PC130-7 SEBM036303.pdf

SEBM036303

MACHINE MODEL

SERIAL NUMBER

PC130-7

70001 and up

• This shop manual may contain attachiments and optional equipment that are not available in your area. Please consult your local Komatsu distributor for those items you may require. Materials and specifications are subject to change without notice. • PC130-7 mounts the SAA4D95LE-3 engine. For details of the engine, see the 95-3 Series Engine Shop Manual.

© 2004 All Rights Reserved Printed in Japan 10-04(02)

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CONTENTS No. of page

01

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

10

STRUCTURE AND FUNCTION .................................................................10-1

20

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

30

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

40

MAINTENANCE STANDARD......................................................................40-1

90

OTHERS ....................................................................................................................90-1

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PC130-7

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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SAFETY

SAFETY NOTICE

SAFETY SAFETY NOTICE IMPORTANT SAFETY NOTICE Proper service and repair is extremely important for safe machine operation. The service and repair techniques recommended by Komatsu and described in this manual are both effective and safe. Some of these techniques require the use of tools specially designed by Komatsu for the specific purpose. To prevent injury to workers, the symbol k is used to mark safety precautions in this manual. The cautions accompanying these symbols should always be followed carefully. If any dangerous situation arises or may possibly arise, first consider safety, and take the necessary actions to deal with the situation.

GENERAL PRECAUTIONS Mistakes in operation are extremely dangerous. Read the Operation and Maintenance Manual carefully BEFORE operating the machine. 1. Before carrying out any greasing or repairs, read all the precautions given on the decals which are fixed to the machine. 2. When carrying out any operation, always wear safety shoes and helmet. Do not wear loose work clothes, or clothes with buttons missing. • •

Always wear safety glasses when hitting parts with a hammer. Always wear safety glasses when grinding parts with a grinder, etc.

3. If welding repairs are needed, always have a trained, experienced welder carry out the work. When carrying out welding work, always wear welding gloves, apron, hand shield, cap and other clothes suited for welding work. 4. When carrying out any operation with two or more workers, always agree on the operating procedure before starting. Always inform your fellow workers before starting any step of the operation. Before starting work, hang UNDER REPAIR signs on the controls in the operator's compartment. 5. Keep all tools in good condition and learn the correct way to use them.

6. Decide a place in the repair workshop to keep tools and removed parts. Always keep the tools and parts in their correct places. Always keep the work area clean and make sure that there is no dirt or oil on the floor. Smoke only in the areas provided for smoking. Never smoke while working. PREPARATIONS FOR WORK 7. Before adding oil or making any repairs, park the machine on hard, level ground, and block the wheels or tracks to prevent the machine from moving. 8. Before starting work, lower blade, ripper, bucket or any other work equipment to the ground. If this is not possible, insert the safety pin or use blocks to prevent the work equipment from falling. In addition, be sure to lock all the control levers and hang warning signs on them. 9. When disassembling or assembling, support the machine with blocks, jacks or stands before starting work. 10.Remove all mud and oil from the steps or other places used to get on and off the machine. Always use the handrails, ladders or steps when getting on or off the machine. Never jump on or off the machine. If it is impossible to use the handrails, ladders or steps, use a stand to provide safe footing.

00-3

SAFETY

PRECAUTIONS DURING WORK 11.When removing the oil filler cap, drain plug or hydraulic pressure measuring plugs, loosen them slowly to prevent the oil from spurting out. Before disconnecting or removing components of the oil, water or air circuits, first remove the pressure completely from the circuit. 12.The water and oil in the circuits are hot when the engine is stopped, so be careful not to get burned. Wait for the oil and water to cool before carrying out any work on the oil or water circuits. 13.Before starting work, remove the leads from the battery. Always remove the lead from the negative (–) terminal first. 14.When raising heavy components, use a hoist or crane. Check that the wire rope, chains and hooks are free from damage. Always use lifting equipment which has ample capacity. Install the lifting equipment at the correct places. Use a hoist or crane and operate slowly to prevent the component from hitting any other part. Do not work with any part still raised by the hoist or crane. 15.When removing covers which are under internal pressure or under pressure from a spring, always leave two bolts in position on opposite sides. Slowly release the pressure, then slowly loosen the bolts to remove. 16.When removing components, be careful not to break or damage the wiring. Damaged wiring may cause electrical fires. 17.When removing piping, stop the fuel or oil from spilling out. If any fuel or oil drips onto the floor, wipe it up immediately. Fuel or oil on the floor can cause you to slip, or can even start fires. 18.As a general rule, do not use gasoline to wash parts. In particular, use only the minimum of gasoline when washing electrical parts.

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SAFETY NOTICE

19.Be sure to assemble all parts again in their original places. Replace any damaged parts with new parts. • When installing hoses and wires, be sure that they will not be damaged by contact with other parts when the machine is being operated. 20.When installing high pressure hoses, make sure that they are not twisted. Damaged tubes are dangerous, so be extremely careful when installing tubes for high pressure circuits. Also, check that connecting parts are correctly installed. 21.When assembling or installing parts, always use the specified tightening torques. When installing protective parts such as guards, or parts which vibrate violently or rotate at high speed, be particularly careful to check that they are installed correctly. 22.When aligning two holes, never insert your fingers or hand. Be careful not to get your fingers caught in a hole. 23.When measuring hydraulic pressure, check that the measuring tool is correctly assembled before taking any measurements. 24.Take care when removing or installing the tracks of track-type machines. When removing the track, the track separates suddenly, so never let anyone stand at either end of the track.

FOREWORD

GENERAL

FOREWORD GENERAL

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

This shop manual mainly contains the necessary technical information for operations performed in a service workshop. For ease of understanding, the manual is divided into the following chapters; these chapters are further divided into the each main group of components.

STRUCTURE AND FUNCTION This section explains the structure and function of each component. It serves not only to give an understanding of the structure, but also serves as reference material for troubleshooting. In addition, this section may contain hydraulic circuit diagrams, electric circuit diagrams, and maintenance standards. TESTING AND ADJUSTING This section explains checks to be made before and after performing repairs, as well as adjustments to be made at completion of the checks and repairs. Troubleshooting charts correlating "Problems" with "Causes" are also included in this section. DISASSEMBLY AND ASSEMBLY This section explains the procedures for removing, installing, disassembling and assembling each component, as well as precautions for them. MAINTENANCE STANDARD This section gives the judgment standards for inspection of disassembled parts. The contents of this section may be described in STRUCTURE AND FUNCTION. OTHERS This section mainly gives hydraulic circuit diagrams and electric circuit diagrams. In addition, this section may give the specifications of attachments and options together.

NOTICE The specifications contained in this shop manual are subject to change at any time and without any advance notice. Use the specifications given in the book with the latest date.

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FOREWORD

HOW TO READ THE SHOP MANUAL

HOW TO READ THE SHOP MANUAL

REVISED EDITION MARK

VOLUMES Shop manuals are issued as a guide to carrying out repairs. They are divided as follows:

When a manual is revised, an edition mark ((1)(2)(3)....) is recorded on the bottom of the pages.

Chassis volume: Issued for every machine model Engine volume: Issued for each engine series Each issued as one Electrical volume: Attachments volume: · volume to cover all models

REVISIONS

}

These various volumes are designed to avoid duplicating the same information. Therefore, to deal with all repairs for any model , it is necessary that chassis, engine, electrical and attachment volumes be available. DISTRIBUTION AND UPDATING Any additions, amendments or other changes will be sent to KOMATSU distributors. Get the most up-todate information before you start any work.

FILING METHOD 1. See the page number on the bottom of the page. File the pages in correct order. 2. Following examples show how to read the page number. Example 1 (Chassis volume): 10 - 3 Item number (10. Structure and Function) Consecutive page number for each item. Example 2 (Engine volume): 12 - 5 Unit number (1. Engine) Item number (2. Testing and Adjusting) Consecutive page number for each item. 3. Additional pages: Additional pages are indicated by a hyphen (-) and number after the page number. File as in the example. Example: 12-203 10-4 12-203-1 10-4-1 Added pages 12-203-2 10-4-2 12-204 10-5

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Revised pages are shown in the LIST OF REVISED PAGES next to the CONTENTS page.

SYMBOLS So that the shop manual can be of ample practical use, important safety and quality portions are marked with the following symbols.

Symbol

Item

Remarks

k

Safety

Special safety precautions are necessary when performing the work.

Caution

Special technical precautions or other precautions for preserving standards are necessary when performing the work.

Weight

Weight of parts of systems. Caution necessary when selecting hoisting wire, or when working posture is important, etc.

Tightening torque

Places that require special attention for the tightening torque during assembly.

Coat

Places to be coated with adhesives and lubricants, etc.

5

Oil, water

Places where oil, water or fuel must be added, and the capacity.

6

Drain

Places where oil or water must be drained, and quantity to be drained.

a

4

3 2

FOREWORD

HOISTING INSTRUCTIONS

HOISTING INSTRUCTIONS HOISTING k Heavy parts (25 kg or more) must be lifted with a hoist, etc. In the DISASSEMBLY AND ASSEMBLY section, every part weighing 25 kg or more is indicated clearly with the symbol 4 •

If a part cannot be smoothly removed from the machine by hoisting, the following checks should be made: 1) Check for removal of all bolts fastening the part to the relative parts. 2) Check for existence of another part causing interference with the part to be removed.

WIRE ROPES 1) Use adequate ropes depending on the weight of parts to be hoisted, referring to the table below: Wire ropes (Standard "Z" or "S" twist ropes without galvanizing) Rope diameter

★

Allowable load

mm

kN

tons

10 11.5 12.5 14 16 18 20 22.4 30 40 50 60

9.8 13.7 15.7 21.6 27.5 35.3 43.1 54.9 98.1 176.5 274.6 392.2

1.0 1.4 1.6 2.2 2.8 3.6 4.4 5.6 10.0 18.0 28.0 40.0

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

100%

88%

79%

71%

41% SAD00479

3) Do not sling a heavy load with one rope alone, but sling with two or more ropes symmetrically wound onto the load. k 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.

4) Do not sling a heavy load with ropes forming a wide hanging angle from the hook. When hoisting a load with two or more ropes, the force subjected to each rope will increase with the hanging angles. The table below shows the variation of allowable load kN {kg} when hoisting is made with two ropes, each of which is allowed to sling up to 9.8 kN {1000 kg} vertically, at various hanging angles. When two ropes sling a load vertically, up to 19.6 kN {2000 kg} of total weight can be suspended. This weight becomes 9.8 kN {1000 kg} when two ropes make a 120° hanging angle. On the other hand, two ropes are subjected to an excessive force as large as 39.2 kN {4000 kg} if they sling a 19.6 kN {2000 kg} load at a lifting angle of 150°.

The allowable load value is estimated to be onesixth or one-seventh of the breaking strength of the rope used.

2) Sling wire ropes from the middle portion of the hook.

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FOREWORD

METHOD OF DISASSEMBLING, CONNECTING PUSH-PULL TYPE COUPLER

METHOD OF DISASSEMBLING, CONNECTING PUSH-PULL TYPE COUPLER k Before carrying out the following work, release the residual pressure from the hydraulic tank. For details, see TESTING AND ADJUSTING, Releasing residual pressure from hydraulic tank.

k Even if the residual pressure is released from the hydraulic tank, some hydraulic oil flows out when the hose is disconnected. Accordingly, prepare an oil receiving container. Disconnection 1) Release the residual pressure from the hydraulic tank. For details, see TESTING AND ADJUSTING, Releasing residual pressure from hydraulic tank. 2) Hold adapter (1) and push hose joint (2) into mating adapter (3). (See Fig. 1) ★ The adapter can be pushed in about 3.5 mm. ★ Do not hold rubber cap portion (4). 3) After hose joint (2) is pushed into adapter (3), press rubber cap portion (4) against (3) until it clicks. (See Fig. 2) 4) Hold hose adapter (1) or hose (5) and pull it out. (See Fig. 3) ★ Since some hydraulic oil flows out, prepare an oil receiving container. Connection 1) Hold hose adapter (1) or hose (5) and insert it in mating adapter (3), aligning them with each other. (See Fig. 4) ★ Do not hold rubber cap portion (4). 2) After inserting the hose in the mating adapter perfectly, pull it back to check its connecting condition. (See Fig. 5) ★ When the hose is pulled back, the rubber cap portion moves toward the hose about 3.5 mm. This does not indicate abnormality, however.

00-8

Type 1

FOREWORD

METHOD OF DISASSEMBLING, CONNECTING PUSH-PULL TYPE COUPLER

Type 3

1) Hold the mouthpiece of the tightening portion and push body (2) in straight until sliding prevention ring (1) contacts contact surface a of the hexagonal portion at the male end.

1) Hold the mouthpiece of the tightening portion and push body (2) in straight until sliding prevention ring (1) contacts contact surface a of the hexagonal portion at the male end.

2) Hold in the condition in Step 1), and turn lever (4) to the right (clockwise).

2) Hold in the condition in Step 1), and push until cover (3) contacts contact surface a of the hexagonal portion at the male end.

3) Hold in the condition in Steps 1) and 2), and pull out whole body (2) to disconnect it.

3) Hold in the condition in Steps 1) and 2), and pull out whole body (2) to disconnect it.

•

•

Disassembly

Type 2

Hold the mouthpiece of the tightening portion and push body (2) in straight until sliding prevention ring (1) contacts contact surface a of the hexagonal portion at the male end to connect it.

Connection

Hold the mouthpiece of the tightening portion and push body (2) in straight until sliding prevention ring (1) contacts contact surface a of the hexagonal portion at the male end to connect it.

00-9

FOREWORD

COATING MATERIALS

COATING MATERIALS ★ ★

The recommended coating materials such as adhesives, gasket sealants and greases used for disassembly and assembly are listed below. For coating materials not listed below, use the equivalent of products shown in this list. Category

Komatsu code

Part No.

Q'ty

Container

Main applications, featuresr

LT-1A

790-129-9030

150 g

Tube

• Used to prevent rubber gaskets, rubber cushions, and cock plug from coming out.

LT-1B

790-129-9050

20 g (2 pcs.)

Polyethylene container

• Used in places requiring an immediately effective, strong adhesive. Used for plastics (except polyethylene, polyprophylene, tetrafluoroethlene and vinyl chloride), rubber, metal and non-metal.

LT-2

09940-00030

50 g

Polyethylene container

• Features: Resistance to heat and chemicals • Used for anti-loosening and sealant purpose for bolts and plugs.

LT-3

790-129-9060 (Set of adhesive and hardening agent)

Adhesive: 1 kg Hardening agent: 500 g

Can

LT-4

790-129-9040

250 g

Polyethylene container

Holtz MH 705

790-126-9120

75 g

Tube

• Used as heat-resisting sealant for repairing engine.

50 g

Polyethylene container

• Quick hardening type adhesive • Cure time: within 5 sec. to 3 min. • Used mainly for adhesion of metals, rubbers, plastics and woods.

Adhesives

Three bond 1735

790-129-9140

• Used as adhesive or sealant for metal, glass and plastic.

Aron-alpha 201

790-129-9130

2g

Polyethylene container

• Quick hardening type adhesive • Quick cure type (max. strength after 30 minutes) • Used mainly for adhesion of rubbers, plastics and metals.

Loctite 648-50

79A-129-9110

50 cc

Polyethylene container

• Resistance to heat, chemicals • Used at joint portions subject to high temperatures.

LG-1

790-129-9010

200 g

Tube

• Used as adhesive or sealant for gaskets and packing of power train case, etc.

LG-5

790-129-9080

1 kg

Can

• Used as sealant for various threads, pipe joints, flanges. • Used as sealant for tapered plugs, elbows, nipples of hydraulic piping.

Tube

• Features: Silicon based, resistance to heat, cold • Used as sealant for flange surface, tread. • Used as sealant for oil pan, final drive case, etc.

LG-6

790-129-9020

200 g

Gasket sealant LG-7

790-129-9070

1g

Tube

• Features: Silicon based, quick hardening type • Used as sealant for flywheel housing, intake manifold, oil an, thermostat housing, etc.

Three bond 1211

790-129-9090

100 g

Tube

• Used as heat-resisting sealant for repairing engine.

Tube

• Features: Silicone type, heat resistant, vibration resistant, and impact resistant sealing material • Used as sealing material for transfer case

Three bond 1207B

00-10

• Used as sealant for machined holes.

419-15-18131

100 g

FOREWORD

Molybdenum disulphide lubricant

Grease

Primer

Adhesive

Caulking material

Komatsu code

Part No.

Q'ty

Container

Main applications, featuresr

LM-G

09940-00051

60 g

Can

• Used as lubricant for sliding portion (to prevent from squeaking).

Tube

• Used to prevent seizure or scuffling of the thread when press fitting or shrink fitting. • Used as lubricant for linkage, bearings, etc.

LM-P

09940-00040

G2-LI

SYG2-400LI SYG2-350LI SYG2-400LI-A SYG2-160LI SYGA-160CNLI

G2-CA

SYG2-400CA SYG2-350CA SYG2-400CA-A SYG2-160CA SYGA-160CNCA

200 g

• General purpose type Various

Various

Various

Various

• Used for normal temperature, light load bearing at places in contact with water or steam.

• Used for heavy load portion

Molybdenum disulphide grease LM-G (G2-M)

SYG2-400M SYG2-400M-A SYGA-16CNM

Hyper White Grease G2-T G0-T (*) *: For use in cold district

SYG2-400T-A SYG2-16CNT SYG0-400T-A (*) SYG0-16CNT (*)

400 g 16 kg

• Seizure resistance and heat resistance higher than molybdenum diBellows type sulfide grease Can • Since this grease is white, it does not stand out against machine body.

Biogrease G2B G2-BT (*) *: For high temperature and large load

SYG2-400B SYGA-16CNB SYG2-400BT (*) SYGA-16CNBT (*)

400 g 16 kg

Bellows type Can

SUNSTAR PAINT PRIMER 580 SUPER

20 ml

Glass container

SUNSTAR GLASS PRIMER 580 SUPER

20 ml

Glass container

400 g × 10 Bellows type 400 g × 20 Bellows type 16 kg Can

417-926-3910

SUNSTAR PENGUINE SEAL 580 SUPER "S" or "W"

320 ml

Polyethylene container

Sika Japan, Sikaflex 256HV

20Y-54-39850

310 ml

Polyethylene container

SUNSTAR PENGUINE SEAL No. 2505

417-926-3920

320 ml

Polyethylene container

SEKISUI SILICONE SEALANT

20Y-54-55130

333 ml

Polyethylene container

• Since this grease is decomposed by bacteria in short period, it has less effects on microorganisms, animals, and plants. • Used as primer for cab side (Using limit: 4 months) • Used as primer for glass side (Using limit: 4 months) Adhesive for cab glass

Category

COATING MATERIALS

• "S" is used for high-temperature season (April - October) and "W" for low-temperature season (November - April) as adhesive for glass. (Using limit: 4 months) • Used as adhesive for glass. (Using limit: 6 months) • Used to seal joints of glass parts. (Using limit: 4 months) • Used to seal front window. (Using limit: 6 months)

00-11

FOREWORD

STANDARD TIGHTENING TORQUE

STANDARD TIGHTENING TORQUE STANDARD TIGHTENING TORQUE TABLE (WHEN USING TORQUE WRENCH) ★ In the case of metric nuts and bolts for which there is no special instruction, tighten to the torque given in the table below. Tightening torque Thread diameter of bolt

Width across flats

mm

mm

Nm

kgm

6 8 10 12 14

10 13 17 19 22

11.8 – 14.7 27 – 34 59 – 74 98 – 123 153 – 190

1.2 – 1.5 2.8 – 3.5 6 – 7.5 10 – 12.5 15.5 – 19.5

16 18 20 22 24

24 27 30 32 36

235 – 285 320 – 400 455 – 565 610 – 765 785 – 980

23.5 – 29.5 33 – 41 46.5 – 58 62.5 – 78 80 – 100

27 30 33 36 39

41 46 50 55 60

1150 – 1440 1520 – 1910 1960 – 2450 2450 – 3040 2890 – 3630

118 – 147 155 – 195 200 – 250 250 – 310 295 – 370

Thread diameter of bolt

Width across flats

mm

mm

Nm

kgm

6 8 10 12

10 13 14 27

5.9 – 9.8 13.7 – 23.5 34.3 – 46.1 74.5 – 90.2

0.6 – 1.0 1.4 – 2.4 3.5 – 4.7 7.6 – 9.2

Tightening torque

Sealing surface

TABLE OF TIGHTENING TORQUES FOR FLARED NUTS ★ In the case of flared nuts for which there is no special instruction, tighten to the torque given in the table below.

SAD00483

Thread diameter

Width across flat

mm

mm

Nm

kgm

14 18 22 24 30 33 36 42

19 24 27 32 36 41 46 55

24.5 ± 4.9 49 ± 19.6 78.5 ± 19.6 137.3 ± 29.4 176.5 ± 29.4 196.1 ± 49 245.2 ± 49 294.2 ± 49

2.5 ± 0.5 5±2 8±2 14 ± 3 18 ± 3 20 ± 5 25 ± 5 30 ± 5

00-12

Tightening torque

FOREWORD

STANDARD TIGHTENING TORQUE

TABLE OF TIGHTENING TORQUES FOR SPLIT FLANGE BOLTS ★ In the case of split flange bolts for which there is no special instruction, tighten to the torque given in the table below.

Thread diameter

Width across flat

Tightening torque

mm

mm

Nm

kgm

10 12 16

14 17 22

59 – 74 98 – 123 235 – 285

6 – 7.5 10 – 12.5 23.5 – 29.5

TABLE OF TIGHTENING TORQUES FOR O-RING BOSS PIPING JOINTS ★ Unless there are special instructions, tighten the O-ring boss piping joints to the torque below.

Thread diameter

Width across flat

mm

mm

14 20 24 33 42

Varies depending on type of connector.

Tightening torque (Nm {kgm})

Norminal No.

02 03, 04 05, 06 10, 12 14

Range 35 – 63 84 – 132 128 – 186 363 – 480 746 – 1010

{3.5 – 6.5} {8.5 – 13.5} {13.0 – 19.0} {37.0 – 49.0} {76.0 – 103}

Target 44 {4.5} 103 {10.5} 157 {16.0} 422 {43.0} 883 {90.0}

TABLE OF TIGHTENING TORQUES FOR O-RING BOSS PLUGS ★ Unless there are special instructions, tighten the O-ring boss plugs to the torque below.

Thread diameter

Width across flat

mm

mm

08 10 12 14 16 18 20 24 30 33 36 42 52

14 17 19 22 24 27 30 32 32 — 36 — —

Tightening torque (Nm {kgm})

Norminal No.

08 10 12 14 16 18 20 24 30 33 36 42 52

Range 5.88 – 8.82 9.8 – 12.74 14.7 – 19.6 19.6 – 24.5 24.5 – 34.3 34.3 – 44.1 44.1 – 53.9 58.8 – 78.4 93.1 – 122.5 107.8 – 147.0 127.4 – 176.4 181.3 – 240.1 274.4 – 367.5

{0.6 – 0.9} {1.0 – 1.3} {1.5 – 2.0} {2.0 – 2.5} {2.5 – 3.5} {3.5 – 4.5} {4.5 – 5.5} {6.0 – 8.0} {9.5 – 12.5} {11.0 – 15.0} {13.0 – 18.0} {18.5 – 24.5} {28.0 – 37.5}

Target 7.35 {0.75} 11.27 {1.15} 17.64 {1.8} 22.54 {2.3} 29.4 {3.0} 39.2 {4.0} 49.0 {5.0} 68.6 {7.0} 107.8 {11.0} 124.4 {13.0} 151.9 {15.5} 210.7 {21.5} 323.4 {33.0}

00-13

FOREWORD

STANDARD TIGHTENING TORQUE

TIGHTENING TORQUE FOR 102 ENGINE SERIES 1) BOLT AND NUTS Use these torques for bolts and nuts (unit: mm) of Cummins Engine. Thread diameter

Tightening torque

mm

Nm

kgm

10 0 2 24 0 4 43 0 6 77 0 12

6 8 10 12

1.02 0 0.20 2.45 0 0.41 4.38 0 0.61 7.85 0 1.22

2) EYE JOINTS Use these torques for eye joints (unit: mm) of Cummins Engine. Thread diameter

Tightening torque

mm

Nm

kgm

802 10 0 2 12 0 2 24 0 4 36 0 5

6 8 10 12 14

0.81 0 0.20 1.02 0 0.20 1.22 0 0.20 2.45 0 0.41 3.67 0 0.51

3) TAPERED SCREWS Use these torques for tapered screws (unit: inch) of Cummins Engine. Thread diameter

Tightening torque

inch

Nm

kgm

301 802 12 0 2 15 0 2 24 0 4 36 0 5 60 0 9

1 / 16 1/8 1/4 3/8 1/2 3/4 1

0.31 0 0.10 0.81 0 0.20 1.22 0 0.20 1.53 0 0.41 2.45 0 0.41 3.67 0 0.51 6.12 0 0.92

TIGHTENING TORQUE TABLE FOR HOSES (TAPER SEAL TYPE AND FACE SEAL TYPE) ★ Tighten the hoses (taper seal type and face seal type) to the following torque, unless otherwise specified. ★ Apply the following torque when the threads are coated (wet) with engine oil. Tightening torque (Nm {kgm}) Nominal size Width across of hose flats

Taper seal type

Face seal type

Nominal thread Thread size size Root diameter - Threads per (mm) inch, Thread series (mm) (Reference)

Range

Target

19

34 - 63 {3.5 - 6.5}

44 {4.5}

14

9 – - 18UNF 16

14.3

22

54 - 93 {5.5 - 9.5}

74 {4.5}

–

11 – - 16UN 16

17.5

24

59 - 98 {6.0 - 10.0}

78 {8.0}

18

–

–

04

27

84 - 132 {8.5 - 13.5}

103 {10.5}

22

13 – - 16UN 16

20.7

05

32

128 - 186 {13.0 - 19.0}

157 {16.0}

24

1 - 14UNS

25.4

06

36

177 - 245 {18.0 - 25.0}

216 {22.0}

30

3 1 – - 12UNF 16

30.3

(10)

41

177 - 245 {18.0 - 25.0}

216 {22.0}

33

–

–

(12)

46

197 - 294 {20.0 - 30.0}

245 {25.0}

36

–

–

(14)

55

246 - 343 {25.0 - 35.0}

294 {30.0}

42

–

–

02

03

00-14

FOREWORD

ELECTRIC WIRE CODE

ELECTRIC WIRE CODE In the wiring diagrams, various colors and symbols are employed to indicate the thickness of wires. This wire code table will help you understand WIRING DIAGRAMS. Example: 5WB indicates a cable having a nominal number 5 and white coating with black stripe.

CLASSIFICATION BY THICKNESS Copper wire Cable O.D. (mm)

Current rating (A)

Applicable circuit

0.88

2.4

12

Starting, lighting, signal etc.

0.32

2.09

3.1

20

Lighting, signal etc.

65

0.32

5.23

4.6

37

Charging and signal

15

84

0.45

13.36

7.0

59

Starting (Glow plug)

40

85

0.80

42.73

11.4

135

Starting

60

127

0.80

63.84

13.6

178

Starting

100

217

0.80

109.1

17.6

230

Starting

Norminal number

Number of strands

Dia. of strands (mm2)

Cross section (mm2)

0.85

11

0.32

2

26

5

CLASSIFICATION BY COLOR AND CODE Circuits Priority Classification

1

Primary

Charging

Ground

Starting

Lighting

Instrument

Signal

Other

Code

W

B

B

R

Y

G

L

Color

White

Black

Black

Red

Yellow

Green

Blue

Code

WR

—

BW

RW

YR

GW

LW

2 Color White & Red

—

Code

—

WB

White & Black Red & White Rellow & Red Green & White Blue & White BY

RB

YB

GR

LR

3

4

Auxiliary

Color White & Black

—

Code

—

WL

Black & Yellow Red & Black Yellow & Black Green & Red Blue & Yellow BR

Color White & Blue

—

Code

—

—

Color White & Green

—

—

Code

—

—

—

Color

—

—

—

WG

RY

Black & Red Red & Yellow RG

YG

GY

LY

Yellow & Green

Green & Yellow

Blue & Yellow

YL

GB

LB

5 Red & Green Yellow & Blue Green & Black Blue & Black RL

YW

GL

6 Red & Blue Yellow & White Green & Blue

n n

00-15

FOREWORD

CONVERSION TABLE

CONVERSION TABLE METHOD OF USING THE CONVERSION TABLE The Conversion Table in this section is provided to enable simple conversion of figures. For details of the method of using the Conversion Table, see the example given below.

EXAMPLE • Method of using the Conversion Table to convert from millimeters to inches 1. Convert 55 mm into inches. (1) Locate the number 50 in the vertical column at the left side, take this as A, then draw a horizontal line from A. (2) Locate the number 5 in the row across the top, take this as B, then draw a perpendicular line down from B. (3) Take the point where the two lines cross as C. This point C gives the value when converting from millimeters to inches. Therefore, 55 mm = 2.165 inches. 2. Convert 550 mm into inches. (1) The number 550 does not appear in the table, so divide by 10 (move the decimal point one place to the left) to convert it to 55 mm. (2) Carry out the same procedure as above to convert 55 mm to 2.165 inches. (3) The original value (550 mm) was divided by 10, so multiply 2.165 inches by 10 (move the decimal point one place to the right) to return to the original value. This gives 550 mm = 21.65 inches. B Millimeters to inches 1 mm = 0.03937 in

A

00-16

0

1

2

3

4

0 10 20 30 40

0 0.394 0.787 1.181 1.575

0.039 0.433 0.827 1.220 1.614

0.079 0.472 0.866 1.260 1.654

0.118 0.512 0.906 1.299 1.693

0.157 0.551 0.945 1.339 1.732

50 60 70 80 90

1.969 2.362 2.756 3.150 3.543

2.008 2.402 2.795 3.189 3.583

2.047 2.441 2.835 3.228 3.622

2.087 2.480 2.874 3.268 3.661

2.126 2.520 2.913 3.307 3.701

5 0.197 0.591 0.984 1.378 1.772 C 2.165 2.559 2.953 3.346 3.740

6

7

8

9

0.236 0.630 1.024 1.417 1.811

0.276 0.669 1.063 1.457 1.850

0.315 0.709 1.102 1.496 1.890

0.354 0.748 1.142 1.536 1.929

2.205 2.598 2.992 3.386 3.780

2.244 2.638 3.032 3.425 3.819

2.283 2.677 3.071 3.465 3.858

2.323 2.717 3.110 3.504 3.898

FOREWORD

CONVERSION TABLE

Millimeters to Inches 1 mm = 0.03937 in

0

1

2

3

4

5

6

7

8

9

0

0.039

0.079

0.118

0.157

0.197

0.236

0.276

0.315

0.354

10

0.394

0.433

0.472

0.512

0.551

0.591

0.630

0.669

0.709

0.748

20

0.787

0.827

0.866

0.906

0.945

0.984

1.024

1.063

1.102

1.142

30

1.181

1.220

1.260

1.299

1.339

1.378

1.417

1.457

1.496

1.536

40

1.575

1.614

1.654

1.693

1.732

1.772

1.811

1.850

1.890

1.929

50

1.969

2.008

2.047

2.087

2.126

2.165

2.205

2.244

2.283

2.323

60

2.362

2.402

2.441

2.480

2.520

2.559

2.598

2.638

2.677

2.717

70

2.756

2.795

2.835

2.874

2.913

2.953

2.992

3.032

3.071

3.110

80

3.150

3.189

3.228

3.268

3.307

3.346

3.386

3.425

3.465

3.504

90

3.543

3.583

3.622

3.661

3.701

3.740

3.780

3.819

3.858

3.898

0

Kilogram to Pound 1 kg = 2.2046 lb

0 0

0

1

2

3

4

5

6

7

8

9

2.20

4.41

6.61

8.82

11.02

13.23

15.43

17.64

19.84

10

22.05

24.25

26.46

28.66

30.86

33.07

35.27

37.48

39.68

41.89

20

44.09

46.30

48.50

50.71

51.91

55.12

57.32

59.53

61.73

63.93

30

66.14

68.34

70.55

72.75

74.96

77.16

79.37

81.57

83.78

85.98

40

88.18

90.39

92.59

94.80

97.00

99.21

101.41

103.62

105.82

108.03

50

110.23

112.44

114.64

116.85

119.05

121.25

123.46

125.66

127.87

130.07

60

132.28

134.48

136.69

138.89

141.10

143.30

145.51

147.71

149.91

152.12

70

154.32

156.53

158.73

160.94

163.14

165.35

167.55

169.76

171.96

174.17

80

176.37

178.57

180.78

182.98

185.19

187.39

189.60

191.80

194.01

196.21

90

198.42

200.62

202.83

205.03

207.24

209.44

211.64

213.85

216.05

218.26

00-17

FOREWORD

CONVERSION TABLE

Liter to U.S. Gallon 1l = 0.2642 U.S. Gal

0

1

2

3

4

5

6

7

8

9

0

0.264

0.528

0.793

1.057

1.321

1.585

1.849

2.113

2.378

10

2.642

2.906

3.170

3.434

3.698

3.963

4.227

4.491

4.755

5.019

20

5.283

5.548

5.812

6.076

6.340

6.604

6.869

7.133

7.397

7.661

30

7.925

8.189

8.454

8.718

8.982

9.246

9.510

9.774

10.039

10.303

40

10.567

10.831

11.095

11.359

11.624

11.888

12.152

12.416

12.680

12.944

50

13.209

13.473

13.737

14.001

14.265

14.529

14.795

15.058

15.322

15.586

60

15.850

16.115

16.379

16.643

16.907

17.171

17.435

17.700

17.964

18.228

70

18.492

18.756

19.020

19.285

19.549

19.813

20.077

20.341

20.605

20.870

80

21.134

21.398

21.662

21.926

22.190

22.455

22.719

22.983

23.247

23.511

90

23.775

24.040

24.304

24.568

24.832

25.096

25.361

25.625

25.889

26.153

0

Liter to U.K. Gallon 1l = 0.21997 U.K. Gal

0

1

2

3

4

5

6

7

8

9

0

0.220

0.440

0.660

0.880

1.100

1.320

1.540

1.760

1.980

10

2.200

2.420

2.640

2.860

3.080

3.300

3.520

3.740

3.950

4.179

20

4.399

4.619

4.839

5.059

5.279

5.499

5.719

5.939

6.159

6.379

30

6.599

6.819

7.039

7.259

7.479

7.969

7.919

8.139

8.359

8.579

40

8.799

9.019

9.239

9.459

9.679

9.899

10.119

10.339

10.559

10.778

50

10.998

11.281

11.438

11.658

11.878

12.098

12.318

12.528

12.758

12.978

60

13.198

13.418

13.638

13.858

14.078

14.298

14.518

14.738

14.958

15.178

70

15.398

15.618

15.838

16.058

16.278

16.498

16.718

16.938

17.158

17.378

80

17.598

17.818

18.037

18.257

18.477

18.697

18.917

19.137

19.357

19.577

90

19.797

20.017

20.237

20.457

20.677

20.897

21.117

21.337

21.557

21.777

0

00-18

FOREWORD

CONVERSION TABLE

kgm to ft. lb 1 kgm = 7.233 ft. lb

0

1

2

3

4

5

6

7

8

9

0

0

7.2

14.5

21.7

28.9

36.2

43.4

50.6

57.9

65.1

10

72.3

79.6

86.8

94.0

101.3

108.5

115.7

123.0

130.2

137.4

20

144.7

151.9

159.1

166.4

173.6

180.8

188.1

195.3

202.5

209.8

30

217.0

224.2

231.5

238.7

245.9

253.2

260.4

267.6

274.9

282.1

40

289.3

296.6

303.8

311.0

318.3

325.5

332.7

340.0

347.2

354.4

50

361.7

368.9

376.1

383.4

390.6

397.8

405.1

412.3

419.5

426.8

60

434.0

441.2

448.5

455.7

462.9

470.2

477.4

484.6

491.8

499.1

70

506.3

513.5

520.8

528.0

535.2

542.5

549.7

556.9

564.2

571.4

80

578.6

585.9

593.1

600.3

607.6

614.8

622.0

629.3

636.5

643.7

90

651.0

658.2

665.4

672.7

679.9

687.1

694.4

701.6

708.8

716.1

100

723.3

730.5

737.8

745.0

752.2

759.5

766.7

773.9

781.2

788.4

110

795.6

802.9

810.1

817.3

824.6

831.8

839.0

846.3

853.5

860.7

120

868.0

875.2

882.4

889.7

896.9

904.1

911.4

918.6

925.8

933.1

130

940.3

947.5

954.8

962.0

969.2

976.5

983.7

990.9

998.2

1005.4

140

1012.6

1019.9

1027.1

1034.3

1041.5

1048.8

1056.0

1063.2

1070.5

1077.7

150

1084.9

1092.2

1099.4

1106.6

1113.9

1121.1

1128.3

1135.6

1142.8

1150.0

160

1157.3

1164.5

1171.7

1179.0

1186.2

1193.4

1200.7

1207.9

1215.1

1222.4

170

1129.6

1236.8

1244.1

1251.3

1258.5

1265.8

1273.0

1280.1

1287.5

1294.7

180

1301.9

1309.2

1316.4

1323.6

1330.9

1338.1

1345.3

1352.6

1359.8

1367.0

190

1374.3

1381.5

1388.7

1396.0

1403.2

1410.4

1417.7

1424.9

1432.1

1439.4

00-19

FOREWORD

CONVERSION TABLE

kg/cm2 to lb/in2 1kg/cm2 = 14.2233 lb/in2

0

1

2

3

4

5

6

7

8

9

0

0

14.2

28.4

42.7

56.9

71.1

85.3

99.6

113.8

128.0

10

142.2

156.5

170.7

184.9

199.1

213.4

227.6

241.8

256.0

270.2

20

284.5

298.7

312.9

327.1

341.4

355.6

369.8

384.0

398.3

412.5

30

426.7

440.9

455.1

469.4

483.6

497.8

512.0

526.3

540.5

554.7

40

568.9

583.2

597.4

611.6

625.8

640.1

654.3

668.5

682.7

696.9

50

711.2

725.4

739.6

753.8

768.1

782.3

796.5

810.7

825.0

839.2

60

853.4

867.6

881.8

896.1

910.3

924.5

938.7

953.0

967.2

981.4

70

995.6

1010

1024

1038

1053

1067

1081

1095

1109

1124

80

1138

1152

1166

1181

1195

1209

1223

1237

1252

1266

90

1280

1294

1309

1323

1337

1351

1365

1380

1394

1408

100

1422

1437

1451

1465

1479

1493

1508

1522

1536

1550

110

1565

1579

1593

1607

1621

1636

1650

1664

1678

1693

120

1707

1721

1735

1749

1764

1778

1792

1806

1821

1835

130

1849

1863

1877

1892

1906

1920

1934

1949

1963

1977

140

1991

2005

2020

2034

2048

2062

2077

2091

2105

2119

150

2134

2148

2162

2176

2190

2205

2219

2233

2247

2262

160

2276

2290

2304

2318

2333

2347

2361

2375

2389

2404

170

2418

2432

2446

2460

2475

2489

2503

2518

2532

2546

180

2560

2574

2589

2603

2617

2631

2646

2660

2674

2688

190

2702

2717

2731

2745

2759

2773

2788

2802

2816

2830

200

2845

2859

2873

2887

2901

2916

2930

2944

2958

2973

210

2987

3001

3015

3030

3044

3058

3072

3086

3101

3115

220

3129

3143

3158

3172

3186

3200

3214

3229

3243

3257

230

3271

3286

3300

3314

3328

3343

3357

3371

3385

3399

240

3414

3428

3442

3456

3470

3485

3499

3513

3527

3542

00-20

FOREWORD

CONVERSION TABLE

Temperature Fahrenheit-Centigrade Conversion ; a simple way to convert a Fahrenheit temperature reading into a Centigrade temperature reading or vice versa is to enter the accompanying table in the center or boldface column of figures. These figures refer to the temperature in either Fahrenheit or Centigrade degrees. If it is desired to convert from Fahrenheit to Centigrade degrees, consider the center column as a table of Fahrenheit temperatures and read the corresponding Centigrade temperature in the column at the left. If it is desired to convert from Centigrade to Fahrenheit degrees, consider the center column as a table of Centigrade values, and read the corresponding Fahrenheit temperature on the right. 1°C = 33.8°F

