 kPa
Suction cracking pressure
{0 - 0.005 kg/cm2}

150 +/- 30 kPa

Bypass valve set pressure
{1.5 +/- 0.3 kg/cm2}

10-46 PW148-8 VEBM720100

STRUCTURE AND FUNCTION, MAINTENANCE STANDARD Hydraulic pump

Hydraulic pump
HPV125

58.8~78.4 Nm 1 PEPC
(6~8 kgm)
Pd2
PSIG

PS

PA

PB
Pd1
Pen
19.6~27.4 Nm
2 3
(2.0~2.8 kgm) 11.8~14.7 Nm
(1.2~1.5 kgm)
4
PA

5
Isig

Im

P LS
98~123 Nm
P LSC (10~12.5 kgm)
PEPB

PM

1. Main pump Im: PC mode selector current PLSC: Load pressure detection port
2. LS valve Isig: S set selector current PS: Pump suction port
3. PC valve PA: Pump delivery port PLSC: LS set selector pressure detection port
4. LS-EPC valve PA: Pump delivery pressure detec- PM : PC set selector pressure detection port
tion port
5. PC-EPC valve PB: Pump pressure input port PEPC: EPC basic pressure input port
Pd1: Case drain port PEPC :EPC basic pressure checking port
Pen: Pump control pressure detec- PEPB: EPC basic pressure checking port
tion port
Pd2: Drain port P M: PC mode change pressure checking
port
PLS: Load pressure input port PSIG: LS set change pressure checking port
Outline
• This pump consists of a variable capacity swash plate piston pumps, PC valve, LS valve, and EPC valve.

PW148-8 VEBM720100 10-47

Hydraulic pump STRUCTURE AND FUNCTION, MAINTENANCE STANDARD

58.8~78.4Nm
{6~8kgm}

1 2 3 4 5 6 7 8 9 10

1. Shaft (Front)
2. Cradle
3. Case (Front)
4. Rocker cam
5. Shoe
6. Piston
7. Cylinder block
8. Valve plate
9. End cap
10. Servo piston

10-48 PW148-8 VEBM720100

STRUCTURE AND FUNCTION, MAINTENANCE STANDARD Hydraulic pump

1 2 3 4 5 6 7 8 9

B A
SJP09037AA

Function
• The rotation and torque transmitted to the pump shaft are
converted into hydraulic energy, and pressurized oil is dis-
charged according to the load.

• It is possible to change the discharge amount by changing

the swash plate angle.

Structure
• Cylinder block (7) is supported to shaft (1) by a spline, and
shaft (1) is supported by the front and rear bearings.

• The tip of piston (6) is a concave ball, and shoe (5) is

caulked to it to form one unit. Piston (6) and shoe (5) form a
spherical bearing.

• Rocker cam (4) has flat surface A, and shoe (5) is always
pressed against this surface while sliding in a circular move-
ment.

• Rocker cam (4) brings high pressure oil at cylinder surface

B with cradle (2), which is secured to the case, and forms a
static pressure bearing when it slides.

• Piston (6) carries out relative movement in the axial direction

inside each cylinder chamber of cylinder block (7).

• The cylinder block seals the pressure oil to valve plate (8)
and carries out relative rotation. This surface is designed so
that the oil pressure balance is maintained at a suitable lev-
el. The oil inside each cylinder chamber of cylinder block (7)
is sucked in and discharged through valve plate (8).

PW148-8 VEBM720100 10-49

Hydraulic pump STRUCTURE AND FUNCTION, MAINTENANCE STANDARD

Operation
1. Operation of pump
• Cylinder block (7) rotates together with shaft (1), and shoe
(5) slides on flat surface A.

• When this happens, rocker cam (4) moves along cylindrical

surface B, so angle a between center line X of rocker cam
(4) and the axial direction of cylinder block (7) changes. (An-
gle a is called the swash plate angle.)

• Center line X of rocker cam (4) maintains swash plate angle

a in relation to the axial direction of cylinder block (7), and
flat surface A moves as a cam in relation to shoe (5).

• In this way, piston (6) slides on the inside of cylinder block

(7), so a difference between volumes E and F is created in-
side cylinder block (7). The suction and discharge is carried
out by this difference F - E.

• In other words, when cylinder block (7) rotates and the vol-
ume of chamber E becomes smaller, the oil is discharged
during that stroke. On the other hand, the volume of cham-
ber F becomes larger, and as the volume becomes bigger,
the oil is sucked in.

• If center line X of rocker cam (4) is in line with the axial di-
rection of cylinder block (7) (swash plate angle = 0), the dif-
ference between volumes E and F inside cylinder block (7)
becomes 0, so the pump does not carry out any suction or
discharge of oil.

• (In actual fact, the swash plate angle never becomes 0.)

10-50 PW148-8 VEBM720100

STRUCTURE AND FUNCTION, MAINTENANCE STANDARD Hydraulic pump

2. Control of discharge amount

• If the swash plate angle α becomes larger, the difference
between volumes E and F becomes larger and discharge
amount Q increases.

• Swash plate angle a is changed by servo piston (102).

• Servo piston (10) moves in a reciprocal movement (↔) ac-

cording to the signal pressure from the PC and LS valves.
This straight line movement is transmitted through rod (11)
to rocker cam (4), and rocker cam (4), which is supported by
the cylindrical surface to cradle (2), slides in a rotating
movement in direction of arrow.

• With servo piston (10), the area receiving the pressure is dif-
ferent on the left and the right, so main pump discharge
pressure (self pressure) PP is always brought to the cham-
ber receiving the pressure at the small diameter piston end.

• Output pressure Pen of the LS valve is brought to the cham- A

ber receiving the pressure at the large diameter end. The re-
lationship in the size of pressure PP at the small diameter 10
piston end and pressure Pen at the large diameter end, and
the ratio between the area receiving the pressure of the
small diameter piston and the large diameter piston controls
the movement of servo piston (10).

11

PW148-8 VEBM720100 10-51

Hydraulic pump STRUCTURE AND FUNCTION, MAINTENANCE STANDARD

LS valve

1. Plug
2. Locknut
3. Sleeve
4. Spring
5. Seat
6. Spool
7. Piston
8. Sleeve

PA: Pump port

PP: Pump port
PDP: Drain port
PLP: LS control pressure output port
PLS: LS pressure input port
PPL: PC control pressure input port
PSIG: LS mode selection pilot port

10-52 PW148-8 VEBM720100

STRUCTURE AND FUNCTION, MAINTENANCE STANDARD Hydraulic pump

PC valve

1. Servo piston assembly

2. Plug
3. Pin
4. Spool
5. Retainer
6. Seat
7. Cover
8. Wiring

PA: Pump port

PA2: Pump pressure pilot port (= PA)
PDP: Drain port
PM: PC mode selector pressure pilot port
PPL: PC control pressure output port (to LS valve)
PPL2: PC control pressure output port (to serve piston)

PW148-8 VEBM720100 10-53

Hydraulic pump STRUCTURE AND FUNCTION, MAINTENANCE STANDARD

Function
1. LS valve
• The LS valve detects the load and controls the discharge
amount.

• This valve controls main pump discharge amount Q accord-

ing to differential pressure ∆PLS (=PP - PLS) [called the LS
differential pressure] (the difference between main pump
pressure PP and control valve outlet port pressure PLS).

• Main pump pressure PP, pressure PLS {called the LS pres-

sure} coming from the control valve output, and pressure 0.64 {6.5} 2.1 {21.5}

Psig {called the LS selector pressure} from the proportional A

solenoid valve enter this valve.

The relationship between discharge amount Q and differen-

tial pressure ∆PLS, (the difference between main pump
pressure PP and LS pressure PLS) (= PP - PLS) changes
as shown in the diagram at the right according to LS pres-
sure selector current isig of the LS-EPC valve.

• When isig changes between 0 and 1A, the set pressure of

the spring changes according to this, and the selector point
for the pump discharge amount changes at the rated central
valve between 0.64 ´ 2.1 MPa {6.5 ´ 21.5 kg/cm²}.

2. PC valve
• When the pump discharge pressure PP1 (self-pressure) is
high, the PC valve controls the pump so that no more oil 0.33A
than the constant flow (in accordance with the discharge
0.43A
pressure) flows even if the stroke of the control valve be-
0.80A
comes larger. In this way, it carries out equal horsepower
control so that the horsepower absorbed by the pump does
not exceed the engine horsepower.

• In other words, If the load during the operation becomes

B
larger and the pump discharge pressure rises, it reduces the
discharge amount from the pump; and if the pump discharge
pressure drops, it increases the discharge amount from the
pump.

The relationship pump discharge pressures (PP) and pump

discharge amount Q is shown on the right, with the current
given to the PC-EPC valve solenoid shown as a parameter.

The controller senses the actual speed of the engine, and if

the speed drops because of an increase in the load, it reduc-
es the pump discharge amount to allow the speed to recov-
er. In other words, when the load increases and the engine
speed drops below the set value, the command current to
the PC-EPC valve solenoid from the controller increases ac-
cording to the drop in the engine speed to reduce the pump
swash plate angle.

10-54 PW148-8 VEBM720100

STRUCTURE AND FUNCTION, MAINTENANCE STANDARD Hydraulic pump

Blank for technical reason

PW148-8 VEBM720100 10-55

Hydraulic pump STRUCTURE AND FUNCTION, MAINTENANCE STANDARD

Operation

Control
valve
Control circuit
pressure setting
valve

10

1. LS valve
1.1 When control valve is at neutral position 10
• The LS valve is a three-way selector valve, with pressure
PLS (LS pressure) from the inlet port of the control valve
brought to spring chamber B, and main pump discharge
pressure PP coming from the control valve output brought to
port H of sleeve (8). The size of this LS pressure PLS +
force Z of spring (4) and the main pump pressure (self pres-
sure) PP determines the position of spool (6). However, the
size of the output pressure PSIG (the LS selection pressure)
of the EPC valve for the LS valve entering port G also
changes the position of spool (6). (The set pressure of the
spring changes).

• Before the engine is started, servo piston (10 is pushed to

the left. (See the diagram on the right)
A
• When the engine is started and the control lever is at the
neutral position, LS pressure PLS is 0 MPa {0 kg/cm²}. (It is
interconnected with the drain circuit through the control
valve spool.)

• At this point, spool (6) is pushed to the right, and port C and
port D are connected. Pump pressure PP enters the large
diameter end of the piston from port K and the same pump
pressure PP also enters port J at the small diameter end of
the piston, so the swash plate is moved to the minimum an-
gle by the difference in the area of the piston (10).

10-56 PW148-8 VEBM720100

STRUCTURE AND FUNCTION, MAINTENANCE STANDARD Hydraulic pump

Control
valve SDP08885
Control circuit
pressure setting
valve

10

AA

1.2 Operation in increase direction for pump discharge

amount
• When the difference between the main pump pressure PP
and LS pressure PLS, in other words, LS differential pres-
sure ∆PLS, becomes smaller (for example, when the area of
opening of the control valve becomes larger and pump PP
drops), spool (6) is pushed to the left by the combined force
of LS pressure PLS and the force of spring (4).

• When spool (6) moves, port D and port E are joined and
connected to the PC valve. When this happens, the PC
valve is connected to the drain port, so circuit D - K be-
comes drain pressure PT. (The operation of the PC valve is
explained later).

• For this reason, the pressure at the large diameter end of

servo piston (10) becomes drain pressure PT, and pump
pressure PP enters port J at the small diameter end, so ser-
vo piston (10) is pushed to the left. Therefore, the swash
plate moves in the direction to make the discharge amount
larger. If the output pressure of the EPC valve for the LS
valve enters port G, this pressure creates a force to move
piston (7) to the right. If piston (7) is pushed to the right, it
acts to make the set pressure of spring (4) weaker, and the
difference between PLS and PP changes when ports D and
E of spool (6) are connected.

PW148-8 VEBM720100 10-57

Hydraulic pump STRUCTURE AND FUNCTION, MAINTENANCE STANDARD

Control
valve
Control circuit
pressure setting
valve

SDP08886

10

AA

1.3 Operation in decrease direction for pump discharge

amount
• The following explains the situation if the servo piston (10)
moves to the right (the discharge amount becomes smaller).
When LS differential pressure ∆PLS becomes larger (for ex-
ample, when the area of opening of the control valve be-
comes smaller and pump pressure PP rises), pump
pressure PP pushes spool (6) to the right.

• When spool (6) moves, main port pressure PP flows from

port C and port D and from port K, it enters the large diame-
ter end of the piston.

• Main pump pressure PP also enters port J at the small di-

ameter end of the piston, but because of the difference in ar-
ea between the large diameter end and the small diameter
end of servo piston (10), servo piston (10) is pushed to the
right.

• As a result, the swash plate moves in the direction to make

angle smaller.

• If LS selection pressure PSIG enters port G, it acts to make

the set pressure of spring (4) weaker.

10-58 PW148-8 VEBM720100

STRUCTURE AND FUNCTION, MAINTENANCE STANDARD Hydraulic pump

Control
valve
Control circuit
pressure setting
valve

SDP08887

10

AA

1.4 When servo piston is balanced

• Let us take the area receiving the pressure at the large di-
ameter end of the piston as A1, the area receiving the pres-
sure at the small diameter end as A0, and the pressure
flowing into the large diameter end of the piston as Pen. If
the main pump pressure PP of the LS valve and the com-
bined force of force Z of spring (4) and LS pressure PLS are
balanced, and the relationship is A0 x PP = A1 x Pen, servo
piston (10) will stop in that position, and the swash plate will
be kept at an intermediate position. (It will stop at a position
where the opening of the throttle from port D to port E and
from port C to port D of spool (6) is approximately the
same.)

• At this point, the relationship between the area receiving the

pressure at both ends of piston (10) is A0: A1 = 1:2, so the
pressure applied to both ends of the piston when it is bal-
anced becomes PP: Pen = 2:1.

• The position where spool (6) is balanced and stopped is the

standard center, and the force of spring (4) is adjusted so
that it is determined when PP - PLS = 2.1 MPa {21.5 kg/
cm²}. However, if PSIG (the output pressure of 0 ↔ 2.9 MPa
{0 ↔ 30 kg/cm²} of the EPC valve of the LS valve) is applied
to port G, the balance stop position will change in proportion
to pressure PSIG between PP - PLS = 2.1 ↔ 0.64 MPa
{21.5 ↔ 6.5 kg/cm²}.

PW148-8 VEBM720100 10-59

Hydraulic pump STRUCTURE AND FUNCTION, MAINTENANCE STANDARD

Control
valve

09143

Control circuit
pressure setting
valve

AA

2. PC valve

2.1 When pump controller is normal

a) When the load on the actuator is small and pump

pressures PP
1. Movement of PC-EPC solenoid (1)

• The command current from the pump controller flows to PC-

EPC solenoid (1).This command current acts on the PC-
EPC valve and outputs the signal pressure. When this signal
pressure is received, the force pushing pin (2) is changed.

• On the opposite side to the force pushing this pin (2) is the
spring set pressure of springs (4) and (6) and pump pres-
sure PP (self pressure) pushing spool (3). Pin (2) stops at a
position where the combined force pushing spool (3) is bal-
anced, and the pressure (pressure of port C) output from the
PC valve changes according to this position.

• The size of command current X is determined by the nature

of the operation (lever operation), the selection of the work-
ing mode, and the set value and actual value for the engine
speed.

10-60 PW148-8 VEBM720100

STRUCTURE AND FUNCTION, MAINTENANCE STANDARD Hydraulic pump

Control
valve

09144

Control circuit
pressure setting
valve

AA

2. Action of spring

• The spring load of springs (4) and (6) in the PC valve is de-
termined by the swash plate position.

• If servo piston (9) moves to the right, spring (6) is com-

pressed, and if it moves further to the right, spring (6) con-
tacts seat (5) and is fixed in position. In other words, the
spring load is changed by servo piston (9) extending or com-
pressing springs (4) and (6).

• If the command circuit input to PC-EPC valve solenoid (1)

changes further, the force pushing pin (2) changes, and the
spring load of springs (4) and (6) also changes according to
the valve of the PC-EPC valve solenoid command current.

• Port C of the PC valve is connected to port E of the LS valve

(see (1) LS valve). Self pressure PP enters port B and the
small diameter end of servo piston (9), and enters port A al-
so.

PW148-8 VEBM720100 10-61

Hydraulic pump STRUCTURE AND FUNCTION, MAINTENANCE STANDARD

• When pump pressures PP is small, spool (3) is on the left

relative to servo piston (9). At this point, port C and D are
connected, and the pressure entering the LS valve becomes
drain pressure PT. If port E and port G of the LS valve are
connected (see 1. LS valve), the pressure entering the large
diameter end of the piston from port J becomes drain pres-
sure PT, and servo piston (9) moves to the left. In this way,
the pump discharge amount moves in the direction of in-
crease.

• As servo piston (9) moves further to the left, springs (4) and
(6) expand and the spring force becomes weaker. When the
spring force becomes weaker, spool (3) moves to the right
relative to servo piston (9), so the connection between port
C and port D is cut, and the pump discharge pressure ports
B and C are connected. As a result, the pressure at port C
rises, and the pressure at the large diameter end of the pis-
ton also rises, so the movement of servo piston (9) to the left
is stopped.

• In other words, the stop position for servo piston (9) (= pump
discharge amount) is decided at the point where the force of
springs (4) and (6) and the pushing force from the PC-EPC
valve solenoid and the pushing force created by the pres-
sures PP acting on the spool (3) are in balance.

10-62 PW148-8 VEBM720100

STRUCTURE AND FUNCTION, MAINTENANCE STANDARD Hydraulic pump

Control
valve

09145

Control circuit
pressure setting
valve

AA

b) When load on actuator is large and pump discharge

pressure is high
• When the load is large and pump discharge pressure PP is
high, the force pushing servo piston (9) to the left becomes
larger and spool (3) moves to the position in the diagram
above. When this happens, as shown in the diagram above,
part of the pressurized oil from port B flows out through port
C where the LS valve is actuated to port D, and the pressu-
rized oil flowing from port C to the LS valve becomes ap-
proximately half of main pump pressure PP.

• When port E and port G of the LS valve are connected (see

1 LS valve), the pressure from port J enters the large diame-
ter end of servo piston (9), and servo piston (9) stops.

• If main pump pressure PP increases further and servo pis-

ton (9) moves further to the left, main pump pressure PP
flows to port C and acts to make the discharge amount the
minimum. When servo piston (9) moves to the right, springs
(4) and (6) are compressed and push back spool (3). When
spool (3) moves to the left relative to servo piston (9), the
opening joining port C and port D becomes larger. As a re-
sult, the pressure at port C (= J) drops, and servo piston (9)
stops moving to the right.

• The position in which servo piston (9) stops when this hap-
pens is further to the right than the position when pump
pressure PP is low.

PW148-8 VEBM720100 10-63

Hydraulic pump STRUCTURE AND FUNCTION, MAINTENANCE STANDARD

• The relation of pressure PP and the position of servo piston

(9) forms a bent line graph because of the double-spring ef-
fect of springs (4) and (6). The relationship between pump
pressure PP and pump discharge amount Q is shown in the
graph on the right.

• If command current X sent to PC-EPC valve solenoid (1) in-

creases further, the relationship between pump pressure PP,
and pump discharge amount Q is proportional to the push-
ing force of the PC-EPC valve solenoid and moves in paral-
lel. In other words, the pushing force of PC-EPC solenoid (1)
is added to the force pushing to the right because of the
pump pressure applied to the spool (3), so the relationship
between the pump pressure PP and Q moves from (2) to (1)
in accordance with the increase in X.

10-64 PW148-8 VEBM720100

STRUCTURE AND FUNCTION, MAINTENANCE STANDARD Hydraulic pump

Control
valve

09146

Control circuit
pressure setting
valve

AA

2.2 When pump controller is abnormal and Emergency

pump drive switch is on

a) When load on main pump is light

• If there is a failure in the pump controller, turn emergency
pump drive switch ON to switch to the resistor side. In this
case, the power source is taken directly from the battery. But
if the current is used as it is, it is too large, so use the resis-
tor to control the current flowing to PC-EPC valve solenoid
(1).

• When this is done, the current becomes constant, so the

force pushing pin (2) is also constant.

• If the main pump pressure PP is low, and the force of PC-

EPC valve solenoid (1) is weaker than the spring set force,
spool (3) is balanced at a position to the left relative to servo
piston (9).

• At this point, port C is connected to the drain port D, and the

large diameter end of the servo piston (9) also becomes the
drain pressure PT through the LS valve. When this happens,
the pressure at the small diameter end of the piston is large,
so servo piston (9) moves in the direction to make the dis-
charge amount larger.

PW148-8 VEBM720100 10-65

Hydraulic pump STRUCTURE AND FUNCTION, MAINTENANCE STANDARD

Control
valve
09147

Control circuit
pressure setting
valve

7AA

b) When main pump load is heavy

• In the same way as in the previous item, when the emergen-
cy pump drive switch is ON, the command current sent to
PC-EPC valve solenoid (1) becomes constant. For this rea-
son, the force of pin (2) pushing spool (3) is constant.

• If main pump pressures PP increase, servo piston (9) moves

further to the left than when the main pump load is light, and
spool (3) is balanced at the position in the diagram above.

• In this case, the pressure from port B flows to port C, this

makes servo piston (9) move to the right (to make the dis-
charge amount smaller) by the same mechanism as ex-
plained in item 2.1.b, and stops at a position to the left of the
position when the load on the pump is light. In other words,
even when the emergency pump drive switch is ON, the
curve for the pump pressure PP and discharge amount Q is
determined as shown in the diagram for the valve of the cur-
rent sent to the PC-EPC valve solenoid through the resistor.

• The curve when the emergency pump drive switch is ON is

curve (2), which is to the left of curve (1) for when the pump
controller is normal.

10-66 PW148-8 VEBM720100

STRUCTURE AND FUNCTION, MAINTENANCE STANDARD Hydraulic pump

LS(PC)-EPC valve

g
1. Body
2. Spool
3. Spring
4. Rod
5. Coil
6. Plunger
7. Connector
PSIG(PM): To LS(PC) valve
PT: To tank
PEPC: PPC pressure from solenoid block valve

PW148-8 VEBM720100 10-67

Hydraulic pump STRUCTURE AND FUNCTION, MAINTENANCE STANDARD

Function
• The EPC valve consists of the proportional solenoid portion
and the hydraulic valve portion.
reference
• When it receives signal current i from the pump controller, it (800, 26.6)

generates the EPC output pressure in proportion to the size

of the signal, and outputs it to the LS (PC) valve.

reference
(500, 10.5)

reference
(300, 4)

300 500

900
AA

Operation

1. When signal current is 0 (coil de-energized)

• When there is no signal current flowing from the controller to
coil (5), coil (5) is de-energized.

• For this reason, spool (2) is pushed to the left in the direction
of the arrow by spring (3).

• As a result, port PEPC closes and the pressurized oil from

the main pump does not flow to the LS (PC) valve.
08890
• At the same time, the pressurized oil from the LS (PC) valve
passes from port PSIG(PM) through port PT and is drained
to the tank. Control circuit
pressure setting
valve

AA

10-68 PW148-8 VEBM720100

STRUCTURE AND FUNCTION, MAINTENANCE STANDARD Hydraulic pump

2. When signal current is very small (coil energized)

• When a very small signal current flows to coil (5), coil (5) is
energized, and a propulsion force is generated which push-
es plunger (6) to the right.

• Push pin (4) pushes spool (2) to the right, and pressurized
oil flows from port PEPC to port PSIG(PM).

• When the pressure at port PSIG(PM) rises and the load of

spring (3) + the force acting on surface a of spool (2) be-
comes greater than the propulsion force of plunger (6),
spool (2) is pushed to the left. The circuit between port
PEPC and port PSIG(PM) is shut off, and at the same time, 08891
port PSIG(PM) and port PT are connected. a
Control circuit
pressure setting
• As a result, spool (2) is moved right or left until the propul- valve
sion force of plunger (6) is balanced with the load of spring
(3) + pressure of port PSIG(PM).

• Therefore, the circuit pressure between the EPC valve and

the LS (PC) valve is controlled in proportion to the size of
the signal current.
AA

3. When signal current is maximum (coil energized)

• When the signal current flows to coil (5), coil (5) is ener-
gized.

• When this happens, the signal current is at its maximum, so

the propulsion force of plunger (6) is also at its maximum. 08892

• For this reason, spool (2) is pushed fully to the right by push
pin (4).

• As a result, the maximum flow of pressurized oil from port

PEPC flows to port PSIG(PM), and the circuit pressure be-
tween the EPC valve and LS (PC) valve becomes the maxi-
mum.

• At the same time, port PT closes and stops the oil from flow- Control circuit
ing to the tank. pressure setting
valve

AA

PW148-8 VEBM720100 10-69

Pilot pressure control (PPC) system STRUCTURE AND FUNCTION, MAINTENANCE STANDARD

Pilot pressure control (PPC) system

C
PA8
pS PB8
TS

PS
T2
PX
P5 2-STAGE
RELIEF
V02

T5
PB
SWING/BRAKE
P1
V03

T4 PBP

2-STAGE BACK S10

PRESSURE
P2 V15
PA3

FWD/REV
V08
PB3
A
S09
P4 TRAVEL
NEUTRAL
V06 PA2
T1

BOOM/STAB.
UP
S13
V10
PA4
B2

BOOM/STAB. PB2
DOWN
S12 V09
PB4
B1
PEPC

P3
PPC LOCK
V01
T3
3
TRAVEL
CREEP
V07

N
13

SUS LOCK
V04

14
4
T/M CLUCH
CONTROL
12
V11
X

B
1.5 BAR
SET 36.5± @10 litre/min~53 litre/min

TP1 A1 T0

R R2 R1
F
1
E
damper branch hose N

T´1
LS
EF CF
T1
2
))((

)(
P

B T´2
from orbitrol valve
load sensing signal T2

R3

X1 X
N
to low gear/high gear
solenoid valve
to orbitrol valve

10-70 PW148-8 VEBM720100

STRUCTURE AND FUNCTION, MAINTENANCE STANDARD Pilot pressure control (PPC) system

1. Gear Pump
2. Steering/Braking priority valve
3. Power Brake Valve
4. Pressure Reducing Valve
Incorporated in Main Solenoid Valve Block

Function
• The PPC Pump less system discharges pressurised oil to
operate the PPC circuit and solenoid valve assemblies.

Operation
• The PPC pump less system utilizes the return line oil from
the power brake valve, oil is supplied to the steering / brak-
ing circuits from a gear pump driven by the engine. Oil is pri-
oritised to the steering circuit via the priority valve with the
remaining oil flow feeding the power brake valve. The return
line from the brake valve passes through a relief valve to
maintain a pressure of 36+/ -1.5 BAR.

PW148-8 VEBM720100 10-71

Control valve STRUCTURE AND FUNCTION, MAINTENANCE STANDARD

Control valve

Outline
The following four types of control valve are set.

• 7-spool (monoboom + service valve)

• 8-spool (monoboom + two service valve)

• 8-spool (2P boom + service valve)

• 9-spool (2P boom + two service valve)

• Each service valve is an add-on type where one valve

each can be added, so it is possible to add valves or re-
move valves if necessary.
(Maximum: 9 spool)

An explanation of the external appearance and the cross section

is given only for the 9-spool valve (2P boom + two service
valve)

A1. To swing motor LH PA1. From swing PPC valve LEFT PP. from main pump

A2. To boom cyl bott PA2. From boom PPC valve RAISE PX. from 2-stage relief sol valve

A3. To travel fwd PA3. From travel PPC valve FORWARD PBP from 2-stage lift check sol valve

A4. To stabilizer cyl bott PA4. From stabilizer PPC valve RAISE P. From pump

A5. To adjust cyl bott PA5. From adjust cyl PPC valve EXTEND BP. from boom RAISE PPC

A6. To arm cyl head PA6. From arm cyl PPC valve DUMP SA1. from boom RAISE PPC valve

A7. To bucket cyl head PA7. From bucket cyl PPC valve DUMP SA6. from travel PPC valve

A8. To service PA8. From service PPC valve SA7. from travel PPC valve

A9. To service PA9. From service PPC valve SB1. from boom RAISE PPC

B1. To swing motor RH PB1. From swing PPC valve RIGHT SB2. from travel PPC valve

B2. To boom cyl head PB2. From boom PPC valve LOWER SB6. from travel PPC valve

B3. To travel rev PB3. From travel PPC valve REVERSE SB7. from travel PPC valve

B4. To stabilizer cyl bott PB4. From stabilizer PPC valve LOWER TSW. to swing motor

B5. To adjust cyl head PB5. From adjust cyl PPC valve TS1. to tank
RETRACT
B6. To arm cyl bott PB6. From arm cyl PPC valve DIG LS. to pump LS valve

B7. To bucket cyl bott PB7. From bucket cyl PPC valve DIG T C. to oil cooler

B8. To service PB8. From service PPC valve TB. to tank

B9. To service PB9. From service PPC valve

10-72 PW148-8 VEBM720100

STRUCTURE AND FUNCTION, MAINTENANCE STANDARD Control valve

F G H J K L M N CC DD AA

A1 A2 A3 A4 A5 A6 A7 A8 A9

D C

TB
B1 B2 B3 B4 B5 B6 B7 B8 B9

PBP
B
F G H J K L M N CC DD AA

Bypass valve 27.8~34.3Nm

{2.8~3.5Kgm}
11.8~14.7Nm
11.8~14.7Nm {1.2~1.5Kgm}
{1.2~1.5Kgm}
TSW
PA1 PA2 PA3 PA4 PA5 PA6 PA7 PA8 PA9

PX

PB1 PB2 PB3 PB4 PB5 PB6 PB7 PB8 PB9

TC
11.8~14.7Nm
{1.2~1.5Kgm} A 11.8~14.7Nm B
{1.2~1.5Kgm}
Arm regeneration valve Tighten bolts in order 1~4
SB1 SB2 SB6 SB7
Pump pressure
98.1~113Nm checking port
{10~11.5Kgm}

BP 3 1

LS

PP

2 4

27.8~34.3Nm
{2.8~3.5Kgm} LS pressure
Swing bleed valve
checking port
SA1 SA6 SA7

P E D C

PW148-8 VEBM720100 10-73

Control valve STRUCTURE AND FUNCTION, MAINTENANCE STANDARD

147~186Nm 147~186Nm 196~240Nm 147~186Nm

{15~19kgm} {15~19kgm} {20~24.5kgm} {15~19kgm}
25 24
1 2 3 4 5 6 7 8 9

11 13 14 15 16 17 18
10 12
20 21 22 23 19
147~186Nm 147~186Nm 147~186Nm
{15~19kgm} {15~19kgm} {15~19kgm}

1. Pressure compensation valve (Swing Left)

2. Pressure compensation valve (Boom Raise)
3. Pressure compensation valve (Travel Forward)
4. Pressure compensation valve (Stabilizer Raise)
5. Pressure compensation valve (2PBoom Raise)
6. Pressure compensation valve (Arm Dump)
7. Pressure compensation valve (Bucket Dump)
8. Pressure compensation valve (Service)
9. Pressure compensation valve (Service)
10. Pressure compensation valve (Swing Right)
11. Pressure compensation valve (Boom Lower)
12. Pressure compensation valve (Travel Reverse)
13. Pressure compensation valve (Stabilizer Lower)
14. Pressure compensation valve (2PBoom Raise)
15. Pressure compensation valve (Arm Dig)
16. Pressure compensation valve (Bucket Dig)
17. Variable pressure compensation valve (Service)
18. Variable pressure compensation valve (Service)
19. Unload valve

10-74 PW148-8 VEBM720100

STRUCTURE AND FUNCTION, MAINTENANCE STANDARD Control valve

Unit:mm

No Check Item Criteria Remedy

Standard size Repair limit

Free length x Installed Installed Free Installed

Outside diameter length load length load

17.6Nm 13.7Nm
20. Control valve spring 32.5 x 14.2 23
(1.8kgm) (1.4kgm)

66.4Nm 53.1Nm
21. Control valve spring 7.8 x 14.2 40
(6.8kgm) (5.4kgm) If damaged or
17.6Nm 13.7Nm deformed, replace
22. Control valve spring 27.5 x 14.2 18 spring
(1.8kgm) (1.4kgm)

17.6Nm 13.7Nm
23. Control valve spring 27.5 x 14.2 18
(1.8kgm) (1.4kgm)

29.4Nm 23.4Nm
24. Control valve spring 36.2 x 5.3 23.5
(3kgm) (2.3kgm)

29.4Nm 23.4Nm
25. Control valve spring 36.5 x 5.3 23.5
(3kgm) (2.3kgm)

PW148-8 VEBM720100 10-75

Control valve STRUCTURE AND FUNCTION, MAINTENANCE STANDARD

1 6 7

10
2 3 4 5 8 9

12 11 13

13

1. Spool (Swing) 6. Spool (Arm)

2. Spool (Boom) 7. Spool (Bucket)
3. Spool (Travel) 8. Spool (Service)
4. Spool (Stabilizer) 9. Spool (Service)
5. Spool (2PBoom) 10. Main relief valve

Unit:mm

No Check Item Criteria Remedy

Standard size Repair limit

Free length x Installed Installed Free Installed

Outside diameter length load length load

55.9Nm 47.3Nm If damaged or

11. Spool return spring 45.7 x 28 45
(5.7kgm) (4.7kgm) deformed, replace
spring
92.2Nm 78.0Nm
12. Spool return spring 42.4 x 28 41
(9.4.kgm) (7.8kgm)

53.5.Nm 45.3Nm
13. Spool return spring 45.6 x 28 45
(5.5kgm) (4.5kgm)

10-76 PW148-8 VEBM720100

STRUCTURE AND FUNCTION, MAINTENANCE STANDARD Control valve

19 8 9
176.6~196.2Nm
{18~20kgm}
1 2 3 4 5 6 7

20

10 11 12 13 14 15 16 17 18
27 137.2~157Nm 34~44Nm
{14~16kgm} {3.5~4.5kgm}
137.2~156.8Nm
108~147Nm
{11~15kgm} {14~16kgm}

21

22
49~63.7Nm
{5~6.5kgm} 23
19.6~27.5Nm
{2~2.8kgm}

49~63.7Nm
{5~6.5kgm} 49~63.7Nm 49~63.7Nm 26 25 28 24
{5~6.5kgm} {5~6.5kgm}

1. N/A 15. Suction valve (Arm Dig)

2. Suction valve (Boom Raise) 16. Suction valve (Bucket Dig)
3. Suction valve (Travel Forward) 17. Variable safety suction valve (Service)
4. N/A 18. Variable safety suction valve (Service)
5. Suction valve (2PBoom Extend) 19. Safety suction valve
6. Suction valve (Arm Dump) 20. 2-stage lift check valve
7. Suction valve (Bucket Dump) 21. LS pressure detection valve
8. Variable safety suction valve (Service) 22. LS pressure plug
9. Variable safety suction valve (Service) 23. Pump pressure detection plug
10. N/A 24. Check valve Bucket
11. Suction valve (Boom Lower) 25. Check valve Arm
12. Suction valve (Travel Reverse) 26. Check valve 2P Boom
13. N/A 27. LS separation valve
14. Suction valve (2PBoom Retract)

Unit:mm
No Check Item Criteria Remedy
Standard size Repair limit
Free length x Installed Installed Free Installed If damaged or
Outside diameter length load length load deformed, replace
5.9Nm 4.7Nm spring
28. Check valve spring 41.5 x 8.5 31.5
(0.6kgm) (0.48kgm)

PW148-8 VEBM720100 10-77

Control valve STRUCTURE AND FUNCTION, MAINTENANCE STANDARD

14.7~19.6Nm
{1.5~2kgm}
2
6

7 1

11

12

8
47.1~58.8Nm
{4.8~6.0Kgm} 5 3

10 M-M 9 4
J-J

Arm control valve Travel control valve

1. Pressure compensation valve

2. Suction valve
3. Suction valve
4. Spool (Travel)
5 Pressure compensation valve
6. Pressure compensation valve
7. Suction valve
8. Suction valve
9. Spool (Arm)
10. Pressure compensation valve
11. Arm regeneration valve

Unit:mm

No Check Item Criteria Remedy

Standard size Repair limit

Free length x Installed Installed Free Installed If damaged or

Outside diameter length load length load deformed,
replace spring
8.8Nm 7Nm
12 Check valve spring 41.5 x 8.5 26.5
(0.9kgm) (0.7kgm)

10-78 PW148-8 VEBM720100

STRUCTURE AND FUNCTION, MAINTENANCE STANDARD Control valve

14.7~19.6Nm
14.7~19.6Nm {1.5~2kgm}
{1.5~2kgm}

2 6 7
1

5
4 3 8
10
N-N 9 DD-DD

Bucket control valve Service control valve

1. Pressure compensation valve

2. Suction valve
3. Suction valve
4. Spool (Bucket)
5. Pressure compensation valve
6. Pressure compensation valve
7. Variable safety suction valve (Service)
8. Variable safety suction valve (Service)
9. Spool (service)
10. Pressure compensation valve

PW148-8 VEBM720100 10-79

Control valve STRUCTURE AND FUNCTION, MAINTENANCE STANDARD

Swing control valve

14.7~19.6Nm
13 1 {1.5~2kgm}

59~78Nm
{6~8kgm}

59~78Nm
{6~8kgm}
14.7~19.6Nm 4
{1.5~2kgm} 3 G-G
2
6
10
5

14

9
14.7~19.6Nm
{1.5~2kgm} 7
59~78Nm
8 12 11 {6~8kgm}

H-H K-K
Boom control valve Stabilizer control valve

1. Pressure compensation valve 7. Suction valve

2. Spool (Swing) 8. Spool (Boom)
3. Pressure compensation valve 9. Pressure compensation valve
4. Swing bleed valve 10. Pressure compensation valve
5. Pressure compensation valve 11. Spool (Stabilizer)
6. Suction valve 12. Pressure compensation valve

Unit:mm

No Check Item Criteria Remedy

Standard size Repair limit

Free length x Installed Installed Free Installed If damaged or

Outside diameter length load length load deformed,
replace spring
8.8Nm 7Nm
13. Bleed spool return spring 41.5 x 8.5 26.5
(0.9kgm) (0.7kgm)

10-80 PW148-8 VEBM720100

STRUCTURE AND FUNCTION, MAINTENANCE STANDARD Control valve

Second boom control valve

14.7~19.6Nm
{4.5~2kgm}

4 5

3 1

2 L-L

1. Suction valve
2. Spool (2nd Boom)
3. Pressure compensation valve
4. Pressure compensation valve
5. Suction valve

PW148-8 VEBM720100 10-81

Control valve STRUCTURE AND FUNCTION, MAINTENANCE STANDARD

34~44Nm
{3.5~4.5kgm} 4

8
1

7
6

AA-AA
147~186.3Nm 19.6~24.5Nm 5
{15~19kgm} {2.0~2.5kgm} F-F
47~58.8Nm
2 {4.8~6kgm}

1. Pressure relief plug

2. Unload valve
3. Main relief valve
4. Oil cooler bypass valve
5. 2-stage lift check valve
6. LS separation valve

Unit:mm

No Check Item Criteria Remedy

Standard size Repair limit

Free length x Installed Installed Free Installed If damaged or

Outside diameter length load length load deformed,
replace spring
135.3Nm 112.7Nm
7. Lift check valve spring 72.7 x 20.6 42.5
(13.8kgm) 11.5(kgm)

135.3Nm 112.7Nm
8. Cooler bypass valve spring 72.7 x 20.6 42.5
(13.8kgm) 11.5(kgm)

10-82 PW148-8 VEBM720100

STRUCTURE AND FUNCTION, MAINTENANCE STANDARD CLSS

CLSS

Outline of CLSS

Features
CLSS is an abbreviation for Closed centre Load Sensing Sys-
tem, and has the following features.

• Fine control not influenced by load

• Control enabling digging even with fine control

• Ease of compound operation ensured by flow divider func-

tion using area of opening of spool during compound opera-
tions

• Energy saving using variable pump control

Structure
• The CLSS consists of a main pump, control valve, and actu-
ators for the work equipment.

• The main pump body consists of the pump itself, the PC

valve and LS valve.

PW148-8 VEBM720100 10-83

CLSS STRUCTURE AND FUNCTION, MAINTENANCE STANDARD

Basic Principle
1. Control of pump swash plate angle
• The pump swash plate angle (pump discharge amount) is
controlled so that LS differential pressure ∆PLS (the differ-
ence between pump (discharge) pressure PP and control
valve outlet port LS pressure PLS) (load pressure of actua-
tor) is constant.

(LS pressure ∆PLS = Pump discharge pressure PP-LS

pressure PLS)

• If LS differential pressure ∆PLS becomes lower than the set

pressure of the LS valve (when the actuator load pressure is
high), the pump swash plate moves towards the maximum
position; if the set pressure becomes higher than the set
pressure of the LS valve (when the actuator load pressure is
low), the pump swash plate moves towards the minimum
position.

• For details of the operation, see HYDRAULIC PUMP.

10-84 PW148-8 VEBM720100

STRUCTURE AND FUNCTION, MAINTENANCE STANDARD CLSS

2. Pressure compensation control

• A pressure compensation valve is installed to the inlet port
side of the control valve spool to balance the load.

When to actuators are operated together, this valve acts to

make pressure difference ∆P between the upstream (inlet
port) and downstream (outlet port) the same, regardless of
the size of the load (pressure). In this way, the flow of oil
from the pump is divided (compensated) in proportion to the
area of openings S1 and S2 of each valve when it is operat-
ed.

PW148-8 VEBM720100 10-85

CLSS STRUCTURE AND FUNCTION, MAINTENANCE STANDARD

Operation for each function and valve

Hydraulic circuit diagram and name of valves

3
5

3 4

4
3 4

11 4
3 4

4
3

3
4

3 4

12

3
10
9

6
2 7 8

10-86 PW148-8 VEBM720100

STRUCTURE AND FUNCTION, MAINTENANCE STANDARD CLSS

1. Unload valve
Set pressure: 3.38 MPa {34.5 kg/cm²}
2. Safety-suction valve
Set pressure: 38.2 MPa {390 kg/cm²}
3. Pressure compensation valve
4. Check valve
5. Safety valve
Set pressure: 24.7 MPa {250 kg/cm²}
6. Main relief valve
Set pressure:
Normal: 34.8 MPa {355 kg/cm²}
When rising: 37.3 MPa {380 kg/cm²}
7. Back pressure valve.
Lo: 0.4 MPa (4kg/cm²)
Hi: 0.8 MPa (8kg/cm²)
8. Cooler bypass valve
Set pressure: 0.4MPa (4kg/cm²)
9. LS separation valve
10. Swing bleed valve
11. Arm check valve
12. Safety valve
Set pressure: 33.3MPa (340kg/cm²)

PW148-8 VEBM720100 10-87

CLSS STRUCTURE AND FUNCTION, MAINTENANCE STANDARD

1. Unload valve

Function
1. When the control valve is at neutral, pump discharge
amount Q discharged by the minimum swash plate angle is
released to the tank circuit. At this time, pump discharge
pressure PP is set at 3.38 MPa {34.5 kg/cm²} by spring (3)
inside the valve. (LS pressure PLS: 0 MPa {0 kg/cm2})

Operation
When control valve is neutral
• Pump discharge pressure PP is acting on the left end of un- 1. Unload valve
load spool (4) and LS pressure PLS is acting on the right 2. Sleeve
end.
3. Spring
• When the control valve is at neutral, LS pressures PLS is 0, 4. Spool
so only pump discharge pressures PP has any effect and
PP is set by only the load of spring (3).
PP: Pump circuit (pressure)
• As pump discharge pressure PP rises and reaches the load
of spring (3), (3.38 MPa {34.5 kg/cm²}) spool (4) is moved to PLS: LS circuit (pressure)
the right in the direction of the arrow. Pump discharge pres- T: Tank circuit (pressure)
sures PP then passed through the drill hole in sleeve (2) and
is connected to tank circuit T.

• In this way, pump discharge pressure PP is set to 3.38 MPa

{34.5 kg/cm²}

10-88 PW148-8 VEBM720100

STRUCTURE AND FUNCTION, MAINTENANCE STANDARD CLSS

2. During fine control of the valve, when the demand flow for
the actuator is within the amount discharged by the mini-
mum swash plate angle of the pump, pump discharge pres-
sure PP is set to LS pressure PLS + 3.38 MPa
{34.5 kg/cm²}.
When the differential pressure between the pump discharge
pressure PP and LS pressure PLS reaches the load of
spring (3) (3.38 MPa {34.5 kg/cm²}), the unload valve opens,
so LS differential pressure PLS becomes 3.38 MPa {34.5
kg/cm²}.

Operation
Fine control of control valve
• When fine control is carried out on the control valve, LS 1. Unload valve
pressure PLS is generated and acts on the right end of the 2. Sleeve
spool (4).
3. Spring
• When this happens, the area of the opening of the control 4. Spool
valve spool is small, so there is a big difference between LS
pressure PLS and pump discharge pressure PP.
PP: Pump circuit (pressure)
• When the differential pressure between pump discharge
pressure PP and LS pressure PLS reaches the load of the PLS: LS circuit (pressure)
spring (3) (3.38 MPa {34.5 kg/cm²}), spool (4) is moved to T: Tank circuit (pressure)
the right in the direction of the arrow, and pump circuit PP
and tank circuit T are connected.

• In other words, pump discharge pressure PP is set to a

pressure equal to the spring force (3.38 MPa {34.5 kg/cm²})
+ LS pressure PLS, and LS differential pressure PLS be-
comes 3.38 MPa {34.5 kg/cm²}.

PW148-8 VEBM720100 10-89

CLSS STRUCTURE AND FUNCTION, MAINTENANCE STANDARD

3. When the control valve is being operated and the demand

flow for the actuator becomes greater than the pump dis-
charge from the minimum swash plate angle, the flow of the
oil out to tank circuit T is cut off and all of pump discharge
amount Q flows to the actuator circuit.

Operation
Control valve operated
• When fine control valve is operated to a bigger stroke, LS 1. Unload valve
pressure PLS is generated and acts on the right end of the 2. Sleeve
spool (4). When this happens, the area of the opening of the
control valve spool is large, so the difference between LS 3. Spring
pressure PLS and pump discharge pressure PP is small. 4. Spool

• For this reason, the differential pressure between pump dis-

charge pressure PP and LS pressure PLS does not reach PP: Pump circuit (pressure)
the load of spring (3) (2.45MPa {25kg/cm²}), so spool (4) is
PLS: LS circuit (pressure)
pushed to the left by spring (3).
T: Tank circuit (pressure)
• As a result, pump circuit PP and tank circuit T are shut off,
and all the pump discharge amount Q flows to the actuator
circuit.

10-90 PW148-8 VEBM720100

STRUCTURE AND FUNCTION, MAINTENANCE STANDARD
2. Introduction of LS pressure
Work equipment valve
Function
• The LS pressure is the actuator load pressure at
the outlet port end of the control valve.
• Actually, pump discharge pressure PP is re-
duced by reducing valve (3) of the pressure com-
pensation valve to the same pressure as
actuator circuit pressure A and sent to LS circuit
PLS.
• In the travel valve, actuator circuit pressure A is
directly introduced to LS circuit PLS.
Operation
• When spool (1) is operated, pump discharge
pressure PP flows from flow control valve (2)
through notch (a) in the spool and bridge pas-
sage (b) to actuator circuit A.
PW148-8 VEBM720100
CLSS
• At the same time, reducing valve (3) also moves
to the right, so pump discharge pressure PP is
reduced by the pressure loss at notch (c). It goes
to LS circuit PLS, and then goes to spring cham-
ber PLSS.
• When this happens, LS circuit PLS is connected
to tank circuit T from LS bypass plug (4) (See the
section on the LS bypass plug).
• The areas at both ends of reducing valve (3) are
the same (SA = SLS), and actuator circuit pres-
sure PA acts on the SA end. The reduced pump
discharge pressure PP acts on SLS at the other
end.
• As a result, reducing valve (3) is balanced at a
position where actuator circuit pressure PA and
the pressure of spring chamber PLSS are the
same. Pump discharge pressure PP reduced at
notch (c) becomes actuator pressure A and is in-
troduced into LS circuit PLS.
10-91
CLSS STRUCTURE AND FUNCTION, MAINTENANCE STANDARD

3. LS bypass plug

Outline
1. This releases the residual pressure of LS pressure PLS.

2. It makes the speed of the rise in pressure of LS pressure

PLS more gentle. In addition, with this discarded throttled
flow, it creates a pressure loss in the throttled flow of the
spool or shuttle valve, and increases the stability by lowering
the effective LS differential pressure.

Operation
• The pressurized oil for the LS circuit PLS passes from the
clearance filter a (formed by the clearance between LS plug
(1) and the valve body) through orifice b and flows to the
tank circuit T.

1. LS bypass plug

PLS: LS circuit (pressure)

T: Tank circuit (pressure)

10-92 PW148-8 VEBM720100

STRUCTURE AND FUNCTION, MAINTENANCE STANDARD CLSS

Blank for technical reason

PW148-8 VEBM720100 10-93

CLSS STRUCTURE AND FUNCTION, MAINTENANCE STANDARD

4. Pressure compensation valve

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

10-94 PW148-8 VEBM720100

STRUCTURE AND FUNCTION, MAINTENANCE STANDARD CLSS

Operation
• When the load pressure of another actuator side (the upper
side) rises during a compound operation, the flow in the ac-
tuator circuit Aa on this side (the lower side) is apt to in-
crease.

• In this case, the LS pressure PLS of another actuator is ap-

plied to the spring chamber PLS1 and pushes the pressure
reducing valve (1) and the flow control valve (2) to the left
side.

• The flow control valve (2) throttles the opening area be-
tween the pump circuit PP and the spool upstream PPA and
causes a pressure loss between PP and PPA.

• The flow control valve (2) and the pressure reducing valve
(1) balance each other where the pressure difference be-
tween PA applied to the both end faces of the pressure re-
ducing valve (1) and PLS becomes the same as the
pressure loss between PP before and after the flow control
valve and PPA.

• So, the pressure differences between the upstream pres-

sures PPA and the downstream pressures PA of the both
spools under compound operation become the same, and
the pump flow is distributed in proportion to the opening ar-
ea of each spool notch a.

PW148-8 VEBM720100 10-95

CLSS STRUCTURE AND FUNCTION, MAINTENANCE STANDARD

5. Area ratio of pressure compensation

valve

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

S1: Area of the flow control valve (2) - area of the piston (3)
S2: Area of the pressure reducing valve (1) - area of the piston
(3)

Area ratio (S1:S2) and compensation characteristics

• When the ratio is 1.00:

The expression [Pump (discharge) pressure PP – Spool
notch upstream pressure PPB] [LS circuit pressure PLS –
Actuator circuit pressure PA (= A)] can be held, and the flow
is distributed as per the spool opening area ratio.

• When the ratio is more than 1.00:

The expression PP – PPB > PLS – PA (= A) can be held,
and the flow is distributed less than the spool opening area
ratio.

• When the ratio is less than 1.00: :

The expression PP – PPB < PLS – PA (= A) can be held,
and the flow is distributed more than the spool opening area
ratio.

10-96 PW148-8 VEBM720100

STRUCTURE AND FUNCTION, MAINTENANCE STANDARD CLSS

Blank for technical reason

PW148-8 VEBM720100 10-97

CLSS STRUCTURE AND FUNCTION, MAINTENANCE STANDARD

6. Boom regeneration circuit

1. Boom lower and own weight fall

Function
• When the boom is lowered and falls due to its own weight
because the bottom pressure A in the cylinder (1) is higher
than the head pressure B, this circuit brings the return flow
on the bottom side to the head side to increase the cylinder
speed.

Operation
• When the boom is lowered and falls due to its own weight,
the bottom side pressure A in the boom cylinder (1) will rise
above the head side pressure B.

• At the time, part of the return flow on the bottom side passes
through the regeneration passage a of the boom spool (2),
pushes the check valve (3) to open it and flows to the head
side.

• This increases the boom lower speed.

10-98 PW148-8 VEBM720100

STRUCTURE AND FUNCTION, MAINTENANCE STANDARD CLSS

2. Boom lower load process

Function
• When the head pressure B of the cylinder (1) is higher than
the bottom pressure A while the boom is lowered and the
boom is in the load process, the check valve (3) will be
closed, and the circuits on the head side and the bottom
side will be interrupted.

Operation
• When the boom is lowered and is in the load process, the
head side pressure B of the boom cylinder (1) rises above
the bottom side pressure A

• At the time, the head side pressure B and the spring (4)
close the check valve (3), and the circuits on the head side
and the bottom side are interrupted.

PW148-8 VEBM720100 10-99

CLSS STRUCTURE AND FUNCTION, MAINTENANCE STANDARD

7. Arm regeneration circuit

1. Arm lower and own weight fall

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

Operation
• When the arm falls for digging due to its own weight, the
head side pressure A in the arm cylinder (1) will rise above 1. Arm cylinder
the bottom side pressure B.
2. Arm spool
• At the time, part of the return flow on the head side passes 3. Check valve
through the regeneration passage of the arm spool (2),
pushes the check valve (3) to open it and flows to the bot-
tom side. A: Head circuit (pressure)

• This increases the arm digging speed. B: Bottom circuit (pressure)

PP: Pump circuit (pressure)

10-100 PW148-8 VEBM720100

STRUCTURE AND FUNCTION, MAINTENANCE STANDARD CLSS

2. Arm digging process

Function
• When the bottom pressure B of the cylinder (1) rises above
the head pressure A and the arm enters the digging proc-
ess, the check valve (3) will be closed and the circuits on the
head side and the bottom side will be interrupted.

Operation
• When the arm is in the digging process, the bottom side
pressure B of the arm cylinder (1) will rise, close the check 1. Arm cylinder
valve (3) and interrupt the circuits on the head side and the
bottom side. 2. Arm spool
3. Check valve

A: Head circuit (pressure)

B: Bottom circuit (pressure)
PP: Pump circuit (pressure)

PW148-8 VEBM720100 10-101

CLSS STRUCTURE AND FUNCTION, MAINTENANCE STANDARD

8. Swing bleeding valve

Function
• When the machine swings, the bleeding valve installed to
the pressure reducing valve works so that the LS pressure
rises gradually and the machine swings smoothly.

PA

a 1

b PLS

PP

Operation (In fine control operation)

• The pressure reducing valve moves to the right and notch a
connects to the LS circuit. As a result, pump circuit PP, 1. Compensation valve piston
bleed-off circuit, and Ls circuit are connected through piston
(1). 2. Spool (Bleeding valve)

• Bleeding spool (2) moves to the left in proportion as swing

PPC pressure PA rises. In the fine control area, notch b
chokes the bleed-off circuit and determines the intermediate
pressure before the lowered pressure is applied to pump
discharge pressure PP and Ls pressure PLS.

• Accordingly, the intermediate pressure is set lower than

pump discharge pressure PP and raised as bleeding spool
(2) moves. As a result, Ls pressure PLS rises gradually.

• When the lever is in neutral or operated fully, the bleed-off

circuit is closed.

10-102 PW148-8 VEBM720100

STRUCTURE AND FUNCTION, MAINTENANCE STANDARD CLSS

9. Variable type pressure compensation

valve (for service)

Function
• It is possible to adjust the division of the oil flow to the serv-
ice valve (for attachment) when operated together with the
main control valve (boom RAISE, etc.). (Variable in propor-
tion to surface area)

• The force of spring (4) can be adjusted with screw (5).

Simultaneous operation with work equipment un-

der heavy load (boom RAISE, etc.)
• Pump pressure PP and LS pressure PLS are determined by
other work equipment. 1. Flow control valve
• When the pressure in chamber a reaches the set pressure 2. Reducing valve
of spring (4), poppet (3) opens and the pressure in chamber 3. Poppet
a is maintained at a pressure lower than the pump pressure
at throttle b. 4. Spring
5. Screw
• As a result, force F, which is trying to close flow control (1) of
the reducing valve (2), becomes small. 6. Locknut
7. Plastic cap
In other words, it is set to a condition where the area ratio
becomes smaller, so flow control valve e (1) moves to the
right and the flow of oil from the pump to the service valve
increases.

PW148-8 VEBM720100 10-103

CLSS STRUCTURE AND FUNCTION, MAINTENANCE STANDARD

10. LS select valve

Function
• When the swing + boom RAISE are operated together, this
valve ensures the pump flow to drive the swing, and pre-
vents the swing LS pressure from flowing into the LS circuit
PLS. In this way, it prevents the boom RAISE speed from
dropping

Operation

1. Normal operation
• Normally, except when boom RAISE is operated, the pilot
pressure does not act on pilot port BP.

• In this condition, pump pressure PP pushes valve (1) open

and goes to reducing valve (4) of the swing valve. When the
swing is operated, LS pressure PLS is generated in accord-
ance with the load pressure and flows to the pump LS valve.

10-104 PW148-8 VEBM720100

STRUCTURE AND FUNCTION, MAINTENANCE STANDARD Centre swivel joint

Centre swivel joint

F 1 3 5 7 9 11 13 B
A
4 4
14
2
A 11
12
8
6 6

A D C
E 2 4 6 8 10 12 14

1. Steering left 11. Blanked off

2. Drain 12. Transmission large clutch
3. Motor volume pilot 13. Suspension lock
4. Travel motor A 14. Transmission small clutch
5. Undercarriage attachment cylinder head A. Slip ring assembly
6. Travel motor B B. Cover
7. Undercarriage attachment cylinder bottom C. Housing
8. Service brake-1 D. Sealing ring
9. Service brake-2 E. O-ring/backup ring seal
10. Steering right F. Rotor

Unit:mm

Criteria
No. Check Item Remedy
Standard Size Standard clearance Repair limit

-0.02
1 Internal shaft
110-0.06 Max.=0.21
>=0.26 Replace
0.15
Min.=0.12
2 External rotor
110 0.10

PW148-8 VEBM720100 10-105

Travel PPC pedal STRUCTURE AND FUNCTION, MAINTENANCE STANDARD

Travel PPC pedal

1 2

3 P

1. Pedal A. To forward-reverse solenoid

2. Pedal Adjuster P. To travel neutral solenoid
3. Valve T. To tank

FORWARD PRESSURE SWITCH

PRESSURE SENSOR

TRAVEL
TRAVEL TRAVEL EPC CONTROL VALVE
NEUTRAL F - R SOLENOID
PEDAL SOLENOID TRAVEL SPOOL
SOLENOID

THE PRESSURE SENSOR IS A

PROPORTIONAL DEVICE WHICH
FEEDS TRAVEL PPC PRESSURE REVERSE PRESSURE SWITCH
DATA TO THE CONTROLLER

10-106 PW148-8 VEBM720100

STRUCTURE AND FUNCTION, MAINTENANCE STANDARD Travel PPC pedal

TRAVEL
EPC SOL

TRAVEL FORWARD
PRESSURE SENSOR
MONITOR
TRAVEL PPC
PRESSURE
SENSOR
PARK HI F-N-R
BRAKE LO SWITCH
SWITCH CREEP

F-R
SOL
T.R.P.S
PUMP
PRESSURE
GOVERNOR SENSOR
CONTROLLER TRAVEL N
MOTOR SOL
STEERING
PUMP

TRAVEL
CONTROL
VALVE

CREEP
SOL

MAIN
PUMP

PARK BRAKE
SOL

ACCUMULATOR

T/M CLUTCH
SOL UPPER

LOWER

TRAVEL
MOTOR

SMALL CLUTCH
SPEED PICKUP
(ELECTRONIC)
LARGE CLUTCH POWER SHIFT
TRANSMISSION

T.R.P.S - Travel Reverse Pressure Sensor

PW148-8 VEBM720100 10-107

Work equipment – Swing PPC valve STRUCTURE AND FUNCTION, MAINTENANCE STANDARD

Work equipment – Swing PPC valve

P. From main pump

T. To tank

P1. Left: Arm DUMP / Right: Boom / Stabilizer LOWER

P2. Left: Arm DIG / Right: Boom / Stabilizer RAISE
P3. Left: Swing LEFT / Right: Bucket DIG
P4. Left: Swing RIGHT / Right: Bucket DUMP

10-108 PW148-8 VEBM720100

STRUCTURE AND FUNCTION, MAINTENANCE STANDARD Work equipment – Swing PPC valve

1. Spool 7. Joint
2. Metering spring 8. Plate
3. Centering spring 9. Retainer
4. Piston 10. Body
5. Disc 11. Filter
6. Nut (For connection of lever)

Unit:mm

No. Check item Criteria Remedy

Standard size Repair limit

Free length x Installed Installed Installed
Centering spring Free length
12 Outside diameter length load load
(For P3 and P4)
9.81 N 7.85 N If damaged or
38.7 x 15.5 34 —
{1.0 kg} {0.8 kg} deformed, replace
Centering spring 17.7 N 14.1 N spring
13 42.5 x 15.5 34 —
(For P3 and P4) {1.8 kg} {1.44 kg}
16.7 N 13.3 N
14 Metering spring 26.5 x 8.2 24.9 —
{1.7 kg} {1.36 kg}

PW148-8 VEBM720100 10-109

Work equipment – Swing PPC valve STRUCTURE AND FUNCTION, MAINTENANCE STANDARD

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

2. During fine control (neutral → fine control)

When piston (4) starts to be pushed by disc (5), retainer (9)
is pushed; spool (1) is also pushed by metering spring (2),
and moves down.

When this happens, fine control hole f is shut off from drain
chamber D, and at almost the same time, it is connected to
pump pressure chamber PP, so pilot pressure oil from the
control circuit passes through fine control hole f and goes
from port P1 to port A.

When the pressure at port P1 becomes higher, spool (1) is

pushed back and fine control hole f is shut off from pump
pressure chamber PP. At almost the same time, it is con-
nected to drain chamber D to release the pressure at port
P1. When this happens, spool (1) moves up or down so that
the force of metering spring (2) is balanced with the pres-
sure at port P1. The relationship in the position of spool (1)
and body (10) (fine control hole f is at a point midway be-
tween drain hole D and pump pressure chamber PP) does
not change until retainer (9) contacts spool (1).

Therefore, metering spring (2) is compressed proportionally

to the amount of movement of the control lever, so the pres- A

sure at port P1 also rises in proportion to the travel of the

control lever. In this way, the control valve spool moves to a
position where the pressure in chamber A (the same as the
pressure at port P1) and the force of the control valve spool
return spring are balanced. (Fig. 2)

10-110 PW148-8 VEBM720100

STRUCTURE AND FUNCTION, MAINTENANCE STANDARD Work equipment – Swing PPC valve

3. During fine control (when control lever is returned)

When disc (5) starts to be returned, spool (1) is pushed up
by the force of centering spring (3) and the pressure at port
P1.

When this happens, fine control hole f is connected to drain

chamber D and the pressure oil at port P1 is released.

If the pressure at port P1 drops too far, spool (1) is pushed

down by metering spring (2), and fine control hole f is shut
off from drain chamber D. At almost the same time, it is con-
nected to pump pressure chamber PP, and the pump pres-
sure is supplied until the pressure at port P1 recovers to a
pressure that corresponds to the lever position.

When the spool of the control valve returns, oil in drain

chamber D flows in from fine control hole f in the valve on
the side that is not working. The oil passes through port P2
and enters chamber B to fill the chamber with oil. (Fig. 3)

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

The oil returning from chamber B passes from port P2

through fine control hole f and flows to drain chamber D.
(Fig. 4)

PW148-8 VEBM720100 10-111

Solenoid valve block STRUCTURE AND FUNCTION, MAINTENANCE STANDARD

Solenoid valve block

Pepc S10 PA3 PB3 S09 PS PB2 PB4 PA2 PA4 14 12 PBP PA8 PB8 Px PB A1

SV3 CP1 SV4 SV5 SV6 CP2 SV8 SV9

SV2

3
TP1
36.5 bar CV1

13 RV1

SV1

T0
SV10
SV11

SV12

T1 A A56 P4 T2 B1 S12 B B2 S13 X N P5 C TS Ps T3 T4 T5 P3 P2 P1

10-112 PW148-8 VEBM720100

STRUCTURE AND FUNCTION, MAINTENANCE STANDARD Solenoid valve block

A To travel pedal valve port A PA2 To Main valve port PA2

A1 Accumulator port PA3 To Main valve port PA3
B To brake valve port B PA4 To Main valve port PA4
B1 To R.H PPC control valve port P1 PA8 Blanked
B2 To R.H PPC control valve port P2 PB To swing motor port PB
N To brake valve port N PBP To Main valve port PBP
P1 To 2nd HCU valve port P PB2 To Main valve port PB2
P2 To 2nd boom valve port P PB3 To Main valve port PB3
P3 To L.H PPC control valve port P PB4 To Main valve port PB4
P4 To travel pedal valve port P PB8 Blanked
P5 To R.H PPC control valve port P PS Blanked
TPI Test point PX To Main valve port PX
TO To tank 3 To swivel joint port 3
T1 To travel pedal valve port T 12 To swivel joint port 12
T2 To R.H PPC control valve port T 13 To swivel joint port 13
T3 To L.H PPC control valve port T 14 To swivel joint port 14
T4 To 2nd boom valve port T
T5 To 2nd HCU valve port T
X To brake valve port X

A56 Travel pressure sensor

S09 Travel reverse pressure switch
S10 Travel forward pressure switch
S12 Boom/stabiliser down pressure switch
S13 Boom/stabiliser up pressure switch
V01 PPC lock solenoid
V02 2 stage relief solenoid
V03 Swing brake solenoid
V04 Suspension lock solenoid
V06 Travel neutral solenoid
V07 Travel creep solenoid
V08 Forward/Reverse solenoid
V09 Boom/stabiliser down solenoid
V10 Boom/stabiliser up solenoid
V11 Transmission clutch control solenoid
V13 Service EPC valve solenoid
V15 2 stage back pressure solenoid

PW148-8 VEBM720100 10-113

Solenoid valve block STRUCTURE AND FUNCTION, MAINTENANCE STANDARD

ON / OFF Solenoid valves (3 way valve)

4
3
5

This solenoid valve is fitted to the following ports:

V01 PPC lock Solenoid

V02 Power MAX. solenoid 3 5 4
V03 Swing brake solenoid
Deactivated
V04 Suspension lock solenoid
V06 Travel neutral solenoid
V07 Travel creep solenoid

P
1. Connector T
2. Plunger
3. Coil A
4. Spool
5. Spring
B

Operation

When solenoid is deactivated

• Since the signal current does not flow from the controller,
coil (3) is turned off
Accordingly, spool (4) is pressed by spring (5) against the
left side.
By this operation, the passage from P to A is closed and the
hydraulic oil from the control circuit does not flow into the ac-
tuator.
At this time, the oil from the actuator is drained through ports
A and T into the tank.

10-114 PW148-8 VEBM720100

STRUCTURE AND FUNCTION, MAINTENANCE STANDARD Solenoid valve block

When solenoid is excited

• The signal current flows from the controller to coil (3), and 3 5 4
the latter is excited.
Accordingly, spool (4) is pushed to the right side. Excited
By this operation, the hydraulic oil from the control circuit
flows through port P and spool (4) to port A then flows into
the actuator.
At this time, port T is closed and the oil does not flow into the
tank.
P
T

PW148-8 VEBM720100 10-115

Solenoid valve block STRUCTURE AND FUNCTION, MAINTENANCE STANDARD

ON / OFF Solenoid valves (4 way valve)

2 5

3 4

This solenoid valve is fitted to the following ports:

3 5 4
V08 Forward / reverse solenoid
V09 Boom / stabiliser down solenoid Deactivated

V10 Boom / stabiliser up solenoid

V14 Clamshell solenoid
V15 2 stage back pressure solenoid
P

T
1. Connector
2. Plunger
A
3. Coil
4. Spool
B
5. Spring

Operation

When solenoid is deactivated

• Since the signal current does not flow from the controller,
coil (3) is turned off
Accordingly, spool (4) is pressed by spring (5) against the
left side.
By this operation, the passage from P to A is closed and the
hydraulic oil from the control circuit does not flow into the ac-
tuator.
At this time, the oil from the actuator is drained through ports
A and T into the tank.

10-116 PW148-8 VEBM720100

STRUCTURE AND FUNCTION, MAINTENANCE STANDARD Solenoid valve block

When solenoid is excited

The signal current flows from the controller to coil (3), and the 3 5 4
latter is excited.
Accordingly, spool (4) is pushed to the right side. Excited
By this operation, the hydraulic oil from the control circuit flows
through port P and spool (4) to port A then flows into the actua-
tor.
At this time, port T is closed and the oil does not flow into the
tank.
P
T

PW148-8 VEBM720100 10-117

Solenoid valve block STRUCTURE AND FUNCTION, MAINTENANCE STANDARD

Hi/ Lo Solenoid valve (4 way valve)

This solenoid valve is fitted to the following ports:

5 4
V11 Transmission clutch control solenoid 3

Deactivated

1. Connector
2. Plunger
3. Coil
4. Spool
5. Spring P

Operation
A
When solenoid is deactivated
• Since the signal current does not flow from the controller,
coil (3) is turned off
C
Accordingly, spool (4) is pressed by spring (5) against the
left side.
By this operation, the passage from P to A is closed and the
hydraulic oil from the control circuit does not flow into the ac-
tuator.
At this time, the oil from the actuator is drained through ports
A and T into the tank.

10-118 PW148-8 VEBM720100

STRUCTURE AND FUNCTION, MAINTENANCE STANDARD Solenoid valve block

When solenoid is excited

• The signal current flows from the controller to coil (3), and
the latter is excited. 5 4
3
Accordingly, spool (4) is pushed to the right side.
By this operation, the hydraulic oil from the control circuit
Excited
flows through port P and spool (4) to port A then flows into
the actuator.
At this time, port T is closed and the oil does not flow into the
tank.

4C

PW148-8 VEBM720100 10-119

Solenoid valve block STRUCTURE AND FUNCTION, MAINTENANCE STANDARD

Attachment PPC valve

A
A

7
7

1 2 3 4 5 6
A

A. Port C (to service solenoid)

B. Port T (to tank)
C. Port P (from PPC pressure reducing valve)

1. Body
2. Spool
3. Spring
4. Push pin
5. Coil
6. Plunger
7. Connector

10-120 PW148-8 VEBM720100

STRUCTURE AND FUNCTION, MAINTENANCE STANDARD Solenoid valve block

Function
• The EPC valve consists of the proportional solenoid portion
and the hydraulic valve portion.

• When it receivers signal current i from the pump controller, it

generates EPC output pressure P in proportion to the size of
the signal, and outputs it to the control valve via the service
solenoid.

Operation
1. When signal current is 0 (coil deactivated) Service
• There is no signal current flowing from the controller to coil Solenoid
(5), coil (5) is deactivated.
2
3 5
• For this reason, spool (2) is pulled to the right in the direction C
of the arrow by spring (3).

• As a result, port P closes and the pressurised oil from the

pressure regulating valve does not flow to the Att pedal.

T P
PPC pressure
reducing valve

2. When signal current is very small (coil excited)

• When a very small signal current flows to coil (5), coil (5) is Service
Solenoid
excited, and a propulsion force is generated, which pushes
plunger (6) to the left in the direction of the arrow.
2 3 4 5 6
• Push pin (4) pushes spool (2) to the left in the direction of C
the arrow and pressurised oil flows from port P to port C.

• When the pressure at port C rises and the load of spring (3)
+ the force acting on surface a of spool (2) becomes greater
than the proportion force of plunger (6), spool (2) is pushed
to the right. The circuit between port P and port C is shut off, T P a
and at the same time, port C and port T are connected.
PPC pressure
reducing valve
• As a result, spool (2) is moved to the left or right until the
propulsion force of plunger (6) is balanced with the load of
spring (3) + pressure of port C.

• Therefore, the circuit pressure between the EPC valve and

the Att pedal is controlled in proportion to the size of the sig-
nal current.

PW148-8 VEBM720100 10-121

Solenoid valve block STRUCTURE AND FUNCTION, MAINTENANCE STANDARD

3. When signal current is maximum (coil excited)

Service
• When the signal current flows to coil (5), coil (5) is excited.
Solenoid
• When this happens, the signal current is at its maximum, so
the propulsion force of plunger (6) is also at its maximum. 2 4 5 6

• For this reason spool (2) is pushed to the left in the direction
of the arrow by push pin (4).

• As a result, the maximum flow of pressurised oil from port P

flows at its maximum to port C, and the circuit pressure be-
tween EPC valve and Att pedal becomes the maximum.
PPC pressure
• At the same time, port T closes and stops the oil from flow- reducing valve
ing to the tank.

10-122 PW148-8 VEBM720100

STRUCTURE AND FUNCTION, MAINTENANCE STANDARD Solenoid valve block

Blank for technical reason

PW148-8 VEBM720100 10-123

Boom safety valve STRUCTURE AND FUNCTION, MAINTENANCE STANDARD

Boom safety valve

High pressure from

1 2 control valve (V port)

Pilot signal
(Pi port)

Overload caution To tank (T port)

signal

To cylinder port
(Cy port)

10-124 PW148-8 VEBM720100

STRUCTURE AND FUNCTION, MAINTENANCE STANDARD Boom safety valve

Operation
Boom Raise
V port
• During boom raising the pilot signal from wrist control oper- 2
ates control valve spool to direct high pressure oil to port V
of hose burst valve.

• This pressure lifts check valve (4) from seat and high pres-
sure oil flows in the bottom of the cylinder raising the boom. To tank

Boom control
Cylinder valve

Control lever

PPC pressure
reducing valve

Boom Lower 2
• During boom lowering the pilot signal reverses the flow
through the control valve spool. High pressure oil flows to
T port
the head side of the cylinder. Oil in the bottom side of the
cylinder flows through the port Cy of the valve. The pilot sig-
nal also opens the spool (2) of the hose burst valve and al- To tank
lows oil to flow back to tank.

Cy port

PPC pressure
reducing valve

When hose burst occurs

V port
(operation to lower safety)
• The sudden loss of pressure at port V will cause check valve
(4) to re-seat and so the valve is locked.

To tank

Boom control
Cylinder valve

Control lever

PPC pressure
reducing valve

PW148-8 VEBM720100 10-125

Hydraulic cylinder STRUCTURE AND FUNCTION, MAINTENANCE STANDARD

Hydraulic cylinder

Boom cylinder

172 ± 24.5 Nm
(17.5 ± 2.5 kgm)

Stroke - 1488 ~ 2390 (1PB)

1500 ~ 2402 (2PB)

Arm cylinder

Stroke - 1702 ~ 2861

Bucket cylinder

Stroke - 1378 ~ 2263

10-126 PW148-8 VEBM720100

STRUCTURE AND FUNCTION, MAINTENANCE STANDARD Hydraulic cylinder

Adjust cylinder

373 +/- 54 Nm
(38.0 +/- 5.5 kgm) 294 +/- 29.4 Nm
(29.9 +/- 3 kgm)
2 1 3

58.9 ~ 73.6 Nm
(5.9 ~ 7.4 kgm)
Stroke - 1125 ~ 1680

Unit:mm

No. Check item Criteria Remedy

Cylinder Standard Tolerance Standard

Repair limit
size Shaft Hole clearance

2 piece boom -0.036 +0.222

70 0.083 ~ 0.312 0.445
-0.090 +0.047
Clearance Arm -0.036 +0.222
between piston 75 0.083 ~ 0.312 0.445 Replace
1 -0.090 +0.047
rod and bush- bushing
ing Bucket -0.030 +0.259
65 0.093 ~ 0.335 0.445
-0.076 +0.063
Adjust -0.036 +0.257
75 0.083 ~ 0.347 0.445
-0.090 +0.047
1 Piece boom -0.036 +0.222
70 0.083 ~ 0.312 0.445
-0.090 +0.047
2 piece boom -0.030 +0.211
80 0.154 ~ 0.271 1.0
-0.060 +0.124
Arm -0.030 +0.211
70 0.154 ~ 0.287 1.0
Clearance -0.076 +0.124
between piston Bucket -0.030 +0.198
2 65 0.154 ~ 0.274 1.0
rod support pin -0.076 +0.124
and bushing
Adjust -0.036 +0.457
80 0.406 ~ 0.547 1.0
-0.090 +0.370
1 Piece boom -0.030 +0.211
70 0.154 ~ 0.271 1.0 Replace
-0.060 +0.124
pin or
2 piece boom -0.030 +0.190 bushing
70 0.100 ~ 0.250 1.0
-0.060 +0.070
Arm -0.030 +0.211
70 0.154 ~ 0.287 1.0
Clearance -0.076 +0.124
between cylin-
Bucket -0.030 +0.198
3 der bottom 65 0.154 ~ 0.258 1.0
-0.060 +0.124
support pin
and bushing Adjust -0.036 +0.457
80 0.406 ~ 0.547 1.0
-0.090 +0.370
1 Piece boom- -0.030 +0.190
70 0.100 ~ 0.250 1.0
-0.060 +0.070

PW148-8 VEBM720100 10-127

Outrigger cylinder STRUCTURE AND FUNCTION, MAINTENANCE STANDARD

Outrigger cylinder

2
10

I
25

3
23 24
4
27 18 26
22

20 21

18 5
19

17 6

16 17
13

14 15
H

28 29 13 7

12 8

11
9
10

10-128 PW148-8 VEBM720100

STRUCTURE AND FUNCTION, MAINTENANCE STANDARD Outrigger cylinder

1. Circlip 16. Cut back-up ring

2. Grease nipple 17. O-ring
3. Piston wear-ring 18. O-ring
4. Piston 19. Cut back-up ring
5. Piston rod 20. Back-up ring
6. Cylinder 21. O-ring
7. Guide 22. Back-up ring
8. O-ring 23. Turcon-Glyd-ring
9. Grub screw 24. O-ring
10. Spherical plain bearing 25. Self locking groove nut
11. Wiper 26. Cut back-up ring
12. O-ring 27. Wiper
13. Rod wear-ring 28. Pilot operated double check valve cartridge
14. O-ring 29. O-ring
15. Back-up ring

Function
Guide (7) guides the piston rod (5) which is sealed by o-ring
(12). O-ring (12) is protected against dirt by wiper (11).
When oil flows through port I to the piston side of the cylinder the
piston rod (5) extends out of the cylinder (6).
The piston is guided in the cylinder (6) by the piston guide ring
(7). It is sealed against the cylinder wall by piston wear-ring (3),
Turcon-glyd-ring (23), o-ring (24) and backup ring (22). The
guide (7) is sealed against the cylinder (6) by O-ring (14) and
backup ring (15).
When oil flows through port H to the rod side of the cylinder the
piston rod retracts.

Imprtant
Depressurising the cylinder
The check valve built into the cylinder prevents any cylinder
movement due to oil leakage within the control block or sudden
loss of hydraulic pressure due to a hose burst.
The built in check valve also holds hydraulic pressure within the
cylinder when the hydraulic hoses are removed from the cylin-
der.

Depressurise the cylinder before opening

To depressurise the cylinder, loosen the plug (28) carefully and
wait until the pressure has been released.
To be absolutely sure the plug can be completely removed.

PW148-8 VEBM720100 10-129

Dozer cylinder STRUCTURE AND FUNCTION, MAINTENANCE STANDARD

Dozer cylinder

Position of the split

plane of the outer ring
11
12
Spherical plain
bearing both sides Caulk spherical plain bearing
four times on both sides
Left handed thead

20

Port piston Port rod 19 1

side M20x1.5 side M20x1.5
18 2
3
4
24 23 21 22 21 22 21 5

17

16

25

26
6
7

H 8
9

32 15 6
28 31 30 29 28 27
10
14 Caulk spherical plain bearing
four times on both sides
13

12

11

Position of the split

plane of the outer ring

10-130 PW148-8 VEBM720100

STRUCTURE AND FUNCTION, MAINTENANCE STANDARD Dozer cylinder

1. O-ring 17. Cylinder

2. Turcon-glyd-ring 18. Piston wear-ring
3. Backup ring 19. Piston
4. O-ring 20. Self locking groove nut
5. Backup ring 21. O-ring
6. Rod wear-ring 22. Backup ring
7. Guide 23. Valve seat
8. O-ring 24. Throttle bolt
9. Backup ring 25. Valve seat
10. O-ring 26. Control spool
11. Spherical plain bearing 27. Screw plug
12 Grease nipple 28. O-ring
13. Wiper 29. Valve poppet
14. U-ring 30. Pressure spring
15. Grub screw 31. Pressure spring
16. Piston rod 32. Screw plug

Function
Guide (7) guides the piston rod (16) which is sealed by u-ring
(14). U-ring (14) is protected against dirt by wiper (13).
When oil flows through port I to the piston side of the cylinder the
piston rod (16) extends out of the cylinder (17).
The piston is guided in the cylinder (17) by the piston guide ring
(7). It is sealed against the cylinder wall by piston wear-ring (18),
Turcon glyd-ring (2), o-ring (1) and backup ring (3). The guide
(7) is sealed against the cylinder (17) by o-ring (8) and backup
ring (9).
When oil flows through port H to the rod side of the cylinder the
piston rod retracts.

Important
Depressurising the cylinder
The check valve built into the cylinder prevents any cylinder
movement due to oil leakage within the control block or sudden
loss of hydraulic pressure due to a hose burst.
The built in check valve also holds hydraulic pressure within the
cylinder when the hydraulic hoses are removed from the cylin-
der.

Depressurise the cylinder before opening

To depressurise the cylinder, loosen the plug (32) carefully using
an allen key and wait until the pressure has been released.
To be absolutely sure the plug can be completely removed.

PW148-8 VEBM720100 10-131

Work equipment STRUCTURE AND FUNCTION, MAINTENANCE STANDARD

Work equipment

D
L E

M G

J
K
H I

10-132 PW148-8 VEBM720100

STRUCTURE AND FUNCTION, MAINTENANCE STANDARD Work equipment

Work equipment

Unit: mm

No. Check item Criteria Remedy

Standard Tolerance Standard Clearance

Clearance between connecting pin size clearance limit
Shaft Hole
1 and bushing of revolving frame and
boom -0.030 +0.074
70 0.014 ~ 0.044 1.0
-0.060 -0.000

Clearance between connecting pin -0.030 +0.1

2 70 0 ~ 0.07 1.0
and bushing of boom and arm -0.100 -0.0

Clearance between connecting pin -0.030 +0.189 Replace

3 60 0.059 ~ 0.159 1.0
and bushing of arm and link -0.080 +0.139

Clearance between connecting pin -0.030 +0.216

4 60 0.102 ~ 0.186 1.0
and bushing of arm and bucket -0.080 +0.182

Clearance between connecting pin -0.030 +0.186

5 60 0.056 ~ 0.156 1.0
and bushing of link and bucket -0.080 +0.136

Clearance between connecting pin -0.030 +0.184

6 60 0.054 ~ 0.154 1.0
and bushing of link and link -0.080 +0.134

PW148-8 VEBM720100 10-133

Work equipment STRUCTURE AND FUNCTION, MAINTENANCE STANDARD

1. Dimension of arm

Unit: mm
PW148-8 Arm Size (M)
Dimension
2.1 2.5 3.0

1 70+0.1
-0

2 80 ±1.2
3 226 +0.2
-0.7

4 ∅ 85
5 293.9 ±2.0 275.7 ±2.0 284.3 ±2.0
6 199.7 ±1.0 199.7 ±1.0 230.3 ±1.0
7 635.0 ±0.5 635.0 ±0.5 635.8 ±1.0
8 2,089.8 2,492.2 2,991.1
9 2,099.9 ±1.5 2,100.0 ±1.5 2,098.9 ±1.5
10 290 ±0.5
11 493 ±0.2
12 422 ±0.2
13 1,382
14 ∅ 60

15 0
259 -1.3
16 ∅ 60

Arm as individual part 0

226-0.5
17
When pressfitting bushing 264
Min. 1,378
18
Max. 2,263

10-134 PW148-8 VEBM720100

STRUCTURE AND FUNCTION, MAINTENANCE STANDARD Work equipment

Blank for technical reason

PW148-8 VEBM720100 10-135

Work equipment STRUCTURE AND FUNCTION, MAINTENANCE STANDARD

2. Dimension of bucket

10-136 PW148-8 VEBM720100

STRUCTURE AND FUNCTION, MAINTENANCE STANDARD Work equipment

Model
PW148-8
No.

1 373

2 38

3 95.80

4 374.9

5 1,197

6 222

7 ∅ 60

8 260

9 50

10 85

11 380

12 ∅ 16

13 ∅ 110

14 101.5

15 138

16 85

17 85

PW148-8 VEBM720100 10-137

Air conditioner STRUCTURE AND FUNCTION, MAINTENANCE STANDARD

Air conditioner

Air conditioner piping

1. Hot water pickup piping A. Fresh air

2. Air conditioner compressor B. Recirculated air
3. Refrigerant piping C. Hot air/cold air
4. Condenser
5. Receiver tank
6. Hot water return piping
7. Air conditioner unit
8. Duct

10-138 PW148-8 VEBM720100

STRUCTURE AND FUNCTION, MAINTENANCE STANDARD Electrical wiring diagramm

Electrical wiring diagramm

Please refer to section 90.

PW148-8 VEBM720100 10-139

Electrical system STRUCTURE AND FUNCTION, MAINTENANCE STANDARD

Electrical system

Engine control

1. Operation of System

Starting engine
• When the starting switch is turned to the START position,
the starting motor. Then, the starting motor turns to start the
engine.

When it happens, the engine controller checks the signal

voltage from the fuel control dial and sets the engine speed
to the speed set by the fuel control dial.

Engine speed control

• The fuel control dial sends a signal voltage corresponding to
the rotation angle to the engine

The engine controller sends a driving signal to the supply

pump depending on the signal voltage to control the fuel in-
jection pump and eventually controls the engine speed.

Stopping engine
• When detecting that the starting switch is set to the STOP
position, the engine controller cuts the signal of the supply
pump drive solenoid to stop the engine.

10-140 PW148-8 VEBM720100

STRUCTURE AND FUNCTION, MAINTENANCE STANDARD Electrical system

2. Component

Fuel control dial

1. Knob
2. Dial
3. Spring
4. Ball
5. Potentiometer
6. Connector

Function
• The fuel control dial is installed near the monitor panel, and
a potentiometer (5) is installed under the knob. The potenti-
ometer shaft is turned by turning the knob (1).

• As the potentiometer shaft is turned, the resistance of the

variable resistor in the potentiometer changes and a throttle
signal is sent to the engine controller.
The hatched area in the graph (shown at right) is the abnor-
mality detection area.

PW148-8 VEBM720100 10-141

Electrical system STRUCTURE AND FUNCTION, MAINTENANCE STANDARD

Engine controller

CN-CE01
(*: Never connect to NC as malfunctions and errors occur)

Pin No. Signal name Title panel Pin No. Signal name Title panel
1 NC (*) 18 NC (*)
2 IMA PWM output 19 NC (*)
3 Air pressure sensor 20 NC (*)
4 NC (*) 21 NC (*)
5 NC (*) 22 NC (*)
6 CAN (-) 23 Intake manifold temperature
7 NC (*) 24 NC (*)
8 CAN (+) 25 Accumulator pressure signal
9 NC (*) 26 Position sensor signal B
10 NC (*) 27 Speed sensor signal
11 NC (*) 28 NC (*)
12 NC (*) 29 NC (*)
13 NC (*) 30 NC (*)
14 Water-in-fuel input 31 NC (*)
15 Coolant temperature input 32 IMA return
16 5V electric power supply for sensor 33 Air pressure sensor spply
17 Oil pressure switch 34 NC (*)

10-142 PW148-8 VEBM720100

STRUCTURE AND FUNCTION, MAINTENANCE STANDARD Electrical system

CN-CE01 (*: Never connect to NC as malfunctions Input/

Pin No. Signal name
and errors occur) Output
14 NC (*)
Title
Pin No. Signal name 15 NC (*)
panel
35 NC (*) 16 NC (*)

36 NC (*) 17 NC (*)
18 NC (*)
37 5V electric power supply for sensor
38 Air pressure sensor return 19 NC (*)

39 NC (*) 20 NC (*)
21 NC (*)
40 NC (*)
41 NC (*) 22 Fuel control dial (+5V)

42 NC (*) 23 Fuel control dial (-)

24 NC (*)
43 NC (*)
44 Boost pressure sensor 25 NC (*)

45 Injector #1 (+) 26 NC (*)

27 NC (*)
46 Injector #3 (+)
47 Position sensor return 28 NC (*)

48 Speed sensor return 29 NC (*)

30 NC (*)
49 NC (*)
50 NC (*) 31 NC (*)

51 NC (*) 32 NC (*)
33 GND
52 Injector #4 (-)
53 Injector #1 (-) 34 NC (*)

54 35 NC (*)
36 NC (*)
55 Injector #4 (+)
56 37 NC (*)

57 Injector #2 (+) 38 NC (*)

39 Key switch (ACC)
58
59 Injector #2 (-) 40 Heater relay drive

60 Injector #3 (-) 41 NC (*)

42 Heater relay return
43 NC (*)
44 NC (*)
CN-CE02 (*: Never connect to NC as malfunctions 45 NC (*)
and errors occur)
46 CAN (+)

Input/ 47 CAN (-)

Pin No. Signal name
Output 48 NC (*)
1 NC (*) 49 Dark current signal
2 NC (*) 50 NC (*)
3 NC (*)
4 NC (*) CN-CE03 (*: Never connect to NC as malfunctions
5 NC (*)
and errors occur)
6 NC (*) Input/
Pin No. Signal name
7 NC (*) Output
8 NC (*) 1 GND
9 Fuel control dial (+) 2 NC (*)
10 NC (*) 3 Power (+24V)
11 NC (*) 4 NC (*)
12 NC (*)
13 NC (*)

PW148-8 VEBM720100 10-143

Electrical system STRUCTURE AND FUNCTION, MAINTENANCE STANDARD

Pump controller

10-144 PW148-8 VEBM720100

STRUCTURE AND FUNCTION, MAINTENANCE STANDARD Electrical system

Input signals

LOGIC SETTING PIN NAME AselGr PIN No SIGNAL NAME FUNCTION REMARK

INPUT V Power Supply PWR_IN_BATT 1 Power

PWR_IN_BATT 4 Power
PWR_CTR_KEY 24 Key Switch (ACC Terminal)
PWR_CTR_KEY 43 Key Switch (ACC Terminal)
PWR_CTR_EXT 62 External Drive Signal (Wake Up)
PWR_IN_BRY 116 SOL Power In
PWR_IN_BRY 118 SOL Power In
PWR_IN_BRY 121 SOL Power In
Power Grounds GND_PWR 2 Power GND
GND_PWR 5 Power GND
GND_ACT 115 SOL GND
GND_ACT 117 SOL GND
GND_ACT 120 SOL GND
Signal Grounds GND_SIG_D 37
GND_SIG_D 81
GND_SIG_A 18 Analog GND
GND_SIG_A 46 Analog GND
GND_SIG_A 47
GND_SIG_A 65
GND_SIG_A 66
GND_SIG_A 70
GND_SIG_P 44 Pulse GND Travel Speed Sensor GND
D Hi/Lo convertible DIS_HL_0 80 Tilting Pod SW
DIS_HL_1 61 Travel F
DIS_HL_2 42 Travel N
DIS_HL_3 23 Travel R
Hi Side fix DIS_H_4 79 Key Switch (ACC Terminal)
DIS_H_5 60 Key Switch (C Terminal)
DIS_H_6 41 Service Brake Pressure Sw.
DIS_H_7 22 Breaker Switch ON/OFF
Lo Side fix DIS_L_8 78 Overload Caution Enabled
DIS_L_9 59 Quick Coupler Warning ON/OFF
DIS_L_10 40 Machine Select 1
DIS_L_11 21 Machine Select 2
DIS_L_12 77 Machine Select 3
DIS_L_13 58 Machine Select 4
DIS_L_14 39 P-Max (Knob switch)
DIS_L_15 20 Wiper Lo Speed
DIS_L_16 76 Wiper INT Speed
DIS_L_17 57 Window Limit Switch
DIS_L_18 38 Swing Emergency SW
DIS_L_19 19 Swing Lock SW
Loside / Ain(220kPdn) DIS_L_20/AIS_V 0 74 Wash/Wipe signal
DIS_L_21/AIS_V 1 55 Travel F Pressure SW
DIS_L_22/AIS_V 1 36 Travel R Pressure SW
DIS_L_23/AIS_V 2 17 Arm Dig Pressure SW
DIS_L_24/AIS_V 2 73 Bucket Dig Pressure SW
DIS_L_25/AIS_V 2 54 Boom/Outrigger Select SW
DIS_L_26/AIS_V 2 35 Travel Power Max Enable <--- Travel (P) Switch Input
DIS_L_27/AIS_V 3 16 Swing Left & Right Pressure SW
DIS_L_28/AIS_V 3 72 Swing Position sensor
DIS_L_29/AIS_V 3 53 Boom Raise Pressure SW
DIS_L_30/AIS_V 3 34 Bucket Dump Pressure SW
DIS_L_31/AIS_V 4 15 Arm Dump Pressure SW
DIS_L_32/AIS_V 4 71 Park Brake Pressure SW
DIS_L_33/AIS_V 4 52 Service Pressure SW
DIS_L_34/AIS_V 4 33 Low Brake Pressure SW
DIS_L_35/AIS_V 4 14 Boom Down Pressure SW
Wiper DIS_L_WIPER0 75 Wiper (P)
DIS_L_WIPER1 56 Wiper (W)
P AC PIAC_CF_0 25 Travel Speed Sensor Sig
PIAC_CF_1 6
A Alternator AIS_ALTR 10
220kPdn/4.7kPup AIS_VO_1 29 Hydraulic Oil Temp
AIS_VO_2 48
AIS_VO_3 67
AIS_V_4 11 Joystick Steering Activate
AIS_V_5 30 SUS lock by Joystick SW.
AIS_V_6 49 F Pump Pressure Sensor
AIS_V_7 68 R Pump Pressure Sensor
AIS_V_8 12 Travel PPC Pressure Sensor
AIS_V_9 31 Boom Bottom Pressure
AIS_V_10 50
AIS_V_11 69 1st Service Potentio 1 220k PD
AIS_V_12 13 1st Service Potentio 2 220k PD
AIS_V_13 32 2nd Service Potentio 1 220k PD
AIS_V_14 51 2nd Service Potentio 2 220k PD

PW148-8 VEBM720100 10-145

Electrical system STRUCTURE AND FUNCTION, MAINTENANCE STANDARD

Output signals

LOGIC SETTING PIN NAME AselGr PIN No SIGNAL NAME FUNCTION REMARK

OUTPUT D BR DOP_BRY 108 Battery Relay

SIG(Src) 100mA(max) DOP_H_0 107
DOP_H_1 84 Joystick Steering Creep/Lo Speed Set New Feature added for Joystick Steering
SIG(Sink) 100mA(max) DOP_L_0 92 PPC Lock Relay
DOP_L_1 100 Boom / Outrigger SOL Relay
A HSW/AOP DOP_H_0/AOP_SO 102 2nd Service RH Flow Control EPC Current
DOP_H_1/AOP_SO 110 Back Pressure Compensation SOL
DOP_H_2/AOP_SO 87 TM / Clutch SOL
DOP_H_3/AOP_SO 95 1st Service LH Flow Control EPC Current
DOP_H_4/AOP_SO 103 1st Service RH Flow Control EPC Current
DOP_H_5/AOP_SO 111 2nd Service LH Flow Control EPC Current
DOP_H_6/AOP_SO 88 LS-EPC Current
DOP_H_7/AOP_SO 96 PC-EPC Current
DOP_H_8/AOP_SO 104 Travel EPC Current
DOP_H_9/AOP_SO 112 Merge Flow Divider SOL (Main)
DOP_H_10/AOP_SO 89 Travel Creep SOL
DOP_H_11/AOP_SO 97 Travel F/R SOL
DOP_H_12/AOP_SO 105 Travel N SOL
DOP_H_13/AOP_SO 113 Suspension Lock SOL
HSW (no current watch) DOP_H_14 85 F-L Outrigger SOL
DOP_H_15 93 F-R Outrigger SOL
DOP_H_16 101 Swing Brake SOL
DOP_H_17 109 2-Stage Relief SOL
DOP_H_18 86 R-L Outrigger SOL
DOP_H_19 94 R-R Outrigger SOL
V AOS_V_0 27
120mA(max) PWR_OUT_5V_0 9 Power (+5V) for sensor power
120mA(max) PWR_OUT_5V_1 8 Power (+5V) for switch power
100mA(max) PWR_OUT_SENS 28 Power (+24V) Swing Alignment Sensor (Road Travelling)
D WIPPER DOP_MOT_1- 114 Wiper Motor (-)
DOP_MOT_1+ 119 Wiper Motor (+)
D WASHER DOP_L_WASHER 3 Washer Motor
COMMS b COMMUNICATIONS COMM_CAN_H_0 45 CAN_0_H
COMM_CAN_L_0 64 CAN_0_L
COMM_CAN_H_1 7
COMM_CAN_L_1 26
CAN_SH 63
COMM_232C_RXD 82
COMM_232C_TXD 90
NC NOT CONNECTED NC 83 --- --- ---
NC 91 --- --- ---
NC 98 --- --- ---
NC 99 --- --- ---
NC 106 --- --- ---

10-146 PW148-8 VEBM720100

STRUCTURE AND FUNCTION, MAINTENANCE STANDARD Electrical control system

Electrical control system

Control function 1
Engine/Pump composite control function

2
Pump/Valve control function

3
One-touch power maximizing function

4
Auto-deceleration function

5
Auto-warm-up/Overheat prevention function
Electronic control system
6
Swing control function

7
Travel control function

8
ATT flow control, ATT direction control

9
System component parts

10
Speed sensing function

• For the self-diagnosis function, see “TROUBLE SHOOT-

ING".

PW148-8 VEBM720100 10-147

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STRUCTURE AND FUNCTION, MAINTENANCE STANDARD

VEBM720100
STRUCTURE AND FUNCTION, MAINTENANCE STANDARD Electrical control system

1. Engine and pump control function

Engine
throttle
controller
Second throttle signal

Travel
Pedal

AM 08:52 P Lo

H H F

C C E

PW148-8 VEBM720100 10-149

Electrical control system STRUCTURE AND FUNCTION, MAINTENANCE STANDARD

Function
• The operator can set the work mode switch on the monitor Travel
panel to mode Travel, P, E, B or L and select proper engine Travel Pmax.
torque and pump absorption torque according to the type of
work. P
• The engine throttle and pump controller detects the speed of
the engine governor set with the fuel control dial and the ac-
tual engine speed and controls them so that the pump will L
absorb all the torque at each output point of the engine, ac-
cording to the pump absorption torque set in each mode.

Ab

Travel
Travel Pmax.
P

AA

P
Travel & Travel Pmax.

10-150 PW148-8 VEBM720100

STRUCTURE AND FUNCTION, MAINTENANCE STANDARD Electrical control system

1. Control method in each mode

Mode P
• Matching point in mode P: Rated speed

Model PW148-8
SJP08758
Mode P Working 1,810 rpm
OR
• If the pump load increases and the pressure rises, the en-
gine speed lowers. 08912

At this time, the controller lowers the pump discharge so that

the engine speed will be near the full output point. If the
pressure lowers, the controller increases the pump dis-
charge so that the engine speed will be near the full output
point.
SJP08759
By repeating these operations, the controller constantly us-
es the engine near the full output point. OR

08913

SJP08760

OR

08914

PW148-8 VEBM720100 10-151

Electrical control system STRUCTURE AND FUNCTION, MAINTENANCE STANDARD

Mode E / Mode B / Mode L

Mode Digging Breaker Finishing

Partial output point 85% 75% 70% SJP08761

OR
Mode PW148-8
08915
Mode E 1,710 RPM
Mode B 1,690 RPM
Mode L 1,485 RPM

• At this time, the controller keeps the pump absorption torque

along the constant horsepower curve and lower the engine
speed by the composite control of the engine and pump.
SJP08762
By this method, the engine is used in the low fuel consump-
tion area. OR

08916

SJP08763

OR

08917

• When travel is activated in each mode matching point

changes to travel matching point. TRAVEL

SJP08761

OR

08915

Ab

10-152 PW148-8 VEBM720100

STRUCTURE AND FUNCTION, MAINTENANCE STANDARD Electrical control system

1.1 Function to control when emergency pump drive switch

is turned ON
• Even if the controller or a sensor has a trouble, the functions 10
of the machine can be secured with pump absorption torque
almost equivalent to mode E by turning on emergency pump
drive switch (10).

In this case, a constant current flows from the battery to the

EPC valve for PC and the oil pressure is sensed by only the
EPC valve for PC.

FUSE BOX

PW148-8 VEBM720100 10-153

Electrical control system STRUCTURE AND FUNCTION, MAINTENANCE STANDARD

2. Pump/valve control function

Stabilizer
Service 1

Service 2

2PBoom

Bucket

Boom

Swing

Travel

Arm
Engine
throttle
controller
Second throttle signal

Monitor Panel

AM 08:52 P Lo

H H F

C C E

SJP09129C

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

10-154 PW148-8 VEBM720100

STRUCTURE AND FUNCTION, MAINTENANCE STANDARD Electrical control system

2.1 LS control function

• The change point (LS set differential pressure) of the pump
discharge in the LS valve is changed by changing the output
pressure from the LS-EPC valve to the LS valve according
to the operating condition of the actuator.

• By this operation, the start-up time of the pump discharge is

optimized and the composite operation and fine control per-
formance is improved. 08922

2.2 Cut-off function

• When the cut-off function is turned on, the PC-EPC current
is increased to near the maximum value.

By this operation, the flow rate in the relief state is lowered

to reduce fuel consumption.

• Operating condition for turning on cut-off function

730 mA
Condition

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

The cut-off function does not work, however, while the machine
is travelling in mode A.

2.3 2-stage relief function 285 345

• The relief pressure in the normal work is 34.8 MPa {355 kg/ A

cm²}. If the 2-stage relief function is turned on, however, the

relief pressure rises to about 37.2 MPa {380 kg/cm²}.

• By this operation, the hydraulic force is increased further.

• Operating condition for turning on 2-stage relief function

Condition Relief
pressure

• During travel 34.8 MPa

• When swing lock switch is turned on {355 kg/cm²}
• When boom is lowered ⇓
• When one-touch power maximising function is 37.2 MPa
turned on {380 kg/cm²}
• When L mode is operated

PW148-8 VEBM720100 10-155

Electrical control system STRUCTURE AND FUNCTION, MAINTENANCE STANDARD

3. One-touch power maximizing function

SJP08766

Engine OR
throttle
controller
08923
Second throttle signal

Monitor Panel

AM 08:52 P Lo

H H F

C C E

Function
• Power can be increased for approximately 8 seconds by de-
pressing the power max switch on LH work equipment lever.

• The power max function is available in "P" and "E" working

modes only.

10-156 PW148-8 VEBM720100

STRUCTURE AND FUNCTION, MAINTENANCE STANDARD Electrical control system

3.1 One-touch power maximizing function

• When the operator needs more digging force to dig up a
large rock, etc., if the left knob switch is pressed, the hydrau-
lic force is increased about 7% to increase the digging force.

• If the left knob switch is turned on in working mode "P" or

"E", each function is set automatically as shown below.

Software cut-off function

Working mode Engine/Pump control 2-stage relief function Operation time

34.8 MPa {355 kg/cm²}

Automatically reset at
P, E Matching at rated output point ⇓ Cancel
8.5 sec.
37.2 MPa {380 kg/cm²}

PW148-8 VEBM720100 10-157

Electrical control system STRUCTURE AND FUNCTION, MAINTENANCE STANDARD

4. Auto-deceleration function

SJP08767
Engine
OR throttle
controller
08924 Second throttle signal

Travel
pedal
Monitor Panel

AM 08:52 P Lo

H H F

C C E

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

• If any lever is operated, the engine speed rises to the set

level instantly.

10-158 PW148-8 VEBM720100

STRUCTURE AND FUNCTION, MAINTENANCE STANDARD Electrical control system

Operation

When control levers are set in neutral

• If all the control levers are set in NEUTRAL while the engine
speed is above the decelerator operation level (about 1,400
rpm), the engine speed lowers instantly to the first decelera-
tion level about 100 rpm lower than the set speed.

• If 4 more seconds pass, the engine speed lowers to the sec-

ond deceleration level (about 1,400 rpm) and keeps at that
level until any lever is operated again.

When any control lever is operated

• If any control lever is operated while the engine speed is
kept at the second deceleration level, the engine speed ris-
es instantly to the level set with the fuel control dial.
Engine speed instruction

All PPC pressure switched : off

A

PW148-8 VEBM720100 10-159

Electrical control system STRUCTURE AND FUNCTION, MAINTENANCE STANDARD

5. Auto-warm-up/Overheat and white smoke prevention

function

SJP08768
Engine
throttle OR
controller
08925

Second throttle signal

Monitor Panel

AM 08:52 P Lo

H H F

C C E

Function
• After the engine is started, if the engine cooling water tem-
perature is below 30°C, the engine speed is raised automat-
ically to warm up the engine. If the engine cooling water
temperature rises too high during work, the pump load is re-
duced to prevent overheating.

• To prevent white smoke the heater relay is activated for 100

seconds if the air temperature is below 30°C.

10-160 PW148-8 VEBM720100

STRUCTURE AND FUNCTION, MAINTENANCE STANDARD Electrical control system

5.1 Auto-warm-up function

• After the engine is started, if the engine cooling water tem-
perature is low, the engine speed is raised automatically to
warm up the engine.

Operating condition (All) Operated

Water temperature: Below 30°C. Engine speed: Max. 1,200 rpm

Engine speed: Max. 1,200 rpm

Resetting condition (Any one) Reset

Auto Water temperature: Above 30°C Engine speed: Any level

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

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

5.2 Overheat prevention function

• If the engine cooling water temperature rises too high during
work, the pump load and engine speed are reduced to pre-
vent overheating.

• This function is turned on when the water temperature rises

above 100°C or hydraulic oil temperature reaches 95°C.

Operating condition Operation/Remedy Resetting condition

Water temperature: Work mode: Any mode Water temperature: Below 105°C
Above 105°C or Engine speed: Low idle Hydraulic oil temperature: Below 105°C
Hydraulic oil tempera- Monitor alarm lamp: Lights up Fuel control dial: Return to low idle posi-
ture: Above 105°C Alarm buzzer: Sounds tion once.
• Under above condition, controller is set
to condition before operation of function.
(Manual reset)

Operating condition Operation/Remedy Resetting condition

Water temperature: Work mode: Mode P, E, OR B Water temperature: Below 102°C

Above 102°C or Engine speed: Keep as is. Hydraulic oil temperature: Below 102°C
Hydraulic oil tempera- Monitor alarm lamp: Lights up. • Under above condition, controller is set
ture: Above 102°C Lower pump discharge. to condition before operation of function.
(Automatic reset)

Operating condition Operation/Remedy Resetting condition

Water temperature: Work mode: Mode P or E Water temperature: Below 100°C

Above 100°Cor Engine speed: Keep as is. Hydraulic oil temperature: Below 100°C
Hydraulic oil tempera- Lower pump discharge. • Under above condition, controller is set
ture: Above 100°C to condition before operation of function.
(Automatic reset)

Operating condition Operation/Remedy Resetting condition

Hydraulic oil tempera- Work mode: Travel
ture: Above 95°C Engine speed: Keep as is.
Lower travel speed.
Water temperature: Below 95°C
Hydraulic oil temperature: Below 95°C
• Under above condition, controller is set
to condition before operation of function.
(Automatic reset)

PW148-8 VEBM720100 10-161

Electrical control system STRUCTURE AND FUNCTION, MAINTENANCE STANDARD

6. Swing control function

Pressure
switch

Monitor Panel

AM 08:52 P Lo

H H F

C C E

SJP09133C

Function
The Swing lock and swing holding brake functions are installed.

10-162 PW148-8 VEBM720100

STRUCTURE AND FUNCTION, MAINTENANCE STANDARD Electrical control system

6.1 Swing lock and swing holding brake functions

• The swing lock function (manual) is used to lock machine
from swinging at any position. The swing holding brake func-
tion (automatic) is used to prevent hydraulic drift after the
machine stops swinging.

• Swing lock switch and swing lock/holding brake

Operation of swing holding brake release switch

• If the controller, etc. has a problem, the swing holding brake

does not work normally, and the machine cannot swing, the
swing lock can be reset with the swing holding brake release
switch.

Lock switch Lock lamp Function Operation

If swing lever is set in neutral, swing brake operates in about 5 sec. If

OFF OFF Swing holding brake swing lever is operated, brake is released and machine can swing
freely.

Swing lock operates and machine is locked from swinging. Even if

ON ON Swing lock swing lever is operated, swing lock is not reset and machine does not
swing.

Swing holding
OFF On (with PPC signal) ON
brake release
(When controller is normal) (when controller is normal) (When control has trouble)
switch

Swing lock switch ON OFF On Off ON OFF

Swing holding Swing lock

Swing lock is Swing lock is Machine will Swing lock is
Swing brake brake is turned is
turned on. turned on swing turned on.
on. cancelled.

• Even if the swing holding brake release switch is turned on,

if the swing lock switch is turned on, the swing brake is not
released.

• If the swing lock is reset, swinging is stopped by only the hy-

draulic brake of the safety valve. Accordingly, if swinging is
stopped on a slope, the upper structure may drift hydrauli-
cally.

6.2 Quick hydraulic oil warm-up function when swing lock

switch is turned on
• If swing lock switch (4) is turned on, the pump-cut function is
cancelled and the relief pressure rises from 34.8 MPa {355
kg/cm²} to 37.2 MPa {380 kg/cm²}. If the work equipment is
relieved under this condition, the hydraulic oil temperature 4
rises quickly and the warm-up time can be shortened.

PW148-8 VEBM720100 10-163

Electrical control system STRUCTURE AND FUNCTION, MAINTENANCE STANDARD

7. Travel control function

Monitor
Auto
Hi
F-N-R Lo Travel PPC
Switch Creep Pressure
Sensor Travel
PPC
F-R
sol
Travel N
35kph or 20kph Steering
sol
Seletor Connector Pump
Controller

Parkbrake
Switch PC - EPC

2 Stage
Backpress LS - EPC
sol

Pump
Pressure
2 Stage Sensor
Backpress Main
Valve Pump
Travel
Control
Creep Valve
sol R F A

Travel R Travel F
press SW press SW

Parkbrake
sol

Engine
throttle TM Clutch
To
controller sol
Position A
(Throttle signal)
(Second throttle signal)

Swivel Joint

Travel
Motor

2nd Clutch

1st Clutch

Powershift
Transmission
Speed
Pick-up

Function
• The pump is controlled and the travel speed is changed
manually or automatically, to secure proper travel perform-
ance matched to the type of work and jobsite during travel.

10-164 PW148-8 VEBM720100

STRUCTURE AND FUNCTION, MAINTENANCE STANDARD Electrical control system

7.1 Pump control function during travel

• If the machine travels in a work mode other than mode P, the
work mode and the engine speed remain unchanged and
the pump absorption torque is increased.

• For details, see ENGINE/PUMP COMPOSITE CON-

TROL FUNCTION.

7.2 Travel speed change function

• Manual change with travel speed button on the monitor pan-
el.

Travel speed AUTO

CREEP LO HI
switch (LO~HI)
Pump
80 100 100
capacity (%)
Motor capac-
Max. Min~Max Min~Max Min~Max
ity
0 - 35
Travel speed 0 - 35
2.5 0 ~8.5 0 - 20
(km/h) 0 - 20
(German spec.)

• If the travel speed switch is changed between CREEP, LO,

and HI, the governor/pump controller controls the pump ca- Max. Engine speed
pacity and motor capacity at each gear speed (as shown in
P max. P normal
the table below) to change the travel speed. (See engine
speed table, right). Travel 2200 rpm 1800 rpm

P Mode 1810 rpm

• Automatic change by engine speed
E Mode 1710 rpm
• The travel speed changes to Hi level automatically if the L Mode 1985 rpm
travel speed has been Hi.
B Mode 1690 rpm
• Automatic change by pump discharge pressure

• While the machine is traveling with the travel speed switch

at Hi, if the load is increased because of an upslope ground,
etc. and the travel pressure keeps above 35 MPa {357 kg/
cm²} for 0.5 seconds, the travel motor capacity is changed
automatically and the travel speed is lowered (to the LO lev-
el) (The travel speed switch is kept at Hi, however).

• While the machine is travelling at LO, if the load is reduced

on a flat or downslope ground, etc. and the travel pressure
keeps below 23 MPa {234 kg/cm²} for 0.5 seconds, the trav-
el motor capacity is changed automatically and the travel
speed is set to Hi again.

• Controller does not change the travel mode in travel HI/LO

switch unless a mode continues for more than 0.5 seconds. Max. Engine speed

• From CREEP to other mode, or from other mode to CREEP, Travel 2200 rpm
travel mode should be changed immediately. P Mode 1810 rpm

E Mode 1710 rpm

• Default mode should be the last mode when starter switch
was turned off. L Mode 1985 rpm

B Mode 1690 rpm

• Maximum speed 2320 rpm.

PW148-8 VEBM720100 10-165

Electrical control system STRUCTURE AND FUNCTION, MAINTENANCE STANDARD

8. ATT flow control, ATT direction control

Engine
throttle
controller

Monitor Panel

AM 08:52 P Lo

HCU control switch H H F

LH
C C E
Att. direction
control

RH

10-166 PW148-8 VEBM720100

STRUCTURE AND FUNCTION, MAINTENANCE STANDARD Electrical control system

9. System component parts

9.1 Engine revolution sensor

1. Sensor
2. Locknut
3. Wiring harness
4. Connector

Function
• The engine revolution sensor is installed to the ring gear of
the engine flywheel. It electrically calculates the number of
the gear teeth which pass in front of it and transmits the re-
sult to the engine throttle and pump controller.

• A magnet is used to sense the gear teeth. Each time a gear

tooth passes in front of the magnet, a current is generated.

PW148-8 VEBM720100 10-167

Electrical control system STRUCTURE AND FUNCTION, MAINTENANCE STANDARD

9.2 PPC oil pressure switch

1. Plug
2. Switch
3. Connector

Specifications
• Type of contacts:
Normally open contacts

• Operating (ON) pressure:

0.5 ± 0.1 MPa
{5.0 ± 1.0 kg/cm²}

• Resetting (OFF) Pressure:

0.3 ± 0.5 MPa
{3.0 ± 0.5 kg/cm²}

Function
• The PPC line has 10 pressure switches, the 12-station sole-
noid block has 4 pressure switches which check the operat-
ing condition of each actuator by the PPC pressure and
transmit it to the governor/pump controller.

10-168 PW148-8 VEBM720100

STRUCTURE AND FUNCTION, MAINTENANCE STANDARD Electrical control system

9.3 Pump pressure sensor

1. Sensor
2. Connector

Function
• The pump pressure sensor is installed to the inlet circuit of
the control valve. It converts the pump discharge pressure
into a voltage and transmits it to the governor/pump control-
ler.

Operation
• The oil pressure applied from the pressure intake part press-
es the diaphragm of the oil pressure sensor, the diaphragm
is deformed.

• The gauge layer facing the diaphragm measures the defor-

mation of the diaphragm by the change of its resistance,
then converts the change of the resistance into a voltage
and transmits it to the amplifier (voltage amplifier).

• The amplifier amplifies the received voltage and transmits it SJP08774

to the governor/pump controller.
OR
• Relationship between pressure P (MPa {kg/cm²}) and output
voltage (V) is as follows.
V = 0.08 [0.008] x P + 0.5. 08930

PW148-8 VEBM720100 10-169

Machine monitor system STRUCTURE AND FUNCTION, MAINTENANCE STANDARD

Machine monitor system

- Water temperature Monitor panel

- Hydraulic oil
- Temperature Switch signals
N
- Fuel level signals

Caution signals
Engine throttle
and pump
controller
Each sensor
Sensor signals

Power
souree

Battery

• The monitor system monitors the condition of the machine

with sensors installed on various parts of the machine. It
processes and immediately displays the obtained informa-
tion on the panel notifying the operator of the condition of
the machine.
The panel is roughly divided as follows.

1. Monitor section to output alarms when the machine has

troubles

2. Gauge section to display the condition constantly (Coolant

temperature, hydraulic oil temperature, fuel level, etc.)

• The monitor panel also has various mode selector switches

and functions to operate the machine control system.

10-170 PW148-8 VEBM720100

STRUCTURE AND FUNCTION, MAINTENANCE STANDARD Machine monitor system

Monitor panel

CN1 CN4

CN2 CN3

Outline
• The monitor panel has the functions to display various items
and the functions to select modes and electric parts.

The monitor panel has a CPU (Central Processing Unit) in it

to process, display, and output the information.

The monitor display unit consists of LCD (Liquid Crystal Dis-

play). The switches are flat sheet switches.

PW148-8 VEBM720100 10-171

Machine monitor system STRUCTURE AND FUNCTION, MAINTENANCE STANDARD

Input and output signals

CON PIN LOGIC SETTING

I/O PW 148-8
CN1 1 PW R_IN_BATT I Battery (24V)
2 PW R_IN_BATT I Battery (24V)
3 GND_PW R_BATT - Battery (GND)
4 GND_PW R_BATT - Battery (GND)
5 *PW R_CTR_EXT I/O W ake Up
6 DOP_BRY1 O Personal Code Relay
7 GND_SIG_D -
8 AIS_OTMP I
9 AIS_FUEL I Fuel Level
10 AIS_W TMP I
11 AIS_ALTR I Battery Charge
12 GND_SIG_A - Analog Signal GND
13 PW R_IN_LIGHT I Light switch
14 DIS_H1 I Key Switch (ACC)
15 DIS_H2 I Key Switch (C)
16 DIS_H3 I Pre-Heat
17 PW R_OUT_USB O
18 GND_PW R_USB -
CN2 1 DIS_L1 I Camera Activation by Joystick
2 DIS_L2 I Engine Oil Level
3 DIS_L3 I Radiator water Level
4 DIS_L4 I Air Cleaner Clogged
5 DIS_L5 I Swing Lock
6 DIS_L6 I Buzzer ON Input
7 GND_SIG_D -
8 COMM_CAN_TERM - CAN Resistor
9 COMM_CAN_H_ɟ I/O CAN_H
10 COMM_CAN_L_ɟ I/O CAN_L
11 COMM_USB_D- I/O
12 COMM_USB_D+ I/O
CN3 1 COMM_232C_CD1 I RS232C CD (KOMTRAX)
2 COMM_232C_RXD1 I RS232C RXD (KOMTRAX)
3 GND_232C1 ҥ RS232C SG (KOMTRAX)
4 GND_SIG_D ҥ Signal GND (KOMTRAX)
5 COMM_MODE_MON I Switch Out (KOMTRAX)
6 COMM_232C_RTS1 O RS232C RTS (KOMTRAX)
7 COMM_232C_TXD1 O RS232C TXD (KOMTRAX)
8 COMM_232C_DTR1 O RS232C DTR (KOMTRAX)
9 COMM_232C_DSR1 I RS232C DSR (KOMTRAX)
10 COMM_232C_CTS1 I RS232C CTS (KOMTRAX)
11 COMM_232C_RI1 I RS232C RI (KOMTRAX)
12 GND_PW R_12V ҥ Power GND (KOMTRAX)
13 DIS_L7 I Input Status CH1 (KOMTRAX)
14 DOS_L1 O Control Output (KOMTRAX)
15 DOS_L2 O Comms Channel CH1 (KOMTRAX)
16 DOS_L3 O Comms Channel CH2 (KOMTRAX)
17 DIS_L8 I Input Status CH2 (KOMTRAX)
18 POW ER_OUT_12V O Power (12V) (KOMTRAX)
CN4 1 GND_PW R_12v ҥ
2 DOS_L4 O
3 GND_SIG_232C ҥ
4 COMM_232C_TXD2 O
5 COMM_232C_RXD2 I
6 AV_A_SPKL O
7 GND_SIG_SPK ҥ
8 AV_A_SPKR O
9 GND_SIG_LINEI ҥ
10 AV_A_LINEIL I
11 AV_A_LINEIR I
12 POW ER_OUT_12V O
CN5 1 PW R_OUT_8V O Camera Power Supply (8V)
2 AV_V_NTSC1 I Camera Video Signal 1
3 AV_V_NTSC2 I Camera Video Signal 2
4 AV_V_NTSC3 I Camera Video Signal 3
5 GND_PW R_8V - Camera power GND
6 GND_SIG_NTSC1 ҥ Camera GND 1
7 GND_SIG_NTSC2 ҥ Camera GND 1
8 GND_SIG_NTSC3 ҥ Camera GND 1

10-172 PW148-8 VEBM720100

STRUCTURE AND FUNCTION, MAINTENANCE STANDARD Machine monitor system

Blank for technical reason

PW148-8 VEBM720100 10-173

Machine monitor system STRUCTURE AND FUNCTION, MAINTENANCE STANDARD

Monitor control, display portion

13 14 15 16 17 18 19 20 21

12
AM N
11

10

9 22

8 23

7 24

6 25

26

N
3 27

2 28

1 29

10-174 PW148-8 VEBM720100

STRUCTURE AND FUNCTION, MAINTENANCE STANDARD Machine monitor system

1. Engine oil pressure monitor

2. Charge level monitor
3. Radiator coolant level monitor
4. Low brake pressure monitor
5. Maintenance interval monitor
6. Engine coolant temperature monitor
7. Hydraulic oil temperature gauge
8. Engine coolant temperature gauge
9. Power max monitor
10. Swing lock monitor
11. Travel swing alignment monitor
12. KOMTRAX message monitor
13. Air conditioner monitor
14. Control lever lock monitor
15. Axle-lock monitor
16. Parking brake monitor
17. Service meter and clock
18. Travel direction monitor
19. Auto-deceleration monitor
20. Working mode monitor
21. Travel speed monitor
22. Undercarriage attachment selection monitor
23. Eco gauge
24. Fuel gauge
25. Fuel level monitor
26. Hydraulic oil temperature monitor
27. Engine oil level monitor
28. Air cleaner clogged monitor
29. Water separator monitor

PW148-8 VEBM720100 10-175

Machine monitor system STRUCTURE AND FUNCTION, MAINTENANCE STANDARD

Monitor items and display

Item
Symbol Display item Display method
No.

Hydraulic oil
7. temperature
gauge

see “Monitor gauge displays” on page 178.

Engine coolant
8. temperature
gauge

Service meter Lights up when service meter is working,

When service meter is
indicator engine not running and ignition is on.

17.

Clock Other than above, clock is shown

18. Travel Directions Displays the travel direction set by the 3 way switch on the right hand wrist control lever.

Auto-decelera-
19. ON ⇔ OFF Displays actuation status
tion

Displays set mode in top left hand corner of monitor as shown in diagram below.
A = Power mode
A B = Economy mode
C = Lifting mode
B D = Breaker mode 100 l/min
E = No 2-way attachment

C
20. Working mode AM N

G0148062

10-176 PW148-8 VEBM720100

STRUCTURE AND FUNCTION, MAINTENANCE STANDARD Machine monitor system

Item
Symbol Display item Display method
No.

B
Travel speed Displays set speed in top right hand corner of monitor.
A = Creep
C B = Low speed
C = High speed
D = Automatic
D
AT
N
21. AM

A P

P
B
Travel speed
(Travel power mode)
P
C

P
D
AT

This monitor displays the current status of chassis attachment selection.

Undercarriage
22. Undercarriage attachment not selected: Monitor background is blue
attachment selection
Undercarriage attachment selected: Monitor background is green

23. ECO gauge see “Monitor gauge displays” on page 178.

24. Fuel gauge see “Monitor gauge displays” on page 178.

PW148-8 VEBM720100 10-177

Machine monitor system STRUCTURE AND FUNCTION, MAINTENANCE STANDARD

Monitor gauge displays

B4 B3 B2 B1 C3 C2 C1

A1 N
A2

A3

D1
A4
D2
A5

A6 C6

B5 B6 C4 C5

Gauge Range Temperature, volume Indicator Buzzer sound

A1 105 Red Yes

A2 102 Red No

Engine coolant A3 100 Green No

temperature (°C) A4 80 Green No

A5 60 Green No

A6 30 White No

B1 105 Red Yes

B2 102 Red No

Hydraulic oil B3 100 Green No

temperature (°C) B4 80 Green No

B5 40 Green No

B6 20 White No

C1 325 Green No

C2 270 Green No

C3 216 Green No
Fuel level (l)
C4 108 Green No

C5 78 Green No

C6 48 Red No

D1 Orange No
ECO gauge
D2 Green No

10-178 PW148-8 VEBM720100

STRUCTURE AND FUNCTION, MAINTENANCE STANDARD Machine monitor system

Item
Symbol Display item Display method Priority
No.

Power Max. switch status Power max. monitor status

Lights up but goes out after approx.

Being pressed
9. Power Max. 9 sec. when kept pressed 2

Not being pressed Flashes

Swing lock switch Swing lock monitor

OFF OFF
10. Swing lock 2

ON ON

Continuous set time Preheating monitor status

Up to 30 sec. ON
Pre-heating 1
From 30 sec. to 40 sec. Flashes

More than 40 sec. OFF

11.

Upper structure When the upper structure is correctly positioned facing forward this display is
2
position constant. If the position is slightly off this display flashes

This monitor lights up when there is a message from KOMATSU

KOMTRAX Lighted up green: There is unread message
12.
message Lighted up blue: There is no unread message
OFF: There are no messages

This monitor displays the working status of the air conditioner.

13. Air conditioner Monitor lighted up: Air conditioner ON
Monitor off: Air conditioner OFF

14. PPC lock When PPC lock switches in the ON position this display is ON.

PW148-8 VEBM720100 10-179

Machine monitor system STRUCTURE AND FUNCTION, MAINTENANCE STANDARD

Item
Symbol Display item Display method Priority
No.

Free axle When displayed:

oscillation Axle can oscillate freely

Locked axle When displayed:

position Axle becomes rigidly fixed

15.

AUTTO
AU When displayed:
Auto axle (free)
Service brake not applied

AUTO Auto axle When displayed:

(locked) Service brake applied

When displayed: Park brake ON

16.
P Parking brake
When not displayed: Park brake OFF

10-180 PW148-8 VEBM720100

STRUCTURE AND FUNCTION, MAINTENANCE STANDARD Machine monitor system

Checks before starting (caution lamps all light up), when mainte-
nance interval is exceeded.

If the checks before starting or maintenance interval is exceeded

items light up, the display of the hydraulic oil temperature gauge
and the hydraulic oil temperature display are stopped, and the
following cautions are displayed.

Item Check before When engine is When engine is run-

Symbol Display item
No. starting item stopped ning

When abnormal, lights

1. Engine oil pressure Yes --
up and buzzer sounds

Lights up when abnor-

2. Battery charge Yes --
mal

Lights up when abnor- When abnormal, lights

3. Radiator water level Yes
mal up and buzzer sounds

Lights up when
4. Low brake pressure No
abnormal

Lights up when maintenance is due. Lights up for

Service interval No
only 30 sec. after key is turned ON, then goes out.

5.

When in L mode:
Overload caution Yes
Lights up when abnormal and buzzer sounds

At low temperatures: Background is white

Engine coolant
6. No At normal temperatures: Background is blue
temperature monitor
At abnormal condition: Background is red

Lights up when
25. Fuel level Yes --
abnormal

PW148-8 VEBM720100 10-181

Machine monitor system STRUCTURE AND FUNCTION, MAINTENANCE STANDARD

Item Check before When engine is When engine is run-

Symbol Display item
No. starting item stopped ning

At low temperatures: Background is white

Hydraulic oil
26. No At normal temperatures: Background is blue
temperature
At abnormal conditions: Background is red.

Lights up when
28. Engine oil level Yes --
abnormal

Lights up when
29. Air filter blocked Yes --
abnormal

10-182 PW148-8 VEBM720100

STRUCTURE AND FUNCTION, MAINTENANCE STANDARD Machine monitor system

Keypad layout

AM N

7 8

6 9

5 10

4 11
3 12

2 13

15 16 14

1. Function switches (F1 to F6) 9. Travel speed selector switch

2. RECIRC/FRESH selector switch (air conditioner)
3. Fan switch - min. (air conditioner)
4. Fan switch - max. (air conditioner)
5. Buzzer cancel switch
6. Auto-deceleration switch
7. Control lever lock switch
8. Working mode select switch
10. Axle lock switch
11. AUTO switch (air conditioner)
12. Air conditioner switch (air conditioner)
13. OFF switch (air conditioner)
14. Temperature set switch - max. (air conditioner)
15. Temperature set switch - min. (air conditioner)
16. Vent selector switch (air conditioner)

PW148-8 VEBM720100 10-183

Machine monitor system STRUCTURE AND FUNCTION, MAINTENANCE STANDARD

Declaration of switch function on keypad

For more details refer to Operation and Maintenance Manual.

Ite
Symbol Name Description
m

Function switches The function of switches on each screen can be confirmed

1.
(F1 to F6) by guidance icons displayed on top of each switch.

RECIRC/FRESH
This switch is used to switch the air source between recirculation
2. selector switch
of the air inside the cab and intake of air from the outside.
(air conditioner)

Fan switch - min. This switch is used to adjust the air flow.
3.
(air conditioner) Press the switch to reduce the air flow.

Fan switch - max. This switch is used to adjust the air flow.
4. (air conditioner) Press the switch to increase the air flow
[figure 7] [for figure input in service menu]

Buzzer cancel When this switch is pressed, the warning buzzer

5. switch for the abnormal warning item stops.
[figure 4] [for figure input in service menu]

Auto-deceleration If the control levers are at neutral, this switch automatically lowers
6. switch the engine speed and turns on the function to reduce fuel consumption.
[figure 1] [for figure input in service menu]

Control lever
This switch operates the control lever lock for operating lever.
7. lock switch
[for figure input in service menu]
[figure 5]

Working mode
This switch is used to set the movement or power of the work equipment.
8. selector switch
[for figure input in service menu]
[figure 2]

Travel speed When the switch is pressed, the travel speed changes between
9. selector switch 4 different travel speed mode (CR, LO, HI and AT)
[figure 2] [for figure input in service menu]

This switch is used to set axle lock to 3 stages (Locked axle position,
Axle lock switch
10. auto axle free and auto axle locked)
[figure 6]
[for figure input in service menu]

10-184 PW148-8 VEBM720100

STRUCTURE AND FUNCTION, MAINTENANCE STANDARD Machine monitor system

Ite
Symbol Name Description
m

AUTO switch With this switch, the air flow, vents, and air source (RECIRC/FRESH)
11. (air conditioner) are automatically selected according to the set temperature.
[figure 9] [for figure input in service menu]

Air conditioner
This switch is used to turn the air conditioner (cooling,
12. switch
dehumidifying, heating) ON or OFF.
(air conditioner)

OFF switch
13. With this switch the air conditioner automatic will be stopped.
(air conditioner)

Temperature set
This switch is used to control the temperature inside the cab.
switch - max.
14. Press the switch to raise the set temperature
(air conditioner)
[for figure input in service menu]
[figure 8]

Temperature set
This switch is used to control the temperature inside the cab.
switch - min.
15. Press the switch to lower the set temperature
(air conditioner)
[for figure input in service menu]
[figure 0]

Vent selector
16. switch This switch is used to select the vents.
(air conditioner)

PW148-8 VEBM720100 10-185

Overload warning device STRUCTURE AND FUNCTION, MAINTENANCE STANDARD

Overload warning device

Outline

Function
• This device is installed to warn the operator when the ma-
chine lifts an excessive weight.

Structure
• When an excessive weight is lifted, the oil pressure increas-
es at the bottom side of the boom cylinders. When this hap-
pens, a pressure switch is activated which lights the monitor
lamp to warn the operator. When the monitor lamp lights, im-
mediately lower the weight to the ground or bring the arm
closer in the operator to prevent the machine from tipping
over.

NOTE
The overload caution system can only be activated when the lift-
ing mode (L) is activated on the monitor panel.

Monitor

Overload warning Lifting mode ’L’

monitor lamp (Must be selected)

10-186 PW148-8 VEBM720100

STRUCTURE AND FUNCTION, MAINTENANCE STANDARD Sensor

Sensor
• The signals from the sensors are input directly to the engine
controller and pump controller monitor.

The contact type sensors are always connected at one end

to the chassis GND

Sensor name Type of sensor When normal When abnormal Input controller

Coolant level Contact ON (Closed) OFF (Open)

Monitor
Engine oil level Contact ON (Closed) OFF (Open)

Engine oil pressure Contact ON (Open) OFF (Closed) Engine

Coolant temperature Resistance — — controller

Fuel level Resistance — —

Air cleaner clogging Contact OFF (Closed) ON (Open) Monitor

Hydraulic oil temperature Resistance — —

Main pump oil pressure — — Pump controller

Analog
Overload caution — — Monitor

Engine speed — — Engine

Resistance
Transmission speed — — controller

Swing proximity Inductive — — Monitor

Travel PPC Analog — —

PPC pressure

Park brake pressure OFF (Open) ON (Closed)

Controller
Brake accumulator low pressure Contact

Brake pressure/Suspension lock activa-

ON (Closed) OFF (Open)
tion switch

PW148-8 VEBM720100 10-187

Sensor STRUCTURE AND FUNCTION, MAINTENANCE STANDARD

Coolant temperature sensor

1. Connector
2. Sensor
3. O-ring

Oil pressure switch

1. Connector
2. Sensor
3. O-ring

10-188 PW148-8 VEBM720100

STRUCTURE AND FUNCTION, MAINTENANCE STANDARD Sensor

Rotation sensor

1. Connector
2. Sensor
3. O-ring

Boost pressure and temperature sensor

1. Connector
2. Sensor
3. O-ring

PW148-8 VEBM720100 10-189

Sensor STRUCTURE AND FUNCTION, MAINTENANCE STANDARD

WIF (Water-In-Fuel detection) sensor

1. Connector
2. Tube
3. Sensor
4. O-ring

Engine oil level sensor

1. Connector
2. Bracket
3. Float
4. Switch

10-190 PW148-8 VEBM720100

STRUCTURE AND FUNCTION, MAINTENANCE STANDARD Sensor

Coolant level sensor

1. Sub-tank
2. Float
3. Sensor
4. Connector

PW148-8 VEBM720100 10-191

Sensor STRUCTURE AND FUNCTION, MAINTENANCE STANDARD

Coolant temperature sensor

Hydraulic oil temperature sensor

main pump

Structure of
circuit

1. Thermistor
2. Body
3. Tube
4. Tube
5. Wire
6. Connector

Fuel level sensor

fuel tank

1. Float
2. Connector
3. Cover
4. Variable resistor

10-192 PW148-8 VEBM720100

STRUCTURE AND FUNCTION, MAINTENANCE STANDARD Sensor

Air cleaner clogging sensor

air cleaner

Structure of
circuit

Overload Caution sensor

PW148-8 VEBM720100 10-193

Sensor STRUCTURE AND FUNCTION, MAINTENANCE STANDARD

Swing proximity sensor

OPERATION
INDICATING LAMP

RED
1 DC10V~30V
PROXIMITY WHITE
2 LOAD
SWITCH
MAIN 250mA MAX.
CIRCUIT
2 x 18V.1 ZENER DIODE

Revolving Frame BLACK

3 OV

Travel PPC sensor

solenoid valve

PPC pressure sensor

10-194 PW148-8 VEBM720100

STRUCTURE AND FUNCTION, MAINTENANCE STANDARD Sensor

Park brake pressure sensor

Brake accumulator low pressure sensor

Brake stop light sensor

PW148-8 VEBM720100 10-195

1st attachment circuit hydraulic performance (main valve bypassed) STRUCTURE AND FUNCTION, MAINTENANCE STANDARD

1st attachment circuit hydraulic performance (main valve

bypassed)
The performance of the hydraulic system when operating the 1st
attachment circuit is shown below.

The pressure Pa is that which is observed at the inlet to the at-

tachment.

The pressure Pb is the pressure observed in the breaker low

back pressure return line (back pressure) measured at the at-
tachment outlet connection.

The figures below show the pressures at points Pa and Pb for

varying flow through the attachment in B mode.

NOTE
The data given here is intended as a guide only. This is because
the data is typical for an excavator of this type therefore there will
be variation from one machine to another.

10-196 PW148-8 VEBM720100

STRUCTURE AND FUNCTION, MAINTENANCE STANDARD Travel system

Travel system

Travel circuit

PW148-8 VEBM720100 10-197

Travel system STRUCTURE AND FUNCTION, MAINTENANCE STANDARD

1. Travel motor

1.1 Shown in neutral position

10-198 PW148-8 VEBM720100

STRUCTURE AND FUNCTION, MAINTENANCE STANDARD Travel system

1.2 Flow path representing

Low Torque - High speed with counterbalance taking up an
active position. (Default for Travel)

The counterbalance valve (3) is activated which allows a

constant flow of oil around the circuit. From port A through to
port B the motor displacement is at minimum pending maxi-
mum speed. the speed of the machine is governed by the
level of motor displacement.

PW148-8 VEBM720100 10-199

Travel system STRUCTURE AND FUNCTION, MAINTENANCE STANDARD

1.3 Introduction of Creep control

High Torque - Low Speed.

It can be seen from the diagram that the spool moves across
on the torque speed control valve (2) which directs the flow
to move the servo and supply the motor displacement to
maximum giving creep speed of 2.5kph

10-200 PW148-8 VEBM720100

STRUCTURE AND FUNCTION, MAINTENANCE STANDARD Travel system

1.4 Opposing load torque on motor increases causing

Torque / Speed control valve to react.
Diagram showing Hi speed with minimum displacement

PW148-8 VEBM720100 10-201

Travel system STRUCTURE AND FUNCTION, MAINTENANCE STANDARD

1.4.1 Motor displacement is increased progressively

towards maximum
High Torque - Low Speed mode. During travel the travel mo-
tor will engage low speed if the spool (2) moves across
which will move the motor displacement towards maximum
providing low speed

10-202 PW148-8 VEBM720100

STRUCTURE AND FUNCTION, MAINTENANCE STANDARD Travel system

1.5 Motor begins to overrun and pressure falls on supply

side: This causes counterbalance valve to begin to
close and throttle return flow from motor.

PW148-8 VEBM720100 10-203

Travel system STRUCTURE AND FUNCTION, MAINTENANCE STANDARD

1.6 Motor begins to overrun and pressure falls on supply

side
This causes counterbalance valve to begin to close and
throttle return to flow motor. Pressure line in return line rises
providing a braking torque.

10-204 PW148-8 VEBM720100

STRUCTURE AND FUNCTION, MAINTENANCE STANDARD Travel system

1.7 Travel Motor Performance.

1.7.1 High Torque - Low Speed.

• represents motor maximum displacement angle (usual-

ly 35°), Fr represents the radial force developed by the hy-
draulic oil pressure which in turn develops the
corresponding driving or braking torque.

• Where a high starting torque is required the operation of the

travel creep solenoid valve will move the motor into this
mode via the torque speed control valve at the motor.

• The same action will occur automatically when the motor

load pressure due to the opposing torque reaches the set-
ting of the torque speed control valve.

• In an overrun situation the rise in pressure in the motor re-

turn line as the counterbalance valve closes will also in-
crease and provide an effective braking torque.

PW148-8 VEBM720100 10-205

Travel system STRUCTURE AND FUNCTION, MAINTENANCE STANDARD

1.7.2 Low Torque - High Speed.

• represents motor minimum displacement angle (usually

about 5 to 7°). Fr represents the radial force developed by
the hydraulic oil pressure which in turn develops the corre-
sponding driving or braking torque.

Motor size:
41 - 120cm³ / rev for machines rated at 35 kph.

10-206 PW148-8 VEBM720100

STRUCTURE AND FUNCTION, MAINTENANCE STANDARD Travel system

2. Travel pedal

2 2

2.1 Travel Pedal Schematic

2.2 Travel Pedal

Located to the extreme right of the steering column on the
floor of the Operators cab, a proportional valve when activat-
ed controls the flow of oil to the travel motor.

PW148-8 VEBM720100 10-207

Travel system STRUCTURE AND FUNCTION, MAINTENANCE STANDARD

3. Forward / Neutral / Reverse switch (F-N-R)

R.H. R.H. R

3.1 F-N-R Switch Schematic.

3.2 F-N-R Switch

Located on the front of the RH control lever, this rocker type
switch determines whether the travel direction is forward, re-
verse or neutral.

NOTE
Machine cannot be started unless the switch is in the neutral po-
sition.

The signals of this switch go to the controller and the controller

operates the travel Neutral solenoid and the travel Forward/Re-
verse solenoid.

F/N/R Status Table

FNR Signal
Status
F N R

0 0 0 N (Error)

0 0 1 N

0 1 0 R

0 1 1 N (Error)

1 0 0 F

1 0 1 N (Error)

1 1 0 N (Error)

1 1 0 N (Error)

10-208 PW148-8 VEBM720100

STRUCTURE AND FUNCTION, MAINTENANCE STANDARD Travel system

4. Forward / Reverse travel solenoid

4.1 Forward / Reverse Travel Solenoid Schematic

4.2 Forward / Reverse Travel Solenoid

Located on the solenoid block in the service compartment at
the rear of the operators cab. This device controls the travel
motor direction (forward or reverse) by a signal from the F-
N-R switch.

Solenoid energised ~Forward or Reverse. Travel is en-

gaged, this is interlocked with the travel neutral solenoid. If
travel Reverse is selected, controller drives this valve and
travel PPC pressure spool is reversed.

PW148-8 VEBM720100 10-209

Travel system STRUCTURE AND FUNCTION, MAINTENANCE STANDARD

5. Travel / neutral solenoid

5.1 Travel Neutral Solenoid Schematic.

5.2 Travel Neutral Solenoid

Located on the solenoid manifold in the service compart-
ment at the rear of the operators cab. This device interlocks
with the forward / reverse solenoid to give supply pressure
to the foot pedal control valve.

Solenoid active - PPC pressure to foot valve

Solenoid inactive - No pressure to foot valve

If the travel neutral signal is selected the controller doesn’t

drive this solenoid so no PPC travel.

10-210 PW148-8 VEBM720100

STRUCTURE AND FUNCTION, MAINTENANCE STANDARD Travel system

6. Travel creep solenoid

6.1 Travel Creep Solenoid Schematic.

6.2 Travel Creep Solenoid

Located on the solenoid manifold in the service compart- Travel Mode Travel Speed
Creep Solenoid
Selected (kph)
ment at the rear of the operators cab. When this device is
activated ’CREEP’ mode is selected and sends PPC pres- On Creep 0 - 1.5
sure to port X on travel motor, ensure travel motor stays at Off Low 0-9
maximum displacement. Off High 0 - 35
Off Auto 0 - 35

PW148-8 VEBM720100 10-211

Travel system STRUCTURE AND FUNCTION, MAINTENANCE STANDARD

Operational and control features

Operational and Control features (1)

• Machine speed relates to hydraulic motor speed.

• Hydraulic motor speed depends upon the flow of hydraulic

oil, which depends upon size of the aperture created by the
position of the spool in the control valve.

• The position of the spool in the main control valve relates to

the pressure level created by the pilot pressure control valve
(PPC). This takes the form of a pressure regulating valve
(pressure reducer) operated by the travel pedal. The further
the pedal is pressed the higher the pilot pressure is generat-
ed, resulting in a greater level of proportional spool move-
ment and corresponding oil flow rate to the motor.

• Hydraulic motor direction is controlled by the position of the

travel ’forward and reverse’ solenoid valve which in turn di-
rects the pilot signal from the foot pedal control valve to the
pilot section of the main control valve travel spool. The foot
pedal control valve receives its pressure supply from the
’travel / neutral solenoid valve’.

• Initiation of the ’forward and reverse’ solenoid is via the

switch on the front face of the RH control lever. This is inter-
locked with the travel / neutral solenoid valve.

Operational and Control features (2)

• For a fixed oil flow the speed of the machine is governed by
the level of motor displacement. Higher the displacement,
the lower the speed and visa versa.

• The level of motor torque per unit of pressure is also a prod-

uct of displacement.

• Motor displacement and the corresponding speed and

torque characteristics are therefore affected by the following
operations:

• Operators Input via travel mode switch

Selection of creep mode by the operation of the travel creep

solenoid. This valve sets the travel motor displacement to
maximum, this in turn represents the lowest speed per litre
of flow and the highest torque per unit of pressure. This rep-
resents a maximum travel speed of 2.5 kph.

• Torque Maximisation

When travel / reverse solenoid is selected the respective

pressure switch in the line initiates the 2 stage relief valve
solenoid valve. This valve directs a pilot signal into connec-
tion Px. This action raises the pressure of the 2 stage relief
valve in the main direction control valve to 385 bar. This in-
crease in pressure raises the torque potential of the hydrau-
lic motor.

10-212 PW148-8 VEBM720100

STRUCTURE AND FUNCTION, MAINTENANCE STANDARD Travel system

Operational and Control features (3)

Operator’s Input via travel mode switch

• In Hi mode the controller automatically defaults the trans-
mission clutch control solenoid valve in to the off condition.
This gives a travel speed range of 0 - 35 kph.

• In Lo mode the controller energises the transmission clutch

control solenoid valve in the on position. This gives a travel
speed of 0 - 10 kph.

NOTE
Signal on Hi mode enables the drive through to Lo mode.

In both of these operating modes, when the motor pressure re-

duces to 310 bar the displacement changes from maximum to
minimum.

The valve has a switching range of 33 bar. This gives a progres-

sive decrease in motor displacement, resulting in a controlled in-
creased rate of speed and corresponding reduction in traction
force.

OVERRUN PROTECTION. This is dealt with through the ac-

tion of the counterbalance spool in the motor control
block.When the machine begins to overrun the travel motor
momentarily changes its operational mode and becomes a
pump. The change in pressure within the supply and return
line causes the normal pilot signal on the counterbalance
valve to fall, thereby allowing it to slightly close. This action
causes the pressure to rise on the motor return side there-
by providing a braking force and controlled vehicle move-
ment.

PW148-8 VEBM720100 10-213

Travel system STRUCTURE AND FUNCTION, MAINTENANCE STANDARD

7. 2-Stage relief solenoid

7.1 2-Stage Relief Solenoid Schematic.

7.2 2-Stage Relief Solenoid

Located on the solenoid manifold in the service compart-
ment at the rear of the operators cab. This device is activat-
ed when the forward / reverse travel solenoid is selected.

• The relief pressure in the normal working mode is 34.8 Mpa

(355 kg/cm²). If the 2-stage relief function is turned on, how-
ever, the relief pressure rises to about 37.2 MPa (380 kg/
cm²).
By this operation, the hydraulic force is increased.

10-214 PW148-8 VEBM720100

STRUCTURE AND FUNCTION, MAINTENANCE STANDARD Travel system

• Operating condition for turning on 2-stage relief function.

Condition Relief pressure

During travel 34.8 Mpa

When swing lock switch is turned on (355 kg/cm2)

When boom is lowered

When one-touch power maximizing function is 37.2 Mpa

turned on.
(380 kg/cm2)
When L mode is operated

PW148-8 VEBM720100 10-215

Travel system STRUCTURE AND FUNCTION, MAINTENANCE STANDARD

8. Transmission clutch control valve

8.1 Transmission Clutch Control Valve Schematic.

8.2 Hi / Lo Solenoid Valve

Located on the solenoid block in the service compartment at
the rear of the operators cab. This device is activated when
‘LO’ speed is selected.

Solenoid On Lo 0 - 9 kph

Solenoid Off Hi 0 - 35 kph *

*: To max speed

10-216 PW148-8 VEBM720100

STRUCTURE AND FUNCTION, MAINTENANCE STANDARD Steering system

Steering system

Operating principles
When the steering wheel is turned the demand for fluid at port
’P’ of the orbitrol valve causes the CF signal level to fall. The pri-
ority spool is now forced upwards by the spring creating a flow
path into the CF port. Turning the steering wheel also connects
the ’P’ port of the orbitrol valve to the service ’L’ and the service
port ’R’ to tank.

Simultaneously the service port pressure is connected to the pri-

ority valve LS connection on its spring side. This action causes
the priority spool to take up a modulation condition balanced by
the pilot pressure ’’pp’’ from the CF line on one side and the
service port pressure and spring on the opposite.

This results in a pressure drop across the metering valve section

of the orbit unit equal to the priority spool spring rating.

Therefore P = pp - LS

= P1 - P2

At this stage the priority valve becomes a pressure compensator

for the steering unit forming a pressure compensated flow con-
trol. This ensures a constant rate of steering irrespective of
changes in steering cylinder forces.

Dynamic Steering
In the static steering unit, the LS connection is drained to tank
via the spool / sleeve set when the steering unit is in the neutral
position.

In the dynamic steering unit the drain connection has been

made active. The spool of the dynamic priority valve has a port
drilled connecting the CF port to the LS port. During normal run-
ning conditions there is approximately 0.5 lpm flowing.

Therefore when the spool in the priority valve is actuated during

steering the spring chamber is filled with oil via the spool drilling.

In the static LS system the LS chamber is filled with oil from the
LS port in the steering unit.

2 - stage principle
Any valve operation in which the main stage is controlled by a pi-
lot stage and involves the application of a control orifice to create
a pressure differential between the ends of the main stage to off-
set the effect of the main stage spring is operating on the 2-
stage principle.

This applies to pressure control valves but also that of flow con-
trol devices incorporating pilot relief valve control.

PW148-8 VEBM720100 10-217

Steering system STRUCTURE AND FUNCTION, MAINTENANCE STANDARD

1. Condition 1

10-218 PW148-8 VEBM720100

STRUCTURE AND FUNCTION, MAINTENANCE STANDARD Steering system

2. Condition 2

PW148-8 VEBM720100 10-219

Steering system STRUCTURE AND FUNCTION, MAINTENANCE STANDARD

3. Condition 3

10-220 PW148-8 VEBM720100

STRUCTURE AND FUNCTION, MAINTENANCE STANDARD Steering system

4. Condition 4

PW148-8 VEBM720100 10-221

Steering system STRUCTURE AND FUNCTION, MAINTENANCE STANDARD

5. Condition 5

10-222 PW148-8 VEBM720100

STRUCTURE AND FUNCTION, MAINTENANCE STANDARD Steering system

6. Condition 6

PW148-8 VEBM720100 10-223

Steering system STRUCTURE AND FUNCTION, MAINTENANCE STANDARD

7. OLS priority valve

10-224 PW148-8 VEBM720100

STRUCTURE AND FUNCTION, MAINTENANCE STANDARD Steering system

8. Load sensing steering unit

Technical data

Small gear set 80 cc/rev.

Displacement OSPD 80/240 Large gear set 160 cc/rev.

Combined gear set 240 cc/rev.

Pilot pressure relief valve

Shock valves

Valve functions Suction valves

Check valves in LS-connection

Check valves in P connection

Pressure Max. steering pressure 195 bar

PW148-8 VEBM720100 10-225

Steering system STRUCTURE AND FUNCTION, MAINTENANCE STANDARD

10-226 PW148-8 VEBM720100

STRUCTURE AND FUNCTION, MAINTENANCE STANDARD Steering system

PW148-8 VEBM720100 10-227

Steering system STRUCTURE AND FUNCTION, MAINTENANCE STANDARD

10-228 PW148-8 VEBM720100

STRUCTURE AND FUNCTION, MAINTENANCE STANDARD Steering system

PW148-8 VEBM720100 10-229

Service brake and suspension system STRUCTURE AND FUNCTION, MAINTENANCE STANDARD

Service brake and suspension system

Braking system
The hydraulic braking system unit contains the following servic-
es.

• Inlet Bypass Valve:

distributing flow to other services when braking demand is
low or not required.

• Accumulators:
for fluid storage providing a number of brake operations
(usually 5 ~ 8 operations depending upon accumulator ca-
pacity)

• Check Valves:
to isolate the inlet supply from the charged accumulators
and isolate individually charged accumulators from each
other, thereby allowing individual brake circuits to be control-
led.

NOTE
Service brakes 1 and 2 are individually supplied but simultane-
ously applied.

• Pressure Limiting Valve:

to control the maximum pressure in the accumulators. This
valve provides relief valve protection and diverts the fluid via
its unloaded valve action.

10-230 PW148-8 VEBM720100

STRUCTURE AND FUNCTION, MAINTENANCE STANDARD Service brake and suspension system

PW148-8 VEBM720100 10-231

Service brake and suspension system STRUCTURE AND FUNCTION, MAINTENANCE STANDARD

10-232 PW148-8 VEBM720100

STRUCTURE AND FUNCTION, MAINTENANCE STANDARD Service brake and suspension system

Operation
• Oil from the steering priority valve passes at a controlled
rate to charge the accumulators. The inlet bypass valve is
spring biased into the position shown and hydraulically bal-
anced.

• When the oil pressure in the accumulators reach the crack-

ing pressure of the pressure limiting valve it begins to open.
The valve in this example has a pressure override of 35 bar.

Between 120 and 155 bar the accumulators continue to

charge until the bottom pilot signal on the inlet bypass valve
is diverted to tank, allowing the inlet bypass valve to move
downwards thereby diverting all the incoming flow to the
auxiliary circuit.

If the break pedal is now operated oil at a controlled pres-

sure will be sent to the service brakes, the brake force being
controlled by the pre-loading of the valve by the action of the
pedal.

As the brakes are applied the accumulator volumes and as-

sociated pressure will fall. This action will allow the pressure
limiting valve to gradually close as the pressure falls below
155 bar.

Eventually, the flow path through the valve will close causing
the pilot signal on the bottom of the inlet bypass valve to be
re-established. This in turn will move the inlet bypass in to its
upper most position, closing off the supply to the auxiliary
circuit and charging the accumulators once again.

PW148-8 VEBM720100 10-233

Service brake and suspension system STRUCTURE AND FUNCTION, MAINTENANCE STANDARD

10-234 PW148-8 VEBM720100

STRUCTURE AND FUNCTION, MAINTENANCE STANDARD KOMTRAX terminal system

KOMTRAX terminal system

• The KOMTRAX terminal system consists of a KOMTRAX

communication modem, communication antenna, machine
monitor, and GPS antenna.

• This system transmits various kinds of machine information

wirelessly. Persons to operate the KOMTRAX can refer to
the information at office to provide various kinds of services
for customers.

• Information transmittable from the KOMTRAX terminal sys-

tem includes the following.

1. Operation map
2. Service meter
3. Position information
4. Error history and others.

★ To provide the services, you need to make an arrangement

for starting the KOMTRAX service separately.

PW148-8 VEBM720100 10-235

KOMTRAX terminal system STRUCTURE AND FUNCTION, MAINTENANCE STANDARD

KOMTRAX communication modem

TH300

1. Communication antenna connection

2. Connector A (14 poles)
3. Connector B (10 poles)

Outline
• The KOMTRAX communication modem is a wireless com-
munication device to transmit various kinds of machine in-
formation or GPS position information the monitor obtains
from network signals or input signals in the machine. The
communication modem can transmit information via the
communication antenna.

• The modem is provided with a LED lamp as a display unit.

The LED is used for maintenance.

Input and output signals

Connector B
Connector A Input/
Pin No. Signal name
Input/ output
Pin No. Signal name
output B-1 Serial signal DCD Output
A-1 Electric power supply Input B-2 Serial signal RXD Output
A-2 NC(*1) — B-3 Serial signal TXD Input
A-3 NC(*1) — B-4 Serial signal DTR Input
A-4 Electric power supply switching Output B-5 Serial signal SGND Input
A-5 NC(*1) — B-6 Serial signal DSR Output
A-6 NC(*1) — B-7 Serial signal RTS (*2) Input
A-7 GND Input B-8 Serial signal CTS (*2) Output
A-8 GND Input B-9 Serial signal RI (*2) Output
A-9 Modem power control 1 (*2) Input B-10 NC(*1) —
A-10 Modem power control 2 (*2) Input *1: Never connect to NC or malfunctions or failures
A-11 Modem serial control (*2) Input will occur.
A-12 Electric field intensity 1 (*2) Output *2: Signal used by TH200
A-13 Electric field intensity 2 (*2) Output
A-14 NC(*1) —
*1: Never connect to NC or malfunctions or failures will
occur.
*2: Signal used by TH200

10-236 PW148-8 VEBM720100

 20 TESTING AND ADJUSTING
Standard value table for engine related parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-2
Standard value table for chassis related parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-3

Testing and adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-101

Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-221
Troubleshooting when failure code is indicated . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-301
Troubleshooting of electrical system (E-MODE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-501
Troubleshooting of electrical system (Error checking of items without Monitor codes) . . . . . . . . . 20-601
Troubleshooting of hydraulic and mechanical system (H-MODE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-701

Note the following when making judgements using the standard value tables for testing, adjusting, or trouble-
shooting.

1. The standard value for a new machine given in the table is the value used when shipping the machine from
the factory and is given for reference. It is used as a guideline for judging the progress of wear after the ma-
chine has been operated, and as a reference value when carrying out repairs.

2. The service limit value given in the tables is the estimated value for the shipped machine based on the re-
sults of various tests. It is used for reference together with the state of repair and the history of operation to
judge if there is a failure.

3. These standard values are not the standards used in dealing with claims.

• When carrying out testing, adjusting, or troubleshooting, park the machine on level ground, insert the
safety pins, and use blocks to prevent the machine from moving.

• When carrying out work together with other workers, always use signals and do not let unauthorized peo-
ple near the machine.

• When checking the water level, always wait for the water to cool down. If the radiator cap is removed
when the water is still hot, the water will spurt out and cause burns.

Be careful not to get caught in the fan, fan belt or other rotating parts.

PW148-8 VEBM720100 20-1

Standard value table for engine related parts TESTING AND ADJUSTING

Standard value table for engine related parts

Applicable model PW148-8

Engine SAA4D107E-1

Standard value for

Item Measurement condition Unit Service limit value
new machine

High idling (Not possible to check in-chassis) 2,450 ±50

Engine speed Low idling rpm 1,050 ±50

Rated speed 2,200 ±20

At sudden acceleration
Bosch Max. 1.2 –
Exhaust gas colour LO idle - HI idle
index
At high idling Max. 1.2 –

Valve clearance Intake valve 0.25 0.152 - 0.381

mm
(Normal temperature) Exhaust valve 0.51 0.381 - 0.762

• SAE0W30E0S,
Min. 0.29 0.25
SAE5W40E0S, High idle
{Min. 3.0} {2.5}
SAE10W30DH,
MPa (kg/
Oil pressure SAE15W40DH,
cm²}
SAE30DH engine oil Min. 0.10 0.07
• Coolant temperature: Low idle
{Min. 1.0} {0.7}
Operating range

Compression Oil temperature: 40–60ºC MPa Min. 2.4 1.69

pressure Engine speed: 250 - 280 rpm {kg/cm2} {Min. 24.6} {17.2}

(Water temperature: operating range) At rated kPa Max. 1.0 2.49

Blow-by pressure
output {mmH2O} {Max. 100} {250}

Whole speed range

Oil temperature ºC 80-110 120
(inside oil pan)

Fan belt tension mm AUTO TENSION AUTO TENSION

Deflection when pressed with finger force of
Air conditioner approx. 58.8 N{6 kg} mm 5–8
compressor belt tension

20-2 PW148-8 VEBM720100

TESTING AND ADJUSTING Standard value table for chassis related parts

Standard value table for chassis related parts

Applicable model PW148-8

Category

Item Measurement Condition Unit Standard value Permissible value

• Engine water temperature: Within opera-

tion range
Pump at relief • Hydraulic oil temperature: Within opera-
1,850 ±100 1,850 ±100
P mode tion range
• Engine at high idling
• Arm in relief condition
Engine speed

• Engine water temperature: Within opera-

tion range
rpm
At pump relief + one • Hydraulic oil temperature: Within opera-
touch power up tion range 1,810 ±100 1,810 ±100
P mode • Engine at high idling
• Arm relief + One-touch power max. switch
in ON condition

Speed when auto- • Engine at high idling

deceleration is oper- • Auto-deceleration switch in ON condition 1,400 ±100 1,400 ±100
ated • All control levers in NEUTRAL condition

Boom control valve

Arm control valve

Bucket control valve

Swing control valve

Spool stroke

8 ±0.5 8 ±0.5
Travel control valve
mm
Adjust control valve
(2PBoom only)

Stabiliser control valve

Bucket Dump
9.5 ±0.5 9.5 ±0.5
2nd Boom Extend Only

Boom control lever 60.5 ±3.5 60.5 ±3.5

Travel of control

Arm control lever 60.5 ±3.5 60.5 ±3.5

• Engine stopped
Bucket control lever 60.5 ±3.5 60.5 ±3.5
levers

• At center of control lever grip

mm
Swing control lever • Max. reading up to stroke end (excepting 60.5 ±3.5 60.5 ±3.5
lever play in NEUTRAL position)
Travel control pedal 9.2 ±0.2 9.2 ±0.2

Play of control lever Max. 3.0 Max. 3.0

PW148-8 VEBM720100 20-3

Standard value table for chassis related parts TESTING AND ADJUSTING

Applicable model PW148-8

Category

Item Measurement Condition Unit Standard value Permissible value

• Hydraulic oil temperature: Within opera- 17 ±3.9 Max. 24.5

Boom control lever
tion range {1.7 ±0.4} {Max. 2.5}
• Engine at high idling
17 ±3.9 Max. 24.5
Arm control lever • At center of control lever grip
{1.6 ±0.4} {Max. 2.5}
• At tip in case of pedal
• Max. reading up to stroke end 14 ±2.9 Max. 21.6
Bucket control lever
{1.4 ±0.3} {Max. 2.2}

14 ±2.9 Max. 21.6

Swing control lever
of control levers
Operating force

{1.4 ±0.3} {Max. 2.2}

Max. 65
Travel control pedal N{kg} 55.4 ±5 {5.5 ±0.5}
{Max. 6.5}

Max. 510
Brake pedal 340 ±17 {35 ±3.5}
{Max. 52.5}

20-4 PW148-8 VEBM720100

TESTING AND ADJUSTING Standard value table for chassis related parts

Applicable model PW148-8 (Std)

Category

Permissible
Item Measurement Condition Unit Standard value
value

• Hydraulic oil temperature: Within operation range

• Engine at high idling
Unload 3.38 ±1.0 3.38 ±1.0
• Working mode: P mode
pressure {34.5 ±10} {34.5 ±10}
• Hydraulic pump output pressure with all control levers in
NEUTRAL position

Boom 34.8 ±1.0 33.3–36.8

Arm • Hydraulic oil temperature: Within operation range {355 ±10} {340–375}
• Engine at high idling
• Working mode: P mode 37.3 ±1.0 36.3–39.2
Bucket
• Hydraulic pump output pressure with all measurement {380 ±10} {370–400}
circuits relieved 30.9 ±1.5 28.9–32.9
Swing
Hydraulic pressure

• Values inside parenthesis: Hydraulic oil pressure with {315 ±15} {295–335}
one-touch power max. switch in ON mode (reference on-
Travel ly) MPa
38.2 ±1.0 37.3–40.2
{kg/
Stabiliser {390 ±10} {380–410}
cm2}
• Hydraulic oil temperature: Within operation range
Control circuit 3.65+0.5 / - 0.015
• Engine running at high idling 3.2–3.65
source
• Control circuit pressure setting valve input (12 station so- {37.2 +0.015 /- 0.015} {32.6–37.2}
pressure
lenoid valve block port B)

• Hydraulic oil tempera-

ture: Within operation
• Roadwheels raised off
range
LS control ground
• Engine at high idling
circuit • LO travel speed 2.16 ±0.1 2.16 ±0.1
• Working mode: L mode
• Service brake disen- {22 ±1} {22 ±1}
( ∆ PLS) • Disconnect the LS EPC
gaged travel pedal fully
solenoid CN V22
depressed
• Hydraulic pump pressure
- LS pressure

PW148-8 VEBM720100 20-5

Standard value table for chassis related parts TESTING AND ADJUSTING

Applicable model PW148-8 (Std)

Category

Permissible
Item Measurement Condition Unit Standard value
value

Swing brake
deg 75 ±10 Max. 90
angle

• Hydraulic oil temperature: Within operation range

• Engine running at high idling
• Working mode: P mode
• Swing circle misalignment amount when stopping after 1
turn
Swing

• Hydraulic oil tempera-

Time taken to
ture: Within operation
swing from sec
range
start
• Engine running at high
idling
• Working mode: P mode 90° 4.0 ±0.3 Max. 4.3
• Time required for passing
point 90° from starting
point.
• Speeds quoted are with
rated bucket (1,260kg)

20-6 PW148-8 VEBM720100

TESTING AND ADJUSTING Standard value table for chassis related parts

Applicable model PW148-8

Category

Permissible
Item Measurement Condition Unit Standard value
value

Time taken to
sec 27.5 ±2.5 Max. 32.5
swing

• Hydraulic oil temperature: Within operation range

• Engine running at high idling
• Working mode: P mode
• Time required for 5 more turns after making initial one turn
Swing

15o

Hydraulic drift of
mm 0 0
swing

• Hydraulic oil temperature: Within operation range

• Engine stopped
• Keeping upper structure transverse on slope of 15 de-
grees
• Notching a mating mark on inner and outer races of swing
circle
• Mating mark misalignment amount during 5 minutes

• Hydraulic oil temperature: Within operation range

Leakage from • Engine running at high idling
cc/min Max. 21
swing motor • Swing lock switch: ON
• Leakage amount for one minute during swing relief

PW148-8 VEBM720100 20-7

Standard value table for chassis related parts TESTING AND ADJUSTING

Applicable model PW148-8

Category

Permissible
Item Measurement Condition Unit Standard value
value

CR 2.5km/h 72±10%

LO 8.5km/h 21 +2 / -0

Travel speed (1) sec.

