SEBM018506
MACHINE MODEL
SERIAL NUMBER
PC128UU-2
5001 and up
•
This shop manual may contain attachments and optional equipment that are not available in your area. Please consult your local Komatsu distributor for those items you may require. Materials and specifications are subject to change without notice.
•
PC128UU-2 mounts the S4D102E-1 engine. For details of the engine, see the 102 Series Engine Shop Manual.
© 2003 1 All Rights Reserved Printed in Japan 07-03(02)
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SAFETY
SAFETY NOTICE
SAFETY SAFETY NOTICE IMPORTANT SAFETY NOTICE Proper service and repair is extremely important for safe machine operation. The service and repair techniques recommended by Komatsu and described in this manual are both effective and safe. Some of these techniques require the use of tools specially designed by Komatsu for the specific purpose.
¤
To prevent injury to workers, the symbol is used to mark safety precautions in this manual. The cautions accompanying these symbols should always be followed carefully. If any dangerous situation arises or may possibly arise, first consider safety, and take the necessary actions to deal with the situation.
GENERAL PRECAUTIONS Mistakes in operation are extremely dangerous. Read the Operation and Maintenance Manual carefully BEFORE operating the machine. 1. Before carrying out any greasing or repairs, read all the precautions given on the decals which are fixed to the machine. 2. When carrying out any operation, always wear safety shoes and helmet. Do not wear loose work clothes, or clothes with buttons missing. • •
Always wear safety glasses when hitting parts with a hammer. Always wear safety glasses when grinding parts with a grinder, etc.
3. If welding repairs are needed, always have a trained, experienced welder carry out the work. When carrying out welding work, always wear welding gloves, apron, hand shield, cap and other clothes suited for welding work. 4. When carrying out any operation with two or more workers, always agree on the operating procedure before starting. Always inform your fellow workers before starting any step of the operation. Before starting work, hang UNDER REPAIR signs on the controls in the operator's compartment. 5. Keep all tools in good condition and learn the correct way to use them.
6. Decide a place in the repair workshop to keep tools and removed parts. Always keep the tools and parts in their correct places. Always keep the work area clean and make sure that there is no dirt or oil on the floor. Smoke only in the areas provided for smoking. Never smoke while working. PREPARATIONS FOR WORK 7. Before adding oil or making any repairs, park the machine on hard, level ground, and block the wheels or tracks to prevent the machine from moving. 8. Before starting work, lower blade, ripper, bucket or any other work equipment to the ground. If this is not possible, insert the safety pin or use blocks to prevent the work equipment from falling. In addition, be sure to lock all the control levers and hang warning signs on them. 9. When disassembling or assembling, support the machine with blocks, jacks or stands before starting work. 10.Remove all mud and oil from the steps or other places used to get on and off the machine. Always use the handrails, ladders or steps when getting on or off the machine. Never jump on or off the machine. If it is impossible to use the handrails, ladders or steps, use a stand to provide safe footing.
00-3
SAFETY
PRECAUTIONS DURING WORK 11. When removing the oil filler cap, drain plug or hydraulic pressure measuring plugs, loosen them slowly to prevent the oil from spurting out. Before disconnecting or removing components of the oil, water or air circuits, first remove the pressure completely from the circuit. 12.The water and oil in the circuits are hot when the engine is stopped, so be careful not to get burned. Wait for the oil and water to cool before carrying out any work on the oil or water circuits. 13.Before starting work, remove the leads from the battery. Always remove the lead from the negative (–) terminal first. 14.When raising heavy components, use a hoist or crane. Check that the wire rope, chains and hooks are free from damage. Always use lifting equipment which has ample capacity. Install the lifting equipment at the correct places. Use a hoist or crane and operate slowly to prevent the component from hitting any other part. Do not work with any part still raised by the hoist or crane. 15.When removing covers which are under internal pressure or under pressure from a spring, always leave two bolts in position on opposite sides. Slowly release the pressure, then slowly loosen the bolts to remove. 16.When removing components, be careful not to break or damage the wiring. Damaged wiring may cause electrical fires. 17.When removing piping, stop the fuel or oil from spilling out. If any fuel or oil drips onto the floor, wipe it up immediately. Fuel or oil on the floor can cause you to slip, or can even start fires. 18.As a general rule, do not use gasoline to wash parts. In particular, use only the minimum of gasoline when washing electrical parts.
00-4
SAFETY NOTICE
19.Be sure to assemble all parts again in their original places. Replace any damaged parts with new parts. • When installing hoses and wires, be sure that they will not be damaged by contact with other parts when the machine is being operated. 20.When installing high pressure hoses, make sure that they are not twisted. Damaged tubes are dangerous, so be extremely careful when installing tubes for high pressure circuits. Also, check that connecting parts are correctly installed. 21.When assembling or installing parts, always use the specified tightening torques. When installing protective parts such as guards, or parts which vibrate violently or rotate at high speed, be particularly careful to check that they are installed correctly. 22.When aligning two holes, never insert your fingers or hand. Be careful not to get your fingers caught in a hole. 23.When measuring hydraulic pressure, check that the measuring tool is correctly assembled before taking any measurements. 24.Take care when removing or installing the tracks of track-type machines. When removing the track, the track separates suddenly, so never let anyone stand at either end of the track.
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. In addition, this section may contain hydraulic circuit diagrams, electric circuit diagrams, and maintenance standards. 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" with "Causes" are also included in this section. DISASSEMBLY AND ASSEMBLY This section explains the procedures for removing, installing, disassembling and assembling each component, as well as precautions for them. MAINTENANCE STANDARD This section gives the judgment standards for inspection of disassembled parts. The contents of this section may be described in STRUCTURE AND FUNCTION. OTHERS This section mainly gives hydraulic circuit diagrams and electric circuit diagrams. In addition, this section may give the specifications of attachments and options together.
NOTICE The specifications contained in this shop manual are subject to change at any time and without any advance notice. Use the specifications given in the book with the latest date.
00-5
FOREWORD
HOW TO READ THE SHOP MANUAL
HOW TO READ THE SHOP MANUAL
REVISED EDITION MARK
VOLUMES Shop manuals are issued as a guide to carrying out repairs. They are divided as follows:
W h en a m an u a l is r e vis ed , a n e d itio n ma rk ( ....) is recorded on the bottom of the pages.
Chassis volume: Issued for every machine model Engine volume: Issued for each engine series Each issued as one Electrical volume: Attachments volume: · volume to cover all models
REVISIONS
}
These various volumes are designed to avoid duplicating the same information. Therefore, to deal with all repairs for any model , it is necessary that chassis, engine, electrical and attachment volumes be available. DISTRIBUTION AND UPDATING Any additions, amendments or other changes will be sent to KOMATSU distributors. Get the most up-todate information before you start any work.
FILING METHOD 1. See the page number on the bottom of the page. File the pages in correct order. 2. Following examples show how to read the page number. Example 1 (Chassis volume): 10 - 3 Item number (10. Structure and Function) Consecutive page number for each item. Example 2 (Engine volume): 12 - 5 Unit number (1. Engine) Item number (2. Testing and Adjusting) Consecutive page number for each item. 3. Additional pages: Additional pages are indicated by a hyphen (-) and number after the page number. File as in the example. Example: 12-203 10-4 12-203-1 10-4-1 Added pages 12-203-2 10-4-2 12-204 10-5
00-6
123
Revised pages are shown in the LIST OF REVISED PAGES next to the CONTENTS page.
SYMBOLS So that the shop manual can be of ample practical use, important safety and quality portions are marked with the following symbols.
Symbol
Item
Remarks
¤
Safety
Special safety precautions are necessary when performing the work.
Caution
Special technical precautions or other precautions for preserving standards are necessary when performing the work.
Weight
Weight of parts of systems. Caution necessary when selecting hoisting wire, or when working posture is important, etc.
Tightening torque
Places that require special attention for the tightening torque during assembly.
Coat
Places to be coated with adhesives and lubricants, etc.
Oil, water
Places where oil, water or fuel must be added, and the capacity.
Drain
Places where oil or water m u s t b e d r a i n e d , a nd quantity to be drained.
s
4 3 2 5 6
FOREWORD
HOISTING INSTRUCTIONS
HOISTING INSTRUCTIONS HOISTING
¤ •
Heavy parts (25 kg or more) must be lifted with a hoist, etc. In the DISASSEMBLY AND ASSEMBLY section, every part weighing 25 kg or more is indicated clearly with the symbol
4
If a part cannot be smoothly removed from the machine by hoisting, the following checks should be made: 1) Check for removal of all bolts fastening the part to the relative parts. 2) Check for existence of another part causing interference with the part to be removed.
WIRE ROPES 1) Use adequate ropes depending on the weight of parts to be hoisted, referring to the table below: Wire ropes (Standard "Z" or "S" twist ropes without galvanizing) Rope diameter
★
Allowable load
mm
kN
tons
10 11.5 12.5 14 16 18 20 22.4 30 40 50 60
9.8 13.7 15.7 21.6 27.5 35.3 43.1 54.9 98.1 176.5 274.6 392.2
1.0 1.4 1.6 2.2 2.8 3.6 4.4 5.6 10.0 18.0 28.0 40.0
Slinging near the edge of the hook may cause the rope to slip off the hook during hoisting, and a serious accident can result. Hooks have maximum strength at the middle portion.
100%
88%
79%
71%
41% SAD00479
3) Do not sling a heavy load with one rope alone, but sling with two or more ropes symmetrically wound onto the load. Slinging with one rope may cause turning of the load during hoisting, untwisting of the rope, or slipping of the rope from its original winding position on the load, which can result in a dangerous accident.
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4) Do not sling a heavy load with ropes forming a wide hanging angle from the hook. When hoisting a load with two or more ropes, the force subjected to each rope will increase with the hanging angles. The table below shows the variation of allowable load kN {kg} when hoisting is made with two ropes, each of which is allowed to sling up to 9.8 kN {1000 kg} vertically, at various hanging angles. When two ropes sling a load vertically, up to 19.6 kN {2000 kg} of total weight can be suspended. This weight becomes 9.8 kN {1000 kg} when two ropes make a 120° hanging angle. On the other hand, two ropes are subjected to an excessive force as large as 39.2 kN {4000 kg} if they sling a 19.6 kN {2000 kg} load at a lifting angle of 150°.
The allowable load value is estimated to be onesixth or one-seventh of the breaking strength of the rope used.
2) Sling wire ropes from the middle portion of the hook.
00-7
FOREWORD
METHOD OF DISASSEMBLING, CONNECTING PUSH-PULL TYPE COUPLER
METHOD OF DISASSEMBLING, CONNECTING PUSH-PULL TYPE COUPLER
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Before carrying out the following work, release the residual pressure from the hydraulic tank. For details, see TESTING AND ADJUSTING, Releasing residual pressure from hydraulic tank. Even if the residual pressure is released from the hydraulic tank, some hydraulic oil flows out when the hose is disconnected. Accordingly, prepare an oil receiving container.
Disconnection 1) Release the residual pressure from the hydraulic tan k. Fo r d e tails , se e TES TIN G AN D ADJUSTING, Releasing residual pressure from hydraulic tank. 2) Hold adapter (1) and push hose joint (2) into mating adapter (3). (See Fig. 1) ★ The adapter can be pushed in about 3.5 mm. ★ Do not hold rubber cap portion (4). 3) After hose joint (2) is pushed into adapter (3), press rubber cap portion (4) against (3) until it clicks. (See Fig. 2) 4) Hold hose adapter (1) or hose (5) and pull it out. (See Fig. 3) ★ Since some hydraulic oil flows out, prepare an oil receiving container. Connection 1) Hold hose adapter (1) or hose (5) and insert it in mating adapter (3), aligning them with each other. (See Fig. 4) ★ Do not hold rubber cap portion (4). 2) After inserting the hose in the mating adapter perfectly, pull it back to check its connecting condition. (See Fig. 5) ★ When the hose is pulled back, the rubber cap portion moves toward the hose about 3.5 mm. This does not indicate abnormality, however.
00-8
Type 1
FOREWORD
METHOD OF DISASSEMBLING, CONNECTING PUSH-PULL TYPE COUPLER
Type 3
1) Hold the mouthpiece of the tightening portion and push body (2) in straight until sliding prevention ring (1) contacts contact surface a of the hexagonal portion at the male end.
1) Hold the mouthpiece of the tightening portion and push body (2) in straight until sliding prevention ring (1) contacts contact surface a of the hexagonal portion at the male end.
2) Hold in the condition in Step 1), and turn lever (4) to the right (clockwise).
2) Hold in the condition in Step 1), and push until cover (3) contacts contact surface a of the hexagonal portion at the male end.
3) Hold in the condition in Steps 1) and 2), and pull out whole body (2) to disconnect it.
3) Hold in the condition in Steps 1) and 2), and pull out whole body (2) to disconnect it.
•
•
Disassembly
Type 2
Hold the mouthpiece of the tightening portion and push body (2) in straight until sliding prevention ring (1) contacts contact surface a of the hexagonal portion at the male end to connect it.
Connection
Hold the mouthpiece of the tightening portion and push body (2) in straight until sliding prevention ring (1) contacts contact surface a of the hexagonal portion at the male end to connect it.
00-9
FOREWORD
COATING MATERIALS
COATING MATERIALS ★ ★
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.
Category
Komatsu code
Part No.
Q'ty
Container
LT-1A
790-129-9030
150 g
Tube
LT-1B
790-129-9050
20 g (2 pcs.)
Polyethylene container
LT-2
09940-00030
50 g
Polyethylene container
LT-3
790-129-9060 (Set of adhesive and hardening agent)
Adhesive: 1 kg Hardenin g agent: 500 g
Can
LT-4
790-129-9040
250 g
Polyethylene container
Holtz MH 705
790-126-9120
75 g
Tube
Three bond 1735
790-129-9140
50 g
Polyethylene container
2g
Polyethylene container
Adhesives
Aron-alpha 201
790-129-9130
Loctite 648-50
79A-129-9110
50 cc
Polyethylene container
LG-1
790-129-9010
200 g
Tube
LG-5
790-129-9070
1 kg
Can
Main applications, featuresr •
Used to prevent rubber gaskets, rubber cushions, and cock plug from coming out.
•
Used in places requiring an immediately effective, strong adhesive. Used for plastics (except polyethylene, polyprophylene, tetrafluoroet hl ene and vi nyl chl oride), rubber, metal and non-metal.
• •
Features: Resistance to heat and chemicals Used for anti-loosening and sealant purpose for bolts and plugs.
•
Used as adhesive or sealant for metal, glass and plastic.
•
Used as sealant for machined holes.
•
Used as heat-resisting sealant for repairing engine.
• • •
Quick hardening type adhesive Cure time: within 5 sec. to 3 min. Used mainly for adhesion of metals, rubbers, plastics and woods.
• •
Quick hardening type adhesive Quick cure type (max. strength after 30 minutes) Used mainly for adhesion of rubbers, plastics and metals.
• • •
Resistance to heat, chemicals Used at joint portions subject to high temperatures.
•
Used as adhesive or sealant for gaskets and packing of power train case, etc.
•
Used as sealant for various threads, pipe joints, flanges. Used as sealant for tapered plugs, elbows, nipples of hydraulic piping.
•
Gasket sealant • LG-6
790-129-9020
200 g
Tube
• •
00-10
Features: Silicon based, resistance to heat, cold Used as sealant for flange surface, tread. mab Used as sealant for oil pan, final drive case, etc.
FOREWORD
Category
COATING MATERIALS
Komatsu code
Part No.
Q'ty
Container
Main applications, featuresr •
LG-7
790-129-9070
1g
Tube
Three bond 1211
790-129-9090
100 g
Tube
LM-G
09940-00051
60 g
Can
•
Adhesives
Molybdenum disulphide lubricant
LM-P
09940-00040
200 g
•
Used as heat-resisting sealant for repairing engine.
•
Used as lubricant for sliding portion (to prevent from squeaking).
•
Used to prevent seizure or scuffling of the thread when press fitting or shrink fitting. Used as lubricant for linkage, bearings, etc.
Tube •
G2-LI
SYG2-400LI SYG2-350LI SYG2-400LI-A SYG2-160LI SYGA-160CNLI
G2-CA
SYG2-400CA SYG2-350CA SYG2-400CA-A SYG2-160CA SYGA-160CNCA
Various
Various
Molybdenum disulphide lubricant
SYG2-400M
400 g (10 per case)
Belows type
Grease
Various
Ftures: Silicon based, quick hardening type Used as sealant for flywheel housing, intake manifold, oil an, thermostat housing, etc.
•
General purpose type
•
Used for normal temperature, light load bearing at places in contact with water or steam.
•
Used for places with heavy load
Various
00-11
FOREWORD
STANDARD TIGHTENING TORQUE
STANDARD TIGHTENING TORQUE STANDARD TIGHTENING TORQUE TABLE (WHEN USING TORQUE WRENCH) ★ In the case of metric nuts and bolts for which there is no special instruction, tighten to the torque given in the table below. Thread diameter of bolt
Width across flats
mm
mm
6 8 10 12 14
10 13 17 19 22
16 18 20 22 24
24 27 30 32 36
27 30 33 36 39
41 46 50 55 60
Thread diameter of bolt
Width across flats
mm
mm
Nm
6 8 10 12
10 13 14 27
7.85 1.95 18.6 4.9 40.2 5.9 82.35 7.85
Nm
kgm
0 0.15 0 0.3 0 0.7 01 02 28.5 0 3 39 0 4 56 0 6 76 0 8.5 94.5 0 10.5 135 0 15 175 0 20 225 0 25 280 0 30 335 0 35
0 1.4 03 07 0 10 0 19 279 0 30 382 0 39 549 0 59 745 0 83 927 0 103 1320 0 140 1720 0 190 2210 0 240 2750 0 290 3290 0 340
1.35 3.2 6.7 11.5 18
13.2 31 66 113 177
kgm
0 0 0 0
0.8 1.9 4.1 8.4
0 0.2 0 0.5 0 0.6 0 0.8
Sealing surface
TABLE OF TIGHTENING TORQUES FOR FLARED NUTS ★ In the case of flared nuts for which there is no special instruction, tighten to the torque given in the table below.
SAD00483
Thread diameter
Width across flat
mm
mm
Nm
kgm
14 18 22 24 30 33 36 42
19 24 27 32 36 41 46 55
24.5 4.9 49 19.6 78.5 19.6 137.3 29.4 176.5 29.4 196.1 49 245.2 49 294.2 49
2.5 0.5 5 2 8 2 14 3 18 3 20 5 25 5 30 5
00-12
Tightening torque
0 0 0 0 0 0 0 0
0 0 0 0 0 0 0 0
FOREWORD
STANDARD TIGHTENING TORQUE
TABLE OF TIGHTENING TORQUES FOR SPLIT FLANGE BOLTS ★ In the case of split flange bolts for which there is no special instruction, tighten to the torque given in the table below.
Thread diameter
Width across flat
Tightening torque
mm
mm
Nm
kgm
10 12 16
14 17 22
65.7 6.8 112 9.8 279 29
0 0 0
6.7 0.7 11.5 1 28.5 3
0
0 0
TABLE OF TIGHTENING TORQUES FOR O-RING BOSS PIPING JOINTS ★ Unless there are special instructions, tighten the O-ring boss piping joints to the torque below.
Thread diameter
Width across flat
Tightening torque
mm
mm
Nm
14 20 24 33 42
Varies depending on type of connector.
34.3 4.9 93.1 9.8 142.1 19.6 421.4 58.8 877.1 132.3
Norminal No.
02 03, 04 05, 06 10, 12 14
kgm
0 0 0 0 0
0 0.5 01 02 06 0 13.5
3.5 9.5 14.5 43 89.5
TABLE OF TIGHTENING TORQUES FOR O-RING BOSS PLUGS ★ Unless there are special instructions, tighten the O-ring boss plugs to the torque below.
Thread diameter
Width across flat
Tightening torque
mm
mm
Nm
kgm
08 10 12 14 16 18 20 24 30 33 36 42 52
14 17 19 22 24 27 30 32 32 n 36 n n
7.35 1.47 11.27 1.47 17.64 1.96 22.54 1.96 29.4 4.9 39.2 4.9 49 4.9 68.6 9.8 107.8 14.7 127.4 19.6 151.9 24.5 210.7 29.4 323.4 44.1
0 0 0 0 0 0 0 0 0 0 0 0 0
0.75 0.15 1.15 0.15 1.8 0.2 2.3 0.2 3 0.5 4 0.5 5 0.5 7 1 11 1.5 13 2 15.5 2.5 21.5 3 33 4.5
Norminal No.
08 10 12 14 16 18 20 24 30 33 36 42 52
0 0 0 0 0 0 0 0 0 0 0 0 0
00-13
FOREWORD
STANDARD TIGHTENING TORQUE
TIGHTENING TORQUE FOR 102 ENGINE SERIES 1) BOLT AND NUTS Use these torques for bolts and nuts (unit: mm) of Cummins Engine. Thread diameter
Tightening torque
mm
Nm
6 8 10 12
10 2 24 4 43 6 77 12
kgm
0 0 0 0
1.02 2.45 4.38 7.85
0 0.20 0 0.41 0 0.61 0 1.22
2) EYE JOINTS Use these torques for eye joints (unit: mm) of Cummins Engine. Thread diameter
Tightening torque
mm
Nm
6 8 10 12 14
8 2 10 2 12 2 24 4 36 5
kgm
0 0 0 0 0
0.81 1.02 1.22 2.45 3.67
0 0.20 0 0.20 0 0.20 0 0.41 0 0.51
3) TAPERED SCREWS Use these torques for tapered screws (unit: inch) of Cummins Engine. Thread diameter
Tightening torque
inch
Nm
1 / 16 1/8 1/4 3/8 1/2 3/4 1
3 1 8 2 12 2 15 2 24 4 36 5 60 9
kgm
0 0 0 0 0 0 0
0.31 0.81 1.22 1.53 2.45 3.67 6.12
0 0.10 0 0.20 0 0.20 0 0.41 0 0.41 0 0.51 0 0.92
TIGHTENING TORQUE TABLE FOR HOSES (TAPER SEAL TYPE AND FACE SEAL TYPE) ★ Tighten the hoses (taper seal type and face seal type) to the following torque, unless otherwise specified. ★ Apply the following torque when the threads are coated (wet) with engine oil. Tightening torque (Nm {kgm}) Nominal size Width across of hose flats
Taper seal type
Face seal type
Nominal thread Thread size size - Threads per Root diameter (mm) (mm) (Reference) inch, Thread series
Range
Target
19
35 - 63 {3.5 - 6.5}
44 {4.5}
14
9 – - 18UNF 16
14.3
22
54 - 93 {5.5 - 9.5}
74 {4.5}
–
11 – - 16UN 16
17.5
24
59 - 98 {6.0 - 10.0}
78 {8.0}
18
–
–
04
27
84 - 132 {8.5 - 13.5}
103 {10.5}
22
13 – - 16UN 16
20.7
05
32
128 - 186 {13.0 - 19.0}
157 {16.0}
24
1 - 14UNS
25.4
06
36
177 - 245 {18.0 - 25.0}
216 {22.0}
30
3 1 – - 12UNF 16
30.3
(10)
41
177 - 245 {18.0 - 25.0}
216 {22.0}
33
–
–
(12)
46
197 - 294 {20.0 - 30.0}
245 {25.0}
36
–
–
(14)
55
246 - 343 {25.0 - 35.0}
294 {30.0}
42
–
–
02
03
00-14
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
Copper wire Cable O.D. (mm)
Current rating (A)
Applicable circuit
0.88
2.4
12
Starting, lighting, signal etc.
0.32
2.09
3.1
20
Lighting, signal etc.
65
0.32
5.23
4.6
37
Charging and signal
15
84
0.45
13.36
7.0
59
Starting (Glow plug)
40
85
0.80
42.73
11.4
135
Starting
60
127
0.80
63.84
13.6
178
Starting
100
217
0.80
109.1
17.6
230
Starting
Norminal number
Number of strands
Dia. of strands (mm2)
Cross section (mm 2)
0.85
11
0.32
2
26
5
CLASSIFICATION BY COLOR AND CODE Circuits Priority Classification
1
Primary
Charging
Ground
Starting
Lighting
Instrument
Signal
Other
Code
W
B
B
R
Y
G
L
Color
White
Black
Black
Red
Yellow
Green
Blue
Code
WR
BW
RW
YR
GW
LW
2 Color White & Red Code
WB
3 Color White & Black Code 4
Auxiliary
WL
Color White & Blue Code
WG
5 Color White & Green Code 6 Color
n n
n n n n n n n n n n
White & Black Red & White Rellow & Red Green & White Blue & White BY
RB
YB
GR
LR
Black & Yellow Red & Black Yellow & Black Green & Red Blue & Yellow BR
RY
Black & Red Red & Yellow
n n n n
RG
YG
GY
LY
Yellow & Green
Green & Yellow
Blue & Yellow
YL
GB
LB
Red & Green Yellow & Blue Green & Black Blue & Black RL
YW
GL
Red & Blue Yellow & White Green & Blue
n n 00-15
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. (1) 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 , then draw a perpendicular line down from . (3) Take the point where the two lines cross as . This point gives the value when converting from millimeters to inches. Therefore, 55 mm = 2.165 inches. 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.
A B
C
C
A
B
B Millimeters to inches 1 mm = 0.03937 in
A
00-16
0
1
2
3
4
5
6
7
8
9
0 10 20 30 40
0 0.394 0.787 1.181 1.575
0.039 0.433 0.827 1.220 1.614
0.079 0.472 0.866 1.260 1.654
0.118 0.512 0.906 1.299 1.693
0.157 0.551 0.945 1.339 1.732
0.197 0.591 0.984 1.378 1.772
0.236 0.630 1.024 1.417 1.811
0.276 0.669 1.063 1.457 1.850
0.315 0.709 1.102 1.496 1.890
0.354 0.748 1.142 1.536 1.929
50 60 70 80 90
1.969 2.362 2.756 3.150 3.543
2.008 2.402 2.795 3.189 3.583
2.047 2.441 2.835 3.228 3.622
2.087 2.480 2.874 3.268 3.661
2.126 2.520 2.913 3.307 3.701
2.165 2.559 2.953 3.346 3.740
2.205 2.598 2.992 3.386 3.780
2.244 2.638 3.032 3.425 3.819
2.283 2.677 3.071 3.465 3.858
2.323 2.717 3.110 3.504 3.898
C
FOREWORD
CONVERSION TABLE
Millimeters to Inches 1 mm = 0.03937 in
0
1
2
3
4
5
6
7
8
9
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
0
Kilogram to Pound 1 kg = 2.2046 lb
0 0
0
1
2
3
4
5
6
7
8
9
2.20
4.41
6.61
8.82
11.02
13.23
15.43
17.64
19.84
10
22.05
24.25
26.46
28.66
30.86
33.07
35.27
37.48
39.68
41.89
20
44.09
46.30
48.50
50.71
51.91
55.12
57.32
59.53
61.73
63.93
30
66.14
68.34
70.55
72.75
74.96
77.16
79.37
81.57
83.78
85.98
40
88.18
90.39
92.59
94.80
97.00
99.21
101.41
103.62
105.82
108.03
50
110.23
112.44
114.64
116.85
119.05
121.25
123.46
125.66
127.87
130.07
60
132.28
134.48
136.69
138.89
141.10
143.30
145.51
147.71
149.91
152.12
70
154.32
156.53
158.73
160.94
163.14
165.35
167.55
169.76
171.96
174.17
80
176.37
178.57
180.78
182.98
185.19
187.39
189.60
191.80
194.01
196.21
90
198.42
200.62
202.83
205.03
207.24
209.44
211.64
213.85
216.05
218.26
00-17
FOREWORD
CONVERSION TABLE
Liter to U.S. Gallon 1l = 0.2642 U.S. Gal
0
1
2
3
4
5
6
7
8
9
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
0
Liter to U.K. Gallon 1l = 0.21997 U.K. Gal
0
1
2
3
4
5
6
7
8
9
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
0
00-18
FOREWORD
CONVERSION TABLE
kgm to ft. lb 1 kgm = 7.233 ft. lb
0
1
2
3
4
5
6
7
8
9
0
0
7.2
14.5
21.7
28.9
36.2
43.4
50.6
57.9
65.1
10
72.3
79.6
86.8
94.0
101.3
108.5
115.7
123.0
130.2
137.4
20
144.7
151.9
159.1
166.4
173.6
180.8
188.1
195.3
202.5
209.8
30
217.0
224.2
231.5
238.7
245.9
253.2
260.4
267.6
274.9
282.1
40
289.3
296.6
303.8
311.0
318.3
325.5
332.7
340.0
347.2
354.4
50
361.7
368.9
376.1
383.4
390.6
397.8
405.1
412.3
419.5
426.8
60
434.0
441.2
448.5
455.7
462.9
470.2
477.4
484.6
491.8
499.1
70
506.3
513.5
520.8
528.0
535.2
542.5
549.7
556.9
564.2
571.4
80
578.6
585.9
593.1
600.3
607.6
614.8
622.0
629.3
636.5
643.7
90
651.0
658.2
665.4
672.7
679.9
687.1
694.4
701.6
708.8
716.1
100
723.3
730.5
737.8
745.0
752.2
759.5
766.7
773.9
781.2
788.4
110
795.6
802.9
810.1
817.3
824.6
831.8
839.0
846.3
853.5
860.7
120
868.0
875.2
882.4
889.7
896.9
904.1
911.4
918.6
925.8
933.1
130
940.3
947.5
954.8
962.0
969.2
976.5
983.7
990.9
998.2
1005.4
140
1012.6
1019.9
1027.1
1034.3
1041.5
1048.8
1056.0
1063.2
1070.5
1077.7
150
1084.9
1092.2
1099.4
1106.6
1113.9
1121.1
1128.3
1135.6
1142.8
1150.0
160
1157.3
1164.5
1171.7
1179.0
1186.2
1193.4
1200.7
1207.9
1215.1
1222.4
170
1129.6
1236.8
1244.1
1251.3
1258.5
1265.8
1273.0
1280.1
1287.5
1294.7
180
1301.9
1309.2
1316.4
1323.6
1330.9
1338.1
1345.3
1352.6
1359.8
1367.0
190
1374.3
1381.5
1388.7
1396.0
1403.2
1410.4
1417.7
1424.9
1432.1
1439.4
00-19
FOREWORD
CONVERSION TABLE
kg/cm2 to lb/in2 1kg/cm2 = 14.2233 lb/in2
0
1
2
3
4
5
6
7
8
9
0
0
14.2
28.4
42.7
56.9
71.1
85.3
99.6
113.8
128.0
10
142.2
156.5
170.7
184.9
199.1
213.4
227.6
241.8
256.0
270.2
20
284.5
298.7
312.9
327.1
341.4
355.6
369.8
384.0
398.3
412.5
30
426.7
440.9
455.1
469.4
483.6
497.8
512.0
526.3
540.5
554.7
40
568.9
583.2
597.4
611.6
625.8
640.1
654.3
668.5
682.7
696.9
50
711.2
725.4
739.6
753.8
768.1
782.3
796.5
810.7
825.0
839.2
60
853.4
867.6
881.8
896.1
910.3
924.5
938.7
953.0
967.2
981.4
70
995.6
1010
1024
1038
1053
1067
1081
1095
1109
1124
80
1138
1152
1166
1181
1195
1209
1223
1237
1252
1266
90
1280
1294
1309
1323
1337
1351
1365
1380
1394
1408
100
1422
1437
1451
1465
1479
1493
1508
1522
1536
1550
110
1565
1579
1593
1607
1621
1636
1650
1664
1678
1693
120
1707
1721
1735
1749
1764
1778
1792
1806
1821
1835
130
1849
1863
1877
1892
1906
1920
1934
1949
1963
1977
140
1991
2005
2020
2034
2048
2062
2077
2091
2105
2119
150
2134
2148
2162
2176
2190
2205
2219
2233
2247
2262
160
2276
2290
2304
2318
2333
2347
2361
2375
2389
2404
170
2418
2432
2446
2460
2475
2489
2503
2518
2532
2546
180
2560
2574
2589
2603
2617
2631
2646
2660
2674
2688
190
2702
2717
2731
2745
2759
2773
2788
2802
2816
2830
200
2845
2859
2873
2887
2901
2916
2930
2944
2958
2973
210
2987
3001
3015
3030
3044
3058
3072
3086
3101
3115
220
3129
3143
3158
3172
3186
3200
3214
3229
3243
3257
230
3271
3286
3300
3314
3328
3343
3357
3371
3385
3399
240
3414
3428
3442
3456
3470
3485
3499
3513
3527
3542
00-20
FOREWORD
CONVERSION TABLE
Temperature Fahrenheit-Centigrade Conversion ; a simple way to convert a Fahrenheit temperature reading into a Centigrade temperature 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 –37.2 –34.4 –31.7 –28.9
–40 –35 –30 –25 –20
–40.0 –31.0 –22.0 –13.0 –4.0
–11.7 –11.1 –10.6 –10.0 –9.4
11 12 13 14 15
51.8 53.6 55.4 57.2 59.0
7.8 8.3 8.9 9.4 10.0
46 47 48 49 50
114.8 116.6 118.4 120.2 122.0
27.2 27.8 28.3 28.9 29.4
81 82 83 84 85
117.8 179.6 181.4 183.2 185.0
–28.3 –27.8 –27.2 –26.7 –26.1
–19 –18 –17 –16 –15
–2.2 –0.4 1.4 3.2 5.0
–8.9 –8.3 –7.8 –7.2 –6.7
16 17 18 19 20
60.8 62.6 64.4 66.2 68.0
10.6 11.1 11.7 12.2 12.8
51 52 53 54 55
123.8 125.6 127.4 129.2 131.0
30.0 30.6 31.1 31.7 32.2
86 87 88 89 90
186.8 188.6 190.4 192.2 194.0
–25.6 –25.0 –24.4 –23.9 –23.3
–14 –13 –12 –11 –10
6.8 8.6 10.4 12.2 14.0
–6.1 –5.6 –5.0 –4.4 –3.9
21 22 23 24 25
69.8 71.6 73.4 75.2 77.0
13.3 13.9 14.4 15.0 15.6
56 57 58 59 0
132.8 134.6 136.4 138.2 140.0
32.8 33.3 33.9 34.4 35.0
91 92 93 94 95
195.8 197.6 199.4 201.2 203.0
–22.8 –22.2 –21.7 –21.1 –20.6
–9 –8 –7 –6 –5
15.8 17.6 19.4 21.2 23.0
–3.3 –2.8 –2.2 –1.7 –1.1
26 27 28 29 30
78.8 80.6 82.4 84.2 86.0
16.1 16.7 17.2 17.8 18.3
61 62 63 64 65
141.8 143.6 145.4 147.2 149.0
35.6 36.1 36.7 37.2 37.8
96 97 98 99 100
204.8 206.6 208.4 210.2 212.0
–20.0 –19.4 –18.9 –18.3 –17.8
–4 –3 –2 –1 0
24.8 26.6 28.4 30.2 32.0
–0.6 0 0.6 1.1 1.7
31 32 33 34 35
87.8 89.6 91.4 93.2 95.0
18.9 19.4 20.0 20.6 21.1
66 67 68 69 70
150.8 152.6 154.4 156.2 158.0
40.6 43.3 46.1 48.9 51.7
105 110 115 120 125
221.0 230.0 239.0 248.0 257.0
–17.2 –16.7 –16.1 –15.6 –15.0
1 2 3 4 5
33.8 35.6 37.4 39.2 41.0
2.2 2.8 3.3 3.9 4.4
36 37 38 39 40
96.8 98.6 100.4 102.2 104.0
21.7 22.2 22.8 23.3 23.9
71 72 73 74 75
159.8 161.6 163.4 165.2 167.0
54.4 57.2 60.0 62.7 65.6
130 135 140 145 150
266.0 275.0 284.0 293.0 302.0
–14.4 –13.9 –13.3 –12.8 –12.2
6 7 8 9 10
42.8 44.6 46.4 48.2 50.0
5.0 5.6 6.1 6.7 7.2
41 42 43 44 45
105.8 107.6 109.4 111.2 113.0
24.4 25.0 25.6 26.1 26.7
76 77 78 79 80
168.8 170.6 172.4 174.2 176.0
68.3 71.1 73.9 76.7 79.4
155 160 165 170 175
311.0 320.0 329.0 338.0 347.0
00-21
FOREWORD
UNITS
UNITS In this manual, the measuring units are indicated with Internatinal System of units (SI). As for reference, conventionally used Gravitational System of units are indicated in parentheses { Example: N {kg} Nm {kgm} MPa {kg/cm2} kPa {mmH2O} kPa {mmHg} kW/rpm {HP/rpm} g/kWh {g/HPh}
00-22
}.
01
GENERAL
General assembly drawing.. .......................... Specifications .. ............................................... Weight table .................................................... List of lubricants and coolant ........................
PC128UU-2
01-2 01-4 01-7 01-S
01-l
GENERAL
GENERAL ASSEMBLY
DRAWING
GENERAL ASSEMBLY DRAWING 500mm-WIDE
SHOE SPECIFICATION (WITH ROAD LINER SHOE) Unit : mm
2490
t--J 1245
9JB00124
The sizes in ( ) are applicable when the machine is equipped with the iron shoe. %l : indicates the size when the offset is 0. %2 : indicates the size when the cab is prevented from interference.
01-2
PC1 28UU-2
GENERAL ASSEMBLY DRAWING
GENERAL
600mm-WIDE
SHOE SPEClFlCATlOh
’ Unit : mm
7435
c 4960
2475
SJPO7601
The sizes in ( ) are applicable when the machine is equipped with the iron shoe. II : indicates the size when the offset is 0. %2 : indicates the size when the cab is prevented from interference. PC128UU-2
01-3
SPECIFICATIONS
GENERAL
SPECIFICATIONS
F
Machine model’
Serial No.
5001 and up
500mm-wide shoe specification
600mm-wide shoe specification
Bucket capacity (SAE)
m3
0.45
0.45
Operating weight
kg
13,400
13,500
Max. digging depth
mm
4,865 [4,800]
4,865 [4,880]
Max. vertical wall depth
mm
3,305 [3,240]
3,305 [3,240]
Max. digging reach
mm
7,285
7,285
2
Max. reach st ground level
mm
7,135
z E
7,145 [7,1351
Max. digging height
mm
8,150 [8,215]
8,150 [8,215]
-
8
c”
P
Max. dumping height
mm
5,850 [5,915]
5,850 [5,715]
Bucket offset amount (left/right)
mm
1,170/1,150
1,170/1,150
Max. blade lifting amount
mm
465 [530]
465 [530]
Max. blade lowering amount
mm
520 [455]
520 [455]
KN (kg]
84.3 (8,600)
84.3 (8,600)
Swing speed
rpm
10
10
Swing max. slope angle
deg.
16
16
Travel speed (Hi/Lo)
km/h
4.613.2
4.613.2
Gradeability
deg.
35
35
kPa {kg/cm*]
36.7 (0.37)
36.7 (0.37)
Overall length (for transport)
mm
7,400
7,455 [7,4001
Overall width
mm
2,490
2,590
Overall width of track
mm
2,490
Overall height (for transport)
mm
2,755 [2,795]
2,755 [2,795]
Overall height to top of cab
mm
2,730 [2,795]
2,730 [2,795]
Ground clearance of counterweight
mm
855 [920]
855 [920]
Min. ground clearance
mm
390 [4551
390 [4551
Tail swing radius
mm
1,480
1,480
mm
1,345 (% 1,450)
1,345 (% 1,450)
-
Max. digging force (bucket)
Ground pressure (standard shoe width: 500 mm)
Min. swing radius of work euipment (when the offset is 0) Height of work equipment at min. swing radius
*
PC1 28UU-2
mm
6,285 [6,350] 6% 6,260 [6,325])
6,285 [6,350] (% 6,260 [6,325])
Distance between centers of idler and sprocket
mm
2,750
2,750
Track gauge
mm
1,990
1,990
Overall length of track
mm
3,480 [3,560]
3,480 [3,560]
Machine cab height
mm
1,935 [2,0001
1,935 [2,000]
Blade width x height
mm
2,490 x 590
2,490 x 590
‘he values shown in the [ ] are tt lose for the machines when the road I ter shoe is equipped. The value marked with % indicates the size when the cab is prevented from interference.
01-4
PC128UU-2
SPECIFICATIONS
GENERAL
PC1 28UU-2
Machine model
500mm-wide shoe specification
Serial No.
5001 and up 600mm-wide shoe specification S4D102E-1
Model.
4-cycle, water-cooled, in-line, vertical, direct injection, with turbochatger
Type No. of cylinders-bore
mm
x stroke
Piston displacement
3.92 (3,920)
Q{cc}
Flywheel horsepower Maximum
4-102xl2u
64/2,200 (8712,200)
IV/rpm{HP/rpm)
torpue
329/I ,300 {33.5/1,300)
High idling speed
rpm
2,400
Low idling speed
vm
950
j/kWh{g/HPh}
224 {I 65)
Min. fuel consumption
ratio
7
Starting motor Alternator Battery Radiator type
24U, 4.5 kw 24U, 25A 12U,64Ahx2
I
12U, 72Ah x 2
I CFI 9-4 1 on each side
Carrier roller
7 on each side
Track roller
Asembly-type triple grouster, 42 on each side [Road liner, 42 on each side]
Track shoe
HPU95 (105cc/rev.) Variable displacement
Type x no. Discharge Set pressure (at operation)
piston type x 1
Q /min
226
VIPa {kg/cm?
31.9 (325) 34.8 (355)
(at traveling)
8-spool type x 1
Type x no.
Hydraulic type
Control method
GM18UL-J Travel motor
Variable displacement piston type (with brake valve, parking brake) x 2 KMF40AEL-3 Fixed displacement piston type (with shockless safety valve, holding brake) x 1
Swing motor
Hydraulic tank Hydraulic filter Hydraulic oil cooler
‘he values shown in the [
PC128UU-2
1 are
lose for the machines
when the road liner shoe is equipped.
SPECIFICATIONS
GENERAL
PC128UU-2
Machine model Serial No.
5001 and up Reciprocating
Type cylinder (inside diameter)
mm
105
Diameter of pistonrod
mm
70
Stroke
mm
1,055
Max. distance between pins
mm
2,555
Min. distance between pins
mm
1,500 Reciprocating
fype Cylinder (inside diameter)
mm
115
Diameter of pistonrod
mm
75
Stroke
mm
272.5
Max. distance between pins
mm
1,230.5
Min. distance between pins
mm
958 Reciprocating
Type Cylinder (inside diameter)
mm
90
Diameter of pistonrod
mm
60
Stroke
mm
885
Max. distance between pins
mm
2,263
Min. distance between pins
mm
1,378 Reciprocating
Type Cylinder (inside diameter)
mm
130
Diameter of pistonrod
mm
70
Stroke
mm
346
Max. distance between pins
mm
1,818
iin.
mm
1,472
distance between pins
Reciprocating
Type
01-6
Cylinder (inside diameter)
mm
115
Diameter of pistonrod
mm
75
Stroke
mm
181
Max. distance between pins
mm
870
Min. distance between pins
mm
689
piston
piston
piston
piston
piston
PC128UU-2
WEIGHT TABLE
GENERAL
WEIGHT TABLE
A
This mass list is for reference
in handling
or transporting
these components.
Machine model
PC1 28UU-2
Serial No.
5001 and up
Engine assembly (without water and oil) Engine (without water and oil)
385
l
Engine mount
5.8
l
PTO
4.1
l
Hydraulic pump
80
Revolving frame
54 1,500
Operator cab
220
Operator seat
12.6
Fuel tank (without fuel)
98
Hydraulic tank (without hydraulic oil)
92
Control valve
106
Self pressure reducing valve
4.8
Counterweight
ko
510
l
Radiator/oil cooler assembly
Unit:
1,880
Swing motor (with brake valve)
26
Swing circle
155
Swing machinery
72.2
Center swivel joint
43.6
Track frame assembly
2,590
l
Track fram.e
1,438
l
Idler assembly
81 x2
l
Recoil spring assembly
l
Carrier roller
11 x2
l
Track roller
21 x 14
l
Travel motor (with speed reducer)
144x2
l
Sprocket
33.7 x 2
72.9 x 2
Track shoe assembly l
Road liner (500mm)
770 x 2
l
Triple grouser shoe (500mm)
740 x 2
l
Triple grouser shoe (600mm)
830 x 2
l
Triple grouser shoe (700)
925 x 2
l
Swamp shoe (750mm)
875 x 2
l
Flat shoe (480mm)
760 x 2
PC1 28UU-2
01-7
WEIGHT TABLE
GENERAL
Unit: kg Machine model
PC1 28UU-2
Serial No.
5001 and up
Boom assembly l
1st boom
536
l
2nd boom
337
l
3rd bracket
217
l
Sub-link
51
Arm assembly
300
Bucket link assembly
85.6
Bucket assembly (with 955mm-wide Blade assembly Boom cylinder assembly
side cutter)
369 647 106.3x2
Arm cylinder assembly
136.9
Bucket cylinder assembly
75.8
Offset cylinder assembly
86.1
Blade cylinder assembly
67.2 x 2
01-8
PC1 28UU-2
GENERAL
LIST OF LUBRICANTS
AND COOLANT
LIST OF LUBRICANTS AND COOLANT RESERVOIR
KIND OF FLUID
AMBIENT TEMPERATURE 22 30
-4 -20
14 -10
32 0
50 10
68 20
86 30
104°F 40°C
T
CAPACITY (!2)
jpecified
Refill
Engine oil pan
17.5
17.0
PTO case
0.75
0.75
2.5
2.5
2.5
2.5
0.090
-
Swing machiney case Final drive casse (each)
!ngine oil
Idler (each)
~.lOO-0.115
Track roller (each)
I I I
Carrier roller (each)
I I I I I
Hydraulic system
-
0.072
-
120
69
195
-
18.2
-
iydraulic Iii
Fuel tank
3iesel fue
Cooling system
Zoolant
PC128UU-2
Add antifreeze
I
I
01-9
LIST OF LUBRICANTS
GENERAL
AND COOLANT
NOTE:
(1) When fuel sulphur
content is less than 0.5%, change oil in the oil pan every periodic maintenance hours described in manual. Change oil according to the following table if fuel sulphur content is above 0.5%. Fuel sulphur content
Change interval of oil in enaine oil Dan
0.5 to 1 .O%
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 SAE 1OW, SAEI OW-30 and SAEI 5W-40, even though an atmospheric temperature goes up to 10°C more or less in the day time. Use API classification CD as engine oil and if API (3) classification CC, reduce the engine oil change interval to half. There is no problem if single grade oil is mixed (4) with multigrade oil (SAEIOW-30,15W-401, but be sure to add single grade oil that matches the temperature in the table on the left. We recommend Komatsu genuine oil which has (5) been specifically formulated and approved for use in engine and hydraulic work equipment applications. * For the H046-HM, use the oil recommended by Komatsu. ASTM: SAE: API:
American Society of Testing and Material Society of Automotive Engineers American Petroleum Institute
Specified capacity: Total amount of oil including oil for components and oil in piping. Refill capacity: Amount of oil needed to refill system during normal inspection and maintenance.
01-10
PC128UU-2
10 STRUCTURE AND FUNCTION
PTO .............................................................. Radiator and oil cooler ............................... Power train.. ................................................ Swing circle ................................................ Swing machinery ....................................... Track frame ................................................. Idler cushion ............................................... Hydraulic equipment layout drawing.. ..... Valve control ............................................... Hydraulic tank and filter.. ........................... Hydraulic pump (Piston pump). ................ Control valve.. ............................................. Suction safety valve ................................... CLSS ............................................................ Self pressure reducing valve.. ................... Center swivel joint.. .................................... Travel motor ....................... t.. ..................... Swing motor.. ............................................. Solenoid valve ............................................ EPC solenoid valve ..................................... PPC accumulator ........................................ PPC valve .................................................... Air-conditioner piping ....... .;....................... Electric equipment layout drawing.. ......... Engine control ............................................ Electric control system.. ............................. Qsystem ...................................................... Monitor system ................. .:.......................
PC1 28UU-2
IO- 2 lo3 lo5 IO- 6 lo7 lo8 lo9 lo- IO IO- 12 IO- 13 lo- 14 lo- 35 lo- 46 lo- 47 lo- 84 lo- 90 IO- 91 IO-100 1O-l 08 1O-l 10 IO-1 15 1O-l 16 lo-127 lo-128 lo-132 IO-140 1O-l 51 lo-174
10-l
STRUCTURE
AND FUNCTION
PTO
PTO
A-A
B-B
9JA01326
1. 2. 3. 4.
Coupling Shaft Breather Gauge
1o-2
5. 6. 7.
Hydraulic pump Oil filler plug Level plug
PC128UU-2
STRUCTURE
AND FUNCTION
RADIATOR AND OIL COOLER
RADIATOR AND OIL COOLER
9JA01327
PC128UU-2
1o-3
STRUCTURE
RADIATOR AND OIL COOLER
AND FUNCTION
Y 9JA01328
1. Oil cooler 2. Radiator 3. Shroud 4. Reservoir tank 5. Oil cooler outlet 6. Oil cooler inlet * 7. Radiator cap 8. Radiator inlet hose 9. Radiator outlet hose 10. Drain valve 11. Fan
1o-4
SPECIFICATION Radiator Core type : CF19-4 Fin pitch : 3.5/2 mm Total heat dissipation surface : 34.06 m* Pressure valve cracking pressure : 49.0 + 14.7 kPa (0.5 & 0.15 kg/cm? Vacuum valve cracking pressure : -4.9 - 0 kPa (-0.05 - 0 kg/cm*) Oil cooler Core type : CF40-1 Fin pitch : 4.512 mm Total heat dissipation surface : 8.79 m*
PC128UU-2
STRUCTURE
POWER TRAIN
AND FUNCTION
POWER TRAIN
9JAOl329
1. 2. 3. 4. 5. 6. 7.
Idler Control valve Self pressure reducing valve PPC lock solenoid valve 2-speed travel changeover solenoid valve Swing hold brake solenoid valve 2-stage relief solenoid valve
PC1 28UU-2
8. 9. 10. 11. 12. 13. 14.
Travel motor Hydraulic pump Engine Swing motor Center swivel joint Swing machinery Swing circle
1o-5
STRUCTURE
AND FUNCTION
SWING CIRCLE
SWING CIRCLE
-
5 4 3 A-A
B-B
‘I
c-c
l--A
9JA01330
1. 2. 4. 5. 6.
Greasing to swing circle bearing Greasing to swing circle pinion Seal Ball Inner race
a. b.
Inner race soft zone position Outer race soft zone position
1 O-6
Specification Reduction ratio : 90/l 1 = 8.182 Grease : G2-LI Amount of filled grease : 9.1 f?
PC1 28UU-2
STRUCTURE
SWING MACHINERY
AND FUNCTION
SWING MACHINERY
0
---I
‘--L
:\c iK l\i ‘\
I
A
t
A-A
.I
9JA01331
1. 2. 3. 4. 5. 6. 7. 8. 9. IO. 11. 12. 13. 14.
Swing pinion (number of teeth : 1 I) Case No. 2 sun gear (number of teeth : 17) No. 2 planetary carrier (number of teeth Ring gear (number of teeth : 61) No. 1 planetary carrier (number of teeth No. 1 sun gear (number of teeth : 14) Oil filler port Swing motor Level gauge No. 1 planetary gear (number of teeth : No. 2 planetary gear (number of teeth :
: 17) : 17)
Specification Reductionratio:(14+61)/14x(17+61)/17=24.58 Swing reduction ratio : 201.11 : 12 rpm Swing speed Lubricating oil : EOBO-CD Lubricating oil amount : 2.5 k?
24) 22)
Drain plug Swing circle (number of teeth : 90)
PC1 28UU-2
1o-7
STRUCTURE
AND FUNCTION
TRACK FRAME
TRACK FRAME
d
i 9JEOO125
1. 2. 3. 4.
idler Track frame Carrier roller Travel motor
1 O-8
5. 6. 7. 8.
Sprocket Track roller Idler cushion Track shoe
PC1 28UU-2
STRUCTURE
AND FUNCTION
IDLER CUSHION
IDLER CUSHION
F==---
-__
__~__
______
95800126
1. 2. 3. 4. 5. 6. 7. 8. 9. 10.
Idler support Yoke Cylinder Recoil spring U-packing Pilot Nut Valve Grease fitting
PC1 28UU-2
Specification Grease : G2-LI Amount of filled grease : 140 cc
1o-9
STRUCTURE
HYDRAULIC
AND FUNCTION
HYDRAULIC EQUIPMENT
EQUIPMENT
LAYOUT DRAWING
LAYOUT DRAWING
-I1. Bucket cylinder 2. Arm cylinder 3. Offset cylinder 4. Boom cylinder 5. Hydraulic tank 6. Swing motor 7. Hydraulic pump 8. Oil cooler 9. L.H. travel motor 10. L.H. work equipment PPC valve 11. Blade PPC valve 12. R.H. work equipment PPC valve 13. Center swivel joint 14. Travel PPC valve 15. Offset PPC valve 16. 5-spool EPC solenoid valve l Boom lower stop EPC valve l Arm curl stop EPC valve l Boom raise stop EPC valve l Offset left stop solenoid valve l Offset right stop solenoid valve Blade cylinder 17. Self pressure reducing valve 18. Control valve 19. 20. 4-spool solenoid valve PPC lock solenoid valve 2-speed travel changeover solenoid valve Swing holding brake solenoid valve 2-stage relief solenoid valve
9JBOO127
10-10
+
PC128UU-2
STRUCTURE
AND FUNCTION
HYDRAULIC
EQUIPMENT
LAYOUT DRAWING
+
9J800128
P;c128UU-2
10-11
STRUCTURE
VALVE CONTROL
AND FUNCTION
VALVE CONTROL 7
I6 1. Control valve
2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18.
R.H. work equipment PPC valve Blade PPC valve 5-spool EPC solenoid valve 4-spool solenoid valve R.H. work equipment control lever -(for controlling boom and bucket) Blade control lever L.H. work equipment control lever (for controlling arm and swing) L.H. work equipment PPC valve Safety lock lever Travel accelerator pedal L.H. travel pedal R.H. travel pedal Travel PPC valve Left travel lever Right travel lever Offset PPC valve Offset pedal
10-12
I5
i4
13
‘I2
‘II
9JBOO129
Lever and pedal position (I) HOLD (2) Boom “LOWER” (3) Boom “RAISE” (4) Bucket “CURL” (5) Bucket “DUMP” (6) HOLD (7) Arm “DUMP” (8) Arm “CURL” (9) Swing “LEFT” (10) Swing “RIGHT” (11) L.H. travel “FORWARD” (12) L.H. travel “REVERSE” (13) R.H. travel “FORWARD” (14) R.H. travel “REVERSE” (15) PPC “FREE” (16) PPC “LOCK” . (17) Blade “RAISE” (18) Blade “LOWER” (I 9) Travel “Lo” (20) Travel “Hi” (21) Offset “LEFT” (22) Offset “RIGHT” PC128UU-2
HYDRAULIC
STRUCTURE AND FUNCTION
TANK AND FILTER
HYDRAULIC TANK AND FILTER
8
9
10
A-A
9JA01337
1. 2. 3. 4. 5. 6. 7. 8. 9. 10.
Hydraulic tank Filter rlement Bypass valve Bypass strainer Suction strainer Drain plug Sight gauge Oil filler cap Pressure valve Vacuum valve
PC1 28UU-2
Specification Tank capacity : 99 f? Hydraulic oil amount in tank : 69 f? Pressure valve cracking pressure : 16.7 + 6.9 kPa (0.17 f 0.07 kg/cm? Vacuum valve cracking pressure : -0.49 - 0 kPa (-0.005 - 0 kg/cm*} Bypass valve set pressure : 103 f 19.6 kPa (1.05 f 0.2 kg/cm*}
10-13
STRUCTURE
AND FUNCTION
HYDRAULIC
PUMP
HYDRAULIC PUMP (PISTON PUMP) MAIN PUMP Type : HPV95 (for 105cdrev.j
+
X
PD
/
PLS
PB
PA
A _i
Y
1. 2. 3. 4. 5.
Main pump LS valve PC valve Fixed throttle valve PC-EPC valve (for changing
10-14
PC mode)
IM : PA : PB : PD : PEPC PLS : PS :
9JUOOO74
PC mode changeover current Main pump delivery Main pump pressure input Main pump drain : EPC valve source pressure inlet Control valve LS pressure inlet Main pump absorption
PC1 28UU-2
STRUCTURE
AND FUNCTION
HYDRAULIC
A-A
PUMP
IO
D4 D-D B-B
1. 2. 3. 4. 5. 6. 7.
Shaft Cradle Case Rocker cam Shoe Piston Cylinder block
PC128UU-2
8. 9. 10. 11. 12. 13.
9JUOOO76
Valve plate End cap Spring Servo last chance filter Servo piston Slider
10-15
STRUCTURE
HYDRAULIC
AND FUNCTION
PUMP
Function l This pump converts engine rotation and torque transmitted to the pump shaft into hydraulic energy and’discharges pressurized oil according to load. l This pump can change delivery when the swash plate angle is changed.
IO A-A
9JUOOO77
Structure The cylinder block (7) is supported to the shaft l (1) with the spline a, and the shaft (1) is supported with the front and rear bearings. The shoe (5) is punched to the tip of the pisl ton (6) with a concave ball so that the piston (6) and the shoe (5) form a spherical bearing. The shoe (5) is always pressed to the plane A l of the rocker cam (4) and slides in a circle. The rocker cam (4) leads highly pressurized oil together with the cylindrical plane B with the cradle (2) fixed to the case, forms a static pressure bearing and slides. The piston (6) moves in the axial direction relal tively in each cylinder of the cylinder block l
l
(7). The cylinder block (7) rotates relatively while sealing pressurized oil against the valve plate (8), and the plane is designed to balance the oil pressure properly. Oil in each cylinder of the cylinder block (7) is absorbed and discharged through the valve plate (8).
JO-16
PC1 28UU-2
STRUCTURE
’ .
HYDRAULIC
AND FUNCTION
PUMP
Operation 1. Pump Operation l The shaft (1) rotates together with the cylinder block (71, and the shoe (5) slides on the plate A. When the rocker arm (4) moves along the cylindrical plane B, the inclination ato the centerline X of the rocker cam (4) and the axial direction of the cylinder block (7) changes. The inclination a is called “swash plate angle.”
B
l
l
l
l
l
SLPOOl63
When the swash plate angle of the center line X of the rocker cam (4) is a to the axial direction of the cylinder block (71, the plane A works like the cam against the shoe (5). Therefore, the piston (6) slides inside the cylinder block (71, and the capacities E and F of the cylinder block (7) come to change differently. Then, the pump absorbs and discharges the difference E-F. When the capacity in the E chamber contracts as the cylinder block (7) rotates, the pump discharges oil during the process. On the other hand, when the capacity in the F chamber increases, the pump absorbs oil during the process. (The figure shows the end of the absorbing process in the Chamber F and the end of the discharging process in the Chamber E. When the centerline X of the rocker cam (4) comes to the axial direction of the cylinder block (7) (when the swash plate angle is 01, the difference between the capacities E and F in the cylinder block (7) comes to 0. And the pump comes to stop absorbing or discharging oil, i.e., the pump stops. (However, the swash plate angle never comes to 0 practically.) In the other words, the swash plate angle a and the pump delivery are in the proportional relations.
PC128UU-2
SLPOOl64
F
X
4
7
9JUOOO80
10-17
STRUCTURE AND FUNCTION
HYDRAULIC
PUMP
Delivery Control When the swash plate angle a increases, the difference between the capacities E and F becomes larger and the delivery Q increases. The servo piston (12) changes the swash plate angle a. The servo piston moves in the direction of according to signal straight reciprocation This pressures of the PC and LS valves. straight motion is transmitted to the rocker arm (4) through the slider (131, and the rocker cam (4), which is supported with the cylindrical plane to the cradle (2), slides in the direction of rotation. 9JUOOO81
l
l
l
.
The servo piston’s (12) area receiving the pressure is different on the right and left sides, and the discharge (self) pressure PP from the main pump is always led to the pressure chamber of the small diameter piston. The output pressure Pen of the LS valve is led to the pressure chamber of the large diameter piston. Motions of the servo piston are controlled according to the relations between the small diameter piston pressure PP and the large diameter piston pressure Pen and the rate of area receiving pressure of the small diameter piston to that of the large diameter piston.
12
I3
9JUOOO82
lo-18
PC128UU-2
STRUCTURE
HYDRAULIC
AND FUNCTION
PUMP
LS AND PC VALVES LS Valve
PiS
PA
PLP
PPL
PD
PS IG
PA 9JUOOO84
1. 2. 3. 4. 5. 6. 7. 8.
Plug Lock nut Sleeve Spring Seat Spool Piston Sleeve
A PD PLP PLS PPL PSIG
: Pump discharge pressure inlet : Drain pressure outlet : LS valve signal pressure outlet : Control valve LS pressure inlet : PC valve signal pressure inlet : EPC valve output pressure inlet of LS control
PC Valve
9JUOOO85
1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11.
Piston Spring Seat Spring Seat Spool Piston Sleeve Lock nut Plug Lock nut
PC1 28UU-2
PA PA2 PD PM PPL
: : : : :
Pump discharge pressure inlet Pump discharge pressure inlet Drain pressure outlet PC mode switching pressure inlet PC valve signal pressure outlet
10-19
STRUCTURE
AND FUNCTION
HYDRAULIC
PUMP
FIXED THROTTLE VALVE
POUT
PIN
9JUOOO86
1. Plug 2. Plug PA : Drain pressure outlet POUT : Control pressure outlet PIN : LS valve signal pressure inlet
1O-20
PC1 28UU-2
STRUCTURE
Function 1. LS Valve . The LS valve controls pump delivery to stroke of the control lever, i.e., requested flows of the actuator. . The LS valve detects requested flow of the actuator from the differential pressure, APLS, between the pump discharge pressure, PP, and the control valve outlet pressure, PLS, to control the pump delivery Q. (Discharge pressure is called PP, the LS pressure PLS and the LS differential pressure APLS.) . This valve detects pressure loss (=LS differential pressure APLS) caused by pump flow passing through the opening area of the control valve spool, controls the pump delivery Q so that the pressure loss remains constant all the time and supplies pump deliveries requested by the actuator. . The relations between the LS differential pressure (APLS) between the pump discharge pressure PP and the LS pressure (PLS) and the pump delivery Q are as shown in the right figure. 2. .
.
.
.
.
PC Valve When the pump discharge pressure PP rises, the control valve spool stroke will increase and the opening area will enlarge. So, the PC valve controls the pump delivery Q so that the delivery Q does not increase above a certain level depending on the discharge pressure PP. The valve also controls the pump absorbing hydraulic horsepower to approximately equal horsepower so that the pump absorbing horsepower does not exceed the engine horsepower. This means that, when a load to the actuator increases during operation and the pump discharge pressure PP rises, this valve will reduce the pump delivery 0, or when the pump discharge pressure PP drops, this valve will increase the delivery 0. In this case, the relations between the pump discharge pressure PP and the pump delivery Qchange as shown in the right figure since the current value given to the PC-EPC valve solenoid is regarded as a parameter. However, some PC valves have the function to sense actual engine speeds in the heavyduty operation mode and to reduce the pump delivery and recover the speed when the speed reduces due to increase of load. In the other words, when an increase of load reduces the engine speed below the set value, the command current from the controller to the PC-EPC valve solenoid will increase as the engine speed reduces and will reduce the pump swash plate angle.
PC1 28UU-2
HYDRAULIC
AND FUNCTION
k/m
PUMP
i n)
I
z c I 2. 2122. LS differential
51
IMPaIta/cl’l)
Dressure
SVPO7602
Q c z :
X=0.
PumP discharge
Pressure
26A
PP SDP02556
10-21
STRUCTURE
HYDRAULIC
AND FUNCTION
PUMP
Operation
lin ve
Direction small
1.
to diameter
SVPO7604
LS Valve 1) When the control valve is at the center value position The LS valve is a 3-way selector valve, and l the pressure PLS (LS pressure) from the control valve inlet is being led to the spring chamber B and the pump discharge pressure PP is being led to the H port of the sleeve (8). The spool (6) position is determined del pending on the force of the LS pressure PLS + the force of spring (4) 2 and the force of the pump discharge pressure (self-pressure) PP.
1o-22
PC1 28UU-2
STRUCTURE
l
l
l
Before the engine starts, the servo piston (12) is pressed to the right side. (See the right figure.) If the control lever is at the “centervalue” position when the engine starts, the LS pressure PLS will be 0 MPa (0 kg/cm*). (The LS valve interconnects to the drain circuit through the control valve spool.) At the time, the spool (6) is pressed to the left side and the C port is connected to the D port. The pump discharge pressure enters from the K port to the piston large diameter side and from the J port to the piston small diameter side respectively. So, the area difference of the servo piston (12) minimizes the swash plate angle.
PC1 28UU-2
HYDRAULIC
AND FUNCTION
A-A
PUMP
9JUOOO89
1 O-23
STRUCTURE
AND FUNCTION
HYDRAULIC
PUMP
PLS
@--I
t
Direction to large diameter
a .
.
1 O-24
Operation in the direction to increase pump delivery When the difference between the pump discharge pressure PP and the LS pressure PLS, i.e., LS differential pressure APLS, reduces (for example, when the control valve opening area increases and the discharge pressure PP drops), the combined force of the LS pressure PLS and the spring (4) force will push the spool (6) to the right side. When the spool (6) moves, the circuit between the D port and the E port will open and the LS valve will be connected to the PC valve. At the time, the PC valve is connected to the drain port, and the drain pressure PT is applied to the circuit D-K. (The operation of the PC valve will be explained later.)
l
SVPO7605
Therefore, the pressure on the large diameter side of the servo piston (12) becomes equal to the drain pressure PT. Since the pump discharge pressure PP is applied to the J port on the small diameter side, the servo piston (12) is pushed to the right side and the swash plate is moved in the direction where the delivery increases.
PC1 28UU-2
STRUCTURE
AND FUNCTION
HYDRAULIC
PC valve
PUMP
PT
PLS lin ve
@--I
Direction to small diameter
3) l
l
Operation in the direction to reduce pump delivery When the servo piston (12) moves to the left side (in the direction to reduce the pump delivery), the LS differential pressure APLS will increase (for example, the control valve opening area decreases and the pump discharge pressure PP increases) and the force of the discharge pressure PP will push the spool (6) to the left side. When the spool (6) moves, the pump discharge pressure PP will be forwarded from the C port to the D port and will come from the K port to the piston large diameter side.
PC128UU-2
l
SVPO7606
Since the pump discharge pressure PP is applied to the J port on the piston small diameter side, the servo piston (12) is pressed to the left side due to the area difference between the large diameter side and the small diameter side of the servo piston (12). So, the swash plate is moved in the direction where the delivery is reduced.
1 O-25
STRUCTURE
AND FUNCTION
HYDRAULIC
PUMP
in ve
PEN -0
ii
SVPO7607
4) l
l
1 O-26
When the servo piston balances Suppose that the area receiving pressure on the piston large diameter side is Al, the area on the piston small diameter side is A0 and the pressure applied to the piston large diameter side is PEN. When the pump discharge pressure PP of the LS valve balances with the combined force of the LS pressure PLS and the spring (4) force 2 and the relations A0 x PP = Al x PEN hold, the servo piston (12) will stop at the position and the swash plate angle will be held at the intermediate position. (The openings of the D port to the E port and of the C port to the D port of the spool (6) stop almost at the same position.)
At the time, the relations of the areas receiving pressure at the both ends of the servo piston are A0 : Al = 1 : 1.75. When they balance with each other, the pressures applied to the both ends of the piston are related as follows: PP : PEN + 1.75 : 1. The spring (4) force has been adjusted so that the spool (6) balance stop position is determined at the center of the standard when PP-PLS = 2.21 MPa (22.5kg/cm2).
PC1 28UU-2
STRUCTURE
AND FUNCTION
HYDRAULIC
PUMP
‘0 m ain -
// I,
Emergency drive switch I^
Direct small Pump
ibn to diameter
0 F F ,, ’
va
IVe
Di rect;on to large diameter Pump controller
I, ‘I
_
ON Resistor
SVPO7608
2.
PC Valve 1) When the pump controller is normal, the load to the actuator is small and the pump discharge pressure PP is low a. Function of PC-EPC Valve Solenoid (1) l The pump controller provides a command current to the PC-EPC valve solenoid (1). This command current actuates the PC-EPC valve and outputs a signal pressure. When receiving the signal pressure, the PC valve changes the force given to the piston (2). l The spool (3) stops where the force to the piston (2) balances with the combined force of the spring setting force of the springs (4) and (6) on the opposite side and the force given to the spool (3) by the pump discharge pres-
PC128UU-2
l
sure PP. And the pressure output from the PC valve (the pressure at the C port) varies with the spool position. The value of the command current X is determined depending on type of work (lever control), selection of working mode, set point of engine speed and actual speed.
1 O-27
STRUCTURE
HYDRAULIC
AND FUNCTION
Pi lot
PUMP
Pressure main valve -
Emergency pump drive switch
SVPO7609
b. l
l
l
1 O-28
Function of Spring The loads to the springs (4) and (6) of the PC valve are determined depending on swash plate position. As the servo piston (9) moves, the piston (7) connected to the slider (8) moves to the right or the left. When the piston (7) moves to the left, the spring (6) will be contracted. If the piston moves further to the left, the spring will be brought to the seat (5) and be fixed there. Thereafter, the spring (4) will only move. This means that the spring load changes as the piston (7) extends or contracts the springs (4) and (6).
l
Also, since the pressing force of the piston (2) changes as the command current input to the PC-EPC valve solenoid (1) changes, the load to the springs (4) and (6) changes depending on the value of the command current.
PC1 28UU-2
STRUCTURE
l
l
l
l
PC1 28UU-2
AND FUNCTION
HYDRAULIC
PUMP
The C port of the PC valve is connected to the E port of the LS valve. The self pressure PP is provided to the A port, the small diameter side of the servo piston (9) and the B port. When the pump discharge pressure PP is small, the spool is located at a position in the left direction. At the time, the C port is connected to the D port, and the pressure to the LS valve becomes the drain pressure PT. If the E port of the LS valve is connected to the G port at the time, the pressure from the J port to the large diameter side of the piston will become the drain pressure PT. And the servo piston will moves to the right side. Then, the pump delivery will come to increase. Also, as the servo piston (9) operates, the slider (8) moves the piston (7) to the right side, and the spring force becomes weak because the springs (4) and (6) expand. As the spring force becomes weak, the spool (3) moves to the right side to disconnect the C port from the D port. Then, the pump discharge pressure ports B and C are connected. As a result, the pressure at the C port rises and the pressure on the large diameter side of the piston rises as well, and the servo piston (9) stops moving to the right side. This means that the stop position of the servo piston (9) (= pump delivery) is determined where the pressing force caused the pressure PP to the spool (3), the pressing force of the PC-EPC valve solenoid and the forces of the springs (4) and (6) balance with each other.
1 O-29
STRUCTURE
HYDRAULIC
AND FUNCTION
Pilot
PUMP
pressure ‘0 main valve -
r
Emergency
Pump
SVPO7610
2)
l
l
When the pump controller is normal, the load to actuator is large and the pump discharge pressure PP is high When the load is large and the pump discharge pressure is high, the force pushing the spool (3) to the left side increases and the spool (3) comes to the position shown in the above figure. Then, the pressure flowing from the C port to the LS valve becomes about 315 of the pump discharge pressure PP because the pressure from the A port partly flows from the C port to the D port through the LS valve as shown in the above figure.
1O-30
l
l
When the E port of the LS valve is connected to the G port, this pressure is led from the J port to the large diameter side of the servo piston (9) and the servo piston comes to stop. When the pump discharge pressure PP increase and the spool (3) moves further to the left side, the discharge pressure PP will flow to the C port so as to minimize the pump delivery.
PC1 28UU-2
STRUCTURE
l
l
l
l
HYDRAULIC
AND FUNCTION
PUMP
When the servo piston (9) moves to the left side, the piston (7) will move to the left. Then, the springs (4) and (6) will be compressed and will push the spool (3) back. If the piston (7) moves further to the left, the ports C and D will open wide. As a result, the pressure at the port C (= J) will drop, and the servo piston (9) will move to the left and will stop. At the time, the servo piston (9) is located further to the left than where it is when the pump discharge pressure PP is low. The positional relations between the pump discharge pressure PP and the servo piston (9) are shown by a broken line because the springs (4) and (6) are 2stage ones. And the relations between the discharge pressure PP and the pump delivery Q are as shown in the right figure.
Also, when the command current X to the PC-EPC valve solenoid increases, the relations between the pump discharge pressure PP and the pump delivery Q will move in parallel in relation to the pushing force of the PC-EPC valve solenoid. Therefore, the force of the PC-EPC valve solenoid (1) will be added to the leftward pressing force of the discharge pressure PP to the spool (31, and the relations between PP and Q will move from @ to @ as X increases.
PC1 28UU-2
Pump
discharge
pressure
PP
SDP02559
Pump
discharge
pressure
PP
SDP02560
10-31
STRUCTURE
HYDRAULIC
AND FUNCTION
Pilot
PUMP
Dressure To Main
Direction to large diameter
SVPO7611
3)
1 O-32
When the pump controller is out of order and the PC redundant switch is set to ON a. In case of light load to main pump . When the pump controller is out of order, set the PC redundant switch to ON to change the circuit to the resistor side. In this case, since the current is too large when the power is directly taken from the battery, the resistor is connected to control the current to the PC-EPC valve solenoid. At the time, the current becomes constant and the piston (2) pressing force becomes constant as well. When the pump discharge pressure is low, the combined force of the force of the PC-EPC valve solenoid (1) and the discharge pressure PP is smaller
l
than the spring set force. So, the spool (3) balances at a position in the left side. At the time, the C port has the same pressure as the drain pressure at the D port, and the drain pressure PT is led to the large diameter side of the servo piston (9) through the LS valve. Then, the servo piston (9) moves in the diction where the delivery increases because the pressure on the small diameter side of the piston is large.
PC128UU-2
STRUCTURE
HYDRAULIC
AND FUNCTION
Pilot
PUMP
pressure in ve
Direction to small diameter
SVPO7612
b. l
l
l
PC1 28UU-2
In case of heavy load to main pump When the PC redundant switch is set to ON just like in the previous paragraph, a constant command current is sent to the PC-EPC valve solenoid (1). So, the piston (2) pushes the spool (3) with a constant force. When the pump discharge pressure PP rises, the spool will moves further to the left side than when the main pump is lightly loaded and will balance at the position shown in the above figure. In this case, since the pressure from the A port is led to the C port, the servo piston (9) will move to the left side (small delivery) and will stop at a position further to the left than when the pump is lightly loaded.
1o-33
STRUCTURE
l
l
HYDRAULIC
AND FUNCTION
This means that the current, which is sent to the PC-EPC valve solenoid through the resistor when the PC redundant switch is set to On, determines the curve between the pump discharge pressure PP and the delivcry Q as shown in the figure. When the PC redundant switch is set to ON, the curve @ is further to the left than the curve 0 drawn when the pump controller is normal.
Q x al .-5 4 ; z
PUnID discharge
1o-34
PUMP
Pressure
PP
~~~07613
PC1 28UU-2
STRUCTURE
CONTROL VALVE
AND FUNCTION
CONTROL VALVE OUTLINE The following two control valves have been set in the system : l 8-spool valve (without service valve) l 9-spool valve (8-spool valve + service valve) * Each service valve is of the add-on type and can be added and removed halfway. Appearance and section are shown for 8-spool valve (without service valve) only. 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14.
Swing bleed valve Travel junction valve Arm regeneration valve Boom hydraulic drift prevention Cover Offset valve Bucket valve Arm valve Blade valve Boom valve R.H. travel valve L.H. travel valve Swing valve PT port block
AA Al A2 A3 A4 A5 A6 A7 A8 Bl B2 B3 B4 B5 B6 B7 B8 BP LS PA1 PA2 PA3 PA4 PA5 PA6 PA7 PA8 PBl PB2 PB3
valve
PB4 : From boom LOWER PPC/EPC valve PB5 : From blade RAISE PPC valve PB6 : From arm IN PPC/EPC valve PB7 : From bucket digging PPC valve PB8 : From L.H. offset PPC/EPC valve : From main pump P PP : To main pump PX : From 2-stage relief solenoid valve SA : From swing stroke regulating solenoid valve SB : From swing stroke regulating solenoid valve TSl : To tank TS2: To tank TB :Totank TC : To oil cooler TSW : To swing motor
: Pressure sensor port (with pressure sensor) : To swing motor MB : To L.H. travel motor A : To R.H. travel motor A : To boom cylinder bottom : To blade cylinder bottom : To arm cylinder head : To bucket cylinder head : To offset cylinder head : To swing motor MA : To L.H. travel motor B : To R.H. travel motor B : To boom cylinder head : To blade cylinder head : To arm cylinder bottom : To bucket cylinder bottom : To offset cylinder bottom : From boom RAISE PPC valve : To pump LS valve : From swing L.H. PPC valve : From L.H. travel forward PPC valve : From R.H. travel reverse PPC valve : From boom RAISE PPC/EPC valve : From blade LOWER PPC valve : From arm OUT PPC valve : From bucket DUMP PPC valve : From R.H. offset PPC valve : From swing R.H. PPC valve : From L.H. travel reverse PPC valve : From R.H. travel forward PPC valve
PC1 28UU-2
1o-35
CONTROL VALVE
STRUCTURE AND FUNCTION
8-spool valve (without
service valve)
BB AA
-rJ
I--
A7
B
A8 --Y
88
87
+A
A5
k
TS2
A3 A2
Al
:
PAl’
-----l-x-BB--i \
k-B
TB
-D
5 0 7 0 9 IO 11
S
12 13 14
I
TSW
PBl
TC 9JYOO291
PC128UU-2
STRUCTURE AND FUNCTION
CONTROL VALVE
Sectional view * The figure shows an 8-spool valve (without service valve). (l/9)
A-A 9JYOO292
1. 2. 3. 4. 5. 6. 7.
Safety valve with suction Suction valve (L.H. travel A) Suction valve (R.H. travel A) Suction valve (boom bottom) Safety valve with suction (blade bottom) Suction valve (arm head) Suction valve (bucket head)
PC128UU-2
8. 9. 10. 11. 12. 13. 14.
Safety valve with suction (offset head) Suction valve (bucket bottom) Suction valve (arm bottom) Suction valve (boom head) Suction valve (R.H. travel B) Suction valve (L.H. travel B) Lift check valve
1o-37
STRUCTURE
CONTROL VALVE
AND FUNCTION
I
B-B 9JYOO293
1. 2. 3. 4. 5. 6. 7. 8. 9.
Main Spool Spool Spool Spool Spool Spool Spool Spool
1 O-38
relief valve (swing) (L.H. travel) (R.H. ravel) (boom) (blade) (arm) (bucket) (offset)
PC1 28UU-2
STRUCTURE
AND FUNCTION
CONTROL VALVE
9JYOO294
1. 2. 3. 4. 5. 6. 7. 8. 9.
Pressure compensation Pressure compensation Pressure compensation Pressure compensation Pressure compensation Pressure compensation Pressure compensation Pressure compensation Unload valve
valve valve valve valve valve valve valve valve
F F F F F F F F
(swing) (L.H. travel) (R.H. travel) (boom) (blade) (arm) (bucket) (offset)
10. 11. 12. 13. 14. 15. 16. 17.
Pressure Pressure Pressure Pressure Pressure Pressure Pressure Pressure
compensation compensation compensation compensation compensation compensation compensation compensation
valve valve valve valve valve valve valve valve
R R R R R R R R
(offset) (bucket) (arm) (blade) (boom) (R.H. travel) (L.H. travel) (swing)
The above F and R means the following valves : F : Flow control valve R : Pressure reducing valve
PC128UU-2
TO-39
STRUCTURE AND FUNCTION
CONTROL VALVE
BB-BB 9JYOO295
1.
2. 3. 4. 5. 6. 7.
LS pressure detection plug LS bypass plug Pump pressure detection plug Check valve (bucket head) Check valve (arm head) Check valve (boom bottom) LS select valve
1O-40
PC 128UU-2
STRUCTURE
CONTROL VALVE
AND FUNCTION
W9)
F-F
G-G
1. 2. 3. 4. 5. 6. 7. 8.
Main relief valve Couler bypass valve Lift check valve LS select valve Spool (swing) Pressure compensation Swing bleed valve Pressure compensation
PC1 28UU-2
‘7
9JUOO108
valve R valve F
10-41
STRUCTURE
AND FUNCTION
CONTROL VALVE
9JUOO109
1. 2. 3. 4. 5. 6.
Suction valve (A) Suction valve (B) Spool (L.H. travel) Pressure compensation Travel junction valve Pressure compensation
1 O-42
valve R
7. 8. 9. 10. 11.
Suction valve (A) Suction valve (B) Spool (R.H. travel) Pressure compensation Pressure compensation
valve R valve F
valve F
PC128UU-2
STRUCTURE
AND FUNCTION
CONTROL VALVE
V/9)
K-K
9JYOO296
1. 2. 3. 4. 5.