°C

°F

°C

°F

°C

°F

°C

°F

–40.4 –37.2 –34.4 –31.7 –28.9

–40 –35 –30 –25 –20

–40.0 –31.0 –22.0 –13.0 –4.0

–11.7 –11.1 –10.6 –10.0 –9.4

11 12 13 14 15

51.8 53.6 55.4 57.2 59.0

7.8 8.3 8.9 9.4 10.0

46 47 48 49 50

114.8 116.6 118.4 120.2 122.0

27.2 27.8 28.3 28.9 29.4

81 82 83 84 85

117.8 179.6 181.4 183.2 185.0

–28.3 –27.8 –27.2 –26.7 –26.1

–19 –18 –17 –16 –15

–2.2 –0.4 1.4 3.2 5.0

–8.9 –8.3 –7.8 –7.2 –6.7

16 17 18 19 20

60.8 62.6 64.4 66.2 68.0

10.6 11.1 11.7 12.2 12.8

51 52 53 54 55

123.8 125.6 127.4 129.2 131.0

30.0 30.6 31.1 31.7 32.2

86 87 88 89 90

186.8 188.6 190.4 192.2 194.0

–25.6 –25.0 –24.4 –23.9 –23.3

–14 –13 –12 –11 –10

6.8 8.6 10.4 12.2 14.0

–6.1 –5.6 –5.0 –4.4 –3.9

21 22 23 24 25

69.8 71.6 73.4 75.2 77.0

13.3 13.9 14.4 15.0 15.6

56 57 58 59 0

132.8 134.6 136.4 138.2 140.0

32.8 33.3 33.9 34.4 35.0

91 92 93 94 95

195.8 197.6 199.4 201.2 203.0

–22.8 –22.2 –21.7 –21.1 –20.6

–9 –8 –7 –6 –5

15.8 17.6 19.4 21.2 23.0

–3.3 –2.8 –2.2 –1.7 –1.1

26 27 28 29 30

78.8 80.6 82.4 84.2 86.0

16.1 16.7 17.2 17.8 18.3

61 62 63 64 65

141.8 143.6 145.4 147.2 149.0

35.6 36.1 36.7 37.2 37.8

96 97 98 99 100

204.8 206.6 208.4 210.2 212.0

–20.0 –19.4 –18.9 –18.3 –17.8

–4 –3 –2 –1 0

24.8 26.6 28.4 30.2 32.0

–0.6 0 0.6 1.1 1.7

31 32 33 34 35

87.8 89.6 91.4 93.2 95.0

18.9 19.4 20.0 20.6 21.1

66 67 68 69 70

150.8 152.6 154.4 156.2 158.0

40.6 43.3 46.1 48.9 51.7

105 110 115 120 125

221.0 230.0 239.0 248.0 257.0

–17.2 –16.7 –16.1 –15.6 –15.0

1 2 3 4 5

33.8 35.6 37.4 39.2 41.0

2.2 2.8 3.3 3.9 4.4

36 37 38 39 40

96.8 98.6 100.4 102.2 104.0

21.7 22.2 22.8 23.3 23.9

71 72 73 74 75

159.8 161.6 163.4 165.2 167.0

54.4 57.2 60.0 62.7 65.6

130 135 140 145 150

266.0 275.0 284.0 293.0 302.0

–14.4 –13.9 –13.3 –12.8 –12.2

6 7 8 9 10

42.8 44.6 46.4 48.2 50.0

5.0 5.6 6.1 6.7 7.2

41 42 43 44 45

105.8 107.6 109.4 111.2 113.0

24.4 25.0 25.6 26.1 26.7

76 77 78 79 80

168.8 170.6 172.4 174.2 176.0

68.3 71.1 73.9 76.7 79.4

155 160 165 170 175

311.0 320.0 329.0 338.0 347.0

00-21

FOREWORD

UNITS

UNITS In this manual, the measuring units are indicated with Internatinal System of units (SI). As for reference, conventionally used Gravitational System of units are indicated in parentheses { Example: N {kg} Nm {kgm} MPa {kg/cm2} kPa {mmH2O} kPa {mmHg} kW/rpm {HP/rpm} g/kWh {g/HPh}

00-22

}.

01 GENERAL

GENERAL ASSEMBLY DRAWING ........................................... 01-2 SPECIFICATIONS ..................................................................... 01-4 WEIGHT TABLE ........................................................................ 01-7 LIST OF LUBRICANTS AND WATER ....................................... 01-9

PC130-7

01-1

GENERAL

GENERAL ASSEMBLY DRAWING

GENERAL ASSEMBLY DRAWING SPECIFICATION DIMENSIONAL DRAWING

PC130-7 Item

Unit 2.5 m arm, 500 mm shoe

3.0 m arm, 700 mm shoe

A

Overall length

mm

7,595

7,485

B

Overall height

mm

2,810

3,170

C

Overall width

mm

2,490

2,490

D

Shoe width

mm

500

700

E

Cab height

mm

2,810

2,810

F

Trail swing radius

mm

2,190

2,190

G

Crawler overall length

mm

3,610

3,610

H

Distance between tambler center

mm

2,880

2,880

01-2

PC130-7

GENERAL

GENERAL ASSEMBLY DRAWING

WORKING RANGE DRAWING

PC130-7 Working range (mm) 2.5 m arm

3.0 m arm

A

Maximum digging radius

8,290

8,785

B

Maximum digging depth

5,520

6,015

C

Maximum digging height

8,610

8,790

D

Maximum vertical wall digging depth

4,940

5,360

E

Maximum dumping height

6,170

6,535

F

Minimum swing radius of work equipment

2,450

2,610

G

Maximum reach at ground level

8,170

8,665

PC130-7

01-3

GENERAL

SPECIFICATIONS

SPECIFICATIONS PC130-7 Machine model 2.5 m arm, 500 mm shoe

Dimension

Bucket capacity (SAE)

0.5

0.5

Operating weight

kg

12,200

13,050

Max. digging depth

mm

5,520

6,015

Max. vertical wall depth

mm

4,940

5,360

Max. digging reach

mm

8,290

8,785

Max. reach st ground level

mm

8,170

8,665

Max. digging height

mm

8,610

8,970

Max. dumping height

mm

6,170

6,535

kN {kg}

93.2 {9,500}

93.2 {9,500}

Swing speed

rpm

11.0

11.0

Swing max. slope angle

deg.

20

20

Travel speed (Hi/Lo)

km/h

2.7/5.5

2.7/5.5

Gradeability

deg.

35

35

Ground pressure

{kg/cm2}

38 {0.39}

29 {0.30}

Max. digging force (bucket)

mm

7,595

7,485

Overall width

mm

2,490

2,690

Overall height (for transport)

mm

2,810

3,170

Overall height to top of cab

mm

2,730

2,730

Ground clearance of counterweight

mm

855

855

Min. ground clearance

mm

400

400

Tail swing radius

mm

2,190

2,190

Min. swing radius of work euipment

mm

2,450

2,610

Height of work equipment at min. swing radius

mm

6,455

6,455

Length of track

mm

3,610

3,610

Distance between tumbler center

mm

2,880

2,880

Track gauge

mm

1,990

1,990

Overall height of machine cab

mm

1,885

1,885

Model

SAA4D95LE-3

Type

4-cycle, water-cooled, in-line, vertical, direct injection, with turbochatger, after cooler mm

4 – 95 x 115

l {cc}

3.260 {3,260}

Rated horsepower

kW/rpm{HP/rpm}

66.2/2,200 {88.7/2,200}

Max. torpue

Nm/rpm{kgm/rpm}

353/1,500 {36.0/1,500}

High idling speed

rpm

2,400

Low idling speed

rpm

1,100

g/kWh{g/HPh}

224 {165}

Performance

Piston displacement Engine

kPa

Overall length (for transport)

No. of cylinders-bore x stroke

Min. fuel consumption ratio

01-4 (3)

70001 and up m3

Working ranges

Performance

Serial No.

3.0 m arm, 700 mm shoe

PC130-7

GENERAL

SPECIFICATIONS

PC130-7 Machine model 2.5 m arm, 500 mm shoe Serial No.

70001 and up 24V, 3.0 kw

Alternator

24V, 25A

Battery

12V, 64 Ah x 2

Radiator type

Aluminum wave (4-line)

Carrier roller

1 on each side

Track roller

7 on each side

Track shoe (iron shoe)

Asembly-type triple grouster, 43 on each side

Hydraulic pump

(road liner) Type x no.

Hydraulic motor Control valve

Type x no.

Road liner, 43 on each side Variable displacement piston type x 1

Discharge Set pressure (at operation)

l /min

226 (at 2,200rpm)

MPa {kg/cm2}

31.9 {325}

(at traveling)

34.8 {355} 7-spool type x 1

Control method

Hydraulic type

Travel motor

Variable displacement piston type (with brake valve, holding brake) x 2

Swing motor

Fixed displacement piston type (with safety valve, holding brake) x 1

Hydraulic tank

Box-shaped, open

Hydraulic filter

Tank return side

Hydraulic cooler

Air cooled

PC130-7

Boom cylinder

Work equipment cylinder

Type

Reciprocating piston tipe

Reciprocating piston tipe

Cylinder inner diameter

mm

105

105

Piston rod diameter

mm

70

70

Stroke

mm

990

990

Max. length betwiin pins

mm

2,490

2,490

Min. length betwiin pins

mm

1,500

1,500

Reciprocating piston tipe

Reciprocating piston tipe

Type Arm cylinder

Undercarriage

Engine

Starting motor

Hydraulic system

3.0 m arm, 700 mm shoe

Cylinder inner diameter

mm

115

115

Piston rod diameter

mm

75

75

Stroke

mm

1,175

1,175

Max. length betwiin pins

mm

2,877

2,877

Min. length betwiin pins

mm

1,702

1,702

01-5

GENERAL

SPECIFICATIONS

PC130-7 Machine model 2.5 m arm, 500 mm shoe

01-6

70001 and up

Type Bucket cylinder

Work equipment cylinder

Hydraulic system

Serial No.

3.0 m arm, 700 mm shoe

Reciprocating piston tipe

Reciprocating piston tipe

Cylinder inner diameter

mm

95

95

Piston rod diameter

mm

65

65

Stroke

mm

885

885

Max. length betwiin pins

mm

2,263

2,263

Min. length betwiin pins

mm

1,378

1,378

PC130-7

GENERAL

WEIGHT TABLE

WEIGHT TABLE

k This weight table is a guide for use when transporting or handling component. Unit: kg Machine model

PC130-7

Serial No.

70001 and up

Engine assembly (excl. water, oil)

449

• Engine (excl. water, oil)

345

• Engine mount

19.6

• PTO

4.1

• Hydraulic pump

80

Radiator, oil cooler assembly

83

Revolving frame

1,110

Operator's cab

279

Operator's seat

35

Fuel tank (excl. fuel)

101

Hydraulic tank (excl. hydraulic oil)

89

Control valve

116

Self pressure reducing valve

4.8

Counterweight

2,455

Swing motor (with brake valve)

26

Swing circle

155

Swing machinery

72.2

Center swivel joint

28.6

Track frame assembly

2,260

• Track frame

1,280

• Idler assembly

79 x 2

• Recoil spring assembly

69.5 x 2

• Carrier roller

16.5 x 2

• Track roller

21 x 14

• Travel motor, final drive assembly

144 x 2

• Sprocket

33.7 x 2

Track shoe assembly • Triple grouser shoe (500mm)

725 x 2

• Triple grouser shoe (600mm)

815 x 2

• Triple grouser shoe (700mm)

905 x 2

• City pad shoe (500mm)

720 x 2

• Road liner (500mm)

780 x 2

PC130-7

01-7

GENERAL

WEIGHT TABLE

Unit: kg Machine model

PC130-7

Serial No.

70001 and up

Boom assembly

1,088

Arm assembly

392.4

Bucket link assembly

92.7

Bucket assembly

369

Boom cylinder assembly

92.7

Arm cylinder assembly

135

Bucket cylinder assembly

82.6

01-8

PC130-7

GENERAL

LIST OF LUBRICANTS AND WATER

LIST OF LUBRICANTS AND WATER

RESERVOIR

KIND OF -22 FLUID -30

AMBIENT TEMPERATURE -4 -20

14 -10

32 0

50 10

68 20

CAPACITY ( ) 86 30

104°F 40°C

Specified

Refill

17.5

16

0.75

0.75

2.5

2.5

2.5

2.5

0.090 --0.105

0.090 --0.105

0.075 --0.085

0.075 --0.085

0.068 --0.076

0.068 --0.076

140

90

SAE 30 SAE 10W

Engine oil pan

SAE 10W-30 SAE 15W-40 PTO case Swing machinery case Final drive case (each)

SAE 30 Engine oil

Idler (each) Track roller (each)

SAE 30

Carrier roller (each) SAE 10W SAE 10W-30

Hydraulic system

SAE 15W-40 Hydraulic oil

Fuel tank

HD46-HM (a) ASTM D975 No.2

Diesel fuel

240

ASTM D975 No. 1 Cooling system

PC130-7

Coolant

Add antifreeze

18.2

01-9

10 STRUCTURE AND FUNCTION

PTO ...........................................................................10- 2 COOLING SYSTEM ..................................................10- 3 POWER TRAIN .........................................................10- 5 SWING CIRCLE ........................................................10- 6 SWING MACHINERY................................................10- 7 TRACK FRAME.........................................................10- 8 IDLER CUSHION ......................................................10- 9 HYDRAULIC COMPONENT LAYOUT ......................10- 10 VALVE CONTROL.....................................................10- 12 HYDRAULIC TANK AND FILTER..............................10- 14 HYDRAULIC PUMP (PISTON PUMP) ......................10- 15 CONTROL VALVE.....................................................10- 36 SUCTION SAFETY VALVE .......................................10- 46 CLSS .........................................................................10- 47 SELF PRESSURE REDUCING VALVE ....................10- 79 CENTER SWIVEL JOINT..........................................10- 86 TRAVEL MOTOR (FINAL DRIVE).............................10- 87 SWING MOTOR ........................................................10- 96 SOLENOID VALVE....................................................10-102 PPC ACCUMULATOR...............................................10-104 PPC VALVE ...............................................................10-105 WORK EQUIPMENT .................................................10-116 AIR CONDITIONER PIPING .....................................10-117 ENGINE CONTROL ..................................................10-118 ELECTRIC CONTROL SYSTEM ..............................10-123 MONITOR SYSTEM..................................................10-150

PC130-7

10-1

STRUCTURE AND FUNCTION

PTO

PTO

1. 2. 3. 4.

Coupling Shaft Cage Hydraulic pump

10-2

5. Level plug 6. Oil filler plug 7. Breather

PC130-7

STRUCTURE AND FUNCTION

COOLING SYSTEM

COOLING SYSTEM

PC130-7

10-3

STRUCTURE AND FUNCTION

1. 2. 3. 4. 5. 6. 7. 8.

COOLING SYSTEM

9. 10. 11. 12. 13. 14. 15. 16.

Reservoir tank Shroud Oil cooler Fan Radiator Fan guard Oil cooler Radiator cap

Charge air inlet hose Radiator inlet hose Charge air outlet hose Oil cooler outlet Drain valve Radiator outlet hose Air condenser Oil cooler inlet

SPECIFICATION Radiator

Oil cooler

Charge air cooler

Aluminium wave (4-line)

CF40

Aluminium wave

(mm)

3.5/2

3.5/2

4.0/2

(m2)

25.58

11.60

9.54

Pressure valve cracking pressure (kPa {kg/cm2})

49.0 ± 14.7 {0.5 ± 0.15}

—

—

Vacuum valve cracking pressure (kPa {kg/cm2})

-4.9 – 0 {-0.05 – 0}

—

—

Core type Fin pitch Total heat dissipation surface

10-4 (3)

PC130-7

STRUCTURE AND FUNCTION

POWER TRAIN

POWER TRAIN

1. 2. 3. 4. 5. 6. 7.

Idler Control valve Self pressure reducing valve Travel motor Hydraulic pump Engine 2-stage relief solenoid valve

PC130-7

8. 9. 10. 11. 12. 13. 14.

Swing hold brake solenoid valve 2-speed travel changeover solenoid valve PPC lock solenoid valve Swing motor Center swivel joint Swing machinery Swing circle

10-5

STRUCTURE AND FUNCTION

SWING CIRCLE

SWING CIRCLE

1. Outer race 2. Ball 3. Inner race a. Inner race soft zone "S" position b. Outer race soft zone "S" position

10-6

SPECIFICATIONS Reduction ratio: –

90 11

= – 8.182

Amount of grease: 6.5 l (Grease: G2-LI)

PC130-7

STRUCTURE AND FUNCTION

SWING MACHINERY

SWING MACHINERY

1. 2. 3. 4. 5. 6. 7. 8. 9.

Swing pinion (No. of teeth: 11) Case No. 2 sun gear (No. of teeth: 17) No. 2 planetary carrier (No. of teeth: 17) Ring gear (No. of teeth: 61) No. 1 planetary carrier (No. of teeth: 17) No. 1 sun gear (No. of teeth: 14) Oil level gauge/ oil filler port Swing motor

PC130-7

10. 11. 12. 13.

No. 1 planetary gear (No. of teeth: 24) No. 2 planetary gear (No. of teeth: 22) Drain plug Swing circle

SPECIFICATION + 61 Reduction ratio: 1414 x

17 + 61 17

= 24.58

10-7

STRUCTURE AND FUNCTION

TRACK FRAME

TRACK FRAME

1. 2. 3. 4.

Idler Track frame Carrier roller Travel motor

10-8

5. 6. 7. 8.

Sprocket Track roller Idler cushion Track shoe

PC130-7

STRUCTURE AND FUNCTION

IDLER CUSHION

IDLER CUSHION

1. 2. 3. 4. 5. 6. 7. 8. 9. 10.

Idler Support Yoke Cylinder Recoil spring U-packing Pilot Nut Valve Grease fitting

PC130-7

SPECIFICATION Grease : G2-LI Amount of filled grease : 140 ml

10-9

STRUCTURE AND FUNCTION

HYDRAULIC COMPONENT LAYOUT

HYDRAULIC COMPONENT LAYOUT

1. 2. 3. 4. 5. 6. 7. 8. 9. 10.

11. 12. 13. 14.

Bucket cylinder Arm cylinder Boom cylinder Hydraulic tank Swing motor Hydraulic pump Oil cooler L.H. travel motor Control valve 4-spool solenoid valve • PPC lock • 2-speed travel speed selection • Swing holding brake • 2-stage relief L.H. PPC valve R.H. PPC valve Travel PPC valve Center swivel joint

10-10

PC130-7

STRUCTURE AND FUNCTION

PC130-7

HYDRAULIC COMPONENT LAYOUT

10-11

STRUCTURE AND FUNCTION

VALVE CONTROL

VALVE CONTROL

10-12

PC130-7

STRUCTURE AND FUNCTION

VALVE CONTROL

1. R.H. work equipment PPC valve 2. R.H. work equipment control lever (for boom and bucket operation) 3. Main pump 4. Control valve 5. 4-spool solenoid valve 6. L.H. work equipment control lever (for arm, swing operation) 7. L.H. work equipment PPC valve 8. Safety lock lever 9. L.H. travel pedal 10. R.H. travel pedal 11. L.H. travel lever 12. R.H. travel lever 13. Travel PPC valve 14. Attachment PPC valve (Attachment installable machine) 15. Attachment pedal (Attachment installable machine) Lever and Pedal Positions (A) HOLD (B) Boom LOWER (C) Boom RAISE (D) Bucket CURL (E) Bucket DUMP (F) HOLD (G) Arm OUT (H) Arm IN (J) Swing LEFT (K) Swing RIGHT (L) L.H. travel FORWARD (M) L.H. travel REVERSE (N) R.H. travel FORWARD (P) R.H. travel REVERSE (Q) PPC FREE (R) PPC LOCK

PC130-7

10-13

STRUCTURE AND FUNCTION

HYDRAULIC TANK AND FILTER

HYDRAULIC TANK AND FILTER

1. 2. 3. 4. 5. 6. 7. 8. 9. 10.

Hydraulic tank Drain plug Oil filler cap Pressure valve Vacuum valve Sight gauge Suction strainer Filter element Bypass strainer Bypass valve

10-14

SPECIFICATION Tank capacity : 130 l Hydraulic oil amount in tank : 90 l Pressure valve cracking pressure : 16.7 ± 6.9 kPa {0.17 ± 0.07 kg/cm2} Vacuum valve cracking pressure : -0.49 – 0 kPa {-0.005 – 0 kg/cm2} Bypass valve set pressure : 103 ± 29.4 kPa {1.05 ± 0.2 kg/cm2}

PC130-7

STRUCTURE AND FUNCTION

HYDRAULIC PUMP

HYDRAULIC PUMP (PISTON PUMP) MAIN PUMP Type : HPV95 (for 105cc/rev.)

1. 2. 3. 4. 5. 6.

Main pump LS valve PC valve Fixed choke valve PC-EPC valve (for PC mode selection) LS-EPC valve (for LS set selection)

PC130-7

IM : PC mode change current PA : Main pump delivery PB : Main pump pressure input PS : Main pump absorption PD1 : Case drain PLS : Control valve LS pressure inlet PEPC : EPC valve basic pressure inlet

10-15

STRUCTURE AND FUNCTION

1. 2. 3. 4. 5. 6. 7.

Shaft Cradle Case Rocker cam Shoe Piston Cylinder block

10-16

HYDRAULIC PUMP

8. 9. 10. 11. 12. 13.

Valve plate End cap Spring Servo last chance filter Servo piston Slider

PC130-7

STRUCTURE AND FUNCTION

HYDRAULIC PUMP

FUNCTION • This pump converts engine rotation and torque transmitted to the pump shaft into hydraulic energy and discharges pressurized oil according to load. • This pump can change delivery when the swash plate angle is changed.

STRUCTURE • Cylinder block (7) is supported to shaft (1) with spline a, and shaft (1) is supported with the front and rear bearings. • Shoe (5) is punched to the tip of piston (6) with a concave ball so that piston (6) and shoe (5) form a spherical bearing. • Shoe (5) is always pressed to plane A of rocker cam (4) and slides in a circle. Rocker cam (4) leads highly pressurized oil together with cylindrical plane B with cradle (2) fixed to the case, forms a static pressure bearing and slides. • Piston (6) moves in the axial direction relatively in each cylinder of cylinder block (7). • Cylinder block (7) rotates relatively while sealing pressurized oil against valve plate (8), and the plane is designed to balance the oil pressure properly. • Oil in each cylinder of cylinder block (7) is absorbed and discharged through valve plate (8). PC130-7

10-17 (3)

STRUCTURE AND FUNCTION

HYDRAULIC PUMP

OPERATION 1. Pump Operation • Shaft (1) rotates together with cylinder block (7), and shoe (5) slides on plate A. When rocker arm (4) moves along cylindrical plane B, the inclination to centerline X of rocker cam (4) and the axial direction of cylinder block (7) changes. Inclination is called "swash plate angle."

•

•

•

•

•

When the swash plate angle of center line X of rocker cam (4) is to the axial direction of cylinder block (7), plane A works like the cam against shoe (5). Therefore, piston (6) slides inside cylinder block (7), and the capacities E and F of cylinder block (7) come to change differently. Then, the pump absorbs and discharges the difference E-F. When the capacity in E chamber contracts as cylinder block (7) rotates, the pump discharges oil during the process. On the other hand, when the capacity in F chamber increases, the pump absorbs oil during the process. (The figure shows the end of the absorbing process in Chamber F and the end of the discharging process in Chamber E. When the centerline X of rocker cam (4) comes to the axial direction of cylinder block (7) (when the swash plate angle is 0), the difference between capacities E and F in cylinder block (7) comes to 0. And the pump comes to stop absorbing or discharging oil, i.e., the pump stops. (However, the swash plate angle never comes to 0 practically.) In other words, swash plate angle and the pump delivery are in the proportional relations.

10-18 (3)

PC130-7

STRUCTURE AND FUNCTION

HYDRAULIC PUMP

2. Delivery Control • When swash plate angle increases, the difference between capacities E and F becomes larger and delivery Q increases. Servo piston (12) changes the swash plate angle . • The servo piston moves in the direction of straight reciprocation according to signal pressures of the PC and LS valves. This straight motion is transmitted to rocker arm (4) through slider (13), and rocker cam (4), which is supported with the cylindrical plane to cradle (2), slides in the direction of rotation.

•

•

•

Servo piston's (12) area receiving the pressure is different on the right and left sides, and the discharge (self) pressure PP from the main pump is always led to the pressure chamber of the small diameter piston. The output pressure Pen of the LS valve is led to the pressure chamber of the large diameter piston. Motions of the servo piston are controlled according to the relations between the small diameter piston pressure PP and the large diameter piston pressure Pen and the rate of area receiving pressure of the small diameter piston to that of the large diameter piston.

PC130-7

10-19 (3)

STRUCTURE AND FUNCTION

HYDRAULIC PUMP

LS AND PC VALVE LS valve

1. 2. 3. 4. 5. 6. 7. 8. 9. 10.

Sleeve Piston Spool Seat Plug Spring Sleeve Nut O-ring Nut

PA : Pump pressure inlet PB : Pump pressure inlet PDP : Drain PLP : Control pressure outlet PLS : Over load pressure inlet PPL : Control pressure intle PSIG : LS mode switching pressure inlet

PC Valve

1. 2. 3. 4. 5. 6. 7. 8. 9.

Piston Spring Seat Spring Seat Spool Piston Sleeve Lock nut

10-20

10. Plug 11. Lock nut PA PA2 PD PM PPL

: Pump discharge pressure inlet : Pump discharge pressure inlet : Drain pressure outlet : PC mode switching pressure inlet : PC valve signal pressure outlet

PC130-7

STRUCTURE AND FUNCTION

HYDRAULIC PUMP

FIXED THROTTLE VALVE

1. Plug 2. Plug PA : Drain pressure outlet POUT : Control pressure outlet PIN : LS valve signal pressure inlet

PC130-7

10-21

STRUCTURE AND FUNCTION

HYDRAULIC PUMP

FUNCTION 1. LS Valve • The LS valve detects loads and controls delivery. • This valve controls main pump delivery Q with differential pressure PLS (PP – PLS) [that is called LS Differential Pressure] between the main pump pressure PP and control valve outlet pressure PLS. • This valve is applied with main pump pressure PP, pressure PLS that is obtained from the control valve output [that is called LS Pressure] and pressure PSIG from the LS-EPC valve [that is called LS Selection Pressure]. • The relations of differential pressure PLS (= PP – PLS) between main pump pressure PP and LS pressure PLS with delivery Q vary with the LS selection current ISIG of the LS-EPC valve as shown in the right figure. • As ISIG changes from 0 to 1A, the spring set force changes accordingly, and the selector point for pump discharge amount changes from 0.64 to 2.1 MPa {6.5 to 21.5 kg/cm2} at the standard median. 2. PC Valve • When pump discharge pressure PP rises, the control valve spool stroke will increase and the opening area will enlarge. So, the PC valve controls pump delivery Q so that delivery Q does not increase above a certain level depending on discharge pressure PP. The valve also controls the pump absorbing hydraulic horsepower to approximately equal horsepower so that the pump absorbing horsepower does not exceed the engine horsepower. • This means that, when a load to the actuator increases during operation and pump discharge pressure PP rises, this valve will reduce pump delivery Q, or when pump discharge pressure PP drops, this valve will increase delivery Q. • In this case, the relations between pump discharge pressure PP and pump delivery Q change as shown in the right figure since the current value given to the PC-EPC valve solenoid is regarded as a parameter. • However, some PC valves have the function to sense actual engine speeds in the heavy-duty operation mode and to reduce pump delivery and recover speed when the speed reduces due to increase of load. • In other words, when an increase of load reduces engine speed below the set value, the command current from the controller to the PCEPC valve solenoid will increase as engine speed reduces and will reduce the pump swash plate angle.

10-22 (3)

PC130-7

STRUCTURE AND FUNCTION

HYDRAULIC PUMP

OPERATION

1. LS Valve 1) When the control valve is at the center value position • The LS valve is a 3-way selector valve, and the pressure PLS (LS pressure) from the control valve inlet is being led to spring chamber B and pump discharge pressure PP is being led to the H port of sleeve (8). • Spool (6) position is determined depending on the force of LS pressure PLS + the force of spring (4) Z and force of the pump discharge pressure (self-pressure) PP.

PC130-7

10-23 (3)

STRUCTURE AND FUNCTION

•

•

•

Before the engine starts, servo piston (12) is pressed to the right side. (See the right figure.) If the control lever is at the "center value" position when the engine starts, LS pressure PLS will be 0 MPa (0 kg/cm2). (The LS valve interconnects to the drain circuit through the control valve spool.) At the time, spool (6) is pressed to the left side and C port is connected to D port. The pump discharge pressure enters from K port to the piston large diameter side and from J port to the piston small diameter side respectively. So, the area difference of servo piston (12) minimizes the swash plate angle.

10-24 (3)

HYDRAULIC PUMP

PC130-7

STRUCTURE AND FUNCTION

2) Operation in direction for maximum pump delivery • When the LS differential pressure PLS between pump discharge pressure PP and LS pressure PLS reduces (when the control valve is large and discharge pressure PP drops, for example), the combined force of LS pressure PLS and spring (4) pushes spool (6) to the right side. • When spool (6) moves, port D is connected to port E to bring the PC valve in line. At the time, the PC valve is connected to the drain port, and circuit D – K is applied with drain pressure PT. (The operation of the PC valve will be explained later.)

PC130-7

HYDRAULIC PUMP

•

•

•

Therefore, pressure on the piston large diameter side of servo piston (12) comes to drain pressure PT, and since the pump discharge pressure PP is applied to port J on the small diameter side, servo piston (12) is pushed to the right side and the swash plate is moved to the delivery increasing direction. When port G is applied with the output pressure of the EPC valve for the LS valve, piston (7) is pushed to the left side. This is effective to reduce spring (4) set force, and the differential pressure between oil pressure PP when ports D and E of spool (6) are connected and PP changes.

10-25 (3)

STRUCTURE AND FUNCTION

3) Operation in direction for minimum pump delivery • The following explains movement of servo piston (12) to the left side (in the direction for minimum pump delivery). When LS differential pressure PLS increases (when the control valve opening area becomes small and pump discharge pressure PP increases, for example), the force of discharge pressure PP pushes the spool (6) to the left side. • As spool (6) moves, pump discharge pressure PP flows from port C to port D and comes from port K to the piston large diameter side.

10-26 (3)

HYDRAULIC PUMP

•

•

Though pump discharge pressure PP comes to port J of the piston small diameter side, servo piston (12) is pushed to the left side due to the area difference between the piston large diameter side and the piston small diameter side of servo piston (12) and the swash plate is moved in the delivery reducing direction. When port G is applied with the LS selection pressure, it is effective to reduce spring (4) set force.

PC130-7

STRUCTURE AND FUNCTION

4) When the servo piston balances • The area receiving pressure on the piston large diameter side is supposed to be A1, the one on the small diameter side is supposed to be A0 and pressure flowing to the piston large diameter side is supposed to be PEN. • When pump discharge pressure PP of the LS valve balances with the combined force of LS pressure PLS and spring (4) force Z and the relations of A0 x PP = A1 x PEN are satisfied, servo piston (12) stops at the position and the swash plate is held at the intermediate position (stops where the opening from port D to port E of spool (6) is almost equal to the one from port C to port D).

PC130-7

HYDRAULIC PUMP

•

•

•

At the time, the relations of areas receiving pressure on both ends of servo piston (12) are A0 : A1 = 1 : 1.75, and the ones of pressures applied on the piston both ends at the balancing time are PP : PEN = 1.75 : 1 approximately. Spring (4) force has been adjusted so that the balance stop position of spool (6) is determined when PP – PLS = 2.21 MPa {22.5 kg/cm 2 } is satisfied at the standard center. When port G is applied with PSIG (EPC valve output pressure for LS valve of 0 – 2.9 MPa {10 – 30 kg/cm 2 }), however, the balance stop position changes proportionally to the PSIG pressure in the range of PP – PLS from 2.1 to 0.6 MPa {21.5 to 6.5 kg/cm2}.

10-27 (3)

STRUCTURE AND FUNCTION

2. PC Valve (1) When the pump controller is normal, the load to the actuator is small and the pump discharge pressure PP is low 1) Function of PC-EPC Valve Solenoid (1) • The pump controller provides a command current to PC-EPC valve solenoid (1). This command current actuates the PC-EPC valve and outputs a signal pressure. When receiving the signal pressure, the PC valve changes the force given to piston (2). • Spool (3) stops where the force to piston (2) balances with the combined force of spring setting force of springs (4) and (6) on the opposite side and the force given to spool (3) by the pump discharge pressure PP.

10-28 (3)

HYDRAULIC PUMP

•

And pressure output from the PC valve (the pressure at C port) varies with the spool position. The value of command current X is determined depending on type of work (lever control), selection of working mode, set point of engine speed and actual speed.

PC130-7

STRUCTURE AND FUNCTION

2) Function of Spring • The loads to springs (4) and (6) of the PC valve are determined depending on swash plate position. • As servo piston (9) moves, piston (7) connected to slider (8) moves to the right or the left. • When piston (7) moves to the left, spring (6) will be contracted. If the piston moves further to the left, the spring will be brought to seat (5) and be fixed there. Thereafter, spring (4) will only move. This means that the spring load changes as piston (7) extends or contracts springs (4) and (6).

PC130-7

HYDRAULIC PUMP

•

•

Also, since the pressing force of piston (2) changes as the command current input to the PC-EPC valve solenoid (1) changes, the load to springs (4) and (6) changes depending on the value of the command current. The C port of the PC valve is connected to the E port of the LS valve. The self pressure PP is provided to A port, the small diameter side of servo piston (9) and B port.

10-29 (3)

STRUCTURE AND FUNCTION

•

•

•

10-30 (3)

HYDRAULIC PUMP

When the pump discharge pressure PP is small, the spool is located at a position in the left direction. At the time, C port is connected to D port, and pressure to the LS valve becomes drain pressure PT. If E port of the LS valve is connected to G port at the time, the pressure from J port to the large diameter side of the piston will become drain pressure PT. And the servo piston will moves to the right side. Then, the pump delivery will increase. Also, as servo piston (9) operates, slider (8) moves piston (7) to the right side, and the spring force becomes weak because springs (4) and (6) expand. As the spring force becomes weak, spool (3) moves to the right side to disconnect C port from D port. Then, the pump discharge pressure ports B and C are connected. As a result, pressure at the C port rises and pressure on the large diameter side of the piston rises as well, and servo piston (9) stops moving to the right side. This means that the stop position of servo piston (9) (= pump delivery) is determined where the pressing force caused pressure PP to spool (3), the pressing force of the PC-EPC valve solenoid and the forces of the springs (4) and (6) balance with each other.

