CEBM207041
SHOP MANUAL KOMAfhJ PC3OOLG5 WITH KDC 614TA ENGINE
PC4OOLG5 WITH CUMMINS
LTA-IOC ENGINE
EXCAVATORS MACHINE
MODEL
PC3OOLC-5 PC4OOLC-5
SERIAL NUMBERS
A30001 A40001
and up and up
This material is proprietary to Komatsu Dresser Company and is not to be reproduced, used, or disclosed except in accordance with written authorization from Komatsu Dresser Company. It is our policy to improve our products whenever it is possible and practical to do so. We reserve the right to make changes or add improvements at any time without incurring any obligation to install such changes on products sold previously. Due to this continuous program of research and development, periodic revisions may be made to this publication. It is recommended that customers contact their distributor for information on the latest revision.
AUG 95 Includes revision @
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The affected pages are indicated by the use of the following marks. It is requested that necessary actions be taken to these pages according to the table below
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30-W
40-l 40-2 40-3 40-4 40-5 40-6 40-7 40-8 #9 40-10 40-11 40-12 40-13 40-14 40-15 40-16 40-17 40-18 40-19 40-20 40-21 40-22 40-23 40-24 40-25 40-26
00-2-4 0
RW
REV
CONTENTS
01
GENERAL
10
STRUCTURE
20
TESTING
30
DISASSEMBLY
40
MAINTENANCE
99
OTHER METRIC
..................................... AND FUNCTION
AND ADJUSTMENT
01-I .......................
IO-I
.......................
20-I
AND ASSEMBLY STANDARD
.....................
........................
CONVERSIONS
.....................
30-I 40-I 99-1
00-7
A
IMPORTANT
SAFETY
NOTICE
Proper service and repair is extremely important for the safe operation of your machine. The service and repair techniques recommended and described in this manual are both effective and safe methods of operation. Some of these operations require the use of tools specially designed for the purpose. To prevent injury to workers, the symbols A and *q are 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.
A GENERAL
PRECAUTIONS
Mistakes in operation are extremely dangerous. Read the Operator’s 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. l Always wear safety glasses when hitting parts with a hammer. l Always wear safety glasses when grinding parts with a grinder, etc. 3. If welding repairs are needed, always have a trained, experienced welder carry out the work. When carrying out welding work, always wear welding gloves, apron, glasses, cap and other clothes suited for welding work. 4. When carrying out any operation with two or more workers, always agree on the operating procedure before starting. Always inform your fellow workers before starting any step of the operation. Before starting work, hang UNDER REPAIR signs on the controls in the operator’s compartment. 5. Keep all tools in good condition correct way to use them.
00-8
and learn the
SAFETY 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 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.
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. use a hoist 14. When raising heavy components, 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.
19. Be sure to assemble original places.
all parts again
in their
Replace any damaged part with new parts. l When installing hoses and wires, be sure that they will not be damaged by contact with other parts when the machine is being operated. high pressure hoses, make 20. When installing 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. or installing parts, always 21. When assembling 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. two holes, never insert your 22. When aligning fingers or hand. Be careful not to get your fingers caught in a hole. hydraulic pressure, check 23. When measuring that the measuring tool is correctly assembled before taking any measurements. or installing the 24. Take care when removing tracks of track-type machines. When removing the track, the track separates suddenly, so never let anyone stand at either end of the track.
be careful not 16. When removing components, to break or damage the wiring, Damaged wiring may cause electrical fires. 17. When removing from spilling out. the floor, wipe it on the floor can even start fires.
piping, stop the fuel or oil If any fuel or oil drips on to up immediately. Fuel or oil cause you to slip, or can
to 18. As a general rule, do not use gasoline wash parts. In particular, use only the minimum of gasoline when washing electrical parts.
00-9
FOREWORD This shop manual has been prepared as an aid to improve the quality of repairs by giving the serviceman an accurate understanding of the product and by showing him the correct way to perform repairs and make judgements. Make sure you understand the contents of this manual and use it to full effect at every opportunity.
This service For divided
shop manual mainly contains the necessary technical information for operations performed in a workshop. ease of understanding, the manual is divided into the following sections. These sections are further into each main group of components.
GENERAL This section lists the general machine dimensions, performance and fuel, coolant and lubricant specification charts. STRUCTURE
specifications,
component
weights,
AND FUNCTION
This section explains the structure and function of each component. It serves not only to give an understanding of the structure, but also serves as reference material for troubleshooting. TESTING
AND ADJUSTING
This section explains checks to be made before and after performing adjustments to be made at completion of the checks and repairs. Troubleshooting charts correlating “Problems” to “Causes” are also included DISASSEMBLY
repairs,
as well
in this section.
AND ASSEMBLY
This section explains the order to be followed when removing, installing, disassembling assembling each component, as well as precautions to be taken for these operations. MAINTENANCE This section
as
or
STANDARD gives the judgement
standards
when
inspecting
disassembled
parts.
I
I NOTICE The specifications contained any advance notice. Contact
I
00-l 0
in this shop manual are subject to change your distributor for the latest information.
at any time and without
I
HOW TO READ THE SHOP MANUAL
HOW TO READ THE SHOP MANUAL VOLUMES
REVISIONS
Shop manuals are issued as a guide to carrying out repairs. They are two manuals for each machine, Chassis volume and Engine volume.
Revised pages are shown at the LIST OF REVISED PAGES between the title page and SAFETY page. SYMBOLS
These volumes are designed to avoid duplication of information. Therefore to deal with all repairs for any model, both chassis and engine volumes are needed. DISTRIBUTION
AND UPDATING
So that the shop manual can be of ample practical use, important places for safety and quality are marked with the following symbols. Symbol
Any additions, amendments or other changes will be sent to your distributors. Get the most upto-date information before you start any work.
A
FILING
Mb?
Item
Special safety precautions are necessary when performing the work Safety
METHOD
e 1. See the page number on the bottom page. File the pages in correct order. examples 2. Following page number: Example
1 (Chassis
show
how
of the
to read the
*
Item number (10. ture and Function)
Example 2 (Engine volume): Refer to the pertinent engine
EDITION
Weight
Weight of parts or systerns. Caution necessary when selecting hoisting wire or when working posture is important, etc.
Tightening torque
Places that require special attention for tightening torque during assembly.
Coat manual.
pages: Additional pages are indi3. Additional cated by a hyphen (-) and numbered after the page number. File as in the example. Example: 20-4 20-4-l Added pages 20-4-2 20-5 REVISED
Caution
Struc-
Consecutive page number for each item
MARK
(0
Q
Extra special safety precautions are necessary when performing the work because it is under internal pressure. Special technical precautions or other precautions for preserving standards are necessary when performing the work.
volume): 6 kg
Remarks
Oil, water
Drain
Places to be coated with adhesives and lubricants etc. Places where oil, water or fuel must be added, and the capacity. Places where oil or water must be drained, and quantity to be drained.
@ @ . ...)
When a manual is revised, an edition mark is recorded on the bottom outside corner of the pages.
00-l1
HOISTING INSTRUCTIONS
HOISTING
A
,
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 symbol
clearly
with the
INSTRUCTIONS
: 264 Ko%
79%
88%
71%
41% FSoO64
1. If a part cannot be smoothly removed from the machine by hoisting, the following checks should be made: l Check for removal of all bolts fastening the part to the relative parts. l
Check for existence of another part causing interface with the part to be removed.
2. Wire ropes 1) Use adequate ropes depending on the weight of parts to be hoisted, referring to the table below: Wire ropes (Standard “2” or “s” twist ropes without galvanizing) Rope diameter (mm)
Allowable
10.0
1.0
11.2 12.5 14.0 16.0 18.0 20.0 22.4 30.0 40.0 50.0 60.0
1.4 1.6 2.2 2.8 3.6 4.4 5.6 10.0 18.0 28.0 40.0
load (tons)
The allowable load value is estimated to be one-sixth or one-seventh of the breaking strength of the rope used.
Do not sling a heavy load with one rope alone, but sling with two or more ropes symmetrically wound on to 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. 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 (kg) when hoisting is made with two ropes, each of which is allowed to sling up to 1000 kg vertically, at various hanging angles. When two ropes sling a load vertically, up to 2000 kg of total weight can be suspended. This weight becomes 1000 kg when two ropes make a 120” hanging angle. On the other hand, two ropes are subject to an excessive force as large as 4000 kg if they sling a 2000 kg load at a lifting angle of 150”. P /2 kg % 2c00
1900 1700 a
2)
00-12
Sling wire ropes from the middle portion of the hook. Slinging near the edge of the hook may cause the rope to slip off the hook during hoisting, and a serious accident can result. Hooks have maximum strength at the middle portion.
0 ‘*
@J
i!yy-h \
30’
w Lifting
90. angle
120’
t 50’
: a Fsocms
STANDARD TIGHTENING
TORQUE
STANDARD 1. STANDARD
TIGHTENING
TORQUE
TIGHTENING
OF BOLTS AND NUTS
The following charts give the standard tightening sections of “Disassembly and Assembly”.
Thread diameter of bolt (mm)
TORQUE
torques
of bolts and nuts. Exceptions
are given in
8 cl
Width across flat (mm) kgm
Nm
I
6 8 10 12 14
10 13 17 19 22
1.35+0.15 3.220.3 6.750.7 11.5+1.0 18.022.0
13.221.4 31.4t2.9 65.7k6.8 11229.8 177219
16 18 20 22 24
24 27 30 32
28.5?3 39+4 56?6 7628 94.5+ 10
279229 383 + 39 549258 745 f 78 927+98
27 30 33 36 39
41 46 50 55 60
135215 175+20 225 fi 25 280 + 30 335 f 35
1320+140 1720+-190 2210+240 2750 2 290 3280 + 340
This torque table does not apply to the bolts with which nylon packings or other non-ferrous washers are to be used, or which require tightening to otherwise specified torque.
metal
t Nm (newton meter): 1Nm & 0.1 kgm
2. TIGHTENING
TORQUE
OF SPLIT FLANGE BOLTS
Use these torques for split flange bolts.
Thread diameter of bolt (mm) 10 12 16
Width across flats (mm) 14 17 22
Tightening
Nm
kgm
I I
6.720.7 11.5+1 28.523
torque
I
65.726.8 11229.8 279 f 29
00-l 3
3. TIGHTENING
TORQUE
Use these torques
FOR NUTS OF FLARED FITTINGS
for nut part of flared.
Thread diameter of nut part (mm)
I
Width across flats of nut part (mm)
14 18 22 24 30 :: 42
-
Nomenclature
coating
materials
Code LT-1 A LT-1 B LT-2*
Adhesives
LT-3 LT -4 LG-1 LG-3
Liquid
Grease (Lithium Molybdenum Disulfide) Vaseline
00-14
MATERIALS
prescribed
in the shop manuals
are listed
below.
Aoolications
1
Used to apply rubber pads, rubber gaskets, and cork plugs. Used to apply resin, rubber, metallic and non-metallic parts when a fast. strona seal is needed. Preventing bolts, nuts, and plugs from loosening oil. Provides an airtight, electrically insulating seal. Used for aluminum surfaces.
and leaking
Used to coat plugs and mating portion
and holes,
(plate shaped, of shaft.
bowl shaped)
Used with gaskets and packings to increase sealing effect. Heat-resistant gasket for precombustion chambers and exhaust piping.
LG-5
Used by itself to seal grease fittings, tapered screw fittings and tapered screw fittings in hydraulic circuits of less than 50 mm in diameter. Silicon
base type used in combination
Has shorter
curina
time than
with
LG-1 and LG-4.
LG-6. and is easier to oeel off.
LM-P
Applied to bearings and taper shafts to facilitate and to prevent sticking, burning or rusting.
G2-LI
Applied to bearings, sliding parts and oils seals for lubrication, rust prevention and facilitation of assembling work.
G2-LI-S
Heat resistance and long life type. Applied to bearings, sliding parts and oils seals for lubrication, rust prevention and facilitation of assembling work.
with MPG ___ -
I
Used by itself on mounting surfaces on the final drive and transmission cases. (Thickness after tightening: 0.07 - 0.08 mm).
LG-6 LG-7
Grease (Lithium synthetic grease)
24.5 f 4.9 49k19.6 78.5k19.6 137.3k29.4 176.5 + 29.4 196.1 249 245.2+49 294.2 2 49
LG-4 gasket
Antifriction compound (Lubricant including molybdenum disulfide) Grease (Lithium areasel
Nm
2.5kO.5 5+2 8+2 14*3 1823 2025 25+5 30+5
I
COATING The recommended
i torque
kgm
19 24 27 32 36 41 46 55
I
Tighteni
*LT-2
press-fitting
Abrasion at lubrication areas is decreased. Applied bearinas, slidina parts and oils seals for lubrication, preveniion and &iIitation of assembling work. Used for protecting is also called
LOCTITE
battery
electrode
terminals
in the shop manuals.
to rust
from corrosion.
ELECTRIC
WIRE CODE
In the wiring diagrams, various colors and symbols are employed to indicate This wire code table will help you understand WIRING DIAGRAMS. Example:
05WB indicates stripe.
CLASSIFICATION
a cable having
a nominal
number
the thickness
05 and white
coating
with black
BY THICKNESS
Applicable
*
of wires.
circuit
Old numbers
CLASSIFICATION
BY COLOR
AND CODE
Signal G Green GW Green White GR Green Red GY Green Yellow GB Green Black GL ~ Green Blue
Y
Yellow &
&
&
YR Yellow & Red YB Yellow & Black YG Yellow & Green ‘YL
&
Yellow & Blue YW
&
Yellow & White
L Blue LW Blue & White LR Blue & Red LY Blue & Yellow LB Blue & Black
00-l 5
00-l 6
01
GENERAL
GENERAL
VIEW
MACHINE
DIMENSIONS
WORKING
RANGE DIMENSIONS
MACHINE
SPECIFICATIONS
MACHINE
DIMENSIONS
WORKING
RANGE DIMENSIONS
MACHINE
SPECIFICATIONS
WEIGHT
TABLE
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01-3 - PC3OOLC-5
. . . . . . . . . . . . . . 01-4
- PC3OOLC-5 . . . . . . . . 01-5
- PC3OOLC-5
- PC400LC-5
. . . . . . . . . . . 01-6
. . . . . . . . . . . . . . 01-8
- PC4OOLC-5
- PC4OOLC-5
. . . . . . . . 01-9
. . . . . . . . . . 01-10
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01-12
REFILL SPECIFICATIONS AND CAPACITIES PC3OOLC-5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01-l 4 PC4OOLC-5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01-l 5
01-l
01-2
GENERAL VIEW PC3OOLG5, PC4OOLG5
Boom Arm cylinder
I
Boom cylinder
Right a Rear
tlucxel cylrnaer 11
Front Bucket
Idler
XOlAD029
If directions
are indicated
in this manual,
they refer to the directions
shown
by the arrows
in the diagram
above. 01-3
MACHINE DIMENSIONS PC3OOLG5
v
7
t
-J 4
B
. OlAD0007
ARM
A
E
Overall
length
Length
on ground
(transport) c
Overall
height
(to top of boom)
2.2 m (7’3’)
2.55 m (8’4”)
3.19 m (10’5”)
4.02 m (13’2”)
10950 mm
10855 mm
10810 mm
(35’11,,)
(35’7”)
(35’6”)
10840 mm (35’7”)
7728 mm
6850 mm
5405 mm
5390 mm
(25’4”)
(22’6”)
(17'9")
(17'8")
3370 mm
3425 mm
3200 mm
3650 mm
(1 l'l")
(11'3")
(10'6")
(12'0")
PC3OOLC-5 D
Overall
width
E
Overall
height
F
Ground
clearance,
I G IMin. H I
around
Tail swina
3290 mm (10’10’) (to top of cab)
3060 mm (10’0”)
counterweight
clearance radius
I
1180 mm (3’10”) I
498 mm (1'8")
I
3225 mm (10'7")
I
Length
J
Track
length
4855 mm (15’11”)
K
Track
gauge
2590 mm (8’6’)
L
Width
of crawler
M
Shoe width
700 mm (28")
N
Grouser
31 mm (1.2”)
1 0
IMachine
P
Machine
Q
Distance,
01-4
of track
3945 mm (12'11")
I
on ground
3290 mm (10’10’)
height I
cab heiaht
2960 mm (9’9”)
cab width swing
center
2495 mm (8’2”)
to rear end
3150 mm (10’4’)
WORKING RANGE DIMENSIONS PC3OOLC-5
ARMS
PC3OOLG5 A
MAXIMUM
DIGGING
B
MAXIMUM
DUMPING
HEIGHT HEIGHT
I I
DIGGING
DEPTH
I I
DIGGING
REACH
C
F
MAXIMUM
MAXIMUM
6355 mm (20’10”)
6705 mm
(22’)
(33’4”)
(34’7”)
9950 mm (32’8”) 4330 mm
BUCKET DIGGING FORCE
I
ARM CROWD
FORCE
I
7380 mm (24’3”)
I
!
(36’5”)
!
10355 mm I
(34’)
(35’10”)
4345 mm
4260 mm
(14’2”)
(14’3”)
18800 kg
18800 kg
(14’) 18800 kg
(41,450
Ib)
19100 kg (42,110 lb)
(41,450
I b)
16700 kg (36,830 I b)
(41,450
lb)
14100 kg (31,080 lb)
(39’1”) 11730 mm
10920 mm I
8180 mm (26’10”)
I
(38’6”) 4280 mm (14’1”) 18800 kg (41,450
I b)
12100 kg (26,680 I b)
01-f
MACHINE SPECIFICATIONS PC3OOLG5
% 3
ti a z B %
x m g E
01-6
g E 8 *
Machine Model
PC3OOLC5
Serial Numbers
A30001 and up
Operating Weight (with operator)
(kg)
31200
Bucket Capacity
(m3)
1.25
Maximum digging depth
(mm)
7380
Vertical wall depth
(mm)
6480
Maximum digging reach
(mm)
11100
Maximum digging reach at ground level
(mm)
10920
Maximum digging height
(mm)
10210
Maximum dumping height
(mm)
7110
Maximum digging force (when using power max.)(kg) Continued
swing speed
17500 (18800)
(rpm)
10
Swing maximum slope angle
(deg.)
20
Travel speed
WV-0
Lo: 3.4, Hi: 5.5
Gradeability
(deg.)
35
Ground pressure (standard triple-shoe)
(kg/cm*)
Overall length (at transportation)
(mm)
10810
Overall width
(mm)
3290
Track width
(mm)
3290
Overall height (at transportation)
(mm)
3200
Height of cab
(mm)
3060
Ground clearance of counterweight
(mm)
1180
Minimum ground clearance
(mm)
498
Tail swing radius
(mm)
3225
Minimum swing radius at front end
(mm)
4260
Arm height at minimum swing radius
(mm)
8445
Length of track on ground
(mm)
3945
Track gauge
(mm)
2590
Machine cab height
(mm)
2495
0.52 (700mm)
Machine Serial Engine
PC3OOLC-5
Model
A30001
Numbers
KDC 614TA
model
4-cycle, in-line, water cooled, direct injection type diesel engine with turbocharger and aftercooler
Type
No. of cylinder
Y B z
- bore x stroke
6 - 114 x 135
(mm)
8270
Total displacement
(cc)
Flywheel
(HP/rpm)
207/2000
(kgm/rpm)
94.7/l
horsepower
Maximum
torque
High idling
speed
Low idling Starting
speed
2200
(rpm)
725 f 25 24V
motor
24V, 45A 12V170Ahx2
Battery Type of radiator A!
Carrier
g:L 33
Track
roller
Track
shoe
:
500
(rpm)
Alternator
3 6 & U 3 d
and up
cwx-3
core
roller
(one side)
8
(one side)
8 Built-up Variable
number
triple
grouser
displacement piston Gear type x 1
L z u 5 d
Type,
Delivery
(P/min)
Piston type: 250 x 2 Gear type: 90
:
Set pressure
(kg/cm*)
Piston type: 325 (350) Gear type: 30
d EL! 5’ 09
Type,
0 + Z8 E$
Travel
motor
Swing
motor
4-spool
number
Control
type and 5-spool
Hydraulic
lever operation
Piston
Piston
type
type
type
assist type
(with brake valve, x2 (with safety valve, 1 Double
type x 2
acting
Hydraulic
cylinder
Hydraulic
tank
Closed
Hydraulic
filter
Tank return
Hydraulic
cooler
parking
parking
brake)
brake) x
piston
box type side
Air cooled
01-7
MACHINE DIMENSIONS PC4OOLC-5 P
* -
t-
II
H.g -
i -I
I-
t
-J
IPC4OOLG5
2.4 m (7’10”)
2.9 m (9’6”)
B
3.38 m _ (11’1”)
-I
Ii+ 01A00007
4.0 m (13’1”)
4.8 m (15’9”)
A
Overall length
11765 mm (38’7”)
11750 mm (38’7”)
11700 mm (38’5”)
11705 mm (38’5”)
11560 mm (37’11”)
B
Length on ground (transport)
8428 mm (27’8”)
7418 mm (24’4”)
6680 mm (20’3”)
6268 mm (20’7”)
5978 mm (19’7”)
G
Overall height (to top of boom)
3660 mm
3680 mm (12’1”)
3450 mm (1 1’4”)
3805 mm
4365 mm (14’4”)
PC4OOLC-5
L
Width of crawler
M Shoe width
(12’)
(12’6”)
Std. Undercarriage
3480 mm (11’5”)
3200 mm (10’6”)
3685 mm (12’1”)
750 mm (29.5”)
750 mm (29.5”)
750 mm (29.5”)
26 mm (1”)
26 mm (1”)
26 mm (1”)
N
Grouser height
0
Machine cab height
2695 mm (8’10”)
2695 mm (8’10”)
2695 mm (8’10”)
P
Machine cab width
2960 mm (9’9”)
2960 mm (9’9”)
2960 mm (9’9”)
Q
Distance, swing center to rear end
3360 mm (11’)
3360 mm (11’)
3360 mm (11’)
01-8
WORKING RANGE DIMENSIONS PC4OOLC-5
xo1*Do34
ARM
PC4OOLG5 A
Maximum
digging
B
Maximum
dumping
height height
2.4 m (7’10”)
2.9 m (9’6”)
3.38 m (11’1”)
4.0 m (13’1”)
4.8 m (15’9”)
10295 mm (33’9”)
10305 mm (33’10”)
10920 mm (35’10”)
11045 mm (36’3”)
11505 mm (37’9”)
7055 mm (23’2”)
7095 mm
7570 mm (24’10”)
7725 mm (25’4”)
8155 mm (26’4”)
6785 mm (22’3”)
7285 mm (23’11”)
7760 mm
9195 mm (30’2”)
(23’3”)
C
Maximum
(25’6”)
8385 mm (27’6”)
f,
Maximum vertical wall digging depth
5335 mm (17’6”)
5680 mm (18’8”)
6850 mm (22’6”)
7280 mm (23’11”)
8215 mm (26’11”)
E
Maximum digging depth of cut for 8’ level
6585 mm (2 1’7”)
7095 mm (23’3”)
7620 mm
9080 mm (29’9”)
F
Maximum
digging
reach
11055 mm (36’3”)
11435 mm (37’6”)
(25,) 12020 mm (39’5”)
8255 mm (27’1”) 12550 mm (41’2”)
13350 mm (43’10”)
C
Maximum ground
digging
reach at
10830 mm (35’6”)
11220 mm (36’10”)
11810 mm (38’9”)
12355 mm (40’6”)
13165 mm (43’2”)
H
Minimum
swing radius
4750 mm (15’7”)
4730 mm (15’6”)
4660 mm (15’3”)
4710 mm (15’5”)
4785 mm (15’8”)
Bucket digging force
22500 kg (49,600 lb)
22400 kg (49,380 lb)
22600 kg
22400 kg
22300 kg
(49,820 lb)
(49,380
lb)
(49,160 lb)
Arm crowd force
25800 kg (56,880 lb)
22900 kg (50,490 lb)
19300 kg (42,550 lb)
17300 kg (38,140 lb)
15200 kg (33,510 lb)
digging depth
01-9
MACHINE SPECIFICATIONS PC4OOLC-5
g 3
; % i n
x E 3 6
01-10
4 E 5 3
Machine Model
PC4OOLC-5
Serial Numbers
A40001 and up
Operating Weight (with operator)
(kg)
42550
Bucket Capacity
(m3)
1.63
Maximum digging depth
(mm)
7760
Vertical wall depth
(mm)
6850
Maximum digging
reach
(mm)
12020
Maximum digging
reach at ground level
(mm)
11810
Maximum digging
height
(mm)
10920
(mm)
7570
Maximum dumping height
Maximum digging force (when using power max.)(kg) Continued
swing speed
21000 (22600)
(rpm)
9.3
Swing maximum slope angle
(deg.)
19
Travel speed
(km/h)
Lo: 3.1, Hi: 5.5
Gradeability
(deg.)
35
Ground pressure (standard triple-shoe)
(kg/cm*)
Overall length (at transportation)
(mm)
11700
Overall width
(mm)
3480
Track width
(mm)
3480
Overall height (at transportation)
(mm)
3450
Height of cab
(mm)
3195
Ground clearance of counterweight
(mm)
1315
Minimum ground clearance
(mm)
555
Tail swing radius
(mm)
3430
Minimum swing radius at front end
(mm)
4660
Arm height at minimum swing radius
(mm)
9220
Length of track on ground
(mm)
4340
Track gauge
(mm)
2740
Machine cab height
(mm)
2695
0.6 (750mm)
Machine Model
PC4OOLC5
Serial Numbers
A40001 and up CUMMINS LTA 10
Engine model
4-cycle, in-line, water cooled, direct injection type diesel engine with turbocharger and aftercooler
Type
Y B 3
No. of cylinder - bore x stroke
(mm)
6 - 125 x 136
Total displacement
(cc)
Flywheel horsepower
(HP/rpm)
276/2000
Maximum torque
(kgm/rpm)
121/1400
High idling speed
(rpm)
2200
Low idling speed
(rpm)
750 + 50
10000
24V
Starting motor
24V, 55A
Alternator
12V 170Ah x 2
Battery
cwx-4
Type of radiator core $
Carrier roller
(one side)
8
n9 20
Track roller
(one side)
8 Built-up triple grouser
Track shoe
3 E t; u i 2 %
%
Variable displacement piston type x 2 Gear type x 1
% z 0 2 d
Type, number Delivery
(P/min)
Piston type: 315 x 2 Gear type: 92
:
Set pressure
(kg/cm*)
Piston type: 325 (350) Gear type: 30
d % 8g
Type, number
0
Travel motor
z! 68 %
Control lever operation
4-spool type and 5-spool type Hydraulic assist type
Piston type (with brake valve, parking brake) x2
Swing motor
Hydraulic
Piston type (with safety valve, parking brake) x 1 cylinder
Double acting piston
Hydraulic tank
Closed box type
Hydraulic filter
Tank return side
Hydraulic
cooler
Air cooled
01-11
WEIGHT
A
TABLE This weight table is a guide for use when transporting
or handling components.
Machine Model
PC3OOLC-5
PC4OOLC-5
Serial Numbers
A30001 and up
A40001 and up
1060
1470
Engine assembly l
Engine
760
1170
l
Damper
20
20
l
Hydraulic
280
280
152
180
224
290
175
190
Revolving frame
2540
3090
Operator’s
cab
238
238
Operator’s
seat
35
35
Counterweight
5420
8470
Swing machinery
440
620
Control valve assembly
236
240
Swing motor assembly
125.5
130
Travel motor assembly
239x2
290x2
43
43
7230
10560
4312
6600
430
585
pump
Radiator and oil cooler assembly Hydraulic tank assembly (without hydraulic Fuel tank (without fuel)
Center swivel joint Track frame assembly
oil)
l
Track frame
l
Swing circle assembly
l
Idler
166x2
235x2
l
Idler cushion
257x2
365x2
0 Carrier roller
31x4
31x4
l
Track roller
52x16
73x16
l
Final drive
426x2
560x2
01-12
1
Machine Model
PC3OOLC-5
PC4OOLC-5
Serial Numbers
A30001 and up
A40001 and up
Triple shoe (600 mm)
3730
4760
Triple shoe (700 mm)
4090
5210
Triple shoe (750 mm)
4270
5440
Wide triple-shoe
(800 mm)
4455
5600
Wide triple-shoe
(850 mm)
4635
Wide triple-shoe
(900 mm)
Track shoe assembly
6110
Boom assembly
2357
2990
Arm assembly
981
1234
Bucket assembly
1014
1300
293x2
400x2
Arm cylinder assembly
425
580
Bucket cylinder assembly
263
345
Link (large) assembly
320
397
Boom cylinder assembly
Boom pin
76+15x2+56+17+42
93+20x2+73+24+54
13+17
17+24
Bucket pin
30x2
34x2
Link pin
27x2
38x2
Arm pin
01-13
REFILL SPECIFICATIONS PC3OOLC
AND CAPACITIES
It is not our policy to approve lubricants or to guarantee oil performance quality of the lubricant must remain with the supplier of the lubricant. Distributor. The lubricants specified for this machine are shown below. (IND OF FLUID
RESERVOIR
.22 .30
AMBIENT -4 14 -20 -10
in service. The responsibility of When in doubt, consult your
TEMPERATURE 32 50 68 86 104°F 0 10 20 30 40°C
Specified
Refill
oil pan
18.9 4 5.0 US gal 4.2 UK gal
18.9 P 5.0 US gal 4.2 UK gal
machinery
23 4 6.1 US gal 5.1 UK gal
22.5 4 5.9 US gal 4.9 UK gal
8.OP 2.1 US gal 1.8 UK gal
7.4 Q 2 US gal 1.6 UK gal
I
Engine
Swing
CAPACITY
Final drive (each)
case
case ingine
Damper
Hydraulic
oil 1.24 0 0.33 US gal 0.27 UK gal
case
370 P 97.7 US gal 81.4 UK gal
system
195 P 51.5 US gal 42.9 UK gal
1 ,I\ All lubrication
Grease
0.2 Multi-purpose lithium grease with 3% molybdenum disulfide
system
Coolant
See “COOLANT
g
01-14
Fill as instructed
F
jiesel fue
Fuel tank
Cooling
fittings
ASTM
SPECIFICATIONS”
D975 No. 1
30 Q 7.9 US gal 6.6 UK gal
REFILL SPECIFICATIONS PC4OOLC
AND CAPACITIES
It is not our policy to approve lubricants or to guarantee oil performance quality of the lubricant must remain with the supplier of the lubricant. Distributor. The lubricants specified for this machine are shown below.
(IND OF FLUID
RESERVOIR
Engine filters
Swing
AMBIENT 14 -4 -20 -10
TEMPERATURE 86 104°F 50 68 32 30 40°C 10 20 0
machinery
casQ
case
Hydraulic
38 4 10 US gal 8.3 UK gal
24 4 i.3 US gal I.3 UK gal
22 Q 5.8 US gal 4.8 UK gal
11.5 P i.0US gal
11 P 2.9 US gal
4604 22 US gal 02 UK gal
fittings
Grease
0.4
lithium grease with Multi-purpose 3% molybdenum disulfide
2.4 UK gal
Coolant
255 Q 67.4 US gal 56.2 UK gal
Fill as instructed 550 Q 145 US gal 121 UK gal
riesel fue
system
38 P 1IO US gal ai.3 UK gal
1.07 Q 28 US gal 23 UK gal
system
Fuel tank
Refill
oil
case
All lubrication
gpecified
1.5 UK gal ngine
Damper
CAPACITY
T
oil pan and
Final drive (each)
Cooling
22 30
in service. The responsibility of When in doubt, consult your
See “COOLANT
g
ASTM
SPECIFICATIONS”
D975 No. 1
I
34 4 9 US gal 7.5 UK gal
01-15
ENGINE Normal
OIL SPECIFICATIONS
Operation
Oil performance
recommendations
are as follows:
The use of a quality engine lubricating critical factors in maintaining engine
oil combined with appropriate performance and durability.
SAE 15W-40 multi-viscosity oil meeting the classification of CE or CF-4 is recommended. NOTE: CD or CD/SF
American
oils may be used in areas where
oil and filter change
Petroleum
Institute
(API)
intervals
are
performance
CE or CF-4 oil is not yet available.
A sulfated ash limit of 1.0 mass percent is suggested for optimum valve and piston deposit and oil consumption control. The sulfated ash must not exceed 1.85 mass percent. The sulfated ash limit of 1.85 mass percent has been placed on all engine lubricating oils recommended for use in the engine. Higher ash oils can cause valve and/or piston damage and lead to excessive oil consumption. The API service symbol displays the following information. The upper half of the symbol displays the appropriate oil categories; the lower half may contain words to describe oil energy conserving features. The center section identifies the SAE oil viscosity grade. Oil viscosity
recommendations
are as follows:
The use of a multi-graded improve engine cranking temperatures.
lubricating oil has been found to improve oil consumption control and in cold temperatures while maintaining lubrication at high operating
While SAE 15W-40 multi-viscosity oil is recommended for most operating previous chart for oil viscosity recommendations for extreme climates.
climates,
refer
to the
Limited use of low viscosity oils, such as SAE low-30 may be used for easier starting and providing sufficient oil flow at ambient temperatures below -5°C (+23”F). However, continuous use of low viscosity oils can decrease engine life due to wear. Special “break-in” lubricating oils are not recommended for a new or rebuilt of oil during the “break-in” as specified for normal operation.
engine.
Use the same type
Additional information regarding lubricating oil availability throughout the world is available in the “E.M.A. Lubricating Oils Data Book for Heavy Duty Automotive and Industrial Engines.” The data book may be ordered from the Engine Manufacturers Association, 401 North Michigan, Chicago, IL U.S.A. 60611. The telephone number is (312) 644-6610. Arctic
Operation
If an engine is operated in ambient temperatures consistently below -23°C (-10°F) and there are no provisions to keep the engine warm when it is not in operation, use a synthetic API performance classification CE or CF-4 engine oil with adequate low temperature properties such as SAE 5W-20 or 5W30. The oil supplier
must be responsible
for meeting
the performance
service
specifications.
NOTICE: The use of a synthetic base oil does not justify extended oil change intervals. Extended oil change intervals can decrease engine life due to factors such as; corrosion, deposits and wear.
GREASE
SPECIFICATIONS
The recommended
01-16
lubricating
grease is No. 2 multi-purpose
lithium
grease with 3% molybdenum
disulfide.
DIESEL
FUEL SPECIFICATIONS
A Do not mix gasoline
or alcohol
with diesel
NOTICE: Due to the precise tolerances of diesel be kept clean and free of dirt or water. both the injection pump and nozzles. For normal service Cetane number of performance under in high altitudes or
WARNING fuel. This mixture
can cause
an explosion.
injection systems, it is extremely important that the fuel Dirt or water in the system can cause severe damage to
above -12°C (+lO”F), the use of ASTM Grade No. 2-D diesel fuel with a minimum 40 is recommended. The use of No. 2-D diesel fuel will result in optimum engine most operating conditions. Fuels with Cetane numbers higher than 40 may be needed extremely low ambient temperatures to prevent misfires and excessive smoke.
At operating temperatures below fuels can reduce fuel economy.
-12°C
(+iO”F),
use ASTM Grade No. 1-D diesel fuel. The use of lighter
Where a winterized blend of Grade No. 2-D and No. 1 -D fuels is available, it may be substituted for Grade No. 1-D fuel. However, it is the supplier’s responsibility to provide the fuel for the anticipated ambient temperature. Use a low sulfur fuel temperature.
content fuel having a cloud point that is at least 10 degrees below the lowest Cloud point is the temperature at which crystals begin to form in the fuel.
The viscosity
of the fuel must be kept above
COOLANT
SPECIFICATIONS
General Selection provides
and maintenance recommendations
of the engine for selecting
1.3 cSt to provide
coolant is important the engine coolant
adequate
fuel system
expected
lubrication.
to long engine life. The following information and maintaining the coolant inhibitors.
Heavy duty diesel engines require a balanced coolant mixture of water, antifreeze, and supplemental coolant additives. Supplemental coolant additive recommendations are included in the section entitled The coolant mixture must be drained and replaced at the specified service “Inhibitors/Conditioners”. interval shown in “23. SCHEDULED MAINTENANCE GUIDE” on page 3-28 of the Operators Manual, or every two years of operation, whichever comes first. Water Use water which has a low mineral content. Water used in conjunction inhibited water must meet the following standards:
with antifreeze,
coolant
filters
and
Total Hardness - Not to exceed 170 parts per million (10 grains/gallon maximum) to prevent scale deposits. Water containing dissolved magnesium and calcium (the usual reason for water hardness) above the specified amount will cause scale deposits to develop in the engine. Chlorides Sulfites
- Not to exceed - Not to exceed
40 parts per million 100 parts per million
(2.5 grains/gallon (5.8 grains/gallon
maximum) maximum)
Dissolved Solids - Not to exceed 340 parts per million (20 grains/gallon sludge deposits, scale deposits, corrosion or a combination of these.
to prevent to prevent maximum)
corrosion. corrosion. to minimize
If any of the above requirements cannot be met, use distilled, de-ionized, or de-mineralized water. To determine if local water supplies meet these standards, water samples can be tested by water treatment laboratories. “Softened” water that is prepared using common salt (sodium chloride) contains excessive amounts of chlorides and should not be used.
01-17
NOTICE: Never use water alone in the cooling system because corrosion will occur. Antifreeze In climates where the temperature is above -37°C (-34”F), use a coolant mixture that contains 50 percent antifreeze. Antifreeze is essential in any climate. It broadens the operating temperature range by lowering the coolant freezing point and by raising its boiling point. Do not use more than 50 percent antifreeze in the mixture unless additional freeze protection is required. Never use more than 68 percent antifreeze under any condition. An antifreeze concentration greater than 68% will adversely affect freeze protection and heat transfer rates. Antifreeze concentrations between 68% and 100% actually have a higher freezing point than a 68% antifreeze concentration and should not be used due to reduced heat transfer rates. Low silicate ethylene glycol antifreeze is recommended. The antifreeze should anhydrous alkali metasilicate. Low silicate antifreeze is recommended to avoid (hydro-gel). This gel formation can occur when the cooling system contains an silicate antifreeze and/or supplemental coolant additive. DO NOT use methanol because of its low boiling point. Antifreeze may retain its freeze protection added to maintain corrosion protection. Antifreeze
formulated
with
methoxy
for more than one season
propanol,
or propylene
glycol,
contain no more than 0.1% the formation of silica-gel over concentration of high or alcohol as an antifreeze
but coolant
conditioners
is not recommended
must be
for this system.
NOTICE: Do not mix types of antifreeze solutions. Mixed solutions make it impossible to determine the protection against freezing. Antifreeze containing sealer or anti-leak additives should NOT be used in this system. Sealer or anti-leak additives will cause plugging problems in the cooling system. Check the solution sufficient protection The following temperatures.
table
periodically and at normal against freezing. shows
the
approximate
In tropical climates the engine cooling
01-18
[+;;I;{ (:: ‘(;I;/ [-;;I -
;;
If;:;] [-;;I;/ [-;$;I -
where antifreeze system.
temperature,
percentage
availability
to be sure the cooling
of antifreeze
Percentage of Antifreeze Concentration by Volume
Approximate Freezing Point 0°C -7°C -12°C -18’C -23°C -29°C -34°C -40°C -46°C -51°C -57°C -62°C
operating
0 15 25 33 40 45 48 53 56 59 62 65 67 68
may be limited,
solution
required
system
for
has
various
Specific Gravity at 16” C (SO’ F) 1 .ooo 1.025 1.040 1.053 1.062 1.070 1.074 1.080 1.083 1.088 1.092 1.095 1.097 1.098
use a corrosion
inhibitor
DCA4, to protect
inhibitors/Conditioners 1. All cooling system inhibitors, including those in antifreeze solutions, become depleted through normal operation. If the inhibitors in antifreeze are allowed to become depleted, the antifreeze becomes corrosive and attacks and coats the metallic surfaces of the cooling system which reduces heat transfer. Cooling system conditioners which contain these inhibitors must be added to maintain corrosion protection. 2. SOLUBLE
OIL IS NOT RECOMMENDED
3. There are no miracle additives water is still the best coolant. 4. DCA4 is recommended
for use in this engine
that will
to inhibit
increase
corrosion
heat transfer
in the cooling
as its use will reduce or prevent
system
overheating.
for the following
l
Improved compatibility concentration occurs.
l
Provides engine protection in the following areas: - Copper corrosion/erosion/stress - Solder corrosion/bloom - Cylinder liner cavitation corrosion - Oil fouling - Seal and gasket degradation - Aluminum cavitation corrosion
MAINTENANCE
OF COOLING
Keeping the engine and corrosion. New machines the Operators
coolant
with
high
SYSTEM
properly
silicate
antifreezes
to minimize
heat transfer.
hydro-gel
Conditioned
reasons: formation
if over
cracking
INHIBITORS
inhibited
will keep the engine
are delivered with antifreeze protection. Manual with a “service” DCA4 filter.
Service
and radiator
at regular
free of rust, scale deposits
scheduled
interval
specified
in
Each time the coolant is drained and replaced, the coolant must be recharged with DCA4. New coolant can be correctly charged with supplemental coolant additives by using DCA4 filters or DCA4 concentrate listed in the table entitled, “DCA4 Unit Guide”. If coolant COOLANT
is added TESTING
between
drain
intervals,
FOR CONDITIONER
additional
DCA4 will be required.
CONCENTRATION
When the cooling system is maintained as recommended, the conditioner concentration should be satisfactory. The DCA4 concentration must not fall below 1.0 unit per 3.8 P (1 US gal) or exceed 2 units per 3.8 P (1 US gal) of coolant. The only accurate method for testing chemical concentrations in coolant with mixed chemical compounds is a laboratory analysis. For this reason, the coolant inhibitor should be maintained.
NOTICE: Inadequate concentration of the coolant additive can result in major corrosive damage to cooling system components. Over concentration can cause formation of “gel” that can cause restriction, plugging of passages and overheating. REPLENISHING COOLANT CONDITIONER Install a “precharge” DCA4 filter when the coolant is changed or a significant (more than 50%) coolant loss occurs. Install a “service” DCA4 filter as specified in “23. MAINTENANCE SCHEDULE CHART” on page 3-28 of the Operators Manual. When antifreeze is added, add coolant conditioner equal to 1.0 unit per 3.8 P (1 US gal) of antifreeze.
NOTICE: Mixing of DCA4 and other supplemental coolant additives is not recommended because there is currently no test kit available to measure concentration levels with mixed chemical solutions.
01-19
DCA4 UNIT MAINTENANCE
GUIDE
Use supplemental coolant additives (corrosion inhibitors) to protect the engine cooling system from corrosion. Antifreeze alone does not provide enough corrosion protection for a heavy duty diesel engine. Supplemental corrosion protection must be supplied through periodic additions of supplemental coolant additives to the coolant. To protect against corrosion, a new coolant charge must be brought up to 0.26 DCA4 unit per liter [one unit per U.S. gallon] of coolant (initial charge). Maintain the correct DCA4 concentration by changing the service coolant filter at each engine oil and filter change interval. Each time the coolant is drained and replace, the coolant must be recharged with supplemental additives. Use the appropriate DCA4 spin-on filter listed in following table. The coolant mixture
coolant
must be
drained and replaced as defined under “General”. The amount of replacement inhibitor is determined by the length of the service interval and the cooling system capacity. Refer to the DCA4 Unit Guide for the selection of the correct filter to replenish the DCA4. If coolant is added between drain intervals, additional DCA4 will be required. Check the coolant DCA concentration level anytime make-up coolant is added to the system. The DCA4 concentration must not fall below 0.13 units per liter or exceed 0.5 units per liter [0.5 units per U.S. gallon or exceed 2 units per U.S. gallon]. DCA4 Unit Guide Fleetguard Part No.
DCA4 Units
DCA4 Coolant Filter WF-2070 WF-2071 WF-2072 WF-2073 WF-2074 WF-2075 WF-2076 WF-2077
2 4 6 8 12 15 23 0
DCA4 Liquid DCAGOL DCA80L
4 (1 Pint) 1760 (55 US gal)
DCA4 Powder DCA95
20
DCA4 Precharge and Service Filters System Capacity Liters
Gallons
19-26
5-7 8-10 11-15 16-20 21-30 31-50
30-38 42-57 61-76 80-l 14 118-190 NOTE 1 -
01-20
Precharge Filter (See NOTE 1) WF-2072 WF-2073 WF-2074 WF-2075 WF-2076 (See NOTE 2)
After draining and replacing coolant, always precharge the cooling DCA4 concentration between 1.0 and 2.0 units per 3.8 0 (1 US gal).
Service Filter (See NOTE 3) WF-2070 WF-2071 WF-2071 WF-2071 WF-2072 WF-2073 system
to maintain
the
NOTICE: When performing service which requires draining the cooling system, discard the coolant. Reusing coolant can introduce contaminates or over concentrated chemicals, resulting in premature failure of cooling system components. NOTE 2 0
To precharge cooling Install
appropriate
systems
service
Example:
filter
larger than listed
114 Q(30 gal) do the following:
in the above table
95 gal (360 Q) cooling -15 Units (1) WF-2075 80 Units
system Filter
based on cooling
system
capacity.
capacity
l
The answer represents the additional units required to precharge the cooling system. Four bottles of powder, part number DCA95, will provide a sufficient amount of DCA4 units (80) to precharge the example cooling system.
0
Install
NOTE 3 -
Change system.
the appropriate the coolant
service filter
filter
at every
at the next and subsequent engine
oil and filter
change
maintenance interval
intervals.
to protect
the cooling
Maintain a nominal concentration of 1 .O DCA4 unit per 3.8 Q(1 US gal) of coolant in the system. Less than 0.5 unit per 3.8 Q(1 US gal) indicates an under-concentrated coolant solution. More than 2.0 units per 3.8 Q (1 US gal) indicates an over-concentrated coolant solution.
To check the DCA4 concentration included with the test kit.
level,
use the Fleetguard
DCA4 Unit Concentration Number of Solution A Drops to Cause Color Change
coolant
test kit, CC2626.
Instructions
are
Guide
Coolant Condition
Action Required
0 - 10 Drops
Extremely under-concentrated less than 0.4 DCA4 units per 3.8 Q (1 US gal)
-
Initially charge the system to a minimum of 1.0 DCA4 unit per 3.8 Q (1 US gal).
11 - 16 Drops
Marginally under-concentrated - 0.45 to 0.8 DCA4 units per 3.8 Q (1 US gal)
Add DCA4 liquid units to maintain 1 .O DCA4 unit per 3.8 4 (1 US gal) minimum or change the DCA 4 coolant filter.
17 - 25 Drops
Acceptable - 0.85 to 1.3 DCA4 units per 3.8 Q (1 US gal)
None.
26 - 35 Drops
Highly acceptable - 1.35 to 2.0 DCA4 units per 3.8 Q (1 US gal)
None.
36 - 55 Drops
Marginally over-concentrated 2.1 to 3.3 DCA4 units per 3.8 Q (1 US gal)
Review
Over 55 Drops
Extremely
Drain 50% of the coolant and replace with water antifreeze mixture. Retest the system for correct DCA4 unit concentration.
over-concentrated
maintenance
practice.
01-21
Co-22
10 STRUCTURE
AND FUNCTION
ENGINE RELATED PARTS AND ENGINE MOUNT PC3OOLC . . . . . . . . . . . . . . . . . . . . . . . 1o-4 ENGINE RELATED PARTS AND ENGINE MOUNT PC4OOLC . . . . . . . . . . . . . . . . . . . . . . . I o-5 RADIATOR PC3OOLC
AND OIL COOLER . . . . . . . . . . . . . . . . . . . . . . .
RADIATOR PC4OOLC
AND OIL COOLER . . . . . . . . . . . . . . . . . . * . . . * 10-7
FUEL TANK AND PIPING PC3OOLC . . . . . . . . . . . . . . . . . . . . . . . FUEL TANK AND PIPING PC4OOLC . . . . . . . . . . . . . . . . . . . . . . . POWER TRAIN
. . . . . . . . . . . . . . . . . .
FINAL DRIVE PC3OOLC . . . . . . . . . . . . . . . . . . . . . . FINAL DRIVE PC4OOLC . . . . . . . . . . . . . . . . . . . . . . SWING CIRCLE PC3OOLC . . . . . . . . . . . . . . . . . . . . . .
1O-6
TRACK FRAME AND RECOIL SPRING PC4OOLC . . . . . . . . . . . . . . . . . . . . . .
lo-18
IDLER PCBOOLC
. . . . . . . , . . . . . . . . . . . . . .
10-19
IDLER PC4OOLC
. . . . . . . . . . . . . . . . . . . . . .
1O-20
TRACKROLLER
. . . . . . . . . . . . . . . . .
10-21
. . . . . . . . . . . . . . . .
10-21
TRACK SHOE PC3OOLC . . . . . . . . . . . . . . . . . . . . . .
1o-22
TRACK SHOE PC4OOLC . . . . . . . . . . . . . . . . . . . . . .
1O-23
HYDRAULIC
PIPING
. . . . . . . . . . . . . .
1O-25
HYDRAULIC
CIRCUIT
DIAGRAM
. . . . . .
1O-27
HYDRAULIC TANK PC3OOLC . . . . . . . . . . . . . . . . . . . . . .
1o-29
HYDRAULIC TANK PC4OOLC . . . . . . . . . . . . . . . . . . . . . .
1O-30
CARRIER
ROLLER
1O-8
1o-9 lo-10
1o-1 1
1o-1 2
10-l 3
OLSS (Open Center
SWING CIRCLE PC4OOLC . . . . . . . . . . . . . . . . . . . . . .
10-14
SWING MACHINERY PC3OOLC . . . . . . . . . . . . . . . . . . . . .
10-15
HYDRAULIC
. .
10-31
. . . . . . . . . . . . . . .
1o-33
. . . . . . . . . . . . . . . . .
1O-52
. . . . . . . . . . . . . . . .
1o-54
. . . . . . . . . . . . . . . . . .
1O-66
Load Sensing PUMP
LINE OIL FILTER CONTROL
VALVE
System)
SWING MACHINERY PC4OOLC
. . . . . . . . . . . . . . . . . . . . .
TRACK FRAME AND RECOIL SPRING PC300LC . . . . . . . . . . . . . . . . . . . . .
lo-16
SWING MOTOR CENTER
SWIVEL JOINT.
. . . . . . . . . . .
1O-69
10-17
10-I
TRAVEL MOTOR PC300LC . . . . . . . . . . . . . . . . . . . . . .
1 O-70
TRAVEL MOTOR PC4OOLC . . . . . . . . . . . . . . . . . . . . . .
1 O-72
VALVE CONTROL
lo-79
. . . . . . . . . . . . . . . .
PPC VALVE . . . . . . . . . . . . . . . . . . . . .
1 O-80
ACCUMULATOR
1 O-86
SAFETY
LOCK VALVE
SOLENOID SHUTTLE
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
VALVE ASSEMBLY
. . . . . . .
lo-87
. . . . . . . . . . . . . . . . .
lo-91
VALVE
. . . . . . . . . . .
lo-92
. . . . . . . . . . . .
lo-95
. . . . . . . . . . . . . . .
lo-98
VALVE
BOOM HOLDING HYDRAULIC
lo-86
CYLINDER
WORK EQUIPMENT
ELECTRICAL WIRING DIAGRAM PC3OOLC . . . . . . . . . . . . . . . . . . . . . . 1o-1 00 ELECTRICAL WIRING DIAGRAM PC4OOLC . . . . . . . . . . . . . . . . . . . . . . 1o-1 02 ELECTRICAL CIRCUIT DIAGRAM PC300LC . . . . . . . . . . . . . . . . . . . . . . 1o-1 05 ELECTRICAL CIRCUIT DIAGRAM PC4OOLC . . . . . . . . . . . . . . . . . . . . . . 1o-1 09 ENGINE CONTROL SYSTEM PC300LC (S/N A30001 THRU A301 10, A301 12 ANDA30114THRUA30116
. . . . . . . . . . . . . .
10-113
ENGINE CONTROL SYSTEM PC300LC (S/N A30111, A30113 AND A30117AND
UP
. . . . . . . . . . . . . . . . .
10-113-l
ENGINE CONTROL SYSTEM PC4OOLC . . . . . . . . . . . . . . . . . . . . . . 10-l 14 PEMC SYSTEM
. . . . . . . . . . . . . . . . . . lo-124
EMACC (ELECTRONIC MONITOR AND CONTROL CONSOLE) . . . . . . . . . 1O-l 53
1 o-2 0
1 o-3
ENGINE RELATED PARTS AND ENGINE PC3OOLC
MOUNT
r-1 ‘-.’
-7
T-‘----
I
:II II
B-B
6
c-c
A-A 12ADOOll
1. Front engine mount 2. Engine 3. Rear engine mount
1 o-4
4. Air cleaner 5. Muffler 6. Damper
ENGINE RELATED PARTS AND ENGINE PC4OOLC
MOUNT
-
I
1 3
I
B-B
View2
u
12Amo12
1. Front engine mount 2. Engine 3. Rear engine mount
4. Air cleaner 5. Muffler 6. Damper
1 o-5
RADIATOR PC3OOLC
AND OIL COOLER
06AH0014
J
1. Oil cooler 2. Radiator 3. Radiator inlet hose
1 O-6
4. Sub-tank 5. Radiator outlet 6. Fan guard
hose
SPECIFICATIONS Radiator: CWX-3 Oil cooler: SF-3
RADIATOR PC4OOLC
AND OIL COOLER
___k’I - .
ji -
11, __ -
1
,(‘A
06AHOOlS
1. Oil cooler 2. Radiator 3. Radiator inlet hose
4. Sub-tank 5. Radiator outlet hose 6. Fan guard
SPECIFICATIONS Radiator: CWX-4 Oil cooler: SF-4
1o-7
FUEL TANK AND PIPING PC3OOLC
1
2
(‘->
\.
-, I,’
12BD0003
1. Drain valve 2. Fuel level sensor 3. Tank
1 O-8
4. Cap 5. Sight gauge
FUEL TANK AND PIPING PC4OOLC
/
6
1. Drain valve 2. Fuel level sensor 3. Tank
4. Cap 5. Sight gauge 6. Fuel filter
1 o-9
POWER TRAIN
1'2
1. 2. 3. 4. 5. 6.
Idler Center swivel joint Control valve assembly Final drive Travel motor Engine
IO-10
205FO5008
7. 8. 9. 10. 11. 12.
Hydraulic pump Swing brake solenoid Travel speed solenoid Swing motor Swing machinery Swing circle
valve valve
FINAL DRIVE PC3OOLC k”
1. 2. 3. 4. 5. 6. 7. a. 9. 10. 11. 12. 13. 14. 15. 16. 17.
Level plug Drain plug No. 1 sun gear (13 teeth) No. 2 sun gear (19 teeth) Cover No. 2 plant gear (30 teeth) No. 2 ring gear (80 teeth) Spacer No. 1 ring gear (80 teeth) No.1 planet gear (33 teeth) Sprocket Floating seal Travel motor Hub Retainer No. 1 planetary carrier No. 2 planetary carrier
SPECIFICATIONS Reduction ratio: _ (?!$?)
x (y)
+ l=
-36.275
,13
Section A -
A
207FO5008
IO-11
FINAL DRIVE’ PC4OOLC
,1
1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17.
Level plug Drain plug No. 2 planet gear (34 teeth) No. 1 sun gear (17 teeth) No. 2 sun gear (12 teeth) No. 2 planetary carrier Cover No. 1 planetary carrier Retainer Sprocket Floating seal Travel motor Hub No. 1 plant gear (32 teeth) No. 1 sun gear (83 teeth)‘ Spacer No. 1 sun gear (81 teeth)
SPECIFICATIONS Reduction ratio: - (9)
8
9
‘lo”
Section A -
A
11
208FO5008
x (J!z$)
+ l=
-44.588
SWING CIRCLE PC3OOLC
Section
A -
A 207FO5009
1. Swing circle outer race Ball bearing 3. Swing circle inner race (90 teeth) a. Outer race soft zone “S” b. Inner race soft zone “S” 2.
SPECIFICATIONS Reduction ratio: 90 = 6 923 13 . Grease volume:
354
IO-13
SWING CIRCLE PC4OOLC
Section
B -
B
Section
1. Swing circle outer race 2. Ball bearing 3. Swing circle inner race (84 teeth) a. Outer race soft zone “S” b. Inner race soft zone “S”
IO-14
A -
A
208FO5009
SPECIFICATIONS Reduction
ratio:
84 = 6 462 13 . Grease volume:
351
SWING MACHINERY PC3OOLC 1.Swing pinion (13 teeth) 2.Cover 3.Case 4.Planetary carrier 5Ring gear (79 teeth) G.Bearing holder 7.Drive gear (17 teeth) 8.Swing motor S.Bearing holder 1O.Cover ll.Driven gear (63 teeth) 12.Planet gear (32 teeth) 13Sun gear (14 teeth) 14.Drain valve 15Breather 16.Level gauge
SPECIFICATIONS Reduction ratio: 63 17
24.618
9
8
16
Section Section
A- A
B -
B 207FO5010
10-15
SWING MACHINERY PC4OOLC
7A
1.Swing pinion (13 teeth) 2.Cover 3.Case 4.Planetary carrier 5.Ring gear (84 teeth) G.Bearing holder 7.Drive gear (17 teeth) 8.Swing motor S.Bearing holder 1O.Cover 11 .Driven gear (86 teeth) 12.Planet gear (34 teeth) 13.Sun gear (15 teeth) 14.Drain valve 15Breather 16.Level gauge
SPECIFICATIONS Reduction ratio: 86 x (84+15 7)
16
= 35.475
18
Section B Section A -
lo-16
A
B 208FO50
TRACK FRAME AND RECOIL SPRING PC3OOLC
207FO5011
1. Idler 2. Track
3. 4. 5. 6. 7. 8. 9.
frame Carrier roller Final drive Track roller Track shoe Center guard Recoil spring Front guard
Depending on the model, the dimensions and number of track rollers and center guards is different, but the basic structure is the same. The above diagram is typical f Number of track rollers PC3OOLC: 8 (each side) * Number of center guards PCBOOLC
3 (each side)
IO-17
TRACK FRAME AND RECOIL SPRING PC400LC
208FO5011
1. 2. 3. 4. 5. 6. 7. 8. 9.
Idler Track frame Carrier roller Final drive Track roller Track shoe Center guard Recoil spring Front guard
IO-18
Depending on the model, the dimensions and number of track rollers and center guards is different, but the basic structure is the same. The above diagram is typical * Number of track rollers PC4OOLC: 8 (each side) *
Number
of center
PC4OOLC
guards
3 (each side)
IDLER PC3OOLC
--'6
_A-1-A
VII
---7 I
Ii -
I 207FO5012
1. Lubricating 2. Support 3. Idler
plug
4. Floating seal 5. Idler shaft 6. Bushing
10-19
IDLER PC4OOLC
---~~--------_______7 -------------------
1
L 208FO5012
1. Lubricating 2. Support 3. Idler
1 O-20
plug
4. Floating seal 5. Idler shaft 6. Bushing
TRACK ROLLER 1
2
3
4
5
1. Lubricating plug Collar Floating seal Track roller Bushing Shaft
2. 3. 4. 5. 6.
_-
II-
-
_I
-
-1
208FO5013
CARRIER
ROLLER .I
I.
2. n a. 4. 5. 6. 7.
I-
Shaft Collar Floating seal Carrier roller Ring Cover Lubricating plug
7
208FO5014
IO-21
TRACK SHOE PC3OOLC
1. Shoe 2. Regular
pin 3. Regular dust seal 4. Regular bushing 5. Master pin 6. Master dust seal 7. Master bushing
1 o-22
8. Link 9. Shoe bolt 10. Shoe nut STANDARD SHOE SPECIFICATIONS l
700mm triple-shoe
l
Link pitch:
l
Number
203mm
of shoes:
100
TRACK SHOE PCIQOOLC
208FO5015
1. 2. 3. 4. 5. 6. 7.
Shoe Master bushing Master dust seal Master pin Regular bushing Regular dust seal Regular pin
8. Link 9. Shoe bolt 10. Shoe nut STANDARD SHOE SPECIFICATIONS l l l
700mm triple-shoe Link pitch: 216mm Number of shoes: 104
1 O-23
SELECTION l
Select
OF TRACK
the most suitable
SHOE track
shoe from the following
table
PC4OOLC
PC3OOLC Specification
Category
Specification
Category
600 mm triple shoe
A
600 mm triple shoe
A
700 mm triple shoe
B
700 mm triple shoe
B
800 mm triple shoe
l
Category Precautions
using
Use
A
Rocky ground, normal river soil
l
Travel in Lo when traveling on rough as large boulders and fallen trees.
B
Normal
l
Cannot be used on rough ground where there are large obstacles such as boulders and fallen trees. Travel in Hi speed only on flat ground and when it is impossible to avoid traveling over obstacles. Lower the travel speed to approx. half of Lo speed.
soil, soft land
l
C
Extremely soft ground (swampy ground)
l
l
l
D
*
when
Category
Paved surface
l
with obstacles
such
Use only for ground where “A” and “B” sink and are impossible to use. Cannot be used on rough ground where there are large obstacles such as boulders and fallen trees. Travel in Hi speed only on flat ground and when it is impossible to avoid traveling over obstacles. Lower the travel speed to approx. half of Lo speed. The shoes are flat, so they have low gradeability.
Categories “B” and “C” are wide shoe, so there are restrictions on their use. Therefore, before using, check the restrictions and consider carefully the conditions of use before recommending a suitable shoe width. If necessary, give the customer guidance in their use.
1 O-24
ground
*
When selecting the shoe width, select the narrowest shoe possible within the range that will give no problem with flotation and ground pressure. If a wider shoe than necessary is used, there will be a large load on the shoe and this may lead to bending of the shoe, cracking of the links, breakage of the pins, loosening of the shoe bolts or other problems.
HYDRAULIC
Foldout 1
PIPING
1. 2. 3. 4. 5. 6. 7.
.12
Bucket cylinder Arm cylinder Boom cylinder Swing motor Accumulator R.H. travel motor Control valve a. Oil cooler 9. Hydraulic filter (PC3OOLC, 1: PC4OOLC, 2) 10. Hydraulic tank 11. Hydraulic pump 12. Line oil filter 13. L.H. travel motor 14. Solenoid valve assembly 15. Arm shuttle valve 16. Swing shuttle valve 17. Boom, bucket shuttle valve la. Arm half flow solenoid valve 19. Safety lock valve 20. Travel shuttle valve 21. L.H. PPC valve 22. Travel PPC valve 23. R.H. PPC valve 24. Center swivel joint i 25. Boom holding valve
i6
207FO5015
1 o-25
: I’
1 O-26
HYDRAULIC
CIRCUIT
Foldout 2
DIAGRAM
i
Arm Cylinder
I
i/ I
] (pcmo~c $160 x $110
(PC~OOLC $185 x 4120 -
I J
1685) 1820)
’
I’ I' I’ I’ I’ I’ I’ I’ I’ 1; II II I I I I I I I
I
’ ’
R.H. travel motor PC3OOLC: HMV280ADT PC4OOLC: HMV355ADT
175/26Occ/rev 1911355cclrev
I I 1
Iili ‘Ill ‘I I, ‘III )lII ,111
Regulator switching 8 kg/cm’
pressure:
Work equipment . swing oil pressure switch
(II fil!
Cracking pressure: 4.3 kg/cm2
KMF160AB2
160.7 cc/rev (R.H. swingl-TL] 1
<
\ <
I
j-_--__---__---___--_---_
----__---------
1 O-27
1 O-28
HYDRAULIC TANK PC3OOLC
Section
Section
A -
B -
B
A
2OJFO5017
1. Bypass valve 2. Bypass filter 3. Filter element 4. Check valve 5. Breather 6. Cap 7. Hydraulic tank 8. Hydraulic oil level sensor 9. Suction strainer 10. Sight gauge 11. Filter case
SPECIFICATIONS Tank capacity: 3150 Oil amount: 1954 Breather Relief set pressure: 0.420.07 kg/cm2 Suction set pressure:0.04*0.01 kg/cm2 Bypass valve set pressure: 1.05 20.2 kg/cm2 Check valve pressure: 1.75 kg/cm2
1 o-29
HYDRAULIC TANK PC4OOLC
Section
Section
A -
B -
B
A
9
-10
208FO5016
1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11.
Bypass valve Bypass filter Filter element Check valve Breather Cap Hydraulic oil level sensor Suction strainer Hydraulic tank Sight gauge Filter case
10-30
SPECIFICATIONS Tank capacity: 3586 Oil amount: 2558 Breather Relief set pressure: 0.420.07 kg/cm2 Suction set pressure:0.04t0.01 kg/cm2 Bypass valve set pressure: 1.0520.2 kg/cm2 Check valve pressure: 2.50 kg/cm2
OLSS (Open Center Load Sensing System) Motor Cylinder
I 0
F205C5006-1
OLSS (Open Center Load Sensing System) is an energy-saved system to reduce the fuel consumption by means of the swash plate angle (delivery) of the variable-displacement swashplate type piston pump. Therefore this system acts to reduce the hydraulic loss during operation, to increase the fine control and to control the pump delivery.
1 o-31
1.
EFFECTIVE HORSEPOWER
USE
OF
ENGINE
IN H mode, the set speed of the engine and the actual speed of the engine are always detected. As a result, even if the load changes during operation, the discharge amount (swash plate angle) of the pump is controlled so that the load on the engine (engine speed) is always maintained constant, thus ensuring effective use of engine horsepower. (Engine speed, oil pressure sensing control)
Main pump delivery
Pump delivery
volume
Q
205F05121A
(Note)
2. 0
l
CUT-OFF CONTROL The cut-off control is a function to reduce relief loss during operations. If the load increases, the discharge pressure of the main pump is increased; if the load comes close to the relief pressure, the discharge volume is decreased. This function is carried out with the CO valve. For details of the operation of the CO valve, see HYDRAULIC PUMP.
H.0: G.0: F.0: L.0:
Heavy duty operation mode, General operation mode. Finishing operation mode, Lifting operation mode
Loss when there is no cut-off
-(\I cut-off
1
Pump discharge
volume
(Q/min.)
F205C5008
3. l
l
l
l
FLOW CONTROL PNC (pump neutral control) When the control levers are at neutral, the pump discharge volume is kept to the minimum to reduce the wasteful flow of oil when the control valve is at neutral. PFC (pump fine control) When the lever is operated, the neccesary flow is ordered to the pump based on the flow command that corresponds with the lever travel. This reduces the wasteful flow of oil that occurs during fine control. At the same time, by increasing the pump discharge pressure to the optimum value according to the lever travel, the fine control performance is improve. This function is carried out with the NC valve and jet sensor. For details of the operation of the NC valve and jet sensor, see HYDRAULIC PUMP.
1 O-32
Lever travel
(mm) 205FO5
145
HYDRAULIC
PUMP
View Z
d
a. b. c. d. e. f.
Jet CO Jet Jet CO Jet
sensor cancel sensor sensor cancel sensor
output pressure pressure PSO IN output pressure output pressure pressure PSO IN output pressure
Pd IN port Pt IN Pd IN port Pt IN
port
1. TVC valve CO*NC valve 3. Front servo valve 4. Rear CO*NC valve 5. Rear servo valve 6. Rear main pump 7. Charging pump 8. Front main pump 9. Charging pump relief valve
2. Front
port port port
1 o-33
1. FRONT
MAIN PUMP AND REAR MAIN PUMP (HPV 160+160)
d
C
b
View Z
I
\
Suction PS port Front main pump drain Pdl port Charging pump pressure . - PC IN port Rear main pump dram Pd2 port Front main pump discharge Ppl port Rear main pump discharge Pp2 port Servo valve output pressure PclA port Rear main pump output pressure Pp2 port
1 o-34
n
I
View Y
View X
a. b. c.. d. e. f. g. h.
m I
/”
207FO5019
i. Front main pump output pressure Charging pump pressure PCI port Servo valve output pressure PclB Servo valve output pressure Pc2B Charging pump pressure Pc2 port Rear main pump output pressure pressure Pc2A 0. Servo valve output
jk. I. m. n.
Ppl port port port Pp2 port port
Section
Section
B -
C -
C
B 207FO5020
1. 2. 3. 4. 5. 6. 7. 8.
Drive gear (61 teeth) Driven gear (42 teeth) Shaft Coupling Front drive shaft Front cradle Front pump case Front rocker cam
9. 10. 11. 12. 13. 14. 15. 16.
Front piston Front cylinder Front valve plate Front end cap Impeller pump Coupling Rear end cap Rear valve plate
17. 18. 19. 20. 21. 22. 23.
Rear Rear Rear Rear Rear Rear Servo
cylinder piston rocker cam pump case cradle drive shaft piston
1 o-35
2. SERVO VALVE f
Section
Section
Section
a. b. c. d. e. f. g.
D- D
The drawing
Section C -
E- E
Servo actuator port Servo actuator port Servo actuator port NC valve output pressure Pi pick-up port Servo valve drain Pdr OUT port Rear main pump output pressure Pp2 IN port Front main pump output pressure Ppl IN port
1 O-36
the servo valve for front
main pump
A- A
B- B
Section
shows
Section
F- F h. i. j. k.
C
Section G -
G
205FO5020
CO@NC valve drain Pdr IN port CO@NC valve output pressure Pin IN port Charging pump pressure Ppo OUT port Rear main pump output pressure Pp2 OUT Port I. Front main pump output pressure Ppi OUT port
/iI/
19
18
17
\‘:I\
16
15
Section A -
14
13
12
A 205FO5021
1.
2. 3. 4. 5. 6. 7.
Lock nut Cover Plug Spring Body Spring Arm
8. Pin 9. Control piston 10. Lock nut 11. Plug 12. Lock nut 13. Cover 14. Sleeve
FUNCTION Discharge volumes Ql and Q2 of main pumps PPI and PP~ are controlled individually by their own servo valve. The relationship between pump discharge volume Q and input signal Pi sent to the servo valve is as shown in the graph on the right. Q changes in proportion to Pi.
15. 16. 17. 18. 19.
Guide spool Spring Plug Cover Lock nut
u E
% z I? / kc/rev)
/
/ CO-NC
valve
output
pressure
PI
(kg/cm’) OZCHOOOI
IO-37
OPERATION 1)
Operation for increasing pump discharges (rocker cam angle changes to the large)
I
I
’ I nn
;
PC
205F05023A
l
l
Charging pump pressure PC is sent to port a. Signal pressure Pi from the NC valve is sent from port b to chamber c. As signal pressure Pi rises, the pressure in chamber C pushes control piston (9) to the left, in the direction of the arrow. The piston stops in a position where it is balanced with the force of springs (4) and (6). At the same time, arm (7) uses servo piston (20) as a fulcrum and moves to the left in the same way as control piston (9) while fluctuating moves guide spool (15) to the left.
1 O-38
l
l
The movement of guide spool (15) closes port a and port d and connects port d with drain chamber e. As a result, servo piston chamber f is also connected to chamber e through port g and port d. At the same time, port a and port h are connected and the flow passes through port i to servo piston chamber j to push servo piston (20) to the left in the direction of the arrow. The rocker cam angle of the main piston pump becomes larger and the pump discharge volume increases. Because of the movement of servo piston (20), arm (7) rotates clockwise around pin (8), moves guide spool (15) to the right and closes port a, port d and port h so the discharge volume increases only by an amount corresponding to signal pressure Pi.
2)
Operation
for decreasing
pump discharges
(rocker
cam angle
changes
‘jig .::::::: ..\.. II
c
to the small)
Pi
j:;.j:j :.:.:.:. :::::: II::::::: I NC valve
205F05024A
l
0
When signal pressure Pi drops, control piston (9) moves to the right in the direction of the arrow to a point where the hydraulic pressure of chamber c is in balance with the force of springs (4) and (6). At the same time, arm (7) uses servo piston (20) as a fulcrum, moves to the right in the same way as control piston (9) and while fluctuating, moves guide spool (15) to the right. The movement of guide spool (15) closes port a and port h and connects port h with drain chamber e. As a result, servo piston chamber j is also connected to chamber e through port i and port h.
0
At the same time, port a and port d are connected and the flow passes through port g to servo piston chamber f to push servo piston (20) to the right in the direction of the arrow. The rocker cam angle of the main piston pump becomes smaller and the pump discharge volume decreases. Because of the movement of servo piston (20), arm (7) rotates counterclockwise around pin (8), moves guide spool (15) to the left and closes port a, port d, and port h so the discharge volume decreases only by an amount corresponding to signal pressure Pi.
1 o-39
3. TVC VALVE
a
b
e
C4
C
d
q4
34567
Section
8
A -
Section
A
B -
B
D4 Section
a. b. c. d. e.
C -
C
Section
Charging pump pressure Ppo IN port Front main DurnD outwt wessure PPI IN Dart Rear main dumb outbut bressure Pi2 IN port TVC valve drain Pdr OUT port TVC valve output pressure Pe OUT port
1 O-40
D -
D
Section
E -
1. Spring 2. Spool 3. Piston 4. Piston 5. Sleeve 6. Piston 7. Body 8. Solenoid
E
Section
F -
F
205FO5025
FUNCTION 1)
AND OPERATION
When command
current
from pump controller
is small
(when pump controller TVC
is normal)
valve
co valve
Servo valve
Servo piston Dec!erease Discharge
PPI
Resistor
FUNCTION l When the pump controller is normal, the main pump discharge volume can be controlled as desired over a wide range according to the command current from the pump controller to carry out the power mode function. l When the pump controller is abnormal, hydraulic sensing is carried out to control the main pump discharge volume according to the load (pump discharge pressure) to carry out the constant torque control function (prolix function). l For details, see PEMC SYSTEM.
205F05026A
OPERATION l
Because of the command current sent from the controller, solenoid push pin (9) moves and piston (2) also moves. It stops at a point where the sum of the force of spring (1) and the force of push pin (9) and the force of TVC output pressure Pt2 acting on piston (3) is in balance. When this happens, the command current is small, so piston (2) balances at the bottom. As a result, port a and port b are almost completely open and almost all the pres-
surized oil from the charging pump is output as TVC output pressure Pts. Because of this, the pump discharge
volume
is maximum.
10-41
2)
When command
current
from pump controller
is large (when
pump controller
is normal)
TVC valve
....,........ .A......
.:.:.:.:.:.:
:.:.:.:.::::::::::,::::::::::::::::::::::::
pi
.. . . . . . .. . . . . . . . . . . . . . . . . . . . . . .
:::::, :.:.:. .:.:. .:.:::: .... :::::: :::.:.
NC va,ve
l--l c0
j:j:j:j:j:
valve
Servo valve
Deer
ett!zLe Discharge
I
Because of the command current sent from the controller, solenoid push pin (9) moves and the piston (2) also moves. It stops at the point where it is balanced with the force of spring (1). When this happens, the command current is large, so piston (2) is balanced at the top. As a result, the flow of oil sent from the charging pump is throttled at port a and port b and the area of the opening at port b and port c (drain port) becomes larger. Because of this, TVC valve output pressure Pt2 drops and the pump discharge volume is reduced.
1 O-42
Resistor
205F05027A
3)
Main pump under
light load (pump
controller
abnormal
and TVC prolix switch
ON)
TVC valve
r Pi
! NC
valve
Servo valve
l-----i Servo piston
Discharge
Resistor 0
205F05028A
Main pump discharge pressures PPI and PP~ are low, so spool (2) is pushed down by spring (1). As a result, charging pump discharge pressure PC and TVC valve output pressure Pt2 are equal. When this happens, TVC valve output pressure Pt2 is maximum and the main pump discharge volume is also maximum.
1 o-43
4)
Main pump under
heavy load (pump
controller
abnormal
and TVC prolix switch
ON)
TVC valve
Pi .,., ,,,,,,NC :.:,: y:::::::::::::::::::::: :.:.:, I‘::::::::‘::::::::::i:::::;::::::::: .:.:. valve :::::
:.:.: ::::: jj{jj ;g j::: :;:i: ::::: :.:.: .:.:. :j:: :.:.: ~‘j&
lco
valve
1
Discharge
C
Pump controller
It-41 @,
When main pump discharge pressure PPI (or PP~) increases, spool (2) is moved up by piston (4) or piston (6). As a result, the flow at port a and port b is throttled by the notch in the spool, and the area of the opening at port b and port c (drain port) becomes larger. Because of this, TVC valve output pressure Pt2 drops and the main pump discharge volume is reduced.
1 o-44
-
I
ON
1 TVC prolix switch Resistor
l
OFF1
205F05029A
4. CO
l
NC Valve *The
diagram
shows
the CO*NC
valve for the front
pump.
a d
9 i
b
e
h
Section A -
a. Charging pump pressure PRO OUT port b. Main pump output pressure Ppi (Pp2) OUT port c. Main pump output pressure Pp2 (Ppi) OUT port d. TVC valve output pressure Pt2 IN port e. TVC valve drain Pdr port f. CO cancel pressure Per (PC,) IN port g. TVC valve output pressure Pt2 F-R connection port h. Jet sensor output pressure Pd IN port i. Jet sensor output pressure Pt IN port
co 1. 2. 3. 4. 5. 6.
*c
A
205FO5030
NC VALVE
VALVE Plug Piston Spring Spool Piston Plug
)
7. 8. 9. 10. 11.
Plug Sleeve Piston Spool Spring 12. Plug
For servo valve
1o-45
FUNCTION 1)
When
AND OPERATION
OF CO VALVE
main pump discharge
pressure
is below relief pressure
NC
valve PC0
Discharge
rlx__l
>c/-
FUNCTION If the load increases during operation and the main pump discharge pressure increases when it becomes nearly the relief pressure, the CO valve carries out the cut-off function to reduce the discharge amount of the pump and reduce the relief loss. At the same time, the pilot pressure of the CO function cancel solenoid valve also has the function of canceling the cut-off. The CO valve is controlled by balancing the spring with the sum of main pump discharge pressure Pp and CO valve output pressure Pi.
1 O-46
205F05031A
OPERATION l Spool (4) is pushed down by spring (3). As a result, port a and port b are completely open and TVC valve output pressure Pi are equal. Because of this, CO valve output pressure Pi becomes maximum and the discharge volume of the main pump is also maximum.
2)
When the main pump discharge
pressure
is higher
than the main relief pressure
Servo valve
l-----i
PP
Servo piston
uecrease
l+l Increase Discharge
205F05032A
l
When main pump discharge pressure PP comes close to the relief pressure owing to an increase in the load, piston (5) is pushed by main pump discharge pressure PP and at the same time piston (5) is pushed by CO valve output pressure PCO. When the force of spring (3) is overcome by the pressing force of the pistons, spool (4) moves upward. As a result, the spool land restricts the oil flow from port a to port b and at the same time the opening areas of port b and port c (drain port) are made larger. With angle reduced by the operation of the servo valve, the main pump discharge is reduced.
1 o-47
3)
When cut-off
function
is canceled
by CO cancel
solenoid
valve
10 cancel ;olenoid
I
Decrease
valve
I
L+ Disch,arge
Increase
I
-
/-
l
When the CO cancel solenoid valve is switched, pilot pressure is taken to port PSO and piston (2) is pushed down. As a result, the setting of spring (3) becomes larger, so even when main pump discharge PP rises and reaches the relief pressure, spool (4) is not actuated and CO valve output pressure Pco remains at the maximum.
1 O-48
205F05033A
FUNCTION 1) Control
AND OPERATION valve at neutral
OF NC VALVE
nsor
Control
valve
205FO5034A
FUNCTION l The NC valve controls the main pump discharge volume according to the amount of operation of the control valve spool, and carries out the function of controlling the oil flow to reduce the neutral loss and fine control loss. l The NC valve is controlled by balancing the sum of jet sensor output pressure Pt and NC valve output pressure Pi with the sum of the force of NC valve spring (12) and jet sensor output pressure Pd. l The jet sensor detects the flow of return oil passing through the control valve and returning to the tank, and takes it as NC valve Pt and Pd.
OPERATION l The differential pressure (Pt - Pd) of the jet sensor reaches the maximum and jet sensor output pressure Pt acting on piston (10) becomes greater than the sum of the force of spring (12) and jet sensor output pressure Pd acting on the lower end of spool (11). As a result, spool (11) is pushed downward causing a restriction of the oil flow between port c and port b and in turn opening port b and port a (drain port). Output pressure Pt of the NC valve is then reduced to the minimum and the main pump discharge is also reduced to the minimum with the swash plate angle minimized through the operation of the servo valve.
1o-49
2)
When the control
valve
is operated
205F05035A
l
With the jet sensor differential pressure (Pt Pd) reduced according to the operation of the control valve spool (11) is pushed upward, fully opening port c and port b. Thus, the NC valve output pressure increases. Together with the increase in the main pump swash plate angle through the servo valve operation, the main pump discharge is also increased. That is to say, the pump discharge increases as the stroke of the lever increases.