Suction valve (A) Boom hydraulic drift prevention valve Suction valve (B) Spool (boom) Pressure compensation valve R
PC1 28UU-2
6. 7. 8. 9. 10.
Pressure compensation valve F Safety valve with suction Spool (blade) Pressure compensation valve R Pressure compensation valve F
1o-43
STRUCTURE
CONTROL VALVE
AND FUNCTION
W9)
5’
M-M
8
,!
‘IO N-N 9JYOO297
1. 2. 3. 4. 5. 6.
Suction valve (A) Suction valve (B) Spool (arm) Pressure compensation valve R Arm regeneration valve Pressure compensation valve F
1o-44
7. 8. 9. 10. 11.
Suction valve (A) Suction valve (B) Spool (bucket) Pressure compensation Pressure compensation
valve R valve F
PC1 28UU-2
STRUCTURE
AND FUNCTION
CONTROL VALVE
W9)
AA-AA 1
9JYOO298
1. 2. 3. 4. 5. 6.
Safety valve with suction Spool (offset) Pressure compensation valve R Pressure compensation valve F Pressure relief plug Unload valve
PC128UU-2
1o-45
STRUCTURE
AND FUNCTION
SUCTION
SAFETY VALVE
SUCTION SAFETY VALVE (SAFETY VALVE WITH SUCTION
FOR SERVICE PORT)
1. Suction valve 2. Main valve 3. Piston 4. Piston spring 5. Poppet 6. Poppet spring 7. Suction valve 8. Sleeve 9. Adjustment screw IO. Lock nut
’
CT
9JUOO112
Specification Part No. (Reference)
1
Set pressure
709-70-74600
24.5 MPa (250 kg/cm? (at the time of 5fYmin.I
709-70-74700
17.2 MPa (175 kg/cm*) (at the time of 5e/min.)
1O-46
1
Use For crusher
PC1 28UU-2
STRUCTURE
AND FUNCTION
CLSS
CLSS OUTLINE OF CL& Features CLSS stands for Closed Center Load Sensing System and is featured as follows : l Fine controllability without affect of load l Controllability that allows digging even in the fine control mode. l Ease of compound operation in which the flow distribution performance depends on spool opening area during compound operation. l Saving of energy by variable pump control Configuration l The CLSS consists of a variable displacement piston pump, a control valve and actuators. l The pump body consists of a main pump, a PC valve and an LS valve.
(
;___________________---I I
PLS
Actuators
Control
\
valve
I
0 I
I I_-________________
LS valve
-------
I
SDP02561
PC1 28UU-2
1o-47
STRUCTURE
AND FUNCTION
CLSS
Basic principle 1. Control of pump swash plate angle l The pump swash plate angle (pump delivery) is controlled so that the LS differential pressure APLS, which is the difference between the pump discharge pressure PP and the LS pressure PLS (actuator load pressure) at the control valve outlet, becomes constant. (LS differential pressure APLS = Pump pressure PP - LS pressure PLS)
Actuator
1
@
Control va I ve
Pump Passage i__________
Servo Piston
APLS
II
It (;
LS valve
SEP0.2562
l
*
When the LS differential pressure APLS reduces below the set pressure of the LS valve (when the actuator load pressure is high), the pump swash plate angle will move in the direction of maximum. When the set pressure is raised (when the actuator load pressure is low), the pump swash plate angle will move in the direction of minimum. For the detail of the operation, see the paragraph of “Hydraulic Pump.”
A Q
-al .z m z m X = : x
Max.
LS valve set Pressure Min.
0
LS differential
Pressure
w APLS SDP02563
1 O-48
PC1 28UU-2
STRUCTURE
2.. l
CLSS
AND FUNCTION
Pressure compensation control A valve (pressure compensation valve) is mounted on the outlet side of the control valve. In case of compound operation of the actuator with this valve, the differential pressure AP between the spool upstream (inlet) and the downstream (outlet) of each valve becomes constant irrespective of load (pressure). So, the flow from the pump is distributed (compensated) in proportion to the opening areas Sl and S2 of each valve being operated.
Load
tor
I
1, AP
SEP02564
PC1 28UU-2
1o-49
STRUCTURE
CLSS
AND FUNCTION
EACH FUNCTION
AND OPERATION OF EACH VALVE
Hydraulic circuit diagram and valve names Pump pressure detection port
IC
LS PreSSUle detection port
sensor ve
PAl' _-L-_
PA& --t--
rm Safety 1Z.llPl
valve
30tdrd
Arm check
valve
,
Blade
m-#‘~t-yLm--~~~ 11
Boom
lock
valve
3oom LB _TSZ
PA4' --t
l-03
iAs(Forward) Reverse
-
R. H.
travel
L. H.
travel
v!! c I L_
--_ L-
&.
1
Rever ‘se
Swine
separarlon
~b
.valve
LJa*n
/check
.-----__ Swine
bleed
Galve
CL_.9 i_
/ Main relife 1,. o/3.. (“PI 0*6/,66t./c31
valve
I 9
i~Z371s
evalve
Tao”3
r
valve
T--l jTs
i
Safety valve 36. I”PI <316L.,C& Hydraulic
1O-50
t
“I
circuit
diagram
SJPO7614
PC1 28UU-2
STRUCTURE
AND FUNCTION
CLSS
1. Unload valve Set pressure : 3.38 MPa (34.5 kg/cm2} 2. Safety valve with suction Set pressure : 35.8 MPa (365 kg/cm21 3. Pressure compensation valve 4. Suction valve 5. Main relief valve Set pressure : normal : 31.9 MPa (325 kg/cm2) Pressure rise : 34.8 MPa (355 kg/cm21 6. Lift check valve 7. Cooler bypass valve 8. LS select valve 9. Swing bleed valve 10. Travel junction valve 11. Boom hydraulic drift prevention valve 12. Arm regeneration valve 13. Safety valve with suction 14. Safety valve with suction
PC1 28UU-2
1o-51
STRUCTURE
CLSS
AND FUNCTION
UNLOAD VALVE 1. When the control valve is neutral Function When the control valve is neutral, the delivery 0 equivalent to the pump minimum swash plate angle l is released to the tank circuit. At the time, the pump discharge pressure PP is set to 2.45 MPa {25.0kg/ cm*} with the spring (3) inside the vale. (The LS pressure PLS is 0 MPa {Okg/cm2).)
SDP03735
Operation The pump discharge pressure PP is applied to the left end face of the spool (4) and the LS pressure PLS is applied to the right end face. Since the LS pressure PLS is 0 when the conl trol valve is neutral, the pump discharge pressure PP is only applied and is set with the lead to the spring (3). When the pump discharge pressure PP rises l to the spring (3) load (2.45 MPa (25.0 kg/cm*}), the spool (4) will move toward the right side and the pump circuit PP will interconnect to the tank circuit T through the drill hole. Therefore, the pump discharge pressure PP l is set to 2.45 MPa (25.0 kg/cm*}. l
1 O-52
1. 2. 3. 4.
Unload valve Sleeve Spring Spool
PLS : LS circuit (pressure) PP : Pump circuit (pressure) T : Tank circuit
PC128UU-2
STRUCTURE
AND FUNCTION
CLSS
2. When the control valve is in the fine control mode Function l When the control valve is in the fine control mode and the requested flow of the actuator is less than the pump minimum swash plate angle, the pump discharge pressure PP is set to the LS pressure PLS + 2.45 MPa (25.0 kg/cm2}. When the differential pressure between the discharge pressure PP and the LS pressure PLS comes to the spring (3) load (2.45 MPa (25.0 kg/cm2}), the unload valve will open and the LS differential pressure APLS will come to 2.45 MPa (25.0 kg/cm*}.
SDP03736
Operation When the control valve is operated in the fine control mode, the LS pressure PLS will occur and will be applied to the right end face of the spool (4). At the time the differential pressure between the LS pressure PLS and the pump discharge pressure PP increases because the opening area of the control valve spool is small. l When the differential pressure between the pump discharge pressure PP and the LS pressure PLS comes to the spring (3) load (2.45 MPa (25.0 kg/cm?), the spool (4) will move to the right side and the pump circuit PP will interconnect to the tank circuit T. l This means that the pump discharge pressure PP is set to the spring force (2.45 MPa (25.0 kg/cm*} + LS pressure PLS, and the LS differential pressure APLS comes to 2.45 MPa (25.0 kg/cm*}. l
PC128UU-2
1. 2. 3. 4.
Unload valve Sleeve Spring Spool
PLS : LS circuit (pressure) PP : Pump circuit (pressure) T : Tank circuit
1o-53
STRUCTURE
CLSS
AND FUNCTION
3. When the control valve is operated Function l If the required flow of the actuator increases over the pump minimum swash plate angle when the control valve is operated, the flow to the tank circuit T will be interrupted and the pump delivery Q will be completely flown to the actuator circuit.
SDP03737
Operation l When the control valve is operated with large stroke, the LS pressure PLS will occur and will be applied to the right end face of the spool (4). At the time, the opening areas of the control valve spool is large and the difference between the LS pressure PLS and the pump discharge pressure PP is small. l So, the differential pressure between the pump discharge pressure PP and the LS pressure PLS does not reach the spring (3) load (2.45 MPa (25.0 kg/cm*)) and the spring (3) pushes the spool (4) to the left side. l Then, the pump circuit PP and the tank circuit Tare interrupted, and the pump delivery Q is completely flown to the actuator circuit.
1o-54
1. 2. 3. 4.
Unload valve Sleeve Spring Spool
PLS : LS circuit (pressure) PP : Pump circuit (pressure) T : Tank circuit
PC128UU-2
STRUCTURE
AND FUNCTION
CLSS
LEADING OF LS PRESSURE Function The LS pressure is load pressure to the actuator on the outlet side of the control valve. In case of a work equipment valve, the pressure reducing valve (3) of the pressure compensation valve reduces the pump discharge pressure PP to the same level as the actuator circuit pressure A and leads the pressure to Work equipment
l
the LS circuit PLS. Also, the orifice C is mounted on the piston (5) halfway from the pump circuit PP to the pressure reducing valve (3), and the orifice has the damper function. The travel valves leads the actuator circuit pressure A directly to the LS circuit PLS.
valve (boom, arm, bucket, swing blade and offset)
SDP03738
Operation l When the spool (1) is operated, the pump discharge pressure PP will be led to the actuator circuit A through the bridge passage b from the flow control valve (2) and the spool notch a. l Since the pressure reducing valve (3) moves to the right at the same time, the pump discharge pressure PP led from the orifice c is reduced due to pressure loss at the notch d and is led to the LS circuit PLS and to the spring chamber PLSl. l At the time, the LS circuit PLS is connected to the tank circuit Tfrom the LS bypass plug (4).
PC1 28UU2
l
l
The both end face areas of the pressure reducing valve (3) are the same (SA = SLS), and the actuator circuit pressure PA (= A) is applied to the SA side and the reduced pump discharge pressure PP is applied to the SLS side on the opposite side. Therefore, the pressure reducing valve balances at the position where the actuator circuit pressure PA becomes equal to the pressure of the spring chamber PLSl. The pump discharge pressure PP reduced at the notch d comes to the actuator circuit pressure A and is led to the LS circuit PLS.
1o-55
STRUCTURE
2.
AND FUNCTION
CLSS
Travel valve
PP
3
SDP03739
Operation When the spool (1) is operated, the pump disl charge pressure PP will be led to the actuator circuit A through the bridge passage b from the flow control valve (2) and the spool notch a. At the same time, the actuator circuit presl sure PA moves the pressure reducing valve (3) to the right side, and the notches c and d interconnect to the travel junction circuit e and the LS circuit PLS respectively. So, the actuator circuit pressure PA (= A) is l led from the notch c to the LS circuit PLS through the notch d. The travel circuit is different from the work * equipment circuit, the actuator circuit pressure PA is directly led to the LS circuit PLS.
1 O-56
PC128UU-2
STRUCTURE
CLSS
AND FUNCTION
LS BYPASS PLUG Function l This plug released residual pressure of the LS pressure PLS. l This plug slows the rising speed of the LS pressure PLS, causes pressure losses at the spool and the throttle of the shuttle valve by the discarded throttled flow and reduces the effective LS differential pressure for higher safety.
PLS
a
SDP03740
Operation l Pressurized oil in the LS circuit PLS flows from the clearance filter a in the space between the LS bypass plug (1) and the valve body to the tank circuit T through the orifice b.
PC1 28UU-2
1.
LS bypass plug
PLS : LS circuit (pressure) T : Tank circuit (pressure)
1o-57
STRUCTURE
AND FUNCTION
PRESSURE COMPENSATION
CLSS
VALVE
Function l When the load pressure becomes lower than another actuator and the flow is going to increase during a compound operation, this valve compensates the load pressure. (At the time, the load pressure of another actuator under compound operation (the upper side) is higher than that of the actuator on this side (the lower side).
\
Aa
(Coyyensated
,”
Pi.3 SVPO7773
1 O-58
PC128UU-2
STRUCTURE
AND FUNCTION
CLSS
Operation l When the load pressure of another actuator side (the upper side) rises during a compound operation, the flow in the actuator circuit A on this side (the lower side) is apt to increase. l In this case, the LS pressure PLS of another actuator is applied to the spring chamber PLSl and pushes the pressure reducing valve (1) and the flow control valve (2) to the left side. l The flow control valve (2) throttles the opening area between the pump circuit PP and the spool upstream PPA and causes a pressure loss between PP and PPA. l The flow control valve (2) and the pressure reducing valve (1) balance each other where the pressure difference between PA applied to the both end faces of the pressure reducing valve (I) and PLS becomes the same as the pressure loss between PP before and after the flow control valve and PPA. l So, the pressure differences between the upstream pressures PPA and the downstream pressures PA of the both spools under compound operation become the same, and the pump flow is distributed in proportion to the opening area of each spool notch a.
PC1 28UU-2
1o-59
STRUCTURE
AND FUNCTION
AREA RATIO OF PRESSURE COMPENSATION
CLSS
VALVE
Function
The pressure compensation valve slightly adjust the ratio (WSI) of the area Sl on the left side of the flow control valve (2) and the area S2 on the right side of the pressure reducing valve (1) to suite the characteristics of each actuator and determines the compensation characteristics. Sl : Area of the flow control valve (2) - area of the piston (3) S2 : Area of the pressure reducing valve (I) - area of the piston (3) l
T
T
9JUOOl26
Area ratio (Sl:S2) and compensation characteristics l When the ratio is 1.00 : The expression [Pump (discharge) pressure PP - Spool notch upstream pressure PPB] + [LS circuit pressure PLS -Actuator circuit pressure PA (= A)] can be held, and the flow is distributed as per the spool opening area ratio. l When the ratio is more than 1 .OO: The expression PP - PPB > PLS - PA (= A) can be held, and the flow is distributed less than the spool opening area ratio. l When the ratio is less than 1.00 : The expression PP - PPB c PLS - PA (= A) can be held, and the flow is distributed more than the spool opening area ratio.
1 O-60
PC1 28UU-2
STRUCTURE
AND FUNCTION
BOOM HYDRAULIC DRIFT PREVENTION
CLSS
VALVE
Function l This valve prevents boom bottom oil from leading from the spool (I) and prevents the boom from falling naturally when the boom lever is out of operation. 1.
At boom raise
QJUOO127
Operation l When the boom is raised, the main pressure from the control valve will push the poppet (5) upward. And the main pressurized oil from the control valve will flow to the boom cylinder bottom through the valve inside.
PC1 28UU-2
lo-61
STRUCTURE
2.
AND FUNCTION
CLSS
Boom lever at neutral
9JUOO128
Operation l When the control lever is returned to NEUTRAL while the boom is raised, the holding pressure on the boom cylinder bottom is confined with the poppet (5). At the same time, the pressurized oil flown in the inside through the orifice a is confined with the pilot spool (3). Then, the boom is held neutral.
1 O-62
PC1 28UU-2
STRUCTURE
3.
AND FUNCTION
CLSS
At boom lower
9JUOOl29
Operation l When the boom is lowered, the pilot pressure Pl from the PPC valve will push the pilot spool (3) and drain pressurized oil from the b chamber inside the poppet. l The pressurized oil from the boom cylinder bottom raises the oil pressure in the Ab port but reduces the pressurized oil in the b chamber through the orifice a. l When the pressure in the b chamber drops below the pressure in the Aa port, the poppet (5) will open, and the pressurized oil from the Ab port will be led to the Aa port and flow in the control valve.
PC1 28UU-2
1O-63
STRUCTURE
AND FUNCTION
CLSS
13ooM REGENERATION CIRCUIT 1. At boom lower and own weight fall Function l When the boom is lowered and falls due to its own weight because the bottom pressure A in the cylinder (1) is higher than the head pressure B, this circuit brings the return flow on the bottom side to the head side to increase the cylinder speed.
9JUOO130
Operation l When the boom is lowered and falls due to its own weight, the bottom side pressure A in the boom cylinder (1) will rise above the head side pressure B.
l
l
1O-64
At the time, part of the return flow on the bottom side passes through the regeneration passage a of the boom spool (2), pushes the check valve (3) to open it and flows to the head side. This increases the boom lower speed.
PC1 28UU-2
STRUCTURE
AND FUNCTION
CLSS
2. At boom lower load process Funiztion l When the head pressure B of the cylinder (1) is higher than the bottom pressure A while the boom is lowered and the boom is in the ioad process, the check valve (3) will be closed, and the circuits on the head side and the bottom side will be interrupted.
9JUOOl31
Operation When the boom is lowered and is in the load process, the head side pressure B of the boom cylinder (1) rises above the bottom side pressure A.
l
PC1 28UU-2
l
At the time, the head side pressure B and the spring (4) close the check valve (31, and the circuits on the head side and the bottom side are interrupted.
1O-65
STRUCTURE
CLSS
AND FUNCTION
ARM REGENERATION CIRCUIT 1. At arm in and own weight fall Function When the arm falls due to its own weight bel cause the head pressure A in the arm cylinder (1) is higher than the bottom pressure B during arm digging, this circuit brings the return flow on the head side to the bottom side to increase the cylinder speed.
T
PLS
9JYOO300
Operation When the arm falls for digging due to its own l weight, the head side pressure A in the arm cylinder (1) will rise above the bottom side pressure B. At the time, part of the return flow on the head l side passes through the regeneration passage a of the arm spool (21, pushes the check valve (3) to open it and flows to the bottom side. This increases the arm digging speed. l
1O-66
1. 2. 3.
Arm cylinder Arm spool Check valve
A : Head circuit (pressure) B : Bottom circuit (pressure) PP : Pump circuit (pressure)
PC1 28UU-2
STRUCTURE
CLSS
AND FUNCTION
2. At arm in process Function l When the bottom pressure B of the cylinder (1) rises above the head pressure A and the arm enters the digging process, the check valve (3) will be closed and the circuits on the head side and the bottom side will be interrupted.
Operation l When the arm is in the digging process, the bottom side pressure B of the arm cylinder (1) will rise, close the check valve (3) and interrupt the circuits on the head side and the bottom side.
PC1 28UU-2
1. 2. 3.
Arm cylinder Arm spool Check valve
A : Head circuit (pressure) B : Bottom circuit (pressure) PP : Pump circuit (pressure)
1O-67
STRUCTURE
AND FUNCTION
TRAVEL JUNCTION
VALVE
(L.H. and R.H. travel junction 1.
When traveling
CLSS
circuit)
straight
SJPO7615
PC128UU-2
STRUCTURE
AND FUNCTION
CLSS
Function l When the L.H. and R.H. travel spool is operated to compensate flow errors in the L.H. and R.H. travel circuits during straight travel, the junction circuit will open. l Then, theflows to the L.H. and R.H. travel motors will become the same during the straight travel, and travel deviation will decrease. l At the time of steering, load pressure difference brings back the pressure reducing valve of the travel valve inside the steering and closes the spool notch opening of the travel junction valve to close the junction circuit for steering. Operation l When the L.H. and R.H. travel spool (I) is operated, the pump delivery will flow from the pump circuit PP to A through the actuator circuit PA. l When traveling straight, the actuator circuit PA will be equalized and the L.H. and R.H. pressure reducing valves (2) will be pressed the same stroke to the right. Then, the notch a and the junction circuit will open. l The L.H. travel forward oil pressure Pl and the R.H. travel forward oil pressure P2 are led to the spring chamber on the both end of the travel junction valve spool (4) through the respective shuttle valves (5). So, Pl = P2, and the spool is at the neutral position, and the notch d is lopen?. l Then, the L.H. and R.H. travel actuator circuits are interconnected with the junction circuit. When any difference occurs in the flows to the L.H and R.H. travel motors, this valve will compensate them and will reduce occurrence of travel deviations.
PC 128UU-2
1 O-69
STRUCTURE
CLSS
AND FUNCTION
..
2.
When operating
travel steering
w
~X11111,,,,,,,
I
\
I
\
I
PP
1O-70
5/
Pl
d:rz SJPO7616
PC128UU-2
STRUCTURE
AND FUNCTION
CLSS
Operation l When the L.H. travel spool (L.H. 1) is returned to the neutral side from the straight traveling state and the steering is operated, there will occur any difference in the load pressures in the L.H. and R.H. travel actuator circuits PA (R.H. A > L.H. A). The LS pressure PLS will become the same as the R.H. A on the higher load pressure side. l Therefore, the flow control valve on the L.H. travel side is pressed to the left side with the LS pressure PLS, i.e., the load pressure on the R.H. travel side, and the notch a closes to interrupt the L.H. and R.H. travel circuits. Also, since the pressures in the spring chambers on the both ends of the travel junction valve spool (4) become different and Pl becomes higher than P2, the spool (4) moves to the PI side and the notch d closes. Then, the steering can be operated. l The damper is provided to relax the transition characteristics of the junction circuit at the time of abrupt operation.
PC1 28UU-2
1o-71
STRUCTURE
AND FUNCTION
CLSS
TRAVEL LS BYPASS CIRCUIT 1.
At normal operation
9JUOO13
1 O-72
16
PC1 28UU-2
STRUCTURE
AND FUNCTION
CLSS
Function When an actuator is operated during travel, this circuit will increase the discarded throttled flow of the LS circuit PLS, loosen the pressure compensation accuracy of the travel circuit and limits reduction of the travel speed to small extent. The bypass circuit is closed in case of independent travel or independent operation of an actuator. Operation When the boom spool (I) is operated, the LS circuit PLS will come to the same pressure as the boom circuit pressure Al. At the same time, the LS circuit pressure PLS is led to the spring chamber PLSI of the pressure reducing valve (2) of the travel valve. Since the travel spool is not operated, the travel actuator circuit PA is closed and the check valve (4) inside the flow control valve (3) is also closed. Therefore, the travel LS bypass circuit is closed in case of independent operation of the boom.
PC1 28UU-2
1o-73
STRUCTURE
2.
AND FUNCTION
At operation
CLSS
of travel + other actuator
9JYOO
PC128UU-2
STRUCTURE
AND FUNCTION
CLSS
Operation When the boom spool (I) is operated, the LS circuit PLS will come to the same pressure as the boom circuit pressure Al. Since the actuator circuit pressure is generally higher at boom RAISE than during travel (Al > A2), the pressure in the spring chamber PLSl of the flow control valve (3) on the travel side is higher than the travel circuit pressure PA. So, the pressure reducing valve (2) moves to the left side, and the LS pressure of the spring chamber PLSl pushes the check valve (4) from the orifice a to open it and flows to the travel circuit PA through the passages b and c. Therefore, when the LS circuit pressure PLS, which has been as high as the boom circuit pressure Al, flows to the travel circuit A2, the pressure will drop.
PC1 28UU-2
1o-75
STRUCTURE
CLSS
AND FUNCTION
3. At simultaneous operation of boom + swing Function l When the boom is raised at the time of swinging, the swing pool stroke will be controlled and the flow to the boom will be distributed more to raise the boom more. 1)
When the boom is not raised
9JYOOO24
Operation l Since the SA and SB ports are interconnected to the drain and no force is given to the piston (2), the stroke of the spool (1) is not controlled. So, the spool (1) comes to the cases (4) and (5) and the stroke increases by STl. This increases the filtering oil flow.
1 O-76
1. 2. 3. 4. 5.
Spool (swing) Piston Plug Case Case
ST1 : Spool stroke
PC128UU-2
STRUCTURE
2)
AND FUNCTION
At simultaneous
operation
CLSS
of boom RAISE
ST0
ST0
9JYOOO25
Operation l When the boom RAISE PPC pressure is led to the piston (2) as the stroke control pilot pressure PS through the SA and SB ports, the piston (2) will be pressed in the inner direction. l At the time, the maximum stroke of the spool (1) will shorten (by STO) due to control of the piston (2). Boom RAISE OFF ST1 > Boom RAISE ON ST0 l The spool (I) stroke is controlled and shortens. If the boom is raised at the time of swing (hoist swing), the notch a opening area will decrease. So, the flow distribution to the boom will increase and the boom will rise higher at the time of hoist swing.
PC1 28UU-2
1o-77
STRUCTURE
CLSS
AND FUNCTION
SWING BLEED VALVE Function l For swing operation, a bleed valve is provided to the pressure reducing valve to raise the LS pressure slowly and to smooth the swing operation. 1.
Swing at neutral position
Bleed-off
circuit
SVPO7617
Operation l Since the notch a of the pressure reducing valve (1) and the LS circuit are closed and the bleed-off circuit and the LS circuit are also closed, the LS pressure PLS is not affected by operation of other work equipment. l The pump discharge pressure PP is also interrupted from the bleed-off circuit with the piston (2) and is not affected. l The notch b of the bleed spool (3) and the bleed-off circuit are interconnected each other.
1 O-78
PC128UU-2
STRUCTURE
2.
AND FUNCTION
At swing fine control
CLSS
’
Bleed-off
circuit
SVPO7616
Operation The pressure reducing valve moves in the right direction, and the notch a and the LS circuit interconnect each other. Also, the pump circuit PP, the bleed-off circuit and the LS circuit interconnect each otherthrough the piston (2). The bleed spool (3) moves in the left direction in proportion to raise of the swing PPC pressure PA. But the notch b throttles and interconnect to the bleed-off circuit in the fine control region and determines the intermediate pressure before the pump discharge pressure PP is reduced and applied to the LS pressure PLS. Therefore, the intermediate pressure is set lower than the pump discharge pressure PP and rises as the bleed spool (3) moves. So, the LS pressure PLS rises slowly.
PC1 28UU-2
1o-79
STRUCTURE
3.
AND FUNCTION
CLSS
At full swing operation
LS circuit
L4
-
Jt2
M PLS
PP
Bleed-off
circuit
SVP07619
Operation l When the swing PPC pressure PA comes to the maximum, the notch b of the bleed spool (3) interrupt the bleed-off circuit. The intermediate pressure becomes equal to the pump discharge pressure PP, and the LS pressure PLS becomes equal to the actuator circuit pressure.
1 O-80
PC1 28UU-2
STRUCTURE
AND FUNCTION
CLSS
VARIABLE PRESSURE COMPENSATION (for’service
VALVE
valve)
Function l Jn compound operation of the service valve (for attachment) and work equipment valve like boom RAISE, this variable pressure compensation valve can adjust flow distribution to the service valve. (The equivalent area ratio is variable.) l Spring (4) force can be adjusted with the screw (5). 1.
In case of compound
operation
with high load work equipment
(like boom RAISE)
To SPOOI
3
4
5
SJPO7620
Operation The pump discharge pressure PP and the LS pressure PLS depends on other work equipment. When the pressure in the a chamber reaches the set pressure of the spring (4), the poppet (3) will open, and the throttle b maintains the pressure in the a chamber below the pump discharge pressure PP. Therefore, the force F, which is required for the pressure reducing valve (2) to close the flow control valve (I), becomes smaller. This means that the flow control valve (1) moves in the right direction and the flow from the pump to the service valve increases just like the area ratio has reduced.
PC1 28UU-2
1. 2. 3. 4. 5. 6. 7.
Flow control valve Pressure reducing valve Poppet Spring Screw Lock nut Polyethylene cap
lo-81
STRUCTURE
AND FUNCTION
CLSS
LS SELECT VALVE Function l At the time of simultaneous operation of swing + boom RAISE, this valve prevents high swing LS pressure from entering the LS circuit PLS and also prevents the boom RAISE speed from reducing by securing the pump flow at the time of swing drive. 1.
During normal operation
To LS valve
SVPO7621
Operation l- The pilot pressure is not generally applied to the pilot port BP except for boom RAISE operation. l In this state, the pump discharge pressure PP pushes the valve (1) to open it and is led to the pressure reducing valve (4) of the swing valve. At the time of swing operation, there occurs the LS pressure PLS suitable for the load pressure, and the pressure is led to the pump LS valve.
1 O-82
PC1 28UU-2
STRUCTURE
2.
AND FUNCTION
At simultaneous
operation
CLSS
of swing + boom RAISE
9JYOOO31
Operation . At the simultaneous operation of swing + boom RAISE, the signal pressure of the PPC circuit is led to the pilot port BP. . When this pilot pressure BP is applied to the piston (2) and reaches a pressure that is stronger than the spring (3), the piston (2) will be pushed to the left side, the valve (I) will close and the pump discharge pressure PP will not come to flow to the pressure reducing valve (4) of the swing valve. . Then, the swing pressure does not cause LS pressure PLS, but the LS pressure PLS cause the boom RAISE pressure is led to the pump LS valve, and the pump delivery is controlled with the boom RAISE LS pressure. . The pilot pressure BP depends on the control lever stroke.
PC128UU-2
1 O-83
STRUCTURE
SELF PRESSURE REDUCING
AND FUNCTION
VALVE
SELF PRESSURE REDUCING VALVE
PR
T
pi
0 0
Z
9JUOOO62
PI : From pump PR : Supply to solenoid valve, PPC valve and EPC va Ive. T : To hydraulic tank
1 O-84
PC1 28UU-2
STRUCTURE
AND FUNCTION
SELF PRESSURE REDUCING
VALVE
A-A
Id
3 B-B
1. 2. 3. 4. 5. 6.
Control valve block Valve (sequence valve) Spring Screw Poppet Spring (pressure reducing valve pilot)
PC1 28UU-2
7. 8. 9. 10. 11.
‘5
ii
9JUOOO63
Spring (pressure reducing valve main) Valve (pressure reducing valve) Spring (safety valve) Ball Filter
1 O-85
STRUCTURE
SELF PRESSURE REDUCING
AND FUNCTION
VALVE
__-_--__-__ Function The self pressure reducing valves reduces the l discharge pressure of the main pump and supplies it to the solenoid valve, the PPC valve, etc. as the control pressure.
M IN3. 66MPa ort
PI P
I
ort
T Port
Hydraulic
circuit SVP07622
1.
At engine stop (total low pressure)
SVP07623
Operation The spring (6) pushes the poppet (5) t the seat, l and the circuit between the ports PR and T is closed. The spring (7) pushes the valve (8) to the left l side, and the circuit between the ports Pl and PR is open.
1O-86
l
The spring (3) pushes the valve (2) to the left side, and the circuit between the ports Pl and P2 is closed.
PC128UU-2
STRUCTURE
AND FUNCTION
SELF PRESSURE REDUCING
VALVE
2. At neutral and reduction of load pressure P2 (at own weight fall i’n boom LOWER and arm IN) Note : When the load pressure P2 is lower than the output pressure PR’of the self pressure reducing valve.
SVP07624
Operation l The spring (3) and the PR pressure (0 MPa (0 kg/cm21 at the time of engine stop) pushes the valve (2) in the direction to close the circuit between the ports Pl and P2. When the hydraulic oil enters the Pl port, the expression (Pl pressure G Spring (7) force + (ad area x PR pressure)) holds, and the self pressure reducing valve will adjust the openings of the ports Pl and P2 so that the Pl pressure can be maintained higher than the PR pressure. l When the PR pressure rises above the set pressure, the poppet (5) will open and the hydraulic oil flows through the route from the PR port, the hole a in the spool (8), the poppet (5) opening to the tank port T.
PC1 28UU-2
l
Therefore, there will occur a differential pressure around the hold a in the spool (8) and the spool will move in the direction to close the port Pl and the PR opening. Then, the Pl pressure is reduced and adjusted to a certain pressure (set pressure) with the opening and is supplied as the PR pressure.
1 O-87
STRUCTURE
3.
AND FUNCTION
SELF PRESSURE REDUCING
VALVE
At raise of load pressure P2
SVP07625
Operation l When the load pressure P2 rises due to digging or other operations, the pump delivery will increase and the Pl pressure will rise. Then, the expression (Pl pressure > Spring (7) force + (ad area x PR pressure)) will hold, and the valve (2) will move to the right side till the stroke end. As a result, the opening between the ports Pl and P2 will increase, the passage resistance will become smaller to reduce engine loss horsepower.
1O-88
l
l
When the PR pressure rises above the set pressure, the poppet (5) will open and the hydraulic oil will flow through the route from the PR port, the hole a in the spool (81, the poppet (5) opening to the tank port T. Therefore, there will occur a differential pressure around the hold a in the spool (8) and the spool will move in the direction to close the port Pl and the PR opening. Then, the Pl pressure is reduced and adjusted to a certain pressure (set pressure) with the opening and is supplied as the PR pressure.
PC1 28UU-2
STRUCTURE
4.
SELF PRESSURE REDUCING
AND FUNCTION
At occurrence
of abnormal
VALVE
high pressure
SVP07626
Operation l When the PR pressure of the self pressure reducing valve rises abnormally high, the ball (10) will separate from the seat against the spring (9) force to flow the hydraulic oil to the output ports PR + T so as to reduce the PR Then, the equipment (PPC valve, pressure. solenoid valve, etc.), to which the oil pressure is supplied, is.protected from the abnormal high pressure.
PC1 28UU-2
1 O-89
STRUCTURE
AND FUNCTION
CENTER SWIVEL JOINT
CENTER SWIVEL JOINT
Rl
E2
c2
A2 F2
DR2
9JAOl352
1. 2. 3. 4. 5. Al A2 Bl B2 Cl C2 Dl 02
Cover Body Slipper seal Dust seal Shaft : From control : To R.H. travel : From control : To L.H. travel : From control : To R.H. travel : From control : To L.H. travel
1O-90
: From travel 2nd speed selector solenoid valve E2 : To L.H./R.H. travel motor D : From control valve (Blade “LOWER”) Fl F2 : To L.H./R.H. blade cylinder bottom : From control valve (Blade “RAISE”) Gl G2 : To L.H./R.H. blade cylinder head DRl : To hydraulic tank DR2 : From L.H. travel motor Cl, R.H. travel motor C2 El
valve (R.H. motor B valve (L.H. motor A valve (R.H. motor A valve (L.H. motor B
travel “Forward”) travel “Forward”) travel “Reverse”) travel “Reverse”)
PC128UU-2
STRUCTURE
AND FUNCTION
TRAVEL MOTOR
TRAVEL MOTOR (FINAL DRIVE)
I-
!_ iI_
i- iT I-Iu. i‘_
9JA01338
A : From control valve (L.H./R.H. travel) B : From control valve (L.H./R.H. travel) Cl : To hydraulic tank (L.H. travel motor) Plug (R.H. travel motor) C2 : Plug (L.H. travel motor) To hydraulic tank (R.H. travel motor) D : From travel 2nd speed selector solenoid valve
PC1 28UU-2
1o-91
STRUCTURE
TRAVEL MOTOR
AND FUNCTION
A-A
34 B-B 9JA01339
1. Plug
2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17.
Check valve spring Check valve Return spring Counterbalance valve Safety valve Safety valve spring End cover Regulator valve Spring Brake piston Cylinder Spring Swash plate Pivot Crankshaft RV gear A
1 O-92
18. 19. 20. 21. 22. 23. 24. 25. 26. 27. 28. 29. 30. 31. 32. 33. 34.
RV gear B Cover Driven gear Drive gear Drain plug Hub Regulator piston Spindle Piston Floating seal Plate Disc Valve plate Spring Piston Plug Check valve
PC1 28UU-2
STRUCTURE
AND FUNCTION
TRAVEL MOTOR
SPECIFICATION Type : GM18VL-J Theoretical delivery (Hi) : 37.2 cm3/rev{37.2 cc/rev} (Lo) : 52.7 cm3/rev{52.7 cc/rev} Rated speed (Hi) : 2916.3 rpm (Lo) : 2147.3 rpm Brake releasing pressure : 0.68 MPa (6.94 kg/cm*} Speed change pressure : 2.94 MPa (30 kg/cm*} Reduction ratio : 72
OUTLINE Travel speed change
9JA01340
l
l
The swash plate has two planes x and y on the back and is supported with the pivot (15). To change the travel speed, the pressurized oil in the control chamber a is sent to the regulator piston (24) to maximize or minimize the angle of the swash plate (14).
PC1 28UU-2
1o-93
STRUCTURE
TRAVEL MOTOR
AND FUNCTION
OPERATION Operation of motor At slow speed (the motor swash plate angle is maximized.)
Z-Staae selection
Travel so
speed
SVPO7774
Since the travel 2nd speed selector solenoid valve is demagnetized, the pressurized oil from the main pump does not flow to the D port. Therefore, the spring (IO) has pressed the regulator valve (9) to the left side. So, the regulator valve (9) stops the main pressurized oil led from the control valve to the end cover by pushing the check valve (34). The pressurized oil in the control chamber drains in the motor case through the passage b of the regulator valve (9). Then, the main pressurized oil from the cylinder c chamber pushes the swash plate (14) in the direction to maximize the swash plate angle and the motor capacity is increased to the maximum for slow speed travel.
1o-94
PC1 28UU-2
STRUCTURE
AND FUNCTION
TRAVEL MOTOR
At high speed (the motor swash plate angle is minimized.)
SVPO7775
l
l
l
When the travel 2nd speed selector solenoid valve is energized, the pilot pressure from the main pump will flow in the D port and push the regulator valve (9) in the right direction. Therefore, the main pressurized oil from the control valve passes through the passage b of the regulator valve (9), flows in the control chamber a and pushed the regulator piston (24) in the left direction. Then, the swash plate (14) is pressed in the direction to minimize the swash plate angle, and the motor capacity is minimized for high speed travel.
PC128UU-2
1o-95
STRUCTURE
TRAVEL MOTOR
AND FUNCTION
Operation of brake valve l The brake valve consists of the check valves (3a) and (3b), the counterbalancevalve (5) and the safety valve (6), and the circuit configuration is as per the right figure. l Functions and operations of these components are as follows :
3a
SJP07627
Counterbalance valve, check valve Function l When traveling down a slope, the own weight falling force will make the machine travel So, traveling faster than the motor rotation. with reduced engine speed is very dangerous because the motor idles and runs away. These valves let the machine travel at a speed appropriate for the engine speed (pump delivery) to prevent this danger.
3a
Operation at oil supply l When the travel lever is operated, the pressurized oil from the control valve will be supplied to the PA port, push and open the check valve (3a) and flow from the MA port on the motor inlet side to the MB port on the motor outlet side. Since the motor outlet circuit is closed with the check valve (3b) and the counterbalance valve (51, however, the supply-side pressure will rise. SJP07628
1 O-96
PC1 28UU-2
STRUCTURE
l
AND FUNCTION
The pressurized oil on the supply side flows in the Sl chamber from the orifice El of the counterbalancevalve (5). When the pressure in the Sl chamber rises above the switching pressure of the counterbalance valve, the counterbalance valve (5) will be pressed in the right direction. So, the circuit between,the outlet side MB port and the PB port will open, the motor outlet circuit will open, and the motor will start rotating.
TRAVEL MOTOR
El
Sl
SJP07629
Brake operation at traveling downhill l If the machine is going to run away when traveling downhill, the motor will idle to reduce the oil pressure on the motor inlet side and the pressure in the Sl chamber through the orifice El. When the pressure in the Sl chamber drops below the switching pressure of the counterbalance valve, the counterbalance valve (5) will be returned in the left direction with the return spring (4), and the outlet side MB port will be throttled. Then, the pressure on the outlet side will rise and rotation resistance will occur to the motor to prevent the machine from running away. This means that the counterbalance valve (5) moves to a position where the machine own weight and the inlet side pressure balance with the pressure at the outlet side MB port, and the outlet circuit is throttled to control the speed to the pump delivery.
PC1 28UU-2
SJPO7630
1o-97
STRUCTURE
AND FUNCTION
TRAVEL MOTOR
Safety valve Function l When stopping a travel (or traveling downhill), the counterbalance valve (5) will close the inlet and outlet circuits of the motor. Since the motor keeps rotating by inertia, however, the pressure on the outlet side of the motor will rise abnormally and the motor and pipes may be damaged. Then, the safety valve leads the abnormally high pressure to the inlet side of the motor to prevent the equipment from being damaged. Operation When the pressurized oil being supplied from the PA port is stopped flowing at the time of travel stop, the return spring (4) will return the counterbalance valve (5) from the right side to the left side (the neutral position). Though the counterbalance valve (5) closes the a chamber on the outlet side circuit, the inertia lets the motor rotate and the pressure in the a chamber rises. The highly pressurized oil in the a chamber passes through the throttle b of the safety valve (6a) and enters in the d chamber from the c chamber. The pressurized oil entered in the d chamber moves the piston (32) to the left side. Meantime, the safety valve (6a) is pushed to open by the pressurized oil in the a chamber, and the pressurized oil in the a chamber flows in the f chamber through the e port. Therefore, the pressurized oil in the a chamber flows in the f chamber at a comparatively slow speed to control the pressure in the a chamber and also to prevent cavitation in the f chamber at the same time. When the piston (32) reaches the stroke end, the pressures in the d and c chambers will rise, the safety valve (6a) will be closed again and the pressure in the a chamber will rise further. Then, the safety valve (6b) will open and the pressurized oil in the a chamber will flow in thef chamber from the g chamber. The pressure in the a chamber can be controlled in two stage as mentioned above, and the hydraulic motor can be smoothly braked to stop.
SJP07631
[ / SJP07632
1 O-98
PC1 28UU-2
STRUCTURE
AND FUNCTION
TRAVEL MOTOR
Operation of parking brake When operating travel When the travel lever is operated, the presl surized oil from the pump will work on the counterbalance valve (51, open the circuit a to the parking brake and flow in the b-chamber of the brake piston (11). pressure in the b chamber overcomes the The l spring (31) and pushed the brake piston (11) in the left direction. This will eliminate the press force to the plate l (28) and the disc (29), and the plate (28) and the disc (29) will separate, and the brake force will be released.
SJP07633
When positioning travel neutral When the travel lever is brought to the neul tral position, the counterbalance valve (5) will return to the neutral position and the circuit a to the parking brake will be closed. The pressurized oil in the b chamber of the l brake piston (11) will be drained in the case, and the spring (31) will push the brake piston in the right direction. Therefore, the plate (28) and the disc (i9) will l be pushed to each other, and the brake will come to work.
SJP07634
PC1 28UU-2
10-99
STRUCTURE
AND FUNCTION
SWING MOTOR
SWING MOTOR TYPE : KMF4OAEL-3
MB
MA
9JYOO302
B S T MA MB
: From swing : From control : To tank : From control : From control
10-100
brake solenoid valve valve valve valve
Specification Type : KMF40AEL-3 Theoretical delivery : 40.2 cm3/rev Safety valve set pressure : 27.5 MPa (280 kg/cm2) Rated speed : 2,011 rpm Brake releasing pressure : 1.4 - 2.2 MPa(l4 - 22 kg/cm2}
PC1 28UU-2
SWING MOTOR
STRUCTURE AND FUNCTION
20
B-B
li
ti
il io
b
A-A 9JYOO303
1. 2. 3. 4. 5. 6. 7. 8. 9.
Drive shaft Spacer Case Disc Plate Brake ring Brake piston Housing Reverse prevention
PC128UU-2
valve
IO. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20.
Center spring Cylinder Valve plate Piston Center shaft Safety valve Check valve Check valve spring Shuttle valve Shuttle valve spring Brake spring
10-101
STRUCTURE
AND FUNCTION
SWING
MOTOR
SWING BRAKE 1. When solenoid valve is demagnetized Operation l When the solenoid valve of the swing brake is demagnetized, the pressurized oil from the control pump will be interrupted and the B port will be connected to the tank circuit. l Then, the brake piston (7) will be pressed downward with the brake spring (8) and will push the disc (4) and the plate (5) to work the brake.
-
Ive
SJP07635
2. When solenoid valve is energized Operation l When the solenoid valve of the swing brake is energized, the valve will be changed over and the pressurized oil from the control pump will enter the B port and will flow in the brake chamber A. l The pressurized oil in the A chamber will push the brake spring (8) and the brake piston (7) will move upward. Then, the disc (4) and the plate (5) will separate to release the brake.
SJP07636
10-102
PC1 28UU-2
STRUCTURE
AND FUNCTION
SWING
MOTOR
BRAKE VALVE Outline l The brake valve consists of the check valve (15), the shuttle valve (17) and the modulating relief valve (19). Function l When the swing stops, the control valve will close the outlet circuit of the motor, but the inertia will keep the motor rotating. So, the motor output pressure rises abnormally and the motor is damaged. So, the brake valve leads the abnormally high pressure from the outlet side (high pressure side) to the S port to prevent the motor from being damaged. 1. When swing starts Operation l When the swing operation lever is turned to the right, the pressurized oil from the pump will be led to the MA port through the control valve. Then, the pressure at the MA port will rise, generate starting torque to the motor and start the motor rotating. The oil from the motor outlet will return to the tank from the MB port through the control valve.
SJP07771
2. When swing stops Operation When the swing operation lever returns to the neutral position, the pressurized oil from the pump will not be led to the MA port. Since the control valve closes the return circuit to the tank, the oil from the motor outlet will raise the pressure at the MB port and generate rotation resistance to the motor to work the brake. When the pressure at the MB port rises above the one at the MA port, the shuttle valve (17a) is pressed and the pressure in the C chamber will rise as high as the one at the MB port. Also, it will be raised to the set pressure of the modulating relief valve (19). So, a high brake torque will work on the motor and stop it. (No. 2 Figure) While the modulating relief valve (19) is operating, the oil relieved from the safety valve and the oil from the S port are led to the MA port side through the checkvalve (15b) to prevent cavitation from occurring in the MA port. SJP07772
PC1 28UU-2
10-103
STRUCTURE
SWING MOTOR
AND FUNCTION
OPERATION OF MODULATING
RELIEF VALVE
Function l The characteristic of the swing motor relief valve is to restrain sharp rise of relief valve as shown in the right figure and to reduce shocks at the times of starting and stopping swing.
P
-:ModuIatina -------:Normal
relief
relief
valve
valve
t
T
SJP07776
1. When circuit pressure is PO Operation l The relief valve does not work.
D2
2. When circuit pressure rises sharply Operation When the circuit pressure reaches Pl, the oil pressure will push the spring (4) due to the area difference (DbD3) of the valve (3). Then, the valve (3) will start opening. At the time, the oil pressure will work on the seat (1) due to the area difference (D2>Dl), and the seat will be apt to follow the valve (3). But the seat is going to compress the oil in the a chamber and moves more slowly than the valve (3) because the passage through which the oil escapes to the S port is throttled with the ball (2). So, the relief pressure will rise slowly from Pl to P2 until the seat (1) comes to the sleeve (5).
03
Dl
S
9JYOO306
9JYOO307
P2
9JYOO306
10-104
PC1 28UU-2
STRUCTURE AND FUNCTION
REVERSE PREVENTION
SWING MOTOR
VALVE
1 0 --I-___ _-J
a
7
5 A-A
1. 2. 3. 4. 5. 6. 7.
MA
L____
Tl
T2
MB Z
9JUOOO72
Valve body Spool (MA side) Spring (MA side) Plug (MA side) Spool (MB side) Spring (MB side) Plug (MB side)
MA : MB: Tl : T2 :
Port Port Port Port
PC128UU-2
10-105
STRUCTURE
AND FUNCTlON
Effect explanation
SWING MOTOR
drawing
_
:With reversal rotation Prevention valve ,Without reversal rotation Prevention valve
MA Pressure
MB Pressure
Motor
rotat
ion
Start
Brake
Time
t
SJPO7637
10406
PC128UU-2
STRUCTURE
SWING MOTOR
AND FUNCTION
Function l This function is used for reducing swing back generated on a swing body that can result from factors such as inertia of the swing body, backlash and rigidity of the machinery system and compressibility of hydraulic oil. l This function helps preventing loose loads at the end of swing or cutting lead time (better positioning performance allows you to proceed to the next operation within a shorter time).
c
I /
II
I I
MB
Not/ch L!J
SJP07777
1. When MB port pressure is generated Operation l MB pressure is conducted to d room via the cutout. Utilizing difference of space (Dl>D2), the pressure compresses the spring (6) and drives the spool (5) leftward to interconnect MB+e. l Since MA pressure at this time is lower than the pressure set on the spring (3), the spool (2) is not moved and pressurized oil remains closed. Thus, the braking force is maintained.
SDP02.036
2. When the motor is once stopped Operation The motor is reverse rotated by charging pressure generated on the MB port (1st reverse rotation). At this time, reversing pressure is generated on the MA port. MA pressure conducted to a room interconnects MA + b by compressing the spring (3) and driving the spool (2) rightward. The pressure is then conducted through drilled hole on the spool (5) to interconnect b + f. Reversing pressure on the MA port is bypassed to the T port to disable the 2nd reverse rotation.
PC1 28UU-2
n c
I
f SDP02037
10-107
STRUCTURE
SOLENOID
AND FUNCTION
VALVE
SOLENOID VALVE FOR PPC LOCK, 2ND TRAVEL SPEED SELECT, SWING HOLD BRAKE AND P-STAGE RELIEF SOLENOID VALVE.
Al
A4
A3
A2
A-A
10
9
9JA01353
1. 2. 3. 4.
PPC lock solenoid valve 2nd travel speed select solenoid valve Swing hold brake solenoid valve 2-stage relief solenoid valve
Solenoid valve 5. Push pin 6. Coil 7. Gauge 8. Spool 9. Block 10. Spring
Al A2 A3 A4 ACC PI T
: To PPC valve : To 2-stage relief valve : To swing hold brake : To 2nd travel speed select valve : To accumulator : From self-pressure reducing valve : To hydraulic oil tank
Check valve 11. Plug 12. Spring 13. Plunger
lo-108
PC128UU-2
STRUCTURE
AND FUNCTION
SOLENOID
VALVE
Operation When solenoid is “demagnetized” l The coil (6) remains demagnetized as long as signal current to it is stopped.. l Thus, the spool (8) is pushed leftward by the spring (10). l Since ports P to A are closed by this spool, flow of pilot oil pressure to the actuator is blocked. At the same time, oil from the actuator. is lead from A port to T port, then drained to the hydraulic oil tank.
SJP07636
When solenoid is “magnetized” The coil (6) is magnetized by signal current conducted to it. Thus, the spool (8) is pushed rightward by the push pin (5). As the result, pilot oil pressure is conducted from P port through the cage (7) and A port up the actuator. At the same time, T port is closed, thereby blocking flow of oil to the hydraulic oil tank.
Excit
I) .
SJP07639
PC1 28UU-2
10409
EPC SOLENOID VALVE
STRUCTURE AND FUNCTION
EPC SOLENOID VALVE FOR 4-SYSTEM
CONTROL
:
A-A
I6 I5 I4
I3 I2 A-A 9JBOOl30
10-110
PC128UU-2
STRUCTURE
1. 2. 3. 4. 5.
AND FUNCTION
EPC SOLENOID
VALVE
Offset right stop solenoid valve Offset left stop solenoid valve Boom up stop EPC valve Arm retract stop EPC valve Boom down stop EPC valve
EPC valve 6. Coil (proportional 7. Push pin 8. Valve spool 9. Guide 10. Return spring 11. Valve body
type)
Solenoid valve 12. Return spring 13. Guide 14. Valve spool 15. Push pin 16. Coil (ON - OFF type) Check valve 17. Plug 18. Spring 19. Ball Al : From offset PPC valve “RIGHT” A2 : From offset:PPC valve “LEFT” A3: From right work equipment PPC valve “BOOM UP” A4 : From right work equipment PPC valve “ARM RETRACT” A5: From right work equipment PPC valve i “BOOM DOWN” Bl : To operation valve “OFFSET RIGHT” B2 : To operation valve “OFFSET RIGHT” B3 : To operation valve “BOOM UP” B4 : To operation valve “ARM RETRACT” B5 : To operation valve “BOOM DOWN” T : To hydraulic oil tank
PC 128UU-2
10-111
STRUCTURE
’
EPC SOLENOID
AND FUNCTION
VALVE
OPERATION Solenoid valve When solenoid is “demagnetized” (circuit is isolated) l The coil (1) is demagnetized when signal current from the controller to it is stopped. l Thus, the spool (2) is pushed up by the return spring (4). l As the result, A port is closed, thereby stopping flow of oil pressure from PPC valve to the operation valve. At the same time, oil from the operation valve is conducted to B port through T port and finally drained to the tank.
SJPO7640
When solenoid is “magnetized” (circuit is in connection) l The coil (1) is magnetized by signal current conducted to it from the controller. l Thus, the spool (2) is pushed down by the push pin (3). l As the result, pressurized oil from the PPC valve is conducted to A portthrough the spool (2) and B port up to the operation valve. At the same time, T port is closed, thereby blocking oil flow to the tank.
Control
valve
SJPO7641
10-112
PC1 28UU-2
STRUCTURE
AND FUNCTION
EPC SOLENOID
VALVE
EPC valve When signal current is maximized (coil is magnetized and circuit pressure at maximum level) l The coil (1) is magnetized when signal current is conducted to it from the controller. Thrust of the coil (1) is maximized at this time. l Thus, the spool (2) is pushed down by the push pin (3). l As the result, all the pressurized oil from the PPC valve is conducted to A port through the spool (2) and B port up to the operation valve. At the same time, T port is closed, thereby blocking flow of oil to the tank.
SJP07642
When signal current is reduced (coil is magnetized and circuit pressure at a reduced level) l If signal from the controller to the coil (1) is reduced, the coil thrust is reduced in proportion to the reduction in signal current though the coil (1) still remains magnetized. l Thus, the push pin (3) pushes the spool (2) downward, thereby conducting pressurized oil from A port to B port. l If working force of the spool (2) against face a becomes greater than thrust of the coil (1) because of increased pressure on B port, the spool (2) is pushed up thereby disconnecting A port from B port and, at the same time, connecting A port to T port. l As the result, the spool (2) moves up and down so that thrust of the coil (1) and pressure on B port may be balanced. l Circuit pressure between PPC valve and operation valve is, as seen above, adjusted in proportion to magnitude of signal current. SJP07643
PC1 28UU-2
10-113
STRUCTURE
AND FUNCTION
EPC SOLENOID
VALVE
Signal current 0 (coil is demagnetized and circuit in isolation) l If signal current from the controller to the coil goes to 0, the coil (1) is demagnetized. l Thus, the spool (2) is pushed up by the return spring (4). l As the result, A port is closed, thereby blocking flow of pressurized oil from the PPC valve to the operation valve. At the same time, oil from the operation valve is passed through B and T ports, and finally drained to the tank.
: Control
valve
wit
,,,i
SJP07644
Signal current 0 + increased + maximum l Operation takes place in the above order of 3 *2+1.
10-114
PC128UU-2
STRUCTURE
PPC ACCUMULATOR
AND FUNCTION
PPC ACCUMULATOR 1. 2. 3. 4. 5. 6.
Gas plug Shell Poppet Holder Bladder Oil port
SBPOO290
Specifications Gas used : Nitrogen gas Gas capacity : 0.3~? Charged gas pressure : 1.18 MPa (12 kg/cm*) at 80°C Maximum operating pressure : 6.86 MPa (70 kg/cm*)
PC1 28UU-2
10-115
STRUCTURE
AND FUNCTION
PPC VALVE
PPC VALVE FOR SWING OF WORK EQUIPMENT
9JYOOO39
P : From main pump Pl : Left: Arm for dump/Right : Boom down P2 : Left : Arm for digging/Right : Boom up
lo-116
P3 : Left : Swing right/Right : Bucket for digging P4: Left : Swing left/Right : Arm for dump T :Totank
PC1 28UU-2
STRUCTURE AND FUNCTION
PPC VALVE
8
I
A-A
D-D
E-E SBPO0274
1. Spool 2. Metering spring 3. Centering spring 4. Piston
PC1 28UU-2
5. 6. 7. 8.
Disk Nut (for linking the lever) Joint Plate
9. Retainer 10. Body 11. Filter
10-117
STRUCTURE
AND FUNCTION
PPC VALVE
Operation 1. In the neutral mode l Pl and P2 ports of the operation valves A and B and the PPCvalve are connected to the drain room D via the fine control hole on the spool (1).
R
1
:::
2. .
.
.
.
.
.
In the fine control mode (neutral 4 fine control) When the piston (4) is pushed by the disk (5), the retainer (9) is also pushed, thereby driving the metering spring (2) down via the spool (1). As the result, the fine control holef is isolated from the drain room D and, almost at the same time, it is connected to the pump pressure PP. Then, pilot pressurized oil for the main pump is conducted from Pl port to A port via the fine control hole f. As pressure on Pl port is increased, the spool (1) is pushed back thereby disconnecting the fine control hole f from the pump pressure room PP. The disconnected spool (1) is in no time connected to the drain room D, resulting in relieving pressure on Pl port. Thus, the spool (1) is moved up and down so that force of the metering spring (2) and pressure on Pl port may be balanced. Positional relationship between the spool (1) and body (IO) (fine control hole f is situated at mid point between the drain room D and pump pressure room PP) remains unchanged until the retainer (9) is contacted against the spool (1). Therefore, the metering spring (2) is compressed in proportion to strokes of the operation lever. So, pressure on Pl port is also increased in proportion to strokes of the operation lever. As the result, the operation valve spool is moved up to the position where pressure in A room (the same pressure level as that on Pl port) and force of the operation valve spool return spring is balanced.
lo-118
/ L!zD
5::
~u,u,,,:: : I
‘5’ : Pl :
/,I
5:: //, ::: P2;
::
5, ,//////, : 5
(Fig
1) SEP0.2569
(Fig
2)
SEP02570
PC128UU-2
,STRUCTURE
3. l
l
l
l
4. l
l
l
AND FUNCTION
In the fine control modeloperating lever shifted back to its original position) As the disk (5) starts returning, the spool (1) is push up by force of the centering spring (3) and pressure of Pl port. Thus, passage between the fine control hole f and drain room D becomes, thereby relieving pressurized oil of Pl port. If Pl port pressure goes excessively low, the spool (1) is pushed down by the metering spring (2) and passage between the fine control hole f and the drain room D is shut down. And, almost at the same time, the hole is connected to the pump pressure room PP and starts supplying pump the pressure. This supply continues until the Pl port pressure is recovered to the level equivalent to the lever position. When the operation valve returns, oil in the drain room D flows in through the fine control hole f’ on the not moving side valve. Oil is then conducted via P2 port to the room B to fill it up.
PPC VALVE
Control
valve
(Fig
3)
SEP02571
In the full stroke mode When the disk (5) pushes down the piston (4) and the retainer (9) pushes down the spool (I), connection of the fine control hole f is switched from the drain room D to the pump pressure room PP. Thus, pilot pressurized oil from the control pump passes through the fine control hole f and conducted to A room via Pl pot-t to push the operation valve spool. Return oil from B room is conducted from P2 port to the drain room D via the fine control hole P.
Control (Fig
PC1 28UU-2
valve 4)
SEP02572
10-119
STRUCTURE
PPC VALVE
AND FUNCTION
FOR TRAVEL
f
Pi
P2
/ Pi
P : From main pump Pl : L.H reverse P2 : L.H forward
10420
A
\ P3
9JYOOO44
P3 : R.H reverse P4 : R.H forward T :Totank
PC128UU-2
STRUCTURE
AND FUNCTION
PPC VALVE
A-A
B-B
c-c
1. 2. 3. 4.
Plate Body Piston Collar
PC1 28UU-2
D-D
5. 6. 7.
9JYOOO45
Metering spring Centering spring Valve
10-121
STRUCTURE
PPC VALVE
AND FUNCTION
Operation 1. In the neutral mode l Pl and P2 ports of the operation valves A, B and PPC valve are connected to the drain room D via the fine control holef on the spool (1).
(Fis.
2. .
.
.
.
In the fine control mode (neutral + fine control) As the piston (4) is pushed by the disk (51, the retainer (9) is pushed, too. At the same time, the spool (1) is also pushed down via the metering spring (2). By this move, connection of the fine control hole f is switched from the drain room D to the pump pressure room PP, and pilot pressurized oil for the main pump is conducted from PI port to A port. As Pl port pressure increases, the spool (1) is pushed back. By this move, connection of the fine control hole f is switched from the pump pressure room PP to the drain room D, thereby relieving PI port pressure. As the result, the spool (1) moves up and down so that force of the metering spring (2) and Pl port pressure may be balanced. Positional relationship between the spool (I) and body (10) (fine control hole f is situated at mid point between the drain room D and pump pressure room PP) remains unchanged until the retainer (9) is contacted against the spool (1). The metering spring (2) is, therefore, compressed in proportion to strokes of the operation lever. Thus, the Pl port pressure, too, increases in proportion to strokes of the operation lever. As the result, the operation valve spool moves to the position where pressure of A room (the same as Pl port pressure) is balanced against force of the operation valve spool return spring.
10-122
1)
SElPO3497
ISelf-Reducing 111 v@f/ lsressure valve]~
(F i s. 2)
SBPO3498
PC128UU-2
STRUCTURE
3. .
.
.
.
4. l
l
l
AND FUNCTION
PPC VALVE
In the ffine control mode (when operation lever is shifted back to its original position) As the disk (5) starts returning, the spool (1) is pushed up by force of the centering spring (3) and Pl port pressure. By this move, the fine control hole f is connected to the drain room D and relieves pressurized oil of Pl port to it. If Pl port pressure goes excessively low, the spool (1) is pushed down by the metering spring (2) and passage between the fine control holef and the drain room D is shut down. And, almost at the same time, the hole is connected to the pump pressure room PP and starts supplying pump the pressure. This supply continues until the PI port pressure is recovered to the level equivalent to the lever position. When the operation valve spool returns, oil in the drain room D flows in through the fine control hole f’ on the not moving side valve. Oil is then conducted via P2 port to the room 6 to fill it up.
(Fig.
In the full stroke mode When the disk (5) pushes down the piston (4) and the retainer (9) pushes down the spool (l), connection of the fine control hole f is switched from the drain room D to the pump pressure room PP. Thus, pilot pressurized oil from the control pump passes through the fine control hole f and conducted to A room via Pl port to push the operation valve spool. Return oil from B room is conducted from P2 port to the drain room D via the fine control hole f’.
3)
SBPO3499
M
1 Pressure
valvd
j/f$Q
,
(F i o. 3) SBPO3495
PC1 28UU-2
10423
STRUCTURE
PPC VALVE
AND FUNCTION
FOR BLADE, OFFSET
A-A
1. 2. 3. 4. 5. 6. 7. 8. 9.
Spool Metering spring Centering spring Piston Lever Plate Retainer Body Filter
P PI P2 T
: From main pump :::Totank
lo-124
9JUOOO15
PC1 28UU-2
STRUCTURE
PPC VALVE
AND FUNCTION
Operation 1. In the neutral mode Pl and P2 ports of the operation valves A, 6 l and PPC valve are connected to the drain room D via the fine control hole f on the spool (1).
Pl
2. .
l
.
.
.
.
.
In the fine control mode (Neutral + fine control) As the piston (4) is pushed by the disk (5), the retainer (7) is pushed, too. At the same time, the spool (1) is also pushed down via the metering spring (2). By this move, connection of the fine control hole f is switched from the drain room D to the pump pressure room PP, and pilot pressurized oil for the control pump is conducted from PI port to A port. As Pl port pressure increases, the spool (1) is pushed back. By this move, connection of the fine control hole f is switched from the pump pressure room PP to the drain room D, thereby relieving Pl port pressure. As the result, the spool (1) moves up and down so that force of the metering spring (2) and Pl port pressure may be balanced. Positional relationship between the spool (1) and body (8) (fine control hole f is situated at mid point between the drain room D and pump pressure room PP) remains unchanged until the retainer (7) is contacted against the spool (1). The metering spring (2) is, therefore, compressed in proportion to strokes of the operation lever. Thus, the Pl port pressure, too, increases in proportion to strokes of the operation lever. As the result, the operation valve spool moves to the position where pressure of A room (the same as Pl port pressure) is balanced against valve spool return force of the operation spring.
PC1 28UU-2
I
SJP07646
SJPO7647
1O-l 25
STRUCTURE
3. l
l
l
PPC VALVE
AND FUNCTION
In the fine control mode (when the operation lever is shifted back to its original position) As the lever (5) starts returning, the spool (1) is pushed up by force of the centering spring (3) and Pl port pressure. By this move, the fine control hole f is connected to the drain room D and relieves pressurized oil of PI port to it. If PI port pressure goes excessively low, the spool (1) is pushed down by the metering spring (2) and passage between the fine control hole f and the drain room D is shut down. And, almost at the same time, the hole is connected to the pump pressure room PP and starts supplying pump the pressure. This supply continues until the Pl port pressure is recovered to the level equivalent to the lever position. When the operation valve spool returns, oil in the drain room D flows in through the fine control hole f’ on the not moving side valve. Oil is then conducted via P2 port to the room B to fill it up. SJP07648
4. l
l
l
In the full stroke mode When the disk (5) pushes down the piston (4) and the retainer (7) pushes down the spool (l), connection of the fine control hole f is switched from the drain room D to the pump pressure room PP. Thus, pilot pressurized oil from the control pump passes through the fine control hole f and conducted to A room via Pl port to push the operation valve spool. Return oil from B room is conducted from P2 port to the drain room D via the fine control hole f’.
Control valve
SJP07649
lo-126
PC128UU-2
STRUCTURE
AIR CONDITIONER
AND FUNCTION
AIR CONDITIONER
PIPING
PIPING
8
9JA01358
1. 2. 3. 4. 5. 6. 7. 8.
Hot water take-off piping Air conditioner compressor Condenser Refrigerant piping Receiver tank Air conditioner unit Hot water return piping Duct
A: Hot air/cold air spurting hole B: Inner air circulation hole
PC1 28UU-2
lo-127
STRUCTURE
ELECTRIC EQUIPMENT
AND FUNCTION
ELECTRIC EQUIPMENT
LAYOUT DRAWING
LAYOUT DRAWING
‘I!
30-
29
28
27
26
25
24 9JBOOl32
lo-128
PC1 28UU-2
STRUCTURE
1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. 21. 22. 23. 24. 25. 26. 27. 28. 29. 30. 31. 32. 33. 34. 35. 36. 37. 38. 39. 40. 41. 42. 43. 44. 45. 46. 47. 48. 49. 50. 51. 52.
AND FUNCTION
ELECTRIC EQUIPMENT
LAYOUT DRAWING
Expanded light (optional) Fuel level sensor Left working lamp PC-EPC solenoid valve Safety relay Starter Engine speed sensor Coolant temperature sensor Alternator Ribbon heater Engine oil pressure sensor Air conditioner compressor Heater relay Engine stop solenoid valve Condenser Washer tank Battery relay ’ Battery Fusible link Controller Emergency arm retracting resistor (IOQ) Emergency boom lifting resistor (5R) Light relay Emergency pump driving resistor (30R) Air conditioner unit Travel acceleration pedal Deceleration controller Travel pressure switch Swing hold brake relief switch Emergency pump driving switch Attachment select connector [Arm] Horn Boom potentiometer Left swing pressure switch Right swing pressure switch Boom down pressure switch [No. 11 Arm retract pressure switch Boom up pressure switch Arm potentiometer 2-stage relief solenoid valve Swing hold brake solenoid valve 2nd travel speed select solenoid valve PPC lock solenoid valve Right working lamp Offset right solenoid valve Offset left solenoid valve Boom up EPC valve Arm retract EPC valve Boom down EPC valve Offset potentiometer Travel alarm (optional) Boom down pressure switch [No. 21
PC1 28UU-2
1O-l 29
STRUCTURE AND FUNCTION
ELECTRIC EQUIPMENT LAYOUT DRAWING
62
63
9JBOOl
10-130
33
PC128UU-2
STRUCTURE
53. 54. 55. 56. 57. 58. 59. 60. 61. 62. 63. 64. 65. 66. 67. 68. 69. 70. 71. 72. 73. 74. 75. 76. 77. 78. 79.
AND FUNCTION
ELECTRIC EQUIPMENT
LAYOUT DRAWING
Hot air control switch Air flow selector switch Air conditioner switch Horn switch Monitor panel Setup switch Mode selector switch One-touch deceleration pilot lamp Starter switch Fuse box Fuel adjusting motor Expanded light switch (optional) Wiper controller Car heater switch (Heater specification) Wiper controller Lamp switch Travel speed selector switch PPC lock switch One-touch deceleration switch Expanded light relay Emergency work equipment operation switch Alarm buzzer Room lamp Antenna Car radio Speaker Wiper motor
PC1 28UU-2
10431
STRUCTURE
AND FUNCTION
ENGINE CONTROL
ENGINE CONTROL
7
V
Z 9JA01361
9
1. 2. 3. 4. 5. 6.
Fuel adjust motor One-touch deceleration Fuel adjust dial Starter Starter switch Engine stop solenoid
pilot lamp
7. 8. 9. 10. 11. 12.
Deceleration controller Battery relay Battery One-touch deceleration Governor Fuel injection pump
switch
‘.
10-132
PC128UU-2
STRUCTURE
AND FUNCTION
ENGINE CONTROL
OPERATING SYSTEM STARTING ENGINE
Enaina stop solenoid valve (Operation) w&& Lo
Ii
Engine
i(Power .a
I
SUPPIY)
deceleration
I_
1 +“l
switch
deceleration
~1 Fuel control box
Battery
dial
1, 1 1
Bat terv
SJPO7650
When the starter switch is shifted to the ON position, the engine stop solenoid drives the governor stop lever to the OPERATION position. Should an error develop in the electric system, this arrangement stops the engine operation that functions as a fail-safe mechanism. Shifting the starter switch to the START position conducts signal current to the starter. The starter is rotated by this current to turn on the engine operation. Since the fuel adjust dial is linked with the fuel adjust motor, the engine is driven at the speed set on the fuel adjust dial.
PC128UU-2
10-133
STRUCTURE
AND FUNCTION
ENGINE CONTROL
ENGINE SPEED CONTROL
Enaina stop solenoid valve -(Operation)
Engine
Hi Lo
Yh
(Cable
extended/contracted)
deceleration
switch
ontrol
dial
Fuel contra motor
\
relay
III
: SJPO7721
l
l
The fuel adjust dial is linked with the fuel adjust motor. The fuel adjust motor drives the cable so that the governor lever position may correspond to that of the fuel adjust dial.
10-134
PC1 28UU-2
STRUCTURE
AND FUNCTION
ENGINE CONTROL
ENGINE STOP
Ensing stop solenoid valve (StoPPing)
Engine
eceleration
switch
ontrol
dial
Fuel contra mtar
\
relay
I
_I I SJP07722
l
If you shift the starter switch to the OFF position, the engine stop solenoid drives the governor stop lever to the STOP position to stop the engine.
PC1 28UU-2
1o-1 35
STRUCTURE
AND FUNCTION
ONE-TOUCH
ENGINE CONTROL
DECELERATION Ene ins stop solenoid valve (Operation)
qwi
(Cableextended)
I(Power
SUPPIY)
deceleration
I
SW itch
deceleration
-SJP07723
.
*
*
Pressing the one-touch deceleration switch conducts the deceleration signal to the deceleration controller. The deceleration controller turns on the onetouch deceleration pilot lamp and, at the same time, drives the fuel adjust motor to slow down the engine speed to low idling level. Pressing the one-touch deceleration switch once turns on low idling and pressing it again restores the speed set on the fuel adjust dial. The one-touch deceleration function applied to stop the engine is cancelled at the next start. Namely, when you resume your operation, the engine operation will be driven at the speed set on the fuel adjust dial. As long as the one-touch deceleration mode is continued, you cannot change the engine speed from the fuel adjust dial, namely the engine speed remains at the low idling.
10436
Engine Speed (r pm)
Decelerated
*
Speed
Max. I--
Deceleration ON
-Time (Sec. 1 Deceleration OFF SJP07778
PC1 28UU-2
STRUCTURE
SYSTkM
ENGINE CONTROL
AND FUNCTION
COMPONENTS
FUEL ADJUST DIAL
IGH
ii
!I
A-*
I!
\
a
9JA01366
1. 2. 3. 4.
One-touch deceleration Fuel adjust dial Boss Boss
PC1 28UU-2
pilot lamp
5. 6. 7. 8.
Shaft Joint Bracket Fuel adjust motor
1o-1 37
STRUCTURE
AND FUNCTION
FUEL ADJUSTING
ENGINE CONTROL
MOTOR
A-A
9JA01367
1. 2. 3.
Motor assembly Cable Connector
10438
PC128UU-2
STRUCTURE
ENGINE CONTROL
AND FUNCTION
DECELERATION CONTROLLER
SFP06891
Input/output signal M-2P [CN-K161 Pin No. 1 2
Signal name Deceleration Deceleration
pilot lamp (+I pilot lamp (-1
SWP-6P [CN-K18] Signal name Pin No. 1 I Motor (+) 1
6
1 Deceleration signal
PC128UU-2
I/O signal output
X-4P [CN-K17] Signal name Pin No. 1 1 Power SUDDIV (24V) 1 1 GND 2 1 NC 3 1 One-touch deceleration 4
1I/O signal I InDut I
I switch 1
InDut
Input
1 I/O signal 1 OUtDUt
1 Outbut
1o-1 39
STRUCTURE
AND FUNCTION
ELECTRIC CONTROL SYSTEM
ELECTRIC CONTROL SYSTEM OVERALL SYSTEM DIAGRAM
I rave I speea selec tor switch
1 II
Swing holding i brake ! - -
Travel
_-_-_----___ E- i I ! L---: I_: m
____ 2-stage
vd’v=I --_--_I_!
! I----
q
I
!
j
III
-rator -
relief/
+=5l I
^,,
!
.
I
;,____:_
-Qm!__i [~~ ,:_____;______~ -__-_______i .___r____l
Monitor
Panel
Alarm buzzer
Emergency Pump
Start switch
ina
a
.:’
a .f rminal SJP07725
PC128UU-2
STRUCTURE
ELECTRIC CONTROL SYSTEM
AND FUNCTION
PUMP CONTROL FUNCTION
Boom
Bucket
R. H. PPC valve
i I
L. H.
R. H.
i-._______________~ I I
I
I I
Control Main relief
valve valve
F
Ensin
PC-EPC va I ve
Offset Offset PPC va I ve
‘p’ ---
i-i
!_______
______J
;_--------_-! &._______________a
Blade Blade PPC va I ve
Battery
(Rotation sisnall (Boom LOWER signal)_ . IEioo~ RAISE signal)_ (Travel signal) (Swing signal), (Arm CURL signal)_ (Power SUP~IY)
& AIS
Battery relay
LOWE
Fuse
box
I
! t
Emergency pump drive switch 1YI1
_
Controller
Resistor
SJPO7726
PC128UU-2
10-141
STRUCTURE
ELECTRIC CONTROL SYSTEM
AND FUNCTION
Function The controller sets up a pump absorption l torque corresponding to the engine speed. As the engine speed goes high, it enhances the pump operating performance by increasing its absorption torque. When the engine speed goes low, the controller reduces the pump absorption torque to prevent the engine from stopping.
Engine torque
64kW/2.200rPm (87PS/2.200r~ml
,” z z
At travel I ins
.-z -z
At operat ina
D=: CCI
Engine
Emergency pump drive If normal operation of the pump became unl available due to failure on the controller, you can fix the situation temporarily and resume your operation by operating the emergency pump drive switch. (1) In normal operation. (2) When a failure occurred.
Pump absorption torsue
speed SJP07727
pum Emergency switch drive Swing brake
holding release
SJPO7728
lo-142
PC1 28UU-2
STRUCTURE
ELECTRIC CONTROL SYSTEM
AND FUNCTION
RELIEF FUNCTION
Control
valve
Main relief
valve
___ ___ ___-- - i
Self Pressure -------7 reducing valve Engine L. H. travel
I )
I 1 II I
;2-stage I solenoid
relief valve
R. H. travel
w __---_-_---__--------------__-_______I_______~
:j:;&-&+ ‘-y_j
Oi I I Pressure switch
i-+-i 1-J
I (Travel
signal) Controller
(Drive
signal:
(Power SUPPIY)
SJP07729
Function 2-stage relief l Relief pressure during normal operation is 31.9 MPa (325 kg/cm2}. When the 2-stage relief function is turned on, it goes up to 34.8. MPa (355 kg/cm*}, thereby increasing hydraulit power.
PC1 28UU-2
Relief pressure
Condition I During
31.9 MPa (325 kg/cm21
travel
1 34.8
MPa (355
kg/cm*)
10-143
STRUCTURE
AND FUNCTION
ELECTRIC CONTROL SYSTEM
SWING CONTROL FUNCjlON
Swing holding
brake!-
I I 1
Swing
-7I I
Ens i
L. H. PPC va I ve
Swing
brake
,
,‘F____________-----_____I I
Arm
Swing holding solenoid valve
Main Pump
II
I=
I z I = I .-m ___________________________-_------___-----_-_________~2 .Oi I Pressure switch
L
E
Controller
Battery
Battery relay
[:ze
Swine holding brake release switch
SJPO7730
10-144
PC1 28UU-2
STRUCTURE
ELECTRIC CONTROL SYSTEM
AND FUNCTION
Fun&m Swing‘holding brake l As soon as swing is stopped, the swing hold brake is automatically activated to prevent hydraulic drift on slopes. * Wlien the swing hold brake is open, the hydraulic brake via the safety valve alone is turned on after swing is stopped. In this case, therefore, reasonable care must be exercised to prevent hydraulic drift. * The swing hold brake must be cancelled while the arm retract operation is continued.
Parking brake or relation release switch Swing hold brake cancel switch
ON (automatic)
ing the swing (1)
During
(2) When
hold brake cancel
normal failure
OFF (cancel)
holding
brake
Operation
l
Swing holding brake release switch l Should the control fail, thereby disabling normal performance of the swing hold brake during your operation, you can turn on swing again by canceling the swing hold brake us-
swing
l
switch.
operation.
Shift the swing operation lever or the arm retract lever to neutral, and the swing hold brake will be turned on in approximately 4 seconds. You can cancel the swing hold brake and free the swing operation from control of the brake by operating the swing operation lever or arm retract lever. Should an error develop in he swing hold brake system, shift the swing hold brake cancel switch to the OFF position to free the swing operation from control of the brake. In this case, however, you cannot activate the swing hold brake again by returning the swing operation lever or arm retract lever back to the neutral position.
occurred.
Emergency Pump drive switch A Swing brake
holding release
SJPO7728
PC128UU-2
10-145
STRUCTURE
ELECTRIC CONTROL SYSTEM
AND FUNCTION
TRAVEL CONTROL FUNCTION
j Travel speed 1selection I solenoid valve
L. H. travel
Oi I Pressure .I swi rcn
Travel speed selector switch
R. H. travel
(Travel
sisnal)
(Trave -ration
I Controller
I act sianal)
d
(Power SUPPIY) L
SJP07732
Function Travel speed selection l Travel speed is switched according to changes in the motor capacity that you can cause from the travel speed selector switch or acceleration pedal.
Travel speed selector switch Motor capacity (cc/rev) Travel speed (km/h) Travel motor angle of inclination
lo-146
1
LOW 1 HIGH (low speed) (high speed) 52.7
37.2
3.2
4.6
Max.
Min.
PC1 28UU-2
STRUCTURE
ELECTRIC CONTROL SYSTEM
AND FUNCTION
PPC LOCK FUNCTION
L. H. travel
R. H. travel
Trave PPC va I ve
L. H. PPC va 1ve
Battery r4-44
IC
Fuse
Battery re,aY 4-k-m-m
I@l
hnv
“uA
(Power
SUPPI
1
Controller
SJP07733
Function l The PPC lock switch is linked with the safety lock lever. And, shifting the safety lock lever to the LOCK position turns the PPC lock switch to the OFF position. l As the PPC lock switch is turned OFF, current to the PPC lock solenoid valve is shut down, thereby making it inoperable from the work equipment operation lever.
PC1 28UU-2
10-147
STRUCTURE
ELECTRIC CONTROL SYSTEM
AND FUNCTION
SYSTEM COMPONENTS Engine speed sensor
SBPOO365
Function l The engine speed sensor is installed on the ring gear of the engine flywheel. It electritally counts number of gear teeth that pass its front side and sends the counting to the pump controller. Remarks: l
Number
1. 2. 3. 4. 5.
Wire Magnet Terminal Housing Connector
of ring gear teeth is 127.
For the count, a magnet is used which generates current every time a gear tooth passes its front side.
lo-148
PC128UU-2
STRUCTURE
ELECTRIC CONTROL SYSTEM
AND FUNCTION
PPC hydraulic switch
: SBPOO366
Specification Contact configuration : Normally open contact Operating (ON) pressure : 490 f 98.1 kPa (5.0 + 1 .O kg/cm*} Reset (OFF) pressure : 294 f 49.0 kPa (3.0 f 0.5 kg/cm*}
1. 2. 3.
