Pc200-6 - Manual - de Serviço (Sebmoi0201k) - Ing

SEBMOI 0201 K
Shop
Manual
PC200
HYDRAULIC EXCAVATOR
SERIAL NUMBERS PC200-6 - Cl0001 andup
This material is proprietary to Komatsu America International Company and is not to be reproduced, used, or
disclosed except in accordance with written authorization from Komatsu America International Company.
It is our policy to improve our products whenever it is possible and practical to do so. We reserve the right to make
changes or add improvements at any time without incurring any obligation to install such changes on products sold
previously.
Due to this continuous program of research and development, periodic revisions may be made to this publication.
It is recommended that customers contact their distributor for information on the latest revision.
February 1998 Copyright 1998 Komatsu America International Company

CONTENTS
No. of page
01 GENERAL ..,.........................................................=........... 01-l
10 STRUCTURE AND FUNCTION . ... .. .. . ... .. .. ... .. .. .. .. .. ... .. .. .. IO-I
20 TESTING AND ADJUSTING ... .. .. . ... .. .. ... .. ... ... .. .. ... ... .. . .. . 20-I
30 DISASSEMBLY AND ASSEMBLY . .. .. ... ... ... .. .. ... . . ... ... . ... 30-I
40 MAINTENANCE STANDARD ,....,.,.,.,.,........................... 40-I
Es
>
E
LLI
90 OTHERS ........................................................................... 90-l
00-2
0
SAFETY SAFETY NOTICE
SAFETY
SAFETY NOTICE
IMPORTANT SAFETY NOTICE
Proper service and repair is extremely important for safe machine operation. The
service and repair techniques recommended by Komatsu and described in this manual
are both effective and safe. Some of these techniques require the use of tools specially
designed by Komatsu for the specific purpose.
To prevent injury to workers, the symbol A is used to mark safety precautions in this
manual. The cautions accompanying these symbols should always be followed care-
fully. If any dangerous situation arises or may possibly arise, first consider safety, and
take the necessary actions to deal with the situation.
GENERAL PRECAUTIONS 6. Decide a place in the repair workshop to

keep tools and removed parts. Always keep
Mistakes in operation are extremely dangerous. the tools and parts in their correct places.
Read the Operation and Maintenance Manual Always keep the work area clean and make
carefully BEFORE operating the machine. sure that there is no dirt or oil on the floor.
Before carrying out any greasing or repairs, Smoke only in the areas provided for smok-
read all the precautions given on the decals ing. Never smoke while working.
which are fixed to the machine.
When carrying out any operation, always PREPARATIONS FOR WORK

wear safety shoes and helmet. Do not wear
loose work clothes, or clothes with buttons 7. Before adding oil or making any repairs,
missing. park the machine on hard, level ground, and
. Always wear safety glasses when hitting block the wheels or tracks to prevent the
parts with a hammer. machine from moving.
. Always wear safety glasses when grind-
8. Before starting work, lower blade, ripper,
ing parts with a grinder, etc.
bucket or any other work equipment to the
If welding repairs are needed, always have a ground. If this is not possible, insert the
trained, experienced welder carry out the safety pin or use blocks to prevent the work
work. When carrying out welding work, al- equipment from falling. In addition, be sure
ways wear welding gloves, apron, hand to lock all the control levers and hang warn-
shield, cap and other clothes suited for welding signs on them.
ing work.
9. When disassembling or assembling, support
When carrying out any operation with two the machine with blocks, jacks or stands
or more workers, always agree on the oper- before starting work.
ating procedure before starting. Always in-
10. Remove all mud and oil from the steps or
form your fellow workers before starting any
other places used to get on and off the ma-
step of the operation. Before starting work,
chine. Always use the handrails, ladders or
hang UNDER REPAIR signs on the controls
steps when getting on or off the machine.
in the operator’s compartment.
Never jump on or off the machine. If it is
5. Keep all tools in good condition and learn impossible to use the handrails, ladders or
the correct way to use them. steps, use a stand to provide safe footing.
00-3
SAFETY SAFETY NOTICE
PRECAUTIONS DURING WORK 19. Be sure to assemble all parts again in their
original places.
11. When removing the oil filler cap, drain plug Replace any damaged parts with new parts.
or hydraulic pressure measuring plugs, . When installing hoses and wires, be sure
loosen them slowly to prevent the oil from that they will not be damaged by contact
spurting out. with other parts when the machine is be-
Before disconnecting or removing compo- ing operated.
nents of the oil, water or air circuits, first
20. When installing high pressure hoses, make
remove the pressure completely from the
sure that they are not twisted. Damaged
circuit.
tubes are dangerous, so be extremely care-
12. The water and oil in the circuits are hot ful when installing tubes for high pressure
when the engine is stopped, so be careful circuits. Also, check that connecting parts
not to get burned. are correctly installed.
Wait for the oil and water to cool before
21. When assembling or installing parts, always
carrying out any work on the oil or water
use the specified tightening torques. When
circuits.
installing protective parts such as guards,
13. Before starting work, remove the leads from or parts which vibrate violently or rotate at
the battery. Always remove the lead from high speed, be particularly careful to check
the negative (-1 terminal first. that they are installed correctly.
14. When raising heavy components, use a hoist 22. When aligning two holes, never insert your
or crane. fingers or hand. Be careful not to get your
Check that the wire rope, chains and hooks fingers caught in a hole.
are free from damage.
23. When measuring hydraulic pressure, check
Always use lifting equipment which has
that the measuring tool is correctly assem-
ample capacity.
bled before taking any measurements.
Install the lifting equipment at the correct
places. Use a hoist or crane and operate
24. Take care when removing or installing the
slowly to prevent the component from hit-
tracks of track-type machines.
ting any other part. Do not work with any
When removing the track, the track sepa-
part still raised by the hoist or crane.
rates suddenly, so never let anyone stand at
15. When removing covers which are under in- either end of the track.
ternal pressure or under pressure from a
spring, always leave two bolts in position
on opposite sides. Slowly release the pres-
sure, then slowly loosen the bolts to remove.
16. When removing components, be careful not

to break or damage the wiring. Damaged
wiring may cause electrical fires.
17. When removing piping, stop the fuel or oil
from spilling out. If any fuel or oil drips onto
the floor, wipe it up immediately. Fuel or oil
on the floor can cause you to slip, or can
even start fires.
18. As a general rule, do not use gasoline to

wash parts. In particular, use only the mini-
mum of gasoline when washing electrical
parts.
00-4
FOREWORD GENERAL
FOREWORD
GENERAL
This shop manual has been prepared as an aid to improve the quality of repairs by giving the
serviceman an accurate understanding of the product and by showing him the correct way to perform
repairs and make judgements. Make sure you understand the contents of this manual and use it to full
effect at every opportunity.
This shop manual mainly contains the necessary technical information for operations performed in a
service workshop. For ease of understanding, the manual is divided into the following chapters; these
chapters are further divided into the each main group of components.
STRUCTURE AND FUNCTION

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

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

This section explains the order to be followed when removing, installing, disassembling or
assembling each component, as well as precautions to be taken for these operations.
MAINTENANCE STANDARD
This section gives the judgement standards when inspecting disassembled parts.
NOTICE
The specifications contained in this shop manual are subject to change at any
time and without any advance notice. Use the specifications given in the book
with the latest date.
I I
00-5
FOREWORD HOW TO READ THE SHOP MANUAL
HOW TO READ THE SHOP MANUAL
VOLUMES REVISED EDITION MARK
Shop manuals are issued as a guide to carrying When a manual is revised, an edition mark
out repairs. They are divided as follows: (@I@@....) is recorded on the bottom of the
Chassis volume: Issued for every machine model pages.
Engine volume: Issued for each engine series
Electrical volume: Each issued as one

volume to cover all REVISIONS
Attachments volume:
models
Revised pages are shown in the LIST OF RE-
These various volumes are designed to avoid VISED PAGES next to the CONTENTS page.
duplicating the same information. Therefore, to
deal with all repairs for any model , it is neces-
sary that chassis, engine, electrical and attach-
SYMBOLS
ment volumes be available.
So that the shop manual can be of ample prac-
DISTRIBUTION AND UPDATING tical use, important safety and quality portions
are marked with the following symbols.
Any additions, amendments or other changes
will be sent to KOMATSU distributors. Get the
most up-to-date information before you start any
work.
FILING METHOD
1. See the page number on the bottom of the Symbol Item Remarks
page. File the pages in correct order.
Special safety precautions are
2. Following examples show how to read the
page number. A Safety necessary when performing
the work.
Example 1 (Chassis volume):
Special technical precautions
10 -3
or other precautions for pre-
* Caution serving standards are neces-
Item number (IO. Structure sary when performing the
and Function) work.
Consecutive page number for
Weight of parts of systems.
each item. Caution necessary when se-
Weight lecting hoisting wire, or when
Example 2 (Engine volume): working posture is important,
etc.
12 - 5
TT l- Places that require special at-
ighteninc I
Unit number (I. Engine) tention for the tightening
torque torque during assembly.
Item number (2. Testing and
Adjusting) Places to be coated with ad-
-t Consecutive page number for Coat
hesives and lubricants, etc.
each item.
Places where oil, water or fuel
Xl. water must be added, and the ca-
3. Additional pages: Additional pages are indi- pacity.
cated by a hyphen (-1 and number after the
Places where oil or water
page number. File as in the example. Drain must be drained, and quan-
Example: tity to be drained.
IO-4 1Z-203
00-6
FOREWORD HOISTING INSTRUCTIONS
HOISTING INSTRUCTIONS
HOISTING
Slinging near the edge of the hook may
Heavy parts (25 kg or more) must be cause the rope to slip off the hook during
lifted with a hoist, etc. In the DISAS- hoisting, and a serious accident can re-
SEMBLY AND ASSEMBLY section, sult. ,Hooks have maximum strength at
every part weighing 25 kg or more is the middle portion.
indicated clearly with the symbol &
. If a part cannot be smoothly removed from

the machine by hoisting, the following checks
should be made:
I) Check for removal of all bolts fastening 100% 88% 79% 71% 41%
the part to the relative parts. SAW0479
2) Check for existence of another part caus- 3) Do not sling a heavy load with one rope
ing interference with the part to be re- alone, but sling with two or more ropes
moved. symmetrically wound onto the load.
A Slinging with one rope may cause

turning of the load during hoisting,
untwisting of the rope, or slipping of
WIRE ROPES
the rope from its original winding
1) Use adequate ropes depending on the
position on the load, which can re-
weight of parts to be hoisted, referring to
sult in a dangerous accident.
the table below:
Wire ropes 4) Do not sling a heavy load with ropes form-

ing a wide hanging angle from the hook.
(Standard “Z” or “S” twist ropes
without galvanizing) When hoisting a load with two or more
ropes, the force subjected to each rope
Rope diameter -I- Allowable load will increase with the hanging angles. The
table below shows the variation of allow-
mm kN tons
able load kN {kg} when hoisting is made
IO 9.8 1.0 with two ropes, each of which is allowed
11.2 13.7 1.4 to sling up to 9.8 kN II000 kg) vertically,
at various hanging angles.
12.5 15.7 1.6
When two ropes sling a load vertically, up
14 21.6 2.2
to 19.6 kN 12000 kg1 of total weight can be
16 27.5 2.8 suspended. This weight becomes 9.8 kN
18 35.3 3.6 {IO00 kg) when two ropes make a 120”
20 43.1 4.4 hanging angle. On the other hand, two

ropes are subjected to an excessive force
22.4 54.9 5.6
as large as 39.2 kN (4000 kg) if they sling
30 98.1 10.0
a 19.6 kN f2000 kg) load at a lifting angle
40 176.5 18.0 of 150”.
a A A
50 274.6 28.0
60 392.2 40.0
* The allowable load value is estimated to

be one-sixth or one-seventh of the break-
ing strength of the rope used.
I I I I I I
2) Sling wire ropes from the middle portion 30 60 90 120 150
of the hook. Lifting angle (decree) SAD00480
00-7
FOREWORD COATING MATERIALS
COATING MATERIALS
Ir The recommended coating materials such as adhesives, gasket sealants and greases used for
disassembly and assembly are listed below.
* For coating materials not listed below, use the equivalent of products shown in this list.
Categon/ :omatsu code Part No. Q’w Container Main applications, features
l Used to prevent rubber gaskets, rubber

LT-IA 790-129-9030 150 g Tube
cushions, and cock plug from coming out.
l Used in places requiring an immediately

effective, strong adhesive. Used for plas-
20 9 I‘olyethylene
LT-1 B 790-129-9050 tics (except polyethylene, polyprophylene,
(2 pes.) container
tetrafluoroethlene and vinyl chloride), rub-
ber, metal and non-metal.
l Features: Resistance to heat and chemi-

I‘olyethylene cals
LT-2 0994040030 50 g container l Used for anti-loosening and sealant pur-
pose for bolts and plugs.
790-I 29-9060 Adhesive: l Used as adhesive or sealant for metal, glass

(Set of adhe- 1 kg and plastic.
LT-3 sive and iardeninc I Can
hardening agent:
agent) 500 g
Adhesives
F‘olyethylene . Used as sealant for machined holes.
LT-4 790-129-9040 250 g
container
Holtz l Used as heat-resisting sealant for repair-

790-126-9120 75 g Tube
MH 705 ing engine.
l Quick hardening type adhesive

Three bond 1
790-129-9140 50 g
1735 l Used mainly for adhesion of metals, rub-
l Quick hardening type adhesive

l Quick cure type (max. strength after 30 min-
Aron-alpha F‘olyethylene
790-129-9130 29 utes)
201 container
l Used mainly for adhesion of rubbers, plas-
1 tics and metals.
l Features: Resistance to heat, chemicals

Loctite F‘olyethylene
r9A-129-9110 50 cc l Used at joint portions subject to high tem-
648-50 container
peratures.
l Used as adhesive or sealant for gaskets

LG-1 790-129-9010 200 g Tube
and packing of power train case, etc.
. Features: Resistance to heat

. Used as sealant for flange surfaces and
Gasket bolts at high temperature locations, used
sealant to prevent seizure.
LG-3 790-l 29-9070 1 kg Can
. Used as sealant for heat resistance gasket
for high temperature locations such as en-
gine precombustion chamber, exhaust
pipe, etc.
00-8
FOREWORD COATING MATERIALS
Category Komatsu code Part No. o’ty Container Main applications, features
l Features: Resistance to water, oil

l Used as sealant for flange surface, thread.
I LG-4 790-129-9020 200 g Tube l
l
Also possible to use as sealant for flanges
with lame clearance.
Used assealant for mating surfaces of fi-
nal drive case, transmission case.
l Used as sealant for various threads, pipe
LG-5 1790-129-9060 1 1 kg / p;;,$;~;e~. $;;:sf’~;;;raulic piping. plugs, elbows,

Used as sealant for tapered
l Features: Silicon based, resistance to heat,

Gasket cold
sealant LG-6 09940-00011 250 g Tube l Used as sealant for flange surface, tread.
l Used as sealant for oil pan, final drive case,
etc.
l Features: Silicon based, quick hardening

type
LG-7 09920-00 150 150 g Tube l Used as sealant for flywheel housing, in-
take manifold, oil an, thermostat housing,
etc.
Three bond l Used as heat-resisting sealant for repairing

/790-129-90901 100 g / Tube ) engine.
1211
l Used as lubricant for sliding portion (to pre-

LM-G
Molybde- ( ogg40-ooo51 ( ” 9 1 Can ( vent from squeaking).
num
disulphide l Used to prevent seizure or scuffling of the
lubricant LM-P 09940-00040 200 g Tube thread when press fitting or shrink fitting.
l Used as lubricant for linkage, bearings, etc.
SYG2-4OOLI l General purpose type

SYG2-35OLI
G2-LI SYG2-4OOLI-A Various Various
SYG2-160LI
SYGA-16OCNLI
l Used for normal temperature, light load

SYG24OOCA bearing at places in contact with water or
Grease
SYG2-350CA steam.
G2-CA SYGP-4OOCA-A Various Various
SYGPI 60CA
SYGA-IGDCNCA
Molybdenum 400 g l Used for places with heavy load

disulphide SYG2-400M (IO per Belows type
lubricant case)
00-9
FOREWORD STANDARD TIGHTENING TORQUE
STANDARD TIGHTENING TORQUE
STANDARD TIGHTENING TORQUES OF BOLTS AND NUTS

Use these torques for metric bolts and nuts. (Always use torque wrench).
Thread diameter Width

of bolt across flats
I I
mm mm Nm
6 10 13.2+ 1.4 1.3550.15
8 13 31f3 3.2& 0.3
10 17 66f7 6.7k 0.7
12 19 113flO 11.5*1
14 22 177+19 18k2
16 24 279+30 28.5?3
18 27 382f39 39k4
20 30 549f59 56f6
22 32 745f83 76k8.5
24 36 927f103 94.5* 10.5
27 41 1320+140 135k15
30 46 1720+190 175k20
33 50 2210f240 225+25
36 55 2750f290 28Ok30
39 60 3290f340 335k35
Threadof diameter
bolt Widthflats
across 0 07
CDL00373
mm mm Nm kgm
6 10 7.85+ 1.95 0.8k 0.2
8 13 18.6f4.9 1.9*0.5
10 14 40.2+ 5.9 4.1kO.6
12 27 82.35k7.85 8.4f0.8
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 2.5f0.5
03 18 24 49f 19.6 5+2
04 22 27 78.5f 19.6 8+2
05 24 32 137.3f29.4 14+3
06 30 36 176.5f29.4 18f3
10 33 41 196.lf49 20+5
12 36 46 245.2f 49 25+5
14 42 55 294.2f 49 3Ok5
TIGHTENING TORQUE OF SPLIT FLANGE BOLTS

Use these torques for split flange bolts.
mm mm Nm k9m
10 14 65.756.8 6.7kO.7
17 17 112f9.8 11.5fl
is 22 279f29 28.5f3
00-l0
TIGHTENING TORQUE OF O-RING BOSS CONNECTOR

Use these torques for O-ring boss connector

Nominal No.
mm mm Nm kgm
02 14 34.3k4.9 3.5kO.5
03,04 20 Varies depending on 93.1 f 9.8 9.5f 1
05,06 24 type of connector. 142.lf 19.6 14.5f2
IO,12 33 421.4f 58.8 43+6
14 42 877.1f 132.3 89.5k13.5
TIGHTENING TORQUE OF O-RING BOSS CONNECTOR

Thread diameter Width across flat Tighteninc I torque

Nominal No. -S
mm mm Nm km
08 8 14 7.35f 1.47 0.75kO.15
10 10 17 11.27f 1.47 1.15f0.15
12 12 19 17.64k1.96 1.8f0.2
14 14 22 22.54k1.96 2.3f0.2
16 16 24 29.4rf:
4.9 3f0.5
18 18 27 39.2f 4.9 4kO.5
20 20 30 49f 4.9 5zko.5
24 24 32 68.6k9.8 7fl
30 30 32 107.8k14.7 llf1.5
33 33 - 127.4f19.6 13+2
36 36 36 151.9f24.5 15.5f 2.5
42 42 - 210.7f29.4 21.5f3
52 52 - 323.4k44.1 33k4.5
,Sealingsurface
TIGHTENING TORQUES OF FLARE NUT

SAW0483

mm mm Nm km
14 19 24.5f 4.9 2.5kO.5
18 24 49+ 19.6 5f2
22 27 78.5f 19.6 8+2
24 32 137.3k29.4 14+3
30 36 176.5f29.4 18+3
33 41 196.lf49 20f5
36 46 245.2f 49 25+5
42 55 294.2f 49 30*5
00-l 1
TIGHTENING TORQUE FOR 102 SERIES ENGINE (BOLT AND NUTS)

Use these torques for metric bolts and nuts of 102 Series Engine.
Thread diameter Tightening torque

mm Nm kam
6 10 k2 1.02 k 0.20
8 24 f 4 2.45 k 0.41
10 43 IL6 4.38 I!I
0.61
12 77 ? 12 7.85 * 1.22
TIGHTENING TORQUE FOR 102 SERIES ENGINE (EYE JOINTS)

Use these torques for metric eye joints of 102 Series Engine.

mm Nm knm
6 8+2 0.81 + 0.20
8 IOk2 1.02 f 0.20
10 12&Z 1.22 f 0.20
12 24 +4 2.45 f 0.41
14 36 f 5 3.67 f 0.51
TIGHTENING TORQUE FOR 102 SERIES ENGINE (TAPERED SCREWS)

Use these torques for inches tapered screws of 102 Series Engine.

inches Nm kgm
I/ 16 3il 0.31 f 0.10
118 8+2 0.81 f 0.20
l/4 12f2 1.22 f 0.20
318 15+2 1.53 f 0.41
l/2 24 + 4 2.45 f 0.41
314 36 f 5 3.67 f 0.51
1 60 f 9 6.12 ic0.92
00-l2
FOREWORD ELECTRIC WIRE CODE
ELECTRIC WIRE CODE
In the wiring diagrams, various colors and symbols are employed to indicate the thickness of wires.
This wire code table will help you understand WIRING DIAGRAMS.
Example: 5WB indicates a cable having a nominal number 5 and white coating with black stripe.
CLASSIFICATION BY THICKNESS
Applicable circuit
0.85
15
40
60
100
CLASSIFICATION BY COLOR AND CODE
Prior-
ity
a Charging Ground
I
Starting
I
Lighting Instrument Signal Other
Y G L
Black 1 Black I Red Yellow Green Blue
- 1 BW 1 RW YR GW LW
- IBlack &White IRed & WhitE Yellow & Red Green &White Blue & White
- 1 BY 1 RB YB I GR I LR
- IBlack & Yellow/ Red & Black Yellow & Black IG reen & Red I Blue & Red
- 1 BR 1 RY YG GY LY
- I Black & Red IRed & Yellov Yellow & Green Green & Yellow Blue & Yellow
- 1 - 1 RG YL GB LB
- I - IRed & Green Yellow & Blue Green & Black Blue & Black
- 1 - 1 RL Yw GL -
6
- I - I Red&Blue Yellow&White Green & Blue -
00-l 3
FOREWORD CONVERSION TABLE
CONVERSION TABLE
METHOD OF USING THE CONVERSION TABLE

The Conversion Table in this section is provided to enable simple conversion of figures. For
details of the method of using the Conversion Table, see the example given below.
EXAMPLE
. Method of using the Conversion Table to convert from millimeters to inches
1. Convert 55 mm into inches.
(I) Locate the number 50 in the vertical column at the left side, take this as @, then draw a horizontal
line from @.
(2) Locate the number 5 in the row across the top, take this as @I, then draw a perpendicular line
down from @.
(3) Take the point where the two lines cross as 0. This point @ gives the value when converting
from millimeters to inches. Therefore, 55 mm = 2.165 inches.
2. Convert 550 mm into inches.

(1) The number 550 does not appear in the table, so divide by 10 (move the decimal point one place
to the left) to convert it to 55 mm.
(2) Carry out the same procedure as above to convert 55 mm to 2.165 inches.
(3) The original value (550 mm) was divided by 10, so multiply 2.165 inches by 10 (move the decimal
point one place to the right) to return to the original value. This gives 550 mm = 21.65 inches.
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
0 i
.. . . . . . . .. . .1.969
. . . .50 . . . . .. . . . . . ..2.008 . . . . .. . . .. . . .. 2.087
. . . . .. . . . . . . ..2.047 .. . . .. .. . . . .. ..2.126
. . . . . .. . . . . . 12.1651 2.205 2.244 2.283 2.323
@- 2.362 2.402 2.441 2.480 2.520 2.559 2.598 2.638 2.677 2.717
60
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
00-14
FOREWORD CONVERSIONTABLE
Millimeters to Inches
1 mm = 0.03937 in
0 1 2 3 4 5 6 7
8
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 ka = 2.2046 lb
T 0
10
20
0
0
22.05
44.09
1
2.20
24.25
46.30
2
4.41
26.46
48.50
3
6.61
28.66
50.71
4
8.82
30.86
51.91
5
11.02
33.07
55.12
6
13.23
35.27
57.32
7
15.43
37.48
59.53
8
17.64
39.68
61.73
9
19.84
41.89
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
I
70 154.32 156.53 158.73 160.94 163.14 165.35 167.55 169.76 171.96 174.17
80 176.37 178.57 180.78 182.98 185.19 187.39 189.60 191.80 194.01 196.21
90 198.42 200.62 202.83 205.03 207.24 209.44 211.64 213.85 216.05 218.26
00-l 5
Liter to U.S. Gallon

It = 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
Literto U.K. Gallon

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 7.969 7.919 8.139 8.359 8.579
40 8.799 9.019 9.239 9.459 9.679 9.899 10.119 10.339 10.559 10.778
50 10.998 11.281 11.438 11.658 11.878 12.098 12.318 12.528 12.758 12.978
60 13.198 13.418 13.638 13.858 14.078 14.298 14.518 14.738 14.958 15.178
70 15.398 15.618 15.838 16.058 16.278 16.498 16.718 16.938 17.158 17.378
80 17.598 17.818 18.037 18.257 18.477 18.697 18.917 19.137 19.357 19.577
90 19.797 20.017 20.237 20.457 20.677 20.897 21.117 21.337 21.557 21.777
00-16
kgm to ft. lb
1 kgm = 7.233 ft. lb
0 1 2 3 4 5 6 7 8 9
\
0 0 7.2 14.5 21.7 28.9 36.2 43.4 50.6 57.9 65.1
10 72.3 79.6 86.8 94.0 101.3 108.5 115.7 123.0 130.2 137.4
20 144.7 151.9 159.1 166.4 173.6 180.8 188.1 195.3 202.5 209.8
30 217.0 224.2 231.5 238.7 245.9 253.2 260.4 267.6 274.9 282.1
40 289.3 296.6 303.8 311.0 318.3 325.5 332.7 340.0 347.2 354.4
50 361.7 368.9 376.1 383.4 390.6 397.8 405.1 412.3 419.5 426.8
60 434.0 441.2 448.5 455.7 462.9 470.2 477.4 484.6 491.8 499.1
70 506.3 513.5 520.8 528.0 535.2 542.5 549.7 556.9 564.2 571.4
80 578.6 585.9 593.1 600.3 607.6 614.8 622.0 629.3 636.5 643.7
90 651.0 658.2 665.4 672.7 679.9 687.1 694.4 701.6 708.8 716.1
100 723.3 730.5 737.8 745.0 752.2 759.5 766.7 773.9 781.2 788.4
110 795.6 802.9 810.1 817.3 824.6 831.8 839.0 846.3 853.5 860.7
120 868.0 875.2 882.4 889.7 896.9 904.1 911.4 918.6 925.8 933.1
130 940.3 947.5 954.8 962.0 969.2 976.5 983.7 990.9 998.2 1005.4
140 1012.6 1019.9 1027.1 1034.3 1041.5 1048.8 1056.0 1063.2 1070.5 1077.7
150 1084.9 1092.2 1099.4 1106.6 1113.9 1121.1 1128.3 1135.6 1142.8 1150.0
160 1157.3 1164.5 1171.7 1179.0 1186.2 1193.4 1200.7 1207.9 1215.1 1222.4
170 1129.6 1236.8 1244.1 1251.3 1258.5 1265.8 1273.0 1280.1 1287.5 1294.7
180 1301.9 1309.2 1316.4 1323.6 1330.9 1338.1 1345.3 1352.6 1359.8 1367.0
190 1374.3 1381.5 1388.7 1396.0 1403.2 1410.4 1417.7 1424.9 1432.1 1439.4
00-l 7
kg/cm* to lb/in*
1 kg/cm* = 14.2233 lb/in*
d
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
IO 142.2 156.5 170.7 184.9 199.1 213.4 227.6 241.8 256.0 270.2
20 284.5 298.7 312.9 327.1 341.4 355.6 369.8 384.0 398.3 412.5
30 426.7 440.9 455.1 469.4 483.6 497.8 512.0 526.3 540.5 554.7
40 568.9 583.2 597.4 611.6 625.8 640.1 654.3 668.5 682.7 696.9
50 711.2 725.4 739.6 753.8 768.1 782.3 796.5 810.7 825.0 839.2
60 853.4 867.6 881.8 896.1 910.3 924.5 938.7 953.0 967.2 981.4
70 995.6 1010 1024 1038 1053 1067 1081 1095 1109 1124
80 1138 1152 1166 1181 1195 1209 1223 1237 1252 1266
90 1280 1294 1309 1323 1337 1351 1365 1380 1394 1408
100 1422 1437 1451 1465 1479 1493 1508 1522 1536 1550
110 1565 1579 1593 1607 1621 1636 1650 1664 1678 1693
120 1707 1721 1735 1749 1764 1778 1792 1806 1821 1835
130 1849 1863 1877 1892 1906 1920 1934 1949 1963 1977
140 1991 2005 2020 2034 2048 2062 2077 2091 2105 2119
150 2134 2148 2162 2176 2190 2205 2219 2233 2247 2262
160 2276 2290 2304 2318 2333 2347 2361 2375 2389 2404
170 2418 2432 2446 2460 2475 2489 2503 2518 2532 2546
180 2560 2574 2589 2603 2617 2631 2646 2660 2674 2688
190 2702 2717 2731 2745 2759 2773 2788 2802 2816 2830
200 2845 2859 2873 2887 2901 2916 2930 2944 2958 2973
210 2987 3001 3015 3030 3044 3058 3072 3086 3101 3115
220 3129 3143 3158 3172 3186 3200 3214 3229 3243 3257
230 3271 3286 3300 3314 3328 3343 3357 3371 3385 3399
240 3414 3428 3442 3456 3470 3485 3499 3513 3527 3542
00-l 8
FOREWORD CONVERSION TABLE
Temperature
Fahrenheit-Centigrade Conversion ; a simple way to convert a Fahrenheit temperature reading into a Centigrade tempera-
ture reading or vice versa is to enter the accompanying table in the center or boldface column of figures.
These figures refer to the temperature in either Fahrenheit or Centigrade degrees.
If it is desired to convert from Fahrenheit to Centigrade degrees, consider the center column as a table of Fahrenheit
temperatures and read the corresponding Centigrade temperature in the column at the left.
If it is desired to convert from Centigrade to Fahrenheit degrees, consider the center column as a table of Centigrade values,
and read the corresponding Fahrenheit temperature on the right.
1°C = 33.8”F
“C “F “C “F “C “F “C “F
-40.4 -40 -40.0 -11.7 11 51.8 7.8 46 114.8 27.2 81 117.8

-37.2 -35 -31.0 -11.1 12 53.6 8.3 47 116.6 27.8 82 179.6
-34.4 -30 -22.0 -10.6 13 55.4 8.9 46 118.4 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 -6 17.6 -2.8 27 80.6 16.7 62 143.6 36.1 97 206.6
-21.7 -7 19.4 -2.2 28 82.4 17.2 63 145.4 36.7 98 208.4
-21.1 -6 21.2 -1.7 29 84.2 17.8 64 147.2 37.2 99 210.2
-20.6 -5 23.0 -1.1 30 86.0 18.3 65 149.0 37.8 100 212.0
-20.0 -4 24.8 -0.6 31 87.8 18.9 66 150.8 40.6 105 221.0

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

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

-13.9 7 44.6 5.6 42 107.6 25.0 77 170.6 71.1 160 320.0
-13.3 8 46.4 6.1 43 109.4 25.6 78 172.4 73.9 165 329.0
-12.8 9 48.2 6.7 44 111.2 26.1 79 174.2 76.7 170 338.0
-12.2 10 50.0 7.2 45 113.0 26.7 80 176.0 79.4 175 347.0
00-19
01 GENERAL
Specification dimension drawings ............. Ol- 2

Specifications.. .............................................. Ol- 4
Weight table ................................................ Ol- 6
Fuel, coolant and lubricants.. ..................... Ol- 8
01-l
GENERAL SPECIFICATION DIMENSION DRAWINGS
SPECIFICATION DIMENSION DRAWINGS

Unit: mm
9425
6685 2740
I-
SLIP03963
* The values marked % are for shovel operations.
01-2
GENERAL SPECIFICATIONS
SPECIFICATIONS
Machine model PC200-6
Serial Number f Cl0001 and up
Bucket capacity m3 0.8
Operating weight f kg 19,880
Max. digging depth mm 6,620
Max. vertical wall depth mm 5,980
Max. digging reach mm 9,875
Max. reach at ground level mm 9,700
Max. digging height mm 9,305
Max. dumping height mm 6,475
Max. digging force kN (kg} 111.7 {I I,4001
Swing speed rpm 12.4
Swing max. slope angle deg. 20
Travel speed km/h Hi: 5.5 Lo: 3.8
Gradeability deg. 35
Ground pressure :Pa {kg/cm* 34.3 (0.351
(standard triple grouser shoe width: 800mm
Overall length (for transport) mm 9,425
Overall width mm 3,000
Overall width of track mm 3,000
Overall height (for transport) mm 2,970
Overall height to chassis mm 2,905
Ground clearance to bottom of upper structure mm 1,085
Min. ground clearance mm 440
Tail swing radius mm 2,750
Min. swing radius of work equipment mm 3,630
Height of work equipment at min. swing radius mm 7,570
Length of track on ground mm 3,270
Track gauge mm 2,200
Height of machine cab mm 2,255
01-4
0
GENERAL SPECIFICATIONS
Machine model
Serial Number
I PC200-6
Cl0001 and up
Model S6D102-1
Type 4-cycle; water-cooled, in-line, vertical,

diredt injection, with turbocharger
No. of cylinders - bore x stroke mm 6-102x120

Piston displacement e ICC} 5.883 (5,883)
Flywheel horsepower kW/rpm (HP/rpmI 95.6/2,000 {I 28/2,0001
E
2 Max. torque Vmlrpm {kgmhpm~ 548.8/1,350 {56/I ,350)
k Max. speed at no load vm 2,200
5 Min. speed at no load t-pm 970
a
Min. fuel consumption g/kWh {g/HPhI 218 (160)
Starting motor 24V, 4.5 kW
Alternator 24V, 35A
Batterv 12V, 110 Ah x 2
Radiator core tvoe cwx-4
Carrier roller 2 on each side
Track roller 7 on each side
Track shoe Assembly-type
triple grouser, 45 on each side
Type x no. HPV95+95, variable displacement

piston type x 2
Deliverv 4?/min Piston type: 206 x 2

Type x No. 6-spool type x 1
Control method Hydraulic type
Travel motor HMVI 10-2, Piston type
(with brake valve, parking brake) x 2
Swing motor KMFgOAB-3, Piston type

(with safety valve, parking brake) x 1
Boom Arm Bucket
Type qeciprocating fqeciprocating Reciprocating

piston piston piston
Inside diameter of cylinder mm 120 135 115
Diameter of piston rod mm 85 95 80
Stroke mm 1,285 1,490 1,120
Max. distance between pins mm 3,155 3,565 2,800
Min. distance between pins mm 1,870 /- 2,075 1,680
Hydraulic tank Box-shaped, open
Hydraulic filter Tank return side
Hydraulic cooler Air cooled (CFT-1)
01-5
0
GENERAL WEIGHT TABLE
WEIGHT TABLE
a This weight table is for use when handling components or when transporting the machine.
Unit: kg

...
Serial Number Cl0001 and up
Engine assembly 742
l Engine 535
l Damper 6
l Hydraulic pump 145
Radiator, oil cooler assembly 109
Hydraulic tank, filter assembly (excl. hydraulic oil) 136
Fuel tank (excl. fuel) 122
Revolving frame 1,556
Operator’s cab 191
Operator’s seat 13
Counterweight 3,750
Swing machinery 164 $

>
8
Control valve 166 LLJ
Swing motor 53
Travel motor 98 x 2
Center swivel joint 42
Track frame assembly 4,280
l Track frame 2,158
l Swing circle 276
l Idler 140x2
l Idler cushion 135 x 2
l Carrier roller 21 x 4
l Track roller 38x 14
l Final drive (incl. travel motor) 340 x 2
01-6
0
GENERAL WEIGHT TABLE
Unit: kg
Serial Number Cl0001 and up
Track shoe assembly
l Triple grouser shoe (800 mm) 1,565 x 2
Boom assembly 1,334
Arm assembly 620
Bucket assembly 619
Boom cylinder assembly 176x 2
Arm cylinder assembly 244
Bucket cylinder assembly 148
Link assembly (large) 68
Link assembly (small) 22 x 2

I
Boom pin 43 + 10 x 2 + 25 + 10 + 20
I
Arm pin
Bucket pin
Link pin
01-7
0
GENERAL FUEL, COOLANT AND LUBRICANTS
FUEL, COOLANT AND LUBRICANTS
AMBIENT TEMPERATURE CAPACITY (t)

<IND OF
RESERVOIR -22 -4 14 32 50 68 86 104°F
FLUID
20
.
.s
Specified Refill
Engine oil pan I 26.3 24.0
Iv;
Damper case 0.75

t
Swing machinery case 5.5 5.5
Final drive case (each side) Engine 4.4 4.2

oil
Idler (1 each) 0.07 - 0.08 0.07 - 0.08
Track roller (I each) 0.19 - 0.21 3.19 - 0.21
Carrier roller (1 each) 0.23 - 0.25 3.23 - 0.25
Hydraulic system 239
iydraulic
oil
Diesel
Fuel tank 340
fuel
Cooling system Coolant Add antifreeze 22.2
01-8
GENERAL FUEL, COOLANT AND LUBRICANTS
NOTE:
(I) When fuel sulphur content is less than 0.5%,
change oil in the oil pan every periodic main-
tenance hours described in this manual.
Change oil according to the following table
if fuel sulphur content is above 0.5%.
Change interval of oil in

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

temperature of lower than O”C, be sure to
use engine oil of SAEIOW, SAEIOW-30 and
SAE15W-40, even though an atmospheric
temperature goes up to 10°C more or less in
the day time.
(3) Use API classification CD as engine oil and if
API classification CC, reduce the engine oil
change interval to half.
g (4) There is no problem if single grade oil is
> mixed with multigrade oil (SAEIOW-30, 15W-
z
0 401, but be sure to add single grade oil that
matches the temperature in the table on the
left.
(5) We recommend Komatsu genuine oil which
has been specifically formulated and ap-
proved for use in engine and hydraulic work
equipment applications.
* For the H046-HM, use the oil recommended
by Komatsu.
ASTM: American Society of Testing and Material

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

ing oil for components and
oil in piping.
Refill capacity: Amount of oil needed to refill
system during normal inspection
and maintenance.
01-9
10 STRUCTURE AND FUNCTION
Engine related parts.. ................................. IO- 2

Radiator loil cooler l aftercooler ............. IO- 3
Engine control ............................................ IO- 4
Power train ................................................. IO- 5
Final drive ................................................... IO- 6
Swing circle ................................................ IO- 7
Swing machinery ....................................... IO- 8
Track frame l recoil spring.. ...................... IO- 9
Track shoe.. ................................................. IO- 10
Hydraulic piping drawing .......................... IO- 12
Hydraulic circuit diagram .......................... IO- 13
Hydraulic tank.. ........................................... IO- 14
Hydraulic pump.. ........................................ IO- 15
Control valve .............................................. IO- 34
Self-reducing pressure valve .................... IO- 42
CLSS ............................................................ IO- 47
Swing motor.. ............................................. IO- 66
Center swivel joint ..................................... IO- 70
Travel motor ............................................... IO- 72
Valve control ............................................... IO- 81
Work equipment l swing PPC valve ........ IO- 82
Travel PPC valve ........................................ IO- 86
Service PPC valve ...................................... IO- 90
Accumulator ................................................ IO- 93
Straight-travel system.. .............................. IO- 94
EPC solenoid valve .................................... IO- 95
Boom holding valve.. ................................. IO- 97
Additional filter for breaker.. ..................... IO-100
Work equipment.. ....................................... IO-101
Actual electrical wiring diagram.. ............. IO-102
Electrical circuit diagram ........................... IO-104
Electric control system .............................. IO-106
Machine monitor system.. ......................... IO-I 12
Sensors ....................................................... 1 O-l 15
10-l
STRUCTURE AND FUNCTION ENGINE RELATED PARTS
ENGINE RELATED PARTS
A-A
io ‘9
B-0 D-D E-E
SAB02598
1. Drive plate OUTLINE

2. Torsion spring . The damper assembly is a wet type.
3. Stopper pin Oil capacity: 0.75 e
4. Friction plate
5. Damper assembly
6. Air cleaner
7. intake connector
8. Muffler
9. Rear engine mount
10. Front engine mount
1o-2
STRUCTURE AND FUNCTION RADIATOR l OIL COOLER l AFTERCOOLER
RADIATOR l OIL COOLER l AFTERCOOLER
SAP03200
1. Reservoir tank SPECIFICATIONS

2. Oil cooler Radiator : cwx-4
3. Radiator Oil cooler : CFT-1
4. Fan
5. Radiator inlet hose
6. Radiator outlet hose
7. Radiator cap
8. Net
9. Shroud
1o-3
STRUCTURE AND FUNCTION ENGINE CONTROL
ENGINE CONTROL
SBPO3244
Lever position
1. Stopper @ STOP
2. Engine control lever @ Low idling
3. Control cable @ High idling
4. Fuel injection pump
1o-4
STRUCTURE AND FUNCTION POWER TRAIN
POWER TRAIN
SBPO260 I
1. Idler 7. Engine (S6D102-1)

2. Center swivel joint 8. Travel speed solenoid valve
3. Control valve 9. Swing brake solenoid valve
4. Final drive 10. Swing motor (KMFgOAB-3)
5. Travel motor (HMVIIO-2) 11. Swing machinery
6. Hydraulic pump (HPV95+95) 12. Swing circle
1o-5
STRUCTURE AND FUNCTION FINAL DRIVE
FINAL DRIVE
I. Level plug
2. Drain plug
3. Cover
4. No. 2 sun gear (No. of teeth: 21)
5. No. 1 sun gear (No. of teeth: IO)
4. No. 1 planetary carrier
6. Cover
8. Sprocket
9. Floating seal
IO. Travel motor
11. Hub
12. No. 2 planetary gear (No. of teeth: 36)
13. Ring gear (No. of teeth: 95)
14. No. 1 planetary gear (No. of teeth: 42)
SPECIFICATIONS
Reduction ratio: - QQg%x(~)+,

= -57.000
/IO
___________
12 II
A-A
SAP0 1244
1O-6
STRUCTURE AND FUNCTION SWING CIRCLE
SWING CIRCLE
A-A
__--.
I’
I
3
I
B-B
SAP00049
1. Swing circle inner race (No. of teeth: 110) SPECIFICATIONS

2. Ball Reduction ratio. llo = 7 333
3. Swing circle outer race -15 .
Amount of grease: 21 k?(G2-LI)
a. Inner race soft zone S position
b. Outer race soft zone S position
1o-7
STRUCTURE AND FUNCTION SWING MACHINERY
SWING MACHINERY
1. Swing pinion (No. of teeth: 15)

2. Cover
3. Case
5. No. 2 sun gear
6. No. 1 ring gear
7. No. 1 sun gear
8. Swing motor
9. Oil level gauge
10. No. 1 planetary gear
12. No. 2 planetary gear
13. Drain plug
SPECIFICATIONS
x 27 + 101
Reduction ratio: 22 z210’
27
= 26.505
I- A-A
SAP02602
1 O-8
STRUCTURE AND FUNCTION TRACK FRAME l RECOIL SPRING
TRACK FRAME l RECOIL SPRING
A-A
SAP02603
1. Idler . The dimensions and number of track rollers

2. Track frame may differ according to the model, but the
3. Carrier roller basic structure is the same.
4. Final drive
5. Track roller . No. of track rollers: 7 (each side)
6. Track shoe
7. Center guard
8. Recoil spring
9. Front guard
1o-9
STRUCTURE AND FUNCTION TRACK SHOE
TRACK SHOE
STANDARD SHOE
Shoe width
(triole shoe) I 800 mm
Link pitch 190 mm

I
No. of shoe
45
(each side)
SELECTION OF TRACK SHOE
I PC200-6
r-- .
Specifications Category
Standard]-
800 mm triple I c
Category Use Precautions when using
Rocky ground, l Travel in Lo speed when traveling on rough ground with obstacles
A
normal river soil such as large boulders and fallen trees.
$
Cannot be used on rough ground where there are large obstacles g
such as boulders and fallen trees. :
Normal soil,
B Travel in Hi speed only on flat ground; when it is impossible to
soft land
avoid traveling over obstacles, lower the travel speed to approx.
half of Lo speed.
l Use only for ground where “A” and “B” sink and are impossible
to use.
l Cannot be used on rough ground where there are large obstacles
C such as boulders and fallen trees.
l Travel in Hi speed only on flat ground; when it is impossible to
avoid traveling over obstacles, lower the travel speed to approx.
half of Lo speed.
D Paved surface l The shoes are flat, so they have low gradeability.
l The shoes are made of rubber, so be careful when traveling on

E Paved su r-face rough ground.
j, Categories “B” and “C” are wide shoes, so * When selecting the shoe width, select the
there are restrictions on their use. There- narrowest shoe possible within the range
fore, before using, check the restrictions and that will give no problem with flotation and
consider carefully the conditions of use be- ground pressure.
fore recommending a suitable shoe width. If If a wider shoe than necessary is used, there
necessary, give the customer guidance in will be a large load on the shoe, and this
their use. may lead to bending of the shoe, cracking of
the links, breakage of the pins, loosening of
the shoe bolts, or other problems.
10-10
0
1. Bucket cylinder
2. Arm cylinder
3. Boom cylinder
4. Hydraulic tank
5. Hydraulic filter
6. Filter (for breaker)
7. Swing motor
8. R.H. travel motor
9. Hydraulic pump
IO. Control valve
11. Junction box
12. Oil cooler
13. L.H. travel motor
14. Arm holding valve
15. Boom holding valve
16. L.H. PPC valve
17. R.H. PPC valve
18. Center swivel joint
19. Travel PPC valve
20. Service PPC valve
21. Accumulator
22. EPC solenoid valve
22A. PPC lock solenoid valve
228. Swing brake solenoid valve
22C. 2 step relief solenoid valve
22D. Travel speed solenoid valve
E20Y06
STRUCTURE AND FUNCTION HYDRAULIC CIRCUIT DIAGRAM
HYDRAULIC CIRCUIT DIAGRAM

* For details of this page, see page 90-5.
STRUCTURE AND FUNCTION HYDRAULIC TANK
HYDRAULIC TANK
SAP02608
1. Sight gauge SPECIFICATIONS

2. Hydraulic tank Tank capacity: 239 .J?
3. Bypass valve Amount of oil inside tank: 166 .Q
4. Filter element Pressure valve
5. Oil filler cap Relief cracking pressure:
6. Hydraulic oil level sensor 16.7 f 3.9 kPa
7. Suction strainer (0.17 2 0.04 kg/cm?
Suction cracking pressure:
0 - 0.49 kPa
(0 - 0.005 kg/cm*}
Bypass valve set pressure:
102.9 f 19.6 kPa
(1.05 + 0.2 kg/cm21
10-14
STRUCTURE AND FUNCTION HYDRAULIC PUMP
HYDRAULIC PUMP
I 2 3 4 3 2
a f
h i i k Q
/
m
5 SAP03204
1. Front main pump PdlF port (pump drain)

2. PC valve it: PenF port (front control pressure detection)
3. LS valve PBF port (pump pressure input)
4. Rear main pump i. PAF port (front pump delivery)
5. PC-EPC valve PAR port (rear pump delivery)
F’ PenR port (rear control pressure detection)
g*
h.
Psig port (LS set selector pilot)
Im (PC mode selector current)
Outline
l This pump consists of 2 variable capacity i. PLSR port (rear load pressure input)
swash plate piston pumps, a PC valve, LS j. lsig (LS set selector current)
valve, and PC-EPC valve. k. PLSF port (front load pressure input)
I. EPC basic pressure detection port
m. Ps port (pump suction)
10-15
MAIN PUMP
HPV95+95
e SAP02786
a. PdlF port (pump drain)

b. PBF port (pump pressure input)
c. PAF port (front pump delivery)
d. PAR port (rear pump delivery)
e. Ps port (suction)
lo-16
HYDRAULIC PUMP
A-A
B-B
7. Cylinder block
1. Shaft (front)
8. Valve plate
2. Cradle
9. End cap
3. Case (front)
10. Shaft (rear)
4. Rocker cam
11. Case (rear)
5. Shoe
12. Servo piston
6. Piston
10-17
SPI ine Spline ij
SAP03438
Function
. The rotation and torque transmitted to the . Rocker cam (4) has flat surface A, and shoe
pump shaft is converted into hydraulic en- (5) is always pressed against this surface
ergy, and pressurized oil is discharged ac- while sliding in a circular movement.
cording to the load. Rocker cam (4) brings high pressure oil at
. It is possible to change the discharge amount cylindrical surface B with cradle (21, which is
by changing the swash plate angle. secured to the case, and forms a static pres-
sure bearing when it slides.
Structure . Piston (6) carries out relative movement in
. Cylinder block (7) is supported to shaft (I) the axial direction inside each cylinder cham-
by a spline, and shaft (I) is supported by the ber of cylinder block (7).
front and rear bearings. l The cylinder block seals the pressure oil to
l The tip of piston (6) is a concave ball, and valve plate (8) and carries out relative rota-
shoe (5) is caulked to it to form one unit. tion. This surface is designed so that the oil
Piston (6) and shoe (5) form a spherical bear- pressure balance is maintained at a suitable
ing. level. The oil inside each cylinder chamber
of cylinder block (7) is sucked in and dis-
charged through valve plate (8).
lo-18
Operation
1) Operation of pump
i)- Cylinder block (7) rotates together with
shaft (I), and shoe (5) slides on flat sur-
face A.
When this happens, rocker cam (4)
moves along cylindrical surface B, so
angle 01 between center line X of rocker
cam (4) and the axial direction of cylin-
der block (7) changes. (Angle a is called
the swash plate angle.)
ii) Center line X of rocker cam (4) main-
tains swash plate angle a in relation to
the axial direction of cylinder block (71, sDPo14o9
and flat surface A moves as a cam in
relation to shoe (5).
In this way, piston (6) slides on the in-
side of cylinder block (71, so a difference
between volumes E and F is created in-
side cylinder block (7). The suction and
discharge is carried out by this differ-
ence F - E.
In other words, when cylinder block (7)
rotates and the volume of chamber E
becomes smaller, the oil is discharged
during that stroke. On the other hand,
the volume of chamber F becomes larger, SDP01410
and as the volume becomes bigger, the
oil is sucked in. F
iii) If center line X of rocker cam (4) is in
line with the axial direction of cylinder
block (7) (swash plate angle = 0), the
difference between volumes E and F in-
side 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.)
7
SDPOl41 I
10-19
2) Control of discharge amount

. If swash plate angle a becomes larger,
the difference between volumes E and F
becomes larger and discharge amount
Cl increases.
l Swash plate angle 0: is changed by servo
piston (12).
. Servo piston (12) moves in a reciprocal
movement (~1 according to the signal
pressure from the PC and LS valves. This
straight line movement is transmitted
through rod (13) to rocker cam (4), and
rocker cam (4), which is supported by
the cylindrical surface to cradle (2), slides
ina rotating movement in direction Cc).
. With servo piston (12), the area receiv-
SDP01412
ing the pressure is different on the left
and right, so main pump discharge pres-
sure (self pressure) PP is always brought
to the chamber receiving the pressure at
the small diameter piston end.
Output pressure Pen of the LS valve is
brought to the chamber receiving the
pressure at the large diameter piston end.
The relationship in the size of pressure
PP at the small diameter piston end and
pressure Pen at the large diameter end,
and the ratio between the area receiving
the pressure of the small diameter pis-
ton and the large diameter piston con-
trols the movement of servo piston (12).
SAP02789
1O-20
LS VALVE
a
SDP01414
a. Port PLS (control valve LS pressure inlet port) 1. Plug

b. Port PA (pump discharge pressure inlet port) 2. Locknut
c. Port PLP (LS valve signal pressure outlet port) 3. Sleeve
d. Port PPL (PC valve signal pressure outlet port) 4. Spring
e. Port Pa (drain pressure outlet port) 5. Seat
f. Port Psig (LS control EPC valve output pressure inlet port) 6. Spool
g. Port PA (pump discharge pressure inlet port) 7. Piston
8. Sleeve
E
t
%
PC VALVE
a b C d
SDP01415
a. Port Pa (drain pressure outlet port) 1. Piston 7. Piston

b. Port PPL (PC valve signal pressure outlet port) 2. Spring 8. Sleeve
c. Port PA (pump discharge pressure inlet port) 3. Seat 9. Locknut
d. Port PA2 (pump discharge pressure inlet port) 4. Spring 10. Plug
e. Port PM (PC mode selector pressure inlet port) 5. Seat 11. Locknut
6. Spool
1o-21
Function
(11 LS valve
The LS valve detects the load and controls (Urnin)
the discharge amount. I
This valve controls main pump discharge
amount 0 according to differential pressure
APLS (=PP - PLS) [called the LS differential
pressure] (the difference between main
pump pressure PP and control valve outlet
port pressure PLS). j \
Main pump pressure PP, pressure PLS {called
the LS pressure] sent by the control valve
2. 2(22. 51 iMPa(t~/cm’l)
output, enter this valve. The relationship be- LS differential Pressure APLS
tween discharge amount 0 and differential SAP03818
pressure APLS, (the difference between main

pump pressure PP and LS pressure PLS) (=
PP - PLS) changes as shown in the diagram
on the right.
(21 PC valve
When the pump discharge pressure PPI (self-
pressure) and PP2 (other pump pressure) are
high, the PC valve controls the pump so that
no more oil than the constant flow (in ac-
cordance with the discharge pressure) flows
even if the stroke of the control valve be-
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. Pump discharge (PPl tPP2) /2
In other words, if the load during the opera- Pressure averaoe
SAP03440
tion becomes larger and the pump discharge
pressure rises, it reduces the discharge
amount from the pump; and if the pump
discharge pressure drops, it increases the
discharge amount from the pump. The rela-
tionship between the average of the front
and rear pump discharge pressures (aver-
age discharge amount of F, R pumps (PPI +
PP2)/2) and pump discharge amount 0 is
shown on the right, with the current given
to the PC-EPC valve solenoid shown as a
parameter. The pump controller senses the
actual speed of the engine, and if the speed
drops because of an increase in the load, it
reduces the pump discharge amount to al-
low the speed to recover. In other words,
when the load increases and the engine
speed drops below the set value, the com-
mand current to the PC-EPC valve solenoid
from the controller increases according to
the drop in the engine speed to reduce the
pump swash plate angle.
10-22
OPERATION
PT
Minimum direction SAP04077
(1) LS valve
1) When control valve is at neutral position of the piston from port K, and the same
The LS valve is a three-way selector valve, pump pressure PP also enters port J at the
with pressure PLS (LS pressure) from the small diameter end of the piston, so the
inlet port of the control valve brought to swash plate is moved to the minimum angle
spring chamber B, and main pump discharge by the difference in area of piston (II).
pressure PP 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
pressure) PP determines the position of spool
(6).
Before the engine is started, servo piston
(11) is pushed to the right. (See the diagram
on the right)
When the engine is started and the control
lever is at the neutral position, LS pressure
PLS is 0 MPa (0 kg/cm?. (It is interconnected
with the drain circuit through the control
valve spool.)
At this point, spool (6) is pushed to the left,
and port C and port D are connected. Pump w SOP03713
pressure PP enters the large diameter end A-A
1 O-23
Maximum direction SAP04078
21 Operation in maximum direction for pump

discharge amount
. When the difference between main pump l For this reason, the pressure at the large
pressure PP and LS pressure PLS, in other diameter end of servo piston (11) becomes
words, LS differential pressure APLS, be- drain pressure PT, and pump pressure PP
comes smaller (for example, when the area enters port J at the small diameter end, so
of opening of the control valve becomes servo piston (11) is pushed to the right.
larger and pump pressure PP drops), spool Therefore, the swash plate moves in the di-
(6) is pushed to the right by the combined rection to make the discharge amount larger.
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 con-
nected to the drain port, so circuit D - K
becomes drain pressure PT. (The operation
of the PC valve is explained later.)
1 O-24
3) Operation in minimum direction for pump

discharge amount
l The following explains the situation if servo . Main pump pressure PP also enters port J at
piston (11) moves to the left (the discharge the small diameter end of the piston, but
amount becomes smaller). When LS differ- because of the difference in area between
ential pressure APLS becomes larger (for the large diameter end and the small diam-
example, when the area of opening of the eter end of servo piston (I I), servo piston
control valve becomes smaller and pump (11) is pushed to the left.
pressure PP rises), pump pressure PP pushes As a result, the swash plate moves in the
spool (6) to the left. direction to make angle smaller.
l When spool (6) moves, main pump pressure
PP flows from port C to port D, and from
port K, it enters the large diameter end of
the piston.
1o-25
41 When servo piston is balanced