• Machine in road travel posture 20km/h 9 + 1/ -0

• Engine running at high idle
• Hydraulic oil temperature 45~55oC
Hi
• Run up for at least 200M or until the
max travel speed is stabilised then
measure time taken to travel the next 35km/h 5.1 +0.5 / -0
50M on flat ground
Travel

CR 2.5km/h 250 ±5%

Travel speed (2) • Raise machine road wheels off ground rpm
using work equipment and chassis at-
tachments
LO 8.5km/h 840±5%
• Engine running at high idle
• Service brake and park brake both dis-
engaged
• Fully depress travel pedal and meas-
ure propshaft rotations.
• Hydraulic oil temperature 45~55oC.
Within operation range

20-8 PW148-8 VEBM720100

TESTING AND ADJUSTING Standard value table for chassis related parts

Applicable model PW148-8

Category

Standard Permissible
Item Measurement Condition Unit
value value
Leakage of travel motor

• Engine running at high idle

• Hydraulic oil temperature 45~55oC. Within operation
Leakage of travel
motor
range. l/min 5 ±1 Max. 10
• Apply service brake and relieve travel circuit.
• Disconnect transmission drain line.

Whole work
equipment
Max. 400 Max. 800
(tooth tip fall
amount)

Boom cylinder
Hydraulic drift of work equipment

(cylinder retrac- Max. 6 Max. 12

tion amount)
Work equipment

Arm cylinder
(cylinder exten- mm Max. 16 Max. 32
sion amount)

(including rated bucket {1260kg})

Bucket cylinder
(cylinder retrac- • Hydraulic oil temperature: Within operation range Max. 26 Max. 52
tion amount) • Flat and level ground
• Work equipment in measurement posture as illustrated
above
Second Boom
• Engine stopped
adjust cylinder
• Work equipment control lever in NEUTRAL position Max. 4 Max. 8
(Cyl retraction
• Fall amount for 15 minutes as measured every 5 min-
amount)
utes starting immediately after initial setting

PW148-8 VEBM720100 20-9

Standard value table for chassis related parts TESTING AND ADJUSTING

Applicable model PW148-8

Category

Permissible
Item Measurement Condition Unit Standard value
value

RAISE
3.6 ±0.3 Max. 5.2

Mono boom
boom lift
• Hydraulic oil temperature: Within operation

LOWER
range
• Engine running at high idle 3.2 ±0.3 Max. 3.8
• Working mode: P
• Time required from raise stroke end till bucket
touches ground

RAISE
3.8 ±0.3 Max. 4.4
Work equipment speed

Two piece boom

Work equipment

1st boom lift

• Hydraulic oil temperature: Within operation sec
LOWER

range
• Engine running at high idle 3.1 ±0.3 Max. 3.2
• Working mode: P
• Time required from raise stroke end till bucket
touches ground
RAISE

5.2 ±0.5 Max. 6.7

Two piece boom

2nd boom
adjust
LOWER

• Hydraulic oil temperature: Within operation 3.7 ±0.5 Max. 6.2

range
• Engine running at high idle
• Working mode: P
• Time required from raise stroke end till lower
stroke end

20-10 PW148-8 VEBM720100

TESTING AND ADJUSTING Standard value table for chassis related parts

Applicable model PW148-8

Category

Permissible
Item Measurement Condition Unit Standard value
value

RAISE
3.6 ±0.5 Max. 5.0
• Hydraulic oil temperature: Within operation
range
• Engine running at high idle
Outrigger
• Working mode: P
• Time required for 1 outrigger raise stroke end

LOWER
to lower stroke end.
Chassis attachment speeds

5.2 ±0.4 Max. 4.8

Chassis attachments

Sec.

RAISE
2.2 ±0.3 Max. 2.6
• Hydraulic oil temperature: Within operation
range
• Engine running at high idle
Dozer Blade
• Working mode: P
• Time required from raise stroke end to lower
LOWER

stroke end.
2.0 ±0.3 Max. 2.6

PW148-8 VEBM720100 20-11

Standard value table for chassis related parts TESTING AND ADJUSTING

Applicable model PW148-8

Category

Permissible
Item Measurement Condition Unit Standard value
value

IN
3.6 ±0.4 Max. 4.5

Arm

OUT
• Hydraulic oil temperature: Within operation 3.3 ±0.3 Max. 3.7
range
• Engine running at high idling
• Working mode: P mode
Work equipment speed

• Time required from dumping stroke end to dig-

ging stroke end

CURL
2.4 ±0.3 Max. 3.5

Bucket
Work equipment

DUMP

sec
2.1 ±0.3 Max. 3.2
• Hydraulic oil temperature: Within operation
range
• Engine running at high idling
• Working mode: P mode
• Time required from dumping stroke end to dig-
ging stroke end
Time lag

Monoboom
Max. 1.0 Max. 1.2
boom lift

• Hydraulic oil temperature: Within operation range

• Engine running at low idling
• Working mode: P mode
• Operate full boom down from stroke end till bucket touch-
es ground. Measure delay from bucket touching ground
to bucket starting to push the machine up.

20-12 PW148-8 VEBM720100

TESTING AND ADJUSTING Standard value table for chassis related parts

Applicable model PW148-8

Category

Standard Permissible
Item Measurement Condition Unit
value value

Arm Max. 1.0 Max. 1.2

• Hydraulic oil temperature: Within operation range

• Engine running at low idling
• Working mode: P mode
• Operate full arm curl from dumping stroke end to full retrac-
tion. Measure delay when arm pauses midway through op-
eration
Time lag

sec
Work equipment

Bucket Max. 1.0 Max. 1.2

• Hydraulic oil temperature: Within operation range

• Engine running at low idling
• Working mode: P mode
• Operate full bucket curl from dumping stroke end to full re-
traction. Measure delay when bucket pauses midway
through operation
Internal leakage

Cylinders • Hydraulic oil temperature: Within operation range 5 20

• Engine running at high idling cc/
• Leakage amount for one minute with cylinder or travel to be min
Center swivel measured in relief condition 10 50
joint

PW148-8 VEBM720100 20-13

Standard value table for chassis related parts TESTING AND ADJUSTING

Applicable model PW148-8

Category

Standard Permissible
Item Measurement Condition Unit
value value

Two piece
boom 1st sec Max. 1.0 Max. 1.2
boom lift • Hydraulic oil temperature: Within operation range
• Engine running at low idle
• Operate full boom down from stroke end till bucket touches
ground. Measure delay from bucket touching ground to
bucket starting to push the machine up.
Time lag

Two piece
boom 2nd Max. 1.0 Max. 1.2
boom adjust

Hydraulic oil temperature: Within operation range

Work equipment

Engine running at low idle

Operate full boom adjust down from stroke end till bucket
touches ground. Measure delay from bucket touching ground sec
to bucket starting to push the machine up.

• Hydraulic oil temperature: Within operation range

• Engine running at low idle
Outrigger • Raise outrigger off ground then operate full lower Max. 1.0 Max. 1.2
• Measure delay from when outrigger touches ground to out-
rigger starting to lift machine up

• Hydraulic oil temperature: Within operation range

• Engine running at low idle
Blade • Raise blade off ground then operate full lower Max. 1.0 Max. 1.2
• ‘Measure delay from when blade touches ground to blade
starting to lift machine up
Performance of
hydraulic pump

Hydraulic pump
See next page l/min See next page
delivery

20-14 PW148-8 VEBM720100

TESTING AND ADJUSTING Standard value table for chassis related parts

Applicable model PW148-8

Cate- Permissible
Item Measurement Condition Unit Standard value
gory value

Discharge amount of hydraulic pump

(N*m) {kg*m}
300
{60}

490 {50}
250

Pump AbsorptionTorque T
Pump Delivery Flow Q (L/min)

392 {40}

200 Flow upper limit (Ref.)

294 {30}

150 Flow lower limit

196 {20}

98 {10}
100
Performance of hydraulic pump

50

4.9 9.8 14.7 19.6 24.5 29.4 34.3 39.2 (MPa)

{50} {100} {150} {200} {250} {300} {350} {400} {kg/cm }

Pressure Torque Pump Pressure PP

kg/cm2 Mpa kgm Nm
46 4.51 13.0 127
228 22.34 44.8 439
260 25.48 44.3 435
288 28.22 42.8 420
320 31.36 43.5 426
350 34.30 43.5 426
380 37.24 42.8 420

MAX 44.8 439

Pump speed: At 2,000 rpm, PC current 323 mA (Travel Mode)

Standard value for Judgement standard

Pump discharge pressure
Check point discharge amount Q lower limit Q
(MPa {kg/cm2})
(l/min) (l/min)

As desired P1 See graph See graph

• When measuring with the pump mounted on the machine, if it is impossible to set the engine speed to the specified speed with
the fuel control dial, take the pump discharge amount and the engine speed at the point of measurement, and use them as a
base for calculating the pump discharge amount at the specified speed.

PW148-8 VEBM720100 20-15

Standard value table for chassis related parts TESTING AND ADJUSTING

Flow control characteristic of PC valve (STD)

• The values in this table are used as reference values when
carrying out troubleshooting.

Applicable model PW148-8 (Std)

Category Item Measurement Condition Unit Reference Value

Mono boom:
Time required for turn-
Characteristics 4.0 ±0.3
ing from 0 to 90
of PC flow con- sec
degrees with boom
trol valve Two piece boom:
raised
4.0 ±0.3

• Hydraulic oil temperature: Within operation range

• Engine at high idling
• Working mode: P mode
• Rated load applied to bucket
• Solid and flat ground
• Time required till passing spot of 90 degrees start-
ing from illustrated posture and with boom raised

20-16 PW148-8 VEBM720100

TESTING AND ADJUSTING

20 TESTING AND ADJUSTING

Measuring engine speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-102
Measuring intake air pressure (boost pressure) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-103
Checking exhaust gas colour . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-104
Adjusting valve clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-106
Measurement of compression pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-108
Measuring blow-by pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-110
Measuring engine oil pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-111
Handling fuel system parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-112
Releasing residual pressure from fuel system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-113
Measuring fuel pressure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-114
Measuring fuel return rate and leakage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-116
Bleeding air from fuel circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-120
Checking fuel circuit for leakage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-122
Checking and adjusting air conditioner compressor belt tension. . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-123
Replacing the fan belt. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-124
Measurement of clearance in swing circle bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-125
Inspection and adjustment of hydraulic oil pressure in hydraulic circuit for work equipment,
swing and travel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-126
Inspection and adjustment of control circuit oil pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-129
Inspection and adjustment of pump PC (valve inlet) control oil pressure . . . . . . . . . . . . . . . . . . . . . 20-131
Inspection and adjustment of pump LS valve control oil pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-134
Measurement of solenoid valve output pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-138
Solenoid valve block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-140
Measurement of PPC valve output pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-143
Adjustment of work equipment and swing PPC valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-145
Measuring and adjusting quick coupler control valve output pressure . . . . . . . . . . . . . . . . . . . . . . . 20-146
Testing travel motor relief pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-147
Adjusting travel motor relief pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-148
Testing propshaft speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-149
Testing transmission clutch control circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-150
Inspection of locations of hydraulic drift of work equipment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-152
Release of remaining pressure in hydraulic circuit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-154
Measurement of oil leakage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-155
Air bleeding of various parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-158
Inspection procedures for diode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-161
Special function of monitor panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-162

PW148-8 VEBM720100 1 20-101

Measuring engine speed
Measuring engine speed
• Measure the engine speed with the monitoring
function of the machine monitor.
• Measure the engine speed under the following
condition.
• Engine coolant temperature: Within operat-
ing range
• Hydraulic oil temperature: Within operating
range
1. Preparation work
Operate the machine monitor so that the engine
speed can be monitored.
• For the operating method of the machine
monitor, see page 20-162.
• Monitoring code: 01002 Engine speed
2. Measuring low idle speed
a. Start the engine and set the fuel control dial
in the low idle (MIN) position.
b. Set all the levers and pedals for work equip-
ment control, swing control, and travel in
neutral and measure the engine speed.
3. Measuring high idle speed
a. Start the engine and set the fuel control dial
in the high idle (MAX) position.
20-102
TESTING AND ADJUSTING
b. Set the working mode in the power mode (P)
and turn the auto-decelerator OFF.
c. Set all the levers and pedals for work equip-
ment control, swing control, and travel in
neutral and measure the engine speed.
4. Measuring 2-pump relief speed
a. Start the engine and operate the arm cylin-
der to the IN stroke end.
b. Set the fuel control dial in the high idle (MAX)
position and set the working mode in the
power mode (P).
c. Operate the left work equipment control lever
to relieve the arm circuit at the IN stroke end
and measure the engine speed.
5. Measuring 2-pump relief and power maximiz-
ing speed (near rated speed)
a. Start the engine and operate the arm cylin-
der to the IN stroke end.
b. Set the fuel control dial in the high idle (MAX)
position and set the working mode in the
power mode (P).
c. While operating the left work equipment con-
trol lever to relieve the arm circuit at the IN
stroke end and depressing the power maxi-
mizing switch, measure the engine speed.
• The power maximizing function is reset auto-
matically in about 8.5 seconds even if the
switch is kept depressed. Accordingly,
measure the engine speed in that period.
6. Measuring auto-deceleration speed
a. Start the engine, set the fuel control dial in
the high idle position (MAX), and turn the au-
to-decelerator ON.
b. Set all the levers and pedals for work equip-
ment control, swing control, and travel in
neutral and measure the engine speed when
the auto-decelerator operates.
• The engine speed lowers to a certain level
about 5 seconds after all the levers and ped-
als are set in neutral. This level is the auto-
deceleration speed.
1 PW148-8 VEBM720100
TESTING AND ADJUSTING Measuring intake air pressure (boost pressure)

Measuring intake air pressure (boost pressure)

• Measuring tools for intake air pressure (boost 2. Install nipple of boost gauge kit R and connect it
pressure) to gauge [2].

Symbol Part No. Part name 3. Run the engine at middle or higher speed and
bleed oil from the hose.
R 799-201-2202 Boost gauge kit

• Insert the connecting parts of the gauge and

Stop the machine on a level ground and lower the
work equipment to the ground.
• Measure the intake air pressure under the follow-
ing condition.
• Engine coolant temperature:
Within operating range
• Hydraulic oil temperature:
Within operating range
1. Open the engine hood and remove intake air
pressure pickup plug (1) from the intake air con-
nector.
hose about a half and open the self-seal on
the hose side repeatedly, and the oil will be
drained.
• If Pm kit (A) is available, you use the air-
bleeding coupling (790-261-1130) in that kit.
• If oil is left in the hose, the gauge does not
work. Accordingly, be sure to drain the oil.
4. Set the working mode in the power mode (P) and
turn the swing lock switch ON.
• If the swing lock switch is turned ON, the
main relief valve is set for high-pressure re-
lief.
5. While running the engine at high idle, relieve the
arm circuit and measure the intake air pressure.

[2]

6. After finishing measurement, remove the meas-

View on X uring tools and return the removed parts.

PW148-8 VEBM720100 20-103

Checking exhaust gas colour TESTING AND ADJUSTING

Checking exhaust gas colour

• Checking tools for exhaust gas colour d. Remove the filter paper and compare it with
the attached scale.
Symbol Part No. Part name
e. After finishing checking, remove the measur-
1 799-210-9001 Handy smoke checker
ing tools and return the removed parts.
A Commercially
2 Smoke meter
available
2. Checking with smoke meter A2
a. Insert probe [1] of smoke meter A2 in the
outlet of the exhaust pipe and fix it to the ex-
Stop the machine on a level ground and lower the haust pipe with a clip.
work equipment to the ground.

Be careful not to touch any hot part when remov-

ing or installing the checking tools.

Check the exhaust gas colour under the following

condition.

• Engine coolant temperature: Within operating

range
If an air source and an electric power source are not
available in the field, use handy smoke checker A1.
When recording official data, use smoke meter A2.
b. Connect the probe hose, receptacle of the
accelerator switch, and air hose to smoke
meter A2.
• Limit the supplied air pressure to 1.5 MPa
{15 kg/cm2}.

1. Measuring with handy smoke checker A1 c. Connect the power cable to an AC recepta-
a. Stick a sheet of filter paper to smoke checker cle.
A1.
★ Before connecting the cable, check that
b. Insert the exhaust gas intake pipe in exhaust the power switch of the smoke meter is
pipe (1). turned OFF.

c. Start the engine and accelerate it suddenly
or run it at high idle and operate the handle
of smoke checker A1 so that the filter paper
will absorb the exhaust gas.
• Absorbing time: 1.4 ± 0.2 sec
d. Loosen the cap nut of the suction pump and
fit the filter paper.
★ Fit the filter paper securely so that the
exhaust gas will not leak.
e. Turn on the power switch of smoke meter
A2.

20-104 PW148-8 VEBM720100

TESTING AND ADJUSTING Checking exhaust gas colour

f. Start the engine and accelerate it suddenly

or run it at high idle and depress the acceler-
ator pedal of smoke meter A2 and collect the
exhaust gas into the filter paper.

g. Place the contaminated filter paper on the

clean filter paper (at least 10 sheets) in the
filter paper holder and read the indicated val-
ue.

h. After finishing checking, remove the check-

ing tools and return the removed parts.

PW148-8 VEBM720100 20-105

Adjusting valve clearance TESTING AND ADJUSTING

Adjusting valve clearance

• Measuring tools for valve clearance 4. Rotate the crankshaft forward with gear C1 and
set wide slit (b) of the rotation sensor ring to pro-
Symbol Part No. Part name jection top (a) of front cover.
1 795-799-1131 Gear
• Projection top (a) must be within the range of
B Commercially
2 Clearance gauge wide slit (b) when it is seen from the air con-
available
ditioner compressor side.

• If you can see the yellow marks of projection

top (a) and wide slit (b), you may set them to
Stop the machine on a level ground and lower the each other.
work equipment to the ground.

• Measure the valve clearance under the following
condition.
• Engine coolant temperature: Normal temper-
ature
When the crankshaft is set as above, the piston
in the No. 1 or No. 4 cylinder is not set to the
compression top dead center (TDC). Take care.

1. Open the engine hood and remove the belt

guard (1) from the top of the air conditioner com-
pressor.

2. Remove cylinder head cover (2).

5. Check the movement of the rocker arm of the

No. 1 cylinder to judge the valve to be adjusted.

• If you can move the rocker arms of air ex-

haust valves (EX) with the hand by the valve
clearance, adjust the valves marked with q
3. Remove plug (3) from the top of the starting mo- in the valve arrangement drawing.
tor and insert gear C1.
• If you can not move the rocker arms of ex-
haust valves (EX) with the hand by the valve
clearance, adjust the valves marked with z
in the valve arrangement drawing.

• Valve arrangement drawing

20-106 PW148-8 VEBM720100

TESTING AND ADJUSTING Adjusting valve clearance

6. Adjust the valve clearance according to the fol-

lowing procedure.
Remove gear C1 without fail.
a. While holding fixing adjustment screw (4),
loosen locknut (5).
 Cylinder head cover mounting nut:
b. Insert clearance gauge C2 in the clearance
24 ± 4 Nm {2.45 ± 0.41 kgm}
between rocker arm (6) and crosshead (7)
and adjust the valve clearance with adjust-
ment screw (4).

• With the clearance gauge inserted, turn

the adjustment screw to a degree that
you can move the thickness gauge light-
ly.

c. While holding adjustment screw (4), tighten

locknut (5).

 Locknut:
24 ± 4 Nm {2.45 ± 0.41 kgm}

• After tightening the locknut, check the valve

clearance again.

d. Rotate the crankshaft forward by 1 turn and

set wide slit (b) to projection top (a) accord-
ing to step 4.

e. Adjust the other valve clearances according

to steps (5) and (6).

• If the valves marked with z in the valve

arrangement drawing were adjusted in
steps (5) and (6), adjust the valves
marked with .

• If the valves marked with  in the valve

arrangement drawing were adjusted in
steps (5) and (6), adjust the valves
marked with z.

f. After finishing adjustment, remove the ad-

justing tools and return the removed parts.

PW148-8 VEBM720100 20-107

Measurement of compression pressure TESTING AND ADJUSTING

Measurement of compression pressure

★ Measuring tools for compression pressure

Symbol Part No. Part name

1 795-502-1590 Compression gauge

2 795-799-6700 Puller
D
795-790-4410 Adapter
3
6754-11-3130 Gasket

Stop the machine on a level ground and lower the

work equipment to the ground.

5. Disconnect injector wiring harness. Using tool

★ Measure the compression pressure under the D2, remove injector (5).
following condition.

• Engine oil temperature: 40 – 60°C

1. Open the engine hood and remove belt guard (1)

from the top of the air conditioner compressor.

2. Remove cylinder head cover (2).

6. Install adapter D3 to the injector mounting part

with the injector holder and connect compression
gauge D1.

★ Install the gasket to the adapter end without

fail.

★ Tighten the holder mounting bolts alternately.

3. Remove the mounting bolts of rocker arm as-
sembly (3) on the exhaust side, and then remove  Injector holder mounting bolt:
rocker arm assembly (3). 8 ± 0.8 Nm {0.8 ± 0.08 kgm}

★ When removing the injector, you do not need ★ If a little quantity of engine oil is applied
to remove the rocker arm assembly on the to the joint of the adapter and gauge, air
intake side. does not leak easily.

4. Remove fuel tube (4), and then remove inlet con- 7. Install rocker arm assembly (3) on the exhaust
nector (7) in the cylinder head. side and adjust the valve clearance.

★ The inlet connector is connecting the fuel  Rocker arm assembly mounting bolt:
tube to the injector. 36 ± 5 Nm {3.67 ± 0.5 kgm}

★ See "Adjusting valve clearance".

20-108 PW148-8 VEBM720100

TESTING AND ADJUSTING Measurement of compression pressure

10. After finishing measurement, remove the meas-

uring tools and return the removed parts.

★ Install the injector and inlet connector ac-

cording to the following procedure.

a. Apply new engine oil (SAE15W-40) to the O-

ring of injector (5) and cylinder head.

b. Install injector (5) with the fuel inlet hole di-

rected to the air intake manifold.

c. Install injector holder (8) and tighten the

mounting bolt by 3 – 4 threads.

8. Disconnect CE03 connector (6) of the engine d. Install inlet connector (7) and tighten inlet
controller. connector retainer (9) temporarily.

e. Tighten the mounting bolt of injector holder

(8) securely.

 Injector holder mounting bolt:

If the connector is not disconnected, the engine
will start during measurement and it will be dan-
gerous. 8 ± 0.8 Nm {0.8 ± 0.08 kgm}

f. Tighten inlet connector retainer (9) securely.

 Inlet connector retainer:

50 ± 5 Nm {5.1 ± 0.5 kgm}
Since the CE03 connector is a part of the power
supply circuit of the engine controller, cover the
connector on the machine side with a vinyl sheet,
etc. to prevent electric leakage and ground fault.

★ Tighten the bolts and nuts other than the in-

jector and inlet connector to the following
torque.

 Injector wiring harness nut:

1.5 ± 0.25 Nm {0.15 ± 0.026 kgm}

 Fuel tube sleeve nut:

9. Rotate the engine with the starting motor and
measure the compression pressure. 35 ± 3.5 Nm {3.6 ± 0.4 kgm}

 Rocker arm assembly mounting bolt:

★ Read the gauge when the pointer is stabi-
lized. 36 ± 6 Nm {3.7 ± 0.6 kgm}

★ Adjust the valve clearance. For details, see

"Adjusting valve clearance":

 Cylinder head cover mounting nut:

24 ± 4 Nm {2.45 ± 0.41 kgm}

PW148-8 VEBM720100 20-109

Measuring blow-by pressure TESTING AND ADJUSTING

Measuring blow-by pressure

• Measuring tools for blow-by pressure 5. While running the engine at high idle, relieve the
arm circuit and measure the blow-by pressure.
Symbol Part No. Part name
• Read the gauge when the pointer is stabi-
1 799-201-1504 Blow-by checker
D lized.
2 799-790-3300 Blow-by tool

Stop the machine on a level ground and lower the 2

work equipment to the ground.

• Measure the blow-by pressure under the follow-

ing condition.

• Engine coolant temperature: Within operat-

ing range

• Hydraulic oil temperature: Within operating

range

1. Remove the breather hose from the oil catcher 6. After finishing measurement, remove the meas-
tube. uring tools and replace the breather hose into the
oil catcher tube.
2. Install tool and adapter [1] of blow-by checker D1
or blow-by tool D2 to breather hose (1) and con-
nect gauge [2].
3.

[1]
CATCHER TUBE

4. Start the engine, set the working mode in the

power mode (P), and turn the swing lock switch
ON.

• If the swing lock switch is turned ON, the

main relief valve is set for high-pressure re-
lief.

20-110 PW148-8 VEBM720100

TESTING AND ADJUSTING Measuring engine oil pressure

Measuring engine oil pressure

• Measuring tools for engine oil pressure 2. Install nipple of hydraulic tester E1 and connect
hydraulic tester E2.
Symbol Part No. Part name
3. Start the engine and turn the auto-decelerator
799-101-5002 Hydraulic tester
1 OFF.
E 790-261-1204 Digital hydraulic tester
4. Run the engine and measure the engine oil pres-
2 799-401-2320 Hydraulic tester
sure at high idle and low idle.

Stop the machine on a level ground and lower the

work equipment to the ground. E2

• Measure the engine oil pressure under the fol-

lowing condition.

• Engine coolant temperature: Within operat-

ing range

1. Open the side cover of the pump room and re-

move oil pressure pickup plug (1) from the en-
gine oil filter (2).

5. After finishing measurement, remove the meas-

uring tools and return the removed parts.

PW148-8 VEBM720100 20-111

Handling fuel system parts TESTING AND ADJUSTING

Handling fuel system parts

• Precautions for checking and maintaining fuel
system

The common rail fuel injection system (CRI) con-

sists of more precise parts than the conventional
fuel injection pump and nozzle. If foreign matter
enters this system, it can cause a trouble.

When checking and maintaining the fuel system,

take care more than the past. If dust, etc. sticks
to any part, wash that part thoroughly with clean
fuel.

• Precautions for replacing fuel filter cartridge

Be sure to use the Komatsu genuine fuel filter

cartridge.

Since the common rail fuel injection system

(CRI) consists of more precise parts than the
conventional fuel injection pump and nozzle, it
employs a high-efficiency special filter to prevent
foreign matter from entering it. If a filter other
than the genuine one is used, the fuel system
may have a trouble. Accordingly, never use such
a filter.

20-112 PW148-8 VEBM720100

TESTING AND ADJUSTING Releasing residual pressure from fuel system

Releasing residual pressure from fuel system

• Pressure is generated in the low-pressure circuit
and high-pressure circuit of the fuel system while
the engine is running.

• Low-pressure circuit:
Feed pump – Fuel main filter – Supply pump

• High-pressure circuit:
Supply pump – Common rail – Injector

• The pressure in both low-pressure circuit and

high-pressure circuit lowers to a safety level au-
tomatically 30 seconds after the engine is
stopped.

• Before the fuel circuit is checked and its parts are

removed, the residual pressure in the fuel circuit
must be released completely. Accordingly, ob-
serve the following.

Before checking the fuel system or removing its

parts, wait at least 30 seconds after stopping the
engine until the residual pressure in the fuel cir-
cuit is released. (Do not start the work just after
stopping the engine since there is residual pres-
sure.)

PW148-8 VEBM720100 20-113

Measuring fuel pressure TESTING AND ADJUSTING

Measuring fuel pressure

• Measuring tools for fuel pressure

Symbol Part No. Part name

799-101-5002 Hydraulic tester

1
790-261-1204 Digital hydraulic tester

Adapter 2
F 6732-81-3170
2 (10 × 1.0 mm -> R1/8)

6215-81-9710 O-ring

3 799-401-2320 Hydraulic tester

b. Install adapter F2 and nipple of hydraulic

Stop the machine on a level ground and lower the tester F1 and connect them to oil pressure
work equipment to the ground. gauge [F3]

• Use the oil pressure gauge of 2.5 MPa

• Measure only the fuel pressure in the low-pres-
sure circuit from the feed pump through the fuel
main filter to the supply pump and the return cir-
cuit from the supply pump/common rail/injector
to fuel tank.
{25 kg/cm²}.
c. Run the engine at low idle and measure the
pressure in the fuel low-pressure circuit.
• If the pressure in the fuel low-pressure circuit
is in the following range, it is normal.

At low idle 0.5 – 1.3 MPa {5.1 – 13.3 kg/cm2}

Since the pressure in the high-pressure circuit
from the supply pump through the common rail During cranking 0.3 – 1.1 MPa {3.1 – 11.3 kg/cm2}
to the injector is very high, it cannot be meas-
ured.

If the engine cannot be started, you may measure

1. Measuring pressure in fuel low-pressure cir- the fuel pressure while rotating the engine with
cuit the starting motor. Do not rotate for more than 20
seconds continuously, however, for protection of
a. Open the engine hood and remove fuel pres-
the starting motor.
sure pickup plug (1) from the fuel main filter
(2).

1
F3

2
d. After finishing measurement, remove the
measuring tools and return the removed
parts.

 Fuel pressure pickup plug:

10 ± 2 Nm {1 ± 0.2 kgm}

20-114 PW148-8 VEBM720100

TESTING AND ADJUSTING Measuring fuel pressure

2. Measuring pressure in fuel return circuit

a. Open the engine hood and remove fuel pres-
sure pickup plug (2) from the fuel return
block.

F3

b. Install nipple [3] of hydraulic tester F1 and d. After finishing measurement, remove the
nipple [1] and connect them to hydraulic test- measuring tools and return the removed
er F3. parts.
• Nipple [3]:  Fuel pressure pickup plug:
790-301-1181, 07002-11223 24 ± 4 Nm {2.4 ± 0.4 kgm}

c. Run the engine at low idle and measure the

pressure in the fuel return circuit.

• If the pressure in the fuel return circuit is

in the following range, it is normal.

At low idle Max. 0.02 MPa

During cranking {Max. 0.19 kg/cm2}

If the engine cannot be started, you may measure

the fuel pressure while rotating the engine with
the starting motor. Do not rotate for more than 20
seconds continuously, however, for protection of
the starting motor.

PW148-8 VEBM720100 20-115

Measuring fuel return rate and leakage TESTING AND ADJUSTING

Measuring fuel return rate and leakage

• Measuring tools for fuel discharge, return and
leakage

Symbol Part No. Part name

Commercially Hose (Internal dimen-

1
available sion: ø14 mm)

2 795-790-4700 Tester kit

3 795-790-6700 Adapter

6754-71-5340 Connector
4
H 6754-71-5350 Washer

Commercially
5 Measuring cylinder
available

Commercially
6 Stopwatch
available c. Crank the engine for 30 seconds and meas-
Commercially Hose (Internal dimen-
ure the discharge with measuring cylinder
7 H5.
available sion: ø12 mm)

★ In order to protect the starter motor, it is

• Since some fuel flows out during check, prepare prohibited to continue cranking for more
an oil (receiving) pan of about 20 l. than 30 seconds for any other purpose
than this measurement.

★ If the discharge from the supply pump is

Stop the machine on a level ground and lower the in the following range, it is normal.
work equipment to the ground.

Engine Speed Discharge

1. Measuring discharge from supply pump 125 rpm Min. 75 cc
a. Open the engine hood, loosen 2 clamps (2) 150 rpm Min. 90 cc
from discharge side tube (1) of the supply
pump, and disconnect tube (1).

d. After finishing checking, remove the measur-

b. Install measuring hose H1 to the discharge
ing tools and return the removed parts.
side nipple of the supply pump.
 Tube sleeve nut:
★ Fix the hose using a wire to prevent the
35 ± 3.5 Nm {3.6 ± 0.4 kgm}
hose from coming off.
 Clamp mounting bolt:
★ Adjust the rout inspection hose so that
24 ± 4 Nm {2.45 ± 0.4 kgm}
there is no slack, and insert its end to the
oil pan.

20-116 PW148-8 VEBM720100

TESTING AND ADJUSTING Measuring fuel return rate and leakage

2. Measuring return rate from supply pump

a. Open the engine hood and disconnect return
hose (3) of the supply pump.

★ The return hose is connected by a quick

coupler.

e. After finishing measurement, remove the

measuring tools and return the removed
parts.

★ When measuring the leakage from the

b. Install connector H4 and the cap nut of tester
kit H2 to stop the fuel from flowing out.
c. Connect test hose [1] of tester kit H2 to the
supply pump.
★ Lay the test hose so that it will not slack-
en and put its end in the oil (receiving)
pan.
pressure limiter or finishing the measure-
ment: Return the removed parts to their
original positions.
★ When measuring the leakage from the
injector: Leave the removed parts as
they are and keep the hose end in the oil
pan.
3. Measuring leakage from pressure limiter
a. Open the engine hood and disconnect return
hose (4) of the pressure limiter.

d. Run the engine at low idle and measure the

return rate for 25 seconds with measuring
cylinder H5.

★ If the return rate from the supply pump is

in the following range, it is normal.

At low idle (750 rpm) Max. 400 cc

PW148-8 VEBM720100 20-117

Measuring fuel return rate and leakage
b. Install connector H4 and the cap nut of tester
kit H2 to the return hose side, to stop the fuel
from flowing out.
c. Connect the measuring hose [1] of tester kit
H2 to the common rail side.
★ Lay the test hose so that it will not slack-
en and put its end in the oil (receiving)
pan.
d. Run the engine at low idle and measure the
return rate in 1 minute with measuring cylin-
der H5.
★ If the leakage from the pressure limiter is
in the following range, it is normal.
At low idle 0 cc (No leakage)
e. After finishing measurement, remove the
measuring tools and return the removed
parts.
20-118
TESTING AND ADJUSTING
4. Measuring return rate from injector
★ The leakage from the injector is measured
while the return hose of the pressure limiter
is connected. Accordingly, before measuring
the leakage from the injector, check that the
leakage from the pressure limiter is normal.
a. Referring to "Measuring return rate from sup-
ply pump", set the supply pump for testing.
The fuel returning from the supply pump flows
out during measurement of the return rate from
the injector. Accordingly, keep the test hose end
in the oil pan.
b. Disconnect return hose (2) of the manifold
part.
c. Install connector H4 to hose (2), and connect
it to hose H7.
★ Fix the hose using a wire to prevent the
hose from coming off.
★ Lay the test hose so that it will not slack-
en and put its end in the oil (receiving)
pan.
PW148-8 VEBM720100
TESTING AND ADJUSTING Measuring fuel return rate and leakage

d. Run the engine at low idle and measure the

return rate in 1 minute with measuring cylin-
der H5.

★ If the return rate from the injector is in

the following range, it is normal.

At low idle Max. 120 cc/min

During cranking Max. 90 cc/min

f the engine cannot be started, you may measure

the fuel return rate while rotating the engine with
the starting motor. Do not rotate for more than 20
seconds continuously, however, for protection of
the starting motor.

e. After finishing measurement, remove the

measuring tools and return the removed
parts.

 Joint bolt:
19.6 – 29.4 Nm {2.0 – 3.0 kgm}

PW148-8 VEBM720100 20-119

Bleeding air from fuel circuit TESTING AND ADJUSTING

Bleeding air from fuel circuit

• If fuel is used up or if a fuel circuit part is re-
moved and installed, bleed air from the fuel cir-
cuit according to the following procedure.

Stop the machine on a level ground and lower the

work equipment to the ground.

1. Fill the fuel tank with fuel.

• Add fuel until the float of the sight gauge

reaches the maximum position.

2. Open the side cover of the pump room.

3. Loosen knob (1) of the feed pump and pull it out,

and then operate it forward and backward.

• Move the knob until it becomes heavy.

• The plug at the top of the fuel main filter does

not need to be removed.

4. After bleeding air, push in and tighten knob (1).

20-120 PW148-8 VEBM720100

TESTING AND ADJUSTING Bleeding air from fuel circuit

• Air bleeding route of fuel circuit

Fuel tank ---> Pre-filter ---> Feed pump ---> Main filter --->
Metering unit ---> Fuel tank

PW148-8 VEBM720100 20-121

Bleeding air from fuel circuit TESTING AND ADJUSTING

Checking fuel circuit for leakage 8. Run the engine at high idle and load it.

• Relieve the arm circuit at the IN stroke end.

9. Check the fuel piping and devices for fuel leak-

• Very high pressure is generated in the high- age.
pressure circuit of the fuel system. If fuel leaks
while the engine is running, it is dangerous ★ Check mainly around the high-pressure cir-
since it can catch fire. cuit parts coated with the color checker for
• After checking the fuel system or removing its fuel leakage.
parts, check it for fuel leakage according to the
following procedure. ★ If any fuel leakage is detected, repair it and
• Stop the machine on a level ground and lower check again from step 2.
the work equipment to the ground.
★ If no fuel leakage is detected, check is com-
pleted.
• Clean and degrease the engine and the parts
around it in advance so that you can check it
easily for fuel leakage.

1. Spray color checker (developer) over the fuel

supply pump, common rail, fuel injector, and
joints of the high-pressure piping.

2. Run the engine at speed below 1,000 rpm and

stop it after its speed is stabilized.

3. Check the fuel piping and devices for fuel leak-

age.

• Check mainly around the high-pressure cir-

cuit parts coated with the color checker for
fuel leakage.

• If any fuel leakage is detected, repair it and

check again from step 2.

4. Run the engine at low idle.

5. Check the fuel piping and devices for fuel leak-

age.

• Check mainly around the high-pressure cir-

cuit parts coated with the color checker for
fuel leakage.

• If any fuel leakage is detected, repair it and

check again from step 2.

6. Run the engine at high idle.

7. Check the fuel piping and devices for fuel leak-

age.

• Check around the high-pressure circuit parts

coated with the color checker for fuel leak-
age.

• If any fuel leakage is detected, repair it and

check again from step 2.

20-122 PW148-8 VEBM720100

TESTING AND ADJUSTING Checking and adjusting air conditioner compressor belt tension

Checking and adjusting air conditioner compressor belt

tension
• After tightening the bolts, check the belt ten-
sion again according to the above proce-
Stop the machine on a level ground and lower the dure.
work equipment to the ground.
(4)

Checking (1)
1. Open the engine hood and remove the belt (3)
guard from the top of the air conditioner com-
pressor.

2. Press the intermediate point of the belt between

fan pulley and compressor pulley with a finger
(2)
and measure deflection (a) of the belt.

• Belt pressing force: 98 N {10 kg}

(4)

Adjusting
• If the belt deflection is abnormal, adjust it ac- 4. After finishing measurement, return the removed
cording to the following procedure. parts.

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

2. Move compressor (3) and bracket (4) together to

adjust the belt tension.

3. After positioning compressor (3), tighten bolts (1)

and (2).

• Check each pulley for breakage, wear of the

V-groove, and contact of the V-belt and V-
groove.

• If the V-belt is so lengthened that the adjust-

ment allowance is eliminated or it has a cut
or a crack, replace it.

• If the belt is replaced, adjust their tension

again after operating the machine for 1 hour.

PW148-8 VEBM720100 20-123

Replacing the fan belt TESTING AND ADJUSTING

Replacing the fan belt

• The auto-tensioner is provided for the fan belt.
Thus, testing and adjustment of the belt is usual-
ly not necessary. Be careful not to get your fingers caught between
the pulley and fan belt (2) during work.
• Disconnect air conditioner compressor belt be-
fore replacing the fan belt.

Parking the machine in a level ground and lower

the work equipment to the ground.

1. Open engine hood and remove fan belt cover

(1).

3. Replace the fan belt (2).

• Check each pulley for breakage and crack.

2. Insert a wrench to the portion (A) (width across

flats 12.7 mm) of the tensioner assembly (3),
and rotate it to the opposite to the winding-up di-
rection to decrease the fan belt (2) tension.

Make sure that the wrench is secured at the por-

tion (A) of the tensioner assembly (3) before ro-
tating it. (The spring of the tensioner assembly
(3) is strong. If the wrench is loosely inserted, the
wrench may accidetally come off while being ro-
tated and it is extremely dangerous.)

After removing the fan belt (2), return the tension-

er assembly (3) slowly with care.

20-124 PW148-8 VEBM720100

TESTING AND ADJUSTING Measurement of clearance in swing circle bearing

Measurement of clearance in swing circle bearing

• Swing circle bearing clearance measurement 4. Hold the arm nearly perpendicular to the ground,
tools and lower the boom until the machine is raised at
the front.
Mark Part No. Part Name
• The upper structure is raised at the front and
H Commercial Product Dial Gauge
lowered at the rear at this time.

• Follow the steps explained below, when measur-

ing clearance in the swing circle bearing on the
actual machine.

150 ~200MM
Be careful not to put a hand or foot under the un-
dercarriage, while taking measurement.

1. Attach dial gauge H to swing circle outer race (1)

or inner race (2), and position the probe end on
5. Read off the value in dial gauge H in this condi-
the surface of the inner race (2) or outer race (1)
tion.
as shown.
• The value indicated in dial gauge H express-
• Set dial gauge H at the machine front or rear.
es clearance in the bearings.

6. Return the machine to the posture in Item 2, and

confirm reading of dial gauge H is zero.

• If zero value is not indicated, repeat the

steps in Items 3 through 5.

2. Keep the work equipment in the max. reach pos-

ture and keep the height of the bucket teeth tip
level with the lower height of the revolving frame.

• The upper structure is lowered at the front

and raised at the rear at this time.

3. Set dial gauge H to zero.

PW148-8 VEBM720100 20-125

Inspection and adjustment of hydraulic oil pressure in hydraulic circuit for work equipment, swing and travel TESTING AND ADJUSTING

Inspection and adjustment of hydraulic oil pressure in

hydraulic circuit for work equipment, swing and travel
• Inspection and adjustment tools c. Start the engine and keep it running until the
hydraulic oil temperature rises to the operat-
Mark Part No. Part Name ing range.
799-101-5002 Hydraulic Tester
1
790-261-1203
Digital Type J1
Hydraulic Tester
J
Grease Fitting
799-101-5220
2 (10 x 1.25 mm)
07002-11023 O-ring

• Hydraulic oil pressure in the hydraulic circuit for

work equipment, swing and travel (hydraulic
pump output pressure) may be also confirmed
with a monitoring function in the monitor panel
(special function of monitor panel).

Measurement
2. Measurement of Unload Pressure
1. Pre-measurement work a. Start the engine.
Lower the work equipment to the ground and
b. Measure hydraulic oil pressure, when the en-
stop the engine. After the engine is stopped, (but
gine is running at high idling and all the con-
with the ignition switch in the ON position and the
trol levers are moved to the NEUTRAL
safety lever still ENGAGED), operate the control
position.
levers several times to release the remaining
pressure in the hydraulic system. Then loosen
• Hydraulic oil pressure when the unload
the oil filler cap to release any pressure in the hy-
valve unloads is displayed.
draulic tank.

a. Remove hydraulic oil pressure measuring 3. Measurement of work equipment relief pres-
plug (1). sure
a. Start the engine and move the cylinder to be
measured to its stroke end.

b. Measure hydraulic oil pressure, when the en-

1 gine is running at high idling and the cylinder
is in relief condition.

• Hydraulic oil pressure when the main re-

lief valve is in relief condition is dis-
b. Fit tool J2 and connect it to oil pressure played.
gauge of hydraulic tester J1.
• If one-touch power max. switch is de-
• Use an oil pressure gauge with the ca- pressed, the oil pressure is turned to
pacity of 58 MPa{600 kg/cm2}. high relief pressure, and if released, it is
turned to low relief pressure.

• Keep the swing lock switch in the OFF posi-

tion during the inspection. If it is moved to
the ON position, hydraulic oil pressure is
J2
turned to high relief pressure, as the con-
stant 2-stage relief valve is moved to the ON
position.

20-126 PW148-8 VEBM720100

TESTING AND ADJUSTING Inspection and adjustment of hydraulic oil pressure in hydraulic circuit for work equipment, swing and travel

4. Measurement of swing relief pressure

a. Start the engine and move the swing lock
switch to the ON position.

b. Measure hydraulic oil pressure when the en-

gine is running at high idling and the swing
circuit is relieved.

• Hydraulic oil pressure when the swing

motor safety valve is relieved is dis-
played.

• The swing motor relief pressure is lower 3

than the main relief pressure.

5. Measurement of travel circuit relief pressure a. Disconnect the pilot hose on main relief
valve (3).
a. Start the engine and apply service brake to
prevent travel, select forward or reverse trav- b. Loosen lock nut (5) and adjust the pressure
el. by turning holder (6).

• If the holder is turned to the right, the

pressure rises.
If the holder is turned to the left, the
pressure falls.

• Adjustment amount per turn of holder:

Approx. 12.5 MPa {approx. 128 kg/cm²}

 Lock nut: 53.5±4.9 Nm{5.5±0.5 kgm

b. Measure hydraulic oil pressure when the en- 6

gine is running at high idling and the travel
circuit is relieved.

• Hydraulic oil pressure with the main re-

lief valve in relief condition is displayed.
In the travel circuit relief, the pressure is
high pressure relief all the time.

5
Adjustment
• The unload valve and the safety valve for boom
LOWER cannot be adjusted. c. Check the pressure again after the adjust-
ment, following the aforementioned steps for
1. Adjustment of main relief pressure measurement.
(high pressure setting side)
• When measuring the pressure, recon-
• If relief pressure of the high pressure in the nect the pilot hose.
work equipment and travel circuits is not nor-
mal, adjust the high pressure setting side of • If high pressure setting side is adjusted,
main relief valve (3) in the following manner. low pressure setting side is also affect-
ed, so adjust it, too.
• The high pressure setting is in the state in
which the 2-stage relief solenoid valve is
turned ON and the pilot pressure is applied
to the changeover port.

PW148-8 VEBM720100 20-127

Inspection and adjustment of hydraulic oil pressure in hydraulic circuit for work equipment, swing and travel TESTING AND ADJUSTING

1. Adjustment of main relief pressure (low pressure
setting side)
• When low pressure relief pressure of the
work equipment is not normal, or when ad-
justment is made of the high pressure setting
side, adjust the low pressure side of the main
relief valve, too.
2. Adjusting swing relief pressure
• If the relief pressure of the swing circuit is
abnormal, adjust swing motor safety valves
(9) according to the following procedure.
9

• The high pressure setting is the state in

which the 2-stage relief solenoid is turned
OFF and NO pilot pressure is applied to the
changeover port.
9
a. Disconnect pilot hose.

b. Loosen lock nut (7) and adjust the pressure

by turning holder (8).

• If the holder is turned to the right, the

pressure rises. If the holder is turned to
the left, the pressure falls.
• Adjustment amount per turn of holder:
Approx. 12.5 MPa{approx. 128 kg/cm²}
 Lock nut: 53.5±4.9 Nm{5.5±0.5 kgm}
a. Hold screw (9), loosen locknut (10).
• Fix the screw with a hexagonal wrench.
b. Turn screw (9) to adjust the pressure.
• If the screw is
Turned to the right, the pressure rises.
Turned to the left, the pressure lowers.

• Quantity of adjustment per turn of screw:

8
Approx. 9.8 MPa {Approx. 100 kg/cm²}

 Lock nut: 39.2 ± 4.9 Nm {4.0 ± 0.5 kgm}

9
7 10
9

c. Check the pressure again after the adjust- 10

ment, following the aforementioned steps for
measurement.

• When measuring the pressure, recon-

nect the pilot hose.
c. After finishing adjustment, check again that
the pressure is normal according to the pro-
cedure for measurement described above.

20-128 PW148-8 VEBM720100

TESTING AND ADJUSTING Inspection and adjustment of control circuit oil pressure

Inspection and adjustment of control circuit oil pressure

• Control circuit oil pressure inspection and adjust- 2. Fit tool J2 and connect it to oil pressure gauge
ment tools (1) of hydraulic tester J1.

Mark Part No. Part Name • Use an oil pressure gauge with the capacity
of 5.9 MPa {60 kg/cm²}.
799-101-5002 Hydraulic Tester
1 Digital Type
790-261-1203
Hydraulic Tester
J
Grease Fitting
799-101-5220
2 (14 x 1.5 mm)

07002-11023 O-ring

J2
Measurement
J1

Lower the work equipment to the ground and

stop the engine. After the engine is stopped, (but
with the ignition switch in the ON position and
safety lever still ENGAGED), operated the control 3. Start the engine and keep it running until the hy-
levers several times to release the remaining draulic oil temperature rises to the operating
pressure in the hydraulic system. Then loosen range.
the oil filler cap to release any pressure in the hy-
draulic tank. 4. Measure oil pressure with the engine running at
high idling and all the control levers in the NEU-
TRAL position.
1. On main pump remove oil pressure measure-
ment plug (1).
1

5. After completing the measurement, remove the

measuring equipment and set the machine to its
original condition.

PW148-8 VEBM720100 20-129

Inspection and adjustment of control circuit oil pressure TESTING AND ADJUSTING

Procedure for pressure reducing adjust-

ment
1. Remove dust cap (1) from relief valve (a).

2. Loosen off adjusting lock screw nut (2).

3. Tighten adjusting screw (3) to increase pressure

and loosen to decrease pressure.

2 3

4. When at correct pressure tighten lock nut (2) and

replace dust cap (1).

20-130 PW148-8 VEBM720100

TESTING AND ADJUSTING Inspection and adjustment of pump PC (valve inlet) control oil pressure

Inspection and adjustment of pump PC (valve inlet) con-

trol oil pressure
• Pump PC control circuit oil pressure inspection
and adjustment tools

Mark Part No. Part Name No. Off

Hydraulic
799-101-5002 2
Tester
1 Digital Type
790-261-1203 Hydraulic 2
J Tester 1
Grease Fitting
799-101-5220 2
2 (10 x 1.25 mm)

07002-11023 O-ring 2

Measurement
• Implement measuring the pump PC control cir-
cuit oil pressure after confirming that the work
equipment, swing and travel circuit oil pressure
as well as the control circuit original oil pressure
are normal.

Lower the work equipment to the ground and
stop the engine. After the engine is stopped, (but
with the ignition switch in the ON position and
safety lever still ENGAGED), operated the control
levers several times to release the remaining
pressure in the hydraulic system. Then loosen
the oil filler cap to release any pressure in the hy-
draulic tank.
2
b. Fit tool J2 to each port (1 and 2), connect
each tool to oil pressure gauge of hydraulic
tester J1.
• Use an oil pressure gauge with the ca-
pacity of 58.8 MPa{600 kg/cm²}

1. Measurement of PC valve output pressure (ser-

vo piston inlet pressure) J2

• Measure PC valve output pressure (servo

piston inlet pressure) and pump delivery
pressure together, and compare the two
pressures.

a. Remove oil pressure measurement plugs (1)

and (2).

• Plug (1): For measuring the pump deliv-

ery pressure

• Plug (2): For measuring the pump PC

valve delivery pressure

PW148-8 VEBM720100 20-131

Inspection and adjustment of pump PC (valve inlet) control oil pressure TESTING AND ADJUSTING

c. Start the engine and keep it running until the 2. Measurement of PC-EPC output pressure
hydraulic oil temperature rises to the operat-
ing range. a. Remove oil pressure measurement plug (5).

b. Fit tool J2 and connect it to oil pressure

d. Measure the pump delivery pressure and PC gauge of hydraulic tester J1.
valve output pressure (servo piston inlet
pressure) together with the engine running at • Use an oil pressure gauge with the ca-
high idling, after setting the machine at the pacity of 5.9 MPa {60 kg/cm²}.
following conditions.

• Working mode: A mode

Swing lock switch: ON (switched to high J2
pressure relief with 2-stage relief turned
ON)
Work equipment, swing and travel cir-
cuit: Arm digging relief

• Judgement method:
When the ratio between the pump deliv-
ery pressure and PC valve output pres-
sure (servo piston output pressure)
reaches the following values, both pres- c. Start the engine and keep it running until the
sures are judged normal. hydraulic oil pressure rises to the operating
range.
Pressure to be measured Pressure ratio

Pump delivery pressure 1 1

PC valve outlet pressure Approx. 3/5

• If there is any abnormality with PC valve or

servo piston, the PC valve output pressure
(servo piston output pressure) equals to the
pump delivery pressure, or approximates to
0 pressure.

e. Disconnect tools J1 and J2 replace plugs (1)

and (2).

20-132 PW148-8 VEBM720100

TESTING AND ADJUSTING Inspection and adjustment of pump PC (valve inlet) control oil pressure

d. Measure the hydraulic oil pressure with all

the control levers kept in the NEUTRAL posi-
tion and the engine running at high idle and 8
at low idle.

• If PC-EPC valve output pressure changes to

the following values, it is judged normal.

Engine Control Hydraulic oil

speed lever pressure
7
2.9 MPa B

Low idle
Neutral {30 kg/cm2}

High idle 0{0}

2. Re-tighten lock nut (7).

e. Disconnect tools J1 and J2. Replace plug
(5). 3. Confirm that the PC valve output pressure (servo
piston inlet pressure) is normal after the adjust-
Adjustment ment, following the measurement steps ex-
plained earlier.
• If any of the phenomena mentioned below oc-
curs and PC valve malfunctioning is suspected,
adjust PC valve (6).

• As workload increases, the engine rpm

sharply drops.
While the engine rpm is normal, the work
equipment moves slowly.

1. Loosen lock nut (7) and make adjustment, turn-

ing adjusting screw (8).

• If the holder is turned to the right, the pump

absorption torque rises.
If the holder is turned to the left, the pump
absorption torque falls.

• The adjustable range with the adjusting

screw is as shown below.
Left turn: Less than 1 turn
Right turn: Less than 1/2 turn (less than 180
degrees)

 Lock nut:
27.50–34.3Nm {2.8–3.5kgm}

PW148-8 VEBM720100 20-133

Inspection and adjustment of pump LS valve control oil pressure TESTING AND ADJUSTING

Inspection and adjustment of pump LS valve control oil

pressure
• Pump LS control circuit oil pressure inspection
and adjustment tools

Mark Part No. Part Name No. Off

799-101-5002 Hydraulic Tester 2

1 Digital Type
790-261-1203 2
Hydraulic Tester

Grease Fitting
K 799-101-5220 2
2 (10 x 1.25 mm)

07002-11023 O-ring 2

Differential Pres-
3 799-401-1340 2
sure Gauge
1

Measurement
• Measure pump LS control circuit oil pressure af-
ter confirming that the work equipment, swing 2
and travel circuit oil pressure as well as control
circuit original pressure are normal.

Lower the work equipment to the ground and

stop the engine. After the engine is stopped, (but
with the ignition switch in the ON position and
safety lever still ENGAGED), operated the control
levers several times to release the remaining
pressure in the hydraulic system. Then loosen
the oil filler cap to release any pressure in the hy-
draulic tank.

b. Fit tool K2 to each port (1 and 2), connect

each tool to oil pressure gauge of hydraulic
1. Measurement of LS valve output pressure
tester K1.
(servo piston inlet pressure)
• Measure LS valve output pressure (servo • Use an oil pressure gauge with the capacity
piston inlet pressure) and pump delivery of 58.5 MPa {600 kg/cm²}.
pressure together, and compare both pres-
sures thereafter.

a. Remove oil pressure measurement plugs (1)

and (2).

• Plug (1): For measuring the pump deliv-

ery pressure

• Plug (2): For measuring the pump LS

valve delivery pressure

20-134 PW148-8 VEBM720100

TESTING AND ADJUSTING Inspection and adjustment of pump LS valve control oil pressure

c. Start the engine and keep it running until the a. Remove oil pressure measurement plugs (1)
hydraulic oil temperature rises to the operat- and (2).
ing range.
• Plug (1): For measuring the pump deliv-
ery pressure
1
• Plug (2): For measuring the pump LS
pressure

d. Measure the pump delivery pressure and

valve output pressure (servo piston inlet
pressure) together with the engine running at
high idling, after setting the machine at the 1 2
following conditions.

• Auto decel: Off. b. Fit tool K2 to each port (1 and 2) connect

each tool to oil pressure gauge of hydraulic
• One touch power max: Off. tester K1 or differential pressure gauge K3.

• Work equipment operation: Neutral. • When using a differential pressure

gauge:
Raise road wheels clear of ground using work Connect pump delivery pressure to the
equipment & chassis attachments. high pressure side and LS pressure to
Release brake. the low pressure side.
Select LO travel speed. A differential pressure gauge requires
Fully depress travel pedal. DC 12V power. Connect it with one bat-
tery.
Judgement method:
When the ratio between the pump delivery pres- • When using an oil pressure gauge:
sure and LS valve output pressure (servo piston Use an oil pressure gauge with the ca-
output pressure) reaches the following values, pacity of 58.5 MPa {600 kg/cm²}.
both pressures are judged normal. The max. differential pressure is no more
than approx. 40 MPa{3.9 kg/cm²}. The
Oil pressure ratio same gauge may be used throughout
Oil pressure to
be measured All control levers the measurement.
During test.
in NEUTRAL

Pump delivery
1
pressure Nearly equal
LS valve deliv- pressure
Approx. 3/5
ery pressure

e. Detach all the measurement tools after the

measurement and make sure that the ma-
chine is back to normal condition.

2. Measurement of LS differential pressure

• LS differential pressure can be obtained by 1 2
measuring pump delivery pressure and LS
pressure (actuator loaded pressure) at the
same time and computing the difference of
both pressures.

PW148-8 VEBM720100 20-135

Inspection and adjustment of pump LS valve control oil pressure TESTING AND ADJUSTING

c. Start the engine and keep it running until the 3. Measurement of LS-EPC valve output pres-
hydraulic oil temperature rises to the operat- sure
ing range. a. Remove oil pressure measurement plug (5).

d. Measure pump delivery pressure and LS

pressure (actuator loaded pressure). Togeth-
er with the engine running at high idling, after
setting the machine at the following condi-
tions.
• Auto decel: Off
b. Fit tool K2 and connect it with oil pressure
gauge (1) of hydraulic tester K1.
• Use an oil pressure gauge with the ca-
pacity of 5.9 MPa{60 kg/cm²}.

• One touch power max.: Off

• Work equipment operation: Neutral

• Raise road wheels clear of ground using

work equipment and chassis attach-
K1
ments. K2
Release brake K2
Select LO travel speed
Fully depress travel pedal

• Attention should be given to the sur-

c. Start the engine and keep it running until the
roundings for safety while operating with
hydraulic oil temperature rises to the operat-
the wheels off the ground.
ing range.
• Calculation of LS differential pressure:
LS differential pressure = Pump delivery 1
pressure – LS pressure

• If LS differential pressure is in the follow-

ing conditions, it is judged normal.

Control lever position LS differential pressure

All levers in Unload pressure

NEUTRAL (see standard value table)

Max. LS differential pres-

During test sure
(see standard value table)

e. Detach all the measurement tools after the

measurement, and make sure that the ma-
chine is back to normal condition.

20-136 PW148-8 VEBM720100

TESTING AND ADJUSTING Inspection and adjustment of pump LS valve control oil pressure

d. Measure the oil pressure under the following Adjustment

conditions:
• When LS differential pressure is not normal, ad-
• Fuel dial: Full just it with LS valve (6).

• Auto decel: Off.

• One touch power max: Off.

• If LS-EPC valve output pressure chang-

es to the following values, the pressure
is normal.
6
Work
Working Travel Hydraulic
Equip.
Mode Pedal Pressure
Operation

A Neutral Neutral {30} 900 mA

Arm dump Pump 1. Loosen lock nut (7) and adjust the pressure by
L {16} 580 mA turning adjusting screw (8).
relief relieved

• If the adjusting screw is turned to the right,

e. Detach all the measurement tools after the
the differential pressure rises.
measurement, and make sure that the ma-
If the adjusting screw is turned to the left, the
chine is back to normal condition.
differential pressure falls.

• Adjustment amount (LS differential pressure)

per turn of adjusting screw:
1.3 MPa{13.3 kg/cm²

 Lock nut: 49–64 Nm {5–7 kgm}

8
A

2. After the adjustment, re-tighten lock nut, confirm

that LS differential pressure is normal, following
the steps for measurement explained earlier.

PW148-8 VEBM720100 20-137

Measurement of solenoid valve output pressure TESTING AND ADJUSTING

Measurement of solenoid valve output pressure

• Solenoid valve output pressure measurement
tools No. Solenoid valve to be measured
3 Travel creep solenoid valve
Mark Part No. Part Name 12 Transmission clutch control (1st Gear)
799-101-5002 Hydraulic Tester 13 Suspension lock solenoid valve
1 14 Transmission clutch control (2nd Gear)
Digital Type
790-261-1203
Hydraulic Tester P1,P2,
L PPC hydraulic pressure lock solenoid valve
P3 or P5
Grease Fitting
799-401-2910 P4 Travel neutral solenoid valve
2 (Size 02)
PA2 Boom/Stabilizer solenoid valve (boom up)
07002-01423 O-ring
PA3 Travel solenoid (Forward)
PA4 Boom/Stabilizer solenoid valve (stabilizer up)
• Measure solenoid valve output pressure after
PA8 Arm rotate solenoid valve (cw)
confirming that control circuit original pressure is
PB2 Boom/Stabilizer solenoid valve (boom down)
normal.
PB3 Travel solenoid (reverse
PB4 Boom/Stabilizer solenoid valve (stabilizer down)
PB8 Arm rotate solenoid valve (acw)
Lower the work equipment to the ground and PBP 2-stage back pressure solenoid valve
stop the engine. After the engine is stopped, (but PB Swing brake solenoid valve
with the ignition switch in the ON position and PS Blanked
safety lever still ENGAGED), operated the control PX 2-stage relief solenoid valve
levers several times to release the remaining
pressure in the hydraulic system. Then loosen 2. Connect fitting L2 to outlet port to be measured.
the oil filler cap to release any pressure in the hy-
draulic tank. 3. Fit tool (1) of hydraulic tester L1 and connect it to
oil pressure gauge (2).

1. Disconnect the hoses of solenoid valve to be • Use an oil pressure gauge with the capacity
measured at the outlet side. of 5.9 MPa {60 kg/cm²}

• Hoses to the solenoid valve block are locat- Pb8 12 Pa4 Pb4 Ps Pb3 Pepc
ed under the walkway in the service area be-
hind the operators cab.

PB Pa8 14 Pb2 Pa3

Px Pbp Pa2

A B1 B2 P3 P2 P1

B X P5 T3 T5
T1 P4 T2 N C T4

3 T0
13

20-138 PW148-8 VEBM720100

TESTING AND ADJUSTING Measurement of solenoid valve output pressure

4. Start the engine and keep it running until the hy-

draulic oil temperature rises to the operating
range.

5. Run the engine at full throttle, then turn each so-

lenoid valve ON or OFF by operating the control
lever switch, and measure the pressure.

• For conditions for turning each solenoid

valve ON or OFF, refer to the ensuing "Table
for Functioning Conditions" for each solenoid
valve.

• How each solenoid valve functions can be

confirmed with monitoring function in the
monitor panel. (Special Function of Machine
Monitor)

• When each output pressure shows the fol-

lowing values, it is judged normal

Solenoid Valve Output Pressure

OFF (De-energised) 0{0}

ON (Energised) 3.8MPa {38.7kg/cm2}

6. Detach all the measurement tools after the

measurement, and make sure that the machine
is back to normal condition.

PW148-8 VEBM720100 20-139

Measurement of solenoid valve output pressure TESTING AND ADJUSTING

Solenoid valve block

Table for Functioning Conditions –

Travel creep solenoid valve

Functioning Condition Functioning

Creep selected On

Travel Creep Creep not selected Off

Stationary On

Table for Functioning Conditions –

Transmission Clutch Control Solenoid valve.
(HIGH gear / LO gear)

Functioning Condition Functioning

LO gear clutch disengaged (Default = HI speed) OFF

HI gear clutch disengaged (LO speed travel) ON

Table for Functioning Conditions –

Suspension lock solenoid valve

Functioning Condition Functioning

Suspension lock switch ON Suspension lock cancelled ON

Suspension lock switch OFF Suspension lock actuated OFF

Table for Functioning Conditions –

PPC lock solenoid valve

Functioning Condition Functioning

Locked OFF
Safety lock lever
Released ON

Table for Functioning Conditions –

Travel neutral solenoid valve

Functioning Condition Functioning

When travel forward selected

On
When travel reverse selected
Travel Neutral
When travel neutral selected
Off
Lock lever raised

Table for Functioning Conditions –

Boom / Stabilizer solenoid valve. (boom / stabilizer UP)

Functioning Condition Functioning

Boom up (Default) OFF

Stab up ON

20-140 PW148-8 VEBM720100

TESTING AND ADJUSTING Measurement of solenoid valve output pressure

Table for Functioning Conditions –

Travel solenoid valve
(forward / reverse)

Functioning Condition Functioning

Forward (Default) OFF

Reverse ON

Table for Functioning Conditions –

Arm rotate solenoid valve
(ANTI-CLOCKWISE / CLOCKWISE)

Functioning Condition Functioning

No operation OFF

Clockwise rotation (Solenoid de-energised) Rotate right

Anti-clockwise rotation (Solenoid actuated) Rotate left

Table for Functioning Conditions –

Boom / Stabilizer solenoid valve. (boom / stabilizer DOWN)

Functioning Condition Functioning

Boom down (Default) OFF

Stab down ON

Table for Functioning Conditions –

2 Stage back pressure solenoid valve

• Functioning Condition Functioning

• Back pressure OFF

• No back pressure ON

Table for Functioning Conditions –

Swing brake solenoid valve

Functioning Condition Functioning

Swing or work equipment lever operated Brake cancelled ON

All levers except travel at neutral (5 seconds after returning to neutral)

Brake on OFF
Swing lock switch is in ON position

PW148-8 VEBM720100 20-141

Measurement of solenoid valve output pressure TESTING AND ADJUSTING

Table for Functioning Conditions –

2 stage relief solenoid valve

Functiong Condition Functioning

When overheat setting of 1st stage is ON

When overheat setting of 2nd stage is ON OFF

When all the signals for work equipment, swing and travel are OFF

When swing lock switch is ON

When travel signal is ON

When working mode is L mode ON

When boom LOWER signal is ON

If signals other than swing operation only ON

When working mode is A or E mode When left knob is switched
If swing operation only is ON
OFF
In conditions other than above

20-142 PW148-8 VEBM720100

TESTING AND ADJUSTING Measurement of PPC valve output pressure

Measurement of PPC valve output pressure

• PPC valve output pressure measurement tools

Mark Part No. Part Name

S03
799-101-5002 Hydraulic Tester S04
S05
M Digital Type S07
S06
790-261-1203
Hydraulic Tester

S02
• Measure PPC valve output pressure after con- S01

firming that control circuit original pressure is

normal.

S12 S13

Lower the work equipment to the ground and

stop the engine. After the engine is stopped, (but
with the ignition switch in the ON position and
safety lever still ENGAGED), operated the control
levers several times to release the remaining
pressure in the hydraulic system. Then loosen
the oil filler cap to release any pressure in the hy-
draulic tank.

1. Remove PPC oil pressure switches (see table) in

the hydraulic circuits to be measured.

No Circuit to be measured Location

S09 S10
S01 Swing right Main valve
2. Fit tool (1) of hydraulic tester M and connect oil
S02 Swing left Main valve pressure gauge (2).
S03 Bucket dump Main valve
• Use an oil pressure gauge with the capacity
S04 Bucket dig Main valve of 5.9 MPa {60 kg/cm²}.
S05 Arm dump Main valve

S06 Arm dig Main valve

S07 2nd Boom extend * Main valve

S08 2nd Boom retract * Main valve

S09 Travel reverse Solenoid valve block

S10 Travel forward Solenoid valve block

S12 Boom/Stabilizer down Solenoid valve block

S13 Boom/Stabilizer up Solenoid valve block

* Pressure switch fitted to this port if a 2 piece boom

is fitted.

PW148-8 VEBM720100 20-143

Measurement of PPC valve output pressure TESTING AND ADJUSTING

3. Start the engine and set the working mode to

power level (P).

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

pressure with with the control switch in neutral
and moved to the max position.. 6

2
2
8
5
4
7

1
3

• If PPC valve output pressure is at the level 1. LH 1 ATT EPC Valve 5. 1 ATT 1st Service spool
shown below, it is judged normal.
2. RH 1 ATT EPC Valve 6. 1 ATT 2nd Service spool

Lever Control Hydraulic Pressure 3. LH 2 ATT EPC Valve 7. 2nd ATT 1st Service spool

In NEUTRAL 0{0} 4. RH 2 ATT EPC Valve 8. 2nd ATT 2nd Service spool

Nearly equal to control

At full stroke original pressure 4. Start the engine and set the working mode in
(see standard value table) power mode (P).

5. Detach all the measurement tools, and make 5. Run the engine in high idle and measure the oil
sure that the machine is back to normal condi- pressure with the control switch in neutral and
tion. moved to the max position.

Checking Proportional Control PPC Cir-

cuit
1. Disconnect the hose of the proportional control
PPC circuit to be measured.

2. Install adaoter P2 and connect the disconnected

hose again.

3. Install nipple of hydraulic tester M1 into adapter

P2 and attach it to oil pressure gauge [2].

★ Use the oil pressure gauge of 5.9 MPa ★ If PPC valve output pressure is at the level
{60 kg/cm²}. shown below, it is judged normal.

Operation of lever Output Pressure

NEUTRAL 0 MPa {0 Kg/cm²}

Max position Almost the same as control cir-

cuit basic pressure (see standard
values table)

6. After finishing measurement, remove the meas-

uring tools and return the removed parts.

20-144 PW148-8 VEBM720100

TESTING AND ADJUSTING Adjustment of work equipment and swing PPC valve

Adjustment of work equipment and swing PPC valve

• If there is excessive play in the work equipment
or swing lever, adjust it in the following manner.

1. Take off boot (1).

2. Loosen lock nut (2) and screw in disc (3) until it

contacts the heads of four pistons (4).

• Do not move the piston while doing this

work.

3. Keep disc (3) in place and tighten lock nut (2) to

the specified tightening torque.

 Lock nut:
98–12 7Nm {10–13 kgm}

4. Install boot (1).

NOTE
This adjustment must be carried out in a clean envi-
ronment. Do not allow dirt particles under the boot.

PW148-8 VEBM720100 20-145

Measuring and adjusting quick coupler control valve output pressure TESTING AND ADJUSTING

Measuring and adjusting quick coupler control valve out-

put pressure
★ Measuring and adjusting tools for oil pressure in Adjustment
quick coupler circuit. If the regulated pressure is not suitable for the quick
coupler to be installed adjust the pressure of the reg-
Symbol Part No. Part name
ulating valve as follows:
799-101-5002 Hydraulic tester
1 1. Loosen the locknut (1a). (using a 17mm span-
790-261-1204 Digital hydraulic tester
J ner).
799-101-5220 Nipple (10 × 1.25 mm)
2
07002-11023 O-ring

1a

Stop the machine on a level ground and lower the

work equipment to the ground. Then, release the
residual pressure from the hydraulic circuit. For
details, see "Releasing residual pressure from
hydraulic circuit".

Measuring
• Measure quick coupler control valve output pres-
sure after checking that work equipment, swing
and travel circuit pressures are normal.
• Fit nipple J2 to port B2 and connect it to oil pres-
sure gauge of hydraulic tester.
2. Turn the adjustment screw (1b) to adjust the
pressure. (Using a 5mm hexagon key).
• If the screw is turned to the right the pres-
sure increases.
• If the screw is turned to the left the pressure
reduces.

• Quantity of adjustment per turn of the screw:

Approx 5.5MPa.

1b

J2

• Use an oil pressure gauge with the capacity of 1a

59MPa (600kg/cm²)

• Start the engine. In order to raise the pressure to

the set pressure of the pressure regulating valve
After required pressure is achieved, hold adjustment
it will be necessary to operate one of the main
screw (1b) and tighten the lock nut (1a). (Torque of
control circuits. Set the swing lock to ON and op-
lock nut (1a) 12+/-2Nm)
erate the swing lever.

NOTE
When delivered from the factory the regulated pres-
sure is set to 4MPa (41kg/cm²).

20-146 PW148-8 VEBM720100

TESTING AND ADJUSTING Testing travel motor relief pressure

Testing travel motor relief pressure

Mb

(Ma opposite side)

• The travel motor has two pressure relief valves

which control the deceleration of the machine.
One operates in forward travel and one in re-
verse.

• Set pressure = 42 MPa (428 kg/cm²)

Measuring travel motor relief pressure

Oil temperature should be 45 - 50°

• Fit a 600 kg/cm² pressure gauge to port Mb on

the front travel motor.

• Test the machine on a downhill slope with a

smooth surface and long enough to allow the
pressure to stabilize. If the slope is steep (more
than 5 degrees) test in LOW mode, otherwise
test in HIGH mode.

• Travel forward at approximately half maximum

speed (for the selected mode), then release the
travel pedal. Read the pressure gauge after the
pressure stabilizes.

NOTE
Always use a gauge which can be read safely while
the machine is travelling.
Alternatively use a gauge which records the pressure
reading and study the data after the machine has
been stopped.

• If it is necessary to check the other relief valve

then swap the relief cartridges between ports
and check the second relief by travelling the ma-
chine forward.

• it is extremely dangerous to travel the machine at

high speed in reverse - always check the relief
valves as shown above.

PW148-8 VEBM720100 20-147

Adjusting travel motor relief pressure TESTING AND ADJUSTING

Adjusting travel motor relief pressure

The valve controlling deceleration of forwards travel is located on the left side of the motor (facing forward) the
same side as port Ma.

The valve controlling deceleration of reverse travel is located on the right side of the motor (facing forward) the
same side as port Mb.

• Remove seal and cap from the valve.

• Loosen locking nut.

• Turn adjustment screw clockwise to increase, and counterclockwise to decrease the pressure.

• Tighten locknut.

NOTE
The set pressure cannot be measured whilst making an adjustment.
Always repeat the measurement to check the set pressure after adjusting.

20-148 PW148-8 VEBM720100

TESTING AND ADJUSTING Testing propshaft speed

Testing propshaft speed

Measuring rotating speed of propshaft

• Lift the wheels from the ground using the blade and outriggers or work equipment.

• Set the machine to high idle.

• Measure in CREEP and LO travel speeds.

• Gently depress the travel pedal to full stroke.

Hazard from rotating wheels exists.

• Allow the speed of the propshaft / wheels to stabilize for a few minutes then measure the rotating speed of
the propshaft using an optical tachometer.

• Gently release the travel pedal to stop the wheel rotation.

• Always change rotating speed slowly. Sudden release of the travel pedal could damage the transmission or
motors.

• Judgement table

Propshaft speed in RPM Oil temperature 45 ~ 50°C

Check Item Unit Standard Remarks

Travel Speed - CREEP A Mode 198 +/-5% If too high check travel EPC valve.

If the speed is out of tolerance refer to

rpm troubleshooting section. Do not
Travel Speed - LO A Mode 990 +/-5%
attempt to adjust travel motor dis-
placement.

NOTE
With the machine in ’Travel Speed-Hi’ it is not possible to judge propshaft speed. In this condition the propshaft
speed will appear to hunt. This phenomenon is caused by the machine overspeed control logic and is not a fault.

PW148-8 VEBM720100 20-149

Testing transmission clutch control circuit TESTING AND ADJUSTING

Testing transmission clutch control circuit

Description
The transmission contains two clutches which engage HI and LO gear. The clutches are engaged or disengaged
by the clutch control solenoid valve. Energising the clutch control solenoid valve will select LO gear and de-ener-
gising the solenoid valve will select HI gear. When the solenoid valve is energised, port Q is connected to tank
(i.e. no pressure) and port P is pressurised. In this condition the LO gear clutch (large diameter) is engaged and
the HI gear clutch (small diameter) is disengaged. If the clutch control solenoid is de-energised, then port P is
connected to tank and port Q is pressurised. In this condition, the HI gear clutch is engaged the LO gear clutch is
disengaged.

LO gear = High torque (LO speed)

HI gear = Low torque (HI speed)

The actuation pressure for the transmission clutches is supplied from an accumulator via a pressure reducing
valve and park brake solenoid valve mounted in the power brake valve. The park brake solenoid valve must be
energised to feed the actuation pressure to either HI or LO clutch. With the park brake valve de-energised, both
clutches are engaged and so the park brake is engaged.

1. Measuring clutch actuation pressure

Oil temperature 45 ~ 55°C

Fit the tee’s to clutch ports P and Q on the transmission. Fit a150 kg/cm² pressure gauge to the third leg of the
tee. With the engine running and the park brake disengaged measure the pressure at port P and Q.

• Judgement table

Travel mode Pressure MPa (kg/cm2)

Port P Port Q

HI (Park brake off) 0 5.8 + / - 0.7 (59 + / - 7)

LO (Park brake off) 5.8 + / - 0.7 (59 + / - 7) 0

CREEP (Park brake off) 5.8 + / - 0.7 (59 + / - 7) 0

PARK BRAKE ON 0 0

If the pressure is low or high then the power brake valve must be exchanged (the pressure reducing valve is not
adjustable). If the pressure is 0, check flow to power brake valve and accumulator charge pressure.

20-150 PW148-8 VEBM720100

TESTING AND ADJUSTING Testing transmission clutch control circuit

PW148-8 VEBM720100 20-151

Inspection of locations of hydraulic drift of work equipment
Inspection of locations of hydraulic drift of work equip-
ment
• If there is any hydraulic drift in the work equip-
ment (cylinders), check in the following manner
to determine if the cause is in the cylinder pack-
ing or in the control valve.
1. Inspection of boom and bucket cylinders
a. Set the work equipment in the same posture
as when measuring hydraulic drift, and stop
the engine.
• Fill the bucket with earth or apply the rat-
ed load to the bucket.
b. Operate the control lever to the RAISE posi-
tion or the bucket control lever to the CURL
position.
• If the lowering speed increases, the cyl-
inder packing is defective.
• If there is no change, the control valve is
defective.
• Operate the control lever with the engine
starting switch in the ON position.
• If pressure in the accumulator has
dropped, run the engine for approx. 10
seconds to recharge the accumulator
again.
2. Inspection of arm cylinder
a. Operate the arm cylinder to move the arm to
the position 100 mm before the digging
stroke end, and stop the engine.
20-152
TESTING AND ADJUSTING
b. Operate the arm control lever to move the
arm to the digging side.
• If the lowering speed increases, the cyl-
inder packing is defective.
• If there is no change, the control valve is
defective.
• Operate the control lever with the engine
starting switch in the ON position.
• If pressure in the accumulator has
dropped, run the engine for approx. 10
seconds to charge the accumulator
again.
[Reference] If the causeof the hydraulic drift is in
the defective packing, and the above operation is
carried out, downward movement is accelerated
for the following reasons.
I. If the work equipment is set to the above
posture (holding pressure applied to the
bottom end), the oil at the bottom end
leaks to the head end. However, the vol-
ume at the head end is smaller than the
volume at the bottom end by the volume
of the rod end, so the internal pressure
at the head end increases because of
the oil flowing in from the bottom end.
II. When the internal pressure at the head
end increases, the pressure at the bot-
tom end also rises in proportion to this.
The balance is maintained at a certain
pressure (this differs according to the
amount of leakage) by repeating this
procedure.
III. When the pressure is balanced, the
downward movement becomes slower. If
the lever is then operated according to
the procedure given above, the circuit at
the head end is opened to the drain cir-
cuit (the bottom end is closed by the
check valve), so the oil at the head end
flows to the drain circuit and the down-
ward movement becomes faster.
PW148-8 VEBM720100
TESTING AND ADJUSTING Inspection of locations of hydraulic drift of work equipment

3. Inspection of PPC valve

Measure the amount of hydraulic drift of the work
equipment when the accumulator is charged with
pressure and the safety lock lever is put to the
LOCK and FREE positions.

• Operate the control lever with the engine

starting switch in the ON position.

• If pressure in the accumulator has dropped,

run the engine for approx. 10 seconds to
charge the accumulator again.

• If there is any difference in the hydraulic drift

between LOCK and FREE positions, the
PPC valve is defective (some internal fail-
ure).

PW148-8 VEBM720100 20-153

Release of remaining pressure in hydraulic circuit TESTING AND ADJUSTING

Release of remaining pressure in hydraulic circuit

1. Release of residual pressure from hydraulic
tank.
The hydraulic tank is enclosed and pressurised.
When removing a hose or a plug connected to
the hydraulic tank, release the residual pressure
from the hydraulic tank according to the follow-
ing procedure.
a. Lower the work equipment to the ground in a
stable posture and stop the engine.
b. Slowly loosen oil filler cap of the hydraulic
tank to release the air from the tank.
3. Release residual pressure from swing motor
circuit.
• Release the residual pressure from the
swing motor circuit by performing the proce-
dure for 2. Release of residual pressure from
hydraulic cylinder.
4. Release of residual pressure from travel mo-
tor circuit
• Since the control valve spool of the travel
motor is open, release the residual pressure
from the travel motor circuit by performing
the procedure for 1. release of residual pres-
sure from hydraulic tank.

2. Release of residual pressure from hydraulic

cylinder circuit.

When disconnecting the piping between a hy-

draulic cylinder and the control valve, release the
residual pressure from the piping according to
the following procedure.

a. Referring to previous step "Release of resid-

ual pressure from hydraulic tank"

• Leave the oil filler cap of he hydraulic

tank removed.

b. Turn the starting switch to the ON position

and set the safety lock lever in the FREE po-
sition, and then operate the work equipment
control levers on both sides forward back-
ward, to the right and to the left.

• The control valve is driven with the pres-

sure in the accumulator. If it is operated
2-3 times, the pressure lowers.

c. Start the engine and run it at low idling for 5

seconds to heighten the pressure in the ac-
cumulator. Stop the engine.

d. Repeat above steps b and c 2-3 times, and

all residual pressure is released from the pip-
ing.

20-154 PW148-8 VEBM720100

TESTING AND ADJUSTING Measurement of oil leakage

Measurement of oil leakage

• Measuring device for oil leakage d. Start measuring the oil leakage 30 seconds
after the boom cylinder is relieved and meas-
Symbol Part Number Part Name ure for 1 minute.
R Purchased Measuring Cylinder

• Measure the oil leakage under the following con-

dition. 1

• Hydraulic oil temperature: Within operating

range.

1. Measuring leakage from boom cylinder

a. Run the engine and raise the boom to the
stroke end.

Referring to RELEASE OF RESIDUAL PRESSURE

FROM HYDRAULIC CIRCUIT, release the residual
pressure from the piping on the boom cylinder e. After finishing the measurement, make sure
head side (Operate the lever only in the RAISE di- that the machine is back to normal condition.
rection, however).

2. Measuring leakage from arm cylinder

b. Disconnect hoses (1) on the cylinder head a. Run the engine and move the arm to the dig-
side block it with a plug. ging stroke end.

Take care not to disconnect the hose on the cyl-
inder bottom side.
c. Run the engine at high idling and relieve the
boom cylinder by operating the boom control
lever in the RAISE direction.
Referring to RELEASE OF RESIDUAL PRESSURE
FROM HYDRAULIC CIRCUIT, release the residual
pressure from the piping on the arm cylinder
head side (Operate the lever only in the digging
direction however).
b. Disconnect hose (2) on the cylinder head
end and block the hose end with a plug.

Take care not to operate the boom control lever

in the lower direction.
Be careful not to disconnect the hose at the cyl-
inder bottom end.

c. Run the engine at high idling and relieve the

arm cylinder by operating the arm control le-
ver in the DIGGING direction.

Take care not to operate the arm control lever in

the DUMP direction.

PW148-8 VEBM720100 20-155

Measurement of oil leakage
d. Continue this condition for 30 seconds, then
measure the oil leakage amount for one
minute.
2
e. After the measurement, make sure that the
machine is back to normal condition.
3. Measuring leakage from bucket cylinder
a. Run the engine and curl the bucket to the
stroke end.
Referring to RELEASE OF RESIDUAL PRESSURE
FROM HYDRAULIC CIRCUIT, release the residual
pressure from the piping on the bucket cylinder
head side (Operate the lever only in the CURL di-
rection).
b. Disconnect hose (3) at the cylinder head end
block the hose end with a plate.
Be careful not to disconnect the hose at the cyl-
inder bottom end.
c. Run the engine at high idling and relieve the
bucket cylinder by operating the bucket con-
trol lever in the CURL direction.
Take care not to operate the bucket control lever
in the DUMP direction.
20-156
TESTING AND ADJUSTING
d. Continue this condition for 30 seconds, then
measure the oil leakage amount for one
minute.
e. After the measurement, make sure that the
machine is back to normal condition.
4. Measuring leakage from swing motor
a. Disconnect drain hose (4) and fit a blind plug
in the hose.
b. Turn the swing lock switch to the ON posi-
tion.
c. Run the engine at high idle and relieve the
swing circuit and measure the oil leakage.
• Start measuring the oil leakage 30 sec-
onds after the swing motor circuit is re-
lieved and measure for 1 minute.
• After the first measurement, turn the up-
per structure by 180 degrees and take
measurement again in the same way.
4
PW148-8 VEBM720100
TESTING AND ADJUSTING Measurement of oil leakage

d. After finishing the measurement, make sure e. After the measurement, make sure that the
that the machine is back to normal condition. machine is back to normal conditon.

Leakage - 4 ~ 6 litres / min Normal

5. Measuring leakage from travel motor Leakage > 10 litres / min Abnormal
a. With the safety lock lever in the ENGAGED
position the PPC switch in the OFF position, Repair or replace travel if motor is found to have
the engine running at high idle and the serv- an abnormal level of oil leakage.
ice brake locked in the ON position. Raise
the hydraulic oil temperature to be in the
range 40~50°C.

b. Disconnect flushing hose (1) of the travel

motor and fit a blind plug in the hose end.

c. Using the travel pedal, put the travel circuit

into relief.

d. Port A or B are set under pressure above the

setting of relief valves (i.e. 380 bar)

• Since any incorrect operation of the con-

trols may lead to a serious accident. On-
ly do this test in a secure area marked
with adequate warning signs.

• Start measuring the oil leakage 30 sec-

onds after the travel motor circuit is re-
lieved and measure for 1 minute.

• Measure the oil leakage several times,

moving the motor little by little (changing
the positions of the valve plate, cylinder,
those of the cylinder and piston).

PW148-8 VEBM720100 20-157

Air bleeding of various parts TESTING AND ADJUSTING

Air bleeding of various parts

Air bleeding item Steps for air bleeding

1 2 3 4 5 6

Bleeding Bleeding Checking

Bleeding air Bleeding
Starting air from air from oil level and
Contents of Work from hydrau- air from
engine swing travel starting
lic pump cylinder
motor motor work

Replacement of hydraulic oil

Cleaning of strainer (See note) (See note)

Replacement of return filter element

Replacement or repair of hydraulic pump

Removing suction piping

Replacement or repair of control valve

Removal of control valve piping

Replacement or repair of cylinder

Removal of cylinder piping

Replacement or repair of swing motor

Removal of swing motor piping

Replacement or repair of travel motor

Removing travel motor piping

Replacement or repair of swivel joint

Removal of swivel joint

NOTE
Bleed air from the swing motor and travel motor only c. After clear oil flows out of bleeder (1) tighten
when oil in the casing is drained. the bleeder.

 Bleeder: 7.8–9.8 Nm {0.8–1.0 kgm}

1. Bleeding air from hydraulic pump
a. Loosen air bleeder (1) by 4 turns and remove
the oil filler cap of the hydraulic tank. 1

• Leave the machine under the above

condition for 10 minutes.

b. After oil flows out of bleeder (1) run the en-

gine at low idle.

• If the engine water temperature is low

and the automatic warm up operation is
started, stop the engine temporarily and
reset the automatic warm up operation
with fuel control dial (Set the starting
switch in the ON position and hold the
fuel control dial in MAX position for 3
seconds and the automatic warm up op-
eration is reset.)

• Set the safety lock lever in the DISEN-

GAGED position so that you will not op-
erate a lever by mistake.

20-158 PW148-8 VEBM720100

TESTING AND ADJUSTING Air bleeding of various parts

2. Starting engine c. Safety valve circuit

When running the engine after the engine after per-
• Normally, air in the safety valve circuit is
forming step 1, keep its speed at low idle for 10 min-
bled by swinging the machine in step 1.
utes.
If abnormal sound comes out from
around the safety valve during swinging
3. Bleeding air from cylinder operation, however, bleed air from the
• If a cylinder was replaced, bleed air from it before safety valve circuit according to the fol-
connecting the work equipment. In particular, the lowing procedure.
boom cylinder does not move to the lowering
I. Loosen fittings (3) and start the engine.
stroke end, if it is installed to the work equipment.
II. Run the engine at low idle. After clear oil
a. Run the engine at low idle for about 5 min-
oozes out, tighten the fitting.
utes.
 Plug: 9.8 - 12.74Nm {1.0 - 1.3kgm}
b. Running the engine at low idle, raise and
lower the boom 4-5 times. 3
2
• Stop the piston rod about 100mm before
each stroke end. Do not relieve the oil.

c. Running the engine at high idle, perform step

2.

d. Running the engine at low idle, move the pis-

ton rod to the stroke end and relieve the oil.

e. Bleed air from the arm cylinder and bucket

cylinder according to steps 2-d.

4. Bleeding air from swing motor

a. Motor unit
5. Bleeding air from travel motor
• Bleed air from the motor unit according a. Loosen motor drain hose fitting (4)
to the following procedure.
b. Run engine at low idle and repeat forward
I. Run the engine at low idle and reverse operations 4 or 5 times. After
clear oil flows out, retighten the fitting.
II. Swing to the right and left slowly to bleed
air. • Limit the operation to the travel to a de-
gree where the machine just starts to
b. Parking brake circuit
move.
• Normally, air in the parking brake circuit 4
is bled by swinging the machine in step
1. If you feel dragging of the brake circuit
according to the following procedure.

I. Loosen the fitting of brake hose (2) and

start the engine.

II. Run the engine at low idle and set the

swing holding brake release switch to
the release switch to the RELEASE and 1
NORMAL positions repeatedly. After
clear oil oozes out, tighten the fitting.

PW148-8 VEBM720100 20-159

Air bleeding of various parts TESTING AND ADJUSTING

6. Checking oil level and starting work

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

b. Check the oil level by the sight gauge at the

back of the hydraulic tank.

• If the oil level is between lines H and L, it

is normal.

• If the oil level is below line L, add new

oil.

20-160 PW148-8 VEBM720100

TESTING AND ADJUSTING
Inspection procedures for diode
• Check an assembled-type diode (10 pins) and
single diode (2 pins) in the following manner.
• The continuity direction of an assembled-type di-
ode is as shown in the diagram below.
7 1
10 5 A
• The continuity direction of a single diode is
shown on the diode surface
1. When using digital type circuit tester
a. Switch the testing mode to diode range and
confirm the indicated value.
• Voltage of the battery inside is displayed
with conventional circuit testers.
b. Put the red probe (+) of the test lead to the
anode (P) and the black probe (–) to the
cathode (N) of diode, and confirm the dis-
played value.
c. Determine if a specific diode is good or no
good with the indicated value.
• No change in the indicated value: No
continuity (defective).
• Change in the indicated value: Continui-
ty established (normal) (Note)
PW148-8 VEBM720100
Inspection procedures for diode
NOTE
A silicon diode shows a value between 400 and 600.
2. When using analog type circuit tester
a. Switch the testing mode to resistance range.
b. Check the needle swing in case of the follow-
ing connections.
I. Put the red probe (+) of the test lead to
the anode (P) and the black probe (–) to
the cathode (N) of diode.
II. Put the red probe (+) of the test lead to
the cathode (N) and the black probe (–)
to the anode (P) of diode.
c. Determine if a specific diode is good or no
good by the way the needle swings.
• If the needle does not swing in Case i),
but swings in Case ii): Normal (but the
breadth of swing (i.e. resistance value)
will differ depending on a circuit tester
type or a selected measurement range)
• If the needle swings in either case of i)
and ii): Defective (short-circuited inter-
nally)
• If the needle does not swing in any case
of i) and ii): Defective (short-circuited in-
ternally)
20-161
Special function of monitor panel TESTING AND ADJUSTING

Special function of monitor panel

3
1
2
6
4
7
5

1 Auto decal switch 6 Axle lock switch

2 Power mode switch 7 Air conditioner control switches
3 Travel speed switch 8 Guidance icon
4 Buzzer cancel switch 9 Function switches
5 PPC lock switch

20-162 PW148-8 VEBM720100

TESTING AND ADJUSTING Special function of monitor panel

Heater specification Lower section of machine monitor (Switch sec-

tion)
a
[1]:Numeral 1 input switch/Auto-decelerator switch
[2]:Numeral 2 input switch/Working mode selector
switch
[3]:Numeral 3 input switch/Travel speed shifting
switch
[4]:Numeral 4 input switch/Alarm buzzer cancel
switch
[5]:Numeral 5 input switch/PPC lock switch
[6]:Numeral 6 input switch/Axle lock switch
[7]:Numeral 7 input switch/Air conditioner or heater
switch
[8]:Numeral 8 input switch/Air conditioner or heater
switch
[9]:Numeral 9 input switch/Air conditioner or heater
switch
[0]:Numeral 0 input switch/Air conditioner or heater
switch
Switch having no numerals: Air conditioner or heater
switch
★ Each switch has the function indicated by graph-
ic mark and the function of inputting a numeral.

★ The machine monitor automatically judges which

function of each switch is currently effective, ac-
cording to the display condition of multi-display.
Upper section of machine monitor (Display sec- ★ The difference between the air conditioner speci-
tion) fication, heater specification, and heaterless
(a): Multi-display specification is only the functions of the switches
★ When the engine is started, the battery voltage in this section.
may lower suddenly, depending on the ambient
temperature and the condition of the battery. In
this case, the machine monitor goes off for a mo-
ment. This phenomenon is not a failure, howev-
er.

Upper section of machine monitor (Switch sec-

tion)
[F1]: F1 function switch
[F2]: F2 function switch
[F3]: F3 function switch
[F4]: F4 function switch
[F5]: F5 function switch
[F6]: F6 function switch
★ The function of each function switch is indicated
by graphic mark in the multi-display (a) above
that function switch.

★ If the graphic mark of a function switch is not dis-

played, that function switch is not working.

PW148-8 VEBM720100 20-163

Special function of monitor panel TESTING AND ADJUSTING

Ordinary functions and special functions of machine monitor

The machine monitor has the ordinary function and special functions and displays information of various types on
the multi-display.
Some items are displayed automatically according to the internal setting of the machine monitor and the others
are displayed according to the operation of the switches.
1. Ordinary functions: Operator mode
The items in this mode are displayed ordinarily. The operator can display and set them by operating the
switches (Display and setting of some items need special operations of the switches).
2. Special functions: Service mode
The items in this mode are not displayed ordinarily. Each serviceman can display them by operating the
switches specially. This mode is used for special setting, testing, adjusting, or troubleshooting.

Page Page
Operator mode (Outline) Service mode
166p 180p
A Display of KOMATSU logo 166p Monitoring 181p
A Display of inputting password 167p Mechanical systems 186p
Abnormality
A Display of check of breaker mode 167p Electrical systems 187p
record
A Display of check before starting 167p Air-conditioning system/Heater system 192p
Display of warning after check before start-
A 168p Maintenance record 193p
ing
A Display of ending of maintenance interval 168p Maintenance mode change 194p
Display of check of working mode and travel
A 168p Phone number entry 196p
speed
A Display of ordinary screen 168p Working mode with key ON 197p
A Display of end screen 169p Setting of unit 198p
O (Special operation)

B Selection of auto-deceleration 169p With/Without attachment 199p

Setting of attachment/maintenance pass-
B Selection of working mode 169p Default 200p
word
B Selection of travel speed 170p Setting of camera 201p
B Operation to stop alarm buzzer 170p Setting of ECO display 202p
B Operation of air conditioner/heater 171p Setting of automatic judgment of breaker 203p
Operation to display camera mode
B 172p Pump absorption torque 204p
(if camera is installed)
Operation to display clock and service Adjustment
B 172p Adjustment of flow to attachment in com-
meter 206p
pound operation
B [KOMTRAX message] 174p
Setting and display of user mode
B 174p
(Including KOMTRAX messages for user) Display of fuel consumption 211p
C Display of energy-saving guidance 174p
C Display of caution monitor 174p Setting condition of terminal 212p
Display of Condition of positioning and
C Display of automatic judgment of breaker 175p 213p
KOMTRAX communication
C Display of user code and failure code 175p MODEM S/N (Model TH300) 214p
O (Special operation) Display of KOMTRAX message 215p
Function of checking display of LCD
D 177p
(Liquid Crystal Display)
D Function of checking service meter 177p
Function of changing attachment/mainte-
D 178p
nance password

20-164 PW148-8 VEBM720100

TESTING AND ADJUSTING Special function of monitor panel

★ Classification of operator mode

A: Display/Function from time when starting switch is turned ON to time when screen changes to ordinary
screen and display after starting switch is turned OFF

B: Display/Function when switch of machine monitor is operated

C: Display/Function when certain condition is satisfied

D: Display/Function which needs special operation of switch

PW148-8 VEBM720100 20-165

Special function of monitor panel TESTING AND ADJUSTING

Operator mode (Outline) ★ Display pattern of operator mode

★ Only outline of the operator mode is described in
The contents of display from the time when start-
this section. For details of contents/operation of
ing switch is turned ON to time when screen
each function/display, see the Structure, function
changes to ordinary screen depends on the set-
and maintenance standard, or Operation and
ting and condition of the machine.
Maintenance Manual.
A : When engine start lock is set effective
B : When engine start lock is set ineffective
★ The following are the displays or functions of the
C : When working mode at start is set to breaker
operator mode explained in this section (includ-
mode (B)
ing some items which need special operations).
D : When there is abnormal item in check-
before-starting items
Display pattern E : When there is maintenance item which is not
A B C D E maintained after specified interval
Display of KOMATSU logo 1 1 1 1 1
Display of inputting password 2 — — — — Display of KOMATSU logo
Display of check of breaker mode — — 2 — — W h e n t h e s ta r t i n g s w i t c h i s t u r n e d O N , t h e
Display of check before starting 3 2 3 2 2 KOMATSU logo is displayed for 2 seconds.
Display of warning after check ★ After the KOMATSU logo is displayed for 2 sec-
— — — 3 —
before starting onds, the screen changes to “Display of inputting
Display of ending of maintenance password”, “Display of check of breaker mode (if
— — — — 3
interval B mode is set)”, or “Display of check before start-
Display of check of working mode ing”.
4 3 4 4 4
and travel speed
Display of ordinary screen 5 4 5 5 5
Display of end screen
Selection of auto-deceleration
Selection of working mode
Selection of travel speed
Operation to stop alarm buzzer
Operation of air conditioner/heater
Operation to display camera mode (if camera is
installed)
Operation to display clock and service meter
Check of maintenance information
Setting and display of user mode (including
KOMTRAX messages for user) ★ The following screen may be displayed instead
Display of energy-saving guidance of the above Display of inputting password
screen.
Display of caution monitor
Display of automatic judgment of breaker ★ If this screen is displayed, call the person re-
Display of user code and failure code sponsible to operation of KOMTRAX in your Ko-
O (Special operation) matsu distributor and ask for remedy.
Function of checking display of LCD (Liquid Crystal
Display)
Function of checking service meter
Function of changing attachment/maintenance pass-
word

20-166 PW148-8 VEBM720100

TESTING AND ADJUSTING Special function of monitor panel

Display of inputting password Display of check before starting

After the KOMATSU logo is displayed, the screen to
input the engine start lock password is displayed.
★ This screen is displayed only when the engine
start lock function is set effective.
★ If the password is input normally, the screen
changes to “Display of check of breaker mode (if
B mode is set)” or “Display of check before start-
ing”.
★ The machine monitor has some password func-
tions other than the engine start lock. Those
functions are independent from one another.
When the screen changes to the check-before-start-
ing screen, the check before starting is carried out for
2 seconds.
★ If any abnormality is detected by the check be-
fore starting, the screen changes to “Display of
warning after check before starting” or “Display
of ending of maintenance interval”.
★ If no abnormality is detected by the check before
starting, the screen changes to “Display of check
of working mode and travel speed”.
★ The monitors (6 pieces) displayed on the screen
are the items under the check before starting.

Display of check of breaker mode

When the starting switch is turned ON, if the working
mode is set to the breaker mode [B], a message to
inform the operator of starting in the breaker mode is
displayed on the screen.
k If an attachment other than the breaker is
used while the working mode is set to the
breaker mode [B], the machine may move
unexpectedly or may not operate normally or
the hydraulic components may be damaged.
★ After operation to check of the breaker mode is
finished, the screen changes to “Display of check
before starting”.
If No is selected: Working mode is set to econo-
my mode [E]
If Yes is selected: Working mode is set to breaker
mode [B]

PW148-8 VEBM720100 20-167

Special function of monitor panel TESTING AND ADJUSTING

Display of warning after check before starting Display of check of working mode and travel
speed
If any abnormality is detected by the check before
starting, the warning monitor is displayed on the If the check before starting is finished normally, the
screen. screen displayed the working mode and travel
speed.
★ The following figure shows that the engine oil
level monitor (a) is warning of low of engine oil
level.
AM N

G0148062

Display of ordinary screen

If the machine monitor starts normally, the ordinary
screen is displayed.
Display of ending of maintenance interval
When the check before starting is carried out, if a ★ Service meter (a) or a clock is displayed at the
maintenance item is near or after the end of the set center upper section of the screen (The service
interval, the maintenance monitor is displayed for 30 meter or clock is selected with [F4]).
seconds to urge the operator to maintenance.
★ ECO gauge (b) is displayed at the right end of
★ This screen is displayed only when the mainte- the screen (It is turned ON and OFF in the serv-
nance function is effective. The color of the ice mode).
maintenance monitor (yellow or red) indicates
the length of the time after the maintenance in-
a
terval.
AM N
★ Set or change the maintenance function in the
service mode.

★ After display of this screen is finished, the screen

changes to “Display of check of working mode b
and travel speed”.

G0148062

20-168 PW148-8 VEBM720100

TESTING AND ADJUSTING
Display of end screen
When the starting switch is turned OFF, the end
screen is displayed for 5 seconds.
★ Another message may be displayed on the end
screen, depending on the message display func-
tion of KOMTRAX.
Selection of auto-deceleration
While the ordinary screen is displayed, if the auto-de-
celeration switch is pressed, large auto-deceleration
monitor (a) is displayed for 2 seconds and the setting
of the auto-deceleration is changed.
★ Each time the auto-deceleration switch is
pressed, the auto-deceleration is turned ON and
OFF alternately.
★ If the auto-deceleration is turned ON, large moni-
tor (a) and auto-deceleration monitor (b) are dis-
played simultaneously.
★ If the auto-deceleration is turned OFF, auto-de-
celeration monitor (b) goes off.
b
a for 5 seconds, the selection is confirmed and
AM N
G0148061
PW148-8 VEBM720100
Special function of monitor panel
Selection of working mode
Select a working mode according to the following
procedure.
1. While the ordinary screen is displayed, press the
working mode selector switch, and the working
mode selection screen is displayed.
★ The following figure is the working mode se-
lection screen displayed when "With attach-
ment" is set (If "With attachment" is not set in
the service mode, the attachment mode
[ATT] is not displayed).
G0148064
2. Operate the function switches or working mode
selector switch to select and confirm the working
mode which you will use.
Function switches
q [F3]: Move to lower working mode
q [F4]: Move to upper working mode
q [F5]: Cancel selection and return to ordinary
screen
q [F6]: Confirm selection and return to ordi-
nary screen
Working mode selector switch
q Press: Move to lower working mode
q Hold down:Confirm selection and return to
ordinary screen
★ If you do not touch any of the function
switches and working mode selector switch
the screen changes to the ordinary screen.
G0148064
20-169
Special function of monitor panel TESTING AND ADJUSTING

3. When the ordinary screen is displayed again, Selection of travel speed

large working mode monitor (a) is displayed for 2
While the ordinary screen is displayed, if the travel
seconds, and then the setting of the working
speed shifting switch is pressed, large travel speed
mode is changed.
monitor (a) is displayed for 2 seconds and the setting
★ When large monitor (a) is displayed, the dis- of the travel speed is changed.
play of working mode monitor (b) is changed,
too. ★ Each time the travel speed shifting switch is
pressed, the travel speed is changed to Cr, Lo,
b Hi, At and Cr again in order.
a
N
★ When large monitor (a) is displayed, the display
AM
of travel speed monitor (b) is changed, too.

b
a
AM N

G0148066

<Precautions for selecting breaker mode [B]>

• If breaker mode [B] is selected, both of the con-

G0148074
trol of the hydraulic pump and the setting of the
hydraulic circuit are changed.

• If an attachment other than the breaker is used,

the machine may move unexpectedly or may not
operate normally or the hydraulic components
may be damaged.
• After the breaker mode is selected, the screen to
confirm the selection of the breaker mode is dis-
played (The buzzer sounds intermittently while
this screen is displayed).
Operation to stop alarm buzzer
While the alarm buzzer is sounding, if the alarm
buzzer cancel switch is pressed, the alarm buzzer
stops.
Even if the alarm buzzer cancel switch is pressed,
the screen does not change.

• If the setting is confirmed on this screen, the

screen changes to the ordinary screen.
If No is selected:
Working mode is set to economy mode [E]
If Yes is selected:
Working mode is set to breaker mode [B]

G0148067

20-170 PW148-8 VEBM720100

TESTING AND ADJUSTING Special function of monitor panel

Operation of air conditioner/heater

While the ordinary screen is displayed, press the air
conditioner switch or heater switch, and the air condi-
tioner adjustment screen or heater adjustment
screen is displayed.

★ While the air conditioner adjustment screen or

heater adjustment screen is displayed, if you do
not touch any switch for 5 seconds, the screen
changes to the ordinary screen.

★ Air conditioner specification

★ Heater specification

PW148-8 VEBM720100 20-171

Special function of monitor panel TESTING AND ADJUSTING

Operation to display camera mode (if camera is
installed)
When a camera is installed, if [F3] is pressed, the
multi-display changes to the camera image (Set the
connection of the camera in the service mode).
AM N a When the clock is selected, adjust the time, set
★ If the images of 2 cameras are displayed simulta-
neously, images are displayed at intervals of 1
second on the right and left screen.
Operation to display clock and service meter
While the ordinary screen is displayed, press [F4],
and section (a) changes to the service meter and
clock alternately.
12-hour or 24-hour display, and set the summer
time with the user mode function.
a

AM N

G0148062

★ Up to 3 cameras can be connected. If the cam-

era mode is selected, however, only the image of
camera 1 is always displayed.
G0148062

★ If a caution is generated in the camera mode, the

caution monitor is displayed at the left upper of
the screen (The low hydraulic oil temperature
caution is not displayed there, however).

★ When an error that there is a user code occurs in

the camera mode, if you do not touch any control
lever for 10 seconds, the screen changes to the
ordinary screen and displays the error informa-
tion.

★ When two or more cameras are connected, the

image of one of them or the images of two of
them can be displayed.

★ If 2-camera image display [F4] is selected, the

image of camera 1 is displayed on the left side of
the screen and the image of camera 2 is dis-
played on the right side. The image of camera 3
is displayed only singly.

20-172 PW148-8 VEBM720100

TESTING AND ADJUSTING Special function of monitor panel

Check of maintenance information Setting and display of user mode

(Including KOMTRAX messages for user)
While the maintenance monitor or ordinary screen is
displayed, press [F5], and the maintenance table While the ordinary screen is displayed, press [F6],
screen is displayed. and the user menu screen is displayed.

AM N AM N

G0148062 G0148062

★ To reset the time left after finishing maintenance, ★ There are following items in the user menu.
more operations are necessary (See "Mainte-
nance record" in the service mode). Breaker/Attachment setting
Attachment 2 settings (if 2 Att. lines)
User message
Screen adjustment
Clock adjustment
Language
Economy mode adjustment

★ The breaker/attachment setting and attachment

2 setting menus are displayed only when "With
attachment" is set in the service mode.

Screen for machine with 1 Attachment line

Screen for machine with 2 Attachment lines

PW148-8 VEBM720100 20-173

Special function of monitor panel
[KOMTRAX message]
• There are 2 types of KOMTRAX message; 1 is
for the user and the other is for the service.
• For user:
A message transmitted from the KOMTRAX
base station for the user. If it is received, the
message monitor is displayed on the ordinary
screen. To see the contents of the message, op-
erate "Message display" in the above user menu.
• For service:
A message transmitted from the KOMTRAX
base station for the service. Even if it is received,
nothing is displayed on the ordinary screen. To
see the contents of the message, operate "KOM-
TRAX message" display in the service menu.
20-174
TESTING AND ADJUSTING
Display of energy-saving guidance
When the machine is set in a certain operating condi-
tion, the energy-saving guidance screen is displayed
automatically to urge the operator to the energy-sav-
ing operation.
★ The energy-saving guidance is displayed when
the following condition is satisfied while the dis-
play setting is set effective in the service mode.
★ Condition for display:
Engine is running + All levers have been in neu-
tral for 5 minutes + Caution (Note) or user code
is not generated (Note)
Note: Excluding hydraulic oil low temperature
caution
★ If any lever or pedal is operated, or [F5] is
pressed, the screen returns to the ordinary
screen.
G0148048
Display of caution monitor
If an abnormality which displays a caution monitor
occurs on the ordinary screen or camera mode
screen, the caution monitor is displayed large for a
moment and then displayed at (a) in the screen.
★ On the camera mode screen, the caution monitor
flashes at the left upper of the screen when the
caution is generated.
PW148-8 VEBM720100
TESTING AND ADJUSTING
Display of automatic judgment of breaker
If the operator performs breaker work in an improper
working mode, the breaker automatic judgment
screen is displayed to urge the operator to select a
proper working mode.
★ The breaker automatic judgment is displayed
when the following condition is satisfied while the
display setting is set effective in the service
mode.
★ Condition for display:
★ When the pump controller measures the rear
pump pressure for a certain time, the obtained
value is similar to the pulsation wave form of
breaker operation which is held in the controller
in advance.
★ The breaker automatic judgment function is set
to Not used (Not displayed) when delivered.
★ If this screen is displayed, check the setting of
the working mode. If the breaker is being used,
select the breaker mode [B].
★ To return to the ordinary screen, press [F5].
PW148-8 VEBM720100
Special function of monitor panel
Display of user code and failure code
If an abnormality which displays a user code and a
failure code occurs on the ordinary screen or camera
mode screen, all the information of the abnormality is
displayed.
(a): User code (3 digits)
(b): Failure code (5 or 6 digits)
(c): Telephone mark
(d): Telephone No.
★ This screen is displayed only when an abnormal-
ity (failure code) for which a user code is set oc-
curs.
★ The telephone mark and telephone No. are dis-
played only when the telephone No. is registered
in the service mode.
★ If multiple abnormalities occur simultaneously, all
the codes are displayed repeatedly in order.
★ Since the information of the displayed failure
code is recorded in the abnormality record in the
service mode, check the details in the service
mode.
a When the caution monitor is also displayed, the
telephone mark is not displayed.
20-175
Special function of monitor panel TESTING AND ADJUSTING

★ Remedies given by displayed user codes to operator to take (The following table is an excerpt from the Oper-
ation and Maintenance Manual)

User code Failure mode Action

Pump control system error
E02
Swing brake system error
E03
Engine controller power source error
E10 Engine controller drive system circuit
error (engine stopped)
Engine controller system error
E11
Output reduced to protect engine
Abnormality in throttle system
E14
Engine sensor (coolant temperature,
E15
fuel pressure, oil pressure) system error immediately.
Network error
E0E
When emergency pump drive switch is at the up (emer-
gency) position, normal operations become possible, but
have inspection carried out immediately.
Move the swing brake cancel switch up to release the
brake. When applying the swing brake, operate the swing
lock switch manually. Depending on the cause of the prob-
lem, it may not be possible to release it. In any case, have
inspection carried out immediately.
Have inspection carried out immediately.
Operate machine to a safe posture and have inspection
carried out immediately.
Operate machine to a safe posture and have inspection
carried out immediately.
Operations are possible, but have inspection carried out
Operate machine to a safe posture and have inspection
carried out immediately.

20-176 PW148-8 VEBM720100

TESTING AND ADJUSTING
Function of checking display of LCD (Liquid
Crystal Display)
While the ordinary screen is displayed, if the follow-
ing numeral input switch and function switch are op-
erated as follows, all the LCD (Liquid Crystal Display)
lights up in white.
• Operation of switches (simultaneous): [4] + [F2]
★ When finishing the operation of the switches, re-
lease [F2] first.
★ If there is a display error in the LCD, only that
part is indicated in black.
★ The LCD panel sometimes has black points
(points which are not lighted) and bright points
(points which do not go off) for the reason of its
characteristics. If the number of the bright points
and black points does not exceed 10, those
points are not a failure or a defect.
★ To return to the former screen, press the function
switch.
PW148-8 VEBM720100
Special function of monitor panel
Function of checking service meter
To check the service meter while the starting switch
is turned OFF, operate the numeral input switches as
follows. At this time, only the service meter section
displays.
• Operation of switches (simultaneous): [4] + [1]
★ Since there is some time lag in start of the LCD,
hold down the switches until the LCD displays
normally.
★ After the machine monitor is used continuously,
blue points (points which do not go off) may be
seen on this screen. This phenomenon does not
indicate a failure or a defect.
20-177
Special function of monitor panel TESTING AND ADJUSTING

Function of changing attachment/maintenance 3. After the New password input screen is dis-
password played, input a new password with the numeral
input switches and confirm it with the function
When changing the attachment/maintenance pass-
switch.
word used for the attachment setting function and
maintenance setting function, follow these proce- a Set a new password of 4 – 6 digits (If it has
dures. only 3 or less digits or has 7 or more digits,
it is not accepted).
1. While the ordinary screen is displayed, perform q [F5]: Reset input numeral/Return to ordinary
the following operation with the numeral input screen
switches. q [F6]: Confirm input numeral
q Operation of switches (While pressing [4],
perform the operation in order):
[4] + [5] o [5] o [5]
a This operation of the switches is not
accepted until 10 minutes pass after the
starting switch is turned on.

AM N

4. After the New password input screen is dis-

played again, input a new password again with
the numeral input switches and confirm it with
the function switch.
G0148062
q [F5]: Reset input numeral/Return to ordinary
screen
2. After the Attachment/Maintenance PASSWORD q [F6]: Confirm input numeral
screen is displayed, input the current password a If a password different from the password
with the numeral input switches and confirm it input before is input, the message to input
with the function switch. again is displayed.
q [F5]: Reset input numeral/Return to ordinary
screen
q [F6]: Confirm input numeral
a Default password: [000000]
a If the input password is correct, the screen
changes to the next screen.
a If the input password is incorrect, the mes-
sage to input the password again is dis-
played.

20-178 PW148-8 VEBM720100

TESTING AND ADJUSTING Special function of monitor panel

5. If the screen to notify completion of setting is dis-

played and then the ordinary screen is dis-
played, the password is changed successfully.

PW148-8 VEBM720100 20-179

Special function of monitor panel TESTING AND ADJUSTING

Service mode a The items which can be selected in the ser-

vice menu are as follows (including some
To change the operator mode to the service mode,
items which need special operations).
perform the following operation.
This operation is always required when you use the 01 Monitoring
service mode. Mechanical systems
02 Abnormality Electrical systems
1. Check of display of screen and operation of
record
switches Air-conditioning system/Heater
While the ordinary screen is displayed, perform system
the following operation with the numeral input 03 Maintenance record
switches. 04 Maintenance mode change
q Operation of switches (While pressing [4],
05 Phone number entry
perform the operation in order):
[4] + [1] o [2] o [3] Working mode with key ON
a This operation of the switches is accepted Setting of unit
only while the ordinary screen is displayed. With/Without attachment
Setting of attachment/
06 Default maintenance password
Setting of camera
Setting of ECO display
Setting of automatic judgment of
breaker
Pump absorption torque (F)
Pump absorption torque (R)
07 Adjustment Setting of travel Lo speed
Adjustment of flow to attachment
in compound operation
08 Reduced cylinder mode operation

2. Selection of service menu 09 No-injection cranking

When the Service menu screen is displayed, the 10 Display of fuel consumption
service mode is selected. Select a service menu Setting condition of terminal
you use with the function switches or numeral
Condition of positioning and
input switches.
11 Display of communication
q [F3]: Move to lower menu KOMTRAX MODEM S/N (Model TH300)
q [F4]: Move to upper menu
q [F5]: Return to ordinary screen (operator MODEM IP address (Model
TH200)
mode)
q [F6]: Confirm selection
a You may enter a 2-digit code with the
numeral input switches to select the menu
of that code and confirm it with [F6].

20-180 PW148-8 VEBM720100

TESTING AND ADJUSTING Special function of monitor panel

Monitoring
The machine monitor can monitor the condition of
the machine in real time by receiving signals from
various switches, sensors, and actuators installed to
many parts of the machine and the information from
the controllers which are controlling switches, etc.

1. Selecting menu
Select “Monitoring” on the service menu screen.

3. Deciding monitoring items

After selecting monitoring items, execute moni-
toring with the function switch or numeral input
switch.
★ Execution with function switch: Double-click
or hold down [F6] (about 2 seconds).

★ Execution with numeral input switch: Input

2. Selecting monitoring items
After the “Monitoring selection menu screen” is
displayed, select items to be monitored with the
function switches or numeral input switches.
• [F1]:Move to next page (screen)
• [F2]:Move to previous page (screen)
• [F3]:Move to lower item
[99999] and press [F6].
★ When monitoring only 2 items, for example,
select them and confirm with [F6]. If [F6] is
pressed once more at this time, monitoring is
executed.
★ If monitoring items are selected up to the lim-
it number, monitoring is executed automati-
cally.

• [F4]:Move to upper item

• [F5]:Reset input numeral/Return to service-

menu screen

• [F6]:Confirm selection

★ Selection with function switches: Select an

item with [F3] or [F4] and confirm it with [F6].

★ Selection with numeral input switches: Enter

a 5-digit code, and the item of that code is
selected directly. Confirm that item with [F6].

★ If the color of the selected box changes from

yellow to red, selection of the item of that box
is confirmed.

★ Up to 6 monitoring items can be selected at

a time. You may not able to set up to 6 items,
however, depending on the display form of
those items.

PW148-8 VEBM720100 20-181

Special function of monitor panel
4. Executing monitoring
After the “Executing monitoring screen” is dis-
played, perform the necessary operation of the
machine and check the monitoring information.
★ Monitoring information is indicated by value,
ON/OFF, or special display.
★ The unit of display can be set to SI unit, met-
ric unit, or inch unit with the Initialization
function in the service mode.
5. Holding monitoring information
The monitoring information can be held and reset
with the function switches.
• [F3]:Reset holding
• [F4]:Hold information (displayed data)
• [F5]:Return to monitoring selection menu
screen
20-182
TESTING AND ADJUSTING
6. Changing machine setting mode
To change the setting of the working mode, travel
speed, or auto-deceleration during monitoring,
operate the corresponding switch under the cur-
rent condition, and the mode setting screen is
displayed.
While this screen is displayed, if the correspond-
ing switch is operated further, the corresponding
mode is changed.
★ After finishing changing the setting, press
[F6] to return to the monitoring information
screen.
★ If the setting is changed during monitoring,
the new setting is held even after the screen
returns to the ordinary screen after monitor-
ing is finished.
★ If the working mode is changed to breaker
mode [B], the screen to confirm the change
of the setting is displayed as in changing the
working mode on the ordinary screen.
PW148-8 VEBM720100
TESTING AND ADJUSTING Special function of monitor panel

Monitoring items table

Unit (Initial setting: ISO) Com-

Code ponent
Monitoring item (Display on screen) Remarks
No. ISO meter inch in
charge
00200 Controller Model Select — PUMP
00201 Machine ID — ENG
01002 Engine speed r/min rpm rpm ENG
01601 2nd Eng. Speed Command r/min rpm rpm PUMP
01100 Pump Pressure MPa kg/cm2 psi PUMP
40011 Travel Speed KpH KpH MpH MON
07101 Travel PPC Pressure MPa kg/cm2 psi PUMP
04107 Coolant Temperature °C °C °F ENG
04401 Hydr. Oil Temperature °C °C °F PUMP
01300 PC-EPC Sol. Curr. mA mA mA PUMP
01500 LS-EPC Sol. Curr. mA mA mA PUMP
01700 Service Sol. Curr. mA mA mA PUMP
01701 Service Solenoid 2 Curr. mA mA mA PUMP
01702 Service Solenoid 3 Curr. mA mA mA PUMP
01703 Service Solenoid 4 Curr. mA mA mA PUMP
01006 Engine Speed rpm rpm rpm PUMP
03200 Battery Voltage V V V PUMP
03203 Battery Power Supply V V V ENG
04300 Battery Charge Vol. V V V MON
32902 Angle sensor Deg.
36400 Rail Pressure MPa kg/cm2 psi ENG
37400 Ambient Pressure kPa kg/cm2 psi ENG
18500 Charge Temperature °C °C °F ENG
Absolute value indication
36500 Boost Pressure kPa kg/cm2 psi ENG (including atmospheric
pressure)
36700 Engine Torque Ratio % % % ENG
18700 Engine Output Torque Nm kgm lbft ENG
03000 Fuel Dial Pos Sens Volt V V V ENG
04200 Fuel Level Sensor Vol. V V V MON
04105 Eng. Water Temp. Vol. Lo V V V ENG
04402 Hydr. Temp. Sensor Vol. V V V PUMP
37401 Ambient Press Sens Volt V V V ENG
18501 Charge Temp Sens Volt V V V ENG
36501 Charge Press Sens Volt V V V ENG
36401 Rail Pressure Sens Volt V V V ENG
17500 Engine Power Mode — ENG
31701 Throttle Position % % % ENG
31706 Final Throttle Position % % % ENG
18600 Inject Fueling Command mg/st mg/st mg/st ENG
36200 Rail Press Command MPa kg/cm2 psi ENG
36300 Injection Timing Command CA CA CA ENG
37300 Fuel Rate l/h l/h gal/h ENG
01602 2nd Eng. Speed Command % % % PUMP
13113 Main Pump Absorb Torque Nm kgm lbft PUMP
15900 Boom Bottom Pressure MPa kg/cm2 psi PUMP

PW148-8 VEBM720100 20-183

Special function of monitor panel TESTING AND ADJUSTING

Unit (Initial setting: ISO) Com-

Code ponent
Monitoring item (Display on screen) Remarks
No. ISO meter inch in
charge
Swing ON•OFF PUMP
Boom Lower ON•OFF PUMP
01900 Pressure Switch 1 Boom Raise ON•OFF PUMP
Arm Curl ON•OFF PUMP
Arm Dump ON•OFF PUMP
Bucket Curl ON•OFF PUMP
Bucket Dump ON•OFF PUMP
01901 Pressure Switch 2 Service ON•OFF PUMP
Travel Forwards ON•OFF PUMP
Travel Reverse ON•OFF PUMP
Travel Junction ON•OFF PUMP
Swing Brake ON•OFF PUMP
02300 Solenoid Valve 1
2-Stage Relief ON•OFF PUMP
Travel Speed ON•OFF PUMP
Suspnsion Lock ON•OFF PUMP
PPC Lock ON•OFF PUMP
2-Stage Back Pressure ON•OFF PUMP
02301 Solenoid Valve 2
Travel Neutral ON•OFF PUMP
Travel Forward/Reverse ON•OFF PUMP
Boom/Outrigger ON•OFF PUMP
Travel Sw. F ON•OFF PUMP
Travel Sw. R ON•OFF PUMP
Travel Sw. N ON•OFF PUMP
02200 Switch Input 1
Lever Sw. (P.Max) ON•OFF PUMP
Swing Release Sw. ON•OFF PUMP
Swing Brake Sw. ON•OFF PUMP
Model Select 1 ON•OFF PUMP
Model Select 2 ON•OFF PUMP
Model Select 3 ON•OFF PUMP
02201 Switch Input 2
Model Select 4 ON•OFF PUMP
Model Select 5 ON•OFF PUMP
Overload Alarm ON•OFF PUMP
02202 Switch Input 3 Key Switch (ACC) ON•OFF PUMP
Boom/Outrigger ON•OFF PUMP
Breaker Sw. ON•OFF PUMP
Service L Sw. ON•OFF PUMP
02203 Switch Input 4
Service R Sw. ON•OFF PUMP
Safty Loch Sw. ON•OFF PUMP
Quick Coupler ON•OFF PUMP
Parking Brake SW. ON•OFF PUMP
Brake Pressure ON•OFF PUMP
02204 Switch Input 5 Travel Position ON•OFF PUMP
Lever Neutral 1 ON•OFF PUMP
Lever Neutral 2 ON•OFF PUMP
03700 Controller Output 1 Battery Relay ON•OFF PUMP
Key Switch ON•OFF MON
Start ON•OFF MON
04500 Monitor input 1 Preheat ON•OFF MON
Light ON•OFF MON
Rad. Level ON•OFF MON

20-184 PW148-8 VEBM720100

TESTING AND ADJUSTING Special function of monitor panel

Unit (Initial setting: ISO) Com-

Code ponent
Monitoring item (Display on screen) Remarks
No. ISO meter inch in
charge
Air cleaner ON•OFF MON
04501 Monitor Input 2 Eng. Oil Level ON•OFF MON
Battery Charge ON•OFF MON
04502 Monitor Input 3 Swing Brake Sw. ON•OFF MON
F1 ON•OFF MON
F2 ON•OFF MON
Monitor Function F3 ON•OFF MON
04503
Switches F4 ON•OFF MON
F5 ON•OFF MON
F6 ON•OFF MON
SW1 ON•OFF MON
SW2 ON•OFF MON
Monitor 1st & 2nd SW3 ON•OFF MON
04504
Row Switches SW4 ON•OFF MON
SW5 ON•OFF MON
SW6 ON•OFF MON
SW7 ON•OFF MON
SW8 ON•OFF MON
Monitor 3rd & 4th SW9 ON•OFF MON
04505
Row Switches SW10 ON•OFF MON
SW11 ON•OFF MON
SW12 ON•OFF MON
SW13 ON•OFF MON
Monitor 5th Row
04506 SW14 ON•OFF MON
Switches
SW15 ON•OFF MON
18800 Water In Fuel ON•OFF ENG WIF: Water In Fuel
20216 ECM Build Version — ENG
20217 ECM CAL Data Ver — ENG
18900 ECM Internal Temp °C °C °F ENG
20400 ECM Serial No — ENG
20227 Monitor Ass'y P/N — MON
20402 Monitor Serial No — MON
20228 Monitor Prog. P/N — MON
20229 Pump Con. Ass'y P/N — PUMP
20403 Pump Con. Serial No — PUMP
20230 Pump Con. Prog. P/N — PUMP
20200 Monitor Prog. Version — MON
20212 Pump Con.Prog. Version — PUMP

a Entry order of items in table

The items are entered in the order of display on the monitoring selection menu screen.
a Unit
The display unit can be set to ISO, meter, or inch freely (Set it with Unit setting in Initialization of the service
menu).
"CA" in the display unit is an abbreviation for crankshaft angle.
"mg/st" in the display unit is an abbreviation for milligram/stroke.
a Component in charge
MON: The machine monitor is in charge of detection of monitoring information.
ENG: The engine controller is in charge of detection of monitoring information.
PUMP: The pump controller is in charge of detection of monitoring information.

PW148-8 VEBM720100 20-185

Special function of monitor panel TESTING AND ADJUSTING

Abnormality record 3. Information displayed on “abnormality record”

(Mechanical system abnormality record) screen
On the “Mechanical systems” screen, the follow-
The machine monitor classifies and records the
ing information is displayed.
abnormalities which occurred in the past or which are
occurring at present into the mechanical systems, (a) : Occurrence order of abnormalities from lat-
electrical systems, and air-conditioning system or est one/Total number of records
heater system. (b) : Failure code
To check the mechanical system abnormality record, (c) : Contents of trouble
perform the following procedures. (d) : Number of occurrence time
(e) : Service meter reading at first occurrence
1. Selecting menu (f) : Service meter reach at last occurrence
Select “Abnormality record” on the “service q [F1]: Move to next page (screen) (if dis-
menu” screen. played)
q [F2]: Move to previous page (screen) (if dis-
played)
q [F5]: Return to abnormality record screen
a If no abnormality record is recorded, "No
abnormality record" is displayed.
a If the number of occurrence time is 1 (first
occurrence), the service meter reading at
the first occurrence and that at the last
occurrence are the same.
a If [E] is displayed on the left of a failure
code, the abnormality is still occurring or
resetting of it has not been confirmed.
a For all the failure codes that the machine
monitor can record, see the failure codes
table in Abnormality record (Electrical sys-
2. Selecting sub menu tems).
After the “Abnormality record” screen is dis-
played, select “Mechanical systems with the
function switches or numeral input switches.
q [F3]: Move to lower item
q [F4]: Move to upper item
q [F5]: Return to service menu screen
q [F6]: Confirm selection
a You may enter a 2-digit code with the
numeral input switches to select the record
of that code and confirm it with [F6].
a The following figure shows the display of
the air conditioner specification. The heater
specification and heaterless specification
are different from each other in the display
of "03 Air-conditioning system", which may
not be displayed in the heaterless specifica-
tion.

20-186 PW148-8 VEBM720100

TESTING AND ADJUSTING
4. Resetting abnormality record
T h e c o n t e n ts o f t h e m e c h a n i c a l s y s t e m
abnormality record cannot be reset.
Abnormality record (Electrical systems)
The machine monitor classifies and records the
abnormalities which occurred in the past or which are
occurring at present into the mechanical systems,
electrical systems, and air-conditioning system.
To check the electrical system abnormality record,
perform the following procedures.
1. Selecting menu
Select “Abnormality record” on the service menu
screen.
2. Selecting sub menu
After the “Abnormality record” screen is dis-
played, select “Electrical systems” with the func-
tion switches or numeral input switches.
q [F3]: Move to lower item
q [F4]: Move to upper item
q [F5]: Return to service menu screen
q [F6]: Confirm selection
a You may enter a 2-digit code with the
numeral input switches to select the record
of that code and confirm it with [F6].
a The following figure shows the display of
the air conditioner specification. The heater
specification and heaterless specification
are different from each other in the display
of "03 Air-conditioning system", which may
not be displayed in the heaterless specifica-
tion.
PW148-8 VEBM720100
Special function of monitor panel
3. Information displayed on “abnormality record”
screen
On the “Electrical systems” screen, the following
information is displayed.
(a) : Occurrence order of abnormalities from lat-
est one/Total number of records
(b) : Failure code
(c) : Contents of trouble
(d) : Number of occurrence time
(e) : Service meter reading at first occurrence
(f) : Service meter reach at last occurrence
q [F1]: Move to next page (screen) (if dis-
played)
q [F2]: Move to previous page (screen) (if dis-
played)
q [F3]: Move to lower item
q [F4]: Move to upper item
q [F5]: Return to “abnormality record” screen
a If no abnormality record is recorded, "No
abnormality record" is displayed.
a If the number of occurrence time is 1 (first
occurrence), the service meter reading at
the first occurrence and that at the last
occurrence are the same.
a If [E] is displayed on the left of a failure
code, the abnormality is still occurring or
resetting of it has not been confirmed.
a For all the failure codes that the machine
monitor can record, see the failure codes
table.
20-187
Special function of monitor panel TESTING AND ADJUSTING

4. Resetting abnormality record
1) While the “Electrical systems” screen is dis-
played, perform the following operation with
the numeral input switches.
q Operation of switches (While pressing
[4], perform the operation in order):
[4] + [1] o [2] o [3]
3) After the “Electrical sys. error reset” screen
is displayed, operate the function switches.
q [F5]: Return to “Electrical systems”
screen (Reset mode)
q [F6]: Execute reset
a The following figure shows the screen
displayed when the items are reset one
by one (which is a little different from
the screen displayed when all the items
are reset together).

2) Check that the screen is set in the reset

mode, and then reset the items one by one
or together with the function switches.
a If the screen is set in the reset mode, 4) If the screen to notify completion of reset is
[CLEAR] graphic mark is indicated at displayed and then the “Electrical systems”
[F2]. (reset mode) screen is displayed, the reset
q [F2]: Reset all items of the abnormality record is completed.
q [F3]: Move to lower item a After a while, the screen returns to the
q [F4]: Move to upper item “Electrical systems” screen.
q [F5]: Return to abnormality record
screen
q [F6]: Reset selected item
a To reset items one by one: Select the
item to be reset with [F3] or [F4] and
press [F6].
a To reset all items together: Press [F2],
and all the items are reset, regardless
of selection of the items.
a If [E] is displayed on the left of a failure
code, the resetting operation is
accepted but the information is not
reset.

20-188 PW148-8 VEBM720100

TESTING AND ADJUSTING Special function of monitor panel

Failure codes table

User Alarm Component
Failure code Trouble (Displayed on screen) Category of record
code buzzer in charge
6B2JMA Travel Hydraulic Abnormality Pump Electrical system
989L00 Engine Controller Lock Caution 1 MON Electrical system
989M00 Engine Controller Lock Caution 2 MON Electrical system
E20 989N00 Engine Controller Lock Caution 3 MON Electrical system
AA10NX Air Cleaner Clogging MON Mechanical system
AB00KE Charge Voltage Low MON Mechanical system
B@BAZG Eng Oil Press. Low e ENG Mechanical system
B@BAZK Eng Oil Level Low MON Mechanical system
B@BCNS Eng Water Overheat e ENG Mechanical system
B@BCZK Eng Water Level Low e MON Mechanical system
B@HANS Hydr Oil Overheat e PUMP Mechanical system
E10 CA111 EMC Critical Internal Failure q ENG Electrical system
E10 CA115 Eng Ne and Bkup Speed Sens Error q ENG Electrical system
E11 CA122 Chg Air Press Sensor High Error q ENG Electrical system
E11 CA123 Chg Air Press Sensor Low Error q ENG Electrical system
E14 CA131 Throttle Sensor High Error q ENG Electrical system
E14 CA132 Throttle Sensor Low Error q ENG Electrical system
CA143 Oil. Pressure, Fueling Error q ENG Electrical system
E15 CA144 Coolant Temp Sens High Error q ENG Electrical system
E15 CA145 Coolant Temp Sens Low Error q ENG Electrical system
CA146 Coolant Temp, Fueling Error q ENG Electrical system
E15 CA153 Chg Air Temp Sensor High Error q ENG Electrical system
E15 CA154 Chg Air Temp Sensor Low Error q ENG Electrical system
E11 CA155 Chg Air Temp High Speed Derate q ENG Electrical system
E15 CA187 Sens Supply 2 Volt Low Error q ENG Electrical system
E15 CA221 Ambient Press Sens High Error q ENG Electrical system
E15 CA222 Ambient Press Sens Low Error q ENG Electrical system
E15 CA227 Sens Supply 2 Volt High Error q ENG Electrical system
CA234 Eng Overspeed ENG Mechanical system
E15 CA238 Ne Speed Sens Supply Volt Error q ENG Electrical system
E11 CA271 IMV/PCV1 Short Error q ENG Electrical system
E11 CA272 IMV/PCV1 Open Error q ENG Electrical system
E11 CA322 Inj #1 (L#1) Open/Short Error q ENG Electrical system
E11 CA324 Inj #3 (L#3) Open/Short Error q ENG Electrical system
E11 CA331 Inj #2 (L#2) Open/Short Error q ENG Electrical system
E11 CA332 Inj #4 (L#4) Open/Short Error q ENG Electrical system
E10 CA342 Calibration Code Incompatibility q ENG Electrical system
E10 CA351 Injectors Drive Circuit Error q ENG Electrical system
E15 CA352 Sens Supply 1 Volt Low Error q ENG Electrical system
E15 CA386 Sens Supply 1 Volt High Error q ENG Electrical system
CA415 Oil, pressure, RPM error q ENG Electrical system
E15 CA428 Water in Fuel Sensor High Error q ENG Electrical system
E15 CA429 Water in Fuel Sensor Low Error q ENG Electrical system
E15 CA435 Eng Oil Press Sw Error q ENG Electrical system
E10 CA441 Battery Voltage Low Error q ENG Electrical system
E10 CA442 Battery Voltage High Error q ENG Electrical system
E11 CA449 Rail Press Very High Error q ENG Electrical system
E11 CA451 Rail Press Sensor High Error q ENG Electrical system
E11 CA452 Rail Press Sensor Low Error q ENG Electrical system
E11 CA488 Chg Air Temp High Torque Derate q ENG Electrical system
E15 CA553 Rail Press High Error q ENG Electrical system
E11 CA559 Rail Pressure Very Low Error q ENG Electrical system
E15 CA689 Eng Ne Speed Sensor Error q ENG Electrical system
E15 CA697 ECM Internal Temperature Sensor High Error PUMP Mechanical system
E15 CA698 ECM Internal Temperature Sensor Low Error PUMP Mechanical system

PW148-8 VEBM720100 20-189

Special function of monitor panel TESTING AND ADJUSTING

User Alarm Component

Failure code Trouble (Displayed on screen) Category of record
code buzzer in charge
E15 CA731 Eng Bkup Speed Sens Phase Error q ENG Electrical system
E10 CA757 All Continuous Data Lost Error q ENG Electrical system
E15 CA778 Eng Bkup Speed Sensor Error q ENG Electrical system
E0E CA1633 KOMNET Datalink Timeout Error q ENG Electrical system
E10 CA1117 Persistant data lost error q ENG Electrical system
E14 CA2185 Throt Sens Sup Volt High Error q ENG Electrical system
E14 CA2186 Throt Sens Sup Volt Low Error q ENG Electrical system
E11 CA2249 Rail Press Very Low Error q ENG Electrical system
E11 CA2311 IMV Solenoid Error q ENG Electrical system
E15 CA2555 Grid Htr Relay Volt High Error q ENG Electrical system
E15 CA2556 Grid Htr Relay Volt Low Error q ENG Electrical system
D110KB Battery Relay Short ENG Electrical system
E01 D19JKZ Personal Code Relay Abnormality q MON2 Electrical system
D862KA GPS Antenna Discon MON2 Electrical system
E02 DA25KP 5 V Sensor 1 Power Abnormality PUMP Electrical system
DA29KQ Model Selection Abnormality PUMP Electrical system
E0E DA2RMC CAN Discon (Pump Con Detected) q PUMP Electrical system
DAFGMC GPS Module Error MON2 Electrical system
E0E DAFRMC CAN Discon (Monitor Detected) q MON Electrical system
E20 DDC3KZ Outrigger Switch Select Abnornality PUMP Electrical system
DDHPAKP Abnornality in Pump Pressure PUMP Electrical system
DDP4KX Travel PPC Pressure Switch Abnormality PUMP Electrical system
E20 DDWCKZ Direction Switch Abnormality PUMP Electrical system
DGH2KB Hydr Oil Sensor Short PUMP Electrical system
DH1OKS Pressure Sensor Power Abnormality
DHPAMA Pump Press Sensor Abnormality PUMP Electrical system
E20 DHS5KX Travel PPC Sensor Abnormality PUMP Electrical system
E20 DLT4KA Speed Sensor Discon PUMP Electrical system
E20 DW27KA Transmission Clutch Solenoid Discon PUMP Electrical system
E20 DW27KB Transmission Clutch Solenoid Short PUMP Electrical system
DW43KA Travel Speed Sol Discon PUMP Electrical system
DW43KB Travel Speed Sol Short PUMP Electrical system
E20 DW44KA Travel FR Solenoid Discon PUMP Electrical system
E20 DW44KB Travel FR Solenoid Short PUMP Electrical system
E03 DW45KA Swing Brake Sol Discon q PUMP Electrical system
E03 DW45KB Swing Brake Sol Short q PUMP Electrical system
E20 DW4AKA Suspension Lock Solenoid Discon PUMP Electrical system
E20 DW4AKB Suspension Lock Solenoid Short PUMP Electrical system
DW4CKA PPC Lock Solenoid Discon PUMP Electrical system
DW4CKB PPC Lock Solenoid Short PUMP Electrical system
E20 DW4MKA Creep Solenoid Discon PUMP Electrical system
E20 DW4MKB Creep Solenoid Short PUMP Electrical system
E20 DW91KA Travel N Sol Discon PUMP Electrical system
E20 DW91KB Travel N Sol Short PUMP Electrical system
DWA2KA Service Sol Discon PUMP Electrical system
DWA2KB Service Sol Short PUMP Electrical system
DWK0KA 2-stage Relief Sol Discon PUMP Electrical system
DWK0KB 2-stage Relief Sol Short PUMP Electrical system
DWK2KA 2 Stage Back pressure Solenoid Discon PUMP Electrical system
DWK2KB 2 Stage Back pressure Solenoid Short PUMP Electrical system
E02 DXA8KA PC-EPC Sol Discon q PUMP Electrical system
E02 DXA8KB PC-EPC Sol Short q PUMP Electrical system
DXE0KA LS-EPC Sol Discon PUMP Electrical system
DXE0KB LS-EPC Sol Short PUMP Electrical system
DXE4KA Service Current EPC Discon PUMP Electrical system
DXE4KB Service Current EPC Short PUMP Electrical system

20-190 PW148-8 VEBM720100

TESTING AND ADJUSTING Special function of monitor panel

User Alarm Component

Failure code Trouble (Displayed on screen) Category of record
code buzzer in charge
DXE5KB Merge-divider Main Sol Short PUMP Electrical system
DY20KA Wiper Working Abnormality PUMP Electrical system
DY20MA Wiper Parking Abnormality PUMP Electrical system
DY2CKA Washer Drive Discon PUMP Electrical system
DY2CKB Washer Drive Short PUMP Electrical system
DY2DKB Wiper Drive (For) Short PUMP Electrical system
DY2EKB Wiper Drive (Rev) Short PUMP Electrical system

a Entry order of items in table

The items are entered in the order of their failure codes (incremental order).
a User code
Attached : If the failure code is detected, the user code, failure code, and telephone No. (if registered)
are displayed on the ordinary screen to notify the operator of the abnormality.
Not attached: Even if the failure code is detected, the machine monitor does not notify the operator of the
abnormality.
a Alarm buzzer
q : When occurrence of an error is notified to the operator, the buzzer sounds (The operator can stop the
buzzer with the alarm buzzer cancel switch).
e: Since the caution monitor is also turned ON, its function sounds the buzzer.
a Component in charge
MON: The machine monitor is in charge of detection of abnormality.
MON2: The KOMTRAX section of the machine monitor is in charge of detection of abnormality.
ENG: The engine controller is in charge of detection of abnormality.
PUMP: The pump controller is in charge of detection of abnormality.
a Category of record
Mechanical system: Abnormality information is recorded in the mechanical system abnormality record.
Electrical system: Abnormality information is recorded in the electrical system abnormality record.

PW148-8 VEBM720100 20-191

Special function of monitor panel
Abnormality record (Air-conditioning abnormali-
ty record/Heater abnormality record)
The machine monitor classifies and records the
abnormalities which occurred in the past or which are
occurring at present into the mechanical systems,
electrical systems, and air-conditioning abnormalities
or heater abnormalities.
To check the air-conditioning abnormality record or
heater abnormality record, perform the following pro-
cedures.
a All the following figures show the air conditioner
specification.
1. Selecting menu
Select “Abnormality record” on the service menu
screen.
2. Selecting sub menu
After the “Abnormality record” screen is dis-
played, select air-conditioning system or heater
system with the function switches or numeral
input switches.
q [F3]: Move to lower item
q [F4]: Move to upper item
q [F5]: Return to service menu screen
q [F6]: Confirm selection
a You may enter a 2-digit code with the
numeral input switches to select the record
of that code and confirm it with [F6].
20-192
TESTING AND ADJUSTING
3. Information displayed on “abnormality record”
screen
On the air-conditioning system or heater system
screen, the following information is displayed.
(a): System/Component name
(b): Number of occurrence time
(c): Condition (Normal or abnormal)
q [F2]: Reset abnormality record
q [F5]: Return to abnormality record screen
a If [E] is displayed on the left of a condition,
the abnormality is still occurring or resetting
of it has not been confirmed.
a If CAN disconnection is displayed in Com-
munication condition, communication can-
not be carried out normally. Accordingly, the
conditions of other items are turned OFF.
4. Resetting abnormality record
While the “abnormality record” screen is dis-
played, press [F2], and the number of occur-
rence time of abnormality is reset. If it is
confirmed at this time that the abnormality has
been reset, the display changes to Normal.
a Heater specification
In the heater specification, the display of Air-
conditioning is replaced with Heater and the
items which are not related to the heater are not
displayed.
a Heaterless specification
In the heaterless specification, the abnormality
record menu and screen are not displayed.
PW148-8 VEBM720100
TESTING AND ADJUSTING Special function of monitor panel

Maintenance record a The following items can be selected in the

maintenance record.
The machine monitor records the maintenance infor-
mation of the filters, oils, etc., which the operator can 01 Engine oil change
display and check by the following operations. When 02 Engine oil filter change
maintenance is carried out, if the data are reset in the 03 Fuel main filter change
operator mode, the number of the times of mainte- 41 Fuel pre-filter change
nance is recorded in this section. 04 Hydraulic oil filter change
05 Hydraulic tank breather change
06 Corrosion resistor change
1. Selecting menu
07 Damper case service
Select “Maintenance record” on the service
menu screen. 08 Final drive case oil change
09 Machinery case oil change
10 Hydraulic oil change

3. Items displayed on maintenance record screen

The following items are displayed.
(a) : Maintenance items
(b) : Number of times of replacement up to now
(c) : Service meter reading (SMR) at previous
replacement

2. Selecting maintenance record item

After the “Maintenance record” screen is dis-
played, select an item to be checked with the
function switches or numeral input switches.
q [F1]: Move to next page (screen)
q [F2]: Move to previous page (screen)
q [F3]: Move to lower item
q [F4]: Move to upper item
q [F5]: Return to service menu screen
a You may enter a 2-digit code with the
numeral input switches to select the item of
that code.

PW148-8 VEBM720100 20-193

Special function of monitor panel
Change of maintenance mode
The operating condition for maintenance function in
the operation mode can be set and changed with this
menu.
q Set function effective or ineffective
q Change set replacement interval (by items)
q Initialize all set replacement intervals
1. Selecting menu
Select of “Maintenance mode change ” on the
service menu screen.
3.
2. Selecting sub menu
After the “Maintenance mode change” screen is
displayed, select an item to be monitored with
the function switches or numeral input switches.
q [F1]: Move to next page (screen)
q [F2]: Move to previous page (screen)
q [F3]: Move to lower item
q [F4]: Move to upper item
q [F5]: Return to service menu screen
a You may enter a 2-digit code with the
numeral input switches to select the item of
that code and confirm it with [F6].
20-194
TESTING AND ADJUSTING
a The following items can be selected on the
Change of maintenance mode screen.
00 Maintenance mode on/off
01 Engine oil change int.
02 Engine oil filter change int.
03 Fuel main filter change int.
41 Fuel pre filter change int.
04 Hyd oil filter change int.
05 Hyd tank breather change int.
06 Corrosion resistor change int.
07 Damper case service int.
08 Final drive case oil change int.
09 Machinery case change int.
10 Hydraulic oil change int.
99 Initialize all items
Contents of setting of Maintenance mode on/off
After selecting Maintenance mode on/off, if the
screen is displayed, set ON or OFF with the
function switches.
q ON: Functions of all maintenance items
are set effective in operator mode
q OFF: Functions of all maintenance items
are set ineffective in operator mode
q [F3]: Move to lower item
q [F4]: Move to upper item
q [F5]: Cancel selection and return to Mainte-
nance mode change screen
q [F6]: Confirm selection and return to Main-
tenance mode change screen
a Even if ON/OFF of each item has been set,
if the above setting is changed, it is applied.
PW148-8 VEBM720100
TESTING AND ADJUSTING Special function of monitor panel

4. Contents of setting of each maintenance item 5. Function of initializing all items

After selecting each maintenance item, if the After selecting "All default value", if the screen is
screen is displayed, set the item with the func- displayed, set with the function switches.
tion switches. q If this operation is executed, the set values
q Initial value: Maintenance interval set in of all the maintenance items are initialized.
machine monitor (Recommended by manu- q [F5]: Return to Maintenance mode change
facturer and not changeable). screen
q Set value: Maintenance interval which can q [F6]: Execute initialization
be set freely. Maintenance functions in a A while after [F6] is pressed, the initializa-
operator mode operate on basis of this set tion completion screen is displayed. Then, if
time (which is increased or decreased by 50 the Maintenance mode change screen is
hours). displayed, initialization is completed.
q ON: Maintenance function of this item is
set effective in operator mode.
q OFF: Maintenance function of this item is
set ineffective in operator mode.
q [F3]: Select Reduce set value (Upper) or
OFF (Lower).
q [F4]: Select Increase set value (Upper) or
ON (Lower).
q [F5]: Cancel setting before confirmation
and return to Maintenance mode
change screen.
q [F6]: Confirm setting of upper or lower line.
a After the setting of the upper and lower lines
is confirmed with [F6] and the screen
changes to the Maintenance mode change
screen with [F5], the setting is effective.
a If the set value of an item set to ON is
changed after 1 or more operating hours
since the start of setting, the change is rec-
ognized as a resetting operation.

PW148-8 VEBM720100 20-195

Special function of monitor panel TESTING AND ADJUSTING

Setting of telephone No. a If [F6] is pressed without inputting a digit,

there is not information of telephone No.
The telephone No. displayed when the user code/
Accordingly, no telephone No. is displayed
failure code is displayed in the operator mode can be
in the operator mode.
input and changed according to the following proce-
dure.
If a telephone No. is not input with this function, no
telephone No. is displayed in the operator mode.

1. Selecting menu
Select “Phone number entry” on the service
menu screen.

2. Registering and changing telephone No.

After the “Phone number entry” screen is dis-
played, register or change the telephone No.
q [F2]: Reset all input No.
q [F3]: Move to left position (if not blank)
q [F4]: Move to right position (if not blank)
q [F5]: Reset input digit/Return to service
menu
q [F6]: Confirm input

a Up to 14 digits can be input from the left.

Input nothing in the surplus positions.
a If one of the input digits is wrong, move to
that digit (orange background) and over-
write it with the correct digit.

20-196 PW148-8 VEBM720100

TESTING AND ADJUSTING Special function of monitor panel

Default (Working mode with key ON)
Check or change various settings related to the
machine monitor and machine by "Default".
The function of working mode with key ON is used to
set the working mode displayed on the machine
monitor when the starting switch is turned ON.
1. Selecting menu
Select “Default” on the service menu screen.
q Mode at previous key-OFF: Final mode in
previous operation is displayed when key is
ON
q [F3]: Move to lower item
q [F4]: Move to upper item
q [F5]: Cancel selection and return to
“Default” screen
q [F6]: Confirm selection and return to
“Default” screen
a When the machine is delivered, Mode at
previous key-OFF is set.
a If "With attachment" is not set, the attach-
ment mode cannot be selected.
a While Attachment mode [ATT] is selected, if
"Without attachment" is set, Power mode
[P] is displayed when the key is turned ON.
a If the engine is stopped while breaker mode
[B] is selected in the operator mode,
Breaker mode [B] is always displayed,
regardless of the above setting.

2. Selecting sub menu

After the “Default” screen is displayed, select
“Key-on mode” with the function switches or
numeral input switches.
a Select this item similarly to an item on the
Service menu screen.

3. Selecting mode
After the “Key-on mode” screen is displayed,
select the mode to be set with the function
switches.
q Power mode: [P] is displayed when key is
ON
q Economy mode: [E] is displayed when key
is ON
q Lifting mode: [L] is displayed when key is
ON
q Breaker mode: [B] is displayed when key is
ON
q Attachment mode: [ATT] is displayed when
key is ON

PW148-8 VEBM720100 20-197

Special function of monitor panel TESTING AND ADJUSTING

Default (Setting of unit) a When the machine is delivered, the SI unit

system is set.
Check or change various settings related to the
machine monitor and machine by "Default".
The unit setting function is used to select the unit of
the data displayed for monitoring, etc.

1. Selecting menu
Select “Default” on the service menu screen.

2. Selecting sub menu

After the “Default” screen is displayed, select
“Unit” with the function switches or numeral input
switches.
a Select this item similarly to an item on the
Service menu screen.

3. Selecting unit
After the “Unit” screen is displayed, select the
unit to be set with the function switches.
q [F3]: Move to lower unit
q [F4]: Move to upper unit
q [F5]: Cancel selection and return to
“Default” screen
q [F6]: Confirm selection and return to
“Default” screen

20-198 PW148-8 VEBM720100

TESTING AND ADJUSTING Special function of monitor panel

Default (With/Without attachment) a When an attachment is installed, if this set-

Check or change various settings related to the
machine monitor and machine by "Default".
The "With/Without attachment" function is used to set
an installed or a remove attachment.
1. Selecting menu
Select "Default" on the service menu screen.
ting is not carried out normally, the attach-
ment cannot be set in the operator mode.
As a result, the attachment may not work
normally or the hydraulic components may
have trouble.(NB setting is made at the fac-
tory depending on whether 1 or 2 attach-
ment lines are fitted).

2 s

BA

If a 2nd attachment line is installed as a field

2. Selecting sub menu
After the "Default" screen is displayed, select
With/Without attachment with the function
switches or numeral input switches.
a Select this item similarly to an item on the
Service menu screen.
kit - "With 2 Attachments" must be selected
in this menu.
Note - If a monitor is replaced for any rea-
son, please follow setting procedure. See
“Default (Proportional Spec.)” on page 207.

3. Selecting With/Without
After the "With/Without attachment" screen is
displayed, select the setting with the function
switches.
q Without: When attachment is not installed
q With : When attachment is installed
q [F3] : Move to lower item
q [F4] : Move to upper item
q [F5] : Cancel selection and return to
Default screen
q [F6] : Confirm selection and return to
Default screen

PW148-8 VEBM720100 20-199

Special function of monitor panel
Default (Setting of attachment/maintenance pass-
word)
Check or change various settings related to the
machine monitor and machine by "Default".
The function of setting attachment/maintenance
password is used to set the display of the password
screen when the functions related to the attachment
and maintenance are used in the operator mode.
1. Selecting menu
Select "Default" on the service menu screen.
2. Selecting sub menu
After the "Default" screen is displayed, select
Attachment/Maintenance password with the
function switches or numeral input switches.
a Select this item similarly to an item on the
Service menu screen.
20-200
TESTING AND ADJUSTING
3. Selecting Disable/Enable
After the With/Without attachment screen is dis-
played, select the setting with the function
switches.
q Disable : Password screen is not displayed
q Enable : Password screen is displayed
q [F3] : Move to lower item
q [F4] : Move to upper item
q [F5] : Cancel selection and return to
"Default" screen
q [F6] : Confirm selection and return to
"Default" screen
4. Displaying attachment/maintenance password
screen
When the following operation is performed, the
password screen is displayed in the operator
mode.
q Maintenance mode: The Maintenance table
screen is changed to the Maintenance inter-
val reset screen.
q User mode: On the User menu screen, the
B r e a k e r / A t ta c h m e n t s e t t i n g m e n u i s
selected and the screen is changed to the
Attachment setting menu screen.
5. Changing attachment/maintenance password
The password can be changed by operating the
switches specially in the operator mode.
a See Attachment/Maintenance password
changing function in the operator mode.
a Default password: [000000]
a If the password setting is changed from
Enable to Disable, the password is reset to
the default. When Enable is set again, be
sure to set a new password.
a The attachment/maintenance password is
different from the engine start lock pass-
word.
PW148-8 VEBM720100
TESTING AND ADJUSTING Special function of monitor panel

Default (Setting of camera) 3. Selecting camera setting

Check or change various settings related to the
machine monitor and machine by "Default".
The camera setting function is used to set installation
and removal of a camera.
1. Selecting menu
Select "Default" on the service menu screen.
2. Selecting sub menu
After the "Default" screen is displayed, select
Camera with the function switches or numeral
input switches.
a Select this item similarly to an item on the
Service menu screen.
After the camera setting screen is displayed,
select the setting with the function switches.
q OFF: Camera is not used
q Original image: Image of connected camera
is displayed in original posi-
tion (as in mirror, used as
back monitor)
q Reverse image:Image of connected camera
is displayed in reverse posi-
tion (as seen directly, used
as front or side monitor)
q [F3]: Move to left item
q [F4]: Move to right item
q [F5]: Cancel setting before confirmation and
return to "Default" screen
q [F6]: Confirm selection in each line
a After Camera screen is displayed, camera 1
can be always set. When 2 or more cam-
eras are connected, if camera 1 is set, the
screen changes to setting of camera 2 auto-
matically.
a After confirming the setting of each line with
[F6], return to the "Default" screen with [F5],
and the setting is effective.
a If a camera is connected but not set nor-
mally with this function, the graphic mark of
camera is not displayed at [F3] in the opera-
tor mode. Accordingly, the image of the
camera cannot be used.
a If 2 or more cameras are connected, be
sure to set the use of them from camera 1 in
order.
a The function of displaying 2 images simulta-
neously is effective when use of camera 1
and camera 2 is set.
a When a camera is installed, check that the
displayed image is not inverted horizontally.

PW148-8 VEBM720100 20-201

Special function of monitor panel TESTING AND ADJUSTING

Default (Setting of ECO display) ordinary screen. Even if the energy saving
guidance is turned ON, however, it is not
Check or change various settings related to the
displayed if the condition for display is not
machine monitor and machine by "Default".
satisfied on the ordinary screen.
The ECO display setting function is used to set the
display of the ECO gauge and energy saving guid-
ance.

1. Selecting menu
Select "Default" on the service menu screen.

a Display of ECO gauge (a)

AM N
a

2. Selecting sub menu

After the "Default" screen is displayed, select
ECO display with the function switches or
numeral input switches.
a Select this item similarly to an item on the
Service menu screen.
G0148062

a Display of energy saving guidance

3. Selecting display setting

After the ECO display screen is displayed, select G0148048
the setting with the function switches.
q ON : Display ECO
q OFF: Do not display ECO
q [F3] : Move to left item
q [F4] : Move to right item
q [F5] : Cancel setting before confirmation
and return to "Default" screen
q [F6] : Confirm selection in each line
a After confirming the setting of the upper and
lower lines with [F6], return to the "Default"
screen with [F5], and the setting is effective.
a If ECO display is turned ON, ECO is dis-
played when the screen changes to the

20-202 PW148-8 VEBM720100

TESTING AND ADJUSTING
Default (Setting of Breaker Detect)
Check or change various settings related to the
machine monitor and machine by "Default".
The function of setting breaker automatic judgment is
used to set the display to give warning when the
breaker is used in an improper working mode.
1. Selecting menu
Select "Default" on the service menu screen.
2. Selecting sub menu
After the "Default" screen is displayed, select
"Breaker Detect" with the function switches or
numeral input switches.
a Select this item similarly to an item on the
Service menu screen.
PW148-8 VEBM720100
Special function of monitor panel
3. Selecting display setting
After the "Breaker Detect" screen is displayed,
select the setting with the function switches.
q [F3]: Move to lower item
q [F4]: Move to upper item
q [F5]: Cancel selection and return to Default
screen
q [F6]: Confirm selection and return to Default
screen
a When the machine is delivered, Disable is
set.
a Display of "Breaker Detect"
20-203
Special function of monitor panel TESTING AND ADJUSTING

Adjustment (Setting of Pump absorption torque 3. Selecting absorption torque

The operator can adjust various items related to the
machine with the machine monitor.
The pump absorption torque function is used to finely
adjust the absorption torque on the front side of the
hydraulic pump.
1. Selecting menu
Select "Adjustment" on the service menu
screen.
After the "Pump Absorption Torque" screen is
displayed, select a set value on the right side
with the function switches.
q Set value: For actual torque adjustment
value, see table
q [F3]: Increase set value
q [F4]: Decrease set value
q [F6]: Confirm setting and return to Adjust-
ment menu screen
a The 3 digits on the left side do not vary
since they are the code of this function.

2. Selecting sub menu

After the Adjustment screen is displayed, select
"Pump Absorption Torque" with the function a Relationship between set value and torque
switches or numeral input switches. adjustment value
a Select this item similarly to an item on the Set
Code Torque adjustment value
Service menu screen. value
000 +39.2 Nm {+4 kgm}
001 +29.4 Nm {+3 kgm}
002 +19.6 Nm {+2 kgm}
003 +9.8 Nm {+1 kgm}
022 004 0 Nm {0 kgm}
005 –9.8 Nm {–1 kgm}
006 –19.6 Nm {–2 kgm}
007 –29.4 Nm {–3 kgm}
008 –39.2 Nm {–4 kgm}

20-204 PW148-8 VEBM720100

TESTING AND ADJUSTING Special function of monitor panel

Adjustment (Setting of Attachment flow adjust- 3. Selecting distribution of oil flow

ment)
The operator can adjust various items related to the
machine with the machine monitor.
The function of "Attachment Flow Adjustment" is
used to finely adjust the oil flow to the attachment in
compound operation.
1. Selecting menu
Select "Adjustment" on the service menu
screen.
After the screen of "Attachment Flow Adjust-
ment" is displayed, select a set value on the right
side with the function switches.
q Set value: For actual distribution of flow,
see table
q [F3]: Increase set value
q [F4]: Decrease set value
q [F6]: Confirm setting and return to Adjust-
ment menu screen
a The 3 digits on the left side do not vary
since they are the code of this function.