Plug Switch Connector
Function l A total of six PPC hydraulic switches are provided on the pressure switch bracket. They monitors operation of respective actuators by detecting PPC pressure and send data to the controller. l Another PPC hydraulic switch is installed on the PPC travel valve to monitor travel operations by detecting PPC pressure. The controller uses this data for driving the 2-stage relief valve.
PC128UU-2
10-149
STRUCTURE
ELECTRIC CONTROL SYSTEM
AND FUNCTION
Controller Resistor * Refer to the section tern”.
describing
Monitor panel Refer to the section describing * System”. PC valve LS valve PC-EPC valve Refer to the section describing * lic Pump (Piston pump)“.
the “4-Sys-
the “Monitor
the “Hydrau-
PPC lock solenoid valve 2nd speed select solenoid valve Swing hold brake solenoid valve 2-stage relief solenoid valve Refer to the section describing the “Solenoid * Valve”.
10-150
PC128UU-2
STRUCTURE
4-SYSTEM
AND FUNCTION
4-SYSTEM l
The 4-system is intended to ensure work safety and to facilitate operationg performance. It is consisted of the following subsystems; Interference Prevention System, Depth Measurement System, Automatic Boom/Arm Stop System and Offset Position Setup System.
CONTROL FUNCTIONS
-I
Reduction function
Stop/alarm
Interference
prevention system
function
Emergency stop/alarm
4
I
function
Canceling function
I
Reset function
r-i
Depth-from-ground-surface function
Depth measurement
1
4-system
display
system
-
ä
Depth-from-datum-plane function
display
Height setup function Automatic
boom/ar Depth setup function
Offset position setup system
Offset position setup function
Boom end cushioning function
Arm end cushioning function
Self-test function
PC1 28UU-2
10-151
STRUCTURE
AND FUNCTION
CSYSTEM
SYSTEM DIAGRAM
Arm
EPC so I en va I ve
Boom
I t 8 1
.mIN
I t t t I
lPPC lock !solenoid
; “‘jj----d
LEFT:
Offset
valve
&ID_j
‘fset
LEFT
:*
___:
llllllr--+LIJl
I I I
I I
Arm
I
Swing!
!____,
‘fset
RIGHT
I I
r---i
.J
-4gl .--. t I
I
7f
II
Offset Offset
II PPC If I va I ve I I____________ &+ ___ ___A
Mon i Pane
I. .
Blade
1 IAttachment% cknnector
Blade PPC va I ve
:I
Controller
Ll
tExtrrinr inkier ce creel small
Terlinet for exterior ieterfereece cancel iloxe
I ..
SJP07734
1O-l 52
PC128UU-2
STRUCTURE
4-SYSTEM
AND FUNCTION
INTERFERENCE PREVENTION
SYSTEM
Cab interference prevention system Structure of the machine’s work equipment can introduce interference of the bucket against the cab when you turn on the left offset operation or operation of the work equipment. This ,interference potentially occurs at front side and right side of the cab. The interference prevention system constantly monitors the bucket position in order to automatically stop move of the work equipment and sound the alarm buzzer if the bucket approaches any of these interfering zones. This function ensures work safety and operating performance in the left offset area.
SJP07735
The controller constantly calculates X, Y and 2 coordinates of point A referencing output signal from the potentiometer on rotation angle of the boom, arm or offset. The potentiometer is provided for each of the boom, arm and offset. If point A approaches the interfering zone (namely, if it enters reduction zone), the system reduces move speed of the work equipment (except the offset). If the controller or one of the potentiometers fails, the system stops move of the work equipment by stopping supply of power to respective solenoid valves. In this case, you can resume the work equipment operation by turning on the emergency work equipment operation switch.
X-
Arm
Potentiometer
Z I
tio r
SJP07736
PC1 28UU-2
10-153
STRUCTURE
4-SYSTEM
AND FUNCTION
Overall operation diagram The bucket position in the diagram is somewhat * descriptions of the system function.
Safety
zone
Reduction (~QOOm)
zone
Stop
modified from that in actual operations
zone
to facilitate
Emergency stop zone \
SJP07737
10-154
PC1 28UU-2
STRUCTURE
1. .
.
.
*
2. .
Ir
*
3. .
.
.
*
4-SYSTEM
AND FUNCTION
Reduction function Speed of the bucket is reduced when it passes through the safety zone and enters the reduction zone. The system ensures smooth reduction of the bucket without introducing undesirable impacts by reducing the “boom up” and “arm retract” speeds. In order to reduce the speed, EPC valve reduces output pressure from PPC valve to the operation valve. When the bucket speed is lower than the Stan-” dard value, the above reduction control is not turned on. No speed reduction zone or function is provided for the offset.
Bucket
speed
(Standard value) .------_____-_____----------------
Bucket position
I
interference Safety
zone
Reduction
zone
_ _zone SJPO7738
Reduction operation
Boom Arm
up retract
Stop/alarm function If the bucket passes through the reduction zone and enters the interference zone, its move is automatically stopped and the alarm buzzer is turned on. The solenoid and EPC valves cut off output pressure from PPC valve to the operation valve to stop the bucket move. You can resume the bucket move by driving the bucket out of the stop zone using the operation not currently disabled. Emergency stop/alarm function If the bucket does not stop at the predetermined stop point due to failures on the solenoid valve or EPC valve and enters the emergency stop zone, the system stops every actuator and sounds the alarm buzzer. When this function is turned on, failure must be present on any of the equipment. In this case, the system notifies the operator of the trouble by flashing the monitor panel electronic system caution lamp and displaying error code “91 mon the depth indicator. Using the solenoid valve, the system cuts off the source pressure from the control pump to the PPC valve. Thus, every operation using the PPC circuit will be disabled. When this function has been turned on, you need to resort to the cancel function for the recovery. See the “Cancel Function” in Section 4.
PC1 28UU-2
Stop operation
Every actuator
Alarm buzzer
Quick sounding interval (once every 0.6 seconds)
Electronic system caution system
Quick flashing (once every 0.6 seconds)
Depth indicator
Error “91 II is displayed
10-155
STRUCTURE
4. .
.
.
*
*
*
*
Cancel function If the emergency stop function is turned on, or if the controller or any of the potentiometers fails, the controller will stop action of every actuator by cutting off signal current to the solenoid valve and EPC valve. This situation requires your immediate checkups. In case the machine must be moved to a safe place before starting the checkups, use the emergency work equipment operation switch situated under the operator seat. Turning this switch on allows you to move the work equipment to any desired location. As soon as the emergency work equipment operation switch is turned on, the alarm buzzer will start sounding and the electronic system caution lamp will also start flashing to notify the operator that the cancel function has been turned on. When you want to swing the work equipment, turn on the swing/park brake release switch at the same time. If any failure is present in the electric system of the solenoid valve or EPC valve, this cancel function is not available. When the error code “Failure in Solenoid System” is displayed on the monitor panel depth indicator, you must not turn on the emergency work equipment operation switch. If you turn on the emergency workequipment operation switch after removing the controller, boom up/down and arm retract (EPC valve system) operation won’t be cancelled. The emergency work equipment operation switch is an auto-return type. Namely, if you move your hand off the switch in the ON position, it will automatically return to the OFF position.
1O-l 56
4-SYSTEM
AND FUNCTION
tmereencv
work eaurpmenr
operation
swi
SJP07739
Stop cancel operation
Every actuator
Alarm buzzer
Sounded for 7 seconds
Electronic system caution lamp
Delayed flashing intervals (once every second)
PC128UU-2
STRUCTURE
5.
‘.
4-SYSTEM
AND FUNCTION
Reset function 1) Input signal (potentiometer mount angle) reset function . If a potentiometer is mounted in an inappropriate angle in its replacement or replacement of a work equipment, error in input signal can result due to error in the mount angle. This reset function allows you to correct the error through a single switch operation without measuring output voltage level or resorting to fine adjustment of the potentiometer. For the correction, enter the input reset signal while maintaining the boom up, arm retract and offset right at the stroke end. And, the computer will determine the difference between the angle computed based actual output voltage from respective potentiometers and the specified angle on the computer (mounting error). The difference will be stored in memory as the “compensation value”. 2) Automatic fore-and-aft stop position reset function . When an error has resulted in the automatic cab fore stop position from errors in measuring the work equipment size (used in the bucket position calculation) or computer calculation error, this function allows you to correct it in a single switch operation. . For the correction, stop the bucket in the specified position, then enter the automatic fore-and-aft stop position reset signal. And this function, referencing the actual output voltage from respective potentiometers, will calculate the difference (calculation error) between the computed value and the standard value and stores it in memory as the “compensation value”. 3) Automatic left-and-right stop position reset function . When an error has resulted in the automatic side stop position of the cab from errors in measuring the work equipment size (used in the bucket position calculation) or computer calculation error, this function allows you to correct it in a single switch operation. . This function can also be used for correcting the stop position when an optional narrower or wider bucket is worn. . For the correction, stop the bucket in the specified position, then enter the automatic left-and-right stop position reset signal. And this function, referencing the actual output voltage from respective potentiometers, will calculate the difference (calculation error) between the computed value and the standard value and stores it in memory as the “compensation value”. .
PC128UU-2
CI
SJPO7740
-
SJP07742
10-157
STRUCTURE
4) l
l
*
Ir
*
AND FUNCTION
4-SYSTEM
Depth indication reset function When an error has resulted in the depth indication from errors in measuring the work equipment size (used in the bucket position calculation) or computer calculation error, this function allows you to correct it in a single switch operation. For the correction, place the bucket on the ground surface at points A and then B, then enter the depth indication reset signal when the bucket is at A as well as at B. And this function will determine the difference (calculation error) between the actual depth and the depth calculated based on the output voltage from respective potentiometers and stores it in memory as the “compensation value”. A compensation value once stored will remain undeleted if you turn off the starter switch. If the work equipment positioned significantly away from the specified position, the compensation value becomes 0 (zero). In this case, the position control is turned on without a compensation value. The system will display an applicable error code on the depth indicator to urge the operator to retry the reset function. For detailed procedures of the resetting, refer to the “Checkups and Adjustment” section.
SJP07743
.
1O-l 58 .
PC1 28UU-2
STRUCTURE
AND FUNCTION
4-SYSTEM
Right side exterior interference prevention system 1 l When the right offset operation or operation of the work equipment is turned on, the bucket can interfere with the right side exterior, deck, revolving frame, hand rail or step in certain areas. It dues from structure of the machine’s work equipment. l If the bucket approaches an interference zone, the interference prevention system, through its electronic control, automatically the boom down, arm retract or offset right operation and turns on the alarm buzzer. l Safety in the right offset area is ensured by this function. B (50-I 50md
S!PO7744
Dimension Dimension l
l
l
A is when “Arm is retracted”. B is when “Boom is down”.
Referencing output from respective potentiometers, the controller detects rotation angle of the boom, arm and offset. And, if the work equipment approaches near to the interference zone (reduction zone), it reduces the work equipment move speed (except the offset). If point A enters the interference zone, the controller automatically stops the work equipment and sounds the alarm buzzer to prevent interference. If the controller or one of the potentiometers fails, the system stops move of the work equipment by stopping supply of power to respective solenoid valves. In this case, you can resume the work equipment operation by turning on the emergency work equipment operation switch.
’
Y’
Arm
Potentiometer
Boom Potentiometer
I \
J
w
WX
Cab SJP07745
PC128UU-2
10-159
STRUCTURE
CSYSTEM
AND FUNCTION
Overall operation diagram * The bucket position in the diagram is somewhat descriptions of the system function.
modified from that in actual operations
to facilitate
Safety
zone
Reduction zone loo--2om,,
!I
StoP’a’arm point Stop
’
Fis
zone
(Interference)
2 SJPO7746
Figure 1 : When “Boom is up”. Figure 2 : When “Arm is retracted”.
lo-160
_
PC128UU-2
STRUCTURE
1. .
.
*
4-SYSTEM
AND FUNCTION
Speed red&ion function Speed of the bucket after leaving the safety zone and entering the reduction zone is reduced. The system ensures smooth reduction of the bucket without undesirable impacts by reducing the “boom up” and “arm retract” speeds. In order to reduce the speed, EPC valve reduces output pressure from PPC valve to the operation valve. No reduction zone or reduction function is provided for the offset right.
Bucket
speed
(Standard value) .------------_--~-~~~~~~~~~~~~~~-Bucket position
Safety
zone
I
_ Reduction
l
Ir
*
Stop/alarm function If the bucket passes through the reduction zone and enters the interference zone, its move is automatically stopped and the alarm buzzer is sounded at the same time. In order to stop move of the bucket, output pressure from the PPC valve to the operation valve is shut down by the solenoid and EPC valves. You can resume operation of the currently stopped bucket by turning on the operation not disabled.
PC1 28UU-2
Ir$Erference z. L
I-
SJP07747
Reduction operation
2.
zone
Boom down Arm retract
Stop operation
Boom down Arm retract Offset right
Alarm buzzer
Delayed sounding intervals (once every second)
lo-161
STRUCTURE
3. .
.
.
*
*
*
*
Cancel function If the controller or any of the potentiometers fails, the controller will stop action of every actuator by cutting off signal current to the solenoid valve and EPC valve. This situation requires your immediate checkups. In case the machine must be moved to a safe place before starting the checkups, use operation the emergency work equipment switch situated under the operator seat. Turning this switch on allows you to move the work equipment to any desired location. As soon as the emergency work equipment switch is turned on, the alarm operation buzzer will start sounding and the electronic system caution lamp will also start flashing to notify the operator that the cancel function has been turned on. When you want to swing the work equipment, turn on the swing/park brake release switch at the same time. If any failure is present in the electric system of the solenoid valve or EPC valve, this cancel function is not available. When the error code “Failure in Solenoid System” is displayed on the monitor panel depth indicator, you must not turn on the emergency work equipment operation switch. If you turn on the emergency work equipment operation switch after removing the controller, boom up/down and arm retract (EPC valve system) operation won’t be cancelled. The emergency work equipment operation switch is an auto-return type. Namely, if you move your hand off the switch in the ON position, it will automatically return to the OFF position.
lo-162
4-SYSTEM
AND FUNCTION
position) hornal work eauiwnt Emergency
Stop cancel operation
operation
SWI
Every actuator
PC1 28UU-2
STRUCTURE
4. l
CSYSTEM
AND FUNCTION
Reset function This function is used for correcting errors in the work equipment dimensions, controller’s calculation errors, or errors in the bucket stop position resulting from special attachments installed. Correction of a bucket stop position is done by correcting stop positions of the boom and arm stop angles.
1) Automatic .
. .
boom down stop position reset function When an error has resulted in the automatic side stop position of the right side exterior from errors in measuring the work equipment size (used in the bucket position calculation) or computer calculation error, this function allows you to correct it in a single switch operation. This function can also be used for correcting the stop position when an optional narrower or wider bucket is worn. For the correction, stop the bucket in the specified position, then enter the automatic exterior stop position reset signal. And this function, referencing the actual output voltage from respective potentiometers, will calculate the difference (calculation error) between the computed value and the standard value and stores the difference in memory as the “compensation value”.
-Caluculated -Standard
Position Position
SJP07749
2) Automatic .
. .
arm retract stop position reset function When an error has resulted in the automatic side stop position of the right side exterior from errors in measuring the work equipment size (used in the bucket position calculation) or computer calculation error, this function allows you to correct it in a single switch operation. This function can also be used for correcting the stop position even when an optional narrower or wider bucket is worn. For the correction, stop the bucket in the specified position, then enter the automatic exterior stop position reset signal. And this function, referencing the actual output voltage from respective potentiometers, will calculate the difference (calculation error) between the computed value and the standard value and stores it in memory as the “compensation value”.
PC1 28UU-2
SJPO7750
10-163
STRUCTURE
4-SYSTEM
AND FUNCTION
DEPTH MEASUREMENT
SYSTEM
This system facilitates your operations by displaying a current digging depth or depth of a target of measurement on the monitor panel. Two depth indication approaches are available from the depth measurement system. One is a measurement from the ground level (G. L) and the other is that from the datum plane. When the starter switch is turned on, a measurement from the ground level is automatically turned on.
(Mode
selector
switch’)
SJPO7751
1. .
Depth-from-Ground-Level display function When this function is turned on, depths measured from the ground level (G.L) are displayed on the monitor panel depth indicator as long as your operation is continued.
Ground
level
[Setup procedure] l Turn the starter switch on and this function will be automatically started. [Display method] . Depth under the ground level is displayed in 0.1 mm step. * Fractions are rounded off at two decimal places. . A height above the ground level is preceded by the indication “UP”. * You must stretch the bucket straight when setting the zero point in this display system. If the bucket is in any other position, discrepancy can result from the displayed and actual depth. * If you select the Depth-from-Datum-Plane Display Function, this function will be cancelled.
SJP07752
SJPO7753
lo-164
PC1 28UU-2
STRUCTURE
4-SYSTEM
AND FUNCTION
2. Depth-from-Datum-Plane display function [Depth 0 set mode] l This function displays a depth from any datum plane you set on the monitor panel depth indicator as long as your operation is continued. * If you select this function, the Depth-fromGround-Level Display Function is automatically cancelled. [Setup procedures] l Turn the mode select switch on to the [Depth Display 0 Set] position. l Move the bucket to the datum plane. l Shift the setup switch to the SET position, then make sure that “0.0” is displayed on the depth indicator.
SJP07754
[Display method] l Depth below the datum plane is indicated in 0.1 step. * Fractions are rounded off at decimal places. l A depth above the datum will be preceded by the indication “UP”. [Canceling procedures] l Turn the mode select switch to the [Depth Display 0 Set] position. l Turn the setup switch to the CLEAR position. * Make sure that the bucket posture when the datum plane is set is the same as that placed on the measurement plane. If the posture is not consistent, a displayed depth may deviate from an actual value. * If you cancel this function, the “Depth-fromGround-Level Display Function” will be restored on the depth indicator. l
Explanatory notes on the depth Ya : Depth from the boom foot level (constant). Yb : Depth from the boom foot plane selected. Yc : Depth from the boom foot ment level.
measurement to the ground
Y
A 1
Boom
foot
X
I
u
Ground
level
(G. L)
to any datum the measure-
Depth from the ground level (G.L) = Yc - Ya. Depth from the datum plane = Yc - Yb.
SJP07755
PC1 28UU-2
10465
STRUCTURE
AUTOMATIC
AND FUNCTION
4-SYSTEM
HEIGHT AND DEPTH STOP SYSTEM Monitor
The automatic height stop function is capable of stopping move of the boom when it reaches the predetermined height during operation. The automatic depth stop function is capable of stopping move of the boom when it reaches the predetermined depth during operation. These functions are helpful in ensuring work safety and efficiency when working in job sites where obstacles such as piping and electric wires are present-;
Panel
Mode
\
selector
switch Depth
Depth indication Oset
SJPO7751
Height setup function [height mode] You can stop move of the boom during operation at any height you have previously set. You can limit height of the work equipment by setting limit on the boom lift height. This function reduces speed of the boom prior to the forced stop to minimize resulting shocks or impacts. Note that this function is not usable for limiting the bucket height.
Specif height
i
[Setup procedures] l Shift the mode select switch to the “Height”. l Lift the boom up to the height where you want to set the limit. l Turn the setup switch to the “SET” position to make sure that the buzzer is sounded three times and the indicator lamp comes on. [Operation] l When the above setting is complete, lower the boom once. Now, whenever the boom reaches the specified height during operation, its move will be stopped there. l This stop is caused by reducing and then shutting down the output pressure from the PPC valve to the boom operation valve (UP side) at the EPC valve. [Canceling procedures] l Shift the mode switch to the “Height”. l Turn the setup switch to the “CLEAR” position, then make sure that the indicator lamp is turned off.
10466
PC128UU-2
STRUCTURE
2. . .
.
* *
4-SYSTEM
AND FUNCTION
Depth setup function [depth mode] You can stop move of the arm top during operation at any depth you have previously set. You can limit digging depth by limiting the boom down move and the arm retract move range. This function reduces speed of the boom down move and arm retract move prior to the forced stop to minimize resulting shocks or impacts. Note that this function is not usable for specifying a bucket depth. This function stops move of the arm top when the lowered boom and retracted arm appreach the specified depth. When the arm was forced to reach the specified depth during its dump operation because of a posture of the work equipment, move of the arm top is not stopped.
[Setup procedures] l Shift the mode select switch to the “Depth”. l Lower the boom and arm to the depth where you want to set the limit. l Turn the setup switch to the “SET” position to make sure that the buzzer is sounded three times and the indicator lamp comes on. [Operation] When the above setting is complete, lower the boom once. Now, whenever the boom and arm reach the specified depth during operation, their move will be stopped there. Boom stop is caused by reducing and then shutting down the output pressure from the PPC valve to the boom operation valve (DOWN side) at the EPC valve. Arm stop is caused by reducing and then shutting down the output pressure from the PPC valve to the arm operation valve (RETRACT side) at the EPC valve.
Specified depth SJP07758
Upper
end
1
(Operable)
Lower
end
SJP07759
[Canceling procedures] l Shift the mode switch to the “Depth”. l Turn the setup switch to the “CLEAR” position, then make sure that the indicator is turned off.
PC128UU-2
lo-167
STRUCTURE
CSYSTEM
AND FUNCTION
OFFSET POSITIONING
SYSTEM
1
Mon i or
Panel
Using this function, you can previously specify the left side offset position to facilitate, for instance, determining a side ditching position. Offset setup function [offset mode] You can stop move of the offset during operation at any left offset position you have previously set. Limiting move range of the left offset allows you to set the offset position easier in continuous operations. [Setup procedures] Shift the mode select switch to the “Offset”. l Implement the left offset up to the position l where you want to set the limit. Turn the setup switch to the “SET” position l to make sure that the buzzer is sounded two times and the indicator lamp comes on. [Operation] When the above setting is complete, implel ment the right offset once. Now, you can stop the left offset whenever it reaches the specified position during operation. This stop is caused by reducing and then Shutl ting down the output pressure from the PPC valve to the offset operation valve at the EPC
(Mode
\
switch
selector Depth
indication LDePth Indicator
IL
Depth indication 0 set SJP07751
ied In
SPecif positit
i
valve. [Canceling procedures] Shift the mode switch to the “Depth”. l Turn the setup switch to the “CLEAR” posil tion, then make sure that the indicator is turned off.
SJP07761
1O-l 68
PC1 28UU-2
STRUCTURE
CSYSTEM
AND FUNCTION
Boom end cushioning function l In the boom up move, this function reduces speed of the boom before it reaches the stroke end to lighten resulting impacts and, thus, to prevent spillage of dirt or dust as well as lighten load to the machine body and cylinder. [Operation] l A cushioning zone is provided before the boom-up stroke end (approximately 10”). l This fuhction reduces move speed of the boom in this zone by reducing output pressure from the boom_PPC valve to the boom operation valve (UP move) at the EPC valve. l This arrangement helps reducing undesirable impacts at the stroke end.
9JB00160
Arm end cushioning function l In the arm retract move, this function reduces speed of the arm before it reaches the stroke to lighten resulting impacts and, thus, to prevent spillage of dirt or dust as well as lighten load to the machine body and cylinder. [Operation] l A cushioning zone is provided before the arm retract stroke end (approximately 10”). l This function reduces, move speed of the arm in this zone by reducing output pressure from the arm PPC valve to the arm operation valve (RETRACT move) at the EPC valve. l This arrangement helps reducing undesirable impacts at the stroke end. Self-test function The controller constantly monitors electronic equipment consisting the system for normal operation. These components include the controller itself, potentiometers to generate input signals, and solenoid valves and EPC valves to receive output signals. If any of the electric equipment fails, the controller diagnoses the symptom and notifies the results to the operator by displaying a corresponding error code on the monitor panel. At the same time, it alerts the operator attention by flashing the electric system caution lamp and sounding the alarm buzzer. For further information on the display and remedial actions, refer to the “Checkups and Adjustment” section.
PC1 28UU-2
9J800161
Monitor
(Caution
lamp)
Panel
(Depth indicator)
SJpO7762
lo-169
STRUCTURE
AND
FUNCTION
4-SYSTEM
SYSTEM COMPONENTS Controlier
M I C-2
1 P
AMP040-20P
AMP040-16P
9JB00162
1.
Controller
2.
Self-test
indicator
Mode select table
Attachment 1 CN-C02-1
Depth display 0 set
X
Depth setup Height setup Offset setup Set/clear
X
0 0
1 CN-C02-19 Standard arm Lona arm
1 CN-C02-20 X
0
I
x
I
0
A lock
select table
Specification
1 CN-C02-3
select table
1 CN-C02-2
select table
1 CN-C02-4
Set
0
X
Clear
X
0
(Arm slide limit switch) (Slide arm retract end) (Other than above)
IO-170
1 CN-C03-5 I 0)
0:GND x : OPEN
(Xl
PC1 28UU-2
STRUCTURE
CSYSTEM
AND FUNCTION
Input/output signals MIC-21P [CN-CO11 Pin No. 1 Signal name 1 2 4
NC PC-EPC valve (+)
8 9 10 11
12 13 14
output output -
Serial clock Arm retract stop EPC (+I
6 7
output
Boom down stop EPC (+)
output
Boom up stop EPC (+)
output -
Controller power (24V) Controller ground NC tNC
I
Travel acceleration NC
Boom down hydraulic switch
Input
8
Boom UD hvdraulic switch
InDut -
ground power (5V)
11
Offset stop and exterior stop position reset signal
Input
12
Angle, depth and fore-aft stop Dosition reset sianal
Input
13
4-system cancel signal
Input
14
Right side exterior interference Drevention cancel signal
Input
-
output
18
Controller Dower (24V)
19
Controller ground
-
20
Offset left stop solenoid (+)
21
PPC lock solenoid (+)
output output
15
output
NC Travel hydraulic signal
output
18
Arm retract hvdraulic switch
19 20
[CN-CO31 Input
2
Slide volume potentiometer
Input
3 4
SDecification
InDut
5 6
Slide arm telescope switch
Input Input
7
Serial strobe 2-stage relief solenoid (+)
output
8
Swing/park
output
9 10 11
Boom angle potentiometer
Input
Offset angle potentiometer
Input Input
select
Engine speed sensor (+)
Input InDut
1 1
Input Input
Input
brake solenoid (+)
InDut
I
output
15
Offset right stop solenoid (+)
output
16
Auto-deceleration
OUtDUt
relav
select signal select signal
-
I/O signal
Signal name Arm angle potentiometer
Electric system caution
1 Attachment 1 Attachment
-
I
INC
16 17
1
PC128UU-2
7
Potentiometer
-
14
Input Input
Potentiometer
Boom up/down stop EPC (-1 Controller power (for solenoid)
Left lever switch Enaine SDeed sensor (-1 INC
1
Swing hydraulic switch
9
15
12 13
1 Kerosene mode
10
16 17
Pin No.
5 6
Input -
switch
~
-
Arm retract stop EPC (-1 PC-EPC valve (-)
AMP040-16P
[CN-COP]
I OutDut
1 Serial data
3 5
AMP040-20P 1 I/O signal
10471
STRUCTURE
4-SYSTEM
AND FUNCTION
Potentiometer
SVP04525
1.
Body
4.
2. 3.
Rotor Bearing
5. 6.
Functions l A potentiometer is installed on each of the boom foot, arm foot and second boom top to detect their angle of the boom, arm and offset work equipment. l Utilizing resistance value of the variable resistor, potentiometers send angle data to the controller by converting the supply voltage (5V) into signal voltage according to the angle of the work equipment.
Sensor Cover Connector
(V) 5-
g
4-
:
3-
5
2
Z
l-
-
0
lo-172
Angle
(' )
SJP07763
PC1 28UU-2
STRUCTURE
CSYSTEM
AND FUNCTION
Resistor
SVPO4527
1. 2.
Resistor Connector
Specification System
Resistance value (a) 5
For boom up/down EPC valve For arm retract EPC valve
10 30
For main DumD PC-EPC valve
Function l This resistor is used to conduct current to the EPC valve appropriate to the intended operation. PPC hydraulic switch * Refer to the “Electric Control System”. Boom down stop EPC valve Arm retract stop EPC valve Boom up stop EPC valve Offset left stop EPC valve Offset right stop EPC valve * (See the “(EPC) Solenoid
PC1 28UU-2
Valve”.)
10-173
STRUCTURE
AND FUNCTION
MONITOR
SYSTEM
MONITOR SYSTEM Buzzer
II
Buzzer
signal
Signal Switch
sensors
Power
signal
SUPPIY
SJP07764
l
l
l
This system monitors the machine status using sensors installed on various parts of the machine, processes the monitoring data and displays it on the panel to notifies the current machine status to the operator. The monitor panel mainly consists of the following blocks: 1. Monitor block that generates alarms should the machine fail. 2. Pilot block that displays status of the machine during operation. 3. Gauge block that constantly displays status of the machine status through in and out of operation. The monitor panel also equips with the 4-systern indicator and its operation switches.
10-174
PC1 28UU-2
STRUCTURE
AND FUNCTION
MONITOR
PANEL
AMP04?-1
MONITOR
6P
SYSTEM
KEQ-4P
\ KES-3P 9JBOO164
Overview l The monitor panel is provided with the monitor display function, gauge display function, service meter function, 4-system display function and 4-system operation switch function. l It also equips with the CPU used to process data as well as to display and output them.
Input/output
signals
AMPO40-16P
ICN-PO11
Pin No. 1 2 3
Signal name Power supply (24V) Strobe Potentiometer
5 6 7
Start signal Coolant temperature Fuel level
8
9
Engine oil pressure
innut -
10 11 12
Charge volume Electric system signal Serial lock
Input Input lnout
1
Input
Signal name
2
Select 1
3 4
Select 2 Ground
PC1 28UU-2
13 14 15 16
Signal name
Preheat Enaine oil volume ( Alarm buzzer 1 Nighttime lighting
I/O signal
Input Input Input Input Input
lnout 1 output ( Input
KES-BP [CN-Cl21
KES-4P [CX-Cl I]
Pin No.1 1 I-
l
Pin No.
ground
1 Serial data
l
LCD is employed for the gauge indication block. An indication lamp is used on the monitor indication block. LCD is employed for the 4-system indication block and indicator.
I/O signal I
1 Ground
4
l
1 I/O signal output output -
Pin No. 1 1 1 Ground 2 3
( Clear. I Set
Signal name
I I/O signal -
I output ( output
10-175
STRUCTURE AND FUNCTION
MONITOR SYSTEM
Operation
SJPO7765
10476
PC128UU-2
STRUCTURE
No.
MONITOR
AND FUNCTION
Display class
Display item
3
-
Clock time
Preheat
tiNhen preheat turned on
is
_ED comes on (for about 18 secDnds) when ttie starter switch is at iEAT. Then it goes off notifying preneat is complete.
Green
LED
Coolant temperature
See figure to the left
3ne applicable segment comes on. iOnly when the top level -15OC or above - is reached, segment is flashed and buzzer is sounded.)
Blue
LCD
3 - 99999.9 h
Gauge
411segments below the applicable level come on. (Only when the lowest level - Empty - reached, segment flashes.)
4
Fuel volume
See figure to the left
%5
Setup switch
-
: Mode setup. SET CLEAR : Mode setup cancel.
-
-
Depth display 0 set : Selects datum plane for depth display. Depth : Specifies boom move down volume. Height : Specifies boom move up volume. Offset : Specifies left offset position.
-
Depth error code
0 to 9.9 m in 2 alphanumeric characters
w Displays bucket depth from ground level. n Indicates “UP” when displaying bucket height above ground level. * In the “Depth display 0 set mode”, depth from datum plane is displayed. l When Qsystem failed, a 2-digit error code is displayed.
Offset stop
When left offset position is specified
It comes on when mode select switch is positioned at OFFSET.
Work equipment heig-ht alarm
When boom up move volume is specified
It comes on when mode select switch is positioned at HEIGHT.
%10
Depth alarm
When boom down move volume is specified
k comes on when mode select switch is positioned at DEPTH.
%I1
Electric system
When failed
Q-system
Charge volume
When failed
charging
Engine sure
If pressure goes below 49 kPa IO.5 kg/cm21
Mode select switch
n6
%7
%9
Depth display
Indicator
--
Caution
emarks
Xration of engine-in-operation iwhen alternator power generation s turned on).
Service meter
Pilot
jisplay color
Display method
Display range
SYSTEM
oil pres-
Lamp remains on as long as starter switch is turned on. It goes after engine has been started.
_
-
Blue
LCD
Red
Lamp
..
For the display and operation of items with % marking, refer to the section of “4-system”.
PC1 28UU-2
10-177
STRUCTURE
MONITOR
AND FUNCTION
SYSTEM
SENSGRS l
Signal from a sensor is directly entered
to the
panel. l
There are two types of sensors, and resistance
l
contact
type
type.
One end of a contact type sensor is connected to the ground on the machine body. Display class
Sensor type
Sensing approach
When normal
When failed
Caution
Engine oil pressure
Contact
OFF (open)
ON (closed)
Resistance
-
-
Resistance
-
-
Coolant temperature Gauge
Fuel level
ENGINE OIL PRESSURE SENSOR
@ Structure
of
circuit
SBDOl537
1. Plug 2. Contact ring
COOLANT TEMPERATURE
3. 4.
Contact Diaphragm
5.
Spring
6.
Terminal
SENSOR
@f=D Structure
1. 2. 3.
of
circuit
SBOO1538
Connector Plug Thermistor
lo-178
PC1 28UU-2
STRUCTURE
AND FUNCTION
MONITOR
SYSTEM
FUEL LEVEL SENSOR
FULL
a a
F Structure
&
EMPTY
E Y
of
circuit
SEP02590
1. 2. 3. 4.
Float Connector Cover Variable resistor
PC1 28UU-2
10-179
20
TESTING AND ADJUSTING _”
STANDADRD
VALUE TABLE
Standard value table for engine .. .. ... . .. .. .. . .. . .. 20-2 Standard value table for chassis . . ... ... ... ... . .. . .. 20-3 Standard value table for electrical parts .. . .. 20-13 TESTING
AND ADJUSTING
TROUBLESHOOTING
. ... .. . .. .. ... . ... .. .. .. . . 20-101
... . . . .. .. .. .. .. .. .. .. ... . ... .. .. . .. . 20-201
Note the following when making judgments 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, inset 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 near the machine. When checking the water level, always wait for the water to cool down. If the radiator cap is removed when the water is still hot, the water will spurt out and cause burns. Be careful not to get caught in the fan, fan belt or other rotating parts.
PC128UU-2
20-l 0
TESTING
STANDARD
AND ADJUSTING
VALUE TABLE FOR ENGINE
STANDARD VALUE TABLE FOR ENGINE Machine
PC1 28U U-2
Model
S4D102E-1
Engine
Item
Engine speed
Unit
Standard value for new machine
Service limit value
High idling
rpm
2,400 f 60
-
Low idling
rpm
900 *-“I
Rated speed
rpm
2,200
Bosch index
Max. 5.5
7.5
Max. 1.0
2.0
Measurement
conditiom
At sudden acceleration Exhaust
gas color
Valve clearance (cold)
Blow-by pressure (SAE 30)
At high idling
Intake valve
mm
0.51
Exhaust valve
High idling (At opreting range of tht engine water temperature gauge)
0.25
Pa mm H,OI
Max. 490 (501
980 {I 00)
343 - 588 13.5 - 6.0)
245 (2.5)
Min. 9.8 11.O)
69 (0.7)
Min. 78 IO.81
69 {0.7)
Max. 110
120
(Water temperature: Operating range At high idling Oil pressure
At low idling (SAE30W)
KPa kg/cm*1
At low idling (SAEIOW)
Oil temperature
Whole speed range (inside oil pan)
Fuel injection timing
Before top dead center
Fan belt tension
Deflection when pressec with finger force of approx. 58.8 N 16 kg). (Alternator pulley -Fan pulley
20-2 0
“C
iegree
14+1
mm
9.5-12.7
1
-
PC1 28UU-2
TESTING
STANDARD
AND ADJUSTING
VALUE TABLE FOR CHASSIS
STANDARD VALUE TABLE FOR CHASSIS PC128UU-2
Machine model
G
Measurement
Item
son
conditions
l
Hydraulic oil temperature:
l
Engine oil pressure:
Unit
Standard value for new machine
Service limit value
2,220 f 100
Min. 2,000
45 - 55 “C When 1 pump is relieved
.
l
Boom control lever
In operating range Engine coolant temperature: In operating range Relief of 1 pump: Relief of arm Center of lever grip Read max. value through stroke. Stop engine.
Arm control lever Bucket control lever Swing control lever
m-n
N + RAISE, LOWER
107.2 + 11
N + IN, OUT
107.2 + 11
N --f CURL, DUMP
107.2 Z!I11 107.2 f 11
N + RIGHT/LEFTSWING mm
Blade control lever Travel control lever
Play of control lever
N + RAISE, LOWER
60.7 It IO
N +
112+ IO
FORWARD, REVERSE (Bothsides1
Work equipment, swing
3’5
Travel
10+3
I I I I I I I I
107.2 + 21 107.2 + 21 107.2 f 21 107.2 * 21 60.7 * 15 112+20 5-8 10+5
Max.19.6 (Max.2.0)
I
Max.27.5 (Max.2.8)
Max.19.6 (Max.2.0)
I
Max.27.5 (Max.2.8)
Bucket control lever
Max.17.7 (Max.l.8)
I
Max.24.5 (Max.2.5)
Swing control lever
MaxL17.7 {Max. I.81
Max.24.5 (Max.2.5)
Blade control lever
Max.24.5 (Max.2.51
Max.31.4 CMax.3.21
Travel control lever
Max.27.5 (Max.2.8)
Max.36.3 IMax.3.7)
2052
20*4
37+_4
37 +- 8
Max.96.1 (Max.9.8)
Max. 134.5 (Max.13.7)
Max.94.1 (Max.9.61
Max.131.7 IMax.13.41
Run engine at full throttle. Oil temperature: 45 - 55 “C Install push-pull scale to center of lever grip for measurement. Read max. value through stroke.
Boom control lever Arm control lever
Offset pedal
Travel pedal
Offset pedal
l
l
l
l
l
l
Travel pedal l
PC1 28UU-2
TIP of pedal Read max. value through stroke. Stop engine.
N + RIGHT/LEFT OFFSET mm N + FORWARD, REVERSE (Both sides1
Run engine at full throttle. Oil temperature: 45 - 55Q Install push-pull scale to tip of pedal for measurement. Read max. value through stroke.
20-3 0
STANDARD
TESTING AND ADJUSTING
.1. Machine
catc
Item
wn
-
3oom
4rm
3ucket
r
model
Measurement
conditions
Jnit
VALUE TABLE FOR CHASSIS
PC128UU-2
Standard value For new machine 31.87’ kg6 j325+ ;” )
Hydraulic oil temperature: 45 - 55 “C Run engine at full throttle. Pressure at pump outlet Relieve only circuit to be measured.
ervice limit value 3 1.87+$: {325- IO1
31.87’ kg6 (325’ ;” ) 31.87+ kg6 (325’;” } 31.38 + 0.98 (320 + IO}
Swing
31.87’ kg6 (325’:” )
31ade raising
31ade lowering
32.36 f 1.47 (330 f 15 1
32.36 * 2.45 (330 * 25)
rravel
34.81 + 0.98 (355 f 10 1
34.81 + 1.96 1355 * 20)
_eft offset
VlPa :g/cml
27.0 z!z1.47 (275 + 15 1
27.0 _+2.45 (275 f 25)
3.24 + 0.20 (33 f 2 )
3.24 f 0.49 (33 f 51
When control lever is n neutral
3.43 f 0.98 {35f IO)
3.43 f 0.98 (35 f IO)
When pump is ‘elieved (Normal operation)
15.98 f 1.47 {163* 15)
15.98 + 2.45 (163 + 251
2.75 + 0.98 {28+ IO}
I--_)
2.21 * 0.1 (22.5 * I}
(-1
3ight offset
&get rlalue Iange
Zontrol Hydraulic oil temperature: 45 - 55 “C Run engine at full throttle.
31.87’ ;g6 1325’;” 1
nput pressure Df servo piston
LS differential pressure
20-4 0
b Hydraulic oil temperature: 45 - 55 “C When all levers are ) Run engine at in neutral full throttle. * LS differential pressure = Pump outlet pressure - LS When no travel load pressure is applied When travel control lever is operated harf
PC1 28UU-2
TESTING
AND ADJUSTING
STANDARD
Machine
G
PC128UU-2
model
Measurement
Item
-w
VALUE TABLE FOR CHASSIS
<
Unit
conditions
Standard value for
new machine
Service limit value
defer to figure A.
t Engine at full throttle 45 - 55°C * Hydraulic oil temperature: one turn and p Stop after swinging measure distance that swing circle moves at Figure in ( 1 shows movement outside of swing circle
Overrun when stopping swing
Deg.
mm)
Max. 55 (5351
defer to figure
Time taken to start swing
l
l
A.
Engine at full throttle 45Hydraulic oil temperature: 55°C Time taken to swing 90” and 180” from starting position Figure in ( ) shows time when bucket is at rated load
2.5 k 0.3 (3.0 z!I0.3)
90”
-
Sec. 3.5 f 0.4 (4.5 * 0.5)
180
Refer to figure
Time taken to swing
Engine at full throttle 45 - 55°C Hydraulic oil temperature: Swing one turn, and measure time taken to swing next 5 turns
Refer to figure
Hydraulic swing
drift of
_eakage from swing motor
A.
Sec.
30+2
Max. 36
B.
Engine stopped 45 -55°C Hydraulic oil temperature: Bucket at rated load (450 kg) or full of soil. Set machine on 15” slope, and set upper structure at an uphill angle 01 45”. Make match marks on swing circle outer race and track frame. Measure distance that match marks move apart after 15 minutes.
Engine at full throttle Hydraulic oil temperature: - Relieve swing circuit.
Deg. YnmI
45 - 55°C Umin
Max. 3
6
PC1 28UU-2
20-5 0
TESTING
AND ADJUSTING
STANDARD
Applicable cate
Item
w
VALUE TABLE FOR CHASSIS
model
Measurement conditions
PC1 28UU-2 Standard value for
Unit -
new machine
Service limit value
Refer to figure C. * Engine at full throttle 9 Hydraulicoil temperature: 45-55% l
rravel speed (I)
Raise track on one side at a time, rotate one turn, then measure time taken for next 5 turns with no load.
-0
Sec.
Max. 39
48
Max. 29
36
Max. 23.7
29
Max. 16.7
20.2
-
Hi
Refer to figure D. l
l
l
rravel speed (2) l
Engine at full throttle Hydraulic oil temperature: 45 -55°C Run up for at least 10 m, and measure time taken to travel next 20 m on flat ground. Figure in ( ) is for rubber shoe specification
-0
Sec.
-
Hi
Refer to figure D & E.
9 Engine at full throttle Hydraulicoil temperature:45-55% Run up for at least 10 m, and measure deviation when traveling next 20 m on flat ground. * Use a hard horizontal surface. l
l
rravel deviation
mm
Max. 200
220
mm
0
0
?/min
Max. 1.1
1.65
Refer to figure F.
iydraulic ravel
drift of
.eakage from travel notor
20-6 a
9 Engine stopped b Hydraulicoil temperature: 45-55°C b Stop machine on 12” slope with sprocket facing straight up the slope. n Measure the distance the machine moves in 5 minutes.
9 Engine at full throttle Hydraulicoil temperature:45_55”C Lock shoes and relieve travel circuit. l
l
PC128UU-2
TESTING
AND ADJUSTING
STANDARD
Machine
Item
r
defer to figure
Total work equipment
Boom cylinder (amount of retraction of cylinder)
r
model
Measurement
conditions
mm
Bucket cylinder (amount of retraction of cylinder)
PC128UU-2
PC1 28U U-2
Standard value for new machine
Service limit value
G.
Arm cylinder (amount of extension of cylinder)
Blade (hydraulic drift at tip of blade)
Unit
Place in posture and measure extension or retraction of each cylinder and downward movement at tip of bucket teeth. Horizontal, flat ground Bucket: Rated load (720 kg) Levers at HOLD Engine stopped Hydraulicoil temperature:45-55°C Start measuring immediately after setting. Measure hydraulic drift every 5 minutes, and judge from results for 15 minutes.
Iefer to figure
VALUE TABLE FOR CHASSIS
Max. 500
700
Max. 15
23
Max. 50
75
Max. 40
60
Max. 31
47
G.
Engine stopped Hydraulic oil temperature: 45 -55°C Set blade at maximum lifting height and measure downward movement at edge of blade for 15 minutes.
20-7 0
TESTING AND ADJUSTING
STANDARD VALUE TABLE FOR CHASSIS
Machine model
LOWER
3.5 ± 0.35
4.7
IN
RAISE
4.7 (Untill touching chshion)
3.6 ± 0.3 (Untill touching chshion)
(Untill touching chshion)
OUT
Cylinder fully extended
39 ± 0.4 (Untill touching chshion)
2.6 ± 0.3 (Untill touching chshion)
3.5 (Untill touching chshion)
CURL
• Engine at full throttle • Hydraulic oil temperature: 45 – 55°C
2.7 ± 0.3
4.0
2.2 ± 0.2
3.0
5.5 ± 0.6
6.5
5.6 ± 0.6
6.6
1.3 ± 03
2.5
1.3 ± 0.2
2.5
Refer to figure I. Arm Cylinder fully retracted
• Engine at full throttle • Hydraulic oil temperature: 45 – 55°C • Offset to right so that clearance between right end of operator’s cab and bucket will be about 350 mm.
Refer to figure J. Bucket Cylinder fully retracted
• Engine at full throttle • Hydraulic oil temperature: 45 – 55°C
DUMP
Work equipment speed
Work equipment
Fully extended
Fully extended
Refer to figure P. Offset Cylinder fully retracted
• Engine at full throttle • Hydraulic oil temperature: 45 – 55°C
Fully extended
Refer to figure K. Blade Blade in contact with ground
Blade fully raised
20-8 (6)
• Engine at full throttle • Hydraulic oil temperature: 45 – 55°C
Standard value for Service limit value new machine
Left offset
Refer to figure H.
Unit
Right offset
Boom Bucket teeth in contact with ground
Measurement conditions
RAISE
Item
LOWER
Category
PC128UU-2
4.5
Sec
PC128UU-2
STANDARD
TESTING AND ADJUSTING
Machine - lcate
Item
wp
T
r
model
Measurement
conditions
Unit
VALUE TABLE FOR CHASSIS
PC128UU-2
itandard value for new machine
‘ervice limit value
Max. 3
3
Max. 2
2
Max. 2
2
Max. 2
2
Max. 3.5
15
Max. IO
50
3efer to figure L.
pEngine at low idling 1Hydraulic oil temperature: 45 - 55°C pFully retract arm and bucket cylinders, then lower boom from maximum height and measure time taken from point where bucket contacts ground to point where chassis rises from ground
Boom
defer to figure M.
1Engine at low idling 1Hydraulic oil temperature: 45 - 55°C 8Set top surface of boom horizontal,
retract bucket cylinder fully, then extend arm cylinder and measure time taken for ;:;;;stm~rt moving again after stopping
Arm
P
Set
iq
defer to figure N.
1Engine at low idling 1Hydraulic oil temperature: 45 - 55°C bSet top surface of boom horizontal,
retract arm cylinder fully, then extend bucket cylinder and measure time taken for bucket to start moving again after stopping at bottom.
Bucket
Refer to figure 0. l
l l
Blade
Engine at low idling Hydraulic oil temperature: 45 - 55°C Lower blade from maximum height and measure time taken from point where blade contacts ground to point where chassis rises from ground
Each cylinder
Leakage
Swivel joint
PC1 28UU-2
Hydraulic oil temperature: 45 - 55Y Engine at full throttle. Apply relief pressure to port being mesured.
:c/mir
20-9 0
STANDARD
TESTING AND ADJUSTING
VALUE TABLE FOR CHASSIS
Figures related to standard valve table tFia
A
Posture measur
kFia
when ine
Posture
when
Posture
when
G
TJP02243
PC1 28UU-2
TESTING
:Fie
lriie
I
Posture
rFia
when
K
Posture
rFia
M when
J Posture
*Fig
L
*Fig
N
Posture
*Fig
0
Posture measur
VALUE TABLE FOR CHASSIS
when
when
Posture
tFia
STANDARD
AND ADJUSTING
when
P
when ina
TJP02241
PC128UU-2
20-11 0
TESTING
STANDARD
AND ADJUSTING
Pump performance
VALUE TABLE FOR CHASSIS
curve
Wm i n)
Upper
Lower
0
t
19. 6 12001
cz
Pump
iimi
discharge
limit
29. 4 (3001
MPa :z
i ke/cm’l
Pressure(MPa(ke/cm’l)
TJ PO0242
20-12 0
PC1 28UU-2
TESTING
AND ADJUSTING
STANDARD
STANDARD
VALUE TABLE FOR ELECTRICAL PARTS
-l-
Name of component
SF
ten
VALUE TABLE FOR ELECTRICAL PARTS
‘ower source voltage
Coni:ctor
Judgment
Measurement conditions
table
If the condition is as shown in the table below, it is normal
co1
[Between (81,(171,(18) and chassis120 - 30 V 1
If the condition is as shown in the table below, it is normal Standard Qtachment
selection
-1
wi
If the condition is as shown in the table below, it is normal Between offset (3) and chassis
co3
Between mono boom (3) and chassis
4- 6V
l
co2 l
lITurn starting switch ON. ?)Insert T-adapter.
Max. 1 V
If the condition is as shown in the table below, it is normal Left, right resetting signal
seset signal
lITurn starting switch ON. ?IInsert T-adapter.
co2
/Lolprrm
specification selecion
lITurn starting switch ON. !) Insert T-adapter.
When normal
Between (I 1) chassis
O-IV
When resetting
Between (I I) chassis
20-30V
I)Turn starting switch ON. ?)Insert T-adapter.
Angle, direction, depth resetting signal
*I
If the condition is as shown in the table below, it is normal soom potentiometer
co3
Between CO2 (IO) - (9)
4.9 -5.1 v
Between CO3 (9) - CO2 (9)
0.54- 0.82V
If the condition is as shown in the table below, it is normal
km potentiometer
PC1 28UU-2
lITurn starting switch ON. !I Insert T-adapter. %)End of boom RAISE stroke. lITurn starting switch ON. !) Insert T-adapter. %)End of arm IN stroke.
co3
20-13 0
STANDARD
TESTING AND ADJUSTING
sys ten
Name
of component
Zonnector No.
VALUE TABLE FOR ELECTRICAL PARTS
Judgment
table
Measurement conditions
f the condition is as shown in the table )elow, it is normal
l)Turn starting switch ON. 2) insert T-adapter. 1 4.9 -5.1 v 1 3) End of right off1Between CO2 (10) - (9) set stroke. Between CO3 (10) - CO2 (9) 12.99 - 4.11 V
3ffset potentiometer
ii ‘;;
Feft offset stop solenoid
2
f the condition is as shown in the table )elow. it is normal
1)Turn starting switch ON. 2) Insert T-adapter.
f the condition is as shown in the table Ielow, it is normal
l)Turn starting switch ON. 2) Insert T-adapter.
f the condition is as shown in the table lelow, it is normal
l)Turn starting switch ON. 2)lnsertT-adapter.
f the condition is as shown in the table oelow, it is normal
l)Turn starting switch ON. 2) Insert T-adapter.
co1
d
% Right offset stop solenoid
Swing holding brake solenoid
co3
co3
5
z
d
E ..!z ii
2
z 2-stage relief solenoid
co3
Note:
“Actuated”
for the items marked % in the Judgment
Table indicates that the solenoid
(relay) is actuated.
When carrying out testing and adjusting of the actuation at the machine end, see MEASUREMENT
OF SOLE-
NOID VALVE OUTPUT PRESSURE.
20-14 0
PC128UU-2
TESTING
7::
STANDARD
AND ADJUSTING
VALUE TABLE FOR ELECTRICAL PARTS
Judgment
Name of component
Measurement conditions
table
If the condition is as shown in the table below, it is normal
1Between (3) - (2)
Boom potentiometer
Between (2) - (I) Between (3) - (I)
1)Turn starting switch OFF. /0.2-7k.Q 1 2) Disconnect connector. 0.2 - 7 kS;1 4-6kQ
If the condition is as shown in the table below. it is normal Arm potentiometer
C23 (male)
1Between (I) - (2)
10.2-7
I Between (2) - (3)
10.2-7
1Between (I) - (3)
1 4-6kQ
1)Turn starting switch OFFS kfi 1 2) Disconnec ;t’connectar. kQ 1
1
If the condition is as shown in the table below, it is normal Offset potentiometer
C22 (male)
Between (3) - (2)
0.2 - 7 k0
Between (2) - (1)
0.2 - 7 kQ
I Between (3) -(I)
Boom RAISE stop EPC solenoid
Arm IN stop EPC solenoid
!
If the condition is as shown in the table below. it is normal I Between (I) - (2)
Cl6 (male)
Cl5 (male)
1 4-6ka
Between (I), (2) -chassis
??z zs 3 .II rs
1 5-25Q Min. 1 MQ
If the condition is as shown in the table below, it is normal Between (I) - (2) Between (I ), (2) - chassis
5-25s2
Cl4 (male)
I Between (I) - (2) Between (I), (2) -chassis
1 5-25Q
Right offset EPC solenoid
PC1 28UU-2
Cl7 (male)
1Between (I) - (2) Between (I), (2) -chassis
Cl8 (male)
lITurn starting switch OFF. 1 2) Disconnect connector.
lITurn starting switch OFF. 2) Disconnect connector.
1)Turn starting switch OFF. 2) Disconnect con1 nector.
1Min. 1 MQ
If the condition is as shown in the table below, it is normal Left offset stop EPC solenoid
1
Min. 1 MQ
If the condition is as shown in the table below, it is normal Boom LOWER stop EPC solenoid
1)Turn starting switch OFF. 2) Disconnect connector.
I35-8OQ
1)Turn starting switch OFF. 2) Disconnect con1 nector.
Min. 1 MQ
If the condition is as shown in the table $? = c below, it is normal m 35-8OQ Between (I) - (2) g.5 r; Min. 1 MQ Between (I ), (2) - chassis
1)Turn starting switch OFF. 2) Disconnect connector.
20-15 0
TESTING
SY
ter
AND ADJUSTING
Name of component
‘PC hydraulic solenoid
lock
STANDARD
Zonnector No.
Judgment
tron
nethod
V07 (male)
1Between
brake
rravel boost solenoid
‘C-EPC solenoid
V04 (male)
V05 (male)
Cl3 (male)
$ g mB $.I? r;
23 3= a3 3.” r;
speed sensor
t; 5 Q
20-M 0
/35-8OQ
1)Turn starting switch OFF. 1 2) Disconnect connector.
Min. 1 MQ in the table 35-8OsZ
(I) - (2)
35-8Os2
Between
(I ), (2) - chassis
Min. 1 ML2
If the condition is within the range shown in the table below, it is normal Between
(I) - (2)
Between
(I), (2) -chassis
8-15Q
1)Turn starting switch OFF. 2) Disconnect connector.
1)Turn starting switch OFF. 2) Disconnect connector.
Min. 1 MQ
If the condition is within the range shown in the table below, it is normal Between
(I) - (2)
500 - 1000 52
Between
(2) - chassis
Min. 1 Ma
with AC range (I) - (2)
1)Turn starting switch OFF. 2) Disconnect connector.
Min. 1 MQ
Between
Between
E07 (male)
in the table
If the condition is within the range shown in the table below, it is normal
Measure ingine
K24 - K25 K24, K25 - chassis
If the condition is as shown $ g below, it is normal (u Between (1) - (2) $;; al .r; Between (I), (2) -chassis
f g a9 3.” rz
Measurement conditions
table
If the condition is as shown below, it is normal
Between
swing holding ;olenoid
VALUE TABLE FOR ELECTRICAL PARTS
0.5 - 3.ov
1)Turn starting switch OFF. 2) Disconnect connector.
I) Start engine. 2) Insert T-adapter.
1)Screw in rotation sensor until it contacts ring gear, then turn back WI/6 turns. 2) It must work normally when adjusted as above.
PC1 28UU-2
TESTING
SYS
tern
STANDARD
AND ADJUSTING
Name of component
VALUE TABLE FOR ELECTRICAL PARTS
Judgment
Measurement conditions
table
If the condition is as shown in the table below, it is normal Boom. arm. bucket. and other levers
(PPC oil pressure switch) Travel
so1
Boom RAISE
so2
.-Fl
Boom LOWER
SIO
Arm IN
so5
Swing left
SO8
E z? z 3 r
Swing right
s30
1)Stat-t engine. 2) CXscXs; nect con-
ti
m
Between (1) - (2)
Min. 1 MQ
Between (I), (2) -chassis
If the condition is as shown in the table below, it is normal
lITurn starting switch ON. 2) InsertT-adapter.
If the condition is as shown in the table below. it is normal
1)Turn starting switch ON. 2) Insert T-adapter.
If the condition is as shown in the table
1)Turn starting switch ON. 2) Insert T-adapter.
Kerosene mode
Travel boost
co1
I below, it is normal Mode SET/CLEAR
co2
II
At SET
Between (3) chassis
At CLEAR
Between (4) chassis
O-IV
% When switch is not operated: 20 - 30 V
If the condition is as shown in the table below, it is normal
Mode selection
co2
1Depth
1 20-30V
1
1Height
1 O-IV
1 20-30V
1
1
1
1
Offset
PC1 28UU-2
O-IV
O-IV
1)Turn starting switch ON. 2) Insert T-adapter.
O-IV
1
20-17 0
TESTING
sy: ter
AND ADJUSTING
Name
of component
STANDARD
nspecbon nethod
ConKtor
VALUE TABLE FOR ELECTRICAL PARTS
Judgment
the condition is as shown elow, it is normal Svstem cancel sianal
lance1 signal
Measurement conditions
table in the table
1)Turn starting switch ON. 2) Insert T-adapter.
co2 Interference When normal When canceled
prevention
cancel sional
Between (14) - chassis
O-IV Ii 20-30V
-
-
20-18 0
PC1 28UU-2
TESTING
sys ten
STANDARD
AND ADJUSTING
Name of component
:onnector No.
‘nspection method
VALUE TABLE FOR ELECTRICAL PARTS
Judgment
Measurement conditions
table
the condition is as shown in Table 1 and Table 2, the monitor Inel is normal. tble 1 (CHECK, CAUTION section) Monitor item (input connector) Engine oil pressure PO1 (9) :HECK, CAUTION ;ection
M~~~~~t~enesnt
I
Display
I
IIConnectTadapter.
Sensor signal input
Engine started
Battery charge PO1 (IO) Preheating PO1 (13)
Engine stopped
ON
20-3OV
OFF
Max. 1 V
1)Turn starting switch OFF, and insert dummy resistance, or measure resistance of sensor. 2)Turn starting switch ON, and check display. 3) Connect socket.
able 2 (Gauges) Display level resistance (Monitor panel input resistance)
Position of gauge display itatting
switch
Starting switch OFF
ON
Min. - Max.
Measure resistance between coolant temperature gauge PO1 (female) (6) - (3)
I
3au,ges Left side
H
(kQ)
3.95 - 6.75
I
6.36 - 10.05
2 1
I
I
Min.
- Max. 0
Right side Measure resistance between fuel level gauge PO1 (female) (7) - (3)
Display losition
J, Left side
PC128UU-2
7 I-i
6
H I
4 3
1 H 2
All OFF
I I I
51 .O - 77.2 72.0 - 800
I 500 - Disconnection
I I I
20-19 a
STANDARD
TESTING AND ADJUSTING
systern
Name of component
Judgment 1 .’
.g
Engine oil pressure sensor
20 ?F :z 3 =%G
T3
IL
Measurement conditions
table
I VDkconnect ter-
1If the condition is as shown in the table below. it is normal I ’ ;“Save 68.6 kPa Max , Q Between .7 kg/cm*) sensor terminal - chassis
t
?low 29.4 kPa $ .3 kg/cm*)
I
Min , Mn
1)Turn starting switch OFF. 2) Disconnect connector.
If the condition is as shown in the table below, it is normal
CN22 (male)
I
I
t
Alternator
I
I
1
I’
I
I
CN18 (male)
Between alternator terminal R chassis
% I When engine is running g $
Z
g 2
startinn
switch OFF. 2) Disconnect connector.
CN21 (male)
If the condition is as shown in the table below, it is normal Fuel level sensor
I lITurn
I If the condition is as shown in the table 1below, it is normal
$ Coolant temperature sensor
minal. 2)Start engine.
I’ i ‘Z
Engine oil level sensor
VALUE TABLE FOR ELECTRICAL PARTS
1)Turn starting switch OFF. I 2) Disconnect connector.
I
1)Start engine.
(l/2 throttle or above) < 27.5 - 29.5 V % If the battery is old, or after starting in cold areas, the voltage may not rise for some time.
PC1 28UU-2
TESTING AND ADJUSTING Tools for testing, adjusting, and troubleshooting ................................................................................ 20-102 Measuring engine speed ........................................................................................................................ 20-103 Measuring exhaust color ........................................................................................................................ 20-104 Adjusting valve clearance ....................................................................................................................... 20-105 Measuring blow-by pressure ................................................................................................................. 20-106 Measuring engine oil pressure .............................................................................................................. 20-106 Testing and adusting fuel injection timing ............................................................................................ 20-107 Testing and adjusting air conditioner compressure belt tension ........................................................ 20-108 Adjusting engine speed sensor .............................................................................................................. 20-108 Adjusting fuel control cable ................................................................................................................... 20-109 Adjusting engine stop solenoid linkage ................................................................................................ 20-110 Testing clearance of swing circle bearing ............................................................................................. 20-111 Measuring wear of sprocket ................................................................................................................... 20-112 Testing and adjusting track shoe ........................................................................................................... 20-113 Testing and adjusting hydraulic pressure in work equipment, swing, travel circuit ......................... 20-114 Testing and adjusting PC valve output pressure (Servo piston input pressure) ................................ 20-117 Testing and adjusting LS valve output pressure (Servo piston input pressure) and LS diffrencial pressure ................................................................ 20-119 Testing and adjusting control circuit oil pressure ................................................................................ 20-122 Testing solenoid valve output pressure ................................................................................................ 20-123 Measuring PPC valve output pressure .................................................................................................. 20-126 Adjusting PPC valve ................................................................................................................................ 20-127 Testing and adjusting travel deviation .................................................................................................. 20-128 Testing parts which cause hydraulic drift of work equipment ............................................................ 20-129 Measuring oil leakage of swing motor .................................................................................................. 20-130 Measuring oil leakage of travel motor .................................................................................................. 20-130 Bleeding from each part ......................................................................................................................... 20-131 Releasing residual pressure from hydraulic circuit .............................................................................. 20-133 Releasing residual pressure from hydraulic tank ................................................................................. 20-133 Procedure of testing diode ..................................................................................................................... 20-134 Resetting procedure of electric system and check of its operation .................................................... 20-135 Replacement procedure of potentiometers .......................................................................................... 20-149 Pm clinic inspection table ....................................................................................................................... 20-150
PC128UU-2
20-101 (6)
TESTING
TOOLS FOR TESTING,
AND ADJUSTING
TOOLS FOR TESTING, ADJUSTING, Check or measurement
item
iymbol
Part No.
ADJUSTING,
AND TROUBLESHOOTING
AND TROUBLESHOOTING Remarks
Part Name
I
L : 60 - 2,000 rpm Digital display
Engine speed
R : 60 - 19,999 rpm
Water and oil temperatures
799-101-1502
Digital
799-101-5002
Hydraulic
799-261-1203
Digital
799-401-2320
Hydraulic
temperature
gauge
tester
1
2
3 Hydraulic
C ~
pressure
1
l
790-261-1311
l
790-261-1321
hydraulic
tester
Pressure gauge : 2.5, 5.9,39.2, 58.8 MPa {25,60,400,600 Kg/cm3 Pressure gauge : 68.6 MPa 1700 kg/cm? 1.O M Pa {I 0 kg/cm*)
gauge
Male, female both 18 x 1.5 (female PT l/8) Male, female both 14 x 1.5 (female PT l/8) Male, female both 22 x 1.5 (female PT l/8)
Adapter
1 790-261-1331 1 l
1 4 1 799-401-2701
-50 - 1,200”C
1 Differential
pressure
gauge Male, female both 14 x 1.5 (female PT l/8) For 14 x 15 blind
5
For blind Fuel injection timing Valve clearance Blow-by
pressure
Valve clearance
E
I 799-2OI-ISM
F
Commercially available
I Blow-by
checker
1 2
0 - 294.2 N {O - 30 kg)
I
Feeler gauge
I
G
color
_t
0 - 4.9 KPa 10 - 500 mm Hz01 Discoloration 0 - 70% (with standard color) (Discoloration % x l/IO k Bosch index)
I Exhaust
1Gear
~-1110
0 - 490.3 N (0 - 50 kg) Operating
Stroke,
H
effort
hydraulic
Work equipment
drift
I
speed
J
Measuring voltage and resistance values
Troubleshooting of wiring harnesses and sensors
El
Push-pull
Commercially available Commercially available
K
20- 102 0
wear of sprocket
Scale Stop watch
79A-264-02 IO
Tester
1
799-601-8000
T-adapter
2
799-601-7370
Adapter
For 6-pin relay
3
799-601-7050
Adapter
For SW-6P
4
799-601-7080
5
799-601-7310
kit
Adapter
For M-IP
L
E-7320
Measuring
scale
M
Adapter
For SW-12P
I Adapter
For SW-16P
7
799-60 I-7340
Adapter
For M-16P
8
799-6-l -7540
Adapter
For 070-18P
796-427-l
Wear gauge
1 IO
PC128UU-2
TESTING
MEASURING
AND ADJUSTING
MEASURING
ENGINE SPEED
*
Measure the engine speed under the following conditions. . Engine coolant temperature: In operating range . Hydraulic oil temperature: 45 - 55 “C
1.
Remove the air conditioner
top cover.
2.
Remove the air conditioner
compressor
3.
Remove cover (I) on the timing gear case side.
4.
Install sensor A2 of multi-tachometer A to the speed pickup port, then connect it to multi-tachometer A.
5.
Start the engine and set the measuring condition, then measure the engine speed. 1) Measuring low idling and high idling speeds: Set the fuel control lever to the low idling and high idling positions, and measure the engine speed at each position. 2) Measuring pump relief speed Run the engine at full throttle and relieve the main pump, and measure the engine speed at this time. 3) Measuring engine speed near rated speed Run the engine at full throttle and operate the arm lever, and measure the engine speed when the arm cylinder is relieved.
PC1 28UU-2
ENGINE SPEED
belt.
20-103 0
TESTING
AND ADJUSTING
MEASURING
EXHAUST
COLOR
MEASURING EXHAUST COLOR . 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. * a
1.
2.
Raise the coolant temperature to the operating range before measuring. When removing or installing the measuring equipment, be careful not to touch any high temperature parts.
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.
Measuring
with smoke meter G2
1) Insert-probe @I into the outlet port of exhaust 2)
3)
4)
5) 6)
7)
pipe (I), then tighten the clip to secure it to the exhaust pipe. Connect the probe hose, accelerator switch plug, and air hose to tool G2. * The pressure of the air supply should be a maximum of 1.47 MPa {I5 kg/cm2}. Connect the power cord to the AC outlet. * When connecting the port, check first that the power switch of tool G2 is OFF. Loosen the cap nut of the suction pump, then fit the filter paper. * Fit the filter paper securely so that the exhaust gas does not leak. Turn the power switch of tool G2 ON. 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. Lay the filter paper used to catch the exhaust gas color on top of unused filter papers (IO sheets or more) inside the filter paper holder, and read the indicated value. BLPO1274
20- 104 0
PC1 28UU-2
TESTING
AND ADJUSTING
ADJUSTING
ADJUSTING
VALVE CLEARANCE
VALVE CLEARANCE
1.
Remove the cylinder head cover.
2.
Using cranking tool D, rotate the crankshaft in the normal direction until timing pin (I) enters the hole in the gear. * This position is the compression top dead center for the No. 1 cylinder.
BEP01219
3.
When No. 1 cylinder is at top dead center, adjust the valves marked 0. Next, rotate the crankshaft one turn (360°C) in the normal direction and adjust the valve clearance of the remaining valves marked 0. * Make a match mark on the crankshaft pulley or damper, then rotate 360”.
Valve arrenaement
TKP00642
4.
To adjust the valve clearance, loosen locknut (41, then insert feeler gauge F between rocker lever and valve stem (5), and turn adjustment screw (6) until the clearance is a sliding fit. Then tighten locknut (7) to hold the adjustment screw in position. w
*
Locknut : 24 Nm (2.4 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 firing order. Firing order : l-342 l
*
--II-
II I
BEW005 16
There is no timing mark on the front pulley, so set to the compression top dead center as follows i) Following the firing order, No. 3 cylinder comes after No. 1 cylinder, so watch the movement of the valve of the No. 2 cylinder and rotate in the normal direction. ii) When the valve clearance of both the intake and exhaust valve of the No. 2 cylinder is 0, the No. 3 cylinder is at compression top dead center. (When setting the No. 2 cylinder, watch the movement of the No. 3 cylinder.)
PC1 28UU-2
20-105
0
TESTING
AND ADJUSTING
MEASURING
MEASURING MEASURING
BLOW-BY PRESSURE ENGINE OIL PRESSURE
BLOW-BY PRESSURE
*
Measure the blow-by pressure under the following conditions. . Coolant temperature: Within operating range . Hydraulic oil temperature: 50 - 80°C
1.
Install the nozzle of blow-by checker E to the blowby hose.
2.
Connect the nozzle and gauge with the hose.
3.
Run the engine at full throttle and relieve the arm circuit.
4.
Measure the blow-by pressure when the gauge indicator remains steady.
BLP01278
MEASURING PRESSURE
ENGINE OIL
*
Measure the engine oil pressure under the following conditions. . Coolant temperature: Within operating range
1.
Remove engine oil pressure sensor (I), install the adapter inside oil pressure gauge kit Cl, then install oil pressure gauge C2 (0.98 MPa {IO kg/cm*)).
2.
Start the engine, and measure the oil pressure with the engine at low idling and high idling.
-F-
BLPO1289
20- 106 0
PC128UU-2
TESTING
AND ADJUSTING
TESTING AND ADJUSTING
TESTING AND ADJUSTING
FUEL INJECTION
TIMING
FUEL INJECTION TIMING
1.
Testing 1) Using cranking tool D, rotate the crankshaft in the normal direction until timing pin (I) enters the hole in the gear. 2) Remove plug (21, reverse timing pin (31, and check that pin (3) meshes with timing pointer (4) at the fuel injection pump end.
2.
Adjusting . If the timing pin does not mesh. i) Remove the fuel injection pump. For details, see REMOVAL OF FUEL INJECTION PUMP ASSEMBLY. ii) Rotate the fuel injection pump camshaft and mesh timing pin (3) with timing pin pointer (4). iii) Install the fuel injection pump assembly. For details, see INSTALLATION OF FUEL INJECTION PUMP ASSEMBLY. 9JFOO287
PC128UU-2
20-107 0
TESTING
AND ADJUSTING
TESTING AND ADJUSTING AIR CONDITIONER COMPRESSOR BELT TENSION ADJUSTING ENGINE SPEED SENSOR
TESTING AND ADJUSTING AIR CONDITIONER COMPRESSOR BELT TENSION *
1. 2. 3.
4.
If the deflection of the belt is not within the standard value when it is pressed at a point midway between the crankshaft pulley and the compressor pulley, or the belt has been replaced or other maintenance has been carried out, adjust the tension as follows. Remove 2 mounting bolts (2) of compressor assembly (1) and 2 adjustment plate bolts (3). Move compressor assembly (I 1to adjust the belt tension. When the position of compressor assembly (I) is decided, tighten adjustment plate bolts (3) and mounting bolts (2) to hold in position. After adjusting the belt tension, repeat the inspection procedure to check that the belt tension has been adjusted to the standard value.
Compressor ~ulleu 12-15mm
Crankshaft ~ullev TKP00643
ADJUSTING SENSOR
ENGINE SPEED
Screw in sensor (I) until it contacts the tip of gear (2). 2. After sensor (I) contacts gear (21, turn it back 1 + l/6 turns. 3. Tighten locknut (3). Ir Be extremely careful to set the sensor wiring so that there is no excessive force on the wiring. Sr Be careful not to make any scratches or let any iron particles stick to the tip of the sensor.
I
1.
20-108 a
BEP01149
PC1 28UU-2
TESTING AND ADJUSTING
ADJUSTING
FUEL CONTROL CABLE
-k :When the fuel injection pump or starting motor is replaced, or when the engine speed is not in the specified range, adjust the fuel control cable according to the following procedure. 1.
Loosen locknuts (2) and (3) of cable (I).
2.
Turn the starting switch to the ON position and set the fuel control dial to the FULL position.
3.
.Pull the outer part of cable (I) to the left until governor lever (4) comes in contact with the full stopper, then tighten locknuts (2) and (3) temporarily. * Check that the cable is not loosened. * Make a mark on locknut (2) with white paint.
4.
Return locknut (2) by 4 turns. * At this time, check that clearance “b” between bracket (5) and locknut (2) is 5 mm.
5.
Tighten locknut (3). ,* Check that the cable boot is not twisted. :w
PC128UU-2
Locknut: 9.8 - 14.7 Nm {IO0 - 150 kgcm)
ADJUSTING
FUEL CONTROL CABLE
TESTING
AND ADJUSTING
ADJUSTING
ADJUSTING
ENGINE STOP SOLENOID
LINKAGE
ENGINE STOP SOLENOID LINKAGE
Testing 1.. Turn the starting switch on, and check that the clearance between lever (I) and stopper (2) is 1 2 mm when in the operating condition. Adjusting 1. Loosen the mounting bolts of solenoid (31, move solenoid assembly (3) to adjust the clearance between lever (I) and stopper (21, then tighten the mounting bolts. * There is an oblong hole at the bracket end.
BEP01424
20-110 0
PC128UU-2
TESTING AND ADJUSTING
TESTING
CLEARANCE OF SWING CIRCLE BEARING
TESTING CLEARANCE OF SWING CIRCLE BEARING 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).. Set the dial gauge at the front or rear.
Or
rame
frame
Di al 0 TLP00733
2.
to the maximum Extend the work equipment to the same bucket reach, and set the tip of the frame. revolving the of height as the bottom will tiltforstructure upper the When this is done, rear will the and down go will ward, so the front rise.
3.
Set the dial gauge to the zero point.
TXP07.245
4.
5.
Set the arm more or less at right angles to ground surface, then lower the boom until front of the machine comes off the ground. When this is done, the upper structure will back, so the front will rise and the rear will down.
tilt go
Read the value on the dial gauge at this point. The value on the dial gauge is the clearance of the swing circle bearing. g
6.
the the
When carrying out the measurement, do not put your hand or feet under the undercarriage.
150i200mm
BWPO4406
Return to the condition in Step 2, and check that the dial gauge has returned to the zero point. If it has not returned to the zero point, repeat Steps 2 to 5.
PC128UU-2
20-111 0
TESTING
MEASURING
AND ADJUSTING
MEASURING
WEAR OF SPROCKET
WEAR OF SPROCKET Wear limit line
TLP01303
1.
Remove the track shoe assembly. * For details, see DISASSEMBLY AND ASSEMBLY, REMOVAL OF STEEL SHOE ASSEMBLY.
2.
Align wear gauge M with the sprocket. * Align the benchmark line, then align pattern.
3.
wave
Judge the wear of the sprocket. * If the sprocket wave pattern is adove the wear limit line, it is possible to use the sprocket as it is. * If the sprocket wave pattern has reached the wear limit line, replace the sprocket with a new part.
20-112 0
PC128UU-2
TESTING TESTING AND ADJUSTING
AND ADJUSTING HYDRAULIC PRESSURE IN WORK EQUIPMENT, SWING, TRAVEL CIRCUIT
TESTING AND ADJUSTING HYDRAULIC PRESSURE IN WORK EQUIPMENT, SWING, TRAVEL CIRCUIT : 1. a
Measuring * Oil temperature when measuring: 45 - 55°C 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 put the safety lock lever in the LOCK position. . Remove pressure pick-up plug (1) (Thread dia.=lOmm, Pitch=1.25mm) from the circuit to be measured, then install oil pressure gauge Cl (58.8 MPa (600 kg/cm2}).
Measuring unload hydraulic pressure Run the engine at full throttle and measure the hydraulic pressure when the control levers are at HOLD.
Measuring main relief (pump relief) pressure 1. Run the engine at full throttle and relieve each actuator, and measure the hydraulic pressure at this time. . Set each actuator under the following condition. 1) When relieving oil by operating the work equipment, set each cylinder at the stroke end.
2) When relieving oil by swinging, dig a hole and 3)
lower the bucket. When relieving oil by traveling, put block (1) against the grouser of the track shoe, or put block (2) between the sprocket and frame to lock the track shoe, then measure one side at a time. * The set pressure of the swing motor safety valve is lower than the set pressure of the main relief valve. Accordingly, if the oil is relieved by swinging, the set pressure of the safety valve is measured.
BLP00170
20-114 0
BLPOOl71
PC128UU-2
TESTING AND ADJUSl-lNG
TESTING
AND ADJUSTING HYDRAULIC PRESSURE IN WORK EQUIPMENT, SWING, TRAVEL CIRCUIT
Adjusting 1. Adjusting main relief valve Disconnect the hose for setting high pressure. high set pressure Adjusting I) . Loosen locknut (2) of main relief valve (I) and turn holder (3) to adjust the high set pressure. If the holder is * . is the pressure Turned clockwise, heightened. . Turned counterclockwise, the pressure is lowered. After adjusting, check the pressure again * according to the above testing procedure. Pressure changed by 1 turn of holder : * Approx. 12.6 MPa 1128 kg/cm21 l
Locknut: 53.9 - 63.7 Nm I5.5 - 6.5 kgm)
m
If the high set pressure is adjusted, the low set pressure is changed. Accordingly, adjust the low set pressure. Adjusting low set pressure Loosen locknut (4) of main relief valve (1) and turn holder (5) to adjust the low set pressure. If the holder is * . is the pressure Turned clockwise, heightened. . Turned counterclockwise, the pressure is lowered. After adjusting, check the pressure again * according to the above measuring procedure. Pressure changed by 1 turn of holder: * Approx. 12.6 MPa (128 kg/cm*) *
2)
l
Locknut : 39.2 - 49.0 Nm I4 - 5 kgm}
m
2.
9JFOO261
Adjusting swing motor safety valve If the swing relief pressure is not normal, ad* just the swing motor safety valve according to the following procedure. 1) Loosen locknut (7) of swing motor safety valve (6) and turn adjustment screw (8) to adjust the swing relief pressure. If the adjustment screw is * is the pressure turned clockwise, heightened. turned counterclockwise, the pressure is lowered. Pressure changed by 1 turn of adjustment * screw: Approx. 14.0 MPa I143 kg/cm*} l
l
PC128UU-2
20-115 a
TESTING
AND ADJUSTING
TESTING AND ADJUSTING HYDRAULIC PRESSURE IN WORK EQUIPMENT, SWING, TRAVEL CIRCUIT
2) After adjusting, tighten locknut (7). B
*
Locknut: 53.9 - 73.5 Nm I5.5 - 7.5 kgm}
After adjusting, check the pressure again according to the above measuring procedure.
9JFOO253
20-116 0
PC128UU-2
TESTING TESTING
AND ADJUSTING
TESTING AND ADJUSTING PC VALVE OUTPUT PRESSURE (SERVO PISTON INPUT PRESSURE) Measuring * Oil temperature
for measurement:
45 - 55 “C
1. Remove oil pressure pickup plugs (I) and (2) (IO mm, P = 1.251, then install oil pressure gauges Cl (39.2 MPa (400 kg/cm2)). 2.
Turn the swing
3.
Run the engine at full throttle and relief the arm cylinder (by IN operation), and measure the pressure at this time.
lock switch
to the ON position.
[Reference] If the LS valve or servo piston is defective, the servo piston input pressure is “about the same as the pump discharge pressure or almost 0”.
PC128UU-2
AND ADJUSTING PC VALVE OUTPUT PRESSURE (SERVO PISTON INPUT PRESSURE)
TESTING
AND ADJUSTING
TESTING AND ADJUSTING PC VALVE OUTPUT PRESSURE (SERVO PISTON INPUT PRESSURE)
Adjusting * If the engine speed lowers as the load increases or if the work equipment speed is low while the engine speed is normal and the pump discharge pressure, LS differential pressure, etc. are normal, adjust PC valve (6) according to the following procedure.
I)
If the speed is low, loosen locknut (4) and turn screw (5) “clockwise”. If the engine speed low, turn screw (5) “counterclockwise”. 2) Remove oil pressure pickup plugs (I) and (2) (IO mm, P = 1.25), then install oil pressure gauges Cl (39.2 MPa (400 kg/cm2)). 3) Turn the swing lock switch to the ON position. 1.