. Let us take the area receiving the pressure . At this point, the relationship between the
at the large diameter end of the piston as area receiving the pressure at both ends of
Al, the area receiving the pressure at the piston (1 I) is A0 : Al = 1 : 2, so the pressure
small diameter end as AO, and the pressure applied to both ends of the piston when it is
flowing into the large diameter end of the balanced becomes PP : Pen = 2 : 1.
piston as Pen. If the main pump pressure PP . The position where spool (6) is balanced and
of the LS valve and the combined force of stopped is the standard center, and the force
force Z of spring (4) and LS pressure PLS of spring (4) is adjusted so that it is deter-
are balanced, and the relationship is A0 x PP mined when PP - PLS = 2.2 MPa (22.5 kg/
= Al x Pen, servo piston (1 I) will stop in cm*).
that position, and the swash plate will be
kept at an intermediate position. (It will stop
at a position where the opening of the throt-
tle from port D to port E and from port C to
port D of spool (6) is approximately the
same.)
1 O-26
Minimum direction Maximum direction
PC prolix switch
PC-EPC Valve
// I_ OFF ,,
I, I/
p ON
SAP03445
(2) PC valve
1) When pump controller is normal
a. When the load on the actuator is small and
pump pressures PPI and PP2 are low
0 Movement of PC-EPC solenoid (I)
l The command current from the pump C) output from the PC valve changes ac-
controller flows to PC-EPC solenoid (I). cording to this position.
This command current acts on the PC- . The size of command current X is deter-
EPC valve and outputs the signal pres- mined by the nature of the operation
sure. When this signal pressure is re- (lever operation), the selection of the
ceived, the force pushing piston (2) is working mode, and the set value and
changed. actual value for the engine speed.
l On the opposite side to the force push- * Other pump pressure
ing this piston (2) is the spring set pres- This is the pressure of the pump at the
sure of springs (4) and (6) and pump opposite end.
pressure PPI (self pressure) and PP2 For the F pump, it is the R pump pres-
(other pump pressure) pushing spool (3). sure
Piston (2) stops at a position where the For the R pump, it is the F pump pres-
combined force pushing spool (3) is bal- sure
anced, and the pressure (pressure of port
1O-27
When connected PO
, Large diameter end

:1,/,,/,/,/,,,,,,,,,,,, 1,x, ,
-
Maximum direction
PC Prolix switch
PC-EPC Valve
II I_ OFF ,, Pump
r-+3
/I I, controller + ’ I
? ON
I
Self-Reducing
Preesure valve
_I
SAP03446
0 Action of spring
. The spring load of springs (4) and (6) in . If the command current input to PC-EPC
the PC valve is determined by the swash valve solenoid (I) changes further, the
plate position. force pushing piston (2) changes, and
. When servo piston (9) moves, piston (71, the spring load of springs (4) and (6)
which is connected to slider (8), also also changes according to the value of
moves to the right or left. the PC-EPC valve solenoid command
. If piston (7) moves to the left, spring (6) current.
is compressed, and if it moves further to
the left, spring (6) contacts seat (5) and
is fixed in position. In other words, the
spring load is changed by piston (5) ex-
tending or compressing springs (4) and
(6).
1 O-28
. Port C of the PC valve is connected to

port E of the LS valve (see (I) LS valve).
Self pressure PPl enters port B and the
small diameter end of servo piston (9),
and other pump pressure PP2 enters port
A.
. When pump pressures PPI and PP2 are
small, spool (3) is on the left. At this
point, port C and port D are connected,
and the pressure entering the LS valve
becomes drain pressure PT. The pres-
sure entering the large diameter end of
the piston from port J becomes drain
pressure PT, and servo piston (9) moves
to the right. In this way, the pump dis-
charge amount moves in the direction
of increase.
. As servo piston (9) moves further, pis-
ton (7) is moved to the left by slider (8).
Springs (4) and (6) expand and the spring
force becomes weaker. When the spring
force becomes weaker, spool (3) moves
to the right, 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 piston also rises, so
the movement of piston (9) to the right
is stopped.
In other words, the stop position for pis-
ton (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 pressures PPI
and PP2 acting on spool (3) are in bal-
ance.
lo-29
Minimum direction
SAP03447
b. When load on actuator is large and pump

discharge pressure is high
l When the load is large and pump dis- . If main pump pressure PP increases fur-
charge pressures PPI and PP2 are high, ther and spool (3) moves further to the
the force pushing spool (3) to the left left, main pump pressure PPI flows to
becomes larger and spool (3) moves to port C and acts to make the discharge
the position shown in the diagram above. amount the minimum. When piston (9)
When this happens, as shown in the dia- moves to the left, piston (7) is moved to
gram above, part of the pressurized oil the left. For this reason, springs (4) and
from port A flows out through the LS (6) are compressed and push back spool
valve from port C to port D and the pres- (3). When spool (3) moves to the left,
surized oil flowing from port C to the LS the opening of port C and port D be-
valve becomes approximately half of comes larger. As a result, the pressure
main pump pressure PP. at port C (= J) drops, and piston (9) stops
. When port E and port G of the LS valve moving to the left.
are connected (see (I) LS valve), the pres- The position in which piston (9) stops
sure from port J enters the large diam- when this happens is further to the left
eter end of servo piston (9), and servo than the position when pump pressures
piston (9) stops. PPI and PP2 are low.
1O-30
. The relation of average pump pressure

(PPI + PP2)/2 and the position of servo
piston (9) forms a bent line because of
the double-spring effect of springs (4)
and (6). The relationship between aver-
age pump pressure (PPI + PP2)/2 and
pump discharge amount Q is shown in
the figure on the right.
Puma discharge (PPl +PPz) 12

pressure average SAP03448
. If command voltage X sent to PC-EPC

valve solenoid (I) increases further, the
relationship between average pump pres-
sure (PPI + PP2)/2, and pump discharge
amount Q is proportional to the pushing
force of the PC-EPC valve solenoid and
moves in parallel. In other words, the
pushing force of PC-EPC solenoid (I) is
added to the force pushing to the left
because of the pump pressure applied
to the spool (3), so the relationship be-
tween the average pump pressure (PPI
+ PP2)/2 and 0 moves from @ to @ in
accordance with the increase in X.
10-31
Maximum direction
IA
PC Prolix switch
PC-EPC Valve
OFF Pump
controller
ON
Self-Reducing
pressure valve Resister
/
,I,
SAP03450
2) When pump controller is abnormal and PC

prolix switch is ON
a. When load on main pump is light
. If there is a failure in the pump control- . At this point, port C is connected to the
ler, turn PC prolix switch ON to switch drain pressure of port D, and the large
to the resistor side. In this case, the diameter end of the piston of servo pis-
power source is taken directly from the ton (9) also becomes the drain pressure
battery. But if the current is used as it is, PT through the LS valve. When this hap-
it is too large, so use the resistor to con- pens, the pressure at the small diameter
trol the current flowing to PC-EPC valve end of the piston is large, so servo pis-
solenoid (I). ton (9) moves in the direction to make
l When this is done, the current becomes the discharge amount larger.
constant, so the force pushing piston (2)
is also constant.
. If main pump pressures PPI and PP2 are
low, the combined force of the pump
pressure and the force of PC-EPC’valve
solenoid (I) is weaker than the spring
set force, so spool (3) is balanced at a
position to the left.
1O-32
Minimum direction
PC prolix swi
SAP03451
b. When main pump load is heavy

. In the same way as in the previous item, discharge amount 0 is determined as
when the PC prolix switch is ON, the shown in the diagram for the value of
command current sent to PC-EPC valve the current sent to the PC-EPC valve so-
solenoid (I) becomes constant. For this lenoid through the resistor.
reason, the force of piston (2) pushing The curve when the PC prolix switch is
spool (3) is constant. ON is curve 0, which is to the left of
. If main pump pressures PPI and PP2 curve @ for when the pump controller is
increase, spool (3) moves further to the normal.
left than when the main pump load is
light, and is balanced at the position in
the diagram above.
. In this case, the pressure from port A
flows to port C, so servo piston (9) moves
to the left (to make the discharge amount
smaller) by the same mechanism as ex-
plained in Item 2)-b, and stops at a posi-
tion to the left of the position when the
load on the pump is light. In other words,
even when the PC prolix switch is ON, I
the curve for the pump pressure PP and Pump discharge ~ressur PP SAP03452
1o-33
STRUCTURE AND FUNCTION CONTROL VALVE
CONTROL VALVE
1. 6-spool valve Outline
2. Cover 1 . This control valve consists of the 6-spool
3. Cover 2 valve (an integrated composition). The junc-
4. Junction box tion box is installed to this.
. Each valve is formed into one unit by the
connection bolt, and the passages are inter-
nally connected, so the structure is compact
and is very easy to service.
. This control valve consists of one spool for
one item of the work equipment, so it has a
simple structure.
a. Port PPI (from rear main pump) dd. Port PX (from 2-stage relief solenoid
b. Port PP2 (from front main pump) valve: pressure rise type)
c. Port A6 (to arm cylinder head) ee. Port BP3 (from travel PPC valve)
d. Port B6 (to arm cylinder bottom) ff. Port BP2 (from PPC valve)
e. Port A5 (to L.H. travel motor) pa. Port PI2 (from arm PPC valve)
f. Port B5 (to L.H. travel motor) pb. Port PI1 (from arm PPC valve)
g. Port A4 (to swing motor) pc. Port PI0 (from L.H. travel PPC valve)
h. Port B4 (to swing motor) pd. Port P9 (from L.H. travel PPC valve)
i. Port A3 (to boom cylinder bottom) pe. Port P8 (from swing PPC valve)
j. Port B3 (to boom cylinder head) pf. Port P7 (from swing PPC valve)
k. Port A2 (to R.H. travel motor) pg. Port P6 (from boom PPC valve)
I. Port B2 (to R.H. travel motor) ph. Port P5 (from boom PPC valve)
m. Port Al (to bucket cylinder head) pi. Port P4 (from R.H. travel PPC valve)
n. Port Bl (to bucket cylinder bottom) pj. Port P3 (from R.H. travel PPC valve)
u. Port T (to tank) pk. Port P2 (from bucket PPC valve)
v. Port CPI (to port CP3) pl. Port PI (from bucket PPC valve)
w. Port CP2 (to port CP4) pm. Port P-2 (from service PPC valve)
x. Port cP3 (to port CPI) pn. Port P-l (from service PPC valve)
y. Port CP4 (to port CP2) po. Port P-4 (from service PPC valve)
aa. Port PLSI (to rear pump control) pp. Port P-3 (from service PPC valve)
ab. Port PLS2 (to front pump control) pq. Port P-6 (from service PPC valve)
bb. Port TS (to tank) pr. Port P-5 (from service PPC valve)
cc. Port BP1 (PPC output pressure for boom
RAISE)
1o-34
6-spool valve (pressure rise type)
-- Iff
h j I n aa
Y
bb w; a bl
SAP03966
10-35
Main structure
(l/5)
I 2 3 4 5
A-A
B-B
SAP03967
1 O-36
(2/5)
SAP03214
1. Pressure compensation valve (Arm) 8. L.H. travel spool

2. Pressure compensation valve (L.H. travel) 9. Swing spool
3. Pressure compensation valve (Swing) 10. Boom spool
4. Pressure compensation valve (Boom) 11. R.H. travel spool
5. Pressure compensation valve (R.H. travel) 12. Bucket spool
6. Pressure compensation valve (Bucket) 13. Safety-suction valve
7. Arm spool 14. Suction valve
1o-37
I D-D -3 i E-E j F-F 3
I’ 3 I
G-G AA-AA H-H
SAP03215
1. Safety-suction valve 7. Arm spool

2. Arm spool 8. Swing spool
3. Pressure compensation valve 9. LS select valve
4. LS shuttle valve 10. Boom spool
5. Check valve for arm regeneration circuit 11. Check valve for boom regeneration circuit
6. Suction valve 12. R.H. travel spool
13. Bucket spool
1 O-38
(415)
K-K
JJ-JJ SAP03968
1. Unload spool
2. Main relief valve (Pressure rise type)
1o-39
CONTROL VALVE
B/5)
J-J
EE-EE
SAP03199
1. LS shuttle valve
2. LS select valve
3. LS bypass valve
1O-40
SAFETY-SUCTION VALVE FOR SERVICE VALVE
1. Suction valve
2. Main valve
3. Piston
4. Piston spring
5. Poppet
6. Poppet spring
7. Suction valve spring
8. Sleeve
9. Adjustment screw
10. Locknut
SBPOO198
SPECIFICATION
Part No. I Set pressure I Use
70%70-74800 1 20.58 MPa (210 kg/cm*) at 190 !J/min 1 For breaker (Okada)
709-70-75100 1 20.09 MPa (205 kg/cm? at 5 e/min For breaker (Mitsubishi Krupp)
7og-yo-753oo I 16.56 MPa (170 kg/cm? at 190 e/min I For breaker (Matsuda)
709-70-74600 1 24.5 MP (250 kg/cm*) at 5 .Q/min For crusher (Okada)
10-41
STRUCTURE AND FUNCTION SELF-REDUCING PRESSURE VALVE
SELF-REDUCING PRESSURE VALVE
a:
a:
SAP03258
a. Port PI (from front pump)

b. Port PR (supply to electromagnetic valve, PPC
valve, EPC valve)
c. Port T (to hydraulic tank)
d. Port PC (to front pump LS valve)
1 O-42
8 7 6 5 ‘4
A-A
IO 9
B-B SAP03259
I. Control valve block 6. Spring (reducing valve pilot)

2. Valve (sequence valve) 7. Spring (reducing valve main)
3. Spring 8. Spring (reducing valve)
4. Screw 9. Spring (safety valve)
5. Poppet 10. Ball
1o-43
Function
l This valve reduces the discharge pressure of
the main pump and supplies it as the control
pressure for the solenoid valve and PPC valve.
Operation
1. When engine is stopped
. Poppet (5) is pushed against the seat by
spring (6), and the passage from port PR +
T is closed.
. Valve (8) is pushed to the left by spring (7),
and the passage from port PI + PR is open. HYDRAULIC CIRCUIT DIAGRM SAP03299
. Valve (2) is pushed to the left by spring (3),
so the passage between port PI + P2 is
closed. (See Fig. I)
(Fig. 1) SAP03300
1o-44
2. At neutral and
When load pressure P2 is low (when moving
down under own weight (boom LOWER or arm
IN))
Note: When load pressure P2 is lower than out-
put pressure PR of the self-reducing pres-
sure valve.
. Valve (2) receives force in the direction to
close the passage from port PI + P2 from
spring (3) and pressure PR (when the engine
is stopped, the pressure is 0 MPa (0 kg/cm21).
However, when hydraulic oil flows in from
port PI, the pressure is balanced so that
pressure PI % force of spring (7) + (area Od x
pressure PR), and the opening from port PI
+ P2 is adjusted so that pressure PI is kept
at a certain value above pressure PR.
. When pressure PR goes above the set pres-
sure, poppet (5) opens, and the hydraulic oil
flows in the following circuit: port PR + hole
a inside spool (8) + opening of poppet (5)
-_j tank port T.
As a result, a pressure difference is created
on both sides of hole a inside spool (8), so
spool (8) moves in the direction to close the
SAP03301
opening from port PI + PR. Pressure PI is
reduced to a certain pressure (set pressure)
by the amount of opening at this point, and
is supplied as pressure PR. (See Fig. 2)
3. When load pressure P2 is high

If load pressure P2 increases and the pump dis-
charge amount also increases because of dig-
ging operations, pressure PI also increases
(pressure PI > force of spring (7) + (area @d x
pressure PR), so valve (2) moves to the right to
the end of the stroke.
As a result, the amount of opening from port PI
+ P2 increases and the resistance in the pas-
sage is reduced, so the loss of engine horse-
power is reduced.
. If pressure PR goes above the set pressure,

poppet (5) opens and the hydraulic oil flows
in the following circuit: port PR + hole a
inside spool (8) + opening of poppet (5) +
tank port T.
As a result, a pressure difference is created
on both sides of hole a is inside spool (8), so
spool (8) moves in the direction to close the
opening from port PI + PR. Pressure PI is
reduced to a certain pressure (set pressure)
by the amount of opening at this point, and
is supplied as pressure PR. (See Fig. 3)
SAP03302
10-45
4. When there is abnormal high pressure

When pressure PR of the self-reducing pressure
valve becomes abnormally high, ball (IO) pushes
against the force of spring (91, separates from
the seat, and allows hydraulic oil to flow from
output port PR + T, so pressure PR goes down.
This action protects the equipment at the desti-
nation for the hydraulic pressure supply (PPC
valve, electromagnetic valve, etc.) from abnor-
mally high pressure. (See Fig. 4)
IO Y
(F i g. 4) SAP03303
1 O-46
STRUCTURE AND FUNCTION CLSS
CLSS
OUTLINE OF CLSS
______--------.
SAP03879
Features Structure
. CLSS stands for Closed center Load Sensing l The CLSS consists of a main pump (2
System, and has the following features. pumps), control valve, and actuators for the
work equipment.
. The main pump body consists of the pump
1) Fine control not influenced by load
2) Control enabling digging even with fine con- itself, the PC valve and LS valve.
trol
3) Ease of compound operation ensured by flow
divider function using area of opening of
spool during compound operations
4) Energy saving using variable pump control
1o-47
Basic principle
Actuator
1) Control of pump swash plate angle
l The pump swash plate angle (pump dis-
charge amount) is controlled so that LS dif-
ferential pressure APLS (the difference be-
tween pump pressure PP and control valve
outlet port LS pressure PLS) (load pressure Control valve
of actuator) is constant. --7
---l
(LS pressure APLS = Pump discharge pres- /-J-r I’
sure PP - LS pressure PLS) 1‘PLS
PUMP Passage I’ u LS Passage
c___,
m c---’ i/
rae current
SBP03454
. If LS differential pressure APLS becomes k

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 it 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.
0
LS differential pressure APLS
SAP03455
1 O-48
2) Pressure compensation
l A pressure compensation valve is installed downstream (outlet port) of the spool of each
to the outlet port side of the control valve to valve the same regardless of the size of the
balance the load. load (pressure).
When two actuators are operated together, In this way, the flow of oil from the pump is
this valve acts to make pressure difference divided (compensated) in proportion to the
AP between the upstream (inlet port) and area of openings Sl and S2 of each valve.
Load
comoensation
SBP03456
1o-49
OPERATION FOR EACH FUNCTION AND VALVE
Hydraulic circuit diagram for system
i PI
rtor
__----- -
-4
$V i ,
- III, : ,,CP3 P3
1
--w
#ina
‘_>_____’
va!v_e
6 -_ .-
-.
,3 _ P 12 ------/-I
SAP03969
1O-50
1. Main relief valve (2 step relief)

Set pressure: 31.9 MPa (325 kg/cm*)
2. Unload valve
Set pressure: 2.9 MPa (30 kg/cm?
3. Bucket spool
4. Pressure compensation valve
5. Safety-suction valve
Set pressure: 35.8 MPa (365 kg/cm*)
6. LS shuttle valve
7. R.H. travel spool
8. Suction valve
9. Boom spool
10. Check valve (for boom regeneration circuit)
11. Swing spool
12. L.H. travel spool
13. Arm spool
14. Check valve (for arm regeneration circuit)
15. LS select valve
A. To bucket cylinder
B. To R.H. travel motor
C. To boom cylinder
D. To swing motor
E. To L.H. travel motor
z F. To arm cylinder
5;
z
1o-51
SYSTEM DIAGRAM
Ir This shows actuator (6A) at the stroke end
relief in the merge mode.
SAP03970
IA. Main pump 7A. Pump passage

IB. Main pump 7B. Pump passage
2A. Main relief valve 8. LS circuit
2B. Main relief valve 9A. Tank passage
3. Unload valve 9B. Tank passage
4. Junction block IO. Valve
5A. Control valve 11. Spring
5B. Control valve 12. LS bypass valve
6A. Actuator
6B. Actuator
1o-52
1. Unload valve
SBPO3219
zi
> Function
% l When the pump flow is merged and the con-
trol valve group on one side is actuated (with
the remaining control valve group at neu-
tral), the sub-unload valve drains the pump
flow to the group that is at neutral.
Operation
l The pressure in pump passages A is received
at the end portion of valve (I). The control
valve is at neutral, so the pressure in LS
circuit B is 0 MPa 10 kg/cm*).
l The pressurized oil in pump passage A is
stopped by valve (1) and cannot escape, so
the pressure rises. When this pressure be-
comes larger than the force of spring (2),
valve (I) moves to the left, ports C and D are
interconnected, and the pump pressure flows
to tank passage E. In addition, the pressu-
rized oil in LS circuit B passes from orifice f
through port D and is drained to tank pas-
sage E. Therefore, in this operation, LS pres-
sure + tank pressure.
. In this unload operation, pump discharge
pressure - LS circuit pressure is greater than
2 f D E SBPO3220
the pump LS control pressure, so a signal is
sent to set the pump swash plate to the
minimum angle.
1o-53
2. Introduction of LS pressure (LS shuttle valve)
-1 SEP00123
1. Main pump 4. Valve

2. Main spool 5. Check valve
3. Pressure compensation valve 6. LS shuttle valve
Function Operation
. LS pressure PLS is the actuator load pres- . When main spool (2) is operated, pump dis-
sure at the output side of the control valve. charge pressure PP starts to flow to actuator
l The upstream pressure (= spool meter-in circuit A.
downstream pressure) of pressure compen- . First, this pump discharge pressure PP
sation valve (3) is taken inside main spool passes through introduction hole a of main
(2) and goes to LS shuttle valve (6). spool (2), and is taken to LS circuit PLS.
. When this happens, it connects actuator cir- . When actuator circuit pressure A rises to the
cuit A and LS circuit PLS through check valve necessary pressure, pump pressure PP rises
(5), and sets so that LS pressure PLS + ac- and check valve (5) inside main spool (2)
tuator load pressure. opens. The high pressure of LS circuit PLS
. Introduction hole a inside main spool (2) has then flows to actuator circuit A.
a small diameter, so it also acts as a throttle. . In this way, LS pressure PLS becomes al-
most the same as actuator circuit pressure
A.
1o-54
3. LS bypass valve
/
a
SBPO3221
1. Main pump Function

2. Main spool . The residual pressure in LS circuit PLS is
3. Pressure compensation valve released from orifices b and c.
4. LS shuttle valve . This reduces the speed of the rise in the LS
5. LS bypass plug pressure, and prevents any sudden change
in the oil pressure. Furthermore, a pressure
loss is generated by the circuit resistance
between LS shuttle valve (4) and throttle a
of main spool (2) according to the bypass
flow from LS bypass plug (5). As a result,
the effective LS differential pressure drops,
and the dynamic stability of the actuator is
increased.
1o-55
4. Pressure compensation valve
PP
1. Main pump
2. Valve
3. Shuttle valve
4. Piston
5. Spring
6. LS shuttle valve
Function Operation
l When the maximum load pressure is gener- . If pump pressure PP and LS pressure PLS
ated during compound operations and dur- are lower than actuator circuit B, shuttle valve
ing independent operations, and the load (3) inside the pressure compensation valve
pressure is higher than other actuators, the moves to the left in the direction of the ar-
pressure compensation valve acts as a load row to interconnect spring chamber C.
check valve to prevent reverse flow in the . When this happens, piston (4) is pushed to
circuit. the right in the direction of the arrow by
spring (5).
. As a results, valve (2) is also pushed to the
right in the direction of the arrow by piston
(4), so pump outlet circuit A closes. This
prevents the oil from flowing back from ac-
tuator circuit B to pump outlet circuit A.
1O-56
From LS shuttle valve for other

work equipment
Upstream pressure of Pressure

compensation valve
(SPOOI meter-in downstream pressure)
PP 4%\ I
SPOOI meter-in upstream Pressure
SBPO3881
Function Operation
. During compound operations, if the load . During compound operations, if the load
pressure is lower than the other actuators pressure for the other actuators rises, the oil
and the flow of oil starts to increase, the flow in actuator circuit B tries to increase.
pressure compensation valve carries out . When this happens, LS pressure PLS for the
compensation. In this case, it tries to make other actuator also increases, so this LS pres-
the load pressure for the other actuators sure PLS pushes shuttle valve (3) of the pres-
greater and reduce the flow of oil. sure compensation valve to the right in the
direction of the arrow, passes through the
passage inside piston (4), and flows to spring
chamber C.
. As a results, piston (4) and valve (2) are
pushed to the right in the direction of the
arrow, and the outlet side of pump circuit
PP is closed, so outlet port pressure A (spool
meter-in downstream pressure) becomes the
same as the outlet port pressure of the other
actuators.
. Pump pressure PP (spool meter-in upstream
pressure) is the same between all actuators,
so pump pressure PP and outlet port pres-
sure A become the same between all spools
that are being operated. Therefore, the pump
flow is divided in proportion to the area of
the opening of each valve.
1o-57
5. Shuttle valve inside pressure compensation

valve (arm, swing, boom, bucket valve)
SBPO3224

2. Valve When holding pressure at port A * LS pressure
3. Shuttle valve inside pressure compensation in spring chamber B
valve l Shuttle valve (3) is pushed to the right by
4. Piston the pressure of port A, and the circuit be-
tween ports A and PLS is shut off. In this
condition, the holding pressure at port A is
taken to spring chamber B, and pushes pis-
ton (4) to the left to prevent piston (4) and
valve (2) from separating.
1 O-58
Shattle valve Al
Spool meter-in downstream ~fe?.sur e
SBPO3461
<Surface area ratio of pressure compensation

valve>
The condition of the flow division changes ac-
cording to the ratio of the area of portion Al
and portion A2 of the pressure compensation
valve.
Area ratio = A2lAl.
When area ratio = 1:
Spool meter-in downstream pressure = Max.
load pressure, and oil flow is divided in pro-
portion to area of opening of spool.
When ratio is more than 1:
Spool meter-in downstream pressure > Max.
load pressure, and oil flow is divided in a
proportion less than area of opening of
spool.
When ratio is less than 1:
Spool meter-in downstream pressure c Max.
load pressure, and oil flow is divided in a
proportion more than area of opening of
spool.
1o-59
6. Boom regeneration circuit
- -
RAISE LOWER
SAP03882

2. Main spool I) Cylinder head pressure < cylinder bottom
3A. Pressure compensation valve pressure (free fall, etc.)
3B. Pressure compensation valve . A return flow circuit is provided from the
4A. Suction valve (with safety) cylinder bottom to the cylinder head so that
4B. Suction valve (with safety) when the bottom is lowered, the return flow
5. Check valve for boom regeneration circuit can be used to increase the flow of oil to the
6. LS shuttle valve cylinder head.
Operation
. When the cylinder head pressure c cylinder
bottom pressure, part of the pressurized oil
from the cylinder bottom passes through the
notch in spool (2), goes through port B, and
enters drain circuit T. The rest of the oil
enters regeneration circuit C, opens check
valve (51, and passes through ports D and E
to flow back to the cylinder head.
1 O-60
SAP03883
2) Cylinder head pressure > cylinder bottom

pressure (digging operations, etc.)
l Check valve (5) in regeneration circuit C acts
to shut off the flow from the cylinder head
to the cylinder bottom.
lo-61
7. Arm regeneration circuit
SAP03884

2. Main spool 1) Cylinder head pressure > cylinder bottom
3A. Pressure compensation valve pressure
3B. Pressure compensation valve . A return flow circuit is provided from the
4A. Suction valve (with safety) cylinder head to the cylinder bottom so that
4B. Suction valve (with safety) when the arm is moved in, the flow of oil to
5. Check valve for arm regeneration circuit the cylinder becomes the pump discharge
6. LS shuttle valve amount + the return flow, and this increases
the cylinder speed.
Operation
. When the cylinder head pressure > cylinder
bottom pressure, the pressurized oil from
the cylinder head passes through the notch
in spool (21, enters port C and opens check
valve (51, then passes through ports D and E
to flow back to the cylinder bottom.
1 O-62
SAP03885
2) Cylinder bottom pressure > cylinder head

pressure
. When the cylinder bottom pressure > cylin-
der head pressure, check valve (5) is closed
by the cylinder bottom pressure and pre-
vents any oil from flowing back from the
cylinder bottom to the head end.
1O-63
8. LS select valve
* The diagram shows the situation when the
swing and left travel are operated at the
same time. (BP pressure ON)
5 1. Valve
PS 2. Spring
'ONJ 3. Piston
4. Piston
5. Swing spool
6. L.H. travel spool
7. Arm spool
8. L.H. shuttle valve
9. LS circuit
\AI
I
Y SBP02627
Function
l This valve is used to increase the ease of
operating the work equipment. It prevents
high pressure from being generated when
the swing is operated. It also prevents the
high LS pressure from the swing circuit from
flowing into any other LS circuit when the
BP
swing is operated together with the work 'OFF)
equipment.
Operation
II When pilot pressure BP is OFF
. Pilot pressure BP is OFF, so piston (3) is
To LS shuttle valve
pushed to the left by spring (2). If the swing
SBP03466
is then operated, swing LS pressure PI
passes through swing spool (5) and enters
port A. It pushes valve (I) to the left and
connects ports A and B. Therefore, swing LS
pressure PI flows to LS shuttle valve (8).
21 When pilot pressure BP is ON
. When pilot pressure BP is ON, piston (3) is
moved to the right against spring (2) by the
BP pressure. It pushes valve (I) to the right
and closes the circuit between ports A and
B. As a result, swing LS pressure PI stops
flowing to LS shuttle valve (8), and even if
To LS shuttle valve
swing LS pressure PI rises to a high pres-
SBP03467
sure, it does not influence any other LS cir-
cuit.
1 O-64
OPERATION OF CLSS SYSTEM AS A WHOLE

1. When all work equipment is at neutral
* The diagram shows the situation when all work equipment is at neutral.
* The valves and circuits that are not connected with the explanation of the operation of the CLSS
hydraulic system have been omitted.
10-65-l
0
1. Hydraulic tank Note: Groups of control valves by main pump circuit

2A. Main pump (front) . Bucket group: Bucket, R.H. travel, boom
28. Main pump (rear) . Arm group: Swing, L.H. travel, arm
3A. PC valve (front)
3B. PC valve (rear) Operation
4A. LS valve (front) . When the levers are at neutral, the pump is
4B. LS valve (rear) at the minimum swash plate angle, and the
5 Junction block oil flow is drained from unload valve (28A).
6. Bucket spool . The LS pressure is connected to hydraulic
7. R.H. travel spool tank (I) by LS bypass valve (31). The LS
8. Boom spool differential pressure APLS (unload pressure
9. Swing spool -tank pressure) at this point is APLS > pump
10. L.H. travel spool LS control pressure, so the pump swash plate
11. Arm spool angle is the minimum.
12. Pressure compensation valve (bucket)
13. Pressure compensation valve (without
shuttle valve) (R.H. travel)
14. Pressure compensation valve (boom)
15. Pressure compensation valve (swing)
16. Pressure compensation valve (without
shuttle valve) (L.H. travel)
17. Pressure compensation valve (arm)
18. Safety-suction valve
19. Suction valve
$ 20. LS shuttle valve (bucket)
>
21. LS shuttle valve (R.H. travel)
::
W 22. LS shuttle valve (boom)
23. LS shuttle valve (L.H. travel)
24. LS shuttle valve (arm)
25. Check valve (for boom regeneration circuit)
26. Check valve (for arm regeneration circuit)
27. Main relief valve
28. Unload valve
29. LS select valve
30. LS check valve
31. LS bypass valve
32. Self-reducing pressure valve
1 O-65-2
0
2. One side actuated, other side neutral

Ir The diagram shows the independent bucket DUMP operation.
Sr For details of this page, see page 90-17.
1O-65-3
0
Operation
1) Bucket group
. When the bucket is operated, pressurized oil
from main pump (28) flows to the bucket
group. The swash plate angle of main pump
(2B) is controlled to match the operation of
bucket spool (6).
. The LS pressure passing through the inside
of bucket spool (6) goes to unload spool
(281, and the unload valve is closed.
2) Arm group
. When the pump flow is divided, all spools
are at neutral, so the oil flow from the mini-
mum swash plate angle of main pump (2A)
is all drained from unload valve (28) of the
arm group. All spools in the arm group are
at neutral, so no LS pressure is generated.
. If the pump pressure - LS pressure becomes
greater than the set pressure of unload valve
(281, the unload valve is actuated and the oil
is drained. The LS differential pressure APLS
at this point is APLS > pump LS control pres-
sure, so the pump swash plate angle is the
$ minimum.
>
Ei
w
1O-65-4
0
3. Arm OUT, standard mode relief (cut-off control)

+ The diagram shows the arm DUMP and standard mode relief.
1 O-65-5
0
Operation
1) When pump swash plate angle is controlled
to minimum
. When the arm is operated to OUT, if the
load increases, the LS pressure passing
through the inside of arm spool (II) rises.
. The LS pressure also goes to unload valve
(28) and unload valve (28) is closed. The
main circuit pressure rises and is relieved at
the standard mode relief pressure.
2) When this happens, the pump pressure sen-

sor detects it and increases the PC-EPC cur-
rent (electronic cut-off control) to set the
pump swash plate angle to the minimum.
1O-65-6
0
4. Bucket DUMP, power max. relief

* The diagram shows bucket DUMP, relief.
1 O-65-7
0
Operation
. Relief valve (27) pilot pressure PB ON.
1) When the bucket is being operated, if the

power max. button is turned ON, pilot pres-
sure PB acts on relief valve (271, so the set
pressure of the relief valve is raised.
2) When the bucket is operated to DUMP and

the load increases, pump pressure PI and
LS pressure PLSI both rise. When this hap-
pens, pilot pressure PB controls relief valve
(27) to the same relief pressure as when the
power max. button is operated.
1 O-65-8
0
5. Boom RAISE
lo-659
0
Operation
. When the boom RAISE is operated, main
pumps (2A) and (2B) are both at the maxi-
mum swash plate angle, and unload valve
(28A) is closed.
. At this point, for the meter-in opening of
boom spool (81, even if both pumps are at
the maximum swash plate angle, the LS dif-
ferential pressure is set to be smaller than
the pump LS control pressure.
In other words, LS differential pressure APLS
is APLS c pump LS control pressure, so the
pump swash plate angle becomes the maxi-
mum.
. In addition, the flow of main pump (2A)
passes through junction block (5) and flows
to boom spool (8).
1O-65 10
CD
6. Swing operated independently

10-65-11
0
Operation
. When the swing is operated, unload valve
(28) is closed.
. When this happens, the oil flow from main
pumps (2A, 2B) is controlled by the LS dif-
ferential pressure and is discharged to match
the area of opening of the meter-in of the
swing spool.
10-65-12
0
7. Travel operated independently

lo-6513
0
Operation
11
. When the straight travel is operated, an oil
flow supplied from the main pump to match
the amount of movement of left and right
travel spools (IO) and (7).
Main pump (2A) oil flow:
To left travel spool (IO) (arm group)
Main pump (2B) oil flow:
To right travel spool (7) (bucket group)
. The ability to travel in a straight line is en-
sured by actuating the pressure compensa-
tion valves and interconnecting the right
travel and left travel through the pistons of
pressure control valves (13) and (16) and
through the external piping.
2)
. From the above condition I), if the steering
control levers are returned (the oil flow is
reduced) or operated in opposite directions
(FORWARD and REVERSE), the travel junc-
tion circuit through the above piston is cut
$ off, and the left and right sides are operated
t
z
LLI
independently
operated.
to enable the steering to be
1O-65 14
0
8. Compound operation
Sr The diagram shows boom RAISE + arm IN.
L
ilin
I-
I I
lo-6515
0
Operation
I)- When the arm and boom are operated si-
multaneously, the swash plate angle for both
pumps becomes the maximum.
When this happens, the load pressure at the
boom RAISE side is higher than at the arm
side, so the LS pressure passes through ports
E and F of boom spool (8). enters LS shuttle
valve (22) and is sent to the LS circuit. This
LS pressure is transmitted to port G of arm
pressure compensation valve (17). and acts
to increase the set pressure of the pressure
compensation valve. Because of this, the
pressure between port H of arm spool (I 1)
and port I of pressure compensation valve
(17) rises, and spool meter-in LS differential
pressure (pump pressure - LS pressure =
APL3 becomes the same as that at the boom
end.
2) Because of the above operation, the oil flow

is divided in proportion to the size of the
opening area of boom spool (8) and the
opening area of arm spool (I I).
2i Meter-in LS differential pressure APLS dur-
> ing boom RAISE + arm IN is APLS c boom
8
w LS control pressure, so the main pump
swash plate angle is set to maximum.
lo-6516
0
STRUCTURE AND FUNCTION SWING MOTOR
SWING MOTOR
KMFgOAB-3
SAP03230
a. Port S SPECIFICATIONS
c. Port MB (from control valve)
e. Port MA (from control valve) Type KMFgOAB-3
d. Port T (to tank)
Theoretical delivery 87.8 cc/rev
e. Port B (from swing brake solenoid valve)
Safety valve set 27.9 MPa

pressure I285 kg/cm*)
Rated speed 2,260 rpm
Brake releasing 2.1 MPa

pressure 121 kg/cm3
1O-66
A-A
c-c
SAP02633
1. Brake spring 11. Cylinder

2. Drive shaft 12. Valve plate
3. Spacer 13. Plate
4. Case 14. Center shaft
5. Disc 15. Center spring
6. Plate 16. Safety valve
7. Brake ring 17. Check valve
8. Brake piston 18. Check valve spring
9. Housing 19. Shuttle valve
10. Piston 20. Shuttle valve spring
1 O-67
Operation of swing lock

1) When swing lock solenoid valve is deacti-
vated
When the swing lock solenoid valve is deac-
tivated, the pressurized oil from the main
pump is shut off and port B is connected to
the tank circuit.
As a result, brake piston (7) is pushed down
by brake spring (I), discs (5) and plates (6)
are pushed together, and the brake is ap-
plied.
2) When swing lock solenoid valve is excited

When the swing lock solenoid valve is ex-
cited, the valve is switched and the pressure
oil from the main pump enters port B and
flows to brake chamber a.
The pressure oil entering chamber a over-
comes brake spring (I) and pushes brake
piston (7) up. As a result, discs (5) and plates
(6) are separated and the brake is released.
SAP03472
1O-68
From port S
RELIEF VALVE PORTION
I) Outline
The relief valve portion consists of check
valves (2) and (3), shuttle valves (4) and (5),
and relief valve (I).
2. Function
When the swing is stopped, the outlet port
circuit of the motor 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 pres-
sure oil is relieved to port S from the outlet
port of the motor (high-pressure side) to pre-
vent any damage to the motor.
3. Operation
11 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 sup-
plied to port MA. As a result, the pressure at
(Fig.I)
E port MA rises, the starting torque is gener- SAP03473
> ated in the motor, and the motor starts to
% rotate. The oil from the outlet port of the From port S
motor passes from port MB through the con-
trol valve and returns to the tank. (Fig. I)
21 When stopping swing
. When the swing control lever is returned to
neutral, the supply 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 shut-
tle valve A (4) and chamber C becomes 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 mo-
tor. (Fig. 2)
. When the relief valve (I) is being actuated,
the relief oil and oil from port S passes
through check valve B (3) and is supplied to
port MA. This prevents cavitation at port MA.
SAP03474
1O-69
STRUCTURE AND FUNCTION CENTER SWIVEL JOINT
CENTER SWIVEL JOINT

4-PORT SWIVEL
Al
El
‘E2
A-A A-4
Tl T2 D2
B2 A2 c2
SBPOO249
1. Cover B2. To. L.H. travel motor port PA

2. Body Cl. From control valve port A2
3. Slipper seal C2. To R.H. travel motor port PA
4. O-ring Dl. From control valve port A5
5. Shaft D2. To L.H. travel motor port PB
El. From travel speed solenoid valve
Al. From control valve port B2 E2. To L.H. and R.H. travel motors port P
A2. To R.H. travel motor port PB Tl. To tank
Bl. From control valve port 85 T2. From L.H. and R.H. travel motors port T
1O-70
STRUCTURE AND FUNCTION CENTER SWIVEL JOINT
6-PORT SWIVEL
Al
Cl
Gl
D2 T2 c2
F2 02 A2 E2
SBP02643
1. Cover C2. To R.H. travel motor port PA

2. Body Dl. From control valve port A5
3. Slipper seal D2.To L.H. travel motor port PB
4. Oil seal El. From control valve port A3
5. Shaft E2. Blind
Fl. From control valve port B3
Al. From control valve port B2 F2. Blind
A2. To R.H. travel motor port PB Gl. From travel speed solenoid valve
Bl. From control valve port B5 G2.To L.H. and R.H. travel motors port P
B2. To. L.H. travel motor port PA Tl. To tank
Cl. From control valve port A2 T2. From L.H. and R.H. travel motors port T
10-71
STRUCTURE AND FUNCTION TRAVEL MOTOR
TRAVEL MOTOR
HMVllO-2
a
SAP01247
a. Port T (to tank) SPECIFICATIONS

b. Port PB (from control valve)
c. Port P (from travel speed solenoid valve) HMVI IO-2
d. Port PA (from control valve)
Min. 75.5 cc/rev
Theoretical delivery
Max. 110.7 cc/rev
Set pressure 34.79 MPa

(355 kg/cm*}
Min. capacity 2,673 rpm
Rated speed
Max. capacity 1,460 rpm
Brake releasing pressure 1.18 MPa

{I 2 kg/cm*}
Travel speed Differential 0.78 MPa

switching pressure pressure {8 kg/cm21
1 O-72
P
0
k-D
\
9
A-A
D-D SAP02754
1. Regulator piston 9. Check valve spring 17. Valve plate

2. Spring IO. Output shaft 18. Counterbalance valve
3. Regulator valve 11. Swash plate 19. Ring
4. Spring 12. Retainer guide 20. Spool return spring
5. Motor case 13. Pin 21. Brake piston
6. Suction safety valve spring 14. Piston 22. Plate
7. Suction safety valve 15. Retainer 23. Disc
8. Check valve 16. Cylinder 24. Ball
1o-73
OPERATION OF MOTOR
1) Motor swash plate angle (capacity) at maxi-
mum
The solenoid valve is deactivated, so the pi- l At the same time, the pressurized oil at regu-
lot pressure oil from the main pump does lator piston (15) passes through orifice c in
not flow to port P. regulator valve (9) and is drained to the
For this reason, regulator valve (9) is pushed motor case.
to the right in the direction of the arrow by l As a result, swash plate (4) moves in the
spring (IO). maximum swash plate angle direction, the
Because of this, it pushes check valve (221, motor capacity becomes maximum.
and the main pressure oil from the control
valve going to end cover (8) is shut off by
regulator valve (9).
Fulcrum a of swash plate (4) is eccentric to
point of force b of the combined force of the
propulsion force of cylinder (61, so the com-
bined force of the piston propulsion force
acts as a moment to angle swash plate (4) in
the direction of the maximum swash plate
angle.
1o-74
2) Motor swash plate angle (capacity) at mini-

mum
SAP03479
. When the solenoid valve is excited, the pilot

pressure oil from the main pump flows to
port P, and pushes regulator valve (9) to the
left in the direction of the arrow.
. Because of this, the main pressure oil from
the control valve passes through passage d
in regulator valve (91, enters regulator pis-
ton (15) at the bottom, and pushes regulator
piston (15) to the right in the direction of the
arrow.
. As a result, swash plate (4) moves in the
minimum swash plate angle direction, the
motor capacity becomes minimum.
1o-75
OPERATION OF PARKING BRAKE

1) When starting to travel
When the travel lever is operated, the pres-
surized oil from the pump actuates counter-
balance valve spool (191, opens the circuit to
the parking brake, and flows into chamber A
of brake piston (12).
It overcomes the force of spring (I I), and
pushes piston (12) to the left in the direction
of the arrow.
When this happens, the force pushing plate
(13) and disc (14) together is lost, so plate
(13) and disc (14) separate and the brake is
released.
II I4 I3 12 22 SAP03480
21 When stopping travel

When the travel lever is placed in neutral,
counterbalance valve spool (19) returns to
the neutral position and the circuit to the
parking brake is closed.
The pressurized oil in chamber A of brake
piston (12) is drained to the case from the
orifice in the brake piston, and brake piston
(12) is pushed to the right in the direction of
the arrow by spring (II).
As a result, plate (13) and disc (14) are
pushed together, and the brake is applied.
A time delay is provided by having the pres-
surized oil pass through a throttle in slow
return valve (22) when the brake piston re-
turns, and this ensures that the brake still
effective after the machine stops.
'SAP03481
1 O-76
OPERATION OF BRAKE VALVE

l The brake valve consists of a suction safety
valve (18A), counterbalance valve (18) in a
circuit as shown in the diagram on the right.
(Fig. I)
l The function and operation of each compo-
nent is as given below.
1) Counterbalance valve, check valve

Function
. When traveling downhill, the weight of the
machine makes it try to travel faster than
the speed of the motor.
As a result, if the machine travels with the
engine at low speed, the motor will rotate
without load and the machine will run away, IFio. 11 SAP03482
which is extremely dangerous.

To prevent this, these valves act to make the
machine travel according to the engine speed
(pump discharge amount).
Operation when pressure oil is supplied

l When the travel lever is operated, the pres- I 0A
surized oil from the control valve is supplied
: to port PA. It pushes open suction safety
> valve (18A) and flows from motor inlet port
5 MA to motor outlet port MB.
However, the motor outlet port is closed by
suction safety valve (188) and spool (19), so
the pressure at the supply side rises. (Fig. 2)
(F i o. 2) SAP03483
l The pressurized oil at the supply side flows

from orifice El and E2 in spool (19) to cham-
ber Sl. When the pressure in chamber Sl
goes above the spool switching pressure,
spool (19) is pushed to the right in the direc-
tion of the arrow.
As a result, port MB and port PB are con-
nected, the outlet port side of the motor is
opened, and the motor starts to rotate. (Fig.
3)
(F i 0. 3) SAP03484
Operation of brake when traveling downhill

. If the machine tries to run away when
traveling downhill, the motor will turn under
no load, so the pressure at the motor inlet
port will drop, and the pressure in chamber
Sl through orifices El and E2 will also drop.
When the pressure in chamber Sl drops
below the spool switching pressure, spool
(19) is returned to the left in the direction of
the arrow by spring (201, and outlet port MB
is throttled.
As a result, the pressure at the outlet port
side rises, resistance is generated to the ro-
tation of the motor, and this prevents the
machine from running away.
In other words, the spool moves to a posi-
tion where the pressure at outlet port MB
balances the pressure at the inlet port and ,, ,,,,,,,,,, e,,,,,,,,,,,,,.. .r Y,,u ,,,,,,,,,,,,,,,,, I_____*
the force generated by the weight of the w -
(Fib 4) SAP03465
machine. It throttles the outlet port circuit
and controls the travel speed according to
the amount of oil discharged from the pump.
(Fi.g 4)
2) Safety valve
Function
l When travel is stopped (or when traveling
downhill), the circuits at the inlet and outlet
ports of the motor are closed by the coun-
terbalance valve, but the motor is rotated by
inertia, so the pressure at the outlet port of
the motor will become abnormally high and
damage the motor or piping. The safety valve
acts to release this abnormal pressure and
send it to the inlet port side of the motor to Sl
prevent damage to the equipment.
Operation
1) When travel is stopped (or when traveling
downhill, rotating to right)
l When the motor inlet port pressure (pres-
sure PA) goes down, the pressure in cham-
ber Sl also goes down. When it goes below
the switching pressure of the spool, spool SAP03486
(19) is returned to the left by spring (20),
and outlet port passage Bl is throttled. When
this happens, the motor continues to rotate
under inertia, so the outlet pressure (pres-
sure MB) rises. (Fig. 5)
. If the pressure goes above the set pressure
of suction-safety valve (18A), the poppet
opens. The oil then passes through large
notch Al in counterbalance valve spool (19)
and flows to chamber MA in the circuit on
the opposite side. (Fig. 6)
Poppet MB MA
2) When rotating to left
The operation is the reverse of when rotat- (Fie. 6) SAP03487
ing to the right.
1 O-78
3) When starting travel (or during normal

travel)
. When the travel lever is operated, the pres-
sure oil from the pump moves counterbal-
ance valve spool (19) to the right. When this
happens, the passage to the suction-safety
valve becomes the circuit flowing through l8A
the small notch in the counterbalance valve
spool. As a result, a big difference in pres-
sure is created, and the pump pressure rises
to provide a powerful drawbar pull. (Fig. 7)
IF i o. 71 SAP03465
1o-79
STRUCTURE AND FUNCTION VALVE CONTROL
VALVE CONTROL
SBPO3971
Lever positions
1. Travel PPC valve 9. Hydraulic pump @ HOLD @ Swing RIGHT
2. Service PPC valve 10. Junction box @ Boom RAISE @ Swing LEFT
3. Service pedal 11. Accumulator @ Boom LOWER @I NEUTRAL
4. L.H. travel lever 12. EPC solenoid valve @ Bucket DUMP @I Travel REVERSE
5. R.H. travel lever 13. L.H. work equipment @ Bucket CURL 0 Travel FORWARD
6. R.H. PPC valve lever @ HOLD @ LOCK
7. R.H. work equipment 14. L.H. PPC valve @ Arm IN @ FREE
lever 15. Safety lock lever @ Arm OUT
8. Control valve
lo-81
STRUCTURE AND FUNCTION WORK EQUIPMENT. SWING PPC VALVE
WORK EQUIPMENT l SWING PPC VALVE
SW00273
a. Port P (from main pump)

b. Port T (to tank)
c. Pot-t P2 (L.H.: Arm IN / R.H.: Boom RAISE)
d. Port P4 (L.H.: Swing LEFT / R.H.: Bucket DUMP)
e. Port PI (L.H.: Arm OUT / R.H.: Boom LOWER)
f. Port P3 (L.H.: Swing RIGHT / R.H.: Bucket CURL)
1O-82
STRUCTURE AND FUNCTION WORK EQUIPMENT. SWING PPC VALVE
D-D
B-B
E-E
SBFUO274
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 connecting lever)
1 O-83
STRUCTURE AND FUNCTION WORK EQUIPMENT l SWING PPC VALVE
OPERATION
I) At neutral
Ports A and B of the control valve and ports
PI and P2 of the PPC valve are connected to
drain chamber D through fine control hole f
in spool (I). (Fig. I)
2) During fine control (neutral + fine control)

When piston (4) starts to be pushed by disc
(5), retainer (9) is pushed; spool (I) is also
pushed by metering spring (2). and moves (Fig. I)
down. SBPO3493
When this happens, fine control hole f is
shut off from drain chamber D, and at al-
most the same time, it is connected to pump
pressure chamber PP, so pilot pressure oil
from the main pump passes through fine
control hole f and goes from port PI to port
A.
When the pressure at port PI becomes
higher, spool (I) is pushed back and fine
control hole f is shut off from pump pres-
sure chamber PP. At almost the same time,
it is connected to drain chamber D to re-
lease the pressure at port PI. When this hap-
pens, spool (I) moves up or down so that
the force of metering spring (2) is balanced
with the pressure at port PI. The relation-
ship in the position of spool (1) and body
(IO) (fine control hole f is at a point midway
between drain hole D and pump pressure
chamber PP) does not change until retainer
(9) contacts spool (I).
Therefore, metering spring (2) is compressed
proportionally to the amount of movement
of the control lever, so the pressure at port
PI 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 pres- (F i s. 2)
SBPO3494
sure at port PI) and the force of the control
valve spool return spring are balanced.
(Fig.21
1O-84
STRUCTURE AND FUNCTION WORK EQUIPMENT l SWING PPC VALVE
3) During fine control

(when control lever is returned) M
When disc (5) starts to be returned, spool (I)
is pushed up by the force of centering spring
(3) and the pressure at port PI.
connected to drain chamber D and the pres-
sure oil at port PI is released.
If the pressure at port PI drops too far, spool
(I) is pushed down by metering spring (21,
and fine control hole f is shut off from drain
chamber D. At almost the same time, it is
connected to pump pressure chamber PP,
and the pump pressure is supplied until the
pressure at port PI 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)
(F i 8. 3)
SEPO3495
At full stroke
When disc (5) pushes down piston (4), and
retainer (9) pushes down spool (I), fine con-
trol hole f is shut off from drain chamber D,
and is connected with pump pressure cham-
ber PP. Therefore, the pilot pressure oil from
the main pump passes through fine control
hole f and flows to chamber A from port PI,
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)
(Fio. 4)
SBPO3496
1O-85
STRUCTURE AND FUNCTION TRAVEL PPC VALVE
TRAVEL PPC VALVE
I
C-4
c d
SAP02660
a. Port P (from main pump)

b. Port T (to tank)
c. Port PZ (L.H. travel FORWARD)
d. Pot-t PI (L.H. travel REVERSE)
e. Port P3 (R.H. travel REVERSE)
f. Port P4 (R.H. travel FORWARD)
1O-86
B-0 A-A
2
0
c-c
SAP02661
1. Plate 5. Metering spring

2. Body 6. Centering spring
3. Piston 7. Valve
4. Collar 8. Bolt
1 O-87
OPERATION
1) At neutral
Ports A and B of the control valve and ports
PI and P2 of the PPC valve are connected to
drain chamber D through fine control hole f
in spool (I). (Fig. I)
2) Fine control (neutral + fine control)

When piston (4) starts to be pushed by disc
(5), retainer (9) is pushed. Spool (I) is also
pushed by metering spring (2) and moves (Fig. 11
SLIP03497
down.
shut off from drain chamber D. At almost
the same time, it is connected to pump pres-
sure chamber PP, and the pilot pressure of
the main pump is sent from port A through
fine control hole f to port PI.
When the pressure at port PI rises, spool (I 1
is pushed back. Fine control hole f is shut
off from pump pressure chamber PP. At al-
most the same time, it is connected to drain
chamber D, so the pressure at port PI es-
capes.
As a result, spool (I) moves up and down
until the force of metering spool (2) is bal-
anced with the pressure of port PI.
The relationship of the position of spool (I)
and body (IO) (fine control hole f is in the
middle between drain hole D and pump pres-
sure chamber PP) does not change until re-
tainer (9) contacts spool (I).
Therefore, metering spring (2) is compressed
in proportion to the travel of the control le-
ver, so the pressure at port PI also rises in
proportion to the travel of the control lever.
In this way, the spool of the control valve (F i 8, 2)
moves to a position where the pressure of SBPO3498
chamber A (same as pressure at port PI)

and the force of the return spring of the
control valve spool are balanced. (Fig.2)
1O-88
3) Fine control (control lever returned)

When disc (5) starts to be returned, spool (I 1
is pushed up by the force of centering spring
(3) and the pressure at port PI.
Because of this, fine control hole f is con-
nected to drain chamber D, and the pressu-
rized oil at port PI is released.
If the pressure at port PI drops too much,
spool (I) is pushed up by metering spring
(2), so fine control hole f is shut off from
drain chamber D. At almost the same time,
it is connected to pump pressure chamber
PP, so the pressure at port PI supplies the
pump pressure until the pressure recovers
to a pressure equivalent to the position of
the lever.
When the control valve returns, oil in drain
chamber D flows in from fine control hole f
of the valve on the side that is not moving.
It passes through port P2 and goes to cham-
ber B to charge the oil. (Fig. 3) (F i o. 3)
SEPO3499
4) At full stroke
Disc (5) pushes down piston (41, and retainer
(9) pushes down spool (1). Fine control hole
f is shut off from drain chamber D, and is
connected to pump pressure chamber PP.
Therefore, the pilot pressure oil from the
main pump passes through fine control hole
f and flows to chamber A from port PI to
push the control valve spool. The return oil
from chamber B passes from port P2 through
fine control hole f’ and flows to drain cham-
ber D. (Fig. 4)
(Fig. 4)
SBPO3695
1 O-89
STRUCTURE AND FUNCTION SERVICE PPC VALVE
SERVICE PPC VALVE