037 002

2. Selecting sub menu

After the Adjustment screen is displayed, select
"Attachment Flow Adjustment" with the function a Relationship between set value and distri-
switches or numeral input switches. bution of flow to attachment
a Select this item similarly to an item on the Set Distribution of flow to
Code
Service menu screen. value attachment
000 50 %
001 70 %
037
002 100 %
003 40 %

PW148-8 VEBM720100 20-205

Special function of monitor panel TESTING AND ADJUSTING

Adjustment (Setting of Attachment EPC1 ~ EPC4

adjustment)
The operator can adjust various items related to the
machine with the machine monitor.
The function of "Attachment EPC1 ~ EPC4 Adjust- 9
ment" is used to finely adjust the oil flow to the
attachment in RH or LH lever proportional 1st or 2nd
attachment control by adjusting EPC current.
1. Selecting menu
Select "Adjustment" on the service menu
screen.
Z

Proportional switch
Adjustment screen Code
operation
03 Attachment EPC1 1st Att.RH lever sw.
049
adjustment slide upwards
04 Attachment EPC2 1st Att. RH lever sw.
048
adjustment slide downwards
05 Attachment EPC3
2nd Att. LH lever sw.
adjustment - (when 2 Att. 066
slide upwards
system equipped)
06 Attachment EPC4
2. Selecting sub menu 2nd Att. LH lever sw.
adjustment - (when 2 Att. 065
After the Adjustment screen is displayed, select slide downwards
system equipped)
"Attachment EPC1 ~ EPC4 Adjustment" with the
function switches or numeral input switches. ★ Relationship between set value and distribu-
a Select this item similarly to an item on the tion of current to attachment EPC.
Service menu screen.
Set Distribution of flow to
Code
value attachment
0 -35 mA
1 -30 mA
2 -25 mA
3 -20 mA
4 -15 mA
5 -10 mA
049 6 -5 mA
048
066 7 0 mA (default)
065 8 +5 mA
9 +10 mA
10 +15 mA
3. Selecting distribution of EPC current
11 +20 mA
After the screen of "Attachment Flow Adjust-
12 +25 mA
ment" is displayed, select a set value on the right
side with the function switches. 13 +30 mA
q Set value: For actual distribution of flow, 14 +35 mA
see table
q [F3]: Increase set value
q [F4]: Decrease set value
q [F6]: Confirm setting and return to Adjust-
ment menu screen
a The 3 digits on the left side do not vary
since they are the code of this function.

20-206 PW148-8 VEBM720100

TESTING AND ADJUSTING Special function of monitor panel

Default (Proportional Spec.)

Every machine is defaulted to "Proportional Spec." before it leaves the factory. If a new monitor is installed - fol-
low the procedure below

3) Selecting Proportional Spec.

1) Selecting menu After the specification menu is displayed
Select "Default" on the service menu select the setting with the function switches:
screen. q Proportional Spec: EU machines
q Standard: Non EU machines [DO NOT
SELECT]
06 q [F3]: Move to lower item
q [F4]: Move to upper item
q [F5]: Cancel selection and return to Default
screen
q [F6]: Confirm selection and return to default
screen

Specification
Standard
BA Proportional Spec.

2) Selecting sub menu

After the "Default" screen is displayed, input
20 to enter the "Specification" menu (NB -
not displayed on the default menu).

20 Z

BA

PW148-8 VEBM720100 20-207

Special function of monitor panel TESTING AND ADJUSTING

Cylinder Cut-Out operation

The operator can perform "Cylinder Cut-Out" opera-
tion with the machine monitor.
"Cylinder Cut-Out" operation means to run the
engine with 1 or more fuel injectors disabled electri-
cally to reduce the number of effective cylinders.
This operation is used to find out a cylinder which
does not output power normally (combustion in it is
abnormal).

1. Selecting menu
Select "Cylinder Cut-Out" on the service menu
screen.

3. Resetting Cut-Out cylinder

2. Selecting cylinder to be disabled
After the "Cylinder Cut-Out" screen is displayed,
select a cylinder to be Cut-Out with the function
switches.
q [F1]: Move selection mark (R) to left
q [F2]: Move selection mark (R) to right
q [F3]: Reset holding
q [F4]: Hold
q [F5]: Return to service menu screen
q [F6]: Confirm selection
a This operation may be performed while the
engine is running.
a When [F6] is pressed, if background (a) of
the selected cylinder No. becomes white,
the cylinder is Cut-Out.
a If the machine monitor Cut-Out a cylinder
but the engine controller cannot Cut-Out
that cylinder, the background of the cylinder
No. becomes yellow.
a If the machine monitor resets a Cut-Out cyl-
inder but the engine controller cannot reset
that Cut-Out cylinder, the background of the
cylinder No. becomes red.
a One or more cylinders can be Cut-Out.
a In the cylinder Cut-Out operation, the auto-
deceleration function can be selected. If the
auto-deceleration is turned ON, auto-decel-
eration monitor (b) is displayed.
When changing a cylinder to be Cut-Out or
when Cylinder Cut-Out operation is finished,
select a Cut-Out cylinder to be reset with the
function switches.
a This operation may be performed while the
engine is running.
a When [F6] is pressed, if background (a) of
the selected cylinder No. becomes blue, the
cylinder is reset.
a The Cut-Out operation is not automatically
reset after the screen returns to the opera-
tor mode. Accordingly, be sure to perform
the resetting operation after the cylinder cut-
out operation is finished.
4. Function of holding displayed information
If [F4] is pressed during the cylinder Cut-Out
operation, the displayed information is newly
held (c) (The real-time information is kept dis-
played on the left side).
While the information is held, if [F3] is pressed,
the holding function is reset.
a The holding function is effective, regardless
of setting of the reduced cylinder mode
operation.

20-208 PW148-8 VEBM720100

TESTING AND ADJUSTING Special function of monitor panel

[Reference]
q If a normally operating cylinder is Cut-Out,
the following phenomena occur.
1) Lowering of engine speed
2) Increase of final injection rate command
(quantity)
q If the engine is running near the high idle,
however, the engine speed may not lower
for the reason of engine control.
q In this case, lower the engine speed with
the fuel control dial and judge by increase of
the injection rate command.

PW148-8 VEBM720100 20-209

Special function of monitor panel TESTING AND ADJUSTING

No injection cranking a Limit the cranking time to 20 seconds to

protect the starting motor.
If the engine is operated after long storage of the
machine, it may be worn or damaged because of
insufficient lubrication with oil. To prevent this, the
function to lubricate the engine before starting it by
cranking it without injecting fuel is installed.
Set the no-injection cranking while the engine is
stopped.

1. Selecting menu
Select "No injection" on the service menu
screen.

4. Finishing no injection cranking

After completing the no injection cranking opera-
tion, press [F6], and finish of no injection crank-
ing is displayed and the screen returns to the
Service menu screen automatically.

2. Displaying check screen

If the "No injection" screen is displayed, the
machine monitor asks the operator if no injection
cranking should be performed. Answer with the
function switch.
q [F5]: Do not perform (Return to Service
menu screen)
q [F6]: Perform
a While the screen is changing to the follow- 5. Prohibiting no injection cranking
ing screen, the screen of "Communication If the operator tries to perform the no injection
between controllers is being checked" is cranking while the engine is running, the mes-
displayed. sage that the engine is running is displayed and
the no injection cranking is not set effective.
a This function can be selected even while
the engine is running. If the no injection
cranking is performed, however, the mes-
sage of "Engine is running" is displayed on
the screen.

3. Starting no injection cranking

If no injection cranking (Fuel injection in no cylin-
ders) becomes effective, that is displayed on the
screen. Under this condition, crank the engine
with the starting motor.
a While the screen is changing to the follow-
ing screen, the screen of "Setting is being
prepared" is displayed.

20-210 PW148-8 VEBM720100

TESTING AND ADJUSTING Special function of monitor panel

Display of fuel consumption 3. Display and function during measurement

Clock mark (a) flashes during measurement.
This function calculates the hourly fuel consumption
a While the fuel consumption is being mea-
from the actual fuel consumption in a measuring
sured, the operator can work with the oper-
period and indicates it.
1. Selecting menu ator mode and other functions.
Select "Fuel consumption" on the service menu Measurement is not finished until this
screen. screen is displayed again and [F1] is
pressed (Even if the starting switch is
turned OFF, this function is kept effective,
although fuel consumption is measured only
while the engine is running).

2. Starting measurement
After the screen of Fuel consumption is dis-
played, start measurement with the function
switches.
q [F1]: Start 4.
q [F2]: Clear
q [F5]: Return to Service menu screen
a When the screen of Fuel consumption is
displayed, if a data is indicated, it is the data
of the previous measurement. This data is 5.
not an obstacle to new measurement and
can be reset by pressing [F2].
a If [F1] is pressed, the data is displayed on
the starting date and time side and mea-
surement starts.
Finishing measurement
Press [F1], and measurement is finished and the
data are displayed on the finishing date and time
side.
Displaying fuel consumption
If the measurement is finished, the hourly fuel
consumption calculated from the fuel consump-
tion calculated by the engine controller and the
elapsed time are displayed.

a The display unit of the fuel changes accord-

ing to the unit set with the default (unit set-
ting) function.
SI and meter: l/h
inch: gal/h

PW148-8 VEBM720100 20-211

Special function of monitor panel TESTING AND ADJUSTING

Display of KOMTRAX (Terminal status) 3. Contents of display of terminal status

The setting condition and operating condition of
KOMTRAX can be checked with Display of
KOMTRAX setting.
Setting condition of terminal is used to check the set-
ting condition of the KOMTRAX terminal.
1. Selecting menu
Select "KOMTRAX Settings" on the service
menu screen.
On the Terminal status screen, the following
items are displayed.
q Terminal type: Model name of KOMTRAX
communication MODEM
q KOMTRAX communication: Executing condi-
tion of station opening inspection
q GMT time: Greenwich Meant Time
q [F5]: Return to KOMTRAX settings screen

2. Selecting sub menu

After the KOMTRAX settings screen is dis-
played, select "Terminal Status" with the function
switches or numeral input switches.
a Select this item similarly to an item on the
Service menu screen.
a The following figure shows the display when
Model TH300 KOMTRAX is installed. When
TH200 is installed, "03 IP Address" is dis-
played.

20-212 PW148-8 VEBM720100

TESTING AND ADJUSTING Special function of monitor panel

Display of KOMTRAX (GPS & communication sta-
tus)
The setting condition and operating condition of
KOMTRAX can be checked with "KOMTRAX Set-
tings".
GPS & communication status is used to check the
condition of positioning and communication of the
KOMTRAX terminal.
1. Selecting menu
Select "KOMTRAX Settings" on the service
menu screen.
3. Contents of display of GPS & communication
status
On the screen of GPS & communication status,
the following items are displayed.
q Positioning: Positioning condition of GPS
q Communication: Communication environ-
ment of communication MODEM and con-
necting condition of communication
MODEM
q Number of message not yet sent: Number
of mails which are saved in machine moni-
tor and not transmitted yet
q [F5]: Return to KOMTRAX settings screen

2. Selecting sub menu

After the KOMTRAX settings screen is dis-
played, select GPS & communication status with
the function switches or numeral input switches.
a Select this item similarly to an item on the
Service menu screen.
a The following figure shows the display when
Model TH300 KOMTRAX is ins talled.
When TH200 is installed, "03 IP Address" is
displayed.

PW148-8 VEBM720100 20-213

Special function of monitor panel TESTING AND ADJUSTING

Display of KOMTRAX (MODEM S/N: Model 3. Contents of display of Modem S/N

TH300) The serial No. of TH300 Modem is displayed.
q [F5]: Return to KOMTRAX settings screen
The setting condition and operating condition of
KOMTRAX can be checked with Display of
KOMTRAX setting.
MODEM S/N is used to check the serial No. of the
KOMTRAX communication MODEM.

1. Selecting menu
Select "KOMTRAX Settings" on the service
menu screen.

2. Selecting sub menu

After the KOMTRAX settings screen is dis-
played, select "Modem S/N" with the function
switches or numeral input switches.
a Select this item similarly to an item on the
Service menu screen.

20-214 PW148-8 VEBM720100

TESTING AND ADJUSTING Special function of monitor panel

Display of KOMTRAX message

3.
Special messages for the serviceman sent from the
KOMTRAX base station (a distributor, etc.) can be
checked with this function.
If there is setting in a message, a return mail can be
sent by using numeral input switches.
1. Operation to display menu
Select "Service message" on the service menu
screen.
Display of message (with return mail function)
If a box to enter a value with the numeral keys is
displayed under the message, enter a proper
number with the numeral input switches and
function switches and confirm it, and the infor-
mation is returned to the KOMTRAX base sta-
tion.
q [F5]: Return to service menu screen
q [F6]: Confirm and return input value
a This message is different from a message
transmitted to the operator in the operator
mode.
a Since this message is special for the ser-
viceman, the message monitor is not dis-
played when it is received as in the operator
mode.

2. Display of message (Read-only)

If there is a message, its contents are displayed.
If there is not a message, "No message" is dis-
played.
q [F5]: Return to service menu screen
a This message is different from a message
transmitted to the operator in the operator
mode.
a Since this message is special for the ser-
viceman, the message monitor is not dis-
played when it is received as in the operator
mode.

PW148-8 VEBM720100 20-215

Special function of monitor panel TESTING AND ADJUSTING

Blank for technical reason

20-216 PW148-8 VEBM720100

 20 TESTING AND ADJUSTING

Troubleshooting
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-221
Points to remember when troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-222
Sequence of events in troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-223
Points to remember when carrying out maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-224
Checks before troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-233
Classification and steps for troubleshooting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-234
Classification of troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-234
Failure-looking phenomenon and troubleshooting no.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-235
How to read electric wire code . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-238
Connector location chart and electrical circuit diagram by system . . . . . . . . . . . . . . . . . . . . . . . . . . 20-242
Connection table for connector pin numbers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-254

Troubleshooting when failure code is indicated . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-301

Troubleshooting of electrical system (E-MODE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-501
Troubleshooting of electrical system (Error checking of items without Monitor codes) . . . . . . . . . 20-601
Troubleshooting of hydraulic and mechanical system (H-MODE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-701

PW148-8 VEBM720100 20-221

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 se-
curely 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. Be extremely careful not to touch
any hot parts or to get caught in any rotating
parts.When removing the plug or cap from a loca-
tion which is under pressure from oil, water, or air,
always release the internal pressure first. When in-
stalling 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 un-
derstand the structure and function. However, a short
cut to effective troubleshooting is to ask the operator
various questions to form some idea of possible caus-
es of the failure that would produce the reported symp-
toms.
1. When carrying out troubleshooting, do not hur-
ry to disassemble the components.
If components are disassembled immediately any
failure occurs:
• Parts that have no connection with the failure or
other unnecessary parts will be disassembled.
• It will become impossible to find the cause of the
failure.
It will also cause a waste of manhours, parts, or oil or
grease, and at the same time, will also lose the confi-
dence of the user or operator.
For this reason, when carrying out troubleshooting, it is
necessary to carry out thorough prior investigation and
to carry out troubleshooting in accordance with the
fixed procedure.
2. Points to ask user or operator
a. Have any other problems occurred apart from
the problem that has been reported?
b. Was there anything strange about the machine
before the failure occurred?
c. Did the failure occur suddenly, or were there
problems with the machine condition before
this?
20-222
TESTING AND ADJUSTING
d. Under what conditions did the failure occur?
e. Had any repairs been carried out before the
failure?
f. When were these repairs carried out?
g. Has the same kind of failure occurred before?
3. Check before troubleshooting
a. Check the oil level
b. Check for any external leakage of oil from the
piping or hydraulic equipment.
c. Check the travel of the control levers.
d. Check the stroke of the control valve spool.
e. Other maintenance items can be checked ex-
ternally, so check any item that is considered
to be necessary.
4. Confirming failure
• Confirm the extent of the failure yourself, and
judge whether to handle it as a real failure or as a
problem with the method of operation, etc.
• When operating the machine to re-enact the trou-
bleshooting symptoms, do not carry out any inves-
tigation or measurement that may make the
problem worse.
5. Troubleshooting
• Use the results of the investigation and inspection
in Items 2 – 4 to narrow down the causes of failure,
then use the troubleshooting flowchart to locate the
position of the failure exactly.
• The basic procedure for troubleshooting is as fol-
lows.
a. Start from the simple points.
b. Start from the most likely points.
c. Investigate other related parts or information.
6. Measures to remove root cause of failure
• Even if the failure is repaired, if the root cause of
the failure is not repaired, the same failure will oc-
cur again.
To prevent this, always investigate why the problem oc-
curred. Then, remove the root cause.
PW148-8 VEBM720100
TESTING AND ADJUSTING Sequence of events in troubleshooting

Sequence of events in troubleshooting

PW148-8 VEBM720100 20-223

Points to remember when carrying out maintenance TESTING AND ADJUSTING

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, cor-
rect operation, maintenance and inspection, troubleshooting,
and repairs must be carried out. This section deals particularly
with correct repair procedures for mechatronics and is aimed at
improving the quality of repairs. For this purpose, it gives sec-
tions on "Handling electric equipment" and "Handling hydraulic
equipment" (particularly gear oil and hydraulic oil).

1. Points to remember when handling electric

equipment

1.1 Handling wiring harnesses and connectors

Wiring harnesses consist of wiring connecting one compo-
nent to another component, connectors used for connecting
and disconnecting one wire from another wire, and protec-
tors or tubes used for protecting the wiring.

Compared with other electrical components fitted in boxes

or cases, wiring harnesses are more likely to be affected by
the direct effects of rain, water, heat, or vibration. Further-
more, 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 neces-
sary to be extremely careful when handling wiring harness-
es.

Main failures occurring in wiring harness

a. Defective contact of connectors (defective contact be-
tween male and female)
Problems with defective contact are likely to occur be-
cause 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.

b. Defective crimping or soldering of connectors

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

20-224 PW148-8 VEBM720100

TESTING AND ADJUSTING Points to remember when carrying out maintenance

c. 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 crimp-
ing of the connector may separate, or the soldering may
be damaged, or the wiring may be broken.

d. High-pressure water entering connector.

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

e. Oil or dirt stuck to connector

If oil or grease are stuck to the connector and an oil film
is formed on the mating surface between the male and
female pins, the oil will not let the electricity pass, so
there will be defective contact.
If there is oil or grease stuck to the connector, wipe it off
with a dry cloth or blow it dry with compressed air and
spray it with a contact restorer.

• When wiping the mating portion of the connector, be

careful not to use excessive force or deform the pins.

• If there is oil or water in the compressed air, the contacts

will become even dirtier, so remove the oil and water
from the compressed air completely before cleaning
with compressed air.

PW148-8 VEBM720100 20-225

Points to remember when carrying out maintenance TESTING AND ADJUSTING

1.2 Removing, installing, and drying connectors and wiring

harnesses
• Disconnecting connectors

a. Hold the connectors when disconnecting.

When disconnecting the connectors, hold the connec-
tors and not the wires. For connectors held by a screw,
loosen the screw fully, then hold the male and female
connectors in each hand and pull apart. For connectors
which have a lock stopper, press down the stopper with
your thumb and pull the connectors apart.

• Never pull with one hand.

b. When removing from clips

When removing a connector from a clip, pull the connec-
tor in a parallel direction to the clip.

• If the connector is twisted up and down or to the left or

right, the housing may break.

c. 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.

• If the machine is left disassembled for a long time, it is

particularly easy for improper contact to occur, so al-
ways cover the connector.

20-226 PW148-8 VEBM720100

TESTING AND ADJUSTING Points to remember when carrying out maintenance

• Connecting connectors

a. Check the connector visually.

I. Check that there is no oil, dirt, or water stuck to the

connector pins (mating portion).

II. Check that there is no deformation, defective con-

tact, corrosion, or damage to the connector pins.

III. Check that there is no damage or breakage to the

outside of the connector.

• If there is any oil, water, or dirt stuck to the connector,

wipe it off with a dry cloth. If any water has got inside the
connector, warm the inside of the wiring with a dryer, but
be careful not to make it too hot as this will cause short
circuits.

• If there is any damage or breakage, replace the connec-

tor.

b. 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.

c. 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 mis-
aligned, or the clamp is out of position, adjust it to its
correct position.

• If the connector cannot be corrected easily, remove the

clamp and adjust the position.

d. If the connector clamp has been removed, be sure to re-

turn it to its original position. Check also that there are
no loose clamps.

PW148-8 VEBM720100 20-227

Points to remember when carrying out maintenance TESTING AND ADJUSTING

• 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 con-
nector must be washed in water, do not use high-pressure water
or steam directly on the wiring harness.

If water gets directly on the connector, do as follows.

a. Disconnect the connector and wipe off the water with a

dry cloth.

• If the connector is blown dry with compressed air, there

is the risk that oil in the air may cause defective contact,
so remove all oil and water from the compressed air be-
fore blowing with air.

b. Dry the inside of the connector with a dryer.

If water gets inside the connector, use a dryer to dry the
connector.

• Hot air from the dryer can be used, but regulate the time
that the hot air is used in order not to make the connec-
tor or related parts too hot, as this will cause deforma-
tion or damage to the connector.

c. Carry out a continuity test on the connector.

After drying, leave the wiring harness disconnected and
carry out a continuity test to check for any short circuits
between pins caused by water.

• After completely drying the connector, blow it with con-

tact restorer and reassemble.

20-228 PW148-8 VEBM720100

TESTING AND ADJUSTING Points to remember when carrying out maintenance

1.3 Handling control box

a. The control box contains a microcomputer and electron-
ic control circuits. These control all of the electronic cir-
cuits on the machine, so be extremely careful when
handling the control box.

b. Do not open the cover of the control box unless neces-

sary.

c. Do not place objects on top of the control box.

d. Cover the control connectors with tape or a vinyl bag.

Never touch the connector contacts with your hand.

e. During rainy weather, do not leave the control box in a

place where it is exposed to rain.

f. 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).

g. Precautions when carrying out arc welding, when carry-

ing out arc welding on the body, disconnect all wiring
harness connectors connected to the control box. Fit an
arc welding ground close to the welding point.

PW148-8 VEBM720100 20-229

Points to remember when carrying out maintenance TESTING AND ADJUSTING

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 relat-

ed connectors are properly inserted.

• Disconnect and connect the related connectors several

times to check.

3. Always connect any disconnected connectors before going

on to the next step.

• If the power is turned ON with the connectors still dis-

connected, 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.

• If there is any change, there is probably defective con-

tact in that circuit.

20-230 PW148-8 VEBM720100

TESTING AND ADJUSTING Points to remember when carrying out maintenance

3. Points to remember when handling hydraulic

equipment
With the increase in pressure and precision of hydraulic equip-
ment, the most common cause of failure is dirt (foreign material)
in the hydraulic circuit. When adding hydraulic oil, or when dis-
assembling 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 hy-
draulic equipment in the field, there is danger of dust enter-
ing the equipment. It is also difficult to confirm the
performance after repairs, so it is desirable to use unit ex-
change. Disassembly and maintenance of hydraulic equip-
ment should be carried out in a specially prepared dustproof
workshop, and the performance should be confirmed with
special test equipment.

3. Sealing openings
After any piping or equipment is removed, the openings
should be sealed with caps, tapes, or vinyl bags to prevent
any dirt or dust from entering. If the opening is left open or is
blocked with a rag, there is danger of dirt entering or of the
surrounding area being made dirty by leaking oil so never do
this.
Do not simply drain oil out on to the ground, collect it and
ask the customer to dispose of it, or take it back with you for
disposal.

4. Do not let any dirt or dust get in during refilling operations.

Be careful not to let any dirt or dust get in when refilling with
hydraulic oil. Always keep the oil filler and the area around it
clean, and also use clean pumps and oil containers. If an oil
cleaning device is used, it is possible to filter out the dirt that
has collected during storage, so this is an even more effec-
tive method.

PW148-8 VEBM720100 20-231

Points to remember when carrying out maintenance TESTING AND ADJUSTING

5. Change hydraulic oil when the temperature is high.

When hydraulic oil or other oil is warm, it flows easily. In ad-
dition, the sludge can also be drained out easily from the cir-
cuit together with the oil, so it is best to change the oil when
it is still warm. When changing the oil, as much as possible
of the old hydraulic oil must be drained out. (Drain the oil
from the hydraulic tank; also drain the oil from the filter and
from the drain plug in the circuit.) If any old oil is left, the con-
taminants and sludge in it will mix with the new oil and will
shorten the life of the hydraulic oil.

6. Flushing operations
After disassembling and assembling the equipment, or
changing the oil, use flushing oil to remove the contami-
nants, sludge, and old oil from the hydraulic circuit.
Normally, flushing is carried out twice: primary flushing is
carried out with flushing oil, and secondary flushing is car-
ried out with the specified hydraulic oil.

7. Cleaning operations
After repairing the hydraulic equipment (pump, control valve,
etc.) or when running the machine, carry out oil cleaning to
remove the sludge or contaminants in the hydraulic oil cir-
cuit.
The oil cleaning equipment is used to remove the ultrafine
(about 3µ) particles that the filter built into the hydraulic
equipment cannot remove, so it is an extremely effective de-
vice.

20-232 PW148-8 VEBM720100

TESTING AND ADJUSTING Checks before troubleshooting

Checks before troubleshooting

Judgement
Item Action
value

Check fuel level, type of fuel — Add fuel

Check for impurities in fuel — Clean, drain
Check hydraulic oil level — Add oil
Lubricating oil,

Check hydraulic oil strainer — Clean, drain

coolant

Check swing machinery oil level — Add oil

Check engine oil level (oil pan oil level) — Add oil
Check coolant level — Add water
Check dust indicator for clogging — Clean or replace
Check hydraulic filter — Replace
Check final drive oil level — Add oil
equipment
Electrical

Check for looseness, corrosion of battery terminal, wiring — Tighten or replace

Check for looseness, corrosion of alternator terminal, wiring — Tighten or replace
Check for looseness, corrosion of starting motor terminal, wiring — Tighten or replace
mechanical
equipment
Hydraulic,

Check for abnormal noise, smell — Repair

Check for oil leakage — Repair
Carry out air bleeding — Bleed air

Check battery voltage (engine stopped) 20 – 30V Replace

Check battery electrolyte level — Add or replace
Electrics, electrical equipment

Check for discolored, burnt, exposed wiring — Replace

Check for missing wiring clamps, hanging wiring — Repair
Check for water leaking on wiring (be particularly careful attention to water leaking — Disconnect
on connectors or terminals) connector and dry
Check for blown, corroded fuses — Replace
Check alternator voltage (engine running at 1/2 throttle or above) After Replace
running for
several
minutes :
27.5 – 29.5V
Check operating sound of battery relay — Replace
(when switch is turned ON/OFF)

PW148-8 VEBM720100 20-233

Classification and steps for troubleshooting TESTING AND ADJUSTING

Classification and steps for troubleshooting

Classification of troubleshooting

Mode Content

Code display Troubleshooting when Service Code (electrical system) and Failure Code (mechanical system) are displayed.

E mode Troubleshooting of electrical system

H mode Troubleshooting of hydraulic and mechanical systems

(Engine) Troubleshooting of engine assembly (refer to the shop manual for engine in 102 series)

Steps for troubleshooting

If some phenomenon occurs on a machine that looks like a
failure, identify the corresponding troubleshooting No.
and proceed to the explanations for diagnosis.

1. Troubleshooting steps when calling User Code display

in the monitor panel
If User Code display, enter service mode on monitor to dis-
play Service Code. Following displayed Service Code for
the electrical system, carry out the troubleshooting along the
corresponding code display.

2. Troubleshooting steps when the electrical system Serv-

ice Code or mechanical system Failure Code is record-
ed in the failure history:
If not calling User Code in the monitor panel, check the elec-
trical system Service Code or mechanical system Failure
Code, using the failure history function of the monitor panel.

• If Service Code in the electrical system is recorded, de-

lete the all codes once and revive the code in the dis-
play again to check if the same abnormality still persists.

• Failure Code in the mechanical system cannot be delet-

ed.

3. Troubleshooting steps without User Code display and

no failure history is available
If there is no display of User Code nor the failure history in
the monitor panel, it is possible that a failure that the monitor
panel cannot diagnose by itself may have occurred in any of
the electrical, hydraulic or mechanical system. In such a
case, re-examine the phenomenon, find out the most similar
phenomenon from among "Failure like Phenomena and
Troubleshooting No." and carry out troubleshooting related
to the phenomenon in question.

20-234 PW148-8 VEBM720100

TESTING AND ADJUSTING Failure-looking phenomenon and troubleshooting no.

Failure-looking phenomenon and troubleshooting no.

Troubleshooting
No. Failure-looking phenomenon Code
E mode H mode (Engine)
display

Action to be taken concerning Service Code, User Code and Failure Code

1 Display User Code in monitor panel According

to
2 Display Service Code in electrical system after checking failure history
displayed
3 Display Failure Code in mechanical system after checking failure history code

Engine-related failure

Engine does not start up easily. (It always takes some time to start up the
4 S-1
engine)

5 Engine does not rotate E-1 S-2 (1)

6 Engine does not start Engine rotates, but there is no exhaust gas S-2 (2)

7 There is exhaust gas, but engine does not start S-2 (3)

8 Engine pickup is poor. (Engine does not follow acceleration) S-3

9 Engine stops while in operation H-2 S-4

10 Engine rotation is irregular. (There is hunting) S-5

11 Engine is short of output, or lacks power H-1 S-6

12 Color of exhaust gas is too dark. (Incomplete combustion) S-7

13 Excessive engine oil consumption, or color of exhaust gas is blue S-8

14 Premature engine oil contamination S-9

15 Excessive fuel consumption S-10

16 Engine cooling water is mixed with engine oil, spurts out or decreases S-11

17 Engine oil amount increases. (Water or fuel gets in) S-13

18 Abnormal noises are heard S-15

19 Excessive vibrations are caused S-16

20 Auto-decelerator does not work E-2 H-5

21 Engine auto warming-up device does not work E-3

22 Engine preheater does not work E-7

Failure related to work equipment, swing and travel

23 Speeds of all work equipment, travel and swing are slow, or they lack power H-1 S-6

24 Engine rotation drops sharply or stalls H-2 S-4

25 All work equipment, travel and swing do not move E-8 H-3

26 There are abnormal noises from around hydraulic pump H-4

27 Fine control mode function works poorly, or shows slow response H-6

PW148-8 VEBM720100 20-235

Failure-looking phenomenon and troubleshooting no. TESTING AND ADJUSTING

Troubleshooting
No. Failure-looking phenomenon Code User
H mode (Engine)
display code

Work equipment-related failure

29 Boom moves slowly or lacks power E-21, 22 H-7

30 Arm moves slowly or lacks power E-23, 24 H-8

31 Bucket moves slowly or lacks power E-25, 26 H-9

32 Boom, arm or bucket does not move H-10

33 Natural drift of work equipment is too fast H-11

34 Work equipment time lag is too big H-12

35 Other work equipment moves, when specific work equipment is relieved H-13

36 One-touch power max. switch does not work E-9, 21–26 H-14

Compound operation-related failure

37 In compound operation, work equipment with larger load moves slowly H-15

38 In swing + boom RAISE operation, boom moves slowly H-16

39 In swing + travel operation, travel speed drops sharply H-17

Travel-related failure

40 Machine tends to swerve while in travel

41 Travel speed is slow

42 Machine is difficult to steer, or lacks power

43 Travel speed cannot be shifted or is slow or fast H18

Swing-related failure

44 Machine does not swing E-27 H-23

45 Swing acceleration is poor, or swing speed is slow H-24

46 Upper structure overruns excessively, when stopping swing H-25

47 There is a big shock caused when stopping swing H-26

48 There is abnormal noise generated when stopping swing H-27

49 There is natural drift while in swing H-28

Monitor panel-related failure (Operator's Menu: ordinary display)

50 No display appears in monitor panel at all E-10

51 Part of display is missing in monitor panel E-11

52 Descriptions on monitor panel do not apply to the machine model E-12

In startup inspection, radiator water level caution symbol is displayed on the

53 B@BCZK
monitor panel, when the engine is running

In startup inspection, engine oil level caution symbol is displayed, when the
54 B@BAZK
engine is stopped (with the starting key in the ON position)

20-236 PW148-8 VEBM720100

TESTING AND ADJUSTING Failure-looking phenomenon and troubleshooting no.

Troubleshooting
No. Failure-looking phenomenon Code User
H mode (Engine)
display code

55 In startup inspection, maintenance hour monitor lamp lights up red Refer to Operation and Maintenance Manual

While engine is running, battery charging caution symbol is displayed on

56 AB00KE
the monitor panel.

57 While engine is running, fuel level monitor lamp lights up red E-13

While engine is running, air cleaner clogging charging caution symbol is

58 AA10NX
displayed on the monitor panel.

While engine is running, engine cooling water temperature gauge is

59 B@BCNS
diplayed in red range

While engine is running, hydraulic oil temperature gauge is diplayed in red

60 B@HANS
range

61 Engine cooling water temperature gauge does not display correctly E-14

62 Hydraulic oil temperature gauge does not display correctly E-15

63 Fuel gauge does not display correctly E-16

64 Swing lock monitor does not display correctly E-17

65 When operating monitor switch, no display appears E-18

66 Windshield wiper does not work E-19

67 Warning buzzer cannot be stopped E-20

Monitor panel-related failure (Service Menu: Special Function Display)

68 In monitoring function, "Boom RAISE" cannot be displayed correctly E-21

69 In monitoring function, "Boom LOWER" cannot be displayed correctly E-22

70 In monitoring function, "Arm DIGGING" cannot be displayed correctly E-23

71 In monitoring function, "Arm DUMPING" cannot be displayed correctly E-24

72 In monitoring function, "Bucket DIGGING" cannot be displayed correctly E-25

73 In monitoring function, "Bucket DUMPING" cannot be displayed correctly E-26

74 In monitoring function, "Swing" cannot be displayed correctly E-27

75 In monitoring function, "Travel" cannot be displayed correctly E-28

76 In monitoring function, "2 Piece Boom" cannot be displayed correctly E-29

Other failure

77 Air conditioner does not work E-301

78 Travel alarm does not sound E-31

PW148-8 VEBM720100 20-237

Failure-looking phenomenon and troubleshooting no. TESTING AND ADJUSTING

How to read electric wire code

• In this section, electric wire codes specific to PW180-7E0
are explained.

In the electric circuit diagram, the material, thickness, and

color of each electric wire are indicated by symbols. The
electric wire code is helpful in understanding the electric cir-
cuit diagram.

Example: AEX 0.85 L --- Indicates blue, heat-resistant, low-voltage wire for automobile, having nominal No. of 0.85

Indicates color of wire by color code.

Color codes are shown in Table 4.

Indicates size of wire by nominal No.

Size (Nominal No.) is shown in Table 2 and Table 3.

Indicates type of wire by symbol.

Type, symbol, and material of wire are shown in Table 1.
(Since AV, AVS, AVSS, and CAVS are classified by size (nominal No.), they are not indi-
cated.)

1. Type, symbol, and material

AV, AVS, and AVSS are different in only thickness and out-
side diameter of the cover. AEX is similar to AV in thickness
and outside diameter of AEX and different from AV, AVS,
and AVSS in material of the cover. CAVS has circularly
compressed conductor and is different from AV and AVS in
outside diameter.

(Table 1)

Using
Type Symbol Material temperature Example of use for reference
range (°C)

Annealed copper for

Low-voltage wire for
automobile
Thin-cover, low-voltage
wire for automobile AVSS
Conductor
electric appliance General wiring
AV
Insulator (Nominal No. 8 and above)
Soft polyvinyl chloride
–30 to +60
Annealed copper for AVS: General wiring
Conductor
AVS electric appliance (Nominal No. 3 – 5)
AVSS: General wiring
Insulator Soft polyvinyl chloride (Nominal No. 2)

Annealed copper for

Heat-resistant, Conductor General wiring in extremely cold
electric appliance
low-voltage wire AEX –50 to +110 district, wiring at high-tempera-
for automobile Heat-resistant crosslinked ture place
Insulator
polyethylene

Thin-cover, low-voltage, Annealed copper for

Conductor General wiring
circularly compressed CAVS electric appliance –30 to +60
(Nominal No. 0.5 – 1.25)
wire for automobile Insulator Soft polyvinyl chloride

20-238 PW148-8 VEBM720100

TESTING AND ADJUSTING Failure-looking phenomenon and troubleshooting no.

2. Dimensions

AVS, AV, AEX, AVSS

(Table 2)

Nominal No. 0.5f (0.5) 0.75f (0.85) 1.25f (1.25) 2f 2 3f 3 5

Number of strands/ 20/ 7/ 30/ 11/ 50/ 16/ 37/ 26/ 58/ 41/ 65/
Diameter of strand 0.18 0.32 0.18 0.32 0.18 0.32 0.26 0.32 0.26 0.32 0.32
Conductor

Sectional area
0.51 0.56 0.76 0.88 1.27 1.29 1.96 2.09 3.08 3.30 5.23
(mm2)

d (Approx.) 1.0 1.2 1.5 1.9 1.9 2.3 2.4 3.0

AVS Standard — — — — — 3.5 3.6 4.4

AV Standard — — — — — — — —
Cover D

AEX Standard 2.0 2.2 2.7 3.0 3.1 — 3.8 4.6

AVS
Standard — — — 2.7 2.7 — — —
S

Nominal No. 8 15 20 30 40 50 60 85 100

Number of
108/ 127/ 169/ 217/
strands/Diameter 50/0.45 84/0.45 41/0.80 70/0.80 85/0.80
0.80 0.80 0.80 0.80
Conductor

of strand

Sectional area
7.95 13.36 20.61 35.19 42.73 54.29 63.84 84.96 109.1
(mm2)

d (Approx.) 3.7 4.8 6.0 8.0 8.6 9.8 10.4 12.0 13.6

AVS Standard — — — — — — — — —

AV Standard 5.5 7.0 8.2 10.8 11.4 13.0 13.6 16.0 17.6
Cover D

AEX Standard 5.3 7.0 8.2 10.8 11.4 13.0 13.6 16.0 17.6

AVS
Standard — — — — — — — — —
S

CAVS
(Table 3)
Nominal No. 0.5 0.85 1.25
Number of strands/
7/Compressed circularly 11/Compressed circularly 16/Compressed circularly
Diameter of strand
Conductor Sectional area
0.56 0.88 1.29
(mm2)
d (Approx.) 0.9 1.1 1.4
Cover D CAVS Standard 1.7 1.9 2.2

"f" of nominal No. denotes "flexible".

PW148-8 VEBM720100 20-239

Failure-looking phenomenon and troubleshooting no. TESTING AND ADJUSTING

3. Color codes table

(Table 4)
Color Code Color of wire Color Code Color of wire
B Black LgW Light green & White
Br Brown LgY Light green & Yellow
BrB Brown & Black LR Blue & Red
BrR Brown & Red LW Blue & White
BrW Brown & White LY Blue & Yellow
BrY Brown & Yellow O Orange
Ch Charcoal P Pink
Dg Dark green R Red
G Green RB Red & Black
GB Green & Black RG Red & Green
GL Green & Blue RL Red & Blue
Gr Gray RW Red & White
GR Green & Red RY Red & Yellow
GW Green & White Sb Sky Blue
GY Green & Yellow Y Yellow
L Blue YB Yellow & Black
LB Blue & Black YG Yellow &Green
Lg Light green YL Yellow & Blue
LgB Light green & Black YR Yellow & Red
LgR Light green & Red YW Yellow & White

Remarks:
In a color code consisting of 2 colors, the first color is the color of
the background and the second color is the color of the marking.

Example:
"GW" means that the background is Green
and marking is White.

4. Types of circuits and color codes

(Table 5)
Type of wire AVS or AV AEX
Charge R WG — — — — R —
Ground B — — — — — B —
Start R — — — — — R —
Light RW RB RY RG RL — D —
Instrument Y YR YB YG YL YW Y Gr
Signal G GW GR GY GB GL G Br
L LW LR LY LB — L —
Type of
Br BrW BrR BrY BrB — — —
circuit
Lg LgR LgY LgB LgW — — —
O — — — — — — —
Others Gr — — — — — — —
P — — — — — — —
Sb — — — — — — —
Dg — — — — — — —
Ch — — — — — — —

20-240 PW148-8 VEBM720100

TESTING AND ADJUSTING Failure-looking phenomenon and troubleshooting no.

Blank for technical reason

PW148-8 VEBM720100 20-241

Connector location chart and electrical circuit diagram by system TESTING AND ADJUSTING

Connector location chart and electrical circuit diagram by

system
Connector type declaration

Connector No. Detailed information

DT Product of Deutsch USA DT type connector (08192-XXXXX)

L Product of Yazaki Corporation L type connector (08056-2XXXX)

J Product of Sumitomo Wiring Systems 090 type splice

M Product of Yazaki M type connector (08056-0XXXX)

Grote Product of Grote & Hartmann Germany

S Product of Yazaki S type connector (08056-1XXXX)

X Product of Yazaki X type connector (08055-0XXXX)

PA Product of Yazaki PA type connector

SWP Product of Yazaki SWP type connector (08055-1XXXX)

DRC Product of Deutsch USA DRC type connector

040 Product of Japan AMP 040 type connector

070 Product of Japan AMP 070 type connector

Y050 Product of Yazaki 050 type connector

S090 Product of Sumitomo 090 type connector

Y090 Product of Yazaki 090 type connector

YAZAKI Yazaki-made connector

KES0 KESO type connector (08027-0XXXX)

KES1 KES1 type connector (08027-1XXXX)

Bullet Round pin type single terminal connector (08021-XXXXX), (08022-XXXXX)

Terminal Ring terminal (08030-XXXXX)

DENSO Product of DENSO (Japan)

Sumitomo Sumitomo made connector

JDK Product of JIDSHA DENKI KOGYO

DTM Product of Deutsch USA DTM type connector

JT2/ECO Product of Tyko Electronics AMP K.K

SHI Produkt of SHINAGAWA Car Electri Co.

BRI Product of Britax

20-242 PW148-8 VEBM720100

TESTING AND ADJUSTING Connector location chart and electrical circuit diagram by system

Connector table for revolving frame harness

(for location of connectors see "Connector diagramm 1/5" in
chapter 90)

Connector No. Type No.of Pin Name of Device Address

A01 X 4 Cab harness (intermediate connector) B-5

A02 X 4 Cab harness (intermediate connector) B/C-4

A03 SWP 14 Cab harness (intermediate connector) B-5

A04 SWP 14 Cab harness (intermediate connector) B-5/6

A05 SWP 16 Cab harness (intermediate connector) C-4/5

A06 SWP 16 Cab harness (intermediate connector) B/C-5

A07 SWP 16 Cab harness (intermediate connector) B-5

A08 SWP 16 Cab harness (intermediate connector) B/C-5

A09 SWP 16 Cab harness (intermediate connector) C-5

A11 DT 6 Swivel Joint Connector H-10

A12 DT 6 Swivel Joint Connector H-10

A16 DT 2 Heated mirrors J-8

A17 DT 2 Heated mirrors G-11

A20 Terminal 1 Battery Relay (E Terminal) L-11/12

A21 Terminal 1 Battery Relay (BR Terminal) L-11/12

A22 Terminal 1 Battery Relay (M Terminal) L-12

A23 Terminal 1 Battery Relay (B Terminal) L-12

A25 Terminal 1 Grid Heater Relay (Contact) L-11

A27 X 2 Starter Safety Relay (S & R Terminals) L-12

A29 Terminal 1 Starter Safety Relay (C Terminal). AJ-7

A31 DT 2 Air cleaner clogged sensor K-11

A33 X 2 Radiator Water Level sensor M-10

A34 L 2 Fusible Link (60A) M-11

A35 M 2 Fusible Link (30A) N-11

A40 Spade 1 Horn (+) I-10

A41 Spade 1 Horn (+) O/P-2

A42 Spade 1 Horn (-) P-2

A43 Spade 1 Horn (-) I-10

A44 DT 2 Air horn L-12

A45 DT 2 Back pressure compensation J-3

A46 DT 2 JSS RH Lock (OPT) J-3

A47 DT 2 JSS dump solenoid J-3

A48 JSS EPC J-3

A50 KESO 2 Washer Motor Connector L/M-9

A51 JT2 3 Pump hydraulic oil pressure sensor G-14

A53 DT 2 Back up alarm (OPT) L/M-17

A54 X 1 Fuel Level Sensor G-12

A55 DT 2 Hydraulic Oil Temperature Sensor J/K-18

A56 JT2 3 Travel PPC oil pressure sensor D-17

PW148-8 VEBM720100 20-243

Connector location chart and electrical circuit diagram by system TESTING AND ADJUSTING

Connector No. Type No.of Pin Name of Device Address

A64 Terminal 1 Revolving frame earth N-10

A65 Terminal 1 Revolving frame earth N-10

A84 DT 12 Counterweight harness N-12

A86 DT 4 Work Equipment Lights O-2

A90 DT 3 Swing proximity switch J-7

A99 SWP 8 Cab harness (intermediated connector) C/D-5

AB Terminal 2 Alternator (B) I-14

CC01 DT 8 Cab harness (intermediated connector) C-4/5

CC02 DT 4 Counterweight harness N-12

CC04 DT 4 Tank camera G-16

CC05 DT 4 Boom camera (OPT) O-2

CE02 DRC 50 Engine controller K-15

CE03 DTP 4 Engine controller K/L-15/16

E03 X 2 Engine oil level sensor K-15

E05 X 1 Compressor for air conditioner K-16

E06 DT 2 Water in fuel sensor K-16

E12 Connector 3 Alternator (IG + L) I/J-14

F01 KES1 4 Flasher unit CK-5

G51 Bullet 1 Engine room lamp (OPT) H-19

G52 KES0 4 Lower wiper (OPT) I-4

G164 JT2 3 Overload Caution Sensor O-3

K02 DT 2 CAN resistor K-16

L01 DT 6 Front light connector (L.H) J-3

L02 DT 6 Front light connector (R.H) G-12

L14 DT 2 Oil tank working light B-18

L15 DT 2 Worklamp, Revo (OPT) H/I-10

L16 DT 2 Worklamp, Revo (OPT) H/I-10

M80 DT 2 Refueling pump connection H-10

RT3 DT 6 Rototilt solenoid H-10

P47 DT 2 WIF sensor J-19

S01 X 2 Swing RH (oil pressure switch) J-12

S02 X 2 Swing LH (oil pressure switch) I-14

S03 X 2 Bucket dump (oil pressure switch) H-14

S04 X 2 Bucket digging (oil pressure switch) I-12

S05 X 2 Arm dump (oil pressure switch) H-14

S06 X 2 Arm digging (oil pressure switch) H-12/13

S07 X 2 2PB extend (oil pressure switch) H-14

S08 X 2 2PB retract (oil pressure switch) I-12

S09 X 2 Travel reverse (oil pressure switch) C-17

S10 X 2 Travel forward (oil pressure switch) C-17

S12 X 2 Boom down/stabilizer (oil pressure switch) C/D-18/19

S13 X 2 Boom up/stabilizer (oil pressure switch) C/D-19

S30 DT 2 Quick coupler pressure switch G-12

20-244 PW148-8 VEBM720100

TESTING AND ADJUSTING Connector location chart and electrical circuit diagram by system

Connector No. Type No.of Pin Name of Device Address

S31 DT 2 JSS LS switch I-4

S60 DT 2 Refuel pump switch G-11

S61 DT 2 Float solenoid B/C-19

V01 DT 2 PPC Pressure Lock Solenoid C-20

V02 DT 2 2 Stage Relief Solenoid B-20

V03 DT 2 Swing Brake Solenoid B-20

V04 DT 2 Suspension Lock Solenoid D-17/18

V06 DT 2 Travel Neutral Solenoid D-18

V07 DT 2 Creep solenoid C/D-17/18

V08 DT 2 Travel F/R solenoid C-18

V09 DT 2 Boom / Stabilizer down solenoid C-18

V10 DT 2 Boom / Stabilizer up solenoid C-18/19

V11 DT 2 Transmission clutch solenoid C-19

V15 DT 2 Back pressure compensation solenoid C-19

V16 DT 2 Quick coupler solenoid G-12

V21 DT 2 PC-EPC solenoid valve J-18

V22 DT 2 LS-EPC solenoid valve J-18

V23 X 2 1st service LH EPC B/C-10

V24 X 2 1st service RH EPC B-10

V25 X 2 2nd Service LH EPC B/C-10

V26 X 2 2nd Service RH EPC B-10

V60 X 2 Travel EPC valve L-8

Y01 DT 6 Autogrease control G-13

Y02 DT 6 Autogrease cycle switch O-2

PW148-8 VEBM720100 20-245

Connector location chart and electrical circuit diagram by system TESTING AND ADJUSTING

Connector table for operator’s cab wiring harness

(Part 1/2)
(for location of connectors see "Connector diagramm 2/5" in
chapter 90)

Connector No. Type No.of Pin Name of Device Address

CM01 070 18 Monitor panel F-4

CM02 070 12 Monitor panel F-4

CM03 070 18 Monitor panel F-4

CM05 070 8 Monitor panel E/F-4

CK01 AMP 14 KOMTRAX controller (not used) E-12

CK02 AMP 10 KOMTRAX controller (not used) E-12

D01 SWP 8 Diode block C-11

D02 SWP 8 Diode block C-11

D05 SWP 8 Diode block C-11

G02 SWP 14 Steering column H/I-6/7

G05 DT 12 Steering column I-6/7

G33 DT 4 Operator’s seat F-8/9

G70 DTM 12 PPC lever F/G-9

G71 DTM 6 PPC lever E/F-6

G72 DTM 12 PPC lever E/F-6

G73 DTM 4 PPC lever F/G-9

H08 M 8 Cab frame harness E/F-12

H09 S 8 Cab frame harness F-12

HM1 DT 2 Holding magnet I-5

J01 090 20 Splice header E/F-11

J02 090 20 Splice header E-10/11

J03 090 20 Splice header E/F-11

J04 090 20 Splice header E-11

J05 090 20 Splice header E-11

J06 090 20 Splice header E-11

J07 090 20 Splice header F-11

J08 090 20 Splice header E-10

J09 090 20 Splice header F-11

J10 090 20 Splice header F-11

K19 M 2 Pump resistor C-10/11

M19 M 2 Cigarette lighter F-4

M31 M 4 Power supply (OPT) E-11

M72 M 4 DC/DC converter E-12

M79 M 2 12V power socket R-30

P10 DT 10 Steering contro panel F-4

R19 SHI 6 Hazard lights C-11

R20 SHI 6 Trailer tip C-10/11

R21 SHI 6 Brake lights C/D-11

20-246 PW148-8 VEBM720100

TESTING AND ADJUSTING Connector location chart and electrical circuit diagram by system

Connector No. Type No.of Pin Name of Device Address

R22 SHI 6 Cruise control C-11

R23 SHI 6 Refuel pump C/D-11

R30 SHI 6 Aircon D-11

RT1 S 16 Rototilt (OPT) F-11/12

RT2 DT 4 Rototilt (OPT) G-10

S14 M 4 PPC lock F/G-9

S17 DT 2 Park brake switch H-6/7

S18 DT 2 Low brake pressure switch H-7

S19 DT 3 Brake lights/cruise control switch I-5

S40 DT 2 Service brake pressure switch I-5

SC02 090 22 Steering controller F-8/9

T05 YAZAKI 1 Earthing point G-11

V12 DT 2 Park brake solenoid H/I-5

W04 M 6 Wiper motor F-4

PW148-8 VEBM720100 20-247

Connector location chart and electrical circuit diagram by system TESTING AND ADJUSTING

Connector table for operator’s cab wiring harness

(Part 2/2)
(for location of connectors see "Connector diagramm 3/5" in
chapter 90)

Connector No. Type No.of Pin Name of Device Address

A01 X 4 Revo harness I/J-11

A02 X 4 Revo harness I/J-12

A03 SWP 14 Revo harness I-11

A04 SWP 14 Revo harness I-10

A05 SWP 14 Revo harness J-12

A06 SWP 14 Revo harness I/J-10

A07 SWP 14 Revo harness I/J-11

A08 SWP 14 Revo harness I/J-11

A09 SWP 14 Revo harness I/J-11

AC01 YAZAKI 8 Air conditioner unit G-6

C01 AMP 81 Pump controller C/D-4

C02 AMP 21 Pump controller D/E-6

C09 S 8 Model select switch E-5

CC01 DT 8 Camera connection J-11/12

D03 KES1 2 Diode block H-3

D04 KES1 2 Diode block H-4/5

H13 S 2 Right hand pod harness E-6

H14 M 12 Right hand pod harness F-7

H15 090 22 Right hand pod harness F/G-7

F01 KES1 4 Flasher unit E-6

FB1 40 Fuse box (1) B/C-5

FB2 20 Fuse box (2) B/C-6

R01 SHI 6 Grid heater C-5

R02 SHI 6 Engine controller (dark current) C-5/6

R03 SHI 6 Engine controller (dark current) C-6

R04 SHI 6 Starter cut (travel neutral) C-6

R05 SHI 6 Boom/revo work lamp C-6

R06 SHI 6 Starter cut C-6/7

R07 SHI 6 Starter cut (personal code) C-7

R08 SHI 6 Counterweight/cab rear worklamps D-5/6

R09 SHI 6 Lower wiper C/D-5

R12 SHI 6 Horn D-6

R13 SHI 6 PPC lock D-6

R14 SHI 6 Operator’s cab front worklamps D-6

R15 SHI 6 Boom/outrigger select D-6/7

R16 SHI 6 Reversing buzzer D-7

R17 SHI 6 Quick coupler D-7

R18 SHI 6 Hazard warning E-5/6

20-248 PW148-8 VEBM720100

TESTING AND ADJUSTING Connector location chart and electrical circuit diagram by system

Connector No. Type No.of Pin Name of Device Address

R31 SHI 6 Air conditioner G-5

S28 090 12 Prolix harness C-3/4

S29 DT 12 Prolix harness D-4

M71 M 2 Interior light D-3/4

N08 DT 12 Service connector D-4/5

N10 SUMITOMO 4 Air conditioner unit G-6

P17 SUMITOMO 2 Air conditioner HI/LO pressure switch I-8

PW148-8 VEBM720100 20-249

Connector location chart and electrical circuit diagram by system TESTING AND ADJUSTING

Connector table various wiring harness (Part 1/2)

(for location of connectors see "Connector diagramm 4/5" in
chapter 90)

Connector No. Type No.of Pin Name of Device Address

Battery relay terminal B G-10

A Terminal 1
Battery +VE terminal J-16

ACC Terminal 1 Starter switch C-3

B
Terminal 1 Starter switch C-3
(console r.h.)

B G-10
Terminal 1 Battery relay terminal M
(starter harness) I-13

BR Terminal 1 Starter switch C-3

C
Terminal 1 Starter switch C-3
(console r.h.)

C G-10
Terminal 1 Starter safety relay terminal C
(starter harness) I-13

Grid heater relay CN-A26 G/H-11

D Terminal 1
Grid heater H-14

D06 YAZAKI 2 Diode D-5

Battery relay terminal M G-10

E Terminal 1
Grid heater relay CN-A24 G-11

E1 Terminal 1 Starter safety relay terminal B G-10

E07 M 3 Fuel dial C-3

Starter terminal B I-13

F Terminal 1
Alternator terminal B H-14

G02 SWP 14 Floor frame E-12

G03 AMP 7 Column switch ass’y C/D-14

G04 AMP 7 Column switch ass’y C-14

G05 DT 12 Floor frame E-12

G101 BRI 2 Indicator LH/RH B-14

G103 BRI 2 Indicator high beam B-14

G105 BRI 2 Road light switch B-14

H13 BRI 5 Floor harness C-6

H14 S 2 Floor harness C-6

H15 M 12 Floor harness C-6

P15 050 2 Sunshine sensor B-11

R1 Terminal 1 Starter switch C-3

S21 DT 6 Emergency pump drive switch H-1

S22 DT 6 Emergency swing switch H-1/2

S28 DT 12 Emergency prolix switches 1 J-6

S29 DT 12 Emergency prolix switches 2 K-6

S41 SWP 6 Park brake B-4

S42 SWP 6 Hazard warning C-3/4

S43 SWP 6 Swing lock C-4

S44 SWP 6 Aux worklamps B/C-4

S45 SWP 6 Aux worklamps B-4

20-250 PW148-8 VEBM720100

TESTING AND ADJUSTING Connector location chart and electrical circuit diagram by system

Connector No. Type No.of Pin Name of Device Address

S46 SWP 6 Beacon switch C-4

S47 SWP 6 Lower wiper C-4

S48 BRI 10 Wuick coupler harness C-4

S49 BRI 10 Autogrease C-4

S50 SWP 6 Heated seat C-4

S51 DT 2 Heated mirror C-4

S95 DT 6 Emergency FNR switch H-2

S96 DT 9 Emergency travel switch H-2

S120 BRI 10 Cruise control B-14

S121 DTM 2 Travel P mode P-14

PW148-8 VEBM720100 20-251

Connector location chart and electrical circuit diagram by system TESTING AND ADJUSTING

Connector table various wiring harness (Part 2/2)

(for location of connectors see "Connector diagramm 5/5" in
chapter 90)

Connector No. Type No.of Pin Name of Device Address

A57F DT 2 Transmission speed sensor J-5

A86M DT 4 Revo harness F-15

AB Terminal 1 Alternator (B) H-14

CC02M DT 4 Revo harness C-6

CC03M DT 4 Counterweight harness C-5

CE01 DRC 50 Engine controller F-10

CE02 DTP 60 Engine controller F-10

CE03 Terminal 1 Engine controller G-10

E01 X 1 Ribbon heater E-10

E03 X 1 Engine oil level sensor K-13/14

E06 DT 2 Fuel dial G-10

E12 AMP 3 Alternator (IG + L) H-14

G10 X 2 Licence plate lamp (OPT) C-4

G10F X 2 Licence plate lamp (OPT) B-4

K02 DT 3 CAN resistor F-10

L03F DT 4 Lamp cluster LH C-6

L04F DT 4 Lamp cluster RH E-2

L05F DT 2 Rear work light (STD) B-3

L06F DT 2 Rear work light (OPT) A-5

L09 YAZAKI 1 Licence plate lamp 1 B-3/4

L10 YAZAKI 1 Licence plate lamp 1 B-3/4

L11F DT 2 LH work lamp C-13

L12F DT 2 RH work lamp (OPT) C-14

L13F DT 3 Arm marker lamp C-13

P47M DT 2 WIF sensor E-2

SB Terminal 1 Starter J-14

SC Terminal 1 Starter J-13

V13 DT 2 Front attachment G-3/4

V14 DT 2 Front attachment G-3/4

V17 DT 2 Rear attachment H-4

V18 DT 2 Rear attachment G/H-4

20-252 PW148-8 VEBM720100

TESTING AND ADJUSTING Connector location chart and electrical circuit diagram by system

Blank for technical reason

PW148-8 VEBM720100 20-253

Connection table for connector pin numbers TESTING AND ADJUSTING

Connection table for connector pin numbers

The terms male and female refer to the pins, while the terms
male housing and female housing refer to the mating portion of
the housing.

X type connector
No.of
pins T-adapter
Male (female housing) Female (male housing)
Part No.

1 Part No.: 08055-00181 Part No.: 08055-00191 799-601-7010

2 799-601-7020

Part No.: 08055-00282 Part No.: 08055-00292

3 799-601-7030

Part No.: 08055-00381 Part No.: 08055-00391

4 799-601-7040

Part No.: 08055-00481 Part No.: 08055-00491, 08055-00492

• Terminal part No.: 79A-222-3370 • Terminal part No.: 79A-222-3390

• Electric wire size: 0.85 • Electric wire size: 0.85
— —
• Grommet: Black • Grommet: Black
• Q’ty: 20 • Q’ty : 20

• Terminal part No.: 79A-222-3380 • Terminal part No.: 79A-222-3410

• Electric wire size: 2.0 • Electric wire size: 2.0
— —
• Grommet: Red • Grommet: Red
• Q’ty: 20 • Q’ty: 20

20-254 PW148-8 VEBM720100

TESTING AND ADJUSTING Connection table for connector pin numbers

SWP type connector

No.of
pins T-adapter
Male (female housing) Female (male housing)
Part No.

6 799-601-7050

Part No.: 08055-10681 Part No.: 08055-10691

8 799-601-7060

Part No.: 08055-10881, 08055-10882 Part No.: 08055-10891, 08055-10892

12 799-601-7310

Part No.: 08055-11281 Part No.: 08055-11291

14 799-601-7070

Part No.: 08055-11481, 08055-11482 Part No.: 08055-11491, 08055-11492

PW148-8 VEBM720100 20-255

Connection table for connector pin numbers TESTING AND ADJUSTING

SWP type connector

No. of
pins T-adapter
Male (female housing) Female (male housing)
Part No.

16 799-601-7320

Part No.: 08055-11681, 08055-11682 Part No.: 08055-11691, 08055-11692

• Terminal part No.: • Terminal part No.:

• Electric wire size: 0.85 • Electric wire size: 0.85
— —
• Grommet: Black • Grommet: Black
• Q’ty: 20 • Q’ty: 20

• Terminal part No.: • Terminal part No.:

• Electric wire size: 1.25 • Electric wire size: 1.25
— —
• Grommet: Red • Grommet: Red
• Q’ty: 20 • Q’ty: 20

20-256 PW148-8 VEBM720100

TESTING AND ADJUSTING Connection table for connector pin numbers

No.of M type connector

pins Male (female housing) Female (male housing) T-adapter Part No.

1 Part No.: 08056-00171 Part No.: 08056-00181 799-601-7080

2 799-601-7090

Part No.: 08056-00271 Part No.: 08056-00281

3 799-601-7110

Part No.: 08056-00371 Part No.: 08056-00381

4 799-601-7120

Part No.: 08056-00471 Part No.: 08056-00481

6 799-601-7130

Part No.: 08056-00671 Part No.: 08056-00681

8 799-601-7390

Part No.: 08056-00871 Part No.: 08056-00881

PW148-8 VEBM720100 20-257

Connection table for connector pin numbers TESTING AND ADJUSTING

S type connector
No.of
pins T-adapter
Male (female housing) Female (male housing)
Part No.

8 799-601-7140

Part No.: 08056-10871 Part No.: 08056-10881

10
799-601-7150
(White)

Part No.: 08056-11071 Part No.: 08056-11081

12
799-601-7350
(White)

Part No.: 08056-11271 Part No.: 08056-11281

16
799-601-7330
(White)

Part No.: 08056-11671 Part No.: 08056-11681, 08056-11682

20-258 PW148-8 VEBM720100

TESTING AND ADJUSTING Connection table for connector pin numbers

S type connector
No.of
pins T-adapter
Male (female housing) Female (male housing)
Part No.

10
—
(Blue)

— —

12
799-601-7160
(Blue)

Part No.: 08056-11272, 08056-11271 Part No.: 08056-11282, 08056-11281

16
799-601-7170
(Blue)

Part No.: 08056-11672, 08056-11671 Part No.: 08056-11682

PW148-8 VEBM720100 20-259

Connection table for connector pin numbers TESTING AND ADJUSTING

No.of MIC type connector

pins Male (female housing) Female (male housing) T-adapter Part No.

7 Body part No.: 79A-222-2640 (Q’ty: 5) Body part No.: 79A-222-2630 (Q’ty: 5) —

11 Body part No.: 79A-222-2680 (Q’ty: 5) Body part No.: 79A-222-2670 (Q’ty: 5) —

5 799-601-2710

Body part No.: 79A-222-2620 (Q’ty: 5) Body part No.: 79A-222-2610 (Q’ty: 5)

9 799-601-2950

Body part No.: 79A-222-2660 (Q’ty: 5) Body part No.: 79A-222-2650 (Q’ty: 5)

13 799-601-2720

Body part No.: 79A-222-2710 (Q’ty: 2) Body part No.: 79A-222-2690 (Q’ty: 2)

20-260 PW148-8 VEBM720100

TESTING AND ADJUSTING Connection table for connector pin numbers

No.of MIC type connector

pins Male (female housing) Female (male housing) T-adapter Part No.

17 799-601-2730

Body part No.: 79A-222-2730 (Q’ty: 2) Body part No.: 79A-222-2720 (Q’ty: 2)

21 799-601-2740

Body part No.: 79A-222-2750 (Q’ty: 2) Body part No.: 79A-222-2740 (Q’ty: 2)

Terminal part No.: 79A-222-2770 Terminal part No.: 79A-222-2760

—
(Q’ty: 50) (Q’ty: 50)

PW148-8 VEBM720100 20-261

Connection table for connector pin numbers TESTING AND ADJUSTING

No.of AMP040 type connector

pins Male (female housing) Female (male housing) T-adapter Part No.

8 799-601-7180

— Housing part No.: 79A-222-3430 (Q’ty: 5)

12 799-601-7190

— Housing part No.: 79A-222-3440 (Q’ty: 5)

16 799-601-7210

— Housing part No.: 79A-222-3450 (Q’ty: 5)

20 799-601-7220

— Housing part No.: 79A-222-3460 (Q’ty: 5)

• Terminal part No.:

79A-222-3470 (No relation with number of pins)

20-262 PW148-8 VEBM720100

TESTING AND ADJUSTING Connection table for connector pin numbers

No.of AMP070 type connector

pins Male (female housing) Female (male housing) T-adapter Part No.

10 799-601-7510

— Part No.: 08195-10210

12 799-601-7520

— Part No.: 08195-12210

14 799-601-7530

— Part No.: 08195-14210

18 799-601-7540

— Part No.: 08195-18210

20 799-601-7550

— Part No.: 08195-20210

PW148-8 VEBM720100 20-263

Connection table for connector pin numbers TESTING AND ADJUSTING

No.of L type connector

pins Male (female housing) Female (male housing) T-adapter Part No.

2 —

— —

No.of Connector for PA

pins Male (female housing) Female (male housing) T-adapter Part No.

9 —

— —

No.of Bendix MS connector

pins Male (female housing) Female (male housing) T-adapter Part No.

10 799-601-3460

— —

20-264 PW148-8 VEBM720100

TESTING AND ADJUSTING Connection table for connector pin numbers

No.of KES 1 (Automobile) connector

pins Male (female housing) Female (male housing) T-adapter Part No.

2 —

Part No.:08027-10210 (Natural color) Part No.:08027-10260 (Natural color)

08027-10220 (Black) 08027-10270 (Black)

3 —

Part No.:08027-10310 Part No.:08027-10360

4 —

Part No.:08027-10410 (Natural color) Part No.:08027-10460 (Natural color)

08027-10420 (Black) 08027-10470 (Black)

6 —

Part No.:08027-10610 (Natural color) Part No.:08027-10660 (Natural color)

08027-10620 (Black) 08027-10670 (Black)

PW148-8 VEBM720100 20-265

Connection table for connector pin numbers TESTING AND ADJUSTING

No.of KES 1 (Automobile) connector

pins Male (female housing) Female (male housing) T-adapter Part No.

8 —

Part No.:08027-10810 (Natural color) Part No.:08027-10860 (Natural color)

08027-10820 (Black) 08027-10870 (Black)

No.of Connector for relay (Socket type)

pins Male (female housing) Female (male housing) T-adapter Part No.

5 799-601-7360

— —

6 799-601-7370

— —

F type connector
No.of
pins T-adapter
Male (female housing) Female (male housing)
Part No.

4 —

— —

20-266 PW148-8 VEBM720100

TESTING AND ADJUSTING Connection table for connector pin numbers

[The pin No. is also marked on the connector

(electric wire insertion end)]

Type HD30 Series connector

(shell
size T-adapter
Body (plug) Body (receptacle)
code) Part No.

Pin (male terminal) Pin (female termial)

799-601-9210

Part No.:08191-11201, 08191-11202, Part No.:08191-14101, 08191-14102,

18-8 08191-11205, 08191-11206 08191-14105, 08191-14106
(1) Pin (female terminal) Pin (male termial)

799-601-9210

Part No.:08191-12201, 08191-12202, Part No.:08191-13101, 08191-13102,

08191-12205, 08191-12206 08191-13105, 08191-13106

Pin (male terminal) Pin (female termial)

799-601-9220

Part No.:08191-21201, 08191-12202, Part No.:08191-24101, 08191-24102,

18-14 08191-21205, 08191-12206 08191-24105, 08191-24106
(2) Pin (female terminal) Pin (male termial)

799-601-9220

Part No.:08191-22201, 08191-22202, Part No.:08191-23101, 08191-23102,

08191-22205, 08191-22206 08191-23105, 08191-23106

PW148-8 VEBM720100 20-267

Connection table for connector pin numbers TESTING AND ADJUSTING

[The pin No. is also marked on the connector

(electric wire insertion end)]

Type HD30 Series connector

(shell
size T-adapter
Body (plug) Body (receptacle)
code) Part No.

Pin (male terminal) Pin (female termial)

799-601-9230

18-20 Part No.:08191-31201, 08191-31202 Part No.:08191-34101, 08191-34102

(3) Pin (female terminal) Pin (male termial)

799-601-9230

Part No.:08191-32201, 08191-32202 Part No.:08191-33101, 08191-33102

Pin (male terminal) Pin (female termial)

799-601-9240

18-21 Part No.:08191-41201, 08191-42202 Part No.:08191-44101, 08191-44102

(4) Pin (female terminal) Pin (male termial)

799-601-9240

Part No.:08191-42201, 08191-42202 Part No.:08191-43101, 08191-43102

20-268 PW148-8 VEBM720100

TESTING AND ADJUSTING Connection table for connector pin numbers

[The pin No. is also marked on the connector

(electric wire insertion end)]

Type HD30 Series connector

(shell
size T-adapter
Body (plug) Body (receptacle)
code) Part No.

Pin (male terminal) Pin (female termial)

799-601-9250

24-9 Part No.:08191-51201, 08191-51202 Part No.:08191-54101, 08191-54102

(5) Pin (female terminal) Pin (male termial)

799-601-9250

Part No.:08191-52201, 08191-52202 Part No.:08191-53101, 08191-53102

Pin (male terminal) Pin (female termial)

799-601-9260

Part No.:08191-61201, 08191-62202, Part No.:08191-64101, 08191-64102,

24-16 08191-61205, 08191-62206 08191-64105, 08191-64106
(6) Pin (female terminal) Pin (male termial)

799-601-9260

Part No.:08191-62201, 08191-62202, Part No.:08191-63101, 08191-63102,

08191-62205, 08191-62206 08191-63105, 08191-63106

PW148-8 VEBM720100 20-269

Connection table for connector pin numbers TESTING AND ADJUSTING

[The pin No. is also marked on the connector

(electric wire insertion end)]

Type HD30 Series connector

(shell
size T-adapter
Body (plug) Body (receptacle)
code) Part No.

Pin (male terminal) Pin (female termial)

799-601-9270

Part No.:08191-71201, 08191-71202, Part No.:08191-74101, 08191-74102,

24-21 08191-71205, 08191-71206 08191-74105, 08191-74106
(7) Pin (female terminal) Pin (male termial)

799-601-9270

Part No.:08191-72201, 08191-72202, Part No.:08191-73101, 08191-73102,

08191-72205, 08191-72206 08191-73105, 08191-73106

Pin (male terminal) Pin (female termial)

799-601-9280

Part No.:08191-81201, 08191-81202 Part No.:08191-84101, 08191-84102

08191-81203, 08191-81204 08191-84103, 08191-84104
24-22 08191-81205, 08191-80206 08191-84105, 08191-84106
(8) Pin (female terminal) Pin (male termial)

799-601-9280

Part No.:08191-82201, 08191-82202 Part No.:08191-83101, 08191-83102

08191-82203, 08191-82204 08191-83103, 08191-83104
08191-82205, 08191-82206 08191-83105, 08191-83106

20-270 PW148-8 VEBM720100

TESTING AND ADJUSTING Connection table for connector pin numbers

[The pin No. is also marked on the connector

(electric wire insertion end)]

Type HD30 Series connector

(shell
size T-adapter
Body (plug) Body (receptacle)
code) Part No.

Pin (male termial) Pin (female terminal)

799-601-9290

Part No.:08191-91203, 08191-91204, Part No.:08191-94103, 08191-94104,

24-31 08191-91205, 08191-91206 08191-94105, 08191-94106
(9) Pin (female terminal) Pin (male termial)

799-601-9290

Part No.:08191-92203, 08191-92204, Part No.:08191-93103, 08191-93104,

08191-92205, 08191-92206 08191-93105, 08191-93106

PW148-8 VEBM720100 20-271

Connection table for connector pin numbers TESTING AND ADJUSTING

[The pin No. is also marked on the connector

(electric wire insertion end)]

DT Series connector
No.of
pins Body (receptacle) T-adapter
Body (plug)
Part No.

2 799-601-9020

Part No.:08192-12200 (normal type) Part No.:08192-12100 (normal type)

08192-22200 (fine wire type) 08192-22100 (fine wire type)

3 799-601-9030

Part No.:08192-13200 (normal type) Part No.:08192-13100 (normal type)

08192-23200 (fine wire type) 08192-23100 (fine wire type)

4 799-601-9040

Part No.:08192-14200 (normal type) Part No.:08192-14100 (normal type)

08192-24200 (fine wire type) 08192-24100 (fine wire type)

6 799-601-9050

Part No.:08192-16200 (normal type) Part No.:08192-16100 (normal type)

08192-26200 (fine wire type) 08192-26100 (fine wire type)

20-272 PW148-8 VEBM720100

TESTING AND ADJUSTING Connection table for connector pin numbers

[The pin No. is also marked on the connector

(electric wire insertion end)]

No.of DT Series connector

pins Body (plug) Body (receptacle) T-adapter Part No.

8GR:799-601-9060
8B:799-601-9070
8
8G:799-601-9080
8BR:799-601-9090

Part No.:08192-1820… (normal type) Part No.:08192-1810… (normal type)

08192-2820… (fine wire type) 08192-2810… (fine wire type)

12GR:799-601-9110
12B:799-601-9120
10
12G:799-601-9130
12BR:799-601-9140

Part No.:08192-1920… (normal type) Part No.:08192-1910… (normal type)

08192-2920… (fine wire type) 08192-2910… (fine wire type)

[The pin No. is also marked on the connector

(electric wire insertion end)]

No.of DTM Series connector

pins Body (plug) Body (receptacle) T-adapter Part No.

2 799-601-9010

Part No.: 08192-02200 Part No.: 08192-02100

PW148-8 VEBM720100 20-273

Connection table for connector pin numbers TESTING AND ADJUSTING

[The pin No. is also marked on the connector

(electric wire insertion end)]

DTHD Series connector

No.of
pins T-adapter Part
Body (plug) Body (receptacle)
No.

2 —

Part No.:08192-31200 (Contact size#12) Part No.:08192-31100 (Contact size#12)

08192-41200 (Contact size #8) 08192-41100 (Contact size #8)
08192-51200 (Contact size #4) 08192-51100 (Contact size #4)

20-274 PW148-8 VEBM720100

TESTING AND ADJUSTING Connection table for connector pin numbers

No.of Miscellaneous connectors

pins Body (plug) Body (receptacle)

Part No.:20K-06-31960 Part No.:

Part No.:20K-06-32130 Part No.:

Part No.:20K-06-32170 Part No.:

Part No.:20K-06-K32160 Part No.:

PW148-8 VEBM720100 20-275

Connection table for connector pin numbers TESTING AND ADJUSTING

No.of Miscellaneous connectors

pins Body (plug) Body (receptacle)

20

Part No.:20K-06-31460 Part No.:

20

Part No.:20K-06-31470 Part No.:

20

Part No.:20K-06-31450 Part No.:

Part No.: Part No.:

Part No.:20K-06-32380 Part No.:

20-276 PW148-8 VEBM720100

TESTING AND ADJUSTING Connection table for connector pin numbers

No. of
Body (plug) Body (receptacle)
Pins

20

Part No.:20K-06-32230 Part No.:

Part No.:198-Z11-2650 Part No.:

Part No.:20K-06-31820 Part No.:

PW148-8 VEBM720100 20-277

Connection table for connector pin numbers TESTING AND ADJUSTING

No. of
Body (plug) Body (receptacle)
Pins

12

Part No.:20K-06-31810 Part No.:

Part No.:20K-06-31870 Part No.:

20

Part No.:7821-92-7370 Part No.:

Part No.:20K-06-31850 Part No.:

20-278 PW148-8 VEBM720100

TESTING AND ADJUSTING Connection table for connector pin numbers

No. of
Body (plug) Body (receptacle)
Pins

Part No.:20K-06-31860 Part No.:

Part No.:20G-06-K1420 Part No.:

Part No.:7821-92-7360 Part No.:

PW148-8 VEBM720100 20-279

Connection table for connector pin numbers TESTING AND ADJUSTING

No. of T-adapter part

Body (plug) Body (receptacle)
Pins No.

Part No.:20Y-06-13590 Part No.:

40 (A) 799-601-9350

- Part No.: 7821-93-3130

40 (B) 799-601-9350

- Part No.: 7821-93-3130

20-280 PW148-8 VEBM720100

TESTING AND ADJUSTING Connection table for connector pin numbers

No. of T-adapter part

Body (plug) Body (receptacle)
Pins No.

24 799-601-9360

- Part No.: 7821-93-3110

PW148-8 VEBM720100 20-281

Connection table for connector pin numbers TESTING AND ADJUSTING

T-boxes and T-adapters table

• The Nos. in the columns are the part Nos. of the T-boxes, T-
adapters, and other parts. The Nos. in the lines are the kit
Nos. of the T-adapter kits.

T-adapter kit

Number of pins

799-601-2500
799-601-2700
799-601-2800
799-601-2900
799-601-3000
799-601-5500
799-601-6000
799-601-6500
799-601-7000
799-601-7100
799-601-7400
799-601-7500
799-601-8000
799-601-9000
799-601-9100
799-601-9200
799-601-9300
Out of kit
Identification
Part No. Part name
symbol

799-601-2600 T-box (for ECONO) 21 { { { { { {

799-601-3100 T-box (for MS) 37 {
799-601-3200 T-box (for MS) 37 {
799-601-3300 T-box (for ECONO) 24 {
799-601-3360 Plate for MS (24-pin) {
799-601-3370 Plate for MS (17-pin) {
799-601-3380 Plate for MS (14-pin) {
799-601-3410 Adapter for BENDIX (MS) 24 MS-24P { {
799-601-3420 Adapter for BENDIX (MS) 24 MS-24P { {
799-601-3430 Adapter for BENDIX (MS) 17 MS-17P { {
799-601-3440 Adapter for BENDIX (MS) 17 MS-17P { {
799-601-3450 Adapter for BENDIX (MS) 5 MS-5P { {
799-601-3460 Adapter for BENDIX (MS) 10 MS-10P { {
799-601-3510 Adapter for BENDIX (MS) 5 MS-5S { {
799-601-3520 Adapter for BENDIX (MS) 17 MS-17P { {
799-601-3530 Adapter for BENDIX (MS) 19 MS-19P { {
799-601-2910 Adapter for BENDIX (MS) 14 MS-14P { {
799-601-3470 Case {
799-601-2710 Adapter for MIC 5 MIC-5P { { { {
799-601-2720 Adapter for MIC 13 MIC-13P { { { {
799-601-2730 Adapter for MIC 17 MIC-17P { { { { { { {
799-601-2740 Adapter for MIC 21 MIC-21P { { { { { { {
799-601-2950 Adapter for MIC 9 MIC-9P { { { {
799-601-2750 Adapter for ECONO 2 ECONO2P { {
799-601-2760 Adapter for ECONO 3 ECONO13P { {
799-601-2770 Adapter for ECONO 4 ECONO4P { {
799-601-2780 Adapter for ECONO 8 ECONO8P { {
799-601-2790 Adapter for ECONO 12 ECONO12P { {
799-601-2810 Adapter for DLI 8 DLI-8P { {
799-601-2820 Adapter for DLI 12 DLI-12P { {
799-601-2830 Adapter for DLI 16 DLI-16P { {
Extension cable
799-601-2840 12 ECONO12P { { {
(ECONO type)
799-601-2850 Case {
799-601-4210 Adapter for DRC 50 DRC50 {
799-601-7010 Adapter for X (T-adapter) 1 {
799-601-7020 Adapter for X 2 X2P { { {
799-601-7030 Adapter for X 3 X3P { { {
799-601-7040 Adapter for X 4 X4P { { {

20-282 PW148-8 VEBM720100

TESTING AND ADJUSTING Connection table for connector pin numbers

T-adapter kit

Number of pins

799-601-2500
799-601-2700
799-601-2800
799-601-2900
799-601-3000
799-601-5500
799-601-6000
799-601-6500
799-601-7000
799-601-7100
799-601-7400
799-601-7500
799-601-8000
799-601-9000
799-601-9100
799-601-9200
799-601-9300
Out of kit
Identification
Part No. Part name
symbol

799-601-7050 Adapter for SWP 6 SW6P { { {

799-601-7060 Adapter for SWP 8 SW8P { { {
799-601-7310 Adapter for SWP 12 SW12P {
799-601-7070 Adapter for SWP 14 SW14P { {
799-601-7320 Adapter for SWP 16 SW16P {
799-601-7080 Adapter for M (T-adapter) 1 { {
799-601-7090 Adapter for M 2 M2P { { { {
799-601-7110 Adapter for M 3 M3P { { { {
799-601-7120 Adapter for M 4 M4P { { { {
799-601-7130 Adapter for M 6 M6P { { { {
799-601-7340 Adapter for M 8 M8P {
799-601-7140 Adapter for S 8 S8P { { { {
799-601-7150 Adapter for S (White) 10 S10P { { { {
799-601-7160 Adapter for S (Blue) 12 S12P { { {
799-601-7170 Adapter for S (Blue) 16 S16P { { { {
799-601-7330 Adapter for S (White) 16 S16PW {
799-601-7350 Adapter for S (White) 12 S12PW {
799-601-7180 Adapter for AMP040 8 A8P {
799-601-7190 Adapter for AMP040 12 A12P { {
799-601-7210 Adapter for AMP040 16 A16P { { { {
799-601-7220 Adapter for AMP040 20 A20P { { { {
799-601-7230 Short connector for X 2 { { { {
799-601-7240 Case { {
799-601-7270 Case {
799-601-7510 Adapter for 070 10 07-10 {
799-601-7520 Adapter for 070 12 07-12 {
799-601-7530 Adapter for 070 14 07-14 {
799-601-7540 Adapter for 070 18 07-18 {
799-601-7550 Adapter for 070 20 07-20
799-601-7360 Adapter for relay 5 REL-5P {
799-601-7370 Adapter for relay 6 REL-6P {
799-601-7380 Adapter for JFC 2 {
799-601-9010 Adapter for DTM 2 DTM2 { {
799-601-9020 Adapter for DT 2 DT2 { {
799-601-9030 Adapter for DT 3 DT3 { {
799-601-9040 Adapter for DT 4 DT4 { {
799-601-9050 Adapter for DT 6 DT6 { {
799-601-9060 Adapter for DT (Gray) 8 DT8GR { {
799-601-9070 Adapter for DT (Black) 8 DT8B { {
799-601-9080 Adapter for DT (Green) 8 DT8G { {
799-601-9090 Adapter for DT (Brown) 8 DT8BR { {
799-601-9110 Adapter for DT (Gray) 12 DT12GR { {
799-601-9120 Adapter for DT (Black) 12 DT12B { {

PW148-8 VEBM720100 20-283

Connection table for connector pin numbers TESTING AND ADJUSTING

T-adapter kit

Number of pins

799-601-2500
799-601-2700
799-601-2800
799-601-2900
799-601-3000
799-601-5500
799-601-6000
799-601-6500
799-601-7000
799-601-7100
799-601-7400
799-601-7500
799-601-8000
799-601-9000
799-601-9100
799-601-9200
799-601-9300
Out of kit
Identification
Part No. Part name
symbol

799-601-9130 Adapter for DT (Green) 12 DT12G { {

799-601-9140 Adapter for DT 12 DT12BR { {
799-601-9210 Adapter for HD30-18 8 D18-8 { {
799-601-9220 Adapter for HD30-18 14 D18-14 { {
799-601-9230 Adapter for HD30-18 20 D18-20 { {
799-601-9240 Adapter for HD30-18 21 D18-21 { {
799-601-9250 Adapter for HD30-24 9 D24-9 { {
799-601-9260 Adapter for HD30-24 16 D24-16 { {
799-601-9270 Adapter for HD30-24 21 D24-21 { {
799-601-9280 Adapter for HD30-24 23 D24-23 { {
799-601-9290 Adapter for HD30-24 31 D24-31 { {
799-601-9310 Plate for HD30 (24-pin) { { {
799-601-9320 T-box (for DT/HD) 12 { { {
799-601-9330 Case {
799-601-9340 Case {
799-601-9350 Adapter for DRC 40 DRC-40 {
799-601-9360 Adapter for DRC 24 DRC-24 {
799-601-9410 Adapter for engine (CRI-T2) 2 G {
Adapter for engine (CRI-T2)
799-601-9420 3 A3 {
Adapter for engine (CRI-T3)
Adapter for engine (CRI-T2)
799-601-9430 2 P {
Adapter for engine (CRI-T3)
799-601-9440 Adapter for engine (CRI-T2) 3 1,2,3 {
795-799-5520 Adapter for engine (HPI-T2) 2 S {
Adapter for engine (HPI-T2)
795-799-5530 2 C {
Adapter for engine (CRI-T3)
Adapter for engine (HPI-T2)
795-799-5540 2 A {
Adapter for engine (CRI-T3)
795-799-5460 Adapter for engine (HPI-T2) 3 {
795-799-5470 Adapter for engine (HPI-T2) 3 {
795-799-5480 Adapter for engine (HPI-T2) 3 {
799-601-4160 Adapter for engine (CRI-T3) 2 OIL {
799-601-4340 Adapter for engine (CRI-T3) 2 1,2,3 {
799-601-4130 Adapter for engine (CRI-T3) 3 FCIN {
799-601-4140 Adapter for engine (CRI-T3) 3 FCIG {
799-601-4150 Adapter for engine (CRI-T3) 3 FCIB {
799-601-4180 Adapter for engine (CRI-T3) 3 FCIP3 {
799-601-4190 Adapter for engine (CRI-T3) 3 1,2,3 {
799-601-4240 Adapter for engine (CRI-T3) 3 1,2,3 {
799-601-4250 Adapter for engine (CRI-T3) 3 1,2,3 {
799-601-4330 Adapter for engine (CRI-T3) 3 1,2,3 {
799-601-4230 Adapter for engine (CRI-T3) 4 1,2,3,4 {
799-601-4260 Adapter for controller (ENG) 4 DTP4 {
799-601-4210 Adapter for controller (ENG) 50 DRC50 {

20-284 PW148-8 VEBM720100

TESTING AND ADJUSTING Connection table for connector pin numbers

T-adapter kit

Number of pins

799-601-2500
799-601-2700
799-601-2800
799-601-2900
799-601-3000
799-601-5500
799-601-6000
799-601-6500
799-601-7000
799-601-7100
799-601-7400
799-601-7500
799-601-8000
799-601-9000
799-601-9100
799-601-9200
799-601-9300
Out of kit
Identification
Part No. Part name
symbol

799-601-4220 Adapter for controller (ENG) 60 DRC60 {

799-601-4280 Box for controller (PUMP) 121 {
799-601-9720 Adapter for controller (HST) 16 HST16A {
799-601-9710 Adapter for controller (HST) 16 HST16B {
799-601-9370 Adapter for controller (HST) 26 HST26A {

PW148-8 VEBM720100 20-285

Connection table for connector pin numbers TESTING AND ADJUSTING

Blank for technical reason

20-286 PW148-8 VEBM720100

 20 TESTING AND ADJUSTING

Troubleshooting when failure code is indicated

Troubleshooting when failure code is indicated . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-301
Before carrying out troubleshooting when failure code is displayed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-304
Information contained in troubleshooting table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-305
Failure code [6B2JMA] – Travel hydraulic abnormality. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-307
Failure code [989L00] – Engine controller lock caution 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-308
Failure code [989M00] – Engine controller lock caution 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-309
Failure code [989N00] – Engine controller lock caution 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-310
Failure code [AA10NX] – Air cleaner clogging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-311
Failure code [AB00KE] – Charge voltage low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-312
Failure code [B@BAZG] – Eng oil press. low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-313
Failure code [B@BAZK] – Eng oil level low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-314
Failure code [B@BCNS] – Eng water overheat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-315
Failure code [B@BCZK] – Eng water level low. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-316
Failure code [B@HANS] – Hydr oil overheat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-317
Failure code [CA111] – EMC critical internal failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-318
Failure code [CA115] – Engine neutral and backup speed sensor error . . . . . . . . . . . . . . . . . . . . . . . . . . 20-319
Failure code [CA122] – Chg air press sensor high error. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-320
Failure code [CA123] – Chg air press sensor low error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-322
Failure code [CA131] – Throttle sensor high error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-324
Failure code [CA132] – Throttle sensor low error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-326
Failure code [CA144] – Coolant temp sens high error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-328
Failure code [CA145] – Coolant temp sens low error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-330
Failure code [CA153] – Chg air temp sensor high error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-332
Failure code [CA154] – Chg air temp sensor low error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-334
Failure code [CA155] – Chg air temp high speed derate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-336
Failure code [CA187] – Sens supply 2 volt low error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-338
Failure code [CA221] – Ambient press sens high error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-340
Failure code [CA222] – Ambient press sens low error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-342
Failure code [CA227] – Sens supply 2 volt high error. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-344
Failure code [CA234] – Eng overspeed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-345
Failure code [CA238] – Ne speed sens supply volt error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-346
Failure code [CA271] – IMV/PCV1 short error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-347
Failure code [CA272] – IMV/PCV1 open error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-348
Failure code [CA322] – Inj #1 (L#1) open/short error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-350
Failure code [CA324] – Inj #3 (L#3) open/short error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-352
Failure code [CA331] – Inj #2 (L#2) open/short error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-354
Failure code [CA332] – Inj #4 (L#4) open/short error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-356
Failure code [CA342] – Calibration code incompatibility. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-358
Failure code [CA351] – Injectors drive circuit error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-360
Failure code [CA352] – Sens supply 1 volt low error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-362
Failure code [CA386] – Sens supply 1 volt high error. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-364
Failure code [CA428] – Water in fuel sensor high error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-366
Failure code [CA429] – Water in fuel sensor low error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-368
Failure code [CA435] – Eng oil press sw error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-370
Failure code [CA441] – Battery voltage low error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-371
Failure code [CA442] – Battery voltage high error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-374
Failure code [CA449] – Rail press very high error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-376
Failure code [CA451] – Rail press sensor high error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-378
Failure code [CA452] – Rail press sensor low error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-380
Failure code [CA488] – Chg air temp high torque derate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-382

PW148-8 VEBM720100 20-301

Troubleshooting when failure code is indicated TESTING AND ADJUSTING

Failure code [CA553] – Rail press high error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-383

Failure code [CA559] – Rail press low error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-384
Failure code [CA689] – Eng Ne speed sensor error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-386
Failure code [CA731] – Eng bkup speed sens phase error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-388
Failure code [CA757] – All continuous data lost error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-390
Failure code [CA778] – Eng bkup speed sensor error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-392
Failure code [CA1633] – KOMNET datalink timeout error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-394
Failure code [CA2185] – Throttle sensor supply voltage high error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-396
Failure code [CA2186] – Throttle sensor supply voltage low error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-397
Failure code [CA2249] – Rail press very low error. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-398
Failure code [CA2311] – IMV solenoid error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-400
Failure code [CA2555] – Grid htr relay volt high error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-402
Failure code [CA2556] – Grid heater relay volt low error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-404
Failure code [D110KB] – Short-circuiting in battery relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-406
Failure code [D19JKZ] – Personal code relay abnormality . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-408
Failure code [D862KA] – GPS antenna disconnection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-410
Failure code [DA25KP] – 5V sensor 1 power abnormality . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-412
Failure code [DA2RMC] – CAN discon (pump con detected) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-414
Failure code [DAFRMC] – GPS module error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-416
Failure code [DAFRMC] – CAN discon (monitor detected) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-418
Failure code [DDP4KX] – Abnormality in travel PPC pressure switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-420
Failure code [DDWCKZ] – Abnormality in travel direction control switch. . . . . . . . . . . . . . . . . . . . . . . . . . . 20-422
Failure code [DFB1KZ] – 1st ATT service lever main potentio 1 abnormality . . . . . . . . . . . . . . . . . . . . . . . 20-424
Failure code [DFB2KZ] – 2nd ATT service lever main potentio 2 abnormality . . . . . . . . . . . . . . . . . . . . . . 20-426
Failure code [DFB3L8] – 1st ATT service lever Potentio 1 error. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-428
Failure code [DFB4L8] – 2nd ATT service lever potentio 2 error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-429
Failure code [DFB5KZ] – 1st ATT service lever main potentio 1 abnormality . . . . . . . . . . . . . . . . . . . . . . . 20-430
Failure code [DFB6KZ] – Service lever potentio 2 abnormality . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-432
Failure code [DGH2KB] – Hydr oil sensor short. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-434
Failure code [DH10KS] – Abnormality in 24V sensor power source . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-436
Failure code [DHPAMA] – F pump press sensor abnormality . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-438
Failure code [DHS5KX] – Abnormality in travel PPC sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-440
Failure code [DHX1MA] – Abnormality in overload caution sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-442
Failure code [DLT4KA] – Disconnection in transmission speed sensor in pump controller system. . . . . . . 20-444
Failure code [DW27KA] – Disconnection in transmission clutch solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . 20-446
Failure code [DW27KB] – Short-circuiting in transmission clutch solenoid . . . . . . . . . . . . . . . . . . . . . . . . . 20-448
Failure code [DW4AKA] – Disconnection in suspension lock solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-450
Failure code [DW4AKB] – Short circuiting in suspension lock solenoid. . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-452
Failure code [DW4CKA] – Disconnection in PPC lock solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-454
Failure code [DW4CKB] – PPC lock sol. S/C. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-456
Failure code [DW4MKA] – Disconnection in creep solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-458
Failure code [DW4MKB] – Short-circuiting in creep solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-460
Failure code [DW44KA] – Disconnection of travel F/R solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-462
Failure code [DW44KB] – Short-circuiting of travel F/R solenoid. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-464
Failure code [DW45KA] – Disconnection in swing parking brake solenoid . . . . . . . . . . . . . . . . . . . . . . . . . 20-466
Failure code [DW45KB] – Swing brake sol. S/C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-468
Failure code [DW91KA] – Disconnection in travel neutral solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-470
Failure code [DW91KB] – Short-circuiting in travel neutral solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-472
Failure code [DWK0KA] – Disconnection in 2-stage relief solenoid. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-474
Failure code [DWK0KB] – Short-circuiting in 2-stage relief solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-476
Failure code [DWK2KA] – Disconnection in 2-stage back pressure solenoid . . . . . . . . . . . . . . . . . . . . . . . 20-478
Failure code [DWK2KB] – Short circuiting in 2-stage back pressure solenoid. . . . . . . . . . . . . . . . . . . . . . . 20-480
Failure code [DXA8KA] – Disconnection in PC-EPC (F) solenoid system . . . . . . . . . . . . . . . . . . . . . . . . . . 20-482
Failure code [DXA8KB] – Short-circuiting in PC-EPC (F) solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-484
Failure code [DXE0KA] – Disconnection in LS-EPC solenoid system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-486
Failure code [DXE0KB] – Short-circuiting in LS-EPC solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-487
Failure code [DXE4KA] – 1st service current EPC discon (left hand) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-488

20-302 PW148-8 VEBM720100

TESTING AND ADJUSTING Troubleshooting when failure code is indicated

Failure code [DXE4KB] – 1st service current EPC short (left hand) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-490
Failure code [DXE7KA] – 1st service current EPC discon (right hand). . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-492
Failure code [DXE7KB] – 1st service current EPC short (right hand) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-494
Failure code [DXE8KA] – 2nd service current EPC discon (left hand) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-496
Failure code [DXE8KB] – 2nd service current EPC short (left hand) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-498
Failure code [DXE9KA] – 2nd service current EPC discon (right hand) . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-500
Failure code [DXE9KB] – 2nd service current EPC short (right hand) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-502
Failure code [DY20KA] – Wiper working abnormality . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-504
Failure code [DY20MA] – Wiper parking abnormality . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-506
Failure code [DY2CKA] – Washer drive discon . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-508
Failure code [DY2CKB] – Washer drive short. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-510
Failure code [DY2DKB] – Wiper drive (for) short . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-512
Failure code [DY2EKB] – Wiper drive (rev) short . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-514

PW148-8 VEBM720100 20-303

Before carrying out troubleshooting when failure code is displayed TESTING AND ADJUSTING

Before carrying out troubleshooting when failure code is

displayed
Connection table of fuse box

★ This connection table shows the devices to which each

power supply of the fuse box supplies power (A switch
power supply is a device which supplies power while the
starting switch is in the ON position and a constant pow-
er supply is a device which supplies power while the
starting switch is in the OFF and ON positions).

★ When carrying out troubleshooting related to the electri-

cal system, you should check the fuses and fusible links
to see if the power is supplied normally.

Type of
Fuse
power Fusible link Fuse Fuse No. Destination of power
capacity
supply
1 10 A Pump Prolix, Swing Prolix
2 20 A Pump Controller, Boom/ Outrigger Sol., Aux Hydraulic Sol.
A34 3 10 A PPC Lock, Starter Cut, Personel Code Relay
(65 A) Cigarette lighter
4 10 A
Windshield washer motor
5 10 A Horn and power max. switch.
6 10 A Lower wiper and auto pre-heat relay, DC/DC Conwerter
7 10 A Beacon
A34
Switch power 8 10 A (Spare)
(65 A) FB1
supply 9 15 A Flasher Unit, Direction Indicator Lamps
10 10 A Refuel pump
11 20 A Air conditioner unit
12 5A Cruise control
A34
13 10 A (Spare)
(65 A)
14 10 A Optional power supply (24V) and heated seat
15 15 A Breaker switch
Starting switch
20 5A Engine controller (ACC signal)
ACC
1 5A Travel FNR, Travel Prolix, Reversing alarm
2 10 A Park brake
3 20 A Work lights (boom + revo), quick coupler
4 25 A Worklights (operators cab, front)
Switched A34 5 20 A Worklights (CWT, operators cab rear)
FB2
power supply (65 A) 6 5A Breake lamps
7 10 A Rototilt controller
8 10 A JSS controller, JSS monitor (opt.)
9 5A Autogrease
10 15 A Heates mirros (opt.)
11 20 A Road lights (Master fuse)
12 10 A Rototilt controller
FB2 13 10 A (Spare)
14 10 A (Spare)
Constant A35
15 10 A (Spare)
power supply (30 A)
16 15 A Air seat compressor, Cab interior light
17 20 A Monitor, Controller, Starter switch, Service connector
FB1
18 15 A Hazard warning lamp, Hazard flasher
19 30 A Engine controller

20-304 PW148-8 VEBM720100

TESTING AND ADJUSTING Information contained in troubleshooting table

Information contained in troubleshooting table

• The troubleshooting table and the related circuit diagrams
contain the following information. Grasp their contents fully
before proceeding to actual troubleshooting work.

User Code Failure Code

Failure
Display in Title of failure phenomenon shown in failure history
Display in monitor panel phenomenon
monitor panel

Failure content Failure status as detected by monitor panel or controller

Response from
Action taken by the monitor panel or controller to protect an affected system or equipment, when they detect some fail-
monitor panel or
ure.
controller

Phenomenon
occurring on Phenomenon that occurs on the machine, resulting from the above action taken by the monitor panel or controller
machine

Relative
Information on the failure occurred as well as the troubleshooting
information

Cause Standard value in normal and references for troubleshooting

<Content Included>
• Standard value in normal by which to pass "Good" or "No good" judgement over the presumed
cause
1 • Reference for passing the above "Good" or "No Good" judgement

<Phenomenon of Wiring Harness Failure>

• Disconnection
There is a faulty contact at the connector or disconnection of wiring harness occurred.
Presumed cause and standard value in normal

2
Cause that presumably
triggered failure in question
3 (The assigned No. is for fil-
ing purpose only. It does
not stand for any priority)
4
• Defective grounding
A wiring harness that is not connected with a grounding circuit has a contact with the grounding
circuit.
• Short-circuiting
A wiring harness that is not connected with a 24 V electric circuit has a contact with the electric
circuit.
<Precaution for Troubleshooting>
1. Connector No. display method and handling of T-adapter
Insert or connect T-adapters in the following manner before starting troubleshooting unless oth-
erwise instructed.
• If there is no indication of "male" or "female" in a specific connector No., disconnect the connec-
tor and insert the T-adapter into both male and female sides.
• If there is an indication of "male" or "female" in a specific connector No., disconnect the connec-
tor and connect the T-adapter with only one side of either "male" or "female".
2. Entry sequence of pin No. and handling of circuit tester lead
Connect the positive (+) lead and the negative (–) lead OFF a circuit tester in the following man-
ner unless otherwise instructed.
• Connect the positive (+) lead with the pin No. indicated at the front or the wiring harness.
• Connect the negative (–) lead with the pin No. indicated at the front or the wiring harness.

PW148-8 VEBM720100 20-305

Information contained in troubleshooting table TESTING AND ADJUSTING

Relative electrical circuit diagram

This is part of the electrical circuit diagram which shows the portion where the failure occurred.

• Connector No.: Indicates (Type - numbers of a pin) (colour)

• Arrow: Roughly indicates the location in the machine where it is installed.

20-306 PW148-8 VEBM720100

TESTING AND ADJUSTING Failure code [6B2JMA] – Travel hydraulic abnormality

Failure code [6B2JMA] – Travel hydraulic abnormality

User Code Failure Code Failure Incorrect non-volatile memory data

— 6B2JMA phenomenon (in pump controller)

• Hydraulic signal activates one pressure switch (Either forward or reverse but R.H PPC work lever switch selects op-
Failure content
posite travel direction.

Response from
• Error code is displayed on the monitor panel.
controller

Phenomenon
occurring on • Engine speed raises when travel pedal is operated but machine does not travel.
machine

Relative • This error occurs when hydraulic PPC travel hoses are connected to incorrect ports.
information Countermeasure - Swap hoses.

• This error occurs if travel forward and travel reverse pres-

sure switches have electrical connetor on wrong switch.
Contermesure - swap switch connection.

• This error occurs if harness branch to either forward or re-

verse pressure switch damaged and short circuit to machine
body.

PW148-8 VEBM720100 20-307

Failure code [989L00] – Engine controller lock caution 1 TESTING AND ADJUSTING

Failure code [989L00] – Engine controller lock caution 1

User code Failure code Engine controller lock caution 1

Trouble
— 989L00 (Machine monitor system)

Contents of
• Engine controller lock is detected (Factor 1).
trouble

Action of • None in particular.

machine monitor • If cause of failure disappears, system resets itself.

Problem that
appears on • Engine cannot be started.
machine

• If this failure code is displayed after machine monitor is replaced, user password must be changed to one before
Related
replacement.
information
• Method of reproducing failure code: Turn starting switch ON.

Possible causes Cause Standard value in normal state/Remarks on troubleshooting

and standard
value in normal Replacement of machine moni-
1 This trouble may be caused by replacement of machine monitor.
state tor

20-308 PW148-8 VEBM720100

TESTING AND ADJUSTING Failure code [989M00] – Engine controller lock caution 2

Failure code [989M00] – Engine controller lock caution 2

User code Failure code Engine controller lock caution 2

Trouble
— 989M00 (Machine monitor system)

Contents of
• Engine controller lock is detected (Factor 2).
trouble

Action of • None in particular.

machine monitor • If cause of failure disappears, system resets itself.

Problem that
appears on • Engine cannot be started.
machine

• If this failure code is displayed after machine monitor is replaced, user password must be changed to one before
Related
replacement.
information
• Method of reproducing failure code: Turn starting switch ON.

Cause Standard value in normal state/Remarks on troubleshooting

Possible causes Replacement of machine moni-

1 This trouble may be caused by replacement of machine monitor.
and standard tor
value in normal
If this failure code is displayed while machine monitor is not replaced,
state
2 Defective machine monitor machine monitor may be defective. (Since trouble is in system, trouble-
shooting cannot be carried out.)

PW148-8 VEBM720100 20-309

Failure code [989N00] – Engine controller lock caution 3 TESTING AND ADJUSTING

Failure code [989N00] – Engine controller lock caution 3

User code Failure code Engine controller lock caution 3

Trouble
— 989N00 (Machine monitor system)

Contents of
• Engine controller lock is detected (Factor 3).
trouble

Action of • Tries automatic resetting.

machine monitor • If cause of failure disappears, system resets itself.

Problem that
appears on
machine

Related
• Method of reproducing failure code: Failure code is not reproduced since system is reset automatically.
information

Possible causes Cause Standard value in normal state/Remarks on troubleshooting

and standard
value in normal If this failure code is displayed repeatedly, engine controller may be defec-
1 Defective engine controller
state tive. (Since trouble is in system, troubleshooting cannot be carried out.)

20-310 PW148-8 VEBM720100

TESTING AND ADJUSTING Failure code [AA10NX] – Air cleaner clogging

Failure code [AA10NX] – Air cleaner clogging

User code Failure code Air cleaner clogging

Trouble
— AA10NX (Machine monitor system)

Contents of • While engine was running, signal circuit of air cleaner clogging switch detected clogging of air cleaner (sensor con-
trouble tact opened).

Action of • Displays air cleaner clogging monitor on machine monitor.

machine monitor • If cause of failure disappears, system resets itself.

Problem that
appears on • If machine is operated as it is, engine may be damaged.
machine

• Condition of air cleaner clogging switch signal can be checked with monitoring function.
Related
(Code: 04501 Monitor input 2)
information
• Method of reproducing failure code: Start engine.

Cause Standard value in normal state/Remarks on troubleshooting

Possible causes Clogging of air cleaner (when Air cleaner may be clogged. Check it for clogging and then clean or replace
1
and standard system is normal) if clogged.
value in normal
If cause 1 is not detected, air cleaner clogging monitor system may be defec-
state Defective air cleaner clogging
2 tive. Carry out troubleshooting for "E-7 Caution item flashes while engine is
monitor system
running" in E-mode.

PW148-8 VEBM720100 20-311

Failure code [AB00KE] – Charge voltage low TESTING AND ADJUSTING

Failure code [AB00KE] – Charge voltage low

User code Failure code Charge voltage low

Trouble
— AB00KE (Machine monitor system)

Contents of
• While engine is running, signal circuit of alternator detected low charge voltage (below 7.8 V).
trouble

Action of • Displays charge level monitor on machine monitor.

machine monitor • Even if cause of failure disappears, system does not reset itself until starting switch is turned OFF.

Problem that
appears on • If machine is operated as it is, battery may not be charged.
machine

Related • Signal voltage of alternator can be checked with monitoring function. (Code: 04300 Charge voltage)
information • Method of reproducing failure code: Start engine.

Cause Standard value in normal state/Remarks on troubleshooting

★ Prepare with starting switch OFF, then start engine and carry out trou-
bleshooting.
Possible causes Defective charge of alternator
1 E12 (male) Engine speed Voltage
and standard (when system is normal)
value in normal Between (1) – chassis
Min. medium speed 27.5 – 29.5 V
state ground

If cause 1 is not detected, charge level monitor system may be defective.

2 Defective charge level monitor Carry out troubleshooting for "E-7 Caution item flashes while engine is run-
ning" in E-mode.

CM01 J01 (Blue)

Battery Charge Level 11

13

14

Alternator

A07 B

E12
9 IG

1 L

20-312 PW148-8 VEBM720100

TESTING AND ADJUSTING Failure code [B@BAZG] – Eng oil press. low

Failure code [B@BAZG] – Eng oil press. low

User code Failure code Engine oil pressure low

Trouble
— B@BAZG (Engine controller system)

Contents of • While engine was running, signal circuit of engine oil pressure switch detected low engine oil pressure (sensor con-
trouble tact opened).

Action of • Displays engine oil pressure monitor on machine monitor.

controller • If cause of failure disappears, system resets itself.

Problem that
appears on • If machine is operated as it is, engine may be damaged.
machine

Related • Engine oil pressure switch signal is input to engine controller and then transmitted to machine monitor.
information • Method of reproducing failure code: Start engine.

Cause Standard value in normal state/Remarks on troubleshooting

Possible causes Lowering of engine oil pressure

1 Engine oil pressure may be low. Check it and remove cause if it is low.
and standard (when system is normal)
value in normal
If cause 1 is not detected, engine oil pressure monitor system may be defec-
state Defective engine oil pressure
2 tive. Carry out troubleshooting for "E-8 Emergency stop item lights up while
monitor system
engine is running" in E-mode.

PW148-8 VEBM720100 20-313

Failure code [B@BAZK] – Eng oil level low TESTING AND ADJUSTING

Failure code [B@BAZK] – Eng oil level low

User code Failure code Engine oil level low

Trouble
— B@BAZK (Machine monitor system)

Contents of • When starting switch is turned ON (but engine is not started), signal circuit of engine oil level switch detected low
trouble engine oil level (sensor contact opened).

Action of • Displays engine oil level monitor on machine monitor.

machine monitor • Even if cause of failure disappears, system does not reset itself until starting switch is turned OFF.

Problem that
appears on • If machine is operated as it is, engine may be damaged.
machine

Related • Engine oil level switch signal can be checked with monitoring function. (Code: 04501 Monitor input 2)
information • Method of reproducing failure code: Turn starting switch ON.

Cause Standard value in normal state/Remarks on troubleshooting

Possible causes Lowering of engine oil level

1 Engine oil level may be low. Check it and add new oil if it is low.
and standard (when system is normal)
value in normal
If cause 1 is not detected, engine oil level monitor system may be defective.
state Defective engine oil level
2 Carry out troubleshooting for "E-2 Basic check item lights up when starting
monitor system
switch is turned ON (but engine is not started)" in E-mode.

20-314 PW148-8 VEBM720100

TESTING AND ADJUSTING Failure code [B@BCNS] – Eng water overheat

Failure code [B@BCNS] – Eng water overheat

User code Failure code Engine coolant overheat

Trouble
— B@BCNS (Engine controller system)

Contents of • While engine was running, signal circuit of engine coolant temperature sensor detected overheating of engine cool-
trouble ant (above about 102°C).

Action of • Displays engine coolant temperature monitor with red on machine monitor.
controller • If cause of failure disappears, system resets itself.

Problem that
appears on • If machine is operated as it is, engine may be seized.
machine

• Engine coolant temperature sensor signal is input to engine controller and then transmitted to machine monitor.
Related • Engine coolant temperature can be checked with monitoring function
information (Code: 04107 Engine coolant temperature)
• Method of reproducing failure code: Start engine.

Cause Standard value in normal state/Remarks on troubleshooting

Possible causes Overheating of engine coolant Engine coolant may be overheating. Check it and remove cause if it is over-
1
and standard (when system is normal) heating.
value in normal
If cause 1 is not detected, engine coolant temperature gauge system may be
state Defective engine coolant
2 defective. Carry out troubleshooting for "E-9 Engine coolant temperature
temperature gauge system
gauge does not work normally" in E-mode.

PW148-8 VEBM720100 20-315

Failure code [B@BCZK] – Eng water level low TESTING AND ADJUSTING

Failure code [B@BCZK] – Eng water level low

User code Failure code Engine coolant level low

Trouble
— B@BCZK (Machine monitor system)

Contents of • When starting switch is turned ON (but engine is not started), signal circuit of radiator coolant level sensor detected
trouble low radiator coolant level (sensor contact opened).

Action of • Displays radiator coolant level monitor on machine monitor.

machine monitor • If cause of failure disappears, system resets itself.

Problem that
appears on • If machine is operated as it is, engine may overheats.
machine

• Condition of radiator coolant level switch can be checked with monitoring function
Related
(Code: 04500 Monitor input 1)
information
• Method of reproducing failure code: Turn starting switch ON.

Cause Standard value in normal state/Remarks on troubleshooting

Possible causes Lowering of radiator coolant

1 Radiator coolant level may be low. Check it and add coolant if it is low.
and standard level (when system is normal)
value in normal
If cause 1 is not detected, radiator coolant level monitor system may be
state Defective radiator coolant level
2 defective. Carry out troubleshooting for "E-2 Basic check item lights up
monitor system
when starting switch is turned ON (but engine is not started)" in E-mode.

20-316 PW148-8 VEBM720100

TESTING AND ADJUSTING Failure code [B@HANS] – Hydr oil overheat

Failure code [B@HANS] – Hydr oil overheat

User code Failure code Hydraulic oil overheat

Trouble
— B@HANS (Pump controller system)

Contents of • While engine was running, signal circuit of hydraulic oil temperature sensor detected overheating of hydraulic oil
trouble (above about 102°C).

Action of • Displays hydraulic oil temperature monitor with red on machine monitor.
controller • If cause of failure disappears, system resets itself.

Problem that
appears on • If machine is operated as it is, engine may be seized.
machine

• Hydraulic oil temperature sensor signal is input to engine controller and then transmitted to machine monitor.
Related • Hydraulic oil temperature can be checked with monitoring function
information (Code: 04401 Hydraulic oil temperature)
• Method of reproducing failure code: Start engine.

Cause Standard value in normal state/Remarks on troubleshooting

Possible causes Overheating of hydraulic oil Hydraulic oil may be overheating. Check it and remove cause if it is over-
1
and standard (when system is normal) heating.
value in normal
If cause 1 is not detected, hydraulic oil temperature gauge system may be
state Defective hydraulic oil tempera-
2 defective. Carry out troubleshooting for "E-10 Hydraulic oil temperature
ture gauge system
gauge does not work normally" in E-mode.

PW148-8 VEBM720100 20-317

Failure code [CA111] – EMC critical internal failure TESTING AND ADJUSTING

Failure code [CA111] – EMC critical internal failure

User code Failure code Critical internal failure

Trouble
E10 CA111 (Engine controller system)

Contents of
• Memory or power supply circuit in engine controller is defective.
trouble

Action of
• None in particular.
controller

Problem that
appears on • Engine does not start.
machine

Related
information

Possible causes Cause Standard value in normal state/Remarks on troubleshooting

and standard
value in normal Engine controller may be defective.
1 Defective engine controller
state (Since trouble is in system, troubleshooting cannot be carried out.)

20-318 PW148-8 VEBM720100

TESTING AND ADJUSTING Failure code [CA115] – Engine neutral and backup speed sensor error

Failure code [CA115] – Engine neutral and backup speed

sensor error

User code Failure code Engine Neutral and Backup speed sensor error
Trouble
E10 CA115 (Engine controller system)

Contents of
• Both signals of engine Neutral speed sensor and engine Backup speed sensor are abnormal.
trouble

Action of
• None in particular.
controller

Problem that
• Engine stops.
appears on
• Engine does not start.
machine

Related
• Method of reproducing failure code: Start engine.
information

Possible causes Cause Standard value in normal state/Remarks on troubleshooting

and standard
value in normal Defective connection of sensor Connectors of Neutral speed sensor and Backup speed sensor may be con-
1
state connector nected defectively (or connected to wrong parts). Check them directly.

PW148-8 VEBM720100 20-319

Failure code [CA122] – Chg air press sensor high error TESTING AND ADJUSTING

Failure code [CA122] – Chg air press sensor high error

User code Failure code Charge air pressure sensor high error
Trouble
E11 CA122 (Engine controller system)

Contents of
• Pressure signal circuit of boost pressure/temperature sensor detected high voltage.
trouble

Action of
• Fixes charge pressure value and continues operation.
controller

Problem that
appears on • Engine output lowers.
machine

• Signal voltage on boost pressure side of boost pressure/temperature sensor can be checked with monitoring func-
Related
tion. (Code: 36501 Boost pressure sensor voltage)
information
• Method of reproducing failure code: Turn starting switch ON.

Cause Standard value in normal state/Remarks on troubleshooting

Defective sensor power supply

1 If failure code [CA227] is also indicated, carry out troubleshooting for it first.
2 system

★ Prepare with starting switch OFF, then turn starting switch ON and carry
out troubleshooting.

Defective boost pressure/tem- BOOST PRESS & IMT Voltage

2 perature sensor [pressure sig- Between (3) – (1) Power supply 4.75 – 5.25 V
nal system]
Voltage is measured with wiring harness connected. Accordingly, if voltage
is abnormal, check wiring harness and controller, too, for another cause of
trouble, and then judge.

★ Prepare with starting switch OFF, then turn starting switch ON and carry
Hot short (Short circuit with 5 V/ out troubleshooting.
3
24 V circuit) in wiring harness Wiring harness between CE01 (female) (44) –
Possible causes Voltage Max. 1 V
and standard BOOST PRESS & IMT (female) (4)
value in normal
★ Prepare with starting switch OFF, then carry out troubleshooting without
state
turning starting switch ON.
Short circuit in wiring harness Wiring harness between CE01 (female) (44) –
4
(with another wiring harness) BOOST PRESS & IMT (female) (4) and between Resist- Min.
CE01 (female) (37) – JC01 – BOOST PRESS & ance 100 kΩ
IMT (female) (3)

Connecting parts between boost pressure/temperature sensor – engine wir-

ing harness – engine controller may be defective. Check them directly.
Defective wiring harness con-
5 • Looseness of connector, breakage of lock, or breakage of seal
nector
• Corrosion, bend, breakage, push-in, or expansion of pin
• Moisture or dirt in connector or defective insulation

★ Prepare with starting switch OFF, then turn starting switch ON and carry
out troubleshooting.
6 Defective engine controller
CE01 Voltage

Between (37) – (47) Power supply 4.75 – 5.25 V

20-320 PW148-8 VEBM720100

TESTING AND ADJUSTING Failure code [CA122] – Chg air press sensor high error

Circuit diagram related to boost pressure/temperature sensor (combina-

tion sensor)

PW148-8 VEBM720100 20-321

Failure code [CA123] – Chg air press sensor low error TESTING AND ADJUSTING

Failure code [CA123] – Chg air press sensor low error

User code Failure code Charge air pressure sensor low error
Trouble
E11 CA123 (Engine controller system)

Contents of
• Pressure signal circuit of boost pressure/temperature sensor detected low voltage.
trouble

Action of
• Fixes charge pressure value and continues operation.
controller

Problem that
appears on • Engine output lowers.
machine

• Signal voltage on boost pressure side of boost pressure/temperature sensor can be checked with monitoring func-
Related
tion. (Code: 36501 Boost pressure sensor voltage)
information
• Method of reproducing failure code: Turn starting switch ON.

Cause Standard value in normal state/Remarks on troubleshooting

Defective sensor power supply

1 If failure code [CA187] is also indicated, carry out troubleshooting for it first.
2 system

★ Prepare with starting switch OFF, then turn starting switch ON and carry
out troubleshooting.

Defective boost pressure/tem- BOOST PRESS & IMT Voltage

2 perature sensor [pressure sig- Between (3) – (1) Power supply 4.75 – 5.25 V
nal system]
Voltage is measured with wiring harness connected. Accordingly, if voltage
is abnormal, check wiring harness and controller, too, for another cause of
trouble, and then judge.

★ Prepare with starting switch OFF, then carry out troubleshooting without
Ground fault in wiring harness turning starting switch ON.
3
(Short circuit with GND circuit) Wiring harness between CE01 (female) (44) – Resist- Min.
Possible causes
and standard BOOST PRESS & IMT (female) (4) ance 100 kΩ
value in normal
★ Prepare with starting switch OFF, then carry out troubleshooting without
state
turning starting switch ON.
Short circuit in wiring harness Wiring harness between CE01 (female) (44) –
4
(with another wiring harness) BOOST PRESS & IMT (female) (4) and between Resist- Min.
CE01 (female) (47) – JC02 – BOOST PRESS & ance 100 kΩ
IMT (female) (1)

Connecting parts between boost pressure/temperature sensor – engine wir-

ing harness – engine controller may be defective. Check them directly.
Defective wiring harness con-
5 • Looseness of connector, breakage of lock, or breakage of seal
nector
• Corrosion, bend, breakage, push-in, or expansion of pin
• Moisture or dirt in connector or defective insulation

★ Prepare with starting switch OFF, then turn starting switch ON and carry
out troubleshooting.
6 Defective engine controller
CE01 Voltage

Between (37) – (47) Power supply 4.75 – 5.25 V

20-322 PW148-8 VEBM720100

TESTING AND ADJUSTING Failure code [CA123] – Chg air press sensor low error

Circuit diagram related to boost pressure/temperature sensor (combina-

tion sensor)

PW148-8 VEBM720100 20-323

Failure code [CA131] – Throttle sensor high error TESTING AND ADJUSTING

Failure code [CA131] – Throttle sensor high error

User code Failure code Throttle sensor high error

Trouble
E14 CA131 (Engine controller system)

Contents of
• Signal circuit of fuel control dial detected high voltage.
trouble

• If trouble occurs while starting switch is in ON position, controller fixes voltage value to level just before detection of
Action of trouble and continues operation.
controller • If starting switch is turned ON while voltage is abnormally high, controller continues operation with voltage at 100%
value.

Problem that
appears on • Engine speed cannot be controlled with fuel control dial.
machine

Related • Signal voltage of fuel control dial can be checked with monitoring function. (Code: 03000 Fuel control dial voltage)
information • Method of reproducing failure code: Turn starting switch ON.

Cause Standard value in normal state/Remarks on troubleshooting

Defective throttle sensor power

1 If failure code [CA2185] is also indicated, carry out troubleshooting for it first.
supply system

★ Prepare with starting switch OFF, then turn starting switch ON and carry
out troubleshooting.

E07 Voltage
2 Defective fuel control dial Between (1) – (3) Power supply 4.75 – 5.25 V

Voltage is measured with wiring harness connected. Accordingly, if voltage

is abnormal, check wiring harness and controller, too, for another cause of
trouble, and then judge.

★ Prepare with starting switch OFF, then turn starting switch ON and carry
Hot short (Short circuit with 5 V/ out troubleshooting.
3
Possible causes 24 V circuit) in wiring harness Wiring harness between CE02 (female) (9) – E06
and standard Voltage Max. 1 V
(female) (2)
value in normal
state ★ Prepare with starting switch OFF, then carry out troubleshooting without
turning starting switch ON.
Short circuit in wiring harness
4 Wiring harness between CE02 (female) (9) – E06
(with another wiring harness) Resist- Min.
(female) (2) and between CE02 (female) (22) –
ance 100 kΩ
E06 (female) (1)

Connecting parts between fuel control dial – machine wiring harness –

engine controller may be defective. Check them directly.
Defective wiring harness con-
5 • Looseness of connector, breakage of lock, or breakage of seal
nector
• Corrosion, bend, breakage, push-in, or expansion of pin
• Moisture or dirt in connector or defective insulation

★ Prepare with starting switch OFF, then turn starting switch ON and carry
out troubleshooting.
6 Defective engine controller
CE02 Voltage

Between (22) – (23) Power supply 4.75 – 5.25 V

20-324 PW148-8 VEBM720100

TESTING AND ADJUSTING Failure code [CA131] – Throttle sensor high error

Circuit diagram related to fuel control dial

A03 H15
(SWP-14) (090-22) E07 (M-3)

PW148-8 VEBM720100 20-325

Failure code [CA132] – Throttle sensor low error TESTING AND ADJUSTING

Failure code [CA132] – Throttle sensor low error

User code Failure code Throttle sensor low error

Trouble
E14 CA132 (Engine controller system)

Contents of
• Signal circuit of fuel control dial detected low voltage.
trouble

• If trouble occurs while starting switch is in ON position, controller fixes voltage value to level just before detection of
Action of trouble and continues operation.
controller • If starting switch is turned ON while voltage is abnormally high, controller continues operation with voltage at 100%
value.

Problem that
appears on • Engine speed cannot be controlled with fuel control dial.
machine

Related • Signal voltage of fuel control dial can be checked with monitoring function. (Code: 03000 Fuel control dial voltage)
information • Method of reproducing failure code: Turn starting switch ON.

Cause Standard value in normal state/Remarks on troubleshooting

Defective throttle sensor power

1 If failure code [CA2186] is also indicated, carry out troubleshooting for it first.
supply system

★ Prepare with starting switch OFF, then turn starting switch ON and carry
out troubleshooting.

E07 Voltage
2 Defective fuel control dial Between (1) – (3) Power supply 4.75 – 5.25 V

Voltage is measured with wiring harness connected. Accordingly, if voltage

is abnormal, check wiring harness and controller, too, for another cause of
trouble, and then judge.

★ Prepare with starting switch OFF, then carry out troubleshooting without
Ground fault in wiring harness turning starting switch ON.
3
Possible causes (Short circuit with GND circuit) Wiring harness between CE02 (female) (9) – E06 Resist- Min.
and standard (female) (2) ance 100 kΩ
value in normal
state ★ Prepare with starting switch OFF, then carry out troubleshooting without
turning starting switch ON.
Short circuit in wiring harness
4 Wiring harness between CE02 (female) (9) – E06
(with another wiring harness) Resist- Min.
(female) (2) and between CE02 (female) (23) –
ance 100 kΩ
E06 (female) (3)

Connecting parts between fuel control dial – machine wiring harness –

engine controller may be defective. Check them directly.
Defective wiring harness con-
5 • Looseness of connector, breakage of lock, or breakage of seal
nector
• Corrosion, bend, breakage, push-in, or expansion of pin
• Moisture or dirt in connector or defective insulation

★ Prepare with starting switch OFF, then turn starting switch ON and carry
out troubleshooting.
6 Defective engine controller
CE02 Voltage

Between (22) – (23) Power supply 4.75 – 5.25 V

20-326 PW148-8 VEBM720100

TESTING AND ADJUSTING Failure code [CA132] – Throttle sensor low error

Circuit diagram related to fuel control dial

A03 H15
(SWP-14) (090-22) E07 (M-3)

PW148-8 VEBM720100 20-327

Failure code [CA144] – Coolant temp sens high error TESTING AND ADJUSTING

Failure code [CA144] – Coolant temp sens high error

User code Failure code Coolant temperature sensor high error

Trouble
E15 CA144 (Engine controller system)

Contents of
• Signal circuit of coolant temperature sensor detected high voltage.
trouble

Action of
• Fixes coolant temperature value and continues operation.
controller

Problem that
• Exhaust gas becomes white.
appears on
• Overheat prevention function does not work.
machine

• Signal voltage of coolant temperature sensor can be checked with monitoring function. (Code: 04105 Coolant tem-
Related
perature sensor voltage)
information
• Method of reproducing failure code: Turn starting switch ON.

Cause Standard value in normal state/Remarks on troubleshooting

★ Prepare with starting switch OFF, then carry out troubleshooting without
turning starting switch ON.
Defective coolant temperature
1
sensor COOLANT TEMP (male) Resistance

Between (A) – (B) 0.18 – 160 kΩ

★ Prepare with starting switch OFF, then carry out troubleshooting without
turning starting switch ON.
Disconnection in wiring harness
Wiring harness between CE01 (female) (15) – Resist- Max.
2 (Disconnection in wiring or
COOLANT TEMP (female) (B) ance 10 Ω
defective contact in connector)
Wiring harness between CE01 (female) (38) – Resist- Max.
JC03 – COOLANT TEMP (female) (A) ance 10 Ω
Possible causes
and standard ★ Prepare with starting switch OFF, then carry out troubleshooting without
value in normal turning starting switch ON.
state Short circuit in wiring harness
3 Wiring harness between CE01 (female) (15) –
(with another wiring harness) Resist- Min.
each of CE01 (female) pins (With all wiring har-
ance 100 kΩ
ness connectors disconnected)

Connecting parts between coolant temperature sensor – engine wiring har-

ness – engine controller may be defective. Check them directly.
Defective wiring harness con-
4 • Looseness of connector, breakage of lock, or breakage of seal
nector
• Corrosion, bend, breakage, push-in, or expansion of pin
• Moisture or dirt in connector or defective insulation

★ Prepare with starting switch OFF, then carry out troubleshooting without
turning starting switch ON.
5 Defective engine controller
CE01 (female) Resistance

Between (15) – (38) 0.18 – 160 kΩ

20-328 PW148-8 VEBM720100

TESTING AND ADJUSTING Failure code [CA144] – Coolant temp sens high error

Circuit diagram related to coolant temperature sensor

PW148-8 VEBM720100 20-329

Failure code [CA145] – Coolant temp sens low error TESTING AND ADJUSTING

Failure code [CA145] – Coolant temp sens low error

User code Failure code Coolant temperature sensor low error

Trouble
E15 CA145 (Engine controller system)

Contents of
• Signal circuit of coolant temperature sensor detected low voltage.
trouble

Action of
• Fixes coolant temperature value and continues operation.
controller

Problem that
• Exhaust gas becomes white.
appears on
• Overheat prevention function does not work.
machine

• Signal voltage of coolant temperature sensor can be checked with monitoring function. (Code: 04105 Coolant tem-
Related
perature sensor voltage)
information
• Method of reproducing failure code: Turn starting switch ON.

Cause Standard value in normal state/Remarks on troubleshooting

★ Prepare with starting switch OFF, then carry out troubleshooting without
turning starting switch ON.
Defective coolant temperature COOLANT TEMP (male) Resistance
1
sensor
Between (A) – (B) 0.18 – 160 kΩ

Between (B) – chassis ground Min. 100 kΩ

★ Prepare with starting switch OFF, then carry out troubleshooting without
Ground fault in wiring harness turning starting switch ON.
2
(Short circuit with GND circuit) Wiring harness between CE01 (female) (15) – Resist- Min.
COOLANT TEMP (female) (B) ance 100 kΩ

Possible causes ★ Prepare with starting switch OFF, then carry out troubleshooting without
and standard turning starting switch ON.
Short circuit in wiring harness
value in normal 3
(with another wiring harness) Wiring harness between CE01 (female) (15) –
state Resist- Min.
each of CE01 (female) pins (With all wiring har-
ance 100 kΩ
ness connectors disconnected)

Connecting parts between coolant temperature sensor – engine wiring har-

ness – engine controller may be defective. Check them directly.
Defective wiring harness
4 • Looseness of connector, breakage of lock, or breakage of seal
connector
• Corrosion, bend, breakage, push-in, or expansion of pin
• Moisture or dirt in connector or defective insulation

★ Prepare with starting switch OFF, then carry out troubleshooting without
turning starting switch ON.

5 Defective engine controller CE01 (female) Resistance

Between (15) – (38) 0.18 – 160 kΩ

Between (15) – chassis ground Min. 100 kΩ

20-330 PW148-8 VEBM720100

TESTING AND ADJUSTING Failure code [CA145] – Coolant temp sens low error

Circuit diagram related to coolant temperature sensor

PW148-8 VEBM720100 20-331

Failure code [CA153] – Chg air temp sensor high error TESTING AND ADJUSTING

Failure code [CA153] – Chg air temp sensor high error

User code Failure code Charge air temperature sensor high error
Trouble
E15 CA153 (Engine controller system)

Contents of
• Temperature signal circuit of boost pressure/temperature sensor detected high voltage.
trouble

Action of
• Fixes charge temperature value and continues operation.
controller

Problem that
• Exhaust gas becomes white.
appears on
• Engine protection function based on boost temperature does not work
machine

• Signal voltage on boost temperature side of boost pressure/temperature sensor can be checked with monitoring
Related
function. (Code: 18501 Boost temperature sensor voltage)
information
• Method of reproducing failure code: Turn starting switch ON.

Cause Standard value in normal state/Remarks on troubleshooting

★ Prepare with starting switch OFF, then carry out troubleshooting without
Defective boost pressure/ turning starting switch ON.
1 temperature sensor
BOOST PRESS & IMT (male) Resistance
[temperature signal system]
Between (2) – (1) 0.18 – 160 kΩ

★ Prepare with starting switch OFF, then carry out troubleshooting without
turning starting switch ON.
Disconnection in wiring harness
Wiring harness between CE01 (female) (23) – Resist- Max.
2 (Disconnection in wiring or
BOOST PRESS & IMT (female) (2) ance 10 Ω
defective contact in connector)
Wiring harness between CE01 (female) (47) – Resist- Max.
JC02 – BOOST PRESS & IMT (female) (1) ance 10 Ω
Possible causes
and standard ★ Prepare with starting switch OFF, then carry out troubleshooting without
value in normal turning starting switch ON.
state Short circuit in wiring harness
3 Wiring harness between CE01 (female) (23) –
(with another wiring harness) Resist- Min.
each of CE01 (female) pins (With all wiring har-
ance 100 kΩ
ness connectors disconnected)

Connecting parts between boost pressure/temperature sensor – engine wir-

ing harness – engine controller may be defective. Check them directly.
Defective wiring harness
4 • Looseness of connector, breakage of lock, or breakage of seal
connector
• Corrosion, bend, breakage, push-in, or expansion of pin
• Moisture or dirt in connector or defective insulation

★ Prepare with starting switch OFF, then carry out troubleshooting without
turning starting switch ON.
5 Defective engine controller
CE01 (female) Resistance

Between (23) – (47) 0.18 – 160 kΩ

20-332 PW148-8 VEBM720100

TESTING AND ADJUSTING Failure code [CA153] – Chg air temp sensor high error

Circuit diagram related to boost pressure/temperature sensor (combina-

tion sensor)

PW148-8 VEBM720100 20-333

Failure code [CA154] – Chg air temp sensor low error TESTING AND ADJUSTING

Failure code [CA154] – Chg air temp sensor low error

User code Failure code Charge air temperature sensor low error
Trouble
E15 CA154 (Engine controller system)

Contents of
• Temperature signal circuit of boost pressure/temperature sensor detected low voltage.
trouble

Action of
• Fixes charge temperature value and continues operation.
controller

Problem that
• Exhaust gas becomes white.
appears on
• Engine protection function based on boost temperature does not work
machine

• Signal voltage on boost temperature side of boost pressure/temperature sensor can be checked with monitoring
Related
function. (Code: 18501 Boost temperature sensor voltage)
information
• Method of reproducing failure code: Turn starting switch ON.

Cause Standard value in normal state/Remarks on troubleshooting

★ Prepare with starting switch OFF, then carry out troubleshooting without
turning starting switch ON.
Defective boost pressure/tem-
1 perature sensor [temperature BOOST PRESS & IMT (male) Resistance
signal system] Between (2) – (1) 0.18 – 160 kΩ

Between (2) – chassis ground Min. 100 kΩ

★ Prepare with starting switch OFF, then carry out troubleshooting without
Ground fault in wiring harness turning starting switch ON.
2
(Short circuit with GND circuit) Wiring harness between CE01 (female) (23) – Resist- Min.
BOOST PRESS & IMT (female) (2) ance 100 kΩ

Possible causes ★ Prepare with starting switch OFF, then carry out troubleshooting without
and standard turning starting switch ON.
value in normal Short circuit in wiring harness
3 Wiring harness between CE01 (female) (23) –
(with another wiring harness) Resist- Min.
state
each of CE01 (female) pins (With all wiring har-
ance 100 kΩ
ness connectors disconnected)

Connecting parts between boost pressure/temperature sensor – engine wir-

ing harness – engine controller may be defective. Check them directly.
Defective wiring harness
4 • Looseness of connector, breakage of lock, or breakage of seal
connector
• Corrosion, bend, breakage, push-in, or expansion of pin
• Moisture or dirt in connector or defective insulation

★ Prepare with starting switch OFF, then carry out troubleshooting without
turning starting switch ON.

5 Defective engine controller CE01 (female) Resistance

Between (23) – (47) 0.18 – 160 kΩ

Between (23) – chassis ground Min. 100 kΩ

20-334 PW148-8 VEBM720100

TESTING AND ADJUSTING Failure code [CA154] – Chg air temp sensor low error

Circuit diagram related to boost pressure/temperature sensor (combina-

tion sensor)

PW148-8 VEBM720100 20-335

Failure code [CA155] – Chg air temp high speed derate TESTING AND ADJUSTING

Failure code [CA155] – Chg air temp high speed derate

User code Failure code Charge air temperature high speed derate
Trouble
E11 CA155 (Engine controller system)

Contents of
• Temperature signal of boost pressure/temperature sensor exceeded control upper temperature limit.
trouble

Action of
• Limits output and continues operation.
controller

Problem that
• Engine output lowers.
appears on
• Engine stops.
machine

Related • Boost temperature can be checked with monitoring function. (Code: 18500 Boost temperature)
information • Method of reproducing failure code: Start engine

Cause Standard value in normal state/Remarks on troubleshooting

Cooling performance of aftercooler may be low. Check following points

directly.
Lowering of cooling perform-
Possible causes 1 • Looseness and breakage of fan belt.
ance of aftercooler
and standard • Insufficiency of cooling air
value in normal • Clogging of aftercooler fins
state Abnormal rise of turbocharger Outlet temperature of turbocharger may be abnormally high. Check related
2
outlet temperature parts directly.

If causes 1 – 2 are not detected, engine controller may be defective. (Since

3 Defective engine controller
trouble is in system, troubleshooting cannot be carried out.)

20-336 PW148-8 VEBM720100

TESTING AND ADJUSTING Failure code [CA155] – Chg air temp high speed derate

Blank for technical reason

PW148-8 VEBM720100 20-337

Failure code [CA187] – Sens supply 2 volt low error TESTING AND ADJUSTING

Failure code [CA187] – Sens supply 2 volt low error

User code Failure code Sensor power supply 2 voltage low error
Trouble
E15 CA187 (Engine controller system)

Contents of
• Low voltage was detected in sensor power supply 2 circuit.
trouble

• Fixes boost pressure value and continues operation.

Action of
• Fixes charge temperature value and continues operation.
controller
• Limits output and continues operation.

Problem that
appears on • Engine output lowers.
machine

Related
• Method of reproducing failure code: Turn starting switch ON.
information

Cause Standard value in normal state/Remarks on troubleshooting

★ Disconnect connector with starting switch OFF, then turn starting switch
ON and carry out troubleshooting.

Disconnect sensors Boost pressure/tem-

BOOST PRESS & IMT
and wiring harness at perature sensor
right in order and carry
Defective sensor or wiring out operation to repro- Common rail pressure
1 FUEL RAIL PRESS
harness duce trouble. If "E" of sensor
failure code goes off
Possible causes
when a sensor or wir-
and standard G sensor CAM SENSOR
ing harness is discon-
value in normal
nected, that sensor or
state
wiring harness is
defective. Engine wiring harness CE01

Connecting parts between each sensor – engine wiring harness – engine

controller may be defective. Check them directly.
Defective wiring harness
2 • Looseness of connector, breakage of lock, or breakage of seal
connector
• Corrosion, bend, breakage, push-in, or expansion of pin
• Moisture or dirt in connector or defective insulation

If causes 1 – 2 are not detected, engine controller may be defective.

3 Defective engine controller
(Since trouble is in system, troubleshooting cannot be carried out.)

20-338 PW148-8 VEBM720100

TESTING AND ADJUSTING Failure code [CA187] – Sens supply 2 volt low error

Circuit diagram related to sensor power supply 2

PW148-8 VEBM720100 20-339

Failure code [CA221] – Ambient press sens high error TESTING AND ADJUSTING

Failure code [CA221] – Ambient press sens high error

User code Failure code Ambient pressure sensor high error

Trouble
E15 CA221 (Engine controller system)

Contents of
• High voltage was detected in signal circuit of ambient pressure sensor.
trouble

Action of
• Fixes ambient pressure value and continues operation.
controller

Problem that
• Engine does not start easily.
appears on
• Engine output lowers.
machine

• Signal voltage of ambient pressure sensor can be checked with monitoring function. (Code: 37401 Ambient pres-
Related
sure sensor voltage
information
• Method of reproducing failure code: Turn starting switch ON.

Cause Standard value in normal state/Remarks on troubleshooting

Defective sensor power supply

1 If failure code [CA386] is also indicated, carry out troubleshooting for it first.
1 system

★ Prepare with starting switch OFF, then turn starting switch ON and carry
out troubleshooting.

AMBIENT PRESURE Voltage

Defective ambient pressure
2 Between (1) – (2) Power supply 4.75 – 5.25V
sensor
Voltage is measured with wiring harness connected. Accordingly, if voltage
is abnormal, check wiring harness and controller, too, for another cause of
trouble, and then judge.

★ Prepare with starting switch OFF, then turn starting switch ON and carry
Hot short (Short circuit with 5V/ out troubleshooting.
3
24V circuit) in wiring harness Wiring harness between CE01 (female) (3) –
Possible causes Voltage Max. 1 V
and standard AMBIENT PRESSURE (female) (3)
value in normal
★ Prepare with starting switch OFF, then carry out troubleshooting without
state turning starting switch ON.
Short circuit in wiring harness Wiring harness between CE01 (female) (3) –
4
(with another wiring harness) AMBIENT PRESSURE (female) (3) and between Resist- Min.
CE01 (female) (33) – AMBIENT PRESSURE ance 100 kΩ
(female) (1)

Connecting parts between ambient pressure sensor – engine wiring harness

– engine controller may be defective. Check them directly.
Defective wiring harness
5 • Looseness of connector, breakage of lock, or breakage of seal
connector
• Corrosion, bend, breakage, push-in, or expansion of pin
• Moisture or dirt in connector or defective insulation

★ Prepare with starting switch OFF, then turn starting switch ON and carry
out troubleshooting.
6 Defective engine controller
CE01 Voltage

Between (33) – (38) Voltage 4.75 – 5.25 V

20-340 PW148-8 VEBM720100

TESTING AND ADJUSTING Failure code [CA221] – Ambient press sens high error

Circuit diagram related to ambient pressure sensor

PW148-8 VEBM720100 20-341

Failure code [CA222] – Ambient press sens low error TESTING AND ADJUSTING

Failure code [CA222] – Ambient press sens low error

User code Failure code Ambient pressure sensor low error

Trouble
E15 CA222 (Engine controller system)

Contents of
• Low voltage was detected in signal circuit of ambient pressure sensor.
trouble

Action of
• Fixes ambient pressure value and continues operation.
controller

Problem that
• Engine does not start easily.
appears on
• Engine output lowers.
machine

• Signal voltage of ambient pressure sensor can be checked with monitoring function. (Code: 37401 Ambient pres-
Related
sure sensor voltage
information
• Method of reproducing failure code: Turn starting switch ON.

Cause Standard value in normal state/Remarks on troubleshooting

Defective sensor power supply

1 If failure code [CA352] is also indicated, carry out troubleshooting for it first.
1 system

★ Prepare with starting switch OFF, then turn starting switch ON and carry
out troubleshooting.

AMBIENT PRESURE Voltage

Defective ambient pressure
2 Between (1) – (2) Power supply 4.75 – 5.25V
sensor
Voltage is measured with wiring harness connected. Accordingly, if voltage
is abnormal, check wiring harness and controller, too, for another cause of
trouble, and then judge.

★ Prepare with starting switch OFF, then carry out troubleshooting without
Ground fault in wiring harness turning starting switch ON.
3
(Short circuit with GND circuit) Wiring harness between CE01 (female) (3) – Resist- Min.
Possible causes
and standard AMBIENT PRESSURE (female) (3) ance 100 kΩ
value in normal
★ Prepare with starting switch OFF, then carry out troubleshooting without
state turning starting switch ON.
Short circuit in wiring harness Wiring harness between CE01 (female) (3) –
4
(with another wiring harness) AMBIENT PRESSURE (female) (3) and between Resist- Min.
CE01 (female) (38) – JC03 – AMBIENT PRES- ance 100 kΩ
SURE (female) (2)

Connecting parts between ambient pressure sensor – engine wiring harness

– engine controller may be defective. Check them directly.
Defective wiring harness
5 • Looseness of connector, breakage of lock, or breakage of seal
connector
• Corrosion, bend, breakage, push-in, or expansion of pin
• Moisture or dirt in connector or defective insulation

★ Prepare with starting switch OFF, then turn starting switch ON and carry
out troubleshooting.
6 Defective engine controller
CE01 Voltage

Between (33) – (38) Voltage 4.75 – 5.25 V

20-342 PW148-8 VEBM720100

TESTING AND ADJUSTING Failure code [CA222] – Ambient press sens low error

Circuit diagram related to ambient pressure sensor

PW148-8 VEBM720100 20-343

Failure code [CA227] – Sens supply 2 volt high error TESTING AND ADJUSTING

Failure code [CA227] – Sens supply 2 volt high error

User code Failure code Sensor power supply 2 voltage high error
Trouble
E15 CA227 (Engine controller system)

Contents of
• High voltage was detected in sensor power supply 2 circuit.
trouble

• Fixes boost pressure value and continues operation.

Action of
• Fixes charge temperature value and continues operation.
controller
• Limits output and continues operation.

Problem that
appears on • Engine output lowers.
machine

Related
• Method of reproducing failure code: Turn starting switch ON.
information

Cause Standard value in normal state/Remarks on troubleshooting

Connecting parts between each sensor – engine wiring harness – engine

Possible causes controller may be defective. Check them directly.
Defective wiring harness
and standard 1 • Looseness of connector, breakage of lock, or breakage of seal
connector
value in normal • Corrosion, bend, breakage, push-in, or expansion of pin
state • Moisture or dirt in connector or defective insulation

If cause 1 is not detected, engine controller may be defective. (Since trouble

2 Defective engine controller
is in system, troubleshooting cannot be carried out.)

Circuit diagram related to sensor power supply 2

20-344 PW148-8 VEBM720100

TESTING AND ADJUSTING Failure code [CA234] – Eng overspeed

Failure code [CA234] – Eng overspeed

User code Failure code Engine overspeed

Trouble
— CA234 (Engine controller system)

Contents of
• Engine speed exceeded control upper speed limit.
trouble

Action of
• Stops injection until engine speed lowers to normal level.
controller

Problem that
appears on • Engine speed fluctuates.
machine

Related • Engine speed can be checked with monitoring function. (Code: 01002 Engine speed)
information • Method of reproducing failure code: Run engine at high idle.

Cause Standard value in normal state/Remarks on troubleshooting

Possible causes 1 Use of improper fuel Fuel used may be improper. Check it directly.
and standard
value in normal 2 Improper use Machine may be used improperly. Teach operator proper using method.
state If cause 1 is not detected, engine controller may be defective. (Since trouble
3 Defective engine controller
is in system, troubleshooting cannot be carried out.)

PW148-8 VEBM720100 20-345

Failure code [CA238] – Ne speed sens supply volt error TESTING AND ADJUSTING

Failure code [CA238] – Ne speed sens supply volt error

User code Failure code Ne speed sensor power supply voltage error
Trouble
E15 CA238 (Engine controller system)

Contents of
• Low voltage was detected in power supply circuit of engine Ne speed sensor.
trouble

Action of
• Continues control with signal from engine Bkup speed sensor.
controller

Problem that
• Engine does not start easily.
appears on
• Engine hunts.
machine

Related
• Method of reproducing failure code: Turn starting switch ON.
information

Cause Standard value in normal state/Remarks on troubleshooting

Disconnect connector with starting switch OFF, then turn starting switch ON
and carry out troubleshooting.

Disconnect sensor and

wiring harness at right
in order and carry out Ne speed sensor CRANK SENSOR
Defective sensor or wiring operation to repro-
1 duce trouble. If "E" of
Possible causes harness
and standard failure code goes off
value in normal when sensor or wiring
state harness is discon-
nected, that sensor or Engine wiring harness CE01
wiring harness is
defective.

Connecting parts between each sensor – engine wiring harness – engine

controller may be defective. Check them directly.
Defective wiring harness
2 • Looseness of connector, breakage of lock, or breakage of seal
connector
• Corrosion, bend, breakage, push-in, or expansion of pin
• Moisture or dirt in connector or defective insulation

Circuit diagram related to engine Ne speed sensor

20-346 PW148-8 VEBM720100

TESTING AND ADJUSTING Failure code [CA271] – IMV/PCV1 short error

Failure code [CA271] – IMV/PCV1 short error

User code Failure code IMV/PCV1 short circuit error
Trouble
E11 CA271 (Engine controller system)

Contents of
• Short circuit was detected in drive circuit of supply pump actuator.
trouble

Action of
• None in particular.
controller

Problem that • Engine speed does not rise from low idle.
appears on • Engine output lowers.
machine • Common rail fuel pressure rises above command value.

Related
• Method of reproducing failure code: Turn starting switch ON.
information

Cause Standard value in normal state/Remarks on troubleshooting

★ Prepare with starting switch OFF, then carry out troubleshooting without
turning starting switch ON.
1 Defective supply pump actuator
CP3 PUMP REGULATOR (male) Resistance

Between (1) – chassis ground Min. 100 kΩ

★ Prepare with starting switch OFF, then carry out troubleshooting without
Ground fault in wiring harness turning starting switch ON.
2
(Short circuit with GND circuit) Wiring harness between CE01 (female) (2) – CP3 Resist- Min.
PUMP REGULATOR (female) (1) ance 100 kΩ

Possible causes ★ Prepare with starting switch OFF, then carry out troubleshooting without
and standard turning starting switch ON.
Short circuit in wiring harness
value in normal 3
(with another wiring harness) Wiring harness between CE01 (female) (2) –
state Resist- Min.
each of CE01 (female) pins (With all wiring har-
ance 100 kΩ
ness connectors disconnected)

Connecting parts between supply pump actuator – engine wiring harness –

engine controller may be defective. Check them directly.
Defective wiring harness
4 • Looseness of connector, breakage of lock, or breakage of seal
connector
• Corrosion, bend, breakage, push-in, or expansion of pin
• Moisture or dirt in connector or defective insulation

★ Prepare with starting switch OFF, then carry out troubleshooting without
turning starting switch ON.
5 Defective engine controller
CE01 (female) Resistance

Between (2) – chassis ground Min. 100 kΩ

Circuit diagram related to supply pump actuator (metering unit)

PW148-8 VEBM720100 20-347

Failure code [CA272] – IMV/PCV1 open error TESTING AND ADJUSTING

Failure code [CA272] – IMV/PCV1 open error

User code Failure code IMV/PCV1 open error
Trouble
E11 CA272 (Engine controller system)

Contents of
• Opening was detected in drive circuit of supply pump actuator.
trouble
Action of
• None in particular.
controller
Problem that
• Engine runs but its operation is unstable.
appears on
• Common rail fuel pressure rises above command value.
machine
Related
• Method of reproducing failure code: Turn starting switch ON.
information

Cause Standard value in normal state/Remarks on troubleshooting

Defective supply pump
1
actuator
Disconnection in wiring
harness (Disconnection in
2 Resistance
wiring or defective contact
in connector)
Hot short (Short circuit with
Possible causes 3 24V circuit) in wiring har-
ness
and standard value
in normal state
Short circuit in wiring
4 harness (with another
wiring harness)
Defective wiring harness
5 • Looseness of connector, breakage of lock, or breakage of seal
connector
6 Defective engine controller
★ Prepare with starting switch OFF, then carry out troubleshooting without turn-
ing starting switch ON.
CP3 PUMP REGULATOR (male) Resistance
Between (1) – (2) Max. 5 Ω
★ Prepare with starting switch OFF, then carry out troubleshooting without turn-
ing starting switch ON.
Wiring harness between CE01 (female) (2) – CP3
Max. 10 Ω
PUMP REGULATOR (female) (1)
Wiring harness between CE01 (female) (32) – CP3
Resistance Max. 10 Ω
PUMP REGULATOR (female) (2)
★ Prepare with starting switch OFF, then turn starting switch ON and carry out
troubleshooting.
Wiring harness between CE01 (female) (2) – CP3
Voltage Max. 3 V
PUMP REGULATOR (female) (1)
★ Prepare with starting switch OFF, then carry out troubleshooting without turn-
ing starting switch ON.
Wiring harness between CE01 (female) (2) – each of
Min.
CE01 (female) pins (With all wiring harness connec- Resistance
100 kΩ
tors disconnected)
Connecting parts between supply pump actuator – engine wiring harness – engine
controller may be defective. Check them directly.
• Corrosion, bend, breakage, push-in, or expansion of pin
• Moisture or dirt in connector or defective insulation
★ Prepare with starting switch OFF, then carry out troubleshooting without turn-
ing starting switch ON.
CE01 (female) Resistance
Between (2) – (32) Max. 5 Ω

Circuit diagram related to supply pump actuator (metering unit)

20-348 PW148-8 VEBM720100

TESTING AND ADJUSTING Failure code [CA272] – IMV/PCV1 open error

Blank for technical reason

PW148-8 VEBM720100 20-349

Failure code [CA322] – Inj #1 (L#1) open/short error TESTING AND ADJUSTING

Failure code [CA322] – Inj #1 (L#1) open/short error

User code Failure code Injector #1 (L#1) open/short circuit error

Trouble
E11 CA322 (Engine controller system)

Contents of
• Opening or short circuit was detected in drive circuit of No. 1 injector.
trouble

Action of
• None in particular.
controller

Problem that
• Combustion becomes irregular or engine hunts.
appears on
• Engine output lowers.
machine

Related
• Method of reproducing failure code: Start engine.
information

Cause Standard value in normal state/Remarks on troubleshooting

If following failure codes are also displayed, trouble is in engine controller.

1 Defective engine controller
[CA322], [CA324], [CA331]

★ Prepare with starting switch OFF, then carry out troubleshooting without
turning starting switch ON.

2 Defective No. 1 injector INJ CYL 1 (male) Resistance

Between (1) – (2) Max. 2 Ω

Between (1) – chassis ground Min. 100 kΩ

★ Prepare with starting switch OFF, then carry out troubleshooting without
turning starting switch ON.
Disconnection in wiring harness
Wiring harness between CE01 (female) (45) – INJ Resist-
3 (Disconnection in wiring or Max. 2 Ω
CYL 1 (female) (1) ance
defective contact in connector)
Wiring harness between CE01 (female) (53) – INJ Resist-
Max. 2 Ω
CYL 1 (female) (2) ance

★ Prepare with starting switch OFF, then carry out troubleshooting without
Ground fault in wiring harness turning starting switch ON.
Possible causes 4
(Short circuit with GND circuit) Wiring harness between CE01 (female) (45) – INJ Resist-
and standard Max. 2 Ω
CYL 1 (female) (1) ance
value in normal
state ★ Prepare with starting switch OFF, then carry out troubleshooting without
turning starting switch ON.

Wiring harness between CE01 (female) (45) –

Resist- Min.
Short circuit in wiring harness each of CE01 (female) pins (With all wiring har-
5 ance 100 kΩ
(with another wiring harness) ness connectors disconnected)

Wiring harness between CE01 (female) (53) –

Resist- Min.
each of CE01 (female) pins (With all wiring har-
ance 100 kΩ
ness connectors disconnected)

Connecting parts between No. 1 injector – engine wiring harness – engine

controller may be defective. Check them directly.
Defective wiring harness
6 • Looseness of connector, breakage of lock, or breakage of seal
connector
• Corrosion, bend, breakage, push-in, or expansion of pin
• Moisture or dirt in connector or defective insulation

★ Prepare with starting switch OFF, then carry out troubleshooting without
turning starting switch ON.

7 Defective engine controller CE01 (female) Resistance

Between (45) – (53) Max. 2 Ω

Between (45) – chassis ground Min. 100 kΩ

20-350 PW148-8 VEBM720100

TESTING AND ADJUSTING Failure code [CA322] – Inj #1 (L#1) open/short error

Circuit diagram related to no. 1 injector

PW148-8 VEBM720100 20-351

Failure code [CA324] – Inj #3 (L#3) open/short error TESTING AND ADJUSTING

Failure code [CA324] – Inj #3 (L#3) open/short error

User code Failure code Injector #3 (L#3) open/short circuit error

Trouble
E11 CA324 (Engine controller system)

Contents of
• Opening or short circuit was detected in drive circuit of No. 3 injector.
trouble

Action of
• None in particular.
controller

Problem that
• Combustion becomes irregular or engine hunts.
appears on
• Engine output lowers.
machine

Related
• Method of reproducing failure code: Start engine.
information

Cause Standard value in normal state/Remarks on troubleshooting

If following failure codes are also displayed, trouble is in engine controller.

1 Defective engine controller
[CA322], [CA324], [CA331]

★ Prepare with starting switch OFF, then carry out troubleshooting without
turning starting switch ON.

2 Defective No. 3 injector INJ CYL 3 (male) Resistance

Between (1) – (2) Max. 2 Ω

Between (1) – chassis ground Min. 100 kΩ

★ Prepare with starting switch OFF, then carry out troubleshooting without
turning starting switch ON.
Disconnection in wiring harness
Wiring harness between CE01 (female) (55) – INJ Resist-
3 (Disconnection in wiring or Max. 2 Ω
CYL 3 (female) (1) ance
defective contact in connector)
Wiring harness between CE01 (female) (52) – INJ Resist-
Max. 2 Ω
CYL 3 (female) (2) ance

★ Prepare with starting switch OFF, then carry out troubleshooting without
Ground fault in wiring harness turning starting switch ON.
Possible causes 4
(Short circuit with GND circuit) Wiring harness between CE01 (female) (55) – INJ Resist-
and standard Max. 2 Ω
CYL 3 (female) (1) ance
value in normal
state ★ Prepare with starting switch OFF, then carry out troubleshooting without
turning starting switch ON.

Wiring harness between CE01 (female) (55) –

Resist- Min.
Short circuit in wiring harness each of CE01 (female) pins (With all wiring har-
5 ance 100 kΩ
(with another wiring harness) ness connectors disconnected)

Wiring harness between CE01 (female) (52) –

Resist- Min.
each of CE01 (female) pins (With all wiring har-
ance 100 kΩ
ness connectors disconnected)

Connecting parts between No. 3 injector – engine wiring harness – engine

controller may be defective. Check them directly.
Defective wiring harness
6 • Looseness of connector, breakage of lock, or breakage of seal
connector
• Corrosion, bend, breakage, push-in, or expansion of pin
• Moisture or dirt in connector or defective insulation

★ Prepare with starting switch OFF, then carry out troubleshooting without
turning starting switch ON.

7 Defective engine controller CE01 (female) Resistance

Between (55) – (52) Max. 2 Ω

Between (55) – chassis ground Min. 100 kΩ

20-352 PW148-8 VEBM720100

TESTING AND ADJUSTING Failure code [CA324] – Inj #3 (L#3) open/short error

Circuit diagram related to no. 3 injector

PW148-8 VEBM720100 20-353

Failure code [CA331] – Inj #2 (L#2) open/short error TESTING AND ADJUSTING

Failure code [CA331] – Inj #2 (L#2) open/short error

User code Failure code Injector #2 (L#2) open/short circuit error

Trouble
E11 CA331 (Engine controller system)

Contents of
• Opening or short circuit was detected in drive circuit of No. 2 injector.
trouble

Action of
• None in particular.
controller

Problem that
• Combustion becomes irregular or engine hunts.
appears on
• Engine output lowers.
machine

Related
• Method of reproducing failure code: Start engine.
information

Cause Standard value in normal state/Remarks on troubleshooting

If following failure codes are also displayed, trouble is in engine controller.

1 Defective engine controller
[CA322], [CA324], [CA331]

★ Prepare with starting switch OFF, then carry out troubleshooting without
turning starting switch ON.

2 Defective No. 2 injector INJ CYL 2 (male) Resistance

Between (1) – (2) Max. 2 Ω

Between (1) – chassis ground Min. 100 kΩ

★ Prepare with starting switch OFF, then carry out troubleshooting without
turning starting switch ON.
Disconnection in wiring harness
Wiring harness between CE01 (female) (54) – INJ Resist-
3 (Disconnection in wiring or Max. 2 Ω
CYL 2 (female) (1) ance
defective contact in connector)
Wiring harness between CE01 (female) (51) – INJ Resist-
Max. 2 Ω
CYL 2 (female) (2) ance

★ Prepare with starting switch OFF, then carry out troubleshooting without
Ground fault in wiring harness turning starting switch ON.
Possible causes 4
(Short circuit with GND circuit) Wiring harness between CE01 (female) (54) – INJ Resist-
and standard Max. 2 Ω
CYL 2 (female) (1) ance
value in normal
state ★ Prepare with starting switch OFF, then carry out troubleshooting without
turning starting switch ON.

Wiring harness between CE01 (female) (54) –

Resist- Min.
Short circuit in wiring harness each of CE01 (female) pins (With all wiring har-
5 ance 100 kΩ
(with another wiring harness) ness connectors disconnected)

Wiring harness between CE01 (female) (51) –

Resist- Min.
each of CE01 (female) pins (With all wiring har-
ance 100 kΩ
ness connectors disconnected)

Connecting parts between No. 2 injector – engine wiring harness – engine

controller may be defective. Check them directly.
Defective wiring harness
6 • Looseness of connector, breakage of lock, or breakage of seal
connector
• Corrosion, bend, breakage, push-in, or expansion of pin
• Moisture or dirt in connector or defective insulation

★ Prepare with starting switch OFF, then carry out troubleshooting without
turning starting switch ON.

7 Defective engine controller CE01 (female) Resistance

Between (54) – (51) Max. 2 Ω

Between (54) – chassis ground Min. 100 kΩ

20-354 PW148-8 VEBM720100

TESTING AND ADJUSTING Failure code [CA331] – Inj #2 (L#2) open/short error

Circuit diagram related to no. 2 injector

PW148-8 VEBM720100 20-355

Failure code [CA332] – Inj #4 (L#4) open/short error TESTING AND ADJUSTING

Failure code [CA332] – Inj #4 (L#4) open/short error

User code Failure code Injector #4 (L#4) open/short circuit error

Trouble
E11 CA332 (Engine controller system)

Contents of
• Opening or short circuit was detected in drive circuit of No. 4 injector.
trouble

Action of
• None in particular.
controller

Problem that
• Combustion becomes irregular or engine hunts.
appears on
• Engine output lowers.
machine

Related
• Method of reproducing failure code: Start engine.
information

Cause Standard value in normal state/Remarks on troubleshooting

If following failure codes are also displayed, trouble is in engine controller.

1 Defective engine controller
[CA323], [CA325], [CA332]

★ Prepare with starting switch OFF, then carry out troubleshooting without
turning starting switch ON.

2 Defective No. 4 injector INJ CYL 4 (male) Resistance

Between (1) – (2) Max. 2 Ω

Between (1) – chassis ground Min. 100 kΩ

★ Prepare with starting switch OFF, then carry out troubleshooting without
turning starting switch ON.
Disconnection in wiring harness
Wiring harness between CE01 (female) (56) – INJ Resist-
3 (Disconnection in wiring or Max. 2 Ω
CYL 4 (female) (1) ance
defective contact in connector)
Wiring harness between CE01 (female) (58) – INJ Resist-
Max. 2 Ω
CYL 4 (female) (2) ance

★ Prepare with starting switch OFF, then carry out troubleshooting without
Ground fault in wiring harness turning starting switch ON.
Possible causes 4
(Short circuit with GND circuit) Wiring harness between CE01 (female) (56) – INJ Resist-
and standard Max. 2 Ω
CYL 4 (female) (1) ance
value in normal
state ★ Prepare with starting switch OFF, then carry out troubleshooting without
turning starting switch ON.

Wiring harness between CE01 (female) (56) –

Resist- Min.
Short circuit in wiring harness each of CE01 (female) pins (With all wiring har-
5 ance 100 kΩ
(with another wiring harness) ness connectors disconnected)

Wiring harness between CE01 (female) (58) –

Resist- Min.
each of CE01 (female) pins (With all wiring har-
ance 100 kΩ
ness connectors disconnected)

Connecting parts between No. 4 injector – engine wiring harness – engine

controller may be defective. Check them directly.
Defective wiring harness
6 • Looseness of connector, breakage of lock, or breakage of seal
connector
• Corrosion, bend, breakage, push-in, or expansion of pin
• Moisture or dirt in connector or defective insulation

★ Prepare with starting switch OFF, then carry out troubleshooting without
turning starting switch ON.

7 Defective engine controller CE01 (female) Resistance

Between (56) – (58) Max. 2 Ω

Between (56) – chassis ground Min. 100 kΩ

20-356 PW148-8 VEBM720100

TESTING AND ADJUSTING Failure code [CA332] – Inj #4 (L#4) open/short error

Circuit diagram related to no. 4 injector

PW148-8 VEBM720100 20-357

Failure code [CA342] – Calibration code incompatibility TESTING AND ADJUSTING

Failure code [CA342] – Calibration code incompatibility

User code Failure code Calibration code incompatibility

Trouble
E10 CA342 (Engine controller system)

Contents of
• Incompatibility of data occurred in engine controller.
trouble

Action of
• None in particular.
controller

Problem that
• Continues normal operation.
appears on
• Engine stops or does not start.
machine

Related
• Method of reproducing failure code: Turn starting switch ON.
information

Possible causes Cause Standard value in normal state/Remarks on troubleshooting

and standard
1 Defect in related system If another failure code is displayed, carry out troubleshooting for it.
value in normal
state 2 Defective engine controller Engine controller may be defective. (Troubleshooting cannot be carried out.)