PC130-7

STRUCTURE AND FUNCTION

(2) When the pump controller is normal, the load to actuator is large and the pump discharge pressure PP is high • When the load is large and the pump discharge pressure is high, the force pushing spool (3) to the left side increases and spool (3) comes to the position shown in the above figure. • Then, the pressure flowing from C port to the LS valve becomes about 3/5 of the pump discharge pressure PP because the pressure from A port partly flows from C port to D port through the LS valve as shown in the above figure.

PC130-7

HYDRAULIC PUMP

•

•

When E port of the LS valve is connected to G port, this pressure is led from J port to the large diameter side of the servo piston (9) and the servo piston comes to stop. When the pump discharge pressure PP increase and spool (3) moves further to the left side, discharge pressure PP will flow to C port so as to minimize the pump delivery.

10-31 (3)

STRUCTURE AND FUNCTION

•

•

When servo piston (9) moves to the left side, piston (7) will move to the left. Then, springs (4) and (6) will be compressed and will push spool (3) back. If piston (7) moves further to the left, ports C and D will open wide. As a result, the pressure at port C (= J) will drop, and servo piston (9) will move to the left and will stop. At the time, servo piston (9) is located further to the left than where it is when pump discharge pressure PP is low.

•

The positional relations between pump discharge pressure PP and servo piston (9) are shown by a broken line because springs (4) and (6) are 2-stage ones. And the relations between discharge pressure PP and pump delivery Q are as shown in the right figure.

•

Also, when the command current X to the PC-EPC valve solenoid increases, the relations between the pump discharge pressure PP and the pump delivery Q will move in parallel in relation to the pushing force of the PC-EPC valve solenoid. Therefore, the force of the PC-EPC valve solenoid (1) will be added to the leftward pressing force of the discharge pressure PP to the spool (3), and the relations between PP and Q will move from to as X increases.

10-32 (3)

HYDRAULIC PUMP

PC130-7

STRUCTURE AND FUNCTION

3) When the pump controller is out of order and the PC redundant switch is set to ON 1) In case of light load to main pump • When the pump controller is out of order, set the PC redundant switch to ON to change the circuit to the resistor side. In this case, since the current is too large when power is directly taken from the battery, the resistor is connected to control the current to the PC-EPC valve solenoid. • At the time, the current becomes constant and piston (2) pressing force becomes constant as well.

PC130-7

HYDRAULIC PUMP

•

•

When the pump discharge pressure is low, the combined force of the force of PC-EPC valve solenoid (1) and discharge pressure PP is smaller than the spring set force. So, spool (3) balances at a position in the left side. At the time, C port has the same pressure as the drain pressure at D port, and the drain pressure PT is led to the large diameter side of servo piston (9) through the LS valve. Then, servo piston (9) moves in the diction where delivery increases because the pressure on the small diameter side of the piston is large.

10-33 (3)

STRUCTURE AND FUNCTION

HYDRAULIC PUMP

2) In case of heavy load to main pump • When the PC redundant switch is set to ON just like in the previous paragraph, a constant command current is sent to PCEPC valve solenoid (1). So, piston (2) pushes spool (3) with a constant force. • When pump discharge pressure PP rises, the spool will moves further to the left side than when the main pump is lightly loaded and will balance at the position shown in the above figure. • In this case, since the pressure from A port is led to C port, servo piston (9) will move to the left side (small delivery) and will stop at a position further to the left than when the pump is lightly loaded.

10-34 (3)

PC130-7

STRUCTURE AND FUNCTION

•

•

PC130-7

HYDRAULIC PUMP

This means that the current, which is sent to the PC-EPC valve solenoid through the resistor when the PC redundant switch is set to On, determines the curve between pump discharge pressure PP and delivery Q as shown in the figure. When the PC redundant switch is set to ON, curve is further to the left than curve drawn when the pump controller is normal.

10-35 (3)

STRUCTURE AND FUNCTION

CONTROL VALVE

CONTROL VALVE OUTLINE The following are 3 types of control valves. • 6-spool valve (without service valve) • 7-spool valve (with service valve) • 8-spool valve (with 2 service valve) a Each service valve is a single add-on type, so it is possible to add or remove the extra valve at any time. External apperance and cross sections shown are for the 7 spool valve only. AA

: Pressure sensor port (pressure sensor is intalled) A1 : To swing motor MB A2 : To L.H. travel motor A A3 : To R.H. travel motor A A4 : To boom cylinder bottom A5 : To arm cylinder head A6 : To bucket cylinder head A7 : To attachment 1 B1 : To swing motor MA B2 : To L.H. travel motor B B3 : To R.H. travel motor B B4 : To boom cylinder head B5 : To arm cylinder bottom B6 : To bucket cylinder bottom B7 : To attachment 1 BP : From boom RAISE PPC/EPC valve LS : To pump LS valve PA1 : From swing L.H. PPC/EPC valve PA2 : From L.H. travel forward PPC valve PA3 : From R.H. travel reverse PPC valve PA4 : From boom RAISE PPC/EPC valve PA5 : From arm OUT PPC/EPC valve PA6 : From bucket DUMP PPC/EPC valve PA7 : From service 1 PPC valve PB1 : From swing R.H. PPC/EPC valve PB2 : From L.H. travel reverse PPC valve PB3 : From R.H. travel forward PPC valve PB4 : From boom LOWER PPC/EPC valve PB5 : From arm IN PPC/EPC valve PB6 : From bucket CURL PPC/EPC valve PB7 : From service 1 PPC valve P : From main pump PP : To main pump PX : From 2-stage relief solenoid valve SA : From swing stroke control solenoid valve SB : From swing stroke control solenoid valve TS1 : To tank TS2 : To tank TB : To tank TC : To oil cooler TSW : To swing motor

10-36 (3)

1. Swing bleed valve 2. Travel junction valve 3. Arm rcheck valve 4. Cover 5. Service valve 6. Bucket valve 7. Arm valve 8. Boom valve 9. R.H. travel valve 10. L.H. travel valve 11. Swing valve 12. PT port block 13. Boom lock valve

PC130-7

STRUCTURE AND FUNCTION

CONTROL VALVE

7 spool valve (6 spool valve + service valve)

PC130-7

10-37 (3)

STRUCTURE AND FUNCTION

CONTROL VALVE

CROSS-SECTIONAL DRAWING a Cross-sectional drawing shows 7-spool valve (6-spool + service valve). (1/8)

1. 2. 3. 4. 5. 6. 7.

Safety-suction valve Suction valve (L.H. travel A) Suction valve (R.H. travel A) Suction valve (Boom bottom) Suction valve (Arm head) Suction valve (Bucket head) Safety-suction valve mount (service A)

10-38 (3)

8 Safety-suction valve mount (service B) 9. Suction valve (Bucket bottom) 10. Suction valve (Arm bottom) 11. Suction valve (Boom head) 12. Suction valve (R.H. travel B) 13. Suction valve (L.H. travel B) 14. Lift check valve

PC130-7

STRUCTURE AND FUNCTION

CONTROL VALVE

(2/8)

1. 2. 3. 4. 5. 6. 7. 8.

Main relief valve Spool (swing) Spool (L.H. travel) Spool (R.H. ravel) Spool (boom) Spool (arm) Spool (bucket) Spool (service)

PC130-7

10-39

STRUCTURE AND FUNCTION

CONTROL VALVE

(3/8)

1. 2. 3. 4. 5. 6. 7. 8.

Pressure compensation valve F (swing) Pressure compensation valve F (L.H. travel) Pressure compensation valve F (R.H. travel) Pressure compensation valve F (boom) Pressure compensation valve F (arm) Pressure compensation valve F (bucket) Pressure compensation valve F (service) Unload valve

10-40 (3)

9. 10. 11. 12. 13. 14. 15.

Pressure compensation valve R (service) Pressure compensation valve R (bucket) Pressure compensation valve R (arm) Pressure compensation valve R (boom) Pressure compensation valve R (R.H. travel) Pressure compensation valve R (L.H. travel) Pressure compensation valve R (swing)

a The above F and R means the following valves : F : Flow control valve R : Pressure reducing valve

PC130-7

STRUCTURE AND FUNCTION

CONTROL VALVE

(4/8)

1. 2. 3. 4. 5. 6.

LS pressure detection plug LS bypass plug Pump pressure detection plug Check valve (bucket head) Check valve (arm head) LS selection valve

PC130-7

10-41 (3)

STRUCTURE AND FUNCTION

CONTROL VALVE

(5/8)

1. 2. 3. 4. 5. 6.

Main relief valve Cooler bypass valve Lift check valve LS selection valve Spool (swing) Pressure compensation valve R

10-42 (3)

7. Swing bleed valve 8. Pressure compensation valve F F : Flow control valve R : Pressure reducing valve

PC130-7

STRUCTURE AND FUNCTION

CONTROL VALVE

(6/8)

1. 2. 3. 4. 5. 6. 7.

Suction valve (A) Suction valve (B) Spool (L.H. travel) Pressure compensation valve R Travel junction valve Pressure compensation valve F Suction valve (A)

PC130-7

8. 9. 10. 11.

Suction valve (B) Spool (R.H. travel) Pressure compensation valve R Pressure compensation valve F

F : Flow control valve R : Pressure reducing valve

10-43

STRUCTURE AND FUNCTION

CONTROL VALVE

(7/8)

1. 2. 3. 4. 5. 6. 7. 8.

Suction valve (A) Boom lock valve Suction valve (B) Spool Pressure compensation valve R Pressure compensation valve F Suction valve (A) Suction valve (B)

10-44 (3)

9. 10. 11. 12.

Spool Pressure compensation valve R Arm regemeration valve Pressure compensation valve F

F : Flow control valve R : Pressure reducing valve

PC130-7

STRUCTURE AND FUNCTION

CONTROL VALVE

(8/8)

1. 2. 3. 4. 5. 6. 7. 8.

Suction valve (A) Suction valve (B) Spool Pressure compensation valve R Pressure compensation valve F Safty-suction valve mount (A) Safty-suction valve mount (B) Spool

PC130-7

9. 10. 11. 12.

Pressure compensation valve R Pressure compensation valve F Pressure relief plug Unload valve

F : Flow control valve R : Pressure reducing valve

10-45 (3)

STRUCTURE AND FUNCTION

SUCTION SAFETY VALVE

SUCTION SAFETY VALVE (SAFETY VALVE WITH SUCTION FOR SERVICE PORT) 1. 2. 3. 4. 5. 6. 7. 8. 9. 10.

Suction valve Main valve Piston Piston spring Poppet Poppet spring Suction valve Sleeve Adjustment screw Lock nut

SPECIFICATION Part No. (Reference)

Set pressure

Use

709-70-74600

24.5 MPa {250 kg/cm2} (at the time of 5l/min.)

For crusher

709-70-74700

17.2 MPa {175 kg/cm2} (at the time of 5l/min.)

10-46

PC130-7

STRUCTURE AND FUNCTION

CLSS

CLSS OUTLINE OF CLSS Features CLSS stands for Closed Center Load Sensing System and is featured as follows : • Fine controllability without affect of load • Controllability that allows digging even in the fine control mode. • Ease of compound operation in which the flow distribution performance depends on spool opening area during compound operation. • Saving of energy by variable pump control

PC130-7

Configuration • The CLSS consists of a variable displacement piston pump, a control valve and actuators. • The pump body consists of a main pump, a PC valve and an LS valve.

10-47

STRUCTURE AND FUNCTION

CLSS

Basic principle 1. Control of pump swash plate angle • The pump swash plate angle (pump delivery) is controlled so that the LS differential pressure PLS, which is the difference between the pump discharge pressure PP and the LS pressure PLS (actuator load pressure) at the control valve outlet, becomes constant. (LS differential pressure PLS = Pump pressure PP - LS pressure PLS)

•

When the LS differential pressure PLS reduces below the set pressure of the LS valve (when the actuator load pressure is high), the pump swash plate angle will move in the direction of maximum. When the set pressure is raised (when the actuator load pressure is low), the pump swash plate angle will move in the direction of minimum. a For the detail of the operation, see the paragraph of "Hydraulic Pump."

10-48

PC130-7

STRUCTURE AND FUNCTION

CLSS

2. Pressure compensation control • A valve (pressure compensation valve) is mounted on the outlet side of the control valve. In case of compound operation of the actuator with this valve, the differential pressure P between the spool upstream (inlet) and the downstream (outlet) of each valve becomes constant irrespective of load (pressure). So, the flow from the pump is distributed (compensated) in proportion to the opening areas S1 and S2 of each valve being operated.

PC130-7

10-49

STRUCTURE AND FUNCTION

CLSS

EACH FUNCTION AND OPERATION OF EACH VALVE Hydraulic circuit diagram and valve names

10-50 (3)

PC130-7

STRUCTURE AND FUNCTION

CLSS

1. Unload valve Set pressure : 3.38 MPa {34.5 kg/cm2} 2. Safety-suction valve Set pressure : 35.8 MPa {365 kg/cm2} 3. Pressure compensation valve 4. Suction valve 5. Main relief valve Set pressure : normal: 31.9 MPa {325 kg/cm2} High pressure : 34.8 MPa {355 kg/cm2} 6. Lift check valve 7. Cooler bypass valve 8. LS selection valve 9. Swing bleeding valve 10. Travel junction valve 11. Arm regeneration valve 12. Boom lock valve

PC130-7

10-51 (3)

STRUCTURE AND FUNCTION

CLSS

UNLOAD VALVE 1. When the control valve is neutral FUNCTION • When the control valve is neutral, the delivery Q equivalent to the pump minimum swash plate angle is released to the tank circuit. At the time, pump discharge pressure PP is set to 2.45 MPa {25.0kg/cm2} with spring (3) inside the vale. (The LS pressure PLS is 0 MPa {0kg/cm2}.)

OPERATION • Pump discharge pressure PP is applied to the left end face of spool (4) and LS pressure PLS is applied to the right end face. • Since the LS pressure PLS is 0 when the control valve is neutral, pump discharge pressure PP is only applied and is set with the lead to spring (3). • When pump discharge pressure PP rises to spring (3) load (2.45 MPa {25.0 kg/cm2}), spool (4) will move toward the right side and pump circuit PP will interconnect to tank circuit T through the drill hole. • Therefore, pump discharge pressure PP is set to 2.45 MPa {25.0 kg/cm2}.

10-52 (3)

1. 2. 3. 4.

Unload valve Sleeve Spring Spool

PLS : LS circuit (pressure) PP : Pump circuit (pressure) T : Tank circuit

PC130-7

STRUCTURE AND FUNCTION

CLSS

When the differential pressure between discharge pressure PP and LS pressure PLS comes to spring (3) load (2.45 MPa {25.0 kg/ cm2}), the unload valve will open and LS differential pressure PLS will come to 2.45 MPa {25.0 kg/cm2}.

2. When the control valve is in the fine control mode FUNCTION • When the control valve is in the fine control mode and the requested flow of the actuator is less than the pump minimum swash plate angle, pump discharge pressure PP is set to LS pressure PLS + 2.45 MPa {25.0 kg/cm2}.

OPERATION • When the control valve is operated in the fine control mode, LS pressure PLS will occur and will be applied to the right end face of spool (4). At the time differential pressure between LS pressure PLS and pump discharge pressure PP increases because the opening area of the control valve spool is small. • When the differential pressure between pump discharge pressure PP and LS pressure PLS comes to spring (3) load (2.45 MPa {25.0 kg/ cm2}), spool (4) will move to the right side and pump circuit PP will interconnect to tank circuit T. • This means that pump discharge pressure PP is set to the spring force (2.45 MPa {25.0 kg/cm2} + LS pressure PLS, and LS differential pressure PLS comes to 2.45 MPa {25.0 kg/cm2}.

PC130-7

1. 2. 3. 4.

Unload valve Sleeve Spring Spool

PLS : LS circuit (pressure) PP : Pump circuit (pressure) T : Tank circuit

10-53 (3)

STRUCTURE AND FUNCTION

CLSS

3. When the control valve is operated FUNCTION • If the required flow of the actuator increases over the pump minimum swash plate angle when the control valve is operated, the flow to tank circuit T will be interrupted and pump delivery Q will be completely flown to the actuator circuit.

OPERATION • When the control valve is operated with large stroke, LS pressure PLS will occur and will be applied to the right end face of spool (4). At the time, the opening areas of the control valve spool is large and the difference between LS pressure PLS and pump discharge pressure PP is small. • So, the differential pressure between pump discharge pressure PP and LS pressure PLS does not reach spring (3) load (2.45 MPa {25.0 kg/ cm2}) and spring (3) pushes spool (4) to the left side. • Then, pump circuit PP and tank circuit T are interrupted, and pump delivery Q is completely flown to the actuator circuit.

10-54 (3)

1. 2. 3. 4.

Unload valve Sleeve Spring Spool

PLS : LS circuit (pressure) PP : Pump circuit (pressure) T : Tank circuit

PC130-7

STRUCTURE AND FUNCTION

CLSS

LEADING OF LS PRESSURE FUNCTION • The LS pressure is load pressure to the actuator on the outlet side of the control valve. • In case of a work equipment valve, pressure reducing valve (3) of the pressure compensation valve reduces pump discharge pressure PP to the same level as actuator circuit pressure A and leads the pressure to LS circuit PLS.

•

Also, orifice C is mounted on piston (5) halfway from pump circuit PP to pressure reducing valve (3), and the orifice has the damper function. The travel valves leads actuator circuit pressure A directly to LS circuit PLS.

1. Work equipment valve (boom, arm, bucket, swing)

OPERATION • When spool (1) is operated, pump discharge pressure PP will be led to actuator circuit A through bridge passage b from flow control valve (2) and spool notch a. • Since pressure reducing valve (3) moves to the right at the same time, pump discharge pressure PP led from orifice c is reduced due to pressure loss at notch d and is led to LS circuit PLS and to spring chamber PLS1. • At the time, LS circuit PLS is connected to tank circuit T from LS bypass plug (4).

PC130-7

•

•

Both end face areas of pressure reducing valve (3) are the same (SA = SLS), and actuator circuit pressure PA (= A) is applied to the SA side and reduced pump discharge pressure PP is applied to the SLS side on the opposite side. Therefore, pressure reducing valve (3) balances at the position where actuator circuit pressure PA becomes equal to the pressure of spring chamber PLS1. The pump discharge pressure PP reduced at notch d comes to actuator circuit pressure A and is led to the LS circuit PLS.

10-55 (3)

STRUCTURE AND FUNCTION

CLSS

2. Travel valve

OPERATION • When spool (1) is operated, the pump discharge pressure PP will be led to actuator circuit A through bridge passage b from flow control valve (2) and spool notch a. • At the same time, the actuator circuit pressure PA moves pressure reducing valve (3) to the right side, and notches c and d interconnect to the travel junction circuit e and LS circuit PLS respectively. • So, actuator circuit pressure PA (= A) is led from notch c to LS circuit PLS through notch d. a The travel circuit is different from the work equipment circuit, actuator circuit pressure PA is directly led to the LS circuit PLS.

10-56 (3)

PC130-7

STRUCTURE AND FUNCTION

CLSS

LS BYPASS PLUG FUNCTION • This plug released residual pressure of the LS pressure PLS. • This plug slows the rising speed of the LS pressure PLS, causes pressure losses at the spool and the throttle of the shuttle valve by the discarded throttled flow and reduces the effective LS differential pressure for higher safety.

OPERATION • Pressurized oil in the LS circuit PLS flows from clearance filter a in the space between LS bypass plug (1) and the valve body to tank circuit T through orifice b.

PC130-7

1. LS bypass plug PLS : LS circuit (pressure) T : Tank circuit (pressure)

10-57 (3)

STRUCTURE AND FUNCTION

CLSS

PRESSURE COMPENSATION VALVE FUNCTION • When the load pressure becomes lower than another actuator and the flow is going to increase during a compound operation, this valve compensates the load pressure. (At the time, the load pressure of another actuator under compound operation (the upper side) is higher than that of the actuator on this side (the lower side).

10-58

PC130-7

STRUCTURE AND FUNCTION

CLSS

OPERATION • When the load pressure of another actuator side (the upper side) rises during a compound operation, the flow in actuator circuit A on this side (the lower side) is apt to increase. • In this case, LS pressure PLS of another actuator is applied to spring chamber PLS1 and pushes pressure reducing valve (1) and flow control valve (2) to the left side. • Flow control valve (2) throttles the opening area between pump circuit PP and spool upstream PPA and causes a pressure loss between PP and PPA. • Flow control valve (2) and pressure reducing valve (1) balance each other where the pressure difference between PA applied to both end faces of pressure reducing valve (1) and PLS becomes the same as the pressure loss between PP before and after the flow control valve and PPA. • So, the pressure differences between upstream pressures PPA and downstream pressures PA of both spools under compound operation become the same, and the pump flow is distributed in proportion to the opening area of each spool notch a.

PC130-7

10-59 (3)

STRUCTURE AND FUNCTION

CLSS

AREA RATIO OF PRESSURE COMPENSATION VALVE FUNCTION • The pressure compensation valve slightly adjust the ratio (S2/S1) of area S1 on the left side of flow control valve (2) and area S2 on the right side of pressure reducing valve (1) to suite the characteristics of each actuator and determines the compensation characteristics. S1 : Area of flow control valve (2) - area of piston (3) S2 : Area of pressure reducing valve (1) - area of piston (3)

Area ratio (S1:S2) and compensation characteristics • When the ratio is 1.00 : The expression [Pump (discharge) pressure PP - Spool notch upstream pressure PPB] [LS circuit pressure PLS - Actuator circuit pressure PA (= A)] can be held, and the flow is distributed as per the spool opening area ratio. • When the ratio is more than 1.00 : The expression PP - PPB > PLS - PA (= A) can be held, and the flow is distributed less than the spool opening area ratio. • When the ratio is less than 1.00 : The expression PP - PPB < PLS - PA (= A) can be held, and the flow is distributed more than the spool opening area ratio.

10-60 (3)

PC130-7

STRUCTURE AND FUNCTION

BOOM HOLDING VALVE FUNCTION • When the boom lever is not being operated, the oil at the boom bottom leaks from spool (1) and prevents hydraulic drift of the boom.

OPERATION 1) At boom RAISE When the control lever is operated to boom RAISE, the main pressure from the control valve pushes poppet (5) up. As a result, the main pressure oil from the control valve passes through the inside of the valve and flows to the boom cylinder bottom.

PC130-7

10-60-1 (3)

STRUCTURE AND FUNCTION

CLSS

2) At boom HOLD When the control lever has been operated to boom RAISE and is then returned to the HOLD position, the holding pressure at the boom cylinder bottom end is closed by poppet (5). At the same time, the oil flowing inside poppet (5) from orifice a in poppet (5) is closed by pilot spool (3). In this way, the boom is held in position.

10-60-2 (3)

PC130-7

STRUCTURE AND FUNCTION

CLSS

3) At boom LOWER When the control lever is operated to boom LOWER, pilot pressure P1 from the PPC valve pushes pilot spool (3) and the pressure oil in chamber b inside the poppet is drained. The oil pressure at port Ab increases because of the pressure oil from the boom cylinder bottom, but the oil pressure in chamber b is lowered by orifice a. If the pressure in chamber b becomes lower than the pressure at port Aa, poppet (5) opens and the pressure oil from port Ab flows to port Aa and goes to the control valve.

PC130-7

10-60-3 (3)

STRUCTURE AND FUNCTION

CLSS

BOOM REGENERATION CIRCUIT FUNCTION 1) When the boom is being lowered, if bottom pressure A of cylinder (1) is higher than head pressure B, and the boom is lowered under its own weight, this sends the return oil flow at the bottom end to the head end to increase the cylinder speed by that amount.

OPERATION • If the boom is lowered under its own weight, pressure A at the bottom end of boom cylinder (1) becomes higher than pressure B at the head end. • When this happens, part of the return oil at the bottom end passes through regeneration passage a of boom spool (1), pushes check valve (3) open, and flows to the head end. • As a result, the boom lowering speed is increased.

10-60-4 (3)

PC130-7

STRUCTURE AND FUNCTION

CLSS

2) When lowering the boom, if head pressure B of cylinder (1) is greater than bottom pressure A, and the work equipment is in the load process, check valve (3) closes and shuts off the circuit between the head and bottom ends.

OPERATION • When the boom is lowered, if the work equipment is in the load process, pressure B at the head end of cylinder (1) becomes higher than pressure A at the bottom end. • When this happens, check valve (3) is closed by spring (4) and pressure B at the head end, so the circuit between the head circuit and bottom circuit is shut off.

PC130-7

10-60-5 (3)

STRUCTURE AND FUNCTION

CLSS

ARM REGENERATION CIRCUIT 1. At arm in and own weight fall FUNCTION • When the arm falls due to its own weight because head pressure A in arm cylinder (1) is higher than bottom pressure B during arm digging, this circuit brings the return flow on the head side to the bottom side to increase the cylinder speed.

OPERATION • When the arm falls for digging due to its own weight, the head side pressure A in arm cylinder (1) will rise above bottom side pressure B. • At the time, part of the return flow on the head side passes through regeneration passage a of arm spool (2), pushes check valve (3) to open it and flows to the bottom side. • This increases the arm digging speed.

PC130-7

1. Arm cylinder 2. Arm spool 3. Check valve A : Head circuit (pressure) B : Bottom circuit (pressure) PP : Pump circuit (pressure)

10-61 (3)

STRUCTURE AND FUNCTION

CLSS

2. At arm in process FUNCTION • When bottom pressure B of cylinder (1) rises above head pressure A and the arm enters the digging process, check valve (3) will be closed and the circuits on the head side and the bottom side will be interrupted.

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

10-62 (3)

1. Arm cylinder 2. Arm spool 3. Check valve A : Head circuit (pressure) B : Bottom circuit (pressure) PP : Pump circuit (pressure)

PC130-7

STRUCTURE AND FUNCTION

CLSS

TRAVEL JUNCTION VALVE (L.H. and R.H. travel junction circuit) 1. When traveling straight

10-64

PC130-7

STRUCTURE AND FUNCTION

CLSS

FUNCTION • When the L.H. and R.H. travel spool is operated to compensate flow errors in the L.H. and R.H. travel circuits during straight travel, the junction circuit will open. • Then, the flows to the L.H. and R.H. travel motors will become the same during the straight travel, and travel deviation will decrease. • At the time of steering, load pressure difference brings back the pressure reducing valve of the travel valve inside the steering and closes the spool notch opening of the travel junction valve to close the junction circuit for steering. OPERATION • When the L.H. and R.H. travel spool (1) is operated, the pump delivery will flow from the pump circuit PP to A through the actuator circuit PA. • When traveling straight, the actuator circuit PA will be equalized and the L.H. and R.H. pressure reducing valves (2) will be pressed the same stroke to the right. Then, the notch a and the junction circuit will open. • The L.H. travel forward oil pressure P1 and the R.H. travel forward oil pressure P2 are led to the spring chamber on the both end of the travel junction valve spool (4) through the respective shuttle valves (5). So, P1 = P2, and the spool is at the neutral position, and the notch d is open. • Then, the L.H. and R.H. travel actuator circuits are interconnected with the junction circuit. When any difference occurs in the flows to the L.H and R.H. travel motors, this valve will compensate them and will reduce occurrence of travel deviations.

PC130-7

10-65 (3)

STRUCTURE AND FUNCTION

CLSS

2. When operating travel steering

10-66

PC130-7

STRUCTURE AND FUNCTION

CLSS

OPERATION • When the L.H. travel spool (L.H. 1) is returned to the neutral side from the straight traveling state and the steering is operated, there will occur any difference in the load pressures in the L.H. and R.H. travel actuator circuits PA (R.H. A > L.H. A). The LS pressure PLS will become the same as the R.H. A on the higher load pressure side. • Therefore, the flow control valve on the L.H. travel side is pressed to the left side with the LS pressure PLS, i.e., the load pressure on the R.H. travel side, and the notch a closes to interrupt the L.H. and R.H. travel circuits. Also, since the pressures in the spring chambers on the both ends of the travel junction valve spool (4) become different and P1 becomes higher than P2, the spool (4) moves to the P1 side and the notch d closes. Then, the steering can be operated. • The damper is provided to relax the transition characteristics of the junction circuit at the time of abrupt operation.

PC130-7

10-67

STRUCTURE AND FUNCTION

CLSS

TRAVEL LS BYPASS CIRCUIT 1. At normal operation

10-68

PC130-7

STRUCTURE AND FUNCTION

CLSS

FUNCTION • When an actuator is operated during travel, this circuit will increase the discarded throttled flow of the LS circuit PLS, loosen the pressure compensation accuracy of the travel circuit and limits reduction of the travel speed to small extent. • The bypass circuit is closed in case of independent travel or independent operation of an actuator. OPERATION • When boom spool (1) is operated, the LS circuit PLS will come to the same pressure as the boom circuit pressure A1. • At the same time, the LS circuit pressure PLS is led to the spring chamber PLS1 of pressure reducing valve (2) of the travel valve. • Since the travel spool is not operated, the travel actuator circuit PA is closed and check valve (4) inside flow control valve (3) is also closed. • Therefore, the travel LS bypass circuit is closed in case of independent operation of the boom.

PC130-7

10-69 (3)

STRUCTURE AND FUNCTION

CLSS

2. At operation of travel + other actuator

10-70

PC130-7

STRUCTURE AND FUNCTION

CLSS

OPERATION • When boom spool (1) is operated, the LS circuit PLS will come to the same pressure as the boom circuit pressure A1. • Since the actuator circuit pressure is generally higher at boom RAISE than during travel (A1 > A2), the pressure in spring chamber PLS1 of flow control valve (3) on the travel side is higher than the travel circuit pressure PA. • So, the pressure reducing valve (2) moves to the left side, and the LS pressure of spring chamber PLS1 pushes check valve (4) from orifice a to open it and flows to the travel circuit PA through passages b and c. • Therefore, when LS circuit pressure PLS, which has been as high as boom circuit pressure A1, flows to travel circuit A2, the pressure will drop.

PC130-7

10-71 (3)

STRUCTURE AND FUNCTION

CLSS

3. At simultaneous operation of boom + swing FUNCTION • When the boom is raised at the time of swinging, the swing pool stroke will be controlled and the flow to the boom will be distributed more to raise the boom more. 1) When the boom is not raised

OPERATION • Since the SA and SB ports are interconnected to the drain and no force is given to piston (2), the stroke of spool (1) is not controlled. So, spool (1) comes to cases (4) and (5) and the stroke increases by ST1. This increases the filtering oil flow.

10-72 (3)

1. 2. 3. 4. 5.

Spool (swing) Piston Plug Case Case

ST1 : Spool stroke

PC130-7

STRUCTURE AND FUNCTION

CLSS

2) At simultaneous operation of boom RAISE

OPERATION • When the boom RAISE PPC pressure is led to piston (2) as the stroke control pilot pressure PS through SA and SB ports, piston (2) will be pressed in the inner direction. • At the time, the maximum stroke of spool (1) will shorten (by ST0) due to control of piston (2). Boom RAISE OFF ST1 > Boom RAISE ON ST0 • The spool (1) stroke is controlled and shortens. If the boom is raised at the time of swing (hoist swing), notch a opening area will decrease. So, the flow distribution to the boom will increase and the boom will rise higher at the time of hoist swing.

PC130-7

10-73 (3)

STRUCTURE AND FUNCTION

CLSS

SWING BLEED VALVE FUNCTION • For swing operation, a bleed valve is provided to the pressure reducing valve to raise the LS pressure slowly and to smooth the swing operation. 1. Swing at neutral position

OPERATION • Since notch a of pressure reducing valve (1) and the LS circuit are closed and the bleed-off circuit and LS circuit are also closed, the LS pressure PLS is not affected by operation of other work equipment. • The pump discharge pressure PP is also interrupted from the bleed-off circuit with piston (2) and is not affected. • Notch b of bleed spool (3) and the bleed-off circuit are interconnected each other.

10-74 (3)

PC130-7

STRUCTURE AND FUNCTION

CLSS

2. At swing fine control

OPERATION • The pressure reducing valve moves in the right direction, and notch a and the LS circuit interconnect each other. Also, pump circuit PP, bleed-off circuit and LS circuit interconnect each other through piston (2). • Bleed spool (3) moves in the left direction in proportion to raise of the swing PPC pressure PA. But notch b throttles and interconnect to the bleed-off circuit in the fine control region and determines the intermediate pressure before pump discharge pressure PP is reduced and applied to LS pressure PLS. • Therefore, the intermediate pressure is set lower than the pump discharge pressure PP and rises as bleed spool (3) moves . So, the LS pressure PLS rises slowly.

PC130-7

10-75 (3)

STRUCTURE AND FUNCTION

CLSS

3. At full swing operation

OPERATION • When the swing PPC pressure PA comes to the maximum, notch b of bleed spool (3) interrupt the bleed-off circuit. The intermediate pressure becomes equal to the pump discharge pressure PP, and the LS pressure PLS becomes equal to the actuator circuit pressure.

10-76 (3)

PC130-7

STRUCTURE AND FUNCTION

CLSS

LS SELECT VALVE FUNCTION • At the time of simultaneous operation of swing + boom RAISE, this valve prevents high swing LS pressure from entering the LS circuit PLS and also prevents the boom RAISE speed from reducing by securing the pump flow at the time of swing drive. 1. During normal operation

OPERATION • The pilot pressure is not generally applied to pilot port BP except for boom RAISE operation. • In this state, the pump discharge pressure PP pushes valve (1) to open it and is led to pressure reducing valve (4) of the swing valve. At the time of swing operation, there occurs the LS pressure PLS suitable for the load pressure, and the pressure is led to the pump LS valve.

PC130-7

10-77 (3)

STRUCTURE AND FUNCTION

CLSS

2. At simultaneous operation of swing + boom RAISE

OPERATION • At the simultaneous operation of swing + boom RAISE, the signal pressure of the PPC circuit is led to pilot port BP. • When this pilot pressure BP is applied to piston (2) and reaches a pressure that is stronger than spring (3), piston (2) will be pushed to the left side, valve (1) will close and the pump discharge pressure PP will not come to flow to pressure reducing valve (4) of the swing valve. • Then, the swing pressure does not cause LS pressure PLS, but the LS pressure PLS cause the boom RAISE pressure is led to the pump LS valve, and the pump delivery is controlled with the boom RAISE LS pressure. • The pilot pressure BP depends on the control lever stroke.

10-78 (3)

PC130-7

STRUCTURE AND FUNCTION

SELF PRESSURE REDUCING VALVE

SELF PRESSURE REDUCING VALVE

P1 : From pump PR : Supply to solenoid valve, PPC valve and EPC valve. T : To hydraulic tank

PC130-7

10-79

STRUCTURE AND FUNCTION

1. 2. 3. 4. 5. 6.

Control valve block Valve (sequence valve) Spring Screw Poppet Spring (pressure reducing valve pilot)

10-80

SELF PRESSURE REDUCING VALVE

7. 8. 9. 10. 11.

Spring (pressure reducing valve main) Valve (pressure reducing valve) Spring (safety valve) Ball Filter

PC130-7

STRUCTURE AND FUNCTION

SELF PRESSURE REDUCING VALVE

FUNCTION • The self pressure reducing valves reduces the discharge pressure of the main pump and supplies it to the solenoid valve, the PPC valve, etc. as the control pressure.

PC130-7

10-81

STRUCTURE AND FUNCTION

SELF PRESSURE REDUCING VALVE

1. At engine stop (total low pressure)

OPERATION • Spring (6) pushes poppet (5) to the seat, and the circuit between ports PR and T is closed. • Spring (7) pushes valve (8) to the left side, and the circuit between ports P1 and PR is open. • Spring (3) pushes valve (2) to the left side, and the circuit between ports P1 and P2 is closed.

10-82 (3)

PC130-7

STRUCTURE AND FUNCTION

SELF PRESSURE REDUCING VALVE

2. At neutral and reduction of load pressure P2 (at own weight fall in boom LOWER and arm IN) Note : When load pressure P2 is lower than output pressure PR of the self pressure reducing valve.

OPERATION • Spring (3) and the PR pressure (0 MPa {0 kg/ cm2} at the time of engine stop) pushes valve (2) in direction to close the circuit between ports P1 and P2. When the hydraulic oil enters P1 port, the expression (P1 pressure Spring (7) force + ( d area x PR pressure)) holds, and the self pressure reducing valve will adjust the openings of ports P1 and P2 so that the P1 pressure can be maintained higher than the PR pressure. • When the PR pressure rises above the set pressure, poppet (5) will open and the hydraulic oil flows through the route from PR port, hole a in spool (8), poppet (5) opening to tank port T.

PC130-7

•

Therefore, there will occur a differential pressure around hold a in spool (8) and the spool will move in the direction to close port P1 and the PR opening. Then, the P1 pressure is reduced and adjusted to a certain pressure (set pressure) with the opening and is supplied as the PR pressure.

10-83 (3)

STRUCTURE AND FUNCTION

SELF PRESSURE REDUCING VALVE

3. At raise of load pressure P2

OPERATION • When the load pressure P2 rises due to digging or other operations, the pump delivery will increase and P1 pressure will rise. Then, the expression (P1 pressure > Spring (7) force + ( d area x PR pressure)) will hold, and valve (2) will move to the right side till the stroke end. As a result, the opening between ports P1 and P2 will increase, the passage resistance will become smaller to reduce engine loss horsepower. • When the PR pressure rises above the set pressure, poppet (5) will open and hydraulic oil will flow through the route from the PR port, hole a in spool (8), poppet (5) opening to tank port T.