Run the engine at full throttle and relief the arm cylinder (by IN operation), and measure the pressure at this time.
BKPOIOIS
[Reference] If the LS valve or servo piston is defective, the servo piston input pressure is “about the same as the pump discharge pressure or almost 0”.
20-118 0
PC128UU-2
TESTING TESTING
AND ADJUSTING
AND ADJUSTING LS VALVE OUTPUT PRESSURE (SERVO PISTON INPUT PRESSURE) AND LS DIFFERENTIAL PRESSURE
TESTING AND ADJUSTING LS VALVE OUTPUT PRESSURE (SERVO PISTON INPUT PRESSURE) AND LS DIFFERENTIAL PRESSURE * 1.
Oil temperature
for measurement:
45 - 55 “C
Measuring LS valve output pressure (servo piston input pressure) 1) Remove oil pressure pickup plugs (I) and (2) (10 mm, P = 1.251, then install oil pressure gauges Cl (39.2 MPa I400 kg/cm*)). 2) Push up the track shoe on one side with the work equipment. 3) Run the engine at full throttle and move the track shoe with no load on it and measure the hydraulic pressure at this time (hydraulic pressure when one track is moved with no load on it).
I
Neutral
I
2.94kO.49 {30f5)
Servo inlet pressure Remarks MPa{kg/cm*} 4bout same pressure 4.41f0.98 Pressure of about 315 I45+ IO)
PC128UU-2
TESTING TESTING
2.
AND ADJUSTING
AND ADJUSTING LS VALVE OUTPUT PRESSURE (SERVO PISTON INPUT PRESSURE) AND LS DIFFERENTIAL PRESSURE
Measuring LS differential pressure 1). Measuring with differential pressure gauge i) Remove oil pressure pickup plugs (1) and (2) (10 mm, P = 1.251, then install differential oil pressure gauge Cl. * Connect pump discharge pressure side (1) to the high pressure side of the differential pressure gauge and connect LS differential pressure side (2) to the low pressure side. ii) Push up the track shoe on one side with the work equipment. iii) Run the engine at full throttle and measure the LS differential pressure under the following condition. LS differential pressure when travel lever is in neutral : 2.75 f 0.98 MPa (28 f 10 kg/cm*} The LS differential pressure when the * travel lever is in neutral is the same as the unload pressure. LS differential pressure when travel lever is operated halfway (when machine travels with no loads) : 1.57 f 0.1 MPa (16 It 1 kg/cm*} 2) Measuring with oil pressure gauges * Since the differential pressure is 1.96 MPa (20 kg/cm*) at most, measure it with oil pressure gauges of the same l
l
type. Remove oil pressure pickup plugs (I) and (2) (IO mm, P = 1.251, then install oil pressure gauges Cl. ii) Install pressure gauge Cl (39.2 MPa (400 kg/cm*)) to the pump discharge pressure pickup plug. * Use a pressure gauge graduated in 0.98 MPa I10 kg/cm*). iii) Push up the track shoe on one side with the work equipment. iv) Run the engine at full throttle and measure the pump discharge pressure under the condition of 1 j-31. * Read the pointer accurately from its front side. VI Run the engine at full throttle and measure the LS pressure under the condition of I)- iii). * Read the pointer accurately from its front side. vi) Calculate the LS differential pressure from the pump discharge pressure and LS pressure [(LS differential pressure) = (Pump discharge pressure) (LS pressure)].
i)
20-120 0
9JFOO120
-
;_ BLP01284
PC128UU-2
TESTING TESTING
3.
AND ADJUSTING
AND ADJUSTING LS VALVE OUTPUT PRESSURE (SERVO PISTON INPUT PRESSURE) AND LS DIFFERENTIAL PRESSURE
Adjusting LS valve Sr If the LS differential pressure is not normal, adjust the LS valve according to the following procedure. 1) Disconnect hose (8) from LS valve (7). 2) Loosen locknut (9) and turn adjustment screw (10) to adjust the LS differential pressure. * If the adjustment screw is turned clockwise, the pressure is heightened. turned counterclockwise, the pressure is lowered. * Pressurechanged by 1 turn of adjustment screw: 1.30 MPa (13.3 kg/cm*) (LS differential pressure) 3) After adjusting, tighten locknut (8). l
l
w *
Locknut
: 59 + 10 Nm (6 + 1 kgm)
After adjusting, check the LS differential pressure again according to the above measuring procedure.
BWPO4497
PC1 28UU-2
20-121 0
TESTING
TESTING AND ADJUSTING
AND ADJUSTING
TESTING AND ADJUSTING CONTROL CIRCUIT OIL PRESSURE Measuring * Oil temperature
a
for measurement:
Lower the work equipment to stop the engine. Then, loosen slowly to release the internal hydraulic tank. Set the safety LOCK position.
CONTROL CIRCUIT OIL PRESSURE
:
45 - 55 “C
the ground and the oil filler cap pressure of the lock lever to the
1.
Remove the valve top cover.
2.
Disconnect hose (I) connected to the solenoid valve, then install adapter C3 and oil pressure gauge Cl (5.9 MPa (60 kg/cm?).
3.
Run the engine at full throttle control circuit oil pressure.
and measure the
Adjusting * If the control circuit oil pressure is not normal, adjustthe control relief valve according to the following procedure. 1.
Loosen locknut (2) and turn adjustment screw (3) to adjust the control circuit oil pressure. * If the adjustment screw is Turned clockwise, the pressure is heightened. Turned counterclockwise, the pressure is lowered. * Pressure changed by 1 turn of adjustment screw: 0.98 MPa {IO kg/cm? l
l
2.
After adjusting,
9JFOO266
tighten locknut (2).
m
Locknut : 19.6 - 24.5 Nm {2.0 - 2.5 kgm}
Jr
After adjusting, check the control circuit oil pressure again according to the above measuring procedure.
20- 122 0
t-
PC128UU-2
TESTING
TESTING SOLENOID
AND ADJUSTING
VALVE OUTPUT PRESSURE
TESTING SOLENOID VALVE OUTPUT PRESSURE Measuring * Oil temperature
for measurement:
45 - 55 “C
1. Measuring output pressure of EPC solenoid valve for automatic stop and control of work equipment 1) Remove oil pressure pickup plug (I). 2) Install oil pressure gauge Cl (5.88 MPa 160 kg/cm?). 3) Measure the output pressure under the conditions shown in Table 1. * The component valves of the 5-spool solenoid valve assembly are lined in the following order from the top. (I) Boom LOWER stop EPC solenoid valve (2) Arm IN stop EPC solenoid valve (3) Boom RAISE stop EPC solenoid valve valve (4) LEFT offset stop EPC solenoid (5) RIGHT offset
stop
EPC solenoid
valve
Table 1 Solenoid 1
2
3
name
BoomRA~SEstop
Measuring
condition
During boom RAISE operation ________-___--______----_._---____-___--_ Stops automatically in automatic stop range
During boom LOWER operation BoomLOWERstop_---__---__------__-Stops automatically in automatic Arm IN stop
PC1 28UU-2
Oil pressure
During arm IN operation ________---_--------Stops automatically in automatic
____.____ stop range
(MPa {kg/cm*))
Remarks
2.94 f 0.49 (30 * 5) 0 2.94 f 0.49 130 * 5) ---_------_ 0
2.94 * 0.49 (30 + 5) ---_--------------stop range 0
20-123 0
TESTING
2.
AND ADJUSTING
TESTING
SOLENOID
VALVE OUTPUT PRESSURE
Measuring ON-OFF solenoid valve output pressure 1) Disconnect hose (2) from the 4-spool or 5spool solenoid valve assembly. 2) Using adapter C3 in the oil pressure gauge kit, install nipple C2 and oil pressure gauge C1 (5.88 MPa {60 kg/cm*)). 3) Measure the solenoid valve output pressure under the conditions shown in Table 2.
Table 2 Solenoid valve
IO.
PPC oil 1 pressure lock
2
4
5
6
Travel speed selector
2-stage relief
Left offset stop
Right offset stop
f Note)
Each solenoid valve is operated as follows. ON : Power is applied (Oil pressure is generated). OFF : Power is not applied (Oil pressure is 0). Only the LS bypass solenoid valve is operated as follows, however. ON : Power is applied (Oil pressure is 0). OFF: Power is not applied (Oil pressure is 30 + 5).
20- 124 0
PC128UU-2
TESTING
AND ADJUSTING
*
The component valves of the 4-spool solenoid valve assembly are lined in the following order from the top. (I) PPC oil pressure lock ON-OFF solenoid valve (2) Travel speed selector ON-OFF solenoid valve (3) Swing holding brake ON-OFF solenoid valve (4) 2-stage relief ON-OFF solenoid valve
*
The component valves of the 5-spool solenoid valve assembly are lined in the following order from the top. (1) Boom LOWER stop EPC solenoid valve (2) Arm IN stop EPC solenoid valve (3) Boom RAISE stop EPC solenoid valve (4) LEFT offset stop EPC solenoid valve (5) RIGHT offset stop EPC solenoid valve
PC1 28UU-2
TESTING
SOLENOID
VALVE OUTPUT PRESSURE
20-125 0
TESTING
MEASURING
AND ADJUSTING
PPC VALVE OUTPUT
PRESSURE
MEASURING PPC VALVE OUTPUT PRESSURE for measurement:
45 - 55 “C
*
Oil temperature
1.
Measuring PPC valve output pressure 1) Disconnect PPC hose (1) of the circuit to be measured. 2) Install adapter C3 between the elbow and hose. 3) Install oil pressure gauge Cl (5.88 MPa (60 kg/cm211 to adapter C3. 4) Run the engine at full throttle and operate the control lever of the circuit to be measured, and measure the output pressure.
J,
Measuring points (From top of main control a : (Service) b : (Service) c : RIGHToffset d : LEFT offset e : Bucket DUMP f : Bucket CURL g : Arm OUT h : Arm IN i : Blade LOWER j : Blade RAISE k : Boom RAISE I : Boom LOWER m : RIGHT reverse travel n : RIGHT forward travel o : LEFT forward travel p : LEFT reverse travel q : Swing LEFT r : Swing RIGHT
valve)
BWP04498
20-126 0
PC128UU-2
TESTING
ADJUSTING *
A
ADJUSTING
AND ADJUSTING
PPC VALVE
PPC VALVE
If the work equipment control lever or swing lever has excessive play, adjust it according to the following procedure. Lower the work equipment to the ground and stop the engine. Then, loosen the oil filler cap slowly to release the internal pressure of the hydraulic tank. Set the safety lock lever to the LOCK position.
1. Remove the PPC valve. 2.
Remove boot (1).
3.
Loosen locknut (2) and tighten disc (3) until it comes in contact with the heads of 4 pistons (4). * Do not move the pistons at this time.
4.
Fix disc (3) and tighten fied torque. w
5.
Locknut:
locknut (2) to the speci-
107.9 f 9.8 Nm {II
f 1 kgm}
Install boot (1). * The clearance between disc (3) and piston (4) is eliminated by the above adjustment.
BVPO3436
PC1 28UU-2
20-127 0
TESTING
TESTING
AND ADJUSTING
TESTING AND ADJUSTING TRAVEL DEVIATION 1.
Travel
AND ADJUSTING
TRAVEL DEVIATION
posture
Measuring when traveling 1) Set the machine in the travel posture. * When setting the machine in the travel posture, extend the bucket and arm cylinder rods fully, and hold the boom at an angle of 45”. 2) Travel for lOm, then measure dimension a the deviation for the next 20m when traveling with the engine at full throttle. * Measure at full throttle. * Install an oil pressure gauge and measure the pump discharge pressure at the same time.
I
TLP00731
k
I
Make a mark at the IOm midpoint
Make
a mark
0 Lay
out,
10m midpoint
strine
-I
Mark /\ Measure dimension this deviation
a
of lMark
TLP00732
20-128 0
PC128UU-2
TESTING TESTING AND ADJUSTING
PARTS WHICH CAUSE HYDRAULIC DRIFT OF WORK EQUIPMENT
TESTING PARTS WHICH CAUSE HYDRAULIC DRIFT OF WORK EQUIPMENT * Oil temperature for measurement: 45 - 55 “C 1.
Work equipment cylinder * If the hydraulic drift of the work equipment is out of the standard range, measure the internal leakage of the cylinder according to the following procedure to see if the cause of the hydraulic drift is on the control valve side. . If the leakage is below the standard value, the cause of the leakage is on the control valve side. . If the leakage is above the standard value, the cause of the leakage is on the cylinder side. 1) Fully extract the rod of the cylinder to be measured, then stop the engine. 2) Disconnect the hose on the head side and plug the hose on the machine side. Boom cylinder: Hose (I) Arm cylinder: Hose (2) Offset cylinder: Hose (3) Bucket cylinder: Hose (4)
A 3)
4)
2.
Take care not to disconnect the bottom side.
Arm CY I inder.
offset
cylinder
2
the hose on TXP02246
Run the evgine at full throttle and apply relief pressure to the bottom side of the cylinder. Sr Boom cylinder: RAISE operation Arm cylinder: IN operation Offset cylinder: RIGHT offset operation Bucket cylinder: CURL operation After 30 seconds, measure the oil leakage for 1 minute.
Testing PPC valve If the hydraulic drift varies with the position of the safety lock lever (while the engine is running), the PPC valve is defective.
Disconnect
l
PC1 28UU-2
I
TEP0033;
20-129 0
TESTING
AND ADJUSTING
MEASURING MEASURING
OIL LEAKAGE FROM SWING MOTOR OIL LEAKAGE FROM TRAVEL MOTOR
MEASURING OIL LEAKAGE FROM SWING MOTOR : * Oil temperature for measurement : 45’- 55 “C 1.
Disconnect drain hose (I) of the swing motor and install a plug to the tank.
2.
Have the bucket dig into the ground to lock the swing mechanism.
3.
Run the engine at full throttle to relief the oil from the swing motor.
4.
After 30 seconds, measure the oil leakage for 1 minute. *
After measuring one time, swing the work equipment by 180 degree, then measure again.
MEASURING OIL LEAKAGE FROM TRAVEL MOTOR * Oil temperature for measurement: 45 155Ae 1.
Disconnect drain hose (I) of the travel motor and install a plug to the tank.
2.
Put block @ against the grouser of the track shoe or put block @ between the sprocket and frame to lock the track shoe.
3.
Run the engine at full throttle to relief the oil from the travel motor.
A 4.
Since a mistake in operation of the lever can cause an accident, make and confirm signs securely.
9JFOOO95
After 30 seconds, measure the oil leakage for 1 minute. * Measure the oil leakage several times, moving the motor little by little (changing the relative positions of the valve plate and cylinder and those of the piston and cylinder).
20- 130 0
PC128UU-2
TESTING
BLEEDING FROM EACH PART
AND ADJUSTING
BLEEDING FROM EACH PART Air bleeding
Contents
of work
l
Replacing hydraulic Cleaning strainer
l
Replacing
l
return
oil
filter element
l
Replacing/Repairing Removing suction
l
Replacing/Repairing
control
Replacing/Repairing Removing cylinder
cylinder piping
l
l
l
l l
l
l
procedure
pump piping valve
Replacing/Repairing swing motor Removing swing motor piping Replacing/Repairing travel motor and swivel Removing travel motor and swivel piping
Note: Bleed the air from the swing and travel motors only when the oil inside the motor case has been drained. 1.
Bleeding air from pump 1) Loosen air bleeder (I) to bleed air through itself. * If oil containing no air flows out, stop bleeding. 2) Tighten air bleeder (I). w *
2.
Bleeder: 17.16 + 2.45 Nm (1.75 + 0.25 kgm} Caution for starting engine After the above work, run the engine low idling for about 10 minutes.
at
Bleeding air from cylinder I) Start and run the engine at low idling for about 5 minutes. 2) Raise and lower the boom 4 - 5 times with the engine speed low. * Move the piston rod to about 100 mm before the stroke end and never relief the oil. 3) Perform the operation of 2) above with the engine at full throttle. Then, run the engine at low speed and move the piston rod to the stroke end to relief the oil. 4) Bleed air from each of the arm, bucket, swing, and blade cylinders by performing above operations of 2) and 3).
PC128UU-2
20-131 0
TESTING AND ADJUSTING
3.
Bleeding air from swing motor 1) Turn ON the swing lock switch and run the engine at low idling. * Bleed air from the swing motor with the pressure at port S. 2) Disconnect hose (1) from the swing motor and plug it. 3) Run the engine at low idling and check that oil flows out of elbow (2). Jc If oil does not flow out of elbow (2), repeat I) above. 4) Connect hose (1).
4.
Bleeding air from travel motor 1) Disconnect motor drain hose (2). 2) Run the engine at low idling and check that oil oozes through the nipple. 3) After oil oozes, connect hose (2).
20-132 0
BLEEDING FROM EACH PART
PC128UU-2
TESTING
AND ADJUSTING
RELEASING RESIDUAL PRESSURE FROM HYDRAULIC CIRCUIT RELEASING RESIDUAL PRESSURE FROM HYDRAULIC TANK
RELEASING RESIDUAL PRESSURE FROM HYDRAULIC CIRCUIT *
When disconnecting the piping between the hydraulic cylinder and control valve, release the residual pressure from the circuit. Since the travel circuit is open, any pressure is not kept in it. Accordingly, just remove the oil filler cap.
1.
Operate the control lever (with the starting switch at the ON position and the safety lock lever at the FREE position). Operate the control lever 2 - 3 times, and the * pressure in the accumulator is released.
2.
Loosen the oil filler cap gradually pressure from the tank.
3.
Run the engine at low idling for about 5 seconds and stop it. Then, operate the control lever. Repeat the above operation 2 - 3 times, and * the all residual pressure is released.
to release the
RELEASING RESIDUAL PRESSURE FROM HYDRAULIC TANK A The hydraulic tank is enclosed and pressurized.
When removing a hose, plug, etc. connected to the hydraulic tank, release the residual pressure in the hydraulic tank according to the following procedure.
I.
Lower the work equipment to the ground and stop the engine.
2.
Loosen the oil filler cap or oil filler plug of the hydraulic tank gradually to release the residual pressure from the tank.
PC1 28UU-2
20-133 0
PROCEDURE OF TESTING
TESTING AND ADJUSTING
DIODE
PROCEDURE OF TESTING DIODE Diode l
l
1.
as
individual
Part
Test a diode unit or a harness containing a diode according to the following procedure. Use a digital tester having a diode measuring range. Apply the red (+I test pin to the anode (PI side of the diode and the black (-1 test pin to the cathode (N) side. * A flow mark is printed on the diode. * If an ordinary tester is set in the diode range, the voltage of the battery in itself is indicated. If this voltage . does not change + There is not continuity. . changes + There is continuity. (Normal) (Note) . is 0 or almost 0 * Diode is shorted internally. Note)
TLP00663
Diode
included
in
wiring
harness
In the case of a silicon diode, the tester indicates a value of 400 - 600 or 0.4 - 0.6, depending on its characteristics.
TLP00664
BLP01357
20-134 0
PC1 28UU-2
RESETTING TESTING
AND ADJUSTING
PROCEDURE OF ELECTRIC SYSTEM AND CHECK OF ITS OPERATION
RESETTING PROCEDURE OF ELECTRIC SYSTEM AND CHECK OF ITS OPERATION When any of the following works is performed or when any error code is displayed, reset the electric system according to the flow chart shown below. 1) When the work equipment is removed and installed for repair. 2) When the work equipment is replaced with a long arm. 3) When the controller is replaced. 4) When a potentiometer is removed, installed, or replaced. 5) When an error code of the reset signal system is displayed.
l
l
Flow chart of resetting
Reset the potentiometer mounting angle first, then reset the front stop position, depth display, left side stop, and prevention of interference of exterior parts (Boom LOWER and arm IN operations). Sr The Nos. in boxes refer to the Nos. in the resetting procedure. * Items marked with % need to be only checked.
l
of electric system
Erroh -____
I
Check and reset automatic stop in arm IN direction for Exee$on oi interference
I
Check and reset automatic stop in boom lowering direction for prevention of external interference
I
Check automatic stop in rigth offset direction for prevention of external interference
~____l____, ; Automatic ; stop I 1position is I I nearer than i I specified 1 ;_p_:$io_n___; 1 7------i I
t
$Zi-rYit~~ -I ; stop I position is I in specified l!?!?!e ____A I
1
i stop t I position is ; ~farfrom I I spe$fied ’ Ip_o_slf’o_“_ __1 1 r------7 I
Error
1
.--+J
I ’ stop I I position is 1 ; in specified I I.____T----: range I 8
Move bucket to right and left to check automatic
I
PC128UU-2
I
t stop position
I
20-135 0
RESETI-ING TESTING
1.
AND ADJUSTING
Resetting of potentiometer input signal 1) Set the work equipment in the following position. i) Boom: RAISE stroke end ii) Arm: IN stroke end iii) Offset: RIGHT offset stroke end * Be sure to turn on the emergency work equipment operation switch and check that the all cylinders at the stroke end. 2) Turn the starting switch to the OFF position to stop the engine, then turn it to the ON position again. 3) Set the mode selector switch to “0 setting of depth” and connect reset power terminal (1) and reset terminal (2). * The reset terminal is taped onto the harness at the rear of the panel. * The reset power terminal (CN-KIO) (I) is a plug (green harness) and the input reset terminal (CN-K8) (2) is a socket (Yellow and blue harness which is not taped). 4) Check that the electric system caution lamp of the monitor panel starts flashing at intervals of 1 second after 2 seconds. * If the input signal (voltage) of the potentiometer is out of the standard range, an error code between 10 and 19 is displayed on the monitor panel. If any error code is not displayed, disconnect 5) terminal (CN-KIO) (I) and (CN-K8) (21, then turn the starting switch to the OFF position. * If the starting switch is turned to the OFF position without disconnecting the terminals, the electric system caution lamp starts flashing again when the starting switch is turned to the ON position next time. 6) Turn the starting switch to the ON position, and the resetting operation is finished. 7) After finishing the resetting operation, tape the reset terminal as before.
20-136 0
PROCEDURE OF ELECTRIC SYSTEM AND CHECK OF ITS OPERATION
1
BWPO4414
PC128UU-2
RESElTING
PROCEDURE OF ELECTRIC SYSTEM AND CHECK OF ITS OPERATION
TESTING AND ADJUSTING
2.
If an abnormality display (error code) was given in Item 1 (reset potentiometer input signal) . If the potentiometer input signal (voltage) is not within the range in the table below when the work equipment is set to the posture in Item 1, an abnormality display will be given during the resetting operation, and it will be impossible to reset the system. * If an abnormality display appears during the resetting operation, turn the starting switch OFF with the abnormality display still displayed, then turn the starting switch ON again. This will delete the input signals that are in the memory. Therefore,
I)
if an abnormality
o’54-o*82
2)
lame of
croup
is
given, remove all the causes and reset the system properly. Potentiometer input signal (when normal) WI Arm
Boom
%
display
Table 1
STD
0.65-1.43
Long arm
0~4-1.52
2g9_4,,
Reenact
system
11
Defective resetting of boom angle
12
Defective resetting of arm angle
q
,3
Defective resetting of boom angle + arm angle
cl
14
Defective resetting of offset angle
[7
,5
Defective resetting of boom angle + offset angle
0
,6
Defective resetting of arm angle + offset angle
q
,7
Defective resetting of boom angle + arm angle + offset angle
cl
2,
Defective resetting of front face stop position
Offset
*
[Measurement] Boom: Between C21 (2) and (1) Arm: Between C23 (2) and (3) Offset: Between C22 (2) and (I) The value will change if an option (long arm) is installed. Content of abnormality display Depending on the nature of the abnormality, one of the displays in Table 1 will be given. i) Abnormality in one system (inside bold lines) The display is one of 1 ‘I, 12, or 14. ii) Simultaneous abnormality in two or more systems (inside thin lines) The last digits are added and the total is displayed. If the resetting operation has not been * carried out properly, when the reset power source terminal and input reset terminal are disconnected, the abnormality display and electrical system caution lamp will flash in a 0.6-second cycle, and the buzzer will also sound in a 0.6-second cycle. In Table 1, all the error codes for the * reset groups are shown.
PC128UU-2
c
Abnormal
leset
cl I
I 2*
Defective resetting of side face stop position
cl
Defective resetting of front face
24
of depth
cl
25
Defective resetting of front face stop position + defective compensation of depth display
[7
26
Defective resetting of side face stop position + defective compensation of depth display
17
Defective resettiqg of front face stop posltron + side face stop position + defective compensation of depth display
q
*,
*
Defective compensation display
The bold lines indicate displays for individual systems.
20-l 37 0
RESETTING TESTING
3)
AND ADJUSTING
PROCEDURE OF ELECTRIC SYSTEM AND CHECK OF ITS OPERATION
Actions to take when error code is displayed * Check that the rod is not bent or scuffed. Reference : Distance “a” between boom potentiometer rod pins: 280 + 2 mm Distance “b” between arm potentiometer rod pins: 416 f 4 mm . Boom potentiometer (I) Check the reset position of the work equipment again. If the position is normal but the error code is still displayed, replace the assembly of potentiometer (1) and case. . Arm potentiometer (2) and offset potentiometer (3) i) Set the work equipment in the reset position and see if the error code is displayed again. Boom : RAISE stroke end Arm : IN stroke end Offset : RIGHT offset stroke end ii) Remove the potentiometer case assembly. iii) Install a new potentiometer. iv) Measure the potentiometer input signal (voltage), and check that it is in the standard range. For the standard value, see 2). * l l
l
20-138 0
PC128UU-2
TESTING AND ADJUSTING
RESETTING PROCEDURE OF ELECTRIC SYSTEM AND CHECK OF ITS OPERATION
3. Check of automatic stop of LEFT offset • After the potentiometer input signal is reset in 1 above, keep the work equipment in the present position and check automatic stop of the LEFT offset. fl Standard distance “L”: 150 - 200 mm 1) Run the engine at low speed and press the pedal fully to move the offset from the right offset stroke end to the left. Check that the offset stops automatically. 2) Run the engine at full throttle and perform the above check. 4. Check of automatic stop of forward operation and stopping distance (Arm OUT operation) 1) Check of automatic stop i) Set the work equipment in the following position. • Boom: Set boom back vertical. • Bucket: Set bucket horizontal (when stopped). • Offset: Bring center of bucket to right end of cab. ii) Run the engine at low speed and operate the arm control lever OUT. Check that the arm stops automatically. iii) Run the engine at full throttle and perform the above check. 2) Check of stopping distance • Check that distance “L” between the bucket tooth tip and cab is in the standard range when the arm is stopped with the engine at full throttle. fl Measure distance “L” when the height above the left deck cover top is “C”. • Height “C”: 700 mm • Standard distance “L”: 300 – 350 mm fl After the arm stops automatically, if the bucket is not horizontal, set it horizontal, then measure distance “L”.
PC128UU-2
20-139 (6)
RESETTING TESTING AND ADJUSTING
5.
When automatic stopping distance is “shorter” than standard value * Even if the automatic stopping distance is a little out of the standard range, it does not make difference to the actual work. Accordingly, it is not necessary to reset (adjust) the stopping distance, except a particular case (e.g. when required by the customer). . Reset (Adjust) the stopping distance according to the following procedure. 1) Move the arm OUT to increase distance “d” between the bucket and cab by about 500 mm. 2) Set emergency work equipment operation switch (4) to the EMERGENCY position and move the arm IN slowly to adjust distance “L” between the cap and bucket tooth tip to 350 mm. Adjust distance “L” while the height * above the left deck cover top is “C”. Height “C”: 700 mm The bucket moves IN about 50 mm fur* ther than the set position because of its inertia. Count in this distance in advance. 3) Turn the starting switch to the OFF position to stop the engine, then turn it to the ON position again. 4) Set the mode selector switch to “Depth” and connect reset power terminal (I) and reset terminal (2). The reset power terminal (CN-KIO) (1) is * a plug (green harness) and the reset terminal (CN-K8) (2) is a socket (Yellow and blue harness which is not taped). 5) Check that the electric system caution lamp of the monitor panel starts flashing at intervals of 1 second after 2 seconds. (CN-KIO) (I) and (CN-K8) 6) Disconnectterminal (21, then turn the starting switch to the OFF position. 7) Turn the starting switch to the ON position, and the resetting operation is finished. Run the engine at full throttle and have * stop automatically to the workequipment check stopping distance “L”. 8) After finishing the resetting operation, tape the reset terminal as before.
I
PROCEDURE OF ELECTRIC SYSTEM AND CHECK OF ITS OPERATION
b
d
6WPO442
1
l
BWP04422
I
TKP00656
PC128UU-2
RESETTING TESTING AND ADJUSTlNG
6.
When automatic stopping distance is “longer” than standard value * Even if the automatic stopping distance is a little out of the standard range, it does not make difference to the actual work. Accordingly, it is not necessary to reset (adjust) the stopping distance, except a particular case (e.g. when required by the customer). . Reset (Adjust) the stopping distance according to the following procedure. I) Move the arm OUT to increase distance “d” between the bucket and cab by about 500 mm. 2) Set emergency work equipment operation switch (4) to the EMERGENCY position and move the arm IN slowly to adjust distance “L” between the cap and bucket tooth tip to 350 mm. * Adjust distance “L” while the height above the left deck cover top is “C”. Height “C”: 700 mm * The bucket moves IN about 50 mm further than the set position because of its inertia. Count in this distance in advance. Turn the starting switch to the OFF position 3) to stop the engine, then turn it to the ON position again. 4) Set the mode selector switch to “Depth” and connect reset power terminal (I) and reset terminal (2). * The reset power terminal (CN-KIO) (1) is a plug (green harness) and the reset terminal (CN-K8) (2) is a socket (Yellow and blue harness which is not taped). 5) Check that the electric system caution lamp of the monitor panel starts flashing at intervals of 1 second after 2 seconds. (CN-KIO) (1) and (CN-K8) 6) Disconnectterminal (21, then turn the starting switch to the OFF position. 7) Turn the starting switch to the ON position, and the resetting operation is finished. * Run the engine at full throttle and have the workequipment stop automatically to check stopping distance “L”. 8) After finishing the resetting operation, tape the reset terminal as before.
PROCEDURE OF ELECTRIC SYSTEM AND CHECK OF ITS OPERATION
BWP0442
1
l
PC128UU-2
BWP04422
TKP00656
20-141
RESETTING TESTlNG
7.
AND ADJUSTING
If an abnormality display (error code) is given for Items 5 or 6 (reset automatic stop output signal) + For details of the abnormality display, see Item 2, Table 1. The adjustment range for the automatic stop position is 300 mm to the front and rear of the automatic stop position, so with the normal reset, there is no reset error, but if an abnormality display is given, carry out the resetting operation within a range that does not give any abnormality display. * Adjustment range: Automatic stop position If: e Dimension e: 300 mm * If the above resetting operation causes any problem with normal operation, carry out the resetting operation again from “1. Reset potentiometer input signal”. * If an abnormality display appears during the resetting operation, remove all the causes, then reset the system properly.
PROCEDURE OF ELECTRIC SYSTEM AND CHECK OF ITS OPERATION
l
BWPO4425
l
8.
Move position of bucket to left and right and check automatic stop position . If the automatic stopping distance has been reset in Item 5 or Item 6, move the bucket to the maximum left offset and the center of the cab, carry out the automatic stop, and check that there is no extreme difference between the distance set previously and the actual distance from the tip of the bucket teeth to the cab. 1) Set the bucket to maximum left offset position (I 1 and carry out the automatic stop. 2) Set the bucket in line with cab center (2) and carry out the automatic stop. * When measuring after stopping, set the bucket in a horizontal position.
20- 142 0
BWP04426
PC128UU-2
RESElTING TESTING AND ADJUSTING
9. Reset compensation for depth display I) Set the work equipment in the following posture. Set the bucket to the end of the DUMP stroke, operate the arm so that the top of the bucket is perpendicular to the ground, and lower the boom to set the bucket teeth in contact with the ground. 2) Set the mode selection switch to HEIGHT. Ir Do not stop the engine. Connect reset power source terminal (1) and 3) reset terminal (2). * Reset power source terminal (CN-KlO)(l) is a female l-pin connector (green wiring harness). Reset terminal (CN-K8)(2) is a male l-pin connector (yellow/blue wiring harness, no taping). Check that electrical system caution lamp (5) 4) on the monitor panel starts to flash 2 seconds later in a l-second cycle. * If abnormality display code 1241 is given, carry out the operation again from “1. Reset potentiometer input signal”. and (CN5) Disconnect terminals (CN-KlO)(l) K8)(2). .6) Set the work equipment in the following posture. Set the arm to the end of the OUT stroke, operate the bucket so that the top of the bucket is perpendicular to the ground, and lower the boom to set the bucket teeth in contact with the ground. ,7) Set the mode selection switch to OFFSET. * Do not stop the engine. 8) Repeat Steps 3) to 5). 9) When the starting switch is turned OFF, then ON again, the resetting operation is completed. 10) After finishing the operation, tape the reset terminals to their original position.
PROCEDURE OF ELECTRIC SYSTEM AND CHECK OF ITS OPERATION
BWPO4492
\
node selection\
TKP00659
BWP04427
PC128UU-2
20-143 0
RESElTlNG TESTING
AND ADJUSTING
PROCEDURE OF ELECTRIC SYSTEM AND CHECK OF ITS OPERATION
TKP00661
10. Check operation of work equipment automatic control * Carry out the operation on a horizontal surface as far as possible. 1) Depth display (function for displaying depth from ground level) i) Set the bucket vertical and in contact with the ground, and check that the depth display shows 10.01. ii) Use the work equipment to raise the chassis and check that the depth display changes. 2) Depth display 0 set mode (function for displaying depth from standard surface) i, Raise the bucket to a point 1 m above the ground and check that the depth display shows UP. ii) In the above posture, set the mode selection switch to DEPTH DISPLAY 0 SET and turn the setting switch to the SET position. Check.that the depth display changes to [O-O1when this is done. iii) Lower the bucket to the ground and check that the depth display changes to i1.01. iv) Turn the setting switch to the CLEAR position to cancel the setting. 3) Depth mode (function for setting depth) i) Raise the bucket so that the tip of the teeth is 0.5 m above the ground. ii) Set the mode selection switch to DEPTH and turn the setting switch to the SET position. * When this is done, the buzzer will sound twice and the indicator will light
TXP02249
I
BWP04426
UP. iii) Raise the boom, then run the engine at full throttle and operate the lever fully to lower the boom and check that it stops at the original position. iv) Turn the setting switch to the CLEAR position to cancel the setting.
20-144 3
BWP04429
PC128UU-2
RESElTlNG TESTING AND ADJUSTING
4)
5)
Height mode (function for setting height) * This mode is not available on the mono boom specification machine. i) Move the arm out fully, then raise the boom until the back face of the boom is perpendicular. ii) Set the mode selection switch to HEIGHT and turn the setting switch to the SET position. * When this is done, the buzzer will sound twice and the indicator will light up. iii) Lower the boom, then run the engine at full throttle and operate the lever fully to raise the boom and check that it stops at the original position. iv) Turn the setting switch to the CLEAR position to cancel the setting.
Offset mode (function for setting left offset) Set the offset to the left offset position. Stop just before the end of the stroke. ii) Turn the setting switch to the SET position. * When this is done, the buzzer will sound twice and the indicator will light up. iii) Offset the bucket to the right side of the center line of the boom, then run the engine at fult throttle and operate the pedal fully to offset the work equipment to the left and check that it stops at the original position. iv) Turn the setting switch to the CLEAR position to cancel the setting.
PROCEDURE OF ELECTRIC SYSTEM AND CHECK OF ITS OPERATION
BWPO4430
i) *
PC128UU-2
ElWPO443 I
20-145 0
RESETTING TESTING AND ADJUSTING
11. Resetting of correction of side stop : . When the bucket is replaced with one having different width and the distance between the new bucket and cab is narrowed 1) Move the offset slowly to the left to adjust distance “L” between the bucket and cab to 260 mm. It The bucket moves IN about 50 mm further than the set position because of its inertia. Count in this distance in advance. 2) Turn the starting switch to the OFF position to stop the engine, then turn it to the ON position again. 3) Connect reset power terminal (I) and’lateral reset terminal (3). * Set the mode selector switch to “Depth”. * The reset power terminal (CN-KIO) (1) is a plug (green harness) and the lateral reset terminal (CN-KS) (3) is a socket (Yellow and blue harness which is taped). 4) Check that the electric system caution lamp of the monitor panel starts flashing at intervals of 1 second after 2 seconds. * If error code “22” is displayed, perform the above procedures again from 1 “Resetting of potentiometer input signal”. 5) Disconnect terminals (CN-KIO) (I) and (CNK9) (31, then turn the starting switch: to the OFF position. 6) Turn the starting switch to the ON position, and the resetting operation is finished. * Run the engine at full throttle and have the work equipment stop automatically to check stopping distance “L”. 7) After finishing the resetting operation, tape the reset terminal as before. When the bucket is replaced with narrow one and the distance between the new bucket and cab is widened 8) Do not reset the correction after the narrow bucket is installed, as a rule. If the correction needs to be reset for replacement of the controller, etc., however, set distance “L” by the following formula. L=260+(6-A)/2)(mm) A : Width of narrow bucket B : Width of standard bucket . 9) Perform the above procedures from 2) to 7).
PROCEDURE OF ELECTRIC SYSTEM AND CHECK OF ITS OPERATION
BWPO4432
TKP00655
Narrow bucket
bucket
TXP02250
20-146 a
PC128UU2
RESElTING TESTING AND ADJUSTING
12. Resetting of right exterior parts interference prevention control (Boom LOWER stop angle) 1) Set the work equipment in the follovving position. Raise the boom to the top (It is not necessary to move the cylinder to the stroke end) and “move the offset to the right end” and “move the arm to the inner end”. a% Operate the emergency work equipment operation switch, and check that the offset cylinder is at the RIGHT stroke end and the arm cylinder is at the IN stroke end. 2) Lower the boom or curl or dump the bucket to bring the work equipment to the desired lowering stop position, taking care not to interfere with the right exterior parts. * Adjust distance “e” between the right exterior parts and bucket tooth tip to 50 150 mm. * The bucket moves IN by some distance further than the set position because of its inertia. Count in this distance in advance. 3) Turn the starting switch to the OFF position to stop the engine, then turn it to the ON position again. 4) Connect reset power terminal (I) and reset terminal (3). * Set the mode selector switch to “Height”. * The reset power terminal (CN-KIO) (1) is a plug (green harness) and the reset terminal (CN-KS) (3) is a socket (green harness which is taped). 5) Check that the electric system caution lamp of the monitor panel starts flashing at intervals of 1 second after 2 seconds. * If error “Fl” (Boom angle reset trouble) is displayed, the correction value is out of the adjustment range (+30 degrees, 10 degrees). In this case, perform the above procedures again from 2). (CN-KIO) (I) and (CN-KS) 6) Disconnectterminal (31, then turn the starting switch to the OFF position. 7) Turn the starting switch to the ON position, and the resetting operation is finished. * Run the engine at full throttle and have the workequipment stop automatically to check that it stops at the desired position. 8) After finishing the resetting operation, tape the reset terminal as before.
PC128UU-2
PROCEDURE OF ELECTRIC SYSTEM AND CHECK OF ITS OPERATION
BWP04434
TKP00659
20-147 0
RESETTING TESTING
AND ADJUSTING
13. Resetting of right exterior parts interference prevention control (Arm IN stop angle) 1) Set the work equipment in the following position. “Set the offset boom horizontal” and “move the offset to the right end”. * Operate the emergency work equipment operation switch, and check that the offset cylinder is at the RIGHT stroke end. 2) Move the arm IN or OUT or curl or dump the bucket to bring the work equipment to the desired lowering stop position, taking care not to interfere with the right exterior parts. * Adjust distance “f” between the right exterior parts and bucket tooth tip to 100 200 mm. * The bucket moves IN by some distance further than the set position because of its inertia. Count in this distance in advance. 3) Turn the starting switch to the OFF position to stop the engine, then turn it to the ON position again. 4) Connect reset powerterminal (I) and resetterminal (3). * Set the mode selector switch to “Depth”. * The reset power terminal (CN-KIO) (I) is a plug (green harness) and the reset terminal (CN-KS) (3) is a socket (green harness which is taped). 5) Check that the electric system caution lamp of the monitor panel starts flashing at intervals of 1 second after 2 seconds. * If error “F2” (Arm angle reset trouble) is displayed, the correction value is out of the adjustment range (+30 degrees, -10 degrees). In this case, perform the above procedures again from 2). 6) Disconnect terminal (CN-KIO) (I) and (CN-KS) (31, then turn the starting switch to the OFF position. 7) Turn the starting switch to the ON position, and the resetting operation is finished. * Run the engine at full throttle and have the workequipment stop automatically to check that it stops at the desired position. 8) After finishing the resetting operation, tape the reset terminal as before.
20- 148 0
PROCEDURE OF ELECTRIC SYSTEM AND CHECK OF ITS OPERATION
BWPO4435
\
Mode
selection
TKP00656
PC128UU-2
TESTING
AND ADJUSTING
REPLACEMENT
PROCEDURE OF POTENTIOMETERS
REPLACEMENT PROCEDURE OF POTENTIOMETERS * Itis impossible to replace only the potentiometers. Accordingly, if the potentiometers need to be replaced, replace the case assemblies. If the case assemblies need to be used again, fix levers (41, (51, and (6) to the potentiometer bodies before removing them. I.
Remove potentiometer assemblies (I), (21, and (3) from the work equipment. Boom potentiometer (I) Arm potentiometer (2) Bucket potentiometer (3) * Do not swing a removed potentiometer assembly around its lever or turn the lever unnecessarily. l
l
l
2.
Install
potentiometer
assemblies
Arm
(I), (21, and (3).
3.
Be sure to reset the input and output signals. Ir For details, see “Resetting procedure of input and output signals of electric system and check of its operation”. Sr Linkages (7) and (8) of the arm potentiometer and boom potentiometer can be connected even if levers (4) and (5) of the potentiometers are inverted. Accordingly, take care of the positions of the potentiometers particularly when the linkages are disconnected. Reference : Distance “a” between boom potentiometer rod pins: 280 f 2 mm Distance “b” between arm potentiometer rod pins: 416 +_4 mm * If the linkages are connected to the opposite side, when the starting switch is turned to the ON position, error code “32” is displayed and the buzzer sounds. In this case, turn the starting switch to the OFF position and connect the linkages correctly.
PC1 28UU-2
20-149 0
TESTING AND ADJUSTING
Pm CLINIC INSPECTION TABLE
Pm CLINIC INSPECTION TABLE
PC128UU-2 # 5001 and up Machine Serial No. Mounted engine
HOUR INSPECTION Work instruction No.
Date of execution Day: Year:
Month:
S4D102E-1
Service meter hours
Inspector
INTERVIEW WITH OPERATOR AND WALK-AROUND CHECK Is there abnormality before starting inspection?
What is maximum level of coolant temperature? (During operation)
.................................................................................................................... ....................................................................................................................
White Green Green Green Green Red Red 1 2 3 4 5 6 7
....................................................................................................................
Outside temperature Max.
˚C
Min. Height
˚C
Check of work equipment for damage Boom foot
Lower part of boom
Arm cylinder bracket
Revolving frame
m
Good
Bad
Good
Bad
Good
Bad
Other parts
Check of coolant level, oil level, and monitor Engine coolant
Engine oil
Display of self-diagnosis
Hydraulic oil
Monitor (
)
Monitor panel
fl If machine is cold, warm it up. Unit
Standard MeasureService limit value for ment Good value new machine result 925 – 975
—
rpm
2,340 – 2,460
—
2,120 – 2,320
Min. 2,000
Max. 0.49 {Max. 50} 0.34 – 0.59 {3.5 – 6.0} Min. 0.10 {Min. 1.0} 0.34 – 0.59 {3.5 – 6.0} Min. 0.08 {Min. 0.8}
Max. 0.98 {Max. 100} Min. 0.25 {Min. 2.5} Min. 0.07 {Min. 0.7} Min. 0.25 {Min. 2.5} Min. 0.07 {Min. 0.7}
—
—
3.5 – 4.3
Max. 4.7
2.3 – 2.9
Max. 3.5
3.3 – 3.9
Max. 4.5
2.4 – 3.0
Max. 4.0
Offset to left (Right → Left)
4.9 – 6.1
Max. 6.5
Offset to right (Left → Right)
5.0 – 6.2
Max. 6.6
1.0 – 1.6
Max. 2.5
27.0 – 33.0
24.0 – 36.0
Max. 29
Max. 36
Max. 39
Max. 48
Max. 500
Max. 700
Item
Condition Low idling
Engine speed
Engine at full throttle
Engine
Arm IN relief Blow-by pressure
kPa {mmAq}
Arm IN relief SAE30 SAE15W-40
Lubricating oil pressure
High idling Low idling
MPa {kg/cm2}
High idling SAE10W Low idling
Work equipment speed
Hydraulic oil 45 – 55 ˚C temperature Boom raised No load applied and (to just before cushion) extended to end Boom in horizontal Arm out position and offset to (to just before cushion) right (until clearance between right end of operator’s cab and Arm in is about 350 (to just before cushion) bucket mm)
Bucket curled
˚C
Bad
Engine at full throttle
Boom and arm in horizontal positions
sec
Blade raised Left 5-turn swing
Engine at full throttle
Right Left
High speed Right 5-turn travel Left Low speed Right Hydraulic drift of work equipment
20-150
Rated load applied and engine stopped
mm/15min
PC128UU-2 (6)
TESTING AND ADJUSTING
Pm CLINIC INSPECTION TABLE
Oil pressure
PC128UU-2 # 5001 and up Condition
Item
Low idling
Pc All levers in neutral
Engine at full throttle
Control oil pressure
All levers in neutral Boom-RAISE circuit relieved
Main relief valve and safety valve
Arm-IN circuit relieved Bucket-CURL circuit relieved Left-offset circuit relieved Right-offset circuit relieved Right-swing circuit relieved Left-swing circuit relieved Blade-RAISE circuit relieved Blade-LOWER circuit relieved Right-travel-forward circuit relieved Right-travel-reverse circuit relieved Left-travel-forward circuit relieved Left-travel-reverse circuit relieved
Engine at full throttle
All levers in neutral
PC
Servo piston input pressure
Bucket-CURL circuit relieved Control lever in neutral
LS 1-side track running idle Travel speed: Hi Travel lever in half position
PC128UU-2 (6)
Main oil pressure
Engine at full throttle LS differential pressure
< >: Reference value Standard MeasureService limit value for ment Unit Good value new machine result <2.45 – 3.43> <2.45 – 3.43> {<25 – 35>} {<25 – 35>} 3.04 – 3.43 2.75 – 3.73 {31 – 35} {28 – 38} <2.45 – 3.43> — {<25 – 35>} — 31.9 – 33.8 30.9 – 33.8 {325 – 345} {315 – 345} 31.9 – 33.8 30.9 – 33.8 {325 – 345} {315 – 345} 31.9 – 33.8 30.9 – 33.8 {325 – 345} {315 – 345} 31.9 – 33.8 30.9 – 33.8 {325 – 345} {315 – 345} 25.5 – 28.4 24.5 – 29.4 {260 – 290} {250 – 300} 30.4 – 32.4 28.9 – 32.9 {310 – 330} {295 – 335} 30.4 – 32.4 28.9 – 32.9 {310 – 330} {295 – 335} MPa 31.9 – 33.8 30.9 – 33.8 {kg/cm2} {325 – 345} {315 – 345} 30.9 – 33.8 29.9 – 34.8 {315 – 345} {305 – 355} 33.8 – 35.8 32.9 – 36.8 {345 – 365} {335 – 375} 33.8 – 35.8 32.9 – 36.8 {345 – 365} {335 – 375} 33.8 – 35.8 32.9 – 36.8 {345 – 365} {335 – 375} 33.8 – 35.8 32.9 – 36.8 {345 – 365} {335 – 375} 2.45 – 4.41 2.45 – 4.41 {25.0 – 45.0} {25.0 – 45.0} 14.5 – 17.5 13.5 – 18.4 {148 – 178} {138 – 188} 1.77 – 3.73 — {18.0 – 38.0} 2.11 – 2.30 {21.5 – 23.5}
Bad
—
20-151
TROUBLESHOOTING Knowledge of troubleshooting Points to remember when troubleshooting ......................................................................................... 20-202 Sequence of events in troubleshooting .............................................................................................. 20-203 Points to remember when carrying out maintenance ........................................................................ 20-204 Checks before troubleshooting ............................................................................................................ 20-212 Types and locations of connectors ...................................................................................................... 20-214 Connector arrangement diagram ........................................................................................................ 20-218 Connection table for connector pin numbers ..................................................................................... 20-222 Explanations of control mechanism of electrical system .................................................................. 20-235 Display method for monitor panel, controller .................................................................................... 20-241 Method of using troubleshooting charts ............................................................................................. 20-247 Troubleshooting of controller, electrical system (E-mode) .................................................................. 20-301 Troubleshooting of controller input signal system (F-mode) .............................................................. 20-401 Troubleshooting of hydraulic, mechanical systems (H-mode) ............................................................ 20-501 Troubleshooting of monitor panel system (M-mode) .......................................................................... 20-601 Troubleshooting of engine (S-mode)..................................................................................................... 20-701
PC128UU-2
20-201 (6)
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.
g
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
a
When disconnecting
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.
careful not to touch any hot parts or to get caught in any rotating parts. wiring, always disconnect the negative
(-1 terminal
of the battery first.
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.
2.
3.
When carrying out troubleshooting, do not hurry to disassemble the components. If components are disassembled immediately any failure occurs: . Parts that have no connection with the failure or other unnecessary parts will be disassembled. . It will become impossible to find the cause of the failure. It will also cause a waste of manhours, parts, or oil or grease, and at the same time, will also lose the confidence of the user or operator. For this reason, when carrying out troubleshooting, it is necessary to carry out through prior investigation and to carry out troubleshooting in accordance with the fixed procedure. Points to ask user or operator I) Have any other problems occured apart from the problem that had been reported? 2) Was there anything strange about the machine before tha failure occurred? 3) Did the failure occur suddenly, or were there problems with the machine condition before this? 4) Under what conditions did the failure occur? 5) Had any repairs been carried out before the failure? When were these repairs carried out? 6) Has the same kind of failure occurred before? Check before troubleshooting 1) Check the oil level.
20-202 0
2)
4.
5.
6.
Check for any external leakage of oil from the piping or hydraulic equipment. 3) Check the travel of the control levers. 4) Check the stroke of the control valve spool. 5) Other maintenance items can be checked externally, so check any item that is considered to be necessary. Confirming failure Confirm the extent of the failure yourself, and judge whether to handle it as a real failure or as a problem with the method of operation, etc. * When operating the machine to reenact the troubleshooting symptoms, do not carry out any investigation or measurement that may make the problem worse. Troubleshooting Use the results of the investigation and inspection in Items 2 - 4 to narrow down the causes of failure, then use the troubleshooting flowchart to locate the position of the failure exactly. * The basic procedure for troubleshooting is as follows. 1) Start from the simple points. 2) Start from the most likely points. 3) Investigate other related parts or information. Measures to remove root cause of failure Even if the dailure is repaired, if the root cause of the failure is not repaired, the same failure will occur again. To prevent this, always investigate why the problem occureed. Then, remove the root cause. PC128UU-2
SEQUENCE
TROUBLESHOOTING
OF EVENTS
IN TROUBLESHOOTING
SEQUENCE OF EVENTS IN TROUBLESHOOTING
TEWOO180
1) When a request for repairs is received, first ask the following points. . Name of customer . Type, serial number of machine . Details of jobsite, etc. 2) Ask questions to gain an outline of the problem. * Condition of failure . Work being carried out at the time of the failure . Operating environment . Past history, details of maintenance, etc.
m
TEW00181
\
step 1 Examination, confirmation of symptoms
-------------
3
Ring
I
Ring
TEWO0182
J
Step 2 IDetermining probable location of caus
1) Look at the table of troubleshooting tools in the shop manual and prepare the necessary tools. . T-adapter . Hydraulic pressure gauge kit, etc. 2) Look in the parts book and prepare the necessary replacement parts.
!
TEWO0183
1) Before starting troubleshooting, locate and
Step 4
*
PC128UU-2
Was there anything strange about the machine before the failure occurred? Did the failure occur suddenly?
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 repairs must be carried out. This section deals particularly with correct repair procedures for mechatronics and is aimed at improving the quality of repairs. For this purpose, it gives sections on “Handling electric equipment” and “Handling hydraulic equipment” (particularly gear oil and hydraulic oil).
1.
POINTS TO REMEMBER ELECTRIC EQUIPMENT
WHEN HANDLING
1)
Handling wiring harnesses and connectors Wiring harnesses consist of wiring connecting one component to another component, connectors used for connecting and disconnecting one wire from another wire, and protectors or tubes used for protecting the wiring. Compared with other electrical components fitted in boxes or cases, wiring harnesses are more likely to be affected by the direct effects of rain, water, heat, or vibration. Furthermore, during inspection and repair operations, they are frequently removed and installed again, so they are likely to suffer deformation or damage. For this reason, it is necessary to be extremely careful when handling wiring harnesses.
Main failures occurring in wiring harness Defective contact of connectors (defective contact between male and female) Problems with defective contact are likely to occur because the male connector is not properly inserted into the female connector, or because one or both of the connectors is deformed or the position is not correctly aligned, or because there is corrosion or oxidization of the contact surfaces.
Improper
insert
ion
TEW00192
Defective crimping or soldering of connectors 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 plating at the joint will peel and cause improper connection or breakage.
Improper
I 20-204 0
compress’
TEW00193
PC128UU-2
TROUBLESHOOTING
WHEN CARRYING
POINTS TO REMEMBER
OUT MAINTENANCE
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 soldering may be damaged, or the wiring may be broken.
\
High-pressure water entering connector The connector is designed to make it difficult for water to enter (drip-proof structure), but if high-pressure water is sprayed directly on the connector, water may enter the conon the direction of the nector, depending 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 shortcircuited by the water, so if any water gets the connector or take in, immediately’dry before passing elecaction other appropriate it. through tricity
TEW00194
*
b\
Oil or dirt stuck to connector If oil or grease are stuck to the connector and an oil film is formed on the mating surface between the male and female pins, the oil will not let the electricity pass, so there will be defective contact. If there is oil or grease stuck to the connector, wipe it off with a dry cloth or blow it dry with compressed air and spray it with a contact restorer. When wiping the mating portion of the * connector, be careful not to use excessive force or deform the pins. If there is oil or water in the compressed * air, the contacts will become even dirtier, so remove the oil and water from the compressed air completely before cleaning with compressed air.
PC128UU-2
20-205 0
TROUBLESHOOTING
POINTS TO REMEMBER
2)
Removing, installing, wiring harnesses
l
Disconnecting connectors Hold the connectors when disconnecting. When disconnecting the connectors, hold the connectors and not the wires. For connectors held by a screw, loosen the screw fully, then hold the male and female connectors in each hand and pull apart. For connectors which have a lock stopper, press down the stopper with your thumb and pull the connectors apart. * Never pull with one hand.
OUT MAINTENANCE
and drying connectors and
Lock steppe
TEW00197
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.
a
I 0
WHEN CARRYING
TBW00485
Action to take after removing connectors After removing any connector, cover it with a vinyl bag to prevent any dust, dirt, oil, or water from getting in the connector portion. * If the machine is left disassembled for a long time, it is particularly easy for improper contact to occur, so always cover the connector.
TEWOO198
20-206 0
PC128UU-2
TROUBLESHOOTING
0
POINTS TO REMEMBER
Connecting connectors Check the connector visually. 1) Check that there is no oil, dirt, or water stuck to the connector pins (mating portion). 2) Check that there is no deformation, defective contact, corrosion, or damage to the connector pins. 3) Check that there is no damage or breakage to the outside of the connector. * If there is any oil, water, or dirt stuck to the connector, wipe it off with a dry cloth. If any water has got inside the connector, warm the inside of the wiring with a dryer, but be careful not to make it too hot as this will cause short circuits. * If there is any damage or breakage, replace the connector.
WHEN CARRYING
OUT MAINTENANCE
Cliks
into position
TEW00199
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 any correct boots, with fitted connectors For protrusion of the boot. In addition, if the wiring harness is misaligned, or the clamp is out of position, adjust it to its correct position. If the connector cannot be corrected eas* ily, remove the clamp and adjust the position. If the connector clamp has been removed, be sure to return it to its original position. Check also that there are no loose clamps.
PC1 28UU-2
I
TBwoo487
20-207 0
TROUBLESHOOTING
l
POINTS TO REMEMBER
WHEN CARRYING
OUT MAINTENANCE
Drying wiring harness If there is any oil or dirt on the wiring harness, wipe it off with a dry cloth. Avoid washing it in water or using steam. If the connector must be washed in water, do not use high-pressure water or steam directly on the wiring harness. If water gets directly on the connector, do as follows. @ Disconnect the connector and wipe off the water with a dry cloth. Sr If the connector is blown dry with compressed air, there is the risk that oil in the air may cause defective contact, so remove all oil and water from the compressed air before blowing with air.
TEW00196
Dry the inside of the connector with a dryer. If water gets inside the connector, use a dryer to dry the connector. * Hot air from the dryer can be used, but regulate the time that the hot air is used in order not to make the connector or related parts too hot, as this will cause deformation or damage to the connector.
TEW00202
Carry out a continuity test on the connector. After drying, leave the wiring harness disconnected and carry out a continuity test to check for any short circuits between pins caused by water. * After completely drying the connector, blow it with contact restorer and reassemble.
T-adapter
TEW00203
20-208 0
PC1 28UU-2
TROUBLESHOOTING
3)
POINTS TO REMEMBER
WHEN CARRYING
OUT MAINTENANCE
Handling control box The control box contains a microcomputer and electronic control circuits. These control all of the electronic circuits on the machine, so be extremely careful when handling the control box. Do not open the cover of the control box unless necessary.
TEWOO204
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 control 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 connected to the control box. Fit an arc welding ground close to the welding point.
I 2.
Points to remember
when troubleshooting
II
TEWOO206
electric circuits
1) Always turn the power OFF before disconnecting or connect connectors. 2) Before carrying out troubleshooting, check that all the related connectors are properly inserted. 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. of circuits (measuring the voltage, resistance, continuity, or 4) When carrying out troubleshooting current), move the related wiring and connectors several times and check that there is no change in the reading of the tester. If there is any change, there is probably defective contact in that circuit. *
PC1 28UU-2
20-209 0
TROUBLESHOOTING
3.
POINTS TO REMEMBER
WHEN
CARRYING
OUT MAINTENANCE
POINTS TO REMEMBER WHEN HANDLING HYDRAULIC EQUIPMENT
With the increase in pressure and precision of hydraulic equipment, the most common cause of failure is dirt (foreign material) in the hydraulic circuit. When adding hydraulic oil, or when disassembling or assembling hydraulic equipment, it is necessary to be particularly careful. 1)
Be careful of Avoid adding repairing the places where
2)
Disassembly and maintenance work in the field If disassembly or maintenance work is carried out on hydraulic equipment in the field, there is danger of dust entering the equipment. It is also difficult to confirm the performance after repairs, so it is desirable to use unit exchange. Disassembly and main-tenance of hydraulic equipment should be carried out in a specially prepared dustproof workshop, and the performance should be confirmed with special test equipment.
3)
Sealing openings After any piping or equipment is removed, the openings should be sealed with caps, tapes, or vinyl bags to prevent any dirt or dust from entering. If the opening is left open or is blocked with a rag, there is danger of dirt entering or of the surrounding area being made dirty by leaking oil so never do this. Do not simply drain oil out on to the ground, collect it and ask the customer to dispose of it, or take it back with you for disposal.
4)
Do not let any dirt or dust get in during refilling operations. Be careful not to let any dirt or dust get in when refilling with hydraulic oil. Always keep the oil filler and the area around it clean, and also use clean pumps and oil containers. If an oil cleaning device is used, it is possible to filter out the dirt that has collected during storage, so this is an even more effective method.
20-210 0
the operating environment. hydraulic oil, replacing filters, or machine in rain or high winds, or there is a lot of dust.
TEW00207
PC1 28UU-2
TROUBLESHOOTING
POINTS TO REMEMBER
5)
is Change hydraulic oil when the temperature high. When hydraulic oil or other oil is warm, it flows easily. In addition, the sludge can also be drained out easily from the circuit together with the oil, so it is best to change the oil when it is still warm. When changing the oil, as much as possible of the old hydraulic oil must be drained out. (Do not 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 equipment, or changing the oil, use flushing oil to sludge, and old oil remove the contaminants, from the hydraulic circuit. Normally, flushing is carried out twice: primary flushing is carried out with flushing oil, and secondary flushing is carried out with the specified hydraulic oil.
WHEN CARRYING
OUT MAINTENANCE
Flushing
oil
TEWOOZIO
7)
Cleaning operations After repairing the hydraulic equipment (pump, control valve, etc.) or when running the machine, carry out oil cleaning to remove the sludge or contaminants in the hydraulic oil circuit. The oil cleaning equipment is used to remove the ultrafine (about 3~) particles that the filter built into the hydraulic equipment cannot remove, so it is an extremely effective device.
TEW00211
PC128UU-2
20-211 0
CHECKS BEFORE TROUBLESHOOTING
TROUBLESHOOTING
CHECKS BEFORE TROUBLESHOOTING Item
T
Judgment
value
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
-
Add oil
7. Check coolant level
-
Add water
8. Check dust indicator for clogging
-
Clean or replace Replace
9. Check hydraulic filter 10. Check final drive oil level
-
Add oil
11. Check for looseness, corrosion of battery terminal, wiring
-
Tighten or replace
12. Check for looseness, corrosion of alternator terminal, wiring
-
Tighten or replace
13. Check for looseness, corrosion of starting motor terminal, wiring
-
Tighten or replace
14. Check operation of instruments
-
Repair or replace
15. Check for abnormal noise, smell
-
Repair
16. Check for oil leakage
-
Repair
17. Carry out air bleeding
-
Bleed air
24 - 26V
Replace
19. Check battery electrolyte level
-
Add or replace
20. Check for discolored, burnt, exposed wiring
-
Replace
21. Check for missing wiring clamps, hanging wiring
-
Repair
22. Check for water leaking on wiring (be particularly careful attention to water leaking on connectors or terminals)
-
23. Check for blown, corroded fuses
-
18. Check battery voltage (engine stopped)
24. Check alternator voltage (engine running at l/2 throttle or a hove) 25. Sound of actuation of battery relay (when starting switch is turned ON, OFF)
20-212 a
After running for several minutes: 27.5 - 29.5 V -
Disconnect connector and dry Replace Replace -
PC1 28UU-2
TROUBLESHOOTING
TYPES AND LOCATIONS
TYPES AND LOCATIONS OF CONNECTORS * Each addresses in the following table refers to the address in the (single
view
arrangement
drawing
drawing).
I I Address
Location ( B3
connector
OF CONNECTORS
1KESI ) 4
1 Intermediate
1
connector
Location :N-92
I
-
2
Limit switch
9
Radio
:N-502AMP040 18
Wiper motor control relay box
21
Controller
DO1 YAZAKI
2
Diode
CO2 AMP040 20
Controller
DO2 YAZAKI
2
Diode
CO3 AMP040 .I6
Controller
DO3 YAZAKI
2
Diode
CO4
M
2
Register
DO4 YAZAKI
2
Diode
CO5
M
6
Emergency pump drive switch
DO5 YAZAKI
2
Diode
CO6
KESI
2
DO6 (YAZAKII
2 1 Diode
co9
x
4
Attachment selector connector
DO7 YAZAKI
2
Diode
Cl1
KES
4
Mode selector
DO8 YAZAKI
2
Diode
Cl2
KES
3
Set/Clear
~09 IYAzAKII
2 I Diode
Cl3
x
2
EPC valve for PC
B4
MIC
co1
switch
switch
D14 IYAZAKI~ 2 I Diode I Cl7
I x I 2 I Left
21 C20
offset solenoid
valve
I
I
SWP
12
Intermediate
connector
CN-1
SWP
16
Intermediate
connector
D21
YAZAKI
2
Diode
CN-2
SWP
12
Intermediate
connector
D22
YAZAKI
2
Diode
CN-3
X
4
Intermediate
connector
CN-4
L
2
Intermediate
connector
CN-5
SWP
14
Intermediate
connector
CN-6
SWP
8
Intermediate
connector
El2
Terminal
1
Revolving
El3
Terminal
1
Starting
El4
ITerminal\
El5
X
3
Intermediate
connector
El6
L
2
Intermediate
connector
El7
L
2
Intermediate
connector
E20
SWP
8
Intermediate
connector
11
CN-76
M
1
Additional
headlamp
CN-77
M
1
Headlamp
(L.H)
6
) Limit switch
ICN-911 Relay I
20-214 0
(R.H)
I
I
frame
ground
motor
I
1 ) Heater relay
PC128UU-2
TYPES AND LOCATIONS
TROUBLESHOOTING
I I Address
Location 1 E30
~Terrninal~ I
KIO
Plug
1
Kll
M
1
K12
M
1
K13
SWP
6
I K14
I
M
I
1 Safety
I 2 I Travelspeed increase selector switch I
M40 I
M
I 2 I One-touch decelerationl~/
M41 I
M
1 6 I Intermediate
connector
M45
M
6
Intermediate
connector
Reset terminal
PO1
AMP040
2
Monitor
Switch to resetonly prevention of exterior part interference Switch to reset only prevention of exterior part interference
PO2
M
2
Light switch
PO4
M
2
Alarm
Lever
~05
2
I Register
UP/DOWN
M
2
Decelerator
controller
1 K17
1 X
1 4
1 Decelerator
controller
K18
SWP
6
Decelerator
controller
K19
-
6
Fuel control
dial
) 2 I Deceleration
I
I
1 Boom working
lamp
l
I
I
I
SO4
1
X
1 2
1 Boom LOWER pressure switch (No. II I
SIO
I
M
I 2 I Intermediateconnector
SIO
lamp
Ml2
KESI
2
Heater
S13
Ml6
I M26
Connector 1
I
M
x Connector
I
2
Boom LOWER pressure switch (No. 2)
1
PPC oil pressure
I
lock switch
ITerminal I 1 I PPC oil pressure lock switch I
S14 1 M
1 2 1 Fusible link 2
1
I Light
S12
L
/
buzzer
I Relay I 6
Fusible link
Ml5
/
R03
2
L
I
I
panel
Fuel level sensor
L
I
X
I
Ml1
I Ml4
I
I
Engine water temperature sensor
K16
M
M39
I
I
2 I Register Register
I MO9 I
B)
switch
2
M
Address
M
M
I
I I
Location
I
relay (Terminal
K15
I K20
OF CONNECTORS
1 2
Intermediate
connector
I
I
I
I
I
I
Fusible link Horn (High tone)
I
I 6 I Air conditioner
M28
X
2
Washer tank motor
M30
X
1
Optional
power supply
Electromagnetic
I
TO1 /Terminal1
1
TO2
Terminal
1
TO2
Terminal
1
TO3
Terminal
1
#TO5
Terminal
1
TO6 ITerminal1
1
clutch for air
Engine stop solenoid
(-1
Ground
Kerosene mode selector connector M37
M
1
Kerosenemode selector connector
M38
M
2
Light switch
PC128UU-2
Tll
ITerminal/
1
Cab ground
20-215 0
TROUBLESHOOTING
TYPES AND LOCATIONS
Location T12
ITerminal1 1
Starting switch (Terminal ACC)
T29
Terminal
1
Swing holding brake reset switch
T30
Terminal
1
Swing holding brake reset switch
VO4
x
2
Swing holding brake solenoid
VO5
x
2
Travel speed selection lock solenoid
V06
X
2
vo7
x
2
1 2-stage
relief valve solenoid
Address
Location
1
PPC oil pressure lock solenoid
I
20-216
OF CONNECTORS
I
I
I
PC1 28UU-2
CONNECTOR
TROUBLESHOOTING
CONNECTOR ARRANGEMENT
ARRANGEMENT
DIAGRAM
DIAGRAM
9
E
MO9 ,
1
\\
8 *
l\
FOl
V06
20-218 0
PC1 28UU-2
TROUBLESHOOTING
CONNECTOR
ARRANGEMENT
DIAGRAM
PO6
'Tl
\
I
I
cti-2
cbi-4 5 BWP04440
PC128UU-2
20-2 19 0
TROUBLESHOOTING
CONNECTOR
ARRANGEMENT
DIAGRAM
M.2
K13 KlO ROS
K6 Tll
PO4
M46
M40
ctq-91 ct+92
DO4
K16 T29 T30
R03
K16 Z
20-220 0
A
BWP04441
PC128UU-2
TROUBLESHOOTING
CONNECTOR
ARRANGEMENT
DIAGRAM
PO7
Dl 6%
A
\
El4
E20
804 Ch-76-l
803
W-76
/ BWP04442
PC128UU-2
20-221 0
TROUBLESHOOTING
CONNECTION
TABLE FOR CONNECTOR
PIN NUMBERS
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS * The terms male and female refer to the pins, while the terms male housing and female
housing
refer to the mating portion of the housing. No. of pins
r
X type connector Male (female housing)
Female (male housing)
1
BEH0014B
BEH00149
J
2
i
I TEwoo221
TEW00222
TEW00223
TEW00224
4
TEWO0225
20-222 0
PC1 28UU-2
CONNECTION
TROUBLESHOOTING
No. of pins
r
TABLE FOR CONNECTOR
PIN NUMBERS
SWP type connector Male (female
Female
housing)
(male
housing)
‘6 TEwoo235
BLFQ0033
a
8
m 0
0
12
___ .__ _____-
Cl 0
TEW00238
1
4
5
8
9
12 BLPOOO35
BLPOOO34
1
4
8
11
3
i
io
‘14
11
8
4
14 Id
7
1
14
TEW00239
4
TEwOO240
1
16
BLPOO036
PC1 28UU-2
20-223 0
CONNECTION
TROUBLESHOOTING
No. of pins
r
TABLE FOR CONNECTOR
PIN NUMBERS
M type connector Male (female housing)
Female (male housing) 2
2
i
BLFO0036
TEwoo243
TEwoo244
3
1
Bi$ 2
4
4
2 TEWO0246
TEW00245
4
1
I!!!$ 3
6
TEWOO247
TEW00246
6Lmoo4i
20-224 0
PC128UU-2
CONNECTION
TROUBLESHOOTING
No. of pins
T
8
TABLE FOR CONNECTOR
PIN NUMBERS
S type connector Female (male housing)
Male (female housing)
1
5
4
‘8
El 1
6
5
io
4
8
TEW00249
TEWOO250
10
TEW00251
10
5
IO BEL00117
5’
PC128UU-2
;2
EEL00113
BELO
12
‘5
BEL00114
20-225 0
CONNECTION
TROUBLESHOOTING
No. of pins
12
TABLE FOR CONNECTOR
PIN NUMBERS
S type connector Male (female housing)
Female (male housing)
3i BLP00043
I
12
‘5
BEL00114
IS
‘7
BEP01698
8
16
7 1
BEP01697
8
16
20-226 0
PC128UU-2
CONNECTION
TROUBLESHOOTING
No. of pins
T
AMP040 Male (female
TABLE FOR CONNECTOR
PIN NUMBERS
type connector
housing)
Female
(male
housing)
8
BLFQOO54
6
12
BLFOOO55
12
6
7
1
16
BLFQOO55
8
16
ii
i TEW00234
PC128UU-2
20-227 0
TROUBLESHOOTING
No. of pins
CONNECTION
T
AMP070
TABLE FOR CONNECTOR
PIN NUMBERS
type connector
Male (female housing)
Female (male housing)
12
1
5
12
BWPO3901
1
7
7
BWP03902
14
4
6
BLPO0069
1
9
18
8
18
BLPOO062
‘8
1 I
IO
20
i
20 BWP03903
20-228 0
BWPO3904
PC1 28UU-2
CONNECTION
TROUBLESHOOTING
No. of pins
T
Automobile Male (female housing)
2
TABLE FOR CONNECTOR
PIN NUMBERS
connector Female (male housing)
B
3
I
3
2 BLPco066
BLFOOO6-9
3
PC1 28UU-2
1
BLpoOO69
BLPO0070
BLPO0071
BLPOOO72
20-229 0
CONNECTION
TROUBLESHOOTING
No. of pins
r
TABLE FOR CONNECTOR
PIN NUMBERS
MIC connector Female (male housing)
Male (female housing) 3
lr uou
1
5
I
I
BLF’OOO45
BLFflOO46
9
1
BLFO0047
BLFOOO46
7
1
13
8
8
13
1
j
BLWO049
BLF30050
9 17
I
17
21
/
i
20-230 0
\
1
TEwoo259
TEW00260
PC128UU-2
CONNECTION
TROUBLESHOOTING
TABLE FOR CONNECTOR
PIN NUMBERS
L type connector
No. of pins
Female (male housing)
Male (female housing)
2
TEW00257
Connector
No. of pins
TEW00258
for PA Female (male housing)
Male (female housing)
rl
9
9
I
5
5 BEH00156
No. of pins
4
9 BEH00157
Bendix MS connector Female (male housing)
Male (female housing)
10
BWWO1218 BWW01219
PC128UU-2
20-231 0
TROUBLESHOOTING
No. of pins
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
T
Connector
for relay (Socket type)
Male (female housing)
Relay (male housing)
2
5
BLP00074
BLPOOO73
___ m 0
i m ______
0
I
5
2
1
BLPOO075
20-232 0
BLPOO076
PC128UU-2
CONNECTION
TROUBLESHOOTING
No. of pins
T
PIN NUMBERS
F type connector Female (male housing)
Male (female housing)
f=7
4
3
PC128UU-2
TABLE FOR CONNECTOR
I
I@c
3’ BWPO3905
2
‘4
BWPO3906
20-233 0
EXPLANATIONS
TROUBLESHOOTING
EXPLANATIONS SYSTEM
OF CONTROL MECHANISM
OF CONTROL MECHANISM
OF ELECTRICAL SYSTEM
OF ELECTRICAL
This section gives the necessary knowledge for troubleshooting of the electrical system, and explains the functions and nature of checks for the monitor panel and controller. 1.
l
Explanation of functions The control mechanism of the electrical system consists of the monitor panel and controller. It carries out various controls such as stopping the work equipment in the interference area, setting the working range (height, depth, offset), displaying the depth. The monitor panel and controller each input the necessary signals, and at the same time, together with the signals selected and set by the monitor panel, the controller inputs and outputs the necessary signals to control the stopping of the work equipment, the setting of the working range (height, depth, offset), displaying the depth. Input/output signal system for monitor and controller
Attachment
selection
selection Engine
speed
Pressure
connector
switch
Z 3LT-
signal
signal Specification selection
Z-Stage swing brake
sional
PC-EPC &Boom &rm
Depth Mode
Potent
iomete
Buzzer
-3
setting
Boom
RAISE
signal
Boom
LOWER stop
signal
signal
Le.ft offset stop solenoid valve solenoid Right
System
cancel
PC128UU2
stop
signal system
code
iometer
otentiometer
signal
Electrical Error
signal
valve
Potentiomet
i:IIent le setting
relief holding LS bypass
signal
valve offset
stop
cancel
TJP02188
20-235 0
TROUBLESHOOTING
EXPLANATIONS
OF CONTROL MECHANISM
OF ELECTRICAL SYSTEM
When troubleshooting
: The controller is equipped with a self-diagnostic function, and troubleshooting is carried out as far as possible by the controller itself. When troubleshooting is carried out, the error codes are displayed on the monitor panel depth display and the controller display. At the same time, the electrical system caution lamp flashes and the alarm buzzer sounds intermittently to warn the operator of the failure mode. The following actions are also carried out. l
Abnormal
system and details of display and action
Abnormality in systems @ @ @ (error codes: 31, 32, 34) Stops operations @ @ @ (makes it impossible to move towards l
interference)
Abnormality in systems @ @ @ (error codes: 52,71,81) Stops operations @ @ @ (makes it impossible to move towards interference) l
’
Abnormality in system @ (error code: 51) Error code 51: Stops operation @ (this is the PPC basic pressure, equipment, travel, and swing is impossible) l
\ ’
\ so movement
When spool of solenoid valve in systems @ @ @ does not close (error code: 91) Stops operation @ (this is the PPC basic pressure, so movement of all work equipment, and swing is impossible), l
’
of all work /
travel,
Abnormality in systems @ @ (error codes: 1 I- 17,21- 27 and Fl, F2) Makes compensation value 0 for potentiometer mount angle and bucket front face stop position, side face stop position, and depth display compensation, but allows normal movement.
\
l
\
/
Abnormality in systems @ @ @ @ (error codes: 54, 61, 62, 64, 68,72) Stops only each respective operation (has no influence on other circuits) l
Abnormality in system @ (error code: 41) Controls operation @ not as actual engine speed but as a certain speed (risk of engine stopping as low idling) l
\ *
/
For all error codes except 91, the condition is kept if it is judged that there is a failure, but for error code 91 only, if the location of the failure is reset, the system returns to the normal mode and the display also goes out.
20-236 0
PC128UU-2
TROUBLESHOOTING
EXPLANATIONS
OF CONTROL
MECHANISM
OF ELECTRICAL SYSTEM
Even if there is any abnormality in input signal systems @ to 0, no abnormality display is given in the display portion, but the controller has a monitor function that checks the input signal. When there is an input signal, the controller starts the movement and gives the monitor display in the display portion. Therefore, when investigating if the cause is in the electrical system or in the hydraulic or mechanical system, there are cases where there is no abnormality display in the display portion but In such cases, the first step when there is an abnormality in the operation of the work equipment. is to use the method in Section 2 Checking operation of electrical system to carrying out troubleshooting check if the necessary signal is being input correctly to the controller. For pressure signal switch 0, if the 2 switches for boom RAISE’and LOWER are switched ON simul* taneously for a certain period of time, error code Cl is displayed to inform the operator that the switch is stuck.
PC128UU2
20-237 0
EXPLANATIONS
TROUBLESHOOTING
2.
Check items (when normal)
Turn starting
switch
OFF
Monitor l
l
ON + 3 set l
@
Turn starting
switch
ON
After 3 set + until starting
l
l
After 5 set
l
@
OF ELECTRICAL SYSTEM
Checking operation of electrical system (4 system) When a sequence of operations is carried out using the procedure below, if the monitor panel and controller carry out the actions given below, the input and output signals, and the monitor panel and controller are normal.
Sequence of operation and condition of machine 3
OF CONTROL MECHANISM
Start engine
(engine
panel
Controller
All OFF
All OFF
l
All displays light up for approx. 3 set Buzzer sounds for approx. 1 set Engine oil pressure, lamp light up
charge
lo.01 is displayed in self-diagnostic display portion Note: Specification, attachment code is displayed (see monitor display)
l
When bucket is above ground level, IUPI is displayed, and when it is below ground level, a number is displayed All caution
lamps OFF
Possible to operate equipment freely Buzzer does not sound
l
at low idling) l
Work equipment stops specified position Buzzer sounds in approx. second cycle
l
@
Bring bucket close to cab from front or side l
@
0
@
Move
bucket away from cab
l
l-
Set the machine to the right maximum offset position, then move the bucket from the front upper position toward the right exterior parts and handrail.
* The bucket stops at the specified position. The buzzer sounds at interval of about 1 sec.
Move the bucket away from the right exterior parts and handrail.
*The bucket moves freely in the direction to move away from the right exterior parts and handrail. (Arm OUT, boom RAISE, left offset)
Set the machine to the neutral offset position and curl the arm to the end and keep the offset boom level, then move the bucket toward the right exterior parts and handrail by setting the machine to the right offset position.
l
l
l
Move the bucket away from the right exterior parts and handrail.
20-238 0
The bucket stops at the specified position. The buzzer sounds at interval of about 1 sec. *
l
60
at
Movement is possible in direction away from cab (arm OUT, right offset) Buzzer sounds until bucket is sufficient distance from cab (canopy), and does not sound after that
l
@
work
The bucket tally in the away from parts and OUT, boom
moves automatidirection to move the right exterior handrail. (Arm RAISE, left offset)
PC1 28UU-2
EXPLANATIONS
TROUBLESHOOTING
Sequence
of operation
Turn system
and condition
Check
of machine
cancel switch ON
Monitor l
v @
Carry out @ and @
l
U Turn system cancel switch OFF
@I
@
0
OF CONTROL MECHANISM
Raise work equipment 0.5 m from ground, set mode selection switch to DEPTH, then turn setting switch to SET u Raise boom, then lower it Raise work equipment 1 m from ground, set mode selection switch to HEIGHT, then turn setting switch to SET II Lower boom, then raise it. Offset arm to left, set mode selection switch to OFFSET, then turn setting switch to SET
l
.
items
(when
Controller Buzzer sounds
Electrical system lamp flashes in approx. l-second cycle Electrical system lamp flashes in approx. l-second cycle
l
Depth
up
mode
indicator
lights
l l
Height mode indicator lights up
l l
Offset mode indicator up
lights
l l l
@
. l
Lower bucket to ground @
Turn starting switch OFF
PC1 28UU-2
l
Work equipment can be oper ated freely (but there is nc automatic stop)
Electrical system lamp goes OFF
Offset arm to right, thUenoffset it to left Raise work equipment 1 m from ground, set mode selector switch to DEPTH DISPLAY 0 SET, then turn settingUswitch to SET
for approx. i
set
l
l
normal)
panel
l
l
OF ELECTRICAL SYSTEM
Depth
display
&o&s
Buzzer sounds twice Work equipment stops near set position Buzzer sounds twice Buzzer sounds twice Arm stops near set position Buzzer sounds twice
[o.o]
Value on depth display creases from 10.11 All OFF
Buzzer sounds twice Work equipment stops near set position Buzzer sounds twice
in-
l
All OFF
20-239 0
TROUBLESHOOTING
EXPLANATIONS
Work equipment posture Operating procedure 0, @ (front)
OF CONTROL MECHANISM
Operating
l
OF ELECTRICAL SYSTEM
procedure @
BWPO4419
l
Operating
BWPO4430
Operating
procedure 0, @ (side)
procedure @
BWP04431
BWP0443:2
l
Operating
t
20-240 0
Operating
procedure 0
BWP04429
procedure @
BWP04428
PC1 28UU-2
DISPLAY METHOD
TROUBLESHOOTING
FOR MONITOR
PANEL, CONTROLLER
DISPLAY METHOD FOR MONITOR PANEL, CONTROLLER 1.