20-358 PW148-8 VEBM720100

TESTING AND ADJUSTING Failure code [CA342] – Calibration code incompatibility

Blank for technical reason

PW148-8 VEBM720100 20-359

Failure code [CA351] – Injectors drive circuit error TESTING AND ADJUSTING

Failure code [CA351] – Injectors drive circuit error

User code Failure code Injectors Drive Circuit Error

Trouble
E10 CA351 (Engine controller system)

Contents of
• There is error in drive power circuit of injector.
trouble

Action of
• Limits output and continues operation.
controller

• Exhaust gas becomes black.

Problem that
• Combustion becomes irregular.
appears on
• Engine output lowers.
machine
• Engine cannot be started.

Related
• Method of reproducing failure code: Start engine.
information

Cause Standard value in normal state/Remarks on troubleshooting

1 Defect in related system If another failure code is displayed, carry out troubleshooting for it.

2 Defective fuse No. 19 If fuse is broken, circuit probably has ground fault.

★ Prepare with starting switch OFF, then turn starting switch ON and carry
out troubleshooting.
Defective relay for engine
3 Replace relay (R03, R04) for engine controller with another relay and per-
controller power supply
form reproducing operation. If "E" of failure code goes off at this time,
Possible causes replaced relay is defective.
and standard ★ Prepare with starting switch OFF, then carry out troubleshooting without
value in normal turning starting switch ON.
state
Wiring harness between FB1-19 – R03, R04 Resist- Max.
Disconnection in wiring harness (female) (3) ance 0.5 Ω
4 (Disconnection in wiring or
defective contact in connector) Wiring harness between R03, R04 (female) (5) – Resist- Max.
CE03 (female) (3) ance 0.5 Ω

Wiring harness between CE03 (female) (1) – Resist- Max.

chassis ground (A65) ance 10 Ω

If causes 1 – 4 are not detected, engine controller may be defective. (Since

5 Defective engine controller
trouble is in system, troubleshooting cannot be carried out.)

20-360 PW148-8 VEBM720100

TESTING AND ADJUSTING Failure code [CA351] – Injectors drive circuit error

Circuit diagram related to engine controller

A65 A02
(X-4)

(Blue)

A08
(SWP-16)
A07
(SWP-16)

R03
Engine
Controller
Relay (1)

CM01 (070-18)
R04
Engine A27
FB1
Controller (X-2)
Relay (2)
R
Starter
Safety
C02 Relay
108

J03 (J-20)
(Grey)
D02
(SWP-8)
A35 (L-2)

A01
(X-4)

A20
FB2
A65
A23
A21

A08
(SWP-16)

PW148-8 VEBM720100 20-361

Failure code [CA352] – Sens supply 1 volt low error TESTING AND ADJUSTING

Failure code [CA352] – Sens supply 1 volt low error

User code Failure code Sensor power supply 1 voltage low error
Trouble
E15 CA352 (Engine controller system)

Contents of
• Low voltage was detected in sensor power supply 1 circuit.
trouble

Action of
• Fixes ambient pressure value and continues operation.
controller

Problem that
• Engine does not start easily.
appears on
• Engine output lowers.
machine

Related
• Method of reproducing failure code: Turn starting switch ON.
information

Cause Standard value in normal state/Remarks on troubleshooting

★ Disconnect connector with starting switch OFF, then turn starting switch
ON and carry out troubleshooting.

Disconnect sensor and

wiring harness at right
Ambient pressure
in order and carry out AMBIENT PRESURE
sensor
Defective sensor or wiring operation to repro-
1 duce trouble. If "E" of
harness
failure code goes off
Possible causes
when sensor or wiring
and standard
harness is discon-
value in normal
nected, that sensor or Engine wiring harness CE01
state
wiring harness is
defective.

Connecting parts between ambient pressure sensor – engine wiring harness

– engine controller may be defective. Check them directly.
Defective wiring harness
2 • Looseness of connector, breakage of lock, or breakage of seal
connector
• Corrosion, bend, breakage, push-in, or expansion of pin
• Moisture or dirt in connector or defective insulation

If causes 1 – 2 are not detected, engine controller may be defective. (Since

3 Defective engine controller
trouble is in system, troubleshooting cannot be carried out.)

20-362 PW148-8 VEBM720100

TESTING AND ADJUSTING Failure code [CA352] – Sens supply 1 volt low error

Circuit diagram related to sensor power supply 1

PW148-8 VEBM720100 20-363

Failure code [CA386] – Sens supply 1 volt high error TESTING AND ADJUSTING

Failure code [CA386] – Sens supply 1 volt high error

User code Failure code Sensor power supply 1 voltage high error
Trouble
E15 CA386 (Engine controller system)

Contents of
• High voltage was detected in sensor power supply 1 circuit.
trouble

Action of
• Fixes ambient pressure value and continues operation.
controller

Problem that
• Engine does not start easily.
appears on
• Engine output lowers.
machine

Related
• Method of reproducing failure code: Turn starting switch ON.
information

Cause Standard value in normal state/Remarks on troubleshooting

Connecting parts between ambient pressure sensor – engine wiring harness

Possible causes – engine controller may be defective. Check them directly.
Defective wiring harness
and standard 1 • Looseness of connector, breakage of lock, or breakage of seal
connector
value in normal • Corrosion, bend, breakage, push-in, or expansion of pin
state • Moisture or dirt in connector or defective insulation

If cause 1 is not detected, engine controller may be defective. (Since trouble

2 Defective engine controller
is in system, troubleshooting cannot be carried out.)

Circuit diagram related to sensor power supply 1

20-364 PW148-8 VEBM720100

TESTING AND ADJUSTING Failure code [CA386] – Sens supply 1 volt high error

Blank for technical reason

PW148-8 VEBM720100 20-365

Failure code [CA428] – Water in fuel sensor high error TESTING AND ADJUSTING

Failure code [CA428] – Water in fuel sensor high error

User code Failure code Water-in-fuel sensor high error

Trouble
E15 CA428 (Engine controller system)

Contents of
• High voltage was detected in signal circuit of water-in-fuel sensor.
trouble

Action of
• None in particular.
controller

Problem that
appears on • Water separator monitor does not display normally.
machine

• Condition water-in-fuel sensor signal can be checked with monitoring function. (Code: 18800 Condition of WIF sen-
Related
sor)
information
• Method of reproducing failure code: Turn starting switch ON.

Cause Standard value in normal state/Remarks on troubleshooting

★ Prepare with starting switch OFF, then carry out troubleshooting without
turning starting switch ON.
1 Defective water-in-fuel sensor
P47 (female) Resistance

Between (1) – (2) Max. 10 Ω

★ Prepare with starting switch OFF, then carry out troubleshooting without
turning starting switch ON.
Disconnection in wiring harness
Wiring harness between CE01 (female) (14) – Resist- Max.
2 (Disconnection in wiring or
P47 (male) (1) ance 10 Ω
defective contact in connector)
Wiring harness between CE01 (female) (47) – Resist- Max.
P47 (male) (2) ance 10 Ω
Possible causes
and standard ★ Prepare with starting switch OFF, then carry out troubleshooting without
value in normal turning starting switch ON.
state Short circuit in wiring harness
3 Wiring harness between CE01 (female) (14) –
(with another wiring harness) Resist- Min.
each of CE01 (female) pins (With all wiring har-
ance 100 kΩ
ness connectors disconnected)

Connecting parts between water-in-fuel sensor – engine wiring harness –

engine controller may be defective. Check them directly.
Defective wiring harness
4 • Looseness of connector, breakage of lock, or breakage of seal
connector
• Corrosion, bend, breakage, push-in, or expansion of pin
• Moisture or dirt in connector or defective insulation

★ Prepare with starting switch OFF, then carry out troubleshooting without
turning starting switch ON.
5 Defective engine controller
CE01 (female) Resistance

Between (14) – (47) Max. 10 Ω

20-366 PW148-8 VEBM720100

TESTING AND ADJUSTING Failure code [CA428] – Water in fuel sensor high error

Circuit diagram related to water-in-fuel sensor

PW148-8 VEBM720100 20-367

Failure code [CA429] – Water in fuel sensor low error TESTING AND ADJUSTING

Failure code [CA429] – Water in fuel sensor low error

User code Failure code Water-in-fuel sensor low error

Trouble
E15 CA429 (Engine controller system)

Contents of
• Low voltage was detected in signal circuit of water-in-fuel sensor.
trouble

Action of
• None in particular.
controller

Problem that
appears on • Water separator monitor does not display normally.
machine

• Condition water-in-fuel sensor signal can be checked with monitoring function. (Code: 18800 Condition of WIF sen-
Related
sor)
information
• Method of reproducing failure code: Turn starting switch ON.

Cause Standard value in normal state/Remarks on troubleshooting

★ Prepare with starting switch OFF, then carry out troubleshooting without
turning starting switch ON.

1 Defective water-in-fuel sensor P47 (female) Resistance

Between (1) – (2) Max. 10 Ω

Between (1) – chassis ground Min. 100 kΩ

★ Prepare with starting switch OFF, then carry out troubleshooting without
Ground fault in wiring harness turning starting switch ON.
2
(Short circuit with GND circuit) Wiring harness between CE01 (female) (14) – Resist- Min.
P47 (male) (1) ance 100 kΩ

Possible causes ★ Prepare with starting switch OFF, then carry out troubleshooting without
and standard turning starting switch ON.
Short circuit in wiring harness
value in normal 3
(with another wiring harness) Wiring harness between CE01 (female) (14) –
state Resist- Min.
each of CE01 (female) pins (With all wiring har-
ance 100 kΩ
ness connectors disconnected)

Connecting parts between water-in-fuel sensor – engine wiring harness –

engine controller may be defective. Check them directly.
Defective wiring harness
4 • Looseness of connector, breakage of lock, or breakage of seal
connector
• Corrosion, bend, breakage, push-in, or expansion of pin
• Moisture or dirt in connector or defective insulation

★ Prepare with starting switch OFF, then carry out troubleshooting without
turning starting switch ON.

5 Defective engine controller CE01 (female) Resistance

Between (14) – (47) Max. 10 Ω

Between (14) – chassis ground Min. 100 kΩ

20-368 PW148-8 VEBM720100

TESTING AND ADJUSTING Failure code [CA429] – Water in fuel sensor low error

Circuit diagram related to water-in-fuel sensor

PW148-8 VEBM720100 20-369

Failure code [CA435] – Eng oil press sw error TESTING AND ADJUSTING

Failure code [CA435] – Eng oil press sw error

User code Failure code Engine oil pressure switch error

Trouble
E15 CA435 (Engine controller system)

Contents of
• There is error in signal circuit of engine oil pressure switch.
trouble

Action of
• None in particular.
controller

Problem that
• Engine protection function based on engine oil pressure does not work.
appears on
• Engine oil pressure monitor does not display normally
machine

Related
• Method of reproducing failure code: Turn starting switch ON or start engine.
information

Cause Standard value in normal state/Remarks on troubleshooting

★ Prepare with starting switch OFF, then carry out troubleshooting without
turning starting switch ON.
Defective engine oil pressure
1
switch OIL PRESSURE SWITCH (male) Resistance

Between (1) – chassis ground Max. 10 Ω

★ Prepare with starting switch OFF, then carry out troubleshooting without
Disconnection in wiring harness turning starting switch ON.
2 (Disconnection in wiring or
defective contact in connector) Wiring harness between CE01 (female) (17) – Resist- Max.
OIL PRESSURE SWITCH (male) (1) ance 10 Ω

Possible causes ★ Prepare with starting switch OFF, then carry out troubleshooting without
and standard turning starting switch ON.
Short circuit in wiring harness
value in normal 3 Wiring harness between CE01 (female) (17) –
state (with another wiring harness) Resist- Min.
each of CE01 (female) pins (With all wiring har-
ance 100 kΩ
ness connectors disconnected)

Connecting parts between engine oil pressure switch – engine wiring har-
ness – engine controller may be defective. Check them directly.
Defective wiring harness
4 • Looseness of connector, breakage of lock, or breakage of seal
connector
• Corrosion, bend, breakage, push-in, or expansion of pin
• Moisture or dirt in connector or defective insulation

★ Prepare with starting switch OFF, then carry out troubleshooting without
turning starting switch ON.
5 Defective engine controller
CE01 (female) Resistance

Between (17) – chassis ground Max. 10 Ω

Circuit diagram related to engine oil pressure switch

20-370 PW148-8 VEBM720100

TESTING AND ADJUSTING Failure code [CA441] – Battery voltage low error

Failure code [CA441] – Battery voltage low error

User code Failure code Battery voltage low error

Trouble
E10 CA441 (Engine controller system)

Contents of
• There is low voltage in controller power supply circuit.
trouble

Action of
• None in particular.
controller

Problem that
• Engine stops.
appears on
• Engine does not start easily.
machine

Related
• Method of reproducing failure code: Turn starting switch ON.
information

Cause Standard value in normal state/Remarks on troubleshooting

Looseness or corrosion of
1 Battery terminal may be loosened or corroded. Check it directly.
battery terminal

★ Prepare with starting switch OFF, then keep starting switch OFF and start
engine and carry out troubleshooting in each case.

2 Low battery voltage Battery (1 piece) Starting switch Voltage

Between (+) – (–) OFF Min. 12 V

terminals START Min. 6.2 V

3 Defective fuse No. 19 If fuse is broken, circuit probably has ground fault. (See Cause 6)

★ Prepare with starting switch OFF, then turn starting switch ON and carry
out troubleshooting.
Defective relay for engine
4 Replace relay (R03, R04) for engine controller with another relay and perform
controller power supply
reproducing operation. If "E" of failure code goes off at this time, replaced relay
is defective.

★ Prepare with starting switch OFF, then carry out troubleshooting without
turning starting switch ON.

Disconnection in wiring Wiring harness between FB1-19 – R03, R04 (female) Resist- Max.
Possible (3) ance 10 Ω
harness (Disconnection in
causes and 5
wiring or defective contact in Wiring harness between R03, R04 (female) (5) – Resist- Max.
standard value
connector) CE03 (female) (3) ance 10 Ω
in normal state
Wiring harness between CE03 (female) (1) – chassis Resist- Max.
ground (A65) ance 10 Ω

★ Prepare with starting switch OFF, then carry out troubleshooting without
turning starting switch ON.
Ground fault in wiring harness
Wiring harness between FB1-19 – R03, R04 (female) Resist- Min.
6 (Short circuit with GND cir-
(3) ance 100 kΩ
cuit)
Wiring harness between R03, R04 (female) (5) – Resist- Max.
CE03 (female) (3) ance 10 Ω

★ Prepare with starting switch OFF, then carry out troubleshooting without
turning starting switch ON.

Wiring harness between CE03 (female) (3) – CE03 Resist- Min.

(female) (1) pin (with battery terminal disconnected) ance 100 kΩ
Short circuit in wiring harness Wiring harness between CE03 (female) (3) – each of
7 Resist- Min.
(with another wiring harness) CE02 (female) pins (With battery terminal discon-
ance 100 kΩ
nected)

Wiring harness between CE03 (female) (1) – each of

Resist- Min.
CE02 (female) pins (With battery terminal discon-
ance 100 kΩ
nected)

PW148-8 VEBM720100 20-371

Failure code [CA441] – Battery voltage low error TESTING AND ADJUSTING

Cause Standard value in normal state/Remarks on troubleshooting

Connecting parts between fuse No. 19 – machine wiring harness – engine con-
troller may be defective. Check them directly.
Defective wiring harness
8 • Looseness of connector, breakage of lock, or breakage of seal
connector
• Corrosion, bend, breakage, push-in, or expansion of pin
Possible
• Moisture or dirt in connector or defective insulation
causes and
standard value ★ Prepare with starting switch OFF, then turn starting switch ON and start
in normal state engine and carry out troubleshooting in each case.

9 Defective engine controller CE03 (female) Starting switch Voltage

ON Min. 24 V
Between (3) – (1)
START Min. 12 V

20-372 PW148-8 VEBM720100

TESTING AND ADJUSTING Failure code [CA441] – Battery voltage low error

Circuit diagram related to engine controller power supply

A65 A02
(X-4)

(Blue)

A08
(SWP-16)
A07
(SWP-16)

R03
Engine
Controller
Relay (1)

CM01 (070-18)
R04
Engine A27
FB1
Controller (X-2)
Relay (2)
R
Starter
Safety
C02 Relay
108

J03 (J-20)
(Grey)
D02
(SWP-8)
A35 (L-2)

A01
(X-4)

A20
FB2
A65
A23
A21

A08
(SWP-16)

PW148-8 VEBM720100 20-373

Failure code [CA442] – Battery voltage high error TESTING AND ADJUSTING

Failure code [CA442] – Battery voltage high error

User code Failure code Battery voltage high error

Trouble
E10 CA442 (Engine controller system)

Contents of
• There is high voltage (36 V or higher) in controller power supply circuit.
trouble

Action of
• None in particular.
controller

Problem that
appears on • Engine may stop.
machine

Related
• Method of reproducing failure code: Turn starting switch ON.
information

Cause Standard value in normal state/Remarks on troubleshooting

★ Prepare with starting switch OFF, then carry out troubleshooting without
turning starting switch ON.
1 Defective battery voltage
Battery Voltage

Between (+) – (–) terminals Max. 32 V

Possible causes ★ Prepare with starting switch OFF, then start engine and carry out trou-
and standard bleshooting.
value in normal 2 Defective alternator E12 (male) Engine speed Voltage
state
Between (1) – chassis
Medium or higher 27.5 – 29.5 V
ground

★ Prepare with starting switch OFF, then turn starting switch ON and carry
out troubleshooting.
3 Defective engine controller
CE03 (female) Voltage

Between (3) – (1) Max. 32 V

20-374 PW148-8 VEBM720100

TESTING AND ADJUSTING Failure code [CA442] – Battery voltage high error

Circuit diagram related to engine controller power supply

A65 A02
(X-4)

(Blue)

A08
(SWP-16)
A07
(SWP-16)

R03
Engine
Controller
Relay (1)

CM01 (070-18)
R04
Engine A27
FB1
Controller (X-2)
Relay (2)
R
Starter
Safety
C02 Relay
108

J03 (J-20)
(Grey)
D02
(SWP-8)
A35 (L-2)

A01
(X-4)

A20
FB2
A65
A23
A21

A08
(SWP-16)

PW148-8 VEBM720100 20-375

Failure code [CA449] – Rail press very high error TESTING AND ADJUSTING

Failure code [CA449] – Rail press very high error

User code Failure code Common rail pressure very high error
Trouble
E11 CA449 (Engine controller system)

Contents of
• There is high pressure error in common rail circuit.
trouble

Action of
• Limits output and continues operation.
controller

Problem that
• Engine sound becomes large when no or light load is applied.
appears on
• Engine output lowers.
machine

• Common rail pressure can be checked with monitoring function.

Related
(Code: 36400 Common rail pressure)
information
• Method of reproducing failure code: Start engine.

Cause Standard value in normal state/Remarks on troubleshooting

1 Defect in related system If another failure code is displayed, carry out troubleshooting for it.

There may be air in low pressure circuit. Check it directly according to the fol-
lowing procedure.
2 Air in low pressure circuit
1. Remove pressure pickup plug (outlet side) of fuel main filter.
2. Operate feed pump of fuel pre-filter.
3. Check pressure pickup plug for leakage of fuel and air.

★ For check of fuel return circuit pressure, see Testing and adjusting,
Checking fuel pressure.
3 Defect in fuel return circuit parts
Fuel return circuit pres- Low idle running or Max. 0.02 MPa
Possible causes sure cranking {Max. 0.19 kg/cm2}
and standard
value in normal ★ Prepare with starting switch ON, then keep starting switch ON and carry
state out troubleshooting in each case.

Monitoring code
Defective common rail pressure Monitoring information
4 (Machine monitor)
sensor
36400
While engine is 0 ± 0.39 MPa
Common rail
pressure
stopped {0 ± 4 kg/cm2}

★ For check of leakage through pressure limiter, see Testing and adjust-
ing, Checking fuel return rate and leakage.
5 Defective pressure limiter
Leakage through pres-
During low idle 0 cc (No leakage)
sure limiter

6 Defective supply pump If causes 1 – 5 are not detected, supply pump may be defective.

20-376 PW148-8 VEBM720100

TESTING AND ADJUSTING Failure code [CA449] – Rail press very high error

Blank for technical reason

PW148-8 VEBM720100 20-377

Failure code [CA451] – Rail press sensor high error TESTING AND ADJUSTING

Failure code [CA451] – Rail press sensor high error

User code Failure code Common rail pressure sensor high error
Trouble
E11 CA451 (Engine controller system)

Contents of
• There is high voltage in signal circuit of common rail pressure sensor.
trouble

Action of
• Limits output and continues operation.
controller

Problem that
• Engine does not start.
appears on
• Engine speed or output lowers.
machine

• Signal voltage of common rail pressure sensor can be checked with monitoring function.
Related
(Code: 36401 Common rail pressure sensor voltage)
information
• Method of reproducing failure code: Turn starting switch ON.

Cause Standard value in normal state/Remarks on troubleshooting

Defective sensor power supply

1 If failure code [CA227] is also displayed, carry out troubleshooting for it first.
2 system

★ Prepare with starting switch OFF, then turn starting switch ON and carry
out troubleshooting.

FUEL RAIL PRESS Voltage

Defective common rail pressure
2 Between (3) – (1) Power supply 4.75 – 5.25 V
sensor
Voltage is measured with wiring harness connected. Accordingly, if voltage is
abnormal, check wiring harness and controller, too, for another cause of
trouble, and then judge.

★ Prepare with starting switch OFF, then turn starting switch ON and carry
Hot short (Short circuit with 5V/ out troubleshooting.
3
24V circuit) in wiring harness Wiring harness between CE01 (female) (25) –
Possible causes Voltage Max. 1 V
and standard FUEL RAIL PRESS (female) (2)
value in normal
★ Prepare with starting switch OFF, then carry out troubleshooting without
state turning starting switch ON.
Short circuit in wiring harness Wiring harness between CE01 (female) (25) –
4
(with another wiring harness) FUEL RAIL PRESS (female) (2) and between Resist- Min.
CE01 (female) (37) – FUEL RAIL PRESS ance 100 kΩ
(female) (3)

Connecting parts between common rail pressure sensor – engine wiring har-
ness – engine controller may be defective. Check them directly.
Defective wiring harness
5 • Looseness of connector, breakage of lock, or breakage of seal
connector
• Corrosion, bend, breakage, push-in, or expansion of pin
• Moisture or dirt in connector or defective insulation

★ Prepare with starting switch OFF, then turn starting switch ON and carry
out troubleshooting.
6 Defective engine controller
CE01 Voltage

Between (37) – (47) Power supply 4.75 – 5.25 V

20-378 PW148-8 VEBM720100

TESTING AND ADJUSTING Failure code [CA451] – Rail press sensor high error

Circuit diagram related to common rail pressure sensor

PW148-8 VEBM720100 20-379

Failure code [CA452] – Rail press sensor low error TESTING AND ADJUSTING

Failure code [CA452] – Rail press sensor low error

Action code Failure code Common rail pressure sensor low error
Trouble
E11 CA452 (Engine controller system)

Contents of
• There is low voltage in signal circuit of common rail pressure sensor.
trouble

Action of
• Limits output and continues operation.
controller

Problem that
• Engine speed or output lowers.
appears on
• Engine does not start.
machine

Related
• Method of reproducing failure code: Turn starting switch ON.
information

Cause Standard value in normal state/Remarks on troubleshooting

• Defective sensor power

1 If failure code [CA187] is also indicated, carry out troubleshooting for it first.
supply 2 system

★ Prepare with starting switch OFF, then turn starting switch ON and carry
out troubleshooting.

FUEL RAIL PRESS Voltage

• Defective common rail
2 Between (3) – (1) Power supply 4.75 – 5.25 V
pressure sensor
Voltage is measured with wiring harness connected. Accordingly, if voltage is
abnormal, check wiring harness and controller, too, for another cause of
trouble, and then judge.

★ Prepare with starting switch OFF, then turn starting switch ON and carry
• Ground fault in wiring out troubleshooting.
harness
3 Wiring harness between ENGINE (female) (25) –
(Short circuit with GND Resist- Min.
Possible causes FUEL RAIL PRESS (female) (2) and chassis
circuit) ance 100 kΩ
and standard ground
value in normal
state ★ Prepare with starting switch OFF, then carry out troubleshooting without
turning starting switch ON.
• Short circuit in wiring har-
4 ness Wiring harness between ENGINE (female) (25) –
(with another wiring harness) FUEL RAIL PRESS (female) (2) and between Resist- Min.
ENGINE (female) (47) – FUEL RAIL PRESS ance 100 kΩ
(female) (1)

Connecting parts between common rail pressure sensor – engine wiring har-
ness – engine controller may be defective. Check them directly.
• Defective wiring harness
5 • Looseness of connector, breakage of lock, or breakage of seal
connector
• Corrosion, bend, breakage, push-in, or expansion of pin
• Moisture or dirt in connector or defective insulation

★ Prepare with starting switch OFF, then turn starting switch ON and carry
out troubleshooting.
6 • Defective engine controller
ENGINE Voltage

Between (37) – (47) Power supply 4.75 – 5.25 V

20-380 PW148-8 VEBM720100

TESTING AND ADJUSTING Failure code [CA452] – Rail press sensor low error

Circuit diagram related to common rail pressure sensor

PW148-8 VEBM720100 20-381

Failure code [CA488] – Chg air temp high torque derate TESTING AND ADJUSTING

Failure code [CA488] – Chg air temp high torque derate

User code Failure code Charge air temperature high torque derate
Trouble
E11 CA488 (Engine controller system)

Contents of
• Temperature signal of boost pressure/temperature sensor exceeded control upper temperature limit.
trouble

Action of
• Limits output and continues operation.
controller

Problem that
appears on • Engine output lowers.
machine

Related • Boost temperature can be checked with monitoring function. (Code: 18500 Boost temperature)
information • Method of reproducing failure code: Start engine.

Cause Standard value in normal state/Remarks on troubleshooting

Cooling performance of aftercooler may be low. Check following points

directly.
Lowering of cooling
Possible causes 1 • Looseness and breakage of fan belt.
performance of aftercooler
and standard Insufficiency of cooling air
value in normal Clogging of aftercooler fins
state Abnormal rise of turbocharger Outlet temperature of turbocharger may be abnormally high. Check related
2
outlet temperature parts directly.

If causes 1 – 2 are not detected, engine controller may be defective. (Since

3 Defective engine controller
trouble is in system, troubleshooting cannot be carried out.)

20-382 PW148-8 VEBM720100

TESTING AND ADJUSTING Failure code [CA553] – Rail press high error

Failure code [CA553] – Rail press high error

User code Failure code Common rail pressure high error

Trouble
E15 CA553 (Engine controller system)

Contents of
• There is high pressure error in common rail circuit.
trouble

Action of
• None in particular.
controller

Problem that
• Engine sound becomes large when no or light load is applied.
appears on
• Engine output lowers.
machine

• Common rail pressure can be checked with monitoring function.

Related
(Code: 36400 Common rail pressure)
information
• Method of reproducing failure code: Start engine.

Cause Standard value in normal state/Remarks on troubleshooting

1 Defect in related system If another failure code is displayed, carry out troubleshooting for it.

Ground terminal may be connected defectively. Check following terminals

Possible causes directly.
and standard Defective connection of ground • Ground terminal of machine ((–) terminal of battery)
value in normal 2
terminal • Ground terminal of engine
state • Ground terminal of engine controller
• Ground terminal of starting motor

Breakage of O-ring of supply

3 O-ring of supply pump actuator may be broken. Check it directly.
pump actuator

PW148-8 VEBM720100 20-383

Failure code [CA559] – Rail press low error TESTING AND ADJUSTING

Failure code [CA559] – Rail press low error

Action code Failure code Common rail pressure low error

Trouble
E15 CA559 (Engine controller system)

Contents of
• There is low pressure error (1) in common rail circuit.
trouble

Action of
• None in particular.
controller

Problem that • Engine does not start at all or does not start easily.
appears on • Exhaust gas becomes black.
machine • Engine output lowers.

Related • Common rail pressure can be checked with monitoring function. (Code: 36400 Common rail pressure)
information • Method of reproducing failure code: Start engine.

Cause Standard value in normal state/Remarks on troubleshooting

Fuel may be leaking to outside. Check it directly (Check visually while run-
1 Fuel leakage to outside
ning engine at low idle).

★ For check of pressure in fuel low pressure circuit, see Testing and ad-
justing, Checking fuel pressure.

During cranking (if 0.3 – 1.1 MPa

Defect in low pressure circuit engine cannot be
2
parts Pressure in fuel low- started) {3.1 – 11.3 kg/cm2}
pressure circuit
During low idle (if 0.5 – 1.3 MPa
engine can be started) {5.1 – 13.3 kg/cm2}

★ For check of leakage through pressure limiter, see Testing and adjust-
ing, Checking fuel return rate and leakage.
3 Defective pressure limiter
Possible causes Leakage through pres-
and standard During low idle 0 cc (No leakage)
sure limiter
value in normal
state ★ For check of return rate from injector, see Testing and adjusting, Check-
ing fuel return rate and leakage.

During cranking (if

Defective injector (including
4 engine cannot be Max. 90 cc/min.
high pressure piping in head) Return rate from injec- started)
tor
During low idle (if
Max. 180 cc/min.
engine can be started)

★ For check of return rate from supply pump, see Testing and adjusting,
Checking fuel return rate and leakage.

During cranking (if

5 Defective supply pump engine cannot be Max. 140 cc/min.
Return rate from sup- started)
ply pump
During low idle (if
Max. 1,000 cc/min.
engine can be started)

20-384 PW148-8 VEBM720100

TESTING AND ADJUSTING Failure code [CA559] – Rail press low error

Blank for technical reason

PW148-8 VEBM720100 20-385

Failure code [CA689] – Eng Ne speed sensor error TESTING AND ADJUSTING

Failure code [CA689] – Eng Ne speed sensor error

User code Failure code Engine Ne speed sensor error

Trouble
E11 CA689 (Engine controller system)

Contents of
• There is error in signal from engine Ne speed sensor.
trouble

Action of
• Continues control with signal from engine Bkup speed sensor.
controller

Problem that • Engine hunts.

appears on • Engine does not start easily.
machine • Engine output lowers.

Related
• Method of reproducing failure code: Start engine.
information

Cause Standard value in normal state/Remarks on troubleshooting

Defective Ne speed sensor

1 If failure code [CA238] is also displayed, carry out troubleshooting for it first.
power supply system

★ Prepare with starting switch OFF, then turn starting switch ON and car-
ry out troubleshooting.

CRANK SENSOR Voltage

Defective engine Ne speed
2 Between (1) – (2) Power supply 4.75 – 5.25 V
sensor
Voltage is measured with wiring harness connected. Accordingly, if voltage
is abnormal, check wiring harness and controller, too, for another cause of
trouble, and then judge.

Breakage or improper
Engine Ne speed sensor may be broken or may have improper clearance.
3 clearance of engine
Check it directly.
Ne speed sensor

Breakage of rotation sensor

4 Rotation sensor wheel may be broken. Check it directly.
wheel

★ Prepare with starting switch OFF, then carry out troubleshooting with-
Possible causes Disconnection in wiring harness out turning starting switch ON.
and standard 5 (Disconnection in wiring or
value in normal defective contact in connector) Wiring harness between CE01 (female) (27) – Resist- Max.
state CRANK SENSOR (female) (3) ance 10 Ω

★ Prepare with starting switch OFF, then carry out troubleshooting with-
Ground fault in wiring harness out turning starting switch ON.
6
(Short circuit with GND circuit) Wiring harness between CE01 (female) (27) – Resist- Min.
CRANK SENSOR (female) (3) ance 100 kΩ

Hot short (Short circuit with 5V/
7
24V circuit) in wiring harness
★ Prepare with starting switch OFF, then turn starting switch ON and car-
ry out troubleshooting.
Wiring harness between CE01 (female) (27) –
Voltage Max. 1 V
CRANK SENSOR (female) (3)

★ Prepare with starting switch OFF, then carry out troubleshooting with-
out turning starting switch ON.

Wiring harness between CE01 (female) (27) –

Resist- Min.
Short circuit in wiring harness CRANK SENSOR (female) (3) or between CE01
8 ance 100 kΩ
(with another wiring harness) (female) (16) – CRANK SENSOR (female) (1)

Wiring harness between CE01 (female) (27) –

Resist- Min.
CRANK SENSOR (female) (3) or between CE01
ance 100 kΩ
(female) (48) – CRANK SENSOR (female) (2)

20-386 PW148-8 VEBM720100

TESTING AND ADJUSTING Failure code [CA689] – Eng Ne speed sensor error

Cause Standard value in normal state/Remarks on troubleshooting

Connecting parts between engine Ne speed sensor – engine wiring harness

– engine controller may be defective. Check them directly.
Defective wiring harness
9 • Looseness of connector, breakage of lock, or breakage of seal
Possible causes connector
• Corrosion, bend, breakage, push-in, or expansion of pin
and standard
• Moisture or dirt in connector or defective insulation
value in normal
state ★ Prepare with starting switch OFF, then turn starting switch ON and car-
ry out troubleshooting.
10 Defective engine controller
CE01 Voltage

Between (16) – (48) Power supply 4.75 – 5.25 V

Circuit diagram related to engine Ne speed sensor

PW148-8 VEBM720100 20-387

Failure code [CA731] – Eng bkup speed sens phase error TESTING AND ADJUSTING

Failure code [CA731] – Eng bkup speed sens phase error

User code Failure code Engine G speed sensor phase error

Trouble
E11 CA731 (Engine controller system)

Contents of
• Phase error was detected in signals from engine Ne speed sensor and engine Bkup speed sensor
trouble

Action of
• Continues control with signal from engine Ne speed sensor.
controller

Problem that • Engine does not start at all or does not start easily.
appears on • Idle speed is unstable.
machine • Exhaust gas becomes black.

Related
• Method of reproducing failure code: Start engine.
information

Cause Standard value in normal state/Remarks on troubleshooting

Breakage of engine Ne speed

1 Engine Ne speed sensor may be broken. Check it directly.
sensor

Breakage of engine G speed

2 Engine G speed sensor may be broken. Check it directly.
sensor

Rotation sensor wheel on crankshaft side may be installed defectively or bro-

ken. Check it according to the following procedure.
Defective installation or
3 breakage of rotation sensor 1. Set No. 1 cylinder at compression top dead center (Match stamped
wheel on crankshaft side mark).
2. If center of oblong hole of rotation sensor wheel is at tip of Ne speed sen-
sor, rotation sensor wheel is installed normally.
Possible causes
Rotation sensor ring on camshaft side may be installed defectively or broken.
and standard
Check it according to the following procedure.
value in normal
state Defective installation or 1. Set No. 1 cylinder at compression top dead center (Match stamped
4 breakage of rotation sensor ring mark).
on camshaft side
2. Remove G speed sensor.
3. If 2 grooves (1 crest) of rotation sensor ring are seen through sensor
mounting hole, rotation sensor ring is installed normally.

Defective timing of crankshaft

5 Timing of crankshaft and camshaft may be defective. Check it directly.
and camshaft

Ground terminal may be connected defectively. Check following terminals

directly.
Defective connection of ground • Ground terminal of machine ((–) terminal of battery)
6
terminal • Ground terminal of engine
• Ground terminal of engine controller
• Ground terminal of starting motor

20-388 PW148-8 VEBM720100

TESTING AND ADJUSTING Failure code [CA731] – Eng bkup speed sens phase error

Blank for technical reason

PW148-8 VEBM720100 20-389

Failure code [CA757] – All continuous data lost error TESTING AND ADJUSTING

Failure code [CA757] – All continuous data lost error

User code Failure code All continuous data lost error

Trouble
E10 CA757 (Engine controller system)

Contents of
• All data in engine controller are lost.
trouble

Action of
• None in particular.
controller

Problem that
• Engine may stop and may not be started again.
appears on
• Monitoring function of machine monitor (engine controller system) may not work normally.
machine

Related
• Method of reproducing failure code: Turn starting switch ON.
information

Cause Standard value in normal state/Remarks on troubleshooting

1 Defect in related system If another failure code is displayed, carry out troubleshooting for it.

Looseness or corrosion of
2 Battery terminal may be loosened or corroded. Check it directly.
battery terminal

★ Prepare with starting switch OFF, then keep starting switch OFF and
start engine and carry out troubleshooting in each case.

3 Low battery voltage Battery (1 piece) Starting switch Voltage

Between (+) – (–) ter- OFF Min. 12 V

minals START Min. 6.2 V

4 Defective fuse No. 19 If fuse is broken, circuit probably has ground fault.

★ Prepare with starting switch OFF, then turn starting switch ON and carry
out troubleshooting.
Defective relay for engine
5 Replace relay (R03, R04) for engine controller with another relay and per-
controller power supply
form reproducing operation. If "E" of failure code goes off at this time,
replaced relay is defective.
Possible causes
and standard ★ Prepare with starting switch OFF, then carry out troubleshooting without
value in normal turning starting switch ON.
state
Wiring harness between FB1-19 – R03, R04 Resist- Max.
Disconnection in wiring harness (female) (3) ance 10 Ω
6 (Disconnection in wiring or
defective contact in connector) Wiring harness between R03, R04 (female) (5) – Resist- Max.
CE03 (female) (3) ance 10 Ω

Wiring harness between CE03 (female) (1) – Resist- Max.

chassis ground (T12) ance 10 Ω

Connecting parts between fuse No. 19 – machine wiring harness – engine

controller may be defective. Check them directly.
Defective wiring harness
7 • Looseness of connector, breakage of lock, or breakage of seal
connector
• Corrosion, bend, breakage, push-in, or expansion of pin
• Moisture or dirt in connector or defective insulation

★ Prepare with starting switch OFF, then turn starting switch ON and start
engine and carry out troubleshooting in each case.

8 Defective engine controller CE03 (female) Starting switch Voltage

ON Min. 24 V
Between (3) – (1)
START Min. 12 V

20-390 PW148-8 VEBM720100

TESTING AND ADJUSTING Failure code [CA757] – All continuous data lost error

Circuit diagram related to engine controller power supply

A65 A02
(X-4)

(Blue)

A08
(SWP-16)
A07
(SWP-16)

R03
Engine
Controller
Relay (1)

CM01 (070-18)
R04
Engine A27
FB1
Controller (X-2)
Relay (2)
R
Starter
Safety
C02 Relay
108

J03 (J-20)
(Grey)
D02
(SWP-8)
A35 (L-2)

A01
(X-4)

A20
FB2
A65
A23
A21

A08
(SWP-16)

PW148-8 VEBM720100 20-391

Failure code [CA778] – Eng bkup speed sensor error TESTING AND ADJUSTING

Failure code [CA778] – Eng bkup speed sensor error

User code Failure code Engine G speed sensor error

Trouble
E15 CA778 (Engine controller system)

Contents of
• There is error in signal from engine G speed sensor.
trouble

Action of
• Continues control with signal from engine Ne speed sensor.
controller

Problem that
• Engine does not start easily.
appears on
• Engine output lowers.
machine

Related
• Method of reproducing failure code: Start engine.
information

Cause Standard value in normal state/Remarks on troubleshooting

Defective sensor power supply

1 If failure code [CA187] is also displayed, carry out troubleshooting for it first.
2 system

★ Prepare with starting switch OFF, then turn starting switch ON and car-
ry out troubleshooting.

CAM SENSOR Voltage

Defective engine G speed
2 Between (1) – (2) Power supply 4.75 – 5.25 V
sensor
Voltage is measured with wiring harness connected. Accordingly, if voltage
is abnormal, check wiring harness and controller, too, for another cause of
trouble, and then judge.

Breakage or improper
Engine G speed sensor may be broken or may have improper clearance.
3 clearance of engine G speed
Check it directly.
sensor

Breakage of rotation sensor

4 Rotation sensor ring may be broken. Check it directly.
ring

Disconnection in wiring har- ★ Prepare with starting switch OFF, then carry out troubleshooting with-
ness (Disconnection in wiring out turning starting switch ON.
Possible causes 5
and standard or defective contact in connec- Wiring harness between CE01 (female) (26) – Resist- Max.
value in normal tor) JC03 – CAM SENSOR (female) (3) ance 10 Ω
state
★ Prepare with starting switch OFF, then carry out troubleshooting with-
Ground fault in wiring harness out turning starting switch ON.
6
(Short circuit with GND circuit) Wiring harness between CE01 (female) (26) – Resist- Min.
JC03 – CAM SENSOR (female) (3) ance 100 kΩ

Hot short (Short circuit with 5V/
7
24V circuit) in wiring harness
★ Prepare with starting switch OFF, then turn starting switch ON and car-
ry out troubleshooting.
Wiring harness between CE01 (female) (26) –
Voltage Max. 1 V
JC03 – CAM SENSOR (female) (3)

★ Prepare with starting switch OFF, then carry out troubleshooting with-
out turning starting switch ON.

Wiring harness between CE01 (female) (26) –

JC03 – CAM SENSOR (female) (3) or between Resist- Min.
Short circuit in wiring harness CE01 (female) (37) – CAM SENSOR (female) ance 100 kΩ
8
(with another wiring harness) (1)

Wiring harness between CE01 (female) (26) –

JC03 – CAM SENSOR (female) (3) or between Resist- Min.
CE01 (female) (47) – CAM SENSOR (female) ance 100 kΩ
(2)

20-392 PW148-8 VEBM720100

TESTING AND ADJUSTING Failure code [CA778] – Eng bkup speed sensor error

Cause Standard value in normal state/Remarks on troubleshooting

Connecting parts between engine G speed sensor – engine wiring harness

– engine controller may be defective. Check them directly.
Defective wiring harness
9 • Looseness of connector, breakage of lock, or breakage of seal
Possible causes connector
• Corrosion, bend, breakage, push-in, or expansion of pin
and standard
• Moisture or dirt in connector or defective insulation
value in normal
state ★ Prepare with starting switch OFF, then turn starting switch ON and car-
ry out troubleshooting.
10 Defective engine controller
CE01 Voltage

Between (37) – (47) Power supply 4.75 – 5.25 V

Circuit diagram related to engine G speed sensor

PW148-8 VEBM720100 20-393

Failure code [CA1633] – KOMNET datalink timeout error TESTING AND ADJUSTING

Failure code [CA1633] – KOMNET datalink timeout error

User code Failure code KOMNET Datalink timeout error

Trouble
E0E CA1633 (Engine controller system)

Contents of • Engine controller detected communication error in KOMNET communication circuit between pump controller and
trouble machine monitor.

Action of • Continues operation in default mode.

controller • If cause of failure disappears, system resets itself.

Problem that
• Information may not transmitted normally by KOMNET communication and machine may not operate normally.
appears on
(Trouble phenomenon depends on failed section.)
machine

Related
• Method of reproducing failure code: Turn starting switch ON.
information

Cause Standard value in normal state/Remarks on troubleshooting

★ Prepare with starting switch OFF, then carry out troubleshooting without
turning starting switch ON.

Wiring harness between CM02 (female) (8), (9) –

Disconnection in wiring harness Resist-
C01 (female) (45), – CE02 (female) (46), – K02 Max. 1 Ω
1 (Disconnection in wiring or ance
(female) (A)
defective contact in connector)
Wiring harness between CM02 (female) (10) –
Resist-
C01 (female) (64), – CE02 (female) (47), – K02 Max. 1 Ω
ance
(female) (B)

★ Prepare with starting switch OFF, then carry out troubleshooting without
turning starting switch ON.

Wiring harness between CM02 (female) (8), (9) –

Resist- Min.
Ground fault in wiring harness C01 (female) (45), – CE02 (female) (46), – K02
2 ance 1 MΩ
(Short circuit with GND circuit) (female) (A), – N08 (male) (3)
Possible causes Wiring harness between CM02 (female) (10) –
and standard Resist- Min.
C01 (female) (64), – CE02 (female) (47), – K02
value in normal ance 1 MΩ
(female) (B), – N08 (male) (10)
state
★ Prepare with starting switch OFF, then turn starting switch ON and carry
out troubleshooting.

Wiring harness between CM02 (female) (8), (9) –

Max.
Hot short (Short circuit with 24V C01 (female) (45), – CE02 (female) (46), – K02 Voltage
3 5.5 V
circuit) in wiring harness (female) (A), – N08 (male) (3)

Wiring harness between CM02 (female) (10) –

Max.
C01 (female) (64), – CE02 (female) (47), – K02 Voltage
5.5 V
(female) (B), – N08 (male) (10)

★ Prepare with starting switch OFF, then carry out troubleshooting without
Defective CAN terminal turning starting switch ON.
4 resistance (Internal short
K02 (male) Resistance
circuit or disconnection)
Between (A) – (B) 120 ± 12 Ω

If causes 1 – 4 are not detected, engine controller may be defective. (Since

5 Defective pump controller
trouble is in system, troubleshooting cannot be carried out.)

20-394 PW148-8 VEBM720100

TESTING AND ADJUSTING Failure code [CA1633] – KOMNET datalink timeout error

Circuit diagram related to CAN communication

3 10 1 2

8
9 45
10 64

12 13 A08
(SWP-16)
46 A
47 B
C

PW148-8 VEBM720100 20-395

Failure code [CA2185] – Throttle sensor supply voltage high error TESTING AND ADJUSTING

Failure code [CA2185] – Throttle sensor supply voltage

high error

User code Failure code Throttle sensor supply voltage high error
Trouble
E14 CA2185 (Engine controller system)

Contents of
• High voltage (5.25 V or higher) was detected in throttle sensor power supply circuit.
trouble

• If trouble occurs while starting switch is in ON position, controller fixes voltage value to level just before detection of
Action of trouble and continues operation.
controller • If starting switch is turned ON while voltage is abnormally high, controller continues operation with voltage at 100%
value.

Problem that
appears on • Engine speed cannot be controlled with fuel control dial.
machine

Related
• Method of reproducing failure code: Turn starting switch ON.
information

Cause Standard value in normal state/Remarks on troubleshooting

★ Prepare with starting switch OFF, then carry out troubleshooting without
turning starting switch ON.

Wiring harness between CE02 (female) (22) –

Short circuit in wiring harness Resist- Min.
1 each of CE02 (female) pins (With E07 discon-
(with another wiring harness) ance 100 kΩ
nected)
Possible causes
and standard Wiring harness between CE02 (female) (22) – Resist- Min.
value in normal CE03 (female) (3) (With E07 disconnected) ance 100 kΩ
state
Connecting parts between fuel control dial – machine wiring harness –
engine controller may be defective. Check them directly.
Defective wiring harness
2 • Looseness of connector, breakage of lock, or breakage of seal
connector
• Corrosion, bend, breakage, push-in, or expansion of pin
• Moisture or dirt in connector or defective insulation

If causes 1 – 2 are not detected, engine controller may be defective. (Since

3 Defective engine controller
trouble is in system, troubleshooting cannot be carried out.)

Circuit diagram related to fuel control dial

Engine Module/ A03 H15 Fuel Dial

CE02 (DRC-50) (SWP-14) (090-22) E07 (M-3)
Fuel Dial (+) 9 1 14 1

Fuel Dial (+5V) 22 2 15 2

Fuel Dial (-) 23 3 16 3

CAB

20-396 PW148-8 VEBM720100

TESTING AND ADJUSTING Failure code [CA2186] – Throttle sensor supply voltage low error

Failure code [CA2186] – Throttle sensor supply voltage

low error

User code Failure code Throttle sensor supply voltage low error
Trouble
E14 CA2186 (Engine controller system)

Contents of
• Low voltage was detected in throttle sensor power supply circuit.
trouble

• If trouble occurs while starting switch is in ON position, controller fixes voltage value to level just before detection of
Action of trouble and continues operation.
controller • If starting switch is turned ON while voltage is abnormally high, controller continues operation with voltage at 100%
value.

Problem that
appears on • Engine speed cannot be controlled with fuel control dial.
machine

Related
• Method of reproducing failure code: Turn starting switch ON.
information

Cause Standard value in normal state/Remarks on troubleshooting

★ Prepare with starting switch OFF, then carry out troubleshooting without
Ground fault in wiring harness turning starting switch ON.
1
(Short circuit with GND circuit) Wiring harness between CE02 (female) (22) – Resist- Min.
E07 (female) (1) ance 100 kΩ

★ Prepare with starting switch OFF, then carry out troubleshooting without
turning starting switch ON.
Possible causes Short circuit in wiring harness
and standard 2 Wiring harness between CE02 (female) (9) –
(with another wiring harness) Resist- Min.
value in normal each of CE02 (female) pins (With E07 discon-
ance 100 kΩ
state nected)

Connecting parts between fuel control dial – machine wiring harness –

engine controller may be defective. Check them directly.
Defective wiring harness
3 • Looseness of connector, breakage of lock, or breakage of seal
connector
• Corrosion, bend, breakage, push-in, or expansion of pin
• Moisture or dirt in connector or defective insulation

If causes 1 – 3 are not detected, engine controller may be defective. (Since

4 Defective engine controller
trouble is in system, troubleshooting cannot be carried out.)

Circuit diagram related to fuel control dial

Engine Module/ A03 H15 Fuel Dial

CE02 (DRC-50) (SWP-14) (090-22) E07 (M-3)
Fuel Dial (+) 9 1 14 1

Fuel Dial (+5V) 22 2 15 2

Fuel Dial (-) 23 3 16 3

CAB

PW148-8 VEBM720100 20-397

Failure code [CA2249] – Rail press very low error TESTING AND ADJUSTING

Failure code [CA2249] – Rail press very low error

User code Failure code Common rail pressure very low error
Trouble
E11 CA2249 (Engine controller system)

Contents of
• There is low pressure error in common rail circuit.
trouble

Action of
• Limits output and continues operation.
controller

Problem that • Engine does not start easily.

appears on • Exhaust gas becomes black.
machine • Engine output lowers.

• Common rail pressure can be checked with monitoring function.

Related
(Code: 36400 Common rail pressure)
information
• Method of reproducing failure code: Start engine.

Possible causes Cause Standard value in normal state/Remarks on troubleshooting

and standard
value in normal 1 Carry out troubleshooting for failure code [CA559].
state

20-398 PW148-8 VEBM720100

TESTING AND ADJUSTING Failure code [CA2249] – Rail press very low error

Blank for technical reason

PW148-8 VEBM720100 20-399

Failure code [CA2311] – IMV solenoid error TESTING AND ADJUSTING

Failure code [CA2311] – IMV solenoid error

User code Failure code IMV solenoid error

Trouble
E11 CA2311 (Engine controller system)

Contents of
• Resistance of supply pump actuator circuit is abnormally high or low.
trouble

Action of
• None in particular.
controller

Problem that
appears on • Engine output lowers.
machine

Related
• Method of reproducing failure code: Start engine.
information

Cause Standard value in normal state/Remarks on troubleshooting

1 Defect in related system If another failure code is displayed, carry out troubleshooting for it.

★ Prepare with starting switch OFF, then carry out troubleshooting without
turning starting switch ON.

2 Defective supply pump actuator CP3 PUMP REGULATOR (male) Resistance

Between (1) – (2) Max. 5 Ω

Between (1) – chassis ground Min. 100 kΩ

★ Prepare with starting switch OFF, then carry out troubleshooting without
turning starting switch ON.
Disconnection in wiring harness
Wiring harness between CE01 (female) (2) – CP3 Resist-
3 (Disconnection in wiring or Max. 5 Ω
PUMP REGULATOR (female) (1) ance
defective contact in connector)
Possible causes Wiring harness between CE01 (female) (32) – Resist-
Max. 5 Ω
and standard CP3 PUMP REGULATOR (female) (2) ance
value in normal
★ Prepare with starting switch OFF, then carry out troubleshooting without
state turning starting switch ON.
Ground fault in wiring harness
4
(Short circuit with GND circuit) Wiring harness between CE01 (female) (2) – CP3 Resist- Min.
PUMP REGULATOR (female) (1) ance 100 kΩ

Connecting parts between supply pump actuator – engine wiring harness –

engine controller may be defective. Check them directly.
Defective wiring harness
5 • Looseness of connector, breakage of lock, or breakage of seal
connector
• Corrosion, bend, breakage, push-in, or expansion of pin
• Moisture or dirt in connector or defective insulation

★ Prepare with starting switch OFF, then carry out troubleshooting without
turning starting switch ON.

6 Defective engine controller CE01 (female) Resistance

Between (2) – (32) Max. 5 Ω

Between (2) – chassis ground Min. 100 kΩ

20-400 PW148-8 VEBM720100

TESTING AND ADJUSTING Failure code [CA2311] – IMV solenoid error

Circuit diagram related to supply pump actuator (metering unit)

PW148-8 VEBM720100 20-401

Failure code [CA2555] – Grid htr relay volt high error TESTING AND ADJUSTING

Failure code [CA2555] – Grid htr relay volt high error

User code Failure code Grid heater relay volt high error
Trouble
E15 CA2555 (Engine controller system)

Contents of
• Disconnection was detected in drive circuit of intake air heater relay.
trouble

Action of
• None in particular.
controller

Problem that
appears on • Intake air heater does not work (Engine does not start easily and exhaust gas becomes white at low temperature).
machine

Related
• Method of reproducing failure code: Turn starting switch ON when engine coolant temperature is below –4°C.
information

Cause Standard value in normal state/Remarks on troubleshooting

★ Prepare with starting switch OFF, then carry out troubleshooting without
turning starting switch ON. (Troubleshooting for relay unit)

R01 (male) Resistance

Between (1) – (2) 300 – 600 Ω

Defective grid heater relay
1
(Internal disconnection) ★ Prepare with starting switch OFF, then turn starting switch ON and carry
out troubleshooting. (Troubleshooting by replacement)

Replace grid heater relay (R01) with another relay and perform reproducing
operation. If "E" of failure code goes off at this time, replaced relay is defec-
tive.

★ Prepare with starting switch OFF, then carry out troubleshooting without
turning starting switch ON.
Disconnection in wiring harness
Wiring harness between CE02 (female) (40) – Resist- Max.
2 (Disconnection in wiring or
Possible causes R01 (female) (1) ance 10 Ω
defective contact in connector)
and standard
value in normal Wiring harness between CE02 (female) (42) – Resist- Max.
state R01 (female) (2) ance 10 Ω

★ Prepare with starting switch OFF, then carry out troubleshooting without
turning starting switch ON.
Short circuit in wiring harness
3 Wiring harness between CE02 (female) (40) –
(with another wiring harness) Resist- Min.
each of CE02 (female) pins (With R01 discon-
ance 100 kΩ
nected)

Connecting parts between grid heater relay – machine wiring harness –

engine controller may be defective. Check them directly.
Defective wiring harness
4 • Looseness of connector, breakage of lock, or breakage of seal
connector
• Corrosion, bend, breakage, push-in, or expansion of pin
• Moisture or dirt in connector or defective insulation

★ Prepare with starting switch OFF, then carry out troubleshooting without
turning starting switch ON.
5 Defective engine controller
CE02 (female) Resistance

Between (40) – (42) 300 – 600 Ω

20-402 PW148-8 VEBM720100

TESTING AND ADJUSTING Failure code [CA2555] – Grid htr relay volt high error

Circuit diagram related to engine preheater/starting motor/charging sys-

tem

A03 (SWP-14)

A08 (SWP-16)
9
10
11
14
CE03 (DTP-4)

A08 (SWP-16)
15
E 3
A01 (X-4)

ZN

ZM

CM01 (070-18)
1
15
2
11
6
16

2
6
(GREY) D02
(SWP-8)
13
14 4

15 8

17
18
5
6
3
4

(PINK) C02 (AMP-40)

108

C01 (AMP- )
60
24
43
42
79
80

SC02 SC01
PPC LOCK 29 18
(AMP-35) (090-22)

2
A02 (X-4)

R06 R07 R01 R04 R02 R03 R13

PW148-8 VEBM720100 20-403

Failure code [CA2556] – Grid heater relay volt low error TESTING AND ADJUSTING

Failure code [CA2556] – Grid heater relay volt low error

User code Failure code Grid heater relay volt low error
Trouble
E15 CA2556 (Engine controller system)

Contents of
• Short circuit was detected in drive circuit of intake air heater relay.
trouble

Action of
• None in particular.
controller

Problem that
appears on • Intake air heater does not work (Engine does not start easily and exhaust gas becomes white at low temperature).
machine

Related
• Method of reproducing failure code: Turn starting switch ON when engine coolant temperature is below –4°C.
information

Cause Standard value in normal state/Remarks on troubleshooting

★ Prepare with starting switch OFF, then carry out troubleshooting without
turning starting switch ON. (Troubleshooting for relay unit)

R01 (male) Resistance

Between (1) – (2) 300 – 600 Ω

Defective grid heater relay
1
(Internal disconnection) ★ Prepare with starting switch OFF, then turn starting switch ON and carry
out troubleshooting. (Troubleshooting by replacement)

Replace grid heater relay (R01) with another relay and perform reproducing
operation. If "E" of failure code goes off at this time, replaced relay is defec-
tive.

★ Prepare with starting switch OFF, then carry out troubleshooting without
Ground fault in wiring harness turning starting switch ON.
2
Possible causes (Short circuit with GND circuit) Wiring harness between CE02 (female) (40) – Resist- Min.
and standard R01 (female) (1) ance 100 kΩ
value in normal
state ★ Prepare with starting switch OFF, then carry out troubleshooting without
turning starting switch ON.
Short circuit in wiring harness
3 Wiring harness between CE02 (female) (40) –
(with another wiring harness) Resist- Min.
each of CE02 (female) pins (With R01 discon-
ance 100 kΩ
nected)

Connecting parts between grid heater relay – machine wiring harness –

engine controller may be defective. Check them directly.
Defective wiring harness
4 • Looseness of connector, breakage of lock, or breakage of seal
connector
• Corrosion, bend, breakage, push-in, or expansion of pin
• Moisture or dirt in connector or defective insulation

★ Prepare with starting switch OFF, then carry out troubleshooting without
turning starting switch ON.
5 Defective engine controller
CE02 (female) Resistance

Between (40) – (42) 300 – 600 Ω

20-404 PW148-8 VEBM720100

TESTING AND ADJUSTING Failure code [CA2556] – Grid heater relay volt low error

Circuit diagram related to engine preheater/starting motor/charging sys-

tem

A03 (SWP-14)

A08 (SWP-16)
9
10
11
14
CE03 (DTP-4)

A08 (SWP-16)
15
E 3
A01 (X-4)

ZN

ZM

CM01 (070-18)
1
15
2
11
6
16

2
6
(GREY) D02
(SWP-8)
13
14 4

15 8

17
18
5
6
3
4

(PINK) C02 (AMP-40)

108

C01 (AMP- )
60
24
43
42
79
80

SC02 SC01
PPC LOCK 29 18
(AMP-35) (090-22)

2
A02 (X-4)

R06 R07 R01 R04 R02 R03 R13

PW148-8 VEBM720100 20-405

Failure code [D110KB] – Short-circuiting in battery relay TESTING AND ADJUSTING

Failure code [D110KB] – Short-circuiting in battery relay

User Code Failure Code Failure Short-circuiting in battery relay

— D110KB phenomenon (• pump controller)

Failure content • Abnormal current flow to the battery relay drive circuit, when power was supplied to the circuit.

• The controller turns OFF power to the battery drive circuit.

Response from
• Even when the failure cause disappears, the relay does not return to normal, unless the engine starting switch is
controller
once turned OFF.

Phenomenon
occurring on • The engine does not stop.
machine

Relative • It can be confirmed in the monitor function how the battery relay works (ON or OFF).
information (Code No. 03700: Controller output)

Cause Standard value in normal and references for troubleshooting

• Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during
Presumed cause and standard value in normal

the troubleshooting.

Battery relay defective Battery relay Continuity & Resistance value

1
(Internal failure) Between A21 (BR terminal) and A20
100 Ω
(E terminal)

Between A21 (BR terminal) and grounding Above 1 MΩ

Grounding fault of wiring • Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during
harness the troubleshooting.
2
(Contact with grounding Between wiring harness from C02 (female) (108) to D01 to J01 Resistance
circuit) Above 1 MΩ
to A08 to A21 (BR terminal) and grounding value

• Turn the engine starting switch OFF for the preparations, and hold it in the ON position during
the troubleshooting.

3 Pump controller defective C02 (female) Engine starting switch OFF Voltage

20 – 30 V
Between (108) and grounding ON → OFF
(for 4 to 7 seconds)

20-406 PW148-8 VEBM720100

TESTING AND ADJUSTING Failure code [D110KB] – Short-circuiting in battery relay

Electrical circuit diagram for battery relay – Pump controller

Governor pump Starting switch

controller B BR R1 R2 C ACC
R1
C02 (AMP - 40) OFF
ACC
ST
Battery relay drive 4

H15 (090 - 22)

Monitor panel 2

CM01 (070 - 18) J01 (J-20)

Battery
11 1
Charge level
2

CAB
3
D01 (SWP - 8) 4
1
2
5
6 11
12
13

A07
(SWP - 16) (Blue)
9
Alternator
A08
Battery relay (SWP-16) B
A20 A21
15 E12 IG
E BR
A65 1 L
2
A22 M B A23
BATTERY ROOM ENGINE

PW148-8 VEBM720100 20-407

Failure code [D19JKZ] – Personal code relay abnormality TESTING AND ADJUSTING

Failure code [D19JKZ] – Personal code relay abnormality

User code Failure code

Trouble Personal code relay abnormality
E01 D19JKZ

Contents of
• Disconnection or short circuit was detected in personal code relay circuit.
trouble

• None in particular (when disconnection is detected).

Action of • Turns output to personal code relay OFF (when short circuit is detected).
controller • If cause of failure disappears, system resets itself (when disconnection is detected).
• Even if cause of failure disappears, system does not reset itself until starting switch is turned OFF.

Problem that
appears on
machine

Related • Method of reproducing failure code: Turn starting switch ON (Disconnection). Trouble cannot be reproduced on
information machine (Short circuit).

Cause Standard value in normal state/Remarks on troubleshooting

1 Defective fuse No. 3 If fuse is broken, circuit probably has ground fault (See cause 4).

★ Prepare with starting switch OFF, then carry out troubleshooting without
turning starting switch ON. (Troubleshooting for relay unit)

R07 (male) Resistance

Defective personal code relay Between (1) – (2) (300 – 600 Ω)

2 (Internal disconnection or short
circuit) ★ Prepare with starting switch OFF, then turn starting switch ON and carry
out troubleshooting. (Troubleshooting by replacement)

Replace personal code relay (R07) with another relay and perform reproduc-
ing operation. If "E" of failure code goes off at this time, replaced relay is
defective.
Possible causes
and standard ★ Prepare with starting switch OFF, then carry out troubleshooting without
value in normal turning starting switch ON.
state Disconnection in wiring harness
Wiring harness between FB1 (3) – R07 (female) Resist-
3 (Disconnection in wiring or Max. 1 Ω
(1) ance
defective contact in connector)
Wiring harness between R07 (female) (2) – CM01 Resist-
Max. 1 Ω
(female) (6) ance

★ Prepare with starting switch OFF, then carry out troubleshooting without
turning starting switch ON.

Ground fault in wiring harness Wiring harness between FB1 (3) – R13 (female) Resist- Min.
4
(Short circuit with GND circuit) (1) ance 1 MΩ

Wiring harness between R07 (female) (2) – CM01 Resist- Min.

(female) (6) ance 1 MΩ

If causes 1 – 4 are not detected, machine monitor may be defective. (Since

5 Defective machine monitor
trouble is in system, troubleshooting cannot be carried out.)

20-408 PW148-8 VEBM720100

TESTING AND ADJUSTING Failure code [D19JKZ] – Personal code relay abnormality

Circuit diagram related to engine preheater/starting motor/charging sys-

tem

A03 (SWP-14)

A08 (SWP-16)
9
10
11
14
CE03 (DTP-4)

A08 (SWP-16)
15
E 3
A01 (X-4)

ZN

ZM

CM01 (070-18)
1
15
2
11
6
16

2
6
(GREY) D02
(SWP-8)
13
14 4

15 8

17
18
5
6
3
4

(PINK) C02 (AMP-40)

108

C01 (AMP- )
60
24
43
42
79
80

SC02 SC01
PPC LOCK 29 18
(AMP-35) (090-22)

2
A02 (X-4)

R06 R07 R01 R04 R02 R03 R13

PW148-8 VEBM720100 20-409

Failure code [D862KA] – GPS antenna disconnection TESTING AND ADJUSTING

Failure code [D862KA] – GPS antenna disconnection

User code Failure code GPS antenna disconnection

Trouble
- D862KA (KOMTRAX system in machine monitor)

Contents of
• Disconnection was detected in GPS antenna circuit.
trouble

Action of • None in particular.

controller • If cause of failure disappears, system resets itself.

Problem that
appears on • GPS cannot measure position.
machine

Related
• Method of reproducing failure code: Turn starting switch ON.
information

Possible causes Cause Standard value in normal state/Remarks on troubleshooting

and standard
value in normal Defective GPS antenna or GPS antenna may be defective and antenna cable may be disconnected or
1
state antenna cable shorted and antenna cable may be connected defectively.

Configuration diagram of KOMTRAX system

20-410 PW148-8 VEBM720100

TESTING AND ADJUSTING Failure code [D862KA] – GPS antenna disconnection

Blank for technical reason

PW148-8 VEBM720100 20-411

Failure code [DA25KP] – 5V sensor 1 power abnormality TESTING AND ADJUSTING

Failure code [DA25KP] – 5V sensor 1 power abnormality

Action code Failure code Pressure sensor power abnormality

Trouble
- DA25KP (Pump controller system)

Contents of
• Abnormal current flowed in pressure sensor power supply (5V) circuit.
trouble

Action of • Turns output to power supply (5V) circuit OFF.

controller • Even if phenomenon of failure disappears, system does not reset itself until starting switch is turned OFF.

Problem that
• Signal of pressure sensor is not input normally.
appears on
• Pressure sensor failure code is displayed at the same time.
machine

Related
information

Cause Standard value in normal state/Remarks on troubleshooting

★ Disconnect connector with starting switch OFF, then turn starting switch
ON and carry out troubleshooting.

Pump pressure sensor A51 connector

Disconnect sensor and Overload caution sen-

Defective pressure sensor G164 connector
1 wiring harness at right sor
(Internal short circuit)
in order. If no failure Travel PPC pressure
code is displayed, that A56 connector
sensor
sensor is defective.
Transmission speed
A57 connector
sensor

★ Prepare with starting switch OFF, then carry out troubleshooting without
turning starting switch ON.
Possible causes Wiring harness between C01 (female) (8) – A03 –
and standard Resist- Min.
A51 (female) (3) and chassis ground [F pump
value in normal ance 1 MΩ
pressure sensor system]
state
Wiring harness between C01 (female) (8) – A03 –
Resist- Min.
Ground fault in wiring harness G164 (female) (3) and chassis ground [R pump
2 ance 1 MΩ
(Short circuit with GND circuit) pressure sensor system]

Wiring harness between C01 (female) (8) – A03 –

Resist- Min.
A56 (female) (3) and chassis ground [Bucket
ance 1 MΩ
CURL pressure sensor system]

Wiring harness between C01 (female) (8) – A03 –

Resist- Min.
A57 (female) (3) and chassis ground [Arm IN
ance 1 MΩ
pressure sensor system]

★ Prepare with starting switch OFF, then turn starting switch ON and carry
out troubleshooting.
3 Defective pump controller
C01 Voltage

Between (8) – (47) 4.5 – 5.5 V

20-412 PW148-8 VEBM720100

TESTING AND ADJUSTING Failure code [DA25KP] – 5V sensor 1 power abnormality

Circuit diagram related to pressure sensor power supply of pump control-

ler

C01 (AMP-80) A06 (SWP-16)

Overload caution sensor 31

Travel PPC pressure sensor 12

F. pump pressure sensor 49

47 A03 (SWP-14) Overload

G164
caution
8 sensor

A04 (SWP-14)

C01 (AMP-80)
GND (Pulse GND) 44
Pump
A51 pressure
Speed pick up
25 sensor
sensor

2.2K Ω

A56 Travel PPC

pressure
A14 sensor
(DT-3)

Swivel Joint

A14
5 6
(DT-6)

A57
(DT-2)
Transmission
speed sensor

PW148-8 VEBM720100 20-413

Failure code [DA2RMC] – CAN discon (pump con detected) TESTING AND ADJUSTING

Failure code [DA2RMC] – CAN discon (pump con detect-

ed)

Action code Failure code CAN disconnection (Pump controller detected)

Trouble
E0E DA2RMC (Pump controller system)

Contents of • Pump controller detected communication error in CAN communication circuit between machine monitor and engine
trouble controller.

Action of • Continues operation with information of CAN communication just before detection of error.
controller • If cause of failure disappears, system resets itself.

Problem that
• Information may not transmitted normally by CAN communication and machine may not operate normally. (Trouble
appears on
phenomenon depends on failed section.)
machine

Related
• Method of reproducing failure code: Turn starting switch ON.
information

Cause Standard value in normal state/Remarks on troubleshooting

★ Prepare with starting switch OFF, then carry out troubleshooting without
turning starting switch ON.

Wiring harness between CM02 (female) (8), (9) –

Disconnection in wiring harness Resist-
C01 (female) (45), – CE02 (female) (46), – K02 Max. 1 Ω
1 (Disconnection in wiring or ance
(female) (A)
defective contact in connector)
Wiring harness between CM02 (female) (10) –
Resist-
C01 (female) (64), – CE02 (female) (47), – K02 Max. 1 Ω
ance
(female) (B)

★ Prepare with starting switch OFF, then carry out troubleshooting without
turning starting switch ON.

Wiring harness between CM02 (female) (8), (9) –

Resist- Min.
Ground fault in wiring harness C01 (female) (45), – CE02 (female) (46), – K02
2 ance 1 MΩ
(Short circuit with GND circuit) (female) (A), – N08 (male) (3)
Possible causes Wiring harness between CM02 (female) (10) –
and standard Resist- Min.
C01 (female) (64), – CE02 (female) (47), – K02
value in normal ance 1 MΩ
(female) (B), – N08 (male) (10)
state
★ Prepare with starting switch OFF, then turn starting switch ON and carry
out troubleshooting.

Wiring harness between CM02 (female) (8), (9) –

Max.
Hot short (Short circuit with 24V C01 (female) (45), – CE02 (female) (46), – K02 Voltage
3 5.5 V
circuit) in wiring harness (female) (A), – N08 (male) (3)

Wiring harness between CM02 (female) (10) –

Max.
C01 (female) (64), – CE02 (female) (47), – K02 Voltage
5.5 V
(female) (B), – N08 (male) (10)

★ Prepare with starting switch OFF, then carry out troubleshooting without
Defective CAN terminal resist- turning starting switch ON.
4 ance (Internal short circuit or
K02 (male) Resistance
disconnection)
Between (A) – (B) 120 ± 12 MΩ

If causes 1 – 4 are not detected, pump controller may be defective. (Since

5 Defective pump controller
trouble is in system, troubleshooting cannot be carried out.)

20-414 PW148-8 VEBM720100

TESTING AND ADJUSTING Failure code [DA2RMC] – CAN discon (pump con detected)

Circuit diagram related to CAN communication

3 10 1 2

8
9 45
10 64

12 13 A08
(SWP-16)
46 A
47 B
C

PW148-8 VEBM720100 20-415

Failure code [DAFRMC] – GPS module error TESTING AND ADJUSTING

Failure code [DAFRMC] – GPS module error

User code Failure code GPS module operation error

Trouble
— DAFGMC (KOMTRAX system in machine monitor)

Contents of trou- • Position data is not sent from GPS module (in machine monitor) to KOMTRAX communication MODEM in 50 sec-
ble onds after KOMTRAX is started.

Action of • None in particular.

machine monitor • If cause of failure disappears, system resets itself.

Problem that
appears on
machine

Related informa- • Method of reproducing failure code: Turn starting switch ON (At least 50 seconds after starting switch is turned
tion ON).

Possible causes Cause Standard value in normal state/Remarks on troubleshooting

and standard
Defective machine monitor GPS module of machine monitor may be defective. (Since trouble is in sys-
value in normal 1 tem, troubleshooting cannot be carried out.)
state

20-416 PW148-8 VEBM720100

TESTING AND ADJUSTING Failure code [DAFRMC] – GPS module error

Blank for technical reason

PW148-8 VEBM720100 20-417

Failure code [DAFRMC] – CAN discon (monitor detected) TESTING AND ADJUSTING

Failure code [DAFRMC] – CAN discon (monitor detected)

Action code Failure code CAN disconnection (Monitor detected)

Trouble
E0E DAFRMC (Machine monitor system)

Contents of • Machine monitor detected communication error in CAN communication circuit between pump controller and engine
trouble controller.

Action of
• If cause of failure disappears, system resets itself.
controller

Problem that
• Information may not transmitted normally by CAN communication and machine may not operate normally. (Trouble
appears on
phenomenon depends on failed section.)
machine

Related
• Method of reproducing failure code: Turn starting switch ON.
information

Cause Standard value in normal state/Remarks on troubleshooting

★ Prepare with starting switch OFF, then carry out troubleshooting without
turning starting switch ON.

Wiring harness between CM02 (female) (8), (9) –

Disconnection in wiring harness Resist-
C01 (female) (45), – CE02 (female) (46), – K02 Max. 1 Ω
1 (Disconnection in wiring or ance
(female) (A)
defective contact in connector)
Wiring harness between CM02 (female) (10) –
Resist-
C01 (female) (64), – CE02 (female) (47), – K02 Max. 1 Ω
ance
(female) (B)

★ Prepare with starting switch OFF, then carry out troubleshooting without
turning starting switch ON.

Wiring harness between CM02 (female) (8), (9) –

Resist- Min.
Ground fault in wiring harness C01 (female) (45), – CE02 (female) (46), – K02
2 ance 1 MΩ
(Short circuit with GND circuit) (female) (A), – N08 (male) (3)
Possible causes Wiring harness between CM02 (female) (10) –
and standard Resist- Min.
C01 (female) (64), – CE02 (female) (47), – K02
value in normal ance 1 MΩ
(female) (B), – N08 (male) (10)
state
★ Prepare with starting switch OFF, then turn starting switch ON and carry
out troubleshooting.

• Wiring harness between CM02 (female) (8), (9)

Max.
Hot short (Short circuit with 24V – C01 (female) (45), – CE02 (female) (46), – Voltage
3 5.5 V
circuit) in wiring harness K02 (female) (A), – N08 (male) (3)

• Wiring harness between CM02 (female) (10) –

Max.
C01 (female) (64), – CE02 (female) (47), – K02 Voltage
5.5 V
(female) (B), – N08 (male) (10)

★ Prepare with starting switch OFF, then carry out troubleshooting without
Defective CAN terminal resist- turning starting switch ON.
4 ance (Internal short circuit or
K02 (male) Resistance
disconnection)
Between (A) – (B) 120 ±12 Ω

If causes 1 Ð 4 are not detected, machine monitor may be defective. (Since

5 Defective machine monitor
trouble is in system, troubleshooting cannot be carried out.)

20-418 PW148-8 VEBM720100

TESTING AND ADJUSTING Failure code [DAFRMC] – CAN discon (monitor detected)

Circuit diagram related to CAN communication

3 10 1 2

8
9 45
10 64

12 13 A08
(SWP-16)
46 A
47 B
C

PW148-8 VEBM720100 20-419

Failure code [DDP4KX] – Abnormality in travel PPC pressure switch TESTING AND ADJUSTING

Failure code [DDP4KX] – Abnormality in travel PPC pres-

sure switch

User Code Failure Code Failure Disconnection in travel PPC pressure switch (in pump
E20 DDP4KX phenomenon controller system)

Failure content • Error code appears on monitor

Response from
• Defaults travel speed to ‘Creep only‘ (after machines stops).
controller

Phenomenon
• In some case, roll back on hill start may becomme worse.
occurring on
• In some case, control of engine speed by travel pedal is not possible.
machine

Relative If machine can travel when travel pedal is fully pressed but direction control switch FNR switch is in neutral, then travel
information neutral solenoid should be replaced.

Cause Standard value in normal and references for troubleshooting

• Turn starting switch OFF for the preparations, and hold it OFF during troubleshooting.

S09
Pressure switch defective
1 Between (1) and (2) Resistence
(Internal short circuiting) Below 1 Ω
standard value in normal

S10 valve
Presumed cause and

Between (1) and (2).

• Turn starting switch OFF for the preparations, and hold it OFF during troubleshooting.
Disconnection of wiring Between C01-36 and S09-2
harness (disconnection or
2 Between C01-55 and S10-2 Resistance
defective contact with con- Below 1 Ω
nector) value
Between S09-1 and A65-1
Between S10-1 and A65-1
• Turn starting switch ON, engine ON,hold F-N-R switch at neutral position
Defective travel neutral
3 If machine can travel when travel pedal is fully pressed but direction control
solenoid
switch FNR switch is in neutral, then travel neutral solenoid should be replaced.

20-420 PW148-8 VEBM720100

TESTING AND ADJUSTING Failure code [DDP4KX] – Abnormality in travel PPC pressure switch

Electrical circuit diagram for travel PPC pressure switch

Travel reverse
S09 (X-2)
pressure switch
Pump controler 1
A06
C01 (AMP-81) (SWP - 16) 2

Travel reverse pressure switch 36 16 Travel forward

S10 (X-2)
Travel forward pressure switch 55 15 pressure switch
U4
1
2

U25

A65

PW148-8 VEBM720100 20-421

Failure code [DDWCKZ] – Abnormality in travel direction control switch TESTING AND ADJUSTING

Failure code [DDWCKZ] – Abnormality in travel direction

control switch

User Code Failure Code Failure Disconnection in direction control switches

E20 DDWCKZ phenomenon (in pump controller system)

Failure content • Error code appears on monitor

Response from
• Defaults travel mode to ’N’ (Neutral).
controller
Phenomenon
occurring on • Machine cannot travel
machine
Relative
information

Cause Standard value in normal and references for troubleshooting

All travel direction signals
OFF
1 Between G71 (1) and G71 (2)
Presumed cause and standard
• Turn starting switch OFF for the preparations, and hold it OFF during troubleshooting.
FNR switch in position F Resistance value
Between G71 (1) and G71 (2) Less than 1 Ω
Between G71 (1) and G71 (3) Above 1 MΩ
Between G71 (1) and G71 (4) Above 1 MΩ
FNR switch in position N Resistance value
Above 1 MΩ
Between G71 (1) and G71 (3) Less than 1 Ω
Between G71 (1) and G71 (4) Above 1 MΩ
FNR switch in position R Resistance value
Between G71 (1) and G71 (2) Above 1 MΩ
Between G71 (1) and G71 (3) Above 1 MΩ

Between G71 (1) and G71 (4) Less than 100 Ω

2 or more travel direction • Turn starting switch OFF for the preparations, then turn ON during troubleshooting.
value in normal

signals ON FNR switch in position F Voltage

2 Between C01 (61) and ground
Disconection of wiring har-
ness (disconection or
deflective contact with con-
nector)
3 Resistance
Between C01 (61) and ground Min. 16V
Between C01 (42) and ground Max. 1V
Between C01 (23) and ground Max. 1V
FNR switch in position N Voltage
Max. 1V
Between C01 (42) and ground Min. 16V
Between C01 (23) and ground Max. 1V
FNR switch in position R Voltage
Between C01 (61) and ground Max. 1V
Between C01 (42) and ground Max. 1V
Between C01 (23) and ground Min. 16V
• Turn starting switch OFF for the preparations and hold OFF during troubleshooting.
Between S29 (1) and G71 (1)
Between S29 (2) and FB2 (1)
Between G71 (2) and C01 (61) Below 1 Ω
value
Between G71 (3) and C01 (42)
Between G71 (4) and C01 (23)

20-422 PW148-8 VEBM720100

TESTING AND ADJUSTING Failure code [DDWCKZ] – Abnormality in travel direction control switch

Electrical circuit diagram for travel direction control switch

F-N-R SW
S96 (OTAX-9) 1 2 3 4
1 2 3 F
Emergancy N
Normal J02 (090-20)
R

2 1 1 2 3 4 7 10 12 13
S29 G71
(DT-12) (DT-6)
FB2 Pump controller
21 1 C01 (AMP-81)
23 Travel R
42 Travel N
61 Travel F

PW148-8 VEBM720100 20-423

Failure code [DFB1KZ] – 1st ATT service lever main potentio 1 abnormality TESTING AND ADJUSTING

Failure code [DFB1KZ] – 1st ATT service lever main poten-

tio 1 abnormality

User code Failure code

Trouble RH Lever main potentiometer (for 1st Att.) has failure
— DFB1KZ
Contents of trouble • Potentiometer’s output voltage is out of range (below 0.4 volts or above 4.6 volts)
Action of • Turns output to service EPC solenoids (EPC1 & EPC2) OFF.
controller • Even if cause of failure disappears, system does not reset itself until starting switch is turned OFF.
Problem that
appears on • 1st Attachment does not operate.
machine
• Main potentio output voltage can be checked with monitoring function.
(Code: 42008 Lever potentio 1 volt (Main))
• Sub potentio output voltage can be checked with monitoring function.
Related informa-
(Code 42009 Lever potentio 1 volt (Sub))
tion
• Potentiometer stroke can be checked with monitoring function.
(Code 42012 Lever potentio 1 stroke)
• Method of reproducing failure code : Turn starting switch to ON + set in attachment mode (ATT).

Cause Standard value in normal state/Remarks on troubleshooting

★ Prepare with starting switch OFF, then turn starting switch ON and carry out trouble-
shooting.
Lever slide sw Neutral 2.5 ± 0.3 V
Lever slide sw Upper max. 4.0 ~ 4.6 V
Monitoring function code : 42008 Lever slide sw Lower max. 0.4 ~ 1.0 V
Lever potentio 1
If voltage is 0V and no movement, disconnection or
Volt (Main)
ground short may be the cause.
Defective RH lever If voltage is 5V and no movement, hot short may be the
1
assembly cause.
G72 (female) Voltage
Between (1) - (2) Potentio 5V supply 4.5 ~ 5.5 V
Possible causes
Lever slide sw Neutral 2.5 ± 0.3 V
and standard value
Between (3) - (2)
in normal state Lever slide sw Upper max. 4.0 ~ 4.6 V
Potentio output
Lever slide sw Lower max. 0.4 ~ 1.0 V
If G72 (1) - (2) voltage 0V, disconnection may be the cause.
Disconnection in ★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting
wiring harness. switch ON.
(Disconnection in Wiring harness between G72 (female) (1) - C01 (female) (9) Resistance Max.1 Ω
2
wiring or defective
contact in Wiring harness between G72 (female) (2) - C01 (female) (18) Resistance Max.1 Ω
connector). Wiring harness between G72 (female) (3) - C01 (female) (69) Resistance Max.1 Ω
★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting
Ground fault in
switch ON.
wiring harness.
3
(Short circuit with Wiring harness between G72 (female) (1) - C01 (female) (9) Resistance Min.100 kΩ
GND circuit)
Wiring harness between G72 (female) (3) - C01 (female) (69) Resistance Min.100 kΩ

20-424 PW148-8 VEBM720100

TESTING AND ADJUSTING Failure code [DFB1KZ] – 1st ATT service lever main potentio 1 abnormality

Cause Standard value in normal state/Remarks on troubleshooting

Hot short ★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting
(Short circuit with 5 switch ON.
4
Volts circuit) in wiring Wiring harness between G72 (female) (3) - G72 (female) (1).
harness. Resistance Min.100 kΩ
(Measure it disconnecting G72 connector).
Possible causes
and standard value Ground fault in wir- ★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting
in normal state ing harness . switch ON.
5 (No secure GND Wiring harness between G72 (female (2) - chassis GND
from pump control- Resistance Max.30 Ω
ler).
Defective pump con- If cause 1 -5 are not detected, pump controller may be defective.
6
troller. (Since trouble is in system, troubleshooting cannot be carried out).

LEVER LH (2nd ATT) LEVER RH (1st ATT)

Sub Potentio 2 Sub Potentio 1

Main Potentio 2 Main Potentio 1

G70 G72
(DTM-12) (DTM-12)
1 2 3 4 1 2 3 4

J02 J06
(J-20) (J-20)

1 2 6 5 Pump Controller

C01
Potentio Power (+5 V)
1st Service Potentio (Sub)
S
ANALOG GND
2nd Service Potentio (Main)
2nd Service Potentio (Sub)
1st Service Potentio (Main)

G0148500

PW148-8 VEBM720100 20-425

Failure code [DFB2KZ] – 2nd ATT service lever main potentio 2 abnormality TESTING AND ADJUSTING

Failure code [DFB2KZ] – 2nd ATT service lever main po-

tentio 2 abnormality

User code Failure code

Trouble LH Lever main potentiometer (for 2nd Att.) has failure
— DFB2KZ
Contents of trouble • Potentiometer’s output voltage is out of range (below 0.4 volts or above 4.6 volts)
Action of • Turns output to service EPC solenoids (EPC3 & EPC4) OFF.
controller • Even if cause of failure disappears, system does not reset itself until starting switch is turned OFF.
Problem that
appears on • 2nd Attachment does not operate.
machine
• Main potentio output voltage can be checked with monitoring function.
(Code: 42010 Lever potentio 2 volt (Main))
• Sub potentio output voltage can be checked with monitoring function.
Related informa-
(Code 42011 Lever potentio 2 volt (Sub))
tion
• Potentiometer stroke can be checked with monitoring function.
(Code 42013 Lever potentio 2 stroke)
• Method of reproducing failure code : Turn starting switch to ON + set in attachment mode (ATT).

Cause Standard value in normal state/Remarks on troubleshooting

★ Prepare with starting switch OFF, then turn starting switch ON and carry out trouble-
shooting.
Lever slide sw Neutral 2.5 ± 0.3 V
Lever slide sw Upper max. 4.0 ~ 4.6 V
Monitoring function code : 42010 Lever slide sw Lower max. 0.4 ~ 1.0 V
Lever potentio 2
If voltage is 0V and no movement, disconnection or
Volt (Main)
ground short may be the cause.
Defective LH lever If voltage is 5V and no movement, hot short may be the
1
assembly cause.
G70 (female) Voltage
Between (1) - (2) Potentio 5V supply 4.5 ~ 5.5 V
Possible causes
Lever slide sw Neutral 2.5 ± 0.3 V
and standard value
Between (3) - (2)
in normal state Lever slide sw Upper max. 4.0 ~ 4.6 V
Potentio output
Lever slide sw Lower max. 0.4 ~ 1.0 V
If G70 (1) - (2) voltage 0V, disconnection may be the cause.
Disconnection in wir- ★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting
ing harness. switch ON.
(Disconnection in Wiring harness between G70 (female) (1) - C01 (female) (9) Resistance Max.1 Ω
2
wiring or defective
contact in connec- Wiring harness between G70 (female) (2) - C01 (female) (18) Resistance Max.1 Ω
tor). Wiring harness between G70 (female) (3) - C01 (female) (69) Resistance Max.1 Ω
★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting
Ground fault in wir-
switch ON.
ing harness.
3
(Short circuit with Wiring harness between G70 (female) (1) - C01 (female) (9) Resistance Min.100 kΩ
GND circuit)
Wiring harness between G70 (female) (3) - C01 (female) (69) Resistance Min.100 kΩ

20-426 PW148-8 VEBM720100

TESTING AND ADJUSTING Failure code [DFB2KZ] – 2nd ATT service lever main potentio 2 abnormality

Cause Standard value in normal state/Remarks on troubleshooting

Hot short ★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting
(Short circuit with 5 switch ON.
4
Volts circuit) in wiring Wiring harness between G70 (female) (3) - G70 (female) (1).
harness. Resistance Min.100 kΩ
(Measure it disconnecting G70 connector).
Possible causes
and standard value Ground fault in wir- ★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting
in normal state ing harness . switch ON.
5 (No secure GND Wiring harness between G70 (female (2) - chassis GND
from pump control- Resistance Max.30 Ω
ler).
Defective pump con- If cause 1 -5 are not detected, pump controller may be defective.
6
troller. (Since trouble is in system, troubleshooting cannot be carried out).

LEVER LH (2nd ATT) LEVER RH (1st ATT)

Sub Potentio 2 Sub Potentio 1

Main Potentio 2 Main Potentio 1

G70 G72
(DTM-12) (DTM-12)
1 2 3 4 1 2 3 4

J02 J06
(J-20) (J-20)

1 2 6 5 Pump Controller

C01
Potentio Power (+5 V)
1st Service Potentio (Sub)
S
ANALOG GND
2nd Service Potentio (Main)
2nd Service Potentio (Sub)
1st Service Potentio (Main)

G0148500

PW148-8 VEBM720100 20-427

Failure code [DFB3L8] – 1st ATT service lever Potentio 1 error TESTING AND ADJUSTING

Failure code [DFB3L8] – 1st ATT service lever Potentio 1

error
User code Failure code
Trouble RH Lever potentiometer (for 1st Att.) has failure
— DFB3L8
Contents of trouble • Summation of Potentiometer’s output voltage is out of range (below 4.5 volts or above 5.5 volts)
Action of • Turns output to service EPC solenoids (EPC1 & EPC2) OFF.
controller • Even if cause of failure disappears, system does not reset itself until starting switch is turned OFF.
Problem that
appears on • 1st Attachment does not operate.
machine
• Main potentio output voltage can be checked with monitoring function.
(Code: 42008 Lever potentio 1 volt (Main))
• Sub potentio output voltage can be checked with monitoring function.
Related informa-
(Code 42009 Lever potentio 1 volt (Sub))
tion
• Potentiometer stroke can be checked with monitoring function.
(Code 42012 Lever potentio 1 stroke)
• Method of reproducing failure code : Turn starting switch to ON + set in attachment mode (ATT)..

• For troubleshooting, carry out [DFB1KZ] and [DFB5KZ]

• Information

<Potentiometer’s output voltage>

As shown below, summation of Main and Sub Potentiometer

output to be constant.
If this value exceeded 5 ± 0.5 V, this Failure code [DFB3L8] is
displayed.
The cause to be Main or Sub potentiometer’s output error,
so need to carry out troubleshooting in [DFB1KZ] and
[DFB5KZ].

Output Voltage (V)

4.3
Main Potentio Output

2.5

Sub Potentio Output

0.7

Lower Neutral Upper

max max
(V)
5 ± 0.5 Summation of Main &
Sub Potentio Output

20-428 PW148-8 VEBM720100

TESTING AND ADJUSTING Failure code [DFB4L8] – 2nd ATT service lever potentio 2 error

Failure code [DFB4L8] – 2nd ATT service lever potentio 2

error
User code Failure code
Trouble LH Lever potentiometer (for 2nd Att.) has failure
— DFB4L8
Contents of trouble • Summation of Potentiometer’s output voltage is out of range (below 4.5 volts or above 5.5 volts)
Action of • Turns output to service EPC solenoids (EPC3 & EPC4) OFF.
controller • Even if cause of failure disappears, system does not reset itself until starting switch is turned OFF.
Problem that
appears on • 2nd Attachment does not operate.
machine
• Main potentio output voltage can be checked with monitoring function.
(Code: 42010 Lever potentio 2 volt (Main))
• Sub potentio output voltage can be checked with monitoring function.
Related information (Code 42011 Lever potentio 2 volt (Sub))
• Potentiometer stroke can be checked with monitoring function.
(Code 42013 Lever potentio 2 stroke)
• Method of reproducing failure code : Turn starting switch to ON + set in attachment mode (ATT)..

• For troubleshooting, carry out [DFB2KZ] and [DFB6KZ]

• Information

<Potentiometer’s output voltage>

As shown below, summation of Main and Sub Potentiometer

output to be constant.
If this value exceeded 5 ± 0.5 V, this Failure code [DFB4L8] is
displayed.
The cause to be Main or Sub potentiometer’s output error,
so need to carry out troubleshooting in [DFB2KZ] and
[DFB6KZ].

Output Voltage (V)

4.3
Main Potentio Output

2.5

Sub Potentio Output

0.7

Lower Neutral Upper

max max
(V)
5 ± 0.5 Summation of Main &
Sub Potentio Output

PW148-8 VEBM720100 20-429

Failure code [DFB5KZ] – 1st ATT service lever main potentio 1 abnormality TESTING AND ADJUSTING

Failure code [DFB5KZ] – 1st ATT service lever main poten-

tio 1 abnormality

User code Failure code

Trouble RH Lever main potentiometer (for 1st Att.) has failure
— DFB5KZ
Contents of trouble • Potentiometer’s output voltage is out of range (below 0.4 volts or above 4.6 volts)
Action of • Turns output to service EPC solenoids (EPC1 & EPC2) OFF.
controller • Even if cause of failure disappears, system does not reset itself until starting switch is turned OFF.
Problem that
appears on • 1st Attachment does not operate.
machine
• Main potentio output voltage can be checked with monitoring function.
(Code: 42008 Lever potentio 1 volt (Main))
• Sub potentio output voltage can be checked with monitoring function.
Related informa-
(Code 42009 Lever potentio 1 volt (Sub))
tion
• Potentiometer stroke can be checked with monitoring function.
(Code 42012 Lever potentio 1 stroke)
• Method of reproducing failure code : Turn starting switch to ON + set in attachment mode (ATT).

Cause Standard value in normal state/Remarks on troubleshooting

★ Prepare with starting switch OFF, then turn starting switch ON and carry out trouble-
shooting.
Lever slide sw Neutral 2.5 ± 0.3 V
Lever slide sw Upper max. 0.4 ~ 1.0 V
Monitoring function code : 42008 Lever slide sw Lower max. 4.0 ~ 4.6 V
Lever potentio 1
If voltage is 0V and no movement, disconnection or
Volt (Main)
ground short may be the cause.
Defective RH lever If voltage is 5V and no movement, hot short may be the
1
assembly cause.
G72 (female) Voltage
Between (1) - (2) Potentio 5V supply 4.5 ~ 5.5 V
Possible causes
Lever slide sw Neutral 2.5 ± 0.3 V
and standard value
Between (4) - (2)
in normal state Lever slide sw Upper max. 0.4 ~ 1.0 V
Potentio output
Lever slide sw Lower max. 4.0 ~ 4.6 V
If G72 (1) - (2) voltage 0V, disconnection may be the cause.
★ Prepare with starting switch OFF, then carry out troubleshooting without turning start-
Disconnection in
ing switch ON.
wiring harness.
2 (Disconnection in Wiring harness between G72 (female) (1) - C01 (female) (9) Resistance Max.1 Ω
wiring or defective Wiring harness between G72 (female) (2) - C01 (female) (18) Resistance Max.1 Ω
contact in connector).
Wiring harness between G72 (female) (3) - C01 (female) (13) Resistance Max.1 Ω

Ground fault in wiring ★ Prepare with starting switch OFF, then carry out troubleshooting without turning start-
ing switch ON.
harness.
3
(Short circuit with Wiring harness between G72 (female) (1) - C01 (female) (9) Resistance Min.100 kΩ
GND circuit)
Wiring harness between G72 (female) (3) - C01 (female) (13) Resistance Min.100 kΩ

20-430 PW148-8 VEBM720100

TESTING AND ADJUSTING Failure code [DFB5KZ] – 1st ATT service lever main potentio 1 abnormality

Cause Standard value in normal state/Remarks on troubleshooting

Hot short ★ Prepare with starting switch OFF, then carry out troubleshooting without turning start-
(Short circuit with 5 ing switch ON.
4
Volts circuit) in wiring Wiring harness between G72 (female) (4) - G72 (female) (1).
harness. Resistance Min.100 kΩ
Possible causes (Measure it disconnecting G72 connector).
and standard value
Ground fault in wiring ★ Prepare with starting switch OFF, then carry out troubleshooting without turning start-
in normal state
harness . ing switch ON.
5
(No secure GND from
Wiring harness between G72 (female (2) - chassis GND Resistance Max.30 Ω
pump controller).
Defective pump con- If cause 1 -5 are not detected, pump controller may be defective.
6
troller. (Since trouble is in system, troubleshooting cannot be carried out).

LEVER LH (2nd ATT) LEVER RH (1st ATT)

Sub Potentio 2 Sub Potentio 1

Main Potentio 2 Main Potentio 1

G70 G72
(DTM-12) (DTM-12)
1 2 3 4 1 2 3 4

J02 J06
(J-20) (J-20)

1 2 6 5 Pump Controller

C01
Potentio Power (+5 V)
1st Service Potentio (Sub)
S
ANALOG GND
2nd Service Potentio (Main)
2nd Service Potentio (Sub)
1st Service Potentio (Main)

G0148500

PW148-8 VEBM720100 20-431

Failure code [DFB6KZ] – Service lever potentio 2 abnormality TESTING AND ADJUSTING

Failure code [DFB6KZ] – Service lever potentio 2

abnormality

User code Failure code

Trouble LH Lever main potentiometer (for 2nd Att.) has failure
— DFB6KZ
Contents of trouble • Potentiometer’s output voltage is out of range (below 0.4 volts or above 4.6 volts)
Action of • Turns output to service EPC solenoids (EPC3 & EPC4) OFF.
controller • Even if cause of failure disappears, system does not reset itself until starting switch is turned OFF.
Problem that
appears on • 2nd Attachment does not operate.
machine
• Main potentio output voltage can be checked with monitoring function.
(Code: 42010 Lever potentio 2 volt (Main))
• Sub potentio output voltage can be checked with monitoring function.
Related informa-
(Code 42011 Lever potentio 2 volt (Sub))
tion
• Potentiometer stroke can be checked with monitoring function.
(Code 42013 Lever potentio 2 stroke)
• Method of reproducing failure code : Turn starting switch to ON + set in attachment mode (ATT).

Cause Standard value in normal state/Remarks on troubleshooting

★ Prepare with starting switch OFF, then turn starting switch ON and carry out trouble-
shooting.
Lever slide sw Neutral 2.5 ± 0.3 V
Lever slide sw Upper max. 0.4 ~ 1.0 V
Monitoring function code : 42011 Lever slide sw Lower max. 4.0 ~ 4.6 V
Lever potentio 2
If voltage is 0V and no movement, disconnection or
Volt (Main)
ground short may be the cause.
Defective LH lever If voltage is 5V and no movement, hot short may be the
1
assembly cause.
G70 (female) Voltage
Between (1) - (2) Potentio 5V supply 4.5 ~ 5.5 V
Possible causes
Lever slide sw Neutral 2.5 ± 0.3 V
and standard value
Between (4) - (2)
in normal state Lever slide sw Upper max. 0.4 ~ 1.0 V
Potentio output
Lever slide sw Lower max. 4.0 ~ 4.6 V
If G70 (1) - (2) voltage 0V, disconnection may be the cause.
Disconnection in ★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting
wiring harness. switch ON.
(Disconnection in Wiring harness between G70 (female) (1) - C01 (female) (9) Resistance Max.1 Ω
2
wiring or defective
contact in Wiring harness between G70 (female) (2) - C01 (female) (18) Resistance Max.1 Ω
connector). Wiring harness between G70 (female) (4) - C01 (female) (51) Resistance Max.1 Ω
★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting
Ground fault in
switch ON.
wiring harness.
3
(Short circuit with Wiring harness between G70 (female) (1) - C01 (female) (9) Resistance Min.100 kΩ
GND circuit)
Wiring harness between G70 (female) (4) - C01 (female) (51) Resistance Min.100 kΩ

20-432 PW148-8 VEBM720100

TESTING AND ADJUSTING Failure code [DFB6KZ] – Service lever potentio 2 abnormality

Cause Standard value in normal state/Remarks on troubleshooting

Hot short ★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting
(Short circuit with 5 switch ON.
4
Volts circuit) in wiring Wiring harness between G70 (female) (4) - G70 (female) (1).
harness. Resistance Min.100 kΩ
(Measure it disconnecting G70 connector).
Possible causes
and standard value Ground fault in ★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting
in normal state wiring harness . switch ON.
5 (No secure GND
from pump Wiring harness between G70 (female (2) - chassis GND Resistance Max.30 Ω
controller).
Defective pump If cause 1 -5 are not detected, pump controller may be defective.
6
controller. (Since trouble is in system, troubleshooting cannot be carried out).

LEVER LH (2nd ATT) LEVER RH (1st ATT)

Sub Potentio 2 Sub Potentio 1

Main Potentio 2 Main Potentio 1

G70 G72
(DTM-12) (DTM-12)
1 2 3 4 1 2 3 4

J02 J06
(J-20) (J-20)

1 2 6 5 Pump Controller

C01
Potentio Power (+5 V)
1st Service Potentio (Sub)
S
ANALOG GND
2nd Service Potentio (Main)
2nd Service Potentio (Sub)
1st Service Potentio (Main)

G0148500

PW148-8 VEBM720100 20-433

Failure code [DGH2KB] – Hydr oil sensor short TESTING AND ADJUSTING

Failure code [DGH2KB] – Hydr oil sensor short

User code Failure code Hydraulic oil temperature sensor short

Trouble
— DGH2KB (Pump controller system)

Contents of trou-
• Ground fault was detected in hydraulic oil temperature sensor circuit.
ble
Action of • Fixes hydraulic oil temperature value at 40°C and continues operation.
controller • If cause of failure disappears, system resets itself.
Problem that
• While hydraulic oil temperature rises normally, hydraulic oil temperature gauge does not move from top of white range
appears on
(bottom of green range).
machine
• Signal voltage of hydraulic oil temperature sensor can be checked with monitoring function.
Related informa-
(Code: 04402 Hydraulic oil temperature sensor voltage)
tion
• Method of reproducing failure code: Start engine.

Cause Standard value in normal state/Remarks on troubleshooting

★ Prepare with starting switch OFF, then carry out troubleshooting without
turning starting switch ON.
Defective hydraulic oil tempera-
1 ture sensor (Internal disconnec- A55 (male) Resistance
tion or short circuit) Between (1) – (2) 3.5 – 90 kΩ
Between (2) – chassis ground Min. 1 MΩ
Possible causes
★ Prepare with starting switch OFF, then carry out troubleshooting without
and standard
Ground fault in wiring harness turning starting switch ON.
value in normal 2
state (Short circuit with GND circuit) Wiring harness between C01 (female) (29) – A55
Resistance Min. 1 MΩ
(female) (2)
★ Prepare with starting switch OFF, then carry out troubleshooting without
turning starting switch ON.

3 Defective pump controller C01 (female) Resistance

Between (29) – (46) 3.5 – 90 kΩ
Between (29) – chassis ground Min. 1 MΩ

20-434 PW148-8 VEBM720100

TESTING AND ADJUSTING Failure code [DGH2KB] – Hydr oil sensor short

Circuit diagram related to hydraulic oil temperature sensor

A06 A55
(SWP-16) (DT-2)

29 5 2
S
46 4 1
18
S
78

REVO

PW148-8 VEBM720100 20-435

Failure code [DH10KS] – Abnormality in 24V sensor power source TESTING AND ADJUSTING

Failure code [DH10KS] – Abnormality in 24V sensor power

source

User Code Failure Code Failure Abnormality in pressure sensor power source
— DH10KS phenomenon (in pump controller system)

Failure content • Abnormal current flow in sensor power supply (24 V) circuit.

• The controller turns OFF power supply to the power source circuit (24 V).
Response from
• Even when the failure cause disappears of itself, the current does not return to normal, unless the engine starting
controller
switch is once turned OFF.

Phenomenon
occurring on • Signals from the pressure sensors and potentiometer are not inputted correctly.
machine

Cause Standard value in normal and references for troubleshooting

Presumed cause and standard value in normal

Disconnect the following equipment one by one. Equipment that shows no service code is defec-
Pressure sensor or potenti- tive, having an internal failure.
1 ometer defective • Turn the engine starting switch OFF for the preparations, and hold it in the ON position during
(Internal short-circuit) the troubleshooting.

Swing proximity sensor A90 Connector

Grounding fault of wiring • Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during
harness the troubleshooting.
2
(Contact with grounding Resistance
circuit) Between C01 (28) and A90 (1) to grounding Above 1 MΩ
value

• Turn the engine starting switch OFF for the preparations, and hold it in the ON position during
the troubleshooting.
3 Pump controller defective
C01 Voltage

Between (28) and (47) 23.5 – 24.5 V

20-436 PW148-8 VEBM720100

TESTING AND ADJUSTING Failure code [DH10KS] – Abnormality in 24V sensor power source

Electrical circuit diagram for 24V sensor power source

A08 (SWP-16)

C01 (AMP-81) A90 (DT-3)

Power (24V) sensor 28 A06 (SWP-16) 1 Swing
Swing position sensor 72 13 2 Proximity
GND (analogue GND) 47 3 3 Switch

PW148-8 VEBM720100 20-437

Failure code [DHPAMA] – F pump press sensor abnormality TESTING AND ADJUSTING

Failure code [DHPAMA] – F pump press sensor abnormal-

ity

Action code Failure code Pump press sensor abnormality

Trouble
— DHPAMA (Pump controller system)

Contents of
• Signal voltage from pump pressure sensor is below 0.3 V or above 4.42 V.
trouble

Action of • Fixes pump pressure at 0 MPa {0 kg/cm2} and continues control.

controller • If cause of failure disappears, system resets itself.

Problem that
appears on • No automatic gear shifting
machine

• If 5V circuit (3) and ground circuit (1) of pressure sensor are connected inversely, pressure sensor will be broken.
Related Accordingly, take extreme care when checking.
information • Input from pump pressure sensor (pressure) can be checked with monitoring function.
(Code 01112: pump pressure

Cause Standard value in normal state/Remarks on troubleshooting

Defective sensor power supply If failure code [DA25KP] is also displayed, carry out troubleshooting for it
1
system first.

★ Prepare with starting switch OFF, then start engine and carry out trou-
bleshooting.
Defective F pump pressure
2 sensor A51 Voltage
(Internal defect) Between (3) – (1) 4.5 – 5.5 V

Between (2) – (1) 0.5 – 4.5 V

★ Prepare with starting switch OFF, then carry out troubleshooting without
turning starting switch ON.

Wiring harness between C01 (female) (8) – A03 – Resist-

Disconnection in wiring harness Max. 1 Ω
A51 (female) (3) ance
3 (Disconnection in wiring or
defective contact in connector) Wiring harness between C01 (female) (47) – A06 Resist-
Max. 1 Ω
– A51 (female) (1) ance
Possible causes
Wiring harness between C01 (female) (49) – A06 Resist-
and standard Max. 1 Ω
– A51 (female) (2) ance
value in normal
state ★ Prepare with starting switch OFF, then carry out troubleshooting without
Ground fault in wiring harness turning starting switch ON.
4
(Short circuit with GND circuit) Wiring harness between C01 (female) (49) – A06 Resist- Min.
– A51 (female) (2) and chassis ground ance 1 MΩ

★ Prepare with starting switch OFF, then turn starting switch ON and carry
out troubleshooting.

Hot short (Short circuit with 24V Wiring harness between C01 (female) (8) – A03 –
5 Voltage Max. 1 V
circuit) in wiring harness A51 (female) (3) and chassis ground

Wiring harness between C01 (female) (49) – A06

Voltage Max. 1 V
– A51 (female) (2) and chassis ground

★ Prepare with starting switch OFF, then start engine and carry out trou-
bleshooting.

6 Defective pump controller C01 Voltage

Between (8) – (47) 4.5 – 5.5 V

Between (49) – (47) 0.5 – 4.5 V

20-438 PW148-8 VEBM720100

TESTING AND ADJUSTING Failure code [DHPAMA] – F pump press sensor abnormality

Circuit diagram related to pump pressure sensor of pump controller

C01 (AMP-81) A06 (SWP-16)

49 Pump
47 pressure
8 sensor

A03 (SWP-14)

PW148-8 VEBM720100 20-439

Failure code [DHS5KX] – Abnormality in travel PPC sensor TESTING AND ADJUSTING

Failure code [DHS5KX] – Abnormality in travel PPC sen-

sor

User Code Failure Code Failure Abnormality in the travel PPC sensor
E20 DHS5KX phenomenon (in pump controller system)

Failure content • A normal signal is not inputted to the signal circuit from the travel PPC sensor.
Response from • No control of engine speed via throttle pedal during travel operation.
controller • If the failure cause disappears of itself, the signal input returns to normal.
Phenomenon
occurring on • The machine lacks speed unless engine fuel dial is turned to ’Hi’ position.
machine
Relative
information

Cause Standard value in normal and references for troubleshooting

• Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the
troubleshooting.
Travel PPC
1 (Internal short-circuiting or A56 (male) Resistance value
disconnection) Between (3) and (2) 500 – 1,000 Ω
Presumed cause and standard value in normal

Between (3) and grounding Above 1 MΩ

• Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the
troubleshooting.

Disconnection of wiring har- Resistance

Wiring harness between C01 (female) (8) and A56 (female) (3) Below 1 Ω
ness value
2
(Disconnection or defective Resistance
contact with connector) Wiring harness between C01 (female) (47) and A56 (female) (1) Below 1 Ω
value
Resistance
Wiring harness between C01 (female) (12) and A56 (female) (2) Below 1 Ω
value
• Turn the engine starting switch OFF for the preparations, and hold it in the ON position during the
Short-circuiting of wiring har- troubleshooting.
3 ness
(Contact with circuit) Wiring harness between C01 (female) (8) and A56 (female) (1)
Voltage Below 1 V
and grounding
• Turn the engine starting switch OFF for the preparations, and hold it in the ON position during the
troubleshooting.

4 Pump controller defective C01 (female) Resistance value

Between (8) and (47) 500 – 1,000 Ω
Between (12) and (47) Above 1 MΩ

A06 A56
C01 (AMP-81) (SWP-16) (AMP-3)
Travel PPC 49
pressure
1 GND
signal

Travel
GND 47 3 2 Signal PPC
sensor

Power (+5V) 8 11 3 +5V

Potentiometer power
A03
(SWP-14)

20-440 PW148-8 VEBM720100

TESTING AND ADJUSTING Failure code [DHS5KX] – Abnormality in travel PPC sensor

Blank for technical reason

PW148-8 VEBM720100 20-441

Failure code [DHX1MA] – Abnormality in overload caution sensor TESTING AND ADJUSTING

Failure code [DHX1MA] – Abnormality in overload caution

sensor

User code Failure code Overload sensor (analog)

Trouble
— DHX1MA (Pump controller system)

Contents of
• Signal voltage of overload alarm pressure sensor circuit is below 0.3 V or above 4.4 V.
trouble
Action of • Outputs overload alarm constantly.
controller • If cause of failure disappears, system resets itself.
Problem that
appears on • If display of overload alarm monitor is set, overload alarm monitor is displayed constantly.
machine
• Overload alarm pressure sensor is installed to only machine on which display of overload alarm monitor is set.
★ If 5V circuit (3) and ground circuit (1) of pressure sensor are connected inversely, pressure sensor will be broken.
Accordingly, take extreme care when checking.
Related informa-
tion
• Overload alarm pressure (Boom cylinder bottom pressure) can be checked with monitoring function. (Code: 15900
Boom bottom pressure)
• Method of reproducing failure code: Turn starting switch ON or start engine.

Cause Standard value in normal state/Remarks on troubleshooting

Defective 5V sensor power sup-
1
ply 1 system
Defective overload alarm pres-
2
sure sensor (Internal defect)
Possible causes
and standard
Disconnection in wiring harness (female) (1)
value in normal 3 (Disconnection in wiring or defec-
state tive contact in connector)
Ground fault in wiring harness
4
(Short circuit with GND circuit)
Hot short (Short circuit with 24V
5
circuit) in wiring harness
6 Defective pump controller
If failure code [DA25KP] is also displayed, carry out troubleshooting for it first.
★ Prepare with starting switch OFF, then turn starting switch ON or start en-
gine and carry out troubleshooting in each case.
G164 Voltage
Between (3) – (1) Power supply 4.5 – 5.5 V
Between (2) – (1) Signal 0.3 – 4.4 V
If voltage is abnormal, replace overload alarm pressure sensor with F pump
pressure sensor or R pump pressure sensor and check failure code. (If "E" of
failure code goes off at this time, overload alarm pressure sensor is defective.)
★ Prepare with starting switch OFF, then carry out troubleshooting without
turning starting switch ON.
Wiring harness between C01 (female) (47) – G164 Resistance Max. 1 Ω
Wiring harness between C01 (female) (31) – G164 Resistance Max. 1 Ω
(female) (2)
Wiring harness between C01 (female) (8) – J06 – Resistance Max. 1 Ω
G164 (female) (3)
★ Prepare with starting switch OFF, then carry out troubleshooting without
turning starting switch ON.
Wiring harness between C01 (female) (8) – G164 Resistance Min. 1 MΩ
(female) (2)
★ Prepare with starting switch OFF, then turn starting switch ON and carry
out troubleshooting.
Wiring harness between C01 (female) (8) – G164 Voltage Max. 1 V
(female) (2)
If causes 1 – 5 are not detected, pump controller may be defective. (Since
trouble is in system, troubleshooting cannot be carried out.)

20-442 PW148-8 VEBM720100

TESTING AND ADJUSTING Failure code [DHX1MA] – Abnormality in overload caution sensor

Electrical Circuit Diagram for Overload Caution

A06
(SWP-16)

3 U21
C01 (AMP-81)
G164
Overload Caution 31 10 (AMP-3)

1
Overload
2 Caution
Ground(Analogue) 47 Sensor
3

Sensor Power (+5V) 8

A03
(SWP-14)

PW148-8 VEBM720100 20-443

Failure code [DLT4KA] – Disconnection in transmission speed sensor in pump controller system TESTING AND ADJUSTING

Failure code [DLT4KA] – Disconnection in transmission

speed sensor in pump controller system

User Code Failure Code Failure Disconnection in transmission speed sensor

E20 DLT4KA phenomenon (in pump controller system)

Failure content • A normal pulse signal is not inputted to the signal circuit in the transmission speed sensor.

Response from • The machine will default to low travel speed only.
controller • If the failure cause disappears of itself, the signal input returns to normal condition.

Phenomenon
• The machine defaults to low speed travel.
occurring on
• Monitor will not display travel speed.
machine

Relative
• Input from the transmission speed sensor (rpm) can be confirmed in the monitor function.
information

Cause Standard value in normalcy and references for troubleshooting

• Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during
Transmission speed the troubleshooting.
sensor fault A57 (male) Resistance value
1
(Internal short-circuiting or
disconnection) Between (1) and (2) 500 – 1,000 Ω
Presumed cause and standard value in normal

Between (1) and grounding Above 1 MΩ

Transmission speed sen- For the inspection and adjustment, refer to the section of "Adjusting Transmission speed Sensor" in
2
sor adjustment improper this manual.

• Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during
the troubleshooting.
Disconnection of wiring
harness Resistance
3 Wiring harness between C01 (female) (25) and A57 (female) (1) Below 1 Ω
(Disconnection or defective value
contact with connector)
Resistance
Between C01 (female) (44) and A57 (2). Below 1 Ω
value

Short-circuiting of wiring
4 harness
(Contact with 24 V circuit)
• Turn the engine starting switch OFF for the preparations, and hold it in the ON position during
the troubleshooting.
Wiring harness between C01 (female) (25) and A57 (female) (2)
Voltage Below 1 V
and grounding

• Turn the engine starting switch OFF for the preparations, and hold it in the ON position during
the troubleshooting.

5 Pump controller defective C01 Resistance value

Between C01 (25) and C01 (44) 500 – 1,000 Ω

Between C01 (25) and grounding Above 1 MΩ

20-444 PW148-8 VEBM720100

TESTING AND ADJUSTING Failure code [DLT4KA] – Disconnection in transmission speed sensor in pump controller system

Electrical circuit diagram for monitor panel power source

C01(AMP-81)
44 GND (Pulse) Pump
25 Speed pick up controller
sensor

A04
11 10 (SWP-14)

Transmission speed sensor

N S

1 2
A57
(DT-2)

A12 A14
(DT-6) (DT-6)

1 1
Swivel
5 5
Joint
6 6

PW148-8 VEBM720100 20-445

Failure code [DW27KA] – Disconnection in transmission clutch solenoid TESTING AND ADJUSTING

Failure code [DW27KA] – Disconnection in transmission

clutch solenoid

User Code Failure Code Failure Disconnection in transmission clutch solenoid

E20 DW27KA phenomenon (in pump controller system)

Failure content • No current flows to the transmission clutch solenoid circuit, when power is supplied to the circuit.

Response from • None in particular (The solenoid does not function as there is no current flowing to it)
controller • When the failure cause disappears of itself, the machine operation returns to normal.

Phenomenon
• The travel speed does not shift to Lo. (Machine defaults to Hi)
occurring on
(The display changes normally in the monitor panel)
machine

• Operation of the transmission clutch solenoid (ON or OFF) can be checked in the monitoring function. (Code No.
Relative
02300: Solenoid valve 1)
information
• The solenoid detects disconnection, when power is ON. Hence be sure to check it with power ON after the repairs.

Cause Standard value in normal and references for troubleshooting

• Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during
Transmission clutch the troubleshooting.
1 solenoid defective V11 (male) Resistance value
Presumed cause and standard value in normal

(Internal disconnection)
Between (1) and (2) 27 – 30 Ω at 20°C

• Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during
the troubleshooting.
Disconnection of wiring
harness Between wiring harness from C02 (female) (87) to A05 to V11 Resistance
2 Below 1 Ω
(Disconnection or defective (female) (1) value
contact with connector)
Resistance
Wiring harness between V11 (female) (2) and grounding Below 1 Ω
value

Short-circuiting of wiring
3 harness
(Contact with 24 V circuit)
• Turn the engine starting switch OFF for the preparations, and hold it in the ON position during
the troubleshooting.
Between wiring harness from C02 (female) (87) to A05 to V11
Voltage Below 1 V
(female) (1).

• Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during
the troubleshooting.
4 Pump controller defective
C02 (female) Resistance value

Between (87) and grounding 20 – 60 Ω

20-446 PW148-8 VEBM720100

TESTING AND ADJUSTING Failure code [DW27KA] – Disconnection in transmission clutch solenoid

Electrical circuit diagram for transmission clutch solenoid in pump con-

troller

Pump
controller
A05 V11 Transmission clutch
C02 (AMP-40) (SWP-16) (DT-2) solenoid valve
T/mission clutch 4 1
87
SOL
2

(ON) (OFF)

A65

CAB REVOLVING FRAME

PW148-8 VEBM720100 20-447

Failure code [DW27KB] – Short-circuiting in transmission clutch solenoid TESTING AND ADJUSTING

Failure code [DW27KB] – Short-circuiting in transmission

clutch solenoid

User Code Failure Code Failure Disconnection in transmission clutch solenoid

E20 DW27KB phenomenon (in pump controller system)

Failure content • Abnormal current flow to the transmission clutch solenoid, when power was supplied to the circuit.

• Power supply to the transmission clutch solenoid circuit is switched OFF.

Response from
• Even after the failure cause disappears of itself, the machine operation does not return to normal,
controller
unless the engine starting switch is once turned OFF.

Phenomenon
• The travel speed does not turn to Hi.
occurring on
(The display in the monitor panel changes correctly)
machine

Relative • Operation of the transmission clutch solenoid (ON or OFF) can be checked in the monitoring function. (Code No.
information 02300: Solenoid valve 1)

Cause Standard value in normal and references for troubleshooting

• Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during
Presumed cause and standard value in normal

the troubleshooting.
Transmission clutch
solenoid defective V11 (male) Resistance value
1
(Internal short-circuiting or
grounding fault) Between (1) and (2) 27 – 30 Ω at 20°C

Between (1) and grounding Above 1 MΩ

Grounding fault of wiring • Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during
harness the troubleshooting.
2
(Contact with grounding Between wiring harness from C02 (female) (87) to A05 to V11 Resistance
circuit) Above 1 MΩ
(female) (1). value

• Turn the engine starting switch OFF for the preparations, and hold it running during the trouble-
shooting.

3 Pump controller defective C02 Travel speed Voltage

Lo Below 1 V
Between (87) and grounding
Hi + Travel operation 20 – 30 V

20-448 PW148-8 VEBM720100

TESTING AND ADJUSTING Failure code [DW27KB] – Short-circuiting in transmission clutch solenoid

Electrical circuit diagram for transmission clutch solenoid

Pump
controller
A05 V11 Transmission clutch
C02 (AMP-40) (SWP-16) (DT-2) solenoid valve
T/mission clutch 4 1
87
SOL
2

(ON) (OFF)

A65

CAB REVOLVING FRAME

PW148-8 VEBM720100 20-449

Failure code [DW4AKA] – Disconnection in suspension lock solenoid TESTING AND ADJUSTING

Failure code [DW4AKA] – Disconnection in suspension

lock solenoid

User Code Failure Code Failure Disconnection in suspension lock solenoid

E20 DW4AKA phenomenon (in pump controller system)

Failure content • No current flows to the suspension lock solenoid circuit, when power is supplied to the circuit.

Response from • None in particular (The solenoid does not function as there is current flowing to it)
controller • When the failure cause disappears of itself, the machine operation returns to normal.

Phenomenon
occurring on • The suspension lock cylinders which should hold the front axle solid do not lock. The axle is always free to oscillate.
machine

• Operation of the suspension lock solenoid (ON or OFF) can be checked in the monitoring function. (Code No.
02301: Solenoid valve 2)
Relative
• The solenoid detects disconnection, when power is ON. Hence be sure to check it with power ON after the repairs.
information
(Operation of the suspension lock solenoid [ON or OFF] can be checked in the monitoring function [code 02301: so-
lenoid valve 2]).

Cause Standard value in normal and references for troubleshooting

• Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during
Suspension lock the troubleshooting.
1 solenoid defective V04 (male) Resistance value
(Internal disconnection)
Presumed cause and standard value in normal

Between (1) and (2) 27 – 30 Ω at 20°C

• Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during
the troubleshooting.
Disconnection of wiring
harness Between wiring harness from C02 (female) (113) to A05 to V04 Resistance
2 Below 1 Ω
(Disconnection or defective (female) (1) value
contact with connector)
Resistance
Wiring harness between V04 (female) (2) and grounding Below 1 Ω
value

Short-circuiting of wiring
3 harness
(Contact with 24 V circuit)
• Turn the engine starting switch OFF for the preparations, and hold it in the ON position during
the troubleshooting.
Between wiring harness from C02 (female) (113) to A05 to V04
(female) (1), or between wiring harness C02 (female) (113) and Voltage Below 1 V
grounding

• Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during
the troubleshooting.
4 Pump controller defective
C02 Resistance value

Between (113) and grounding 20 – 60 Ω

20-450 PW148-8 VEBM720100

TESTING AND ADJUSTING Failure code [DW4AKA] – Disconnection in suspension lock solenoid

Electrical circuit diagram for suspension lock solenoid in pump controller

Pump
controller
A05 V04 Suspension Lock
CO2 (AMP-40) (SWP - 16) (DT - 2) solenoid valve
Suspension Lock 113 12 1
Solenoid
2
(ON) (OFF)

A65

CAB REVOLVING FRAME

PW148-8 VEBM720100 20-451

Failure code [DW4AKB] – Short circuiting in suspension lock solenoid TESTING AND ADJUSTING

Failure code [DW4AKB] – Short circuiting in suspension

lock solenoid

User Code Failure Code Failure Short circuit of suspension lock solenoid
E20 DW4AKB phenomenon (in pump controller system)

Failure content • Abnormal current flew to the suspension lock solenoid circuit, when power was supplied to the circuit.

• Power supply to the suspension lock solenoid circuit is switched OFF.

Response from
• Even after the failure cause disappears of itself, the machine operation does not return to normal,
controller
unless the engine starting switch is once turned OFF.

Phenomenon
occurring on • The suspension lock cylinders which should hold the front axle solid do not lock. The axle is always free to oscillate.
machine

Relative • Operation of the suspension lock solenoid (ON or OFF) can be checked in the monitoring function.
information (Code No. 02301: Solenoid valve 2)

Cause Standard value in normal and references for troubleshooting

• Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during
Presumed cause and standard value in normal

the troubleshooting.
Suspension lock solenoid
defective V04(male) Resistance value
1
(Internal short-circuiting or
grounding fault) Between (1) and (2) 27 – 30 Ω at 20°C

Between (1) and grounding Above 1 MΩ

Grounding fault of wiring • Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during
harness the troubleshooting.
2
(Contact with grounding Between wiring harness from C02 (female) (113) to A05 to V04 Resistance
circuit) Above 1 MΩ
(female) (1). value

• Turn the engine starting switch OFF for the preparations, and hold it in the ON position during
the troubleshooting.

3 Pump controller defective C02 Voltage

Below 1 V
Between (113) and grounding
20 – 30 V

20-452 PW148-8 VEBM720100

TESTING AND ADJUSTING Failure code [DW4AKB] – Short circuiting in suspension lock solenoid

Electrical circuit diagram for suspension lock solenoid in pump controller

Pump
controller
A05 V04 Suspension Lock
CO2 (AMP-40) (SWP - 16) (DT - 2) solenoid valve
Suspension Lock 113 12 1
Solenoid
2
(ON) (OFF)

A65

CAB REVOLVING FRAME

PW148-8 VEBM720100 20-453

Failure code [DW4CKA] – Disconnection in PPC lock solenoid TESTING AND ADJUSTING

Failure code [DW4CKA] – Disconnection in PPC lock sole-

noid

User Code Failure Code Failure Disconnection in PPC lock solenoid

DW4CKA phenomenon (in pump controller system)
Failure content • No current flows to the PPC lock solenoid circuit, when power is supplied to the circuit.
Response from • None in particular (The solenoid does not function as there is no current flowing to it)
controller • When the failure cause disappears of itself, the machine operation returns to normal.
Phenomenon
occurring on • None of the machines work equipment functions operate.
machine
• Operation of the PPC lock solenoid (ON or OFF) can be checked in the monitoring function. (Code No. 02300: Sole-
Relative
noid valve 1)
information
• The solenoid detects disconnection, when power is ON. Hence be sure to check it with power ON after the repairs.

Cause Standard value in normal and references for troubleshooting

• Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the
PPC lock solenoid troubleshooting.
1 defective (Internal V01 (male) Resistance value
disconnection)
Between (1) and (2) 27 – 30 Ω at 20°C
R13 (Male) Resistance value
Between (1) - (2) 300 - 600 Ω
Defective PPC lock
2 relay (Internal discon- • Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. (Trouble-
nection) shooting by replacement)
• Replace PPC lock relay (R13) with another relay and perform reproducing operation. If "E" of failure
code goes off at this time, replaced relay is defective.
• Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the
Presumed cause and standard value in normal

troubleshooting.
Wiring harness between C01 (female) (80) to R13 to A05 to V01 Resistance
Below 1 Ω
(female) (1) value
Resistance
Disconnection of Between wiring harness from S14 (male) (2) to R13 (female) (3) Below 1 Ω
value
wiring harness
Resistance
3 (Disconnection or defec- Between wiring harness from S14 (male) (1) to FB1 (female) (3) Below 1 Ω
value
tive contact with con-
nector) Resistance
Wiring harness between V01 (female) (2) and grounding Below 1 Ω
value
Resistance
Between wiring harness from S14 (male) (1) to R13 (1) Below 1 Ω
value
Resistance
Between wiring harness from C02 (female) (92) to R13 (2) Below 1 Ω
value

Short-circuiting of • Turn the engine starting switch OFF for the preparations, and hold it in the ON position during the trou-
Wiring harness bleshooting.
4
(Contact with 24V Between wiring harness C01 (female) (80) and R13 and A05 and V01
circuit) Voltage Below 1 V
(1) and grounding
• Prepare with starting switch OFF, with PPC lock switch OFF (LH pod down) then carry out trouble-
shooting without turning starting switch ON.
Defective PPC lock S14 (female) Resistance
5
switch
Between (1) and (2) Below 1 Ω
Between (1) and (3) Above 1 MΩ
• Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the
troubleshooting.
Pump controller
6
defective C01 (female) Resistance value
Between (80) and grounding Below 1 Ω

20-454 PW148-8 VEBM720100

TESTING AND ADJUSTING Failure code [DW4CKA] – Disconnection in PPC lock solenoid

Electrical circuit diagram for ppc lock solenoid in pump controller

PPC Lock Switch

1 2 3
Pod
OFF
down
ON Pod up

1 2 3 S14
(M-3)

CO2 (DRC-40)
92 PPC Lock (Relay)

FB1
Y 3 CO1 (AMP-81)

10A 80 PPC Lock (IN)

PPC Lock
Relay R13

1 2 3 5 6

A05 V01 PPC press lock

(SWP-16) (DT-2) solenoid valve
3 1

A65

PW148-8 VEBM720100 20-455

Failure code [DW4CKB] – PPC lock sol. S/C TESTING AND ADJUSTING

Failure code [DW4CKB] – PPC lock sol. S/C

Action code Failure code PPC lock solenoid short

Trouble
DW4CKB (Pump controller system)

Contents of
• Abnormal current flowed at output to PPC lock solenoid circuit.
trouble

Response from • None in particular (The solenoid does not function as there is no current flowing to it)
controller • When the failure cause disappears of itself, the machine operation returns to normal.

Problem that
appears on • None of the machines work equipment functions operate.
machine

Related • Operating condition of PPC lock solenoid (ON/OFF) can be checked with monitoring function. (Code 02301: Sole-
information noid valve 1)

Cause Standard value in normal state/Remarks on troubleshooting

★ Prepare with starting switch OFF, then carry out troubleshooting without
turning starting switch ON.
Defective PPC lock solenoid
1 (Internal short circuit or V01 (male) Resistance
ground fault) Between (1) – (2) 27 – 30 Ω at 20°C

Between (1) – chassis ground Min. 1 MΩ

★ Prepare with starting switch OFF, then carry out troubleshooting without
turning starting switch ON.

Wiring harness between C01 (female) (80) –

R13 – A05 – V01 (female) (1) and chassis Resistance Min. 1 MΩ
ground
Possible
Wiring harness between V01 (female) (2) and
causes and Resistance Below 1 Ω
ground.
standard value
in normal state Ground fault in wiring harness
2 Wiring harness between C01 (female) (80) -
(Short circuit with GND circuit) Resistance Min. 1 MΩ
S14 (male) (2) and ground.

Wiring harness between S14 (male) (1) - FB1

Resistance Min. 1 MΩ
(3) and ground.

Wiring harness between S14 (male) (1) - R13

Resistance Min. 1 MΩ
(1) and ground.

Wiring harness between R13 (female) (2) and

Resistance Min. 1 MΩ
ground.

★ Prepare with starting switch OFF, then start engine and carry out trouble-
shooting.
3 Defective pump controller
C01 Voltage

Between (80) – chassis ground 20 – 30 V

20-456 PW148-8 VEBM720100

TESTING AND ADJUSTING Failure code [DW4CKB] – PPC lock sol. S/C

Circuit diagram related to swing holding brake solenoid of pump controller

PPC Lock Switch

1 2 3
Pod
OFF
down
ON Pod up

1 2 3 S14
(M-3)

CO2 (DRC-40)
92 PPC Lock (Relay)

FB1
Y 3 CO1 (AMP-81)

10A 80 PPC Lock (IN)

PPC Lock
Relay R13

1 2 3 5 6

A05 V01 PPC press lock

(SWP-16) (DT-2) solenoid valve
3 1

A65

PW148-8 VEBM720100 20-457

Failure code [DW4MKA] – Disconnection in creep solenoid TESTING AND ADJUSTING

Failure code [DW4MKA] – Disconnection in creep sole-

noid

User Code Failure Code Failure Disconnection in creep solenoid

E20 DW4MKA phenomenon (in pump controller system)

Failure content • No current flows to the creep solenoid circuit, when power is supplied to the circuit.

Response from • None in particular (The solenoid does not function as there is current flowing to it)
controller • When the failure cause disappears of itself, the machine operation returns to normal.

Phenomenon
occurring on • The travel speed does not turn to Creep.
machine

• Operation of the creep solenoid (ON or OFF) can be checked in the monitoring function. (Code No. 02300: Solenoid
Relative
valve 1)
information
• The solenoid detects disconnection, when power is ON. Hence be sure to check it with power ON after the repairs.

Cause Standard value in normal and references for troubleshooting

• Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during
Presumed cause and standard value in normal

the troubleshooting.
Creep solenoid defective
1 V07 (male) Resistance value
(Internal disconnection)

Between (1) and (2) 27 – 30 Ω at 20°C

• Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during
the troubleshooting.
Disconnection of wiring
harness Between wiring harness from C02 (female) (89) to A05 to V07 Resistance
2 Below 1 Ω
(Disconnection or defective (female) (1) value
contact with connector)
Resistance
Wiring harness between V07 (female) (2) and grounding Below 1 Ω
value

Short-circuiting of wiring
3 harness
(Contact with 24 V circuit)
• Turn the engine starting switch OFF for the preparations, and hold it in the ON position during
the troubleshooting.
Between wiring harness from C02 (female) (89) to A05 to V07
(female) (1), or between wiring harness C02 (female) (89) and Voltage Below 1 V
grounding

20-458 PW148-8 VEBM720100

TESTING AND ADJUSTING Failure code [DW4MKA] – Disconnection in creep solenoid

Electrical circuit diagram for creep solenoid in pump controller

Pump
controller
A05 V07 Creep
CO2 (AMP-40) (SWP-16) (DT-2) solenoid valve
Creep SOL 89 9 1
2
(ON) (OFF)

A65

CAB REVOLVING FRAME

PW148-8 VEBM720100 20-459

Failure code [DW4MKB] – Short-circuiting in creep solenoid TESTING AND ADJUSTING

Failure code [DW4MKB] – Short-circuiting in creep sole-

noid

User Code Failure Code Failure Short-circuit in creep solenoid

E20 DW4MKB phenomenon (in pump controller system)

Failure content • Abnormal current flow to the creep solenoid, when power was supplied to the circuit.

• Power supply to the creep solenoid circuit is switched OFF.

Response from
• Even after the failure cause disappears of itself, the machine operation does not return to normal,
controller
unless the engine starting switch is once turned OFF.

Phenomenon
occurring on • The travel speed does not turn to Creep.
machine

Relative • Operation of the creep solenoid (ON or OFF) can be checked in the monitoring function. (Code No. 02300: Solenoid
information valve 1)

Cause Standard value in normal and references for troubleshooting

• Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during
Presumed cause and standard value in normal

the troubleshooting.
Creep solenoid defective
V07 (male) Resistance value
1 (Internal short-circuiting or
grounding fault) Between (1) and (2) 27 – 30 Ω at 20°C

Between (1) and grounding Above 1 MΩ

Grounding fault of wiring • Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during
harness the troubleshooting.
2
(Contact with grounding Between wiring harness from C02 (female) (89) to A05 to V07 Resistance
circuit) Above 1 MΩ
(female) (1). value

• Turn the engine starting switch OFF for the preparations, and hold it running during the trouble-
shooting.

3 Pump controller defective C02 Travel speed Voltage

Lo Below 1 V
Between (89) and grounding
Hi + Travel operation 20 – 30 V

20-460 PW148-8 VEBM720100

TESTING AND ADJUSTING Failure code [DW4MKB] – Short-circuiting in creep solenoid

Electrical circuit diagram for creep solenoid in pump controller

Pump
controller
A05 V07 Creep
CO2 (AMP-40) (SWP-16) (DT-2) solenoid valve
Creep SOL 89 9 1
2
(ON) (OFF)

A65

CAB REVOLVING FRAME

PW148-8 VEBM720100 20-461

Failure code [DW44KA] – Disconnection of travel F/R solenoid TESTING AND ADJUSTING

Failure code [DW44KA] – Disconnection of travel F/R sole-

noid

User Code Failure Code Failure Disconnection in travel F/R solenoid

E20 DW44KA phenomenon (in pump controller system)

Failure content • No current flows to the travel F/R solenoid circuit, when power is supplied to the circuit.

Response from • None in particular (The solenoid does not function as there is current flowing to it)
controller • When the failure cause disappears of itself, the machine operation returns to normal.

Phenomenon
occurring on • It is difficult to steer the machine while travelling.
machine

• Operation of the travel F/R solenoid (ON or OFF) can be checked in the monitoring function. (Code No. 02301: So-
Relative
lenoid valve 2)
information
• The solenoid detects disconnection, when power is ON. Hence be sure to check it with power ON after the repairs.

Cause Standard value in normal and references for troubleshooting

• Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during
Travel F/R the troubleshooting.
1 solenoid defective V08 (male) Resistance value
Presumed cause and standard value in normal

(Internal disconnection)
Between (1) and (2) 27 – 30 Ω at 20°C

• Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during
the troubleshooting.
Disconnection of wiring
harness Between wiring harness from C02 (female) (97) - S29 (6) - S96 - Resistance
2 Below 1 Ω
(Disconnection or defective S29 (5) - J02 (14) - J02 (15) - A05 (7) - V08 (female) (1). value
contact with connector)
Resistance
Wiring harness between V08 (female) (2) and grounding Below 1 Ω
value

Short-circuiting of wiring
3 harness
(Contact with 24 V circuit)
• Turn the engine starting switch OFF for the preparations, and hold it in the ON position during
the troubleshooting.
Between wiring harness from C02 (female) (97) - S29 (6) - S96 -
Voltage Below 1 V
S29 (5) - J02 (14) - J02 (15) - A05 (7) - V08 (female) (1).

• Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during
the troubleshooting.
4 Pump controller defective
C02 (female) Resistance value

Between (97) and grounding 20 – 60 Ω

20-462 PW148-8 VEBM720100

TESTING AND ADJUSTING Failure code [DW44KA] – Disconnection of travel F/R solenoid

Electrical circuit diagram for travel F/R solenoid

EMERGENCY FNR SW.

EMERGENCY S95 (OTAX-6)
TRAVEL SW
1 2 3 4 5 6
S96

CN-S95
FNR SW. 1 2 3 4 5 6 7 8 9 F
EMERGENCY N
F NORMAL R
N
R

1 2 3 4
G71 S29
(DT-12)

J04
(090-20)

FB2
5A

Fuse
Box 2

A05
(SWP-16)

J02 (J-20) (Orange)

D03
(KESI-2)

D03
(KESI-2)

A07
(SWP-16) A01 C01 (AMP-81)
(X-4)
23 Travel R
36 Travel R Pressure SW.
42 Travel N

55 Travel F Pressure SW.

61 Travel F

C02 (AMP-40)
V08 Travel F/R Solenoid
Travel F/R Sw. 97
(DT-2)
A06 105 Travel N Solenoid
(SWP-16)

(OFF) (ON)
Travel Reverse
Press. SW.
S09
(X-2)
V06
Travel Neutral Sw. (DT-2)

Travel Forward
Press. SW.
(OFF) (ON) S10
(X-2)

A53
Backup Alarm (DT-2)

A65 A64

PW148-8 VEBM720100 20-463

Failure code [DW44KB] – Short-circuiting of travel F/R solenoid TESTING AND ADJUSTING

Failure code [DW44KB] – Short-circuiting of travel F/R so-

lenoid

User Code Failure Code Failure Short-circuiting in travel F/R solenoid

E20 DW44KB phenomenon (in pump controller system)

Failure content • Abnormal current flow to the travel F/R solenoid circuit, when power was supplied to the circuit.

• Power supply to the travel F/R solenoid circuit is switched OFF.

Response from
• Even after the failure cause disappears of itself, the solenoid circuit does not return to normal, unless the engine
controller
starting switch is once turned OFF.

Phenomenon
occurring on • Machine will not reverse.
machine

Relative • Operation of the travel F/R solenoid (ON or OFF) can be checked in the monitoring function. (Code No. 02301: So-
information lenoid valve 2)

Cause Standard value in normal and references for troubleshooting

Presumed cause and standard value in normal

• Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during
the troubleshooting.
Swing and parking brake
solenoid defective V08 (male) Resistance value
1
(Internal short-circuiting or
grounding fault) Between (1) and (2) 27 – 30 Ω at 20°C

Between (1) and grounding Above 1 MΩ

• Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during
the troubleshooting.
Grounding fault of wiring
harness
2 Between wiring harness from C02 (female) (97) - S29 (6) - S96 -
(Contact with grounding Resistance
circuit) S29 (5) - J02 (14) - J02 (15) - A05 (7) - V08 (female) (1) and Above 1 MΩ
value
grounding

20-464 PW148-8 VEBM720100

TESTING AND ADJUSTING Failure code [DW44KB] – Short-circuiting of travel F/R solenoid

Electrical circuit for travel F/R solenoid in pump controller

EMERGENCY FNR SW.

EMERGENCY S95 (OTAX-6)
TRAVEL SW
1 2 3 4 5 6
S96

CN-S95
FNR SW. 1 2 3 4 5 6 7 8 9 F
EMERGENCY N
F NORMAL R
N
R

1 2 3 4
G71 S29
(DT-12)

J04
(090-20)

FB2
5A

Fuse
Box 2

A05
(SWP-16)

J02 (J-20) (Orange)

D03
(KESI-2)

D03
(KESI-2)

A07
(SWP-16) A01 C01 (AMP-81)
(X-4)
23 Travel R
36 Travel R Pressure SW.
42 Travel N

55 Travel F Pressure SW.

61 Travel F

C02 (AMP-40)
V08 Travel F/R Solenoid
Travel F/R Sw. 97
(DT-2)
A06 105 Travel N Solenoid
(SWP-16)

(OFF) (ON)
Travel Reverse
Press. SW.
S09
(X-2)
V06
Travel Neutral Sw. (DT-2)

Travel Forward
Press. SW.
(OFF) (ON) S10
(X-2)

A53
Backup Alarm (DT-2)

A65 A64

PW148-8 VEBM720100 20-465

Failure code [DW45KA] – Disconnection in swing parking brake solenoid TESTING AND ADJUSTING

Failure code [DW45KA] – Disconnection in swing parking

brake solenoid

User Code Failure Code Failure Disconnection in swing and parking brake solenoid
E03 DW45KA phenomenon (in pump controller system)

Failure content • No current flows to the swing parking brake solenoid circuit, when power is supplied to the circuit.

Response from • None in particular (The solenoid does not function as there is no current flowing to it)
controller • When the failure cause disappears of itself, the machine operation returns to normal.

Phenomenon
occurring on • The machine's upper structure does not swing.
machine

• Operation of the swing parking brake solenoid (ON or OFF) can be checked in the monitoring function. (Code No.
02300: Solenoid valve 1)
• If there is abnormality neither with the solenoid nor with wiring harnesses, the upper structure can swing by moving
the emergency swing brake release switch to the FREE position. (In this case, however, the parking brake does not
Relative
work, when stopping the machine)
information
• While in troubleshooting, hold both the swing lock switch and the emergency swing release switch in the OFF posi-
tion.
• The solenoid detects disconnection, when power is ON. Hence be sure to check it with power ON after the repairs.
(For how to turn power ON or OFF, refer to the troubleshooting under Failure Code [DW45KB])

Cause Standard value in normal and references for troubleshooting

• Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the
Swing parking brake sole- troubleshooting.
1 noid defective (Internal V03 (male) Resistance value
disconnection)
Between (1) and (2) 27 – 30 Ω at 20°C
• Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the
troubleshooting.
Swing lock switch defec-
2 tive S43 (female) Swing lock switch Resistance value
(Internal disconnection) OFF Below 1 Ω
Between (3) and (4)
Presumed cause and standard value in normal

ON Above 1 MΩ

Defective assembled-type • Prepare with starting switch OFF, then carry out troubleshooting with turning starting switch.
3 diode D01 D01 (male) Digital circuit tester Continuity
(Internal Disconnection)
Between (3) and (7). Diode mode There is continuity
• Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the
troubleshooting.
Resistance
Wiring harness between C02 (female) (101) and D01 (female) (7) Below 1 Ω
Disconnection of value
wiring harness
Between wiring harness from D01 (female) (3) to J10 to H15 to S43 Resistance
4 (Disconnection or defec- Below 1 Ω
(female) (3) value
tive contact with connec-
tor) Between wiring harness from S43 (female) (4) to H15 to A05 to V03 Resistance
Below 1 Ω
(female) (1) value
Resistance
Wiring harness between V03 (female) (2) and grounding Below 1 Ω
value
• Turn the engine starting switch OFF for the preparations, and hold it in the ON position during the
Short-circuiting of troubleshooting.
5 Wiring harness
(Contact with 24V circuit) Between wiring harness C02 (female) (101) and D01 (female) (7) and
Voltage Below 1 V
grounding
• Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the
troubleshooting.
6 Pump controller defective C02 (female) Disconnect D01 and connect Resistance value
pins (3) and (7) of the female
Between (101) and grounding side. 20 – 60 Ω

20-466 PW148-8 VEBM720100

TESTING AND ADJUSTING Failure code [DW45KA] – Disconnection in swing parking brake solenoid

Electrical circuit diagram for swing and parking brake solenoid in pump
controller

Emergency Swing Park Brake Release Swing Lock Switch

S22 S43(SWP-6)
1 2 3 4 5 6 1 2 3 4 5 6

EMERGENCY OFF

NORMAL ON

D01 (SWP-8)

J10 (Orange)
(DT-12)

(090-22)

8 9 10 11 7 3 11 12 13 8 10 19 20
S28

H15

J05
1 4
(Pink)

D G

A05 V03
FB1 C01 (AMP-81) (SWP-16) (DT-2)
1 38 EMERGENCY SWING 5 1

L 19 SWING LOCK SWITCH 2

(ON) (OFF)
10A

A65
A02 4
(X-4)

J04
A64
4
(PINK)
1

C02 (AMP-40)

101 SWING BRAKE SOL.

H11
8
(S-16)
CM02 (070-12)

5 SWING LOCK

SWING LOCK1

PW148-8 VEBM720100 20-467

Failure code [DW45KB] – Swing brake sol. S/C TESTING AND ADJUSTING

Failure code [DW45KB] – Swing brake sol. S/C

User code Failure code Swing holding brake solenoid short

Trouble
E03 DW45KB (Pump controller system)

Contents of
• When output to swing holding brake solenoid was turned ON, short circuit was detected in circuit.
trouble

Action of • Turns output to swing holding brake solenoid OFF.

controller • Even if cause of failure disappears, system does not reset itself until starting switch is turned OFF.

Problem that
appears on • Machine cannot swing (Swing holding brake is not reset).
machine

• If solenoid and wiring harness are normal, operator can swing machine by setting swing holding brake release
switch in release position (Swing holding brake does not work, however, when machine stops).
• Keep swing lock switch in OFF position and swing holding brake release switch in release position during trouble-
Related
shooting.
information
• Operating condition of swing holding brake solenoid can be checked with monitoring function.
• (Code: 02300: Solenoid 1)
• Method of reproducing failure code: Start engine + Swing with left work equipment control lever.

Cause Standard value in normal state/Remarks on troubleshooting

★ Prepare with starting switch OFF, then carry out troubleshooting without
turning starting switch ON.
Defective swing holding brake
1 solenoid (Internal short circuit V03 (male) Resistance
or ground fault) Between (1) – (2) 20 – 60 Ω

Between (1) – chassis ground Min. 1 MΩ

Possible causes ★ Prepare with starting switch OFF, then carry out troubleshooting without
and standard Ground fault in wiring harness turning starting switch ON.
value in normal 2 (Disconnection in wiring or
state Wiring harness between C02 (female) (101)
defective contact in connector) Resist-
– D01 – J10 – S43 – V03 (female) (1) , S28 Min. 1 MΩ
ance
(female) (9)

★ Prepare with starting switch OFF, then carry out troubleshooting without
turning starting switch ON.

3 Defective pump controller C02 (female) Resistance

Between (101) Ð Disconnect D01 20 – 60 Ω

chassis ground Min. 1 MΩ

20-468 PW148-8 VEBM720100

TESTING AND ADJUSTING Failure code [DW45KB] – Swing brake sol. S/C

Circuit diagram related to swing holding brake solenoid of pump controller

Emergency Swing Park Brake Release Swing Lock Switch

S22 S43(SWP-6)
1 2 3 4 5 6 1 2 3 4 5 6

EMERGENCY OFF

NORMAL ON

D01 (SWP-8)

J10 (Orange)
(DT-12)

(090-22)

8 9 10 11 7 3 11 12 13 8 10 19 20
S28

H15

J05
1 4
(Pink)

D G

A05 V03
FB1 C01 (AMP-81) (SWP-16) (DT-2)
1 38 EMERGENCY SWING 5 1

L 19 SWING LOCK SWITCH 2

(ON) (OFF)
10A

A65
A02 4
(X-4)

J04
A64
4
(PINK)
1

C02 (AMP-40)

101 SWING BRAKE SOL.

H11
8
(S-16)
CM02 (070-12)

5 SWING LOCK

SWING LOCK1

PW148-8 VEBM720100 20-469

Failure code [DW91KA] – Disconnection in travel neutral solenoid TESTING AND ADJUSTING

Failure code [DW91KA] – Disconnection in travel neutral

solenoid

User Code Failure Code Failure Disconnection in travel neutral solenoid

E20 DW91KA phenomenon (in pump controller system)

Failure content • No current flows to the travel neutral solenoid circuit, when power is supplied to the circuit.

Response from • None in particular (The solenoid does not function as there is current flowing to it)
controller • When the failure cause disappears of itself, the machine operation returns to normal.

Phenomenon
occurring on • Machine will not travel.
machine

• Operation of the travel neutral solenoid (ON or OFF) can be checked in the monitoring function. (Code No. 02301:
Relative Solenoid valve 2)
information • The solenoid detects disconnection, when power is ON. Hence be sure to check it with power ON after the repairs.
(For how to turn power ON or OFF, refer to the troubleshooting under Failure Code [DW91KB])

Cause Standard value in normal and references for troubleshooting

• Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during
Presumed cause and standard value in normal

Travel neutral the troubleshooting.

1 solenoid defective V06 (male) Resistance value
(Internal disconnection)
Between (1) and (2) 27 – 30 Ω at 20°C

• Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during
the troubleshooting.
Disconnection of wiring
harness Between wiring harness from C02 (female) (105) to S29 (4) to Resistance
2 Below 1 Ω
(Disconnection or defective S96 to S29 (3) to J02 to A05 to V06 (female) (1). value
contact with connector)
Resistance
Wiring harness between V06 (female) (2) and grounding. Below 1 Ω
value

• Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during
the troubleshooting.
3 Pump controller defective
C02 (female) Resistance value

Between (105) and grounding 20 – 60 Ω

20-470 PW148-8 VEBM720100

TESTING AND ADJUSTING Failure code [DW91KA] – Disconnection in travel neutral solenoid

Electrical circuit diagram for travel neutral solenoid

EMERGENCY FNR SW.

EMERGENCY S95 (OTAX-6)
TRAVEL SW
1 2 3 4 5 6
S96

CN-S95
FNR SW. 1 2 3 4 5 6 7 8 9 F
EMERGENCY N
F NORMAL R
N
R

1 2 3 4
G71 S29
(DT-12)

J04
(090-20)

FB2
5A

Fuse
Box 2

A05
(SWP-16)

J02 (J-20) (Orange)

D03
(KESI-2)

D03
(KESI-2)

A07
(SWP-16) A01 C01 (AMP-81)
(X-4)
23 Travel R
36 Travel R Pressure SW.
42 Travel N

55 Travel F Pressure SW.

61 Travel F

C02 (AMP-40)
V08 Travel F/R Solenoid
Travel F/R Sw. 97
(DT-2)
A06 105 Travel N Solenoid
(SWP-16)

(OFF) (ON)
Travel Reverse
Press. SW.
S09
(X-2)
V06
Travel Neutral Sw. (DT-2)

Travel Forward
Press. SW.
(OFF) (ON) S10
(X-2)

A53
Backup Alarm (DT-2)

A65 A64

PW148-8 VEBM720100 20-471

Failure code [DW91KB] – Short-circuiting in travel neutral solenoid TESTING AND ADJUSTING

Failure code [DW91KB] – Short-circuiting in travel neutral

solenoid

User Code Failure Code Failure Short-circuiting in travel neutral solenoid

E20 DW91KB phenomenon (in pump controller system)

Failure content • Abnormal current flow to the travel neutral solenoid circuit, when power was supplied to the circuit.

• Power supply to the travel neutral solenoid circuit is switched OFF.

Response from
• Even if the failure cause disappears of itself, the solenoid circuit does not return to normal, unless the engine start-
controller
ing switch is once turned OFF.

Phenomenon
occurring on • Machine will not drive.
machine

Relative • Operation of the travel neutral solenoid (ON or OFF) can be checked in the monitoring function. (Code No. 02301:
information Solenoid valve 2)

Cause Standard value in normal and references for troubleshooting

Presumed cause and standard value in normal

• Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during
the troubleshooting.
Travel neutral solenoid
defective V06 (male) Resistance value
1
(Internal short-circuiting or
grounding fault) Between (1) and (2) 27 – 30 Ω at 20°C

Between (1) and grounding Above 1 MΩ

• Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during
the troubleshooting.
Grounding fault of wiring
harness
2 Between wiring harness from C02 (female) (105) to S29 (4) to
(Contact with grounding Resistance
circuit) S96 to S29 (3) to J02 to A05 to V06 (Female) (1), or between Above 1 MΩ
value
S29 (9), or between D04 (1) and grounding.

20-472 PW148-8 VEBM720100

TESTING AND ADJUSTING Failure code [DW91KB] – Short-circuiting in travel neutral solenoid

Electrical circuit diagram for travel neutral solenoid

EMERGENCY FNR SW.

EMERGENCY S95 (OTAX-6)
TRAVEL SW
1 2 3 4 5 6
S96

CN-S95
FNR SW. 1 2 3 4 5 6 7 8 9 F
EMERGENCY N
F NORMAL R
N
R

1 2 3 4
G71 S29
(DT-12)

J04
(090-20)

FB2
5A

Fuse
Box 2

A05
(SWP-16)

J02 (J-20) (Orange)

D03
(KESI-2)

D03
(KESI-2)

A07
(SWP-16) A01 C01 (AMP-81)
(X-4)
23 Travel R
36 Travel R Pressure SW.
42 Travel N

55 Travel F Pressure SW.

61 Travel F

C02 (AMP-40)
V08 Travel F/R Solenoid
Travel F/R Sw. 97
(DT-2)
A06 105 Travel N Solenoid
(SWP-16)

(OFF) (ON)
Travel Reverse
Press. SW.
S09
(X-2)
V06
Travel Neutral Sw. (DT-2)

Travel Forward
Press. SW.
(OFF) (ON) S10
(X-2)

A53
Backup Alarm (DT-2)

A65 A64

PW148-8 VEBM720100 20-473

Failure code [DWK0KA] – Disconnection in 2-stage relief solenoid TESTING AND ADJUSTING

Failure code [DWK0KA] – Disconnection in 2-stage relief

solenoid

User Code Failure Code Failure Disconnection in 2-stage relief solenoid

— DWK0KA phenomenon (in pump controller system)

Failure content • When output to 2-stage relief solenoid is turned OFF, disconnection was detected in circuit.

Action of • None in particular. (Since no current flows, solenoid does not operate.)
controller • If cause of failure disappears, system resets itself.

Problem that
• Power maximizing function does not work.
appears on
• Travel power is low.
machine

Relative • Operating condition of 2-stage relief solenoid can be checked with monitoring function. (Code: 02300 Solenoid 1)
information • Method of reproducing failure code: Turn starting switch ON + Set machine in mode other than (L).

Cause Standard value in normal and references for troubleshooting

Presumed cause and standard value in normal

• Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch
2-stage relief solenoid ON.
1 defective
V02 (male) Resistance
(Internal disconnection)
Between (1) and (2) 20 – 60 Ω

Disconnection of wiring • Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch
harness ON.
2 (Disconnection in wiring or
Wiring harness between C02 (female) (109) Ð V02 (female) (1) Resistance Max. 1 Ω
defective contact in con-
nector) Wiring harness between V02 (2) - A65 (1) Resistance Max. 1 Ω

• Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch
ON.

3 Pump controller defective C02 (female) Resistance

Between (109) and chassisground

Above 1 MΩ
(V02 is disconnected)

20-474 PW148-8 VEBM720100

TESTING AND ADJUSTING Failure code [DWK0KA] – Disconnection in 2-stage relief solenoid

Electrical circuit diagram for 2-stage relief solenoid in pump controller

Pump
controller
A05 V02 2 - stage relief
C02 (AMP - 40) (SWP - 16) (DT - 2) solenoid valve

2 - stage relief SOL 109 2 1

2

(ON) (0FF)

U6

U24

A65

REVOLVING FRAME

PW148-8 VEBM720100 20-475

Failure code [DWK0KB] – Short-circuiting in 2-stage relief solenoid TESTING AND ADJUSTING

Failure code [DWK0KB] – Short-circuiting in 2-stage relief

solenoid

User Code Failure Code Failure Short-circuiting in 2-stage relief solenoid

— DWK0KB phenomenon (in pump controller system)

Failure content • When output to 2-stage relief solenoid is turned ON, short circuit was detected in circuit.

Action of • Turns output to 2-stage relief solenoid OFF.

controller • Even if cause of failure disappears, system does not reset itself until starting switch is turned OFF.

Problem that
• Power maximizing function does not work.
appears on
• Travel power is low.
machine

• Operating condition of 2-stage relief solenoid can be checked with monitoring function.
Related infor-
(Code: 02300 Solenoid 1)
mation
• Method of reproducing failure code: Turn starting switch ON + Set machine in working mode (L).

Cause Standard value in normal and references for troubleshooting

Presumed cause and standard value in normal

• Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch
2-stage relief solenoid ON.
defective
1
(Internal short-circuiting or V02 (male) Resistance
grounding fault)
Between (1) and (2) 20-60 Ω

Ground fault in wiring har- • Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch
2 ness (Short circuit with ON.
GND circuit) Wiring harness between C02 (female) (109) Ð V02 (female) (1) Resistance Min. 20 Ω

• Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch
ON. (Disconnect V02)
3 Pump controller defective C02 female Voltage

Between (109) and chassis ground Min. 1 MΩ

20-476 PW148-8 VEBM720100

TESTING AND ADJUSTING Failure code [DWK0KB] – Short-circuiting in 2-stage relief solenoid

Electric circuit diagram for 2-stage relief solenoid in pump controller

Pump
controller
A05 V02 2 - stage relief
C02 (AMP - 40) (SWP - 16) (DT - 2) solenoid valve

2 - stage relief SOL 109 2 1

2

(ON) (0FF)

U6

U24

A65

REVOLVING FRAME

PW148-8 VEBM720100 20-477

Failure code [DWK2KA] – Disconnection in 2-stage back pressure solenoid TESTING AND ADJUSTING

Failure code [DWK2KA] – Disconnection in 2-stage back

pressure solenoid

User Code Failure Code Failure Disconnection in 2-stage back pressure solenoid
— DWK2KA phenomenon (in pump controller system)

Failure content • No current flows to the 2-stage back pressure solenoid circuit, when power is supplied to the circuit.

Response from • None in particular (The solenoid does not function as there is current flowing to it)
controller • When the failure cause disappears of itself, the machine operation returns to normal.

Phenomenon
occurring on • Travel may be uncomfortable due to excessive noise from travel motor.
machine

• Operation of the 2-stage back pressure solenoid (ON or OFF) can be checked in the monitoring function. (Code No.
02301: Solenoid valve 2)
Relative
• The solenoid detects disconnection, when power is ON. Hence be sure to check it with power ON after the repairs.
information
(Operation of the 2 stage back pressure solenoid [ON or OFF] can be checked in the monitoring function [code
02301: solenoid valve 2]).

Cause Standard value in normal and references for troubleshooting

• Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during
Presumed cause and standard value in normal

2-stage back pressure the troubleshooting.

1 solenoid defective V15 (male) Resistance value
(Internal disconnection)
Between (1) and (2) 27 – 30 Ω at 20°C

• Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during
the troubleshooting.
Disconnection of wiring
harness Between wiring harness from C02 (female) (110) to A05 to V15 Resistance
2 Below 1 Ω
(Disconnection or defective (female) (1) value
contact with connector)
Resistance
Wiring harness between V15 (female) (2) and grounding Below 1 Ω
value

• Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during
the troubleshooting.
3 Pump controller defective
C02 Resistance value

Between (110) and grounding 20 – 60 Ω

20-478 PW148-8 VEBM720100

TESTING AND ADJUSTING Failure code [DWK2KA] – Disconnection in 2-stage back pressure solenoid

Electrical circuit diagram for 2-stage back pressure solenoid in pump con-
troller

Pump
controller
A05 V02 2 - stage back pressure
C02 (AMP - 40) (SWP - 16) (DT - 2) solenoid valve

2 - stage relief SOL 110 6 1

2

(ON) (0FF)

U8

U6

U24

A65

REVOLVING FRAME

PW148-8 VEBM720100 20-479

Failure code [DWK2KB] – Short circuiting in 2-stage back pressure solenoid TESTING AND ADJUSTING

Failure code [DWK2KB] – Short circuiting in 2-stage back

pressure solenoid

User Code Failure Code Failure Short circuit of 2-stage back pressure solenoid
— DWK2KB phenomenon (in pump controller system)

Failure content • Abnormal current flew to the 2-stage relief solenoid circuit, when power was supplied to the circuit.

• Power supply to the 2-stage relief solenoid circuit is switched OFF.

Response from
• Even after the failure cause disappears of itself, the machine operation does not return to normal,
controller
unless the engine starting switch is once turned OFF.

Phenomenon
occurring on • Travel may be uncomfortable due to excessive noise from travel motor.
machine

• Operation of the 2-stage back pressure solenoid (ON or OFF) can be checked in the monitoring function.
Relative
(Code No. 02301: Solenoid valve 2)
information
• Metode of reproducing failure code: Turn starting switch ON + set machine in working mode (L).

Cause Standard value in normal and references for troubleshooting

Presumed cause and standard value in normal

• Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during
the troubleshooting.
2-stage back pressure
solenoid defective V15 (male) Resistance value
1
(Internal short-circuiting or
grounding fault) Between (1) and (2) 27 – 30 Ω at 20°C

Between (1) and grounding Above 1 MΩ

Grounding fault of wiring • Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during
harness the troubleshooting.
2
(Contact with grounding Between wiring harness from C02 (female) (110) to A05 to V15 Resistance
circuit) Above 1 MΩ
(female) (1). value

• Turn the engine starting switch OFF for the preparations, and hold it in the position OFF during
the troubleshooting.
3 Pump controller defective
C02 Resistance value

Between (110) and grounding 20 – 60 Ω

20-480 PW148-8 VEBM720100

TESTING AND ADJUSTING Failure code [DWK2KB] – Short circuiting in 2-stage back pressure solenoid

Electrical circuit diagram for 2-stage back pressure solenoid in pump con-
troller

Pump
controller
A05 V02 2 - stage back pressure
C02 (AMP - 40) (SWP - 16) (DT - 2) solenoid valve

2 - stage relief SOL 110 6 1

2

(ON) (0FF)

U8

U6

U24

A65

REVOLVING FRAME

PW148-8 VEBM720100 20-481

Failure code [DXA8KA] – Disconnection in PC-EPC (F) solenoid system TESTING AND ADJUSTING

Failure code [DXA8KA] – Disconnection in PC-EPC (F) so-

lenoid system

User Code Failure Code Failure PC-EPC (F) solenoid system disconnection
E02 DXA8KA phenomenon (Pump controller system)

Contents of
• When PC-EPC (F) solenoid was driven, disconnection was detected in circuit.
trouble

Action of • None in particular (Since no current flows, solenoid does not operate).
controller • If cause of failure disappears, system resets itself.

Problem that
appears on • If pump load increases, engine speed lowers largely and engine may stall.
machine

• Drive current of PC-EPC (F) solenoid can be checked with monitoring function. (Code: 01300 PC-EPC solenoid
Related infor-
current (F))
mation
• Method of reproducing failure code: Turn starting switch ON.

Cause Standard value in normal and references for troubleshooting

Presumed cause and standard value in normal

• Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch
Defective PC-EPC (F) ON.
1 solenoid (Internal discon-
V21 Resistance
nection)
Between (1) and (2) 7 – 14 Ω

• Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch
ON.