10-50
5. CHARGING
PUMP
Suction 0
lDischarge 0
‘7
Section A -
1. Filter 2. Relief valve 3. Collar 4. Body 5. Housing 6. Drive gear 7. Driven gear
A
207FO5021
SPECIFICATIONS Theoretical delivery:
32.3 cc/rev
Operating
30 kg/cm2
pressure:
1 o-51
LINE OIL FILTER
From pump -
_F
To control valve
207FO5022
1. Bracket Cartridge 3. Element 4. Drain plug 2.
1 o-52
1 o-53
CONTROL
VALVE
Y
X
ee
nm.
dd
cc
bb
aa
mn
kk
207FQ5023
1 o-54
1. Travel shuttle valve 2. Four-spool valve (Built-in arm throttle valve) 3. Five-spool valve (Built-in
straight-travel
valve,
swing priority
valve)
P3 port (From arm PPC valve) :: PL port (From rear main pump) PR port (From front main pump) dc: B3L port (To bucket cylinder bottom side) e. B2L port (To boom cylinder head side) f. BlL port (To L.H. travel motor PB port) P5 port (From swing PPC shuttle valve) PPC shuttle R: P4 port (From boom bucket valve) oil pressure i. P6 port (To work equipment switch) AlL port (To L.H. travel motor PA port) d: A2L port (To boom cylinder bottom side) I. A3L port (To bucket cylinder head side) m. P4AL port (From arm PPC valve) n. PBAL port (From bucket PPC valve) 0. PSAL port (From boom PPC valve) PlAL port (From L.H. travel PPC valve) ;: PRL port (From 2-stage relief solenoid valve) r. PRR port (From 2-stage relief solenoid valve) port (From 2-stage relief solenoid S. PlAR valve) t. P3AR port (Service) U. P4AR port (From arm PPC valve) V. P5AR port (From R.H. travel PPC valve) w. A3R port (Service) port (To swing motor MA port) X. AlR Y. BlR port (To swing motor port MB) 2. B3R port (Service)
OUTLINE l This control valve consists of a four-spool valve and a five-spool valve. In addition, it also has a travel shuttle valve. It has a built-in straight-travel valve, arm throttle valve and swing priority valve. l The four-spool valve and the five-spool valve are connected by bolts to form one unit. The oil flow merges inside the valve, so the valve is compact and provides excellent ease of maintenance.
aa. B4R port (To arm cylinder bottom side) bb. B5R port (To R.H. travel motor PA port) cc. T port (To tank) dd. A5R port (To R.H. travel motor PB port) ee. A4R port (To arm cylinder head side) ff. PtL port (To rear NC valve) gg. PdL port (To rear NC valve) hh. PtR port (To front NC valve) ii. PdR port (To front NC valve) jj. PlBL port (From L.H. travel PPC valve) kk. PSBL port (From boom PPC valve) II. P3BL port (From bucket PPC valve) mmTs port (To tank) nn. PSBR port (From R.H. travel PPC valve) 00. P4BR port (From arm PPC valve) pp. PBBR port (Service) qq. PiBR port (From swing PPC valve)
1 o-55
Section
Section
1. 2. 3. 4. 5.
Spool Spool Spool Spool Spool
1 O-56
return spring (L.H. travel) (Boom-Lo) (Bucket) (Arm-Hi)
A -
B -
A
B
207FO5024
6. 7. 8. 9.
Jet sensor orifice Jet sensor relief valve Main relief valve Spool (Straight-travel) valve) 10. Spool (Arm throttle
Section C -
C
10’
Section D -
D 207FO5025
1. 2. 3. 4. 5.
Spool Spool Spool Spool Spool
return spring (Swing) (Boom-Hi) (Service) (Arm-Lo)
6. 7. 8. 9. 10.
Spool (R.H. travel) Jet sensor relief valve Jet sensor orifice Main relief valve (five-spool) Spool (Swing priority)
1 o-57
/’ '2
Section
E -
E Section
3
4
Section
5
G -
6
7
6
F
9
Section
G
F -
H -
10
H 207FO5026
1. 2. 3. 4. 5. 6.
Check Check Spool Spool Spool Spool
IO-58
valve valve spring (L.H. travel) (Straight-travel) (Swing priority) (Swing)
7. 8. 9. 10. 11.
Suction valve Spool (Boom-Lo) Check valve Spool (Boom-Hi) Safety-suction valve.
Section
J -
Section
1. 2. 3. 4. 5.
Safety-suction valve Spool (Bucket) Spool (Arm throttle) Spool (Service) Spool (Arm-Hi)
J
L -
L
2OJFO5027
6. Check valve 7. Spool (Arm-Lo) 8. Safety-suction valve 9. Check valve 10. Spool (R.H. travel)
1 o-59
TRAVEL
SHUTTLE
VALVE a
/
d
b
’
C
I
Section A -
A
Section C -
Section B -
a. Ps port (Work equipment* swing switch) b. P4 port (From boom l bucket shuttle valve) c. Ps port (From swing shuttle valve) d. P3 port (From arm shuttle valve)
1 O-60
j
C
Section D -
B
D
207FO5028 e.
f. g. h. i.
P4a port (To arm throttle valve) P6a port (To swing priority valve) PT port (To tank) PO port (To straight-travel valve) PI port (From L.H. travel control valve)
j. P2 port (From control valve) 1. Cover 2. Spool return 3. Body 4. Spool
L.H. travel
spring
FUNCTIONS l The travel shuttle valve is installed to the top of the four-spool valve control valve. It takes the PPC valve pressures from the left travel, work equipment, and swing and sends pilot pressure to the straight-travel valve when the travel and work equipment or swing are operated at the same time. OPERATION Travel lever at “FORWARD” (other levers at “NEUTRAL”) l Pilot pressure oil flows to Pl port from the left travel circuit and pushes the spool to the right. Therefore, ports P3, P4, P5 and PO are connected through the groove in the spool and are also connected to the straight-travel valve. However, there is no flow of pilot pressure oil from the shuttle valves of the PPC valves, so the straight-travel valve is not actuated. (When operating in “REVERSE”, pressure oil is sent to port P2 and pushes the spool to the left.)
To arm E+ throttle valve
From shu&le valve of arm PPC valve
From shut& valve of boom bucket PPC valve
pressure switch From shuttle valve of swing PPC valve 205F2032-2
During simultaneous operation When the arm and travel FORWARD are operated at the same time, pilot pressure oil flows from the left travel circuit to port Pl and pushes the spool to the right. At the same time, when the arm is operated, pilot pressure oil flows to port P3 from the shuttle valve of the arm PPC valve. This passes through the groove in the spool and port PO and then flows to the straight-travel valve. The pilot pressure oil from the shuttle valve of the swing PPC valve flows port P5 -+ port PO - straight-travel valve and the pilot pressure oil from the shuttle valve of the boom and bucket PPC valves flows port P4 - port PO - straight-travel valve.
e
arm PPC valve
valve of boom, bucket PPC valve
throttle valve
From shuttle valve of swing PPC valve 205F2033-2
lo-61
STRAIGHT-TRAVEL
VALVE
FUNCTION l While operating the swing, boom, arm or bucket when traveling, the pressure oil flowing to the R.H. and L.H. travel circuit branches into the swing, boom, arm, or bucket circuit. Since the supply of pressure oil in a branched travel circuit is less than that in the circuit before the branch, the motor naturally slows down, resulting in a turn. l
When the straight-travel valve is switched over to establish continuity between the R.H. and L.H. travel circuits, this undesired turning is prevented by equalizing the supply of pressure oil to the R.H. and L.H. travel motors so that they rotate at the same speed.
OPERATION When traveling only l Since no pilot hydraulic oil flows from the shuttle valve in the PPC valve, no hydraulic oil flows from the travel shuttle valve to the straight-travel valve. l Therefore, the circuit between port PR (R.H. travel circuit) and port PL (L.H. travel circuit) remains closed and both circuits remain independent.
205FO5042
While operating the swing, boom, arm or bucket when traveling l Spool (1) of the straight-travel valve is pushed to the right by the pilot pressure from the travel shuttle valve. l Port PR and port PL then become connected to each other and an equal amount of pressure oil is supplied to the R.H. and L.H. travel motors, allowing both motors to rotate at the same speed. The machine travels thus in a straight line.
205FO5043
1 O-62
SWING
PRIORITY
VALVE
FUNCTION l When operating the swing and arm at the same time, most of the oil flows to the arm, which has less load. The flow of oil to the swing circuit is reduced so the arm speed is faster than the swing speed. This makes combined operations difficult. l To prevent this, the swing priority valve is switched to restrict the flow of pressure oil to the arm-Lo control valve. This restricts the arm speed and makes it easier to operate the arm and swing at the same time. OPERATION When swing is at neutral l No pilot pressure oil flows from the travel shuttle valve, so the swing priority valve is not switched. Because of this, the pressure oil from the front main pump passes through port PR and all the oil flows to the arm-Lo control valve.
205FO5044
When swing is operated l
When the swing is operated, spool (1) of the swing priority valve is pushed to the left by the pilot pressure from the travel shuttle valve. Because of this, the pressurized oil flowing from front main pump - port PR to the arm-Lo control valve is throttled and the arm speed is controlled, so the simultaneous operation performance is improved.
205FO5045
1 O-63
ARM THROTTLE
VALVE l
FUNCTION l
When the arm control lever and boom control lever are operated at the same time, most of the pressure oil flows to the arm circuit, where the load is less. The amount of oil flowing to the boom circuit drops, so the arm speed is faster than boom speed. This makes combined operations difficult. (Particularly when using “ARM OUT” and “BOOM RAISE” at the same time.) When this happens, the arm throttle valve is switched and the flow of oil to the arm-Hi control valve is restricted. This regulates the arm speed and makes combined operations easier.
The arm is actuated by the merged oil flow from two pumps, and the bucket is actuated by the flow from one pump. For this reason, when the arm and bucket are operated together, the flow of oil to the arm circuit is greater, so the arm moves much faster than the bucket. This makes combined operations difficult. (Particularly when using “ARM OUT” and “BUCKET CURL” at the same time.) When this happens, the arm throttle valve is switched and the flow of oil to the arm-Hi control valve is restricted. This regulates the arm speed and makes combined operations easier. Arm-Hi
OPERATION When arm is operated independently 0 The pilot pressure does not flow from the travel shuttle valve, is not actuated and rear pump passes flows to the arm Hi
so the arm throttle valve the pressure oil from the through port PL and all control valve.
205FO5046
1
Simultaneous l
Arm-Hi
/
operation
When the arm is operated together with the boom or bucket, the pilot pressure from the travel shuttle valve pushes spool (1) of the arm throttle valve to the left. When this happens, the flow of pressure oil from the rear pump to the arm-Hi control valve is throttled, and the arm speed is controlled to improve the ease of simultaneous operation.
205FO5047
1 O-64
1 O-65
SWING MOTOR
View 2
e 207FO5029
a. b. c. d. e.
T2 port (To tank) S port MA port (From control valve) MB port (From control valve) C port (From swing brake solenoid
valve)
SPECIFICATIONS Type: KMF160AB-2 Theoretical delivery: 160.7 cc/rev Safety valve set pressure: PC3OOLC: 275+: kg/cm* at 244 P/min PC4OOLC: 260+‘:
kg/cm*
at 300 P/min
Rated speed: PC3OOLC: 1,560 rpm PC4OOLC: 1,925 rpm Brake release pressure: 16.5+2
1 O-66
kg/cm*
I-LU
LL_JJ
Section
A -
A
Section
Section
C -
B -
B
C 207FO5030
1. Safety valve End cover 3. Brake spring 4. Brake piston 5. Plate 6. Disc 7. Housing 8. Cover 9. Drive shaft 2.
10. 11. 12. 13. 14. 15. 16. 17.
Cylinder Center spring Piston Plug Valve plate Center shaft Check valve spring Check valve
1 O-67
SWING
HOLDING
BRAKE
OPERATION 1) When swing brake solenoid valve is deactivated When the swing brake solenoid valve is deactivated, the pressurized oil from the charging pump is shut-off and port B is connected to the tank circuit. Because of this, brake piston (4) is pushed down in the direction of the arrow by brake spring (3), so disc (6) and plate (5) are pushed together and the brake is applied.
205F05050K
2)
When swing brake solenoid valve is excited When the swing brake solenoid valve is excited, the valve is switched and the pressurized oil from the charging pump enters port B and flows to brake chamber a. The pressurized oil entering chamber a overcomes the force of brake spring (3), and brake piston (4) is pushed up in the direction of the arrow. Because of this, disc (6) and plate (5) separate, and the brake is released.
pump
7
U
1 O-68
205FO5051
K
CENTER SWIVEL JOINT
.A1
Cl
.F2
Section A -
A
TI
T2
View Z
r-77 62
DP
A2
CZ 207FO5031
1. 2. 3. 4. 5. 6.
Cover Plate Body Slipper seal Oil seal Shaft
Al :
From control
valve AIR port
Dl:
From control
valve AIL port
A2: Bl: 82: Cl:
To R.H. travel motor PB port From control valve PIL port
D2: Fl:
To L.H. travel motor PA port From travel speed solenoid valve
To R.H. travel motor PB port From control valve BAR port
F2: Tl:
c2:
To R.H. travel
T2:
To L.H. and R.H. travel motor P port To tank From L.H. and R.H. travel motor T port
motor
PA port
1O-69
TRAVEL MOTOR PC300LC
\e
I
_
207FO5032
a. b. c. d. e.
T2 port
(To tank) PB port (From control valve) P port (From travel speed solenoid PA port (From control valve) TI port (To tank)
valve)
SPECIFICATIONS Type: Theoretical delivery: Rated pressure: Rated speed: Brake releasing Hi-Lo switching
IO-70
pressure: pressure:
HMV280ADT Min. 175.1 cc/rev Max. 280.0 cc/rev 325 kg/cm2 Min. 1,430 rpm Max. 895 rpm 1353 kg/cm2 87;’ kg/cm2
Section
C -
C
\
26
Section
Section
1. 2. 3. 4. 5. 6. 7. 8. 9.
Output shaft Motor case Regulator piston Cradle Rocker cam Piston Cylinder Valve plate End cover
B -
6
D -
D
207FQ.5033
10. 11. 12. 13. 14. 15. 16. 17. 18.
Check valve Check valve spring Regulator valve Spring Air bleeder Brake spring Brake piston Plate Disc
19. 20. 21. 22. 23. 24. 25. 26. 27.
Regulator piston Spring Check valve spring Check valve Counterbalance valve Spool return spring Piston Safety valve Check valve
IO-71
TRAVEL MOTOR PC4OOLC
View 2 208FO5017
a. b. c. d. e.
port (To tank) PB port (From control valve) P port (From travel speed solenoid PA port (From control valve) TI port (To tank) T2
valve)
SPECIFICATIONS Type: Theoretical delivery: Rated pressure: Rated speed: Brake releasing Hi-Lo switching
1 O-72
pressure: pressure:
HMV355ADT Min. 191.3 cc/rev Max. 355.4 cc/rev 355 kg/cm2 Min. 1,620 rpm Max. 870 rpm 13 + 3 kg/cm* 8:: kg/cm2
1
2
3
4
5
6
7
8
9
Section c - c
/I
20
19
rYI
18
17
16
\\
15
26
14
Section A - A
27
Section D - D
Section B - B
1. 2. 3. 4. 5. 6. 7.
Output shaft Motor case Regulator piston Cradle Rocker cam Piston Cylinder a. Valve plate 9. End cover
208FO5010
10. Check valve 11. Check valve spring 12. Regulator valve 13. Spring 14. Air bleeder 15. Brake spring 16. Brake piston 17. la.
Plate
Disc
19. Regulator piston Spring Check valve spring Check valve Counterbalance valve Spool return spring Piston Safety valve Check valve
20. 21. 22. 23. 24. 25. 26. 27.
1 o-73
MOTOR OPERATION 1) At Lo speed
(motor
rocker
cam angle
at maximum)
205F05059K l
l
The solenoid valve is deactivated, so the pilot pressure oil from the charging pump does not flow to port P. For this reason, regulator valve (12) is pushed to the right in the direction of the arrow by spring (13). Because of this, it pushes check valve (27) and the main pressure oil from the control valve to end cover (9) passes through passage a in regulator valve (12), enters regulator piston (3a) at the top, and pushes regulator piston (3a) to the right in the direction of the arrow.
1 o-74
0
l
At the same time, the pressurized oil at regulator piston (3b) at the bottom passes through orifice b in regulator valve (9) and is drained to the motor case. As a result, rocker cam (5) moves in the maximum rocker cam angle direction, the motor capacity becomes maximum and the system is set to Lo speed.
2)
At Hi speed
(motor
rocker
cam angle
at minimum)
Traveling speed solenoid v
205F05060K
The solenoid valve is excited, so the pilot pressure oil from the charging pump flows to port P, and pushes regulator valve (12) to the left in the direction of the arrow. Because of this, the main pressure oil from the control valve passes through passage c in regulator valve (12), enters regulator piston (3b) at the bottom, and pushes regulator piston (3b) to the right in the direction of the arrow.
l
l
At the same time, the pressurized oil at regulator piston (3a) at the top passes through orifice d in regulator valve (12) and is drained to the motor case. As a result, rocker cam (5) moves in the minimum rocker cam angle direction, the motor capacity becomes minimum and the system is set to Hi speed.
1 o-75
PARKING
BRAKE
OPERATION 1) l
When starting to travel When the travel lever is operated, the pressurized oil from the pump actuates counterbalance valve spool (23), the circuit to the parking brake is opened and the oil flows into chamber a of brake piston (16), overcomes the force of spring (15), and pushes piston (16) to the right in the direction of the arrow. When this happens, the force pushing plate (17) and disc (18) together is lost, so plate (17) and disc (18) separate and the brake is released.
205FO5061
2) l
When stopping travel When the travel lever is placed in neutral, counterbalance valve spool (23) returns to the neutral position and the circuit to the parking brake is closed. The pressurized oil in chamber a of brake piston (16) is drained to the case from the orifice in the brake piston and brake piston (16) is pushed to the left in the direction of the arrow by spring
18 17
(15). As a result, plate (17) and disc (18) are pushed together and the brake is applied.
Travel control
valve
205F05062K
1 O-76
K
BRAKE
VALVE Control valve
l
l
The brake valve consists of a check valve, counterbalance valve and safety valve in a circuit as shown in the diagram on the right (Fig. 1). The function and operation of each component is as given below.
(Fig. 1) 1. COUNTERBALANCE FUNCTION
VALVE,
CHECK
VALVE
When traveling down a slope, the weight of the machine makes it try to travel faster than the speed of the motor. As a result, if the machine travels with the engine at low speed, the motor will rotate without load and will run away, which is extremely dangerous. To prevent this, these valves act to make the machine travel according to the engine speed (pump discharge volume). OPERATION WHEN PRESSURE IS SUPPLIED l When the travel lever is operated, the pressurized oil from the control valve is supplied to port PA. It pushes open check valve (22a) and flows from motor inlet port MA to motor outlet port MB. However, the motor outlet port is closed by check valve (22b) and spool (23), so the pressure at the supply side rises (Fig. 2). l The pressurized oil at the supply side slows from orifice El in spool (23) to chamber Sl, and when the pressure in chamber Sl goes above the spool switching pressure, spool (23) is pushed to the right in the direction of the arrow. As a result, port MB and port PB are connected, the outlet port side of the motor is opened and the motor starts to rotate (Fig. 3).
I
205FO5063
I
Control valve
l
EI
S,-
(gi
205F05064A
Control valve
EI
S,-
(Fig. 3)
205FO5065
1 o-77
OPERATION OF BRAKE WHEN TRAVELING DOWNHILL l If the machine tries to run away when traveling downhill, the motor will turn under no load, so the pressure at the motor inlet port will drop and the pressure in chamber Sl through orifice El will also drop. When the pressure in chamber Sl drops below the spool switching pressure, spool (23) is returned to the left in the direction of the arrow by spring (24) and outlet port MB is throttled. As a result, the pressure at the outlet port side rises, resistance is generated to the rotation of the motor and this prevents running away. In other words, the spool is moved to a position where the pressure at outlet port MB balances the pressure at the inlet port and the force generated by the weight of the machine. It throttles the outlet port circuit and controls the speed according to the discharge volume of the pump (Fig. 4).
(Fig. 4)
205FO5066
2. SAFETY VALVE FUNCTION l When travel is stopped (or when traveling downhill), the circuit at the inlet and outlet ports of the motor are closed by the counterbalance valve, but the motor is rotated by inertia, so the pressure at the outlet port of the motor will become abnormally high and damage the motor or piping. The safety valve acts to release this abnormal pressure and send it to the inlet port side of the motor to prevent damage to the equipment. OPERATION l When stopping travel (or when traveling downhill), chamber E in the outlet port circuit is closed by the check valve of the counterbalance valve, but the pressure at the outlet port rises because of inertia (Fig. 5). l If the pressure goes above the set pressure, the force produced by the difference in area between Dl and D2 [x/4 (D: - DE) x pressure] overcomes the force of the spring and moves the poppet to the right, so the oil flows to chamber F in the circuit on the opposite side (Fig. 6).
1 O-78
(Fig. 5)
205F2044
(Fig. 6)
205F2045
DI
VALVE CONTROL
Bucket dump
Boom low&
Boom raise _
y&y’,:
/
___
4---
1'
i6 207FO5035
control
lever
2. R.H. travel control 3. R.H. PPC valve
1. L.H. travel
lever
4. 5. 6. 7. 8.
R.H. work equipment control Accumulator Control valve Hydraulic pump Arm half flow solenoid valve
lever
9. 10. 11. 12. 13. 14. 15. 16.
Arm shuttle valve Swing shuttle valve Boom*bucket shuttle valve Travel shuttle valve Safety lock valve L.H. work equipment control L.H. PPC valve Travel PPC valve
lever
1 o-79
PPC VALVE FOR WORK EQUIPMENT
AND SWING
\ a
c
View 2
a. b. c. d. e. f.
P port (From charging pump) T port (To tank) P3 port (L.H.: arm in/RH.: bucket dump) P2 port (L.H.: R.H.: swing/RH.: boom lower) P4 (L.H.: arm out/R.H.: bucket curl) PI (L.H.: L.H. swing/R.H.: boom raise)
1 O-80
d
e
205FO5068
Section A -
A
Section B -
Section D -
Section C -
1. 2. 3. 4. 5. 6.
Spool Metering spring Centering spring Pilot piston Pilot spring Piston
B
D
C
7. Disc 8. LWer 9. Joint 10. Plate 11. Collar 12. Body
IO-81
FOR TRAVEL
I
,
I
\
a
207FO5036
a. b. c. d. e. f.
P port (From charging T port (To tank) P2 port (L.H. reverse) P4 port (R.H. reverse) PI port (L.H. forward) P3 port (R.H. forward)
1 O-82
pump)
I
1’
Section
Section
A -
C -
A
Section
B -
B
Section
D -
D
C 207FO5037
1. Spool Metering spring 3. Centering spring 4. Piston 2.
5. Bolt
6. Plate 7. Collar 8. Body
1 O-83
OPERATION 1) At neutral
*
The operation depends on the work ment and swing PPC valve.
equip-
Ports Pl and P2 of the PPC valves in circuits A and B of the control valve are connected to drain chamber D through fine control hole f in spool (1). (Fig. 1)
2)
Control lever operated slightly (fine control) When piston (4) starts to be pushed by disc (2), retainer (7) is pushed. Valve (10) is also pushed by spring (9) and moves down. When this happens, fine control hole f is shut-off from drain chamber D. At almost the same time it is connected to pump pressure chamber Pp, and the pilot pressure of the control valve is sent through fine control hole f to port Pl. When the pressure at port Pl rises, valve (10) is pushed back. Fine control hole f is shut-off from pump pressure chamber Pp. At almost the same time it is connected to drain chamber D, so the pressure at port Pl escapes to drain chamber D. Valve (10) moves up and down until the force of spring (9) is balanced with the pressure of port Pl. The relationship of the positions of spool (1) and body (12) (fine control hole f is in the middle between drain hole D and pump pressure chamber Pp), does not change until damper piston (4) contacts piston (6). Therefore, spring (2) is compressed in proportion to the travel of the control lever, so the pressure at port Pl also rises in proportion to the travel of the control lever. The spool of the control valve moves to a position where the pressure of port A (same as pressure at port Pl) and the force of the return spring of the control valve are balanced (Fig. 2).
1 O-84
Control valve (Fig. I)
205FC
(Fig. 2)
205FO5073
3)
During
fine control
(control
lever returned)
When disc (7) starts to be returned, spool (1) is pushed up by the force of centering spring (3) and the pressure at port Pl. Because of this, fine control hole f is connected to drain chamber D, and the pressurized oil at port Pl is released. If the pressure at port Pl drops too much, spool (1) is pushed down by metering spring (2), so fine control hole f is shut-off from drain chamber D. At almost the same time it is connected to pump pressure chamber Pp, so the pressure at port Pi supplies the pump pressure until the pressure recovers to a pressure equivalent to the position of the lever. When the control valve spool returns, oil in drain chamber D from fine control hole f’ of the valve on the side that is not moving flows through port P2 and goes to chamber B, so the oil is charged (Fig. 3).
iiL
wt
1 \ 8
4 a
3,
:j
205FO5074
4)
At full stroke Disc (7) pushes down piston (6), but damper piston (4) also follows this and pushes down spool (1). Fine control hole f is shut-off from drain chamber D, and is connected to pump pressure chamber Pp. Therefore, the pilot pressure oil from the charging pump passes through fine control hole f and flows to chamber A from port Pl to push the control valve spool. The return oil from chamber B passes from port P2 through fine control hole f’ and flows to drain chamber D. With damper piston (4) that was following piston (6), the pressurized oil in the spring chamber flows out from orifice a, and damper piston (4) and spool (1) are pushed back by the force of metering spring (2) and the hydraulic pressure at port Pl. The time lag when the lever is suddenly operated is prevented by damper piston (4). (During fine control, damper piston (4) does not follow piston (6), so the fine control performance is maintained.) (Fig. 4).
\I
(Fig. 4)
205FO5075
1 O-85
ACCUMULATOR
1. 2. 3. 4. 5. 6.
Gas plug Shell Poppet Holder Bladder Oil port
SPECIFICATION Gas capacity: PC300LC:
300 cc
PC4OOLC:
500 cc
205FO5076
SAFETY LOCK VALVE
3. 4. 2. 1. Seat Ball Body Lever
5. End cap
2
3
4
5 207FO5038
1 O-86
SOLENOID FOR 2-STAGE
VALVE ASSEMBLY RELIEF,
CO CANCEL,
SWING
BRAKE AND TRAVEL
i a
a. b. c. d. e. f.
T port (To tank) P port (From charging pump) To front and rear NC valve To main relief valve To L.H. and R.H. travel motor To swing motor
1. 2. 3. 4.
SPEED
b
CO cancel solenoid valve 2-stage relief solenoid valve Travel speed solenoid valve Swing brake solenoid valve
1 O-87
1.
FOR P-STAGE
1
RELIEF,
2
CO CANCEL
3
4
AND TRAVEL
5
6
SPEED
7 1. 2. 3. 4. 5. 6. 7.
Connector Plunger Coil Push pin Spool Spring Bracket
205FO5079
OPERATION Solenoid deactivated l No signal current flows from the controller, so solenoid is deactivated. Because of this, port A is closed, and the pressurized oil from the charging pump does not’flow to the actuator. At the same time, the oil from the actuator flows from port B to port C and is drained to the tank.
205FO5080-1
Solenoid excited l When the signal current flows from the controller to solenoid, solenoid is excited. As a result, the pressurized oil from the charging pump flows from port A to port B, and to the actuator. At the same time, port C is closed, and the pressurized oil from the charging pump does not flow to the tank.
205FO5081-1
1 O-88
2.
FOR SWING
BRAKE
1. Connector 2. Plunger 3. Coil 4. Spring 5. Spool 6. Body 7. Plug
205FO5082
OPERATION Solenoid deactivated l No signal current flows from the controller, so coil is deactivated. Because of this, port P is closed, and the pressurized oil from the charging pump does not flow to the swing motor. At the same time, the oil from the swing motor flows from port A to port T and is drained to the tank.
205FO5083-1
Solenoid excited 0 When the signal current troller, coil is excited.
flows
from the con-
Because of this, port P and port A are interconnected, and the pressurized oil from the charging pump flows to the swing motor. At the same time, port T is closed, so the oil does not flow to the tank.
Exci
205FO5084-1
1 O-89
FOR ARM HALF FLOW
1. 2. 3. 4. 5. 6. 7.
Connector Plunger Coil Spring Spool Body Plug
205FO5085
OPERATION Solenoid deactivated l No signal current flows from the controller, so coil is deactivated. Because of this, port P and port S are interconnected, so the pressurized oil from the PPC valve flows to the control valve.
205FO5086-1
Solenoid excited l When the signal current troller, coil is excited.
flows
from the con-
Because of this, port P is closed, pressurized oil from the PPC valve flow to the control valve. At the same time, port S and port T connected, so the pressurized oil control valve is drained to the tank.
and the does not are interfrom the
Exci
205FO5087-1
1 O-90
SHUTTLE VALVE FOR BOOM
. BUCKET
AND
TRAVEL e
1. 2. 3. 4. a.
x
I i
I
Section A -
A
?
Section B -
/3
B
‘lug 3all 3ody ‘lug
port (Bucket dump) j3.H. reverse] b. ‘3~ port (Bucket curl) 1R.H. forward] C. ‘4~ port (Boom raise) 1L.H. forward] d. ‘2~ port (Boom lower) 1L.H. reverse] e. 3s port (Travel shuttle valve) :Travel oil pressure switch] f. 238 port (Bucket curl) 1R.H. forward] g. ‘1~ port (Bucket dump) 1R.H. reverse] h. ‘28 port (Boom lower) 1L.H. reverse] i. ‘4~ port (Boom raise) 1L.H. forward] ( ): For boom*bucket [ 1: For travel ‘1~
207FO5039
FOR ARM AND SWING
a
b
c
1. Ball 2. Body 3. Plug
Pin port (Arm :: P3 port (Travel [Blind plug] Psn port (Arm d”: Pie port (Arm e. PUB port (Arm ( ): For arm, [
Section A -
A
I
d
out) [L.H. swing] shuttle valve) in) [R.H. swing] out) [L.H. swing] in) [R.H. swing] 1: For swing
\
e
207FO5040
1 o-91
BOOM HOLDING
VALVE
a
b
Section A -
A
d
207FO5041
a. T port (To tank) b. Pi port (From boom PPC valve) c. Cy port (To boom cylinder) d. V port (From boom control valve)
1 o-92
1. 2. 3. 4. 5.
Safety-suction Pilot spring Pilot spool Poppet spring Poppet
valve
OPERATION 1)
At boom RAISE When the boom is raised, the main pressure from the control valve pushes up poppet (5) in the direction of the arrow. Because of this, the main pressure oil from the control valve passes through the valve and flows to the bottom end of the boom cylinder.
205FO5091
2)
Boom lever at NEUTRAL When the boom is raised and the control lever is returned to NEUTRAL, the circuit for the holding pressure at the bottom end of the boom cylinder is closed by poppet (5) in the direction of the arrow. Because of this, the main pressure oil from the control valve passes through the valve and flows to the bottom end of the boom cylinder.
A
1 BOOT-LO
1
205FO5092
1 o-93
3)
Boom LOWER When the boom is lowered, the pilot pressure from the PPC valve pushes pilot spool (3) and the pressurized oil in chamber b inside the poppet is drained. When the pressure at port Cy rises because of the pressurized oil from the bottom end of the boom cylinder, the pressure of the pressurized oil in chamber b is lowered because of orifice a. If the pressure in chamber b drops below the pressure at port V, poppet (5) opens, the pressurized oil flows from port Cy to port V, and then flows to the control valve. If any abnormal pressure is generated in the circuit at the bottom end of the boom cylinder safety valve (1) is actuated.
205FO5093
1 o-94
HYDRAULIC
CYLINDER
1. BOOM CYLINDER PC3OOLC
\
i6
207FO5042
PC4OOLC
16
2. ARM CYLINDER
208FO5019
PC3OOLC
1
2
3
4
5
6
7
8
9
10
11
12
13
19
17
14
15
18 207FO5043
1 o-95
PC4OOLC
1
2
3
4
5
6
7
8
9
10
11
12
19 3. BUCKET
CYLINDER
13
14
18 208FO5020
PC3OOLC
207FO5044
PC4OOLC
208FO5021
1. 2. 3. 4. 5. 6. 7.
Bottom side bushing Piston Cylinder head Rod packing Buffer ring Wear ring Cylinder
1 O-96
8. 9. 10. 11. 12. 13. 14.
Head side cushion Piston Piston ring Wear ring Ring Spacer Bottom side tube
plunger
Bottom side bushing Head side tube Spacer Bottom side cushion plunger 19. Ball 15. 16. 17. 18.
SPECIFICATIONS Unit: mm Cylinder Boom
Arm
I
Bucket
Item
1 o-97
WORK EQUIPMENT
1. 2. 3. 4. 5. 6.
Arm Bucket cylinder Arm cylinder Boom Boom cylinder Bucket
1 O-98
1 o-99
ELECTRICAL WIRING DIAGRAM PC3OOLC
19
/ 18
/' l7
I 16 15
1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11.
Monitor panel Swing lock switch Horn switch Starting switch Fuel control dial Cigarette lighter Buzzer Service meter Radio TVC prolix switch Swing lock prolix switch
10-100
08DD0012 12. 13. 14. 15. 16. 17. 18. 19. 20. 21. 22.
Pump controller Engine throttle controller TVC prolix resistor Power maximizing switch Light relay Heater Hi relay Heater Low relay Speaker Wiper relay Fuse box Ether injector switch
08DD0030
23. 24. 25. 26. 27. 28. 29. 30. 31. 32. 33. 34. 35. 36. 37. 38. 39.
Working lamp Head lamp Battery Battery relay Fuel level sensor Horn (Low tone) Horn (High tone) Ether injector Room lamp Front pump pressure sensor Rear pump pressure sensor Work equipment lswing oil pressure’switch Alternator Coolant level sensor Coolant temperature sensor Governor motor Shut off valve
40. 41. 42. 43. 44. 45. 46. 47. 48. 49. 50. 51. 52. 53.
Starting motor Engine speed sensor TVC valve Engine oil pressure switch Engine oil level sensor Hydraulic oil lever sensor Arm half flow solenoid valve Swing brake solenoid valve Travel speed solenoid valve 2-stage relief solenoid valve CO cancel solenoid valve Travel oil pressure switch Wiper motor Washer motor
1 O-l01
ELECTRICAL WIRING DIAGRAM PC4OOLC
08DD0034
1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11.
Monitor panel Swing lock switch Horn switch Starting switch Fuel control dial Cigarette lighter Buzzer Service meter Radio TVC prolix switch Swing lock prolix switch
IO-102
12. 13. 14. 15. 16. 17. 18. 19. 20. 21. 22. 23.
Pump controller Engine throttle controller TVC prolix resistor Power maximizing switch Light relay Heater Hi relay Heater Low relay Speaker Wiper relay Fuse box Ether injector switch Service meter relay
36
37
08DD0035
24. 25. 26. 27. 28. 29. 30. 31. 32. 33. 34. 35. 36. 37. 38. 39. 40.
Working lamp Head lamp Battery Battery relay Fuel level sensor Horn (High tone) Horn (Low tone) Ether injector Room lamp Front pump pressure sensor Rear pump pressure sensor Work equipment*swing oil pressure Alternator Coolant level sensor Shut off valve Governor motor Coolant temperature sensor
switch
41. 42. 43. 44. 45. 46. 47. 48. 49. 50. 51. 52. 53. 54.
Starting motor Engine speed sensor TVC valve Engine oil pressure switch Engine oil level sensor Hydraulic oil lever sensor. Arm half flow solenoid valve Swing brake solenoid valve Travel speed solenoid valve 2-stage relief solenoid valve CO cancel solenoid valve Travel oil pressure switch Wiper motor Washer motor
10-103
10-104
ELECTRICAL PC3OOLC Please remove
CIRCUIT
DIAGRAM
this page and insert
Foldout
3 from rear of book
IO-105
IO-106
ELECTRICAL PC3OOLC Please
remove
CIRCUIT
DIAGRAM
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1 O-l 07
IO-108
ELECTRICAL PC4OOLC Please remove
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DIAGRAM
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10-109
10-110
ELECTRICAL PC4OOLC
Please
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DIAGRAM
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10-111
IO-112
ENGINE CONTROL PCSOOLC
SYSTEM
S/N A30001
A30112
THRU A30110,
AND A30114
THRU A30116
View Z
1. 2. 3. 4. 5. 6. 7. 8. 9.
Battery relay Battery Fuel control dial Starting switch Starting motor Engine throttle controller Fuel injection pump Governor motor Fuel shut off valve
OUTLINE l The engine can be started and stopped simply by using the starting switch. l The engine speed can be controlled using a dial control system for the fuel control. l The engine throttle controller also controls the engine speed at the same time using signals from the pump controller. * For details, see PEMC SYSTEM.
IO-113 0
ENGINE CONTROL PC3OOLC S/N A30111,
A30113
SYSTEM
AND A30117
AND UP
View Z X12BVO72
1. 2. 3. 4. 5. 6. 7. 8. 9.
Battery relay Battery Fuel control dial Starting switch Starting motor Engine throttle controller Fuel injection pump Governor motor Fuel shut off valve
1 O-l 13-1 0
OUTLINE l The engine can be started and simply by using the starting switch. l
0
stopped
The engine speed can be controlled using a dial control system for the fuel control. The engine throttle controller also controls the engine speed at the same time using signals from the pump controller. * For details, see PEMC SYSTEM.
1 O-l 13-2 0
ENGINE CONTROL PC4OOLC
SYSTEM
12BVOO28
1. 2. 3. 4. 5. 6. 7. 8. 9.
Battery relay Battery Fuel control dial Starting switch Starting motor Engine throttle controller Fuel injection pump Governor motor Fuel shut off valve
IO-114
OUTLINE l The engine can be started and stopped simply by using the starting switch. l The engine speed can be controlled using a dial control system for the fuel control. l The engine throttle controller also controls the engine speed at the same time using signals from the pump controller. * For details, see PEMC SYSTEM.
GOVERNOR S/N A30001
MOTOR
LINKAGE
THRU A30110,
A30112
- PC3OOLC AND A30114
THRU A30116
FULL SPEED
ANGLE ORIGIN (MOTOR STOP POSITION) /
12BV0029
1. 2. 3. 4. 5. 6.
g
Governor actuator Engine governor Spring assembly Yoke Lock nut Pin
10-115 0
GOVERNOR S/N A30111,
MOTOR
LINKAGE
- PC300LC
30113 AND 30117 AND UP
FULL SPEED
I,
LOW IDLE
ANGLE ORIGIN tMnTOR STOP POSITION) \.I._
SPEED
LOW IDLE
b-
X12BV073
1. 2. 3. 4. 5. 6.
1 O-l 15-I 0
Governor actuator Engine governor Spring assembly Ball joint Lock nut Lock nut
1 O-l 15-2 0
GOVERNOR
MOTOR
LINKAGE
- PC4OOLC FULL SPEED
XlZBV070
1. 2. 3. 4. 5. 6.
IO-116
Governor actuator Engine governor Spring assembly Yoke Lock nut Pin
OPERATION
OF SYSTEM
STARTING ENGINE 0 When the starting switch is turned to the START position, the start signal flows to the starting and the starting motor turns to start the engine. Power also flows from the starting switch engine shutoff valve, energizing the valve and allowing fuel to flow to the engine. When this happens, and sets the engine
the engine throttle controller speed to the set speed.
checks
the signal
voltage
motor to the
from the fuel control
dial
e-*--
(Throttle
signal)
controller
(Power source)
12BVOOll
ENGINE SPEED CONTROL l The fuel control dial sends a signal voltage to the engine throttle controller according to the position of the dial. The engine throttle controller calculates the angle of the governor motor according to this signal voltage and drives the governor motor so that it is set to that position. When this happens, it detects the operating angle of the governor motor using a potentiometer and observes the governor motor.
12BV0012
IO-117
STOPPING ENGINE l When the starting switch is placed at the OFF position, the shut-off valve closed so the supply of fuel to the engine is shut off and the engine stops.
r
1
e,,;,
a
Starting motor
C3
II
Engine throttle (Throttle signal)
Control
Starting switch-
I
kr 12BV0013
IO-118
COMPONENT EQUIPMENT OF SYSTEM 1. ENGINE THROTTLE CONTROLLER I
I
@
@
@
II
=
IJ
Z
i
View 2
1. Self-diagnostic
nwt Pin No.
’
display
and output
LEDs
signals Name of signal
I
Ipower
El
CN -
source
VB
+
1 Input
1 12
2
IPower
source
ground
I
I
I Input
I
Input/ output
Name of signal GND
13
3
Motor
drive A
A
output
14
Motor
drive A
A
output
4
Motor
drive
B
output
15
Motor
drive
B
output
APSiG
1Output
1 16
AP +
output
17
Model
SP +
output
18
Fuel dial GND
SPSiG
Input
19
No. 2 throttle
B
5
IPotentiometer
signal
6
Potentiometer source +
power
7
Fuel dial power
8
Fuel dial signal
source
+
9
INo. 2 throttle
PC +
I Input
10
Throttle
SA +
output
11
Auto-deceleration
PAD
Input
+ signal
I
20 21
B
IPotentiometer
IThrottle
GND
selection
-
-
Warming-up
AP SEL
Input
SP -
output
PC -
Input
SA signal
1Output
1Output
TL
IO-119
1
1
(Input signal)
(Output
signal)
Control function of controller 0
Pump controller
The engine throttle controller receives the input signals shown in the diagram on the right, processes these internally and sends output signals to the pump controller and governor motor.
Fuel control dial
Pump controller (Auto-deceleration sIgnal) (No. 2 throttle signal)
signal)
Governor potent,ometer (Potentiometer
An output signal that matches input voltage a corresponding to the position of the fuel control dial is sent so that the governor motor is set to turning angle b. Turning angle b is fed back to the controller by the potentiometer signal and the operation of the governor motor is always observed.
E a -
Governor motor
E 2 5
(Engine warming-up
trol dial
-z
(Throttle slgnall
Monitor panel
1) Engine speed set function using fuel con-
(Throttle signal)
b %
.-E ? w
signal)
Controller
output
characteristics
Fuel control
dial output
Fuel cktrol
dial output
205FO5110
2)
Engine speed control by No. signal from pump controller
2 throttle
The pump controller controls the engine speed directly using the No. 2 throttle signal in order to carry out the PEMC system. The engine throttle controller controls the engine using the lower signal (higher voltage) of the throttle signal from the fuel control dial and the No. 2 throttle signal from the pump controller. Example: Even if the fuel control dial is set to the MAX. position, if [finishing operation mode and S mode] is selected for the working mode and power mode, the engine speed will automatically be set to partial speed. * For details, s.ee PEMC SYSTEM.
IO-120
3)
Auto-deceleration celeration signal
function using autodefrom pump controller
When the pump controller detects that all levers are at neutral, it sends the autodeceleration signal to the engine throttle controller. When this signal is received, the engine throttle controller reduces the engine speed to the deceleration position. * For details, see PEMC SYSTEM. 4)
5)
INTERNAL STRUCTURE OF CONTROLLER The inside of the controller consists of the input circuit, microcomputer and drive circuit shown in the diagram, these have the various functions described below. Input circuits These receive the signals from the fuel control dial (throttle signal), pump controller (No. 2 throttle signal, auto-deceleration signal) and monitor (warming-up signal) and send them to the microcomputer. In this portion, the noise in the signal is removed and the wave pattern of the signal is regulated.
Automatic warming-up function using warming-up signal from monitor After the engine is started, if the engine water temperature is low, the monitor sends the warming-up signal to the engine throttle controller. When this signal is received, the engine throttle controller raises the engine speed to carry out warming-up. * For details, see PEMC SYSTEM. Self-diagnostic
In addition, it makes the power source (approx. 5V) for the governor motor potentiometer and fuel control dial.
7-v
function
Three LED’s (red, green and red) light up and go out to indicate that the machine is normal or to indicate the location of any failure when any abnormality occurs. * For details, see TROUBLESHOOTING.
2)
Microcomputer The angle of the governor motor is calculated from the input signals sent from the input circuits, and the pulse signal to drive the governor motor is sent to the drive circuit.
3)
Drive circuit The pulse signal sent from the microcomputer is used to switch the direction of the current flowing to the governor motor to rotate the motor clockwise or counterclockwise.
IO-121
2. FUEL CONTROL
DIAL
1. Knob 2. Dial
3. 4. 5. 6.
Machine forward
MIN.
Section A
-
--I
A
2
‘0
A
Spring Ball Potentiometer Connector
Composition of circuit
c3
a 3
FUNCTION l This is installed under the monitor panel. A potentiometer is installed under the knob, and when the knob is turned, it rotates the potentiometer shaft This rotation changes the resistance of the variable resistor inside the potentiometer, and sends the desired throttle signal to the engine throttle controller. The shaded area in the graph on the right shows the abnormal detection area and the engine speed is set to low idling.
IO-122
205FO5113
(%) 100
Hi
‘D ? m 1 n
0
0.25
1
4
Throttle voltage characteristics (VI
4.75
5
205FO5114
3. GOVERNOR
MOTOR
1. Potentiometer 2. Cover 3. Shaft 4. Dust seal 5. Bearing 6. Motor 7. Gear 8. Connector
Section A - A
I-
\
Composition of circuit
8
205FO5115
FUNCTION l
l
The motor is rotated and the governor lever of the fuel injection pump is controlled by the drive signal from the engine throttle controller. A stepping motor is used for the motor which provides the motive power. In addition, a potentiometer to give feedback is installed to allow observation of the operation of the motor. The rotation of the motor is transmitted to the potentiometer through a gear.
OPERATION Motor stationary l Both A phase and B phase of the motor are continuous. Motor rotating l A pulse current is applied to the A phase and B phase by the engine throttle controller to give synchronous rotation with the pulse.
IO-123
PEMC SYSTEM Working mode selection function Pump & engine mutual control system Power set selection function
Pump flow control (PFC, PNC) function
<~~ZEi~[~/lIZLn
1
Power maximizing system
Auto-deceleration
system
PEMC system Engine automatic warming-up Engine automatic warming-up overheat prevention system
function
and Engine overheat prevention function
Swing lock function
I
Swing control system
Swing holding brake function
(Pump control function When machine is traveling) -Automatic function
I *
Self-diagnostic
function
PEMC system: Pump and Engine Mutual Control l The PEMC system is a system of total control by controlling both the pump and engine.
IO-124
1
Hi-Lo travel speed shift
205FO5116
System to give a high level of both power and fuel economy
Travel
motor
I-
I
i
PPC shuttle valve I Controlvalve
____
__$___L+,
1 i
IJet
!’
i I , L
I!-= :
L : ;
d
Zharginl ,urllp
Enginethrottle
I Power max. switch
Swing lock switch
jwing ock volix #witch
8 I
(Front oil pressure sensor signal),,
I
(Drive signal) (Work equlpment.swing
lever sIgnal)
(Travel lever signal) (Drive signal (Swing lock switch signal) (Engine mode signal)’ (Swing
lock switch
signal1
“’
IO-125
PUMP AND ENGINE MUTUAL CONTROL AND POWER SET SELECTION)
SYSTEM
(WORKING
MODE
SELECTION
Engine
Travel control lever
NCvalve 1
I
PPC shuttle valve
m IEn*“”
IPWd
my?
pnell
2
-
Engine throttle controller
-
4
(Throttle sIgnal Pump controller ,NO 2Engine fhroftlecontrall~r,
A
Fuel control dial
!
(Travel lever signal)
‘H.0 G.0 F.0 LO 0000
_;
hutch
sqnal)
(Switch signal)
WORKING MODE @
8 8 b 205FO5 118A
The combination of the 4-level working mode and 3-level power set makes it possible to choose a pump absorption torque corresponding to the nature of the work, so it is possible to use the engine more effectively while also reducing fuel consumption. Normally, the combination of the working mode and power mode takes the working mode as the basic mode and the power mode is automatically set according to the selection of the working mode.
OUTLINE 0 The changes in the engine speed caused by the pump load are detected by the engine speed sensor and fuel control dial output signal. The pump controller calculates these signals and sends the results to the TVC valve as a signal to control the pump discharge volume. In this way, it can always give the optimum matching of the engine torque and pump absorption torque.
Engine torque
Engine horsepower L.0 + L
G.O. F.O. L.0 + S
t-
H.O+S
Main pump delivery L.0 + L
H
3
s e B aY .E 0, 5 Engine speed N Note)
IO-126
205FO5,,
9A
Engine speed N
H.0:
Heavy duty operation mode, G.0: General operation mode,
F.0:
Finishing
operation
mode,
L.0:
Lifting
operation
mode.
205FO5120A
Pump delivery volume 0
CONTROL OF H MODE When using H.0, G.0, F.0 or L.O. mode and H mode l
Working
mode:
0 0
Power set: CO function:
l
Pump absorption:
Actuated At rated output
horsepower:
point
PCBOOLC 207 HP/2,000
Engine torque
Same for any mode H
I rpm
l
PC4OOLC 276 HP/2,000
rpm Engine speed N 205FO5
When the pump controller receives the power set [H] signal from the monitor, it sends out an electric command for the H mode output setting to the engine throttle controller. The engine throttle controller receives this and uses the governor motor to set the engine governor lever to the FULL position. If the pump load becomes too high and the engine speed drops, the engine speed sensor reduces the pump discharge amount, and momentarily resets the engine speed to the rated point. In this way, the engine torque and pump absorption torque are always matched at the rated point and the engine horsepower can be used to the maximum. The CO (Cut-off) function is actuated and when it reaches near the relief pressure, the pump discharge amount is reduced to reduce hydraulic loss and power loss.
l
122
Engine horsepower
V
I
Engine speed N 205FO5123
l
Main pump delivery
Pump delivery volume Q 205FO5124
IO-127
0
Power
0
CO function: Pump absorption
l
set:
horsepower:
l
Engine torque
CONTROL OF S MODE When using H.O. mode and S mode l Working mode: H.O.
I
b B
0
S Actuated At 85% partial output point
0 z 2 E ._ P W
Engine speed N
PC4oOLC
PC3OOLC 177.5 HP/2400
rpm
Engine horsepower
n
Engine speed N 205FO5126
205FO5125
236.6 HP/2,000 rpm Main pump delivery L
l
l
When the pump controller receives the working mode [H.O.] and power set [S] signal from the monitor, it sends out an electric command for the S mode output setting to the engine throttle controller. The engine throttle controller receives this and uses the governor motor to set the governor lever to the FULL position. The pump absorption horsepower and engine speed are different, but the control is basically the same as for [H] mode (engine speed sensing at the matching point).
Pump delivery volume Q 205FO5133
When using G.O., F.O. or L.O. mode and S mode l
Working
0 0
Power set: CO function:
l
Pump absorption horsepower:
mode:
S Actuated At 85% partial output point
l
Engine torque
G.O., F.O. or L.O.
%
+
J
“..,
P B
s 8
ii!
177.5 HP/l ,860 rpm
0
l
236.6 HP/l,800
L
L5:
PC4oOLC
E
Engine speed N
rpm
When the pump controller receives the working mode [G.O.] (or [F.O.] [L.O.]) and power set [S] signal from the monitor, it sends out an electric command for the S mode output setting to the engine throttle controller. The engine throttle controller receives this and uses the governor motor to set the governor lever to the partial position. The pump absorption horsepower and engine speed are different, but the control is basically the same as for [H] mode (engine speed sensing at the matching point).
205FO5128
l
3
_.ml
-2
‘5
PC3OOLC
hi
Engine horsepower
‘6 15
Engine speed N 205FO5129
Main pump delivery
Pump delivery volume Q 205FO5136
lo-128
CONTROL
l
OF L MODE
When using H.O. mode and L mode l
Working
0
Power
0
CO function: Pump absorption
l
mode:
Engine torque
Engine horsepower
cl
H.O. L
set:
horsepower:
Actuated At 70% partial output point I
I
I
Engine speed N PC4OOLC
PC3OOLC. 147.9 HP/2,000
rpm
Engine speed N
205FO5131
205FO5132
192.3 HP/2,000 rpm l
Main pump delivery
0
When the pump controller receives the working mode [H.O.] and power set [L] signal from the monitor, it sends out an electric command for the L mode output setting to the engine throttle controller. The engine throttle controller receives this and uses the governor motor to set the governor lever to the FULL position.
o- I
l
The pump absorption horsepower and engine speed are different, but the control is basically the same as for [H] mode (engine speed sensing at the matching point).
a’i Pump delivery volume Q 205FO5127
When using G.O. or F.O. mode and L mode l
0 0 l
Working mode: Power set: CO function: Pump absorption horsepower:
G.O. or F.O. L Actuated
l
Engine torque
l
Engine horsepower
UJ
205FO5135
At 70% partial output point
PC3OOLC
PC400LC
147.9 HP/l ,800 rpm
192.3 HP/l ,800 rpm 205FO5134
l
l
When the pump controller receives the working mode [G.O.] (or [F.O.]) and power set [L]‘,’ signal from the monitor, it sends out an electric command for the L mode output setting to the engine throttle controller. The engine throttle controller receives this and uses the governor motor to set the governor lever to the partial position. The pump absorption horsepower and engine speed and different, but the control is basically the same as for [H] mode (engine speed sensing at the matching point).
l
Main pump delivery
205FO5130
IO-129
l
When using L.O. mode and L mode l
Working
0
Power
mode:
0 0
CO function: Pump absorption
L.O.
set:
L
horsepower: PC3OOLC 128.2 HP/l,400
Engine torque
Actuated At 62% partial output point.
I rpm
1
PC46OLC 172.5 HP/l,400
rpm
When the pump controller receives the working mode [L.O.] and power set [L] signal from the monitor, it sends out an electric command for the L mode output setting to the engine throttle controller. The engine throttle controller receives this and sets the governor lever to the partial position. The pump absorption horsepower and engine speed are different, but the control is basically the same as for [H] mode (engine speed sensing at the matching point). The area around the matching point is a highly efficient area for engine fuel consumption, so the fuel reduction effect is extremely large. At the same time, by throttling the pump output, it is possible to obtain a high level of fine control performance to match fine control operation.
Engine speed N 205FO5137 l
Engine horsepower
Engine speed N 205FO5138
l
Main pump delivery
Pump delivery volume Q 205FO5139
1 o-1 30
CONTROL OF POWER MAXIMIZING FUNCTION l When the power max. switch is OFF.
l
Engine torque
H.O. or G.O. Same for any mode Actuated Depends on the setting for working mode and power set.
l Working mode: 0 Power set: 0 CO function: l Pump absorption horsepower:
u
Engine speed N 205FO5122
l
When power
maximizing
l Working mode: 0 Power set: 0 CO function: l Pump absorption horsepower: 0 Operation time:
l
switch
ON.
H.O. H Cancel At rated output point
*
Engine horsepower
Even if the switch is kept ON, it is automatically canceled after 8.5 seconds.
When the working mode switch is at [H.O.] or [G.O.] and the power max. switch is pushed ON, the following functions are actuated while the switch is being pressed. 1. If either of the working modes and any of the power sets is selected, the system will switch to [H.O.] and [HI. 2. The CO (cut-off) function is canceled and the flow‘ at near relief pressure is increased. * l=ysTc$ails see, PUMP CONTROL *
l
Even if the switch is kept pressed, the above function is automatically canceled after 8.5 seconds and the system is reset to the condition before the switch was pressed. This function does not work when the working mode switch is at _ [F.O.] - or [L.O.]. -
Y
I
Engine speed N
l
205FO5
123
205FO5
140
Main pump delivery
Pump delivery volume Q
1 o-1 31
CONTROL FUNCTIONS WHEN TRAVELING l When the travel is operated, even if any working mode or power set is selected, the , working mode and engine speed will stay as they are, and only the power set is switched to the equivalent of H mode to increase the pump absorption torque.
l
Engine torque
Engine speed N 205FO5141
l
CONTROL FUNCTION WHEN TVC PROLIX SWITCH IS ON l If any abnormality occurs in the controller or sensors, a constant current flows form the battery to the TVC valve so that the function can be maintained through a pump absorption torque more or less equivalent to S mode In this condition, only hydraulic sensing using the TVC valve is used.
Engine horsepower
Engine speed N
l
207FO5053
Main pump delivery
Pump delivery volume Q 207FO5079
1 o-1 32
SELECTION
OF MODE
Foldout 7 Power maximizing switch “OFF”
g g
Manual selection mode
P z 4
Auto-selection function
Power set PC3OOLC
Auto decel
PC4OOLC
CO cnacel
Power set PC3OOLC
PC4OOLC
Auto decel
CO cancel
Half flow mode
S 177.5 HP/2,000 rpm 236.6 HP/2,000 rpm L 147.9 HP/2,000 rpm 192.3 HP/2,000 rpm H
ON (Operation)
(Cancel) OFF
‘I_’
ON/ OFF
_
~~
Pump a#,rary YOlUrnC 0
Eng”.PwdN
H
ON
KZrtZelJ
KZelI
!“\
i\-
276 HP/2,000 rpm
207 HP/2,000 rpm
Engine speed N
205FO5173
205FO5172
P
Pump d*h”wv lOlYme 0
205FO5180
205FO5181
1. Full power used by engine speed sensing 2. Power increased by cancellation of
1. Fuel consumption improved by partial use of engine power
ON/ 276 HP/2,000 rpm
207 HP/2,000 rpm
ON/ OFF
Level of achievement
1. Full power used by engine speed sensing 2. Power increased by cancellation of
276 HP/2,000 rpm
207 HP/2,000 rpm
OFF
S
9 ”
Level of achievement
1. Full power used by engine speed sensing
ON
z
Auto-selection function
Manual selection mode
Half flow mode
H
,9
Power maximizing switch “ON”
177.5 HP/l ,800 rpm 236.6 HP/l ,800 rpm L
ON
(Operation) ON
KZzt!Zel)
1;:
ON/
in
Ef?+w Ipeed N
147.9 HP/l ,800 rpm 192.3 HP/l ,800 rpm OFF
ON
H
Pump WV YOlunl~ a
KZ!elI
I:::-:
pi\-.
276 HP/2,000 rpm
207 HP/2,000 rpm
Engtne sped N
205FO5175
205FO5174
CCYrZelI
205FO5180
I
H
Pump d*llvery YOlUme Q 205FO5181
1. Ease of operation improved by half flow mode function
ON/ 276 HP/2,000 rpm
207 HP/2,00O rpm
d
OFF
S
ON 177.5 HP/l ,800 rpm 236.6 HP/l ,800 rpm OFF = (Operation) L
(Operation)
+
Same control as when power max. switch is OFF
*
Same control as when power max. switch is OFF.
ON/
147.9 HP/l ,800 rpm 192.3 HP/l ,800 rpm OFF H 207 HP/2,000rpm
,0
1. 2.
ON/ 276 HP/2,000rpm
Increase of fine control range Improvement in efficiency by lowering engine speed
OFF
S
i
177.5 HP/l ,800 rpm 236.6 HP/l ,800 rpm
ON/ OFF
ON (Operation) (Operation) f :
ON
:I~...--.-..-
I\:.._.~~
L
1 OFF 128.2 HP/l ,400 rpm 172.5 HP/l ,400 rpm * *
En*,ns rpes6 N 205FO5178
The thick lines mark the modes and functions that are automatically selected according to selection of the working mode. When the starting switch is turned ON, working mode LG.01 and the default modes and functions are automatically set.
Pump dollvely “OlYrnL Q 205FO5179
IO-133
1 o-1 34
PUMP CONTROL
SYSTEM Travel control
1 (S$ch
,-
signal), I
(Switch
signal)
-
Pump controller
I
lever
1
(Drive signal) ‘;jDrive signal!, (Drive signal) (Travel lever signal) 205FO5144
OUTLINE l By controlling the main pump discharge volume according to the stroke of the control lever, it is possible to reduce the neutral loss and fine control loss. l The half flow mode function that is automatically set by the working mode produces excellent fine control performance. l The cut-off function and cut-off cancel function, together with the 2-stage relief function provide both reduction of relief loss and increase of digging power.
IO-135
1)
FLOW CONTROL FUNCTION PNC (Pump Neutral Control) l When the control levers are at neutral, the pump discharge volume is controlled to the minimum to reduce the wasted oil flow that occurs when the control valve is at neutral.
I
Lever stroke L
PFC (Pump Fine Control) l When the lever is operated, the control for the necessary oil flow is sent to the pump based on the flow command corresponding to the stroke of the lever. In this way, the wasted oil flow that occurs during fine control is reduced. l At the same time, by increasing the pump discharge volume by a suitable amount to correspond to the stroke of the lever, the fine control performance is improved. * For details see, HYDRAULIC PUMP. 2)
3)
205FO5145
I
CUT-OFF (CO) FUNCTION 0 When the load increases during operations and the main pump discharge pressure rises, it reduces the pump discharge volume when the pressure is near the relief pressure and acts to reduce relief loss. For details see, HYDRAULIC PUMP. *
cut off
Pump
Operation
of switches
and cut-off
ON CO function
Note 1)
Canceled
Swing
Operated
Neutral
ON
Canceled
Actuated
Canceled
or [G.O].
0
volume
is
function.
Travel lever
This is only effective is at [H.O]
IO-136
OFF Actuated
Pump discharge
Pump
Power maximum switch (Note 1)
volume
205FO5146
CUT-OFF CANCEL FUNCTION l When the load increases during operations and the main pump discharge pressure rises, the pump discharge volume is not cut-off even when the pressure is near the relief pressure. This ensures the flow of oil and prevents any drop in speed. l Actuation and cancellation of the cut-off function is automatically determined by the position of the power max. switch, travel lever and swing lock switch. l
discharge
when the working
lock switch OFF Actuated
mode switch
discharge
volume
Q 205FO5147
Quick warming up of hydraulic oil when swing lock switch is ON. When the swing lock switch is turned ON, the CO function is canceled. In this condition, if the work equipment is relieved, the hydraulic oil temperature can be raised quickly to reduce the time taken for warming up. 4)
HALF FLOW MODE FUNCTION When [F.O.] or [L.O.] is selected with the working mode switch the operation of the control valve for the arm Hi (acceleration) is stopped. The pumps actuating the boom and arm are separated, so the digging (finishing) operation is not affected by the load on the other circuit. This improves the fine control and finishing precision. l Relationship between working mode and pump discharge volume (during independent operation).
* *
The portion for one pump is taken as 100%. When the arm is OUT and the bucket is operated simultaneously, the half flow mode does not function.
5) 2-STAGE RELIEF FUNCTION When the power max. switch is pushed ON (Note l), the P-stage relief solenoid valve pilot pressure raises the set pressure of the main relief valve from 325 kg/cm2 to 350 kg/cm2 to increase the digging power.
1Power max. switch (Note 1) 1 ON Main relief valve set pressure (kg/cm2)
Note 1)
350
I
OFF 325
This is only effective when the working mode switch is at [H.O.] or [G.O.].
IO-137
POWER
MAXIMIZING
FUNCTION Control valve [Jet -/ sensor
, R.H. travel
E
Arm-Lo
E
Service
E
3
E
Arm-Hi
3
E
Arm throttle
3
E
Swing priority 3 Boom-Hi
Bucket
3
Boom-Lo
3
Straight-travel
3
Swing
L.H. travel
I
Engine Fuel injection
Governor motor
1
t Engine throttle controller
(Swim:
(Engine speed signal) (Throttle signal)
[Tq sET @ OUTLINE l
the switch on the left work equipment lever knob, the maximum digging power is increased to give superior production.
By pressing
1 O-138
signal) ,
(Drive signal) _
Rump controller
,;,
I I
(Drive,signal)
=,’
[“o”]
(Switch signal) (Switch signal) woaklNc MODE@ 205FO5
148
0
When the working mode is switched to [H.O.] or [G.O.], and the power max. switch is switched ON, the following functions are actuated.
Power max. switch
Mode function OFF Working mode Power set ICO function
ON
H.O. or Go . .
H.O.
Any mode
H
1 Actuated
I
i
1
Main relief valve pressure 1 ks3/2c5m21 Length of operation
*
This function mode switch
Canceled
I
350 kg/cm2
1
Even when pressed continuously, it is canceled after 8.5 sec.
does not work if the working is at [F.O.] or [L.O.].
10-139
AUTO DECELERATION
SYSTEM
Engine
_.
.
. .. .
I
fuel control alal
HI
n
I
I
Governor mntnr
Fuel injection
(Throttle signal) L.H. control
R.H. control
-_
Enaine throttle controller
Travel control lever
PPC shuttle valve
c,
Oil pres. switch
(Work equipment + swing lever signal)
I* ~..L_L_:--_I\
207FO5054
OUTLINE l
is a fully electronic control type and when all the work equipment, swing and travel levers are at neutral, and the pump controller receives the signal, it sends a command to the engine throttle controller.
This
When
this
is received,
the
controller drives the governor duce the engine speed, thereby consumption and noise.
engine
throttle
motor to rereducing fuel
Fuel control dial setting rpm
mm
Control lever Neutral
Control lever Operation 205FO5 150
1 O-l 40
OPERATION When
auto-deceleration
switch
ON
1. If the fuel control dial is set at a position higher than 1500 rpm, and all control levers are at neutral, the pump controller receives the neutral signal and sends the auto-decelto the engine throttle eration signal controller. When the engine throttle controller receives the signal, it sends the drive signal to the governor motor to drive the governor motor and pull back the injection pump governor lever to the No. 1 deceleration position. It holds it at this position for approximately 4 seconds. When this happens, the engine speed is lowered by about 100 rpm from the dial setting. 2. After the levers have been at neutral for more than 4 seconds, the drive signal is again sent from the engine throttle controller to the governor motor, and the governor lever is pulled back and held in the No. 2 deceleration position. The engine speed in this position is approx. 1400 rpm.
FO20705002
condition, if any control 3. In the deceleration lever is operated, the pump controller receives the signal and cancels the auto-deceleration signal sent to the engine throttle controller. When this happens, the engine throttle controller sends a drive signal to the governor motor to return the governor lever to its original setting. When auto-deceleration switch is OFF l The engine speed can be set as desired using the fuel control dial and even if all the levers are at neutral, the engine speed is not reduced.
FO20705003
IO-141
ENGINE
AUTOMATIC
WARMING-UP
AND
4
nD
1 Monitor panel /
OVERHEAT
PREVENTION
FUNCTION
Engine Coolant temp. sensor Governor
Fuel control dial Hi f Lo
1 (Warming-up
signal)
-
(Working mode signal) (Power set signal)
c
Engine throttle controller
Pump controller
e 205FO5154
OUTLINE 0
After the engine is started, this raises engine speed automatically to warm-up engine. (Automatic warming-up function.)
the the
In addition, to protect the engine, if the coolant temperature rises too high, it lowers the pump load and engine speed to prevent overheating of the engine. (Overheat prevention function.)
1 O-l 42
1) 0
AUTOMATIC WARMING-UP Actuation table
FUNCTION
Action
Conditions \_ Coolant temperature: Fuel control dial: sr
u
a,
L!
0” 2) 0
Engine speed: 1,450 r 100 rpm
If all the above conditions are satisfied, the automatic warming-up function is actuated.
Coolant temperature: Fuel control dial:
Above 30°C Held above 70% of high idling for more than 3 sec. At least 10 minutes Warming up time: sr If any of the above conditions is applicable, the automatic warming-up function is canceled.
OVERHEAT PREVENTION Actuation table
r
Less than 30°C Below set speed [set speed: 1450 rpm]
T
Engine speed: As desired
FUNCTION
Action
Conditions Power set:
Coolant temperature: (Coolant temperature
102” - 107°C gauge: Red range)
Selected mode
Action mode
H.0 and H,S mode
H.0 and L mode
G.0 and H,S mode
G.L and L mode
F.0 and H,S mode
F.0 and L mode
L.0 and H,S mode
L.0 and L mode
Engine
speed:
Default
mode
speed
Coolant temperature: (Coolant temperature
Above 107°C gauge: Red range)
Power set: L mode (same as No. 1 setting) Engine speed: Low idling Warning lamp, buzzer: ON
Coolant temperature: (Coolant temperature
Under 102°C gauge: Green range)
Power set: Default mode Engine speed: Default mode speed
*
Automatic
reset
When coolant temperature is less than 102°C. return fuel control dial to low idling position. * Manual reset
Power set: Default mode Engine speed: Fuel control dial set speed (as desired)
IO-143 0
SWING
CONTROL
SYSTEM Swing
L.H. control
motor
Swing holding
lever
brake Swing
I
I PPC shutlle valve
Oil pres. switch
I
A
(Swina lock sianal)
1
Pump controller
1_-
Eying
lever sign-$)
205FO51558
OUTLINE l
The swing
is controlled
comprehensively
both
when stopping and when operating the swing or work equipment, by the swing lock, swing holding brake and swing priority function.
1 O-l 44
1)
SWING LOCK AND AUTOMATIC HOLDING BRAKE SYSTEM
l
SWING
The swing lock (manual) and swing holding brake (automatic) are employed to lock the swing in the desired position and to prevent hydraulic drift after stopping the swing.
*
*
*
Swing lock prolix switch function When the pump controller is abnormal and the swing holding brake function does not work normally, the swing lock prolix switch cancels the swing brake and operates the swing. Even when the swing lock prolix switch is turned ON, the swing lock switch stays ON and the swing brake is not canceled. When the swing brake is canceled, the swing has only a hydraulic brake operated by the safety valve, so if the swing is stopped on a slope, there may be hydraulic drift.
Actuation
between
swing
lock
lamp
and
Lock lamp
Actuation
OFF (Switch OFF) (Swing holding brake applied)
The swing brake is applied approx. 4 seconds after the swing or work equipment control lever is placed at neutral. When the swing or work equipment control lever is operated, the swing brake is released and the upper structure can swing freely.
ON (switch ON) (Swing lock applied)
The upper structure is held in place by the swing brake and even if the swing or work equipment control lever is operated, the swing brake is not canceled, so the upper structure does not swing.
table
Swing lock prolix switch Swing switch
lock
Swing
brake
2)
Relationship the brake.
(when
I
ON controller is abnormal)
ON Swing
lock applied
(when
I
ON
OFF fzfdg
lock can-
OFF controller
Swing plied
lock ap-
is normal) OFF
Swing holding brake applied
HYDRAULIC OIL QUICK WARM-UP FUNCTION WHEN SWING LOCK SWITCH IS ON. * For details see, PUMP CONTROL SYSTEM
IO-145
TRAVEL
CONTROL
SYSTEM
Travel control
lever
Travel motor
Fuel control
dial ,.,
[yiyjing signal,
)
Pump controller
4
I
(Drive signal)
205FO5
OUTLINE l This increases the pump absorption torque and drawbar pull when traveling. l The travel performance is improved by switching the travel speed manually or automatically.
1 O-l 46
156
1)
2)
PUMP CONTROL FUNCTION WHEN TRAVELING When traveling, the following functions are actuated. l If any of the working mode and power set are selected, the working mode and engine speed stay as they are and the power set only is switched to the equivalent of H mode. * For details see, ENGINE AND PUMP MUTUAL CONTROL SYSTEM. TRAVEL
SPEED
SWITCHING
FUNCTION
The switching of the travel speed can be carried out manually or automatically, and has the following functions. 0 When the travel speed switch is switched, the solenoid valve is switched. The action of the pilot pressure then changes the motor rocker cam angle and changes the travel speed. ii) If the speed setting of the fuel control dial is set to less than approx. 1200 rpm: When traveling in Lo, even if it is switched to Hi, the transmission is not shifted. l When traveling in Hi, the transmission is automatically shifted to Lo. Automatic switching between Hi and Lo according to pump discharge pressure. When traveling with the travel speed switch at Hi, if the machine travels up a slope and the pressure in the travel circuit goes above 310 kg/cm2 for more than 1 .O second for the PC3OOLC, or 2.0 seconds for the PC4OOLC, the solenoid valve is deactivated (closed) and the travel speed is switched to Lo. If the machine continues to travel at Lo (with the travel speed switch still at Hi) and it comes again to flat ground or travels downhill, and the pressure in the travel circuit drops below 210 kg/cm2 for more than 1.0 second, the solenoid is excited (opened) and the speed is switched again to high speed. * Detection of the pressure in the travel circuit when only the travel is being operated is made by sensing the pressure for both the front pump and the rear pump, and taking the higher value; for compound operations, only the sensor for the rear pump pressure is used. l
iii)
I
High speed travel
I-I
1
(Travel speed switch at Hi)
Uphill slope I
(Travel pressure continues at more than 3 10 kg/cm2 for more than 1 .O
(FC3OOLC), 2.0 (PC4OOLC) seconds)
(Travel pressure continues at less than 210 kg/cm2 for more than 1 .O seconds)
I
I
(Travel speed switch at Hi)
IO-147
SYSTEM 1.
COMPONENT
EQUIPMENT
PUMP CONTROLLER
CN-C3
CN-C2
CN-Cl
1.
Self-diagnostic display window
l----A
Section A- A 205FO5157
IO-148
nput and output
signal
:N-Cl
CN-C
No
Signal name
In or Out
Signal name
In or Out
Travel oil pressure switch
input
Service oil pressure switch 1
Input
Travel speed
6
Arm half flow solenoid
output
CO cancel solenoid
output
Swing brake solenoid
output
TVC valve 10
1
(+)
1
output
I
]NC
Input
Swing lock
1
Input
Power set (a)
I
Input
1
Power set (b)
I
Input
1
I
Input
I
Input
I
Input
I
output
I
Input
I
Input
I
Input
I
Auto-deceleration I
I
GND
8
I
I
9 I Model
I
IO
I Throttle (t)
selection
11
NC
I
II
I No. 2 throttle
12
GND
I
12
( Power maximizing
13 14
I
13
I Service oil pressure switch 2
I
I
14
I Working mode (a)
15
I Working mode (b)
IGND INC
(t)
15
I 2-stage relief solenoid
I
output
I
16
I Travel speed solenoid
I
output
I
16
I Engine mode
17
I NC
I
output
I
17
I Coolant temperature
1020
I
18
I Coolant temperature
105*
valve (-)
I I I I I I I I I I
Input I Input
I
Input I Input
I
In or Out
I
19
k 20 21
CN-C3 Signal name
I
10-149
2.
ENGINE
SPEED
SENSOR
Composition
of circuit 205FO51588
1. 2. 3. 4. 5.
3.
4. 5. 6.
Magnet Terminal Case Boot Connector
ENGINE THROTTLE CONTROLLER, FUEL CONTROL DIAL AND GOVERNOR MOTOR * For detail see, ENGINE CONTROL SYSTEM. MONITOR PANEL * For detail see, EMACC. TVC VALVE j, For detail see, HYDRAULIC PUMP. 2-STAGE RELIEF SOLENOID VALVE CO CANCEL SOLENOID VALVE TRAVEL SPEED SOLENOID VALVE ARM HALF FLOW SOLENOID VALVE * For detail see, SOLENOID VALVE ASSEMBLY.
IO-150
FUNCTION l The engine speed sensor is installed to the ring gear of the engine flywheel and acts to count electrically the number of gear teeth that pass in front of the sensor. This detection is carried out magnetically and the sensor contains a magnet and detection coil.
7.
PUMP
PRESSURE
SENSOR
3
2
1. Amplifier 2. Cord 3. Connector 4. Flange 5. Detect module of oil pressure 6. Introduction pipe of oil pressure
1
'6 Amplifier
Composition of circuit 205FO5159A
OUTLINE The pump discharge pressure is converted to l a voltage and the signal is sent to the pump controller. FUNCTION l The voltage pressure.
output
is proportional
to
OPERATION
To amplifier
Isolation seam
the
Oil pressure
When the pressurized oil entering from pressure introduction pipe (6) is pressurized by the diaphragm of pressure sensor module (5), the diaphragm shape changes. A bridge is formed on the opposite face of this diaphragm by a strain gauge and the deflection of the diaphragm is converted from a resistance value of the strain gauge to the bridge output voltage and is sent to the voltage amplifier (amp).
l
The voltage is further amplified by the amplifier and is output to the controller.
205FO5161
Relationship between output and pressure P(kg/cm’). V = 0.008 x Pt1.0.
voltage
160
l
Oil pressure P (kg/cm21
l
205FO5
V (v)
10-151
8.
WORK
EQUIPMENT*SWING
OIL PRESSURE
SWITCH,
ap--*
TRAVEL
I
OIL PRESSURE
-21
Composition
of circuit 202FO5
1. 2. 3. 4. 5. 6. 7.
Plug Diaphragm Back up spring Pin Guide pin Movable contacts Connector
IO-152
SWITCH
SPECIFICATIONS Actuation pressure: Reset pressure:
I65
5.0 + 1 .O kg/cm* 3.0 f 0.5 kg/cm*
EMACC (ELECTRONIC
MONITOR
AND CONTROL
Monitor panel
CONSOLE) Relay
Electrical parts
Engine throttle controller
Sensor signal
Warming-up
signal
I=7
-:’
Sensor
Power source
Pump controller
Buzzer signal I Coolant temp. signal Buzzer
Battery 205FO5162
0
The Electronic Monitor And Control Console (EMACC) observes the condition of the machine through the sensors installed to various parts of the machine and processes this information quickly. The system informs the operator of the condition on the panel.
l
Various modes selector switches are built into the monitor panel and it acts as the control portion of the machine control systern.
The content of the panel displays can be broadly divided into the following. 1. Monitor portion that gives warnings when any abnormality occurs in the machine. 2. The gauge portion (coolant temperature, fuel level) that always informs the condition of the machine.
IO-153
MONITOR
PANEL
WORKING
MODE
205FO5 163
CN-Pl
l
The monitor panel has the switch functions for the electrical parts, mode selection and monitor display functions. It has a built-in Central Processing Unit (CPU) and processes the data and outputs the display. The monitor display uses a Liquid Crystal Display (LCD). The switches are flat sheet switches.
1 O-l 54
CN-PP
Input and output signal CN-P2 No
Signal name
In or Out
1 2 3
Swing lock
4
Travel speed
output
5
Power set (a)
output
6
Power set (b)
output
7
Auto-deceleration
output
Input
1 8
1 Working mode (a)
I
output
9
Working mode (b)
I
output
I II
I Engine warming-up
I 12 I Coolant Temperature 1 13
1Coolant temperature
I 14
I
1 16
1GND
IONIC 105*C
I I I
~1
I
output
I
output
I
Output
I
CN-Pl
INOI
Signal name
1
Power source +24V
2
Power source +24V
I 3
I In or Out I
I
I
IGND
I Fuel level
I
Input
I
6
I Coolant temperature
I
Input
I
7
I Charge level
Input
I
8
I Starting signal
Input
I
I
Input
I
I
output
I
I 5
10 I Hydraulic
oil level
I I
11
I Buzzer
12
I Heater Fan Lo
13
I Heater Fan Hi
I output I I output I
14
I Lamp
I
output
I
15
1Wiper
I
output
I
16
I Engine oil pressure
Input
I
17
I Coolant level
18
I Engine oil level
19
I (PPC oil pressure)
20
I (Over-load warning)
I I
Input
I
Input
I
I
Input
I
I
Input
I
IO-155
1. MONITOR
12345
1. Coolant
temperature gauge oil level caution lamp Coolant level lamp Coolant temperature caution lamp Coolant level caution lamp Engine oil pressure caution lamp Fuel level caution lamp Charge level caution lamp Hydraulic oil level caution lamp Fuel level gauge
2. Engine
3. 4.
5. 6. 7. 8. 9. 10.
9
8
7
6 llAJ0050
Classification of indication
Symbol
Q
b 43 8
9 m
Item
Coolant level
Condition for displaying abnormalities Below low level
Engine oil level
Below low level
Hydraulic
Below low level
oil level
Indicates when placing the starting
Eswitch to ON before starting the cengine. If it is normal, the lamp goes off. - If it is an abnormality, the lamp 1flashes.
Engine oil pressure
0.5 kg/cm* max.
Indicates while the engine is tunning ‘and the starting switch is set to ON.
Coolant level
Below low level
Coolant temperature
107°C min.
If it is normal, the lamp goes off. the lamp If it is an abnormality, iFlashes and the buzzer sounds.
Charge level
When charging
Fuel level
Below low level 67
8
Description
Coolant temperature
76
83
90
system fails.
$7 102
Indicates when the engine is running and the starting switch is set to ON. If it is normal, the lamp goes off. If it is an abnormality, the lamp flashes.
107°C
Appropriate lights up.
place (one place)
All light up below appropriate level
IO-156
2. SWITCH
5
205FO5
l
The switches consist of four mode selector switches and four electrical component switches; every time the switch is pressed, the condition of the machine changes. The present condition is displayed by the lighting up of the LED above the switch.
8. Wiper switch 9. Swing lock lamp
165
Switch
actuation
table
Item
Action
Working mode
G.O. - H.O. - L.O. - F.O.
Power set
1
Auto decel
ON - OFF
Travel speed
Lo - Hi
Fan
OFF - Lo - Hi
Wiper
OFF - Lo 4 Hi OFF-1
Lamp Buzzer cancel
*
S-H-L
1
-2
OFF - ON
The bold letters indicated the default values when the starting switch is turned ON.