1. Pin
2. Cam
3. Ball
4. Piston
5. Cover
6. Sleeve
7. Centering spring
8. Metering spring
9. Spool
10. Body
a. Port T (to tank)

b. Port P (from main pump)
c. Port A (to service valve P-l)
d. Port B (to service valve P-2)
d
SBPOO285
1O-90
OPERATION
At neutral
l The pressurized oil from the control pump
enters from port P and is blocked by spool
(9).
. Ports A and B of the control valve and ports
a and b of the PPC valve are connected to
drain port T through fine control hole X of
spool (9).
SBP03500
When operated
. When cam (2) is moved, metering spring (8)
is pushed by ball (31, piston (41, and sleeve
(61, and spool (9) is pushed down by this.
. As a result, fine control hole X is shut off
from the drain circuit. At almost the same
time, fine control portion Y is connected with
port a, and the pressurized oil from port P
flows from port a to port A of the control
valve.
SFlPO3501
10-91
l When the pressure at port a becomes higher,

spool (9) is pushed back by the force acting
on the end of the spool. When fine control
portion Y closes, fine control hole X is con-
nected to the drain circuit at almost the same
time.
. As a result, spool (9) moves up and down to
balance the force at port a and the force at
metering spring (8).
l Therefore, metering spring (8) is compressed
in proportion to the amount the control le-
ver is moved. The spring force becomes
larger, so the pressure at port a also in-
creases in proportion to the amount the con-
trol lever is operated.
In this way, the control valve spool moves
to a position where the pressure of port A
(the same as the pressure at port a) is bal-
anced with the force of the return spring of
SBPO3502
the control valve spool.
1 O-92
STRUCTURE AND FUNCTION ACCUMULATOR
ACCUMULATOR
FOR PPC VALVE
1. Gas plug
2. Shell
3. Poppet
4. Holder
5. Bladder
6. Oil port
Specifications
Type of gas : Nitrogen gas
Gas volume : 300 cc
SDP01626
Function
l The accumulator is installed between the
main pump and the PPC valve. Even if the
engine is stopped with the work equipment
raised, pilot oil pressure is sent to the main
control valve by the pressure of the nitrogen
gas compressed inside the accumulator, so
it is possible to lower the work equipment
under its own weight.
Operation
. Before actuation After actuation
After the engine stops, when the PPC valve
is at neutral, chamber A inside the bladder A A
is compressed by the oil pressure in cham-
ber B.
. If the PPC valve is operated, the oil pressure
in chamber B becomes less than 2.9 MPa
(30 kg/cm*), so the bladder expands under
the pressure of the nitrogen gas in chamber
A. The oil entering chamber B is sent as the
pilot pressure to actuate the main control
valve.
SEP01628
1o-93
STRUCTURE AND FUNCTION STRAIGHT-TRAVEL SYSTEM
STRAIGHT-TRAVEL SYSTEM
Boom Bucket Junction block
1
---y: r---‘ L.H.travel motor R.H. travel motor
_---____p--j--_
Arm DUMP FOR"Afl"ERSE ry “ERSE
/ +c
:--I~____I__
’ I--- Arm CURL
Arm Swing
II I
I I I iI r--lj:
Ij I+-___i__~___
Bucket CURL
Travel PPC valve
c<o>-;
I I
;,p~~------------‘t____------_
I
R, H, trave, RE” ERSE
I ‘-+------__ ______ +-------___ R. ,,. t rave, FORWARD

I 1
I I I I
t ‘----,~___________----‘:L___________ ~~~~~~~~~~ REVERSE
I
L-,+L------,+L ___________ ---+L __________L, ,,, travel FORWAR,,

I I I
I I
I
‘---<?--J
I____________________J
I
SAP03887
Function
l This system interconnects the pressure com-
pensation valves for L.H. and R.H. travel I
Travel PPC Pressure
FORWARD and REVERSE with external pip-
ing to ensure the ability to travel in a straight /,eft (right)
line.
l As shown in the diagram on the right, the
left and right ports are interconnected
through passage a inside travel pressure
compensation valve (I ).
. By setting the throttle in junction circuit a to
a suitable value, it is possible to fulfill the
requirements for steering ability and the abil-
ity to maintain a straight line.
1o-94
STRUCTURE AND FUNCTION EPC SOLENOID VALVE
EPC SOLENOID VALVE

FOR PPC LOCK, SWING BRAKE, TRAVEL SPEED, 2 STEP RELIEF EPC SOLENOID VALVE
A2
/
ACC
Al A4 A3 A2
ACC PI
SAP04273
1. PPC lock EPC solenoid valve Al. To PPC valve

2. Swing brake EPC solenoid valve A2. To travel motor
3. Travel speed EPC solenoid valve A3. To swing motor swing brake
4. 2 step relief solenoid valve A4. To main relief valve
ACC. To accumulator
Pl. From main pump
T. To tank
1o-95
0
STRUCTURE AND FUNCTION EPC SOLENOID VALVE
1. Connector
2. Movable core
3. Coil
4. Cage
5. Spool
6. Block
7. Spring
i 6
SAP03237
Operation
When solenoid is deactivated
l When the signal current does not flow from
the PPC lock switch or swing lock switch,
solenoid (3) is deactivated.
For this reason, spool (5) is pushed fully to
the right by spring (6).
As a result, the circuit between ports P and
A closes and the pressurized oil from the
main pump does not flow to the actuator.
At the same time, the pressurized oil from
the actuator flows from port A to port T, and
is then drained to the tank.
SAP03888
When solenoid is excited
l When the signal current flows from the PPC Actuator 1
lock switch or swing lock switch to solenoid
(3), solenoid (3) is excited.
For this reason, spool (5) is pushed to the
left in the direction of the arrow.
As a result, the pressurized oil from the main Exit
pump flows from port P through the inside
of spool (5) to port A, and then flows to the
actuator. At the same time, port T is closed,
and this stops the oil from flowing to the
tank.
SAP03889
1O-96
STRUCTURE AND FUNCTION BOOM HOLDING VALVE
BOOM HOLDING VALVE

* For machine equipped with arm holding valve, the structure and function of arm holding valve is
the same as this valve.
a b
B-B
A-A
‘C
SDPO1321
1. Safety-suction valve a. Port T (to tank)

2. Pilot spring b. Port Pi (from boom LOWER PPC valve)
3. Pilot spool c. Port Cy (to boom cylinder bottom)
4. Poppet spring d. Port V (from boom control valve)
5. Poppet
1o-97
OPERATION
1) At boom RAISE
When the boom is raised, the main pressure
from the control valve pushes poppet (5) up
in the direction of the arrow.
Because of this, the main pressure from the
control valve passes through the valve and
flows to the bottom end of the boom cylin-
der.
SBP03507
2) Boom lever at NEUTRAL

When the boom is raised and the control
lever is returned to NEUTRAL, the circuit for
the holding pressure at the bottom end of
the boom cylinder is closed by poppet (5).
and at the same time, the oil flowing into
poppet (5) through orifice a of poppet (5) is
I
,
closed by pilot spool (3). I
/
As a result, the boom is held in position. /
/
: Control lever
0
SBPO3508
1 O-98
31 At boom LOWER
When the boom is lowered, the pilot pres-
sure from the PPC valve pushes pilot spool
(3) and the pressurized oil in chamber b in-
side the poppet is drained.
When the pressure at port B rises because
of the pressurized oil from the bottom end
of the boom cylinder, the pressure of the
pressurized oil in chamber b is lowered by
orifice a.
If the pressure in chamber b drops below
the pressure at port A, poppet (5) opens the
pressurized oil flows from port B to port A,
and then flows to the control valve.
If any abnormal pressure is generated in the
circuit at the bottom end of the boom cylin-
der, safety valve (I) is actuated.
SBPO3509
1o-99
STRUCTURE AND FUNCTION ADDITIONAL FILTER FOR BREAKER
ADDITIONAL FILTER FOR BREAKER

* FOR MACHINE EQUIPPED WITH BREAKER
SBPO2669
1. Head cover SPECIFICATIONS

2. Element Rated pressure : 6.86 MPa (70 kg/cm?
3. Case Flow : 102 Umin
4. Drain plug Relief valve cracking pressure:
5. Valve 0.34 + 0.049 MPa
6. Spring (3.5 + 0.5 kg/cm*)
7. Spring set plug Filter mesh size : 6 pm
Filtering area : 3160 cm*
10-100
STRUCTURE AND FUNCTIO WORK EQUIPMENT
N
WORK EQUIPMENT
SBPO2670
1. Arm
2. Bucket cylinder
3. Arm cylinder
4. Boom
5. Boom cylinder
6. Bucket
10-101
STRUCTURE AND FUNCTION ACTUAL ELECTRICAL WIRING DIAGRAM
ACTUAL ELECTRICAL WIRING DIAGRAM

\ \
10-102
0
E20Y06
1. Fuel level sensor

2. Working lamp
3. PC control EPC solenoid valve
4. Rear lamp
5. Engine speed sensor
6. Engine oil pressure switch
7. Washer tank
8. Travel alarm
9. Horn (high tone)
10. Horn (low tone)
11. Battery relay
12. Battery
13. Front lamp
14. PPC lock solenoid valve
35
16. 2 step relief solenoid valve
17. Travel speed solenoid valve
18. Engine water temperature sensor
19. Electrical Intake air heater
20. Air conditioner compressor magnet switch
21. Engine oil level sensor
22. Alternator
23. Starting motor
24. R.H. additional front lamp
25. Room lamp
26. L.H. additional front lamp
27. Wiper motor
28. Alarm buzzer
29. Pump controller
30. Horn switch
31. Speaker
32. Monitor panel
33. Starting switch
34. Fuse box
35. Radio
36. Wiper switch
36 37. Swing lock switch
38. Optional lamp switch
39. PPC lock switch
40. Heater
41. Light relay
42. Heater relay
43. Shift down foot switch
STRUCTURE AND FUNCTION ELECTRICAL CIRCUIT DIAGRAM
ELECTRICAL CIRCUIT DIAGRAM

(l/2)
* For details of this page, see page 90-I 1.
STRUCTURE AND FUNCTION ELECTRICAL CIRCUIT DIAGRAM
W2)
STRUCTURE AND FUNCTION ELECTRIC CONTROL SYSTEM
ELECTRIC CONTROL SYSTEM

TOTAL SYSTEM DIAGRAM
lever
Arm SWinP
L. H.
PPC
valve
Boom Bucket
limit switch
R. H.
PPC
valve
6-+
R. H L. H
Travel Travel
Trave I
PPC I
valve I
I
!
@g-q- T+
I
Ensine I
I
2Y!!s25
F R
Main
DUlllP
Servo Servo
valve valve
Travel
Monitor Panel
$fzjqqf
Pump
controller
c_ I I
~
SAP03972
lo-106
1. PUMP CONTROL FUNCTION
----------------__________, r--------------
! !
Control valve
Junction block
Engine
I
I
I
:.
---- LS valve p--y-
1 PC-EPC valve Pump prolix switch
10A
0 0 m Pump
controller
Battery
Fuse
box i
Battery relay
10-107
Function Engine horsepower

l The pump controller sets the pump absorp-
tion torque to match the engine speed.
. When the engine is running at high speed, it
raises the pump absorption torque to boost
the productivity. When the engine is run-
ning at low speed, it throttles the pump ab-
sorption torque to prevent the engine from
stalling.
Ensine speed
SAP03896
lo-108
Pump controller
\
\\
CONTROLLER, TVC 0
CN-CO 1
SAP03228
Input/output signals
CN-CO1
1 Pin No. 1 Name of signal 1Input/output 1 Pin No. Name of signal Input/output
1 Power source (24V) Input 181 1 Input I

2 NC -
I 3 I Engine speed sensor 1 Input I
13 EPC solenoid I-1 output
10-109
2. SWING LOCK, PPC LOCK, TRAVEL SPEED SELECT FUNCTION
Sefetu lock lever
L. H.
PPC
valve
PPC lock
Boom Bucket
1
limit switch
--I
ft.H.
PPC
valve Main relief valve
Ii. H L. H
Travel Travel Trava I
speed
Travel
PPC
valve
Enaine
Swing
lock
m
Monitor Panel
/k
Battery
Battery relay
SAP03973
10-110
Operation
I) Swing lock function
. The swing can be locked at any position
desired by using the swing lock switch
(manual).
. Operation of swing lock switch
Lock switch Pilot lamp Function Operation
Swing lock Swing lock is always actuated, and upper structure

ON Lights up
ON does not swing even when swing lever is operated
Swing lock Swing lock is canceld, and upper structure swings

OFF Goes out
OFF when swing lever is operated
2) PPC lock function

l The PPC lock switch is interconnected
with the safety lock lever. When the
safety lock lever is at the LOCK position,
the PPC lock switch is turned OFF.
l When the PPC lock switch is turned OFF,
E the electric current going to the PPC lock
z solenoid valve is shut off, and the work
8 equipment will not move even if the work
equipment control levers are operated.
3) Travel speed select function

If the travel speed switch is set to Lo, Hi, the
motor volume is switched and travel speed
changes.
10-111
3. TRAVEL SPEED CONTROL
SFJPO4265
1. Shift down foot switch Outline

2. Travel speed switch . If shift down foot switch (I) is pressed, the
travel speed is set low, even if travel speed
switch (2) is at the Hi position (priority is
given to the shift down foot switch). g
. Use this switch when it is difficult to operate z
travel speed switch (2) by hand or when 2
more power is needed to remove the ma-
chine from soft ground.
System electrical circuit
Opt ion I Foot suitch

Power / Re I ay II,
I
FUSE No. 6
-CN-M2Y
FUSE No. 5 aid
60000~
9
n CN-HO2
,00001
I I
SAP04272
10-111-l
0
STRUCTURE AND FUNCTION MACHINE MONITOR SYSTEM
MACHINE MONITOR SYSTEM
buzzer
Ll signal
Snitch signal
Power
Source
Battery
SBPO3898
FUNCTION
l The machine monitor system monitors the l In addition, the monitor panel is equipped
machine conditions with sensors mounted with switches for each electrical device.
on each part of the machine, and processes
and displays the condition data to inform
the operator of the condition.
l Details of the information displayed on the
monitor panel are as follows:
1. Monitor section which gives an alarm
when abnormality occurs in the machine.
2. Pilot section which displays the condi-
tion of the machine when operated.
3. Gauge section which always displays the
machine condition.
10-l12
MONITOR PANEL
CNyPl
CN-P2
CN-P3
SXPOOO44
OUTLINE Input and output signal

. The monitor panel has monitor/display func- CN-Pl (Monitor panel)
tion and switch function for electrical de-
INo. Signal name 1 I/O 1
vices.
. CPU (Central Processing Unit) is mounted in 1 1 1Power source: t24V 1- 1
the panel, which processes, displays and out- 12 1Power source: t24V I - I 10 I Charge level I Input I
l-l
puts the data.
I31GND
. The gauge display uses a liquid crystal dis-
play (LCD) and the monitor display uses 1 4fGND l-l
lamps.
a - -
CN-P2 (Light switch) CN-P3 (Heater switch)
No. Signal name I/O
2 Heater Hi output
3 Heater Lo output
4 GND -
10-113
9 0 li 5 SXPOOO45
1. Service meter 6. Preheating pilot lamp

2. Coolant temperature gauge 7. Swing lock pilot lamp
3. Fuel level gauge 8. Charge level caution lamp
4. Light switch 9. Engine oil pressure caution lamp
5. Heater switch
z: 1 Symbol Display item Display range Display method
0.05 MPa lo.5 kg/cm*) Normal operation: OFF

Engine oil pressure
or lower Upon abnormality: ON
When charging level When abnormlity occurs during engine

Charge level I running,buzzer sounds. 1
is insufficient
\. w Correspoding segment lights up.

Coolanttemperature
ii5EQ SDP00963
Only when the rightmost one lights up, the
i segment flashes and the buzzer sounds. I
Correspoding segment and lower ones al lights up.
Fuel level \\i\ Only when the level lowers to the leftmost
IF IF SDP00964 l one, it flashes. I
When the starting switch is set to “HEAT”, this lamp
Preheating During preheating will light up for 30 seconds, and then flashes for 10
seconds to indicate the completion of preheating.
Swing lock When swing is locked Lights up when the swing lock switch is ON.
Lo: Heater fan Lo

Heater switch Hi: Heater fan Hi
1: Monitor panel lights up

Light switch
2: Monitor panel, head light and work lamp light up
10-114
STRUCTURE AND FUNCTION SENSORS
. The signals from the sensors are input di-

rectly to the panel.
. One side of the contact-type sensors is al-
ways connected to the chassis GND.
Classification of indication Type of sensor Sensing type Normal Abnormal
CAUTION Engine oil pressure Contact type ON OFF
Coolant temperature Resistance type - -

GAUGE GROUP
Fuel level Resistance type - -
1) Engine oil pressure sensor
1. Plug
2. Contact ring
3. Contact
4. Diaphragm
5.
63
Spring
6. Terminal
Structure of c ircuit
Operations (ON) pressure:
49 f 19.6 kPa (0.5 r 0.2 kg/cm*)
SBD01537
2) Coolant temperature sensor
1. Connector
2. Plug
3. Thermistor
wStructure of circuit
SEDOl538
10-l15
STRUCTURE AND FUNCTION SENSORS
3) Fuel level sensor
1. Float
2. Connector
3. Cover
4. Variable resistance
FULL
EMPTY
3 4
&
Structure of circuit
SEP04165
10416
20 TESTING AND ADJUSTING
Standard value table for engine related parts . . 20- 2 Testing and adjusting PC valve output
Standard value table for chassis related parts . 20- 3 pressure (servo piston input pressure) . . . . 20-I 15
Standard value table for electrical system . . . . . . . . . 20- 11 Testing and adjusting LS valve output pressure
Tools for testing, adjusting, (servo piston input pressure) and LS
and troubleshooting . . . . . . . .._......................... 20-101 differential pressure . . . . . . . . .._........................ 20-I 17
Measuring engine speed . . . . . . . . . . . . . .._................... 20-102 Testing and adjusting control
Measuring exhaust color . . . .._.._......................... 20-103 circuit oil pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-120
Adjusting valve clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-104 Testing solenoid valve output pressure . . . . . . . . . . 20-121
Measuring compression pressure . . . . . . . . . . . . . . . . . . . . 20-105 Measuring PPC valve output pressure . . . . . . . . . . . . 20-122
Measuring blow-by pressure . . . . . . .._................... 20-105 Adjusting work equipment, swing PPC valve . . 20-124
Testing and adjusting fuel injection timing . . . 20-106 Testing travel deviation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-125
Measuring engine oil pressure . . . . . . . . .._............. 20-107 Testing locations causing hydraulic drift
Testing and adjusting fan belt tension . . . . . . . . . . . 20-108 of work equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-126
Testing and adjusting belt tension for air Measuring oil leakage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-128
conditioner compressor . . . . . . . .._................... 20-108 Releasing remaining pressure
Adjusting engine speed sensor . . . . . . . . . . . . . . . . .._..... 20-109 in hydraulic circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-130
Adjusting fuel control lever . . .._....._................... 20-l IO Testing clearance of swing circle bearing . . . . . . 20-131
Testing and adjusting hydraulic pressure in Testing and adjusting track shoe tension . . . . . . . 20-132
work equipment, swing, travel circuit . . . . . . 20-I 12 Bleeding air . . . . . . . . . . . . . . .._....................................... 20-133
Troubleshooting . . . . .._........................................... 20-201
* Note the following when making judgements using the standard value tables for testing, adjusting, or
troubleshooting.
1. The standard value for a new machine given in the table is the value used when shipping the machine from
the factory and is given for reference. It is used as a guideline for judging the progress of wear after the
machine has been operated, and as a reference value when carrying out repairs.
2. The service limit value given in the tables is the estimated value for the shipped machine based on the results
of various tests. It is used for reference together with the state of repair and the history of operation to judge
if there is a failure.
3. These standard values are not the standards used in dealing with claims.
A When carrying out testing, adjusting, or troubleshooting, park the machine on level ground, insert the safety
pins, and use blocks to prevent the machine from moving.
When carrying out work together with other workers, always use signals and do not let unauthorized people
A
near the machine.
g When checking the water level, always wait for the water to cool down. If the radiator cap is removed when
the water is still hot, the water will spurt out and cause burns.
A Be careful not to get caught in the fan, fan belt or other rotating parts.
20-l
0
TESTING AND ADJUSTING STANDARD VALUE TABLE FOR ENGINE RELATED PARTS
STANDARD VALUE TABLE FOR ENGINE RELATED PARTS
Engine S6D102-1
f
Standard ‘ermissible
Item Measurement condition Unit
value value
High idling I 2,200 + 70 -
Engine speed Low idling rpm 970 + 50
Rated
At sudden acceleration Bosch
2,000
Max. 5.5 7.0

Exhaust gas color
index
At high idling Max. 0.5 2.0
0.25
Valve clearance
0.51 -
Difference
between
Oil temperature: Min. 2.4
MPa cylinders
Compression pressure 40 - 60°C {Min. 24.61
kg/cm: Min. 1.0
(engine speed: 250rpm) I (Min. IO.31
Max. 1.2 5.1

Blow-by pressure
{Max. 1231 {520)
(Coolant temperature:
operating range)
At high idling MPa 0.34 - 0.52 0.21

Oil pressure (SAE15W-40) {kg/cm; 13.5 - 5.31 i2.11
At low idling Min. 0.1 0.07

(SAE15W-40) {Min. 1.0) lo.71
Whole speed range

Oil temperature “C 80-110 120
(inside oil pan)
Before top dead center ’

Fuel injection timing 17+ 1 17+ 1
(B.T.D.C.) {degree
Deflection
when Fan-tension Min. 10
8
pressed Max. 6
Belt tension with finger mm
force of Fan-
approx. air conditioner 5-8
5-8
58.8N{6kg) compressor
20-2
0
TESTING AND ADJUSTING STANDARD VALUE TABLE FOR CHASSIS RELATED PARTS
STANDARD VALUE TABLE FOR CHASSIS RELATED PARTS
Machine model
T PC200-6
Cate-
Item Measurement conditions Jnit Standard value ‘ermissible value
gory
. Hydraulic oil temperature:

B
x
v) . Coolant temperature:
45 - 55°C
At 2-pump relief Within operating range rpm 2,000+100 2,000~100

.-?
. 2-pump relief: Arm relief
p
Lu
e
Boom control valve r 1
mm
- 9.5kO.5
g Swing control valve
Travel control valve

I 1
Boom control lever . Center of lever knob 100 k 10 100 f 10

. Read max. value to end of
travel
z Arm control lever 100 ? IO 100 iI 10
. Engine stopped
P
2 . Excluding neutral play
Bucket control lever 100 f 10 100 f 10
z-.
E
8 Swing control lever nm 100 f 10 100 + 10
%
Max. 127
z Travel control lever 115 * 12
Min. 103
g-
c Work equipment,
Max. 5 Max. 5
swing
Play of control lever
Travel Max. 10 Max. 10
. Engine at high idling 15.7 f 3.9 15.7 & 3.9

f 1 Boom control lever
II.6 f 0.41 II.6 f 0.4)
. Oil temperature: 45 - 55°C
L’
Arm control lever
. Fit push-pull scale to center 15.7 * 3.9 15.7 * 3.9
E (I.6 ?Y0.4) (1.6 ? 0.41
of control lever knob to
8
6 measure N 13.7 + 2.9 13.7 ? 2.9
Bucket control lever
g . Measure max. value to end :kgl II.4 + 0.3) II.4 + 0.31
,o of travel 13.7 * 2.9 13.7 f 2.9
2 Swing control lever
.- (1.4 + 0.31 (1.4 + 0.31
;i
z 24.5 ? 5.9 24.5 ? 5.9
Travel control lever
0” (2.5 ? 0.6) 12.5 ? 0.6)
20-3
0
Machine model r PC200-6
Item Measurement conditions Unit Standard value F‘ermissible value

45 - 55°C
3.9 + 1.0 3.9 k 1.0
Unload pressure . Engine at high idling
I40 + 101 (40 * IO}
. All levers at neutral
. Pump output pressure
Boom . Hydraulic oil temperature:

45 - 55°C
31.9 k 1.0 Max. 33.8 13451
Arm . Relief pressure with engine
I325 + IO) Min. 30.4 I3101
at high idling (Relieve only
circuit to be measured) MPa
Bucket
. Pump outlet port pressure {kg/
*: For travel, measure oil cm*) Max. 30.9 I3151
Swing
pressure for relief on one
28.9 ‘;:,” I295 -‘;a Min. 27.4 {280}
side Max. 33.8 1345)
Travel 34.8 ‘;:o” {355 -‘:a
Min. 30.4 {3101
Max. 3.4 I351
Self-reducing pressure valve 3.2 f 0.2 I33 f 21
Min. 2.9 1301
2.9 f 1.0 130 + 101 2.9 * 1.0 130 ? 101

LS differential
pressure
2.2 f 0.1 {22 * II 2.2 * 0.1 (22 + 11
20-4
0
Applicable model PC200-6
Cats
Item Measurement conditions Unit Standard value ‘ermissible value
gor
Work equipment Max. reach
posture
deg.
Swing brake angle Max. 100 Max. 130
TKPOlII5 mm
. Engine at high idling
Hydraulic oil temperature: 45-55°C
Stop after swinging one turn and
measure distance that swing circle
Work equipment Max.

posture reach
90” 3.1 f 0.3 Max. 3.7
Time taken to TKPOll16 sec.

start swing
45 - 55°C 180’ 4.4 f 0.8 Max. 5.6
In H/O mode + H mode
Time taken to swing 90” and
180” from starting position
Work equipment Max. reach

posture
Time taken to swing sec. 24 ? 3.5 Max. 30

TKPOl115
. In H/O mode t H mode
Swing one turn, and measure time
taken to swing next 5 turns
Hydraulic drift of swing Engine stopped mm 0

Set machine on 15” slope, and set
upper structure at 90” to the side.
Make match marks on swing circle
outer race and track frame.
Measure distance that match
marks move apart after 5 minutes.

Leakage from swing . Hydraulic oil temperature: 45-55X !/min Max. 5 Max. 10
motor . Swing lock switch ON
. Relieve swing circuit.
20-5
0
Applicable model r
f
PC200-6
I
Cats Jnit Standard value ‘ermissible value
Item Measurement conditions
gor
-
STD: STD:
40.5 + 5 35.5 - 48.5
Lo
LC: LC:
44.0 + 5 39.0 ? 52.0
BKP-30104
Travel speed (1) - sec. +

Engine at high idling
Hydraulic oil temperature:
45 - 55°C STD: STD:
In H/O mode 27.5 & 2 25.5 - 31.5
Hi
Raise track on one side at a LC: LC:
time, rotate one turn, then 30 + 2.5 27.5 - 35
measure time taken for
next 5 turns with no load. -
Lo 21 ?C 2.5 18.5 - 24.5
Travel speed (2) Engine at high idling

- sec.
45 - 55°C
In H/O mode
Run up for at least 10 m, Hi 13* 1 12 - 15
and measure time taken to
travel next 20 m on flat
ground.
-

45 - 55°C
. Run up for at least 10 m, and
Travel deviation measure deviation when mm Max. 200 300
traveling next 20 m on flat
ground.
t Use a hard horizontal surface.
1 10m _I
BKP00107
t Measure dimension X.
20-6
0
Applicable model
T PC200-6
Item Measurement conditions Unit Standard value Permissible value
Hydraulic drift of travel mm 0 0

Engine stopped
45 - 55°C
Stop machine on 12O slope
with sprocket facing straight
up the slope.
Measure the distance the
machine moves in 5 minutes.
Leakage of travel motor Lock Pin ‘/min 13.6 27.2

TKPOl117

45 - 55°C
Lock shoes and relieve travel
circuit.
Work equipment posture

Total work equip-
ment Max. 960 Max. 1,440
(hydraulic drift at
tip of bucket teeth)
Boom cylinder BKPOOllO
(amount of retrac- Max. 50 Max. 75

tion of cylinder)
Place in above posture and
. -2
measure extension or retrac-
tion of each cylinder and
d downward movement at tip of
i mm
Arm cylinder bucket teeth.
(amount of exten- Bucket: Rated load Max. 160 Max. 240
, sion of cylinder) Horizontal, fiat ground
i Levers at neutral
Engine stopped
45 - 55°C
Start measuring immediately
Bucket cylinder
after setting.
(amount of retrac- Max. 35 Max. 53
Measure hydraulic drift every 5
tion of cylinder)
minutes, and judge from
results for 15 minutes.
20-7
0
Applicable model PC200-6
Item Measurement conditions Unit Standard value ‘ermissible value
Boom
3.5kO.4 Max. 4.3
Bucket teeth in
contact with ground
TKPOlll8
z
Cylinder fully
Hydraulic oil temperature: 2.8kO.3 Max. 3.2
extended
45 - 55°C
. In H/O mode
Arm 3.6kO.4 Max. 4.5
Cylinder fully
retracted
TKPOlll9
X
Fully extended . Hydraulic oil temperature: 2.9kO.3 Max. 3.5
45 - 55°C
. In H/O mode
Bucket 2.8kO.4 Max. 3.5
Cylinder fully
retracted
TKPOIIZO
$
Fully extended set 2.1?0.3 Max. 2.7
45 - 55°C
\ &a’
//////////////////////,
BKP00114
Boom Max. 1.0 Max. 1.2
. Lower boom and measure time
taken from point where bucket
contacts ground to point where
chassis rises from ground
. Engine at low idling
45 - 55°C
Max. 1.0 Max. 2.8

BKP00115
Stop arm suddenly and measure

time taken for arm to stop
. Engine at low idling
45 - 55°C
20-8
0
Applicable model
T PC200-6
Cat6 Unit Standard value ‘ermissible value

Item Measurement conditions
gor
Bucket sec. Max. 1.0 Max. 3.6
Stop bucket suddenly and

measure time taken for bucket
to stop at bottom and then
start again.
Engine at low idling
45 - 55°C
Cylinders . Hydraulic oil temperature: 4.5 20

45 - 55°C
c/mil
Center swivel joint Relieve circuit to be measured 10 50

45 - 55°C
* Use a hard horizontal surface.
Travel deviation when

!-- 20m -I
work equipment + mm Max. 200 Max. 220
travel are operated
BKP00107
Sr Measure dimension X.
Piston pump See next page See next page
20-9
0
TESTING AND ADJUSTING TSTANDARD VALUE TABLE FOR CHASSIS RELATED PARTS
PC200-6: Discharge amount of main piston pump
(P/mint
300
Pump discharge oressure
TKPOlOOl
l Pump speed: At 2000 rpm, PC current 260 mA
Test pump Discharge Average Standard value Judgement

discharge pressure of pressure for discharge standard lower
Check point
pressure other pump amount 0 limit Q
(MPa {kg/cm21) (MPa {kg/cm*}) (MPa {kg/cm*}) (E/min) Wmin)
Pl + P2
cdesiredpmm 1 P2 1 2 1 See graph 1 See graph
Sr As far as possible, bring pump discharge pressure PI and P2 as close as possible to the
average pressure when measuring.
The error is large near the point where the graph curves, so avoid measuring at this point.
20-10
0
TESTING AND ADJUSTING STANDARD VALUE TABLE FOR ELECTRICAL SYSTEM
STANDARD VALUE TABLE FOR ELECTRICAL SYSTEM
Name of Zonnectol Measurement

Judgment table
component No. conditions
If the condition is as shown in the table I) Turn starting

below, it is normal switch OFF.
a Disconnect
connector X05.
x05
Swing lock switch
(male)
When switch Between @ - @ Min. 1 MR
is LOCK Between @ - @ Max. 1 R
If the condition is within the range shown in 1) Turn pump

the table below, it is normal prolix switch
Cl3 OFF.
PC-EPC solenoid Between (i) - @? 7-14R 2) Disconnect
(male)
connector C13.
Between @ - chassis Min. 1 MQ
If the condition is within the range shown in 1) Turn starting

the table below, it is normal switch OFF.
Swing holding 2) Disconnect
vo4
brake solenoid Between @ - @ 20 - 60 R connector V04.
(male)
valve
-chassis 1 Min. 1 MQ 1

PPC oil pressure vo7 2) Disconnect
lock solenoid valve 1 (male) Between @ - @ 20 - 60 R connector V07.
Between @ - chassis 1 Min. 1 MR 1

2) Disconnect
Model connector.
Model selection co9 -co1 CO90 - COl@ No continuity
section 1 3) Connect
Model T-adapter to
CO90 - COl@ Continuity
section 2 harness side.
20-l 1
0
TESTING AND ADJUSTING STANDARD VALUE TABLE FOR ELECTRICAL PARTS
j- Name of Ionnectol ispection Measurement

Judgment table
n omponent No. nethod conditions
If the condition is as shown in the table 1) Turn starting
Power source below, it is normal switch ON.
voltage co1 2) Insert
Between @ - @ 20 - 30 v T-adapter.

below, it is normal switch ON.
2) Set throttle
PC-EPC Between @ - @ 320 ? 80 mA lever to FULL.
co1 3) Turn pump
solenoid
prolix switch
OFF.
4) Place all levers
at HOLD.

2) Disconnect
Model co1 Model selection 1 @ - @ No continuity connector.
selection 3) Connect
Model selection 2 @ - @ Continuity T-adapter to
wiring harness
end.

2) Disconnect
Kerosene co1 In normal mode @J - @ No continuity connector.
mode 3) Connect g
In kerosene mode @ - @ Continuity T-adapter to >
wiring harness z
end. W
Between When enaine is runnina (l/2 throttle or above 1) Start engine.

alternator + 27.<- 29.5 V -
Alternator terminal L sx If the battery is old, or after starting in cold
and areas, the voltage may not rise for some
chassis time.
If the condition is as shown in the table I) Turn starting

2) Disconnect
Coolant
PO7 Normal temperature (25°C) Approx. 37 - 50 kQ connector P07.
temperature
(male) 3) Insert
sensor
1oo”c Approx. 3.5 - 4.0 kR T-adapter in
connector at
sensor end.
If the condition is as shown in the table 1) Install oil

below, it is normal pressure
measurement
Engine oil pressure gauge.
Min. 1 MD
above 70 kPa IO.7 kg/cm*} 2) Remove wiring
harness
Engine oil pressure a
Sll terminal.
sensor Engine oil pressure
Man. 1 R 3) Start engine.
below 30 kPa IO.3 kg/cm21 4) Contact tester
between
sensor
terminal and
chassis ground
20-12
0
TESTING AND ADJUSTING STANDARD VALUE TABLE FOR ELECTRICAL PARTS
-
sy!S- Name of (Ionnector Measurement
Judgment table
ter n component No. conditions
7 ’ the condition is as shown in the table 1) Turn starting
blelow, it is normal switch OFF.
2) Disconnect
connector P06.
Max. approx. 3) Drain fuel and
12 R remove fuel
level sensor.
PO6 4) Insert
Fuel level sensor
(male) 1 T-adapter in
Approx. sensor.
85-110R % Connect the
T-adapter to
the connector
and sensor
flange.
-
IiF the condition is as shown in the table 1) Turn starting
t jelow, it is normal switch OFF.
2) Disconnect
connector E07.
1
Engine speed 1) Insert
E07 h/leasure with AC range
sensor T-adapter.
Between @ - @ 1 0.5 - 3.0 v 1 2) Start engine.
[
1 ) Screw in until speed sensor contacts ring

tj
g gear, then turn back 1 * l/6 turn.
2 ) Sensor should work normally when ad-
a justed as above.
20-13
0
TESTING AND ADJUSTING TOOLS FOR TESTING, ADJUSTING, AND TROUBLESHOOTING
TOOLS FOR TESTING, ADJUSTING, AND TROUBLESHOOTING
Check or measurement iten jymbo I Part No. Part Name Remarks
799-203-8001 Multi-tachometer Digital display L: 60 - 2,000 rpm

Engine speed A or H: 60 - 19,999 rpm
799-608-1000 Tachometer (electrical type) 0 - 3,000 rpm
Coolant and oil temperature: B 799-101-1502 Digital temperature gauge -99 - 1,299”C
- -
Pressure gauge
799-101-5002 Hydraulic tester 2.5, 5.9, 39.2, 58.8 MPa
(25, 60, 400, 600 kg/cm*}
1
Pressure gauge
790-261-1203 Digital hydraulic tester 69 MPa I700 kg/cm*}
- II
2 799-401-2320 1 Hydraulic gauge
_ _ 1 1.0 MPa {IO kg/cm’}
Both male and female

14 x 1.5 (female PT l/8)
3 .790-261-1321 Adapter
Oil pressure C 18 x 1.5 (female PT l/8)
l790-261-1331 22 x 1.5 (female PT l/8)
-
4 799-401-2700 Differential pressure gauge (12V)
-
790-261-1360 Adapter
14 x 1.5 (female PT l/8)
790-261-1370 Nut For 14 x 1.5 blind

5
07003-31419 Gasket For blind
07040-I 1409 Plug For 14 x 1.5 blind

-
1 795-502-1205 Compression gauge 0 - 6.9 MPa (0 -70 kg/cm*}
Compression pressure D
2 795-502-1700 Adapter
- -
1 799-201-1504 Blow-by checker 0 - 4.9 MPa {O - 500 mmHzO1
E -
Blow-by pressure
2 795-790-1950 Nozzle Orifice diameter 0 5.613 mm
- -
Valve clearance F
1
1 799-201-9000 Handy Smoke Checker
Exhaust color G ~
2
Air supply pressure Pressure -101.3 - 199.9 kPa I-760 - 1,500 mmHg1
(boost pressure) H 799-401-2201 gauge
79A-264-0020 0 - 294N {O - 30 kg1
Operating effort J Push-pull scale
79A-264-0090 0 - 490N {O - 50 kg1
Stroke, hydraulic drift K &$$~~ciallyScale -
Work equipment speed L $$!$~~&cial’y Stop watch -
Measuring voltage and 79A-264-02 10 Tester -

resistance values M
1 799-601-7100 T-adapter assembly -
Troubleshooting
harnesses
Measuring
Fuel in-ection
valve c1earance
of wiring
and sensors
wear
timing
of sprocke
and
I
N
Q
2
799-601-2720
799-601-7330
799-601-7360
796-427-l
795-799-l
190
130
Adapter
Wear
Adapter
gauge
For MIC 13P
For S 16P (White)
For relay 5P
20-101
0
TESTING AND ADJUSTING MEASURING ENGINE SPEED
MEASURING ENGINE SPEED

AWhen removing or installing the measuring
equipment, be careful not to touch any high
temperature parts.
Jr Measure the engine speed under the following
conditions.
l Coolant temperature: Within operating range
. Hydraulic oil temperature : 45 - 55°C
1. Installation of tachometer
I) Mechanical meter
i) Remove the cover under the front pul-
ley, then set probe @ of tachometer A
on stand @ facing pulley (1).
ii) Stick silver paper to pulley (I) at one
place.
iii) Connect probe @ and tachometer A with
the cable.
A When measuring the speed, be careful
not to touch any rotating part or high
temperature part.
2) Electric meter
i) Install T-adapter Nl to connector CN-EO7
(2) of the engine speed sensor.
ii) Connect the power source cable to the
BLPO2114
battery (24V).
2. Start the engine, and measure the engine speed

when it is set to the conditions for measuring.
I) Measuring at low idling and high idling:
Measure the engine speed with the fuel con-
trol lever set to low idling and high idling.
2) Measuring speed at pump relief:
Run the engine at full throttle and measure
the engine speed when the pump is relieved.
3) Measure the speed at near the rated speed.
Run the engine at full throttle, operate the
arm lever, and measure the speed when the
arm circuit is relieved.
20-102
0
TESTING AND ADJUSTING MEASURING EXHAUST GAS COLOR
MEASURING EXHAUST GAS

COLOR
l When measuring in the field when there is no

air or power supply, use smoker checker Gl,
when recording official data, use smoke meter
G2.
* Raise the coolant temperature to the operating
range before measuring.
AWhen removing or installing the measuring
equipment, be careful not to touch any high
temperature parts.
1. Measuring with handy smoke checker Gl

1) Fit filter paper in tool Gl.
2) Insert the exhaust gas intake port into the
exhaust pipe, accelerate the engine suddenly,
and at the same time operate the handle of
tool Gl to catch the exhaust gas on the filter
paper.
3) Remove the filter paper and compare it with
the scale provided to judge the condition.
BLPOPlI5
2. Measuring with smoke meter G2

I) Insert-probe @ into the outlet port of ex-
haust pipe, then tighten the clip to secure it
to the exhaust pipe.
2) Connect the probe hose, accelerator switch
plug, and air hose to tool G2.
j, The pressure of the air supply should be
less than 1.47 MPa 115 kg/cm21.
3) Connect the power cord to the AC outlet.
* When connecting the port, check first that
the power switch of tool G2 is OFF.
4) Loosen the cap nut of the suction pump, BLPO2116
then fit the filter paper.
* Fit the filter paper securely so that the
exhaust gas does not leak.
5) Turn the power switch of tool G2 ON.
6) Accelerate the engine suddenly, and at the
same time, depress the accelerator pedal of
tool 62 and catch the exhaust gas color on
the filter paper.
7) Lay the filter paper used to catch the ex-
haust gas color on top of unused filter pa-
pers (IO sheets or more) inside the filter pa-
per holder, and read the indicated value.
BLPO2117
20-103
0
TESTING AND ADJUSTING ADJUSTING VALVE CLEARANCE
ADJUSTING VALVE
CLEARANCE
1. Remove the cylinder head cover.
2. Using cranking tool Q, rotate the crankshaft in

the normal direction until timing pin (I) enters
the hole in the gear.
Ir This position is the No. 1 cylinder compres-
sion top dead center.
3. When No. 1 cylinder is at compression top dead

Valve arrauoement diagram
center, adjust the valves marked 0. Next, rotate
the crankshaft one turn (360”) in the normal di-
rection and adjust the valve clearance of the
remaining valves marked 0.
* Make match marks on the crankshaft pulley
or damper, then rotate 360”.
4. To adjust the valve clearance, loosen locknut lKP00738
(6), then insert feeler gauge F between rocker

lever (3) and valve stem (41, and turn adjust-
ment screw (5) until the clearance is a sliding fit.
Then tighten locknut (6) to hold the adjustment
screw in position.
w Locknut : 44.1 + 4.9 Nm (4.5 f 0.5 kgm}
* After adjusting No. 1 cylinder at compression

top dead center, it is also possible to turn the
crankshaft 180” each time and adjust the valve
clearance of each cylinder according to the fir-
ing order.
. Firing order : 1 - 5 - 3 - 6 - 2 - 4
* After tightening the locknut, check the valve
clearance again.
+ There is no timing mark on the front pulley,
so set to compression top dead center as
follows.
i) If the firing order is followed, the next
cylinder after No. 1 cylinder is No. 5 cyl-
inder, so watch the movement of the
No. 2 cylinder valves and rotate in the
normal direction.
ii) When the clearance of both the intake
and exhaust valves of the No. 2 cylinder
is 0, the No. 5 cylinder is at compression
top dead center. (For the No. 3 cylinder,
watch the movement of the No. 4 cylin-
der valves.)
20-104
a
MEASURING BLOW-BY PRESSURE
TESTING AND ADJUSTING MEASURING COMPRESSION PRESSURE
MEASURING COMPRESSION
PRESSURE
A When measuring the

careful not to touch
compression pressure, be
the exhaust manifold or
muffler, or to get your clothes caught in the fan,
fan belt or other rotating parts.
1. Adjust the valve clearance.
For details, see ADJUSTING VALVE CLEARANCE.
2. Warm up the engine to make the oil tempera-
ture 40 - 60°C.
3. Remove the nozzle holder assembly from the
cylinder to be measured.
4. Install adapter D2 in the mount of the nozzle
holder, then connect pressure gauge Dl.
5. Set tachometer A in position.
6. Disconnect the fuel control rod, place the gover-
nor lever of the injection pump in the NO IN-
JECTION position, then crank the engine with
the starting motor and measure the compres-
sion pressure.
Measure the compression pressure at the point
where the pressure gauge indicator remains
steady.
When measuring the compression pressure,
measure the engine speed to confirm that it is
within the specified range.
After measuring the compression pressure, in-
stall the nozzle holder assembly.
MEASURING BLOW-BY
PRESSURE
* Measure the blow-by pressure under the follow-

ing conditions.
. Coolant temperature: Within operating range
. Hydraulic oil temperature: 50 - 80°C.
1. Install nozzle E2 of blow-by checker E to blow-
by hose.
2. Connect the nozzle and gauge with the hose.
3. Run the engine at high idling and relieve the
arm circuit.
4. Measure the blow-by at the point where the
gauge indicator remains steady.
20-105
0
TESTING AND ADJUSTING TESTING AND ADJUSTING FUEL INJECTION TIMING

FUEL INJECTION TIMING
1. Testing
1) Using cranking tool Q, rotate the crankshaft
in the normal direction until timing pin (I)
enters the hole in the gear.
2) Remove plug (2), reverse timing pin (3), and
check that pin (3) is meshed with timing pin
pointer (4) at the injection pump side.
2. Adjusting
. If the timing pin does not mesh
i) Remove the fuel injection pump.
For details, see REMOVAL OF FUEL INJEC-
TION PUMP ASSEMBLY.
ii) Rotate the camshaft of the injection pump
and mesh timing pin (3) with timing pin
pointer (4).
iii) Install the fuel injection pump assembly.
For details, see INSTALLATION OF FUEL IN-
JECTION PUMP ASSEMBLY.
-
BLPOlO51 1 BLPO1052
20-106
0
TESTING AND ADJUSTING MEASURING ENGINE OIL PRESSURE
MEASURING ENGINE OIL

PRESSURE
* Measure the engine oil pressure under the fol-

lowing conditions.
. Coolant temperature: Within operating range
1. Remove engine oil low pressure sensor (I), then

install the adapter of oil pressure gauge kit Cl
and oil pressure gauge C2 (1.0 MPa {IO kg/cm*).
2. Start the engine, and measure the oil pressure

at the low pressure end with the engine at low \ / BLPO2123
idling and at the high pressure end with the
engine at high idling.
20- 107
0
TESTING AND ADJUSTING FAN BELT TENSION
TESTING AND ADJUSTING TESTING AND ADJUSTING BELT TENSION FOR AIR CONDITIONER COMPRESSOR

FAN BELT TENSION
Testing
. Check the deflection of the belt when the belt is
pressed with a finger force of approx. 58.8 N {S
kg} at a point midway between the tension pul-
ley and fan pulley.
Adjusting
1. Loosen mounting bolts (2) and (3), bolt (4), nut
(51, and belt tension adjustment bolt (6) of ten-
sion pulley (1).
2. Move tension pulley (I) and watch the tension
of the fan belt through the clearance from the
cylinder block. When the tension is correct,
tighten adjustment bolt (6) first, then tighten ten-
sion pulley mounting bolts (2) and (31, and nut
(5).
3. After adjusting the belt tension, check again to
confirm that the belt tension is within the stand-
ard value.
* After adjusting the belt, run the engine for at
least 15 minutes, then measure the deflection of
the belt again.

BELT TENSION FOR AIR
CONDITIONER COMPRESSOR
* If the deflection of the belt when it is pressed at

a point midway between the drive pulley and
the compressor pulley is not within the stand-
ard value, or when carrying out maintenance
after replacing the belt, adjust the belt tension
as follows. TLP01003
1. I
Loosen bolts (I) and (2).
2. Lever with a bar between (3) and (4) to adjust
the belt tension.
3. When the position of the compressor is fixed,
tighten bolts (2) and (1) to secure in position.
Wtmm
4. After adjusting the belt tension, repeat the above
procedure to check that the belt tension is within
the standard value.
c:“T’
BLPO2128
20-108
0
TESTING AND ADJUSTING MEASURING SPEED SENSOR
MEASURING SPEED SENSOR
1. Screw in until the tip of sensor (I) contacts gear

(2).
2. When gear (2) contacts sensor (I), turn back 1 f
l/6 turn. (a: clearance)
3. Tighten locknut (3).
* Be particularly careful when securing the sensor
wiring to ensure that no excessive force is
brought to bear on the wiring.
* Be careful not to let the tip of the sensor be
scratched or to let any iron particles stick to the
sensor tip.
BEP01149
20-l 09
0
TESTING AND ADJUSTING ADJUSTING FUEL CONTROL LEVER
ADJUSTING FUEL CONTROL LEVER
(when lever is free) Ena~ne side Low idling

stop I Hiah idling
TKP01004
20-110
0
TESTING AND ADJUSTING ADJUSTING FUEL CONTROL LEVER
l Set the operator’s seat to rear end position.

1. Adjust the mounting dimension of yoke (2) of
cable (I) to dimension a. (Both the clutch and
engine ends1
* Yoke mounting dimension a: 12 mm
2. Set fuel control lever (3) to the idling position,
then adjust the mounting dimension of cable (I 1
to dimension b.
Ir Cable mounting dimension b: 217 mm
3. Check that governor lever (4) is in the idling
range, then install the cable at the engine end to
dimension c. (If it is not within the idling range,
adjust with nut d or e.)
* Cable mounting dimension c: 239 mm
4. Check the engine speed when fuel control lever
(3) is at the idling position.
j, Engine idling speed: 970 + 50 rpm
(If it is not within the idling range, repeat
Step 3 to adjust.)
5. Move fuel control lever (3) (including the play)
towards the STOP position until governor lever
(4) comes to the STOP position, then adjust stop-
per bolt (5) so that the clearance between fuel
control lever (3) and stopper bolt (5) is 0.
$ * Basic dimension f of stopper bolt: 13 mm
> * After adjusting, tighten the locknut of the
zl stopper bolt securely.
LLI
6. Move fuel control lever (3) (including the play)
towards the FULL position until governor lever
(4) comes to the STOP position, then adjust stop-
per bolt (6) so that the clearance between fuel
control lever (3) and stopper bolt (6) is 0.
Ir Basic dimension g of stopper bolt: 18 mm
Ir After adjusting, tighten the locknut of the
stopper bolt securely.
20-l11
0
TESTING AND ADJUSTING HYDRAULIC PRESSURE
TESTING AND ADJUSTING IN WORK EQUIPMENT, SWING, TRAVEL CIRCUIT
TESTING AND ADJUSTING HYDRAULIC PRESSURE IN WORK

EQUIPMENT, SWING, TRAVEL CIRCUIT
* For details of the adjustment procedure for the
variable pressure compensation valve of the
service valve, see Service News.
Measuring
Jr Oil temperature when measuring: 45 - 55°C
A Lower the work equipment completely to the
ground and stop the engine. Loosen the oil
filler cap slowly to release the pressure in-
side the hydraulic tank, then set the safety
lock lever to the LOCK position.
. Remove pressure pick-up plug (1) or (2)
(Thread dia.= 10 mm, Pitch=1.25) of the cir-
cuit to be measured, then install oil pressure
gauge Cl (58.8 MPa (600 kg/cm*)).
l (1): Front pump
l (2): Rear pump
1. Measuring unload oil pressure
Run the engine at full throttle and measure the
oil pressure with all control levers at HOLD.
20-112
0
TESTING AND ADJUSTlNG IN WORK EQUIPMENT, SWING, TRAVEL CIRCUIT
2. Measuring pump relief pressure

1) Low setting (oil pressure: 31.9 MPa (325 kg/
cm*})
i) Measure the pressure when each actua-
tor except the travel actuator is relieved
with the engine at full throttle.
* Note that the set pressure of the
safety valve for the swing motor and
head end of the boom is lower than
the main relief low set pressure, so
the value measured will be the relief
pressure of the safety valve.
* When measuring the swing relief
pressure, measure with the swing
lock turned switch ON.
2) High setting (oil pressure: 34.8 MPa I355 kg/

cm*})
i) When travel is operated
Measure the oil pressure when the travel
is relieved on each side separately with
the engine at full throttle.
* To relieve the travel circuit, put block
@ under the track shoe grouser, or
put block @ between the sprocket
and frame to lock the track. BLP00170 BLPo0171
20-113
0
TESTING AND ADJUSTING IN WORK EQUIPMENT, SWING, TRAVEL CIRCUIT
3. Adjusting Relief valve Relief valve

1) Adjusting high pressure setting
Loosen locknut (3), then turn holder (4) to
adjust.
+ Turn the holder to adjust as follows.
To INCREASE pressure, turn CLOCK-
WISE.
To DECREASE pressure, turn COUNTER-
CLOCKWISE.
* Amount of adjustment for one turn of
holder: Approx. 12.5 MPa I128 kg/cm?
w Locknut TKP01005
: 53.9 + 4.9 Nm 6.5 f 0.5 kgml
Ir When the high pressure setting is ad-
justed, the low pressure setting will also
change, so adjust the low pressure set-
ting also.
Adjusting low pressure setting PXI

2)
Loosen locknut (5), then turn holder (6) to
adjust.
* Turn the holder to adjust as follows.
WISE.
BLP0023E I
CLOCKWISE.
* Amount of adjustment for one turn of
holder: Approx. 12.5 MPa I128 kg/cm*}
w Locknut:
39.2 f 4.9 Nm (4.0 + 0.5 kgm}
+ Normally, the pressure applied to port
PXI is 0 MPa 10 kg/cm*); at the high pres-
sure setting, it is 2.9 MPa (30 kg/cm*}.
3) Swing motor safety valve

Loosen locknut (I), then turn adjustment
screw (2) to adjust.
* Turn the adjustment screw to adjust as
follows.
WISE.
CLOCKWISE.
j, Amount of adjustment for one turn of
holder: Approx. 6.7 MPa 168.4 kg/cm*}
w Locknut:
90.6 f 12.3 Nm 19.25 f 1.25 kgml
BKP02439
20-114
0
TESTING AND ADJUSTING PC VALVE OUTPUT
TESTING AND ADJUSTING PRESSURE (SERVO PISTON INPUT PRESSURE)
TESTING AND ADJUSTING PC

VALVE OUTPUT PRESSURE
(SERVO PISTON INPUT
PRESSURE)
MEASURING
* Hydraulic oil temperature when measuring: 45 -
55°C
1. Remove pressure measurement plugs (I), (2),
(3), and (4) (Thread dia.=10 mm, Pitch=1.25 mm),
and install oil pressure gauge Cl.
* Relationship between plug and pressure
measured
* Install a 39.2 MPa (400 kg/cm*} gauge to the

servo valve end, and a 58.8 MPa {SO0 kg/
cm*} gauge to the pump outlet port end.
2. Run the engine at high idling, and measure the
oil pressure when the arm IN circuit is relieved.
* Check that the servo piston input pressure is
approx. l/2 of the pump discharge pressure.
BLPO2134
[Reference]
If there is any abnormality in the LS valve or
servo piston, the servo piston input pressure
will be almost the same or 0 of the pump dis-
charge pressure.
32
TESTING AND ADJUSTING PC VALVE OUTPUT PRESSURE
TESTING AND ADJUSTING (SERVO PISTON INPUT PRESSURE)
ADJUSTING
* If the load becomes larger, the engine speed
will drop. Or if the engine speed remains nor-
mal, the work equipment speed will drop. In
such cases, if the pump discharge pressure and
LS differential pressure are normal, adjust the
PC valve as follows.
1) Loosen locknut (61, and if the speed is slow,

turn screw (7) to the right; if the engine speed
drops, turn the screw to the left. ,
Ir If the screw is turned to the right, the fffI TLP00741
pump absorption torque will be in-
creased, and if it is turned to the left, the
pump absorption torque will be reduced.
Ir The adjustment range for the screw is a
maximum of 1 turn to the left and 180”
to the right.
Sr Amount of adjustment for one turn of
screw: 1.5 mm movement of servo pis-
ton stroke
2) After completing the adjustment, tighten the

locknuts.
w Locknut (51:
34.3 f 4.9 Nm 13.5 f 0.5 kgm1 BKP0241I
Locknut (6):
100.5 f 12.3 Nm I10.25 f 1.25 kgm1
20-116
0
TESTING AND ADJUSTING LS VALVE OUTPUT PRESSURE
TESTING AND ADJUSTING (SERVO PISTON INPUT PRESSURE) AND LS DIFFERENTIAL PRESSURE
TESTING AND ADJUSTING LS VALVE OUTPUT PRESSURE (SERVO

PISTON INPUT PRESSURE) AND LS DIFFERENTIAL PRESSURE
* Oil temperature when measuring: 45 - 55°C
1. Measuring LS valve output pressure (servo pis-
ton input pressure)
1) Remove pressure measurement plugs (I),
(Z), (31, and (4) (Thread dia.= 10 mm,
Pitch=1.25 mm), and install oil pressure
gauge Cl.
Ir Plug and measured pressure
* Install a 39.2 MPa 1400 kg/cm? gauge to

the servo valve end, and a 58.8 MPa {600
kg/cm*} gauge to the pump outlet port
end.
. Oil pressure when travel is rotating under
no load on one side
i) Use the work equipment to raise the track
assembly on one side.
ii) Run the engine at full throttle, set to the
conditions in Table 1, and measure the
pump discharge pressure and servo in-
put pressure.
For the front pump, measure the oil pres- FlLPO2134
sure simultaneously at plugs (I) and (3);
for the rear pump, measure the oil pres-
sure simultaneously at plugs (2) and (4).
Table 1
Pump Servo inlet

Travel port pressure Remarks
pressure
lever MPa {kg/cm?) MPa {kg/cm*1
Neutral 3.7 + 0.7 3.7 * 0.7 About same
(38 * 71 {38 + 71 pressure
Half 6.9 f 1.0 3.4 f 1.0 About ‘It2 of
(70 + 101 (35 & 101 pressure
32
2. Measuring LS differential pressure

1) Measuring with differential pressure gauge
i) Remove oil pressure measurement plugs
(1) and (2), and install adapter C3 to
hoses (5) and (6).
ii) Fit differential pressure gauge C4 to the
front circuit and rear circuit.
* Plug and measured pressure
Front pump discharge

I oressure I 5 I Front LS pressure
2 Rear pump discharge
6 Rear LS pressure
pressure I I
* Connect the pump discharge pressure

to the high-pressure side of the differen-
tial gauge and the LS pressure to the
low-pressure side.
iii) Set to the conditions in Table 2 and
measure the LS differential pressure.
Table 2
I I MAX Levers at neutral
Track Assembly on one side

MAX rotate under no load (travel 2.2 Yh0.1
lever operated half way) {22 f I}
2) Measuring with oil pressure gauge

* The maximum differential-pressure is 2.9
f 1.0 MPa {30 f 10 kg/cm*)), so measure
with the same gauge.
i) Remove oil pressure measurement plugs
(1) and (2), fit adapter C3 to hoses (5)
and (6), then install the plugs inside hy-
draulic tester Cl.
ii) Install oil pressure gauge Cl (58.8 MPa
I600 kg/cm*)) to the measurement plug
for the pump discharge pressure.
* Use a gauge with a scale in units of
1.0 MPa {IO kg/cm*).
(If no 58.8 MPa 1600 kg/cm*) pres-
sure gauge is available, a 39.2 MPa
{400 kg/cm*) pressure gauge can be
used.)
iii) Set to the conditions in Table 2 and
measure the pump discharge pressure.
Ir Stand directly in front of the indica- @' ElLPO2409
tor and be sure to read it correctly.
20-118
0
iv) Remove oil pressure gauge Cl, then fit

LS pressure measurement adapter C3.
v) Set to the conditions in Table 2 and
measure the LS pressure.
* Stand directly in front of the indica-
tor and be sure to read it correctly.
(Pump discharge pressure) - (LS
pressure) = LS differential pressure
P-J’ ELPO2140
Oil pressure gauge
3. Adjusting LS valve
When the differential pressure is measured un-
der the conditions above, and the results show
that the differential pressure is not within the
BLPOO138
J
Front PIJ~P
standard value, adjust as follows. LS valve
1) Loosen locknut (7) and turn screw (8) to ad-
just.
. Turn the screw to adjust the differential
pressure as follows.
To INCREASE pressure, turn CLOCKWISE
CLOCKWISE
Sr Amount of adjustment (LS differential Rear PUrnP
LS valve
pressure) for one turn of screw: 0.65 MPa
16.6 kg/cm21
-.c==
20-119
0
(SERVO PISTON INPUT PRESSURE) AND LS DIFFERENTIAL PRESSURE
TESTING AND ADJUSTING TESTING AND ADJUSTING CONTROL CIRCUIT OIL PRESSURE
2) After adjusting, tighten locknut (7).

w Locknut:
56.4 f 7.4 Nm 15.75 + 0.75 kgml
Note: Always measure the differential pressure
while adjusting.
BKP02410

CONTROL CIRCUIT OIL
PRESSURE
Measuring
A Lower the work equipment to the ground and
stop the engine. Loosen the oil filler cap slowly
to release the pressure inside the hydraulic tank.
Then set the safety lock lever to the LOCK posi-
tion.
1) Remove circuit pressure measurement plug

(I) and install oil pressure gauge Cl (5.8
MPa {60 kg/cm*}).
2) Start the engine and measure with the en-

gine at full throttle.
BLPO2143
20- 120
0
TESTING AND ADJUSTING TESTING SOLENOID VALVE OUTPUT PRESSURE
TESTING SOLENOID VALVE

OUTPUT PRESSURE
Measuring
Measuring output pressure of ON-OFF solenoid
valve
I) Disconnect output hose (2) of the solenoid
valve, then use adapter C3 in the oil pres-
sure gauge kit to install oil pressure gauge
Cl (5.9 MPa (60 kg/cm*}).
2) Measure the solenoid valve output pressure
under the conditions in Table 1.
Name of 1 Operating condition Condition

of Oil pressure
Measurement conditions Remarks
- )lenoid solenoid(MPa {kg/cm2})
Hydraulic pressure
Min. 2.7
Safety lock lever at FREE in PPC valve ON
PPC {Min. 281
circuit
1 hydraulic
lock No hydraulic
Safety lock lever at LOCK pressure in PPC OFF 0 IO1
valve circuit
-
Swing or work equipment lever Min. 2.7
Brake canceled ON
operated I I {Min. 281
2
All levers except travel at neutral
0 101
(5 set after returning to neutral) Brake actuated /
-
Min. 2.7 Motor swash
Travel speed selector switch at Hi Travel speed Hi ON {Min. 28) plate angle at
Travel minimum
3 speed
Motor swash
Travel speed selector switch at Lo Travel speed Lo OFF 0 WI plate angle at
maximum
-
Travel lever operated Pressure rise

4 2-stage
I I
relief
OFF 0 (01
-
Note 1: Operation of solenoid valve
ON: Energized (oil pressure generated), OFF: Deenergized (oil pressure: 0)
Note 2: The measurement conditions in the table are the typical conditions for measuring the output
pressure.
In some cases, the solenoid valve may be actuated (ON/OFF) in conditions other than the
measurement conditions.
A When operating the levers, operate slightly and be careful not to move the machine.
20-121
0
TESTING AND ADJUSTING MEASURING PPC VALVE OUTPUT PRESSURE
MEASURING PPC VALVE

OUTPUT PRESSURE
Ir Oil temperature when measuring: 45 - 55°C
1. Measuring PPC valve output pressure

I) Disconnect hose (l).of the circuit to be meas-
ured.
2) Install adapter C3 between hose (1) and el-
bow (2).
3) Install oil pressure gauge Cl (5.9 MPa 160
kg/cm*}) to adapter C3.
4) Run the engine at full throttle, operate the
control lever of the circuit to be measured,
and measure the oil pressure.
% If the output at the control valve end is low,
measure the input pressure of the PPC valve.
If it is normal, there is defective actuation of
the PPC valve.
20- 122
0
TESTING AND ADJUSTING MEASURING PPC VALVE OUTPUT PRESSURE
Plug location diagram

Interruption block seen from rear of machine
Arm IN
R.H.swins
Bucket DUMP
Boom RAISE
Bucket CURL
L.H.swina
Boom LOWER
Junction block
P4 ,~I____kK?--11
TKP01007
20-123
0
TESTING AND ADJUSTING ADJUSTING WORK EQUIPMENT l SWING PPC VALVE
ADJUSTING WORK
EQUIPMENT lSWING PPC
VALVE
* If there is excessive play in the work equipment

or swing lever, adjust as follows.
a Lower the work equipment to the ground and
stop the engine. Loosen the oil filler cap slowly
to release the pressure inside the hydraulic tank.
Then set the safety lock lever to the LOCK posi-
tion.
1. Remove the PPC valve.