10-84 (3)

•

Therefore, there will occur a differential pressure around hold a in spool (8) and the spool will move in the direction to close port P1 and PR opening. Then, the P1 pressure is reduced and adjusted to a certain pressure (set pressure) with the opening and is supplied as the PR pressure.

PC130-7

STRUCTURE AND FUNCTION

SELF PRESSURE REDUCING VALVE

4. At occurrence of abnormal high pressure

OPERATION • When PR pressure of the self pressure reducing valve rises abnormally high, ball (10) will separate from the seat against spring (9) force to flow hydraulic oil to the output ports PR o T so as to reduce the PR pressure. Then, the equipment (PPC valve, solenoid valve, etc.), to which the oil pressure is supplied, is protected from the abnormal high pressure.

PC130-7

10-85 (3)

STRUCTURE AND FUNCTION

CENTER SWIVEL JOINT

CENTER SWIVEL JOINT

1. 2. 3. 4. 5.

Cover Body Slipper seal O-ring Shaft

10-86

A1 : A2 : B1 : B2 : C1 : C2 : D1 : D2 : E1 : E2 : DR1 : DR2 :

From control valve (R.H. travel Forward) To R.H. travel motor B From control valve (L.H. travel Forward) To L.H. travel motor A From control valve (R.H. travel Reverse) To R.H. travel motor A From control valve (L.H. travel Reverse) To L.H. travel motor B 2-stage travel selection solenoid valve To L.H./R.H. travel motor D To hydraulic tank From L.H. travel motor C1 and R.H. travel motor C2

PC130-7

STRUCTURE AND FUNCTION

TRAVEL MOTOR

TRAVEL MOTOR (FINAL DRIVE)

A : From control valve (L.H./R.H. travel) B : From control valve (L.H./R.H. travel) C1 : To hydraulic tank (L.H. travel motor) Plug (R.H. travel motor) C2 : Plug (L.H. travel motor) To hydraulic tank (R.H. travel motor) D : From travel 2nd speed selector solenoid valve

PC130-7

10-87

STRUCTURE AND FUNCTION

1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17.

Plug Check valve spring Check valve Return spring Counterbalance valve Safety valve Safety valve spring End cover Regulator valve Spring Brake piston Cylinder Spring Swash plate Pivot Crankshaft RV gear A

10-88

TRAVEL MOTOR

18. 19. 20. 21. 22. 23. 24. 25. 26. 27. 28. 29. 30. 31. 32. 33. 34.

RV gear B Cover Driven gear Drive gear Drain plug Hub Regulator piston Spindle Piston Floating seal Plate Disc Valve plate Spring Piston Plug Check valve

PC130-7

STRUCTURE AND FUNCTION

TRAVEL MOTOR

SPECIFICATION Type Theoretical delivery (cm3/rev{cc/rev}) Rated speed (rpm)

GM18VL3 Hi

33.2 {33.2}

Lo

52.7 {52.7}

Hi

3,562

Lo

2,291

Brake releasing pressure (MPa{kg/cm2})

0.68 {6.94}

Hi-Lo switching pressure (MPa{kg/cm2})

2.94 {30}

Final drive reduction ratio

66

OUTLINE Travel speed selection

• •

Swash plate (14) has 2 faces (x, y) behind it, and is supported by pivot (15). When pressure of comtrol chamber a rises, it pushes regulator piston (24), then swash plate angle becomes minimum, then travel speed goes high.

PC130-7

10-89 (3)

STRUCTURE AND FUNCTION

TRAVEL MOTOR

OPERATION Operation of motor At slow speed (the motor swash plate angle is maximized.)

•

• •

•

•

Since the travel 2nd speed selector solenoid valve is demagnetized, pressurized oil from the main pump does not flow to the D port. Therefore, spring (10) has pressed regulator valve (9) to the left side. So, regulator valve (9) stops the main pressurized oil led from the control valve to the end cover by pushing check valve (34). The pressurized oil in the control chamber drains in the motor case through passage b of regulator valve (9). Then, the main pressurized oil from cylinder c chamber pushes swash plate (14) in the direction to maximize the swash plate angle and the motor capacity is increased to the maximum for slow speed travel.

10-90 (3)

PC130-7

STRUCTURE AND FUNCTION

TRAVEL MOTOR

At high speed (the motor swash plate angle is minimized.)

•

•

•

When the travel 2nd speed selector solenoid valve is energized, pilot pressure from the main pump will flow in D port and push regulator valve (9) in the right direction. Therefore, the main pressurized oil from the control valve passes through passage b of regulator valve (9), flows in control chamber a and pushed regulator piston (24) in the left direction. Then, swash plate (14) is pressed in the direction to minimize the swash plate angle, and the motor capacity is minimized for high speed travel.

PC130-7

10-91 (3)

STRUCTURE AND FUNCTION

TRAVEL MOTOR

Operation of brake valve • The brake valve consists of check valves (3a) and (3b), counterbalance valve (5) and safety valve (6), and the circuit configuration is as per the right figure. • Functions and operations of these components are as follows :

Counterbalance valve, check valve Function • When traveling down a slope, the own weight falling force will make the machine travel faster than the motor rotation. So, traveling with reduced engine speed is very dangerous because the motor idles and runs away. These valves let the machine travel at a speed appropriate for the engine speed (pump delivery) to prevent this danger. Operation at oil supply • When the travel lever is operated, pressurized oil from the control valve will be supplied to the PA port, push and open check valve (3a) and flow from MA port on the motor inlet side to MB port on the motor outlet side. Since the motor outlet circuit is closed with check valve (3b) and counterbalance valve (5), however, the supply-side pressure will rise.

10-92 (3)

PC130-7

STRUCTURE AND FUNCTION

•

TRAVEL MOTOR

The pressurized oil on the supply side flows in the S1 chamber from orifice E1 of counterbalance valve (5). When the pressure in S1 chamber rises above the switching pressure of the counterbalance valve, counterbalance valve (5) will be pressed in the right direction. So, the circuit between outlet side MB port and PB port will open, the motor outlet circuit will open, and the motor will start rotating.

Brake operation at traveling downhill • If the machine is going to run away when traveling downhill, the motor will idle to reduce oil pressure on the motor inlet side and the pressure in S1 chamber through orifice E1. When the pressure in S1 chamber drops below the switching pressure of the counterbalance valve, counterbalance valve (5) will be returned in the left direction with return spring (4), and outlet side MB port will be throttled. Then, pressure on the outlet side will rise and rotation resistance will occur to the motor to prevent the machine from running away. This means that counterbalance valve (5) moves to a position where the machine own weight and inlet side pressure balance with the pressure at outlet side MB port, and the outlet circuit is throttled to control speed to the pump delivery.

PC130-7

10-93 (3)

STRUCTURE AND FUNCTION

TRAVEL MOTOR

Safety valve Function • When stopping a travel (or traveling downhill), counterbalance valve (5) will close the inlet and outlet circuits of the motor. Since the motor keeps rotating by inertia, however, pressure on the outlet side of the motor will rise abnormally and the motor and pipes may be damaged. Then, safety valve leads the abnormally high pressure to the inlet side of the motor to prevent equipment from being damaged. Operation • When the pressurized oil being supplied from PA port is stopped flowing at the time of travel stop, return spring (4) will return counterbalance valve (5) from the right side to the left side (neutral position). • Though counterbalance valve (5) closes a chamber on the outlet side circuit, the inertia lets the motor rotate and the pressure in a chamber rises. • The highly pressurized oil in a chamber passes through throttle b of safety valve (6a) and enters in d chamber from c chamber. The pressurized oil entered in d chamber moves piston (32) to the left side. Meantime, safety valve (6a) is pushed to open by the pressurized oil in a chamber, and the pressurized oil in a chamber flows in f chamber through e port. Therefore, the pressurized oil in a chamber flows in f chamber at a comparatively slow speed to control the pressure in a chamber and also to prevent cavitation in f chamber at the same time. • When piston (32) reaches the stroke end, the pressures in d and c chambers will rise, safety valve (6a) will be closed again and the pressure in a chamber will rise further. • Then, safety valve (6b) will open and the pressurized oil in the a chamber will flow in f chamber from g chamber. The pressure in a chamber can be controlled in two stage as mentioned above, and the hydraulic motor can be smoothly braked to stop.

10-94 (3)

PC130-7

STRUCTURE AND FUNCTION

TRAVEL MOTOR

Operation of parking brake When operating travel • When the travel lever is operated, pressurized oil from the pump will work on counterbalance valve (5), open circuit a to the parking brake and flow in b chamber of brake piston (11). • The pressure in b chamber overcomes spring (31) and pushed brake piston (11) in the left direction. • This will eliminate the press force to plate (28) and disc (29), and plate (28) and disc (29) will separate, and the brake force will be released.

When positioning travel neutral • When the travel lever is brought to the neutral position, counterbalance valve (5) will return to the neutral position and circuit a to the parking brake will be closed. • The pressurized oil in b chamber of brake piston (11) will be drained in the case, and spring (31) will push the brake piston in the right direction. • Therefore, plate (28) and disc (19) will be pushed to each other, and the brake will come to work.

PC130-7

10-95 (3)

STRUCTURE AND FUNCTION

SWING MOTOR

SWING MOTOR TYPE : KMF40ABE-3

B S T MA MB

: : : : :

From swing brake solenoid valve From control valve To tank From control valve From control valve

10-96

SPECIFICATION Type : KMF40ABE-3 Theoretical delivery : 40.2 cc/rev Safety valve set pressure : 27.5 MPa {280 kg/cm2} Rated speed : 2,413 rpm Brake releasing pressure :1.77 MPa{18.0 kg/cm2}

PC130-7

STRUCTURE AND FUNCTION

1. 2. 3. 4. 5. 6. 7. 8. 9. 10.

Drive shaft Spacer Case Disc Plate Brake ring Brake piston Housing Reverse prevention valve Center spring

PC130-7

SWING MOTOR

11. 12. 13. 14. 15. 16. 17. 18. 19. 20.

Cylinder Valve plate Piston Center shaft Safety valve Check valve Check valve spring Shuttle valve Shuttle valve spring Brake spring

10-97

STRUCTURE AND FUNCTION

SWING MOTOR

SWING BRAKE 1. When solenoid valve is demagnetized Operation • When the solenoid valve of the swing brake is demagnetized, pressurized oil from the control pump will be interrupted and the B port will be connected to the tank circuit. • Then, brake piston (7) will be pressed downward with brake spring (8) and will push disc (4) and plate (5) to work the brake.

2. When solenoid valve is energized Operation • When the solenoid valve of the swing brake is energized, the valve will be changed over and pressurized oil from the control pump will enter the B port and will flow in to the brake chamber A. • Pressurized oil in the A chamber will push brake spring (8) and brake piston (7) will move upward. Then, disc (4) and plate (5) will separate to release the brake.

10-98 (3)

PC130-7

STRUCTURE AND FUNCTION

SWING MOTOR

REVERSE PREVENTION VALVE

1. 2. 3. 4. 5. 6. 7.

Valve body Spool (MA side) Spring (MA side) Plug (MA side) Spool (MB side) Spring (MB side) Plug (MB side)

MA : Port MB : Port T1 : Port T2 : Port

PC130-7

10-99

STRUCTURE AND FUNCTION

SWING MOTOR

Effect explanation drawing

10-100

PC130-7

STRUCTURE AND FUNCTION

SWING MOTOR

FUNCTION • This function is used for reducing swing back generated on a swing body that can result from factors such as inertia of the swing body, backlash and rigidity of the machinery system and compressibility of hydraulic oil. • This function helps preventing loose loads at the end of swing or cutting lead time (better positioning performance allows you to proceed to the next operation within a shorter time).

1. When MB port pressure is generated Operation • MB pressure is conducted to d room via the cutout. Utilizing difference of space (D1>D2), the pressure compresses spring (6) and drives spool (5) leftward to interconnect MB o e. • Since MA pressure at this time is lower than the pressure set on spring (3), spool (2) is not moved and pressurized oil remains closed. Thus, the braking force is maintained.

2. When the motor is once stopped Operation • The motor is reverse rotated by charging pressure generated on the MB port (1st reverse rotation). • At this time, reversing pressure is generated on the MA port. MA pressure conducted to a room interconnects MA o b by compressing spring (3) and driving spool (2) rightward. • The pressure is then conducted through drilled hole on spool (5) to interconnect b o f. Reversing pressure on the MA port is bypassed to the T port to disable the 2nd reverse rotation.

PC130-7

10-101 (3)

STRUCTURE AND FUNCTION

SOLENOID VALVE

SOLENOID VALVE FOR PPC LOCK, 2ND TRAVEL SPEED SELECT, SWING HOLD BRAKE AND 2-STAGE RELIEF SOLENOID VALVE.

1. 2. 3. 4.

PPC lock solenoid valve 2nd travel speed select solenoid valve Swing hold brake solenoid valve 2-stage relief solenoid valve

Solenoid valve 5. Push pin 6. Coil 7. Gauge 8. Spool 9. Block 10. Spring

A1 : To PPC valve A2 : To 2-stage relief valve A3 : To swing hold brake A4 : To 2nd travel speed select valve ACC : To accumulator P1 : From self-pressure reducing valve T : To hydraulic oil tank

Check valve 11. Plug 12. Spring 13. Plunger

10-102

PC130-7

STRUCTURE AND FUNCTION

SOLENOID VALVE

OPERATION When solenoid is "demagnetized" • Coil (6) remains demagnetized as long as signal current to it is stopped.. • Thus, spool (8) is pushed leftward by spring (10). • Since ports P to A are closed by this spool, flow of pilot oil pressure to the actuator is blocked. At the same time, oil from the actuator is lead from A port to T port, then drained to the hydraulic oil tank.

When solenoid is "magnetized" • Coil (6) is magnetized by signal current conducted to it. • Thus, spool (8) is pushed rightward by push pin (5). • As the result, pilot oil pressure is conducted from P port through cage (7) and A port up the actuator. At the same time, T port is closed, thereby blocking flow of oil to the hydraulic oil tank.

PC130-7

10-103 (3)

STRUCTURE AND FUNCTION

PPC ACCUMULATOR

PPC ACCUMULATOR 1. 2. 3. 4. 5. 6.

Gas plug Shell Poppet Holder Bladder Oil port

SPECIFICATIONS Gas used : Nitrogen gas Gas capacity : 0.3 l Charged gas pressure : 1.18 MPa (12 kg/cm2) at 80°C Maximum operating pressure : 6.86 MPa (70 kg/cm2)

10-104

PC130-7

STRUCTURE AND FUNCTION

PPC VALVE

PPC VALVE FOR SWING, WORK EQUIPMENT

P : From main pump P1 : Left : Arm OUT/Right : Boom LOWER P2 : Left : Arm IN/Right : Boom RAISE

PC130-7

P3 : Left : Swing RIGHT/Right : Bucket CURL P4 : Left : Swing LEFT/Right : Bucket DUMP T : To tank

10-105

STRUCTURE AND FUNCTION

1. 2. 3. 4. 5.

Spool Metering spring Centering spring Piston Disk

10-106

PPC VALVE

6. 7. 8. 9. 10.

Nut (for linking the lever) Joint Plate Retainer Body

PC130-7

STRUCTURE AND FUNCTION

PPC VALVE

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

2) During fine control (neutral o fine control) When piston (4) starts to be pushed by disc (5), retainer (9) is pushed; spool (1) is also pushed by metering spring (2), and moves down. When this happens, fine control hole f is shut off from drain chamber D, and at almost the same time, it is connected to pump pressure chamber PP, so pilot pressure oil from the main pump passes through fine control hole f and goes from port P1 to port A. When the pressure at port P1 becomes higher, spool (1) is pushed back and fine control hole f is shut off from pump pressure chamber PP. At almost the same time, it is connected to drain chamber D to release the pressure at port P1. When this happens, spool (1) moves up or down so that force of metering spring (2) is balanced with the pressure at port P1. The relationship in the position of spool (1) and body (10) (fine control hole f is at a point midway between drain hole D and pump pressure chamber PP) does not change until retainer (9) contacts spool (1). Therefore, metering spring (2) is compressed proportionally to the amount of movement of the control lever, so the pressure at port P1 also rises in proportion to the travel of the control lever. In this way, the control valve spool moves to a position where the pressure in chamber A (the same as the pressure at port P1) and the force of the control valve spool return spring are balanced. (Fig. 2)

PC130-7

10-107

STRUCTURE AND FUNCTION

PPC VALVE

3) During fine control (when control lever is returned) When disc (5) starts to be returned, spool (1) is pushed up by the force of centering spring (3) and the pressure at port P1. When this happens, fine control hole f is connected to drain chamber D and the pressure oil at port P1 is released. If the pressure at port P1 drops too far, spool (1) is pushed down by metering spring (2), and fine control hole f is shut off from drain chamber D. At almost the same time, it is connected to pump pressure chamber PP, and the pump pressure is supplied until the pressure at port P1 recovers to a pressure that corresponds to the lever position. When the spool of the control valve returns, oil in drain chamber D flows fine control hole f' in the valve on the side that is not working. The oil passes through port P2 and enters chamber B to fill the chamber with oil. (Fig. 3)

4) At full stroke When disc (5) pushes down piston (4), and retainer (9) pushes down spool (1), fine control hole f is shut off from drain chamber D, and is connected with pump pressure chamber PP. Therefore, the pilot pressure oil from the main pump passes through fine control hole f and flows to chamber A from port P1, and pushes the control valve spool. The oil returning from chamber B passes from port P2 through fine control hole f' and flows to drain chamber D. (Fig. 4)

10-108

PC130-7

STRUCTURE AND FUNCTION

PPC VALVE

FOR TRAVEL

P T P1 P2

: From main pump : To tank : L.H reverse : L.H forward

PC130-7

P3 : R.H reverse P4 : R.H forward P5 : Travel signal

10-109

STRUCTURE AND FUNCTION

1. 2. 3. 4.

Plate Body Piston Collar

10-110

PPC VALVE

5. 6. 7. 8.

Metering spring Centering spring Valve Pin

PC130-7

STRUCTURE AND FUNCTION

PPC VALVE

OPERATION 1. In the neutral mode • P1 and P2 ports of the operation valves A, B and PPC valve are connected to drain room D via the fine control hole f on spool (1).

2. In the fine control mode (neutral o fine control) • As piston (4) is pushed by disk (5), retainer (9) ia also pushed. At the same time, spool (1) is also pushed down via the metering spring (2). • By this move, connection of the fine control hole f is switched from drain room D to the pump pressure room PP, and pilot pressurized oil for the main pump is conducted from P1 port to A port. • As P1 port pressure increases, spool (1) is pushed back. By this move, connection of the fine control hole f is switched from pump pressure room PP to drain room D, thereby relieving P1 port pressure. • As the result, spool (1) moves up and down so that force of metering spring (2) and P1 port pressure may be balanced. Positional relationship between spool (1) and body (10) (fine control hole f is situated at mid point between drain room D and pump pressure room PP) remains unchanged until retainer (9) is contacted against spool (1). • Metering spring (2) is, therefore, compressed in proportion to strokes of the operation lever. Thus, the P1 port pressure, too, also increases in proportion to strokes of the operation lever. • As the result, the operation valve spool moves to the position where pressure of A room (the same as P1 port pressure) is balanced against force of the operation valve spool return spring.

PC130-7

10-111 (3)

STRUCTURE AND FUNCTION

PPC VALVE

3. In the fine control mode (when operation lever is shifted back to its original position) • As disk (5) starts returning, spool (1) is pushed up by force of centering spring (3) and P1 port pressure. • By this move, the fine control hole f is connected to drain room D and relieves pressurized oil of P1 port to it. • If P1 port pressure goes excessively low, spool (1) is pushed down by metering spring (2) and passage between the fine control hole f and drain room D is shut down. And, almost at the same time, the hole is connected to pump pressure room PP and starts supplying pressure to the pump. This supply continues until P1 port pressure is recovered to the level equivalent to the lever position. • When the operation valve spool returns, oil in drain room D flows in through the fine control hole f' on the not moving side valve. Oil is then conducted via P2 port to room B to fill it up.

4. In the full stroke mode • When disk (5) pushes down piston (4) and retainer (9) pushes down spool (1), connection of the fine control hole f is switched from drain room D to pump pressure room PP. • Thus, pilot pressurized oil from the control pump passes through the fine control hole f and conducted to A room via P1 port to push the operation valve spool. • Return oil from B room is conducted from P2 port to drain room D via the fine control hole f'.

10-112 (3)

PC130-7

STRUCTURE AND FUNCTION

PPC VALVE

FOR SERVICE

1. 2. 3. 4. 5. 6. 7. 8. 9.

Spool Metering spring Centering spring Piston Lever Plate Retainer Body Filter

PC130-7

P T P1 P

: From self pressure reducing valve : To tank : To blade or service valve : To blade or service valve

10-113

STRUCTURE AND FUNCTION

PPC VALVE

OPERATION 1. In the neutral mode • P1 and P2 ports of the operation valves A, B and PPC valve are connected to drain room D via the fine control hole f on spool (1).

2. In the fine control mode (Neutral o fine control) • As piston (4) is pushed by disk (5), retainer (7) is also pushed. At the same time, spool (1) is also pushed down via metering spring (2). • By this move, connection of the fine control hole f is switched from drain room D to pump pressure room PP, and pilot pressurized oil for the control pump is conducted from P1 port to A port. • As P1 port pressure increases, spool (1) is pushed back. By this move, connection of the fine control hole f is switched from pump pressure room PP to drain room D, thereby relieving P1 port pressure. • As the result, spool (1) moves up and down so that force of metering spring (2) and P1 port pressure may be balanced. • Positional relationship between spool (1) and body (8) (fine control hole f is situated at mid point between drain room D and pump pressure room PP) remains unchanged until retainer (7) is contacted against spool (1). • Metering spring (2) is, therefore, compressed in proportion to strokes of the operation lever. Thus, the P1 port pressure, also increases in proportion to strokes of the operation lever. • As the result, the operation valve spool moves to the position where pressure of A room (the same as P1 port pressure) is balanced against force of the operation valve spool return spring.

10-114 (3)

PC130-7

STRUCTURE AND FUNCTION

PPC VALVE

3. In the fine control mode (when the operation lever is shifted back to its original position) • As lever (5) starts returning, spool (1) is pushed up by force of centering spring (3) and P1 port pressure. By this move, the fine control hole f is connected to drain room D and relieves pressurized oil of P1 port to it. • If P1 port pressure goes excessively low, spool (1) is pushed down by metering spring (2) and passage between the fine control hole f and drain room D is shut down. And, almost at the same time, the hole is connected to pump pressure room PP and starts supplying pressure to the pump. This supply continues until the P1 port pressure is recovered to the level equivalent to the lever position. • When the operation valve spool returns, oil in drain room D flows in through the fine control hole f' on the not moving side valve. Oil is then conducted via P2 port to the room B to fill it up.

4. In the full stroke mode • When disk (5) pushes down piston (4) and retainer (7) pushes down spool (1), connection of the fine control hole f is switched from drain room D to pump pressure room PP. • Thus, pilot pressurized oil from the control pump passes through the fine control hole f and conducted to A room via P1 port to push the operation valve spool. • Return oil from B room is conducted from P2 port to drain room D via the fine control hole f'.

PC130-7

10-115 (3)

STRUCTURE AND FUNCTION

WORK EQUIPMENT

WORK EQUIPMENT

1. 2. 3. 4. 5. 6. 7.

Bucket Link Bucket cylinder Arm Arm cylinder Boom Boom cylinder

10-116

PC130-7

STRUCTURE AND FUNCTION

AIR CONDITIONER PIPING

AIR CONDITIONER PIPING

A: B: C: D:

Hot air/cold air spurting port Internal air circulation port External air inlet Refrigerant checking port

1. 2. 3. 4.

Hot water inport piping Air conditioner compressor Condenser Refrigerant piping

PC130-7

5. 6. 7. 8.

Receiver tank Hot water return piping Air conditioner unit Duct

10-117

STRUCTURE AND FUNCTION

ENGINE CONTROL

ENGINE CONTROL

1. 2. 3. 4. 5. 6. 7. 8. 9.

Starting switch Fuel control dial Governor motor Starting motor Linkage Battery relay Battery Engine throttle and pump controller Fuel injection pump

10-118 (3)

OUTLINE • The engine can be started and stopped with only starting switch (1). • The engine throttle and pump controller (8) reveives the signal of fuel control dial (2) and transmits the drive signal to governor motor (3) to control the governor lever angle of fuel injection pump (9) and control the engine speed.

PC130-7

STRUCTURE AND FUNCTION

ENGINE CONTROL

1. OPERATION OF SYSTEM Starting engine • When the starting switch is turned to the START position, the starting signal flows to the starting motor, and the starting motor turns to start the engine. When this happens, the engine throttle and pump controller checks the signal from the fuel control dial and sets the engine speed to the speed set by the fuel control dial.

Engine speed control • The fuel control dial sends a signal to the engine throttle and pump controller according to the position of the dial. The engine throttle and pump controller calculates the angle of the governor motor according to this signal, and sends a signal to drive the governor motor so that it is at that angle. When this happens, the operating angle of the governor motor is detected by the potentiometer, and feedback is sent to the engine throttle and pump controller, so that it can observe the operation of the governor motor.

Stopping engine • When the starting switch is turned to the STOP position, the engine throttle and pump controller drives the governor motor so that the governor lever is set to the NO INJECTION position. • When this happens, to maintain the electric power in the system until the engine stops completely, the engine throttle and pump controller itself drives the battery relay.

PC130-7

10-119

STRUCTURE AND FUNCTION

ENGINE CONTROL

2. COMPONENT Fuel control dial 1. 2. 3. 4. 5. 6.

Knob Dial Spring Ball Potentiometer Connector

FUNCTION • The fuel control dial is installed under the monitor panel, and a potentiometer is installed under the knob. The potentiometer shaft is turned by turning the knob. • As the potentiometer shaft is turned, the resistance of the variable resistor in the potentiometer changes and a throttle signal is sent to the engine throttle and pump controller. The hatched area in the graph shown at right is the abnormality detection area.

10-120

PC130-7

STRUCTURE AND FUNCTION

ENGINE CONTROL

GOVERNOR MOTOR

1. 2. 3. 4. 5. 6. 7. 8.

Potentiometer Cover Shaft Dust seal Bearing Motor Gear Connector

OPERATION While motor is stopped • Electric power is applied to both phases A and B of the motor. While motor is running • The engine throttle and pump controller supplies a pulse current to phases A and B, and the motor revolves, synchronizing to the pulse.

FUNCTION • The motor is turned according to the drive signal from the engine throttle and pump controller to control the governor lever of the fuel injection pump. This motor used as the motive power source is a stepping motor. • A potentiometer for feedback is installed to monitor the operation of the motor. • Revolution of the motor is transmitted through the gear to the potentiometer. PC130-7

10-121

STRUCTURE AND FUNCTION

ELECTRIC CONTROL SYSTEM

ELECTRIC CONTROL SYSTEM CONTROL FUNCTION

1 Engine/Pump composite control function

2 Pump/Valve control function

3 One-touch power maximizing function

4 Auto-deceleration function

5 Electric control system

Auto-warm-up/Overheat prevention function

6 Swing control function

7 Travel control function

8 ATT flow control, circuit selector function (if equipped)

Self-diagnosis function

10-122

PC130-7

STRUCTURE AND FUNCTION

ELECTRIC CONTROL SYSTEM

MACHINE CONTROL SYSTEM DIAGRAM

10-124 (3)

PC130-7

STRUCTURE AND FUNCTION

PC130-7

ELECTRIC CONTROL SYSTEM

10-125

STRUCTURE AND FUNCTION

ELECTRIC CONTROL SYSTEM

1. ENGINE AND PUMP CONTROL FUNCTION

10-126

PC130-7

STRUCTURE AND FUNCTION

ELECTRIC CONTROL SYSTEM

FUNCTION • This function is for selecting any of the four working modes "A," "B", "E" and "L" with the working mode selector switch on the monitor panel. The controller can select optimum engine torques or pump absorption torques for works to be expected. •

The controller detects the engine governor speed set with the fuel control dial depending on the pump absorption torque set in each mode and detects actual engine speeds. Then, the controller controls all torques at each output point of the engine so that the pump can absorb them.

•

When an engine speed was lowered, the controller prevents the engine from stopping by throttling the pump absorption toque.

PC130-7

10-127 (3)

STRUCTURE AND FUNCTION

1. CONTROL METHOD IN EACH MODE Mode A • Matching point in Mode A • When a load to the pump increases and the pressure rises and the engine speed lowers. At the time, the controller reduces the pump delivery so that the speed lowers to the speed at the full output point or so. If the pressure drops on the contrary, the controller increases the pump delivery so that the speed comes to the speed at the full output point or so. The controller repeats these controls so that the engine can always be used at speeds at the full output point or so.

10-128

ELECTRIC CONTROL SYSTEM

A Travel (A1)

66.2 kW/2,200 rpm {88.7 HP/2,200 rpm}

A Work (A2)

65.5 kW/2,200 rpm {87.8 HP/2,200 rpm}

PC130-7

STRUCTURE AND FUNCTION

ELECTRIC CONTROL SYSTEM

Mode E / Mode B / Mode L Mode Partial output point

Model

E

B

L

90%

90%

56%

PC130-7

Mode E

58.8 kW/2,000 rpm {78.9 HP/2,000 rpm}

Mode B

58.8 kW/2,000 rpm {78.9 HP/2,000 rpm}

Mode L

36.8 kW/1,500 rpm {70 HP/1,500 rtpm}

•

•

At this time, the controller keeps the pump absorption torque along the constant horsepower curve and lower the engine speed by the composite control of the engine and pump. By this method, the engine is used in the low fuel consumption area.

PC130-7

10-129

STRUCTURE AND FUNCTION

ELECTRIC CONTROL SYSTEM

2. FUNCTION TO CONTROL PUMP DURING TRAVEL • If the machine travels in mode work A, B, E, or L, the working mode does not change, but the pump absorption torque and engine speed rise to travel A mode.

3. PUMP DRIVE IN AN EMERGENCY • Even if controllers and sensors get out of order, the emergency pump drive switch (S) will enable to maintain functions of the machine with absorption torques quite similar to those in the Mode E. In this case, a constant current flows from the battery to the PC-EPC valve, and the valve detects the oil pressure only. (1) Normal (2) Emergency a The emergency pump drive switch (S) is of the alternative type. If the machine is operated after the switch is set to "Emergency (2)" even though the machine is normal, the user code "E02" will be shown on the display.

10-130

PC130-7

STRUCTURE AND FUNCTION

ELECTRIC CONTROL SYSTEM

2. PUMP/VALVE CONTROL FUNCTION

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

PC130-7

10-131

STRUCTURE AND FUNCTION

ELECTRIC CONTROL SYSTEM

1) Cut-off function • When the cut-off function is turned on, the PC-EPC current is increased to near the maximum value. By this operation, the flow rate in the relief state is lowered to reduce fuel consumption. • Operating condition for turning on cut-off function. •

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

The cut-off function does not work, however, while the machine is traveling in mode A, the lock switch is turned on. 2) 2-stage relief function • The relief pressure in the normal work is 31.9 MPa {325 kg/cm2}. If the 2-stage relief function is turned on, however, the relief pressure rises to about 34.8 MPa {355 kg/cm2}. By this operation, the hydraulic force is increased further. • Operating condition for turning on 2-stage relief function • • • •

Condition Relief pressure During travel When swing lock switch is 31.9 MPa turned on {325 kg/cm2} When one-touch power maxi⇓ mizing function is turned on 34.8 MPa When L mode is operated {355 kg/cm2}

10-132

PC130-7

STRUCTURE AND FUNCTION

ELECTRIC CONTROL SYSTEM

3. ONE-TOUCH POWER MAXIMIZING FUNCTION

FUNCTION • Power can be increased for about 8.5 sec. by operating the left knob switch.

PC130-7

10-133

STRUCTURE AND FUNCTION

ELECTRIC CONTROL SYSTEM

1) One-touch power maximizing function • When the operator needs more digging force to dig up a large rock, etc., if the left knob switch is pressed, the hydraulic force is increased about 9% to increase the digging force. • If the left knob switch is turned on in working mode "A" or "E", each function is set automatically as shown below.

⇓ Software cut-off function Working mode

Engine/Pump control

A, E

Matching at rated output point

10-134

2-stage relief function 31.9 MPa {325 kg/cm2} ⇓

34.8 MPa {355 kg/cm2}

Operation time Automatically Cancel reset at 8.5 sec

PC130-7

STRUCTURE AND FUNCTION

ELECTRIC CONTROL SYSTEM

4. AUTO-DECELERATION FUNCTION

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

PC130-7

10-135

STRUCTURE AND FUNCTION

ELECTRIC CONTROL SYSTEM

OPERATION When control levers are set in neutral • If all the control levers are set in NEUTRAL while the engine speed is above the decelerator operation level (about 1,400 rpm), the engine speed lowers instantly to the first deceleration level about 100 rpm lower than the set speed. • If 4 more seconds pass, the engine speed lowers to the second deceleration level (about 1,400 rpm) and keeps at that level until any lever is operated again. When any control lever is operated • If any control lever is operated while the engine speed is kept at the second deceleration level, the engine speed rises instantly to the level set with the fuel control dial.

10-136

PC130-7

STRUCTURE AND FUNCTION

ELECTRIC CONTROL SYSTEM

5. AUTO-WARM-UP/OVERHEAT PREVENTION FUNCTION

FUNCTION • After the engine is started, if the engine coolant temperature is low, the engine speed is raised automatically to warm up the engine. If the engine coolant temperature rises too high during work, the pump load is reduced to prevent overheating.

PC130-7

10-137 (3)

STRUCTURE AND FUNCTION

ELECTRIC CONTROL SYSTEM

1) Auto-warm-up function • After the engine is started, if the engine coolant water temperature is low, the engine speed is raised automatically to warm up the engine. Operating condition (All)

Operated

⇒

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

Engine speed: Max. 1,200 rpm

⇓ Resetting condition (Any one) Auto Manual

Coolant temperature: Above 30°C Auto-warm-up operation time: Min. 10 minutes

Reset

⇒

Engine speed: Any level

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

Operating condition

Operation/Remedy

Resetting condition Coolant and oil temperature: Below 105?C

Coolant and oil temperature: Above 105°C

⇒

Operating condition Coolant and oil temperature: Above 102°C

⇒

10-138 (3)

Work mode: Mode A, E, OR B Engine speed: Keep as is. Monitor alarm lamp: Lights up. Lower pump discharge.

⇒

Work mode: Mode A Engine speed: Keep as is. Lower pump discharge.

⇒

⇒

• Under above condition, controller is set to condition before operation of function. (Manual reset)

Coolant and oil temperature: Below 102°C • Under above condition, controller is set to condition before operation of function. (Automatic reset) Resetting condition

⇒

Operation/Remedy Work mode: Travel Engine speed: Keep as is. Lower travel speed.

Fuel control dial: Return to low idle position once.

Resetting condition

Operation/Remedy

Operating condition

Coolant and oil temperature: Above 95°C

⇒

Operation/Remedy

Operating condition

Coolant and oil temperature: Above 98°C

Work mode: Any mode Engine speed: Low idle Monitor alarm lamp: Lights up Alarm buzzer: Sounds

Coolant and oil temperature: Below 98°C • Under above condition, controller is set to condition before operation of function. (Automatic reset) Resetting condition

⇒

Coolant and oil temperature: Below 95°C • Under above condition, controller is set to condition before operation of function. (Automatic reset)

PC130-7

STRUCTURE AND FUNCTION

ELECTRIC CONTROL SYSTEM

6. SWING CONTROL FUNCTION

1. 2. 3. 4. 5. 6. 7. 8. 9. 10.

Battery Battery relay Fusible link Starting switch Fuse box Controller Swing holding brake release switch Swing lock switch Monitor panel Swing holding brake solenoid valve

Input/Output Signals a. Controller power supply b. Solenoid power supply c. Monitor panel power supply d. S-NET signal

PC130-7

11. 12. 13. 14. 15. 16. 17. 18.

PPC lock solenoid valve Swing motor L.H. work equipment PPC valve Arm IN PPC oil pressure switch Swing PPC oil pressure switch Engine Hydraulic pump Control valve 18a. Self pressure reducing valve 18b. Main relief valve

e. Solenoid valve drive signal f. Swing PPC oil pressure switch signal g. Arm IN PPC oil pressure switch signal

10-139

STRUCTURE AND FUNCTION

FUNCTION Swing lock and swing holding brake • The swing lock (manual type) is for locking swing at optional positions. The swing holding brake (automatic type) interlocks with swing and prevents hydraulic drift from occurring after stop of swing. a When the swing lock is released, only the hydraulic brake with the safety valve is effective for swing. So, note that, when a swing stops on a slope, a hydraulic drift may occur sometimes. a Even during arm IN operation, release the swing holding brake.

ELECTRIC CONTROL SYSTEM

Swing lock switch

OFF

ON

Release of swing holding brake • If the controller gets out of order and no swing is possible because the swing holding brake does not work normally, use the swing holding brake release switch (S), and the swing holding brake will be released and swing will become possible. (1) Normal (2) Release a Even if the swing holding brake release switch is set to "ON," the swing holding brake is not be released while the swing lock switch is set to "ON."

Swing lock monitor

Function

Operation

The lamp Swing goes holding OUT. brake

• When the swing control lever is set to NEUTRAL, the swing holding brake works 4 sec. later. • When the swing control lever or the arm IN lever is operated, the swing holding brake is released and free swing becomes possible.