10-157
SENSOR l
The signals from the sensors are input directly to the monitor panel. One of the contact points of the sensors with contacts is always connected to the chassis GND. Classification indication
of
Type of sensor Coolant
CHECK MONITOR GROUP
Engine
level oil level
Hydraulic Engine
CAUTION
Coolant GAUGEGROUP
1. COOLANT
oil level oil pressure temperature
Fuel level
Sensing
type
Normal
Abnormal
Contact
type
ON (close)
OFF (open)
ON (close)
OFF (open)
Electrostatic capacity method Contact
type
ON (close)
OFF (open)
Contact
type
OFF (open)
ON (close)
Resistance
type
Resistance
type
LEVEL SENSOR PC4OOLC
PC3OOLC
Composition
of circuit
0 0 X08CD044
1. Sub-tank 2. Float 3. Sensor 4. Connector
1O-158
205FO5166
1. 2.
3. 4.
Connector Plug Switch Float
2. ENGINE
OIL LEVEL SENSOR
J-1
t+ BATTERY)
1. Coil 2. Plug 3. Connector
l_I_rTE1 IO-32v
0 CSIGNALI
A (TEST1
3. HYDRAULIC
OIL LEVEL SENSOR
1. 2. 3. 4.
Connector Bracket Float Switch
&-=+ Composition of circuit 205F05167A
IO-159
4. ENGINE
OIL PRESSURE
SENSOR
1. Plug 2. Connector
5. COOLANT
TEMPERATURE
1
IO-160
SENSOR
2
3
1. Thermistor 2. Plug 3. Connector
6. FUEL LEVEL SENSOR
1. Float 2. Connector 3. Cover 4. Variable resistance
2------E pJ
P
FEy Composition of circuit
Section A - A 205FO5171
lo-161
IO-162
20 TESTING
TABLE OF JUDGEMENT STANDARD TOOLS
AND ADJUSTING
STANDARD
VALUE TABLE
FOR TESTING,
VALUE
......................................
FOR ELECTRICAL
ADJUSTING
SYSTEM
...............................
AND TROUBLESHOOTING
ADJUSTING
TRAVEL
OF GOVERNOR
MOTOR
ADJUSTING
ENGINE
SPEED SENSOR
LEVER
20-2 20-27
.........................
20-39
...............................
20-40
..........................................
20-41
TESTING AND ADJUSTING HYDRAULIC PRESSURE IN WORK EQUIPMENT, ................................................ SWING AND TRAVEL CIRCUIT
20-42
............................
20-45
TESTING
AND ADJUSTING
CHARGING
PUMP PRESSURE
TESTING
AND ADJUSTING
MAIN PUMP CONTROL
TESTING
AND ADJUSTING
TRAVEL
STROKE
OF SERVO PISTON
MEASURING
OUTPUT
PRESSURE
ADJUSTING TESTING
PPC SHUTTLE
MEASURING TESTING
SOLENOID
LOCATIONS
BLEEDING RELEASING
A A A
WORK EQUIPMENT
AIR
VALVE
20-54
.......................................
20-57
..................................
OF PPC VALVE
AND SWING PPC VALVE
20-58
............................
20-59
...............................................
VALVE OUTLET CAUSING
20-47
...................................
DEVIATION
MEASURING
........................
PRESSURE
20-60 ...........................
PORT PRESSURE
HYDRAULIC
DRIFT OF WORK EQUIPMENT
20-61 ...............
..20-6
.........................................................
REMAINING
PRESSURE
IN HYDRAULIC
Before performing inspection, adjustment check the safety pin and chock. When performing the machine.
joint work,
20-62
CIRCUIT
or faultfinding,
make appropriate
signals
......................... park the machine
and allow
20-66 on level ground
only authorized
personnel
When checking the water level, allow the engine to cool down before removing the radiator to prevent the risk of being scalded by hot water which may spurt out if the engine is hot. Take great care to avoid
getting
caught
in rotating
4
and
near
cap
parts such as the fan, etc.
A
20-I
TABLE OF JUDGEMENT l
STANDARD
VALUE
FOR ENGINE Machine
Model
KDC 614TA
Engine
Item
Engine speed
Measurement conditions
Unit
Standard valve
High idling Low idling Rated speed
vm wm vm
2225 240 750 250 2000
At sudden *
Exhaust
f
Bosch index
Oil pressure
CUM LTAlO
f
‘ermissible value
__ __ __
Standard value 2200 250 750 250 2000
Permissible value
__ __
__
__
__
__
__
__
-_
__
At high idling
Bosch index
Intake valve
mm
0.30
__
0.36
__
mm
0.61
__
0.69
__
__
__
Exhaust
valve
(Coolant temperature: Operating range) At high idling
Blowby pressure (SAE oil)
*
acceleration
gas color
* Valve clearance (normal temperature)
PC4OOLC
PC3OOLC
mmH20
(Coolant temperature: Operating range) 4t rated speed (15W-40)
3.5
2.1
3.5
2.1
2.1
0.7
2.1
0.7
_-
__
kg/cm2 At low idling
*
Whole speed range (inside oil pan)
Oil temperature
*
(15W-40)
‘C
B.T.D.C.
Fuel injection timing
__
__
22”
__
Alternator *
Using
Belt tension
gauge (ST-l 293)
t
*
Refer to Engine
20-2
Service
Manual.
Between fan and water pump
kg
-_
__
__
__
.
FOR CHASSIS
*
The standard values and permissible operation) and H mode.
(PC3OOLC) values shown in this table are all values for H.0 (heavy-duty
T
Mac hi ne model
Classifi cation
I
Item
At l-pump
relief
Measurement
conditions
Pc3ooLc
Unit
Standard value
Permissible value
2,100 f 100
-
I . Hydraulic oil temperature: 45 _ 55°C . Engine oil pressure: Within operating range
Speed when autodeceleration is actuated
. Fuel
control dial at MAX. Control lever at neutral
1,4QO* 120
Boom-Lo control valve
P
a
b
b
a
Boom-Hi control valve
Arm-Lo
Arm-Hi
control valve
mm
control valve
1 f 0.
5 11 f 0.5
202F2302
Travel control valve
Boom control
Arm control
. Center of lever knob . Read max. value to end . Engine stopped . Except for neutral play
lever
lever
Bucket control
65?10
Max. 75 Min. 55
65+10
Max. 75 Min. 55
65~10
Max. 75 Min. 55
65+10
Max. 75 Min. 55
110f11
Max. 121 Min. 99
Max. 15
Max. 20
2.3tO.3
Max. 3.1
1.ato.3
Max. 2.6
1.8tO.3
Max. 2.6
2.3tO.4
Max. 3.1
Lever
3.0 f 0.75
Max. 4.8
Pedal
8.4 f 2.1
Max. 13.4
of travel
lever mm
Play of travel lever
I Boom control
lever
Engine at high idling 1 _. Oil temperature: 45-55°C
. Fit .
Swing control
lever
Travel control
lever
push-pull scale to center of control lever knob to measure Measure max. value to end of
I
20-3
I
Machine Classification
I
model
Measurement
Unit
conditions
PC3OOLC Standard
value
325? 10
Arm
t350::3 Oil temperature: 45-55’C Relief pressure with engine at high idling. H.O. and H mode ( ): When using power maximizing (reference) At outlet of pump Oil pressure when travel is relieved on one side.
Bucket
285 +I;
Swing
Max. 345 Min. 310
Max.38 ( Min.335 4
Max. 310 Min. 258
Max. 370 Min. 335
Travel
Charging
I
Permissible value
pump
Control neutral
TVC valve output pressure
Oil temperature: 45-55°C Engine at high H.O. and H mode
lever at
l-pump relief [2-pump average oil pressure]
I
--pt+p2_
32;;
Max. 38 Min. 28
2621
18 -
1921
Max. 20 Min. 17
rg/cm2
2
o-5
CO*NC valve output pressure
Oil temperature 4555°C Engine at high idling H.O. and H mode Measure at NC valve outlet port
38
0 -
5.5
full track rotat18 -
38
17 -
38
valve both not
o-5
0 -
5.5
valve not actuated] Lever at
-F
Jet sensor differential pressure
20-4
neutral
Lever at end of travel
Oil temperature: 4555°C Engine at high idling Control lever at neutral Oil temperature: 45-55’C Engine at high idling Control lever at end of travel (Pump discharge pressure as desired)
Max. 24 Min. 18
21*3
0 -
2.5
0 -
2.5
r
Machine model
Classifi cati on
Measurement Working equipment
Swing brake angle
Unit
Standard value
Permissible value
Max. reach
2cQF2323 Deg. at high idling mm) Hydraulic oil temperature: 45 - 55’C ‘Stop after swinging one turn and measure distance that swing circle moves ( I: Distance of movement on outside circumference of swins circle
. Engine
Work equipment
Time taken to start swing
conditions
Pc3ool_c
Max. reach
Max. 78
Max. 88
3.4 + 0.3
Max. 4.0
5.0 f 0.5
Max. 6.0
30 * 2
Max. 36
1
sec. . Engine at high idling . Hydraulic oil temperature: 45 - 55°C H.0 and H mode Time taken from starting position to swing 90’ and 180” Work equipment posture
180’
Max. reach
sec.
Time taken to swing . Engine at high idling 202F2323 . Hydraulic oil temperature: 45 - 55Oc H.0 and H mode Swing one turn, and measure time taken to swina next 5 turns
Hydraulic swing
drift of
* Engine stopped Hydraulic oil temperature:
-
mm
0
llmin
Max. 5
0
45 - 55Oc - Set machine on 15’ slope, and set upper structure at 90° to the side. * Make match marks on swing circle outer race and track frame. - Measure distance that match marks move apart after 5 minutes.
Leakage from swing motor
* Engine at * Hydraulic *
high idling oil temperature: 45 - 55Oc Swing lock switch ON Relieve swing circuit.
Max. 10
20-5
PC300LC
Machine model
Classifications
Measurement
Item
Unit
conditions
Standard
value
Permissible value
PC3OOLC
PC300
PC3OOLC
PC300
50.6 f 3
53.8 k 3
Max. 56.6 Vlin. 47.6
Max. 59.8 Min. 50.8
31.3 * 2.
33.3 * 2
Max. 35.3 Min. 29.3
Max. 37.3 Min. 31.3
Lo
21.2 f 2
Max. 25.2 Min. 19.2
Max. 25.2 Min. 19.2
Hi
13.1 It 2
Max. 17.1 Min. 11.1
Max. 17.1 Min. 11 .l
Lo
Travel speed (1) Engine at high idling Hydraulic oil temperature: 45-555°c H.0 and H mode Raise track on one side at a time, rotate one turn, then measure time taken for next 5 turns.
Hi
205F2409
Travel speed (2)
-
. Engine at high idling . Hydraulic oil temperature: 45 - 55Oc . H.O and H mode . Run up for at least 10 m, and measure time taken to travel next 20 m on flat around.
205F2409
Travel deviation
. Engine at high idling . Hydraulic oil temperature: 45-555=c Run up for at leats lOm, and measure deviation when traveling next 20 m on flat ground. * Use a hard horizontal surface
I
20 m
205F240:
t Measure dimension
20-6
x
mm
Max. 200
Max. 220
Machine
Classifi cation
PC3OOLC _~
model
Unit
Standard value
Permissible value
mm
0
0
Urnin
Max. 20
Max. 40
Total work equipment (hydraulic drift at tip of bucket teeth)
Max. 450
Max. 675
Boom cylinder (amount of retraction of cylinder)
Max. 25
Max. 38
Max. 135
Max. 203
Max. 20
Max. 30
Item
Hydraulic travel
drift of . Engine stopped . Hydraulic oil temperature: 45-555Oc . Stop machine on 12’ slope with sprocket facing straight up the slope. Measure the distance the machine moves in 5 minutes.
Leakage of travel motor
Lock’pin F20703008
* Engine at high idling - Hydraulic oil temperature: 45-555Oc * Lock shoes and relieve travel circuit.
Work equipment
Arm cylinder (amount of extension of cylinder)
Bucket cylinder (amount of retraction of cylinder)
posture
Place in above posture and measure extension or retraction of cylinder and downward movement at tip of bucket teeth. . Bucket: Rated load . Horizontal,flat ground . Levers at neutral . Engine stopped Hydraulic oil temperature: 45 - 55Oc . Start measuring immediately after setting. . Measure hydraulic drift for each 5 minutes, and judge from results for 15 minutes.
mm
20-7
PCBOOLC
Machine model
Classificati on
r
Item
Measurement
conditions
Jn it
Boom Bucket teeth in contact with ground
cylinder fully ?xtended
. Engine at high idling . Hydraulic oil temperature: 45-55Oc . H.0 and H mode
Arm Cylinder fully retracted
fully extended
Standard value
Permissible value
3.5 f 0.4
Max. 4.3
3.1 f 0.3
Max. 3.7
4.1 f 0.4
Max. 4.9
3.1 f 0.3
Max. 3.8
4.8 i 0.5
Max. 5.8
2.8 f 0.3
Max. 3.4
205F2422 .
.
Engine at high idling Hydraulic oil temperature:
45-555Oc . H.O and H mode
But ket Cylinder fully retracted
fully extended
Sec.
.
.
Engine at high idling Hydraulic oil temperature:
45 - 5!.Fc . H.0 and H mode
Boom
Max: 3.0
. Lower
bucket to ground and measure time taken for chassis to rise from ground . Engine: Low idling . Hydraulic oil temperature: 45-55Oc
Arm
Max. 3.0
. Amount of time when arm stops for a moment. . Engine: Low idling . Hydraulic oil temperature: 45-555Oc
20-8
-
PCBOOLC ._
Machine modal
Classif cation
Item
Measurement
conditions
Bucket
Permissible value
Unit
Stand value
Sec.
Max. 3.0
-
Max. 4.5
Max. 20
Max. 10
Max. 50
Max. 400
Max. 440
Min. 90
Min. 82
Amount of time when bucket stops for a moment. Engine: Low idling Hydraulic oil temperature: 45 - 55Oc
Cylinders
Center swivel joint
. Hydraulic oil temperature: 4555Oc . Engine at high idling Relieve circuit to be measured
c/mir
. Engine at high idling Hydraulic oil temperature: 4555°C * Use a hard horizontal surface.
20 m Travel deviation (travel and work equipment)
mm
205F2402
* Measure dimension x
. Hydraulic
Charging pump
oil temperature:
4555°C . Measure with engine running at rated speed. . At relief valve set pressure (32 kgfcm’ )
Simir
i Piston pump
See next page
See next page
20-9
Classification
Discharge
volume of PC3OOLC main piston pump (H mode)
300
200
100
L
(1
Pump discharge pressure
=
PI + P2 7
(kg/cm’
)
L
Pum’p rated speed:
Check point
1,950
rpm
Discharge pressure of test pump (kg/cm’)
Discharge pressure of other pump
*
*
20-I 0
PI
(kg/cm*)
(kg/cm*)
P*
Standard value for discharge amount Q (Q/min)
Average Pressure
I As desired
205FO5644A
Q (Q/min)
I
I PI + P,
Judgement standard value
See graph
See graph (Lower limit)
Bring discharge pressure P, and P, for the pump as close as possible to the average pressure when measuring. The error is greatest around the area where the graph bends, so avoid measuring at these ponts. When measuring with the pump mounted on the machine, if it is not possible to set the engine to the specified speed with the fuel control dial, use the engine speed and pump discharge amount as a base to calculate the pump discharge amount at the specified speed.
Classification
Dischargevolume of PC3OOLCmain piston pump (S mode)
200
I
Lower limit
200
Pump discharge pressure
300
=
Pl + P2 7
4
^.
tkg/cm’ 1
205F05645A
L
Pump rated speed:
1,950
rpm
Discharge pressure of test pump
Check point
Discharge pressure of other pump
(kg/cm’ ) I
As desired
*
*
(kg/cm’
PI
)
(kg/cm’) I
I
P,
Standard value for discharge amount Cl (Q/min)
Average Pressure
Cl (Q/min) I
I
PI + P* 2
Judgement standard value
See graph
See graph (Lower limit)
Bring discharge pressure P, and P2 for the pump as close as possible to the average pressure when measuring. The error is greatest around the area where the graph bends, so avoid measuring at these ponts. When measuring with the pump mounted on the machine, if it is not possible to set the engine to the specified speed with the fuel control dial, use the engine speed and pump discharge amount as a base to calculate the pump discharge amount at the specified speed.
20-11
cation
Dischargevolume of PC3OOLCmain piston pump (L mode)
Pl + P2 (kg/cm’ Pump discharge pressure = 2
Pump rated speed:
1,950
I Discharge pressure of test pump
(kg/cm’) As desired
*
*
PI
205F05742A
rpm
I Check point
)
I
I Discharge pressure of other pump (kg/cm’ P,
)
Average Pressure (kg/cm* P, + P, 2
)
I Standard value for discharge amount Q (Urnin)
Judgement standard value
See graph
See graph (Lower limit)
Bring discharge pressure P, and P2 for the pump as close as possible to the average pressure when measuring. The error is greatest around the area where the graph bends, so avoid measuring at these ponts. When measuring with the pump mounted on the machine, if it is not possible to set the engine to the specified speed with the fuel control dial, use the engine speed and pump discharge amount as a base to calculate the pump discharge amount at the specified speed.
20-12
Q’(Umin)
TABLE OF SPEEDS FOR S, L MODES *
The values in this table are reference values for the speed of the work equipment,
swing, and travel
when switching from H.0 and H mode to other modes
Classification
Item
Measurement
PC3OOLC
Unit
condition
3.O+SjF.O+SIL.O+L
ii
Boom (Bucket teeth in contact with ground * cylinder fully extended)
. Measure full stroke for each cylinder (for boom only, measure time taken to lower to the ground) . Set the machine on a flat horizontal surface. No load in bucket . Engineat high idling . Hydraulic oil temperature: 45-55Oc . When measuring boom: arm, bucketcylinders fully retracted, When measuring arm: top surface of boom horizontal bucket cylinder fully retaracted When measuring bucket: top surface of boom horizontal, arm cylinder fully retracted
Arm (Cylinder fully retracted cf fully extended)
Bucket (Cylinder fully retracted + fully extended)
.-F
m
;
J
-
z SW.
4.5 f 0.5
I 8.0
I
f 0.8
* 0.3 3.4 4.9 zt 0.5
. No load in bucket one turn, then measure time taken to swing next two turns.
. Swing
. Engine at high idling Hydraulic oil temperature: 45 - 55Oc Raise track on oneside at a time, rotate one turn, then measure time taken to rotate the next two turns.
l
10.0 i 1.0
I
I
I
3.4 + 0.3
1
3.7 f 0.4
I
I I 4.9
6.2 * 0.6
rt 0.5
2.9
Time taken to swing
Travel speed
3 -a:
Sec.
Lo
* 0.3 2.9
f 0.3
3.0 * 0.3
I I
13.3 * 0.7
I 13.3 * 0.7
I 16.7 f 0.8
23.6 f 1.2
I
I
Sec.
I
14.9 * 0.7
Hi
23.6 * 1.2
29.3 * 1.5
I
I I 14.9
f 0.7
18.8 f 0.9
Amount of deviation when traveling 20 m as shown below Us a hard horizontal surface.
mm
Travel deviation
Max. 200
205F2402
l
Measure dimension x
20-I 3
20-14
l
_*
For Chassis
PC4OOLC
The standard values and permissible operation)
values shown in this table are all values
and H mode.
T
Machine model
Classifi. cation
Measurement
Item
At l-pump
Unit
Hydraulic oil temperature: 45 - 55°C Engine oil pressure: Within operating range . Coolant temperature: Within opkrating range . l-pump relief: Bucket relief 2-pump relief: Arm relief
relief
Speed when autodeceleration is actuated Boom-Lo valve
conditions
control
Arm-Hi
control valve
_
. Fuel
control dial at MAX. Control lever at neutral
b
valve
mm
-
11
io.
valve 202F2302
. Center of lever knob Read max. value to end of travel . Engine stopped Except for neutral play
lever
II * 0.5
t-l!2
65+10
lever
b
a
1
A_-
Travel control valve
lever
1,600 + li0
1,600 t 120
Swing control valve
Bucket control
2,100 It 100
I
Arm-Lo
Arm control
Permissible value
P
Boom-Hi control valve
Boom control
Standard value
rpm
control
Bucket control
PC4OOLC
.
relief
At 2-pump
i
for H.0 (heavy-duty
11 * 0.5 11 i 0.5
Max. 75 Min. 55
65+10
Max. 75 Min. 55
65110
Max. 75 Min. 55
mm Swing control
lever
65210
Max. 75 Min. 55
Travel control
lever
120t11
Max. 131 Min. 109
Max. 15
Max. 20
2.3 k 0.6
Max. 3.8
1.8 f 0.5
Max. 3.0
1.8 -I 0.5
Max. 3.0
2.3 jz 0.6
Max. 3.8
Lever
3.0
Max. 4.8
Pedal
a.4 i 2.1
Max. 13.4
Play of travel lever
I
BY/*l/yntroll trave’
Measure max. value to end of
Swing control
lever
Travel control
lever
I
20-15 0
r
Machine lassification
model
Measurement
Item
Unit
conditions
Standard
value
3255 10
Arm
Bucket
Swing
275 +A;
Max. 300 Min. 249
Max. 370 Min. 325
Travel
Charging
Max. 345 Min. 310
Max.37 ( Min.3354
(35C$)
Oil temperature: 45-55°C Relief pressure with engine at high idling. (Relieve only circuit to be measured) H.O. and H mode ( ): When using power maximizing (reference) At outlet of pump Oil pressure when travel is relieved on one side.
value
pump
Control neutral
Oil temperature: 45-55’ c Engine at high H.O. and H mode
TVC valve output pressure
lever at
l-pump relief [2-pump average oil pressu re] 4%
_
32:
Max. 38 Min. 28
27~1
18 -
2021
Max. 21 Min. 18
38
rg/cm2
2 170-180 kg/cm2 -.
.
CO* NC valve output pressure
Oil temoerature 45-55+ Engine at high idling H.O. and H mode Measure at NC valve outlet port
IControl lever a+ neutral [CO valve not actuated, NC valve actuated: Travel lever at full track rotating freely [CO valve, NC valve both not Iactuated]
0 -
o-5
18 -
38
17 -
0 -
o-5
5.5
38
5.5
valve not actu-
. . . differential pressure
20-16
. . .
Oil temperature: 45-55’C Engine at high idling Control lever at neutral Oil temperature: 45-55°C Engine at high idling Control lever at end of travel (Pump discharge pressure as desired)
2123
0 -
2.5
Max. 24 Min. 18
0 -
2.5
PC4OOLC
Machine model
Classifi cation
Item
Measurement Working equipment
Swing brake angle
conditions
Standard value
Permissible value
Deg. (mm)
Max. 90
Max. 120
3.6 i 0.4
Max. 4.4
5.3 * 0.5
Max. 6.3
sec.
32 rt 2
Max. 38
mm
0
Qlmir
Max. 5
Max. reach
. Engine at high idling . Hydraulic oil temperature: 45 - 55’C Stop after swinging one turn and measure distance that swing circle moves ( 1: Distance of movement on outside circumference of swing circle work equipment
Unit
Max. reach
90”
Time taken to start swing
sec. . Engine at high idling . Hydraulic oil temperature: 4555Oc . H.0 and H mode . Time taken from starting position to swing 90’ and 180’ Work equipment posture
180”
Max. reach
Time taken to swing Engine at high idling 202F2323 Hydraulic oil temperature: 45 - 55°C . H.0 and H mode Swing one turn, and measure time taken to swing next 5 turns
‘4’
Hydraulic swing
drift of
Leakage from swing motor
F20703006
* Engine stopped + Hydraulic oil temperature: 45-555Oc + Setmachine on 15’ slope, and set upper structure at 90” to the side. * Make match marks on swing circle outer race and track frame. * Measure distance that match - marks move apart after 5 minutes.
*
Engine at high idling Hydraulic oil temperature: 45 - 55°C - Swing lock switch ON 1 Relieve swing circuit.
Max. 10
20-17
T
Machine model
Classifications
Measurement
Item
conditions
Unit
PC400LC
Standard
PC400
3
65.2 k 3
Max. 67.5 Min. 58.5
Max. 71.2 Min. 62.2
Hi
34.6 zt 2
36.8 f 2
Max. 38.6 Min. 32.6
Max. 40.8 Min. 34.8
Lo
23.2 * 2
23.2 k 2
Max. 27.2 Min. 21.2
Max. 27.2 Min. 21.2
Max. 17.1 Min. 11.1
Max. 17.1 Min. 11.1
Lo
Travel speed (I)
61.5rt
PC4OOLC
sec. Engine at high idling . Hydraulic oil temperature: 45 - 5!i”c H.0 and H mode Raise track on one side at a time, rotate one turn, then measure time taken for next 5 turns.
sec.
-
Travel speed (2) . Engine at high idling . Hydraulic oil temperature: 45 - 55Oc H.0 and H mode . Run up for at least IO m, and measure time taken to travel next 20 m on flat ground.
Hi
. Engine at high idling . Hydraulic oil temperature: 45 - 55Oc . Run up for at leats IOm, and measure deviation when traveling next 20 m on flat ground. * Use a hard horizontal surface
205F2402 l
20-18
Permissible value
PC4OOLC
PC400
Travel deviation
value
Measure dimension x
13.1 f 2
mm
13.1 * 2
Max. 200
Max. 220
Machine
Classifi cation
PC4OOLC
model
Item
Hydraulic travel
drift of
Unit
Standard value
mm
0
0
Zlmir
Max. 20
Max. 40
Max. 600
Max. 900
Max. 25
Max. 38
Max. 85
Max. 128
Max. 30
Max. 45
Permissible value
. Engine stopped . Hydraulic oil temperature: 45-55°C . Stop machine on 12’ slope with sprocket facing straight up the slope. . Measure the distance the machine moves in 5 minutes.
Leakage of travel motor
Lock/pin F20703008
* Engine at high idling . Hydraulic oil temperature: 45-55°C . Lock shoes and relieve travel circuit.
Work equipment
posture
Total work equipment (hydraulic drift at tip of bucket teeth)
Boom cylinder (amount of retraction of cylinder)
Arm cylinder (amount of extension of cylinder)
Bucket cylinder (amount of retraction of cylinder)
200F1001
Place in above posture and measure extension or retraction of cylinder and downward movement at tip of bucket teeth. Bucket: Rated load Horizontal, flat ground Levers at neutral Engine stopped Hydraulic oil temperature: 4555°C Start measuring immediately after setting. Measure hydraulic drift for each 5 minutes, and judge from results for 15 minutes.
mm
20-I 9
PC4OOLC
Machine model
T
Classification
Measurement
conditions
Jn it
Boom Bucket teeth in contact with ground
Standard value
Permissible value
3.8 i 0.4
Max. 4.6
3.1 * 0.3
Max. 3.7
4.8 + 0.5
Max. 5.8
3.9 * 0.4
Max. 4.7
4.8 f 0.5
Max. 5.8
2.9 f 0.3
Max. 3.5
s :ylinder fully extended
. Engine at high idling . Hydraulic oil temperature: 455!i”c . H.0 and H mode
Arm Cylinder fully .etracted $ ‘ully extended
. Engine at . Hydraulic
high idling 205F2422 oil temperature:
4555°C H.0 and H mode
But ket Cylinder fully retracted
SW.
5 fully extended
Engine at high idling Hydraulic oil temperature: 45 - 55Oc . H.0 and H mode
.
.
Boom
Max. 3.0
-
. Lower bucket to ground and measure time taken for chassis to rise from ground . Engine: Low idling . Hydraulic oil temperature: 45 - 55Oc
Max. 3.0
. Amount of time when arm stops for a moment. f Engine: Low idling . Hydraulic oil temperature: 45-555°C
20-20
-
Machine model
Classif cation!
PC4OOLC
Measurement
Item
conditions
Bucket
Unit
Stand value
Sec.
Max. 3.0
Permissible value
-
Amount of time when bucket stops for a moment. . Engine: Low idling . Hydraulic oil temperature: 45-55°C
Cylinders
Center swivel joint
Hydraulic oil temperature: 45-55Oc . Engine at high idling Relieve circuit to be measured
Max. 4.5
Max. 20
Max. 10
Max. 50
Max. 400
Max. 440
Min. 90
Min. 82
c/min
. Engine at high idling oil temperature: 45-55°C * Use a hard horizontal surface.
. Hydraulic
I
20 m
Travel deviation (travel and work equipment)
mm
205F2402
* Measure dimension x
Charging pump
Piston pump
. Hydraulic oil temperature: 45-55OC . Measure with engine running at rated speed. . At relief valve set pressure (32 kg/cm’ )
See next page
Qimin
See next page
20-21
Classification
Dischaige
volume
of PC4OOLC main piston pump
(H mode)
/ Lower limit
Pump discharge pressure =
Pump rated speed:
Check point
2,000
As desired
Sr
tr
20-22
P,
)
::::;; ,. ,.,.II ::..
(kg/cm’
)
rpm
Discharge pressure of test pump (kg/cm*
PI + P2 2
\
Discharge pressure of other pump (kg/cm’)
P*
Average Pressure (kg/cm*) PI + P, 2
Standard value for discharge amount Q (Q/min) See graph
Judgement standard value Q (Q/min) See graph (Lower limit)
discharge pressure P, and Pz for the pump as close as possible to the average pressure when measuring. The error is greatest around the area where the graph bends, so avoid measuring at these ponts. When measuring with the pump mounted on the machine, if it is not possible to set the engine to the specified speed with the fuel control dial, use the engine speed and pump discharge -amount as a base to calculate the pump discharge amount at the specified speed. Bring
’
Classification
Dischargevolume of PC4CKrLC main piston pump (S mode)
300
Pump discharge pressure
Pump rated speed:
2,000
I Discharge pressure of test pump (kg/cm’
As desired
*
*
P,
)
Pl + P2 2
(kg/cm’
)
205F05647A
rpm
I Check point
=
I Discharge pressure of other pump (kg/cm’
P*
1
I Average Pressure (kg/cm’ P, + P, 2
)
I Standard value for discharge amount Q (Qlmin) See graph
Judgement standard value Q (Q/min) See graph (Lower limit)
Bring discharge pressure P, and P, for the pump as close as possible to the average pressure when measuring. The error is greatest around the area where the graph bends, so avoid measuring at these ponts. When measuring with the pump mounted on the machine, if it is not possible to set the engine to the specified speed with the fuel control dial, use the engine speed and pump discharge amount as a base to calculate the pump discharge amount at the specified speed.
20-23
Clanification
Dischargevolume of PC4OOLC main pi&n pump
iL mode)
I-
I
1 Pl + P2 Pump discharge pressure = (kg/cm*) 2
Pump rated speed: 2,000
Check point
As desired
*
t
20-24
rpm
Discharge pressure of test pump
Discharge pressure of other pump
(kg/cm’)
(kg/cm*)
1 1
PI
205F05648A
j 1
P,
Standard value for discharge amount Q (Qlmin)
Average Pressure (kg/cm’ 1 I
p,
) j
L
1
See graph
Judgement standard value
Q’ Wmin) See graph (Lower limit)
Bring discharge pressure P, and P2 for the pump as close as possible to the average pressure when measuring. The error is greatest around the area where the graph bends, so avoid measuring at these ponts. When measuring with the pump mounted on the machine, if it is not possible to set the engine to the specified speed with the fuel control dial, use the engine speed and pump discharge amount as a base to calculate the pump discharge amount at the specified speed.
TABLE *
OF SPEEDS
FOR S, L MODES
The values in this table are reference values for the speed of the work equipment, when switching from H.0 and H mode to other modes
Classification
Measurement
PC400LC
Unit
condition
swing, and travel
w
Boom (Bucket teeth in contact with ground *cylinder fully extended)
Arm (Cylinder fully retracted * fully extended)
Bucket (Cylinder fully retracted + fully extended)
. Measure full stroke for each cylinder (for boom only, measure time taken to lower to the ground) . Set the machine on a flat horizontal surface. . No load in bucket . Engine at high idling Hydraulic oil temperature: 45 - 55°C . When measuring boom: arm, bucket cylinders fully retracted . When measuring arm: top surface of boom horizontal bucket cylinder fully retaracted When measuring bucket: top surface of boom horizontal, arm cylinder fully retracted
3.2 2 0.3
I
3.2 * 0.3
I z SW.
* 0.4 4.1
* 0.3 3.1
I
I
4.1 * 0.4
II
I
. Engine at high idling oil temperature: 45 - 55Oc Raise track on one side at a time, rotate one turn, then measure time taken to rotate the next two turns.
. Hydraulic Travel speed
Sec.
14.6 * 0.7
4.4 * 0.4
II
3.1 f 0.3
I Time taken to swing
3.4 * 0.4
5.4 I 9.7 I 12.7 f 0.5 * 1.0 * 1.3 1
. No load in bucket Swing one turn, then measure time taken to swing next two turns.
I
I
3.7 * 0.4
I 14.6 * 0.7
18.4 f 0.9
LO
Sec. Hi
. Amount of deviation when traveling 20 m as shown below * Us a hard horizontal surface.
I
20 m mm
Travel deviation
Max. 200
ZOSF2402
* Measure dimension x
20-25
20-26
STANDARD *Note
1:
VALUE TABLE FOR ELECTRICAL
(Male)
and
(Female)
in the
Connector
No. column
SYSTEM indicates
the mating
at the terminal
(pin). (For details, see CONNECTION TABLE FOR CONNECTORS). 2: The figure in ( ) in the Judgement table column indicates the pin number.
Classiflication!
I
Connector
Measurement
No.
Judgement
table
conditions
If the condition is as shown in the table below, it is normal
Fuel control
dial
1) Turn starting switch OFF.
Between
(1)
-
(2)
I
0.25 - 7kCl
I
Between
(2) -
(3)
j
0.25-7kS2
1
Between
(1)
-
(3)
I
4-6K2
1) Turn starting switch OFF. 2)
Between
(1)
-
(2)
I
0.25 - 7kR
I
Between
(2) -
(3)
I
0.25 - 7kR
I
Between
(1)
-
(3)
I
Disconnect connector.
E4 (Male)
4-6162
I
If the condition is as shown in the table below, it is normal
Motor
Disconnect connector.
I
If the condition is as shown in the table below, it is normal
Potentiometer
2)
E6 (Male)
1) Turn starting switch OFF
Between
(1)
-
(2)
4-9A-2
Between
(3) -
(4)
4-9R
Between
(1)
-
(3)
E5 (Male)
I
No continuity
(1) - chassis
No continuity
(3) - chassis
No continuity
2)
I
1) Turn starting switch ON.
If the condition is as shown in the table below, it is normal
2)
Power source voltage
Disconnect connector
Between
(1) -
(12)
20 - 3ov
Between
(2) -
(121
20 - 3ov
Insert T-adapter.
1) Turn starting switch ON. 2) Fuel control dial (Throttle
Insert T-adapter.
signal) El
If the condition is as shown in the table below, it. is normal
1) Turn starting switch ON. 2)
Governor Potentiometer
Insert T-adapter.
)I
Between
(6) -
(16)
4.75 - 5.25V
20-27
CliaSifi cations
Connector
Component
Judgment table
No.
conditions
If the condition is as shown in the taba below, it is normal
No. 2 throttle signal
Between
(9) -
(19)
1) Turn starting switch ON. 2)
0.25 - 4.75V
If the condition is as shown in the table below, it is normal
1 ) Turn starting switch ON.
6
2)
If the condition is as shown in the table below, it is normal
1) Turn starting switch ON.
Warming-up signal
2)
Auto-deceleration signal
motor
2)
El Between
(3) -
(14)
2.8 - 6.3V
Between
(4) -
(15)
2.8 - 6.3V
I
2) (13) -
(12)
Insert T-adapter.
Insert Tdapter
1) Turn starting switch ON.
If the condition is as shown in the table below, it is normal Between
Insert T-adapter.
1) Turn starting switch ON.
If the condition is as shown in the table below, it is normal. Governor
Insert T-adapter
20 - 3ov
I
Insert T-adapter
Batterv relay *This is only for 2.5 seconds after turning the starting switch ON + OFF. At other times, it is 0 V. If the condition is as shown in the table below, it is normal Model selection
2) Between (17) - (12)
20-28
1) Turn starting switch OFF. Disconnect connector
Classifi cation
Component
Connector
Judgment
No.
If the condition is as shown table below, it is normal.
Throttle signal (engine throttle controller)
Measurement
table
conditions
in the
1) Turn starting switch ON.
c2 Between
(20) -
(10)
If the condition is as shown table below, it is normal.
Engine speed sensor
E7
-
Between
(1)
(2)
Between
(2) - chassis
2)
0.25 - 4.75
in the
1) Turn starting switch OFF. 500 -
I
Min.
1,ooon
-
(1)
2)
Disconnect connector.
I)
Start
2)
Insert Tadapter.
1MD
Measure at AC range
Between
Insert T-adapter
(2)
engine
1) Screw in speed sensor until it contacts ring gear, then turn back one turn. 2) Work normally adjustment.
after carrying
If the condition is as shown table below, it is normal For boom, Work equipment swing oil pressure switch
.
out above
in the
arm, bucket and swing
1) Start engine. (Charge accumulator) control
2)
Min. 1 MR
(l), (2) - chassis
If the condition is as shown table below, it is normal. For travel control
oil pressure
Between
S4 (Male)
(1)
-
1) Start engine. (Charge accumulator).
lever
Min.
cl),
Max.
C7 (Rear) C8 (Front)
I
Disconnect connector.
1.D
Min. 1 M.Q
(2) - chassis
I
If the condition is as shown in the table below, it is normal. Between
2) 1 Ma
(2) Lever operated
Between
I
in the
Lever at neutral
Pump pressure sensor
Disconnect connector.
Sl (Male)
Between
Travel swicth
levers
(1)
-
(2)
18 - 28V
I
Start engine. Fuel control dial at MAX.
3)
Insert T-adapter.
1
I
1
I
I) 2)
IBetween (,) _ (3)i ,4”,‘:::;:, 1o.5- 1.5v / ARM
IN relief
3.1 - 4.5v
20-29
Inspec-
Classificat ions
Component
Connector
No.
tion method
8 Swing
lock switch
C2 (Female)
5 z ‘E i 2
hdgment
If the condition is as shown table below, it is normal.
Between
(8) -
Measurement conditions
table
1) Turn starting switch OFF.
in the
Switch
OFF
Min. 1 M.Q
Switch
ON
Max. 1 a
2)
(4)
Disconnect connector c2.
z If the condition is as shown table below, it is normal TVC
solenoid
valve
C4 (Male)
k Ei
-
Between
(1)
Between
(2) -chassis
&I =
Swing brake solenoid valve
z E 8
Vl
(Male)
Between
(1) -
Between
(2) - chassis
V2 (Male)
-
Between
(1)
V4 (Male)
Between
(2) - chassis
Between
(1) -
(2)
Between
(2) - chassis
If the condition is as shown table below, it is normal. 2-stage relief solenoid valve
V7 (Male)
-
Between
(1)
Between
(2) -
in the
IO-335.Q Min. 1 Ma
(2)
1
I
in the
(2)
If the condition is as shown table below, it is normal. CO cancel solenoid valve
Min. 1 MS2
(2)
If the condition is as shown table below, it is normal Travel speed solenoid valve
IO-22.D
(2)
If the condition is as shown table below, it is normal.
1) Turn TVC prolix switch OFF. 2) Turn starting switch OFF. 3) Disconnect connector C4.
in the
50 -
1) Turn starting switch OFF. 2) Disconnect connector v2.
looa
Min. 1 Ma
in the
I
50 -
loon
I
Min. lMS1
in the
I
chassis
50 -
100Q
Min. 1MQ
1) Turn starting switch OFF. 2) Disconnect connector Vl .
I
1) Turn starting switch OFF. 2) Disconnect connector v4.
1) Turn starting switch OFF. 2) Disconnect connector v7
I
I If the condition is as shown table below, it is normal. Arm half flow solenoid valve
20-30
V5 (Male)
Between
(1) -
(2)
Between
(2) - chassis
in the
lo-35sL Min.1
Ma
I
1) Turn starting switch OFF. 2) Disconnect connector v5.
Classifi cati ens
aonent
Connector
No.
Measurement conditions
Judgment table
I ) Turn starting switch OFF. !) Insert T-adapter.
If the condition is as shown in the table below, it is normal. Pov\Er source volt age
Between (12).
(13)-(31,
(4)
20 - 3ov
1)
If the condition is as shown in the table below, it is normal.
Turn start, ing switch ON. 2) insert T-adapter.
If the condition is as shown in the table below, it is normal.
1) Turn start. ing switch ON. 2) Insert T-adapter.
Wor king mode swit ch
c2
Between
(8) -
(5)
10 -
13v
Between
(8) -
(6)
10 -
13V
Between
(8) -
(5)
o-
Between
(8) -
(6)
10 -
Between
(8) -
(5)
* 0 -
Between
(8) -
(6)
H mode
Powe r set switch
c2
1v
S mode 13V IV
L mode
1t
10 -
13V when working
o-1v
mode is L.0 mode
If the condition is as shown in the table below, it is normal. Auto- deceleration switct 7
Tr; 3vel speed SWitch
Power switch
I
I
I
I
I
I
/
I
c2
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 below, it is normal.
1) Turn starting switch ON. 2) Insert Tadapter.
c2
c2
1) Turn starting switch ON. 2) Insert Tdadapter.
Switch OFF Switch ON
Between (8) - (12)
20 - 28V o-1v
20-31
Classil cati on
Connector
Component
3001ant temperatun signal (102”C,
Measurement
No.
Adgment
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 below, it is normal.
1) Turn starting switch ON. 2) Insert T-adapter.
If the condition is as shown in the table below, it is normal.
1) Start engine. 2) Insert T-adapter. 3) All levers at neutral
If the condition is as shown in the table below, it is normal.
1) Turn starting switch ON. [Coolant temperature gauge is within green range1 2) Insert T-adapter.
c2
c2
Autodeceleration output signal
c2
Between (21)-(11)
PCBOOLC
H.0 mode or H mode signal
c2
1G.O.
F.O. L.0 and S mode, G.0, F.0 and L mode
L.0 and L mode When coolant temperature is above 10°C
0.75 -
1 .ov
1.23 -
1.53V
/ 1
2.10 -
2.4OV
Swing brake solenoid
Cl
PC4OOLC 0.75 -
1 .ov
I
1
4.0 -
4.25V
If the condition is as shown in the table below, it is normal.
20-32
conditions
107OC)
Model selection
No. 2 throttle
table
,
I 1.35 -
1.65V
2.20 -
2.5OV
4.0 - 4.25V
1) Start engine. 2) Turn swing lock switch OFF. 3) Turn swing lot k prolix switch OFF. 4) Insert T-adapter.
Classif cation
Ispee Component
Connector
No.
1
Iti on lathoc
If the condition is as shown table below, it is normal.
Travel speed solenoid
2-stage relief solenoid
Travel speed switch at Lo
Cl
1) Start engine. 2) Insert Tadapter. 3) Fuel control dial at MAX. 4) Travel on flat ground
o_3”’ r----i 20 - 3ov
K5h)--(m
If the condition is as shown table below, it is normal.
in the
1 ) Turn starting switch ON. 2) Insert T-adapter. 3) H.0 or G.0 mode
If the condition is as shown table below, it is normal.
in the
1) Turn starting switch ON. 2) Insert T-adapter.
Cl
I
I
LI
If the condition is as shown table below, it is normal.
Arm half flow solenoid
in the
Between
/I
I CO cancel solenoid
Measurement conditions
Judgment table
Cl
in the
I
1) Turn starting switch ON. 2) Insert T+dapter.
-
20-33
Classif cation
onnector
CHECK,
CAUTION
group Buzzer signal The voltage for H and L in the table are as follows. %I.
12.
Engine oil pressure signal H: 3.5 - 30V L: Approx. OV Starting signal H:7-30V L: Approx. OV
The starting signal is H once, but after that it becomes L. However, until the starting switch is turned OFF, the starting signal is held in the memory inside the monitor panel as H.
I nspection method
I I
No.
Measurement conditions
Judgment table
If the condition is as shown in Table 1, Table 2, and Table 3, the monitor pa nel is normal. group) Ta ible 1 (CHECK, CAUTION 7
z -1
Monitor auxiliary signal input
itg:_$ior Monitor display
h ii
Zoolant level ‘1 (17)
1
ingine oil eve1 ‘1 (18) iydraulic oil
eve1
I
I
I
(
I
1
L
I
H
/I
L
‘I (IO)
Flasing
Alternator signal H: 2030V L: Max. 5V
%4.
Sensor signal H:3.5-30V L: Approx. OV
‘reheat ‘I (9) Flashing
Iuel level ‘1 (5)
I Flashing Engine oil pressure signal H and starting signal H
cressure
able 2 (Buzzer signal)
-
A
Pl (4) P2 (I),
Open (no connecting (2), (14).
wiring)
(15)
B
Starting switch ON 20 - 3ov
Pl (1) - (3) (+24V input)
Starting switch OFF ov c
PI (II) (Alarm buzzer output) - (3) Disconnect P8 (coolant level sensor) 5 Connect short connector
to P8
Remove connector, and buzzer sounds, or the following cycle is repeated. Over 2OV: 0.8 set 3V: 0.8 set When short connector is connected, buzzer stops or voltage is OV.
20-34
I
OFF
OFF %3.
I) Start engine 2) Insert T-adapter
(
Classil cation
GAUGE group
Connector No.
I nspection
Table 3 (GAUGE
group)
\jjj_\\\
I)
Position of gauge display
Display level resistance (kS1) (Monitor panel input resistance)
Starting switch ON
Starting switch OFF
Measure reslstante between coolant temperature gauge Pl (female) (6) - (3)
Min. -
I I
0.5 -
position
Left
(5) -
(3)
- 4.222
-
I
I
- 6.248
I
5.844
- 7.713
7.086
-
I
Coolant temperature below 102’C Coolant above1020C temperature
9.455
-
10.17
I
Disconnection
17.51
- 27.32
23.52
- 34.07
I
29.98 - 39.55
I I
35.15
1
611.82
-
- 44.38
1
Disconnection
I)
Turn starting switch ON. 2) Insert T-adapter.
is as shown in the table below,
(12) -
(16)
10 -
13V
Between (13) -
(16)
10 -
13V
Between
~ O-1”
~ Between(12)-(16)
/
below 107eC’
Between
(13) -
(16)
10 -
Coolant temperature above 107’C
Between
(12) -
(16)
o-
1v
Between
(13) -
(16)
o-
1v
If the condition it is normal. P2
3.419
3.946 5.092
If the condition it is normal.
signal
I
3.665
4.764
I I I I
t
ride
Warming-up
-
side
Left
P2
3.015
Right
IisIlay losi:ion
Coolant temperature signal
I
3.245
I
I
ride
Turn starting switch OFF, insert dummy resistance, or measure resistance (kn) (Monitor panel input resistance) 2) Turn starting switch ON, and check display. 3) Connect socket.
Max.
0 -0.7
Dis-
plav
Measure resistance between fuel level gauge Pl (female)
Measurement conditions
Judgment table
13V
is as shown in the table below,
Coolant temperature below IO’C Coolant temperature above 50’ C
Between (ll)-(16)
I)
Trun starting switch ON. 2) Insert T-adapter.
Max. 1 V 8-12V
20-35
Classif cation
Connector
No.
If the condition
Working mode switch
Measurement conditions
Judgment table is as shown in the table below.
1) Turn starting switch ON. 2) Insert T-adapter.
is as shown in the table below,
1) Turn starting switch ON. 2) Insert T-adapter.
P2
1 F.0 mode
-1
1 LO mode
-1
If the condition it is normal.
Between
(5) -
(16)
IO-13v
Between
(6) -
(16)
10 -
H mode
Power set switch
P2 Ismode
-1
~ Lmode
-1
l
10 -
13V when working
If the condition it is normal. Auto-deceleration switch
I
P2
Coolant level sensor
I
Between (7) - (16)
1) Turn starting switch ON. 2) Insert T-adapter. 1
Max. 1 V 8-12v
1)
isas shown in the table below,
Turn starting switch ON. 2) Insert T-adapter.
If the condition it is normal.
is as shown in the table below,
1) Turn starting switch OFF. 2) Disconnect connector P8.
P2
P8 (Male)
Coolant level normal
P5 (Male)
Continuity No. continuity
is as shown in the table below,
Engine oil level.normal Engine oil level abnormal
20-36
mode
If the condition it is normal.
If the condition it is normal.
-.
if L.0
1
ON
Coolant level abnormal
Engine oil level sensor
mode
is as shown in the table below,
OFF
Travel speed switch
l3V
Continuity No continuity
1) Turn starting switch OFF. 2) Disconnect connector P5.
Classif cation
Component
Connector NO.
Inspection method
Judgment table
If the condition it is normal.
Hydraulic
oil level sensor
P9 (Male)
isas shown in the table below,
I
Measurement conditions
1)
Turn starting switch OFF. 2) Pisconnect
21
If the condition it is normal.
connector
is as shown in the table below,
1) Turn starting switch OFF 2)
Coolant temperature sensor
P7 (Male)
If the condition it is normal.
pg.
Disconnect connector PJ.
isas shown in the table below,
1) Start engine. 2) Disconnect wiring.
isas shown in the table below,
1)
)
Engine oil pressure sensor
If the condition it is normal. Fuel level sensor
P6 (Male)
Alternator
Between alternator terminal R - chassis
When engine is running (l/2 throttle or above): 27.5 - 29.5V * If the battery is old, or after starting in cold areas, the voltage may not rise for some time.
Turn starting switch OFF. 2) Disconnect connector P6.
1) Start engine.
20-37
20-38
TOOLS FOR TESTING, Check or measurement item
ADJUSTING
Symbol
Part Name
Part Number I
A
799-203-8000
Water and oil temperatures
B
799-l 01-l 500
I I I’I
790-261-l
pressure
I Multitachometer
Digital
Digital temperature gauge
799-l 01-5002
Hydraulic
Remarks
I
speed
Engine
AND TROUBLESHOOTING
Hydraulic Digital
203
tester
hydraulic tester
display: L: 60-2,000 rpm H: 60-19,999 rpm
_50 _ 1 2oooc
Pressure gauge 25, 60, 400, 600 kg/cm2 Pressure
gauge
700 kg/cm2
”
2
.790-261-l
310
*790-261-l
320
Adapter
l790-261-1330 Blow-by
pressure
Valve clearance
Exhaust
799-201-l
504
Blow-by
checker
F
Commercially available
Feeler gauge
Commercially available
Smoke
O-500 mmH20
color
Operating Stroke
E
force
hydraulic
drift
H
1 79A-264-0020
1 Push-pull
I
1 790-301-1410
1
Work equipment speed
J
Pump performance
K
Troubleshooting wiring harness sensors
of and
799-201-l
120
1 790-303-1003
scale
Scale
%x1 /lO
=
1 I
Stop watch 1
Flowmeter
1
799-601-2600
T-adapter
2
799-601-7000
Adapter
kit
I
box assy
L 799-60 l-2730 3
(Discoloration Bosch index)
meter
*Kit Part Number . T-adapter kit 799-60 l-71 00
Adapter 799-601-2740
Troubleshooting of voltage and resistance values
M
79A-264-0210
Tester
20-39
ADJUSTING
TRAVEL OF GOVERNOR
MOTOR LEVER
ADJUSTING
Pc3OOLC 1. Turn the starting switch OFF.
FULL
SPEED
2. Pull out pin (6), then disconnect spring rod (3) from governor motor lever (2). 3. Adjust the length of spring rod (3) and yoke (4) and temporarily assemble so that governor motor lever (1) and governor lever (2) are at the FULL position (stopper position).
ANOE ORlow IYOTOR STOF
PC3OOLC 4. After temporarily assembling, loosen yoke (4) P-turns, then secure it with locknut (5). l
The distance between the pins will increase by 2.5 mm.
Pc4OOLC PC4OOLC 4. After temporarily assembling, tighten yoke (4) 4-turns, then secure it with locknut (5). l
20-40
The distance between the pins will decrease by 5mm.
ADJUSTING
ENGINE
SPEED SENSOR
PC3oOLC
Screw in so that tip of sensor (1) contacts gear (2). 2. When sensor (1) contacts gear (2), turn it back one turn. 3. Tighten locknut (3). * When connecting the wiring, be careful to prevent any excessive force from bearing on the wiring of the sensor. * Be careful not to scratch the top of the sensor or to get any metal powder stuck to it. 1.
OBCDDD27
Pc4OOLC
205FO5661
‘2
Clearance 205FO5222
20-41
TESTING AND ADJUSTING HYDRAULIC PRESSURE EQUIPMENT, SWING AND TRAVEL CIRCUIT
1) *
Measuring Oil temperature
A4Y
S
when
measuring:
IN WORK
45-55°C.
Lower the work equipment to the ground and stop the engine. Operate the control levers several times to release the remaining pressure in the hydraulic piping. Then loosen the oil filler cap slowly to release the pressure inside the hydraulic tank.
Put the safety lock lever in the LOCK position. 1. Remove pressure pick-up plug (1) or (2) (Thread dia. = 1Omm Pitch = 1.25mm) from the circuit to be measured, then install oil pressure gauge Cl (600 kg/cm2). 2. Start the engine, set to the H.O. and H mode and measure the main relief pressure with the engine at high idling. l Condition of actuator to be measured: 0 For the work equipment, set each cylinder to the end of its stroke. ii) For swing, turn the swing lock switch ON. iii) For travel, fit block @ under the track shoe grouser. Or fit block @ between the sprocket and frame to lock the track shoe. Measure one side at a time. Table1
-
‘Y
305FO!i662
1
//
205FO5224
Actuator controlled l l l l l l
2
Rear pump
l l
Arm cylinder Boom cylinder Swing motor* R.H. travel motor Arm cylinder Boom cylinder* Bucket cylinder L.H. travel motor 205F05225
*
The set pressure of safety valve for the boom head end and swing motor is lower than the set pressure of the main relief valve, so be careful.
20-42
FO20705006
2)
Adjusting Main relief valve 1 Adjusting high set pressure: i)
Loosen locknut (4) to adjust. j,
0
*
(3) and
turn
i) ii)
holder
Adjust the holder as follows: To INCREASE pressure, turn CLOCKWISE. To DECREASE pressure, turn COUNTERCLOCKWISE. u Locknut: 11.5+ 1 .O kgm
1
iii-\
2051 :05663
low set pressure: Loosen locknut (5). * Check that elbow (6) moves. Loosen locknut (7) and turn holder (8) to adjust. l To INCREASE pressure, turn CLOCKWISE. l To DECREASE pressure, turn COUNTERCLOCKWISE.
Amount of adjustment for one turn of holder: 128 kg/cm2 w Locknut: 4.5kO.5 kgm Normally, the pressure applied to port PR is approx. 13 kg/cm2 or less and at high set pressure, is approx. 30 kg/cm2.
3
*
Swing
motor safety valve locknut (9) and turn adjustment screw (10) to adjust. * Adjust the adjustment screw as follows. l To INCREASE pressure, turn CLOCKWISE. l To DECREASE pressure, turn COUNTERCLOCKWISE. * Amount of adjustment for one turn of the adjustment screw: 48.6 kg/cm2 u Locknut: 4+1 kgm * After adjusting, repeat the procedure in Step 1 to check again. Adjustment of the safety valve set pressure is only for the swing motor. Do not try to adjust the safety valve set pressure for any other part.
1 Loosen
*
/
When the high set pressure is adjusted, the low set pressure also changes so always adjust the low set pressure also.
2. Adjusting
*
For rear pump
For front pump \
4
PR
7
5
6
8
I
205FO5664
I
R.H. swing
J
L.H. swing
205FO5665
I
9 \
\
/
10 /
205FO5666
20-43
PRECAUTIONS WHEN MEASURING LIC PRESSURE
HYDRAU-
1. Measuring hydraulic pressure under normal operation. Relieve the boom, arm and bucket cylinders when measuring. *
Do not operate
the power
max. switch.
2 Measuring hydraulic pressure when P-stage relief is actuated. Push the power max. switch when measuring. If the power max. switch is pressed, the * CO cancel solenoid valve are actuated. * When the CO valve is canceled, the relief pressure is different when one side is relieved and when both sides are relieved.
Reference Set pressure of safety valve 1. The set pressure of the safety valves in the swing motor and at the boom cylinder head end is lower than the main relief set pressure, so for these two, the safety valve relief pressure is measured. 2. The set pressure of the actuators other than these is higher than the main relief set pressure, so it is impossible to measure them directly. However, it is possible to judge if they are correct or not as follows. l When measuring the main relief pressure at two or more actuators, if any actuator is lower than the main relief pressure, the set pressure of the safety valve for that actuator has dropped. l If all of the actuators have low pressure, the set pressure of the main relief valve has dropped.
Table 2
of safety valves for each
Head end
Set pressure (kg/cm*) 290
Bottom end
365
Head end
365
Arm cylinder
Bottom end
365
Head end
365
Bucket cylinder
Bottom end
365
Actuator
Boom cylinder
Swing motor
I l
20-44
Set pressure actuator.
Travel motor
( ): Value for PC4OOLC
I
275 (260) 335 (355)
I
TESTING
AND ADJUSTING
MEASURING Oil temperature
1. *
when
measuring:
CHARGING
PUMP PRESSURE
4555°C.
1. Remove pressure pick-up plug (1) (Thread dia: 14mm, Pitch: 15mm) and install hydraulic pressure gauge Cl (60 kg/cm2). 2. Start the engine and measure with the engine running at high idling. When measuring for internal leakage from * equipment in the charging circuit, use the parts given below to shut off the following parts of the circuit when measuring the relief pressure. Equipment that can be inspected
No
Selection of hydraulic circuit shut off
1
Piston pump inlet port
Piston pump
2
Charging pump outlet POfl Solenoid valve inlet Port Travel PPC valve inlet POfl L.H. PPC valve inlet POfl R.H. PPC valve inlet Port
Charging pump
3 4 5 6
Solenoid valve Travel ppc va,ve
L.H. PPC valve I
Items No. 2 and below can be checked
*
Items No. 2 and below can be checked if the equipment in the previous number is normal. Use the parts given below to shut off the circuit.
l
For elbow: Sleeve nut: 07221-20315,
-‘---h-t’
R.H. PPC valve
*
*
205FO5667
205FO5668
/
Plug
205FO5669
// 07221-20422,
07221-20520 Plug: 07222-50325,
07222-00414
07222-00515 .
For Plug:
07376-50522
Pump
r-I-l= L
Solenoid
valve
Travel
:@
>a
R.H. PPC valve 5
2
07376-50422,
n T-^-u
I-
-
PPC valve
1
tiharging pump
hose:
07376-50315,
Piston
I
Safety
::
lock
1 L.H. PPC valve
rY?J 205FO5234
20-45
2. ADJUSTING 1. Loosen locknut (2) screw (3) to adjust. *
and
turn
adjustment
Adjust
the adjustment screw as follows. To INCREASE pressure, turn CLOCKWISE. l To DECREASE pressure, turn COUNTERCLOCKWISE. Amount of adjustment for one turn of adjustment screw: 5.4 kg/cm2. l
j, u
Locknut:
6.5rt 1 .O kgm. 205FO5235
*
20-46
After completion of adjustment, repeat the procedure in Step 1 to check the set pressure again.
1
TESTING
1)
AND ADJUSTING
MAIN PUMP CONTROL
PRESSURE
valve output pressure Measuring * Oil temperature when measuring: 45-55°C. * Measure the relief pressure of the charging pump first and check that it is normal.
TVC
*
The TVC valve pump discharge
(Pf+P22
output pressure pressure
average
for the
pressure),
so 205FO5670
before measuring always adjust the main relief pressure to the specified pressure. 1. Remove pressure pick-up plug (1) (Thread dia. = lOmm, Pitch= 1.25mm) and install oil pressure gauge Cl (60 kg/cm2). 2. Set to H.O. and H mode, run the engine at high idling and measure the hydraulic pressure with the control lever at neutral and at pump relief.
[Reference] 1. The average pressure at one pump relief is approx. 175 kg/cm2. (The discharge pressure of the pump being relieved is 325 kg/cm2 and the discharge pressure of the pump not being relieved is approx. 20 kg/cm2.) 2. For the relationship between the change in the TVC valve output pressure and the pump discharge amount, see graphs 1 and 2.
Graph 1
100 Pump
discharge
pressure
200 -”
+ ” 2
300
= Average
pressure
(kg/cm*)
205FO5231
3
Graph 2
\
control
Pump
discharge
V
TVC
valve control
When
CO function
area
pressure
area
is canceled
co valve control area
v
= Average
pressure
(kg/cm*)
205FO5239
20-47
Adjusting *
If the results of the measurements show that the hydraulic pressure is not within the standard, adjust as follows. 1. Loosen locknut (2). 2. Turn adjustment screw (3) to adjust. *
If the adjustment screw is stiff, do not use excessive force. If excessive force is used to then the screw, the tip may break.
screw as follows. 3. Adjust the adjustment 0 To INCREASE pressure, turn CLOCKWISE. l To DECREASE pressure, turn COUNTERCLOCKWISE. Amount of adjustment for one turn of * adjustment screw: Approx. 3.5 kg.cm2. After adjusting with the adjustment screw, * repeat the procedure in measuring to check the output pressure. If the adjustment screw is stiff and excessive * force is used to turn it, the tip may break, so in this case, remove the TVC valve assembly, remove the cover assembly and put lubricant on the screw before trying to move it.
r 3
L
20-48
205FO5241
2)
Output
pressure
of CO valve and NC valve
[Reference] The output pressure of the NC valve controls the discharge amount of the piston pump flowing to the servo valve. The oil flows TVC valve - CO valve - NC valve - servo valve and the output pressure changes as follows according to the movement of the control lever of work equipment. *
*
*
Control levers at neutral. The NC valve is actuated by the differential pressure of the jet sensor and the output pressure drops below 5.5 kg/cm2. When hydraulic cylinder is relieved. The CO valve is actuated and lowers the pressure of the oil entering the NC valve to below 5.5 kg/cm2. The NC valve supplied this pressure as it is to the servo valve. (The pump discharge amount in this case is the minimum.) Work equipment, swing and travel actuated. The output pressure of the TVC valve is not affected by the CO valve and NC valve and is supplied as it is to the servo valve. (The discharge amount of the pump varies between the maximum and the point where the CO valve is actuated.)
205FO567;
,
Measuring Oil temperature when measuring: 45-55°C. l Remove pressure pick-up plug (4) (Thread dia. = 1Omm, Pitch = 1.25mm) and install oil pressure gauge Cl (60 kg/cm2). * This is at the body side of the servo valve. 4 I. Pressure when NC valve is actuated. Set to H.O. and H mode, run the engine at high idling and measure the pressure when all control levers are at neutral. * Turn the auto-deceleration switch OFF. * If the output pressure is more than 5.5 kg/cm2, measure the differential pressure of the jet sensor.
*
20-49
2. Pressure when CO valve is actuated. Run the engine at high idling and measure the hydraulic pressure when any of the boom (except LOWER) arm or bucket are relieved. 3. Pressure when work equipment or swing are actuated.
A
The work equipment is actuated when the pressure is measured, so be careful of the surrounding area. Measure the hydraulic pressure when relieving the swing (F pump) and when rotating the track under no load (F, R pump) at the same time as measuring the output pressure of the TVC valve. *
*
If there is a big difference from the TVC valve output pressure, the operation of the CO valve or NC valve is probably defective. The CO valve is canceled when the travel is operated.
Adjusting 1. CO valve. *
If the set pressure of the CO valve is high, the discharge amount is not reduced when the circuit is relieved, so the relief pressure becomes high. For this reason, always adjust the pressure to the specified pressure. i) Loosen locknut (5) and turn adjustment screw (6) to adjust. Adjust the adjustment screw as * follows. 0
To INCREASE CLOCKWISE.
pressure,
205FO5673
turn
To DECREASE pressure, turn COUNTERCLOCKWISE. Amount of adjustment for one * turn of adjustment screw: 41.25 kg/cm2. If the hydraulic pressure does not * drop even when the adjustment screw is adjusted, there is probably a defect inside the CO valve. After adjusting, repeat the procedure in measuring to check the set pressure again. 0
ii)
20-50
6
205FO5246
2. NC Valve. j, The NC valve is actuated by the differential pressure of the jet sensor, so when adjusting it, always check first that the differential pressure of the jet sensor is correct. i) Loosen locknut (7) and turn adjustment screw (8) to adjust. *
Adjust the follows.
0
To INCREASE pressure, turn CLOCKWISE. To DECREASE pressure, turn COUNTERCLOCKWISE. Amount of adjustment for one turn of holder: Approx. 4.3kg/cm2.
0
*
adjdstment
screw
NCnvalve
as
205FO5674
20-51
3)
Differential pressure [Reference]
of jet sensor
High pressure and low pressure (high pressure - low pressure = differential pressure) is formed at the outlet port of the control valve and this differential pressure controls the NC valve. The differential pressure is at its maximum when the control levers are at neutral and is at its minimum when the control levers are operated to the end of their travel.
r
Relationship between travel of control lever and differential pressure of jet sensor
““\
O Control lever travel (mm) 205FO5249
Measuring
AY
Y
Loosen the oil filler the pressure inside
cap slowly to release the hydraulic tank.
k40il temperature when measuring: 4555°C. 1. Remove pressure pick-up plugs (9) (high pressure side) and (10) (low pressure side) (PT l/8). * For both front and rear sides, the plug farthest from the engine is the high-pressure side. 60 kg/cm2 at 2. Install oil pressure gauge Cl 1 at low preshigh pressure side, 25 kg/cm sure side). 3. Set to H.O. and H mode, run the engine at high idling and measure the differential pressure with the control levers at neutral. * High pressure (Pt) - low pressure (Pd) = Differential pressure. raise the track 4. Using the work equipment, frame on one side and measure the differential pressure with the track rotating freely (control lever operated to the end of its travel). Any actuator can be measured but it is * easiest to measure the free rotation of the track because the measurement time can be chosen as desired. pressure is the minimum * The differential (below 2.5 kg/cm2).
20-52
205FO5675
Adjusting * If the results of the measurement show that the differential pressure is not within the standard value, adjust as follows. 1. Loosen locknut (11) and turn adjustment screw (12) to adjust. i) Adjust the adjustment screw as follows. l To INCREASE pressure, turn CLOCKWISE. l
ii)
turn
205FO5676
Amount of adjustment for one turn of the adjustment screw: Approx. 16.6 kg/cm* a
*
To DECREASE pressure, COUNTERCLOCKWISE.
Jet sensor relief valves
Locknut:
7.0? 1 .O kgm.
After adjusting the adjustment screw, repeat the procedure in measuring to check the differential pressure again.
I
F20505398
20-53
TESTING
AND ADJUSTING
TRAVEL DEVIATION
Travel posture
1) Measuring when traveling 1. Set the machine in the travel
posture.
*
For the travel posture, extend the bucket and arm cylinder rods fully and hold the boom angel at 45”. 2. Travel for lOm, then measure the deviation when traveling for the next 20m. j,
Set to H.O.+H mode and measure the engine at high idling.
*
Install the hydraulic pressure measure the pump discharge the same time.
with
gauge and pressure at 0
20m
RunupforlOm
I Do not stop; continue to travel for the whole distance
Make a mark
20 m point
Make a mark
Make a mark at the 10 m midway point
Lay out a string \
\ Mark Measure the amount of dimension a at this point
2)
__ Mark
202F5258
Adjusting If the results of the measurements are not within the standard value, adjust as follows. *
Measurement procedure.
Condition of deviation
1
pressure
and
adjustment
Pressure when measuring
1Deviates to riaht 1Deviates to left
Discharge pressure: 100 kg/cm2
Remove shim at Remove shim at front pump rear pump to adjust (a). to adjust (b).
Discharge pressure: 180 kg/cm2
Screw in at rear Screw in at front pump to pump to adjust adjust (d). (c).
l
20-54
If the travel deviation does not within the standard value even adjusted, go to Troubleshooting “Travel deviation is excessive”.
come when item
u
205FO5678
1. Shim adjustment procedure. i) Loosen 4 bolts (1). *
ii)
Split shims are used so it is not necessary to remove the bolts. Remove the appropriate thickness of shim (2) to match the amount of deviation, then tighten bolts (1). *
Amount of deviation of shim to remove.
and amount
PC3OOLC ,679
2 8a c:
5-z
E 10
z -0 3
'
5 ri 0
h0
200
loo 0.1
0.2
0.3
0.4
0.5
;$z SB =z $ .E I rJ + u
Amount of shim to remove (mm) 205FO5680
PC4OOLC 20 z ,< Z" Q) & z= .u 3
15
300
10
200
5
100
0 ii
0
0.1
0.2
0.3
0.4
0.5
Amount of shim to remove (mm) 205FO5681
* u
Do not remove more than 0.4mm of shim. Mounting bolt: 5.5?2 kgm.
2. Screw adjustment procedure. i) Loosen locknut (4) of servo valve (3). ii) Screw in adjustment screw (5) the appropriate amount to match the deviation, then tighten locknut (4). Amount of travel deviation and amount to screw in.
20-55
PC3OOLC 25
500
TE BE
20
400
5 8
15
300
b 0 =
10
200
5
100
Is ii O
0
20
40
60
80
100
120
Angle to screw in (deg) 205FO5682
_
PC4OOLC
0
20
40
60
80
100
120
Angle to screw in (deg) 205FO5683
* u *
20-56
Do not screw in more than 100“. Locknut: 0.820.2 kgm. The travel deviation is an estimated value and will change according to the type of soil and travel surface condition, so use the value as a guide and travel the machine again after adjusting to check the deviation.
MEASURING
STROKE OF SERVO PISTON
*
If the output pressure of the NC valve is normal and it is considered that the pump performance is defective, inspect as follows to determine if the servo valve is defective or not.
1.
PREPARE
THE TOOL.
Make up gauge @ from the following parts. 1. Servo piston cap (side which has spring). 2. Dump truck brake wear measurement gauge (566-98-41120). 3. Tap PT l/4 threads in the center of the cap and install the gauge.
2.
MEASURING 1. Remove the cap (with the spring) from the side to be measured. 2. Fit the shims that were removed and install gauge @ . * Do not let the shims catch on the threaded portion of the bolt. 3. Stop the engine, push the rod in fully, then measure the dimension of the rod. 4. Raise the track shoe on the side where the gauge is installed and measure the dimension of the rod when the engine is run at high idling and the track is rotated freely. Standard stroke: * PCBOOLC: Approx. 8.9mm PC4OOLC: Approx. 11.2mm *
205FO5254
205FO5677
When the track shoe is rotated freely, push the rod by hand and check at the same time that the rod moves smoothly in accordance with the travel of the control lever.
20-57
MEASURING
*
OUTPUT
PRESSURE
OF PPC VALVE
Oil temperature when measuring: 4555°C. 1. Disconnect the hose (see diagram below) from the circuit to be measured. 2. install elbow.
adapter
C2
between
the
hose
and
3. Install oil pressure gauge Cl (60 kg/cm2) to adapter C2. 4. Run the engine at high idling, operate the control lever for the circuit to be measured and measure the hydraulic pressure.
Travel PPC valve
1 ml
R.H.
J-P(R)
I
I
r
1 I L-a(y)
\!4.P
cy
L.H. PPC
1-1
*
Color
code:
6: Black, Br: Brown, W: White, Bu: Blue, G: Green, R: Red
20-58
205F05685A
Y: Yellow
ADJUSTING
*
*
WORK EQUIPMENT
AND SWING PPC VALVE
If there is excessive play in the work equipment or swing lever, adjust as follows.
Y A 4
Lower the work equipment to the ground and stop the engine. Operate the control levers several times to release the remaining pressure in the hydraulic piping. Then loosen the oil filler cap slowly to release the pressure inside the hydraulic tank. Set the safety lock lever to the LOCK position.
1. Remove the boot, loosen the lever mounting bolt, then remove the lever. 2. Hold down disc (1) and loosen locknut (2). 3. Turn disc (1) and adjust the clearance. * Adjust the clearance with the disc as follows. l To DECREASE clearance, turn CLOCKWISE. To INCREASE clearance, turn COUNTERCLOCKWISE. When adjusting the clearance, adjust four pistons (3) separately. (Two pistons in the front-to-rear direction (A-a) and two pistons in the left-toright direction (B-b).) Set disc (1) so that it contacts one of the pistons in the front-to-rear direction (A-a), then adjust the clearance between disc (1) and piston (3) on the opposite side to 0.3-05mm. After adjusting in the front-to-rear direction, adjust in the left-to-right direction (B-b). l
0
ii)
iii)
iv)
*
If the change change ton (3), m
clearance exceeds 0.5mm, the position of disc (1) or the mounting position of pisthen check again. Locknut: 11.5t1.5 kgm.
0.3 - 0.5 mm
1 3
205FO5257 L
If no clearance is made, even when the lever is at neutral, the work equipment will move or the hydraulic drift will increase, so always provide a clearance.
20-59
TESTING
PPC SHUTTLE VALVE
f
If the auto-deceleration does not work, the swing brake is not canceled, the travel lacks power or if there is any other problem and the pressure switch is normal, check the operation of the PPC shuttle valve as follows. (Check first that the electrical system is normal.)
j,
Oil temperature
when testing:
45-55°C.
1. Remove the pressure switch from the circuit to be tested. l Work equipment*swing pressure switch l
(1). Travel
pressure
switch
i
205FO5256
(2).
2. Install pressure gauge Cl (60 kg/cm*). 3. Run the engine at high idling, operate the following control lever and measure the hydraulic pressure. In the case of switch (l), operate the work equipment or swing lever. In the case of switch (2), operate the travel lever.
I
20-60
2
205FO5686
MEASURING l
Measure place.
SOLENOID
each solenoid
valve at the following
1Measurement
Solenoid
1 No. 1
VALVE OUTLET PORT PRESSURE
location
205FO5687
205 iFO5688
1.
Disconnect the hose and install adapter between the measurement point and hose. -k
C2 the
4. CO cancel solenoid valve. Turn the swing lock switch ON. 5. 2-stage relief solenoid valve Push the power max. switch ON.
Adapter Size
I
1
Part No.
02
790-261-l 310
03
790-261-l 320
04
1
790-261-l 330
Install oil pressure gauge Cl (60 kg/cm2) to the adapter. 3. Run the engine at high idle and measure the hydraulic pressure under the following conditions. 1. Arm half flow solenoid valve. If the working mode switch is set to heavyduty or general mode and the arm is operated, the PPC valve output pressure is supplied; if the working mode switch is set to finishing or lifting mode, the pressure should be 0 kg/cm2. 2. Swing brake solenoid valve. Operate the swing. 3. Travel speed solenoid valve. Set the travel speed switch to Hi. 2.
r
L
205FO5263
20-61
TESTING LOCATIONS WORK EQUIPMENT
CAUSING
HYDRAULIC
DRIFT OF
If there is any hydraulic drift in the work equipment (cylinders), check as follows to determine if the cause is in the cylinder packing or in the control valve. 1.
CHECKING PACKING 1. Checking i)
FOR
DEFECTIVE
boom and bucket
CYLINDER cylinders.
ii)
Operate the boom control lever to RAISE or the bucket control lever to CURL. l If the lowering speed increases, the packing is defective. l If there is no change, the holding valve (boom) or the control valve (bucket) is defective. 2. Checking arm cylinder. i) Operate the arm cylinder to move the arm in fully, then stop the engine. ii) Operate the arm control lever to IN. l If the lowering speed increases, the packing is defective. l If there is no change, the control valve is defective. * If the pressure in the accumulator has been lost, run the engine for approx. 10 seconds to change the accumulator again before operating.
[Reference] If the cause of the hydraulic drift is in the packing and the above operation is carried out, the downward movement becomes faster because of the following reasons. 1. If the work equipment is set to the above posture (holding pressure applied to the bottom end), the oil at the bottom end leaks to the head end. However, the volume at the head end is smaller than the volume at the bottom end by the volume of the rod, so the internal pressure at the head end increases because of the oil flowing in from the bottom end.
20-62
PC3OOLC: 2,160 kg PC4OOLC: 2,880 kg
Set in the same posture as when measuring hydraulic drift and stop the engine.
I
\. c
\
205FO5264
205FO5265
2. When the internal pressure at the head end increases, the balance is maintained by a certain pressure (this differs according to the amount of leakage) in proportion to it. 3. When the pressure is balanced, the downward movement becomes slower. If the lever is then operated according to the procedure given above, the circuit of the head end is opened to the drain circuit (the bottom end is closed by the check valve), so the oil at the head end flows to the drain circuit and the downward movement becomes faster.
2. *
CHECKING
A4Y
BOOM
HOLDING
VALVE
Set the work equipment at the maximum reach and the top of the boom horizontal, then stop the engine. Lock the work equipment and release the pressure draulic tank.
control levers inside the hy-
1. Disconnect pilot hose (1) of the boom holding valve and install a blind plug in the hose. * *
Blind plug: 07376-50315 Leave the holding valve
2. Start the engine, charge then stop the engine. 3. Operate the boom LOWER position. *
end open. the
control
205FO5690
accumulator, lever
to
the
If any oil leaks from the port that is left open, the holding valve is defective.
3.
CHECKING PPC VALVE If the hydraulic drift differs when the safety lock lever is in the LOCK or FREE position (engine running) the PPC valve is defective.
4.
MEASURING THE INTERNAL LEAKAGE OF THE CYLINDERS l If the hydraulic drift of any cylinder exceeds specification, see if the cause of the hydraulic drift is in the cylinder or in the control valve by performing the following. * Oil temperature at time of measurement: 45-55” C.
i) ii)
A
Fully extend the rod of the cylinder to be tested and stop the engine. Disconnect the piping on the head side and plug the piping on the machine body side with a plate. Do not disconnect the bottom side.
the piping
lOBR0023
on
iii)
Start the engine and run it at full throttle to apply the relief pressure to the bottom side. iv) After 30 seconds, measure the leakage during one minute.
20-63
BLEEDING ORDER
AIR
FOR OPERATIONS
AND PROCEDURE
FOR BLEEDING Air bleeding
AIR
procedure 6
1
Nature l l
Bleed air from pump
of work
Change hydraulic Clean strainer
l
Replace element
l
Replace repair pump Change clean line filter element Remove suction piping
l
l
return
oil
Replace, valve
repair
control
l
Replace Remove ing
cylinder cylinder
pip-
Replace Remove piping
swing swing
motor motor
Replace travel swivel Remove travel swivel piping
motor
l l
l
l
Note 1:
0
0
filter
l
l
Start operation
0
0
d-A-l--
motor
Bleed the air from the swing been drained.
0
0
0
0
0
and travel
oil
After completing the above procedure and starting the engine, run the engine at low idle for 10 minutes. If the coolant temperature is low and automatic warming-up is carried out, cancel it by using the fuel control dial after starting the engine.
motors
0
0
0
0
the plug hole until 4. Pour in oil through oozes out from the bleeder. 5. Tighten plug 0. u Plug: 7.02 1 .O kgm. 6. Tighten bleeder @ . * Precautions when starting the engine.
20-64
0
OI O I
AIR FROM PUMP 1. BLEEDING 1. Loosen bleeder @ and check that oil oozes out from the bleeder. 2. When oil oozes out, tighten bleeder @ . a Bleeder: 0.920.1 kgm. * If no oil oozes out from the bleeder: and remove plug@ 3. Leave bleeder@loosened
-k
0
0
only when
the oil inside
0
the motor
case has
2.
BLEEDING DERS
AIR FROM
1. Start the engine and approx. 5 minutes.
HYDRAULIC run at low
CYLINidling
for
2. Run the engine at low idling, then raise and lower the boom 4-5 times in succession. * Operate the piston rod to approx. 100mm before the end of its stroke. Do not relieve the circuit under any circumstances. 3. Run the engine at high idling and repeat step (2). After that, run the engine at low idling and operate the piston rod to the end of its stroke to relieve the circuit.
4. Repeat steps 2 and 3 to bleed the arm and bucket cylinders. *
the air from
If the hydraulic cylinder has been replaced, it is better to bleed the air before connecting the work equipment again. (In particular, for the LOWER end of the boom cylinder, if it contacts the boom, the cylinder cannot be operated to the end of its stroke.)
3. BLEEDING AIR FROM SWING MOTOR 1. Run the engine at low idling, loosen air bleed plug (3) and check that oil oozes out. * If no oil oozes out from the air bleed plug: 2. Stop the engine and pour oil into the motor case from plug (3). 3. Tighten air bleed plug (3). u Plug: 14.Ok2.0 kgm.
4. BLEEDING AIR FROM TRAVEL MOTOR 1. Run the engine at low idling, loosen air bleeder (4) when oil oozes out, tighten again. u Bleeder: 0.9kO.l
205FO5692
20-65
1
RELEASING
REMAINING
PRESSURE
*
If the piping between the hydraulic cylinder and the control valve is disconnected, remove the remaining pressure from the circuit as follows. The travel circuit is an open circuit, so there is no remaining pressure. It is enough to remove the oil filler cap.
1.
Loosen the oil filler cap slowly pressure inside the tank.
2.
Operate the control levers. -k When the levers are operated 2-3 times, the pressure stored in the accumulator is removed. Start engine, run at low idling for approx. 5 minutes, then stop the engine and operate the control levers. * Repeat the above operation 2-3 times to release all the remaining pressure.
3.
20-66
to release the
IN HYDRAULIC
CIRCUIT
TROUBLESHOOTING POINTS
TO REMEMBER
SEQUENCE
OF EVENTS
PRECAUTIONS
IN TROUBLESHOOTING
WHEN CARRYING
HANDLING
YAZAKI
HANDLING
PACKARD
CHECKS
WHEN TROUBLESHOOTING
............................... ..................................