2. Remove boot (I).
3. Loosen locknut (2), then screw in disc (3) until it
contacts the 4 heads of piston (4).
+ When doing this, do not move the piston.
4. Screw disc (3) in position, then tighten locknut
(2) to the specified torque.
m Locknut: 107.8 f 9.8 Nm {II + 1 kgm}
5. Install boot (I).
+ With the above adjustment, the clearance
between disc (3) and piston (4) becomes 0.
20-124
0
TESTING AND ADJUSTING TESTING TRAVEL DEVIATION
TESTING TRAVEL DEVIATION
+ When traveling on level ground. Travel Posture

1. Set the machine in the travel posture.
Ir For the travel posture, extend the bucket and
arm cylinder rods fully, and hold the boom
angle at 45”.
2. Travel for IO m, then measure the deviation A
when traveling for the next 20 m.
Ir Measure with the engine at high idling.
Sr Install the hydraulic pressure gauge and
measure the pump discharge pressure at the
same time.
TDP00328
20m 0 Run UP for IOm

-I
t t
Make a mark Make a mark at the Make a mark
10m midway Doint
Mark
Measure the amount of
distance A at this Point
TEP00329
ZO-125
0
TESTING LOCATIONS CAUSING
TESTING AND ADJUSTING HYDRAULIC DRIFT OF WORK EQUIPMENT
TESTING LOCATIONS CAUSING HYDRAULIC DRIFT OF WORK

EQUIPMENT
j, If there is any hydraulic drift in the work equip-
ment (cylinders), check as follows to determine
if the cause is in the cylinder packing or in the
control valve.
1. Checking for defective cylinder packing
1) Checking boom and bucket cylinders
i) Set in the same posture as when meas-
uring hydraulic drift, and stop the en-
gine.
ii) Operate the boom control lever to RAISE
or the bucket control lever to CURL.
. If the lowering speed increases, the TOP00333
packing is defective.
. If there is no change, the boom hold- PC200-6: 1,260kg
ing valve (boom) or the control valve
(bucket) is defective.
2) Checking arm cylinder
i) Operate the arm cylinder to move the
arm in fully, then stop the engine.
ii) Operate the control lever to arm IN.
. If the lowering speed increases, the
packing is defective.
. If there is no change, the control
valve is defective.
+ If the pressure in the accumulator
has dropped, run the engine for
approx. 10 seconds to charge the BKP00159
accumulator again before operating.
[Reference] If the cause of the hydraulic drift is
in the packing, and .the above op-
erations is carried out, the down-
ward movement becomes faster for
the following reasons.
1) If the work equipment is set to the above
posture (holding pressure applied to the bot-
tom end), the oil at the bottom end leaks to
the head end. However, the volume at the
head end is smaller than the volume at the
bottom end by the volume of the rod, so the
internal pressure at the head end increases
because of the oil flowing in from the bot-
tom end.
2) When the internal pressure at the head end
increases, the pressure at the bottom end
also rises in proportion to this. The balance
is maintained at a certain pressure (this dif-
fers according to the amount of leakage) by
repeating this procedure.
3) When the pressure is balanced, the down-
ward movement becomes slower. If the le-
ver is then operated according to the proce-
dure given above, the circuit at the head
end is opened to the drain circuit (the bot-
tom end is closed by the check valve), so
the oil at the head end flows to the drain
circuit and the downward movement be-
comes faster.
zo- 126
0
TESTING LOCATIONS CAUSING
TESTING AND ADJUSTING HYDRAULIC DRIFT OF WORK EQUIPMENT
2. Checking boom holding valve

A Set the work equipment at the maximum reach,
and the top of the boom horizontal, then stop
the engine.
Lock the work equipment control levers and re-
lease the pressure inside the hydraulic tank.
A To prevent danger, never stand under the work
equipment.
I) Disconnect pilot hose (I) of the boom hold-
ing valve, and install a blind plug in the
hose.
Ir Blind plug: 07376-50315 BLPOPl52
* Leave the boom holding valve end open.

* If any oil leaks from the port that is left
open, the boom holding valve is defec-
tive.
3. Checking PPC valve

If the hydraulic drift differs when the safety lock
lever is in the LOCK or FREE position, (engine
running), the PPC valve is defective.
20-127
a
TESTING AND ADJUSTING MEASURING OIL LEAKAGE
MEASURING OIL LEAKAGE
* Hydraulic oil temperature when measuring: Posture for measuring boom cylinder
45 - 55°C
1. Work equipment cylinder
+ If the hydraulic drift of the work equipment is
outside the standard value, measure the leak-
age inside the cylinder as follows, and judge if
the cause of the hydraulic drift is in the cylinder
or in the control valve.
. If the leakage is with in the standard value,
the problem is in the control valve.
. If the leakage is greater then the standard /
TEP00334
value, the problem is in the cylinder.
1) Fully extend the rod of the cylinder to be
measured, then stop the engine.
Posture for measuring arm. bucket cylinder
2) Disconnect piping (I) at the head end, then
block the piping at the chassis end with a
blind plug.
&I Be careful not to disconnect the piping
at the bottom end.
3) Start the engine and apply the relief pres-
sure to the bottom end of the cylinder with
the engine at high idling.
4) Continue this condition for 30 seconds, then
measure the oil leakage for the next one
minute.
TEP00335
Boom cylinder
,. ~,,
TLP00745
Arm cylinder
TLP00746
20-128
0
TESTING AND ADJUSTING MEASURING OIL LEAKAGE
Bucket cylinder
-1
I TLP00747 1
n Disconnect
TEP00337
ZO-129
0
MEASURING OIL LEAKAGE
TESTING AND ADJUSTING RELEASING REMAINING PRESSURE IN HYDRAULIC CIRCUIT
2. Swing motor
1) Disconnect drain hose (I) from the swing
motor, then fit a blind plug at the tank end.
2) Set the swing lock switch ON.
3) Start the engine and operate the swing re-
lief with the engine at high idling.
minute.
* After measuring, swing 180” and measure
again.
3. Travel motor
I) Disconnect drain hose (2) from the travel
motor, then fit a blind plug at the hose end.
2) Fit block @ under the track shoe grouser, or
fit block @ between the sprocket and frame
to lock the track.
3) Start the engine and operate the travel relief
with the engine at high idling.
A When measuring the oil leakage from
the travel motor, mistaken operation of
the control lever may lead to a serious
accident, so always use signals and check
when carrying out this operation. ,Gw // BLPO2155
minute.
* When measuring, move the motor slightly
(to change the position between the valve
plate and cylinder, and piston and cylinder),
and measure several times.
RELEASING REMAINING
PRESSURE IN HYDRAULIC
CIRCUIT
* If the piping between the hydraulic cylinder and
BLPO0171
the control valve is disconnected, release the
remaining pressure from the circuit as follows.
The travel ciucuit is an open circuit, so there is
no remaining pressure. It is enough to remove
the oil filler cap.
1. Loosen the oil filler cap slowly to release the
pressure inside the tank.
2. Operate the control levers.
* When the levers are operated 2 - 3 times,
the pressure stored in the accumulator is
removed.
3. Start the engine, run at low idling for approx. 5
minutes, then stop the engine and operate the
control levers.
* Repeat the above operation 2 - 3 times to
release all the remaining pressure.
20- 130
0
TESTING AND ADJUSTING TESTING CLEARANCE OF SWING CIRCLE BEARING
TESTING CLEARANCE OF
SWING CIRCLE BEARING
1
Method of testing clearance of swing circle bearing
when mounted on machine
1. Fix a magnet-type dial gauge to the outer circle
(or inner circle) of the swing circle, and put the
tip of the probe in contact with the inner circle
(or outer circle). frame
Set the dial gauge at the front or rear.
Dial gauge
TEP00339
2. Extend the work equipment to the maximum

reach, and set the tip of the bucket to the same
height as the bottom of the revolving frame.
When this is done, the upper structure will tilt
forward, so the front will go down and the rear
will rise.
3. Set the dial gauge to the zero point.
BKP00173
4. Set the arm more or less at right angles to the

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

The value on the dial gauge is the clearance of
the swing circle bearing.
A When carrying out the measurement, do not BKP00174
put your hand or feet under the undercarriage.
6. Return to the condition in Step 2, and check that

the dial gauge has returned to the zero point. If
it has not returned to the zero point, repeat Step
2 to 5.
20-131
0
TESTING AND ADJUSTING TESTING AND ADJUSTING TRACK SHOE TENSION

TRACK SHOE TENSION
TESTING
1.
and measure the clearance between the bottom
of the track frame and the top of the track shoe.
. Clearance a: 303 * 20 mm
Measurement position
PC200-6 : 4th track roller from the sprocket.
ADJUSTING
* If the track shoe tension is not within the stand-
ard value, adjust as follows.
1 . When the tension is too high: BLP00175
Loosen plug (I) gradually, and release the
grease.
AThere is danger that the plug may fly out
under the high internal pressure of the
grease, so never loosen plug (I) more than
1 turn.
* If the grease does not come out easily, move
the machine backwards or forwards slowy.
2. If track is too loose:

Pump in grease through grease fitting (2).
* If the grease cannot be pumped in easily,
move the machine backwards and forwards
slowly. BLPO2156
20-132
0
TESTING AND ADJUSTING BLEEDING AIR
BLEEDING AIR
Order for operation and porocedure for bleeding air
Air bleeding item Air bleeding procedure
1 2 3 4 5 6
Bleeding Bleeding Bleeding Bleeding

Start
air from Start engine air from air from air from
operations
Nature of work pomp cylinder swing motor travel motor
* Replace hydraulic oil

- Clean strainer 0 A 0 J+ 0
$ ‘(NoteI) ql\lotel+ O
I I
* Replace return filter element 0 ’ ) 0
I I
* Replace, repair pump > 0
* Remove suction piping
o+oJ+o
I I
I ,
- Replace, repair control valve 0 $0’ I I
> 0
I
I
- Replace cylinder
* Remove cylinder piping 0 I, 0 ’ > 0
I
* Replace swing motor
* Remove swing motor piping
* Replace travel motor, swivel I

* Remove travel motor, swivel piping I I >o+ 0
Note 1: Bleed the air from the swing and travel motors only when the oil inside the motor case has been drained.
ts
t
z
LLI 1. Bleeding air from pump
1) Loosen air bleed plug (I), and check that oil
oozes out from the plug.
2) When oil oozes out, tighten plug (I).
m Plug:
17.15 f 2.45 Nm Il.75 f 0.25 kgm1
* If no oil oozes out from the air bleed plug:
3) Leave plug (I) loosened and remove hose
(2) and elbow (3).
4) Pour in oil through the elbow mount hole
until oil oozes out from plug (I).
5) Fit elbow (3) and install hose (2).
6) Tighten air bleed plug (I).
w Plug: BLPO2157
17.15 f 2.45 Nm 11.75 + 0.25 kgml

* Precautions when staring the engine
After completing the above procedure and
starting the engine, run the engine at low
idling for 10 minutes.
BLPO2158
20-133
0
TESTING AND ADJUSTING BLEEDING AIR
2. Bleeding air from hydraulic cylinders

1) Start the engine and run at idling for approx.
5 minutes.
2) Run the engine at low idling, then raise and
lower the boom 4 - 5 times in succession.
* Operate the piston rod to approx. 100
mm before the end of its stroke. Do not
relieve the circuit under any circum-
stances.
3) Run the engine at full throttle and repeat
Step 2). After that, run the engine at low
idling, and operate the piston rod to the end
of its stroke to relieve the circuit.
4) Repeat Steps 2) and 3) to bleed the air from
the arm and bucket cylinders.
* When the cylinder has been replaced, bleed
the air before connecting the piston rod.
Be particularly careful not to operate the cyl-
inder to the end of its stroke when the pis-
ton rod has been connected to the LOWER
end of the boom cylinder.
3. Bleeding air from swing motor

1) Run the engine at low idling, loosen air bleed
plug (I), and check that oil oozes out.
* If no oil oozes out from the air bleed plug:
2) Stop the engine, and pour oil into the motor
case from plug (1).
3) Tighten air bleed plug (I).
m Plug : 166.6 f 16.6 Nm I17 + 2 kgml
4. Bleeding air from travel motor

Run the engine at low idling, loosen air bleed
plug (21, and when oil oozes out, tighten the
plug again.
20-134
0
TROUBLESHOOTING
Points to remember when troubleshooting ....................................................................................... 20-202
Sequence of events in troubleshooting .............................................................................................. 20-203
Precautions when carrying out maintenance.. ................................................................................... 20-204
Checks before troubleshooting.. .......................................................................................................... 20-212
Connector types and mounting locations .......................................................................................... 20-214
Connection table for connector pin numbers .................................................................................... 20-220
Method of using troubleshooting charts ............................................................................................ 20-230
Troubleshooting of engine system (S mode) .................................................................................... 20-301
Troubleshooting of electrical system (E mode) ................................................................................. 20-351
Troubleshooting of hydraulic and mechanical system (H mode). ................................................... 20-401
Troubleshooting of machine monitor system (M mode). ................................................................. 20-451
20-201
0
TROUBLESHOOTING POINTS TO REMEMBER WHEN TROUBLESHOOTING
POINTS TO REMEMBER WHEN TROUBLESHOOTING
A Stop the machine in a level place, and check that the safety pin, blocks, and parking brake are securely fitted.
A 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.
A If the radiator cap is removed when the engine is hot, hot water may spurt out and cause burns, so wait for
the engine to cool down before starting troubleshooting.
A Be extremely careful not to touch any hot parts or to get caught in any rotating parts.
A When disconnecting wiring, always disconnect the negative (-) terminal of the battery first.
A When removing the plug or cap from a location which is under pressure from oil, water, or air, always release
the internal pressure first. When installing measuring equipment, be sure to connect it properly.
The aim of troubleshooting is to pinpoint the basic cause of the failure, to carry out repairs swiftly, and to
prevent reoccurrence of the failure.
When carrying out troubleshooting, and important point is of course to understand the structure and function.
However, a short cut to effective troubleshooting is to ask the operator various questions to form some idea
of possible causes of the failure that would produce the reported symptoms.
1. When carrying out troubleshooting, do not hurry 4) Check the stroke of the control valve spool.
to disassemble the components. 5) Other maintenance items can be checked ex-
If components are disassembled immediately any ternally, so check any item that is considered
failure occurs: to be necessary.
. Parts that have no connection with the fail- 4. Confirming failure
ure or other unnecessary parts will be disas- . Confirm the extent of the failure yourself,
sembled. and judge whether to handle it as a real fail-
. It will become impossible to find the cause ure or as a problem with the method of op-
of the failure. eration, etc.
It will also cause a waste of manhours, parts, or * When operating the machine to reenact
oil or grease, and at the same time, will also lose the troubleshooting symptoms, do not
the confidence of the user or operator. carry out any investigation or measure-
For this reason, when carrying out troubleshoot- ment that may make the problem worse.
ing, it is necessary to carry out thorough prior 5. Troubleshooting
investigation and to carry out troubleshooting in . Use the results of the investigation and in-
accordance with the fixed procedure. spection in Items 2 - 4 to narrow down the
2. Points to ask user or operator causes of failure, then use the troubleshoot-
1) Have any other problems occurred apart from ing flowchart to locate the position of the
the problem that has been reported? failure exactly.
2) Was there anything strange about the ma- * The basic procedure for troubleshooting
chine before the failure occurred? is as follows.
3) Did the failure occur suddenly, or were there 1) Start from the simple points.
problems with the machine condition before 2) Start from the most likely points.
this? 3) Investigate other related parts or in-
4) Under what conditions did the failure occur? formation.
5) Had any repairs been carried out before the 6. Measures to remove root cause of failure
failure? . Even if the failure is repaired, if the root cause
When were these repairs carried out? of the failure is not repaired, the same failure
6) Has the same kind of failure occurred be- will occur again.
fore? To prevent this, always investigate why the
3. Check before troubleshooting problem occurred. Then, remove the root
1) Check the oil level cause.
2) Check for any external leakage of oil from
the piping or hydraulic equipment.
3) Check the travel of the control levers.
20-202
0
TROUBLESHOOTING SEQUENCE OF EVENTS IN TROUBLESHOOTING
SEQUENCE OF EVENTS IN TROUBLESHOOTING
ber of machine
an outline of the prob-
. Condition of failure
- Work being carried out at the time of the TEW00182
failure
. Operating environment
* Past history, details of maintenance, etc.
srep 2
Determining probable location of causel TEW00183
1) Look at the troubleshooting section of the

shop manual to find locations of possible
causes.
TEW00184 /
\
Step 3
]Preparation of troubleshooting tools
1) Look at the table of troubleshooting tools in

the shop manual and prepare the necessary Step 7
tools. I. Pinooint locations of failure (carrv out I
I’
. T-adapter troubleshooting)
. Hydraulic pressure gauge kit, etc. . Decide action to take
2) Look in the parts book and prepare the nec-
essary replacement parts. 1) Before starting troubleshooting, locate and
TEW00186 I repair simple failures.
. Check before starting items
. Other check items
-/ 2) See the Troubleshooting Section of the shop
manual, select a troubleshooting flowchan
Eii that matches the symptoms, and carry out
troubleshooting.
TEW00187
I
m !@J-Jhh&
Step 6
Re-enacting failure
. Drive and operate the machine to confirm

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

chine before the failure occurred?
* Did the failure occur suddenly?
- Had any repairs been carried out before the
TEW00189 failure?
TEWOOlSC
20-203
0
TROUBLESHOOTING POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE
POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE
To maintain the performance of the machine over a long period, and to prevent failures or other
troubles before they occur, correct operation, maintenance and inspection, troubleshooting, and re-
pairs must be carried out. This section deals particularly with correct repair procedures for mechatronics
and is aimed at improving the quality of repairs. For this purpose, it gives sections on “Handling
electric equipment” and “Handling hydraulic equipment” (particularly gear oil and hydraulic oil).
1. POINTS TO REMEMBER WHEN HANDLING

ELECTRIC EQUIPMENT
I) Handling wiring harnesses and connectors

Wiring harnesses consist of wiring connecting
one component to another component, connec-
tors used for connecting and disconnecting one
wire from another wire, and protectors or tubes
used for protecting the wiring.
Compared with other electrical components fit-
ted in boxes or cases, wiring harnesses are more
likely to be affected by the direct effects of rain,
water, heat, or vibration. Furthermore, during
inspection and repair operations, they are fre-
quently removed and installed again, so they
are likely to suffer deformation or damage. For
this reason, it is necessary to be extremely care-
ful when handling wiring harnesses.
TEW00191
Main failures occurring in wiring harness

Defective contact of connectors (defective
contact between male and female)
Problems with defective contact are likely to
Improper insertion
occur because the male connector is not
properly inserted into the female connector,
or because one or both of the connectors is
deformed or the position is not correctly
aligned, or because there is corrosion or
oxidization of the contact surfaces.
I TEW00192
Defective crimping or soldering of connec-

tors
The pins of the male and female connectors
are in contact at the crimped terminal or
soldered portion, but if there is excessive
force brought to bear on the wiring, the plat-
ing at the joint will peel and cause improper
connection or breakage.
I TEW00193
20-204
0
@ Disconnections in wiring
If the wiring is held and the connectors are
pulled apart, or components are lifted with a
crane with the wiring still connected, or a
heavy object hits the wiring, the crimping of
the connector may separate, or the solder-
ing may be damaged, or the wiring may be
broken.
\ TEW00194
@ High-pressure water entering connector

The connector is designed to make it diffi-
cult for water to enter (drip-proof structure),
but if high-pressure water is sprayed directly
on the connector, water may enter the con-
nector, depending on the direction of the
water jet.
As already said, the connector is designed
to prevent water from entering, but at the
same time, if water does enter, it is difficult &
\
for it to be drained. Therefore, if water should
get into the connector, the pins will be short-
TEW00195
circuited by the water, so if any water gets
in, immediately dry the connector or take
other appropriate action before passing elec-
tricity through it.
@ Oil or dirt stuck to connector

If oil or grease are stuck to the connector
and an oil film is formed on the mating sur-
face between the male and female pins, the
oil will not let the electricity pass, so there
will be defective contact.
If there is oil or grease stuck to the connec-
tor, wipe it off with a dry cloth or blow it dry
with compressed air and spray it with a con-
TEW00196
tact restorer.
* When wiping the mating portion of the
connector, be careful not to use exces-
sive 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 clean-
ing with compressed air.
20-205
0
2) Removing, installing, and drying connectors and

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

When removing a connector from a clip, pull
the connector 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.
I TBW00485 1
@ 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.
Ir If the machine is left disassembled for a
long time, it is particularly easy for im-
proper contact to occur, so always cover
the connector.
TEW00198
20-206
0
0 Connecting connectors
0 Check the connector visually.
I) Check that there is no oil, dirt, or water
stuck to the connector pins (mating por-
tion).
2) Check that there is no deformation, de-
Clicks into position
fective contact, corrosion, or damage to
the connector pins.
3) Check that there is no damage or break-
age to the outside of the connector.
* If there is any oil, water, or dirt stuck to
the connector, wipe it off with a dry cloth. II TEW00199
If any water has got inside the connec-
tor, warm the inside of the wiring with a
dryer, but be careful not to make it too
hot as this will cause short circuits.
* If there is any damage or breakage, re-
place the connector.
0 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.
Correct any protrusion of the boot and any

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

be sure to return it to its original position.
Check also that there are no loose clamps. TBWW487
20-207
0
l Drying wiring harness

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

follows.
@ Disconnect the connector and wipe off the
water with a dry cloth.
* If the connector is blown dry with com-
TEW00196
pressed air, there is the risk that oil in
the air may cause defective contact, so
remove all oil and water from the com-
pressed air before blowing with air.
Q Dry the inside of the connector with a dryer.

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

After drying, leave the wiring harness dis-
connected and carry out a continuity test to
check for any short circuits between pins
caused by water.
* After completely drying the connector,
blow it with contact restorer and reas-
semble. T-adapter
TEW00203
20-208
0
3) Handling control box

Thecontrol box contains a microcomputer
and electronic control circuits. These control
all of the electronic circuits on the machine,
so be extremely careful when handling the
control box.
Do not open the cover of the control box
unless necessary.
TEW00204
Do not place objects on top of the control

box.
Cover the control connectors with tape or a
vinyl bag.
Never touch the connector contacts with your
hand.
During rainy weather, do not leave the con-
trol box in a place where it is exposed to
rain.
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).
Precautions when carrying out arc welding
When carrying out arc welding on the body,
disconnect all wiring harness connectors con-
nected to the control box. Fit an arc welding
ground close to the welding point.
II TEW00206
2. Points to remember when troubleshooting electric circuits

I) Always turn the power OFF before disconnecting or connect connectors.
2) Before carrying out troubleshooting, check that all the related connectors are properly inserted.
Ir 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 disconnected, unnecessary abnormality
displays will be generated.
4) When carrying out troubleshooting of circuits (measuring the voltage, resistance, continuity, or
current), move the related wiring and connectors several times and check that there is no
change in the reading of the tester.
Jr If there is any change, there is probably defective contact in that circuit.
20-209
0
3. POINTS TO REMEMBER WHEN HANDLING

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

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

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

If disassembly or maintenance work is carried
out on hydraulic equipment in the field, there is
danger of dust entering the equipment. It is also
difficult to confirm the performance after repairs,
so it is desirable to use unit exchange. Disas-
sembly and main-tenance of hydraulic equip-
ment should be carried out in a specially pre-
pared dustproof workshop, and the performance
should be confirmed with special test equipment.
F TEW00207
3) Sealing openings
After any piping or equipment is removed, the
openings should be sealed with caps, tapes, or
vinyl bags to prevent any dirt or dust from en-
tering. If the opening is left open or is blocked
with a rag, there is danger of dirt entering or of
the surrounding area being made dirty by leak-
ing oil so never do this.
Do not simply drain oil out on to the ground,
collect it and ask the customer to dispose of it,
or take it back with you for disposal.
TEW00208
4) Do not let any dirt or dust get in during refilling

operations.
Be careful not to let any dirt or dust get in when
refilling with hydraulic oil. Always keep the oil
filler and the area around it clean, and also use
clean pumps and oil containers. If an oil clean-
ing device is used, it is possible to filter out the
dirt that has collected during storage, so this is
an even more effective method.
20-210
0
5) Change hydraulic oil when the temperature is

high.
When hydraulic oil or other oil is warm, it flows
easily. In addition, the sludge can also be drained
out easily from the circuit together with the oil,
so it is best to change the oil when it is still
warm. When changing the oil, as much as pos-
sible of the old hydraulic oil must be drained
out. (Drain the oil from the hydraulic tank; also
drain the oil from the filter and from the drain
plug in the circuit.) If any old oil is left, the
contaminants and sludge in it will mix with the
new oil and will shorten the life of the hydraulic
oil.
6) Flushing operations
After disassembling and assembling the equip-
ment, or changing the oil, use flushing oil to
remove the contaminants, sludge, and old oil
from the hydraulic circuit.
Normally, flushing is carried out twice: primary
flushing is carried out with flushing oil, and sec-
ondary flushing is carried out with the specified
hydraulic oil.
$
t
z TEW00210
Lu
7) Cleaning operations
After repairing the hydraulic equipment (pump,
control valve, etc.) or when running the ma-
chine, carry out oil cleaning to remove the sludge
or contaminants in the hydraulic oil circuit.
The oil cleaning equipment is used to remove
the ultrafine (about 3t.r) particles that the filter
built into the hydraulic equipment cannot re-
move, so it is an extremely effective device.
I TEW00211
20-211
0
TROUBLESHOOTING CHECKS BEFORE TROUBLESHOOTING
CHECKS BEFORE TROUBLESHOOTING
Item .ff~~ment Action
1. Check fuel level, type of fuel - Add fuel

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

2. Check for looseness, corrosion of alternator terminal, wiring - Tighten or replace
3. Check for looseness, corrosion of starting motor terminal, wiring - Tighten or replace
1. Check for abnormal noise, smell - Repair

2. Check for oil leakage - Repair
3. Carry out air bleeding - Bleed air
1. Check battery voltage (engine stopped) 20 - 3ov Replace

2. Check battery electrolyte level - Add or replace
3. Check for discolored, burnt, exposed wiring - Replace
4. Check for missing wiring clamps, hanging wiring - Repair
5. Check for water leaking on wiring (be particularly careful attention - Disconnect
to water leaking on connectors or terminals) connector and dry
6. Check for blown, corroded fuses - Replace
7. Check alternator voltage (engine running at l/2 throttle or above) Vter running Replace
for several
minutes:
27.5 - 29.5 v
8. Check operating sound of battery relay (when switch is turned ON/OFF) - Replace
20-212
0
TROUBLESHOOTING CONNECTOR TYPES AND MOUNTING LOCATIONS
CONNECTOR TYPES AND MOUNTING LOCATIONS
Add.
Mounting location
ress
Ml2 1KESI 1 3 I,Heater 1 K-3

Ml4 1L 1 2 1Fusible link 1 D-3
~16 ITerminalI I I Horn (high tone) 1 E-4
Ml7 M 6 Wiper motor l-l
Ml8 M 3 Wiper switch K-2
Ml9 M 2 Wiper switch K-2
M20 Terminal 1 Horn (low tone) E-4
M21 PA 9 Radio K-l
M22 ;onPZCtor 1 Horn switch e-3
1 Horn switch speaker

G-4
M23 ;;nP;Ctor H-4
M24 2&tor 1 SpeakerH-4 H-4
M26 IM / 6 I Air conditioner unit I F-7

M27 l-pin 1 Room lamp G-4
connector
M28 KESO 2 Window washer motor (option) D-9
MZ% I~~~~~CtnrI I I Option ground connection I 1-5
M30 l:~%torI 1 I Additional front lamp (option) F-5
M31 / KESO 1 4 I Wiper motor 1 H-5

M31 I~;~~~CtorI I I Option power source I ~-6
Air conditioner unit powersource
iqi--j 1 / AddItional
.’ left front lamp (opt) G-7
M42 12kAorI
1 I AddItIonal
.. rear lamp (option) A-8
M43 l-pin 1 Option power source E-4
connector
PO1 040 16 Monitor panel H-4
PO2 KESI 4 Light switch H-5
PO4 M 2 Buzzer G-3
PO6 Ix I I IFuel level sensor I c-3

PO7 x 2 Engine water temperature sensor Q-4
RB Terminal 1 Battery relay terminal B R-8
20-214
0
Mounting location r 1 pe ~ p:is 1 Mounting location 17
1 RE /Terminal 1 1 1 Battery relay terminal E 1 R-7

1 RM ITerminal 1 1 I Battery relay terminal M I R-T
R05 R 6 Travel Hi-Lo relay G-2
SC Terminal1 1 Starting motor terminal C o-2
so1 x 2 Travel pressureswitch (for travel alarm) M-4
Sl 1 Terminal 1 Engine oil pressure switch R-3
s12 l-pin
connector
1 PPC hydraulic lock switch l-l
s13 l-pin
connector
1 PPC hydraulic lock switch J-l
S14 M 2 PPC hydraulic lock switch K-l
TO2 Terminal 1 Revolving frame ground connection Q-6
1 TO3 ITerminal I 1 IRevolving frame ground connection 1 P-6

TO5 ITerminal I 1 IFloor ground connection I F-7
TO6 ITerminal 1 1 1Starting switch (B) I l-5
TO7 Terminal , Starting switch (BR) l-5
Travel HI-LO floor ground connection F-7
TO9 Terminal 1 Starting switch (C) l-5
TIO ITerminalI 1 IStarting switch (RI) I 1-5

Tll ITerminalI 1 I Cab ground connection ( K-5
T12 ITerminalI 1 I Starting switch (ACC) I l-5
vo7 Ix I 2 I PPC hydraulic lock solenoid valve I M-8

x05 IM I 4 I Swing lock switch I K-l
TBPOl125
20-21.6
0
T06.TlO
M23
M23
M22
D20
PO4 M12
Ml9
Ml6
HO2 / / )\
Ml7 / /
s12 s13 /M36 x05
El3
vo7 vo4 V06
\
TO2
El2
X TBPOll27
TROUBLESHOOTING CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS

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

of
pins Male (female housing) Female (male housing)
@El
DO
BEHOOl48 BEH00149
TEW00221
1 3 3 1
TEW00223
1 3
3 1
2 4
TEW00225 TEW00226
20-220
0
No.
of
T SWP type connector
3 6
TEW00235 6 3 BLmoo33
4 8
8 4
TEW00237 TEW00238
12
0
0
__.__.
i@El 4 1
BLPooO34
1 4 8 11 11 8 4 1
14
3 7 10 i4
14 10 7 3
TEW00239 TEW00240
A 1
16
9
BLm0036
19 i6 BLrn0037
20-221
0
No. M type connector

of
1 BLPOC03B
3 2
I,
3
El Y
1
s
TEW00243 TEW00244
4 2
TEW00246
4 1
sl 3’ ‘6
TEW00247
@
TEW00248
BLPOO041
20-222
0
No. S type connector

of
5 1
4
/ \
8 *’ \4
16
(White
Q -
0
1
18
8
BEP01697 I6 .7 RFPOlfiSR
8 1
16
(White
7 16BLW0044 16/ ‘7 TEW00256
20-223
a
No. MIC connector

of
1x1
h BLPOOO45 ELPOOO46
BLPOoo47 BLPco046
7 7 \= ii
1 "/&__/I
00000
00
13
8 13 8
Ir
13
BLWO049 J BLPOO050
1 9
,o),7
17
L
r’
I J 6LPO0051 BLPO0052
21
I I
I J TEW00259
TEW00260
20-224
0
No. AMP040 type connector

of
4 8
f-7
8
BLPOOO53 BLPcoO54
6 12 12 6
1 7
BLPOO055 i i BLW0056
8 16
16 8
16
9 1
1 9
BLPOOO57 TEW00232
20
TEW00234
20-225
0
No. L type type connector

of
En
m
2
m
TEW00257 TEW00258
20-226
0
No.
of
T Automobile connector
BEH00150 BEHO
BLPOOO64
3
FB BDHOOI 52
2 3
BDH00153
I 2
3 4
4 3 BDH00154 BDH00155
BLPOOO69 BLPcKlO70
20-227
0
No.
of
T Relay connector
EEr /
1 3 6 5 6
BLPOOO73 BLPOOO74
6 4 6 5
n \
Eir i-8
i
i
2
BLFU0076
20-228
0
No. PA connector
of
9
p”1
5 9
BEH00157
BEHO
20-229
TROUBLESHOOTING METHOD OF USING TROUBLESHOOTING CHARTS
METHOD OF USING TROUBLESHOOTING CHARTS

1. Category of troubleshooting code number
Troubleshooting Code No. 1 Component
s-00 Troubleshooting of engine related parts
E-00 Troubleshooting of electrical system
H-00 Troubleshooting of hydraulic, mechanical system
M-00 Troubleshooting of machine monitor
2. Method of using troubleshooting table for each troubleshooting mode

1) Troubleshooting code number and problem
The title of the troubleshooting chart gives the troubleshooting code, service code, and failure
mode (problem with the machine). (See Example (I))
2) Distinguishing conditions
Even with the same failure mode (problem), the method of troubleshooting may differ accord-
ing to the model, component, or problem. In such cases, the failure mode (problem) is further
divided into sections marked with small letters (for example, a), so go to the appropriate
section to carry out troubleshooting. (See Example (2)) If the troubleshooting table is not
divided into sections, start troubleshooting from the first check item in the failure mode.
3) Method of following troubleshooting chart
YES
. Check or measure the item inside v , and according to the answer follow either the
YES line or the NO line to go to the next I. (Note: The number written at the top right $
corner of the 1 is an index number; it does not indicate the order to follow.) >
. Following the YES or NO lines according to the results of the check or measurement will i
lead finally to the Cause column. Check the cause and take the action given in the Remedy
column on the right. (See Example (3))
. Below the I there are the methods for inspection or measurement, and the judgement
values. If the judgement values below the 1 are correct or the answer to the question
inside the 1 is YES, follow the YES line; if the judgement value is not correct, or the
answer to the question is NO, follow the NO line.
. Below the I is given the preparatory work needed for inspection and measurement, and
the judgement values. If this preparatory work is neglected, or the method of operation or
handling is mistaken, there is danger that it may cause mistaken judgement, or the equip-
ment may be damaged. Therefore, before starting inspection or measurement, always read
the instructions carefully, and start the work in order from Item I).
4) General precautions
When carrying out troubleshooting for the failure mode (problem), precautions that apply to all
items are given at the top of the page and marked with * (See Example (4)) .
The precautions marked * are not given in the I, but must always be followed when
carrying out the check inside the I.
5) Troubleshooting tools
When carrying out the troubleshooting, prepare the necessary troubleshooting tools. For de-
tails, see TOOLS FOR TESTING, ADJUSTING, AND TROUBLESHOOTING.
20-230
0
TROUBLESHOOTING METHOD OF USING TROUBLESHOOTING CHARTS
6) Installation position, pin number

A diagram or chart is given for the connector type, installation position, and connector pin
number connection. When carrying out troubleshooting, see this chart for details of the con-
nector pin number and location for inspection and measurement of the wiring connector
number appearing in the troubleshooting flow chart for each failure mode (problem).
<Example>
(1) M-4 Abnormality in PPC oil pressure lock solenoid system
(4) Sr Before carrying out troubleshooting, check that all the related connectors are prop-
erly inserted.
* Always connect any disconnected connectors before going on the next step.
* Check that fuses 2 is normal.
(2) a) Is not actuated (safety lock is not released)

Divided into sections a) and b)
b) Remains actuated (safetu lock is not applied)
(3)
Cause Remedy
4YES
GotoA
Defective contact or
disconnection in wiring
harness between V07 Repair or
(female) (2) - HO2 (7) - replace
-Swinglock lever S14(1)-s12

,
I
NO
LOCK: 20 - 30 v
RELEASE: Max. 1 V
harness between fuse 2 -
Repair or
replace
HO6 (4) - V07 (female) (1)
Defective PPC oil

Replace
pressure lock switch
1 andS13
. Check PPC oil pressure lock
* Turn starting Defective PPC oil
switch as individual part.
switch OFF. pressure lock solenoid Replace
* Disconnect V07. NO switch
*20-60I2
5 YES
30 to H mode (H-3)
From A+$%L-J[ Iefective contact or

iisconnection in wiring
?epair or
larness between S13 -
NO eplace
*Turn starting ;14 (2) - HO2 (5) -
switch OFF. :hassis ground
* Disconnect S13.
* Max.1 R
Table 1
Safety lock lever Resistance value
OFF Max. 1 Q
LOCK Min. 1 MR
20-231
0
TROUBLESHOOTING OF ENGINE SYSTEM
(S MODE)
Method of using troubleshooting charts . .. . . . . . . . . .. . . . . . .. . . . . . . . . . .. . . . . . . .. . . .. . . . . . .. . . . . . . .. . . . . . . . .. . . . . . . .. . .. . . .. . .. . . . . .. . . 20-302

s- 1 Starting performance is poor (starting always takes time) ................................................. .20-306
s- 2 Engine does not start ............................................................................................................... 20-307
(I) Engine does not turn.. ........................................................................................................ 20-307
(2) Engine turns but no exhaust smoke comes out (fuel is not being injected) .............. 20-308
(3) Exhaust smoke comes out, but engine does not start (fuel is being injected) ........... 20-309
s- 3 Engine does not pick up smoothly (follow-up is poor) ........................................................ 20-310
s- 4 Engine stops during operations .............................................................................................. 20-31 1
s- 5 Engine does not rotate smoothly (hunting) ........................................................................... 20-312
S- 6 Engine lacks output (no power). .............................................................................................. 20-313
s- 7 Exhaust smoke is black (incomplete combustion) ............................................................... .20-314
S- 8 Oil consumption is excessive (or exhaust gas is blue). ....................................................... .20-315
s- 9 Oil becomes contaminated quickly ......................................................................................... 20-316
S-IO Fuel consumption is excessive ................................................................................................ 20-317
S-l 1 Oil is in cooling water, or water spurts back, or water level goes down .......................... 20-318
g
& S-l 2 Oil pressure caution lamp lights up (drop in oil pressure) ................................................. .20-319
s-13 Oil level rises (water, fuel in oil) ............................................................................................. 20-320
z
S-l 4 Water temperature becomes too high (overheating) ............................................................ 20-321
S-l 5 Abnormal noise is made .......................................................................................................... 20-322
S-16 Vibration is excessive ............................................................................................................... 20-323
20-30 1
0
TESTING AND ADJUSTING METHOD OF USING TROUBLESHOOTING CHARTS
METHOD OF USING TROUBLESHOOTING CHARTS
This troubleshooting chart is divided into three

sections: questions, check items, and troubleshoot-
ing. The questions and check items are used to
pinpoint high probability causes that can be located
from the failure symptoms or simple inspeciton with-
out using troubleshooting tools.
Next, troubleshooting tools or direct inspection
are used to check the high probability causes to
make final confirmation.
[Questions]
Sections @ + @ in the chart on the right corre-
sponds to the items where answers can be ob-
tained from the user. The items in @ are items
that can be obtained from the user, depending
on the user’s level.
[Check items]
The serviceman carries out simple inspection to
narrow down the causes. The items under 0 in I Causes I
the chart on the right correspond to this.
The serviceman narrows down the causes from
information @ that he has obtained from the
user and the results of 0 that he has obtained
from his own inspection.
[Troubleshooting]
Troubleshooting is carried out in the order of
probability, starting with the causes that have
been marked as having the highest probability
from information gained from [Questions] and
[Check items].
2 (a)
@ 2 (b) 0
%
\I 5 Cc) 0
4 ” Cd) 0
20-302
0
The basic method of using the troubleshooting chart

is as follows.
Items listed for [Questions] and [Check items] that
have a relationship with the Cause items are marked
with 0, and of these, causes that have a high prob-
ability are marked with 0.
Check each of the [Questions] and [Check items] in
turn, and marked the 0 or Q in the chart for items
where the problem appeared. The vertical column
(Causes) that has the highest number of points is
the most probable cause, so start troubleshooting
for that item to make final confirmation of the cause.
%I. For [Confirm recent repair history] in the
[Questions] Section, ask the user, and mark
the Cause column with A to use as reference
for locating the cause of the failure. How-
ever, do not use this when making calcula-
tions to narrow down the causes.
z-2. Use the n in the Cause column as reference
for [Degree of use (Operated for long pe-
riod)] in the [Questions] section as reference.
As a rule, do not use it when calculating the
points for locating the cause, but it can be
included if necessary to determine the order
for troubleshooting.
1 I1 Confirm recent repair history
3~2 Degree of use Operatred for long period arm
20-303
0
. Example of troubleshooting when exhaust gas is black

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

General causes why exhaust gas is black
. Insufficient intake of air
. Improper condition of fuel injection
. Excessive injection of fuel
20-304
a
Five causes
Step 1
Clarify the relationship between the three

symptoms in the [Questions] and [Check items1
section and the five Cause items in the vertical
z
I column.
I
Three symptoms
------Jt
Step 2
Add up the total of Oand 0 marks where the

horizontal lines for the three symptoms and the
vertical columns for the causes intersect.
(I) Clogged air cleaner element: 000
(2) Air leakage between turbocharger
and head: 00
(3) Clogged, seized injection nozzle: 0
(4) Defective contact of valve, valve seat: 0
(5) Worn piston ring, cylinder: 0
Step 3
The calculation in Step 2 show that the closest

relationship is with [Clogged air cleaner
element]. Follow this column down to the
troubleshooting area and carry out the
troubleshooting item marked 0. The Remedy is
given as [Clean], so carry out cleaning, and the
exhaust gas color should return to normal.
20-305
0
TESTING AND ADJUSTING S-l
S-l Starting performance is poor (starting always takes time)

General causes why exhaust smoke comes out but
engine takes time to start
. Defective electrical system
. Insufficient supply of fuel
. Improper selection of fuel
(At ambient temperature of 10°C or below, use
ASTM D975 No. 1)
* Battery charging rate
. The specific gravity should exceed the value

for the charging rate of 70% in the above table.
. In cold areas the specific gravity must ex-
ceed the value for the charging rate of 75%
in the above table.
Legend
0 : Possible causes (judging from Questions and check items)
d : Most orobable causes fiudaina from Questions and Check items)
n : Possible causes due to length of use (used for a long period)
l : Items to confirm the cause
Confirm recent repair history
Degree of use of machine 1Operated for long period
Gradually bet;
Ease of starting
WV v er
plug is loosened I I I I I I I I I I I I I I I
Leakage from fuel piping I I lOjO\ I
There is hunting from engine (rotation is irregular) I I I IW I I I I I I IOlOl
.
not return (Carry out inspection after pump is removed)
When fuel cap is inspected directly, it is found to be clogged 0
w~)ooo z- z
z; ““““%a,:,,
Rernedy$~~~~$~~~$~$~$$
rzQJJJ~~uulx<e”uK
20-306
0
TESTING AND ADJUSTING s-2
S-2 Engine does not start

(I) Engine does not turn I Causes I
General causes why engine does not turn

. Internal parts of engine seized
* If internal parts of the engine are seized,
carry out troubleshooting for “Engine
stops during operations”.
. Defective electrical system
Legend
0: Possible causes (judging from Questions and check items)
0 : Most probable causes (judging from Questions and Check items)
: Items to confirm the cause.
When starting switch is
turned to START, pinion
moves out, but
Specific gravity of electrolyte, voltage of battery is low 0

For the following conditions 1) 5). turn the starting switch
OFF, connect the cord, and carry out troubleshooting at ON

a
1) When terminal B and terminal C of starting switch are
connected, engine starts

I
2) When terminal B and terminal C of starting motor are +

0 2
Ls
IL
3) When terminal B and terminal C of safety relay are s
0 v:
4) Engine starts when safety switch terminal and starting

a
motor B terminal is connected
5) There is no 24V between battery relay terminal M and
terminal E I I I I /@I 1 I
When ring gear is inspected directly, tooth surface is
found to be chipped
20-307
0
(2) Engine turns but no exhaust smoke comes

out (fuel is not being injected)
* Check that the monitor panel does not dis-

play any abnormality in the governor control
system.
General causes why engine turns but no ex-
haust smoke comes out
l Supply of fuel impossible
. Supply of fuel is extremely small
. Improper selection of fuel (particularly in win-
Causes
ter)
* Standards for use of fuel
Ambient temprature
Type of fuel -22 -4 14 32 50 68 86 104°F
.30 -20 -10 0 10 20 30 40°C
Diesel fuel

0 : Most probable causes (judgingfrom Questionsand Check items)
A: Possible causes due to length of use (used for a long period)
20-308
0
(3) Exhaust smoke comes out but engine does

not start
(Fuel is being injected)
* General causes why exhaust smoke comes

out but engine does not start Causes
. Lack of rotating force due to defective elec-
trical system
. Improper selection of fuel and oil
Legend
A : Possible causes due to length of use (used for a long period)
l : Items to confirm the cause.
m Operated for long period
When engine is cranked with starting motor,

1) Little fuel comes out even when injection pump
sleeve nut is loosened
2) No fuel comes out even when fuel filter air bleed
olua is loosened
There is leakage from fuel piping
When exhaust manifold is touched immediately after
starting engine, temperature of some cylinders is low
When fuel filter is drained. no fuel comes out
Remove head cover and check directly

When control rack is pushed, it is found to be heavy, or does not return
When compression pressure is measured, it is found to be low %##
._P When fuel filter, strainer are inspected directly, they are found to be clogged 1 1.1 a
5 When feed pump strainer is inspected directly, it is found to be clogged 1 IO
##+rt
2
c When air cleaner element is inspected directly, it is found to be clogged 7 0
P
rl Heater mount does not become warm
z a
.L Either specific gravity
_ of electrolyte or voltage of battery is low I I I I
I-
When feed pump is operated, operation is too light or too heavy I 1.1 I I
1 When iniection nozzleistested asindividual part, spray condition isfoundto be poor ll I
When fuel cap is inspected directly, it is found to be clogged
Remedy
20-309
0
S-3 Engine does not pick up smoothly (follow-up is poor)

Causes
General causes why engine does not pick up smoothly
. Improper fuel used
Legend
a : Possible causes due to length of use (used for a long period)
’’H
,I t Engine pick-up suddenly became poor I lol I IQI lolol I

Blue under light load 0
Color of exhaust gas
Black 0 0 6 0
Clanging sound is heard from around cylinder head
I Ial I I I
Mud is stuck to fuel tank cap
There is leakage from fuel piping
High idling speed under no load is normal,
but speed suddenly drops when load is applied
There is hunting from engine (rotation is irregular)
When exhaust manifold is touched immediately after

starting engine, temperature of some cylinders is low
20. Blow-by gas is excessive
When air cleaner element is inspected directly, it is found to be clogged
When fuel filter, strainer are inspected directly, they are found to be clogged
When feed pump strainer is inspected directly, it is found to be clogged
20-3 10
0
S-4 Engine stops during operations

General causes why engine stops during opera-
tions
. Seized parts inside engie
. Insufficient supply of fuel Causes
. overheating
* If there is overheating and the engine stops,
carry out troubleshooting for overheating.
. Failure in main piston pump
Ir If the engine stops because of a failure in the
main piston pump, carry out troubleshooting
for the hydraulic system (H MODE).
Legend
0 : Most probable causes (judgingfrom Questions and Check items)
Abnormal noise was heard
Condition when
it is found to be abnormal
S-5 Engine does not rotate smoothly (hunting)

General causes why engine does not rotate
smoothly
. Air in fuel system
. Defective governor mechanism
. Defective electric governor mechanism
* If hunting does not occur when the rod be-
tween the governor motor and the injection
pump is disconnected, troubleshoot by us-
ing the electrical system troubleshooting (E
mode).
Questions and check items)

om Questions and Check items)
of use (used for a long period)
Condition of hunting
Replacement of filters has not been carried out according
When feed pump is operated,
-
1 When governor lever is moved it is found to be stiff I.1 I.1 I I -
When injection pump is tested, governor is found to be
improperly adjusted
l
-
.-F When control rack is pushed, it is found to be heavy, or
ij 0
2 does not return
-
L When fuel cap is inspected directly, it is found to be clogged
x2 0 -
7
5 When feed pump strainer is inspected directly, it is found to
c
0
be clogged
-
When fuel filter, strainer are inspected directly, they are
found to be clogged
a
-
z
ii 5‘0 zb
L
2” 0
i -
20-312
0
TESTING AND ADJUSTING S-6
S-6 Engine lacks output (no power)

General causes why engine lacks output
. insufficient intake of air
. Improper fuel used Causes
(if non-specified fuel is used, output drops)
. Lack of output due to overheating
* If there is overheating and insufficient output,
carry out troubleshooting for overheating.
Legend
20-3 13
0
S-7 Exhaust smoke is black

(incomplete combustion)
Causes
I I / / / / I I,,
General causes why exhaust smoke is black

Legend
0 : Moss probable causes (judging from Questions and Check items)
I / I I I I I I I I,
Degree of use of machine Operated for long period nnn n

1 Suddenly became black 0 0
Color of exhaust gas 1 Gradually became black I 101 I I I I I lol I I
I Blue under light load I I loI I I I I I I I I
Engine oil must be added more frequently 0
Power was lost

Suddenly 0 0 0 0
Gradually 00 00
Non-specified fuel is being used
Noise of interference is heard from around turbocharaer
Clanging sound is heard from around cylinder head I I I I I I Iol I I I I

Exhaust noise is abnormal lol I lo1 I I 101 I I I
Muffler is crushed I I I I I I I 101 I I I
Leakage of air between turbocharger and head, loose clamp ) I I 1 I I I I 10 I I I
.-P
i;
_?
z
E
:
:
When muffler is removed, exhaust color returns to normal I I.1 I I 1
When control rack is pushed, it is found to be heavy, or does not return 0
20-314
0
S-8 Oil consumption is excessive (or exhaust smoke is blue)