Monitor panel 1) Machine monitor portion When the starting switch is turned ON, all monitors and gauges light up for approx. 3 seconds, and the buzzer sounds for approx. 1 second. The monitor itself carries out selfdiagnosis, and displays the specification and attachment codes for 3 seconds to 5 seconds. The specification code and attachment code are indicated as H or L as follows. i) The first digit shows the specification and the second digit shows the attachment. l
Specification
Display code
Offset specification
-1
.
Example of display If the machine has the offset specification and is equipped with the standard arm, [H.H] is displayed. 2) Mode indicator portion The settings for the depth mode, height mode, and offset mode light up. * Multiple mode settings are possible. * When the starting switch is turned OFF, all the settings are cleared. 3) Depth display portion i) Depth display (normal display) The depth from the ground level or the depth set from the standard level is displayed as follows. When the bucket is below the ground level or the standard level, a numeral is displayed. When it is above the ground level or the standard level, [UP] is displayed.
TJP02189
l
l
Display for depth
from ground level
Display for depth from standard level
I
Display
Above ground level
Above standard level
UP
Ground level
Standard level
0.0
1Below ground level 1Below standard level
PC128UU-2
1
2.5
I
1
20-241 a
DISPLAY METHOD
TROUBLESHOOTING
ii)
Self-diagnostic display (abnormality display) When the self-diagnostic function of the controller detects an abnormality, an error code is displayed on the controller itself, and at the same time, it is also displayed on the depth display. The display is the same as for the controller, and is given as an error code from 11 to 91 and Cl. Note that no dot is displayed between letters. * For details of the error codes that are displayed, see 2. Controller The display on the right gives an example of error code 31 (abnormality in boom potentiometer system).
FOR MONITOR
PANEL, CONTROLLER
l
l
Example
of display Display
Code
Abnormal
system Controller
31
Monitor panel
Abnormality in boom potentiometer system
I
Display
If a communications error occurs with an abnormality in the depth display signal system and mode setting signal system, the monitor itself displays error code [EEI. iii) Monitoring mode If the work equipment control lever is operated with the SET/CLEAR switch at the CLEAR position, the controller display shows the applicable monitor code. (For 1 second only) l
.
Table of code numbers Monitor code
System Boom RAISE pressure
switch
Boom LOWER pressure Swing
left, right pressure
Arm IN pressure Travel pressure
20-242 0
switch switch
switch switch
PI P2 P3 P5 P7
PC128UU-2
I
TROUBLESHOOTING
2.
DISPLAY METHOD
FOR MONITOR
PANEL, CONTROLLER
Controller 1) Normal display After the starting switch is turned ON, code [OO] is displayed if the condition is normal.
When normal
2)
/
O0
I
I
Self-diagnostic
Display
Code
Condition
display
/
m
I
(abnormality
/ 1
dis-
play) If any abnormality occurs in the controller itself or in the input signal system and output signal system, the controller displays the appropriate error code continuously. Display Abnormality in single system The error code for the system with the abnormality is displayed directly. Abnormality in two or more systems i) Abnormalities in same group The first digit of the error code (the group code) is kept for the first digit, and the total for the second digits (the individual code) is displayed as the second digit.
BDP01232
l
l
l
PC128UU-2
Re-enacting display Once the starting switch is turned OFF, the error codes are cleared, so carry out the check with the starting switch ON. Ir When checking, turn the cancel switch OFF. If the starting switch is turned OFF, it is possible to re-enact the abnormality display as follows. 4: Turn the starting switch ON. c]: Start the engine, set the work equipment to the reset posture, then connect the reset terminal. A: Start the engine and bring the bucket closer to the interference area. * During normal operations, if there is a disconnection in any of the ON/OFF solenoid group, the output for that system may stop without any abnormality display being given. However, for the PPC lock solenoid system, swing holding brake solenoid system, it is not possible to re-enact a disconnection. Monitor display In addition to the information displayed in the monitoring mode on the monitor panel, [Hi] is displayed when the travel boost switch is ON, and [UPI is displayed when the optional knob switch is ON. l
l
l
l
3)
20-243 0
TROUBLESHOOTING
DISPLAY METHOD
FOR MONITOR
PANEL, CONTROLLER
boom stop position
boom angle + arm angle
angle + offset angle Defective 17
2,
resetting
boom angle+ offset angle Defective
of
arm angle+
resetting
of front
face stop position z z.? CT
22
Defective
resetting
of side
face stop position Defective
resetting
23
face stop position face stop position
24
Defective
compensation
Defective
resetting
face stop position defective
0
Single
•l
Single
0
21+22
0
of front + side
of
depth display
25
II+12 + ,4
Single
0
21 +24
c]
Defective
compensation
of
53
resetting
of side +
compensation
of
22 +24
q
depth display
9 E Q) 0 tc
54
resetting
face stop position 27
20-244 0
of front + side
face position
+ defective
compensation display
of depth
: The bold lines indicate
PPC hydraulic + left offset
Defective swing brake solenoid Defective
55 Defective
Defective
lock solenoid
51+52
n
Single
H
51+54
H
52 + 54
n
stop solenoid
face stop position defective
PPC hydraulic
of front +
depth display
26
Defective
occurrence
21+22 + 24
Defective
cl 56
PPC hydraulic
lock solenoid holding
holding
+ swing
brake solenoid left offset
solenoid + swing brake solenoid
holding
of a single abnormality.
PC1 28UU-2
TROUBLESHOOTING
Nad;t grouF
rror ode
DISPLAY METHOD
I
Abnormal
system
Single, multipll
FOR MONITOR
PANEL,
CONTROLLER
Renac -
Defective PPC hydraulic 5,
lock solenoid + left offset
51+5i
stop solenoid + swing
+ 24
holding brake solenoid 62
63
Defective LS bypass solenoid Defective LS-EPC solenoid + LS bypass solenoid
64
Defective 2-stage relief solenoid (opt)
6B
Defective swift slow-down controller signal system
Single
61 +6i
Single
Single
7,
Defective boom RAISE EPC Single solenoid
72
Defective boom LOWER
u .-
0
6 z
EPC solenoid
cn
Single
73
Defective boom RAISE EPC solenoid + boom LOWER 71 +72 EPC solenoid
74
Defective PC-EPC solenoid
75
solenoid
Single
Defective boom RAISE EPC + PC-EPC sole-
71+34
noid
76
Defective boom LOWER EPC solenoid + PC-EPC
72 i- 74
solenoid Defective boom RAISE EPC 77
solenoid
+ boom RAISE
EPC solenoid + PC-EPC
71 +72 f 74
solenoid 6,
Defective arm IN EPC solenoid
9,
Defective valve open system
’
c .;
C,
Boom pressure switch (RAISE) and (LOWER) input simultaneously than 3 sec.
PC1 28UU-2
for more
Single
Single
Single * The bold lines indicate occurrence of a single abnormality.
20-245 0
TROUBLESHOOTING
3.
Chart showing alarm
DISPLAY METHOD
pattern of ‘actuation for monitor
g
Monitor
-
-
-
stop is
is ON
0
When automatic mode is set
control
When automatic control is actuated (automatic stop)
When abnormality
’
Abnormality in communications circuit system
i
and
Alarm
buzzer
Sounds (Isecond cycle) Sounds (I second cycle)
Error code [911 displayed
Flashes (0.6second cycle)
Sounds (0.6second cycle)
Error code displayed when abnormality occurs
Error code displayed when abnormality occurs
Flashes (Isecond cycle)
Sounds (for 7 seconds only)
Becomes IO.01 when DEPTH MODE 0 SET is set
-
-
-
-
-
Error code displayed
Error code [EEI displayed
OFF
-
Error code [EEI displayed
Flashes (0.6second cycle)
Sounds (2 times in 0.4-second cycle) (Does not sound in DEPTH DISPLAY 0 SET mode) Sounds (0.6second cycle)
-
-
-
-
Abnormality in electric system signal system
-
-
Lights up
-
When reset (when normal)
-
-
Flashes (Isecond cycle)
-
-
E
._
lamp,
Error code [911 displayed
Error code displayed
occurs
Abnormality in controller power source system
2
caution
Electric system caution lamp
When R.H. interference prevention is actuaterd
d
:
Controller
-
When cancel switch
5 (D
panel
-
z 05
Cz= x E ;
system
-
When emergency actuated
-z t( a, ‘ii u .u,
electric
When cab interference prevention is actuated (automatic stop)
s
: g
controller,
PANEL, CONTROLLER
buzzer Item
.+ =
panel,
FOR MONITOR
When reset (when abnormal)
Error code displayed
Error code displayed
Flashes (0.6second cycle)
When reset terminal is disconnected in case of above abnormality
Error code displayed
Error code displayed
Flashes (0.6second cycle)
ii $ 5 : 5
_ g ._ b
When starting switch is turned OFF, and then ON
E w
*
again without disconnecting reset terminal after resetting
-
For operations not listed here, the normal operation Monitor panel: Depth is displayed Controller: Normal code 00 is displayed Electric system caution lamp: OFF Alarm buzzer: Does not sound
-
Sounds (0.6second cycle)
lashes 2
Does not sound
seconds after starting switch is turned ON
from 2 seconds after starting switch is turned ON
and display is given for each component.
l
l
l l
20-246 0
PC128UU-2
TROUBLESHOOTING
METHOD
OF USING TROUBLESHOOTING
METHOD OF USING TROUBLESHOOTING 1.
Category of troubleshdoting Troubleshooting
2.
CHARTS
CHARTS
code number
Code No
Component
E-00
Troubleshooting
of electrical
F-00
Troubleshooting
of pump controller
H-00
Troubleshooting
of hydraulic,
M-00
Troubleshooting
of machine
system input signal system
mechanical monitor
system
system
Method of using troubleshooting table 1) Troubleshooting code number and problem The top left of the troubleshooting chart gives the troubleshooting code number and the problem with the machine. 2) Distinguishing conditions Even with the same problem, the method of troubleshooting may differ according to the model, component, or problem. In such cases, the troubleshooting chart is further divided into sections marked with small letters (for example, a), b)), so go to the appropriate section to carry out troubleshooting. If the troubleshooting table is not divided into sections, start troubleshooting from the first check item. 3) General precautions When using the troubleshooting chart, precautions that apply to all items are given at the top of the page and marked with *. The precautions marked J, are not given in then but must always be followed when carrying out the check inside the 0. chart 4) Method of following troubleshooting YES . Check or measure the item inside a0 , 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 then is an index number; it does not indicate the order to follow.) Following the YES or NO lines according to the results of the check or measurement will lead finally to the Cause column. Check the cause and take the action given in the Remedy column on the right. Below the n there are the methods for inspection or measurement, and the judgement values. If the judgement values below the n are correct or the answer to the question inside the 0 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 them is given the preparatory work needed for inspection and measurement, and the judgement values. If this preparatory work is neglected, or the method of operation or handling is mistaken, there is danger that it may cause mistaken judgement, or the equipment may be damaged. Therefore, before starting inspection or measurement, always read the instructions carefully, and start the work in order from Item I). Troubleshooting tools When carrying out the troubleshooting, prepare the necessary troubleshooting tools. For details, see TOOLS FOR TESTING, ADJUSTING, AND TROUBLESHOOTING. Installation position, pin number A diagram or chart is given for the connector type, installation position, and connector pin number connection. When carrying out troubleshooting, see this chart for details of the connector pin number and location for inspection and measurement of the wiring connector number appearing in the troubleshooting flow chart. l
l
l
5)
6)
PC1 28UU-2
20-247 0
METHOD
TROUBLESHOOTING
OF USING TROUBLESHOOTING
CHARTS
@ E-l
o*
Before carrying out troubleshooting,
* 0
Error code [EE] (abnormality communications system)
Always connect any disconnected
in controller power source system or
check that all the related connectors connectors
are properly inserted.
before going on to the next step.
a) Abnormality *
in controller power source system The monitor panel displays [EE] and none of the work equipment blade and travel work).
or swing move (only the
Cause
1 YES Is voltage between CO1 (8). (17), (18)
-2O-30V -Turn starting switch ON.
20-248 0
NO
Remedy
Defective controller
Replace
Defective contact, or disconnection in wiring harness between fuse(2)CO1 (female) (8). (17). (18)
Repair wiring harness, or
PC128UU-2
TROUBLESHOOTING OF CONTROLLER, ELECTRICAL SYSTEM (E MODE)
Action taken by self-diagnostic
function
and problems on machine
.................................................
20-304
Judgement
table for 4 system .. __..........................................................................................................
20-308
Judgement
table for chassis related
20-310
parts ............................................................................................
Electrical circuit diagram for controller Points to remember Precautions
when carrying
when handling
and work equipment
system ....................................................................................
out troubleshooting
cancel switch when abnormality
stops ....... _ .....................................
E- 1 Error code [EEI (Abnormal-y or communications
of controller
in controller
system)
is displayed
a) Abnormality
in controller
b) Abnormality
in communications
20-312
system .................................
20-314
display is given
......................................................................
20-317
power source system .....................................................................................
20-318
power source system ....................................................................
20-318
system ................................................................................
E- 2 Error code 1311 (Abnormality
in boom potentiometer
E- 3 Error code [32] (Abnormal-w
in arm potentiometer
E- 4 Error code 1341 (Abnormal-m
in offset potentiometer
20-320
system) is displayed .............................
20-321
................................
20-322
............................
.20-323
E- 5 Error code 1411 (Abnormal-&y
in engine speed sensor system) is displayed .............................
20-324
E- 6 Error code [511 (Abnormal-rty
in PPC hydraulic
system) is displayed system) is displayed
lock solenoid
E- 7 Error code [521 (AbnormaliEgr in left offset stop solenoid
system) is displayed
system) is displayed
................ .20-325
....................... .20-326
E- 8 Error code 1541 (Abnormal-ity
in swing holding brake solenoid
E- 9 Error code [621 (Abnormal-w
in offset stop solenoid system) is displayed.. .............................
E-10 Error code 1641 (Abnormal-m
in 2-stage relief solenoid system) is displayed.. ........................ .20-329
E-l 1 Error code 1711 (Abnormal-&y
in boom RAISE stop EPC solenoid system) is displayed..
........ .20-330
E-12 Error code [721 (Abnormal-y
in boom LOWER stop EPC solenoid
....... .20-331
E-13 Error code [741 (Abnormal-&y
in PC-EPC solenoid system) is displayed ....................................
20-332
E-14 Error code 1811 (Abnormal-&y
in arm IN stop solenoid system) is displayed.. ...........................
20-333
E-15 Error code [Cl] (3 seconds simultaneously) E-16 Abnormality
is displayed
system) is displayed..
........... .20-327
system) is displayed
20-328
passed after boom LOWER and RAISE pressure switches were input __........................................................’
in travel speed selection
.. .. .. . .. .. .. . .. .. . . .. .. .. . . ... .. . ... ... . ... ... 20-333
solenoid system
(Travel speed does not rise or does not decrease) . .. .. .. .. .. .. . . .. ... . .. .. .. . . .. ... . .. .. .. . . .. . .. . . ... ... . ... ... .... .. . 20-334 a) Travel speed does not Gse (but keeps low) .. ... . ... . .. . .. .. . .. . .. . ... . .. .. .. . . .. ... . .. .. .. .. .. . .. . .. .. . ... ... . ... ... . .. 20-334 b) Travel speed does not ioorver (but keep high) .. . .. .. .. .. ... .. .. . .. . .. ... . .. . .. . .. .. .. .. . .. . .. . .. .. . . ... .. .. .. ... .. .. ... 20-335 E-17 Work equipment
does not move after work equipment
E-18 Work equipment
moves amberwork equipment
lock lever is released . . .. . .. .. .. ... . ... ... . ... 20-336
lock lever is set in LOCK position . .. ..._.........
20-337
E-19 Depth mode, height mode, offset mode do not work properly (go beyond set position before E-20 Impossible
stopping
or stop before reaching set position) . .. . ... . .. ... . ... ... . .. 20-338
to select and sep depth display 0 set mode, depth mode, height mode,
offset mode . .. .. ... . ... .. .. ..__._------.......................................................................................................
PC1 28UU-2
20-339
20-301 0
E-21 Cancel switch is not turned ON, but alarm buzzer sounds for 7 seconds and electrical system caution lamp flashes.. ...................................................... E-22 Automatic
: i.. .......................
20-340
stop is not carried out for boom RAISE, LOWER, arm IN, left offset, right offset 20-341
(when error code 1911 is not displayed) ........................................................................................ a) All operations
stop immediately
b) There is interference
before interference
..................................
I.. .......................
.................................................................................................................
20-341 20-341
E-23 Swing does not work (when no error display is given). ..............................................................
20-342
E-24 Excessive hydrauli,c drift of swing.. ...............................................................................................
20-343
E-25 Offset does not work (particularly
left offset). ..............................................................................
20-344
E-26 Offset does not work (Particularly,
right offset) ...........................................................................
20-345
E-27 Engine does not start .....................................................................................................................
20-346
a) When starting motor does not rotate ......................................................................................
20-346
does not work .......................................................................................
20-350.
b) Engine stop solenoid
E-28 Engine does not stop.. ....................................................................................................................
20-351
E-29 Wiper does not operate.. ................................................................................................................
20-352
E-30 Engine control is abnormal.. ..........................................................................................................
20-353
a) When engine does not start or it starts but stops soon . . .. .. . ... . ... .. .. . ... .. . .. .. .. . .. .. ... . ... . .. ... .. . .. .. . 20-353 b) Swift slow-down does not work . ... . .. .. .. . .. ... .. .. .. ... ... .. .. .. .. .. . . .. ... . .. ... .. . ... .. .. . .. .. . .. ... . ... .. .. . .. ... . .. . ... 20-355 c) Works at near idling speed, but does not work up to full throttle (load becomes high)..... 20-355
20-302 0
PC1 28UU-2
ACTION TAKEN BY SELF-DIAGNOSTIC FUNCTION AND PROBLEMS ON MACHINE
TROUBLESHOOTING
ACTION TAKEN BY SELF-DIAGNOSTIC LEMS ON MACHINE &play code
Abnormal
31
Boom potentiometer
32
Arm potentiometer
34
Offset potentiometer
37
Potemtionmenter system
FUNCTION AND PROBNature of abnormality
system
I) Disconnection in wiring harness (in one of three wiring harnesses) 2) Short circuit between wires in wiring harness (two of three wiring harnesses) 3) Wiring harness short circuiting with ground 4) Defective potentiometer
system
system
system
power
I) Short circuit 2) Hot short
source
in power
source wiring
1) Disconnection in wiring harness 2) Defective adjustment or defective 41
51
52
Rotation
harness
rotation
sensor
sensor system
PPC hydraulic
lock solenoid
Left offset stop solenoid
system
1) @ end of solenoid (between VO7(1) - COl(21)) short circuiting with ground 2) Short circuit inside solenoid 3) Contact between wiring harness at ground end and @ end of solenoid
I) @end of solenoid (between C17(2) circuiting with ground 2) Disconnection at @ end of solenoid COl(21)) 3) Short circuit inside solenoid (if internal resistance of solenoid is 4) Disconnection inside solenoid 5) Contact between wiring harness at end of solenoid
system
- COl(21)) short (between extremely ground
C17(2) low)
end and @
1) @ end of solenoid (between VO4(1) - CO3(8)) short circuiting with ground 2) F;;p8l;ection at @ end of solenoid (between VO4(1) 54
62
64
20-304 0
Swing
holding
brake solenoid
Right offset stop solenoid
2-stage relief solenoid
system
system
system
3) Short circuit inside solenoid (if internal resistance of solenoid is extremely low) 4) Disconnection inside solenoid 5) Contact between wiring harness at ground end and @ end of solenoid
I) @ end of solenoid (between C18(2) - CO3(15)) short circuiting with ground 2) Disconnection at @ end of solenoid (between C18(2) CO3(15)) 3) Disconnection or short circuit inside solenoid I) @end of solenoid (between VO6U) - CO3(7)) short circuiting with ground 2) Disconnection or defective contact inside solenoid
PC1 28UU-2
ACTION TAKEN BY SELF-DIAGNOSTIC FUNCTION AND PROBLEMS ON MACHINE
TROUBLESHOOTING
Condition
(voltage,
when
current,
Action
normal
when is detected
by controller
abnormality
resistance)
I) Turn off outputs for solenoids to stop raising boom, moving arm in, and moving offset to left . (Reduce current to OA). Ir Display fault continuously even Voltage between CO3 (I) and CO2 (9) after faulty parts is repaired (Operation is kept stopped). [C23 (2) and (1 )I: 0.3 - 4.7 V
Voltage between CO3 (9) and CO2 (9) LC21 (2) and (I)]: 0.3 - 4.7 V
Problem that appears on machine when there is abnormality I) Machine cannot raise boom, move arm in, and move offset to left.
Voltage between CO3 (IO) and CO2 (9) [C22 (2) and (I)]: 0.3 -4.7 V Voltage between CO2 (IO) and (Power source): 4.9 - 5.1 V
(9)
I) Resistance betweenC03 (4) and (12) IE07 (I) and (211:500 - 1,000 Sz !) Voltage between K3 (4) and (12) [CN20 (I) and (2)l: 0.5 - 0.3 V * Use AC range.
I) Recognize engine speed as partial output [Output a current equivalent to engine partial output (535 f 20 mA) to PC-EPC solenoid.1
I) Pump absorption horsepower is insufficient (Production is insufficient). 2) Engine stalls when its speed is lowered.
I) Turn off outputs for solenoids to stop raising boom, moving arm in, and moving offset to left (Reduce current to OA). * This system does not check for wire breakage by itself (Work equipment stops without displaying fault).
1) Machine cannot move work equipment, travel, swing, and move blade.
1) Turn off outputs for solenoids to stop raising boom, moving arm in, and moving offset to left (Reduce current to OA). * Even if wire is broken during operation, this system does not display any fault, but offset operation stops.
I) Machine cannot raise boom, move arm in, and move offset to left.
I) Turn off output for swing holding brake solenoid. * Even if wire is broken during operation, this system does not display any fault and release swing holding brake.
I) Machine does not switch (Swing holding brake is not released). * If solenoid is broken, swing holding brake is not released even if swing holding brake release switch is operated. Take care.
Resistance of solenoid: 35 - 80 Q
I) Turn off output to solenoid to stop offset to right.
Machine cannot offset to right.
Resistance of solenoid: 35 - 80 Q
I) Turn off output for 2-stage relief solenoid.
Resistance of solenoid: 37 - 60 Sz
Resistance of solenoid: 37 - 60 S2
PC128UU-2
l
Relief pressure does not rise when travel force is required. Accordingly, travel force is insufficient.
20-305 0
ACTION TAKEN BY SELF-DIAGNOSTIC FUNCTION AND PROBLEMS ON MACHINE
TROUBLESHOOTING
Iisplay code
71
72
Abnormal
Boom
Boom
Nature of abnormality
system
RAISE stop solenoid
EPC system
LOWER stop EPC solenoid
system
1) Disconnection inside solenoid 2) Short circuit inside solenoid or short circuit with ground 3) Disconnection in wiring harness between C16(1), (2) COI, or short circuit with ground
1) Disconnection inside solenoid 2) Short circuit inside solenoid or short circuit with ground 3) Disconnection in wiring harness between C14(i), COI, or short circuit with ground
(2) -
1) Disconnection inside solenoid 2) Short circuit inside solenoid or short circuit with 74
81
91
PC-EPC solenoid
3) !%z%fnection in wiring harness between CO1(5), (15), or short circuit with ground
system
Arm IN stop solenoid
EPC system
1) @ end of solenoid (between C15(1) - COl(3)) short circuiting with ground 2) Short circuit inside solenoid or short circuit with ground 3) Disconnection in wiring harness between C15(1), (2) CO1(3), (14), or short circuit with ground
1) Valve for solenoids for boom RAISE stop, arm IN stop, offset stop blocked by dirt and staying open (bucket inside interference range) 2) Water inside connectors (K18, K50, K52) of boom, arm, and offset potentiometers
Valve open system
Defective
Cl
EE
20-306 0
C13(1), (2) -
boom
RAISE or boom
LOWER pressure
switch
Boom RAISE pressure switch and boom LOWER pressure switch input at same time for more than 3 seconds
Communications system power source system
or controller
1) Defective contact or disconnection between CO1 (I) and PO1 (I) 2) Defective contact or disconnection between CO1 (2) and PO1 (12) 3) Defective contact or disconnection between CO3 (6) and PO1 (2) 4) When power source is not input to 5) When voltage is more than 38V or
in wiring
harness
in wiring
harness
in wiring
harness
controller less than 9.5V
PC128UU-2
ACTION TAKEN BY SELF-DIAGNOSTIC FUNCTION AND PROBLEMS ON MACHINE
TROUBLESHOOTING
Condition when normal (voltage, current, resistance) I) Resistance of solenoid: 5 - 25 d 2) Voltage between CO1 (16) - (9): ob;7c5kk,3.0V (in safe range for
Action
when is detected
by controller
abnormality
Problem that appears on machint when there is abnormality
1) Turns output OFF (current OA) to solenoids for boom RAISE stop, arm IN stop, left offset stop j: Even when the location of the failure is restored, the abnormality display continues to be displayed. (The operation also remains stopped)
I) Boom RAISE, arm IN, and left offset cannot be operated
Turns output OFF (current OA) to solenoid for boom LOWER stop solenoid
Boom LOWER cannot
1) Resistance of solenoid: 10 - 22 Q 2) Voltage between CO1 (5) - (15) engine full, lever N : 0 - 5 V engine siow, lever N : 6 - 13 V
1) Turns output OFF (current OA) to PC-EPC solenoid * Even when the location of the failure is restored, the abnormality display continues to be displayed. (The operation also remains stopped)
I) Excessive drop in engine speed when there is heavy load
I) Resistance of solenoid: 5 - 25 s2 2) Voltage between CO1 (14) - (9): ob;7c5k,t;.0 V (in safe range for
I) Turns output OFF (current OA) to solenoids for boom RAISE stop, arm IN stop, left offset stop * Even when the location of the failure is restored, the abnormality display continues to be displayed. (The operation also remains stopped)
I) Boom RAISE, arm IN, and left offset cannot be operated
z Impossible system
I) Turns output OFF (current OA) to PPC lock solenoid * If the location of the failure is restored, the abnormality display goes out, and it returns to normal operation.
All operations
Does not carry out any particular action.
1) When boom RAISE switch is stuck, there is no particular change 2) When boom LOWER switch is stuck, boom does not go up
I) Communications system: Does not carry out any particular action. 2) Controller power source system: Stops all functions, but if power source voltage becomes normal, it returns to normal operation. * The abnormality display also goes out.
1) Communications system: Operations are possible in normal way, but (I) F; display is given except
I) Between At boom Lever at 2) Between At boom Lever at l
l
l
l
to measure
CO2 (7) and chassis: LOWER: Max. 1 V HOLD: 20 - 30 V CO2 (8) and chassis: LOWER: Max. 1 V HOLD: 20 - 30 V
1) Resistance between (8): Max. IO Q 2) Resistance between (12): Max. 10 Q 3) Resistance between (2): Max. IO Q 4) Voltage: 24 - 30 V
PC1 28UU-2
electrical
CO1 (I) - PO1 CO1 (2) - PO1 CO3 (6) - PO1
be operated
stop
(2) Buzzer does not sound 2) Controller power source system: None of the work equipment swing can be operated (travel, blade still work)
or
20-307 0
TROUBLESHOOTING
JUDGEMENT
JUDGEMENT
TABLE FOR 4 SYSTEM
TABLE FOR 4 SYSTEM Self-diagnostic display (abnormality display)
EE
Failure mode
31
32
0
0
\E Boom RAISE does not work
0
Boom LOWER does not work
0
(
0
1
0
I
0
I
0
I
0
1
E-2
1
E-3
1
E4
Arm IN does not work Left offset does not work Right offset does not work Boom RAISE does not carV out automatic stop properly
Arm IN does not carry out automatic stop properly
Left & right offset do not carry out automatic stop properly
All operations stop immediately
before interference
There is interference All operations stop immediately
before interference
There is interference All operations stop immediately
before interference
There is interference
Depth mode cannot be used Height mode cannot be used Offset mode cannot be used Automatic stop distance is too close (during operation) Automatic stow distance is too far (durina oPeration) Abnormality in depthmodesop (after setting, during operation)
Abnormality in height mode stop (after setting, during operation)
Abnormality in offset mode stop (after setting, during operation)
Goesto0 far beforestopping Stops too soon Goes too far before stopping
Goes too far before stopping Stops too SOOn
When automatic stop is carried out 3uzzer does not sound
When cancel switch is ON When setting mode, stopped During self-diagnostic display (display is given)
;;;x&switch
is not turned ON, but buzzer sounds for 7 seconds and electric system lamf
ilectric system caution lamp keeps flashing 4utomatic stop is not carried out for ,oom RAISE, arm IN, left offset *2
All operations stop immediately
before interference
There is interference
Work equipment moves even when work equipment lock lever is at LOCK position froubleshooting
code when abnormality display is given
froubleshooting
code when abnormality is confirmed by monitoring
*1 *2
E-l
EE is displayed on monitor panel, but no display is given on the controller panel. When error code I91 I is not displayed
20-308 0
PC128UU-2
TROUBLESHOOTING
JUDGEMENT
TABLE FOR 4 SYSTEM
H-l 1
H-30 H-30
H-30
H-29
E-20
E-20
M-l 1 (a)
E-21 M-14 E-22 E-21
PC128UU-2
20-309 0
TROUBLESHOOTING
JUDGEMENT
JUDGEMENT
TABLE FOR CHASSIS
RELATED PARTS
TABLE FOR CHASSIS RELATED PARTS Self-diagnostic
display (abnormality display)
* : Option
,
Failure mde
\I
,
Speeds of all work equipment
,
\m
Error code
EE
32
51
(
52
62
swing travel are slow or lack power
There is excessive drop in engine speed, or engine stalls No work eauioment, travel, swinq move 1Abnormal noise aenerated (around ourno) Fine control ability is poor or response is poor Boom is slow or lacks power Arm is slow or lacks power Bucket is slow or lacks power
1Excessive hvdraulic drift
Travel deviation E E 6
Deviation is excessive Deviation is excessive when starting
Travel soeed is slow
F
Steering is difficult to turn or lacks power
z
Travel speed does not switch or is faster than set speed Does not move (one side only)
I
Does not swing
Swing acceleration is poor
1 Both left and right
Both left and right One direction only
E z z
Excessive overrun when stopping swing
F ,-
Excessive abnormal noise when stopping swing
R
Excessive hydraulic drift of swing
Both left and right One direction only
07
When brake is ON When brake is OFF
1Blade is slow or lacks power Excessive hydraulic drift of blade Troubleshooting code when error code is displayed Troubleshooting code when abnormality isconfirmed
*
by monitorins
With the left offset stop solenoid system, disconnections are not detected during actuation, so if the operation stops but no abnormality display is given, carry out troubleshooting for E-27.
20-310 0
PC128UU-2
TROUBLESHOOTING
JUDGEMENT
TABLE FOR CHASSIS
I
I
I
RELATED PARTS
I
H-l
H-13 H-15 H-16
H-24 I
I
I I
1 E-11 1 E-12 1 E-13 1 E-14 ( H-30 1
I
I
H-25
) E-161 IF-1 1 F-2
PC128UU-2
,
F-3 1 Fa
F-5 1 F-6
I
-
20-311 0
TROUBLESHOOTING
ELECTRICAL CIRCUIT DIAGRAM
ELECTRICAL CIRCUIT DIAGRAM 1.
FOR CONTROLLER
SYSTEM
FOR CONTROLLER SYSTEM
4 system
COntlDIler
co1(MlC7.1)
. _...
CN-S14 CN-SIO
PPC lock rritch
(HZ)lmls) iWP)lfsmls)
ention
diode
RIotIt
offset
__-__
TJP02190
20-312 a
PC1 28UU-2
TROUBLESHOOTING
ELECTRICAL CIRCUIT DIAGRAM
I
I
FOR CONTROLLER
(KESl
SYSTEM
2) (MI
;;i -< : ” _; L
so5 (X2)
-1
TJP02192
PC128UU-2
20-3 13 a
TROUBLESHOOTING
POINTS TO REMEMBER WHEN CARRYING OUT TROUBLESHOOTING OF CONTROLLER SYSTEM
POINTS TO REMEMBER WHEN CARRYING OUT TROUBLE: SHOOTING OF CONTROLLER SYSTEM l
l
1.
The controller for interference prevention and automatic control mounted on this machine has special control features that do not appear on conventional machines, such as automatic stop of the work equipment and reducing the speed before carrying out the automatic stop. For this reason, particular phenomena appear on this machine which do not appear on conventional machines. The following types of phenomena are not failures, so it is important to confirm the operating condition properly before carrying out troubleshooting.
After the machine has carried out automatic stop, the boom RAISE, arm IN, and left offset operations cannot be carried out even when the work equipment is moved a to the front or right direction. (The diagram shows movement to the front.) a:50-IOOmm ; At 50 - 100 mm, the work equipment is still inside the interference range, so operations will be possible if the work equipment is moved further.
a
BWP04448
2.
After automatic stop, even when the work equipment is moved less than b to the front, when the boom RAISE and arm IN are operated, the speed is slow. b:700 mm * The work equipment is still inside the reduced speed area, so the speed will return to normal if it is moved further. l
BWP04449
3.
After automatic stop with the left offset operation, the work equipment automatically stops if the arm is moved to the front and an attempt is made to return to the original posture. * The work equipment is still inside the interference area in the left offset direction, so operations will become possible if it is offset approx. 50 mm to the right.
20-314 0
-
PC128UU-2
TROUBLESHOOTING
4.
POINTS TO REMEMBER WHEN CARRYING OUT TROUBLESHOOTING OF CONTROLLER SYSTEM
After automatic stop, if the cancel switch is turned ON, the bucket is brought closer to the cab (canopy), and then the cancel switch is turned OFF, the self-diagnostic display shows error code 1911, . and it becomes impossible to operate the work equipment or swing. * If the cancel switch is turned ON and the bucket is moved away from the cab (canopy), the operating condition will return to normal and the error code will go out. BWPO4450
5.
When the cutting edge or bottom of the bucket is put in contact with the ground, the depth display does not show fO.01. * The ground surface is sloping or the machine is at an angle.
BLP01370
6.
The depth display varies according to the position where the bucket is put in contact with the ground.
BLP01371
7.
When the potentiometers are removed and installed again, the automatic stop position is out of place. * Reset the input/output signal and the condition will return to normal. For details, see TESTING AND ADJUSTING.
PC1 28UU2
20-3 15 0
TROUBLESHOOTING
8.
POINTS TO REMEMBER WHEN CARRYING OUT TROUBLESHOOTING OF CONTROLLER SYSTEM
When the interference prevention function and automatic control function are actuated in cold areas, the automatic stop position is out of place. * Error code 1911 may also be displayed, but when the oil temperature rises, the condition will return to normal.
Points to remember if problems are reset during operations In the following cases, there is a high probability of the same problem occurring again, so be sure to follow up the situation properly. 1) 2)
The abnormality was naturally reset, or During the troubleshooting operation after the abnormality occurred, the connectors were disconnected and a T-adapter was inserted, or the T-adapter was removed and the connector was returned to its original position, and the service code display went out. Or the monitor became normal.
20-316 0
PC128UU-2
TROUBLESHOOTING
PRECAUTIONS WHEN HANDLING CANCEL SWITCH WHEN ABNORMALITY DISPLAY IS GIVEN AND WORK EQUIPMENT STOPS
PRECAUTIONS WHEN HANDLING CANCEL SWITCH WHEN ABNORMALITY DISPLAY IS GIVEN AND WORK EQUIPMENT STOPS If error codes [521, [711, [721, or [811 are displayed and the work equipment stops when there is an abnormality in the solenoid system, if the cancel switch is turned ON and fuse 3 blows, check the solenoid system where the abnormality occurred, and also check the related diode at the same time. The cause of the abnormality in the solenoid system may be a shot-t circuit inside the solenoid or a short circuit between the ground and wiring harness between the controller and the solenoid. In such cases, when the cancel switch is turned ON, an excessive current will flow, and before the fuse burns out, the resistance inside the diode may become 0. * The PPC lock solenoid system checks only for a short circuit inside the solenoid or a short circuit between the ground and the wiring harness at the positive end, so if error code 1511 is shown, do not turn the cancel switch ON under any circumstances. Carry out the troubleshdoting first. l
Abnormal system
62
Right offset stop solenoid
71
Boom RAISE stop solenoid
72
Boom LOWER stop solenoid
81
Arm IN stop solenoid
PC128UU-2
0 0
0
0
0 0
0
0
20-317 a
E-l
TROUBLESHOOTING
E-l
Error code [EE] (Abnormality in controller power source system or communications system) is displayed
* *
Before carrying out troubleshooting, check that all the related connectors are properly inserted. Always connect any disconnected connectors before going on to the next step.
a)
Abnormality in controller power source system * The monitor panel displays [EEI and nothing works.
I
1 YES Is voltage between
_ Co1 (8). (17).
t=t= I_
(18)
I_ *20-30V *Turn starting switch ON.
NO
Defective controller
Replace
Defective contact, or disconnection in wiring harness between fuse(2)CO1 (female) (S), (17). (18)
Repair wiring harness, or
-c-1
E-l a) Related electric circuit diagram
I
I
A
Fusible
link
+IBattery
Controller
-I
CO1 (040161 Power source
input
(+24V\ @j-l
GND
Battery
Solenoid Power source
input
Power
input
source
relay
(t24V)
TJPO2194
PC128UU-2
20-3 0
19
TROUBLESHOOTING
b)
Abnormalityjn
E-l
communications
system Cause
2 YES
Defective controller
Remedy
Replace
ditions as when IT measuring Item l? System
YES
3 1With svstem in L”‘y Jw’LL” 1 1which ihere is
1 II
I
* Turn starting switch ON.
Table 1 Monitor panel
Controller Between CO1 (I) -chassis
Between PO1 (8) -chassis
Between CO1 (2) -chassis
Between PO1 (12)
Between CO3 (6) -chassis
Between PO1 (2) -chassis
- chassis
. Min. 1 MQ * Disconnect connectors at both controller and monitor panel end. * Turn starting switch OFF.
N(
is reset
-
Defective contact, or disconnection in wiring harness between monitor panel and controller
?.epair wiring larness, or replace
Defective monitor panel
Replace
Wiring harness between monitor panel and controller short circuiting with ground
qepair wiring iamess, or replace
I
Voltage (V)
16-20
E-l b) Related electric circuit diagram
:ontroller
Monitor Panel
co1 blICi1) Serial
PO i (040 16)
clock
I CO3 (04016)
Serial
clock
I
TJPOZI 95
20-320 0
PC128UU-2
E-2
TROUBLESHOOTING
E-2 * *
Error code [31] (Abnormality played
in boom potentiometer
system) is dis-
Before carrying out troubleshooting, check that all the related connectors are properly inserted. Always connect any disconnected connectors before going on to the next step.
I
I I
YE
H 2 YES
Defective controller
Table 1
electric
circuit
Reolace
System is reset
I
1Defective contact. or disconnection in wiring.harness between CO2 (female) (10). (9X20 (male) (3). (1) or wiring harness short circuiting with ground
wiring harness beYEiS tween CO3 (female) (9) and C20 (male) (2) normal, and is circuit insulated 3
Is resistance between C20 (female: (3) - (1). and (2) (1) as shown in Table l?
* Disconnect C20. * Turn starting switch OFF.
E-2 Related
Remedy
Is [31 I displayed under same conditions as whlen measuring Item 1?
-Turn starting swi tch NO ON.
- 0.3 - 4.7 v . Turn starting switch ON.
Cause
Defective contact, or disconnection in wiring harness between CO3 (female) (9) -
Tepair wiring larness, or replace
. . Resistance Galue of wiring harness: Max. 1 Q
. Between wiring harness and chassis: Min. 1 MR _._ NC)
Defective boom potentiometer
Replace
diagram
Controller
co2 (04O;‘O) Potentiometer Potentiometer
GND Power source
co3 (040 16)
I
Boom Potentiometer Signal
CN6 (SWPB) C20 LSWP121 C21 (X3) @
3
@
3
@
3
Boom Potent i;ometer
GND
TJP02196
PC1 28UU-2
20-32 1 0
E-3
TROUBLESHOOTING
E-3 * *
Error code [32] (Abnormality played
in arm potentiometer
system) is dis-
Before carrying out troubleshooting, check that all the related connectors are properly inserted. Always connect any disconnected connectors before going on to the next step. Remedy
2+_~
leplace
Is [321 displayed
r
YES
ON.
1
H
Is voltage between CO3 (I) and (12) normal?
wiring harness be-
N
3 1Is resistance between C23 (male) (1) - (3). and (2) (3) as shown in
Table 1 Resistance
1
Between(3)-(1) Between (2) -
(1)
4-6kQ
epair wiring arness, or replace
Y
* 0.3 - 4.7 v *Turn starting switch ON.
C23 (male)
I Defective contact. or disconnection in wiring ‘harness between CO2 (female) HO), (9) - C23 (female) (1). (3) or wiring harness short circuiting with ground
. Disconnect C23. * Turn starting switch OFF.
(2) normal, and is circuit insulated
Resistance value of wiring harness: Max. 1 L2 Between wiring harness and chassis: Min. 1 MQ Defective arm potentiometer
NC
0.2 - 7 kR
Defective contact, or disconnection in wiring harness between CO3 (female) (1) -
R,epair wiring harness, or replace
. FSeplace
E-3 Related electric circuit diagram
t
Controller
I co2 (04OiO)
m!’ Potentiometer
IP8) Power source
C
(SWP12)
c21 (X3) ‘ter
co3 (040 16) pzzy-p$
TJP02197
20-322 0
PC128UU-2
TROUBLESHOOTING
E-4 * *
E-4
Error code [34] (Abnormality played
in offset potentiometer
system) is dis-
Before carrying out troubleshooting, check that all the related connectors are properly inserted. Always connect any disconnected connectors before going on to the next step. Cause
2
YES
Defective controller
Remedy
Replace
YE S El-
1
H
i
ON.
Is voltage between CO2 (10) and (12) normal?
Y
* 0.3 - 4.7 v . Turn starting switch ON.
Is resistance between C23 (male) (3) - (I), and (2) y;;s, s$own rn
F Table 1 C23 (male) Between (3) - (1)
4-6kS2
Between (2) - (1)
E-4 Related
* Disconnect C23. * Turn starting switch OFF.
Resistance
0.2-7
electric
Is resistance in wiring harness between CO3 (female) (IO) and K52 (female) (2) normal, and is circuit insulated from chassis?
Defective contact, ordisconnection in wiring harness between CO2 (female) (10). S (9) -C23 (female) (1). (3) or wiring harness short circuiting with ground _I
- Disconnect CO3 and C2: -Turn starting switch OFF * Resistance value of wiring harness: Max. 1 C . Between wiring harnes: 5 and chassis: Min. 1 MD
0
kQ
circuit
System is reset
. Turn starting switch NO
Repair wiring harness, or replacc
Defective contact, or disconnection in wiring harness between CO3 (female) (10) C23 (female) (2!, or wiring harness short crrcuiting with ground
Repair wiring harness, or replace
Defective offset potentiometer
Replace
diagram
Controller
0 (SWPl21
C23 (X31 t iometer
CO3 (040 16) Offset
potentiometer
Signal
GND
TJP02198
PC1 28UU-2
20-323 0
TROUBLESHOOTING
E-5 * *
E-5
Error code [41] (Abnormality played
in engine speed sensor system) is dis-
Before carrying out troubleshooting, check that all the related connectors are properly inserted. Always connect any disconnected connectors before going on tc he next steo. Remedy Cause
2 YES YES I
r
~500-1OOOR *Turn starting switch NO OFF. * Disconnect E07.
Is resistance between ~03 (female) _ (4) and (12)
Iefective controller
leplace
Xsconnection in wiring larness between CO3 female) (4), (12) - E07 (13). 14)wiring harness short Srcuiting with ground
leplace or repai viring harness
Defective engine speed iensor
7eplace
E-5 Related electric circuit diagram
Controller
Engine speed sensor
TJPO.2199
20-324 0
PC128UU-2
TROUBLESHOOTING
E-6 * * * *
E-6
Error code [51] (Abnormality is displayed
in PPC hydraulic lock solenoid system)
Before carrying out troubleshooting, check that all the related connectors are properly inserted. Always connect any disconnected connectors before going on to the next step. This detects only short circuits between wires or the wiring harness between the controller and the solenoid circuiting with the ground. If movement stops but no abnormality display is given, go to E-l 5. Remedy
Cause
2 YES Is there continuity in
harness between CO1 YES (female) (21) and v07 _ 1 /%%?$&ulated from chassis?
/
#I J
t l
(1) and (2) normal
. Between VO7 (male) (1) and (2) : 35 -80Q~o - Between V07 (male) (1). (2) and chassis: Min. 1 Q * Disconnect V07. - Turn starting switch OFF.
NO * Disconnect CO1 and V07. * Measure on CO1 (female) side in diode range (Note). *Turn starting switch OFF.
Defective controller
Short circuit with chassis ground in wiring harness between CO1 (female) (21) V07 (female) (1)
Defective PPC lock solenoid
I
Note: If an ordinary tester is set in the diode range, the voltage of the battery in itself is indicated. When a harness containing a diode is checked with this tester, “if this voltage does not change, there is not continuity”, and “if this voltage changes, there is continuity”.
E-6 Related electric circuit diagram
TJP02200
PC1 28UU-2
20-325 0
TROUBLESHOOTING
E-7 * * *
E-7
Error code [52] (Abnormality displayed
in left offset stop solenoid system) is
Before carrying out troubleshooting, check that all the related connectors.are properly inserted. Always connect any disconnected connectors before going on to the next step. If the wiring harness between the controller and the solenoid is short circuiting with the ground, a display is given during operations. In the case of a disconnection, no display is given, but the work equipment stops. [If this happens, carry out troubleshooting for E-23.1 Cause
3 YEE
YE
.
zYEk Is there continuity in harness between CO1 (female) (20) and Cl7 (female) (2)? Is harness insulated from chassis?
Is resistance between Cl7 (female) (1) and chassis ground normal?
Remedy
Ilefective controller
Replace
Defective contact or disconnection in wiring harness between Cl7 (female) (1) -chassis groun
Sepair or replace iarness
Defective contact, disconnection or short circuit with chassis ground in wiring harness between CO1 (female) (20) - Cl7 (female) (2)
Xepair or replace larness
Defective diode DO9
Replace
Defective left offset stop solenoid
Replace
-
Nf * Max. 1R * Disconnect C17. *Turn starting switch OFF.
* Disconnect CO1 and’ 07. NO - Measure on CO1 (female) side in diode range (Note). *Turn starting switch OFF. * Between Cl7 (male) (I) and (2): 35 - 9OQ * Between Cl7 (male) (1). (2) and chassis: Min. 1 MC - Disconnect CO1 and c17. -Turn starting switch OFF.
Note: If an ordinary tester is set in the diode range, the voltage of the battery in itself is indicated. When a harness containing a diode is checked with this tester, “if this voltage does not change, there is not continuity”, and “if this voltage changes, there is continuity”.
E-7 Related electric circuit diagram
DO9 Controller
I
CO1 (MlC21)
00
ctq5 (SWP14)
Cl7 (x2)
Left offset stop solenoid valve
3
$iJ
3
7%
20-326 0
TJPOZZOI
PC1 28UU-2
TROUBLESHOOTING
E-8
E-8
Error code [54] (Abnormality tern) is displayed
in swing holding- brake solenoid sys-
Before carrying out troubleshooting, check that all the related connectors are properly inserted. Always connect any disconnected connectors before going on Remedy to the next step. If the wiring harness between the controller and the solenoid is ? short circuiting with the ground, a display is given during operations. In the case of a disconnection, no L \,F.. ’ lc3 Defective controller Replace display is given, but the Isresistance between swing stops. [If this happens, *YEs_v04 (female) (2) and _ chassis ground carry out troubleDefective contact or Is there continuity normal? disconnection in wiring Repair or replace shooting for E-21 .I in harness between YES
~03 (female) (8) and _ * Max. IQ - Turn starting switch V04 (female) (l)? Is OFF. harness insulated * Disconnect V04. from chassis? * Disconnect CO3 and . zsure
on co3 (fe/E)
side in diode range (Note). *Turn starting switch OFF. + Between V04 (male) (1) and (2): 35 - SOL2I
~0
harness between V04 (female) (2) - chassis groutnd
narness
Defective diode DO3 Defective contact, disconnection or short circ :ui with chassis ground in wiring harness between CO3 (female) (8) - V04 (female) (1)
Replace Repair or replace harness
I Replace
* Disconnect V04.
Note: If an ordinary tester is set in the diode range, the voltage of the battery in itself is indicated. When a harness containing a diode is checked with this tester, “if this voltage does not change, there is not continuity”, and “if this voltage changes, there is continuity”.
E-8 Related electric circuit diagram CNi (SWP16)
vo4 (X2)
Swine holding
brake
Controller
r*&
I
I
TJP02202
PC1 28UU-2
20-327 0
TROUBLESHOOTING
E-9 * * *
E-9
Error code 1621 (Abnormality played
in offset stop solenoid system) is dis-
Before carrying out troubleshooting, check that all the related connectors are properly inserted. Always connect any disconnected connectors before going on to the next step. If the wiring harness between the controller and the solenoid is short circuiting with the ground, a display is given during operations. In the case of a disconnection, no display is given, but the work equipment stops. (If this happens, carry out troubleshooting for E-23.) Cause
3 YE!
Defective controller
Remedy
Replace
Is resistance between
4 t-t ft=
I’% Cl8 (female) (1) and _ ~_ chassis ground Is there continuity in normal? harness between * Max. I!,2 NO _ YES_ ~03 (female) (15) and Cl8 (female) (2)? - Disconnect C18. Is harness insulated * Turn starting switch from chassis? OFF. 1 * Disconnect CO3 and Is resistance between Cl8 (male) NO C18. _ * Measure on CO3 (female) . (I) and (2) normal and are they side in diode range (Note). insulated from.. * Turn starting switch OFF. chassis? . Between Cl8 (male) (1) and (2) : 35 - 8OQ . Between Cl8 (male) (1). (2) and chassis : Min. 1 MQ -Disconnect C18. * Turn starting switch OFF.
Defective contact or disconnection in wiring harness between Cl8 (female) (I) -chassis ground Defective contact, disconnection or short circuit with chassis ground in wiring harness between CO3 (female) (15) - Cl8 (female) (2) Defective diode D23
Defective right offset stop solenoid
Repair or replac harness
Replace
Replace
Note: If an ordinary tester is set in the diode range, the voltage of the battery in itself is indicated. When a harness containing a diode is checked with this tester, “if this voltage does not change, there is not continuity”, and “if this voltage changes, there is continuity”.
E-9 Related electric circuit diagram
D23 Controller
CO3 (040;61 mRbll'."::i;'
cN5 (SWP14) -3
Cl8 (X2)
Right offset stop solenoid valve
3 3
TJP02203
20-328 0
PC128UU-2
TROUBLESHOOTING
E-10
E-10 Error code 1641 (Abnormality played * *
Before carrying Always connect
in 2-stage relief solenoid system) is dis-
out troubleshooting, check that all the related connectors are properly any disconnected connectors before going on to the next step.
inserted.
Cause
3 YES
I
e.E,tweenI
(female) (2) and I Ichassisground
1L
,~,_,__,,~~_L.,_,,
,c,,~~~?Trm -1 *Turn=-ingswitch * Max. 10 Q / -Ezonnect * Between C03(female) (7) and chassis : NO Min. 1 M Q - uisconnect V06. *Turn starting switch OFF.
?H
____ *35-8051 * Between V06 (male) (I), (2) and NO chassis : Min. IMR * Disconnect V06. *Turn starting switch OFF.
E-10 Related electric
Defective controller
Replace
l-l
11
V06 (male) (1) and (2) normal and are they insulated from
K28.
Remedy
NO
Defective contact or disconnection in wiring harness between V06 (female) (2) -chassis grounc
Repair or replace
Defective contact, disconnection or short circuit with chassis ground in wiring harness between CO3 (female) (7) - V06 (female) (1)
Repair or replacr
Defective 2-stage relief solenoid
Replace
diagram
circuit
II-4 @(I)
Controller I
CO3 (04Oi6) pzxiJy&
I
DO5 CN2 (SWP12) 3 V06 (X2)
Two-stage
relief
TJP02204
PC128UU2
20-329 0
E-II
TROUBLESHOOTING
E-l 1 Error code [71] (Abnormality tem) is displayed *
in boom RAISE stop EPC solenoid sys-
check that all the related connectors are properly inserted. Before carrying out troubleshooting, Always connect any disconnected connectors before going on to the next step.
J,
Defective controller
i,
YE 1
Is there continuity in harness between CO1 (female) (7) and Cl6 (female) (l)? Is harness insulated 1from chassis? * Disconnect CO1 and C16. . Measure on CO1 (female) side in diode range (Note). * Turn starting switch OFF.
Is harness insulated 1from chassis? *.I * Between harnEaTs;;u * Between harness and ,-hrae&.r .. .. . .. ‘1 MO “..___.“. Min *Turn starting switch
Defective contact, disconnection or short circuit with chassis around in wiring harness between co1 (female) (16) - c16 (female) (2)
IU
I replace disconnection or short circuit with chassis ground in wiring harness between CO1 (female) (7) - Cl6 Replace
Defective diode D12
* Between Cl6 (male) (I) and (2) : 5 - 25R * Between Cl6 (male) ! -1 (I), (2) and chassis : Min. 1 MC * Disconnect C16. * Turn starting switch OFF.
replace
L%tL%;
boom RAISE stop
Replace
Note: If an ordinary tester is set in the diode range, the voltage of the battery in itself is indicated. When a harness containing a diode is checked with this tester, “if this voltage does not change, there is not continuity”, and “if this voltage changes, there is continuity”.
E-l 1 Related electric circuit diagram
D12 Controller
I
I
CO1 (MlCil)
LrLl
CN5 (SWP14)
Cl6 (X2)
Boom RAISE stop EPC valve
Boom-RAISE, LOWER stop EPC(+I
TJP02205
20-330 0
PC1 28UU-2
E-12
TROUBLESHOOTING
E-12 Error code [72] (Abnormality tem) is displayed * *
in boom LOWER stop EPC solenoid sys-
Before carrying out troubleshooting, check that all the related connectors are properly inserted. Always connect any disconnected connectors before going on to the next step. Cause
3 YE:
l-33 -
harness between YE .S Cl4 (female) (2) and CO1 (male) (16)? Is 2 harness insulated Isthere continuity in YES harness between N( * Max. 1R CO1 (female) (6) and - Disconnect CO1 and C14. - Cl4 (female) (l)? Is - -Turn aarting switch OFF harness insulated - Turn emerqency work from chassis? 1 equipment-operating switch OFF. * Disconnect CO1 and Is resistance between c14. Cl4 (male) (1) and (2) N IO . normal and are they - - Max. IOR insulated from * Measure on CO1 (female) side in chassis? diode range (Note). * Turn starting switch OFF. * Between Cl4 (male) (1) and (2): 35 - 80R * ,“l;~2~ar$‘ch;;s;~’
NO
Min. 1 MQ - Disconnect C14. -Turn starting switch OFF.
From
A{=[
4 YE:
- Switch NC OFF: Max. IQ ON: Min. 1 MQ *Turn starting switch OFF. * Disconnect switch terminal.
Remedy
Defective controller
Replace
GotoA
Defective contact, disconnection or short circuit with chassis ground in wiring harness between CO1 (female) (6) - Cl4 (female) (I)
Repair or replace harness
Defective boom LOWER stop EPC solenoid
Replace
Defective contact, disconnection or short circuit with chassis ground in wiring harness between CO1 (female) (16) - Cl4 (female) (2) Defective diode D13
Repair or replacf harness
Defective switch
Replace
Replace
Note: If an ordinary tester is set in the diode range, the voltage of the battery in itself is indicated. When a harness containing a diode is checked with this tester, “if this voltage does not change, there is not continuity”, and “if this voltage changes, there is continuity”. E-12 Related electric circuit diagram
Controller
I
D13 CN5 (SWP14)
C14 (X2)
Boom LOWERstop EPC valve
Boom RAISE, LOWER stop EPC(-1
Emergency work equipment operation switch TJP02206
PC1 28UU-2
20-33 1 0
TROUBLESHOOTING
E-13 Error code [74] (Abnormality *: *.
Before carrying Always connect
in PC-EPC solenoid system) is displayed inserted.
are properly check that all the related connectors out troubleshooting, step. next the to on before going connectors any disconnected Cause
Is resistance between3 YES CO1 (female) (5) and y2ES_ Cl3 (female) (I) normal and are they insulated from Are resistance chassis? between CO5 Max. 1Q NC YES (male) (1) and (2) _ and resistance - * Between CO1 (female) (5) (3) and between (2) and chassis: Min. 1 MD normal and are Turn starting switch OFF. they insulated from * Disconnect CO1 and C13. chassis? Is resistance between * Max. IQ Cl3 (male) (1) and (2) NO * Turn emeraencv normal and are they pump drivkswikh OFF. * Turn starting switch OFF. * Disconnect C05. * Between Cl3 (malt l
I
Remedy
GotoA
Defective contact, disconnection or short circuit with chassis ground in wiring harness between Kl (female) (5) - Cl3 (female) (I)
Repair or replao harness
l
Min. 1 MD * Turn starting switch OFF. * Disconnect C13.
4 YES
* Max.lR NO * Between CO1 (female) (15) and chassis : Min. 1 MD starting switch *:Tu:u~r;:
Defective emergency pump drive switch
Replace
Defective PC-EPC solenoid
Replace
Defective controller
Replace
Defective contact, disconnection or short circuit with chassis ground in wiring harness between CO1 (female) (15) - Cl3 (female) (2)
Repair or replace harness
* Disconnect CO1 and Cl3
E-13 Related electric circuit diagram
operation
s
Fuse
F7iz-l
PC-EPC
(+I
TJP02207
20-332 0
PC1 28UU-2
E-14, E-15
TROUBLESHOOTING
E-14 Error code [81] (Abnormality played :
in arm IN stop solenoid system) is dis-
-)r Before carrying out troubleshooting, check that all the related connectors are properly inserted. * Always connect any disconnected connectors before going on to the next step.
I 3 YES YE5 2 Is there continuih/ in harness between CO1 (female) (3) and _ Cl5 (female) (I)? Is harness insulated from chassis?
YE
* Disconnect CO1 and
i
Is resistance between CO1 (female) (14) and Cl5 (female) (2) normal and are they insulated from chassis?
Cause
Defective controller
Mm.
Replace
Defective contact, disconnection or short circui with chassis ground in * Between harn;a=$;QNO wiring harness betvveen CO1 (female) (14) - Cl5 (female) * Between harness and (2) chassis: Min. 1 MQ
qepair or replace larness
- Disconnect CO1 and C15. -Turn starting switch Defective contact, qepair or replace OFF. disconnection or short circus larness
~iijf2~~~itch ~/Fi%EJY;~g:ZY~
(female) side in diode range (Note). * Between Cl5 (male) (I) and (2): 5 - 25Q * Between Cl5 (male) (I), (2) and chassis : __ - --
Remedy
3eplace
Defective arm IN stop solenoid
0
Replace
1 Ml2
* Disconnect Cl 5. -Turn starting switch OFF.
Note: If an ordinali/ tester is set in the diode range, the voltage of the battery in itself is indicated. When a harness containing a diode is checked with this tester, “if this voltage does not change, there is not continuity”, and “if this voltage changes, there is continuity”. E-14 Related electric circuit diagram
CN5 (SWP14)
Cl5 (X2)
Arm IN stop EPC valve
3 3
I
TJP02208
E-15 Error code [Cl] (3 seconds passed after boom LOWER and RAISE pressure switches were input simultaneously) is displayed I. 2.
For inspection For inspection
PC128UU-2
of boom RAISE pressure switch, see F-l. of boom LOWER pressure switch, see F-2.
20-333 0
TROUBLESHOOTING
E-16 Abnormality in travel speed selection solenoid system (Travel speed does not rise or does not lower) * *
Before carrying out troubleshooting, check that all the related connectors are properly inserted. Always connect any disconnected connectors before going on to the next step.
a)
Travel speed does not rise (but keeps low) Reme’dy
chassis normal? YES
Is voltage between
r-l V05 (1) and chassis 1 Inormal? Is resistance 020-3~. “” Turn starting between M25 or switch ON. M39 (male) (1) and (2) normal? 2
YES
-
l-
Defective contact or disconnection in wiring harness between M25 (female) (1) or M39 (female) (1) -chassis ground
.epair or replace arness
Breakage of fuse (2) Defective contact or disconnection in wiring harness between fuse (2) V05 (female) (1)
NO
eplace fuse eplace wiring arness
_ Defective travel speed selector switch
,eplace
Defective travel speed selection solenoid
leplace
*Turn startin switch OFF * Disconnect a 25 (Seesaw switch) or M39 (Pedal switch).
I
* Between V05 (male) (1) and (2) : 35 - 8052 * Between V05 (male) (11, (2) and chassis: Min. 1 MD Turn starting switch OFF. * Disconnect V05.
(Seesaw switch) or
l
‘When sw~~is,o~~
epair or replace arness
1
* When switch is ON: Max. X2
Is resistance between V05 (male) (1) and (2) normal and are they insulated from chassis?
I
*Turn starting switch
Defective contact or disconnection in wiring harness between V05 (female) (2) - M25 (female) (2) or M39 (female) (2)
I
NO
l
E-16 a) Related electric circuit diagram
m-2
Controller
I
CO1 (MIC21)
(SWPl2) vo5 (x2)
Trave
select
I speed ion
yj
3
.a
-----.-a
Ml39 (M2)
Trave I speed selection switch OFF ON
1
Q2 0 -
Travel
20-334 0
speed
selection
M25 (M2)
Travel Hi-Lo selection switch
TJP02209
PC1 28UU-2
E-16
TROUBLESHOOTING
b)
Travel speed does not lower (but keeps high)
2, I
Is resistance between M25 or 1 - M39 (female) (2) and chassis normal?
I
*.I
_
Remedy
I
Go to troubleshooting of hydraulic, mechanical system (See H-21)
YES _ Is resistance between M25 or M39 (male) (1) and 2 normal?
Cause
Short circuit with chassis ground in wiring harness between M39 (female) (2) V05 (female) (2)
Min. 1 MR NO *Turn starting switch OFF. * Disconnect M25 (Seesaw switch) or M39 (Pedal switch) and V05. l
Defective travel speed selector switch
*When switch is ON: Max. 1Q NO *When switch is OFF: Min. 1 MD *Turn starting switch OFF. Disconnect M25 (Seesaw switch) or M39 (Pedal switch).
Repair or replace harness
Replace
l
E-16 b) Related electric circuit diagram
Controller
CN-2 (SWP12) V05 (X2)
Travel select
speed ion
3 3
Ml39 (M2) :( Fuse
-
Travel
PC128UU-2
DO7
speed
selec
K&l tion
Travel speed selection switch OFF ON
1
8'
M25 (M2)
Trave I Hi-Lo select ion switch
TJP02209
20-335 0
TROUBLESHOOTING
E-17
E-17 Work equipment released * * * *
does not move after work equipment
lock lever is
When error code 1911 (Valve open) is not displayed. Before carrying out troubleshooting, check that all the related connectors are properly inserted. Always connect any disconnected connectors before going on to the next step. Wire breakage of this system is not checked or displayed by the self-diagnosis system.
Cause
2 YES YE
See H-3
Is resistance between S13 and chassis ground normal?
Defective contact or disconnection in wiring harness between S13 and chassis ground
Between harne;;zshNO
1
Disconnect S13. Turn starting switch OFF.
5YES
Is voltage between lock switch inlet
:S 4
*When lever is locked: 20-30V *When lever is released: Max. 1V *Turn starting switch ON.
YE
1R NC . Disconnect S12 and V07. . Turn starting switch OFF.
$zEj
-35-80R I - Disconnect V07. NIO -Turn starting switch OFF.
-When lever is locked: Min. 1 MR *When lever is released: Max. 1R * Turn starting switch OFF.
E-17 Related
electric
circuit
iepair or replace iarness
Defective contact or disconnection in wiring harness between S12 and V07 (female) (2)
iepair or replace larness
Defective PPC oil pressure lock solenoid
Ieplace
Defective PPC oil pressure lock switch
teplace
diagram
PPC lock PPCDo?ck D20 --
m Y
$13
2 Controller
iepair or replace iarness
Defective diode D4
iii%GJH - Max.
3 Is resistance of lock switch normal?
Remedy
t
:: s
5314 (maI e) (M2) SlO (female) (M2)
8%
R&
TJP02210
20-336 0
PC1 28UU-2
TROUBLESHOOTING
E-18
E-18 Work equipment LQCK position * *
Before carrying Always connect
moves after work equipment
out troubleshooting, any disconnected
lock lever is set in
check that all the related connectors are properly connectors before going on to the next step.
Cause
2 YES YES -
1
_ Is resistance of lock switch normal? I
Is resistance between S12 and chassis normal?
inserted.
Remedy
Malfunction of solenoid valve spool (Go to H-3)
-
*Min. 1 MQ NO -Turn starting switch OFF. * Disconnect S12 and V07.
Short circuit with chassis ground in wiring harness betweenS12andV07 (female) (2)
Repair or replace harness
Defective PPC oil pressure lock switch
Replace
1
* When lever is locked: Min. 1 MR NO * When lever is released: Max. 1Q . Turn starting switch OFF.
E-18 Related electric circuit diagram
ock
-1
6! ,
Controller
1 co1 (MlCil)
2
S14 (male) SlO(femaIe)
(M2I (M2)
p?x%-p
CN6 (SWP14) TJP02210
PC1 28UU-2
20-337 0
TROUBLESHOOTING
E-19
E-19 Depth mode, height mode, offset mode do not work properly (go beyond set position before stopping or stop before reaching set position) * *
Before carrying out troubleshooting, check that all the related connectors are properly inserted. Always connect any disconnected connectors before going on to the next step.
Cause
YES
Loose potentiometer . Bent linkage
1 Is potentiometer and linkage mount loose or bent? _ NO
Remedy
2 YES
-S
Is voltage of potentiometer signal as shown in Table l?
moun
tepair or replace
Cjefective operation of olenoid valve in defective S ystem
lepair or replace
P‘otentiometer V oltage
NO
with defecti\ is defective
lepair or replace
.
Table 1
Measurement
posture
Boom potentiometer
Arm potentiometer
Between C21 (2) - (1)
% Between C23 (2) - (1)
Between C22 (2) - (1)
Offset boom
Boom: End of RAISE aroke Arm: End of IN stroke
Offset potentiometer
0.73 - 1.01 v
Offset: End of right offset stroke
STD
0.65 - 1.43 V
Long
0.74 - 1.52 V
2.99-4.11
v
% The value depends on the optional attachment (long arm)
E-19 Related electric circuit diagram
Left offset stop solenoid valve
.
_ .
b?roencr
Offset
potentiomete
Riht
offset stop solenoil(t)
Boom
RAISE
work
Boom Potent
iometer
Arm Potent
iometer
Offset Potent
iometer TJP02211
20-338 0
PC1 28UU-2
TROUBLESHOOTING
E-20 Impossible to select and set depth display 0 set mode, depth mode, height mode, offset mode : Ir * *
Before carrying out troubleshooting, check that all the related connectors are properly inserted. Always connect any disconnected connectors before going on to the next step. Check that the selection and setting is being carried out outside the interference area. Cause
YES 2
i
Is voltage between CO2 (3),(4), and (9) as shown in Table 2?
3
YES
Is continuity p between -Turn starting switch - setting/resetting ON. NO switch terminals as shown in Table 2?
Is voltage between CO2 U).(2). and (9) as shown in Table
N
Replace
Defective contact, or discon nection in wiring harness between Cl2 (female) (2). (3) and CO2 (female) (4), (3)
qepair wiring iarness, or .eplace
Defective contact, or disconnection in wiring harness between Cl 1 (female) (1). (2) and CO2 (female) (2). (1)
4 YES
I
Defective controller
Defective setting switch
* Turn starting switch NO OFF.
-Turn starting switch ON.
Remedy
Is continuity between mode selection switch terminals as shown in Table l?
qepair wiring larness, or *eplace
Defective selection switch
* Turn starting switch NO OFF. Table 2
Table 1 Terminal No. of controller CO2
@
1 Terminal No. of controller CO2 1
0
‘0 C 2 P
‘E r
g g E ‘Z ag.c I=
$ 0 (Max. 1 V) (Max. 1 V)
Offset
E-20 Related electric circuit diagram
’
I
@
I
(GNU
l
SET Neutral
0
(Min. 16V) (Max. 1 V) (Min. 16 V) (Min. 16 V)
l
CLEAR
0
IMax. 1 VI (Min. 16 VI
0
Mode selection
I
Controller
I@ 3
Switch terminal No.
Cl.1 (KES4)
switch
I
Mode selection Mode selection
h
Cl2 (KES3)
J
PC128UU-2
TJP02212
20-339 0
TROUBLESHOOTING
E-21
E-21 Cancel switch is not turned ON, but alarm buzzer sounds for 7 seconds and electrical system caution lamp flashes * -k
Before carrying out troubleshooting, check that all the related connectors are properly inserted. Always connect any disconnected connectors before going on to the next step.
Cause
2 YES 1 Is voltage between CO2(13) and (9) normal?
-
Is voltage between CO3 (14) and (12) normal?
YES
Defective monitor panel
Defective controller
-Cancel switch NO *Whennormal: 6 - 10 V *When abnormal: Max. 1 V *Turn starting switch ON. 3 YES
* Cancel switch Is continuity *When OFF: between K13(male) Max. 1 V NO between (1) - (2) as *When ON: shown in Table l? 20-30V . Turn starting switch * Turn starting switch ON. OFF.
Remedy
Replace
Wiring harness behveen CO: 3epair wiring (female) (13) - K13 (female) qarness, or (1) in contact with power replace source wiring harness Defective emergency operation switch for work equipment
NO
Table 1
E-21 Related
electric
circuit
diagram
Emergency work operation
To each circuit Controller
equipment
switch
cancel A
I
K13 (SWP6)
.
PO5 (X2)
x
i
CO2 (040201 System
cancel
1 Signal
GND
switch !d
Monitor
CN2 (SWP 12)
2 ’
’
d
)h
PO1 (04016)
CO3 (040 16)
Buzzer Electrical
Signal
Panel
output system
GND I
TJP02213
20-340 0
PC1 28UU-2
TROUBLESHOOTING
E-22
E-22 Automatic stop is not carried out for boom RAISE, LOWER, arm IN, left offset, right offset (when error code [911 is not displayed) * * *
Before carrying out troubleshooting, check that all the related connectors are properly inserted. Always connect any disconnected connectors before noina on to the next step. Check that error cobe [911 is not being displayed. -
a)
All operations
b)
stop immediately
before interference
Cause
Remedy
Internal resistance of diode Dl5isO
There is interference
Replace
I
Go to E-17
E-22 Related electric circuit diagram
PPC lock
DO4
PPC lock D20
(ma I e) (M2) SlO (female) (M21 S14
1) ‘- -bid I r1 T,,
co2
(04Oi
CN2 (SWP12)
vo7
(X2)
1
ppc ’ OCk . cnlonnid valve
CN5 (SWP14) FBl q&J Fuse
D15 PPC lock
PC1 28UU-2
Emereencv operation
work equipment switch TJP02214
20-34 1 0
E-23
TROUBLESHOOTING
E-23 Swing does not work (when no error display is given) * * J,
Before carrying out troubleshooting, check that all the related connectors are properly inserted. Always connect any disconnected connectors before going on to the next step. The controller does not detect disconnection of the wiring in the solenoid system, so use this flow chart to check. Remedy
Cause
* Defective
.Odefective contact or disconnection in wiring harness between CO3 (female) (8) - V04 (female) (l), or defective contact or disconnection in wiring harness between V04 (female) (2) and chassis ground
2 YES Is resistance YES 1 Is monitor display of pressure switch normal?
between V04 (male) (1) and (2) normal?
Defective swing holding brake solenoid
*35-8021 NO *Turn starting switch OFF. * Disconnect V04.
electric
circuit
Replace
-
diagram
Controller )ioo*
Replace or repair wiring harness
Defective pressure switch on side where display is defective when lever is operated (See F Mode)
* Swing : P3 * Start engine. NO - Operate swing lever. * Check in monitoring mode. .%See the section on the monitor panel display in the TROUBLESHOOTING Volume.
E-23 Related
diode (D03)
Swing
Chl (SWP16)
holding
brake
,
I-
I I
5 (X2)
7h-TO3 Arm IN Pressure
m
switch
3 (X21 Left swine Pressure switch
DO3 Swing holding brake
DO6 Swine ;;;;knB
3 1x21 Right swing Pressure switch
TJP02215
20-342 0
PC1 28UU-2
E-24
TROUBLESHOOTING
E-24 Excessive hydraulic drift of swing Ir * *
Before carrying out troubleshooting, check that all the related connectors are properly inserted. Always connect any disconnected connectors before going on to the next step. Carry out out troubleshooting for the swing holding brake release switch at the CANCEL position.
Cause
So to troubleshooting lydraulic, mechanical system (See H-29)
YES
4YES
1 YES V04 (1) and chassis
3
Is resistance YES between swing 5 sec. after - holding brake release switch lever is returned to 2 p terminals normal? neutral: Max. 1 V p *When lever is Is monitor display * Automatic position: operated: 20 - 30 v _ of pressure switch Min. 1 MR * Start engine. NO normal? * Cancel position : Max. 1 .Q I
NO
between CO3
- (female) (8) and
chassis when CO3 is disconnected?
* Approx.
* Swing : P3 *Start engine. * Operate swing lever.
Is there voltage
,
it-
of
iNiring harness between CO: [female) (8) - V04 (female) (1) in contact with power source wiring harness
eplace or repail firing harness
Defective controller
:eplace
Defective swing holding brake release switch
;eplace
-
NC * Lever at neutral: Max. 1 V * Turn starting switch ON. * Disconnect C03.
NO
Remedy
_-Defective pressure switch system on side where display is defective when lever is operated (See F Mode)
E-24 Related electric circuit diagram
SrlnP
~1888ur8
Switch
holding
holding
Pressure
switch
Pressure
switch
TJP02215
PC128UU-2
20-343 0
E-25
TROUBLESHOOTING
E-25 Offset does not work (particularly * * *
left offset)
Before carrying out troubleshooting, check that all the related connectors are properly inserted. Always connect any disconnected connectors before going on to the next step. The controller does not detect disconnection of the wiring in the solenoid system, so use this flow chart to check.
Cause
Remedv
Defective diode (DOS) 1 YES
Eefective contact or disconnection in wiring harness between CO1 (male) (20) - Cl7 (male) (2)
Is resistance between Cl7 (male) (1) - (2) normal? *35-80R *zTur starting switch
Defective left offset stop solenoid
NO
Replace wiring harness
Replace
* Disconnect C17.
E-25 Related electric circuit diagram
I
DO9
I
Controller I?),
CN5(SWP14) p-J
C17tX2)
Left offset stop solenoid valve
g) 3
TJP02201
20-344 0
PC1 28UU-2
E-26
TROUBLESHOOTING
E-26 * * *
Offset does not work (particularly right offset)
Before carrying out troubleshooting, check that all the related connectors are properly inserted. Always connect any disconnected connectors before going on to the next step. The controller does not detect disconnection of the wiring in the solenoid system, so use this flow chart to check.
1
Or
YES
Defective contact or disconnection in wiring harness between CO3 (female) (15) - Cl8 (female) (2)
Is resistance between Cl8 (male) (1) - (2) normal?
Defective right offset stop solenoid
NO -35-8022 * Turn starting switch OFF. * Disconnect C18.
Replace wiring harness
Replace
E-25 Related electric circuit diagram
023 Controller 1
co3 (040 16) solenoid(t)
Ctl5 (SWP14)
m(7) 1
I
$J
Cl8 (X2)
Right offset stop solenoid valve
3 3
TJ PO2203
PC1 28UU-2
20- 345 0
E-27
TROUBLESHOOTING
E-27 Engine does not start * * *
check that all the related connectors’are properly inserted. Before carrying out troubleshooting, before going on to the next.step. connectors disconnected any connect Always check the circuit related to fuse 1 for short circuit with broken, is it (If broken. not is 1 fuse that Check chassis ground.)
a)
When starting
motor does not rotate YES 4 YES -
Is voltage between terminal B of starting motor and chassis ground normal? _ *20-30V * Turn starting switch ON.
No
YES 5 Is voltage b.et-ween terminal M of battery relay and chassrs ground normal? *20-30V * Turn starting NO switch ON.
YES
6 Is voltage between terminal B of battery relay and chassis ground normal?
-
NO *20-30V * Turn starting switch ON. ‘ES Is jumping out sound of starting motor pinion heard?.
8
1
Turn starting switch between ON and START positions.
YI
YES
Is voltage between terminal C of safety relay and chassis ground l--lnormal?
1
*20-30V - Turn starting switch to START.
.20-30V Turn starting switch ON. l
YES -
Is operating sound of battery relay heard?
n
starting motor and
NO
*Turn starting switch between ON and START positions.
and specific gravity of battery fluid I
I
* Check while engine is running.
NO
20-346 0
PC1 28UU-2
E-27
TROUBLESHOOTING
I
Cause
Remedy
eplace
I
Defective contact or lepair or replace
Leplace
Defective contact or disconnection in wiring - harness between battery terminal t+) - battery relay terminal B
lepair or replace
Defective contact or disconnection in wiring harness between safety relay terminal C-starting motor terminal S
lepair or replace
leplace
lepair or replace Is voltage betwee
*Max. 13V *Turn starting switch ON. * Max. 13 V Disconnect terminal Ft. * Turn starting switch ON.
Defective contact, disconnection or short circuit with power source in wiring harness between alternator terminal R - MO2 (female) (2)
leplace
Defective alternator
lepair or replace
Defective contact or disconnection in wiring harness between starting switch terminal C (TQ) - MO2 (female) (1)
leplace
Defective starting switch (C circuit)
;epair or replace
Defective starting motor
Ieplace
l
*20-30V -Turn starting switch to START. h
13 YES
’
Is voltage between terminal C (TO9) of starting switch and chassis ground normal?
*20-30V NO - Turn starting switch to START.
GotoA
Insufficient battery capacity
PC128UU-2
-ill up or replace
20-347 a
E-27
TROUBLESHOOTING
Cause
15 YES Is there continuity in harness between terminal E of battery relay and chassis ground?
YES r
14
A
-
Is voltage between terminal BR of battery relay and chassis ground normal?
l20-30V
-y *Turn starting switch NO OFF. -
YES 16
Is voltage between terminal BR of - starting switch and NO chassis ground normal?
* Turn starting switch ON.
I
Defective battery relay
qeplace
Defective contact or disconnection in wiring harness between battery relay E -chassis ground
Repair or replace
Defective contact or disconnection in wiring harness between starting switch terminal BR (T7) battery relay terminal BR
Repair or replace
Defective starting switch (BR circuit)
Replace
Defective contact or disconnection in wiring harness between outlet of fuse 1 - starting switch terminal B (T6)
Repair or replace
Defective contact or disconnection in wiring harness between battery terminal (+) - inlet of fuse 1
Repair or replace
Is voltage between
*20-30V * Turn starting switch ON.
starting switch and
.20-30V Turn starting switch OFF. l
18YEh Is voltage between inlet of fuse 1 and chassis ground normal? *20-30V Na -Turn starting switch OFF.