OUT MAINTENANCE
CONNECTORS
20-69 20-70
..............................
20-71
.............................................
CONNECTORS
20-76
...........................................
BEFORE TROUBLESHOOTING
20-77
.........................................
20-80
ELECTRICAL
CIRCUIT
DIAGRAM,
ENGINE
THROTTLE
CONTROLLER
SYSTEM
(PC3OOLC)
.....
20-81
ELECTRICAL
CIRCUIT
DIAGRAM,
ENGINE
THROTTLE
CONTROLLER
SYSTEM
(PC4OOLC)
.....
20-82
PUMP CONTROLLER
SYSTEM
(PC3OOLC) ........................................
20-83
PUMP CONTROLLER
SYSTEM
(PC4OOLC) ........................................
20-84
MONITOR
SYSTEM
(PC3OOLC)
................................................
20-85
MONITOR
SYSTEM
(PC4OOLC)
................................................
20-86
POSITION
OF CONNECTORS
FOR TROUBLESHOOTING
TABLE - PCBOOLC
POSITION
OF CONNECTORS
FOR TROUBLESHOOTING
- PC3OOLC .....................
20-89
POSITION
OF CONNECTORS
FOR TROUBLESHOOTING
TABLE - PC4OOLC
20-91
POSITION
OF CONNECTORS
FOR TROUBLESHOOTING
- PC4OOLC .....................
...............
...............
20-87
20-93
CONNECTION
TABLE
FOR CONNECTOR
(N-SLC TYPE)
CONNECTION
TABLE
FOR CONNECTOR
(M TYPE)
.................................
20-96
CONNECTION
TABLE
FOR CONNECTOR
(S TYPE)
.................................
20-98
CONNECTION
TABLE
FOR CONNECTOR
(AMP040)
.................................
20-99
CONNECTION
TABLE
FOR CONNECTOR
(SWP TYPE)
..............................
20-100
CONNECTION
TABLE
FOR CONNECTOR
(MIC TYPE)
..............................
20-101
CONNECTION
TABLE
FOR CONNECTOR
(X TYPE)
CONNECTION
TABLE
FOR CONNECTOR
.............................
................................
20-102
.......................................
EXPLANATION OF THE FUNCTIONS OF THE CONTROL THE ELECTRICALSYSTEM .................................................
MECHANISM
20-95
20-103 OF 20-104
20-67
DISPLAY METHOD FOR MONITOR ENGINE THROTTLE CONTROLLER
PANEL, PUMP CONTROLLER AND . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . _ _ . _ . _ . . 20-107
ACTION OF SELF-DIAGNOSTIC FUNCTION AND SYMPTONS ON MACHINE ENGINE THROTTLE CONTROLLER SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-l 11 ACTION
OF SELF-DIAGNOSTIC
PUMP CONTROLLER
SYSTEM
FUNCTION
AND SYMPTOMS
METHOD
OF USING JUDGEMENT
METHOD
OF USING TROUBLESHOOTING
TABLE
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-117 CHARTS
TROUBLESHOOTING
OF ENGINE
TROUBLESHOOTING
OF PUMP SYSTEM,
TROUBLESHOOTING
OF PUMP CONTROLLER
TROUBLESHOOTING
OF HYDRAULIC
TROUBLESHOOTING
OF MONITOR
20-68
ON MACHINE
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-l 13
CONTROLLER
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-l 19
SYSTEM,
C-MODE
. . . . . . . . . . . . . . . . . . . . 20-121
................................
INPUT SIGNAL
AND MECHANICAL SYSTEM,
E-MODE
P-MODE
SYSTEM,
SYSTEM,
20-149 F-MODE
H-MODE
..........
20-181
. . . . . . . . . . . . . 20-191
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-223
POINTS TO REMEMBER
A
l
Stop the machine securely fitted.
l
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. Be extremely careful not to touch any hot parts or to get caught in any rotating parts. When disconnecting wiring, always disconnect the negative (-) terminal of the battery first. When removing the plug from a location which is under pressure from oil, water or air always release the internal pressure first. When installing measuring equipment be sure to connect it properly. The aim of troubleshooting is to pinpoint the basic cause of the failure, to carry out repairs swiftly and to prevent reoccurrence of the failure.
l l
*
A4
Y
WHEN TROUBLESHOOTING
l
l
in’a level place and check that the safety pin, blocks
and parking
brake are
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 cases of the failure that would produce the reported symptoms. 1. When carrying out troubleshooting, do not hurry to disassemble the components. If components are disassembled immediately any failure occurs: l Parts that have no connection with the failure or other unnecessary parts will be disassembled. l 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 thorough prior investigation and to carry out troubleshooting in accordance with the fixed procedure. 2. Points to ask user or operator: Have any other problems occurred apart * from the problem that has been reported? * *
*
Was there anything strange about the machine before the failure occurred? Did the failure occur suddenly or were there problems with the machine condition before this? Under what conditions did the failure oc-
cur?
Check for any external the piping or hydraulic
Check the travel of the control levers. Check the stroke of the control valve spool. * Other maintenance items can be checked externally, so check any item that is considered to be necessary. 4. Confirming failure: l 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, do not carry out any investigation or measurement that may make the problem worse. 5. Troubleshooting: l 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. i) Start from the simple points. ii) Start from the most likely points. iii)
Had any repairs been carried out before the failure? When were these repairs carried out? Has the same kind of failure occurred * before? 3. Check before troubleshooting: * Check the oil level. *
*
* *
leakage of oil from equipment.
Investigate other related or information.
parts
6. Measures to remove root cause of failure. l Even if the failure 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 occurred. Then, remove the root cause.
20-69
SEQUENCE
OF EVENTS IN TROUBLESHOOTING
a Step
\
1
1Examination, 1)
When
confirmation a request
’
Type,
for repavs
serial
*
Details
1f
is received.
Ring!
points.
number
of jobsite,
Ask questions
1
of symptoms
first ask the following . Name of customer
2)
Jobsite
Ring1
--------
----
of machine
--
--
3
etc.
to gain an outline
of the
problem. ’
Condition
’
Work
of failure
bemg
carried
out at the time
of the failure * .
Operating
environment
Past history,
details
of maintenance,
etc.
Step
2 Determining 1)
probable
location
Look
at the troubleshootmg
shop
manual
to find
of cause section
locations
of the
of possible
,---fi
causes
Step
3
1Preparation 1)
Look
of troubleshootmg at the table
in the shop
manual
tools
of troubleshooting and prepare
tools the
necessary tools. . T-adapter . 2)
Look
Hydraulic
pressure
I” the parts
necessary
book
replacement
gauge
kit, etc.
and prepare
troubleshooting)
the
parts.
I
I
r
*
Decide
action
1)
Before
starting
repair
2)
simple
*
Check
*
Other
to take troubleshootlng.
before check
manual,
flowchart
and
starting
items
items
See the Troubleshooting shop
locate
failures
select
that
Section
of the
a troubleshooting
matches
the symptoms.
and
carry out troubleshooting.
*
Drive
and operate
the condltlon
the machlne
and judge
if there
1
to conflrm is really
a
failure.
, Step
4 /I
r\
.
1-y
I I
Step
/
5
/ Ask
operator
questions
to confirm
details
I Was
there
machine
anything before
Did the failure
20-70
strange
the failure occur
about occurred’
suddenly?
the
of
1
-
PRECAUTIONS
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 hydraulic oil).
WHEN 1. PRECAUTIONS ELECTRIC EQUIPMENT
HANDLING
1) Handling
wiring harness 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 protector 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. F20505201
Main failures occurring in wiring harness contact of connectors (defective 1. 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
insertion
F20505202
20-71
2. Defective nectors.
compression
or soldering
of con-
Improper
compressio
The pins of the male and female connectors are in contact at the compressed terminal or soldered portion but there is excessive force on the wiring and the plating peels to cause improper correction or breakage.
F56103079
in wiring. 3. Disconnections 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 compression of the connector may be lost or the soldering may be damaged or the wiring may be broken.
F20505204
4. High pressure water entering connector. The connector is designed to make it difficult for water to enter (drip-proof structure) but if high-pressure water is sprayed directly on the connector, water may enter the connector depending on the direction of the water jet. The connector is designed to prevent water from entering but at the same time, if the water does enter, it is difficult for it to be drained. Therefore, if water should get into the connector, the pins will be short circuited so if any water gets in, by the water, immediately dry the connector or take other appropriate action before passing electricity through it. 5. Oil or dirt stuck to connector. If oil or grease are stuck to the connector and an oil film is formed on the mating 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 or dirt stuck to the connector, wipe it off with a dry cloth or blow dry with 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.
20-72
*
b F20505205
I
F20505206
-k
2)
Removing,
If there is water or oil in the air, it will increase the contamination of the points, so clean with air from which all the water and oil has been removed.
installing
and
drying
connec-
tors and wiring harness Disconnecting connectors when disconnecting. 1 Hold the connectors 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.
v
F20505207
2. 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.
F2050520E
Connecting connectors 1. Check the connector visually
for the follow-
ing: l
l
l
*
*
Check that there is no oil, dirt or water stuck to the connector pins (mating portion). Check that there is no deformation, defective contact, corrosion or damage to the connector pins. 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 place the connector.
or breakage,
re-
20-73
2. Fix the connector
securely.
Align the position of the connector then insert it securely. For connectors with lock stopper: Push in the connector into position.
correctly,
until the stopper
Clicks
into
clicks
II 3. Correct any protrusion of the boot and any misalignment of the wiring harness. For connectors fitted with boots, correct any protrusion or the boot. In addition, if the wiring harness is misaligned or the clamp is out of position, adjust it to its correct position. j, When blowing with dry air, there is danger that the oil in the air may cause improper contact, so clean with air from which all the water and oil has been removed.
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. 1. Disconnect the connector and wipe off the water with a dry cloth. -k If the connector is blown dry with air, there is the risk that oil in the air may cause defective contact, so avoid blowing with air. 2. Dry the inside of the connector with a dryer. If water gets inside the connector, use a dryer to dry the connector. * Hot air from the dryer can be used but be careful not to make the connector or related parts too hot, as this will cause deformation or damage to the connector.
II
F20505209
F20505210
F20505211
F20505212
20-74
3. 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
F20505213
3) Handling control box 1. The control box contains a microcomputer and electronic control circuits. These control all of the electronic circuits on the machine, so be extremely careful when handling the control box. 2. Do not open the cover of the control box unless necessary.
F20505214
3. Do not place objects on top of the control box. 4. Cover the control connectors with tape or a vinyl bag. 5. During rainy weather, do not leave the control box in a place where it is exposed to rain. 6. Do not place the control box on oil, water or soil or in any hot place, even for a short time. (Place it on a suitable dry stand.) 7. Precautions when carrying out arc welding. When carrying out arc welding on the body, disconnect all wiring harness connectors connected to the control box. Fit an arc welding ground close to the welding point.
F20505215
F20505216
20-75
HANDLING
CONNECTORS
YAZAKI TYPE CONNECTOR
r 1 When
removing the connectors from the clips, pull the connector in a parallel direction to the clip. *
If the connector is twisted to the left and right or up and down, the housing may break. 205FO5609
2. When disconnecting male and female connectars, release the lock and pull in parallel with both hands. * Never try to pull out with one hand.
/
205FO5611
3. When the wiring harness clamp of the connector has been removed, always return it to its original condition and check that there is no looseness of the clamp.
205FO5612
20-76
HANDLING PACKARD
CONNECTORS
COMPANY
CONNECTOR
1. When removing the connectors from the clips, pull the connector in a parallel direction to the clip. *
If the connector is twisted to the left and right or up and down, the housing may break.
08CD0024
I
08CD0025
2. When disconnecting male and female connectors, release the lock and pull in parallel with both hands. j, Never try to pull out with one hand.
08CD0026
20-77
1. POINTS
TO HANDLING EQUIPMENT
REMEMBER WHEN HYDRAULIC
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 orwhen disassembling or assembling hydraulic equipment, it is necessary to be particularly careful.
1)
2)
Be careful of the operating environment. Avoid adding hydraulic oil, replacing filters repairing the machine in rain or high winds places where there is a lot of dust.
or or
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 so it is desirable to use unit repairs, exchange. Disassembly and maintenance 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 dimply 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.
20-78
F20505217
F20505218
F20505219
5) Change hydraulic oil when the temperature is high. When hydraulic oil or other oil is warm, it flows easily. In addition, the sludge can also be drained out easily from the circuit together with the oil, so it is best to change the oil when it is still warm. When changing the oil, as much as 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 remove the contaminants, sludge and old oil from the hydraulic circuit. Normally, flushing is carried out twice: pri mary flushing is carried out with flushing oil and secondary flushing is carried out with the specified hydraulic oil. F20505220
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 34 particles that the filter built into the hydraulic equipment cannot remove, so it is an extremely effective device.
20-79
Electrical
components
Other check items
I
I
Hydraulic, mechanical eaubments
I
I
I
Electrical equipments
I
I
I
I
2
x
0-. -
3
-.
Lubricating
items
I
I
oil, cooling
Check before starting
I
I
water
I
ELECTRICAL ENGINE
CIRCUIT
THROTTLE
DIAGRAM
CONTROLLER
SYSTEM
Starting switch
Ml 1 (L2)
Battery
R
M7(L2)
r
Governor
motor
Enginethrottle controller
El (MlC21)
___._ Fuel dial (-1 No. 2-Tthrottle (-) Throttle (-) Warming-up
L
+ 20
0.58 0.5BW 0.56
21 p’5Ly
r
E6 (M3)
1
Y
0.858
Fuel control dial
0
08DD0024
20-81
ELECTRICAL ENGINE
CIRCUIT
THROTTLE
DIAGRAM
CONTROLLER
SYSTEM
PC4OOLC E-10
-TQay
1
m 6
ii Starting
switch
Ml 1 (L2)
$3 ,-a Alternator Battery 24V 45A
1.25L
Fuse 3mm cc,3 NZZ dd 0.85GY
2WR
II
II
E-9
21
5WR
10A -2 20A _
9
M7(L2) 0.85BW
I
I
Governor
Fuel
eleratlon lection
“.JL 1 \ 7g 0.5B / ,. n 0.5w it.,-
motor
control
dial
I
I
0.5G
*““‘n i [’ Work
08DD0025
20-82
PUMP CONTROLLER
SYSTEM
PC3OOLC Battery relay
Swing lock
Work equipment - swing oil
Battery
Ml1
TVC prolix switch
(LZ)
I
G-Hi
Swing lock switch
Arm half flow
L-2
TVC prolix resistor
TVC solenoid
er
C2(MlC21P)
1
Power maximlzlng switch
I
Engine speed sensor
08DD0026,
20-83
SYSTEM
PUMP CONTROLLER PC4OOLC
Work equipment - swing oil
Battery
Battery relay
Swing lock prolix switch
Travel oil pressure
switch
service r pressure switch 2
011 -sa pressure switch 1
pressure switch
4
Swing lock switch
I
M34
II
llt
Arm half flow solenoid valve
mfl
--
TVC crolix resistor
Cl (MlC17P)
solenoid valve
TVC solenoid
1
1 i
Engine throttle controller fi1-C21P)
Power maximizing switch
Engine speed sensor
I
I
I’
II
1 Lm 20-84
c-9
08DD0027
MONITOR
SYSTEM
PC3OOLC Service meter Fuse
Wiper motor
(KES4)
M4(KES4)
Ml1
M7 (L2)
(L2)
A A
M5(M4)
,_A__
Light relay
Heater Hi relay
Heater Lo relay
Wiper relay
1-d
P9 (X2)
Starting switch
M3 (S16)
MI
I
I
IL”
125R E
R.H. heqp
:
08DD0028
20-85
MONITOR
SYSTEM
PC4OOLC D20
-I e
A
SWVlCe meter relay
$5
00
u Sewce
meter
v&&motor
D19
(KES4)
M4CKES4)
I Ir-l
M5iM4)
Light relay
Heater HI relay
Heater Lo relay
Wiper relay
1 Pl (AMP20P)
P2
cAMPlGP)
1
l
L-1
P9 (X2)
M3 CS161
IIIII
I
II
Starting
switch
I
I
Frame ground
I’
Wlndow M291(M2)
washer Switch]
Ml0
M9
Boom lamp
Ma
R H head lamp
08DD0029
20-86
POSITION CN No.
OF CONNECTORS
ELECTRICAL
COMPONENT
FOR TROUBLESHOOTING No. of pin
Type
- PC3OOLC No.
CN
ELECTRICAL
No.
I I
COMPONENT
Type
M21 IRadio I
switch
C6 TVC prolix
resistor
c7
I
M
Rear pump oil pressure sensor
GIm~oil
pressure
controller, governor controller (Model selection)
1
161
MIC
21
connector
S
12
E4 Governor
potentiometer
x
3
E5 IGovernor
motor
El
Engine
(Diode)
throttle
E2 Intermediate
E6 IFuel control E7 Engine
controller
dial
connector
E9 jlntermediate
connector
Fl
Shut-off
valve
Intermediate
switch
M2 IStarting
motor
M3 Intermediate M4 Wiper
2
SWP
8
I SW
I
Packard
6 3
M
4
S
16
KES
4
L
2
KES
2
L
2
Ml2 Heater
KES
3
Ml3 Speaker
KES
2
S
8
connector
link
connector
I KES I 1 I
Ml7 Horn (Low tone) switch 1
KES
1
M
2
M
14
oil level sensor
P6 Fuel level sensor I
I M Ill 1 M 111
connector
-
141
1 M 121
buzzer
P5 Engine
I M 141
connector
M20 Intermediate
2
P4 IWarning
x
M7 Intermediate
lock prolix
M
1 16 1
10
Ml8 Swing
1
1 AMP
S
(High tone)
M
panel
131
connector
MlGjHorn
I
unit
2
P2 /Monitor
M
M6 Intermediate
Ml4 Intermediate
swing
connector
M PI KES
I
connector
Ml 1 Fusible
switch
M31 Intermediate M34jFree
I
motor
1201
M5 jlntermediate
Ml0 Intermediate
M29 Washer
wiper
1 AMP
connector
light
M28 Windshield
I connector
panel
motor
M9 IWorking
I 4 I
or
M44 Ether injector qi
I M 161 I x 121
M8 IHeadlight
KES
for cooler
Pl IMonitor
connector
Ml IStarting
2
I x 141
speed sensor
E8 Intermediate
El0
I
M
Max. Switch
M27jlntermediate
121
injector
12
M
M25 Power
3
I MI31
1
2
x
1
1 4 j
M
M26 Power source Iair conditioner
1 3
I
M23 Horn switch
2
-
ID15jEther
max. button
M
x
1 KES I
MPPjPower
C5 jTVC prolix
of pin
P7 Coolant
11
temperature
Pl 0 IService
meter
R3 IHeater
Hi relay
R4 jLight s1
sensor
4
x
1
Packard
2
I KES I 2 I
relay
Work equipment I pressure switch
Packard
l
swing
I
I51
I
I 5
oil
I-
2
x I
I I
I
S2 ISwing
oil pressure
switch
j
X
I 2
S4 ITravel
oil pressure
switch
l
x
12
V2 ITravel
speed solenoid
valve
l
x
12
V5 Arm half flow solenoid
valve
1
20-87
20-88
POSITION
OF CONNECTORS
FOR TROUBLESHOOTING
- PC3OOLC
Foldout
8
M3 PlO
M21
E2
I
I
P8
M36 _-
c7
\
P7 I
64. E5. ES
P4 M29 w3
\
\\
I
E6 P2
“‘\
ti
.
/ M7
/
M4
Mi3
I
I
\
s2, s4, ss, SlO
II
//
M5
/
/
M27
M31\ \ \ \ Ai6
\ Ml4 \\ d4
-
\
M’l2
Mli
/ Ml8
/i
/
\ R3 08DD0033
08DD0017A
20-89
20-90
POSITION CN I No. I Cl
OF CONNECTORS
FOR TROUBLESHOOTING CN
ELECTRICAL
COMPONENT
1 Type 1“;it
No.
Pump controller
MIC
17
C2 Pump controller
MIC
21
C3 Pump controller C4 TVC valve C5 TVC prolix
switch
C6 TVC prolix
resistor
I I I I c7
Rear pump oil pressure sensor
c8
I
cg
Front pump sensor
I I
ID15jEther
iniector (Diode) . , D16 Shut-off valve (Diode)
I
9
x
2
M
6
M
2
x
3
I
x
3
I
M I I
3 I
-
12
D19 Monitor
panel
(Diode)
2
D20 Service
meter
(Diode)
2
(High - tone) Swing lock prolix
Ml8
M20 Intermediate
M26 Power source air conditioner
M
2
M
4
KES
4
M
2
M
2
KES
4
M
2
I
1 KES
1 2
MPOlWasher
switch
1
M
12
M36jEnaine I ”
mode connector
II
M
jlI
injector
1 KES
M46 Ether injector Pl I Monitor 1 P2 IMonitor
switch
panel
I AMP I AMP
E4 Governor
potentiometer
x
3
P6 Fuel level sensor
E5 Governor
motor
x
4
P7 Coolant
M
3
oil level sensor temperature
oil level sensor
PlO Service
meter
Pll
pressure
Rl
Engine
sensor
level sensor
P9 Hydraulic
2 I
2
Packard
4
x
1
Packard
2
x
2
x
1
KES
2 3
Packard
switch
20
I 16 1
M
buzzer
P8 Coolant
1 1
M
oanel
P5 Engine
5
Wiper relay
M
4
R2 Heater
Lo relay
5
switch
M
6
R3 Heater
Hi relay
5
motor
x
2
R4 Light
S
16
I RlO IService
KES
4
I I
Fl
Intermediate
Ml
Starting
M2 Starting
M3 Intermediate M4 Wioer
I
M28jMotor
P4 Warning
dial
or
connector
I
12
E6 Fuel control
switch
for cooler
S
E2 Intermediate
controller
1 ‘1
max. button
connector
throttle
1 KES
M23 Horn switch
21
Engine
I
M21 Radio M22 Power
No. of Din
I
connector
MIC
El
Type
M17jHorn
M44jEther 2
COMPONENT
I
M27 Intermediate
oil pressure
Pump controller, governor (Model selection) I controller
MIC
ELECTRICAL
- PC4OOLC
connector
connector
motor
s1
relay
5
I
meter relav
Work equipment pressure switch
l
swing
oil
I
5 2
x
M5 Intermediate
connector
M
4
M6 Intermediate
connector
S
10
S2 Swing
oil pressure
switch
x
2
M7 Intermediate
connector
L
2
S4 Travel
oil pressure
switch
x
2
M
1
M8 Headlight
I
S9 Service
oil pressure
switch
X
2
SlO Service
oil pressure
switch
X
2
valve
X
2
valve
X
2
x
2
X
2
x
2
Vl
Swing
brake solenoid
V2 Travel
speed solenoid
V4 CO cancel
solenoid
valve
V5 Arm half flow solenoid Ml4
Intermediate
Ml6
Horn (Low tone)
connector
S
8
KES
1
I
v7
2-stage relief solenoid valve
l
valve
CO cancel
20-91
20-92
POSITION
OF CONNECTORS
FOR TROUBLESHOOTING
Foldout 9
- PC4OOLC
M3 PlO D20
E2
M2’ \
/
M36
M44
;;;
E4, ES, ES \
P8
.c2 -Ml8
M46 ’
Ml3
/
\\\\\
M7 M5 ‘I
I
\\\\\ M27
\ \ \ \ \ M.31 \ \ \ \ \ hi6 \ Ml4 \\\ d4
v/Y
\ R3 \
I
A
I I
I
\
G/i I Mi2
\
\ ti22
lbh6
Mb5
RlO 08DD0037
08DD0036
20-93
20-94
CONNECTION *
Display
TABLE FOR CONNECTOR
of male and female
connectors.
All the displays of male and female show the mating portion at the terminal (pin) end. therefore, the diagram does not always match the male and female at the housing mating end. In the circuit diagrams, the pointed side (the part inside the pointed line) as shown in the diagram below is the male side. r
Male side of terminal
Female side of terminal
I 2 2x6
Governor
potentiometer
3 F20505399
T
No. 0’ F pins
N-SLC CONNECTOR Male connector
Female connector
423F349
423F350
423F351
423F352
423F353
423F354
4
20-95
CONNECTION
TABLE FOR CONNECTOR
No. 01 pins
M TYPE CONNECTOR Female connector
Male connector
205FO5318
205FO5317
\
1
i
205FO5319
205FO5320
205FO5321
205FO5322
205FO5323
205FO5324
3
20-96
CONNECTION
TABLE FOR CONNECTOR
T
No. o F pins
M TYPE CONNECTOR Male connector
Female connector
6
3/
\
6 205FO5325
6
3 205FO5326
20-97
CONNECTION
TABLE FOR CONNECTOR
T
No. o f pins
S TYPE CONNECTOR Male connector
Female connector
8
8
4
205FO5327
1
6
205FO5328
6
1
10
5
6
1
12
5
10
205FO5329
12
205FO5332
205FO5331
16
7
8
1
8
1
16
i
0
16
@
205FO5333
20-98
205FO5
‘334
CONNECTION
No.
TABLE FOR CONNECTOR
-r
AMP040
oiF
pins
TYPE CONNECTOR Female connector
Male connector
16
i 205FO5336
205FO5335
20
i
1‘ 1 2c 15FO5337
/
11
\
1
205FO5338
20-99
CONNECTION
TABLE FOR CONNECTOR
T
No. oiF pins
SW/P TYPE CONNECTOR Female connector
Male connector
1 \
/”
4
1
w
II
6
3
6 205FO5339
H 6
0
3 205FO5340
8
205FO5341
20-100
205FO5342
CONNECTION
TABLE FOR CONNECTOR
T
No. 0’ f pins
MIC CONNECTOR Female connector
Male connector
9
205FO5343
205FO5344
ouooLloLloolJo
17
1
142F414
1 nun
0
olJolJo
0
I
142F415
11
ouo
21
142F416
142F417
20-101
CONNECTION
No. of pins
TABLE FOR CONNECTOR
X TYPE CONNECTOR Female connector
Male connector
1
205FO5309
205FO5310
205FO5311
205FO5312
205FO5313
205FO5314
2
3
1
3
4
GEII
205FO5315
20-102
205FO5316
CONNECTION No. of pins
TABLE FOR CONNECTOR
l-
PACKARD
COMPANY
Male Connector
CONNECTOR Female
Connector
,B
(Coolant
temperature
sensor)
08cD0011
(Engine
oil
pressure
sensor1
OBCOOO18
oncooo19
D C
A
08CDOO22
00c00023
20-103
EXPLANATION OF THE FUNCTIONS THE ELECTRICAL SYSTEM
OF THE CONTROL
This section gives the functions and details of checks throttle controller needed to carry out troubleshooting
MECHANISM
for the monitor panel, pump controller of the electrical system.
OF
and engine
1) Explanation of functions The control mechanism for the electrical system consists of the monitor engine throttle controller. It carries out control by changing the absorption set) or by changing the output of the engine (working mode).
panel, pump controller and torque of the pump (power
Monitor panel and both the controllers each input the necessary signals and combine the signals selected by the monitor panel. The controllers input and output the necessary signals to control the absorption torque of the pump and the engine output.
l
Input
and output
signal
system
of monitor
panel and both controllers
(Fig. 1).
Monitor panel
Work eauipment ipeed swtch
.
slgnal
D
controller Pump
K
Fuel control dial signal -a
205FO5714
20-104
The pump controller and engine throttle controller have a self-diagnostic function and if any electrical abnormality (disconnection, contact with ground, internal short circuit or short circuit between wires) occurs in the output signals (input signal for the receiving controller) for numbers @ - @ in Fig. 1, the content of the abnormality is displayed.
l
l
If 01 to the If 11 No. 2
09 or 25 are displayed (if a short circuit or other fault causes a current above the specified level to flow controller, the controller stops the operation of that system). 28 are displayed, there is a disconnection (the operation of that system stops) or there is contact of the pin of the solenoid with the ground (the solenoid continues to operate).
Even if there is any abnormality in the input signal system for @ - 0, the abnormality is not displayed in the display area but the pump controller has a built-in monitor function to check the input signals. The controller starts to work only when there is an input signal and it gives a display on the display panel. Therefore, when investigating if the cause is in the electrical system or in the hydraulic or mechanical system in the case of “There is no abnormality display on the display panel but there is an abnormality in the movement of the unit”, the first step when carrying out troubleshooting is to use the method of checking the operation of the electrical system in Item 2 to check if the necessary signal is being output to the pump controller correctly.
20-105
2) Checking
operation
of electrical
system
When the set of operations given below is carried out in the order given and the action of the monitor panel, pump controller and engine throttle controller are as given in the table, the monitor panel (EMACC) and both the controller are normal. 0
The IH.1.1 display and other displays given in the table controller if the input and output signals are normal.
0
The monitor display of the pump controller is displayed for 1.5 seconds after the signal is input and after that the operation mode is displayed. For items @ ,a, and 0, the system automatically enters the auto-deceleration mode, so set the auto-deceleration switch on the monitor panel OFF.
0
Operation
procedure.and
condition
Items
of
machine
D
3
Monitor
l
.. Turn
starting
l
Turn
fuel
Turn
switch
OFF.
control
di& t&IN.
switch
ON.
starting
panel
are the monitor
for confirmation Pump
-
.AlllampsOFF
All lamps
b
Display lamps light UP G.0 and S mode is
m
(when
displays
Engine
All lamps
is displayed
throttle
FEzE
~~~~~~~~&~d for 5 set)
B
carry
temperature
Turn
engine
fuel
G.0
control
Set working
mode
Raise engine
speed
* B
* 3
mode
Set working
switch
to H.0
of H.0
mode
point
of
mode
Raise engine
speed
to G.0 from
travel
speed
work
Cancel
equipment
deceleration
speed
control
dial, governor
rises
is displayed
throttle
speed
(fuel
systems
normal)
rise (No. 2
signal
system
normal1
L.0 and L mode
of
-W
L.0 mode.
is
Engine j:_.‘-:]
is displayed
displayed
throttle
Engine
of G.0
of
-
speed
drops
signal
(No. 2
system
normal)
mode :$ldvSsTode
m
is displayed
Z?;;g;le
speed
rises again
signal
(No.
system
mode.
OFF. -
switch
switch
Engine
display
OFF.
switch
maximizing
I;-:.[
is displayed
H 0 mode.
FULL speed
to FULL speed
Set auto-deceleration
power
H.0 and H mode
of
FULL speed
to FULL speed
is displayed
potentiometer
to L.0 mode from
5 sec. normal
m
Engine
FULL speed of
After
flashes
OFF.
switch
speed
Set working
Switch
model
mode
from
mode
engine
Operate IzJ
in FULL speed
to FULL speed
Lower
Press
[Operating Decimal
Set auto-deceleration
L.0 mode l
3
speed
*
G.0
up and
mode.
Set auto-deceleration
*
+
dial to MAX.
.
B
a
warming
30°C.
speed.
Raise engine 9
is below
out automatic
increase
l
-1 .‘zt .r_ &I is displayed
engine If coolant
controller
OFF
display
Start
Hi and LO -)
between
is displayed -I:::“jTravel speed pm_ is displayed
[l
-
1.5 secl
[l
-
1.5 secl
Hi -Lo
or swing and raise engine
-
Ip.21
1; ~~lagy~~cl
mi
;: ““py;;,,
speed. Switch 0
auto-deceleration
Engine
speed
speed
Q
Switch
@
Operate
Return @
0
20-106
after
swing
travel
fuel
Engine
Turn
a few
lock
control
starting
ON.
to deceleration
ON and OFF.
slightly.
dial to MIN. drops
switch
Deceleration -)
is
displayed
seconds.
switch
lever
speed
switch
drops
to low
OFF.
-
Swing lock lamp OFF -=I:and ON is displayed
+
pm_
-_) idling.
r
by the
normal)
controller
OFF
given
Engine
speed
control
dial system
Engine
stops
(battery
relay
drops
system
(fuel normal)
normal)
DISPLAY METHOD FOR MONITOR ENGINE THROTTLE CONTROLLER 1. MONITOR
PANEL
PANEL,
PUMP
Model
l
Approximately 2 seconds after the starting switch is turned ON, all monitor and gauge lamps light up and the buzzer sounds for approximately 1 second. This is the selfdiagnostic function of the monitor panel. After this, the display returns to normal.
CONTROLLER
AND
code display. 1
Model
LED’s (Light Emitting Diodes) Red
Green
Red
OYF
O?F
O’N
Red
Green
Red
OFF
o’\l
OFF
PC3OOLC
PC400LC CONTROLLER 2. ENGINE THROTTLE 1 Model code display function (normal display) When the starting switch is turned ON, the model code is displayed for approximately 5 seconds on the controller display panel. * After 5 seconds, the model code display changes to the normal display or the abnormal display (self-diagnostic dis-
u Red
Green
Red
OFF
o’\l
O?F
Normal display
play).
2. Self-diagnostic display (abnormal display). l The abnormal display consists of 3 LED’s and the ON/OFF combination of these displays the type of abnormality (abnormal system). l If two or more abnormalities occur at the same time, the abnormalities are displayed in the order of priority shown in the table on the right. l Once the starting switch is turned OFF, the self-diagnostic display is reset. Check the abnormal display with the starting switch ON. l When the abnormality is removed, the display is automatically reset, so if the abnormality occurs intermittently, the abnormal display and normal display will appear alternately and the display may appear to be flashing.
Self-diagnostic
l
display
LED’s Order of priority (Light Emitting Diodes) Abnormal
I
Red
system
Green 0 OFF
Red 0 OFF
Power source system or controller system
&
Green 0 OFF
Red 0 ON
Short circuit in governor motor system
Red
Green
Red
1 OFF Red 2
5 OFF Red
$ Green
&
system or motor
Red fuel control dial
6 o’\l Red
&
$4
Green
Red
O’N
OFF
7 &
Abnormality in No. 2 throttle signal system
20-I 07
l
3. PUMP CONTROLLER 1. Model code display function (normal display). When the starting switch is turned ON, the model code is displayed for approximately 0.5 seconds on the controller display panel. 2. Operation display).
mode
display
function
Model code display Model
Code
Display
(normal
The operation mode is displayed unless there is any change or abnormality in the input or output system for the pump controller on controller.
l
Operation mode display
Power mode selection system
Working mode selection system Mode
Code
Display
1
\ \
General
2
-\ \Z
Finishing
3
-\ 3
Heavy-duty
\
)
Power source’ monitor
Lifting
1
4
1
\-\
Engine speed signal monitor When engine speed signal is
Lights up when
input
power is ON
Flashes
(At 2,000 rpm, approx. 2‘0 times/ 10 set)
3. Input signal display function (normal display). When the input signal to the controller is switched, the input signal is displayed for approx. 1 - 1.5 second. Ir If it is not displayed, there is an abnormality in the input signal system. * After the input signal is displayed for 1 - 1.5 seconds, the display changes to the operation mode display.
20-I 08
0
Input signal display
.:
;
1
T
Abnormality
4. Self-diagnostic display function (abnormal display). l If there is any abnormality in the controller output signal system and sensor system, the abnormal display and operation mode are shown alternately. If two or more abnormalities occur at the * same time, all of the abnormality displays and operation mode display are shown in turn. l
l
*
4
%
If 01 - 09, 25 are displayed, there is danger that the controller may be broken, so the controller automatically stops the output to the system where the abnormality has occurred. Once the starting switch is turned OFF, the abnormal display is reset, so check with the starting switch ON. If the starting switch is turned OFF, reenact the abnormal display as follows. n System Turn the starting switch ON. 17 System Turn starting switch ON (Engine stopped) and operate the control lever. A Start the engine and operate the control lever. If no signal comes from the engine speed sensor stopped, defective (engine clearance at sensor, etc.), the central decimal point does not flash. Example of display. i) H.O. and H mode when normal. \\
.\-\. ii)
1 \
circuit in 2-stage
,elief solenoid jhort
circuit in arm half flow
;olenoid jhort jhort
03
system
circuit in swing brake
;olenoid
04
system
cirucit in travel speed
;olenoid
but “throttle
signal
05
system -I-
Short circuit in CO cancel solenoid system
07
Short circuit in TVC solenoid
08
system (I ) Short circuit in TVC solenoid
09
system (2) Xsconnection *elief solenoid
in 2-stage system
Disconnection
in arm half flow
11 13
solenoid system Disconnection
in swing brake
14
solenoid system Disconnection
15
solenoid system
-in CO
cancel solenoid Disconnection
Throttle
17
system in TVC solenoic
system No. 2 throttle
i-
signal system
signal System
-l-i
\\-\ u 1.7
H
H
.
\.
\\-\
.
\.a
\
n
23
Rear pump pressure sensor system
24 25
svstem
26
output
28
svstem system
29 Dot only
Controller Power source system
I
’
.q
22
system
Auto-deceleration
18 21
Front pump pressure sensor
Overheat
n
I
in travel speed
Disconnection
-’ :.s . \\ \
.
I
Engine speed sensor system
in turn with
G$Q
C
01
system
Pressure sensor power source
Same as i) above system abnormal” \\ \ .\-\. \ and flashes
jhort
Code
system
I
All OFF
H
20-l 09
/
20-110
ACTION o
OF SELF-DIAGNOSTIC
ENGINE THROTTLE CONTROLLER
FUNCTION
SYSTEM
*
AND
SYMPTOMS
This table shows how the controller lFnr
Red
Green
Red
OFF
OFF
OFF
Disconnection
i
harness
thnca
between between
El (1) and fuse El (2) - M20
between
Ml
reacts and what symptoms havn
\nrhn
(2) (3) -
Foldout IO
ON MACHINE
M20
nnnri
the machine displays
I Inricarctanriinn
nf
mnrhatmnirc
if any abnormality
Red
Green
Red Short circuit in governor motor
ON
OFF
system
ON
Disconnection in governor motor system
Red
Green
Red
OFF
ON
ON
1. Short circuit inside governor motor 2. Short circuit of wiring harness between El wiring harness between El (14) - E2 (4) 3. Short circuit of wiring harness between El wiring harness between El (15) - E2 (9) 4. Wiring harness in Item 2 or 3 in contact with
1. 2. 3. 4. 5. 6.
1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11.
Disconnection inside governor motor Disconnection in wiring harness between El Disconnection in wiring harness between El Disconnection in wiring harness between El Disconnection in wiring harness between El Defective contact of connectors El, E2, E5
(12)
qut
using
this
table.)
(4) Cannot
ing harness
should occur in the
trnllhlnchnntinn
control
and chassis
(3) - E2 (3) E5 (2) (4) - E2 (10) E5 (4) ground
Makes motor drive current 0. (Abnormal display disappears when startrng switch is turned OFF.) * If the failure location is reset during opera-
E5 (1) with E5 (2) with
1. During operation Speed drops to low idling. 2) Engine does not stop. 2. When engine stops 1) Engine starts, but stays at low idling. 2) Engine does not stop after starting.
1)
connection occurs simultaneously for A phase and B phase, it is the same as short circuit in the governor motor (3) - E2 (3) - E5 (1) (4) - E2 (I 0) - E5 (3) (14) - E2 (4) - E5 (2) (15) - E2 (9) - E5 (4)
Same
as short
circuit
for governor
motor
system
No particular
action
is taken.
phase or B phase, 1) Engine does not stop. 2) Stops moving at position just before failure occurred, so engine speed cannot be controlled. ’
ple,
Short circuit in wiring
harness between El (5) - (6). (6) - (I 6). (5) Short circuit in wiring harness between E2 (1) (2). (2) - (7). (1) Short circuit in wiring harness between E4 (1) (2). (2) - (3). (1) Short circuit in wiring harness between E6 (1) (2), (2) - (3). (1) Short circuit in wiring harness between El (10) - (20). (C20 (10) Short’circuit in wiring harness between El (7) - (B), (8) - (18). (7) Disconnection in wiring harness between El (6) - E2 (1) E4 (1). Disconnection in wiring harness between El (5) - E2 (2) - E4 (2). Disconnection in wiring harness between El (16) - E2 (7) - E4 (3). Defective governor potentiometer. Defective contact of connectors El, E2, E5
-
-
-
(16). 17). (3). (3). (20)). (18).
Controls by calculating the position of motor from the voltage value just before currence of the abnormality.
the
following
cases
may
the oc3) Auto-deceleration warming-up speed high or too low).
or automatic are defective (too
Fuel control dial
Red
Green
Red Abnormality in fuel control dial system
ON
ON
1. Short
Fuel control dial At MAX: 0.25 - 1 .OV At MIN: 4.0 - 4.75V
circuit
ON
Holds the engine speed at the fuel control dial position just before the abnormality occurs. *
5. Disconnection in wiring harness 6. Disconnection in wiring harness 7. Defective fuel control dial 8. Defective contact of connectors
Red
Green
Red
0
0
0
ON
ON
OFF
Abnormality in No. 2 throttle signal system
1. 2. 3. 4. 5.
between between El,
El El
PEMC
control
impossible
(8) - E6 (2). (18) - E6 (3).
E6
Contact of wiring between harnesses between El (9) - (19) Disconnection in wiring harness between El (9) - C2 (1 1). Disconnection in wiring harness between El (19) - C2 (21). Abnormality in pump controller signal Defective contact of connectors El, C2
(C2 (11)
-
21)).
Between El (9) -
(19)
(C2 (11)
-
(21)): 0.25
-
4.75V
Actuated by the movement of the fuel control dial. * In the case of Item 2. the pump controller also displays.
When power set is set to S or L mode, speed does not drop. * PEMC control impossible
engine
20-I 12
.
PUMP CONTROLLER isplay 3de
System with abnormality
SYSTEM
*
This table shows how the controller reacts and what symptoms sensors or actuators. (For those who have good understanding
Details of abnormality
Condition when normal (voltage, current, resistance values)
the machine displays if any abnormality should occur in the of mechatronics, troubleshooting can be carried out using this table.) Action of controller when abnormality is detected
Foldout 11
Symptoms shown by machine when there is abnormality
01
2-stage relief solenoid
Resistance value of solenoid: 50 - 100 R
The relief pressure is not increased when using the power maximizing function, so there is lack of power
03
Arm half flow solenoid
Resistance value of solenoid: 10-350
In F.0 mode, the Hi circuit is not cut, so the fine control is poor. (The digging speed is the same as in G.0 mode)
04
Swing brake solenoid
05
Travel speed solenoid
07
CO cancel solenoid
Short circuit inside solenoid or between solenoid pins (I) - (2). (When resistance inside solenoid is extremely low) Excessive current flows
Resistance value of solenoid: 10-350
Resistance value of solenoid: 501000
Resistancevalue of solenoid: 50-
1000
TVC (+) line in contact with ground (excessive current flows)
08 TVC solenoid
Short circuit or contact with ground inside TVC solenoid (excessive current flows)
09
2-stage relief solenoid
Resistance value of solenoid: 501000
13
Arm half flow solenoid
Resistance value of solenoid: IO-35fl
14
Swing brake solenoid
15
Travel speed solenoid
Resistance value of solenoid: 501000
17
CO cancel solenoid
Resisistance value of solenoid: 50-loon
1) Disconnection inside solenolu (The resistance inside the solenoid is extremely large) 2) Disconnection in wiring harness between solenoid pin (2) and controller 3) Contact with ground at pin (2) of solenoid
1) Disconnection inside solenoid or dis-
21
TVC solenoid
No. 2 throttle signal
connection in wiring harness between controller Cl (9). (17) TVC solenoid 2) Contact of wiring harness between controller Cl (I 7) - TVC solenoid C4 (2) with ground
Wiring harness between controller C2 (1 1) - engine throttle controller El (9) in contact with ground
Resistance value of solenoid: IO-350
swing
operations,
the
motor
brake
is not released, SO the
machine does not swing
Travel speed does not change switch is operated
(stays in Lo) when travel speed
Action of CO valve does not stop when using the power maximizing function, so the pump discharge amount is minimum. Therefore, the speed is low in this pressure range.
Current does not flow to the TVC solenoid. Therefore, when the load is high, the engine speed drops excessively, and the engine may even stall. (All of H, S, and L modes)
Resistance value of solenoid: IO-220
11
18
During
It makes the current to the solenoid 0. However, the abnormality is temporary (momentary short circuit, etc.), so if the system returns to normal, the drive current is output again when all control levers are returned to neutral. t However, the display does not disappear (it disappears when the power is turned OFF). * The above automatic reset is repeated up to three times.
1. In cases 1) and 2). current stops flowing to the solenoid, so not particular action is carried out. Therefore, if abnormal places are reset by the vibration of the machine, they become normal again. * However, the display does not disappear (disappears when power is turned OFF.) 2. In case 31, electric current continues to flow to the solenoid, but the controller does not carry out any action. Therefore, if the abnormal places are reset, they return to normal. * However, the display does not disappear (disappears when power is turned OFF.) * When the controller sends the command to turn the solenoid current OFF, the voltage at portion @ should be 20 - 30V; if there is any disconnection or contact with the ground, the voltage at portion 0 is low (almost OV), so it can be judged that there is an abnormality.
1. In cases 1) and 21, it is the same as display 0 1.
1. In cases I) and 2). it is the same as display 03. 2. In the case of 3). the Hi circuit remains cut, so the speed for normal work is low. 1. In cases 1) and 2). it is the same as display 04. 2. In the case of 3). the brake stays released, so the brake has no effect even when the lever is returned to neutral. (The upper structure will swing on slopes.) 1. In cases I) and 21, it is the same as display 05. 2. In the case of 3). the solenoid continues to be actuated and stays at Hi.
1. In cases “”
1) and 21, it is the same as display 07.
205FO5348
Resistance value of solenoid: 10-220 Value
of
current
H mode
0.10
-
0.25A
S mode
0.59
-
0.89A
L mode
0.80
-
1.03A
1. In the case of 11, it is the same as Item 1 above. 2. In the case of 2). current continues to flow (approx. IA) to the solenoid 3. Other items are the same as Item 2 above.
1. In the cases 11, it is the same as display 08,09. 2. In the cases 2). the same current (approx. 1 A) continues to flow to the TVC solenoid, so the TVC valve output pressure drops and the total speed becomes slower. (There is no change even when the power set is switched between H, S, and L.)
There is an abnormal display, but no particular action is taken. Therefore, if the places in contact wit!: the ground are reset by the vibration of the machine, the condition returns to normal. * However, the display does not disappear (disappears when power is turned OFF.)
Even when the fuel control dial is set to MAX and the autodeceleration is canceled, the high idling speed of the engine does not change for H.0 + H mode or G.0 + S mode.
Engine at high idling, H.0 mode. (Auto-deceleration OFF, levers at neutral) 1. Voltage between Cl (1 I) and (12) : 0.8 - 4.2V 2. Resistance value between Cl (female) (1 1) and El (9) : Min. 1 M n (Disconnect El)
20-114
rolaouI
w-m_._
Display code
22
23
System with abnormality
Throttle signal
24
Pump pressure sensor signal
25
Pump pressure sensor power source
Details of abnormality
Condition when normal (voltage, current, resistance values)
1) Disconnection in wiring harness (1). 2) Wiring harness (1) in contact with ground 3) Disconnection in wiring harness (2). 4) Disconnection in wiring harness (3) or contact with ground 5) Disconnection in wiring harness (4) 1. Between El (8) and (18) or contact with ground (MAX) 0.25 - 4.75 V (MIN) 6) Disconnection in wiring harness (5). 2. Between El (7) and (18) <*is,6,dI : 5 f 0.5v Inmi!ir Engine &a, C0011B1C dldi ; (31 CO”l,Ol 3. Between C2 (10) and (20) t,v_: < 5 - 0,“#,-1 : (MAX) 0.25 - 4.75 V (MIN) (9,UC .SP %a 2 -h-,,,< -5 P”rn0 . i D,.,. CO”frOl*r 2) ’ .nr”“‘e 2051053L9 !z%I * In the case of 2), 4), 5). and S), the engine throttle controller also show abnormality. ” 1) Defective pressure sensor 2) Disconnection in wiring harness between pressure sensor (3) pin and ii 205FO5350 controller, .or contact with ground a:d (1) (6) C3 Between 1. beharness wiring in 3) Disconnection : 0.5 - 4.5v tween pressure sensor (1) pin and 2. Between C7 (1) and (2) controller : 18-28V 4) Disconnection in wiring harness be3. Resistance value between C3 tween pressure sensor (2) pin and (female) (6) and (1). and becontroller, or contact with ground tween (6) and chassis I) Defective pressure sensor : Min. 1 M R 2) Wiring harness between pressure (Disconnect connector of pressensor (2) pin and controller in consure sensor and connector at
1) Disconnection inside speed sensor 26
28
29
JI off
0
Engine speed sensor signal
(When the resistance inside the sensor has become extremely high) 2) Disconnection in wiring harness between speed sensor E7 (1) (2) pin and controller
Resistance value: 500 -
1000
(1
Action of controller when abnormality is detected
lt acts when the fuel control dial is set to MAX. If it is reset, it acts again in proportion to the movement of the fuel control dial. * However, the display does not disappear (disappears when power is turned OFF.) * In the case of 2). 4), 5). and 6). the engine throttle controller also shows abnormality.
Operate with pressure at 0 kg/cm*. If the abnormal place is reset, it operates normally. * However. the display does not disappear (disappears when power is turned OFF.)
Operates with pressure at 0 kg/cm’. When it detects an abnormality, it turns the output OFF; when all control levers
current to the TVC solenoid. If it is reset during operation, it returns to normal. * However, the display does not disappear (disappears when power is turned OFF.) 2. When the sensor function has been lost because of disconnection inside the speed sensor, the speed sensor monitor on the controller does not flash.
.
Symptoms shown by machine when there is abnormality
l)or3), i) Operates normally when the fuel control dial is set to MAX. ii) When the fuel control dial is set to “partial”, the power feels less than S mode although it is in H mode. 2. In case of 2), 4). 5), or 6). The engine speed does not change even when the fuel control dial is turned. 1. Inthecaseof
1. Cannot carry out PEMC control in S or L mode
(There is a horsepower difference between H, S, and L mode) 2. Travel speed does not change automatically (does not change from Hi to Lo) * Can be changed manually.
Same as display 23
The output pressure of the TVC valve drops, so the pump discharge Pressure drops (the engine load becomes lighter), and the total speed becomes slower.
Auto-deceleration signal
1) Disconnection in wiring harness between controller C2 (19) and engine throttle controller El (1 1) 2) Wiring harness between C2 (14) and El (1 1) in contact with ground 3) When auto-deceleration is canceled, and voltage between C2 (19) and (21) drops below 7V.
1. Voltage between C2 (19) and chassis 0 - 1V l During deceleration: 12V l When canceled: 8 2. Resistance value between C2 (19) and chassis: Min. 1 fl
It does not carry out any particular action. Therefore, if it is reset during operation, and all control levers are returned to neutral, the output starts again.
When the auto-deceleration switch on the panel is ON I) When the engine speed has dropped to deceleration speed, it becomes FULL speed. Or, if the engine is running at FULL speed, the engine speed does not drop to deceleration speed even when the levers are placed in neutral. 2) Even when the levers are operated, deceleration is not canceled.
Overheat signal
When voltage between controller C2 (17). (18) - (8) is below IV (when engine is overheating and monitor temperature coolant gives panel warning)
1. Voltage between C2 (17) and chassis, and between (1.8) and chassis 13V l When normal: 10 signal is overheat l When given: 0 - 2V
1. When 102°C signal is input: No. 2 throttle circuit outputs L mode speed command to engine throttle controller 2. When 107°C signal is input: No. 2 throttle circuit outputs low idling command to engine throttle controller.
1. In the case of I), it becomes L mode (controller display also becomes L) 2. In the casecf 2), the engine speed becomes low idling.
All functions stop, but when the power source voltage becomes normal, the functions return to normal. * The display also becomes normal
1. Upper structure does not swing because swing brake is not released. 2. Current of TVC solenoid becomes 0. (If the load is high, the drop in engine speed is large, and the engine may stall) 3. Travel speed is not switched. 4. Engine speed does not go down to deceleration speed.
Except for swing brake circuit, all functions stop. * However, TVC solenoid only gives a fixed Output Of approx. 0.7A.
Apart from swing brake and TVC solenoid, same as above.
Power source
1) Power source is not input 2) When voltage is more than 38V or less than 19V.
Only dot lights up
Self-diagnostic check inside controller (cannot be measured from outside)
Voltage:
20 -
30V
i12
METHOD
OF USING JUDGEMENT
TABLE
This judgement table is a tool to determine if the problem with the machine is caused by an abnormality in the electrical system or by an abnormality in the hydraulic or mechanical system. The symptoms are then used to decide which troubleshooting table (E-o-o, C-o-o, H-o-o) matches the symptoms. The presence of any self-diagnostic display given in the judgement table indicates which troubleshooting table to use. display (warning) given by the monitor panel leads directly to troubleshooting of the * The abnormality vehicle (P-o-o). (See the contents for troubleshooting of the vehicle monitor system.) table for engine throttle controller,
engine related parts.
1)
Judgement
0
If the self-diagnostic display gives an abnormal display, go to the troubleshooting code (E-o) given on the bottom line of the judgement table. (There is a l given in the column where the failure mode and self-diagnostic display, go to the troubleshooting code (E-o or engine shop manual) given in the column on the right of the judgement table for that failure mode.
c Example>
Failure
mode “Lack of output
power”.
[Procedure] Check the three LEDs on the side face of the controller abnormal display for the self-diagnostic display.
to see if their
ON/OFF
combination
gives an
[Judgementl If there is an abnormal
If there is no abnormal
l
display
display
(for example,
l-
on the self-diagnostic
display:
Go to troubleshooting
E-2 of the electrical
system
........... Starting motor rotates:
on the self-diagnostic
r
Check that the starting motor rotates
VI)
display:
Go to troubleshooting of mechanical system (see engine shop manual)
Starting
motor does not rotate:
............
Go to troubleshooting of electrical system Fl , 2, or 6
20-117
2)
Judgement table for pump controller, hydraulic related parts. l If the self-diagnostic display gives an abnormal display, go to the given on the bottom line of the judgement table. (There is a l given in the column where the failure mode and together.) l For any problem where there is no abnormal display given by the the chart for the place where the failure mode and input signal marked 0).
troubleshooting
code
(C-o-o)
self-diagnostic
display
come
self-diagnostic display come
display, together
check (place
If the display is normal, go to the troubleshooting code (H-o-o) given in the column on the right of the judgement table. If the input signal is not displayed, go to the troubleshooting code (F-o-o) given on the bottom line. c Example>
Failure
mode “Auto-deceleration
[Procedure] Check if an abnormal display of the controller are flashing.
[Judgement] If there is an abnormal
If there is no abnormal
display
display
is given
does not work”.
by the
(for example,
self-diagnostic
display
or if the numbers
on the side face
28) on the self-diagnostic display: Go to troubleshooting C-21 of the electrical
on the self-diagnostic
display,
and the auto-deceleration
does.not
Display given: ...................... Go to troubleshooting hydraulic system H-7 .
Check the monitor controller
for the pump
.;
input signal
work: of
‘,1>
‘.Go t& tr;&-l@fi&q$f No display given:. ..... . . 1:..... electrical
20-118
system.
system
Fl , 2, 3, or 6
METHOD
OF USING TROUBLESHOOTING
1) Category of troubleshooting Troubleshooting Code No.
2)
CHARTS
code number
Component
E-o-o
Troubleshooting of engine controller system.
throttle
c-o-o
Troubleshooting system.
F-o-o
Troubleshooting of pump controller input signal system.
H-o-o
Troubleshooting of hydraulic mechanical system.
P-o-o
Troubleshooting
of pump controller
of monitor
Method of using troubleshooting
and system.
table.
Troubleshooting code number and problem. The top left of the troubleshooting chart gives the troubleshooting code number and the problem with the machine. Distinguishing condition. 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)), 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. Method of following troubleshooting chart. Check or measure the item inside the box and according to the answer follow either the YES line or the NO line to go to the next box. (Note: The number written at the top right corner of the box 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 box there are the methods for inspection or measurement and the judgement values. If the judgement values below the box are correct or the answer to the question inside the box is YES, follow the YES line; if the judgement value is not correct or the answer to the question is NO, follow the NO line. Below the box 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 1. 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 *are not given in the box but must always be followed when carrying out the check inside the box. Troubleshooting tools. When carrying out the troubleshooting, see TOOLS FOR TESTING, ADJUSTING
prepare the necessary troubleshooting AND TROUBLESHOOTING.
tools.
For details,
20-119
Installation
position,
pin number.
A diagram or chart is given for the connector type, installation position and connector pin number connection table, so when carrying out troubleshooting, see this chart for details of the connector pin number and location for details of the connector pin number and locations for inspection and measurement of wiring connector number oo appearing in the troubleshooting flow chart. -CExample
>
[Short
circuit
in governor
motor]
is displayed.
(There are cases where the troubleshooting is divided into Sections a), b), etc.). * If this happens during operation, because of the force of the spring: l Engine speed changes to low idling. It
If the problem occurred when the engine was stopped: l Engine starts but remains at low idling.
A
Stop the engine
*
Before carrying inserted.
*
Always
connect
out
before
carrying
out any checks.
teoubleshooting,
any disconnected
check connectors
that
all the
before
going
related
connectors
Defecrive CO”I,Ollei “‘I Green
ON
OFF
Red
ON
El
Remedy
each pin-chassis as shown in Table 1,
rhroffle
Short circuit in wiring harness for Problem pin NO. (berween ElEZE5) * See Fig, 1
wifch OFF. i Dirconnect
El. Defective mo7or
20-120
engine
(female),and
Is resistance befween each pin of ! E5 (ma,e),a”d
properly
on to the next step.
Cause
Red
are
governor
TROUBLESHOOTING OF ENGINE SYSTEM (E-MODE) ENGINE
THROTTLE
CONTROLLER
OR IN ENGINE
RELATED
PARTS
CONTROLLER
. . . . . . . . . . . . . . . . . . . 20-123
POINTS TO REMEMBER WHEN CARRYING OUT TROUBLESHOOTING ON ENGINE THROTTLE CONTROLLER SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-125 E-l
[ABNORMALITY
IN POWER SOURCE SYSTEM OR CONTROLLER] ..................................................
IS DISPLAYED
(ALL LAMPS OFF) CIRCUIT
IN GOVERNOR
E-2
[SHORT
E-3
[DISCONNECTION
E-4
[ABNORMALITY
IN GOVERNOR
E-5
[ABNORMALITY
IN FUEL CONTROL
DIAL]
E-6
[ABNORMALITY
IN NO.2 THROTTLE
SIGNAL]
E-7
ENGINE
DOES NOT START (PC3OOLC)
...................................
20-136
E-7
ENGINE
DOES NOT START (PC4OOLC)
...................................
20-138
E-8
ENGINE
ROTATION
E-9
LACK OF OUTPUT
E-10
ENGINE
E-l 1
AUTOMATIC
IN WIRING
MOTOR]
HARNESS
OF GOVERNOR
POTENTIOMETER]
IS IRREGULAR
WARMING-UP
..................... MOTOR]
IS DISPLAYED.
IS DISPLAYED
IS DISPLAYED. ...............
......................
IS DISPLAYED.
...................
......................................
POWER (MAX. ENGINE
DOES NOT STOP.
IS DISPLAYED.
20-126
SPEED IS TOO LOW)
IS DEFECTIVE
...
20-129 20-130 20-132 20-134
20-142 .................
............................................ OPERATION
20-128
20-144 20-146
.......................
20-148
20-121
20-122
20-124
POINTS TO REMEMBER WHEN CARRYING OUTTROUBLESHOOTING ENGINE THROTTLE CONTROLLER SYSTEM The engine on the PC3OOLC and PC4OOLC is controlled by an engine The problems that may arise with this system are as follows.
throttle
ON
controller.
1. Low idling speed in too high (low). 2. High idling speed is too low. 3. Auto-deceleration speed is too high (low). 4. Automatic warming-up speed is too high (low). 5. There is hunting. 6. Engine does not stop.
If an abnormality occurs and the abnormality is displayed by the self-diagnostic display, use the charts to go to the applicable troubleshooting flowchart G-l - G-7. However, it there is no self-diagnostic display and there is an abnormality in the machine, it is necessary to determine if the problem is in the mechanical system or in the electrical system. For example, if there is defective adjustment of the linkage between the governor motor and injection pump, the above problems 1 - 6 may occur. troubleshooting procedure. therefore, if any of the above problems 1 - 6 occurs, carry out the following
Yes
2
Yes
b
pump is disconnected and pump governor lever is operated by hand or is secured with wire?
I l
Set starting switch No at ON position and operate fuel control dial and working mode switch.
Defective adjustment of governor motor linkage. See TESTING AND ADJUSTING.
GO to troubleshooting of electrical system E-8 - E-10.
See Engine Shop Manual
If the engine does not stop, push the governor lever to the STOP position and check if the engine stops.
After disconnecting or adjusting mechanical system or electrical f For details of the procedure
the ,linkage as shown above, go to the troubleshooting flow chart for the system. for adjusting the linkage, see TESTING AND ADJUSTING.
20-125
El mj
[ABNORMALITY
IN POWER SOURCE
CONTROLLER] *
IS DISPLAYED
If fuses 2 and 9 are not blown. If they are blown, check for a short circuit switch.
f
If battery
* *
Before Always
in the wiring
SYSTEM OR
(ALL LAMPS OFF)
harness
between
fuse - controller
is normal.
carrying connect
out troubleshooting, any disconnected
check that all the related connectors are properly connectors before going on to the next step. 4 1s there between (female) battery terminal
YES 3
Is voltage . El (2).and normal?
Yl
continuitv El (12) and
-
E?
0 Turn starting switch OFF.
between El (12)
-
Is voltage El
(1)
and
.20-30V 0 Turn starting switch ON.
between El (12)
0 Disconnect
NO
NO El. YES
Is voltage between starting switch terminal 6R and chassis normal? .20-30V 0 Turn starting switch ON.
.20-30V 0 Turn starting switch ON.
YES
relav
5
2
NO
JO
* YES switch
6 I
ON.
r
Is voltage between battery relay terminal 6 R and chassis normal? _
7
.20-3ov l Turn
switch
starting ON.
NE
Is voltage between starting switch terminal BR and chassis normal? .20-30V l Turn starting switch ON.
Starting switch
MI(M4)
YES
-
NO
DIO
Engine throttle controller
F20505355A
20-126
or starting
inserted.
CaL4S.e
Defective
engine
controller
Remedy
throttle
Replace
Defective contact, or disconnection in wiring harness between El (female) (12) - Ml4 (8)
Repair replace
or
Defective contact, or disconnection in wiring harness between El (female) (2) -starting switch terminal ACC
Repair replace
or
Defective
Replace
starting
switch
Defective contact, or disconnection in wiring harness between E1 (female) (1) -fuse 2 outlet port
Repair replace
Defective
Replace
battery
relay
Defective contact, or disconnection in wiring harness between starting switch terminal B R - M7 (2) -battery relay terminal 8R
Defective
starting
switch
Repair
or
or
replaCe
Replace
20-I 27
E2 li$ii
[SHORT CIRCUIT
IN GOVERNOR
MOTOR]
IS DISPLAYED.
If this happens during operation, because of the force of the spring: 1. Engine speed changes to low idling. 2. Engine does not stop. If the problem occurred when the engine was stopped: * 1. Engine starts but remains at low idling. 2. Engine starts but does not stop.
*
A
Stop the engine (Place the governor before carrying out any checks.
*
Before
carrying
out troubleshooting,
*
Always
connect
any disconnected
lever of the injection
pump in the NO INJECTION
check that all the related connectors
before
going
connectors
are properly
Table
inserted.
on to the next step.
Remedy
CaUSe
?
position)
YES
Defective controller
engine
throttle
Replace
Short circuit in wiring harness for problem pin NO. (between ElE2-E5) l See Fig. 1
Repair replace
Defective motor
Replace
governor
or
1.
Between
E5 (male)
El (female)
(1) - (2)
(3) - (14)
4-90
(3) - (4)
(4) - (15)
4-90
(2) - (3)
(3) - (4)
Min. 1Mn
(2) - (4)
(3)~(15)
Min. 1Mn
pins (l),
(2), (3), (4) - chassis
Between
pin
(3), (4), (14), (15) - chassis
Resistance
value
Min. 1 MQ
Fig. 1 Engine throttle controller
E I (MIC21)
205FO5352-2
20-128
[DISCONNECTION MOTOR] *
During operation: 1. If there is disconnection Engine Engine
speed changes does not stop.
2. If there
IN WIRING
HARNESS OF GOVERNOR
IS DISPLAYED.
simultaneously
in the A phase and B phase:
to low idling.
is a disconnection
in either
A phase or B phase:
The engines speed stays the same as immediately before the problem If the problem occurred when the engine was stopped:
*
1. Engine
starts
2. Engine
does not stop.
A * *
but remains
at low idling.
Stop the engine (place the governor before carrying out any checks.
Before carrying Always connect
occurred.
out troubleshooting, any disconnected
lever of the injection
pump in the NO INJECTION
check that all the related connectors are properly connectors before going on to the next step.
position)
inserted.
Remedy
I
2 YES IRed
Green
Red
s
ON
OFF
Defective controller
ND
. ~~~,:: * Turn
starting
switch
OFF.
engine
throttle
Replace
Short circuit in wiring harness for problem Pin No. (between El - E2 -E5) l See Fig. 1
3epair ,eplace
Defective motor
Replace
or
chassis as shown in Table I?
OFF
~
Table
Is resistance .;,.,..,. between each pin of E5 (male),
YES
15 resistance between each pin of El (female). and
. Turn starting switch OFF. * Disconnect E5.
governor
No
1.
Between
Resistance
value
E5 (male)
El (female)
(1) - (2)
(3) - (14)
4-9n
(3) - (4)
(4) - (15)
4-90
(2) - (3)
(3) - (4)
Min. 1MSl
(2) - (4)
(3)-(15)
Min. 1MQ
pins (l),
(2), (3), (4) - chassis
Between
pin
(3), (4), (14), (15) -
chassis
Min. 1 Mn
Fig 1 Engine throttle
controller
205FO5352-2
20-129
E4 ml
[ABNORMALITY
IN GOVERNOR
POTENTIOMETER]
IS DISPLAYED. *
If the pump controller
*
Before
carrying
out troubleshooting,
displays
only “22”, go to troubleshooting
f
Always
connect
any disconnected
check
C-18.
that all the related
connectors
before
going
connectors
are properly
Is resistance between El (female) (6) - (5). (5) (16). (6) - (16) as shown in Table l?
YES 3
YES _
r
Is resistance between E4 (male) (1) - (2). (I) - (3). (2) (3) as shown in Table
Governor motor potentiometer display and pump controller display 1221
I
-
- Turn starting switch OFF. - Disconnect El.
l?
. Turn
starting switch OFF. . Disconnect E4.
t
-chassis
.
I
Min. 100 k.Q . Between wiring chtzz
aMn;. 1 Ma starting switch OFF, ‘Disconnect El and
NC
C2.
a Turn starting switch OFF. * Disconnect El. Table
.
ND
normal?
* Turn
l?
Turn startina switch OFF.. Disconnect E4.
Engine throttle
inserted.
on the next step.
NO
1 IO
controller
E I (MIC21)
Pump controller
Fuel control
Governor
dial
potentiqmeter
F205F05357A
20-130
T .. .,-
.
Remedy
:
-
.
.
6 Is resistance between El (female) (7) - (8), (8) (18), (7) - (18) as shown in Table 17
YES 5 T between E6 (male) (1) - (2). (1) - (3). (2) (3) as shown in
switch OFF. . Disconnect
-
* Turn starting * Disconnect
switch El.
.
YES
engine
throttle
Replace
Wiring harness between El (female) (7) - E6 (female) (1) in contact with ground, or Contact with other wiring harness
ND OFF.
“I E6.
Defective controller
NO
Defective fuel control dial
Replace
Wiring harness between El (female) (6)-E2 (1) -E4 (female) (1) in contact with ground, or contact with other wiring harness.
Repair replace
Defective motor
Replace
i
NO
or
I
.
Table
governor
Short circuit in wiring harness between El (female) (10). (20) ‘c2 (ft?inale) (10). (201, or contact with ground
Repair replace
Defective throttle
Recdace
engine controller
or
Defective wiring harness in system where resistance value is defective
Repair reDlaCe
Defective motor
Replace
governor
or
1. E4 (male)
E6 (male)
Between
(1) - (3) Between
(1) - (3)
Between
(3) - (2)
Between
(1) - (2)
Between
(2) - (1)
Between
(2) - (3)
El (female) Between Between Between
(6) - (16) (6) - (5) (5) - (16)
Between (6), (5), (16) - chassis
El (female) Between Between Between
(7) - (18)
Resistance
value
4-6
(7) - (8)
0.25 - 7.0
(8) - (18)
0.25 - 7.0
Between (7), (8), (18) - chassis
(KQ)
Min. 1MQ
20-131
I
[ABNORMALITY When the relevant abnormality at the same time.
IN FUEL CONTROL
is displayed,
Before
carrying
out troubleshooting,
Always
connect
any disconnected
“Pump controller
abnormality
check that all the related connectors
before
going
DIAL] IS DISPLAYED display
connectors
22” is also displayed
are properly
inserted.
on to the next step.
Cause
3 YE
YE
YE
Red
Green
Red between
ON
ON
ON
u
Turn starting switch OFF. Disconnect El.
E6
(3) ar shown
I
NI
. Min. lOOka . Between wiring harness - chassis: Min. 1 MS1 ’ Turn starting switch OFF. * Disconnect El
and
C;
in
* Turn starting switch OFF. Disconnect E6.
*
Table
1.
I
E5 (male) .
Between
(1) - (3)
Between
(1) - (2)
Between
I
El (female)
I
Between Between
(2) - (3)
Between
-
IBetween Fig.
1
(7) - (18)
throttle
Replace
Resistance
value
(Kn)
Short circuit in wiring harness between El (female) (10). (20) C2 (female) (10). (20), or contact with ground
Repair reolace
or
Defective wiring harness in system where resistance value is defective
Repair replace
or
Defective dial
Replace
fuel
control
1
4-6
(7) - (8)
0.25 - 7.0
(8) - (18)
(7), (8), (18) - chassis
engine
E[
2 Is resistance between El (female) (7) - (S), (7) (18), (8) - (18) as shown in Table I? t
Defective cO”trOller
RW”edY
0.25 - 7.0
I
Min. 1Mn
I
1 throttle controller
Engine
E I (tvlIC21)
C2(MIC21)
r-k IO
Throttle (+)
\ E6(M3)
I
1
Pump controller
Throttle (-)
I Fuel control dial
0
r
,, L
T e Sensor power source 5V
20-132
F2050.5358
[ABNORMALITY
E-6 mj
IN NO.2 THROTTLE
SIGNAL]
IS DISPLAYED. -k f
Before carrying Always connect
out troubleshooting, any disconnected
check that all the related connectors are properly connectors before going on to the next step.
4
inserted.
YES
Yl . Switch working
mode switch.
2 Is resistance berwee”
Red G
Red
We”
0
0 ON
between OFF
M
Table
. Turn starting switch OFF. a Disconnect El.
starting OFF. Disconnect El.
NO
Pump controller
Engine throttle controller El
El (female)
(female)
-
Resistance value
C2 (female) I
Between
* Turn ’ s:i,h
ND
1.
Between
I
Turn starting switch OFF. Disconnect El and C2.
El
0
ON
El
(female) (9). (19) - C2 (female) (11). (21) asshown in Table l?
I
(9) - (19)
1
(9) - chassis
1
-
1
Min. 1Mn
- chassis 1
-
I
Min. 1MO
Between (19)
EI(MIC21)
Min.
1
1Mfi
Between (9) - (11)
Max. ln
Between (19) - (21)
Max. lg
-J
205FO5358
Voltage
Table 2 Condition I11
Engine speed (rpm) 205FO5359
20-134
I)
132(YlC2
I
when measuring When overheatina
PC3ooLC
1 4.0-4.25
(V
PC4ooLC
1 4.0-4.25
CaUSe
.
Defective
engine
Remedy
throttle
Replete
controller
Defective controller
pump
Replace
Contact of wiring harness between El (female) (9), (19)C2 (female) (ll), (21)
Repair replace
or
Disconnection in wiring harness between El (female) (9). (19)-C2 (female) (11). (21)
Repair replace
or
Repair replace
or
Wiring harness between El (female) (9). (19)C2 (female) (11). (21) contact with ground
in
20-135
E-7 ENGINE
DOES NOT START
When the cranking motor does not turn. Check that fuse 9 is not blown before starting troubleshooting. 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. 4 IS voltage betueen Yes starting motor -terminal chassis
* Turn starting switch ON. * Approximately
3 Is there any sound .of a starting motor pinion moving out.
No Yes
24'4. 5
-
* Turn starting switch to START.
Yes
B normal?
Is voltage between starting motor terminal C chassis normal?
i No
f
Turn starting witch to START. * Approximately 24'4.
No
2
Yes
Is there continuity Yes between battery 11 -terminal (-) battery relay terminal - b?
Is any noise heard frcm the batterv
* Turn starting
Is resistance of Yes wiring harness -between starting switch BR - battery relay BR normal
switch
10 1
I between gravity
starting
I
u
normal?
INo
* Between starting switch BR- battery 1 relay BR: Max. 1 ohm. . Bet&en wiring harness chassis: MIN. 111 ohm. * Disconnect at both startifvg witch and
battery relay &_
Min. 24V * Specific gravity: Min. 1.26
I No
Is voltage ing switch B normal?
switch ON. * Remwe terminal
at startterminal -
* Connect (-) pole of tester to (-) terminal of battery. * 20 - 29V.
No 8.
No
No
starting switch
08DD0019
20-136
-
Defective
starting
Defective contact of Miring harness batwen battery terminal (+) starting motor terminal
7
* Approximately . Turn starting switch ON.
-
NO
12V.
a
Yes
- Approximately 24V. Is voltage between * Turn starting starting switch switch to START -terminal C and position. NO chassis ground? * Approximately 24V. . Turn starting to START position.
starting
Defective
safety
Repair B
motor+;
relay
Defective contact, or disc-tion in wiring harness between ~8(2)alternator terminal D, or defective alternator
Replace
Repair or replace
Defective contact, or discornaction in wiring harness between starting switch terminal C-M(4)M14(1)-EBtl)-MZ(l)safety relay terminal S
Repair or replace
Defective
starting
Repair
Defective
battery
switch
NO relay
Defective ccntact of wiring harness between battery terminal (-)battery relay terminal-b Defective contact, or disconnection in wiring harness between starting switch terminal BR-Ml (21-117 (2Mattery relay tensinal RR Defective starting switch (between terminal B-RR) Defective contact, or disconnection in wiring harness between battery terminal (+I-Ml-H7 (1)-M (l)-starting switch terminal B (including fusible link) VBattery
Replace
Yes
Is voltage between Yes safety relay -terminal R end 6 chassis grow-d? Is voltage between safety relay terminal S and chassis ground?
Defective
Replace
motor
capacity
too 10~
Replace
Repair or replace
Repair or replace
Replace
Repair or replace
Charge or replace
20-137
E-7 ENGINE
DOES NOT START
PC3OOLC b) When the cranking motor is normal. * 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 2,
Defective shut-off valve
Replace
Defective contact or disconnection in wiring harness between ElD(B)E9(4)-E8(7)- safety relay terminal C.
Repair or replace
Defective contact or disconnection in wiring between ElO(A)E9(3)-M14(4)-M1(5)- starting switch terminal (ACC).
Repair or replace
Defective starting switch.
Replace
tween El0 (female)
1 l
Is voltage between ElD(A)- chassis normal?
l
l
Turn starting switch OFF Disconnect El0 and safety relay terminal C. Max. In
Turn starting switch ON * Approximately 24V. l
3
Yes -harness
starting switch N~%!k:'n!!~~~ l
l
1 Lo
Turn starting switch ON. Approximately 24V.
Safety Relay
El0
Valve
20-I 38
M14CS83
Ml
tM81
Starting Switch
E9tSWP81 1
08DD0020
E-7 ENGINE
DOES NOT START
PC4OOLC b) * *
When the cranking motor 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.
inserted.
Cause
Remedy
Yes Defective shut-off valve.
!eplace.
1 Is voltage between shut-off valve terminal - chassis normal?
-
Yes
1 l
l
Turn starting switch ON. Approximately 24V.
Is voltage between starting switch terminal (Act)-
l
l
Turn starting switch ON. Approximately 24V.
EBISWP61 Shut-off
valve
Defective contact or disconnection in wiring harness between starting switch terminal (Act)-M(5) -M14(4)-E8(3)- shut-off valve terminal.
Defective starting switch.
lepair or replace
leplace
No
M14(Si31 Starting switch
08DD0021
20-l 39
E-8 ENGINE
ROTATION
IS IRREGULAR
a) Idling rotation is irregular. * Before starting troubleshooting,
* *
Before Always
carrying connect
YES
check
out troubleshooting, any disconnected
Adjust linkage bet&e” governor motor and injec tion pump. Does it become “or”lal? * See TESTING ADJUSTING.
the model
code.
check that all the related connectors are properly connectors before going on to the next step.
:
_
NO
AND
Warming-up
,
. Turn OFF.
starting
signal
6
YES
Is voltage
1 Is motor lever at low idling position when linkage is disconnected?
inserted.
Starting
signal
between El (21) -(12) normal and stable?
YES -
5
Is voltage between El (2) - (12) normal and stable?
YES -
switch
Potentiometer
4
Is voltage. YES
between
Fuel
-
NO
control
dial
Is voltage between El (8) - (18) normal and stable? - At MIN.: 4.0 - 4.75v - At MAX.: 0.25 - l.OV
-
(16)
and
3 *At _
low
El
(5)
_
* When 20-30V
~
-
* When warming-up VO operating: Max. 1V * When warming-up canceled: 8 - 12V
operating: NO
normal
stable? idling
PC3coLc: PC4OOLC:
2.6 - 2.9v 2.6 - 3.OV
No
NO
Engine throttle controller
E6 (M3)
El (MIC21)
-0
3 E4 (X3)
1 .O Governor
P2 (MIC16)
.O
11
potentiometer
7 Monitor
panel
@ 08DD0022
20-140
I
Cause
Defective of linkage
adjustment
Defective
injection
Pump
Defective motor
governor
Remedy
Adjust
;ee Engine nanual
sho
Replace
SeeE_ll Defective contact of wiring harness between starting switch BR - Ml (2) - M20 (4), (3) - El (female) (21, or defective starting switch
See
Repair replace
or
E-4
20-I 41
E-8 ENGINE
ROTATION
b)
There is hunting.
*
Before
* Ir
Before carrying Always connect
starting
troubleshooting,
check the model
out troubleshooting, any disconnected ._
‘ES
IS IRREGULAR
2
code.
check that all the related connectors are properly connectors before going on to the next step.
inserted.
YES
Adjust linkage between governor motor and injection pump. Does it become flOrmal?
i
YES
Starting
7 -
signal
Is voltage r
Deceleration signal
1 ~~~~~~;~is-
iS No.
- Turn
_
2 throttle
* Move
Is voltage between El (11) _ (12)
* When
. between El (5) - (16) normal and stable?
YES Fuel
,NO
control
dial
Is voltage between El (8) - (18) normal and stable?
3
-
At MIN.: 4.0 - 4.75v At MAX.: 0.25 - 1.OV
*At low idling: 63ooLc: 2.6 - 2.9v 64WLc: 2.5 - 3.ov *At high idling: 0.5 - 0.9v *When decelerating: *When warming-up:
6
normal stable?
starting switch ON. fuel Control dial from MIN. to MAX. and stop on tne way.
- When _
20-30V
NO
and
auto-decele-
ration operating: Max. 1V When auto-deceleration canceled: 8 - 12V
NO
1.7 - 2.OV 63KILc: 64OOLc:
1.8 - 2.2V 1.9 - 2.3V
NO
Voltage
1 when measurinrr
1 (1) 1
When overheating
(2)
L.O. and L mode G.O., F.O. and S mode
(3)
(rpm)
205FO5362
(V)
1 PC3OOLC 1PClOOLc] 1 4.0-4.25
1 4.0-4.25 1
2.1 o-2.46
2.20-2.50
1.23-l 53
1.35-l .65
G.O.. F.O. and L mode
l(4) 1 H.O. mode or H mode
20-142
engine
NO
1 Condition
speed
running:
1
Table
Engine
between El (2) - (12) normal and stable?
YES
1. 0.75-1.0
1 0.75-1.0 1
CSSe
Warming-up
signal
Is VOItage between El (21) - (12) normal and stable?
-
6
YES
Remedy
Defective adjustment of linkage
tdj “St
Defective pump
injection
ee Engine shol 1anual
Defective motor
governor
3ePlaCe
-
. When
See E-1;
-
Defective contact of wiring harness between starting switch BR - Ml (2) - M20 (4). 13) El (female) (2) starting switch, or defective starting switch
warming-up NO operating: Max. 1 V When warming-up canceled: 8 - 12V
qepair or ,eplaCe
See-P-l?