Sr Do not run the engine at idling for more than
20 minutes continuously. (Both low and high
idling)
General causes why oil consumption is exces-
sive
. Abnormal combustion of oil
. External leakage of oil
. Wear of lubrication system
Causes
Legend
When compression pressure is measured, it is found to be low
When breather element is inspected, it is found to be clogged with dirly oil 0

There is external leakage of oil from engine l O.f ,
C Pressure-tightness test of oil cooler shows there is leakage I.1 I
2 Excessive play of turbocharger shaft
6
Inspect rear seal directly 0
When intake manifold is removed, dust is found inside 0
I I When intake manifold is removed, inside is found to be dirty with oil 0
20-315
0
S-9 Oil becomes contaminated quickly

General causes why oil becomes contaminated
quickly
. Intake of exhaust gas due to internal wear
. Clogging of lubrication passage
. Improper fuel
. Improper oil used
. Operation under excessive load
Possible causes (judging from Questions and check items)
Excessive
Amount of blow-by gas
None
When oil filter is inspected, metal particles are found 0 00 E

!!2
When exhaust pipe is removed, inside is found to be dirty with oil 0 0
Engine oil temperature rises quickly 5

0 L
TESTING AND ADJUSTING S-IO
S-10 Fuel consumption is excessive

General causes why fuel consumption is exces-
sive
. Leakage of fuel
/ Causes I
Legend
Condition of fuel
20-317
0
TESTING AND ADJUSTING S-II
S-l 1 Oil is in cooling water, or water spurts back, or water level goes down
General causes why oil is in cooling water
. Internal leakage in lubrication system
. Internal leakage in cooling system
Legend
0 : Most probable causes (judgingfrom Questions and Check items)
a: Possible causes due to length of use (used for a long period)
Hard water is being used as cooling water 0 0

yu)
8 E Engine oil level has risen, oil is cloudy white 0 00
6 ” Excessive air bubbles inside radiator, spurts back 00
20-318
S-12 Oil pressure caution lamp lights up (drop in oil pressure)

General causes why oil pressure lamp lights up
. Leakage, clogging, wear of lubricating system
. Defective oil pressure control
. Improper oil used (improper viscosity)
. Deterioration of oil due to overheating
Ir Standards for engine oil selection
I Ambient temperature
Legend
Replacement of filters has not been carried out according
Condition when oil
pressure lamp lights up
When oil pressure is measured, it is found to be within
standard value
S-13 Oil level rises (water, fuel in oil)

* If there is oil in the cooling water, carry out
troubleshooting for “Oil is in cooling water”.
General causes why oil level rises
. Water in oil
. Causes
Fuel in oil (diluted, and smells of diesel fuel)
. Entry of oil from other component
Legend
0 : Possible causes (judging from Questions and check items1
a: Possible causes due to length of use (used for a long period)
I
.P Degree of use of machine Operated for long period
zi
% When engine is first started, drops of water come from muffler
cc
Exhaust smoke is white
There is oil in radiator cooling water
Leave radiator cap open. When engine is run at idling, an
abnormal number of bubbles appear, or water spurts back
Water pump breather hole is clogged with mud

C
When water pump breather hole is cleaned, water comes out
‘:
m
Oil level goes down in damper chamber
6
Oil level goes down in hydraulic tank
Engine oil smells of diesel fuel
Fuel must be added more frequently
1 Pressure-tightness test of oil cooler shows there is leakage I.1 I I I I I I I I I

I Pressure-tightness test of cylinder head shows there is leakage I I.1 I I I I I I I I
When compression pressure is measured, it is found to be low
Remove water pump and inspect directly
Remove rear seal and inspect directly
When main pump is removed, seal is found to be damaged

0 Remove head cover and inspect directly
$
Remove injection pump and inspect directly
Defective contact of thermostat seal valve
Remove oil pan and check directlv
20-320
0
S-14 Water temperature becomes too high (overheating)

General causes why water temperature becomes too
high
. Lack of cooling air (deformation, damage of fan)
. Drop in heat dissipation efficiency
. Defective cooling circulation system
Possible causes (judging from Questions and check items)
open even at cracking temperature

o
z
When water temperature is measured, it is found to be normal 0
c When oil cooler is inspected directly, it is found to be clogged 0
When measurement is made with radiator cap tester, set
0
pressure is found to be low
When compression pressure is measured, it is found to be low a

Remove oil pan and inspect directly 0
4
Remedy 28 t; t; 2% _m
E E _m
E 28 2x _m
8 2P
F 2
aooLCaSd2czbS
0s: 0 0 a a a P E
20-321
0
S-15 Abnormal noise is made

Causes
Ir Judge if the noise is an internal noise or an
external noise.
General causes why abnormal noise is made
. Abnormality due to defective parts
. Abnormal combustion
. Air sucked in from intake system
Legend
0 : Possible causes (judging from Questions and check items1
0 : Most probable causes (judgingfrom Questionsand Check items)
a : Possible causes due to length of use (used for a long period)
Condition of abnormal noise
20-322
0
S-16 Vibration is excessive

* If there is abnormal noise together with the
vibration, carry out troubleshooting for “Ab-
normal noise is made”.
General causes why vibration is excessive
. Defective parts (abnormal wear, breakage)
. Improper alignment
l Abnormal combustion
Legend
Condition of vibration
Remove oil pan and inspect directly l

p Remove side cover and inspect directly a
._
Inspect directly for loose engine mounting bolts, broken cushion 0
E
f Inspect inside of output shaft (damper) directly l
s
B
Remove front cover and inspect directly 0
z
c Remove head cover and inspect directly 0
Injection pump test shows that injection amount is incorrect a

I
20-323
0
TROUBLESHOOTING OF ELECTRICAL SYSTEM
(E MODE)
Judgement table for electrical, hydraulic, and mechanical systems . . . . . . . .. . .. . .. . .. . . . . . . .. . . . . . . . . . .. . . . . . . .. . .. 20-352

Electrical circuit diagram for each system . . .. . . .. . . . . . . . . .. . . . . . . . .. . . .. . . . . . . .. . . . . . . . . .. . . . . . . .. . . . . . . . . . .. . . . . . . . . . . .. . . . . . .. . .. 20-354
Failure codes
E-l Abnormality in PC-EPC control system
a) Engine stops even when throttle lever is not returned to STOP position.
When sudden load is applied, engine stalls. . . . . . ..__.......................................................... 20-355
b) Lacks power when throttle lever is at FULL, work equipment speed is slow . . . . . . . .. . . . 20-356
E-2 Abnormality in travel speed selector system (travel speed does not switch) .. . . . . . . .. . . .. . . . . . 20-358
E-3 Abnormality in swing holding brake solenoid system
a) Swing holding brake solenoid is not actuated (cannot swing) . .. . .. . . . . . . . .. . . . . . .. . . .. . . . . . . . . . .. 20-359
b) Remains actuated (swing cannot be locked) .. . . . . . . . . . . .. . . .. . . .. .. . . . . . . . .. . .. . . . . . . .. . . . . . . .. . .. . . . . . . .. . . .. 20-360
E-4 Abnormality in PPC oil pressure lock solenoid system
a) Solenoid is not actuated (safety lock is not canceled) .......... .................. .................. ..... 20-361
b) Remains actuated (safety lock is not actuated) . .. . . . . . . . . . . .. . . . . . .. . .. . . . . . . . .. .. . . . . . . .. . . . . . . .. .. . . . . . . . .. 20-362
E-5 Abnormality in engine starting system (engine does not start) .__....................................... 20-364
20-351
0
JUDGEMENT TABLE FOR ELECTRICAL,
TROUBLESHOOTING HYDRAULIC, AND MECHANICAL SYSTEMS
JUDGEMENT TABLE FOR ELECTRICAL, HYDRAULIC, AND

MECHANICAL SYSTEMS
Parts causing failure

1. Insert T-adapter in pump
regulator connector KOl).
2. Turn starting switch to
3. Is voltage between V06
3. Turn pump prolix switch (I) and chassis as shown
in table below?
Failure mode
Does not swin
20-352
0
JUDGEMENT TABLE FOR ELECTRICAL,
TROUBLESHOOTING HYDRAULIC, AND MECHANICAL SYSTEMS
Solenoid valve
6
Swing holding brake solenoid PPC hydraulic solenoid ;;
t
1. Insert T-adapter in swing holding brake 1. Insert T-adapter in PPC hydraulic lock solenoid
m
solenoid connector (VO4). connector (VO7). .o
2. Turn starting switch ON. 2. Turn starting switch ON. E
-orn
3. Is voltage between V04 (I) and (2) as shown 3. Is voltage between V07 (I) and (2) as shown PE
in table below? in table below? Eb
.-0’ =
= A?
(When normal) (When normal)
H-l
H-2
0 H-3
H-4
H-5
H-6
H-7
H-8
H-9
H-10
20-353
0
TROUBLESHOOTING ELECTRICAL CIRCUIT DIAGRAM FOR E MODE SYSTEM
ELECTRICAL CIRCUIT DIAGRAM FOR E MODE SYSTEM
Starting switch
ioht switch
pressure switch
Bracket
,Electrical Pump
parking brake
Engine speed
L____.___._._.J
Engine Pump control box
Pump control redundancy switch
___-.-.
Changeover switch
Iect
, of kerosens mode
I Jointino:kerosene
’ Cutting off:Diesel oil Tb:Poloo8
20-354
0
TROUBLESHOOTING E-l
E-l Abnormality in PC-EPC control system

* Before carrying out troubleshooting, check that all the related connectors are properly inserted.
Ir Always connect any disconnected connectors before going on to the next step.
* Check that fuse 2 is normal.
Sr Check that the pump prolix switch is OFF.
a) Engine stops even when throttle lever is not returned to STOP position. When sudden load is
applied, engine stalls.
Cause Remedy
Replace or
2 YES Troubleshooting of turn pump
c
Is voltage pump regulator prolix switch
YE ; between CO1 Short circuit, disconnection,
ON.
(female) (1) and defective contact in wiring
(8) normal? harness between fuse (2) - Repair or
HO6 (4k CO1 (female) (11, or replace
* Turn starting
between CO1 (female) (8)
switch ON.
and chassis ground
* Disconnect COI.
Does LED of
* 20 - 30 v
pump regulator Go to H mode (H-2)
Is continuity
YES between CO1
(female) (5) - (10). Short circuit,
* Turn starting disconnection, or defective
3 (6) - (10) normal? Repair or
switch ON. contact in wiring harness
- Turn starting switch OFF. NO
between CO1 (female) (5) -
replace
Is LED of pump *Disconnect COl.
- . No continuity between (5) and (10) (lo), (6) -(IO)
- regulator
N ’ flashing? -Continuity between (6) and (10)
5 YES
+A
*Turn starting Is resistance
switch ON. between Cl3
NO (male) (1) and (2)
normal?
I I I
c Failure of solenoid Replace
* T;;;,starting switch ~0
. Disconnect C13.
.7-14R Replace or
7 YES Abnormality in pump turn pump
regulator prolix switch
Disconnection in wiring ON.
harness between CO1
(femalel (7) - CO5 cl)- (31- Repair or
Cl3 (female) (1). between
reolace
Cl3 (female) (2) - co5 (4) -
A-
(2l- CO1 Ifemale) (13)
Wiring harness between CO1

* Disconnect COI. (female) (7) - CO5 (1) - (3) - Repair or
c Cl3 (female) (11, or between
* Min. 1 MR NO replace
Cl3 (female) (2) - CO5 (4) -
(2) - CO1 (female) (13) short
circuiting with chassis
ground
20-355
0
TROUBLESHOOTING E-l
b) Lacks power when throttle lever is at FULL, work equipment speed is slow
Cause Remedy
3 YES Troubleshooting of
* Replace
Is resistance pump regulator
YES between CO1 Short circuit,
2 - (female) (3) and disconnection, or defective
- (4) normal? contact in wiring harness Repair or
Is resistance
between CO1 (female) (3)
YE between E07 *Turn starting NO replace
and E07 (female) (1). or
(male) (I) and (2) switch OFF.
1 between CO1 (female) (4)
normal? * Disconnect COI. and E07 (female) (2)
* 500 - 1000 R
* Turn starting L Troubleshooting of Replace
switch OFF. NO speedsensor
* Disconnect E07.
~500-1000R
*Turn starting 4 YES Abnormality in pump Replace
switch ON.
regulator
. Set throttle lever Is continuitybetween
to FULL. CO1 (female)(5)and _ Short circuit,
I\ (10).(61and (101 disconnection, or
normal? Repair or
defective contact in
*Turn starting NO wiring harness between replace
switch OFF. CO1 (female) (5) and (lo),
* Disconnect COl. or between (6) and (IO)
* No continuity between (5)
and (IO)
* Continuity between (6)
and (10)
20-356
0
TROUBLESHOOTING E-l
E-l Related electric circuit diagram
Fuse box Ho6 (S8) CO1 (MICl3) Pump controller
Ensine speed sensor (input:
Engine speed sensor (GND)
Machine select I
Machine select 2
EPC solenoid (+I
Kerosene mode
Prolix resister
select switch
Revolving
Pump prolix snitch
*’ ON
OFF
TKPOI 009
20-357
0
TROUBLESHOOTING E-2
E-2 Abnormality in travel speed selector system (travel speed does

not switch)
* Before carrying out troubleshooting, check that all the re- Cause Remedy
lated connectors are properly inserted.
Ir Always connect any disconnected connectors before going
on to the next step.
YES
* Check that fuse 5 is normal. Go toH mode(H-20)
3, I
YE
Defective travel Hi-Lo
Replace
relay
~
(1) and (2) as shown GotoA

. Tgu;;,startingswitch N(
*20-30V
-Turn starting * Replace relay.
-__ *Turn starting switch ON
switch UFI -TurnHi-Lo switch ON. Defective travel Hi-Lo
(male) (1) and (2) * Disconnect M38. 1 Replace
NO relay switch
* Turn starting
switch OFF. I Defective travel Hi-Lo
I
* Disconnect V06. Replace
NO solenoid valve
*20-60R
5YE! harness between M38 Repair or
(female) (1) - HO2 (1) - HO6 replace
(2) - R05 (female) (1)
A{=[ Defective contact or
Repair or
harness between fuse (5) -
*Turn starting NC replace
HO6 (8) - HO2 (9) - M38
switch ON.
(female) (2). and between
*20-30V
Table 1 R05 (female) (5) - HO3 (15)
- M30 - V06 (female) (1)
Travel Hi-Lo switch Resistance value
HIGH Max. 1 Q
Travel speed switch
LOW Min. 1 MQ
E-2 Related electrical circuit diagram
HO6 (S8) HO2 (S16) M38 (M2)

I \ 1 I I 1
Travel speed relay
H03(SlGwhite) VO6 (X2)

M30
’ @t--T--3j
,,llr
1
I, n\ 3
DO7
Travel
solenoid
speed
valve
TKPOlOlO
I 1 I
20-358
0
TROUBLESHOOTING E-3
E-3 Abnormality in swing holding brake solenoid system
-)r Before carrying out troubleshooting, check that all the related connectors are properly inserted.
j, Always connect any disconnected connectors before going on the .next step.
a) Swing holding brake solenoid is not actuated (cannot swing)

Cause Remedy
4YEI
Go to H-21
IL
harness between V04
3 normal? Repair or
-Turn
starting NC
(female) (2) - HO2 (3) -
X05 (female) (4),
replace
switch ON. between X05 (female) (3)
*Swing lock - HO2 (5) -chassis
switch LOCK:
ground
zo-3ov
* Turn starting * Swing lock switch Defective contact or
switch ON. CANCEL: Max. 1 V disconnection in wiring Repair or
as shown in Table *20-30V harness between fuse 2 - replace
HO6 (4) - V04 (female) (1)
Is resrstance + Turn startrng
between V04 switch OFF.
/ Defective swing lock Replace
(male) (1) and (2) * Disconnect X05.
NO switch
normal?
*Turn starting
switch OFF. Defective swing lock
* Disconnect V04. solenoid valve Replace
.20-600 NO
Table 1
Swing holding brake switch Resistance value
CANCEL Max. 1 Q
LOCK Min. 1 MQ
E-3 a) Related electric circuit diagram
Swine lock switch
DO5
I i I
HO2 (S16)
r-r---
2 X05 (M4) a
3 a ($
4 @
BDP00258
20-359
0
TROUBLESHOOTING E-3
b) Remains actuated (swing cannot be locked)
Cause Remedy
3 YES
Go to H Mode (H-21)
I Is resistance II
Short ciucuit with chassis
ground in wiring harness
Repair or
between V04 (female) (2)
replace
- HO2 (3) -X05 (female)
(4)
* Disconnect V04 and X05.
Defective swing holding Replace
between V04
brake switch
(male) (I) and (2)
- Disconnect X05.
Defective operation of
* Turn starting swing holding brake
I Replace
switch OFF. solenoid valve (short
NO
* Disconnect V04. circuit with ground at (2))
*20-60R
Table ‘I
CANCEL Max. 1 Q
LOCK Min. 1 MR
E-3 b) Related electric circuit diagram
Fuse HO6 (S8) vo4 (X2)

2 holding
@ 3 Swing
brake solenoid
3 valve
Swing lock SW; tch
1 HO2 (S16)
2 X05 (M4) @
3 3 ($
4 @
BDP00258
20-360
0
TROUBLESHOOTING E-4
E-4 Abnormality in PPC oil pressure lock solenoid system
Ir Before carrying out troubleshooting, check that all the related connectors are properly inserted.
Ir Check that fuses 2 is normal.
a) Solenoid is not actuated (safety lock is not canceled)

Cause
4YEI
GotoA
chassis normal? disconnection in wiring
Is voltage harness between V07 Repair or
YES between V07 (1) (female) (2) - HO2 (7) - replace
and chassis S14(1)-s12
2 . Safety lock lever
~ normal? LOCK: 20 - 30 V Defective contact or
Is resistance RELEASE: Max. 1 V
* Turn starting I disconnection in wiring Repair or
YES between Sl2 and
S13 as shown in - switch ON. NO harness between fuse 2 - replace
*20-30V HO6 (4) -VO7 (female) (1)
i
Table I?
Is resistance *Turnstarting Defective PPC oil
H
between V07 switch OFF. I pressure lock switch
Replace
(male) (1) and (2) * Disconnect S12 NO
1
normal? II
1
and S13.
- Check PPC oil pressure lock
-Turn starting switch as individual part. Defective PPC oil
switch OFF.
pressure lock switch
* Disconnect ~07. NO
*20-60R
5 YES
Go to H mode (H-3)
Repair or
harness between S13 -
replace
. Turn starting NC S14 (2) - HO2 (5) -
switch OFF. chassis ground
* Disconnect S13.
- Max.1 R
Table 1
RELEASE Max. 1 Q
LOCK Min. 1 MQ
E-4 a) Related electric circuit diagram
HO6 (S8) vo7 (x02)

PPC oil
pressure lock
solenoid valve
PPC oil Pressure
lock switch
BDP00257
20-36 1
0
TROUBLESHOOTING E-4
b) Remains actuated (safety lock is not actuated)
Short ciucuit with chassis

ground in wiring harness
1 YES Replace wiring
between V07 (female) (2)
Is resistance harness
- HO2 (7) - S14 (I) and
between S12 and s12
S13 as shown in
table l? Defective PPC oil
Replace
NO pressure switch
*Turn starting
switch OFF.
- Disconnect S12
and S13.
.--.-
Table 1
RELEASE Max. 1 Q
LOCK Min. 1 MQ
E-4 b) Related electric circuit diagram
Fuse HO6 (S8) vo7 (X02)

3 PPC OI I
Pressure lock
I !3? solenoid valve
PPC oil Pressure
lock switch
CANCEL LOCK ~1 2
S14 (M2) HO2 (S16)
03 a (--
g$ g a
s13 ElDP00257
20-362
0
TROUBLESHOOTING E-5
E-5 Abnormality in engine starting system (engine does not start)
* When the starting motor does not turn.

j, Always connect any disconnected connectors before going on the next step.
YES
YES
Is there sound of
ES 6
starting motor
pinion engaging? 1.
IS voltage between
---I
* Turn starting terminal S and
switch to START.
% Same conditions
as in Step 5.
Yl
4 NO
*Turn starting
switch to START.
starting motor
terminal B and *20-30V
When starting
YES switch is turned chassis normal? VO
r OFF, is sound heard
from battery relay? * Turn starting
I 1 switch ON.
. Turn starting *20-30V
switch ON +
OFF.
12 YES
Is resistanceof wiring
1
Is voltage and
specific gravity of
battery normal?
I
.20-3ov.
* Specific gravity:
Min. 1.26 switch ON. NO
* Remove terminal B.
* Connect (4 end
of tester to
battery terminal
(4
.20-30V
20-364
0
TROUBLESHOOTING E-5
Cause Remedy
Defective starting motor qepair or

(motor proper) .eplace
Defective starting motor qepair or

(magnetic switch) .eplace
7
Is voltage between Defective contact or
starting motor disconnection in wiring
YES harness between safety qepair or
terminal C and
8 relay terminal C-T13 (1) replace
chassis normal?
- Is voltage between -starting motor terminal
.x Same conditions safety relay C
as in Step 5. NO terminal C and 9 YES
chassis normal? Defective safety relay qeplace
_ Is voltage
% Same conditions between MO2
as in Step 5. NO (female) (2) and
chassis normal?
Defective alternator 3eplace
* Turn starting NO
switch ON. Defective contact or
* Max. 13 V disconnection in wiring
harness between starting qepair or
switch terminal C - HO3 replace
(3) - MO.2 (1) - safety
relay terminal S
Defective starting switch
(between terminals B Replace
and C)
Defective contact of wiring
harness between battery Repair or
terminal (+) - battery relay replace
terminal B-terminal M -
starting motor terminal B
Defective battery relay Replace

harness between starting
Repair wiring
switch terminal BR - HO3
harness
(1) -battery relay
terminal BR
Defective starting switch

Replace
(between B and BR)
disconnectionin wiring
harness between battery
relay terminal (+I - battery Repair wiring
relay terminal B- Ml1 (1). (2 harness
- Hd3 (2) -fuse 1 - starting
switch terminal B (including
fusible link)
Charge or
Lack of battery capacity
replace
20-365
0
TROUBLESHOOTING E-5
E-5 Related electric circuit diagram
Fuse
Starting switch
Starter Alternator
HO3 (S16white)
Fusible link
Safety
relay
///
Battery [“\ , \_,\., ,
I
El2
(X2)
E08 (Xl)
Battery relay
TKPOlOl 1
20-366
0
TROUBLESHOOTING OF HYDRAULIC AND
MECHANICAL SYSTEM
(H MODE)
Table of failure modes and causes . .. . .. . . . . . .. . . . . . . . .. . .. . . . . . . . .. . .. . . . . . . .. . .. . . . . . . .. .. . .. . . . .. . . . . . . . . .. .. . . . . . . . .. . . . . .. . .. . . . . .. 20-402

H-l Speeds of all work equipment, travel, swing are slow or lacks power.. ....................... 20-406
H-2 There is excessive drop in engine speed, or engine stalls ............................................. .20-408
H-3 No work equipment, travel, swing move .......................................................................... .20-409
H-4 Abnormal noise generated (around pump) ...................................................................... .20-409
H-5 Fine control ability is poor or response is poor.. ............................................................. .20-409
H-6 Boom is slow or lacks power .............................................................................................. 20-412
H-7 Arm is slow or lacks power.. ............................................................................................... 20-414
H-8 Bucket is slow or lacks power.. ........................................................................................... 20-416
H-9 Work equipment (boom, arm, bucket) does not move
(but travel and swing are normal) ...................................................................................... 20-416
H-10 Excessive hydraulic drift (boom, arm, bucket) ................................................................. .20-417
H-l 1 Excessive time lag (engine at low idling) ......................................................................... .20-418
H-12 Other equipment moves when single circuit is relieved ................................................. .20-418
H-13 In compound operations, work equipment with larger load is slow.. ........................... 20-418
H-l 4 In swing + boom RAISE, boom RAISE is slow.. ............................................................... .20-419
g H-15 In swing + travel, travel speed drops excessively ............................................................ 20-419
&
H-16 Travel deviation.. ................................................................................................................... 20-420
2
a) Deviation is excessive in normal travel ....................................................................... 20-420
b) Deviation is excessive when starting ........................................................................... 20-420
H-17 Travel speed is slow.. ........................................................................................................... 20-421
H-18 Steering does not turn easily or lacks power.. ................................................................. .20-422
H-19 Travel does not move (one side only). ............................................................................... 20-423
H-20 Travel speed does not switch.. ............................................................................................ 20-423
H-21 Does not swing ..................................................................................................................... 20-424
a) Does not swing to either left or right .......................................................................... 20-424
b) Does not swing in one direction.. ................................................................................. 20-424
H-22 Swing acceleration is poor or swing speed is slow ........................................................ .20-426
H-23 Excessive overrun when stopping swing ........................................................................... 20-428
a) One direction only.. ........................................................................................................ 20-428
b) Both directions.. .............................................................................................................. 20-428
H-24 Excessive shock when stopping swing (one direction only). .......................................... .20-429
H-25 Excessive abnormal noise when stopping swing ............................................................ .20-429
H-26 Excessive hydraulic drift of swing ...................................................................................... 20-430
a) When swing lock is ON ................................................................................................. 20-430
b) When swing lock is OFF ................................................................................................ 20-430
20-401
0
TROUBLESHOOTING TABLE OF FAILURE MODES AND CAUSES
TABLE OF FAILURE MODES AND CAUSES (l/Z)

- - - -
Parts causing failure
Piston pump 5
F
-r P
E
F R
3 s
- - 9 -
!?
2
I
h
0)
.F
2
9 s -0
2 i &
5
Failure mode F 9 = I ?
2 cz
L
E
;
\ ? tj
-2 ul
r
-
; Speeds of all work equipment, swing, travel are slow or lack power I 0
- - - -
i-e There is excessive drop in engine speed, or engine stalls 0
- 0
- - -
$2
zd No work equipment, travel, swing move - - 0
- 0
- -
2 6 Abnormal noise generated (around pump) - - - 0
- - -
2 Fine control ability is poor or response is poor - - - -
Boom is slow or lacks power - - - - - 0
Arm is slow or lacks power - - - - - 0
r;
Bucket is slow or lacks power - - - - - 0
E
.a - Boom does not move - - - - - 0
$ Arm does not move - - - - - 0
Bucket does not move - - - - - 0
z
3
Excessive hydraulic drift - - - - - 0
-
Excessive time lag (engine at low idling) _ - - - -
Other equipment moves when single circuit is relieved - - - - - -
$ ,g In compound operations, work equipment with larger load is slow - - - - -
ef In swing + boom (RAISE), boom is slow _ - - - - -
5 8 In swing + travel, travel speed drops excessively - - - -
Deviation is excessive during normal travel
_ - z
- - - 0
-
Deviation is excessive when startina
tz _ - - -
z
I ~~
2 Travel speed is slow - - - - -

B Steering does not turn or lacks power - - - - -
;
t Does not move (one side only) - - - - -
Travel speed does not switch - - - -
Does not swing
1 Both left and riaht
- - - - -
One direction only
- - - - -
Swing acceleration is poor Both left and right - - - - -
or swing speed is slow One direction only
- - - - -
Excessive overrun Both left and right
One direction only
- - - _ -
when stopping swing - - - -
Excessive shock when stopping swing (one direction only) - - - - -
Excessive abnormal noise when stopping swing - - - - -
Excessive hydraulic When brake ON _ - -
1 drift of swing 1 When brake OFF - - -
* In the failure modes, modes for compound operations are used when independent operations are normal
A: When there is an abnormality for both front and rear
20-402
0
- - -
- - - - -
Control
- -
valve
- -
T 3
1
Re- J
genera-
$ tion kcz
dalve .E
J z I: 9
6 2”
1
G 9 : $ s f
3
Troubleshooting code
s E P
a, E
al
: “0 9 =
9
F 9
B
E z5 Y
8
1” 1” e
J _c
s
a2 i
a
G .-6 E
s
.c
3
o
5
3 x k
C
E 2 1 z 5 F 9
z
C C
2 .z
z 32 5 2 II !
2 -zi 3 2
u 2 s
z .- 7 E
.g 9 I .i
.k
P .k
0
E al
tj 2 5 .-F
2 3 k I Y 13 Y I? 2 5 z c L 2
- - - - - - - - - - - -
r- i
- - - - - - - - - - - - - I H-l
- - - - - - - - - - - - - -
H-2
- - - - - - - - - - - - - - H-3
- - I
- - - - - - - - -
H-A
- - - - - 0
- - - -
H-5
- - 0 - - 5 - - - 0 -
0 0 - H-6
- - 0 - - -6
- - - 0
- 0 - 0 - -
H-7
- - 0
- - - - - - - 0
- - 0 - H-8
- - - - - - - - - 0 -
-
4
- -
- - - - - - - - - - - 0 - -
H-9
- - - - - - - - - 0
- - -
- - 0 - - - - - - 0 - - - - H-10
- - 0 - - - - - 0
- - - - -
I H-11
- - 0 - - - - - - - - - - -
H-l 2
- - 0
- - - - - - - - - - - H-13
- - - 0
-
- - - - - - - -
- - - 75
- -- - - - - - -
- - 0
_ - - -- - - - - 0 - -
- - - - -- - - - -
- 0
- - -
- - - - 0 0
- - -
H-17
0 - 0 -
_I
- - - - - -- - - - -
- - - - - -- - - - 0
- - - -
- - - - -- - - - - - - -
- - - - - -- - - - - - -
- - - - - - - - 0
- - -
- - - c
- 0
0 - - - - - - - -
- - - - - - -
0 - - - - 0
- - -
- - - - - - - - - - - - q---+--
- - - - - - - - - - - 0 - 0
- - - - - - - - - - - 0
- - 0
-
- - - - - - - - - - - - - -
H-25
- - - - - - - - - - - - - H-26
- - 0 - - - - - - - - - - -
20-403
0
TABLE OF FAILURE MODES AND CAUSES (2/2)
Parts causing failure Solenoid Swing

valve motor
2
2
a,
9
Failure mode
Does not swing
when stopping swing
* In the failure modes, modes for compound operations are used when independent operations are normal
A: When there is an abnormality for both front and rear
20-404
0
E20Y06
0 Swing machinery
0 Final drive
TROUBLESHOOTING H-l
H-l Speeds of all work equipments, travel, swing are slow or lacks
power
Ir Check that there is no abnormal normal from the main pump before starting troubleshooting.
(If there is any abnormal noise, carry out Troubleshooting H-4.)
YES
4
Does condition
YE become normal
when PC valve is 5 YES
adjusted?
Does condition
* For details, see become normal when
TESTING AND NO PCvalve assembly is
L-t
Is servo piston input ADJUSTING. replaced?
YE pressure approx. l/2
of main circuit NO
pressure?
* Engine at high 6 YES

idling
2 * Arm IN relieved Does condition
L become normal when
YES Is main pump N~ LS valve assembly is
- relief pressure replaced?
normal?
* Distribution NO
between LS
f 30.4 - 33.8 MPa
valve and piston pump (servo piston).
I310 - 345 kg/cm? YES
* Engine at high
7
1 idling
* Arm IN relieved Does condition
Is output pressure
become normal
of self-reducing
I\ when main relief 8 YES
pressure valve
normal? valve is adjusted?
Does condition
-1
* 30.4 - 33.8 MPa _ become normal
x Check and
(310 - 345 NO when unload
measure circuit
kg/cm21 valve is replaced?
oil pressure.
* Engine at high NO
For details, see * 3.9 f 1.O MPa
idling
TESTING AND {40 i 10 kg/cm21
* Arm IN relieved
ADJUSTING. * Engine at high idling
. Arm IN relieved
I
NO
Note 1:Measuring servo piston input pressure

. Measure the input pressure to the large diameter end of the servo piston when the arm is
relieved. (Approx. 15.7 MPa (Approx. 160 kg/cm?)
[Basically the pressure at the large diameter end is approx. l/2 that of the small diameter
end. (For details, see TESTING AND ADJUSTING.)]
20-406
0
TROUBLESHOOTING H-l
Cause Remedy
Defective adjustment of
f- PC valve
Adjust
Defective PC valve Repair or

assembly replace
Repair or
Defective piston pump
replace
Defective LS valve Repair or

assembly replace
Defective piston pump Repair or

(servo piston) replace
Defective adjustment of
main relief valve Adjust
unload valve Replace
main relief valve Replace
Defective hydraulic
equipment in self-
Adjust or
reducing pressure valve
replace
output circuit
(For details, see TESTING
AND ADJUSTING.)
20-407
0
TROUBLESHOOTING H-2
H-2 There is excessive drop in engine speed, or engine stalls

* Check that the main relief pressure is normal.
hlzizzL
Cause Remedy
servo or filter inside Clean

servo
Adjust or
YES replace PC
31 Defective PC valve
valve
Does condition assembly
servo or filter YES become normal
- when PC valve - Adjust or
assembly is 4 YES replace LS
replaced? Does condition Defective LS valve
valve
become normal assembly
2 - when LS valve -
NO assembly is
Replace
Is engine speed replaced?
Defective servo piston (piston pump
normal at arm NC
N assembly)
-1
.X Seebelow.
NO
See troubleshooting
engine (S mode)
for
-
Note 1:Replace the defective servo valve assembly with a new part. If the engine speed is lower than
the reference value given below, go to troubleshooting for S mode.
If it is higher, the servo valve system is defective, so replace it.
Note 2:Engine speed at arm relief when engine and pump are normal (reference value)
Engine speed at arm relief Conditions
. Engine at high idling.

. With arm at end of stroke, move lever slowly to high
Min. 1900 rpm
idling and read engine speed at point where there is
maximum drop in speed.
20-408
0
TROUBLESHOOTING H-3, H-4
H-3 No work equipment, travel, swing move
Cause Remedy
Defective self-reducing
2 YES pressure valve or Replace
[Whenmainpump 11 defective control circuit
YE
1
Defective damper Replace

solenoid valve - Crank with
starting motor.
* Hold outlet hose PPC lock solenoid valve Adjust
by hand and NO or safety lock lever
operate lock
lever.
H-4 Abnormal noise generated (around pump)
Cause Remedy
3 YES
YIESEl- Goto4
Change
2 Improper hydraulic oil
hydraulic oil
NO
Are there
YE
bubbles inside
hydraulic tank? YES Clogged by external
object (cloth, etc.)
(strainer)
Is suction strainer 5 YEI
clogged by
Is suction strainer Repair or
NO external object? Defect inside pump
clogged with replace
Is hydraulic tank
metal particles or
oil level normal? - External object:
NG are metal Inspect again
Cloth, etc. Operate for a short time
particles stuck to (depending on
drain plug? and watch for any
NC change in symptoms changes in
symptoms)
Lack of hydraulic oil Add hydraulic

oil
20-409
0
TROUBLESHOOTING H-5
H-5 Fine control ability is poor or response is poor
Cause Remedy
1 YES Clogged throttle in LS

Clean
circuit
Is throttle in LS
circuit clogged?
Defective LS valve, or Replace
NO defective servo piston
20-410
0
TROUBLESHOOTING H-6
H-6 Boom is slow or lacks power

* When travel and swing speeds are normal.
5 YES
Yt
4
* LS shuttle for
YfIS front and rear
R.H. travel and
pumps normal
when boom RAISE bucket
is relieved?
3
* 30.4 - 33.8 MPa
a pressure
YES compensation valve I310 - 345 kg/cm’)
normal, or does * Engine at high h
praSS”ra
idling
compensation piston
move smooth1 ? - 4.9 i 2.9 MPa
9 El
* It is also possible (50 k 30 kg/cm*)
to check by - Engine at high
interchanging with idling
other i
compensation Ni
valve.
Is output Note: After checking, always return
pressure of PPC - to original positions.
valve normal? NO
* Min. 2.7 MPa

(28 kg/cm’)
* Engine at high
idling NO
20-412
0
TROUBLESHOOTING H-6
Cause Remedy
Defective boom cylinder Correct or

piston packing replace
Defective operation of Correct or

control valve spool replace
Defective PPC valve Replace
20-413
0
TROUBLESHOOTING H-7
H-7 Arm is slow or lacks power

* When travel and swing speeds are normal.
6 YES
YES Is leakage from

- arm cylinder
5
_ normal?
YES Does LS shuttle
- valve move _ *Max. 20 cc/min NO
4 smoothly? * Engine at high
idling
Are relief pressure p
YES of F and R pumps * Check LS shuttle
normal when arm - for L.H. travel, NO
3 circuit is relieved? boom, R.H.
~ travel and
YES compensation valvefor - 30.4 - 33.8 MPa bucket
- armnormal,or does - (310 - 345 kg/cm? NO
pressure compensation * Engine at high
2 pinon idling
Does control * It is also possible
YES valve spool for _ to interchange _
arm move with other NO
1 smoothly? compensation
valve.
* See Note 1.
valve normal? NO
* Min. 2.7 MPa

{28 kg/cm21
* Engine at high NO
idling
Note 1: After inspection, do not forget to return the interchanged valves to the original position.
20-414
0
TROUBLESHOOTING H-7
I Cause Remedy
arm regeneration valve Correct or
or arm counterbalance replace
valve
Defective arm cylinder Correct or

Defective operation of LS
shuttle valve (LS shuttle Correct or
for L.H. travel, boom, replace
R.H. travel or bucket)
Defective safety-suction
Replace
valve for arm
arm pressure
Correct or
compensation valve or
replace
pressure compensation
piston

20-415
0
TROUBLESHOOTING H-8, 9
H-8 Bucket is slow or lacks power

+ When travel and swing speeds are normal.
Cause Remedy
Repair or
safety-suction valve for
replace
YES Is leakage from bucket
- bucket cylinder
Is pressure normal?
Defective bucket cylinder Repair or
compensation valve
YES_ for bucket normal, or _ * Max. 20 cc/mir
does pressure * Engine at high
2 Defective operation of
- compensation piston idling
Does control pressure compensation
move smoothlv? Repair or
valve for bucket or
valve spoot for - * It is also possible NO replace
bucket move pressure compensation
1 to interchange
smoothlv? piston
_ with other compensation valve.
* See Note 1. Defective operation of
I Correct or
control valve spool for
NO replace
valve normal? bucket
* Min. 2.1 MPa

128 kg/cm’) Defective PPC valve Replace
* Engine at high NO
idling
H-9 Work equipment (boom, arm, bucket) does not move (but travel
and swing are normal)
* When boom, arm, and bucket are each operated inde-
pendently.
Cause Remedy
1 YES Defective control valve Correct or

spool replace
Is output
pressure of PPC -
valve normal?
* Min. 2.7 MPa NO
{28 kg/cm*}
* Engine at high
idling
20-416
0
TROUBLESHOOTING H-10
H-10 Excessive hydraulic drift (boom, arm, bucket)

I) Excessive hydraulic drift of boom
Cause Remedy
Defective hydraulic
Replace
cylinder piston packing
downward movement
become faster when Defective operation of
Replace
safety-suction valve
* See TESTING
1
safety-suction valve is
AND N
ADJUSTING. interchanged? l-l Correct or
* It is also possible NO boom lock valve replace
to measure
leakage of
cylinder.
* Max. 20 cclmin
* At relief
* Engine at high
idling
2) Excessive hydraulic drift of arm or bucket
Cause Remedy
YFS Defective hydraulic

cylinder piston packing
1 I
Does speed of
downward movement _ YES Defective operation of
become faster when Replace
3 I safety-suction valve
lever is operated?
Does condition
* See TESTING become normal
AND NO when safety- Defective control valve
Is slipper seal of YES
ADJUSTING. suction valve is spool Replace
pressure
* It is also possible interchanged? _ compensation valve
to measure - damaged? Damaged slipper seal of
leakage of No Or does wessure pressure compensation Correct or
cylinder.
valve, or defective
* Max. 20 cc/min replace
operation of pressure
+ At relief
* It is also possible to interchange with compensation piston
* Engine at high
other compensation valve.
idling
* See Note 1.
20-417
0
TROUBLESHOOTING H-II, H-12, H-13
H-II Excessive time lag (engine at low idling)
YE
1
Boom, arm
J Defective safety-suction
valve, or defective
regeneration valve
Replace
I Is wessure I / Defective safety-suction

Bucket Replace
1!i.g~;;$t valve
* It is also possible pressure compensation Correct or
to interchange 10 valve or pressure replace
with other compensation piston
compensation valve.
- See Note 1.
H-12 Other equipment moves when single circuit is relieved
Cause Remedy
valve slipper seal
~ (The slipper seal in the Replace
valve of the circuit that
moved is defective.)
H-13 In compound operations, work equipment with larger load is slow
Cause Remedy
Defective operation of pressure Replace (replace pressure compensation
compensation valve valve on side where load is lower)
Combination of compound operation Side where load is larger

1 Boom RAISE + arm IN Boom RAISE
I I
2 Boom RAISE + arm OUT Arm OUT

3 Boom RAISE + bucket CURL Boom RAISE
4 Arm OUT + bucket CURL Arm OUT
5 Boom LOWER + arm OUT Arm OUT
20-418
0
H-14 In swing + boom RAISE, boom RAISE is slow

-k If swing and boom RAISE work normally when operated independently.
Cause Remedy
Defective operation of LS Correct or

select valve replace
$ H-15 In swing + travel, travel speed drops excessively

t
z * See H-14.
w (When the swing and travel are normal in independent operations.)
Cause Remedy
Defective operation of LS Correct or

shuttle valve (LS shuttle replace
for L.H. travel or swing)
20-419
a
H-16 Travel deviation (deviation is excessive in normal travel and

when starting)
a) Deviation is excessive in normal travel
Cause Remedy
4YES Defective travel motor Correct or

assembly replace

Correct or
YE normal when * Check as travel pressure
replace
individual part. NO compensation valve
rotating under no
I J
1
Is difference between * For conditions Adjust or
Defective LS valve
and standard replace
NO
values, see
TESTING AND
ADJUSTING.
YES
5
NIC
Defective self-reducing
Replace
pressure valve
* Min. 3.3 MPa
(Min. 34 kg/cm21
* Engine at high
idling
b) Deviation is excessive when starting
r-- Cause I Remedy
Defective operation of travel

Correct or replace
counterbalance valve
Clogged throttle inside servo of

Correct or replace
bottom or R pump
20-420
0
H-17 Travel speed is slow

* Check that the spool of the travel PPC valve is moving the full stroke before carrying out trouble-
shooting.
Cause Remedy
4YE$ Correct or
control valve suction
Does condition replace
valve
YES become normal
3 when suction
Ispressure valve is replaced? Defective travel motor Correct or
YES compensationvalve assembly replace
- normal,or does NC
2 pressurecompensation
- pistonmovesmoothly?
YES Does control Defective operation of
* It is also possible pressure compensation Correct or
- valve spool move - to check by
NO valve or pressure replace
smoothly? interchanging with other compensation valve.
compensation piston
1 _ Note: After checking, always return to original
positions. Defective operation of Correct or
pressuresof leftand control valve soool replace
NO
normal,and is output
5 YES
- Difference Defective PPC valve Replace
between output Is output pressure
pressure in of self-reducing
FORWARD and NO Eess,“L7evalVe
REVERSE: Defective self-reducing Replace
Within 0.4 MPa pressure valve
+ Output pressure: NO
I4 kg/cm? Min. 3.3 MPa
* Output pressure: (34 kg/cm*}
Min. 2.7 MPa * Engine at high
(28 kg/cm? idling
* Engine at high
idling
. Relieve travel
circuit
20-42 1
0
H-18 Steering does not turn easily or lacks power
Cause Remedy
Defective control valve

2 suction valve
Does condition
3 YES Defective travel motor Correct or

check valve replace
- Interchange let? !ZZ&-jH--

and right spoo1s.h
Is travel relief
Defective travel motor Replace
pressure normal?
NO safety valve
I
* 34.0’::05 MPa
(355% kg/cm? Defective main relief
* Engine at-high Replace
0 valve
idling
20-422
0
H-19 Travel does not move (one side only)
Cause Remedy
YES Correct or
Defective final drive
replace
1
Isany foreign 3 YES suction valve of control Replace
material found in condition
Does valve
oil drained from YES becomenormalwhen
final drive? - left and right suction -
2 valvesof controlvalve
are interchanged? Defective operation of
Is amount of oil counterbalance valve or Replace
drained from NO
travel motor safety valve
NO travel motor
normal?
* Max. 30 e/min Defective travel motor Replace

* Engine at high NO
idling
. Relieve travel
circuit.
H-20 Travel speed does not switch
2 YES travel motor speed Replace
Is output pressure selector servo piston
YES of travel speed
1 selector solenoid
- valve normal? Defective operation of Correct or
Is travel speed - travel speed selector replace
. Min. 2.7 MPa NO solenoid valve
selector electrical -
{28 kg/cm?
circuit normal?
* Set travel speed
Defective travel speed
selector switch to Hi. Correct or
* Disconnect selector switch or relay,
connector V06. NO chassis wiring harness
* Start engine.
* Set travel speed
switch to Hi
* Use tester to
check that
voltage at
chassis wiring
harness end of
connector V06 (I)
is 27.5 - 29.5 V.
20-423
0
H-21 Does not swing

a) Does not swing to either left or right
Cause Remedy
YES Defective swing Repair or

machinery replace
oil drained from

1swing machinery? Defective swing holding Repair or
NO brake or swing motor replace
* Min. 2.7 MPa I holding brake cancel Correct or
(28 kg/cm? NO solenoid valve replace
* Swing lock
switch OFF
b) Does not swing in one direction
Cause Remedy
Defective swing motor

2 YES safety valve or suction Replace
Does control valve
YES valve spool for
1 swing move
smoothly? Correct or
Is PPC valve control valve spool for
NO replace
output pressure - swing
normal?
- Min. 2.7 MPa Defective PPC valve

(28 kg/cm? NO
* Swing lock
switch OFF
20-424
0
H-22 Swing acceleration is poor or swing speed is slow

Ir If condition is normal when work equipment is operated independently.
2 YES
Does LS shuttle
Both left
- valve move
and right
smoothly?
NO
6 YES
Does condrtron
become normal
YES when left and right
acceleration poor 5 safety valves of
~ swing motor are
in both directions Is pressure interchanged?
compensation valve ~ -
YES for swing normal, or * Itii;o~W~Ie to NO
does pressore
4 compensation piston pressure of swing motor.
- move smoothly? . Relief pressure: 27.5 - 30.4
Does control MPa 1280 - 310 kg/cm?
* It is also possible
YES valve spool for
NO *See Note 1.
r swing move
- to interchange
with other
smoothly? compensation valve.
* See Note 1.
One direction 8
- only output pressure
NO
(left or right)
LLI
I I
* Min. 2.7 MPa

(28 kg/cm21
* Engine at high NO
idling
* Swing lock
switch OFF
20-426
0
Cause
/ Defective swing motor

Replace
assembly
Defective operation of LS
Correct or
shuttle valve (all LS
replace
shuttles)
swing motor safety valve Replace

Replace
suction valve
pressure compensation Correct or
valve or compensation replace
piston
Correct or
control valve spool for
replace
swing
20-427
0
H-23 Excessive overrun when stopping swing

a) One direction only
3 YES 1 Defective swing PPC Correct or

Is problem reversed stow return valve replace
YES when left and right
- swing PPC slow -
2 return valves are
Is problem reversed interchanged?
YES when left and right Defective PPC valve Replace
NO
output hoses of -
PPC valves are
Does control Defective swing motor

valve spool for I Replace
NO safety valve
control valve spool for Correct or
swing replace
b) Both directions
Cause Remedy
Defective swing motor Repair or replace
20-428
0
H-24 Excessive shock when stopping swing (one direction only)
I I
Cause Remedy
Defective swing PPC

1 YES slow return valve (check
Correct or
Doesconditionbecome replace
valve)
normalwhen left and right
swingPPC slow return
valvesareinterchanged?
NO
H-25 Excessive abnormal noise when stopping swing
YES N
swing motor safety valve
1
Is output pressure
of swing motor YES Defective swing motor
solenoid valve Replace
2 suction valve
normal?
- Does condition
become normal
- when swing motor - Defective swing Repair or
machinery replace
machinery? 1 Lo
I1 i$fe;tiw I
backPressure 1 F;;zc; or /
20-429
0
H-26 Excessive hydraulic drift of swing

a) When swing lock is ON
Cause Remedy
1 YES Defective operation of Repair or

Is output pressure swing holding brake replace
of swing holding
brake solenoid
valve normal? Correct or
swing lock solenoid
NO replace
* Min 2.7 MPa valve
I28 kg/cm?
-Turn swing lock
switch OFF.
b) When swing lock is OFF
Cause Remedy
BYES Defective swing motor

Replace
safety valve
safety valves are

Defective swing motor Correct or
problem side normal, or suction valve replace
One direction only
compensation piston
Defective pressure
compensation valve, or Correct or
excessive inboth defective operation of replace
NO
directions (left and pressure compensation
piston
4 YES Defective control valve Replace

spool
- Roth left and right ]EH-
Repair or
l 10 elmin NO replace
+ Engine at high
idling
* Relieve swing
circuit
20-430
0
TROUBLESHOOTING OF
MACHINE MONITOR SYSTEM
(M MODE)
Monitor system electrical circuit diagram . .. . .. . . . . . . . .. . . . . . .. . . . .. . .. . . . . . . . .. . . . . . .. . . .. . . . . . . .. . .. . . . . . . .. . .. . . . . . .. .. . . . . . .. . .. 20-452

M- 1 When the starting switch is turned ON, no display is given
(lamps do not light up for 3 seconds). ............................................................................ .20-453
M- 2 When starting switch is turned ON, lamps light up for 3 seconds,
but then do not go out ...................................................................................................... 20-453
M- 3 When starting switch is turned ON, some lamps do not light up for 3 seconds ....... 20-454
a) No gauge lamps light up (caution lamps light up) .................................................. 20-454
b) Swing lock, preheating lamps do not light up (all gauge lamps light up). .......... 20-454
c) Charge caution lamp does not light up ..................................................................... 20-454
d) Engine oil pressure caution lamp does not light up ................................................ 20-454
M- 4 When power is turned on (before engine is started), charge caution lamp
does not light up ................................................................................................................ 20-455
M- 5 When power is turned on (before engine is started), engine oil pressure
caution lamp does not light up ......................................................................................... 20-455
M- 6 During preheating, preheating pilot lamp does not light up.. ...................................... .20-456
M- 7 When switch is operated, swing lock lamp does not light up ..................................... .20-456
M- 8 Engine oil pressure caution lamp lights up when engine is running
(engine oil pressure is normal) ......................................................................................... 20-457
M- 9 Charge caution lamp lights up when engine is running.. ............................................. .20-457
M-10 Abnormality in coolant temperature gauge. .................................................................... 20-458
$ a) After engine is started, level stays at bottom (white range) and
t 20-458
does not move.. ............................................................................................................
Z
ul b) After engine is started, level immediately rises
Engine is not overheating but indicator enters red range.. .................................... .20-458
c) Coolant temperature gauge goes out ........................................................................ 20-458
M-l 1 Abnormality in fuel gauge ................................................................................................. 20-459
a) All fuel gauge segments go out ................................................................................. 20-459
b) Even when fuel level goes down, fuel gauge continues to show FULL.. ............. 20-459
c) Even when tank is filled, fuel gauge does not show FULL .................................... .20-459
M-12 Defective operation of alarm buzzer ................................................................................. 20-461
a) Buzzer does not sound ................................................................................................ 20-461
b) Buzzer continues to sound and does not stop .......................................................... 20-461
M-13 Engine is running, but service meter does not move .................................................... 20-462
a) Charge caution lamp lights up ................................................................................... 20-462
b) Charge caution lamp does not light up.. .................................................................. .20-462
M-14 Night lighting does not light up.. ...................................................................................... 20-463
a) Gauge lighting does not light up ............................................................................... 20-463
b) Service meter lighting does not light up (service meter is working normally) .... 20-463
M-15 Wiper does not move, or does not stop moving ............................................................ 20-464
a) Wiper does not move when wiper switch is turned to ON.. .................................. .20-464
b) Wiper moves even when wiper switch is not turned to ON .................................. .20-464
M-16 Heater does not work ......................................................................................................... 20-465
a) Does not work at either Hi or Lo.. .............................................................................. 20-465
b) Does not work at Lo only. ........................................................................................... 20-465
c) Does not work at Hi only ............................................................................................ 20-465
20-451
0
TROUBLESHOOTING MONITOR SYSTEM ELECTRICAL CIRCUIT DIAGRAM
MONITOR SYSTEM ELECTRICAL CIRCUIT DIAGRAM
Monitor panel
7------- “06MESIII 1 Fuse
I Starting switch FBI Swins lock switch
Alarm buzzer
Horn (Hioh tone)
390Hz
Horn (Low tone)

33OHz
Horn switch
Wiper
Fuel level sensor I IIIII I

I
switch 1
._ _-_-_-
El Revolvins
r
frame
Batter
relay
lKP01012
20-452
0
TROUBLESHOOTING M-l, M-2
M-l When the starting switch is turned ON, no display is given (lamps
doe not light up for 3 seconds)
j, Before carrying out troubleshooting, check that all the related connectors are properly inserted.
t Always connect any disconnected connectors before going on the next step.
Remedy
YES
Defective monitor panel Replace
1 I
Is voltaoe .I I disconnection in wiring
between PO1
harness between PO1
(famale) (l)(2) and 2 YES Repair or
(l)(2) and fuse 2, or
(3)(4) normal? between PO1 (3)(4) - HO3 replace
*Turn starting Is fuse 2 mormal (I 1) -chassis ground
switch ON. Ng (not blown)? Replace fuse
after inspectins
*20-30V
Blown fuse 2 and repairing
--L
cause of blown
fuse
M-l Related electrical circuit diagram
PO1
Monitor Panel (0401 6) Fuse
Revolving
EDP00263
M-2 When starting switch is turned ON, lamps light up for 3 seconds,
but then do not go out
* Before carrying out troubleshooting, check that

all the related connectors are properly inserted.
* Always connect any disconnected connectors
before going on the next step.
Ir Check the fuses 2 before troubleshooting.
ci Defective monitor panel Replace
20-453
0
TROUBLESHOOTING M-3
M-3 When starting switch is turned ON, some lamps do not light up
for 3 seconds
* Before carrying gout troubleshooting, check that all the related connectors are properly inserted.
* Check the fuse before troubleshooting.
a) No gauge lamps light up (caution lamps light up)
Cause Remedy
Defective monitor panel
bl Swing lock, preheating lamps do not light up

(all gauge lamps light up)
1 YES Blown bulb in lamp
which does not light up Replace
Is there
disconnection in
lamp which does
not light up?
* Check visually for NO
blown bulb.
c) Charge caution lamp does not light up
Blown bulb of charge

caution lamp Replace
- Check visually for NO

blown bulb.
d) Engine oil pressure caution lamp does not light up
Blown bulb of engine oil

Replace
presusure caution lamp
blown bulb.
20-454
0
TROUBLESHOOTING M-4, M-5
M-4 When power is turned on (before engine is started), charge

caution lamp does not light up
* Before carrying out troubleshooting, check that all Remedy
the related connectors are properly inserted.
* Always connect any disconnected connectors before
going on the next steo.
Lamp bulb is blown Replace
1
Is voltage I disconnection in wiring
between PO1 (IO)
harness between PO1 Repair or
and PO1 (3), (4) (female) (IO) - HO3 (7) - replace
normal? t MO2 (2) - E08 (I) - El2
* Turn starting (1) -alternator terminal L
switch ON.
F Defective D14 Replace
*o-5v
Defective alternator Replace

* Turn starting NO
switch ON.
* Disconnect PO1 and D14.
*Max. 1OV
M-4 Related electric circuit diagram r
Battery relay
El 2 (X2)
I GND -A-
TKP01013
M-5 When Dower is turned on (before engine is started), engine oil

press&e caution lamp does not light-up
* Before carrying out troubleshooting, check that all the re-
lated connectors are properly inserted. Cause Remedy
* Always connect any disconnected connectors before going
on the next step.
* Check for blown lamp bulb before starting troubleshooting.
2 YES
Is continuity
YES between PO1
Repair or
harness between PO1
engine oil pressure replace
I starting
(female) (9) - HO3 (IO) -
E08 (male) (8)
Defective engine oil

lTurn starting Replace
pressure sensor
switch ON.
.Max.O-5R
M-4 Related electric circuit diagram

Engine oil
Pressure switch
Monitor Panel PO1 (04016) HO3 (SlGwhite)
I \ I I \ I
TKP01014
20-455
0
M-6 During preheating, preheating pilot lamp does not light up