20-348 0
Remedy
PC128UU-2
E-27
TROUBLESHOOTING
E-27 a) Related electric circuit diagram
Startine
switch
D14 (KEsi 2) Ml1 (L2) link
Fusible
Safety
ry
re lay
relay
Battery
Startins
PC1 28UU-2
motor
Alternator
TJP02218
20-349 0
TROUBLESHOOTING
E-27
b): Engine stop solenoid does not work
2 YES resistance ttween engine op solenoid rminal (T2) and iassis normal?
!rminal (T2). --- ---ting switch OFF. 3 YES
l20-30V *Turn starting switch ON. NO
Is voltage between starting switch terminal ACC and chassis normal? *20-30V NO . Turn starting switch ON.
Defective engine stop solenoid
Defective contact or disconnection in wiring harness between solenoid terminal (T2) and chassis
Replace wiring harness
Defective contact or disconnection in wiring harness between starting switch terminal ACC (T12) solenoid terminal (Tl)
Replace wiring harness
Defective starting switch (between B and ACC)
Replace
E-27 b) Related electric circuit diagram
Sta
TJP02219
20-350 0
PC1 28UU-2
TROUBLESHOOTING
E-28
E-28 Engine does not stop Ir *
Before carrying dut troubleshooting, check that all the related connectors are properly inserted. Always connect any disconnected connectors before going on to the next step.
Cause
YES
1 I 1 Is voltaae between II engineStop solenoid termipal ;;r)z;$ chassis * Max. 1 V -Turn starting switch OFF.
N&
2 YES Is voltage between starting switch terminal ACC (T12) and chassis normal?
- Max.
NO 1V *Turn starting switch OFF.
E-28 Related
electric’circuit
Remedy
Defective engine stop solenoid
leplace
Contact of 24 V line with wiring harness between starting switch terminal ACC (T12) - solenoid terminal (Tl)
leplace wiring larness
Defective starting switch (between B and ACC)
{eplace
diagram
Sta
TJ PO22 I9
PC1 28UU-2
20-351 0
E-29
TROUBLESHOOTING
D-29 Wiper does not operate *
out troubleshooting, Before carrying Always connect any disconnected
*
check that all the related connectors are properly inserted. connectors before going on to the next step.
‘1
Remedy
Cause
4 YES Defective Is resistance between CN502 YES - (female) (2). (3) 3 and CN75 (female) (1). (4) normal? Is resistance p Max. 1Q YES_ between Ml8 NO * Disconnect CN502 and (female) (1) and (2) CN75. 2 normal? * Turn starting switch Is voltage between OFF. *Wiper switch YES CN75 (3) and 1R Max. ON: NO chassis ground OFF: Min. 1 ML2 normal? * Disconnect M18. 1* Turn starting switch OFF. -2O-30V l
-.
Is voltage between Ml8 (1) and chassis ground normal?
* pr.n starting switch NO
5 YES
*20-30V * Turn starting switch ON. NO
Is horn sound
wiper motor or defective wiper motor control rela; box
Defective contact or disconnection in wiring harness of circuit having improper resistance
Replace
Replace harness
Defective wiper switch
Replace
Defective contact or disconnection in wiring harness between Ml8 (female) (1) - CN75 (female) (3)
Replace harness
Defective contact or disconnection in wiring harness between fuse (3) Ml8 (female) (1)
Replace harness
Breakage of fuse
Replace
normal?
II
I
* Turn starting switch NO ON.
E-29 Related electric circuit diagram . .
r
,L:& her
Limit switch
relay
Windo~O;as CN-92
L
Wiper l-G--
motor
relay
control I T I
box
_
1 :ank
M16 Wip switch
Horn
(high
sound)
TJP02221
20-352 0
PC1 281JU-2
E-30
TROUBLESHOOTING
E-30 Engine control is abnormal f * * f
When the controller does not indicate any abnormality Before carrying out troubleshooting, check that all the related connectors are properly inserted. Always connect any disconnected connectors before going on to the next step. Check that fuel control cable is not damaged or bent sharply.
a) When engine does not start or it starts but stops soon Remedy
ES
3 YES
between motors is disconnected, does
Malfunction linkage
of fuel control
Fuel control
motor
Replace
Replace
Is voltage at K18
YES (female) terminal 2
as shown l?
in Table
between . K,, (,) an,jchassis_ - Disconnect
Is voltage
R
ground
normal?
-2O-30V *Turn starting ON.
switch
K18 and NO connect T-adapter to female side. *Turn starting switch ON.
NO
Defective one-touch deceleration controller
Replace
Breakage of fuse (3) or harness between fuse (3) K17 (female) (I)
Repair or replace harness
E-30 a) Related electric circuit diagram
One touch controller Motor
decelerator
K19
K18 (SWPG)
Throttle control
motor
drive
(+24v) One touch Motor
decelerator
drive
Accelerator
signal
Decelerator
signal
Power
signal
source
(+24V)
GND Monitor
terminal
Decelerator
signal
~~40
K16 (M2) Indicator
[t)
Indicator
(-)
One touch (M2)1 decelerator cwitr-h
K20 (M2)
w\
,--A& TJP02222
PC128UU-2
20-353 0
E-30
TROUBLESHOOTING
Table 1 Checking actuation Operation
of relay box (controller) Voltage and connector pin No. at check end
and connector pin No. at operation end
Connector pin No. K18 (female)
Type of signal
Connector pin No. K18 (female)
Operation
Voltage 20-30
Accelera_ Short (accelerator) 1
Between (2) - (5)
2
Between (2) - (6)
3
Between (2) - (3) Press knob at same time
tor signal o
Between (1) - (4)
pen (neutral)
0 (both terminals +24V) %I 20-30
Decelera_ Short (decelerator)
%I: Both terminals
Between (4) - (I)
tar signal Open (neutral) Swift Short (swift slow-down) slow-down signal Open (neutral)
1) 2) 3)
20-30 Between (4) - (I 1
0 (both terminals +24V) %I
are +24V, so 24V is measured between (1) and GND and between (4) and GND.
Note: The motor drive terminal voltage is reversed for acceleration Method
0 (both terminals +24V) El
and deceleration.
of checking actuation Disconnect K18 and connect a T-adapter to the (female) end only. Do not disconnect K17. Turn the starting switch ON, carry out the operation in Table 1,
and measure the motor drive
voltage.
Table 2 Check chart for continuity
between accelerator
motor teiminals
(when normal)
Fuel control dial position
Stop position of fuel injection pump governor lever
%
Between (2) - (5) (accelerator signal)
FULL position
Slow speed position
Connector K18 (male)
Connector K18 (male)
Between (2)- (6) (decelerator signal)
Between (2) - (3) (swift slowdown signal)
FULL position
A
A
0
Intermediate position
0
A
0
Idling position
0
A
A
Between (2) - (5) (accelerator signal)
Between (2) - (6) (decelerator signal)
Between (2) - (3) (swift slowdown signal)
0
0
A
0
0
A
A
A
.A
Troubleshooting procedure 1) Check the position where the fuel injection pump governor lever stops. 2) Connect a T-adapter to K18 (male). 3) Set the fuel control dial to the FULL or IDLING position, and measure the continuity between the terminals. *: 0 = Continuity A = No continuity If the governor lever stops at the FULL position in the chart above: i) The condition is normal if there is continuity between (2) and (3) when the fuel control dial is at FULL, or between (2) and (6) and between (2) and (3) when the fuel control dial is at slow speed position.
20-354 0
PC1 28UU-2
E-30
TROUBLESHOOTING
b)
Swift slow-down
does not work Cause
2 YES Is voltage of CN67 (female) terminal as shown in Table I?
YES
1-j
-, Does deceleration indicator light up? L
Is voltage between
YES
41 I
I
* Engine at full throttle *Turn knob switch ON. *20-30V
Defective fuel control motor
Ieplace
Defective deceleration controller
seplace
Defective contact or disconnection in wiring harness between K3 (female) (16) and Kll (female) (4)
lepair or replace
Defective chassis control controller
seplace
Defective contact, or disconnection in wiring harness between S21 (female) CNIO (7) - K3 (female) (I I), or wiring harness short circuiting with ground or defective left knob switch
lepair or replace
_
* Turn starting switch NO ON. * Disconnect CN67 and connect T-adapter Y to (female) end.
* Engine at full throttle * Turn knob switch ON.
Remedy
n
.xSame conditions as Item 4. * Disconnect S21.
6
NC
YES
GotoA
Defective contact or disconnection in wiring harness between S21 (male) - CNIO 18) - CNI (2) -chassis ground
lepair or replace
Defective left knob switch
teplace
Aj$Zj@JP I
I
,
* Turn starting NO switch OFF. *When knob switch is ON: Max. 1 Q When knob switch is OFF: Min. 1 MD * Disconnect S20 and S21.
c)
Works at near idling speed, but does not work up to full throttle
2 YES Does fuel control cable move lightly and smoothly?
YES
Is voltage between K17 (1) and GND normal?
-
%tDisconnect at motor NO end and try to move by hand.
Turn starting switch ON. NO *20-30V
l
PC128UU-2
(load becomes high)
Insufficient fuel control motor torque
Replace
Fuel control cable bent, twisted, or defective operation of governor lever
Adjust or replace
* Blown fuse (3) or defective contact or disconnection in wiring harness between fuse (3) and K17 (female) (I)
Replace Repair wiring harness or replace
20-355 0
E-30
TROUBLESHOOTING
E-30 b), cl Related electric circuit diagram
decelerator
One touch ler :ontrol Motor
K18 (SWP6)
KlS
Throttle control
motor
drive
k24V) One touch Motor
decelerator
drive
Accelerator
sional
Decelerator
sional
Power
sianal
source
(+24V)
GND Monitor
terminal signal
Decelerator
Indicator
(+I
Indicator
(-)
touch One decelerator
TJ PO2222
20-356 0
PC1 28UU-2
TROUBLESHOOTING OF CONTROLLER INPUT SIGNAL SYSTEM (F MODE)
* %
When the monitoring mode is checked, if the following input signals are not displayed or do not light up, carry out troubleshooting for that item. Note that no display is given on the monitor for problems F-6 ; the display appears only on the controller.
F- 1 Monitor
does not display [PI I (Boom RAISE pressure switch) ..................................................
20-402
F- 2 Monitor
does not display [P21 (Boom LOWER pressure switch) ................................................
20-403
F- 3 Monitor
does not display [P31 (Swing pressure switch) .............................................................
20-404
F- 4 Monitor
does not display [P5] (Arm IN pressure switch) ............................................................
20-405
F- 5 Monitor
does not display [P71 (Travel pressure switch) ..............................................................
20-406
F- 6 Monitor
does not display [Hi] (Travel speed selector switch). ...................................................
.20-407
PC128UU-2
20-401 0
TROUBLESHOOTING
F-l
F-l
Monitor does not display [PI] (Boom RAISE pressure switch)
AWhen * * *
measuring with the engine running, operate the lever slightly and make sure that the work equipment does not move. Before carrying out troubleshooting, check that all the related connectors are properly inserted. Always connect any disconnected connectors before going on to the next step. When [EE] is not displayed on the monitor panel.
I YES
Cause
I
1 Defective controller
Remedy
Replace
1
Is voltage between CO2 (8) and chassis
* Lever at neutral: 20-30V Boom RAISE operated: Max. 1 V * Start engine.
l
Is resistance
Is resistance in wiring harness between SO2 (male) _ (T) and (2) normal, NIO and js circuit msuta ‘_“pfrom chas&:
- Boom
3 in wir-
YES
p
from chassis? _
1
* BetweenSO (female) NO (I) - COP(female) (8) : Max. 1 Q * Between SOS(female) (1) -chassis : Min. 1 MC * Disconnect S02, C02.
Defective contact or disconnection in wiring harness between SO2 (female) (2) and chassis
Repair or replace
Defective contact, or disconnection in wiring harness between SO2 (female) (1) CO2 (female) (St, or wiring harness short crrcuiting with ground
Repair or replace
Defective boom RAISE pressure switch
RAISE operated: Max. 1 R NO * Lever at neutral: Min. 1 MQ * Start engine. - Disconnect S02. %lt is also possible to fit a short connector and judge the condition. In this case, check the voltage between CO2 (8) and the chassis. If it is 20 - 3OV: Go to YES * If it is less than IV: Go to NO
Replace
I
l
F-l
Related electric circuit diagram
Controller
I CO2 (04020)
RAISE Pressure switch
Boom
CN6 (SWP8) 3
I
so2 -3
3
(X2) Boom RAISE Pressure switch
TJP0.2223
20-402 0
PC128UU-2
F-2
TROUBLESHOOTING
F-2 :
A * * *
Monitor does not display [P2] (Boom LOWER pressure switch)
When measuring while the engine is running, operate the lever to a degree that the work equipment does not move. check that all the related connectors are properly inserted. Before carrying out troubleshooting, Always connect any disconnected connectors before going on to the next step. When [EEI is not displayed on the monitor panel
Cause
YES
Remedy
Defective controller
1 3 YES
Is voltage between CO2 (7) and chassis ground normal?
Is resistance between 94, SlO (female) (1) and CO2 (female) (7) normal and are they insulated from chassis?
YES 2
With lever in Is resistance neutral: 20 - 30 V between S04, SlO _ _ (male) (1) and (2) * Boom LOWER normal and are ~0 operation: * Between SO4 or SlO NO from insulated they Max. 1V (female) (1) and CO2 (female) (7): Max. 1R chassis? * Start engine. * Between CO2 and chassis: Min. 1 MQ * Boom LOWER Disconnect S04, SlO, and C02. operation: Max. 1Q * With lever in neutral NO : Min. 1 MD * Start engine. * Disconnect SO4 and SlO. .X Short connector may be installed for judgment. In this case, if voltage between CO2 (7) and chassis is - 20-30V,gotoYES * Below 1 V, go to NO
l
l
Defective contact or disconnection in wiring harness between SO4, SlO (female) (2) -chassis
Repair or replace
Defective contact, disconnection or short circuit with chassis ground in wiring harness between S04, SlO (female) (1) - CO2 (female) (7)
Repair or replace
Defective boom LOWER $z.s;ure switch No. 1 or
Replace
F-2 Related electric circuit diagram
Controller
Pressure
switch
Boom LOWER switch Pressure (NO. 1) Boom LOWER switch Pressure (NO. 2) TJP02224
PC128UU-2
20-403 0
TROUBLESHOOTING
F-3
A * * *
F-3
Monitor does not display [P3] (Swing pressure switch)
When measuring while the engine is running, operate the lever to a degree that the work equipment does not move. Before carrying out troubleshooting, check that all the related connectors are properly inserted. Always connect any disconnected connectors before going on to the next step. When [FE] is not displayed on the monitor panel Remedy
Cause
- Only swing to left
Defective left swing pressure switch
. Only swing to right
Defective right swing pressure switch
In what operation does [P31 disappear from monitor panel?
Replace
Defective contact or
3YEs disconnection in wiring
harness between SOS, S30 (female) (2) -chassis groun
YE {F[
-With lever in neutral: 20 - 30 V . Turn startina switch
Defective contact or disconnection in wiring NC harness between CO2 (female) (6) -SOS, S30 (1)
4 YES *With lever in neutral: 20 - 30 V *Turn starting switch ON.
N
chassis normal? * Disconnect C02. * Min. 1 MD *Turn starting switch OFF.
Defective controller
Short circuit with chassis ground in wiring harness NO between CO2 (female) (6) SOS, S30 (female) (1)
Repair or replac
Repair or replac
Replace
Repair or replac
F-3 Related electric circuit diagram
Controller
.
Swing Pressure
left switch
Swine r ieht Pressure switch TJP02225
20-404 0
PC1 28UU-2
TROUBLESHOOTING
F-4
A * * *
F-4
Monitor does not display [P5] (Arm IN pressure switch)
When measuring while the engine is running, operate the lever to a degree that the work equipment does not move. Before carrying out troubleshooting, check that all the related connectors are properly inserted. Always connect any disconnected connectors before going on to the next step. When [EEI is not displayed on the monitor panel Cause
II s With lever in neutral: 20 - 30 V * Arm IN operation: Max. 1V . Start enaine.
3 Is resistance between SO5 (female) (1) and CO2 (female) (18) normal and are they insulated from chassis?
YES 2
Is resistance between SO5 (male) _ (1) and (2) normal _ NO and are they insulated from sis? *Arm IN operation: -2:
YES
II -
* Between SO5 (female) (1) and CO2 (!%ale) (18): Max. 1R * Between SO5 (female) (1) and chassis: Min. 1 MR * Disconnect SO5 and C02.
Eer
in neutral: No Min. 1 MQ * Start engine. * Disconnect SO5 % Short connector may be installed for judgment. In this case, if voltage between CO2 (18) and chassis is * 20-30V,gotoYES - Below 1 V, go to NO
Remedy
Defective controller
Replace
Defective contact or disconnection in wiring harness between SO5 (female) (2) - chassis
Repair or replace
Defective contact, disconnection or short circuit with chassis ground in wiring harness between SO5 (female) (1) - CO2 (female) (18)
Repair or replace
Defective arm IN pressure switch
Replace
F-4 Related electric circuit diagram
Controller
I
CO2 (04020) Arm
IN
Pressure
switch
CN6 (SWP8)
so5 .a
-3
(X2) Arm IN Pressure
switch
TJP02226
PC128UU-2
20405 0
TROUBLESHOOTING
F-5 A * * *
F-5
Monitor does not display [p7] (Travel pressure switch)
When measuring while the engine is running, operate the lever to a degree that the work equipment does not move. Before carrying out troubleshooting, check that all the related connectors are properly inserted. Always connect any disconnected connectors before going on to the next step. When [EEI is not displayed on the monitor panel
Remedy
Cause
YES
3
YES
Is resistance between SO1 (female) (1) and CO2 (female) (17) *With lever in neutral: 20 - 30 V * Right or left travel
between SO1 (male)
NO * Between SO1 (female) (1) and CO2 (female) (17): Max. 1Q f Between harness and chassis: Min. 1 MQ * Disconnect SO1 and C02.
operation: * Travel ._ _.
* lZtl:Er in neutral: No Min. 1 MD . Start engine. * Disconnect SO1 I Short connector may be installed for judgment. In this case, if voltage between CO2 (17) and chassis is * 20-30V,gotoYES * Below 1 V, go to NO
Defective controller
Replace
Defective contact or disconnection in wiring harness between SO1 (female) (2) - chassis
Repair or replace
‘kir%%c%%tshort circuit with chassis ground in wiring harness between SO1 (female) (2) - CO2 (female) (17) Defective travel pressure switch
Repair or replace
Replace
F-5 Related electric circuit diagram DO2
so1 (X2)
CN2 (SWP 121
Trave’ Pressure
Travel
switch
alarm
Fuse i TJP02227
20-406 0
PC1 28UU-2
TROUBLESHOOTING
F-6 % * *
F-6
Monitor does not display [Hi] (Travel speed selector switch)
Displayed on only the display unit of the controller. : Before carrying out troubleshooting, check that all the related connectors are properly inserted. Always connect any disconnected connectors before going on to the next step.
Cause
3
YES *When switch is ON: Max. 1 V *When switch is OFF: Min. 4 V *Turn starting switchN ON.
2
..
.-
H
1R NO * Disconnect M25 (seesaw switch)
* Max.
between M25 or M39 (male) (1) and (2) normal? . When switch is ON:
Is resistance between M25 or M39 (female) (1) chassis normal?
YES
or M39 (pedal switch). *Turn starting switch OFF.
1
. ?
Remedy
Iefective controller
ieplace
Iefective contact or fisconnection in wiring larness between M25 of v139 (female) (2) - CO1 female) (12)
leplace harness
Iefective contact, iisconnection or short :ircuit with chassis ground n wiring harness between kl25 or M39 (female) (1) :hassis
teplace harness
Defective travel speed selector switch
{eplace
F-6 Related electric circuit diagram Controller
CN-? (S,WP,l2)V05 (X2)
Travel
speed
CO1 (MICh Travel
TT
Hi switch I
FBl mj
1
Fuse
3
selection
switch
OFF ON
1
02
2
M25 (M2)
DO7
Trave I speed
PC128UU-2
x
Ml39 (M2)
a-3
I
I
-
sel ect ion
Trave I Hi-Lo select ion swi tch
TJP02209
20-407 0
TROUBLESHOOTING OF HYDRAULIC, MECHANICAL SYSTEM (H MODE) Table of failure modes and causes . .. . ... . .. .. .. .. .. ... .. ... . .. . .. .. ... . . .. . . . .. .. .. . ... . .. .. ... .. . . ... . . .. .. .. . . .... .. ... .. . ... . .. .. .. .. . 20-502 H- 1 All work equipment,
travel, and swing speed or power is low ..................................
H- 2 Engine speed lowers remarkably H- 3 Work equipment
. .............. 20-504 .20-505
or engine stalls.. ...................................................................
does not move at all and machine does not travel or swing ....................... or response is low.. .......................................................................................
H- 5 Fine controllability
20-506 20-506
sound comes out (from around pump) .....................................................................
H- 4 Abnormal
20-507
H- 6 Boom speed or power is low.. ......................................................................................................
20-507
H- 7 Arm speed or power is low ..........................................................................................................
20-508
.:.............. 20-509
H- 8 Bucket speed or power is low ......................................................................................
H- 9 Blade speed or power is low ........................................................................................................
20-509
H-10 Offset speed or power is low.. ......................................................................................................
20-510
H-l 1 Work equipment
or blade) does not move.. ........... .20-511
(Boom, arm, bucket, offset mechanism,
H-12 Hydraulic drift (Boom, arm, bucket, or blade) is large ...............................................................
20-51 1
H-13 Time lag is long (Engine speed is low) ........................................................................................
20-512
H-14 When work equipment
is relieved independently,
other work equipment
H-15 Speed of heavier operation is slower during compound H-16 Boom RAISE speed is low during compound boom SWING and RAISE operations.. H-17 Travel speed lowers during compound equipment H-18 Machine
or swinging
operation
move.. ................. .20-512 20-512
operation ......................................... of
20-513
......................................................................................... operation
of work
and travel ...............................................................................................
20-513
i.. ............ 20-514
deviates.. ..........................................................................................................
20-515
H-19 Travel speed is low ........................................................................................................................ H-20 Steering condition
-20-516
is bad or steering force is low.. ...................................................................
20-518
H-21 Travel speed does not change ...................................................................................................... H-22 Machine
does not travel (Only one side). ....................................................................................
H-23 Machine
does not swing .............................................................................................
20-518
..- ............... 20-519
a) When machine does not swing in either direction.. ..............................................................
.20-519
b) When machine does not swing in only derection ..................................................................
20-519
H-24 Swing acceleration
or swing speed is low in either clirection ....................................
b) When swing acceleration
or swing is low in only one derection
H-25 Work equipment
20-520
or swing speed is low ..................................................................................
a) When swing acceleration
.........................
20-520
.:.............. 20-520 20-521
overruns ............................................................................................................
a) When work equipment
overruns
b) When work equipment
pverruns in only derection
in either direction
..............................................................
20-521
...............................................................
20-521
H-26 Large shock is made when machine stops swinging
(In only one direction)
H-27 Large noise is made when machine stops swinging
................................................................
..........................
H-28 Hydraulic drift of swing is large ...................................................................................................
20-522 .20-522 20-523
a) When swing holding brake is applied .....................................................................................
20-523
b) When swing holding brake is released ..................................................................................
.20-523
H-29 Error code [911 is displayed on monitor panel and all of boom RAISE, arm IN, and offset LEFT operations
stop just before machine interferes .................................
H-30 Boom RAISE, arm IN, and offset LEFT operations automatically
PC128UU-2
and machine interferes
20-524
do not stop
.........................................................................................
20-524
20-501 0
TROUBLESHOOTING
TABLE OF FAILURE MODES AND CAUSES
TABLE OF FAILURE MODES AND CAUSES -
T
Parts causing failure
-
Main pump
Control valve
-
-
r”
P
z
-5
Y
z
‘3 :
i ii,
$
Failure mode
All work eauipment,
travel, and swina soeed or Dower is low
Enaine soeed lowers remarkablv
or enaine stalls
Work equipmentdoesnot moveat all and machinedoes not travel or swing Abnormal
sound comes out (from around pump)
Fine controllability
or response is low
-
Bucket speed or power is low
-
Offset speed or power is low
-
Blade speed or power is low
-
Boom does not move
-
Arm does not move
-
Bucket does not move
-
does not work
-
Blade does not move Hvdraulic drift (Boom, arm, bucket, or blade) is larae laa is lona (Enaine soeed is low)
When work equipment is relieved independently, other work equipment move Speed of heavier operation is slower during compound operation Boom raising speed is low during compound boom SWING and RAISE operations Travel speed lowers during compound equipment or swinging and travel
-
Machine deviates laraelv at start
Steering condition is bad or steering force is low Travel speed does not change
-
Machine does not travel (Onlv one side)
Swing acceleration or swing speed is low
-
operation of work
Travel soeed is low
Machine does not swing
-
operation of
Machine deviates largely during constanttravel
Machine deviates
-
Arm soeed or Dower is low
iime
I -
Boom speed or power is low
Offset mechanism
-
In either direction
-
In only one direction In either direction In Onlv one direction
-
Work equipment
overruns
In either direction In only one direction
Lame shockis madewhen machinestoesswinaina(In onlv one direction) Larae noise is made when machine stoos swinaina Hydraulic drift of swing is large
20-502 0
When swing holding brake is applied When swing holding brake is released
-
I
F 6 f ? z E F u 5 z : 2? - Ei
E ?
&I
22
8
_c
1 dz 2
5 -
F
E
s 9 rn
zr z- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- --- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- i
0
I”
5 2 F 22 h F
6 z
e zz- I ---z-- - - zI - ---- ---- ---- ---- ---- ---- ---- ---- ---- ---- ---- ---- ---- ---- ---- ---- ---- ---- --- z- - - ---- ---- ---- ---- ---- ---- ---- ---- ---- ---- ----
i?! F
-
z
s 1 .gj 5 b
5 : 0 5
g s i: B g ; ? <
I -
-
-
B
-
5 6 6 i
z -
-
I -
PC128UU-2
Failure mode
7
7
Engine system
2-stage relief
PPC lock
cylinder
0
WNd
7
0
Hydraulic
Travel speed selector
Motor
Final drive
solenoid
valve
3
v) -5% SZ 5
8-I
Travel speed selector
valve and piston
ti “: (P
Check valve
valve
Counterbalance
H-l
TROUBLESHOOTING
H-l
All work equipment,
travel, and swing speed or power is low
Before starting diagnosis, check that abnormal sound is not heard from the pump. sound is heard, perform H-4.)
(If any abnormal
Cause
4 YES -
Defective main pump.
Remedy
Rlepair or replace
YE 3 Is output pressure of PC valve (input pressure of servo
YE
2 l
YE
pressure (output pressure reducing * 3.24 * 0.49 MPa I33 * 5 kg/cm21 * Run engine at full throttle.
Is main pump relief pressure normal? * 31.87 :;j; MPa {325+:zkg/cm? * Run engine-at full N throttle. *Relief arm.
*See TESTING AND ADJUSTING.
See TESTING AND ADJUSTING.
IO
6 YES
NC
A
Defective PV valve or PCEPC valve
A;epair or replace
Defective main relief valve
Rlepair or replace
Defective unload valve
Rlepair or replace
Defective self-pressure reducing valve
R;epair or replace
FH_
* 2.7: i., MPa
NO
{28:&kg/cm2> . Run engine at full throttle.
0
5 YES
[Pressure reducing valve, LS :ircuit) R,epair or replace Malfunction of main valve
pressure normal? NO * 2.2 + 0.1 MPa {22.5 f 1 kg/cm21 * Run engine at full throttle. Run travel mechanism on one side idle.
Defective pump LS valve
Replace
l
Note: Referring to TESTING AND ADJUSTING, devices of the control circuit.
20-504 0
Testing and adjusting control circuit oil pressure, test the
PC128UU-2
H-2
TROUBLESHOOTING
H-2 * *
Engine speed lowers remarkably
or engine stalls
Before starting diagnosis, check that the emergency pump release switch is under the normal condition. Before starting diagnosis, check that the main pump relief pressure is normal.
Cause
YE
r
Is orifice for pump servo clogged?
3
YES
Remedy
Clogging of orifice for pump servo
Clean
Defective servo piston
Xepair or replace
WIIs output pressure of PC valve (input pressure of servo piston) normal?
% See below.
NO
Defective engine system (Go to S mode troubleshooting)
i
* See TESTING AND ADJUSTING.
Defective PC valve
iepair or replace
Defective PC-EPC valve
seplace
Is output pressure _ of PC-EPC valve _ II normal? .
NO
l
Engine speed to relieve pump when engine and pump are normal Conditions
Engine speed to relieve arm l
2,220 f 100 rpm
l
Run engine at full throttle. With arm at stroke end, operate lever to FULL side slowly, and read lowest engine speed during this operation.
PC1 28UU-2
20-505 0
H-3
TROUBLESHOOTING
H-3
Work equipment or swing
does not move at all and machine does not travel
Cause
3 YES Is voltage between V07 (1) and chassis ground normal?
YES
YES
1 I Is main PPC
pressure (output oressure of self-
I
Is PPC lock lever limit switch normal?
NO
1
Defective PPC lock solenoid valve
Replace
Defective chassis harness
Repair or replace
Defective self-pressure reducing valve
Repair or replace
Defective main pump
Repair or replace
Defective PTO
Repair or replace
II u
YES * 3.24 t 0.49 MPa {33 * 5 kg/cm21 * Run engine at full throttle.
Remedy
4
-
NO
If main pump outlet hose is disconnected, does oil flow out of pump?
5 YES p Does main pump
NO
shaft rotate?
NO
20-506 0
PC128UU-2
H-4, H-5
TROUBLESHOOTING
H-4
Abnormal sound comes out (from around pump)
Cause
3 YES
Remedy
Go to 4.
j-
YE
H
NO
L
Hydraulic oil of bad quality
Replace hydraulic oil
Clogging of suction strainer with foreign matter (cloth, etc.)
Remove foreign matter
Are there bubbles in hydraulic tank?
Y
4
Is suction strainer clogged with foreign matter?
No Is oil level in hydraulic tank normal?
4
I
% With foreigh matter
5 ‘ES Internal defect of main 1
F
Is suction strainer clogged with metalhc matter or are metal chips sticking to drain plug?
pump
Operate for a while and see i NC change of condition.
Hydraulic oil of bad quality
H-5
Fine controllability
Repair or replace
Test again (accordin to change o9 condrtion)
Replace hydraulic oil
or response is low
‘ES
Clogging of orifice for pump servo
Clean
Defective LS valve
Replace
Defective servo piston
Replace
Is orifice for pump
2 YES If LS valve is _ replaced, does 1 pump operate normally?
_
NO
PC1 28UU-2
20-507 0
TROUBLESHOOTING
H-6
H-6
Boom speed or power is low
5 YES YE
YE
Is main pump relief pressure normal?
FH_
* Max. 15 cc/min *Run engine at full throttle..
3
YES 2
YE 1
Does spool of valve move smoothly?
I6 * 31 .BZ ;:;z MPa I325 Z g kg/cm21 * Run engine at full N throttle.
YES
pressure reducing valve piston free
NO
*This valve may be replaced with another one. Note) Be sure to return borrowed one after testing, however.
- control I
Is pressure compensation valve (Pressure reducin valve piston, wow control valve and pressure reducing valve) normal and does it move smoothly?
NO
t
Is output pressure 1
valve normal?
NO
* 3.24 + 0.49 MPa (33 f 5 kg/cm?) * Run engine at full throttle. * Operate lever fully.
20-508 0
PC128UU-2
H-7, H-8, H-9
TROUBLESHOOTING
Cause
H-7 *
l l
Replace
Defective hydraulic cylinder
Replace
Malfunction of flow control valve or pressure reducing valve
Repair or rep1
Malfunction of control valve spool
Repair or repl
Develo&ent
Replace
PPC valve
Arm speed or power is low
Bucket speed or power is low
See diagnosis
H-9 Ir
Malfunction of suction valve
See diagnosis mode [H-6]. Add arm regeneration check valve to the Cause column on YES side of Step 5, however. (The remedy column is not changed.)
H-8 *
Remedy
mode [H-61.
Blade speed or power is low
See diagnosis mode [H-6]. For the main pump relief pressure in Step 4, however, see the following. Blade RAISE relief pressure: 31.87’ i:g MPa 1325’ i” kg/cm21 Blade LOWER relief pressure: 32.36 + 1.47 MPa (330 + 15 kg/cm21
PC1 28UU-2
20-509 0
H-10
TROUBLESHOOTING
H-10 Offset speed or power is low
I
A YE!
3
I
I
J YES
N
Is output pressure of PPC valve on PPC valve side 1normal? I
- 3.0 f 0.5 MPa 130 f 5 k&m21 - Run engine at full throttle.
YES
hydraulic cylinder . Max. 15 cc/min * Run engine at full throttle.
1
1 NO
20-5 10 0
u 3
Llalfunction of flow control valve or pressure reducing valve
Vlalfunction of control valve
NO
Vlalfunction of left offset stop solenoid valve
Iefective
PPC valve
iepair or replace
iepair or replace
?eplace
ieplace
Vlalfunction of suction valvf
ieplace
Defective hydraulic cylinder
ieplace
Defective main relief valve of unload valve
Replace
Defective pressure reducing valve piston
Repair or replacr
NO
YES
valve piston free
n
Remedy
P
SPOOI
- 3.0 + 0.5 MPa (30 * 5 kg/cm21 *Run engine at full throttle.
I
pressure normal?
Is pressure compensation - Left offset: valve (Pressure 31.87: A;%MPa YES reducin valve I325: $ kg/cm21 - piston, 8ow control - Right offset: valve and pressure 27.0? 1.47 MPa reducing valve) 2 normal and does it 1275 f 15 kg/cm21 move smoothly? - Run engine at full Does control valve throttle. * This valve may be Yl ‘5 spool move replaced with NO smoothly? another one. 1 Note) Be sure to return borrowed V one after testing, however. of PPC valve on control valve side
Cause
PC1 28UU-2
I
H-II,
TROUBLESHOOTING
H-II *
H-12
Work equipment (Boom, arm, bucket, offset mechanism, or blade) does not move (Machine travels and swings normally, however)
When the boom, arm, bucket, offset mechanism,
or blade is operated singly
Cause
of PPC valve on control valve side * 3.0 + 0.5 MPa (30 * 5 kg/cm21 * Run engine at full throttle. R
NO - 3.0 ?r0.5 MPa f30 f 5 kg/cm? -Run engine at full throttle. _ Arm OUT, bucket, blade
Remedy
Defective control valve
Repair or replace
Defective solenoid valve for stopping
Repair or replace
Defective PPC valve
Replace
Defective PPC valve
Replace
H-12 Hydraulic drift (Boom, arm, bucket, or blade) is large
I
Remedy
Cause
valve seat
YES
If suction valve or suction safety valve (blade) is replaced, is hydraulic drift normal?
1
I
Boom, arm, bucket
L Blade
hydraulic cylinder
Defective centralized safety valve
iepair or replace
Repair or replacf
valve is replaced,
NO
_ Low oil-tightness of control panel spool
Replace
Defective hydraulic cylinder
Replace
Arm, bucket
Low oil-tightness of control panel spool
Replace
Boom
Defective boom lock valve
Repair or replacl
* Run engine at full throttle.
I NO
PC1 28UU-2
N()
20-511 0
H-13, H-14, H-15
TROUBLESHOOTING
H-13 T?me lag is long (Engine speed is low)
Cause
m,., press_& reduding valve piston move smoothlv?
1 YES
n
valve may be NO replaced with another one. * Be sure to return borrowed one after testing, however.
- Each
H-14 When work equipment ment move
Remedy
Defective suction valve
Replace
Defective flow control valve, pressure reducing valve, or pressure reducing valve piston
Repair or replace
is relieved independently,
other work equip-
*:r”-..
InsufficIent pressure relieve from main spool
H-15 Speed of heavier operation is slower during compound operation Compound
operation
Heavier load side
Lighter load side
1
Boom RAISE + Arm IN
Boom RAISE
Arm IN
2
Boom RAISE + Arm OUT
Arm OUT
Boom RAISE
3
Boom RAISE + Bucket CURL
Boom RAISE
Bucket CURL
4
Arm OUT + Bucket CURL
Arm OUT
5 ) Boom LOWER + Arm OUT
20-5 12 0
( Arm OUT
I
Bucket CURL
1 Boom LOWER
PC128UU-2
H-16,
TROUBLESHOOTING
H-16 Boom RAISE speed is low during compound SWING and RAISE operations *
When single swing operation
operation
H-17
of boom
is normal
Cause
1 YES Is circuit pressure of LS selector valve normal?
NO * 2.4 - 3.6 MPa 124 - 37 kg/cm? -Run engine at full throttle. * Raise boom fully. - Outlet of shuttle valve.
Remedy
Malfunction of LS selector valve
Repair or replace
Defective boom RAISE PPC valve
Repair or replace
H-17 Travel speed lowers during compound operation of work equipment or swinging and travel *
When swing operation
and single travel operation
are normal
Cause
r
1 If pressure reducing valve of travel pressure compensation valve is replaced, is travel speed normal?
NO
Defective travel pressure reducing valve
H 2 YES
If piston of swing or work equipment pressure reducing valve is replaced, is travel speed normal?
NO
PC1 28UU-2
Remedy
Defective piston of swing or travel pressure reducing valve
Replace
Malfunction of travel flow control valve
Replace
20-513 0
H-18
TROUBLESHOOTING
H-l 8 Machine deviates a)
When machine deviates
during constant
travel Cause
crefective
pressure valve or nialfunction of pressure C ompensation valve spool
Repair or replace
refective travel motor assembly
Repair or replace
hAalfunction of control valve NC )s pool
Repair or replace
3 YES Tlf flow control valve I and pressure reducing valve on YE . both sides are exchan ed with each ot R r, does machine deviate inversely? t
4 YE6 ic
YES interconnection
1
hJalfunction of irlterconnection
UO
pressure between both pilot signals of interconnection
C ompensation
I
Does spool of control valve on slower side move smoothly? H
valve
lefective PPC valve -(: Defective spring or check ” ,alve)
5
Remedy
Repair or replace
Replace
If travel PPC spring case replaced, i NO does machine
6
travel normally?
NO
If interconnection valve assembly is replaced, does machine travel normally?
YES
When machine deviates
Replace
jefective main valve Spool, spring)
NO
b)
cdefective ball check valve in irIterconnection valve block
Replace
at start
Table 1 Cause counterbalance
20-5 0
14
I valve
Remedy
I Repair
or replace
I I
PC128UU-2
TROUBLESHOOTING
H-19
H-19 Travel speed is low
Cause
3 YES
YE
I
NO
Malfunction of travel pressure reducing valve
Replace
Malfunction of main spool
Replace
See MACHINE DEVIATES
Replace
Defective travel PPC
Replace
1 Low in only one direction
Is travel PPC
pressure normal?
N
PC1 28UU-2
in both directions
Remedy
20-515 0
H-20
TROUBLESHOOTING
H-20Steering condition is bad or steering force is low
2 1
I In both directions i
$~~~~i~~~s
4 YES
/ EH_
R
1
1
1
3 NO
When travel pump is relieved, is pump discharge pressure normal?
Is steering condition bad in both directions or in one direction?
5 YES
1 Nl
* 2.35 - 3.6 MPa NO (24 - 37 kg/cm?) * Run engine at full throttle. * Move travel lever a little. 6 YES
In only one direction _
If pressure compensation valve (flow control valve + pressure reducing valve) on both sides _ are exchanged with each other, is steerin condition normal.$ NO
YES
7 If suction valve of control valve is replaced, is steering condition inverted?
8 YES If travel motor suction valves are Ng
:;$%R::,Th steerin condition normal.3
-
NO
20-5 16 0
PC128UU-2
TROUBLESHOOTING
H-20
I
.
PC128UU-2
Cause
I
Remedy
improper adjustment or malfunction of pump PC valve
Repair or replace
Defective center swivel joint
Repair or replace
Defective main relief valve
Repair or replace
Defective 2-stage relief solenoid valve
Repair or replace
Malfunction of pressure compensation valve or pressure compensation piston
Repair or replace
Malfunction of suction valve of control valve
Repair or replace
Defective travel motor check valve
Replace
Defective travel motor safety valve
Replace
20-517 0
H-21, H-22
TROUBLESHOOTING
H-21 Travel speed does not change
1 YES
I
NO * 2.4 - 3.6 MPa {24 - 37 kg/cm21 * Run engine at full throttle. * Travel speed selector switch: HIGH (ON)
Defective travel motor speed selector valve and piston
Replace
Defective travel speed selector solenoid valve
Replace
H-22 Machine does not travel (Only one side)
Cause
YES
1
2
Is foreign matter drained from final
-
YE
drive?
If suction valves of control valves on both sides are exchanged with each other, does machine travel
2 N
Is draining rate of -
NO
Defective final drive
Ieplace
Iefective suction valve of :ontrol valve
Ieplace
QVE
Iefective safety valve of ravel motor
Xeplace
K
Defective counterbalance lalve of travel motor
Xeplace
Iefective travel motor
Xeplace
vES
If safety valves of travel motor on both sides are exchanged with
travel motor normal? *lOe/min * Run engine at full throttle. * Relieve travel motor.
20-518 0
Remedy
Nl
NO
PC1 28UU-2
TROUBLESHOOTING
H-23
H-23 Machine does not swing a)
When machine does not swing in either direction
Cause
3 YES
I
YE 2
NO
-320 C 10 kg/cm? * Run engine at full throttle.
brake solenoid
-2.35 - 3.6 MPa (24 - 37 kg/cm*) N'0 . Run engine at full throttle. . Swing lock switch: OFF . Move swing lever or arm IN lever a little.
b)
fective swing machinery
lepair or replace
fective swing motor or ing holding brake
;epair or replace
fective swing motor ‘ety valve
lepair or replace
fective swing holding rke solenoid valve
lepair or replace
EH_
YEiS 1
Remedy
When machine does not swing in only one direction
Cause
YES 2 YES -
1 Is output pressure
If swing motor suction valves are exchanged with each other, is condition inverted? p * Exchange both _ VdVeS with each NO other.
of PPC valve
* Exchange both valves with each other.
- 2.4
- 3.6 MPa (24 - 37 kg/cm21 . Run engine at full throttle. -Operate lever fully.
PC1 28UU-2
3
NO
YES
If swing motor check valves are exchanged with each other, is condition inverted?
NO
T
Remedy
Defective swing motor suction valve
Repair or replace
Defective swing motor check valve
Repair or replace
Defective control valve spool
Repair or replace
Defective PPC valve
Repair or replace
20-519 0
H-24
TROUBLESHOOTING
H-24 Swing acceleration or swing speed is low a)
When swing acceleration
or swing speed is low in either direction
Cause
Remedy
Defective swing motor safety valve
Repair or replace
Defective swing motor or parking brake
Repair or replace
replaced, swing condition is
b)
When swing acceleration
or swing speed is low in only one direction
Cause
YES
I
2
I If swina motor -11 vcc I suctiorTvalves are I I IL= ex;kan$ ;ith condition ihverted?
I
1
1
l
output pressure
of PPC valve normal?
I
* 2.4 - 3.6 MPa {24 - 37 kg/cm9 * Run engine at full throttle. * Operate lever fully.
20-520 0
Exchange both with each other.
VdVeS
t-l 1
NO
~0
-
YES
3 If swing motor check valves are exchanged with each other, if condition inverted?
I * Exchanae
both valves with each other.
Remedy
Iefective swing motor ;uction valve
tepair or replace
Iefective swing motor :heck valve
Iepair or replacs
-
II
NO
Iefective control valve ipool
Defective PPC valve
Repair or replac’
PC128UU-2
TROUBLESHOOTING
H-25
H-25 Work equipment a)
overruns
When work equipment overruns in either direction (When throttling of PPC circuit and operation of control valve spool are normal)
Cause
YES
1 If swing motor safety valve is replaced, does work equipment stop normally?
Defective swing motor safety valve
Repair or replace
Defective swing motor
Repair or replace
-
NO
b)
Remedy
When work equipment
overruns in only one direction
Cause
Remedy
Defective PPC valve
Repair or replace
Defective swing motor suction valve
Repair or replace
Defective swing motor :heck valve
Repair or replace
Defective control valve WOOI
Repair or replace
1
If PPC valve hoses are exchanged with each other, is condition inverted?
2 suction valves are
N
3 YES
condition inverted?
p$jgiyJI
NO
PC1 28UU-2
20-521 0
H-26, H-27
TROUBLESHOOTING
H-26 Large shock is made when machine stops swinging (In only one direction)
Cause
1 YES
Remedy
Defective PPC valve
leplace
Malfunction of control valve spool
leplace
Does control valve spool move smoothly?
NO
H-27 Large noise is made when machine stops swinging
Cause
YES
Defective swing motor safety valve
I
If safety valve is
I Y
replaced, does 2
N0
20-522 0
Remedy
Seplace
3efective swing motor suction valve
3 YES
swing machinery? NO
Defective swing machinery
iepair or replace
Jefective back pressure valve
Repair or replac
PC128UU-2
H-28
TFtOUBLESHOOTlNG
H-28 Hydraulic drift of swing is large ’
a)
When swing holding brake is applied
Cause
1
.
YES
Isoutput pressure of swing holding brake solenoid valve normal? A - 0 MPa {O kg/cm*) NG *Start engine. -5 set or more after swing lever is set in neutral
b)
YES
2
Remedy
Defective swing motor holding brake
Repair or replace
Defective swing holding brake solenoid valve
Repair or replace
Defective swing PPC pressure switch Replace
Replace
Is swing PPC pressureswitch
-
normal?
NO
When swing holding brake is released
Cause
YES 21
1 Ononly
large on only one side or on both
Defective swing motor suction valve
repair or replace
Defective swing motor check valve
lepair or replace
Defective pressure compensation valve and pressure compensation piston
tepair or replace
Defective swing motor safety valve
Xepair or replace
Defective control valve spool
?eplace
Defective swing motor
iepair or replace
suction valves are
one side
3
YES
If swing motor check valves are exchanged with NO each other, is i condition Inverted?
H
NO
4
- On both sides
i
If swing motor safety valves are exchanged with each other, is condition inverted?
II
Is leakage from
n
swing motor normal?
I
PC128UU-2
Remedy
l-l II I
kC
20-523 0
TROUBLESHOOTING
H-29, H-30
H-29 Error code [91] is displayed on monitor panel and all of boom RAISE, arm IN, and offset LEFT operations stop just before machine interferes Check that water is not in the potentiometer (C21, C22, and C23).
*
connectors
of the boom, arm, and offset mechanism
Cause
Malfunction of solenoid valve
H-30 Boom RAISE, arm IN, and offset LEFT operations matically and machine interferes *
Remedy
Repair or replace
do not stop auto-
If this failure occurs, the failure of H-32 occurs, too.
Cause
1 YES
Remedy
Defective controller
Replace
Malfunction of PPC lock solenoid valve (It does not return)
Repair or replace
Does PPC lock solenoid valve move smoothly? NO
20-524 0
PC1 28UU-2
TROUBLESHOOTING OF MONITOR SYSTEM (M MODE)
Electric circuit diagram of monitor system .. .. . ... .. . .. . .. . . .. .. .. ... ... .. .. .. . .. .. . .. . . . . .. .. .. . .. .. . .. ... . .. .. .. . . ... . .. . .. .. .. .. .. 20-602 M- 1
After starting switch is turned to ON position,
....................................
20-603
M- 2
After starting switch is turned to ON position, self-check items (which should light up for 3 set) are turned on but not turned off.. .......................................
20-603
After starting switch is turned to ON position, some of self-check items (which should light up for 3 set) are not turned on .................................................................
20-604
M- 3
M- 4 M- 5
nothing is displayed..
a) No gauges (Fuel, engine coolant temperature) are turned on Pre-heatin pilot lamp does not light up.. ............................................................................... b) Caution lamps (Engine oil pressure, charge) do not light up.. ............................................ c) Electric system caution lamp does not light up ................................................................... After starting switch is turned to ON position (before engine is started), charge caution lamp does not light up .........................................
20-604 20-604 20-604 20-605
After starting switch is turned to ON position (before engine is started), engine oil pressure caution lamp does not light up ....................
20-606
pilot lamp does not light up.. ... 20-607
M- 6
After starting switch is turned HEAT position, pre-heating
M- 7
Engine oil pressure caution lamp lights up while engine is running
M- 8
Charge caution lamp lights up while engine is running ..........................................................
20-609
M- 9
Abnormality
gauge .................................................................
20-610
in engine coolant temperature
.....................................
20-608
a) Even if engine is operated for long time, coolant temperature level does not rise at all .......................................................................................................... ’ b) Level rises soon after engine is started (to red range while engine is not overheated). c) Related electric circuit diagram M-10
Abnormality
in fuel gauge ..........................................................................................................
a) All segments
M-l 1
.............................................................................................
of fuel gauge go off .........................................................................................
20-610 .. 20-610 20-610 20-611 20-611
b) Fuel gauge indicates full while fuel is lowered ....................................................................
20-611
c) Fuel gauge does not indicate full even if fuel tank is full.. ...................................................
20-612
Malfunction
of alarm buzzer .......................................................................................................
20-613
a) Buzzer does not sound ............. . .............................................................................................
20-613
b) Buzzer does not stop sounding.. ............................................................................................
20-613
Service meter does not operate while engine is running ........................................................
20-614
a) When charge level caution lamp does not light up .............................................................
20-614
b) When charge level caution lamp lights up ...........................................................................
20-614
Lamps do not light up at night ...................................................................................................
20-615
a) Lamp for gauges does not light up .......................................................................................
20-615
b) Lamp for service meter does not light up .............................................................................
20-615
M-14
Electric system caution lamp keeps lighting up .......................................................................
20-615
M-15
Heater does not work ..................................................................................................................
20-617
M-12
M-13
PC1 28UU-2
20-601 0
ELECTRIC CIRCUIT DIAGRAM
TROUBLESHOOTING
ELECTRIC CIRCUIT DIAGRAM OF MONITOR
Controller
SYSTEM
SYSTEM R05
2.2Kcl , ., i
OF MONITOR
(~6)
...j
relay
ZL d
.
itch
FBl itch PO2
(M2)
1
Light
PO4
relay
(M2) Buzzer
CN-
Battery
D14 relavH
,06 (xII)
i7,
Fualfil
sensor
r
E20
(SWP8)
PO7
(X2)
Batte
itcJfiCOOlant Alternator
(IDWuessard
temperature
wsens
TJP02228
20-602 0
PC1 28UU-2
M-l,
TROUBLESHOOTING
M-l * * *
After starting switch is turned to ON:position,
M-2
nothing is displayed
Before carrying out troubleshooting, check that all the related connectors are properly inserted. Always connect any disconnected connectors before going on to the next step. Before carrying out troubleshooting, check fuse 2.
VFS
Defective monitor panel
PO1 (female) (1) and (3) normal? .20-30V * Turn starting switch ON.
Defective contact or disconnection in wiring harness between PO1 (female) (1) -fuse or between PO1 (female) (3) chassis ground
2 YES
-
NO
Is fuse 2 normal?
-
Broken fuse 2
NO
M-l
I
Replace
Repair or replace harness
Remove cause 01 breakage of fuse, then replace fuse
Related electric circuit diagram Fusible
Monitor
link
Panel
~,po1), Power
source
(+24V)
TJP02229
M-2 * *
After starting switch is turned to ON position, self-check items (which should light up for 3 set) are turned on but not turned off
Before carrying out troubleshooting, check that all the related connectors are properly Always connect any disconnected connectors before going on to the next step.
Defective monitor panel
PC1 28UU-2
inserted.
Replace
20-603 0
M-3
TROUBLESHOOTING
M-3
After starting switch is turned to ON position, some of self-check items (which should light up for 3 set) are not turned .on
*
Before carrying out troubleshooting, check that all the related connectors are properly inserted. 9~ Always connect any disconnected connectors before going on to the next step.
a)
No gauges (Fuel, engine coolant temperature) Pre-heating pilot lamp does not light up
are turned on
Remedy
Cause
Defective monitor panel
b)
Caution lamps (Engine oil pressure, charge) do not light up
Cause
I
IIs bulb broken?
YES
Broken bulb
II_
- Visually check bulb for breakage.
c)
Replace
I
Remedy
Replace
-
Go to M-4.
NO
Electric system caution lamp does not light up Cause
I
YES
Remedy
Ebroken bulb
Replace
IIefective monitor panel
Replace
Is bulb of items which is not turned on broken? . Visually check bulb for breakage.
NO
:
20-604 0
PC 128UU-2
M-4
TROUBLESHOOTING
M-4 Ir -k
After starting switch is turned to ON position started), charge caution lamp does not light up
(before engine is :
Before carrying out troubleshooting, check that all the related connectors tire properly inserted. Always connect any disconnected connectors before going on to the next step.
Cause
YES 1 Is voltage between PO1 (female) (IO)
-
2 YES
and (3) normal? * Start engine. * 27.5 - 29.5 v
Is voltage between alternator terminal R and chassis ground normal?
~0
Remedy
Defective monitor panel
eplace
Defective contact or disconnection in wiring harness between PO1 (female) (10) -alternator terminal R
tepair or replace larness
Defective alternator * Start engine. * 27.5 - 29.5 V
M-4
Related electric circuit diagram
Monitor
Panel
I
Alternator
PO1 (04016) Battery
charge
TJP02230
PC1 28UU-2
20-605 0
M-5
TROUBLESHOOTING
M-5 * *
After starting switch is turned to ON position (before engine is started), engine oil pressure caution lamp does not light up
Before carrying out troubleshooting, check that all the related connectors are properly Always connect any disconnected connectors before going on to the next step.
Cause
2
I
* Max. 0.5R * Disconnect (+I terminal of sensor 617). *Turn starting switch OFF.
M-5
YES
* Disconnect POl. *Turn starting switch OFF.
NO
inserted.
Remedy
Defective monitor panel
Replace
Defective contact or disconnection in wiring harness between PO1 (female) (9) - S17 (Harness side)
Repair or replace harness
Defective engine oil pressure switch
Replace
Related electric circuit diagram
Monitor
Panel I
PO1 (04016)
CbJ-2 (SWP12)
E20 (SWP8)
Engine oil Pressure switch
TJP02231
20-606 0
PC1 28UU-2
TROUBLESHOOTING
M-6 f *
M-6
After starting switch is turned HEAT position, pre-heating pilot lamp does not light up
Before carrying out troubleshooting, check that all the related connectors are properly inserted. Always connect any disconnected connectors before going on to the next step.
Cause
YES
I Is voltage between PO1 (13) and (3) normal?
-
*Turn starting switch to HEAT position. *20-30V
M-6
Related
Monitor
I
NO
electric
circuit
I
Remedy
Defective monitor panel
Replace-
Breakage of harness between PO1 (female) (13) starting switch terminal Rl or defective starting switch
Rep&r. or replace
diagram
Panel
I PO1 (04016)
Start
ina
switch
TJ PO2232
PC1 28UU-2
20-607 0
M-7
TROUBLESHOOTING
M-7 f * *
Engine oil pressure caution lamp lights up while engine is running
Before carrying out troubleshooting, check that all the related connectors are properly inserted. Always connect any disconnected connectors before going on to the next step. When the engine oil pressure is normal.
Cause
YES 1 Does engine oil pressure caution lamp go off? p * Disconnect S17. * Start engine.
-
2 YES *
Defective engine oil pressure switch
Replace
Defective monitor panel
Replace
Is PO1 (female) (9) _ insulated from
NO chassis ground?
Short circuit with chassis
, ground in harness between
NO
Repair or replace harness
PO1 (female) (9) - S17
*Min. 1 MQ * Disconnect PO1 and S17. * Turn starting switch OFF.
M-7
Remedy
Related electric circuit diagram
Monitor
Panel
I
PO1 (04016)
w-2 (SWP12)
E20 (SWP8)
Eneine oil Pressure switch
@cl-
TJP02231
20-608 0
PC128UU-2
M-8
TROUBLESHOOTING
M-8 * * *
Charge caution lamp lights up while engine is running
Before carrying out troubleshooting, check that all the related connectors are properly Always connect any disconnected connectors before going on to the next step. When the battery is charged normally.
Remedy
Cause
2 YES II
. Defective monitor panel
Short circuit with chassis ground in harness between PO1 (female) (IO) - alternator terminal R Insufficient generation by alternator
* Start engine. I - Measure voltage NO between alternator terminal R and chassis ground. -27.5 - 29.5 V
M-8
inserted.
Replace
Repair or replace
Replace
Related electric circuit diagram
Monitor
Panel I
PO1 (04016)
w-2 (SWP12) -yj
Alternator
El7 (X2) 3
-o
--oR 0
TJP02230
PC1 28UU-2
20-609 0
M-9
TROUBLESHOOTING
M-9 *
Abnormality
in engine coolant temperature
gauge
* *
Before carrying out troubleshooting, check that all the related connectors are properly inserted. Always connect any disconnected connectors before going on to the next step. When the engine coolant temperature is normal.
a)
Even if engine is operated for long time, coolant temperature
level does not rise at all Remedy
Cause
YES
Does level rise 1 by 1, then go off?
2 YES
- Turn starting switch _ Does level rise 1 by NO 1, then go off? ON. *Connect shorting I connector to P07. * Short PO1 (6) with (3)F10 * See Note 1). See Note 1). -Turn starting switch ON. l
l
b)
Defective engine coolant temperature sensor
Replace
Defective contact or disconnection in wiring harness between PO1 (female) (6) - P7 (female) (1) or between P2 (female) (2) chassis ground
qepair or replace larness
Defective monitor panel
Replace
Note 1) If normal, level rises 1 by 1 at interval of 2 sec.
Level rises soon after engine is started (to red range while engine is not overheated) Remedy
Cause
2 YE 1
PO1 (3) and chassis
YES
. Start engine. * Min. 4 kA2 Disconnect P07.
Defective engine coolant temperature sensor
NO
l
Start engine. *Max. 0.1 V
Defective contact or disconnection in wiring harness between PO1 (female) (3) -chassis ground
l
M-9
Replace
Defective monitor panel
Is resistance between PO7 (male) (1) and (2) normal?
NO
Repair or replace harness
Related electric circuit diagram
clq-2 (SWPl2) 3 lonitor
panel
3
I
PO1 (04016) _
Cbj-1 (SWP16) 3
E20 (SWP8)
PO7 (x2)
3
-----a
3
-3
Coolant temperature
I TJP02235
20-6 10 0
PC128UU-2
M-10
TROUBLESHOOTING
M-10 Abnormality
in fuel gauge
* * *
Before carrying out troubleshooting, check that all the related connectors are properly inserted. Always connect any disconnected connectors before going on to the next step. When the fuel level is normal.
a)
All segments
of fuel gauge go off Cause
2 YES
12 Does fuel gauge indicate full (Do all _ segments light up)?
. Short PO1 (7) with NO (3). *Wait for about 1 min. -Turn starting switch ON.
* Short PO6 (female) (1) with chassis NO ground. Wait for about 1 min. *Turn starting switch ON.
Remedy
Defective fuel level sensor (Internal wire breakage)
7eolace
Defective contact or disconnection in wiring harness between PO1 (female) (7) - PO6 (female) (1) or between (4 terminal of fuel level sensor - chassi: ground
lepair or replace iarness
Defective monitor panel
leolace
l
b)
Fuel gauge indicates full while fuel level is lowered
Cause
3 YES
Remedy
Defective monitor panel
Replace
Short circuit with chassis ground in wiring harness between PO1 (female) (7) PO6 (female) (1)
Repair or replace harness
Defective fuel level sensor
Replace
Defective contact or disconnection in wiring harness between PO1 (female) (3) - chassis grounc
Repair or replace harness
YES
2-r
YE
level sensor normal?
_
etr
*Disconnect P06. NO Wait for about 1 min. Turn starting switch ON. l l
Is voltage between PO1 (3) and chassis
* Start engine. * Max. 0.1 V
PC128UU-2
. Remove sensor. * Move float with hand and measure NO resistance between PO6 (male) (1) and chassis * %%~‘04; F. Max 1OR * Position El Min.‘85R * Disconnect PO6
20-611 0
M-10
TROUBLESHOOTING
c)
Fuel gauge does not indicate full even if fuel tank is full.
2 YES YES 1
Is resistance level sensor normal?
of fuel _
Is voltage between PO1 (3) and chassis ground normal? p * Start engine. - Max. 0.1 V
Defective
monitor
panel
Replace
NO
* Remove sensor. *rny;z;;;r;ith handNO
Defective contact or disconnection in wiring harness between PO1 (female) (3) -chassis ground
Repair or replace harness
Defective
Replace
fuel level sensor
resistance between PO6 (male) (1) and chassis ground. * Position F: Max. 10R * Disconnect P06.
M-10
Related electric circuit diagram
Monitor
Panel
7
PO 1 (040 16)
CN-2
Fuel level sensor
TJP02236
20-612 0
PC1 28UU-2
M-l 1
TROUBLESHOOTING
M-II *
Malfunction
of alarm buzzer
*
Before carrying out troubleshooting, check that all the related connectors are properly inserted. Always connect any disconnected connectors before going on to the next step.
a)
Buzzer does not sound
Cause
I
Remedv
Replace
Defective contact or disconnection in wiring harness between PO4 (female) (1) - PO1 (female) (15) or defective buzzer
’ NO *20-30V * Turn starting switch ON.
* Turn starting switch ON. _...
b)
Defective contact or disconnection in wiring harness between battery relay terminal M - PO4 (female) (2) or breakage of fuse 5
Repair or replace harness
Repair or replace !I I
Buzzer does not stop sounding Cause
YES
I If PO1 is disconnected, does buzzer stop?
NO * Disconnect POl. *Turn starting switch ON.
I
Remedy
Defective monitor panel
Replace
Short circuit with chassis ground in wiring harness between PO1 (female) (15) PO4 (female) (1)
Repair or replace harness
M-l 1 Related electric circuit diagram
Fusible
Monitor
link
Panel
Buzzer
I PO1 (04016) output
GND
CN-2 (SWP12) Battery
II
IIII
+
-11
I@ TJP02237
PC128UU-2
20-613 0
M-12
TROUBLESHOOTING
M-12 Service meter does not operate while engine is running * *
Before carrying out troubleshooting, check that all the related connectors are properly inserted. Always connect any disconnected connectors before going on to the next step.
a)
When charge level caution lamp does not light up
I Is voltage between PO1 (female) (10) and (3) normal? * Start engine. *20-30V
b)
YES
Defective monitor panel
-
b2. Short circuit with chassis ground in wiring harness between PO1 (female) (10) - El7 (female) (2)
NO
When charge level caution lamp lights up
Cause
Repair or replace harness
1
Remedy
Defective monitor panel
Replace
Short circuit with chassis ground in wiring harness between PO1 (female) (10) alternator terminal R
Repair or replace
1
Insufficient generation alternator -
*-----I Start engine. . Measure voltage NO between alternator terminal R and chassis ground. - 27.6 - 29.5 V
M-12
Replace
by
Replace
Related electric circuit diagram
Monitor
Panel
1
PO1 (04016)
ck2 csWP12)
Alternator
El7 (X2)
---la I1
I
a3 0
R
0
TJP02238
20-614 0
PC1 28UU-2
M-13
TROUBLESHOOTING
M-13 Lamps do not light up at night * *
Before carrying out troubleshooting, check that all the related connectors are properly inserted. Always connect any disconnected connectors before going on to the next step.
a)
Lamp for gauges does not light up I.-. Remedy -.
Cause
Breakage of bulb for lighting at night (inside monitor panel)
YES 1 Is voltage between PO1 (female) (16) and (3) normal?
-
2
Defective contact or disconnection in wiring harness between PO1 [female) (16) - R03 (female) 15)
YES
lf relay R03 is replaced with *Disconnect POl. _ another one of same *Turn starting NO type, does lamp switch ON. light up normally? *Turn light switch ON. *Turn starting switch NO -2O-30V ON. . Turn light switch ON. .20-30V
b)
Defective relay R03 for light
Replace
I Repair or replace hamess
Replace
Lamp for service meter does not light up Remedy
Cause
Defective monitor panel
M-13
Related electric circuit diagram
Light
relay
Battery
R03 (R6)
Monitor
Panel
I
PO1 (04016)
I
FB1
d&T11
Battery
relay
I
Fuse TJP92239
PC128UU-2
20-615
M-14
TROUBLESHOOTING
M-14 Electric system caution lamp keeps lighting up :(Controller displays no abnormality * *
and operation is normal)
Before carrying out troubleshooting, check that all the related connectors are properly Always connect any disconnected connectors before going on to the next step.
Cause
YES 1 Is voltage between PO1 (11) and (3) normal? -
* Max. 1 V * Turn starting switch ON.
-
2 YES ) If CO3 (female) (11) is connected to chassisground, does caution lamp go off?
NO
-Turn starting switch ON.
M-14
r
NO
inserted.
Remedy
Defective monitor panel
Replace
Defective controller
Replace
Defective contact or disconnection in wiring harness between PO1 (female) (11) - CO3 (female) (14)
Repair or replace harness
Related electric circuit diagram
Monitor
Controller
Panel
PO1 (04Oi6)
CO3 (04016)
TJP02238
20-6 16 0
PC1 28UU-2
M-15
TROUBLESHOOTING
M-15 Heater does not work * *
check that all the related connectors are properly inserted. Before carrying out troubleshooting, before going on to the next step. connectors Always connect any disconnected
a)
Heater does not work in either position of Lo and Hi
See troubleshooting heater.
+ Disconnect M06. * Au,r,: starting switch ‘N,
b)
of
Defective contact or disconnection in wiring harness between MO6 (female) (4) - chassis grc
Repair or replace
Defective heater switch
Replace
Heater does not work in only Lo position Remedy
Cause
2 YES Is there continuity in harness between Ml2 (female) (2) and chassis ground?
Yf 1
NO - Disconnect M12. * Set heater switch to Lo position. - PFp starting switch
between MO6 (male) (3) and (4)? - Disconnect M06.
See troubleshooting heater.
of
Defective contact or disconnection in wiring harness between MO6 (female) (3) - Ml2 (female) (2)
Iepair or replace
Defective heater switch
ieplace
-Turn starting switch OFF.
c)
Heater does not work in only Hi position
I YES 1 Is there continuity between MO6 (male) (2) and (4)?
I
See troubleshooting
I
Is there continuity in harness between Ml2 (female) (3) and chassis ground?
NO *Disconnect M12. * Set heater switch to Hi position. * Turn starting switch OFF.
* Disconnect M06. - Set heater switch to NO Hi position. -Turn starting switch OFF.
PC1 28UU-2
T
Remedy
of
b2. Defective contact or disconnection in wiring harness between MO6 (female) (3) - Ml2 (female) (2)
Repair or replace
Defective heater switch
Replace
20-6 17 0
M-15
TROUBLESHOOTING
’ M-15
Related electric circuit diagram
switch
Heater
OFF LOW 1
_ HI
M~~(KES~
h112 (KES~ 3)
4)
g
3
@
3
@
Fuse
3
HYE__switch I I
--! 1
I
r% TJP02241
20-618 0
PC128UU-2
TROUBLESHOOTING OF ENGINE (S MODE)
Method of using troubleshooting charts ............................................................................................. 20-702 S- 1 Starting performance is poor (Starting always takes time) ...................................................... 20-706 S- 2 Engine does not start ................................................................................................................... 20-708 (1) Engine does not turn ............................................................................................................. 20-708 (2) Engine turns but no exhaust smoke comes out (Fuel is not being injected) .................... 20-709 (3) Exhaust smoke comes out but engine does not start (Fuel is being injected) ................. 20-710 S- 3 Engine does not pick-up smoothly (Follow-up is poor) ............................................................ 20-711 S- 4 Engine stops during operations .................................................................................................. 20-712 S- 5 Engine does not rotate smoothly (Hunting) ............................................................................... 20-713 S- 6 Engine lacks output (or lacks power) .......................................................................................... 20-714 S- 7 Exhaust gas is black (incomplete combustion) .......................................................................... 20-715 S- 8 Oil consumption is excessive (or exhaust gas is blue).............................................................. 20-716 S- 9 Oil becomes contaminated quickly ............................................................................................. 20-717 S-10 Fuel consumption is excessive .................................................................................................... 20-718 S-11 Oil is in cooling water, or water spurts back, or water level goes down ................................. 20-719 S-12 Oil pressure caution lamp lights up (Drop in oil pressure) ....................................................... 20-720 S-13 Oil level rises (Water, fuel in oil) ................................................................................................. 20-721 S-14 Water temperature becomes too high (Overheating) ............................................................... 20-722 S-15 Abnormal noise is made .............................................................................................................. 20-723 S-16 Vibration is excessive ................................................................................................................... 20-724
PC128UU-2
20-701 (6)
TROUBLESHOOTING
METHOD OF USING TROUBLESHOOTING CHARTS
METHOD OF USING TROUBLESHOOTING CHARTS This troubleshooting chart is divided into three sections: questions, check items, and troubleshooting. The questions and check items are used to pinpoint high probability causes that can be located from the failure symptoms or simple inspeciton without using troubleshooting tools. Next, troubleshooting tools or direct inspection are used to check the high probability causes to make final confirmation. [Questions] Sections A + B in the chart on the right corresponds to the items where answers can be obtained from the user. The items in B are items that can be obtained from the user, depending on the user’s level. [Check items] The serviceman carries out simple inspection to narrow down the causes. The items under C in the chart on the right correspond to this. The serviceman narrows down the causes from information A that he has obtained from the user and the results of C that he has obtained from his own inspection. [Troubleshooting] Troubleshooting is carried out in the order of probability, starting with the causes that have been marked as having the highest probability from information gained from [Questions] and [Check items].
Causes
A
Questions
(b) (2) (3)
(a)
w w
(b) w
(c) (d)
c c
B
Troubleshooting
C
Check items
(e)
20-702 (6)
i ii iii
b b b
PC128UU-2
METHOD OF USING TROUBLESHOOTING CHARTS
inje ctio n)
Causes
Seiz
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 !, and of these, causes that have a high probability are marked with T. Check each of the [Questions] and [Check items] in turn, and marked the ! or T in the chart for items where the problem appeared. The vertical column (Causes) that has the highest number of points is the most probable cause, so start troubleshooting for that item to make final confirmation of the cause. ª1. For [Confirm recent repair history] in the [Questions] Section, ask the user, and mark the Cause column with # to use as reference for locating the cause of the failure. However, do not use this when making calculations to narrow down the causes. ª2. Use the # in the Cause column as reference for [Degree of use (Operated for long period)] in the [Questions] section as reference. As a rule, do not use it when calculating the points for locating the cause, but it can be included if necessary to determine the order for troubleshooting.
ed t urbo cha Clog rger ged , int air c erfe lean Wor renc er e n pi e lem ston e n ring Clog t , cyl ged inde , sei r zed Imp inje rope ctio r inj n no e ctio Defe zzle n tim ctiv e in ing ject ion pum p (e xces sive
TROUBLESHOOTING
ª1
Confirm recent repair history
ª2
Degree of use
Operatred for long period
w
PC128UU-2
20-703 (6)
TROUBLESHOOTING
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
Causes
Legend : Possible causes (judging from Questions and check items) : Most probable causes (judging from Questions and Check items) : Possible causes due to length of use (used for a long period) : Items to confirm the cause.
Seiz ed t Clog urboch arge ged r, in air Wor terfe n pis cleaner elem rence ton Clog ring ent ged , cyli , se nde Imp r rope ized inje r c tion inje Defe ctio ctiv n tim nozzle e in ing Imp rope jection pum r va Cru lve p (e she c xces le d, c aran sive logg Lea ce inje kag e d ctio muf e of n) fler Defe air b ctiv etw e e e con n tu Deff t a r ectiv boc ct o harg f va e in lve, er a ject valv ion nd h e se pum ead at p (ra ck, p lung er s eize d)
•
METHOD OF USING TROUBLESHOOTING CHARTS
Confirm recent repair history Degree of use
Operated for long period
Questions
Suddenly became black Color of exhaust gas
Gradually became black Blue under light load
Engine oil must be added more frequently Power was lost
Suddenly Gradually
Non-specified fuel has been used Noise of interference is heard from around turbocharger Dust indicator is red Blow-by gas is excessive
Check items
Engine pickup is poor and combustion is irregular When exhaust manifold is touched immediately after starting engine, temperature of some cylinders is low Match marks on fuel injection pump are out of alignment Seal on injection pump has come off Clanging sound is heard from around cylinder head Exhaust noise is abnormal Muffler is crushed Leakage of air between turbocharger and head, loose clamp When turbocharger is rotated by hand, it is found to be heavy When air cleaner is inspected directly, it is found to be clogged
Troubleshooting
When compression pressure is measured, it is found to be low Speed of some cylinders does not change when operating on reduced cylinders When check is made using delivery method, injection timing is found to be incorrect Injection pump test shows that injection amount is incorrect When valve clearance is checked directly it is found to be outside standard value When muffler is removed, exhaust gas color returns to normal
20-704 (6)
Replace
Repair
Replace
Adjust
Replace
Adjust
Adjust
Replace
Replace
Clean
Remedy
Replace
When control rack is pushed, it is found to be heavy or does not return
PC128UU-2
TROUBLESHOOTING
METHOD OF USING TROUBLESHOOTING CHARTS
Five causes Step 1 Clarify the relationship between the three symptoms in the [Questions] and [Check items] section and the five Cause items in the vertical column.
Three symptoms
Step 2 Add up the total of and marks where the horizontal lines for the three symptoms and the vertical columns for the causes intersect. (1) Clogged air cleaner element: (2) Air leakage between turbocharger and head: (3) Clogged, seized injection nozzle: (4) Defective contact of valve, valve seat: (5) Worn piston ring, cylinder: Step 3 The calculation in Step 2 show that the closest relationship is with [Clogged air cleaner element]. Follow this column down to the troubleshooting area and carry out the troubleshooting item marked . The Remedy is given as [Clean], so carry out cleaning, and the exhaust gas color should return to normal.
PC128UU-2
20-705 (6)
TROUBLESHOOTING
S-1
S-1 Starting performance is poor (Starting always takes time) General causes why exhaust smoke comes out but engine takes time to start Defective electrical system Insufficient supply of fuel Insufficient intake of air Improper selection of fuel (At ambient temperature of -10ºC or below, ASTM D975 No. 2 diesel fuel is used)
Causes
n pi ston Defe ring , cyl ctive inde cont Clog r act o ged f val a i r ve, v clea Clog ner ged elem alve sea fuel t Clog ent filte ged r, st rain feed e Elec r p ump trica gau l int ze fi ake lter air h eate r
• • • •
fl Battery charging rate Ambient temperature
Charging rate
20°C 0°C –10°C
90 %
80 %
75 %
70 %
1.28 1.29 1.30
1.26 1.27 1.28
1.24 1.25 1.26
1.23 1.24 1.25
1.22 1.23 1.24
The specific gravity should exceed the value for the charging rate of 70% in the above table. In cold areas the specific gravity must exceed the value for the charging rate of 75% in the above table.
•
Wor
•
100 %
Questions
Confirm recent repair history Degree of use of machine
Operated for long period
Ease of starting
Gradually became worse Starts when warm
Indicator lamp does not light up Engine oil must be added more frequently Replacement of filters has not been carried out according to operation Manual Non-specified fuel has being used Dust indicator lamp is red Battery charge lamp is ON Starting motor cranks engine slowly When exhaust manifold is touched immediately after starting engine, temperature of some cylinders is low
Check items
Engine does not pick up smoothly, and combustion is irregular Blow-by gas is excessive Timing lock on fuel injection pump does not match Mud is stuck to fuel tank cap When engine is cranked with starting motor, 1) Little fuel comes out even when injection pump piping sleeve nut is loosened 2) Little fuel comes out even when fuel filter air bleed plug is loosened Leakage from fuel piping There is hunting from engine (rotation is irregular) When compression pressure is measured, it is found to be low When air cleaner element is inspected directly, it is found to be clogged
Troubleshooting
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 Heater mount does not become warm Is voltage 26–30V between alternator terminal B and terminal E with engine at low idling?
Yes No
Either specific gravity of electrolyte or voltage of battery is low Speed does not change when operation of certain cylinders is stopped When control rack is pushed, it is found to be heavy or does not return (check after removing fuel injection pump)
20-706 (6)
Replace
Clean
Clean
Clean
Correct
Remedy
Replace
When fuel tank cap is inspected directly, it is found to be clogged
ª Use a test stand
PC128UU-2
PC128UU-2
Replace
Replace
Clean
Correct
Replace
ªAdjust
Replace
Replace
Replace
Replace Defe ctive regu Defe lato ctive r a ltern Defe ator ctive or d Defe eter ctive iora ted injec Defe batt tion tive ery nozz injec le Defe tion tive timi injec ng Leak tion age, p ump clog (rac Clog ging k, pl ged , air ung a i i n r er st brea fuel Defe uck) ther pipi ctive ng h o f e l e in ed p Defe fuel ump ctive tank boo st co mpe nsat or c ance l
TROUBLESHOOTING S-1
Causes
20-707
(6)
TROUBLESHOOTING
S-2
S-2 Engine does not start (1) Engine does not turn Causes
General causes why engine does not turn
fl If internal parts of the engine are seized, carry out troubleshooting for "Engine stops during operations". Defective electrical system Failure in power train
Confirm recent repair history Degree of use of machine Operated for long period Condition of horn when Horn sounds starting switch is turned Horn volume is low ON Speed of rotation is low When starting switch is Makes grating noise turned to START, pinion Soon disengages pinion again moves out, but Makes rattling noise and does not turn When starting switch is turned to START, pinion does not move out When starting switch is turned to ON, there is no clicking sound
20-708 (6)
Replace
—
Replace
Remedy
Replace
For the following conditions 1) - 5), turn the starting switch OFF, connect the cord, and carry out troubleshooting 1) When terminal B and terminal C of starting switch are connected, engine starts 2) When terminal B and terminal C of starting motor are connected, engine starts 3) When terminal B and terminal C of safety relay are connected, engine starts 4) When terminal of safety switch and terminal B of starting motor are connected, engine starts 5) There is no 24V between battery relay terminal b and terminal E When ring gear is inspected directly, tooth surface is found to be chipped Cannot be moved by hand even when linkage of fuel cut solenoid is disconnected
Replace
Troubleshooting
Specific gravity of electrolyte, voltage of battery is low
Replace
When battery is checked, battery electrolyte is found to be low
Replace
When starting switch is turned ON, linkage is not actuated
Replace
Battery terminal is loose
Replace
Check items
Questions
• •
Defe ctiv ew iring Defe ctiv of s e or tarti Defe dete ng c ctiv rior ircu e st ated it artin Bro batt ken gm ery r o i n t or g ge Defe ar ctiv e sa fety Defe rela ctiv y or e ba Defe ttery safe ctiv ty s r e lay e ba witc Defe ttery h ctiv t e rmin e fu el cu al co Defe t so nne ctiv leno e st ctio artin n id g sw itch
Internal parts of engine seized
Troubleshooting of defective wiring in starting circuit
•
PC128UU-2
TROUBLESHOOTING
S-2
(2) Engine turns but no exhaust smoke comes out (Fuel is not being injected) General causes why engine turns but no exhaust smoke comes out Supply of fuel impossible Supply of fuel is extremely small Improper selection of fuel (particularly in winter)
★
Standards for use of fuel AMBIENT TEMPRATURE
KIND OF FLUID
-4 -20
14 -10
32 0
50 10
68ºF 20ºC
ASTM D975 No.2
Diesel fuel
Bro
ASTM D975 No.1
ken inje ctio Defe n pu ctiv mp e in driv ject Seiz ion e sh ed, pum aft, brok key p (ra en f Clog ck, p eed ged p lung fuel ump Clog er s filte pist ged eize r, st on d) feed rain Insu e p r u ffici mp ent stra fuel Clog iner in ta ged , lea nk Clog king ged fuel air b pipi Defe reat ng ctiv her e hole fuel Imp in fu cut rope sole el ta r fue noid nk l us ed
• • •
Causes
Questions
Confirm recent repair history Degree of use of machine Operated for long period Exhaust smoke suddenly stops coming out (when starting again) Replacement of filters has not been carried out according to Operation Manual Fuel tank is found to be empty There is leakage from fuel piping Mud is stuck to fuel tank cap Check items
When starting switch is turned ON, linkage is not actuated When fuel filter is drained, fuel does not come out When engine is cranked with starting motor, 1) No fuel comes out even when fuel filter air bleed plug is loosened 2) No fuel spurts out even when injection pump piping sleeve nut is loosened Rust and water are found when fuel tank is drained
Troubleshooting
Inspect injection pump directly When control rack is pushed, it is found to be heavy, or does not return Inspect feed pump directly 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 When fuel cap is inspected directly, it is found to be clogged
PC128UU-2
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Remedy
Replace
Cannot be moved by hand even when linkage of fuel cut solenoid is disconnected
20-709 (6)
TROUBLESHOOTING
S-2
General causes why exhaust smoke comes out but engine not start •
Lack of rotating force due to defective electrical system Insufficient supply of fuel Insufficient intake of air Improper selection of fuel and oil
Defe
• • •
Causes ctive , bro Defe ken valv ctiv e sys e in ject tem Wor ion (valv n pi pum e, ro ston p (ra cker Clog ring leve ck, p ged , cyl r, etc lung inde fuel Clog .) e r f r i l l stuc i t ner ged er, s k) f t e r a e iner d pu Clog mp ged stra air c Defe iner l e ane ctiv r ele e el men ectr Defe ical t ctiv inta e or ke a Lea dete i kag r he rior e, cl ater ated ogg Clog b a i n ttery ged g, a ir in inje Clog ctio fuel n no ged syst zzle a em i r br Imp , defe eath rope ctiv er h r fue e ole spra l us in fu y ed el ta nk c ap
(3) Exhaust smoke comes out but engine does not start (Fuel is being injected)
Confirm recent repair history Degree of use of machine Operated for long period Questions
Suddenly failed to start When engine is cranked, abnormal noise is heard from around cylinder head Engine oil must be added more frequently Non-specified fuel is being used Replacement of filters has not been carried out according to Operation Manual Rust and water are found when fuel tank is drained Dust indicator lamp is red Indicator lamp does not light up Starting motor cranks engine slowly Mud is stuck to fuel tank cap When fuel lever is placed at FULL position, it does not contact stopper
Check items
When engine is cranked with starting motor, 1) Little fuel comes out even when injection pump piping sleeve nut is loosened 2) No fuel comes out even when fuel filter air bleed plug is loosened There is leakage from fuel piping
Troubleshooting
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 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 When air cleaner element is inspected directly, it is found to be clogged Heater mount does not become warm Either specific gravity of electrolyte or voltage of battery is low When feed pump is operated, there is no response, or operation is too heavy Speed does not change when operation of certain cylinders is stopped
20-710 (6)
Clean
Clean
Correct
Replace
Correct
Clean
Clean
Clean
Replace
Replace
Remedy
Replace
When fuel tank cap is inspected directly, it is found to be clogged
PC128UU-2
TROUBLESHOOTING
S-3
S-3 Engine does not pick-up smoothly (Follow-up is poor)
Causes
General causes why engine does not pick up smoothly Insufficient intake of air Insufficient supply of fuel Improper condition of fuel injction Improper fuel used
Clog ged air c Clog lean ged er e lem f uel Clog ent filte ged r, st feed rain Clog er pum ged p st inje rain Seiz ctio er ed i n no njec zzle tion , de Wor fect pum n pi ive p pl ston spra Seiz ung ring y er ed t , cylin urbo d Imp e c harg r lin rope er er, i r va nter Clog lve fere clea ged nce ranc air b e Clog reat her ged hole , lea Defe king in fu ctiv fuel el ta e co nk c pipi ntac ng ap t of valv e an d va lve seat
• • • •
Questions
Confirm recent repair history Degree of use of machine Operated for long period Replacement of filters has not been carried out according to Operation Manual Non-specified fuel is being used Engine oil must be added more frequently Engine pick-up suddenly became poor Rust and water are found when fuel tank is drained Dust indicator lamp is red Noise of interference is heard from around turbocharger Color of exhaust gas
Blue under light load Black
Check items
Clanging sound is heard from around cylinder head 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
Troubleshooting
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 Speed does not change when operation of certain cylinders is stopped 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 When turbocharger is rotated by hand, it is found to be heavy When valve clearance is checked directly, it is found to be outside standard value When fuel tank cap is inspected directly, it is found to be clogged
PC128UU-2
Replace
Correct
Clean
Adjust
Replace
Replace
Replace
Correct
Clean
Clean
Remedy
Clean
When feed pump is operated, operation is too light or too heavy
20-711 (6)
S-4
TROUBLESHOOTING
S-4 Engine stops during operations General causes why engine stops during operations Seized parts inside engine Insufficient supply of fuel Overheating
Causes ken , sei zed Bro pist ken on, , sei co n zed Brok nec cran en d ting ksha ynam ro d ft be Bro i c va ken a ring lve s , sei ys te Bro zed m ( ken gea valv pum r tra e, ro in p au Bro c k er ken x leve i l i ary fuel r, et equ Insu pum c.) ipm ffici p driv ent ent e sh fuel Clog aft, in ta ged key nk fuel Clog filte ged r, st rain feed Bro er pum ken p st , sei rain z Clog ed f er eed ged , lea pum king Clog p pi ston fuel ged pipi air b Defe ng r e a ther ctiv e in hole ject Fail in fu ion ure el ta pum in p nk owe p (r a r tra c k , in plun ger stuc k)
• • •
fl If there is overheating and the engine stops, carry out troubleshooting for overheating. •
Failure in power train
Bro
fl If the engine stops because of a failure in the power train, carry out troubleshooting for the chassis.