See E-6
See E-5
Fuel control
Governor
dial
potentiometer
20-143
E-9 LACK OF OUTPUT Before
* *
starting
Before carrying Always connect
POWER (MAX. ENGINE SPEED IS TOO LOW)
troubleshooting,
check the model
out troubleshooting, any disconnected
code.
check that all the related connectors are properly connectors before going on to the next step.
inserted.
NO. 2 throttle
Potentiometer
- start engine. . Fuel control is at MAX. . Heavy-duty +H mode.
El (5) - (161 normat and stable?
Fuel control dial
dial Yes
Is voltage
. At low idling: 6300LC: 2.6-2.9V. 6400LC: 2.6-3.OV. * At high idling: * tien decelerating: * Uhen warming-up:
batuaen
. At MIN: 4.0-4.75V. At MAX: 0.25-l.OV.
*
linkage between governor rotor *
I
3
H I No L 6300LC. 630O~C. 6300LC: 6400~~:
NO
6400LC: 0.5-0.9V. 64OOLC: 1.7-2.OV. 1.8-2.2V. 1.9-2.3V.
I NO
No
NO
l"J.ZCtlO"
Pnp.
it become
normal?
. See TESTING AOJUSTING.
E 4.0 -
DOeS
NO
AND
@
E Table
p 3.0 5 ._
1
Voltage
(V)
N
Enginespeed
1
(rpm) 205FO5364
20-I
44
(4)(
H.O. mode or H, mode
1 0.75-1.0 1 0.75-1.0
Defective
injection
pimp
;ee Engine Shop
lanua 1 Yarming-up
signal
7
Yes Defective
Stertina Yes IS volt&x between signal 6 p Is vottage between El (2) - (12) * Uhen warming-up operating: Max. 1V. normal and stable? * Uhen warming-up canceled: 8-12V. ~ No * When engine 4Refer rwing: 20 - 30V.
governor
motor
eplace
Refer to E-11
to P-19
to E-6
to E-4
to E-5
Defective adjustment of governor motor linkage
djust
Defective
ee Engine Shop anual
injection
Fuel control
Governor
pnp
dial
potentiometer
Pump controller
Monitor
panel
20-145
E-l 0 ENGINE
A *
DOES NOT STOP.
Stop the engine (place the governor lever of the injection before carrying out any checks.
Before starting troubleshooting,
pump in the NO INJECTION position)
check the model code.
~1
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.
PCBOOLC
Remedy
Cause Yes
Repair or replace
[-IDefective No
shut-off valve.
Starting
@ 0 El-K
Safety Relay
M14CS83
Ml
0
El0
Valve
20-146
Replace
I
E9lSWP61
1
CM61
Switch
Act
E-IO ENGINE
A *
DOES NOT STOP.
Stop the engine (place the governor before carrying out any checks.
Before
starting
troubleshooting,
lever of the injection
check the model
pump
position)
code.
*I
* f
in the NO INJECTION
:
Before carrying Always connect
out troubleshooting, any disconnected
check that all the related connectors are properly connectors before going on to the next step.
inserted.
PC4OOLC
Remedy
Cause I
Yes
Does engine when wiring of shut-off terminal is
Defective starting switch or wiring harness between starting switch terminal (Act)-M1(5)-M14(4)-E8(3)shut-off valve terminal in contact with +24 volts.
stop harness valve removed GDefective No
shut-off valve.
Fuse
Repair or replace
Replace
9
MlfM63 EBISWPGI Shut-off
valve
M141S81
0 Starting switch
08DD0021
20-147
E-l 1 AUTOMATIC f
WARMING-UP
OPERATION
IS DEFECTIVE
Warming-up is not carried out when the coolant temperature is under 30°C or does not stop when the coolant temperature goes above 30°C. (When it is canceled by the fuel control dial, there is no change in the voltage.) Conditions for carrying out warming-up: 1. Coolant temperature below 30°C. 2. Fuel control dial set at about 50% or below (warming-up signal: Max. 1V). Conditions for canceling warming-up: 1. Coolant temperature above 30°C. 2. Fuel control dial raised to above 70% and kept there for at least 3 seconds in power set switch H or S mode (see Note 1). 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.
*
*
j, f
Note 1: Note 2:
When the fuel control dial is turned unless the starting switch is turned When the fuel control dial is turned change.
up to cancel warming-up, warming-up OFF and then turned ON again. up to cancel warming-up, the voltage
will not start again of El (21) does not
Remedy
YES (See
-
:
Warming-up operation canceled
I
2)
2
Defective controller
7
l--I
See
- When canceled: a-12V * Fuel control dial at MIN. * Start engine.
t
- Turn starting switch OFF. - Disconnect El and
4
YEg2’
-11 Warming-up operation “of start
does
I
Is voltage between ~1 (21) - (12) normal?
I
Between El (female) (21) - chassis Between El (female) (21) - P2 (female) (11)
I
P-21
Disconnection in wiring harness between El (female) (21)P2 (female) (11), or contact with ground
Repair replace
Defective cO”trOller
Replace
See
Engine 1
Reolace
engine
throttle
or
P-21
Max. 1V dial at MIN.
1
Wiring harness
throttle
NO
* Warming-up: - Fuel control - Start engine.
Table
engine
voltage
Is between El (21) - (12) normal?
is not
1 Warming-up operation is not canceled, or warmina-uo
Note
throttle
controller
Resistance value EltMIC211
Min. 1MQ I] Max. l!J
P21040163 Warming-
I
@
UP
08DD0023
20-148
TROUBLESHOOTING
OF PUMP SYSTEM
(C MODE)
CHART FOR DISTINGUISHING IF FAILURE IS IN PUMP CONTROLLER OR IN HYDRAULIC RELATED PARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-151 c-1
[OFF]
c-2
[SHORT
CIRCUIT
IN 2-STAGE
c-3
[SHORT
CIRCUIT
IN ARM HALF FLOW SOLENOID
c-4
[SHORT
CIRCUIT
IN SWING
C-5
[SHORT
CIRCUIT
IN TRAVEL
C-6
[SHORT
CIRCUIT
IN CO CANCEL
c-7
[SHORT
CIRCUIT
IN TVC SOLENOID
SYSTEM
C-8
[SHORT
CIRCUIT
IN TVC SOLENOID
VALVE SYSTEM
c-9
[DISCONNECTION
IN 2-STAGE
c-10
[DISCONNECTION
IN ARM HALF FLOW SOLENOID
C-l 1
[DISCONNECTION
IN SWING BRAKE SOLENOID
C-l 2
[DISCONNECTION
IN TRAVEL
c-13
[DISCONNECTION
IN CO CANCEL
C-l 4
[DISCONNECTION
IN TVC SOLENOID
c-1 5
[ABNORMALITY
IN NO.2 THROTTLE
C-1 6
[ABNORMALITY
IN THROTTLE
c-17
[ABNORMALITY ISDISPLAYED
IN FRONT PUMP PRESSURE ...................................................
[ABNORMALITY IS DISPLAYED
IN REAR PUMP PRESSURE .....................................................
C-l 8
SELF-DIAGNOSTIC
DISPLAY
RELIEF SOLENOID
BRAKE SOLENOID
VALVE SYSTEM]
SOLENOID
VALVE SYSTEM]
SIGNAL
SYSTEM]
[ABNORMALITY
IN PRESSURE
SENSOR
c-20
[ABNORMALITY
IN ENGINE
c-21
[ABNORMALITY
IN AUTO-DECELERATION
c-22
[ABNORMALITY
IN OVERHEAT
C-23
[CONTROLLER
SYSTEM1
20-157 20-158 20-159
...........
20-160 ...
IS DISPLAYED
IS DISPLAYED
20-161
. . 20-162 ....
20-163
....
20-164
......
20-165
............
IS DISPLAYED
20-166
.............
IS DISPLAYED
20-167
.................
SIGNAL
20-168
SYSTEM] ..20-17
SENSOR
SIGNAL
0
SYSTEM] 20-172
POWER SOURCE
SPEED SENSOR
SIGNAL
.....
........
IS DISPLAYED
IS DISPLAYED
SENSOR
20-156
IS DISPLAYED
VALVE SYSTEM]
SYSTEM]
.....
IS DISPLAYED
VALVE SYSTEM]
VALVE SYSTEM]
20-155
................
(2)] IS DISPLAYED
VALVE SYSTEM] SIGNAL
IS DISPLAYED
VALVE SYSTEM]
SPEED SOLENOID SOLENOID
IS DISPLAYED
20-154
...
IS DISPLAYED
(1)) IS DISPLAYED
RELIEF SOLENOID
....
IS DISPLAYED
VALVE SYSTEM]
VALVE SYSTEM
20-153
IS DISPLAYED
VALVE SYSTEM]
VALVE SYSTEM]
SPEED SOLENOID
c-19
ABNORMAL
DOES NOT LIGHT UP. ........
OF CONTROLLER
SYSTEM]
SIGNAL SYSTEM]
SYSTEM]
IS DISPLAYED.
OUTPUT
SYSTEM]
IS DISPLAYED
IS DISPLAYED
IS DISPLAYED ............ IS DISPLAYED
.................
.........................
...
20-174 20-176
. . 20-177 20-178 20-179
20-149
20-150
20-I 52
C-l I!& ti2 1 COFFl SELF-DIAGNOSTIC (.yu.L!J JNOT LIGHT UP.
DISPLAY
OF CONTROLLER
DOES
Check if fuse 1 is blown. If the fuse is blown, check if the wiring harness between the fuse l-Cl and (4) is in contact with the ground. 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
Cause
YES
1 IS
_
Defective pump controller
I
voltage
between Cl (3) (4) - (13) normal?
-
20-30V a Turn starting switch ON.
_
2 Is voltage at outlet h$ end of fuse 1 normal? * 20-30V * Turn starting switch ON.
Replace
Defective contact, or disconnection in wiring harness between fuse 1 M20 (2). (1) - M3 (3) - Cl (female) (3). (4)
YES
(3)
Defective contact, YES or disconnection in wiring harness between Ml1 (female) * Is voltage between cl)-MM7 (l)-fuse 1 - Ml1 (1) -chassis NO norma’i? Defective contact, or disconnection in wiring NO harness between fusible . 20- 30V link or Ml 1 (female) * Turn starting (2)-battery switch ON.
3
Repair or replace
Repair or replace
Repair or replace
Fusible link
M20(M4)
v
-
(i)@
($0
Mll(L2)
Pump controller Cl
(MICl7)
M3(Sl6)
M7(L2)
Battery
205FO5369-1
20-153
‘;\ c-2I._.
*
* *
1
\ [SHORT CIRCUIT IN 2-STAGE SYSTEM] IS DISPLAYED
RELIEF
If the starting switch is turned OFF after the abnormality occurs, the power max. switch to ON and check that the display is [Ol]. been reset.) Before carrying out troubleshooting, check that all the related Always connect any disconnected connectors before going on
SOLENOID
turn the starting switch ON, then set (If it is not displayed, the system has connectors are properly to the next step. Cause
2
\-\
\
J-J.
\
Is resistance between Cl (female) (31,(4) and (151,(15) and chassis as shown in Table l?
. Engine . Power
YES
VALVE
inserted.
Remedy
Defective pump controller
Replace
Contact between wiring harness of power source and wiring harness betweer Cl (female) (15) and V7 (female) (2)
Repair or replace
Defective 2-stage relief solenoid valve
Replace
at high idling maximizing switch
ON
. Turn starting switch OFF . Disconnect Cl
3 Is resistance between V7 (male) (I) and (2) as shown in Table I?
A -4
. Turn starting switch OFF . Disconnect V7
Table 1
YES
H NO
1 Cl (female)
Between
(3), (4) and (15)
Between
(15) and chassis
V7 (male)
I
Between Between
1 Resistance value
(1) and (2)
xl - 100a
(2) and chassis
Min. lM0
M20(M4) Pump controller
Fuse
D9
205FO5370-1
20-154
c-3 I\:\ --\ ][SHORT CIRCUIT IN ARM SYSTEM] IS DISPLAYED &“.
a-1
HALF
-
FLOW
SOLENOID
VALVE
If the starting switch is turned OFF after the abnormality occurs, turn the starting switch ON, set the working mode switch to F.O. mode and check that the display is 1031. (If it is not displayed, the system has been reset.) 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, Interchange with wiring of CO cancel solenoid. Is [03] displayed?
YES
1 P
\-\
-\
.\A 3
_
Is resistance between Cl (female) (3), (4) and (6). (6) and chassis as shown in Table l?
Defective pump controller
NO _
. interchange v5 andv4 . Turn starting switch ON . Set working mode switch to F.0 mode
. Turn
starting switch OFF . Disconnect Cl.
To A
NO
a I ISresistance
bet-
1
YES
I I I
I
NO
. Turn starting switch OFF. . Disconnect V5
Table
YES I
Contact between wiring Iarness of power source ant Niring harness between Cl female) (6) and V5 (female) :2)
Repair or replace
Defective arm half flow jolenoid valve
Replace
1. Cl
(female)
Between
(3), (4) and (6)
Between
(6) and chassis
V5 (lamp) Between Between
Resistance
(1) and (2)
value
10-350
(2) and chassis
Min. 1MQ
M20(M4) Pump controller
Cl (MiCl71
Fuse
I-
I
I
I
I
I
V7(X2) I,
I
1
rly,Iy,
205FO5726
20-155
\J~,][~H~RT CIRCUIT IN SWING BRAKE SOLENOID VALVE c-4 [._. SYSTEM] IS DISPLAYED If the starting switch is turned OFF after the abnormality occurs, start the engine, operate the swing and check that the display is [04]. (If it is not displayed, the system has been reset.) 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
Remedy
Defective pump controller
Replace
YES
1 Is resistance
bet-
f . St$eng&e
and operate
1
_
To A
. Turn starting switch OFF . Disconnect Cl
YE
Is resistance bet-
YES ween M3 (male) (1) and (9). (1) or (9) and chassis normal? Is resistance between VI (male) (1) and (2) as shown in Table l?
AL
Y’
. Turn starting switch OFF . Disconnect Vl
Table
. Turn _.
1 .
N(
starting switch OFF. Disconnect M3.
Repair or replace
. Defective
Replace
swing lock switch Contact between wiring harness of power source and wiring harness between M3 (male) (1) - lock switch - M3 (male) (9)
- (9) :
. BeWMyxn # . (1) ;,‘p
. Turn
Contact between wiring larness of power source and Niring harness between Cl :female) (8) - M3 (female) (9 Contact between wiring harness of power source and Niring harness between M3 jzmale) (I) and Vl (female)
y--chassis:
starting__^ switch OFF’
usconnect
MJ
Defective swing brake solenoid valve
NO
Repair or replace
Repair or replace
Replace
1
Between
(3), (4) and (8)
Between
(8) and chassis
Between Between
(1) and chassis lack prolix
Pump controller
Cl (MICl7)
Between
(3) and (1)
Swina
2
Vl (male)
M3 (male)
M3 (female)
Cl (female)
Between
(1) and (9)
Between
(9) and chassis
switch
Swina
Between
lock switch
VI(X2)
6
I
I
_
I
M3El6)
Swing brake S solenoid Id _
Min. 1MQ
5
r-l&
4
value
lo-3!5n
(2) and chassis
e+l
I
Resistance
(1) and (2)
I-W 1
lZ71 I
I
I I%\ L
Eii
_Swing brake solenoid t valve
D2
r!_!
r \I Fuse
M20Uvl4) 205FO5727
20-156
C-5 [.‘z\_“,] [SHORT CIRCUIT IN TRAVEL SYSTEM] IS DISPLAYED
SPEED
SOLENOID
VALVE
If the starting switch is turned OFF after the abnormality occurs, turn the starting switch ON, set the fuel control dial to MAX. and the travel speed switch to Hi and check that the display is [05]. (If it is not displayed, the system has been reset.) 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
CG3K.e
2 Interchange I^.
YES
Defective controller
with
Pump
3eplace
~H~~~~~ . Place * Turn starting switch OFF. * Disconnect Cl.
travel
speed
switch
at
Hi.
IT-... NO
3 ,
A
-
Is resistance between V2 (male) (1) as shown in Table 11
YES 1 1
(2)
- Turn starting switch OFF. - Disconnect V2.
Table
Contact between wiring harness of power Source and wiring harness between Cl (female) (16)-V2 (female) (2)
Repair *eplace
Defective solenoid
Replace
or
-
NO
travel valve
speed
1 Cl
(female)
V2 (male)
Between
(3), (4) - (16)
Between
(16) - chassis
Between Between
Resistance
value
(1) - (2)
50 - 1000
(2) - chassis
Min. 1MQ
V Pump
controller
Cl (MICl7)
M3(Sl6)
M20(M4) (i)@ Fuse
I
205FO5373-1
20-l 57
r\ 7 1[SHORT CIRCUIT IN co CANCEL SOLENOID VALVE SYSTEM C-6 [.-. _IS DISPLAYED If the starting switch is turned OFF after the abnormality occurs, turn the starting switch ON, then set the power max. switch to ON and check that the display reads [07]. (If it is not displayed, the system has been reset.) It is also possible to operate the travel lever with the engine at high idling. 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
YES
YE‘S ._ 1
r
lefective pump :ontroller
Interchange with wiring of 2-stage relief solenoid.
. Interchange
V4 and V3. Turn starting switch ON. Set power max. switch to ON.
. Turn starting switch OFF . Disconnect Cl
A
Is resistance between V4 (male) (1) _ and (2) as shown in Table I?
=
. Turn
NO
startina switch OFF . Disconnect V4
Table
Contact between wiring harness of power source and wiring harness letween Cl (female) (7) and /4 (female) (2)
qepair or .eplace
Defective CO cancel solenoid valve
Replace
1 Cl
V4 (male)
(female)
Between
(3), (4) and (7)
Between
(7) and chassis
Between Between
Resistance
(1) and (2)
value
50 - loon
(2) and chassis
Min. 1MO
I
M20(M4) Pump controller
Cl fMICl7) 1 \
Fuse
_I
I
\
I
V4(X2)
_
CO cancel solenoid valve
205FO5374-1
20-158
C-7 [_“@,\[SHORT CIRCUIT IS DISPLAYED * * :
IN TVC SOLENOID
SYSTEM (I)]
If the starting switch is turned OFF after the abnormality occurs, turn the starting switch ON and check that the display reads [08]. (If it is not displayed, the system has been reset.) Turn the TVC prolix switch OFF. 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 1I
~~ToA - Turn startina switch OFF. Disconnect C4.
NO
! {ES
NO
I
. Disconnect
* Turn starting switch OFF. . Disconnect C5.
Table
C5.
Between Between
C5 (female)
(female) (9) - (17)
Between
(17) - chassis Between
Between
I
(3) - (4)
(4) - chassis
Defective
pump
Defective
TVC
Controller
solenoid
Wiring harness between Cl (female) (9)-C5 (female) (1) in contact with ground, or in COntaCt with GND wiring * Wiring harness between C5 (male) (l)-prolix switch-C5 (male) (3) in contact with ground, or in contact with GND wiring - Defective TVC prolix switch
Wiring harness between C5 (female) (3)C4 (female) (1) in contact with ground, or in contacl with GND wiring
NO
1 Cl
Remedy
C4 (male) Between Between
Resistance
Repke
Repair replace
or
Repair replace
or
Repair reDlaCe
or
value
(1) - (2)
10 - 22n
(2) - chassis
Min. 1MQ
C5 (male) (1) - (3), (2) - (4)
Replace
Max. 10
TVC prolix switch ON
Resistor
205FO5375-1 Pump controller
20-I 59
C-8 [.I._ ‘;\,$][SHORT
CIRCUIT IS DISPLAYED
IN TVC SOLENOID
VALVE SYSTEM
(2)]
If the starting switch is turned OFF after the abnormality occurs, turn the starting switch ON and check that the display reads [09]. (If it is not displayed, the system has been reset.) Turn the TVC prolix switch OFF. 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.
* Turn starting switch OFF. * Disconnect ~4.
I
YES
F[
* Turn starting switch OFF. * Disconnect C5. * Turn starting switch OFF. Disconnect C5.
*
1
pump
Defective
TVC
controller
ReDlaCe
solenoid
ReDlaCe
NO
4
Table I
Defective
Wiring harness between Cl (female) (9)-C5 (female) (1) in contact with ground, or in contact with GND wiring . Wiring harness between C5 (male) (l)--prolix switchC5 (male) (3) in contact with ground, or in contact with GND wiring * Defective TVC prolix switch
or
Repair
or
replaCe
airing harness between C5 (male) (3)-C4 (female (I) in contact with ground 3r in contact with GND Niring
10
Repair replace
Repair replace
1 Cl
Between Between
I
C5 /female)
(female)
1
(9) - (17)
(17) - chassis
Between Between
Between
(4)
(3) - (4)
1
- chassis
C5 (male) (1) - (3), (2)
lVC
C4 (male) Between Between
(1) - (2)
I Resistance value
I
1
I
(2) - chassis
- (4)
10-229 Min. 1Mn Max. ln
prolix switch
ON CSM6) Resistor
205FO5375.1 Pump controller
20-160
or
C-9 [. \ . \l[DISCONNECTION IN 2-STAGE SYSTEM] IS DISPLAYED * * *
RELIEF
SOLENOID
VALVE
If there is a disconnection in the solenoid or wiring harness, the solenoid is not actuated. If pin (2) of the solenoid is short circulating with the ground, the solenoid stays actuated. If the starting switch is turned OFF after the abnormality occurs, turn the starting switch ON and check that the display reads [ll]. (If it is not displayed, the system has been reset.) If [l l] is displayed, start the engine and press the power max. switch. If there is no difference in the digging force between when the switch is pressed and when it is not pressed, start troubleshooting from Item 4 in the flow chart below. 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.
z
Cause
2 YES In same conditions as when measuring Item 1, is [l l] displayed?
YE
1 . Turn starting switch ON.
Replace
Already reset
NO
YES
3
Is resisiance between Cl (female) (3) (4) and (15). (15) and chassis as .~shown in Table l?
-
h
. Turn
starting switch OFF . Disconnect Cl
4
L ND
Is resistance between V7 (male) (1) and (2) as shown in Table l?
. Turn
starting switch OFF. . Disconnect V7.
Table
Defective pump controller
HI
_-I
. Turn starting switch ON. . Power max. switch: ON: 0 - 3V (8.5 set) OFF: 20 - 30V
Remedy
YES
Disconnection in wiring harness between Cl (female (3), (4). (15) - V7 (female) (1) (2), or wiring harness between Cl (female) (15) V3 (female) (2) in contact with ground
Defective 2-stage relief NC solenoid valve
Repair or replace
Replace
1 Cl
Between Between
V7 (male)
(female) (3), (4) and (15) (15) and chassis
Between Between
(1) and (2)
(2) and chassis
Resistance
value
50 - 1OOR Min. ln
205FO5370-1
20-161
c-10 [. \ .-31 1DISCONNECTION SYSTEM] * * * *
:
IN ARM HALF FLOW SOLENOID IS DISPLAYED
VALVE
If there is a disconnection in the solenoid or wiring harness, the solenoid is not actuated. If pin (2) of the solenoid is short circuiting with the ground, the solenoid stays actuated. If the starting switch is turned OFF after the abnormality occurs, turn the starting switch ON and check that the display reads [14]. (If it is not displayed, the system has been reset.) Always turn the swing lock prolix switch OFF and set the swing lock switch at OFF before starting to check. If [14] is displayed, start the engine. If the swing brake is not released when the swing is operated, start troubleshooting from Item 4 in the flow chart below. 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
Cause
Defective Controller
pump
YE
Already
3
NO
. Turn starting switch . Finishing, lifting .
mode: Max. Heavy-duty. mode: 20 -
I
ON.
I
3v general 30V
IS resistance bewee” Cl
(female) I31 (4) - (6). I61 chassi* as shown
in
Table
l?
1
;ES
H ILTToA
* Turn starting switch OFF. . Disconnect Cl.
6
4
F
--c
Is resistance between V5 (male) (1) - (2). (2) chassis es shown in Table l? * Turn starting switch OFF. . Disconnect v5.
Table
resistance between M6 (female) (7) - (6). (6) chassis es shown in Table 17 . Turn
*
YES
M3 YES between (male) (3) (5).(5)- chassis 5 - ar show”in
Is
YE5 -
starting
OFF. Disconnect
Table
1’
Y( J
.
Turn starting switch OFF. . Disconnect M3.
Disconnection in wiring harness between Cl (female) (3)(4)-M3 (female) (3)(51, or wiring harness between Cl (female) (6)-M3 (female) (5) in contact with ground Disconnection in wirina harness between M3 (male) (3)(51-~6 (male) (7)(61, or wiring harness between M6 (female) (51-M6 (male) (6) in contact with ground Disconnection in wiring ?ar”ess between M6 :female) (7) (6) - V5 Ifemale) (1) 12). or wiring harness between M6 Ifemale) (7) - V5 (female 2) in contact with grounc
switch M6.
reset
NO
Defective arm half flow solenoid valve
ND
3epair or ‘eDlace
9epair ‘eplace
or
Repair ‘eplace
or
=teplace
1 Cl
(female)
Between
(3), (4) - (6)
Between
(6) - chassis
M3 (male) Between Between
(3) - (5)
(5) - chassis
M6 (female)
V5 (male) Between Between
(1) - (2)
(2) - chassis
Pump
Between Between
Resistance
(7) - (6)
10 - 359
(6) - chassis
Min. 1MSi
controller
w
20-162
value
205FO5371-1
C-II
1. \‘J,] .
[ DISCONNECTION IN SWING SYSTEM] IS DISPLAYED
BRAKE
SOLENOID
VALVE
If there is a disconnection in the solenoid or wiring harness, the circuit up to the solenoid is not actuated. If pin (2) of the solenoid is short circuiting with the ground, the circuit up to the solenoid stays actuated. If the starting switch is turned OFF after the abnormality occurs, turn the starting switch ON and check that the display reads [14]. (If it is not displayed, the system has been reset.) Always turn the swing lock prolix switch OFF and set the swing lock switch at OFF before starting to check. If [14] is displayed, start the engine. If the swing brake is not released when the swing is operated, start troubleshooting from Item 4 in the flow chart below. 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
Remedy
Iefective pump :ontroller
7eplace
jIZ$@ZHT
u
.
Is voltage between Cl (8) and chassis normal?
L_
-
YES
1:\
. Lever at neutral: . Lever operated: . Turn swing lock
Max. 3V 20 - 30V switch
OFF.
. Turn
starting switch ON.
Already reset
NW
Turn starting switch ON . Turn swing lock switch OFF
p L ND
3 Is resistance between Cl (female) (3) (4) and (8), (8) and chassis as shown in Table l?
. Disconnect
-
Cl.
4
N$
. Turn
N(
starting switch OFF. . Disconnect Vl.
6
1
I
Cl
(female)
Between
(3), (4) and (8)
Between
(8) and chassis
M3 (female) Between Between
(3) and (1)
(1) and chassis
I
YE:
To A
Iefective swing brake solenoid valve
Replace
Disconnection in wiring harness between Cl (female) (8) - M3 (female) (9). or contact with ground Defective swing lock switch Disconnection in wiring harnes between M3 (male) (1) - lock switch - M3 (male) (9). or contact with ground Disconnection in wiring narness between M3 (female (1) (3) - Vl (female) (I) (2) 01 wiring harness between M3 (female) (1) and Vl (female) (2) in contact with ground
. Turn starting switch OFF. Disconnect M3.
Table
YEE
Is resistance between Vl (male) (1) and (21, (21 and chassis as shown in Table l?
M3 (male) Between Between
(1) and (9)
(9) and chassis Swing lock prolix switch
Vl
I
(male)
Between Between
(1) and (2)
(2) and chassis
Repair or reolace
Repair or replace
Repair or replace
1Resistance value lo-35n Min. 1MQ
Swing lock switch
Swing brake solenoid valve
C-J
205FD5727
20-163
c-12 [* \‘-,I .*
*
*
:
[DISCONNECTION IN TRAVEL SYSTEM] IS DISPLAYED
SPEED
SOLENOID
VALVE
If there is a disconnection in the solenoid or wiring harness, the circuit up to the solenoid is not actuated. If pin (2) of the solenoid is short circuiting with the ground, the circuit up to the solenoid stays actuated. If the starting switch is turned OFF after the abnormality occurs, turn the starting switch ON, set the travel speed switch to Lo and check that the display reads [15]. (If it is not displayed, the system has been reset.) If [15] is displayed, start the engine and if the speed does not become Hi when the travel speed switch is set to Hi and the engine is at high idling, start troubleshooting from “A” in the flow chart below. 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
Already
\ .
\-
_
* Turn ON.
Is voltage between Cl (16) -chassis nromal?
starting
pump
reset
\
switch
-
3
1.11
* At Lo: * At Hi: * Switch
ZO-30V Max. 3V travel NOspeed switch. . Turn starting switch ON.
Is resistance between Cl (female) (3) (4) -116),(16)chassis as show” in Table I?
* Turn
starting
OFF. * Disconnect
YES
NO
To
A
switch Cl,
4
* Turn starting switch OFF. a Disconnect V2.
Table
Remedy
YE!
Disconnection in wiring harness between Cl (female) (3) (4) (16) v2 (female) (1) (2). or wiring harness between Cl (female) (16) - V2 (female) (2) in contact with ground Defective solenoid
travel valve
speed
1 Cl
(female)
- (16)
Between
(3), (4)
Between
(16) - chassis
I 1
Resistance
V2 (male) Between Between
(1) - (2)
1
(2) - chassis
value
50 - loon Min. 1MfI n
Pump
controller
Cl (MICl7)
205FO5373-1
20-164
1
c-13[. \ .71 * *
f
* *
[DISCONNECTION IN CO SYSTEM] IS DISPLAYED
CANCEL
SOLENOID
VALVE
If there is a disconnection in the solenoid or wiring harness, the solenoid is not actuated. If pin (2) of the solenoid is short circuiting with the ground, the solenoid stays actuated. If the starting switch is turned OFF after the abnormality occurs, turn the stating switch ON, then turn the swing lock switch ON and check that the display reads [17]. (If it is not displayed, the system has been reset.) If [17] is displayed, start the engine and if there is no difference in the digging force between when the swing lock switch is ON and when the swing lock switch is OFF, start troubleshooting from “A” in the flow chart below. 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
Cause
2
YES
Iefective pump :ontroller
+JG&$qt
\_
\-\I
Is voltage between Cl (71 and chassis
4lready reset
NO
. Turn starting switch ON
l-l
I
switch OFF
. Disconnect
Cl
4
YE
~---~H
N
. Turn starting switch OFF . Disconnect V4
Table
Xsconnection in wirinq ?arness between Cl (female ‘31 (41. (71 - V4 lfemalel 111 jZj,‘or&ring harness be< Neen Cl (female) (7) and V4 :female) (2) in contact with ground
Repair or replace
Defective CO cancel solenoid valve
Replace
1 Cl
V4 (male)
(female)
Between
(3), (4) and (7)
Between
(7) and chassis
Between Between
Resistance
value
(1) and (2)
50 - 1ooa
(2) and chassis
Min. 1MQ
M20fM4) Pump
controller
Fuse
co cancel solenoid
205FO5374-1
20-165
c-14
1.\wj 1DISCONNECTION .--,
IN TVC SOLENOID
VALVE SYSTEM]
IS DISPLAYED *
* *
2
If there is a disconnection in the solenoid or wiring harness, the circuit up to the solenoid is not actuated. If pin (2) of the solenoid is short circuiting with the ground, the current (approx. IA) continues to flow to the solenoid. If the starting switch is turned OFF after the abnormality occurs, turn the starting switch ON and check that the display reads [18]. (If it is not displayed, the system has been reset.) Turn the TVC prolix switch OFF. 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 r) ‘
YES I-
Is resistance befwee” Cl (female) (9) (17). (17) chassis as show” in Table I?
* Turn
3
starting switch _ OFF. NO . Disconnect Cl.
* Turn starting switch OFF. . Disconnect C4.
I
YES -
Is resistance between C5 {Fjmp;;)-(3) -
_
chdssis as show” in Table l?
NO
. Turn starting switch OFF. . Disconnect C5.
4
YES .A
CaUSe
Defective controller
Table
Replace
TO A Disconnection in wiring harness between C5 (female) (3). [4)-C4 (female) (1). (21, or wiring harness between C5 (female) (4)-C4 (female) (2) in contact with ground
Repair replace
Defective
Replace
TVC
solenoid
Disconnection in wiring harness between C5 (female) (1). (2kCl (female) (9). (17). or wiring harness between C5 (female) (2)-Cl (female) (17) in contact with
* Turn starting switch OFF. . Disconnect C5.
pump
Remedy
or
Repair replace
Or
Repair replace
or
ground
Defective TVC prolix switch, or defective wirina harness between switch-C5
1 Cl (female)
C5 (female) C4 (male) I 1 Between (3) - (4) 1 Between (1) - (2) Between (2) - chassis Between (17) - chassis 1 Between (4) - chassis Between C5 (male) (1) - (3), (2) - (4) Between
(9) - (17)
1Resistance value (Q) 10 - 22 1 Min. 1MO
-
Max. 1
n TVC prolix watch
205FO5375-1 Pump controller
20-166
c-15p ._.
\] [ABNORMALITY
IN NO.2 THROTTLE
SIGNAL
SYSTEM]
IS DISPLAYED If the starting switch is turned OFF after the abnormality occurs, turn the starting switch ON and check that the display reads [21]. (if it is not displayed, the system has been reset.) 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. CZllSe
Al ready
Remedy
reset
Is same condition
Defective
Pump
3eDlace
controller
ES I
4 YE
I I
Defective engine throttle controller
See E-6 * Switch working mode switch.
. Min. IMa * ~;,onnect
-
Turn
El (f&ale) (19) - (9) as shown in Table l? l-l h
Defective pump controller
- Turn starting switch ON. . Switch working mode switch. * Disconnect El.
C2 and
starting Switclh
OFF.
:
Disconnectionin wiring harness between C2 (female) (11). (21) - El (female) (9). (19). or contact with ground
1 NO
Pump controller
C2(MIC21)
Repair
or
replace
Engine throttle controller
E I (MIC21)
205F05383-K
Table Engine speed (rpm)
1
Condition when measuring
Pc3ooLC
Pc4ooLC
(1) When overheating
4.0-4.25
4.0-4.25
(2) L.O. and L mode
2.10-2.40
2.20-2.50
1.23-l 53
1.3!5-1.65
0.75-l .o
0.751 .o
(3) G.O., F.O., L.O. and S mode G.O., F.O. and L mode (4) H.O. mode or H mode
20-167
C-l6[7~1 _-_\_-_-,
2 **
[ABNORMALITY IS DISPLAYED
IN THROTTLE
SIGNAL
SYSTEM]
If an abnormality is displayed for the engine throttle controller, go first to troubleshooting E-6. If the starting switch is turned OFF after the abnormality occurs, turn the starting switch ON and check that the display reads [22]. (If it is not displayed, the system has been reset.) 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.
CalSe
2 I
YES
,
Defective controller
Already * Turn ON.
starting
pump
Remedy
3eplwa
reset
switch Disconnection in wiring harness between C2 (female
3 * Turn starting - Fuel control MIN.-MAX.
switch dial
YES
ON. h
FH_
*
0.25-4.75V . Turn starting ON. Fuel control MIN. -MAX.
*
Pump controller
C2(MICl7)
NO
(10). (20) - El (female) (10). (20). or wiring harness between C2 (female) (IO) - El (female) (IO) in contact with ground
Repair replace
or
See E-6
switch dial
Engine throttle
controller
EI(MIC21)
205F05385A
20-168
20-169
c-17 [;3 .-.- a]
* * *
[ABNORMALITY IN FRONT PUMP SIGNAL SYSTEM] IS DISPLAYED
PRESSURE
SENSOR
If the starting switch is turned OFF after the abnormality occurs, turn the starting switch ON and check that the display reads [23]. (If it is not displayed, the system has been reset.) 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.
2 YES -
In same condition as when measuring Item 1, is [231 displayed?
YES
NO
* Turn ON.
starting
switch
1 5 -\ \-
-\
YES
IS voltage
-\ -
be;y)y:,crn/;
IS voltage between C8 (3) - (I) normal?
YES 4 -
-
.a.. 0.5-4.5v a Start engine. (High idling)
-
3
+ . Repeat relief.
IS voltage between C8 (2) (1) normal?
YES -
bucket
Is resistance between C3 (female) (6)
_ No
* 0.5-4.5v * Start engine.(High
-
+ . Repeat relief.
p + 18-2au _
_
. z&n
starting
-
NO idling)
bucket
SwitchNO
(I), (6) chassis normal? * Min. IMCZ - Turn starting switch OFF. - Disconnect C3 and C8.
NO
Pump controller
C3(MIC9)
C8(X3)
F) Pressure sensor(-) Front pump pressure sensor
R) Pressure sensor( -)
24V(+)
iFl pressure sensor (SIG)
lzl
I -I
Rear pump pressure sensor
205FO5386-1
20-170
Remedy
Defective controller
Already
pump
Reulace
reset
Defective contact, or disconnection in wiring harness between C3 (female) cl)-C8 (female) (1)
Repair replace
Defective pressure
Replace
front sensor
pump
Defective contact, or disconnection in wirinq harness between C3 _ (female) (3)-C8 (female) (2) Short circuit in wiring harness between C3 (female) (61, (l)-C7. (female) (3). (1). or contact with ground
C8
or
Repair replace
or
Repair reDlace
or
20-171
C-18 [‘3’-‘\] .-. * * *
[ABNORMALITY IN REAR PUMP SIGNAL SYSTEM] IS DISPLAYED
PRESSURE
SENSOR
If the starting switch is turned OFF after the abnormality occurs, turn the starting switch ON and check that the display reads [24]. (If it is not displayed, the system has been reset.) 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.
2 YES r
YES
In same conditions as when measuring Item 1. is 1241 displayed? NO - Turn ON.
starting
switch
1
7 \0-o
\ \ _
5 IS voltage between C3 (7) - (2) normal?
_
* 0.5-4.5v engine. (High idling)
* Start
YES -
arm
relief.
P Is resistance between C3 (female) (7) - (2). (7) chassis normal?
NO
Is voltage c7 (2) normal?
3
+ * Repeat
1s voltage between C7 (3) - (1) normal?
YES
-1
- Min. 1M.l-2 - Turn starting switch OFF. - Disconnect C3 and
_
between (1)
* 18-28V . ;:.Istarting
-
4 -
switch
-
NO
f 0.5-4.511 . Start engine. (High idling)
*
YES
+ Repeat
arm
relief.
NO
NO
C7.
Pump controller
C3(MIC9)
C8(X3)
Front pump pressure sensor
,F, pressure sensor (SIG)
Rear pump pressure sensor
205FO5386-1
20-172
CaUSe
t--Defective
Pump
Controller
Al ready
Remedy
Replace
reset
Defective contact, or disconnection in wiring harness between C3 (female) (2) - C7 (female) (1)
Repair replace
Defective pressure
Replace
rear pump sensor
Defective contact, or disconnection in wiring harness between c3 (female) (3)c7 (female) (2) Short circuit in wiring harness between C3 (female) (71. (2) C7 C8 (female) (3). (1). or contact with ground
Repair
or
or
repliX.5
Repair replace
or
20-I 73
[ABNORMALITY
c-19 pq .-.a
IN PRESSURE IS DISPLAYED
SYSTEM] j, * *
SENSOR
POWER SOURCE
If the starting switch is turned OFF after the abnormality occurs, turn the starting switch ON and check that the display reads [25]. (If it is not displayed, the system has been reset.) 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.
‘
Is same conditions as when measuring Item 1, is [251 displayed?
YES -
1
-\ \-
Is voltage
\-\
-
:,“,::,7
between (‘)
e-o* 18-28V * Turn starting ON.
switch
r
I:
3
Disconnect C8. IS voltage between C3 (3) - (1) normal?
NO
* Disconnect C8. . 18-28V . Turn starting switch ON. a Disconnect C7. . 18-28V h * ;;,n starting switct
~~~ N OFF. . Disconnect and
C3,
C7.
C8.
Pump controller
C8(X3)
C3(MIC9) -
I (F) Pressure
sensor(-)
(R)Pressure
sensor(
Front pump pressure sensor
-)
Rear pump pressure sensor
(F) Pressure sensw (SIG) (RI pressure sensor (S(G)
I
I
1 205FO5386-1
20-174
Remedy
Defective pump controller
Already
Seolace
reset
Defective front pump pressure sensor
3eplace
Defective rear pump pressure sensor
Replace
Defective pump controller
Replace
Disconnection in wiring harness or contact with ground between . C3 (female) (1) and C8 (female) (1) . C3 (female) (3) and C7, C8 (female) (2) . C3 (female) (2) and C7 (female) (I)
Repair or reolace
20-I 75
c-20[;3’;,] .-.* -k f
[ABNORMALITY IS DISPLAYED
IN ENGINE SPEED SENSOR
SYSTEM]
If the starting switch is turned OFF after the abnormality occurs, turn the starting switch ON and check that the display reads [26]. (If it is not displayed, the system has been reset.) 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. NOTE:
If the decimal point on the pump controller the engine is started, go to troubleshooting
self-diagnostic F-8. -
3 YES 2 -
YES _
1
Note Is resistance between E7 (male) (1) (2) normal?
-
Is resistance between C3 (female) (8) (4) normal?
When engine is started, is [261 displayed? . Start engine.
monitor
YES
*
display . _ does not flash when
Defective pump controller
-
NC
Already reset (see Note)
Disconnectionin wiring harness between C3 (female) (8). (4) - M3 (1 2). (4) - E2 (1 11. (12) - E7 (female) (2). (1 i, or contact with
* 500-l 0oo.Q NO . Turn starting switch OFF. - Disconnect C3.
Repair or replace
Replace
Pump controller
C3(MIC9)
M3(S16)
E2(Sl2)
E7(X2) Engine speed sensor
205FO5389-1
20-176
c-21 p-p,,] ._.I * *
:
[ABNORMALITY IN AUTO-DECELERATION SYSTEM] IS DISPLAYED
SIGNAL OUTPUT
When the auto-deceleration switch is ON. If the starting switch is turned OFF after the abnormality occurs, turn the starting switch ON, turn the auto-deceleration switch ON, operate the control lever (Neutral-operated) and check that the display reads 1281. (If it is not displayed, the system has been reset.) 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. C
Cause
2 YES I
I
IDefective c:ontroller
II” same conditions1 YES es when measuring Item 1, is [281 displayed? NO
IS voltage between C2 (19) _ chassis es show” in Table I?
-
.
starting
pump
Replace
t
1 . Turn ON.
Remedy
Already
reset
swtc”
YES
3
Turn starting switch ON. ND
Disconnect C2. Is voltage between El (11) - (12) normal?
4 YE /
* Turn
starting
switch
ON. - ;yi2synnected:
IS reLilIl”Ce berwee” c2 (female) (19)--ET (ternale) (11). and
L No
SI
3efective 1throttle
engine controller
_ Disconnection
;~T~y$%%
Replace
in
harness between JO wiring C2 (female) (19)--El
r. - Turn starting switch OFF. . &connect C2 and
Table
(female) contact
(11). or with ground
Repair replace
or
1 Voltage
Operation Auto-deceleration
switch
ON, lever at neutral
Auto-deceleration
switch
OFF, lever at neutral
between
C2 (female) o8-
(19) - chassis
1v 12V
Table 2 Resistance
Connector Between
C2 (female)
Between
(19) - El (female)
C2 (female)
(19) - chassis
(11)
value
Max. lfl Min. 1 MR
Pump
controller
C2(MIC21)
Engine
throttle
controller
EI(MIC21)
205F05390A
20-177
c-22
: *
[.-.7 $1
[ABNORMALITY IS DISPLAYED
IN OVERHEAT
SIGNAL
SYSTEM]
If [29] is displayed again when engine is restarted. Before carrying out troubleshooting, check that all the related connectors are properly Always connect any disconnected connectors before going on to the next step.
CaLIS
See Engine manual
YES
inserted.
Remedy
shop
17
-\ \.-•_-t
\-\ -\
Does monitor panel display overheating?
. Turn starting switch ON.
YES
2 IS
&
voltage c2 (17). normal?
between (18)--(S)
3
-
4 . When normal: lo-13v . When overheated: O-IV - Start engine
Pump
YE
Is resistance betwee” P2 (female) NO
(12). (13) - (16). (12) (13) chassis normal? . Min. 1MSZ . Disconnect P2.
controller
C2(MIC21)
-
N C2
and
Replace
Defective controller
pump
Defective panel
monitor
Replace
Disconnection in wiring harness between c2 (female) (17). (18)P2 (female) (12). (13). or contact with ground
Monitor
Repair replace
or
panel
P2(04016)
205FO5391-1
20-178
C-23 [tp!p\] ._.Q
[CONTROLLER
ABNORMAL
SYSTEM]
IS DISPLAYED
Remedy
Q-1 Q-Q_
.QZ!.QzQ
Defective controller
pump
ReDlace
20-I 79
20-180
TROUBLESHOOTING SIGNAL F-l
PUMP CONTROLLER [WORK EQUIPMENT
OF PUMP CONTROLLER SYSTEM (F MODE)
MONITOR DOES NOT DISPLAY . SWING OIL PRESSURE SWITCH]
INPUT
. . . . . . . . . . . . . . . . . . . . . . . 20-182
F-2
PUMP CONTROLLER MONITOR DOES NOT DISPLAY [TRAVEL OIL PRESSURE SWITCH] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-183
F-3
PUMP CONTROLLER
MONITOR
DOES NOT DISPLAY
[SWING
F-4
PUMP CONTROLLER
MONITOR
DOES NOT DISPLAY
OR [TRAVEL
F-5
PUMP CONTROLLER [AUTO-DECELERATION
MONITOR DOES NOT DISPLAY SWITCH] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-l 86
F-6
PUMP CONTROLLER
MONITOR
F-7
MONITOR DOES NOT DISPLAY PUMP CONTROLLER [DECIMAL POINT OF ENGINE SPEED SENSOR] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-188
F-8
PUMP CONTROLLER
WORKING
F-9
PUMP CONTROLLER
POWER SET DISPLAY
DOES NOT DISPLAY
MODE DISPLAY
[POWER
LOCK SWITCH]
SPEED SWITCH]
MAXIMIZING
DOES NOT SWITCH
DOES NOT SWITCH
. . . . . . . 20-184
SWITCH]
. . 20-185
. 20-187
. . . . . . . . . . . . . 20-189
. . . . . . . . . . . . . . . . 20-190
20-181
Fl
PUMP CONTROLLER [WORK EQUIPMENT
MONITOR DOES NOT DISPLAY [“> Iz\ 1 l SWING OIL PRESSURE SWIT&]“’
After starting the engine and operating the work equipment lever or swing lever, it is displayed for approx. 1 second. 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
Before
operating
the swing
lever, turn the swing
lock switch
ON.
Remedy
Cause
2 YE
In same conditions as when measuring Item 1, is [P21 displayed?
. Start enaine . 0perate”lever
1
YES
Already reset
NO
Iefective :ontroller
_
YES
C3 (5) and chassis J
I
. Lever
at neutral : 20 - 3ov . Lever operated : Max. 1V . Start engine.
~~ . Between wiring harness ;t
F . Lever operated: Max. 1R . Lever at neutral: Min. 1MR . Start engine . Disconnect Sl
LD
Pump controller
c;;;is:
pump
lefective contact, or fisconnection in wiring larness between Sl (female) 1) - Cl (female) (12), (13), 01 :ontact with ground
qepair or ,eolace
lefective contact, disconnection in wiring larness between C3 (female) (5) and Sl (female) (2). or contact with ground
Repair or replace
Defective oil pressure switch % If the condition does not return to normal when the switch is replaced, go to H-7.
Reolace
Work equipment. swing oil pressure
switch
Cl fMICl7)
205FO5728
20-I 82
F-2
* * *
PUMP CONTROLLER MONITOR DOES NOT DISPLAY [TRAVEL OIL PRESSURE SWITCH]
\I.\-\7 .\x 1
After starting the engine and operating the travel lever, it is displayed for approx 1 second. 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
operating
it is not displayed
the travel when
lever,
operating
check that the surrounding the travel
area is safe.
lever on one side, the PPC shuttle
valve
is defective.
ChJSe
2 YE
-
lready
Defective controller
. Start engine. . Operate travel lever
1 Is voltage C2 (1)
YES
In same conditions as when measuring Item 1, is [P61 displayed?
:
I
-
1I * Between
b
*
Lever Max.
reset
pump
Replace
Defective contact, disconnection in wiring harness between S4 (female) (1) - Cl (female) (12). (13). or contact with ground
between chassis
I - Lever at neutral 20 - 3ov Travel lever operated: Max. - Start engine.
Remedy
operated: 1.Q
wiring
Min. 1Mn * Start engine. Disconnect S4.
*
Pump
and
chassis:
Defective travel oil pressure switch * If the condition does not become normal even when the switch is replaced, go to H-7.
NO
Lever at neutral:
harness
Defective contact, disconmection in Wiring harness between C2 (female) (I) - M3 (13) - S4 (female) (2). or contact with ground
Travel
controller
Repair ,eplace
or
Repair replace
or
RC+DlaCe
oil
pressure
switch
Cl (MICl7)
GND
I I
I
I
C3( MIC9) \ I
205FO5394-1
20-183
F-3 f * * *
PUMP CONTROLLER MONITOR [SWING LOCK SWITCH]
DOES NOT DISPLAY [ .-.\-,‘=,j
After starting the engine and turning the swing lock switch ON, it is displayed for approx. 1 second. If the panel display is normal (if the swing lock lamp on the panel lights up, go to P-21.) 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
swing lock switch ON * OFF.
ND
lock switch: ON: Max. 1V OFF: 18 - 28V . Turn starting switch ON
Defective pump controller
Replace
. Defective
3
. Swing
Already reset
.
. Turn Is voltage between W;Ia/d (8)
YES
In same conditions as when measuring item 1, is [b5] displayed?
Remedy
YES
Is there continuin/ _ between C2 (female) _ NO (4) and swing lock switch (l)?
. Turn
starting switch OFF Disconnect C2
swing lock switch Disconnection in wiring harness between C2 (female) (8) and swing lock swith (2), or contact with ground
NO
Disconnection in wiring harness between C2 (female) (4) and lock switch (1)
Repair or replace
Repair or replace
Swing brake solenoid valve
M20(M4) Fuse Pump controller
cl(~lcl7p) \
Swing
brake
GND
switch ON (lock)
Pum
205FO5730
20-184
F-4
PUMP CONTROLLER
DOES NOT DISPLAY (:-\ . ,] [TRAVEL SPEED SWITCH]
OR[: ._.I \-\ ] * * * j,
MONITOR
After starting the engine and switching the travel speed switch to Hi or Lo, it is displayed for approx. 1 second. If the monitor panel display is normal (if the panel display is not normal, go to P-19). Before carrying out troubleshooting, check that all the related connectors are properly inserted. Always connect any disconnected connectors before going on the next step.
2 YES -
1
In same conditiens as when measuring Item is [Hi] or [LOI displayed?
1,
YES
Already
-
NO Is volrage between C2 (3) - (8) as shown in table 17
switch
Disconnect P2. voltage between P2 (female) (4) (16) as shown below?
NO
YES
Is -
-
Table 1 Travel speed switch speed
pump
Defective panel
monitor
Replace
Defective contact, disconnection in wiring harness between C2 (female) (3) - P2 (female) (4). or contact with ground
NO
- Turn starting switch ON. * P2 disconnected: 10 - 13v
Travel
Defective controller
-
3 . Turn starting switch ON. * Travel speed Hi-LO
reset
switch
Lo
10 - 13V
Hi
Max. 1V
Pump
controller
Repair reolace
or
Repair
Or
replace
Monitor
panel
205FO5396
20-185
F-5
PUMP CONTROLLER MONITOR DOES NOT DISPLAY [!p, .-,-\I [AUTO-DECELERATION SWITCH]
After starting the engine, set the auto-deceleration switch to ON. It is displayed for approx. 1 second. If the monitor panel display is normal (if the auto-deceleration display on the panel does not change, go to P-18). Before carrying out troubleshooting, check that all the related connectors are properly inserted. Always connect any disconnected connectors before going on the next step.
Cause
2
YES
Already
In same conditiYES ons es when measuring Item 1, is [Ad] displayed?
1
- Turn starting
* Turn
starting switch ON. * P2 disconnected: 10 - 13v
Table 1 Auto-deceleration Auto-deceleration
switch switch
ON
Max. 1V 10 - 13V
reset
Defective pump controller
Replace
Defective P.3”el
Replace
monitor
Defective contact, or disconnection in wiring harness between C2 (female) (7) - P2 (female) (7)
NO
OFF
Remedy
Pump controller
Repair
or
replace
Monitor panel
P2 (04016)
205FO5397
20-186
F-6
PUMP CONTROLLER [POWER MAXIMIZING
MONITOR SWITCH]
DOES NOT DISPLAY I!!‘2 l.r,r.r
1 J
After starting the engine and pressing the power maximizing switch, it is displayed for approx. second. Before carrying out troubleshooting, check that all the related connectors are properly inserted. Always connect any disconnected connectors before going on the next step.
C.3US3
Already
L
I
3 YES
* When switch is not pressed: _ 20 - 3ov NO . When switch is pressed: Max. 1V
IS resistance between switch (1) - (2) nOrmal?
* When switch is not NO pressed: Min. 1M0_ * When switch is pressed: Max. 152
Remedy
reset
Defective Pump controller
Replace
Defective contact, or disconnection in wiring harness between ~2 (female) (12). (8) - switch
Repair or replace
Defective power maximizing switch
3eplace
Pump controller
C2(MIC21) Power maximizing switch
205FO5398
20-187
1
F-7
2 *
PUMP CONTROLLER MONITOR DOES NOT DISPLAY [lp\tp,] [DECIMAL POINT OF ENGINE SPEED SENSOR] ‘-*-
The display flashes when the engine is started. Before carrying out troubleshooting, check that all the related connectors are properly Always connect any disconnected connectors before going on the next step.
inserted.
Remedy
CaUSe
Defective adjustment engine speed sensor
of
=t(ewklce
YI IS Defective controller
pump
Defective sensor
engine
3eplaCe
1 IS resirfance between c3
El (female)
-e
(8) -
(4).
(81 -chassis and is C,,C”if insulated from charris?
. Measure with AC range. 3v - Start engine.
norma
500 - 1oooc2 * Turn starting switc OFF. Disconnect C3.
. 0.5 -
-
.
4
h Is resistance between E7 (male) (I) (2). (2) - chassis normal UO and is circuit insulated from chassis’
YES
-
-
:
NO
speed
Defective contact, disconnection in wiring harness between C3 (female) (8). (4) - M3 I1 2). (4) - E2 (1 1). (12) - E7 (female) (2). (1). or contact with ground
qepair .eplaCe
Defective
qeplace
speed
sensor
or
* Between (1) and (2): 500 - 100052 * Between (1) and chassis: Min. 1 Ma Turn starting switch OFF. - Disconnect E7.
.
Pump
controller
C3(MIC9)
M3(Sl6)
E2 (Sl2)
E7(X2) Engine
speed sensor
205FO5389-1
20-188
F-8
PUMP CONTROLLER WORKING DOES NOT SWITCH [ \ 2 z,‘-\]
MODE DISPLAY
The working mode is displayed approx. 1 second after the starting switch is turned ON. If the monitor panel display is normal and the working mode does not switch, go to Troubleshooting P-l 6. Before carrying out troubleshooting, check that all the related connector are properly inserted. Always connect any disconnected connectors before going on to the next step.
* *
:
Cause
Remedy
tAlready measur,ng Irem l.doerwokrI”g mode mD”IfOr
YES -
between c2 (14) (15) and (8) as $own in Table
-
di*pIaySWlfCh “D~ITT~IIY’
1
.
is voltage
NO
Switch working mode on monitor Panel
-
3
. *
Turn starting switch ON. Switch working mode on monitor panel
. .
Table 1 Mode Between C2 (14 - (8)
YES
When P2 IS dIsconnected. IS voltage between P2 (female) (8) 191 and (16) as rhown below’
NO
Turn starting switch ON. When P2 is disconnected: 10 - 13v
Between
reset
Defective controller
pump
Defective
monitor
ReplaCe
Panal
Defective contact Or disconnection in wiring harness between C2 (female) (14) - P2 (female) (8). and between C2 (female) (15) - P2 (female) 19).
NO
Replace
Repair replace
or
C2
(15) - (8)
H.O.
lo-
13v
G.O.
lo-
13v
10 - 13v
o-iv
F.O.
o-
1v
10 - 13v
L.O.
o-
1v
0 - 1v
Monitor panel
Pump controller
C2 (MIC21)
I
P2 (04016) I I
I
Working mode (a) Working
mode
lb)
205FO5627
20-I 89
F-9
PUMP
CONTROLLER
1\87\\-2 \\_ 1
POWER
SET DISPLAY
DOES NOT SWITCH
The power set is displayed approx. 1 second after the starting switch is turned ON. If the monitor panel display is normal and the power set does not switch, go to Troubleshooting P-17. However, if the coolant temperature gauge on the monitor panel is showing the red range (over 102”C), the pump controller displays L mode. 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.
CFIUSS
Already
1
1
Is voltage between C2 (5). (6) and (8) _ as shown in Table 17
*
‘L YES
When P2 1sdirconnected, II voltage between P2 if&ale1 (5) (6) and 116) as Show” below?
NO
. .
Table
SWltC”
normally’
3
* Turn
starting switch ON. Switch power mode on monitor panel.
dlspla”
. Switch power mode on monitor panel.
Turn starting switch ON. When P2 is disconnected: lo-13v
Remedy
reset
Defective controller
pump
Defective
monitor
Replace
panel
Defective contact, or disconnection in wiring harness between C2 (female) (5) - P2 (female) (5), and between C2 (female) (6) - P2 (female) (6).
NO
Replace
Repair replace
or
1
~!~.
Monitor
Pump controller
C2 (MIC21) I \
1
panel
P2 (04016) I I
205FO5628
20-190
I
TROUBLESHOOTING OF HYDRAULIC AND MECHANICAL SYSTEM (H-MODE) H-l
SPEEDS
H-2
THERE IS EXCESSIVE
H-3
WORK EQUIPMENT, EXTREMELYSLOW
OF WORK EQUIPMENT,
TRAVEL AND SWING ARE ALL SLOW
DROP IN ENGINE
SPEED OR ENGINE
20-192
.............
20-194
TRAVEL AND SWING DO NOT MOVE OR SPEED IS ..................................................
H-4
WORK EQUIPMENT,
H-5
POWER SET SELECTION
H-6
ABNORMAL
H-7
AUTO-DECELERATION
H-8
BOOM AND ARM SPEED IS EXTREMELY
H-9
WORK EQUIPMENT
H-10
WHEN BOOM AND ARM IS OPERATED
H-l 1
WORK EQUIPMENT
H-12
EXCESSIVE
HYDRAULIC
H-13
EXCESSIVE
TIME LAG
H-14
DOES NOT ENTER F.O. MODE (HALF FLOW FUNCTION)
H-15
WHEN ARM AND SWING ARE OPERATED
H-16
WHEN MACHINE
H-17
EXCESSIVE
DEVIATION
DURING
H-18
EXCESSIVE
DEVIATION
WHEN STARTING
H-19
TRAVEL
LACKS POWER (OR SPEED IS SLOW)
H-20
TRAVEL
SPEED DOES NOT SWITCH
H-21
MACHINE
H-22
DOES NOT SWING
H-23
SWING
H-24
EXCESSIVE
OVERRUN
H-25
EXCESSIVE
SHOCK WHEN STOPPING
H-26
EXCESSIVE
ABNORMAL
NOISE WHEN STOPPING
H-27
EXCESSIVE
HYDRAULIC
DRIFT OF SWING
H-28
WHEN OPERATED
TRAVEL AND SWING LACK POWER SYSTEM
NOISE GENERATED
DOES NOT SWITCH (FROM AROUND
DOES NOT WORK
(BOOM,
(BOOM,
SLOW
......................
20-198
.......................
PUMP)
20-198
......................
20-199 20-199
.............................
ARM AND BUCKET)
20-200
SPEED IS SLOW
SIMULTANEOUSLY,
ARM AND BUCKET)
DRIFT
20-196
.................................
BOOM
LACKS POWER
...............
20-202
IS SLOW. ........ ................
20-204
...............................................
IS TRAVELING,
20-206 ......................
SIMULTANEOUSLY,
20-206
ARM IS SLOW
IT DEVIATES
NATURALLY
TO ONE SIDE
COMPOUND
OPERATIONS
....................
.......
..........
................................. ..............................
.....................................
WHEN STOPPING
.............................
SIMULTANEOUSLY
MODES
AND CAUSES
20-208 20-211 20-212 20-214
20-215 20-216
IS POOR ........................
SWING
SWING
20-206
20-214
..................................................
SPEED IS SLOW OR ACCELERATION
20-204 20-204
.........................................
DOES NOT MOVE (ONE SIDE ONLY)
TABLE OF FAILURE
STALLS
............
............................
.............................. SWING
.....................
................................
WITH ARM, SWING SPEED IS SLOW .........
20-218 20-219 20-219 20-220 20-220 20-220
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-221
20-191
H-l
*
SPEEDS OF WORK EQUIPMENT, ARE ALL SLOW If there are other
gg
1.
x
2.
problems,
such as travel
deviation
TRAVEL AND SWING
or low bucket
or swing
speed,
go to H-16.
If the pressure is not at least 27 kg/cm2, the spool of the acceleration (Hi) end is not fully actuated. The discharge pressure of the pump has an effect on the TVC valve set pressure, so check it before adjusting the TVC valve set pressure.
4 YES IS engine speed YES normal when pump is relieved with CO canceled? n I I L
Is relief pressure of F, R pump normal?
YEiS
1 Is relief pressure at charging pump
I
* Engine at high idling
* 30
zz kg/cm?
%l
20-192
20 ::
Does condition become normal when TVC valve
kg/cm’N
- H.0 + H mode - l-pump relief * Engine at high idling
*At normalrelief PCKKJLC: 310345 kg/cm* PC4LMLc: Does condition 314-343 kg/cm* become nOrr73al *At *-stage relief NO when main relief PIXWLC: valve is adjusted? 345375 kg/cm* PC4WLc: 34%378 k&m* -l-LO. and% mode *Engine at high idling %2 N0
normal relieved: 2100 + 100 rpm
*When CO cancelled: PC300LC: 2050+ 100 mm PC4OOLC: 2040+100 rpm lH.0. + H mode *Engine at high idle s YES*Arm relieved
XXiwLc:19?+ kg/cm’
P‘tititi
. When
6 YES
NO
NO
II-l
CG3.E.e
1 k_;ge
Remedy
Replace pump
inside
assembly
Adjust
Defective
Defective of main
2I
F;ztive
(Go
TVC
valve
adjustment relief valve
main
to
H-3,
Item
relief
Replace
4djust
qeplace
3)
20-I 93
H-2
THERE IS EXCESSIVE OR ENGINE STALLS
DROP IN ENGINE SPEED
2
* output
When pump is relieved, is output pressure of CO valve normal?
YES
. 3.-I
* At *
Is set pressure TVC valve n0r”lel?
. PCBOOLC l
pc400Lc
* Engine at high H.0 + H mode
idling
20 t;
kg/cm
pressure becomes normal Problem does not change
. 1 -pump relief . H.0 + H mode at high
Set pressure becomes normal Condition becomes normal
become normal when TVC valve set pressure is
. set pressure NO L[
does not become normal
also
I-
. output pressure becomes normal Condition also becomes . normal
*
* output _
set
20-I 94
__
NO
kg/cm
idling
_ NO
Does output pressure become normal when CO valve is adjusted?
*
of
30 ‘;
* Engine
normal relief: Max. 5.5 kg/cm= When CO canceled: Same pressure at TVC pressure
pressure becomes normal Problem does not change
pressure does not become normal
Remedy
C?NJSG!
See
Engine
shop
manual
Defective CO valve
adjustment
Defective
CO
TVC
valve
Adjust
Replace
valve
Defective adjustment TVC valve
Defective
of
of
4djust
Replace
20-I 95
H-3
WORK SPEED
:QUIPMENT, TRAVEL S EXTREMELY SLOW
AND
* When there is a big difference from the permissible * Auto-deceleration is normal. Jc Mode selection is H.O. and H mode
DO NOT
MOVE
OR
value.
I
I
*Crank with cranking motor. Disconnect governor motor connector and set governor lever to NO INJECTION.
1
SWING
l
Do not move, or speed is extremely slow?
NO
YES L
TO
Item
3 above
5
Speed is extremelY
slow
-
is set pressure TVCvalve normal?
of 6 Does
lPCSOOLC:
NO 17-20 kg/cm2 lPC4OOLC: 18-21 kg/cm2 lH.O.+ mode *Engine at high idling
Fig. 1 Control
YES
condition
~~fnrn~,n,O\~l’v’e
-
is adjusted?
NO
circuit
Travel PPC valve Solenoid valve
R.H. PPC valve
205FO5300
20-196
Cause
Remedy
Excessive internal leakage inside equipment in relevant system
Defective
charging
Replace
ReplaGS
Pump
Defective charging relief valve
pump
Replace lalve
* Defective damper (PTO) * Defective main pump (broken shaft, etc.)
3epair
Defective of TVC
4djust
or
‘eplaCe
set pressure valve
Defective operation TVC valve
relief
of
20-197
H-4 *
WORK EQUIPMENT,
Mode selection
TRAVEL AND SWING LACK POWER
is H.O. and H mode
Cause
3 ”
YE
CO
correct or
valve
replace
_1-!Z&ZJ
n
- See conditions Item 4 below.
When digging force is maximized
PCSOOLC: 345-375 ka/cm* Pc4ooLc:’ 348-378 ka/cm’ *Engine at-high idling.
Defective
Remedy
for
N(
4
YE!
Defective solenoid
Drop main
CO cancel valve
in set pressure relief valve
Replace
of
Adjust replace
or
l
l digging force is maximized, or during normal
’ It is also During normal operation
H-5
possible hose
valve outlet
1
POWER SET SELECTION
I
. When
digging force is maximized: 27 - 35 kg/cm2 . During normal operation: 0 kg/cm2
to hold the solenoid by hand to judge.
N(
Defective 2.stage relief solenoid valve
Replace
Drop in set pressure of main relief valve
Adjust replace
SYSTEM DOES NOT SWITCH CZlUSX
Remedy
I IWhen TVC valve solenoid is removed, and mode selection switch is operated with con nectar still connected, does spool of solenoid move? I)
Turn starting switch ON.
20-l 98
YES
I NO
Or
Defective
TVC
valve
Replace
Defective
TVC
solenoid
Replace
H-6
ABNORMAL
NOISE GENERATED
(FROM AROUND
PUMP) Remedy
CWSe
Clogged
Loose
4
YE:
t
Is oil level in hydraulic tank “OVllal?
strainer
piping
Defective
clamp
Tighten
Replace
pump
FH N
N(
Operate for a time and watch any changes in symptoms
Inspect again Depending on changes in symptoms)
Add Lack
H-7
AUTO-DECELERATION
of oil
DOES NOT WORK Cause
YES Is hydraulic pressure at inlet port of travel shuttle valve “OVllZll?
.27 -
35 kg/cm2
NO
hydraulic
oil
Defective Valve
travel
Defective valve
PPC
Remedy
shuttle
shuttle
20-199
H-8 l
*
BOOM AND ARM SPEED IS EXTREMELY
Mode selection is H.O. and H mode. When the travel, swing and bucket speeds
SLOW
are normal.
C.?NS.e
1 Does travel valve spool smoothly?
shuttle move
YES
control
20-200
on
top valve
of
Repair
Defective operation of straight-travel valve
or
replaCe
Defective
*Valve
Remedy
NO
-
travel
operation shuttle
valve
Of
Repair replace
or
20-201
H-9 *
WORK EQUIPMENT
(BOOM,
ARM AND BUCKET)
SPEED IS SLOW
When the travel and swing speeds are normal. (However, if there is any travel deviation and the bucket or boom speed is slow when operated individually, go first to “H-14, When machine is traveling, it deviates naturally to one side”.) Mode selection is H.O. and H mode.
l
3
YES
Is
Boom
only
operation of boom holding valve normal?
] -
-
I
INO
* Check movement valve with Your
of hand.
4 YES
I
Arm
only
Is hydraulic pressure at outlet port of arm half flow solenoid valve normal?
-
rt
YES
IS output pressure at PPC valve
normal?
rl
r-!
. 30 ‘z
1
* Engine
Is
hydraulic drift of slow cylinder within standard value?
YES
NO
. Finishing or lifting mode: 0 kg/cm* 1 Normal operation: 27 - 35 kg/cm2 l It is also possible to hold the solenoid hose by hand to judge.
I L[
Bucketonly
valve
Outlet
]
kg/cm2 at high I NO
idling
YES
tic YES NO . See TESTING AND ADJUSTING. * It is also possiole 10 measure the amount of leakage fror- II lLII_ ha
.~ _.
. 30 cclmin When relieved . Engine at high
-
idling
I,
6 Does condition become normal when safety (suction) valves are interchanged?
. For details of the type of safety valve, see Table
-
Arm,
-c
bucket
7 YES
NO
1.
c
1
Boom
only
Is boom holding valve normal?
I1 . Check movement of valve with your hand.
Table 1
Table of locations and types of safety valves used for each cylinder. ( ): Set pressure
Cylinder Boom Arm Bucket
20-202
Bottom
end (kg/cm’)
1 Safety - suction valve (365) Safety
- suction
valve
(365)
Safety - suction
valve
(365)
Head end (kg/cmL) I 1 Safety - suction valve (290) Safety valve (365) Safety - suction
valve
(365)
NO
Remedy
Defective operation control valve spool (boom)
Defective of boom
operation holding valve
Defective operation control valve spool
Defective solenoid
of
arm valve
of (arm)
half
flow
Defective operation control valve spool (bucket)
of
Repair or replace control valve assembly
Repair replace
or
Repair
or
replace control valve assembly
Replace
Repair or replace control valve assembly
Replace
Defective
PPC
valve
Defective packing
cylinder
Defective valve
safety
Defective of control
oil-tightness valve spool
Reolace
Defective valve
boom
Replace
piston
(suction)
holding
ReplaCe
Replace
I
20-203
H-IO 0
WHEP BOO\
When usual operation
Defective valve
arm
Repair
throttle
ARM
IS OPERATED
is normal.
or
WORK EQUIPMENT
(BOOM, ARM AND BUCKET) LACKS POWER
When the travel and swing speeds are normal. Mode selection
is H.O. and H mode. 2 Is main
YE:
when force zed?
l-
digging is maximi-
lPCSOOLC: 345 l
Does this problem occur when digging force is maximized, or during normal operation?
3
YES
relief
pressure normal
When digging force is maximized
1
*
NO
375 kg/cm2
PC4OOLC: 348 - 378 kg/cm’ Engine at high idling
jES
4
r
Both
Nl
end
. See
and
(
One
H-12
1
EXCESSIVE
Go to H-9, Item 5.
20-204
HYDRAULIC
DRIFT
end
only
YES
1 j-HP
bottom end, or at one end only?
NO
Table
ends
Is there lack of power at both head
During normal operation
c
*
SIMULTANEOUSLY,
replaCe
H-l 1 * *
BOOM AND IS SLOW.
]
Table
1.
NO
,
I
CaUSe
Remedy
Replace
Defective operation of 2.stage relief solenoid valve
(Go
to
H-9,
Item
2)
(Go
to H-9,
Item
5)
Defective (suction)
safety valve
Replace
Replace
20-205
H-13 It
EXCESSIVE
If the work
equipment
H-14
operation valve
(if the speed
is slow, go first to H-9, Item 2). Sec.
Boom
Max. 3.0
Arm
Max. 3.0
Bucket
Max. 3.0
Replace
DOES NOT ENTER F.O. MODE (HALF FLOW FUNCTION) Remedy
Defective operation of arm half flow solenoid valve
Replace
WHEN ARM AND SWING ARM IS SLOW
If the operation Cause
Defective operation swing priority valve
20-206
is normal
Remedy
CaUSe
H-15
speed
Time lag
C.NlSe
Defective of suction
TIME LAG
of the auto-deceleration Remedy
Of
ARE OPERATED
is normal
(if the auto-deceleration
SIMULTANEOUSLY, is defective,
go first to H-7).
20-207
H-16
* *
WHEN MACHINE ONE SIDE
IS TRAVELING,
IT DEVIATES
NATURALLY
TO
When the travel speed is normal. Mode selection is H.O. and H mode.
a) Deviates in same direction both in forward and reverse. YE
5 YES
Direction
of
4-,
1 _
c
1
NO
.
Is main pressure
1
I
4
see AND
NO
YES
the same as the TVC output pressure. . Lever at neutral: Max. 5.5 kg/cm= . Engine at high idling
relief normal?
For details, TESTING ADJUSTING.
6
. When track is rota1 ted freely or during normal travel, pressure must be Nc
*At travel relief: PC3OOLC: 325-355 kg/cm2 PC4OOLC: 340-370 kg/cm2 *At work equipment _ relief: PC3OOLC: 310-340 kg/cm2 PC4OOLC: 314-343 kg/cm2 *Engine at high idling
hoses are changed between F and R, does direction of
Is servo piston stroke normal?
Is output pressure of NC valve normal?
* For details, see TESTING AND ADJUSTING.
YES
-
Is differential Pressure of jat sensor normal?
-
* Lever at neutral: 18 - 24 kg/cm2
NO
. SeeNote.
LNO YES
10 YES _
Are metal particles found in oil drained from final drive on side which deviates?
_
YES
11 DOBS dilecfio” Of
deviafionchange when _ left andrighthcses _ NO be,V,Be” CO”T,D, “ad an.3IWiWljoint are inrsrchangedl
9 YES Does -
Direction of deviation does not change
30 +5 -3
20-208
valve NO
Is output pressure of PPC valve normal? I
Note:
control spool move smoothly?
NO
kg/cm2
When the track is rotated freely, if the output pressure of the NC valve is the same as the output pressure of the TVC valve, both the jet sensor and NC valve are normal.
l= Remedy
Defective of pump
Leakage
See TESTING AND ADJUSTING
adjustment
of inside
ReplaCe
pump
Defective of servo
7
YES
Does condition become norm.9 when relief valve of jet sensor is interchanged or adjusted? - Lever operated: Max. 2.5 kg/cm* Engine at high
-
NO
YES
Does direction of deviation change when ,ef* and rigtn hole* for SWiYd joint O”fbI port are interchanged?
NO
Defective OperatiO” of NC valve
Adjust replace
Drop in set pressure of jet sensor relief Valve
Adjust
Defective orifice
jet
Clean
Sensor
or
or
replaCe
Drop main
in set pressure relief Valve
1 ,“;ztive
final
Of
Adjust replace
or
Repair replace
01
Defective control valve body
Ftepl.332
Defective joint
Swivel
Replace
Defective motor
travel
Replace assembly
Defective Operation control valve spool
Replace
idling
12 r
operation valve
Defective
PPC
valve
Of
motor
Replace
Replace
20-209
b) Deviates in different direction in forward and reverse (See Fig. 1)
2
YES
Ct%E.e
Remedy
Defective swivel joint packing
Repair or replace
Defective
Repair or replace
pressure YES IS OUtpUt of PPC valve 1 normal? Is relief pressure normal at travel relief?
l
l
H PC30OLC: 325-355 kg/cm2 PC4OOLc:
340-370 *Engine
. 30 ‘; kg/cm= * Engine at high
idling Drop in set pressure of travel motor safety valve
1 NO
kg/cm2 at high idling.
Fig. 1
Location of defective swivel joint packing and direction of deviation in travel Drain
Right reverse OIllv c
Does not dewate
Rear right (A)
Right reverse and
Front left (6)
c
left forward
Front right (C)
Right forward
Rear left (D)
Left reverse only
left reverse
t,
I
20-210
PPC valve
No
F
I
and
Replace safetv valve assemblr
H-17 *
EXCESSIVE
If individual
travel
DEVIATION
DURING COMPOUND
OPERATIONS
is normal.
Remedy
Is oil pressure at inlet port of travel shuttle valve normal?
. 27 - 35 kg/cm2 10
If the pressure
Repair or replace
Defective operation travel shuttle valve
Of
Repair or replaCe
Defective operation PPC shuttle valve
of
Repair or replace
Does spool of travel shuttle valve move
YE
1
f
Defective operation of straight-travel valve
in Item 1 is lost, the auto-deceleration
also will not work.
20-211
H-18
EXCESSIVE
DEVIATION
WHEN STARTING
When the travel speed is normal. If there is also deviation during normal travel, go to “H-16 When machine is traveling, it deviates naturally to one side.” For deviation during simultaneous operations with the work equipment, go first to “H-17 Excessive deviation during compound operations.” Bleed all air completely from the circuit.
YES
Deviates at full stroke
_
When pump outlet hoses for F, R are interchanged, is problem reversed?
4 _ YES
3 -
NO
When hoses at swivel outlet port are interchanged, is problem reversed?
NO
Does machine deviate at lever full stroke, or
6
Machine deviates when starting,
N -
Full
stroke
1,
pressure of jet sensor at fast side (outside Of
. Control lever at neutral 18 - 24 kg/cm2 Control lever at full stroke Max. 2.5 kg/cm2 Engine at high idling
YES
- Control lever at NO neutral: Max.5.5 kg/cm2 * Track rotating freely: Min. . Engine at high idling 7 When of jet
YES
relief valves sensor are
.
.
20-212
problem
YES
When hoses at swivel inlef port are inferchanged, is problem reversed?
reversed? NO
18
kg/cm’
Remedy
Cause
Defective of servo
operation valve
Replace
Defective valve
Control
Replace
Defective
SwiVel
joint
Repair replace
Defective
travel
mOtOr
Replace
Defective operation servo valve
Defective NC valve
adjustment
of
Replace
of
Repair or rep lace
Defective jet relief valve
Sensor
Repair replace
Defective orifice
SensOr
Replace
jet
or
or
20-213
H-IQ -k * *
TRAVEL LACKS POWER (OR SPEED IS SLOW)
The mode selected is H.O. mode (the power set is automatically set to H) When there is no travel deviation. If the main relief pressure has dropped, there is also lack of power for normal operations using the work equipment. If there are problems in the CO cancel system, there is lack of power when using the power max. switch.
’ Cause
2 Is oil pressure at outlet port of CO cancel solenoid valve normal?
YEiS
1
I
At travel relief, is main relief pressure normal?
YES
NO
relief and when using power maximizing: 27 - 35 kg/cm2 . During normal operations: 0 kg/cm*
NIO PCSOOLC: 325-355 kg/cm2 PC4OOLC: 340-370 kg/cm2 Engine at high idling
% It is also possible to hold the solenoid valve outlet hose by hand to judge.
f
Replace
Defective CO cancel solenoid valve
Replace
Drop in set pressure of main relief valve
Idjust or replace
I
l
H-20
Defective CO valve
_
. At travel
*At travel relief:
TRAVEL SPEED DOES NOT SWITCH
When the travel
speed
is normal
at Hi or Lo.
1 Is hydraulic pressure at outlet port of travel speed solenoid normal? Hi: 27 - 35 kg/cm* At Lo: 0 kg/cm2
20-214
YES
Remedy1
F= 1. Cause
. At
Remedy
Defective travel motor * Speed change servo valve
Replace motor ass’y
Defective travel speed solenoid valve
Replace
-
NO
H-21
MACHINE
DOES NOT MOVE (ONE SIDE ONLY)
Cause
2 YES Is any foreign material found in oil drained from final drive?
Yl
3
I *At travel relief: PCSOOLC: 325-355 kg/cm2 b PC400LC: 340-370 kg/cm2 *Engine at high idling
H YES
normal at motor relief when safety valves are interchanged?
.
For
standard
see Item
value,
NO
Defective
final
Travel motor dragging
drive
brake
Repair replace
or
Replace motor assem b I Y
Defective travel motor safety valve
Replace valve
safety
Defective motor
Replace assembly
motor
travel
1.
20-215
H-22 l l
*
DOES NOT SWING
When other work equipment and travel Mode selection is H.O. and H mode. Turn swing lock switch OFF.
speeds
are normal.
YES
4 Is any foreign material found in oil drained from swing machinery?
YES
3 Is hydraulic pressure at left and right relief normal?
YES_
2
. Lever
Does not swing either direction, in one direction
operated: 27 - 35 kg/cm2 Lever at neutral: 0 kg/cm2 *It is also possible
.
in Or
Does not swing in one direction
l-
20-216
NO
NO
YES
NO
is also possible to measure the hydraulic pressure to judge. PCSOOLC: 270-300 kg/cm2 PC4OOLC: 255-285 kg/cm2 *Engine at high idling
* It
.-[
PC3OOLC:
the
solenoid
YES
Does control valve spool move smoothly?
270-300 kg/cm2 PC4OOLC: No 255-285 kg/cm2 *Engine at high idling
to hold
6 When left and right safety valves are interchanged, is problem reversed?
NO
_
Is hydraulic _ pressure at swing brake solenoid valve outlet port normal?
l-
-
_
5
_
valve
outlet
hose
by
hand
to judge.