Ir If the lamps do not light up for 3 seconds when the starting switch is turned ON, go to M-2.
Cause Remedy
1 YES
Is voltage
between PO1 (13)
and (3)(4)
normal? disconnection in wiring
Repair or
harness between PO1
* Turn starting NO replace
(female) (13) and
switch to HEAT. starting switch Rl, or
*20-30V defective starting switch
M-6 Related electrical circuit diagram
ar tins switch
HO3 (S16)
1
6DP00266
M-7 When switch is operated, swing lock lamp does not light up
2 YES *
Is there continuity
YES between PO1 Defective contact or
1 (female) (12) and disconnection in wiring
chassis normal? harness between PO1
Repair or
Is there continuity (female) (12) - HO3 (9) -
_ *Disconnect PO1 NO replace
between X05 HO2 (IO) -X05 (female)
(male) (1) and (2)? *Turn swing lock (I), or X05 (female) (2) -
switch ON. HO2 (5) -chassis ground
* Disconnect X05. Defective swing lock
Replace
* Turn swing lock NO switch
switch ON.
M-7 Related electrical circuit diagram I

1
PO1 LOCK7 P OFF /
Monitor Panel (04016) HO3 (S16) HO2 (Sl6) X05 (M4)
IiT
Swing lock @ (-$ J$ .B 1
2
GND @ - (iJ 3 3
GND @
I l
Swing lock 4
3
20-456 switch
BOP00267
0
M-8 Engine oil pressure caution lamp lights up when engine is running
(engine oil-pressure is normal) -
Before carrying out troubleshooting, check that all the re-

Cause Remedy
Always connect any disconnected connectors before go-
ing on the next step.
YES Defective engine oil Replace
1 1 pressure sensor switch
Does engine oil

pressure caution - 2 YES
go off7 Defective monitor panel Replace
Is circuit between
. Disconnect PO1 (female) (9)
engine oil NO and chassis Contact of chassis wiring
pressure switch ground insulated? harness with wiring
Repair or
terminal or E08. ’* Turnstarting NO
harness between PO1
replace
* Start engine. (female) (9) - HO3 (10) -
switch OFF.
E08 (male) (8)
lCheck continuity between PO1
(female) (9) and chassis ground.
*Min. 1 MR

Engine oil
Pressure switch
Monitor Panel PO1 (04016) HO3 (SlGwhite)
I \ I I \ I
TKP01014
M-9 Charge caution lamp lights up when engine is running

It Before carrying out troubleshooting, check that all the re-
Cause Remedy
* Always connect any disconnected connectors before go-
YES
n
‘
I Defective monitor panel IReplace
Is voltage Contact of chassis ground

YES between PO1 with wiring harness
(female) (IO) and 3 YES Repair or
between PO1 (female) (10)
(3)(4) normal? Is resistance - HO3 (7) - E08 (2) - replace
lp between alternator alternator terminal L
~- * Start engine.
- terminal L (wiring .
Is voltage between
alternator terminal _
L and chassis
ground normal?
~20-3ov NO harness end),
IllJrmal?
* Disconnect
1 NO
harness between PO1
(female) (10) - HO3 (7) -
Repair or
replace
alternator terminal E08 (2) - alternator
l Start engine. L and POl. terminal L
*20-30V * Min. 1 MQ Defective generation of
Replace
NO electricity by alternator

Alternator
Monitor Panel PO1 (04016) HO3 (S16whi te) E08 (Xl)
Battery @ 7
chareins rate
GND 3- (g
GND 4
TKPOlOlS
20-457
0
TROUBLESHOOTING M-10
M-10 Abnormality in coolant temperature gauge
Sr Before carrying out troubleshooting, check that all the related connectors are properly inserted.
Sr Always connect any disconnected connectors before going on the next step.
a) After engine is started, level stays at bottom (white range) and does not move
Cause Remedy
YES Defective coolant

Replace
temperature sensor
&I disconnection in wiring
2 YES harness between PO1 Repair or
I< (female) (6) - HO3 (5) -
E08 (6) - PO7 (female) (I),
replace
or between PO7 (female)

(2) -chassis ground
3efective monitor panel Replace

ctor to PO7 * Turn starting NO
(female). switch ON.
* Short circuit PO1
(6) and (3)(4).
b) After engine is started, level immediately rises

Engine is not overheating but indicator enters red range
2 YES
Is resistance
YES between PO7
1 r (male) (1) and (2)
normal? Defective coolant
Is voltage Replace
between PO1 * Disconnect P07. NO temperature sensor
(3)(4) and chassis * Start engine.
ground normal? * Resistance: Defective contact
- Min.4 kR After
* Start engine. between PO1 (female)
inspection,
* Max. 0.1 V NO (3)(4) - HO3 (I 1) -chassis
repair
ground
c) Coolant temperature gauge goes out
YES Defective coolant
Replace
1 I temperature sensor
Does lowest level

light up? 2 YES
Is resistance
* Turn starting between PO1
Iontact chassis ground
switch ON. NO (female) (6) -
Nith wiring harness
- Remove PO7 (3)(4) normal?
letween PO1 (female) (6)
Repair or
- Disconnect POl. NO replace
- HO3 (5) - E08 (6) - PO7
+ Resistance: female) (1). or leak
Min. 1 kR

Engine water
Monitor Panel PO1 (04016) HO3 (SlGwhi te) PO7 (X2) temperature sensor
Engine water
@ @ 3
temperature
3 cg 3
GND
4 1
GND
TKP01016
20-458
a
TROUBLESHOOTING M-II
M-II Abnormality in fuel gauge
al all fuel gauge segments go out Cause Remedy
Defective fuel level

YES sensor (failure in qeplace
1 I disconnection mode)
qepair or
harness between PO1
replace
(female) (7) - HO6 (6)
-PO6 (female) (1)

(female) to * Turn starting NO
chassis ground. switch ON.
*Wait for approx. * Short circuit PO1 (7) and (3).
1 minute. -Wait for approx. 1 minute.
b) Even when fuel level goes down, fuel gauge continues to show FULL
3 YES
Defective monitor panel qeplace
YES
Contact chassis ground
2
with wiring harness
Repair or
Is resistance of between PO1 (female) (7)
YE * Remove P06. NO replace
fuel level sensor - - HO6 (6) - PO6 (female)
*Turn starting (1)
1 normal?
switch ON.
* Remove sensor *Wait for approx.1 minute. Defective fuel level
Replace
. Move float by sensor
NO
(3)(4) and chassis hand and
measure resistance between PO6 (male) and chassis ground. Defective contact or
. F position : Max. approx. 12 R disconnection in wiring After
* Start engine.
E position : Approx. 85 - 110 Q harness between PO1 inspection,
* Max. 0.1 V
h (female) (3)(4) - HO3 (11) repair
-chassis ground
c) Even when tank is filled, fuel gauge does not show FULL
YES
1 I
disconnection in wiring After
Z YES
harness between PO1 inspection,
(female) (3)(4) - HO3 (11) repair
-chassis ground
Defective fuel level

Replace
(male) -chassis * Start enoine. NO sensor
ground * Max. 0.1 V
* F position : Max.
approx. 12 R
20-459
0
TROUBLESHOOTING M-l 1
M-l 1 Related electrical circuit diagram
PO 1
Revolving
BDPOO270
20-460
0
M-12 Defective operation of alarm buzzer
Ir Before carrying out troubleshooting, check that all the related connectors are properly inserted.
a) Buzzer does not sound

Cause Remedy
Does buzzer
sound when PO1
1
YES
I
I
1 Defective monitor panel
Replace
(female) (15) and 2 YES harness between PO4 Repair or
(3) are connected? Is voltage k (female) (1) and PO1 replace
between PO4 (2) (female) (15), or defective
* Connect PO1
buzzer
(female) (15) NO and chassis
and (3). ground normal? Defective contact or
Repair or
* Turn starting disconnection in wiring
*Turn starting NO replace
switch ON. harness between fuse 2
switch ON.
and PO4 (female) (2)
*20-30V
b) Buzzer continues to sound and does not stop
1 YES Defective monitor panel Replace

Does buzzer stop
when PO1 is
Contact chassis ground
removed?
with wiring harness Repair or
between PO4 (female) (1) replace
* Remove PO1 NO
and PO1 (female) (15)
* Turn starting
switch ON.
PO1
Monitor Panel (04016) PO4 (M2) Buzzer
Buzzer 3
GND @
GND
Dll
Fuse 3
g-J
I I \ BOP00271
20-461
0
M-13 Engine is running, but service meter does not move
a) Charge caution lamp lights up

Cause Remedy
3 YES harness between PO1 Repair or
IIs resistancebetween 1 7 (10) - HO3 (7) - E08 (2) - replace
alternator terminal L
Is voltage between
* Start engine. L
l20-30V NC Contact of chassis
alternator terminal ground with wiring Repair or
Land chassis harness between PO1
* Disconnect NO replace
ground normal? (female) (IO) - HO3 (7) -
alternator E08 (2) -alternator
* Start engine. terminal Land POl. terminal L
*20-30V *Min. 1 MD Defective generation of
Replace
NO electricity by alternator
$
b) Charge caution lamp does not light up t
%
Lu
Cause Remedy
Alternator
Monitor panel PO1 (04016) HO3 (Slfiwhite) E08 (Xl)
7 1
chareine rate
@
1
TKPO1015
20-462
0
M-14 Night lighting does not light up
Ir Always connect any disconnected connectors before going on the next step.
a) Gauge lighting does not light up

Cause Remedy
Bulb of night lifhting

(inside monitor panel) Replace
1 blown
Is voltage Defective contact or
between PO1 disconnection in wiring
YES Repair or
(female) (16) and harness between PO1
2 replace
(3)(4) normal? (female) (16) and PO2
~ Is voltage (female) (3)
* Turn starting
between PO2 (3)
3 YES
* Z?grZCl;witch No ~:~u~~~:ma,7 Defective light switch Replace
ON. Is voltage
-2O-30V * Turn starting between PO2 (4)
switch ON. NO and chassis Disconnection in wiring
*Turn light switch ground normal? harness between PO2 Repair or
ON. - Turn starting (female) (4) and fuse 4, replace
NO
*20-3ov or blown fuse
switch ON.
.20-3ov
$
>
z
Lu
b) Service meter lighting does not light up (service meter is working normally)
Cause Remedy
Defective monitor panel
PO2
(KESl, 4) Lamp switch
PO1
Monitor Panel (()A() 16) To working lamp -=.I ~ 2 Lamp
3 Panel lighting
HO3 (S16) $$ Power source
------I
Fuse
1 4
I-
I I BDP00272
20-463
0
M-15 Wiper does not move, or does not stop moving
* Always con-ne& any disconnected connectors before going on the next step.
Cause Remedy
a) Wiper does not move when wiper switch is turned to ON
3 YES Replace
Defective wiper motor
Is voltage
YES between M31
- (female) (1) and -
harness between Ml8
chassis normal? Repair or
2-p (female) (2) - HO2 (15) -
- *Turn starting NO Ml7 (1) - M31 (female) replace
Is voltage switch OFF. (I), or short circuit with
YI between Ml8 _ * Disconnect M31. ground
’ (male) (2) and * Connect T-adapter to M31
chassis normal? Defective contact or
(male).
1 * Turn starting * Turn starting switch ON.
harness between fuse 3 -
switch OFF. *Turn wiper switch ON.
H03(8)-H02(6)-Ml8 Repair or
between terminals * Disconnect M18. *20-30V
(1) -wiper switch
of wiper switch as * Connect replace
NO terminal B, or between
T-adapter to Ml8
wiper switch terminal L
(male).
* Turn starting and Ml8 (male) (21, or
-Turn starting switch ON.
switch OFF. short circuit with ground
-Turn wiper switch ON.
*20-30V
Defective wiper switch Replace
P
b) Wiper moves even when wiper switch is not turned to ON

r Cause T Remedy
2 YES
Defective wiper motor Replace
Is voltage
YES between M31
Power short in wiring
- (female) (1) -
1 chassis normal?
harness between Ml8
Repair or
(female) (2) - HO2 (15) -
Is continuity replace
* Turn starting NO Ml7 (I) - M31 (female)
between terminals -
switch ON. (1)
of wiper switch as
* Turn wiper
shown in Fig. l?
. switch OFF.
Turn starting * Max. 1 V
switch OFF.
Defective wiper switch Replace
NO
20-464
Fig. 1
Wiper switch
M 19 (M2)
TKP01017
Window washer
(Opt ion)
-
Wiper switch
Wiper motor
Fuse HO3 (Sl 6)
TKP01018
20-465
0
M-16 Heater does not work

* Before carrying out troubleshooting, check that all the
-
related connectors are properly inserted.
Cause Remedy
* Always connect any disconnected connectors before go-
a) Does not work at either lij Ye,’

Go to troubleshooting of -
Istherecontinuity heater
YES between MO6 (4)
Repair or
harness between MO6
heater switch replace
-Turn starting NO (female) (4) and chassis
between terminals -
of MO6 (male) as switch OFF. ground
shown in Table l?
* Turn starting
switch OFF. Defective heater switch Replace
NO
* Disconnect M06.
Table 1
Cause Remedy
b) Does not work at Lo only

2 YES Go to troubleshooting of -
Is there continuity heater
YES between Ml2
1 (female) (2) and
chassis ground? disconnection in wiring
harness between MO6 Repair or
Is there continuity P -
* Disconnect M12. NO (female) (3) and Ml2 replace
between MO6
*Turn starting (female) (2)
(male) (3) and (4)?
switch OFF.
* Heater switch at Lo.
* Disconnect M06.
Defective heater switch Replace
* Turn starting NO
switch OFF.
* Heater switch at Lo.
c) Does not work at Hi only2 YES

Go to troubleshooting of -
heater
harness between MO6 Repair or
(female) (2) and Ml2 replace
(female) (3)
* Heater switch at Hi.

* Disconnect M06.
Defective heater switch Replace
-Turn starting NO
switch OFF.
. Heater switch at Hi.
Heater switch MO6 (KES14) Ml2 (KES13)

I \ I I I I I I
Heater Hi
Heater Lo Heater
HO5 (L2)
Fuse
BKP02453
20-466
0
30 DISASSEMBLY AND ASSEMBLY
METHOD OF USING MANUAL .................. .30- 3 CENTER SWIVEL JOINT ASSEMBLY

PRECAUTIONS WHEN CARRYING OUT Removal and Installation .................... 30-44
OPERATION ............................................ 30- 4 Disassembly and Assembly.. .............. 30-46
SPECIAL TOOL LIST.. .................................. 30- 6 FINAL DRIVE ASSEMBLY
SKETCHES OF SPECIAL TOOLS ............... 30-10 Removal and Installation .................... 30-47
STARTING MOTOR ASSEMBLY Disassembly ........................................... 30-48
Removal and Installation .................... 30-I 1 Assembly ............................................... .30-51
ALTERNATOR ASSEMBLY SPROCKET
Removal and Installation .................... 30-12 Removal and Installation ..................... .30-56
AIR CONDITIONER COMPRESSOR ASSEMBLY SWING MOTOR, SWING MACHINERY
Removal and Installation .................... 30-13 ASSEMBLY
CONDENSER ASSEMBLY Removal and Installation ..................... .30-57
Removal and Installation .................... 30-‘l4 Disassembly .......................................... .30-59
ENGINE OIL COOLER CORE ASSEMBLY Assembly ................................................ 30-63
Removal and Installation .................... 30-15 REVOLVING FRAME ASSEMBLY
FUEL INJECTION PUMP ASSEMBLY Removal .................................................. 30-68
Removal ................................................. 30-I 6 Installation .............................................. 30-69
Installation ............................................ 30-19 SWING CIRCLE ASSEMBLY
WATER PUMP ASSEMBLY Removal .................................................. 30-70
Removal and Installation .................... 30-21 Installation .............................................. 30-71
NOZZLE HOLDER ASSEMBLY IDLER RECOIL SPRING ASSEMBLY
l
TURBOCHARGER ASSEMBLY RECOIL SPRING ASSEMBLY
Removal and Installation .................... 30-24 Disassembly .......................................... .30-73
THERMOSTAT ASSEMBLY Assembly ................................................ 30-74
Removal and Installation .................... 30-25 IDLER ASSEMBLY
CYLINDER HEAD ASSEMBLY Disassembly .......................................... .30-75
Removal ................................................. 30-27 Assembly ................................................ 30-76
Installation ............................................ 30-31 TRACK ROLLER ASSEMBLY
RADIATOR HYDRAULIC
l OIL COOLER Removal and Installation ..................... .30-78
ASSEMBLY Disassembly ........................................... 30-79
Removal ................................................. 30-34 Assembly ................................................ 30-81
Installation ............................................ 30-36 CARRIER ROLLER ASSEMBLY
ENGINE MAIN PUMP ASSEMBLY
l Removal and Installation ...................... 30-83
Removal ................................................. 30-37 Disassembly .......................................... .30-84
Installation ............................................ 30-41 Assembly ............................................... .30-86
DAMPER ASSEMBLY TRACK SHOE ASSEMBLY
FUEL TANK ASSEMBLY
Removal and Installation .................... 30-43
30-l
0
HYDRAULIC TANK ASSEMBLY BOOM CYLINDER ASSEMBLY
Removal ................................................ 30- 89 Removal . . .. . . . .. . . . . . . . . . .. . . . . . .. . . . .. . . . . . . . . . .. . . . . . 30-I 22
Installation ............................................ 30- 90 Installation . . . . . . . .. . . .. . . . . . .. . . . . . . . . . . .. . . .. . . . . . . . . 30-123
MAIN PUMP ASSEMBLY ARM CYLINDER ASSEMBLY
Removal ................................................ 30- 91 Removal . . .. . . .. . . . . . . . . .. .. . . . . . .. . . .. . . . . . . . .. .. . . . . . . 30-I 24
Installation ............................................ 30- 93 Installation . . . . . . . .. . . . . . . . . . .. . . . . . . . .. . .. . . .. . . . . . . .. 30-125
MAIN PUMP INPUT SHAFT OIL SEAL BUCKET CYLINDER ASSEMBLY
Removal and Installation ................... .30- 94 Removal . . .. . .. . . . . . . . . . .. . . . . . . . .. . . .. . . . . . .. .. . . . . . . . . 30-I 26
CONTROL VALVE ASSEMBLY Installation . . . . .. . .. . . . . . .. . .. . . . . . . . .. . . .. . . . . . . . . . . .. 30-I 27
Removal ................................................ 30- 95 HYDRAULIC CYLINDER ASSEMBLY
Installation ............................................ 30- 97 Disassembly . . .. . . .. . . . . . . .. .. . . . . . . .. . . . .. . . . . . . .. 30-128
Disassembly ........................................ 30- 98 Assembly .. . . . . . . . . . . . .. . .. . . . . . . .. . . .. . . .. . . . .. . . . . . . . 30-131
Assembly .............................................. 30-103 WORK EQUIPMENT ASSEMBLY
MAIN RELIEF VALVE ASSEMBLY Removal . . . . . . . .. . . .. . . . . . . . .. . .. . . . . . . .. . .. . . . . . . . . .. .. 30-135
Disassembly and Assembly.. ............. .30-109 Installation . . . . . . . . . . . .. . . . .. . . . . . . .. . . . . . . .. . . .. . . . . . . 30-136
PC VALVE ASSEMBLY BUCKET ASSEMBLY
Removal and Installation .................. ..30- 1 IO Removal . . .. . . . .. . .. . . . . . . . .. . . . . . . . . . . .. . .. . . . . . . . . .. .. 30-137
LS VALVE ASSEMBLY Installation .. . . . . . . .. . . .. . . . . . . . . .. .. . . . . . . .. . . . .. . .. . . 30-138
Removal and Installation .................. ..30- 1 12 ARM ASSEMBLY
PC-EPC VALVE ASSEMBLY Removal . . .. . . . .. . .. . . . . . . . .. . . . . . . . . . . .. . .. . . . . . . . .. . .. 30-139
Removal and Installation .................. ..30- 1 13 Installation . . . . . . . .. . . .. . . . .. . . .. .. .. . . . . . . .. . .. . . . . . . . 30-140
SOLENOID VALVE ASSEMBLY BUCKET ARM ASSEMBLY
l
Removal and Installation .................. ..30-114 Removal . . .. .. . . . . . . . . . . .. . . . . . . .. . . . .. . . . . . . . .. . .. . . . . . 30-I 41

WORK EQUIPMENT SWING PPC VALVE
l Installation . . . . . . .. . . . . .. .. . .. . . . . . . .. . . .. . . . .. . . .. .. .. 30-I 42
ASSEMBLY BOOM ASSEMBLY
Removal and Installation ................... .30-115 Removal . . . . . . . . . . . .. . . . . . . . .. . . .. . . . . . .. . .. .. .. . . . . . . . . 30-I 43
Disassembly ....................................... ..30-116 Installation . .. . . . . . . . . . .. . . .. . . . . . . . .. . . .. . . . . . . .. . .. . . 30-I 44
Assembly .............................................. 30-I 17 OPERATOR’S CAB ASSEMBLY
TRAVEL PPC VALVE ASSEMBLY Removal and Installation . . . . . . . . .. . .. . . . . ...30-145
Removal and Installation .................. ..30- 1 18 COUNTERWEIGHT ASSEMBLY
Disassembly and Assembly.. ............. .30-l 19 Removal and Installation . . . . . . . .. . .. . . . . . . .. 30-I 46
BOOM LOCK VALVE ASSEMBLY MONITOR ASSEMBLY
Removal and Installation ................... .30-121 Removal and Installation . . . .. . .. . . . . . .. . . ...30-147
30-2
0
DISASSEMBLY AND ASSEMBLY METHOD OF USING MANUAL
METHOD OF USING MANUAL
1. When removing or installing unit assemblies

@ When removing or installing a unit assembly, the order of work and techniques used are given
for the removal operation; the order of work for the installation operation is not given.
@ Any special techniques applying only to the installation procedure are marked m, and the
same mark is placed after the relevant step in the removal procedure to indicate which step in
the installation procedure it applies to.
(Example)
REMOVAL OF 0 0 0 0 ASSEMBLY.. .......... Title of operation
&I ...................................................................... Precautions related to safety when carrying out
the operation
1. XXXX(1) ..................................................... Stepinoperation
* ................................................................... Technique or important point to remember
when removing XXXX (1).
2. a a a a (2): ............................................... m Indicates that a technique is listed for use
during installation
3. 0 0 0 0 assembly (3)
............................................................ Quantity of oil or water drained
INSTALLATION OF 0 0 0 0 ASSEMBLY .. ..Titl e of operation

l Carry out installation in the reverse order to removal.
m .............................................................. Technique used during installation
* ................................................................... Technique or important point to remember when
installing n a n a (2).
. Adding water, oil ................................. Step in operation
* ............................................................ Point to remember when adding water or oil
%# ......................................................... Quantity when filling with oil and water
2. General precautions when carrying out installation or removal (disassembly or assembly) of units
are given together as PRECAUTIONS WHEN CARRYING OUT OPERATION, so be sure to follow
these precautions when carrying out the operation.
3. Listing of special tools

@ For details of the description, part number, and quantity of any tools (Al, etc.) that appear in
the operation procedure, see the SPECIAL TOOLS LIST given in this manual.
30-3
0
DISASSEMBLY AND ASSEMBLY PRECAUTIONS WHEN CARRYING OUT OPERATION
PRECAUTIONS WHEN CARRYING OUT OPERATION

[When carrying out removal or installation (disassembly or assembly) of units, be sure to follow the
general precautions given below when carrying out the operation.]
1. Precautions when carrying out removal work
. If the coolant contains antifreeze, dispose of it correctly.
. After disconnecting hoses or tubes, cover them or fit blind plugs to prevent dirt or dust from
entering.
. When draining oil, prepare a container of adequate size to catch the oil.
. Confirm the match marks showing the installation position, and make match marks in the neces-
sary places before removal to prevent any mistake when assembling.
. To prevent any excessive force from being applied to the wiring, always hold the connectors when
disconnecting the connectors. Do not pull the wires.
. Fit wires and hoses with tags to show their installation position to prevent any mistake when
installing.
. Check the number and thickness of the shims, and keep in a safe place.
. When raising components, be sure to use lifting equipment of ample strength.
. When using forcing screws to remove any components, tighten the forcing screws uniformly in
turn.
. Before removing any unit, clean the surrounding area and fit a cover to prevent any dust or dirt
from entering after removal.
* Precautions when handling piping during disassembly
Fit the following blind plugs into the piping after disconnecting it during disassembly operations.
1) Hoses and tubes using sleeve nuts
Nominal Sleeve nut (elbow end) Use the two items below as a set
Plug (nut end)
number I
02 07376-50210 07221-20210 (Nut), 07222-00210 (Plug)
03 07376-50315 07221-20315 (Nut), 07222-00312 (Plug)
04 07376-50422 07221-20422 (Nut), 07222-00414 (Plug)
05 07376-50522 07221-20522 (Nut), 07222-00515 (Plug)
06 07376-50628 07221-20628 (Nut), 07222-00616 (Plug)
10 07376-51034 07221-21034 (Nut), 07222-01018 (Plug)
12 07376-51234 07221-21234 (Nut), 07222-01219 (Plug)
2) Split flange type hoses and tubes
Nominal head (tube end) Split flange

Flange (hose end) Sleeve
number I I
04 I 07379-00400 07378-I 0400 I 0737 I-30400
05 07379-00500 I 07378-I 0500 07371-30500
3) If the part is not under hydraulic pressure, the following corks can be used.
Nominal
Part Number
number
08 07049-008’. . ., _.
IO 07049-01012 10 8.
12 07049-01215 12 1
16 I 07049-01620 t 16 113.51 20
18 07049-01822
DEW00401
30-4
0
DISASSEMBLY AND ASSEMBLY PRECAUTIONS WHEN CARRYING OUT OPERATION
2. Precautions when carrying out installation work

. Tighten all bolts and nuts (sleeve nuts) to the specified (KES) torque.
. Install the hoses without twisting or interference.
. Replace all gaskets, O-rings, cotter pins, and lock plates with new parts.
. Bend the cotter pins and lock plates securely.
. When coating with adhesive, clean the part and remove all oil and grease, then coat the threaded
portion with 2 - 3 drops of adhesive.
. When coating with gasket sealant, clean the surface and remove all oil and grease, check that there
is no dirt or damage, then coat uniformly with gasket sealant.
Clean all parts, and correct any damage, dents, burrs, or rust.
Coat rotating parts and sliding parts with engine oil.
When press fitting parts, coat the surface with anti-friction compound (LM-PI.
After fitting snap rings, check that the snap ring is fitted securely in the ring groove.
When connecting wiring connectors, clean the connector to remove all oil, dirt, or water, then
connect securely.
. When using eyebolts, check that there is no deformation or deterioration, screw them in fully, and
align the direction of the hook.
When tightening split flanges, tighten uniformly in turn to prevent excessive tightening on one
side.
* When operating the hydraulic cylinders for the first time after reassembling cylinders, pumps and
other hydraulic equipment removed for repair, always bleed the air as follows:
1. Start the engine and run at low idling.
2. Operate the work equipment control lever to operate the hydraulic cylinder 4 - 5 times,
stopping the cylinder 100 mm from the end of its stroke.
3. Next, operate the hydraulic cylinder 3 - 4 times to the end of its stroke.
4. After doing this, run the engine at normal speed.
j, When using the machine for the first time after repair or long storage, follow the same
procedure.
3. Precautions when completing the operation

. If the coolant has been drained, tighten the drain valve, and add water to the specified level. Run
the engine to circulate the water through the system. Then check the water level again.
. If the hydraulic equipment has been removed and installed again, add engine oil to the specified
level. Run the engine to circulate the oil through the system. Then check the oil level again.
. If the piping or hydraulic equipment have been removed, always bleed the air from the system
after reassembling the parts.
Ir For details, see TESTING AND ADJUSTING, Bleeding air.
l Add the specified amount of grease (molybdenum disulphide grease) to the work equipment parts.
30-5
0
DISASSEMBLY AND ASSEMBLY SPECIAL TOOL LIST
SPECIAL TOOL LIST
Tools with part number 790T-0000000cannot be supplied (they are items to be locally manufac-
tured).
Necessity: W: Cannot be substituted, should always be installed (used)
0: Extremely useful if available, can be substituted with commercially available part
New/remodel:N: Tools with new part numbers, newly developed for this model.
R: Tools with upgraded part numbers, remodeled from items already available for
other models.
Blank: Tools already available for other models, used without any modification.
Tools marked 0 in the Sketch column are tools introduced in special sketches (See SKETCHES OF
SPECIAL TOOLS).
N Nature of work,
Component Symbol Part No. Part Name ketch
remarks
l Removal, installa- 790-331-1110 Wrench Tightening of

tion of cylinder cylinder head bolt
assembly
l Removal, installa- 795-799-l 130 Gear Barring
tion of fuel injection
pump assembly 795-799-l 390 Puller Removal of drive
gear
l Removal, installa- 795-799-l 170 Puller Removal of nozzle

tion of nozzle holder holder
assembly
l Engine, main pump

assembly
l Radiator, hydraulic
cooler assembly
l Control pump
assembly B 796-460-1210 Oil stopper
l Main pump assem-
bly
l Removal, installa-
tion of servo valve
assembly
790-101-2501 Push-puller
'790-101-2510 .Block
'790-101-2520 ‘Screw
,791-l 12-1180 .Nut

Disassembly
of center swivel joint D .Washer
assembly
,790-101-2630 .Leg
.Plate
,790-101-2560 .Nut
,790-101-2650 .Adapter
Disassembly, 796-426-l 120 Push tool Press fitting of

assembly of swing bearing
machinen/
30-6
0
Nature of work,
Component Symbol Part No. Part Name rtc$el Sketch
remarks
Removal, installa-
1 796-427-1200 Wrench n 1
tion of round nut
-
796T-427-12201 Push tool ImIiI lOI
I I ,
I I I
790-101-2510 Block w 1
792-104-3940 Bolt n 2
2 05180-11613
I
Nut
I
n I
2
I
Disassembly, assem- 01643-31645 Washer n 2 Press fitting of

bly of final drive G I I I I I bearing inner race
assembly 01643-32060 Washer n 2
790-105-2100 Jack n 1
790-101-I 102 Pump n 1

Tightening of final
3 790-331-I 110 Wrench n 1
drive cover mount-
ing bolt
Installation of
4 791-545-1510 Installer w 1 floating seal
791-600-2001 Compressor (A) n 1

or
791-685-8005 Compressor (B) n 1 Removal, press

fitting of master pin
791-635-3160 Extension n 1
Removal, installation
of recoil spring H
assembly
Installation of dust
seal on recoil
Removal, installation Removal, press

of track shoe I fitting of master pin
T
Removal, installation 1
of road liner (rubber l-l
Commercially
availableHexagonal socket 0 17 mm
pad type) 2 1
Installation of
1 790-434-1630 Installer n 1 floatina seal
Assembly of idler
790-101-1000 Oil pump n 1 Charging with oil,
assembly
checking for air
leakage
790-434-1640 Installer n 1 Installation of

floating seal
Disassembly, assem- 791-601-1000 Oil pump 0 1 Charging with oil,

bly of track roller checking for air
leakage
assembly
Tightening of track
-L
3 790-331-I 110 Wrench n 1
roller assembly
mounting bolt
30-7
0
leces New/ Nature of work,

Component Symbol Part No. Part Name l’ty ;ketct
-sity remode remarks
1 797-101-I 121 Wrench n

I-
I Removal,
tion of nut
installa-
Press fitting of
Disassembly,
bly of carrier
assembly
assem-
roller L
2 796-430-I 110 Push tool
A-- bearing
Installation of
3 791-434-1650 Installer 1 floating seal
Charging with oil,
4 791-601-1000 Oil pump 1 checking for air leakage
Installation of track Tightening of track
roller M 790-331-I 110 Wrench 1 roller bolt
Replacement of pumr 791-463-1141 Push tool 1

N
shaft oil seal
790-201-2740 Spacer 1
Cylinder repair stand 1
Pumo :1
Removal, installation
790-I 02-4300 Wrenchassembly
of oiston assemblv
Replacement pin for

Pin n
wrench assemblv
Expansion of piston
Expander 0
ring
796-720-I 670 Rubber band 0

Clamp
796-720-I 660 Rubber band 0

Disassembly, assem-
bly of hydraulic 0 Clamp
cylinder
Push tool kit n
.790-201-1831 .Push tool
~790-101-5021 .Grip
~01010-50816 .Bolt
790-201-1702 Push tool kit n
~790-201-1930 .Push tool

5
.790-101-5021 .Grip
.Bolt
790-201-1702 Push tool kit n Boom z

F
~790-201-1940 .Push tool a
~790-101-5021 .Grip
~01010-50816 .Bolt
-
30-8
0
-
Neces Nature of work,
Component Symbol Part No. Part Name ZYty fi$el Sketch
sity remarks
- -
790-201-1500 Push tool kit 0 1 Bucket
.790-201-1640 .Push tool 1.
~790-101-5021 .Grip 1
.OlOlO-50816 .Bolt 1
Disassembly, assem-
790-201-1980 Plate 0 1 Boom
bly of hydraulic 0 6
cylinder 790-101-5021 Grip 1
01010-50816 Bolt 1
,790-201-1990 Plate 0 1 Arm
~790-101-5021 Grip 1
01010-50816 Bolt 1
l Removal, installation 796-900-1200 Remover n 1 Removal of boom

of work equipment foot pin
P 790-I 01-4000 (490kN
Puller (50ton)
long) n 1
assembly
l Boom assembly 790-101-I 102 Pump(294kN(3MonI) W 1
-
30-9
0
DISASSEMBLY AND ASSEMBLY SKETCHES OF SPECIAL TOOLS
SKETCHES OF SPECIAL TOOLS

Note: Komatsu cannot accept any responsibility for special tools
manufactured according to these sketches.
G2 Push tool
CKP04076
v 1 796T-427-1220 n
30-10
0
DISASSEMBLY AND ASSEMBLY STARTING MOTOR
REMOVAL OF STARTING
MOTOR ASSEMBLY
a Disconnect the cable from the negative (-1 ter-

minal of the battery.
1. Open engine hood.
2. Disconnect 3 wires (I).
3. Remove 2 bolts (2). m
4. Remove starting motor assembly (3). a CLPO3201
INSTALLATION OF STARTING
MOTOR ASSEMBLY
. Carry out installation in the reverse order to

removal.
m Starting motor mounting bolt :

43 = 6 Nm I4.38 f 0.61 kgm1
6 Both faces of starting motor gasket :

Gasket sealant (LG-I)
30-l 1
0
DISASSEMBLY AND ASSEMBLY ALTERNATOR
REMOVAL OF ALTERNATOR
ASSEMBLY
g Disconnect the cable from the negative (-) ter-

2. Remove fan guard (I) and right fan guard mount-

ing bracket (2).
3. Disconnect wiring (3) and connector (41, and re-

move X-connector (5) from bracket.
Using wrench 0, raise tensioner (6) and remove

7r CLPO3204
belt (7).
a Be extremely careful not to get your fingers
caught when removing the belt.
-
H CLPO3205
5. Remove alternator mounting bolts (8) and (91,

then remove alternator assembly (IO).
INSTALLATION OF
ALTERNATOR ASSEMBLY
l Carry out installation in the reverse order to

removal.
30-12
0
DISASSEMBLY AND ASSEMBLY AIR CONDITIONER COMPRESSOR
REMOVAL OF AIR
ASSEMBLY
A Loosen the flange mounting

.
bolts of the air
conditioner hose, and release the refrigerant (R-
134a) slowly.
2. Remove fan guard (I).
3. Disconnect connector (2).
4. Disconnect hoses (3). m
5. Loosen adjustment bolt (4) and remove belt (5).

m
6’ -- CLPO3802
6. Remove 4 mounting bolts (6), then remove com-

pressor assembly (7).
INSTALLATION OF AIR
ASSEMBLY
removal.
a
Ir When installing the hoses, check that the O-
rings are not damaged or deteriorated, then
connect the hoses.
* Adjust the belt tension.

For details, see TESTING AND ADJUSTING,
Testing and adjusting air conditioner belt ten-
sion.
. Fill with refrigerant (R-134a).
30-13
0
DISASSEMBLY AND ASSEMBLY CONDENSER
REMOVAL OF CONDENSER
ASSEMBLY
1. Open engine hood (I) and side cover (2) at left

side of chassis.
2. Remove cover (3) on top of condenser.
3. Disconnect air conditioner hose (41, then dis-

connect hose (5) at receiver drier end and hose
(6) at condenser end. m
* Loosen hoses (41, (5) and (6) slightly and
release the refrigerant (R134a) completely
before disconnecting hoses.
* Fit blind plugs into the condenser port and
hoses to prevent the entry of moisture, dust
or dirt.
4. Remove receiver drier (7) together with bracket.
5. Remove condenser assembly (8).
INSTALLATION OF
CONDENSER ASSEMBLY

removal.
* Check that the O-rings are not damaged or

deteriorated, then connect the hoses.
. Fill with refrigerant Wl34a).
30-14
0
DISASSEMBLY AND ASSEMBLY ENGINE OIL COOLER CORE
REMOVAL OF ENGINE OIL

COOLER CORE ASSEMBLY
2. Remove adiabatic cover (I).
3. Remove turbocharger lubrication hose (2) and

oil filter (3).
4. Disconnect connector (4) with alternator wiring,

and remove connector bracket (5) of intermedi-
ate clamp. CLPO3213
5. Remove oil cooler cover assembly (6). a
6. Remove cooler core (7) from oil cooler cover

assembly (6).
INSTALLATION OF ENGINE OIL

COOLER CORE ASSEMBLY

removal.
m Sleeve nut (2) of turbocharger lubrica-

tion hose :
24 2 4 Nm I2.45 z 0.41 kgm}
m Oil filter (3) : 13 + 2 Nm il.33 2 0.20 kgm} CLPO3228
* Or bring the seal surface into contact, then

tighten 314 turns.
Ir Tighten in the order (I) - (14) as shown in

the diagram.
m Mounting bolt (6) of oil cooler cover as-
sembly : 24 t 4 Nm I2.45 = 0.41 kgm}
CLPO3215
30-l 5
0
DISASSEMBLY AND ASSEMBLY FUEL INJECTION PUMP
REMOVAL OF FUEL INJECTION

PUMP ASSEMBLY
A Disconnect the cable from the negative H ter-

2. Remove cover (I) on top of condenser, then

remove stay (2) at counterweight.
3. Remove fan guard (3) and left bracket (4).
4. Disconnect water temperature sensor connector

(5).
5. Remove bracket (6) for compressor hose clamp.

* Tighten together with the fuel inlet hose
clamp.
6. Remove lock clips (8) (2 places) and lock bracket

(7) of dipstick guide.
7. Disconnect governor motor rod (9) at governor

end. m
* Rotate the shaft of the governor motor and
do not stop it suddenly.
* Always disconnect the guide motor connec-
tor before disconnecting the rod.
8. Disconnect 6 delivery tubes (IO). m
9. Disconnect fuel supply hose (I I) and return hose

(12).
* Fuel will flow out when the hoses are dis-
connected, so insert wooden plugs in the
hoses to prevent the fuel from leaking.
30-16
0
10. Disconnect tube clamp (15) (4 places) and tubes

(13) and (14) between fuel filter and fuel injec-
tion pump.
11. Remove lubrication tube (16).
12. Remove mounting bolt (17) of support bracket

at bottom of fuel injection pump.
13. Using tool A2, rotate engine in normal direc-

tion, and push No. 1 cylinder compression top
dead center positioning pin (18) into gear.
Push the pin light& against the gear and
rotate the engine slowly.
After determining the TDC position, check if
the meshing of the timing pin has come out.
g
t
z
Lu
14. Remove 2 fan belts (191, then move fan tension

pulley (20) and adjustment bar (21) towards fan
shaft. m
* Loosen mounting bolt (23) of adjustment bolt
bottom bracket (221, then loosen adjustment
bolt (24).
15. Turn cap (25) and remove.
CLPO3226
16. Remove washer (27) and nut (26) inside case.

m
* Be extremely careful not to drop the nut and
washer inside the case when removing.
17. Using tool A3, pull drive gear of fuel injection

pump and loosen from shaft.
CLPO3229
18. Remove 4 nuts (28), then remove fuel injection

pump assembly (29). m
30-18
0
INSTALLATION OF FUEL
INJECTION PUMP ASSEMBLY
removal.
Adjust the governor lever.

Adjusting governor motor lever stroke.
m Delivery tube sleeve nut (IO) :

24 f 4 Nm I2.45 f 0.41 kgm}
Ir Adjust the belt tension.

Testing and adjusting fan belt tension.
m Drive nut (26) :

95 + IO Nm 19.7 + 1.01 kgm}
Install the fuel injection pump assembly as

follows.
Check that the No. 1 cylinder is at compres-
sion top dead center.
Ir For details, see Removal Step 13.
Remove plug (30), then remove timing pin

(31).
3) Reverse the position of timing pin (311, align

the timing pin groove with pointer (32) in-
side the pump, then temporarily tighten plug
(30).
* If the tooth of pointer (32) cannot be
aligned with the timing pin hole, rotate
the shaft of the fuel injection pump to
align the pointer tooth.
CLP03233
4) Align pump camshaft with pump drive gear

and install fuel injection pump assembly (29),
then tighten nut (28).
m Nut (28) :
43 f 6 Nm 14.38 + 0.61 kgm}
I
5) Assemble washer (27), and tighten nut (26)
temporarily.
Ir Be extremely careful not to drop the nut
and washer inside the case when install-
ing.
m Temporary tightening of nut (26) :
12.5 2 2.5 Nm Il.27 f 0.25 kgm1
Ir This is not the final torque value.
* To prevent damage to the timing pin, be
careful not to tighten the nut to more
than the above tightening torque.
6) Remove meshing of engine timing pin (18).
I I CLP03235
7) Remove plug (30), reverse position of tim-

ing pin (31), then assemble and install plug
to fuel injection pump.
w Plug : 14.7 Nm Il.5 kgm1
8) Tighten nut (26) of fuel iniection pump fully.

e Nut (26) : -
95 + IO Nm (9.7 I 1.01 kgm}
9) For remaining installation, carry out in re-

verse order to removal.
. Bleeding air CLP03236

* Bleed the air from fuel system.
30-20
0
DISASSEMBLY AND ASSEMBLY WATER PUMP
REMOVAL OF WATER PUMP

ASSEMBLY
1. Drain coolant.
3. Remove fan guard (I), then remove left and right

side covers (2) and (3) of fan guard mount.
4. Using wrench 0, raise tensioner (41, then re-

move belt (5). Q/--i
5. Loosen adjustment bar (7) of fan tension pulley

(61, then loosen fan belt (8). m
CLPO3240
6. Loosen mounting bolt (1 I) of fan pulley (IO) and

fan shaft (9) 2 - 3 mm, then move towards ra-
diator.
30-2 1
0
DISASSEMBLY AND ASSEMBLY WATER PUMP
7. Remove water pump assembly (12).
42
INSTALLATION OF WATER
PUMP ASSEMBLY
removal.
* Adjust the belt tension.

Testing and adjusting of fan belt tension.
. Refilling with water

Sr Add water through the water filler to the
specified level.
Run the engine to circulate the water through
the system. Then check the water level again.
30-22
0
DISASSEMBLY AND ASSEMBLY NOZZLE HOLDER
REMOVAL OF NOZZLE
HOLDER ASSEMBLY
2. Disconnect delivery tube (I) at nozzle holder as-

sembly end. m
3. Remove spill tube (2). m
4. Remove nozzle holder assembly (3). a

Ir If it is difficult to remove the nozzle holder
assembly, use tool A4 to remove it.
Ir Be careful not to let dirt or dust get into the
nozzle holder assembly mount.
INSTALLATION OF NOZZLE
HOLDER ASSEMBLY

removal.
w Delivery tube sleeve nut :

30 2 5 Nm I3.06 z 0.51 kgm1
m Joint bolt : 8 = 2 Nm iO.81 2 0.20 kgm}
am Nozzle holder assembly .

60 2 5 Nm (6112 t 0.51 kgm1
& Nozzle holder assembly thread portion :
Seizure prevention compound
(Molycoat 1000)
* When assembling the nozzle holder, clean
the nozzle holder mount, and check that there
is no dirt or dust inside the sleeve before
assembling.
30-23
0
DISASSEMBLY AND ASSEMBLY TURBOCHARGER
REMOVAL OF
TURBOCHARGER ASSEMBLY
1. Open engine hood, and remove adiabatic cover

(I) of turbocharger assembly.
2. Remove air cleaner intake connector (2) and air

supply tube (3) between turbocharger and
aftercooler. a
3. Remove connector clamp (4).
4. Remove lubrication inlet tube (5) and lubrica- CLPO3245

tion return tube (6), then remove turbocharger
assembly (7). m
* After removing the lubrication tube, close
all the ports to prevent the entry of mud or
dirt.
CLP03246
INSTALLATION OF
TURBOCHARGER ASSEMBLY

removal.
m Intake tube band clip :

10 f 2 Nm Il.02 + 0.21 kgm}
m Lubrication inlet tube sleeve nut :

35 = 5 Nm 13.6 + 0.5 kgm)
w Lubrication return tube mounting bolt :
24 + 4 Nm 12.45 f 0.41 kgm)
w Turbocharger assembly mounting nut :
10 2 2 Nm il.02 + 0.20 kgm}
30-24
0
DISASSEMBLY AND ASSEMBLY THERMOSTAT
REMOVAL OF THERMOSTAT
ASSEMBLY
1. Drain coolant.
2. Open engine hood, and remove fan guard (I)

and right side guard mounting bracket (2).
3. Using wrench 0, raise tensioner (31, then re-

move fan belt (4).
4. Remove alternator assembly top mounting bolt

(5) from bracket, then move alternator assembly
(6) towards partition plate end.
Ir Loosen the mounting bolts at the bottom of
the alternator assembly.
CLPO3250
5. Disconnect radiator inlet hose (7) and aeration

hose (8).
6. Remove alternator bracket (9).

DISASSEMBLY AND ASSEMBLY THERMOSTAT
7. Remove thermostat housing (IO).
CLPO3252
8. Remove thermostat (11).
I CLP03253 j
INSTALLATION OF
THERMOSTAT ASSEMBLY

removal.
m Thermostat housing mounting bolt :

24 + 4 Nm 12.45 2 0.41 kgm}

* Add water through the water filler to the
specified level.
30-26
0
DISASSEMBLY AND ASSEMBLY CYLINDER HEAD
REMOVAL OF CYLINDER HEAD

ASSEMBLY
a Disconnect the cable from the negative (-) ter-

1. Drain coolant.
3. Remove fan guard (I), then remove left and right

side covers (2) and (3) of fan guard mount.
4. Remove turbocharger assembly.

For details, see REMOVAL OF TURBOCHARGER
ASSEMBLY.
5. Remove exhaust manifold cover (4).
6. Remove adiabatic plate mounting bracket (5) for

turbocharger.
* In order to remove mounting bolt (61, do as
follows.
1) Remove muffler drain pipe. (main pump
end)
2) Loosen muffler mounting U-bolt. m
3) Rotate connector (7) at the muffler end
up slightly to a position where it is pos-
sible to remove the mounting bolts.
7. Remove exhaust manifold (8). m
8. Disconnect electrical intake air heater wiring (91,

water temperature sensor connector (IO), and
compressor connector (I I).
9. Remove mounting bracket (12) of intermediate

clamp for wiring and air conditioner hose at
engine end.
IO. Remove air conditioner belt (131, then remove

compressor assembly (14) together with bracket,
and move towards counterweight. a
11. Remove mounting

dipstick guide.
plate (16) and clamp (15) of I I3 II
CLP03.258
30-27
0
12. Disconnect radiator inlet hose (17), heater hose

(181, and aeration hose (19).
13. Using wrench 0, raise tensioner (20), then re-

move belt (21).
g Be extremely careful not to get your fingers
* Before removing the belt, loosen 4 mount-
ing bolts of air conditioner pulley (22).
14. Remove air conditioner pulleys (22).
15. Remove alternator assembly top mounting bolt

(23) from bracket, then move alternator assem-
bly (24) towards partition plate.
Sr Loosen the mounting bolts at the bottom of
the alternator assembly.
16. Remove alternator bracket (25), pulley hub (26)

and tensioner (20) together with bracket (27).
m
30-28
0
17. Remove intake connector (28).
18. Remove 6 delivery tubes (29). m
19. Disconnect tubes (30) and (31) between fuel fil-

ter and fuel injection pump, then disconnect fuel
return hose (32) at fuel filter end. m
20. Remove fuel filter assembly (33) together with

bracket.
r
21. Remove intermediate clamps (34) (3 places) of
fuel return hose (321, then remove spill tube
(35). m
22. Remove nozzle holder assembly (36). m
23. Remove head cover (37).
30-29
24. Remove rocker arm assembly (38).
25 Remove push rod (39).
26. Remove mounting bolts of cylinder head in or-

der shown in diagram. m
I CEW00394
27. Lift off cylinder head assembly (40).
el
kg Cylinder head assembly: 52 kg
28. Remove cylinder head gasket (41). m
CLPO3269
30-30
0
INSTALLATION OF CYLINDER
HEAD ASSEMBLY
removal.
m Muffler mounting U-bolt :

12 + 2.5 Nm Il.22 f; 0.26 kgm}
1121
* Tighten the mounting bolts in the order @ -
@ shown in the diagram on the right.
m Exhaust manifold mounting bolt :
43 + 6 Nm I4.38 + 0.61 kgm}
Ir Adjust the belt tension.

Testing and adjusting air conditioner belt ten-
sion.
w Pulley hub mounting bolt :

33 z 5 Nm I3.37 = 0.51 kgm1
w Tensioner bracket mounting bolt :
24 = 4 Nm i2.45 +. 0.41 kgm}
m~ Exhaust hose clamp :

10 2 2 Nm Il.02 f 0.20 kgm1
w Sleeve nut at injection pump end :

24 f 4 Nm 12.45 f 0.41 kgm1
m Sleeve nut at nozzle holder end :
30 t 5 Nm I3.06 = 0.51 kgm}
m Fuel tube joint bolt (301, (31) :

24 + 4 Nm I2.45 2 0.41 kgm}
m Fuel hose joint bolt (32) :
30 + 5 Nm (3.06 2 0.51 kgm}
30-3 1
0
m Spill tube joint bolt :

8 t 2 Nm jO.81 + 0.20 kgm)
m Nozzle holder assembly :

60 +. 9 Nm (6.12 + 0.92 kgm}
m Head cover mounting bolt :

24 f 4 Nm I2.45 + 0.41 kgm}
piij ~1 m rx141
. Install the rocker arm assembly and cylinder
head assembly as follows.
* Check that there is no dirt or dust on the
cylinder mount surface or inside the cylin-
der.
I) Set cylinder head gasket (41) to cylinder
block.
* Check that the gasket is aligned correctly
with the holes in the block.
2) Raise cylinder head assembly (40) and set to

cylinder block.
3) Assemble push rod (39).

& Add engine oil (15W-40) to the push
rod socket portion.
4) Fit rocker arm assembly (38). and tighten

mounting bolts by hand.
Sr Check that the ball portion of the adjust-
ment screw is fitted securely in the socket
portion of the push rod.
& Put engine oil (15W-40) on the seat
surface and thread of the 8 mm and
12 mm diameter mounting bolts.
30-32
0
5) Tighten cylinder head mounting bolts in or-

der shown in diagram.
& Put engine oil (15W-40) on the seat
surface and thread of the mounting
bolts.
m Cylinder head mounting bolt :
1st step: Tighten in order @ - @ to 90 t 5 Nm

(9.18 2 0.51 kgm}.
2nd step: Tighten in order 0, 8, 0, @, @, @ to
120 z 5 Nm 112.24 = 0.51 kgm}.
3rd step: i) When using tool Al CEW00394
l Using angle tightening wrench
(tool Al), tighten bolts a further
90” in order @ - 8.
ii) When not using tool Al
l Make match marks with a felt
pen on bolt and head, then
tighten bolt a further 90”.
CLPO4084
Tighten rocker arm assembly mounting bolts

(diameter: 8 mm). Make marks on cvllnder
,head and bolt
QKl Rocker arm mounting bolt :
24 + 4 Nm (2.25 t 0.41 kgm}
7) Adjust valve clearance.

Adjusting valve clearance.
DKP00485

* Refill to the specified level, and run the
engine to circulate the water through the
system. Then check the water level again.
CLPO1522
DISASSEMBLY AND ASSEMBLY RADIATOR l HYDRAULIC OIL COOLER
REMOVAL OF RADIATOR,
HYDRAULIC OIL COOLER
ASSEMBLY
a Lower the work equipment completely to the
ground and stop the engine. Then loosen the oil
filler cap slowly to release the pressure inside
the hydraulic tank.
. 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 CLPO3276
tank and inside the system.
- : Hydraulic tank : Approx. 170 t
. Drain coolant.
1. Remove condenser assembly.

For details, see REMOVAL OF CONDENSER AS-
SEMBLY.
2. Remove undercover at bottom of condenser and

bottom of radiator.
+ Set a container under the machine to catch
the oil.
3. Disconnect hoses (I), then remove sub-tank (2).
4. Remove sub-tank mounting bracket (3).
5. Remove coupling (4) at oil cooler inlet port end.

m
6. Remove holder bracket (6) of oil cooler inlet

port tube (5), then disconnect tube.
CLPO3807
7. Remove coupling (7) at oil cooler outlet port

end, then remove holder bracket (8), and dis-
connect oil cooler outlet port tube (9). m
CLPO3808
30-34
0
8. Remove fan guard (IO).
9. Disconnect radiator upper hose (II).
-
10. Disconnect radiator lower hose (12) and heater
hose (13), then remove intermediate clamp (14)
of radiator lower hose. m
8
t
282
::
w
11. Remove 2 clamps (16) of heater hose (15).
12. Disconnect left and right support rods (17) of

radiator.
13. Sling radiator and hydraulic oil cooler assembly

(181, remove bottom mounting bolts, then lift
off radiator and hydraulic oil cooler assembly
slowly.
* When raising the radiator and hydraulic oil
cooler assembly, be extremely careful not to
hit the fan.
&I kg Radiator l hydraulic oil cooler assembly:

112 kg
30-35
0
INSTALLATION OF RADIATOR,
HYDRAULIC OIL COOLER
ASSEMBLY

removal.
m piq
m Coupling : 16.7 = 2 Nm Il.7 + 0.2 kgml
QEI Radiator hose band clip :

8.83 = 0.98 Nm IO.9 2 0.1 kgml
l Refilling with water

specified level.
. 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.
30-36
0
DISASSEMBLY AND ASSEMBLY ENGINE l MAIN PUMP
REMOVAL OF ENGINE l MAIN

PUMP ASSEMBLY

n
1
the hydraulic tank.

l When not using tool B, remove the drain CLP03276
plug, and drain the oil from the hydraulic
w
: Hydraulic tank : Approx. 170 P.
. After disconnecting the piping, fit tags to distin-

guish the mounting position.
. Drain coolant.
1. Remove engine hood (1).
$
z
lCLPO3299
zi
Lu
2. Remove main pump top cover (2).
3. Remove right side cover (3) together with cover

mounting frame (4).
* Remove the cover at the bottom of the main
pump and the cover at the bottom of the
engine, then set a container under the main
pump to catch the oil.
CLPO3300
4. Remove connector (5) from bracket, then dis-

connect.
CLPO3612
5. Disconnect F and R pump discharge hoses (6)

and (71, F and R LS pressure hoses (8) and (9),
and EPC basic pressure hose (IO).
Ir Protect with the sleeve nut to prevent dam-
age to the nipple or elbow taper seal por-
tion.
6. Disconnect pump servo pressure hose (II) and

pump drain hose (121, and remove intermediate
clamp (13) of hose.
* Protect with the sleeve nut to prevent dam-
tion.
7. Disconnect suction tube (14) at pump end.

Ir Cover the suction tube port portion with plas-
tic.
CCPO3814
8. Remove engine partition plates 115), (16), and

(17).
9. Remove bracket (18) at counterweight end.
10. Remove fan guard (191, then remove left and

right side brackets (20) and (21) of fan guard
mount.
30-38
0
11. Disconnect oil level sensor connector (22) of oil (Counterweiahtl

pan, wiring (23) for oil pressure sensor, and II
ground connection (24).
12. Remove intermediate clamp (25) of heater hose.
(Engine oil pan) DLPOO486
13. Remove governor control cable (26) from gov-

ernor and bracket, and disconnect speed sensor
connector (27).
26 21
$
>
7 CLPO3833
z
w
14. Disconnect starting motor wiring (28) and statt-

ing motor connectors (29) and (301, and remove
from clamp.
15. Disconnect fuel supply hose (31) and fuel return

hose (321, then remove intermediate clamp (33).
I
=32----- 31----- CLPO3755
30-39
0
16. Disconnect electrical intake air heater wiring (34)

and air conditioner connector (35).
17. Remove compressor assembly (36).