The lamp Swing turns ON. lock

• The swing holding brake works, and the swing is locked. • Even if the swing control lever is operated, the swing holding brake cannot be released, and no swing is possible.

Swing ON holding (when the controller brake reis out of order) lease switch Swing lock switch

Swing brake

OFF (when the controller is in order)

ON

OFF

ON

OFF

The swing lock works.

The swing lock is released.

The swing lock works.

The swing holding brake works.

Input/Output signal time chart

10-140

PC130-7

STRUCTURE AND FUNCTION

ELECTRIC CONTROL SYSTEM

7. TRAVEL CONTROL FUNCTION

1. 2. 3. 4. 5. 6. 7. 8. 9.

Battery Battery relay Fusible link Starting switch Fuse box Controller Monitor panel Travel speed selector solenoid valve L.H. travel motor

Input/Output signals a. Controller power supply b. Solenoid power supply c. Monitor panel power supply d. S-NET signal

PC130-7

10. 11. 12. 13. 14. 15.

R.H. travel motor Engine speed sensor Pump pressure sensor Engine Hydraulic pump Control valve 15a. Self pressure reducing valve 15b. Main relief valve

e. Solenoid valve drive signal f. Engine speed signal g. Pump pressure signal

10-141

STRUCTURE AND FUNCTION

FUNCTION Travel Speed Selection 1. Travel Speed "Manual" Change • When the travel speed selector switch is set to LOW or HIGH, the motor capacity changes and travel speeds can be selected.

ELECTRIC CONTROL SYSTEM

Travel speed selector switch

LOW (low speed)

HIGH (high speed)

Motor capacity (cc/rev)

52.7

33.2

Travel speed (km/h)

2.7

5.5

Maximum

Minimum

Travel motor swash plate angle

2. "Automatic"change of travel speed 1) Automatic selection corresponding to engine speed • If engine speed drops to 1,500 rpm or less when travel speed selector switch is in HIGH and travel speed is HIGH, travel speed changes to LOW automatically. • If engine speed becomes 1,700 rpm or less when travel speed selector switch is in HIGH and travel speed is LOW, travel speed changes to HIGH automatically. a If travel speed selector switch is in LOW, travel speed is not changed automatically. 2) Automatic selection corresponding to discharge pressure of pump • If travel pressure of 30.4MPa {310 kg/ cm2} or higher continues for 0.2 seconds or more when travel speed selector switch is in HIGH, travel speed changes to LOW automatically. • If travel pressure of 16.7MPa {170 kg/ cm2} or lower continues for 0.2 seconds or more when travel speed selector switch is in HIGH, travel speed changes to HIGH automatically. a If travel speed selector switch is in LOW, travel speed is not changed automatically.

10-142 (3)

PC130-7

STRUCTURE AND FUNCTION

ELECTRIC CONTROL SYSTEM

8. PPC LOCK FUNCTION

1. 2. 3. 4. 5. 6. 7. 8. 9.

Battery Battery relay Fusible link Starting switch Fuse box Controller Safety lock lever PPC lock switch PPC lock solenoid valve

10. 11. 12. 13. 14. 15. 16.

Left work equipment PPC valve Right work equipment PPC valve Traveling PPC valve Blade PPC valve (Blade specification) Engine Hydraulic pump Operation valve 16a. Self pressure reducing valve 16b. Man relief valve

Input/Output signals a. Power supply of controller b. Power supply of solenoids c. Solenoid valve driving signals

Function • PPC lock switch works with safety lock lever. Setting safety lock lever to "Lock", PPC lock switch turns to "OFF". • Turning PPC lock switch to "OFF" shuts off current to PPC lock solenoid valve, making operation lever on the work equipment disabled.

PC130-7

10-143

STRUCTURE AND FUNCTION

ELECTRIC CONTROL SYSTEM

SELF DIAGNOSIS FUNCTION 1. Error code display/Alarm functions • Controller always watches electronic devices which constitutes the system, including controller itself, each potentiometer which issues input signals, each solenoid valve which receives output signals, and EPC valves, to check for they normal operation. • If an abnormality occurred in any of these devices, the controller diagnoses it and display the results on display (1) of monitor panel as a "USER CODE" or "SERVICE CODE", sounding alarm buzzer at the same time to notify the abnormality to operator. a Refer to the "TROUBLESHOOTING" section as for the details of display and measures to be taken. 2. Error code memory function • Controller takes in memory the error code diagnosed about an abnormality which occurred in advanced system. a Refer to the "TESTING AND ADJUSTING" section as for the details of display and how to reset.

10-144

PC130-7

STRUCTURE AND FUNCTION

ELECTRIC CONTROL SYSTEM

SYSTEM COMPONENTS ENGINE SPEED SENSOR

FUNCTION • The engine speed sensor is installed on the ring gear of the engine flywheel. It electrically counts number of gear teeth that pass its front side and sends the counting to the controller.

1. 2. 3. 4. 5.

Magnet Terminal Case Boots Connector

Remarks : Number of ring gear teeth is 127. •

For the count, a magnet is used which generates current every time a gear tooth passes its front side.

PC130-7

10-145

STRUCTURE AND FUNCTION

ELECTRIC CONTROL SYSTEM

PPC HYDRAULIC SWITCH

SPECIFICATION Contact structre : Normally opened Operating (ON) pressure : 490 ± 98.1 kPa {5.0 ± 1.0 kg/cm2} Resetting (OFF) pressure : 294 ± 49.0 kPa {3.0 ± 0.5 kg/cm2}

1. Plug 2. Switch 3. Connector

FUNCTION • 8 switches installed to junction block sense operating condetion of each actuator, and send it to controller. • 1 switch installed to travel PPC valve sense travel operating condition, and send it to controller.

10-146

PC130-7

STRUCTURE AND FUNCTION

ELECTRIC CONTROL SYSTEM

CONTROLLER

PC130-7

10-147

STRUCTURE AND FUNCTION

ELECTRIC CONTROL SYSTEM

Input/output signals CN-1

CN-2

Pin No.

Signal name

Input/ output

Pin No.

CN-3 Signal name

Input/ output

Pin No.

Output

1

Control power supply

Input Input

Signal name

1

NC

Input

1

NC

2

NC

Input

2

Swing prolix switch

Input

2

Solenoid power supply

3

NC

Input

3

NC

Input

3

SOL_COM

Input/ output

—

4

Signal GND

—

4

232C_RxD

Input

4

Battery relay drive

Output

5

NC

Input

5

NC

Input

5

Motor drive a (+)

Output

6

NC

Input

6

Over load caution enable switch

Input

6

LS_EPC

Output

7

Overload pressure sensor

Input

7

NC

Output

8

Pump pressure sensor

Input

8

NC

Output

Input

9

NC

10

Signal GND

—

11

Knob switch

Input

12

NC

Input

13

Feed back signal

Input

14

NC

Input

15

NC

Input

16

SENS_PWR

17

Start switch (C)

Input

18

NC

Input

19

Fuel dial

Input

20

NC

Input

21

Analog GND

Output

Machine select 4

8

NC

Output

9

NC

Output

POT_PWR

23

Start switch (Acc)

Output Input

24

NC

Input

Input

10

NC

Input

11

NC

Output

12

CAN shield

13

Machine select 5

14

232C_TxD

15

NC

— Input Output Input

16

NC

Input

17

Machine select 3

Input

18

NC

Output

19

NC

Output

20

NC

Input

—

22

10-148

7

21

S_NET

22

CANO_L

23

CAN1_L

Input/ Output Input/ Output Input/ Output

9

Bucket curl switch

Input

10

Boom ralse switch

Input

11

Control power supply

Input

12

Solenoid power supply

Input

13

SOL_COM

—

14

Key signal

Input

15

Motor drive a (-)

Output

16

PC-EPC

Output

17

NC

Output

18

Heater relay solenoid

Output

19

Bucket dump switch

Input

20

Boom lower switch

Input

21

GND

22

Solenoid power supply

23

SOL_COM

24

Key signal

25

Motor drive b (+)

Output

— Input — Input

24

Flash memory write enable signal

Input

26

NC

Output

25

NC

Input

27

Travel speed solenoid

Output

26

NC

Input

28

2-stage rellef solenoid

Output

27

Machine select 2

Input

29

Swing switch

Input

28

NC

Input

30

Arm curl switch

Input

29

Puls GND

—

31

GND

—

30

NC

Input

32

GND

—

31

GND (S_NET GND)

—

33

GND

—

32

CAN0_H

34

NC

33

CAN1_H

Input/ Output Input/ Output

35

Motor drive b (-)

Output

36

NC

Output

37

Swing brake solenoid

Output

38

NC

Output

34

GND (232C GND)

—

35

Service switch

—

36

NC

Input

37

Machine select 1

Input

38

Swing lock switch

Input

39

Puls GND

40

Eng. speed

39

Travel switch

Input

40

Arm dump switch

Input

— Input

PC130-7

STRUCTURE AND FUNCTION

ELECTRIC CONTROL SYSTEM

PUMP PRESSURE SENSOR

1. Plug 2. Sensor 3. Connector

FUNCTION • Mounted on the inlet circuit of control valve, this sensor changes discharging pressure of pump into voltage, and send it to automatic travel speed change controller.

Monitor panel a Refer to the section describing the "Monitor System". PC valve LS valve PC-EPC valve a Refer to the section describing the "Hydraulic Pump (Piston pump)". LS-EPC valve a Refer to the section describing the "Hydraulic Pump (Piston pump)". PPC lock solenoid valve 2nd speed select solenoid valve Swing hold brake solenoid valve 2-stage relief solenoid valve a Refer to the section describing the "Solenoid Valve".

PC130-7

10-149

STRUCTURE AND FUNCTION

MONITOR SYSTEM

MONITOR SYSTEM

1. 2. 3. 4. 5.

Monitor panel Battery Controller Sensors and switches Wiper motor, window washer motor

Description • The monitor system monitors conditions of the machine with sensors mounted on its each section, processes promptly the information obtained, and displays it on panel to let operator know the conditions of the machine.

Input/Output signals a. Power supply b. Switch signal c. Caution signal d. Sensor/switch signal e. Sensor/switch signal f. Output for driving

10-150

PC130-7

STRUCTURE AND FUNCTION

MONITOR SYSTEM

MONITOR PANEL

OUTLINE • The monitor panel has the functions to display a monitor, gauge, service meter and electric system. It has also an alarm buzzer built in. • A CPU (Central Processing Unit) mounted inside processes, displays and outputs information.

Input/Output signals AMP070-12P [CN-P01] Pin No. 1 2 3 4 5 6 7 8 9 10 11 12

PC130-7

Signal name Starting switch (battery) Starting switch (battery) Window washer motor output Starting switch (C-terminal) Wiper W-contact GND GND VB + (24V) Wiper motor (+) Wiper motor (–) Alarm buzzer ON signal Wiper P-contact

•

•

The monitor's switch section consists of three flat type sheet switches. Pressing any of these switches changes the conditions of the machine, which are shown by LEDs located above the switches turned ON. The monitor does not give correct display if any of the monitor panel unit, controller, or the wiring between monitor-panel and controller is in abnormal condition.

AMP040-20P [CN-P02] I/O signal Input Input Output Input Input — — Input Output Output Input Input

Pin No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20

Signal name Engine coolant temperature Fuel level Radiator coolant level NC Air cleaner clogging NC Engine oil pressure Engine oil level S-NET signal S-NET signal Battery charge level Hydraulic oil level GND (analog signal) NC Pull-up window limit switch Alarm buzzer cancel Swing lock Preheating Lamp switch GND (S-NET)

I/O signal Input Input Input Input Input Input Input Input Input/Output Input/Output Input Input — — Input Input Input Input Input —

10-151

STRUCTURE AND FUNCTION

MONITOR SYSTEM

METER DISPLAY

No. 1

Display category

Display item

Service meter

[*1] 2 Display 3a Gauge 3b Caution

Coolant temperature

4a Gauge 4b Caution

5

Fuel level

Pilot

[*2] 7

8 9 10 Caution 11

12

Display method

Time counting while engine is in operation (alternator is generating) (Always lit even if starting switch is OFF) Count time during engine operates. Alphanumerics in 2 Displays 2 digit alphanumerics (user code or digits service code) if electric control system is in abnormal condition. See picture above All the segments of the corresponding level and lower are turned ON. Specified tempera- (Level 8 (102°C or higher):Monitor lamp blinks. ture (102°C) or Level 9: Monitor lamp blinks and alarm buzzer higher sounds.) See picture above All the segments of the corresponding level and lower are turned on. (Level 1 (42 l or less): Specified level Monitor lamp blinks.) (42 l) or lower

Display Remarks color

0 – 99999.9 h

Blue

LCD

Red

LED

Blue

LCD

Red

LED

Turned on for about 30 seconds after starting switch was turned to "HEAT". It blinks (for about 10 seconds) after preheating was over to notify it to operator, and then it is turned off. • Turned on when the swing lock function is acWhen swing-lock is tive. Swing lock in operation • Blinks when swing holding brake release Green switch was turn on. • Turned ON when specified oil maintenance periods (125h, 250, and 500h) elapsed. (Also, When specified oilOil elapsed time and telephone No. of your dealmaintenance perimaintenance er are shown on service meter.) ods elapsed • Not turned on if no oil maintenance period has been specified. Engine oil level Max. low level Charge in fault Battery charge (charge voltage < level battery voltage) Turned ON when starting switch was turned on; Air cleaner turned off after engine started running. At clogging clogging In normal condition : turned OFF Red In abnormal condition : turned ON Lower than the Engine oil (As for engine oil pressure, charge and over specified pressure pressure 49 kPa {0.5 kg/cm2} load alarm buzzer sounds if the pressure became abnormal when engine was running.) Min. specified presOver load sure 16.7 MPa {170 kg/cm2} Preheating

6

Display area

During preheating

Lamp

[*1] As for display and operation, refer to the "Self Diagnosis Function" section. [*2] As for display and operation, refer to the "Troubleshooting" chapter.

10-152

PC130-7

STRUCTURE AND FUNCTION

MONITOR SYSTEM

MONITOR SWITCH

No.

Name

Function

Operation

Used to select a travel speed from two of them. "Lo" is lit: Travel in low speed. 1 Travel speed selector switch "Hi" is lit: Travel in high speed. Lo Hi Activates the function to reduce fuel consumption. Turned ON: The function is active. ON OFF 2 Auto-deceleration switch Turned OFF: The function is not active. (Lit) Activates wiper of front glass. "ON" is lit: Wiper works continuously. OFF INT ON 3 Wiper switch "INT" is lit: Wiper works intermittently. (Not lit) (Intermittent) (Continuous) Not lit: Wiper is not working. [When wiper is not working] ON : Washer fluid is sprayed and wiper works continuously. OFF : Wiper works twice and stops after the switch was released. [When wiper is working intermit4 Windshield washer switch Sprays washer fluid onto front glass. tently] ON : Washer fluid is sprayed and wiper works continuously. OFF : Wiper works twice and returns to intermittent operation after the switch was released. Sets the movement and force of the working equipment. "A" is lit: A mode (for heavy duty work) * Operation mode selector A E L B 5 switch "E" is lit: E mode (for fuel economical operation) "L" is lit: L mode (for fine control work) "B" is lit: B mode (for breaker work)

*

You can change the default settings which become active when starting switch is turned on. Refer to the "TROUBLESHOOTING" chapter. a Signs written in bold fonts in the "Operation" column above represent the positions switches default to when starting switched is turned on.

PC130-7

10-153 (3)

STRUCTURE AND FUNCTION

MONITOR SYSTEM

SENSORS • • •

Signal from a sensor is directly entered to the panel. There are two types of sensors, contact type and resistance type. One end of a contact type sensor is connected to the ground on the machine body. Display class Caution Gauge

Sensor type Engine oil pressure Coolant temperature Fuel level Hydraulic oil temperature

Sensing approach Contact Resistance Resistance Resistance

When normal OFF (open) — — —

When failed ON (closed) — — —

ENGINE OIL PRESSURE SENSOR

1. Plug 2. Contact ring 3. Contact

4. Diaphragm 5. Spring 6. Terminal

COOLANT TEMPERATURE SENSOR HYDRAULIC OIL TEMPERATURE SENSOR

1. Connector 2. Plug 3. Thermistor

10-154

PC130-7

STRUCTURE AND FUNCTION

MONITOR SYSTEM

FUEL LEVEL SENSOR

1. 2. 3. 4.

Float Connector Cover Variable resisto

PC130-7

10-155

20 TESTING AND ADJUSTING STANDARD VALUE TABLE FOR ENGINE.......... 20- 2 STANDARD VALUE TABLE FOR CHASSIS........ 20- 3 TESTING AND ADJUSTING................................ 20-101 TROUBLESHOOTING ......................................... 20-201

Note the following when making judgements using the standard value tables for testing, adjusting, or troubleshooting. 1. The standard value for a new machine given in the table is the value used when shipping the machine from the factory and is given for reference. It is used as a guideline for judging the progress of wear after the machine has been operated, and as a reference value when carrying out repairs. 2. The service limit value given in the tables is the estimated value for the shipped machine based on the results of various tests. It is used for reference together with the state of repair and the history of operation to judge if there is a failure. 3. These standard values are not the standards used in dealing with claims. When carrying out testing, adjusting, or troubleshooting, park the machine on level ground, inset the safety pins, and use blocks to prevent the machine from moving. When carrying out work together with other workers, always use signals and do not let unauthorized people near the machine. When checking the water level, always wait for the water to cool down. If the radiator cap is removed when the water is still hot, the water will spurt out and cause burns. Be careful not to get caught in the fan, fan belt or other rotating parts.

PC130-7

20-1 (1)

TESTING AND ADJUSTING

STANDARD VALUE TABLE FOR ENGINE

STANDARD VALUE TABLE FOR ENGINE

Item

Model name

PC130-7

Engine

SAA4D95LE-3

Measurement condition

Unit

Standard value

Permissible value

2,350 ± 100

2,350 ± 100

1,100 ± 50

1,100 ± 50

2,200

—

Max. 4.5

Max. 6.5

Max. 1.0

Max. 2.0

0.35

—

0.50

—

MPa {kg/cm2} (rpm)

Min. 2.9 {Min. 30} (320 – 360)

2.0 {20} (320 – 360)

kPa {mmH2O}

Max. 0.49 {Max. 50}

0.98 {100}

0.34 – 0.59 {3.5 – 6.0}

0.25 {2.5}

0.29 – 0.54 {3.0 – 5.5}

0.21 {2.1}

Min. 0.1 {Min. 1.0} Min. 0.08 {Min. 0.8}

0.07 {0.7} 0.07 {0.7}

°C

90 – 110

120

°

6 ± 0.75

6 ± 0.75

High idling Engine speed

Low idling

rpm

Rated speed During sharp acceleration Exhaust gas color During high idling Valve clearance (Cooled) Compression pressure

Blow-by pressure

Bosch index

Intake valve mm Exhaust valve Oil temperature: 40 – 60 °C (Engine speed) Coolant temperature: Within operating range At rated output Coolant temperature: Within operating range At high idling (SAE30)

Oil pressure

At high idling (SAE10W)

MPa {kg/cm2}

At low idling (SAE30) At high idling (SAE10W) Oil temperature

Through speed range (In oil pan)

Fuel injection timing

Before top dead center (BTDC)

Fan belt tension

Deflection under finger pressure of 58.8 N {6 kg}

mm

6 – 10

6 – 10

Air conditioner compressor belt tension

Deflection under finger pressure of 58.8 N {6 kg}

mm

6 – 10

6 – 10

20-2 (1)

PC130-7

TESTING AND ADJUSTING

STANDARD VALUE TABLE FOR CHASSIS

STANDARD VALUE TABLE FOR CHASSIS Model name Category

Item

Unit

Standard value

Permissible value

rpm

2,120 ± 100

2,120 ± 100

rpm

2,180 ± 100

2,180 ± 100

rpm

1,400 ± 100

1,400 ± 100

8.0 ± 0.5

8.0 ± 0.5

9.5 ± 0.5

9.5 ± 0.5

8.0 ± 0.5

8.0 ± 0.5

Bucket control valve

8.0 ± 0.5

8.0 ± 0.5

Swing control valve

8.0 ± 0.5

8.0 ± 0.5

Travel control valve

8.0 ± 0.5

8.0 ± 0.5

85 ± 10

85 ± 10

85 ± 10

85 ± 10

85 ± 10

85 ± 10

Swing control lever

85 ± 10

85 ± 10

Travel control lever

112 ± 15

112 ± 15

Play of control lever

10 ± 15

10 ± 15

15.7 ± 3.9 {1.6 ± 0.4} 15.7 ± 3.9 {1.6 ± 0.4}

Max. 24.5 {Max. 2.5} Max. 24.5 {Max. 2.5}

12.7 ± 2.9 {1.3 ± 0.3}

Max. 21.6 {Max. 2.2}

12.7 ± 2.9 {1.3 ± 0.3}

Max. 21.6 {Max. 2.2}

Travel control lever

24.5 ± 5.9 {2.5 ± 0.6}

Max. 39.2 {Max. 4.0}

Travel control pedal

80.4 ± 20.1 {8.2 ± 2.0}

Max. 107.9 {Max. 11}

Engine speed

Pump relief

Pump relief + Onetouch power maximizing

During auto-deceleration

Control valve spool stroke

Boom control valve

Control lever stroke

Measurement condition • Engine coolant temperature: Within operating range • Hydraulic oil temperature: 45 – 55 °C • Engine speed: High idling • Working mode: A • Arm OUT relief • Engine coolant temperature: Within operating range • Hydraulic oil temperature: 45 – 55 °C • Engine speed: High idling • Arm OUT relief + One-touch power maximizing switch ON • Engine speed: High idling • Auto-decelerator switch: ON • All control levers in neutral • Engine: Stopped IN

Arm control valve OUT mm

Boom control lever

Operating effort of control lever

PC130-7

Arm control lever

• Engine: Stopped • Center of lever grip • Read max. value to stroke end (Exclude play in neutral position).

Bucket control lever mm

Boom control lever Arm control lever Bucket control lever Swing control lever

PC130-7

• Hydraulic oil temperature: Within operating range • Engine speed: High idling • Center of lever grip • Tip of pedal • Read max. value to stroke end

N {kg}

20-3 (1)

TESTING AND ADJUSTING

STANDARD VALUE TABLE FOR CHASSIS

Model name Category

Item

Unload pressure

Boom relief pressure

Oil pressure

Arm relief pressure

Bucket relief pressure

PC130-7

Measurement condition

Unit

Standard value

Permissible value

MPa {kg/cm2}

2.9 ± 0.5 {30 ± 5}

2.9 ± 0.5 {30 ± 5}

At normal relief

31.9 + 2.0 0 {325 + 20 0 }

33.3 – 36.8 {340 – 375}

At power max.

34.8 ± 1.0 {355 ± 10} 31.9 + 2.0 0 {325 + 20 0 } 34.8 ± 1.0 {355 ± 10} 31.9 + 2.0 0 {325 + 20 0 }

36.3 – 39.2 {370 – 400} 33.3 – 36.8 {340 – 375} 36.3 – 39.2 {370 – 400} 33.3 – 36.8 {340 – 375}

34.8 ± 1.0 {355 ± 10}

36.3 – 39.2 {370 – 400}

28.9 ± 1.5 {295 ± 15} 34.8 ± 1.0 {355 ± 10}

28.9 – 32.9 {295– 335} 36.3 – 39.2 {370 – 400}

3.23 ± 0.2 {33 ± 2}

2.84 – 3.43 {29 – 35}

2.7 +– 1.0 0.7 {28 +– 107 }

2.7 +– 1.0 0.7 {28 +– 107 }

2.2 ± 0.1 {22.5 ± 1}

2.2 ± 0.1 {22.5 ± 1}

• Hydraulic oil temperature: 45 – 55 °C • Engine speed: High idling • Working mode: A • Pump outlet pressure when all levers are in neutral • Hydraulic oil temperature: 45 – 55 °C • Engine speed: High idling • Working mode: A • Pump outlet pressure when measured circuit is relieved

At normal relief At power max. At normal relief

MPa {kg/cm2}

At power max.

Swing relief pressure Travel relief pressure

Control circuit basic pressure

LS differential pressure

20-4 (1)

• Hydraulic oil temperature: 45 – 55 °C • Engine speed: High idling MPa • Outlet pressure of self-reducing pres{kg/cm2} sure valve when all levers are in neutral • Hydraulic oil temperature: When all 45 – 55 °C levers are • Engine speed: High idling in neutral MPa • Working mode: A {kg/cm2} When • Pump pressure - LS prestravel syssure tem runs idle at Hi

PC130-7

TESTING AND ADJUSTING

STANDARD VALUE TABLE FOR CHASSIS

Model name Category

Item

Overrun of swing

PC130-7

Measurement condition

• Hydraulic oil temperature: 45 – 55 °C • Engine speed: High idling • Working mode: A • Quantity of overrun of swing circle when it stops after 1 turn • ( ): Qty of overrun of periphery of swing circle

Unit

Standard value

Permissible value

deg (mm)

75 ± 10 {730 ± 100}

Max. 90 (Max. 870)

2.9 ± 0.3

Max. 3.5

4.0 ± 0.4

Max. 8.5

sec

28.6 ± 4.8

28.6 ± 5.8

mm

0

0

90°

• Hydraulic oil temperature: 45 – 55 °C • Engine speed: High idling 180° • Working mode: A • Time taken to swing 90° and 180° after starting

sec

Swing

Time taken to start swinging

Time taken to swing • Hydraulic oil temperature: 45 – 55 °C • Engine speed: High idling • Working mode: A • Time taken to swing 5 turns after swinging 1 turn

Hydraulic drift of swing • Hydraulic oil temperature: 45 – 55 °C • Engine: Stopped • Set upper structure at 90° to machine body on slope of 15°. • Make match marks on inner race and outer race of swing circle. • Measure deviation of match marks in 15 minutes.

PC130-7

20-5 (1)

TESTING AND ADJUSTING

STANDARD VALUE TABLE FOR CHASSIS

Model name

Swing

Category

Item

Leakage from swing motor

PC130-7

Measurement condition

Unit

Standard value

Permissible value

l/min

Max. 3

Max. 6

46.1 ± 9.2

46.1 ± 9.2

Hi

21.9 ± 2.2

23.1 ± 3.0

Lo

27.6 ± 5.1

27.6 ± 7.1

Hi

13.2 ± 1.2

13.2 ± 1.7

Max. 200

Max. 220

• Hydraulic oil temperature: 45 – 55 °C • Engine speed: High idling • Swing lock switch: LOCK • Measure leakage for 1 minutes while swing circuit is relieved.

Lo

Travel speed (Idle run)

sec • Hydraulic oil temperature: 45 – 55 °C • Engine speed: High idling • Working mode: A • Measure time taken to rotate track shoe 5 turns after 1 turn.

Travel

Travel speed (Actual travel)

Travel deviation

20-6 (1)

• Hydraulic oil temperature: 45 – 55 °C • Engine speed: High idling • Working mode: A • Hard and level place • Measure time taken to travel 20 m after running up 10 m.

• Hydraulic oil temperature: 45 – 55 °C • Engine speed: High idling • Working mode: A • Travel speed: Lo • Hard and level place • Measure travel deviation in travel of 20 m after running up 10 m.

mm

PC130-7

TESTING AND ADJUSTING

STANDARD VALUE TABLE FOR CHASSIS

Model name Category

Item

PC130-7

Measurement condition

Unit

Standard value

Permissible value

mm

0

0

l/min

Max. 5

Max. 10

Whole work equipment (Hydraulic drift of tooth tip)

Max. 460

Max. 700

Boom cylinder (Retraction of cylinder)

Max. 10

Max. 12

Max. 80

Max. 90

Max. 22

Max. 40

3.7 ± 0.4

Max. 4.3

2.6 ± 0.5

Max. 3.2

Travel

Hydraulic drift of travel

Hydraulic drift of work equipment Work equipment speed

Work equipment

Leakage from travel motor

PC130-7

• Hydraulic oil temperature: 45 – 55 °C • Engine: Stopped • Stop machine on slope of 12 degrees with sprocket on upper side. • Measure hydraulic drift of travel in 5 minutes. • Hydraulic oil temperature: 45 – 55 °C • Engine speed: High idling • Lock sprocket. • Measure leakage for 1 minutes while travel circuit is relieved.

• Hydraulic oil temperature: 45 – 55 °C • Level and flat place • Bucket: Full of dirt and sand or filled Arm cylinder with rated load (1,080 kg) (Extension of cylinder) • Level boom top, retract arm cylinder fully, and extract bucket cylinder fully. • Engine: Stopped • Work equipment control lever: Neutral Bucket cylinder • Start measuring hydraulic drift just (Retraction of cylinder) after setting machine and measure every 5 minutes for 15 minutes.

mm

RAISE

Boom speed

• Hydraulic oil temperature: 45 – 55 °C • Engine speed: High idling • Working mode: A LOWER • Measure time taken to move bucket between RAISE stroke end and ground touch point of bucket.

sec

20-7 (1)

TESTING AND ADJUSTING

STANDARD VALUE TABLE FOR CHASSIS

Model name Category

Item

PC130-7

Measurement condition

Unit

CURL

Work equipment

Work equipment speed

Arm speed

(1)

• Hydraulic oil temperature: 45 – 55 °C • Engine speed: High idling • Working mode: A DUMP • Measure time taken to move bucket between DUMP stroke end and CURL stroke end

Boom time lag

Permissible value

3.2 ± 0.4

Max. 4.4

3.1 ± 0.3

Max. 3.7

2.9 ± 0.3

Max. 3.7

2.3 ± 0.2

Max. 2.9

Max. 3.0

Max. 4.0

sec

CURL

Bucket speed

Time lag

20-8

• Hydraulic oil temperature: 45 – 55 °C • Engine speed: High idling • Working mode: A DUMP • Measure time taken to move arm between OUT stroke end and IN stroke end (between starting points of cushion).

Standard value

sec

sec • Hydraulic oil temperature: 45 – 55 °C • Engine speed: Low idling • Working mode: A • Lower boom from RAISE stroke end and measure time taken to start raising front of machine after bucket touches ground.

PC130-7

TESTING AND ADJUSTING

STANDARD VALUE TABLE FOR CHASSIS

Model name Category

Item

Measurement condition

Unit

Standard value

Permissible value

sec

Max. 2.0

Max. 3.0

sec

Max. 2.0

Max. 3.0

Max. 3.5

Max. 15

Max. 10

Max. 50

Max. 500

Max. 500

• Hydraulic oil temperature: 45 – 55 °C • Engine speed: Low idling • Working mode: A • Move IN arm from OUT stroke end and measure time taken to start moving arm again after it is stopped. • For measuring posture, see WORK EQUIPMENT 6.

Time lag

Work equipment

Arm time lag

PC130-7

Bucket time lag

Compound operation performance

Oil leakage

• Hydraulic oil temperature: 45 – 55 °C • Engine speed: Low idling • Working mode: A • Curl bucket from DUMP stroke end and measure time taken to start moving bucket again after it is stopped. • For measuring posture, see WORK EQUIPMENT 7. • Hydraulic oil temperature: 45 – 55 °C • Engine speed: High idling • Relieve cylinder to be measured or Center swivel joint travel circuit and measure leakage in 1 minute. Cylinder

Travel deviation in compound operation of work equipment and travel

PC130-7

cc/min

• Hydraulic oil temperature: 45 – 55 °C • Engine speed: High idling • Working mode: A • Travel speed: Lo • Hard and level place • Measure travel deviation in travel of 20 m after running up 10 m. mm

20-9 (1)

TESTING AND ADJUSTING

STANDARD VALUE TABLE FOR CHASSIS

Model name Category

PC flow control characteristics

Measurement condition

• Hydraulic oil temperature: 45 – 55 °C • Engine: High idling • Working mode: A Time taken to swing • Bucket: Filled with rated load 90° in compound oper- • Hard and level place ation of raising boom • Set arm vertically and lower back of and starting swinging bucket to ground. • Raise boom and start swinging simultaneously from above posture and measure time taken to pass 90° point.

Pump performance

Item

Hydraulic pump capacity

20-10 (1)

• See graph.

PC130-7 Unit

Standard value

Permissible value

sec

4.0 (Reference value)

l/min

See graph.

PC130-7

TESTING AND ADJUSTING

STANDARD VALUE TABLE FOR CHASSIS

Model name Category

Item

PC130-7

Measurement condition

Unit

Standard value

Permissible value

Pump performance

Hydraulic pump performance

• PC-EPC current: 400 mA • Pump speed: 2,000 rpm Check point

Test pump discharge pressure (MPa{kg/cm2})

Standard discharge (l/min)

Lower limit of discharge (l/min)

Any point

P

Q (See graph)

Q (See graph)

a Avoid measuring near a broken point of the graph, since the error becomes large at that point. a When measuring without removing the pump from the machine, if the engine speed cannot be set to the specified speed with the fuel control dial, calculate the pump discharge pressure at the specified speed from the engine speed and pump discharge at the time of measurement.

PC130-7

20-11 (1)

TESTING AND ADJUSTING TOOLS FOR TESTING, ADJUSTING, AND TROUBLESHOOTING ......................................................... 20-102 TESTING AND ADJUSTING ENGINE SPEED .......................................................................................... 20-104 MEASURING EXHAUST GAS COLOR ..................................................................................................... 20-105 ADJUSTING VALVE CLEARANCE ........................................................................................................... 20-107 MEASURING COMPRESSION PRESSURE ............................................................................................. 20-109 MEASURING BLOW-BY PRESSURE ....................................................................................................... 20-110 MEASURING ENGINE OIL PRESSURE ................................................................................................... 20-111 TESTING AND ADJUSTING FOR FUEL INJECTION TIMING ................................................................ 20-112 ADJUSTING ENGINE SPEED SENSOR .................................................................................................. 20-116 TESTING AND ADJUSTING FAN BELT TENSION .................................................................................. 20-117 TESTING AND ADJUSTING AIR CONDITIONER COMPRESSOR BELT TENSION .............................. 20-118 MEASURING CLEARANCE OF SWING CIRCLE BEARING .................................................................... 20-119 TESTING AND ADJUSTING TRACK SHOE TENSION ............................................................................ 20-120 TESTING AND ADJUSTING OIL PRESSURE IN WORK EQUIPMENT, SWING, AND TRAVEL CIRCUITS....... 20-122 MEASURING CONTROL CIRCUIT BASIC PRESSURE ........................................................................... 20-125 TESTING AND ADJUSTING OIL PRESSURE IN PUMP PC CONTROL CIRCUIT .................................. 20-126 TESTING AND ADJUSTING OIL PRESSURE IN PUMP LS CONTROL CIRCUIT .................................. 20-129 MEASURING SOLENOID VALVE OUTPUT PRESSURE ......................................................................... 20-133 MEASURING PPC VALVE OUTPUT PRESSURE .................................................................................... 20-135 ADJUSTING PLAY OF WORK EQUIPMENT AND SWING PPC VALVES ............................................... 20-136 TESTING PARTS WHICH CAUSE HYDRAULIC DRIFT OF WORK EQUIPMENT .................................. 20-137 MEASURING OIL LEAKAGE ..................................................................................................................... 20-139 RELEASING RESIDUAL PRESSURE IN HYDRAULIC CIRCUIT ............................................................. 20-142 BLEEDING AIR FROM EACH PART ......................................................................................................... 20-143 TESTING PROCEDURE FOR DIODE ...................................................................................................... 20-146 SPECIAL FUNCTIONS OF MONITOR PANEL ......................................................................................... 20-147 PREPARATION WORK FOR TROUBLESHOOTING FOR ELECTRIC SYSTEM .................................... 20-166 PM-CLINIC SERVICE ................................................................................................................................. 20-167

PC130-7

20-101 (1)

TOOLS FOR TESTING, ADJUSTING, AND TROUBLESHOOTING

TESTING AND ADJUSTING

Testing and adjusting item

Measuring exhaust gas color

Part No.

Part name

Q'ty

Symbol

TOOLS FOR TESTING, ADJUSTING, AND TROUBLESHOOTING Remarks

1 799-203-9000

Handy smoke checker

1

Commercially 2 available

Smoke meter

1

Pollution level: 0 – 70% (With standard color) (Pollution level x 1/10 C Bosch index)

Commercially available

Feeler gauge

1

(Air intake side: 0.35 mm, Exhaust side: 0.50 mm)

795-502-1205

Compression gauge

1

0 – 6.9MPa {0 – 70kg/cm2}

795-502-1370

Adapter

1

6204-11-3880

Gasket

1

799-201-1504

Blow-by checker

1

799-101-5002

Hydraulic tester

1

Pressure gauge: 2.5,5.9,39.2,58.8MPa {25,60,400,600kg/cm2}

790-261-1203

Digital hydraulic tester

1

Pressure gauge: 58.8MPa {600kg/cm2}

E 2 799-401-2320

Hydraulic tester

1

Pressure gauge: 0.98MPa {10kg/cm2}

Adapter

1

Size: 06

799-101-5220

Nipple

1

07002-11023

O-ring

1

Spring pusher

1

A

B

Adjusting valve clearance

Measuring compression pressure

C

For 95E-3 engine

Measuring blow-by pressure

D

—

1

Measuring engine oil pressure

3 799-401-3500 4

Size: 10 x 1.25mm

1 795-102-2103 Measuring fuel injection timing

For delivery valve method

F

Measuring clearance of swing circle bearing

2 Commercially available

Dial gauge

1

Commercially available

Dial gauge

1

799-101-5002

Hydraulic tester

1

790-261-1203

Digital hydraulic tester

1

799-101-5220

Nipple

1

07002-11023

O-ring

1

799-101-5002

Hydraulic tester

1

790-261-1203

Digital hydraulic tester

1

799-101-5230

Nipple

1

07002-11423

O-ring

1

799-101-5002

Hydraulic tester

1

790-261-1203

Digital hydraulic tester

1

799-101-5230

Nipple

2

07002-11423

O-ring

2

G

Testing and adjusting oil pressure in work equipH ment, swing, and travel circuits

1

* Same as E1

2

* Same as E4

1 Measuring control circuit basic pressure

J

* Same as E1

2

Size: 14 x 1.5mm

1 Testing and adjusting oil pressure in pump PC control circuit

—

K

* Same as H (Only quantity is different)

2

20-102 (1)

PC130-7

Part name

Q'ty

Testing and adjusting item

TOOLS FOR TESTING, ADJUSTING, AND TROUBLESHOOTING

Symbol

TESTING AND ADJUSTING

799-101-5002

Hydraulic tester

1

790-261-1203

Digital hydraulic tester

1

799-101-5230

Nipple

2

07002-11423

O-ring

2

Differential pressure gauge

1

799-101-5002

Hydraulic tester

1

790-261-1203

Digital hydraulic tester

1

Adapter

1

799-101-5002

Hydraulic tester

1

790-261-1203

Digital hydraulic tester

1

Adapter

1

Part No.