Questions
Confirm recent repair history Degree of use of machine Operated for long period Abnormal noise was heard and engine stopped suddenly Condition when engine Engine overheated and stopped stopped Engine stopped slowly There was hunting and engine stopped Replacement of filters has not been carried out according to Operation Manual Non-specified fuel is being used Fuel level lamp lights up Fuel tank is found to be empty When feed pump is operated, operation is too light or too heavy
Check items
Mud is stuck to fuel tank cap Engine rotates, but stops when power train is operated Does not turn at all When it is attempted to turn by hand using barring tool
Turns in opposite direction Moves amount of backlash Shaft does not turn Troubleshooting of chassis
Rust and water are found when fuel tank is drained Metal particles are found when oil is drained Remove oil pan and inspect directly Troubleshooting
Remove head cover and inspect directly When gear train is inspected, it does not turn Rotates when pump auxiliary equipment is removed 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 Inspect feed pump directly
20-712 (6)
Replace
Clean
Correct
Replace
Replace
Clean
Clean
Add
Replace
Replace
Replace
Replace
Remedy
Replace
When control rack is pushed, it is found to be heavy, or does not return —
PC128UU-2
S-5
TROUBLESHOOTING
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 (engine with electric governor)
Causes
Defe ctiv e op Defe erat ctiv ion e ad of g Defe ove just rn o r men ctiv e op t of gov Low erat erno ion idlin of c r g sp Insu ontr eed ffici o l rac is to ent k o fuel Clog in ta low ged nk feed Clog pum ged p st fuel rain Clog f ilter er ged, , stra air in iner Clog c i rcuit ged, betw air in een Clog circu fuel ged it be tank air b t w and een reat feed feed her pum pum hole p p an in fu d no el ta zzle nk
• • •
fl If hunting stops when electric governor rod is disconnected, carry out troubleshooting for the chassis.
Confirm recent repair history
Questions
Degree of use of machine Operated for long period Occurs at a certain speed range Condition of hunting
Occurs at low idling Occurs even when speed is raised Occurs on slopes
Replacement of filters has not been carried out according to Operation Manual Fuel tank is found to be empty Rust, water are found when fuel tank is drained
Check items
Leakage from fuel piping When feed pump is operated, 1) No response, light, return is quick 2) No response, light, return is normal Engine speed sometimes rises too far Engine is sometimes difficult to stop Seal on injection pump has come off
Troubleshooting
When governor lever is moved it is found to be stiff When injection pump is tested, governor is found to be improperly adjusted When control rack is pushed, it is found to be heavy, or does not return When fuel tank cap is inspected directly, it is found to be clogged When feed pump strainer is inspected directly, it is found to be clogged
PC128UU-2
Clean
Correct
Correct
Clean
Clean
Add
Adjust
Adjust
Adjust
Remedy
Adjust
When fuel filter, strainer are inspected directly, they are found to be clogged
20-713 (6)
TROUBLESHOOTING
S-6
S-6 Engine lacks output (or lacks power) General causes why engine lacks output
•
Clog
fl If there is overheating and lack of output, carry out troubleshooting for overheating.
Seiz
Insufficient intake of air Insufficient supply of fuel Improper condition of fuel injection Improper fuel used (if non-specified fuel is used, output drops) Lack of output due to overtaking
ged air c lean ed t er e urbo lem Wor cha ent rger n pi , int ston erfe Clog ring renc ged , cyl e inde fuel Clog r filte ged r , s f t e r a ed p Clog ump iner ged stra inje Seiz iner c tion ed i noz njec zle, Imp tion defe rope pum ctiv r va p pl e sp Defe lve u ray nge clea ctiv r ranc e co e ntac Ben t fue t of valv l lev Clog e an er li ged nka d va ge, , lea lve d k seat Clog efec ing fuel tive ged adju pipi a i r brea Defe ng stm ther ent ctiv e bo hole Defe o s in fu t co ctiv el ta mpe ew estg nk nsa t ate diap or diap hrag hrag m m
Causes
• • • •
Confirm recent repair history Degree of use of machine Operated for long period
Questions
Power was lost
Suddenly Gradually
Engine oil must be added more frequently Replacement of filters has not been carried out according to Operation Manual Non-specified fuel is being used Dust indicator lamp is red Color of exhaust gas
Black Blue under light load
Noise of interference is heard from around turbocharger Blow-by gas is excessive
Check items
Engine pickup is poor and combustion is irregular High idling speed under no load is normal, but speed suddenly drops when load is applied When exhaust manifold is touched immediately after starting engine, temperature of some cylinders is low There is hunting from engine (rotation is irregular) Clanging sound is heard from around cylinder head High idling speed of engine is low Leakage from fuel piping When air cleaner element is inspected directly, it is found to be clogged When turbocharger is rotated by hand, it is found to be heavy
Troubleshooting
When compression pressure is measured, it is found to be low 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 Speed does not change when operation of certain cylinders is stopped When control rack is pushed, it is found to be heavy, or does not return When valve clearance is checked directly, it is found to be outside standard value When lever is placed at FULL position, it does not contact stopper When feed pump is operated, operation is too light or too heavy
20-714 (6)
Replace
Replace
Clean
Correct
Adjust
Replace
Adjust
Replace
Correct
Clean
Clean
Replace
Replace
Remedy
Clean
When fuel tank cap is inspected directly, it is found to be clogged
PC128UU-2
S-7
TROUBLESHOOTING
S-7 Exhaust smoke is black (Incomplete combustion) General causes why exhaust smoke is black Insufficient intake of air Improper condition of fuel injection Excessive injection of fuel
Causes Seiz ed t urbo Clog cha rger ged , int air c Wor erfe lean renc n pi er e ston e lem Clog ent ring ged , cyl i i nde njec Imp r tion rope noz r inj zle, Defe ecti o ctiv n tim defecti e in ve s ing Imp ject pray i rope on p r u v m a Cru p l v ( e e she xces clea d, c ranc sive logg Lea e inje ed m kag ctio e of u n) f fler air b Defe e ctiv twe e en t con Defe urbo tact ctiv cha of v e in rger alve ject and and ion hea pum valv d e se p (ra at ck, p lung er s eize d)
• • •
Confirm recent repair history Degree of use of machine Operated for long period
Questions
Suddenly became black Color of exhaust gas
Gradually became black Blue under light load
Engine oil must be added more frequently Power was lost
Suddenly Gradually
Non-specified fuel is being used Noise of interference is heard from around turbocharger Dust indicator lamp is red Blow-by gas is excessive
Check items
Engine pickup is poor and combustion is irregular When exhaust manifold is touched immediately after starting engine, temperature of some cylinders is low Timing lock on fuel injection pump does not match Seal on injection pump has come off Clanging sound is heard from around cylinder head Exhaust noise is abnormal Muffler is crushed Leakage of air between turbocharger and head, loose clamp When turbocharger is rotated by hand, it is found to be heavy When air cleaner element is inspected directly, it is found to be clogged Troubleshooting
When compression pressure is measured, it is found to be low Speed does not change when operation of certain cylinders is stopped When check is made using delivery method, injection timing is found to be incorrect Injection pump test shows that injection amount is incorrect When valve clearance is checked directly it is found to be outside standard value When muffler is removed, exhaust color returns to normal
PC128UU-2
Replace
Replace
Correct
Replace
Adjust
Adjust
Adjust
Replace
Replace
Clean
Remedy
Replace
When control rack is pushed, it is found to be heavy, or does not return
20-715 (6)
TROUBLESHOOTING
S-8
S-8 Oil consumption is excessive (or exhaust smoke is blue)
General causes why oil consumption is excessive Abnormal combustion of oil External leakage of oil Wear of lubrication system
Bro
• • •
Causes
ken pist on r Wor ing n pi ston Clog ring ged , cyl inde brea Lea r (lin ther kag er le or b e fro ss e reat Lea mo ngin her kag il fil h e) e fro ose ter o mo Lea r o i l co il pi kag ping e fro oler mo Lea kag il dr e fro ain plug mo Bro ken il pa oil c n or oole Wor cylin r n se der al a hea t tur Wor d bine n se a e l n at b d Wor low n, b er e roke nd n re Dus Turb ar s t su eal, cked och seal arge Wor in fr surf r n va om ace inta lve (ste ke s m, g yste uide m ), br oke n se al
fl Do not run the engine at idling for more than 20 minutes continuously. (Both low and high idling)
Confirm recent repair history Degree of use of machine Operated for long period
Questions
Oil consumption suddenly increased Engine oil must be added more frequently Engine oil becomes contaminated quickly Exhaust smoke is blue under light load Amount of blow-by gas
Excessive None
Area around engine is dirty with oil Check items
There is oil in engine cooling water When exhaust pipe is removed, inside is found to be dirty with oil When turbocharger air supply pipe is removed, inside is found to be dirty with oil Oil level in clutch or TORQFLOW transmission damper chamber rises Clamps for intake system are loose
Troubleshooting
When compression pressure is measured, it is found to be low When breather element is inspected, it is found to be clogged with dirty oil There is external leakage of oil from engine Pressure-tightness test of oil cooler shows there is leakage Excessive play of turbocharger shaft Inspect rear seal directly When intake manifold is removed, dust is found inside
20-716 (6)
Correct
Correct
Correct
Replace
Replace
Replace
Correct
Correct
Correct
Correct
Clean
Replace
Remedy
Replace
When intake manifold is removed, inside is found to be dirty with oil
PC128UU-2
S-9
TROUBLESHOOTING
S-9 Oil becomes contaminated quickly General causes why oil becomes contaminated quickly Entry of exhaust gas due to internal wear Clogging of lubrication passage Improper fuel Improper oil used Operation under excessive load
Causes
Wor n pi ston Clog ring , cyl ged inde brea Clog r lin ther ged er , bre o athe i l filt Wor r ho er n va se lve, Clog valv ged e gu oil c ide Clog oole ged r turb Defe och ctiv arge e se r oil Exh al a drai aus t tur n tu t sm boc be harg oke is b e r turb lack ine end
• • • • •
Questions
Confirm recent repair history Degree of use of machine Operated for long period Engine oil must be added more frequently Non-specified oil is being used Color of exhaust gas
Blue under light load Black Carry out troubleshooting for “Exhaust smoke is black”.
Check items
Excessive Amount of blow-by gas
None
When oil filter is inspected, metal particles are found When exhaust pipe is removed, inside is found to be dirty with oil Engine oil temperature rises quickly
When breather element is inspected directly, hose is broken or is found to be clogged with dirty oil When oil filter is inspected directly, it is found to be clogged When oil cooler is inspected directly, it is found to be clogged Turbocharger oil drain tube is clogged
PC128UU-2
Replace
Clean
Clean
Replace
Replace
Remedy
Clean
Excessive play of turbocharger shaft When safety valve is directly inspected, spring is found to be catching or broken Replace
Troubleshooting
When compression pressure is measured, it is found to be low
—
20-717 (6)
S-10
TROUBLESHOOTING
S-10 Fuel consumption is excessive General causes why fuel consumption is excessive Leakage of fuel Improper condition of fuel injection Excessive injection of fuel
Defe ctive injec tion Defe pum ctive p (ex nozz Defe cess le ho ive i ctive lder njec spra i n j e tion Defe ction y ) ctive pum fuel p plu Exte injec n ger rnal tion leak timi age ng Leak from age fuel of fu pipin el in Defe side g, fu ctive el fil h oil s ead ter Defe e c a o l v insid ctive er e fee adju d pu stme mp nt o (pist f fue on) l con trol linka ge
• • •
Causes
Questions
Confirm recent repair history Degree of use of machine Operated for long period Condition of fuel consumption
More than for other machines of same model Gradually increased Suddenly increased Black
Exhaust smoke color
White
Seal on injection pump has come off
Check items
There is irregular combustion When exhaust manifold is touched immediately after starting engine, temperature of some cylinders is low Match mark on injection pump is misaligned There is external leakage of fuel from engine Engine oil level rises and smells of diesel fuel Engine low idling and high idling speeds are high Injection pump measurement shows that injection amount is excessive
Troubleshooting
Speed does not change when operation of certain cylinders is stopped When control rack is pushed, it is found to be heavy, or does not return When check is made using delivery method, injection timing is found to be incorrect Remove head cover and inspect directly Remove feed pump and inspect directly
20-718 (6)
Adjust
Correct
Correct
Correct
Adjust
Replace
Replace
Remedy
Adjust
When engine speed is measured, low idling and high idling speeds are found to be high
PC128UU-2
S-11
TROUBLESHOOTING
S-11 Oil is in cooling water, or water spurts back, or water level goes down
Causes
General causes why oil is in cooling water Internal leakage in lubrication system Internal leakage in cooling system Brok en o il co oler Brok cor e en c , O-r ylind ing er h Brok e en p ad, h owe e a d r tra Hole gask in oi s ca et l coo used ler by p Inter ittin nal c g rack s in cylin der bloc k
• •
Questions
Confirm recent repair history Degree of use of machine Operated for long period Oil level
Suddenly increased Gradually increased
Hard water is being used as cooling water
Excessive air bubbles inside radiator, spurts back Hydraulic oil, transmission oil is cloudy white When hydraulic oil, transmission oil is drained, water is found Pressure-tightness test of oil cooler shows there is leakage Pressure-tightness test of cylinder head shows there is leakage
PC128UU-2
Replace
Replace
Replace
Remedy
Replace
Remove oil pan and inspect directly
Replace
Troubleshooting
Check items
Engine oil level has risen, oil is cloudy white
20-719 (6)
TROUBLESHOOTING
S-12
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
fl Standards for engine oil selection
Type of oil
Selection of SAE No. according to ambient temperature –30 –20
–10
0
10
20
30
Causes
40°C
SAE10WCD SAE10W-30CD
Clog
SAE15W-40CD
Wor
Engine oil
ged oil f ilter n be arin Clog g, jo urna ged stra l Clog iner ged insi d o e oi i l pip Bro l pa ken e in n suct side ion Defe o i l pipe pan ctiv e oi braz Lack l pu ing mp of o i l in Defe oil p ctiv an e re gula Defe tor v ctiv e re alve lief Lea valv king e , cru Defe she d hy ctiv e oi drau l pre Defe lic p ssur ctiv ipin e oi e se g l n leve sor Wat l sen er, f sor uel in o il
SAE30CD
Questions
Confirm recent repair history Degree of use of machine Operated for long period Replacement of filters has not been carried out according to Operation Manual Non-specified oil is being used Caution lamp lights up Lights up at low idling Condition when oil pressure lamp lights up
Lights up at low, high idling Lights up on slopes
Check items
Sometimes lights up There is crushing, leakage from hydraulic piping (external) Oil level sensor lamp lights up When oil level in oil pan is inspected, it is found to be low Metal particles are found when oil is drained Metal particles are stuck to oil filter element
Carry out troubleshooting for “Oil level rises”.
Oil is cloudy white or smells of diesel oil
Remove oil pan and inspect directly Oil pump rotation is heavy, there is play There is catching of relief valve or regulator valve, spring or valve guide is broken When oil level sensor is replaced, oil level sensor lamp goes out
20-720 (6)
Replace
Replace
Correct
Adjust
Adjust
Add
Replace
Correct
Clean
Clean
Remedy
Clean
When oil pressure is measured, it is found to be within standard value Clean
Troubleshooting
When oil filter is inspected, it is found to be clogged
—
PC128UU-2
S-13
TROUBLESHOOTING
S-13 Oil level rises (Water, fuel in oil) fl If there is oil in the cooling water, carry out troubleshooting for “Oil is in cooling water”.
Water in oil (milky white) Fuel in oil (diluted, and smells of diesel fuel) Entry of oil from other component
Bro
• • •
ken oil c oole Defe r co ctiv re, O e no Bro -ring zzle ken hold cylin er s Wor der leev n, d hea e ama d, h ead Defe ged gas rear ctiv ket e pu seal Lea mp surf kag aux ace e of i l iary fuel Defe equ from ctiv ipm e pa pipi ent Defe rt in n seal g in ctiv s i d side e e th i n hea j erm ecti Hole d co on p osta sm ver ump t ade Crac by p ks in ittin g side cylin der bloc k
General causes why oil level rises
Causes
Questions
Confirm recent repair history Degree of use of machine Operated for long period There is oil in radiator cooling water Fuel must be added more frequently
Check items
Exhaust smoke is white When engine is first started, drops of water come from muffler Leave radiator cap open. When engine is run at idling, an abnormal number of bubbles appear, or water spurts back Oil level goes down in clutch, TORQFLOW transmission, or damper chamber Oil level goes down in hydraulic tank Engine oil smells of diesel fuel Water temperature is low Pressure-tightness test of oil cooler shows there is leakage Troubleshooting
Pressure-tightness test of cylinder head shows there is leakage When compression pressure is measured, it is found to be low Inspect rear seal directly When pump auxiliary equipment is removed, seal is found to be damaged Remove head cover and inspect directly Remove injection pump and inspect directly Defective contact with thermostat seal valve
PC128UU-2
Replace
Replace
Correct
Replace
Correct
Replace
Correct
Replace
Replace
Remedy
Replace
Remove oil pan and check directly
20-721 (6)
TROUBLESHOOTING
S-14
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 Rise in oil temperature in power train fl Carry out troubleshooting for chassis.
Bro ken wat er p Clog ump ged , cru Clog she d ra ged diat radi or fi Defe ator ns ctiv core e ther Defe mos ctiv tat ( ew doe ater Lack s no tem of c t op pera ooli en) Fan ture n g w belt g a aug t e s r l e i p Clog ping ged , wo , bro rn fa Defe ken n pu ctiv oil c lley e pr oole essu Bro r ken r e va cylin lve Hole der sm h ead ade , hea Rise by p d ga ittin in to sket g rque con vert er o il te mpe ratu re
• • • •
Causes
Confirm recent repair history Questions
Degree of use of machine Operated for long period Condition of overheating
Suddenly overheated Always tends to overheat
Water temperature gauge
Rises quickly Does not go down from red range
Radiator water level sensor lights up Fan belt whines under sudden load Cloudy white oil is floating on cooling water Cooling water flows out from overflow hose
Check items
Excessive air bubbles inside radiator, water spurts back Engine oil level has risen, oil is cloudy white There is play when fan pulley is rotated Radiator shroud, inside of underguard are clogged with dirt or mud When light bulb is held behind radiator, no light passes through Water is leaking because of cracks in hose or loose clamps When belt tension is inspected, it is found to be loose
Temperature difference between top and bottom radiator tanks is excessive Temperature difference between top and bottom radiator tanks is slight When water filler port is inspected, core is found to be clogged When function test is carried out on thermostat, it does not open even at cracking temperature
Carry out troubleshooting for chassis.
Troubleshooting
Power train oil temperature enters red range faster than engine water temperature
When water temperature is measured, it is found to be normal When oil cooler is inspected directly, it is found to be clogged When measurement is made with radiator cap tester, set pressure is found to be low When compression pressure is measured, it is found to be low
20-722 (6)
Replace
Replace
Replace
Replace
Correct
Add
Replace
Replace
Correct
Correct
Remedy
Replace
Remove oil pan and inspect directly
—
PC128UU-2
S-15
TROUBLESHOOTING
S-15 Abnormal noise is made fl Judge if the noise is an internal noise or an external noise.
• • •
Abnormality due to defective parts Abnormal combustion Air sucked in from intake system
Exce ssive wea Seiz r of ed t pisto urbo n rin Mis c g, cy harg sing linde er, i , sei r (lin n t e z Clog rfer ed b er le enc ged ss en ush e , i n gine s g e Defe ized ) ctiv i n ject e in i on n ject Defe ion ctiv pum ozzle e in p (ra Defo ject ion ck, p rme pum d fa lung Defe p (e n, fa er s x ctiv n be cess eize e ad d) lt in ive Brok just i t n e ject r fere men en d ion) nce ynam t of valv Imp ic va rope e cl e lve s r ge aran yste Leak a m (v ce r train age alve of ai b , ackl rock r bet Defe er le ash wee ct in ver, n tu r side etc.) b o ch muf arg e fler ( r an d divid ing b cylin o ard d er h out o ead f pos ition )
General causes why abnormal noise is made
Causes
Questions
Confirm recent repair history Degree of use of machine Operated for long period Condition of abnormal noise
Gradually occurred Suddenly occurred
Non-specified fuel is being used Engine oil must be added more frequently Color of exhaust gas
Blue under light load Black
Metal particles are found in oil filter Blow-by gas is excessive
Check items
Noise of interference is heard from around turbocharger Engine pickup is poor and combustion is abnormal When exhaust manifold is touched immediately after starting engine, temperature of some cylinders is low Seal on injection pump has come off Abnormal noise is loud when accelerating engine Clanging sound is heard from around cylinder head Leakage of air between turbocharger and cylinder head, loose clamp Vibrating noise is heard from around muffler When compression pressure is measured, it is found to be low When turbocharger is rotated by hand, it is found to be heavy Troubleshooting
Remove gear cover and inspect directly Speed does not change when operation of certain cylinders is stopped When control rack is pushed, it is found to be heavy, or does not return Injection pump test shows that injection amount is incorrect Fan is deformed, belt is loose When valve clearance is checked, it is found to be outside standard value Remove cylinder head cover and inspect directly
PC128UU-2
Replace
Replace
Replace
Correct
Replace
Correct
Replace
Correct
Replace
Replace
Replace
Remedy
Replace
When muffler is removed, abnormal noise disappears
20-723 (6)
S-16
TROUBLESHOOTING
S-16 Vibration is excessive
General causes why vibration is excessive • • •
Defective parts (abnormal wear, breakage) Improper alignment Abnormal combustion
Causes Wor n co nne ctin Wor g ro n ca d, m m bus Loo ain hing bea se e ring ngin Bro e mou ken ntin part g bo Cen insi lts, de o ter o brok utpu f en en c Imp gine t s h ush rope a a f t nd p ion (dam r ge owe Defe a per) r train r tra ctive i n d b y ackl mis nam Defe alig ic va ash ctiv ned lve s e in ystem ject (valv ion e, ro pum cker p (e lever xces , etc. sive stuck fuel ) inje ctio n)
fl If there is abnormal noise together with the vibration, carry out troubleshooting also for “Abnormal noise is made”.
Questions
Confirm recent repair history Degree of use of machine Operated for long period Condition of vibration
Suddenly increased Gradually increased
Non-specified oil is being used Metal particles are found in oil filter Metal particles are found when oil is drained
Check items
Oil pressure is low at low idling Vibration occurs at mid-range speed Vibration follows engine speed Exhaust smoke is black Seal on injection pump has come off Remove oil pan and inspect directly Troubleshooting
Remove side cover and inspect directly Inspect directly for loose engine mounting bolts, broken cushion Inspect inside of output shaft (damper) directly When face runout and radial runout are inspected, they are found to be incorrect Remove front cover and inspect directly Remove head cover and inspect directly
20-724 (6)
Adjust
Replace
Correct
Correct
Replace
Replace
Replace
Remedy
Replace
Injection pump test shows that injection amount is incorrect
PC128UU-2
30
DISASSEMBLY AND ASSEMBLY
Method of using manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . Precautions when carrying out operation . . . Special tool list . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Sketches of special tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . ENGINE, MAIN PUMP Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . RADIATOR, HYDRAULIC OIL COOLER Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FUEL TANK Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . CENTER SWIVEL JOINT Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . Disassembly and Assembly . . . . . . . . . . . . . . . . . . . . . SWING MOTOR, SWING MACHINERY Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . SWING MACHINERY Disassembly .............................................. Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . REVOLVING FRAME Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SWING CIRCLE Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . RECOIL SPRING Disassembly .............................................. Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . IDLER Disassembly .............................................. Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TRACK ROLLER Disassembly .............................................. Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TRACK SHOE Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . HYDRAULIC TANK Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MAIN PUMP Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PC1 28UU-2
30- 3 30- 4 30- 6 30- 10 30- 13 30-14 30- 15 30-16 30-17 30-18 30- 19 30-20 30-21 30-24 30-28 30-29 30-30 30-31 30-32 30-33 30-34 30-36 30-38 30-40 30-41 30-42 30-43 30-44
MAIN CONTROL VALVE Removal and Installation . . . . . . . . . . . . . . . . . . . .. . . . . . CONTROL VALVE Disassembly .............................................. Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . LS SELECT VALVE Disassembly and Assembly . . . . . . . . . . . . . . . . . . . . . MAIN RELIEF VALVE Disassembly .............................................. Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WORK EQUIPMENT PPC VALVE (BOOM, BUCKET, ARM, SWING) Disassembly .............................................. Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TRAVEL PPC Disassembly .............................................. Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ARM CYLINDER Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . OFFSET CYLINDER Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . HYDRAULIC CYLINDER Disassembly .............................................. Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . OFFSET CYLINDER Disassembly .............................................. Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WORK EQUIPMENT Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ARM Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SECOND BOOM Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . OPERATOR CAB Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
30-45 30-46 30-51 30-57 30-58 30-59
30-60 30-61 30-62 30-63 30-64 30-65 30-66 30-67 30-68 30-71 30-75 30-77 30-79 30-81 30-82 30-85 30-86 30-89 30-91 30-92
30-l 0
FLOOR FRAME Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30- 93 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30- 95 AIRCONDITIONER COMPRESSOR Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . 30- 96 AIRCONDITIONER CAPACITOR Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . 30- 97 AIRCONDITIONER UNIT Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30- 98 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30- 99 COUNTERWEIGHT Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . 30- 100
30-2 0
PC1 28UU-2
DISASSEMBLY
AND ASSEMBLY
METHOD 1.
OF USING
METHOD
OF USING
MANUAL
MANUAL
When removing or installing unit assemblies 0 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 0000
ASSEMBLY
. . . . . . . . . . . . . . . Title of operation
.................... .................................................. Precautions
1.
2. 3.
related to safety when carrying out the operation XXXX(1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Stepinoperation * . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Technique or important point to remember when removing XXXX (1). A A A A (2): . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . m Indicates that a technique is listed for use during installation 0 0 0 0 assembly (3)
:
.................................................................... Quantity
of oil or water
drained
INSTALLATION OF 0000 ASSEMBLY . . . . .Title of operation Carry out installation in the reverse order to removal. ‘@ ............................................................. Technique used during installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Technique or important point to remember when installing A A A 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 are given together as PRECAUTIONS WHEN CARRYING OUT OPERATION, 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 the operation procedure, see the SPECIAL TOOLS LIST given in this manual.
PC1 28UU-2
or assembly) of units so be sure to follow
in
30-3 0
DISASSEMBLY
PRECAUTIONS
AND ASSEMBLY
PRECAUTIONS
WHEN CARRYING
WHEN
CARRYING
OUT OPERATION
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 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 necessary 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. Nominal number
I)
end)
Use the two items
07376-502
07221-20210
(Nut),
07222-00210
(Plug)
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)
and
tubes
using
Flange
10
nut (elbow
03
Nominal number
30-4 0
Sleeve
02
Hoses
2) 3)
Plug (nut end)
sleeve
(hose end)
below
as a set
nuts Sleeve
head (tube end)
Split flange
04
07379-00400
07378-l
0400
0737 I-30400
05
07379-00500
07378-I
0500
0737 I-30500
Split flange type hoses and tubes If the part is not under hydraulic pressure,
the following
corks can be used.
PC1 28UU-2
DISASSEMBLY
2. . . . .
AND ASSEMBLY
PRECAUTIONS
WHEN
CARRYING
OUT OPERATION
Precautions when carrying out installation work Tighten all bolts and nuts (sleeve nuts) to the specified (KES) torque. Install the hoses without twisting or interference. Replace all gaskets, O-rings, cotter pins, and lock plates with new parts. Bend the cotter pins and lock plates securely. When coating with adhesive, clean the part and remove all oil and grease, then coat the threaded portion with 2 - 3 drops of adhesive. When coating with gasket sealant, clean the surface and remove all oil and grease, check that there is no dirt or damage, then coat uniformly with gasket sealant. Clean all parts, and correct any damage, dents, burrs, or rust. Coat rotating parts and sliding parts with engine oil. When press fitting parts, coat the surface with anti-friction compound (LM-P). After fitting snap rings, check that the snap ring is fitted securely in the ring groove. When connecting wiring connectors, clean the connector to remove all oil, dirt, or water, then connect securely. When using eyebolts, check that there is no deformation or deterioration, screw them in fully, and align the direction of the hook. When tightening split flanges, tighten uniformly in turn to prevent excessive tightening on one side. 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. + 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. + For details, see TESTING AND ADJUSTING, Bleeding air. Add the specified amount of grease (molybdenum disulphide grease) to the work equipment parts.
PC1 28UU-2
30-5 0
DISASSEMBLY
AND ASSEMBLY
SPECIAL TOOL LIST
SPECIAL TOOL LIST -k -k
*
Tools with part number 79OT-000-0000 cannot be supplied (they are items to be locally manufactured). Necessity: n : .......... 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.
Component
T
NW/Ske.
5;ym bol
Part No.
Part Name
1
Disassembly, assembly of engine
1795-799-1131 1Gear
IWII
1 Puller
3 I 795-799-1170
I Puller
4 I 790-331-I
110
I Wrench
796-460-I
210
Oil stopper
n
I
790-460-I
220
Rod
n
1
5 -
I
MII MII MII
2 1 795-799-1390
A
Removal of engine main pump assembly and engine assembly
I:; arv ;;ie, tch Nature
l
790-101-2560
l
Nut
1
l
790-101-2570
l
Plate
1
Rotation of crankshaft
I I I
Removal of fuel injection pump drive gear Removal
F
puller
790-101-1102
Hydraulic oil pump
n n
1
796T-426-1140
Push tool
n
l
790-201-2680
Plate
n
1
of cylinder
Oil stopper
in hydraulic oil
I Extension
MII
I
ImIll
1
I
l
Grip
l
Bolt
2 I 791-635-3160 690-201-2800
Press fit of oil seal
I
I l790-101-5421
I 791-685-8006
0
Im I I I
Plate
I Installer
Push tool KIT
of bearing
‘l
I Compressor(B)
l
head
I
I I I I
I
01010-51240
I
I III I III I III MII
4 I l790-101-5441
L
-
I
Puller (294 kN (30 ton})
1 I 791-675-1510 Disassembly, assembly of idler recoil spring assembly
ImI
790-101-4200
l
30-6 0
I Bearing
2
-
Tightening
Removal
I 790-101-3101
of nozzle holder
tank
1
Disassembly, assembly of swing machinery assembly
of work, remarks
Press fit of bearing race
inner
Press fit of bearing race l For main bearing l For sub-bearing
outer
Application
Compression
of floating
seal
of spring
PC1 28UU-2
DISASSEMBLY AND ASSEMBLY
Component
;ymbol
SPECIAL TOOL LIST
Part
Part
Name
New’
!;
Ske alty ;;ie, tch
n
1
790-101-1600
Cylinder (686 kN (70 ton})
n
‘l
790-101-1102
Pump
n
1
l
2
No.
790-201-2770
l
Spacer
Disassembly, assembly of idler recoil spring assembly
Nature
of work,
Compression
remarks
of spring
Press fit of piston dust seal
Disassembly, assembly of track roller assembly
1
791-675-I
510
n
Installer
1
Application
1
Sealing of oil and checking of air leak
M 2
791-601-1000 I 790-616-1040
Expansion, installation of track shoe assembly
R
Removal, installation of main pump input shaft oil seal
Oil pump
0
I Remover & installer I n I 1 I Cylinder (297 kN (30 ton})
n
’
791-101-1102
Pump
n
1
791-463-1141
Push tool
n
1
790-201-2740
Spacer
n
1
7go-105-1
‘loo
S
1 790-101-2501 .790-101-2510
Disassembly, assembly of center swivel joint assembly
. Block
l
791-101-2520
l
Screw
l
790-101-2540
l
Washer
1 l791-112-1180
T
1 Push puller
1 *Nut
of floating
seal
I Removal, pin
press fit of master
Press fit of oil seal
I.III I III I III I III I III
I I I I I
Disconnection shaft
of rotor from
790-502-I
003
Repair stand
n
1
Pump
n
1
1 790-101-1102 I 790-102-4300
Disassembly, assembly of hydraulic cylinder assembly
I Wrench
ass’y
In I I I
Disassembly, cylinder I
Boom, arm, bucket and offset cylinders Offset cvlinder (removal, installation of piston nut)
assembly
of
.Removal .
I
rnstallatron n+ nic+nn “I
fJ’.TL””
U 1 790-201-1702
1 Push tool KIT
Im 1 1 1
1
1
Press fit of bucket cylinder roll bushing
1 1
#n
-
PC1 28UU-2
1
l
790-201-1811
1 . Push tool
1
I III
I
Press fit of boom and offset cylinder roll bushings
30-7 0
DISASSEMBLY
AND ASSEMBLY
Component
SPECIAL TOOL LIST
T T I Symbol
-
NeWi Ske. Part No.
Part Name
-
l
790-101-5021
l
01010-50816
790-201-1702
l
Grip
l
1 Push tool KIT
3
-
l
790-201-1821
1 l Push tool
l
790-101-5021
I
l
01010-50816
1 Bolt
790-201-1500
arv ,,,$ tch Nature of work, remarks 1
1 Bolt
l
i;
Grip
l
1 Push tool KIT
I III MII I III I III I III MII
I I I I I I
Press fit of boom and offset cylinder roll bushings
Press fit of arm and blade cylinder roll bushings
Press fit of bucket cylinder dust seal
790-201-1500 l
790-201-I
l
790-101-5021
l
01010-50816
4 Disassembly, assembly of hydraulic cylinder assembly
1 Push tool KIT 620
l
Plate
l
Grip
U
790-201-1500
1 Bolt l
1 Push tool KIT
l
790-201-1630
1
l
Plate
l
790-101-5021
I
l
Grip
796-720-1660
1Ring
07281-01159
I Clamp
796-720-1670
1Ring
07281-01279
I Clamp
790-330-3802
I Wrench
796T-470-1150
I Spacer
796T-470-I
I Plate
6
Removal, installation, disassembly, assembly of work equipment ant removal/installation of hydraulic cylinder
V
-
30-8 0
7 -
140
ass’y
1
-
Application of boom and offset cylinder dust seal
Application of arm and blade cylinder dust seal
stt
5 -
-
I I I I I I I
1
-
-
MII I III I III I III MII I III I III 0
1
0
1
0
1
I.III I.III bill bill MII bill MII n
1
n
1
n
1
n +#
1
790-I 01-2102
Puller (294 kN (30 ton})
n
‘l
790-101-1102
Pump
n
I
Extension
of piston ring
Bucket cylinder
I I I I I lo lo
Arm, boom and blade cylinders
Installation of piston ring
Offset cylinder Removal, installation cylinder head
Removal trunnion
of
of arm cylinder pin
PC1 28UU-2
DISASSEMBLY
AND
ASSEMBLY
Component
symbol
-
SPECIAL
Part
No.
Part
796F470-1120
2 Removal, installation, disassembly, assembly of work equipment ant removal, installation of hydraulic cylinder
1Screw
796F470-1110
I Plate
796F470-1
I Plate
I 30
3 -
-
X
l
of work,
remarks
0
I ImlII lo ImlII lo IdII I
I Washer
n
2
790-101-2102
n
’
790-101-1102
Pump
n
1
796-900-I
Remover
n
1
790-101-4000
Puller (490 kN (50 ton})
n
‘)
790-101-1102
Pump
n
1
799-703-1200
I Service
799-703-1100
I Vacuum pump(lOOV)I
799-703-I 790-703-I
200
Nature
LIST
I=111
Puller (294 kN (30 ton))
1622
Removal
of offset pint
Removal
of boom foot pin
I
Recycle of air-conditioning gas
I1 I
I
For Japan
110
I Vacuum pump(220V) In I 1 I
I
For overseas
120
I Vacuum pump(24OV) In I 1 I
I
For overseas
799-703-1400
PC1 28UU-2
Ske alty m$e,tch
Nut
02215-I
V
Newi
!:;
n
Sleeve
790-438-I 110
790-101-2540
-
Recycle of new CFC gas
Name
TOOL
tool KIT
I Gas leak tester
In I I I
n
IdII
I
30-9 0
DISASSEMBLY
SKETCHES
AND ASSEMBLY
OF SPECIAL
TOOLS
SKETCHES OF SPECIAL TOOLS Note:
Komatsu sketches.
cannot
accept
any responsibility
for
special
tools
manufactured
according
to
these
F2. Push tool
PUSH TOOL
* VI.
Unless
otherwise
specified,
there shall be no burrs or flushes
at the corner.
Spacer 230
Ii!? --------------------6'0"
(66)
160
I34
1
CLPO2176
HEAT TREATMENT
1
MATERIAL
9-
------------------------------
30-10 0
PC1 28UU-2
DISASSEMBLY AND ASSEMBLY
SKETCHES OF SPECIAL TOOLS
VI. Plate
CLPO2177
V2. Sleeve
_----_--------------------------
CLPOZl73
_-------------------------------
v
PC128UU-2
DISASSEMBLY AND ASSEMBLY
SKETCHES OF SPECIAL TOOLS
V2. Plate
. <
2 _
I
c1
Ii-
s: 2
I
Lt II
6
CLPOZl74
Cl
V2. Plate
. <
Cl
CLPOZl75
30-12 0
PC128UU-2
DISASSEMBLY
AND
ASSEMBLY
ENGINE,
MAIN
PUMP
REMOVAL OF ENGINE, MAIN PUMP ASSEMBLY g Completely ground the work equipment. g
Disconnect tery.
the negative
(-) terminal
of the bat-
1. Remove the radiator, hydraulic oil cooler assembly by referring to “REMOVAL OF RADIATOR, HYDRAULIC 2. Disconnect tanks. 3. Remove
OIL COOLER ASSEMBLY”. hose (I) between the radiator
bracket
(2) from
upper
the fuel tank together
with the reserve tank. 4. Disconnect bracket (3) from the main pump. * The EPC valve connector is attached to it. 5. 6. 7. 8.
Disconnect Disconnect Disconnect Disconnect
PPC main pressure hose (4). earth cable (5). LS pressure input hose (6). EPC valve connector (7) (C13).
9. 10. 11. 12.
Disconnect Disconnect
suction tube (8) from the main pump. main pump output hose (9).
Disconnect main pump pressure input hose (IO). Disconnect case drain hose (11). 13. Disconnect engine oil filter (12) from the hydraulic oil tank and put it near the main pump.
14. Remove 15. Remove 16. Remove 17. Remove
stays (13), (14) and (15). adiabatic cover (16). muffler drain tube (17). muffler (18).
+ Loosen the turbo charger clamp beforehand. 18. Disconnect heater outlet hose (19). hose (20). 19. Disconnect air conditioner *
Disconnect the hose after completely bleeding the air conditioning gas (R134a) using tool X.
+
Apply the blind plug to prevent from entering the hose.
+
Be careful
not to damage
dust or water
or lose the O-ring.
20. Disconnect 21. Disconnect
accelerator cable (21). fuel inlet hose (22) and return
(23). 22. Disconnect
air conditioner
hose clamp
m hose
(24) at two
positions. 23. Disconnect engine connectors: (25) El 5, (26) E20, (27) El6 and (28) E07 to remove clamp (29). 24. Disconnect fuel spill hose (30). +
Apply
PC1 28UU-2
the blind plug to the hose.
30-l 3 0
DISASSEMBLY
AND ASSEMBLY
ENGINE,
MAIN
PUMP
25. Disconnect clamp (31) to remove hose (32). 26. Remove engine side cover (33) 27. Disconnect engine connectors (34) MO2 and (35) E17. 28. Disconnect starter wire (36) El3 and safety wire (37) E30. 29. Disconnect heater return hose (38). 30. Remove three of four engine mounts (39). lift engine 31. Temporarily remove the remaining fully lift the assembly Engine
&
relay
main pump assembly (40), mounting bolt and careto remove
main pump
it.
assembly
1121
: 270 kg
INSTALLATION OF ENGINE MAIN PUMP ASSEMBLY l
Installation
is performed
in the opposite
way to
removal.
+
Adjust
the cable
JUSTMENT
+
Install
length
by referring
OF FUEL CONTROL
the engine
main
pump
placing the engine mounting in the figure w
Engine
to “AD-
CABLE”.
assembly
by
rubber as shown
below.
mounting
tightening
277.0 I- 31.9 Nm {28.25
bolt
:
z 3.25 kgm)
Supplying water Supply water from the water filler port to the specified level, start the engine to circulate coolant and recheck the level. Supplying oil (hydraulic oil tank) Supply oil from the oil filler port to the specified level, start the engine to circulate oil in the piping and recheck the oil level. Bleeding air Bleed air from the main pump by referring to “BLEEDING AIR FROM EACH PART” in “INSPECTION AND
ADJUSTMENT”.
Filling air conditioning gas Fill air conditioning gas (R134a) tioning
circuit using tool X.
i i (Maln
in the air condi(Fan
side
PWIP
side
mount)
mount) DXPOlO36
30-14 0
PC1 28UU-2
DISASSEMBLY
AND
ASSEMBLY
RADIATOR,
REMOVAL OF RADIATOR, HYDRAULIC OIL COOLER ASSEMBLY A Gradually loosen the hydraulic oil tank cap to bleed the internal air after completely grounding the work equipment and stopping the engine. 1. Remove the counterweight assembly to “REMOVAL OF COUNTERWEIGHT BLY“. 2. Remove the hydraulic the oil using tool A5. +
-
by referring ASSEM-
oil tank strainer
and stop
If tool A5 is not used, remove the drain plug to drain the oil from the hydraulicoil tankand the piping. :
oil : 100 Pi
Hydraulic
3. Drain coolant. -
:
Coolant
4. Remove 5. Remove
: 15 e
stay (I). stay (2).
+
Disconnect the accelerator cable clamped to stay (2). 6. Remove bracket (3) together with the washer tank. +
Disconnect the washer motor connector from the hose. 7. Remove two batteries (4). 8. Remove battery relay (5). 9. Remove silencer (6) and tube cleaner assembly (8).
(M28)
(7) to remove
air
10. Remove bracket (9). 11. Disconnect air conditioner capacitor pipings (IO) and (11). * Disconnect the hose after completely bleeding the air conditioning X. + +
gas (R134a)
using tool
Apply the blind plug to prevent dust or water from entering the hose. Be careful not to damage or lose the O-ring.
+
Make sure to double-engage the wrench before disconnection. 12. Remove the mounting bolt to remove air conditioner capacitor assembly (12). 13. Remove clamp (13) to remove bracket (14). 14. Disconnect oil cooler outlet hose (15) and inlet hose (16). 15. Disconnect radiator outlet hose (17) and inlet hose (18) as well as reserve tank hose (19).
PC1 28UU-2
HYDRAULIC
OIL COOLER
DISASSEMBLY
AND ASSEMBLY
RADIATOR,
HYDRAULIC
OIL COOLER
16. Temporarily lift radiator, hydraulic oil cooler assembly (20) to remove the four mounting bolts on the bottom. +
Carefully lift and remove the assembly after slightly lifting it and pulling it to the opposite side from the engine to make sure that it does not come in contact with the fan.
&
Radiator/hydraulic
oil cooler
: 55 kg
assembly
INSTALLTION OF RADIATOR, HYDRAULIC OIL COOLER ASSEMBLY Installation removal.
is performed
Supplying water Supply water from
in the opposite
the water
specified level, start the engine ant and recheck the level.
filler
way to
port to the
to circulate
cool-
Supplying oil (hydraulic oil tank) Supply oil from the oil filler port to the specified level, start the engine
to circulate
oil in the piping
and recheck the oil level. Filling air conditioning
gas
Fill air conditioning gas (R134a) tioning circuit using tool X.
30-16 0
in the air condi-
PC1 28UU-2
DISASSEMBLY AND ASSEMBLY
FUEL TANK
REMOVAL OF FUEL TANK ASSEMBLY A Completely ground the work equipment. A
Disconnect
the negative
(-) terminal
of the bat-
tery. 1.
Drain the fuel. -
:
Fuel tank
: 140 e
2.
Remove two hand rails (I) to remove side covers (2) and (3), and upper covers (4), (5), (6) and (7). + The shapes of the hand rails differ.
3.
Disconnect
4. 5.
ing bolt and bracket (9) together with the reserve tank. Disconnect engine fuel return hoses (IO) and (11). Disconnect fuel sensor connector (12) (PO6) to re-
6.
hose (8) from the radiator,
the mount-
move clamp (13). Remove brackets (14) and (15) on the left side of the fuel tank.
7. 8.
Disconnect mounting bolt (16) on the right side. Disconnect hoses (17) (to the fuel pump) and (18) (for draining) from the bottom of the fuel tank. + Lift the fuel tank before disconnection.
9.
Temporarily lift fuel tank (19), remove the mounting bolt and then carefully lift the tank to remove it. m &
Fuel tank assembly
INSTALLATION ASSEMBLY l
Installation removal.
&
: 100 kg
OF FUEL TANK
is performed
in the opposite
Fuel tank mounting
bolt screw
Liquefied w
l
Supplying Supply
PC1 28UU-2
oil (fuel tank)
fuel.
:
adhesive
Fuel tank mounting bolt : 277.0 + 31.9 Nm I28.25
way to
(LT-2)
+ 3.25 kgml
DISASSEMBLY
AND ASSEMBLY
CENTER
SWIVEL
JOINT
REMOVAL OF CENTER SWIVEL JOINT ASSEMBLY
A
Gradually
loosen
the hydraulic
oil tank cap to
bleed the internal air after completely grounding the work equipment and stopping the engine.
A
Disconnect
the negative
(-) terminal
of the bat-
tery.
1. Remove boom rear covers (I) and (2). 2.
Disconnect 10 hoses (3) from center swivel joint.
3.
Remove
4.
Disconnect 7 hoses (5) from the top of the center swivel joint. m
5.
Disconnect connect
6.
elbow
the bottom
(4).
the cotter
pin and pin and then dis-
plate (6) from the center swivel
Temporarily
of the
lift the center
swivel
joint.
joint assembly
and remove the mounting bolt from the bottom to remove center swivel joint assembly (7). &
Center
swivel
joint assembly
: 45 kg
INSTALLATION OF CENTER SWIVEL JOINT ASSEMBLY l
Installation removal.
&
is performed
Mounting
in the opposite
bolt screw
:
Liquefied w
Mounting
way to
adhesive
(LT-2)
bolt :
98.1 - 123.0 Nm {IO.0 - 12.5 kgml l
Supplying oil (hydraulic oil tank) Supply oil from the oil filler port to the specified level, start the engine to circulate oil in the piping and recheck the oil level.
30-18 0
PC1 28UU-2
DISASSEMBLY
AND
ASSEMBLY
CENTER
SWIVEL
JOINT
DISASSEMBLY OF CENTER SWIVEL JOINT ASSEMBLY Remove
cover (1).
Remove
snap ring (2).
Using tool 0, from swivel Remove
pull out swivel
snap
and slipper
rotor (4) and ring (3)
shaft (5). ring (6), then
remove
oil seal (7)
seal (8).
ASSEMBLY OF CENTER SWIVEL JOINT ASSEMBLY 1. Assemble 2.
seal (8) to swivel
shaft (5).
Using push tool 0, press fit oil seal (7) to swivel rotor (4), then install snap ring (6). &
3.
slipper
Lip of oil seal
CWPO7964
: Grease (G2-LI)
Set swivel shaft (5) to block, and using push tool, tap swivel rotor (4) with a plastic hammer to install. Ir Be extremely careful not to damage the oil seal and slipper seal when
the lip of installing
the rotor. 4.
Install
5.
Fit O-ring w
ring (3) and secure with snap ring (2). and install cover (1).
Swivel
joint mounting bolt : 31.4 + 2.9 Nm 13.2 t 0.3 kgml
Cl PDT3146
CLPO2169
PC1 28UU-2
30-19 a
DISASSEMBLY AND ASSEMBLY
SWING MOTOR, SWING
MACHINERY
REMOVAL OF SWING MOTOR, SWING MACHINERY ASSEMBLY A Gradually loosen the hydraulic oil tank cap to bleed
the internal
ing the work gine. A
Disconnect tery.
1.
Remove
2.
Disconnect
air after completely
equipment
the negative
boom
ground-
and stopping
(-) terminal
rear covers
the en-
of the bat-
(I) and (2).
MB and MA port hoses (3) and (4), S
port hose (5), and B and T port hoses (6) and (7). 3.
Remove the mounting bolt and tighten forcing screw 0 to disconnect swing motor, swing machinery (8) from the revolving frame. m Ir Temporarily lift the swing motor/swing machinery assembly and gradually lift it upward according to the amount forcing screw.
4.
Lift and
remove
assembly
(8).
&
swing
disconnected
motor/swing
Swung motor, swing .
by the
machinery
machinery
assembly :lOOkg
INSTALLATION OF SWING MOTOR, SWING MACHINERY ASSEMBLY l
Installation removal.
6
is performed
Swing
machinery Gasket
w
Mounting
bolt
277.0 l
in the opposite
fitting
surface
sealant
way to
:
(LG-4 or LG-6)
:
+ 31.9 Nm I28.25
+ 3.25 kgml
Bleeding air Bleed air from the swing motor by referring to “BLEEDING AIR FROM EACH PART” in “INSPECTION AND
30-20 0
ADJUSTMENT”.
PC1 28UU-2
DISASSEMBLY
AND
SWING
ASSEMBLY
MACHINERY
OF SWING MACHINERY
DISASSEMBLY
ASSEMBLY 1.
Draining oil Loosen drain
plug and drain oil from
swing
ma-
chinery. 2.
:
Swing
machinery
Swing motor Remove swing
motor
case
assembly
: Approx.
2.5 Q
(1).
CLPO1647
3.
No. 1 carrier, No. 2 sun gear assembly 1) Remove No. 1 sun gear (2). 2)
Remove No. 1 carrier sembly (3).
and No. 2 sun gear as-
CLPO2138
3)
Disassemble
No. 1 carrier
and No. 2 sun gear
assembly (3) as follows. i) Remove snap ring (4), then remove washer washer
(5), gear (6), bearing (8).
thrust
(7), and thrust
11
I
IJ CLPO2139
ii)
iii)
Knock in pin (9) and knock out shaft (10). Ir After removing the shaft, remove pin (9). Remove snap ring (1 I), then remove 2 sun gear (12) from carrier (13).
No.
I
PC1 28UU-2
CLPO2140
30-21 0
DISASSEMBLY
AND ASSEMBLY
4.
Ring gear Remove ring gear (14).
5.
No. 2 carrier assembly 1) Remove spacer (15). 2)
Remove
No. 2 carrier
SWING
assembly
MACHINERY
(16).
14 CLPO2141
3)
CLP02142
Disassemble No. 2 carrier assembly as follows. i) Push in pin (17), and knock out shaft (18) from carrier (19). + After removing the shaft, remove pin ii)
(17). Remove bearing
thrust
washer
(20),
(22), and thrust washer
gear
(21),
(23).
CLPO2143
6.
Retainer, collar 1) Remove retainer 2)
3)
(24).
Set shaft and case assembly to press, push split collar (25) with push tool 0, and press fit bearing (26). Ir Operate the press gradually and press fit the bearing to a point where lar can be removed. Remove split collar (25).
the split col-
CLPO2144
7.
Shaft 1)
assembly
Set block@
to shaft and case assembly
then using push tool 0, bly (28) with press. 2)
Remove
bearing
remove
(27),
shaft assem-
(26).
CLPO2146
30-22 0
CLPO2146
CLPO2147
PC1 28UU-2
DISASSEMBLY
3)
AND
ASSEMBLY
SWING
Set shaft assembly to press, then using push tool Fl, remove bearing (29) and collar (30) from shaft (31).
-
8.
MACHINERY
CKPO314g
Oil seal, bearing outer race 1) Remove oil seal (32) from case (33).
CLPO2149
2)
Using puller 0, remove bearing (34) and (35) from case (33).
outer
I
races
CLPO2160
PC1 28UU-2
30-23 0
DISASSEMBLY
AND ASSEMBLY
SWING
MACHINERY
ASSEMBLY OF SWING MACHINERY ASSEMBLY *
Clean all parts, and checkfor dirt or damage. Coat the sliding surfaces of all parts with engine oil before
installing.
1.
Bearing outer races Using push tool, press fit outer races (34) and (35) to case (33).
2.
Shaft assembly 1) Fit O-ring to inside of collar (30) and install to
II CLPO4760
shaft (31). 2)
Using push tool @, press fit bearing press.
(29) with
J
3)
Set case assembly
4)
Using push tool 0, press fit bearing (26) with a press to a point where split collar (25) enters. + Press-fitting force : Max. 11.76 kN {I 200 Ir
(36) to shaft assembly
kg) Press fit the bearing
slowly
while
CLPO2162
(28).
rotating
the case.
5) 6)
Install split collars
(25).
Screw bolt (12mm,
P=l.75mm)
into case, then
using push- pull scale @, measure force in direction of rotation. Ir +
tangential
Tangential force : Max. 176.4 N (18 kg} The tangential force is the maximum force at the start of rotation.
25 CLPO2166
30-24 0
CLPO2166
PC1 28UU-2
DISASSEMBLY AND ASSEMBLY
3.
SWING
MACHINERY
Oil seal Using push tool F2, press fit oil seal (32). * Replace the oil seal with a new part. Lip of oil seal : Grease (G2-LI)
CLPO3160
4.
Retainer Install
retainer
(24).
I 5.
“I”
DBP00217
No. 2 carrier assembly 1) Assemble No. 2 carrier assembly as follows. Assemble bearing (22) to gear (21). i) ii) Fit top and bottom thrust washers (20) and (23), then set gear assembly to carrier (19).
DBPOO218
iii)
Align position of pin holes of shaft carrier, then tap with plastic hammer install shaft (18). * When installing
the shaft,
rotate
planetary gear, and be careful damage the thrust washers. iv)
and and the
not to
Insert pin (17). * After inserting the pin, caulk the carrier pin portion.
OBPOO219
PC1 28UU-2
30-25 0
DISASSEMBLY
AND ASSEMBLY
SWING
2)
Install No. 2 carrier assembly case assembly.
3)
Install spacer
MACHINERY
(16) to shaft and
(15).
Ring gear Assemble O-ring to shaft and case assembly, install ring gear (14).
and
DDPOOZZI
No. 1 carrier, 1) Assemble
No. 2 sun gear assembly No. 1 carrier and No. 2 sun gear
assemblv as follows. i) Assemble No. 1 carrier ii)
iii)
(13) to No. 2 sun
gear (12), and install snap ring (11). Align position of pin holes of shaft
and
carrier, then tap with a plastic hammer to install shaft (IO). Insert pin (9). + After inserting the pin, caulk the carrier pin portion. +
Check that the stepped difference a between the shaft and carrier is less than 0.2 mm. thrust washer (8), bearing (7), iv) Assemble gear (6), and thrust stall snap ring (4).
washer
(5), then
DBPOOZZ2
in-
DaPool98
30-26 0
PC1 28UU-2
DISASSEMBLY
2) 3)
8.
SWING
ASSEMBLY
Install No. 1 carrier and No. 2 sun gear sembly (3). Install No. 1 sun gear (2).
Swing motor assembly Install swing motor assembly w
.
AND
Refilling
with
Swing
PC1 28UU-2
oil (swing
machinery
+ 1.25 kgml
case)
the oil filler to the specified machinery
case
as-
(1).
Mounting bolt : 110.25 + 12.5 Nm III.25
Add oil through
MACHINERY
: Approx.
level.
2.5 fi
30-27 0
DISASSEMBLY
AND ASSEMBLY
REVOLVING
FRAME
REMOVAL OF REVOLVING FRAME ASSEMBLY A 1.
Disconnect tery.
the negative
(-) terminal
of the bat-
Remove the work equipment assembly by referring to “REMOVAL OF WORK EQUIPMENT ASSEMBLY”.
2.
Disconnect boom cylinder hoses (I) (right) and (2) (left). Ir Be sure to apply the blind plug to the disconnected
3.
Remove
4.
Temporarily
hose.
covers
(3) and (4).
lift the boom cylinder
(5) on the bottom. Ir Check the number
to remove
and position
of the shims
mounted. 5.
Lift boom &
6.
pins
m
cylinder
assembly
Boom cylinder
(6) to remove
assembly
it.
: 120 kg
Remove operator cab assembly (7) by referring to “REMOVAL OF OPERATOR CAB ASSEMBLY”.
Disconnect seven hoses center swivel joint. Disconnect
the top of the
plate (8) from the center swivel joint.
Remove mounting front and rear.
30-28 0
(8) from
bolts (9) except the two on the 1121
PC1 28UU-2
DISASSEMBLY
AND
REVOLVING
ASSEMBLY
FRAME
10. Lift revolving frame assembly (16) to loosen remaining bolts (15). Ir Carefully remove the remaining bolts by balancing them using the crane. Ir
Carefully
lift and
remove
them
them from coming in contact swivel joint or other parts. Revolving
&
frame
to prevent
with the center
assembly
: 6,100
kg
INSTALLATION OF REVOLVING FRAME ASSEMBLY l
Installation removal.
is performed
Surface
in the opposite
inside bushing
during
way to
pin assem-
bly : Hyper white grease (GO-T, G2-T) or lubricant with molybdenum disulfide (LM-P) Greasing
after pin assembly
:
Hyper white grease (GO-T, G2-T) or lubricant with molybdenum disulfide (LM-G)
l
A
Never put your finger in the pin hole when adjusting the position.
+
Adjust the clearance between the mount on the boom cylinder bottom and the frame using the shims so that it becomes 1 mm or less.
circle contacting face : Liquefied gasket
6
Swing
6
Revolving
w
Revolving
frame
(LG-1)
mounting bolt screw : Liquefied adhesive (LT-2)
frame mounting bolt : 277.5 +. 32.4 Nm (28.3 +. 3.3 kgm}
Supplying oil (hydraulic oil tank) Supply oil from the oil filler port to the specified level, start the engine
to circulate
oil in the piping
and recheck the oil level. l
Bleeding
air
Bleed air by referring to “BLEEDING AIR FROM EACH PART” in “INSPECTION AND ADJUSTMENT”.
PC1 28UU-2
30-29 0
DISASSEMBLY
SWING
AND ASSEMBLY
REMOVAL OF SWING CIRCLE ASSEMBLY A Gradually loosen the hydraulic oil tank cap bleed the air from the tank after grounding work equipment and stopping the engine lock the safety
CIRCLE
to
the and
lock lever.
Remove the revolving frame assembly by referring to “REMOVAL OF REVOLVING FRAME ASSEMBLY”. Temporarily
lift swing
move the 38 mounting Remove &
swing Swing
circle assembly bolts.
circle assembly circle assembly
(1).
(I) to rem m
: 170 kg
INSTALLATION OF SWING CIRCLE ASSEMBLY l
Installation removal.
is performed
in the opposite
'RONT
way to
&
Swing
circle mounting bolt screw : Liquefied adhesive (LT-2)
w
Swing
circle mounting bolt : 245 - 308.9 Nm I25 - 31.5 kgm) Target
+
Lift swing
value
: 279.3
circle assembly
the track frame
OBPOO226
Nm 128.5 kgml
(1) and install it on
with the inner wheel
soft zone
S symbol of the inner race facing the right side of the body as shown in the figure. &
30-30 0
Amount
of circle grease sealed : 9.1 e (G2-LI grease)
PC1 28UU-2
DISASSEMBLY AND ASSEMBLY
RECOIL SPRING
DISASSEMBLY OF RECOIL SPRING ASSEMBLY
‘J
1.
Remove valve
lock plate (I), then remove
seat (2) and
(3).
2.
Remove yoke piston spring assembly (4).
3.
Disassembly 1)
DBPOOZZS
assembly
of recoil spring
(5) from
recoil
assembly
Set recoil spring assembly (4) to tool L2. The recoil spring is under large installed load, so be sure to set the tool prop-
A
+
erly. Failure to do this is dangerous. Installed load of spring : 78.4 kN (8,000
2)
(Rubber shoe) Apply hydraulic pressure slowly to compress spring, then remove nut (6).
i * +
4.
Compress the spring to a point where the nut becomes loose. Release the hydraulic pressure slowly to remove the spring tension. Remove pilot (8), spacer @A) (for rubber shoe specification machine), cylinder (9), and dust seal (IO) from spring (7).
Disassembly 1) Remove 2)
CLPO3166
kg)
of yoke piston assembly wear ring (12) from yoke piston (11).
Remove snap ring (13), then remove ing (14).
PC1 28UU-2
U-pack-
30-31 0
DISASSEMBLY
RECOIL SPRING
AND ASSEMBLY
ASSEMBLY OF RECOIL SPRING ASSEMBLY Assembly 1) 2)
of yoke piston
L3
assembly
Assembly of recoil spring assembly 1) Using tool L3, install dust seal (IO) to cylinder 2)
IO
Assemble U-packing (14) to yoke piston (1 I), and secure with snap ring (13). Assemble wear ring (12).
Y
(9). Assemble cylinder (9) and pilot (8) to spring (7), and set to tool L2.
3)
Apply hydraulic pressure slowly to compress spring, and tighten nut (6) so that installed length of spring is dimension “a”. Installed length “a” of spring : 390 mm +
4)
Remove L2.
recoil spring
Fill inside of cylinderwith grease. 6
Inside cylinder
Assemble yoke spring assembly 6
assembly
(4) from tool
a minimum
CLPO3167
Fill with grease
of 120 ccof
: Grease (G2-LI)
piston (4).
Yoke piston sliding
assembly
(5) to recoil
portion
wear ring : Grease (G2-LI)
DLPOO453
Fit valve (3) and seat (2), and secure with lock plate (1). + Install the valve so that the direction fitting is to the outside.
30-32 0
of the
PC1 28UU-2
IDLER
DISASSEMBLY AND ASSEMBLY
DISASSEMBLY OF IDLER ASSEMBLY 1.
2.
Remove
dowel
Remove floating
pin (I), then remove seal (3) from support
support
(2).
(2) and idler
(4).
3.
Pull out idler (4) from
shaft
sembly (7). + It is filled with approx.
(5) and support
as-
90 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 idler (4) and shaft (5) and support assembly (7).
5.
Remove dowel from shaft (5).
6.
Remove
pin (8), then
bushings
remove
(9) and (IO) from
support
i
DBP00233
(7)
idler (4).
CLPO2206
CLPO2207
PC1 28UU-2
CLPO2208
30-33 0
DISASSEMBLY
IDLER
AND ASSEMBLY
ASSEMBLY OF IDLER ASSEMBLY Press fit bushings
(9) and (IO) to idler (4).
IO
CLPO2209
Fit O-ring and install support dowel pin (8).
CLPO2210
(7) to shaft (5) with
Using tool Ll, install floating seal (6) to idler (4) and shaft (5) and support assembly (7). Ir Coat the sliding surface of the floating seal with oil, and be careful dust get stuck to it. +
not to let any dirt or
Remove all grease and oil from the contact surface of the O-ring and the floating seal.
I
CLPO2.206
CLPO3164
CLPO2211
30-34 0
PC1 28UU-2
DISASSEMBLY AND ASSEMBLY
Assemble idler (4).
IDLER
shaft (5) and support
Add oil between
assembly
(7) to
shaft (5) and idler (4).
Oil : 90 cc (E030-R)
Q
Using tool Ll, install floating seal (3) to idler (4) and support (2). * 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.
CLPO2214
Install O-ring,
then install support
(2) with dowel
pin (1).
CLPO3155
2’
PC1 28UU-2
DBPOO233
TRACK ROLLER
DISASSEMBLY AND ASSEMBLY
DISASSEMBLY OF TRACK ROLLER ASSEMBLY I 1. 2.
Remove
pin (I), then remove
Remove
floating
collar (2).
seal (3) from collar (2) and roller
(4).
II 3
H
CLPO2218
CLPO2219
CLPO2220
3.
Pull out roller (4) from shaft (5). Ir It is filled with 100 - 115 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 roller (4) and shaft (5).
side) from
CLPO2222
30-36 0
CLPO2221
CLPO2223
PC1 28UU-2
DISASSEMBLY
AND
TRACK
ASSEMBLY
5.
Remove
collar (8) from shaft (5).
6.
Remove
bushings
(9) and (‘IO) from
ROLLER
roller (4).
6
CLPO2226
PC1 28UU-2
30-37 0
DISASSEMBLY
AND ASSEMBLY
TRACK
ROLLER
ASSEMBLY OF TRACK ROLLER ASSEMBLY 1.
Using push tool 0, to roller (4).
2.
Assemble
3.
Using tool Ml, +
install floating
seal (6) to shaft (5).
When assembling the floating seal, clean the contact surface of O-ring (6~) and floating seal (6a), remove all grease and oil, and dry it. Make sure that no dirt or dust sticks to the surface
of the floating
CLPO3168
seal.
Using tool Ml, install floating seals (6) and (3) to roller (4). * For details of the precautions when installing floating seals (6b) and (6d), and (3b) and (3d), see
5.
(9) and (IO)
collar (8) to shaft (5).
contact 4.
press fit bushings
Assemble
the precautions
marked
*
for Step 3.
shaft (5) to roller (4).
6.
Turn over roller (4) and shaft (5) assembly.
7.
Using tool Ml, install floating seal (3) to collar (2). * For details of the precautions when installing
CLPO3169
CLPO2229
CLPO2230
CLPO3160
floating seals (3a) and (3c), see the precautions marked Ir for Step 3. 5
8.
Assemble
collar (2) to shaft (5), and install pin (1).
CLPO2232
30-38 0
PC1 28UU-2
DISASSEMBLY
AND
TRACK
ASSEMBLY
ROLLER
9. Using tool M2, apply standard pressure to roller oil filler port and check air leakage. Ir Standard pressure :0.1 MPa {I kg/cm3 +
Method of checking The standard pressure 10 seconds and the shall not go down.
shall
be maintained
indicator
10. Using tool M2, fill track roller assembly then tighten
for
of the gauge
with oil,
plug (11).
Track roller oil : 100 - 115 cc (E030-RI
CLPO3161
To vacuum Pump DJPOf042
CLP0223
PC128UU-2
30-39 0
DISASSEMBLY
TRACK
AND ASSEMBLY
SHOE
REMOVAL OF TRACK SHOE ASSEMBLY Lower
work
lubricator A
equipment
to ground,
(I), and relieve
loosen m
The adjustment cylinder is under extremely high pressure. Never loosen the lubricator more than one turn. If the grease does not come out, move the machine forwards.
Move
then
track tension.
machine
forward
backwards
so that position
ter pin is at front of idler, and set blocka tion. Using tool R, pull out master Remove
and
of masin posi-
m
pin.
tool R, pull out temporary
pin, and re-
move dust seal, then drive machine lay out track (2).
in reverse to m
-
INSTALLATION OF TRACK SHOE ASSEMBLY l
Carry out installation moval.
in the reverse
order
CLPO3163
to re-
m *
Adjust the track tension. For details, see TESTING ing and adjusting
*
AND ADJUSTING,
Test-
track tension.
Use tool C and press fit the master pin so that the protrusion of the master pin is dimension “a”. Protrusion Ua” of master pin : 5.5 f 2 mm
When assembling the dust seal, coat the bushing contact surface with grease (G2-LI). If the rubber of the road liner (rubber pad type) becomes worn or broken and the head of the mounting bolt becomes damaged, replace the shoe with a new part immediately. If the head of the mounting bolt becomes flattened, it will be impossible
30-40 0
to remove
it.
PC1 28UU-2
DISASSEMBLY
AND ASSEMBLY
HYDRAULIC
REMOVAL OF HYDRAULIC ASSEMBLY
a
TANK
Gradually loosen the hydraulic oil tank cap to bleed the internal air after completely grounding the work equipment and stopping the engine.
A
Disconnect tery.
the negative
1. Drain the hydraulic -
:
Hydraulic
(-) terminal
of the bat-
oil.
oil : 100 Q
2. Remove the fuel tank assembly by referring to “REMOVAL OF FUEL TANK ASSEMBLY”. 3. Disconnect the clamp from the swing machinery oil level gauge pipe. 4. Disconnect inter-oil cooler hose (2) and inter-control valve hose (3) to disconnect hose clamp (4). 5. 6. 7. 8.
Disconnect main pump suction hose (5). Disconnect PPC valve drain hose (6). Disconnect harness clamp (7). Disconnect engine oil filter bracket (8). * Move the filter assembly close to the engine. + Put the reserve tank on the main pump.
9. Disconnect self pressure reducing valve drain hose (91, swing motor drain hose (IO), boom lock valve drain hose (1 I), solenoid valve drain hose (121, main pump drain hose (13) and travel motor drain hose (14).
10. Temporarily lift hydraulicoiItank(15) and remove the mounting bolt to slowly lift and remove it. m & kg
PC1 28UU-2
Hydraulic
oil tank assembly
:95 kg
TANK
DISASSEMBLY
AND ASSEMBLY
HYDRAULIC
TANK
INSTALLATION OF HYDRAULIC TANK ASSEMBLY l
Carry out installation moval.
in the reverse
of hydraulic
order to re-
tank mounting Thread tightener
bolt : (LT-2)
6
Thread
m
Hydraulic tank mounting bolt : 277.0 f 31.9 Nm I28.25 f 3.25 kgm}
Refilling with oil (hydraulic tank) Add oil through the oil filler to the specified level. Run the engine to circulate the oil through the system. Then check the oil level again. Bleeding air Bleed the air. For details, see TESTING Bleeding air from hydraulic
30-42 0
AND ADJUSTING, cylinder.
PC1 28UU-2
DISASSEMBLY
MAIN
AND ASSEMBLY
REMOVAL OF MAIN PUMP ASSEMBLY a
Completely
ground
a
Drsconnect . tery.
the negative
the work equipment. (-1 terminal
of the bat-
1. Remove the hydraulic oil tank strainer and stop the oil using tool A5. + When tool A5 is not used, remove the drain plug to drain the oil from the hydraulic oil tank and the piping. -
:
Hydraulic
oil : 100 i?
2. Remove the counterweight assembly by referring to “REMOVAL OF COUNTERWEIGHT ASSEMBLY“. 3. Disconnect hose (1) from the radiator upper tank to remove bracket (2) from the fuel tank together with the reserve tank. 4. Remove bracket (3). + An EPC valve connector is mounted to it. 5. Disconnect PPC main pressure hose (4). 6. Disconnect earth cable (5) from the pump side. 7. Disconnect LS pressure input hose (6). 8. Disconnect EPC valve connector (7) (C13). 9. Disconnect suction tube (8) from the pump. 10. Disconnect pump output hose (9). 11. Disconnect pump pressure input hose (IO). 12. Disconnect case drain hose (11). 13. Disconnect muffler drain tube (12). 14. Remove adiabatic cover (13). 15. Disconnect joint (14) between the turbo charger and the muffler and remove muffler assembly(15) by removing the mounting bolt. 16. Drain the oil from the flywheel case. -
:
Flywheel
case : 0.75 e
lift the pump to remove the mount17. Temporarily ing bolt and lift main pump assembly (16) to rem move it. * Carefully remove it to prevent it from coming in contact with the engine oil filter. * It can be removed easier by lifting it at two points to make it parallel using a lever block. & kg
PC1 28UU-2
Main pump assembly:
95 kg
PUMP
DISASSEMBLY
INSTALLATION ASSEMBLY l
Carry out installation moval.
6
MAIN
AND ASSEMBLY
Mating
PUMP
OF MAIN PUMP in the reverse
order to re-
surface of pump case : Gasket sealant
(LG-6)
Refilling with oil (PTO gear case) Add engine oil through the oil filler to the 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. Bleeding air Bleed the air from main pump. For details, see TESTING AND Bleeding air.
30-44 0
ADJUSTING,
PC1 28UU-2
DISASSEMBLY
AND ASSEMBLY
MAIN
CONTROL
VALVE
REMOVAL OF MAIN CONTROL VALVE ASSEMBLY
a A
Gradually loosen the hydraulic oil tank cap to bleed the internal air after completely grounding the work equipment and stopping the engine. Bleed the remaining pressure from the hydraulic circuit bv referring to “BLEEDING REMAINING PRESSURE FROM HYDRAULIC CIRCUIT”. Remove two hand rails (I), upper cover (2) and side cover (3). Disconnect the right and left PPC hoses, the control valve outlet hose, the hose between the pump and the control valve and drain hose (4). * The main control valve hoses are arranged as follows from the top : 0 (Service) @ Offset @ Bucket @ Arm @ Blade @ Boom 0 Right travel @ Left travel @ Swing + When removing a hose, remove the nipple as necessary. + Affix a label or the like to the disconnected hose nipple. Lift main control valve assembly (5) to remove it. & kg
Main control valve assembly
: 120 kg
INSTALLATION OF MAIN CONTROL VALVE ASSEMBLY l
Carry out installation moval.
in the reverse order to re-
.
Refilling with oil (hydraulic tank) Add oil through the oil filler to the specified level. Run the engine to circulate the oil through the system. Then check the oil level again.
.
Bleeding air. Bleed the air from the circuit between the valve and the hydraulic cylinder. For details, see TESTING AND ADJUSTING, Bleeding air.
PC1 28UU-2
30-45 0
DISASSEMBLY AND ASSEMBLY
DISASSEMBLY
CONTROL VALVE
OF CONTROL VALVE ASSEMBLY
132
Z
Offset Bucket Arm Blade Boom R. H. travel L H. travel Swing
L
L
K
K
H
H
G
G
F
F
E
E
D
D
C
C
B
B
A
A t Y
DJP01043
30-46 0
PC1 28UU-2
DISASSEMBLY AND ASSEMBLY
CONTROL VALVE
DJPOlO44
PC1 28UU-2
30-47 0
DISASSEMBLY AND ASSEMBLY
CONTROL VALVE
(Boom)
DJPOlO46
30-48 0
PC1 28UU-2
DISASSEMBLY
-k
1.
2.
3.
4.
5.
6.
AND ASSEMBLY
CONTROL
Since pressure is applied to the suctionequipped safety valve circuit for a while after the machine is stopped, release the internal pressure by gradually loosening depressurizing plug (1). Do not disassemble the suction-equipped safety valve when it is mounted on the machine since the pressure cannot be set in the state. Be sure to mark the spool and the pressure compensation valves (flow control valve, depressurizing valve, piston) when removing them since they are not interchangeable among each valve and the direction of assembly is specified. Valve assembly 1) Remove main relief valve assembly (2). 2) Remove suction-equipped safety valve assemblies (3), (4) and (5). 3) Remove unload valve assembly (6). 4) Remove ten suction valve assemblies (7). 5) Remove LS select valve assembly (8). Lift check valve and cooler bypass valve 1) Remove case (9) to remove spring (IO), piston (11) and sleeve (12). 2) Remove case (13) to remove spring (14), piston (15) and sleeve (16). Swing control valve 1) Remove two plugs (17) to remove two pistons (18). 2) Remove two cases (19) to remove two springs (20) and two retainers (21). 3) Remove plug (22) to remove spool assembly (23). * Loosen plug (22) while spool (23) is engaged. Swing bleed valve 1) Remove flange (24). 2) Remove plug (25) to remove spring (26) and spool (27). 3) Remove plug (28) to remove ball (29). Left and right travel control valves 1) Remove two cases (30) to remove springs (31) and retainer (32). 2) Remove spool (33).
two
Travel junction valve 1) Remove two plugs (24) to remove two springs (35), two retainers (36) and two spools (37).
PC1 28UU-2
2)
Remove two balls (39).
plugs
VALVE
(38) to remove
two
7. Boom control valve 1) Remove two cases (20) to remove two springs (41) and two retainers (42). 2) Remove plugs (43) and (44) to remove spring (45), valve (46) and spool (47). -k Loosen plugs (43) and (44) while spool (47) is engaged. 8. Boom hydraulic drift prevention valve + When disassembling the boom hydraulic drift prevention valve by removing it from the body, remove four bolts (48) and two bolts (49). The bolt (50) is designed to mount plate +
1) 2) 3)
(51). When disassembling the boom hydraulic drift prevention valve without removing it from the body, remove four bolts (48) and one bolt (50). Remove plate (51) to remove spring (52), piston (53) and valve (54). Remove spring (55) to remove piston (56). Remove plug (57) to remove sleeve (58).
9. Blade control valve 1) Remove two cases (59) to remove two springs (60) and two retainers (61). 2) Remove plug (62) to remove spool (63). * Loosen plug (62) while spool (63) is engaged. 10. Arm control valve 1) Remove two cases (64) to remove two springs (65) and two retainers (66). 2) Remove two plugs (67) to remove spool assembly (68). * Loosen plugs (67) while spool (68) is engaged. 11. Arm regeneration valve Remove plug (69) to remove valve (71).
spring (70) and
12. Bucket control valve 1) Remove two cases (72) to remove two springs (73) and two retainers (74). 2) Remove plug (75) to remove spool assembly (76). * Loosen plug (75) while spool (76) is engaged.
30-49 0
DISASSEMBLY
AND ASSEMBLY
CONTROL
13. Offset control valve 1) Remove two cases (77) to remove two springs (78) and two retainers (79). 2) Remove plug (80) to remove spool assembly (81). + Remove plug (80) while spool (81) is engaged.