For details, see REMOVAL OF AIR CONDITIONER
COMPRESSOR ASSEMBLY.
* After removing the compressor assembly,
put it on top of the counterweight.
CLP03834
18. Remove fan (371, and move towards radiator.
19. Remove radiator upper hose (381, radiator lower

hose (39), heater hose (40), and air cleaner con-
nector (41).
20. Remove mount bolt, then raise engine and main

pump assembly (42) slowly, and lift off.
* When removing the engine and main pump
assembly, check that all the wiring and pip-
ing has been disconnected. m
elkg Engine, main pump assembly : 770 kg
CLPO3759
30-40
0
INSTALLATION OF ENGINE,
MAIN PUMP ASSEMBLY
removal.
* Set the engine mount rubber as shown in

the diagram, then install the engine and main
pump assembly.
m Engine mount bolt :
277 d 32 Nm (28.3 = 3.3 kgml Engine rear side Engine front side
DKP00487
specified level.

level.
g Bleeding air
> l
* Bleed the air from the main pump.
! For details, see TESTING AND ADJUSTING,
Bleeding air.
30-4 1
0
DISASSEMBLY AND ASSEMBLY DAMPER
REMOVAL OF DAMPER
ASSEMBLY
1. Remove main pump assembly.

For details, see REMOVAL OF MAIN PUMP AS-
SEMBLY.
2. Remove damper assembly (1).
\
’ CLPO3298
INSTALLATION OF DAMPER
ASSEMBLY
removal.
30-42
0
DISASSEMBLY AND ASSEMBLY FUEL TANK
REMOVAL OF FUEL TANK

ASSEMBLY
g Disconnect the cable from the negative (-1 ter-

1. Loosen drain valve (I) of fuel tank and drain

fuel.
w
: Fuel tank :
Approx. 340 ~2(when tank is full)
2. Disconnect fuel supply hose 12) and return hoses

(3) and (4).
3. Remove handrail (5), battery case (61, and cover

(7).
&I kg Battery case : 28 kg
4. Disconnect fuel sensor connector (81, then re-

move wiring from clamp.
5. Sling fuel tank assembly (91, then remove mount-

ing bolts, and lift off fuel tank assembly (9).
m
&I k9 Fuel tank assembly : 122 kg
INSTALLATION OF FUEL TANK

ASSEMBLY

removal.
m Fuel tank mounting bolt :

277 + 32 Nm 128.3 + 3.2 kgm1
. Refilling with fuel (fuel tank)

Add fuel.
30-43
0
DISASSEMBLY AND ASSEMBLY CENTER SWIVEL JOINT
REMOVAL OF CENTER SWIVEL

JOINT ASSEMBLY
g Release the remaining pressure in the hydraulic
circuit. For details, see TESTING AND ADJUST-
ING, Releasing remaining pressure from hydrau-
lic circuit.
* Mark all the piping with tags to prevent mis-
takes in the mounting position when installing.
1. Disconnect hoses (I), (21, (3), and (4) between
travel motor and swivel joint.
2. Remove elbow (5).
3. Disconnect drain hose (6).

4. Disconnect hoses (7) and (8) between control
valve and swivel joint.
5. Disconnect travel speed selector hose (9).
6. Disconnect plate (IO).
7. Remove center swivel joint assembly (11). a
& kg Center swivel joint assembly : 45 kg
30-44
0
INSTALLATION OF CENTER
SWIVEL JOINT ASSEMBLY
removal.
m
* Assemble the center swivel as shown in the
Center swivel
diagram below. joint
. Refilling with oil (hydraulic tank) c ‘Sprocket
level. Run the engine to circulate the oil
through the system. Then check the oil level
again. DKP00488
. Bleeding air
* Bleed the air form the travel motor. For de-
tails, see TESTING AND ADJUSTING, Bleed-
ing air.
30-45
0
DISASSEMBLY OF CENTER
1. Remove cover (I).
2. Remove snap ring (2).
3. Using tool D, pull out swivel rotor (4) and ring

(3) from swivel shaft (5).
4. Remove O-ring (6) and slipper seal (7) from

swivel rotor.
ASSEMBLY OF CENTER
1. Assemble slipper seal (7) and O-ring (6) to swivel

rotor.
2. Set swivel shaft (5) to block, then using push

tool, tap swivel rotor (4) with a plastic hammer
to install.
CLPO3841
& Contact surface of rotor, shaft :
Grease (GZ-LI)
* When installing the rotor, be extremely care-
ful not to damage the slipper seal and the
O-ring.
3. Install ring (3) and secure with snap ring (2).
4. Fit O-ring and install cover (I).

m Mounting bolt :
31.36 I 2.94 Nm I3.2 + 0.3 kgm}
L CLPO3842
30-46
0
DISASSEMBLY AND ASSEMBLY FINAL DRIVE
REMOVAL OF FINAL DRIVE

ASSEMBLY
1. Remove sprocket. For details, see REMOVAL OF

SPROCKET.
the hydraulic tank.
2. Remove cover (I).
3. Disconnect 4 travel motor hoses (2), and lift off

final drive assembly (3). m
* Be extremely careful not to damage the nip-
ple tool surface of the hose mount.
&l kg Final drive assembly : 300 kg
* Never use tap hole for cover when slinging
final drive assembly.
INSTALLATION OF FINAL
t$ DRIVE ASSEMBLY
i
removal.
w Final drive mounting bolt:

276.8 2 31.8 Nm 128.25 + 3.25 kgm}
. Bleeding air
* Bleed the air from the travel motor. For de-
tails, see TESTING AND ADJUSTING, Bleed-
ing air.
l Refilling with oil (hydraulic tank)

Sr Add oil through the oil filler to the specified
again.
30-47
0
DISASSEMBLY OF FINAL
DRIVE ASSEMBLY
1
1. Draining oil
Remove drain plug and drain oil from final drive
case.
:
w Final drive case : Approx. 4.2 e
2. Cover
Remove mounting bolts, then remove cover (I) 12
using eyebolts 0.
* When raising ring gear (12) and cover (I) as CLPOl427
one unit, tap the ring gear with a wooden

hammer to remove the ring gear.
3. Spacer
Remove spacer (2).
CLPO1417
4. No. 1 carrier assembly

1) Remove No. 1 carrier assembly (3).
CLPO1418
2) Disassemble No. 1 carrier assembly as fol-

lows.
i) Push in pin (4), and pull out shaft (5)
from carrier (6).
* After removing the shaft, remove pin
(4).
ii) Remove thrust washer 17), gear (8), bear-
ing (9), and thrust washer (IO).
CLPO1419
30-48
0
5. No. 1 sun gear shaft

Remove No. 1 sun gear shaft (II).
CLPO1428
6. Ring gear
Remove ring gear (12).
7. Thrust washer
Remove thrust washer (13).
8. No. 2 sun gear

Remove No. 2 sun gear (14).
CLPO1429
9. Thrust washer
Remove thrust washer (15).

CLPO1430

lows.
i) Push in pin (17) and pull out shaft (18)
from carrier (19).
(17).
ii) Remove thrust washer (20), gear (21),
bearing (221, and thrust washer (23).
CLPO1431
30-49
0
11. Nut
1) Remove lock plate (24).
2) Using tool Gl, remove nut (25).
CLP01432 CLPO1433
12. Hub assembly

I) Using eyebolts 0, remove hub assembly (26)
from travel motor.
CLPO1434
2) Disassemble hub assembly as follows.

i) Remove floating seal (27).
ii) Remove bearings (28) and (29) from hub
(30).
* When removing bearing (281, do not hit
the resin retainer of the bearing.
3) Remove floating seal (31) from travel motor

(32).
CLPO1436
30-50
0
ASSEMBLY OF FINAL DRIVE

ASSEMBLY
* Clean all parts, and check for dirt or damage.

Coat the sliding surfaces of all parts with engine
oil before installing.
1. Hub assembly
I) Using push tool, press fit bearings (28) and
(29) to hub (30).
2) Usina tool G4, install floating seal (26).

Rimove ail oil and grease from the O-
G4
ring and O-ring contact surface, and dry
the parts before installing the floating
seal.
After installing the floating seal, check
that the angle of the floating seal is
within 1 mm.
After installing the floating seal, coat the
sliding surface thinly with engine oil.
I I
I CKP03843
3) Using tool G4, install floating seal (31) to

travel motor (32).
* The procedure for installation is the same
as in Step 2) above.
32
CLPO1436
4) Using eyebolts 0, set hub assembly (26) to

travel motor, then using push tool, tap to
press fit bearing portion.
I CCPO1434
2. Nut G2
I) install nut as follows.
i) Using tool G2, push bearing inner race
portion.
Do not heat the bearing with a
burner, or directly push or hit the 3
resin retainer.
Pushing force:
8.82 - 12.74 kN IO.9 - 1.3 ton)
Rotate the hub 2 - 3 times before
applying the pushing force to the
bearing inner race. CLF'03844
ii) Measure dimension a in the condition in
Step i) above.
iii) Measure thickness b of nut itself.
iv) Calculate a - b = c.
v) Using tool Gl, tighten nut (25) to a point
where dimension d is c$.,.
CLPO1437
vi) Using push-pull scale 0, measure tan-

gential force in direction of rotation of
hub in relation to motor case.
* Tangential force : Max. 294 N (30 kg)
* The tangential force is the maximum
force when starting rotation.
CLPO3845
vii) Install lock plate (24).
CLPO1438
30-52
0
* Install the lock plate as shown in the

diagram.
6 Thread of mounting bolt:
GOOD
Thread tightener (LT-2)
* Do not coat the tap portion of the
nut with thread tightener (LT-2).
Install to a Place where

there is no casting notch.
lock Plate and saline
DLPOO489

1) Assemble No. 2 carrier assembly as follows.
Replace thrust washers (20),.(23) and pin
(17) with new ones.
There are the remains of the caulking
when the pin is inserted at the end face
of hole h at the side of the carrier, so
remove the caulked metal from the in-
side diameter of the hole before starting
to assemble. h
i) Assemble bearing (22) to gear (211, fit I
top and bottom thrust washers (20) and CLPO1439
(231, and set gear assembly in carrier
(19).
ii) Align position of pin holes of shaft and
carrier, then tap with a plastic hammer
to install shaft (18).
* When installing the shaft, rotate the
planetary gear. Be careful not to dam-
age the thrust washer.
iii) Insert pin (17).
Sr After inserting the pin, caulk the pin
portion of the carrier.
Ir After assembling the carrier assembly,
check that gear (21) rotates smoothly.
CLPO1440
2) Install No. 2 carrier assembly (16).

* Align the position so that the three tips
of the gear shafts of carrier assembly
(16) enter the three hollows in the end
face of the motor case, then install.
CLPO1441
30-53
0
4. Thrust washer
Install thrust washer (15).
5. No. 2 sun gear

Install No. 2 sun gear (14).
6. Thrust washer
Install thrust washer (13).
7. No. 1 sun gear shaft

Install No. 1 sun gear shaft (11).
CLPO1442

I) Assemble No. 1 carrier assembly as follows.
* Replace thrust washers (7), ilO) and pin
(4) with new ones.
* There are the remains of the caulking
to assemble.
i) Assemble bearing (9) to gear (8), fit top
and bottom thrust washers (7) and (IO), CLP01422
and set gear assembly in carrier (6).
ii) Align position of pin holes of shaft and

carrier, then tap with a plastic hammer
to install shaft (5).
Ir When installing the shaft, rotate the
planetary gear. Be careful not to dam-
age the thrust washer.
j, After inserting the pin, caulk the pin
* After assembling the carrier assembly,
check that gear (8) rotates smoothly.
CLP01423
9. Spacer
Install spacer (2).
CLPO1443
30-54
0
10. Ring gear

Fit O-ring to hub end, then using eyebolts 0,
align position of bolt holes of hub and ring gear
(121, and install.
* Remove all grease and oil from the mating
surface of the ring gear and hub.
* Do not put any gasket sealant on the mating
surface of the ring gear and hub under any
circumstances.
CLPOl444
11. Cover
Using eyebolts 0, fit cover (I), then tighten
mounting bolts with angle tightening wrench
G3.
6 Mounting surface of cover :
Gasket sealant (LG-6)
w Mounting bolt :
1st pass: 98 Nm {IO kgm1
2nd pass: Turn 80’- 90”
Refilling with oil

Tighten drain plug and add engine oil through
oil filler.
Q Final drive case : Approx. 4.2 e

* Carry out a final check of the oil level at the
determined position after installing the final
drive assembly to the chassis.
CLPO1446
30-55
0
DISASSEMBLY AND ASSEMBLY SPROCKET
REMOVAL OF SPROCKET
1. Remove track shoe assembly. For details, see

REMOVAL OF TRACK SHOE ASSEMBLY.
2. Swing work equipment 90”, then push up chas-

sis with work equipment and set block @ be-
tween track frame and track shoe.
3. Lift off sprocket (I). m
--?\‘_ J‘TX-=T -c 7 c_
CLPO4033
INSTALLATION OF SPROCKET
removal.
& Thread mounting bolt :

of sprocket
w Sprocket mounting bolt :
465.5 z 24.5 Nm I47.5 2 2.5 kgml
30-56
0
DISASSEMBLY AND ASSEMBLY SWING MOTOR AND SWING MACHINERY
REMOVAL OF SWING MOTOR,

SWING MACHINERY
ASSEMBLY
g Lower the work equipment to the ground and

stop the engine. Loosen the hydraulic tank oil
the hydraulic tank. Then set the safety lock lever
to the LOCK position.
1. Remove hose clamps (I) and (2) (2 places each).
2. Disconnect swing motor inlet and outlet hoses

(3) and (41, and disconnect suction hose (5).
3. Remove hose clamp (6).
4. Disconnect drain hoses (7) and (8), then discon-

nect pilot hose (9).
5. Remove 12 mounting bolts (IO) at swing ma-

chinery end, then lift off swing motor and swing
machinery assembly (I I). m
* When removing the swing motor and swing
machinery assembly, be careful not to dam-
age the hoses, and lift off slowly.
&l kg Swing motor, swing machinery assem-
bly : 225 kg
30-57
0
DISASSEMBLY AND ASSEMBLY SWING MOTOR AND SWING MACHINERY
INSTALLATION OF SWING
MOTOR, SWING MACHINERY
ASSEMBLY

removal.
m Swing machinery mounting bolt :

549 + 59 Nm (56 +. 6 kgm)

level.
. Bleeding air
* Bleed the air from the swing motor.
Bleeding air.
30-58
0
DISASSEMBLY AND ASSEMBLY SWING MACHINERY
DISASSEMBLY OF SWING
MACHINERY ASSEMBLY
1. Draining oil
Loosen drain plug and drain oil from swing ma-
chinery case.
b
& Swing machinery case : Approx. 5.5 e
2. Swing motor assembly

1) Set swing motor and swing machinery as-
sembly to block 0. CLPO2923
2) Remove mounting bolts, then remove swing
motor assembly (I).
3. No. 1 thrust washer

Remove No. 1 thrust washer (2).
4. No. 1 sun gear


/I
CLPO2926

lows.
Knock pin (51, and remove shaft (6), gear (7),
bearing (8), and thrust washer (9).
Ir After removing shaft (61, remove pin (5)
from the shaft.
CLPO2927
6. Ring gear
Remove ring gear (IO).

Remove No. 2 thrust washer (11).
8. No. 2 sun gear

30-60
0
9. Bolt
Remove holder mounting bolt (13).

.PO2931

lows. 18
i) Push in pin (15), and knock shaft (16) out
18
from carrier (17).
19
(15).
ii) Remove thrust washer (18), gear (19), 20
bearing (20), and thrust washer (21).
iii) Remove plate (22). 21
‘15
CLPO293
11. Shaft assembly

1) Remove mounting bolts (23).
2) Set shaft and case assembly to press, then
using push tool 0, remove shaft assembly
(24) from case assembly (25).
CLPO2933 CLPO2934
3) Disassemble shaft assembly as follows.

i) Using push tool 0, remove cover as-
sembly (26) and bearing (27) from shaft
(28).
ii) Remove oil seal (29) from cover (30).
CLPO2935 CLPO2936
30-61
0
12. Bearing
Using push tool, remove bearing (31) from case
(32).
CLPO2937
30-62
0
ASSEMBLY OF SWING
MACHINERY ASSEMBLY
* Clean all parts and check for dirt or damage.

Coat the sliding surfaces of all parts with engine
oil before installing.
1. Bearing
Using push tool 0, press fit bearing (27) to case
(32).
CLPO2938
2. Cover assembly
1) Using push tool 0, press fit oil seal (29) to
cover (30).
& Outside circumference of oil seal :
* Be careful not to let the gasket sealant
(LG-6) get on the oil seal lip when press
fitting.
CLPO2939
2) Fit cover assembly (26) to case (32), and

tighten mounting bolts (23).
& Cover mounting surface :
Gasket sealant (LG-6) 32
m Mounting bolt :
66.2 z 7.4 Nm i6.75 + 0.75 kgm}
& Lip of oil seal : Grease (G2-LI)
CLPO2940
Case Assembly
Set case assembly (25) to shaft (281, then using
push tool 8, press fit bearing inner race por-
tion.
* When setting the case assembly to the shaft,
be extremely careful not to damage the oil
seal.
CLP02941
4. Bearing
Using tool F, press fit bearing (31).
Sr Press the bearing inner race and outer race
at the same time when press fitting. Do not
press only the inner race when press fitting.
* After press fitting the bearing, check that the
case rotates smoothly.
CLPO2942

1) Assemble No. 2 carrier assembly as follows.
* There are the remains of the caulking
to assemble.
i) Assemble plate (22) to carrier (17).
ii) Assemble bearing (20) to gear (191, fit
top and bottom thrust washers (18) and
(21) and set gear assembly to carrier (17). CLPO2943
iii) Align with position of pin holes of shaft
and carrier, then tap with a plastic ham-
mer to install shaft (16).
* When installing the shaft, rotate the
planetary gear, and be careful not to
damage the thrust washer.
iv) Insert pin (15).
* After inserting the pin, caulk the pin
CLPO2944
6. Bolt
Tighten bolt (13).
& Mounting bolt :
w Mounting bolt :
176.5 + 19.6 Nm I18 + 2.0 kgm}
CLPO2931
30-64
0
7. No. 2 sun gear


Install No. 2 thrust washer (I 1).
9. Ring gear
Install ring gear (IO).
& Case side mounting surface :

I) Assemble No. 1 carrier assembly as follows.
* There are the remains of the caulking at
the end face of carrier side hole k made
when inserting the pin, so remove the
remains of the caulking on the inside
diameter of the hole before starting as-
sembly.
i) Assemble bearing (8) to gear (71, then fit
top and bottom thrust washers (9) and
set gear assembly to carrier.
CLPO2945
30-65
ii) Align pin hole position of carrier and

shaft, then tap with plastic hammer and
install shaft (6).
* Rotate the planet gear when install-
ing the shaft, and be careful not to
damage the thrust washer.
* After inserting the pin, caulk the pin
CLPO2946
iv) Install No. 1 carrier assembly (4).
/I
CLPO
11. No. 1 sun gear


Install No. 1 thrust washer (2).
.PO2924
30-66
0
13. Swing motor assembly

Install swing motor assembly (I).
& Ring gear side mounting surface :
CLPO2923
Ir Coat the outside diameter of the hole only

at the hole in the ring gear where there is a
distinguishing protrusion on the case. (See
the diagram on the right.)
w Mounting bolt : _
176.5 +. 19.6 Nm I18 I 2.0 kgm}
14. Refilling with oil

Projection for
Tighten drain plug and add engine oil through identificati
oil filler to specified level.
30-67
0
DISASSEMBLY AND ASSEMBLY REVOLVING FRAME
REMOVAL OF REVOLVING
FRAME ASSEMBLY
1. Remove 2 boom cylinder assemblies. For de-

tails, see REMOVAL OF BOOM CYLINDER AS-
SEMBLY.
2. Remove work equipment assembly. For details,

see REMOVAL OF WORK EQUIPMENT ASSEM-
BLY.
3. Remove countemeight assembly. For details, see

REMOVAL OF COUNTERWEIGHT ASSEMBLY.
4. Disconnect top mounting hoses (I), (21, and (3)

of swivel joint assembly at swivel joint assem-
bly end.
5. Remove stopper link (4).
6. Remove mounting bolts, then lift off revolving

frame assembly (5). a
* Leave 2 bolts @ each at the front and rear,
use a lever block to adjust the balance of the
revolving frame assembly to the front and
rear, and left and right, then remove the
remaining bolts, and lift off.
a When removing the revolving frame as-
sembly, be careful not to hit the center
swivel joint assembly.
&I kg Revolving frame assembly: 5,200 kg CLPO3849

I
30-68
0
DISASSEMBLY AND ASSEMBLY REVOLVING FRAME
INSTALLATION OF REVOLVING
FRAME ASSEMBLY

removal.
Mating surface of swing circle :

Gasket sealant (LG-I)
Thread of revolving frame mounting
bolt : Thread tightener (LT-2)
Revolving frame mounting bolt :

* Add oil through the oil filler to the speci-
fied level. Run the engine to circulate
the oil through the system. Then check
the oil level again.
. Bleeding air
Ir Bleed the air. For details, see TESTING
AND ADJUSTING, Bleeding air.
30-69
0
DISASSEMBLY AND ASSEMBLY SWING CIRCLE
REMOVAL OF SWING CIRCLE

ASSEMBLY
1. Remove revolving frame assembly. For details,

see REMOVAL OF REVOLVING FRAME ASSEM-
BLY.
2. Remove swing circle mounting bolts (I), leaving

1 bolt each in front and rear direction. m
* Swing circle assembly mounting bolts: 32
PCS.
A--k CLPO3850
3. Sling swing circle assembly (2) at three points,
then remove remaining mounting bolts.
4. Lift off swing circle assembly (2). m
&I kn Swing circle assembly : 280 kg
30-70
0
DISASSEMBLY AND ASSEMBLY SWING CIRCLE
INSTALLATION OF SWING
CIRCLE ASSEMBLY
. Carry out installation in the reverse order to 1 Swing circle start mark
removal.
6 Thread of swing circle mounting bolt : k

m Swing circle mounting bolt :
1st pass: mark
Tighten to 191.2 t 19.6 Nm (19.5 + 2 kgm}
2nd pass: DKP00491
i) Using the angle of the bolt head as the

base, make start marks on the swing cir-
cle and socket.
Inner race
2) Make an end mark at a point (on swing ,soft zone
circle) 48k5” from the start mark. race
zclne
3) Tighten so that the start mark on the
socket is aligned with the end mark on
the swing circle at the 48+5” position.
m
* 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
track frame. DLPOO492
& Swing circle : Grease (G2-LI) 21.Q.
30-71
0
DISASSEMBLY AND ASSEMBLY IDLER l RECOIL SPRING
REMOVAL OF IDLER l RECOIL

SPRING ASSEMBLY
1. Remove track shoe assembly. For details, see

REMOVAL OF TRACK SHOE ASSEMBLY.
2. Sling idler and recoil spring assembly (I), and

pull out to the front to remove.
&I kg Idler l recoil spring assembly : 275 kg
3. Disconnect recoil spring assembly (3) from idler

assembly (2). m
&Jkg Idler assembly : 140 kg
r%kg Recoil spring assembly : 135 kg
INSTALLATION OF IDLER l
RECOIL SPRING ASSEMBLY

removal.
CLPO3855
* When installing the idler assembly and re-

coil spring assembly, assemble so that the
position of the greasing plug on the idler is
on the outside for the right side of the ma-
chine and on the inside for the left side of
the machine.
30-72
0
DISASSEMBLY AND ASSEMBLY RECOIL SPRING
DISASSEMBLY OF RECOIL
SPRING ASSEMBLY
I
I 84
7 a
I ii; ;
L______-_--_-___-------_-_-__-JL-_-______ -Ll/
CLPO3856
1. Remove piston assembly (2) from recoil spring

assembly (I).
2. Disassembly of recoil spring assembly

1) Set recoil spring assembly (I) to tool HI.
g The recoil spring is under large installed
load, so be sure to set the tool properly.
Failure to do this is dangerous.
* Installed load of spring
: 108.8 kN {II,100 kg1
$3
> 2) Apply hydraulic pressure slowly to compress CLPO3857
z
w spring, and remove lock plate (3), then re-
move nut (4).
j, Compress the spring to a point where
the nut becomes loose.
* Release the hydraulic pressure slowly
and release the tension of the spring.
Ir Free length of spring : 558 mm
3) Remove yoke (6), cylinder (71, and dust seal

(8) from spring (5).
3. Disassembly of piston assembly

1) Remove lock plate (IO) from piston (9), then
remove valve (I I).
2) Remove snap ring (12), then remove U-pack-
ing (13) and ring (14).
30-73
0
DISASSEMBLY AND ASSEMBLY RECOIL SPRING
ASSEMBLY OF RECOIL SPRING

ASSEMBLY
H2
1. Assembly of piston assembly

1) Assemble ring (14) and U-packing (13) to
piston (91, and secure with snap ring (12).
2) Tighten valve (11) temporarily, and secure
with lock plate (IO).
7
2. Assembly of recoil spring assembly
1) Using tool H2, install dust seal (8) to cylin-
der (7).
CLPO3858
2) Assemble cylinder (7) and yoke (6) to spring
(51, and set in tool HI.
& Sliding portion of cylinder :
Grease (G2-LI)
3) Apply hydraulic pressure slowly to compress

spring, and tighten nut (4) so that installed
length of spring is dimension “a”, then se-
cure with lock plate (3).
* Installed length “a” of spring : 437 mm
4) Remove recoil spring assembly (I) from tool

Hl.
CLPO3859
3. Assemble piston assembly (2) to recoil spring
assembly (I).
6 Sliding portion of piston, wear ring:
Grease (G2-LI)
* Assemble the cylinder assembly so that the
mounting position of the valve is 90” to the
side.
* Fill the inside of the cylinder with 300 cc of
grease (G2-LI), then bleed the air and check
that grease comes out of the grease hole.
30-74
0
DISASSEMBLY AND ASSEMBLY IDLER
DISASSEMBLY OF IDLER
ASSEMBLY
1. Remove dowel pin (I), then remove support (2).
2. Remove floating seal (3) from support (2) and

idler (4).
3. Pull out idler (4) from shaft (5) and support (7)
assembly.
j, It is filled with 80 cc. of oil, so drain the oil at
this point or lay a cloth to prevent the area
from becoming dirty.
CLPO3660
4. Remove floating seal (6) on opposite side from

idler (4) and shaft (5) and support (7) assembly.
CLP03661
5. Remove dowel pin (8), then remove support (7)

from shaft (5).
6. Remove bushings (9) and (IO) from idler (4).
CLPO3662 CLP03663
30-7.5
0
ASSEMBLY OF IDLER
ASSEMBLY
1. Press fit bushings (9) and (IO) to idler (4).
CLP022lC
2. Fit O-ring and install support (7) to shaft (5) with

dowel pin (8).
3. Using tool Jl, install floating seal (6) to idler (4)

and shaft (5) and support (7) assembly.
* Coat the sliding surface of the floating seal
with oil, and be careful not to let any dirt or
dust get stuck to it.
* Remove all grease and oil from the contact
surface of the O-ring and the floating seal.
CLP03661
Jl
CKP03667
4. Assemble shaft (5) land support (7) assembly to

idler (4). 7
4
CLP03866
30-76
0
5. Using tool Jl, install floating seal (3) to idler (4)

and support (2).
Sr Coat the sliding surface of the floating seal
4 2 3
with oil, and be careful not to let any dirt or
dust get stuck to it.
* Remove all grease and oil from the contact
surface of the O-ring and the floating seal.
CLPO3869
I I
I CKP03870
6. Install O-ring, then install support (2) with dowel

pin (I).
7. Add oil and tighten plug.
%# Oil : Approx. 80 cc (SAE30)
m Plug : 205.8 +. 49 Nm I21 2 5 kgm}
2
CLPO3860
30-77
0
DISASSEMBLY AND ASSEMBLY TRACK ROLLER
REMOVAL OF TRACK ROLLER

ASSEMBLY
1. Lower work equipment, then loosen lubricator

(I), and relieve track tension. m
-
F
g The adjustment cylinder is under extremely
high pressure. Never loosen the lubricator
more than one turn. If the grease does not
come out easily, move the machine back-
wards and forwards. I ’
2. Remove mounting bolts of track roller, then
swing work equipment 90”, jack up machine,
and remove track roller assembly (2) towards CLPO3872
outside of machine. m
r+ kg Track roller assembly : 40 kg
INSTALLATION OF TRACK
ROLLER ASSEMBLY

removal.
Adjust the track tension. For details, see CLPO3873

TESTING AND ADJUSTING, Testing and ad-
justing track tension.
Place the plug on the outside of the chassis,

and set the track roller assembly in the
mounting position.
Operate the work equipment levers to lower
the machine slowly, then tighten the mount-
ing bolts temporarily.
Operate the work equipment levers to lower
the machine completely to the ground, then
tighten the mounting bolts fully.
w Track roller assembly mounting bolt: CLPO3874
1st pass :
Tighten to 196 2 19.6 Nm I20 I 2 kgm1
2nd pass :
1. When using tool M.
. Using an angle tightening
wrench, tighten bolt 90 r 5”.
start
2. When not using tool M.
I) Using the angle of the bolt head
as the base, make start marks on
the track roller and socket.
2) Make an end mark at a point 90 f track roller
5” from the start mark. / end mark Socket start mark
Socket
3) Tighten so that the start mark on
DLP00493
the socket is aligned with the end
mark on the track roller at the
90+5” position.
30-78
0
DISASSEMBLY OF TRACK
ROLLER ASSEMBLY
1. Remove pin (I), then remove collar (2).
II
3
CLPO2218
2. Remove floating seal (3) from collar (2) and roller

(4).
CLPO2220 CLP02221
3. Pull out roller (4) from shaft (5).

* It is filled with 190 - 215 cc. of oil, so drain
the oil at this point or lay a cloth to prevent
the area from becoming dirty.
4. Remove floating seal (6) on opposite side from I

roller (4) and shaft (5).
CLPO2222 CLP02223
30-79
0
5. Remove pin (71, then remove collar (8) from

shaft (5).
6. Remove bushings (9) and (IO) from roller (4.
CLPO2224 CLPO27.25
30-80
0
ASSEMBLY OF TRACK ROLLER

ASSEMBLY
1. Using push tool 0, press fit bushings (9) and
(IO) to roller (4).
2. Assemble collar (8) to shaft (51, and install pin

(7).
3. Using tool Kl, install floating seal (6) to shaft

(5).
* When assembling the floating seal, clean the 9 IO 8
contact surface of O-ring (6~) and floating CLP00803
seal (6a), remove all grease and oil, and dry
it. Make sure that no dirt or dust sticks to
the contact surface of the floating seal.
4. Using tool Kl, install floating seals (6) and (3) to

roller (4).
* For details of the precautions when install-
ing floating seals (6b) and (6d), and (3b) and
(3d), see the precaution for Step 3.
9
5. Assemble shaft (5) to roller (4).
IO
6. Turn over roller (4) and shaft (5) assembly.
CLPO2226
7. Using tool Kl, install floating seal (3) to collar
(2).
* For details of the precautions when install-
ing floating seals (3a) and (3c), see the pre-
caution for Step 3. Kl
CLPO3886 CLPO3887
CLPO3888 CLP03889
30-81
0
8. Assemble collar (2) to shaft (5), and install pin

(I).
CLPO3890
9. Using tool KS!, apply basic pressure to roller oil

filler port, and check for leakage of air from
seal.
* Basic pressure : 0.1 MPa {I kg/cm2)
li Method of checking
The basic pressure shall be maintained for
10 seconds and the indicator of the gauge
shall not go down.
CLPO3891
10. Using tool K2, fill track roller assembly with oil,
K2
then tighten plug (II).
m Plug : 14.7 t. 4.9 Nm Il.5 + 0.5 kgm}
& Track roller oil : 190 - 215 cc (SAEBO)
To oil PUMP 1
To vacuum tank
DLP00529
- CLP
30-82
0
DISASSEMBLY AND ASSEMBLY CARRIER ROLLER
REMOVAL OF CARRIER
ROLLER ASSEMBLY

A The adjustment cylinder is under extremely
more than one turn. If the grease does not
come out, move the machine backwards and
forwards.
2. Using hydraulic jack 0, push up track to a posi-

tion where carrier roller assembly can be re- CLP03872
moved, then remove carrier roller assembly (2).
m
INSTALLATION OF CARRIER
ROLLER ASSEMBLY

removal.
Adjust the track tension. For details, see CLPO3894

Thread of carrier roller assembly mounting bolt:

30-83
0
ISASSEMBLY OF CARRIER
3LLER ASSEMBLY I I\
1. Remove plug (I) and drain oil.
:
w Carrier roller assembly : 230 - 250 cc
2. Set carrier roller assembly on stand 0.

3. Remove cover (2).
4. Remove ring (3).
CLPO3895
CLPO3896 CLPO3897
5. Using tool Ll, remove nut (4).

6. Using push tool 0, pull out shaft assembly (5)
from roller (6) with press, then remove inner
race (7).
CLPO3898 CLPO3899
8
7. Remove outer races (8) and (9) from roller (6).
6. Disassembly of shaft assembly

1) Using puller 0, remove inner race (IO). 6
ZiK CLPO3900
9
1 1 ----bK3901
30-84
0
2) Remove floating seals (II).

3) Using push tool 0, remove collar (12) from
shaft (13). 0
13
I2
>_-
CLP03902
+-
CLP03903
30-85
0
ASSEMBLY OF CARRIER
ROLLER ASSEMBLY
1. Using push tool 0, press fit outer races (8) and 0
(9) to roller (6). 6

2. Assembly of shaft assembly
i+
1) Using push tool 8, press fit collar (12) to
-
shaft (13).
* When press fitting, be careful that there 13 12
9
is no scuffing.
6 Fitting portion of shaft : SAEBO +
!ZI-&I.I
2) Using tool L3, assemble floating seals (II). CLPO3904 ' CLPO3905
Ir When assembling the floating seal, clean

the contact surface of O-ring (11~) and
floating seal (I la), remove all grease and
oil, and dry it. Make sure that no dirt or
dust sticks to the contact surface of the
Ln
floating seal.
3) Assemble floating seals (I I), then using tool
L2, press fit inner race (IO).
Sr For details of the precautions when in-
stalling floating seals (11 b) and (I Id), see
the precaution for Step 2).
L--J CLPO1447
3. Assemble roller (6) to shaft assembly (5).
4. Using tool L2, press fit inner race (7).

* When press fitting the bearing, rotate the
roller, and press fit to a point where the
rotation becomes slightly heavier.
5. Using tool Ll, tighten nut (4) to a point where

drill hole in shaft is aligned with drill hole in
nut.
cLPo144a cLPo389a
6. Install ring (3).

3
7. Using push-pull scale @, check that it rotates
smoothly.
-3
0 _ u
@
cLPo3897 CLPO3909
30-86
0
8. Fit O-ring and install cover (2).
I CLPO3910
9. Using tool L4, apply basic pressure to roller oil

filler port, and check for leakage of air from
seal.
* Basic pressure : 0.1 MPa {I kg/cm*)
* Method of checking
The basic pressure shall be maintained for
10 seconds and the indicator of the gauge
shall not go down.
zs
>
z
W
10. Using tool L4, fill carrier roller assembly with

oil, then tighten plug (I).
G Carrier roller oil : 230 - 250 cc (SAE30)
To oil PUMP
To vacuum tank
DLP00494
30-87
0
DISASSEMBLY AND ASSEMBLY TRACK SHOE
REMOVAL OF TRACK SHOE

ASSEMBLY
1. Stop machine at a point where master pin is

midway between idler and carrier roller, and
where there is space to lay out track assembly
on ground.

g The adjustment cylinder is under extremely
more than one turn. If the grease does not CLP03872
come out, move the machine backwards and
forwards.
3. Using tool I, pull out master pin (2). m
4. Remove tool I, and move machine forward so

that position of temporary pin @ is at front of
idler, and set block @ in position.
5. Remove temporary pin 0, and remove dust seal,

then drive machine in reverse to lay out track
(3).
a
CLP03913
INSTALLATION OF TRACK
SHOE ASSEMBLY
Adjust the track tension. For details, see

Use tool I and press fit so that the protru-

sion of the master pin is dimension “a”.
Protrusion “a” of master pin : 4 f 2 mm LP03914
When assembling the dust seal, coat the

bushing contact surface with grease (G2-LI).
Ir Replace the shoes with new ones when rubber
pads get worn to the same height (or lower) as
the heads of their mounting bolts.
It is impossible to remove or install mounting
bolts once the heads get damaged, crushed or
deformed.
30-88
0
DISASSEMBLY AND ASSEMBLY HYDRAULIC TANK
REMOVAL OF HYDRAULIC
TANK ASSEMBLY
1. Drain oil from hydraulic tank.
:
w Hydraulic tank : Approx. 170 e
2. Remove engine hood (I), pump top cover (2),

and control valve top cover (3).

mounting frame (5).
4. Remove engine partition plates (6) and (7) and

mounting bracket for partition plate on hydrau-
lic tank side.
5. Disconnect hydraulic oil return tube (8).
6. Remove pump suction tube (9) together with

joint hose (IO).
7. Remove LS pressure hose clamp (11).
8. Disconnect 7 hydraulic tank return hoses (12).

* After disconnecting the hoses, fit tags to dis-
tinguish them.
tion.
9. Sling hydraulic tank assembly (131, then remove

mounting bolts, and lift off hydraulic tank as-
sembly. $zJ
&I kg Hydraulic tank assembly : 136 kg
CLPO3820
DISASSEMBLY AND ASSEMBLY HYDRAULIC TANK
INSTALLATION OF HYDRAULIC
TANK ASSEMBLY

removal.
m Hydraulic tank drain plug :

68.5 = 10 Nm (6.98 z 1.01 kgm}
w Hydraulic tank mounting bolt :

277 +32 Nm I28.3 f 3.2 kgml

Ir Add oil through the oil filler to the specified
level.
& Hydraulic tank : Approx. 170 J?.
. Bleeding air
* Bleed the air.
Bleeding air.
30-90
0
DISASSEMBLY AND ASSEMBLY MAIN PUMP
REMOVAL OF MAIN PUMP

ASSEMBLY
A Disconnect the cable from the negative (-) ter-

the hydraulic tank.

. When not using tool B, remove the drain
I - CLPO3276
:
w Hydraulic tank : Approx. 170 .t
. Drain oil from damper case.
1. Remove engine hood cover (I).
2. Remove main pump top cover (2).

$ mounting frame (4).
&
z
4. Remove connector (5) from bracket and discon-

nect.
I \\\ I CLPO3812
5. Disconnect F and R pump discharge hoses (6)

and (7), F and R LS pressure hoses (8) and (9),
and EPC basic pressure hose (IO).
-)r Protect with the sleeve nut to prevent dam-
tion.
30-91
0
6. Disconnect pump servo pressure hose (11) and

pump drain hose (12), and remove intermediate
clamp (13) of hose.
tion.
7. Disconnect suction tube (14) at pump end.

* Cover the suction tube port portion with plas-
tic.
8. Remove engine partition plates (15), (16), and

(17).
I
9. Remove muffler drain pipe (18) and clamp
mounting bracket (19).
IO. Remove main pump assembly (20) as follows.

1) Leaving 2 i 3 mounting bolts, remove other
mounting bolts.
2) Sling main pump assembly and install 2
guide bolts @ on diametrically opposite
sides.
3) Remove remaining mounting bolts, then pull
out slowly until main pump assembly sepa-
rates from spline shaft.
4) Lift off main pump assembly. m
A kg Main pump assembly : 150 kg
30-92
0
INSTALLATION OF MAIN
PUMP ASSEMBLY

removal.
& Involute spline of main pump :

Anti-friction compound (LM-G)
& Mating surface of main pump case :
. Refilling with oil (damper)

Ir Add engine oil through the oil filler to the
specified level. Run the engine to circulate
the oil through the system. Wait for at least
15 minutes, then check the oil level again.
%# Damper : Approx. 0.7 e

-f Add oil through the oil filler to the specified
level.
$
) . Bleeding air
I2
W * Bleed the air from main pump.
Bleeding air.
30-93
0
DISASSEMBLY AND ASSEMBLY MAIN PUMP INPUT SHAFT OIL SEAL
REMOVAL OF MAIN PUMP

INPUT SHAFT OIL SEAL
1. Remove main pump assembly. For details, see

REMOVAL OF MAIN PUMP ASSEMBLY.
2. Remove snap ring (I), then remove spacer (2).
3. Lever up oil seal (3) with a screwdriver to re-

move. m
* When removing the oil seal, be extremely
careful not to damage the shaft.
CLPO3916
INSTALLATION OF MAIN
PUMP INPUT SHAFT OIL SEAL

removal.
& Lip of oil seal : Grease (G2-LII

& Coat the outside circumference of the oil
seal with grease (G2-LII thinly, then press
fit.
Ir Using tool N, press fit oil seal (3).
CLPO3917
30-94
0
DISASSEMBLY AND ASSEMBLY CONTROL VALVE
REMOVAL OF CONTROL
VALVE ASSEMBLY
a Run the engine at low idling, operate the cylin-

der to the end of its stroke without relieving the
circuit, then lower the work equipment to the
ground.
For details, see TESTING AND ADJUSTING, Re-
leasing pressure in hydraulic circuit.
After stopping the engine, do as follows.
. Loosen the oil filler cap slowly to release the

pressure inside the tank.
. Operate the control levers.
* Operate the control levers several times to
release the pressure in the accumulator.
. Start the engine and run at low idling for approx.
5 seconds, then stop the engine and operate the
control levers.
5
Ir Repeat the above operation several times to
release the remaining pressure completely.
1. Open engine hood, and remove valve top cover

(I) and air cleaner top cover (2).
$ 2. Remove partition plate covers (3) and (4) be-

t
tween engine and control valve, move partition
z
w plate cover (5) under intake hose towards en-
gine.
3. Disconnect pump discharge hoses (6) and (71,

and remove hose clamp (8).
4. Remove self-reducing pressure valve (9).

Sr The length of the mounting bolts is differ-
ent. See below.
Left side mounting bolts (2 bolts) :
L = 120 mm
Right side mounting bolts (2 bolts) :
L = 125 mm
5. Disconnect hoses (IO) between control valve and

relay block, hose (1 I) between control valve and
timing valve, travel valve pilot hose (12),2 boom
valve pilot hoses (131, and 2 relief valve pilot
hoses (I 4).
tinguish them.
tion.
6. Disconnect 2 travel valve junction hoses (15).
7. Disconnect 2 LS pressure pilot hoses (16).

tinguish them.
8. Remove timing valve (Ii’) and drain tube (18).
9. Disconnect 10 hoses (19) connected to each

valve.
Ir After disconnecting the hoses, fit tags to dis-
tinguish them.
Ir Protect with the sleeve nut to prevent dam-
tion.
cLPo3aza
16. Disconnect 2 each of bucket valve tube (201,

boom valve tube (211, and arm valve tube (22).
11. Disconnect 2 each of right travel valve hose (231,

swing valve hose (241, and left travel valve hose
(25).
12. Disconnect 2 LS select valve pilot hoses (26).
13. Sling control valve assembly (27). then remove

mounting bolts, and lift off control valve assem-
bly.
&I kg Control valve assembly : 170 kg
30-96
0
INSTALLATION OF CONTROL
VALVE ASSEMBLY

removal.

level.
. Bleeding air
Ir Bleed the air from the circuit between the
valve and the hydraulic cylinder.
Bleeding air.
30-97
0
DISASSEMBLY OF CONTROL
VALVE ASSEMBLY
(l/3)
-2
22 23
21 ,24
20 25
I! 26
18 27
DKP00526
30-98
0
W3)
I
/ I ’ ‘--/ \
33 32 31 43 42 F-F 41
34
Bucket valve Gina valve
IO
II
12
13
I4 E-E
5; 4i ;a i7
Travel valve
I5
A-A
.57
D-D I
Boom valve Arm valve 74
DKP00527
30-99
0
(3/3)
--
I L-L
I
B-B
J-J
50 49 AA-AA 48 47
DKP00528
30-100
0
Ir The set pressure of the safety valve cannot be

adjusted when it is installed on the machine, so
do not disassemble.
. This section explains the procedure for the 6-
spool valve.

Remove main relief valve (2).
2. Unload valves, safety-suction valves, suction

va Ives
1) Remove unload valves (I) and (17).
2) Remove safety-suction valves (23), (221, (271,
(18), and (20).
3) Remove suction valves (251, (241, (21), (26),
and (19).
3. Pressure compensation valves

* Before removing any pressure compensa-
tion valve, check and mark its mounting po-
sition.
1) Remove bucket DUMP pressure compensa-
tion valve (81, R.H. travel REVERSE pressure
compensation valve (71, boom RAISE pres-
sure compensation valve (61, right swing
pressure compensation valve (51, L.H. travel
REVERSE pressure compensation valve (4),
and arm OUT pressure compensation valve
(3).
2) Remove bucket CURL pressure compensa-
tion valve (IO), R.H. travel FORWARD pres-
sure compensation valve (I I), boom LOWER
pressure compensation valve (121, left swing
pressure compensation valve (13), L.H. travel
FORWARD pressure compensation valve
(14), and arm IN pressure compensation
valve (15).
* After removing the pressure compensation
valves, remove check valve (35) from each
pressure compensation valve mount.
4. LS select valve
Remove LS select valve (38).
30-101
0
5. LS shuttle valves, pump merge/divider valve, 10. Boom control valve

boom regeneration valve 1) Remove case (57), then remove spring
1) Remove LS shuttle valves (79) and (81). (55) and retainer (60).
2) Remove block (80), then remove boom 2) Remove case (64), then remove spring
regeneration spring (61) and boom re- (53) and retainer (63).
generation valve (62). 3) Remove spool assembly (54).
* Do not disassemble spool assembly
6. Remove covers (9) and (16). (54).
7. Arm control valve 11. Bucket control valve

1) Remove case (70), then remove spring 1) Remove case (30), then remove spring
(74) and retainer (69). (31) and retainer (32).
2) Remove case (66), then remove spring 2) Remove case (34), then remove spring
(67) and retainer (78). (28) and retainer (33).
3) Remove spool assembly (68). 3) Remove spool assembly (29).
j, Do not disassemble spool assembly * Do not disassemble spool assembly
(68). (29).
8. Swing control valve

1) Remove case (40), then remove spring
(39) and retainer (41).
3) Remove spool assembly (37).
+ Do not disassemble spool assembly
(37).
9. R.H. travel, L.H. travel control valves

2) Remove case (50), spring (44), and re-
tainer (49).
3) Remove spool assembly (45).
_j, Do not disassemble spool assembly
(45).
30-102
0
ASSEMBLY OF CONTROL
VALVE ASSEMBLY
(l/3)
\ kl /
Bucket
RH travel
Boom
Swing
LH travel
Arm
23
24
25
26
18 27
DKP00526
30-103
0
43 42 F-F il
Bucket valve Swine valve
IO
II
12
I3
I4 \
E-E
Travel valve
;a 47
I5
A-A
-57
I I
D-D I
Boom valve Arm valve 74
DKP00527
30-104
0
(3/3)
24 21
25 20
0 0 0
26 I!
18
c-c
J-J
50 49 AA-AA 48 i7
OKP00528
30- 105
0
l Coat the sliding surfaces of all parts with 3) Assemble retainer (41) and spring (39),
engine oil before installing. then fit O-ring to case (40) and install.
w Case mounting bolt :
1. Bucket control valve spool 30.87 2 3.43 Nm 13.15 +. 0.15 kgm)
1) Assemble spool assembly (29) to valve
body. 5. Arm control valve
2) Assemble retainer (33) and spring (28), 1) Assemble spool assembly (68) to valve
then fit O-ring to case (34) and install. body.
w Case mounting bolt : 2) Assemble retainer (78) and spring (67),
30.87 +. 3.43 Nm i3.15 2 0.35 kgm) then fit O-ring to case (66) and install.
3) Assemble retainer (32) and spring (31) D Case mounting bolt :
to spool, then fit O-ring to case (30) and 30.87 2 3.43 Nm (3.15 + 0.15 kgm}
install. 3) Assemble retainer (69) and spring (74),
m Case mounting bolt : then fit O-ring to case (70) and install.
30.87 f 3.43 Nm 13.15 = 0.35 kgm) m Case mounting bolt :
30.87 f. 3.43 Nm 13.15 + 0.15 kgml
2. Boom control valve spool
body.
2) Assemble retainer (63) and spring (53),
then fit O-ring to case (64) and install.
m Case mounting bolt :
30.87 + 3.43 Nm I3.15 + 0.35 kgm}
3) Assemble spring (56) and piston (59),
then install plug (58).
m Plug :
107.8 + 14.7 Nm III.0 = 1.5 kgm)
then install case (57).
QIGKI Case mounting bolt :
30.87 t. 3.43 Nm I3.15 t: 0.15 kgm)
3. R.H. travel, L.H. travel control valves

body.
QZFI Case mounting bolt :
30.87 + 3.43 Nm I3.15 + 0.15 kgm}
3) Assemble retainer (48) and spring (46)
to spool, then fit O-ring to case (47) and
install.
m Case mounting bolt :
30.87 + 3.43 Nm (3.15 + 0.15 kgm)
4. Swing control valve spool

body.
w Case mounting bolt :
30.87 +. 3.43 Nm 13.15 t 0.15 kgm)
30-106
0
6. Covers
1) Fit O-ring to cover (161, then install.
2) Fit O-ring to cover (91, then install.
& Mating surface of covers (16), (9) :
Seal end 242 or equivalent
+ Tighten the mounting bolts in the order
shown in the diagram on the right.
m Mounting bolt :
166.6 +. 9.8 Nm I17 + 1 kgm}
7. LS shuttle valves, pump merge/divider valve,

CKP00820
boom regeneration valve
1) Assemble boom regeneration valve (62) and
spring (61) to valve body, then install block
(80).
* Tighten the mounting bolts in the order
shown in the diagram on the right.
w Mounting bolt :
166.6 2 9.8 Nm {I7 = 1 kgml
2) Install LS shuttle valves (81) and (79).
w Mounting bolt :
66.15 2 7.35 Nm I6.75 f 0.75 kgm}
LS select valve
Install LS select valve (38).
m LS select valve :
127.4 = 19.6 Nm I13 t 2 kgml
9. Pressure compensation valves

. Check the marks made on each pressure
compensation valve during disassembly, and
install in the correct position.
1) Before installing pressure compensation
valves below, install check valve (35).
2) Fit O-ring, then install arm IN pressure com-
pensation valve (15), L.H. travel FORWARD
pressure compensation valve (14), left swing
pressure compensation valve (131, boom
LOWER pressure compensation valve (121,
R.H. travel FORWARD pressure compensa-
tion valve (II), and bucket CURL pressure
compensation valve (IO).
w Pressure compensation valves :
392 2 19.6 Nm I40 +. 2 kgm1
3) Fit O-ring, then install arm OUT pressure
compensation valve (31, L.H. travel REVERSE
pressure compensation valve (4), right swing
pressure compensation valve (5), boom
RAISE pressure compensation valve (6), R.H.
travel REVERSE pressure compensation
valve (71, and bucket DUMP pressure com-
pensation valve (8).
m Pressure compensation valves :
392 + 19.6 Nm I40 2 2 kgml
30- 107
0
IO. Unload valves, safety-suction valves, suction

va Ives
1) Fit O-rings and install suction valves (191,
(261, (21), (241, and (25).
w Suction valve :
147 + 9.8 Nm (15 + 1 kgm}
2) Fit O-rings and install safety-suction valves
(181, W’), (221, and (23).
m Safety-suction valve :
147 2 9.8 Nm I15 +. 1 kgm}
3) Fit O-rings and install unload valves (17) and
(I). CKPOOSZO
QZI Unload valve assembly :

166.6 + 19.6 Nm (17 +. 2 kgm}

. Fit O-ring and install main relief valve as-
sembly (2).
w Main relief valve :
53.9 + 4.9 Nm 15.5 + 0.5 kgm1
30-108
0
DISASSEMBLY AND ASSEMBLY MAIN RELIEF VALVE
DISASSEMBLY OF MAIN
RELIEF VALVE ASSEMBLY
CKP03919
1. Loosen locknut (91, remove plug (81, then re-

move retainer (6).
2. Loosen locknut (IO), then remove holder (71,
spring (II), seat (121, and poppet (5).
3. Remove ring (I), then remove valve (3) and
spring (4).
sr If any abnormality is found in any part after
disassembly, replace the whole main relief valve
assembly.
$
>
i
ASSEMBLY OF MAIN RELIEF

VALVE ASSEMBLY
. Coat the sliding surfaces with engine oil.
1. Assemble spring (4) and valve (31, then install

ring (I).
2. Install seat (121, poppet (5), spring (II), and
holder (71, and secure in position with locknut
(IO).
w Locknut : 53.9 2 4.9 Nm 15.5 2 0.5 kgml
3. Fit retainer (61, then install plug (8) and secure
in position with locknut (9).
w Locknut : 39.7 + 4.9 Nm (4.0 + 0.5 kgml
* After installing main relief valve to control valve
assembly, adjust pressure referring to section
TESTING AND ADJUSTING, testing and adjust-
ing hydraulic pressure in work equipment, swing,
travel circuit.
30-109
0
DISASSEMBLY AND ASSEMBLY PC VALVE
REMOVAL OF PC VALVE
ASSEMBLY
n
a Disconnect the cable from the negative t-1 ter-
filler cap slowly to release the pressure inside ,B
the hydraulic tank.

l When not using tool B, remove the drain CLPO3276
:
. There are PC valve assemblies installed to both

the front pump and the rear pump, but the pro-
cedure for removal is the same.
1. Remove nut (I), then remove hose assembly

(2). m
2. Install locknut @ (708-2L-28290).

w Locknut :
100.5 +. 12.5 Nm (10.25 + 1.25 kgm}
3. Turn nut (3) in direction of loosening, then

tighten at locknut 0 end.
Ir Angle of turning for nut (3): Approx. 30”
4. Fit tool to width across flats (22 mm) of hexago-

nal portion of sleeve (41, then loosen and re-
move PC valve assembly (5). m
I CKP03719
30-110
0
DISASSEMBLY AND ASSEMBLY PC VALVE
INSTALLATION OF PC VALVE
ASSEMBLY

removal.
m Nut (2) :
100.5 + 12.5 Nm (IO.25 = 1.25 kgml
* After installing the PC valve assembly, re-

move locknut 0.
* Adjust the PC valve assembly.

Testing and adjusting PC valve output pres-
sure (servo piston inlet pressure).
w Nut (3) :
100.5 t: 12.5 Nm {IO.25 +. 1.25 kgml

level.
30-l 11
0
DISASSEMBLY AND ASSEMBLY LS VALVE
REMOVAL OF LS VALVE
ASSEMBLY
g Disconnect the cable from the negative (4 ter-

g Lower the work equipment completely to the
the hydraulic tank.

. When not using tool B, remove the drain CLP03276
:
l There are LS valve assemblies installed to both

the front pump and the rear pump, but the pro-
cedure for removal is the same.
1. Disconnect hose (I).
2. Fit tool to width across flats (30 mm) of hexago-

nal portion of sleeve, then loosen and remove
LS valve assembly (2). m
INSTALLATION OF LS VALVE
ASSEMBLY

removal.
* Adjust the LS valve assembly.

Testing and adjusting LS valve output pres-
sure (servo piston inlet pressure) and LS dif-
ferential pressure.
m Sleeve :
139.7 2 12.3 Nm (14.75 + 1.25 kgm}

level.
30-112
0
DISASSEMBLY AND ASSEMBLY PC-EPC VALVE
REMOVAL OF PC-EPC VALVE

ASSEMBLY

the hydraulic tank.
1. Remove the main pump bottom cover.
2. Disconnect wiring connectors (I) (2 places).

* After disconnecting the connectors, fit tags
to distinguish them.
3. Disconnect hose (2). m
4. Remove PC-EPC valve assembly (3). a
INSTALLATION OF PC-EPC
VALVE ASSEMBLY

removal.
aw Hose sleeve nut :

24.5 + 4.9 Nm I2.5 I 0.5 kgm}
m PC-EPC valve assembly mounting bolt :

13.3 = 1.5 Nm Il.35 = 0.15 kgm}
30-l 13
0
DISASSEMBLY AND ASSEMBLY SOLENOID VALVE
REMOVAL OF SOLENOID
VALVE ASSEMBLY

1. Remove 3 solenoid wiring connectors (I) from

clip and disconnect.
* Mark the male and female ends of each con-
nector with tags to prevent mistakes when
connecting.
2. Disconnect 2 hoses (2) installed to bottom of

valve.
tinguish them.
3. Disconnect 4 hoses (3) installed to top of valve.