1 Testing and adjusting oil pressure in pump LS control circuit

L

1 M

2 799-401-3100

Measuring PPC valve output pressure

* Same as H (Only quantity is different)

2

3 799-401-2701

Measuring solenoid valve output pressure

Remarks

1 N

2 799-401-3100

—

* Same as E1

Size: 03

* Same as E1

* Same as M2

Measuring oil leakage

P

Commercially available

Measuring cylinder

1

Measuring water temperature and oil temperature

—

799-101-1502

Digital thermometer

1

-99.9 – 1,299°C

Measuring operating effort and pressing force

79A-264-0021 Push-pull scale

1

0 – 294N {0 – 30kg}

— 79A-264-0091 Push-pull scale

1

0 – 490N {0 – 50kg}

Measuring stroke and hydraulic drift

—

Commercially available

Scale

1

—

Measuring work equipment speed

—

Commercially available

Stopwatch

1

—

Measuring voltage and resistance

—

Commercially available

Circuit tester

1

—

a For the model names and part Nos. of the T-adapters and boxes used for troubleshooting for the monitor panel, controllers, sensors, actuators, and wiring harnesses, see TROUBLESHOOTING, Layout of connectors and electric circuit diagram of each system.

PC130-7

20-103 (1)

TESTING AND ADJUSTING

TESTING AND ADJUSTING ENGINE SPEED MEASURING 1. Preparation work 1) Turn the starting switch ON and set the monitor panel in the "Monitoring function [02]" to prepare for measurement of the engine speed. a For the operating method, see "Special functions of monitor panel". • Monitoring code: 010 (Engine speed) a The engine speed is displayed in rpm. 2) Warm up the engine to the following operating condition. • Engine coolant temperature: Within operating range • Hydraulic oil temperature: 45 – 55°C a Measure the engine speed with the working mode switch in the A-mode position.

TESTING AND ADJUSTING ENGINE SPEED

4. Measuring pump relief and one-touch power maximizing speed 1) Set the fuel control dial in the high idling (MAX) position. 2) Relieve the arm circuit by moving the arm IN, keeping pressing the one-touch power maximizing switch, and measure the engine speed. a The one-touch power maximizing function is reset automatically in about 8.5 seconds even if the switch is kept held. Accordingly, measure the engine speed in that period. 5. Measuring auto-deceleration speed 1) Start the engine and set the fuel control dial in the high idling position (MAX). 2) Set the work equipment control, swing control, and travel levers in neutral and measure the engine speed. a The engine speed lowers to a certain level about 5 seconds after all the levers are set in neutral. This level is the autodeceleration speed. ADJUSTING Adjusting governor spring a If the high idling speed is out of the standard range or the engine speed is unstable (the engine hunts), adjust the governor spring with "Governor adjustment function [03]" of the monitor panel. a For the adjustment procedure, see SPECIAL FUNCTIONS OF MONITOR PANEL.

1. Measuring low idling speed 1) Set the fuel control dial in the low idling (MIN) position. 2) Set the work equipment control, swing control, and travel levers in neutral and measure the engine speed. 2. Measuring high idling speed 1) Turn the auto-decelerator switch OFF. 2) Set the fuel control dial in the high idling (MAX) position. 3) Set the work equipment control, swing control, and travel levers in neutral and measure the engine speed. 3. Measuring pump relief speed 1) Set the fuel control dial in the high idling (MAX) position. 2) Relieve the arm circuit by moving the arm IN and measure the engine speed.

20-104 (1)

PC130-7

TESTING AND ADJUSTING

MEASURING EXHAUST GAS COLOR

MEASURING EXHAUST GAS COLOR a Measuring instruments for exhaust gas color Symbol A

Part No.

2. Measuring with smoke meter A2 1) Insert probe [1] of smoke meter A2 in the outlet of exhaust pipe (1) and fix it to the exhaust pipe with a clip.

Part name

1

799-201-9000

Handy Smoke Checker

2

Commercially available

Smoke Meter

k When installing and removing the measuring instruments, take care not to touch a hot part. a If an air source and an electric power source are not available in the field, use handy smoke checker A1. When recording official data, use smoke meter A2. 1. Measuring with handy smoke checker A1 1) Stick a sheet of filter paper to smoke checker A1. 2) Insert the exhaust gas intake pipe in exhaust pipe (1). 3) Run the engine. 4) Accelerate the engine suddenly or run it at high idling and operate the handle of smoke checker A1 so that the filter paper will absorb the exhaust gas.

2) Connect the probe hose, receptacle of the accelerator switch, and air hose to smoke meter A2. a Limit the supplied air pressure to 1.5 MPa {15 kg/cm2}. 3) Connect the power cable to a receptacle of AC 100 V. a Before connecting the cable, check that the power switch of the smoke meter is turned OFF. 4) Loosen the cap nut of the suction pump and fit the filter paper. a Fit the filter paper securely so that the exhaust gas will not leak. 5) Turn on the power switch of smoke meter A2.

5) Remove the filter paper and compare it with the attached scale. 6) After finishing measurement, remove the measuring instrument and return the removed parts. 6) Start the engine and heighten the engine coolant temperature to the operating range.

PC130-7

20-105 (1)

TESTING AND ADJUSTING

MEASURING EXHAUST GAS COLOR

7) Accelerate the engine suddenly or run it at high idling and press the accelerator pedal of smoke meter A2 and collect the exhaust gas into the filter paper. 8) Place the contaminated filter paper on the clean filter paper (at least 10 sheets) in the filter paper holder and read the indicated value. 9) After finishing measurement, remove the measuring instrument and return the removed parts.

20-106 (1)

PC130-7

TESTING AND ADJUSTING

ADJUSTING VALVE CLEARANCE

ADJUSTING VALVE CLEARANCE a Adjusting instrument for valve clearance Symbol

Part No.

B

Commercially available

4. While the No. 1 cylinder is at the compression top dead center, adjust the valve clearances marked with q in the valve arrangement drawing according to the following procedure.

Part name Feeler gauger

1. Open the engine hood and remove all cylinder head covers (1).

2. Remove the engine undercover (on the radiator side). 3. Rotate the crankshaft forward to bring the stamped "1.4TOP" line (a) of the crank pulley to pointer (2) and set the No. 1 cylinder to the compression top dead center. a Crank the crankshaft with the crank pulley mounting bolt. a There are 2 stamped "1.4TOP" lines on the crank pulley. Use the one at the diagonal position of "2.3TOP". a When the No. 1 cylinder is at the compression top dead center, the rocker arm of the No. 1 cylinder can be moved by the valve clearance with the hand. If the rocker arm cannot be moved, the No. 1 cylinder is not at the compression top dead center. In this case, rotate the crankshaft one more turn.

1) Insert feeler gauge B in clearance (b) between rocker arm (3) and valve stem (4) and adjust the clearance with adjustment screw (5). a With the feeler gauge inserted, turn the adjustment screw to a degree that you can move the filler gauge lightly. 2) Secure adjustment screw (5) and tighten locknut (6). 3 Locknut: 39.2 – 49 Nm {4 – 5 kgm} a After tightening the locknut, check the valve clearance again. a After adjusting all of the valves marked with q, go to the next procedure.

5. Rotate the crankshaft forward to bring the stamped "1.4TOP" line (a) of the crank pulley to pointer (2) and set the No. 4 cylinder to the compression top dead center.

PC130-7

20-107 (1)

TESTING AND ADJUSTING

ADJUSTING VALVE CLEARANCE

6. While the No. 4 cylinder is at the compression top dead center, adjust the valve clearances marked with Q in the valve arrangement drawing. a Adjust the valve clearance according to step 4 above. 7. After finishing adjustment, return the removed parts.

3 Cylinder head cover mounting bolt: 7.84 – 9.8 Nm {0.8 – 1.0 kgm}

20-108 (1)

PC130-7

TESTING AND ADJUSTING

MEASURING COMPRESSION PRESSURE

MEASURING COMPRESSION PRESSURE a Measuring instruments for compression pressure Symbol C

Part No.

Part name

795-502-1205

Compression gauge

795-502-1370

Adapter

6204-11-3880

Gasket

a When measuring the compression pressure, take care not to burn yourself on the exhaust manifold, muffler, etc. or get caught in a rotating part. 6. Remove governor spring (2). 1. Adjust the valve clearance. a See Adjusting valve clearance.

7. Put governor lever (3) of the fuel injection pump to the STOP side stopper and fix it.

2. Warm up the engine until the engine oil temperature is 40 – 60°C. 3. Prepare for measuring the engine speed. a See Testing and adjusting engine speed. 4. Open the engine hood and remove nozzle holder (1) of the cylinder to measure the compression pressure.

8. Crank the engine with the starting motor and measure the compression pressure. a Read the compression gauge when its pointer is stabilized. a When measuring the compression pressure, measure the engine speed, too, and check that it is in the measurement condition range.

5. Install adapter [1] of compression gauge C to the mounting part of the nozzle holder and connect gauge [2]. a Install the gasket to the end of the adapter. a Secure the adapter with the clamping holder and mounting bolt for the nozzle holder. 3 Mounting bolt: 39.2 – 49 Nm {4 – 5 kgm}

PC130-7

9. After finishing measurement, remove the measuring instruments and return the removed parts. a Check that the fulcrum of the clamping holder for the nozzle holder is seated on the cylinder head, and then tighten the mounting bolt. 3 Mounting bolt: 39.2 – 49 Nm {4 – 5 kgm}

20-109 (1)

MEASURING BLOW-BY PRESSURE

TESTING AND ADJUSTING

MEASURING BLOW-BY PRESSURE a Measuring instruments for blow-by pressure Symbol

Part No.

D

799-201-1504

5. Run the engine at high idling and measure the blow-by pressure. • Working mode: A • Work equipment, swing, and travel circuit: Relieve the travel circuit.

Part name Blow-by checker

1. Remove the engine undercover (on the flywheel side). 2. Install nozzle [1] of blow-by checker C to the end of blow-by hose (1) and connect it to gauge [2].

6. After finishing measurement, remove the measuring instruments and return the removed parts.

3. Start the engine and lock the travel mechanism.

k Put pin [3] between the sprocket and track frame to lock the travel mechanism securely.

4. Start the engine and warm it up to the operating range. • Engine coolant temperature: Within operating range • Hydraulic oil temperature: 45 – 55°C

20-110 (1)

PC130-7

TESTING AND ADJUSTING

MEASURING ENGINE OIL PRESSURE

MEASURING ENGINE OIL PRESSURE

5. Measure the oil pressure during low idling and high idling.

a Measuring instruments for engine oil pressure Symbol 1 E

2 3 4

Part No.

Part name

799-101-5002

Hydraulic tester

790-261-1203

Digital hydraulic tester

799-401-2320

Hydraulic tester

799-401-3500

Adapter (Size: 06)

799-101-5220

Nipple (10 x 1.25 mm)

07002-11023

O-ring

1. Open the pump room cover and disconnect outlet hose (1) of the engine oil filter.

6. After finishing measurement, remove the measuring instruments and return the removed parts.

2. Install adapter E3 and connect the disconnected hose again. 3. Install nipple E4 and connect it to hydraulic tester E2.

4. Start the engine and heighten the engine coolant temperature to the operating range.

PC130-7

20-111 (1)

TESTING AND ADJUSTING FOR FUEL INJECTION TIMING

TESTING AND ADJUSTING

TESTING AND ADJUSTING FOR FUEL INJECTION TIMING a Testing and adjusting instruments for fuel injection timing (for delivery valve method) Symbol F

Part No.

Part name

1

795-102-2103

Spring pusher

2

Commercially available

Dial gauge

TESTING AND ADJUSTING BY MATCH MARK METHOD a After removing and installing the fuel injection pump without repairing it or when only checking the injection timing, test and adjust the injection timing according to the following procedure. TESTING 1. Open the engine hood and remove all cylinder head covers (1).

4. Remove cover (3) of the fuel injection pump drive shaft. 5. Insert pin [1] in the mounting bolt hole of the front cover (on the outside of the engine) to check the fuel injection timing. a Use a pin 4.0 – 4.5 mm in diameter and about 80 mm in length. a If the pin enters smoothly to inside of the drive gear of the fuel injection pump, the fuel injection timing is normal. In this case, return the removed parts. a If the pin touches the drive gear of the fuel pump, the fuel injection timing is abnormal. In this case, adjust the fuel injection timing.

2. Remove the engine undercover (on the radiator side). 3. Rotate the crankshaft forward to bring the stamped "1.4TOP" line (a) of the crank pulley to pointer (2) and set the No. 1 cylinder to the compression top dead center. a Crank the crankshaft with the crank pulley mounting bolt. a There are 2 stamped "1.4TOP" lines on the crank pulley. Use the one at the diagonal position of "2.3TOP". a When the No. 1 cylinder is at the compression top dead center, the rocker arm of the No. 1 cylinder can be moved by the valve clearance with the hand. If the rocker arm cannot be moved, the No. 1 cylinder is not at the compression top dead center. In this case, rotate the crankshaft one more turn.

20-112 (1)

ADJUSTING a If the fuel injection timing is abnormal, adjust it according to the following procedure. 1. Remove the fuel pump, holder, and drive gear together. a See DISASSEMBLY AND ASSEMBLY, Removal, installation of fuel pump assembly.

PC130-7

TESTING AND ADJUSTING

TESTING AND ADJUSTING FOR FUEL INJECTION TIMING

2. Remove bolt (3) and fix drive gear (4) to holder (5) with fixing bolt [2]. a As fixing bolt [2], use a bolt 6 mm in thread diameter and 35 mm in length. a Pass the fixing bolt through the screw hole of bolt (3) and tighten it into the screw hole of the drive gear, and the fuel injection pump is fixed in the fuel injection timing.

ADJUSTING BY DELIVERY VALVE METHOD a After repairing or replacing the fuel injection pump or timing gear, adjust the injection timing according to the following procedure. ADJUSTING a Apply the delivery valve method to only adjustment of the injection timing. 1. Open the engine hood and remove all cylinder head covers (1).

3. Install the fuel injection pump, holder, and drive gear together. a See DISASSEMBLY AND ASSEMBLY, Removal, installation of fuel pump assembly. a After installing the fuel injection pump temporarily, check the fuel injection timing according to the above described procedure. 4. After finishing adjustment, remove the measuring tools and return the removed parts. k Be sure to remove pin [1] and fixing bolt [2]. 3 Cylinder head cover mounting bolt: 7.84 – 9.8 Nm {0.8 – 1.0 kgm}

PC130-7

2. Remove the engine undercover (on the radiator side). 3. Rotate the crankshaft forward to bring the stamped "1.4TOP" line (a) of the crank pulley to pointer (2) and set the No. 1 cylinder to the compression top dead center. a Crank the crankshaft with the crank pulley mounting bolt. a There are 2 stamped "1.4TOP" lines on the crank pulley. Use the one at the diagonal position of "2.3TOP". a When the No. 1 cylinder is at the compression top dead center, the rocker arm of the No. 1 cylinder can be moved by the valve clearance with the hand. If the rocker arm cannot be moved, the No. 1 cylinder is not at the compression top dead center. In this case, rotate the crankshaft one more turn.

20-113 (1)

TESTING AND ADJUSTING

TESTING AND ADJUSTING FOR FUEL INJECTION TIMING

4. Remove snap ring (6) of the rocker arm shaft on the No. 1 cylinder side, and then remove rocker arm (7) of the No. 1 air intake valve. a Remove the valve stem cap, too.

8. Install dial gauge F2 on the valve stem of No. 1 air intake valve (11) and set it to the 0 point. a Since the No. 1 cylinder is at the compression top dead center, set this point as the 0 point. 9. Rotate the crankshaft about 45° in reverse.

5. Using spring pusher F1, remove valve cotter (8) of the No. 1 air intake valve. 6. Loosen spring pusher F1 and remove seat (9) and spring (10).

7. While No. 1 air intake valve (11) is in contact with the top of piston (12), turn the valve stem with the hand to press No. 1 air intake valve (11) against the piston. a Since the piston stroke will be measured at the valve stem top, check that the valve bottom is in contact with the piston top securely.

20-114 (1)

10. Rotate the crankshaft forward slowly so that dial gauge F2 will indicate fuel injection timing dimension (a). a When adjusting the crankshaft to fuel injection timing dimension (a), be sure to rotate it forward so that the adjustment will not be affected by the backlash of the drive gear. (If the crankshaft passes the adjustment dimension, return it sufficiently, and then adjust it again forward.) a Fuel injection timing dimension (a) and fuel injection timing Fuel injection timing dimension (a) Fuel injection timing (Reference)

mm °

0.42 ± 0.08 6 ± 0.75

11. Disconnect all of connected fuel injection tubes (12), if there are any.

PC130-7

TESTING AND ADJUSTING

TESTING AND ADJUSTING FOR FUEL INJECTION TIMING

12. Remove delivery valve holder (14) for the No. 1 cylinder of fuel pump (13), delivery valve (15), and spring (16), and then install delivery valve holder (14) again.

13. Remove governor spring (17), and then put the governor lever (18) of the fuel injection pump to the stopper on the FULL side and fix it.

16. Tighten 4 mounting nuts (19) of fuel injection pump (13) securely and alternately.

17. After finishing adjustment, remove the adjusting tools and return the removed parts. a Replace the O-ring and copper gasket of the delivery valve with new ones. k Tighten the delivery valve securely in 3 times. (If it is not tightened sufficiently, the gasket may be broken.) 3 Delivery valve holder: 39.2 – 44.1 Nm {4 – 4.5 kgm} 3 Fuel injection tube sleeve nut: 19.6 – 24.5 Nm {2 – 2.5 kgm}

14. Remove the fixing bracket and lubrication tube of fuel injection pump (13), loosen 4 mounting nuts (19), and lean the fuel injection pump outward fully. a Loosen the mounting nuts to a degree that the fuel injection pump can be moved in and out within the range of the oblong hole (Do not loosen them so much that the fuel injection pump will have play).

3 Cylinder head cover mounting bolt: 7.84 – 9.8 Nm {0.8 – 1.0 kgm} a After finishing adjustment, if the stamped lines of the fuel injection pump and holder are not at the same position or there is not a stamped line on the fuel injection pump, stamp a new line to show that the fuel injection timing has been adjusted.

15. Operating priming pump (20) of fuel injection pump 13, move the injection pump gradually toward the cylinder block and stop when the fuel stops flowing out of No. 1 delivery valve holder (14), and then tighten the mounting nuts temporarily. a The position where fuel stops flowing out of the No. 1 delivery valve holder is the position to start fuel injection in the No. 1 cylinder (fuel injection timing).

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20-115 (1)

TESTING AND ADJUSTING

ADJUSTING ENGINE SPEED SENSOR a If the engine speed sensor has been removed and installed or its signal contains an error, adjust it according to the following procedure. a Remove engine speed sensor (1) before adjusting it and check that its tip is free from steel chips (The engine speed sensor is installed to the right side of the flywheel housing).

ADJUSTING ENGINE SPEED SENSOR

4. After finishing adjustment, check that the monitor panel displays the engine speed normally in the "Monitoring mode". a For the operating method, see "Special functions of monitor panel". • Monitoring code: 010 (Engine speed)

1. Screw in sensor (1) until its tip touches the tooth tip of flywheel ring gear (2). 2 Threads: Gasket sealant (LG-6)

2. Return sensor (1) by the specified angle. a Returning angle of sensor: 1 ± 1/6 turn a After this adjustment, clearance (a) between the sensor tip and gear tooth tip is 1.25 – 1.75 mm. 2 Nut: 49 – 68.6 Nm {5 – 7 kgm}

3. Fixing sensor (1), tighten nut (3).

20-116 (1)

PC130-7

TESTING AND ADJUSTING

TESTING AND ADJUSTING FAN BELT TENSION

TESTING AND ADJUSTING FAN BELT TENSION

ADJUSTING a If the deflection of the belt is abnormal, adjust it according to the following procedure.

TESTING 1. Open the engine hood and remove the belt cover from above the alternator.

1. Loosen alternator mounting bolts (1) and (2).

2. Press the intermediate point of the belt between the fan pulley and alternator pulley with a finger and measure deflection (a) of the belt. • Force to press belt: Approx. 58.8 N {6 kg} • Deflection (a): 6 – 10 mm

2. Adjust the belt tension by moving alternator (5) with adjustment bolt (4). a Turn the adjusting belt to left, the belt tension tight. 3. Tighten locknut (3) and mounting bolts (2) and (1). a Check breakage of the pulleys, wear of the V-grooves, and contact of the belts and Vgrooves. a If a belt is lengthened to the adjustment limit, cut, or cracked, replace it with new one.

4. After finishing adjustment, return the covers. a If a V-belt is replaced, adjust its tension again after 1 operating hour.

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20-117 (1)

TESTING AND ADJUSTING

TESTING AND ADJUSTING AIR CONDITIONER COMPRESSOR BELT TENSION TESTING 1. Open the engine hood and remove the belt cover from above the air conditioner compressor. 2. Press the intermediate point of the belt between the fan pulley and alternator pulley with a finger and measure deflection "a" of the belt. • Force to press belt: Approx. 58.8 N {6 kg} • Deflection (a): 6 – 10 mm

TESTING AND ADJUSTING AIR CONDITIONER COMPRESSOR BELT TENSION

ADJUSTING a If the deflection of the belt is abnormal, adjust it according to the following procedure. 1. Loosen compressor bracket mounting bolts (1) and (2). 2. Adjust the belt tension by moving compressor (3) and bracket (4) together. a Use a bar, etc. to move the bracket (Do not push the compressor directly with a bar, etc.) 3. Tighten mounting bolts (2) and (1). a Check breakage of the pulleys, wear of the V-grooves, and contact of the belts and Vgrooves. a If a belt is lengthened to the adjustment limit, cut, or cracked, replace it with new one.

4. After finishing adjustment, return the covers. a If a V-belt is replaced, adjust its tension again after 1 operating hour.

20-118 (1)

PC130-7

TESTING AND ADJUSTING

MEASURING CLEARANCE OF SWING CIRCLE BEARING

MEASURING CLEARANCE OF SWING CIRCLE BEARING a Measuring instrument for clearance of swing circle bearing Symbol

Part No.

G

Commercially available

Part name Dial gauge

a When measuring the clearance of the swing circle bearing on the actual machine, observe the following procedure. k While measuring, do not put your hands or foot under the undercarriage. 1. Fix dial gauge G to outer race (1) or inner race (2) of the swing circle and apply the probe to the end face of inner race (2) or outer race (1) on the opposite side. a Set dial gauge G on the front or at rear side of the machine

4. Set the arm at almost a right angle to the ground and lower the boom until the track shoe at the front side of the machine is floated. a At this time, the front end of the upper structure rises and the rear end lowers. 5. Under this condition, read dial gauge G. a Dial gauge G indicates the clearance of the bearing.

2. Set the work equipment in the maximum reach posture and set the bucket tip to the height of the revolving frame bottom. a At this time, the front end of the upper structure lowers and the rear end rises.

6. Return the machine to the posture of step 2 and check that dial gauge G indicates 0 again. a If dial gauge G does not indicate 0, repeat steps 3 – 5.

3. Set the dial gauge G to the 0 point.

7. After finishing measurement, remove the measuring instruments and return the removed parts.

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20-119 (1)

TESTING AND ADJUSTING

TESTING AND ADJUSTING TRACK SHOE TENSION TESTING 1. Running the engine at low idling, move the machine forward by the length of track on ground and stop slowly. 2. Place straight bar [1] on the track shoe between the idler and the 1st carrier roller. a As straight bar [1], use an L-shape steel, etc. which will be deflected less. 3. Measure maximum clearance (a) between straight bar [1] and track shoe. • Standard maximum clearance (a): 10 – 30 mm

TESTING AND ADJUSTING TRACK SHOE TENSION

ADJUSTING a If the track shoe tension is out of the standard range, adjust it according to the following procedure. 1. When tension is too high 1) Loosen valve (1) gradually to discharge the grease.

k Since the valve may jump out because of the high-pressure grease in it, do not loosen it more than 1 turn. a If the grease is not discharged well, drive the machine forward and in reverse slowly. 2) Tighten valve (1). 3 Valve: 58.8 – 88.2 Nm {6 – 9 kgm} 3) After finishing adjustment, check again that the track shoe tension is normal according to the above described procedure.

2. When tension is low 1) Add grease through valve (2). a If the track shoe is not tensed well, drive the machine forward and in reverse slowly. 2) After finishing adjustment, check again that the track shoe tension is normal according to the above described procedure.

20-120 (1)

PC130-7

TESTING AND ADJUSTING

TESTING AND ADJUSTING TRACK SHOE TENSION

a You may supply grease until distance (b) between the idler guide and track frame end is 0 mm. If the tension is still low, the pin and bushing are worn excessively. In this case, turn over or replace the pin and bushing.

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20-121 (1)

TESTING AND ADJUSTING

TESTING AND ADJUSTING OIL PRESSURE IN WORK EQUIPMENT, SWING, AND TRAVEL CIRCUITS

TESTING AND ADJUSTING OIL PRESSURE IN WORK EQUIPMENT, SWING, AND TRAVEL CIRCUITS a Testing and adjusting instruments for oil pressure in work equipment, swing, and travel circuits Symbol 1 H 2

Part No.

Part name

799-101-5002

Hydraulic tester

790-261-1203

Digital hydraulic tester

799-101-5220

Nipple (10 x 1.25 mm)

07002-11023

O-ring

a The oil pressure in work equipment, swing, and travel circuits (pump discharge pressure) can be checked with monitoring function [02] of the monitor panel. • Monitoring code: 011, 012 (Pump discharge pressure) a The pump discharge pressure is displayed in 1 kg/cm2.

2) Install nipple H2 and connect it to oil pressure gauge [1] of hydraulic tester H1. a Use the oil pressure gauges of 58.8 MPa {600 kg/cm2}.

3) Run the engine and heighten the hydraulic oil temperature to 45 – 55°C.

MEASURING 1. Preparation work

k Lower the work equipment to the ground and stop the engine. Operate the control levers several times to release the residual pressure in the piping, and then loosen the oil filler cap of the hydraulic tank slowly to release the internal pressure of the hydraulic tank. 1) Remove the top cover of the control valve, and then remove pump pressure pickup plug (1) from the top of the control valve.

20-122 (1)

2. Measuring unload pressure 1) Start the engine. 2) Run the engine at high idling and set all the control levers in neutral and measure the oil pressure. a The pressure measured when the unload valve is unloaded is indicated.

PC130-7

TESTING AND ADJUSTING

TESTING AND ADJUSTING OIL PRESSURE IN WORK EQUIPMENT, SWING, AND TRAVEL CIRCUITS

3. Measuring work equipment circuit relief pressure 1) Start the engine and move the cylinder to be measured to the stroke end. 2) Run the engine at high idling and relieve the cylinder and measure the oil pressure. a The pressure measured when the main relief valve is relieved is indicated. a If the one-touch power maximizing switch is released, the main relief valve is relieved at low pressure. If the former is pressed, the latter is relieved at high pressure. a If the swing lock switch is set in the LOCK position, the 2-stage relief solenoid valve is turned ON and the main relief valve is relieved at high pressure. Accordingly, keep the swing lock switch turned OFF.

ADJUSTING a The unload valve cannot be adjusted. 1. Adjusting main relief pressure (High pressure setting side) a If the high relief pressure of the work equipment circuit and travel circuit is abnormal, adjust the high pressure setting side of main relief valve (2) according to the following procedure. a The high relief pressure is the pressure applied when the 2-stage relief solenoid valve is turned ON and the pilot pressure is applied to the selector port.

4. Measuring swing circuit relief pressure 1) Start the engine and set the swing lock switch in the LOCK position. 2) Run the engine at high idling and relieve the swing circuit and measure the oil pressure. a The pressure measured when the swing motor safety valve is relieved is indicated. a The swing motor relief pressure is lower than the main relief pressure. 5. Measuring travel circuit relief pressure 1) Start the engine and lock the travel mechanism. k Set pin [2] between the sprocket and track frame to lock the travel mechanism securely.

1) Disconnect pilot hose (3). 2) Fixing holder (4), loosen locknut (5). 3) Turn holder (4) to adjust the pressure. a If the holder is • turned to the right, the pressure rises. • turned to the left, the pressure lowers. a Quantity of adjustment per turn of holder: Approx. 12.6 MPa {Approx. 128 kg/cm2} 4) Fixing holder (4), tighten locknut (5). 3 Locknut: 39.2 – 49 Nm {4 – 5 kgm}

2) Run the engine at high idling and relieve the travel circuit and measure the oil pressure. a The pressure measured when the main relief valve is relieved is indicated. The travel circuit is always relieved at high pressure. 5) Connect pilot hose (3).

PC130-7

20-123 (1)

TESTING AND ADJUSTING

TESTING AND ADJUSTING OIL PRESSURE IN WORK EQUIPMENT, SWING, AND TRAVEL CIRCUITS

6) After finishing adjustment, check again that the pressure is normal according to the above described measurement procedure. a If the high pressure setting side is adjusted, the low pressure setting side changes. Accordingly, adjust the low pressure setting side, too. 2. Adjusting main relief pressure (Low pressure setting side) a If the low relief pressure of the work equipment circuit is abnormal or the high pressure setting was adjusted, adjust the low pressure setting side of main relief valve (2) according to the following procedure. a The low relief pressure is the pressure applied when the 2-stage relief solenoid valve is turned OFF and the pilot pressure is not applied to the selector port. 1) Disconnect pilot hose (3). 2) Fixing holder (6), loosen locknut (7). 3) Turn holder (6) to adjust the pressure. a If the holder is • turned to the right, the pressure rises. • turned to the left, the pressure lowers. a Quantity of adjustment per turn of holder: Approx. 12.6 MPa {Approx. 128 kg/cm2} 4) Fixing holder (6), tighten locknut (7). 3 Locknut: 53.9 – 63.7 Nm {5.5 – 6.5 kgm}

5) Connect pilot hose (3). 6) After finishing adjustment, check again that the pressure is normal according to the above described measurement procedure.

20-124 (1)

3. Adjusting swing relief pressure a If the relief pressure of the swing circuit is abnormal, adjust swing motor safety valve (8) according to the following procedure.

1) Fixing adjustment screw (9), loosen locknut (10). 2) Turn adjustment screw (9) to adjust the pressure. a If the adjustment screw is • turned to the right, the pressure rises. • turned to the left, the pressure lowers. a Quantity of adjustment per turn of adjustment screw: Approx. 14 MPa {Approx. 143 kg/cm2} 3) Fixing adjustment screw (9), tighten locknut (10). 3 Locknut: 53.9 – 73.5 Nm {5.5 – 7.5 kgm}

4) After finishing adjustment, check again that the pressure is normal according to the above described measurement procedure.

PC130-7

TESTING AND ADJUSTING

MEASURING CONTROL CIRCUIT BASIC PRESSURE

MEASURING CONTROL CIRCUIT BASIC PRESSURE a Measuring instruments for control circuit basic pressure Symbol 1 J 2

Part No.

4. Run the engine at high idling and set all the control levers in neutral and measure the oil pressure.

Part name

799-101-5002

Hydraulic tester

790-261-1203

Digital hydraulic tester

799-101-5230

Nipple (10 x 1.25 mm)

07002-11423

O-ring

k Lower the work equipment to the ground and stop the engine. Operate the control levers several times to release the residual pressure in the piping, and then loosen the oil filler cap of the hydraulic tank slowly to release the internal pressure of the hydraulic tank. 1. Open the pump room cover and remove control circuit basic pressure pickup plug (1) under the hydraulic pump.

5. After finishing measurement, remove the measuring instruments and return the removed parts. a Do not adjust the relief valve for the control circuit basic pressure is not adjustable.

2. Install nipple J2 and connect it to oil pressure gauge [1] of hydraulic tester J1. a Use the oil pressure gauges of 5.9 MPa {60 kg/cm2}.

3. Run the engine and heighten the hydraulic oil temperature to 45 – 55°C.

PC130-7

20-125 (1)

TESTING AND ADJUSTING OIL PRESSURE IN PUMP PC CONTROL CIRCUIT

TESTING AND ADJUSTING

TESTING AND ADJUSTING OIL PRESSURE IN PUMP PC CONTROL CIRCUIT

•

(2): PC valve output pressure pickup plug (at top of hydraulic pump)

a Testing and adjusting instruments for oil pressure in pump PC control circuit Symbol 1 K 2

Part No.

Part name

799-101-5002

Hydraulic tester

790-261-1203

Digital hydraulic tester

799-101-5220

Nipple (10 x 1.25 mm)

07002-11023

O-ring

MEASURING Measuring PC valve output pressure (servo piston inlet pressure) a Before measuring the PC valve output pressure (servo piston inlet pressure), check that the oil pressure in the work equipment, swing, and travel circuits and the basic pressure in the control circuit are normal. a Measure the PC valve output pressure (servo piston inlet pressure) and pump discharge pressure simultaneously and compare them.

3. Install nipple K2 and connect it to oil pressure gauge [1] of hydraulic tester K1. a Use the oil pressure gauge of 58.8 MPa {600 kg/cm2}. • The drawing shows the pump discharge pressure side.

k Lower the work equipment to the ground and stop the engine. Operate the control levers several times to release the residual pressure in the piping, and then loosen the oil filler cap of the hydraulic tank slowly to release the internal pressure of the hydraulic tank. 1. Remove the top cover of the control valve and open the pump room cover. 2. Remove oil pressure pickup plugs (1) and (2). • (1): Pump discharge pressure pickup plug (at top of control valve)

•

The drawing shows the PC valve output pressure side.

4. Run the engine and heighten the hydraulic oil temperature to 45 – 55°C.

20-126 (1)

PC130-7

TESTING AND ADJUSTING OIL PRESSURE IN PUMP PC CONTROL CIRCUIT

TESTING AND ADJUSTING

ADJUSTING Adjusting PC valve a If either of the following phenomena occurs and the PC valve seems to be defective, adjust PC valve (3) according to the procedure shown below. • As the working load increases, the engine speed lowers remarkably. • The engine speed is normal but the work equipment speed is low. a The figure shows the hydraulic pump seen from the front side of the machine.

5. While running the engine at high idling, measure the pump discharge pressure and PC valve output pressure (servo piston inlet pressure) simultaneously. • Working mode: A • Swing lock switch: LOCK (2-stage relief valve is turned ON and relief pressure is set high) • Work equipment, swing, and travel circuits: Relieve arm circuit by moving arm IN. a Method of judgment: If the pump discharge pressure and PC valve output pressure (servo piston output pressure) are in the following ratio, they are normal. Measured oil pressure

Ratio of oil pressure

Pump discharge pressure

1

PC valve output pressure (Servo piston inlet pressure)

Approx. 3/5

a If the PC valve or the servo piston is abnormal, the PC valve output pressure (servo piston inlet pressure) is "the same as the pump discharge pressure" or "almost 0". 6. After finishing measurement, remove the measuring instruments and return the removed parts.

1. Loosen hose fixing (4). 2. Fixing sleeve (5), loosen locknut (6). 3. Turn sleeve (5) to the right or left to adjust the pump absorption torque. a If the sleeve is • turned to the right, the pump absorption torque increases. • turned to the left, the pump absorption torque decreases. a Limit the turning angle of the sleeve to the following range. • Right turning: Max. 1 turn (360°) • Left turning: Max. 1/2 turn (180°) a Change of servo piston stroke per turn of sleeve: 1.5 mm 3 Locknut: 88 – 113 Nm {9 – 11.5 kgm}

4. Fixing sleeve (5), tighten locknut (6).

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20-127 (1)

TESTING AND ADJUSTING

TESTING AND ADJUSTING OIL PRESSURE IN PUMP PC CONTROL CIRCUIT

5. Tighten hose fixing nut (4).

6. After finishing adjustment, check that the pressure is normal according to the above described procedure.

20-128 (1)

PC130-7

TESTING AND ADJUSTING OIL PRESSURE IN PUMP LS CONTROL CIRCUIT

TESTING AND ADJUSTING

TESTING AND ADJUSTING OIL PRESSURE IN PUMP LS CONTROL CIRCUIT

•

(2): LS valve output pressure pickup plug (at top of hydraulic pump)

a Testing and adjusting instruments for oil pressure in pump LS control circuit Symbol 1 L

2 3

Part No.