Emergency pump drive

S28 (male) Resistance
switch
Defective emergency
2 pump drive switch (Inter- Normal Max. 1 Ω
nal disconnection) Between (3) – (2)
Emergency Min. 1 MΩ

Normal Max. 1 Ω
Between (6) – (5)
Emergency Min. 1 MΩ

• Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch
ON.

Disconnection in wiring Wiring harness between C02 (female) (96) - S28 (female) (3) Resistance Max. 1 Ω
harness (Disconnection in
3 Wiring harness between S28 (female) (2) - V21 (female) (1) Resistance Max.1 Ω
wiring or defective contact
in connector) Wiring harness between C02 (female) (115), (117), (120) - S28
Resistance Max. 1 Ω
(female) (6)

Wiring harness between S28 (female) (5) and V21 (female) (2) Resistance Max. 1 Ω

• Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch
ON.
4 Pump controller defective
C02 (female) Resistance

Between (96) and (115), (117), (120). 7 – 14 Ω

20-482 PW148-8 VEBM720100

TESTING AND ADJUSTING Failure code [DXA8KA] – Disconnection in PC-EPC (F) solenoid system

Electrical circuit diagram for PC-EPC solenoid in pump controller

FB1

10A 1 Fuse box

Emergency pump
drive switch
1 2 3 4 5 6 S21
K19 Emergency
Resistor (M - 2)
S28
Normal
1 (090 - 16)
D
2 1
(30 )
2
Pump 3
controller
4

CAB
C02 (AMP - 40) 5
F F
Solenoid GND 115 6

Solenoid GND 113

PC - EPC 96

Solenoid GND 120

3
J04
A04 1 (090 - 20)
(SWP - 14) (Pink)
1 2 (Green)
A01
(X - 4)
3

HYD PUMP
PC - EPC V21
solenoid valve (DT - 2)
U12
1
2 A64

PW148-8 VEBM720100 20-483

Failure code [DXA8KB] – Short-circuiting in PC-EPC (F) solenoid TESTING AND ADJUSTING

Failure code [DXA8KB] – Short-circuiting in PC-EPC (F)

solenoid

User Code Failure Code Failure PC-EPC (F) solenoid system short
E02 DXA8KB phenomenon (Pump controller system)

Failure content • When PC-EPC (F) solenoid was driven, short circuit was detected in circuit.

Action of • Turns output to PC-EPC (F) solenoid OFF.

controller • Even if cause of failure disappears, system does not reset itself until starting switch is turned OFF.

Problem that
appears on • If pump load increases, engine speed lowers largely and engine may stall.
machine

• Drive current of PC-EPC (F) solenoid can be checked with monitoring function.
Related infor-
• (Code: 01300 PC-EPC solenoid current (F))
mation
• Method of reproducing failure code: Turn starting switch ON.

Cause Standard value in normal and references for troubleshooting

• Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during
the troubleshooting.
Defective PC-EPC (F)
1 solenoid (Internal short cir- V21 (male) Resistance
cuit or ground fault) Between (1) and (2) 7 – 14 Ω

Between (1) and chassis ground Min. 1 MΩ

Possible causes and standard value in normal state

• Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch
ON.
Grounding fault of wiring Emergency pump drive
harness S28 (male) Resistance
2 switch
(Contact with grounding
circuit) Between (2), (3) – (4) Min. 1 MΩ

Between (2), (3) – chassis Normal

Min. 1 MΩ
ground

• Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch
ON.
Ground fault in wiring har- Wiring harness between C02 (female) (96) – S28
3 ness (Contact with GND Resistance Min. 1 MΩ
(female) (3)
circuit)
Wiring harness between S28 (female) (5) – V21 (female)
Resistance Min. 1 MΩ
(2)
• Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch
ON.

4 Defective pump controller C02 (female) Resistance value

Between (96) – (115), (117), (120) 7 – 14 Ω

Between (96) – chassis ground Min. 1 MΩ

20-484 PW148-8 VEBM720100

TESTING AND ADJUSTING Failure code [DXA8KB] – Short-circuiting in PC-EPC (F) solenoid

Electrical circuit diagram for PC-EPC solenoid in pump controller

FB1

10A 1 Fuse box

Emergency pump
drive switch
1 2 3 4 5 6 S21
K19 Emergency
Resistor (M - 2)
S28
Normal
1 (090 - 16)
D
2 1
(30 )
2
Pump 3
controller
4

CAB
C02 (AMP - 40) 5
F F
Solenoid GND 115 6

Solenoid GND 113

PC - EPC 96

Solenoid GND 120

3
J04
A04 1 (090 - 20)
(SWP - 14) (Pink)
1 2 (Green)
A01
(X - 4)
3

HYD PUMP
PC - EPC V21
solenoid valve (DT - 2)
U12
1
2 A64

PW148-8 VEBM720100 20-485

Failure code [DXE0KA] – Disconnection in LS-EPC solenoid system TESTING AND ADJUSTING

Failure code [DXE0KA] – Disconnection in LS-EPC sole-

noid system

User Code Failure Code Failure LS-EPC solenoid system disconnection

— DXE0KA phenomenon (Pump controller system)
Failure content • When LS-EPC solenoid was driven, disconnection was detected in circuit.
Action of • None in particular (Since no current flows, solenoid does not operate).
controller • If cause of failure disappears, system resets itself.
Problem that
• Travel speed is high at Lo and Mi.
appears on
• Work equipment speed and swing speed are high in lifting mode (L).
machine
• Drive current of LS-EPC solenoid can be checked with monitoring function. (Code: 01500 LS-EPC sole-
Related infor-
noid current)
mation
• Method of reproducing failure code: Turn starting switch ON.

Cause Standard value in normal state/Remarks on troubleshooting

• Prepare with starting switch OFF, then carry out troubleshooting
Defective LS-EPC solenoid without turning starting switch ON.
1
(Internal disconnection) V22 (male) Resistance
Between (1) – (2) 7 – 14 Ω
• Prepare with starting switch OFF, then carry out troubleshooting
Possible without turning starting switch ON.
causes and Disconnection in wiring harness
Wiring harness between C02 (female)
standard value 2 (Disconnection in wiring or Resistance Max. 1 Ω
in normal state (88) – V22 (female) (1)
defective contact in connector)
Wiring harness between C02 (female)
Resistance Max. 1 Ω
(115), (117), (120) – V22 (female) (2)
• Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
3 Defective pump controller
C02 (female) Resistance
Between (88) – (115), (117), (120) 7 – 14 Ω

Electrical circuit diagram for LS-EPC solenoid in pump controller

Pump
controller

C02 (AMP - 40)

LS - EPC
Solenoid GND 115 A04 (SWP - 14) V22 (DT - 2) solenoid
LS - EPC 88 4 1

Solenoid GND 117 5 2

Solenoid GND 120

CAB HYDRAULIC PUMP

20-486 PW148-8 VEBM720100

TESTING AND ADJUSTING Failure code [DXE0KB] – Short-circuiting in LS-EPC solenoid

Failure code [DXE0KB] – Short-circuiting in LS-EPC sole-

noid

User Code Failure Code Failure LS-EPC solenoid system short

— DXE0KB phenomenon (Pump controller system)
Failure content • When LS-EPC solenoid was driven, short circuit was detected in circuit.
Action of • Turns output to LS-EPC solenoid OFF.
controller • Even if cause of failure disappears, system does not reset itself until starting switch is turned OFF.
Problem that
• Travel speed is high at Lo and Mi.
appears on
• Work equipment speed and swing speed are high in lifting mode (L).
machine
• Drive current of LS-EPC solenoid can be checked with monitoring function.
Related infor-
(Code: 01500 LS-EPC solenoid current)
mation
• Method of reproducing failure code: Turn starting switch ON.

Cause Standard value in normal state/Remarks on troubleshooting

• Prepare with starting switch OFF, then carry out troubleshooting without
turning starting switch ON.
Defective LS-EPC sole-
1 noid (Internal short cir- V22 (male) Resistance value
cuit or ground fault) Between (1) and (2) 7 – 14 Ω
Between (1) and chassis ground Min. 1 MΩ
Possible
causes and • Prepare with starting switch OFF, then carry out troubleshooting without
standard Ground fault in wiring turning starting switch ON.
value in nor- 2 harness (Short circuit
with GND circuit) Between wiring harness C02 (female) (88) and Resist- Min.
mal state
V22 (female) (1) ance 1 MΩ
• Prepare with starting switch OFF, then carry out troubleshooting without
turning starting switch ON.
Defective pump control- C02 (female) Resistance value
3
ler
Between (88) - (115), (117), (120) 7 – 14 Ω
Between (88) and chassis ground Min. 1 MΩ

Electrical circuit diagram for LS-EPC solenoid in pump controller

Pump
controller

C02 (AMP - 40)

LS - EPC
Solenoid GND 115 A04 (SWP - 14) V22 (DT - 2) solenoid
LS - EPC 88 4 1

Solenoid GND 117 5 2

Solenoid GND 120

CAB HYDRAULIC PUMP

PW148-8 VEBM720100 20-487

Failure code [DXE4KA] – 1st service current EPC discon (left hand) TESTING AND ADJUSTING

Failure code [DXE4KA] – 1st service current EPC discon

(left hand)

User code Failure code Service current EPC solenoid disconnection

Trouble
— DXE4KA (Pump controller system)

Contents of
• When service EPC solenoid was driven, disconnection was detected in circuit.
trouble
Action of • None in particular (Since no current flows, solenoid does not operate).
controller • If cause of failure disappears, system resets itself.
Problem that
appears on • Attachment does not operate.
machine
• Drive current of service EPC solenoid can be checked with monitoring function.
Related
(Code: 01700 service solenoid current)
information
• Method of reproducing failure code: Turn starting switch ON + Set in attachment mode (ATT).

Cause Standard value in normal state/Remarks on troubleshooting

★ Prepare with starting switch OFF, then carry out troubleshooting without
turning starting switch ON.
Defective service EPC solenoid
1
(Internal disconnection) V23 (male) Resistance
Between (1) – (2) 7 – 14 Ω
★ Prepare with starting switch OFF, then carry out troubleshooting without
Possible causes turning starting switch ON.
and standard Disconnection in wiring harness
value in normal Wiring harness between C02 (female) (95) – V23
2 (Disconnection in wiring or defec- Resistance Max. 1 Ω
state (female) (1)
tive contact in connector)
Wiring harness between C02 (female) (115), (117),
Resistance Max. 1 Ω
(120) – V23 (female) (2)
★ Prepare with starting switch OFF, then carry out troubleshooting without
turning starting switch ON.
3 Defective pump controller
C02 (female) Resistance
Between (95) – (115), (117), (120) 7 – 14 Ω

20-488 PW148-8 VEBM720100

TESTING AND ADJUSTING Failure code [DXE4KA] – 1st service current EPC discon (left hand)

Circuit diagram related to the 1st and 2 nd service EPC solenoids

C02 (AMP-40)
Solenoid GND 115
1st Service EPC
95
(left)
Solenoid GND 117 F
1st Service EPC
110
(Right)
Solenoid GND 120 F
2nd Service EPC
111
(Left)
2nd Service EPC
102
(Right)

F F
F

5 6 9 10 7 8 13 14
A03 A04
(SWP-14) (SWP-14)

V26
1 2nd Service EPC

2 Solenoid (R.H)

V25
1 2nd Service EPC

2 Solenoid (L.H)

V24
1 1st Service EPC

2 Solenoid (R.H)

V23
1 1st Service EPC

2 Solenoid (L.H)

DXE4KAA

PW148-8 VEBM720100 20-489

Failure code [DXE4KB] – 1st service current EPC short (left hand) TESTING AND ADJUSTING

Failure code [DXE4KB] – 1st service current EPC short

(left hand)

User code Failure code Service current EPC solenoid short

Trouble
— DXE4KB (Pump controller system)

Contents of
• When service EPC solenoid was driven, short circuit was detected in circuit.
trouble
Action of • Turns output to service EPC solenoid OFF.
controller • Even if cause of failure disappears, system does not reset itself until starting switch is turned OFF.
Problem that
appears on • Attachment does not operate.
machine
• Drive current of service EPC solenoid can be checked with monitoring function.
Related
(Code: 01700 service EPC solenoid current)
information
• Method of reproducing failure code: Turn starting switch ON + Set in attachment mode (ATT).

Cause Standard value in normal state/Remarks on troubleshooting

★ Prepare with starting switch OFF, then carry out troubleshooting without
turning starting switch ON.
Defective service EPC solenoid
1 (Internal short circuit or ground V23 (male) Resistance
fault) Between (1) – (2) 7 – 14 Ω
Between (1) – chassis ground Min. 1 MΩ
Possible causes
★ Prepare with starting switch OFF, then carry out troubleshooting without
and standard
Ground fault in wiring harness turning starting switch ON.
value in normal 3
state (Short circuit with GND circuit) Wiring harness between C02 (female) (95) – V23
Resistance Min. 1 MΩ
(female) (1)
★ Prepare with starting switch OFF, then carry out troubleshooting without
turning starting switch ON.

4 Defective pump controller C02 (female) Resistance

Between (95) – (115), (117), (120) 7 – 14 Ω
Between (95) – chassis ground Min. 1 MΩ

20-490 PW148-8 VEBM720100

TESTING AND ADJUSTING Failure code [DXE4KB] – 1st service current EPC short (left hand)

Circuit diagram related to the 1st and 2nd service EPC solenoids

C02 (AMP-40)
Solenoid GND 115
1st Service EPC
95
(left)
Solenoid GND 117 F
1st Service EPC
110
(Right)
Solenoid GND 120 F
2nd Service EPC
111
(Left)
2nd Service EPC
102
(Right)

F F
F

5 6 9 10 7 8 13 14
A03 A04
(SWP-14) (SWP-14)

V26
1 2nd Service EPC

2 Solenoid (R.H)

V25
1 2nd Service EPC

2 Solenoid (L.H)

V24
1 1st Service EPC

2 Solenoid (R.H)

V23
1 1st Service EPC

2 Solenoid (L.H)

DXE4KAA

PW148-8 VEBM720100 20-491

Failure code [DXE7KA] – 1st service current EPC discon (right hand) TESTING AND ADJUSTING

Failure code [DXE7KA] – 1st service current EPC discon

(right hand)

User code Failure code Service current EPC2 solenoid disconnection

Trouble
— DXE7KA (Pump controller system)

Contents of
• When service EPC2 solenoid was driven, disconnection was detected in circuit.
trouble
Action of • None in particular (Since no current flows, solenoid does not operate).
controller • If cause of failure disappears, system resets itself.
Problem that
appears on • Attachment does not operate.
machine
• Drive current of service EPC2 solenoid can be checked with monitoring function.
Related
(Code: 01700 service solenoid current)
information
• Method of reproducing failure code: Turn starting switch ON + Set in attachment mode (ATT).

Cause Standard value in normal state/Remarks on troubleshooting

★ Prepare with starting switch OFF, then carry out troubleshooting without
turning starting switch ON.
Defective service EPC solenoid
1
(Internal disconnection) V24 (male) Resistance
Between (1) – (2) 7 – 14 Ω
★ Prepare with starting switch OFF, then carry out troubleshooting without
Possible causes turning starting switch ON.
and standard Disconnection in wiring harness
value in normal Wiring harness between C02 (female) (100) – V24
2 (Disconnection in wiring or defec- Resistance Max. 1 Ω
state (female) (1)
tive contact in connector)
Wiring harness between C02 (female) (115), (117),
Resistance Max. 1 Ω
(120) – V24 (female) (2)
★ Prepare with starting switch OFF, then carry out troubleshooting without
turning starting switch ON.
3 Defective pump controller
C02 (female) Resistance
Between (100) – (115), (117), (120) 7 – 14 Ω

20-492 PW148-8 VEBM720100

TESTING AND ADJUSTING Failure code [DXE7KA] – 1st service current EPC discon (right hand)

Circuit diagram related to the 1st and 2nd service EPC solenoids

C02 (AMP-40)
Solenoid GND 115
1st Service EPC
95
(left)
Solenoid GND 117 F
1st Service EPC
110
(Right)
Solenoid GND 120 F
2nd Service EPC
111
(Left)
2nd Service EPC
102
(Right)

F F
F

5 6 9 10 7 8 13 14
A03 A04
(SWP-14) (SWP-14)

V26
1 2nd Service EPC

2 Solenoid (R.H)

V25
1 2nd Service EPC

2 Solenoid (L.H)

V24
1 1st Service EPC

2 Solenoid (R.H)

V23
1 1st Service EPC

2 Solenoid (L.H)

DXE4KAA

PW148-8 VEBM720100 20-493

Failure code [DXE7KB] – 1st service current EPC short (right hand) TESTING AND ADJUSTING

Failure code [DXE7KB] – 1st service current EPC short

(right hand)

User code Failure code Service current EPC solenoid short

Trouble
— DXE7KB (Pump controller system)

Contents of
• When service EPC solenoid was driven, short circuit was detected in circuit.
trouble
Action of • Turns output to service EPC solenoid OFF.
controller • Even if cause of failure disappears, system does not reset itself until starting switch is turned OFF.
Problem that
appears on • Attachment does not operate.
machine
• Drive current of service EPC solenoid can be checked with monitoring function.
Related
(Code: 01700 service EPC solenoid current)
information
• Method of reproducing failure code: Turn starting switch ON + Set in attachment mode (ATT).

Cause Standard value in normal state/Remarks on troubleshooting

★ Prepare with starting switch OFF, then carry out troubleshooting without
turning starting switch ON.
Defective service EPC solenoid
1 (Internal short circuit or ground V24 (male) Resistance
fault) Between (1) – (2) 7 – 14 Ω
Between (1) – chassis ground Min. 1 MΩ
Possible causes
★ Prepare with starting switch OFF, then carry out troubleshooting without
and standard
Ground fault in wiring harness turning starting switch ON.
value in normal 3
state (Short circuit with GND circuit) Wiring harness between C02 (female) (100) – V24
Resistance Min. 1 MΩ
(female) (1)
★ Prepare with starting switch OFF, then carry out troubleshooting without
turning starting switch ON.

4 Defective pump controller C02 (female) Resistance

Between (100) – (115), (117), (120) 7 – 14 Ω
Between (100) – chassis ground Min. 1 MΩ

20-494 PW148-8 VEBM720100

TESTING AND ADJUSTING Failure code [DXE7KB] – 1st service current EPC short (right hand)

Circuit diagram related to the 1st and 2nd service EPC solenoids

C02 (AMP-40)
Solenoid GND 115
1st Service EPC
95
(left)
Solenoid GND 117 F
1st Service EPC
110
(Right)
Solenoid GND 120 F
2nd Service EPC
111
(Left)
2nd Service EPC
102
(Right)

F F
F

5 6 9 10 7 8 13 14
A03 A04
(SWP-14) (SWP-14)

V26
1 2nd Service EPC

2 Solenoid (R.H)

V25
1 2nd Service EPC

2 Solenoid (L.H)

V24
1 1st Service EPC

2 Solenoid (R.H)

V23
1 1st Service EPC

2 Solenoid (L.H)

DXE4KAA

PW148-8 VEBM720100 20-495

Failure code [DXE8KA] – 2nd service current EPC discon (left hand) TESTING AND ADJUSTING

Failure code [DXE8KA] – 2nd service current EPC discon

(left hand)

User code Failure code Service current EPC solenoid disconnection

Trouble
— DXE8KA (Pump controller system)

Contents of trouble • When service EPC solenoid was driven, disconnection was detected in circuit.
Action of • None in particular (Since no current flows, solenoid does not operate).
controller • If cause of failure disappears, system resets itself.
Problem that
appears on • Attachment does not operate.
machine
• Drive current of service EPC solenoid can be checked with monitoring function.
Related
(Code: 01700 service solenoid current)
information
• Method of reproducing failure code: Turn starting switch ON + Set in attachment mode (ATT).

Cause Standard value in normal state/Remarks on troubleshooting

★ Prepare with starting switch OFF, then carry out troubleshooting without
Defective service EPC solenoid turning starting switch ON.
1
(Internal disconnection) V25 (male) Resistance
Between (1) – (2) 7 – 14 Ω
★ Prepare with starting switch OFF, then carry out troubleshooting without
Possible causes turning starting switch ON.
and standard Disconnection in wiring harness
value in normal Wiring harness between C02 (female) (111) – V25
2 (Disconnection in wiring or defec- Resistance Max. 1 Ω
state (female) (1)
tive contact in connector)
Wiring harness between C02 (female) (115), (117),
Resistance Max. 1 Ω
(120) – V25 (female) (2)
★ Prepare with starting switch OFF, then carry out troubleshooting without
turning starting switch ON.
3 Defective pump controller
C02 (female) Resistance
Between (111) – (115), (117), (120) 7 – 14 Ω

20-496 PW148-8 VEBM720100

TESTING AND ADJUSTING Failure code [DXE8KA] – 2nd service current EPC discon (left hand)

Circuit diagram related to the 1st and 2nd service EPC solenoids

C02 (AMP-40)
Solenoid GND 115
1st Service EPC
95
(left)
Solenoid GND 117 F
1st Service EPC
110
(Right)
Solenoid GND 120 F
2nd Service EPC
111
(Left)
2nd Service EPC
102
(Right)

F F
F

5 6 9 10 7 8 13 14
A03 A04
(SWP-14) (SWP-14)

V26
1 2nd Service EPC

2 Solenoid (R.H)

V25
1 2nd Service EPC

2 Solenoid (L.H)

V24
1 1st Service EPC

2 Solenoid (R.H)

V23
1 1st Service EPC

2 Solenoid (L.H)

DXE4KAA

PW148-8 VEBM720100 20-497

Failure code [DXE8KB] – 2nd service current EPC short (left hand) TESTING AND ADJUSTING

Failure code [DXE8KB] – 2nd service current EPC short

(left hand)

User code Failure code Service current EPC3 solenoid short

Trouble
— DXE8KB (Pump controller system)

Contents of trouble • When service EPC solenoid was driven, short circuit was detected in circuit.
Action of • Turns output to service EPC solenoid OFF.
controller • Even if cause of failure disappears, system does not reset itself until starting switch is turned OFF.
Problem that
appears on • Attachment does not operate.
machine
• Drive current of service EPC solenoid can be checked with monitoring function.
Related
(Code: 01700 service EPC solenoid current)
information
• Method of reproducing failure code: Turn starting switch ON + Set in attachment mode (ATT).

Cause Standard value in normal state/Remarks on troubleshooting

★ Prepare with starting switch OFF, then carry out troubleshooting without
turning starting switch ON.
Defective service EPC solenoid
1 (Internal short circuit or ground V25 (male) Resistance
fault) Between (1) – (2) 7 – 14 Ω
Between (1) – chassis ground Min. 1 MΩ
Possible causes
★ Prepare with starting switch OFF, then carry out troubleshooting without
and standard
Ground fault in wiring harness turning starting switch ON.
value in normal 3
state (Short circuit with GND circuit) Wiring harness between C02 (female) (111) – V25
Resistance Min. 1 MΩ
(female) (1)
★ Prepare with starting switch OFF, then carry out troubleshooting without
turning starting switch ON.

4 Defective pump controller C02 (female) Resistance

Between (111) – (115), (117), (120) 7 – 14 Ω
Between (111) – chassis ground Min. 1 MΩ

20-498 PW148-8 VEBM720100

TESTING AND ADJUSTING Failure code [DXE8KB] – 2nd service current EPC short (left hand)

Circuit diagram related to the 1st and 2nd service EPC solenoids

C02 (AMP-40)
Solenoid GND 115
1st Service EPC
95
(left)
Solenoid GND 117 F
1st Service EPC
110
(Right)
Solenoid GND 120 F
2nd Service EPC
111
(Left)
2nd Service EPC
102
(Right)

F F
F

5 6 9 10 7 8 13 14
A03 A04
(SWP-14) (SWP-14)

V26
1 2nd Service EPC

2 Solenoid (R.H)

V25
1 2nd Service EPC

2 Solenoid (L.H)

V24
1 1st Service EPC

2 Solenoid (R.H)

V23
1 1st Service EPC

2 Solenoid (L.H)

DXE4KAA

PW148-8 VEBM720100 20-499

Failure code [DXE9KA] – 2nd service current EPC discon (right hand) TESTING AND ADJUSTING

Failure code [DXE9KA] – 2nd service current EPC discon

(right hand)

User code Failure code Service current EPC solenoid disconnection

Trouble
— DXE9KA (Pump controller system)

Contents of trouble • When service EPC4 solenoid was driven, disconnection was detected in circuit.
Action of • None in particular (Since no current flows, solenoid does not operate).
controller • If cause of failure disappears, system resets itself.
Problem that
appears on • Attachment does not operate.
machine
• Drive current of service EPC solenoid can be checked with monitoring function.
Related
(Code: 01700 service solenoid current)
information
• Method of reproducing failure code: Turn starting switch ON + Set in attachment mode (ATT).

Cause Standard value in normal state/Remarks on troubleshooting

★ Prepare with starting switch OFF, then carry out troubleshooting without
Defective service EPC solenoid turning starting switch ON.
1
(Internal disconnection) V26 (male) Resistance
Between (1) – (2) 7 – 14 Ω
★ Prepare with starting switch OFF, then carry out troubleshooting without
Possible causes turning starting switch ON.
and standard Disconnection in wiring harness
value in normal Wiring harness between C02 (female) (102) – V26
2 (Disconnection in wiring or defec- Resistance Max. 1 Ω
state (female) (1)
tive contact in connector)
Wiring harness between C03 (female) (115), (117),
Resistance Max. 1 Ω
(120) – V26 (female) (2)
★ Prepare with starting switch OFF, then carry out troubleshooting without
turning starting switch ON.
3 Defective pump controller
C02 (female) Resistance
Between (102) – (115), (117), (120) 7 – 14 Ω

20-500 PW148-8 VEBM720100

TESTING AND ADJUSTING Failure code [DXE9KA] – 2nd service current EPC discon (right hand)

Circuit diagram related to the 1st and 2nd service EPC solenoids

C02 (AMP-40)
Solenoid GND 115
1st Service EPC
95
(left)
Solenoid GND 117 F
1st Service EPC
110
(Right)
Solenoid GND 120 F
2nd Service EPC
111
(Left)
2nd Service EPC
102
(Right)

F F
F

5 6 9 10 7 8 13 14
A03 A04
(SWP-14) (SWP-14)

V26
1 2nd Service EPC

2 Solenoid (R.H)

V25
1 2nd Service EPC

2 Solenoid (L.H)

V24
1 1st Service EPC

2 Solenoid (R.H)

V23
1 1st Service EPC

2 Solenoid (L.H)

DXE4KAA

PW148-8 VEBM720100 20-501

Failure code [DXE9KB] – 2nd service current EPC short (right hand) TESTING AND ADJUSTING

Failure code [DXE9KB] – 2nd service current EPC short

(right hand)

User code Failure code Service current EPC solenoid short

Trouble
— DXE9KB (Pump controller system)

Contents of
• When service EPC solenoid was driven, short circuit was detected in circuit.
trouble

Action of • Turns output to service EPC solenoid OFF.

controller • Even if cause of failure disappears, system does not reset itself until starting switch is turned OFF.

Problem that
appears on • Attachment does not operate.
machine

• Drive current of service EPC solenoid can be checked with monitoring function.
Related
(Code: 01700 service EPC solenoid current)
information
• Method of reproducing failure code: Turn starting switch ON + Set in attachment mode (ATT).

Cause Standard value in normal state/Remarks on troubleshooting

★ Prepare with starting switch OFF, then carry out troubleshooting without
turning starting switch ON.
Defective service EPC solenoid
1 (Internal short circuit or ground V26 (male) Resistance
fault) Between (1) – (2) 7 – 14 Ω

Between (1) – chassis ground Min. 1 MΩ

Possible causes ★ Prepare with starting switch OFF, then carry out troubleshooting without
and standard Ground fault in wiring harness turning starting switch ON.
value in normal 3
(Short circuit with GND circuit) Wiring harness between C02 (female) (102)
state Resistance Min. 1 MΩ
– V26 (female) (1)

★ Prepare with starting switch OFF, then carry out troubleshooting without
turning starting switch ON.

C02 (female) Resistance

4 Defective pump controller
Between (102) – (115), (117),
7 – 14 Ω
(120)

Between (102) – chassis ground Min. 1 MΩ

20-502 PW148-8 VEBM720100

TESTING AND ADJUSTING Failure code [DXE9KB] – 2nd service current EPC short (right hand)

Circuit diagram related to the 1st and 2nd service EPC solenoids

C02 (AMP-40)
Solenoid GND 115
1st Service EPC
95
(left)
Solenoid GND 117 F
1st Service EPC
110
(Right)
Solenoid GND 120 F
2nd Service EPC
111
(Left)
2nd Service EPC
102
(Right)

F F
F

5 6 9 10 7 8 13 14
A03 A04
(SWP-14) (SWP-14)

V26
1 2nd Service EPC

2 Solenoid (R.H)

V25
1 2nd Service EPC

2 Solenoid (L.H)

V24
1 1st Service EPC

2 Solenoid (R.H)

V23
1 1st Service EPC

2 Solenoid (L.H)

DXE4KAA

PW148-8 VEBM720100 20-503

Failure code [DY20KA] – Wiper working abnormality TESTING AND ADJUSTING

Failure code [DY20KA] – Wiper working abnormality

Action code Failure code Wiper working abnormality

Trouble
— DY20KA (Pump controller system)

Contents of
• When windshield wiper works, W signal of working ends is not input.
rouble

Action of • Turns working output to wiper motor OFF.

monitor panel • If cause of failure disappears, system resets itself.

Problem that
appears on • Wiper motor does not work.
machine

• Condition of W contact signal of wiper working area can be checked with monitoring function.
Related
(Code: 02204 switch 5)
information
• Method of reproducing failure code: Turn starting switch ON + Set wiper switch to INT or ON.

Cause Standard value in normal state/Remarks on troubleshooting

★ Prepare with starting switch OFF, then carry out troubleshooting without
turning starting switch ON.

Defective wiper motor (Internal W04 (female) Wiper blade Resistance

1
disconnection) Operating range top Max. 1 Ω
Between (6) – (5) Other than operating
Min. 1 MΩ
range top

★ Prepare with starting switch OFF, then carry out troubleshooting without
Possible causes turning starting switch ON.
and standard Disconnection in wiring harness
value in normal Wiring harness between C01 (female) (56) – W04 Resist-
2 (Disconnection in wiring or Max. 1 Ω
state (male) (6) ance
defective contact in connector)
Wiring harness between W04 (female) (5) – J04 – Resist-
Max. 1 Ω
chassis ground (A64) ance

★ Prepare with starting switch OFF, then carry out troubleshooting without
turning starting switch ON.

C01 Wiper blade Resistance

3 Defective pump controller
Operating range top Max. 1 Ω
Between (56) – chas-
sis ground Other than operating
Min. 1 MΩ
range top

20-504 PW148-8 VEBM720100

TESTING AND ADJUSTING Failure code [DY20KA] – Wiper working abnormality

Circuit diagram related to wiper motor of machine monitor

Pump controler

C01(AMP-81)

56
15

C02(AMP-40)
114
119

A01(X-4)
E U12
A64

6 1
J04 (Pink)
(J-20)

PW148-8 VEBM720100 20-505

Failure code [DY20MA] – Wiper parking abnormality TESTING AND ADJUSTING

Failure code [DY20MA] – Wiper parking abnormality

Action code Failure code Wiper parking abnormality

Trouble
— DY20MA (Pump controller system)

Contents of
• When windshield wiper parks, P signal of storage area is not input.
trouble

Action of • Turns parking output to wiper motor OFF.

monitor panel • If cause of failure disappears, system resets itself.

Problem that
appears on • Wiper motor does not park.
machine

• Condition of P contact signal of wiper parking area can be checked with monitoring function.
Related
(Code: 02204 switch 5)
information
• Method of reproducing failure code: Turn starting switch ON + Set wiper switch to INT/ON to OFF.

Cause Standard value in normal state/Remarks on troubleshooting

★ Prepare with starting switch OFF, then carry out troubleshooting without
turning starting switch ON.
Defective wiper motor (Internal W04 (female) Wiper blade Resistance
1
disconnection)
Storage area Max. 1 Ω
Between (4) – (5)
Working area Min. 1 MΩ

★ Prepare with starting switch OFF, then carry out troubleshooting without
Possible causes turning starting switch ON.
and standard Disconnection in wiring harness
value in normal Wiring harness between C01 (female) (75) – W04 Resist-
2 (Disconnection in wiring or Max. 1 Ω
state (male) (4) ance
defective contact in connector)
Wiring harness between W04 (female) (5) – J04 – Resist-
Max. 1 Ω
chassis ground (A64) ance

★ Prepare with starting switch OFF, then carry out troubleshooting without
turning starting switch ON.

3 Defective pump controller C01 Wiper blade Voltage

Between (75) – chas- Storage area Max. 1 Ω

sis ground Working area Min. 1 MΩ

20-506 PW148-8 VEBM720100

TESTING AND ADJUSTING Failure code [DY20MA] – Wiper parking abnormality

Circuit diagram related to wiper motor of machine monitor

Pump controler

C01(AMP-81)

56
15

C02(AMP-40)
114
119

A01(X-4)
E U12
A64

6 1
J04 (Pink)
(J-20)

PW148-8 VEBM720100 20-507

Failure code [DY2CKA] – Washer drive discon TESTING AND ADJUSTING

Failure code [DY2CKA] – Washer drive discon

Action code Failure code Window washer drive system disconnection

Trouble
— DY2CKA (Pump controller system)

Contents of • When output to window washer drive system was turned OFF (when ground circuit was connected), disconnection
rouble was detected in circuit.

Action of • None in particular (Since no current flows, washer motor does not operate).
controller • If cause of failure disappears, system resets itself.

Problem that
appears on • Window washer does not operate.
machine

Related
• Method of reproducing failure code: Turn starting switch ON.
information

Cause Standard value in normal state/Remarks on troubleshooting

1 Defective fuse No. 4 If fuse is broken, circuit probably has ground fault. (See cause 5.)
★ Prepare with starting switch OFF, then carry out troubleshooting without
turning starting switch ON.
Defective washer motor (Internal A50 (male) Resistance
2
short circuit or ground fault)
Between (1) – (2) 5 – 20 Ω
Between (1), (2) – chassis ground Min. 1 MΩ
★ Prepare with starting switch OFF, then carry out troubleshooting without
turning starting switch ON.
Defective assembled-type diode
3
D02 (Internal short circuit) D03 (female) Continuity (Resistance)
Between (4) – (8) No continuity (Min. 1 Mz)

Possible causes
and standard
value in normal Disconnection in wiring harness
state 4 (Disconnection in wiring or defec-
tive contact in connector)
Ground fault in wiring harness
5 Resistance
(Short circuit with GND circuit)
6 Defective pump controller
★ Prepare with starting switch OFF, then carry out troubleshooting without
turning starting switch ON.
Wiring harness between FB1 (4) – J03 – A50
Resistance Max. 1 Ω
(female) (1)
Wiring harness between C01 (female) (3) – J07 –
Resistance Max. 1 Ω
A50 (female) (2)
★ Prepare with starting switch OFF, then carry out troubleshooting without
turning starting switch ON.
Wiring harness between FB1 (4) – J03 – A50
Min. 1 MΩ
(female) (1), – D01 (female) (4)
Wiring harness between C01 (female) (3) – J07 –
Resistance Min. 1 MΩ
A50 (female) (2), – D01 (female) (8)
★ Prepare with starting switch OFF, then turn starting switch ON and carry
out troubleshooting.
C01 (female) Voltage
Between (3) – chassis ground 20 – 30 V

20-508 PW148-8 VEBM720100

TESTING AND ADJUSTING Failure code [DY2CKA] – Washer drive discon

Circuit diagram related to wiper motor of machine monitor

Pump controler

C01(AMP-81) 6

7
3
2
1
(Black)

1
11
12
(Grey)

PW148-8 VEBM720100 20-509

Failure code [DY2CKB] – Washer drive short TESTING AND ADJUSTING

Failure code [DY2CKB] – Washer drive short

Action code Failure code Window washer drive system short

Trouble
— DY2CKB (Pump controller system)

Contents of • When output to window washer drive system was turned ON (ground circuit was disconnected), short circuit was
trouble detected in circuit.

Action of • Turns output to washer motor OFF.

controller • Even if cause of failure disappears, system does not reset itself until starting switch is turned OFF.

Problem that
appears on • Window washer does not operate.
machine

Related
• Method of reproducing failure code: Turn starting switch ON + Turn washer switch ON.
information

Cause Standard value in normal state/Remarks on troubleshooting

★ Prepare with starting switch OFF, then carry out troubleshooting without
turning starting switch ON.
Defective washer motor (Inter-
1
nal short circuit) A50 (male) Resistance
Possible causes
Between (1) – (2) 5 – 20 Ω
and standard
value in normal ★ Prepare with starting switch OFF, then turn starting switch ON and carry
state out troubleshooting.
Hot short (Short circuit with 24V
2
circuit) in wiring harness Wiring harnesses between C01 (female) (3) – J07
Voltage Max. 1 V
– A50 (female) (2), – D01 (female) (8)

If causes 1 and 2 are not detected, pump controller may be defective. (Since
3 Defective pump controller
trouble is in system, troubleshooting cannot be carried out.)

20-510 PW148-8 VEBM720100

TESTING AND ADJUSTING Failure code [DY2CKB] – Washer drive short

Circuit diagram related to window washer motor of machine monitor

Pump controler

C01(AMP-81) 6

7
3
2
1
(Black)

1
11
12
(Grey)

PW148-8 VEBM720100 20-511

Failure code [DY2DKB] – Wiper drive (for) short TESTING AND ADJUSTING

Failure code [DY2DKB] – Wiper drive (for) short

Action code Failure code Wiper motor drive forward system short
Trouble
— DY2DKB (Pump controller system)

Contents of
• When output to wiper motor drive forward side was turned ON, short circuit was detected in circuit.
trouble

Action of • Turns output to wiper motor drive forward side OFF.

controller • Even if cause of failure disappears, system does not reset itself until starting switch is turned OFF.

Problem that
appears on • Windshield wiper does not operate.
machine

Related
• Method of reproducing failure code: Turn starting switch ON + Set wiper switch to INT or ON.
information

Cause Standard value in normal state/Remarks on troubleshooting

★ Prepare with starting switch OFF, then carry out troubleshooting without
turning starting switch ON.
Defective wiper motor (Internal W04 Continuity/Resistance
1
short circuit or ground fault)
Possible causes Between (3) – (1) There is continuity
and standard Between (3) – chassis ground Min. 1 MΩ
value in normal
state ★ Prepare with starting switch OFF, then carry out troubleshooting without
Ground fault in wiring harness turning starting switch ON.
2
(Short circuit with GND circuit) Wiring harness between C02 (female) (119) – Resist- Min. 1
W04 (male) (3) ance MΩ

If causes 1 and 2 are not detected, pump controller may be defective. (Since
3 Defective pump controller
trouble is in system, troubleshooting cannot be carried out.)

20-512 PW148-8 VEBM720100

TESTING AND ADJUSTING Failure code [DY2DKB] – Wiper drive (for) short

Circuit diagram related to wiper motor of machine monitor

Pump controler

C01(AMP-81)

56
15

C02(AMP-40)
114
119

A01(X-4)
E U12
A64

6 1
J04 (Pink)
(J-20)

PW148-8 VEBM720100 20-513

Failure code [DY2EKB] – Wiper drive (rev) short TESTING AND ADJUSTING

Failure code [DY2EKB] – Wiper drive (rev) short

Action code Failure code Wiper motor drive reverse system short
Trouble
— DY2EKB (Pump controller system)

Contents of
• When output to wiper motor drive reverse side was turned ON, short circuit was detected in circuit.
trouble

Action of • Turns output to wiper motor drive reverse side OFF.

controller • Even if cause of failure disappears, system does not reset itself until starting switch is turned OFF.

Problem that
appears on • Windshield wiper does not operate.
machine

Related
• Method of reproducing failure code: Turn starting switch ON + Set wiper switch to INT or ON.
information

Cause Standard value in normal state/Remarks on troubleshooting

★ Prepare with starting switch OFF, then carry out troubleshooting without
turning starting switch ON.
Defective wiper motor (Internal W04 (female) Continuity/Resistance
1
short circuit or ground fault)
Possible causes Between (1) – (3) There is continuity
and standard Between (1) – chassis ground Min. 1 MΩ
value in normal
state ★ Prepare with starting switch OFF, then carry out troubleshooting without
Ground fault in wiring harness turning starting switch ON.
2
(Short circuit with GND circuit) Wiring harness between C02 (female) (114) – Resist- Min. 1
W04 (male) (1) ance MΩ

If causes 1 and 2 are not detected, pump controller may be defective. (Since
3 Defective pump controller
trouble is in system, troubleshooting cannot be carried out.)

20-514 PW148-8 VEBM720100

TESTING AND ADJUSTING Failure code [DY2EKB] – Wiper drive (rev) short

Circuit diagram related to wiper motor of machine monitor

Pump controler

C01(AMP-81)

56
15

C02(AMP-40)
114
119

A01(X-4)
E U12
A64

6 1
J04 (Pink)
(J-20)

PW148-8 VEBM720100 20-515

Failure code [DY2EKB] – Wiper drive (rev) short TESTING AND ADJUSTING

Blank for technical reason

20-516 PW148-8 VEBM720100

 20 TESTING AND ADJUSTING

Troubleshooting of electrical system (E-Mode)

Troubleshooting of electrical system (E-Mode) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-521
Preparations for troubleshooting of electrical system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-522
Troubleshooting of electrical system (E-mode). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-526
Information contained in troubleshooting table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-529
E-1 When starting switch turned ON, machine monitor displays nothing . . . . . . . . . . . . . . . . . . . . . 20-530
E-2 When starting switch turned ON (before starting engine), basic check item lights up. . . . . . . . 20-532
E-3 Engine does not start (engine does not rotate). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-535
E-4 Preheater does not operate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-538
E-5 Automatic warm-up system does not operate (in cold season) . . . . . . . . . . . . . . . . . . . . . . . . . . 20-540
E-6 All work equipment, swing and travel mechanism do not move or cannot be locked . . . . . . . . 20-541
E-7 Precaution lights up while engine is running . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-543
E-8 Emergency stop item lights up while engine is running . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-548
E-9 Engine coolant temperature gauge does not indicate normally . . . . . . . . . . . . . . . . . . . . . . . . . . 20-550
E-10 Hydraulic oil temperature gauge does not indicate normally . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-551
E-11 Fuel level gauge does not indicate normally . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-553
E-12 Contents of display by machine monitor are different from applicable machine . . . . . . . . . . . 20-556
E-13 Machine monitor does not display some items. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-556
E-14 Function switch does not work. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-556
E-15 Auto-decelerator does not operate normally. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-557
E-16 Working mode does not change . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-558
E-17 Travel speed does not change . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-559
E-18 Alarm buzzer cannot be stopped . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-560
E-19 Windshield wiper and window washer do not operate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-562
E-20 Power maximising function does not operate normally. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-564
E-21 Swing holding brake does not operate normally . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-565
E-21 – "Boom/Stabiliser RAISE" is not correctly displayed in monitor function . . . . . . . . . . . . . . . . 20-567
E-22 Travel alarm does not sound or does not stop sounding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-568
E-23 Air conditioner does not operate normally (including air conditioner abnormality record) . . . 20-570
E-24 When starting switch is turned OFF, service meter is not displayed . . . . . . . . . . . . . . . . . . . . . 20-581
E-25 Machine monitor cannot be set in service mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-581
E-26 Monitoring function does not display lever control signal normally . . . . . . . . . . . . . . . . . . . . . 20-582
E-27 KOMTRAX system does not operate normally . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-594

PW148-8 VEBM720100 20-521

Preparations for troubleshooting of electrical system TESTING AND ADJUSTING

Preparations for troubleshooting of electrical system

★ When troubleshooting the electric circuit related to the ma-
chine monitor, pump controller, engine controller or KOM-
TRAX terminal, expose the related connectors according to
the following procedure.

1. Machine monitor
1. Remove monitor (1).
1
★ The cover is fixed with two upper and lower clips. Pull it
up for the removal.

★ If the sunlight sensor is equipped for an air conditioner,

disconnect P15 connector at the cover rear side.

2. Remove the 3 mounting screws to disconnect machine

monitor (2) from the mount.

★ Use care so that the screws may not fall into the con-
sole.

3. Insert or connect troubleshooting T-adapter in or to connec-

tors CN1, CN2, CN3, and CN4 of machine monitor. 2

20-522 PW148-8 VEBM720100

TESTING AND ADJUSTING Preparations for troubleshooting of electrical system

2. Engine controller
★ The engine controller is installed in the left side of the
engine.

1. Open the engine hood.

2. Insert or connect troubleshooting T-adapter in or to connec-

tors ENGINE, CE02 and CE03 of engine controller (3).
ENGINE
CE02
★ Connectors are fixed with screw. Loosen the screws be-
fore disconnecting them.

★ When returning the connectors back to their position,

tighten them to the specified torque.

3. Screw: 2.82 Nm {0.288 kgm}

CE03 3

3. Pump controller
★ The engine throttle and pump controller are installed in
the cover situated in the rear side of the operator seat.

1. Remove cover (5).

2. Insert or connect troubleshooting T-adapter in or to connec-

tors CP01, CP02 and CP03 of pump controller (6).

★ Connectors are fixed with screws. Loosen the screws

before disconnecting them.

★ When returning the connectors back to their position,

tighten them to the specified torque.

3. Screw: 2.82 Nm {0.288 kgm}

CN2

CN1

4. Screw: 2.82 Nm {0.288 kgm}

★ Cable (8) is used for the communication antenna (2 sys-

tems).

PW148-8 VEBM720100 20-523

Preparations for troubleshooting of electrical system TESTING AND ADJUSTING

4. Removing and installing the atmospheric pressure and

temperature sensor, the engine oil pressure switch, and
position sensor (cam and crank)
• Removal
Shift the lever in the arrowhead direction (a) and pull it
out while pushing lock (b).

• Installation
Insert the connector and then shift the lever in the ar-
rowhead direction (f).

20-524 PW148-8 VEBM720100

TESTING AND ADJUSTING Preparations for troubleshooting of electrical system

Blank for technical reason

PW148-8 VEBM720100 20-525

Troubleshooting of electrical system (E-mode) TESTING AND ADJUSTING

Troubleshooting of electrical system (E-mode)

Before carrying out troubleshooting of electrical system

Connection table of fuse box

★ This connection table shows the devices to which each power supply of the fuse box supplies power (A
switch power supply is a device which supplies power while the starting switch is in the ON position and a
constant power supply is a device which supplies power while the starting switch is in the OFF and ON posi-
tions).

★ When carrying out troubleshooting related to the electrical system, you should check the fuses and fusible
links to see if the power is supplied normally.

Type of power Fuse Box Fuse capac-

Fuse No. Destination of power
supply (Fusible link) ity
• PC-EPC (F) solenoid valve
[When pump drive switch is operated in emergency]
1 10 A
Swing holding brake solenoid valve
[When swing holding brake release switch is operated]
Pump controller (Solenoid power supply)
2 20 A Boom/outrigger solenoid
Aux hydraulic solenoid
Switch power FB1 PPC oil pressure lock solenoid valve
supply (65 A)
3 10 A Starting motor cut-out relay (PPC lock)
Starting motor cut-out relay (Personal code)
Cigarette lighter
4 10 A
Windshield washer motor
Horn relay
5 10 A Horn
Power max switch
Lower wiper
6 10 A Pre-heat relay
DC/DC converter

Switch power FB1 7 10 A Beacon

supply (65 A) 8 10A (Spare fuse)
Direction indicators
9 10 A
Indicator flash unit
10 10 A Refuel pump
11 20 A Air conditioner unit
12 5A Cruise control

Switch power FB1 13 10 A (Spare fuse)

supply (65 A) Optional power supply (1)
14 10 A
Heated seat
15 15 A Breaker switch

20-526 PW148-8 VEBM720100

TESTING AND ADJUSTING Troubleshooting of electrical system (E-mode)

Air seat compressor

16 15 A
Interior light
Starting switch
Machine monitor
Constant power FB1 17 20 A
Pump controller
supply (30 A)
Service connection
Hazard warning lamps
18 15 A
Flasher unit
19 30 A Engine controller
Switch power Starting switch
20 5A Engine controller (ACC signal)
supply ACC
Travel FNR
Travel prolix
1 5A
[when travel drive system is operated in emergency]
Reversing alarm
Switch power FB2 2 10 A Parking brake
supply (65 A)
Work lamp (boom & revo)
3 20 A
Quick coupler
4 25 A Work lamp (cabin front)
5 20 A Work lamp (cabin rear & cut)
6 5A Brake lamps
7 10 A Rototilt controller (switched power)
Switch power FB2
8 10 A Steering controller
supply (65 A)
9 5A Autogrease
10 15 A Heated mirror (OPT)
11 20 A Road lights (master fuse)
12 10 A Rototilt controller
Switch power FB2
13 10 A (Spare fuse)
supply (30 A)
14 10 A (Spare fuse)
15 10 A (Spare fuse)
16 5A Side light (LH)
FB2 17 5A Side ligtht (RH)
Constant power
Fuse 11
supply 18 15 A Dipped beam
(20 A)
19 15 A Main beam
not not
20 10 A (Spare fuse)
connected connected

PW148-8 VEBM720100 20-527

Troubleshooting of electrical system (E-mode) TESTING AND ADJUSTING

Location of fusible links

Battery
A34 (65A)
Revo frame
A35 (30A)

Location of fuse box and fuse numbers

FB1

G0148207
2
FB2 FB1
1

G0148206
FB2

G0148207

20-528 PW148-8 VEBM720100

TESTING AND ADJUSTING Information contained in troubleshooting table

Information contained in troubleshooting table

• The following information are edited and contained in the
"Information Contained in Troubleshooting Table". You are
required to proceed with troubleshooting after fully grasping
the contents.

Failure
Phenomena occurring on machine
information

Relative
Information on occurred failures and troubleshooting
information

Cause Standard value in normal and references for troubleshooting

<Contents of description>
• The standard values in normal by which to judge "good" or "no good" about presumed causes.
• References for making judgement of "good" or "no good"
1
<Phenomena of wiring harness fault>
• Failure due to disconnection
Possible causes and standard value in normal state

Defective contact with connector or disconnection of wiring harness has occurred.

• Grounding fault
A wiring harness that is not originally connected with a grounding circuit is in contact with it.
2 • Failure due to short-circuiting
A wiring harness that is not originally connected with a power source circuit (24 V) is in contact
with it.

<Points to remember in troubleshooting>

Possible causes of trouble
(given numbers are refer- 1. Connector denotation method and handling of T-adapters
3 Insert or connect T-adapters in the following manner, unless specifically otherwise instructed.
ence numbers, which do
not indicate priority) • If there is no indication of (male) or (female) in the connector No., pull off a connector and insert
a T-adapter into both sides of male and female.
• If there is an indication of (male) and (female) in the connection No., pull off a connector and in-
sert a T-adapter into only one side of (male) or (female).
2. Description sequence of pin No. and handling of circuit tester leads
4 Connect the positive lead (+) and negative lead (–) for troubleshooting in the following manner
unless specifically otherwise instructed.
• Connect the positive lead (+) to a pin No. marked at the front or wiring harness.
• Connect the negative lead (–) to a pin No. marked at the rear or wiring harness.

Relative electrical circuit diagram

This drawing is a part of the circuit diagram related to troubleshooting.

• Connector No.: Indicates (Model – Number of pins) and (Colour).
• “Connector No. and pin No.” from each branching/merging point: Shows the ends of branch or source of merging within the parts of the
same wiring harness.
• Arrow ( ): Roughly shows the location on the machine.

PW148-8 VEBM720100 20-529

E-1 When starting switch turned ON, machine monitor displays nothing TESTING AND ADJUSTING

E-1 When starting switch turned ON, machine monitor dis-

plays nothing

Trouble • When starting switch turned ON, machine monitor displays nothing.
• When starting switch is turned ON, machine monitor displays KOMATSU logo, screen to input password
(if set), screen to check breaker mode (if set), screen of check before starting, screen to check working
Related informa-
mode and travel speed, and ordinary screen in order.
tion
• When the engine is started, the battery voltage may lower suddenly, depending on the ambient temper-
ature and the condition of the battery.

Cause Standard value in normal state/Remarks on troubleshooting

★ Prepare with starting switch OFF, then carry out troubleshooting without
turning starting switch ON.
1 Low charge level of battery Electrolyte specific gravity
Battery voltage (2 pieces)
(1 piece)
Min. 24 V Min. 1.26
Defective fusible link F05 or fuse If fusible link or fuse is broken, circuit probably has ground fault. (See
2
No. 20 Cause 5.)
Machine monitor connector may be connected wrongly. Check it
3 Wrong connection of connector
directly. (Check mounting bracket plate with connector.)
★ Prepare with starting switch OFF, then carry out troubleshooting without
turning starting switch ON.
Wiring harness between battery (–) – chassis
Resistance Max. 1 z
ground
Wiring harness between battery (+) – R04 – F05
Resistance Max. 1 z
(male) (1)
Disconnection in wiring harness
Wiring harness between F05 (male) (2) – F01-16D Resistance Max. 1 z
4 (Disconnection in wiring or defec-
Wiring harness between F01-17 – J06 – CM01
tive contact in connector) Resistance Max. 1 z
(female) (1), (2)
Possible causes
Wiring harness between CM01 (female) (3), (4) –
and standard Resistance Max. 1 z
chassis ground (T05)
value in normal
state Wiring harness between F01-17 – H15 (female) (1) Resistance Max. 1 z
Wiring harness between H15 (female) (5) – J03 –
Resistance Max. 1 z
CM01 (female) (14)
★ Prepare with starting switch OFF, then carry out troubleshooting without
turning starting switch ON.
Wiring harness between battery (+) – R04 – F05
Resistance Min. 1 Mz
(male) (1)
Ground fault in wiring harness Wiring harness between F05 (male) (2) – F01-16D Resistance Min. 1 Mz
5
(Short circuit with GND circuit) Wiring harness between F01-17 – J06 – CM01
Resistance Min. 1 Mz
(female) (1), (2)
Wiring harness between F01-17 – H15 (female) (1) Resistance Min. 1 Mz
Wiring harness between H15 (female) (5) – J03 –
Resistance Min. 1 Mz
CM01 (female) (14)
★ Prepare with starting switch OFF, then hold starting switch OFF and ON
and carry out troubleshooting in each case.
CM01 Starting switch Voltage
6 Defective machine monitor Between
OFF 20 – 30 V
(1), (2) – (3), (4)
Between
ON 20 – 30 V
(14) – (3), (4)

20-530 PW148-8 VEBM720100

TESTING AND ADJUSTING E-1 When starting switch turned ON, machine monitor displays nothing

Circuit diagramm related to machine monitor power supply

PW148-8 VEBM720100 20-531

E-2 When starting switch turned ON (before starting engine), basic check item lights up TESTING AND ADJUSTING

E-2 When starting switch turned ON (before starting

engine), basic check item lights up
Trouble (1) Radiator coolant level monitor lights up red.
• Although radiator coolant level monitor is basic check item, it is also checked while engine is running. (If monitor
Related informa- lights up red while engine is running, carry out this troubleshooting, too.)
tion • Condition of radiator coolant level switch signal can be checked with monitoring function.
(Code: 04500 Monitor input 1)

Cause Standard value in normal state/Remarks on troubleshooting

Lowering of radiator coolant level Coolant level in radiator sub tank may be low. Check it and add coolant if nec-
1
(When system is normal) essary.
★ Prepare with starting switch OFF, then carry out troubleshooting without
turning starting switch ON.

Defective radiator coolant level A33 (male) Sub tank coolant level Resistance
2
switch (Internal disconnection) Between
Max. 1 Ω
Between (1) – (2) FULL – LOW
Below LOW Min. 1 MΩ
Possible causes
★ Prepare with starting switch OFF, then carry out troubleshooting without
and standard
turning starting switch ON.
value in normal Disconnection in wiring harness
state Wiring harness between CM02 (female) (3) – A33
3 (Disconnection in wiring or defec- Resistance Max. 1 Ω
(female) (1)
tive contact in connector)
Wiring harness between A33 (female) (2) – chassis
Resistance Max. 1 Ω
ground (A65)
★ Prepare with starting switch OFF, then turn starting switch ON and carry
out troubleshooting.
CM02 Sub tank coolant level Voltage
4 Defective machine monitor
Between
Between (3) – Max. 1 V
FULL – LOW
chassis ground
Below LOW 20 – 30 V

20-532 PW148-8 VEBM720100

TESTING AND ADJUSTING E-2 When starting switch turned ON (before starting engine), basic check item lights up

Circuit diagram related to radiator coolant level switch

PW148-8 VEBM720100 20-533

E-2 When starting switch turned ON (before starting engine), basic check item lights up TESTING AND ADJUSTING

Trouble (2) Engine oil level monitor lights up red.

Related informa- Condition of engine oil level switch signal can be checked with monitoring function.
tion (Code: 04501 Monitor input 2)

Cause Standard value in normal state/Remarks on troubleshooting

Lowering of engine oil level
1 Engine oil level may be low. Check it and add oil if necessary.
(When system is normal)
★ Prepare with starting switch OFF, then carry out troubleshooting without
turning starting switch ON.
Defective engine oil level switch E03 (male) Engine oil level Resistance
2
(Internal disconnection)
Between (1) – Between H – L Max. 1 Ω
Possible causes chassis ground Below L Min. 1 MΩ
and standard
value in normal ★ Prepare with starting switch OFF, then carry out troubleshooting without
Disconnection in wiring harness turning starting switch ON.
state
3 (Disconnection in wiring or defec-
tive contact in connector) Wiring harness between CM02 (female) (2) – E03
Resistance Max. 1 Ω
(female) (1)
★ Prepare with starting switch OFF, then turn starting switch ON and carry
out troubleshooting.

4 Defective machine monitor CM02 Engine oil level Voltage

Between (2) – Between H – L Max. 1 V

chassis ground Below L 20 – 30 V

Circuit diagram related to engine oil level switch

20-534 PW148-8 VEBM720100

TESTING AND ADJUSTING E-3 Engine does not start (engine does not rotate)

E-3 Engine does not start (engine does not rotate)

Failure
• The engine does not start (the engine does not rotate).
information

• The following two engine start locking mechanisms are provided in the engine starting circuit.
Relative
information 1. Engine start locking by means of password in the monitor panel (*)
2. Engine start locking by means of safety lock lever

Cause Standard value in normal and references for troubleshooting

Shortage in battery Battery voltage Battery electrolyte specific gravity

1
capacity Above 24 V Above 1.26

Fuse box 1 nos. 3 and When a fuse or fusible link is blown, there is a big possibility that grounding fault occurred in the circuit.
2 17 and Fusible Links If a monitor lamp does not light up in the monitor panel, check the power source circuit between the bat-
A34 and A35 fault tery and the specific fuse.

• Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the
Engine starting switch troubleshooting.
fault H15 (male) Position Resistance value
3
(Internal
disconnection) OFF Above 1 MΩ
Between (1) and (4)
Start Below 1 Ω

• Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the
troubleshooting.
Safety lock switch fault
4 (Internal S14 (female) Lock lever Resistance value
short-circuiting) FREE Above 1 MΩ
Presumed cause and standard value in normal

Between (1) and (3)

LOCK Below 1 Ω

• Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the
Engine starting motor troubleshooting.
cut relay, R04, R06
and R07 R04 (male) & R06 (male) & R07 (male) Resistance value
5 defective
Between (1) and (3) 100 – 500 Ω
(Internal
disconnection or short- Between (3) and (5) Above 1 MΩ
circuiting)
Between (3) and (6) Below 1 Ω

• Turn the engine starting switch OFF for the preparations, and keep the engine running during the
troubleshooting. (If all of the power source, grounding (GND), generation signal and engine start input
are normal and yet the engine start output is not normal, the engine starting motor relay is defective)

Engine starting
Safety relay Voltage
switch
Engine starting motor
fault Power source: Between B terminal and grounding 20 – 30 V
6 (Internal
GND (grounding): Between E terminal and grounding Connected
disconnection or short-
circuiting) Generation signal: Between R terminal (A27 (2)) and
Below 1 V
grounding Start

Engine start input: Between C terminal and grounding 20 – 30 V

Engine start output: Between S terminal (A27 (1)) and

20 – 30 V
grounding

• Turn the engine starting switch OFF for the preparations, and keep the engine running during the
troubleshooting. (If all of the power source, grounding (GND), generation signal and engine start input
are normal and yet the engine start output is not normal, the engine starting motor relay is defective)
Engine starting motor
fault Engine starting
7 Engine starting motor Voltage
(Internal disconnection switch
or damage)
Power source: B (SB) terminal and grounding 20 – 30 V
Start
Engine start input: C (SC) terminal and grounding 20 – 30 V

PW148-8 VEBM720100 20-535

E-3 Engine does not start (engine does not rotate) TESTING AND ADJUSTING

Cause Standard value in normal and references for troubleshooting

• Turn the engine starting switch OFF for the preparations, and hold it in the ON position or running
Alternator fault during the troubleshooting.
8 (Internal
E12 (male) Voltage
short-circuit)
Between (1) and grounding Max 1 V
• Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the
troubleshooting.
Resistance
Wiring harness between FB1-17 outlet and H15 (female) (1) Max 1 Ω
value
Wiring harness from H15 (female) (4) to J01 to R06 (female) (5) Resistance Max 1 Ω
Wiring harness between R06 (female) (3) and R04 (female) (3) Resistance Max 1 Ω
Disconnection of
Wiring harness between R04 (female) (5) and R07 (female) (6) Resistance Max 1 Ω
wiring harness
9 (Disconnection or Wiring harness between R07 (female) (3) to A07 to A27 (female) (1). Resistance Max 1 Ω
Presumed cause and standard value in normal

defective contact with

Wiring harness between engine starting motor relay C terminal and
connector) Resistance Max 1 Ω
engine starting motor C terminal
Wiring harness between FB1-3 and S14 (male) (1) Resistance Max 1 Ω
Wiring harness between S14 (male) (3) and R06 (female) (1) Resistance Max 1 Ω
Wiring harness between R06 (female) (2) to J04 and R04 (female) (2) Resistance Max 1 Ω
Wiring harness from R06 (female) (2) to J04 to A02 (male) (4) to
Resistance Max 1 Ω
grounding
• Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the
troubleshooting.
Between wiring harness from battery relay B terminal (A23) to A35 to
Resistance Min 1 MΩ
A01 to FB1-17 and grounding
Wiring harness between FB1-17 outlet and H15 (female) (1) and
Resistance Min 1 MΩ
grounding
Between wiring harness from H15 (female) (4) to J01 to R06 (female)
Resistance Min 1 MΩ
(5) and grounding
Grounding fault of wir- Wiring harness between R06 (female) (3) and R04 (female) (3) and
Resistance Min 1 MΩ
ing harness grounding
10
(Contact with
Wiring harness between R04 (female) (5) and R07 (female) (6) Resistance Below 1 Ω
grounding circuit)
Wiring harness between R07 (female) (3) to A07 to A27 (female) (1). Resistance Min 1 MΩ
Wiring harness between engine starting motor relay C terminal and
Resistance Min 1 MΩ
engine starting motor C terminal and grounding
Wiring harness between FB1-3 and S14 (female) (1) and grounding Resistance Min 1 MΩ
Wiring harness between S14 (female) (3) and R11 (female) (1) and
Resistance Min 1 MΩ
grounding
Between wiring harness from R07 (female) (2) to CM01 (female) (6)
Resistance Min 1 MΩ
and grounding
standard value in normal

Cause Standard value in normal and references for troubleshooting

Presumed cause and

• Turn the engine starting switch OFF for the preparations, and hold it in the ON position during the
troubleshooting.
Hot short of
wiring harness Wiring harness between A27 (female) (2) and E12 (female) (1), or wir-
11
(Contact with 24 V cir- ing harness from A27 (female) (2) to A07 to J01 to D01 (female) (6), or
cuit) Voltage Max 1 V
between wiring harness between A27 (female) (2) to J01 to CM01
(female) (18) and grounding.

20-536 PW148-8 VEBM720100

TESTING AND ADJUSTING E-3 Engine does not start (engine does not rotate)

Electrical circuit diagram for engine start, stop and battery charging

1 2 3 4 7 8 9 10 12 13 14

(Blue)

CM01 (070-18)

CM01 (070-18) (Pink)

11
15
12
CM01 (070-18) 13
Battery charge 18
Personal code
6
relay

J03 (J-20)
C01 (AMP-81) (Grey)
Starting switch C 3
60
Starting switch 4
79
ACC
14
C02 (AMP-40)
18
Battery relay drive 108

Travel N 42

R06

Starter
Cut
Relay

J02
(J-20) H15
(Orange) (090-22)
R07
Starting
Cut
Relay
(Personal
Code)

R04
A08
Starter (SWP-16)
Cut 15
A01
Relay
(Travel N) 3 (X-4)

A64

SB
A23 A22

A21 A20 C
SC
A65
A34 A35 AB

IG

E12

E
S
B

R
A27 C
(X-2) Starter
Safety
Relay

BJP14331B

PW148-8 VEBM720100 20-537

E-4 Preheater does not operate TESTING AND ADJUSTING

E-4 Preheater does not operate

Trouble (1) When starting switch is turned to HEAT position, preheating monitor does not light up or flash.
• Preheater monitor lights up when starting switch is turned to HEAT and starts flashing about 30 seconds after to notify
completion of preheating (It stops flashing about 10 seconds after).
Related informa- • If engine coolant temperature is below 20°C, automatic warm-up system operates and preheating monitor lights up
tion for up to 30 seconds.
• Condition of starting switch (preheating) signal can be checked with the monitoring function.
(Code: 04500 Monitor input 1)

Cause Standard value in normal state/Remarks on troubleshooting

★ Prepare with starting switch OFF, then keep starting switch OFF and turn
it to HEAT and carry out troubleshooting in each case.
Defective starting switch (Internal H15 (male) Starting switch Resistance
1
disconnection)
OFF Min. 1 MΩ
Between (1) – (3)
HEAT Max. 1 Ω
Possible causes
★ Prepare with starting switch OFF, then carry out troubleshooting without
and standard Disconnection in wiring harness turning starting switch ON.
value in normal 2 (Disconnection in wiring or defec-
state Wiring harness between CM01 (female) (16)
tive contact in connector) Resistance Max. 1 Ω
J01 – H15 (female) (3)
★ Prepare with starting switch OFF, then keep starting switch OFF and turn
it to HEAT and carry out troubleshooting in each case.
3 Defective machine monitor CE02 Starting switch Voltage
Between (16) – OFF Max. 1 V
chassis ground HEAT 20 – 30 V

Trouble (2) When starting switch is turned to HEAT position, intake air heater mounting part does not become warm.
Related informa- • Check that engine can be turned with starting motor (If engine cannot be turned, carry out troubleshooting for E-1 En-
tion gine does not start (Engine does not turn)).

Cause Standard value in normal state/Remarks on troubleshooting

★ Prepare with starting switch OFF (with wiring harness connected), then
keep starting switch OFF and turn it to HEAT and carry out troubleshoot-
ing in each case.
Defective heater relay (Internal Heater relay Starting switch Continuity/Resistance
1
disconnection) Between A25 –
OFF There is continuity
chassis ground
Between power
HEAT Max. 1 Ω
supply terminal – A26
★ Prepare with starting switch OFF (with wiring harness connected), then
Possible causes turn starting switch to HEAT and carry out troubleshooting in each case.
and standard E01 Starting switch Voltage
value in normal Defective intake air heater (Inter-
2 Between terminal – chas-
state nal disconnection) HEAT 20 – 30 V
sis ground
If voltage is normal but heater mounting part does not become warm, intake air
heater is defective.
★ Prepare with starting switch OFF, then carry out troubleshooting without
turning starting switch ON.
Wiring harness between H15 (female) (3) –
Disconnection in wiring harness J01 – heater relay A25 Resistance Max. 1 Ω
3 (Disconnection in wiring or defec-
Wiring harness between battery relay A22 – heater
tive contact in connector) Resistance Max. 1 Ω
relay contact terminal
Wiring harness between heater relay A26 – intake
Resistance Max. 1 Ω
air heater E01

20-538 PW148-8 VEBM720100

TESTING AND ADJUSTING E-4 Preheater does not operate

Circuit diagram related to engine preheater

J03 (J-20)

(Grey)
J01 (J-20) 4 3
(Blue)

16
17
18
19
20

R01

Grid
J05 (J-20) Heater
Relay
15
11 4 U15

A02 A64
(X-4)

CM01 (070-18)
16

A07 A08
(SWP-16) (SWP-16)
9 10

A21 A20

Grid
A23 A22 Heater
Relay Ribbon
Heater
A24 A26
A25 E01

E
S B
A28

R C
Starter
Safety
Relay

BWP14333A

PW148-8 VEBM720100 20-539

E-5 Automatic warm-up system does not operate (in cold season) TESTING AND ADJUSTING

E-5 Automatic warm-up system does not operate

(in cold season)
Trouble • Automatic warm-up system does not operate (in cold season).
• When engine coolant temperature is below 30°C automatic warm-up system raises engine speed to 1,200 rpm.
• If fuel control dial is opened more than 70% for 3 seconds when starting switch is turned ON or after engine is started,
Related informa- automatic warm-up system is turned OFF. (Automatic warm-up system stops automatically after operating for 10
tion minutes.)
• If engine coolant temperature is below 10°C turbocharger protection function operates to keep the engine speed at
low idle.

Cause Standard value in normal state/Remarks on troubleshooting

★ Turn starting switch ON or start engine and carry out troubleshooting.
Engine coolant Coolant temperature
Monitoring code
temperature level
105°C 6 (a: Red)
102°C 5 (a: Red)
Possible causes 04107
Defective engine coolant temper- 100°C 4 (a: Blue)
and standard 1 Engine coolant
ature signal system
value in normal temperature 85°C 3 (a: Blue)
state 60°C 2 (a: Blue)
30°C 1 (a: White)
If level of coolant temperature gauge is different from actual coolant tempera-
ture, carry out troubleshooting for E-9 Engine coolant temperature gauge does
not indicate normally.
If cause 1 is not detected, engine controller may be defective. (Since trouble is
2 Defective engine controller
in system, troubleshooting cannot be carried out.)

Engine coolant temperature gauge and engine coolant tem-

perature monitor

20-540 PW148-8 VEBM720100

TESTING AND ADJUSTING E-6 All work equipment, swing and travel mechanism do not move or cannot be locked

E-6 All work equipment, swing and travel mechanism do

not move or cannot be locked

Failure
• All the work equipment, swing and travel do not move.
information

Relative
—
information

Cause Standard value in normal and references for troubleshooting

1 Fuse No. 3 fault If the fuse is blown, there is a big possibility that grounding fault occurred in the circuit.

• Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the
troubleshooting.
Safety switch lock
defective S14 (female) Safety control lever Resistance value
2
(Internal disconnec-
tion) OFF Above 1 MΩ
Between (1) and (2)
ON Below 1 Ω

• Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the
troubleshooting.
Presumed cause and standard value in normal

PPC lock solenoid

fault V01 (male) Resistance value
3
(Internal disconnection
or short-circuiting) Between (1) and (2) 20 – 60 Ω

Between (1) and grounding Above 1 MΩ

• Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the
troubleshooting.
Disconnection of wir- Resistance
ing harness Wiring harness between FB1 (3) outlet and S14 (male) (1) Below 1 Ω
value
4 (Disconnection or
defective contact with Wiring harness from S14 (male) (2) to R45 to A05 to V01 (female) Resistance
Below 1 Ω
connector) (1) value

Resistance
Wiring harness between V01 (female) (2) and grounding Below 1 Ω
value

• Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the
troubleshooting.
Grounding fault of
wiring harness Wiring harness between FB1 (3) outlet and S14 (male) (1) and Resistance
Above 1 MΩ
5 (Contact with grounding value
grounding (GND)
Wiring harness from C02 (male) (9) to R45 (2) to V01 (female) (1), or
circuit) Resistance
between wiring harness between C02 (male) (9) and R45 (female) Above 1 MΩ
value
(3) and grounding.

Hot short (short circuit • Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
6 with 24V circuit) in wir-
ing harness Wiring harness between R13 (female) (6) - V01 (female) (1) Voltage Max 1V

PW148-8 VEBM720100 20-541

E-6 All work equipment, swing and travel mechanism do not move or cannot be locked TESTING AND ADJUSTING

Electrical circuit diagram for PPC lock solenoid

PPC hydraulic
lock switch (Tilting Pod))
OFF (Pod Down)
ON (Pod Up)

S14
(M - 3) FB1
3 10A
1 Fuse box 1
2
3

Note:
Monitor communicates
with controller through A05 V01 PPC lock
the “CAN” network (SWP - 16) (DT - 2) solenoid valve

3 1
2
C02 (AMP-40) (ON) (OFF)
PPC lock (OUT) 92 A65

C01 (AMP-40)
PPC lock (IN) 80
R13
PPC lock

1 2 3 5 6

CAB REVOLVING FRAME

20-542 PW148-8 VEBM720100

TESTING AND ADJUSTING E-7 Precaution lights up while engine is running

E-7 Precaution lights up while engine is running

Trouble (1) Charge level monitor lights up red.

Related informa- • Signal voltage of alternator can be checked with monitoring function.
tion (Code: 04300 Charge voltage)

Cause Standard value in normal state/Remarks on troubleshooting

★ Prepare with starting switch OFF, then start engine and carry out trouble-
shooting.
Defective generation by alternator
1 E12 (male) Engine speed Voltage
(when system is normal)
Between (1) – chassis
Middle or higher 27.5 – 29.5 V
ground
★ Prepare with starting switch OFF, then carry out troubleshooting without
Disconnection in wiring harness turning starting switch ON.
Possible causes 2 (Disconnection in wiring or defec-
tive contact in connector) Wiring harness between CM01 (female)
and standard Resistance Max. 1 Ω
(11) – J01 – E12 (female) (1)
value in normal
state ★ Prepare with starting switch OFF, then carry out troubleshooting without
Ground fault in wiring harness turning starting switch ON.
3
(Short circuit with GND circuit) Wiring harness between CM01 (female)
Resistance Min. 1 MΩ
(11) – J01 – E12 (female) (1), – circuit branch end
★ Prepare with starting switch OFF, then start engine and carry out trouble-
shooting.
4 Defective machine monitor CM02 Engine Voltage
Between (11) –
Running Min. 7.8 V
chassis ground

PW148-8 VEBM720100 20-543

E-7 Precaution lights up while engine is running TESTING AND ADJUSTING

Circuit diagram related to engine preheater/starting motor/charging

system

A03 (SWP-14)

A08 (SWP-16)
9
10
11
14
CE03 (DTP-4)

A08 (SWP-16)
15
E 3
A01 (X-4)

ZN

ZM

CM01 (070-18)
1
15
2
11
6
16

2
6
(GREY) D02
(SWP-8)
13
14 4

15 8

17
18
5
6
3
4

(PINK) C02 (AMP-40)

108

C01 (AMP- )
60
24
43
42
79
80

SC02 SC01
PPC LOCK 29 18
(AMP-35) (090-22)

2
A02 (X-4)

R06 R07 R01 R04 R02 R03 R13

20-544 PW148-8 VEBM720100

TESTING AND ADJUSTING E-7 Precaution lights up while engine is running

Trouble (2) Fuel level monitor lights up red.

Related informa- • Signal voltage of fuel sensor can be checked with monitoring function.
tion (Code: 04200 Fuel sensor voltage)

Cause Standard value in normal state/Remarks on troubleshooting

Possible causes
Low fuel level (when system is
and standard 1 Fuel level may be low (below about 41 l). Check it and add fuel if necessary.
normal)
value in normal
state If cause 1 is not detected, fuel level gauge system may be defective. Carry out
2 Defective fuel level gauge system
troubleshooting for E-11 Fuel level gauge does not indicate normally.

Trouble (3) Air cleaner clogging monitor lights up red.

Related informa- • Condition of signal of air cleaner clogging switch can be checked with monitoring function.
tion (Code: 04501 Monitor input 2)

Cause Standard value in normal state/Remarks on troubleshooting

Clogging of air cleaner (when sys-
1 Air cleaner may be clogged. Check it, then clean or replace if necessary.
tem is normal)
★ Prepare with starting switch OFF, then start engine and carry out trouble-
shooting.
P23 (male) Air cleaner Resistance

Defective air cleaner clogging When normal

2 (Air intake Max. 1 Ω
switch (Internal disconnection)
resistance: *1)
Between (1) – (2)
When clogged
(Air intake Min. 1 MΩ
resistance: *2)
Possible causes
★ Prepare with starting switch OFF, then carry out troubleshooting without
and standard
turning starting switch ON.
value in normal
Disconnection in wiring harness
state Wiring harness between CM02 (female) (4) – P23
3 (Disconnection in wiring or defec- Resistance Max. 1 Ω
(female) (1)
tive contact in connector)
Wiring harness between P23 (female) (2) – chassis
Resistance Max. 1 Ω
ground (T09)
★ Prepare with starting switch OFF, then start engine and carry out trouble-
shooting.
CM02 Air cleaner Voltage
When normal
4 Defective machine monitor (Air intake Max. 1 V
Between (4) – resistance: *1)
chassis ground When clogged
(Air intake 20 – 30 V
resistance: *2)

*1: Max. –3,430 Pa {Max. –350 mmH2O}

*2: –7,470 ± 490 Pa {–762 ± 50 mmH2O}

PW148-8 VEBM720100 20-545

E-7 Precaution lights up while engine is running TESTING AND ADJUSTING

Circuit diagram related to air cleaner clogging switch

A06
(SWP-16)

U24

T09

BWP14238A

20-546 PW148-8 VEBM720100

TESTING AND ADJUSTING E-7 Precaution lights up while engine is running

Trouble (4) Engine coolant temperature monitor lights up white.

• Signals of engine coolant temperature sensor are input to engine controller and then transmitted to machine monitor
Related informa- through communication system.
tion • Engine coolant temperature can be checked with monitoring function.
(Code: 04107 Engine coolant temperature)

Cause Standard value in normal state/Remarks on troubleshooting

If monitor lights up white, engine coolant temperature may be low
Insufficient warm-up of (below about 30°C). Warm up engine.
Possible causes 1 machine (when system is nor-
and standard • Lighting up white: Engine coolant temperature is low.
mal)
value in normal • Lighting up blue: Engine coolant temperature is proper.
state
If cause 1 is not detected, engine coolant temperature gauge system
Defective engine coolant tem-
2 may be defective. Carry out troubleshooting for E-9 Engine coolant
perature gauge system
temperature gauge does not indicate normally.

Trouble (5) Water separator monitor lights up red.

Related informa- • Condition of signal of water-in-fuel sensor switch can be checked with monitoring function.
tion (Code: 18800 WIF sensor condition)

Cause Standard value in normal state/Remarks on troubleshooting

Possible causes
• Water separator is full (when
and standard 1 • Water separator may be full of water. Check it, then drain if full.
system is normal)
value in normal
state • Defective water-in-fuel sensor • If cause 1 is not detected, water-in-fuel sensor system may be defective.
2
system Carry out troubleshooting for failure codes [CA428] and [CA429].

Trouble (6) Hydraulic oil temperature monitor lights up white.

• Signals of hydraulic oil temperature sensor are input to pump controller and then transmitted to machine monitor
Related informa- through communication system.
tion • Hydraulic oil temperature can be checked with monitoring function.
(Code: 04401 Hydraulic oil temperature)

Cause Standard value in normal state/Remarks on troubleshooting

If monitor lights up white, hydraulic oil temperature may be low (below about
Possible causes Insufficient warm-up of machine 20°C). Warm up engine.
1
and standard (when system is normal) • Lighting up white: Hydraulic oil temperature is low.
value in normal • Lighting up blue: Hydraulic oil temperature is proper.
state
If cause 1 is not detected, hydraulic oil temperature gauge system may be
Defective hydraulic oil tempera-
2 defective. Carry out troubleshooting for E-10 Hydraulic oil temperature gauge
ture gauge system
does not indicate normally.

PW148-8 VEBM720100 20-547

E-8 Emergency stop item lights up while engine is running TESTING AND ADJUSTING

E-8 Emergency stop item lights up while engine is running

Trouble (1) Engine coolant temperature monitor lights up red.

• Signals of engine coolant temperature sensor are input to engine controller and then transmitted to machine monitor
Related informa- through communication system.
tion • Engine coolant temperature can be checked with monitoring function.
(Code: 04107 Engine coolant temperature)

Cause Standard value in normal state/Remarks on troubleshooting

If monitor lights up red, engine coolant temperature may be high (above about
102°C). Cool down engine coolant (Run engine at low idle).
Possible causes Overheating of engine coolant
1 • Lighting up red:Engine coolant temperature is high
and standard (when system is normal)
(overheating).
value in normal
• Lighting up blue: Engine coolant temperature is proper.
state
If cause 1 is not detected, engine coolant temperature gauge system may be
Defective engine coolant temper-
2 defective. Carry out troubleshooting for E-9 Engine coolant temperature gauge
ature gauge system
does not indicate normally.

Trouble (2) Hydraulic oil temperature monitor lights up red.

• Signals of hydraulic oil temperature sensor are input to pump controller and then transmitted to machine monitor
Related informa- through communication system.
tion • Hydraulic oil temperature can be checked with monitoring function.
(Code: 04401 Hydraulic oil temperature)

Cause Standard value in normal state/Remarks on troubleshooting

If monitor lights up red, hydraulic oil temperature may be high (above about
Possible causes Overheating of hydraulic oil 102°C). Cool down hydraulic oil (Run engine at low idle).
1
and standard (when system is normal) • Lighting up red: Hydraulic oil temperature is high (overheating).
value in normal • Lighting up blue: Hydraulic oil temperature is proper.
state If cause 1 is not detected, hydraulic oil temperature gauge system may be
Defective hydraulic oil tempera-
2 defective. Carry out troubleshooting for E-10 Hydraulic oil temperature gauge
ture gauge system
does not indicate normally.

Trouble (3) Engine oil pressure monitor lights up red.

Related informa- • Signals of engine oil pressure switch are input to engine controller and then transmitted to machine mon-
tion itor through communication system.

Cause Standard value in normal state/Remarks on troubleshooting

Possible causes
Lowering of engine oil pressure Engine oil pressure may be low. If it is low, carry out troubleshooting for S-12
and standard 1
(when system is normal) Oil pressure lowers.
value in normal
state Defective engine oil pressure If cause 1 is not detected, engine oil pressure gauge system may be defective.
2
switch system Carry out troubleshooting for failure code [CA435].

Trouble (4) When left knob switch is released, work equipment power does not return to normal level.
Related informa- • Condition of left knob switch signal can be checked with monitoring function.
tion (Code: 02200 Switch input 1)

Cause Standard value in normal state/Remarks on troubleshooting

★ Prepare with starting switch OFF, then turn starting switch ON and carry
Possible causes
Hot short (Short circuit with 24V out troubleshooting.
and standard 1
circuit) in wiring harness Wiring harness between C02 (female) (109) – V02
value in normal Voltage Max. 1 V
state (female) (1)
If cause 1 is not detected, pump controller may be defective. (Since trouble is
2 Defective pump controller
in system, troubleshooting cannot be carried out.)

20-548 PW148-8 VEBM720100

TESTING AND ADJUSTING E-8 Emergency stop item lights up while engine is running

Circuit diagram related to 2-stage relief solenoid

U6

U24

A65

BWP14684A

PW148-8 VEBM720100 20-549

E-9 Engine coolant temperature gauge does not indicate normally TESTING AND ADJUSTING

E-9 Engine coolant temperature gauge does not indicate

normally

(1) While engine coolant temperature is rising normally, temperature gauge does not rise from white range (C).
Trouble
(2) While engine coolant temperature is stabilized normally, temperature gauge rises to red range (H).
• Signals of engine coolant temperature sensor are input to engine controller and then transmitted to machine monitor
Related informa- through communication system.
tion • Engine coolant temperature can be checked with monitoring function.
(Code: 04107 Engine coolant temperature)

Cause Standard value in normal state/Remarks on troubleshooting

Possible causes
Defective engine coolant temper- If cause 1 is not detected, engine coolant temperature sensor system may be
and standard 1
ature sensor system defective. Carry out troubleshooting for failure codes [CA144] and [CA145].
value in normal
state If cause 1 is not detected, machine monitor may be defective. (Since trouble is
2 Defective machine monitor
in system, troubleshooting cannot be carried out.)

(3) Display of coolant temperature gauge is different from actual engine coolant temperature.
Trouble
(4) Display of engine coolant temperature gauge is different from display of engine coolant temperature monitor.
• Signals of engine coolant temperature sensor are input to engine controller and then transmitted to machine monitor
Related informa- through communication system.
tion • Engine coolant temperature can be checked with monitoring function.
(Code: 04107 Engine coolant temperature)

Cause Standard value in normal state/Remarks on troubleshooting

★ Turn starting switch ON or start engine and carry out troubleshooting.
Engine coolant Coolant temperature
Colour of monitor light (a)
temperature level
Possible causes
105°C 6
and standard Red
value in normal 1 Defective machine monitor 102°C 5
state 100°C 4
85°C 3 Blue
60°C 2
30°C 1 White

Engine coolant temperature gauge and engine coolant tempera-

ture monitor

20-550 PW148-8 VEBM720100

TESTING AND ADJUSTING E-10 Hydraulic oil temperature gauge does not indicate normally

E-10 Hydraulic oil temperature gauge does not indicate

normally

(1) While hydraulic oil temperature is rising normally, temperature gauge does not rise from white range (C).
Trouble
(2) While hydraulic oil temperature is stabilized normally, temperature gauge rises to red range (H).
• Signals of hydraulic oil temperature sensor are input to pump controller and then transmitted to machine monitor
Related informa- through communication system.
tion • Hydraulic oil temperature can be checked with monitoring function.
(Code: 04401 Hydraulic oil temperature)

Cause Standard value in normal state/Remarks on troubleshooting

★ Prepare with starting switch OFF, then carry out troubleshooting without
turning starting switch ON.
Defective hydraulic oil tempera-
1 ture sensor (Internal disconnec- A55 (male) Resistance
tion or short circuit) Between (1) – (2) 3.5 – 90 kΩ
Between (2) – chassis ground Min. 1 MΩ
★ Prepare with starting switch OFF, then carry out troubleshooting without
turning starting switch ON.
Disconnection in wiring harness
Wiring harness between C01 (female) (29) – A55
2 (Disconnection in wiring or defec- Resistance Max. 1 Ω
(female) (2)
tive contact in connector)
Wiring harness between C01 (female) (46) – A55
Resistance Max. 1 Ω
(female) (1)
Possible causes
★ Prepare with starting switch OFF, then carry out troubleshooting without
and standard
Ground fault in wiring harness turning starting switch ON.
value in normal 3
state (Short circuit with GND circuit) Wiring harness between C01 (female) (29) – A55
Resistance Min. 1 MΩ
(female) (2)
★ Prepare with starting switch OFF, then turn starting switch ON and carry
Hot short (Short circuit with 24V out troubleshooting.
4
circuit) in wiring harness Wiring harness between C01 (female) (29) – A55
Voltage Max. 1 V
(female) (2)
★ Prepare with starting switch OFF, then carry out troubleshooting without
turning starting switch ON.
5 Defective pump controller C01 (female) Resistance
Between (29) – (46) 3.5 – 90 kΩ
Between (29) – chassis ground Min. 1 MΩ
If causes 1 – 5 are not detected, machine monitor may be defective. (Since
6 Defective machine monitor
trouble is in system, troubleshooting cannot be carried out.)

Circuit diagram related to hydraulic oil temperature sensor

A06 A55
(SWP-16) (DT-2)

29 5 2
S
46 4 1
18
S
78

REVO

PW148-8 VEBM720100 20-551

E-10 Hydraulic oil temperature gauge does not indicate normally TESTING AND ADJUSTING

(3) Display of hydraulic oil temperature gauge is different from actual hydraulic oil temperature.
Trouble
(4) Display of hydraulic oil temperature gauge is different from display of hydraulic oil temperature monitor.
Signals of hydraulic oil temperature sensor are input to pump controller and then transmitted to machine monitor through
Related informa- communication system.
tion Hydraulic oil temperature can be checked with monitoring function.
(Code: 04401 Hydraulic oil temperature)

Cause Standard value in normal state/Remarks on troubleshooting

★ Turn starting switch ON or start engine and carry out troubleshooting.
Hydraulic oil Hydraulic oil temperature
Colour of monitor light (a)
temperature level
Possible causes
105°C 6
and standard Red
value in normal 1 Defective machine monitor 102°C 5
state
100°C 4
85°C 3 Blue
40°C 2
20°C 1 White

Hydraulic oil temperature gauge and hydraulic oil temperature

monitor

20-552 PW148-8 VEBM720100

TESTING AND ADJUSTING E-11 Fuel level gauge does not indicate normally

E-11 Fuel level gauge does not indicate normally

(1) While fuel is added, fuel level gauge does not rise from red range (E).
Trouble
(2) While fuel level is low, fuel level gauge does not lower from green range top (F)
Related informa- • Signal voltage of fuel level sensor can be checked with monitoring function.
tion (Code: 04200 Fuel level sensor voltage)

Cause Standard value in normal state/Remarks on troubleshooting

★ Prepare with starting switch OFF, then carry out troubleshooting without
turning starting switch ON.
Defective fuel level sensor (Inter- A54 (male) Fuel level Resistance
1
nal disconnection or short circuit)
Between (1) – FULL 7 – 11 Ω
chassis ground EMPTY 85 – 95 Ω
★ Prepare with starting switch OFF, then carry out troubleshooting without
Disconnection in wiring harness turning starting switch ON.
2 (Disconnection in wiring or defec-
tive contact in connector) Wiring harness between CM01 (female) (9) – A54
Resistance Max. 1 Ω
(female) (1)
Possible causes
★ Prepare with starting switch OFF, then carry out troubleshooting without
and standard
Ground fault in wiring harness turning starting switch ON.
value in normal 3
state (Short circuit with GND circuit) Wiring harness between CM01 (female) (9) – A54
Resistance Min. 1 MΩ
(female) (1)
★ Prepare with starting switch OFF, then turn starting switch ON and carry
Hot short (Short circuit with 24V out troubleshooting.
4
circuit) in wiring harness Wiring harness between CM01 (female) (9) – A54
Voltage Max. 1 V
(female) (1)
★ Prepare with starting switch OFF, then carry out troubleshooting without
turning starting switch ON.

5 Defective machine monitor CM01 (female) Fuel level Resistance

Between (9) – FULL 7 -11 Ω

chassis ground EMPTY 85 – 95 Ω

PW148-8 VEBM720100 20-553

E-11 Fuel level gauge does not indicate normally TESTING AND ADJUSTING

Circuit diagram related to fuel level sensor

A06 A54
(SWP-16)
14

REVO

BWP14241A

20-554 PW148-8 VEBM720100

TESTING AND ADJUSTING E-11 Fuel level gauge does not indicate normally

(3) Display of fuel level gauge is different from actual fuel level.
Trouble
(4) Display of fuel level gauge is different from display of fuel level monitor.
Related informa- • Signal voltage of fuel level sensor can be checked with monitoring function.
tion (Code: 04200 Fuel level sensor voltage)

Cause Standard value in normal state/Remarks on troubleshooting

★ Turn starting switch ON or start engine and carry out troubleshooting.
Reading of fuel level
Quantity of fuel Colour of monitor light (a)
gauge
Possible causes
289 l 6
and standard
value in normal 1 Defective machine monitor 244.5 l 5
state 200 l 4 Blue
100 l 3
60 l 2
41 l 1 Red

Fuel level gauge and fuel level monitor

PW148-8 VEBM720100 20-555

E-12 Contents of display by machine monitor are different from applicable machine TESTING AND ADJUSTING

E-12 Contents of display by machine monitor are different

from applicable machine

Trouble Contents of display by machine monitor are different from applicable machine.
Related informa-
tion

Cause Standard value in normal state/Remarks on troubleshooting

★ Turn starting switch ON and carry out troubleshooting (with monitoring
function).

Possible causes Monitoring code Normal display

and standard 1 Defective model code signal 20KPH: PW148-8-20KPH
value in normal 00200 Controller model code
35KPH: PW148-8-35KPH
state
If display of monitoring is abnormal, carry out troubleshooting for failure code
[DA29KQ].
If cause 1 is not detected, machine monitor may be defective. (Since trouble is
2 Defective machine monitor
in system, troubleshooting cannot be carried out.)

E-13 Machine monitor does not display some items

Trouble • Machine monitor does not display some items.

• The LCD panel sometimes has black points (points which are not lighted) and bright points (points which do not go
Related informa-
off) for the reason of its characteristics. If the number of the bright points and black points does not exceed 10, those
tion
points are not a failure or a defect.

Cause Standard value in normal state/Remarks on troubleshooting

★ Turn starting switch ON and carry out troubleshooting.
Possible causes
Defective machine monitor (LCD When following switches are operated, if all LCD panel is lighted up (all surface
and standard 1
panel) becomes white), LCD panel is normal.
value in normal
state • Operation of switches: [4] + [F2] (Press simultaneously)
If cause 1 is not detected, machine monitor may be defective. (Since trouble is
2 Defective machine monitor (body)
in system, troubleshooting cannot be carried out.)

E-14 Function switch does not work

Trouble • Function switch does not work.

Related informa- • Condition of signal of function switch can be checked with monitoring function.
tion (Code: 04503 Monitor function switch)

Possible causes Cause Standard value in normal state/Remarks on troubleshooting

and standard
value in normal Machine monitor may be defective.
1 Defective machine monitor
state (Since trouble is in system, troubleshooting cannot be carried out.)

20-556 PW148-8 VEBM720100

TESTING AND ADJUSTING E-15 Auto-decelerator does not operate normally

E-15 Auto-decelerator does not operate normally

Trouble (1) When auto-decelerator switch is operated, auto-decelerator monitor does not light up or does not go off.
Related informa- • Condition of signal of auto-decelerator switch can be checked with monitoring function.
tion (Code: 04504 Monitor 1st, 2nd line switches)

Possible causes Cause Standard value in normal state/Remarks on troubleshooting

and standard
value in normal Machine monitor may be defective. (Since trouble is in system, troubleshoot-
1 Defective machine monitor
state ing cannot be carried out.)

Trouble (2) Auto-decelerator is not operated or reset with lever.

Related informa- • Set speed of auto-decelerator is 1,400 rpm. If fuel control dial is not set above this speed, auto-decelerator is not op-
tion erated or reset.

Cause Standard value in normal state/Remarks on troubleshooting

★ Start engine and carry out troubleshooting (with monitoring function).
Monitoring code Item Normal display
Swing
Travel
When lever is
01900 Boom lower operated: ON
Pressure switch 1 Boom raise When lever is in
neutral: OFF
1 Defective PPC pressure signal Arm curl
Possible causes Arm dump
and standard
Bucket curl When lever is
value in normal
01901 operated: ON
state Bucket dump
Pressure switch 2 When lever is in
Service neutral: OFF
If display of monitoring is abnormal, carry out troubleshooting for
E-26 Monitoring function does not display lever control signal normally.
If cause 1 is not detected, machine monitor may be defective. (Since trouble is
2 Defective machine monitor
in system, troubleshooting cannot be carried out.)
If cause 1 is not detected, pump controller may be defective. (Since trouble is
3 Defective pump controller
in system, troubleshooting cannot be carried out.)
If cause 1 is not detected, engine controller may be defective. (Since trouble is
4 Defective engine controller
in system, troubleshooting cannot be carried out.)

PW148-8 VEBM720100 20-557

E-16 Working mode does not change TESTING AND ADJUSTING

E-16 Working mode does not change

Trouble (1) When working mode switch is operated, working mode selection screen is not displayed.
Related informa- • Condition of signal of working mode switch can be checked with monitoring function. (Code: 04504 Monitor 1st, 2nd
tion line switches)

Possible causes Cause Standard value in normal state/Remarks on troubleshooting

and standard
value in normal Machine monitor may be defective. (Since trouble is in system, troubleshoot-
1 Defective machine monitor
state ing cannot be carried out.)

Trouble (2) When working mode is changed, setting of engine and hydraulic pump is not changed.
Related informa-
tion

Cause Standard value in normal state/Remarks on troubleshooting

Possible causes
Machine monitor may be defective. (Since trouble is in system, troubleshoot-
and standard 1 Defective machine monitor
ing cannot be carried out.)
value in normal
state Pump controller may be defective. (Since trouble is in system, troubleshooting
2 Defective pump controller
cannot be carried out.)

20-558 PW148-8 VEBM720100

TESTING AND ADJUSTING E-17 Travel speed does not change

E-17 Travel speed does not change

Trouble (1) When travel speed switch is operated, travel speed monitor does not change.
Related informa- • Condition of signal of travel speed switch can be checked with monitoring function.
tion (Code: 04504 Monitor 1st, 2nd line switches)

Possible causes Cause Standard value in normal state/Remarks on troubleshooting

and standard
value in normal Machine monitor may be defective. (Since trouble is in system, troubleshoot-
1 Defective machine monitor
state ing cannot be carried out.)

Trouble (2) When travel speed is shifted, actual travel speed does not change.
Related informa-
• If cause 1 occurs, actual travel speed does not lower when travel speed is shifted to Lo.
tion

Cause Standard value in normal state/Remarks on troubleshooting

★ Prepare with starting switch OFF, then turn starting switch ON and carry
Hot short (Short circuit with 24V out troubleshooting.
Possible causes 1
circuit) in wiring harness Wiring harness between C02 (female) (87) – V04
and standard Voltage Max. 1 V
(female) (1)
value in normal
state If cause 1 is not detected, machine monitor may be defective. (Since trouble is
2 Defective machine monitor
in system, troubleshooting cannot be carried out.)
If cause 1 is not detected, pump controller may be defective. (Since trouble is
3 Defective pump controller
in system, troubleshooting cannot be carried out.)

Circuit diagram related to travel speed shifting solenoid

V11
A05 (DT-2)

U24 U6 U8

A65

BWP14125A

PW148-8 VEBM720100 20-559

E-18 Alarm buzzer cannot be stopped TESTING AND ADJUSTING

E-18 Alarm buzzer cannot be stopped

Trouble • Alarm buzzer cannot be stopped, even pressing Alarm Buzzer Cancel sw [4] on Monitor panel..
Related informa- • Condition of signal of alarm buzzer cancel switch can be checked with monitoring function.
tion (Code: 04503 Monitor 1st, 2nd line switches)

Cause Standard value in normal state/Remarks on troubleshooting

Machine monitor may be defective. (Since trouble is in system, troubleshooting
1 Defective machine monitor
cannot be carried out.)
★ Turn the engine starting switch OFF for the preparation and hold it in the
OFF position during troubleshooting.
Possible causes Quick coupler grounding fault of
and standard value wiring harness. Wiring harness between CM02 (female) (6)
2 Resistance Above 1 MΩ
in normal state (Contact with grounding [GND] and ground.
circuit)
Wiring harness between C01 (female) (59)
Resistance Max 1 Ω
and ground removing connector S30.

Remove connector S30. Check continuity Engine OFF Max 1 Ω

3 Defective pressure switch
between S30 (male) (1) and (2). Engine ON Min 1 MΩ

Note] Quick Coupler Circuit Pressure low caution buzzer can not
be stopped by Buzzer Cancel SW on monitor panel.

In case it comes from actual pressure low, need to check Hy-

draulic Circuit and to fix leaking portions.

20-560 PW148-8 VEBM720100

 LH LEVER
Quick Coupler SW RH CONSOLE
Quick coupler switch

PW148-8
OFF
ON
2 6 5 1 10 9

B
Quick
TESTING AND ADJUSTING

Coupler D
Solenoid

VEBM720100
G70
11 R17

V16 J06

G73 R40 H15 H14

1 1 2 3 4 5 1 2 10 6 10 7 8 9
A05

11
FB2 BB
CM02
3
BUZZER Monitor
Power 6 ON
Supply SIGNAL Panel 1
FUSE BOX
Circuit diagram for Quick Coupler system

5 J05 CAN
Network
9
Quick Coupler C01
Circuit Low P50
Pressure SW Quick Coupler Pump
4
A02 1 12 59 Circuit Low Controller
Pressure SW
A06
2
U14
Hydraulic
Pressure A65

A65

CAB REVO FRAME CAB

E-18 Alarm buzzer cannot be stopped

20-561
E-19 Windshield wiper and window washer do not operate TESTING AND ADJUSTING

E-19 Windshield wiper and window washer do not operate

Trouble (1) When wiper switch is operated, wiper monitor does not light up or go off.
Related informa- • Condition of wiper switch signal can be checked with monitoring function.
tion (Code: 04504 Monitor 1st, 2nd line switches)

Possible causes Cause Standard value in normal state/Remarks on troubleshooting

and standard
value in normal Machine monitor may be defective. (Since trouble is in system, troubleshooting
1 Defective machine monitor
state cannot be carried out.)

Trouble (2) When wiper switch is operated, wiper does not operate.
Related informa- • Condition of window rear limit switch signal can be checked with monitoring function.
tion (Code: 02204 Switch 5)

Cause Standard value in normal state/Remarks on troubleshooting

★ Prepare with starting switch OFF, then carry out troubleshooting without
turning starting switch ON.
Defective window rear limit switch W03 (male) Front window Resistance
1
(Internal short circuit)
When installed to front Min. 1 MΩ
Between (1) – (2)
When retracted to rear Max. 1 Ω
★ Prepare with starting switch OFF, then carry out troubleshooting without
turning starting switch ON.
Defective wiper motor (Internal
2
disconnection) W04 (female) Continuity
Between (1) – (3) There is continuity
★ Prepare with starting switch OFF, then carry out troubleshooting without
turning starting switch ON.
Disconnection in wiring harness
Possible causes Wiring harness between C02 (female) (119) – W04
3 (Disconnection in wiring or defec- Resistance Max. 1 Ω
and standard (male) (3)
tive contact in connector)
value in normal Wiring harness between C02 (female) (114) – W04
state Resistance Max. 1 Ω
(male) (1)
★ Prepare with starting switch OFF, then carry out troubleshooting without
Ground fault in wiring harness turning starting switch ON.
4
(Short circuit with GND circuit)
C01 (female) (57) – W03 (female) (1) Resistance Min. 1 MΩ
★ Prepare with starting switch OFF, then carry out troubleshooting without
turning starting switch ON.
Defective pump controller (Rear C01 (female) Front window Resistance
limit switch system)
Between (57) – When installed to front Min. 1 MΩ
5 chassis ground When retracted to rear Max. 1 Ω
★ Prepare with starting switch OFF, then carry out troubleshooting without
turning starting switch ON.
Defective pump controller (Wiper
motor system) C02 (female) Continuity
Between (119) – (114) There is continuity

20-562 PW148-8 VEBM720100

TESTING AND ADJUSTING E-19 Windshield wiper and window washer do not operate

Circuit diagram related to windshield and window washer

A50 (KESO-2)

13 14
A05
FB1
4

1
D01 (SWP-8) 2
3

J07
1
2
W04 3

1
3
4 J04
5 1
6 5
11
14

3 3
A02 A01

A64

BWP14136A

Trouble (3) When window washer switch is operated, window washer does not operate.
Related informa- • Condition of window washer switch signal can be checked with monitoring function.
tion (Code: 04504 Monitor 1st, 2nd line switches)

Possible causes Cause Standard value in normal state/Remarks on troubleshooting

and standard
value in normal Machine monitor may be defective. (Since trouble is in system, troubleshoot-
1 Defective machine monitor
state ing cannot be carried out.)

PW148-8 VEBM720100 20-563

E-20 Power maximising function does not operate normally TESTING AND ADJUSTING

E-20 Power maximising function does not operate

normally

(1) When left knob switch is pressed, one-touch power maximizing monitor is not displayed.
Trouble
(2) When left knob switch is pressed, work equipment power is not increased.
• One-touch power maximizing function does not work when working mode is not power mode (P) or economy mode
Related informa- (E).
tion • Condition of left knob switch signal can be checked with monitoring function.
(Code: 02200 Switch input 1)

Cause Standard value in normal state/Remarks on troubleshooting

1 Defective fuse No. 9 If fuse is broken, circuit probably has ground fault. (See cause 4.)
★ Prepare with starting switch OFF, then carry out troubleshooting without
turning starting switch ON.
Defective left knob switch (Inter-
2 M23 (male) Left knob switch Resistance
nal disconnection)
Released Min. 1 MΩ
Between (2) – (10)
Pressed Max. 1 Ω
★ Prepare with starting switch OFF, then carry out troubleshooting without
Disconnection in wiring harness turning starting switch ON.
3 (Disconnection in wiring or defec- Wiring harness between F01-9 – M23 (female) (10) Resistance Max. 1 Ω
Possible causes tive contact in connector) Wiring harness between M23 (female) (2) – C01
Resistance Max. 1 Ω
and standard (female) (41)
value in normal ★ Prepare with starting switch OFF, then carry out troubleshooting without
state turning starting switch ON.
Ground fault in wiring harness
4 Wiring harness between F01-9 – M23 (female) (10) Resistance Min. 1 MΩ
(Short circuit with GND circuit)
Wiring harness between M23 (female) (2) – C01
Resistance Min. 1 MΩ
(female) (41)
★ Prepare with starting switch OFF, then carry out troubleshooting without
turning starting switch ON.
5 Defective pump controller C01 (female) Left knob switch Resistance
Between (41) – Released Min. 1 MΩ
chassis ground Pressed Max. 1 Ω
Machine monitor may be defective. (Since trouble is in system, troubleshoot-
6 Defective machine monitor
ing cannot be carried out.)

Circuit diagram related to left knob switch

LH Lever

Pump controller
Left knob
C01 G70 switch
Knob switch 41 7

FB1
10 A 5

CAB
9JS04427B

20-564 PW148-8 VEBM720100

TESTING AND ADJUSTING E-21 Swing holding brake does not operate normally

E-21 Swing holding brake does not operate normally

Trouble (1) When swing lock switch is operated, swing lock monitor does not light up or go off.
• Condition of swing lock switch signal can be checked with monitoring function.
Related informa-
(Machine monitor system code: 04502 Monitor input 3)
tion
(Pump controller system code: 02200 Switch input 1)

Cause Standard value in normal state/Remarks on troubleshooting

★ Prepare with starting switch OFF, then carry out troubleshooting without
Defective swing lock switch turning starting switch ON.
1 (Internal disconnection or S43 (male) Swing lock switch Resistance
short circuit) OFF Min. 1 MΩ
Between (5) – (6)
ON Max. 1 Ω
★ Prepare with starting switch OFF, then carry out troubleshooting without
Disconnection in wiring har- turning starting switch ON.
ness (Disconnection in wiring Wiring harness between CM02 (female) (5) – S43
Possible causes 2 Resistance Max. 1 Ω
or defective contact in con- (female) (5)
and standard
nector) Wiring harness between S43 (female) (6) – J05 –
value in normal Resistance Max. 1 Ω
state chassis ground (A64)
★ Prepare with starting switch OFF, then carry out troubleshooting without
Ground fault in wiring harness turning starting switch ON.
3
(Short circuit with GND circuit) Wiring harness between CM02 (female) (5) – J02 –
Resistance Min. 1 MΩ
S43 (female) (5), – C01 (female) (19)
★ Prepare with starting switch OFF, then turn starting switch ON and carry
out troubleshooting.
4 Defective machine monitor CM02 Swing lock switch Voltage
Between (5) – OFF 20 – 30 V
chassis ground ON Max. 1 V

Trouble (2) When swing lock switch is turned ON, swing lock does not operate. (Hydraulic drift of swing occurs on slope.)
Related informa-
tion

Cause Standard value in normal state/Remarks on troubleshooting

★ Prepare with starting switch OFF, then carry out troubleshooting without
turning starting switch ON.
Defective swing lock switch (Inter- S04 (male) Swing lock switch Resistance
1
nal short circuit)
OFF Min. 1 MΩ
Between (3) – (4)
ON Max. 1 Ω
★ Prepare with starting switch OFF, then carry out troubleshooting without
Possible causes turning starting switch ON.
and standard Defective swing holding brake Swing holding brake
value in normal 2 release switch (Internal short cir- S25 (male) Resistance
release switch
state cuit)
Lock Min. 1 MΩ
Between (13) – (14)
Release Max. 1 Ω
★ Prepare with starting switch OFF, then turn starting switch ON and carry
out troubleshooting.
Hot short (Short circuit with 24V Wiring harness between D01 (female) (3) – J10 –
3 Voltage Max. 1 V
circuit) in wiring harness S43 (female) (3), – S28 (female) (9)
Wiring harness between S43 (female) (4) – V03
Voltage Max. 1 V
(female) (1), – D03 (female) (3)

PW148-8 VEBM720100 20-565

E-21 Swing holding brake does not operate normally TESTING AND ADJUSTING

Electrical circuit diagram for Swing Lock switch

J05 (J-20)
(Pink)
Emergency Swing Parking
Brake Release Swing Lock Switch

1 2 3 4 5 6 S22 1 2 3 4 5 6 S43

EMERGENCY ON
5 1
NORMAL OFF

4
J04 8 9 10 11 S28 19 20 8 10 H15 A02
(J-20) (090-12) (090-22)
(Green)

U14
1 4

A64

C01 (AMP-81)

P02 (040-20) 38 Swing Emergency Switch

L
Swing Lock 17 19 Swing Lock Switch

E 11 12 13 J10
(J-20)
(Orange)
C02 (AMP -40)
FB1 101 Swing Brake Sol.
10A 1
D01
(SWP-8)
7

A05
5 (SWP-16)
V03 (DT-2) Swing
Brake Sol.
1
Sol.
2
3 A01
(X-4)

A64 A65

20-566 PW148-8 VEBM720100

TESTING AND ADJUSTING E-21 – "Boom/Stabiliser RAISE" is not correctly displayed in monitor function

E-21 – "Boom/Stabiliser RAISE" is not correctly displayed

in monitor function

Failure
• "Boom/Stabiliser RAISE" is not correctly displayed in the monitor function on the monitor panel
information
Relative
• Monitoring code: 01900 (Pressure switch 1)
information

Cause Standard value in normal and references for troubleshooting

• Turn the engine starting switch OFF for the preparations, and keep the engine running during the
Boom/Stabiliser troubleshooting.
RAISE PPC hydraulic
1 switch fault S13 (male) Boom control lever Resistance value
(Internal disconnection NEUTRAL Above 1 MΩ
or short-circuiting) Between (1) and (2)
RAISE Below 1 Ω
Presumed cause and standard value in normal

• Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the
Disconnection of troubleshooting.
wiring harness
Resistance
2 (Disconnection or Wiring harness between C02 (female) (35) and S13 (female) (2) Below 1 Ω
value
defective contact with
connector) Resistance
Wiring harness between S13 (female) (1) and grounding Below 1 Ω
value

Grounding fault of • Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the
wiring harness troubleshooting.
3 (Contact with
grounding (GND) Wiring harness between C02 (female) (35) and S13 (female) (2) and Resistance
Above 1 MΩ
circuit) grounding value

Short-circuiting of • Turn the engine starting switch OFF for the preparations, and hold it in the ON position during the
wiring harness troubleshooting.
4
(Contact with Wiring harness between C02 (female) (35) and S13 (female) (2) and
24 V circuit) Voltage Below 1 V
grounding

• Turn the engine starting switch OFF for the preparations, and hold it in the ON position during the
troubleshooting.
Pump controller C02 Boom control lever Voltage
5
defective
NEUTRAL 20 – 30 V
Between (35) and grounding
RAISE Below 1 V

Electrical circuit diagram for boom RAISE PPC hydraulic switch

Pump
controller Boom/Stabiliser
A09 S13 RAISE pressure
C02 (DRC - 40) (SWP - 8) (X- 2) switch
Boom RAISE
35 1 2
pressure switch
1

A65

CAB PPC CONNECTING

PW148-8 VEBM720100 20-567

E-22 Travel alarm does not sound or does not stop sounding TESTING AND ADJUSTING

E-22 Travel alarm does not sound or does not stop

sounding

Trouble (1) Alarm does not sound during travel.

Related informa-
tion

Cause Standard value in normal state/Remarks on troubleshooting

1 Defective fuse No. 15 If fuse is broken, circuit probably has ground fault. (See cause 4.)
★ Start engine and carry out troubleshooting.
Monitoring code Item Normal display
When FNR switch is
2 Travel signal fault operated (R): ON
02200 Travel reverse
When FNR switch is
operated (F/N): OFF
If display of monitoring is abnormal, carry out troubleshooting for
Possible causes E-26 Monitoring function does not display lever control signal normally.
and standard ★ Prepare with starting switch OFF, then carry out troubleshooting without
value in normal turning starting switch ON.
state Disconnection in wiring harness
Wiring harness between FB2 (1), R16 (3), S29 (2) -
3 (Disconnection in wiring or defec- Resistance Max. 1 Ω
G71 (1) - R16 (5), A53 (1)
tive contact in connector)
Wiring harness between R16 (1), J02, G71 (4) -
Resistance Max. 1 Ω
R16(2), S04, H02 (3), A64
★ Prepare with starting switch OFF, then carry out troubleshooting without
Ground fault in wiring harness turning starting switch ON.
4
(Short circuit with GND circuit) Wiring harness between FB2 (1), R16 (3), S29 (2) -
Resistance Min. 1 MΩ
R16 (5), A07 (3), A53 (1) - R16 (1)
Defective travel alarm (Internal
5 If causes 1 – 4 are not detected, travel alarm is defective.
defect)

Trouble (2) Alarm does not stop sounding while machine is stopped.
Related informa-
tion

Cause Standard value in normal state/Remarks on troubleshooting

★ Start engine and carry out troubleshooting.
Monitoring code Item Normal display
When FNR switch is
1 Travel signal fault operated (R): ON
02200 Travel reverse
When FNR switch is
operated (F/N): OFF
Possible causes If display of monitoring is abnormal, carry out troubleshooting for E-26 Monitor-
and standard ing function does not display lever control signal normally.
value in normal
state ★ Prepare with starting switch OFF, then carry out troubleshooting without
Defective assembled-type diode turning starting switch ON.
2 D05 (Short circuit with GND cir-
R16 Continuity
cuit)
Between (1) – (2) No continuity
★ Prepare with starting switch OFF, then carry out troubleshooting without
Ground fault in wiring harness turning starting switch ON.
3
(Short circuit with GND circuit) Wiring harness between C01 (23) and chassis
Resistance Min. 1 MΩ
ground

20-568 PW148-8 VEBM720100

TESTING AND ADJUSTING E-22 Travel alarm does not sound or does not stop sounding

Electrical circuit diagram for travel PPC hydraulic switch and travel alarm

EMERGENCY FNR SW FNR SW

S95

G71
(DTM-6)

C01(AMP-81)
61
42
23

97
105

R16

S04
15 16

D03 (KES1-2)

D04 (KES1-2)

A01

11 12
(PINK) A02

R04

PW148-8 VEBM720100 20-569

E-23 Air conditioner does not operate normally (including air conditioner abnormality record) TESTING AND ADJUSTING

E-23 Air conditioner does not operate normally

(including air conditioner abnormality record)

Trouble (1) When air conditioner switch is operated, air conditioner control screen is not displayed.
Related informa- • Condition of air conditioner switch signal can be checked with monitoring function.
tion (Code: 04505 Monitor 3rd, 4th line switches, 04506 Monitor 5th line switch)

Possible causes Cause Standard value in normal state/Remarks on troubleshooting

and standard
value in normal Machine monitor may be defective. (Since trouble is in system, troubleshoot-
1 Defective machine monitor
state ing cannot be carried out.)

Trouble (2) When air conditioner switch is operated, air conditioner does not operate at all.
Related informa-
tion

Cause Standard value in normal state/Remarks on troubleshooting

1 Defective fuse No. 11 If fuse is broken, circuit probably has ground fault. (See cause 4.)
2 Defective fuse in unit If fuse in unit is broken, circuit in unit probably has ground fault. (See cause 4.)
★ Prepare with starting switch OFF, then carry out troubleshooting without
turning starting switch ON.
Disconnection in wiring harness
Wiring harness between FB1-11 – fuse in unit –
3 (Disconnection in wiring or defec- Resistance Max. 1 Ω
ACW (wiring side) (6)
tive contact in connector)
Wiring harness between ACW (wiring side) (16) –
Resistance Max. 1 Ω
chassis ground (A64)
Possible causes
and standard ★ Prepare with starting switch OFF, then carry out troubleshooting without
value in normal Ground fault in wiring harness turning starting switch ON.
state 4
(Short circuit with GND circuit) Wiring harness between FB1-11 – fuse in unit –
Resistance Min. 1 MΩ
ACW (wiring side) (6), – circuit branch end
★ Prepare with starting switch OFF, then turn starting switch ON and carry
out troubleshooting.
Defective air conditioner control- ACW (wiring side) Voltage
5
ler
Between (6) – (16) 20 – 30 V
If above voltage is normal, air conditioner controller may be defective.
If causes 1 – 5 are not detected, machine monitor may be defective. (Since
6 Defective machine monitor
trouble is in system, troubleshooting cannot be carried out.)

Trouble (3) Air does not come out (Air flow is insufficient).
Related informa-
tion

20-570 PW148-8 VEBM720100

TESTING AND ADJUSTING E-23 Air conditioner does not operate normally (including air conditioner abnormality record)

Cause Standard value in normal state/Remarks on troubleshooting

★ Prepare with starting switch OFF, then carry out troubleshooting without
turning starting switch ON (coil side).
R20 (male) Resistance
Between (1) – (3) 140 – 340 Ω
Defective blower relay (Inter-
1 ★ Prepare with starting switch OFF, then turn starting switch ON and carry
nal disconnection)
out troubleshooting (contact side).
R20 Air conditioner switch Voltage
Between (4) –
Air blow position 20 – 30 V
chassis ground
★ Prepare with starting switch OFF, then turn starting switch ON and carry
out troubleshooting.
Defective power transistor
2 Fan switch If air flow changes according to opera-
(Internal defect)
Operate between Low and Medium tion of fan switch, power transistor is
and High. normal.

★ Prepare with starting switch OFF, then turn starting switch ON and carry
out troubleshooting.
Possible causes Defective blower motor (Inter- MB (wiring side) Air conditioner switch Voltage
and standard 3
nal defect) Between (1) – (2) Air blow position 20 – 30 V
value in normal
state If above voltage is normal and blower motor does not revolve, blower motor is
defective.
★ Prepare with starting switch OFF, then carry out troubleshooting without
turning starting switch ON.
Wiring harness between FB1-11 – fuse in unit – R20
Resistance Max. 1 Ω
(female) (1)
Wiring harness between R20 (female) (3) – ACW
Resistance Max. 1 Ω
(wiring side) (36)
Wiring harness between FB1-11 – R20 (female) (5) Resistance Max. 1 Ω
Disconnection in wiring har-
Wiring harness between R20 (female) (4) – MB (wir-
ness (Disconnection in wiring Resistance Max. 1 Ω
4 ing side) (1)
or defective contact in con-
nector) Wiring harness between MB (wiring side) (2) – PTR
Resistance Max. 1 Ω
(wiring side) (3)
Wiring harness between PTR (wiring side) (1) –
Resistance Max. 1 Ω
chassis ground (A64)
Wiring harness between PTR (wiring side) (2) –
Resistance Max. 1 Ω
ACW (wiring side) (8)
Wiring harness between PTR (wiring side) (4) –
Resistance Max. 1 Ω
ACW (wiring side) (7)

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E-23 Air conditioner does not operate normally (including air conditioner abnormality record) TESTING AND ADJUSTING

Cause Standard value in normal state/Remarks on troubleshooting

★ Prepare with starting switch OFF, then carry out troubleshooting without
turning starting switch ON.
Wiring harness between R20 (female) (3) – ACW
Resistance Min. 1 MΩ
(wiring side) (36)
Ground fault in wiring harness Wiring harness between R20 (female) (4) – MB (wir-
5 Resistance Min. 1 MΩ
Possible causes (Short circuit with GND circuit) ing side) (1)
and standard Wiring harness between MB (wiring side) (2) – PTR
value in normal Resistance Min. 1 MΩ
(wiring side) (3)
state
Wiring harness between PTR (wiring side) (2) –
Resistance Min. 1 MΩ
ACW (wiring side) (8)
Defective air conditioner control- If causes 1 – 5 are not detected, air conditioner controller may be defective.
6
ler (Since trouble is in system, troubleshooting cannot be carried out.)
If causes 1 – 5 are not detected, air conditioner system may be defective. See
7 Defective air conditioner system Machine Component Volume of Shop Manual, Air conditioner, Troubleshoot-
ing.

20-572 PW148-8 VEBM720100

TESTING AND ADJUSTING E-23 Air conditioner does not operate normally (including air conditioner abnormality record)

Trouble (4) Air is not cooled (Cooling performance is insufficient).

Related informa-
tion

Cause Standard value in normal state/Remarks on troubleshooting

★ Prepare with starting switch OFF, then carry out troubleshooting without
turning starting switch ON (coil side).
R31 (male) Resistance
Between (1) – (3) 140 – 340 Ω
Defective compressor relay
1 ★ Prepare with starting switch OFF, then turn starting switch ON and carry
(Internal disconnection)
out troubleshooting (contact side).
R31 Air conditioner switch Voltage
Between (2) –
Cooling position 20 – 30 V
chassis ground
Internal air sensor may be defective. Carry out troubleshooting for Abnormality
2 Defective internal air sensor
in internal air sensor.
Defective high and low pres- High and low pressure switches may be defective. Carry out troubleshooting
3
sure switches for “Abnormality in refrigerant”.
Defective compressor clutch
4 Compressor clutch may be defective. Check it directly.
(Internal defect)
Defective compressor (Inter-
Possible causes 5 Compressor may be defective. Check it directly.
and standard
nal defect)
value in normal ★ Prepare with starting switch OFF, then carry out troubleshooting without
state turning starting switch ON.
Wiring harness between FB1-11 – fuse in unit – R31
Disconnection in wiring har- Resistance Max. 1 Ω
(female) (1)
ness (Disconnection in wiring
6 Wiring harness between R31 (female) (3) – E05
or defective contact in con- Resistance Max. 1 Ω
(wiring side) (35)
nector)
Wiring harness between FB1-11 – R31 (female) (4) Resistance Max. 1 Ω
Wiring harness between R31 (female) (2) – E05
Resistance Max. 1 Ω
(female) (1)
★ Prepare with starting switch OFF, then carry out troubleshooting without
turning starting switch ON.
Ground fault in wiring harness Wiring harness between R21 (female) (3) – ACW
7 Resistance Min. 1 MΩ
(Short circuit with GND circuit) (wiring side) (35)
Wiring harness between R21 (female) (2) – AC02
Resistance Min. 1 MΩ
(female) (1)
Defective air conditioner con- If causes 1 – 7 are not detected, air conditioner controller may be defective.
8
troller (Since trouble is in system, troubleshooting cannot be carried out.)
Defective air conditioner sys- If causes 1 – 7 are not detected, air conditioner system may be defective. See
9
tem Machine Component Volume of Shop Manual, Air conditioner, Troubleshooting.

PW148-8 VEBM720100 20-573

E-23 Air conditioner does not operate normally (including air conditioner abnormality record) TESTING AND ADJUSTING

(5) Air conditioner abnormality record: Communication condition “CAN disconnection”, Communication condition
Trouble
“Abnormal”
• While abnormality in communication is being detected, “CAN disconnection” is displayed.
• If abnormality in communication has been detected and reset, “Abnormality” is displayed.
Related informa-
• If “CAN disconnection” is displayed as communication condition, communication cannot be carried out normally. Ac-
tion
cordingly, condition of other items is not displayed.
• Method of reproducing abnormality record: Turn starting switch ON.

Cause Standard value in normal state/Remarks on troubleshooting

Disconnection in wiring harness
Wiring harness between N10 (female) (2) – CM02
1 (Disconnection in wiring or defec-
(female) (8), (9)
tive contact in connector)
Wiring harness between N10 (female) (1) – CM02
(female) (10)
Ground fault in wiring harness
2
(Short circuit with GND circuit)
Possible causes
and standard
value in normal
state
Hot short (Short circuit with 24V
3
circuit) in wiring harness
Defective CAN terminal resist-
4 ance (Internal short circuit or dis-
connection)
Defective air conditioner control-
5
ler
6 Defective machine monitor
★ Prepare with starting switch OFF, then carry out troubleshooting without
turning starting switch ON.
Resistance Max. 1 Ω
Resistance Max. 1 Ω
★ Prepare with starting switch OFF, then carry out troubleshooting without
turning starting switch ON.
Wiring harness between N10 (male) (2) – CM02
(female) (8), (9), – C01 (female) (45), – CE02 Resistance Min. 1 MΩ
(female) (46), – K02 (female) (A), – N08 (male) (3)
Wiring harness between N10 (female) (1) – CM02
(female) (10), – C01 (female) (64), – CE02 (female) Resistance Min. 1 MΩ
(47), – K02 (female) (B), – N08 (male) (10)
★ Prepare with starting switch OFF, then turn starting switch ON and carry
out troubleshooting.
N10 (male) (2) – CM02 (female) (8), (9), – C01
(female) (45), – CE02 (female) (46), – K02 (female) Voltage Max. 5.5 V
(A), – N08 (male) (3)
Wiring harness between N10 (female) (1) – CM02
(female) (10), – C01 (female) (64), – CE02 (female) Voltage Max. 5.5 V
(47), – K02 (female) (B), – N08 (male) (10)
★ Prepare with starting switch OFF, then carry out troubleshooting without
turning starting switch ON.
K02 (male) Resistance
Between (A) – (B) 47 – 67 Ω
If causes 1 – 4 are not detected, air conditioner controller may be defective.
(Since trouble is in system, troubleshooting cannot be carried out.)
If causes 1 – 4 are not detected, machine monitor may be defective. (Since
trouble is in system, troubleshooting cannot be carried out.)

20-574 PW148-8 VEBM720100

TESTING AND ADJUSTING E-23 Air conditioner does not operate normally (including air conditioner abnormality record)

Trouble (6) Air conditioner abnormality record: Setting condition “Abnormality”

• If setting of air conditioner controller model is different from setting of machine monitor model, “Abnormality” is dis-
played.
Related informa-
• If “CAN disconnection” is displayed as communication condition, communication cannot be carried out normally. Ac-
tion
cordingly, this condition is not displayed.
• Method of reproducing abnormality record: Turn starting switch ON.

Cause Standard value in normal state/Remarks on troubleshooting

Possible causes
Defective air conditioner control- Air conditioner controller may be defective. (Since trouble is in system, trouble-
and standard 1
ler shooting cannot be carried out.)
value in normal
state Machine monitor may be defective. (Since trouble is in system, troubleshoot-
2 Defective machine monitor
ing cannot be carried out.)

Trouble (7) Air conditioner abnormality record: Internal air sensor “Abnormality”
• If “CAN disconnection” is displayed as communication condition, communication cannot be carried out normally. Ac-
Related informa-
cordingly, this condition is not displayed.
tion
• Method of reproducing abnormality record: Turn starting switch ON + Turn air conditioner (A/C) switch ON.

Cause Standard value in normal state/Remarks on troubleshooting

Defective internal air sensor
1 (Internal disconnection or short
circuit)
Disconnection in wiring harness
2 (Disconnection in wiring or defec-
Possible causes tive contact in connector)
and standard
value in normal
state
Short circuit in wiring harness
3
(with GND circuit)
Hot short (Short circuit with 24V
4
circuit) in wiring harness
Defective air conditioner control-
5
ler
★ Prepare with starting switch OFF, then carry out troubleshooting without
turning starting switch ON.
THI (device side) Resistance
Between (1) – (2) 300 – 430 kΩ
★ Prepare with starting switch OFF, then carry out troubleshooting without
turning starting switch ON.
Wiring harness between ACW (wiring side) (11) –
Resistance Max. 1 Ω
THI (wiring side) (2)
Wiring harness between ACW (wiring side) (27) –
Resistance Max. 1 Ω
THI (wiring side) (1)
★ Prepare with starting switch OFF, then carry out troubleshooting without
turning starting switch ON.
Wiring harness between ACW (wiring side) (11) –
Resistance Min. 1 MΩ
THI (wiring side) (2)
★ Prepare with starting switch OFF, then turn starting switch ON and carry
out troubleshooting.
Wiring harness between ACW (wiring side) (11) –
Voltage Max. 1 V
THI (wiring side) (2)
If causes 1 – 4 are not detected, air conditioner controller may be defective.
(Since trouble is in system, troubleshooting cannot be carried out.)

Trouble (8) Air conditioner abnormality record: External air sensor “Unused”
• External air sensor is not used in air conditioner system of this machine.
Related informa-
• If “CAN disconnection” is displayed as communication condition, communication cannot be carried out normally. Ac-
tion
cordingly, this condition is not displayed.

Possible causes Cause Standard value in normal state/Remarks on troubleshooting

and standard
value in normal Since external air sensor is not used in air conditioner system of this machine,
1 Normal display
state above display is normal.

PW148-8 VEBM720100 20-575

E-23 Air conditioner does not operate normally (including air conditioner abnormality record) TESTING AND ADJUSTING

Trouble (9) Air conditioner abnormality record: Air flow sensor “Abnormality”
• If “CAN disconnection” is displayed as communication condition, communication cannot be carried out normally. Ac-
Related informa-
cordingly, this condition is not displayed.
tion
• Method of reproducing abnormality record: Turn starting switch ON + Turn air conditioner (A/C) switch ON.

Cause Standard value in normal state/Remarks on troubleshooting

★ Prepare with starting switch OFF, then carry out troubleshooting without
Defective air flow sensor (Internal turning starting switch ON.
1
disconnection or short circuit) THF (device side) Resistance
Between (1) – (2) 100 – 115 kΩ
★ Prepare with starting switch OFF, then carry out troubleshooting without
turning starting switch ON.
Disconnection in wiring harness
Wiring harness between ACW (wiring side) (12) –
2 (Disconnection in wiring or defec- Resistance Max. 1 Ω
THF (wiring side) (2)
Possible causes tive contact in connector)
Wiring harness between ACW (wiring side) (27) –
and standard Resistance Max. 1 Ω
THF (wiring side) (1)
value in normal
state ★ Prepare with starting switch OFF, then carry out troubleshooting without
Short circuit in wiring harness turning starting switch ON.
3
(with GND circuit) Wiring harness between ACW (wiring side) (12) –
Resistance Min. 1 MΩ
THF (wiring side) (2)
★ Prepare with starting switch OFF, then turn starting switch ON and carry
Hot short (Short circuit with 24V out troubleshooting.
4
circuit) in wiring harness Wiring harness between ACW (wiring side) (12) –
Voltage Max. 1 V
THF (wiring side) (2)
Defective air conditioner control- If causes 1 – 4 are not detected, air conditioner controller may be defective.
5
ler (Since trouble is in system, troubleshooting cannot be carried out.)

Trouble (10) Air conditioner abnormality record: Daylight sensor “Abnormality”

• If “CAN disconnection” is displayed as communication condition, communication cannot be carried out normally. Ac-
Related informa-
cordingly, this condition is not displayed.
tion
• Method of reproducing abnormality record: Turn starting switch ON + Turn air conditioner (A/C) switch ON.

Cause Standard value in normal state/Remarks on troubleshooting

Defective daylight sensor (Inter-
1 Daylight sensor may be defective.
nal defect)
★ Prepare with starting switch OFF, then carry out troubleshooting without
turning starting switch ON.
Disconnection in wiring harness
Wiring harness between ACW (wiring side) (3) – Resistance Max. 1 Ω
2 (Disconnection in wiring or defec-
P15 (female) (1)
tive contact in connector)
Wiring harness between ACW (wiring side) (15) – Resistance Max. 1 Ω
P15 (female) (2)
★ Prepare with starting switch OFF, then carry out troubleshooting without
Possible causes turning starting switch ON.
and standard
Short circuit in wiring harness Wiring harness between ACW (wiring side) (3) –
value in normal 3 Resistance Min. 1 MΩ
(with GND circuit) P15 (female) (1), – circuit branch end
state
Wiring harness between ACW (wiring side) (15) –
Resistance Min. 1 MΩ
P15 (female) (2)
★ Prepare with starting switch OFF, then turn starting switch ON and carry
out troubleshooting.
Hot short (Short circuit with 24V Wiring harness between ACW (wiring side) (3) –
4 Voltage Max. 1 V
circuit) in wiring harness P15 (female) (1), – circuit branch end
Wiring harness between ACW (wiring side) (15) –
Voltage Max. 1 V
P15 (female) (2)
Defective air conditioner control- If causes 1 – 4 are not detected, air conditioner controller may be defective.
5
ler (Since trouble is in system, troubleshooting cannot be carried out.)

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TESTING AND ADJUSTING E-23 Air conditioner does not operate normally (including air conditioner abnormality record)

Trouble (11) Air conditioner abnormality record: Air outlet damper “Abnormality”
• If “CAN disconnection” is displayed as communication condition, communication cannot be carried out normally. Ac-
Related informa-
cordingly, this condition is not displayed.
tion
• Method of reproducing abnormality record: Turn starting switch ON + Turn air conditioner (A/C) switch ON.

Cause Standard value in normal state/Remarks on troubleshooting

Defective air outlet servo-
1 Air outlet servomotor may be defective.
motor (Internal defect)
Disconnection in wiring harness ACW (wiring side) (27)
2 (Disconnection in wiring or defec-
tive contact in connector)
Possible causes
and standard
value in normal
state Ground fault in wiring harness
3 Resistance
(Short circuit with GND circuit)
Hot short (Short circuit with 24V
4 Voltage
circuit) in wiring harness
Defective air conditioner control-
5
ler
★ Prepare with starting switch OFF, then carry out troubleshooting without
turning starting switch ON.
Wiring harness between MV1 (wiring side) (1) –
Resistance Max. 1 Ω
ACW (wiring side) (3)
Wiring harness between MV1 (wiring side) (3) –
Resistance Max. 1 Ω
Wiring harness between MV1 (wiring side) (5) –
Resistance Max. 1 Ω
ACW (wiring side) (9)
Wiring harness between MV1 (wiring side) (6) –
Resistance Max. 1 Ω
ACW (wiring side) (24)
Wiring harness between MV1 (wiring side) (7) –
Resistance Max. 1 Ω
ACW (wiring side) (23)
★ Prepare with starting switch OFF, then carry out troubleshooting without
turning starting switch ON.
Wiring harness between MV1 (wiring side) (1) –
Resistance Min. 1 MΩ
ACW (wiring side) (3), – circuit branch end
Wiring harness between MV1 (wiring side) (5) –
Min. 1 MΩ
ACW (wiring side) (9), – circuit branch end
Wiring harness between MV1 (wiring side) (6) –
Resistance Min. 1 MΩ
ACW (wiring side) (24), – circuit branch end
Wiring harness between MV1 (wiring side) (7) –
Resistance Min. 1 MΩ
ACW (wiring side) (23), – circuit branch end
★ Prepare with starting switch OFF, then turn starting switch ON and carry
out troubleshooting.
Wiring harness between MV1 (wiring side) (1) –
Voltage Max. 1 V
ACW (wiring side) (3), – circuit branch end
Wiring harness between MV1 (wiring side) (5) –
Max. 1 V
ACW (wiring side) (9), – circuit branch end
Wiring harness between MV1 (wiring side) (6) –
Voltage Max. 1 V
ACW (wiring side) (24), – circuit branch end
Wiring harness between MV1 (wiring side) (7) –
Voltage Max. 1 V
ACW (wiring side) (23), – circuit branch end
If causes 1 – 4 are not detected, air conditioner controller may be defective.
(Since trouble is in system, troubleshooting cannot be carried out.)

PW148-8 VEBM720100 20-577

E-23 Air conditioner does not operate normally (including air conditioner abnormality record) TESTING AND ADJUSTING

Trouble (12) Air conditioner abnormality record: A/M damper “Abnormality”

• If “CAN disconnection” is displayed as communication condition, communication cannot be carried out normally.
Related informa-
Accordingly, this condition is not displayed.
tion
• Method of reproducing abnormality record: Turn starting switch ON + Turn air conditioner (A/C) switch ON.

Cause Standard value in normal state/Remarks on troubleshooting

Defective air mix servomotor
1 Air mix servomotor may be defective.
(Internal defect)
★ Prepare with starting switch OFF, then carry out troubleshooting without
turning starting switch ON.
Wiring harness between MAM (wiring side) (1) –
Resistance Max. 1 Ω
ACW (wiring side) (27)
Wiring harness between MAM (wiring side) (3) –
Disconnection in wiring harness ACW (wiring side) (3) Resistance Max. 1 Ω
2 (Disconnection in wiring or
defective contact in connector) Wiring harness between MAM (wiring side) (5) – Resistance Max. 1 Ω
ACW (wiring side) (2)
Wiring harness between MAM (wiring side) (6) –
Resistance Max. 1 Ω
ACW (wiring side) (21)
Wiring harness between MAM (wiring side) (7) –
Resistance Max. 1 Ω
ACW (wiring side) (22)
★ Prepare with starting switch OFF, then carry out troubleshooting without
turning starting switch ON.
Possible causes
Wiring harness between MAM (wiring side) (3) –
and standard Resistance Min. 1 MΩ
ACW (wiring side) (3), – circuit branch end
value in normal
state Ground fault in wiring harness Wiring harness between MAM (wiring side) (5) –
3 Resistance Min. 1 MΩ
(Short circuit with GND circuit) ACW (wiring side) (2), – circuit branch end
Wiring harness between MAM (wiring side) (6) –
Resistance Min. 1 MΩ
ACW (wiring side) (21), – circuit branch end
Wiring harness between MAM (wiring side) (7) –
Resistance Min. 1 MΩ
ACW (wiring side) (22), – circuit branch end
★ Prepare with starting switch OFF, then turn starting switch ON and carry
out troubleshooting.
Wiring harness between MAM (wiring side) (3) –
Voltage Max. 1 V
ACW (wiring side) (3), – circuit branch end
Hot short (Short circuit with 24V Wiring harness between MAM (wiring side) (5) –
4 Voltage Max. 1 V
circuit) in wiring harness ACW (wiring side) (2), – circuit branch end
Wiring harness between MAM (wiring side) (6) –
Voltage Max. 1 V
ACW (wiring side) (21), – circuit branch end
Wiring harness between MAM (wiring side) (7) –
Voltage Max. 1 V
ACW (wiring side) (22), – circuit branch end
Defective air conditioner control- If causes 1 – 4 are not detected, air conditioner controller may be defective.
5
ler (Since trouble is in system, troubleshooting cannot be carried out.)

20-578 PW148-8 VEBM720100

TESTING AND ADJUSTING E-23 Air conditioner does not operate normally (including air conditioner abnormality record)

Trouble (13) Air conditioner abnormality record: Refrigerant “Abnormality”

• If “CAN disconnection” is displayed as communication condition, communication cannot be carried out normally. Ac-
Related informa-
cordingly, this condition is not displayed.
tion
• Method of reproducing abnormality record: Turn starting switch ON + Turn air conditioner (A/C) switch ON.

Cause Standard value in normal state/Remarks on troubleshooting

Insufficient refrigerant (gas)
1 Refrigerant (gas) may be insufficient. Check it directly.
(when system is normal)
★ Prepare with starting switch OFF, then carry out troubleshooting without
Defective high and low pressure turning starting switch ON.
2
switches (Internal disconnection) P17 (male) Resistance
Possible causes
Between (1) – (2) Max. 1 Ω
and standard
value in normal ★ Prepare with starting switch OFF, then carry out troubleshooting without
state turning starting switch ON.
Disconnection in wiring harness
Wiring harness between ACW (wiring side) (4) –
3 (Disconnection in wiring or defec- Resistance Max. 1 Ω
P17 (female) (1)
tive contact in connector)
Wiring harness between P17 (female) (2) – chassis
Resistance Max. 1 Ω
ground (A64)
Defective air conditioner control- If causes 1 – 3 are not detected, air conditioner controller may be defective.
4
ler (Since trouble is in system, troubleshooting cannot be carried out.)

PW148-8 VEBM720100 20-579

E-23 Air conditioner does not operate normally (including air conditioner abnormality record) TESTING AND ADJUSTING

Circuit diagram related to air conditioner

20-580 PW148-8 VEBM720100

TESTING AND ADJUSTING E-24 When starting switch is turned OFF, service meter is not displayed

E-24 When starting switch is turned OFF, service meter is

not displayed

Trouble • When starting switch is turned OFF, service meter is not displayed.
• While starting switch is at OFF position, if following switches are operated, service meter is displayed at top centre of
Related informa-
screen.
tion
Operation of switches: [4] + [1] (Press simultaneously)

Cause Standard value in normal state/Remarks on troubleshooting

When starting switch is turned ON, if machine monitor displays nothing,
Possible causes
Defective backup power supply backup power supply system may be defective. In this case, carry out trouble-
and standard 1
system shooting for “E-1 When starting switch turned ON, machine monitor displays
value in normal
nothing”.
state
If cause 1 is not detected, machine monitor may be defective. (Since trouble is
2 Defective machine monitor
in system, troubleshooting cannot be carried out.)

E-25 Machine monitor cannot be set in service mode

Trouble • Machine monitor cannot be set in service mode.

Related informa- • If following switches are operated, machine monitor is set in service mode.
tion Operation of switches: [4] + [1] → [2] → [3] (While pressing [4], press other switches in order)

Possible causes Cause Standard value in normal state/Remarks on troubleshooting

and standard
value in normal Machine monitor may be defective. (Since trouble is in system, troubleshoot-
1 Defective machine monitor
state ing cannot be carried out.)

PW148-8 VEBM720100 20-581

E-26 Monitoring function does not display lever control signal normally TESTING AND ADJUSTING

E-26 Monitoring function does not display lever control

signal normally
Failure
(1) "Boom/Stabiliser RAISE" is not correctly displayed in the monitor function on the monitor panel
information
Relative
• Monitoring code: 01900 (Pressure switch 1)
information

Cause Standard value in normal and references for troubleshooting

• Turn the engine starting switch OFF for the preparations, and keep the engine running during the
Boom/Stabiliser troubleshooting.
RAISE PPC hydraulic
1 switch fault S13 (male) Boom control lever Resistance value
(Internal disconnection NEUTRAL Above 1 MΩ
or short-circuiting) Between (1) and (2)
RAISE Below 1 Ω
Presumed cause and standard value in normal

• Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the
Disconnection of troubleshooting.
wiring harness
Resistance
2 (Disconnection or Wiring harness between C01 (female) (53) and S13 (female) (2) Below 1 Ω
value
defective contact with
connector) Resistance
Wiring harness between S13 (female) (1) and grounding Below 1 Ω
value

Grounding fault of • Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the
wiring harness troubleshooting.
3 (Contact with
grounding (GND) Wiring harness between C01 (female) (53) and S13 (female) (2) and Resistance
Above 1 MΩ
circuit) grounding value

Short-circuiting of • Turn the engine starting switch OFF for the preparations, and hold it in the ON position during the
wiring harness troubleshooting.
4
(Contact with Wiring harness between C01 (female) (53) and S13 (female) (2) and
24 V circuit) Voltage Below 1 V
grounding

• Turn the engine starting switch OFF for the preparations, and hold it in the ON position during the
troubleshooting.
Pump controller C01 Boom control lever Voltage
5
defective
NEUTRAL 20 – 30 V
Between (53) and grounding
RAISE Below 1 V

Electrical circuit diagram for boom RAISE PPC hydraulic switch

Pump
controller Boom/Stabiliser
A09 S13 RAISE pressure
C01 (AMP - 81) (SWP - 16) (X- 2) switch
Boom RAISE
35 1 2
pressure switch
1

A65

CAB PPC CONNECTING

BWP10440C

20-582 PW148-8 VEBM720100

TESTING AND ADJUSTING E-26 Monitoring function does not display lever control signal normally

Failure (2) "Boom/Stabiliser LOWER" is not correctly displayed in the monitor function on the monitor panel.
information
Relative
• Monitoring code: 01900 (Pressure switch 1)
information

Cause Standard value in normal and references for troubleshooting

• Turn the engine starting switch OFF for the preparations, and keep the engine running during the
Boom/Stabiliser troubleshooting.
LOWER PPC hydrau-
1 lic switch fault S12 (male) Boom control lever Resistance value
(Internal disconnection NEUTRAL Above 1 MΩ
or short-circuiting) Between (1) and (2)
LOWER Below 1 Ω
Presumed cause and standard value in normal

• Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the
Disconnection of troubleshooting.
wiring harness
Resistance
2 (Disconnection or Wiring harness between C01 (female) (14) and S12 (female) (2) Below 1 Ω
value
defective contact with
connector) Resistance
Wiring harness between S12 (female) (1) and grounding Below 1 Ω
value

Grounding fault of • Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the
wiring harness troubleshooting.
3 (Contact with ground-
ing (GND) Wiring harness between C01 (female) (14) and S12 (female) (2) and Resistance
Above 1 MΩ
circuit) grounding value

Short-circuiting of • Turn the engine starting switch OFF for the preparations, and hold it in the ON position during the
wiring harness troubleshooting.
4
(Contact with 24 V cir- Wiring harness between C01 (female) (14) and S12 (female) (2) and
cuit) Voltage Below 1 V
grounding

• Turn the engine starting switch OFF for the preparations, and hold it in the ON position during the
troubleshooting.
Pump controller C01 Boom control lever Voltage
5
defective
NEUTRAL 20 – 30 V
Between (14) and grounding
LOWER Below 1 V

Electrical circuit diagram for boom LOWER PPC hydraulic switch

Pump
controller Boom/Stabiliser
A09 S12 LOWER pressure
C01 (AMP - 81) (SWP - 16) (X - 2) switch
Boom LOWER
pressure switch 14 2 2
1

A65

CAB PPC CONNECTING BLOCK

BWP10441C

PW148-8 VEBM720100 20-583

E-26 Monitoring function does not display lever control signal normally TESTING AND ADJUSTING

Failure
(3) "Arm DIGGING" is not correctly displayed in the monitor function (special function) on the monitor panel.
information
Relative
• Monitoring code: 01900 (Pressure switch 1)
information

Cause Standard value in normal and references for troubleshooting

• Turn the engine starting switch OFF for the preparations, and keep the engine running during the
troubleshooting.
Arm DIGGING PPC
hydraulic switch fault S06 (male) Arm control lever Resistance value
1
(Internal disconnection
or short-circuiting) NEUTRAL Above 1 MΩ
Between (1) and (2)
DIGGING Below 1 Ω
Presumed cause and standard value in normal

• Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the
Disconnection of troubleshooting.
wiring harness
Resistance
2 (Disconnection or Wiring harness between C01 (female) (17) and S06 (female) (2) Below 1 Ω
value
defective contact with
connector) Resistance
Wiring harness between S06 (female) (1) and grounding Below 1 Ω
value

Grounding fault of • Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the
wiring harness troubleshooting.
3 (Contact with
grounding (GND) Wiring harness between C01 (female) (17) and S06 (female) (2) and Resistance
Above 1 MΩ
circuit) grounding value

Short-circuiting of • Turn the engine starting switch OFF for the preparations, and hold it in the ON position during the
wiring harness troubleshooting.
4
(Contact with Wiring harness between C01 (female) (17) and S06 (female) (2) and
24 V circuit) Voltage Below 1 V
grounding

• Turn the engine starting switch OFF for the preparations, and hold it in the ON position during the
troubleshooting.
Pump controller C01 Arm control lever Voltage
5
defective
NEUTRAL 20 – 30 V
Between (17) and grounding
DIGGING Below 1 V

Electrical circuit diagram for arm DIGGING PPC hydraulic switch

Pump
controller
A09 S06 Arm DIG
C01 (AMP - 81) (SWP - 16) (X - 2) pressure switch
Arm DIG
pressure switch 17 3 2
1

A65

CAB PPC CONNECTING BLOCK

BWP10442C

20-584 PW148-8 VEBM720100

TESTING AND ADJUSTING E-26 Monitoring function does not display lever control signal normally

Failure
(4) Arm DUMPING" is not correctly displayed in the monitor function (special function) on the monitor panel."
information
Relative
• Monitoring code: 01900 (Pressure switch 1)
information

Cause Standard value in normal and references for troubleshooting

• Turn the engine starting switch OFF for the preparations, and keep the engine running during the
troubleshooting.
Arm DUMPING PPC
hydraulic switch defect S05 (male) Arm control lever Resistance value
1
(Internal disconnection
and short-circuiting) NEUTRAL Above 1 MΩ
Between (1) and (2)
DUMPING Below 1 Ω
Presumed cause and standard value in normal

• Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the
Disconnection of troubleshooting.
wiring harness
Resistance
2 (Disconnection or Wiring harness between C01(female) (15) and S05 (female) (2) Below 1 Ω
value
defective contact with
connector) Resistance
Wiring harness between S05 (female) (1) and grounding Below 1 Ω
value

Grounding fault of • Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the
wiring harness troubleshooting.
3 (Contact with
grounding (GND) Wiring harness between C01 (female) (15) and S05 (female) (2) and Resistance
Above 1 MΩ
circuit) grounding value

Short-circuiting of • Turn the engine starting switch OFF for the preparations, and hold it in the ON position during the
wiring harness troubleshooting.
4
(Contact with Wiring harness between C01 (female) (15) and S05 (female) (2) and
24 V circuit) Voltage Below 1 V
grounding

• Turn the engine starting switch OFF for the preparations, and hold it in the ON position during the
troubleshooting.
Pump controller C01 Arm control lever Voltage
5
defective
NEUTRAL 20 – 30 V
Between (15) and grounding
DUMPING Below 1 V

Electrical circuit diagram for arm DUMPING PPC hydraulic switch

Pump
controller
A09 S05 Arm DUMP
C01 (AMP - 81) (SWP - 16) (X - 2) pressure switch
Arm DUMP
pressure switch 15 4 2
1

A65

CAB PPC CONNECTING BLOCK

BWP10443C

PW148-8 VEBM720100 20-585

E-26 Monitoring function does not display lever control signal normally TESTING AND ADJUSTING

Failure
(5) "Bucket DIGGING" is not correctly displayed in the monitor function (special function) on the monitor panel.
information
Relative
• Monitoring code: 01901 (Pressure switch 2)
information

Cause Standard value in normal and references for troubleshooting

• Turn the engine starting switch OFF for the preparations, and keep the engine running during the
troubleshooting.
Bucket DIGGING PPC
hydraulic switch fault S04 (male) Bucket control lever Resistance value
1
(Internal disconnection
and short-circuiting) NEUTRAL Above 1 MΩ
Between (1) and (2)
DIGGING Below 1 Ω
Presumed cause and standard value in normal

• Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the
Disconnection of troubleshooting.
wiring harness
Resistance
2 (Disconnection or Wiring harness between C01 (female) (73) and S04 (female) (2) Below 1 Ω
value
defective contact with
connector) Resistance
Wiring harness between S04 (female) (1) and grounding Below 1 Ω
value

Grounding fault of wir- • Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the
ing harness troubleshooting.
3 (Contact with ground-
ing (GND) Wiring harness between C01 (female) (73) and S04 (female) (2) and Resistance
Above 1 MΩ
circuit) grounding value

Short-circuiting of • Turn the engine starting switch OFF for the preparations, and hold it in the ON position during the
wiring harness troubleshooting.
4
(Contact with Wiring harness between C02 (female) (36) and S04 (female) (2) and
24 V circuit) Voltage Below 1 V
grounding

• Turn the engine starting switch OFF for the preparations, and hold it in the ON position during the
troubleshooting.
Pump controller C01 Bucket control lever Voltage
5
defective
NEUTRAL 20 – 30 V
Between (73) and grounding
DIGGING Below 1 V

Electrical circuit diagram for bucket DIGGING PPC hydraulic switch

Pump
controller
A09 S04 Bucket DIG
C01 (AMP - 81) (SWP - 16) (X - 2) pressure switch
Bucket DIG
73 5 2
pressure switch
1

A65

CAB PPC CONNECTING BLOCK

BWP10444C

20-586 PW148-8 VEBM720100

TESTING AND ADJUSTING E-26 Monitoring function does not display lever control signal normally

Failure
(6) "Bucket DUMPING" is not correctly displayed in the monitor function (special function) on the monitor panel.
information
Relative
• Monitoring code: 01901 (Pressure switch 2)
information

Cause Standard value in normal and references for troubleshooting

• Turn the engine starting switch OFF for the preparations, and keep the engine running during the
Bucket DUMPING troubleshooting.
PPC hydraulic switch
1 fault S03 (male) Bucket control lever Resistance value
(Internal disconnection NEUTRAL Above 1 MΩ
and short-circuiting) Between (1) and (2)
DUMPING Below 1 Ω
Presumed cause and standard value in normal

• Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the
Disconnection of troubleshooting.
wiring harness
Resistance
2 (Disconnection or Wiring harness between C01 (female) (34) and S03 (female) (2) Below 1 Ω
value
defective contact with
connector) Resistance
Wiring harness between S03 (female) (1) and grounding Below 1 Ω
value

Grounding fault of • Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the
wiring harness troubleshooting.
3 (Contact with
grounding (GND) Wiring harness between C01 (female) (34) and S03 (female) (2) and Resistance
Above 1 MΩ
circuit) grounding value

Short-circuiting of • Turn the engine starting switch OFF for the preparations, and hold it in the ON position during the
wiring harness troubleshooting.
4
(Contact with Wiring harness between C01 (female) (34) and S03 (female) (2) and
24 V circuit) Voltage Below 1 V
grounding

• Turn the engine starting switch OFF for the preparations, and hold it in the ON position during the
troubleshooting.
Pump controller C01 Bucket control lever Voltage
5
defective
NEUTRAL 20 – 30 V
Between (34) and grounding
DUMPING Below 1 V

Electrical circuit diagram for bucket DUMPING PPC hydraulic switch

Pump
controller
A09 S03 Bucket DUMP
C01 (AMP - 81) (SWP - 16) (X - 2) pressure switch
Bucket DUMP
34 6 2
pressure switch
1

A65

CAB PPC CONNECTING BLOCK

B
BWP10445C

PW148-8 VEBM720100 20-587

E-26 Monitoring function does not display lever control signal normally TESTING AND ADJUSTING

Failure
(7) "SWING" is not correctly displayed in the monitor function (special function) on the monitor panel.
information

Relative
• Monitoring code: 1900 (Pressure switch 1 )
information

Cause Standard value in normal and references for troubleshooting

• Turn the engine starting switch OFF for the preparations, and keep the engine running during the
troubleshooting.
Swing PPC hydraulic
switch, right, fault S01 (male) Swing control lever Resistance value
1
(Internal disconnection
or short-circuiting) NEUTRAL Above 1 MΩ
Between (1) and (2)
Right Below 1 Ω

• Turn the engine starting switch OFF for the preparations, and keep the engine running during the
troubleshooting.
Swing PPC hydraulic
switch, left, fault S02 (male) Swing control lever Resistance value
2
(Internal disconnection
or short-circuiting) NEUTRAL Above 1 MΩ
Between (1) and (2)
Presumed cause and standard value in normal

Left Below 1 Ω

• Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the
troubleshooting.
Disconnection of Wiring harness between C01 (female) (16) and S01 (female) (2), or Resistance
wiring harness Below 1 Ω
wiring harness between C01 (female) (16) and S02 (female) (2) value
3 (Disconnection or
defective contact with Resistance
Wiring harness between S01 (female) (1) and grounding Below 1 Ω
connector) value

Resistance
Wiring harness between S02 (female) (1) and grounding Below 1 Ω
value

Grounding fault of • Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the
wiring harness troubleshooting.
4 (Contact with Wiring harness between C01 (female) (16) and S01 (female) (2), or
grounding (GND) Resistance
wiring harness between C01 (female) (16) and S02 (female) (2) and Above 1 MΩ
circuit) value
grounding

• Turn the engine starting switch OFF for the preparations, and hold it in the ON position during the
Short-circuiting of troubleshooting.
wiring harness
5 Wiring harness between C01 (female) (16) and S01 (female) (2), or
(Contact with
24 V circuit) wiring harness between C01 (female) (16) and S02 (female) (2) and Voltage Below 1 V
grounding

• Turn the engine starting switch OFF for the preparations, and hold it in the ON position during the
troubleshooting.
Pump controller C01 Swing control lever Voltage
6
defective
NEUTRAL 20 – 30 V
Between (16) and grounding
Right or left Below 1 V

20-588 PW148-8 VEBM720100

TESTING AND ADJUSTING E-26 Monitoring function does not display lever control signal normally

Electrical circuit diagram for right and left swing PPC hydraulic switches

Swing RIGHT
S01 (X - 2) pressure switch
2
Pump 1
controller
A09 Swing LEFT
C01 (AMP - 81) (SWP - 16) S02 (X - 2) pressure switch
Swing pressure U2
16 7 2
switch U3
1

A65

CAB PPC CONNECTING

BWP10446C

PW148-8 VEBM720100 20-589

E-26 Monitoring function does not display lever control signal normally TESTING AND ADJUSTING

Failure
(8) "TRAVEL" is not correctly displayed in the monitor function (special function) on the monitor panel.
information

Relative
• Default travel indication is neutral
information

Cause Standard value in normal and references for troubleshooting

• Turn the engine starting switch OFF for the preparations, and keep the engine running during the
troubleshooting.

G71 (male) Travel control lever Resistance value

Travel PPC hydraulic
switch fault NEUTRAL Above 1 MΩ
1
(Internal disconnection Between (1) and (2)
or short-circuiting) Forward Below 1 Ω

NEUTRAL Above 1 MΩ
Between (1) and (4)
Reverse Below 1 Ω

• Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the
Presumed cause and standard value in normal

troubleshooting.
Disconnection of Resistance
wiring harness Wiring harness from C01 (female) (61) to G71 (female) (2) Below 1 Ω
value
2 (Disconnection or
defective contact with Resistance
Wiring harness from C01 (female) (42) to J02 to G71 (female) (3) Below 1 Ω
connector) value

Resistance
Wiring harness from C01 (female) (23) to J02 to G71 (4) Below 1 Ω
value

Grounding fault of • Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the
wiring harness troubleshooting.
3 (Contact with
grounding (GND) Wiring harness from C01 (female) (61), or C01 (42), or between wir- Resistance
Above 1 MΩ
circuit) ing harness between C01 (female) (23) and grounding value

Short-circuiting of • Turn the engine starting switch OFF for the preparations, and hold it in the ON position during the
wiring harness troubleshooting.
4
(Contact with Wiring harness from C01 (female) (61), or C01 (42), or between wir-
24 V circuit) Voltage Below 1 V
ing harness between C01 (female) (23) and grounding.

• Turn the engine starting switch OFF for the preparations, and hold it in the ON position during the
troubleshooting.

C01 Travel control lever Voltage

Pump controller
5
defective Between (61) and grounding
NEUTRAL 20 – 30 V
Between (42) and grounding

Between (23) and grounding Forward or backward Below 1 V

20-590 PW148-8 VEBM720100

TESTING AND ADJUSTING E-26 Monitoring function does not display lever control signal normally

Electrical circuit diagram for travel PPC hydraulic switch and travel alarm

EMERGENCY FNR SW FNR SW

S95

G71
(DTM-6)

C01(AMP-81)
61
42
23

97
105

R16

S04
15 16

D03 (KES1-2)

D04 (KES1-2)

A01

11 12
(PINK) A02

R04

PW148-8 VEBM720100 20-591

E-26 Monitoring function does not display lever control signal normally TESTING AND ADJUSTING

Failure
(9) "2 Piece Boom" is not correctly displayed in the monitor function (special function) on the monitor panel.
information

Relative
—
information

Cause Standard value in normal and references for troubleshooting

• Turn the engine starting switch OFF for the preparations, and keep the engine running during the
2 Piece Boom troubleshooting.
(Extend) PPC hydrau-
1 lic switch fault S07 (male) Service pedal Resistance value
(Internal disconnection NEUTRAL Above 1 MΩ
or short-circuiting) Between (1) and (2)
Front Below 1 Ω

• Turn the engine starting switch OFF for the preparations, and keep the engine running during the
2 Piece Boom troubleshooting.
(Retract) PPC hydrau-
2 lic switch fault S08 (male) Service pedal Resistance value
(Internal disconnection NEUTRAL Above 1 MΩ
Presumed cause and standard value in normal

or short-circuiting) Between (1) and (2)

Rear Below 1 Ω

• Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the
Disconnection of troubleshooting.
wiring harness
Wiring harness between C01 (female) (52) and S07 (female) (2), or Resistance
3 (Disconnection or Below 1 Ω
wiring harness between C01 (female) (6) and S08 (female) (2) value
defective contact with
connector) Wiring harness between S07 (female) (1) and grounding or Wiring Resistance
Below 1 Ω
harness between S08 (female) (1) and grounding value

Grounding fault of • Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the
wiring harness troubleshooting.
4 (Contact with g Wiring harness between C01 (female) (52) and S07 (female) (2), or
rounding (GND) Resistance
between wiring harness between C01 (female) (52) and S08 Above 1 MΩ
circuit) value
(female) (2) and grounding

• Turn the engine starting switch OFF for the preparations, and hold it in the ON position during the
Short-circuiting of troubleshooting.
wiring harness
5 Wiring harness between C01 (female) (52) and S07 (female) (1), or
(Contact with
24 V circuit) between wiring harness between C01 (female) (52) and S08 Voltage Below 1 V
(female) (1) and grounding

• Turn the engine starting switch OFF for the preparations, and hold it in the ON position during the
troubleshooting.
Pump controller defec- C01 Service pedal Voltage
6
tive
NEUTRAL 20 – 30 V
Between (52) and grounding
Front or rear Below 1 V

20-592 PW148-8 VEBM720100

TESTING AND ADJUSTING E-26 Monitoring function does not display lever control signal normally

Electrical circuit diagram for 2 piece boom PPC hydraulic switch

Pump
controller
A09
C02 (AMP - 81) (SWP - 16)
Service
pressure switch 6 8

S08 2pc boom retract

(X - 2) pressure switch
2
1

S07 2pc boom extend

(X - 2) pressure switch
2
1

A65

BWP10447C

PW148-8 VEBM720100 20-593

E-27 KOMTRAX system does not operate normally TESTING AND ADJUSTING

E-27 KOMTRAX system does not operate normally

Trouble • KOMTRAX system does not operate normally.

• If KOMTRAX system administrator makes request for checking system on machine side for trouble, carry out follow-
Related informa- ing troubleshooting.
tion • Even if KOMTRAX system has trouble, it does not particularly appear on machine.
• Carry out all troubleshooting on service menu screen of machine monitor.

Cause Standard value in normal state/Remarks on troubleshooting

★ Turn starting switch ON and check “Setting condition or terminal” screen.
1 Defective communication 1 Check item Normal display
Communication start check Completion
★ Turn starting switch ON and check “Condition of positioning and commu-
nication” screen.
Check item Normal display

2 Defective GPS N ###,##,## (Latitude)

Positioning E ###,##,## (Longitude)
Possible causes In positioning
and standard
value in normal If display is abnormal, notify KOMTRAX service hot line.
state ★ Turn starting switch ON and check “Condition of positioning and commu-
nication” screen.

Defective communication environ- Check item Normal display

3
ment Zone level 1 – Zone level 3
Communication
In communication
If display is abnormal, notify KOMTRAX service hot line.
★ Turn starting switch ON and check “Condition of positioning and commu-
nication” screen.
4 Defective communication 2
Check item Normal display
Number of items not transmitted 0–9

20-594 PW148-8 VEBM720100

 20 TESTING AND ADJUSTING

Troubleshooting of electrical system

(Error checking of items without monitor codes)
• This troubleshooting is carried out when there is still an abnormality

• Before carrying out any troubleshooting check all related connectors are properly inserted.

• Always connect any disconnected connectors before moving on to next step.