VALVE
21. Combination stud bolt (service valve added) + Disassemble as follows when a service valve is added : 1) Removefournuts(132)toremovethefour stud bolts. + Use a flat-head screwdriver to remove the bolts. 2) Remove cover (133).
14. Swing pressure compensation valve 1) Remove plug (82) to remove valve (83) and spring (84). 2) Remove plug (85) to remove spring (86), piston (87) and valve (88). 15. Left and right travel pressure compensation valves 1) Remove plug (89). 2) Remove bolt (90) to remove spring (91). 3) Remove plug (92) to remove valve (93). 4) Remove plug (94) to remove spring (95) and valve (96). 16. Boom pressure compensation valve 1) Remove plug (97) to remove valve and spring (99). 2) Removeplug(100)toremovespring(101), piston (102) and valve (103).
(98)
17. Blade pressure compensation valve 1) Remove plug (104) to remove valve (105) and spring (106). 2) Remove plug (107) to remove spring (108), piston (109) and valve (1 IO). 18. Arm pressure compensation valve 1) Removeplug(Ill)toremovevalve(112) and spring (113). 2) Removeplug(114)toremovespring(115), piston (116) and valve (117). 19. Bucket pressure compensation valve 1) Remove plug (118) to removevalve and spring (120). 2) Removeplug(121)toremovespring(122), piston (123) and valve (124).
(119)
20. Offset pressure compensation valve 1) Remove plug (125) to remove valve (126) and spring (127). 2) Remove valve (128) to remove spring (1291, piston (130) and valve (131).
30-50 0
PC1 28UU-2
DISASSEMBLY AND ASSEMBLY
ASSEMBLY
CONTROL VALVE
OF CONTROL VALVE ASSEMBLY
Z
L
Offset
K
Bucket
H
Arm
G
Blade
F
Boom
E
R. H. travel
D
L H. travel
C
Swing
B A J
t Y
DJP01043
PC1 28UU-2
30-5 1 0
DISASSEMBLY AND ASSEMBLY
CONTROL VALVE
DJPOlO44
30-52 0
PC1 28UU-2
DISASSEMBLY AND ASSEMBLY
CONTROL VALVE
F-F
(Blade)
(Arm)
L-L
K-K
PC1 28UU-2
(Offset)
DJPOlO45
30-53 0
DISASSEMBLY
AND ASSEMBLY
*
Apply engine oil to the sliding surface of each part before assembly.
1.
Combination stud bolt (service valve added) * Assemble as follows when a service valve is added: 1) Temporarily tighten the four stud bolts. 2) Install the service valve assembly. 3) Install cover (133). 4) Engage the four washers and tighten nuts (132). + Tighten nuts 0 to @ in the above sequence and by following the procedure below. w Nut: Isttime :58.8-68.6Nm{6-7kgmI 2nd time : 78.5 - 88.3 Nm I8 - 9 kgm} 3rd time : 98.1 - 113 Nm {IO- 11.5 kgm} When tightening, make sure that the height from the upper surface of the nut to that of the stud bolt is between 0.5mm and 3mm. If not, loosen the nut and adjust the mounting length of the stud bolt using a flathead screwdriver.
2.
3.
4.
CONTROL
5.
Blade pressure compensation valve 1) Mountvalve (1 IO), piston (109) and spring (108) to mount plug (107). m Plug (107) : 196 - 240 Nm I20 - 24.5 kgm} 2) Mount spring (106) and valve (105) to mount plug (104). m Plug (104) : 147 - 186 Nm {I5 - 19 kgm}
6.
Boom pressure compensation valve 1) Mount valve (103), piston (102) and spring (101) to mount plug (100). m Plug (100) : 147 - 186 Nm {I5 - 19 kgm) 2) Mount spring (99) and valve (98) to mount plug (97). m Plug (97) : 196 - 240 Nm I20 - 24.5 kgm}
7.
Arm pressure compensation valve 1) Mountvalve(117),piston(116)andspring (115) to mount plug (114). m Plug (114) : 147 - 186 Nm {I5 - 19 kgm} 2) Mount spring (113) and valve (112) to mount plug (111). m Plug (111) : 147 - 186 Nm {I5 - 19 kgm}
30-54 0
Right and left travel pressure compensation valves 1) Mount valve (96) and spring (95) to mount
2)
Offset pressure compensation valve 1) Mountvalve (131), piston (130) and spring (129) to mount valve (128). m Valve: 196-240Nm{20-24.5kgmI 2) Mount spring (127) and valve (126) to mount plug (125). w Plug : 147 - 186 Nm {I5 - 19 kgm) Bucket pressure compensation valve 1) Mountvalve (124), piston (123) and spring (122) to mount plug (121). m Plug (121) : 147 - 186 Nm {I5 - 19 kgm) 2) Mount spring (120) and valve (119) to mount plug (118). m Plug (118) : 196 - 240 Nm I20 - 24.5 kgm)
VALVE
3)
4)
8.
plug (94). w Plug (94) : 147 - 186 Nm {I5 - 19 kgm) Mount valve (93) to mount plug (92). m Plug (92) : 147 - 186 Nm {I5 - 19 kgm) Mount spring (91) to mount bolt (90). & Apply a drop of liquefied adhesive (Loctite 638) to the position 2mm to 3mm away from the end of the plug screw. w Bolt (90) : 11.8-14.7 Nm 11.2-1.5 kgm) * Completely degrease and dry the bolt and the female screw using a drying spray and do not pressurize them for two hours after tightening. Mount plug (89). m Plug (89) : 98 - 123 Nm {IO - 12.5 kgm)
Swing pressure compensation valve 1) Mount valve (88), piston (87) and spring (86) to mount plug (85). m Plug (85) : 147 - 186 Nm {I5 - 19 kgm) 2) Mount spring (84) and valve (83) to mount plug (82). m Plug (82) : 196 - 240 Nm I20 - 24.5 kgm)
PC128UU-2
DISASSEMBLY
AND ASSEMBLY
CONTROL
9. Offset control valve 1) Engage spool (81) with the body. 2) Mount plug (80). + Tighten plug (80) while spool (81) is engaged with the body. 6 Apply a drop of liquefied adhesive (Loctite 638) to the position 2mm to 3mm away from the end of the plug screw. m Plug : 14.7 - 19.6 Nm Il.5 - 2 kgm} * Completely degrease and dry the bolt and the valve chamber screw using a drying spray and do not pressurize them for two hours after tightening. 3) Mount two retainers (79) and two springs (78) to mount two cases (77). w Mounting bolt : 11.8-14.7Nm{1.2-1.5kgml * Since the plug mounting procedure and the case tightening torque are common to all spools, refer to this section (“Offset control valve”) for the following parts. 10. Bucket control valve 1) Engage spool (76) with the body. 2) Mount plug (75). -k Tighten plug (75) while spool (76) is engaged with the body. 3) Mount two retainers (74) and two springs (73) to mount two cases (72). 11. Arm regeneration valve Mount valve (71) and spring
(70) to mount
12. Arm control valve 1) Engage spool (68) with the body. 2) Mount two plugs (67). -k Tighten plugs (67) while spool (68) is engaged with the body. 3) Mount two retainers (66) and two springs (65) to mount two cases (64). 13. Boom hydraulic drift prevention valve 1) Mount sleeve (58) to mount plug (57). 2) Mount piston (56) to mount spring (55). 3) Mount valve (54), piston (53) and spring (52) to mount plate (51). m Mounting bolts (48) and (49) : 27.4 - 34.3 Nm I2.8 - 3.5 kgm} Mounting bolt (50) : 11.8-14.7Nm{1.2-1.5kgmI
PC1 28UU-2
14. Boom control valve 1) Engage spool (47) with the body. 2) Mount plugs (43) and (44). -k Tighten plugs (43) and (44) while spool (47) is engaged with the body. 3) Mount two retainers (42) and two springs (41) to mount two cases (40). 15. Travel junction valve 1) Mount two balls (39) to mount two plugs (38). m 2)
Plugs (38) : 5.9 - 8.8 Nm IO.6 Mount spool (37), retainer (36) springs (35) to mount two plugs m Plugs (34) : 49 - 62.7 Nm I5.0 -
0.9 kgm1 and two (34). 6.4 kgm}
16. Right and left travel control valves 1) Engage spool (35) with the body. 2) Mount two retainers (32) and two springs (31) to mount two cases (30). 17. Swing bleed valve 1) Mount ball (29) to mount plug (28). m Plug : 5.9 - 8.8 Nm IO.6 - 0.9 kgm} 2) Mount spool (27) and spring (26) to mount
3)
4)
plug (69).
VALVE
plug (25). w Plug : 24.5 -34.3 Mount flange (24). w Mounting bolt 11.8- 14.7 Mount plug (22). -k Tighten plug (22) engaged with the
Nm I2.5 - 3.5 kgm}
: Nm Il.2 - 1.5 kgml while spool (23) is body.
18. Swing control valve 1) Mount spool (23) to the body. 2) Mount two retainers (21) and two springs (20) to mount two cases (19). 19. Cooler bypass valve and lift check valve 1) Mount sleeve (16), piston (15) and spring (14) to mount case (13). w Mounting bolt : 27.5 - 34.3 Nm I2.8 - 3.5 kgml 2) Mount sleeve (12), piston (11) and spring (IO) to mount case (9). w Mounting bolt : 27.5 - 34.3 Nm {2.8- 3.5 kgml
30-55 0
DISASSEMBLY
AND ASSEMBLY
CONTROL
VALVE
20. Valve assembly 1) Mount LS select valve assembly (8). w LS select valve assembly : 108 - 147 Nm {II - 15 kgm} 2) Mount ten suction valve assemblies (7). m Suction valve assemblies : 137 - 157 Nm {I4 - 16 kgm} 3) Mount unload valve assembly (6). w Unload valve assembly : 147 - 186.3 Nm {I5 - 19 kgm} 4) Mount suction-equipped safety valve assemblies (3), (4) and (5). w Suction-equipped safety valve assembly (3) : 176.6 - 196.2 Nm {I8 - 20 kgm} m Suction-equipped safety valve assemblies (4) and (5) : 137 - 157 Nm {I4 - 16 kgml 5) Mount main relief valve assembly (2). m Main relief valve assembly : 88.3 - 107.9 Nm 19 - 11 kgm} 21. Depressurizing plug Mount depressurizing plug (1). w Depressurizing plug : 34 - 44 Nm I3.5 - 4.5 kgm}
30-56 0
PC1 28UU-2
DISASSEMBLY AND ASSEMBLY
DISASSEMBLY
LS SELECT VALVE
OF LS SELECT VALVE
CLP02267
1.
Remove
sleeve (2) and spring (3) from sleeve (1).
2.
Remove O-rings sleeve (1).
3.
Remove plug (71, then remove and spring (IO).
4.
Remove O-ring (11) from plug (7), then remove seal (12) and O-ring (13) from piston (9). + After disassembling, if there is any abnormality in any part except O-rings (41, (51, (1 I), or seal (6), replace the whole LS select valve assem bly.
ASSEMBLY VALVE
(4) and (5), and seal (6) from
pistons (8) and (91,
OF LS SELECT
*
Before assembling engine oil.
1.
Install O-ring (13) and seal (12) to piston (9), then assemble piston (8) and spring (IO), and install in sleeve (1).
2.
Assemble O-ring sleeve (1). m
3.
4.
coat the sliding
surface with
(11) to plug (7) and install to
Plug : 68.6 f 9.8 Nm I7 f 1 kgm}
Assemble spring sleeve (1). Install O-rings
(3) to sleeve
(2), and install to
(4) and (51, and seal (6) to sleeve
(1).
PC1 28UU-2
30-57 0
DISASSEMBLY
MAIN
AND ASSEMBLY
DISASSEMBLY
RELIEF VALVE
OF MAIN RELIEF VALVE ASSEMBLY
DBP00273
1.
Remove
ring (1) to remove
valve (2) and spring
(3). 2.
Loosen nut (4) to remove plug (5) and remove ring (6) and nut (4) from plug (5).
O-
3.
Loosen nut (7) to remove holder (8) and remove retainer (9), O-ring (IO) and nut (7) from holder (8).
4.
Remove spring (12) and puppet (13) from sleeve (11) and remove sleeve (14) and seat (15).
5.
Remove
6.
Remove O-ring (18), seal (19) and O-ring (20) from sleeve (11). If any abnormality is detected on valve (2), holder (8), retainer (9), sleeve (14), seat (15), ring (16), Oring (17) or sleeve (II), replace the entire main relief valve assembly.
-k
30-58 0
ring (16) and O-ring (17) from seat (15).
PC1 28UU-2
DISASSEMBLY AND ASSEMBLY
ASSEMBLY
MAIN RELIEF VALVE
OF MAIN RELIEF VALVE ASSEMBLY
DBP00273
.
Apply engine oil to the sliding surface before assembly.
8.
Mount O-ring (17) and ring (16) on seat (15) to engage sleeve (11).
*
Engage sleeve (14) with sleeve (11). Mount nut (7) and O-ring (10) on holder (8) and assemble retainer (9), poppet (13) and spring (12) to engage them with sleeve (11). + Completely engage the contacting faces of seat (15) and poppet (13).
Tighten the nut (4) with the specified w
torque.
Nut : 44.1 f 4.9 Nm I4.5 f 0.5 kgm}
After mounting it on the control valve assembly, adjust the pressure by referring to “INSPECTION AND ADJUSTMENT OF WORK EQUIPMENT, SWING AND TRAVEL CIRCUIT OIL PRESSURE” in “INSPECTION AND ADJUSTMENT”.
Engage nut (4) and O-ring (6) with plug (5) to mount them on holder (8). Engage spring (3) and valve (2) with sleeve (11) to mount ring (1) on them. Mount O-rings sleeve (11). Tighten m
PC1 28UU-2
(20) and (18) and seal (19) on
nut (7) with the specified
torque.
Nut : 68.8 f 4.9 Nm 16 f 0.5 kgml
30-59 0
DISASSEMBLY
WORK EQUIPMENT
AND ASSEMBLY
DISASSEMBLY OF WORK EQUIPMENT (PPC VALVE FOR BOOM, BUCKET, ARM, SWING CONTROL) 1.
Remove
nut (I), then remove
PPC VALVE
PPC VALVE ASSEMBLY
disc (2) and boot
(3). 2.
Remove bolts, then remove plate (5). -k Do not remove joint (4) unless it is to be replaced.
3.
Remove
4.
Pull out piston (81, and remove retainer (91, springs (IO) and (II), and shim (12). * Spring (lO),(ll) consists of each one of two types of springs with different installed loads in four places, so check the mounting position (oil pressure port) and mark with tags to prevent mistakes when installing.
5.
Pull out valve (13) from body (14).
seal (6) and collar (7).
CLP02285
30-60 0
PC1 28UU-2
DISASSEMBLY
WORK EQUIPMENT
AND ASSEMBLY
PPC VALVE
ASSEMBLY OF WORK EQUIPMENT PPC VALVE ASSEMBLY (PPC VALVE FOR BOOM, BUCKET, ARM, SWING CONTROL) 1. Assemble
valve (13) to body (14).
2.
Assemble shim (12) and spring (11) to valve (13). + When assembling spring (1 I), set the end with the small coil diameter (inside diameter) 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.
I
1
Position of port
1
PI, P2
I
44.4mm
I
P3, P4
I
42.4mm
I
I I
Free length of spring
+
The position of each port is marked on the bottom of the valve body. 6 Piston : Grease (G2-LI) * When assembling the piston, coat the outside of the piston and the inside of the hole in the body with grease. 4.
Fit O-ring to collar (7) and assemble then install seal (6).
5.
Install plate (5). w Mounting bolt : 13.23 f 1.47 Nm Il.35
6.
m *
-k
f 0.15 kgm}
Install joint (4). & Sliding portion of joint : Grease (G2-LI) 6 Female thread of body : Thread tightener (LT-2) *
7.
in body (141,
Coat two places on the female thread with one drop each of Loctite as shown in the diagram below. Joint : 44.1 f 4.9 Nm I4.5 f 0.5 kgm} Keep strictly to the tightening torque.
Assemble boot (3) and disc (21, and tighten with nut (1). w Nut: 112.7 f 14.7 Nm Ill.5 f 1.5 kgm} After assembling the disc, adjust the height of the disc. For details, see TESTING AND ADJUSTING, Adjusting PPC valve.
PC1 28UU-2
30-6 1 0
DISASSEMBLY
TRAVEL PPC VALUE
AND ASSEMBLY
DISASSEMBLY OF TRAVEL PPC VALVE ASSEMBLY 1. Remove
screw (I) to remove
lever (2).
2.
Remove mounting assembly (4).
3.
Remove mounting bolt (5) to remove plate (6) together with damper assembly (7). -k Check the thickness and the mounting position of washer (18).
4.
Remove mounting bolt (8) to remove sembly (7) from plate (6).
5.
Remove
6.
Remove piston (11) to remove retainer (12), springs (13) and (14) and shim (15). -k Store shim (15) after checking the thickness and the number of shims at each mounting position.
7.
Remove
bolt (3) to remove
case shaft
damper
as-
seal (9) and collar (IO).
valve (16) from body (17).
CEP00533
l
Details of body (17)
CLPO1455
30-62 0
PC1 28UU-2
DISASSEMBLY
AND ASSEMBLY
TRAVEL PPC VALUE
ASSEMBLY OF TRAVEL PPC VALVE ASSEMBLY 1. Engage valve (16) with body (17). 2.
Engage shim (15) and spring (14) with valve (16). + Mount shim (15) on the position which has been checked at the time of disassembly with the proper thickness and number. Standard shim thickness : 0.3mm * Since spring (14) is not symmetric vertically, engage it with the smaller diameter side facing the shim.
3.
Mount spring (13), retainer 6
Piston outside
(12) and piston (11).
perimeter
and body hole : Grease
(G2-LI)
4.
Place the O-ring on collar (IO) to engage them with body (17) and mount seal (9) on them.
5.
Mount tighten
6.
(6) and
Mounting
bolt : Adhesive
m
Mounting
bolt : 4.4 f 0.5 Nm IO.45 f 0.05 kgm}
(LT-2)
Mount washer (18) together with damper assembly (7) and tighten mounting bolt (5). * Engage washer (18) with a standard washer (1.6mm) beforehand. After completing assembly, measure the difference in the angles when the left and right levers are at full strokes. If it is larger than 0.7”, change the thickness of the washer (18) to make it 0.7” or less. l Washer thickness : 1 .O, 1.3 or 1.6mm * Reducing the washer thickness by 0.3mm increases the full stroke angle by 0.39”. Mounting bolt : 31.0 f 3.4 Nm I3.15 f 0.35 kgml
Mount case shaft assembly ing bolt (3). & w
8.
(7) on plate
6
w
7.
damper assembly mounting bolt (8).
(4) and tighten mount-
Shaft swaying part, and lever and piston contacting part : Grease (G2-LI) Mounting bolt : 28.0 f 3.4 Nm I2.85 f 30.35 kgm}
Mount
lever (2) and tighten
&
part : Grease (G2-LI) Screw : 8.8 f 1.0 Nm IO.9 f 0.1 kgm}
w
PC1 28UU-2
screw (1).
Lever pin and plate swaying
CEP00533 L
30-63 0
DISASSEMBLY AND ASSEMBLY
ARM CYLINDER
REMOVAL OF ARM CYLINDER ASSEMBLY a Pull in the bucket, lower the work equipment completely to the ground, with stand 0. 1. Sling arm cylinder
2.
and support the arm
(I), and remove
head pin (2). m
Start engine, and retract piston rod, then tie piston rod with wire to prevent it from coming out. a
Loosen the sleeve nut of the hose slowly and check that no oil spurts out, then remove.
3.
Disconnect
4.
Using tool VI, pull out cylinder mounting pins (41, then lift off arm cylinder assembly (1). m * There are shims installed, so check the number and thickness, and keep in a safe place. & kg
CLPO2306
hose (3).
Arm cylinder
assembly
: 140 kg
CLPO2306
-
30-64 0
DJPOt046
PC1 28UU-2
DISASSEMBLY
INSTALLATION ASSEMBLY l
ARM CYLINDER
AND ASSEMBLY
Carry out installation moval.
OF ARM CYLINDER in the reverse order to re-
Inside surface of bushing when assembling pin : Hyper white grease (GO-T, G2-T) or molybdenum disulphide lubricant (LM-PI Greasing after assembling pin : Hyper white grease (GO-T, G2-T) or molybdenum disulphide lubricant (LM-G) aligning the position of the pin hole, ALWhen never insert your fingers in the pin hole. +
l
shim thickness
: 1.0,2.0
mm
&
Inside surface of bushing when assembling pin : Hyper white grease (GO-T, G2-T) or molybdenum disulphide lubricant (LM-PI
6
Greasing after assembling pin : Hyper white grease (GO-T, G2-T) or molybdenum disulphide lubricant (LM-G)
a
When aligning the position of the pin hole, never insert your fingers in the pin hole. Standard shim thickness : 1.5 mm
* l
Standard
Bleeding air Bleed the air. For details, see TESTING Bleeding air from hydraulic
AND ADJUSTING, cylinder.
Refilling with oil (hydraulic tank) Run the engine to circulate the oil through system. Then add oil to the specified level.
PC1 28UU-2
the
30-65 0
DISASSEMBLY
OFFSET CYLINDER
AND ASSEMBLY
REMOVAL OF OFFSET CYLINDER ASSEMBLY a
Run the engine at low idling, operate the control levers to retract the arm cylinder and boom cylinder, and lower the work equipment completely to the ground. When doing this, be careful not to relieve the circuit at the end of the cylinder stroke.
1. Sling offset cylinder (I), then using tool V2, rem move head pin (2). -k There are shims installed, so check the number and thickness, and keep in a safe place. 2.
Start engine, and retract piston rod, then tie piston rod with wire to prevent it from coming out. Loosen the sleeve nut of the hose slowly and a check that no oil spurts out, then remove.
3.
Disconnect
4.
Using tool V2, pull out bottom pin (4), then lift off m offset cylinder assembly (I). -k There are shims installed, so check the number and thickness, and keep in a safe place. & kg
30-66 0
CLPO2311
hose (3).
Offset cylinder
assembly
: 90 kg
PC1 28UU-2
DISASSEMBLY
AND ASSEMBLY
INSTALLATION ASSEMBLY l
Carry out installation moval.
OFFSET CYLINDER
OF OFFSET CYLINDER in the reverse order to re-
Inside surface of bushing when assembling pin : Hyper white grease (GO-T, G2-T) or molybdenum disulphide lubricant (LM-PI Grease after assembling pin : Hyper white grease (GO-T, G2-T) or molybdenum disulphide lubricant (LM-G)
A
a
l
l
When aligning the position of the pin hole, never insert your fingers in the pin hole. + Standard shim thickness : 1.5 mm
&
Inside surface of bushing when assembling pin : Hyper white grease (GO-T, G2-T) or molybdenum disulphide lubricant (LM-P)
6
Grease after assembling pin : Hyper white grease (GO-T, G2-T) or molybdenum disulphide lubricant (LM-G)
When aligning the position of the pin hole, never insert your fingers in the pin hole. * Standard shim thickness : 0.5 mm Bleeding air Bleed the air. For details, see TESTING Bleeding air from hydraulic
AND ADJUSTING, cylinder.
Refilling with oil (hydraulic tank) Run the engine to circulate the oil through system. Then add oil to the specified level.
PC1 28UU-2
the
30-67 0
DISASSEMBLY
HYDRAULIC
AND ASSEMBLY
CYLINDER
DISASSEMBLY OF HYDRAULIC CYLINDER ASSEMBLY *
This section explains how to disassemble and assemble the boom, arm, bucket and blade cylinders. For how to disassemble and assemble the offset cylinder, refer to “DISASSEMBLY AND ASSEMBLY OF OFFSET CYLINDER ASSEMBLY”.
1.
Piston rod assemblv 1) Remove the piping from the cylinder assembly. 2) Remove the mounting bolt to disconnect head assembly (1). 3) Remove piston rode assembly (2). * Place an oil pan or the like under the cylinder to receive oil. 4) Disassemble the piston rod assembly with the following procedure. i) Set piston rod assembly (2) on tool Ul.
ii)
CLPO3941
Remove piston assembly lock screw (3). Screw size Ml2 x 1.75 pitch : Boom, arm and blade Ml 0 x 1.5 pitch : Bucket
CLPO3779
+
If screw (3) is caulked too tightly to be removed, force the screw in once and then tap it to remove it.
3
Tap
DXP01039
30-68 0
PC1 28UU-2
DISASSEMBLY AND ASSEMBLY
iii)
Use tool U2 to remove
HYDRAULIC CYLINDER
piston assembly
(4). l
u2
If tool U2 is not used, use the four drill holes (diameter = IO) to loosen the piston assembly.
I iv) Remove
the head assembly
DJP01048
(5).
CWPO7942
v)
Remove cap (6) to remove eleven balls (7) and cushion plunger (8). l For the arm cylinder only.
CWPO7943
2.
Sub-disassembly of piston assembly 1) Remove ring (9). 2) 3) 4)
Remove Remove Remove
wear ring (IO). piston ring (11). the O-ring and backup ring (12).
CWPO7944
PC1 28UU-2
30-69 0
DISASSEMBLY
3.
HYDRAULIC
AND ASSEMBLY
Disassembly of cylinder head assembly 1) Remove O-ring and backup ring (13). 2) Remove snap ring (14), then remove dust seal 3) 4) 5)
(15). Remove Remove Remove
rod packing (16). buffer ring (17). bushing (18).
H
I
1
CYLINDER
A20
I! I7 18
CLP02322
30-70 0
PC1 28UU-2
DISASSEMBLY
HYDRAULIC
AND ASSEMBLY
CYLINDER
ASSEMBLY OF HYDRAULIC CYLINDER ASSEMBLY * *
1.
Be careful not to damage the packing, the dust seal, the O-ring or the like Do not forcibly insert the backup ring but make it warm with hot water (50 to 60°C) before insertion. Sub-assembly of cylinder head 1) Press fit bushing (18) using 2) Engage buffer ring (17). 3) Engage rod packing (16). 4) Mount dust seal (15) using with snap ring (14). 5) Mount the backup ring and
assembly tool U3.
tool U4 and fix it
CWPO7946
O-ring (13).
17
I6
CWPO7946
2.
Sub-assembly of piston assembly 1) Expand piston ring (11) using tool U5. + Set the piston ring on tool U5 and expand it by rotating the handle eight to ten times. Reduce piston ring (11) using tool U6. 2)
CWPO7947
3) 4) 5)
Mount the backup ring and O-ring (12). Engage wear ring (IO). Engage ring (9). * Be careful not to expand the ring abutment joint too much. & Ring groove : Grease (G2-LI)
CWPO7941
PC1 28UU-2
DISASSEMBLY
3.
AND ASSEMBLY
Piston rod assembly 1) Set piston rod assembly
2)
Engage
head assembly
HYDRAULIC
CYLINDER
(2) on tool Ul.
(5).
CWPO7942
3)
Set cushion plunger (8) on the piston rod and engage 11 balls (7) and fix them using cap (6).
4)
l For the arm cylinder only. Assemble piston assembly (4) in the following procedure. l When the rod and piston assembly (4) are reused * Completely wash them and clear them of cut powder or dust. i) Screw piston assembly (4) and tighten it using tool U2 until the screw hole position completely fits. -k Eliminate screw burrs using a file or the like. ii) Tighten screw (3).
6 m
[c
CWPO7943
Screw (3) : Liquefied adhesive (Loctite 262 or its equivalent) Screw (3) : Boom, arm and blade : 58.9 - 73.6 Nm {S - 7.5 kgm} Bucket : 27.5 - 34.3 Nm I2.8 - 3.5 kgm}
DJP01048
30-72 0
PC1 28UU-2
DISASSEMBLY
iii) Caulkthescrewatfour punching. l
HYDRAULIC
AND ASSEMBLY
CYLINDER
pointsthrough
When new rod and/or piston assembly (2) are/is used rod, -k For the bottom cushion-equipped markthe cushion plug position on the rod end surface. l For the arm cylinder only.
Punch
m
i)
Screw piston assembly (4) until it comes in contact with rod end surface & -k
l
2
Piston assembly (4) : 294 f 29.4 Nm I30 f 3.0 kgm} After tightening the piston, make sure that there is some play with plunger. For the boom and arm cylinders only.
,f ii)
Drill a hole for mounting screw (3). * Engage the drill with the screw Vshaped grooves of piston (4) and rod (2) for horizontal processing. -k Process the bottom cushionequipped cylinder (arm cylinder) on other part than the cushion plug position. l Screw processing dimensions (mm)
1
Bucket
8.5
1
27
I’lOx1.5
1
20
CWPO7959
CWPO7948
iii) Clear it of cut powder and dust and completely wash it after processing. iv) Tighten screw (3). Screw (3) : Liquefied adhesive (Loctite 262 or its equivalent) m Screw (3) : Boom, arm and blade : 58.9 - 73.6 Nm 16 - 7.5 kgm} Bucket : 27.5 - 34.3 Nm I2.8 - 3.5 kgml Caulkthescrewatfourpointsthrough punching. 6
VI
CLPO377!
PC1 28UU-2
DISASSEMBLY AND ASSEMBLY
5)
Engage &
+
+
piston rod assembly
HYDRAULIC CYLINDER
(2)
Seal : Grease (G2-LI) Set the ring abutment joint horizontally and align the axes of the piston rod assembly and the cylinder tube to insert them. After insertion, make sure that the ring is not damaged or dropped and completely push the piston rod.
End sap’ in ring DJP01047
Mount head assembly (I) and tighten the mounting bolt. w Mounting bolt :
7)
it with
Moun t the piping. CLPO3941 I
30-74 0
PC1 28UU-2
DISASSEMBLY
OFFSET CYLINDER
AND ASSEMBLY
DISASSEMBLY OF OFFSET CYLINDER ASSEMBLY 1.
Cylinder assembly 1) Set cylinder assembly (1) on tool Ul. 2) Use a hydraulic pump or a powerwrench and tool U7 to loosen head assembly (2). 3) Remove piston rod assembly (3). -k Place an oil pan or the like under the cylinder to receive oil.
CWPO7936
CWPO-5577
2.
Piston rod assembly 1) Set piston rod assembly (3) on tool Ul. 2) Use a hydraulic pump or a powerwrench tool U2 to remove nylon nut (4). -k Width across nut flats: 80mm
3)
Remove
piston assembly
4)
(5). Remove
head assembly
and
(6) from piston rod (2).
CWPO7937
PC1 28UU-2
DISASSEMBLY
3.
AND ASSEMBLY
OFFSET CYLINDER
Sub-disassembly of piston assembly 1) Remove wear ring (7). 2) Remove piston ring (8). * Remove the piston ring by applying a screwdriver or the like to it, and hitting its handle using a hammer to cut it.
CWPO7938
4.
Sub-disassembly of cylinder head assembly 1) Remove the O-ring and backup ring (9). 2) Remove O-ring (IO). 3) Remove snap ring (11) and dust seal (12). 4) Remove rod packing (13). 5) Remove bushing (14).
9
IO II CWPO7939
30-76 0
PC1 28UU-2
DISASSEMBLY
AND ASSEMBLY
OFFSET CYLINDER
ASSEMBLY OF OFFSET CYLINDER ASSEMBLY *
-k
Apply engine oil to the sliding surface of each part and be careful not to damage the packing, the dust seal, the O-ring or the like. Do not forcibly insert the backup ring but make it warm with hot water (50 - 60°C) before insertion.
1. Sub-assemblv of cvlinder head 1) Press fit bushing (14) using 2) Mount rod packing (13). 3) Mount dust seal (12) using with snap ring (11). 4) Mount O-ring (IO). 5) Mount the backup ring and
assemblv tool U6. _ tool U7 and fix it CWPO7940
O-ring (9).
9
13
14
IO I2 CWPO7939
2.
Sub-assembly of piston assembly 1) Expand piston ring (8) using tool U5. + Set the piston ring on tool U5 and expand it by rotating the handle eight to ten times. 2) Reduce piston ring (8) using tool U6.
CWPO7941
3)
Engage wear ring (7). * Be careful not to expand ment joint too much.
the ring abut-
1: CWPO7938
PC1 28UU-2
30-77 0
DISASSEMBLY
3.
AND ASSEMBLY
OFFSET CYLINDER
Piston rod assembly 1) Engage head assembly (2) with piston rod (5). 2) Engage piston assembly (6) with piston rod 3) 4)
(5). Set piston rod assembly (3) on tool Ul. Tighten nylon nut (4) using tool U2. 6 m
Nylon nut : Liquefied adhesive (Loctite 262 or its equivalent) Nylon nut : 3.97 f 0.40 kNm I405 f 40.5 kgm}
CWPO7937
’CLPO7936
i
4.
Cylinder assembly 1) Set the cylinder on tool Ul. 2) Engage piston rod assembly (3). * Set the ring abutment joint horizontally and align the axes of the piston rod assembly and the cylinder tube to insert them. * After insertion, make sure that the ring is not damaged or dropped and completely push the piston rod. 0 \
3)
CWPO6677
Tighten head assembly (2) using a hydraulic pump or a power wrench and tool U7. m
Head assembly : 1.03 f 0.10 kNm II05
f 10.5 kgm}
CWPO7936
30-78 0
PC1 28UU-2
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).
2.
Remove left and right working lamp connectors (2), and disconnect ground connection (3).
3.
Sling boom cylinder assembly (4), and remove head pin (51, then lower boom cylinder assembly (4) on block (1). m * There are shims installed, so check the number and thickness, and keep in a safe place. Loosen the sleeve nut of the hose slowly and a check that no oil spurts out, then remove.
CLPO2329
'02330
4.
Remove control valve cover, and disconnect hoses (6) from control valve.
5.
Remove
6.
Disconnect
PC1 28UU-2
boom angle potentiometer boom angle potentiometer
6
cover. linkage (8).
DISASSEMBLY
AND ASSEMBLY
WORK EQUIPMENT
7.
Remove
8.
Raise work equipment assembly, remove plate, then remove foot pin (9) using tool V3, and remove work equipment assembly (IO). m -k There are shims installed, so check the number and thickness, and keep in a safe place. & kg
lock plate (8).
Work equipment
assembly
: 3,200 kg
CWPO7916
I
30-80 0
CLPO2334
PC1 28UU-2
DISASSEMBLY
INSTALLATION ASSEMBLY l
WORK EQUIPMENT
AND ASSEMBLY
Carry out installation moval.
OF WORK EQUIPMENT in the reverse order to re-
m +
When tightening the locknut, tighten so that the clearance between the plate and nut is 0.5 - 1.5 mm.
Inside surface of bushing when assembling pin : Hyper white grease (GO-T, G2-T) or molybdenum disulphide lubricant (LM-PI
CLPO2303
Grease after assembling pin : Hyper white grease (GO-T, G2-T) or molybdenum disulphide lubricant (LM-G)
a
When aligning the position of the pin hole, never insert your fingers in the pin hole. Adjust the shim thickness so that’clearance a between cylinder rod (11) and 1st boom (12) is less than 1 mm. Standard shim thickness : 1.0 mm
II CLPO2336
Inside surface of bushing when assembling pin : Hyper white grease (GO-T, G2-T) or molybdenum disulphide lubricant (LM-PI Grease after assembling pin : Hyper white grease (GO-T, G2-T) or molybdenum disulphide lubricant (LM-G)
AL When never +
* l
l
aligning the position of the pin hole, insert your fingers in the pin hole. Adjust the shim thickness so that clearance b between 1st boom (12) and bracket (13) is less than 0.5 mm. Standard shim thickness : 0.5, 1.0 mm
Bleeding air Bleed the air. For details, see TESTING Bleeding air from hydraulic
AND ADJUSTING, cylinder.
Refilling with oil (hydraulic tank) Run the engine to circulate the oil through system. Then add oil to the specified level.
PC1 28UU-2
CLP02336
the
30-8 1 0
DISASSEMBLY AND ASSEMBLY
REMOVAL
ARM
OF ARM ASSEMBLY
Swing the work equipment
for 180”.
Set the back of the bucket facing down, lower the work equipment completely to the ground, and set the safety lock lever to the LOCK position. 1.
Remove
band
(I).
\ 2.
Remove
lock pin (2).
3.
Remove connecting pin (3) between link and bucket. -k 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.
CLPO2157
m
CLPO2156
5.
Remove
band (4).
6.
Remove
lock pin (5).
7.
Remove
plate (6).
8.
Remove connecting pin (7) between arm and bucket. -k There are shims installed, so check the number and thickness, and keep in a safe place. CLPO2159
9.
After raising work equipment, nect bucket assembly (8). & kg
Bucket assembly
swing
: 370 kg
to discon-
CLPO2160
v 0
0
0
0
CLPO2161
30-82 0
PC1 28UU-2
DISASSEMBLY
ARM
AND ASSEMBLY
10. Set block 0 under arm and bucket cylinder sembly (91, and lower work equipment. 11. Remove
potentiometer
as-
cover (‘IO).
12. Sling arm cylinder (1 I), remove pin (12),then pull in cylinder rod and lower on to 2nd boom (13). 113
13. Disconnect bucket cylinder hoses (14) and (15). Loosen the sleeve nut of the hose slowly and a check that no oil spurts out, then remove. * After disconnecting the hoses, install blind plugs in them. 14. Disconnect
arm angle potentiometer
15. Disconnect
wiring
16. Remove
connector
hose clamp (18).
(17).
linkage (16).
--cr I8 \
hI
II 1
PC1 28UU-2
CWPO7912
30-83 0
DISASSEMBLY
ARM
AND ASSEMBLY
17. Remove connecting offset bracket (20).
pin (21) between arm (19) and
18. Use cancel switch and raise boom, then swing and remove arm and bucket cylinder assembly (9). it’ There are shims installed, so check the number and thickness, and keep in a safe place. & kg
Arm, bucket cylinder
assembly
: 470 kg
’ CWPO7913
30-84 0
PC1 28UU-2
DISASSEMBLY
AND ASSEMBLY
INSTALLATION l
Carry out installation moval.
&
&
A +
&
&
A + +
ARM
OF ARM ASSEMBLY in the reverse order to re-
Inside surface of bushing when assembling pin : Hyper white grease (GO-T, G2-T) or molybdenum disulphide lubricant (LM-PI Grease after assembling pin : Hyper white grease (GO-T, G2-T) or molybdenum disulphide lubricant (LM-G) When aligning the position of the pin hole, never insert your fingers in the pin hole. Standard shim thickness : 1.0,2.0 mm
Inside surface of bushing when assembling pin, inside surface, end face of collar : Hyper white grease (GO-T, G2-T) or molybdenum disulphide lubricant (LM-PI Grease after assembling pin : Hyper white grease (GO-T, G2-T) or molybdenum disulphide lubricant (LM-G) When aligning the position of the pin hole, never insert your fingers in the pin hole. Set the O-ring at the end face of the bucket boss securely. Standard shim thickness : 0.5,l.O mm
r
Inside surface of bushing when assembling pin : Hyper white grease (GO-T, G2-T) or molybdenum disulphide lubricant (LM-PI Grease after assembling pin : Hyper white grease (GO-T, G2-T) or molybdenum disulphide lubricant (LM-G) When aligning the position of the pin hole, never insert your fingers in the pin hole. Standard shim thickness : 1.0,2.0 mm
d_l
AL +
Inside surface of bushing when assembling pin : Hyper white grease (GO-T, G2-T) or molybdenum disulphide lubricant (LM-PI Grease after assembling pin : Hyper white grease (GO-T, G2-T) or molybdenum disulphide lubricant (LM-G) When aligning the position of the pin hole, never insert your fingers in the pin hole. Adjust the shim thickness so that the clearante a between arm (19) and offset bracket (20) is less than 0.5 mm. Standard shim thickness : 0.5, 1.0 mm
l
AL +
*
PC1 28UU-2
.
CWPO7914
Bleeding air Bleed the air. For details, see TESTING AND ADJUSTING, Bleeding air from hydraulic cylinder. Refilling with oil (hydraulic tank) Run the engine to circulate the oil through the system. Then add oil to the specified level.
30-85 0
DISASSEMBLY
AND ASSEMBLY
SECOND
BOOM
REMOVAL OF SECOND BOOM ASSEMBLY Remove arm assembly. For details, see REMOVAL A
OF ARM ASSEMBLY.
Loosen the sleeve nut of the hose slowly and check that no oil spurts out, then remove.
Sling arm cylinder assembly (I), and disconnect hose (2). * After disconnecting the hoses, install blind plugs in them. CLPO2337
Using tool VI, pull out trunnion pins (3), then lift off arm cylinder assembly (1). m -k There are shims installed, so check the number and thickness, and keep in a safe place. & kg
Arm cylinder
assembly
VI
I
: 140 kg
--
CWPO
Sling offset cylinder assembly (4), and using tool V2, remove head pin (5). m -k Start the engine, and retract the piston rod, then tie the piston rod with wire to prevent it from coming out, * There are shims installed, so check the number and thickness, and keep in a safe place. Disconnect hoses (6), and using tool V2, pull out bottom pin (71, then lift off offset cylinder assem1131 bly (4). A kg
30-86 0
Offset cylinder
assembly
: 90 kg
CLPO2339
PC1 28UU-2
DISASSEMBLY
6.
AND ASSEMBLY
SECOND
BOOM
Remove arm potentiometer wiring clamp (8), pull out pins (9) and (IO), then remove offset link (11). m
CLPO2341
7. *
8.
Remove clamp (12) (wiring clamp for arm, bucket cylinder hose and arm potentiometer). m Make marks to show the mounting positions of the hoses.
Sling offset bracket (13), and using tool V2, pull out top and bottom pins (14), then lift off offset bracket (13). m There are shims installed, so check the num+ ber and thickness, and keep in a safe place. f+ kg
Offset bracket : 220 kg
CWPO7919
9.
Disconnect
PC1 28UU-2
grease hose (15).
30-87 0
DISASSEMBLY
AND ASSEMBLY
10. Disconnect
grease hose (16).
11. Disconnect
connector
SECOND
BOOM
(17).
12. Remove offset angle potentiometer move spacer.
(IS), then rem
46
13. Sling second boom assembly (19), and using tool V2, pull out pins (201, then lift off second boom 1181 assembly (19). * There are shims installed, so check the number and thickness, and keep in a safe place. * The hoses pass through the inside of the boom, so be careful when handling the 2nd boom.
f3 kg
Second
boom : 350 kg CLP02347
CWPO7920
30-88 0
PC1 28UU-2
DISASSEMBLY
AND ASSEMBLY
INSTALLATION ASSEMBLY l
Carry out installation moval.
SECOND
BOOM
OF SECOND BOOM in the reverse order to re-
Inside surface of bushing when assembling pin : Hyper white grease (GO-T, G2-T) or molybdenum disulphide lubricant (LM-P) Grease after assembling pin : Hyper white grease (GO-T, G2-T) or molybdenum disulphide lubricant (LM-G)
a *
When aligning the position of the pin hole, never insert your fingers in the pin hole. Standard shim thickness : 1.5 mm
Inside surface of bushing when assembling pin : Hyper white grease (GO-T, G2-T) or molybdenum disulphide lubricant (LM-PI Grease after assembling pin : Hyper white grease (GO-T, G2-T) or molybdenum disulphide lubricant (LM-G)
AL When never +
aligning the position of the pin hole, insert your fingers in the pin hole. Standard shim thickness : 0.5 mm
&
Inside surface of bushing when assembling pin : Hyper white grease (GO-T, G2-T) or molybdenum disulphide lubricant (LM-PI
6
Grease after assembling pin : Hyper white grease (GO-T, G2-T) or molybdenum disulphide lubricant (LM-G)
a
When aligning the position of the pin hole, never insert your fingers in the pin hole. Standard shim thickness : 0.5 mm
*
Inside surface of bushing when assembling pin : Hyper white grease (GO-T, G2-T) or molybdenum disulphide lubricant (LM-PI Grease after assembling pin : Hyper white grease (GO-T, G2-T) or molybdenum disulphide lubricant (LM-G)
AL When never +
aligning the position of the pin hole, insert your fingers in the pin hole. Standard shim thickness : 1.0 mm
PC1 28UU-2
30-89 0
DISASSEMBLY
-k
AND ASSEMBLY
Be sure to clamp rectly.
SECOND
the hoses and wiring
BOOM
cor-
Inside surface of bushing when assembling pin : Hyper white grease (GO-T, G2-TI or molybdenum disulphide lubricant (LM-PI Grease after assembling pin : Hyper white grease (GO-T, G2-TI or molybdenum disulphide lubricant (LM-G)
a * m -k
When aligning the position of the pin hole, never insert your fingers in the pin hole. Standard shim thickness : 0.5 mm
After completing all processes in the work of installing the 2nd boom assembly, reset the input and output signals of the electrical system and check the operation. For details, see TESTING AND ADJUSTING, Procedure for resetting input and output signals of electrical system and checking operation.
Inside surface of bushing when assembling pin : Hyper white grease (GO-T, G2-T) or molybdenum disulphide lubricant (LM-PI Grease after assembling pin : Hyper white grease (GO-T, G2-T) or molybdenum disulphide lubricant (LM-G)
a *
When aligning the position of the pin hole, never insert your fingers in the pin hole. Standard shim thickness : 0.5 mm
Bleeding air Bleed the air. For details, see TESTING Bleeding air from hydraulic
AND ADJUSTING, cylinder.
Refilling with oil (hydraulic tank) Run the engine to circulate the oil through system. Then add oil to the specified level.
30-90 0
the
PC1 28UU-2
DISASSEMBLY
AND ASSEMBLY
OPERATOR
REMOVAL OF OPERATOR CAB ASSEMBLY a
Completely
ground
a
Drsconnect . tery.
the negative
1. Remove
the work equipment. (-1 terminal
of the bat-
louver (1).
2.
Remove four screws switch panel (2).
3.
Remove
4.
Disconnect air conditioner connectors M31) (5) and (6) to remove duct (4).
5.
Disconnect
6.
Disconnect window washer hose (8). + Bend it to prevent detergent liquid from flowing out of the washer tank.
air conditioner
screw (3) to slide duct (4) forward.
Disconnect Remove
to remove
wiper
motor connector
radio connector
controller
housing
(Ml2
(CN-75)
and
(7).
(B3). panel cover (9).
Remove mounting bolt (IO), disconnect panel assembly (11) from the operator cab and put it at the rear of the operator seat.
PC1 28UU-2
CAB
DISASSEMBLY
AND ASSEMBLY
OPERATOR
10. Remove the mounting bolt and lift operator assembly (12) to remove it. & kg
Operator
cab assembly
CAB
cab
: 240 kg
INSTALLATION OF OPERATOR CAB ASSEMBLY l
Installation removal.
30-92 0
is performed
in the opposite
way to
PC1 28UU-2
DISASSEMBLY
AND ASSEMBLY
FLOOR FRAME
REMOVAL OF FLOOR FRAME ASSEMBLY
a a
Gradually loosen the hydraulic oil tank cap to bleed the internal air after completely grounding the work equipment and stopping the enDrsconnect g!ne. tery.
the negative
(-1 terminal
of the bat-
1. Remove the operator cab assembly by referring to “REMOVAL OF OPERATOR CAB ASSEMBLY”. 2. Remove
the left side cover.
3. Disconnect connectors CNI (I), CN2 (21, CN3 (31, CN4 (4), CN5 (5) and CN6 (6). Disconnect
earth cable (7).
Remove
hand rail (8).
Remove
covers (9) and (IO).
Lift and remove cover frame and the engine.
(11)
between
the floor
8. Disconnect PPC hose (12) (bucket DUMP, arm IN, boom LOWER and bucket TILT from the top). 9. Disconnect PPC hose (13) (arm IN, boom LOWER, right and left SWING from the top). + If the colored tape is damaged and thus cannot be identified, attach a label or the like for identification. 10. Disconnect
two travel (right-side)
11. Disconnect
two travel (left-side)
PC1 28UU-2
PPC hoses (14). PPC hoses (15).
FLOOR FRAME
DISASSEMBLY
AND ASSEMBLY
12. Disconnect va Ive.
four hoses (16) from the blade
13. Disconnect va Ive.
four hoses (17) from the offset PPC
14. Disconnect
PPC main pressure
PPC
hose (18) (Al).
15. Disconnect PPC drain hose (19). * Drain the hydraulic oil. -
:
Hydraulic
oil : 90 e
pipings (20). 16. Disconnect two air-conditioning * Disconnect the hoses after completely bleeding the air conditioning gas (R134a) using tool X. -k Apply the blind plug to prevent dust or water from entering the hoses. -k Be careful not to damage or lose the O-ring.
30-94 0
PC1 28UU-2
DISASSEMBLY
AND ASSEMBLY
FLOOR FRAME
17. Lift and remove floor frame assembly (21). + Be careful not to damage the PPC hose. & kg
Floor frame assembly
: 65 kg
INSTALLATION OF FLOOR FRAME ASSEMBLY Installation removal.
is performed
in the opposite
way to
Supplying oil (hydraulic oil tank) Supply oil to the specified level after starting the engine to circulate oil in the piping. Filling air conditioning gas Fill air conditioning gas (R134a) tioning circuit using tool X.
PC1 28UU-2
in the air-condi-
30-95 0
DISASSEMBLY
AIR CONDITIONER
AND ASSEMBLY
COMPRESSOR
REMOVAL OF AIR CONDITIONER COMPRESSOR ASSEMBLY a
Completely
ground the work equipment.
g
Disconnect tery.
the negative
(-) terminal
of the bat-
1. Open cover (1).
cover (2).
2.
Remove
3.
Disconnect hoses (3) and (4). Disconnect the hoses after completely bleedgas (R134a) using tool ing the air-conditioning X. Apply the blind plug to prevent dust or water from entering the hoses. Be careful not to damage or lose the O-ring.
4.
Disconnect
5.
bolt (6) and adjustment Loosen belt tension (8). belt drive remove to (7) bolt mounting
6.
Remove bolts (6) and (7) to remove air conditioner compressor assembly (9).
connector
(5) (M34).
INSTALLATION OF AIR CONDITIONER COMPRESSOR ASSEMBLY l
l
Installation removal.
is performed
in the opposite
gas Filling air conditioning (R134a) gas Fill air conditioning tioning circuit using tool X.
30-96 0
way to
in the air condi-
PC1 28UU-2
DISASSEMBLY AND ASSEMBLY
AIR CONDITIONER CAPACITOR
REMOVAL OF AIR CONDITIONER CAPACITOR ASSEMBLY
a
Completely
ground
a
Drsconnect . tery.
the negative
the work equipment. (-1 terminal
of the bat-
1.
Remove the counterweight assembly by referring to “REMOVAL OF COUNTERWEIGHT ASSEMBLY”.
2.
Remove
covers (1) and (2).
3.
Remove
air cleaner
4.
Disconnect battery relay (4) from the bracket. + Move it forward after disconnection.
5.
Disconnect hose (6) coming from the air conditioner compressor and hose (5) running to the receiver tank. Make sure to double-engage the wrench before disconnection. Disconnect the hoses after completely bleeding the air conditioning gas (R134a) using tool X. Apply the blind plug to prevent dust or water from entering the hoses. Be careful not to damage or lose the O-ring.
6.
Remove the mounting bolt to remove air conditioner capacitor assembly (7). + Carefully remove it since the fin is soft.
assembly
(3).
INSTALLATION OF AIR CONDITIONER CAPACITOR ASSEMBLY l
l
Installation removal.
is performed
Filling air conditioning
in the opposite
gas
Fill air conditioning gas (R134a) tioning circuit using tool X.
PC1 28UU-2
way to
in the air condi-
30-97 0
DISASSEMBLY
AND ASSEMBLY
AIR CONDITIONER
UNIT
REMOVAL OF AIR CONDITIONER UNIT ASSEMBLY a
Completely
ground the work equipment.
a
Drsconnect . tery.
the negative
(-) terminal
1. Remove
floor mat (1).
2. Remove
covers (2) and (3).
of the bat-
3. Remove louver (4) and the four screws to remove switch panel (5). 4. Remove
screw (6) to slide duct (7) forward.
Disconnect air conditioner switch connectors (8) and (9) to remove duct (7). Remove grommet (IO). Remove the mounting bolt to disconnect duct (11) from the air conditioner unit. Disconnect air conditioner unit connector (12) (M26). * It is located on the bottom of the centralized harness. 9. Disconnect heater hoses (13) and (14) at the rear of the air conditioner unit. * Since coolant flows out, bend and disconnect the hose and apply the blind plug to it. 10. Disconnect air conditioner hoses (15) and (16). * Make sure to double-engage the wrench before disconnection. * Disconnect the hoses after completely bleeding the air conditioning gas (R134a) using tool X. -k Apply the blind plug to prevent dust or water from entering the hoses. -k Be careful not to damage or lose the O-ring. 11. Disconnect
30-98 0
two relay connectors
(17).
PC1 28UU-2
DISASSEMBLY AND ASSEMBLY
AIR CONDITIONER UNIT
12. Remove the mounting
bolt to remove air conditioner unit assembly (18). * Make sure that duct (11) is completely disconnected and remove it by sliding it forward.
INSTALLATION CONDITIONER l
l
Installation removal.
OF AIR UNIT ASSEMBLY
is performed
Filling air conditioning
in the opposite
gas
Fill air conditioning gas (R134a) tioning circuit using tool X.
PC1 28UU-2
way to
in the air condi-
30-99 0
DISASSEMBLY
AND ASSEMBLY
COUNTERWEIGHT
REMOVAL OF COUNTERWEIGHT ASSEMBLY a
Completely
ground the work equipment.
a
Drsconnect . tery.
the negative
1. Remove
engine
(-1 terminal
of the bat-
upper cover (1).
2.
Disconnect
flywheel
case oil filler hose (2).
3.
Remove fuel gauge connector (3) from the clamp. * This is intended to prevent it from coming in contact with the frame when the counterweight is lifted.
4.
m Remove three mounting bolts (4). -k Bolt : Width across flats = 65mm * Lift the counterweight assembly beforehand.
5.
Slowly it.
lift counterweight
A kg
Counterweight
assembly
assembly
(5) to remove
: 1,880 kg
INSTALLATION OF COUNTERWEIGHT ASSEMBLY l
Installation removal.
m
is performed
Mounting bolt : 385.4 - 4,707.4
in the opposite
way to
Nm (393.0 - 480.0 kgm)
PC1 28UU-2
MAINTENANCE STANDARD
SWING MACHINERY
SWING MACHINERY
56.4* 56.4*
(5.79
14.2Nm 1.45bd
110.3* (1 1.25*
277.0531.9Nm t28.25* 3.25kom)
14.2Nm
(5.75* 1.45kml 12.3Nm 1.25koml
\
9JA01381
40-2
PC128UU-2
MAINTENANCE STANDARD
SWING MACHINERY
Unit: mm
No.
Check item
Criteria
Remedy
Standard clearance
Clearance limit
0.07 – 0.18
0.4
1
Backlash of swing motor shaft and No. 1 sun gear
2
Backlash between No. 1 sun gear and No. 1 planetary gear
0.13 – 0.31
0.6
3
Backlash between No. 1 planetary gear and ring gear
0.15 – 0.34
0.7
4
Backlash between No. 1 planetary carrier and No. 2 sun gear
0.14 – 0.34
0.7
5
Backlash between No. 2 planetary gear and ring gear
0.15 – 0.34
0.7
6
Backlash between No. 2 sun gear and No. 2 planetary gear
0.13 – 0.31
0.7
7
Backlash between No. 2 planetary carrier and swing pinion
0.08 – 0.19
0.4
8
Backlash between swing pinion and swing circle
0.13 – 1.16
2.3
9
Wear on swing pinion collar’s contact surface against oil seal
PC128UU-2
Replace
Standard size
Tolerance
Repair limit
145
0 – 0.100
144.8
Apply hardchrome plating recondition, or replace
40-3 (6)
MAINTENANCE STANDARD
SWING CIRCLE
SWING CIRCLE
Unit: mm
No.
Check item
1
Clearance between bearing and circle
40-4 (6)
Criteria
Remedy
Standard size
Clearance limit
0.5 – 1.6
2.6
Replace
PC128UU-2
MAINTENANCE
STANDARD
TRACK FRAME. IDLER CUSHION
TRACK FRAME, IDLER CUSHION
31.9Nm .3.25koml
‘304.0*4.9Nm (31.0* 0.5kml
3
9JBOOl67
Unit: mm
No< -
Check item
Criteria I
I 1
Idler guide top and bottom width
Standard size
89
82
77
replace
Track frame
185
193
Rebuild
Idler support
183
I
Recoil spring
PC1 28UU-2
Rebuild or
Rebuild or replace
I Standard size
3
I
84
Idler
Idler guide left and right width
Clearance limit
I
Rebuild
Track frame
support
2
Remedy
I
I
Free length
l~$,a$~d
Installed load
502
390
84.3 kN (8,600 kg)
Repair limit Free length
490
Installed load 75.0 kN (7,650 kg)
Replace
40-5
SPROCKET
MAINTENANCE STANDARD
SPROCKET
/
-
\\
/
SOP01827
Unit: mm
No -
Wear on tooth bottom diameter
2
Wear on addendum diameter
3
Wear on addendum
4
Wear on tooth bottom width
5
Tooth bottom wall thickness
547.4
I width
1
607
27
+I.0 -2.0
535
-
595
I I
I 111.7
Repair limit
Tolerance
Standard size
1
Remedy
Criteria
Check item
-
+ 1.5 +0.465 -1.160
I
I
22
Rebuild or replace
39
105.5
PC128UU-2
MAINTENANCE STANDARD
TRACK SHOE
TRACK SHOE TRIPLE SHOE, ROAD LINER, CITY PAD SHOE
ª1. Triple shoe and city pad shoe ª2. Road liner fl
P portion shows the link of bushing press fitting end.
PC128UU-2
40-13 5
MAINTENANCE STANDARD
TRACK SHOE
Unit: mm
No.
1
Check item
Criteria Standard size
Repair limit
175.25
178.25
Link pitch
Bushing outer diameter 46.3
3
Link height
4
Link wall thickness (at the section where bushing is to be press fit)
Reverse or replace
When turned
Standard size 2
Remedy
Normal load
Impact load
—
42.3
Standard size
Repair limit
86
81
Reverse or replace
24
5
102.4 Replace
6
Shoe bolt pitch
86.4
7
57
8 9
Link
10
Inner width
52.4
Total width
35 30.1
Width of tread
11
Pin protrusion volume
5.5
12
Regular bushing protrusion volume
3.75
13
Total pin length
173
14
Total bushing length (master bushing)
86.7
15
Bushing wall thickness
7.8
16
Spacer thickness
—
17 18
Bushing Press fitting Regular pin force
ª 19
Master pin
Reverse or replace
Adjust or replace
39.2 – 137.3 kN {4 – 14 ton} 78.5 – 186.3 kN {8 – 19 ton}
—
39.2 – 98.1 kN {4 – 10 ton}
Items with ª marking are applicable to the dry type shoe.
40-14 5
PC128UU-2
MAINTENANCE STANDARD
TRACK SHOE
Unit: mm
No.
Check item
Criteria
Remedy
Tightening torque (Nm {kgm}) Additional tightening angle (deg)
a. Regular link
• Triple • City pat
196.1 ± 19.6 {20 ± 2}
90 ± 10
147 ± 10 {15 ± 1}
50 ± 5
• Road liner
Shoe bolt 20
Retighten
Tightening torque (Nm {kgm})
Additional tightening angle (deg)
Lower limit torque (Nm {kgm})
—
—
—
b. Master link
Number of shoes (on one side)
Tolerance
Standard size 21
22
Hole
46
+0.387 +0.347
+0.062 0
0.285 –0.387
30
+0.150 0
–0.198 –0.250
0.198 – 0.400
Tolerance
Standard size 23
Clearance between regular pin and bushing 30
ª 24
Interference between master pin and link
Clearance between master pin and bushing
Grouser height
a. Road liner
Shaft
Hole
+0.150 0
+0.830 +0.330
0.180 – 0.830
Shaft
Hole
Standard interference
+0.020 –0.020
–0.198 –0.250
0.178 – 0.270
Shaft
Hole
Standard clearance
–0.200 –0.300
+0.630 +0.230
Tolerance
Standard size 30
26
Standard clearance
Tolerance
Standard size 30
ª 25
Standard interference
Shaft
Interference between bushing and link
Interference between regular pin and link
—
42
Adjust or replace
0.430 – 0.930
Standard size
Repair limit
58
21
Replace
Items with ª marking are applicable to the dry type shoe.
PC128UU-2
40-15 5
MAINTENANCE STANDARD
TRACK SHOE
Triple shoe and city pat shoe
Unit: mm
No.
Check item
1
Grouser height
2
Shoe height
3
Plate thickness
4
Criteria Standard size
Repair limit
25
15
33
23 8 24
Grouser base length 5
19
6
18 Grouser edge length
7 8
Remedy
Rebuild or replace
11 18
40-16 5
PC128UU-2
MAINTENANCE STANDARD
HYDRAULIC PUMP
HYDRAULIC PUMP MODEL : HPV95 (for 105 cc/rev)
40-18
PC128UU-2
MAINTENANCE
CONTROL VALVE
STANDARD
CONTROL VALVE 8-SPOOL VALVE (WITHOUT
SERVICE VALVE)
(l/10)
B
P2
III
PC128UU-2
--I_
lT0
P4
9JYOOO39
40-19
MAINTENANCE
CONTROL VALVE
STANDARD
(2/10)
147*9.8lNm ~15.0*1.0kom1
4 \
5 \\I
.8lNm .OkSd
147*9 115.0 f 1
186*9.81Nm (19.0* l.Okaml
\
186i9.81N-m ~l9.0*l.Okoml
I
\ 3
2
A-A 9JYOO310
Unit: mm
Criteria
Check item
1 Repair limit
Standard size Installed length
Installed load
46.8 x 7.50
40.6
5.50f0.40N {0.56HI.O4kg}
-
4.40 N (0.45 kg}
Suction valve spring
16.0 x 16.0
12.0
5.70 N (0.58 kg)
-
4.50 N {0.46 kg)
Piston spring
10.5 x 7.0
5.7
2.65 N (0.27 kg)
-
2.16 N (0.22 kg)
Free length
20.0 x 7.0
Piston spring
40-20
Replace spring if any damages or deformations are found
1.67 N (0.17 kg}
Suction valve spring 5
Installed load
Free length x O.D.
Suction valve spring
Remedy
14.0
1.18 N (0.12 kg}
-
0.98 N (0.10 kg}
I
PC1 28UU-2
MAINTENANCE
CONTROL VALVE
STANDARD
(3/10)
I
L
L
L
2
B-B 9JYOO31 I
Unit: mm Remedy
Check item Repair limit
Standard size Fr,$;gth 1
Spool return spring
ItxA$d
. .
Installed load
Free length
Installed load
45.6 x 28.0
43.0
230f14.7N {23.5&l .50kg)
-
184N 08.8 kg)
45.7 x 28.0
43.0
222+13.7N {22.6+1.40kg}
-
178 N (18.1 kg)
I
2 1 Spool return spring
PC128UU-2
Replace spring if any damages or deformations are found
40-21
MAINTENANCE
CONTROL VALVE
STANDARD
(4/10)
216*19.6Nm ~22.0*2.Okaml
106*9.6lNm~ 1 I l.O* l.Okoml
-
,--
19.6Nm 2.0ksml
--
._. 19.6Nm 117.0*2.0koml
t22.0*2.0koml
I
/
-
D-D 9JYOO312
Unit: mm
Criteria
Check item
No.
Remedy Repair limit
Standard size I
2
3
Installed load
‘Free length x O.D.
installed length
Installed load
36.2 x 5.30
32.0
9.81zL0.98N {I .MO.IOkg}
-
7.85 N (0.80 kg)
Pressure reduction valve spring
27.5 x 14.2
18.0
17.7k0.98N (I .8&0.1 Okg}
-
13.7 N {I .40 kg}
Pressure reduction valve spring
28.2 x 14.5
26.0
29.4k2.94N (3.0f0.30kg)
-
23.5 N (2.40 kg}
Flow control valve spring
40-22
Free length
Replace spring if any damages or deformations are found
PC1 28UU-2
MAINTENANCE
STANDARD
CONTROL VALVE
(5110)
.23.5*3.92Nm (2.40*0.40kPml
39.2*4.90Nm (4.0_t0.50koml
55.9*6.86Nm (5.70~0.70kml
23.5*3.92Nm i2.40*0.40kml
0
55.956.86Nm
9JYOO313
Unit: mm
No.
Standard size Fry$;gth 1
Check valve spring
Remedy
Criteria
Check item
Itxs;i$d
. . 41.5 x 8.50
Repair limit
1
Free length
‘nEAed 31.5
5.88 N (0.60 kg)
15.6
3.14 N (0.32 kg)
‘nEAed 4.71 N (0.48 kg)
-
I Check valve spring
PC1 28UU-2
20.3 x 13.7
I
-
I
Replace spring if any damages or deformations are found
2.25 N (0.26 kg)
40-23
MAINTENANCE
CONTROL VALVE
STANDARD
(6/10)
F-F
!fTY
9JYOOO62
Unit: mm
No.
Remedy
Criteria
Check item
Repair limit
Standard size
1
2
Bleed spool return spring
Installed load
Installed length
Installed load
72.7 x 20.6
42.5
135f4.90N {I 3.8f0.50kgI
-
113N (1 I.5 kg)
23.3 x 12.5
23.0
3.92*0.98N (0.40fO.lOkgI
-
2.94 N (0.30 kg)
Fr,$;gth Lift check valve spring Cooler bypass valve spring
. .
Free length
Replace spring if any damages or deformations are found
-
40-24
PC1 28UU-2
MAINTENANCE
CONTROL VALVE
STANDARD
(7/10)
9JYOOO63
J-J
Unit: mm
No, -
Remedy
Criteria
Check item
Repair limit
Standard size Fry$;gth
1
Travel junction spool return spring
. . 17.7 x 8.20
PC1 28UU-2
I1,st,&$d
13.0
Installed load 13.7fO.lON {I .4MO.l Okg)
Free length
-
Installed load 10.1 N (1.10 kg)
Replace spring if any damages or deformations are found
40-25
MAINTENANCE STANDARD
.
CONTROL VALVE
(8/W
/
\ K-K
9JYOO314
Unit: mm
No.
Check item
Criteria
Remedy
Standard size 1
Lift check valve spring
40-26
Repair limit
Free length x O.D.
Installed length
Installed load
26.1 x 17.0
25.0
26.5&l .57N {2.7&0.16kg)
Free length
-
Installed load 21.2 N (2.16 kg}
Replace spring if any damages or deformations are found
PC128UU-2
MAINTENANCE
STANDARD
CONTROL VALVE
(9/10)
~5.4*0.6koml M-M
9JYOO315
Unit: mm
No.
1
Check item
Check valve spring
PC128UU-2
I
Criteria
Remedy
Standard size
Repair limit
Free length x O.D.
Installed length
Installed load
41.5 x 8.50
31.5
5.88 N (0.60 kg}
I
I
Free length
Installed load
-
4.71 N (0.48 kg) I
Replace spring if any damages or deformations are found I
40-27
MAINTENANCE
CONTROL VALVE
STANDARD
(lO/lO)
39.2k4.90Nm i4.0*0.50kPml /
19.6Nm :Z.Okaml
AA-AA
cc-cc 9JYOO316
40-28
PC128UU-2
MAINTENANCE
STANDARD
SUCTION
SAFETY VALVE
SUCTION SAFETY VALVE FOR SERVICE VALVE
m
(15.0*
l.Okpml
9JYOOO66
Unit: mm
No, -
Check item Repair limit
Standard size 1
2
Suction valve spring
Piston spring
PC1 28UU-2
Installed load
Free length x O.D.
Installed length
Installed load
16.3 x 21.3
9.50
2.06 N (0.21 kg)
-
1.57 N (0.16 kg}
20.0 x 7.0
14.0
2.06 N (0.21 kg}
-
1.57 N (0.16 kg}
Free length
Replace
40-29
MAINTENANCE
SELF PRESSURE REDUCTION
STANDARD
VALVE
SELF PRESSURE REDUCTION VALVE
A-A \
9JUOOO66
Unit: mm
ssure reduction
4
Spring (safety valve)
40-30
deformations
16.1
x
7.80
13.4
61.7 N (6.30 kg}
-
58.8 N 16.0 kg)
PC1 28UU-2
MAINTENANCE
TRAVEL MOTOR
STANDARD
TRAVEL MOTOR GM18VL-J
14.7Nm 127.5* 113.0*1.5ksml
I
78.5*19.6Nm (8.0*2.0kPml
PC1 28UU-2
15.7Nm 102.0-t (10.4*1.6hl
9.8Nm 57.95 t5.9* I.Okoml
/
\ 127.5*19.6Nm 29.4i 4.9Nm 353.0*39.2Nm i13.0i2.0koml (3.0*0.5koml (36.0*4.0koml A-A
98.1f 19.6Nm IlO.O*2.0lwm)
686.5*49.0Nm ~70.0*5.0koml
58.8* 19.6Nm {6.0*2.0ksml
9JA01387
40-31
MAINTENANCE
STANDARD
SWING
MOTOR
SWING MOTOR yMODEL:
KMF40AEL-3
29.4*4.9Nm 13*0,5kPml
30.9*i.4Nm (3.15*0.35koml
166.7519.6Nm i17.0*2.OkPml
A-A
9JYOO317
Unit: mm
Check item
Remedy
Criteria Repair limit
Standard size 1
2
Check valve spring
Shuttle valve spring
40-32
Free length x O.D.
Installed load
installed length
Installed load
33.0 x 13.8
23.0
1.28 N (0.13 kg}
-
0.98 N (0.10 kg}
33.0 x 13.8
19.5
1.77 N (0.18 kg}
-
1.47 N (0.15 kg}
Free length
Replace spring if any damages or deformations are found
PC1 28UU-2
MAINTENANCE
SOLENOID
STANDARD
VALVE
SOLENOID VALVE FOR PPC LOCK, 2ND TRAVEL SPEED SELECTOR, SWING AND PARK BRAKE, AND 2STAGE RELIEF SOLENOID VALVE
(2.2*0.22bml B-B
9JA01388
PC128UU-2
40-33
MAINTENANCE
STANDARD
EPC SOLENOID
VALVE
EPC SOLENOID VALVE FOR 4-SYSTEM
CONTROL
8.34i0.98Nm {0.85~O.l!-aml /
A-A
3.92i0.49Nm {0.4*0.05kPml
5.39*0.49Nm (0.55*0.05koml
A-A 9JBOO168
40-34
PC1 28UU-2
MAINTENANCE STANDARD
CENTER SWIVEL JOINT
CENTER SWIVEL JOINT
142.2234.3Nm {14.5*3.5koml
31.4*2.9Nm ~3.2*0.3kamI
19.6*4.9Nm {2*0.5km) 9JA01391
No.
Check item Standard size
,
Clearance between rotor and shaft
PC128UU-2
Remedy
Criteria
I
Standard clearance
clearance limit
0.056 - 0.105
0.111
Replace 80
40-35
MAINTENANCE
PPC VALUE
STANDARD
PPC VALVE FOR WORK EQUIPMENT,
FOR SWING
13.2i 1.47Nm ~1.35*0.15kahl
A-A
9JYOOO5i
E-E
Unit: mm
No.
1
Remedy
Criteria
Check item
Centering spring (for P3 and P4 ports)
I42.4 x 15.5 2
34.0
29.4 N (3.0 kg}
-
23.5 N (2.40 kg)
Replace spring if any damages or deformations are found
3
40-36
24.9
16.7 N (1.70 kg}
-
13.7 N {I .40 kg)
PC128UU-2
MAINTENANCE
STANDARD
0
n
PPC VALVE
0
@ n A-A
9JYOOO57
D-D
c-c
Unit: mm
No.
Remedy
Criteria
Check item
Repair limit
Standard size Fre,ecz;gth 1
2
Metering spring
Centering spring
PC128UU-2
Ins&A$d
. .
Installed load
Free length
Installed load 13.7 N
26.5 x 8.15
24.7
16.7 N (1.70 kg)
-
{la40 kg)
48.1 x 15.5
32.5
108N (11.0 kg)
-
86.3 N (8.80 kg)
Replace spring if any damages or deformations are found
40-37
.
MAINTENANCE
STANDARD
PPC VALVE
FOR BLADE, FOR SERVICE
Unit: mm
I
I
I
Check item
Criteria
Remedy Repair limit
Standard size FrF$;gth 1
2
Centering spring
Metering spring
40-38
l~~tal$d
. .
‘YZed
33.9 x 15.3
28.4
125 N (12.7 kg}
22.7 x 8.10
22.0
16.7 N (1.70 kg)
Free length
Installed load
-
100 N (10.2 kg)
-
13.3 N (I.36 kg)
Replace spring if any damages or deformations are found
PC128UU-2
MAINTENANCE STANDARD
HYDRAULIC CYLINDER
HYDRAULIC CYLINDER BOOM CYLINDER
‘6
9JBOO169
ARM CYLINDER
95800170
OFFSET CYLINDER
9JBOO171
PC128UU-2
40-39
MAINTENANCE
STANDARD
HYDRAULIC
CYLINDER
BUCKET CYLINDER
9JB00172
BLADE CYLINDER
9JA01395
40-40
PC128UU-2
MAINTENANCE
T
No ‘.
STANDARD
Check item
Clearance between piston rodI and bushing
2
Clearance between piston rot support shaft anI bushing
3
Clearance between cylinder bottom support shaft and bushin
Criteria
Boom Arm Cylinder head tightening torqu’ e
Offset
6
Cylinder piston tightening torque3
Cylinder piston lock screw tightening torque
PC128UU-2
1
269.7 + 39.2 Nm (27.5 f 4.0 kgm) 1,029.7 f 103.0 Nm {I 05.0 + 10.5 kgm) 171.6 + 24.5 Nm (17.5 + 2.5 kgm)
Blade _
269.7 + 39.2 Nm (27.5 + 4.0 kgm)
Boom
294.2 f 29.4 Nm (30.0 k 3.0 kgm)
Offset
Remedy
171.6 * 24.5 Nm (17.5 + 2.5 kgm)
Bucket
Arm 5
CYLINDER
Unit: mm
1
4
HYDRAULIC
294.2 f 29.4 Nm (30.0 + 3.0 kgm) 3,971.7 + 397.2 Nm (405.0 f 40.5 kgm)
Bucket
294.2 + 29.4 Nm (30.0 f 3.0 kgm)
Blade
294.2 f 29.4 Nm (30.0 f 3.0 kgm}
Boom
66.2 f 7.4 Nm (6.75 f 0.75 kgm}
Arm
66.2 + 7.4 Nm (6.75 f 0.75 kgm)
Offset
-
Bucket
30.9 f 3.4 Nm (3.15 f 0.35 kgm)
Blade
66.2 + 7.4 Nm (6.75 f 0.75 kgm)
Re-tightening
40-41
MAINTENANCE STANDARD
WORK EQUIPMENT
WORK EQUIPMENT
QJBOO173
PC128UU-2
40-43
WORK EQUIPMENT
MAINTENANCE STANDARD
B-B
G-G
8
7
R-R
P-P
9
H-H
IO
N-N
s-s
T-T
II
9JBOO174
40-44
PC1 28UU-2
MAINTENANCE
WORK EQUIPMENT
STANDARD
Unit: mm
No.
1
Criteria
Check item
Clearance between 1 st boom and revolving frame mounting pin and bushing
Shaft
Hole
Standard clearance
Clearance limit
- 0.030 -0.104
+0.240 +0.174
0.204 0.344
0.8
110
-0.036 - 0.090
+0.207 +0.120
0.156 0.297
0.8
110
-0.036 - 0.090
+0.207 +0.120
0.156 0.297
0.8
60
- 0.030 -0.104
+0.197 +0.137
0.167 0.301
0.8
60
- 0.030 -0.104
+0.197 +0.137
0.167 0.301
0.8
70
- 0.030 -0.100
+0.141 +0.074
0.104 0.241
0.8
60
- 0.030 - 0.080
+0.129 +0.074
0.1040.209
0.8
0.030 - 0.080
+0.135 +0.074
0.1040.215
0.8
65
- 0.030 - 0.080
+0.133 +0.074
0.1040.213
0.8
60
- 0.030 -0.080
+0.130 +0.074
0.1040.210
0.8
-0.030 -0.100
+0.198 +O. 124
0.154
0.298
0.8
Standard size 0 80
2
Clearance between 1 st boom and 2nd boom mounting pin and bushing
0
3
Clearance between 2nd boom and 3rd bracket mounting pin and bushing
0
4
Clearance between 1st boom and sub-link mounting pin and bushing
0
5
Clearance between 3rd bracket and sub-link mounting pin and bushing
0
6
Clearance between 3rd bracket and arm mounting pin and bushing
0
7
Clearance between arm and bucket mounting pin and bushing
0
8
Clearance between arm and link mounting pin and bushing
0 60
9
Clearance between link and link mounting pin and bushing
0
10
Clearance between link and bucket mounting pin and bushing
0
11
Clearance between blade and track frame mounting pin and bushing
0 70
PC1 28UU-2
Tolerance
Remedy
:
Replace bushing, pin
40-45
MAINTENANCE
STANDARD
DIMENSION
DIMENSION
OF WORK EQUIPMENT
OF WORK EQUIPMENT
ARM
B-B
9JBOOl77
40-46
PC128UU-2
MAINTENANCE
STANDARD
DIMENSION
OF WORK EQUIPMENT
Unit: mm PC1 28UU-2 No.
Measuring
position
Tolerance
Standard size Shaft
1
I
-
0 70
I
Hole
-0.030 -0.104
I
Arm side
82.5
+I.0 0
Cylinder head side
80
+1.2
Boom side
226
+0.5 0
Arm side
226
+O.lOO 0
2
3
-0.2 -0.7
4
-
5
-
220.4
f2.0
6
-
271.3
+1.0
7
-
501.3
f0.5
8
-
2,108.6
-
9
-
2,111.6
f2.5
10
-
289.6
+0.5
11
-
487
f0.2
12
-
415
f0.5
13
-
374.9
14
-
1,175.l
15
-
0 60
Link side
i
16 Bucket side 17
0 70
-0.030 -0.104
+O.lOO 0
-0.030 -0.080
259
+0.200 0 J.0 +1.0
261
-
0 60
Arm side
226
-:.5
Bucket side
274
-
- 0.030 -0.080
+0.200 0
18
Min.
1,378
f2.0
Max.
2,263
-
19
PC128UU-2
40-47
MAINTENANCE STANDARD
DIMENSION OF WORK EQUIPMENT
BUCKET
9JA01399
40-48
PC1 28UU-2
MAINTENANCE
STANDARD
DIMENSION
OF WORK EQUIPMENT
Unit: mm PC1 28UU-2 No. Measuring -
1 2 3
position
I I
-
I I
Standard size
Tolerance
371.3
* 0.5
51.6 97.9”
I I
I
f 0.5 -
-
-
374.9
5
-
1,I 59.6
-
6
-
190.5
-
7
-
5”
-
8
-
0”
-
9
-
0 60
+0.2 0
10
-
0 64
-
11
-
0 80
+0.25 0
12
-
261
f 1.0
13
-
50
-
14
-
85
-
4
I
16
I
-
I
0 18
I
I
-
-
-
0 110
18
-
0 130
-
19
-
pr 132
-
20
-
0 108
-
21
-
274
-
22
-
51
-
23
-
34
-
24
-
106.7
-
25
-
124.3
-
26
-
74
-
27
-
65
-
17
PC128UU-2
I
40-49
90
OTHERS
90-3 Hydraulic circuit diagram .............................. (l/2) .90-5 Electric circuit diagram ......................... Electric circuit diagram (2/2). ........................ .90-7 Air conditioner circuit diagram .................... .90-9
PC1 28UU-2
90-l
OTHERS
AIR CONDITIONER
AIR CONDITIONER
Temperature controllino swi
CIRCUIT DIAGRAM
CIRCUIT DIAGRAM
Air
4 B
‘c
6
L-
Y
-.
I
-
I
I
I
Electronic thermostat
L---
---
Valve
Pressure
’
COntaCtOr (Compressor)
cut
Switch
’
Register El ower Valve T.--T Xir caadiliantr Unit1 ______G-__._______________ ____-__-__-__Motor
Contactor (Condenser)
'III
I I
__________________-________-__-__-..
1
DC24V_
SVPO7770
PC128UU-2
90-9
TO:
:
Komatsu
subsidiary
Komatsu
Liaison
Office
PROPOSAL
;
NAME
5
DEPARTMENT/SECTION:
5 :
NAME:
FOR MANUAL
OF COMPANY:
MANUAL
NAME:
MANUAL
No.:
Given in upper right hand corner
MACHINE 1. Details
Attached
2. Include
photo
your
request
or opinion?
3.
Include
user’s opinion?
or sketch.
1. One sheet should
sheet.
be used for each proposal. in blue ink.
2.
Please do not write
3.
If there is no manual
09-94(03)30001
of cover.)
MODEL:
If you need more space, use another
KS-9OE
REVISION
No., please write
machine
model,
type and date of publication.