Part name

799-101-5002

Hydraulic tester

790-261-1203

Digital hydraulic tester

799-101-5220

Nipple (10 x 1.25 mm)

07002-11023

O-ring

799-400-2701

Differential pressure gauge

MEASURING 1. Measuring LS valve output pressure (servo piston inlet pressure) a Before measuring the LS valve output pressure (servo piston inlet pressure), check that the oil pressure in the work equipment, swing, and travel circuits and the basic pressure in the control circuit are normal. a Measure the LS valve output pressure (servo piston inlet pressure) and pump discharge pressure simultaneously and compare them. k Lower the work equipment to the ground and stop the engine. Operate the control levers several times to release the residual pressure in the piping, and then loosen the oil filler cap of the hydraulic tank slowly to release the internal pressure of the hydraulic tank. 1) Remove the top cover of the control valve and open the pump room cover. 2) Remove oil pressure pickup plugs (1) and (2). • (1): Pump discharge pressure pickup plug (at top of control valve)

PC130-7

3) Install nipple L2 and connect it to oil pressure gauge [1] of hydraulic tester L1. a Use the oil pressure gauge of 58.8 MPa {600 kg/cm2}. • The drawing shows the pump discharge pressure side.

•

The drawing shows the LS valve output pressure side.

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TESTING AND ADJUSTING OIL PRESSURE IN PUMP LS CONTROL CIRCUIT

TESTING AND ADJUSTING

4) Run the engine and heighten the hydraulic oil temperature to 45 – 55°C, and then push up the track shoe on either side with the work equipment.

6) After finishing measurement, remove the measuring instruments and return the removed parts. 5) While running the engine at high idling, measure the pump discharge pressure and LS valve output pressure (servo piston inlet pressure) simultaneously. • Working mode: A • Travel speed switch: Hi • Work equipment, swing, and travel circuits: Set all levers in neutral and run track shoe on one side idle. k Checking the safety around the machine, run the track shoe pushed up idle. a Method of judgment: If the pump discharge pressure and LS valve output pressure (servo piston output pressure) are in the following ratio, they are normal.

2. Measuring LS differential pressure a Measure the pump discharge pressure and LS pressure (actuator load pressure) simultaneously and calculate the difference between them. 1) Remove the top cover of the control valve and remove oil pressure pickup plugs (1) and (3). • (1): Pump discharge pressure pickup plug • (3): LS pressure pickup plug

Pump LS valve discharge output Ratio of oil presTravel lever pressure pressure sure MPa {kg/cm2} Neutral

2.9±0.5 {30±5}

2.9±0.5 {30±5}

Almost same pressure (1:1)

Full (Idle running)

7.8±2.0 {80±20}

4.4±1.0 {45±10}

Almost 3/5 (1:0.6)

20-130 (1)

PC130-7

TESTING AND ADJUSTING

2) Install nipple L2 and connect it to the oil pressure gauge of hydraulic tester L1. a When using differential pressure gauge: Connect the pump discharge pressure to the high pressure side (back side) and connect the LS pressure to the low pressure side (lower side). Since the differential pressure gauge needs a 12-V power source, connect it to a battery. a When using oil pressure gauge: Use the oil pressure gauge of 58.8 MPa {600 kg/cm2}. Since the differential pressure is about 2.9 MPa {30 kg/cm2} at maximum, measure it by installing the same gauge to the pickup plugs alternately.

TESTING AND ADJUSTING OIL PRESSURE IN PUMP LS CONTROL CIRCUIT

4) While running the engine at high idling, measure the pump discharge pressure and LS valve output pressure (servo piston inlet pressure) simultaneously. • Working mode: A • Travel speed switch: Hi • Work equipment, swing, and travel circuits: Set all levers in neutral and run track shoe on one side idle. k Checking the safety around the machine, run the track shoe pushed up idle. a Calculation of LS differential pressure (when oil pressure gauge is used): LS differential pressure = Pump discharge pressure - LS pressure a If the LS differential pressure is as follows, it is normal. Travel lever

LS differential pressure

Neutral

LS differential pressure in neutral (See standard values table)

Specified LS differential pressure Full (Idle running) (See standard values table)

3) Run the engine and heighten the hydraulic oil temperature to 45 – 55°C, and then push up the track shoe on either side with the work equipment.

5) After finishing measurement, remove the measuring instruments and return the removed parts.

PC130-7

20-131 (1)

TESTING AND ADJUSTING

ADJUSTING Adjusting LS valve a If the LS differential pressure is abnormal, adjust LS valve (4) according to the procedure shown below. a The figure shows the hydraulic pump seen from the front side of the machine.

TESTING AND ADJUSTING OIL PRESSURE IN PUMP LS CONTROL CIRCUIT

6. After finishing adjustment, check that the pressure is normal according to the above described procedure.

1. Loosen hose sleeve nut (4). 2. Fixing plug (5), loosen locknut (6). 3. Turn plug (5) to adjust the differential pressure. a If the plug is • turned to the right, the differential pressure rises. • turned to the left, the differential pressure lowers. a Quantity of adjustment (LS differential pressure) per turn of plug: 1,304 kPa {13.3 kg/cm2} a Tighten the hose sleeve nut (4) temporarily and turn the plug, while checking the LS differential pressure. 3 Locknut: 98 – 122.5 Nm {10 – 12.5 kgm}

4. Fixing plug (5), tighten locknut (6).

5. Tighten hose sleeve nut (4).

20-132 (1)

PC130-7

TESTING AND ADJUSTING

MEASURING SOLENOID VALVE OUTPUT PRESSURE

MEASURING SOLENOID VALVE OUTPUT PRESSURE a Measuring instruments for solenoid valve output pressure Symbol M

Part No.

1 2

a Use the oil pressure gauges of 5.9 MPa {60 kg/cm2}. a The figure shows the measuring instruments connected to the outlet hose of the 2-stage relief solenoid valve.

Part name

799-101-5002

Hydraulic tester

790-261-1203

Digital hydraulic tester

799-401-3100

Adapter (Size 02)

a Before measuring the solenoid valve output pressure, check that the basic pressure in the control circuit is normal.

k Lower the work equipment to the ground and stop the engine. Operate the control levers several times to release the residual pressure in the piping, and then loosen the oil filler cap of the hydraulic tank slowly to release the internal pressure of the hydraulic tank.

4. Run the engine and heighten the hydraulic oil temperature to 45 – 55°C.

1. Remove the undercover of the control valve and disconnect outlet hoses (1) – (4) of the solenoid valves to be measured. No. 1

Solenoid valve to be measured 2-stage relief solenoid valve

2

Swing holding brake solenoid valve

3

Travel speed solenoid valve

4

PPC pressure lock solenoid valve

a Since outlet hose (4) of the PPC pressure lock solenoid valve has a quick coupler, measure the output pressure on the PPC valve side.

2. Install adapter M2 and connect the disconnected hose again.

5. Run the engine at high idling, operate the control levers and switches to turn the solenoid valve ON or OFF, and measure the oil pressure. a For the conditions for turning the solenoid valve ON and OFF, see the operations table of each solenoid valve. a The operating condition of the solenoid valve can be also checked with the monitoring function [02] of the monitor panel (excluding the PPC pressure lock solenoid valve). a If the output pressure is as follows, the solenoid valve is normal. Solenoid valve

Output pressure

OFF (Deenergized)

0 MPa {0kg/cm2}

ON (Energized)

Almost same as control basic pressure (See standard values table)

3. Install nipple [1] of hydraulic tester M1 and connect it to hydraulic gauge [2].

PC130-7

20-133 (1)

MEASURING SOLENOID VALVE OUTPUT PRESSURE

TESTING AND ADJUSTING

6. After finishing measurement, remove the measuring instruments and return the removed parts. Operation table of 2-stage relief solenoid valve Operation

Operating condition One-touch power maximizing switch: ON (8.5-sec timer) Tr avel signal

ON

Swing lock switch Other than above condition

OFF

Operation table of swing holding brake solenoid valve Operation

Operating condition Work equipment, swing, and travel signals

Any one is turned ON

ON

Swing holding brake release switch: RELEASE (Upper) position Other than above condition

OFF

Operation table of travel speed brake solenoid valve Operating condition

Operation

Travel speed switch: Lo Auto shift function operates during run at Hi

Engine speed: Below 1,500 rpm Pump pressure: Above 30.4 MPa {310 kg/cm2}

OFF

Overheat prevention function operates during run Hydraulic oil temperature: Above 95°C at Hi Other than above condition

ON

Operation table of PPC pressure lock solenoid valve Operating condition Safety lock lever

20-134 (1)

Operation

LOCK position

OFF

FREE position

ON

PC130-7

TESTING AND ADJUSTING

MEASURING PPC VALVE OUTPUT PRESSURE

MEASURING PPC VALVE OUTPUT PRESSURE a Measuring instruments for PPC valve output pressure Symbol

Part No.

N

Part name

799-101-5002

Hydraulic tester

790-261-1203

Digital hydraulic tester

a Before measuring the PPC valve output pressure, check that the basic pressure in the control circuit is normal.

k Lower the work equipment to the ground and stop the engine. Operate the control levers several times to release the residual pressure in the piping, and then loosen the oil filler cap of the hydraulic tank slowly to release the internal pressure of the hydraulic tank.

a Since PPC oil pressure switches (10) and (11) are installed in the battery room, open the battery room cover.

1. Disconnect PPC oil pressure switches (1) – (4) of the circuit to be measured. No. Circuit to be measured No. Circuit to be measured 1

Boom RAISE (S06)

7

Swing RIGHT (S07)

2

Boom LOWER (S02)

8

Swing LEFT (S03)

3

Arm IN (S04)

9

Travel (S30)

4

Arm OUT (S04)

1ATT on front side 10 (S10)

5

Bucket CURL (S08)

1ATT on rear side 11 (S11)

6

Bucket DUMP (S01)

a Since PPC oil pressure switches (1) – (8) are installed in the battery room, open the battery room cover.

a Since PPC oil pressure switch (9) is installed on the under side of the floor frame, remove the cab undercover (on the front side).

PC130-7

2. Install nipple [1] of hydraulic tester N and connect it to oil pressure gauge [2]. a Use the oil pressure gauges of 5.9 MPa {60 kg/cm2}. a The figure shows the measuring instruments installed to the mounting part of the swing LEFT PPC pressure switch.

3. Run the engine and heighten the hydraulic oil temperature to 45 – 55°C.

20-135 (1)

TESTING AND ADJUSTING

MEASURING SOLENOID VALVE OUTPUT PRESSURE, ADJUSTING PLAY OF WORK EQUIPMENT AND SWING PPC VALVES

ADJUSTING PLAY OF WORK EQUIPMENT AND SWING PPC VALVES a If the work equipment and swing levers have large play, adjust them according to the following procedure. 1. Remove the work equipment and swing PPC valve assembly. 2. Remove bellows (1).

4. Run the engine at high idling and measure the oil pressure while the control lever or pedal of the measured circuit is in neutral and while it is operated to the stroke end. a If the PPC valve output pressure is as follows, the solenoid valve is normal. Lever/Pedal

Output pressure

In neutral

0 MPa {0kg/cm2}

Operated to stroke end

Almost same as control basic pressure (See standard values table)

3. Loosen locknut (2) and tighten disc (3) until it touches the heads of 4 pistons (4). a Do not move the piston at this time. 4. Fix disc (3) and tighten locknut (2) to the specified torque. 3 Locknut: 69 – 88 Nm {7 – 9 kgm}

5. Install bellows (1). 6. Install the work equipment and swing PPC valve assembly.

5. After finishing measurement, remove the measuring instruments and return the removed parts.

20-136 (1)

PC130-7

TESTING AND ADJUSTING

TESTING PARTS WHICH CAUSE HYDRAULIC DRIFT OF WORK EQUIPMENT

TESTING PARTS WHICH CAUSE HYDRAULIC DRIFT OF WORK EQUIPMENT a If the work equipment (cylinder) drifts hydraulically, check to see if the cause is on the cylinder packing side or control valve side or hydraulic drift prevention valve side (if equipped) according to the following procedure. 1. Testing boom cylinder and bucket cylinder 1) Set the machine in the position of measuring hydraulic drift and stop the engine. a Fill the bucket with a rated load or with dirt and sand.

2) When testing the boom cylinder, set the boom control lever in the RAISE position. When testing the bucket cylinder, set the bucket control lever in the CURL position. • If the lowering speed is increased at this time, the cylinder packing is defective. • If the lowering speed does not change at this time, the control valve or hydraulic drift prevention valve (if equipped) is defective. a Operate the control lever while the starting switch is in the ON position. a If the pressure in the accumulator is lost, run the engine for about 10 seconds to heighten the pressure in the accumulator. 2. Testing arm cylinder 1) Stop the arm cylinder about 100 mm before the IN stroke end and stop the engine.

PC130-7

2) Operate the arm control lever in the IN position. • If the lowering speed is increased at this time, the cylinder packing is defective. • If the lowering speed does not change at this time, the control valve is defective. a Operate the control lever while the starting switch is in the ON position. a If the pressure in the accumulator is lost, run the engine for about 10 seconds to heighten the pressure in the accumulator.

[Reference] Reason why the lowering speed is increased by the above operation when the cylinder packing is the cause of the hydraulic drift: 1) If the machine is set in the above position (where the holding pressure is applied to the bottom side), the oil leaks from the bottom side to the head side. Since the volume on the head side is less than that on the bottom side by the volume of the rod, the pressure in the head side is increased by the oil flowing in from the bottom side. 2) As the pressure in the head side is increased, it is balanced at a certain level (which depends on the leakage), and then the lowering speed is lowered. 3) If the circuit on the head side is opened to the drain circuit by the above operation of the lever (the bottom side is closed by the check valve at this time), the oil on the head side flows in the drain circuit. As a result, the pressure is unbalanced and the lowering speed is increased.

20-137 (1)

TESTING AND ADJUSTING

TESTING PARTS WHICH CAUSE HYDRAULIC DRIFT OF WORK EQUIPMENT

3. Testing PPC valve While the pressure in the accumulator is high, set the safety lock lever in the LOCK/FREE position and measure the lowering distance. a Operate the control lever while the starting switch is in the ON position. a If the pressure in the accumulator is lost, run the engine for about 10 seconds to heighten the pressure in the accumulator. a If there is a difference in the lowering distance between the LOCK position and FREE position, the PPC valve is defective (it has an internal defect).

20-138 (1)

PC130-7

TESTING AND ADJUSTING

MEASURING OIL LEAKAGE

MEASURING OIL LEAKAGE a Measuring instruments fro oil leakage Symbol

Part No.

P

Commercially available

Part name Measuring cylinder

1. Measuring oil leakage from boom cylinder 1) Run the engine and heighten the engine oil temperature to 45 – 55°C, and then move the boom cylinder to the RAISE stroke end.

k Release the residual pressure in the piping on the boom cylinder head side. For details, see RELEASING RESIDUAL PRESSURE IN HYDRAULIC CIRCUIT (Operate the lever in the boom RAISE direction only, however). 2) Disconnect hose (1) on the cylinder head side and block the hose side with a plate.

2. Measuring oil leakage from arm cylinder 1) Run the engine and raise the engine oil temperature to 45 – 55°C, and then move the arm cylinder to the IN stroke end. k Release the residual pressure in the piping on the arm cylinder head side. For details, see RELEASING RESIDUAL PRESSURE IN HYDRAULIC CIRCUIT (Operate the lever in the arm IN direction only, however). 2) Disconnect hose (2) on the cylinder head side and block the hose side with a plate.

k Take care not to disconnect the hose on the cylinder bottom side. a Use the following part to block the hose side. 07376-50522 (Plug No. 05)

k Take care not to disconnect the hose on the cylinder bottom side. a Use the following part to block the hose side. 07376-50422 (Plug No. 04)

3) Run the engine at high idling and relieve the arm circuit by moving the arm IN. k Take care not to "move the arm OUT". 4) Measure the oil leakage for 1 minute after 30 seconds since relieving is started. 5) After finishing measurement, return the removed parts. 3) Run the engine at high idling and relieve the boom circuit by raising the boom.

k Take care not to "lower the boom". 4) Measure the oil leakage for 1 minute after 30 seconds since relieving is started. 5) After finishing measurement, return the removed parts.

PC130-7

20-139 (1)

TESTING AND ADJUSTING

3. Measuring oil leakage from bucket cylinder 1) Run the engine and raise the engine oil temperature to 45 – 55°C, and then move the bucket cylinder to the CURL stroke end and stop the engine.

k Release the residual pressure in the piping on the bucket cylinder head side. For details, see RELEASING RESIDUAL PRESSURE IN HYDRAULIC CIRCUIT (Operate the lever in the arm CURL direction only, however). 2) Disconnect hose (3) on the cylinder head side and block the hose side with a plate.

MEASURING OIL LEAKAGE

4. Measuring oil leakage from swing motor 1) Run the engine and raise the engine oil temperature to 45 – 55°C. 2) Disconnect drain hose (4) and block the hose side with a plug. a Use the following part to block the hose side. 07376-50522 (Plug No. 05)

k Take care not to disconnect the hose on the cylinder bottom side. a Use the following part to block the hose side. 07376-50422 (Plug No. 04)

3) Turn the swing lock switch ON. 4) Run the engine at high idling and relieve the swing circuit by swinging. a Measure the oil leakage for 1 minute after 30 seconds since relieving is started. a After measuring 1 time, swing 180°, and then measure again. 5) After finishing measurement, return the removed parts. 3) Run the engine at high idling and relieve the bucket circuit by curling the bucket.

k Take care not to "dump the bucket". 4) Measure the oil leakage for 1 minute after 30 seconds since relieving is started. 5) After finishing measurement, return the removed parts.

20-140 (1)

PC130-7

TESTING AND ADJUSTING

MEASURING OIL LEAKAGE

5. Measuring oil leakage from travel motor 1) Run the engine and raise the engine oil temperature to 45 – 55°C, and then remove the travel motor cover. 2) Run the engine and lock the travel system. k Put pin [1] between the sprocket and track frame to lock the travel system securely.

3) Disconnect drain hose (5) of the travel motor and block the hose side with a plug. a Use the following part to block the hose side. 07376-50422 (Plug No. 04)

4) Run the engine at high idling, relieve the travel circuit, and measure the oil leakage.

k Wrong operation of the lever can cause an accident. Accordingly, make signs and checks securely. a Measure the oil leakage for 1 minute after 30 seconds since r elieving is started. a Measure several times, moving the motor a little (changing the position of the valve plate and cylinder and that of the cylinder and piston) each time. 5) After finishing measurement, return the removed parts.

PC130-7

20-141 (1)

TESTING AND ADJUSTING

RELEASING RESIDUAL PRESSURE IN HYDRAULIC CIRCUIT

RELEASING RESIDUAL PRESSURE IN HYDRAULIC CIRCUIT 1. Releasing residual pressure in hydraulic tank

k Since the hydraulic tank is enclosed and pressurized, release the residual pressure in it when removing a hose or a plug connected to it. 1) Lower the work equipment to the ground in a stable position and stop the engine. 2) Loosen oil filler cap (1) of the hydraulic tank gradually to release the air in the tank. a If you open the pump room cover, you can loosen the oil filler cap from the right side of the machine.

4) Repeat steps 2) and 3) above 2 – 3 times, and the residual pressure in the piping is released completely. 3. Releasing residual pressure in swing motor circuit a The residual pressure in the swing motor circuit can be released by performing the operation for RELEASING RESIDUAL PRESSURE IN HYDRAULIC CYLINDER CIRCUIT (Operate the lever in the swing direction only, however). 4. Releasing residual pressure in travel motor circuit a Since the control valve spool of the travel motor circuit is open, the pressure in this circuit can be released by performing RELEASING RESIDUAL PRESSURE IN HYDRAULIC TANK.

2. Releasing residual pressure in hydraulic cylinder circuit

k When disconnecting a pipe between a hydraulic cylinder and the control valve, release the residual pressure in the piping according to the following procedure. 1) Release the residual pressure in the hydraulic tank. For details, see RELEASING RESIDUAL PRESSURE IN HYDRAULIC TANK. a Keep the oil filler cap of the hydraulic tank removed. 2) Turn the starting switch ON and set the safety lock lever in the FREE position, and then operate the work equipment control levers on both sides forward, backward, to the right, and to the left. a The control valve is operated by the pressure in the accumulator. The pressure in the accumulator is used up, however, after the control valve is operated 2 – 3 times. 3) Run the engine at low idling for 10 seconds to heighten the pressure in the accumulator.

20-142 (1)

PC130-7

TESTING AND ADJUSTING

BLEEDING AIR FROM EACH PART

BLEEDING AIR FROM EACH PART Air bleeding procedure Air bleeding item

Contents of work • Replacing hydraulic oil • Cleaning strainer

1

2

Bleeding air from hydraulic pump

Starting engine

q

q

4

5

Bleeding air Bleeding air Bleeding air from swing from travel from cylinder motor motor

q

q

q

(See note)

(See note)

6 Checking oil level and starting operation

q

q

• Replacing return filter element • Replacing and repairing hydraulic pump • Removing suction piping

3

q

q

q

q

q

• Replacing and repairing control valve • Removing control valve piping

q

q

q

• Replacing and repairing cylinder • Removing cylinder piping

q

q

q

• Replacing and repairing swing motor • Removing swing motor piping

q

• Replacing and repairing travel motor • Removing travel motor piping

q

• Replacing and repairing swivel joint • Removing swivel joint piping

q

q

q q

q q

Note: Bleed air from the swing motor and travel motor only when the oil in the motor cases is drained. 1. Bleeding air from hydraulic pump 1) Open the pump room cover, loosen bleeder (1), and check that oil flows out. 2) If the oil does not flow out, disconnect drain hose (2) and fill the pump case with oil through the drain port. a Fix the drain hose adapter to a place higher than the oil level in the hydraulic tank. a Fill the pump case with oil until oil containing no bubbles flows out of the bleeder. 3) After oil containing no bubbles flows out of bleeder (1), tighten the bleeder. 3 Air bleeder: 7.8 – 9.8 Nm {0.8 – 1.0 kgm} a If the drain hose has been disconnected, connect it after tightening the bleeder.

PC130-7

2. Starting engine When running the engine after performing step 1, keep its speed at low idling for 10 minutes. a If the engine coolant temperature is low and the automatic warm-up operation is started, stop the engine temporarily and reset the automatic warm-up operation with the fuel control dial (Set the starting switch in the ON position and hold the fuel control dial in the MAX position for 3 seconds, and the automatic warm-up operation is reset).

20-143 (1)

TESTING AND ADJUSTING

BLEEDING AIR FROM EACH PART

3. Bleeding air from cylinder a If a cylinder was replaced, bleed air from it before connecting the work equipment. In particular, the boom cylinder does not move to the lowering stroke end, if it is installed to the work equipment. 1) Run the engine at low idling for about 5 minutes. 2) Running the engine at low idling, raise and lower the boom 4 – 5 times. a Stop the piston rod about 100 mm before each stroke end. Do not relieve the oil. 3) Running the engine at high idling, perform step 2). 4) Running the engine at low idling, move the piston rod to the stroke end and relieve the oil. 5) Bleed air from the arm cylinder and bucket cylinder according to steps 2) – 4).

5. Bleeding air from travel motor 1) Remove the travel motor cover and run the engine at low idling. 2) Loosen drain hose (4) and check that oil oozes out, and then tighten the drain hose.

4. Bleeding air from swing motor 1) Run the engine at low idling. 2) Loosen air bleeding plug (3) and check that the oil oozes out, and then tighten the air bleeding plug.

3) Running the engine at low idling and using the work equipment, raise the track shoe on either side.

3 Air bleeding plug: 25.5 – 34.3 Nm {2.5 – 3.5 kgm} 3) If the oil does not oozes out, remove air bleeding plug (3) and fill the pump case with oil.

4) Running the engine at low idling, run the raised track shoe idle slowly for about 2 minutes. a Run the track shoe forward and in reverse as evenly as possible. a Run the track shoe on the opposite side idle similarly. 4) Run the engine at low idling and swing slowly 2 turns or more in each direction.

20-144 (1)

PC130-7

TESTING AND ADJUSTING

BLEEDING AIR FROM EACH PART

6. Checking oil level and starting work 1) Run the engine, retract the arm cylinder and bucket cylinder to the stroke ends, lower the work equipment to the ground, and stop the engine.

2) Check the oil level by sight gauge (5) on the side of the hydraulic tank. a If the oil level is between lines H and L, it is normal. a If the oil level is below line L, add new oil.

PC130-7

20-145 (1)

TESTING AND ADJUSTING

TESTING PROCEDURE FOR DIODE

TESTING PROCEDURE FOR DIODE a Test an assembled-type diode (18-pin) or a diode (2-pin) according to the following procedure. a The conductive direction of an assembled-type diode is shown in the following figure.

a The conductive direction of a diode is marked on its surface.

2. When using an analog circuit tester 1) Set the circuit tester in the resistance range. 2) Apply the test pins as shown below and check movement of the pointer. i) Apply the red (+) test pin to the anode (P) side of the diode and the black (-) test pin to the cathode (N) side. ii) Apply the red (+) test pin to the cathode (N) side of the diode and the black (-) test pin to the anode (P) side. 3) Judge the condition of the diode from movement of the pointer. • The pointer does not move in i) above but moves in ii): Normal (Moving angle (Resistance) depends on the type and measurement range of the circuit tester, however) • The pointer moves in both i) and ii): Defective (Internal short circuit) • The pointer does not move in either of i) and ii): Defective (Internal disconnection)

1. When using a digital circuit tester 1) Set the circuit tester in the diode range and check the indicated value. a If an ordinary tester is used, the voltage of the battery in itself is indicated. 2) Apply the red (+) test pin to the anode (P) side of the diode and the black (-) test pin to the cathode (N) side and read the indicated value. 3) Judge the condition of the diode from the indicated value. • The indicated value does not change: There is not continuity (Defective). • The indicated value changes: There is continuity (Normal) (Note). Note) In the case of a silicon diode, the circuit tester indicates a value of 460 – 600.

20-146 (1)

PC130-7

TESTING AND ADJUSTING

SPECIAL FUNCTIONS OF MONITOR PANEL

SPECIAL FUNCTIONS OF MONITOR PANEL

Section to display special functions 1. Display section 2. Service meter section

PC130-7

Section to operate special function 1 (Basic operation) 3. Caution buzzer stop switch 4. Auto-decelerator switch 5. Setting switch (Black switch) 6. Travel speed shifting switch

Section to operate special function 2 (Selecting operation and special operation) 7. Working mode selector switch (UP) 8. Working mode selector switch (DOWN) 9. Swing lock switch

20-147 (1)

TESTING AND ADJUSTING

SPECIAL FUNCTIONS OF MONITOR PANEL

Ordinary functions and special functions of monitor panel The monitor panel has the ordinary functions and special functions and displays various pieces of information on display section (1) and service meter section (2). Some items are displayed automatically according to the internal setting of the monitor panel and the others are displayed by operating switches. 1. Ordinary functions: Operator menu The items in this menu are displayed normally or displayed automatically when a trouble occurs. 2. Special functions: Service menu The items in this menu are not displayed normally. Each serviceman can display them by operating special switches. These functions are used for special setting, testing, adjusting, or troubleshooting. Flow of each function

1

Function of displaying service meter

O 2

Function of displaying user code

Special functions (Service menu)

O

Ordinary functions (Operator menu) 3

Function of displaying error code [01]

4

Monitoring function [02]

5

Function of adjusting governor [03]

6

Function of selecting maintenance period [04]

7

Function of selecting default working mode [05]

8

Special function of monitoring replacement of engine oil

a Each number in [ ] is a code No. displayed in the service meter section when the menu is selected.

20-148 (3)

PC130-7

TESTING AND ADJUSTING

Display of operator menu a Only outline of the operator menu is described in this section. For details of each menu, see O P E R AT I O N M A N U A L o r t h e v o l u m e o f STRUCTURE AND OPERATION. 1. Function of displaying service meter While the machine is used normally, the monitor panel displays the following information. • Display section (1): Nothing is displayed • Service meter section (2): Service meter

SPECIAL FUNCTIONS OF MONITOR PANEL

2. Function of displaying user code If the machine has any trouble, the corresponding user code is displayed automatically in display section (1) and the caution buzzer is turned ON to urge the operator to take a proper remedy, depending on the degree of the trouble. a Service meter section (2) continues displaying the service meter. a For displayed user codes and the remedies shown to the operator, see "User codes and remedies shown to operator". a Each user code simply shows occurrence of a trouble to the operator. To find out the cause of the trouble, a serviceman must check the error code with the "Function of displaying error code [01]" in the service menu.

A user code is displayed only when a serious trouble occurs. Even if a user code is not displayed, a trouble may have occurred. If you feel any abnormality, be sure to check for an error code with the "Function of displaying error code [01]" in the service menu.

PC130-7

20-149 (1)

SPECIAL FUNCTIONS OF MONITOR PANEL

TESTING AND ADJUSTING

a User codes and remedies shown to operator User code

Error mode

Remedy (shown to operator)

Caution buzzer

Error in pump control system

If the emergency pump drive switch is set in the upper position, the machine can operate normally. Have the machine inspected immediately, however.

q

E03

Error in swing brake system

Set the swing holding brake release switch in the upper position to release the brake. Apply the swing brake manually with the swing lock switch, if necessary. The brake may not be released, depending on the cause of the failure. In any case, have the machine inspected immediately.

q

E05

Error in governor system

Have the machine inspected immediately.

q

E02

20-150 (1)

PC130-7

TESTING AND ADJUSTING

Operation and display of service menu How to select service menu a When using the general functions in the service menu, perform the following switch operation to change the screen of the monitor panel. 3. 4. 5. 6.

Function of displaying error code [01] Monitoring function [02] Function of adjusting governor [03] Function of selecting maintenance period [04] 7. Function of selecting default working mode [05] 1) Operating switches Holding caution buzzer stop switch (3), hold auto decelerator switch (4) for 2.5 seconds.

SPECIAL FUNCTIONS OF MONITOR PANEL

3) Selecting menu Holding caution buzzer stop switch (3), operate working mode selector switches (7) and (8) to select a menu you will use. • UP switch (7): Menu No. increases. • DOWN switch (8): Menu No. decreases. Menu No.

Service menu (Excluding special functions)

01

Function of displaying error code

02

Monitoring function

03

Function of adjusting governor

04

Function of selecting maintenance period

05

Function of selecting default working mode

4) Executing menu Select a menu you will use and press set switch (5), and the menu is executed.

2) Displaying display section and service meter section If the switches are operated as shown above, the first menu No. [01] (Monitoring function) is displayed in service meter section (2). a Nothing is displayed in display section (1).

5) Finishing service menu Holding caution buzzer stop switch (3), hold auto decelerator switch (4) for 2.5 seconds (similarly to the selecting operation). a The service menu is finished and the ordinary screen appears. a The service menu can be also finished by turning the starting switch OFF while the service menu is selected. (In this case, the ordinary screen appears when the starting switch is turned ON again.) a To use the special functions in the service menu, you must operate the switches differently from the above. See details of each menu. 8. Function of adjusting service meter 9. Special function of monitoring replacement of engine oil

PC130-7

20-151 (1)

TESTING AND ADJUSTING

SPECIAL FUNCTIONS OF MONITOR PANEL

3. Function of displaying error code [01] With this function, you can check the error code of a trouble which is occurring at present or has occurred in the past.

1) Selecting and executing function i) Select menu No. [01] in the menu selection mode. ii) Press set switch (5) to execute this function. 2) Information displayed in display section and service meter section 1 (When error code is recorded) If an error code is recorded, the following information is displayed in display section (1) and service meter section (2). (a): Error code (b): Service meter reading increased after trouble occurred (c): Mark [E] to indicate that trouble is occurring at present a Mark [E] to indicate that a trouble is occurring at present indicates that the error code is being detected now. It is not displayed if the trouble has been repaired or the error code is not detected. a For the error codes which the monitor panel and governor and pump controller can detect, see the "Error codes table".

20-152 (1)

3) Information displayed in display section and service meter section 2 (When error code is not recorded) If an error code is not recorded, display section (1) and service meter section (2) display as shown below.

4) Number of recorded error codes and display order of them This function can record up to 20 error codes, which are displayed in order from the latest one. a If a new trouble occurs while 20 error codes are recorded, the oldest error code is deleted and the error code of the new trouble is recorded.

PC130-7

TESTING AND ADJUSTING

SPECIAL FUNCTIONS OF MONITOR PANEL

5) Change of displayed error codes Holding caution buzzer stop switch (3), operate working mode selector switches (7) and (8) to change the displayed error codes. • UP switch (7): Next error code appears. • DOWN switch (8): Previous error code appears. 6) How to delete error code i) Holding caution buzzer stop switch (3), turn the starting switch OFF and keep holding caution buzzer stop switch (3). ii) Under the above condition, turn the starting switch ON again and hold caution buzzer stop switch (3) for 5 seconds. a An error code having the mark [E] cannot be deleted.

PC130-7

20-153 (1)

SPECIAL FUNCTIONS OF MONITOR PANEL

TESTING AND ADJUSTING

Error codes table User code

Error code

—

104

Clogging of air cleaner

—

108

Overheating of engine coolant

—

112

Short circuit in wiper motor drive forward system

—

113

Short circuit in wiper motor drive reverse system

—

114

Short circuit in windshield washer drive system

—

115

Trouble in operation of windshield wiper

—

116

Trouble in storage of windshield wiper

E03

203

Short circuit in swing holding brake solenoid

—

205

Short circuit in 2-stage relief solenoid

—

206

Short circuit travel speed shifting solenoid

E03

213

Disconnection in swing holding brake solenoid

—

215

Disconnection in 2-stage relief solenoid

—

216

Disconnection travel speed shifting solenoid

—

217

Abnormality in input model code

—

218

Disconnection in S-NET signal line

—

222

Short circuit in LS-EPC solenoid

—

223

Disconnection in LS-EPC solenoid

—

224

Abnormality in pump pressure sensor

—

226

Abnormality in pressure sensor power supply

—

227

Abnormality in engine speed sensor

E02

232

Short circuit in PC-EPC solenoid

E02

233

Disconnection in PC-EPC solenoid

—

251

Abnormality in overload pressure sensor

—

301

Engine low idling speed out of standard range

—

302

Engine high idling speed out of standard range

—

306

Abnormality in governor potentiometer

E05

308

Abnormality in fuel control dial

—

315

Short circuit in battery relay output line

—

316

Step-out of governor motor

E05

317

Disconnection in phases A and B of governor motor

E05

318

Short circuit in phases A and B of governor motor

20-154 (1)

Trouble

PC130-7

TESTING AND ADJUSTING

SPECIAL FUNCTIONS OF MONITOR PANEL

4. Monitoring function [02] With this function, you can monitor the revolution speed, oil pressure, current, voltage, input condition, output condition, etc. in real time by the signals from the sensors, switches, and solenoids installed to various parts of the machine.

1) Selecting and executing function i) Select menu No. [02] in the menu selection mode. ii) Press set switch (5) to execute this function.

3) Information displayed in display section and service meter section 1 (When numeral code is displayed) If a numeral monitoring code is selected, the following information is displayed in display section (1) and service meter section (2). (a): Monitoring code (b): Monitoring information (Value is displayed)

2) Selecting and executing monitoring code Holding caution buzzer stop switch (3), operate working mode selector switches (7) and (8) to select a monitoring code displayed in service meter section (1). • UP switch (7): Code No. increases. • DOWN switch (8): Code No. decreases. a This function displays monitoring code [001] and its information first. a For the items and code Nos. which you can monitor, see the "Monitoring codes table".

PC130-7

20-155 (1)

TESTING AND ADJUSTING

SPECIAL FUNCTIONS OF MONITOR PANEL

4) Information displayed in display section and service meter section 2 (When 6-bit code is displayed) If a 6-bit monitoring code is selected, the following information is displayed in display section (1) and service meter section (2). (a): Monitoring code (b): Monitoring information (6 pieces of information are displayed in bits) a In the 6-bit display mode, only the top and bottom of the 7-segment mark are used to display. "Solid black" indicates the ON state, and "white on black background" indicates the OFF state. a For the No. of each bit, see the "Monitoring codes table" and the drawing attached to it.