Troubleshooting of electrical system (Error checking of items without monitor codes) . . . . . . . . . 20-601
Information in troubleshooting table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-603
Radio cassette & telephone socket. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-604
PPC lock circuit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-606
Brake light circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-608
Undercarriage attachments – Mode selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-610
Undercarriage attachments - Mode activation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-612
Undercarriage attachments – Front left outrigger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-614
Undercarriage attachments – Front right outrigger. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-616
Undercarriage attachments – Rear left outrigger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-618
Undercarriage attachments – Rear right outrigger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-620
Heated seat does not warm up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-622
Suspension lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-624
Lower wiper does not work (optional fitment) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-626
Work lights (operator cab front left) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-628
Work lights (operator cab front right) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-630
Work lights (operator cab rear) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-632
Worklights (Boom - left hand) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-634
Worklights (Boom - right hand) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-636
Worklights (Revolving frame - left hand) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-638
Worklights (Revolving frame - right hand) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-640
Worklights (Counterweight - left hand). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-642
Worklights (Counterweight - right hand) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-644
Worklights (Oil tank - side mount). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-646
Flashing beacon (Operator’s cabin mount) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-648
Flashing beacon (Counterweight mount) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-650
Flashing beacon (Fuel tank mount). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-652
Air seat compressor (option – air suspension seat) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-654
Operator cab interior light . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-656
Cigarette lighter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-658
Park brake (not activating) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-660
Park brake (displayed symbol) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-662
RH PPC Lever clamshell roller switch pushed to the RH position. . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-664
RH PPC Lever clamshell roller switch pushed to the RH or LH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-666
Horns . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-668

PW148-8 VEBM720100 20-601

Troubleshooting of electrical system (Error checking of items without monitor codes) TESTING AND ADJUSTING

Swing lock – Normal operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-670

Swing lock – Emergency operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-672
Neutral start (engine) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-674
Neutral start (engine) cont’d (A) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-676
Neutral start (engine) cont’d (B) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-678
Neutral start (engine) cont’d (C) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-680
Emergency travel control – Forward . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-682
Emergency travel control – Neutral . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-684
Emergency travel control – Reverse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-686
Driving lights – Main beam . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-688
Driving lights – Main beam flash . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-690
Driving lights – Main beam dipped. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-692
Driving lights – Position lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-694
Indicators – Right hand . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-698
Indicators – Left hand . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-700
Hazard warning lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-702
Hazard warning lights cont’d (A) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-703
Swing lock proximity switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-706

20-602 PW148-8 VEBM720100

TESTING AND ADJUSTING Information in troubleshooting table

Information in troubleshooting table

★ The following information is summarized in the troubleshooting table and the related electrical circuit dia-
gram. Before carrying out troubleshooting, understand that information fully.

Trouble Trouble which occurred in the machine

Related informa-
Information related to detected trouble or troubleshooting
tion

Cause Standard value in normal state/Remarks on troubleshooting

<Contents of description>
• Standard value in normal state to judge possible causes
• Remarks on judgment
1
<Troubles in wiring harness>
• Disconnection
Connector is connected imperfectly or wiring harness is bro-
ken.
• Ground fault
Wiring harness which is not connected to chassis ground cir-
cuit is in contact with chassis ground circuit.
• Hot short
Wiring harness which is not connected to power source (24 V)
2
circuit is in contact with power source (24 V) circuit.
• Short circuit
Possible causes Independent wiring harnesses are in contact with each other
and standard Possible causes of trouble abnormally.
value in normal (Given numbers are refer-
ence numbers, which do <Precautions for troubleshooting>
state
not indicate priority) 1) Method of indicating connector No. and handling of T-adapter
Insert or connect T-adapter as explained below for trouble-
shooting, unless otherwise specified.
3 • If connector No. has no marks of “male” and “female”, dis-
connect connector and insert T-adapters in both male side
and female side.
• If connector No. has marks of “male” and “female”, discon-
nect connector and connect T-adapter to only male side or
female side.
2) Entry order of pin Nos. and handling of tester leads
Connect positive (+) lead and negative (–) lead of tester as
explained below for troubleshooting, unless otherwise speci-
fied.
4
• Connect positive (+) lead to pin No. or wiring harness
entered on front side.
• Connect negative (–) lead to pin No. or harness entered on
rear side.

Related circuit diagram

This drawing is a part of the circuit diagram related to troubleshooting.

• Connector No.: Indicates (Model – Number of pins) and (Colour).
• “Connector No. and pin No.” from each branching/merging point: Shows
the ends of branch or source of merging within the parts of the same wir-
ing harness.
• Arrow ( ): Roughly shows the location on the machine.

PW148-8 VEBM720100 20-603

Radio cassette & telephone socket TESTING AND ADJUSTING

Radio cassette & telephone socket

*When fuse no.6 (Fuse box 1) is not blown

START

Does M72
Pin 2 have good NO
Correct poor
connection to ground
ground?

YES

Does M72 NO
Pin 4 have good Replace DC/DC
connection to converter
ground?

YES
Defective
connector or
Does M79 disconnection in
NO
Pin 2 have good wiring between
connection to M79 Pin 2 and
ground? J07 Pin 18 & 19
J10 Pin 14 & 16
YES M72 Pin 4

Is voltage NO
between Replace DC/DC
M72 Pin 3 & converter
Chassis normal?

YES
Defective
Is voltage connector or
NO disconnection in
between
M79 Pin 1 & wiring between
Chassis normal? M72 Pin 3 & J10
Pin 17 & J10 Pin
20 & M79 Pin 1
YES

Is voltage NO
between Replace socket
M79 Pin 2 & M79
Chassis normal?
Defective
YES connector or
disconnection in
wiring between
Is voltage NO M40 Pin 8 & M50
between
Pin 8 & H08 Pin
M40 Pin 8 &
2 & J10 Pin 15&16
Chassis normal?
J07 Pin 18 & 19
& M79 Pin 2
Defective
YES connector or
disconnection in
Is voltage NO wiring between
between M72 Pin 3 & J10
M40 Pin 4 & Pin 17 & J10
Chassis normal? Pin 18 & H08
Pin 1 & M50 Pin 4
YES
Defective
Is voltage NO connector or
between disconnection in
M40 Pin 7 & wiring between
Chassis normal? M72 Pin 3 & J10
Pin 17 & J10
Pin 19 & H08
YES Pin 3 & M50 Pin 7
& M40 Pin 7

Replace
damaged radio
unit

20-604 PW148-8 VEBM720100

TESTING AND ADJUSTING Radio cassette & telephone socket

Electrical circuit diagram for radio cassette & telephone socket

LEFT RIGHT
SPEAKER SPEAKER

M72 (M-4)

DC / DC RADIO CASSETTE
CONVERTER

1 2 3 4 4 7 8 1 2 7 8 1 2 1 2
M73 M13

M41
M40
(M-2) (M-2)

4 7 8 1 2 7 8
M50 M51
FB1 (AMP-8) (AMP-8)
10A

J09 (J-20) J07 (J-20)

(Pink) (Black)

1 6 18 19 T02 (Cab GND)

J10 H08 1 2 7 8
14 15 16 17 18 19 20
(J-20) (M-8)
(Orange)

Revo T05 (Floor Frame)

M79 (M-2)
Frame
1
Telephone
socket 2
RADIO CASSETTE & TELEPHONE SOCKET B

PW148-8 VEBM720100 20-605

PPC lock circuit TESTING AND ADJUSTING

PPC lock circuit

*When Fuse No.3 (Fuse box 1) is not blown

START

Is voltage Does V01 Pin

YES YES Replace
between V01 2 have good
damaged
Pin 1 & Chassis connection to
solenoid valve
normal? ground?
NO
Defective NO
connector or
Defective
disconnection in Is voltage Correct poor
connector or
wiring between YES between R45 ground
disconnection in
R13 Pin 1 & Pin 6 & Chassis
wiring between
Fuse No. 3 normal?
V01 Pin 1 &
R13 Pin 6
NO
NO
Is voltage Is voltage Does R13 Is voltage
YES between R13 YES between R13 YES YES between R13
Circuit OK Pin 2 have good
Pin 5 & Chassis Pin 1 & Chassis connection to Pin 3 & Chassis
normal? normal? ground when normal?
PPC Lock switch
NO is depressed? NO
Defective
Replace NO Is voltage connector or
damaged relay between S13 YES disconnection in
R13 Pin 2 & Chassis wiring between
Defective
normal? R13 Pin 3 &
connector or
S14 Pin 2
disconnection in NO
wiring between
R13 Pin 2 & Defective
C02 Pin 92 Is voltage
between S14 NO connector or
Pin 1 & Chassis disconnection in
normal? wiring between
S14 Pin 1 &
FB1 Pin 3 (fuse)
YES

Replace
damaged
lock switch

20-606 PW148-8 VEBM720100

TESTING AND ADJUSTING PPC lock circuit

Circuit diagram for PPC lock circuit

Replay For
PPC Lock
R13 PPC Hydraulic Lock Switch

1 2 3
OFF (Pod: down)

1 2 3 5 6 ON (Pod: up)

1 2 3 5 6 1 2 S14
(M-3) C02 (AMP - 40)
FB1 92 PPC Lock (OUT)
10A 3
C03 (AMP - 81)
T 80 PPC Lock (IN)
T

A05
(SWP - 16)
3
V01
PPC Pressure (DT-2)
Lock Solenoid
1
SOL
2
A65
PPC & BRAKE LIGHT INTERLOCK B

PW148-8 VEBM720100 20-607

Brake light circuit TESTING AND ADJUSTING

Brake light circuit

Start 1 Start 2
(LH light) (RH light)

Does L03 pin 2 Does L04 pin 2

Correct poor No
have good Correct poor No
have good
ground connection to ground connection to
ground? ground?

Yes Yes

Is voltage Is voltage
between L03 between L04
Replace damaged Replace damaged
pin 8 and Yes pin 8 and Yes
lamp unit lamp unit
chassis ground chassis ground
normal? normal?

No No

Is voltage
between R21
Check continuity R21 pin
pin 5 and Yes
5 to L03 & L04 pin 4
chassis ground
normal?

No

Is voltage
between R21
Check continuity FB2 pin
pin 1 & 3 and Yes
6 to R21 pin 1 & 3
chassis ground
normal?

No

Does R21 pin 2

has good Yes
Replace damaged relay
connection to unit
ground?

No

Does S19 pin 2

has good Yes
Replace damaged
connection to pressure switch
ground?

No

Check continuity S19 pin 2

to A64 pin 1

20-608 PW148-8 VEBM720100

TESTING AND ADJUSTING Brake light circuit

Circuit diagram for brake light circuit

CAB REVO FRAME

Brake lights

L04 2 4 2 4 L03
(DT-4) 2 4 2 4 (DT-3)

FB2

26 B
5A
6 C

2 4
A84 (DT-12)
2 4

Brake lights relay R21

A07 (SWP-16)
6 6 A65
5 5 15 15
3 3
2 2
1 1

J05 (J-20)
J05 (J-20) (Pink)
(Pink)
16 3 3
20 A64

S18 (DT-2)
1 2

1 2

PW148-8 VEBM720100 20-609

Undercarriage attachments – Mode selection TESTING AND ADJUSTING

Undercarriage attachments – Mode selection

Start

Does icon appear on

monitor display when See "undercarriage
chassis attachment Yes attachments - mode
mode is activated from activation"
RH control lever?

No

Does icon appear on

Defective connector or
monitor display when
disconnection in wiring
No chassis attachment
between G72 pin 10
mode is activated from
and T05
RH control lever?

Yes

Is voltage between G72

Replace damaged
pin 9 and chassis Yes
control lever.
ground correct?

No

Defective connector or
Is voltage between C01
disconnection in wiring
pin 54 and chassis Yes
between C01 pin 54
ground correct?
and G72 pin 9.

No

Replace damaged
pump controller

20-610 PW148-8 VEBM720100

TESTING AND ADJUSTING Undercarriage attachments – Mode selection

Circuit diagram for undercarriage attachments – Mode selection

BOOM/OUTRIGGER
1 2 3 5 6 SELECT RELAY
PUMP CONTROLLER
C02 (AMP-40)

R15
1 2 3 5 6
F-L OUTRIGGER SOL. 85
R-L OUTRIGGER SOL. 86
F-R OUTRIGGER SOL. 93
R-R OUTRIGGER SOL. 94
BOOM/OUTRIGGER SOL. 100 FB1
POWER(SOLENOIDS) 116 20A
C C
POWER(SOLENOIDS) 118
2
POWER(SOLENOIDS) 121

4 5 6 7
4 5 6 7

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

1 2 3 4 5 6 1 2 3 4 5 6 V09 (DT-2) BOOM STABILISER

DOWN SOLENOID
1 1
SOL
2 2

SWIVEL JOINT
V10 (DT-2) BOOM STABILISER
UP SOLENOID
1 1
SOL
1 2 3 4 5 6 1 2 3 4 5 6 2 2

1 2 3 4 5 6

V13 (DT-2) FRONT LH

STABILISER SOLENOID
1 1
SOL
BOOM/CARRIAGE 2 2
ATT SW

V14 (DT-2) FRONT RH

STABILISER SOLENOID
A 1 1
SOL
2 2

V17 (DT-2) REAR LH

STABILISER SOLENOID
A 1 1
SOL
2 2

V18 (DT-2) REAR RH

G72 A
STABILISER SOLENOID
1 1
9 10 (DT-12) SOL
2 2

T20

20
J09
(J-20)
16
(PINK)

PUMP CONTROLLER
C01 (AMP-81)
BOOM/OUTRIGGER SELECT SW 54
T05

PW148-8 VEBM720100 20-611

Undercarriage attachments - Mode activation TESTING AND ADJUSTING

Undercarriage attachments - Mode activation

* When Fuse No2 (Fuse Box 1) is not blown

* When “Undercarriage attachments - mode selection” is working OK

Start 1 Start 2

Correct poor ground Correct poor ground

No No

Does V09 pin 2 has Is voltage between V09 Is voltage between V10 Does V10 pin 2 has
good connection to Yes pin 1 and chassis pin 1 and chassis Yes good connection to
ground? ground normal? ground normal? ground?

Yes Yes
No No

Replace damaged Replace damaged

solenoid valve solenoid valve

Is voltage between R20 Defective connector or

pin 5 and chassis Yes disconnection in wiring between
ground normal? R20 pin 5 and V09 & V10 pin 1

No

Is voltage between C02 Is voltage between R21

Replace damaged
No pin 116, 118 & 121 and No pin 1 & 3 and chassis
pump controller
chassis ground normal? ground normal?

Yes Yes

Defective connector or
disconnection in wiring Does R21 pin 2 has
between C02 and R15 good connection to Yes Replace damaged relay unit
pin 1 & 3 ground?

No

Does C02 pin 100 has Defective connector or

good connection to Yes disconnection in wiring between
ground? C02 and R15 pin 2

No

Replace damaged
pump controller

20-612 PW148-8 VEBM720100

TESTING AND ADJUSTING Undercarriage attachments - Mode activation

Circuit diagram for undercarriage attachments – Mode activation

BOOM/OUTRIGGER
1 2 3 5 6 SELECT RELAY
PUMP CONTROLLER
C02 (AMP-40)

R15
1 2 3 5 6
F-L OUTRIGGER SOL. 85
R-L OUTRIGGER SOL. 86
F-R OUTRIGGER SOL. 93
R-R OUTRIGGER SOL. 94
BOOM/OUTRIGGER SOL. 100 FB1
POWER(SOLENOIDS) 116 20A
C C
POWER(SOLENOIDS) 118
2
POWER(SOLENOIDS) 121

4 5 6 7
4 5 6 7

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

1 2 3 4 5 6 1 2 3 4 5 6 V09 (DT-2) BOOM STABILISER

DOWN SOLENOID
1 1
SOL
2 2

SWIVEL JOINT
V10 (DT-2) BOOM STABILISER
UP SOLENOID
1 1
SOL
1 2 3 4 5 6 1 2 3 4 5 6 2 2

1 2 3 4 5 6

V13 (DT-2) FRONT LH

STABILISER SOLENOID
1 1
SOL
BOOM/CARRIAGE 2 2
ATT SW

V14 (DT-2) FRONT RH

STABILISER SOLENOID
A 1 1
SOL
2 2

V17 (DT-2) REAR LH

STABILISER SOLENOID
A 1 1
SOL
2 2

V18 (DT-2) REAR RH

G72 A
STABILISER SOLENOID
1 1
9 10 (DT-12) SOL
2 2

T20

20
J09
(J-20)
16
(PINK)

PUMP CONTROLLER
C01 (AMP-81)
BOOM/OUTRIGGER SELECT SW 54
T05

PW148-8 VEBM720100 20-613

Undercarriage attachments – Front left outrigger TESTING AND ADJUSTING

Undercarriage attachments – Front left outrigger

* When attachment ‘mode activation’ circuit is fully functional

* When attachment ‘mode activation’ circuit is fully functional

Start

Is voltage between V13 Does V13 pin 1 have

Replace damaged
pin 2 and chassis No good connection to Yes
solenoid valve
ground correct? ground?

No No

Correct poor ground

Defective connector or Is voltage between A14 connection
disconnection in wiring Yes pin 1 and chassis
between A14 pin 2 and V14 pin 2 ground correct?

No

Is voltage between A12

Replace damaged
pin 1 and chassis Yes
swivel joint
ground correct?

No

Is voltage between C02 Defective connector or

pin 85 and chassis Yes disconnection between C02
ground correct? pin 85 and A12 pin 1

No

Replace damaged
pump controller

20-614 PW148-8 VEBM720100

TESTING AND ADJUSTING Undercarriage attachments – Front left outrigger

Circuit diagram for undercarriage attachments – Mode selection

BOOM/OUTRIGGER
1 2 3 5 6 SELECT RELAY
PUMP CONTROLLER
C02 (AMP-40)

R15
1 2 3 5 6
F-L OUTRIGGER SOL. 85
R-L OUTRIGGER SOL. 86
F-R OUTRIGGER SOL. 93
R-R OUTRIGGER SOL. 94
BOOM/OUTRIGGER SOL. 100 FB1
POWER(SOLENOIDS) 116 20A
C C
POWER(SOLENOIDS) 118
2
POWER(SOLENOIDS) 121

4 5 6 7
4 5 6 7

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

1 2 3 4 5 6 1 2 3 4 5 6 V09 (DT-2) BOOM STABILISER

DOWN SOLENOID
1 1
SOL
2 2

SWIVEL JOINT
V10 (DT-2) BOOM STABILISER
UP SOLENOID
1 1
SOL
1 2 3 4 5 6 1 2 3 4 5 6 2 2

1 2 3 4 5 6

V13 (DT-2) FRONT LH

STABILISER SOLENOID
1 1
SOL
BOOM/CARRIAGE 2 2
ATT SW

V14 (DT-2) FRONT RH

STABILISER SOLENOID
A 1 1
SOL
2 2

V17 (DT-2) REAR LH

STABILISER SOLENOID
A 1 1
SOL
2 2

V18 (DT-2) REAR RH

G72 A
STABILISER SOLENOID
1 1
9 10 (DT-12) SOL
2 2

T20

20
J09
(J-20)
16
(PINK)

PUMP CONTROLLER
C01 (AMP-81)
BOOM/OUTRIGGER SELECT SW 54
T05

PW148-8 VEBM720100 20-615

Undercarriage attachments – Front right outrigger TESTING AND ADJUSTING

Undercarriage attachments – Front right outrigger

* When attachment ‘mode activation’ circuit is fully functional

* When attachment ‘mode activation’ circuit is fully functional

Start

Is voltage between V14 Does V14 pin 1 have

Replace damaged
pin 2 and chassis No good connection to Yes
solenoid valve
ground correct? ground?

No No

Correct poor ground

Defective connector or Is voltage between A14 connection
disconnection in wiring Yes pin 2 and chassis
between A14 pin 2 and V14 pin 2 ground correct?

No

Is voltage between A12

Replace damaged
pin 2 and chassis Yes
swivel joint
ground correct?

No

Is voltage between C02 Defective connector or

pin 93 and chassis Yes disconnection between C02
ground correct? pin 85 and A12 pin 1

No

Replace damaged
pump controller

20-616 PW148-8 VEBM720100

TESTING AND ADJUSTING Undercarriage attachments – Front right outrigger

Circuit diagram for undercarriage attachments – Mode selection

BOOM/OUTRIGGER
1 2 3 5 6 SELECT RELAY
PUMP CONTROLLER
C02 (AMP-40)

R15
1 2 3 5 6
F-L OUTRIGGER SOL. 85
R-L OUTRIGGER SOL. 86
F-R OUTRIGGER SOL. 93
R-R OUTRIGGER SOL. 94
BOOM/OUTRIGGER SOL. 100 FB1
POWER(SOLENOIDS) 116 20A
C C
POWER(SOLENOIDS) 118
2
POWER(SOLENOIDS) 121

4 5 6 7
4 5 6 7

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

1 2 3 4 5 6 1 2 3 4 5 6 V09 (DT-2) BOOM STABILISER

DOWN SOLENOID
1 1
SOL
2 2

SWIVEL JOINT
V10 (DT-2) BOOM STABILISER
UP SOLENOID
1 1
SOL
1 2 3 4 5 6 1 2 3 4 5 6 2 2

1 2 3 4 5 6

V13 (DT-2) FRONT LH

STABILISER SOLENOID
1 1
SOL
BOOM/CARRIAGE 2 2
ATT SW

V14 (DT-2) FRONT RH

STABILISER SOLENOID
A 1 1
SOL
2 2

V17 (DT-2) REAR LH

STABILISER SOLENOID
A 1 1
SOL
2 2

V18 (DT-2) REAR RH

G72 A
STABILISER SOLENOID
1 1
9 10 (DT-12) SOL
2 2

T20

20
J09
(J-20)
16
(PINK)

PUMP CONTROLLER
C01 (AMP-81)
BOOM/OUTRIGGER SELECT SW 54
T05

PW148-8 VEBM720100 20-617

Undercarriage attachments – Rear left outrigger TESTING AND ADJUSTING

Undercarriage attachments – Rear left outrigger

* When attachment ‘mode activation’ circuit is fully functional

* When attachment ‘mode activation’ circuit is fully functional

Start

Is voltage between V17 Does V17 pin 1 have

Replace damaged
pin 2 and chassis No good connection to Yes
solenoid valve
ground correct? ground?

No No

Correct poor ground

Defective connector or Is voltage between A14 connection
disconnection in wiring Yes pin 3 and chassis
between A14 pin 3 and V17 pin 2 ground correct?

No

Is voltage between A12

Replace damaged
pin 3 and chassis Yes
swivel joint
ground correct?

No

Is voltage between C02 Defective connector or

pin 86 and chassis Yes disconnection between C02
ground correct? pin 86 and A12 pin 3

No

Replace damaged
pump controller

20-618 PW148-8 VEBM720100

TESTING AND ADJUSTING Undercarriage attachments – Rear left outrigger

Circuit diagram for undercarriage attachments – Mode selection

BOOM/OUTRIGGER
1 2 3 5 6 SELECT RELAY
PUMP CONTROLLER
C02 (AMP-40)

R15
1 2 3 5 6
F-L OUTRIGGER SOL. 85
R-L OUTRIGGER SOL. 86
F-R OUTRIGGER SOL. 93
R-R OUTRIGGER SOL. 94
BOOM/OUTRIGGER SOL. 100 FB1
POWER(SOLENOIDS) 116 20A
C C
POWER(SOLENOIDS) 118
2
POWER(SOLENOIDS) 121

4 5 6 7
4 5 6 7

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

1 2 3 4 5 6 1 2 3 4 5 6 V09 (DT-2) BOOM STABILISER

DOWN SOLENOID
1 1
SOL
2 2

SWIVEL JOINT
V10 (DT-2) BOOM STABILISER
UP SOLENOID
1 1
SOL
1 2 3 4 5 6 1 2 3 4 5 6 2 2

1 2 3 4 5 6

V13 (DT-2) FRONT LH

STABILISER SOLENOID
1 1
SOL
BOOM/CARRIAGE 2 2
ATT SW

V14 (DT-2) FRONT RH

STABILISER SOLENOID
A 1 1
SOL
2 2

V17 (DT-2) REAR LH

STABILISER SOLENOID
A 1 1
SOL
2 2

V18 (DT-2) REAR RH

G72 A
STABILISER SOLENOID
1 1
9 10 (DT-12) SOL
2 2

T20

20
J09
(J-20)
16
(PINK)

PUMP CONTROLLER
C01 (AMP-81)
BOOM/OUTRIGGER SELECT SW 54
T05

PW148-8 VEBM720100 20-619

Undercarriage attachments – Rear right outrigger TESTING AND ADJUSTING

Undercarriage attachments – Rear right outrigger

* When attachment ‘mode activation’ circuit is fully functional

* When attachment ‘mode activation’ circuit is fully functional

Start

Is voltage between V18 Does V18 pin 1 have

Replace damaged
pin 2 and chassis No good connection to Yes
solenoid valve
ground correct? ground?

No No

Correct poor ground

Defective connector or Is voltage between A14 connection
disconnection in wiring Yes pin 4 and chassis
between A14 pin 4 and V18 pin 2 ground correct?

No

Is voltage between A12

Replace damaged
pin 4 and chassis Yes
swivel joint
ground correct?

No

Is voltage between C02 Defective connector or

pin 94 and chassis Yes disconnection between C02
ground correct? pin 94 and A12 pin 4

No

Replace damaged
pump controller

20-620 PW148-8 VEBM720100

TESTING AND ADJUSTING Undercarriage attachments – Rear right outrigger

Circuit diagram for undercarriage attachments – Mode selection

BOOM/OUTRIGGER
1 2 3 5 6 SELECT RELAY
PUMP CONTROLLER
C02 (AMP-40)

R15
1 2 3 5 6
F-L OUTRIGGER SOL. 85
R-L OUTRIGGER SOL. 86
F-R OUTRIGGER SOL. 93
R-R OUTRIGGER SOL. 94
BOOM/OUTRIGGER SOL. 100 FB1
POWER(SOLENOIDS) 116 20A
C C
POWER(SOLENOIDS) 118
2
POWER(SOLENOIDS) 121

4 5 6 7
4 5 6 7

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

1 2 3 4 5 6 1 2 3 4 5 6 V09 (DT-2) BOOM STABILISER

DOWN SOLENOID
1 1
SOL
2 2

SWIVEL JOINT
V10 (DT-2) BOOM STABILISER
UP SOLENOID
1 1
SOL
1 2 3 4 5 6 1 2 3 4 5 6 2 2

1 2 3 4 5 6

V13 (DT-2) FRONT LH

STABILISER SOLENOID
1 1
SOL
BOOM/CARRIAGE 2 2
ATT SW

V14 (DT-2) FRONT RH

STABILISER SOLENOID
A 1 1
SOL
2 2

V17 (DT-2) REAR LH

STABILISER SOLENOID
A 1 1
SOL
2 2

V18 (DT-2) REAR RH

G72 A
STABILISER SOLENOID
1 1
9 10 (DT-12) SOL
2 2

T20

20
J09
(J-20)
16
(PINK)

PUMP CONTROLLER
C01 (AMP-81)
BOOM/OUTRIGGER SELECT SW 54
T05

PW148-8 VEBM720100 20-621

Heated seat does not warm up TESTING AND ADJUSTING

Heated seat does not warm up

*When Fuse No.14 (Fuse box 1) is not blown

Defective connector or
NO disconnection in wiring
between S50 Pin 5
& FB1 Pin 14
Is voltage between
NO
S50 Pin 5 & chassis
normal
Is voltage
NO between S50
Pin 6 & Chassis
normal? YES
Is voltage
between G33
Pin 3 & Chassis
normal? Replace seat heater
YES switch S50

Defective connector or
YES disconnection in wiring
between S50 Pin 6 &
G33 Pin 3

Replace heating
element

20-622 PW148-8 VEBM720100

TESTING AND ADJUSTING Heated seat does not warm up

Circuit diagram for the heated seat

HEATED SEAT
SWITCH
1 2 3 4 5 6
OFF
ON

1 2 3 4 5 6

S50
1 2 3 4 5 6

H14 (M-12)
OPTIONAL SEAT 6 7
6 7

FB1
10A

(OPT) 14

HEATED SEAT

1 1
2 2 J09 (J-20)
(Pink)
3 3
4 4 3 3
1 1
G33 P
(DT-4)

T05

PW148-8 VEBM720100 20-623

Suspension lock TESTING AND ADJUSTING

Suspension lock

Defective connector or
YES disconnection in wiring
between C02 Pin 113 &
V04 Pin 1
Is voltage between
C02 Pin 113 &
NO chassis OK when
suspension lock
button is
depressed?

NO Change defective
controller
Is voltage
between
V04 Pin 1 &
Chassis OK?
Does V04
Pin 2 have
YES Replace
YES good
damaged
connection to
solenoid
Chassis
ground?

NO

Poor
connection to
Chassis
ground

20-624 PW148-8 VEBM720100

TESTING AND ADJUSTING Suspension lock

Circuit diagram for suspension lock

A05
(SWP-16)

C02 12
(AMP-40) V04 (DT-2) Suspension lock
solenoid
SUSPENSION LOCK SOL. 113 1
U6 SOL
2
A65

SUSPENSION LOCK

PW148-8 VEBM720100 20-625

20-626
Start

Defective connector or Defective connector or Defective connector or

Is voltage between R09 Is voltage between H14
disconnection in wiring disconnection in wiring disconnection in wiring
pin 1 and chassis No pin 4 and chassis Yes
between R09 pin 6 between R09 pin 2 between H14 pin 4
* When fuse No 6 (Fuse Box 1) is not blown

ground correct? ground correct?

and G52 pin4 and A64 and R09 pin 1

Yes Yes Yes No

Lower wiper does not work (optional fitment)

Is voltage between R09 Is voltage between G52 Does J05 pin 11 have Does R09 pin 2 have Is voltage between H14
Replace damaged
No pin 6 and chassis No pin 4 and chassis Yes good connection to No good connection to pin 5 and chassis Yes
wiper switch
ground correct? ground correct? ground? ground? ground correct?

Yes Yes No

Defective connector or
Is voltage between G52 Does G52 pin 2 have Is voltage between G52 Is voltage between J10
Replace damaged disconnection in wiring
Yes pin 1 and chassis good connection to Yes pin 3 and chassis pin 9 and chassis Yes
wiper motor ass'y between J10 pin 9 and
ground correct? ground? ground correct? ground correct?
R09 pin 5

No No Yes No

Defective connector or Defective connector or

Is voltage between R09
disconnection in wiring disconnection in wiring
Yes pin 3 and chassis
between R09 pin 3 between G52 pin 2
ground correct?
and G52 pin 1 and A64

No

Defective connector or
Is voltage between R09 Is voltage between J10
disconnection in wiring
pin 5 and chassis pin 9 and chassis Yes
between J10 pin 9 and
Lower wiper does not work (optional fitment)

ground correct? ground correct?

G52 pin 5

Yes No

PW148-8
Replace damaged Defective connector or
No
relay unit disconnection in wiring
between J10 pin 9 and
FB1 pin 6
TESTING AND ADJUSTING

VEBM720100
TESTING AND ADJUSTING Lower wiper does not work (optional fitment)

Circuit diagram for lower wiper

LOWER WIPER
SWITCH
1 2 3 4 5 6
OFF
ON

1 2 3 4 5 6
1 2 3 4 5 6
S47

LOWER WIPER

M
H14 (M-12)

4 5 LOWER WIPER
4 5

G52 (KESO-4)
1 2 3 5 6 1 2 3 4
1 2 3 4
R09

1 2 3 5 6

A07 (SWP-16)
8 8
12 12
16 16

A64
J05 (J-20)

J10 (J-20)
(Orange)

11 12 1 3 7 8 9 10
(Pink)

11 12 1 3 7 8 9 10
A02 (X-4)

4
4
10A
FB1

A64

PW148-8 VEBM720100 20-627

Work lights (operator cab front left) TESTING AND ADJUSTING

Work lights (operator cab front left)

Does M40 pin 2

Start have good No Correct poor
connection to ground
ground?

Yes

Is voltage
Replace
between M40 Yes
damaged work
pin 1 & chassis lamp
normal?

No

Is voltage Is voltage Does R14 pin 6

between R14 pin No between R14 pin Yes have good No Correct poor
2 & chassis 1 & chassis connection to ground
normal? normal? ground?

Yes No Yes

Disconnection in Disconnection in Is voltage

wiring between wiring between Yes Replace
between R14 pin
damaged relay
R14 pin 2 & M40 FB2 pin 4 & R14 5 & chassis
R14
pin 1 pin 1 normal?

No

Is voltage Defective connector or

between S44 pin Yes connection in wiring
6 & chassis between S44 pin 6 &
normal? R14 pin 5

No

Is voltage
Yes Replace
between S44 pin
damaged switch
5 & chassis
S44
normal?

No

Defection in
wiring between
S44 pin 5 & FB2
pin 3

20-628 PW148-8 VEBM720100

 WORKLAMP(1)
SWITCH
1 2 3 4 5 6

PW148-8
OFF
B00M/REVO CAB FRONT
ON
S44 (SWP-6) WORKLAMP WORKLAMP
1 2 3 4 5 6
J07
1 2 3 4 5 6 D05 (090-20)
(SWP-8) (Black)
J09 (090-20)
TESTING AND ADJUSTING

(Pink)
C

VEBM720100
1 2 3 4 5 6 1 2 3 4 5 6 1 5 8 9
7 8 9 10 11 12 13 6 7 H15 1 4 5 11 12 13 14
J06 (090-20) (090-22)
(Orange) 7 8 9 10 11 12 13 6 7 1 4 5 11 12 13 14 1 2 3 4 5 6 1 2 3 4 5 6 1 5 8 9
R05 R114

FB2
20A
3
25A
4

L11 (M-2) U46 A86 (DT-4) A07 (SWP-16)

1 1 2 2 2 2
U13
2 2 3 3

L12 (M-2)
1 1
2 2

L15 (M-2) A05 (SWP-16)

U28
Circuit diagram for worklights - Worklight switch (1)

1 1 16 16 TO SIDE
2 2 LIGHTS
CIRCUIT

L16 (M-2)
1 1
2 2

M40 (M-2)
1 1
2 2 H09 (S-8)
3 3
T
4 4
M41 (M-2)
5 5
1 1 6 6
2 2 T05 A64
Work lights (operator cab front left)

20-629
Work lights (operator cab front right) TESTING AND ADJUSTING

Work lights (operator cab front right)

Does M41 pin 2

Start have good No Correct poor
connection to ground
ground?

Yes

Is voltage
Replace
between M41 Yes
damaged work
pin 1 & chassis lamp
normal?

No

Is voltage Is voltage Does R14 pin 6

between R14 pin No between R14 pin Yes have good No Correct poor
4 & chassis 3 & chassis connection to ground
normal? normal? ground?

Yes No Yes

Disconnection in Disconnection in Is voltage

wiring between wiring between Yes Replace
between R14 pin
damaged relay
R14 pin 4 & M41 FB2 pin 4 & R14 5 & chassis
R14
pin 1 pin 3 normal?

No

Is voltage Defective connector or

between S44 pin Yes connection in wiring
6 & chassis between S44 pin 6 &
normal? R14 pin 5

No

Is voltage
Yes Replace
between S44 pin
damaged switch
5 & chassis
S44
normal?

No

Defection in
wiring between
S44 pin 5 & FB2
pin 3

20-630 PW148-8 VEBM720100

 WORKLAMP(1)
SWITCH
1 2 3 4 5 6

PW148-8
OFF
B00M/REVO CAB FRONT
ON
S44 (SWP-6) WORKLAMP WORKLAMP
1 2 3 4 5 6
J07
1 2 3 4 5 6 D05 (090-20)
(SWP-8) (Black)
J09 (090-20)
TESTING AND ADJUSTING

(Pink)
C

VEBM720100
1 2 3 4 5 6 1 2 3 4 5 6 1 5 8 9
7 8 9 10 11 12 13 6 7 H15 1 4 5 11 12 13 14
J06 (090-20) (090-22)
(Orange) 7 8 9 10 11 12 13 6 7 1 4 5 11 12 13 14 1 2 3 4 5 6 1 2 3 4 5 6 1 5 8 9
R05 R114

FB2
20A
3
25A
4

L11 (M-2) U46 A86 (DT-4) A07 (SWP-16)

1 1 2 2 2 2
U13
2 2 3 3

L12 (M-2)
1 1
2 2

L15 (M-2) A05 (SWP-16)

U28
Circuit diagram for worklights - Worklight switch (1)

1 1 16 16 TO SIDE
2 2 LIGHTS
CIRCUIT

L16 (M-2)
1 1
2 2

M40 (M-2)
1 1
2 2 H09 (S-8)
3 3
T
4 4
M41 (M-2)
5 5
1 1 6 6
2 2 T05 A64

20-631
Work lights (operator cab front right)
Work lights (operator cab rear) TESTING AND ADJUSTING

Work lights (operator cab rear)

Does 40B pin 2

Start have good No Correct poor
connection to ground
ground?

Yes

Is voltage
Replace
between 40B Yes
damaged work
pin 1 & chassis lamp
normal?

No

Is voltage Is voltage Does R08 pin 6

between R08 pin No between R08 pin Yes have good No Correct poor
4 & chassis 3 & chassis connection to ground
normal? normal? ground?

Yes No Yes

Disconnection in Disconnection in Is voltage

wiring between wiring between Yes Replace
between R08 pin
damaged relay
R08 pin 4 & 40B FB2 pin 5 & R08 5 & chassis
R08
pin 1 pin 3 normal?

No

Is voltage Defective connector or

between S45 pin Yes connection in wiring
6 & chassis between S45 pin 6 &
normal? R08 pin 5

No

Is voltage
Yes Replace
between S45 pin
damaged switch
5 & chassis
S45
normal?

No

Defection in
wiring between
S45 pin 5 & FB2
pin 3

20-632 PW148-8 VEBM720100

 WORKLAMP(2)
SWITCH

PW148-8
1 2 3 4 5 6
OFF
B00M/REVO
ON
WORKLAMP
S44 1 2 3 4 5 6
(SWP-6) J09
TESTING AND ADJUSTING

1 2 3 4 5 6 (090-20)
(Pink)

VEBM720100
J07 (090-20)
C (Black)

1 2 3 4 5 6 7 1
1 2 3 7 10 H15 6 17 8 10 11 12 13
J06 (090-20)
(Orange) (090-22)
1 2 3 7 10 6 17 8 10 11 12 13 1 2 3 4 5 6 7 1
R08

T
FB2
20A
3 TO SIDE T05
20A LIGHTS
5 CIRCUIT 2 6 D05
(SWP-8)
2 6
L05 (M-2) A84 (DT-12)
1 1 5 5
2 2 A 9 9
D
Circuit diagram for worklights - worklight switch (2)

L17 (M-2) L06 (DT-2)

1 1 1 1
2 2 2 2 A65

A08 (SWP-16)
L14 (M-2) 1 1
1 1 16 16
2 2 VW
U13

40B (M-2) 40 (M-2) H09 (S-8)

1 1 1 1 1 1
2 2 2 2 4 4
A
A64

20-633
Work lights (operator cab rear)
Worklights (Boom - left hand) TESTING AND ADJUSTING

Worklights (Boom - left hand)

Does L11 pin 2

Start have good No Correct poor
connection to ground
ground?

Yes

Is voltage
Replace
between L11 Yes
damaged work
pin 1 & chassis lamp
normal?

No

Is voltage Is voltage Does R05 pin 6

between R05 pin No between R05 pin Yes have good No Correct poor
2 & chassis 1 & chassis connection to ground
normal? normal? ground?

Yes No Yes

Disconnection in Disconnection in Is voltage

wiring between wiring between Yes Replace
between R05 pin
damaged relay
R05 pin 2 & L11 FB2 pin 3 & R05 5 & chassis
R05
pin 1 pin 1 normal?

No

Is voltage Defective connector or

between S44 pin Yes connection in wiring
6 & chassis between S44 pin 6 &
normal? R05 pin 5

No

Is voltage
Yes Replace
between S44 pin
damaged switch
5 & chassis
S44
normal?

No

Defection in
wiring between
S44 pin 5 & FB2
pin 3

20-634 PW148-8 VEBM720100

 WORKLAMP(1)
SWITCH
1 2 3 4 5 6

PW148-8
OFF
B00M/REVO CAB FRONT
ON
S44 (SWP-6) WORKLAMP WORKLAMP
1 2 3 4 5 6
J07
1 2 3 4 5 6 D05 (090-20)
(SWP-8) (Black)
J09 (090-20)
TESTING AND ADJUSTING

(Pink)
C

VEBM720100
1 2 3 4 5 6 1 2 3 4 5 6 1 5 8 9
7 8 9 10 11 12 13 6 7 H15 1 4 5 11 12 13 14
J06 (090-20) (090-22)
(Orange) 7 8 9 10 11 12 13 6 7 1 4 5 11 12 13 14 1 2 3 4 5 6 1 2 3 4 5 6 1 5 8 9
R05 R114

FB2
20A
3
25A
4

L11 (M-2) U46 A86 (DT-4) A07 (SWP-16)

1 1 2 2 2 2
U13
2 2 3 3

L12 (M-2)
1 1
2 2

L15 (M-2) A05 (SWP-16)

U28
Circuit diagram for worklights - Worklight switch (1)

1 1 16 16 TO SIDE
2 2 LIGHTS
CIRCUIT

L16 (M-2)
1 1
2 2

M40 (M-2)
1 1
2 2 H09 (S-8)
3 3
T
4 4
M41 (M-2)
5 5
1 1 6 6
2 2 T05 A64
Worklights (Boom - left hand)

20-635
Worklights (Boom - right hand) TESTING AND ADJUSTING

Worklights (Boom - right hand)

Does L12 pin 2

Start have good No Correct poor
connection to ground
ground?

Yes

Is voltage
Replace
between L12 Yes
damaged work
pin 1 & chassis lamp
normal?

No

Is voltage Is voltage Does R05 pin 6

between R05 pin No between R05 pin Yes have good No Correct poor
2 & chassis 1 & chassis connection to ground
normal? normal? ground?

Yes No Yes

Disconnection in Disconnection in Is voltage

wiring between wiring between Yes Replace
between R05 pin
damaged relay
R05 pin 2 & L12 FB2 pin 3 & R05 5 & chassis
R05
pin 1 pin 1 normal?

No

Is voltage Defective connector or

between S44 pin Yes connection in wiring
6 & chassis between S44 pin 6 &
normal? R05 pin 5

No

Is voltage
Yes Replace
between S44 pin
damaged switch
5 & chassis
S44
normal?

No

Defection in
wiring between
S44 pin 5 & FB2
pin 3

20-636 PW148-8 VEBM720100

 WORKLAMP(1)
SWITCH
1 2 3 4 5 6

PW148-8
OFF
B00M/REVO CAB FRONT
ON
S44 (SWP-6) WORKLAMP WORKLAMP
1 2 3 4 5 6
J07
1 2 3 4 5 6 D05 (090-20)
(SWP-8) (Black)
J09 (090-20)
TESTING AND ADJUSTING

(Pink)
C

VEBM720100
1 2 3 4 5 6 1 2 3 4 5 6 1 5 8 9
7 8 9 10 11 12 13 6 7 H15 1 4 5 11 12 13 14
J06 (090-20) (090-22)
(Orange) 7 8 9 10 11 12 13 6 7 1 4 5 11 12 13 14 1 2 3 4 5 6 1 2 3 4 5 6 1 5 8 9
R05 R114

FB2
20A
3
25A
4

L11 (M-2) U46 A86 (DT-4) A07 (SWP-16)

1 1 2 2 2 2
U13
2 2 3 3

L12 (M-2)
1 1
2 2

L15 (M-2) A05 (SWP-16)

U28
Circuit diagram for worklights - Worklight switch (1)

1 1 16 16 TO SIDE
2 2 LIGHTS
CIRCUIT

L16 (M-2)
1 1
2 2

M40 (M-2)
1 1
2 2 H09 (S-8)
3 3
T
4 4
M41 (M-2)
5 5
1 1 6 6
2 2 T05 A64
Worklights (Boom - right hand)

20-637
Worklights (Revolving frame - left hand) TESTING AND ADJUSTING

Worklights (Revolving frame - left hand)

Does L15 pin 2

Start have good No Correct poor
connection to ground
ground?

Yes

Is voltage
Replace
between L15 Yes
damaged work
pin 1 & chassis lamp
normal?

No

Is voltage Is voltage Does R05 pin 6

between R05 pin No between R05 pin Yes have good No Correct poor
2 & chassis 3 & chassis connection to ground
normal? normal? ground?

Yes No Yes

Disconnection in Disconnection in Is voltage

wiring between wiring between Yes Replace
between R05 pin
damaged relay
R05 pin 2 & L15 FB2 pin 3 & R05 5 & chassis
R05
pin 1 pin 1 normal?

No

Is voltage Defective connector or

between S44 pin Yes connection in wiring
6 & chassis between S44 pin 6 &
normal? R05 pin 5

No

Is voltage
Yes Replace
between S44 pin
damaged switch
5 & chassis
S44
normal?

No

Defection in
wiring between
S44 pin 5 & FB2
pin 3

20-638 PW148-8 VEBM720100

 WORKLAMP(1)
SWITCH
1 2 3 4 5 6

PW148-8
OFF
B00M/REVO CAB FRONT
ON
S44 (SWP-6) WORKLAMP WORKLAMP
1 2 3 4 5 6
J07
1 2 3 4 5 6 D05 (090-20)
(SWP-8) (Black)
J09 (090-20)
TESTING AND ADJUSTING

(Pink)
C

VEBM720100
1 2 3 4 5 6 1 2 3 4 5 6 1 5 8 9
7 8 9 10 11 12 13 6 7 H15 1 4 5 11 12 13 14
J06 (090-20) (090-22)
(Orange) 7 8 9 10 11 12 13 6 7 1 4 5 11 12 13 14 1 2 3 4 5 6 1 2 3 4 5 6 1 5 8 9
R05 R114

FB2
20A
3
25A
4

L11 (M-2) U46 A86 (DT-4) A07 (SWP-16)

1 1 2 2 2 2
U13
2 2 3 3

L12 (M-2)
1 1
2 2

L15 (M-2) A05 (SWP-16)

U28
Circuit diagram for worklights - Worklight switch (1)

1 1 16 16 TO SIDE
2 2 LIGHTS
CIRCUIT

L16 (M-2)
1 1
2 2

M40 (M-2)
1 1
2 2 H09 (S-8)
3 3
T
4 4
M41 (M-2)
5 5
1 1 6 6
2 2 T05 A64
Worklights (Revolving frame - left hand)

20-639
Worklights (Revolving frame - right hand) TESTING AND ADJUSTING

Worklights (Revolving frame - right hand)

Does L16 pin 2

Start have good No Correct poor
connection to ground
ground?

Yes

Is voltage
Replace
between L16 Yes
damaged work
pin 1 & chassis lamp
normal?

No

Is voltage Is voltage Does R05 pin 6

between R05 pin No between R05 pin Yes have good No Correct poor
4 & chassis 3 & chassis connection to ground
normal? normal? ground?

Yes No Yes

Disconnection in Disconnection in Is voltage

wiring between wiring between Yes Replace
between R05 pin
damaged relay
R05 pin 4 & L16 FB2 pin 3 & R05 5 & chassis
R05
pin 1 pin 3 normal?

No

Is voltage Defective connector or

between S44 pin Yes connection in wiring
6 & chassis between S44 pin 6 &
normal? R05 pin 5

No

Is voltage
Yes Replace
between S44 pin
damaged switch
5 & chassis
S44
normal?

No

Defection in
wiring between
S44 pin 5 & FB2
pin 3

20-640 PW148-8 VEBM720100

 WORKLAMP(1)
SWITCH
1 2 3 4 5 6

PW148-8
OFF
B00M/REVO CAB FRONT
ON
S44 (SWP-6) WORKLAMP WORKLAMP
1 2 3 4 5 6
J07
1 2 3 4 5 6 D05 (090-20)
(SWP-8) (Black)
J09 (090-20)
TESTING AND ADJUSTING

(Pink)
C

VEBM720100
1 2 3 4 5 6 1 2 3 4 5 6 1 5 8 9
7 8 9 10 11 12 13 6 7 H15 1 4 5 11 12 13 14
J06 (090-20) (090-22)
(Orange) 7 8 9 10 11 12 13 6 7 1 4 5 11 12 13 14 1 2 3 4 5 6 1 2 3 4 5 6 1 5 8 9
R05 R114

FB2
20A
3
25A
4

L11 (M-2) U46 A86 (DT-4) A07 (SWP-16)

1 1 2 2 2 2
U13
2 2 3 3

L12 (M-2)
1 1
2 2

L15 (M-2) A05 (SWP-16)

U28
Circuit diagram for worklights - Worklight switch (1)

1 1 16 16 TO SIDE
2 2 LIGHTS
CIRCUIT

L16 (M-2)
1 1
2 2

M40 (M-2)
1 1
2 2 H09 (S-8)
3 3
T
4 4
M41 (M-2)
5 5
1 1 6 6
2 2 T05 A64

20-641
Worklights (Revolving frame - right hand)
Worklights (Counterweight - left hand) TESTING AND ADJUSTING

Worklights (Counterweight - left hand)

Does L17 pin 2

Start have good No Correct poor
connection to ground
ground?

Yes

Is voltage
Replace
between L17 Yes
damaged work
pin 1 & chassis lamp
normal?

No

Is voltage Is voltage Does R08 pin 6

between R08 pin No between R08 pin Yes have good No Correct poor
2 & chassis 1 & chassis connection to ground
normal? normal? ground?

Yes No Yes

Disconnection in Disconnection in Is voltage

wiring between wiring between Yes Replace
between R08 pin
damaged relay
R08 pin 2 & L17 FB2 pin 5 & R08 5 & chassis
R08
pin 1 pin 1 normal?

No

Is voltage Defective connector or

between S45 pin Yes connection in wiring
6 & chassis between S45 pin 6 &
normal? R08 pin 5

No

Is voltage
Yes Replace
between S45 pin
damaged switch
5 & chassis
S45
normal?

No

Defection in
wiring between
S45 pin 5 & FB2
pin 3

20-642 PW148-8 VEBM720100

 WORKLAMP(2)
SWITCH

PW148-8
1 2 3 4 5 6
OFF
B00M/REVO
ON
WORKLAMP
S44 1 2 3 4 5 6
(SWP-6) J09
TESTING AND ADJUSTING

1 2 3 4 5 6 (090-20)
(Pink)

VEBM720100
J07 (090-20)
C (Black)

1 2 3 4 5 6 7 1
1 2 3 7 10 H15 6 17 8 10 11 12 13
J06 (090-20)
(Orange) (090-22)
1 2 3 7 10 6 17 8 10 11 12 13 1 2 3 4 5 6 7 1
R08

T
FB2
20A
3 TO SIDE T05
20A LIGHTS
5 CIRCUIT 2 6 D05
(SWP-8)
2 6
L05 (M-2) A84 (DT-12)
1 1 5 5
2 2 A 9 9
D
Circuit diagram for worklights - worklight switch (2)

L17 (M-2) L06 (DT-2)

1 1 1 1
2 2 2 2 A65

A08 (SWP-16)
L14 (M-2) 1 1
1 1 16 16
2 2 VW
U13

40B (M-2) 40 (M-2) H09 (S-8)

1 1 1 1 1 1
2 2 2 2 4 4
A
A64
Worklights (Counterweight - left hand)

20-643
Worklights (Counterweight - right hand) TESTING AND ADJUSTING

Worklights (Counterweight - right hand)

Does L17 pin 2

Start have good No Correct poor
connection to ground
ground?

Yes

Is voltage
Replace
between L17 Yes
damaged work
pin 1 & chassis lamp
normal?

No

Is voltage Is voltage Does R08 pin 6

between R08 pin No between R08 pin Yes have good No Correct poor
2 & chassis 1 & chassis connection to ground
normal? normal? ground?

Yes No Yes

Disconnection in Disconnection in Is voltage

wiring between wiring between Yes Replace
between R08 pin
damaged relay
R08 pin 2 & L17 FB2 pin 5 & R08 5 & chassis
R08
pin 1 pin 1 normal?

No

Is voltage Defective connector or

between S45 pin Yes connection in wiring
6 & chassis between S45 pin 6 &
normal? R08 pin 5

No

Is voltage
Yes Replace
between S45 pin
damaged switch
5 & chassis
S45
normal?

No

Defection in
wiring between
S45 pin 5 & FB2
pin 3

20-644 PW148-8 VEBM720100

 WORKLAMP(2)
SWITCH

PW148-8
1 2 3 4 5 6
OFF
B00M/REVO
ON
WORKLAMP
S44 1 2 3 4 5 6
(SWP-6) J09
TESTING AND ADJUSTING

1 2 3 4 5 6 (090-20)
(Pink)

VEBM720100
J07 (090-20)
C (Black)

1 2 3 4 5 6 7 1
1 2 3 7 10 H15 6 17 8 10 11 12 13
J06 (090-20)
(Orange) (090-22)
1 2 3 7 10 6 17 8 10 11 12 13 1 2 3 4 5 6 7 1
R08

T
FB2
20A
3 TO SIDE T05
20A LIGHTS
5 CIRCUIT 2 6 D05
(SWP-8)
2 6
L05 (M-2) A84 (DT-12)
1 1 5 5
2 2 A 9 9
D
Circuit diagram for worklights - worklight switch (2)

L17 (M-2) L06 (DT-2)

1 1 1 1
2 2 2 2 A65

A08 (SWP-16)
L14 (M-2) 1 1
1 1 16 16
2 2 VW
U13

40B (M-2) 40 (M-2) H09 (S-8)

1 1 1 1 1 1
2 2 2 2 4 4
A
A64
Worklights (Counterweight - right hand)

20-645
Worklights (Oil tank - side mount) TESTING AND ADJUSTING

Worklights (Oil tank - side mount)

Does L14 pin 2

Start have good No Correct poor
connection to ground
ground?

Yes

Is voltage
Replace
between L14 Yes
damaged work
pin 1 & chassis lamp
normal?

No

Is voltage Is voltage Does R08 pin 6

between R08 pin No between R08 pin Yes have good No Correct poor
4 & chassis 3 & chassis connection to ground
normal? normal? ground?

Yes No Yes

Disconnection in Disconnection in Is voltage

wiring between wiring between Yes Replace
between R08 pin
damaged relay
R08 pin 4 & L14 FB2 pin 5 & R08 5 & chassis
R08
pin 1 pin 3 normal?

No

Is voltage Defective connector or

between S45 pin Yes connection in wiring
6 & chassis between S45 pin 6 &
normal? R08 pin 5

No

Is voltage
Yes Replace
between S45 pin
damaged switch
5 & chassis
S45
normal?

No

Defection in
wiring between
S45 pin 5 & FB2
pin 3

20-646 PW148-8 VEBM720100

 WORKLAMP(2)
SWITCH

PW148-8
1 2 3 4 5 6
OFF
B00M/REVO
ON
WORKLAMP
S44 1 2 3 4 5 6
(SWP-6) J09
TESTING AND ADJUSTING

1 2 3 4 5 6 (090-20)
(Pink)

VEBM720100
J07 (090-20)
C (Black)

1 2 3 4 5 6 7 1
1 2 3 7 10 H15 6 17 8 10 11 12 13
J06 (090-20)
(Orange) (090-22)
1 2 3 7 10 6 17 8 10 11 12 13 1 2 3 4 5 6 7 1
R08

T
FB2
20A
3 TO SIDE T05
20A LIGHTS
5 CIRCUIT 2 6 D05
(SWP-8)
2 6
L05 (M-2) A84 (DT-12)
1 1 5 5
2 2 A 9 9
D
Circuit diagram for worklights - worklight switch (2)

L17 (M-2) L06 (DT-2)

1 1 1 1
2 2 2 2 A65

A08 (SWP-16)
L14 (M-2) 1 1
1 1 16 16
2 2 VW
U13

40B (M-2) 40 (M-2) H09 (S-8)

1 1 1 1 1 1
2 2 2 2 4 4
A
A64
Worklights (Oil tank - side mount)

20-647
Flashing beacon (Operator’s cabin mount) TESTING AND ADJUSTING

Flashing beacon (Operator’s cabin mount)

Start

Does F02B pin 2 have

good connection to No Correct pour ground
ground?

Yes

Does F02B pin 2 have

Replace damaged
good connection to Yes
ground? beacon lamp

No

Is voltage between S46 pin Defective connector or disconnection

Yes in wiring between S46 pin 6 and F02B
6 and chassis normal?
pin 1

No

Is voltage between S46 pin Replace damaged

Yes
5 and chassis normal? switch S46

No

Defective connector or
disconnection in wiring
between S46 pin 5 and
FB1 pin 7

20-648 PW148-8 VEBM720100

TESTING AND ADJUSTING Flashing beacon (Operator’s cabin mount)

Circuit diagram for cab, counterweight & fuel tank beacon light

BEACON SWITCH
Cab
1 2 3 4 5 6 beacon
OFF lamp

S46 (SWP-6)
ON

F02B (DT-2)
1 2 3 4 5 6
1 2
1 2 3 4 5 6 1 2

H14 (M-12)

H14 (M-12)
2 3 1 2

2 3 1 2

FB1 H09 (S-8)

AA
10A 7 7
Fuel tank 7 8 8
beacon T05
lamp Counterweight
beacon
(SWP-16)
L07 (DT-2)

lamp
4
1 2

L08 (DT-2)
A07

4
1 2
1 2

1 2
B
A84 (DT-2)
U22
9 9
8 8
A65

PW148-8 VEBM720100 20-649

Flashing beacon (Counterweight mount) TESTING AND ADJUSTING

Flashing beacon (Counterweight mount)

*When fuse no. 7 (Fuse Box 1) is not blown
*When bulb is fitted correctly and is functional
*When beacon light switch is in the "ON" position

Start

Does L08 pin 2 have

good connection to No Correct pour ground
ground?

Yes

Is voltage between L08

Replace damaged
pin 1 and chassis Yes
normal? beacon lamp

No

Is voltage between S46 pin Defective connector or disconnection

Yes in wiring between S46 pin 6 and L08
6 and chassis normal?
pin 1

No

Is voltage between S46 pin Replace damaged

Yes
5 and chassis normal? switch S46

No

Defective connector or
disconnection in wiring
between S46 pin 5 and
FB1 pin 7

20-650 PW148-8 VEBM720100

TESTING AND ADJUSTING Flashing beacon (Counterweight mount)

Circuit diagram for cab, counterweight & fuel tank beacon light

BEACON SWITCH
Cab
1 2 3 4 5 6 beacon
OFF lamp

S46 (SWP-6)
ON

F02B (DT-2)
1 2 3 4 5 6
1 2
1 2 3 4 5 6 1 2

H14 (M-12)

H14 (M-12)
2 3 1 2

2 3 1 2

FB1 H09 (S-8)

AA
10A 7 7
Fuel tank 7 8 8
beacon T05
lamp Counterweight
beacon
(SWP-16)
L07 (DT-2)

lamp
4
1 2

L08 (DT-2)
A07

4
1 2
1 2

1 2
B
A84 (DT-2)
U22
9 9
8 8
A65

PW148-8 VEBM720100 20-651

Flashing beacon (Fuel tank mount) TESTING AND ADJUSTING

Flashing beacon (Fuel tank mount)

*When fuse no. 7 (Fuse Box 1) is not blown
*When bulb is fitted correctly and is functional
*When beacon light switch is in the "ON" position

Start

Does L07 pin 2 have

good connection to No Correct pour ground
ground?

Yes

Is voltage between L07

Replace damaged
pin 1 and chassis Yes
normal? beacon lamp

No

Is voltage between S46 pin Defective connector or disconnection

Yes in wiring between S46 pin 6 and L07
6 and chassis normal?
pin 1

No

Is voltage between S46 pin Replace damaged

Yes
5 and chassis normal? switch S46

No

Defective connector or
disconnection in wiring
between S46 pin 5 and
FB1 pin 7

20-652 PW148-8 VEBM720100

TESTING AND ADJUSTING Flashing beacon (Fuel tank mount)

Circuit diagram for cab, counterweight & fuel tank beacon light

BEACON SWITCH
Cab
1 2 3 4 5 6 beacon
OFF lamp

S46 (SWP-6)
ON

F02B (DT-2)
1 2 3 4 5 6
1 2
1 2 3 4 5 6 1 2

H14 (M-12)

H14 (M-12)
2 3 1 2

2 3 1 2

FB1 H09 (S-8)

AA
10A 7 7
Fuel tank 7 8 8
beacon T05
lamp Counterweight
beacon
(SWP-16)
L07 (DT-2)

lamp
4
1 2

L08 (DT-2)
A07

4
1 2
1 2

1 2
B
A84 (DT-2)
U22
9 9
8 8
A65

PW148-8 VEBM720100 20-653

Air seat compressor (option – air suspension seat) TESTING AND ADJUSTING

Air seat compressor (option – air suspension seat)

*When Fuse No.16 (Fuse box 1) is not blown

START

Is voltage Defective
NO
between G33 connector or
Pin 1 & Chassis disconnection in
normal? wiring between
G33 Pin 1 &
YES FB1 Pin 16

Does G33
NO
Pin 2 have good Correct poor
connection to ground
ground?

YES

Change
defective seat

20-654 PW148-8 VEBM720100

TESTING AND ADJUSTING Air seat compressor (option – air suspension seat)

Circuit diagram for air seat compressor (option – air suspension seat)

FB1
G33
15A
1 1
M 2 2
16

T05

1 2
J09 (J-20)
1 2 (Pink)

PW148-8 VEBM720100 20-655

Operator cab interior light TESTING AND ADJUSTING

Operator cab interior light

*When Fuse No.16 (Fuse box 1) is not blown

*When bulb is fully functional & fitted correctly

START

Is voltage Defective
NO
between connector or
M71 Pin 2 & disconnection in
Chassis normal? wiring between
M71 Pin 2 &
YES FB1 Pin 16

Disconnect lamp
NO
unit & check if good
Correct poor
ground connection
ground
to cab frame

YES

Change
defective lamp
unit

20-656 PW148-8 VEBM720100

TESTING AND ADJUSTING Operator cab interior light

Circuit diagram for operator cab interior light

A02
(X-4)
4

J05
(J-20)
LAMP UNIT 1 4 (Pink)

M71 (M-2)
ON
1 A64

OFF
2

FB1
16 20A

Cab frame
OPERATOR CAB INTERIOR LIGHT_C

PW148-8 VEBM720100 20-657

Cigarette lighter TESTING AND ADJUSTING

Cigarette lighter

*When Fuse No.4 (Fuse box 1) is not blown

START

Replace Does M19 Is voltage

YES Pin 2 have good YES between
damaged cigarette
lighter connection to M19 Pin 1 &
ground? Chassis normal?

NO NO

Correct poor Defective

ground connector or
disconnection in
wiring between
M19 Pin 1 &
FB1 Pin 4

20-658 PW148-8 VEBM720100

TESTING AND ADJUSTING Cigarette lighter

Circuit diagram for cigarette lighter

S

2 1 J03
(J-20)
CIGARETTE (Grey)
LIGHTER

FB1
4 10A

M19
(YAZAKI-2)
1

2
A02
(X-4)

1 4 J05
A64 (J-20)
(Pink)

PW148-8 VEBM720100 20-659

Park brake (not activating) TESTING AND ADJUSTING

Park brake (not activating)

*When Fuse No.2 (Fuse box 2) is not blown

START

Does V12 Is voltage

Replace YES Pin 2 have good YES between V12
damaged connection to Pin 1 & Chassis
solenoid valve ground? normal?

NO NO

Correct poor Is voltage Defective

ground between S41 YES connector or
Pin 3 & Chassis disconnection in
normal? wiring between
V12 Pin 1 &
NO S41 Pin 3

Is voltage NO
between S41 Defective
Pin 4 & Chassis connector or
normal? disconnection in
wiring between
YES S41 Pin 4 &
FB2 Pin 2
Replace
damaged park
brake switch

20-660 PW148-8 VEBM720100

TESTING AND ADJUSTING Park brake (not activating)

Circuit diagram for park brake

PARK BRAKE SWITCH

1 2 3 4 5 6
OFF
S41 (SWP-6)

ON

1 2 3 4 5 6

1 2 3 4 5 6

C02 (AMP-81)
D06 (DT-2)
1 1 71 PARK BRAKE PRESSURE SW.
2 2

H15 (090-22) D06 (DT-2)

6 6 1 1
9 9 2 2
10 10
11 11

D06 (DT-2)
1 1
J05 (J-20)
2 2
BRAKE VALVE (Pink)
SOLENOID 1 1
5 5
G 11 11
13 13
FB2
10A
2
A02 (X-4)

4
4

A64

PW148-8 VEBM720100 20-661

Park brake (displayed symbol) TESTING AND ADJUSTING

Park brake (displayed symbol)

*When Fuse No.2 (Fuse Box 2) is not blown

START

Is voltage
between C02 NO Replace
Pin 71 & Chassis damaged
normal? controller

YES
Defective
Is voltage connector or
between S17 NO disconnection in
Pin 1 & Chassis wiring between
normal? S17 Pin 1 &
C02 Pin 71
YES

Is voltage
between S17 NO Replace
Pin 2 & Chassis damaged
normal? pressure switch

YES
Defective
Is voltage connector or
between D06 NO disconnection in
Pin 2 & Chassis wiring between
normal? S17 Pin 2 &
D06 Pin 2
YES

Is voltage
NO Replace
between D06
Pin 1 & Chassis damaged
normal? diode D06

YES

Is voltage Defective
between S41 NO connector or
Pin 5 & Chassis disconnection in
normal? wiring between
D06 Pin 1 &
YES S41 Pin 5

Is voltage
NO Replace
between S41
Pin 6 & Chassis damaged
normal? switch S41

YES
Correct poor
ground

20-662 PW148-8 VEBM720100

TESTING AND ADJUSTING Park brake (displayed symbol)

Circuit diagram for park brake

PARK BRAKE SWITCH

1 2 3 4 5 6
OFF
S41 (SWP-6)

ON

1 2 3 4 5 6

1 2 3 4 5 6

C02 (AMP-81)
D06 (DT-2)
1 1 71 PARK BRAKE PRESSURE SW.
2 2

H15 (090-22) D06 (DT-2)

6 6 1 1
9 9 2 2
10 10
11 11

D06 (DT-2)
1 1
J05 (J-20)
2 2
BRAKE VALVE (Pink)
SOLENOID 1 1
5 5
G 11 11
13 13
FB2
10A
2
A02 (X-4)

4
4

A64

PW148-8 VEBM720100 20-663

RH PPC Lever clamshell roller switch pushed to the RH position TESTING AND ADJUSTING

RH PPC Lever clamshell roller switch pushed to the RH

position

Start

Does V24 pin Does C02 pin

2 have good No No Replace
115,117,120 have
connection to damaged
good connection
controller
ground? to ground?

Yes Yes

Is voltage Defective connector or

Replace Yes between V24 disconnection in wiring
damaged EPC
pin 1 & chassis between C02 pin 115 &
solenoid valve
normal? V24 pin 2

No

Is voltage Defective connector or

Replace No Yes
between C02 disconnection in wiring
damaged
pin 100 & chassis between C02 pin 100 &
controller
normal? V24 pin 1

20-664 PW148-8 VEBM720100

TESTING AND ADJUSTING RH PPC Lever clamshell roller switch pushed to the RH position

Circuit diagram for clamshell control

C01 (AMP-81)
9 POWER (5V) [SWITCH]
13 1ST SERVICE POT (2)
69 1ST SERVICE POT (1)
18 GND (ANALOGUE)
46 GND (ANALOGUE)
78 GND (ANALOGUE)

C02 (AMP-40)
95 1ST SERVICE EPC (LEFT)
100 1ST SERVICE EPC (RIGHT)
F F
115 GND (SOLENOID)
F
117 GND (SOLENOID)
120 GND (SOLENOID)

PW148-8 VEBM720100 20-665

RH PPC Lever clamshell roller switch pushed to the RH or LH TESTING AND ADJUSTING

RH PPC Lever clamshell roller switch pushed to the RH or

LH

Start

Defective connector or
Is voltage between G72
No disconnection in wiring
pin 1 and chassis
between C01 pin 9 and G72
normal? pin 1

Yes

Does G72 pin 3 have Does C01 pin 18,46,78

No No Replace damaged
good connection to have good connection to
controller
ground? ground?

Yes Yes

Is voltage between C01 Is voltage between C01
Yes
pin 13 and chassis pin 13 and chassis
normal? normal?
Defective connector or
Is voltage between G72
No disconnection in wiring
pin 4 and chassis
between C01 pin 18,46,78
normal? and G72 pin 3

No Yes

Is voltage between G72

Replace damaged No Replace damaged RH
pin 2 and chassis
controller PPC lever
normal?

Yes

Defective connector or
Is voltage between C01
disconnection in wiring No
pin 69 and chassis
between C01 pin 69 and
G72 pin 2 normal?

Yes

Circuit ok

20-666 PW148-8 VEBM720100

TESTING AND ADJUSTING RH PPC Lever clamshell roller switch pushed to the RH or LH

Circuit diagram for clamshell control

C01 (AMP-81)
9 POWER (5V) [SWITCH]
13 1ST SERVICE POT (2)
69 1ST SERVICE POT (1)
18 GND (ANALOGUE)
46 GND (ANALOGUE)
78 GND (ANALOGUE)

C02 (AMP-40)
95 1ST SERVICE EPC (LEFT)
100 1ST SERVICE EPC (RIGHT)
F F
115 GND (SOLENOID)
F
117 GND (SOLENOID)
120 GND (SOLENOID)

PW148-8 VEBM720100 20-667

Horns TESTING AND ADJUSTING

Horns
*When Fuse No.5 (Fuse box 1) is not blown

START

YES Does A43 Pin 1 YES Is voltage Is voltage YES Does A42 Pin 1 YES
Change have a good between A43 between A42 have a good Change
damaged horn connection to Pin 1 & Chassis Pin 1 & Chassis connection to damaged horn
ground? normal? normal? ground?

NO NO NO

Correct poor Correct poor

ground ground
NO
Defective
connector or
Is voltage YES disconnection in
between R12
wiring between
Pin 5 & Chassis
A90 Pin 1,
normal?
A41 Pin 1 &
R12 Pin 5
NO

Defective
Is voltage connector or
between R12 NO disconnection in
Pin 1 & Chassis wiring between
normal? R12 Pin 1 &
FB1 Pin 5
YES
Defective
Is voltage NO connector or
between R12 disconnection in
Pin 3 & Chassis wiring between
normal? R44 Pin 3 &
FB1 Pin 5
YES

Does G70 NO
Pin 9 have good Correct poor
connection to ground
ground?

YES

Does G70
Pin 20 have good
connection to NO Change
ground when damaged PPC
PPC lever horn lever
switch is
depressed?

YES

Does J10 Pin

15 have good Defective or
Does G03 Pin 6 YES connection to NO disconnection in
NO
Correct poor have good ground when wiring between
ground connection to PPC lever horn G70 Pin 10 &
ground? switch is J09 Pin 15
depressed?
YES

Does G04 Pin 1

have good
Change NO connection to
damaged ground when
steering column steering column
switch horn switch is
depressed

YES

Defective Does J09 Pin

connector or 14 have good
disconnection in NO connection to
wiring between ground when
G04 Pin 1 & steering column
J09 Pin 14 horn switch is
depressed

YES

Does J09
Replace Pin 16 have good
damaged splice NO connection to
header ground when
connector J09 either horn
switch is
depressed

YES

Defective Does R12

connector or Pin 2 have good
disconnection in NO connection to
wiring between ground when
J09 Pin 16 & either horn
R44 Pin 2 switch is
depressed

YES

Replace
damaged relay
R12

20-668 PW148-8 VEBM720100

TESTING AND ADJUSTING Horns

Circuit diagram for horn

R12 HORN RELAY

1 2 3 5 6

FB1 1 2 3 5 6
A07
5 (SWP-16) A41

10A
RD 1 1

1
A43

Indicator stalk

Horn Switch HORNS

15 H
LH PPC LEVER A40
On HORN SWITCH
1
Off
1
J10 A42
(J-20) 14 15 16 10 9 G70
(Orange) (DT-12)
6 1
G03 G04
A64

3
A01
G02
(X - 4)
(DT-12)
1 J09
T05 (J-20)
7 17 16 (Pink)

CM01 (070-18)
GND 3 E

GND 4 J04
(J-20)
1 9 8 10 (Pink)

H10
(S-16) 4

PW148-8 VEBM720100 20-669

20-670
Start
Swing lock – Normal operation

Does CM02 pin 5 have Does C01 pin 19 have good Is voltage between V03 Does V03 pin 2 have
Replace damaged YES YES Replace damaged YES YES Replace damaged
good connection with C01 connection with CM02 pin 1 and chassis good connection to
monitor panel (Pin 19 disconnected) Pin 5 disconnected
controller solenoid
normal? ground?

NO NO NO NO

Defective connector or Defective connector or Defective connector or Defective connector or

Does H15 pin 8 have good Is voltage between S43
YES disconnection in wiring disconnection in wiring YES disconnection in wiring disconnection in wiring YES
connection to CM02 pin 5 & pin 20 and chassis Correct pour ground
between CM02 pin 5 & H15 between CM02 pin 5 & H15 between C01 pin 19 & H15 between V03 pin 1 & X05
C01 pin 19 normal?
pin 8 pin 8 pin 8 pin 4

NO NO NO

Is voltage between S43

YES Replace damaged swing
pin 3 and chassis
Does S93 pin 5 have good NO lock switch
Correct pour ground normal?
c o n n e c t i o n t o g ro u n d ?

NO
YES
Defective connector or
Swing lock – Normal operation

Is voltage between D01

Is voltage between S93 pin disconnection in wiring YES
pin 3 and chassis
5&6 normal when switch is NO Replace damaged swing between S43 pin 3 and D01
pin 3 normal?
ON and not normal when lock switch X05
OFF?
NO
YES

Is voltage between D01

YES Replace damaged diode
pin 7 and chassis
block D01
Circuit OK normal?

NO

Defective connector or
Is voltage between C02
disconnection in wiring YES
pin 101 and chassis
between D01 pin 7 and C02
pi n 101 normal?

NO

Replace damaged
controller

PW148-8
TESTING AND ADJUSTING

VEBM720100
TESTING AND ADJUSTING Swing lock – Normal operation

Circuit diagram for swing lock

EMERGENCY SWING LOCK

SWING SWITCH SWITCH
1 2 3 4 5 6 1 2 3 4 5 6
OFF OFF
S22 (SWP-6)

S43 (SWP-6)
ON ON

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

1 2 3 4 5 6 1 2 3 4 5 6
D01 (KES-12)

H15 (090-20)
S28 (DT-12)

J10 (J-20)
(Orange)

8 9 10 11 8 9 11 12 13 19 20 8 10

8 9 10 11 3 7 11 12 13 19 20 8 10

CM02 (070-12)
5 PARK BRAKE PRESSURE SW.
L
C01 (AMP-81)
38 SWING EMERGENCY
19 SWING LOCK SWITCH
FB1
10A
1

A05 (SWP-16) V03 (DT-2)

E
5 5 1 1
2 2
SWING BRAKE
J04 (J-20)

1 4 4 3 SOLENOID
A02 (X-4)

A01 (X-4)
(Green)

A65
1 4 4 3

C02 (AMP-40)
101 SWING BRAKE SOLENOID

A64

PW148-8 VEBM720100 20-671

20-672
*Emergency swing switch is in ‘Emergency’ position
*Fuse No.1 (Fuse box 1) is not blown START

Change Does C01 Is voltage Does V03

YES YES YES Change
damaged Pin 38 have good between V03 Pin 2 have good
connection to Pin 1 & Chassis connection to damaged
controller solenoid
ground? normal? ground?
Swing lock – Emergency operation

NO NO NO
Defective Defective
connector or Does S22 Pin 6 have connector or Is voltage Correct poor
YES good connection to
disconnection in disconnection in YES between S43 ground
wiring between ground with wiring between Pin 5 & Chassis
C02 Pin 2 & emergency switch in V03 Pin 1 & normal?
S22 Pin 6 normal position. X05 Pin 4
NO
NO

Is voltage between Is voltage

between S43 YES Replace
Replace NO S22 Pin 6 & S22
damaged switch Pin 6 & Chassis damaged swing
Pin 5 normal with lock switch
S22 emergency switch normal?
in emergency
position NO

Defective
YES Is voltage YES connector or
between S22 disconnection in
Does S22 Pin 6
Swing lock – Emergency operation

Does S22 Pin 6 Pin 3 & Chassis wiring between

have good have good normal?
YES NO X05 Pin 3 &
connection to connection to
ground with Circuit OK S22 Pin 3
ground with NO
emergency switch in emergency switch in
emergency position normal position
Is voltage YES Replace
NO YES between S22 damaged switch
Pin 2 & Chassis S22
Replace damaged normal?
Correct poor
ground switch S22
NO

Defective
connector or

PW148-8
disconnection in
wiring between
S22 Pin 2 &
FB1 Pin 1
TESTING AND ADJUSTING

VEBM720100
TESTING AND ADJUSTING Swing lock – Emergency operation

Circuit diagram for swing lock

EMERGENCY SWING LOCK

SWING SWITCH SWITCH
1 2 3 4 5 6 1 2 3 4 5 6
OFF OFF
S22 (SWP-6)

S43 (SWP-6)
ON ON

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

1 2 3 4 5 6 1 2 3 4 5 6
D01 (KES-12)

H15 (090-20)
S28 (DT-12)

J10 (J-20)
(Orange)

8 9 10 11 8 9 11 12 13 19 20 8 10

8 9 10 11 3 7 11 12 13 19 20 8 10

CM02 (070-12)
5 PARK BRAKE PRESSURE SW.
L
C01 (AMP-81)
38 SWING EMERGENCY
19 SWING LOCK SWITCH
FB1
10A
1

A05 (SWP-16) V03 (DT-2)

E
5 5 1 1
2 2
SWING BRAKE
J04 (J-20)

1 4 4 3 SOLENOID
A02 (X-4)

A01 (X-4)
(Green)

A65
1 4 4 3

C02 (AMP-40)
101 SWING BRAKE SOLENOID

A64

PW148-8 VEBM720100 20-673

Neutral start (engine) TESTING AND ADJUSTING

Neutral start (engine)

*When Fuses No.3, 15, 17 (Fuse box 1) and fuse No. 1 (Fuse box 2) are not blown Start

*When travel emergency switch is set to Normal

*When FNR switch is set to Neutral
Is voltage between Does starter relay
*When LH pod is raised (PPC hydraulic lock switch) YES YES Replace damaged
A27 Pin 1 & body have good
*When personal code has been entered (if active) A chassis normal? connection to
ground
starter relay

NO NO
Defective
connector or
disconnection in YES Is voltage between Correct poor
wiring between R07Pin 3 & ground
A27 Pin 1 & chassis normal?
R07 Pin 3
NO

Replace damaged YES Is voltage between

relay R01 R07 Pin 6 &
chassis normal?

NO
Defective
Is voltage between YES connector or
R04 Pin 5 & disconnection in
chassis normal? wiring between
R04 Pin 5 &
NO R07 Pin 6

YES
Is voltage between
B R04 Pin 3 &
chassis normal?

NO
Defective
Is voltage between YES connector or
R06 Pin 3 & disconnection in
chassis normal? wiring between
R06 Pin 3 &
NO R04 Pin 3

YES Is voltage between

C R06 Pin 5 &
chassis normal?

NO
Defective
connector or
Is voltage between YES
disconnection in
H15 Pin 4 &
wiring between
chassis normal?
R06 Pin 5 &
NO H15 Pin 4

Is voltage between
YES H15 Pin 1 & Pin 4 YES Is voltage between
Replace Starter switch
normal with starter H15 Pin 1 &
switch in off position chassis normal?

NO NO

Circuit OK Defective
connector or
disconnection in
wiring between
H15 Pin 1 & FB1
Pin 17

20-674 PW148-8 VEBM720100

TESTING AND ADJUSTING Neutral start (engine)

Circuit diagram for neutral start (engine)

RELAY FOR STARTER CUT RELAY FOR STARTER CUT RELAY FOR STARTER CUT
(PERSONAL CODE) (TRAVEL NEUTRAL) RELAY FOR CM850 (1) RELAY FOR CM850 (2)
R07 R06 R04 R02 R03 STARTER SWITCH

B BR R1 R2 C ACC

R1

OFF
1 2 3 5 6 1 2 3 5 6 1 2 3 5 6 1 2 3 5 6 1 2 3 5 6
ACC
1 2 3 5 6 1 2 3 5 6 1 2 3 5 6 1 2 3 5 6 1 2 3 5 6
ST

HF

Y
H15
(090-22)
3 4 1 2 4

FB1
J08 J03
(J-20) 2 4 7 8 9 10 12 13 3
(090-20) 10A
(Black)

P02 (040-20) 17
20A
PERSONAL CODE 6
6 9 A07 FNR SWITCH
KEY SWITCH (C) 15 (SWP-16)
1 2 3 4
PPC HYDRAULIC LOCK A27
SWITCH (Tilting pod) 1 2 F
(X-2) FB2
1 2 3
N 1
5A
OFF (Pod down)
S R
ON (Pod up) R

STARTER E G70
S14
SAFETY (DT-6) 1 2 3 4
(M-3) 1 2 3
RELAY

EMERGENCY TRAVEL SWITCH

S96 1 2 3 4 5 6 7 8 9

NORMAL

EMERGENCY

S29
5 6 7 9 10 12 13 14 16 17 18 J02 (DT-12)
(J-20)
(Orange) 1

5
D01
(SWP-8) 6
C03 (DRC-40)
11 12 13 2
J04 61 TRAVEL F
(J-20) 6
(Pink)
42 TRAVEL N D02 (SWP-8)
2
23 TRAVEL R
4

E 6
60 KEY SWITCH (C)
H0
8
3 A01

97 TRAVEL F/R SOL

A08
11 14
(SWP-14)
A64
CE02 (DRC-50)
1
D04 33 GROUND
2 (SWP-8)

49 DARK CURRENT SIGNAL

1
D03
2 (SWP-8)

NEUTRAL START (ENGINE)

PW148-8 VEBM720100 20-675

Neutral start (engine) cont’d (A) TESTING AND ADJUSTING

Neutral start (engine) cont’d (A)

Is voltage Defective connector or

between R07 No disconnection in wiring
pin 1 & chassis between R07 pin 1 &
normal? FB1 pin 3

Yes

Does R07 pin 2 Does CM01 pin

have good No 14 have good No Replace
connection to connection to damaged
monitor
ground? ground?

Yes Yes

Is voltage Defective connector or

Circuit Yes between R07 disconnection in wiring
ok pin 2 & chassis between R07 pin 2 &
normal? CM01 pin 6

No

Replace
damaged relay
R07

20-676 PW148-8 VEBM720100

TESTING AND ADJUSTING Neutral start (engine) cont’d (A)

Circuit diagram for neutral start (engine)

RELAY FOR STARTER CUT RELAY FOR STARTER CUT RELAY FOR STARTER CUT
(PERSONAL CODE) (TRAVEL NEUTRAL) RELAY FOR CM850 (1) RELAY FOR CM850 (2)
R07 R06 R04 R02 R03 STARTER SWITCH

B BR R1 R2 C ACC

R1

OFF
1 2 3 5 6 1 2 3 5 6 1 2 3 5 6 1 2 3 5 6 1 2 3 5 6
ACC
1 2 3 5 6 1 2 3 5 6 1 2 3 5 6 1 2 3 5 6 1 2 3 5 6
ST

HF

Y
H15
(090-22)
3 4 1 2 4

FB1
J08 J03
(J-20) 2 4 7 8 9 10 12 13 3
(090-20) 10A
(Black)

P02 (040-20) 17
20A
PERSONAL CODE 6
6 9 A07 FNR SWITCH
KEY SWITCH (C) 15 (SWP-16)
1 2 3 4
PPC HYDRAULIC LOCK A27
SWITCH (Tilting pod) 1 2 F
(X-2) FB2
1 2 3
N 1
5A
OFF (Pod down)
S R
ON (Pod up) R

STARTER E G70
S14
SAFETY (DT-6) 1 2 3 4
(M-3) 1 2 3
RELAY

EMERGENCY TRAVEL SWITCH

S96 1 2 3 4 5 6 7 8 9

NORMAL

EMERGENCY

S29
5 6 7 9 10 12 13 14 16 17 18 J02 (DT-12)
(J-20)
(Orange) 1

5
D01
(SWP-8) 6
C03 (DRC-40)
11 12 13 2
J04 61 TRAVEL F
(J-20) 6
(Pink)
42 TRAVEL N D02 (SWP-8)
2
23 TRAVEL R
4

E 6
60 KEY SWITCH (C)
H0
8
3 A01

97 TRAVEL F/R SOL

A08
11 14
(SWP-14)
A64
CE02 (DRC-50)
1
D04 33 GROUND
2 (SWP-8)

49 DARK CURRENT SIGNAL

1
D03
2 (SWP-8)

NEUTRAL START (ENGINE)

PW148-8 VEBM720100 20-677

Neutral start (engine) cont’d (B) TESTING AND ADJUSTING

Neutral start (engine) cont’d (B)

Does R04 Pin 2

NO
Correct poor have good
ground connection to
ground?

YES

YES Is voltage between

Replace damaged
relay R22 R04 Pin 1 &
chassis normal?

NO
Defective
connector or
Is voltage between YES disconnection in
G71 Pin 4 &
wiring between
chassis normal?
R04 Pin 1 &
NO G71 Pin 4

Replace damaged YES Is voltage between

PPC lever (RH) G71 Pin 1 &
chassis normal?

NO
Defective
connector or
Is voltage between YES disconnection in
S29 Pin 1 & wiring between
chassis normal? G71 Pin 1 &
S29 Pin 1
NO

Replace damaged YES Is voltage between

emergency travel S29 Pin 2 &
switch S96 chassis normal?

NO

Defective
connector or
disconnection in
wiring between
S29 Pin 2 & FB2
Pin 1

20-678 PW148-8 VEBM720100

TESTING AND ADJUSTING Neutral start (engine) cont’d (B)

Circuit diagram for neutral start (engine)

RELAY FOR STARTER CUT RELAY FOR STARTER CUT RELAY FOR STARTER CUT
(PERSONAL CODE) (TRAVEL NEUTRAL) RELAY FOR CM850 (1) RELAY FOR CM850 (2)
R07 R06 R04 R02 R03 STARTER SWITCH

B BR R1 R2 C ACC

R1

OFF
1 2 3 5 6 1 2 3 5 6 1 2 3 5 6 1 2 3 5 6 1 2 3 5 6
ACC
1 2 3 5 6 1 2 3 5 6 1 2 3 5 6 1 2 3 5 6 1 2 3 5 6
ST

HF

Y
H15
(090-22)
3 4 1 2 4

FB1
J08 J03
(J-20) 2 4 7 8 9 10 12 13 3
(090-20) 10A
(Black)

P02 (040-20) 17
20A
PERSONAL CODE 6
6 9 A07 FNR SWITCH
KEY SWITCH (C) 15 (SWP-16)
1 2 3 4
PPC HYDRAULIC LOCK A27
SWITCH (Tilting pod) 1 2 F
(X-2) FB2
1 2 3
N 1
5A
OFF (Pod down)
S R
ON (Pod up) R

STARTER E G70
S14
SAFETY (DT-6) 1 2 3 4
(M-3) 1 2 3
RELAY

EMERGENCY TRAVEL SWITCH

S96 1 2 3 4 5 6 7 8 9

NORMAL

EMERGENCY

S29
5 6 7 9 10 12 13 14 16 17 18 J02 (DT-12)
(J-20)
(Orange) 1

5
D01
(SWP-8) 6
C03 (DRC-40)
11 12 13 2
J04 61 TRAVEL F
(J-20) 6
(Pink)
42 TRAVEL N D02 (SWP-8)
2
23 TRAVEL R
4

E 6
60 KEY SWITCH (C)
H0
8
3 A01

97 TRAVEL F/R SOL

A08
11 14
(SWP-14)
A64
CE02 (DRC-50)
1
D04 33 GROUND
2 (SWP-8)

49 DARK CURRENT SIGNAL

1
D03
2 (SWP-8)

NEUTRAL START (ENGINE)

PW148-8 VEBM720100 20-679

Neutral start (engine) cont’d (C) TESTING AND ADJUSTING

Neutral start (engine) cont’d (C)

Does R06 pin

2 have good No Correct
connection to poor ground
ground?

Yes

Is voltage
Replace
between R06 Yes
damaged
pin 1 & chassis relay R06
normal?

No

Is voltage Defective connector or

between S14 pin Yes disconnection in wiring
3 & chassis between S14 pin 3 &
normal? R06 pin 1

No

Is voltage
Yes Replace
between S14 pin
damaged lock
1 & chassis
switch S14
normal?

No

Defective connector or
disconnection in wiring
between FB1 pin 3 &
S14 pin 1

20-680 PW148-8 VEBM720100

TESTING AND ADJUSTING Neutral start (engine) cont’d (C)

Circuit diagram for neutral start (engine)

RELAY FOR STARTER CUT RELAY FOR STARTER CUT RELAY FOR STARTER CUT
(PERSONAL CODE) (TRAVEL NEUTRAL) RELAY FOR CM850 (1) RELAY FOR CM850 (2)
R07 R06 R04 R02 R03 STARTER SWITCH

B BR R1 R2 C ACC

R1

OFF
1 2 3 5 6 1 2 3 5 6 1 2 3 5 6 1 2 3 5 6 1 2 3 5 6
ACC
1 2 3 5 6 1 2 3 5 6 1 2 3 5 6 1 2 3 5 6 1 2 3 5 6
ST

HF

Y
H15
(090-22)
3 4 1 2 4

FB1
J08 J03
(J-20) 2 4 7 8 9 10 12 13 3
(090-20) 10A
(Black)

P02 (040-20) 17
20A
PERSONAL CODE 6
6 9 A07 FNR SWITCH
KEY SWITCH (C) 15 (SWP-16)
1 2 3 4
PPC HYDRAULIC LOCK A27
SWITCH (Tilting pod) 1 2 F
(X-2) FB2
1 2 3
N 1
5A
OFF (Pod down)
S R
ON (Pod up) R

STARTER E G70
S14
SAFETY (DT-6) 1 2 3 4
(M-3) 1 2 3
RELAY

EMERGENCY TRAVEL SWITCH

S96 1 2 3 4 5 6 7 8 9

NORMAL

EMERGENCY

S29
5 6 7 9 10 12 13 14 16 17 18 J02 (DT-12)
(J-20)
(Orange) 1

5
D01
(SWP-8) 6
C03 (DRC-40)
11 12 13 2
J04 61 TRAVEL F
(J-20) 6
(Pink)
42 TRAVEL N D02 (SWP-8)
2
23 TRAVEL R
4

E 6
60 KEY SWITCH (C)
H0
8
3 A01

97 TRAVEL F/R SOL

A08
11 14
(SWP-14)
A64
CE02 (DRC-50)
1
D04 33 GROUND
2 (SWP-8)

49 DARK CURRENT SIGNAL

1
D03
2 (SWP-8)

NEUTRAL START (ENGINE)

PW148-8 VEBM720100 20-681

Emergency travel control – Forward TESTING AND ADJUSTING

Emergency travel control – Forward

* When fuse no. 1 (Fuse Box 2) is not blown

* When emergency travel switch is set to "Emergency" Start

* When emergency FNR switch is set to "F"

Does V06 pin 2 have Is voltage between V06

NO NO
Connect poor ground good connection to pin 1 and chassis
ground? normal?

YES YES

Defective connector or
Is voltage between S95
Replace damaged NO disconnection in wiring
pin 4 and chassis
solenoid V06 between S95 pin 4 and V06
normal? pin 1

YES

Is voltage between S95 Replace damaged

NO
pin 5 and chassis emergency FNR switch
normal? S95

YES

Defective connector or
Is voltage between S96 NO disconnection in wiring
pin 1 & chassis normal? between S96 pin 1 & S95
pin 5

YES

Replace damaged
Is voltage between S96 NO
emergency travel switch
pin 2 & chassis normal?
S96

YES

Defective connector or
disconnection between
S96 pin 2 and FB2 pin 1

20-682 PW148-8 VEBM720100

TESTING AND ADJUSTING Emergency travel control – Forward

Circuit diagram for travel direction control

Emergency FNR switch

S95 (DTAX-6)

Emergency
Travel SW F
FNR SW. Emergency N
S96
Normal R
F

N
R

G72 S29
(DT-12) (DT-12)

R04 R16

J04
(Green)
11 12 15
(090-20)

FB2
J
5A
A01
(X-4)

Fuse
Box 2
A64

A05
J02 (J-20) (Orange) (SWP-16)

D03
(KES1-2)
2
1

D04
(KES1-2)
2
1

A07
(SWP-16) C01 (AMP-81)
23 Travel R
36 Travel R Pressure SW.
42 Travel N

55 Travel F Pressure SW.

61 Travel F

C02 (AMP-40)
97 Travel F/R Sol.
105 Travel N Sol.

V08
Travel F/R Sw. (DT-2)
A06
(SWP-16)

(OFF) (ON)
Travel Reverse
Press. SW.
S09
(X-2)
V06
Travel Neutral Sw. (DT-2)

Travel Forward
Press. SW.
(OFF) (ON) S10
(X-2)

A53
Backup Alarm (DT-2)

A65

PW148-8 VEBM720100 20-683

Emergency travel control – Neutral TESTING AND ADJUSTING

Emergency travel control – Neutral

*When Fuse No. 1 (Fuse box 2) is not blown

When emergency travel switch is set to ‘Emergency’ Start

*When emergency FNR switch is set to ‘N’

Is voltage
Go to ‘Neutral No between R04
Start’ section on
Pin 1 & Chassis
fault finding
normal?
Yes
Defective
Is voltage connector or
between S95 No disconnection in
Pin 1 & Chassis wiring between
normal? R04 Pin 1 &
Yes S95 Pin 1

Replace Is voltage
damaged No between S95
emergency FNR Pin 5 & Chassis
switch S95 normal?
Yes
Defective
Is voltage connector or
between S96 Yes disconnection in
Pin 1 & Chassis wiring between
normal? S96 Pin 1 &
Yes S95 Pin

Is voltage
Replace damaged No
between S96
emergency travel
Pin 2 & Chassis
switch S95
normal?
Yes

Defective
connector or
disconnection in
wiring between
S95 Pin 2 &
FB2 Pin 1

20-684 PW148-8 VEBM720100

TESTING AND ADJUSTING Emergency travel control – Neutral

Circuit diagram for travel direction control

Emergency FNR switch

S95 (DTAX-6)

Emergency
Travel SW F
FNR SW. Emergency N
S96
Normal R
F

N
R

G72 S29
(DT-12) (DT-12)

R04 R16

J04
(Green)
11 12 15
(090-20)

FB2
J
5A
A01
(X-4)

Fuse
Box 2
A64

A05
J02 (J-20) (Orange) (SWP-16)

D03
(KES1-2)
2
1

D04
(KES1-2)
2
1

A07
(SWP-16) C01 (AMP-81)
23 Travel R
36 Travel R Pressure SW.
42 Travel N

55 Travel F Pressure SW.

61 Travel F

C02 (AMP-40)
97 Travel F/R Sol.
105 Travel N Sol.

V08
Travel F/R Sw. (DT-2)
A06
(SWP-16)

(OFF) (ON)
Travel Reverse
Press. SW.
S09
(X-2)
V06
Travel Neutral Sw. (DT-2)

Travel Forward
Press. SW.
(OFF) (ON) S10
(X-2)

A53
Backup Alarm (DT-2)

A65

PW148-8 VEBM720100 20-685

Emergency travel control – Reverse TESTING AND ADJUSTING

Emergency travel control – Reverse

*When Fuse No. 1 (Fuse box 2) is not blown Replace

*When emergency travel switch is set to ‘Emergency’ damaged
Start solenoid
*When emergency FNR switch is set to ‘R’
Yes

Is voltage Does V06

Replace Does travel No Yes No
between V06 Pin 2 have good Correct poor
damaged neutral sol.
Pin 1 & Chassis connection to ground
solenoid V08 Operate correctly
normal? ground?
Yes Yes
No
Does V08 Is voltage Defective connector
Correct poor No Pin 2 have good Yes between V08 Is voltage
between D04 No or disconnection in
ground connection to Pin 1 & Chassis wiring between
ground? normal? Pin 1 & Chassis
D04 Pin 4 & V06
normal?
No Pin 1
Defective connector No
Is voltage
or disconnection in No Is voltage
between D02 Replace
wiring between between D04 Yes
Pin 2 & Chassis damaged
D04 Pin 2 & V08 Pin 2 & Chassis
normal? diode D04
Pin 1 normal?
Yes

Is voltage
Replace No between D02
damaged
Pin 6 & Chassis
diode D03 normal?
No No
Defective connector
Is voltage
or disconnection in Yes between S96
wiring between
Pin 1 & Chassis
S96 Pin 1 & J02
normal?
Pin 4 and Pin 6
Yes

Is voltage
between S96 Yes Replace damaged
emergency travel
Pin 2 & Chassis
switch S96
normal?
No

Defective connector
or disconnection in
wiring between
S96 Pin 2 & FB2
Pin 1

20-686 PW148-8 VEBM720100

TESTING AND ADJUSTING Emergency travel control – Reverse

Circuit diagram for travel direction control

Emergency FNR switch

S95 (DTAX-6)

Emergency
Travel SW F
FNR SW. Emergency N
S96
Normal R
F

N
R

G72 S29
(DT-12) (DT-12)

R04 R16

J04
(Green)
11 12 15
(090-20)

FB2
J
5A
A01
(X-4)

Fuse
Box 2
A64

A05
J02 (J-20) (Orange) (SWP-16)

D03
(KES1-2)
2
1

D04
(KES1-2)
2
1

A07
(SWP-16) C01 (AMP-81)
23 Travel R
36 Travel R Pressure SW.
42 Travel N

55 Travel F Pressure SW.

61 Travel F

C02 (AMP-40)
97 Travel F/R Sol.
105 Travel N Sol.

V08
Travel F/R Sw. (DT-2)
A06
(SWP-16)

(OFF) (ON)
Travel Reverse
Press. SW.
S09
(X-2)
V06
Travel Neutral Sw. (DT-2)

Travel Forward
Press. SW.
(OFF) (ON) S10
(X-2)

A53
Backup Alarm (DT-2)

A65

PW148-8 VEBM720100 20-687

Driving lights – Main beam TESTING AND ADJUSTING

Driving lights – Main beam

*Standard notes
*When fuse No.15 & 19 (Fuse box 2) are not blown
*When bulbs are fitted correctly and fully functional

Correct poor
Start
ground

No

Yes Does L01 Pin 1 Yes Is voltage between No

Replace damaged have good Does front left main
G13 Pin 3 & Correct poor
lamp unit connection to beam work?
chassis normal? ground
ground?
No No
Yes
Defective
connector or
Yes Is voltage between Does L02 Pin 1
disconnection in No Is voltage between Yes Yes
FB2 Pin 19 & Does front right have good
wiring between L02 Pin 3 & Replace damaged
chassis normal? main beam work? connection to
FB2 Pin 19 & G13 chassis normal? lamp unit
Pin 3 or G12 Pin3 ground?
No
No

Replace damaged Yes Is voltage between

FB2 Pin 39 &
Fuse box 2 FB2
chassis normal?

No
Defective
connector or
Yes Is voltage between
disconnection in
G4 Pin 5 &
wiring between
chassis normal?
FB2 Pin 39 & G4
Pin 5 No

Replace damaged Yes Is voltage between

main beam switch G4 Pin 3 &
chassis normal?

No

Defective
connector or
Yes Is voltage between
disconnection in
G105 Pin 3 &
wiring between
chassis normal?
G105 Pin 3 &
G4 Pin 3
No

Replace damaged road Yes Is voltage between

lights switch G105 G105 Pin 5 &
chassis normal?

No

Defective
connector or
disconnection in
wiring between
G105 Pin 5 &
FB2 Pin 11

20-688 PW148-8 VEBM720100

 HIGH BEAM
INDICATOR

PW148-8
1 2
G103

ROAD LIGHTS MAIN BEAMS

+ 1 2 3 4 30 56 56B 56A
G105

OFF DIPPED BEAM

POSITION MAIN BEAM

TESTING AND ADJUSTING

DIPPED FLASH

VEBM720100
5 1 2 3 4

2 3 4 5

G4
C

2 3 4 12 14 15 16 17 J07 6 9 10 11 9 10 11 12 STEERING COLUMN

(J-20)

G05
(DT-12)
(Black)

G02
(SWP-14)
Circuit diagram for driving lights

3 13 14

A08
(SWP-8)
A07
(SWP-16)

15 G51
ENGINE ROOM LAMP (OPT)
1

A05
(SWP-16)
A86
1

FB2 4
20A G12 L04
15 2
(DT-6) (DT-4)
RH REAR SIDE LIGHT
4 3
SIDE LIGHT
A91
3 A04
(DT-2)
(DT-6)
15A 1 2 2

RIGHT
G10
39 19 R.H MAIN BEAM 2 LICENCE PLATE LIGHT
B (X-2)
2 1 1
ARM DIPPED BEAM 3
MARKER
5A LAMPS 6
16 G13
36 (DT-6) 3
L.H DIPPED BEAM 10 LH REAR SIDE LIGHT
1 2
MAIN BEAM L03
15A (DT-4)
18
LEFT 2
38
3 A65
SIDE LIGHT
5A 4 DRIVING LIGHTS
37 17

20-689
Driving lights – Main beam
Driving lights – Main beam flash TESTING AND ADJUSTING

Driving lights – Main beam flash

*Standard notes
*When fuse No.15 & 19 (Fuse box 2) are not blown
*When bulbs are fitted correctly and fully functional

Correct poor
Start
ground

No

Yes Does L01 Pin 1 Yes Is voltage between No

Replace damaged have good Does front left main
G13 Pin 3 & Correct poor
lamp unit connection to beam work?
chassis normal? ground
ground?
No No
Yes

Defective No Yes Does L02 Pin 1 Yes

Does front right Is voltage between
connector or have good Replace damaged
main beam work? L02 Pin 3 &
disconnection in Yes Is voltage between connection to lamp unit
chassis normal?
wiring between FB2 Pin 19 & ground?
FB2 Pin 19 & chassis normal?
L01 Pin 3 or L02 No
Pin 3 No

Replace damaged Yes Is voltage between

Fuse box 2 FB2 FB2 Pin 39 &
chassis normal?

No

Defective
connector or
Yes Is voltage between
disconnection in
G4 Pin 5 &
wiring between
chassis normal?
FB2 Pin 39 &
G4 Pin 5 No

Replace damaged Yes Is voltage between

main beam (flash) G4 Pin 2 &
switch chassis normal?

No

Defective
connector or
disconnection in
wiring between
G4 Pin 2 &
FB2 Pin 11

20-690 PW148-8 VEBM720100

 HIGH BEAM
INDICATOR

PW148-8
1 2
G103

ROAD LIGHTS MAIN BEAMS

+ 1 2 3 4 30 56 56B 56A
G105

OFF DIPPED BEAM

POSITION MAIN BEAM

TESTING AND ADJUSTING

DIPPED FLASH

VEBM720100
5 1 2 3 4

2 3 4 5

G4
C

2 3 4 12 14 15 16 17 J07 6 9 10 11 9 10 11 12 STEERING COLUMN

(J-20)

G05
(DT-12)
(Black)

G02
(SWP-14)
Circuit diagram for driving lights

3 13 14

A08
(SWP-8)
A07
(SWP-16)

15 G51
ENGINE ROOM LAMP (OPT)
1

A05
(SWP-16)
A86
1

FB2 4
20A G12 L04
15 2
(DT-6) (DT-4)
RH REAR SIDE LIGHT
4 3
SIDE LIGHT
A91
3 A04
(DT-2)
(DT-6)
15A 1 2 2

RIGHT
G10
39 19 R.H MAIN BEAM 2 LICENCE PLATE LIGHT
B (X-2)
2 1 1
ARM DIPPED BEAM 3
MARKER
5A LAMPS 6
16 G13
36 (DT-6) 3
L.H DIPPED BEAM 10 LH REAR SIDE LIGHT
1 2
MAIN BEAM L03
15A (DT-4)
2
LEFT
38 18

3 A65
SIDE LIGHT
5A 4 DRIVING LIGHTS
37 17
Driving lights – Main beam flash

20-691
Driving lights – Main beam dipped TESTING AND ADJUSTING

Driving lights – Main beam dipped

*When Fuse No.15 & 18 (Fuse box 2) are not blown

*When bulbs are fully functional & fitted correctly
Start

Correct poor
ground

No

Does L01 Pin Yes

No Is voltage between Yes 1 have good Replace damaged
Correct poor Does front left L01 Pin 2 &
ground dipped beam work? connection to lamp unit
chassis normal? ground?
Yes
No

Does L02 Pin

Yes 1 have good Yes Is voltage between No
Replace damaged Does front right
connection to L02 Pin 2 & No
lamp unit dipped beam work?
ground? chassis normal?

No

Defective connector or
disconnection in wiring Yes Is voltage between
between FB2 Pin 18 & FB2 Pin 18 &
G13 Pin 2 or G12 Pin 2 chassis normal?

No

Yes Is voltage between

Replace damaged
fuse box 2 FB2 FB2 Pin 38 &
chassis normal?

No

Defective connector or
Yes Is voltage between
disconnection in wiring
G4 Pin 4 &
between FB2 Pin 38 &
chassis normal?
G4 Pin 4
No

Replace damaged Yes Is voltage between

main beam G4 Pin 3 &
switch chassis normal?

No
Defective connector
or disconnection in Yes Is voltage between
wiring between G105 Pin 3 &
G4 Pin 3 & chassis normal?
G105 Pin 3
No

Replace damaged Is voltage between

Yes
road lights switch G105 Pin 5 &
G105 chassis normal?

No

Defective connector
or disconnection in
wiring between
G105 Pin 5 & FB2
Pin 15

20-692 PW148-8 VEBM720100

 HIGH BEAM
INDICATOR

PW148-8
1 2
G103

ROAD LIGHTS MAIN BEAMS

+ 1 2 3 4 30 56 56B 56A
G105

OFF DIPPED BEAM

POSITION MAIN BEAM

TESTING AND ADJUSTING

DIPPED FLASH

VEBM720100
5 1 2 3 4

2 3 4 5

G4
C

2 3 4 12 14 15 16 17 J07 6 9 10 11 9 10 11 12 STEERING COLUMN

(J-20)

G05
(DT-12)
(Black)

G02
(SWP-14)
Circuit diagram for driving lights

3 13 14

A08
(SWP-8)
A07
(SWP-16)

15 G51
ENGINE ROOM LAMP (OPT)
1

A05
(SWP-16)
A86
1

FB2 4
20A G12 L04
15 2
(DT-6) (DT-4)
RH REAR SIDE LIGHT
4 3
SIDE LIGHT
A91
3 A04
(DT-2)
(DT-6)
15A 1 2 2

RIGHT
G10
39 19 R.H MAIN BEAM 2 LICENCE PLATE LIGHT
B (X-2)
2 1 1
ARM DIPPED BEAM 3
MARKER
5A LAMPS 6
16 G13
36 (DT-6) 3
L.H DIPPED BEAM 10 LH REAR SIDE LIGHT
1 2
MAIN BEAM L03
15A (DT-4)
18
LEFT 2
38
3 A65
SIDE LIGHT
5A 4 DRIVING LIGHTS
37 17
Driving lights – Main beam dipped

20-693
Driving lights – Position lights TESTING AND ADJUSTING

Driving lights – Position lights

*When fuse No.15 & 16 (Fuse box 2) are not blown

*When bulbs are fitted correctly and fully functional

Correct poor
Start ground

No

No Yes Does L01 Pin 1 Yes

Correct poor Does front left Is voltage between have good Replace damaged
ground sidelight work? L01 Pin 4 & connection to lamp unit
chassis normal? ground?
Yes
No
No

Yes Does L02 Pin 1 Yes

Replace damaged have good No Defective
lamp unit connection to Is voltage between Yes connector or
Does front right Is voltage between
ground? L02 Pin 4 & disconnection in
sidelight work? FB2 Pin 16 &
chassis normal? wiring between
chassis normal?
L01 Pin 4 &
No Yes FB2 Pin 16
No

Defective
connector or Yes Is voltage between
disconnection in 1
FB2 Pin 16 &
wiring between
chassis normal?
L02 Pin 4 &
FB2 Pin 16
No

Correct poor
ground

1 No

No Yes Does G8 Pin 2 Yes

Is voltage between have good
Does rear right Replace damaged
Correct poor G8 Pin 3 & connection to
sidelight work? lamp unit
ground chassis normal? ground?

No
No

Does L03 Pin 2 Defective

Yes Yes Is voltage between connector or
Replace damaged have good Does rear left
L03 Pin 3 & Is voltage between Yes
lamp unit connection to disconnection in
chassis normal? sidelight work? FB2 Pin 17 & wiring between
ground?
chassis normal? L04 Pin 3 & FB2
No Pin 17
No
Defective
connector or Yes Is voltage between
disconnection in
FB2 Pin 17 &
wiring between
chassis normal? 2
L03 Pin 3 & FB2
Pin 17
No

Correct poor
ground

2 No

Does G51
No Is voltage between Yes have good Yes
Does engine room connection to Replace damaged
G51 Pin 1 &
lamp work? ground when lamp unit
Correct poor chassis normal?
switched on?
ground Yes
No
No

Defective
Yes Does G10 Pin 2 have Yes Is voltage between No connector or
Replace damaged
good connection to G10 Pin 1 & Does license plate Yes disconnection in
lamp unit Is voltage between
ground chassis normal? light work? wiring between
FB2 Pin 16 &
chassis normal? G51 Pin 1 &
No FB2 Pin 16
No
Defective
connector or Yes Is voltage between
disconnection in
FB2 Pin 17 &
wiring between
chassis normal? 2
1
G10 Pin 1 &
FB2 Pin 17
No

20-694 PW148-8 VEBM720100

TESTING AND ADJUSTING Driving lights – Position lights

Driving lights - Position lights cont’d (1) and (2)

2 1

Yes Is voltage between Is voltage between Yes

Replace damaged Replace damaged
FB2 Pin 37 & FB2 Pin 36 & fuse box FB2
fuse box FB2
chassis normal? chassis normal?

No

Defective
connector or
Is voltage between Yes
disconnection in
G105 Pin 1 &
wiring between
chassis normal?
FB2 Pin 36, G105
Pin 1 & FB2 Pin 37
No

Is voltage between Yes

Replace damaged
G105 Pin 5 & roads light sw G105
chassis normal?

No

Defective
connector or
disconnection in
wiring between
FB2 Pin 15 &
G105 Pin 5

PW148-8 VEBM720100 20-695

 HIGH BEAM
INDICATOR

20-696
1 2
G103

ROAD LIGHTS MAIN BEAMS

+ 1 2 3 4 30 56 56B 56A
G105

OFF DIPPED BEAM

POSITION MAIN BEAM

Driving lights – Position lights

DIPPED FLASH

5 1 2 3 4

2 3 4 5

G4
C

2 3 4 12 14 15 16 17 J07 6 9 10 11 9 10 11 12 STEERING COLUMN

(J-20)

G05
(DT-12)
(Black)

G02
(SWP-14)
Circuit diagram for driving lights

3 13 14

A08
(SWP-8)
A07
(SWP-16)

15 G51
ENGINE ROOM LAMP (OPT)
1

A05
(SWP-16)
A86
1

FB2 4
20A G12 L04
15 2
(DT-6) (DT-4)
RH REAR SIDE LIGHT
4 3
SIDE LIGHT
A91
3 A04
(DT-2)
(DT-6)
15A 1 2 2

RIGHT
G10
39 19 R.H MAIN BEAM 2 LICENCE PLATE LIGHT
B (X-2)
2 1 1
ARM DIPPED BEAM 3
MARKER
5A LAMPS 6
16 G13
36 (DT-6) 3

PW148-8
L.H DIPPED BEAM 10 LH REAR SIDE LIGHT
1 2
MAIN BEAM L03
15A (DT-4)
2

LEFT
38 18

3 A65
SIDE LIGHT
5A 4 DRIVING LIGHTS
37 17
TESTING AND ADJUSTING

VEBM720100
TESTING AND ADJUSTING Driving lights – Position lights

Blank for technical reason

PW148-8 VEBM720100 20-697

Indicators – Right hand TESTING AND ADJUSTING

Indicators – Right hand

*When Fuse No. 9 (Fuse box 1) is not blown

*When bulbs are fitted correctly and fully functional
Correct poor
ground
Start
No
Correct poor Is voltage between Does L02 Pin 6 Replace
ground Does front right No Yes Yes
L02 Pin 5 & Chassis have good connection to damaged lamp
indicator work?
No normal? ground? unit
Yes
No
Does L04 Pin Is voltage
Replace Yes Yes No
2 have good between L04 Does rear right
damaged lamp Defective connector or
connection to Pin 1 & Chassis indicator work? Is voltage between
unit Yes disconnection in wiring
ground? normal? G03 Pin 2 & Chassis
between L02 Pin 5
No normal?
& G03 Pin 2
Defective No
connector or Is voltage
Yes
disconnection in between G03
wiring between Pin 2 & Chassis
L04 Pin 1 & normal?
G03 Pin 2
No

Replace
Yes Is voltage between
damaged
G03 Pin 5 &
indicator stalk
Chassis normal?
switch
No
Defective connector
Is voltage between Yes or disconnection in
F01 Pin 4 & wiring between
Chassis normal? G03 Pin 5 & F01
Pin 4
No
Is voltage between Yes Replace damaged
F01 Pin 3 &
flasher unit
Chassis normal?
No
Defective connector
or disconnection in Yes Is voltage between
wiring between S92 Pin 4 &
F01 Pin 3 & S92 Chassis normal?
Pin 4
No

Is voltage between Yes Replace

S42 Pin 3 & damaged Hazard
Chassis normal? switch S92

No

Defective connector
or disconnection in
wiring between
S92 Pin 3 & FB1
Pin 9

20-698 PW148-8 VEBM720100

 TELL-TALE INDICATORS
INDICATOR SWITCH
INDICATOR HIGH BEAM
HAZARD HAZARD 45A L RIGHT/LEFT INDICATOR
R
POWER SWITCHING

HAZARD SWITCH LEFT

NEUTRAL

PW148-8
1 2 3 4 5 6

OFF RIGHT 1 2 1 2

G101
G103
ON G03 S 3 2

R18
R19
1 2 3 4 5 6 1 2 3 4 5 6
1 2 3 4 5 6

S42
TESTING AND ADJUSTING

VEBM720100
8
1 G05 (DT-12) 1 2 5 6 8 12

J09 (J-20)
(Pink)
P

H15 (090-22) 10 13 18 21 22 H14 (090-16) 1 D05 7 3

F01 (KEAS1-4)

A64 FLASHER UNIT J05 (J-20)

G02 (SWP-14) 4 5 6 12 (Pink) 1 5 16 17 18
L B E
4 3 2 1
FB1
10A
18

15A
9
A02
(X-4) 4 3

FB2
A07 (SWP-16) 11 10
15A
39
6 1
L02 L04
(DT-6) (DT-4)
5 2
Circuit diagram for indicators & hazard warning

5 1
L01 L03
(DT-6) (DT-4)
6 2

FRONT REAR
INDICATOR A64 INDICATOR
LIGHTS LIGHTS

J08 (J-20)
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
(Black)
Indicators – Right hand

20-699
Indicators – Left hand TESTING AND ADJUSTING

Indicators – Left hand

*When Fuse No. 9 (Fuse box 1) is not blown Correct poor

*When bulbs are fitted correctly and fully functional ground
Start
No
Correct poor Is voltage between Does L01 Pin 6 Replace
Does front left No Yes Yes
ground L01 Pin 5 & Chassis have good connection to damaged lamp
indicator work?
No normal? ground? unit
Yes
Does L03 Pin Is voltage No
Replace Yes Yes No
2 have good between L03 Does rear left
damaged lamp Defective connector or
connection to Pin 1 & Chassis indicator work? Is voltage between Yes
unit disconnection in wiring
ground? normal? G03 Pin 3 & Chassis
between L01 Pin 5
normal?
No & G3 Pin 3
Defective
Is voltage No
connector or
disconnection in Yes between G03
wiring between Pin 3 & Chassis
L03 Pin 1 & normal?
G03 Pin 3
No

Replace
Yes Is voltage between
damaged
G03 Pin 5 &
indicator stalk
Chassis normal?
switch

No
Defective connector
Is voltage between Yes or disconnection in
F01 Pin 4 & wiring between
Chassis normal? G03 Pin 5 & F01
Pin 4
No
Is voltage between Yes Replace damaged
F01 Pin 3 &
flasher unit
Chassis normal?
No
Defective connector
or disconnection in Yes Is voltage between
wiring between S42 Pin 4
F01 Pin 3 & Chassis normal?
S42 Pin 4
No

Is voltage between Yes Replace

S42 Pin 3 & damaged Hazard
Chassis normal? switch S42

No

Defective connector
or disconnection in
wiring between
S42 Pin 3 & FB1
Pin 9

20-700 PW148-8 VEBM720100

 TELL-TALE INDICATORS
INDICATOR SWITCH
INDICATOR HIGH BEAM
HAZARD HAZARD 45A L RIGHT/LEFT INDICATOR
R
POWER SWITCHING

HAZARD SWITCH LEFT

NEUTRAL

PW148-8
1 2 3 4 5 6

OFF RIGHT 1 2 1 2

G101
G103
ON G03 S 3 2

R18
R19
1 2 3 4 5 6 1 2 3 4 5 6
1 2 3 4 5 6

S42
TESTING AND ADJUSTING

VEBM720100
8
1 G05 (DT-12) 1 2 5 6 8 12

J09 (J-20)
(Pink)
P

H15 (090-22) 10 13 18 21 22 H14 (090-16) 1 D05 7 3

F01 (KEAS1-4)

A64 FLASHER UNIT J05 (J-20)

G02 (SWP-14) 4 5 6 12 (Pink) 1 5 16 17 18
L B E
4 3 2 1
FB1
10A
18

15A
9
A02
(X-4) 4 3

FB2
A07 (SWP-16) 11 10
15A
39
6 1
L02 L04
(DT-6) (DT-4)
5 2
Circuit diagram for indicators & hazard warning

5 1
L01 L03
(DT-6) (DT-4)
6 2

FRONT REAR
INDICATOR A64 INDICATOR
LIGHTS LIGHTS

J08 (J-20)
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
(Black)
Indicators – Left hand

20-701
20-702
Start

Does front right indicator No Is voltage between L02 pin Yes Does L02 pin 6 have good Yes
Hazard warning lights

Replace damaged lamp unit

work? 5 and chassis normal? connection to ground?

Yes No No

Does L04 pin 2 have Is voltage between L04 Is voltage between R19
Replace damaged lamp Yes Yes No Does rear right indicator
good connection to pin 1 and chassis pin 4 and chassis Correct poor ground
unit work?
ground? normal? normal?

No No Yes

Defective connector or
Is voltage between R19
No Is voltage between S42 pin Yes disconnection in wiring
Correct poor ground pin 2 and chassis
6 and chassis normal? between S42 pin 5 and FB1
Hazard warning lights

normal? pin 18

Yes

Defective connector or
Is voltage between L01
Replace damaged Does front left indicator No Yes disconnection in wiring Yes Replace damaged lamp
pin 5 and chassis
hazard relay R19 work? between S42 pin 5 and FB1 unit.
normal? pin 18

Yes No No

Replace damaged lamp Yes Does L03 pin 2 have good Yes Is voltage between L03 pin No Does rear left indicator
Correct poor ground
unit. connection to ground? 1 and chassis normal? work?

No

Is voltage between R19

Replace damged hazard Yes Is voltage between R19 pin No Yes Replace damged hazard
pin 4 and chassis
relay R19 2 & chassis normal? relay R19
normal?

No

Defective connector or
Is voltage between S42
Yes disconnection in wiring
pin 6 and chassis
between S42 pin 5 and FB1
normal? pin 18

No

Is voltage between R18

PW148-8
Yes Replace damaged
pin 5 and chassis
hazard power relay R18
normal?

A
TESTING AND ADJUSTING

VEBM720100
TESTING AND ADJUSTING Hazard warning lights cont’d (A)

Hazard warning lights cont’d (A)

Is voltage between S42 Is voltage between S42

Yes
pin 5 and chassis pin 5 and chassis
normal? normal?

No

Defective connector or
Is voltage between F01
Yes disconnection in wiring
pin 4 and chassis
between F01 pin 4 and R19
normal? pin 1 and pin 3

No

Is voltage between F01

Yes Replace damaged
pin 3 and chassis
flasher unit F01
normal?

No

Defective connector or
disconnection in wiring
between F01 pin 3 and R18
pin 2

PW148-8 VEBM720100 20-703

 TELL-TALE INDICATORS
INDICATOR SWITCH
INDICATOR HIGH BEAM
HAZARD HAZARD 45A L RIGHT/LEFT INDICATOR
R
POWER SWITCHING

20-704
HAZARD SWITCH LEFT

1 2 3 4 5 6 NEUTRAL

OFF RIGHT 1 2 1 2

G101
G103
ON G03 S 3 2

R18
R19
1 2 3 4 5 6 1 2 3 4 5 6
1 2 3 4 5 6

S42
9
Hazard warning lights cont’d (A)

8
1 G05 (DT-12) 1 2 5 6 8 12

J09 (J-20)
(Pink)
P

H15 (090-22) 10 13 18 21 22 H14 (090-16) 1 D05 7 3

F01 (KEAS1-4)

A64 FLASHER UNIT J05 (J-20)

G02 (SWP-14) 4 5 6 12 (Pink) 1 5 16 17 18
L B E
4 3 2 1
FB1
10A
18

15A
9
A02
(X-4) 4 3

FB2
A07 (SWP-16) 11 10
15A
39
6 1
L02 L04
(DT-6) (DT-4)
5 2
Circuit diagram for indicators & hazard warning

5 1
L01 L03
(DT-6) (DT-4)
6 2

FRONT REAR
INDICATOR A64 INDICATOR
LIGHTS LIGHTS

J08 (J-20)
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
(Black)

PW148-8
TESTING AND ADJUSTING

VEBM720100
TESTING AND ADJUSTING Hazard warning lights cont’d (A)

Blank for technical reason

PW148-8 VEBM720100 20-705

Swing lock proximity switch TESTING AND ADJUSTING

Swing lock proximity switch

*With machine upper structure locked in the travel position

Start

Is Voltage between No Is Voltage between No Replace

A90 Pin 1 & chassis C01 Pin 28 & chassis damaged
normal normal controller

Yes

Defective connector or
Yes
disconnection in wiring
between C01 Pin 28 &
A90 Pin 1

Is Voltage between No Is Voltage between No Replace

A90 Pin 2 & chassis C01 Pin 72 & damaged
normal chassis normal controller
Yes

Defective connector or
Yes
disconnection in wiring
between C01 Pin 12 &
A90 Pin 2

Is Voltage between No Replace damaged

A90 Pin 3 & chassis proximity switch A90
normal
Yes

Does A90 Pin 3 have No Does C01 Pin 47 have No Replace

a good ground a good ground damaged
connection connection controller
Yes Yes

Circuit OK Defective connector or

disconnection in wiring
between C01 Pin 47 &
A90 Pin 3

20-706 PW148-8 VEBM720100

TESTING AND ADJUSTING Swing lock proximity switch

Brake and swing lock proximity switches

Main Controller

C01 (DRC-24)
47 GND (Sig)

28 Power (+24V) sensor

72 Swing Proximity

A06 A08
(SWP-16) (SWP-8)
3 13 8

A90
(DT-3) 2 3
1

Swing Proximity Switch

PW148-8 VEBM720100 20-707

Swing lock proximity switch TESTING AND ADJUSTING

Blank for technical reason

20-707 PW148-8 VEBM720100

 20 TESTING AND ADJUSTING

Troubleshooting of hydraulic and mechanical system

(H-MODE)
Troubleshooting of hydraulic and mechanical system (H-MODE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-711
System chart for hydraulic and mechanical systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-713
Information contained in troubleshooting table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-717
H-1 – All work equipment lacks power, or travel and swing speeds are slow . . . . . . . . . . . . . . . . . . 20-718
H-2 – Engine speed sharply drops or engine stalls. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-719
H-3 – No work equipment, travel or swing move . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-720
H-4 – Abnormal noise is heard from around hydraulic pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-720
H-5 – Auto-decelerator does not work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-721
H-6 – Fine control mode does not function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-721
H-7 – Boom moves slowly or lacks power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-722
H-8 – Arm moves slowly or lacks power. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-723
H-9 – Bucket moves slowly or lacks power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-724
H-10 – Work equipment does not move in its single operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-724
H-11 – Work equipment hydraulic drift is too fast . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-725
H-12 – Work equipment has big time lag . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-726
H-13 – Other work equipment moves when relieving single circuit. . . . . . . . . . . . . . . . . . . . . . . . . . . 20-726
H-14 – One-touch power max. switch does not operate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-727
H-15 – In compound operation, work equipment with larger load moves slowly. . . . . . . . . . . . . . . . 20-727
H-16 – In swing + boom RAISE operation, boom moves slowly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-727
H-17 – In swing + travel, travel speed drops sharply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-728
H-18 – Travel speed does not switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-729
H-19 – Travel speed does not shift, or it is too slow or fast . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-730
H-20 – Machine does not swing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-731
H-21 – Swing acceleration is poor, or swing speed is slow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-732
H-22 – Excessive overrun when stopping swing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-733
H-23 – There is big shock when stopping swing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-734
H-24 – There is loud abnormal noise caused when stopping swing . . . . . . . . . . . . . . . . . . . . . . . . . . 20-734
H-25 – Swing natural drift is too big . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-735
H-26 – Swing speed is faster than specified swing speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-735
Quick coupler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-736

Troubleshooting of engine (S-MODE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-738

S-1 – Starting performance is poor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-741
S-2 – Engine does not start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-742
S-3 – Engine does not pick up smoothly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-745
S-4 – Engine stops during operations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-746
S-5 – Engine does not rotate smoothly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-747

PW148-8 VEBM720100 20-711

Troubleshooting of hydraulic and mechanical system (H-MODE) TESTING AND ADJUSTING

S-6 – Engine lacks output (or lacks power). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-748

S-7 – Exhaust smoke is black (incomplete combustion) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-749
S-8 – Oil consumption is excessive (or exhaust smoke is blue). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-750
S-9 – Oil becomes contaminated quickly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-751
S-10 – Fuel consumption is excessive. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-752
S-11 – Oil is in coolant (or coolant spurts back or coolant level goes down) . . . . . . . . . . . . . . . . . . . 20-753
S-12 – Oil pressure drops . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-754
S-13 – Oil level rises (Entry of coolant/fuel) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-755
S-14 – Coolant temperature becomes too high (overheating). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-756
S-15 – Abnormal noise is made . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-757
S-16 – Vibration is excessive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-758

20-712 PW148-8 VEBM720100

TESTING AND ADJUSTING System chart for hydraulic and mechanical systems

System chart for hydraulic and mechanical systems

32 See Detail D

Pressure
relief valve
Travel EPC valve Travel PPC valve

27 See Detail C

Travel
2P
Boom Travel creep SOL.
PPC
8

Travel neutral SOL.

5 8

18 17
25 See Detail E

Suspension lock valve SOL.

24

Swing brake SOL.

23

1 2 9 12 15 16 2-stage relief SOL.

PPC lock SOL.

7
6
34
5 Travel Forward / Reverse SOL.

Pump pressure
11
10
36 Stabilizer / Boom up SOL.
9

Pump
14
Gear 13
Pump
Stabilizer / Boom down SOL.
12

28

2-stage back pressure SOL.

33
29 See Detail C

Clutch control Hi - Lo SOL.

30

19 20

21 22

Proportional
Control
Valve
Block

AC

PW148-8 VEBM720100 20-713

System chart for hydraulic and mechanical systems TESTING AND ADJUSTING

• This is a system chart that has been drawn up by simplifying

the whole hydraulic circuit chart. Use it as a reference mate-
rial when troubleshooting the hydraulic and mechanical sys-
tems.

Control Valve

LS

LS

LS

Dump Dig

LS

Dump Dig

LS

Ext. Ret.

LS

Up Down

LS

Fwd. Rev.

LS

Up Down

LS
26

Left Right

LS

LS

AB

20-714 PW148-8 VEBM720100

TESTING AND ADJUSTING System chart for hydraulic and mechanical systems

Detail A Detail B

Up
Down

Up Down

Detail C
29
27 33
B
A

Travel
motor

Powershift
Transmission

PW148-8 VEBM720100 20-715

System chart for hydraulic and mechanical systems TESTING AND ADJUSTING

Accumulators

Detail D

35

To Service
32 brakes

Brake valve

30

Detail E

35
LH Steer
Priority
valve
LH Steer

RH Steer
RH Steer
32

25
Orbitrol valve

20-716 PW148-8 VEBM720100

TESTING AND ADJUSTING Information contained in troubleshooting table

Information contained in troubleshooting table

• Troubleshooting Table and Related Circuit Diagram collec-
tively carry the following information. Carry out troubleshoot-
ing work after fully grasping their contents.

Failure information Phenomena occurring on machine

Relative information Information on occurred failures and troubleshooting

Cause Standard value in normal condition and references for troubleshooting

Presumed cause and standard value in normal condition

Cause for presumed

failure <Contents>
3 (The attached No. for • The standard values in normal condition by which to judge "good" or "no good" about
filing and reference presumed causes.
purpose only. It does not stand for • References for making judgement of "good" or "no good"
any priority)
4

PW148-8 VEBM720100 20-717

H-1 – All work equipment lacks power, or travel and swing speeds are slow TESTING AND ADJUSTING

H-1 – All work equipment lacks power, or travel and swing

speeds are slow

Failure information • All the work equipment lacks power, or their travel and swing speeds are slow.

Relative information • Set the working mode at P mode for troubleshooting.

Cause Standard value in normal condition and references for troubleshooting

• Stop engine for preparations. Start troubleshooting at engine high idling.

Control lever Unload pressure

1 Malfunctioning of unload valve
3.38 ± 1.0 MPa
All control levers in NEUTRAL
{34.5 ± 10kg/cm 2}

• Stop engine for preparations. Start troubleshooting at engine high idling.

Control lever Main relief pressure

Improper adjustment or malfunc- 34.8 – 37.3 MPa
2 Arm, DIGGING
tioning of main relief valve
{355 – 380kg/cm2}

If the pressure does not return to normal condition even after the adjustment, malfunction-
ing of main relief valve or its internal failure is suspected. In that case, check the valve itself.

• Stop engine for preparations. Start troubleshooting at engine high idling.

Presumed cause and standard value in normal condition

Malfunctioning of relief valve on Control lever Control circuit source pressure

3
solenoid block
3.5 – 3.8 MPa
All control levers in NEUTRAL
{35.7 – 38.8kg/cm2}

• Stop engine for preparations. Start troubleshooting at engine high idling.

Oil pressure to be
Measurement condition Oil pressure ratio
measured
Improper adjustment or malfunc-
4 Pump delivery pressure Swing lock: ON 1
tioning of PC valve
PC valve output pressure Arm digging relief Approx. 0.6 (3/5)

If the oil pressure does not return to normal condition even after the adjustment, malfunc-
tioning of PC valve or its internal failure is suspected. In that case, check the valve itself.

• Stop engine for preparations. Start troubleshooting at engine high idling.

Travel speed Travel mode LS-EPC output pressure

5 Malfunctioning of LS-EPC valve 3.5 - 3.8 MPa
Lo NEUTRAL
{35.7 - 38.8 kg/cm2}

Hi Travel F/R lever 0{0}

• Stop engine for preparations. Start troubleshooting at engine high idling.

Oil pressure ratio

Oil pressure to be
measured Travel without load travel
NEUTRAL
Improper adjustment or malfunc- pedal held at half stroke
6
tioning of LS valve Pump delivery pressure 1
Nearly equal pressure
LS valve output pressure Approx. 0.6 (3/5)

If the oil pressure does not return to normal condition even after the adjustment, malfunc-
tioning of LS valve or its internal failure is suspected. In that case, check the valve itself.

7 Malfunctioning of servo piston Malfunctioning of servo piston is suspected. Check the piston itself.

If none of the above listed causes is detected, the piston pump is suspected of deteriorated
8 Piston pump defective
performance, malfunctioning or internal failure.

20-718 PW148-8 VEBM720100

TESTING AND ADJUSTING H-2 – Engine speed sharply drops or engine stalls

H-2 – Engine speed sharply drops or engine stalls

Failure information • The engine speed sharply drops or the engine stalls.

Relative information • Relative Information

Cause Standard value in normal condition and references for troubleshooting

• Stop engine for preparations. Start troubleshooting at engine high idling.

Control lever Main relief pressure

Improper adjustment or malfunc- 34.8 – 37.3 MPa

1 Arm, DIGGING
tioning of main relief valve {355 – 380kg/cm2}

If the oil pressure does not return to normal condition even after the adjustment, malfunc-
Presumed cause and standard value in normal condition

tioning of the main relief valve or its internal failure is suspected. In that case, check the
valve itself.

• Stop engine for preparations. Start troubleshooting at engine high idling.

Oil pressure to be measured Measurement condition Oil pressure ratio

Improper adjustment or malfunc- Pump delivery pressure Swing lock: ON 1

2
tioning of PC valve Arm digging relief
PC valve output pressure Approx. 0.6 (3/5)

If the oil pressure does not return to normal condition even after the adjustment, malfunc-
tioning of the PC valve or its internal failure is suspected. In that case, check the valve itself.

• Stop engine for preparations. Start troubleshooting at engine high idling.

Oil pressure ratio

Oil pressure to be measured Travel without load

Travel
(travel pedal held at half
Improper adjustment or malfunc- NEUTRAL
3 stroke)
tioning of LS valve
Pump delivery pressure 1
Nearly equal pressure
LS valve output pressure Approx. 0.6 (3/5)

If the oil pressure does not return to normal condition even after the adjustment, malfunc-
tioning of the LS valve or its internal failure is suspected. In that case, check the valve itself.

Orifice or filter in servo equipment The orifice or filter in the pump servo equipment is suspected of clogging. Check the equip-
4
clogged ment itself.

5 Malfunction of servo piston The servo piston is suspected of malfunction. Check the piston itself.

PW148-8 VEBM720100 20-719

H-3 – No work equipment, travel or swing move TESTING AND ADJUSTING

H-3 – No work equipment, travel or swing move

Failure information • No work equipment or travel and swing functions can be set in motion.

Relative information • Set the working mode at P mode for the troubleshooting.

Cause Standard value in normal condition and references for troubleshooting

Presumed cause and standard value in normal condition

• Stop engine for preparations. Start troubleshooting at engine high idling.

Safety lock lever Main relief pressure

Malfunctioning of PPC lock sole-
1 Locked 0{0}
noid valve
3.5 – 3.8 MPa
Released
{35.7 – 38.8kg/cm2}

• Stop engine for preparations. Start troubleshooting at engine high idling.

Malfunction of relief valve in sole- Control lever Control circuit source pressure
2
noid valve block.
3.5 – 3.8 MPa
All control levers in NEUTRAL position
{35.7 – 38.8kg/cm2}

The piston pump is suspected of malfunctioning or an internal failure. Diagnose it in the fol-
lowing manner.
3 Piston pump defective
Remove the oil pressure measurement plug and crank the engine. If oil flows out, it is in
normal condition.

It is presumed that the pump shaft does not rotate due to some internal failure of the
4 Damper defective
damper. Check the damper itself.

H-4 – Abnormal noise is heard from around hydraulic

pump

Failure information • An abnormal noise is heard from around the hydraulic pump.

Relative information —

Cause Standard value in normal condition and references for troubleshooting

Presumed cause and standard value in normal condition

1 Hydraulic oil level lowered Make a visual check.

2 Quality of hydraulic oil bad Air may have mixed with the oil. Make a visual check.

Hydraulic tank cap breather It is presumed that the breather in the cap of hydraulic tanks is clogged, thereby causing
3
clogged negative pressure inside the tank. Make a visual check.

It is presumed that the strainer in the hydraulic tank is clogged, thereby causing negative
4 Hydraulic tank strainer clogged
pressure in the suction circuit. Make a visual check.

5 Piston pump defective The piston pump is suspected of an internal failure. Check the pump itself.

20-720 PW148-8 VEBM720100

TESTING AND ADJUSTING H-5 – Auto-decelerator does not work

H-5 – Auto-decelerator does not work

Failure information • The auto-decelerator does not work.

• This troubleshooting mode is applied when the auto-decelerator does not work, while operating the travel
control pedal. (A shuttle valve is provided between PPC valve and the hydraulic switch only in the travel cir-
Relative information
cuit -actually located inside PPC valve)
• Set the working mode at P mode for the troubleshooting.

Cause Standard value in normal condition and references for troubleshooting

dard value in normal condition
Presumed cause and stan-

• Stop engine for preparations. Start troubleshooting at engine high idling.

Travel mode PPC valve output pressure

Malfunctioning of NEUTRAL 0{0}

1 travel PPC
(solenoid valve)
3.5 - 3.8 MPa
Operation
{35.7 - 38.8 kg/cm2}

H-6 – Fine control mode does not function

Failure information • The fine control mode poorly functions or its response is slow.

Relative information • Set the working mode at P mode for the troubleshooting.

Cause Standard value in normal condition and references for troubleshooting

• Stop engine for preparations. Start troubleshooting at engine high idling.

LS-EPC valve output pres-

Travel speed Travel mode
sure
Malfunctioning of LS-
1
EPC valve 3.5 - 3.8 MPa
Lo NEUTRAL
{35.7 - 38.8 kg/cm2}
dard value in normal condition

Hi F/R 0{0}
Presumed cause and stan-

Orifice in LS circuit
2 The orifice in the LS circuit is presumed to be clogged. Check the orifice itself.
clogged

• Stop engine for preparations. Start troubleshooting at engine high idling.

Oil pressure ratio

Oil pressure to be measured Travel without load

TRAVEL
Improper adjustment (travel pedal held at half
NEUTRAL
3 or malfunctioning of stroke)
LS valve Pump delivery pressure 1
Nearly equal oil pressure
LS valve output pressure Approx. 0.6 (3/5)

If the oil pressure does not return to normal condition even after the adjustment, malfunctioning
of the LS valve or its internal failure is suspected. In that case, check the valve itself.

Malfunctioning of
4 Malfunctioning of the servo piston is suspected. Check the piston itself.
servo piston

PW148-8 VEBM720100 20-721

H-7 – Boom moves slowly or lacks power TESTING AND ADJUSTING

H-7 – Boom moves slowly or lacks power

Failure information • The boom moves slowly or lacks power

Relative information • Set the working mode at P mode for the troubleshooting.

Cause Standard value in normal condition and references for troubleshooting

• Stop engine for preparations. Start troubleshooting at engine high idling.

Boom lever PPC valve output pressure

Malfunctioning of right PPC valve
1 NEUTRAL 0{0}
(in boom circuit)
Presumed cause and standard value in normal condition

3.5 - 3.8 MPa

RAISE or LOWER
{35.7 - 38.8 kg/cm2}

Malfunctioning of boom control

2 The spool in the boom control valve is presumed to malfunction. Check the valve itself.
valve (spool)

Malfunctioning of boom control

The pressure compensation valve in the boom control valve is presumed to malfunction.
3 valve (pressure compensation
Check the valve itself.
valve)

Malfunctioning of boom control The regeneration valve in the boom control valve or the seal is presumed to malfunction.
4
valve (regeneration valve) Check the valve itself.

Malfunctioning of safety valve or The safety valve is presumed to malfunction, or the seal is suspected to be defective.
5
seal defective Check the valve itself.

Malfunctioning of boom control

The suction valve in the boom control valve is presumed to malfunction, or the seal is sus-
6 valve (suction valve) or seal
pected to be defective.
defective

Malfunctioning of boom control

The safety and suction valves in the boom control valve are presumed to malfunction, or
7 valve (safety and suction valves)
the seal is suspected to be defective. Check those valves themselves.
or seal defective

• Stop engine for preparations. Start troubleshooting at engine high idling.

8 Boom cylinder defective Boom lever Amount oil leakage from cylinder

Raise relief 15 cc/min

20-722 PW148-8 VEBM720100

TESTING AND ADJUSTING H-8 – Arm moves slowly or lacks power

H-8 – Arm moves slowly or lacks power

Failure information • The arm moves slowly, or lacks power.

Relative information • Set the working mode at P mode for the troubleshooting.

Cause Standard value in normal condition and references for troubleshooting

• Stop engine for preparations. Start troubleshooting at engine high idling.

Presumed cause and standard value in normal condition

Arm lever PPC valve output pressure

Malfunctioning of left PPC valve
1 NEUTRAL 0{0}
(arm circuit)
3.5 - 3.8 MPa
DIGGING or DUMPING
{35.7 - 38.8 kg/cm 2}

Malfunctioning of arm control

2 The spool in the arm control valve is presumed to malfunction. Check the valve itself.
valve (spool)

Malfunctioning of arm control

The pressure compensation valve in the arm control valve is presumed to malfunction.
3 valve (pressure compensation
Check the valve itself.
valve)

Malfunctioning of arm control The generation valve in the arm control valve is presumed to malfunction, or the seal is sus-
4
valve (regeneration valve) pected to be defective. Check the valve itself.

Malfunctioning of arm control

The safety and suction valves in the arm control valve are presumed to malfunction, or the
5 valve (safety and suction valves)
seal is suspected of defect. Check those valves themselves.
or seal defective

• Stop engine for preparations. Start troubleshooting at engine high idling.

6 Arm cylinder defective Arm lever Amount oil leakage from cylinder

Digging relief 15 cc/min

PW148-8 VEBM720100 20-723

H-9 – Bucket moves slowly or lacks power TESTING AND ADJUSTING

H-9 – Bucket moves slowly or lacks power

Failure information • The bucket moves slowly, or lacks power.

Relative information • Set the working mode at P mode for the troubleshooting.

Cause Standard value in normal condition and references for troubleshooting

• Stop engine for preparations. Start troubleshooting at engine high idling.

Bucket lever PPC valve output pressure

Malfunctioning of right PPC valve
1 NEUTRAL 0{0}
(bucket circuit)
dard value in normal condition

3.5 - 3.8 MPa

Presumed cause and stan-

DIGGING or DUMPING
{35.7 - 38.8 kg/cm2}

Malfunctioning of bucket control The spool in the bucket control valve is presumed to malfunction. Check the valve
2
valve (spool) itself.

Malfunctioning of bucket control

The pressure compensation valve in the bucket control valve is presumed to malfunc-
3 valve (pressure compensation
tion. Check the valve itself.
valve)

Malfunctioning of bucket control

The safety and suction valves in the bucket control valve are presumed to malfunc-
4 valve (safety and suction valves)
tion, or the seal is suspected to be defective. Check those valves themselves.
or seal defective

• Stop engine for preparations. Start troubleshooting at engine high idling.

5 Bucket cylinder defective Bucket lever Amount oil leakage from cylinder

Digging relief 15 cc/min

H-10 – Work equipment does not move in its single opera-

tion

• The boom does not move when operated independently.

Failure information • The arm does not move when operated independently.
• The bucket does not move when operated independently.

Relative information • Set the working mode at P mode for the troubleshooting.

Cause Standard value in normal condition and references for troubleshooting

dard value in normal condition
Presumed cause and stan-

• Stop engine for preparations. Start troubleshooting at engine high idling.

Work equipment control lever PPC valve output pressure

1 Malfunctioning of PPC valve NEUTRAL 0{0}

3.5 - 3.8 MPa

Operation
{35.7 - 38.8 kg/cm2}

Malfunctioning of work equipment The spool in the work equipment control valve is presumed to malfunction. Check the
2
control valve (spool) valve itself.

20-724 PW148-8 VEBM720100

TESTING AND ADJUSTING
H-11 – Work equipment hydraulic drift is too fast
Failure information (1)
Relative information
Presumed cause and stan-
dard value in normal
1 Boom cylinder defective
condition
2
3
Failure information (2)
Relative information
1 Arm cylinder defective
dard value in normal condition
Presumed cause and stan-
2
3
4
Failure information (3)
Relative information
1 Bucket cylinder defective
dard value in normal condition
Presumed cause and stan-
2
3
4 compensation valve) seal defec-
PW148-8
H-11 – Work equipment hydraulic drift is too fast
• Hydraulic drift of the boom is a bit too fast.
• Set the working mode at P mode for the troubleshooting.
Cause Standard value in normal condition and references for troubleshooting
• Stop engine for preparations. Start troubleshooting at engine high idling.
Boom control lever Amount oil leakage from cylinder
Raise relief 15 cc/min
Boom control lever (lock valve) The seal at lock valve in the boom control lever is suspected to be defective. Check
seal defective the valve itself.
Seal at safety valve for lock valve The seal at the safety valve in the lock valve is suspected to be defective. Check the
defective valve itself.
• Hydraulic drift of the arm is a bit too fast.
• Set the working mode at P mode for the troubleshooting.
Cause Standard value in normal condition and references for troubleshooting
• Stop engine for preparations. Start troubleshooting at engine high idling.
Arm control lever Amount oil leakage from cylinder
Digging relief 15 cc/min
The seal for safety and suction valves in the arm control valve is suspected to be
defective. Check the valve itself.
Arm control valve (safety and • Whether the seal is defective or not may well be determined by changing for other
suction valves) seal defective safety and suction valves. (Do not attempt to change them for the safety and suc-
tion valves for the boom LOWER and the lock valve, because the set pressure dif-
fers)
Arm control valve (spool) seal The seal for spool in the arm control valve is suspected to be defective. Check the
defective seal itself.
Arm control valve (pressure com- The seal for pressure compensation valve in the arm control valve is suspected to be
pensation valve) seal defective defective. Check the seal itself.
• Hydraulic drift of the bucket is a bit too fast.
• Set the working mode at P mode for the troubleshooting.
Cause Standard value in normal condition and references for troubleshooting
• Stop engine for preparations. Start troubleshooting at engine high idling.
Bucket control lever Amount oil leakage from cylinder
Digging relief 15 cc/min
The seal for the safety and suction valves in the bucket control lever is suspected to
be defective. Check the seal itself.
Bucket control valve (safety and • Whether the seal is defective or not may well be determined by changing for other
suction valves) seal defective safety and suction valves. (Do not attempt to change them for the safety and suc-
tion valves for the boom LOWER and the lock valve, because the set pressure dif-
fers)
Bucket control valve (spool) seal The seal for spool in the bucket control valve is suspected to be defective. Check the
defective seal itself.
Bucket control valve (pressure
The seal for pressure compensation valve in the bucket control valve is suspected to
be defective. Check the seal itself.
tive
VEBM720100 20-725
H-12 – Work equipment has big time lag TESTING AND ADJUSTING

H-12 – Work equipment has big time lag

Failure information • The work equipment has a big time lag.

Relative information • Set the working mode at P mode for the troubleshooting.

Cause Standard value in normal condition and references for troubleshooting

• Stop engine for preparations. Start troubleshooting at engine high idling.

LS-EPC valve output

Travel speed Travel mode
pressure
1 Malfunctioning of LS-EPC valve
dard value in normal condition

3.5 - 3.8 MPa

Presumed cause and stan-

Lo NEUTRAL
{35.7 - 38.8 kg/cm2}

Hi Operation 0{0}

Malfunctioning of control valve

The regeneration valve in the control valve is presumed to malfunction. Check the
2 (regeneration valve) - with boom
valve itself.
and arm only

Malfunctioning of control valves
3
(safety & suction valve)
The safety and suction valves of the control valve are presumed to malfunction.
Check those valves themselves directly.
• For the arm and boom, whether they are defective or not, may well be determined
by changing them for other safety and suction valves. (Do not attempt to change
them for the safety and suction valves for the boom LOWER and the lock valve,
because each set pressure differs)

Malfunctioning of control valve The pressure compensation valve of the control valve is presumed to malfunction.
4
(pressure compensation valve) Check the valve itself directly.

H-13 – Other work equipment moves when relieving single

circuit

Failure information • Other work equipment moves when relieving the single circuit of specific work equipment.

Relative information • Set the working mode at P mode for the troubleshooting.

Cause Standard value in normal condition and references for troubleshooting

Presumed cause and
standard value in
normal condition

Control valve (pressure compen- The seal for pressure compression valve in the control valve is suspected to be
1
sation valve) seal defective defective. Check the seal itself.

20-726 PW148-8 VEBM720100

TESTING AND ADJUSTING H-14 – One-touch power max. switch does not operate

H-14 – One-touch power max. switch does not operate

Failure information • The one-touch power max. switch does not operate.
Relative information • Set the working mode at P mode for the troubleshooting.
standard value in normal condition

Cause Standard value in normal condition and references for troubleshooting

• Stop engine for preparations. Start troubleshooting at engine high idling.
Presumed cause and

Swing lock switch Solenoid valve output pressure

Malfunctioning of 2-stage solenoid
1 OFF 0{0}
valve
3.5 - 3.8 MPa
ON
{35.7 - 38.8 kg/cm2}

2 Malfunctioning of main relief valve The main relief valve is presumed to malfunction. Check the valve itself.

H-15 – In compound operation, work equipment with

larger load moves slowly

Failure information • In a compound operation, work equipment with larger load tends to move slowly.
Relative information —

Cause Standard value in normal condition and references for troubleshooting

dard value in normal condition
Presumed cause and stan-

The pressure compensation valve for the work equipment with larger load is presumed
to malfunction. Check the valve itself.
Combination of compound operation Work equipment with larger load
Malfunctioning of pressure com- Boom RAISE + arm DIGGING Boom RAISE
1 pensation valve for work equipment
Boom RAISE + arm DUMPING Arm DUMPING
with larger load
Boom RAISE + bucket DIGGING Boom RAISE
Arm DUMPING + bucket DIGGING Arm DUMPING
Boom LOWER + arm DUMPING Arm DUMPING

H-16 – In swing + boom RAISE operation, boom moves

slowly

Failure information • In a compound operation of swing + boom RAISE, the boom tends to move slowly.
• If the boom moves slowly in the single operation of boom RAISE, carry out the "Boom moves slowly or lacks
Relative information
power" checks first - see page 20-712.
dard value in normal condition

Cause Standard value in normal condition and references for troubleshooting

Presumed cause and stan-

Malfunctioning of swing & boom The swing & boom control valves are presumed to malfunction, or the seal is sus-
1
control valves or seal defective pected to be defective. Check the valves and seals.

PW148-8 VEBM720100 20-727

H-17 – In swing + travel, travel speed drops sharply TESTING AND ADJUSTING

H-17 – In swing + travel, travel speed drops sharply

Failure information • In a compound operation of swing + travel, the travel speed drops sharply.

• If the travel speed is slow in the single operation of travel, carry out the "Travel speed does not shift or it is
Relative information
too slow or fast" checks first - see page 20-720.

Cause Standard value in normal condition and references for troubleshooting

dard value in normal condition
Presumed cause and stan-

Malfunctioning of travel and swing The travel & swing control valves are presumed to malfunction. Check both of them
1
control valves. directly.

20-728 PW148-8 VEBM720100

TESTING AND ADJUSTING H-18 – Travel speed does not switch

H-18 – Travel speed does not switch

Failure information • The machine's travel speed is slow.

Relative information • Set the working mode at P mode for the troubleshooting.

Cause Standard value in normal condition and references for troubleshooting

• Stop engine for preparations. Start troubleshooting at engine high idling.

Malfunctioning of travel PPC Travel control lever PPC valve output pressure
1
valve
3.5 - 3.8 MPa
Forward or reverse
{35.7 - 38.8 kg/cm 2}

• Stop engine for preparations. Start troubleshooting at engine high idling.

Presumed cause and standard value in normal condition

Malfunctioning of self-pressure Control lever Control circuit source pressure

2
decompression valve
All control levers and pedals in 3.5 - 3.8 MPa
NEUTRAL {35.7 - 38.8 kg/cm 2}

• Stop engine for preparations. Start troubleshooting at engine high idling.

LS-EPC valve output pres-

Travel speed Travel control pedal
sure
3 Malfunctioning of LS-EPC valve
Approx. 2.9 MPa
Lo NEUTRAL
{approx. 30 kg/cm 2}

Hi Travel control pedal 0 {0}

Malfunction of travel control valve

4 The spool in the travel control valve is presumed to malfunction. Check the spool itself.
(spool)

Malfunctioning of travel control

The pressure compensation valve in the travel control valve is presumed to malfunction.
5 valve (pressure compensation
Check the valve itself.
valve)

Malfunctioning of travel control The suction valve in the travel control valve is presumed to malfunction. Check the valve
6
valve (suction valve) itself.

• Stop engine for preparations. Start troubleshooting at engine high idling.

7 Malfunction of travel motor Travel control pedal Amount of oil leakage from travel motor

Travel relief 6 l/min

8 Travel speed does not switch Malfunction of speed sensing system

PW148-8 VEBM720100 20-729

H-19 – Travel speed does not shift, or it is too slow or fast TESTING AND ADJUSTING

H-19 – Travel speed does not shift, or it is too slow or fast

Failure information • Travel speed does not shift, or it is either too fast or slow.

Relative information • Set the working mode at P mode for the troubleshooting.

Cause Standard value in normal condition and references for troubleshooting

• Stop engine for preparations. Start troubleshooting at engine high idling.

Travel speed Travel control pedal Monitoring [15]

Presumed cause and standard value in normal condition

Lo 419 mA
Fine control
Creep (to the extent that the 583 mA
decelerator is released)
Hi 0 mA
1 Malfunctioning of LS-EPC valve
• Stop engine for preparations. Start troubleshooting at engine high idling.

LS-EPC valve output pres-

Travel speed Travel control pedal
sure

3.5 - 3.8 MPa

Lo NEUTRAL
{35.7 - 38.8 kg/cm2}

Hi Operation 0 {0}

• Stop engine for preparations. Start troubleshooting at engine high idling.

Transmission clutch con-

Travel speed Park brake valve
trol solenoid feed
Malfunctioning of transmission
2
clutch control solenoid valve ON 0 {0}
Lo or Hi 3.5 - 3.8 MPa
OFF
{35.7 - 38.8 kg/cm2}

Malfunctioning of travel motor The travel motor is presumed to malfunction when shifting speed. Check the speed shifting
3
(speed shifting) portion directly.

20-730 PW148-8 VEBM720100

TESTING AND ADJUSTING H-20 – Machine does not swing

H-20 – Machine does not swing

Failure information (1) • The machine swings neither to the right nor to the left.

Relative information • Set the working mode at P mode for the troubleshooting.

Cause Standard value in normal condition and references for troubleshooting

• Stop engine for preparations. Start troubleshooting at engine high idling.

Swing Solenoid valve

Malfunctioning of swing parking
Presumed cause and standard value in normal condition

1 NEUTRAL 0 {0}
brake solenoid valve
3.5 - 3.8 MPa
Operation
{35.7 - 38.8 kg/cm 2}

Malfunctioning of swing motor The parking brake portion of the swing motor is presumed to malfunction.
2
(parking brake) Check it directly.

• Stop engine for preparations. Start troubleshooting at engine high idling.

Swing lock switch Swing control lever Swing relief pressure

Improper adjustment or malfunc-
3 tioning of swing motor (safety 27.5 – 28.0 MPa
ON Swing relief
valve) {280 – 285 kg/cm2}

If the oil pressure does not return to normal condition even after the adjustment, the safety
valve is presumed to malfunction, or suspected of an internal failure. Check the valve itself.

• Stop engine for preparations. Start troubleshooting at engine high idling.

4 Swing motor defective Swing control lever Amount of oil leakage from swing motor

Swing relief Below 6 cc/min

The swing machinery is suspected of an internal failure. Check the inside of the swing
machinery directly.
5 Swing machinery defective
• A failure inside the swing machinery may well be determined by an abnormal noise from
within, abnormal heat generated or metal dust or chips contained in the drained oil.

Failure information (2) • The machine does not swing in one direction.

Relative information • Set the working mode at P mode for the troubleshooting.

Cause Standard value in normal condition and references for troubleshooting

Presumed cause and standard value in normal condition

• Stop engine for preparations. Start troubleshooting at engine high idling.

Left control lever PPC valve output pressure

1 Malfunctioning of PPC valve NEUTRAL 0 {0}

3.5 - 3.8 MPa

Swing operation
{35.7 - 38.8 kg/cm 2}

Malfunctioning of swing control

2 The spool in the swing control valve is presumed to malfunction. Check the spool itself.
valve (spool)

The seal in the suction valve of the swing motor is suspected of defect. Check the seal
Swing motor (suction valve) seal itself.
3
defective • Whether the seal is defective or not may well be determined by swapping the right and
left suction valves and watching if there is any change.

The seal in the check valve of the swing motor is suspected of defect. Check the seal itself.
Swing motor (check valve) seal
4 • Whether the seal is defective or not may well be determined by swapping the right and
defective
left check valves and watching the result.

PW148-8 VEBM720100 20-731

H-21 – Swing acceleration is poor, or swing speed is slow TESTING AND ADJUSTING

H-21 – Swing acceleration is poor, or swing speed is slow

Failure information (1) • Swing acceleration is poor, or swing speed is slow.

Relative information • Set the working mode at P mode for the troubleshooting.

Cause Standard value in normal condition and references for troubleshooting

Presumed cause and standard value in normal condition

The LS shuttle valves for all the control valves are presumed to malfunction. Check them
1 Malfunctioning of LS shuttle valve
directly.

Malfunctioning of swing motor

2 The parking brake portion of the swing motor is presumed to malfunction. Check it directly.
(parking brake)

• Stop engine for preparations. Start troubleshooting at engine high idling.

Swing lock switch Swing control lever Swing relief pressure

Improper adjustment or malfunc-
3 tioning of swing motor (safety 27.5 – 28.0 MPa
ON Swing relief
valve) {280 – 285 kg/cm2}

If the oil pressure does not return to normal condition even after the adjustment, the safety
valve is presumed to malfunction, or suspected of an internal failure. Check the valve itself.

• Stop engine for preparations. Start troubleshooting at engine high idling.

Swing control lever Amount of oil leakage from swing motor

4 Swing motor defective

Swing relief Below 6 cc/min

Failure information (2) • Swing acceleration is poor only on one side, or swing speed is slow.

Relative information • Set the working mode at P mode for the troubleshooting.

Cause Standard value in normal condition and references for troubleshooting

Presumed cause and standard value in normal condition

• Stop engine for preparations. Start troubleshooting at engine high idling.

Swing control lever PPC valve output pressure

1 Malfunctioning of PPC valve NEUTRAL 0 {0}

3.5 - 3.8 MPa

Left or right
{35.7 - 38.8 kg/cm2}

Malfunctioning of swing control

2 • The spool in the swing control valve is presumed to malfunction. Check the valve itself.
valve (spool)

Malfunctioning of swing motor • The pressure compensation valve in the swing motor is presumed to malfunction. Check
3
(pressure compensation valve) the valve itself.

The seal in the suction valve of the swing motor is suspected of defect. Check the seal
Swing motor (suction valve) seal itself.
4
defective • Whether the seal is defective or not may well be determined by swapping the right and
left suction valves and watching the result.

The seal in the check valve of the swing motor is suspected of defect. Check the seal itself.
Swing motor (check valve) seal
5 • Whether the seal is defective or not may well be determined by swapping the right and
defective
left check valves and watching the result.

20-732 PW148-8 VEBM720100

TESTING AND ADJUSTING H-22 – Excessive overrun when stopping swing

H-22 – Excessive overrun when stopping swing

Failure information (1) • The work equipment overruns excessively when stopping swing.

Relative information • Set the working mode at P mode for the troubleshooting.

Cause Standard value in normal condition and references for troubleshooting

• Stop engine for preparations. Start troubleshooting at engine high idling.

dard value in normal condition
Presumed cause and stan-

Swing lock switch Swing control lever Swing relief pressure

Improper adjustment or malfunc- 27.5 – 28.0 MPa
1 tioning of swing motor (safety ON Swing relief
{280 – 285 kg/cm2}
valve)
If the oil pressure does not return to normal condition even after the adjustment, the
safety valve is presumed to malfunction, or suspected of an internal failure. Check
the valve itself.

• Stop engine for preparations. Start troubleshooting at engine high idling.

2 Swing motor defective Control lever Amount of oil leakage from swing motor

Swing relief Below 6 cc/min

Failure information (2) • Swing acceleration is poor only on one side, or swing speed is slow.

Relative information • Set the working mode at P mode for the troubleshooting.

Cause Standard value in normal condition and references for troubleshooting

• Stop engine for preparations. Start troubleshooting at engine high idling.

Swing control lever PPC valve output pressure

1 Malfunctioning of PPC valve NEUTRAL 0 {0}

3.5 - 3.8 MPa

dard value in normal condition

Left or right
Presumed cause and stan-

{35.7 - 38.8 kg/cm2}

The PPC slow return valve is suspected of clogging. Check the valve itself.
Swing PPC slow return valve
2 • Whether the valve is clogged or not may well be determined by swapping the right
clogged
and left valves and watching the result.

Malfunctioning of swing control

3 The spool in the swing control valve is resumed to malfunction. Check the valve itself.
valve (spool)

The seal in the suction valve of the swing motor is suspected of defect. Check the
Swing motor (suction valve) seal seal itself.
4
defective • Whether the seal is defective or not may well be determined by swapping the right
and left suction valves and watching the result.

The seal in the check valve of the swing motor is suspected of defect. Check the seal
Swing motor (check valve) seal itself.
5
defective • Whether the seal is defective or not may well be determined by swapping the right
and left check valves and watching the result.

PW148-8 VEBM720100 20-733

H-23 – There is big shock when stopping swing TESTING AND ADJUSTING

H-23 – There is big shock when stopping swing

Failure information • There is a big shock caused when stopping a swing motion.

Relative information • Set the working mode at P mode for the troubleshooting.

Cause Standard value in normal condition and references for troubleshooting

dard value in normal condition
Presumed cause and stan-

• Stop engine for preparations. Start troubleshooting at engine high idling.

Swing control lever PPC valve output pressure

Malfunctioning of swing PPC
1 NEUTRAL 0 {0}
valve
3.5 - 3.8 MPa
Left or right
{35.7 - 38.8 kg/cm2}

The swing PPC slow return valve is presumed to malfunction. Check the valve itself.
Malfunctioning of swing PPC slow
2 • Whether the valve malfunctions or not may well be determined by swapping the
return valve
right and left valves and watching the result.

H-24 – There is loud abnormal noise caused when stop-

ping swing

Failure information • There is a loud abnormal noise caused when stopping a swing motion.

Relative information • Set the working mode at P mode for the troubleshooting.

Cause Standard value in normal condition and references for troubleshooting

Malfunctioning of back pressure

1 The backpressure valve is presumed to malfunction. Check the valve itself.
valve
dard value in normal condition
Presumed cause and stan-

Malfunction of swing motor The safety valve in the swing motor is presumed to malfunction. Check the valve
2
(safety valve) itself.

The seal in suction valve of the swing motor is suspected of defect. Check the seal
Malfunction of swing motor (suc- itself.
3
tion valve) • Whether the seal is defective or not may well be determined by swapping the right
and left valves and watching the result.

4 Swing machinery defective
The swing machinery is suspected of an internal failure. Check the inside of the
machinery itself.
• A failure inside the swing machinery may well be determined by monitoring abnor-
mal noise, abnormal heat generated or metal dust or chips contained in the
drained oil.

20-734 PW148-8 VEBM720100

TESTING AND ADJUSTING H-25 – Swing natural drift is too big

H-25 – Swing natural drift is too big

Failure information (1) • Natural drift of the swing is too big (when the parking brake is activated).

• When the emergency swing release switch is in the OFF position (this is a normal condition), the swing and
Relative information
parking brake is activated and the swing is fixed with a disc brake.