Remedy
CaUSe
Defective
swing
Defective
motor
machinerv
brake
Defective operation control valve spool
Defective
swing
q-1
Defective
safety
Defective
PPC
valve
valve
or
Replace assembly
Repair
motor
or
replaCe
Replace assemblv
motor
Defective operation swing brake solenoid valve
-
of
Repair rep,ace
motor
Of Replace
Replace
Replace
20-217
H-23 f *
SWING SPEED IS SLOW OR ACCELERATION
When other work equipment and travel speeds are normal. normal travel, go first to “H-16 When machine is traveling, Mode selection is H.O. and H mode.
IS POOR
(If there is also deviation (to right) it deviates naturally to one side”.)
C3X.e
3 YI
YE:
Y
Both right
left
and
I
1
Must be the same a TVC valve output pressure - At relief: 5.5 kg/cm= Measure at NC valve.
Remedy
Excessive leakage inside swing motor, or brake dragging
Replace assembly
motor
Defective operation control valve spool
of
Replace valve
contrc
Drop in set pressure co valve
of
Defective co valve
Of
Does spool move smoothly when operated?
n
IS OUtpUt pressure of co valve at swing relief normal?
4
YE
value,
N
6
YE
.
Adiust
Does condition become normal
r
Max.
*
* For standard see Item 2.
both left and right, or in one direction only?
*‘Time taken to start swing (set) (90”): PC3OOLC: Max. 4.0 PC4OOLC: Max. 4.4 *Time taken for swing (set) (5 turns) PC3OOLC: Max. 36 PC4OOLC: Max. 38 *Engine at high idling
20-218
problem
Drop safety
operation
in set pressure valve
Defective
safety
Defective
PPC
valve
of
Replace
Adjust
Replace
reversed?
also possible to measure the hydraulic pressure to judge. lPCSOOLC: 270-300 kg/cm2 lPC4OOLC: 255-285 kg/cm2 *Engine at high idling *IS
during
valve
Replace
ti-24 A
EXCESSIVE
If the speed
is slow or the acceleration
1
I
excessive to both left and right, or in one direction Only?
-Overturn stopping
OVERRUN
YFS r
Both
HI
IL
when swing:
1
left
and
~~,),?eydirectio”
WHEN STOPPING is poor,
go first to H-23.
] 11
Leakage
] ]_I
Defective
H-25 *
inside
motor
safety
valve
Replace assembly
motor
Replace adjust
or
No
lPC3QOLC: Max. 88” lPC4OOLC: Max. 120” *Engine
SWING
I
at high idling.
EXCESSIVE
When the swing
speed
SHOCK WHEN STOPPING
SWING
is normal.
CAlE+Z
3 YES
Y
Both right
left
and 31
1
---I
. Lever . Lever
Is shock excessive on both left and right, or in one direction only?
*
;
One O”lY
direction
-
Is hydraulic pressure at swing brake solenoid valve Outlet port normal?
operated: at neutral:
27 - 35 kg/cm* 0 kg/cm*
Defective machinery
swing
Defective brake
swing
mot01
Replace
Defective solenoid
swing valve
brake
Replace
Defective
safety
valve
Replace
Repair
Is any foreign ,material found in oil drained from swing machinery?
2V
YES
Remedy
-
ND
NC
When the swing is operated and the lever is returned to neutral, the hydraulic pressure becomes 0 after approx. 4 sec.
1
20-219
H-26 *
EXCESSIVE
When the swing
speed
ABNORMAL
NOISE WHEN STOPPING
SWING
is normal. CW.WS
2
YES
Defective machinery
swing
Defective valve
lift
Defective
safety
Defective
suction
Remedy
Repair
1
Y
I
NO
check
Replace
on both left and right, or in one direction only?
One Only
H-27
valve
EXCESSIVE
HYDRAULIC
valve
Replace
DRIFT OF SWING CWSl?
Is hYdraulic pressure at swing brake solenoid valve outlet port normal?
Repl.XC!
direction
Remedy
Defective brake
swing
motor
Replace %sembly
Defective solenoid
swing valve
brake
Replace
motor
-
ND
. never at neutral: 0 kg/cm= Lever operated: 27 - 35 kg/cm2
*
H-28 l
WHEN OPERATED SIMULTANEOUSLY IS SLOW
When the usual swing cause Defectite operation swing priority valve
20-220
speed
Remedy
of
Repair replace
or
is normal.
WITH ARM, SWING SPEED
TROUBLESHOOTING P-l
P-2
P-3
P-4
P-5
P-6
P-7
P-7
P-8
OF MONITOR
SYSTEM
MONITOR PANEL LAMPS DO NOT LIGHT UP FOR 3 SECONDS SWITCH IS TURNED ON .............................................. MONITOR PANEL LAMPS ALL LIGHT UP WHEN STARTING BUT DO NOT GO OUT ...............................................
WHEN STARTING 20-225
SWITCH
IS TURNED
WHEN STARTING SWITCH IS TURNED ON (ENGINE CAUTION ITEMS FLASH ..............................................
ON 20-226
WHEN STARTING SWITCH IS TURNED ON (ENGINE STOPPED), CHECK ITEMS FLASH (LEVELS FOR CHECK ITEMS ARE AS SPECIFIED) WHEN STARTING SWITCH IS TURNED ON AND ENGINE CHECK ITEMS FLASH ................................................
(P-MODE)
...........
20-227
IS STARTED, 20-230
STOPPED), 20-231
WHEN STARTING SWITCH IS TURNED ON AND ENGINE IS STARTED, CAUTION ITEMS ........ FLASH (WHEN THERE IS NO ABNORMALITY IN CHECK ITEMS OR ENGINE)
20-232
(a) WHEN STARTING SWITCH IS TURNED ON (ENGINE STOPPED), BUZZER DOES NOT SOUND FOR 1 SECOND CAUTION ITEM IS FLASHING BUT BUZZER DOES NOTSOUND ......................................................
20-235
(b) THERE IS NO ABNORMALITY DISPLAY ON THE MONITOR .................................................. BUZZER SOUNDS
20-235
BUT THE
PANEL LIGHTING OF MONITOR PANEL DOES NOT LIGHT UP (LIQUID CRYSTAL DISPLAY IS NORMAL) ..................................
P-9
COOLANT
TEMPERATURE
SHOWS ABNORMALITY
P-10
COOLANT TEMPERATURE GAUGE GIVES NO DISPLAY (DURING .................................... NO LEVEL OF GAUGE IS DISPLAYED) DISPLAYS
LOW TEMPERATURE
FUEL GAUGE ALWAYS
P-12
FUEL GAUGE
P-13
(a) LAMPS DO NOT LIGHT.UP
P-l 3
(b) LAMPS
20-237
OPERATION, 20-237
P-14
(a) WIPERS
P-14
(b) WIPERS WORK EVEN WHEN WIPER SWITCH
P-15
(a) FAN DOES NOT WORK
P-15
(b) FAN WORKS EVEN WHEN FAN SWITCH
P-16
WORKING
P-17
POWER SET DOES NOT SWITCH
P-18
AUTO-DECELERATION AUTO-DECELERATION
20-238
.......................................
20-238
..........................................
LIGHT UP EVEN WHEN LAMP SWITCH DO NOT WORK
...........
FULL ...................................
P-l 1
GIVES NO DISPLAY
20-236
20-240 ............
IS NOT OPERATED.
20-240
...........................................
20-242
IS NOT OPERATED
..............
20-242
............................................
MODE DOES NOT SWITCH
20-244
IS NOT OPERATED
.................
20-244
....................................
20-246
.......................................
DOES NOT SWITCH IS NOT CANCELED)
SPEED DOES NOT SWITCH
20-248
(DOES NOT ENTER AUTO-DECELERATION; ................................
BETWEEN
HI AND LO.
....................
P-19
TRAVEL
P-20
WARMING-UP OPERATION IS NOT CARRIED OUT BELOW 3O”C, OR WARMING-UP OPERATION IS NOT CANCELED EVEN WHEN TEMPERATURE GOES ABOVE 30°C
20-248 20-249
....
20-250
20-223
P-21
EVEN WHEN SWING LOCK SWITCH IS TURNED ON (LOCK), SWING LOCK LAMP ON MONITOR PANEL DOES NOT LIGHT UP
P-22
FUEL LEVEL SENSOR
P-23
COOLANT
P-24
ENGINE
P-25
COOLANT
P-26
HYDRAULIC
20-224
SYSTEM
TEMPERATURE
OIL LEVEL SENSOR LEVEL SENSOR
SYSTEM
SYSTEM
SYSTEM
OIL LEVEL SENSOR
................................
DEFECTIVE
SENSOR
DEFECTIVE
DEFECTIVE
DEFECTIVE
SYSTEM
. . . . . . . . . . . . . . . . 20-251
......................
........................... ............................
DEFECTIVE
........................
20-252 20-253 20-254 20-255 20-256
P-l a)
MONITOR PANEL LAMPS WHEN STARTING SWITCH No monitor
panel
DO NOT LIGHT IS TURNED ON
UP FOR 3 SECONDS
lamps light up.
Remedy
2 YE
1 terminals of fuse 3 - chassis ground
. Voltage 20 . Turn starting ON.
.
Is voltage between Pl (female) (1) (3) normal?
* Voltage 20 * Turn starting ON.
30V switch
YES
)efective
-
monitor
panel
Iefective contact, or lisconnection in wiring harness between fuse 3 ‘1 (female) (I) or Pl female) (3) - M6 (9) :hassis ground
NO
3ov switcl
Iisconnectio”
in fuse
7eplace
:iean defective :ontact) eplace
or
eplace after lspecting cause f disconneCti
PI (040201 Id-1
Fuse
205FO5300
b)
Some monitor
panel lamps do not light up Defective
monitor
panel
replace
20-225
P-2
MONITOR PANEL LAMPS ALL LIGHT UP WHEN STARTING IS TURNED ON BUT DO NOT GO OUT
SWITCH
Remedy
20-226
P-3
WHEN STARTING SWITCH IS TURNED ON (ENGINE STOPPED), CHECK ITEMS FLASH (LEVELS FOR CHECK ITEMS ARE AS . SPECIFIED)
a) 8
(Coolant
*
level)
flashes
Check that the coolant is at the specified lever before carrying out the troubleshooting.
Cause
Defective coolant level sensor (reserve tank) systen (See P-26)
YES
YES off when short Is continuity betYES_ ween Pl (female) (17) and (3) as 2 shown in table?
. Connect
short connector to P8 (female) . Turn starting switch ON.
I
Is there continuity between P8 (female) _ 1 (2) and chassis ground?
1 Continuitv
Pl(O4020)
Defective monitor panel
leplace
Defective contact, or disconnection in wiring harness between P8 (femals (1) - E8 (2) - M6 (1) - PI (female) (17)
:lean(defective :ontact) or eplace
Defective contact, or disconnection in wiring harness between P8 (female (2) and chassis ground
>lean (defectiv ontact) or
I
. Connect
NO and disconnect short connector to P8 (femalel. 1 . g; starting switch
. Turn starting switch OFF.
Table 1 Short connector
-
eDlaCe
1
E
8EWPl4)
P8(X2) Coolant level sensor
m 205FO5731
20-227
b) 6 *
(Engine oil level) flashes
Use the dipstick troubleshooting.
to check
that the engine
oil is at the specified
level
before
Cause
carrying
out
Remedy
Yes Yes Is there continuity -between P5 (female) (B) - chassis ground les Is voltage between -P5(C) and chassis ground normal? Does display go off when PS (female) (1) is connected to chassis ground?
-
020 - 3ov. *Turn starting switch ON.
-
1
Defective engine oit level sensor system. (See P-24) -
No
No
the
Defective contact or disconnection in wiring harness between P5fB) - E8C3) or E9(1) - chassis.
CLean (defective or replace.
contact)
Defective contact or disconnection in wiring harness between P5K) - E8(3) - startor E9(3) - H14(4) ing switch terminal Act.
Clean (defective contact) or replace.
Defective
Replace
Yes *Connect PS (female) to chassis ground. *Turn starting switch ON.
(18)
- (3)
as
*Connect and disconnect P5 (female) to chassis ground.
monitor
panel.
Defective contact or disconnection in wiring harness between P5ffemale) (0) E8(5) or E9(5) - Ml4 (5) Pl (female) (18).
No
Clean (defective contact) or replace.
Table p
PltO40201 Monitor oanel
F-l-l@
hu4tsal
PC3OOLC ESCSWPBI PC4OOLC
Eatswa3
Engine oil level sensor
X08DD054
20-228
c) @
(Hydraulic oil level) flashes
YES
Defective hydraulic oil level sensor system (See P-27)
1 Does display go off _ when P9 (female) (1) is connected to chassis ground? . Turn starting switch ON.
_ NO
2 Is continuiv between Pl (female) (10) and (3) as shown in table?
. Connect
T-adapter to Pl (female)
YES )
Defective monitor panel
Replace
Defective contact, or disconnection in wiring harness between P9 (female (1) - M3 (7) - Pl (female) (10)
Clean (defective contact) or replace
_
.
NO
Pl(O40201
M3El6)
P9(XI)
Hydraulic oil level sensor
-3 I
@
205FO5733
20-229
P-4
*
WHEN STARTING SWITCH IS TURNED ON AND ENGINE STARTED, CHECK ITEMS FLASH
Check
both the alternator
system
and engine
oil pressure
system.
a) Alternator system
cause
2
YES
Defective
Is voltage between PI (female) (7) chassis ground normal? tween alternator terminal R chassis ground
. 26-30V * Start engine, and run at half throttle or above.
. 26 - 3QV * Start engine, and run at half throttle or above.
I\
NO
panel
when
Clean (defectiv contact) or replace
Defective
Replace
alternator
2
NO Is there contiwiry between Pl (female) (16) chassis ground? -
*Remove engine oil i pressure sensor Pl 1. switch
ON. l
engine sensor
Oil
Contact of wirinCJ%Gess between Pl 1 (C) - E9(2) or EB(2) - Ml4 (7) - Pl (female) (16) with chassis ground
_
removed7
YES
NO
Defective
monitor
panel
engine oil pressure sensor Pl 1. Remove
Pl(O4020)
Monitor panel
M14(S8)
Pc3ooLc: E9(SWP6) PCQOOLC: E8(SWP8) 0
Pll
Alternator D terminal
Pc3ooLc:
XOSDD055
20-230
ReDlace
Wective contact or dismnnection in wiring iarness between alternator terminal D - E8(2) or E9(2) 1 Ml4 (2) - Pl (female) (7)
Defective pressure
YES
starting
monitor
is normal.
1
+ turn
Remedy
IO
b) Engine oil pressure system * When the engine oil pressure
Does display go off wiring harness terminal of engine oil pressure sensor is
IS
:heck that erminal is not lefective (conact, insertion), :heck operation )f sensor ac:ording to standard Value rable for electical :ompone”ts, he” replace After epair
inspectiol or replaC
Replace
P-5
*
WHEN STARTING SWITCH CAUTION ITEMS FLASH
When the engine oil pressure
IS TURNED
ON (ENGINE
is normal.
Defective Is voltage between alternator terminal D - chassis ground 20 - 3OV?
YaS
3 -
*Do not start engine. *Remove alternator terminal D wiring.
1 Is there continuity between Pl(female) (16) - chassis ground?
-
*Remove engine oil No pressure sensor (Pll).
PNO4020)
Ml4(S8)
Wiring harness between Yes alternator terminal D -EM21 or E9(2) - M14(2) Pl (female) (7) in contact with +24V. Defective
Yes wharness Is there continuity between Pl(female) -(A) - (C) terminal? NO
alternator.
.
Is voltage between -P1(7) - chassis NO ground 20 - 3OV? *DO not start engine. *Turn starting witch ON.
-4
STOPPED),
monitor
panel.
1
Replace
After inspection repair or replace.
Replace.
No
Disconnection in wiring between Pl(16) Ml4(famaLe) (7) - E8(2) or between PllIA) - E8(1) or E9)l) - chassis growd.
Repair
or replace.
Defective engine oil pressure sensor.
Check that terminal is not defective (contact. in. sertion), check operation of sensor according to Standard Values Table for electri. cal corrponents, the replace.
Pc3ooLc: E9BWP6) PC400LC: EB(SWP8)
Alternator ’ D terminal PI1 Engine oil pressure sensor Pc3ooLc: E9(SWP6) Pc4ooLc:
20-231
P-6
a)
WHEN STARTING SWITCH IS TURNED ON AND ENGINE IS STARTED, CAUTION ITEMS FLASH (WHEN THERE IS NO ABNORMALITY IN CHECK ITEMS OR ENGINE)
(Engine oil pressure)
&
flashes
LJ
YES
1
Defective pressure
I
Z l
Remove engine oil pressure sensor P(ll).
between
Pl
chassis
ground?
* Turn OFF.
starting
switch
HNC-I
ZZ%? Monitor ) panel
20-232
++)
YWS)
oil
Contact of chassis ground with wiring harness between Pll (C)E8(2) or E9(2) - M14(7) - Pl(female) (16).
YES
Defective
Pc3ooLc:
Pl(O4020)
engine sensor
: Pi1 Engine oil pressure sensor
monitor
panel
c) $
(Coolant
temperature)
flashes
CXISEZ
2
Defective coolant temperature sensor system (See P-24)
YES
~~
.-1 Start
engine,
Remedy
-
Defective
monitor
panel
Replace
Defective
monitor
panel
Replace
and
PI (04020)
Ml4lS8)
E8WVPl4)
P7(X2)
Monitor panel
205FO5738
d) m
(Charge)
flashes Cause
2 Is voltage between Pl (female) (7) chassis ground normal?
YES
1 Is voltage between alternator terminal R chassis ground normal?
-
-
Defective
-
monitor
panel
Defective contact, or disconnection in wiring harness between alternator terminal R - E8 (8) - Ml4 (2) -
NO
*20-30V a Start
YES
Remedy
engine.
Pl
Replace
Clean (defectiv :ontact) or replace
e
(female) (7)
*
20 -.3ov * Start engine, and run at half throttle Or above.
NO
Pl(O4020) Monitor panel
Defective
Ml4681 \
3
7 ,
Replace
alternator
E86WP8) 0
Alternator
R terminal
205FO5739
20-233
e) @
*
(Fuel level) flashes
Check that there
is fuel before
carrying
out troubleshooting. Remedy
CEASe
2 Does display go off when P6 is removed?
YES
1
- Remove P6. . Start engine. . Wait for approx.
IS fuel gauge within red range?
L----J *
l The
Start engine, and run at half throttle or above.
[
delay
level
-
NO
Defective
monitor
panel
Defective
monitor
panel
2 minutes
surface of the fuel varies, so there is a built into the display for the fuel level.
ND
PI (040201 Monitor
Defective fuel sensor system (See P-23)
YES
M6
P6tXI)
Fuel level sensor
panel
205FO5309
20-234
P-7(a)
f
WHEN STARTING SWITCH IS TURNED ON (ENGINE STOPPED), BUZZER DOES NOT SOUND FOR 1 SECOND CAUTION ITEM IS FLASHING BUT BUZZER DOES NOT SOUND.
Of the CAUTION
item, the buzzer does not sound if there is any abnormality
in the charge or fuel level. ? Remedy
1 Does buzzer sound when Pl (female) (11) and chassis ground are connetted?
* Turn
starting
YES
Defective
-
I
panel
Disconnection in Wiring harness between PI (female) (11) P4 (2) - buzzer 1-j. or between +24V - P4 (1) -buzzer (+), or defective buzzer
-
NO
switch
ON.
P-7(b)
monitor
THERE IS NO ABNORMALITY THE BUZZER SOUNDS
DISPLAY ON THE MONITOR
Cause
I -now-__ ----_ h1177G.T sound when removed?
I I Pl
Remedy
Contact of chassis ground with wiring harness between Pl (female) (11) - buzzer (-)
After
Defective
Replace
inspection
repair or replace
is -
* Remove Pl. * Turn starting ON.
BUT
monitor
panel
NO switch
+24V P4tM3) f’I(O4020)
Monitor
panel
-
Buzzer
.+ _-
205FO5310
20-235
P-8
PANEL LIGHTING OF MONITOR PANEL (LIQUID CRYSTAL DISPLAY IS NORMAL)
DOES
NOT
C.XSe
1 Is bulb broken or is there defective contact?
YES
Bulb broken contact
20-236
NO of
or defective
monitor
UP
Remedy
Seplace bulb, :lean (defective :ontact)
-
Defective * Remove bulb. - Check condition bulb visually.
LIGHT
panel
RePlace
o
P-9 *
COOLANT TEMPERATURE TEMPERATURE
If the coolant
temperature
actually
remains
SHOWS ABNORMALITY low, check
the engine
LOW
system.
CaUSe
Defective temperature (See
gauge off?
levels
go
2
starting
system
Panel
monitor
ReDlace
Defective contact, or disconnection in wiring
switch
harness between PI (female) (6) - Ml4 (6) E8 (5) - P7 (female) (I) or P7 (female) (2) - E8 (6) - chassis ground
NO . Connect short connector to P7 (male). * Turn starting switch OFF.
P-l 0
coolant sensor
P-24)
Defective
Is there continuity _ between Pl NO (female) (6) chassis ground?
* Connect short connector to P7 (male) . Turn ON.
YES
Remedy
Clean (defective :ontact) or replace
COOLANT TEMPERATURE GAUGE GIVES NO DISPLAY (DURING OPERATION, NO LEVEL OF GAUGE IS DISPLAYED)
F
Cause
Defective coolant temperat”re sensor system
YES
Gee
-
P-24)
I
1C+act
pf chassis ground harneSS oetween P7 (female) (1) -
perature gauge appear when P7
with
Is there
* Remove P7 (female). * Turn starting ON.
switch
continuity between PI (6) chassis ground when P7 is removed? - Remove P7. . Turn starting OFF.
P-9, 10
E8 (5) (female)
panel
(6) -
PI
,fter inspection rpair,or replac
Defective
monitor
panel
IepIC
NO switch
M14(S81
E8C3WPl4)
CIRCUIT
DIAGRAM
P7(X2) Coolant
Monitor
Ml4 (6)
-
RELATED ELECTRICAL
Pl(O4020)
wmng
temperature
sensor
6 1
d7
205FO5738
20-237
P-l 1 *
Check
FUEL GAUGE ALWAYS DISPLAYS first if the fuel tank is actually
full before
carrying
FULL out troubleshooting. CZlUSl?
Defective fuel sensor system (See P-23)
YES
1 I Does display of fuel gauge go off when P6 is removed?
_
Is there continuity between Pl (5) chassis ground when P6 is removed?
- Remove P6 (male). - Turn starting switch’ ON. . Wait for approx. 2 minutes.
. The surface the display
2
NO
varies, level.
-
Contact of chassis ground with wiring harness between P6 (female) (1) M6 (4) - Pl (female) (5)
rfter inspection epair, or eplace
Defective
7eplace
monitor
panel
NO
so there
is a delay
built
into
P-12
FUEL GAUGE GIVES NO DISPLAY
*
if there
Check
level
-
- P6 is removed? * Turn starting switch OFF.
of the fuel for the fuel
YES
Remedy
is any fuel before
carrying
out troubleshooting.
Remedy
C2aE.e
Defective fuel sensor- wster” (See P-23)
YES
1
I
Defective
level
monitor
-
panel
Defective contact, Or disconnection in wiring *
Connectshort
to P6 (female). - Turn starting OFF.
P-l 1 ,I 2
harness between P6 (female) (1) - M6 (4) Pl (female) (5)
connector
7ePlace
&an (defectiv ontact) or eplace
switch
RELATED ELECTRICAL Pl(O4020)
CIRCUIT
DIAGRAM P6(XII Fuel
level sensor
Monitor panel
205FO5309-1
20-238
20-239
LAMPS DO NOT LIGHT UP
P-l 3(a)
c
YES
Defective
2 Does lamp light when PI (female) (14) and chassis ground are connetted?
YES -
lp
’
Do LEDs on monitor panel light up?
* Turn ON. * Turn ON.
starting lamp
-
ND
3 _YES
Is there any disconnection or defective contact in lamp?
-
- Check
visually.
NO
switch switch
Disconnection, defective in lamp
contact
Defective contact, or disconnection in wiring harness between Pl (female) (14) - lamp relay R4 (2). between lamp relay R4 (1) -fuse (5). between lamp relay R4 (5) - M6 (3) - M8 cl), or between M6 (3) - Ml0 (1) - M9 (1) Defective
NO
P-13(b)
panel
monitor
LAMPS LIGHT UP EVEN WHEN LAMP SWITCH NOT OPERATED
panel
3 Is there continuity between Pl (female) (14) chassis ground?
YES 2 -
Does lamp light upwhen Pl (female) is
1 Are LEDs on monitor panel out?
. Turn ON. * Turn OFF
20-240
starting lamp
removed?
-
* Remove Pl(female). . -&u;.n starting switch
* Turn -
* NO
starting
OFF. Disconnect
switch Pl.
YES
I
Clean (defecti\ contact) or replace
I
Clean (defecti\ contact) or replace
Replace
IS
CX4Se
YES_
Replace
up
* Connect Pl (female) (14) and chassis ground. * Turn starting switch ON.
-
monitor
Remedy
Contact of chassis ground with wiring harness between Pl (female) (14) lamp relay R4 (2). or defective lamp relay Wiring harness between M6 (female) (3) - M8 (female) (I) or M6 (male) (3) - Ml0 (1) - M9 (female) (I) in contact with +24V
After inspection, repair or replace
After inspection, repair or replace
Defective
monitor
panel
Replace
Defective
monitor
panel
Replace
switch switch
NO
+24V
M6(SIO)
M8lMI)
-3
Monitor
R.H. head lamp
Lamp relay (R4
M9tMIl Boom head lamp
A7
205FO5313-1
20-241
P-l 4 (a)
WIPERS
DO NOT WORK . CZil.Se
4
v Is there continuity between M4 (female) (2) chassis ground?
YES 3 r
Do LEDs on monitor panel light up?
Turn ON. - Turn ON.
startina wiper
swit switch
Connect Pl(female (15) and chassis ground. Turn starting switc, ON.
1 1
NC
P-14(b)
NO Is voltage between M4 (female) (1) - chassis ground normal?
* Turn
ON. . Turn ON.
starting wiper
_
. Turn starting switch OFF. - Disconnect M4.
switch switch
NO
YE
h
Defective
monitor
Defective
wiper
Remedy
panel
motor
Defective ConfaSt! or disconnection in wlrlng harness between M4 (female) (2) - M5 (2) - chassis ground Defective wiper relay, or defective contact, or disconnection in wiring harness between wioer relav Rl (3) M6 (1) - ti4 (female)
monitor
WIPERS WORK EVEN WHEN WIPER SWITCH NOT OPERATED
Panel
20-242
Yean (defective :ontact) or ‘eplace
:lean (defective :ontact) repair ,r replace
qeplace
IS
Remedy
Contact of chassis wound with wiring harries; between Pl (female) (15) Gyiper relay Rl (female)
OFF
3eo1ace
(1) Defective
Cause
-Ehko
qeplace
.iter inspection wair or !place
Wiring harness between wiper relay RI (3) M5 (1) - M4 (1) in contact with +24V, or defective wiper relay
fter inspection !pair or !place
Defective
monitor
panel
eplC3Ce
Defective
monitor
panel
;epkXe
+24V
M 5lM4)
M4(KES4)
(KES4)
205FO5314
20-243
FAN DOES NOT WORK
P-l 5 (a)
C3JS.e
Defective
YE
.
. 1
*
Do LEDs on monitor panel
* Turn ON. Turn
.
starting fan
connect ~1 (12) (or (13)) and chassis ground. Turn starting switch ON.
IS there continuity between R2 (female) (3) - Ml 2 (female) I_, (2,. or between R3 (female) (3) G)yl 2 (female)
YE
R2 (female) (3) (Lo side) or R3 (female) (3) (Hi side) - chassis around normal? *o-1v * Turn starting switch ON. * Turn fan switch
switct
. Turn OFF.
starting
S Defective
I 0
swi tcl
s Does
ON.
*
switch
ON.
* f IO
heater
heater
Replace
Clean (defectiv contact) or replace
Defective
Replace
heater
relay
work
Disconnection in wiring harness between R2 (female) (2) Pl (12) IO (female), or between R3 Interchange lamp rela V (female) (2) - Pl (13) and heater relay. (female) Turn starting switch ON. Turn heater switch 01 v. Defective monitor panel
3
r Yl ES -
Does fan work when PI (female) is removed?
1 Are LEDs on monitor panel
* Turn
starting
ON. * Turn OFF.
fan
20-244
: Remove
-
Is there continuity between Pl (female) (12) (or (13)) -chassis ground?
* Turn oFF.
starting
switch
YES
NO
Repair
Reolace
Remedy
Contact of chassis ground with wiring harness between Pl (female) (12) heater relay R2 (2). Or between Pl (female) (13) - heater relay R3 (2)
After inspection, repair or replace
Contact of chassis ground with wiring harness between heater - Ml2 (2) (of (3)) heater relay R2 (3) or R3 (3). or defective heater relay R2 or R3
After inspection, repair Or replace
Defective
monitor
Panel
Replace
Defective
monitor
panel
Replace
P!(fem$).[
* ‘0”~: stamngswitch
NO
switcl h
switch
L NO
or
replace
IS NOT OPERATED CaUSe
YES 2 -
Replace
Defective contact! or disconnection in wlrlng Iharness between Pl Ifemale) (12) - heater relay R2 (2). between PI (female) (13) - heater relay R3 (2). between Ml: (female) (2) - heater relay R2 (3), or between Ml2 (female) (3) heater relay R3 (3)
FAN WORKS EVEN WHEN FAN SWITCH
P-15(b)
panel
4
H
Does fan work when Pl (female) (12) (or (13)) chassis ground are connected?
monitor
Remedy
+ 24V
M 12
PI (04020)
205FO5315
20-245
WORKING
P-l 6
MODE DOES NOT SWITCH Cause
a)
Even when monitor panel switch is pressed, mode display (LED) above switch does not change. I
b)
Remedy
When display
3efective
monitor
panel switch
(LED) above switch
is pressed,
>ump
Table
3eplace
changes. jee
starting
panel
mode
YFS
* Turn ON.
monitor
troubleshooting controller
Of
system
Disconnection in wiring ,arness between C2 (14) - P2 (8) or oetween c2 (15) - P2 (9,hoC;;h;rt circuit
Correct
Defective
Replace
monitor
panel
replace
or
switch
1
Table 2 Between
Note:
If the voltage
(8) - (16)
is not 12V and is unstable,
Pump
controller
C2 (MIC21)’
take the answer
as YES.
Monitor
panel
P2 (04016)
205FO5627
20-246
P-l 7
POWER SET DOES NOT SWITCH CaUSe
a)
Even when monitor panel switch is pressed, mode display (LED) above switch does not change. Defective
b)
When
monitor
panel switch
above switch
is pressed,
mode display
. Turn ON.
See troubleshooting pump cO”trOller
between (8) and (6) - (8) in Table
starting
switc
2
ReplaCe
Is voltage P2 (5) -
of system
Disconnection in wiring harness between C2 (5) - P2 (5) or between C2 (6) - P2 (6). or short circuit with GND
YES
between (16) and
~‘“i_e
monitor
Table
panel
(LED)
YES
Is voltage C2 (5) between as shown I?
monitor
changes.
1
1
panel
Repair replace
or
Replace
Table 2
Power set
Note:
Remedy
Between (5) - (8)
Between (6) - (8)
Power set
H
12V (Note)
12V (Note)
H
12V (Note)
12V (Note)
S
Max. IV
12V (Note)
S
Max. 1V
12V (Note)
L
Max. IV
Max. 1V
L
Max. 1V
Max. 1V
If the voltage is not 12V and is unstable, take the answer as YES.
Pump controller
Note:
Between (5) - (16) Between (6) - (16)
If the voltage is not 12V and is unstable, take the answer as YES.
Monitor panel
205FO5628
20-247
P-l 8
AUTO-DECELERATION AUTO-DECELERATION: NOT CANCELED)
DOES NOT SWITCH (DOES NOT ENTER AUTO-DECELERATION IS
CaUSe
a)
Even when monitor (LED) above switch
panel switch is pressed, does not change.
ON-OFF
display
I
b)
When
-
monitor
panel switch
(LED) above switch
is pressed,
ON-OFF
Remedy
I3efective
monitor
panel
3eplaCZ
display
changes. ‘
See troubleshooting Controller I,u”lp iystem
YES
of
14
voltagebetween
Is C2 (7) shown p * Turn ON.
- (8) as in Table l?
starting
-
2
_ Is voltage p2 (7) _
switch NO
show”
~YES
-(
between (,6J as
in Table
INO starting
:orrect
or
,epl.Xe
l?
I * Turn
in wiring [Iisconnection t wness between C2 7) - P2 (7). or with chassis c:o”tact cUOU”d
_I
3efective
monitor
panel
Redace
switch
ON.
Table
Note:
1
If the voltage is not 12V and is unstable, take the answer as YES.
Pump
controller
C2(MIC21)
Monitor
panel
P2 (04016)
m_Ei
205FO5397
20-248
P-l 9
TRAVEL SPEED DOES NOT SWITCH
BETWEEN
HI AND LO
C3.E.e
a)
Even when monitor (LED) above switch
panel switch is pressed, does not change.
Lo -
Hi display
I
b)
kfective
When monitor panel switch is pressed, (LED) above switch changes.
Lo -
YES
-
monitor
lee troubleshooting wmp controller
2
panel
YES
Is voltage between Turn starting switch A- P2 (4) - (16) as ON. NO shown in Table l?
of system
)isconnection in wiring ,arness between C2 (3) - P2 (41. or contact vith chassis ground
:orrect
Iefective
7eplace
NO a Turn ON.
Note:
starting
replace
Hi display
11 Is voltage between C2 (3) - (8) as shown in Table l?
Remedy
switch
monitor
panel
,r eplace
If the voltage is not 12V and is unstable, take the answer as YES.
Pump controller
Monitor panel
P2 (04016)
205FO5396
20-249
P-20
*
WARMING-UP OPERATION IS NOT CARRIED OUT BELOW 3O”C, OR WARMING-UP OPERATION IS NOT CANCELED EVEN WHEN TEMPERATURE GOES ABOVE 30°C
Carry out troubleshooting
first for E-l 1 Automatic
warming-up
is defective.
Cause
Remedy
See E-11
Is voltage between P2 (11) and (16) as shown in Table l?
. Turn
starting switch ON.
Defective coolant temperature sensor svstem (See P-23) ~ ~..~ --.
YES
1
‘)
6
Warming-up operation cannot be carried out
I
I
a
‘Can warming-up be carried out?
3
1
Is there continuity between Pl NC (female) (6) and chassis ground? H . Remove P7.
. Start engine.
YE!
NC
‘
Warming-up operation is not canceled
1
H
I
Can warming-up be canceled?
3 YE:
. Connect
short connector to P7 (female) . Start engine.
NC1-H
. Connect
short connector to P7 (female)
Table
Repair or replace
Defective monitor panel
~~_~__ Defective coolant temperature sensor system (See P-23)
YES 9
Wiring harness between Pl (female) (6) - Ml4 (6) - E8 (4) or E9 (4) - Pi’(A) in contact with chassis ground or other GND wiring
NC
Defective contact or disconnection in wiring harness between Pl (female) (6) M14 (6) - E8‘(4) or ’ ‘-’ E9 (4) - P7(A).
Repair or replace
Defective monitor panel
Replace
1 Voltage Auto warming-up Auto warming-up
Note:
(actuated)
Max. 1V
(not actuated)
12V (Note)
If the voltage is not 12V and is unstable, take the answer as YES.
Pc3ooLc: E-8 (SWP8) Pl(O4020)
M14(S8)
Pc4ooLc: E-9 (SWPG)
P7
Coolant temperature
XOSDD057
20-250
P-21
*
EVEN WHEN SWING LOCK SWITCH IS TURNED ON (LOCK), SWING LOCK LAMP ON MONITOR PANEL DOES NOT LIGHT UP
Only carry
out this troubleshooting
if the swing
lock is actually
applied.
CFllK3e
1 Is voltage between P2 (3) - (16) as shown in Table l?
YES
Defective
Turn ON.
Table
starting
panel
Flepke
Disconnection in wiring harness between swing lock switch (1) - P2 (3)
NO
.
monitor
Remedy
switch
1
correct
or
replaCe
Voltage
1 Swing
lock switch
1 Swing
lock switch
ON
Max. 1V
OFF 1 20 - 30V 1
Swing
lock switch
P2(04016)
Monitor
panel
205FO5741
20-251
P-22
FUEL LEVEL SENSOR
SYSTEM DEFECTIVE
Note 1:
f
Difference between fuel level and gauge display. If the gauge display position is “lo”, the fuel level display is 78% or 100%; if it is “l”, the fuel level display is less than 14.5%. If the machine is on a slope, the display and the actual fuel level will be different. Therefore, when checking, always stop the machine on level ground and wait for at least two minutes before reading the gauge. (The fluid level changes when the machine is moving, so a time delay is provided to give a stable display.) Remove the fuel level sensor when carrying out this troubleshooting.
Remedy
C.SlSe
3 YES 2 -
YES
Does the arm smoothly)
IS the float badly cracked. chwped. damaged,
or
YES
Interference lnslde tank
with
sensor
(Note 2)
-
Defect!ve
contact
of connector
Clean COnnectOr or replace
Defectw
sensor
(Note 2)
Re&ce
NO
move
1 Move the float up and down. Is the resnstance between Connector (1 and flange as shown I” Table 1,
NO
I
4
~0
YES ~
Is wr,ng of w,r,ng harness broken? Is reswance between connector (1 and sensor terminal below 1 II?
EMPTY stopper position
Repar w,r,ng harness or replace sensor
Defective
ReDlaCe
j
-
Table 1 FULL stopper position
D!sconnectlon I” w,r,ng harness (Note 3) (Defective clamp)
Approx.
sensor
NO
1222 or less
Approx. 85 - 1lOQ
F20205053
Note 2: Note 3:
20-252
There is probably interference with the sensor inside the tank or defective installation. Install carefully when replacing. Check for any vibration at the connector mount and take the necessary action if the vibration is excessive.
P-23
COOLANT
TEMPERATURE
SENSOR
SYSTEM DEFECTIVE CaUSe
YES
1I temperature sansor connector (male) (A) and (B) as shown in
100°C
contact
Defectwe
sensor
of connector
Clean connector or replace sen*or
2 -
YES
IS wirmg of wring harness broken? Is resistance between connector (male) and sensor termmal below 1 f2?
25” C
.
Replace
-
NO
Table 1 Normal temperature
Defecwe (Note 1)
Remedy
Dtsconnectmn I” wnrn”g harness (Note 2) (Defectwe clamp)
Repau wrmg harness or replace sensor
Approx. 37 - 50kQ Approx. 3.5 - 4.0kQ
Connector
Sensor
-F20205054
Note 1: Note 2:
If the problem occurs again, the connector (female) at the chassis end is probably defective, so replace the connector (harness) at the chassis end. Check for any vibration at the connector mount and take the necessary action if the vibration is excessive.
20-253
P-24
ENGINE
Note 1:
Variations in oil level. The oil level changes according to the angle of the temperature, so if any display is given, stop the machine before carrying out the check again.
: *
OIL LEVEL SENSOR
SYSTEM DEFECTIVE machine, the on flat ground
engine speed and oil and check the oil level
Remove the engine level sensor when carrying out this troubleshooting. To check the performance of the sensor, prepare engine oil in a container. Prepare a power source giving lo-32V DC. Cause Yes
When sensor is inserted in engine oil, is resistance between connector (D) and (B) as shown in table? *Connect power source to (B) and (0. (C) is positive and (B) is negative.
Note 2: Note 3:
Remedy
Defective contact of connector. (See Note 2)
Clean connector or replace sensor.
Yes -Disconnection in wiring harness. (See Note 3) 2 (Defective clamp
Repair wiring harness or replace sensor.
Can any broken wires -be seen when check- No ing visually?
-Defective No
sensor.
Replace.
If the problem occurs again, the connector (female) at the chassis end is probably defective, so replace the connector (harness) at the chassis end. Check for any vibration at the connector mount and take the necessary action if the vibration is excessive.
Table In oil In air
08DDOOll
20-254
P-25
COOLANT
Note 1:
Variation in coolant level. The coolant level changes according to the angle and swaying of the machine, so if any abnormal display is given, stop the machine on flat ground and check the coolant level before carrying out the check again.
*
Remove
the coolant
LEVEL SENSOR
level sensor
when
carrying
SYSTEM DEFECTIVE
out this troubleshooting.
RemedY
Callse
YES
YES
Defectw because
Is any dirt or dust stuck in float?
-
3
L
1
-
1
NO
Move the float up and down. Is the resistance between Connector (1) and flange as shown I” Table 1 ?
IS float badly cracked, chipped, damaged?
YES
mOYeme”t of dirt
Resonance
of mount
of float
Ck?afl
(Note 2)
Replace
sen?.or
or _
Defectwe
NO
contact
Clean COnnectOr or replace
or connector
4 Is wlrlng of wnng harness broken? Is resstance between connector (1). (2) and sensor below 1R?
L NO
Dlsconnectlon I” wnng harness (Note 3) (Defectwe clamp)
YES
Repar wr,ng harness or replace sensor
_
FWplWX
NO
Table
Float UP
I
I
PC3OOLC
1 Float DOWN
Max. l!A I
Min. 1Mfl
PC4OOLC
A I
DOWN+ F20205056
Note 2: Note 3:
k+----
F20505366
There is a strong possibility that the mount is resonating, so check the mount of the subtank. Check for any vibration at the connector mount and take the necessary action if the vibration is excessive.
20-255
~,oat
P-26
HYDRAULIC
Note 1:
Variations in hydraulic oil level. The oil level changes according to the angle of the temperature, so if any display is given, stop the machine before carrying out the check again.
*
Remove
the engine
OIL LEVEL SENSOR
level sensor
when
carrying
SYSTEM DEFECTIVE machine, the on flat ground
engine speed and oil and check the oil level
out this troubleshooting. Remedy
2 YES
1
lS any dirt or dust stuck in movable part of float?
-4 I
Excessive contamination of oil
qeplace filter zlement, change )il
Defective contact of connector (Note 2)
Clean connector or replace sensor
Asconnection in wiring harness (Note 3) (Defective clamp)
Repair wiring harness or replace sensor
-
Move the float UP
and down Is the res~3ance berween connector (1) and -flange as shown I” Table 1)
YES
NO
Is wiring of wiring
YES
harness broken? Is I L resistance between NO connector (male) and sensor terminal below 1Q
Replace NO
Table
1 Float UP
Max. 1fI
Float DOWN
Min. 1MQ
F20205055
Note 2: Note 3:
20-256
If the problem occurs again, the connector (female) at the chassis end is probably defective, so replace the connector (harness) at the chassis end. Check for any vibration at the connector mount and take the necessary action if the vibration is excessive.
30 DISASSEMBLY
METHOD
OF USING
PRECAUTIONS OPERATION
MANUAL
. . . . . . . . 30-5
WHEN CARRYING OUT . . . . . . . . . . . . . . . . . . 30-6
AND ASSEMBLY
INSTALLATION OF ENGINE, HYDRAULIC PUMP ASSEMBLY..
. . . . .
30-28
PUMP ASSEMBLY.
. . ; . . .
30-30
INSTALLATION OF ENGINE, HYDRAULIC PUMP ASSEMBLY.
. . . . . .
30-30
REMOVAL OF DAMPER ASSEMBLY __. . __. ___. . . . . . . . . . .
30-32
INSTALLATION OF DAMPER ASSEMBLY . . . . . . . . . . . . . . . . . . . . .
30-32
REMOVAL HYDRAULIC
SPECIAL TOOL LIST PC3OOLC . . . . . . . . . . . . . . . . . . . . . . . 30-8 SPECIAL TOOL LIST PC4OOLC . . . . . . . . . . . . . . . . . . . . . . WEIGHT
TABLE
. . . . . . . . . . . . . . . . . .
30-l 1
OF ENGINE,
30-l 4
TIGHTENING TORQUES AND STANDARD VALUES TABLE . . . . . . . . . . . . . . . 30-l 5 . . .
30-21
REMOVAL OF CENTER SWIVEL JOINT ASSEMBLY . . . . . . . . . . . . . . . .
30-34
REMOVAL OF GOVERNOR MOTOR ASSEMBLY . . . . . . . . . . . . . . .
30-22
INSTALLATION SWIVEL JOINT
OF CENTER ASSEMBLY.
. . . . . . . . .
30-34
REMOVAL OF HYDRAULIC COOLER ASSEMBLY . . . . . . . . . . . . . .
30-24
DISASSEMBLY SWIVEL JOINT
OF CENTER ASSEMBLY . . . . . . . . . .
30-34
INSTALLATION OF HYDRAULIC COOLER ASSEMBLY . . . . . . . . . . . . . .
30-24
ASSEMBLY OF CENTER SWIVEL JOINT ASSEMBLY
. . . . . . . . . .
30-34
REMOVAL OF HYDRAULIC COOLER ASSEMBLY . . . . . . . . . . . . . .
30-24
REMOVAL OF FINAL DRIVE ASSEMBLY . . . . . . . . . . . . . . . . . . . . .
30-36
INSTALLATION OF HYDRAULIC COOLER ASSEMBLY . . . . . . . . . . . . . .
30-24
INSTALLATION OF FINAL DRIVE ASSEMBLY . . . . . . . . . . . . . . . .
30-36
REMOVAL OF RADIATOR, HYDRAULIC OIL COOLER
30-26
DISASSEMBLY OF FINAL DRIVE ASSEMBLY . . . . . . . . . . . . . . . .
30-36
ASSEMBLY ASSEMBLY
30-40
LUBRICANT
AND COOLANT
TABLE
. . . . . . . . . .
INSTALLATION OF RADIATOR, HYDRAULIC OIL COOLER ASSEMBLY . . . . . . . . . . . . . . . . . . . . . REMOVAL OF ENGINE, HYDRAULIC PUMP ASSEMBLY..
OF FINAL DRIVE . . . . . . . . . . . . . . . . . . . . .
30-26 DISASSEMBLY OF TRAVEL MOTOR ASSEMBLY (HMV280ADT)(HMV355ADT)
. . . . .
30-44
30-28
30-I
ASSEMBLY OF TRAVEL MOTOR ASSEMBLY (HMV280ADT) (HMV355ADT)
30-49
REMOVAL OF IDLER, RECOIL SPRING ASSEMBLY . . . . . . . . . . . . . .
REMOVAL
30-58
INSTALLATION
OF SPROCKET
. . . . . . . . . .
RECOIL SPRING INSTALLATION REMOVAL ASSEMBLY
OF SPROCKET
. . . . . . .
INSTALLATION OF SWING MOTOR ASSEMBLY . . . . . . . . . . . . . . . DISASSEMBLY ASSEMBLY
INSTALLATION OF SWING MACHINERY ASSEMBLY..
. . . . . . . .
. . . . . . . .
30-80
DISASSEMBLY OF RECOIL SPRING ASSEMBLY . . . . . . . . . . . . . .
30-82
ASSEMBLY
OF RECOIL
ASSEMBLY
. . . . . . . . . . . . . . . . . . . . .
SPRING 30-82
30-58
ASSEMBLY OF SWING MOTOR ASSEMBLY (KMF160) . . . . . . . . . . . . . . . . . . . 30-63
. . . . . . . . . . .
ASSEMBLY
30-58
OF SWING MOTOR (KMF160) . . . . . . . . . . . 30-60
REMOVAL OF SWING MACHINERY ASSEMBLY
OF IDLER,
30-58
OF SWING MOTOR . . . . . . . . . . . . . . . . . . . . .
30-80
REMOVAL OF TRACK ROLLER ASSEMBLY . . . . . . . . . . . . . . . . . . . .
30-84
INSTALLATION OF TRACK ROLLER ASSEMBLY . . . . . . . . . . . . .
30-84
REMOVAL OF CARRIER ROLLER ASSEMBLY . . . . . . . . . . . . .
30-84
INSTALLATION OF CARRIER ROLLER ASSEMBLY . . . . . . . . . . . . .
30-84
REMOVAL OF TRACK SHOE ASSEMBLY . . . . . . . . . . . . . . . . . . . .
30-86
30-68
30-68
REMOVAL OF SWING MACHINERY ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
30-68
INSTALLATION OF TRACK SHOE ASSEMBLY . . . . . . . . . . . . . . .
30-86
INSTALLATION OF SWING MACHINERY ASSEMBLY . . . . . . . . . .
30-68
REMOVAL OF CHARGING PUMP ASSEMBLY . . . . . . . . . . . . . . .
30-86
DISASSEMBLY OF SWING MACHINERY ASSEMBLY . . . . . . . . . .
30-70
INSTALLATION OF CHARGING PUMP ASSEMBLY . . . . . . . . . . . . . . .
30-86
ASSEMBLY OF SWING MACHINERY ASSEMBLY
. . . . . . . . . .
30-72
REMOVAL OF HYDRAULIC PUMP ASSEMBLY . . . . . . . . . . . . . . .
30-88
REMOVAL OF REVOLVING FRAME ASSEMBLY . . . . . . . . . . . . . .
30-78
INSTALLATION OF HYDRAULIC PUMP ASSEMBLY . . . . . . . . . . . . . . .
30-88
INSTALLATION OF REVOLVING FRAME ASSEMBLY . . . . . . . . . . . . . . .
30-78
REMOVAL OF HYDRAULIC PUMP ASSEMBLY . . . . . . . . . . . . . . .
30-88
REMOVAL OF SWING CIRCLE ASSEMBLY . . . . . . . . . . . . . . . . . . . . .
30-80
INSTALLATION OF HYDRAULIC PUMP ASSEMBLY . . . . . . . . . . . . . . . .
30-88
INSTALLATION OF SWING CIRCLE ASSEMBLY . . . . . . . . . . . . . . .
30-80
DISASSEMBLY ASSEMBLY
OF HYDRAULIC PUMP (HPV160+160) . . . . . . . 30-91
ASSEMBLY ASSEMBLY
OF HYDRAULIC PUMP (HPV160 + 160) . . . . . . . 30-98
30-2
CHECKING CONTACT BETWEEN CYLINDER BLOCK AND VALVE PLATE, AND ROCKER CAM AND CRADLE . . . . . .30-112
REMOVAL OF WORK EQUIPMENT PPC VALVE ASSEMBLY . . . . . . . . . . . . . . . . . . . . . 30-127
REMOVAL OF HYDRAULIC PUMP INPUT SHAFT OIL SEAL
INSTALLATION OF WORK EQUIPMENT PPC VALVE
. . . . . . 30-115
ASSEMBLY INSTALLATION
. . . . . . . . . . . . . . . . . . . . .30-127
OF HYDRAULIC
PUMP INPUT SHAFT OIL SEAL
. . . . . . 30-115
OF CONTROL . . . . . . . . . . . . . . .30-l VALVE ASSEMBLY
DISASSEMBLY OF WORK EQUIPMENT PPC VALVE ASSEMBLY
. . 30-l 27
REMOVAL
INSTALLATION
17
OF CONTROL . . . . . . . . . . . . . . . 30-l 17
ASSEMBLY
OF WORK
EQUIPMENT PPC VALVE ASSEMBLY . . . . . . . . . . . . . . . . . .
. . 30-l 27
REMOVAL OF TRAVEL PPC VALVE ASSEMBLY . . . . . . . . . . . .
. . 30-129
INSTALLATION OF TRAVEL PPC VALVE ASSEMBLY . . . . . . . . . . . .
. . 30-l 29
DISASSEMBLY OF TRAVEL PPC VALVE ASSEMBLY . . . . . . . . . . . .
. . 30-l 29
VALVE ASSEMBLY
DISASSEMBLY OF CONTROL . . . . . . . . . . . . . . . 30-l 19 VALVE ASSEMBLY ASSEMBLY OF CONTROL . . . . . . . . . . . . . . . 30-121 VALVE ASSEMBLY REMOVAL OF MAIN RELIEF . . . . . . . . . . . . . . . 30-l 23 VALVE ASSEMBLY INSTALLATION OF MAIN RELIEF VALVE ASSEMBLY DISASSEMBLY OF MAIN RELIEF VALVE ASSEMBLY
ASSEMBLY OF TRAVEL PPC . . . . . . . . . . . . . . . 30-129 VALVE ASSEMBLY . . . . . . . . . . 30-l 23 REMOVAL OF BOOM HOLDING . . . . . . . . . . . . . . . 30-131 VALVE ASSEMBLY . . . . . . . . . . 30-123
ASSEMBLY OF MAIN RELIEF . . . . . . . . . . . . . . . 30-l 23 VALVE ASSEMBLY REMOVAL OF TVC VALVE ASSEMBLY . . . . . . . . . . . . . . . . . . . . . 30-125 INSTALLATION ASSEMBLY
OF TVC VALVE
INSTALLATION OF BOOM HOLDING VALVE ASSEMBLY
. . . . . . . . 30-131
DISASSEMBLY OF BOOM HOLDING VALVE ASSEMBLY
. . . . . . . . 30-131
ASSEMBLY OF BOOM HOLDING VALVE ASSEMBLY
. . . . . . . . 30-131
. . . . . . . . . . . . . . . . . . . . . 30-125
REMOVAL OF COoNC VALVE ASSEMBLY . . . . . . . . . . . . . . . . . . . . . 30-l 25 INSTALLATION OF CO.NC . . . . . . . . . . . . . . . 30-125 VALVE ASSEMBLY REMOVAL OF SERVO VALVE ASSEMBLY . . . . . . . . . . . . . . . . . . . . . 30-l 25 INSTALLATION
OF SERVO . . . . . . . . . . . . . . . 30-l 25 VALVE ASSEMBLY
REMOVAL OF PPC SHUTTLE . . . . . . . . . . . . . . . 30-133 VALVE ASSEMBLY INSTALLATION OF PPC SHUTTLE VALVE ASSEMBLY REMOVAL
OF BOOM
CYLINDER
ASSEMBLY.
. . . . . . . . 30-l 33
. . . . . . . . . . . . 30-135
INSTALLATION OF BOOM CYLINDER ASSEMBLY. . . . . . . . . . . . . 30-135
30-3
REMOVAL OF ARM CYLINDER ASSEMBLY . . . . . . . . . . . . . . . . . . . . . 30-137
INSTALLATION OF COUNTERWEIGHT
INSTALLATION
REMOVAL OF ENGINE THROTTLE CONTROLLER
OF ARM
CYLINDER
ASSEMBLY
. . . . . . . . . . . . .30-l
REMOVAL
OF BUCKET
CYLINDER
ASSEMBLY
. .
INSTALLATION
c
.
37
INSTALLATION
. . . . . . . . . . . . . . . . . 30-139
THROTTLE REMOVAL
OF BUCKET
. . . . . . . . . . . . . . .30-153
. . . . . . . . . . 30-l 55
OF ENGINE
CONTROLLER
. . . . . . . . . . 30-155
OF PUMP
. . . . . . . . . . . . 30-139
CONTROLLER
ASSEMBLY
. . . . . . . . . .30-155
DISASSEMBLY OF HYDRAULIC CYLINDER ASSEMBLY. . . . . . . . . . . . . 30-141
INSTALLATION CONTROLLER
OF PUMP ASSEMBLY
. . . . . . . . . . 30-155
ASSEMBLY
REMOVAL
CYLINDER
CYLINDER
ASSEMBLY.
OF HYDRAULIC ASSEMBLY.
REMOVAL OF WORK EQUIPMENT ASSEMBLY
. . . . . . . . . . . . 30-143
. . . . . . . . . . . 30-145
INSTALLATION OF WORK EQUIPMENT ASSEMBLY . . . . . . . . . . . 30-145 REMOVAL OF BUCKET ASSEMBLY . . . . . . . . . . . . . . . . . . . . . 30-147 INSTALLATION OF BUCKET ASSEMBLY . . . . . . . . . . . . . . . . . . . . . 30-l 47 REMOVAL
OF ARM ASSEMBLY
. . . . . . 30-147
INSTALLATION OF ARM ASSEMBLY . . . . . . . . . . . . . . . . . . . . . 30-l 47 REMOVAL
OF ARM, BUCKET
ASSEMBLY
. . . . . . . . . . . . . . . . . . . . . 30-149
INSTALLATION OF ARM, BUCKET ASSEMBLY . . . . . . . . . . . . . . 30-l 49 REMOVAL
OF BOOM ASSEMBLY
. . . . . 30-151
INSTALLATION OF BOOM ASSEMBLY . . . . . . . . . _ . . . . . . . . . . . 30-151 REMOVAL OF OPERATOR’S CAB ASSEMBLY . . . . . . . . . . . . . . . . . 30-153 INSTALLATION OPERATOR’S
OF CAB ASSEMBLY
REMOVAL OF COUNTERWEIGHT
30-4
. . . . . . . 30-l 53
. . . . . . . . . . . . . . . 30-153
OF MONITOR
PANEL ASSEMBLY
. . . . . . . . . . . . . . . 30-155
INSTALLATION OF MONITOR PANEL ASSEMBLY . . . . . . . . . . . . . . . . . . . . . 30-155 PROCEDURE CIRCUIT
FOR FLUSHING HYDRAULIC . . . . . . . . . . . . . . . . . . . . 30-l 57
PROCEDURE CIRCUIT
FOR FLUSHING HYDRAULIC . . . . . . . . . . . . . . . . . . . . 30-165
METHOD
OF USING MANUAL
1. When removing or installing unit assemblies
(1) When
removing or installing a unit assembly, the order of work and techniques used are given for the removal operation; the order of work for the installation operation is not given. (2) Any special techniques applying 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) REMOVALOFOOOASSEMBLY
A
...........
............................
l.XXXX(l) . . . . . . . . . . . . . . . . . . . . . . . . * . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.
A A A (2) . . . . . . . . . . . . . . . . . . . . . . . . . .
3. q El 0 q assembly
Title of operation Precautions
related
to
safety
when
carrying out the operation Step in operation important point Technique or remember when removing XXXX (1). m Indicates for use during
that a technique installation
See Lubricant
and Coolant
to
is listed
(3)
: -
. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Table
INSTALLATION l
2.
3.
OF 0 0 0 ASSEMBLY . . . . . . Title of operation Carry out installation in the reverse order to removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . Technique used during installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Technique or important point remember when installing A A A (2).
General precautions when carrying out installation or removal (disassembly or assembly) of units are given together as PRECAUTIONS WHEN CARRYING OUT OPERATION, so be sure to follow these precautions when carrying out the operation.
Listing of special tools (1) For details of the description, part number, and quantity operation procedure, see the SPECIAL TOOLS LIST given
4.
to
of any tools (A,) that in this manual.
appear
in the
Listing of tightening torque, weight, refill amount for oil and water (1) If symbols
such as u,
&,
or
@l
appear
in the operation
procedure,
TORQUES AND STANDARD VALUES TABLE, MAINTENANCE STANDARD and LUBRICANT AND COOLANT TABLE for details of the values.
see TIGHTENING
TABLE, WEIGHTTABLE,
30-5
PRECAUTIONS
WHEN CARRYING
OUT OPERATION
[When carrying out removal or installation (disassembly or assembly) general precautions given below when carrying out the operation.]
of units,
be sure to follow
the
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 When draining oil, prepare a container of adequate size to catch the oil.
dirt or dust from entering.
Confirm the match marks showing the installation position, and make match places before removal to prevent any mistake when assembling.
marks in the necessary
To prevent any excessive force from being applied to the wiring, always hold the connectors when disconnecting the connectors. 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 alternately. 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 1) Hoses and tubes using sleeve nuts Nominal number
I
02
I
Plug (nut end)
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)
1
12
07376-51034
07221-21034 (Nut),07222-01018 (Plug)
1
07376-51234
Split flange
07221-21234 (Nut),07222-01219 (Plug)
type hoses and tubes
Nominal number
Flange (hose end)
Sleeve head (tube end)
Splitflange
04
07379-00400
07378-10400
07371-30400
05
07379-00500
07378-10500
07371-30500
If the p art is not i nder hydraulic
30-6
operations.
07221-20210 (Nut),07222-00210 (Plug)
1
03
10
disassembly
Sleeve nut (elbow end) Usethetwo items below as a set
I
0737550210
it during
pressure,
the following
corks can be used.
Dimensions
Nominal number
Part number
06
07049-00608
6
5
8
08
07049-00811
8
6.5
11
10
07049-01012
#10 8.5
12
12
07049-01215
12
10
14
07049-01418
14
11.5
18
16
07049-01620
#16 13.5
20
DdL
18
07049-01822
181 15
20
07049-02025
20
22
07049-02228
22
24
07049-02430
27
07049-02734
#24
17
+
-
A
Taperl/8
15 r
t
) 22 25
18.5 28 20
30
27122.5
1 34
202F2001
2.
Precautions Tighten Install
for installation
operations
all bolts and nuts (sleeve the hoses without
Replace
all gaskets,
twisting
o-rings,
nuts) to the specified
cotter
pins and lock plates with
Bend the cotter pin or lock plate securely. When coating with adhesive, clean the part and remove portion with 2-3 drops of adhesive. 0
torque.
or interference. new parts.
all oil and grease,
When coating with adhesive, clean the part and remove all oil and grease, 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
then
coat the threaded
check that there is no dirt
(LM-P).
l
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, then screw them fully and align the direction of the hook. When tightening split flanges, tighten uniformly in turn to prevent excessive tightening on one side.
3.
Precautions
l
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. Check the water level again. If the hydraulic equipment has been removed and installed again, add the engine oil to the specified level. Run the engine to circulate the oil through the system. Check the oil level again. If the piping or hydraulic equipment, such as hydraulic cylinders, pumps or motors, have been removed for repair, always bleed the air from the system after reassembling the parts. f For details, see TESTING AND ADJUSTING, bleeding air. Add the specified amount of grease (molybdenum disulfide grease) to the work equipment related parts.
l
l l
l
when completing
the operations
30-7
SPECIAL TOOL LIST PC3OOLC Nature
of work
Part No.
Symbol
Disassembly, assembly of final drive assembly
1
791-580-l
510
2
796-570-l
110
Part Name
Remarks
I QtY
Installer
Installation seal
of floating
Adjustment of bearing
of clearance
A I
Disassembly, assembly of recoil spring assembly
B
791-600-2001
Compressor
A
791-6&8005
Compressor
B
791-635-3160 790-l 01-l 600 790-l 01-l 102
Disassembly, assembly of track shoe assembly
C
791-630-3000
Remover
& installer
I
790-l 01-l 300
Cylinder
(100 t)
I
790-l 01-l 102 l
Removal, installation of charging pump assembly l Removal, installation of main pump assembly Disassembly, assembly of hydraulic cylinder assembly l
Removal, installation assembly l Removal, installation equipment assembly
30-8
D
I
1
E
of boom F
1 1
1
000
Expander
1
680
Ring
1
07281-01589
Clamp
1
796-760-l
Remover
1
310
790-720-l 796-720-l
2
800
790-l 01-3800
of work 790-l 01-l 102
of
---rOil stopper
796-760-l
Removal, press fitting master pin
Puller
(50 t)
Expansion
of piston
ring
LJ%G&
Pulling pin
out boom foot
Nature
of work
Part No.
Symbol
QtY
Part Name
Remarks
790-501-5000 Repair stand
1
790-901-2110
Bracket
1
790-901-1361
Plate
1
799-301-1600
Oil leak tester
1
796-765-1140
Bolt
1
01580-03024
Nut
1
01643-33380
Washer
1
796-765-1150
Washer
1
790-201-2720
Push tool
1
Press fitting inner race
of bearing
796-765-1120
Push tool
1
Press fitting inner race
of bearing
796-765-1110
Push tool
1
Press fitting outer race
of bearing
790-101-5201
Push tool kit
1
Plate Grip . Bolt
1 1 1
Press fitting
of oil seal
l
Push tool
1
Press fitting pin
of dowel
Repair stand
1
790-901-2110
Bracket
1
790-901-1470
Plate
1
796-730-2120
Screwdriver
1
796-720-2220
Socket
1
790-201-2840
Push tool
1
Press fitting inner race
4 -
796-766-1110
Guide
1
Assembly
5
790-201-2860
Push tool
1
Press fitting outer race
796-720-3800
Wrench
1
790-5oqr-5200 1
2 -
3
Disassembly, assembly of travel motor assembly
G
4 5 6 -
7 8
790-101-5311 790-101-5221 01010-51225
l
796-765-1130
-
Removal
of brake piston
Removal, installation of spring of cylinder block
790-501-5000 790-5oqr-5200 1
2
Disassembly, assembly of swing motor assembly
H
3 -
6 -
795-630-1803
Torque
wrench
set
1
Removal, installation of retainer mounting screw of bearing
of drive
Measurement torque
shaft
of bearing
of rotating
A
30-9
Nature of work
Remarks
Part Name
Part No.
Symbol
790-501-5000
Repair stand 790-5::-5200 790-901-2110
Bracket
1
790-901-1450
Plate
1
790-901-1460
Spacer
1
790-767-1120
Plate
1
796-720-2270
Screwdriver
1
796-720-2250
Screwdriver
1
796-720-2220
Socket
1
796-767-1140
Wrench
1
796-730-2120
Screwdriver
1
796-720-2220
Socket
1
791-746-2770
Hook
1
796-767-1100
Gauge
1
796-767-1110 796-720-4640 790-445-2921
*Plate *Pin *Bar
796-720-4681
Gauge
796-720-4691 796-720-4640 790-445-2921
*Plate @Pin *Bar
796-730-2300
Wrench
795-630-l
Torque
1
2 -
3
-
Disassembly, assembly of hydraulic pump
J
4 5 6 -
7 -
a -
30-10
803
of
Removal, installation impeller mounting screw, shoe retainer mounting screw and cam plate mounting screw
of
Removal, installation strainer of charging pump
of
Removal, installation of cam stopper mounting screw Measurement clearance
1
wrench
set
1
Measurement torque
of
side)
Adjustment of stroke servo piston (Min. angle
1
of shoe
Adjustment of stroke servo piston (Max. angle
9 -
Removal, installation gear plate mounting screw
of
side)
of rotating
SPECIAL TOOL LIST PC4OOLC Nature
of work
Disassembly, assembly of final drive assembly
Part No.
Symbol
Part Name
QtY
Remarks
1
796-627-l
020
installer
1
Installation seal
of floating
2
796-627-l
010
Plate
1
Adjustment of bearing
of clearance
A t
Disassembly, assembly of recoil spring assembly
B
Disassembly, assembly of track shoe assembly
C
791-600-2001
Compressor
A
1
791-6%8005
Compressor
B
1
791-635-3 160
Extension
790-l 01-l 600
Cylinder
790-l 01-l 102
Pump
791-630-3000
Remover
& installer
1
790-l 01-l 300
Cylinder
(100 t)
1
790-l 01-l 102
Pump
1
796-760-l
310
Oil stopper
1
790-720-l
000
Expander
796-720-l
680
Ring
1 (70 t)
1 1
Removal, press fitting master pin
of
l
Removal, installation of charging pump assembly l Removal, installation of main pump assembly
D
1
Disassembly, assembly of hydraulic cylinder assembly
l
Removal, installation assembly l Removal, installation equipment assembly
of boon
I E
07281-o 1589
Clamp
796-720-l
Ring
Expansion
of piston
ring
2
F
690
1
07281-02 169
Clamp
796-760-l
Remover
800
790-l 01-3800
Puller
790-l 01-l 102
Pump
of work
(50 t)
Pulling pin
out boom foot
30-11
Nature
of work
Q~Y
Part Name
Part No.
Symbol
Remarks
790-501-5000 Repair stand
1
790-901-2110
Bracket
1
796-660-l
010
Plate
1
799-301-l
600
Oil leak tester
1
796-765-l
140
Bolt
1
01580-03024
Nut
1
01643-33380
Washer
1
796-765-l
Washer
1
790-5001-5200 1
2
3
Disassembly, assembly of travel motor assembly
150
Removal
of brake piston
Removal, installation of spring of cylinder block
4
790-201-2720
Push tool
1
Press fitting inner race
of bearing
5
796-765-l
120
Push tool
1
Press fitting inner race
of bearing
6
796-765-l
110
Push tool
1
Press fitting outer race
of bearing
790-l 01-5201
Push tool kit
1
7
790-l 01-5311 790-l 01-5221 01010-51225
0 Plate l Grip l Bolt
1 1 1
Press fitting
of oil seal
8
796-765-l
Push tool
1
Press fitting pin
of dowel
Repair stand
1
790-90 l-2 110
Bracket
1
790-901-l
Plate
1
796-730-2120
Screwdriver
1
796-720-2220
Socket
1
3
790-201-2840
Push tool
1
Press fitting inner race
4
796-766-l
Guide
1
Assembly
5
790-201-2860
Push tool
1
Press fitting outer race
796-720-3800
Wrench
1
795-630-l
Torque
130
790-501-5000 790-5oqr-5200 1
470
2 Disassembly, assembly of swing motor assembly
110
6
30-12
803
wrench
set
1
Removal, installation of retainer mounting screw of bearing
of drive
Measurement torque
shaft
of bearing
of rotating
Nature
of work
Symbol
QtY
Part Name
Part No.
Remarks
790-501-5000 Repair stand
1
790-901-2110
Bracket
1
790-901-l
450
Plate
1
790-901-l
460
Spacer
1
790-767-l
120
Plate
1
796-720-2270
Screwdriver
1
796-720-2250
Screwdriver
1
796-720-2220
Socket
1
796-767-l
Wrench
1
796-730-2120
Screwdriver
1
796-720-2220
Socket
1
791-746-2770
Hook
1
796-660-l
Gauge
1
790-500:-5200
1
2 -
3
Removal, installation gear plate mounting screw
of
Removal, installation impeller mounting screw, shoe retainer mounting screw and cam plate mounting screw
of
Removal, installation strainer of charging pump
of
Disassembly, assembly of hydraulic pump
J
4
140
5 6 -
7 -
8 -
100
790-445-2950 790-720-4640 790-445-2921
*Plate *Pin *Bar
796-720-4681
Gauge
796-720-4691 796-720-4640 790-445-2921
lPlate
796-730-2300
Wrench
795-630-l
Torque
803
Measurement clearance
1
*Pin @Bar
wrench
set
1
Measurement torque
of
side)
Adjustment of stroke servo piston (Min. angle
1
of shoe
Adjustment of stroke servo piston (Max. angle
9 -
Removal, installation of cam stopper mounting screw
of
side)
of rotating
30-13
WEIGHT
TABLE Unit:kg Machine
model
Serial Cylinder
Engine
PC3OOLC
No.
f
head assembly
Hydraulic
cooler
Radiator,
hydraulic
Engine,
Turbocharger, Center
cooler
assembly
pump assembly
exhaust
swivel
joint
assembly
130
440
620
430
585
7850
8700
430
600
166
235
257X2
365X2
52X1 6
73X1 6
assembly
31x4
31x4
pump assembly
280
280
240
240
293x2
400X2
425
580
263
345
4352
5524
1014
1300
981
1234
1995
2534
2357
2990
circle
Control Hydraulic
system
motor
assembly
assembly assembly
assembly
frame assembly
recoil
spring
spring
assembly
roller
assembly assembly
roller
valve assembly
Boom cylinder Arm cylinder Bucket
assembly assembly
cylinder
assembly
Work equipment Bucket
assembly
assembly
Arm assembly Arm, bucket
assembly
Boom assembly Work Equipment, External Parts
Operator’s
cab assembly
240
240
Operator’s
seat assembly
35
35
5420
8470
110
150
50
50
90
100
Counterweight Engine
hood
Final drive Battery
cover
upper
cover
Side cover (hydraulic
30-14
26
125
Swing
Hydraulic
1470
75
machinery
Carrier
1060
50
Swing
Track
180
850X2
motor
Recoil
152
665X2
travel
Idler assembly Undercarriage
90
43
Swing
Idler,
81 up
70
manifold
Sprocket
Revolving
A40001
43
Final drive,
Power train
& up
98
assembly
hydraulic
A30001
PC400LC
pump side)
35
TIGHTENING
TORQUES
AND STANDARD
VALUES TABLE Machine PC300LC
1
Engine,
hydraulic
pump mounting
kgm
Rear 1
Damper assembly
2
Final drive assembly
3
Final drive assembly @ Mounting
Power train
bolt
mounting
bolt
bolt 1 kgm
39.25
k4.25
94.5 + 10.5
94.5 k10.5
94.5 k10.5
11.25 k1.25
11.25 21.25
56 t6.0
56 26.0
73.5 24.5
91 +4
39.25
f 4.25
76 28.5
@ Mounting
bolt
@ Mounting
bolt
6.75 +0.75
11.25 + 1.25
@ Mounting
bolt
53 +5
53 +5
@ Mounting
bolt
6.75 20.75
11.25 21.25
Max. 50
Max. 68
@ Starting force
l
mounting
PC4OOLC
bolt
Front
Engine
Model
Unit
Item
Component
kg
Final Drive
205FO5512
30-15
Component
Machine Model
Unit
Item
PC3OOLC
1
Travel motor assembly 1. Cradle mounting bolt
28.25 +3.25
2. End cover assembly @ Plug
5.4 20.6
I I I I
@ Bleeder @
@
PC4OOLC
@ Plug
@ Plug
I
I I I
@ End cover assembly mounting bolt
hj
@ Mountmg plug of counterbalance
1
6.5 21.0
6.5 k1.0
0.9 +O.l
0.9
2.4 a0.4
2.4 20.4
11.25 21.25
11.25 f 1.25
5825
58 &5
1%
valve
20.1
26 +3 66.5 -+7.5 42.75 24.75
3. Plug of regulator piston
I
[
37?4
37 a4 65 +5
Power train
0.5 20.1 1.35 51.5 2. Plug of check valve
1
1
5626
56 +6
3. Relief valve
I
I
3525
35 *5
1
1
36+-2
36 +2
I
I
94.5 + 10.5
94.5 f 10.5
I
I
18 +2
28.25 f 3.25
I
I 39.25
4. Valve case mounting
bolt
Swing machinery assembly mounting bolt Swing machinery assembly 0 Carrier pin mounting bolt
k4.25
39.25 k4.25
@ Bearing cage mounting bolt
6.75 +0.75
~ 6.75 +0.75
Revolving frame assembly mounting bolt
94.5 + 10.5
~ 94.5 +10.5
Swing circle mounting bolt
94.5 + 10.5
94.5 510.5
17,680
24,735
795
857
648
707
@ Carrier assembly plate mounting bolt
Recoil spring assembly 1. Installed load of spring Undercarriage
kg
2. Free length of spring 3. Installed length of spring
mm
331 220
Amount of slack for track Track roller assembly mounting bolt
30-16
kgm
67 +7
~
358 +20
~ 91.5 28.5
l
End Cover
F20705360
l
Swing
Machinery
30-I7
Machine PC3OOLC Main pump assembly @ Plate mounting bolt @ Mounting bolt for hydraulic shaft housing assembly Main pump assembly 1. Rocker cam support 2. Plate mounting 3. Bearing
mounting
mounting
4. Rear pump mounting
screw
screw
bolt
5. Pump sub-assembly 6. Charging
pump input
screw
retainer
mounting
pump driven
bolt
pump end
Main shaft end 7. End cap mounting
bolt
8. impeller
screw
9. Servo
mounting piston
cap mounting
10. Servo valve assembly 11. TVC valve 12. CO
l
mounting
NC valve
14. Sleeve
3.2 +0.3
3.2 20.3
3.2 2.03
3.2 kO.3
3.2 +0.3
3.2 20.3
3.2 20.3
3.2 +0.3
11.5 21.0
11.5 k1.0
18 22
18 22
1
11.5 21.0
1
11.5 k1.0
1
11.5 k1.0
I
11.5 21.0
I
5.5 20.7
I
5.5 20.7
6.7 +0.7 bolt
1
3.2 kO.3
1
3.2 rt0.3
I
5 *2
I
5 +2
I
23 23
I
23 +3
I
19 21
I
19 +l
I
5.5 +0.5
I
5.5 +0.5
I
19 +l
I
19 +l
bolt
assembly
nut of hose l
NC valve
Charging 15. End cap mounting
pump
nut and bolt
valve assembly
@ Plug for check valve @ Safety-suction @ Jet sensor
valve
relief valve
@ Main relief valve
30-18
6.7 20.7
bolt
CO
Control
PC4OOLC
6.7 kO.7
bolt
mounting
mounting
13. Plug of strainer
1
gear Charging
Hydraulic System
Model
Unit
Item
Component
mount
l
Main Pump
205FO5515
0’
Control Valve
205FO55
205FO55
I6
205F055
I7
I8 205FO55
IS
30-19
1 Unit
item
Component
7 5
Work equipment
PPC valve assembly
@ Joint
11.25 21.25
11.25 21.25
@ Nut
11.5 k1.5
11.5 k1.5
19 *l
19 21
4 to.5
4 a0.5
11.25 + 1.25
11.25 f 1.25
Boom lock valve assembly @ Safety valve @ Spool
mounting
@ Check valve
s Hydraulic 1. Bucket
plug
body
cylinder
mounting
bolt
assembly
cylinder
2. Arm cylinder
Head mounting
bolt
38 25.5
54 28
Head mounting
bolt
54 +8
91 +14
6.75 20.75
16 +2
38 +5
54 r8
185 210
390 a40
Screw Head mounting
3. Boom cylinder
s - Counterweight l
Work Equipment
I+
mounting
PPC Valve
bolt
bolt
l
Boom Holding
Valve
205FO552 205FO5520
30-20
I
LUBRICANT
AND COOLANT
TABLE Unit: P
Machine
Model
PC3OOLC
PC4OOLC Remarks
Serial
No.
A30001
& up
A40001
& up
Cooling
water
30 4
34 P
Engine
oil pan
18.9 Q
38 P
Swing
machinery
22.5 Q
22 0
7.4 P
11 4
195 P
255 P
1.24 Q
1.07 e
Final drive Hydraulic
case
case tank
PTO case Note: The values for oil volumes
are the values for normal oil changes
I
during
inspection
Each side
and maintenance.
30-21
REMOVAL OF GOVERNOR MOTOR ASSEMBLY PC3OOLC
A
PC3OOLC
PC4OOLC
Disconnect the cable from the negative (-) terminal of the battery.
1. Remove control rod (1). * Remove the pin at governor motor end. 2. Disconnect wiring connectors (2). 3. Remove governor motor assembly (3).
INSTALLATION OF GOVERNOR MOTOR ASSEMBLY PC3OOLC l
PC4OOLC
Carry out installation installation.
30-22
in the reverse order to
PC4OOLC
REMOVAL OF HYDRAULIC COOLER ASSEMBLY
REMOVAL OF HYDRAULIC COOLER ASSEMBLY
PCSOOLC
PC4OOLC
YY
4
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.
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.
1. Remove 1. Disconnect hose (1). (See Fl) 2. Remove net (2). (See Fl) * Loosen the mounting bolts and pull the net up to remove. 3. Remove the hydraulic oil cooler assembly (3). (See F2) * Sling the hydraulic oil cooler assembly, then remove the mounting bolts and bracket, and pull the hydraulic oil cooler assembly out from below. The bolts marked E are the mounting * bolts for the radiator and hydraulic oil cooler assembly, so do not remove them. (See F3) See Weight
Table
INSTALLATION OF HYDRAULIC COOLER ASSEMBLY
YY
A
4
l
Carry out installation in the reverse order to removal. Refilling with oil * Add engine oil to the specified level, and run the engine to circulate the oil through the system. Then check the oil level again.
Table
2. Disconnect hose (1). (See Fl) 3. Remove net (2). (See Fl) *
Loosen the mounting bolts and pull the net up to remove. 4. Remove hydraulic oil cooler assembly (3). (See F2) * Sling the hydraulic oil cooler assembly, then remove the mounting bolts and bracket, and pull the hydraulic oil cooler assembly out from below. The bolts marked B are the mounting * bolts for the radiator and hydraulic oil cooler assembly, so do not remove them. (See F3) See Weight
Table
INSTALLATION OF HYDRAULIC COOLER ASSEMBLY PC4OOLC l l
30-24
Be careful when removing the hood, because it is under tension from the spring. See Weight
PC3OOLC l
hood.
Carry out installation in the reverse order to removal. Refilling with oil * Add engine oil to the specified level, and run,the engine to circulate the oil through the system. Then check the oil level again.’
Fl
F2070532E
F2
F3
5328
30-25
REMOVAL OF RADIATOR, HYDRAULIC OIL COOLER
Fl
A 4
3 Y
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. 1. Drain cooling water. 2. Remove hood (1). (See Fl)
A4Y
Y
Be careful when removing the hood, because it is under tension from the spring.
See Weight Table kg EE?l 3. Remove hoses (2) and (3). (See F2) 4. Remove fan guard (4). (See F2) 5. Remove hoses (5). (See F3) 6. Remove radiator and hydraulic assembly (6). (See F4) * Sling the radiator and hydraulic oil remove the upper assembly, bracket and lower mount bolts, remove the radiator and hydraulic assembly. See Weight
cooler cooler mount then cooler
Table
INSTALLATION OF RADIATOR, HYDRAULIC OIL COOLER ASSEMBLY l l
l
Carry out installation in the reverse order to removal. Refilling with oil -k Add engine oil to the specified level, and run the engine to circulate the oil through the system. Then check the oil level again. Refilling with water -k Add water to specified level, and run the engine to circulate the water through the system. Then check the water level again.