Ir After disconnecting the hoses, fit tags to dis-
tinguish them.
4. Remove mounting bolts, then remove solenoid

valve assembly (4).
. When removing solenoid valve as an individual

part
i) When washing valve, loosen mounting bolt
(5) and remove. m
INSTALLATION OF SOLENOID
VALVE ASSEMBLY

removal.
w Bolt : 3.9 t 0.39 Nm IO.4 2 0.04 kgm}
CKP01453
30-l 14
0
DISASSEMBLY AND ASSEMBLY WORK EQUIPMENT l SWING PPC VALVE
REMOVAL OF WORK
EQUIPMENT SWING l PPC
VALVE ASSEMBLY

the hydraulic tank.
1. Remove control stand case.

For details, see REMOVAL OF CONTROL STAND
CASE.
CLPOO821
2. Remove joint bolt (I), and disconnect hose (2).

m
3. Remove mounting bolts, raise PPC valve assem-

bly (3), then disconnect hoses (4) and (5), and
remove. m
Ir Before disconnecting the hoses, make match
marks to show the connecting position.
$
z INSTALLATION OF WORK
z
EQUIPMENT SWING PPC l
VALVE ASSEMBLY

removal.
w Hose mount joint bolt :

29.4 2 4.9 Nm (3.0 5 0.5 kgm)
QZZI Hose mount joint bolt :

39.2 + 4.9 Nm (4.0 I 0.5 kgm)
Ir If there is excessive play in the control le-
vers, adjust the PPC valve.
Adjusting PPC valve.
30-l 15
0
DISASSEMBLY AND ASSEMBLY WORK EQUIPMENT l SWING PPC VALVE
DISASSEMBLY OF WORK
VALVE ASSEMBLY
1. Remove nut (I), then remove disc (2) and boot

(3).
2. Remove bolts, then remove plate (5).

* Do not remove joint (4) unless it is to be
replaced.
3. Remove seal (6) and collar (7).
4. Pull out piston (81, and remove retainer (91,

springs (IO) and (II), and shim (12).
* Spring (IO) consists of a set of two types of
springs with different installed loads, so
check the mounting position (oil port) and
mark with tags to prevent mistakes when
installing.
5. Pull out valve (13) from body (14).
CLP03924
30-l 16
0
DISASSEMBLY AND ASSEMBLY WORK EQUIPMENT. SWING PPC VALVE
ASSEMBLY OF WORK
VALVE ASSEMBLY
1. Assemble valve (13) to body (14).
2. Assemble shim (12) and spring (11) to valve

(13).
* When assembling spring (II), set the end
with the small coil diameter (inside diam-
eter) at shim (12) end.
3. Assemble spring (IO), retainer (9), and piston (8).

* The number of loops in the coil for spring
(IO) is different for each of the hydraulic
ports below, so be careful when installing.
The position of each port is marked on the

bottom of the valve body.
& Piston : Grease (G2-LB
When assembling piston (81, coat the out-
side of the piston and the inside of the hole
in the body with grease.
4. Fit O-ring to collar (7) and assemble in body 1 , 5-7mm

I
(141, then install seal (6).
5. Install plate (5).

m Mounting bolt :
13.23 2 1.47 Nm (I.35 2 0.15 kgml I /I I
(
6. Install joint (4).
,Q& Sliding portion of joint :
Grease (G2-LII, 2 - 4 cc
CKP03925
& Female thread of body :
Thread tightener (LT-21
j, Coat two places on the female thread with
one drop each of Loctite as shown in the
diagram.
w Joint : 44.1 + 4.9 Nm 14.5 f 0.5 kgm1
* Keep strictly to the tightening torque.
7. Assemble boot (3) and disc (2), and tighten with

nut (I).
& Contact surface of piston and disc :
Grease (G2-LI), 0.3 - 0.8 cc
m Nut : 112.7 = 14.7 Nm Ill.5 t 1.5 kgm1
j, After assembling the disc, adjust the height
of the disc. For details, see TESTING AND
ADJUSTING, Adjusting PPC valve.
30417
0
DISASSEMBLY AND ASSEMBLY TRAVEL PPC VALVE
REMOVAL OF TRAVEL PPC

VALVE ASSEMBLY

the hydraulic tank.
1. Remove travel PPC valve undercover.
2. Remove floor mat.
3. Remove pedals (I) and levers (2). Ill CEPO0426
4. Remove cover (3).
5. Remove covers (41, then remove springs (5).
6. Disconnect 6 PPC hoses (71, then remove travel

PPC valve assembly (8). a
CEP00427
INSTALLATION OF TRAVEL
PPC VALVE ASSEMBLY

removal.
Cover mounting bolt :

19.6 2 1.96 Nm 12.0 + 0.2 kgm} 5 CEP00428
Hose mount joint bolt :

(width across flats : 30 mm) :
39.2 + 4.9 Nm I4.0 + 0.5 kgm1
Hose mount elbow :
(width across flats : 22 mm) :
34.3 z 4.9 Nm (3.5 e 0.5 kgm1
8
Hose mount joint bolt :
(width across flat : 17 mm) :
24.5 f 4.9 Nm 12.5 2 0.5 kgm1
I 7- 0
CEP00429
30-l 18
0
DISASSEMBLY AND ASSEMBLY TRAVEL PPC VALUE
DISASSEMBLY OF TRAVEL PPC

VALVE ASSEMBLY
I. Remove screws (I), then remove levers (2).
2. Remove mounting bolts (3), then remove case

and shaft assembly (41.
3. Remove mounting bolts (51, then remove plate

(6) and damper assembly (7) as one unit.
* Check the thickness and mounting position
of washer (18).
* Never disassemble damper assembly (7).
4. Remove mounting bolts (8), then remove damper

assembly (7) from plate (6).
5. Remove seal (9) and collar (IO).
6. Pull out piston (II), and remove retainer (12),

springs (13) and (14), and shims (15).
* Check the number and thickness of shims
(15) for each mounting position, and keep in
a safe place.
7. Pull out valve (16) from body (17).
CLP03926
30-l 19
0
DISASSEMBLY AND ASSEMBLY TRAVEL PPC VALVE
ASSEMBLY OF TRAVEL PPC

VALVE ASSEMBLY
I. Assemble valve (16) in body (17).
2. Assemble shim (15) and spring (14) to valve

(16).
* Assemble the same number and thickness
of shim (15) as was removed during disas-
sem bly.
Standard shim thickness : 0.3 mm
* Spring (14) is not symmetrical at the top
and bottom, so assemble with the small coil
diameter (inside diameter) at the shim end.
3. Assemble spring (13), retainer (121, and piston

(II).
& Outside circumference of piston,
body hole : Grease (G2-LI)
4. Fit O-ring to collar (IO) and assemble in body

(171, then install seal (9).
5. Install damper assembly (7) to plate (61, then

tighten mounting bolts (8).
& Mounting bolt : Thread tightener (LT-2)
m Mounting bolt:
4.41 + 0.49 Nm IO.45 t 0.05 kgm}
6. Install plate (6) and damper assembly (7) as one

unit, then tighten mounting bolts (5).
* Check the thickness of washer (18) and as-
semble in the position checked during dis-
assembly.
w Mounting bolt:
30.87 f 3.43 Nm I3.15 = 0.35 kgm)
7. Install case and shaft assembly (4), then tighten

mounting bolts (3).
* Check that the out-of-parallel of shaft and
CLP03926
damper assembly (7) of case and shaft as-
sembly (4) is less than 0.5.
& Rocking portion of shaft,
connection of lever and piston :
Grease (G2-LI)
w Mounting bolt:
27.93 z 3.43 Nm 12.85 + 0.35 kgm}
8. Install levers (21, then tighten screws (I).

* Adjust so that lever (2) can slightly move.
& Rocking portion of lever pin and plate :
Grease (G2-LI)
w Screw : 8.82 t. 0.98 Nm iO.9 + 0.1 kgm}
30- 120
0
DISASSEMBLY AND ASSEMBLY BOOM LOCK VALVE
REMOVAL OF BOOM LOCK

VALVE ASSEMBLY

ground, then release the remaining pressure in
the hydraulic circuit. For details, see TESTING
AND ADJUSTING, Releasing remaining pressure
in hydraulic circuit.
1. Disconnect tube (I) and hoses (2).
2. Disconnect tube (3).

/ CLPO3927
3. Remove mounting bolts of bracket (4), then re-

move boom lock valve (5) together with bracket
(4).
INSTALLATION OF BOOM
LOCK VALVE ASSEMBLY
0” removal.
>
CLPO3928
z Refilling with oil (hydraulic tank)
LLI l

again.
. Bleeding air
It Bleed the air. For details, see TESTING AND
ADJUSTING, Bleeding air.
30-121
0
DISASSEMBLY AND ASSEMBLY BOOM CYLINDER
REMOVAL OF BOOM
CYLINDER ASSEMBLY
a Extend the arm and bucket fully, lower the work

equipment completely to the ground, and put
the safety lock lever in the LOCK position.
1. Disconnect grease hose (I).
2. Sling boom cylinder assembly (2), and remove

lock bolt (3). m
3. Remove plate, then remove head pin (4). a CLPO3929

* There are shims installed, so check the
number and thickness, and keep in a safe
place.
4. Start engine, and retract piston rod, then tie

piston rod with wire to prevent it from coming
out.
* Set stand @ under the cylinder assembly,
and adjust the position for slinging.
A Release the remaining pressure in the hy-
draulic circuit. For details, see TESTING AND
ADJUSTING, Releasing remaining pressure
5. Disconnect hoses (5).
6. Remove plate, then using forcing screws 0, re-

move bottom pin (61, and remove boom cylin-
der assembly (2). m
place.
I+ kg Boom cylinder assembly : 190 kg
30-122
0
DISASSEMBLY AND ASSEMBLY BOOM CYLINDER
CYLINDER ASSEMBLY

removal.
a
Ir When tightening the locknut, tighten so that
clearance a between the plate and nut is 0.5
- 1.5 mm.
a
& Inside surface of bushing when CKP03932
assembling pin :
Anti-friction compound (LM-P)
6 Greasing after assembling pin :
Grease (LM-G)
g When aligning the position of the pin hole,
never insert your fingers in the pin hole.
* Adjust the shim thickness so that clearance
b between cylinder rod (7) and plate (8) is
below 1 mm.
* Standard shim thickness : 0.8 mm, 1.5
mm
Inside surface of bushing when CLP03933

assembling pin :
Anti-friction compound (LM-PI
Greasing after assembling pin :
Grease (LM-G)
c between cylinder bottom (9) and bracket
(IO) is below 1 mm.
Ir Standard shim thickness : 0.8 mm, 1.5
mm

* Add oil through the oil filler to the specified CLPO3934
again.
. Bleeding air
* Bleed the air from the cylinder. For details,
see TESTING AND ADJUSTING, Bleeding air
from hydraulic cylinder.
30-123
0
DISASSEMBLY AND ASSEMBLY ARM CYLINDER
REMOVAL OF ARM CYLINDER

ASSEMBLY
A Extend the arm cylinder piston rod approx. 200

mm, lower the work equipment completely to A
the ground, then set the remaining safety lock
lever to the LOCK position.
1. Set block @ between arm cylinder and boom.
2. Remove plate, then remove head pin (I). m
J
3. Start engine, and retract piston rod, then tie CLP03935
out.
4. Disconnect hoses (2).
5. Disconnect grease hose (3).
6. Raise arm cylinder assembly, remove plate, re-

move bottom pin (41, then remove arm cylinder
assembly (5). m
Sr There are shims installed, so check the
place.
&I kg Arm cylinder assembly : 265 kg
30-124
0
DISASSEMBLY AND ASSEMBLY ARM CYLINDER
INSTALLATION OF ARM
CYLINDER ASSEMBLY

removal.
Inside surface of bushing when

assembling pin :
Greasing after assembling pin :
Grease (LM-G)
A When aligning the position of the pin hole, I a CLPO3936
& Inside surface of bushing when

assembling pin :
6 Greasing after assembling pin :
Grease (LM-G)
A When aligning the position of the pin hole,
Ir Adjust the shim thickness so that clearance
a between cylinder bottom (6) and bracket
(7) is below 1 mm.
mm

again.
. Bleeding air
30- 125
0
DISASSEMBLY AND ASSEMBLY BUCKET CYLINDER
REMOVAL OF BUCKET
CYLINDER ASSEMBLY
a Extend the bucket cylinder piston rod approx.

200 mm, lower the work equipment completely
to the ground, then set the safety lock lever to
the LOCK position.
1. Set block @ under arm top.

2. Set block @ between link and arm, and block @
between bucket cylinder and arm.
3. Remove lock bolt (I). m
4. Remove plate, then remove head pin (2). 1121 CLPO3937
j, There are shims installed, so check the
place.
out.
6. Disconnect 2 hoses (3).
7. Raise bucket cylinder assembly, remove plate,
remove bottom pin (41, then remove bucket cyl-
inder assembly (5). m -PO3938
place.
&I kg Bucket cylinder assembly : 165 kg
30-126
0
DISASSEMBLY AND ASSEMBLY BUCKET CYLINDER
INSTALLATION OF BUCKET
CYLINDER ASSEMBLY

removal.
m
Sr When tightening the locknut, tighten so that
- 1.5 mm.
a
assembling pin :
& Grease after assembling pin :
b
Grease (LM-G)
b between link (6) and link (7) is below 1
mm.
mm
Inside surface of bushing when -PO3939

assembling pin :
Grease after assembling pin :
Grease (LM-G)
a When aligning the position of the pin hole,
c between cylinder bottom (8) and bracket
(9) is below 1 mm.
mm

* Add oil through the oil filler to the specified CLP03940
again.
Bleeding air
30- 127
0
DISASSEMBLY AND ASSEMBLY HYDRAULIC CYLINDER
DISASSEMBLY OF HYDRAULIC
CYLINDER ASSEMBLY
1. Piston rod assembly

1) Remove piping from cylinder assembly.
2) Remove mounting bolts and disconnect head
assembly (I).
3) Pull out piston rod assembly (2).
* Place a container under the cylinder to
catch the oil.
CLPO3941
4) Disassemble piston rod assembly as follows.

i) Set piston rod assembly (2) in tool 01.
CLPO3778
ii) Remove stopper screw (3) of piston as-

sembly.
* Common screw size for boom, arm,
and bucket cylinder: Ml2 x Pitch 1.75
CLPO3779
* If the caulking of screw (3) is too

strong and it cannot be removed, Tap
tighten the screw fully, then fit a tap

to the thread and remove the screw.
I DKP00498
30- 128
0
iii) Using tool 02, remove piston assembly

(4).
. When not using tool 02, use the drill
holes (0 10, 4 places) and loosen the
piston assembly.
DLPOO499
iv) Remove plunger (5).

Boom and arm cylinder only
v) *Remove collar (6).
Boom and arm cylinder only
vi) kemove head assembly (7).
CLPO3782
vii) Remove cap (8), and pull out 12 balls

(9), then remove plunger (IO).
. Boom and arm cylinder only
CKP03783
2. Disassembly of piston assembly

I) Remove rings (II).
2) Remove wear rings (12).
3) Remove piston ring (13).
4) Remove O-ring and backup ring (14).
CLP03784
30- 129
0
3. Disassembly of cylinder head assembly

1) Remove O-ring and backup ring (15).
2) Remove snap ring (161, then remove dust
seal (17).
3) Remove rod packing (18).
4) Remove buffer ring (19).
5) Remove bushing (20).
CLPO2322
30-130
0
ASSEMBLY OF HYDRAULIC
CYLINDER ASSEMBLY
j, Be careful not to damage the packings, dust I

seals, and O-rings.
* Do not try to force the backup ring into position.
Warm it in warm water (50 - 60°C) before fitting
it.
1. Assembly of head assembly

1) Using tool 05, press fit bushing (20).
2) Assemble buffer ring (19).
3) Assemble rod packing (18). CLPO3786
CLPO3787
4) Using tool 06, install dust seal (17), and se-

cure with snap ring (16).
5) Install backup ring and O-ring (15).
20
19
I8
CLPO2322
2. Assembly of piston assembly

1) Using tool 03, expand piston ring (13).
* Set the piston ring on tool 03, and turn
the handle 8 - 10 times to expand the
ring.
2) Set tool 04 in position, and compress piston
ring (13).
CKP03788 CLPO3789
3) Install backup ring and O-ring (14).

4) Assemble wear ring (12).
5) Assemble ring (II).
* Be careful not to open the end gap of
the ring too wide.
& Ring groove : Grease (G2-LI)
CLPO3784
30-l 31
0
3. Piston rod assembly

1) Set piston rod assembly (2) to tool 01.
CLPO3778
2) Assemble head assembly (7).
3) Fit O-ring and backup ring to collar (61, then

assemble.
4) Assemble plunger (5).

* Check that there is a small amount of
play at the tip of the plunger.
. Arm cylinder only
CLPO3782
5) Set cushion plunger (IO) to piston rod, then

assemble 12 balls (9) and secure with cap
(8).
l
Arm cylinder only
CKP03783
6) Assemble piston assembly (4) as follows.

l When using rod and piston again:
* Wash thoroughly and remove all
metal particles and dirt.
i) Screw in piston assembly (41, then
use tool 02 to tighten piston assem-
bly (2) so that position of screw
thread hole matches.
* Remove all burrs and flashes with
a file.
ii) Tighten screw (3).
m Screw (3) : DLP00499
66.2 + 7.35 Nm 16.75 + 0.75 kgm)
30-132
0
iii) Caulk thread at 2 places with punch.
. When using a new part for either or both

of rod or piston assembly (2)
Ir For the rod with bottom cushion,
mark the cushion plug position on
the end face of the rod.
. Arm cylinder only
DKP00500
i) Screw in until piston assembly (4)

contacts end face of rod, then use
tool 02 to tighten.
w Piston assembly (4):
294 t 29.4 Nm I30 + 3.0 kgm)
* After tightening the piston, check
that there is play in plunger (5).
. Boom, arm cylinder only
DKP00501
ii) Machine one of holes used to install

screw (3).
* Align a drill horizontal with the
V-groove of the thread of rod (2)
and piston (4), then carry out
machining.
* For the cylinder with bottom
cushion (arm cylinder), avoid the
cushion plug position when ma-
chining.
. Screw machining dimension
(mm)
CLPO3792
iii) After machining, wash thoroughly to

remove all metal particles and dust.
iv) Tighten screw (3).

m Screw (3) :
66.2 f 7.35 Nm 16.75 r 0.75 kgm}
v) Caulk thread at 2 places with punch.
CLPO3779
30-133
0
7) Assemble piston rod assembly (2).

& Seal portion : Grease (G2-LI)
Ir Set the end gap of the ring horizontal (at
side position), align axial center of cylin-
der tube, then insert.
* After inserting, check that the ring is not
broken and has not come out, then push
in fully.
End ~a; in rina
DLPOO502
8) Tighten head assembly (I) with mounting

bolts.
w Mounting bolt :
Cylinder 1 Tightening torque
Bucket 1 270-e39Nm {27.5&4.0kgm)
Arm 1 373?54Nm {38.0+5.5kgm}
Boom 270+39Nm {27.5+4.0kgm}
9) Install piping.
CLPO3941
30-134
0
DISASSEMBLY AND ASSEMBLY WORK EQUIPMENT
REMOVAL OF WORK
EQUIPMENT ASSEMBLY
a Extend the arm and bucket fully, lower the work

equipment to the ground, and set the safety
lock lever to the LOCK position.
1. Disconnect grease hose (1).

lock bolt (3). m
3. Remove plate, then remove head pin (4) m CLPO3929

place.

out, and lower it onto block.
* Disconnect the boom cylinder on the oppo-
site side in the same way.
$ in hydraulic circuit.
z
c: 5. Disconnect hoses (5), and secure it to valve with
rope.
* Hoses (6) are for machines equipped with
an additional attachment circuit.
6. Disconnect wiring connector (6) for working

lamp.
7. Sling work equipment assembly, remove plate,

then remove foot pin (7) using tool P, and re-
move work equipment assembly (8). m
place. CLPO4028
&I kg Work equipment assembly : 3,300 kg
CLPO4029
30- 135
0
DISASSEMBLY AND ASSEMBLY WORK EQUIPMENT
INSTALLATION OF WORK
EQUIPMENT ASSEMBLY

removal.
a -- -t----------
* When tightening the locknut, tighten so that
clearance a between the plate and nut is 0.5 =@=
- 1.5 mm.
t I
a
assembling pin :
Grease (LM-G)
b
b between cylinder rod (IO) and plate (I I) is
below 1 mm.
Standard shim thickness : 0.8 mm, 1.5
mm
1
Inside surface of bushing when CLPO3947

assembling pin :
Grease (LM-G)
c between boom (12) and bracket (13) is be-
low 1 mm.
* Standard shim thickness :
0.8 mm, 1.0 mm, 1.5 mm
C
* Add oil through the oil filler to the specified CLPO3948
again.
. Bleeding air
30- 136
0
DISASSEMBLY AND ASSEMBLY BUCKET
REMOVAL OF BUCKET
ASSEMBLY
g Set the back of the bucket facing down, lower

the work equipment completely to the ground, ,I
and set the safety lock lever to the LOCK posi-
tion. 2
1. Remove lock bolt (I). m
2. Remove connecting pin (2) between link and

bucket. m
place.

out.
4. Remove lock bolt (3).
5. Remove plate (41, the remove connecting pin (5)

between arm and bucket. m
Jr There are shims installed, so check the
place.
6. After raising work equipment, swing to discon-

nect bucket assembly (6).
el
kg Bucket assembly : 650 kg
30- 137
0
DISASSEMBLY AND ASSEMBLY BUCKET
INSTALLATION OF BUCKET
ASSEMBLY
removal.
q Ten tightening the locknut, tighten so that

- 1.5 mm.
a a
assembling pin :
Grease (LM-G)
b between bucket boss (7) and link (8) is
below 1 mm.
mm
m
CLPO3952
assembling pin :
Grease (LM-G)
* Set the O-ring at the end face of the bucket
boss securely.
c between arm top (9) and spacer (IO) is 0.5
- 1.0 mm.
mm
CLPO3953
30- 138
0
DISASSEMBLY AND ASSEMBLY ARM
REMOVAL OF ARM ASSEMBLY
1. Remove bucket assembly. For details, see RE-

MOVAL OF BUCKET ASSEMBLY.
2. Secure front link to arm with wire.
3. Pull in arm so that it is easy to remove pin at

arm cylinder head, then lower arm and bucket
c linder assembly (I) on to block 0.
i Set the safety lock lever to the LOCK posi-
tion.
CLPO5181
4. Set block @ between arm cylinder and boom.
5. Remove plate, then remove arm cylinder head

pin (2). m

out.
g Release the remaining pressure in the hy-
$
7. Disconnect 2 hoses (3).
&
* Install blind plugs at the male end and in the
z
disconnected hoses.
8. Remove plate, then remove connecting pin (4)

between arm and boom. a
place.
9. After raising boom, swing to remove arm and

bucket cylinder assembly (I ).
&I kg Arm, bucket cylinder assembly : 950 kg
30- 139
0
DISASSEMBLY AND ASSEMBLY ARM
INSTALLATION OF ARM
ASSEMBLY

removal.
& Inside surface of bushing when

assembling pin :
6 Grease after assembling pin :
Grease (LM-G)
g When aligning the position of the pin hole, CLPO3955
6 Inside surface of bushing when

assembling pin :
6 Grease after assembling pin :
Grease (LM-G)
A When aligning the position of the pin hole,
a between boom top (6) and arm bottom (7)
is below 1.0 mm.
* Standard shim thickness : 0.8 mm

again.
l Bleeding air
30- 140
0
DISASSEMBLY AND ASSEMBLY BUCKET l ARM
REMOVAL OF BUCKET l ARM

ASSEMBLY
a Extend the arm cylinder piston rod approx. 200

mm, lower the work equipment completely to
the ground, then set the safety lock lever to the
LOCK position.
1. Set block @I between arm cylinder and boom.
2. Remove plate, then remove arm cylinder head

pin (1). m
CLPO3956
out.
4. Disconnect hoses (2) and (3).

* Install blind plugs at the male end and in the
disconnected hoses.
$ 5. Raise bucket and arm assembly, remove plate,

> arm
then remove connecting pin (4) between CLPO3957
z
W and boom, and remove bucket and arm assem-
bly (5). a
place.
&I kg Bucket, arm assembly : 1,650 kg
30-l 41
0
DISASSEMBLY AND ASSEMBLY BUCKET l ARM
INSTALLATION OF BUCKET l
ARM ASSEMBLY

removal.

assembling pin :
Grease (LM-G)
a When aligning the position of the pin hole, CLPO3955
,=Q.= Inside surface of bushing when

assembling pin :
Grease (LM-G)
j, Adjust the shim thickness so that clearance
a between boom top (6) and arm bottom (7)
is below 1 mm.
* Standard shim thickness : 0.8 mm

+ Add oil through the oil filler to the specified
again.
. Bleeding air
30-142
0
DISASSEMBLY AND ASSEMBLY BOOM
REMOVAL OF BOOM
ASSEMBLY
1. Remove bucket and arm assembly. For details,

see REMOVAL OF BUCKET, ARM ASSEMBLY.
2. Lower boom assembly completely to ground,

and set safety lock lever to LOCK position.
3. Disconnect grease hose (I).

lock bolt (3). a CLPO3929
5. Remove plate, then remove head pin (4). m

Sr There are shim installed, so check the
place.

out, and lower it onto block.
* Disconnect the boom cylinder on the oppo-
site side in the same way.
a Release the remaining pressure in the hy-
Disconnect hoses (51, and secure to valve with

rope.
8. Disconnect wiring connector (6) for working

lamp.
9. Raise boom assembly and remove plate, remove

foot pin (7) using tool P, then remove boom
assembly (8). m
place. CLPO4028
elkg Boom assembly : 1,650 kg
PO0538
DISASSEMBLY AND ASSEMBLY BOOM
ASSEMBLY
Carry out installation in the reverse order to
-=@$
l
removal.
-_ _+-_-__r_-
Ir When tightening the locknut, tighten so that
- 1.5 mm.
a
assembling pin :
g
Grease (LM-G)
When aligning the position of the pin hole, u r!d b
b between cylinder rod (IO) and plate (II) is
below 1 mm.
mm
FLL Inside surface of bushing when

assembling pin :
CLPO3947

Grease (LM-G)
g When aligning the position of the pin hole, 12 13
j, Adjust the shim thickness so that clearance
c between boom (12) and bracket (13) is be-
low 1 mm.
* Standard shim thickness :
0.8 mm, 1.0 mm, 1.5 mm
C
Sr Add oil through the oil filler to the specified CLPO3948
again.
. Bleeding air
j, Bleed the air from the cylinder. For details,
30-144
0
DISASSEMBLY AND ASSEMBLY OPERATORS CAB
REMOVAL OF OPERATOR’S
CAB ASSEMBLY
a Disconnect the cable from the negative (-) ter-

1. Remove floor mat.
2. Disconnect speaker wiring (I), room lamp wir-

ing (2), antenna wiring (3), and washer hose (4).
* Fit tags to mark the male and female ends
of the connectors to prevent mistakes when
connecting. CLPO4021
3. Disconnect wiper motor wiring connector (5).
4. Remove 9 cab mounting bolts.

Ir Check the position of the chassis ground
connection.
5. Lift off operator’s cab asseembly (6).
&I kg Operator’s cab assembly : 250 kg
CLPO4022
INSTALLATION OF
OPERATOR’S CAB ASSEMBLY

removal.
CLPO4,023
1024
DISASSEMBLY AND ASSEMBLY COUNTERWEIGHT
REMOVAL OF
COUNTERWEIGHT ASSEMBLY
1. Set eyebolts @ to counterweight assembly (I),
and sling.
2. Remove mounting bolts (2) and (3). a

* Be careful not to lose the shims when re-
moving.
3. Lift off counterweight (I) horizontally with wire

or chain block. m
Ir Be careful not to hit the engine, radiator and
cooler assembly.
b-*4 - CLPO3959
r+ kg Counterweight assembly : 3,430 kg
INSTALLATION OF
COUNTERWEIGHT ASSEMBLY
removal.
& Thread of counterweight mounting bolt:

D Counterweight mounting bolt :
1,323 +. 147 Nm I135 f 15 kgm1
* Installing and adjusting counterweight

1) Sling counterweight with crane and set
in position on frame.
2) Push counterweight and install shim and
mounting bolts (2) and (3), and adjust to
following dimensions.
. Clearance from revolving frame :
10 f 5 mm (left and right)
. Clearance from bodywork door : Door Unit:mm
10 + 5 mm (left and right)
. Stepped difference b from revolving
2 -Counterweiaht
frame in left-to right direction :
I:
Max. 5 mm
. Stepped difference a from bodywork __ a=10+4
door in left-to right direction :
10 +4mm
. Stepped difference c from bodywork
top cover in up-down direction :
Max. 5 mm
Revolving frame DKP00503
30- 146
0
DISASSEMBLY AND ASSEMBLY MONITOR
REMOVAL OF MONITOR
ASSEMBLY
g Disconnect the cable from the negative (-1 ter-

1. Remove boot (2) from cover (I), raise to top,

then remove lever (3).
* Check the direction of the lever.
2.
3.
Disconnect
Remove
(4).
horn wiring.
cover (I), and disconnect 3 connectors wCLPO4025
4. Remove monitor assembly (5) from cover (1).

m
INSTALLATION OF MONITOR
ASSEMBLY
$ Carry out installation in the reverse order to
> ’
8 removal.
LLI
a
w Mounting nut of monitor assembly :

8.33 + 0.49 Nm IO.85 2 0.05 kgm}
30-l 47
0
40 MAINTENANCE STANDARD
Swing machinery ......................................... 40- 2

Swing circle ................................................. 40- 4
Final drive .................................................... 40- 6
Track frame l Recoil spring.. ...................... 40- 8
Idler.. .............................................................. 40-10
Carrier roller ................................................ 40-12
Track roller.. ................................................. 40-13
Track shoe.. .................................................. 40-14
Hydraulic pump.. ........................................ 40-19
Control valve ............................................... 40-20
Self-reducing pressure valve ..................... .40-27
Swing motor.. .............................................. 40-28
Travel motor ................................................ 40-29
Work equipment l Swing PPC valve.. ....... .40-30
Travel PPC valve .......................................... 40-31
Service PPC valve ........................................ 40-32
Center swivel joint ..................................... 40-33
Boom holding valve.. .................................. .40-35
Hydraulic cylinder ...................................... 40-36
Work equipment.. ....................................... 40-38
Dimension of work equipment ................. 40-40
40-l
MAINTENANCE STANDARD SWING MACHINERY
SWING MACHINERY
SAP02735
40-2
MAINTENANCE STANDARD SWING MACHINERY
Unit: mm
No. Check item Criteria Remedy
I
Standard clearance Clearance limit
Backlash between swing motor
1 shaft and No. 1 sun gear
0.18 - 0.29 -
Backlash between No. 1 sun gear

2 0.15 - 0.47 1.00
and No. 1 planetary gear
Backlash between No. 1 planetary

3 gear and ring gear 0.17 - 0.55 1.10

4 carrier and No. 2 sun gear 0.36 - 0.63 1.20
Replace
Backlash between No. 2 sun gear
5 and No. 2 olanetary oear 0.14 - 0.44 0.90
-
6 0.16 - 0.51 1 .oo
gear and ring gear I I I

7 0.09 - 0.20 -
carrier and swing pinion
Backlash between swing pinion and

8 swing circle
0.22 - 1.32 2.00
Clearance between plate and

9 0.68 - 1.12 -
planetary carrier
- I
Apply hard
Wear of swing _._.__ s”rraCe
-.._I___ Standard size Repair limit chrome
p,mon
10 contact:.._
,,,9 ..,:+I.
yylll~ oil seal
plating
recondition,
125 -!100 124.7
or replace
40-3
MAINTENANCE STANDARD SWING CIRCLE
SWING CIRCLE
Ist:191.3fl9.6Nm lst:294.2f29.4Nm
(19.5+2kaml (30i3ksml
2nd :4af5’ 2nd:60*6'
A-A
SAP02736
Unit: mm

Axial clearance of bearing
1 Replace
(when mounted on chassis)
0.5 - 1.6 3.2
40-4
MAINTENANCE STANDARD FINAL DRIVE
FINAL DRIVE
2’ N-l II
‘“II
ii-
:; II
r----- ---- ----_--- hi _
----__-
_J- t
SAP01252
40-6
MAINTENANCE STANDARD FINAL DRIVE
Unit: mm
No. 1 sun gear and
Backlash between No. 2 sun gear and
n No. 2 planetary
Repair limit: 6
Rebuild or
Standard size Repair limit replace
9 Width of sprocket tooth
71 66
40-7
MAINTENANCE STANDARD TRACK FRAME l RECOIL SPRING
TRACK FRAME l RECOIL SPRING

* Figure shows PC200-6.
8
<
.’
rr---------
I I
I
_______---
________-__-__ _______
II I
I
I
/
SAP02737
Unit: mm
No Check item Criteria Remedy

-
Standard Repair
Tolerance
size limit
1 Vertical width of idler guide Track frame 107
Rebuild or
Idler support 105
replace
Track frame 250

2 Horizontal width of idler guide
Idler support 247.4
3 Recoil spring Replace
40-8
MAINTENANCE STANDARD IOLER
IDLER
8 7
4
SBPO2738
40-10
MAINTENANCE STANDARD IDLER
Unit: mm
NC Check item Criteria Remedy

?I
> -
Standard size Repair limit
% 1 Outside diameter of protruding
560 -
2 Outside diameter of tread 520 508

Rebuild or
replace
3 Width of protrusion 85 -
4 Total width 164 -

-
5 Width of tread 39.5 45.5

I I
-
Standard Standard Clearance

size b clearance limit
Clearance between shaft and Replace
6
bushing oushing
I I
-0.250 +0.074 0.214 -

65 1.5
-0.350 -0.036 0.424
-
Clearance between shaft and -0.250 -0.110 0.03 - -
7 65 Replace
support -0.290 -0.220 0.180
Standard Standard Interference

Interference between idler and size k interference limit
8 bushing
I I
I
- I 72
+0.089
+0.059
-0.006
-0.072
0.065 -
0.161
- Replace
bushing
9 Side clearance of idler (each)

I Standard clearance
II Clearance limit
0.39 - 1.00 1.5

1
40-H
MAINTENANCE STANDARD CARRIER ROLLER
CARRIER ROLLER
14.7i4.9Nm
1.5* 0.5koml
ifi
>
%
SBP02739
Unit: mm

1 Outside diameter of flange
(outside) -
165
Rebuild or
replace
2 Outside diameter of tread 140 130
3 Width of tread 43 50
I I I
Tolerance
Standard Standard interference
size interference limit
Interference between shaft and Shaft Hole
4
bearing
50 0 0 -0.016 - -
-0.016 -0.012 0.012
Replace
Interference between roller and 0 -0.021 -0.008 -
5 -
bearing 80 -0.013 -0.051 0.051
I
6 Side clearance of roller
0.01 - 0.18 -
40-l 2
MAINTENANCE STANDARD TRACK ROLLER
TRACK ROLLER
,!!!‘,I ii/ i I I III
L-44 SBPO2740
E
>
Unit: mm
% -

Outside diameter of flange
1 (outside)
188 -
Rebuild or
2 Outside diameter of tread 156 144 replace
3 Width of tread 44.5 52
4 Width of flange 25.5 -

-
5 Clearance between shaft and

bushing
I 60 -0.215
-0.315 +0.195
0 0.215
0.510- 1.5
Replace
bushing
Tolerance
Standard Standard Interference
size interference limit
Interference between roller and
6 Shaft Hole
bushing
I 67
+o. 153
+0.053
+0.030
0
0.023 -
0.153
-

7 Side clearance of roller Replace
0.5 - 1.0 1.5
40-13
MAINTENANCE STANDARD TRACK SHOE
TRACK SHOE
(l/2)
Y 14 8 23 22 21 6 5 12 II 24
\ \ \ I
\ I ,,I
\ \ II \ \ I I,: ---t
IO 2 18 7 17 25 19
3 20a
SBPO3974
* P portion shows the link of bushing press fitting end.
40-14
0
Unit: mm
-
-

1 Link pitch
190.25 194.25
Reverse or
When turned replace
Standard size
2 Bushing outside diameter Normal load Impact load
59.3 - 54.3

Repair or
3 Link height
replace
105 97
Thickness of link metal

4 28.5
(bushing press-fitting portion)
5 160.4
Replace
6 Shoe bolt pitch 62
7 18
8 Inside width 84.8
Repair or
9 Link Overall width 45.5 replace
-
10 Tread width 40.3
11 Protrusion of pin 4
12 Protrusion of regular bushing 4.85
13 Overall length of pin 220

Adjust or
-
replace
14 Overall length of bushing 128.7
15 Thickness of bushing metal 10.4
16 Thickness of spacer -
17 Bushing 88.2 - 245 kN {9 - 25 ton)
18 Press-fitting force Regular pin 127.4 - 274.4 kN 113 - 2% ton) -

3%
19 Master pim 78.4 - 147 kN 18 - 15 ton)
-
% : Dry type track link
40-15
0
9 14 0 23 22 21 S 5 !2 !I ?4
I I / / I \ \
Lu
2 18 7 17 25 I! I5
SBP03974
Ir P portion shows the link of bushing press fitting end.
40-16
0
Unit: mm
-
No. Check item Criteria
T Remedy
Tightening torque Additinal tightening

(Nm Ikgm}) angle (deg.)
a. Regular link
490+49 {50+5} 120~10

Shoe bolt Retighten
Tightening torque Additinal tightening Lower limit torque
20
(Nm Ikgm)) angle (deg.) (Nm {kgm))
b. Master link
- - -
No. of shoes (each side) 45 -

- I
Interference between
21
bushing and link
Interference between +0.222 -0.138

22 regular pin and link 38 +0.072 -0.200 0.210 - 0.422
Tolerance
Standard Standard
size clearance
Clearance between
23 Shaft Hole
regular pin and bushing
+0.222 +0.902 Adjust or

38 +0.072 +0.402 0.180 - 0.830
replace
-
%
Interference between
24
master pin and link
Tolerance
Standard Standard
I size clearance
Clearance between
25 Shaft Hole
master pin and bushing
-0.200 +0.902
38 0.602 - 1.302
-0.400 +0.402
% : Dry type track link
40-17
TRIPLE GROUSER SHOE
SDD01629
Unit: mm

-

Height
26 16
2 Thickness 10
-
3 27
_ Rebuild or
Length of base replace
4 22
-
5 21
6 Length at tip 14
I I
7 19
40-18
MAINTENANCE STANDARD HYDRAULIC PUMP
HYDRAULIC PUMP
HPV95 + 95
40-19
MAINTENANCE STANDARD CONTROL VALVE
CONTROL VALVE
6-SPOOL VALVE
(l/5)
--
166.7*9.8Nm
k- G-I
(17*1kml
30.9*3.4Nm
(3.15*0.35kml
SAP03975
40-20
(Z/5)
3 2 3 3 2 I
B-B
SAP03976
Unit: mm
Standard size
Spool return spring
40-21
(3/5)
H-H
SAP03253
40-22
Unit: mm
Piston return spring
40-23
m- 166.7* 19.6Nm m 75.5*9.8Nm

(7.7* 1 koml
K-K L-L
SAP03977
Unit: mm

I
I I
1 Valve spring
2 Relief spring
83.3 N 66.6 N
3 Unload spring 35 x 10.4 26 18.5 kg} - 16.8 kg}
40-24
W5)
127.5*19.6Nm
(13*2kml
23.5*3.9Nm
12.4*0.4kml
J-J
JJ-JJ
39.254.9Nm
14*0.5bml
SAP03255
40-25
SAFETY-SUCTION VALVE (FOR SERVICE VALVE)
147ilONm
{15*lkoml SAP02748
Unit: mm
Free length Installed Installed Free Installed

1 Suction valve spring x 0 .D. length load length load
Replace
16.3 x 21.3 9.5 2.1 N 1.6 N
(0.21 kg} - IO.16 kg)
-
2.1 N 1.6 N
2 Piston spring 20 x 7 14
(0.21 kg} - fO.16 kg}
40-26
MAINTENANCE STANDARD SELF-REDUCING PRESSURE VALVE
SELF-REDUCING PRESSURE VALVE
A-A
SAP03294
Unit: mm
Spring Free length Installed Installed Free Installed

1
(reducing pressure valve, main) x O.D. length load length load Replace
17.7 N spring if
19.2 x 1.2 16.1 12 kg1
19.6 N - Il.8 kg} any
damages
2 Spring 16.5 x 7.2 12.7 20.6 N 18.6 N or defor-
(reducing pressure valve, pilot) {2.1 kg} - II.9 kg} mations
are found.
199.8 N 186.2 N
3 Spring 71 x 18 59
f20.4 kg} - {19 kg)
61.7 N 58.8 N
4 Spring (safety valve) 16.1 x 7.8 13.4 16.3 kg} - 16 kg}
40-27
MAINTENANCE STANDARD SWING MOTOR
SWING MOTOR
KMFgOAB-3
SAP03256
Unit: mm
Standard size I Renair

.._r_.. limit I
Replace
CheCK valve spnng

Free lenath 1 Installed 1 Installed
..-_-.._- 1 Free Installed spring if
1
I x O.D.
I
length
I
load
3.5 N
I
_*L
lengm I load
2.8 N
any
damages
or defor-
62.5 x 20.0 35.0
IO.36 kg} - IO.29 kg} mations
are found.
Shuttle valve spring 13.7 N 10.8 N
2 16.4 x 8.9 11.5
Il.4 kg} - U.1 kg)
40-28
MAINTENANCE STANDARD TRAVEL MOTOR
TRAVEL MOTOR
HMVI IO-2
A-A
\
3
B-B c-c
SAP02750
Unit: mm
Free length Installed Installed Free Installed Replace

1 Check valve spring
x O.D. length load length load spring if
any
2.55 N 2.06 N
31.6 x 6.5 24.2 damages
lo.26 kg} - lo.2 kg} or defor-
1.96 N 1.57 N mations
2 Check valve spring 13.0 x 6.5 9.5 are found.
IO.2 kg} - IO.16 kg}
411 N 329 N
3 Return spring 58.43 x 30 42.6 141.9 kg} - 133.5 kg)
40-29
MAINTENANCE STANDARD WORK EQUIPMENT l SWING PPC VALVE
WORK EQUIPMENT l SWING PPC VALVE
1.5Nm
0.15kPml
A-A
B-B
E-E SAP02751
Unit: mm
Standard size
Centering spring (for P3, P4)

MAINTENANCE STANDARD TRAVEL PPC VALVE
TRAVEL PPC VALVE
SAP02752
Unit: mm
-I
Replace
Free length Installed Installed Free Installed spring if
1 Metering spring
x 0 .D. length load length load
any
damages
16.7 N 13.7 N
26.5 x 8.15 24.7 or defor-
Il.7 kg} - (I.4 kg}
mations
107.8 N 86.2 N are found.
2 Centering spring 48.1 x 15.5 32.5
111 kg} - 18.8 kg}
40-31
MAINTENANCE STANDARD SERVICE PPC VALVE
SERVICE PPC VALVE
SEW0436
Unit: mm
Replace
Free length Installed Installed Free Installed
1 Centering spring spring if
x 0 .D. length load length load
any
46.1 N damages
64.6 x 16.6 44.1 N
40.5 (62.9) or defor-
14.7 kg1 t4.5 kg}
mations
2 Metering 25.5 N 24.5 N are found.
spring 26.0 x 10.5 25.0 (25.2)
12.6 kg1 i2.5 kg}
40-32
MAINTENANCE STANDARD CENTER SWIVEL JOINT
CENTER SWIVEL JOINT

4 PORT SWIVEL JOINT
Unit: mm
Standard size Standard clearance Clearance limit

1 Clearance between rotor and shaft Replace
90 0.056 - 0.105 0.111
40-33
MAINTENANCE STANDARD CENTER SWIVEL JOINT
6 PORT SWIVEL JOINT
-
7
i
=
E
-
\
-\--- -I
i’:f
_!---
-.__
SBPO2753
Unit: mm
Standard size Standard clearance Clearance limit

1 Clearance between rotor and shaft Replace
100 0.056 - 0.105 0.111
40-34
MAINTENANCE STANDARD BOOM HOLDING VALVE
BOOM HOLDING VALVE

* For machine equipped with arm holding valve, the Maintenance Standard of arm holding valve is
the same as this valve.
w 39*5Nm
(4.Ot O.Slarml
\ I
B-B
SDPO1354
Unit: mm

Replace
Free length Installed Installed Free Installed spring if
1 Pilot valve spring x O.D. length load length load any
damages
4.7 N 3.7 N or defor-
26.5 x 11.2 25.0
(0.48 kg} - fO.38 kg) mations
are found.
35.3 N 28.4 N
2 Check valve spring 37.2 x 16.2 30.0
{3.6 kg} - 12.9 kg}
40-35
MAINTENANCE STANDARD HYDRAULIC CYLINDER
HYDRAULIC CYLINDER
BOOM CYLINDER
m 270*39Nm
(27.5*4koml
SAP02756
ARM CYLINDER
1
SAP02757
BUCKET CYLINDER
m 270*39Nm
(27.5*4km)
SAP02758
40-36
MAINTENANCE STANDARD HYDRAULIC CYLINDER
Unit: mm
No
-
Clearance between
piston rod and
Clearance between
2 piston rod support
pin and bushing
Clearance between
cylinder bottom
3 support pin and
40-37
MAINTENANCE STANDARD WORK EQUIPMENT
WORK EQUIPMENT
F-F
-11 I I II
A-A
G-G
c-c
E-E K-K
SAP02 1763
40-38
MAINTENANCE STANDARD WORK EQUIPMENT
SBPO2762
Unit: mm

-
Clearance between connecting pin

and bushing of revolving frame
and boom
-0.036 +0.342 0.305 -
90 1.0
-0.07 1 +0.269 0.412
Clearance between connecting pin -0.036 +0.153 0.133 -

2 and bushing of boom and arm 90 -0.071 +0.097 0.224 1.0
Replace
3 and bushinq of arm and link 70 -0.076 +0.275 0.411 1.0

4 and bushing of arm and bucket 80 -0.076 +0.273 0.413 1 .o

5 and bushing of link and bucket 80 -0.076 +0.273 0.413 1.0
6 and bushing of link and link 70 -0.076 +0.275 0.411 1.0

Clearance between connecting pin I -0.030 +0.335 0.303 - I
40-39
0
MAINTENANCE STANDARD DIMENSION OF WORK EQUIPMENT
DIMENSION OF WORK EQUIPMENT

1. ARM PORTION
I I I
i- Al’
z-z
x-x SAP02764
40-40
Unit: mm
PCZOO-6
+o. 1
1 080 o
5 361.7?1
6 187.2kO.5
7 829.1tl
-
8 2,919
9 2,631.3?1
10 41O-cl
11 64OkO.2
12 6OO-cO.5
13 458.1
14 1,486
15 080
16 326.5*1
17 080
Arm as
individual part 311 j.5
18
When press-
fitting bushing 325
-
Min. 1,680
19
Max. 2,800
40-41
0
2. BUCKET PORTION
c
21 II ,_
16
L
P 16
-
:
IO / II
I3
A-A SAP02765
40-42
Unit: mm
PC200-6
1 457.620.5
2 22kO.5
3 92045'
I
4 458.1
5 1,477.4
6 159.8
7 I -
8 0
+0.2
9 080 o
10
I 326.5+1
11 56
12 106
13 470
14 022
15 0140
16 0190
17 132
18 129
I
19 I 107
20 I 82
21 348.5+;
I
22 38
I
40-43
0
90 OTHERS
Hydraulic piping drawing ........................................................................... 90- 3

Hydraulic circuit diagram ........................................................................... 90- 5
Actual electrical wiring diagram (l/2) ....................................................... 90- 7
Actual electrical wiring diagram (2/2) ....................................................... go- 9
Electrical circuit diagram (l/2) ................................................................... 90-I 1
Electrical circuit diagram (2/2) ................................................................... 90-13
Operation of CLSS svstem as a whole
1. When all work’equipment is at neutral ......................................... 90-15
2. One side actuated, other side neutral ............................................ 90-17
3. Arm OUT, standard mode relief (cut-off controll) ....................... .90-19
4. Bucket DUMP, power max. relief .................................................... 90-21
5. Boom RAISE.. .................................................................................... 90-23
6. Swing operated independently ....................................................... 90-25
7. Tavel operated independently ........................................................ 90-27
8. Compound operation ....................................................................... 90-29
90-l
0
STRUCTURE AND FUNCTION HYDRAULIC PIPING DRAWING
HYDRAULIC PIPING DRAWING
12
1. Bucket cylinder
2. Arm cylinder
3. Boom cylinder
4. Hydraulic tank
5. Hydraulic filter
6. Filter (for breaker)
7. Swing motor
8. R.H. travel motor
‘13 9.
10.
Hydraulic pump
Control valve
11. Junction box
12. Oil cooler
13. L.H. travel motor
14. Arm holding valve
15. Boom holding valve
16. L.H. PPC valve
17. R.H. PPC valve
18. Center swivel joint
19. Travel PPC valve
20. Service PPC valve
21. Accumulator
22. EPC solenoid valve
22A. PPC lock solenoid valve
22B. Swing brake solenoid valve
SBP03964
22C. 2 step relief solenoid valve
22D. Travel speed solenoid valve
90-3
0
STRUCTURE AND FUNCTION ACTUAL ELECTRICAL WIRING DIAGRAM (l/21
ACTUAL ELECTRICAL WIRING DIAGRAM

(l/2)
SBP04276
STRUCTURE AND FUNCTION ACTUAL ELECTRICAL WIRING DIAGRAM (2/2)
ACTUAL ELECTRICAL WIRING DIAGRAM (2/2)
1. Fuel level sensor

2. Working lamp
3. PC control EPC solenoid valve
4. Rear lamp
5. Engine speed sensor
6. Engine oil pressure switch
7. Washer tank
8. Travel alarm
9. Horn (high tone)
10. Horn (low tone)
11. Battery relay
12. Battery
13. Front lamp
V
14. PPC lock solenoid valve
16. 2 step relief solenoid valve
17. Travel speed solenoid valve
18. Engine water temperature sensor
19. Electrical Intake air heater
20. Air conditioner compressor magnet switch
21. Engine oil level sensor
22. Alternator
23. Starting motor
24. R.H. additional front lamp
25. Room lamp
26. L.H. additional front lamp
27. Wiper motor
28. Alarm buzzer
29. Pump controller
30. Horn switch
31. Speaker
32. Monitor panel
33. Starting switch
34. Fuse box
35. Radio
36. Wiper switch
37. Swing lock switch
U 38. Optional lamp switch
39. PPC lock switch
40. Heater
41. Light relay
42. Heater relay
SBPO4277 43. Shift down foot switch
90-9
0
OPERATION OF CLSS SYSTEM AS A WHOLE

1. When all work equipment is at neutral
Sr The diagram shows the situation when all work equipment is at neutral.
* The valves and circuits that are not connected with the explanation of the operation of the CLSS hydraulic system have been omitted.
1
II
11
PL 52
( )
I
I I Ii -5
SAP04167
90-15
0
2. One side actuated, other side neutral

* The diagram shows the independent bucket DUMP operation.
II Max Min Min Max

PI I I
28 2A
I1
)
I ”
SAP04168
90-17
0
3. Arm OUT, standard mode relief (cut-off control)

* The diagram shows the arm DUMP and standard mode relief.
r r Max\
Min
I
PLSl
PP-
SAP04169
90-19
0
4. Bucket DUMP, power max. relief

* The diagram shows bucket DUMP, relief.
PI bl P
( 1 (
I
I I
II i’i”““““““““‘“““‘i’i”“”
L
SAP04170
90-2 1
0
5. Boom RAISE
Min Max
i’i
28 IA
jl PI
) (
Pl
@-t
SAP04171
90-23
0
6. Swing operated independently
2B 2A
PI bl
1
SAP04172
90-25
0
7. Travel operated independently
28 2A
PLSl PI 52
(
SAP04173
90-27
0
8. Compound operation
* The diagram shows boom RAISE + arm IN.
PI il P
) I
n Iu
,
‘,
SAP04174
90-29
0
Komatsu America International Company
440 North Fairway Drive
Vernon Hills, IL 60061-8112 U.S.A.
Attn: Technical Publications PROPOSAL FOR MANUAL REVISION
Fax No. (847) 9704186
IFOR INTERNAL USE ONLY - No. PMR
P NAME OF COMPANY:
;
P
; 1 DEPARTMENT: DATE:
I
MANUAL NAME:
I I
MANUAL NO:
MACHINE MODEL:
S/N IF APPLICABLE:
=AGE NO:
‘ROBLEM:
4ttach photo or sketch.

f more space is needed, use another sheet.
FOR INTERNAL USE ONLY

ZORRECTIVE ACTION:
m
PFMRl 081696

Pc200-6 - Manual - de Serviço (Sebmoi0201k) - Ing

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Pc200-6 - Manual - de Serviço (Sebmoi0201k) - Ing

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SEBMOI 0201 K

SERIAL NUMBERS PC200-6 - Cl0001 andup

February 1998 Copyright 1998 Komatsu America International Company

01 GENERAL ..,.........................................................=........... 01-l

10 STRUCTURE AND FUNCTION . ... .. .. . ... .. .. ... .. .. .. .. .. ... .. .. .. IO-I

40 MAINTENANCE STANDARD ,....,.,.,.,.,........................... 40-I

IMPORTANT SAFETY NOTICE

GENERAL PRECAUTIONS 6. Decide a place in the repair workshop to

When carrying out any operation, always PREPARATIONS FOR WORK

16. When removing components, be careful not

18. As a general rule, do not use gasoline to

STRUCTURE AND FUNCTION

TESTING AND ADJUSTING

DISASSEMBLY AND ASSEMBLY

HOW TO READ THE SHOP MANUAL

VOLUMES REVISED EDITION MARK

Electrical volume: Each issued as one

. If a part cannot be smoothly removed from

A Slinging with one rope may cause

Wire ropes 4) Do not sling a heavy load with ropes form-

20 43.1 4.4 hanging angle. On the other hand, two

* The allowable load value is estimated to

l Used to prevent rubber gaskets, rubber

l Used in places requiring an immediately

l Features: Resistance to heat and chemi-

790-I 29-9060 Adhesive: l Used as adhesive or sealant for metal, glass

Holtz l Used as heat-resisting sealant for repair-

l Quick hardening type adhesive

l Quick hardening type adhesive

l Features: Resistance to heat, chemicals

l Used as adhesive or sealant for gaskets

. Features: Resistance to heat

l Features: Resistance to water, oil

I LG-4 790-129-9020 200 g Tube l

LG-5 1790-129-9060 1 1 kg / p;;,$;~;e~. $;;:sf’~;;;raulic piping. plugs, elbows,

l Features: Silicon based, resistance to heat,

l Features: Silicon based, quick hardening

Three bond l Used as heat-resisting sealant for repairing

l Used as lubricant for sliding portion (to pre-

SYG2-4OOLI l General purpose type

l Used for normal temperature, light load

Molybdenum 400 g l Used for places with heavy load

STANDARD TIGHTENING TORQUE

STANDARD TIGHTENING TORQUES OF BOLTS AND NUTS

Thread diameter Width

TIGHTENING TORQUE OF HOSE NUTS

TIGHTENING TORQUE OF SPLIT FLANGE BOLTS

Thread diameter Width across flat Tightening torque

TIGHTENING TORQUE OF O-RING BOSS CONNECTOR

Thread diameter Width across flat Tightening torque

TIGHTENING TORQUE OF O-RING BOSS CONNECTOR

Thread diameter Width across flat Tighteninc I torque

TIGHTENING TORQUES OF FLARE NUT

Thread diameter Width across flat Tightening torque

TIGHTENING TORQUE FOR 102 SERIES ENGINE (BOLT AND NUTS)

Thread diameter Tightening torque

TIGHTENING TORQUE FOR 102 SERIES ENGINE (EYE JOINTS)

Thread diameter Tightening torque

TIGHTENING TORQUE FOR 102 SERIES ENGINE (TAPERED SCREWS)

Thread diameter Tightening torque

ELECTRIC WIRE CODE

CLASSIFICATION BY COLOR AND CODE

Black 1 Black I Red Yellow Green Blue