Cause Standard value in normal condition and references for troubleshooting

dard value in normal condition
Presumed cause and stan-

• Stop engine for preparations. Start troubleshooting at engine high idling.

Swing control lever Solenoid valve output pressure

Swing and parking brake solenoid
1 NEUTRAL 0 {0}
valve malfunctioned
3.5 - 3.8 MPa
Left or right
{35.7 - 38.8 kg/cm2}

Swing motor (parking brake por- The parking portion of the swing motor is suspected of malfunctioning and interior
2
tion) malfunctioned failure. Check that portion directly.

Failure information (2) • Natural drift of the swing is too big (when the parking brake is released).

• When the emergency swing release switch is in the ON condition (this is an emergent condition), the swing
Relative information
and parking brake is released and the swing is retained only hydraulically.

Cause Standard value in normal condition and references for troubleshooting

Swing control valve (spool) mal- The seal in the spool of the swing control valve is suspected of defect. Check the
dard value in normal condition

1
Presumed cause and stan-

functioned spool itself directly.

Swing control valve (pressure

The pressure compensation valve seal in the swing control valve is suspected of
2 compensation valve) malfunc-
defect. Check the valve itself directly.
tioned

Swing motor (safety valve) defec- The safety valve seal in the swing motor is suspected of defect. Check the valve itself
3
tive directly.

Swing motor (suction valve) The suction valve seal in the swing motor is suspected of defect. Check the valve
4
defective itself directly.

Swing motor (check valve) defec- The check valve seal in the swing motor is suspected of defect. Check the valve itself
5
tive directly.

H-26 – Swing speed is faster than specified swing speed

Failure information (1) • Swing speed is greater than specified speed.

Relative information • When operating the swing system.

Cause Standard value in normal condition and references for troubleshooting

dard value in normal condition
Presumed cause and stan-

1 Operation of LS valve defective. Is output of the LS-EPC solenoid valve normal.

Output pressure of the LS-EPC solenoid valve is abnormal.

2 Defective LS-EPC solenoid.
Correct or replace the LS-EPC solenoid.

PW148-8 VEBM720100 20-735

Quick coupler TESTING AND ADJUSTING

Quick coupler

FB2
3
Power
Quick Coupler Switch Supply
OFF
ON Fuse Box
M38 1 5 10 9

J03
1 4
(Black)
4 6
H10

H15
18 Quick Coupler
R54
6

P01
11
Quick 1 2 3 5 6
7 Coupler
Buzzer
6

13 14
A02 A05 V16 Solenoid for
8 11 1 Quick Coupler

A64 X-4 SWP-16 2

A65 (Revoframe)

CAB REVO FRAME

Trouble (1) Quick coupler cylinder will not extend

Related information
Possible causes and
standard value in normal
state
Quick coupler block assembly has 2 cartridge valves in it, a 3 port pressure reducer to regulate the pressure to
both the solenoid valve and quick coupler cylinder and a 4/2 solenoid operated directional control valve, this
functions as follows:
Default position allows oil to flow to extend quick coupler cylinder [lock].
Cause Remarks on troubleshooting
If there is insufficient pressure achieved at the quick coupler cylinder,
Pressure setting too low for par- then it wont move. Adjust pressure according to quick coupler specifi-
1
ticular quick coupler cation (refer to Testing and Adjusting Section 30 for measuring and
adjustment procedure)
This will result in solenoid coil being energised and oil being directed
to retract the quick coupler cylinder
Power supply to solenoid coil
2 ★ Prepare with starting switch OFF, then turn starting switch ON (but
not removed
quick coupler switch OFF) and carry out troubleshooting.
V16 (female) between (1) - (2). Voltage below 1V.
Directional control valve may have a malfunction (eg. sticking spool).
Directional control valve mal-
3 Check it directly and replace complete directional control valve if nec-
function
essary.
This may result in insufficient pressure being available. Measure pres-
sure as explained in "Testing and Adjusting Section 30" then check if
4 Malfunction of pressure reducer
pressure can be adjusted, if it can’t replace complete pressure
reducer.

20-736 PW148-8 VEBM720100

TESTING AND ADJUSTING Quick coupler

Trouble (2) Quick coupler cylinder will not extend (but buzzer does not sound)
Quick coupler block assembly has 2 cartridge valves in it, a 3 port pressure reducer to regulate the pressure to
the solenoid valve and quick coupler cylinder and a 4/2 solenoid operated directional control valve, this func-
tions as follows:
Related information
-When operation switch in operators cab is in "ON" position solenoid is energised switching valve which allows
oil to flow to retract quick coupler cylinder [UNLOCK]. At the same time a warning buzzer sounds and the lamp
on the switch comes on.
Cause Remarks on troubleshooting
Valve will not switch
★ Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
1 Defective solenoid coil V16 (male) between (1) (+ positive) and (2) ( - negative) resistance
30+/-1.5Ω
V16 (male) between (1) (+ positive) and chassis ground resistance Min
1MΩ
Valve will not switch
★ Prepare with starting switch OFF, then turn starting switch ON and
2 No power supply to solenoid coil
quick coupler switch ON and carry out troubleshooting
Possible causes and V16 (female) between (1) - (2). Voltage 20-30 V.
standard value in normal
★ Prepare with starting switch OFF, then carry out troubleshooting
state
Ground fault in wiring harness without turning starting switch ON.
3
(short circuit with GND circuit) V16 (female) (1) - P51 (female) (1) resistance above 1MΩ
V16 (female) (1) - S42 (female) (1) and (10) resistance above 1MΩ
Directional control valve may have a malfunction (eg sticking spool).
Directional control valve mal-
4 Check it directly and replace the complete directional control valve if
function
necessary.
This may result in insufficient pressure being available. Measure pres-
sure as explained in "Testing and Adjusting Section 30" then check if
5 Malfunction of pressure reducer
pressure can be adjusted, if it can’t replace complete pressure
reducer.
Pilot operated check in quick
6 Consult specific quick coupler manufacturer for the specification.
coupler falling to operate

Trouble (3) Buzzer does not sound (but quick coupler cylinder does retract)
When operation switch in operators cab is in "ON" position a buzzer sounds and light on the switch comes on
Related information
to warn the operator.
Cause Remarks on troubleshooting

Possible causes and ★ Prepare with starting switch OFF, then turn starting switch ON and
standard value in normal 1 No power supply to buzzer quick coupler switch ON and carry out troubleshooting
state P51 (female) between (11) - (6) voltage 20-30 V.
2 Buzzer malfunction If (1) above is OK then replace buzzer.

Trouble (4) Quick coupler cylinder extends and retracts slowly

Cause Remarks on troubleshooting
Possible causes and
1 Restriction in tank line Check that hose isn’t crushed or kinked.
standard value in normal
state Hydraulic system pressure too Depending on the design of the quick coupler it may be necessary to
2
low operate the swing lever to raise the pressure in the hydraulic system.

PW148-8 VEBM720100 20-737

Troubleshooting of engine (S-MODE) TESTING AND ADJUSTING

Troubleshooting of engine (S-MODE)

Method of using troubleshooting chart
The troubleshooting chart consists of the "questions", "check
items", "causes", and "troubleshooting" blocks.

The questions and check items are used to pinpoint high proba-
bility causes by simple inspection or from phenomena without
using troubleshooting tools.

Next, troubleshooting tools or direct inspection are applied to

check the narrowed causes in order from the most probable one
to make final confirmation according to the troubleshooting pro-
cedure.

Questions
Items to be drawn from the user or operator. They correspond to
A and B in the chart on the right. The items in A are basic ones.
The items in B can be drawn from the user or operator, depend-
ing on their level.

Check items
Simple check items used by the serviceman to narrow the caus-
es. They correspond to C in the chart on the right.

Causes
Items to be narrowed from the questions and check items. The
serviceman narrows down the probable causes from A, B, and
C.

Troubleshooting
Items used to find out the true cause by verifying the narrowed
causes finally in order from the most probable one by applying
troubleshooting tools or direct inspection.

Items listed in the [Questions] and [Check items] and related to

the [Causes] are marked with U, , and .

U: Causes to be referred to for questions and check items

: Causes related to questions and check items

: Causes highly probable among ones marked with

When narrowing the "causes", apply the items marked with

before those marked with .

When narrowing the causes, do not apply the items marked with
U. (If no items have other marks and the causes cannot be nar-
rowed, however, you may apply them.)

20-738 PW148-8 VEBM720100

TESTING AND ADJUSTING Troubleshooting of engine (S-MODE)

<Example of troubleshooting> 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 rela-
tionship with this problem: [Exhaust gas slowly became black],
[Power slowly became weaker], and [Air cleaner clogging cau-
tion lamp is flashing].

If we look from these three symptoms to find the causes, we find

that there is a relationship with five causes.

PW148-8 VEBM720100 20-739

Troubleshooting of engine (S-MODE) TESTING AND ADJUSTING

Let us explain here the method of using this causal relationship

to pinpoint the most probable cause.

20-740 PW148-8 VEBM720100

TESTING AND ADJUSTING S-1 – Starting performance is poor

S-1 – Starting performance is poor

General causes why starting performance is poor Causes

• Defective electrical system

Leaking or clogged fuel piping, entry of air

Clogged air breather hole of fuel tank cap
• Insufficient supply of fuel

Defective alternator (generator section)

Defective alternator (regulator section)
• Insufficient intake of air

Defective contact of valve, vale seat

Stuck, seized supply pump plunger

• Improper selection of fuel

Defective intake air heater system

• The common rail fuel injection system (CRI) recognizes the fuel injection timing

Defective, deteriorated battery

electrically. Accordingly, even if the starting operation is carried out, the engine

Clogged air cleaner element

Clogged fuel filter, element

may not start until the crankshaft revolves 2 turns at maximum. This phenome-

Worn piston ring, cylinder

non does not indicate a trouble, however.

Defective injector
Confirm recent repair history
Degree of use of machine Operated for long period U U U
Became worse gradually
Starting performance
Engine starts easily when warm
Questions

Non-specified fuel is being used

Replacement of filters has not been carried out according to Operation and Maintenance
Manual
Engine oil must be added more frequently
When engine is preheated or when temperature is low, preheating monitor does not indi-
cate normally
During operation, charge level monitor indicates abnormal charge
Dust indicator is red
Air breather hole of fuel tank cap is clogged
Fuel is leaking from fuel piping
When priming pump is operated, it makes no reaction or it is heavy
Starting motor cranks engine slowly
If air bleeding plug of fuel filter is removed, fuel does not flow
While engine is cranked out
with starting motor
Check items

If spill hose from injector is disconnected, little fuel spills

When exhaust manifold is touched immediately after starting engine, temperature of some
cylinders is low
Engine does not pick up smoothly and combustion is irregular
There is hunting from engine (rotation is irregular)
Blow-by gas is excessive

Inspect air cleaner directly

When compression pressure is measured, it is found to be low
When air is bled from fuel system, air comes out
Troubleshooting

Inspect fuel filter, strainer directly

Carry out troubleshooting according to "Rail Press (Very) Low Error (*1)" indicated by code
When a cylinder is cut out for reduced cylinder mode operation, engine speed does not
change
When starting switch is turned to HEAT, intake air heater mount does not become warm
Is voltage 20 – 30 V between alternator terminal B and terminal E with engine Yes
at low idle? No
When specific gravity of electrolyte and voltage of battery are measured, they are low
Replace
Replace

Replace
Replace
Replace
Replace
Replace
Replace
correct
Clean

Clean

Clean

Remedy
*1: Displayed failure codes [CA559] and [CA2249]

PW148-8 VEBM720100 20-741

S-2 – Engine does not start TESTING AND ADJUSTING

S-2 – Engine does not start

A) Engine does not turn Causes

Defective connection of battery terminal

Defective starting motor (motor section)

General causes why engine does not turn
• Internal parts of engine seized
See "S-4 Engine stops during operations

Defective or deteriorated battery

Defective starting circuit wiring

• Defective electrical system

Broken flywheel ring gear

• Problem in drive devices on applicable machine side

Defective starting switch

Defective battery relay
Carry out troubleshooting for devices on applicable machine

Defective safety relay

Confirm recent repair history
Questions

Degree of use of machine Operated for long period U U

Condition of horn when Horn does not sound

starting switch is turned ON Horn volume is low
Battery electrolyte is low
Battery terminal is loose
When starting switch is turned ON, there is no operating sound from battery relay
When starting switch is turned to START, starting pinion does not move out
Check items

Speed of rotation is low

When starting 7switch is Makes grating noise
turned to START, starting
pinion moves out, but Soon disengages again
Makes rattling noise and does not turn

Inspect flywheel ring gear directly

When specific gravity of electrolyte and voltage of battery are measured, they are low

Carry out troubleshooting on

applicable machine side
There is not voltage (20 – 30 V) between battery relay terminal B and
terminal E
Troubleshooting

When terminal B and terminal C of starting switch are connected,

engine starts
Turn starting switch OFF,
When terminal B and terminal C at safety relay outlet are connected,
connect cord, and carry out
engine starts
troubleshooting at ON
Even if terminal B and terminal C at safety relay outlet are connected,
engine does not start
When safety switch terminal and terminal B of starting motor are con-
nected, engine starts
Replace
Replace

Replace
Replace
Replace
Replace
Correct

Remedy —

20-742 PW148-8 VEBM720100

TESTING AND ADJUSTING S-2 – Engine does not start

B) Engine turns but no exhaust smoke comes out Causes

Defective operation of overflow valve (Does not close)

General causes why engine turns but no exhaust smoke comes out
• Fuel is not being supplied
• Supply of fuel is extremely small
• Improper selection of fuel (particularly in winter)

Leaking or clogged fuel piping, entry of air

Clogged air breather hole of fuel tank cap

Defective common rail pressure limiter

Seized, abnormally worn feed pump

Stuck, seized supply pump plunger

Defective supply pump MPROP
Clogged fuel filter element

Broken supply pump shaft

Insufficient fuel in tank

Defective fuel injector

Use of improper fuel
Confirm recent repair history
Questions

Degree of use of machine Operated for long period U U

Exhaust smoke suddenly stopped coming out (when starting again) U
Replacement of filters has not been carried out according to Operation and Maintenance
U
Manual
When fuel tank is inspected, it is found to be empty
Air breather hole of fuel tank cap is clogged
Rust and water are found when fuel tank is drained U U U
When fuel filter is removed, there is not fuel in it
Fuel is leaking from fuel piping
Check items

When priming pump is operated, it makes no reaction or it is heavy

If air bleeding plug of fuel filter is removed, fuel does not
While engine is cranked flow out
with starting motor
If spill hose from injector is disconnected, little fuel spills

When air is bled from fuel system, air comes out

Inspect fuel filter directly
Inspect feed pump directly
Troubleshooting

Carry out troubleshooting according to "Rail Press (Very) Low Error (*1)" indicated by code
Carry out troubleshooting according to "IMV/PCV1 Short (Open) Error (*2)" indicated by
code
Inspect overflow valve directly
Engine can be started in reduced cylinder mode.
If pressure limiter return pipe is disconnected, fuel flows out
Replace

Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Add

*1: Displayed failure codes [CA559] and [CA2249] Remedy

*2: Displayed failure codes [CA271] and [CA272]

PW148-8 VEBM720100 20-743

S-2 – Engine does not start TESTING AND ADJUSTING

C) Exhaust smoke comes but engine does not start Causes

(fuel is being injected)

Worn dynamic valve system (Valve, rocker lever, etc.)

Defective coolant temperature sensor, wiring harness

General causes why exhaust smoke comes out but engine does not start
• Lack of rotating force due to defective electrical system
• Insufficient supply of fuel

Leaking or clogged fuel system, entry of air

Clogged air breather hole of fuel tank cap
• Insufficient intake of air
• Improper selection of fuel

Stuck, seized supply pump plunger

Defective intake air heater system

Clogged injector, defective spray
Worn piston ring, cylinder liner

Defective, deteriorated battery

Clogged air cleaner element

Use of improper fuel

Clogged fuel filter

Confirm recent repair history
Degree of use of machine Operated for long period U U U
Suddenly failed to start
Questions

Non-specified fuel is being used

Replacement of filters has not been carried out according to Operation and Maintenance
Manual
Engine oil must be added more frequently
When engine is preheated or when temperature is low, preheating monitor does not indi-
cate normally
Dust indicator is red
Air breather hole of fuel tank cap is clogged
Rust and water are found when fuel tank is drained
When fuel filter is removed, there is not fuel in it
Fuel is leaking from fuel piping
When priming pump is operated, it makes no reaction or it is heavy
Starting motor cranks engine slowly
When engine is cranked, abnormal sound is generated around cylinder head
Check items

If air bleeding plug of fuel filter is removed, fuel does not

While engine is cranked flow out
with starting motor,
If spill hose from injector is disconnected, little fuel spills
When exhaust manifold is touched immediately after starting engine, temperature of some
cylinders is low

Inspect air cleaner directly

Inspect dynamic valve system directly
When compression pressure is measured, it is found to be low
Troubleshooting

When air is bled from fuel system, air comes out

Inspect fuel filter directly
Carry out troubleshooting according to "Rail Press (Very) Low Error (*1)" indicated by code
Engine can be started in reduced cylinder mode.
When specific gravity of electrolyte and voltage of battery are measured, they are low
Coolant temperature gauge does not indicate normally
When starting switch is turned to HEAT, intake air heater mount does not become warm
Replace
Replace
Replace

Replace
Replace
Replace
Replace
Replace
Correct
Clean

Clean

Clean

Remedy
*1: Displayed failure codes [CA559] and [CA2249]

20-744 PW148-8 VEBM720100

TESTING AND ADJUSTING S-3 – Engine does not pick up smoothly

S-3 – Engine does not pick up smoothly

General causes why engine does not pick up smoothly Causes

• Insufficient intake of air

Seized turbocharger, interference of turbocharger

• Insufficient supply of fuel
• Defective condition of fuel spray

Leaking or clogged fuel piping, entry of air

• Improper selection of fuel

Clogged air breather hole of fuel tank cap

Defective contact of valve and valve seat
• Controller is controlling in derate mode (limiting injection rate (output) because of an er-
ror in electrical system)

Stuck, seized supply pump plunger

Clogged injector, defective spray
Worn piston ring, cylinder liner
Clogged air cleaner element

Improper valve clearance

Clogged fuel filter

Confirm recent repair history
Degree of use of machine Operated for long period U U U U
Questions

Engine pick-up suddenly became worse

Non-specified fuel is being used
Replacement of filters has not been carried out according to Operation and Maintenance Manual
Oil must be added more frequently
Dust indicator is red
Air breather hole of fuel tank cap is clogged
Rust and water are found when fuel tank is drained
Fuel is leaking from fuel piping
When priming pump is operated, it makes no reaction or it is heavy
When exhaust manifold is touched immediately after starting engine, temperature of some cylin-
ders is low
Blue under light load
Color of exhaust gas
Check items

Black
When engine is cranked, abnormal sound is generated around cylinder head
When engine is cranked, interference sound is generated around turbocharger
High idle speed under no load is normal, but speed suddenly drops when load is applied
There is hunting from engine (rotation is irregular)
Blow-by gas is excessive

Inspect air cleaner directly

When compression pressure is measured, it is found to be low
Troubleshooting

Inspect valve clearance directly

When turbocharger is rotated by hand, it is found to be heavy
When air is bled from fuel system, air comes out
Inspect fuel filter, strainer directly
Carry out troubleshooting according to "Rail Press (Very) Low Error (*1)" indicated by code
When a cylinder is cut out for reduced cylinder mode operation, engine speed does not change
Replace

Replace
Replace

Replace
Replace
Correct
Adjust
Clean

Clean

Clean

Remedy
*1: Displayed failure codes [CA559] and [CA2249]

PW148-8 VEBM720100 20-745

S-4 – Engine stops during operations TESTING AND ADJUSTING

S-4 – Engine stops during operations

General causes why engine stops during operations Causes

• Seized parts inside engine

Broken dynamic valve system (valve, rocker arm, etc.)

Broken auxiliary equipment (pump, compressor, etc.)

Problem in drive devices on applicable machine side
• Insufficient supply of fuel
• There is overheating
• Problem in drive devices on applicable machine side
Carry out troubleshooting for devices on applicable machine

Clogged air breather hole of fuel tank cap

Broken, seized piston, connecting rod

Stuck, seized supply pump plunger

Broken, seized crankshaft bearing

Leaking, clogged fuel piping

Broken, seized feed pump

Broken supply pump shaft
Broken, seized gear train
Insufficient fuel in tank

Clogged fuel filter

Confirm recent repair history
Degree of use of machine Operated for long period U
Abnormal noise was heard and engine stopped sud-
denly
Condition when engine
Questions

Engine overheated and stopped

stopped
Engine stopped slowly
There was hunting and engine stopped
Non-specified fuel is being used
Replacement of filters has not been carried out according to Operation and Mainte-
nance Manual
Fuel level monitor indicates low level (if monitor is installed)
When fuel tank is inspected, it is found to be empty
Air breather hole of fuel tank cap is clogged
Fuel is leaking from fuel piping
When priming pump is operated, it makes no reaction or it is heavy
Rust and water are found when fuel tank is drained
Check items

Metal particles are found when oil is drained

Does not turn at all
When engine is cranked Turns in opposite direction
by hand Moves by amount of gear backlash
Supply pump shaft does not turn
Engine turns, but stops when load is applied to machine

Inspect dynamic valve system directly

Carry out troubleshooting

Inspect piston, connecting rod directly

on applicable machine

Inspect crankshaft bearing directly

Troubleshooting

Inspect gear train directly

Inspect fuel filter, strainer directly
Inspect feed pump directly
Carry out troubleshooting according to "Rail Press (Very) Low Error (*1)" indicated
by code
Engine rotates when pump auxiliary equipment (pump, compressor, etc.) is
removed
Replace
Replace
Replace
Replace

Replace
Replace
Replace
Replace
Correct
Clean

Clean
Add

Remedy —
*1: Displayed failure codes [CA559] and [CA2249]

20-746 PW148-8 VEBM720100

TESTING AND ADJUSTING S-5 – Engine does not rotate smoothly

S-5 – Engine does not rotate smoothly

General causes why engine does not rotate smoothly Causes

• Air in fuel system

Clogged injector, defective spray (dirt in injector)

• Defective speed sensor (Error at degree that it is not indicated)

Defective Bkup speed sensor, wiring harness

Defective Ne speed sensor, wiring harness
Leaking or clogged fuel piping, entry of air
Clogged air breather hole of fuel tank cap
Insufficient fuel in tank

Clogged fuel filter

Confirm recent repair history
Degree of use of machine Operated for long period U
Questions

Occurs at a certain speed range

Occurs at low idle
Condition of hunting
Occurs even when speed is raised
Occurs on slopes
Replacement of filters has not been carried out according to Operation and Maintenance Manual
When fuel tank is inspected, it is found to be empty
Air breather hole of fuel tank cap is clogged
Check items

Rust and water are found when fuel tank is drained

Fuel is leaking from fuel piping
When priming pump is operated, it makes no reaction or it is heavy

When air is bled from fuel system, air comes out

Troubleshooting

Inspect fuel filter, strainer directly

When a cylinder is cut out for reduced cylinder mode operation, engine speed does not change
Carry out troubleshooting according to "Eng Ne Speed Sensor Error (*1)" indicated by code
Carry out troubleshooting according to "Eng Bkup Speed Sensor Error (*2)" indicated by code
Replace
Replace
Replace
Replace
Replace
Clean
Add

*1: Displayed failure codes [CA689] Remedy

*2: Displayed failure code [CA778]

PW148-8 VEBM720100 20-747

S-6 – Engine lacks output (or lacks power) TESTING AND ADJUSTING

S-6 – Engine lacks output (or lacks power)

General causes why engine lacks output Causes
• Insufficient intake of air

Stuck, seized supply pump plunger

• Insufficient supply of fuel

Air leakage from air intake piping

boost pressure sensor (air leakage)

Worn piston ring, cylinder liner
• Defective spray condition of fuel

Clogged air cleaner element

Leaking, clogged fuel piping

• Improper selection of fuel

defective spray (dirt in injector)

Improper valve clearance
• There is overheating

interference of turbocharger

Clogged air breather hole

Defective drive of injector

Defective boost pressure

See "S-14 Coolant temperature becomes too high

Defective installation of

sensor, wiring harness

Clogged spill piping
(Overheating)".

Seized turbocharger,

valve and valve seat

Clogged fuel filter

Defective contact of
• Controller is controlling in derate mode (limiting injection rate

(signal, solenoid)
Clogged injector,
of fuel tank cap
(output) because of an error in electrical system)

Confirm recent repair history

Degree of use of machine Operated for long period U U U U
Suddenly
Questions

Power was lost

Gradually
Non-specified fuel is being used
Replacement of filters has not been carried out according to Operation
and Maintenance Manual
Engine oil must be added more frequently
Dust indicator is red
Air breather hole of fuel tank cap is clogged
Fuel is leaking from fuel piping
Output becomes insufficient after short stop of operation
Black
Color of exhaust gas
Blue under light load
When exhaust manifold is touched immediately after starting engine,
temperature of some cylinders is low
When engine is cranked, interference sound is generated around turbo-
Check items

charger
When engine is cranked, abnormal sound is generated around cylinder
head
High idle speed is too high
High idle speed under no load is normal, but speed suddenly drops
when load is applied
Engine does not pick up smoothly and combustion is irregular
There is hunting from engine (rotation is irregular)
Blow-by gas is excessive

Inspect air cleaner directly

Inspect air intake piping directly
When boost pressure is measured, it is found to be low
When compression pressure is measured, it is found to be low
Inspect valve clearance directly
Troubleshooting

Inspect fuel piping

Inspect fuel filter, strainer directly
Inspect spill port check valve directly
Carry out troubleshooting according to "Rail Press (Very) Low Error (*1)"
indicated by code
When a cylinder is cut out for reduced cylinder mode operation, engine
speed does not change
Inspect boost pressure sensor mount directly
Carry out troubleshooting according to "Chg Air Press Sensor High
(Low) Error (*2)" indicated by code
Replace

Replace

Replace

Replace
Replace
Replace

Replace

Replace
Replace
Correct

Correct

Correct
Adjust
Clean

Clean

*1: Displayed failure codes [CA559] and [CA2249] Remedy

*2: Displayed failure codes [CA122] and [CA123]

20-748 PW148-8 VEBM720100

TESTING AND ADJUSTING S-7 – Exhaust smoke is black (incomplete combustion)

S-7 – Exhaust smoke is black (incomplete combustion)

General causes why exhaust smoke is black Causes

• Insufficient intake of air

Leakage of air between turbocharger and cylinder head

• Defective condition of fuel injection

Defective coolant temperature sensor, wiring harness

• Improper selection of fuel

Seized turbocharger, interference of turbocharger

• There is overheating
See "S-14 Coolant temperature becomes too high (Overheating)".
• Controller is controlling in derate mode (limiting injection rate (output) be-

Defective contact of valve and valve seat

cause of an error in electrical system)

Stuck, seized supply pump plunger

Improper fuel injection pressure

Worn piston ring, cylinder liner

Improper fuel injection timing

Clogged air cleaner element

Improper valve clearance

Crushed, clogged muffler

Abnormally worn injector

Confirm recent repair history
Degree of use of machine
Questions
Clogged, seized injector
Operated for long period U U U U
Suddenly became black

Color of exhaust gas Gradually became black

Blue under light load
Non-specified fuel is being used
Oil must be added more frequently
Suddenly
Power was lost
Gradually
Dust indicator is red
Muffler is crushed
Air leaks between turbocharger and cylinder head, clamp is loosened
Engine is operated in low-temperature mode at normal temperature
When exhaust manifold is touched immediately after starting engine, temperature of
some cylinders is low
When engine is cranked, interference sound is generated around turbocharger
Check items

When engine is cranked, abnormal sound is generated around cylinder head

Pump relief speed is high (Fuel is injected excessively)
Exhaust noise is abnormal
Engine does not pick up smoothly and combustion is irregular
Blow-by gas is excessive
If spill hose from injector is disconnected, abnormally much fuel spills

Inspect air cleaner directly

When turbocharger is rotated by hand, it is found to be heavy
When compression pressure is measured, it is found to be low
Inspect valve clearance directly
Troubleshooting

When muffler is removed, exhaust sound improves

Carry out troubleshooting according to "Rail Press (Very) Low Error (*1)" indicated by
code
When a cylinder is cut out for reduced cylinder mode operation, engine speed does not
change
Carry out troubleshooting according to "Coolant Temp Sens High (Low) Error (*2)" indi-
cated by code
Check with monitoring function
Replace
Replace

Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Adjust
Clean

*1: Displayed failure codes [CA559] and [CA2249] Remedy

*2: Displayed failure codes [CA144] and [CA145]

PW148-8 VEBM720100 20-749

S-8 – Oil consumption is excessive (or exhaust smoke is blue) TESTING AND ADJUSTING

S-8 – Oil consumption is excessive (or exhaust smoke is

blue)

General causes why oil consumption is excessive Causes

• Abnormal consumption of oil

Worn seal at turbocharger end Turbocharger

• Long-time operation of engine at low idle or high idle (Do not run engine

Oil leakage from oil pan, cylinder head, etc.

Worn, damaged valve (stem, guide, seal)
at idle for more than 20 minutes continuously)
• External leakage of oil
• Wear of parts in lubrication system

Dust sucked in from intake system

Clogged breather, breather hose

Worn piston ring, cylinder liner

Oil leakage from oil drain plug

Worn, damaged rear oil seal

Oil leakage from oil cooler

Oil leakage from oil piping

Worn seal at blower end

Oil leakage from oil filter

Broken piston ring

Broken oil cooler

Confirm recent repair history
U U U U
Questions

Degree of use of machine Operated for long period

Oil consumption suddenly increased
Oil must be added more frequently
Oil becomes contaminated quickly
Outside of engine is dirty with oil
There are loose piping clamps in intake system
Inside of turbocharger intake outlet pipe is dirty with oil
Inside of turbocharger exhaust outlet pipe is dirty with oil
Check items

There is oil in coolant

Oil level in damper chamber of applicable machine is high
Exhaust smoke is blue under light load
Excessive
Amount of blow-by gas
None

When intake manifold is removed, dust is found inside

When intake manifold is removed, inside is found to be abnormally dirty
Troubleshooting

Excessive play of turbocharger shaft

Check breather and breather hose directly
When compression pressure is measured, it is found to be low
Inspect rear oil seal directly
Pressure-tightness test of oil cooler shows there is leakage
There is external leakage of oil from engine
Replace
Replace

Replace
Replace

Replace
Replace
Correct
Correct

Correct

Correct
Correct
Correct
Correct
Clean

Remedy

20-750 PW148-8 VEBM720100

TESTING AND ADJUSTING S-9 – Oil becomes contaminated quickly

S-9 – Oil becomes contaminated quickly

General causes why oil becomes contaminated quickly Causes

• Entry of exhaust gas into oil due to internal wear

Clogged turbocharger lubrication drain tube

Defective seal at turbocharger turbine end
• Clogging of lubrication passage
• Use of improper fuel
• Use of improper oil
• Operation under excessive load

Clogged breather, breather hose

Worn piston ring, cylinder liner

Defective oil filter safety valve

Worn valve, valve guide

Exhaust smoke is bad

Clogged oil cooler
Clogged oil filter
Confirm recent repair history
Questions

Degree of use of machine Operated for long period U U U

Non-specified fuel is being used
Engine oil must be added more frequently
Metal particles are found when oil is drained
Inside of exhaust pipe is dirty with oil
Engine oil temperature rises quickly
Blue under light load
Check items

Color of exhaust gas color

Black
Excessive
Amount of blow-by gas
None

Excessive play of turbocharger shaft

When compression pressure is measured, it is found to be low
Troubleshooting

Check breather and breather hose directly

See S-7
Inspect oil cooler directly
Inspect oil filter directly
Spring of oil filter safety valve is hitched or broken
Inspect turbocharger lubrication drain tube directly
Replace
Replace
Replace

Replace
Replace
Clean
Clean

Clean

Remedy —

PW148-8 VEBM720100 20-751

S-10 – Fuel consumption is excessive TESTING AND ADJUSTING

S-10 – Fuel consumption is excessive

General causes why fuel consumption is excessive Causes

• Leakage of fuel

Defective coolant temperature sensor, wiring harness

• Defective condition of fuel injection (fuel pressure, injection timing)
• Excessive injection of fuel

Fuel leakage from fuel filter, piping, etc.

Defective common rail pressure

Fuel leakage inside head cover

Defective supply pump plunger

Defective operation of injector

Improper fuel injection timing
Defective feed pump oil seal

Defective spray by injector

Confirm recent repair history
U U U
Questions

Degree of use of machine Operated for long period

More than for other machines of same model
Condition of fuel consump-
Gradually increased
tion
Suddenly increased
There is external leakage of fuel from engine
Combustion is irregular
Engine oil level rises and oil smells of diesel fuel
When exhaust manifold is touched immediately after starting engine, temperature of some cylinders is
low
Check items

Low idle speed is high

Pump relief speed is high
Black
Exhaust smoke color
White

Remove and inspect head cover directly

Inspect feed pump oil seal directly
Troubleshooting

Carry out troubleshooting according to "Rail Press (Very) Low Error (*1)" indicated by code
When a cylinder is cut out for reduced cylinder mode operation, engine speed does not change
If spill hose from injector is disconnected, much fuel spills
Carry out troubleshooting according to "Coolant Temp Sens High (Low) Error (*2)" indicated by code
Check with monitoring function
Replace
Replace

Replace
Replace
Replace
Replace
Correct
Correct

Correct

*1: Displayed failure codes [CA559] and [CA2249] Remedy

*2: Displayed failure codes [CA144] and [CA145]

20-752 PW148-8 VEBM720100

TESTING AND ADJUSTING S-11 – Oil is in coolant (or coolant spurts back or coolant level goes down)

S-11 – Oil is in coolant (or coolant spurts back or coolant

level goes down)

General causes why oil is in coolant Causes

• Internal leakage in lubrication system

Broken hydraulic oil cooler on applicable machine side

• Internal leakage in cooling system

Broken cylinder head, head gasket

Internal cracks in cylinder block

Broken oil cooler core, O-ring

Holes caused by pitting
Confirm recent repair history
U U
Questions

Degree of use of machine Operated for long period

Suddenly increased
Oil level
Gradually increased
Hard water is being used as coolant
Oil level has risen, oil is milky
Check items

There are excessive air bubbles in radiator, coolant spurts back

Hydraulic oil on applicable machine side is milky
When hydraulic oil on applicable machine side is drained, water is found

Pressure-tightness test of cylinder head shows there is leakage Carry out

Trouble-

troubleshooting
Inspect cylinder block, liner directly
on applicable
Pressure-tightness test of oil cooler shows there is leakage machine side
Replace
Replace
Replace
Replace

Remedy —

PW148-8 VEBM720100 20-753

S-12 – Oil pressure drops TESTING AND ADJUSTING

S-12 – Oil pressure drops

General causes why oil pressure drops Causes

• Leakage, clogging, wear of lubrication system

Leaking, crushed, clogged hydraulic piping

• Defective oil pressure control

Defective oil level sensor, wiring harness

• Improper selection of fuel (improper viscosity)
• Deterioration of oil due to overheating

Clogged, broken pipe in oil pan

Clogged strainer in oil pan

Defective regulator valve

Worn journal of bearing
Lack of oil in oil pan

Defective oil pump

Coolant, fuel in oil

Clogged oil filter

Confirm recent repair history
U U U
Questions

Degree of use of machine Operated for long period

Oil pressure monitor indicates low oil pressure
Non-specified oil is being used
Replacement of filters has not been carried out according to Operation and Maintenance Manual
Indicates pressure drop at low idle

Oil pressure monitor Indicates pressure drop at low, high idle

(if installed) Indicates pressure drop on slopes
Sometimes indicates pressure drop
Oil level monitor indicates oil level drop
Oil level in oil pan is low
External hydraulic piping is leaking, crushed
Check items

Oil is milky or smells of diesel oil

Metal particles are found when oil pan is drained
Metal particles are found when oil filter is drained

Metal particles are found in oil filter

Troubleshooting

Inspect oil pan strainer, pipe directly

See S-13

Oil pump rotation is heavy, there is play in oil pump

Valve spring of regulator valve is fatigued, damaged
Inspect oil filter directly
If oil level sensor is replaced, oil pressure monitor indicates normally
Replace

Replace
Correct
Adjust
Clean

Clean
Clean

Clean
Add

Remedy —

20-754 PW148-8 VEBM720100

TESTING AND ADJUSTING S-13 – Oil level rises (Entry of coolant/fuel)

S-13 – Oil level rises (Entry of coolant/fuel)

General causes why oil level rises Causes

• Coolant in oil (milky)

Defective seal of auxiliary equipment (pump, compressor)

• Fuel in oil (smells diluted diesel fuel)
• If oil is in coolant, carry out troubleshooting for "S-11 Oil is in coolant"

Broken cylinder head, head gasket

Broken oil cooler core, O-ring

Worn, damaged rear oil seal
Cracks inside cylinder block

Defects in supply pump

Holes caused by pitting
Broken injector O-ring
Confirm recent repair history
Questions

Degree of use of machine Operated for long period U U U U

Fuel must be added more frequently
Coolant must be added more frequently
There is oil in coolant
Oil smells of diesel fuel
Oil is milky
When engine is started, drops of water come from muffler
When radiator cap is removed and engine is run at low idle, an abnormal number of bubbles appear, or
Check items

coolant spurts back

Exhaust smoke is white
Oil level in damper chamber of applicable machine is low
Oil level in hydraulic tank of applicable machine is low

When compression pressure is measured, it is found to be low

Remove injector and inspect O-ring
Troubleshooting

Inspect cylinder block, liner directly

Inspect rear oil seal directly
Pressure-tightness test of oil cooler shows there is leakage
Remove and inspect supply pump directly
Inspect seal of auxiliary equipment directly
Replace

Replace
Replace

Replace
Replace
Replace
Correct

Correct

Remedy

PW148-8 VEBM720100 20-755

S-14 – Coolant temperature becomes too high (overheating) TESTING AND ADJUSTING

S-14 – Coolant temperature becomes too high (overheat-

ing)
General causes why coolant temperature becomes too high Causes
• Lack of cooling air (deformation, damage of fan)

Rise of hydraulic oil temperature on applicable machine side

• Drop in heat dissipation efficiency
• Problem in coolant circulation system
• Rise in oil temperature in power train
Carry out troubleshooting for machine

Defective radiator cap (pressure valve)

Defective coolant temperature gauge

Broken cylinder head, head gasket

Defective operation of thermostat

Slipping fan belt, worn fan pulley

Clogged, crushed radiator fins
Clogged, broken oil cooler
Holes caused by pitting

Clogged radiator core

Broken water pump
Lack of coolant
Confirm recent repair history
Degree of use of machine Operated for long period U U U U
Questions

Sudden overheated
Condition of overheating
Always tends to overheat
Coolant temperature Rises quickly
gauge (if installed) Does not go down from red range
Radiator coolant level monitor indicates drop of coolant level (if monitor is installed)
Engine oil level has risen and oil is milky
Fan belt tension is low
When fan belt is turned, it has play
Milky oil is floating on coolant
There are excessive air bubbles in radiator, coolant spurts back
Check items

When light bulb is held behind radiator core, no light passes through
Radiator shroud, inside of underguard on applicable machine side are clogged with dirt
or mud
Coolant is leaking because of cracks in hose or loose clamps
Coolant flows out from radiator overflow hose
Fan belt whines under sudden acceleration
Hydraulic oil temperature enters red range faster than engine coolant temperature

When compression pressure is measured, it is found to be low

on applicable machine side

Inspect cylinder liner directly

Carry out troubleshooting

Inspect oil cooler directly

Troubleshooting

Temperature difference between upper and lower tanks of radiator is large

When operation of thermostat is carried out, it does not open at cracking temperature
Temperature difference between upper and lower tanks of radiator is slight
Inspect radiator core directly
When operation of radiator cap is carried out, its cracking pressure is low
Inspect fan belt, pulley directly
When coolant temperature is measured, it is fount to be normal
Replace
Replace
Replace

Replace
Replace

Replace

Replace
Correct
Correct

Correct
Add

Remedy —

20-756 PW148-8 VEBM720100

TESTING AND ADJUSTING S-15 – Abnormal noise is made

S-15 – Abnormal noise is made

General causes why abnormal noise is made Causes

• Abnormality due to defective parts

Deformed cooling fan, loose fan belt, interference of fan belt

• Abnormal combustion

Defective inside of muffler (dividing board out of position)

Leakage of air between turbocharger and cylinder head
• Air sucked in from intake system
• Judge if the noise is an internal noise or an external noise before starting

Improper fuel injection timing (abnormality in coolant

low temperature sensor, boost temperature sensor)
Broken dynamic valve system (valve, rocker lever)
troubleshooting.

Interference of turbocharger, seized turbocharger

• The engine is operated in the low-temperature mode while it is not warmed
up sufficiently. Accordingly, the engine sound becomes a little larger. This

Excessive wear of piston ring, cylinder liner

does not indicate abnormality, however.
• When the engine is accelerated, it is operated in the acceleration mode and
its sound becomes a little larger for up to about 3 seconds. This does not in-
dicate abnormality, however.

Improper gear train backlash

Removed, seized bushing
Improper valve clearance

Clogged, seized injector

Dirt caught in injector
Confirm recent repair history
Degree of use of machine Operated for long period U
Questions

Condition of abnormal Gradually occurred

noise Sudden occurred
Non-specified fuel is being used
Oil must be added more frequently
Metal particles are found when oil filter is drained
Air leaks between turbocharger and cylinder head
When engine is cranked, interference sound is generated around turbocharger
When engine is cranked, abnormal sound is generated around cylinder head
When engine is cranked, beat noise is generated around muffler
Check items

When exhaust manifold is touched immediately after starting engine, temperature of

some cylinders is low
Blue under light load
Color of exhaust gas
Black
Engine does not pick up smoothly and combustion is irregular
Abnormal noise is loud when engine is accelerated
Blow-by gas is excessive

When turbocharger is rotated by hand, it is fount to be heavy

Inspect dynamic valve system directly
When muffler is removed, abnormal noise disappears
Troubleshooting

Inspect valve clearance directly

When compression pressure is measured, it is found to be low
Inspect gear train directly
Inspect fan and fan belt directly
When a cylinder is cut out for reduced cylinder mode operation, engine speed does not
change
Abnormal noise is heard only when engine is started
Confirm with INSITE or monitoring function on applicable machine side
Replace
Replace

Replace
Replace
Replace
Replace
Replace

Replace
Replace

Replace
Correct

Correct

Remedy

PW148-8 VEBM720100 20-757

S-16 – Vibration is excessive TESTING AND ADJUSTING

S-16 – Vibration is excessive

General causes why vibration is excessive Causes

• Defective parts (abnormal wear, breakage)

Improper injection timing (Abnormality in coolant temperature sensor, boost temperature sensor)
• Misalignment between engine and chassis
• Abnormal combustion
• If abnormal noise is made and vibration is excessive, carry out troubleshooting for "S-15 Abnor-
mal noise is made", too.

Misalignment between engine and devices on applicable machine side

Broken output shaft, parts in damper on applicable machine side
Stuck dynamic valve system (valve, rocker lever)

Loose engine mounting bolts, broken cushions

Worn main bearing, connecting rod bearing
Improper gear train backlash
Worn camshaft bushing
Confirm recent repair history
Questions

Degree of use of machine Operated for long period U U U

Suddenly increased
Condition of vibration
Gradually increased
Non-specified oil is being used
Metal particles are found when oil filter is drained
Metal particles are found when oil pan is drained
Oil pressure is low at low idle
Check items

Vibration occurs at mid-range speed

Vibration follows engine speed
Exhaust smoke is black

Inspect dynamic valve system directly

Inspect main bearing and connecting rod bearing directly
Troubleshooting

Inspect gear train directly

Inspect camshaft bushing directly
Check with monitoring function
Inspect engine mounting bolts and cushions directly
When alignment is checked, radial runout or facial runout is detected
Inspect inside of damper directly
Replace
Replace
Replace
Replace
Replace
Replace

Replace
Adjust

Remedy

20-758 PW148-8 VEBM720100

 30 DISASSEMBLY AND ASSEMBLY
How to read this manual. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-6
Removal and installation of assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-6
Special tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-6
Removal of parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-6
Installation of parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-6
Sketches of special tools. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-6
Coating material lists. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-7
Special tools list . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-10
Sketches of special tools. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-12
List of tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-14
Precautions when performing operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-15
Removal and installation of fuel supply pump assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-17
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-17
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-18
Removal and installation of fuel injector assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-20
Special tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-20
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-20
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-22
Removal and installation of front oil seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-25
Special tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-25
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-25
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-25
Removal and installation of rear oil seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-27
Special tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-27
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-27
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-28
Removal and installation of cylinder head assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-30
Special tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-30
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-30
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-35
Removal and installation of fuel cooler assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-40
Removal and installation of combination cooler assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-41
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-41
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-43
Removal and installation of engine and hydraulic pump assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-44
Special tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-44
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-44
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-49
Removal and installation of engine hood assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-51
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-51
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-51
Removal and installation of travel motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-53
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-53
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-54
Disassembly and assembly of travel motor assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-56
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-56
Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-58
Removal and installation of swing motor and swing machinery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-60
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-60
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-61

PW148-8 VEBM720100 30-1

 DISASSEMBLY AND ASSEMBLY

Removal of swing motor assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-62

Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-62
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-63
Disassembly and assembly of swing motor and swing machinery . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-64
Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-64
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-66
Removal and installation of front axle assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-70
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-70
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-71
Disassembly and assembly of front axle. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-72
Disassembly of steering cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-72
Assembly of steering cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-74
Disassembly of epicyclic reduction gear and brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-78
Assembly of epicylic reduction gear and brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-82
Disassembly of joint box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-88
Assembly of joint box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-92
Disassembly of beam trumpet and differential unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-97
Assembly of beam trumpet and differential unit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-100
Disassembly of pinion group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-106
Assembly of pinion group. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-108
Toe-in adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-114
Steering angle adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-115
Removal and installation of rear axle and transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-116
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-116
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-117
Disassembly and assembly of rear axle assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-118
Special tools. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-118
Removal of epicyclic reduction gear and brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-118
Installation of epicylic reduction gear and brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-122
Disassembly of beam trumpet and differential unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-129
Installation of beam trumpet and differential unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-133
Disassembly of pinion group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-139
Installation of pinion group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-142
Disassembly and assembly of transmission. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-148
Special tools. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-148
Removal of travel motor and flange . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-148
Installation of travel motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-149
Removal of transmission box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-152
Installation of transmission box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-160
Removal and installation of propshaft assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-171
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-171
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-171
Removal and installation of wheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-172
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-172
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-172
Removal and installation of suspension lock cylinder assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-173
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-173
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-173
Disassembly and assembly of suspension lock cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-174
Change Rod Seal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-174
Removal and installation of outrigger assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-175
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-175
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-175

30-2 PW148-8 VEBM720100

DISASSEMBLY AND ASSEMBLY

Disassembly and assembly of outriggers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-176

Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-176
Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-176
Removal and installation of dozer blade assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-177
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-177
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-177
Disassembly and assembly of dozer blade . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-178
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-178
Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-178
Removal and installation of swing circle assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-179
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-179
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-179
Removal and installation of revolving frame assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-180
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-180
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-182
Removal and installation of centre swivel joint . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-183
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-183
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-185
Disassembly and assembly of centre swivel joint assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-186
Special tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-186
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-186
Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-187
Removal and installation of fuel tank assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-188
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-188
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-189
Removal and installation of hydraulic tank assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-190
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-190
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-192
Removal and installation of control valve assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-193
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-193
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-195
Removal and installation of LS separation valve assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-196
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-196
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-196
Removal and installation of pressure compensation valve assembly . . . . . . . . . . . . . . . . . . . . . . . . 30-197
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-197
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-197
Removal and installation of main relief valve assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-198
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-198
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-198
Removal and installation of LS control EPC valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-199
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-199
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-199
Removal and installation of PC EPC valve assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-200
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-200
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-200
Removal and installation of PPC valve block assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-201
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-201
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-201

PW148-8 VEBM720100 30-3

 DISASSEMBLY AND ASSEMBLY

Removal and installation of oil seal in hydraulic pump input shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-202
Special tools. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-202
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-202
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-202
Disassembly and assembly of work equipment PPC valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-203
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-203
Disassembly and assembly of hydraulic cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-204
Special tools. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-204
Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-204
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-206
Removal and installation of monoboom work equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-210
Special tools. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-210
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-210
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-211
Removal and installation of 2 piece boom work equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-212
Special tools. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-212
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-212
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-213
Removal and installation of air conditioner unit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-214
Special tools. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-214
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-214
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-217
Removal and installation of counterweight. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-218
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-218
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-219
Removal and installation of operator cab assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-220
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-220
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-221
Removal and installation of monitor assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-222
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-222
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-222
Removal and installation of pump controller assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-223
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-223
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-223
Removal and installation of engine controller assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-224
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-224
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-225
Removal and Installation of KOMTRAX terminal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-226
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-226
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-226

30-4 PW148-8 VEBM720100

DISASSEMBLY AND ASSEMBLY

Blank for technical reason

PW148-8 VEBM720100 30-5

How to read this manual
How to read this manual
Removal and installation of assem-
blies
Special tools
• Special tools that are deemed necessary for re-
moval or installation of parts are listed.
• List of the special tools contains the following
kind of information.
1. Necessity
„: Special tools which cannot be substituted,
should always be used.
z: Special tools which are very useful if availa-
ble, can be substituted with commercially availa-
ble tools.
2. Distinction of new and existing special tools
N: Tools with new part numbers, newly devel-
oped for this model.
R: Tools with upgraded part numbers, remodeled
from already available tools for other models.
Blank: Tools already available for other models,
used without any modification.
3. Circle mark () in sketch column:
A circle mark means that a sketch of the special
tool is presented in the section of Sketches for
Special Tools.
★ Part No. of special tools starting with 79*T
means that they are locally made parts and as
such not interchangeable with those made by
Komatsu in Japan e.g. 79*T--- xxx --- xxxx.
30-6
DISASSEMBLY AND ASSEMBLY
Removal of parts
• The REMOVAL Section contains procedures,
precautions and the amount of oil or water to be
drained.
• Various symbols used in the REMOVAL Section
are explained and listed below.
This mark indicates safety-related precautions
which must be followed when doing the work.
★ This mark gives guidance or precautions when
doing the procedure.
[*1] This mark shows that there are instructions or
precautions for installing parts.
This mark shows oil or water to be drained.
Installation of parts
• Except where otherwise instructed, install parts
is the reverse order of removal.
• Instructions and precautions for installing parts
are shown with mark in the INSTALLATION Sec-
tion, identifying which step the instructions are in-
tended for.
• Marks shown in the INSTALLATION Section
stand for the following.
This mark indicates safety-related precautions
which must be followed when doing the work.
★ This mark gives guidance or precautions when
doing the procedure.
 This mark stands for a specific coating
agent to be used.
 This mark indicates the specified torque.
This mark indicates an amount of oil or wa-
5 ter to be added.
This mark indicates the mass of the assem-
4 bly to be lifted.
Sketches of special tools
• Various special tools are illustrated for the con-
venience of local manufacture.
PW148-8 VEBM720100
DISASSEMBLY AND ASSEMBLY How to read this manual

Coating material lists

• The recommended coating materials such as adhesives, gasket sealants, and greases used for disassembly
and assembly are listed below.

• For coating materials not listed below, use the equivalent of products shown in this manual.

Cate- Komatsu
Part number Q'ty Container Main features and applications
gory code

• Used to prevent rubber gaskets, rubber cushions,

LT-1A 790-129-9030 150 g Tube
and cork plugs from coming out.

• Used for plastic (except polyethylene, polypropyl-

20 g Polyethylene ene, tetrafluoroethylene and vinyl chloride), rub-
LT-1B 790-129-9050
(2 pcs.) container ber, metal, and non-metal parts which require
immediate and strong adhesion.

Polyethylene • Features: Resistance to heat and chemicals.

LT-2 09940-00030 50 g
container • Used to fix and seal bolts and plugs.

790-129-9060
Adhesive: 1 kg
LT-3 (Set of adhesive Can • Used to stick and seal metal, glass, and plastics.
Hardener: 500 g
and hardener)

Polyethylene
Adhesive

LT-4 790-129-9040 250 g • Used to seal plugs.

container

Holtz MH 705 790-129-9120 75 g Tube • Heat-resistant seal used to repair engines.

• Quick-setting adhesive.
ThreeBond Polyethylene • Setting time: Within 5 sec. to 3 min.
790-129-9140 50 g
1735 container • Used mainly to stick metals, rubbers, plastics,
and woods.

• Quick-setting adhesive.
• Quick-setting type.
Aron-alpha Polyethylene
790-129-9130 2g (max. strength is obtained after 30 minutes)
201 container
• Used mainly to stick rubbers, plastics, and met-
als.

• Features: Resistance to heat and chemicals.

Loctite Polyethylene
79A-129-9110 50 cc • Used for fitted portions used at high tempera-
648-50 container
tures.

• Used to stick or seal gaskets and packing of pow-

LG-1 790-129-9010 200 g Tube
er train case, etc.

• Used to seal various threaded portions, pipe

Polyethylene joints, and flanges.
LG-5 790-129-9080 1 kg
container • Used to seal tapered plugs, elbows, and nipples
of hydraulic piping.

• Features: Silicon-based heat and cold-resistant

Gasket sealant

sealant.
LG-6 790-129-9020 200 g Tube • Used to seal flange surfaces and threaded por-
tions.
• Used to seal oil pan, final drive case, etc.

• Features: Silicon-based quick-setting sealant.

LG-7 790-129-9070 1 kg Tube • Used to seal flywheel housing, intake manifold, oil
pan, thermostat housing, etc.

ThreeBond
790-129-9090 100 g Tube • Gasket sealant used to repair engine.
1211

• Features: Silicon-based, heat and cold-resistant,

ThreeBond
419-15-18131 100 g Tube vibration-resistant, impact-resistant sealant.
1207B
• Used to seal transfer case, etc.

PW148-8 VEBM720100 30-7

How to read this manual DISASSEMBLY AND ASSEMBLY

Cate-
Komatsu code Part number Q'ty Container Main features and applications
gory

• Used to lubricate sliding portions.

disulfide lubricant

LM-G 09940-00051 60 g Can

Molybdenum

(to prevent squeaking)

• Used to prevent scuffing and seizure of press-fitted

LM-P 09940-00040 200 g Tube portions, shrink-fitted portions, and threaded portions.
• Used to lubricate linkages, bearings, etc.

SYG2-400LI
SYG2-350LI
G2-LI SYG2-400LI-A Various Various • General purpose type.
SYG2-160LI
SYGA-160CNLI

SYG2-400CA
SYG2-350CA
• Used for bearings used at normal temperature under
G2-CA SYG2-400CA-A Various Various
light load in contact with water or steam.
SYG2-160CA
SYGA-160CNCA

400 g x
Molybdenum SYG2-400M 10 Bellows-type
Grease

disulfide grease SYG2-400M-A 400 g x container • Used for parts under heavy load.
LM-G (G2-M) SYGA-16CNM 20 Can
16 kg

Hyper White
SYG2-400T-A
Grease G2-T, 400 g Bellows-type • Seizure resistance and heat resistance higher than
SYG2-16CNT
G0-T (*) container molybdenum disulfide grease.
SYG0-400T-A (*)
*: For cold dis- 16 kg Can • Not conspicuous on machine since color is white.
SYG0-16CNT (*)
trict

Bio-grease
G2-B, G2-BT (*) SYG2-400B
400 g Bellows-type • Since this grease is decomposed by natural bacteria
*: For use at SYGA-16CNB
container in short period, it has less effects on microorganisms,
high tempera- SYG2-400BT (*)
16 kg Can animals, and plants.
ture and under SYGA-16CNBT (*)
high load

SUNSTAR • Used as primer for cab side.

Glass con-
PAINT PRIMER 20 ml (Using limit: 4 months after date of manufac-
tainer
580 SUPER ture)

SUNSTAR 417-926-3910
• Used as primer for glass side.
GLASS Glass con-
20 ml (Using limit: 4 months after date of manufac-
PRIMER 580 tainer
Adhesive for cab glass

ture)
SUPER

SUNSTAR • Used as primer for painted surface on cab side.

Glass con-
Primer

PAINT PRIMER 22M-54-27230 20 ml (Using limit: 4 months after date of manufac-

tainer
435-95 ture)

• Used as primer for black ceramic-coated sur-

SUNSTAR
face on glass side and for hard polycarbonate-
GLASS
22M-54-27240 150 ml Can coated surface.
PRIMER
(Using limit: 4 months after date of manufac-
435-41
ture)

SUNSTAR • Used as primer for sash (Almite).

Glass con-
SASH PRIMER 22M-54-27250 20 ml (Using limit: 4 months after date of manufac-
tainer
GP-402 ture)

30-8 PW148-8 VEBM720100

DISASSEMBLY AND ASSEMBLY How to read this manual

Cate-
Komatsu code Part number Q'ty Container Main features and applications
gory

• “S” is used for high-temperature season and

SUNSTAR PEN-
Polyethyl- “W” for low-temperature season as adhesive for
GUINE SEAL
417-926-3910 320 ml ene con- glass.
580 SUPER “S”
tainer (Using limit: 4 months after date of manufac-
or “W”
ture)
Adhesive

Polyethyl- • Used as adhesive for glass.

Sika Japan,
20Y-54-39850 310 ml ene con- (Using limit: 6 months after date of manufac-
Sikaflex 256HV
tainer ture)

Adhesive for cab glass

SUNSTAR PEN- Ecocart • Used as adhesive for glass.
GUINE SUPER 22M-54-27210 320 ml (Special (Using limit: 6 months after date of manufac-
560 container) ture)

SUNSTAR PEN- Polyethyl- • Used to seal joints of glass parts.

GUINE SEAL 417-926-3920 320 ml ene con- (Using limit: 4 months after date of manufac-
No. 2505 tainer ture)
Caulking material

SEKISUI SILI- Polyethyl- • Used to seal front window.

CONE SEAL- 20Y-54-55130 333 ml ene con- (Using limit: 6 months after date of manufac-
ANT tainer ture)

• Used to seal joint of glasses.

GE TOSHIBA
Translucent white seal.
SILICONES 22M-54-27220 333 ml Cartridge
(Using limit: 12 months after date of manufac-
TOSSEAL 381
ture)

PW148-8 VEBM720100 30-9

How to read this manual DISASSEMBLY AND ASSEMBLY

Special tools list

Component Symbol Part number Part name Nature of work, remarks

1 795-799-6700 Puller Removal of fuel injector

Cylinder head
Positioning with 3RD and 4TH
assembly, fuel 2 795-799-1131 Gear
cylinder Top
injector assembly
3 795-799-8150 Remover Removal of inlet connector

Engine front seal 4 795-799-6400 Seal puller Installation of engine front seal

Engine rear seal 5 795-799-6500 Seal puller Installation of engine rear seal
A
Wrench Angle tightening of bolt
6 790-331-1120
Cylinder head (Angle)
assembly Judgment of cylinder head bolt
7 795-790-4510 Gauge
length

8 796T-401-1110 Plate Removal and installation of

Engine and hydrau-
engine and hydraulic pump
lic pump assembly 9 795-790-9300 Lifting tool assembly

Hydraulic pump 10 796-460-1210 Oil stopper Stopping oil

assembly, Engine
and hydraulic pump
assembly, Control D
valve assembly, 11 796-770-1320 Adaptor
Center swivel joint
assembly

30-10 PW148-8 VEBM720100

DISASSEMBLY AND ASSEMBLY How to read this manual

Component Symbol Part number Part name Nature of work, remarks

1 790-502-1003 Cylinder repair stand

790-101-1102 Pump

790-102-4300 Wrench Assembly

2
790-102-4310 Pin

3 790-720-1000 Expander

796-720-1670 Rubber Band (for boom and arm)

07281-01279 Clamp
4
796-720-1660 Rubber band (for bucket)

07281-01159 Clamp

790-201-1702 Push tool kit

• 790-201-1831 Push tool (for bucket)

Hydraulic cylinder
U • 790-201-1931 Push tool (for arm)
assembly 5
• 790-201-1940 Push tool (for boom)

• 790-101-5021 Grip

• 01010-50816 Bolt

790-201-1500 Push tool kit (for bucket)

• 790-201-1640 Push tool

• 790-101-5021 Grip

• 01010-50816 Bolt
6
790-201-1980 Plate (for boom)

790-201-1990 Plate (for arm)

790-101-5021 Grip

01010-50816 Bolt

796-670-1100 Remover Removal of foot pin

796-670-1110 • Sleeve

796-670-1120 • Plate

796-670-1130 • Screw
Work equipment
P 791-775-1150 • Adapter
assembly
01643-33080 • Washer

01803-13034 • Nut

790-101-4000 Puller (490 kN {50 t} long)

790-101-1102 Pump (294 kN {30 t})

799-703-1200 Service tool kit

799-703-1100 Vacuum pump (100 V)

Air conditioner
S 799-703-1111 Vacuum pump (220 V) Refilling of gas for air conditioner
assembly
799-703-1121 Vacuum pump (240 V)

799-703-1401 Gas leak detector

Operator’s cab 793-498-1210 Lifter (Suction cup) Removal and installation of oper-
glass 20Y-54-13180 Adapter ator’s cab glass

PW148-8 VEBM720100 30-11

How to read this manual DISASSEMBLY AND ASSEMBLY

Sketches of special tools

NOTE
Komatsu cannot accept any responsibility for special tools manufactured according to this sketch.

F2 Push Tool: Swing Motor

30-12 PW148-8 VEBM720100

DISASSEMBLY AND ASSEMBLY How to read this manual

Blank for technical reason

PW148-8 VEBM720100 30-13

How to read this manual DISASSEMBLY AND ASSEMBLY

List of tools

Part Number Part Name Area Used on Machine

799-201-2202 Boost Gauge Kit Air boost pressure

799-101-5210 Fitting (PT 1/4) Air boost pressure

799-201-9000 Handy Smoke Checker Measurement of exhaust colour

795-799-1131 Gear Adjustment of valve clearance

795-799-1900 Pin Assembly Adjustment of valve clearance

799-201-1504 Blow By Kit Measurement of blow by

795-790-1950 Tool (Nozzle) Measurement of blow by

795-799-1131 Gear Adjustment of fuel injection timing

795-799-1900 Pin Assembly Adjustment of fuel injection timing

795-799-1950 Lock Pin Adjustment of fuel injection timing

799-101-5002 Hydraulic Tester Measurement of engine oil pressure

790-261-1203 Digital Type Hydraulic Tester Measurement of engine oil pressure

799-401-2320 Hydraulic Tester Measurement of engine oil pressure

673-281-3170 Joint Measurement of engine oil pressure

621-581-9710 O-Ring Measurement of engine oil pressure

796-627-1130 Wear Gauge Inspection of wear on the sprocket

799-101-5220 Nipple (10 x 1.25mm) Hydraulic testing

799-101-1340 Differential Pressure Gauge Hydraulic testing

799-401-2910 Nipple (Size 02) Solenoid valve output

799-401-2920 Nipple (Size 03) Measurement of solenoid valve output

795-502-1205 Compression Gauge Cylinder compression

795-502-1700 Adapter Cylinder compression

30-14 PW148-8 VEBM720100

DISASSEMBLY AND ASSEMBLY Precautions when performing operation

Precautions when performing operation

Be sure to follow the general precautions given be- • Fasten tags to wires and hoses to identify and
low when performing removal or installation (disas- show their installation position and help prevent
sembly or assembly) of units. any mistakes when re-installing.

• Count and check the number and thickness of

1. Precautions when performing removal work
• If the engine coolant water contains antifreeze,
dispose of it correctly.
• After disconnecting hoses or tubes, cover them
or install blind plugs to prevent dirt or dust from
entering.
• When draining oil, prepare a container of ade-
quate size to catch the oil.
• Confirm the match marks showing the installa-
tion position, and make match marks in the nec-
essary places before removal to prevent any
mistake when assembling.
• To avoid loosening any wire contacts, do not pull
on the wires. In-order to prevent excessive force
to the wiring, hold onto the connectors when dis-
connecting them.
the shims, and keep them in a safe place.
• When raising or lifting components, be sure to
use proper lifting equipment of ample strength
and safety.
• When using forcing screws to remove any com-
ponents, tighten the forcing screws uniformly in
turn.
• Before removing any unit, clean the surrounding
area and install a cover to prevent any dust or
dirt from entering after removal.
★ Precautions when handling piping during disas-
sembling
Fit the following blind plugs into the piping after
disconnecting it during disassembly operations.

A. Hoses and tubes using sleeve nuts

Nominal number Plug (nut end) Sleeve nut (elbow end) Use the two items below as a set
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)

B. Split flange type hoses and tubes

Nominal number Flange (hose end) Sleeve head (tube end) Split flange
04 07379-00400 07378-10400 07371-30400
05 07379-00500 07378-10500 07371-30500

C. If the part is not under hydraulic pressure, the following corks can be used:
Dimensions
Nominal number Part 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
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
22 07049-02228 22 18.5 28
24 07049-02430 24 20 30
27 07049-02734 27 22.5 34

PW148-8 VEBM720100 30-15

Precautions when performing operation
2. Precautions when carrying out installation
work
• Tighten all bolts and nuts (sleeve nuts) to the
specified (KES) torque.
• Install the hoses without twisting or interfer-
ence.
• Replace all gaskets, O-rings, cotter pins and
lock plates with new parts.
• Bend the cotter pin or lock plate securely.
• When coating with adhesive, clean the part
and remove all oil and grease, then coat the
threaded portion with two or three drops of
adhesive.
• When coating with gasket sealant, clean the
surface and remove all oil and grease, check
that there is no dirt or damage, then coat uni-
formly with gasket sealant.
• Clean all parts, and correct any damage,
dents, burrs or rust.
• Coat rotating parts and sliding parts with en-
gine oil.
• When press-fitting parts, coat the surface
with anti-friction compound (LM-P).
• After installing snap rings, check that the
snap ring is installed securely in the ring
groove.
• When connecting wiring connectors, clean
the connector to remove all oil, dirt or water
then connect securely.
• When using eye bolts, check that there is no
deformation or deterioration, screw them in
fully and align in the direction of the hook.
• When tightening split flanges, tighten uni-
formly in turn to prevent excessive tightening
on one side.
★ When operating the hydraulic cylinders for the
first time after reassembling cylinders, pumps
and other hydraulic equipment removed for re-
pair, bleed the air as follows:
30-16
DISASSEMBLY AND ASSEMBLY
1. Start the engine and run it at low idle.
2. Operate the work equipment control lever to op-
erate the hydraulic cylinders, 4 - 5 times, stop-
ping the cylinders 100 mm from the end of their
stroke.
3. Next operate the hydraulic cylinder 3 - 4 times to
the end of its stroke.
4. After doing this run the engine at normal speed.
★ When using the machine for the first time after
repair or long storage, follow the same proce-
dure.
3. Precautions when completing the operations
• If the engine coolant water has been
drained, tighten the drain valve and add
coolant water to the specified level. Run the
engine to circulate the coolant water through
the system. Then check the coolant water
level again.
• If the hydraulic equipment has been re-
moved and installed again, add hydraulic oil
to the specified level. Run the engine to cir-
culate the oil through the system. Then
check the hydraulic oil level again.
• If the piping or hydraulic equipment, have
been removed for repair, bleed the air from
the system after reassembling the parts.
• For details, see TESTING AND ADJUST-
ING, Bleeding air.Add the specified amount
of grease (molybdenum disulphide grease)
to the work equipment related parts.
PW148-8 VEBM720100
DISASSEMBLY AND ASSEMBLY Removal and installation of fuel supply pump assembly

Removal and installation of fuel supply pump assembly

Removal (Do not use wooden plugs since chips

may enter the fuel line.)

6. Disconnect fuel return hose (6).

Befor starting work, turn the starting switch to
the OFF position, wait over one minute, the turn
off the battery main switch and take out the bat-
tery main switch key.

1. Close fuel stop valve (1) under the fuel tank.

2. Open the engine hood.

3. Disconnect clamp (3) of fuel hose (2) from brack-

et (4).

★ When loosening the bolt, fix the nut with

wrench so that the hose will not be twisted.
(If the hose is dragged and twisted, an ex-
cessive force is applied to the connector and
the inside of the connector may be broken.)

4. Remove clamp bracket (4). 7. Disconnect hose (7) connected to the fuel filter.

5. Disconnect fuel return hose connector (5) con- ★ Before disconnecting hose (7), be sure to
nected to the supply pump. [*1] perform steps 3 to 5.

★ When removing a connector of quick coupler 8. Disconnect wiring connector (8).

type, observe the following points.
• Remove mud from each hose joint in ad-
vance (since the lock may be stuck in
the mud).
9. Disconnect hose (9) connected to the prefilter.
[*2]
10. Disconnect hose (10) connected to the fuel filter.

• Never use pliers or a screwdriver to dis-

connect the connector.

• Pull out lock (L) of each hose joint

straight (in direction [a]) while pressing it
from both sides.
(If the connector is disconnected forcibly
by twisting or bending it to the right and
left, its inside may be broken.)

• Put plugs in the adapters of the discon-

nected hoses to prevent fuel from flow-
ing out.

PW148-8 VEBM720100 30-17

Removal and installation of fuel supply pump assembly
11. Remove 2 high-pressure pipe bellows (11) from
common rail (12) and fuel supply pump (13). [*3]
12. Disconnect 2 high-pressure pipe clamps (14) be-
tween the common rail (12) and fuel supply
pump (13). [*4]
★ Since each clamps are divided two, take
care not to drop them in the end cover when
removing.
13. Disconnect high-pressure pipe (15) from fuel
supply pump (13). [*5]
★ Loosen the sleeve nut on the common
rail side in advance.
14. Remove the 3 fuel supply pump mounting nuts
and fuel supply pump assembly (7). (Locations of
nuts: [A]) [*6]
Installation
• Carry out installation in the reverse order to re-
moval.
[*1]
When installing a connector of quick coupler
type, observe the following points.
★ Replace the connector with new one in the
following cases.
1] The connector was removed with pliers or
a screwdriver or by bending it to the right and
left.
2] There is damage or deformation in the
connector.
30-18
DISASSEMBLY AND ASSEMBLY
★ Check that mud or dirt is not sticking to the
hose adapter in advance.
★ Press and insert the connector straight (in di-
rection [b]) without bending it to the right or
left.
(If it is difficult to insert the connector, do not
push it in forcibly but pull it out. Then, check
the convex and concave parts for abnormali-
ty and mud.)
[*2]
 Joint bolt
19.6 - 29.4 Nm (2.0 - 3.0 kgm)
[*3]
★ Install each bellows with the slits out and down.
★ The bellows are installed so that fuel will not
spout over the hot parts of the engine and catch
fire when it leaks for some reason.
[*4]
 Clamp mounting bolt:
24 ± 4 Nm {2.45 ± 0.41 kgm}
[*5]
★ Temporarily tighten the high-pressure pipe
sleeve nuts on the common rail side and fuel
supply pump side and then tighten them to the
specified torque in the order of the pump side
and common rail side.
 Sleeve nut:
35 ± 3.5 Nm {3.6 ± 0.36 kgm}
[*6]
If too much grease is applied to an O-ring at as-
sembly, it will ooze out during operation.
Accordingly, do not apply grease too much. (Ap-
ply grease to the O-ring groove area of part A.)
PW148-8 VEBM720100
DISASSEMBLY AND ASSEMBLY Removal and installation of fuel supply pump assembly

When the supply pump mounting stud bolts of

the gear housing were removed, apply adhesive
to thier root side and mount them.

 Stud bolt: Adhesive (LT-2)

 Stud bolt:
12 ± 2 Nm {1.22 ± 0.2 kgm}

 Fuel supply pump mounting nut

24 ± 4 Nm {2.45 ± 0.41 kgm}

PW148-8 VEBM720100 30-19

Removal and installation of fuel injector assembly DISASSEMBLY AND ASSEMBLY

Removal and installation of fuel injector assembly

Special tools 5. Disconnect wiring (5).

New/Remodel
6. Disconnect bracket (6).

Necessity

Sketch
Q'ty
Symbol Part No. Part name 7. Remove high-pressure pipe bellows (7) from the
cylinder head and common rail. [*3]

1 795-799-6700 Puller „ 1
A 2 795-799-1131 Gear „ 1
3 795-799-8150 Remover z 1

Removal

Befor starting work, turn the starting switch to

the OFF position, wait over one minute, the turn
off the battery main switch and take out the bat-
tery main switch key. 8. Remove high-pressure pipe (8). [*4]

1. Close fuel stop valve (1) under the fuel tank.

9. Remove retaining nut (9) and then remove inlet

connector (10) .

2. Remove blow-by duct (2) mounting bolts and dis- ★ Tool A3 is prepared for remove the inlet con-
connect blow-by duct (2). [*1] nector (10).

3. Remove cylinder head cover mounting bolts (3) ★ Check that the inlet connector is free from
and remove cylinder head cover (4). [*2] flaw and dirt.

4. Referring to Testing and adjusting, "Adjusting 10. Disconnect wiring (11).

valve clearance", set the No. 1 and 4 cylinders to
the top dead center. ★ Since different cylinders have different wiring
colors, record their combinations.

30-20 PW148-8 VEBM720100

DISASSEMBLY AND ASSEMBLY Removal and installation of fuel injector assembly

11. Loosen locknut (12) and then loosen adjustment 14. Remove fuel injector assembly mounting bolt
screw (13) thoroughly. (16).

12. Remove rocker arm (14).

15. Using tool A1, remove fuel injector assembly

(17).
13. Remove crosshead (15).
★ Cover injector sleeve with cloth after remov-
★ Since the shapes of holes [a] and [b] of the ing fuel injector assembly for free from flaw
crosshead are different, record the installed and dirt.
position of the crosshead.

PW148-8 VEBM720100 30-21

Removal and installation of fuel injector assembly DISASSEMBLY AND ASSEMBLY

Installation
1. Fuel injector assembly

★ Check that fuel injector sleeve (18) is free

from flaw and dirt.

e. Apply engine oil (EO15W-40) to O-ring (22)

of inlet connector (10) and the inlet connec-
tor mounting hole. While setting part of key
to the groove on the head, insert inlet con-
nector (10) to the end.
a. Fit O-ring (20) and gasket (21) to fuel injector
(19). ★ If the injector was replaced with new
one, replace the inlet connector with new
★ Replace O-ring and gasket with new
one, too.
one.
★ Check of inlet connector
b. Apply engine oil (EO15W-40) to the O-ring of
Check the inlet connector for the follow-
the fuel injector (19) and the mounting hole
ing defects. If any defect is detected, re-
on the head.
place the inlet connector.
c. While setting the concave and convex (A),
• Burrs and deformation of inlet and outlet
install holder (22) to fuel injector (19).
of connector

• Clogging and dirt of edge filter

(If there is sediment here, do not use
connector)

• Breakage and deterioration of O-ring

• Wear, improper contact and trace of

leakage on outlet seal

★ If high-pressure fuel leaks, the seat sur-

d. Install fuel injector assembly (17) to the fuel
injector sleeve and tighten the mounting bolt
by 3 - 4 turns.
face is eroded and fine streaks or flaws
are made.
If this erosion is detected, replace the in-
let connector and injector.

★ When installing the fuel injector assem-

bly, check the direction of the inlet con-
nector mounting hole.

30-22 PW148-8 VEBM720100

DISASSEMBLY AND ASSEMBLY Removal and installation of fuel injector assembly

f. Install and finger-tighten retainer (9). 2. Install crosshead (15).

g. Tighten right and left mounting bolts (16) of
fuel injector assembly alternately.
 Fuel injector mounting bolt:
8 ± 0.8 Nm {0.8 ± 0.08 kgm}
h. Tighten retaining nut (9) to the specified
torque.
★ Since the shapes of holes [a] and [b] of the
crosshead are different, take care when in-
stalling.
(Install the crosshead in the direction of the
intake and exhaust valves recorded when it
was removed.)

 Retaining nut:
50 ± 5 Nm {5.1 ± 0.5 kgm}

3. Install rocker arm (14).

★ Before installing the rocker arm, check that

adjustment screw (13) is loosened thorough-
ly.

★ Check that the ball of the adjustment screw

is fitted to the socket of the push rod.

 Rocker arm mounting bolt:

36 ± 5 Nm {3.7 ± 0.5 kgm}

PW148-8 VEBM720100 30-23

Removal and installation of fuel injector assembly DISASSEMBLY AND ASSEMBLY

4. Install wiring (11). ★ Before installing the high-pressure pipe, check it

for the following defects. If there is any of these
★ Since different cylinders have different wire defects, it can cause fuel leakage. Accordingly,
colors, check their combinations before in- replace the high-pressure pipe with new one.
stalling.
• Check the taper seal of the connecting part
★ Installed positions of wirings (Part "j": Part of 2 mm from the end) for visi-
ble lengthwise slit "k" and dent "l".
Wiring color Cylinder No.

White 1, 3 • Check part "m" (End of the taper seal: Part at

2 mm from the end) for stepped-type wear
Black 2, 4
(fatigue) which your nail can feel.

 Wiring mounting nut:

1.5 ± 0.25 Nm {0.15 ± 0.03 kgm}

• Install the high-pressure pipe according to

the following procedure.

a. Install the high-pressure pipe and temporari-

ly tighten the sleeve nuts on the common rail
5. Adjusting valve clearance side and cylinder head side.
Referring to Testing and adjusting, "Adjusting
valve clearance", adjust the valve clearance.  Sleeve nut:
0.2 - 0.8 Nm {0.02 - 0.08 kgm}
• Carry out the following installation in the reverse
order to removal. b. Tighten the sleeve nuts on the common rail
side and cylinder head side to the specified
[*1] torque.
 Blow-by duct mounting bolt:  Sleeve nut:
7 ± 2 Nm {0.7 ± 0.2 kgm} 35 ± 3.5 Nm {3.57 ± 0.36 kgm}

[*2] c. Install the sleeve nuts on the common rail

side and cylinder head side.
★ If the stud bolts were removed, tighten them to
the following torque. ★ Install each bellows with the slits out and
 Stud bolt:
down.

24 ± 4 Nm {2.4 ± 0.4 kgm} ★ The bellows are installed so that fuel will
not spout over the hot parts of the engine
[*3] [*4] and catch fire when it leaks for some
reason.

★ If all of the No. 1 - No. 4 injector assemblies were

• Do not bend the high-pressure pipe to collect removed, install the high-pressure pipes, refer-
before installing. ring to "Removal and installation of cylinder head
• Be sure to use the genuine high-pressure pipe assembly".
clamps and observe the tightening torque.
• After installing the high-pressure pipe, be sure
to install the bellows to the sleeve nut.

30-24 PW148-8 VEBM720100

DISASSEMBLY AND ASSEMBLY Removal and installation of front oil seal

Removal and installation of front oil seal

Special tools Installation

1. Using tool A4, install front oil seal (3).

New/Remodel
Necessity

Sketch
Sym-
★ Replace the front oil seal with new one.

Q'ty
Part No. Part name
bol

★ Before installing the seal, check that the end

4 795-799-6400 Seal puller „ 1 corners and lip sliding surfaces of the crank-
A shaft are free from flaw, burr, and rust of the
6 790-331-1120 Wrench (Angle) z 1
housing.

Removal ★ When installing the seal, do not apply oil or

grease to the shaft and seal lip "a". Wipe off
1. Remove the engine assembly. For details, see the oil from the shaft.
"Removal and installation of engine assembly".

2. Remove crank pulley mounting bolts (1) and

crank pulley (2).

★ The projection and runout of seal (3) from

cover (C) must be as follows.

• Projection x: Max. 0.38 mm

3. Remove seal (3).
• Runout y: Max. 0.25 mm

PW148-8 VEBM720100 30-25

Removal and installation of front oil seal DISASSEMBLY AND ASSEMBLY

2. Crank pulley

a. While checking the dowel pin hole on the

back side of the crank pulley (2), install crank
pulley (2) to the crankshaft.

★ If the dowel pin was removed, install it

before installing the crank pulley.

b. Tightening order of crank pulley mounting

bolts (1)

I. Tighten the bolts to

55 ± 5 Nm {5.6 ± 0.5 kgm}
in the diagonal order.

II. Loosen the bolts by 180 °.

III. Tighten the bolts to

55 ± 5 Nm {5.6 ± 0.5 kgm}
in the diagonal order.

IV. Tighten the bolts by

90 ° ± 5 °
(with angle tightening tool A6).

• When not using angle tightening tool

Make a mark on the crank pulley and
each bolt with paint and then tighten the
bolt by 90 ° ± 5 °.

• Carry out the installation in the reverse order to

removal.

30-26 PW148-8 VEBM720100

DISASSEMBLY AND ASSEMBLY Removal and installation of rear oil seal

Removal and installation of rear oil seal

Special tools 3. Removal of flywheel

New/Remodel
a. Remove 2 flywheel mounting bolts (3) on a

Necessity
diagonal line and install guide bolts [2]. [*1]

Sketch
Sym-

Q'ty
Part No. Part name
bol
b. Sling flywheel (4) and remove the remaining
mounting bolts.
A 5 795-799-6500 Seal puller „ 1
c. Pull out flywheel (4) toward you.

Removal d. Remove guide bolts [2] and lift off flywheel

(4).

4 Flywheel 35 kg
Befor starting work, turn the starting switch to
the OFF position, wait over one minute, the turn
off the battery main switch and take out the bat-
tery main switch key.

1. Remove the work equipment assembly. For de-

tails, see "Removal and installation of work
equipment assembly".

2. Removal of damper

a. Remove 1 damper mounting bolt (1) at the

top. 4. Removal of rear oil seal

a. Install tool A5 to the crankshaft.

b. Tighten tapping screw [3] of tool A5 into the

seal carrier of rear oil seal (5).

c. Turn the handle clockwise to remove rear oil

seal (5).

b. Install guide bolt [1] and remove the 7 re-

maining damper mounting bolts (1).

c. Remove damper (2).

PW148-8 VEBM720100 30-27

Removal and installation of rear oil seal DISASSEMBLY AND ASSEMBLY

Installation 4. Install rear seal (5) on flywheel housing (7) to the

proper depth by using tool A5.
1. Install the rear seal according to the following
procedure. ★ Push in rear seal (5) taking care that there
are no bend etc. on it.
★ Replace the front oil seal with new one.
★ Extrusion of rear seal (5) from flywheel hous-
★ Do not remove pilot [4] which is attached to ing (7)
rear seal (5) until rear seal (5) is inserted to (X): less than 0.38 mm
the crankshaft.

★ Before installing the rear seal, degrease,

clean and dry the crankshaft sealing face
and the seal lip face to prevent oil leakage.

2. Insert pilot [4] to crankshaft (6) and push rear

seal (5) into flywheel housing (7).

3. Push in rear seal (5) further and pull out pilot [4].

• Carry out the rest of installation in the reverse or-

der to removal.

30-28 PW148-8 VEBM720100

DISASSEMBLY AND ASSEMBLY Removal and installation of rear oil seal

[*1] • Measurement of facial runout

★ Tighten the 8 flywheel assembly mounting bolts
in the order of [1] through [8] as shown in the fig-
ure below.
 Flywheel assembly mounting bolt:
137 ±7 Nm {13.97 ± 0.71 kgm}
★ Facial runout: less than 0.20 mm
d. As in the case of measurement of radial ru-
nout, bring the dial gauge probe into contact
with end surface (b) near the outer perimeter
of the flywheel at a right angle.

★ Conduct measurement pulling the crank-

shaft to either the front or rear side to
prevent errors caused by shakiness.

e. Rotate the flywheel 360 ° and measure the

difference of the maximum swing of the dial
gauge indicator.

★ Tighten the bolts using bar [5] for preventing

rotation of the flywheel assembly.

• Measurement of radial runout

★ Radial runout: less than 0.13 mm

a. Set dial gauge [6] to the stand, and set it to

flywheel housing (7).

b. Bring the dial gauge probe into contact with

faucet joint portion (a) or the outer perimeter
surface of the flywheel at a right angle.

c. Rotate the flywheel 360° and measure the

difference of the maximum swing of the dial
gauge indicator.

★ Check that the dial gauge indicator is

back in the original position after the fly-
wheel is rotated 360°.

PW148-8 VEBM720100 30-29

Removal and installation of cylinder head assembly DISASSEMBLY AND ASSEMBLY

Removal and installation of cylinder head assembly

Special tools 3. Removal of hoses and guard above engine

New/Remodel
a. Remove air conditioner compressor drive

Necessity
belt guard (2).

Sketch
Sym-

Q'ty
Part No. Part name
bol
b. Remove radiator hose (3). [*1]

1 795-799-6700 Puller „ 1 c. Remove aftercooler hose (5). [*2]

2 795-799-1131 Gear „ 1
d. Disconnect heater hose (6).
A 3 795-799-8150 Remover z 1
6 790-331-1120 Wrench (Angle) z 1 5 2
3
7 795-790-4510 Gauge z 1

Removal

Befor starting work, turn the starting switch to

the OFF position, wait over one minute, the turn
off the battery main switch and take out the bat- 6
tery main switch key.
4. Disconnection of air conditioner compressor as-
sembly
1. Open the right rear inspection cover and open fu-
el drain valve (1) to drain the fuel. a. Disconnect wiring connector A01 (7).

When fuel tank is full: 275 l b. Remove 2 air conditioner compressor

mounting bolts (8).

c. Remove drive belt (9).

d. Disconnect air conditioner compressor as-

sembly (10) and move it so that it will not be
an obstacle.

e. Remove bracket (11).

Drain the coolant from the engine.

6 Coolant water: Approx. 25 l

2. Removal of engine hood

Remove the engine hood. For details, see "Re-

moval and installation of engine hood".

30-30 PW148-8 VEBM720100

DISASSEMBLY AND ASSEMBLY Removal and installation of cylinder head assembly

5. Removal of alternator b. Loosen 2 U-bands (17).

a. Insert the wrench in part A and turn it to the 17

direction of [a] to loosen fan belt (12).

b. Remove fan belt (12) from alternator (13).

• Set the wrench in hole A securely and then turn

the tension pulley to direction [a]. (The tension
pulley spring is very strong. If the wrench is in-
stalled halfway and turned, it may come off and
can cause a serious accident.)
• After removing the fan belt, return the wrench
slowly and carefully. c. Remove clamp top covers (18) and (19).
• Take care not to catch your fingers between the
pulley and fan belt during the work.

c. Remove the alternator mounting bolts and

disconnect alternator assembly (13). (Move
the alternator without removing wirings (14)
and (15) so that it will not be an obstacle.)

d. Remove clamp (20).

e. Slant muffler assembly (21) outward.

21 20

6. Disconnection of muffler and turbocharger as-

sembly

a. Remove guard (16).

16

PW148-8 VEBM720100 30-31

Removal and installation of cylinder head assembly DISASSEMBLY AND ASSEMBLY

7. Removal of turbocharger assembly and exhaust

manifold

a. Disconnect hose (25) between the turbo-

charger and air cleaner from the turbocharg-
er. [*3]

b. Loosen the aftercooler lower hose at air con-

nector (26). [*4]

c. Disconnect the air intake connector from the

turbocharger. [*5]

d. Remove lubrication upper hose (27). [*6] h. Remove turbocharger assembly (30).
★ Fix the connector mounting nut with a
spanner to prevent it from being
dragged.

e. Remove cylinder head cover (28). [*7]

★ If the cylinder head cover is not re-

moved, the lubrication return tube
mounting bolt on the cylinder head side
cannot be removed.

f. Remove 4 mounting nuts (29) of turbocharg-

er assembly (30) and place turbocharger as- i. Remove exhaust manifold (33). [*10]
sembly (30) on the bolts. [*8]

★ If turbocharger assembly (30) is not

raised to increase the clearance, the
mounting bolts on the inside of the lubri-
cation return tube cannot be removed.

8. Disconnect of wiring

a. Disconnect wiring connectors (34) and (36).

b. Disconnect wiring clamp mounting brackets

(37) and (38).
g. Remove 2 lubrication return tube mounting c. Move wiring (39) toward the counter weight
bolts (31) and disconnect lubrication return side.
tube (32). [*9]

★ Mounting bolt:
Hexagon head bolt (M6 × 1.0)

30-32 PW148-8 VEBM720100

DISASSEMBLY AND ASSEMBLY
9. Disconnect fuel return hose
a. Remove partition (40).
b. Disconnect fuel return hose (41).
10. Remove oil level gauge guide (42).
11. Removal of fuel high-pressure pipe
a. Remove high-pressure pipe bellows (43) be-
tween the common rail and cylinder head
and that between the common rail and fuel
supply pump. [*11]
b. Remove high-pressure pipe (44) between
the common rail and cylinder head.
c. Disconnect high-pressure pipe (45) between
the common rail and fuel supply pump from
the common rail.
★ Remove 2 high-pressure pipe clamps
between the common rail and fuel sup-
ply pump and loosen the high-pressure
pipe sleeve nut on the supply pump side.
PW148-8 VEBM720100
Removal and installation of cylinder head assembly
12. Remove common rail (46). [*13]
★ Do not remove fuel pressure sensor (a) for a
reason other than replacement.
★ When removing the fuel pressure sensor to
replace, remove all mud from and clean
around it thoroughly.
13. Referring to Testing and adjusting, "Adjusting
valve clearance", check that the No. 1 and 4 cyl-
inders are at the top dead center.
14. Removal of injector and rocker arm housing
a. Disconnect wiring (48) from the injector.
[*14]
b. Loosen retaining nut (49) and remove inlet
connector (50). [*15]
★ Tool A3 is prepared for removal of the in-
let connector.
c. Remove rocker arm mounting bolts (51) and
rocker arm (52) and its seat. [*16]
★ Loosen lock nut (53) and then loosen ad-
justment screw (54) thoroughly.
30-33
Removal and installation of cylinder head assembly
d. Remove crosshead (55). [*18]
★ Record the position and direction
(shapes of holes "a" and "b") of each
crosshead. (When reinstalling the cross-
head, set it in the same direction.)
e. Remove push rod (56).
15. Remove 18 cylinder head mounting bolts (61)
f. Remove 2 fuel injector assembly mounting
bolts (57). [*19]
30-34
DISASSEMBLY AND ASSEMBLY
g. Using tool A1, remove fuel injector assembly
(58). [*20]
h. Remove 5 rocker arm housing mounting
bolts (59) and rocker arm housing assembly
(60). [*21]
and lift off cylinder head assembly (62). [*22]
4 Cylinder head assembly Assembly:
50 kg
PW148-8 VEBM720100
DISASSEMBLY AND ASSEMBLY Removal and installation of cylinder head assembly

Installation [*6]

Carry out installation in the reverse order to removal.  Lubrication inlet hose mounting nut:
24 ± 4 Nm {2.4 ± 0.4 kgm}
[*1]
★ When nut on turbocharger side was loos-
 Radiator hose mounting clamp bolt: ened
10.8- 11.8 Nm {1.1- 1.2 kgm}
 Nut on turbocharger side:
[*2] [*4] 36 ± 5 Nm {3.7 ± 0.5 kgm}
★ Procedure for installing MIKALOR clamp [*7]
• When tightening the clamp, apply the following ★ When stud bolt was removed
lubricating oil or equivalent to its threaded part
[C].  Stud bolt:
Lubricating oil: Threebond (PANDO 18B) 24 ± 4 Nm {2.4 ± 0.4 kgm}

• Adjust bridge [A] so that it will be under band [B]. [*8]

• Tighten until dimensions [L] and [M] are set to  Turbocharger mounting nut:
the specified dimensions. 24 ± 4 Nm {2.4 ± 0.4 kgm}

Dimension L ★ When stud bolt was removed

Between aftercooler and air intake connector:
Aftercooler side: 10 (+0/-3) mm  Stud bolt:
10 ± 2 Nm {1.0 ± 0.2 kgm}
Air intake connector side:
16 (+0/-3) mm [*9]

Between aftercooler and turbocharger connec-  Lubrication return hose mounting bolt:
tor: 10 (0/-3) mm 10 ± 2 Nm {1.0 ± 0.2 kgm}

Dimension M: Min. 5 mm [*10]

• If the tightened dimensions are out of the above ★ Tighten the exhaust manifold mounting bolts ac-
ranges, replace the clamp with new one. cording to the following procedure.

• Do not use an impact wrench. 1. Tighten the bolts to

24 ± 4 Nm {2.4 ± 0.4 kgm} in the order shown in
the figure.

2. Tighten the bolts to

53 ± 5 Nm {5.4 ± 0.51 kgm} in the order shown in
the figure.

3. Tighten only [1]- [4] in the figure to

53 ± 5 Nm {5.4 ± 0.51 kgm} again.

[*3]

 Air hose clamp bolt:

10.0- 11.0 Nm {1.02- 1.12 kgm}

[*5]

 Connector mounting nut:

10 ± 2 Nm {1.02 ± 0.2 kgm}

PW148-8 VEBM720100 30-35

Removal and installation of cylinder head assembly
[*11] [*12]
• Precautions for installing high-pressure pipe
• Do not bend the high-pressure pipe to collect
before installing.
Be sure to use the genuine high-pressure pipe
clamps and observe the tightening torque.
After installing the high-pressure pipe, be sure
to install the bellows to the sleeve nut.
• Direct each bellows out and down.
★ Before installing the high-pressure pipe, check it
for the following defects. If there is any of these
defects, it can cause fuel leakage. Accordingly,
replace the high-pressure pipe.
• Check the taper seal of the connecting part (Part
"j": Part of 2 mm from the end) for visible length-
wise slit "k" and dent "l".
• Check part "m" (End of the taper seal: Part at 2
mm from the end) for stepped-type wear (fatigue)
which your nail can feel.
• Install the high-pressure pipe according to the
following procedure.
(Between common rail and cylinder head)
1. Tighten all the high-pressure pipes temporarily.
 Sleeve nut:
0.2 - 0.8 Nm {0.02 - 0.08 kgm}
2. Tighten the high-pressure pipes to the specified
torque in the following order.
 Sleeve nut:
35 ± 3.5 Nm {3.57 ± 0.36 kgm}
1) #1 cylinder head side
2) #4 cylinder head side
3) #4 common rail side
4) #1 common rail side
5) #2 cylinder head side
6) #3 cylinder head side
7) #2 common rail side
8) #3 common rail side
30-36
DISASSEMBLY AND ASSEMBLY
(Between common rail and supply pump)
1. Finger-tighten the high-pressure pipes on the
supply pump side and common rail side.
2. Tighten the high-pressure pipes to the specified
torque in the order of the fuel supply pump side
and common rail side.
 Sleeve nut:
35 ± 3.5 Nm {3.57 ± 0.36 kgm}
• Install clamp bracket.
 Mounting bolt:
24 ± 4 Nm {2.4 ± 0.4 kgm}
• Install the bellows to all the high-pressure pipe
sleeves.
★ Install each bellows with the slits out and
down.
★ The bellows are installed so that fuel will not
spout over the hot parts of the engine and
catch fire when it leaks for some reason.
[*13]
• Handling of fuel pressure sensor and relief valve
1. Procedure for installing fuel pressure sensor
If the sensor was removed from the common rail,
be sure to replace it with new one.
a. Check the sensor connector for cracking/
breakage, damage of seal, foreign matter at
pin, corrosion/bend/breakage of pin, etc.
b. Install a new sensor.
★ Apply clean gear oil #90 to the threaded part.
Tightening torque:
70 ± 5 Nm {7.1 ± 0.5 kgm}
c. Connect the wiring connector. At this time,
take care not to connect the connector in re-
verse. (After starting the engine, check for
leakage. For the checking procedure, see
"Shop Manual, Testing and Adjusting".)
2. Procedure for installing relief valve
a. If the leakage through the relief valve ex-
ceeds the specified value, do not reuse that
relief valve.
b. Install the relief valve.
★ Apply clean gear oil #90 to the threaded part.
Tightening torque:
100 ± 4 Nm {10.2 ± 0.4 kgm}
★ Tightening too strongly can cause leakage.
PW148-8 VEBM720100
DISASSEMBLY AND ASSEMBLY Removal and installation of cylinder head assembly

(After starting the engine, check for leak- d. Install fuel injector assembly (58) to the fuel
age. For the checking procedure, see "Shop injector sleeve and tighten the mounting bolt
Manual, Testing and Adjusting".) by 3 - 4 turns.

[*14] ★ When installing the fuel injector assem-

bly, direct the fuel inlet hole (inlet con-
Wiring mounting bolt: nector mounting hole) toward the air
intake manifold.
1.5 ± 0.25 Nm {0.15 ± 0.03 kgm}

★ Connect the wirings to their original cylin-

ders.

Wiring color Cylinder No.

White 1, 3

Black 2, 4

[*15] [*19] [*20]

• Procedure for installing fuel injector

★ Check that fuel injector sleeve (63) is free e. Apply engine oil (EO15W-40) to O-ring (68)
from flaw and dirt. of inlet connector (50) and the inlet connec-
tor mounting hole.

f. While setting part B of the inlet connector to

the groove (upper side) on the head, insert
inlet connector (50) to the end.

a. Fit O-ring (65) and gasket (66) to fuel injector

(64).

★ Replace O-ring and gasket with new

one.
g. Install and finger-tighten retaining nut (49).
b. Apply engine oil (EO15W-40) to the O-ring of
the fuel injector (64) and the mounting hole
on the head.

c. While setting the concave and convex (A),

install holder (67) to fuel injector (64).

PW148-8 VEBM720100 30-37

Removal and installation of cylinder head assembly DISASSEMBLY AND ASSEMBLY

h. Tighten right and left mounting bolts (57) of c. Install rocker arm (52) and tighten the
injector assembly (58) alternately. mounting bolt (51).

 Fuel injector mounting bolt: ★ Check that adjustment screw (54) is loos-
8 ± 0.8 Nm {0.8 ± 0.08 kgm} ened thoroughly.

i. Tighten retaining nut (49) to the specified  Rocker arm mounting bolt:
torque. 36 ± 5 Nm {3.7 ± 0.5l kgm}

 Retaining nut:
50 ± 5 Nm {5.1 ± 0.5 kgm}

• Adjusting valve clearance

Referring to Testing and adjusting, "Adjusting
valve clearance", adjust the valve clearance.
[*16] [*17] [*18]
[*21]
• Installation of rocker arm
 Rocker arm housing mounting bolt:
a. Install push rod (56). 24 ± 4 Nm {2.4 ± 0.4 kgm}

b. Install crosshead (55). [*22]

★ Install the crosshead to the position in the di- • Precautions for installing cylinder head assembly
rection recorded when it was removed
(Check the shapes of holes "a" and "b"). ★ Use a new gasket.

★ Measure stem length "a" of every bolt and

check that it is less than the using limit.

★ Using limit length of bolt stem: 132.1 mm

★ If the stem length of a bolt is longer than the

using limit, do not reuse that bolt but replace
it.

★ Tool A7 (Gauge) is prepared for measure-

ment of the stem length of the bolts.

30-38 PW148-8 VEBM720100

DISASSEMBLY AND ASSEMBLY Removal and installation of cylinder head assembly

• Tighten each cylinder head mounting bolt 2 - 3

turns with the fingers first and then tighten them
in the following order.

★ Apply engine oil (SAE15W-40) to the thread-

ed part of each bolt.

a. Tighten the bolts to 70 ± 6 Nm {7.14 ± 0.61

kgm} in the order of 1 - 18.

b. Loosen all the bolts by 360 ± 5°.

c. Tighten the bolts to 105 ± 3 Nm

{110.7 ± 0.31 kgm} in the order of 1 - 18.

d. Tighten the bolts by 90 ± 5° in the order of

1 - 18.

★ Tool A6
(wrench) is prepared for angle tighten-
ing.

• When not using angle tightening tool

Make a mark on the cylinder head and each bolt
with paint and then tighten the bolt by 90° ± 5° in
the order of 1 - 18.

PW148-8 VEBM720100 30-39

Removal and installation of fuel cooler assembly DISASSEMBLY AND ASSEMBLY

Removal and installation of fuel cooler assembly

Removal
★ If the fuel is too much, drain the fuel in order to
stop the fuel flow from the fuel tank return hose.

1. Disconnect fuel hose (1) and (2) with the precau-

tion described below.

★ Be sure to disconnect the hoses in avoiding

the input force to the cooler body by fixing el-
bow (L) with wrench (1).

★ Be sure to use wrench [1], otherwise the

force is loaded to the cooler body and the
weld portion (M) may be separated.

2. Remove fuel cooler assembly (3).

Installation
Installation is done in the reverse order of removal.

30-40 PW148-8 VEBM720100

DISASSEMBLY AND ASSEMBLY Removal and installation of combination cooler assembly

Removal and installation of combination cooler assembly

Removal 6. Remove brackets (6).

Lower the work equipment completely to the

ground and stop the engine. Then loosen the oil
filter cap slowly to release the pressure inside
the hydraulic tank. 7 7

• Remove the hydraulic tank strainer, and using

tool B stop the oil.

• When not using tool B, remove the drain plug,

and drain the oil from the hydraulic tank and in- 7. Disconnect oil cooler inlet (8) and outlet (9)
side the system. pipes.
8
1. Drain the engine cooling water.

6 Engine cooling water: Approx. 6.8 l

2. Open up the engine hood and remove the hood

(see page 30-51).

3. Remove machine cab cover above the cooling 9

compartment.

4. Disconnect fuel cooler (see page 30-40).

8. Disconnect pipes (8) and (9) at point (10), also

remove brackets (11).
2
8

NB Door removed for clarity only ! 10 9

5. Remove condenser (3) by removing 8 bolts (4).
Ensure hoses are disconnected (5).
Ensure fuel hoses are unclipped (6).
11
5

4 4

5
6

3
4

PW148-8 VEBM720100 30-41

Removal and installation of combination cooler assembly DISASSEMBLY AND ASSEMBLY

9. Disconnect reservoir tank (11). 12. Remove radiator and 4 CAC hoses (13).

12

14
14

10. Remove guard (13).

13. Remove support stays (15) - (either side of the
cooler assembly)

13
15

11. Remove cover (16). 14. Sling radiator assembly with two lifting hooks.

16

15. Remove 4 mounting bolts (17) and lift radiator

assembly out.

18

17

30-42 PW148-8 VEBM720100

DISASSEMBLY AND ASSEMBLY Removal and installation of combination cooler assembly

Installation
• Install in reverse order of removal.

 Radiator hose clamp bolt:

0.55 - 0.65 kgm

★ To maintain the heat balance, make sure that

sponge sheets are assembled in the original
position.

★ Adjust clearance A between the cooling fan

circumference and the shroud, adjuster ring
using oblong hole B for mounting the bell
mouth shroud, adjuster ring so that the clear-
ance may be even all around the circumfer-
ence.

★ Check that clearance A shows the following

value, measured at four points on the right,
left, top and bottom sides.

• Standard clearance A (on all the circum-

ference): More than 10 mm

• Fan diameter C: ∅ 545

• Shroud inner diameter D: ∅ 580

• Adjustable plate inner ∅ = D-5 ∅ 575mm

Centre of
D
C

fan

A B

• Refilling engine cooling water

Refill engine cooling water through the water fill-

er port up to the specified level. Let the water cir-
culate to release any air pockets by starting the
engine. Check the water level again.

5 Engine cooling water: Approx. 6.8 l

PW148-8 VEBM720100 30-43

Removal and installation of engine and hydraulic pump assembly DISASSEMBLY AND ASSEMBLY

Removal and installation of engine and hydraulic pump

assembly

Special tools 3. Close fuel drain valve (3).

New/Remodel
Necessity

Sketch
Sym- 3

Q'ty
Part No. Part name
bol

10 796-460-1210 Oil stopper z 1

D
11 796-770-1320 Adapter z 1

Removal

• Stop the machine on a level ground, lower the 4. Loosen hydraulic oil drain plug (4) to drain the
work equipment to the ground, stop the engine, work equipment oil. [*1]
and set the lock lever in the lock position. 6 Hydraulic tank: 131 l
• Befor starting work, turn the starting switch to
the OFF position, wait over one minute, the turn
off the battery main switch and take out the
battery main switch key.
• Loosen the hydraulic tank cap gradually to re- 4
lease the residual pressure in the hydraulic tank.

1. Remove undercover (1).

★ When using tool D11, remove the hydraulic

tank strainer and stop the oil with tool D10.

2. Drain the coolant through coolant drain port (2).

6 Coolant: 18 l

30-44 PW148-8 VEBM720100

DISASSEMBLY AND ASSEMBLY Removal and installation of engine and hydraulic pump assembly

5. Remove the engine hood. For details, see page 8. Disconnection of air conditioner compressor as-
30-51. sembly

6. Removal of covers a. Disconnect wiring connector E05 (16).

a. Remove cover (5). b. Remove 2 air conditioner compressor

mounting bolts (17).
b. Remove cover (6).
5 c. Remove drive belt (18).

6 d. Disconnect air conditioner compressor as-

sembly (19) and move it aside so that it will
not be an obstacle. [*7]

7. Removal of hoses

a. Remove radiator hose (7) [*2]

b. Remove aftercooler hose (8). [*3]

c. Disconnect heater hose (9). 9. Disconnect electrical intake air heater wiring ter-
minal E01 (20) from the air intake connector and
d. Disconnect air hose (10) between the turbo- remove clips (20a), (20b) and (20c).
charger and air cleaner. [*4]
20b
e. Disconnect hose (11) between the turbo-
charger and aftercooler from connector (12). 20a
20c 20
[*5]

f. Remove guard (13).

9 8 13 7

10. Disconnection of fuel supply pump hose and

12 clamp
11 10 a. Disconnect clamp (22) of fuel hose (21) from
bracket (23).
g. Disconnect radiator lower hose (14) and
heater lower hose (15). [*6] ★ When loosening the bolt, fix the nut with
wrench so that the hose will not be twisted.
(If the hose is dragged and twisted, an ex-
cessive force is applied to the connector and
the inside of the connector may be broken.)

b. Remove clamp bracket (23).

c. Disconnect fuel return hose (24) connected

to the supply pump. [*8]
15 14

PW148-8 VEBM720100 30-45

Removal and installation of engine and hydraulic pump assembly DISASSEMBLY AND ASSEMBLY

★ When removing a connector of quick coupler f. Disconnect hose (27) connected to the fuel
type, observe the following points. filter.

• Remove mud from each hose joint in ad- ★ Before disconnecting hose (27), be sure to
vance (since the lock may be stuck in perform steps 1 to 5.
the mud).
g. Disconnect wiring connector (28).
• Never use pliers or a screwdriver to dis-
connect the connector. h. Disconnect hose (29) connected to the prefil-
ter.
• Pull out lock (L) of each hose joint
straight (in direction [a]) while pressing it i. Disconnect hose (30) connected to the fuel
from both sides. filter.
(If the connector is disconnected forcibly
by twisting or bending it to the right and
left, its inside may be broken.)

• Put plugs in the adapters of the discon-

nected hoses to prevent fuel from flow-
ing out.
(Do not use wooden plugs since chips
may enter the fuel line.)

d. Disconnect fuel return hose (25).

e. Disconnect hose (26) connected to the fuel

cooler. Ensure fuel hoses are unclipped from 11. Disconnect wiring connectors CE02 (31) and
engine. CE03 (32) of the engine controller.

★ Do not disconnect ECM connector (33) but

leave it connected, since it is on the engine
side.

31

33

32

30-46 PW148-8 VEBM720100

DISASSEMBLY AND ASSEMBLY Removal and installation of engine and hydraulic pump assembly

12. Disconnection of starting motor wiring b. Disconnect oil level sensor E03 (38), alterna-
tor wiring E12 (38a), AB (38b) and clamp
a. Disconnect starting motor terminal B wiring (39).
SB (34).

b. Disconnect starting motor wiring connector

SC (35).
38a
★ Pull connector (36) out of bracket [a] and
disconnect the male and female pieces. 38b

39

38

c. Disconnect ground wire (40).

13. Disconnect water separator sensor wiring con-

nector E06 (36).

★ The wiring connector No. on the engine side

is WIF (female). 40

15. Removal of wirings and hoses around hydraulic

pump

a. Disconnect wiring connectors V22 (41), V21

(42) and A55 (43).

b. Disconnect suction tube (44).

★ When disconnecting the hose, place a

receiving pan under the pump.

41
14. Disconnection of wiring from under chassis

a. Disconnect fuel hose clamp bracket (37)

from the engine block. 42

43 44

PW148-8 VEBM720100 30-47

Removal and installation of engine and hydraulic pump assembly DISASSEMBLY AND ASSEMBLY

c. Disconnect hoses (45), (46), (47), (48) and 17. Lift off engine and hydraulic pump assembly
(49) and clip (50). (51).

49 48 47 46 45

4 Engine and hydraulic pump assembly:

16. Sling engine and hydraulic pump assembly (51) 610 kg
and remove 4 mounting bolts (52). [*9]

(Left of engine side) (Right of engine side)

(Right and left of hydraulic pump side)

30-48 PW148-8 VEBM720100

DISASSEMBLY AND ASSEMBLY
Installation
• Carry out installation in the reverse order to re-
moval.
[*1]
 Hydraulic oil drain plug:
58.8 - 78.5 Nm {6.0 - 8.0 kgm}
[*2] [*6]
 Radiator hose clamp bolt:
(Both upper hose and lower hose)
10.8 - 11.8 Nm {1.1 - 1.2 kgm}
[*3]
★ Procedure for installing MIKALOR clamp
• When tightening the clamp, apply the following
lubricating oil or equivalent to its threaded part
[C].
Lubricating oil: Threebond (PANDO 18B)
• Adjust bridge [A] so that it will be under band [B].
• Tighten until dimensions [L] and [M] are set to
the specified dimensions.
Dimension L
Between aftercooler and air intake connector:
Aftercooler side: 10 (+0/-3) mm
Air intake connector side:
16 (+0/-3) mm
Between aftercooler and turbocharger connec-
tor: 10 (0/-3) mm
Dimension M: Min. 5 mm
• If the tightened dimensions are out of the above
ranges, replace the clamp with new one.
• Do not use an impact wrench.
[*4]
 Hose clamp between turbocharger and
air cleaner: (Turbocharger side)
10.0 - 11.0 Nm {1.02 - 1.12 kgm}
PW148-8 VEBM720100
Removal and installation of engine and hydraulic pump assembly
[*5]
 Connector mounting bolt:
10 ± 2 Nm {1.02 ± 0.2 kgm}
[*6]
 Radiator lower hose clamp:
10.8 - 11.8 Nm {1.12 - 1.2 kgm}
[*7]
• If the air conditioner compressor bracket was re-
moved, install it according to the following proce-
dure.
a. Tighten bolt A temporarily.
b. While setting L-bracket D to stay E, tighten
bolt B permanently.
★ After tightening permanently, the clear-
ance between L-bracket D and stay E
must not exceed 2 mm.
c. Loosen bolt A and move stay E to adjust the
level difference in the forward and backward
directions.
d. Tighten bolts A and C in order.
[*8]
When installing a connector of quick coupler type,
observe the following points.
★ Replace the connector in the following cases.
e. The connector was removed with pliers or a
screwdriver or by bending it to the right and
left.
f. There is damage or deformation in the con-
nector.
★ Check that mud or dirt is not sticking to the hose
adapter in advance.
30-49
Removal and installation of engine and hydraulic pump assembly DISASSEMBLY AND ASSEMBLY

★ Press and insert the connector straight (in direc-

tion [b]) without bending it to the right or left.
(If it is difficult to insert the connector, do not
push it in forcibly but pull it out.

Then, check the convex and concave parts for abnor-

mality and mud.)

[*9]

 Mounting bolt:
245 - 308.7 Nm {25 - 31.5 kgm

30-50 PW148-8 VEBM720100

DISASSEMBLY AND ASSEMBLY Removal and installation of engine hood assembly

Removal and installation of engine hood assembly

Removal Installation
Carry out installation in the reverse order to removal.

Befor starting work, turn the starting switch to [*1]

the OFF position, wait over one minute, the turn
off the battery main switch and take out the bat-
tery main switch key.
• Adjustment procedure for installed engine hood
1. Install engine hood hinge (2) with the 4 mounting
bolts.

1. Sling the engine hood and remove gas springs (1). ★ Tighten the bolts to the degree that the en-
gine hood does not move in the right, left,
forward or backward direction when it is
opened and closed.

1 2. Lower engine hood (3) slowly to bring U-bolt (4)

to near catch (7) on the chassis side.

3. Check that U-bolt (4) is set normally in catch (7)

on the chassis side (adjust nuts (5) to suit).

★ U-bolt (4) must be set in groove (a) of catch

2. Remove the mounting bolts and disconnect hing-
es (2). [*1]
★ Before removing the bolts, check the in-
stalled positions of the hinges (right and left).
(7).
★ Distances (b1) on the left and (b2) on the
right must be even.
4. If the U-bolt is not set normally, loosen 2 mount-
ing bolts (9) of catch bracket (8) and adjust catch
bracket (8) in the forward, backward, right or left
direction.

★ Repeat steps 2) and 3) until the engine hood

is opened and closed smoothly.

★ If the engine hood cannot be adjusted per-

fectly by steps 2) and 3), loosen the mount-
ing bolts of hinge (2) and adjust the position
of hinge (2) and then repeat steps 2) and 3)
again.

3. Lift off engine hood (3). 5. After finishing adjustment, tighten the mounting
bolts of hinge (2) and catch bracket (8) to the
6 Engine hood: spcified torque.
50 kg
★ Illustration "CPP14612" shows engine hood
(3) and U-bolt (4) seen from the front of the
machine.

★ Illustration "CPP14612" shows catch (7),

catch bracket (8) and step (6) seen from
above the machine.

PW148-8 VEBM720100 30-51

Removal and installation of engine hood assembly DISASSEMBLY AND ASSEMBLY

30-52 PW148-8 VEBM720100

DISASSEMBLY AND ASSEMBLY Removal and installation of travel motor

Removal and installation of travel motor

PW148-8 Is fitted with a single propshaft.

Removal
Blanking Kit
Description Part Number Qty Where Used
Cap Plug 07376-70422 1
Top Drain Hose
O-ring 02896-11012 1
Cap Plug 07376-70210 1
Top Pilot Pressure Hose
O-ring 02896-11008 1
Flange 07379-01260 2
O-ring 07000-13038 2
Front Main Travel Hoses
Bolt 01010-51245 8
Washer 01643-51032 8

1. Remove cover (1) {if fitted} by removing bolts (2).

2 2

2. Drain oil out of transmission and travel motor.

3. Attach an identification tag to hoses to avoid incorrect connection during re-assembly.

4. Attach vacuum pump to hydraulic tank.

5. Disconnect each hose individually and plug with blank/plug and O-ring from blanking kit to prevent oil spillage
and contamination (3 through 6).

3 4

5
6

PW148-8 VEBM720100 30-53

Removal and installation of travel motor DISASSEMBLY AND ASSEMBLY

6. Remove drain hose (7).

7. Remove 4 bolts (8) and remove travel motor (9) in direction to disengage the splined shaft. (Weight approx.
66kg).

Installation
• Install in reverse order of removal.

• Tightening torque for propshaft nuts is: 25 - 31.5 kgf-m

• Refill the transmission oil to the required level (4.85 litres).

• Top up hydraulic through oil filler port to the specified level and let the oil circulate in the hydraulic system by
starting the engine. Then check oil again.

• Air bleeding

• Refer to the Air Bleeding of Various Part section in the TESTING AND ADJUSTING chapter of this manual.

30-54 PW148-8 VEBM720100

DISASSEMBLY AND ASSEMBLY Removal and installation of travel motor

Blank for technical reason

PW148-8 VEBM720100 30-55

Disassembly and assembly of travel motor assembly DISASSEMBLY AND ASSEMBLY

Disassembly and assembly of travel motor assembly

Disassembly

Counterbalance
Qmax adjustment
valve assembly
screw

Port plate Qmin adjustment Rotary group

assembly screw assembly

30-56 PW148-8 VEBM720100

DISASSEMBLY AND ASSEMBLY Disassembly and assembly of travel motor assembly

1. Put the unit in a bench with a hole or place it on a 3. Before removing the port plate measure and
fixture for assembly. record dimension X of the Qmin adjustment
screw and dimension Y of the Qmax adjustment
screw.

X
Y

2. Remove the counterbalance valve by loosening 4. Remove the adjustment screws completely from
the six fixing bolts. the motor casing.

Counter
balance
valve

Qmin
screw

Qmax
screw

Fixing
bolt

PW148-8 VEBM720100 30-57

Disassembly and assembly of travel motor assembly DISASSEMBLY AND ASSEMBLY

5. Insert the Qmin adjustment screw into the Qmax Assembly

threaded hole and turn screw until the rotary
group is at the zero displacement position 1. Do not remove rotary group from casing, just
(should be vertical). check for signs of damage or wear.

Port Replace O-ring and install into position using

plate grease.

Insert
Qmin
screw

New
o-ring

6. Remove the port plate by loosen the eight fixing 2. Apply grease to control lens sliding surface.
bolts.
Port plate

Fixing screw

Control Sliding
lens surface

30-58 PW148-8 VEBM720100

DISASSEMBLY AND ASSEMBLY Disassembly and assembly of travel motor assembly

3. Assemble the port plate by locating the lens plate 5. Assemble the counterbalance valve assembly
onto the rotary group. using the six fixing bolts.

Secure the port plate by tightening the eight fix- Tightening torque - 205 Nm.
ing bolts.
Counterbalance
Tightening torque - 310 Nm Fixing
valve
Port plate bolt

Fixing
bolt

4. Insert the Qmin and Qmax adjustment screws

and set at dimensions X and Y which were re-
corded during the disassembly procedure.

PW148-8 VEBM720100 30-59

Removal and installation of swing motor and swing machinery DISASSEMBLY AND ASSEMBLY

Removal and installation of swing motor and swing ma-

chinery

Removal

(4)
Lower the work equipment to the ground com-
pletely, after the engine is stopped, loosen the
hydraulic tank cap gradually to reduce the pres-
sure inside, and set the lock lever in the lock po-
sition.

★ Attach an identification tag to each piping to

avoid a mistake in the position of installation lat-
er. 4. Disconnect swing motor drain hose (5) from port.
1. Remove undercover (1) below engine.

(1)
(5)

5. Disconnect the 4 swing motor hoses (6), (7), (8)

2. Open engine hood (2) and remove cover (3). and (9).

(2) • (6): Between swing motor -control valve

(port MA)

• (7): Between swing motor - control valve

(port MB)
(3) • (8): Suction hose (port S)

• (9): PPC hose to sol. valve block

(swing brake) (port B)

(9)

3. Drain oil from swing machinery case (into a suit-

able receptacle) by removing plug (4). (7)
(8)
6 Swing machinery case: Approx. 2.5 l

(6)

6. Disconnect drain hose (10) at rear of swing ma-

30-60 PW148-8 VEBM720100

DISASSEMBLY AND ASSEMBLY Removal and installation of swing motor and swing machinery

chinery. Installation
• Installation is done in the reverse order of remov-
al.

 Mating surface of swing machinery

(10) gasket sealant (LG-4) or (LG-6)

[*1]

 Mounting bolt:
248 - 308.7 Nm {25 - 31.5 kgm)

• Refilling with oil (hydraulic tank)

7. Remove 12 pcs. of mounting bolt (11). [*1] Refill hydraulic oil through the oil filler port to the
specified level. Let the oil circulate in the hydrau-
lic system by starting the engine. Then check the
(12) oil level again.

• Air bleeding

Bleed the air from the circuit between the valve

(11)
and the hydraulic cylinder. For details, see Test-
ing and adjusting, air bleeding of various parts.

8. Lift and remove the swing motor and swing ma-

chinery Assembly (12).

★ Take care that the assembly will not interfere with

the hoses around it.

4 Swing motor and swing machinery

Assembly: 85 kg

PW148-8 VEBM720100 30-61

Removal of swing motor assembly DISASSEMBLY AND ASSEMBLY

Removal of swing motor assembly

Removal

(4)
Lower the work equipment to the ground com-
pletely, after the engine is stopped, loosen the
hydraulic tank cap gradually to reduce the pres-
sure inside, and set the lock lever in the lock po-
sition.

★ Attach an identification tag to each piping to

avoid a mistake in the position of installation lat-
er.
4. Disconnect swing motor drain hose (5) from port.
1. Remove undercover (1) below engine.

(1)

(5)

2. Open engine hood (2) and remove cover (3).

5. Disconnect the 4 swing motor hoses (6), (7), (8)
(2) and (9).

• (6): Between swing motor – control valve

(port MA)

• (7): Between swing motor – control valve

(3)
(port MB)

• (8): Suction hose (port S)

• (9): PPC hose to sol. valve block

(swing brake) (port B)

3. Drain oil from swing machinery case (into a suit- (9)

able receptacle) by removing plug (4).
(7)
6 Swing machinery case: Approx. 2.5 l (8)

(6)

30-62 PW148-8 VEBM720100

DISASSEMBLY AND ASSEMBLY Removal of swing motor assembly

6. Remove 13 pcs. of mounting bolts (10), remove

2 plugs (12). Sling swing motor assembly (11),
then use forcing screws to remove (2 places)

4 Swing motor : 25 kg

(11)

(10)

(12)

Installation
Carry out installation in reverse order to removal.

 Mating surfaces of swing motor

gasket sealant (LG-4 or LG-6)

 Tightening torque of mounting bolts

98 - 122.5 Nm (10 - 12.5 kgm)

PW148-8 VEBM720100 30-63

Disassembly and assembly of swing motor and swing machinery DISASSEMBLY AND ASSEMBLY

Disassembly and assembly of swing motor and swing ma-

chinery

New/Remodel
Necessity
Symbol

Sketch
Q'ty
Part No. Part name

790-101-2501 Push puller kit z 1

• 790-101-2510 • Block 1
• 790-101-2550 • Leg 2
1 • 790-101-2560 • Nut 2
• 790-101-2570 • Plate 2
790-101-3101 Bearing puller z 1
790-101-4200 Puller z 1
796T-426-1140 Push tool „ 1 Q
2
790-201-2680 Plate „ 1
3. No. 1 carrier, No. 2 sun gear assembly
F 1 790-201-2850 Spacer z 1
3 a. Remove No. 1 sun gear (2).
2 790-201-2750 Spacer z 1
790-101-5401 Push tool kit z 1 b. Remove No. 1 carrier and No. 2 sun gear as-
• Plate sembly (3).
• 790-101-5461 1
(For main bearing)
4 • Plate
• 790-101-5441 1
(For sub bearing)
• 790-101-5421 • Grip 1
• 01010-51240 • Bolt 1
790-201-2850 Spacer z 1
5
790-201-2650 Plate z 1

Disassembly

1. Draining oil
Loosen drain plug and drain oil from swing ma-
chinery. c. Disassemble No. 1 carrier and No. 2 sun
gear assembly (3) as follows.
6 Swing machinery case : Approx. 2.5 l
I. Remove snap ring (4), then remove
thrust washer (5), gear (6), bearing (7),
2. Swing motor
and thrust washer (8).
Remove swing motor assembly (1).

4 Swing motor assembly : 30 kg

30-64 PW148-8 VEBM720100

DISASSEMBLY AND ASSEMBLY Disassembly and assembly of swing motor and swing machinery

II. Knock in pin (9) and knock out shaft (10). II. Remove thrust washer (20), gear (21),
bearing (22), and thrust washer (23).
★ After removing the shaft, remove pin (9).

III. Remove snap ring (11), then remove No.

2 sun gear (12) from carrier (13).

6. Retainer, collar
a. Remove retainer (24).

4. Ring gear b. Set shaft and case assembly to press, push

split collar (25) with push tool F5, and press
Remove ring gear (14). fit bearing (26).

5. No. 2 carrier assembly ★ Operate the press slowly, and press fit
the bearing to a position where it is pos-
a. Remove spacer (15). sible to remove the split collar.
b. Remove No. 2 carrier assembly (16). c. Remove split collar (25).

c. Disassemble No. 2 carrier assembly as fol-

lows.

I. Push in pin (17), and knock out shaft

(18) from carrier (19).

★ After removing the shaft, remove pin

(17).

PW148-8 VEBM720100 30-65

Disassembly and assembly of swing motor and swing machinery DISASSEMBLY AND ASSEMBLY

7. Shaft assembly b. Using puller [5], remove bearing outer races

a. Set block [2] to shaft and case assembly (34) and (35) from case (33).
(27), then using push tool [3], remove shaft
assembly (28) with press .

b. Remove bearing (26).

Assembly
★ Clean all parts, and check for dirt or damage.
c. Using push tool F1, remove bearing (29) and
collar (30) from shaft (31). Coat the sliding surfaces of all parts with engine
oil before installing.

1. Bearing outer races

Using push tool F4, press fit outer races (34) and
(35) to case (33).

8. Oil seal, bearing outer race

a. Remove oil seal (32) from case (33).

30-66 PW148-8 VEBM720100

DISASSEMBLY AND ASSEMBLY Disassembly and assembly of swing motor and swing machinery

2. Shaft assembly d. Using push tool F3-2, press fit bearing (26)
a. Fit O-ring to inside of collar (30) and install to to a position where it is possible to insert split
shaft (31). collar.

b. Using push tool F3-1, press fit bearing (29) ★ Press-fitting force : 11.8 kN {1,200 kg}
with press.
★ Rotate the case and gradually press fit
the bearing.

e. Install split collars (25).

c. Set case assembly (36) to shaft assembly
(28). f. Screw bolt (Thread dia.=12mm,
Pitch=1.75mm) into case, then using push-
pull scale [8], measure tangential force in di-
rection of rotation.

★ Tangential force : Max. 176.5 N {18 kg}

★ The tangential force is the maximum

force when starting rotation.

PW148-8 VEBM720100 30-67

Disassembly and assembly of swing motor and swing machinery DISASSEMBLY AND ASSEMBLY

3. Oil seal III. Align position of pin holes of shaft and

Using push tool F2, press fit oil seal (32). carrier, then tap with plastic hammer to
install shaft (18).
★ Replace the oil seal with a new part.
★ When installing the shaft, rotate the plan-
 Lip of oil seal : Grease (G2-LI) etary gear, and be careful not to damage
the thrust washers.
 Periphery of oil seal:
Gasket sealant (LG-6) IV. Insert pin (17).

★ Take care that the gasket sealant will not ★ After inserting the pin, caulk the pin por-
stick to the oil seal lip and shaft. tion of the carrier.

4. Retainer b. Install No. 2 carrier assembly (16) to shaft

Install retainer (24). and case assembly.

c. Install spacer (15).

5. No. 2 carrier assembly

a. Assemble No. 2 carrier assembly as follows.

I. Assemble bearing (22) to gear (21). 6. Ring gear

II. Fit top and bottom thrust washers (20) Assemble O-ring (37) to shaft and case assem-
and (23), then set gear assembly to car- bly, and install ring gear (14).
rier (19).

30-68 PW148-8 VEBM720100

DISASSEMBLY AND ASSEMBLY Disassembly and assembly of swing motor and swing machinery

7. No. 1 carrier, No. 2 sun gear assembly b. Install No. 1 carrier and No. 2 sun gear as-
a. Assemble No. 1 carrier and No. 2 sun gear sembly (3).
assembly as follows.
c. Install No. 1 sun gear (2).
I. Assemble No. 1 carrier (13) to No. 2 sun
gear (12), and install snap ring (11).

II. Align position of pin holes of shaft and

carrier, then tap with a plastic hammer to
install shaft (10).

III. Insert pin (9).

★ After inserting the pin, caulk the pin por-

tion of the carrier .

★ Check that the stepped difference a be-

tween the shaft and carrier is less than
0.2 mm.

8. Swing motor assembly

Install swing motor assembly (1).

 Mounting bolt :
110.3 ± 12.3 Nm {11.25 ± 1.25 kgm}

IV. Assemble thrust washer (8), bearing (7),

gear (6), and thrust washer (5), then in-
stall snap ring (4).

9. Refilling with oil

Tighten the drain plug and add engine oil through
oil filler.
5 Swing machinery case : Approx. 2.5 l

PW148-8 VEBM720100 30-69

Removal and installation of front axle assembly DISASSEMBLY AND ASSEMBLY

Removal and installation of front axle assembly

Removal 6. Remove all nuts (3) from propshaft (4), then re-
tract propshaft (4).
1. Drain oil out of front axle and hubs.
6 Front Axle: Approx. 10.5 Litres
Hubs: Approx.2.5 Litres (Each)

2. Retract front attachment fully.

3. Remove 4 hoses (1). 3

1
1
1 1
7. Remove pin (5).

4. Remove hose (2).

8. Use work equipment to lift undercarriage above

the axle.

5. Support propshaft weight with suitable equip-

mant.

9. Roll axle out on wheels.

10. Place supports in place of axle.

30-70 PW148-8 VEBM720100

DISASSEMBLY AND ASSEMBLY Removal and installation of front axle assembly

Installation
• Install in reverse order of removal.

• Grease all cylinders before installation

• Tightening torque for propshaft nuts (3):

58.8 - 73.5 Nm.

PW148-8 VEBM720100 30-71

Disassembly and assembly of front axle DISASSEMBLY AND ASSEMBLY

Disassembly and assembly of front axle

Disassembly of steering cylinder 4. Remove the screws (5).

1. Remove the safety split pins (1).

Reject the used split pins.

5. Unscrew the heads of the steering cylinder (6).

2. Remove the joint pivots (2) and the shims (4).

6. Remove the screws (7) of the steering cylinder.

3. Remove the steering bars (3).

30-72 PW148-8 VEBM720100

DISASSEMBLY AND ASSEMBLY Disassembly and assembly of front axle

7. Remove the head of the cylinder (8). Strike by 11. Remove the head of the cylinder (14).
means of a plastic hammer.

12. Remove O-ring (15).

8. Remove the gaskets (11), (12) and the scraper
ring.

13. Lock the rod of the cylinder (16) in a vice after

having screwed on the head (6).
9. Remove the O-rings (9) and (10).

14. Remove the cylinder liner (17).

10. Remove the rod complete with cylinder (16) and
cylinder liner (17).

PW148-8 VEBM720100 30-73

Disassembly and assembly of front axle DISASSEMBLY AND ASSEMBLY

15. Remove the O-ring (20) and the setting shims Assembly of steering cylinder
(24).
1. Fit the gaskets (21) and (22) and the scraper
ring.

16. Remove the gaskets (21), (22) and the scraper

ring (23).
2. Fit the piston gaskets (18) and (19).

The gasket cuts (18) should not coincide.

3. Thicknesses to be fitted.

30-74 PW148-8 VEBM720100

DISASSEMBLY AND ASSEMBLY Disassembly and assembly of front axle

4. Measuring of value F1. (20).

5. Measuring of value F2. 9. Assemble the O-rings (9) and (10).

6. Measuring of value F3. 10. Assemble the gaskets (11), (12) and the scraper
ring (13).

7. Measuring of value F4.

11. Assemble the O-ring (15).

8. Assemble the thicknesses x (24) and the O-ring

PW148-8 VEBM720100 30-75

Disassembly and assembly of front axle DISASSEMBLY AND ASSEMBLY

12. Lubricate with grease the contact surface. 16. Assemble the rod complete with cylinder (16)
and the cylinder liner (17).

13. Assemble the head of the cylinder (14).

17. Lubricate with grease the gaskets of the left cyl-
inder rod.

14. Lock the rod of the cylinder (16) on a vice after

having screwed the head (6) and assemble the
cylinder liner (17). 18. Assemble head of cylinder (8). Strike by means
of a plastic hammer. Apply Loctite® 510.

15. Lubricate with grease the gaskets of the right cyl-

inder rod.

30-76 PW148-8 VEBM720100

DISASSEMBLY AND ASSEMBLY Disassembly and assembly of front axle

19. Assemble screws (7) of steering cylinder. 23. Assemble steering bars (3).

Torque = 560Nm (57.1 kgf-m) Apply Loctite®

242.

24. Assemble joint pivots (2) and thicknesses (4).

20. Lubricate the threads of the steering cylinder with

grease.

25. Assemble safety split pins (1).

21. Screw heads of steering cylinder (6).

22. Fit screws (5). Torque = 117Nm (12 kgf-m)

PW148-8 VEBM720100 30-77

Disassembly and assembly of front axle DISASSEMBLY AND ASSEMBLY

Disassembly of epicyclic reduction gear 4. Remove the planetary gear carrier cover (3) and
and brake O-ring (30).

1. Before draining the oil, position the wheel hub (1)

with the plug on the upper part and loosen it off
some turns in order to eliminate any possible in-
ner pressure, then remove it completely. Turn the
wheel hub upside down till the hole is in the low-
est point.

Drain the oil completely.

5. Remove split ring (4).

2. Remove fastening screws (2) from the cover of

the planetary gears carrier.

6. Remove ring bevel gear (5) complete with carrier

(28) and split ring (29).

3. Use the levers inside the preset slots to detach

the planetary gear carrier cover.

7. Remove brake discs (6).

30-78 PW148-8 VEBM720100

DISASSEMBLY AND ASSEMBLY Disassembly and assembly of front axle

8. Remove fastening screws of piston (7) and 12. Remove spacer (25).
springs (15).

13. Remove screws (11) and washers (21) from

9. Remove piston (8). brake carrier (12).

10. Remove seal rings (9) and (10) from piston (8). 14. Assemble carrier (28) and split ring (4). Remove
brake carrier (12).

11. Remove snap ring (24).

15. Remove bushes (22).

PW148-8 VEBM720100 30-79

Disassembly and assembly of front axle DISASSEMBLY AND ASSEMBLY

16. Remove seal rings (13) and (14) from brake car- 19. Remove the drain valve (17).
rier (12).

20. Remove seal ring (19).

17. Remove shims (26).

21. Remove inner cup of bearing (18).

18. Remove wheel hub (16) with bearings (19) and
(20) and seal ring (19).

30-80 PW148-8 VEBM720100

DISASSEMBLY AND ASSEMBLY Disassembly and assembly of front axle

22. Remove outer cup of bearing (20).

23. Remove outer cup of bearing (18).

24. Remove snap ring (31). Remove planetary gears

(23) from planetary gear carrier cover (3).

PW148-8 VEBM720100 30-81

Disassembly and assembly of front axle DISASSEMBLY AND ASSEMBLY

Assembly of epicylic reduction gear and 5. Fill seal ring (19) on wheelhub (16). Use tool
brake 2897003.

1. Fit outer cup of bearing (18) wheel hub (16).

6. Lubricate axle shaft to assemble the wheel hub.

2. Fit outer cup of bearing (20) wheel hub (16).

Polish hub and oil holes.

3. fit the remaining part of bearing 18) on wheel hub

(16).

7. Assemble the whole wheel hub (16). Alternately

strike bearings (18).

The roller bearing should be rested on the beam

trumpet.

4. Apply Loctite® 510 on seal ring (19).

30-82 PW148-8 VEBM720100

DISASSEMBLY AND ASSEMBLY Disassembly and assembly of front axle

8. Preheat bearing (20) on proper plate up to 11. Use a depth gauge to measure dimension (g) of
100°C. wheel hub.

9. Fit bearing (20) inside beam trumpet. 12. Use a depth gauge to measure dimension F of
brake carrier (12).

Wear gloves to avoid getting burnt.

13. Calculate shims X1 of adjustment shims by using

the following procedure: X1 (G-F) + 0.05.

10. Assemble the tool 2897013, 3 draw plates M10 x

285 and 3 nuts M10.

14. Assemble previously calculated shims (26) X1.

PW148-8 VEBM720100 30-83

Disassembly and assembly of front axle DISASSEMBLY AND ASSEMBLY

15. Assemble O-rings (9) and (10) on piston (8). 18. Fit the whole unit of the brake carrier on wheel
hub.

The brake carrier and beam trumpet holes should

coincide.

16. Assemble O-rings (13) and (14) on brake carrier

(12).

19. Assemble brake discs (6).

17. Fit piston (8) on brake carrier (12) with springs During assembly operations all the inner disc
(15) and screws (7). Apply Loctite® 638 on the slots should coincide.
screws (7).

30-84 PW148-8 VEBM720100

DISASSEMBLY AND ASSEMBLY Disassembly and assembly of front axle

20. Assemble brake discs (6).During assembly oper- 23. Fit snap ring (4).
ations all the outer disc slots should coincide.

24. Remove plug (27).

21. Fit ring bevel gear (5) with carrier (28) and split
ring (29).

25. Fit an adapter instead of the plug.

22. Test the brake by temporarily fitting two screws

(11).

Do not assemble bushes (22).

26. Test the brakes by considering that pressure

should be 100-50 bar for about one minute.

PW148-8 VEBM720100 30-85

Disassembly and assembly of front axle DISASSEMBLY AND ASSEMBLY

27. Fit bushes (22). 30. Line up brake discs. Use tool 2897014.

Pay attention to the assembly direction of bush- A tooth should coincide with a brake fastening
es. screw (7).

28. Apply Loctite® 242 inside slots. 31. Put brakes under pressure to avoid outer disc
misalignment.

29. Fit screws (11) and shims (21).

32. Lubricate with grease and fit O-ring (30).
Tightening torque: 68Nm

30-86 PW148-8 VEBM720100

DISASSEMBLY AND ASSEMBLY Disassembly and assembly of front axle

33. Heat the planetary gear bearing at 110°C. As- 37. Apply Loctite® 242 on screw.
semble planetary gear.

38. Fit screws (2) according to the proper tightening

34. Assemble snap ring. torque (48Nm).

35. Lubricate with grease the contact surface of 39. Remove oil drain plug and turn the final drive up
planetary gear cover (3). Apply Loctite® 510 in to meeting item (28) hole.
the holes.

40. Apply pressure of 45-50 bar and check the dis-

36. Fit the planetary gear cover (3) and discharge tance between brake locking and unlocking (Min:
pressure from the hydraulic pump. 1.7mm; Max: 3.8 mm)

PW148-8 VEBM720100 30-87

Disassembly and assembly of front axle DISASSEMBLY AND ASSEMBLY

Disassembly of joint box 4. Remove the planetary gear carrier cover (3) and
O-ring (6).
1. Before draining the oil, position the wheel hub (1)
with the plug on the upper part and loosen it off
some turns in order to eliminate any possible in-
ner pressure, then remove it completely. Turn the
wheel hub upside down till the hole is in the low-
est point.

Drain the oil completely.

5. Remove split ring.

2. Remove fastening screws (2) from the cover of

the planetary gears carrier.

6. Remove spacer (5).

3. Use the levers inside the preset slots to detach

the planetary gear carrier cover.

7. Remove the screw (7).

30-88 PW148-8 VEBM720100

DISASSEMBLY AND ASSEMBLY Disassembly and assembly of front axle

8. Remove the screw (8). 12. Remove the complete joint group.

9. Secure the joint box to a hoisting equipment. 13. Remove the complete joint (11).

10. Screw two screws M12 x 100 and remove the 14. Remove the gasket (12).
pivot.

15. Remove the gasket (13).

11. Screw screws M12 x 100 and remove the pivot.

PW148-8 VEBM720100 30-89

Disassembly and assembly of front axle DISASSEMBLY AND ASSEMBLY

16. Remove gasket (30). 20. Remove the bush (21).

17. Use an extractor to remove bush (18). 21. Remove the O-ring (22) and the disk (23).

18. Remove the O-ring (20). 22. Remove the gasket (24).

19. Remove the disk (20). 23. Remove the bush (25).

30-90 PW148-8 VEBM720100

DISASSEMBLY AND ASSEMBLY Disassembly and assembly of front axle

24. Remove pins (26).

25. Remove the spacer (27).

26. Remove gaskets (28).

27. Remove the bush (29).

PW148-8 VEBM720100 30-91

Disassembly and assembly of front axle DISASSEMBLY AND ASSEMBLY

Assembly of joint box 4. Assemble the O-ring (22) and the disk (23). Pay
attention to assembling direction.
1. Assemble the disk (20).

Pay attention to assembling direction.

5. Assemble the bush (21).

Use tool 2897017.

2. Assemble the O-ring (19).

6. Assemble the bush (25).

3. Assemble the bush (18).
Use tool 2897017.
Use tool 2897017.

7. Apply Loctite® 510 on the gasket (24).

30-92 PW148-8 VEBM720100

DISASSEMBLY AND ASSEMBLY Disassembly and assembly of front axle

8. Assemble the gasket (24). 11. Assemble the gasket (28).

Use tool 2897017. Use tool 2897017.

9. Assemble the bush (29). 12. Assemble the pins (26).

Use tool 2897016.

13. Grease and assemble the spacer (27).

10. Apply Loctite® 510 on the gasket (28).

14. Assemble gasket (30).

PW148-8 VEBM720100 30-93

Disassembly and assembly of front axle DISASSEMBLY AND ASSEMBLY

15. Assemble the gasket (12). Pay attention to as- 19. Lubricate and assemble the pivot.
sembling direction.

20. Lubricate and assemble the pivot (9).

16. Assemble the gasket (13). Pay attention to as-
sembling direction.

21. Apply Loctite® 242 and assemble the screw (7).

17. Assemble the complete joint (11). Torque - 285Nm (29 kgf-m)

18. Grease tabs of the joint group and assemble. 22. Apply Loctite® 242 and assemble the screw (8).

Torque - 285 (29kgf-m)

30-94 PW148-8 VEBM720100

DISASSEMBLY AND ASSEMBLY Disassembly and assembly of front axle

23. Assemble the snap ring (4). 26. Put brakes under pressure to avoid outer discs
misalignment.

24. Assemble the snap ring (4).

27. Lubricate with grease and fit O-ring (30).

25. Line up brake discs. Use tool 2897014.

28. Lubricate with grease the contact surface of
planetary gear cover (3).

A tooth should coincide with a brake fastening Apply Loctite® 510 in the holes.
screw (7)

29. Fit the planetary gear cover (3) and discharge

pressure from the hydraulic pump.

PW148-8 VEBM720100 30-95

Disassembly and assembly of front axle DISASSEMBLY AND ASSEMBLY

30. Apply Loctite® 242 on screw (2).

31. Fit screws (2).

Torque - 55 Nm (6 kgf-m)

30-96 PW148-8 VEBM720100

DISASSEMBLY AND ASSEMBLY Disassembly and assembly of front axle

Disassembly of beam trumpet and differ- 5. Lift the whole differential unit.
ential unit
1. Remove the axle unit. Sling and slightly tension
the rope. Turn and then fix it in vertical position.

6. Use an extractor and remove from housing (4)

the outer cup of bearing (5).

2. Loosen and remove screws (1) with washers

(27).

7. Remove shims (6).

3. Sling the beam trumpet (3) and slightly lift it.

8. Use an extractor and remove from housing (3)

the outer cup of bearing (7).

4. Remove O-ring (9).

PW148-8 VEBM720100 30-97

Disassembly and assembly of front axle DISASSEMBLY AND ASSEMBLY

9. Remove shims (8).

10. Use an extractor to remove bearing (7) from dif- 13. Remove ring bevel gear (2) by means a mallet.
ferential unit.

14. Check marking points (11) and (12) that will be

11. Use an extractor to remove bearing (5) from dif- useful during the assembly.
ferential unit.

12. Unscrew all fastening screws (10) of bevel gear NOTE

crown (2). Without differential torque limiter.

15. Remove planetary gear (23) and shim (25).

This operation makes both differential half boxes

free, so take care not to drop the inner compo-
nents.

30-98 PW148-8 VEBM720100

DISASSEMBLY AND ASSEMBLY Disassembly and assembly of front axle

16. Remove differential pins (13 and (14), planetary 19. Remove planetary gear (30).
gears (15), (16), (17) and (18) and spheric wash-
ers (19), (20), (21), and (22).

20. Remove differential pins (31 and (32), planetary

gears (33), (34), (35) and (36) and spheric wash-
17. Remove planetary gear (24) and shim (26). ers (37), (38), (39), and (40).

21. Remove planetary gear (41).

NOTE
With differential torque limiter.

18. Remove discs (28) and (29).

22. Remove discs (42) and (43).

PW148-8 VEBM720100 30-99

Disassembly and assembly of front axle DISASSEMBLY AND ASSEMBLY

Assembly of beam trumpet and differen- 4. Fit the differential unit pin (13) and planetary
tial unit. gears (15) and (16) and washers (19) and (20).

NOTE
Without differential torque limiter.

1. Apply a thin layer of molicote G-n plus paste on

half boxes of differential (11) and (12).

Remove rests do dope.

5. Fit the differential unit pin (14) and planetary

gears (17) and (18) and washers (21) and (22).

2. Apply a thin layer of molicote G-n plus paste on

6. Fit ring bevel gear (23) and washer (25).
planetary gears (15), (16), (17) and (18) and on
crown wheels (23) and (24).

3. Set crown Wheel (24) and washer (26).

30-100 PW148-8 VEBM720100

DISASSEMBLY AND ASSEMBLY Disassembly and assembly of front axle

10. Assemble planetary gears (41).

NOTE
With differential torque limiter.

7. Apply a thin layer of Molicote G-n plus paste on

half boxes of differential (44) and (45).

Remove rests of dope.

11. Fit the differential unit pin (31) and planetary

gears (33), (34) and washers (37) and (38).

8. Apply a thin layer of Molicote G-n plus paste on

planetary gears (33), (34), (36) and on crown
wheels (30) and (41). 12. Fit differential unit pin (32) and planetary gears
(35), (36) and washers (39) and (40).

9. Assemble discs (42) and (43).

PW148-8 VEBM720100 30-101

Disassembly and assembly of front axle DISASSEMBLY AND ASSEMBLY

13. Assemble planetary gears (30). 16. Fit ring bevel gear (2) by using a hammer.

14. Assemble discs (28) and (29). 17. Apply Loctite® 242 on thread of screws (10).

15. Fit the two half boxes of differential unit (11) and 18. Tighten screws (10)
(12).
Torque - 205 Nm (21 kgf-m)

Carefully check that the marks of both differential NOTE

half boxes coincide. Fix differential housing in the vice.

30-102 PW148-8 VEBM720100

DISASSEMBLY AND ASSEMBLY Disassembly and assembly of front axle

19. Press bearing (7) or assemble after preheating. 22. Use tool 2897004 to fit bearing washer (5) on
beam trumpet (4).

20. Press bearing (5) assemble after the preheating.

23. Fit O-ring (9) on beam trumpet (3). Lubricate O-
ring (9)with grease.

21. Fit adjustment shims (6) X1 = 1.8 on beam trum-

pet (4).
24. Position adjusting shims (8) X2 on beam trumpet
(3).

PW148-8 VEBM720100 30-103

Disassembly and assembly of front axle DISASSEMBLY AND ASSEMBLY

25. Use tool 2897004 to fit the bearing outer washer 28. While Screwing the tool nut until the value of
(7) on beam trumpet (3). 10Nm has been reached turn the ring bevel gear
and strike it with a hammer to fix whole unit.

26. Position the differential unit beam trumpet (4).

29. Measuring of value G.

27. Position tool 2897001 for 20K-23-31000. Posi-

tion tool 2897002 for 20K-23-32000. Assemble 30. Value written on beam trumpet (3) F1
half bearing (7) inside tool.

30-104 PW148-8 VEBM720100

DISASSEMBLY AND ASSEMBLY Disassembly and assembly of front axle

31. Drawing used to determine backlashes between 33. Apply Loctite® 510 on contact surface of beam
the bevel gear pair teeth for 20K-23-31000. trumpet (4).

X1 = 1.8

Check adjusting shims X2 through the suggested

procedure for 20K-23-31000 axles

X2 = G - (19 + F1) + 0.15 / 0.1

F1 = addition of the dimensions printed on the

housings 19 + 0.1 / 0.15 is the bearing preload-
ing

34. Apply Loctite® 242 on screws (1).

32. Move alternately the pinion tag and take note of

the backlash between pinion and ring bevel gear 35. Assemble screws (1).
(detected through a compactor).
Torque - 560Nm (57 kgf-m)
Make sure that the feeler touches the screw
head mounted on the flange and is located at 90
degrees.

Check if the value of the detected backlash is

within the preset field: 0.15/0.25 mm.

Should the backlash be insufficient or excessive,

adjust shim X1=1.8 by increasing or decreasing.

PW148-8 VEBM720100 30-105

Disassembly and assembly of front axle DISASSEMBLY AND ASSEMBLY

Disassembly of pinion group 5. Lift the whole differential unit.

1. Remove the axle unit. Sling and slightly tension

the rope. Turn and then fix it in vertical position.

6. Loosen the nut (6).

2. Loosen and remove screws (1) with washers

(14).

7. Remove the nut (6) and the flange (10).

3. Sling the beam trumpet (3) and slightly lift it.

8. Remove the gasket (7).

4. Remove O-ring (5).

30-106 PW148-8 VEBM720100

DISASSEMBLY AND ASSEMBLY Disassembly and assembly of front axle

9. Take the bevel pinion out of its housing, by beat- 12. Take the cup of the taper roller bearing (11) out of
ing with hammer made of soft material on the the central body, using a chisel and hammer.
splined end.

13. Remove the outer cup of the taper roller bearing

10. Once the bevel pinion (2) has been removed, (13) and shims (9) from the central body. Use a
collect shims (9) and spacer (8). chisel and a hammer.

11. Take the bearing cone (13) out of the bevel pin-
ion end, using a suitable extractor.

PW148-8 VEBM720100 30-107

Disassembly and assembly of front axle DISASSEMBLY AND ASSEMBLY

Assembly of pinion group S = X - (V+B)

1. Bevel pinion adjustment for 20E-23-31000. Example:

shim S = 163.6 - (132.80 + 29.25) =1.55 mm
X 155.50 155.50 155.70

B 29.25 29.45 29.45

V 125.00 125.20 124.80

A 154.25 154.65 154.05

S 1.25 0.85 1.65

4. Bearings adjustment.

G 30.50 30.00 30.60

S 1.25 0.85 1.65

L1 2.25 2.25 2.57

L2 2.25 2.25 2.57

S1 36.25 35.35 37.39

B1 34.40 34.50 34.40

S2 1.85 0.85 2.99

Preloading reduction ca. 0.02 - 0.04 for a 2-3 Nm

torque.

Preloading reduction ca. 0.02 - 0.04 for a 2-3 Nm

torque.

2. Value stamped on beam trumpet.

3. To determine shim (S) between pinion and bear-

ing it is enough to add value (V) printed on pinion
head (V = prescribed conical distance) to value B
- bearing width - and subtract X from the value
printed on beam

30-108 PW148-8 VEBM720100

DISASSEMBLY AND ASSEMBLY Disassembly and assembly of front axle

5. To determine shim S2. 8. Position half bearing (11) on beam trumpet (4).

S2 = B1 - (L1 - S - G - L2)

S = previously detected shims

G = beam value

9. Position adjusting shims (9) and inner bearing

washer (13) on beam trumpet (4).

6. B1 = spacer eight (8).

Alternative procedure, use starting spacer S =

1.5.

10. Insert the cups of the taper roller bearings on

their housings using the special tools included on
the kit 2897006 (20K-23-31000) 25897007 (20K-
23-32000).

7. B1 = spacer eight (8).

Alternative procedure, use starting spacer

S = 1.5.

PW148-8 VEBM720100 30-109

Disassembly and assembly of front axle DISASSEMBLY AND ASSEMBLY

11. Press inner bearing (13) on pinion (2). 14. Fit bearing (11) in relevant housing on beam
trumpet (4).
Use tool 2897009.

Use a special glove to protect fromscorching.

12. Fit the whole pinion of the bearing on beam trum-

pet (4) spacer (8) and shims (12).

15. Grease shaft pinion (2).

13. Preheat bearing (11) on proper plate up to

100ºC.

16. Fit oil seal (7) inside tool 2897015.

Apply Loctite® 510 on the oil seal outer edge.

30-110 PW148-8 VEBM720100

DISASSEMBLY AND ASSEMBLY Disassembly and assembly of front axle

17. Assemble the oil seal by slightly striking with a 20. Assemble the flange (10) and the nut (6).
plastic hammer.

NOTE
Clean the box with a rolling brush.

21. Apply tool 2987001.

Torque - 340 Nm (35 kgf-m)

18. Apply Loctite® 242 on nut (6).

22. Drive the nut (6)with a tool.

19. Use a hammer to assemble flange (10) together

with guard (14).

PW148-8 VEBM720100 30-111

Disassembly and assembly of front axle DISASSEMBLY AND ASSEMBLY

23. Carry out the preloading measurement (P) of the 26. Apply Loctite® 510 on contact surface of beam
pinion taper roller using a dynamometer whose trumpet (4).
cord is wound on the flange diameter. The ad-
justment is performed by gradually increasing
shims (12) mounted under bearing (11).

All preloadings should be measured without the

seal ring.
P = 2/3 Nm

27. Fit screws (1) and tighten.

Torque - 205 Nm (21 kgf-m)

24. Assemble the whole differential unit.

28. To test the marks of the bevel gear teeth, paint

the ring gear with red lead paint and detect the
contact. The marking test should be always car-
ried out on the ring bevel gear teeth and on both
sides.

25. Assemble O-ring (5) on beam trumpet (3).

Grease the O-ring (5)

30-112 PW148-8 VEBM720100

DISASSEMBLY AND ASSEMBLY Disassembly and assembly of front axle

29. OK - Correct contact.

If the bevel gear is well adjusted, the mark on the

teeth surfaces will be regular

Z - Excessive contact on the tooth tip

Approach the pinion to the ring bevel gear and

then move the ring bevel gear away from the pin-
ion in order to adjust the backlash.

X - Excessive contact at the tooth base

Move the pinion away from the ring bevel gear

and then approach the ring bevel gear to the pin-
ion in order to adjust the backlash.

30. Movements to correct

1 - Move the pinion for type X contact adjust-

ment.

2 - Move the pinion for type Z contact adjust-

ment.

PW148-8 VEBM720100 30-113

Disassembly and assembly of front axle
Toe-in adjustment
1. Put 2 equal one meter long linear bars on the
wheel sides and lock them with two nuts on the
wheel hub stud bolt.
The 2 bars should be fixed on their middle so that
they are perpendicular to the supporting surface
and parallel to the pinion shaft. Align the 2 bars.
2. Measure the distance in mm between the bar
ends with a tapeline (M).
NOTE
Keep the minimum value, swinging the measurement
point.
30-114
DISASSEMBLY AND ASSEMBLY
3. Check that the difference of the measurements
between the wheel hubs diameters ends is within
the requested tolerance range (Tolerance = 0)
The nominal toe-in (A) value is referred to the ex-
ternal diameter of the wheel hubs flange, there-
fore the measured toe-in value (M) at the bars
ends must be related to the ratio between length
of the bar and flange diameter.
Nominal toe-in Measured
(Tolerance = 0) = A±1 Toe-in = M±3
4. If toe-in is incorrect, remove the pivots of the
steering cylinder heads, screw them in and out
equally till the toe-in is within the requested toler-
ance.
PW148-8 VEBM720100
DISASSEMBLY AND ASSEMBLY Disassembly and assembly of front axle

5. After adjusting, screw in the lock nuts. (Tighten- 3. Adjust the steering mechanical retainer, screwing
ing torque = 117Nm) in or out the right screw on the bar body, locking
it with a locknut. (Tightening torque - 150Nm)

Steering angle adjustment 4. Steer completely towards the other side and re-
1. Use the same bars assembled for the toe-in ad- peat the previous operations.
justment and a long bar perfectly balanced over
the machined part of the central body (pinion
side), so that the 2 bars form an acute angle at
the maximum steering.

2. Adjust a goniometer to the to the requested an-

gle 32°/26.2° (inner/outer) and position it on the
long bar.

Move a wheel side till it forms with the 2 bars, the

angle fixed by the goniometer.

PW148-8 VEBM720100 30-115

Removal and installation of rear axle and transmission DISASSEMBLY AND ASSEMBLY

Removal and installation of rear axle and transmission

Removal 4. Attach an identification tag to hoses to avoid in-

correct connection during re-assembly.
Blanking Kit

Description Part Number Qty Where Used 5. Attach vacuum pump to hydraulic tank and apply
vacuum.
Cap Plug 07376-70210 1
Rear Clutch Hose
O-ring 02896-11008 1
6. Disconnect each hose individually from the travel
Cap Plug 07376-70210 1
Top Clutch Hose
motor and hose from top of the transmission plug
O-ring 02896-11008 1 with blank / plug and O-ring from blanking kit to
Plug 02789-00210 2 Brake fittings prevent oil spillage and contamination (3 through
7)
Cap Plug 07376-70210 2
Hub Brake Lines
O-ring 02896-11008 2

4 5
1. Drain oil out of rear axle and hubs. 3

6 Rear Axle: Approx. 9.5 Litres

6
Rear Hubs: Approx. 2.0 Litres (Each) 7

2. Lower work equipment to raise undercarriage so

that rear axle is clear of ground.

7. Disconnect hose (8) from rear axle and plug with

blank/plug and O-ring from blanking kit to pre-
vent oil spillage and contamination.

3. Remove cover (1) by removing bolts (2).

8

2 2

30-116 PW148-8 VEBM720100

DISASSEMBLY AND ASSEMBLY Removal and installation of rear axle and transmission

8. Disconnect electrical connection (9). 11. Remove bolts(14).

14

9. Disconnect brake lines (10), (11) and plug with
blank/plug and O-ring from blanking kit. Also put
cap on nipple fittings to prevent oil spillage and
contamination.
12. Roll axle and wheels clear of machine.
13. Position supports in place of axle.
14. To remove travel motor (15) {option} remove 4
bolts (16) and extract motor in direction shown to
disengage splined shaft.

15

10

16 Disengage from
transmission

Installation
• Install in reverse order of removal.

• Grease all cylinders before installation.

11

• Tightening torque for axle mounting bolts (14):

662.-828.5 Nm.

• Tightening torque for propshaft nuts (13):

58.8-73.5 Nm.
10. Disconnect propshaft (12) by removing bolts (13)
and retracting propshaft in direction shown. • Tightening torque for travel motor bolts (16):
25-31.5 kgf-m.

13
• Refill oil in transmission (4.85litres).
12

• Refill oil in rear axle (9.5 litres).

ct
tra
Re • Top up hydraulic oil through oil filler port to the
specified level and let the oil circulate in the hy-
draulic system by starting the engine. Then
check oil again.

• Air bleeding see section on air bleeding in the

TESTING AND ADJUSTING section of the manual.

PW148-8 VEBM720100 30-117

Disassembly and assembly of rear axle assembly DISASSEMBLY AND ASSEMBLY

Disassembly and assembly of rear axle assembly

PW148-8 is fitted with a single propshaft. 2. Remove fastening screws (2) from the cover of
the planetary gears carrier.
Special tools
Part Number Part Name Quantity

2897101 Carrier removal 1

2897102 Hub removal 1

2897002 Torque control device 1

2897003 Chuck for bushings 1

2897004 Chuck for bushings 1

2897007 Assemble pin 1

2897009 Pin 1

2897012 Assemble device 1

3. Use the levers inside the preset slots to detach
the planetary gear carrier cover.
2897013 Assemble device 1

2897014 Brake centring 1

2897015 Assemble pin 1

2897039 Assemble pin 1

Removal of epicyclic reduction gear and

brake
1. Before draining the oil, position the wheel hub (1)
with the plug on the upper part and loosen it off
some turns in order to eliminate any possible in-
ner pressure, then remove it completely. Turn the
4. Remove the planetary gear carrier cover (3) and
wheel hub upside down till the hole is in the low-
O-ring (30).
est point.

Drain the oil completely.

30-118 PW148-8 VEBM720100

DISASSEMBLY AND ASSEMBLY Disassembly and assembly of rear axle assembly

5. Remove split ring (4). 9. Remove piston (8).

6. Remove ring bevel gear (5) complete with carrier 10. Remove seal rings (9) and (10) from piston (8).
(28) and split ring (29).

11. Remove screws (11) and washers (21) from

7. Remove brake discs (6). brake carrier (12).

8. Remove fastening screws of piston (7) and 12. Assemble carrier (28) and split ring (4). Remove
springs (15). brake carrier (12).

PW148-8 VEBM720100 30-119

Disassembly and assembly of rear axle assembly DISASSEMBLY AND ASSEMBLY

13. Remove bushes (22). 17. Remove the drain valve (17).

14. Remove seal rings (13) and (14) from brake car- 18. Remove seal ring (19).
rier (12).

19. Remove inner cup of bearing (18).

15. Remove shims (26).

16. Remove wheel hub (16) with bearings (19) and

(20) and seal ring (19) using tool 2897102.

30-120 PW148-8 VEBM720100

DISASSEMBLY AND ASSEMBLY Disassembly and assembly of rear axle assembly

20. Remove outer cup of bearing (20). 24. Remove snap ring (32) planetary gears (33).

21. Remove outer cup of bearing (18). 25. Remove universal joint (31).

22. Remove sleeve (25).

23. Remove shaft and pinion (24).

PW148-8 VEBM720100 30-121

Disassembly and assembly of rear axle assembly DISASSEMBLY AND ASSEMBLY

Installation of epicylic reduction gear 5. Apply Loctite® 510 on seal ring (19).
and brake
1. Assemble universal joint (31).

6. Fit seal ring (19) on wheelhub (16). Use tool

2897003.

2. Fit outer cup of bearing (18) wheel hub (16).

7. Lubricate axle shaft to assemble the wheel hub.

3. Fit outer cup of bearing (20) wheel hub (16).

Polish hub and oil holes.

4. Fit the remaining part of bearing 18) on wheel

hub (16).

30-122 PW148-8 VEBM720100

DISASSEMBLY AND ASSEMBLY Disassembly and assembly of rear axle assembly

8. Assemble the whole wheel hub (16). Alternately 11. Assemble the tool 2897013, 3 draw plates M10 x
strike bearings (18). 285 and 3 nuts M10.

The roller bearing should be rested on the beam

trumpet.

12. Use a depth gauge to measure dimension (g) of

wheel hub.

9. Preheat bearing (20) on proper plate up to

100°C.

13. Use a depth gauge to measure dimension F of

brake carrier (12).

10. Fit bearing (20) inside beam trumpet.

Wear gloves to avoid getting burnt.

PW148-8 VEBM720100 30-123

Disassembly and assembly of rear axle assembly DISASSEMBLY AND ASSEMBLY

14. Calculate shims X1 of adjustment shims by using 18. Fit piston (8) on brake carrier (12) with springs
the following procedure: X1 (G-F) + 0.05. (15) and screws (7). Apply Loctite® 638 on the
screws (7).

19. Fit the whole unit of the brake carrier on wheel

15. Assemble previously calculated shims (26) X1. hub.

The brake carrier and beam trumpet holes should

coincide.

16. Assemble O-rings (9) and (10) on piston (8).

20. Assemble brake discs (6).

During assembly operations all the inner disc

slots should coincide.

17. Assemble O-rings (13) and (14) on brake carrier

(12).

30-124 PW148-8 VEBM720100

DISASSEMBLY AND ASSEMBLY Disassembly and assembly of rear axle assembly

21. Assemble brake discs (6). 24. Fit snap ring (4).

During assembly operations all the outer disc

slots should coincide.

25. Remove plug (27).

22. Fit ring bevel gear (5) with carrier (28) and split
ring (29).

26. Fit an adapter instead of the plug.

23. Test the brake by temporarily fitting two screws

(11).

Do not assemble bushes (22).

27. Test the brakes by considering that pressure
should be 100-50 bar for about one minute.

PW148-8 VEBM720100 30-125

Disassembly and assembly of rear axle assembly DISASSEMBLY AND ASSEMBLY

28. Fit bushes (22). 31. Line up brake discs. Use tool 2897014.

Pay attention to the assembly direction of bush- A tooth should coincide with a brake fastening
es. screw (7).