205FO5552
F4
205FO555:
30-26
30-27
REMOVAL OF ENGINE, HYDRAULIC PUMP ASSEMBLY
INSTALLATION OF ENGINE, HYDRAULIC PUMP ASSEMBLY
PC3OOLC
PC3OOLC
A
e Carry out installation
Disconnect the cable from the negative (-) terminal of the battery
in the reverse order to
removal. m
Lower the work equipment to the ground A and stop the engine. Loosen the oil filler 4 cap slowly to release the pressure inside the hydraulic tank. Remove hydraulic tank strainer, and use tool D to stop the oil. (See Fl) l When not using tool D, remove drain plug and drain the oil from hydraulic tank and piping.
SLY
*
1.
2. 3. 4.
5. 6. 7. a. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20.
: See Lubricant and Coolant Table After removing the piping, mark with tags to prevent mistakes when installing. Drain cooling water. Remove hoses (1). (See P2) Disconnect wiring connector (2). (See P3) Remove sub-tank (3). (See P3) * Remove the sub-tank together with the bracket. Remove tube (4). (See P2) Remove air cleaner assembly (5). (See P2) Disconnect wiring (6). (See P4) Disconnect wiring connector (7). (See P4) Disconnect ground connection (8). (See P4) Disconnect fuel hoses (9). (See P5) Disconnect wiring connectors (10). (See P5) * Disconnect three connectors. Remove fan guard (11). (See P5) Remove fan (12). (See P5) Disconnect wiring connector (13). (See P6) Disconnect hoses (14). (See P7) Remove hoses (15) and (16). (See F8) Disconnect hoses (17). (See F8) * Disconnect 5 pilot hoses. Disconnect tubes (18). (See F8) Disconnect wiring connector (19). (See F8) Remove engine and hydraulic pump assembly (20). (See F9) m * When removing the engine and hydraulic pump assembly, check that all the piping and wiring has been removed, then remove the assembly, taking care that there is no interference.
el kg
30-28
See Weight Table
u
l
Mounting bolt: See Tightening Torques and Standard Values Table Refilling with oil and water * Fill with oil and water to the specified levels. Q
l
See Lubricant and Coolant Table.
Bleeding air Bleed the air from the fuel system. * Bleed the air from the hydraulic pump. * TESTING AND see For details, ADJUSTING, Bleeding air from all parts. After bleeding the air from the hydraulic * pump, check the hydraulic tank level and radiator (sub-tank) level.
Fl
-D
I
lOBV0032
I
12AD0016
P7
P2
F8
12ADO014
205FO5558
lZAD0020
F9
205F65559
REMOVAL OF ENGINE, HYDRAULIC PUMP ASSEMBLY PC4OOLC
A
Disconnect the cable from the negative (-) terminal of the battery
Lower the work equipment to the ground A and stop the engine. Loosen the oil filler 4 cap slowly to release the pressure inside the hydraulic tank. Remove hydraulic tank strainer, and use tool D to stop the oil. (See Fl) l When not using tool D, remove drain plug and drain the oil from hydraulic tank and piping.
22. Remove engine and hydraulic pump assembly (22). (See FlO) m f When removing the engine and hydraulic pump assembly, check that all the piping and wiring has been removed, then remove the assembly, taking care there is no interference. *&S
SLY
*
1.
2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15.
: See Lubricant and Coolant Table After removing the piping, mark with tags to prevent mistakes when installing. Drain cooling water. Disconnect hose (1). (See P2) Disconnect wiring connector (2). (See P2) Remove hose (3). (See P2) Remove fan guard Remove fan (4). (See P2) Disconnect fuel hoses (5) and (6) (See P3) Disconnect wiring connector (7). (See P3) * Disconnect three connectors Disconnect starting motor wiring (8). (See P4) Disconnect wiring connector (9). (See P4) Remove heater hose (10). (See P5) Remove sub-tank hose (11). (See P5) Remove radiator inlet hose (12). (See P5) Disconnect wiring connector (13). (See P6) Remove side cover (14). (See P7) * Sling the side cover together with the frame, remove the mounting bolts, then remove.
el kg
ee Weight Table
INSTALLATION OF ENGINE, HYDRAULIC PUMP ASSEMBLY PC4OOLC 0
Carry out installation removal.
in the reverse order to
m u
l
l
Mounting bolt: See Tightening Torques and Standard Values Table Refilling with oil and water * Fill with oil and water to the specified levels. See Lubricant and Coolant Table. Q1 Bleeding air Bleed the air from the fuel system. * Bleed the air from the hydraulic pump. * see TESTING AND For details, ADJUSTING, Bleeding air from all parts. After bleeding the air from the hydraulic * pump, check the hydraulic tank level and radiator (sub-tank) level.
Fl
See Weight Table
Remove frame (15). (See F7) Disconnect ground connection (16). (See F8) Disconnect hoses (17) and (18). (See F9) Disconnect hoses (19). (See F9) * Disconnect 5 pilot hoses 20. Disconnect tube (20). (See F9) m 21. Disconnect wiring connector (21). (See F9) 16. 17. 18. 19.
30-30
lOBV0032
P2
P7
2-a
12ADW18
12AD0024
P3
-16
12ADOO19
P4
12ADO021
P6
12AD0026
FlO
REMOVAL OF DAMPER ASSEMBLY 1. Hydraulic pump assembly l Remove hydraulic pump assembly. For details, see REMOVAL OF HYDRAULIC PUMP ASSEMBLY. 2. Remove damper assembly (1). (See Fl) m
INSTALLATION ASSEMBLY l
OF DAMPER
Carry out installation removal
Xl 2AFOl
in the reverse order to
m & & m
30-32
Damper spline: Anti-friction compound (LM-P) Pump mounting bolt hole (2) only: Liquid gasket (LG-6) Mounting bolt: See Tightening Torques and Standard Values Table
30-33
REMOVAL OF CENTER SWIVEL JOINT ASSEMBLY
A4Y
ZL
Lower the work equipment to the ground and release the remaining pressure in the circuit. For details, see TESTING AND Releasing pressure in ADJUSTING, hydraulic circuit for machines with PPC valve. 1. Disconnect hoses (l), (2), (3). (See Fl)
2. 3. 4. 5.
Remove elbow (4). (See Fl) Disconnect hose (5). (See F2) Disconnect link (6). (See F2) Remove center swivel assembly See Weight
f%ka
(3). (See F4)
l
Carry out installation in the reverse order to removal. Refilling with oil f Run the engine to circulate the oil through the system. Then check the oil level again.
30-34
1. Remove cover (1). (See F4) 2. Remove snap ring (2). (See F4) @ , pull out swivel rotor (4) 3. Using push-puller ring (3) from swivel shaft (5). and (See F4, F5) 4. Remove snap ring (6), then remove oil seal (7) and slipper seal (8). (See F4)
ASSEMBLY OF CENTER SWIVEL JOINT ASSEMBLY
Table
OF CENTER INSTALLATION SWIVEL JOINT ASSEMBLY l
DISASSEMBLY OF CENTER SWIVEL JOINT ASSEMBLY
1. Assemble slipper seal (8) to swivel rotor (4). (See F4) 2. Using push tool 0, press fit oil seal (7) to swivel rotor (4), and install snap ring (6). (See F4, F6) e
Lip of oil seal: Grease
(G2-LI)
3. Set swivel shaft (5) on block, then using push tool, tap swivel rotor (4) with a plastic hammer and install. (See F4) -k When installing the rotor, be extremely careful not to damage the lips of the slipper seal and the oil seal. 4. Install ring (3), and secure with snap ring (2). (See F4) 5. Fit O-ring and install cover (4). (See F4)
Fl
F4
---
205FO5567
..
205FO5568
J
5
n 205FO542C
F3
205FO5569
205FO542
I
F6
205FO5422
30-35
REMOVAL OF FINAL DRIVE ASSEMBLY
DISASSEMBLY OF FINAL DRIVE ASSEMBLY
1.
1.
Sprocket l
*
2.
Remove
A4Y
Loosen the oil filler cap slowly to inside the release the pressure hydraulic tank. cover,
and
2.
3.
3. 4.
Remove
4.
f
assembly
(3). (See F3)
Sling the final drive assembly, then remove the mounting bolts, and lift off the final drive assembly. See Weight
Table
INSTALLATION OF FINAL DRIVE ASSEMBLY l
Carry out installation removal.
in the reverse
order to
m & u
l
Mounting bolt: Thread tightener Mounting bolt: See Tightening Torques Standard Values Table Bleeding air *
*
30-36
(LT-2) and
Bleed the air from the motor TESTING AND see For details, ADJUSTING, Bleeding air from travel motor. After bleeding the air from the motor, check the level of the hydraulic tank.
plug
and drain
oil from
final
: -
See Weight Table r5 kg Disconnect hose (2). (See F2) final drive
oil
Remove drain drive case.
sprocket
Remove cover (1). (See Fl) * Using eyebolts, sling the remove the mounting bolts.
Draining
Final drive case: See Lubricant
and Coolant
Table
Cover Using forcing screws and eyebolts , remove cover (1). (See F4) Thrust washer Remove thrust washer (2). (See F5) No. 2 sun gear shaft
Remove sun gear shaft (3). (See F5) 5. No. 2 carrier assembly 1. Remove carrier assembly (4). (See F5) 2. Disassembly of carrier assembly Remove the mounting bolts (5), then 0 remove holder. (See F6) ii) Set carrier assembly (4) in press, then using push tool 0, pull out pin (6), and remove gear assembly (7). (See F7) iii) Remove bearing (9) and spacer (10) from gear (8). (See F8) iv) Remove outer race (11). (See F8)
F’4
Fl li
1 1.
205FO5425
205FO5570
F5 I
_
I
-‘I-
II-
-‘\
_\_
205FO557
F3 I
I
LF-----
205FO5424
205FO5427
i
205FO542E
205FO5429
30-37
6. Ring gear 1. Remove ring gear (12). (See Fl) 2. Remove 7.
ring (10). (See Fl)
No. 1 sun gear Remove
sun gear (14). (See Fl)
8.
Thrust washer
9.
Remove thrust washer (15). (See F2) No. 2 carrier assembly
1. Remove carrier assembly (16). (See F2) 2. Disassembly of carrier assembly i) ii)
Remove mounting bolts (17), then remove holder. (See F3) Set carrier assembly (16) in press, then using push tool @ , pull out pin (18), and remove gear assembly (19). (See F4)
iii)
Remove bearing (21) and spacer (22) from gear (20). (See F5) iv) Remove outer race (23). (See F5)
10. No. 1 ring gear Remove
ring gear (24). (See F6)
11. Gear coupling Remove coupling 12. Spacer Remove
mounting bolts, (25). (See F6) spacer
then
remove
gear
(26). (See F7)
13. Hub assembly 1. Using eyebolts @, remove hub assembly (27) from travel motor. (See F8) 2. Remove floating seal (28). (See F9) 3. Remove cage (29), then remove floating seal (30). (See FlO) 4. Remove bearings (31) and (32). (See FlO)
30-38
Fl
F2
F8 I 15
205FOS572
16
1 27.
I
205FOSS73
F9
205FO5437
F’n
f 205FOS433
205FO5438
205FO5575
F
r
Y
21
23
205FOS434
:6
F7
25
24 I
2OSFOS574
205FO5436
30-39
ASSEMBLY ASSEMBLY
OF FINAL DRIVE
1. Hub assembly 1. Using push tool, (31). (See Fl)
press fit bearings
(32) and
2. Using tool A,, install floating seal (30) to cage, then install cage (29). (See Fl) & Cage mounting surface: u
Liquid gasket Mounting bolt:
(LG-6)
See Tightening Torques and Standard Values Table floating seal (28). 3. Using tool A,, install (See F2, F3) When installing the floating seals, remove * all oil and grease from the O-Ring and Oring contact surface, and dry completely before installing. After installing the floating seals, coat the * sliding surfaces thinly with engine oil. 4. Using eyebolts @ , set hub assembly (27) on travel motor, then using push tool, tap to press fit bearing. (See F4) 2. Adjusting bearing clearance 1. Using tool A,, hold bearing, and temporarily tighten 2 bolts. (See F5) 2. Rotate hub 2 - 3 turns to seat bearing. 3. Loosen bolts of tool A,, and then tighten again to a torque of 2.0 kgm to 3.0 kgm. (See F5) 4. Using a depth micrometer, measure stepped difference a between end face and face of shaft and inner race. (See F6) * Measure two places and take the average value. 5. Select a spacer to give a value of a -0.1 -0.15 mm. Ir Select the suitable thickness of spacer from the 7 types of spacer. 6. Install the selected spacer (26). (See F7) 3. Gear coupling 1. Fit gear coupling (25), and tighten mounting bolts. (See F8) & Mounting bolt: Thread tightener (LT-2) u Mounting bolt: See Tightening Standard Values
30-40
Torques Table
with
and
2. Check adjustment of bearing clearance again. Hook spring scale @ , in the tap hole for the sprocket mounting bolt, pull to rotate the hub on the shaft and measure the staring force. (See F9) Starting force: * See Tightening Torques and Standard Values Table If the starting force is higher than the * standard value, there is a preload on the bearing, so adjust again. 4. No. 2 ring gear Fit ring gear (24). (See F8) & *
Ring gear mounting
surface:
Liquid gasket (LG-6) Coat liquid gasket only on ring surface.
gear
upper
Fl
F6
:2
A2
30 29
31
\
I
8
Inner
L
205FO5431
205FO5575
205FO5578
3
F7
F8
?-----24 /
25
205FO5436
205FO5509
F4
205FO5574
F9
\
I
I
205FO5437
205F2469A
F5
205FO5577
30-41
5. No. 1 carrier assembly 1. Assembly of carrier assembly *
(See F7) * When press fitting the pin, be extremely careful of the angle of the pin, and rotate the gear while press fitting.
The inner race, outer race, and spacer form one set for the taper roller bearing, so assemble the sets with the same marks.
iv)
0
Using push tool, press fit outer race (23) in gear (20). (See Fl) ii) Assemble spacer (22) and bearing (21). (See Fl) iii) Set carrier assembly (16) in press, assemble gear assembly (19), then using push tool @ , press fit pin (18). (See F2) * When press fitting the pin, be extremely careful of the angle of the pin, and rotate the gear while press fitting. iv) Fit holder and tighten with mounting bolts (17). (See F3) & Mounting bolt: Thread tightener (LT-2) w Mounting bolt: See Tightening Torques and Standard Values Table 2. Install 6.
carrier
8. 1 I.
u
thrust
washer
2. Align with teeth surface of carrier, and install ring gear (12). (See F5) a Ring gear mounting surface: Liquid gasket (LG-6) No. 2 carrier assembly 1. Assembly of carrier assembly * The inner race, outer race, and spacer form one set for the taper roller bearing, so assemble the sets with the same marks. 0 Using push tool, press fit outer race (11) in gear (8). (See F6) ii) Assemble spacer (10) and bearing (9). (See F6) iii) Set carrier assembly (4) in press, assemble gear assembly (7), then using push tool @ , press fit pin (6).
9.
30-42
(LT-2)
bolt: Torques Values and
10. No. 2 sun gear shaft Assemble
sun gear shaft (3). (See F9)
11. Thrust washer Assemble
thrust
washer
(2). (See F9)
12. Cover cover Using eyebolts @ , install (See FlO) a Cover mounting surface: Liquid gasket (LG-6) a Mounting bolt: See Tightening Torques Standard Values Table
(15). (See F4)
No. 2 ring gear Install ring (13). (See F5) & Mounting surface of ring: Liquid gasket (LG-6)
mounting
2. Align with teeth surface of ring gear, install carrier assembly (4). (See F9)
(16). (See F4)
No. 1 sun gear Assemble sun gear (14). (See F5)
Mounting
See Tightening and Standard Table
Thrust washer Assemble
7.
assembly
Fit holder and tighten with bolts (5). (See F8) & Mounting bolt: Thread tightener
(1).
and
13. Refilling with oil Tighten through
drain
plug
and
Final drive
engine
oil
level.
case:
See Lubricant *
add
oil filler to the specified
and Coolant
Table
Carry out the final check of the oil level after installing the final drive assembly to the machine. Check the level again at the specified position.
F6
Fl
23 205F05429
205FO5434
F7
F8
7 I
205FO544
1 205FO5442
205FO543i
I
F4
205FO5427
J
9
15
16
205F0542E
205FO5573
j
Fl
5
r
205FO5579
205FO5425
30-43
DISASSEMBLY
1.
OF TRAVEL MOTOR ASSEMBLY
(HMV280ADT) (HMV355ADT)
Motor assembly Remove motor assembly from final drive assembly. f For details, see DISASSEMBLY OF FINAL
DRIVE ASSEMBLY. 2.
Spring, pistons Remove springs (1) and pistons (2). f Mark match marks on the case, pistons and the springs.
3.
Set motor
assembly
the
I
(3) in tool Gl.
F2070531
F20705362
End cover assembly, valve plate 1. Loosen plug (4) of checkvalve and mounting
4.
plug (5) of counterbalance valve. * If the end cover is an individual tightening torque is too large difficult to remove.
part, the and it is
2. Remove safety valve assembly (6), then remove end cover assembly (7). j, Lift off using the mounting plug portion of the counterbalance valve.
A
The part to fit the lifting tool is small, so be careful when lifting the assembly.
6
5
I
F20705363
3. Remove valve plate (8). * If the valve plate is to be used again, keep it in a safe place and be careful not to damage the cylinder block mounting surface.
e
F20705364
,’
30-44
F20705365
end cover as follows. 4. Disassemble 0 Remove bearing (9). ii) Remove plug (4), then remove spring (10) and valve (11). remove then (12), plug iii) Remove spring (13) and valve (14). iv) Remove plug (15), then remove ball v)
vi)
I
(16). Remove bleeder (17) and plug (18), then remove spring (19) and spool (20). Remove plug (21), then remove piston
(22). vii) Remove plug (5), then remove spring (23), ring (24) and spool (25). viii) Remove dowel pin (26). 5.
Spring Remove
parking
brake spring
(27).
10-S
8
Q-24 fl
F20705367
1705366
6. Piston assembly 1. Set tool G2 to hole of brake piston. 2. Taking care that air does not leak from brake piston hole, blow in air and remove brake piston (28). -k If the air is blown in at high pressure, the brake piston may fly out. 7.
Disc, plate Remove plate in order.
(29), disc
(30), and plate
6. Cylinder block, piston assembly 1 Remove cylinder block (32) and assembly (33).
(31)
I
Tool settina
bosition
F2070536S
piston
28
F20205258
I
F2070537i
30-46
32
2. Disassembly
cylinder
as follows.
Using tool G3, compress Remove snap ring (35).
iii)
Loosen nut of tool G3 gradually until extend spring tension removed.
iv)
Remove seat (36), spring (37) and pin (38). *
i) ii)
spring
(34).
of piston
Remove retainer Remove piston retainer (40).
35
and is
G3
(34), seat
Align the notched portion of the washer (tool part number: 796765-1 150) with the head of the snap ring.
3. Disassembly
9.
block
i) ii)
36 I
3d
F2070537:
3j
assembly guide (39). (41) from
shoe
Rocker cam Remove
rocker
cam (42).
10. Cradle Remove 8 bolts (43) from then remove cradle (44).
final
drive
end,
40’ F20705374
/
42
F20205264
11. Oil seal 1. Remove snap ring (45). 2. Using forcing screw (Dia. l.O), remove cage (46). 3. Using
push tool,
remove
= 6 mm, Pitch oil seal (47).
12. Shaft assembly 1. Remove shaft assembly (48). 2. Remove outer race (49) and spacer shaft. 3. Disassemble
shaft assembly
(50) from
as follows.
i) ii) iii)
Remove snap ring (51). Remove ring (52) Using bearing puller, remove bearing (53). iv) Using bearing puller, remove race (54). 4. Outer race Using
push tool,
remove
=
outer
FL20705377
II
F20705371
main inner
race (55).
F20705380
F20705&1
30-48
ASSEMBLY
OF TRAVEL MOTOR ASSEMBLY
Precautions when assembling 1. Clean all parts, check for dirt or damage, repair
(HMV280ADT) (HMV355ADT)
and
any burrs.
2. Coat the rotating
and sliding surfaces of all parts with engine oil (EOlO-CD) before installing. f Always use the following parts as a set. i) ii) iii)
Cradle and rocker cam Cylinder block and valve plate. Main bearing and spacer
1. Set motor case (56) to tool Gl 2. Outer race Using case.
push tool,
press fit outer
3. Shaft assembly 1. Assemble shaft assembly i)
ii)
race (55) to
as follows. press fit inner
Using tool G4, (54) to shaft. j, Press fit until it is in tight with the end of the shaft. Using tool
race
contact
G5, press fit main bearing
55
(53). * Align the match marks on the main bearing, and assemble. * Press fit until the end face of the main bearing inner race is in tight contact with the shaft.
F20705381
G4
54
F20705382
1
Rear side
Front side --t-
/Spacer Outer race Inner race
F20705385
30-49
iii)
Install
ring (52).
iv)
Install
snap ring (51).
2. Install spacer (50), shaft assembly.
and
outer
race
(49) to
3. Using tool G6, press fit shaft assembly case.
(48) in
52 5
F2070538t
-
F20705385
4. Oil seal 1. Using tool G7, press fit oil seal (47) in case. coat the * Use your fingertip to circumference of the lip portion with one drop of grease at four places, then spread the grease uniformly around the whole lip with your fingertip. A Lip of oil seal: Grease (G2-LI-S) 2. Install case (46) to motor. 3. Secure with snap ring (45).
F20705379
I
1
'7
F20705:611
F207053781
F20705377
30-50
5. Cradle 1. Align with dowel pin, set cradle (44) in position, then tighten with 8 mounting bolts, (43). u
Mounting
bolt:
See Tightening Torques and Standard Values Table 2 Fit dial gauge @ to motor case, move shaft in axial direction, and measure amount of movement (end play) of shaft in axial direction. * j,
6.
End play: 0.05 - 0.30 mm If the end play is not within the standard value, check the mounting condition of the bearing in Step 2 and the mounting condition of the cradle in Step 5-1.
F20705375
Rocker cam Install rocker cam (42). * Install the flange of the rocker cam (thin side) facing the small port hole side (angle change piston side). -k After installing the rocker cam, check that the rocker cam moves smoothly by hand.
block, piston assembly 7. Cylinder 1 Assemble piston assembly as follows. i) Assemble piston (41) to shoe retainer
ii)
I
I
F20705387
(40). * The variation between the thickness of the shoe lips must be within 0.01 mm. (Spare parts are supplied in a kit within these dimensions.) Assemble retainer guide (39).
40’ F20705374
30-51
2. Assemble i) ii) iii)
3. Assemble assembly install. 8.
cylinder
block
as follows.
Assemble pin (38), seat (37), spring (34) and seat (36). Using tool G3, compress spring (34). Secure with snap ring (35). cylinder block (33), align with
G3
(32) and piston shaft spline, then
Disc, plate Install order.
plate (32), disc (30), and plate
(29) in
$8
F20705373
3j
da
32
II
30-52
II
\
F20205262
*
* 9.
The space between the cut teeth for the spline on the disc is uneven, so match and fit on top then assembling. 6 plates and 5 discs.
I
Piston assembly Assemble O-ring and backup ring, then install brake piston assembly (28).
*
*
Assemble so that the groove of the brake piston is aligned with the end cover dowel pin. Assemble the backup ring in the direction shown in the diagram.
T
F20705388
10. Spring Install *
parking
brake spring
(27).
Assemble the spring so that the outside circumference is facing in the “closed” direction.
F20705389
Backup ring
O-rings
Backup ring
F20205298
11. End cover assembly 1. Assemble *
i) * ii)
iii)
end cover
l
valve plate
assembly
as follows.
Precautions when installing plug Remove all grease from the plug, then apply two drops of adhesive to the thread (thread tightener: Loctite No. 638). Using tool G8, install dowel pin (26). Install the dowel pin grooved side facing the valve plate. Assemble spool (25), ring (24), and spring (23) in order, then fit O-ring and tighten plug (5) temporarily. Assemble piston (22) and fit O-ring. Apply (2) drops Loctite 638 or 648 to plug (21), then tighten. u
Plug: See Tightening Torques Standard Values Table
16 f 0.3 F20705390
and
iv) Assemble spool (20) and spring (19), fit O-ring, then tighten plug (18) and install bleeder (17).
v)
and
Bleeder: See Tightening Torques Standard Values Table
and
Assemble ball (16) and fit O-ring. Apply (2) drops Loctite 638 or 648 to plug (15), then tighten.
u
vi)
Plug: See Tightening Torques Standard Values Table
Plug: See Tightening Torques Standard Values Table
F20705367
and ’
Assemble valve (14) and spring (13), then fit O-ring and tighten plug (12). u
Plug: See Tightening Torques Standard Values Table
and
vii) Assemble valve (11) and spring (l), then fit O-ring and tighten plug (4) temporarily. viii) Install
30-54
bearing
(9).
‘05366
2. Install
end cover
assembly
i)
Install
ii)
Fit O-ring, then that it matches dowel pin with and install end
u
iii) u
valve
adjust valve plate so dowel pin, then align brake piston groove, cover assembly (7).
Mounting bolt: See Tightening Standard Values Install
as follows.
plate (8).
Torques Table
safety valve assembly
and
I
(6).
Safety valve assembly: See Tightening Torques Standard Values Table
F2070536E
and
iv) Apply (2) drops of Loctite 638 or 648 to plug (5) of counterbalance valve and tighten. Apply (2) drops of Loctite 638 or 648 to plug (4) of check valve and tighten. Mounting plug of counterbalance valve: See Tightening Torques and Standard Values Table Plug of check valve: See Tightening Torques Standard Values Table
and
12. Spring 0 Piston Align match marks, assemble piston (2) and spring (l), then fit O-ring and apply (2) drops of Loctite 638 or 648 to plug and tighten. u
0
Plug: See Tightening Standard Values Table
When storing assembly, use
or
transporting
Torques
the
and
6
I
5
’
F20705363
motor
your finger to coat the lip surface of the oil seal thinly with engine oil (EO-10).
F20705362
F20705361
30-55
BETWEEN CHECKING CONTACT CYLINDER BLOCK AND VALVE PLATE, AND ROCKER CAM AND CRADLE 1.
Checking contact between cylinder and valve plate. tool for the cylinder 1. Make a centering and valve plate.
Cylinder block
block
Centering tool
block
*
The tool can be made of a soft material such as plastic or bakelite. 2. Remove grease from the parts to be checked * Do not wipe with a cloth. 3. Set the tool in position, and coat the cylinder block side with inspection paint. * Apply the paint thinly. 4. Put the valve plate on top, push with a force of 4 - 5 kg, and rotate 2 - 3 times. 5. Remove the valve plate, transfer the contact surface to the tape, and check the contact surface. jr The standards for the contact surface are as follows.
1
F20703037
Valve plate
Cylinder block F20705391
30-56
2.
Checking contact between rocker cam and cradle
1. Remove grease from the parts to be checked. j, Do not wipe with a cloth. 2. Set the tool in position, and coat the cradle side with inspection paint. *
Apply
the paint thinly.
3. Put the rocker cam on top, push with a force of 4 - 5 kg, and move 2 - 3 times from the stopper contact position to the maximum angle. 4. Remove the rocker cam, transfer the contact surface to tape, and check the contact surface. *
The standard for the contact surface be a shown in the diagram below.
shall
*
If there is no contact at the center but only at the outside, the contact is no good.
Contact less ontact 50% -
90%
ontact more Contact 50% -
Cradle
Reference: If the contact in not within standard value, when carrying always lap both parts together. * Parts with scratches cannot
90%
F20205290
the contact out lapping, be used.
30-57
REMOVAL 1.
MOTOR
Track shoe assembly l
Remove
track
shoe assembly.
For details, see REMOVAL SHOE ASSEMBLY. 2.
REMOVAL OF SWING ASSEMBLY
OF SPROCKET
A4
% Y OF TRACK
Jacking up machine
Lower the work equipment to the ground and release the remaining pressure inside the circuit. For details, see TESTING AND remaining Releasing ADJUSTING, pressure in hydraulic circuit for machines with PPC valve.
-k Swing the work equipment
90” to jack up the machine, then set block @ between the track frame and the track shoe. (See Fl)
3.
Disconnect
2.
Remove swing motor assembly (2). (See F3) * Using eyebolts, sling the swing motor assembly, then remove the mounting bolts, and remove the swing motor assembly.
Remove sprocket (1). (See Fl) * Sling the sprocket, then remove the mounting bolts, and lift out the sprocket. & kg
See Weight
INSTALLATION l
1.
Table
& kg
in the reverse
Mounting
u
Thread Tightener Mounting bolt:
l
bolt:
See Tightening Standard Values
30-58
l
(LT-2) Torques Table
Table
order
m a
See Weight
INSTALLATION OF SWING MOTOR ASSEMBLY
OF SPROCKET
Carry out the installation to removal.
hose (1). (See F2)
and
Carry out installation in the reverse order to removal. Bleeding air Bleed the air from the swing motor. For * details. see TESTING AND ADJUSTING, Bleeding air from all parts. After bleeding the air from the swing * motor, check the level in the hydraulic tank.
F2
Fl -
I
r
ezz-7
-
F20705329
‘F20505315
F3
F20705330
30-59
DISASSEMBLY 1.
2.
Motor assembly Set swing motor Valve
OF SWING MOTOR ASSEMBLY assembly
(KMF160)
(1) on tool Hl.
case assembly
1. Remove mounting bolts (2) of valve case 2. Using eyebolts @ (Thread dia. = 12 mm, Pitch = 1.75 mm), lift off valve case (3). 3.
4.
Relief valve Remove relief valve assembly Check
valve
Remove plug (5), then remove valve (7). 5.
Belleville Remove
6.
7.
(4).
spring
(6) and
spring belleville
Valve plate Remove valve
spring
(8).
plate (9).
Cylinder block Remove cylinder
block
(10). F20703013
F20705391
F20705396
30-60
8. Spring Remove 9.
spring
(11) and center
ring (12).
Retainer Using tool H2, remove 7 mounting then remove retainer (13).
screws,
10. Shaft, piston Remove
center
shaft (14) and 7 pistons
11. Brake piston 1. Remove brake piston * Using an oil leak pressure through the brake piston. * If the air pressure will fly out, so slowly. 2. Remove O-ring (17) from piston.
(15).
(16). tester, supply air under the oil port and remove is too high, the piston raise the air pressure and
backup
12. Plate, disc 1. Remove plate (19) and disc 2. Remove plate (21).
ring
(18)
(20). F20705399
13. Cover 1. Remove case assembly from tool Hi and turn over. 2. Remove snap ring (22), then remove cover
F20705400
\
(23). 14. Shaft assembly 1. Remove snap ring (24), then
1 remove
spacer
(25).
F20703014
F20705402
30-61
2. Set case assembly in press, then shaft assembly (26) from case (27). 3. Remove
bearing
(28A) and (288)
remove
from shaft
(29).
15. Bearing, spacer, belleville spring 1. Remove bearing and outer race (30). 2. Remove
spacer
(31)
and
belleville
spring
(32). 16. Outer race Remove outer
race (33A).
1F20705403
97
32
(i
31
i F2070540E,
F20705406
wn7n54n7
30-62
ASSEMBLY ASSEMBLY Precautions
OF SWING (KMFI 60)
MOTOR
when assembling
*
Clean all parts, and check for dirt or damage. Coat the sliding surfaces of all parts with engine oil before installing.
*
Always use all the parts supplied in the kit. Do not reuse the retainer mounting screw.
1. Shaft assembly 1. Install bearing outer race (33A). (Outside diameter: 140 mm) to brake case (27). 2. Using tool H3, press fit bearing (28B) (Inside diameter: 65 mm) to shaft (29). f
Press fit until the end face of the bearing inner race is in tight contact with the shaft. 3. Install outer race (338) and spacers (34) and (35). 4. Using tool H3, press fit bearing (28A) (Inside diameter: 65 mm). * Do not use any bearing if it is uncertain which set it belongs to. 5. To prevent the drive shaft from being at an angle, set tool H4 in position, and install shaft (29) to brake case (27). * Push in the outer race with a plastic bar from groove @ . (Do not use a metal bar; this will damage the outer race.)
35
F20705401
H4
‘-31
Ia- ’
F20705409
30-63
6. Assemble spring (33) and spacer (32), then using tool. H5, ‘install outer race. (30). (Outside diameter: 120 mm) * Align the inside diameter (shaft end) to install the spring. (With the outside diameter open). 7. Support shaft (26) at both ends, then use tool H3 to press fit bearing (28) (inside diameter: 65 mm). force is 400 - 2035 kg, * The press-fitting but up to 2200 kg is possible (when coated with engineoil). _ force is less than 2200 * If the press-fitting kg, always push in at 2200 kg after press fitting.
I
32
IP I F2070541C
*
Press fit until the spacer is in tight contact. of 2 spacers (25) using a. Select thickness procedure and table below. i) Measure dimension @ between seat portion @ of shaft and end face of inner race of bearing (28), then select 2 spacers from table below.
F20705411
F20705412]
r
Spacer selection
Unit: mm Measured value of dimension a
No.
1
table
1 1
Necessary spacer thickness of(possible as thickness 2 spacers)
Select 2 spacers
marked
o or o from table below.
Spacer thickness 2.3
2.5
12.250 - 12.449
4.6
2
12.450 - 12.649
4.6
0
0
3
12.650 - 12.849
5.0
0
00
4
12.850 - 13.049
5.2
5
13.050 - 13.249
5.4
2.7
00 I
Spacer
30-64
part number
I
0
0 0
00 706-77-42440
706-77-42450
706-77-42460
9. Assemble
spacer
(25), then
install
snap ring
(24). * Check that the snap ring is fitted in the groove.
securely
10. Support motor case, push end face of shaft (26) at 500 - 2200 kg in direction of arrow, and check that movement when doing this is 0.1 - 0.4 mm. * *
When doing this, check that the spacer (25) cannot be moved by hand. If the movement of the shaft is not within the standard valve, adjust the spacer so that it comes within the standard valve.
11. Rotate approx.
*
torque:
0.15 - 0.5 kgm
Supply the bearing with ample oil when measuring. If the rotating torque is not within the standard valve, replace the bearing with a new bearing.
2. Cover 1. Press fit oil seal and fit O-ring, cover (23). 2. Install snap ring (22). 3. 1. 2. 3.
-
shaft at a speed of 1 turn every 5 seconds and measure the rotating
torque. Rotating * *
F207054 .13
then
500 - 2200 kg w
install
F20705414
Plate, disc Set vase assembly on tool H 1. Install plate (21). Install disc (20) and plate (19).
F20705415
F20703014
30-65
4. Brake piston 1. install O-ring (17) and backup ring (18) to piston. * See illustration for direction of installation of O-ring and backup ring. 2. Install brake piston (16). 5. Piston, shaft 1. Set 7 pistons (15) and center shaft (14). 2. Install retainer (13) and using tool H2, tighten 7 mounting screws. & Mounting screw: Adhesive (LT-2) Mounting screw: See Tightening Torques and Standard Values Table Direction of installation may be clockwise * or counter-clockwise. After installing, check that the pistons * move smoothly and can fall under its own weight. If the movement is not smooth, loosen, then tighten again. * The screws must not be used again. mounting screws, measure 3. After installing clearance of piston ball. i) Set dial gauge @ on ball. ii) Pull piston in axial direction of pump sub assembly, and measure clearance between ball and retainer. * Ball clearance: Max. 0.25 mm
F20705400
F202052E
u
6.
7.
Spring Fit center
ring (12) and install
Cylinder block Install cylinder block
spring
F20705399
F2070539Z
Play
(11).
(10).
I=2070301
1
F20703012
F20705396
30-66
6.
9.
Valve install
plate valve plate
Belleville
spring
Set belleville *
(9).
spring
(8).
See illustration for direction of belleville spring.
of installation
-F20705394 F20705416
10. Check valve Fit valve (7) and spring (6), fit O-ring, install plug (5). u Plug: See Tightening Torques Standard Values Table 11. Relief valve Fit O-ring and (4). u
install
relief
the and
valve
assembly
Relief valve: See Tightening and Standard Values Table
Torques 5
F20703013
12. Valve case assembly 1. Fit O-ring and using eyebolts @ (Thread dia. = 12 mm, Pitch = 1.75 mm), set valve case (3). Correctly match dowel pin and valve plate. 2. Tighten mounting bolts (2). m Mounting bolt: See Tightening Torques and Standard Values Table of rotating torque of drive shaft 13. Inspection 1. From C port, apply more than 25 25 kg/cm* pressure, then release brake.
-2 F20705417
2. Set tool H6 and rotate drive shaft at a speed of 1 turn every approx. 5 seconds and measure the rotating torque. * Check that there is no uneven rotation in the rotating torque.
-k
Uneven width: Within 0.15 kgm Rotating torque: 0.6 - 15.5 kgm range If the uneven width is more, reassemble.
F2070541E
REMOVAL OF SWING MACHINERY ASSEMBLY
REMOVAL OF SWING MACHINERY ASSEMBLY
PC3OOLC
PC4OOLC
1.
Swing l
2.
motor
assembly
Remove swing motor assembly. For details, see REMOVAL OF SWING MOTOR ASSEMBLY
Remove swing (See Fl) m *
machinery
assembly
(1).
Sling the swing machinery assembly, then using the forcing screws, remove the swing machinery assembly.
el kg
See Weight
1.
Swing 0
motor
assembly
Remove swing motor assembly. For details, see REMOVAL OF SWING MOTOR ASSEMBLY
2.
Disconnect
3.
Remove
4. 5.
Remove clamp (4). (See F2) Remove swing machinery (See F3) m
Table
*
hoses
bracket
(1) and (2). (See F2) (3). (See F2) assembly
(5).
Sling the swing machinery assembly, then using forcing screws, remove the swing machinery assembly.
INSTALLATION OF SWING MACHINERY ASSEMBLY
See Weight
Table
PC3OOLC l
Carry out installation removal.
in the reverse
order to
m u
l
Mounting bolt: See Tightening Torques and Standard Values Table Refilling with oil * Run the engine to circulate the oil through the system. Then check the oil level again.
INSTALLATION OF SWING MACHINERY ASSEMBLY PC4OOLC l
Carry out installation removal.
order to
m u
l
Mounting bolt: See Tightening Standard Values Refilling with oil *
30-68
in the reverse
Torques Table
and
Run the engine to circulate the oil through the system. Then check the oil level again.
Fl I
F2
F3
30-69
DISASSEMBLY OF SWING MACHINERY ASSEMBLY 1.
Draining oil Remove drain plug and drain machinery case.
oil from
swing
: -
Swing machinery See Lubricant
case: and Coolant
Table
2. Cover assembly 1. Remove mounting bolts, then using eyebolts 0, remove cover assembly (1). (See Fl) * There are 9 mounting bolts at the top and three mounting bolts at the bottom. 2. Disassembly of cover assembly i) Remove cages (2) and (3). (See F2) * Check the number and thickness of the shims, and keep in a safe place. ii) Remove outer races (4) and (5) from cage. (See F3, F4) iii) Remove mounting bolts, then remove cover (6). (See F5) iv) Remove gear assemblies (7) and (8). (See F6) v) Remove bearings (9) and (10) from gear. (See F7,F8) vi) Remove inner races (12) and (13) from case (11). (See F9) 3.
4.
Shaft Remove
shaft
(14). (See FlO)
Ring gear Remove
ring gear (15). (See FlO)
5. Carrier assembly 1. Remove mounting bolts, then remove carrier assembly (16). (See Fll) 2. Disassembly of carrier assembly i) Remove mounting bolts (17), then remove holder. (See F12) ii) Set carrier assembly (16) in press, and using push tool @ , remove pin (18), then remove gear assembly (19). (See F12,F13) iii) Remove holder (20). (See F13)
30-70
F2
Fl
F9
i 205FO5444
F3
205FO5445
205FO5452
F:4
205FO5446
F5
FIO I
205FO5447
205FO5453
F6
31
F12
18
205FO5448
:7
205FO5449
F8
205FO5455
F13
1
205FO5450
205FO5454
I
17
10
205FO545
1
ia
205FO5456
iv) v)
Remove bearing (22) and spacer (23) from gear (21). (See Fl) Remove inner race (24). (See Fl)
6. Shaft assembly 1. Loosen mounting
1.
bolts
(25). (See F2)
2. Set shaft and case assembly (26) in press, and using push tool 0, remove shaft assembly (27). (See F3) 3. Disassembly of shaft assembly
i)
Remove spacer (See F4)
ii) iii)
Remove bearing (30). (See F4) Remove cover (31). (See F5) Remove oil seal (32) from cover. (See F6)
iv)
7.
(29) from
bearing
shaft
Case assembly
1. Using push tool, press fit bearing (See F8) 2. Assemble spacer (29). (See F9)
(33).
3. Using push (See F9)
(30).
tool,
press
fit
bearing
(28). 2. Shaft assembly 1. Assembly of shaft assembly i) & ii)
Case assembly Remove
ASSEMBLY OF SWING MACHINERY ASSEMBLY
(33). (See F7) & iii)
Using push tool @ , press fit oil seal (32). (See FlO,Fll) Outer circumference of oil seal: Liquid gasket (LG-6) Assemble cover (31) to shaft (See F12)
Grease (G2-LI) Set case assembly in press, press fit shaft assembly (See F13) iv) Tighten mounting bolts (25). F13) x=Z& Cover mounting surface: Liquid gasket (LG-6)
(28). and (27). (See
3. Carrier assembly 1. Disassembly of carrier assembly i) Using push tool, press fit inner race (24). (See F14) ii) Assemble spacer (23) and bearing (22) to gear (21). (See F14)
30-72
:g--
Fl
205FO5463
205FO5457
205FO546f
FlO
'11
32
205FO5458
205FO5462
205FO5465
205FO5459
F12
‘5
F13
28
28
31
205FO5461
205FO5460
F6
205FO5461
205FO546e
F14
17
32
205FO5462
205FO5463
205FO5457
30-73
iii) Assemble holder (20). (See Fl) iv) Set carrier assembly (16) in press, then assemble gear assembly (19), and using push tool @ , press fit pin (18). (See F2) * Be careful to keep the pin straight and rotate the gear when press fitting the pin. *
After press fitting the pin, check that the gear rotates smoothly. v) Fit holder and tighten with mounting bolts (17). (See F3) K& Mounting bolt: Thread tightener (LT-2) m Mounting bolt: See Tightening Torques and Standard Values Table 2. Fit carrier assembly (16), and tighten with mounting bolts. (See F4) &?&, Mounting bolt: Thread tightener (LT-2) u Mounting bolt: See Tightening Torques and Standard Values Table 4. Q
5.
Ring gear Install ring gear (15). (See F5) Ring gear mounting surface: Liquid gasket (LG-6) Shaft Assemble
shaft (14). (See F5)
6. Cover assembly 1. Assembly of cover assembly i) Using push tool, press fit inner races (13) and (12) in case (11). (See F6) ii) Using push tool @ , press fit bearing (10) in gear. (See F7) iii) Using push tool @ , Press fit bearing (9) in gear. (See F8) iv) Install gear assemblies (8) and (7). (See F9) v) Fit cover (6) and tighten with mounting bolts. (See FlO) & Cover mounting surface: Liquid gasket (LG-6) vi)
30-74
Using push tool, press fit outer races (5) and (4) in cage. (See Fl 1 ,F12)
7. Adjusting preload of bearing 1. Remove O-ring, and install cages (3) and (2). (See F13) f Install 2 bolts each at a and b. f Rotate the spline shaft for the motor 5 - 6 turns, then tighten the bolts to the specified torque. u Bolt: See Tightening Torques Standard Values Table
and
Fl
F2
205FO5467
II
205FO5468
205FO5469
1
FlO
F9
I
205FO5455
Y
205FO5449
205FO5454
I/
:I1
-5
205F0544E
F12
-r-----
205FO5453
L
205FO5447
II
205FO5446
F13
a
205FO5452
b .
205FO547’
2. Selecting shims Measure points “c” gauge, then select below.
and “cl” with a feeler shims from the table
mm Clearance
Above
at c, d
Below
Shim thickness
*
Types
0.2 0.4 0.6 0.8 1.0 1.2 1.4 1.6 1.8 2.0 2.2 2.4 0.4 0.6 0.8 1.0 1.2 1.4 1.6 1.8 2.0 2.2 2.4 2.6 0.6 0.7 0.8 0.9 1.0 1.1 1.2 1.3 1.4 1.5 1.6 1.7
of shims:
t = 0.4,
t = 0.5,
t = 0.7,
t = 0.8
t = 0.6
3. Remove cages (3) and (2). (See Fl) 4. Fit O-rings and install cages (3) and (See Fl) a Mounting bolt:
(2).
See Tightening Torques and Standard Values Table * Check that the spline shaft for the motor mount rotates smoothly by hand. 5. Using eyebolts 0 , install cover assembly (1). (see Fl) e Cover assembly mounting surface: Liquid gasket (LG-6)
Refilling with oil Tighten drain plug through oil filler. Swing
and
machinery
See Lubricant
30-76
add
engine
oil
case: and Coolant
Table
C
205FO5471
F2 I
w
u
205FO544L
30-77
13. Remove
REMOVAL OF REVOLVING FRAME ASSEMBLY
*
1. Remove l
boom cylinder assembly. For details, see REMOVAL OF CYLINDER ASSEMBLY.
BOOM f
2.
Remove work equipment assembly. l For details, see REMOVAL OF WORK EQUIPMENT ASSEMBLY.
3.
Remove
4.
Remove cab. l For details, ASSEMBLY.
5.
6. 7. 6.
9.
counterweight. * see
REMOVAL
OF
CAB
Remove hood (1). (See Fl) * Y Be careful when removing the hood, because it is under tension from the + spring. See Weight Table & kg Disconnect hose (2) (See F2) Disconnect wiring connector (3). (See F2) Remove frame (4). (See F2) l Remove the frame together with the subtank Disconnect wiring connector (5). (See F3)
10. Remove
cover
frame
assemblv
(9).
-
For the mounting bolts marked 0, move the control box assembly, remove the grommets, then remove the mounting bolts. (See F6) Leave 2 bolts each at the front and rear, then use a lever lock to adjust the balance of the revolving frame assembly to the front, rear, left, and right, then remove the remaining bolts, and remove. When removing the revolving frame assembly, be careful not to hit it against the center swivel joint assembly.
Aka
See Weight
Table
INSTALLATION OF REVOLVING FRAME ASSEMBLY l
(6). (See F3)
See Weight Table & kg 11. Disconnect hoses (7). (See F4) 12. Remove link (8). (See F4)
e
30-78
revolvina
(See F5) m
Carry out installation in the reverse order to removal. * The length of the mounting bolts differs according to the mounting position, so refer to the diagram when installing. (See F7) Length of mounting bolts marked s :155mm PC300LC :175mm PC4OOLC Length of other mounting bolts :140mm PC3OOLC :165mm PC4OOLC Swing circle mating surface: Liquid gasket (LG-1)
&&
Mounting bolt: Thread tightener
u
Mounting bolt: See Tightening Values Table
(LT-2) Torques
and Standard
Fl
-5
205FO555C
)
F6
F2
F
205FO5582
F7
F3
205FO5584
3%
205FO5586
205FO5585
30-79
REMOVAL OF SWING CIRCLE ASSEMBLY
REMOVAL OF IDLER, RECOIL SPRING ASSEMBLY
1.
1.
2.
Remove revolving frame assembly. For details, see REMOVAL OF REVOLVING FRAME ASSEMBLY. Remove swing circle assembly (1). (See Fl) * Remove 36 mounting bolts. r5 kg
See Weight Table
INSTALLATION OF SWING CIRCLE ASSEMBLY 0
Carry out installation removal.
*
PC3OOLC Install swing circle assembly (1) with the inside soft zone (S) mark facing 90” to the right.
*
in the reverse order to
PC400LC Align the positions of the (S) mark of the inner circle soft zone and the outer circle soft zone (plug) when installing the swing circle assembly. (See F2) Mounting bolt: Thread tightener (LT-2) Mounting bolt: See Tightening Torques and Standard Values Table Circle teeth surface: Grease (MPG) Amount of grease:
334 (PC300LC) 35e (PC400LC)
30-80
Track shoe assembly 0 Remove track shoe assembly. For details, see REMOVAL OF TRACK SHOE ASSEMBLY. 2. Remove idler and recoil spring assembly (1). (See F3) * Sling the idler and recoil spring assembly, and pull out to the front to remove. See Weight Table & kg 3. Disconnection of idler and recoil spring assembly Secure recoil spring with block @ , then sling idler assembly, remove mounting bolts, and disconnect idler assembly (2) and recoil spring assembly (3). (See F4) * Make match marks on the matching surface of the idler and the recoil spring. See Weight Table
INSTALLATION OF IDLER, RECOIL SPRING ASSEMBLY l
Carry out installation removal.
in the reverse order to
F3
Fl
---LA
205FO5477
F20505318
F2
F4
F20705331
205FO5478
30-81
ASSEMBLY ASSEMBLY
DISASSEMBLY OF RECOIL SPRING ASSEMBLY 1. 2.
Remove piston spring assembly Disassembly
1. Set recoil (See F2) *
3. 3. 1. 2.
of recoil spring
spring
assembly
from
recoil
assembly (1) to tool
B.
Y A 4
*
2.
assembly (2) (1). (See Fl)
The spring is under large installed load, so be sure to set the tool Failure to do this is properly. dangerous. Spring installed load:
See Tightening Torques and Standard Values Table Apply hydraulic pressure slowly to compress spring, then remove lock plate (3), and remove nut (4). (See Fl) * Compress the spring to a point where the nut becomes loose. f Release the hydraulic pressure slowly and release the tension of the spring. * Free length of spring: See Tightening Torques and Standard Values Table Remove yoke (6), cylinder (7), and dust seal (8) from spring (5). (See Fl) Disassembly of piston assembly Remove lock plate (10) from piston (9), then remove valve (11). (See Fl) Remove snap ring (12), then remove Upacking (13) and ring (14). (See Fl)
30-82
1.
Assembly
OF RECOIL SPRING
of piston
assembly
1. Assemble ring (14) and U-packing (13) to piston (9), and secure with snap ring (12). (See Fl) 2. Fit valve (11) and secure with lock plate (10). (See Fl) 2. Assembly 1. Assemble (See Fl)
of recoil spring assembly dust seal (8) to cylinder
(7).
& Lip of dust seal: Grease (G2-LI) 2. Assemble cylinder (7) and yoke (6) to spring (5), and set in tool C. (See Fl) 3. Apply hydraulic pressure slowly to compress spring. tighten nut (4) so that installed length of spring is dimension “a’, then secure with lock plate (3). (See F3) * Installed length of spring: See Tightening Torques and Standard Values Table 4. Remove recoil spring assembly (1) from tool B. (See F2) 3. Assemble piston assembly (2) to recoil spring assembly (1). (See Fl) JC& Piston: Grease (G2-LI) -k Assemble the cylinder assembly so that the mounting position of the valve is exactly at side.
Fl
1
205FOS479
2
F3
1
205FOS48
205FO5587
30-83
REMOVAL OF TRACK ROLLER ASSEMBLY 1.
Loosen * *
2.
(1). (See Fl)
Loosen the lubricator, track shoe tension.
A4Y
Remove m *
lubricator
REMOVAL OF CARRIER ROLLER ASSEMBLY 1.
and
loosen
the
The adjustment cylinder is under extremely high pressure. Never loosen the lubricator more than one turn. If the track tension is not relieved, move the machine backwards and forwards. track
roller
assembly
shoe assembly
*
2.
Using hydraulic track to a position assembly can be Remove carrier roller
jack 0, push up the where the carrier roller removed. (See Fl) assembly (1). (See F3)
m r5 kg
See Weight
Table
(2). (See F2)
Remove the mounting bolts of the track roller, then swing the work equipment 90”, jack up the machine, and remove the track roller assembly. See Weight
Track
INSTALLATION OF CARRIER ROLLER ASSEMBLY l
Table
Carry out installation removal.
in the reverse
m AZ&
INSTALLATION OF TRACK ROLLER ASSEMBLY l
Carry out installation removal.
in the reverse
order to
m -k
A a
*
30-84
Set the track roller assembly to the mounting position, then operate the control levers to lower the machine slowly, and tighten the mounting bolts temporarily. Mounting bolt: Thread tightener (LT-2) Mounting bolt: See Tightening Torques and Standard Values Table Operate the control levers to lower the machine completely to the ground, then tighten the mounting bolts fully.
Mounting bolt: Thread tightener
(LT-2)
order to
Fl
F3 -__ __
3 F20505320
F20505322
'2
F20505321
30-85
REMOVAL OF TRACK SHOE ASSEMBLY
REMOVAL OF CHARGING PUMP ASSEMBLY
1. Positioning
Y Y
track
Ir
Stop the machine in a position where the track can be laid out to the front and rear when the master pin is pulled, then loosen the lubricator (1) to relieve the track tension. (See Fl) * Y The adjustment cylinder is under extremely high pressure. Never loosen the lubricator more than one turn. If the track tension is not machine the move relieved, backwards and forwards. Remove master pin (2) m
A 4
A 4
2.
-k 3.
Using tool (See F2)
Remove *
*
track
C, pull
out
shoe assembly
the
master
Remove hydraulic tank strainer, and use tool D to stop the oil. (See F5) * When not using tool D, remove drain plug and drain the oil from the hydraulic tank and piping. : u
pin. 1. 2.
(3) m
Move the machine forward so that the position of the temporary pin is at the front of the idler, then put block @ in contact with the grouser, pull out temporary pin @ , and remove the dust seal. (See F3) Drive the machine in reverse to lay out the track.
3.
l
Carry out installation removal.
in the reverse
l
order to
*
Using tool C, press fit the master
pin.
*
Deflection of track a (See F4) See Tightening Torques and Standard Values Table
m
hoses
and Coolant
Table
(1). (See F6)
Disconnect tube (2). (See F6) Remove charging pump assembly (See F6)
(3).
Carry out installation in the reverse order to removal. Refilling with oil Refill to the specified level, and run the * engine to circulate the oil through the system. Then check the oil level again.
%a 1
m
30-86
See Lubricant
Disconnect
INSTALLATION OF CHARGING PUMP ASSEMBLY l
INSTALLATION OF TRACK SHOE ASSEMBLY
Lower the work equipment to the ground and stop the engine. Operate the control levers several times to release the remaining pressure in the hydraulic piping. Then loosen the oil filler cap slowly to release the pressure inside the hydraulic tank.
See Lubricant
and Coolant
Table
Fl
5
I
I
-D
FI
F20505320
1229
1
6
F2
F20505323
F3
F4
I J
Track
frame
I
_
t
‘Track
shoe
F9883
30-87
REMOVAL OF HYDRAULIC PUMP ASSEMBLY
REMOVAL OF HYDRAULIC PUMP ASSEMBLY
PC3OOLC
PC4OOLC % Y Lower the work equipment
Lower the work equipment to the ground and stop the engine. Operate the control levers several times to release the remaining pressure in the hydraulic piping. Then loosen the oil filler cap slowly to release the pressure inside the hydraulic tank. Remove hydraulic tank stainer, and use tool D to stop the oil. (See Fl) * When not using tool D, remove drain plug and drain the oil from the hydraulic tank and piping.
l
1.
2. 3. 4. 5. 6.
: Draining
See Lubricant oil from damper
and Coolant chamber
0
See Weight Table & kg Remove tube (2). (See F3)
connector
3. 4.
(7). (See F3)
Remove bracket (8). (See F3) Remove hydraulic pump assembly (See F4) See Weight
1.
2.
hoses (3), (4), (5). and (6). * Disconnect 5 hoses (6). wiring
a
Table
: See Lubricant and Coolant Table Remove side cover (1). (See F2) * Sling the side cover and the frame as one unit, remove the mounting bolts, then remove.
Disconnect (See F3) Disconnect
A 4
(9).
5. 6.
Table
to the ground and stop the engine. Operate the control levers several times to release the remaining pressure in the hydraulic piping. Then loosen the oil filler cap slowly to release the pressure inside the hydraulic tank. Remove hydraulic tank stainer, and use tool D to stop the oil. (See F5) * When not using tool D, remove drain plug and drain the oil from the hydraulic tank and piping. : u Draining
See Lubricant oil from damper
and Coolant chamber
Table
: See Lubricant and Coolant Table Remove side cover (1). (See F6) * Sling the side cover and the frame as one unit, remove the mounting bolts, then remove. See Weight Table & kg Remove frame (2). (See F6) Disconnect tube (3). (See F7) Disconnect hoses (4), (5), (6), and (7). (See F7) * Disconnect 5 hoses (7). Disconnect wiring connector (8). (See F7) Remove hydraulic pump assembly (9). (See F8) See Weight
Table
INSTALLATION OF HYDRAULIC PUMP ASSEMBLY PC3OOLC and PC4OOLC l
& l
Carry out installation removal. Pump mounting
in the reverse
order to
bolt hole (2) only:
Liquid gasket (LG-6) Refilling with oil * Refill to the specified level, and run the engine to circulate the oil through the system. Then check the oil level again. * Add oil to the damper chamber to the specified level.
Q
See Lubricant
and Coolant
Table
I l
Xli.AFOll
Bleeding air f Bleed the air from the hydraulic pump. TESTING AND details, see For ADJUSTING, Bleeding air from all parts. -k
30-88
After bleeding the air from the hydraulic pump, check the hydraulic tank level.
:5
Fl
FI 1229
FI 1229 6
F2
Ti \\
205FO5589
205FO5592
F7
F3
3 205FO5593
F8
*I
+i4zLzA 1 T
205FO559I
I4
:
30-89
DISASSEMBLY Note)
OF HYDRAULIC
PUMP ASSEMBLY
The procedure for disassembly is basically the same for both front and rear pumps, so this section describes the disassembly of the front pump only. When there are differences, however, they will be notes at the appropriate place in the description.
*\ 1
(HPV160+160) Fz==?l \\-
\ \
\
1.
Rear pump assembly 1. Set pump assembly (1) in tool Jl. 2. Remove hoses (2) and (3). 3. Remove 4 nuts (4) of front pump end, then lift off rear pump assembly (5).
2.
* 3.
*
Separate
f
Loosen 4 rear pump end cap mounting bolts (Width across flats = 30 mm).
4 -+. F20705419
end cap at center.
NC, CO*NC valve assembly Remove TVC valve (6) and CO*NC assembly (7) as a set. TVC valve installed only front pump. Servo valve assembly Remove servo valve assembly
valve
(8). 20705420
F20705421
30-90
4.
Charging
pump
drive
gear
(Front
pump
onW 1. Remove charging pump drive gear as follows. i) Remove cover (9). ii)
Using tool 52, remove then remove plate (11).
screw
iii)
Using
gear (12).
2. Remove follows.
puller
charging
@ , remove pump
driven
(lo),
gear
as
i)
Stop gear from turning, bolt (13) and plate (14).
and remove
ii)
Using
gear (15).
puller
0,
remove
F20705422
5. End cap 1 Using puller 0, push shaft (16) to end cap side, then hold tension of spring inside cylinder block.
F20705425
F2070542
F20705427
*
For rear pump, remove cover (17), bolt (18), and plate (19), then use the mounting holes of plate (19) and the cover to set puller @ in position. 2. Remove coupling (20). 3. Using tool 53, remove 4 screws 4. Remove impeller (22). 5. Remove 6. Remove 7. Remove *
:919
(21).
snap rings (23). spacers (24) and (25). thrust bearings (26).
Impeller not installed on rear pump, so remove plate (27), then remove end cap.
F20705428
F207054
F20705432
30-92
8. Loosen 7 bolts gradually, and when spring in cylinder block is fully extended, remove end cap (28). * Before removing end cap (28), remove the puller @ installed in Step 5-1. 9. Remove
bearing
(29) from end cap (28).
10. Remove valve plate (30). * When removing valve plate, be careful not to damage valve plate and cylinder block because valve plate adheres to cylinder block. 6. Pump sub-assembly 1. Remove cradle mounting bolts. 2. Support shaft on front and rear, and remove pump sub-assembly (31) from case. 7. Charging pump assembly 1. Remove charging pump assembly (32). 2. Remove plug (33A), then using tool remove strainer (33B).
J4,
F2070543!
F20705431
J4
333
F20705438
a. Charging pump drive shaft assembly (front 1.
pump only) Remove housing (34).
2. Using push tool, housing (34).
remove
oil seal
(35) from
3. Remove drive shaft assembly (36) by knocking out from charging pump end. 4. Disassemble drive shaft assembly as follows. i) Remove key, then push tool to remove collar (38), bearing (39), collar (40), and bearing (41) from shaft (37). ii)
Remove coupling
iii)
Remove
F20705439
F20705440
pin (42), then remove (43) from shaft (37). snap ring (45) from case.
9. Servo piston assembly 1. Remove caps (46) and (47), and shims and (49) by using forcing screw. 2. Remove spring (50). 3. Remove servo piston (51).
(48)
F20705443
30-94
1.
Cylinder, shaft
1. Set pump sub-assembly in a vice. * Be careful not to damage the flange surface of the cradle. 2. Remove slider (53) and cylinder block (54). of cylinder block 3. Disassembly Remove snap ring (55), then remove retainer (56), spring (57) and washer (58) from cylinder block (54). 4. Using forcing screw, remove housing (59). * Check the number and thickness of shims and keep in a safe place. 5. Using push tool, remove oil seal (60) from housing (59). 6. Remove shaft assembly (61). 7. Disassembly of shaft Using puller @ , remove collar (63) and inner race (64) from shaft (62). * Remove only the inner race for the rear
F20705441
F20205329
pump. 2. Piston 1. Using tool 53, remove 4 screws (65), then remove bearing retainer (66), shoe retainer (67) and piston (69).
I
F20705445
~
F20705447
F20703022-111
F2070544E
1
F20703036
F20705448
2. Using tool 53, remove remove plate (71). 3. Remove
rocker
screws
Cradle Using push tool, cradle (75).
then
(73),
then
J3
cam (72).
4. Using tool 55, remove screws remove rocker cam stopper (74). 3.
(70),
remove
bearing
(76) from
l-f
F2070545C
F20705449
h7ll
13
30-96
F20705451
F20705452
ASSEMBLY l
OF HYDRAULIC
PUMP ASSEMBLY
(HPV160+160)
Precautions when assembling Always use all parts supplied in the kit. In addition, always use the following parts as an assembly. 1. Cradle
2. Cylinder
and rocker cam block and valve
plate.
Preparatory work 0 Clean all parts, and check for dirt or damage. Coat the sliding surfaces of all parts with engine oil (EOlO-CD, new oil) before installing.
76 F20705452
-
ASSEMBLY
OF PUMP SUB-ASSEMBLY 8-
1. Cradle and piston assembly 1. Install bearing (76) mm) in cradle (75). &Mounting Grease
(Outside
surface (G2-LI)
diameter
110
of bearing:
shims to hold bearing as follows. Measure distance @ between bearing i) (76) and end face of cradle. ii) Measure distance @ of housing (59). * Measure distance @ of cover. (Rear pump) iii) Select shim thickness as follows. Shim thickness = @ - @ - (0 to 0.1
2. Select
mm) * There are 3 kinds of shim 0.15, 0.1 and (thickness = 0.05 mm). 3. Fit dowel pin, and using tool 55, install rocker cam stopper (74) with screws (73). &
Stopper
screw:
Iz--]
Stopper screw: See Tightening Standard Values
Ir
F2070301
F20205351
E
&7ll
F20705451
Thread tightener (LT-2) (Loctite #262)
Torques Table
and
30-97
4. Fit dowel pin to cradle, set rocker cam (72) in position, then using tool 53 install plate (71) with screws (70). *
Install the grooved side of the rocker arm facing the cradle oil hole.
H=C&
Plate screw:
Thread (Loctite
u
tightener #262)
Plate screw: See Tightening and Standard Table
f
(LT-2)
After tightening the bolts, check rocker cam moves smoothly.
Torques Values
that the
5. Select i)
the spacer thickness as follows. Assemble piston (69) to shoe retainer (67), put on the level block, then measure distance @ to top surface of shoe retainer. ii) Select spacer thickness as follows. Spacer thickness = distance @ + (0.03 to 0.07 mm). -k There are three types of spacers. 6. Install spacer (68) selected in Step 5....i) and 5....ii), then install piston (69), shoe retainer (67) and bearing retainer (66).
69 &
Bearing
retainer screw: Thread tightener (Loctite
u
Bearing
67 (LT-2)
#262)
retainer screw: See Tightening Torques Standard Values Table
7. Using tool 53, install
screw
and
(65).
65
F20705448
30-98
1
a. Hold
rocker cam in position, using tool J6, pull piston (69) with a force of 5 - 6 kg, and measure clearance @ between piston shoe and rocker cam. *
* *
2.
Measure the clearance with the rocker cam in position a or b, and measure for all 9 pistons. Clearance: 0.03 - 0.07 mm If clearance @ is not within the standard range, adjust the spacer again.
Cylinder Align *
*
Rocker
Bearing
block
piston
and install
cam
retainer
F20703021
cylinder
block
(54).
Install the spring and washer inside the cylinder after adjusting the preload of the bearing Always install the valve plate (which forms a set with the cylinder) together with the cylinder.
3. Shaft assembly 1. Using push tool, press fit inner race (64), O-ring, collar (63) (inside diameter: 60 mm) on shaft (62). * Be sure to install inner race in correct direction.
Pull
J6
f0 F20505442
*
For the rear pump, use a push tool to install inner race (78) to shaft (77), then fit plate (19) and tighten with bolt (18).
&
Mounting
bolt: Thread
tightener
(LT-2) (Loctite m
Mounting
#262)
bolt: See Tightening Torques Standard Values Table
and F2070302:
2. Set cradle and piston assembly (79) in vice. * Put a block under the cylinder. 3. Align shaft assembly (61) with cylinder, and install. 4. Install housing as follows. i)
Install oil seal (60) (outside 95 mm) to housing (59).
diameter: Block
&
Lip of oil seal: Grease ii)
(G2-LI)
Fit shim selected in Step 1 - 2, and install housing (59) to cradle. F2070545E
ASSEMBLY 1.
Charging
OF PUMP ASSEMBLY pump
drive
shaft assembly
(front
pump only) 1. Sub-assembly of shaft assembly. i) Install coupling (43) in shaft (37), secure with pin (42). ii) Using push tool, install bearing collar (40), bearing (39), collar (inside diameter: 35 mm) to
then (41), (38) shaft
(37). F20705446
F20705445
42
F20703024
30-I 00
I
F20705456
iii)
Using push tool, install to case (44).
snap ring (45)
2. Install
f
drive shaft assembly (36) to case. Check that shaft rotates smoothly.
3. Using
housing *
&
push tool, (34).
When installing deform it.
install
oil
oil seal, be careful
install
(35)
to
.44
not to .45
Lip of oil seal: Grease
4. Fit O-ring,
seal
housing
(G2-LI) F20705457
(34) to pump.
Servo piston 1. Install servo piston (51) in case. * Servo piston is the same for front pump and rear pump. 2. Adjust stroke of servo piston as follows. i) Align tool 57 with dowel pin and groove for servo valve arm of servo piston, and set tool 57 in position.
2.
As seen from the rear of the pump, the right side (the side with the spring) is the maximum swash plate angle side. (maximum flow side) Note: For the rear pump, use the same tool turned over. *
35\ 34’
L F2070302E
F20705439
51 F2050544C
J7 F20505450
30-101
ii)
Measure distance piston and case.
iii) iv)
Measure distance @ of cap (46). Select shim thickness as follows. @ - @ = @ k 0.05 mm *
@ between
After adjusting the shim, a set with the cap.
servo
put it in
46 F20205356
Servo valve mounting surface Pump case Cleara
\
Servo piston Clearance
0
Clearance 0 F20703026
To adjust the minimum swash plate angle, replace tool 58 with the tool for the minimum angle, and repeat the same procedure as in Steps 2 . . . . i) - 2 . . . . iv). Note that the case faces in the opposite direction from the maximum swash plate angle side. 3. Pump sub-assembly 1. Install slider (53) and O-rings. * install O-rings on pilot bore portion.
and
joint
2. Install joint to case. * Install with small hole facing cradle side. 3. Align slider with servo piston, so it supports the shaft and install pump sub-assembly (31). * Be careful that O-ring is not caught.
30-I 02
_J
’ F20703027
4.
Charging
pump
driven
gear
(front
pump
only) 1 Fit key on shaft, then shrink fit gear (15). (Charging pump end) * Shrink-fitting temperature: 100°C for 1 hour. 2. Fit plate (14) and tighten bolt (13). D
Bolt: See Tightening Standard Values Table
Torques
and
3. Fit key, then shrink fit gear (12). (Main shaft end) 4. Using tool 52, install split plate (11) with screw (10). * Push plate into bottom of groove of shaft completely, then tighten screws alternatively to prevent plate from moving. AX,
Mounting
bolt: Thread (LT-2) (Loctite
u
Mounting bolt: See Tightening Torques Values Table
F20705458
F2070542t5
r
tightener #262)
F20705459
and Standard
5. Select i)
*
plate (11) as follows. Install gear (12). * When shrink fitting gear, install gear after temperature becomes low. ii) Select proper plate from 5 kinds of plate so that clearance @ becomes the smallest. a = 0 - 0.1 (Best selection of plate is to fit in position by knocking plate in slightly.) 11’
F20703029
30-103
5. End cap 1. Using push tool, install bearing (29) (outside diameter: 54 mm) and ring (80) to end cap (28) 2. Coat with grease (G2-LI), align with dowel pin and ring (80), then install valve plate (30). *
6.
Check that the suction and discharge ports of the valve plate are aligned with the ports in the end cap.
Adjusting bearing
1. Install
joint
end play of front (rear) shaft F20705434
*
Install with the small hole facing opposite side from the end cap. 2. Install end cap (28) to case. u
Mounting
the
bolt:
See Tightening Torques and Standard Values Table 3. Coat with grease (G2-LI), and install thrust bearing (26). * Install the thrust bearing with the outside race (the side with the larger inside diameter) surface facing the end cap. Pay attention also to the direction of installation of the ball (Grooved portion of ball holder). (See diagram on right) 4. Install spacers (24) and (25), then install snap ring (23).
Outer race seat
End cap
Grooved of ball holder
F20705432
30-104
F20705461
to case end.
F20705461
_ Yi 26
F20705462
5. Select spacer (24) as follows. From the 5 thicknesses of spacers, spacer (24) that gives the minimum from the snap ring (23). 6. Using tool 53, screws (21).
install
impeller
select the clearance (22)
Bearin
with
7. Set dial gauge @ on case and measure axial play of shaft. * Axial play: 0.1 - 0.4 mm Ir If axial play is not within specified range, select plate from the five thicknesses of plate.
24
Shaft F20705463
-
F20705431
_,__
Clearance 0.1 - 0.4 mm
F20703031
,464
8. Install selected plate, measure between impeller and end cap. * Clearance: 0.65 f 0.18 mm 9. After completing measurements, impeller and end cap. *
7.
On the rear pump, there is no impeller.
plate
(27)
clearance
remove is used;
Washer, spring, snap ring Assemble washer (59), spring (58) and retainer (57) to cylinder block, then install snap ring (56). -k Be sure to install washer in correct direction.
F20705465
Clearance:
0.65 f 0.18 7-h
F20705466
F2070546;
F20703032
30-106
F20705468
II
F20705469
I
8. Impeller 1. Secure shaft (16) with puller @ . 2. Fit O-ring, then install end cap. * For details see step 5 and 6 - 1, 2. 3. Coat with grease (G2-LI), and install thrust bearing (26). * For details 4. Install spacers ring (23).
see Step 6 - 3, 4. (25) and (24), then install snap
*
When doing this, press the shaft with a force of 170 - 190 kg from the case side to the end cap side. 5. Align bearing, and install impeller (22). 6. Using tool 53, tighten K&
Screw:
screw
Adhesive
(21).
(LT-2) (Loctite
u
Screw: See Tightening Standard Values Table
7. After tightening 8. Measure i)
ii)
rotating
screws, torque
remove
#262) Torques
puller
and
@ .
of pump.
Using tool J9, rotate pump shaft at 1 revolution every 3 - 5 seconds, then measure rotating torque. There must be no variation in the rotating torque (Range of variation: Max. 0.3 kgm) and the rotating torque must be less than 2.0 kgm. (At minimum swash plate angle.)
F20705432
l-l
F20705431
n
I
F2Oi
30-107
9.
Servo piston cap
1. Align f
servo
piston,
Install on left from rear.
install side
spring
when
(50).
viewing
pump
2. Fit O-ring and shims (49) and (48) selected step 2, then install caps (47) and (46). u
Mounting
in
bolt: See Tightening Torques Standard Values Table
and
10. Servo valve assembly Fit O-ring and servo piston, assembly (8). u
Mounting
align then
lever with groove of install servo valve
bolt: See Tightening Torques Standard Values Table
and
u
*
Mounting
bolt: See Tightening Torques Standard Values Table
TVC valve is installed
> 6P \ 51
11. TVC,
CO*NC valve assembly Fit O-ring and install TVC valve (6) CO*NC valve assembly (7) and a set.
48
and
d0
F20705443
and
only on front pump.
F20705421
30-I 08
12. Charging pump assembly 1. Using tool 54, install strainer then install u
assembly
(34),
Torques
and
plug.
Plug: See Tightening Standard Values Table
2. Fit O-ring, then assembly (32).
install
charging
pump
13. Rear pump assembly 1. Install coupling (20). 2. Fit O-ring to end cap, and raise rear pump assembly (5), then tighten 4 nuts (4). m
End cap mounting
nut and bolt:
See Tightening Torques Standard Values Table *
Also tighten 4 rear mounting bolts (Width mm). 3. Install hoses (2) and (3).
u
u
Sleeve
Sleeve
F20705438
pump across
and
end cap flats = 30
‘32
nut of hose (2): See Tightening Torques Standard Values Table
and
nut of hose (3): See Tightening Torques Standard Values Table
and
F20705472
F20705420
F20705419
14. Cover Install cover (9).
F2070542
30-110
CHECKING CONTACT BETWEEN CYLINDER AND ROCKER CAM AND CRADLE 1.
Checking contact between cylinder and valve plate 1. Make a centering tool for the cylinder and valve plate.
block
BLOCKAND
VALVE PLATE,
......... .l---l& ... .... Centering tool
Cylinder block
block
*
The tool can be made of a soft material such as plastic or bakelite. 2. Remove grease from the parts to be checked * Do not wipe with a cloth. 3. Set the tool in position, and coat the cylinder block side with inspection paint. -k Apply the paint thinly. 4. Put the valve plate on top, push with a force of 4 - 5 kg, and rotate 2 - 3 times.
............... ... . . . ............. :.:.:.: .......................... ..........................................................
::::~:~.:.:.:.:.:.:.:.:.
............
:.:.:.:.:
........................
I
..................................... .......................
7.y.: :.:.:.:
...................... ..........................
................................. ....................................... .....................
.
5. Remove the valve plate, transfer the contact surface to the tape, and check the contact surface. * The standards for the contact surface are as follows. 1
Valve plate Cylinder block
Valve plate
1 a. Seal a. Seal
1 Min. 80% 1 Min. 80%
F20703037
Cylinder block F20703038
30-111
2.
Checking contact between rocker cam and cradle
1. Remove grease from the parts to be checked. * Do not wipe with a cloth. 2. Set the tool in position, and coat the cradle side with inspection paint. * Apply the paint thinly. 3. Put the rocker cam on top, push with a force of 4-5 kg, and move 2 - 3 times from the stopper contact position to the maximum angle. 4. Remove the rocker cam, transfer the contact surface to tape, and check the contact surface. * The standard for the contact surface are as follows. Pump model
a Dimension (mm)
Contact surface
Contact b from a to outside
HPVl60
70
Min. 90%
Min. 60%
*
If there is no contact at the center but only at the outside, the contact is no good.
Reference If the contact is not within standard value, when carrying always lap both parts together. * Parts with scratches cannot
30-112
the contact out lapping, be used.
30-113
REMOVAL OF HYDRAULIC PUMP INPUT SHAFT OIL SEAL 1. Remove l
hydraulic pump assembly. see REMOVAL For details, HYDRAULIC PUMP ASSEMBLY.
2.
Remove
cover
3.
Remove
plate
(2). (See Fl) m
4.
Remove
drive
gear (3). (See Fl)
5.
f Using a puller, remove Remove housing assembly m *
6.
l
(1). (See Fl)
the drive gear. (4). (See F2, F3)
remove Using eyebolts, assembly and the shim.
Remove
OF
the
housing
oil seal (5). (See F3) m
Remove
the oil seal from the housing.
INSTALLATION OF HYDRAULIC PUMP INPUT SHAFT OIL SEAL l
Carry out installation removal.
m e
in the reverse
order to
Mounting bolt: Thread tightener (LT-2) Mounting bolt: See Tightening Torques and Standard Values Table
m
m u
Mounting bolt: See Tightening Values Table
Torques
and Standard
m * &
Using tool 0, press fit oil seal housing (4). (See F4) Lip of oil seal: Grease (G2-LI)
30-114
(5) in
205FO5595
F2
L
-
205FO5486
F‘3
5 2OUFOl21
I-K
30-115
REMOVAL OF CONTROL VALVE ASSEMBLY
1.
2.
3. 4. 5. 6. 1. 2.
7. 1. 2.
8.
Lower the work equipment to the ground and release the remaining pressure inside the circuit. For details, see TESTING AND remaining Releasing ADJUSTING, pressure in hydraulic circuit for machines with PPC valve. After removing the piping, mark with tags * to prevent mistakes when installing. ._ ~. Remove frame (1). (See Fl) l Remove the block between the hydraulic filters. (PC4OOLC) Disconnect wiring connectors (2). (See Fl) * Disconnect the connectors of the front and rear pump pressure sensors and work equipment and swing pressure switches. Disconnect tubes (3). (See Fl) * Disconnect 2 tubes. Remove bracket (4). (See Fl) Disconnect hose (5). (See Fl) Disconnect R.H. control valve hoses Disconnect hoses (6). (See Fl) * Disconnect 6 hoses Disconnect PPC hoses (7). (See Fl) * Disconnect 3 hoses at the front, 3 hoses at the rear, and 2 hoses at the bottom. Disconnect L.H. control valve hoses. Disconnect hoses (8). (See Fl) f Disconnect 7 hoses Disconnect PPC hoses (9). (See Fl) * Disconnect 3 hoses at the front, 5 at the rear, 3 hoses at the top, and 2 hoses at the bottom. Remove control valve assembly (10). (See F2) * When removing the control valve assembly, check that all the piping and wiring has been removed, then remove the assembly, taking care that there is no interference. * Sling the control valve assembly, remove the mounting bolts, then remove together with the bracket. See Weight Table
30-116
INSTALLATION OF CONTROL VALVE ASSEMBLY l l
Carry out installation in the reverse order to removal. Bleeding air Ir Fill with oil to the specified level, then bleed the air. For details, see TESTING AND ADJUSTING, Bleeding air from all parts. * After bleeding the air, check the hydraulic tank level.
Fl
F2
F20705333
30-117
6.
DISASSEMBLY OF CONTROL VALVE ASSEMBLY *
The set pressure of the safety valve cannot be adjusted when the safety valve is installed on the machine, so do not disassemble it.
l
The following explanation control valve as the example.
1.
Main relief valve, jet sensor valve Remove main relief valve relief valve (2). (See Fl)
2.
Safety-suction
the
left
(1) and jet sensor
valve
Remove safety-suction (See Fl) 3.
uses
l
valve (3), (4), and (5).
Check valve Remove plug (6), then remove check valve (8). (See Fl)
spring
(7) and
4. L.H. travel valve 1 Remove case (9), remove retainer (lo), shim (ll), spring (12), retainer (13), spring (14), and retainer (15), then remove spool (16). 2. Remove case (17), then remove retainer (18), shim (19), spring (20), retainer (21), spring (22), and retainer (23). l This applies to the swing, R.H. travel, boom Hi (R.H. control valve), and boom Lo (L.H. control valve) spools. l Swing spool (R.H. control valve) i) Shim (11) and retainer (13) are not assembled. ii) Shim (19) and retainer (21) are not assembled. l Boom Hi (R.H. control valve) i) 2 shims (11) are assembled. ii) There is a plate installed instead of parts (17) - (23) in step 2. l Boom Lo spool (L.H. control valve) i) Shim (11) is not assembled. ii) Parts (18) - (21) in step 2 are not assembled. 5. Arm throttle valve 1. Remove plug (24) and spring (25). 2. Remove plate (26), and pull out spool (27). l For the swing priority valve (R.H. control valve), parts (24), (25), and (26) in steps
1 and 2 are installed in the opposite way.
30-118
Bucket valve
1. Remove case (28), then remove spring (29) and retainer (30), and pull out spool (31). 2. Remove case (32), then remove spring (33) and retainer (34). l This applies to the arm Lo, service (R.H. control valve), and arm Hi (L.H. control valve) spools. l Arm Lo (R.H. control valve) There is a retainer assembled between case (32) and spring (33). Arm Hi (L.H. control
valve)
Shim (35) is assembled. 7. Straight 1. Remove 2. Remove
travel valve plate (36), then plug
remove
spring
(38), then pull out spool
(37). (39).