29. Apply Loctite® 242 inside slots. 32. Put brakes under pressure to avoid outer disc
misalignment.

30. Fit screws (11) and shims (21).

33. Lubricate with grease and fit O-ring (30).
Tightening torque: 68Nm

30-126 PW148-8 VEBM720100

DISASSEMBLY AND ASSEMBLY Disassembly and assembly of rear axle assembly

34. Heat planetary gear bearing at 110ºC. Assemble 37. Fit sleeve (25).
planetary gear (23).

38. Lubricate with grease the contact surface of

35. Assemble snap ring (32). planetary gear cover (3). Apply Loctite® 510 in
the holes.

36. Fit pinion shaft (24).

39. Fit the planetary gear cover (3) and discharge
pressure from the hydraulic pump.

PW148-8 VEBM720100 30-127

Disassembly and assembly of rear axle assembly DISASSEMBLY AND ASSEMBLY

40. Apply Loctite® 242 on screw (2). 43. Apply a pressure of 45-50 bar and check the dis-
tance between brake locking and unlocking
(MIN: 1.7mm, MAX: 3.8mm).

41. Assemble screws(2). (Tightening torque - 46Nm)

42. Remove oil drain plug and turn the final drive up
to meeting the item (28) hole.

NOTE
Brakes wear check.

30-128 PW148-8 VEBM720100

DISASSEMBLY AND ASSEMBLY Disassembly and assembly of rear axle assembly

Disassembly of beam trumpet and differ- 4. Remove O-ring (9).

ential unit
1. Remove the axle unit. Sling and slightly tension
the rope. Turn and then fix it in vertical position.

5. Lift the whole differential unit.

2. Loosen and remove screws (1) fixing beam trum-

pet (3) to the body (4).

6. Use an extractor and remove from housing (4)

the outer cup of bearing (5).

3. Sling the beam trumpet (3) and slightly lift it.

PW148-8 VEBM720100 30-129

Disassembly and assembly of rear axle assembly DISASSEMBLY AND ASSEMBLY

7. Remove shims (6). 11. Use an extractor to remove bearing (5) from dif-
ferential unit.

8. Use an extractor and remove from housing (3)

the outer cup of bearing (7). 12. Unscrew all fastening screws (10) of bevel gear
crown (2).

This operation makes both differential half boxes

free, so take care not to drop the inner compo-
nents.

9. Remove shims (8).

13. Remove ring bevel gear (2) by means of a mal-

let.

10. Use and extractor to remove bearing (7) from dif-

ferential unit.

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DISASSEMBLY AND ASSEMBLY Disassembly and assembly of rear axle assembly

14. Check marking points (11) and (12) that will be 17. Remove planetary gear (24) and shim (26).
useful during the assemblage.

NOTE
Without differential torque limiter
15. Remove planetary gear (23) and shim (25).
NOTE
With differential torque limiter
18. Remove discs (28) and (29).

19. Remove planetary gear (30).

16. Remove differential pins (13) and (14), planetary
gears (15), (16), (17) and (18) and spheric wash-
ers (19), (20), (21) and (22).

PW148-8 VEBM720100 30-131

Disassembly and assembly of rear axle assembly DISASSEMBLY AND ASSEMBLY

20. Remove differential pins (31), (32), planetary

gears (33), (34), (35) and spheric washers (37),
(38), (39) and (40).

21. Remove planetary gear (41).

22. Remove discs (42) and (43).

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DISASSEMBLY AND ASSEMBLY Disassembly and assembly of rear axle assembly

Installation of beam trumpet and differ- 4. Fit differential unit pin (13) and planetary gears
ential unit (15), (16) and washers (19) and (20).

1. Apply a thin layer of molicote G-n plus paste on

half boxes of differential (11) and (12).

Remove remains of old sealing compound.

5. Fit the differential unit pin (14) and planetary

gears (17), (18) and washers (21), (22).

2. Apply a thin layer of molicote G-n plus paste on

planetary gears (15), (16), (17) and on planetary
gears (23) and (24).

6. Assemble planetary gears (23) with shim (25).

3. Assemble planetary gears (24) with shim (26).

PW148-8 VEBM720100 30-133

Disassembly and assembly of rear axle assembly DISASSEMBLY AND ASSEMBLY

7. Apply a thin layer of molicote G-n plus paste on 10. Assemble planetary gears (41).
half boxes of differential (44) and (45)

Remove remains of old sealing compound.

11. Fit differential unit pin (31) and planetary gears

(33) and (34) and washers (37) and (38).

8. Apply a thin layer of molicote G-n plus paste on

plantetary gears (33), (34), (35) and (36) and on
planetary gears (30) and (41).

12. Fit differential unit pin (32) and planetary gears

(35) and (36) and washers (39) and (40).

9. Assemble discs (42) and (43).

30-134 PW148-8 VEBM720100

DISASSEMBLY AND ASSEMBLY Disassembly and assembly of rear axle assembly

13. Assemble planetary gears (30). 16. Fit ring bevel gear (2) by using a hammer.

14. Assembly discs (28) and (29). 17. Apply loctite®242 on thread of screws (10).

15. Fit the two half boxes of differential unit (11) and 18. Tighten screws (10).
(12).
 Screws (10) torque: 205Nm

Carefully check that the marks of both differential NOTE

half boxes coincide Fix differential housing in the vice

PW148-8 VEBM720100 30-135

Disassembly and assembly of rear axle assembly DISASSEMBLY AND ASSEMBLY

19. Fit bearing (7). 22. Assemble cup of bearing (5).

20. Press bearing (5). 23. Assemble O-ring (9).

21. Fit adjustment shims (6) (X1)=1.8. 24. Assemble adjusting shims (8) (X2).

30-136 PW148-8 VEBM720100

DISASSEMBLY AND ASSEMBLY Disassembly and assembly of rear axle assembly

25. Assemble cup of bearing (3). 28. While screwing the tool nut until the value of
10Nm has been reached, turn the ring bevel gear
and strike it with a hammer to fix the whole unit.

26. Assemble differential unit.

29. Measuring of value G.

27. Install tool 2897001. Assemble half bearing (7)

inside tool.
30. Value (F1) written on axle beam (3).

PW148-8 VEBM720100 30-137

Disassembly and assembly of rear axle assembly DISASSEMBLY AND ASSEMBLY

31. Drawing used to determine backlashes between 33. Apply loctite® 510 on contact surface of beam
the bevel gear pair teeth. trumpet (4).

X1 = 1.8

Check adjusting shims X2 through the suggested

procedure: X2 = F1.

34. Apply loctite® 242 on screws (1).

32. Move alternately the pinion tang and take note of

the backlash between pinion and ring bevel gear
(detected through a comparator).

Make sure that the feeler touches the screw

head mounted on the flange and is located at
90°.
35. Assemble screws (1) and washers (27) and tight-
Check if the value of the detected backlash is en screws (1).
within the preset field: 0.15 / 0.25mm.
 Screws (1) torque: 285Nm
Should the backlash be insufficient or excessive,
adjust shim X1 = 1.8 by increasing or decreas-
ing.

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DISASSEMBLY AND ASSEMBLY Disassembly and assembly of rear axle assembly

Disassembly of pinion group 4. Remove O-ring (5).

1. Remove the axle unit. Sling and slightly tension

the rope. Turn and then fix it in vertical position.

5. Lift the whole differential unit.

2. Loosen and remove screws (1) fixing beam trum-

pet (3) to the body (4).

6. Remove bush (7).

3. Sling the beam trumpet (3) and slightly lift it.

PW148-8 VEBM720100 30-139

Disassembly and assembly of rear axle assembly DISASSEMBLY AND ASSEMBLY

7. Remove sleeve (8). 10. Remove O-ring (22).

8. Remove gear wheel (9). 11. Remove snap ring (16).

9. Remove O-ring (18), ring (19) and seal (20). 12. Remove the disc (17).

30-140 PW148-8 VEBM720100

DISASSEMBLY AND ASSEMBLY Disassembly and assembly of rear axle assembly

13. Take the bevel pinion out of its housing, by beat- 16. Take the cup of the taper roller bearing (11) out of
ing with a hammer made of soft material on the the central body using a chisel and hammer.
splined end.

17. Remove the outer cup of the taper roller bearing

14. Once the bevel pinion (2) has been removed, (13) and shims (9) from the central body. Use a
collect shims (9) and spacer (8). chisel and hammer.

15. Take the bearing cone (13) out of the bevel pin-
ion end, using a suitable extractor.

PW148-8 VEBM720100 30-141

Disassembly and assembly of rear axle assembly DISASSEMBLY AND ASSEMBLY

Installation of pinion group 3. To determine shim (S) between pinion and bear-
ing it is enough to add value (V) printed on pinion
1. Bevel pinion adjustment. head (V = prescribed conical distance) to value B
- bearing width - and subtract X from the value
X 155.50 155.50 155.70
printed on beam.
B 29.25 29.45 29.45
S=X - (V+B)
V 125.00 125.20 124.80

A 154.25 154.65 154.05 Example: shim S = 163.6 - (132.80 + 29.25) =

S 1.25 0.85 1.65 1.55mm.

4. Bearings adjustment ASP125.

G 30.50 30.00 30.60

S 1.25 0.85 1.65

L1 2.25 2.25 2.57

L2 2.25 2.25 2.57

S1 36.25 35.35 37.359

B1 34.50 34.50 34.40

S2 1.85 0.85 2.99

Preloading reduction ca. 0.02 - 0.04mm for a 2-3 Nm

torque.

2. Value stamped on beam trumpet X.

30-142 PW148-8 VEBM720100

DISASSEMBLY AND ASSEMBLY Disassembly and assembly of rear axle assembly

5. To determine shim S2 8. Position half bearing (11) on beam trumpet (4).

S2 = B1 - (L1 - S - G - L2)

S = previously detected shims

G = beam value

9. Position adjusting shims (9) and inner bearing

washer (13) on beam trumpet (4).

6. L1 = bearing height

L2 = bearing height

10. Press inner bearing (13) on pinion (2).

7. B1= spacer (8) height.

Alternative procedure, use starting spacer S=

1.5.

PW148-8 VEBM720100 30-143

Disassembly and assembly of rear axle assembly DISASSEMBLY AND ASSEMBLY

11. Fit the whole pinion of bearing on beam trumpet 14. Grease bevel pinion.
(4), spacer (14) and shims (12).

15. Assemble the disc (17).

12. Preheat bearing (11) on proper plate up to
100°C.

16. Assemble snap ring (16).

13. Fit bearing (11) in revelant housing on beam

trumpet (4).

Use a special glove to protect from scorching.

30-144 PW148-8 VEBM720100

DISASSEMBLY AND ASSEMBLY Disassembly and assembly of rear axle assembly

17. Assemble O-ring (22). 20. Assemble the bush (8).

18. Assemble O-ring (18), ring (19) and seal (20). 21. Assemble sleeve (7) and grease surface.

19. Grease gear wheel (9) and assemble. 22. Assemble flange (10) and nut (6).
(Tightening torque - 400Nm).

PW148-8 VEBM720100 30-145

Disassembly and assembly of rear axle assembly DISASSEMBLY AND ASSEMBLY

23. Carry out the preloading measurement (P) of pin- 26. Apply Loctite® 510 on contact surface of beam
ion taper roller using a dynamometer whose cord trumpet (4).
is wound on the flange diameter.

The adjustment is performed by gradually in-

creasing shims mounted under bearing.

All preloadings should be measured without the

seal ring.
P = 2 / 3 Nm

27. Fit screws (1) and tighten according to the pre-

scribed torque: 285 Nm.

24. Assemble whole differential unit.

28. NOTE
To test the marks of the bevel gear teeth, paint
the ring gear with red lead paint and detect the
contact.

The marking test should ALWAYS be carried out

on the ring bevel gear teeth and on both sides.

25. Assemble the O-ring (5) on beam trumpet (3).

Grease the O-ring (5).

30-146 PW148-8 VEBM720100

DISASSEMBLY AND ASSEMBLY Disassembly and assembly of rear axle assembly

29. OK - Correct contact

If bevel gear is well adjusted, the mark on teeth

surfaces will be regular.

Z - Excessive contact on the tooth tip.

Approach the pinion to the ring bevel gear and

then move the ring bevel gear away from the pin-
ion in order to adjust the backlash.

X - Excessive contact at the tooth base.

Move the pinion away from the ring bevel gear

and then approach the ring gear to the pinion in
order to adjust the backlash.

30. Movements to correct.

1 - Move the pinion for type X contact adjust-

ment.

2 - Move the pinion for type Z contact adjust-

ment.

PW148-8 VEBM720100 30-147

Disassembly and assembly of transmission DISASSEMBLY AND ASSEMBLY

Disassembly and assembly of transmission

Special tools 4. Remove disc (3).

Part Number Part Name Quantity

1743047 O-Ring, gasket assembly 1

2897005 Seal Assembly 1

2897008 Snap Ring Assembly 1

2897039 Handle 1

2912484 O-Ring, gasket assembly 1

Removal of travel motor and flange

1. Remove drain plug and drain oil from transmis-
sion and travel motor. 5. Remove spring (4).

6 Transmission:
Approx. 4.85 l

2. Remove screws (1).

6. Remove O-ring (5).

3. Remove the motor (2).

30-148 PW148-8 VEBM720100

DISASSEMBLY AND ASSEMBLY Disassembly and assembly of transmission

7. Loosen nut (6). 11. Remove flange protection (9).

8. Remove nut (6). 12. Loosen and remove screws (10).

9. Remove flange (7). 13. Remove hydraulic motor flange (11) and O-ring
(12).

10. Use an extractor to remove the inner ring of the

bearing (8).

Installation of travel motor

PW148-8 VEBM720100 30-149

Disassembly and assembly of transmission DISASSEMBLY AND ASSEMBLY

1. Assemble flange (11) and O-ring (12). 5. Assemble inner ring (8) of the bearing.

2. Apply Loctite® 242 on screws (10). 6. Assemble the flange (7).

3. Assemble screw (10). 7. Apply Loctite® 242 on nut (6).

(Tightening torque - 117Nm)

8. Assemble nut (6).

4. Assemble flange protection (9) on flange (7).

30-150 PW148-8 VEBM720100

DISASSEMBLY AND ASSEMBLY Disassembly and assembly of transmission

9. Carry out caulking on nut (6). 13. Assemble the travel motor (2).

10. Assemble O-ring (5). 14. Apply Loctite® 242 on screws (1).

11. Assemble spring (4). 15. Assemble screws (1).

(Tightening torque - 285Nm)

12. Assemble disc (3).

PW148-8 VEBM720100 30-151

Disassembly and assembly of transmission DISASSEMBLY AND ASSEMBLY

Removal of transmission box 5. Remove springs (4), (5) and (6).

1. Remove screws (1).

6. Unlock the clutch by pressing with 50-100 bar,

through gearbox hole.
2. Remove screws (2).

7. Remove snap ring (7).

3. Remove transmission box.

8. Remove ring (8).

4. Remove the O-ring (3).

30-152 PW148-8 VEBM720100

DISASSEMBLY AND ASSEMBLY Disassembly and assembly of transmission

9. Remove discs (9). 13. Remove thrust plate (13) from bush (11).

10. Remove disc (10). 14. Remove screws (14).

11. Remove bush assembly. 15. Remove the box assembly.

12. Remove the thrust ring (12). 16. Remove complete planetary gears carrier.

PW148-8 VEBM720100 30-153

Disassembly and assembly of transmission DISASSEMBLY AND ASSEMBLY

17. Remove shaft (15). 21. Remove ring (19).

18. Remove gear (16). 22. Use an extractor to remove bering inner cup
(20).

19. Use an extractor to remove the bearing (17).

23. Use an extractor to remove gearwheel (21) from
planetary gears carrier (22).

20. Remove shims(18).

24. Remove washers (23), pins (24), bearings (25),

and gears (26) from the planetary gears carrier
(22).

30-154 PW148-8 VEBM720100

DISASSEMBLY AND ASSEMBLY Disassembly and assembly of transmission

25. Remove O-ring (27). 29. Remove spin assembly.

26. Remove snap ring (28). 30. Remove pin (30) from bearing (31).

Use tool 2897008

31. Remove bearing outer cup (31).

27. Remove bearing (20).

32. Remove piston (32).

28. Remove ring (29).

PW148-8 VEBM720100 30-155

Disassembly and assembly of transmission DISASSEMBLY AND ASSEMBLY

33. Remove gasket (33) and O-ring (34). 37. Remove O-ring (40.

34. Remove piston (35) and springs (36), (37). 38. Removedisc (41).

35. Remove bearing cup (38). 39. Remove the pin (42).

36. Remove gasket (39). 40. Remove snap ring (43).

30-156 PW148-8 VEBM720100

DISASSEMBLY AND ASSEMBLY Disassembly and assembly of transmission

41. Remove hollow wheel assembly. 45. Remove disc (48).

42. Remove bearing (44). 46. Remove discs (49), (50), (51) and (52).

43. Remove snap ring (45). 47. Remove piston assembly.

44. Remove external geared wheel (46) from hollow 48. Remove O-ring (53).
wheel (47).

PW148-8 VEBM720100 30-157

Disassembly and assembly of transmission DISASSEMBLY AND ASSEMBLY

49. Remove piston gasket (54) and O-ring (55). 52. Loosen screw (60).

50. Remove outer ring (56) from piston (57). 53. Remove screw (60), washer (61), spring (62),
and ball (63).

51. Remove gasket (58) and O-ring (59) from seat.

54. Remove pin (64) and O-ring (65).

30-158 PW148-8 VEBM720100

DISASSEMBLY AND ASSEMBLY Disassembly and assembly of transmission

55. Remove screws (66). 58. Remove gasket (69).

56. Remove the cover (67). 59. Remove snap ring (70).

57. Remove disc (68). 60. Remove bearing (71).

PW148-8 VEBM720100 30-159

Disassembly and assembly of transmission DISASSEMBLY AND ASSEMBLY

Installation of transmission box 4. Assemble oil seal (69) on tool 2897005.

1. Assemble bearing (71).

NOTE
Clean the box with a rolling brush.

2. Assemble snap ring (70).

5. Assemble disc (68).

3. Install oil seal ring (69) inside tool 2897005.

Apply Loctite® 510 on seal ring outer edge.

6. Install cover (67).

30-160 PW148-8 VEBM720100

DISASSEMBLY AND ASSEMBLY Disassembly and assembly of transmission

7. Apply Loctite® 242 on screws (66).

NOTE
To unlock the transmission in case of need, turn the
eccentric pin 180° (notch upward).

8. Fix cover (67) with screws (68).

10. Assemble ball (63), spring (62), washer (61) and

screw (60).

9. Assemble O-ring (65) on the pin (64) and apply a

light layer of grease. Assemble the pin.

11. Tighten screw (60). (Tightening torque - 400Nm)

PW148-8 VEBM720100 30-161

Disassembly and assembly of transmission DISASSEMBLY AND ASSEMBLY

12. Assemble gasket (58) and O-ring (59) in the ring 16. Lubricate and install pistom using tool 1743047.
(56).
Make sure that the oil groove coincides with the
toothed disc grooves.

Warning make sure that the piston does not key.

13. Assemble outer ring (56) on piston (57) ensuring

the notches match.

17. Assemble discs (49), (50), (51) and (52).

14. Assemble gasket (54) and O-ring (55).

NOTE
Check the sequence of discs.

15. Assemble O-ring (53).

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DISASSEMBLY AND ASSEMBLY Disassembly and assembly of transmission

18. Assemble disc (48). 22. Assemble hollow wheel assembly.

19. Assemble external geared wheel (46) on the hol- 23. Assemble snap ring (43).
low wheel (47).

24. Assemble pin (42).

20. Assemble snap ring (45).

25. Assemble disc (41).

21. Assemble bearing (44) on hollow wheel assem-
bly.

PW148-8 VEBM720100 30-163

Disassembly and assembly of transmission DISASSEMBLY AND ASSEMBLY

26. Assemble O-ring (40). 30. Apply grease on pistion (35) to prevent springs
from falling and insert springs (36), (37) and (38).

27. Assemble gasket (39).

Springs are ssembled as follows:

N.1 series with 1 spring;
N.1 series with 2 spring;
N.1 series with 1 spring;
N.3 series with 2 spring;
N.1 series with 1 spring;
N.1 series with 2 spring.
Repeat this operation twice.

28. Assemble O-ring (38).

29. Install O-ring (38) and gasket (39). 31. Assemble piston assembly

Use tool 2912484.

30-164 PW148-8 VEBM720100

DISASSEMBLY AND ASSEMBLY Disassembly and assembly of transmission

32. Assemble O-ring (34) and gasket (33). 36. Assemble pin (30).

33. Assemble piston (32). 37. Assemble ring (29).

34. Assemble cup of bearing (31). 38. Assemble bearing outer cup (20).

35. Assemble bearing (31). 39. Assemble snap ring (28).

Use tool 2897008.

PW148-8 VEBM720100 30-165

Disassembly and assembly of transmission DISASSEMBLY AND ASSEMBLY

40. Assemble O-ring (27). 44. Align the holes of the wheel (21) with the holes of
the planetary gears carrier (22).

41. Assemble gears (26), bearings (25), pins(24)

and washers (23) on the planetary gears carrier 45. Apply Loctite® 638 on inner race of bearing (20).
(22).

46. Assemble the ring (19).

42. Assemble pins (24).

47. Measure shim (S) of bearing (17).

43. Assemble gear wheel (21) on planetary gears
carrier (22).

30-166 PW148-8 VEBM720100

DISASSEMBLY AND ASSEMBLY Disassembly and assembly of transmission

48. Measure the distance (A) between supporting 51. Apply Loctite® 638 on inner race of bearing (17)
plate and the bearing detent (17). and assemble it.

49. Measure the distance (B) btween the case sup- 52. Assemble gear (16).
porting plate and the upper detent of the bear-
ing(17).

53. Assemble shaft (15).

50. The dimension X= A-(B+S) determins the value

of the shims (18) to be fitted, with a tolerance of
0.5 - 0.7.

54. Assemble the planetary gears carrier.

PW148-8 VEBM720100 30-167

Disassembly and assembly of transmission DISASSEMBLY AND ASSEMBLY

55. Assemble bush (11) and thrust plate (13). 58. Assemble the complete bush.

NOTE
Pay attention to assembly direction.

59. Apply Loctite® 242 on screws (14).

56. Install thrust ring (12).

60. Assemble screws (14).

Screw in screws to tightening torque - 117Nm.

57. Assemble the complete box.

61. Assemble disc (10).

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DISASSEMBLY AND ASSEMBLY Disassembly and assembly of transmission

62. Assemble disc (9). 66. Assemble snap ring (7).

63. Assemble the ring (8). 67. Assemble springs (4), (5) and (6).

64. Unlock the clutch by pressing 50 - 100 bar. 68. Assemble O-ring (3).

Apply Loctite® 510.

65. Measure the lowering of the discs using a digital

gauge.
69. Assemble transmission box.
The stroke should be between 1.7 and 1.9 mm.
Otherwise replace the ring (8) with one of differ-
ent thickness.

PW148-8 VEBM720100 30-169

Disassembly and assembly of transmission DISASSEMBLY AND ASSEMBLY

70. Apply Loctite® 242 on screws (2). 73. Assemble screws (2).

(Tightening torque - 285Nm)

71. Assemble scres (2).

(Tightening torque - 70Nm) 74. Unlock clutch by pressing with 50 - 100 bar.
Measure the lowering of discs using a digital
guage.

The stroke should be between 2.2 and 2.4 mm.

72. Apply Loctite® 242 on screws (1).

30-170 PW148-8 VEBM720100

DISASSEMBLY AND ASSEMBLY Removal and installation of propshaft assembly

Removal and installation of propshaft assembly

Removal 5. Remove nuts (4), then retract from the studs on

the axle housing.
1. Remove guard (1) by removing 4 bolts (2).

4 Guard approx.: 28 kg

Retract

2 2
4

6. Carefully lift propshaft away.

4 Propshaft Assembly: 19.6kg

2. Support propshaft in 2 places with suitable

equipment.
3. Remove nuts (3), then retract the propshaft clear
of studs on transmission housing.
Installation
• Install in reverse order of removal.
• Tightening torque of propshaft nuts
58.8-73.5 Nm (6 - 7.5 kgm).

Retract

4. Ensure propshaft is supported safely.

PW148-8 VEBM720100 30-171

Removal and installation of wheel DISASSEMBLY AND ASSEMBLY

Removal and installation of wheel

Removal 4. Release 8 of the wheel retaining nuts leaving 2

diagonally opposite each other remaining (1+2).
1. Stop engine and ensure brake pedal is engaged. Once you have checked there is no pressure on
the remaining 2 nuts remove these as well.
2. Raise the chassis with the boom so that the tyres
are raised above the ground. Then, place axle
stands below the front (1) and rear (2) axles.

3. Lower onto stands and deflate tyre completely by Installation

removing valve (3) with appropriate tool. • Install in reverse order of removal.

• When inflating tyres, inflate to:

Always stand to the side while deflating the tyre. Tyre Tyre Pressure (bar)

10.00 - 20 14 ply 6.75

10.00 - 20 16 ply 7.25

• Check there is no damage to wheel and rims.

30-172 PW148-8 VEBM720100

DISASSEMBLY AND ASSEMBLY Removal and installation of suspension lock cylinder assembly

Removal and installation of suspension lock cylinder as-

sembly

Removal
1. Remove front wheels, see page 30-172.

2. Remove tube (1).

1

3. Remove the 4 bolts (2) attaching the suspension

lock cylinders to the chassis.

4 Suspension cylinder assembly: 35kg

Installation
• Install in reverse order of removal.

• Be sure to grease axle pads when installing cyl-

inders.

PW148-8 VEBM720100 30-173

Disassembly and assembly of suspension lock cylinders DISASSEMBLY AND ASSEMBLY

Disassembly and assembly of suspension lock cylinders

Change Rod Seal

5. Investigate wiper ring position 6 with respect to
1. Remove screw plug position 10.
damages, if necessary replace it.
2. Press rod position 2 downwards.
6. Grease the seals.

7. Mount the rod.

Do not damage rod surface!

With all repairs pay attention to extreme cleanli-

3. Take out U - ring position 7 using aa tool without ness!
sharp edges.

Do not damage groove!

4. Insert new U -ring in a reniform squeezed state

and press it into the groove ensuring that there
are no kinks.

30-174 PW148-8 VEBM720100

DISASSEMBLY AND ASSEMBLY Removal and installation of outrigger assembly

Removal and installation of outrigger assembly

Removal 7. Sling outrigger assembly at points marked (4).

1. Lower outriggers untill they just touch the ground

but do not take any of the weight of the machine.

2. Turn off engine.

3. Depressurise the outrigger hydraulic circuit.

4. Remove cover (1).

4
1

8. Remove all bolts (5) and remove outriggers.

5. Remove 2 pipes (2).

Installation
• Install in reverse order of removal.

6. Remove 2 pipes (3). • Grease all pins and cylinders before installing.

4 Outrigger assembly: 970kg

PW148-8 VEBM720100 30-175

Disassembly and assembly of outriggers DISASSEMBLY AND ASSEMBLY

Disassembly and assembly of outriggers

Disassembly 5. Remove pin (4).

1. Insert plugs into oil connectors to prevent dirt

blocking connectors.

2. Insert support block below cylinder at (1).

1 6. Slowly sling cylinder and remove from outrigger.

Assembly
3. Remove pin (2). • Install in reverse order of removal.

• Grease all pins and cylinders before installing.

• Grease bearing points after assembly.

4. Attach sling to cylinder at location (3).

30-176 PW148-8 VEBM720100

DISASSEMBLY AND ASSEMBLY Removal and installation of dozer blade assembly

Removal and installation of dozer blade assembly

Removal Installation
1. Sling at shown points (1). • Install in reverse order to removal.

1 • Grease all pins and cylinders.

1 1 4 Dozer blade assembly: 780kg

2. Lower dozer blade until it just touches the

ground, but don’t take any of the weight of the
machine.

3. Turn off engine.

4. Depressurise dozer blade circuit.

5. Remove 4 pipes (2).

2
2

6. Attach lifting tackle.

7. Remove bolts (3) and remove dozer blade as-

sembly.

PW148-8 VEBM720100 30-177

Disassembly and assembly of dozer blade DISASSEMBLY AND ASSEMBLY

Disassembly and assembly of dozer blade

Disassembly 4. Attach lifting tackle to cylinder at location (4).

1. Remove plate (1).

1 4

5. Remove pin (5).

2. Remove plate (2). 5

3. Remove pin (3).

6. Slowly sling cylinder and remove from dozer.

Assembly
• Install in reverse order of removal.

• Grease all pins and cylinders before installing.

• Grease bearing points after assembly.

3

30-178 PW148-8 VEBM720100

DISASSEMBLY AND ASSEMBLY Removal and installation of swing circle assembly

Removal and installation of swing circle assembly

Removal  Swing circle mounting bolt:

1. Remove revolving frame assembly. For details, 1st pass:

see REMOVAL OF REVOLVING FRAME AS-
SEMBLY. Tighten to 245 ~ 308.9Nm {25 ~ 31.5kgm}

2. Remove 38 mounting bolts (1) to remove the 2nd pass:

swing circle assembly.
3. Lift off swing circle assembly (2).
4 Swing circle assembly: 163 kg
[*1]
a. Using the angle of the bolt head as the base,
[*2] make start marks on the swing circle and
socket.
b. Make an end mark at a point (on swing cir-
cle) 48 ± 5° from the start mark.
2
c. Tighten so that the start mark on the socket
is aligned with the end mark on the swing cir-
cle at the 48 ± 5° position.

[*2]

★ Set the soft zone S mark on the inside ring of

the inner race facing the right side as shown
in the diagram. Then install to the chassis.

 Swing circle:
Grease (G2-L1) 14.6 l

Installation
• Install in reverse order of removal.

[*1] Outer race

soft zone
Front of machine

 Thread of swing circle mounting bolt:

Thread tightener (LT-2)

Inner race
soft zone

PW148-8 VEBM720100 30-179

Removal and installation of revolving frame assembly DISASSEMBLY AND ASSEMBLY

Removal and installation of revolving frame assembly

Removal 7. Remove plate (3) and pin (4) and lift off boom
cylinder assembly (2) to remove it.

★ Remove the boom cylinder assembly on the

Extend the arm and bucket fully, then lower the opposite side in the same manner.
work equipment to the ground and move the
safety lock lever to the LOCK position. 4 Boom cylinder assembly: 120 kg

1. Drain oil from hydraulic system.

2. Attach identification tags to the hoses to avoid in- 4

correct connection during re-assembly

3. Remove work equipment assembly so refer to ei- 3

ther 30-210 (Monoboom work equipment) or 30-
212 (2 piece boom work equipment).

4. Remove the counter weight, see page 30-218.

5. Disconnect boom cylinder hoses (1) and plug the

hoses to prevent flow of oil.
8. Move hoses (5) out of the way of the swivel joint.
5

1 1

6. Sling boom cylinders (2).

30-180 PW148-8 VEBM720100

DISASSEMBLY AND ASSEMBLY Removal and installation of revolving frame assembly

9. Disconnect the 13 hoses on the swivel joint as-

sembly at the swivel joint side.

(5): Suspension lock

(6): Brake 2
(7): Attachment bottom
(8): 2nd clutch 5
(9): 1st clutch 6
(10): Steer right
(11): Brake 1
(12): Travel B
(13): Travel A
(14): Attachment Head
(15): Drain
(16): Motor volume pilot
(17): Steer left
7 14

9 8

17

10 11
16

10. Remove pin (18) from swivel joint, take care not
to lose split pin. Hinge torque arm clear of swivel
15 13 12
joint.

11. Disconnect connector (19).

19

18

PW148-8 VEBM720100 30-181

Removal and installation of revolving frame assembly DISASSEMBLY AND ASSEMBLY

12. Remove the 34 revolving frame mounting bolts Installation

and remove revolving frame assembly (20) by
lifting it off. [*2] • Install in reverse order of removal.

★ Attain fore and aft balance and right and left  Swivel circle mating surface:
balance of the revolving frame assembly Gasket sealant (LG-1)

 Threads of revolving frame mounting

without two mounting bolts at the front and
rear being removed and using a lever block.
bolt: Adhesive compound (LT-2)
Only when the right balance is obtained, re-
move the remaining two bolts.  Revolving frame mounting bolt
245 - 308.7 Nm (60 - 69 kgm)

• Refilling hydraulic oil

When removing the revolving frame assembly, Refill hydraulic oil through the oil filler port to the
take care so that it does not hit the swivel joint specified level, and let the oil circulate in the hy-
assembly. draulic system by starting the engine. Then
check the level again.

• Air bleeding
Bleed air from the travel motor, refer to the Air
Bleeding of Various Parts section in the TEST-
ING AND ADJUSTING chapter of this manual.

20

4 Revolving frame assembly

Upper Revolving frame only

Assembly (Reference value)

PW148-8 6,580 kg 1,197 kg

30-182 PW148-8 VEBM720100

DISASSEMBLY AND ASSEMBLY Removal and installation of centre swivel joint

Removal and installation of centre swivel joint

Removal 3. Disconnect connectors (14) and (15) [A14 & A13]

14 , 15

Release the remaining pressure in the hydraulic

circuit. For details, see TESTING AND ADJUST-
ING, release of remaining pressure in hydraulic
circuit.

1. Remove oil from hydraulic tank and drain oil from

system.

2. Disconnect 13 hoses (1) through (13).

4. Disconnect 14 hoses (16) through (28).
★ When removing hoses mark all hoses with
tags to prevent mistakes when installing. (16): Suspension lock
(17): Brake 2
(1): Travel B (18): Attachment bottom
(2): Brake 1 (19): 2nd clutch
(3): Attachment bottom (20): 1st clutch
(4): 1st clutch (21): Steer right
(5): Drain (22): Brake 1
(6): 2nd clutch (23): Travel B
(7): Travel A (24): Travel A
(8): Suspension lock (25): Attachment Head
(9): Steer left (26): Drain
(10): Steer right (27): Motor volume pilot
(11): Brake 2 (28): Steer left
(12): Attachment head’
(13): Motor volume pilot

19
1 16
20
2
3
4
5

12 21 22 18 17
11

10
6
9
7

PW148-8 VEBM720100 30-183

Removal and installation of centre swivel joint DISASSEMBLY AND ASSEMBLY

6. Remove pin from torque arm (31).

24 23 25 31

7. Remove 4 of the 6 mounting bolts (32).

26 28 27 32

5. Disconnect connectors (29) and (30). 8. Sling centre swivel joint then remove 2 remaining
29 30 mounting bolts (32) and remove.

4 Center swivel joint assembly: 95 kg

30-184 PW148-8 VEBM720100

DISASSEMBLY AND ASSEMBLY Removal and installation of centre swivel joint

Installation
• Install in reverse order of removal.

Install the center swivel joint facing in the direc-

tion shown in the diagram.

(The diagram shows the machine as seen from

above)
Front

Centre swivel joint

Refilling with oil (hydraulic tank)

★ Add oil through the oil filter 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 travel motor. For details
see TESTING AND ADJUSTING, Air Bleeding of
Various Parts.

PW148-8 VEBM720100 30-185

Disassembly and assembly of centre swivel joint assembly DISASSEMBLY AND ASSEMBLY

Disassembly and assembly of centre swivel joint assem-

bly

Special tools 3. Remove the end cover and protection seal (3)
VA130.
Part Nece Distinc-
Mark Part No. Qty Sketch
Name ssity tion*
Push
790-101-2501 z 1
puller
790-101-2510 Block 1
790-101-2520 Screw 1
791-112-1180 Nut 1
E
790-101-2540 Washer 1
790-101-2630 Leg 2
790-101-2570 Plate 4
790-101-2560 Nut 2 3
790-101-2650 Adapter 2
*Distinction between new and existing part.
4. Remove housing (4) with appropriate tools.

Disassembly
1. Remove the electric slip ring (1) on the enclosure
flange.
1

5. Prevent any possibility of damage on chromium

plated surface of spool.

6. Remove all of the wearing (5) seals from the

grove of housing.
2. Remove all 4 screws (2) TE M10 x 30 on enclo-
sure flange.

2
5

30-186 PW148-8 VEBM720100

DISASSEMBLY AND ASSEMBLY Disassembly and assembly of centre swivel joint assembly

7. Remove the seals (6) from the end and top grove
of housing.

6 6

Assembly
• Assemble in reverse order of disassembly.

• Clean all surfaces before assembly.

• Grease shaft before assembly.

 Contact surface of rotor, shaft:

Grease (G2-L1)

 Enclosure Flange Mounting bolt:

26 - 36 Nm {2.6 - 3.7 kgm)

PW148-8 VEBM720100 30-187

Removal and installation of fuel tank assembly DISASSEMBLY AND ASSEMBLY

Removal and installation of fuel tank assembly

Removal 5. Remove P-clip (9), disconnect electrical connec-

tor (10) [S30] and (11) [A54].
1. Empty fuel tank.
6 Fuel Tank: 275 l (Max.)
10 9
2. Disconnect fuel hoses (1), (2), (3) and (4).

3 4

11

1
6. Remove toolbox cover (12) by removing bolts
(13) and handrail (14).
2
13
14
3. Remove cover (5) and holding down bolts (6) 6
places. Remove handrail at points (5).
6

13
5

6 12

7. Attach lifting hooks to tank at points (15).

4. Remove handrail (7) holding down bolt (8) 4 15

places.
7

8
8 ★ Please ensure that electric connections are dis-
connected if a side viev camera.

30-188 PW148-8 VEBM720100

DISASSEMBLY AND ASSEMBLY Removal and installation of fuel tank assembly

8. Loosen 4 mounting bolts (16).

16 16

9. Ensure lifting equipment takes the weight of the

fuel tank.

10. Once the lifting equipment has taken the weight

remove mounting bolts (16).

11. Remove the fuel tank.

4 Fuel tank assembly: 110 kg

Installation
• Install in reverse order of removal.

PW148-8 VEBM720100 30-189

Removal and installation of hydraulic tank assembly DISASSEMBLY AND ASSEMBLY

Removal and installation of hydraulic tank assembly

Removal 6. Disconnect solenoid valve block (7) by removing

4 bolts (8).
1. Drain oil from hydraulic tank.
6 Hydraulic oil: 131 l
8
2. Open up the engine hood.

3. Remove engine hood (1) (see page 30-51).

1

7. Remove hose clips (9) 3 places.

9

4. Remove main valve cover (2).

8. Disconnect steering hose (10) from hydraulic

tank.
2

5. Remove frame (3) by removing 4 bolts (4) and

frame (5) by removing 4 bolts (6).

6 4

3 10

4 5

30-190 PW148-8 VEBM720100

DISASSEMBLY AND ASSEMBLY Removal and installation of hydraulic tank assembly

9. Disconnect suction hose (11) and main pump re- 12. Disconnect steer drain hose (16) from hydraulic
turn hose (12) from hydraulic tank. tank and disconnect P-clip (17).

16

12

17

11

10. Disconnect harness clip (13) and return hose 13. Ensure all hose and clips are disconnected. Re-
(14) (swing bleed valve) from tank. move 4 of 6 mounting bolts (18).

13

18
18

14

14. Sling at points (19).

19
11. Disconnect all return hoses (15).
15 15
19

★ Please ensure that electric connectors are

15 15 disconnected if a beacon or side lamp is fit-
ted.

PW148-8 VEBM720100 30-191

Removal and installation of hydraulic tank assembly DISASSEMBLY AND ASSEMBLY

15. Remove remaining 2 mounting bolts and wash- ★ Install the hose clamp and tighten the clamp
ers (20). screw as shown in the diagram below.

20 20

16. Remove hydraulic tank.

[*3]

 Hose clamp screw:

4 Hydraulic tank assembly: 150 kg
245.2 - 308.9 Nm {25 - 31.5 kgm}
Installation
Refilling with oil (hydraulic tank)
• Install in reverse order of removal.
★ Add oil through the oil filler to the specified
[*1] level.

 Hydraulic tank drain plug:

Run the engine to circulate the oil through
the system. Then check the oil level again.
58.8 - 78.5 Nm {6.0 - 8.0 kgm}
5 Hydraulic tank: Approx. 131 l
[*2]
• Bleeding air
★ After tightening the suction hose clamp
screw, check that the screw is located within ★ Bleed the air.
the range shown in the diagram. For details, see TESTING AND ADJUST-

 Hose clamp screw:

ING. Air Bleeding of Various Parts.

8.8 ± 0.5 Nm {90 ± 5 kgm}

30-192 PW148-8 VEBM720100

DISASSEMBLY AND ASSEMBLY Removal and installation of control valve assembly

Removal and installation of control valve assembly

Removal 6. Disconnect arm cylinder hoses (4) and bucket

cylinder hoses (5).

Lower the work equipment to the ground for safe-

ty and stop the engine. Unscrew the oil filler cap
on the hydraulic tank slowly to release pressure
inside the tank. Then move the safety lock lever
5
to the LOCK position. 4

★ Remove pressure from all circuits.

1. Drain oil from the hydraulic tank and then drain

oil out of the system.
7. Disconnect hose (6) 2PB adjust cylinder (option)
2. Attach an identification tag to pipe/hose to avoid and hose (7) arm cylinder SV PPC (option) and
incorrect connection during re-assembly. hose (8) adjust cylinder SV PPC (option) from
main valve.
3. Repeat for electrical connections.

4. Remove machine cab cover (1).

6

1
6
7

8. Disconnect stabiliser and travel hoses (9).

Also disconnect hoses (23 and 24) from swing
machinery to aid removal of control valve and im-
5. Disconnect service spool hoses (2) and (3), 1 & 2 prove accessibility.
attachment (optional).
9.

3 9

PW148-8 VEBM720100 30-193

Removal and installation of control valve assembly DISASSEMBLY AND ASSEMBLY

10. Disconnect boom raise cylinder hoses (10) and 13. Continue to disconnect PPC hoses (13) 4 places.
swing motor hoses (11) from the main valve.

11
13

10 13
10
11
11

11. Disconnect oil cooler hose (12). 14. Disconnect proportional control hoses (14) (op-
tion) 4 places.

14
14
12

12. Disconnect PPC assembly hose (13) 4 places

from main valve.
15. Disconnect LS line connections (15) and pump
pressure line (16).
13

13

13

16 15 17 18

16. Disconnect hose connections (17) and (18).

30-194 PW148-8 VEBM720100

DISASSEMBLY AND ASSEMBLY Removal and installation of control valve assembly

17. Disconnect delivery hose (19), P-clip (20) 2 plac-
es and drain hose (21).
20. Sling bracket assembly and take the weight of
the assembly. (mass = 165kg) Rig a sling to lift
main valve assembly from the machine, remove
holding down bolts and then remove from the
machine.

19

20 21

18. Disconnect electrical connections (22) to main

valve (S01, S02, S03, S04, S05, S06, S07, S08
21. To remove the control valve from base plate, re-
and A51).
move bolts (24) from underside of plate.

22

24

19. Ensure all hoses and electrical connections are

disconnected from the main valve. Loosen hold- Control valve assembly with baseplate:
ing down bolts (23) 4 places. 4 165kg
Control valve assembly complete
with fittings: 152 kg

Installation
• Install in reverse order of removal.

23 Refilling with oil (hydraulic tank)

★ Add oil through the oil filler to the specified level.
Run the engine to circulate the oil through the
system. Then check the oil level again.

Bleeding air
★ Bleed the air from the circuit between the valve
and the hydraulic cylinder.
For details, see TESTING AND ADJUSTING, Air
Bleeding of Various Parts.

PW148-8 VEBM720100 30-195

Removal and installation of LS separation valve assembly DISASSEMBLY AND ASSEMBLY

Removal and installation of LS separation valve assembly

Removal
1. Remove hose (1).

2. Remove Elbow (2) if required.

3. Remove LS separation valve (3) from control

valve.

3 2

Installation
• Install in reverse order of removal.

• Tightening torque for LS separation valve (3):

108 - 147 Nm. (11 - 15 kgm).

• New O-rings:
07002-11423
02896-11008.

30-196 PW148-8 VEBM720100

DISASSEMBLY AND ASSEMBLY Removal and installation of pressure compensation valve assembly

Removal and installation of pressure compensation valve

assembly

Removal
1. Remove any hoses that interfere with the remov-
al of pressure compensation valve.

2. Remove sleeve (1).

3. Remove pressure compensation valve (2).

3
2
1

Installation
• Install in reverse order of removal.

• Tightening torque for cap (1) is:

137 - 157Nm (14 - 16 kgm).

• Replace O-ring (3), 709-25-11390.

PW148-8 VEBM720100 30-197

Removal and installation of main relief valve assembly DISASSEMBLY AND ASSEMBLY

Removal and installation of main relief valve assembly

Removal
1. Remove elbow (1).

2. Remove main relief valve (2).

2 1

Installation
• Install in reverse order to removal.

• Tightening torque for main relief valve (2):

88.3 - 107.9Nm. ( 9 - 11kgm)

• O - rings 02896-11008

• O - ring 07002-114213

• O - ring 07002-13334

30-198 PW148-8 VEBM720100

DISASSEMBLY AND ASSEMBLY Removal and installation of LS control EPC valve

Removal and installation of LS control EPC valve

Removal
1. Remove bolts (1). (2 off M6 x 35 hex. socket
head).

2. Carefully remove LS control EPC valve (2), do

not bend or pull harness (3) with more than 4.9N.

2
1

Installation
• Install in reverse order of removal.

• Tightening torque for LS control EPC valve bolts

(1): 11.8 - 14.7 Nm. (1.2 - 1.5kgm).

PW148-8 VEBM720100 30-199

Removal and installation of PC EPC valve assembly DISASSEMBLY AND ASSEMBLY

Removal and installation of PC EPC valve assembly

Removal
1. Remove bolts (1) (2 off M6 x 35, hex. socket
head).

2. Carefully remove EPC solenoid valve (2), do not

bend or pull harness (3) with more than 4.9N.

1
2

Installation
• Install in reverse order of removal.

• Tightening torque for EPC solenoid valve bolts

(1):
11.8 - 14.7 Nm. (1.2 - 1.5 kgm).

30-200 PW148-8 VEBM720100

DISASSEMBLY AND ASSEMBLY Removal and installation of PPC valve block assembly

Removal and installation of PPC valve block assembly

Removal 4. Remove all hoses (2) from fittings on the sole-

noid valve block:-
1. Ensure ignition is off before disconnecting elec- T0, 3, 13, T1, P1, P2, P3, PS, A, P4, B1, B2, T3,
trical connections. T4, T5, N, B, T2, Pepc, Pa3, Pb3, Pb2, Pb4,
NB - This installation is for a machine with 2PB, Pa2, Pa4, 14, 12, Pbp, Px, P6, X, Ps, Pb, Pb8
the ports P2 and T4 have plugs when 1PB is fit- and Pbp.
ted.
5. Ensure all hoses and electrical connections have
identification tags.

6. Loosen holding down bolts (3) and washers, 4

2. Attach an identification tag to hoses and electri- places (bolt M10 x 123).
cal connections to avoid incorrect connection
during re-assembly. 3

3. Remove all electrical connections (1) V03, V02,

V11, V10, V09, V08, S08, S09, S10, V01, V15,
S12, S13, V06, A56, V04, V07, L07, L14
andS61.

7. Sling the solenoid valve block assembly, remove

bolts and remove the valve assembly.

4 Solenoid Valve: approx. 27kg

Installation
• Install in reverse order of removal.

• Tightening torque for solenoid mounting bolts (3):

59 - 74Nm (6 - 7.5 Kgm).

• O - rings
02896-11008,
02896-11009,
02896-11012,
02896-11018.

PW148-8 VEBM720100 30-201

Removal and installation of oil seal in hydraulic pump input shaft DISASSEMBLY AND ASSEMBLY

Removal and installation of oil seal in hydraulic pump in-

put shaft

Special tools Installation

Part Neces- Distinc- • Install in reverse order of removal.
Mark Part No. Qty Sketch
Name sity tion*
Push [*1]
790-201-2000 „ 1
 Oil seal lip portion: Grease (G2-LI)
N tool
790-201-2740 Spacer „ 1
*Distinction between new and existing part.  Oil seal outer circumference:
Grease (G2-LI)
Removal ★ Coat the oil seal outer circumference thinly
1. Remove the hydraulic pump assembly, see page with grease.
30-44.
★ Press-fit oil seal (3), using tool N.
2. Remove snap ring (1) and then remove spacer
(2).

3. Pry off oil seal (3) with a screwdriver. [*1]

★ When attempting to pry off the seal, do not

damage the shaft.

30-202 PW148-8 VEBM720100

DISASSEMBLY AND ASSEMBLY Disassembly and assembly of work equipment PPC valve

Disassembly and assembly of work equipment PPC valve

★ This section deals with only precautions to be fol- ★ When assembling piston (8), coat the piston
lowed when reassembling the PPC valve assem- outer periphery and body hole inner periph-
bly for work equipment. ery with grease.

 Plate (5) mounting bolt:

11.8 - 14.7 Nm (1.2 -1.5 kgm)

 Joint (4) sliding surface:

Grease 2 - 4 cc (G2-LI)

 Body female screw portion:

Adhesive compound (LT-2)

★ Coat the female screw body with Loctite® at

two spots as shown in the diagram below.
Each spot is to be coated with a drop (ap-
prox. 0.02 g).

 Joint (4):
39 - 49 Nm (4 - 5 kgm)

 Nut (1):
98 - 127 Nm (10 - 13 kgm)

★ Strictly follow the specified torque for the

joint.

Assembly
• Reassembling work equipment PPC valve:-

★ Install spring (11) so that the end surface of

smaller end coil diameter (inner diameter)  Contact surfaces of piston and disc (2):
will face the shim (12) side. Grease 0.3 - 0.8 cc (G2-LI)

★ Springs (10) in use differ in the number of  Nut (1):

turns according to hydraulic ports as classi- 98 - 127 Nm (10 - 13 kgm)
fied in the table below. Hence take care
when installing one. ★ After assembling the disc, refer to the Adjust-
ment of Work Equipment and Swing PPC
Port location Spring free length Valve section of the TESTING AND AD-
JUSTING chapter of this manual.
P1, P2 42.48 mm

P3, P4 38.71 mm

★ The location of each port is stamped in the

lower part of the valve body.

 Piston (8): Grease (G2-LI)

PW148-8 VEBM720100 30-203

Disassembly and assembly of hydraulic cylinder DISASSEMBLY AND ASSEMBLY

Disassembly and assembly of hydraulic cylinder

Special tools ★ Place a container under the cylinder to

catch the oil.

Necessity
Symbol

Sketch
Q’ty
N/R
Part number Part name

Cylinder repair
790-502-1003 z 1
1 stand
790-101-1102 Pump z 1
790-102-4300 Wrench assembly „ 1
2
790-102-4310 Pin „ 2
3 790-720-1000 Expander z 1
Rubber band
796-720-1670 z 1
(for boom and arm)
07281-01279 Clamp z 1
4
Rubber band
796-720-1660 z 1 d. Disassemble the piston rod assembly as fol-
(for bucket)
07281-01159 Clamp z 1 lows.
Push tool
790-201-1702 „ 1 I. Set piston rod assembly (2) in tool U1.
kit
• Push tool
• 790-201-1831 1
(for bucket)
• Push tool
U 5 • 790-201-1930 1
(for arm)
• Push tool
• 790-201-1940 1
(for boom)
• 790-101-5021 • Grip 1
• 01010-50816 • Bolt 1
Push tool
790-201-1500 kit z 1
(for bucket)
• 790-201-1640 • Push tool 1
• 790-101-5021 • Grip 1
• 01010-50816 • Bolt 1 II. Remove stopper screw (3) of piston as-
6
790-201-1980
Plate
z 1
sembly.
(for boom)
Plate ★ Common to the boom, arm and bucket
790-201-1990 z 1
(for arm) cylinder. Screw size:
790-101-5021 Grip z 1 M12 x Pitch 1.75
01010-50816 Bolt z 1

Disassembly

1. Piston rod assembly

a. Where necessary remove piping from the
cylinder assembly.

b. Remove the mounting bolts and then discon-

nect head assembly (1).

c. Pull out piston rod assembly (2).

30-204 PW148-8 VEBM720100

DISASSEMBLY AND ASSEMBLY Disassembly and assembly of hydraulic cylinder

★ If the caulking of screw (3) is too strong and it VII. Remove cap (8), and pull twelve balls
cannot be removed, tighten the screw fully, then (9), then remove plunger (10).
fit tap (T) to the thread and remove the screw.
• Arm cylinder only

III. Using tool U2, remove piston assembly

(4).
2. Disassembly of piston assembly
• When not using tool U2, use the drill a. Remove ring (11).
holes (H)(ø 10: 2 places) and loosen pis-
ton assembly. b. Remove wear ring (12).

c. Remove piston ring (13).

d. Remove O-ring and backup ring (14).

IV. Remove plunger

• Boom and arm cylinder only

V. Remove collar (6).

• Boom and arm cylinder only

VI. Remove head assembly (7).

PW148-8 VEBM720100 30-205

Disassembly and assembly of hydraulic cylinder DISASSEMBLY AND ASSEMBLY

3. Disassembly of cylinder head assembly

a. Remove O-ring and backup ring (15).

b. Remove snap ring (16) and then remove

dust seal (17).

c. Remove rod packing (18).

d. Remove buffer ring (19).

e. Remove busing (20).

2. Disassembly of piston assembly

a. Using tool U3, expand piston ring (13).

★ Set the piston ring on tool U3, and turn

the handle 8-10 times to expand the ring.

b. Set tool U4, and compress piston ring (13).

Assembly
★ Be careful not to damage the packing, dust
seals, and O-rings.

★ Clean each part, then cover the piping ports and

pin-inserting hole to prevent dust from entering
them.

★ Do not try to force the backup ring into position.

Warm it in warm water (50 Ð 60ûC) before in-
stalling it.
c. Install the backup ring and O-ring (14).
1. Disassembly of recoil spring assembly
d. Assemble wear ring (12).
a. Using tool U5, press fit bushing (20).
e. Assemble ring (11).
b. Assemble buffer ring (19).
★ Be careful not to open the end gap of the
c. Assemble rod packing (18). ring too wide.
d. Using tool U6, install dust seal (17), and se-  Ring groove: Grease (G2-L1)
cure with snap ring (16).

e. Install the backup ring and O-ring (15).

30-206 PW148-8 VEBM720100

DISASSEMBLY AND ASSEMBLY Disassembly and assembly of hydraulic cylinder

★ Put a mark on the end face of the rod so

that the processing hole position of cap
(8) is visual from outside.

• Arm cylinder only

3. Piston rod assembly

a. Set piston rod assembly (2) in tool U1.

f. Assemble piston assembly (4) as follows.

• When using piston rod assembly (2)

and piston assembly (4) again

★ Wash thoroughly and remove all metal particles

and dirt.

I. Screw in piston assembly (4) by using

b. Assemble head assembly (7).
c. Fit O-ring and backup ring to collar (6), then
assemble.
• Boom and arm cylinder only
tool U2, and tighten piston assembly (4)
until the position of the screw thread hole
(H1) which is in piston rod assembly (2)
halfway matches.
★ Remove all burrs and flashes on the
threaded portion with a file.

d. Assemble plunger (5).

• Boom and arm cylinder only

e. Set plunger (10) on the piston rod, assemble

12 balls (9) to it and secure with cap (8).

★ Check that there is a small amount of

play at the tip of the plunger.

PW148-8 VEBM720100 30-207

Disassembly and assembly of hydraulic cylinder DISASSEMBLY AND ASSEMBLY

II. Tighten screw (3). ★ Align a drill horizontal with the V-groove
Screw part female screw side: of the thread of piston rod assembly (2)
Loctite No.262 and piston assembly (4), then carry out
Screw: machining.
58.9 – 73.6 Nm {6 – 7.5 kgm}
★ For the arm cylinder, avoid the cap ma-
III. Caulk thread at four places (a) of screw chining holes position when machining.
(3) with punch. (See step 3.5.)

• Screw machining dimension (mm)

Bottom hole Bottom

Tap used Tap depth
drill diameter hole depth
10.3 24 12x1.75 20
Bucket Cyl. 8.5 27 10x1.5 20

III. After machining, wash thoroughly to re-

move all metal particles and dust.

IV. Tighten screw (3).

• When using a new part for either or
both of piston rod assembly (2) and
piston assembly (4)
★ For the rod with bottom cushion, mark
the cap position on the end surface of
rod. (See step 3.5.)
• Arm cylinder only
I. Screw in until piston assembly (4) con-
tacts end surface (B) of rod, then use
tool to tighten.
 2 Screw part female screw side:
Loctite No.262
 3 Screw:
58.9 – 73.6 Nm {6 – 7.5 kgm}
 3 Bucket Cylinder Tightening torque:
27.5 – 34.3 Nm {2.8 – 3.5 kgm}
V. Caulk thread at four places (a) of screw
(3) with punch.

 3 Piston assembly:
294 ± 29.4 Nm {30 ± 3.0 kgm}

★ After tightening the piston, check that

there is play in plunger (5).

• Boom, arm and bucket cylinder only

g. Set piston rod assembly (2) in tool U1.

II. Machine one of the hole used to install

screw (3).

30-208 PW148-8 VEBM720100

DISASSEMBLY AND ASSEMBLY Disassembly and assembly of hydraulic cylinder

h. Assemble the cylinder tube to piston rod as-

sembly (2).

★ Align axial center of the cylinder tube,

then insert.

★ Check that the ring is not broken and

has not come out, then push in fully.

i. Tighten head assembly (1) with mounting

bolts.
Mounting bolt:

Cylinder name Tightening torque

Bucket 172±24.5Nm {17.5±2.5kgm}
Arm 270±39Nm {27.5±4.0kgm}
Boom 172±24.5Nm {17.5±2.5kgm}
*Adjust
373±54Nm {38.0±5.5kgm}
cylinder
* Variable 2 pieces boom specification

j. Install piping.

PW148-8 VEBM720100 30-209

Removal and installation of monoboom work equipment DISASSEMBLY AND ASSEMBLY

Removal and installation of monoboom work equipment

Special tools ★ Fasten the piston rod with wire so that it will
not slip out and lower the cylinder onto a
Part Nece- Qt Distinc- stand, or place a support under the bottom of
Mark Part No. Sketch
Name ssity y tion*
the cylinder to support it. In the latter case,
796-900-1200 Remover „ 1 remove the grease fitting on the bottom side
Puller first.
790-101-4000 (490 kN „ 1
R 50-T-long) ★ Remove the boom cylinder on the other side
Pump in the same manner.
790-101-1102 (294 kN „ 1
30 T) 5. Disconnect HCU hose (6), arm cylinder and
*Distinction between new and existing part. bucket cylinder hoses (7), attachment hoses (8).

★ Disconnect any SV drain or PPC hoses and

Removal quick coupler hoses where necessary.

★ Plug the hoses to prevent oil flow-out, and

fasten them on the valve side.
Extend the arm and bucket fully. Lower the work
equipment to the ground and set the safety lock 6. Disconnect intermediate connector CN-A86 (9)
lever to the lock position. for a working lamp.

Release the residual pressure in the hydraulic

circuit. Refer to the Release of Remaining Pres- 7
sure in Hydraulic Circuit section in the TESTING
AND ADJUSTING chapter of this manual. 8

9
1. Disconnect grease hose (1).

2. Sling boom cylinder assembly (2), and remove

lock bolt (3). 7. Lift off the work equipment and remove plate (10)
and then pin (11) at the foot. [*2]
3. Remove plate (4), then remove head pin (5). [*1]

★ There are shims installed, so check the 11

number and thickness, and keep them in a
safe place.
1 10

5
4

2 • When removing them, first remove plate (10)

and then remove pin (11) at the foot, using
Tool R.

★ Shims are installed, so do not forget to check

4. Start the engine and retract the piston rod. their number and each location of installa-
tion.

30-210 PW148-8 VEBM720100

DISASSEMBLY AND ASSEMBLY Removal and installation of monoboom work equipment

Inside surface of bushing when

 assembling pin:
Anti-friction compound (LM-P)

 Grease after assembling pin:

Grease (LM-G)

When aligning the position of the pin hole, never

11 insert your fingers into the pin hole.

★ Adjust the shim thickness so that clearance

8. Lift off work equipment assembly (12) and disas- a between cylinder rod (13) and plate (4) is
semble it. below 1 mm.
4 Work equipment assembly ★ Standard shim thickness: 1.0 mm and
1,900 kg 2.0 mm.

12

15

Inside surface of bushing when

 assembling pin:
Installation Anti-friction compound (LM-P)

 Grease after assembling pin:

• Install in reverse order of removal.

[*1] Grease (LM-G)

★ When tightening the locknut, tighten so that

clearance a between the plate and nut is 0.5
- 1.5 mm. When aligning the position of the pin hole, never
insert your fingers into the pin hole.

Bleeding air
★ Bleed the air from the cylinder. For details, see
TESTING AND ADJUSTING, Air Bleeding of Var-
ious Parts.

Refilling with oil (hydraulic tank)

★ Add oil through the oil filler to the specified level.
Run the engine to circulate the oil through the
system. Then check the oil level again.

PW148-8 VEBM720100 30-211

Removal and installation of 2 piece boom work equipment DISASSEMBLY AND ASSEMBLY

Removal and installation of 2 piece boom work equipment

Special tools ★ Fasten the piston rod with wire so that it will
not slip out and lower the cylinder onto a
stand, or place a support under the bottom of
Mark Part No.
Part Nece- Qt Distinc-
Sketch the cylinder to support it. In the latter case,
Name ssity y tion* remove the grease fitting on the bottom side
796-900-1200 Remover „ 1 first.
Puller
790-101-4000 (490 kN „ 1 ★ Remove the boom cylinder on the other side
R 50-T-long) in the same manner.
Pump
790-101-1102 (294 kN „ 1 5. Disconnect all 2 piece boom cylinder hoses (6),
30 T) arm cylinder hoses, bucket cylinder hoses (7),
*Distinction between new and existing part. service hoses (8) HCU return (9), safety valve
drain hoses, PPC hoses and quick coupler hoses
where necessary.
Removal
★ Plug the hoses to prevent oil flow-out, and
fasten them on the valve side.

Extend the arm and bucket fully. Lower the work 6. Disconnect intermediate connector CN-A86 (11)
equipment to the ground and set the safety lock for a working lamp.
lever to the lock position.
7
7

Release the residual pressure in the hydraulic 10

circuit. Refer to the Release of Remaining Pres- 9
sure in Hydraulic Circuit section in the TESTING
AND ADJUSTING chapter of this manual. 6 8

8
1. Disconnect grease hose (1). 11

2. Sling boom cylinder assembly (2), and remove 7. Lift off the work equipment and remove plate (12)
lock bolt (3). and then pin (13) at the foot. [*2]

3. Remove plate (4), then remove head pin (5). [*1]

★ There are shims installed, so check the

number and thickness, and keep them in a
safe place. 13
4

1 12

5
3

★ When removing them, first remove plate (12)

and then remove pin (13) at the foot, using
2 Tool R.

★ Shims are installed, so do not forget to check

their number and each location of installa-
4. Start the engine and retract the piston rod. tion.

30-212 PW148-8 VEBM720100

DISASSEMBLY AND ASSEMBLY Removal and installation of 2 piece boom work equipment

When aligning the position of the pin hole, never

insert your fingers into the pin hole.

★ Adjust the shim thickness so that clearance

a between cylinder rod (15) and plate (4) is
below 1 mm.
13
★ Standard shim thickness: 1.0 mm and
2.0 mm.

8. Lift off work equipment assembly (14) and disas-

semble it.

4 Work equipment assembly

2,200 kg

15

 Inside surface of bushing when

assembling pin:
14 Anti-friction compound (LM-P)

 Grease after assembling pin:

Grease (LM-G)

Installation
When aligning the position of the pin hole, never
• Install in reverse order of removal.
insert your fingers into the pin hole.
[*1]

★ When tightening the locknut, tighten so that Bleeding air

clearance a between the plate and nut is 0.5
- 1.5 mm. ★ Bleed the air from the cylinder. For details, see
TESTING AND ADJUSTING, Air Bleeding of Var-
ious Parts.

Refilling with oil (hydraulic tank)

★ Add oil through the oil filler to the specified level.
Run the engine to circulate the oil through the
system. Then check the oil level again.

 Inside surface of bushing when

assembling pin:
Anti-friction compound (LM-P)

 Grease after assembling pin:

Grease (LM-G)

PW148-8 VEBM720100 30-213

Removal and installation of air conditioner unit DISASSEMBLY AND ASSEMBLY

Removal and installation of air conditioner unit

Special tools 3. Remove floor mat (1).

Nece Distinc-
Mark Part No. Part Name Qty Sketch
ssity tion*
Service
799-703-1200 „ 1
tool kit
Vacuum
799-703-1100 Pump „ 1
(100 V)
Vacuum
S 799-703-1111 Pump „ 1
(220 V)
Vacuum
799-703-1121 Pump „ 1
1
(240 V)
Gas leak
799-703-1401 „ 1 4. Open air filter cover (2) and remove outside air
tester
filter (3).
*Distinction between new and existing part.

3
Removal
2

Befor starting work, turn the starting switch to

the OFF position, wait over one minute, the turn
off the battery main switch and take out the bat-
tery main switch key.

1. Drain cooling water.

5. Remove monitor panel lower covers (4) and (5).
6 Cooling water: Approx. 22.8 l
★ When removing cover (4), first remove the
2. Bleed gas from the air conditioner, using tool S. M19 wiring for cigarette lighter.

30-214 PW148-8 VEBM720100

DISASSEMBLY AND ASSEMBLY Removal and installation of air conditioner unit

6. Remove duct (6) on the right side. 9. Remove plate (11).

11
6

7. Remove operator seat by removing 4 mounting

bolts (7). When removing the seat be sure to dis-
10. Remove plate (12) and then remove duct (13).
connect connector G33 (if fitted), then remove
carefully. 11. Remove plate (14) and right duct (15).

12

15

13
7

14
8. Remove rear covers (8), (9) and (10).
9
12. Disconnect cab intermediate connectors at the
following two points. (Refer to page 20-222)

• H09: Upper side

10
• H08: Lower side
8 13. Remove duct (16).

14. Remove cover (17).

17

16

PW148-8 VEBM720100 30-215

Removal and installation of air conditioner unit DISASSEMBLY AND ASSEMBLY

15. Disconnect connectors N10 (18) and AC01 (19). 21. Remove the 7 mounting bolts and air conditioner
unit assembly (27).
16. Disconnect connectors ECU10 and ECU11 (20)
from the air conditioner controller (ACCONT).

17. Loosen tie-wrap (21) and draw in wiring harness

(22).

18. Remove cover (23).

19. Remove mounting bolt (24) and disconnect air

conditioner tube (25). [*1]

20. Disconnect heater hose (26).

★ Check the connecting point.

30-216 PW148-8 VEBM720100

DISASSEMBLY AND ASSEMBLY Removal and installation of air conditioner unit

Installation
• Install in reverse order of removal.

★ IWhen installing the air conditioner circuit hoses,

use care so that dirt, water, may not enter.

★ Make sure before the installation that there is O

ring at the piping connector of the air conditioner
hose.

★ Check that there is no defect or deterioration on

the O ring.

★ When connecting the refrigerant piping, coat the

O ring with compressor oil for new refrigerant
(R134a) (Denso: ND-OIL8, Zexcel: ZXL100PG
(PAG 46 or equivalent)).

 Mounting bolt: 8 - 12 Nm (0.8 - 1.2 kgm)

• Filling of air conditioning gas

By using tool X1, fill the air conditioner gas
(R134a) inside the air conditioner circuit.

★ Filling quantity:850 ± 50 g

PW148-8 VEBM720100 30-217

Removal and installation of counterweight DISASSEMBLY AND ASSEMBLY

Removal and installation of counterweight

★ Before beginning with removal of all the counter- 4. Loosen 4 bolts (3).
weight make sure all electrical connectors are
disconnected.

★ Attach tags to all wires to avoid confusion when

installing counterweight.

Removal
1. Open hood (1) and remove, see page 30-51.
3
1

5. Ensure lifting equipment is supporting the weight

of the counterweight.

6. Remove mounting bolts (3).

7. Remove counterweight in the direction shown.

2. Remove caps (2) from counterweight.

★ Be careful not to hit the engine or cooler.

4 Counterweight assembly
PW148: 2,580 kg
3. Insert lifting eye’s into holes. The lifting eye’s you
require are:
Thread - 48x3
Must have safe working load of - 2,580 Kg (min).

30-218 PW148-8 VEBM720100

DISASSEMBLY AND ASSEMBLY Removal and installation of counterweight

Installation
• Install in reverse order of removal.

 Thread of counterweight mounting bolt:

Thread tightener (LT-2)

 Counterweight mounting bolt:

1,520 - 1,910 Nm {155 - 195 kgm}

[*2]

★ Installing and adjusting counterweight.

Sling counterweight with crane and place in position

on the frame.
Push counterweight, install mounting bolts, and ad-
just to the following dimensions.

• Clearance from revolving frame:

10 ± 5 mm (left and right)

• Clearance from bodywork door:

10 ± 5 mm (left and right)

• Stepped difference b from revolving frame in left-

to right direction: Max. 5 mm

• Stepped difference a from bodywork door in left-

to right direction: 10 ± 4

• Stepped difference c from bodywork top cover in

up-down right direction:
Max. 5 mm

PW148-8 VEBM720100 30-219

Removal and installation of operator cab assembly DISASSEMBLY AND ASSEMBLY

Removal and installation of operator cab assembly

Removal 4. Disconnect all PPC hoses at (4).

4
Befor starting work, turn the starting switch to
the OFF position, wait over one minute, the turn
off the battery main switch and take out the bat-
tery main switch key.

Release the residual pressure in the hydraulic

circuit. Refer to the Release of Remaining Pres-
sure in Hydraulic Circuit section in the TESTING
AND ADJUSTING chapter of this manual.
5. Remove plate (5) by removing bolts (6).

1. Remove floor mat (1).

6
5 5

1 6. Disconnect hoses (7) from orbitrol valve.

2. Remove covers (2) and (3) under the monitor 7

panel. 7

★ When removing cover (2), first disconnect

the M19 wiring for cigarette lighter.

3. Remove air conditioner unit, for details see page

30-214.

30-220 PW148-8 VEBM720100

DISASSEMBLY AND ASSEMBLY Removal and installation of operator cab assembly

7. Disconnect hoses (8) from brake valve. 11. Disconnect window washer hose (12). Ensure it
8 is clear of operator cab before lifting operation.

8 12
8

8. Label each electrical connector (9) then discon-

nect (10 places) A01, A02, A03, A04, A05, A06,
A07, A08, A09, A99 and CC01. 12. Ensure all hoses and cables, where applicable,
are loose and all clips have been removed.

13. Attach lifting equipment at points (13).

13
9 13

14. Loosen off 4 mounting bolts (14) inside the cab.

9. Remove 3 hoses (10) from engine and 1 hose 14
from the dryer (11).
10

14
10 11

15. Have lifting equipment take the weight of the op-

erator cab.

16. Remove mounting bolts (14) and lift operator cab

10. Ensure operator cabin door is securely fastened. off.

4 Operator cab assembly: 662 kg

Installation
• Install in reverse order of removal.

PW148-8 VEBM720100 30-221

Removal and installation of monitor assembly DISASSEMBLY AND ASSEMBLY

Removal and installation of monitor assembly

Removal

Befor starting work, turn the starting switch to

the OFF position, wait over one minute, the turn
off the battery main switch and take out the bat-
tery main switch key.

1. Remove cap (1)

2. Remove cover (2) for steeringcontrol panel.

3. Remove duct (4).

5. Remove the 4 mounting bolts and lift monitor as-
4. Remove cover (5) as follows. [*1] sembly (6). [*2]

I. Insert flat-head screwdriver inside slit 6. Disconnect connectors CM01 (7), CM02 (8) and
(SL) and push it upward. CM03 (9).

II. Release lock (L) and remove the cover.
III. Disconnect wiring connector M19 of the
cigarette lighter from the back of cover
(5)..
★ Since CM02 (8) and CM03 (9) can be in-
stalled reversely, be careful not to mistake.
CM 03 (9) is a green connector.

Installation
• Install in reverse order of removal.

30-222 PW148-8 VEBM720100

DISASSEMBLY AND ASSEMBLY Removal and installation of pump controller assembly

Removal and installation of pump controller assembly

Removal

Befor starting work, turn the starting switch to

the OFF position, wait over one minute, the turn
off the battery main switch and take out the bat-
tery main switch key. Then disconnect the cable
from positive terminal (+) of the battery.

1. Remove cover (1).

Installation
• Install in reverse order of removal.

2. Disconnect bracket (2) and put it to the right side.

3. Disconnect wiring connectors C01 (3) and C02

(4) as follows.

• Tilt lock (L12) inside while pressing lock (L1).

★ Bar (B) comes out and the lock is released.

4. Remove the 4 mounting bolts and pump control-

ler assembly (8).

5
2

3 4

PW148-8 VEBM720100 30-223

Removal and installation of engine controller assembly DISASSEMBLY AND ASSEMBLY

Removal and installation of engine controller assembly

Removal

Before starting work, turn the starting switch to

the OFF position, wait over one minute, then turn
off the battery main switch and take out the bat-
tery main switch key.

1. Turn the upper structure by 90 degrees.

2. Remove cover (1).

3. Open the engine hood.

4. Disconnect connectors CE02 (2) and (3) from the

engine controller.

★ The connector is locked with the inside hex

head bolt L6 (4 mm).

5. Disconnect connector CE03 (4) from the engine

controller by pushing the lock.

6. Remove the mounting bolt and engine controller

(5).

★ Ground (E) and harness clamp are tightened

together with.

30-224 PW148-8 VEBM720100

DISASSEMBLY AND ASSEMBLY Removal and installation of engine controller assembly

Installation
Install in reverse order of removal.

★ Reference

• How to replace the seal of O ring of power

source connector (4).
Seal of O ring:

1010-074-0406 (NIHON-DEUTSCH Ltd.)

1. Remove cover (6) by nipping the tab with tweez-

ers [1].

2. Remove O ring (7) with tweezers [1].

PW148-8 VEBM720100 30-225

Removal and Installation of KOMTRAX terminal DISASSEMBLY AND ASSEMBLY

Removal and Installation of KOMTRAX terminal

Removal

Befor starting work, turn the starting switch to

the OFF position, wait over one minute, the turn
off the battery main switch and take out the bat-
tery main switch key.

1. Remove covers (1) - (4).

2. Twist antenna wire (5) and disconnect it.

3. Disconnect connectors K01(6) and CK02 (7).

4. Remove the 4 mounting bolts and KOMTRAX

communication modem assembly (8).

Installation
Install in reverse order of removal.

30-226 PW148-8 VEBM720100

 90 OTHER
Hydraulic circuit diagram (1/3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-3
Hydraulic circuit diagram (2/3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-5
Hydraulic circuit diagram (3/3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-7
Electrical circuit diagram (cabin 1/4) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-9
Electrical circuit diagram (cabin 2/4) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-11
Electrical circuit diagram (cabin 3/4) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-13
Electrical circuit diagram (cabin 4/4) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-15
Electrical circuit diagram (machine 1/4)) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-17
Electrical circuit diagram (machine 2/4)) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-19
Electrical circuit diagram (machine 3/4)) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-21
Electrical circuit diagram (machine 4/4)) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-23
Connector diagramm 1/5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-25
Connector table for revolving frame harness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-25
Connector diagram 2/5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-27
Connector table for operator‘s cab wiring harness (Part 1/2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-27
Connector diagram 3/5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-29
Connector table for operators cab wiring harness (Part 2/2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-29
Connector diagram (4/5) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-31
Connector table various wiring harness (Part 1/2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-31
Connector diagram (5/5) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-33
Connector table various wiring harness (Part 2/2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-33

PW140-7 VEBM410101 90-1

 OTHER

Blank for technical reason

90-2 PW140-7 VEBM410101

Hydraulic circuit diagram (1/3)

EPC VALVE SERVICE 1 #02

C
PA8 0.8
T
P
TO MAIN VALVE P A8 TO MAIN VALVE P B8
0.6
#02 RED & RED WHITE & WHITE #02 pS PB8
PUMP PRESSURE LS PRESSURE T1
PRESSURE SENSOR CHECKING PORT LS CHECKING PORT
TS Tsw QUICK COUPLER 40 bar
V24 V23
SERVICE 2 (OPTION) SOLENOID VALVE
SAFETY VALVE SUCTION STRAINER CAP SAFETY VALVE
BLOCK
PS 24.7MPa(250kg/cm 2 ) 150 MESH (105µm) OPENING PRESS
TO MAIN VALVE P TO MAIN VALVE P 1850cm 2 0.17± 0.07kg/cm 2
A9 B9 T2 PP SAFETY VALVE
V16
#02 GREEN & BLACK & #02 PX (2 STAGE RELIEF) 24.7MPa(250kg/cm 2 ) FILTRATION AREA CHECK VALVE CRACKING
UNLOADING VALVE PRESS -0.005~0kg/cm 2
GREEN GREEN RED & YELLOW P5 2-STAGE YELLOW & BROWN #02 3.38MPa(34.5kg/cm 2 )
A9

#02
V26 V25 RELIEF SERVICE 2
BLUE & WHITE #02 (OPTION)
SEE
V02
RIGHT PPC VALVE T B9 SHEET 40 bar

P4 P T 2/3
BYPASS STRAINER
PROPOTIONAL CONTROL BLUE & BROWN T5 HYD TANK 40 MESH
#02 S30
BLACK VALVE BOLCK PB (SWING BRAKE) GREEN & GREEN PA9 PB9 BLACK & GREEN B2
(SERVICE 1 AND 2) PRESSURE SENSOR
SWING/BRAKE BROWN & WHITE #02 BYPASS CHECK VALVE
DUMP RED & BROWN P1 0.15± 0.03MPa
V03 (1.5± 0.3kg/cm 2 )
2PB 2ATT (9 SPOOL) A B B1 CRACKING PRESSURE
BUCKET T4 PBP (2 STAGE BACK PRESSURE) SAFETY VALVE
2
HYDRAULIC
BLACK & BLACK
24.7MPa(250kg/cm ) TANK
DIG 2-STAGE BACK SEE
S10 A8
P3 PRESSURE SWITCH - TRAVEL FORWARD SHEET DRY VOLUME 170 LITRE
P2 SEE WET VOLUME 123 LITRE BREAKER
#02 V15 2/3 #10

#03
WHITE SERVICE 1 WITH WORK EQUIPMENT
GREEN
PA3 (TRAVEL FORWARD)
B8 SHEET IN CHECK POSITION. SEE
#02 BLACK & WHITE #02 ROTATE ROTATE
2/3 (OIL LEVEL MID POINT
P2 A56
BLACK & RED (TRAVEL REVERSE) (CW) (ACW)
SUCTION STRAINER ON GAUGE.)
SHEET
FWD/REV TO MAIN VALVE P
#02

(OIL COOLER BYPASS VALVE)

UP PRESSURE SENSOR
PB3
B3
RED & RED PA8 PB8 WHITE & WHITE 125µm 2/3
V08
A

#02
100 MESH BLACK & BLUE SWITCH - TRAVEL REVERSE
BOOM/
STABILIZER
ITALIAN OPTION ONLY

'
S09

d1
PRIORITY VALVE 'EF' OR RETURN FILTER
RED & GREEN P4 SAFETY VALVE

ORBITROL VALVE 'T'

MAIN PUMP 'P

TRAVEL
PA2 24.7MPa(250kg/cm 2 ) JJS VALVE 'F' (JSS OPTION) 20 75 10 8 5 3

MAIN VALVE 'T B'

V06 (BOOM UP)

SWING MOTOR 'T'

DOWN NEUTRAL (100 MESH) FILTRATION
#02

QUICK COUPLER
T1 GREEN PARTICLE SIZE
P1 BLACK & BLUE PA13 BLACK & BLUE
SWITCH
A7
MAIN VALVE 'T S1 ' 1.36m 2 FILTRATION AREA
BROWN
#02 BOOM/STABILIZER BOOM/STAB. #02 S03 BUCKET
UP UP SEE
RED & YELLOW PO1 RED & YELLOW DUMP DIG SHEET SWIVEL JOINT PORT '2'
S13
V10
PA4 (STABILIZER UP)
PA7 B7 WHITE
P GREEN B2 GREEN & BROWN #02 PB7 2/3
#02 RED & GREEN PA1 RED & GREEN BROWN BLACK SB7 SOLENOID BLOCK 'TO' ARM CYL S/VALVE (OPTION)
RED & WHITE (BOOM DOWN)
SWITCH #02 TO MAIN VALVE P B2 SA7 SEE
BLUE & GREEN BOOM/STABILIZER PB2
#02 TRAVEL GREEN PA5 GREEN DOWN
BOOM/STAB.
S05 FROM 'T' BLOCK BLUE & ADJUST CYL S/VALVE (OPTION) SHEET
DOWN

#02
S04 YELLOW
EPC VALVE 2/3

OIL COOLER
#02
RED & GREEN S12 V09
PB4 (STABILIZER DOWN)
#02 TO MAIN VALVE P BOOM CYL S/VALVE

#02
#02 BROWN PA7 BROWN BROWN B1 GREEN & WHITE
B4

PA6
TRAVEL T P PEPC A6 0.7
ARM
A BLACK YELLOW
BLUE & YELLOW PA3 BLUE & YELLOW SA6
& BLUE #02 #02 TO HYD. TANK
P3 DUMP DIG
B6
GREEN &

TO ARM CYL SEE

GREEN

BLACK P41 BLACK S/VALVE (OPTION)

P T TO MAIN VALVE P A7
PPC LOCK 0.7 SHEET
V60 V01
BLUE 2/3
WHITE P31 WHITE T3 PB6
TO MAIN VALVE P B7
A BLACK
3 ARRANGMENT FOR
& BLUE (TRAVEL CREEP)
BROWN & YELLOW P81 BROWN & YELLOW TO SWIVEL JOINT PORT 3 SB6
TO MAIN VALVE P B5 TRAVEL BLACK & BROWN ITALIAN OPTION
S06 TO ORBITROL
CREEP TO HYD TANK

#03
#03

#10
TO TANK VALVE 'LS'

LS
YELLOW & YELLOW P71 YELLOW & YELLOW
TO MAIN VALVE P
V07
ARM CHECK
A5 SUCTION STRAINER
A5
SECOND BOOM OR
VALVE SEE JSS VALVE 'P'
#02 N
BLUE &

(OPTION)

#76.2
WHITE

BLUE P51 BLUE

#10
#06
(JSS OPTION)

TO BRAKE VALVE 'P'

EXTEND RETRACT B5
TO MAIN VALVE P #03 SHEET

#06
B6
BLUE & BLUE BLUE & BLUE PA5
13

EF
#02 (SUS LOCK VALVE) TO ADJ CYL S/VALVE
BLUE YELLOW P61 YELLOW TO SWIVEL JOINT PORT 13 2/3 #04

P
TO MAIN VALVE P YELLOW & BLACK YELLOW & (OPTION)

#06
& GREEN A6
RED & BLUE YELLOW
SUS LOCK
#02 BROWN & YELLOW

CF
RED P21 RED V04
T P 'T' BLOCK TO MAIN VALVE P PB5
YELLOW

A1 TANDUM GEAR PUMP

BLUE &

#04
14 (2nd GEAR) S07 TO ORBITROL
BACK P2 NO COLOUR P11 NO COLOUR TO SWIVEL JOINT PORT 14 VALVE 'P'
(STEERING 14.0cc/rev
BRAKE 7.0cc/rev)
RETRACT BROWN & YELLOW #02 BLUE & TO MAIN VALVE P B1
T/M CLUCH GREEN & YELLOW S08
GEAR RATIO 0.97
YELLOW CONTROL #04
GREEN & PA12 GREEN & GREEN
GREEN 12 (1st GEAR)
TO SWIVEL JOINT PORT 12 0.8 A4
2ND BOOM X V11
YELLOW & WHITE STABILIZER #04
BULKHEAD #02 PUMP OUTPUT PRESSURE
FITTINGS UP DOWN B4 CHECKING PORT.
P1 B PA4 PB4 AIR BLEEDER
EXTEND YELLOW & YELLOW
#02 ORBITROLL #03 GREEN & BROWN GREEN & WHITE DRAIN PLUG
FRONT
VALVE SET 36.5± 1.5 BAR
@10 litre/min~53 litre/min
0.8 PRIORITY
VALVE
STRAINER
75µm (200 MESH) Pd2 PC PA Pd1 PS
BLUE & YELLOW
#02
FILTRATION AREA
200cm 2 X X
ACCUMULATOR TP1 A1 T0 SAFETY VALVE
OPTION LEFT PPC VALVE T
40.2MPa(410kg/cm 2 )
P2 TRAVEL A3
#02
BLUE
L R INPUT SHAFT
DIG
FORWARD REVERSE B3
240~260 bar 240~260 bar PA3 PB3 E
BLACK & BLACK &

#02
#02

#06
#06
WHITE
ARM
RED CLOCKWISE ROTATION
GEAR PUMP 19cc/rev
(FOR STEERING CUMMINS
#03

LS1 AND BRAKE) ENGINE MAX

DUMP
P1 0.8 SAFETY VALVE GEAR RATIO 0.97 Hi = 2320rpm

YELLOW #02 A2 33.3MPa(340kg/cm 2 ) RATED = 2200rpm MIN

Lo = 1050rpm

#04

#04
BOOM SEE X
WHITE
RE D &

NO COLOUR
#02 UP DOWN SHEET P
en
P4 PA2 B2 TO BOOM CYL S/VALVE
RIGHT #04 2/3 FEEDBACK
GREEN
100 MESH
RED &
BLUE
5±0.5 bar BROWN
1.0 LINK
LS SET CHANGE
PB2 CONTROL PRESSURE
SWING RED &
YELLOW 70± 8 bar PRESSURE SWITCH
FOR STOP LIGHT
0.6 CHECKING PORT PB PRESSURE
CHECKING PORT.
LOW BRAKE
0.75 LITRE
AND CRUISE CONTROL SB2 GREEN & GREEN
PRESSURE SWITCH S02
#02
LEFT RED &
YELLOW
70cc/rev
40± 5 bar
A1 PLS 0.6
)(
P3
#02 S18
SUSPENSION LOCK
SWITCH
PA1 SWING 0.7
#03
#03

#03

RED 100cc/rev LEFT RIGHT

'P' BLOCK RED B1
190~195 bar
SA1 S01 0.7 P
LSCX
F R R2 R1
P LOAD PRESSURE
RED & YELLOW #02 63 +70 bar N'
TS1
NO PB1

#10
COLOUR CHECKING PORT
5±1.5 bar PARKING BRAKE SB1
#02
Psig X
S19 LS COMPENSATION
PRIORITY RELEASE PRESS. VALVE
VALVE T'1 STRAINER
18 kg/cm 2 (MIN)

#04
LS
75µm (200 MESH)
S31 V36
P T LS B
P LS DUMP T1 LS SEPARATION 0.6 FILTRATION AREA
T VALVE BP 200cm2 CONSTANT POWER
SOL ARRANGMENT FOR #02 COMPENSATOR
)(

EF
JOYSTICK STEERING P
)(

. PBP

P
LS SWING BLACK & BLACK
(JSS) OPTION S40 BLEEDING
T'2 VALVE
PX P X EPC

CF
TC
B YELLOW & BROWNPX #10 MAIN RATED DISCHARGE M EPB P
EF CF
MAINRELIEF VALVE SAFETY PUMP 224 /min PC MODE CHANGE
T2
155 bar

M
120 bar

34.8/37.3MPa VALVE TB PRIORITY MAX 112cc/rev PRESSURE

(355/380kg/cm 2 ) VALVE MIN 13cc/rev CHECKING PORT EPC BASIS
38.2MPa(390kg/cm 2 )
PRESSURE
P ITALIAN COOLER BYPASS VALVE BACK PRESSURE VALVE CHECKING PORT
TO ORBITROL Z OPTION 0.4MPa(4kg/cm 2 ) Lo: 0.4MPa(4kg/cm 2 )
VALVE S A51 Hi: 0.8MPa(8kg/cm 2 )
PORT 'LS'
6 bar 20 bar #03 R3 P #02
200 bar
F
58±7 bar #02 4 TRAVEL FORWARD
OIL
COOLER #06
R 6 TRAVEL REVERSE
#06 13 SUS LOCK
0.75 LITRE TO SOLENOID VALVE PORT 13 YELLOW & BLACK
50~55 bar #02 STABILIZER UP
TO HYD. #05
5

7 STABILIZER DOWN FOR PC-EPC FOR LS-EPC

TANK V35 V12 #05 VALVE VALVE
2 DRAIN (WHITE BAND)
LH & RH A FILTER V21 (RED BAND) V22
#04 3 TRAVEL CREEP
EPC SOL X1 X N TO SOLENOID VALVE PORT 3 BLACK & BROWN
24/100/24 MESH #02 1ST GEAR SEE SHEET 3/3
TO BRAKE VALVE 'P' BRAKE TO SOLENOID VALVE PORT 12 YELLOW & WHITE
#02
12

14 2ND GEAR
OR S17 VALVE TO SOLENOID VALVE PORT 14 GREEN & YELLOW
#02
SETTING PRESSURE 11

ITALIAN OPTION B
280kg/cm 2 1 LH STEER
#04
TO HYD. )(
10 RH STEER
#04
TANK MA (SWING RIGHT) MB (SWING LEFT)
#03
8 SERVICE BRAKE 1
40± 5 bar 9 SERVICE BRAKE 2
R LS PARK BRAKE
#05 #03
P Z
V37
PRESSURE SWITCH
#05
LH & RH #02 SWING MACHINERY #04 SWIVEL
T
LOCK SOL #02 KMF40ABE-3 MOTOR JOINT
#04 (706-73-01181)
#04 SWING MOTOR 40.2cc/rev
PW148-8 - 1/3

PW148-8 VEBM720100 90-3

Hydraulic circuit diagram (2/3)

#04 #04
2 ATT HCU OPTION - BREAKER RETURN
2P BOOM 21.7xt2.8
SPEC. ONLY SEE 21.7xt2.8
ARM CYLINDER ASSY X
SHEET (STD 115x 75-1159)
#05 #05
1/3 T

SAFETY VALVE 21.7xt2.8 21.7xt2.8

X
OPTION B6
#05 #05
#05
V TO BUCKET
A6 27.2xt3.2 X
#05 #05 CYLINDER
#05 CY B9 B8
SEE
PB6 #02
SHEET
SEE BUCKET
1/3
X
CYLINDER
P1 PCY SEE A9 SEE A8
SHEET SHEET X
1/3 1/3 #05 TO BUCKET
CYLINDER
ARM CYLINDER SAFETY VALVE
2P BOOM CRACKING PRESSURE 38.2MPa(390kg/cm 2 )
SPEC. ONLY 34xt4 34xt4 34xt4
X
#05 #10 #10 #10

SAFETY VALVELESS ARM CYLINDER

(STD 115x 75-1159)
OPTION B6
#05 #05
SEE #10
A6 SHEET
SEE #05 #05
1/3
SHEET
1/3 ARM CYLINDER 21.7xt2.8 21.7xt2.8
X
#05 #05

#03 #03 HCU (STD) OPTION - CLAMSHELL AND BREAKER ONLY

ADJUST CYLINDER
SEE T
SHEET
1/3

21.7xt2.8 21.7xt2.8
X
#05 #05
ADJUST CYLINDER SAFETY VALVE V
ADJUST
CRACKING PRESSURE 38.2MPa(390kg/cm2) TO BUCKET
X
CYLINDER ASSY CY #05 CYLINDER
(STD 140x 75-555) B8

SEE BUCKET
CYLINDER
X
ADJUST SEE A8
P1 PCY CYLINDER ASSY SHEET X
PB5 #02
(STD 140x 75-555)
1/3 #05 TO BUCKET
A5 #05 A5 #05 CYLINDER
B5 #05 21.7xt2.8
B5 #05 21.7xt2.8
SEE 34xt4 34xt4
SEE 34xt4
X
SHEET #10 #10 #10
SHEET #05
1/3
1/3

SEE #10
SHEET
SAFETY VALVELESS OPTION SAFETY VALVE OPTION 1/3

X
#05
27.2xt2.8
A7
#05 #05
#03 BUCKET CYLINDER ASSY
T BOOM CYLINDER ASSY
LEFT HAND (STD 95x 65-885)
(STD 105x 70-902)
SEE
SEE L.H. BOOM CYLINDER SAFETY VALVE (LEFT) B7 #05
CRACKING PRESSURE 38.2MPa (390kg/cm 2 ) SHEET 27.2xt2.8 #05
X
SHEET 2 PIECE BOOM #05
1/3
1/3 V

21.7xt2.8
#05 21.7xt2.8
CY
BOOM CYLINDER ASSY
LEFT HAND
#04

(STD 105x 70-902)

P1 PCY
BUCKET CYLINDER
A2 #05
#05 MONO BOOM
B2 #05
#05

G164
SEE
SHEET
PB2 T
#02

1/3 #02

BOOM CYLINDER ASSY 16xt2 16xt2

RIGHT HAND A X
#02 #02
OVER LOAD (STD 105x 70-902)
CAUTION V TO QUICK
#05 21.7xt2.8 2 PIECE BOOM COUPLER
CY
SEE
B #02 #02
X
SHEET 16xt2 16xt2
(RIGHT)
1/3
BOOM CYLINDER ASSY
P1 PCY RIGHT HAND
(STD 105x 70-902)

BOOM CYLINDERS
#02
R.H. BOOM CYLINDER SAFETY VALVE
QUICK COUPLER PIPING
2
CRACKING PRESSURE 38.2MPa (390kg/cm )
#02 MONO BOOM PW148-8 - 2/3

PW148-8 VEBM720100 90-5

Hydraulic circuit diagram (3/3)

TRAVEL FORWARD 4
#10
TRAVEL REVERSE 6 V32
#10
SUS LOCK 13
FRONT O/R REAR O/R REAR O/R #02
R.H. CYLINDER R.H. CYLINDER R.H. CYLINDER
STABILIZER UP 5 H1 Standard
OUTRIGGER CYL. ASSY
OUTRIGGER CYL. ASSY
( 110x 70-521)
( 110x 70-521)
STABILIZER DOWN 7 H2 Option: Trailer C U/C AUX. HYDRAULICS

DRAIN 2 8 LITRE/MIN
#04
A
SEE
SHEET
TRAVEL CREEP 3
#02
J1 Standard
H2
A1
1/3 1ST GEAR 12
#02
J2 Option: Trailer
B
V14 V18 V18
2ND GEAR 14
#02
H3
11

LH STEER 1
#04
A B E C C RH STEER 10 V33 150 bar
#04
#03 #03 #03 #03
SERVICE BRAKE 1 8

#03 #03 #03 SERVICE BRAKE 2 9 D E

J2 J3
#03 #03 #03

SWIVEL JOINT
#03 #03 #03 #03
B A D B B V34

V13 V17 V17

#02

#02
OPTION: AUXILARY CIRCUT
A

#04 #04 #04

#05

#05

#05

#05
10xt1

H1 J1 H1 J1
10xt1
FRONT O/R H3 J3 REAR O/R
L.H. CYLINDER
H3 J3 REAR O/R
L.H. CYLINDER
L.H. CYLINDER

FOUR O/R REAR O/R - FRONT LESS

M1
REAR DOZER
FRONT O/R R.H. CYLINDER
R.H. CYLINDER
REAR DOZER 0.8
OUTRIGGER CYL. ASSY R.H. CYLINDER MA T2
( 110x 70-521)

#02

#02
A
V14 (FRONT O/R R.H.)
V18 (REAR O/R R.H.)
AXLE
SERIES 420
A1 25 BAR X
#03

#03

S Y
0.6
A B E C
#03 #03 PLUG

#03
#05
J1, J3 SERIES 420
25 BAR
# 03

#03

V17 (REAR DOZER) H1, H3

RH
#03 #05
V15 (FRONT DOZER)
B
#03 #03 DOZER CYL ASSY
B A D B ( 90x 50-240)
DOZER CYL ASSY
( 90x 50-240)
LH
#03

#03

T U
#03

G ext MB
#03

A
G
#04 #04
#05

#05

29~100cc/rev AXLE TRANSMISSION

H1 J1 REAR DOZER
L.H. CYLINDER
TRAVEL MOTOR TRANSMISSION 1st GEAR RATIO 4.93
STEERING CYL.
FRONT O/R
L.H. CYLINDER
H3 J3 REAR DOZER
PART OF
2.0 TRANSMISSION 2nd GEAR RATIO 1.32
L.H. CYLINDER AXLE GEAR RATIO 18.6
V13 (FRONT O/R L.H.) REAR DOZER - FRONT LESS (DRAWN FOR THIS OPTION) AXLE ASSY.
V17 (REAR O/R L.H.) BORE 80 #04
FRONT DOZER - REAR LESS SERVICE BRAKE
REAR DOZER - FRONT O/R (DRAWN FOR THIS OPTION) SERVICE BRAKE ROD 40 (REAR)
(FRONT)
FRONT DOZER - REAR O/R STROKE 170
SUS LOCK CYLINDER
( 85-170 STROKE)
BRAKE CYL. 1) 1st GEAR (Lo SPEED): 2nd GEAR CLUTCH DISENGAGED (PRESSURE APPLIED TO PORT Y)
PART OF AXLE ASSY 2nd GEAR (HI SPEED): 1st GEAR CLUTCH DISENGAGED (PRESSURE APPLIED TO PORT X)
2) MACHINE DEFAULTS TO Hi SPEED AT START UP

3) MACHINE DEFAULTS TO HI SPEED BEFORE ENG. START. PW148-8 - 3/3

PW148-8 VEBM720100 90-7

Electrical circuit diagram (cabin 1/4)

PUMP (PC) 30
A RELAY FOR GRID RELAY FOR RELAY FOR RELAY FOR STARTER CUT TO MODEL SELECT SWITCH TO RIGHT HAND CONTROL LEVER RESISTOR TO RIGHT CONSOLE UPPER HARNESS

CN-D03

CN-D04
HEATER RELAY CM850(1) CM850(2) (TRAVEL N) TO EMERGENCY PUMP / SWING / TRAVEL SWITCHES

KES1

KES1
4 3 4 4
F (TO ) 4 (TO ) 4 B E (TO ) 4 (TO ) 4
D (TO 44) A
SERVICE CONNECTOR CN-J01
M CN-J02

10
11
12
13
14
15
16
17
18
19
20

10
11
12
13
14
15
16
17
18
19
20
1
2
3
4
5
6
7
8
9

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

1
2
3
5
6

1
2
3
5
6

1
2
3
5
6
BLUE

CN-G71

CN-G72
CN-R01

CN-R02

CN-R03

CN-R04
090

1
2
1
2

1
2

CN-K19
ORANGE

CN-N08

CN-C09

12

12
11
10

13
14
15
16
17
18
19
20

11
10

13
14
15
16
17
18
19
20
11
10
11
12

10
11
12

9
8

9
8
7

7
6
5

6
5
4

4
3
2

3
2
1

1
090

10

12

10
11
12

10
11
12
13
14
15
16
17
18
19
20
21
22
1
2
5
6
7
8
9

1
2
3
4
5
6
7
8

1
2
3
4
5
6

1
2
3
4
5
6
7
8
9

1
2
3
4
5
6
7
8
9

5
6
7
8
9

1
2
3
4
5
6
7
8
9
BG

BM

1
2

1
2
BW
BC
BD

BH

BN

BR

BU
1
2
3
5
6

1
2
3
5
6

1
2
3
5
6

1
2
3
5
6

BA
BB

BE

BK

BP

BS

BV

BX
BY

CN-S28

CN-S29
1
2
3
4

1
2
3
4
BF

BT

BZ
BL
DT DT CN-H15

2RW

2RW

0.5GW

0.5WG
0.5WG
2LR

2LR

0.5RW

0.85WG

0.5RW

0.5WR
DTM DTM

0.85W
090

0.5BW

0.85WR

0.5WB
0.85RW

0.85WR
0.85GR
0.5W

0.5W
0.85WB

0.85WB
0.5WL

0.5LW

0.85W

0.5LW
0.85W
0.5YG

0.5GB
0.85LW

0.5YG
0.85GR

0.85LW
0.5G
0.5YR

0.85YG

0.85GY
0.5R
0.5R
0.5YB

0.5YB

0.5YB

0.5GL

0.5YB
0.85RY

0.5YB
0.5BrW

0.85RY
0.85RB
0.5Y

0.5RL
0.5B

0.5B

0.5Y

0.5B

0.5B

0.5B

0.5Y

0.5B

0.5B

0.5B

0.5B
0.85R

0.5B

0.5RL
0.85YB

0.5B

0.5B
0.85R

0.85GL

0.85YB
0.5LY

0.85B

0.85B

0.85B
0.5LgR

0.5LgR

0.85RL
0.85LR

0.5LgR

0.5YL
0.85P

0.5YL
0.5L

0.5L

0.5L

0.5L

0.5L
0.85L

0.85RB(HG)
0.5Br

0.5Br

0.5RW(CM01-15)
0.5WG(G71-3)

0.5WG(R04-1)
0.5WG(C01-42)

0.5WL(CM01-11)
0.85WG(S29-7)

0.85RW(H15-4)
0.5RW(C01-60)
0.85RW(R06-5)

0.5WL(D01-6)

0.5R(CM01-16)
0.5YG(D04-1)

0.5YG(A05-8)
0.5YG(S29-9)

0.85WL(A07-9)
0.5RB(D01-1)

0.5RB(D01-2)
0.5YB(D03-1)

0.5R(D02-1)
0.85YG(S29-3)
0.5YB(A05-7)
0.5YB(S29-5)

0.85R(H15-3)
0.5RL(R16-1)

0.85R(R01-5)
0.5LY(G72-3)

0.85RL(G71-4)
0.5LY(SC02-7)

0.85R(A07-5)
0.5RL(C01-23)
0.5LgR(D04-2)
0.5LgR(D03-2)

0.85RB(A08-15)
0.5LY(C01-69)

0.5LgR(S29-8)
S

HE HD D
HF
C

(TO 34) WA
WB
WC
J

WD
W
D

HG

HC

CA
CB
E CC

CD CN-C01 AMP Sig i TYPE

1.25RY
CE 1 +VB (24V CONTROLLER PWR) PWR i 24V
1.25B
CF 2 GND(PWR) PWR i GND
0.85GW
CG 3 WASHER MOTOR (-) O Lo
1.25RY
CH 4 +VB (24V CONTROLLER PWR) PWR i 24V
1.25B
CJ 5 GND(PWR) PWR i GND
6 --- i PULSE
7 --- i\O CAN

(TO 44)
YC 0.5WB
CK 8 POWER (+5V) SENSOR PWR O 5V
Z Q 0.5WL
CL 9 POWER (+5V) SWITCHING PWR O 5V
10 --- i ALTR
0.5L
11 1ST SERVICE EPC SOL. CUT i 0~5V
C CM
0.5RW
12 TRAVEL PPC PRESS.SENSOR i 0~5V
F CN
0.5LW
13 1ST SERVICE POT (2) i 0~5V
0.5BrR
CP 14 BOOM DOWN PRESSURE SW. i Lo
0.5BrW
CR 15 ARM DUMP PRESSURE SW. i Lo
0.5GL
CS 16 SWING PRESSURE SW. i Lo
0.5LgR
CT 17 ARM DIG PRESSURE SW. i Lo
0.5B
CU 18 GND(ANALOGUE GND) O GND
0.5RW
CV 19 SWING LOCK SW i Lo
L 0.5WY
CW 20 WIPER Lo SPEED i Lo
0.5YG
21 MACHINE SELECT 2 i Lo
0.5Y
CX 22 BREAKER SW. i Hi
0.5RL
CY 23 TRAVEL R i Hi
0.5LW
CZ 24 KEY SW. (ACC TERMINAL) PWR i KEY
0.5G
C1 25 SPEED PICK-UP SENSOR i PULSE
C2 26 --- i\O CAN
G C3 27 --- O 0~5V
0.5GY
28 POWER (+24V) SENSOR PWR O 24V
0.5LY
29 HYD OIL TEMP i
0.5L
30 SUS LOCK (JOYSTICK SW.) i 0~5V
0.5W
31 OVERLOAD CAUTION i 0~5V
0.5LY
32 2ND SERVICE POT (1) i 0~5V
0.5BR
33 LOW BRAKE PRESSURE SW. i Lo
0.5LgW
34 BUCKET DUMP PRESSURE SW. i Lo
0.5GY
35 TRAVEL (P) SW. i Lo
0.5BrW
36 TRAVEL R PRESSURE SW i Lo
SA 37 --- O GND
0.5RL
SB 38 SWING EMERGENCY SW i Lo
0.5RY
SC 39 P-MAX (WORKING) i Lo
0.5R
SD 40 MACHINE SELECT 1 i Lo
0.5LG
H SE
0.5WG
41 SERVICE BRAKE PRESSURE SW i Hi
SF 42 TRAVEL N i Hi
0.5LW
SG 43 KEY SW. (ACC TERMINAL) PWR i KEY
0.5L

(TO 44) SH
SJ
SK
S
0.5W
0.5B
0.5B
44 GND (PULSE GND)
45 CAN0_H
46 GND(ANALOGUE GND)
O
i\O
O
GND
CAN
GND
SL 47 GND(ANALOGUE GND) O GND
S SM
0.5GR
48 --- i
SN 49 F PUMP PRESSURE SENSOR i 0~5V
SP 50 --- i 0~5V
0.5LG
SR 51 2ND SERVICE POT (2) i 0~5V
0.5LgY
SS 52 SERVICE PRESSURE SW. i Lo
0.5BrY
ST 53 BOOM RAISE PRESSURE SW. i Lo
0.5GL
SU 54 BOOM/OUTRIGGER SELECT SW. i Lo
0.5BrB
I SV
0.5LR
55 TRAVEL F PRESSURE SW i Lo
56 WIPER (W) i Lo
0.5YR
57 WINDOW LIMIT SW. i Lo
SWP CN-A99 0.5GW
58 MACHINE SELECT 4 i Lo
0.5WB 0.5LW
LEFT SHUT OFF SOL. 1 59 Q/C LOW PRESSURE SW. i Lo
0.5Y 0.5RW
RIGHT SHUT OFF SOL. 2 60 KEY SW. (C TERMINAL) i Hi
0.5P 0.5W
LS DUMP SOL. 3 61 TRAVEL F i Hi
0.5G 0.5Y
LEFT STEER EPC SOL. 4 62 WAKE-UP SIGNAL PWR i 24V
0.5L ZP
GND (LEFT STEER EPC) 5 63 --- CAN O GND
0.5G 0.5L
RIGHT STEER EPC SOL. 6 64 CAN0_L i\O CAN
0.5L ZR
GND (RIGHT STEER EPC) 7 65 --- O GND
1.25RY
HEATED MIRROR 8 66 --- O GND
67 --- i
0.5YB
68 R PUMP PRESSURE SENSOR i 0~5V
SWP CN-A08 0.5LY
69 1ST SERVICE POT (1) i 0~5V
J C/W LIGHT 1
1.25GL
70 --- O GND
0.85G 0.5YR
REFUELING PUMP 2 71 PARK BRAKE PRESSURE SW i Lo
0.85RB 0.5W
DIPPED LIGHT 3 72 SWING POSITION SENSOR i Lo
0.5G 0.5LgB
F.L. OUTRIGGER/BLADE 4 73 BUCKET DIG PRESSURE SW. i Lo
0.5Y 0.5Br
F.R. OUTRIGGER 5 74 WASH/WIPE SIGNAL i Lo
0.5L 0.5LW
R.L. OUTRIGGER/BLADE 6 75 WIPER (P) i Lo
0.5Br 0.5RW
R.R. OUTRIGGER 7 76 WIPER INT SPEED i Lo
0.5GY 0.5YB
SENSOR POWER 8 77 MACHINE SELECT 3 i Lo
0.5Y 0.5B
HEATER RELAY 1 9 78 GND(ANALOGUE GND) i Lo
0.5YB 0.5LW
HEATER RELAY 2 10 79 KEY SW. (ACC TERMINAL) i Hi
0.5RY 0.5LgR
PWM OUTPUT 11 80 PPC LOCK (TILT POD SW.) i Hi
0.5W
CAN (H) 12 81 --- O GND
0.5L
CAN (L) 13
0.85B
GND 14 CN-C02 AMP
K BATTERY RELAY BR 15
0.85RB
82 --- RXD 232C
1.25R
FUEL TANK WORK LAMP 16 83 --- --- --- ---
0.5W
84 CREEP/LOW SIG. (STEERING) O Hi
0.5G
85 F-L OUTRIGGER SOL. O Hi
0.5L
86 R-L OUTRIGGER SOL. O Hi
0.5R
CN-J03 87 T/M CLUTCH SOL. O Hi
0.5G
88 LS_EPC O Hi
GREY 0.5GR
89 TRAVEL CREEP SOL. O Hi
10
11
12
13
14
15
16
17
18
19
20
1
2
3
4
5
6
7
8
9

090 90 --- TXD 232C

12
10
11

13
14
15
16
17
18
19
20

91 --- --- --- ---

9
8
6
7
5
4
2
3
1

0.5B
92 PPC LOCK (RELAY SINK) O Lo
0.5Y
93 F-R OUTRIGGER SOL. O Hi
0.5Br
2RY(FB1-17)

0.5LW(CM01-14)
0.85WL(M19-1)

1.25RY(CM01-1)
1.25RY(CM01-2)

0.5LW(SC02-5)

94 R-R OUTRIGGER SOL.

0.5WL(D01-4)

O Hi
1.25WL(FB1-4)

0.5LW(C01-79)
0.85LW(N08-2)
0.85LW(H15-5)

0.5LW(C01-43)
0.5LW(C01-24)
0.5WL(A05-13)

0.85LW(FB1-40)
0.85RY(N08-1)
0.85RY(H15-1)

1.25RY(C01-1)
1.25RY(C01-4)

0.5GW
95 1ST SERVICE EPC (LEFT) O Hi
0.5GB
L 0.5YB
96 PC-EPC O Hi
97 TRAVEL F/R SOL. O Hi
98 --- --- --- ---
T
99 --- --- --- ---
0.5BrG
100 BOOM/OUTRIGGER SOL. O Lo
0.5LW
101 SWING BRAKE SOL. O Hi
0.5GR
102 2ND SERVICE EPC (RIGHT) O Hi
0.5GY
103 1ST SERVICE EPC (RIGHT) O Hi
0.5V
104 TRAVEL EPC (+) O Hi
0.5RL
105 TRAVEL NEUTRAL SOL. O Hi
106 --- --- --- ---
107 --- O Hi
0.5R
108 BATTERY RELAY DRIVE SIG. O BRY
0.5GL
109 2 STAGE RELIEF SOL. O Hi
0.5G
M 0.5GL
110 BACK PRESS. COMPENSATION O Hi
111 2ND SERVICE EPC (LEFT) O Hi
CN-J04 0.5BrR
112 MERGE/FLOW DIVIDER SOL. O Hi
0.5G
PINK 113 SUS LOCK SOL. O Hi
0.85L
114 WIPER MOTOR (-) O MOT
10
11
12
13
14
15
16
17
18
19
20
1
2
3
4
5
6
7
8
9

090 1.25B
115 GND(SOLENOIDS) PWR O GND
C 1.25RY
12
13
14

17
10
11

15
16

18
19
20

116 POWER(SOLENOIDS) PWR i BRY

9
8
6
7
5
4
2
3
1

F 1.25B
117 GND(SOLENOIDS) PWR O GND
1.25RY
118 POWER(SOLENOIDS) PWR i BRY
2B(E)

2B(E2)

0.85YL
1.25B(E)

0.5B(HM1-2)

119 WIPER MOTOR (+) O MOT

1.25B(W04-5)

1.25B(CM01-4)
1.25B(CM01-3)

0.5B(G70-8)
0.5B(R06-2)

0.5B(R16-2)
1.25B(G02-1)
0.5B(H08-6)

0.5B(R04-2)

1.25B(C01-5)
1.25B(C01-2)
0.5B(P17-2)
0.85B(S28-4)
0.85B(S28-10)

1.25B
120 GND(SOLENOIDS) PWR O GND
1.25RY
121 POWER(SOLENOIDS) PWR i BRY

E MAIN
CONTROLLER
E2
G
0.85LgR
0.85BrY
0.5LgW

0.85LW
0.5BrW

0.5BrW
0.85LG

0.85LG
0.5LgR

0.85LR
0.5LgB

0.5LgY

0.85LY
0.5BrR
0.5BrB

0.5BrY
0.5RW
0.5GR

0.5LW
0.5GB

0.5GL
0.5YB

0.5GL

0.5YB
0.5LR
0.5LY

0.5W

0.5W
0.5B

0.5B
0.5B

0.5Y

CN-J05
CN-P17

CN-A09
CN-A06

PINK
VD
VC

RG
VA
VB

VE

QC

RC
RD

RH

KG
QG
VF

KW
QH

KM
QD

JW
RA
RB

RE

RK

KC
KD

HG
KH

KN

KR

KU

HM
QB

QE

JG
QA

HC
HD

HH

HN

HR

HU
JM
QF

KA
KB

KE

KK

KP

KS

KV

KX
KY
RF

O
HA
HB

HE

HK

HP

HS
JC
JD

JH

JN

JR

JU
KF

KT

KZ

HF

HT
RL

JA
JB

JE

JK

JP

JS

JV

HL
KL

K1
K2
K3
K4
K5
K6

JF

JT
JL
JJ
1 1
2 2

1
2
3
4
5
6
7
8
9

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

10
11
12
13
14
15
16
10
11
12
13
14
15
16
17
18
19
20
1
2
3
4
5
6
7
8
9

090
SENSOR ANALOG GND

TRAVEL FORWARD SW.

FUEL PUMP FLOAT SW

TRAVEL REVERSE SW.

ROTOTILT EXTRA SOL.

BUCKET DIGGING SW.
TRAVEL PPC SENSOR
12
11

13
14
15
16
17
18
19
20
10

OVERLOAD CAUTION
9
7
8
6
4
5
3
2
1

Q/C LOW PRESS SW.

ROTOTILT TOOL ATT

TILT / ROTATE SOL.
FUEL PUMP ON SW.

R PUMP PRESSURE
F PUMP PRESSURE

ROTOTILT Q/C SOL.

BUCKET DUMP SW.
RAD WATER LEVEL
SENSOR GND(24V)

ARM DIGGING SW.

SWING PROX. SW.

SWP

BOOM DOWN SW.

GND (ROTOTILT)

GND (ROTOTILT)

(TO 24) (TO 44) (TO 34) (TO 24) (TO 24) (TO 24)
BOOM RISE SW.
2B(G)

ARM DUMP SW.

2B(E2)
1.25B(G)

HYD OIL TEMP

FUEL SENSOR

J
SWP
0.5B(S19-A)
0.85B(M19-2)
0.85B(M71-1)

0.5B(G73-1)
0.85B(M31-2)

K H
0.5B(C09-8)
0.5B(N08-9)

0.5B(D02-2)
0.5B(D02-7)

0.85B(G05-6)
1.25B(SC02-1)

0.5B(R09-2)

0.5B(S18-1)
0.5B(V12-2)
0.5B(N08-12)
0.5B(H15-10)

0.85B(F01-1)

AIR CLEANER

SERVICE SW.

0.5LgR
SWING SW.

0.5GW
0.5WB

0.5WB

0.5RG

0.5GR
0.5GY

0.5GL
0.5YB

0.5GL
0.5W
3RW

0.5G

0.5G

0.5G

0.5G
0.5G
0.5B

0.5B

0.5B

0.5B

0.5B
0.5B

0.5V
0.5B

0.5Y
0.5L

0.5L

0.5L
3RL
A/C HI/LO
R

3R
3R
3B

2B

3B
3B
PRESSURE SW. V Q CN-D02 SWP
CN-D01 SWP

CN-A01

CN-A04
CN-A02

CN-A03
0.5R 0.5RB
1 1 1 1
---
---

0.5Br 0.5RB

1
2
3
4

1
2
3
4

1
2
3
4
5
6
7
8
9

1
2
3
4
5
6
7
8
9
10
11
12
13
14

10
11
12
13
14
2 2 2 2
0.5LW 0.5YB
3 3 3 3

JOYSTICK STEER PRESS SW

AUTOGREASE SUPPLY (24V)

0.5Br 0.5WL

ENGINE CONTROLLER PWR

P 4 4 4 4 X

AUTOGREASE INDICATOR
0.5B 0.5R

SWP

SWP

JOYSTICK STEER SPEED

5 5 5 5
0.5RB 0.5WL
1/4

SPEED PICK UP(GND)

POTENT SUPPLY +5V
6 6 6 6

2ND SERVICE RH (+)

1ST SERVICE RH (+)

2ND SERVICE LH (+)

2ND SERVICE RH (-)

1ST SERVICE LH (+)
GND(POWER)REVO

1ST SERVICE RH (-)

2ND SERVICE LH (-)

0.5B 0.5LW

1ST SERVICE LH (-)

AUTOGREASE SW.
REGULAR POWER
7 7 7 7

TRAILER TIP SOL.

FUEL DIAL (PWR)
FUEL DIAL (GND)
0.5RY 0.5GW
PW220-8 (06)

TRAVEL EPC (+)

FUEL DIAL (SIG)

SPEED PICK UP
TRAVEL EPC (-)
8 8 8 8

ENG OIL LEVEL

KEY SW (ACC)
RIBBON HEATER RELAY PW200-8 (06)

PC EPC(+)
BATTERY RELAY (1)

LS EPC(+)
PC EPC(-)

LS EPC(-)
CM850 <ENGINE> RELAY (1) BATTERY RELAY (2)

GND(1)

GND(2)

GND(3)
PW180-8 (06)

+24V
+24V
LOWER WIPER SWING LOCK
CM850 <ENGINE> RELAY (2) WASHER MOTOR
PW160-8 (06)
PW148-8 (06)
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23

PW148-8 VEBM720100 90-9

 I

L
K
E
B
A

J
F

N
H
D
C

M
G

P
O
2RW(FB2-5) 0.5GW(D01-8) 1.25B(P) 0.85LW(R09-3)
1 1 1 1 1 1 1 1

PW148-8
1.25RW(R08-1) 0.85GW(C01-3) 0.85B(G33-2) 0.5LW(D02-3)
2 2 2 2 2 2 2 2
1.25RW(R08-3) 0.5GW(A05-14) 0.85B(G33-4) 0.85LW(A07-8)
3 3 3 3 3 3 3 3
0.5LW(SC02-13) 0.5B(R05-6) 0.5BY(G02-7)

1
090

090
4 4 4 4 4 4 4 4

090
0.5LW(C01-51) 0.5BR(CM01-13) 0.5B(R14-6) 0.5BY(G70-10)
5 5 5 5 5 5 5 5

090
0.5LW(G70-4) 0.85BR(FB2-36) 0.85B(M72-2) 0.5BY(R12-2)
6 6 6 6 6 6 6 6
2W(FB2-3) 0.85BR(FB2-37) 0.5B(R08-6) 0.85L(A07-12)
7 7 7 7 7 7 7 7
1.25W(R05-1) 1.25BR(G05-10) 0.5B(R18-6) 0.85L(R09-5)
8 8 8 8 8 8 8 8

SWP
1.25W(R05-3) 0.5BR(D05-1) 0.5B(R19-6) 0.85L(ZA)
9 9 9 9 9 9 9 9

8
7
6
5
4
3
2
1
0.85W(H15-6) 0.5BR(D05-2) 0.5L(H14-5)
10 10 10 10 10 10 10 10

VEBM720100
2WL(FB2-4) 0.5R(H15-17) 0.85GL(H15-7) 0.5YB(D01-3)
11 11 11 11 11 11 11 11

SIDE LIGHTS
SIDE LIGHTS
8
7
6
5
4
3
2
1
CN-J06
CN-J07
CN-J09
CN-J10
1.25WL(R14-1) 0.5R(R08-5) 0.5GL(R05-5) 0.85YB(S28-9)
12 12 12 12 12 12 12 12

LEFT INDICATOR
1.25WL(R14-3) 0.5R(D05-6) 0.5GL(R14-5) 0.85YB(H15-19)

RIGHT INDICATOR
13 13 13 13 13 13 13 13

CN-D05
0.85L(FB1-12) 0.5GL(D05-5) 0.85BrB(M72-4)
14 14 14 14 14 14 14 14

0.5Y
0.5Y

0.5R
0.5L(G05-2) 1.25G(FB2-11) 0.85BrB(H08-2)

2
0.5GL

0.5YR
0.5BR
0.5BR
15 15 15 15 15 15 15 15

0.5YG
0.5L(R22-3) 0.85G(G02-9) 0.85B(P) 0.85BrB(J07-18)
16 16 16 16 16 16 16 16
0.5P(HM1-1) 0.85G(G05-9) 0.5B(G70-9) 0.85R(M72-3)

PINK
17 17 17 17 17 17 17 17

BLACK
0.5P(R22-5) 0.85BrB(J10-16) 0.5B(G72-6) 0.85R(H)
18 18 18 18 18 18 18 18

ORANGE
ORANGE
0.5P(R22-1) 0.85BrB(M79-2) 0.5B(G72-8) 0.5R(P10-1)
19 19 19 19 19 19 19 19
0.5P(G05-1) 0.5BrB(P10-2) 0.5B(G72-10) 0.85R(M79-1)
20 20 20 20 20 20 20 20

CN-R05
1.25W
1 1
1.25GL

3
2 2
1.25W
3 3
1.25R
4 4
0.5GL
5 5
B00M/REVO
WORKLAMP

0.5B
6 6
CN-R06
0.85R 0.5GL
Electrical circuit diagram (cabin 2/4)

1 1 1 1

12V
0.85BrB 0.5B
2 2 2 2
0.5BW

SOCKET
3 3
0.85W
5 5

M
CN-M79

4
6 6
STARTER CUT

CN-R07
0.5WR
1 1
0.5BR
2 2
0.85RW
3 3
5 5
0.85BrW
6 6
STARTER CUT
(PERSONAL CODE)

CN-R08

5
1.25RW
1 1
1.25GL
2 2
1.25RW
3 3
1.25R
4 4
0.5R
5 5
VW

0.5B
WORKLAMP

6 6
CWT/REAR CAB

CN-R09
0.5LR
1 1
0.5B
2 2
0.85LW
3 3

6
0.85L
5 5
0.85LB
6 6
LOWER WIPER

CN-R10
1 1
2 2
3 3
5 5
(NOT FITTED)

6 6

7
CN-R11
1 1
MA 2 2
MB 3 3
MC 5 5
MD
(NOT FITTED)

6 6
ME
MF
MG
CN-R12
MH
0.5GW
1 1

8
MK
0.5BY
2 2
ML
0.85GW
3 3
0.85G
HORN

MM
RD

5 5
MN 6 6
MP
MR
MS
CN-R13
CN-R14 0.5WR
MT 1 1
MU
1.25WL 0.5B
1 1 2 2

(TO 34)
MV
1.25R 0.5LgR
2 2 3 3
MW
1.25WL
3 3 5 5

9
1.25R 0.5LgR

M
PPC LOCK

MX 4 4 6 6
MY
0.5GL
5 5
CAB FRONT

0.5B
WORKLAMPS

MZ 6 6
M1
M2
M3
M4
KA
SWP CN-A05 KB
0.5BrR KC
MERGE DIVIDER SOL. 1
0.5GL KD
2-STAGE RELIEF SOL. 2
0.5LgR KE

10
PPC LOCK SOL. 3
0.5R KF
T/M CLUTCH SOL. 4
0.5YL KG
SWING BRAKE SOL. 5
0.5G KH
BACK PRESSURE COMP. 6
0.5YB KK
TRAVEL F/R 7
0.5YG KL
TRAVEL N 8
0.5GR KM
TRAVEL CREEP SOL. 9
0.5RB KN
BOOM/STABILISER SOL. 10
0.5LgY KP
QUICK COUPLER SOL. 11
0.5G KR
SUS LOCK SOL. 12
0.5WL KS
WASHER MOTOR(+) 13
0.5GW KT
WASHER MOTOR(-) 14

11
0.85RW KU
SIDE LIGHT (RH) 15
1.25R
(FROM 14 )

SPARE LIGHT 16 KV
KW
KX
K

KY
KZ
K1
K2
K3
K4
K5

12
K6

ZA JA
ZB JB
ZC JC
ZD JD
ZE JE
ZF JF
ZG JG
ZH JH

13
ZK JJ
ZL JK
ZM JL

(TO 34)
ZN JM
ZP JN
(FROM 14 )

Z
ZR JP
ZS JR
J

ZT JS
JT
JU
JV

14
SWP CN-A07 JW
0.85G
HOR N 1
1.25GL
BOOM LAMPS 2
0.85RL HA
TRAVEL ALARM (POWER) 3
0.85Y HB
BEACON(C/W) 4
0.85R HC
ENG(HEATER RELAY) 5
0.85RW HD
STARTER RELAY S 6
0.85W HE
ENG(A/C COMPRESSOR) 7
0.85LW HF
LOWER WIPER 1 8
0.85WL HG
ALTERNATOR L 9
0.85YG HH
TURN L.H. 10

15
0.85YR HK
TURN R.H. 11
0.85L HL
LOWER WIPER 2 12
0.85GY HM
MAIN LIGHT 13
0.85RB HN
SIDE LIGHT (LH) 14
0.5GY
(FROM 14 )

BRAKE LIGHT 15 HP
0.85LB HR
LOWER WIPER 3 16
H

HS
HT
HU

CN-R15
0.5RY

16
1 1
0.5BrG
2 2
0.5RY
3 3
0.5RB
5 5
SELECT

DT
M

6 6
CN-V12
0.5YL
BOOM/OUTRIGGER

BRAKE VALVE 1 1
0.5B 0.85Y(R19-1) CN-R16
SOLENOID 2 2 1 1
0.85Y(R19-3) 0.5RL
2 2 1 1
0.85Y(F01-4) 0.5B
3 3 2 2
0.85Y(G02-4) 0.85WR
4 4 3 3
DT

0.85RL
17

5 5 5 5
BUZZER

CN-S17 0.5YG(R18-4)
6 6 6 6
REVERSING

0.5YR 0.85YG(R19-2)
PARK BRAKE
CN-J08

1 1 7 7
0.5L 0.5YG(D05-7)
PRESS SW 2 2 8 8
0.85YG(G02-5) CN-R17
9 9
0.85YG(A07-10) 0.5LW
10 10 1 1
0.85YR(R19-4) 0.5G
BB

11 11 2 2
DT

0.5YR(D05-8) 0.5LW
BLACK

12 1 2 3 3
CN-S18 0.85YR(G02-6) 0.5LgY
QUICK

13 13 5 5
0.5B 0.85YR(A07-11)
COUPLER

LOW BRAKE 1 1 14 14 6 6
0.5BR 0.85GY(H15-21)
090

PRESS SW 2 2 15 15
0.85GY(R18-2)
18

16 16 CN-R18
0.85GY(F01-3)
17 17
DT

0.5WR(H15-22) 0.85LW
18 18 1 1
CN-S19 0.5WR(R18-5) 0.85GY
19 19 2 2
0.5B 0.5WR(R19-5) 0.5P
A A 20 20 3 3
(N.O) STOP LIGHT 0.5G 0.5GY
B B 4 4
0.5LB 0.5WR
POWER

(N.C) CRUISE CTRL

HAZZARD

C C 5 5
0.5B
6 6
DT

CN-R19
CN-S40 0.85Y
19

1 1
0.5RY 0.85YG
BRAKE SUSPENSION 1 1 2 2
0.5GW 0.85Y
LOCK PRESS SW 2 2 3 3
0.85YR
4 4
0.5WR
HAZZARD

5 5
SWITCHING

0.5B
6 6
0.85B
E

1 1
0.85GY
2 2 CN-R20
3 3
UNIT

0.85Y 0.5RB
BL

4 4 1 1
0.5G
FLASHER

CN-F01 2 2
N

0.5RY
20

KES1 3 3
0.5G
VA 4 4
0.5RY
VB 5 5
AUXILIARY

0.5RW
HYDRAULICS

VC 6 6
DT

VD
0.5P
VE 1
0.5L CN-R21
VF 2
0.5BW 0.5L
3 1 1
0.5RY 0.5LB
(FROM 14 )
AT

4 2 2
0.5Y 0.5L
5 3 3
0.85B 0.5GY
V
BRAKE

6 5 5
0.85Br
0.85Br

0.85BrY
LIGHTS

0.5BrR

0.85LgR
0.85LY
0.85LR
0.85B

0.85BrW
0.85BrW

0.85LG
0.85GL

0.85G
0.85G

0.85LW

0.5LB
0.85W

0.85GW
0.85GW

7 6 6
21

0.5Y
8
4
3
2
1
9
8
7
6
5
4
3
2
1

0.85G
16
15
14
13
12
11
10

9 CN-R22
1.25BR
10
4
3
2
1
9
8
7
6
5
4
3
2
1

16
15
14
13
12
11
10

0.85L 0.5P
11 1 1
0.5GY 0.5LB
S CN-RT1

12 2 2
DT CN-RT2

0.5L
3 3
CN-G05 0.5P
5 5
CRUISE
CONTROL

6 6

SWP CN-R23
22

1.25B 0.5G
YA

1 1 1
(TO 44)

0.5RW 0.5YB
2 2 2
-

6
5
4
3
2
1
7
6
5
4
3
2
1
+
S

0.5WY 0.85LG
3 3 3
T

1
5
2
6

0.85Y 0.85G
PUMP

4 5 5
GND
REFUEL

0.5B
0.5P

1
5
2
6

0.85YG
5 6 6
0.85YR
6
EXTRA SOL.

ON
0.5BY
POWER (GND)
POWER (+24V)
KEY SW. (ACC)

Q/C LOCK SOL.

OFF 7
DT

0.85Br
Q/C LOCK SW. (1)
Q/C LOCK SW. (2)
Q/C LOCK SW. (3)
Q/C LOCK SW. (4)
2 2
1 1

8
TOOL CONNECTED
TILT / ROTATE SOL.

1
5
2
6

0.85G
TOOL MOUNT SW. (-)
TOOL MOUNT SW. (+)

GND (Q/C LOCK SOL.)

CN-HM1

9
ROTOTILT CONTROL UNIT

0.85L
CONNECTION TO ENGCON

10
2/4
(SUPPLIED IN ENGCON KIT)

0.85GY
MAGNET

11
SHIFT SWITCH (MOMENTARY)

23

0.85RB
QUICK

12
PW148-8 (06)
PW160-8 (06)
PW180-8 (06)
PW200-8 (06)
PW220-8 (06)
ROTOTILT CONTROLLER

0.5G
SWITCH

13
CRUISE CONTROL

COUPLER

14
CN-G02
90-11
Electrical circuit diagram (cabin 3/4)

A
R (FROM 14) M (FROM 24) PROPORTIONAL
STEERING/HCU
CONTROL SW.
AXLE
LOCK
FRONT FACE BUTTON SW.

P-MAX HORN KOMATSU

Q/COUPLER SW
UPPER BUTTON SW.

ROTOTILT EXTRA
(TILT / COUPLER)
TRIGGER BUTTON SW.

SPARE

DC/DC
CONVERTER

RG

MG
RD

RH

MD
RC

MH
MC
RB

RE

MB

ME

MM

MR

MU
RA

RK

MA

MK
RF

MF

MN
MP

MS

MV

MX
MY
RL

ML

MW
MT

MZ
M1
M2
M3
M4
GND(+24V)

GND(+12V)
LEFT KNOB

+24V

+12V
CN-M72
B 1 2 3 4
OPTIONAL SEAT
1 2 3 4
M

0.85R
0.85B
0.85L

0.85BrB
AIR SUS
COMPRESSOR
M

(OPT)
G (TO 44)
C HEATED SEAT

CN-G70

CN-G73
10
11
12
1
2
3
4
5
6
7
8
9

1
2
3
4
PPC HYDRAULIC

CN-H14

CN-H13
0.85WB
1 1 LOCK SWITCH

10
11
12
10
11
12

1
2
3
4
5
6
7
8
9

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

1
2
2 2
0.85B M S FUSE BOX 1 (TILTING POD)
0.85RL
3 3 DTM DTM

1.25RW
0.5RG

0.5WL

0.5WL
0.85LW

0.5G
0.5LG
1.25RY

0.5LG

0.5BY
0.5Y

0.5B

0.5B
0.85YB
0.5P

0.5B

0.5B
0.5LR
0.85GL

0.5LY

0.5LY
0.5LgR
0.85Y

0.85RL

0.5L
0.5L

0.5L

0.5BrR
0.85B 0.85LW

0.5Br
4 4 1 2 3
3RW
OFF (POD DOWN)
3R
DT CN-G33 ON (POD UP)
3R
3R

CN-FB1
D 21 26 31 36 40

10A

20A

10A

10A

10A

10A

10A

10A

15A

10A

20A

10A

10A

15A

15A

20A

15A

30A
5A

5A

0.5W
0.5R
0.5B
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20

3RW
2W

2RY
2RY

0.85GW
1.25WR

0.85WB

0.5W
1.25WL

0.85LW
2Br
0.5Y
0.85GL

0.85LG

0.85YB
0.85P

0.85LR
1.25L

0.85L

CN-S14

1 1
2 2
3 3
M

0.85WR

0.5GL
0.5LgR
E
0.85YB X
1
0.85B
(OPT) 2
0.5Br
POWER SUPPLY 3
0.5L
4 Y

M CN-M31

F ZA

YB

G AA

ZN
ZM

P
H WIRING TABLE FOR FUSE BOX 1 (CN-FB1)
5B

FUSE NO. RATED SYSTEM 60B

BG
BC
BD

BH
BE

BK
BB

BM
BA

BF

BW
BL

BN
1 10A

BR

BU
BP

BS

BV

BX
BY
BT

BZ
PUMP PROLIX, SWING PROLIX CN-T05
2 20A
CONTROLLER (SOL. PWR), BOOM/OUTRIGGER SOL, TRAILER TIP SOL.
3 10A
PPC LOCK, STARTER CUT RELAY, PERSONAL CODE RELAY REVOLVING FLOOR FRAME
(FROM 14) B
0.85BrB

FRAME
0.5YR
0.85R

0.85R

1.25R

1.25R

1.25R
1.25B

1.25B
0.85Y
0.85B
4 10A
WINDOW WASHER & CIGAR LIGHTER
0.5B

I 3B

CN-H09
5 10A
HORN & POWER MAX SW.
CN-H08

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

6 10A
LOWER WIPER, PRE-HEAT RELAY, DC/DC CONVERTER
1
2
3
4
5
6
7
8

1
2
3
4
5
6
7
8
7 10A S
FLASHING BEACON
3B

M
0.5YR
0.5B
0.85R

0.85R

1.25R

1.25R

1.25R
1.25B

1.25B
0.85Y
0.85B
0.85Br

8 10A
( SPARE FUSE )
9 15A
DIRECTION INDICATOR / FLASHER UNIT

J 10 10A
REFUELING PUMP
11 20A
A/C UNIT
12 5A
CRUISE CONTROL FUSE BOX 2
13 10A
( SPARE FUSE ) 3RW 0.85BR
3R 0.85BR
14 10A
HEATED SEAT, OPT POWER SUPPLY (24V) 3R 0.85GY
0.85RB
15 15A
BREAKER SW. (RH PPC LEVER)
K
16 15A
AIR SEAT COMPRESSOR, CAB INTERIOR LIGHT A

CN-FB2
10A

20A

25A

20A

10A

10A

15A

20A

10A

10A

10A

10A

15A

15A

10A
17 20A

5A

5A

5A

5A

5A
MONITOR, CONTROLLER, STARTER SW, SERVICE CONNECTION
18 15A 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
HAZARD WARNING LAMPS / FLASHER UNIT

2RW
2W

2WL
M CN-W03

1.25RW

0.85RW
CAB GND

0.5RG

0.85W
0.85WR

0.85WR

0.85GY
1.25G

0.85RB

0.85RB
0.85GL

1.25Y
0.85L
1.25R

1.25R
1.25R
1.25B

1.25B

0.85Y
0.85B
1.25B
19 30A
3B

ENGINE CONTROLLER CN-T02

1 1
2 2

CN-F02
20 5A
ENGINE CONTROLLER (KEY SW. ACC)
0.5YR

CN-40
CN-M41
0.5B

CN-M40
1
2

1
2

1
2
1
2
L
1
2

1
2

1
2
1
2

CN-CR1 CN-CR1
1

2
REAR LIMIT SW.

M M M M
0.85GW

0.85GW
0.85LW

0.85LW
0.85Br

0.85G

0.85G
0.85R

0.85R

WIRING TABLE FOR FUSE BOX 2 (CN-FB2)

0.85L

0.85L

FUSE NO. RATED SYSTEM

CN-M50

CN-M51

CN-M03
CN-M02
1 1
2 2

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

1 1
2
3
4
5
6
7
8

1 5A
TRAVEL FNR, TRAVEL PROLIX, REVERSING ALARM
1
2
3
4
5
6
7
8

2
3
4
5
6
7
8

M
1.25R

1.25R

1.25R

1.25R
1.25B

1.25B

1.25B

1.25B

2 10A
PARK BRAKE
3 20A M M
WORK LIGHTS (BOOM & REVO), QUICK COUPLER K
1
2

1
2

1
2

1
2
CN-CR3

CN-CR3
CN-CR2

CN-CR2

4 25A
WORK LIGHTS (OP. CAB FRONT)
1
2

1
2

1
2

1
2

10A
5 20A
WORK LIGHTS (CWT & OP. CAB REAR)
6 5A RADIO / CD / MP3 M M M M
BRAKE LAMPS
7 10A
(OPT - EURO SPEC) ANTENNA
N ROTOTILT CONTROLLER (SWITCHED POWER) SPEAKER SPEAKER
8 10A (LEFT) (RIGHT)
STEER CONTROLLER, STEER SW. PANEL
HEAD LAMP HEAD LAMP
9 5A
AUTOGREASE (LH) (RH)
TO SPEAKER
0.85Y
0.85B

10 15A
HEATED MIRROR (OPTION)
OPERATOR CAB
1.25R
1.25B

CN-F02B

11 20A
ROAD LIGHTS ( MASTER FUSE ) FRONT WORKLAMPS
1
2

12 10A
ROTOTILT CONTROLLER (REGULAR POWER)
(OPTION)
1
2
CN-40B

O
1
2

13 10A
( SPARE FUSE )
DT
1
2

14 10A

WC

WD
WA

WB

ZM
ZG
ZC

ZD

ZH

ZN

ZR
( SPARE FUSE )

ZA

ZB

ZE

ZK

ZP

ZS
ZF

ZT
ZL
M
15 10A
( SPARE FUSE )
16 5A
SIDE LIGHT ( LH )
17 5A
SIDE LIGHT ( RH )
REAR CAB LAMP
W (FROM 14) Z (FROM 24)
18 15A
P DIPPED BEAM
(OPTION)
19 15A
MAIN BEAM 3/4
BEACON LAMP
PW220-8 (06)
20 10A
( SPARE FUSE ) (OPTION) PW200-8 (06)
PW180-8 (06)
PW160-8 (06)
PW148-8 (06)
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23

PW148-8 VEBM720100 90-13

Electrical circuit diagram (cabin 4/4)

A
EMERGENCY PROLIX SWITCHES (RIGHT CONSOLE)

EMERGENCY
EMERGENCY FNR SW
TRAVEL SW RH WRIST CONTROL
1 2 3 4 5 6 LEVER SWITCHES
CN-S96 UP

CN-S95
1 2 3 4 5 6 7 8 9 F
EMERGENCY N MIDDLE SUNSHINE SENSOR WIPER INDICATORS MAIN BEAM / FLASH
HORN WASH
B NORMAL R DOWN FRONT FACE BUTTON SW. TOP FACE BUTTON SW. 050

INDICATOR RIGHT/LEFT
PROPORTIONAL 15 H 15 53C 15 J 53 31B 49A L R 30 56 56B 56A

HIGH BEAM INDICATOR

TELL-TALE

0.85GW

0.85WG
0.85WB
ROAD LIGHTS

0.85W

0.85GR
0.85YG
CONTROL SW.

0.85G
0.85YB
0.85Y

0.85Y
0.85RL
CAMERA BOOM/CARRIAGE AUXILIARY

0.85L

0.85L
EMERGENCY PUMP BREAKER SPARE INDICATORS ON OFF
EMERGENCY ACTIVATION ATT SW HYDRAULICS CRUISE CONTROL OFF LEFT DIPPED BEAM
DRIVE SWITCH SWING SW 1 3 7 4 2 6 8 10 9 + 1 2 3 4 OFF ON
TRAVEL
CN-S21 1 2 3 4 5 6 CN-S22 1 2 3 4 5 6 P-MAX I ACTIVATE I NEUTRAL MAIN BEAM
FNR SW OFF
UP NORMAL EMERGENCY UP 0 NEUTRAL

CN-G101

CN-G103
1 2 3 4 1 2 II RIGHT FLASH
DOWN EMERGENCY NORMAL DOWN II CANCEL 1 2 1 2 1 2 POSITION
F OFF

CN-P15
0.85W

0.85W
0.85GR N 1 2 1 2 1 2

0.85B
0.85B
0.85B

0.85B
0.85RL

0.85LY

0.85L

CN-S120
ON 1 3 7 4 2 6 8 10 9 DIPPED
R

CN-G105
0.5BW

0.5GY
0.5RY

0.5Y
0.5B

0.5B
0.75WG

0.75W

1.0LW

0.5G
1.0P

0.5P

0.5B
0.75R

0.5LB
0.75RL
C

5
1
2
3
4
CN-S121
DTM 1 2

0.75G
0.75BR
1 2

0.75L

BWG
0.5GY

BW

WB
0.5B

BG
BR

BY

W
B

Y
B

Y
COLUMN SWITCH ASSEMBLY L.H.

A 6 7 1 4 5 3 2 7 1 6 2 3 4 5
C
CN-G03 6 7 1 4 5 3 2 7 1 6 2 3 4 5
B CN-G04

0.5Gr
0.5Br

0.5W

0.5W
0.5O

0.5O
0.5G
0.5R

0.5R
0.5Y

0.5B
0.5Y
0.5B
0.5P

0.75RW
0.75WY

0.75YG

0.75GY
0.5BY

0.75G
0.75YR

0.75RB
1.0B

0.75Y

0.75L
D

0.75Br
20K-06
DTM DTM
1 2 3 4 5 6 1 2 3 4 5 6 7 8 9 10 11 12 D 31860
CN-G71 CN-G72

(FROM 14 ) E

E C

0.85GW
0.85WG
0.85WB
0.85GR

0.85GR
0.85YG

0.85YB
0.85RL

0.85RL
0.85LY
0.85W

0.85W

0.85W

0.85G
0.85B
0.85B
0.85B

0.85B

0.85Y
0.85L

0.75RW
0.75WY

0.75YG

0.75GY
0.75BR

0.75YR

0.75RB
0.5BW

0.75Br
1.0LW

0.5GY
0.5RY

0.75G

0.5BY

0.75G
0.75B
0.5LB

0.75Y
0.75L

0.75L

0.5G
1.0P

0.5Y

0.5Y

1.0B
STEERING COLUMN
CN-S28

CN-S29
DT SWP
1
2
3
4
5
6
7
8
9

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

10
11
12
DT DT

10
11
12

10
11
12
13
14
1
2
3
4
5
6
7
8
9

1
2
3
4
5
6
7
8
9
COMPRESSOR
BLOWER RELAY RELAY
CN-G05 CN-G02

F
Q (FROM 14 )
(FROM 14 ) D
(FROM 24 ) T

SYSTEM FUNCTION LAMP

1
2
3
4
5

1
2
3
4
CN-R30

CN-R31

ACTIVATE SYSTEM SW.

1
2
3
4
5

1
2
3
4
QA QB QC QD QE QF QG QH

2RY
0.5LW

0.85W
2Br

0.5BrW
0.5R

0.5R
CIGAR

0.85Br

POWER (+12V)
GND (POWER)
LIGHTER

G MODEL SELECTION SWITCH INFORMATION

CAN_H
CAN_L

EXCEPT GERMANY, FRANCE AND AUSTRIA

PW140-8 PW160-8 PW180-8 PW200/220-8
FB 20E-06-41160 20G-06-41380 20J-06-41120 20K-06-41220
CN-M19 STEERING CONTROLLER

CN-P10
0.85WL FA DT
1 1 DT CN-SC01

1
2
3
4
5
6
0.85B 1.25B
WIPER MOTOR 2 2 1 GND (POWER)
0.75Y
2 POWER (+24V)

0.5O
0.5YR
0.5R

0.5V
0.5L
0.75Y

0.5BrB
3 POWER (+24V)
0.5G
4 RIGHT STEER EPC SOL.
CN-W04

0.5W

0.5W

0.5W

0.5W
0.5W

0.5W

0.5W
0.5W
0.5W

0.5W

0.5W

0.5W
0.5G
5 LEFT STEER EPC SOL.
M ROOM 0.5WB
LEFT SHUT OFF SOL.
M CN-M71 6
1
2
3
4
5
6

H LAMP 0.5Y
RIGHT SHUT OFF SOL.
7
0.85B 1 2 3 4 5 6 7 8 1 2 3 4 5 6 7 8 1 2 3 4 5 6 7 8 1 2 3 4 5 6 7 8
1 1 8 ---
0.5LW

0.5LR
1.25B
0.85YL

ON
0.85L

CAB 0.85WB
MONITOR 2 2 9 ---
GND DT 0.5P
OFF 10 LS DUMP SOL.

FOR GERMANY, FRANCE AND AUSTRIA

0.5L PW140-8 PW160-8 PW180-8 PW200/220-8
SA 11 SYSTEM FUNCTIION LAMP
CA SE
CN-SC02
12 --- 20E-06-31290 20G-06-31420 20J-06-41130 20K-06-41230
1.25B 1.25B A 0.75Y
CN-CM01 070
CB SB 1 1 13 POWER (+24V)
0.5G 0.5G B 0.75Y
CC SC 2 2 14 POWER (+24V)
1.25RY 0.5WB 0.5WB 0.5L
VB+(24V) 1 SD 3 3 15 1 ATT EPC CUT SIG.
1.25RY 0.5Y 0.5Y 0.5LW
VB+(24V) 2 CD SG 4 4 16 KEY SW. (ACC)
1.25B 0.5LW 0.5LW
GND (PWR) 3 CE SF 5 5 17 ---
I 1.25B 0.5W 0.5W
GND (PWR) 4 CF SH 6 6 18 ---

0.5W

0.5W

0.5W

0.5W

0.5W
0.5W

0.5W

0.5W

0.5W
0.5Y 0.5LY 0.5LY 0.5O
WAKE UP (PWR) 5 1 7 7 19 CAN_H

(FROM )
CG SJ

0.5BrW

0.5BW
0.5BR 0.5YR 0.5YR 0.5V

0.5LW

0.5GB
0.5RY
PERSONAL CODE RELAY 6 CH 8 8 20 CAN_L

0.5W
0.5R
4

0.5L
2RY
0.5G 0.5G

2Br
--- 7 CJ SL 9 9 21 ---

2B
0.5L 0.5B 1 2 3 4 5 6 7 8 1 2 3 4 5 6 7 8 1 2 3 4 5 6 7 8 1 2 3 4 5 6 7 8
--- 8 SM 10 10 22 GND (SIGNAL)
0.5Y 0.5V 0.5V
FUEL LEVEL 9 S 11 11 23 ---

CN-AC01
1 2 3 4 5 6 7 8 1 2 3 4 0.5GL 0.5GL 0.5YR

CN-N10
--- 10 SN 12 12 24 ACTIVATE SYSTEM SW.
0.5WL 0.5LG 0.5LG 0.5LG
BATTERY CHARGE 11 1 2 3 4 5 6 7 8 1 2 3 4
SK 13 13 25 2ND SERVICE POT (2)
0.5B 0.5G 0.5G 0.5LY
GND (ANALOGUE) 12 1 14 14 26 2ND SERVICE POT (1)

(FROM )
CK SP
0.5BR 0.5L 0.5B 0.5GL
LAMP SW 13 CL SR 15 15 27 LS PRESSURE SW.
KEY SW(ACC) 14
0.5LW 4 0.5O
16 16
0.5O 0.5W
28 TRAVEL CREEP/LOW SIG.
0.5RW 1.25Y 1.25Y 0.5LgR
J KEY SW(C) 15 SS 17 17 29 PPC LOCK LEVER SW.
PREHEAT 16
0.5R
CM C ST
0.5LgR
18 18
0.5LgR
30 ---

(FROM 14 )
0.5L 0.5L
--- 17 CN SU
0.5P
19 19
0.5P
31 --- F
--- 18 CP A/C UNIT SV 20 20 32 ---
0.5L 0.5L
CR 21 21 33 ---
0.5G
CS 22 22 34 SPEED SENSOR SIG.
CN-CM02 CT 35 ---
070
CU
0.5L
CAMERA ON (JOYSTICK) 1 CV
0.5YB
ENG OIL LEVEL 2 CW
0.5GL
COOLANT LEVEL 3 CX
0.5LR
K AIR CLEANER CLOG 4
0.5RW
CY
SWING LOCK 5 CZ
0.5LY
BUZZER ON SIGNAL 6 C1
--- 7 ON: LOCK ON: LOCK
0.5W
CAN RESISTOR 8
0.5W MJ
C2
OFF: RELEASE OFF: RELEASE
CAN_H 9 C3 PARK BRAKE HAZARD SWING LOCK WORKLAMP(1) WORKLAMP(2) BEACON LOWER WIPER HEATED SEAT
0.5L FUEL SWITCH SWITCH SWITCH SWITCH SWITCH
CAN_L 10 SWITCH SWITCH SWITCH
--- STARTER SWITCH DIAL QUICK COUPLER AUTOGREASE
11 1 2 3 4 5 6 1 2 3 4 5 6 1 2 3 4 5 6 1 2 3 4 5 6 1 2 3 4 5 6 1 2 3 4 5 6 1 2 3 4 5 6 2 6 8 4 1 5 7 10 9 2 6 8 4 1 5 7 10 9 1 2 3 4 5 6 HEATED
--- 12 OFF OFF OFF OFF OFF
B BR R1 R2 C ACC OFF OFF OFF OFF OFF MIRROR
ON ON ON ON ON ON ON ON

CN-E07
R1 ON ON
KOMTRAX CONTROLLER (TH300)
CN-SSW

OFF

CN-S44

CN-S45

CN-S46

CN-S47

CN-S50

CN-S51
CN-S41

CN-S42

CN-S43

1
2
3
4
5
6

1
2
3
4
5
6

1
2
3
4
5
6

1
2
3
4
5
6

1
2
3
4
5
6
L 1 2

1 1
2 2
3 3

1
2
3
4
5
6

1
2
3
4
5
6

1
2
3
4
5
6
CN-CM03

SWP

SWP

SWP

SWP

SWP

SWP
SWP

SWP
070 ACC
CN-CK01

1
2
3
4
5
6

1
2
3
4
5
6

1
2
3
4
5
6

1
2
3
4
5
6

1
2
3
4
5
6
1 2 DT

1
2
3
4
5
6

1
2
3
4
5
6

1
2
3
4
5
6
0.5YB AMP ST 2 6 8 4 1 5 7 10 9 2 6 8 4 1 5 7 10 9

CN-S48

CN-S49
RS232C CD (KOMTRAX) 1
0.5BrW 0.5RY M
RS232C RXD (KOMTRAX) 2 1 POWER (12V)

1.25RW
0.5W

0.5W
0.5WR

0.5WR
0.85WR

0.5RW
0.5LW

0.85W

0.5LW

0.5RG
0.5WB

0.5R

1.25RY
0.85LW
0.85GL
0.85GY

0.85GY
0.5P
0.5B

0.5B

0.5B

0.5Y

0.5B
0.5LR

0.85BY
0.85P

0.85Y

0.5LY

0.5LgR

0.85RL
0.5YB

0.5L
0.85YL
0.5B

0.5P

0.5P
0.5B

0.5B
0.5LgB

0.5YL
0.5L
0.85RW

0.85LW
0.85RY

0.85RB

RS232C SIG (KOMTRAX) NC

0.85R

3 2
0.5B
SIGNAL GND (KOMTRAX) 4 3 RESERVED
0.5RG 0.5RG
SWITCH OUT (KOMTRAX) 5 4 SWITCH OUT
0.5LgY
RS232C RTS (KOMTRAX) 6 5 NC
0.5GL
RS232C TXD (KOMTRAX) 7 6 NC
0.5WL 0.5B
RS232C DTR (KOMTRAX) 8 7 SIGNAL GND
0.5BrR 0.5B E
RS232C DSR (KOMTRAX) 9 8 GND (12V POWER)
0.5BrY 0.5Y A
RS232C CTS (KOMTRAX) 10 9 CONTROL OUTPUT
M 0.5LB 0.5RW C
RS232C RI (KOMTRAX) 11 10 COMMS CH1
0.5B 0.5LW
POWER GND (KOMTRAX) 12 11 COMMS CH2
0.5GY 0.5GY D
INPUT STATUS CH1 13 12 INPUT STATUS CH1
0.5Y 0.5YG
CONTROL OUTPUT 14 13 INPUT STATUS CH2
0.5RW B
COMMS CH1 15 14 NC
0.5LW
COMMS CH2 16
0.5YG
INPUT STATUS CH2 17
0.5RY
POWER (12V) 18 CN-CK02
AMP
0.5YB
1 RS232C CD (KOMTRAX)
0.5BrW
CN-CM04 2 RS232C RXD (KOMTRAX)
N 070 0.5GL
3 RS232C TXD (KOMTRAX)
0.5WL
RESERVED 1 4 RS232C DTR (KOMTRAX)
0.5LgB
RESERVED 2 5 SWITCH SIG (KOMTRAX)
0.5BrR
RESERVED 3 6 RS232C DSR (KOMTRAX)
0.5LgY
RESERVED 4 7 RS232C RTS (KOMTRAX)
0.5BrY
RESERVED 5 8 RS232C CTS (KOMTRAX)
0.5LB
RESERVED 6 9 RS232C RI (KOMTRAX)
RESERVED 7 10 NC
RESERVED 8
RESERVED CN-D06
9
0.5P
RESERVED 10 1 TELECOMMS ANTENNA 1 1
O RESERVED 2 2
0.5L
11
RESERVED 12

CN-CM05 070 DT CN-CC01

SS
0.08V V1 0.5V
CAMERA POWER (8V) 1 1 CAMERA POWER (8V)
0.08R V2 0.5R
CAMERA-1 VIDEO SIG 2 2 CAMERA-1 VIDEO SIG
0.85RW

0.85WR

1.25RW
0.85LW

0.85LW
0.85GY

0.85GY
0.85RY
0.85RB

1.25RY
0.85BY
0.85RL

0.5LgR
0.85YL
0.5RW

0.5WR

V3
0.5WB

0.08O 0.5O
0.85W

0.5LW

0.5RG
0.5GL

0.5YB
0.85R

0.5LR
0.85P

0.5YL

0.85Y

0.5LY
CAMERA-2 VIDEO SIG 3 3 CAMERA-2 VIDEO SIG
0.5R
0.5B

0.5B

0.5P

0.5Y
0.5L

0.5L

0.5L

0.08L V4 0.5L
CAMERA-3 VIDEO SIG 4 4 CAMERA-3 VIDEO SIG
0.5BW
CAMERA POWER GND 5 5 CAMERA POWER GND
P CAMERA GND 1 6
0.08G V5 0.5G
6 CAMERA GND 1 CN-H15 M
10
S
4/4
11
12
1
2
3
4
5
6
7
8
9

1
2
3
4
5
6
7
8
9

1
2
V6
10
11
12
13
14
15
16
17
18
19
20
21
22

0.08Y 0.5Y
CAMERA GND 2 7
0.08B V7 0.5B
7 CAMERA GND 2 090 PW220-8 (06)
CAMERA GND 3 8 8 CAMERA GND 3
CN-H14 CN-H13 PW200-8 (06)
PW180-8 (06)
GPS ANTENNA 1 PW160-8 (06)
(FROM 14) A (FROM34) G PW148-8 (06)

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23

PW148-8 VEBM720100 90-15

Electrical circuit diagram (machine 1/4))

(TO24)
SOLENOID BLOCK
OPT LOWER
A WIPER
CN-V01 DT
A M
BOOM/ARM
CAMERA X 0.75LgR
1 1
SWING CN-S01 0.75B
(HARNESS 2 2 PPC PRESSURE LOCK
ALIGNED 0.5B

VIDEO SIGNAL
DETAILS 1 1
SEE COUNTER SENSOR 0.5GL SWING RH

POWER (8V)
AA AB AC AD AE AF AG AH AK AL AM AN AP AR AS AT AU AV 2 2 CN-V02 DT
WEIGHT 1.SYMBOLS IN THE DRAWING SHOW

+24V

GND
X 0.75GL

SIG
CAMERA) CN-S02 1 1
0.75B 2 STAGE RELIEF R.H DECK FOLLOWING CONNECTORS.

SHIELD
0.5B 2 2

KES0
1 1

GND
U2 0.5GL SWING LH
2 2 CN-V03

LW
DT

LB
0.75LY

B
X

CN-A90
1 1
DT CN-S03 0.75B M YAZAKI "M" TYPE. DT DEUTSCH "HD" TYPE.

CN-G52
SWING BRAKE

CN-CC05
0.5B 2 2
1234 1234 123 1 1 BEACON WORK LAMP
0.5LgW BUCKET DUMP D08056-0XXXX D08192-XXXXX
2 2 CN-V04 (OPT) (OPT)
1234 1234 DT 123 DT
X 0.75WB
CN-S04 1 1
0.75B SUS LOCK

0.5W
2 2

SHIELD

0.5GY
0.75LW

0.5G
0.5B

0.5B
0.5R
B

0.5Y
0.75B

0.75LB
0.75L
1 1 S YAZAKI "S" TYPE. DRC DEUTSCH "DRC" TYPE
0.5LgB BUCKET DIG
2 2 CN-V05 DT
X 0.75BrR PW200 & D08056-1XXXX
CN-S05 0.75B
1 1 PW220
2 2 MERGE / DIVIDE ONLY DT DT
0.5B

CN-L17

CN-L18
1 1 1 2 1 2
DT 0.5BrW ARM DUMP
2 2 CN-V06 DT 1 2 1 2
CN-CC01 X 0.75YG
1 1
L YAZAKI "L" TYPE. HDP DEUTSCH "HDP" TYPE
1
0.5R CN-S06 0.75B TRAVEL NEUTRAL ONLY
CAMERA POWER (8V) 2 2 (HARNESS D08056-2XXXX
0.5Y 0.5B

1.0R
1.0B
0.75Y
0.75B
CAMERA-1 VIDEO SIG. 2 1 1 DETAILS PW148-8
0.5Y 0.5LgR ARM DIG
CAMERA-2 VIDEO SIG. 3 2 2 CN-V07 SEE COUNTER PW160-8
0.5Y DT L.H DECK

PRESSURE SW.
CAMERA-3 VIDEO SIG. 4 X 0.75GR WEIGHT
0.5B CN-S07 1 1
SHIELD 5 0.75B CREEP CAMERA)
CAMERA-1 GND 6
0.5G 0.5B
1 1
2PC BOOM 2 2
PW200 &
X YAZAKI "X" TYPE. 040 AMP 040 TYPE
7
0.5G 0.5LgY
2 2
EXTEND PW220 D08055-0XXXX
CAMERA-2 GND
0.5G ONLY
C CAMERA-3 GND 8 X
CN-S08 OIL TANK BACK UP FUEL LEVEL
CN-V08 TRAVEL FRONT REAR
0.5B 2 PC BOOM 0.75YB
DT
PPC PUMP PUMP
OVERLOAD CAMERA ALARM(OPT) SENSOR
1 1 1 1 CAUTION
SWP U5 0.5LgY RETRACT PRESSURE
CN-A09 2 2 0.75B TRAVEL F/R PRESSURE PRESSURE
SENSOR SWP YAZAKI "SWP" TYPE. 070 AMP 070 TYPE
0.5BrY 2 2 SENSOR SENSOR SENSOR
BOOM RISE PRESSURE 1

GND

GND

G ND
GND
0.5BrR DT CN-S31 D08055-1XXXX

+5V

+5V

+5V
SIG

SI G

SIG
+5V
SIG
BOOM DOWN PRESSURE 2
0.5LgR 0.5GL JOYSTICK CN-V09 DT
ARM DIGGING PRESSURE 3 1 1 0.75BrG WASHER MOTOR
0.5BrW 0.5B 1 1
ARM DUMP PRESSURE. 4 2 2 0.75B BOOM(DOWN)/STABILISER
0.5LgB 2 2

VIDEO SIGNAL
BUCKET DIGGING PRESSURE 5
0.5LgW DT CN-S30 KES0 KES D08027-0XXXX ECO AMP ECONOSEAL J MARK II+

POWER (8V)
BUCKET DUMP PRESSURE 6
0.5GL 0.5LW QUICK CN-V10 DT TYPE
SWING PRESSURE SW. 7 1 1 U7 0.75BrG
1 1

AEX1.25Y
0.5LgY 0.5B COUPLER 0.75B M
8 2 2 BOOM(UP)/STABILISER

SHIELD
SERVICE PRESSURE 2 2
0.75LW U3
9 X

1.0B
ROTOTILT Q/C LOCK SOL.

GND
0.75LR CN-S09

1.0B
1.0B

1.0B
1.0B
GND (ROTOTILT) 10
0.75LY 0.5B TRAVEL
D TILT / ROTATE SOL. 11
0.75BrY 0.5BrW
1 1
(REV) DT
DT KES0 KES1 KES D08027-1XXXX
ROTOTILT EXTRA SOL. 12 2 2 CN-V11 DT X

CN-CC04
DT DT

CN-G164
0.75LG 2.INDICATES TWISTED PAIR.

CN-A54
CN-A56

CN-A51

CN-A52

CN-A53
0.75R

CN-L07

CN-L14
GND (ROTOTILT) 13 X 123 123 123 123 1234 1 2 1 1 2 1 2 1 2

CN-A50
0.75LgR CN-S10 1 1
ROTOTILT TOOL CONNECT 14 0.75B TRANSMISSION CLUTCH SOL
0.5B TRAVEL 2 2 123 123 123 123 1234 1 2 1 1 2 1 2 1 2
--- 15 1 1 JT2 JT2 JT2 JT2
16
0.5BrB
2 2
(FWD)
--- CN-V15 DT

0.5RW

0.75GW
0.5WB

0.5WB

0.5WB

0.5WB

SHIELD
0.5W
0.5GR

0.75WL
0.5G
0 .5 R

1.0R
0.5YB
0.5B

0.5B

0.5B

0.5B

0.5Y

0.5B

1.0B
0.5RL

0.75Y

0.75Y
0 .7 5 B
X 0.75G
SWP CN-S12 1 1
CN-A04 BOOM/ U8 0.75B BACK PRESSURE COMP.
AEX0.75G 0.5B 2 2
PC EPC (+) 1 1 1 STABILIZER

2B
AEX0.75L 0.5BrR
PC EPC (-) 2 2 2 DOWN
AUTOGREASE SUPPLY (24V) 0.75RG
3 X
LS EPC (+) 4
AEX0.75G CN-S13 BOOM/
AEX0.75L U4 0.5B CN-V16 DT
LS EPC (-) 5 1 1 STABILIZER 0.75Y
0.75LgR 0.5BrY 1 1
AUTOGREASE SW. 6 2 2 UP 0.75B
2 2 QUICK COUPLER
2ND SERVICE EPC CTRL LH(+) 0.75GL
7

1 .0 B
E 2ND SERVICE EPC CTRL LH(-) 8
0.75B CN-V21 DT
0.75Y AEX0.75G
AUTOGREASE INDICATOR 9