1
205FO5909
205FO59
I C,
30-119
ASSEMBLY OF CONTROL VALVE ASSEMBLY
l
1.
Straight-travel valve 1. Assemble spool (39), then fit O-ring and install plug (38). (See Fl) 2. Fit spring (37) and install plate (36). (See Fl) 2. Bucket valve 1. Assemble spool (31), fit retainer (34) and spring (33), then fit O-ring and install case (32). (See Fl) 2. Fit retainer (30) and spring (29), then fit Oring and install case (28). (See Fl) l This applies to the arm Lo, service (R.H. control valve), and arm Hi (L.H. control valve) spools. l
Arm Lo (R.H. control
l
Assemble retainer between case (32) and spring (33). (See Fl) Arm Hi (L.H. control valve)
5.
Check valve Install check valve (8) and spring (7), then fit O-ring and install plug (6). (See Fl) u
6.
valve)
Assemble shim (35). (See Fl) valve 3. Arm throttle 1. Assemble spool (27), then fit O-ring and install plate (26). (See Fl) 2. Fit spring (25), then fit O-ring and install plug (24). (See Fl) l For the swing priority valve (R.H. control valve), parts (24), (25), and (26) in steps 1 and 2 are installed in the opposite way. (See Fl) 4. L.H. travel valve 1 Assemble spool (16), install retainer (23), spring (22), retainer (21), spring (20), shim (19), and retainer (18), then fit O-ring and install case (17). (See Fl) (15), spring (14), retainer (13), 2. Fit retainer spring (12), shim (1 l), and retainer (lo), then fit O-ring and install case (9). (See Fl) l This applies to the swing, R.H. travel, boom Hi (R.H. control valve), and boom Lo (L.H. control valve) spools. l Swing spool (R.H. control valve) i) Shim (11) and retainer (13) are not assembled. (See Fl) ii) Shim (19) and retainer (21) are not assembled. (See Fl)
30-120
l
7.
Boom Hi (R.H. control valve) i) Assemble 2 shims (11). (See Fl) ii) Install a plate instead of parts (17) - (23) in step 2. (See Fl) Boom Lo spool (L.H. control valve) i) Shim (11) is not assembled. (See Fl) ii) Parts (18) - (21) in step 2 are not assembled. (See Fl)
Plug: See Tightening Standard Values
Safety-suction
Torques Table
and
valve
Install safety-suction valve (5), (4), and (3). (See Fi) u Safety-suction valve: See Tightening Torques and Standard Values Table Jet sensor relief valve, main relief valve Install jet sensor relief valve (2) and main relief valve (1). (See Fl) u Jet sensor relief valve: See Tightening Torques and Standard Values Table m Main relief valve: See Tightening Torques and Standard Values Table
Fl
205FO5909
205FO59
IO
30-121
REMOVAL OF MAIN RELIEF VALVE ASSEMBLY
A4Y
*
DISASSEMBLY OF MAIN RELIEF VALVE ASSEMBLY
Lower the work equipment to the ground and stop the engine. Operate the control levers several times to release the remaining pressure in the hydraulic piping. Then loosen the oil filler cap slowly to release the pressure inside the hydraulic tank.
1.
Disconnect
2.
Remove R.H. control (2). (See Fl) m
valve
main relief valve
3.
Remove L.H. control (3). (See Fl) m
valve
main relief
hoses
Carry out installation removal. D
l
2. 3.
(1). (See Fl)
valve
4. 5.
6. 7.
INSTALLATION OF MAIN RELIEF VALVE ASSEMBLY l
1. Loosen
in the reverse
Main relief valve: See Tightening Standard Values After installing the main machine, adjust the set see For details, ADJUSTING, Adjusting
Remove spring (6) and poppet (7). (See F3) Remove sleeve (8), then remove seat (9), backup ring (lo), spring (1 l), and valve (12). (See F3) Remove plug (14) from sleeve (13). (See F3) Remove backup ring (15) from sleeve (13). (See F3)
order to
ASSEMBLY OF MAIN RELIEF VALVE ASSEMBLY Torques and Table relief valve on the pressure. TESTING AND main relief valve.
1.
Assemble backup ring sleeve (13). (See F3)
2.
Install plug (14) to sleeve (13). (See F3) Assemble backup ring (10) and O-ring to seat (9), then install valve (8) to sleeve (13). (See F3) Assemble poppet (7) and spring (6). (See F3) Assemble nut (5) and O-ring to holder (4), and install to sleeve (13). (See F3) * Adjust so that protrusion dimension b of the holder from the end face of the nut is the same as when it was disassembled, then secure with the nut. (See F2)
3.
4. 5.
6. 7.
30-122
nut (2), and remove plug (1). (See F3) * Before loosening the nut, measure protrusion dimension a of the plug from the end face of the nut. (See F2) Remove retainer (3) (See F3) Loosen nut (5), and remove holder (4). (See F3) * Before loosening the nut, measure protrusion dimension b of the holder from the end face of the nut. (See F2)
(15)
and
O-ring
in
Assemble retainer (3). (See F3) Assemble nut (2) and O-ring to plug (l), and install to sleeve (13). (See F3) * Adjust so that protrusion dimension a of the plug from the end face of the nut is the same as when it was disassembled, then secure with the nut. (See F2)
Fl
._
a b
205FO559:
w
’ -- -
2-g 3-9
lO-2 11--D 12-d
Q 13'-
8 14---&j
15-Q
0 0 205FO5598
30-I
23
REMOVAL OF TVC VALVE ASSEMBLY
REMOVAL OF SERVO VALVE ASSEMBLY
1.
Disconnect
1.
2.
Remove
wiring
connector
(1). (See Fl)
TVC valve assembly
(2). (See Fl) 2.
INSTALLATION ASSEMBLY l
Carry out installation removal.
OF TVC VALVE
in the reverse
1.
2.
VALVE
Remove hoses (1). (See F2) * Remove the hoses (4 hoses for front pump, 5 hoses for rear pump). Remove CO *NC valve assembly (2). (See F2) j, Remove the CO*NC valve of the front pump as an assembly with the TVC valve.
Carry out installation removal.
30-124
in the reverse
servo valve assembly
(1). (See F3)
order to
INSTALLATION OF CO.NC VALVE ASSEMBLY l
Remove
VALVE
INSTALLATION OF SERVO VALVE ASSEMBLY l
REMOVAL OF CO.NC ASSEMBLY
Remove CO*NC assembly. For details, see REMOVAL OF CO*NC ASSEMBLY.
order to
Carry out installation removal.
in the reverse
order to
F3
:1
F20505336
F2 i
\\Y@!i
30-125
REMOVAL OF WORK EQUIPMENT PPC VALVE ASSEMBLY
A4
% Y
1. 2.
Lower the work equipment to the ground and stop the engine. Operate the control levers several times to release the remaining pressure in the hydraulic piping. Then loosen the oil filler cap slowly to release the pressure inside the hydraulic tank.
3.
Plate (1). (See Fl) Seat assembly (2). (See Fl) Wiring connector (3). (See F2)
4.
Lever assembly
5.
Cover
6.
Bracket f
3. 4.
6.
(4). (See F2)
(6). (See F3)
Remove the mounting bolts, and the bracket towards the window.
move
Hoses (7). (See F3) * Disconnect 6 hoses
8.
PPC valve assembly (8). (See F3) f Remove the mounting bolts, then remove the valve assembly together with the hose.
INSTALLATION OF WORK EQUIPMENT PPC VALVE ASSEMBLY Carry out installation removal.
in the reverse
order to
m *
Fit the slide inside lever.
stopper
DISASSEMBLY EQUIPMENT ASSEMBLY 1. 2.
Disassembly of valve assembly Push retainer (16) to remove collar (15), then remove retainer (16), spring (17), and shim (18) from valve (19). (See F4)
(5). (See F2) m
7.
l
Remove piston assembly (5). (See F4) Disassembly of piston assembly Remove the following parts from piston (6). (See F4) 1 Remove collar (7), then remove dust seal (8). (See F4) 2. Remove collar (9), then remove seal (10). (See F4) 3. Remove piston (li), and spring (12). (See F4) 5. Remove valve assembly (13), then remove spring (14). (See F4)
Remove nut (See F4) Remove joint (See F4)
securely
into
the
OF WORK PPC VALVE
(l), (3),
then
remove
disc
(2).
then
remove
plate
(4).
ASSEMBLY OF WORK EQUIPMENT PPC VALVE ASSEMBLY 1.
Assembly of valve assembly Assemble shim (18), spring (17), and retainer (16) to valve (19), and push down retainer (16) to install collar (15). (See F4) spring (14) and install valve 2. Assemble assembly (13). (See F4) 3. Assembly of piston assembly Assemble the following parts to piston (6). 1. Assemble spring (12) and piston (11). (See F4) e Piston: grease (G2-LI) 2. Fit seal (10) to collar (9) and assemble. (See F4) 3. Fit dust seal (8) to collar (7) and assemble. (See F4) 4. Install piston assembly (5). (See F4) 5. Fit plate (4) and install joint (3). (See F4) u Joint:
6.
See Tightening Torques and Standard Values Table Fit disk (2) and install nut (1). (See F4) 0 Adjust the clearance between disc (2) and piston (6). see TESTING AND For details, ADJUSTING, Adjusting PPC valve for work equipment. a Nut: See Tightening Standard Values
30-126
Torques Table
and
‘\
-2
@ 2---i_ O
63 !3
/1
F20505369
F3
I
I
F20505371
205FO5493
30-127
DISASSEMBLY OF TRAVEL PPC VALVE ASSEMBLY
REMOVAL OF TRAVEL PPC VALVE ASSEMBLY Y A 4
*
Lower the work equipment to the ground and stop the engine. Operate the control levers several times to release the remaining pressure in the hydraulic piping. Then loosen the oil filler cap slowly to release the pressure inside the hydraulic tank.
1.
Disconnect
yokes
2.
Disconnect
hose (2). (See Fl)
* 3.
Disconnect
Remove (See Fl)
travel
(1). (See Fl)
1. Remove
2.
3. 4.
valve
assembly
(3).
INSTALLATION OF TRAVEL PPC VALVE ASSEMBLY
Disassembly
Carry out installation removal.
in the reverse
order to
2. 3.
4.
30-128
assembly
ASSEMBLY OF TRAVEL PPC VALVE ASSEMBLY 1. Assembly
l
of valve
Push retainer (9) to remove collar (8), then remove retainer (9), spring (lo), and shim (11) from valve (12). (See F2)
6 hoses. PPC
plate (l), then remove piston assembly (2). (See F2) Disassembly of piston assembly. Remove collar (4) from piston (3), then remove seal (5). (See F2) Remove valve assembly (6), then remove spring (7). (See F2)
of valve assembly Assemble shim (1 l), spring (lo), and retainer (9) in valve (12), then push down retainer (9) to install collar (8). (See F2) Assemble spring (7), and install valve assembly (6). (See F2) Assembly of piston assembly Assemble seal (5) to collar (4), and install to piston (3). (See F2) Assemble piston assembly (2), and install plate (1). (See F2)
Fl
-_k
5--
I
4-a
205FO5599
@
0
205FO5495
30-I 29
REMOVAL OF BOOM HOLDING VALVE ASSEMBLY
DISASSEMBLY OF BOOM HOLDING VALVE ASSEMBLY
YY
*
The set pressure of the safety valve cannot be adjusted when the safety valve is installed on the machine, so do not disassemble it.
1.
Remove safety valve assembly (1). (See F2) Remove plug (2), then remove spacer (3), spring (4), seat (5), and spool (6). (See F2)
A
4
1.
2. 3.
Lower the work equipment to the ground and release the remaining pressure in the circuit. For details, see TESTING AND Releasing pressure in ADJUSTING, hydraulic circuit for machines with PPC valve. Disconnect hoses (1). (See Fl) Disconnect tubes (2). (See Fl) Remove boom holding valve assembly (See Fl)
2. 3.
Remove body (7), then remove spring check valve (9). (See F2)
(8) and
(3).
INSTALLATION OF BOOM HOLDING VALVE ASSEMBLY
ASSEMBLY OF BOOM HOLDING VALVE ASSEMBLY 1. Assemble
l l
Carry out installation in the reverse order to removal. Refilling with oil * Refill to the specified level, and run the engine to circulate the oil through the system. Then check the oil level again.
30-I 30
check valve (9) and spring (a), then fit O-ring and install body (7). (See F2) u Mounting bolt: See Tightening Torques and Standard Values Table
2.
Fit seat (5) to spool (6) and insert in body (7), then install spring (4), spacer (3), plug (2) and O-ring. (See F2) u Plug: See Tightening Torques and Standard Values Table
3.
Fit O-ring and install safety valve (See F2) m Safety valve: See Tightening Torques Standard Values Table
(1).
and
Fl
205FO5900
1
205FO5497
1
30-131
REMOVAL OF PPC SHUTTLE VALVE ASSEMBLY
A4 Y
Y
INSTALLATION OF PPC SHUTTLE VALVE ASSEMBLY
Lower the work equipment to the ground and stop the engine. Operate the control levers several times to release the remaining pressure in the hydraulic piping. Then loosen the oil filler cap slowly to release the pressure inside the hydraulic tank.
1. Arm PPC shuttle valve assembly 1. Disconnect hoses (1). (See Fl) * Disconnect 2 hoses at the front, hoses at the rear.
and 3
2. Remove arm PPC shuttle valve assembly (See Fl) 2. Swing PPC shuttle valve assembly 1. Disconnect hoses (3). (See Fl) -k
2. 3. 3. 1.
2. 4. 1.
2. 3.
(2).
Disconnect 2 hoses at the front, and 3 hoses at the rear. Remove pressure switch (4). (See Fl) Remove swing PPC shuttle valve assembly (5). (See Fl) Boom, bucket PPC shuttle valve assembly Disconnect hoses (6). (See Fl) * Disconnect 4 hoses at the front, and 5 hoses at the rear. Remove boom, bucket PPC shuttle valve assembly (7). (See Fl) Travel PPC shuttle valve assembly Disconnect hoses (8). (See Fl) f Disconnect 4 hoses at the front, and 4 hoses at the rear. Remove pressure switch (9). (See Fl) Remove travel PPC shuttle valve assembly (10). (See Fl)
30-132
l
Carry out installation removal.
in the reverse
order to
Fl
I
1
2
3
6
8
205FO5901
30-133
INSTALLATION OF BOOM CYLINDER ASSEMBLY
REMOVAL OF BOOM CYLINDER ASSEMBLY
A 1.
Extend the arm and bucket fully, lower the work equipment to the ground, and operate the control levers 2 or the times. Disconnect hose (1). (See F2)
2.
Remove
3.
Remove pin (3). (See F2) w] * Sling the boom cylinder remove the pin.
A *A
l
m RI assembly,
5.
6.
Release the remaining pressure in the circuit. For details, see TESTING AND 4 ADJUSTING, Releasing pressure in hydraulic circuit for machines with PPC valve. Disconnect hose (4). (See F3)
Remove pin (5). (See F4) m wj * Sling the boom cylinder assembly, then use forcing screws @ to remove the pin. Remove cylinder assembly (6). (See F4)
*
Adjust with shims so that the clearance between cylinder rod (7) and plate (8) is less than lmm. (See F5)
*
Adjust with shims so that the clearance between cylinder bottom (9) and bracket (10) is less than 1 mm. (See F6)
XI& *
Table
Inside surface of bushing: For grease, use MPG.
LM-P
Bleeding air f Bleed the air from the cylinder. TESTING AND For details, see ADJUSTING, Bleeding air from hydraulic cylinder. f
34
the and
When aligning the position of the pin hole, run the engine at low idling. Never insert your fingers in the pin hole.
l
30-I
order to
and
Start the engine, and retract the rod of the boom cylinder, tie the rod with wire to prevent it from coming out, then lower it onto the block.
See Weight
in the reverse
Tighten with the locknut so that clearance between the boom boss nut is 0.5 - 1.5 mm. (See F5)
lock bolt (2). (See F2) m
Y
4.
Carry out installation removal.
After bleeding cylinder, check hydraulic tank.
the air from hydraulic the level of the oil in the
Fl I
7
F5
mm
\
I
205FO5499
9
1
F20705344
F6
F2
_
Max. 1 mm
\ F20505332
10
F20705345
F3
F20505333
F4 I
-1 0.5 -
1.5 mm
30-I 35
REMOVAL OF ARM CYLINDER ASSEMBLY
A
Set block @ between the arm and the boom, then extend the arm fully, lower the work equipment to the ground, and operate the control levers 2 or 3 times.
*
Sling the arm cylinder
1.
Remove
A
INSTALLATION OF ARM CYLINDER ASSEMBLY l
assembly.
Carry out installation removal.
in the reverse
order to
When aligning the position of the pin hole, run the engine at low idling. Never insert your fingers in the pin hole.
pin (1): (See Fl) mm] Start the engine, and retract the rod of the arm cylinder, then tie the rod with wire to prevent it from coming out.
Adjust with shims so that the clearance between cylinder bottom (6) and bracket (7) is less than 1 mm. (See F2)
YY
2. 3. 4.
Release the remaining pressure in the circuit. For details, see TESTING AND 4 ADJUSTING, Releasing pressure in hydraulic circuit for machines with PPC valve. Disconnect hose (2). (See Fl) Disconnect hose (3). (See Fl) Remove pin (4). (See Fl) mm\
5.
Remove
A
el kg
arm cylinder
See Weight
30-136
Table
assembly
(5). (See Fl)
Inside
surface
For grease, l
of bushing:
LM-P
use MPG.
Bleeding air Bleed the air from the cylinder. * see TESTING AND For details, ADJUSTING, Bleeding air from hydraulic cylinder. After bleeding the air from hydraulic * cylinder, check the level of the oil in the hydraulic tank.
Fl
I
F20505334
F2
30-I
37
REMOVALOF ASSEMBLY
A A
INSTALLATION OF BUCKET CYLINDER ASSEMBLY
BUCKETCYLINDER
Extend the arm and bucket fully, lower the work equipment to the ground, and operate the control levers 2 or three times. Set block @ between the link and arm and sling the bucket cylinder assembly.
1.
Remove
lock bolt (1). (See Fl) m
2.
Remove
pin (2). (See Fl) m
A Y A 4
%
mj
f
5.
Remove (See Fl)
bucket
See Weight
cylinder Table
assembly
in the reverse
order to
Tighten with the locknut so that the clearance between the link boss and nut is 0.5 - 1.5 mm. (See F2)
m
A
Release the remaining pressure in the circuit. For details, see TESTING AND ADJUSTING, Releasing pressure in hydraulic circuit for machines with PPC valve.
Disconnect hose (3). (See Fl) Remove pin (4). (See Fl) mm1
Carry out installation removal.
m
Start the engine, and retract the rod of the bucket cylinder, then tie the rod with wire to prevent it from coming out.
3. 4.
30-138
m
l
-k
Adjust the shims so that the clearance between link (6) and link (7) is less than 1 mm. (See F3)
-k
Adjust with shims so that the clearance between cylinder bottom (8) and bracket (9) is less than 1 mm. (See F4)
&&, (5).
* l
When aligning the position of the pin hole, run the engine at low idling. Never insert your fingers in the pin hole.
Inside surface of bushing: For grease, use MPG.
LM-P
Bleeding air * Bleed the air from the cylinder. TESTING AND details, see For ADJUSTING, Bleeding air from hydraulic cylinder. * After bleeding the air from hydraulic cylinder, check the level of the oil in the hydraulic tank.
Fl
‘2050533!
5
F2
----k-I 0.5 - 1.5 mm
2OSF6065
F3
F4 _
Max. 1 mm
9
F20705348
30-I 39
DISASSEMBLY OF HYDRAULIC CYLINDER ASSEM BLY 1. Cylinder assembly 1. Remove mounting bolts, and disconnect head assembly (1). (See Fl) 2. Pull out piston rod assembly (2). (See Fl) * Put and oil pan or container under the cylinder to catch the oil. 2. Piston rod assembly 1. Remove mounting bolts, then remove spacer (3). (See F2) 2. Remove piston assembly (4). (See F2) 3. Remove plunger (5). (See F2) l Plunger (5) is for the boom and arm cylinders only. 4. Remove collar assembly (6). (See F2) l Collar assembly (6) is for the boom and arm cylinders only. 5. Remove head assembly (7). (See F2) 6. Remove screw (8), then take out balls (9) (Qty 11 for PC3OOLC, 12 for PC400LC), then remove plunger (10). (See F3) l Plunger (10) is for the arm cylinder only. 7. Remove O-ring and backup ring (11). (See F3)
3. 1. 2. 3.
Disassembly of piston assembly Remove Remove Remove
30-140
ring (12). (See F4) wear ring (13). (See F4) piston ring (14). (See F4)
4.
Disassembly of collar assembly
Disassembly of the collar assembly is for the boom and arm cylinders only. 1. Remove O-ring and backup ring (15). (See F5) 2. Remove collar (17) and ring (18) from collar (16). (See F5) l
5.
Disassembly of cylinder head assembly
1. Remove (See F6)
O-ring
and
2. Remove snap ring seal (21). (See F6)
(20),
backup then
ring remove
3. Remove 4. Remove
rod packing (22). (See F6) buffer ring (23). (See F6)
5. Remove
bushing
(24). (See F6)
(19). dust
Fl
F5
202FO546
5
4
I
205FOE.904
5 19
21
24
23 22
7 205FO5902
202FO5486
F3
i
2OSFO5903
202FO5485
30-141
ASSEMBLY OF HYDRAULIC CYLINDER ASSEMBLY * f
Be careful not seals or O-rings Do not try to position. Warm before fitting it.
to damage packings, dust when installing. force the backup ring into it in warm water (50 - 60°C)
1. Assembly of head assembly 1. Press fit bushing 2. Assemble buffer 3. Assemble 4. Assemble snap ring 5. Assemble (See Fl) 2. Assembly 1. Assemble (16). (See 2. Assemble (See F2)
(24). (See Fl) ring (23). (See Fl)
rod packing (22). (See Fl) dust seal (21), and secure (20). (See Fl) O-ring and backup ring
with (19).
4. Piston rod assembly 1. Assemble O-ring and backup ring (11). (See F5) 2. Set plunger (10) to piston rod, and assemble 12 balls (9) (11 balls on 6400LC) and tighten screw (8). (See F5) u Screw: See Tightening Torques and Standard Values Table * After tightening the screw to the specified torque, stake it with center punch. *
Check that there is a small play at the tip of the plunger.
l
Plunger
3. Assemble 4. Assemble
(10) is for the arm cylinder head assembly collar assembly
of
only.
(7). (See F6) (6). (See F6)
Collar assembly (6) for boom and arm cylinders only. 5. Assemble plunger (5). (See F6) l Plunger (5) is for the boom and arm cylinders only. 6. Assemble piston (4). (See F6) 7. Fit spacer (3) and tighten with mounting bolts. (See F6) 5. Cylinder assembly 1. Assemble piston rod assembly (2). (See F7) & Seal: Grease (G2-LI) -k Set the end gap of the ring in a horizontal (sideways) position, align it with the center of the axis of the cylinder, then insert. (See F7) * After inserting, check that the rings are not broken of missing, then insert fully. 2. Tighten head assembly (1) with mounting bolts. (See F9) u Mounting bolt: l
of collar assembly ring (18) and collar (17) to collar F2) O-ring and backup ring (15).
3. Assembly of piston assembly piston ring (14). 1. Using tool E,, expand (See F3) * Set the piston ring on tool E, and turn the handle 8 - 10 times to expand the ring. 2. Set tool E, in position, and compress piston ring (14). (See F4) 3. Assemble wear ring (13). (See F4) 4. Assemble ring (12). (See F4) * Be careful not to open the end gap of the ring too far. & Ring groove: Grease (G2-LI)
See Tightening Standard Values
30-142
amount
Torques Table
and
F5
Fl
24 19 23 21 22
9
202FO5486
205FO5906
F6
F2
7
6
5 205FO5907
205FO.5905
F3 E:2
.
14.
End gaps of rings
202FO541
38 /
I
205FO5908
F4
I
202FO5485
202FO548
I
INSTALLATION OF WORK EQUIPMENT ASSEMBLY
REMOVAL OF WORK EQUIPMENT ASSEMBLY
A 1.
Extend the arm and bucket fully, lower the work equipment to the ground, and operate the control levers 2 or 3 times.
2.
Disconnect hose (l), (See Fl) Remove lock bolt (2). (See Fl) m
3.
Remove *
pin (3). (See Fl) 1m
Sling the boom remove the pin
A
cylinder
ml
l
Carry out installation removal.
order to
m *
Ml
assembly
in the reverse
and m
Start the engine and retract the boom cylinder rod fully, then tie the rod with wire to prevent it from coming out, and lower it onto the block.
Disconnect the boom cylinder on the opposite side in the same way. % Y Release the remaining pressure in the circuit. For details, see TESTING AND ADJUSTING, Releasing pressure in the hydraulic circuit for machines with PPC valve. Disconnect hose (4). (See F2)
When tightening the locknut, tighten so that the clearance between the boss of the boom and the nut is “0.5 - 1.5 mm”. (See F5)
A
When aligning the position of the pin hole, run the engine at low idling. Never insert your fingers in the pin hole.
*
Adjust with shims so that the clearance between cylinder rod (8) and plate (9) is less than 1 mm. (See F6)
A 4
4. 5. 6.
7.
Adjust with shims so that the clearance between boom (10) and bracket (11) is less than 1 mm. (See F7)
Disconnect wiring (5). (See F2) Remove pin (6). (See F3) m ml * Sling work equipment assembly (7), then using tool F, remove the pin (See F3) Remove work equipment assembly (7). (See F4) See Weight
30-144
Table
Inside surface of bushing: For grease, use MPG. l
LM-P
Bleeding air f Bleed the air from the cylinder. For details, see TESTING AND ADJUSTING, Bleeding air from hydraulic cylinder. -k After bleeding the air from the cylinder, check the level of the hydraulic tank.
Fl
1
\
0.5 - 1.5 mm 2OSF6065
205FO5499
F6
8
9 F20705349
205FO5500
F7 Max. 1 mm
I
11 205FO5501
10 F20705350
30-145
REMOVAL OF BUCKET ASSEMBLY
REMOVAL 1.
A
Set the back of the bucket facing down, lower the work equipment to the ground, and operate the control levers 2 or 3 times.
1.
Remove
lock bolt (1). (See Fl) m
2.
Remove
plate
3.
Remove
pin (3). (See Fl) m
4.
Remove
lock plate (4) (See Fl) m
5.
Remove
pin (5) (See Fl) m
6.
Remove bucket assembly (6). (See Fl) * Raise the work equipment and disconnect the arm from the bucket.
-k
Sling the arm cylinder assembly, and remove the pin. Start the engine, and retract the rod of the arm cylinder, then tie the rod with wire to prevent it from coming out. * Y Release the remaining pressure in the circuit. For details, see TESTING AND ADJUSTING, Releasing pressure in hydraulic circuit for machines with PPC valve.
A A 4
in the reverse
order to
Tighten with the locknut so that the clearance between the bucket boss and nut is 0.5 - 1.5 mm. (See F2) Adjust the shim thickness so that the clearance between bucket boss (7) and spacer (8) is 2 mm. (See F3)
3. 4.
Disconnect hose (2). (See F4) Remove pin (3) (See F4) m mj
5.
Remove arm assembly (4). (See F4) * Raise the boom and disconnect the boom from the arm.
el kg
l
surface
For grease,
of bushing:
See Weight
Table
INSTALLATION ASSEMBLY
When aligning the position of the pin hole, run the engine at low idling. Never insert your fingers in the pin hole.
Inside
OF BUCKET
Work equipment set j, Secure the bucket cylinder assembly to the arm, pull in the arm, and lower it onto block 0. (See F4) mj mj
OF BUCKET
Carry out installation removal.
assembly
Remove bucket assembly For details, see REMOVAL ASSEMBLY.
2.
Table
INSTALLATION ASSEMBLY l
l
(2). (See Fl) m
See Weight
Bucket
OF ARM ASSEMBLY
Carry out installation removal.
OF ARM
in the reverse
order to
When aligning the position of the pin hole, run the engine at low idling. Never insert your fingers in the pin hole.
LM-P
use MPG. Adjust with shims so that the clearance between boom (5) and arm (6) is less than 1 mm. (See F5)
Inside surface of bushing: For grease, use MPG. 0
Bleeding air * Bleed the air from details, see TESTING Bleeding air. *
30-146
LM-P
the cylinder. For AND ADJUSTING,
After bleeding the air from the cylinder, check the level of the hydraulic tank.
F
F20505338
F20505336
1
F5 Max. 1 mm
.
0.5 - 1.5 mm
2OSF6065
i-
7
Clearance
I
8
I
6
5
F20705351
Shim
2 wmm II F20505337
30-147
INSTALLATION OF ARM, BUCKET ASSEMBLY
REMOVAL OF ARM, BUCKET ASSEMBLY
A 1.
Extend the arm and bucket fully, lower the work equipment to the ground, and operate the control levers 2 or 3 times.
Remove f
l
pin (1) (See Fl) mjm
Disconnect hose (2). (See F2) Remove pin (3). (See F2) m mj *
4.
Sling the arm and bucket assembly, remove the pin. Remove arm and bucket assembly (4). See Weight
30-148
Table
Inside
surface
For grease, l
then
order to
Adjust with shims so that the clearance between boom (5) and arm (6) is less than 1 mm. (See F3)
4
2. 3.
in the reverse
When aligning the position of the pin hole, run the engine at low idling. Never insert your fingers in the pin hole.
Set block @ between the arm and the boom, then sling the arm cylinder assembly, and remove the pin. (See Fl) Start the engine, and retract the rod of the arm cylinder, then tie the rod with wire to prevent it from coming out. Y Release the remaining pressure in the circuit. For details, see TESTING AND ADJUSTING, Releasing pressure in hydraulic circuit for machines with PPC valve.
A 3L
Carry out installation removal.
of bushing:
LM-P
use MPG.
Bleeding air Bleed the air from * details, see TESTING Bleeding air. After bleeding the air * check the level of the
the cylinder. For AND ADJUSTING, from the cylinder, hydraulic tank.
I
F20505339
1
F2
F20505340
F3 Max. 1 mm ~
I
\
5
F20705351
30-149
REMOVAL 1.
OF BOOM ASSEMBLY
2.
Arm and bucket assembly l Remove arm and bucket assembly. Disconnect hose (1). (See Fl)
3.
Remove
lock bolt (2). (See Fl) m
4.
Remove
pin (3). (See Fl) mj
*
m
INSTALLATION ASSEMBLY l
m
5. 6.
Disconnect Disconnect
7.
Remove *
6.
the and
Adjust with shims so that the clearance between the cylinder rod (8) and plate (9) is less than 1 mm. (See F6)
hose (4). (See F2) wiring (5). (See F2)
Adjust with shims so that the clearance between boom (10) and bracket (11) is less than 1 mm. (See F7)
pin (6). (See F3) mm[
Sling the boom assembly, then use tool F to remove the pin. (See F3)
Remove
& kg
order to
When aligning the position of the pin hole, run the engine at low idling. Never insert your fingers in the pin hole.
A 4
Y
in the reverse
Tighten with the locknut so that clearance between the boom boss nut is 0.5 - 1.5 mm. (See F5)
Sling the boom cylinder assembly, and remove the pin. Start the engine, and retract the rod of the boom cylinder, then tie the rod with wire to prevent it from coming out, then lower it onto the block. Disconnect the boom cylinder assembly on the opposite side in the same way. Y Release the remaining pressure in the circuit. For details, see TESTING AND ADJUSTING, Releasing pressure in hydraulic circuit for machines with PPC valve.
A *
Carry out installation removal.
OF BOOM
assembly
See Weight
(7). (See F4)
Inside surface of bushing: For grease, use MPG.
Table l
30-150
Bleeding air * Bleed the air from details, see TESTING Bleeding air. * After bleeding the air check the level of the
LM-P
the cylinder. For AND ADJUSTING, from the cylinder, hydraulic tank.
Fl I
F5
--4---I \
0.5 - 1.5 mm
205FO5499
F2
2OSF6065
F6
205FO5500
F20705349
F7
F3
Max. 1 mm
11 205FO5501
F4 I
1
10 F20705350
I
F20505341
30-151
REMOVAL OF OPERATOR’S CAB ASSEMBLY
REMOVAL OF COUNTERWEIGHT
1.
1. Remove counterweight (1). (See F4) m * Sling the counterweight, then remove the mounting bolts. * Width across the flats of bolt: 45mm (PCBOOLC) 65mm (PC4OOLC)
Remove seat assembly (1). (See Fl)
See Weight Table 6 kg 2. Disconnect wiper motor wiring (2). (See Fl) 3. Disconnect antenna wiring (3). (See F2) 4. Disconnect room lamp wiring (4). (See F2) 5. Disconnect ground connection (5). (See F2) 6. Remove instrument panel assembly (6) (See F2) * Remove the cover, then loosen the mounting bolts, and move the instrument panel assembly towards the inside. 7. Remove cab assembly (7). (See F3) kg r5zl
See Weight Table
el kg
See Weight Table
INSTALLATION OF COUNTERWEIGHT l
Carry out installation removal.
in the reverse order to
m
INSTALLATION OF OPERATOR’S CAB ASSEMBLY l
Carry out installation removal.
30-152
in the reverse order to
u
Mounting bolt: See Tightening Torques and Standard Values Table
Fl
‘1
c
2
Y
\
/
L
F20505372
\ /
/.....--yy-+\
1
‘\ F20505342
_J
F2
205FO5504
30-I 53
REMOVAL OF ENGINE THROTTLE CONTROLLER 1.
Pump controller
2.
REMOVAL For details, see CONTROLLER ASSEMBLY. Wiring connector (1). (See Fl)
assembly.
1.
*
3. 4. 5.
REMOVAL OF MONITOR PANEL ASSEMBLY
Disconnect the connector clamp. Bracket (2). (See Fl)
OF
from the wiring
Wiring connector (3). (See Fl) Bracket (4). (See Fl) *
6.
Remove the mounting bolts, and the bracket toward the inside. Engine throttle controller assembly (See F2)
move
Carry out installation removal.
in the reverse
order to
REMOVAL OF PUMP CONTROLLER ASSEMBLY 1.
2.
Box assembly (1). (See F3) * Disconnect the antenna wiring of the radio, the wiring connectors, and the ground connection, then remove together with the radio. Wiring connector (2). (See F4)
3.
Pump controller
INSTALLATION CONTROLLER l
assembly
30-154
(3). (See F4)
OF PUMP ASSEMBLY
Carry out installation removal.
in the reverse
3.
Monitor
panel assembly
(3). (See F5)
INSTALLATION OF MONITOR PANEL ASSEMBLY
(5).
INSTALLATION OF ENGINE THROTTLE CONTROLLER l
2.
Screws (1). (See F5) * Remove 4 screws, and move the monitor panel assembly upward. Wiring connector (2). (See F5)
PUMP
order to
l
Carry out installation removal.
in the reverse
order to
rI
./
-5 I
F20505373
F20505377
F2
F20505374
F4
30-155
PROCEDURE
FOR FLUSHING
HYDRAULIC
CIRCUIT
PC3OOLC *
When carrying out flushing to remove dirt in the hydraulic circuit, use the following procedure. one of the patterns below to match the level of contamination in the hydraulic circuit.
No. ,
Flushing pattern
level
Hydraulic equipment is broken; metal particles in the circuit
Parts in the circuit have been disassembled and assembled (there are no metal particles in the circuit)
3
Periodic
4
After assembly at job site following disassembly and transportation
3
Extension circuit
hose for PPC
7
Extension circuit
nipple
*
to these,
For details,
30-I 56
B
flushing
Parts to prepare * The figures in the table
In addition
A
there are
2
1.
l
Contamination
below
for PPC
a stopper
see “Installation
C
show the number
of parts required.
07102-20340
5
5
-
21T_04_1 158O
3
S
_
is also needed of filter
as a blind
element”.
plug for the hydraulic
tank filter
case.
Select
2.
Order of operations The following explanation describes the procedure for short-circuiting the piping, installation of the filter element, cleaning of the cylinder, and flushing of the PPC circuit that is carried out in the operation for each flushing pattern.
the piping 1 Short-circuiting Using the piping short-circuiting
Position
Attachment
1 2
(E) and (P)
I
I
Arm
(G) and U-0
short-circuit
Part No.
Con~~~~ons
Boom I
flange,
CYty
07377-01018 I
2 I
1 (C) and (D) 107377-01018
Bucket
(A) and (B)
07377-01018
1
4
Swing
(I) and (J)
07377-01018
1
I
Travel
(K) and (L) 07377-01018 I (2 places) I
piping.
Method for short-circuiting piping The whole hydraulic circuit, including the hoses and tubes, is flushed, so short-circuit the supply and return pipes in the circuit. I
1 1
3
5
the following
I
2
Flange
F20505378
F20705337
30-157
2.
Installation
of filter
element
Plate22 RelieZlI Small strainer-9 0
Flashing element (Install)
.-:..
*.*
4
O-ring -----+
Strainer (Clean) /
F20705338
*
When removing the element from the return filter, use the stopper to prevent the dirt inside the filter case from entering the tank. l Inside diameter of hole: 53mm
*
When parts have been removed for shortcircuiting, clean the individual parts and blow with air, then mask with tape to prevent dirt from entering, and store in a safe place until assembling again. When replacing the pilot filter, always use the special tool. For details, see TESTING AND ADJUSTING.
*
30-158
LJ
F2070533
3. Cleaning cylinder f Disassemble all cylinders i)
Remove cylinder piston rod
and clean them
head, then
pull out
F20505382
ii)
Fix cylinder at an angle, then use a pump to clean with flushing fluid. *
If no pump is available, use a crane, collect the flushing fluid at the bottom end, shake well, then drain the flushing fluid, and blow with air.
Pump
Cylinder \
F20505383
iii)
Apply flushing fluid to the cylinder head and piston and brush well with a nylon brush, then blow with air. f Dirt is likely to collect particularly in the insert portions, so clean these parts well. iv) Check inside of cylinder for damage. l l
;
*
Any verticle scratches in cylinder Any breakage or seizure of wear rings, piston rings, or guard ring Scratches on piston If there is any scuffing of the piston or cylinder, replace the assembly. If only the wear ring, piston ring, or guard ring are damaged, replace the damaged part with a new part, and use again.
Rod
Piston \
Piston \
ring Wear I
ring
Guard
ring
Space1
I//
..
F2070534C
30-I 59
4. Flushing
PPC circuit Disconnect PPC hose from main valve, then fit blind plug in main valve
It is not necessary to remove noses for port P and port T. /
Port P
Use nipple to connect hose -
_ Using extension hose, return PPC circuit hose directly to hydraulic filter
1
Replace element and clean small strainer
\
Hydraulic tank
F20505386
i)
Disconnect PPC circuit hose from main valve, and return directly to hydraulic tank filter case * The ARM IN PPC circuit hoses are connected to both the 4-spool and 5-spool main valves, so disconnect from both main valves, and return to the hydraulic tank. *
30-160
Carry out the PPC valve.
operation
for one
ii)
Run the engine at high idling, operate the control lever in each direction and hold it for 2 minutes in each position.
iii)
Repeat the procedure at least 5 times.
iv)
Carry out the procedure 4 . . . . i), 4 . . . . ii), and 4 . . . . iii) circuit.
in Step 4....ii) in Steps for each
3.
Flushing pattern [A]
iii)
1. Disassembly, cleaning, and reassembly i) Failed parts f If the part is badly damaged, replace it. ii) Hydraulic tank iii) Suction strainer iv) Oil cooler Ir If excessive amounts of dirt and dust are stuck in the core, replace. v) Cylinder *
For details, see cylinder”. vi) Other hydraulic equipment 2. Preparatory work for flushing
“Cleaning
Install the flushing element, clean the small strainer, then install it again. Replace the pilot filter with a new part. * For details, see “Installing filter element”. ii) Short-circuit the cylinder circuit, swing motor circuit, and travel motor circuit. * For details, see “Short-circuiting the piping”. oil to the specified iii) Add hydraulic level. iv) Bleed the air from the main pump. 3. Flushing cylinder circuit, swing motor circuit, travel motor circuit i) Run the engine at low idling for 30 minutes. -k The control levers must not be moved during this time. ii) Run the engine at midrange speed for 30 minutes. * The control levers must not be moved during this time. * If the oil temperature is low, increase the length of the operation in Steps 3....i), and 3....ii) to raise the temperature. The oil temperature should be 50 - 80°C.
i)
Run the engine at high idling and carry out the following operation. l Operating pattern Boom RAISE - Boom LOWER Arm IN - Arm OUT - Bucket CURL 4 Bucket DUMP - Right swing - Left swing - Left travel Right travel l Operating time Hold the lever in each position for two minutes. l Number of times of operation
4. Restoring
Repeat the above pattern at least 5 times. cylinder circuit. swina motor circuit
i)
Restore the cylinder &it and swing motor circuit to the standard circuit. * Keep the travel motor circuit short-circuited. ii) Add hydraulic oil to the specified level. iii) Bleed the air from the main pump, cylinders, and swing motor. 5. Flushing center swivel joint i) Run the engine at high idling and carry out the following operation. 0 Operating patternLeft and right FORWARD + 90” swing Left and right REVERSE + 90” swing Swing 90’ to either the left or * right, but swing in the same direction each time. l Operating time Hold the lever in each position for 2 minutes 0 Number of times of operation Repeat the above’pattern 4 times, and rotate the swing one turn. *
The purpose of swinging 90” each is to remove dirt inside the center swivel from the oil grooves on the rotor side and shaft side around the whole circumference.
30-161
6. Restoring the travel circuit i) Restore the travel standard circuit. ii)
Replace the flushing new part. j, For details, see element”.
circuit
to
element
with
“Installing
iii) Bleed the air from the travel 7. Flushing PPC circuit. i) Flush the PPC circuit
the a
filter
motor.
*
For details, see “Flushing PPC circuit”. 8. Restoring PPC circuit i) Restore the PPC circuit to the standard circuit. 9. Flushing during actual operation i) With the flushing element installed, carry out normal operations for 10 20 hours * If the oil temperature is low, carry out the warming-up operation. 10. Replacing element i) Replace the return filter with a standard element, clean the small strainer and install it again. Replace the pilot filter with a new part. * For details, see “Installing filter element”. ii) Add hydraulic oil to the specified level. iii) Bleed the air from the main pump.
30-162
4. Flushing pattern [B] 1. Preparatory work for flushing Install the flushing element, clean strainer and install it again. * For details, see “Installing 2. Flushing PPC circuit
the small
filter element”.
Flush the PPC circuit. * For details, see “Flushing PPC circuit”. 3. Restoring PPC circuit Restore the PPC circuit to the standard circuit. 4. Flushing during actual operation With the flushing element installed, carry out normal operations for 10 - 20 hours. *
If the oil temperature is low, carry out the warming-up operation.
5. Replacing element Replace the return filter with a standard element, clean the small strainer and install it again. Replace the pilot filter with a new part. _k For details, see “Installing filter element”.
5.
Flushing pattern [C] * If the cylinder piping
is connected and the cylinder is operated before the system is flushed, there is danger that the dirt that entered during assembly operations will be circulated inside the cylinder. Therefore, do not wait until completion of assembly to flush the out flushing before carry system; connecting the piping to the cylinder.
1. Preparatory i)
ii)
work for flushing
Short-circuit the cylinder circuit. -k For details, see “Short-circuiting the piping”. Install the flushing element, clean the small strainer and install it again. * For details, see “Installing filter element”.
4. Flushing
during actual operation With the flushing element installed, carry out normal operations for 10 20 hours. If the oil temperature is low, carry out the warming-up operation. i)
*
5. Replacing element Replace the return filter with a standard element, clean the small strainer and install it again. Replace the pilot filter with a new part. *
For details,
see “Installing oil
to
filter
element”.
the
specified
i)
Add hydraulic level.
ii)
Bleed the air from the main pump.
2. Flushing i) Run the engine at low idling for 30 minutes. * The control levers must not be moved during this time. ii) Run the engine at midrange speed for 30 minutes. * The control levers must not be moved during this time. iii) Run the engine at high idling and carry out the following operation. l Operating pattern Boom RAISE - Boom LOWER Arm IN - Arm OUT - Bucket CURL - Bucket DUMP l Operating time Hold the lever in each position for two minutes. 0 Number of times of operation Repeat the above pattern at least 5 times. 3. Restoring cylinder circuit 0 Restore the cylinder circuit to the standard circuit. oil to the specified ii) Add hydraulic level. iii) Bleed the air from the main pump and cylinders.
30-163
PROCEDURE
FOR FLUSHING
HYDRAULIC
CIRCUIT
PC4OOLC *
When carrying out flushing to remove dirt in the hydraulic circuit, use the following procedure. one of the patterns below to match the level of contamination in the hydraulic circuit.
No. ~~
I
,
Contamination
Hydraulic
equipment
I
Flushing pattern
level
is broken;
Select
there are
A
* 2 I
disassembled and assembled (there are no metal particles in the circuit)
3
/Periodic
4
After assembly at job site following and transportation Idisassembly
B
flushina C
I
1. Parts to prepare * The figures in the table below show the number
l
In addition *
30-I 64
to these,
For details,
a stopper
see “Installation
is also needed of filter
of parts required.
as a blind
element”.
plug for the hydraulic
tank filter
case.
2.
Order of operations The following explanation describes the procedure for short-circuiting the piping, installation of the filter element, cleaning of the cylinder, and flushing of the PPC circuit that is carried out in the operation for each flushing pattern. 1. Short-circuiting the piping Using the piping short-circuiting flange, short-circuit the following piping. Method
Position
Attachment
con~~$ons
Part No.
Q’ty
2
Arm
(E) and (P) (C) and (H) (C) and (D)
07377-01018
1
3
Bucket
(A) and (B)
07377-01018
1
4
Swina
(I) . , and (J) . .
07377-01018
1
5
Travel
(K) and (L) (2 places)
07377-01018
2
1
Boom
07377-01018
2
for short-circuiting
The whole hydraulic circuit, including the hoses and tubes, is flushed, so short-circuit the supply and return pipes in the circuit.
Flange
C
piping
F20505378
D
F20705341
30-I
65
2. Installation
of filter
element Plate& Spring Relief valve
Small strainer-3 0
.:::.
Flashing element (Install) 4 O-ring-----d?
1 /
*
*
*
30-166
When removing the element from the return filter, use the stopper to prevent the dirt inside the filter case from entering the tank. l Inside diameter of hole: 53mm When parts have been removed for shortcircuiting, clean the individual parts and blow with air, then mask with tape to prevent dirt from entering, and store in a safe place until assembling again.
When replacing the pilot filter, always use the special tool. For details, see TESTING AND ADJUSTING.
Strainer (Clean)
3. Cleaning cylinder * Disassemble all cylinders
0
Remove cylinder piston rod.
and clean them.
head, then
pull out
Cylinder I
Rod \
Head I
F20505382
ii)
Fix cylinder at an angle, then use a pump to clean with flushing fluid. *
If no pump is available, use a crane, collect the flushing fluid at the bottom end, shake well, then drain the flushing fluid, and blow with air.
F20505383
iii)
Apply flushing fluid to the cylinder head and piston and brush well with a nylon brush, then blow with air. j, Dirt is likely to collect particularly in the insert portions, so clean these parts well. iv) Check inside of cylinder for damage. l Any verticle scratches in cylinder l Any breakage or seizure of wear rings, piston rings, or guard ring l Scratches on piston * If there is any scuffing of the piston or cylinder, replace the assembly. f If only the wear ring, piston ring, or guard ring are damaged, replace the damaged part with a new part, and use again.
Rod
Piston
Piston
ring Wear
ring Guard
ring Spacer
F20705340
30-167
4. Flushing
PPC circuit
It is not necessary to remove noses for sort P and Prt T.
Disconnecti PPC hose from main valve, then fit ^I..^ :- ..,.“:.. .,.
From charg pump -
Main valve
nioDle . . to connect hose -
/
Using extension hose, return PPC circuit hose directly to hydraulic filter case
nnnn
Replace element and clean small strainer
F20505386
0
*
*
30-168
hose from directly to
ii)
Run the engine at high idling, operate the control lever in each direction and hold it for 2 minutes in each position.
The ARM IN PPC circuit hoses are connected to both the 4-spool and 5spool main valves, so disconnect from both main valves, and return to the hydraulic tank. Carry out the operation for one PPC valve.
iii)
Repeat the procedure at least 5 times.
iv)
Carry out the procedure 4 . . . . i), 4 . . . . ii), and 4....iii) circuit.
Disconnect PPC circuit main valve, and return hydraulic tank filter case
in Step 4....ii) in Steps for each
3. Flushing pattern [A] 1. Disassembly, cleaning, i)
ii) iii) iv)
v)
Failed parts jlr If the part replace it. Hydraulic tank Suction strainer
iii) and reassembly is
badly
Oil cooler * If excessive amounts dust are stuck in replace.
of dirt and the core,
For details, cylinder”.
see
iii)
Operating pattern Boom RAISE - Boom LOWER Arm IN - Arm OUT - Bucket DUMP - Right CURL - Bucket swing - Left swing 4 Left travel Right travel
*
For loader specification machines, continue the above operating pattern as follows: Bottom dump OPEN - Bottom dump CLOSE.
0
Operating time Hold the lever in each position two minutes. Number of times of operation
“Cleaning
vi) Other hydraulic equipment 2. Preparatory work for flushing i) Install the flushing element, clean the small strainer, then install it again. Replace the pilot filter with a new part. * For details, see “Installing filter element”. the cylinder circuit, ii) Short-circuit swing motor circuit, and travel motor circuit. * For details, see “Short-circuiting the piping”. Add hydraulic oil to the specified level. iv) Bleed the air from the main pump. 3. Flushing cylinder circuit, swing motor circuit, travel motor circuit i) Run the engine at low idling for 30 minutes. * The control levers must not be moved during this time. ii) Run the engine at midrange speed for 30 minutes The control levers must not be * moved during this time. If the oil temperature is low, * increase the length of the operation in Steps 3....i), and 3....ii) to raise the temperature. The oil temperature should be 50 - 80°C.
and
l
damaged,
Cylinder -k
Run the engine at high idling carry out the following operation.
0
Repeat the above 5 times.
pattern
for
at least
4. Restoring cylinder circuit, swing motor circuit 0 Restore the cylinder unit and swing motor circuit to the standard circuit. * Keep the travel motor circuit short-circuited. oil to the specified ii) Add hydraulic level. iii) Bleed the air from the main pump, cylinders, and swing motor. 5. Flushing center swivel joint i) Run the engine at high idling and carry out the following operation. 0 Operating pattern Left and right FORWARD + 90” swing Left and right REVERSE + 90” swing Swing 90” to either the left or * right, but swing in the same direction each time. l
l
*
Operating time Hold the lever in each position 2 minutes Number of times of operation
for
Repeat the above pattern 4 times, and rotate the swing one turn. The purpose of swinging 90” each is to remove dirt inside the center swivel from the oil grooves on the rotor side and shaft side around the whole circumference.
30-I 69
6. Restoring the travel circuit i) Restore the travel standard circuit. ii)
Replace the flushing new part. * For details, see element”.
circuit element
For details, circuit”.
see
the
with
“Installing
iii) Bleed the air from the travel 7. Flushing PPC circuit. i) Flush the PPC circuit -k
to
a
filter
motor.
“Flushing
PPC
8. Restoring PPC circuit i) Restore the PPC circuit to the standard circuit. 9. Flushing during actual operation i) With the flushing element installed, carry out normal operations for 10 20 hours. f If the oil temperature is low, carry out the warming-up operation. 10. Replacing element i) Replace the return filter with a standard element, clean the small strainer and install it again. Replace the pilot filter with a new part. * For details, see “Installing filter element”. ii) Add hydraulic oil to the specified level. iii) Bleed the air from the main pump.
30-170
4. Flushing pattern [B] 1. Preparatory work for flushing Install the flushing element, clean the small strainer and install it again. f For details, see “Installing filter element”. 2. Flushing PPC circuit Flush the PPC circuit. *
For details,
see “Flushing
3. Restoring PPC circuit Restore the PPC circuit circuit.
PPC circuit”. to
the
standard
4. Flushing during actual operation With the flushing element installed, carry out normal operations for 10 - 20 hours. * If the oil temperature is low, carry out the warming-up operation. 5. Replacing element Replace the return filter with a standard element, clean the small strainer and install it again. Replace the pilot filter with a new part. * For details, see “Installing filter element”.
5.
Flushing pattern [C] j, If the cylinder piping is connected and the cylinder is operated before the system is flushed, there is danger that the dirt that entered during assembly operations will be circulated inside the cylinder. Therefore, do not wait until completion of assembly to flush the carry out flushing before system; connecting the piping to the cylinder.
1. Preparatory work for flushing i) Short-circuit the cylinder * ii)
For details, the piping”.
4. Flushing during actual operation i) With the flushing element carry out normal operations 20 hours. f
If the oil temperature is low, carry out the warming-up operation.
5. Replacing element Replace the return filter with a standard element, clean the small strainer and install it again. Replace the pilot filter with a new part. *
circuit.
installed, for 10 -
For details, i)
see “Short-circuiting ii)
see “Installing
filter
element”.
Add hydraulic oil to the specified level. Bleed the air from the main pump.
Install the flushing element, clean the small strainer and install it again. * For details, see “Installing filter element”.
2. Flushing i) Run the engine at low idling for 30 minutes. * The control levers must not be moved during this time. ii)
Run the engine at midrange speed for 30 minutes. f The control levers must not be moved during this time. iii) Run the engine at high idling and carry out the following operation. . Operating pattern Boom RAISE - Boom LOWER Arm IN - Arm OUT - Bucket CURL - Bucket DUMP Operating time Hold the lever in each position for two minutes. Number of times of operation Repeat the above pattern at least 5 times. 3. Restoring cylinder circuit 0 Restore the cylinder circuit to the standard circuit. oil to the specified ii) Add hydraulic level. iii) Bleed the air from the main pump and cylinders.
30-171
30-I 72
40 MAINTENANCE
STANDARD
..........
...........................................
40-4
FINAL DRIVE, PC4OOLC ..........
...........................................
40-6
FINAL DRIVE, PC300LC
SWING MACHINERY,
PCBOOLC
....
...........................................
40-8
SWING MACHINERY,
PC4OOLC
....
...........................................
40-l 0
SWING CIRCLE,
PCBOOLC ........
...........................................
40-l 2
SWING CIRCLE,
PC4OOLC
...........................................
40-l 3
........
TRACK FRAME AND RECOIL
SPRING,
PC3OOLC
.................................
..40-14
TRACK FRAME AND RECOIL
SPRING,
PC4OOLC
.................................
..40-15
IDLER, PCBOOLC ...............
...........................................
40-l 6
IDLER, PC4OOLC ...............
...........................................
40-l 8
TRACK ROLLER,
PC3OOLC ........
...........................................
40-20
TRACK ROLLER,
PC4OOLC ........
...........................................
40-21
...........................................
40-22
CARRIER
ROLLER
..............
TRACK SHOE,
PCBOOLC
.........
...........................................
40-24
TRACK SHOE,
PC4OOLC
.........
...........................................
40-26
CHARGING
PUMP AND RELIEF VALVE
CONTROLVALVE
.......................................................
TRAVELSHUTTLEVALVE SWING
MOTOR
..........................................
.................................................
. ..........................................................
40-28 ..40-2
9
..40-3
6
40-37
TRAVEL
MOTOR,
PCBOOLC
................................................
..40-3
8
TRAVEL
MOTOR,
PC4OOLC
................................................
..40-3
9
40-I
PPC VALVE,
FOR WORK EQUIPMENT
PPCVALVE,FORTRAVEL
.................................
.................................................
PPCSHUTTLEVALVE BOOM HOLDING
AND SWING
.................................................... VALVE
....................................................
40-40 ..40-4
1
..40-4
2
40-43
HYDRAULIC
CYLINDER,
PC3OOLC
............................................
.40-44
HYDRAULIC
CYLINDER,
PC4OOLC
............................................
.40-45
WORK EQUIPMENT,
PC3OOLC
................................................
40-46
WORK EQUIPMENT,
PC400LC
................................................
40-48
40-2
40-3
FINAL DRIVE PCSOOLC
.
7“’
‘\,,f. ;’
.
.
..
m-
3.
.1
,
~7+lkgm------
6
IJ
20JF05056K
40-4
Unit: Check
I
item Standard
Clearance
clearance
0.19 - 0.54
mm
Remedy
limit
1 .oo
2
gear and No. 1 ring No. gear Backlash between 1 planet
0.21 - 0.62
3
Backlash between No. 1 planet carrier and idle gear
0.06 - 0.22
1.20
4
Backlash between No. 2 sun gear and No. 2 planet gear
0.19 - 0.54
1 .oo
5
Backlash between No. 2 planet gear and ring gear
0.21 - 0.62
1.10
6
Backlash between No. 2 planet carrier and No. 1 sun gear
0.39 - 0.67
I
1.10
I
Replace
7
1 End play of sprocket
8
Amount tooth
9
Width
shaft
I I
0.10 - 0.15
of wear on sprocket
Repair limit: Standard
of sprocket
I
size
6 Repair
tooth 87
Rebuild or replace
84
40-5
FINAL DRIVE PC4OOLC .
40-6
.,
Unit: No. 1
Check
Backlash between No. 1 sun gear and No. 1 planet gear
2
Backlash between No. 1 planet gear and No. 1 ring gear
3
Backlash between No. 1 planet carrier and idle gear
4
5
Criteria
item
Backlash between No. 2 sun I gear and No. 2 planet gear Backlash between No. 2 planet gear and ring gear
Standard
mm
Remedy Clearance
clearance
0.20 - 0.57
limit
1 .oo
0.06 - 0.21 Replace 0.19 - 0.53
0.20 - 0.57
1.10
0.41 - 0.73 0.10 - 0.15 8
Amount tooth
9
Width
of wear on sprocket
Repair limit: Standard
of sprocket
I
size
6 Repair
tooth 90
Rebuild or replace
87
40-7
SWING
MACHINERY
PC3OOLC
1
10
2
2OJFO505 7
40-8
Unit: mm No. ~~ 1
I
Check
Criteria
item
Backlash between swing motor shaft and drive gear
Standard
clearance
Remedy Clearance
limit
0.07 - 0.18 0.18 - 0.49
1.00
0.07 - 0.18 4
Backlash between and planet gear
5 6
sun gear
0.21 - 0.59
1.10
Backlash between planet gear and ring gear
0.22 - 0.63
1.10
Backlash between planet carrier and swina oinion
0.07 - 0.22
Replace
0 - 1.21 0.38 - 0.82 Standard
Repair limit
Size
139.7
0140 O/-6.169 Standard
clearance
Adiust
I
I
Clearance
Apply hardchrome plating, recondition or reolace
limit Adjust
11
shim
Axial clearance of driven aear
40-9
SWING
MACHINERY
PC4OOLC
1
10
2 _. .
8
208FO5629
40-I 0
Unit: mm Check 1
item Standard
Backlash between swing motor shaft and drive gear
between driven gear and sun gear
0.09 - 0.21
4
Backlash between and planet gear
0.21 - 0.59
5
Backlash between planet gear and ring gear
0.24 - 0.71
6
Backlash between planet carrier and swing pinion
0.10 - 0.23
7
Backlash between swing pinion and swing circle
0 - 1.22
9
10
11
play of swing Wear of swing face contacting seal Axial gear Axial gear
clearance
sun gear
pinion
limit
1 .oo
Replace
1.10 I 1.10 I
1
pinion surwith oil
0.39 - 0.87 Standard
1.90 I
Standard
of driven
limit
149.7
0150 o/-0.100 of drive
Adjust
Repair
Size
Clearance
clearance
_
0.08-0.32 clearance
Remedy
0.07 - 0.18 0.18 - 0.50
81End
Clearance
clearance
Backlash between drive gear and driven gear
2
I
Criteria
Apply hardchrome plating, recondition or replace
limit Adjust
shim
0.08-0.32 I
I
40-11
SWING CIRCLE PC300LC
Section
A- A
207FO5058
Unit: mm Check
No.
Standard 1
Axial
clearance
size
Clearance
limit Replace
of bearing 0.5 - 1.6
40-12
Remedy
Criteria
item
3.2
SWING CIRCLE PC4OOLC
94.5 f 10.5 kgm
w
94.5 f 10.5 kgm
Section A -
A
208FO5030
Unit: mm No.
Check
item
Criteria Standard
1
Axial
clearance
size
Remedy
Clearance
of bearing
limit Replace
0.5 - 1.6
3.2
40-13
TRACK FRAME AND RECOIL SPRING PC3OOLC
207FO5059
Unit: mm No.
1
2
Vertical guide
width
Standard size
of idler
Horizontal width idler guide
of
Recoil spring
123
+2 -1
127
Idler support
120
20.5
118
Track frame
266
+3.
271
Idler support
261
Free length 795 x 241
40-14
Repair limit
Tolerance
Track frame
Standard 3
Remedy
Criteria
Check item
648
259
I
Repair limit
size
Installation lenath
Rebuild or replace
Installation load 17,680 kg
Free length
Installation load 14,140 kg
Replace
TRACK FRAME AND RECOIL SPRING PC4OOLC
208FO5031
Unit: mm No.
Check item
Vertical guide
1
width
Standard size
of idler
Horizontal width idler guide
2
of
I
Recoil spring
I
Tolerance
Repair limit
Track frame
148
+_:
152
Idler support
145
+0.5
143
Track frame
302
+3 -1
307
Idler suooort
297 Standard
3
Remedy
Criteria
Free length I
857 x 270
295 Repair limit
size
Installation lenath 707
Rebuild or replace
I
Installation load 23,375 kg
II
Free length
II
Installation load
I
Replace
19,500 kg
40-15
IDLER PC3OOLC
1
/ 3
----_
_-f
\
I
\
‘\
1 --_ ---.
5
’
L
8
’
:I I
\
T
!
I
\
/ i d
I
1
! -
L /
-
II 207FO5060
40-16
Unit: mm No.
Criteria
Check item Outside
diameter
of protru-
Outside
diameter
of tread
Standard
Remedy
size
Repair limit Rebuild
590
3
Width of protrusion
101
4
Total width
190
5
Width of tread
44.5
6
Clearance bushing
between
shaft and
7
Clearance support
between
shaft and
I
8
Interference between and bushing
9
Side clearance
80
I Tolerance
80
I
replace
50.5
I Standard size
Or
578
I Standard clearance
Shaft
Hole
-0.225 -0.325
+0.130 -0.010
0.215 0.205
-0.225 -0.290
-0.085 -0.195
0.030 0.205
I Clearance limit
-
Replace bushing
1.5
I
I
Replace
idler
Standard
size
Repair limit
of idler (each) 2
40-17
IDLER PC4OOLC
I
1
J
f
-
--1;
-
I
‘I L
208FO5032
40-18
Unit: mm
Clearance
Interference
between
between
shaft and
idler
40-19
TRACK ROLLER PC3OOLC
-I-
7
-67*7 I
L---L-l 3
4
kgm
207FO5061
Unit: mm
Clearance
Interference
between
between
Side clearance
40-20
shaft and
roller
of roller
TRACK ROLLER PC4OOLC
4J
-,76
+ 8.5 kgm
A---------3 /!I
r-
_
I
I
l---l-l 3
4
_I
T
-1 207F05601A
Unit: mm
Clearance
Interference
between
between
Side clearance
shaft and
roller
of roller
40-21
CARRI ER ROLLER ,. I-
Unit: mm
Clearance
between
shaft and
Standard 6
Side clearance
0.01
40-22
size
of roller
- 0.24
Repair limit
40-23
TRACK SHOE PC3OOLC
9
40-24
207FO5063
Unit: No. ___~
I-
I ~~
Check item
I Remedy
Criteria Standard
1
mm
Repair limit
size
Link pitch 203.45 Outside ing
2
diameter
of bush-
Turn or
207.45
-r----
I
66.9
61.9
Lug 3
Height
of grouser
31
19
4
Height
of link
116
107
5
Interface link
of bushing
welding, rebuild or replace Rebuild or replace
and Replace
6
Interference and link
of regular
pin
44.6 (Shaft) 44.35 (Hole)
t 0.235 + 0.085
t 0.062 0
0.3500.464
0.140
44.4 (Shaft) 44.35 (Hole)
t 0.230 t 0.200
t 0.062 0
o.iaa0.280
0.080
I 7
Interference of regular master pin and link
Replace with larger one
5.25 2 0.3 Initial tightening torque: 4025 kgm Additional tighteneing angle: 120-~10”
Replace
I
40-25
TRACK SHOE PC4OOLC
i
r
1
-I
‘8
9
40-26
.-
208FO5033
Unit: mm No.
Criteria
Check item Standard
1
size
Remedv
I
Repair limit
I
220.25
Link pitch 216.25 Outside ing
diameter
of bush-
Height
of grouser
36
21
Height
of link
129
119
74.3
Turn or replace
69.3
I
Lug
5
6
Interface link
of bushing
Interference and link
and
of regular
pin
Interference of regular master pin and link
9
Protrusion
of bushing
Tightening bolt
torque
of shoe
Standard size
Tolerance
Standard clearance
welding, rebuild or replace Rebuild or replace Interference limit
Shaft
Hole
71
+0.494 +0.454
+ 0.074 0
0.380 0.494
0.100
47.0 (Shaft) 46.72 (Hole)
+ 0.235 + 0.085
+ 0.062 0
0.303 0.515
0.190
46.8 (Shaft) 46.72 (Hole)
+ 0.230 + 0.200
+0.062 0
0.218 0.310
0.130
Replace
Replace with larger one
5.25 2 0.3 Initial tightening torque: 4025 kgm Additional tighteneing angle: 120?10’
Replace
40-27
CHARGING
PUMP AND RELIEF VALVE ,. m
6.5 f 0.5 kgm
6.75 f 0.75 kgm
I-
Section
A -
A 207FO5064,
Unit: mm No.
Standard 1
Top clearance
Remedy
Criteria
Check item
Repair limit
size
of gear 0.145
0.090 - 0.130 2
Side clearance
3
Clearance between shaft and bushing Delivery
4
0.055 - 0.075
of gear
Engine oil CLASS-CD 5025°C 30 kg/cm2
gear
0.13
0.045 - 0.076 Standard
SAElOW
40-28
Charging
relief valve spring
Replace
Repair limit
value
Revolution speed (rpm)
Delivery (elmin)
Revolution speed (rpm)
Delivery (elmin)
3,200
90
3,200
62
Standard
5
0.105
I
size
I
Free length x O.D.
Installed length
Installed load
30.3x13.0
26.1
10.4 kg
Repair limit Free length
Installed load
9.4 kg
Replace spring if any damages or deformations are found
CONTROL
VALVE
. _ . ._:. ,-2i>;O:?k .. :.1
c,-’
, .
w
10.0 f 1.0 kgm
.’
e.O.9
t 0.1 kgm
’
~
207FO5065
40-29
f
5.5
f 0.5
kgm
5.5 f 0.5 kgm
3.0 + O&‘kgm
. ._ .I..
SectionA-A
207FO5066
._
Unit: mm Check
No.
Criteria
item
I
I
I 1
I Main relief valve poppet spring
pilot
size
Installed length
30.7 x 9.6
26.8
33.1 kg
26.5 kg
30.4 x 11.3
25.0
4.6 kg
3.7 kg
0.31 kg
1 InrEyd
Main relief valve valve spring
3
Jet sensor relief valve pilot poppet spring
26.3 x 8.0
26.1
0.39 kg
4
Jet sensor relief valve main valve spring
23.8 x 7.8
18.1
2.41 kg
5
Spool return spring (Straight-travel valve)
78.3 x 22.1
54.5
14.3 kg
Spool return (arm throttle
53.8 x 26.5
40-30
spring valve)
Repair limit
Free length x O.D.
2
6
main
Standard
1 1
1 l~~~~h
I
-
10.6 kg
I
I
52.5
1 Installed
1.93 kg 11.4 kg
I -
8.5 kg
1 Remedy I 1 1
Replace spring if any damages or defor, mations are found
I
_ _
. .
."-.I.9
.
_
.
* 1.0 lyrn 3
Qzl
5.5 f 0.5
r- ., kgm
14.5 ?r:2.0 kgm Section IJ -
Section C 1 C
.
.
. .
.
D
207FO50$1
Unit: mm Check
No.
Criteria
item Standard
1
Main relief valve poppet spring
pilot
Repair
size
limit
Free length x O.D.
Installed length
30.7 x 9.6
26.8
33.1 kg
-
26.5 kg
30.4 x 11.3
25.0
4.6 kg
-
3.7 kg
Installed load
Free length
Installed
2
Main relief valve valve spring
3
Jet valve pilot sensor poppet relief spring
26.3 x 8.0
26.1
0.39 kg
-
0.31 kg
4
Jet sensor relief valve main valve spring
23.8 x 7.8
18.1
2.41 kg
-
1.93 kg
PC3OOLC
53.8 x 27.5
52.5
12.2 kg
-
9.8 kg
PC4OOLC
53.8 x 26.5
52.5
10.6 kg
-
8.5 kg
$;; 5
(Swing priority valve)
return
main
Remedy
Replace spring if any damages or deformations are found
40-31
w
w
9.0 * 0.5 kgm -.20>
14.5 f 2.0 kgm
f 2.0 kgm ‘-
-1
20.0 k 2.0 kgm
1
w Section
15.5 f 2.5 kgm
m
Section
20.0 k 2.0 kgm
E -
F -
F
E
w
15.5 f 2.5 kgm
\
-19.0
f 1.0 kgm
3
I \
\
.5 kgm
.5
3/
w
\
‘6
4’ Section
40-32
G -
G
m
19.0 + 1.0 kgm
\ Sedtion
5 H -
H
207FO5068
Unit: mm No.
Check
Criteria
item Standard
Check valve
Remedy Repair limit
size
spring Replace spring if any damages or deformations are found
6
Spool
return
spring
21 x 16.9
21
0 kg
20
7
Check valve
spring
55.9 x 30.2
29
0.8 kg
-
0.64 kg
40-33
w
4
19.0 * 1.0 kgm
Section m
5.0 * 0.5 kgm
I
I
7.0 * 1.0 kgm
J -
-\5.0
19.0 * 1.0 kgm
J
f 0.5 kgm Section
2
3
m
19:0*1.0
K -
K
15.5 * 2.5 kgm
_.__.__- ,. .-/ ..,_ _-,.I.. .; ,.,., _ ._ .._ . . .,
.
Section _.
40-34
L -
L
.-.
:
-
207FO5069
kgm
Unit: mm No.
Check
Criteria
item Standard
1
Spool
return
spring
Remedy Repair
size Installed load
Free length
limit
Free length x O.D.
Installed length
Installed load
54.8 x 34
53.5
12.7 kg
-
10.2 kg
2
Spool
return
spring
30.7 x 32.5
26.5
26 kg
-
20.8 kg
3
Spool
return
spring
54 x 34.2
52
26 kg
-
20.8 kg
1 Check valve
spring
-
1 0.64 kg
4
1 55.9 x 30.2
1
29
1
0.8 kg
1
Replace spring if any damages or deformations are found 1
40-35
TRAVEL SHUTTLE VALVE
1
m
w
: ;.
2.25 f 0.25 kgm
2.25 f 0.25 kgm I
w
2.25 f 0.25 kgm
‘LT.
:
.I
_.
_ _=_._
,.
_ 207EO5070, .,.
_..
-,
Unit: mm No.
Check
item
Criteria Standard
1
40-36
Spool
return
spring
Remedy
size
Free length x O.D.
Installed length
53.7 x 13.4
34.0
Repair Installed load 4.6 kg
Free length -
limit Installed load 3.7 kg
Replace . spring if any damages or deformations are found
SWING MOTOR
w
56.7 f 6.0 kgm
!
Section
6 -
6
207FO5071
Unit: mm No.
Check
Criteria
item Standard
1
Check valve
spring
Free length x O.D. 66.5 x 25.6
Repair limit
size
Installed length 45
Remedy
Installed load 0.71 kg
Free length -
Installed load 0.57 kg
Replace spring if any damages or deformations are found
40-37
TRAVEL MOTOR PCBOOLC -_.
_..
.-._
,_ I
.,
_-
I km
r
_. :
.,.__
..--.
‘.,
-.
w
A :.
.
_
.2.4 f 0.4 kgm
_‘.
37.0 rt 4.0 kgm
2
w
w
428,&4.7.kgm.
66.5 f 7.5 kgm
\
.6 kgm
I
Section
A .-
Section
..A-.
B -
B
207FQ5072
Unit: mm No.
Check
Standard 1
Spool
return
spring
Free length x O.D. 42.5 x 40
2
Check
valve
3
Regulator spring
piston
4
Pilot piston
5
Check valve
40-38
spring
Remedy
Criteria
item
Installed length 41
Repair limit
size
Free length
Installed load 37.8 kg
-
Installed load 26.5 kg
52.7 x 22.4 55 x 9 I
I
spring spring
Replace spring if anv
82.7 x 19.4
60.5
63.7 kg
-
51 .o
9.4 x 4.6
7.75
0.05 kg
-
0.04 kg
mations are found
TRAVEL MOTOR PC4OOLC
76 k 8.5 kgm
I--
2.4 + 0.4 kgm
.A”
1
2
m
42.8 rt 4.7 kgm
5.4 f 0.6 kgm
m
66.5 f 7.5 kgm
.O kgm Section A -
A
0.9 k 0.1 kgm
Section 0 -
B 208FO5034
Unit: No.
Check
Standard 1
Spool
return
2
Check valve
3
Regulator spring
4
Pilot piston
5
Check valve
spring
spring
piston spring spring
Remedy
Criteria
item
Free length x O.D.
Repair limit
size
Installed length
mm
Installed load
Free length
Installed load
42.5 x 40
41
37.9 kg
-
26.5 kg
52.7 x 22.4
37
0.5 kg
-
0.4 kg
55 x 9
50
10kg
-
8.0
82.7 x 19.4
60.5
63.7 kg
-
51.0
9.4 x 4.6
7.75
0.05 kg
-
0.04 kg
Replace spring if any damages or deformations are found
40-39
PPC VALVE FOR WORK
EQUIPMENT
AND SWING
-I
,w
11.5 f 1.5 kgm
1.8 k 0.4 kgm
F
Min. 3 kgm
205FO5198
Unit:
4
40-40
Centering spring (For P,, P&
45.2 x 16.8
36.5
3.8 kg
-
3.0 kg
mm
PPC VALVE FOR TRAVEL
,- 3.5 kgm w
Min. 3 kgm
\
FO20705004
Unit: mm No.
Check
item
Criteria Standard
1
2
Metering
Centering
spring
spring
Remedy Repair limit
size Installed load
Free length x O.D.
Installed length
Free length
Installed load
31.4 x 7.4
29.4
1.7 kg
-
1.4 kg
47.4 x 16.8
36.5
2.3 kg
-
1.8 kg
Replace spring if any damages or deformations are found
40-41
PPC SHUTTLE VALVE FOR BOOM
. BUCKET
AND TRAVEL
m
3.5 ? 0.5 kgm \
.
.
.
,
‘.
,
.,
-,
.
_‘-
w
3.5 * 0.5 kgni 207FO5073
FOR ARM AND SWING w
w
40-42
3.5 ?Z 0.5 kgm
3.0 f 1 :O kgm
207FO5074
BOOM HOLDING
VALVE
w.4.0
.w
+ 0.5 kgm
I
11.25 f 1.25kgm
_ SectionA -19.0
f 1.0 kg!
:
- A
_;
207FO5075
Unit: No.
Check
Standard 1
2
Pilot valve
spring
Check valve
spring
Remedy
Criteria
item
Repair
size Installed load
mm
Free length
limit Installed load
Free length x O.D.
Installed length
26.0 x 11.5
24.5
0.64 kg
-
0.51 kg
49.7 x 24.6
45.0
2.2 kg
-
1.76 kg
Replace spring if any damages or deformations are found
40-43
HYDRAULIC
CYLINDER
PC300LC *
The drawing shows boom cylinder
,.; ._ w
Soom:: 38.0 * 5,5 kgm Arm:: 64.9 f 8.0,kgm
w
Boom: 11.5 ? 1.0 kgm Arm: 18.0 i 2.0 kgm
I’, B.ucket,:. 38.0 f 5.5 kgm
Bucket:
.-’
11.5 f 1.0 kgm
,’
207FO5076
Unit: mm No.
Cylinder name
1
Clearance between rod and bushing
Remedy
Criteria
Check item Standard size
Boom
piston
Tolerance Shaft
Hole
-0.036
+ 0.257 + 0.047
+ -0.090
Standard clearance
I
Clearance limit
I
Arm 0.083 0.347
Bucket
Boom
2
-0.036 -0.090
Boom Clearance between cylinder bottom support and bushing
Arm
~
40-44
Bucket
+0.457
I +0.370
0.406 0.547
--I--
Bucket
3
0.406 0.528
100
Clearance between piston rod support and bushing
100
90
-
1.0
I
I
-0.036 0.090
+0.457 +0.370
-0.036 -0.090
+0.457 +0.370
-0.036 -0.090
+ 0.457 + 0.370
0.406 0.547
-
-0.036 ~ -0.090
+0.457 +0.370
0.406 0.547
-
I
0.447
I 1 .o
I
1 .o
I
I 1.0
!
HYDRAULIC
CYLINDER
PC4OOLC Sr The drawing shows boom
m
Boom: 54.0 k 8.0 kgm Arm: 91.0 f 14.0 kgm Bucket: 54.0 + 8.0 kgm
m
Boom, Arm, Bucket:
cylinder
18.0 i 2.0 kgm
208FO5035
Unit: mm No.
Check item
Remedy
Criter Standard clearance
1
Clearance between rod and bushing
Boom
piston
Clearance between piston rod support and bushing
3
Clearance between cylinder bottom support and bushing
-0.036 -0.090
+ 0.257 + 0.047
f
I 2
110
I
Arm
I
120
-0.036
+0.263
I -0.090
I +0.048
Bucket
110
-0.036 -0.090
+0.261 + 0.047
Boom
110
-0.036 -0.071
+ 0.457 + 0.370
Arm
110
-0.036 -0.090
+ 0.457 + 0.370
Bucket
100
-0.036
+ 0.457
I -0.090
I + 0.370
0.083 0.353
I
0.406 0.547
I
0.453
1.0
I
I
40-45
WORK EQUIPMENT PCBOOLC .-,_.
‘..
.
:;
._ -
.
,_‘D _ ,
..
.‘_
_
_ _.
.
-.
I_
.
\/.
.:,:
‘A.
.i
207FO5077
_
,.
. Section
Section
B -
,__
I
D -
. .
_._
D
Section
E -
E
Section
F -
F
.-.
-
B
Section Section
C -
Section
40-46
K -
K
C G -
G
207F05078A
Unit: mm No.
Criteria
Check item
Clearance
between
Remedy
bushing
and connect-
2
Clearance between bushing ing pin of boom and arm
and connect-
110
-0.036 -0.090
+ 0.354 + 0.275
0.311 0.444
1.0
3
Clearance between bushing ing pin of arm and link
and connect-
90
-0.036 -0.090
+ 0.338 +0.272
0.308 0.428
-
1.0
4
Clearance between bushing ing pin of arm and bucket
and connect-
90
-0.036 -0.090
+0.337 +0.271
0.307 0.427
1.0
5
Clearance between bushing ing pin of link and bucket
and connect-
6
Clearance between bushing ing pin of link and link
and connect-
90
-0.036 -0.090
+ 0.346 + 0.275
0.311 0.436
1.0
7
Bucket
clearance
(a)
0.5 - 1.0
a
Bucket clearance
(bl
2.0
Replace
I
Shim adjust
40-47
WORK EQUIPMENT PC4OOLC D’
207FO5077
Section ,
.
,
.
Section
. . _
..-,._
Section
Section
.
_. .
A -
A
..
^.
B -
C -
D
Section
H -
H
K -
K
k3
.-
,,_. . . .
Section
E -
E
Section
F -
F
B
Section
C
Section
40-48
D -
G -
G
207F05078A
Unit: mm No.
Check item
Criteria Standard size
Tolerance
Standard clearance
Clearance limit
1
Clearance between ing pin of revolving
2
Clearance between bushing ing pin of boom and arm
and connect-
120
-0.036 -0.090
+0.316 +0.219
0.255 0.406
1.0
3
Clearance between bushing ing pin of arm and link
and connect-
100
-0.036 -0.090
+ 0.379 +0.259
0.295 0.469
1.0
4
Clearance between bushing ing pin of arm and bucket
and connect-
100
-0.036 -0.090
+0.340 +0.267
0.303 0.430
1.0
5
Clearance between bushing ing pin of link and bucket
and connect-
100
-0.036 -0.090
+ 0.329 + 0.259
0.295 0.419
1.0
6
Clearance between bushing ing pin of link and link
and connect-
7
Bucket clearance
(a)
0.5 - 1.0
8
Bucket
(b)
2.0
clearance
bushing and connectframe and boom.
Remedy
Shaft
Hole
I
Replace
Shim adjust
40-49