20-156 (1)

PC130-7

TESTING AND ADJUSTING

SPECIAL FUNCTIONS OF MONITOR PANEL

Monitoring codes table Code

Monitoring item

Unit

001

Monitor panel model code

Numeral

002

Governor and pump controller model code (Pump side)

Numeral

003

Governor and pump controller model code (Engine throttle side)

Numeral

008

Connecting condition of network

Numeral

010

Engine speed

10rpm

011

Pump discharge pressure

kg/cm2

012

Pump discharge pressure

kg/cm2

013

PC-EPC solenoid output current

10mA

015

LS-EPC solenoid output current

10mA

016

2nd throttle speed

10rpm

018

(Unused)

—

019

(Unused)

—

020

021

022

023

PC130-7

a

Swing oil pressure switch (ON)

(6bit)

b

Travel oil pressure switch (ON)

(6bit)

c

Boom LOWER oil pressure switch (ON)

(6bit)

d

Boom RAISE oil pressure switch (ON)

(6bit)

e

Arm IN oil pressure switch (ON)

(6bit)

f

Arm OUT oil pressure switch (ON)

(6bit)

a

Bucket CURL oil pressure switch (ON)

(6bit)

b

Bucket DUMP oil pressure switch (ON)

(6bit)

c

(Unused)

(6bit)

d

Service oil pressure switch (ON)

(6bit)

e

(Unused)

(6bit)

f

(Unused)

(6bit)

a

(Unused)

(6bit)

b

(Unused)

(6bit)

c

One-touch power maximizing switch (ON)

(6bit)

d

Swing holding brake release switch (RELEASE)

(6bit)

e

Swing lock switch (LOCK)

(6bit)

f

(Unused)

(6bit)

a

(Unused)

(6bit)

b

(Unused)

(6bit)

c

Swing holding brake solenoid (ON)

(6bit)

d

(Unused)

(6bit)

e

2nd relief solenoid (ON)

(6bit)

f

Travel speed shifting solenoid (ON)

(6bit)

Remarks

Input condition of switch 1

Input condition of switch 2

Input condition of switch 3

Drive condition of solenoid valve

20-157 (1)

SPECIAL FUNCTIONS OF MONITOR PANEL

TESTING AND ADJUSTING

Code 024

027

Monitoring item (Unused)

Input condition of model selection signal

Unit —

a

Model selection 1 (Connected to ground)

(6bit)

b

Model selection 2 (Connected to ground)

(6bit)

c

Model selection 3 (Connected to ground)

(6bit)

d

Model selection 4 (Connected to ground)

(6bit)

e

Model selection 5 (Connected to ground)

(6bit)

f

(Unused)

(6bit)

030

Fuel control dial input voltage

10mV

031

Governor potentiometer input voltage

10mV

032

Controller power source voltage

100mV

033

Governor motor phase A output current

10mA

034

Governor motor phase B output current

10mA

035

Battery relay BR output voltage

100mV

036

037

a

(Unused)

(6bit)

b

(Unused)

(6bit)

c

(Unused)

(6bit)

d

(Unused)

(6bit)

e

Starting switch signal C (START)

(6bit)

f

(Unused)

(6bit)

a

Battery relay (DRIVEN)

(6bit)

b

(Unused)

(6bit)

c

(Unused)

(6bit)

d

(Unused)

(6bit)

e

(Unused)

(6bit)

f

(Unused)

(6bit)

Input condition of signal

Output condition of signal

041

Engine coolant sensor input voltage

10mV

042

Fuel level sensor input voltage

10mV

043

Alternator input voltage

10mV

044

(Unused)

045

— a

Starting switch signal ACC (ON)

(6bit)

b

Starting switch signal C (START)

(6bit)

c

Starting switch signal R1 (HEAT)

(6bit)

d

Lamp switch (ON)

(6bit)

e

(Unused)

(6bit)

f

(Unused)

(6bit)

Input condition 4 of switch

20-158 (1)

Remarks

PC130-7

TESTING AND ADJUSTING

SPECIAL FUNCTIONS OF MONITOR PANEL

Code

046

049

Monitoring item

Unit

a

Air cleaner clogging switch (OPEN)

(6bit)

b

(Unused)

(6bit)

c

Engine oil pressure switch (OPEN)

(6bit)

d

Engine oil level switch (OPEN)

(6bit)

e

(Unused)

(6bit)

f

Alternator (Normal generation)

(6bit)

a

Swing lock switch (LOCK)

(6bit)

b

Caution buzzer stop switch (ON)

(6bit)

c

Windows limit switch (ON)

(6bit)

d

Wiper contact W (ON)

(6bit)

e

Wiper contact P (ON)

(6bit)

f

(Unused)

(6bit)

Input condition of sensor

Input condition 5 of switch

200

Monitor panel program version

Numeral

201

Governor and pump controller program version

Numeral

Display of numeral code

PC130-7

Remarks

Display of 6bit

20-159 (1)

TESTING AND ADJUSTING

5. Function of adjusting governor [03] This function is used to adjust the governor lever stroke after the governor actuator, fuel injection pump, or governor spring is removed and installed or replaced, or when the high idling speed is low or engine speed is not stabilized.

1) Selecting and executing function i) Select menu No. [03] in the menu selection mode. ii) Press set switch (5) to execute this function. 2) Condition of governor motor If this function is executed, all the governor control functions are cancelled, and then the operating angle of the governor actuator follows up only the operation signal of the fuel control dial. a While this function is executed, [GOV] is displayed in display section (1) and [gSET] is displayed in service meter section (2).

SPECIAL FUNCTIONS OF MONITOR PANEL

3) Adjusting governor lever stroke a The turning direction of the governor spring described below is the direction when the governor actuator is seen from the fuel injection pump side. i) Keep the fuel control dial in the MAX position. ii) Loosen locknut (2) on the governor actuator side of governor spring (1). iii) Turn governor spring (1) clockwise to reduce its installed length (a) and return governor lever (3) of the fuel injection pump to a position where it does not touch the full stopper. iv) Turn governor spring (1) counterclockwise to increase its installed length (a) and stop it when governor lever (3) of the fuel injection pump touches the full stopper. • Standard installed length (a) (Reference): 262 mm v) Turn governor spring (1) counterclockwise further by 2.5 turns to compress the spring in governor spring (1). a Since the inside spring is compressed, only the outer cylinder of governor spring (1) moves toward the fuel injection pump by about 3.1 mm (the installed length does not change). vi) Fixing governor spring (1), tighten locknut (2) on the governor actuator side. a Before fixing the locknut, check that the water drain hole of the governor spring is directed down. If the water drain hole is not directed down, loosen locknut (4) on the fuel injection pump side and turn the whole governor spring to adjust (Take care not to change the adjustment dimension of the governor spring). 3 Locknut: 11.8 – 19.6 Nm {1.2 – 2.0 kgm}

20-160 (1)

PC130-7

TESTING AND ADJUSTING

SPECIAL FUNCTIONS OF MONITOR PANEL

vii) Return the fuel control dial to the MIN position, and then turn it again slowly toward the MAX position. At this time, check that governor spring is compressed by about 3.1 mm after governor lever (3) reaches the full stopper.

PC130-7

20-161 (1)

TESTING AND ADJUSTING

SPECIAL FUNCTIONS OF MONITOR PANEL

6. Function of selecting maintenance period [04] With this function, you can adjust the maintenance period of the engine oil for the function of the engine oil replacement monitor.

3) Settling maintenance period The display or maintenance period becomes effective when it is selected. Accordingly, perform the ordinary finishing operation. 1) Selecting and executing function i) Select menu No. [04] in the menu selection mode. ii) Press set switch (5) to execute this function. 2) Selecting maintenance period The current display mode or maintenance period is displayed in service meter section (2). Press set switch (5) to select a maintenance period. a Nothing is displayed in display section (1). a Each time the set switch is pressed, the display mode or maintenance period changes in the following order. Display 0

20-162 (1)

Display mode/Maintenance period Reset maintenance function

125

125-hour interval

250

250-hour interval

500

500-hour interval

d

a For the method of displaying the engine oil replacement monitor, method of checking the elapsed time after replacement of engine oil, method of clearing the elapsed time, and method of displaying demonstration mode, see "9. Special functions of engine oil replacement monitor".

Demonstration mode

PC130-7

TESTING AND ADJUSTING

7. Function of selecting default working mode [05] With this function, you can freely select the working mode which is set automatically when the starting switch is turned ON (When the machine is delivered, mode A is set).

SPECIAL FUNCTIONS OF MONITOR PANEL

3) Settling default working mode Press set switch (5) to settle the selected working mode.

1) Selecting and executing function i) Select menu No. [05] in the menu selection mode. ii) Press set switch (5) to execute this function. 2) Selecting default working mode The currently set working mode is displayed in service meter section (2). Press working mode selector switches (7) and (8) to select a working mode. • UP switch (7): Next mode is displayed. • DOWN switch (8): Previous mode is displayed. a Nothing is displayed in display section (1). a The working mode changes in the following order. AoEoB a Mode L cannot be set as the default.

PC130-7

20-163 (1)

TESTING AND ADJUSTING

SPECIAL FUNCTIONS OF MONITOR PANEL

8. Special functions of engine oil replacement monitor 1) Ordinary display of engine oil replacement monitor If the rest of time before the set engine oil replacement time is 10 hours or shorter, engine oil replacement monitor (10) lights up and display the elapsed time in service meter section for 20 seconds each time the starting switch is turned ON.

4) Function of demonstration mode If the demonstration mode is selected, you can perform demonstration of the oil maintenance function when teaching the operation to a customer. The functions and display of the demonstration mode are as follows.

2) Checking elapsed time To check the elapsed time while engine oil replacement monitor (10) is OFF, turn the starting switch OFF and press set switch (5) and then turn the starting switch ON and keep holding set switch (5).

1. The internally set interval is recognized as 250 hours and the elapsed time is recognized as 240 hours. 2. When the starting switch is turned ON after the demonstration mode is set, the ordinary display is repeated up to 3 times (number of the times of turning the starting switch ON). 3. After the demonstration is finished, resetting of maintenance setting [0] is recognized. a When the demonstration is repeated 3 times, resetting of maintenance setting is recognized. If setting is necessary at this time, see "Function of selecting maintenance period".

3) Clearing elapsed time To clear the elapsed time after replacing the engine oil, hold set switch (5) for 3 seconds while the elapsed time is displayed. a If the above operation is performed, the elapsed time in the monitor panel is set to 0 hour.

20-164 (3)

PC130-7

TESTING AND ADJUSTING

PREPARATION WORK FOR TROUBLESHOOTING FOR ELECTRIC SYSTEM

PREPARATION WORK FOR TROUBLESHOOTING FOR ELECTRIC SYSTEM

2. Governor and pump controller a The governor and pump controller is installed in the cover at the rear of the operator's seat. 1) Remove the 3 mounting bolts and cover (3).

a When carrying out troubleshooting for an electric circuit related to the monitor panel and governor and pump controller, expose the related connectors according to the following procedure. 1. Monitor panel 1) Remove cover (1) a The cover is fixed with 2 clips at the top and bottom. Just pull it up to remove it. a If the daylight sensor of the air conditioner is installed, disconnect connector P15 on the back side of the cover. 2) Insert or connect testing T-adapters in or to connectors C01, C02, and C03 of governor and pump controller (4). a Since the connectors are secured with screws, loosen those screws before disconnecting. a When connecting the connectors again, tighten their screws to the specified torque. 3 Screw: 2.82 Nm {0.288 kgm}

2) Remove the 3 mounting screws, and then remove monitor panel (2) from the mount. a Take care not to drop the mounting screws into the console. 3) Insert or connect testing T-adapters in or to connectors P01 and P02 of the monitor panel. a Connector P70 clamped near the above connectors is not used.

PC130-7

20-165 (3)

Pm-Clinic Service Model

Serial No.

Service meter

PC130-7

Boom Arm Bucket

h

User's name

Date of inspection

Inspector

Main parts

Specifications Attachments

Shoe width

Standard Standard Standard

( ( (

) ) )

1 att. Blade 2-piece boom

( (

) )

(

500 mm 600 mm 700 mm

)

Check of oil and coolant levels When necessary Damper case oil Machinery case oil

Radiator coolant Engine oil Hydraulic oil Max. range of engine coolant temperature

(Top)

Max. range of hydraulic oil temperature

(Bottom)

Final drive case oil ( )

Ambient temperature

Altitude m Operator's opinion

Visual inspection result

Error code history

Memo

PC130-7

20-167 (2)

TESTING AND ADJUSTING

PM-CLINIC SERVICE

Items related to engine

20-168 (1)

PC130-7

TESTING AND ADJUSTING

PM-CLINIC SERVICE

Items related to hydraulic equipment

PC130-7

20-169 (1)

20-170

(1)

PC130-7

Full (MAX)

Low (MIN)

Low (MIN)

Full (MAX)

Full (MAX)

Full (MAX)

2

3

4

5

6

7

A

A

A

A

A

A

A

Working mode

ON

OFF

OFF

OFF

OFF

OFF

OFF

Auto decelerator

OFF

ON

ON

OFF

OFF

OFF

OFF

One-touch power max. switch

Condition

Serial No.

Full (MAX)

Full (MAX)

Full (MAX)

Full (MAX)

Full (MAX)

Full (MAX)

Full (MAX)

2

3

4

5

6

7

8

A

A

A

L

E

A

A

A

Working mode

Boom top on level, no load

Boom top on level, no load

Boom top on level, no load

Boom top on level, no load

Max. reach, no load

Position of work equipment

Push up track shoe 1 side by 1

Max. reach

Engine speed

Blow-by pressure

Engine speed

Engine oil pressure

Engine speed

Engine oil pressure

Engine speed

Measured item

Travel (5 turns)

Swing (5 turns)

Hi

Lo

Bucket CURL

Arm IN (*1)

Arm IN (*1)

Arm IN (*1)

Arm OUT (*1)

Boom RAISE (*1)

Measured item

Left

Right

19.7 – 24.1

19.7 – 24.1

36.9 – 55.3

36.9 – 55.3

Right Left

23.8 – 33.4

23.8 – 33.4

2.6 – 3.2

3.7 – 5.1

3.0 – 3.8

2.8 – 3.6

2.8 – 3.4

3.3 – 4.1

Standard value for new machine

Left

Right

sec

Unit

1,300 – 1,500

0.98 {100}

2,080 – 2,280

0.15 {1.5}

1,050 – 1,150

0.25 {2.5}

2,250 – 2,450

Service limit value

20.1 – 26.1

20.1 – 26.1

36.9 – 55.3

36.9 – 55.3

22.8 – 34.4

22.8 – 34.4

Max. 3.7

Max. 5.4

Max. 4.6

Max. 4.4

Max. 3.7

Max. 4.3

Service limit value

Standard value

1,300 – 1,500

Max. 0.49{Max. 50}

kPa{mmH2O} rpm

2,080 – 2,280

Min. 0.18{Min. 1.8}

1,050 – 1,150

rpm

MPa{kg/cm }

2

0.34–0.54{3.5–5.5}

MPa{kg/cm2} rpm

2,250 – 2,450

Standard value for new machine

Standard value

Date of inspection

rpm

Unit

User's name

Hydraulic oil temperature: 45 – 55 °C

All levers in neutral

Arm DUMP relief

Arm DUMP relief

All levers in neutral

All levers in neutral

All levers in neutral

All levers in neutral

Operation of work equipment

Service meter

Arm top and boom foot on level, no load

*1: Until cylinder cushion starts working

Full (MAX)

Fuel control dial

1

No.

Condition

2. Work equipment, switch, and travel speed

Full (MAX)

Fuel control dial

1

No.

1. Engine

Model

Measured value

Measured value

Judgmen

Good/Bad

Good/Bad

Good/Bad

Judgment

Inspector

PC130-7

20-171

(1)

Full (MAX)

Full (MAX)

Full (MAX)

5

6

A

A

A

A

A

Full (MAX)

Full (MAX)

A

A

Full (MAX)

Full (MAX)

A

Full (MAX)

Fuel control Working dial mode

4

3

2

1

No.

Condition

OFF

OFF

OFF

OFF

OFF

OFF

OFF

OFF

OFF

OFF

OFF

OFF

OFF

ON

OFF

OFF

Lowering distance of bucket tip (in 15 min)

Measured item

Swing relief pressure (Motor safety valve)

Swing lock (Switch: LOCK)

60kg/cm2

(4)

Right front

PC control pressure (PC valve)

Left rear (1):(3)=1:0.5

{370–400kg/cm2}

36.3–39.2MPa

Left

{21.5–23.5kg/cm2}

2.1–2.3MPa

{21–38kg/cm2}

1.96–3.7MPa

{370–400kg/cm2}

36.3–39.2MPa

{343–378kg/cm2}

33.3–37.0MPa

{29–35kg/cm2}

2.84–3.43MPa

Point (Service limit value)

Good/Bad

Judgment

28.9–32.9MPa

Servo inlet Control basic pressure pressure

600kg/cm2

(3)

Measured value

{295–335kg/cm2}

LS pressure

600kg/cm2

600kg/cm2 Pump pressure

(2)

Max. 700

(1)

Max. 460

Service limit value

Standard value Standard value for new machine

{kg/cm2}

MPa

Unit

mm

Unit

Right

LS differential pressure (LS valve: Operated)

LS differential pressure (LS valve: Neutral)

Pump relief pressure (Main relief valve: High pressure)

Pump relief pressure (Main relief valve: Low pressure)

Control basic pressure (Self-reducing pressure valve)

Travel relief pressure Right rear Travel lock (Main relief valve) (With sprocket fixed) (Motor safety valve) Left front

Swing lock (Switch: LOCK)

Idle travel (With shoe raised)

All levers in neutral

Arm DUMP relief

Arm DUMP relief

All levers in neutral

Measured item (Tested part)

Hydraulic oil temperature: 45 – 55 °C

Arm top and boom foot on level, rated load on bucket

Position of work equipment

Condition

Hydraulic oil temperature: 45 – 55 °C

Auto One-touch power Operation of work decelerator max. switch equipment

Working mode

Engine stopped

Fuel control dial

4. Oil pressure

1

No.

3. Hydraulic drift of work equipment

TROUBLESHOOTING POINTS TO REMEMBER WHEN TROUBLESHOOTING ......................................................................... 20-202 SEQUENCE OF EVENTS IN TROUBLESHOOTING ................................................................................ 20-203 POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE ...................................................... 20-204 INSPECTION BEFORE TROUBLESHOOTING ........................................................................................ 20-212 CLASSIFICATION OF AND PROCEDURES FOR TROUBLESHOOTING ............................................... 20-213 CONNECTOR ARRANGEMENT DRAWING AND ELECTRIC CIRCUIT DIAGRAM OF EACH SYSTEM ....... 20-217 CONNECTION TABLE FOR CONNECTOR PIN NUMBERS .................................................................... 20-234 T-BRANCH BOX AND T-BRANCH TABLE ............................................................................................... 20-257

PC130-7

20-201 (1)

TROUBLESHOOTING

POINTS TO REMEMBER WHEN TROUBLESHOOTING

POINTS TO REMEMBER WHEN TROUBLESHOOTING k Stop the machine in a level place, and check that the safety pin, blocks, and parking brake are securely fitted. k 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.

k If the radiator cap is removed when the engine is hot, hot water may spurt out and cause burns, so wait for

the engine to cool down before starting troubleshooting.

k Be extremely careful not to touch any hot parts or to get caught in any rotating parts.

k When disconnecting wiring, always disconnect the negative (–) terminal of the battery first.

k When removing the plug or cap from a location which is under pressure from oil, water, or air, always release

the internal pressure first. When installing measuring equipment, be sure to connect it properly. The aim of troubleshooting is to pinpoint the basic cause of the failure, to carry out repairs swiftly, and to prevent reoccurrence of the failure. When carrying out troubleshooting, and important point is of course to understand the structure and function. However, a short cut to effective troubleshooting is to ask the operator various questions to form some idea of possible causes of the failure that would produce the reported symptoms. 1. When carrying out troubleshooting, do not hurry to disassemble the components. If components are disassembled immediately any failure occurs: • Parts that have no connection with the failure or other unnecessary parts will be disassembled. • It will become impossible to find the cause of the failure. It will also cause a waste of manhours, parts, or oil or grease, and at the same time, will also lose the confidence of the user or operator. For this reason, when carrying out troubleshooting, it is necessary to carry out thorough prior investigation and to carry out troubleshooting in accordance with the fixed procedure. 2. Points to ask user or operator 1) Have any other problems occurred apart from the problem that has been reported? 2) Was there anything strange about the machine before the failure occurred? 3) Did the failure occur suddenly, or were there problems with the machine condition before this? 4) Under what conditions did the failure occur? 5) Had any repairs been carried out before the failure? When were these repairs carried out? 6) Has the same kind of failure occurred before? 3. Check before troubleshooting 1) Check the oil level 2) Check for any external leakage of oil from the piping or hydraulic equipment. 3) Check the travel of the control levers. 4) Check the stroke of the control valve spool.

20-202 (1)

5) Other maintenance items can be checked externally, so check any item that is considered to be necessary. 4. Confirming failure • Confirm the extent of the failure yourself, and judge whether to handle it as a real failure or as a problem with the method of operation, etc. a When operating the machine to reenact the troubleshooting symptoms, do not carry out any investigation or measurement that may make the problem worse. 5. Troubleshooting • Use the results of the investigation and inspection in Items 2 – 4 to narrow down the causes of failure, then use the troubleshooting flowchart to locate the position of the failure exactly. a The basic procedure for troubleshooting is as follows. 1) Start from the simple points. 2) Start from the most likely points. 3) Investigate other related parts or information. 6. Measures to remove root cause of failure • Even if the failure is repaired, if the root cause of the failure is not repaired, the same failure will occur again. To prevent this, always investigate why the problem occurred. Then, remove the root cause.

PC130-7

TROUBLESHOOTING

SEQUENCE OF EVENTS IN TROUBLESHOOTING

SEQUENCE OF EVENTS IN TROUBLESHOOTING

PC130-7

20-203 (1)

TROUBLESHOOTING

POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE

POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE To maintain the performance of the machine over a long period, and to prevent failures or other troubles before they occur, correct operation, maintenance and inspection, troubleshooting, and repairs must be carried out. This section deals particularly with correct repair procedures for mechatronics and is aimed at improving the quality of repairs. For this purpose, it gives sections on “Handling electric equipment“ and “Handling hydraulic equipment” (particularly gear oil and hydraulic oil). 1. Points to remember when handling electric equipment 1) Handling wiring harnesses and connectors Wiring harnesses consist of wiring connecting one component to another component, connectors used for connecting and disconnecting one wire from another wire, and protectors or tubes used for protecting the wiring. Compared with other electrical components fitted in boxes or cases, wiring harnesses are more likely to be affected by the direct effects of rain, water, heat, or vibration. Furthermore, during inspection and repair operations, they are frequently removed and installed again, so they are likely to suffer deformation or damage. For this reason, it is necessary to be extremely careful when handling wiring harnesses. Main failures occurring in wiring harness 1) Defective contact of connectors (defective contact between male and female) Problems with defective contact are likely to occur because the male connector is not properly inserted into the female connector, or because one or both of the connectors is deformed or the position is not correctly aligned, or because there is corrosion or oxidization of the contact surfaces.

2) Defective crimping or soldering of connectors The pins of the male and female connectors are in contact at the crimped terminal or soldered portion, but if there is excessive force brought to bear on the wiring, the plating at the joint will peel and cause improper connection or breakage.

20-204 (1)

PC130-7

TROUBLESHOOTING

POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE

3) Disconnections in wiring If the wiring is held and the connectors are pulled apart, or components are lifted with a crane with the wiring still connected, or a heavy object hits the wiring, the crimping of the connector may separate, or the soldering may be damaged, or the wiring may be broken.

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. As already said, the connector is designed to prevent water from entering, but at the same time, if water does enter, it is difficult for it to be drained. Therefore, if water should get into the connector, the pins will be short-circuited by the water, so if any water gets in, immediately dry the connector or take other appropriate action before passing 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 stuck to the connector, wipe it off with a dry cloth or blow it dry with compressed air and spray it with a contact restorer. a When wiping the mating portion of the connector, be careful not to use excessive force or deform the pins. a If there is oil or water in the compressed air, the contacts will become even dirtier, so remove the oil and water from the compressed air completely before cleaning with compressed air.

PC130-7

20-205 (1)

TROUBLESHOOTING

POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE

2) Removing, installing, and drying connectors and wiring harnesses •

Disconnecting connectors 1) Hold the connectors when disconnecting. When disconnecting the connectors, hold the connectors and not the wires. For 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. a Never pull with one hand. 2) When removing from clips When removing a connector from a clip, pull the connector in a parallel direction to the clip. a If the connector is twisted up and down or to the left or right, the housing may break.

3) Action to take after removing connectors After removing any connector, cover it with a vinyl bag to prevent any dust, dirt, oil, or water from getting in the connector portion. a If the machine is left disassembled for a long time, it is particularly easy for improper contact to occur, so always cover the connector.

20-206 (1)

PC130-7

TROUBLESHOOTING

•

POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE

Connecting connectors 1) Check the connector visually. 1) Check that there is no oil, dirt, or water stuck to the connector pins (mating portion). 2) Check that there is no deformation, defective contact, corrosion, or damage to the connector pins. 3) Check that there is no damage or breakage to the outside of the connector. a 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. a If there is any damage or breakage, replace the connector. 2) Fix the connector securely. Align the position of the connector correctly, then insert it securely. For connectors with lock stopper, push in the connector until the stopper clicks into position. 3) Correct any protrusion of the boot and any misalignment of the wiring harness For connectors fitted with boots, correct any protrusion of the boot. In addition, if the wiring harness is misaligned, or the clamp is out of position, adjust it to its correct position. a If the connector cannot be corrected easily, remove the clamp and adjust the position. 4) If the connector clamp has been removed, be sure to return it to its original position. Check also that there are no loose clamps.

•

Connecting connectors (DT type connector) Since the DT 8-pole and 12-pole DT type connectors have 2 latches respectively, push them in until they click 2 times. 1. Male connector, 2. Female connector • Normal locking state (Horizontal): a, b, d • Incomplete locking state (Diagonal): c

PC130-7

20-207 (1)

TROUBLESHOOTING

•

POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE

Drying wiring harness If there is any oil or dirt on the wiring harness, wipe it off with a dry cloth. Avoid washing it in water or using steam. If the connector must be washed in water, do not use high-pressure water or steam directly on the wiring harness. If water gets directly on the connector, do as follows. 1) Disconnect the connector and wipe off the water with a dry cloth. a If the connector is blown dry with compressed air, there is the risk that oil in the air may cause defective contact, so remove all oil and water from the compressed air before blowing with air. 2) Dry the inside of the connector with a dryer. If water gets inside the connector, use a dryer to dry the connector. a Hot air from the dryer can be used, but regulate the time that the hot air is used in order not to make the connector or related parts too hot, as this will cause deformation or damage to the connector.

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. a After completely drying the connector, blow it with contact restorer and reassemble.

20-208 (1)

PC130-7

TROUBLESHOOTING

POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE

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

3) Do not place objects on top of the control box. 4) Cover the control connectors with tape or a vinyl bag. Never touch the connector contacts with your hand. 5) During rainy weather, do not leave the 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.

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

PC130-7

20-209 (1)

TROUBLESHOOTING

POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE

3. Points to remember when handling hydraulic equipment With the increase in pressure and precision of hydraulic equipment, the most common cause of failure is dirt (foreign material) in the hydraulic circuit. When adding hydraulic oil, or when disassembling or assembling hydraulic equipment, it is necessary to be particularly careful. 1) Be careful of the operating environment. Avoid adding hydraulic oil, replacing filters, or repairing the machine in rain or high winds, or places where there is a lot of dust. 2) Disassembly and maintenance work in the field If disassembly or maintenance work is carried out on hydraulic equipment in the field, there is danger of dust entering the equipment. It is also difficult to confirm the performance after repairs, so it is desirable to use unit exchange. Disassembly and main-tenance of hydraulic equipment should be carried out in a specially prepared dustproof workshop, and the performance should be confirmed with special test equipment. 3) Sealing openings After any piping or equipment is removed, the openings should be sealed with caps, tapes, or vinyl bags to prevent any dirt or dust from entering. If the opening is left open or is blocked with a rag, there is danger of dirt entering or of the surrounding area being made dirty by leaking oil so never do this. Do not simply drain oil out on to the ground, collect it and ask the customer to dispose of it, or take it back with you for disposal.

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

20-210 (1)

PC130-7

TROUBLESHOOTING

POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE

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. (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: primary flushing is carried out with flushing oil, and secondary flushing is carried out with the specified hydraulic oil.

7) Cleaning operations After repairing the hydraulic equipment (pump, c o n tr o l v a lv e , e t c .) o r wh e n r u n ni n g t he 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 3µ) particles that the filter built into the hydraulic equipment cannot remove, so it is an extremely effective device.

PC130-7

20-211 (1)

TROUBLESHOOTING

INSPECTION BEFORE TROUBLESHOOTING

INSPECTION BEFORE TROUBLESHOOTING

1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12.

Hydraulic and Electrical mechanical equipment equipment

Lubricating oil/Coolant

Item Check of level and type of fuel Check of fuel for foreign matter Check of fuel filter cartridge for clogging Check of level and type of oil in engine oil pan Check of engine oil filter for clogging Check of coolant level Check of air cleaner for clogging Check of level and type of hydraulic oil Check of hydraulic oil strainer for clogging Check of hydraulic oil filter for clogging Check of level and type of swing machinery oil Check of level and type of final drive oil

Add fuel Clean or drain Replace Add oil Replace Add coolant Clean or replace Add oil Clean or drain Replace Add oil Add oil

1. Check of battery terminal wires for looseness and corrosion 2. Check of alternator terminal wires for looseness and corrosion 3. Check of starting motor terminal wires for looseness and corrosion

— — —

Retighten or replace Retighten or replace Retighten or replace

1. Check for abnormal sound and smell 2. Check for oil leakage 3. Air bleeding operation

— — —

Repair Repair Bleed air

Electrical parts

3. 4. 5. 6. 7.

8.

(1)

Remedy

— — — — — — — — — — — —

1. Check of battery voltage (with engine stopped) 2. Check of electrolyte level

20-212

Criterion

20 – 30V —

Charge or replace Add distilled water or replace electrolyte Check of wires for discoloration, burn, and removal of covers — Replace Check of wires for removal of clamps and looseness — Repair Check of wires for wetting with water (Particularly check connectors and — Disconnect and dry terminals for wetting) connectors Check of fuses for breakage and corrosion — Replace Check of alternator voltage (with engine at medium or higher speed) Must be 27.5 - Replace 29.5 V after operation of several minutes. Check of operating sound of battery relay (when starting switch is — Replace turned OFF and ON)

PC130-7

TROUBLESHOOTING

CLASSIFICATION OF AND PROCEDURES FOR TROUBLESHOOTING

CLASSIFICATION OF AND PROCEDURES FOR TROUBLESHOOTING Classification of troubleshooting Mode Code display

Contents Troubleshooting when error code is displayed

E-mode

Troubleshooting for electric system

H-mode

Troubleshooting for hydraulic and mechanical system

S-mode

Troubleshooting for engine unit

Procedure for troubleshooting If a phenomenon looking like a trouble occurs in the machine, select a proper troubleshooting No. according to the following procedure, and then go to the corresponding troubleshooting section. 1. Procedure for troubleshooting to be taken when user code is displayed on monitor panel: If a user code is displayed on the monitor panel, display the error code by using the error code display function of the monitor panel. Carry out the troubleshooting for the corresponding "Code display" according to the displayed error code. 2. Procedure for troubleshooting when electrical system error code or mechanical system error code is recorded in error history: If a user code is not displayed on the monitor panel, check the error code with the error code display function of the monitor panel. If the error code is recorded, carry out troubleshooting for the corresponding "Code display" according to the displayed error code. a If error codes are recorded, delete all of them and reproduce them, and then see if the trouble is still detected. a If an error code is still output, the mark of "E" is displayed at the left end of the lower line. 3. Procedure for troubleshooting to be taken when user code is not displayed and error history is not recorded: If a user code is not displayed in the monitor panel and an error code is not recorded, a trouble that the machine cannot find out by itself may have occurred in the electrical system or hydraulic and mechanical system. In this case, check the phenomenon looking like a trouble again and select the same phenomenon from the table of "Phenomena looking like troubles and troubleshooting Nos.", and then carry out troubleshooting related to that phenomenon in the "E mode", "H mode", or "S mode".

PC130-7

20-213 (1)

TROUBLESHOOTING

CLASSIFICATION OF AND PROCEDURES FOR TROUBLESHOOTING

Phenomena looking like troubles and troubleshooting Nos. Troubleshooting No.

Phenomenon looking like trouble

Code display

E-mode

H-mode

S-mode

Phenomena related to user code or error code 1

User codes are displayed on monitor panel

2

If error code display function is checked, error codes are displayed

According to displayed code

Phenomena related to engine 3

Engine does not start easily (It always takes time to start)

S-1

4

Engine does not crank

5

Engine cranks but exhaust smoke does not come out (Fuel is not injected)

S-2 b)

6

Exhaust smoke comes out but engine does not start (Fuel is injected)

S-2 c)

7

Engine speed does not rise sharply (Follow-up performance is low)

8

Engine stops during operation

E-2

S-4

9

Engine rotation is abnormal (Engine hunts)

E-3

S-5

10

Output is insufficient (Power is low)

S-6

11

Exhaust gas color is bad (Incomplete combustion)

S-7

12

Oil is consumed much (or exhaust gas color is bad)

S-8

13

Oil becomes dirty quickly

S-9

14

Fuel is consumed much

S-10

15

Coolant contains oil (or it blows back or reduces)

S-11

16

Engine oil pressure caution lamp lights up (Oil pressure lowers)

S-12

17

Oil level rises (Water or fuel is mixed in oil)

S-13

18

Water temperature rises too high (Overheating)

S-14

19

Abnormal sound comes out

S-15

20

Vibration is excessive

S-16

21

Engine does not stop

E-4

22

Auto-decelerator does not operate

E-5

23

Automatic warm-up system does not operate

E-6

24

Preheater does not operate

E-7

Engine does not start

E-1

S-2 a)

S-3

H-5

Phenomena related to work equipment, swing, and travel 25

Speed or power of whole work equipment, travel, and swing is low

H-1

S-6

26

Engine speed lowers extremely or engine stalls

H-2

S-4

27

Work equipment, travel, and swing systems do not work

28

Abnormal sound comes out from around hydraulic pump

H-4

29

Fine control performance or response is low

H-6

20-214 (1)

E-8

H-3

PC130-7

TROUBLESHOOTING

CLASSIFICATION OF AND PROCEDURES FOR TROUBLESHOOTING

Troubleshooting No.

Phenomenon looking like trouble

Code display

E-mode

H-mode

S-mode

Phenomena related to work equipment 30

Speed or power of boom is low

H-7

31

Speed or power of arm is low

H-8

32

Speed or power of bucket is low

H-9

33

Work equipment does not move singly

H-10

34

Hydraulic drift of work equipment is large

H-11

35

Time lag of work equipment is large

H-12

36

One-touch power maximizing function does not work

E-9

H-13

Phenomena related to compound operation 37

In compound operation of work equipment, speed of part loaded more is low

H-14

38

When machine swings and raises boom simultaneously, boom rising speed is low

H-15

39

When machine operates work equipment or swings and travels simultaneously, travel speed lowers largely

H-16

Phenomena related to travel 40

Machine deviates during travel

H-17

41

Travel speed is low

H-18

42

Machine is not steered well or steering power is low

H-19

43

Travel speed does not change

H-20

44

Travel motor does not work (only 1 side)

H-21

45

Travel alarm does not sound or does not stop sounding

E-33

Phenomena related to swing 46

Upper structure does not swing

H-22

47

Swing acceleration or swing speed is low

H-23

48

Upper structure overruns remarkably when it stops swinging

H-24

49

Large shock is made when upper structure stops swinging

H-25

50

Large sound is made when upper structure stops swinging

H-26

51

Hydraulic drift of swing is large

H-27

Phenomena related to monitor panel (Operator menu: Ordinary screen) 52

No items are displayed on monitor panel

E-10

53

7-segment LED's of monitor panel display partially

E-11

54

Monitor lamp of monitor panel is different from mounted model

E-12

55

When starting switch is turned ON, basic check items light up or flash

E-13

56

While engine is running, caution items flash

E-14

57

While engine is running, emergency stop items flash

E-15

58

Engine coolant thermometer does not display normally

E-16

59

Fuel level gauge does not display normally

E-17

60

Swing lock monitor does not display normally

E-18

PC130-7

20-215 (1)

TROUBLESHOOTING

CLASSIFICATION OF AND PROCEDURES FOR TROUBLESHOOTING

Troubleshooting No.

Phenomenon looking like trouble

Code display

E-mode

61

When monitor switches are operated, display by lamps does not change

E-19

62

Windshield wiper or windshield washer does not operate

E-20

63

Lower wiper does not operate

E-21

64

Caution buzzer cannot be stopped

E-22

H-mode

S-mode

Phenomena related to monitor panel (Service menu: Special function screen) 65

Monitoring function does not display "Boom RAISE" normally

E-23

66

Monitoring function does not display "Boom LOWER" normally

E-24

67

Monitoring function does not display "Arm IN" normally

E-25

68

Monitoring function does not display "Arm OUT" normally

E-26

69

Monitoring function does not display "Bucket CURL" normally

E-27

70

Monitoring function does not display "Bucket DUMP" normally

E-28

71

Monitoring function does not display "Swing" normally

E-29

72

Monitoring function does not display "Travel" normally

E-30

73

Monitoring function does not display "Service" normally

E-31

Other phenomena 74

Air conditioner does not operate (Troubleshooting for air conditioner system)

20-216 (1)

E-32

PC130-7

CONNECTOR ARRANGEMENT DRAWING AND ELECTRIC CIRCUIT DIAGRAM OF EACH SYSTEM

TROUBLESHOOTING

CONNECTOR ARRANGEMENT DRAWING AND ELECTRIC CIRCUIT DIAGRAM OF EACH SYSTEM Connectors list

Connector No A01 A02 A03 A04 A05 A06 A07 A09 A10 A11 A12 A13 A14 A15 A16 A20 A21 A22 A23 A25 A26 A27 A29 A31 A33 A34 A35 A41 A42 A43 A44 A50 A50 A51 A60 A61 A70 A71K A80 A95 A96 A97 A98 A99

PC130-7

Type X X DT SWP SWP SWP SWP SWP Terminal Terminal Terminal Terminal Terminal Terminal Terminal Terminal Terminal Terminal Terminal Terminal Terminal X Terminal D X L M 090-II X X One-pin connector X KES0 D X D D D — D D D D SWP

a The address of each connector roughly shows the place of the connector in the connectors stereogram and the circuit diagram of each system. No. of pins

Name of device

Stereogram S-1 T-1 N-3 N-1 T-1 N-1 S-1 N-2 I-1 I-2 I-2 I-2 L-1 J-2 J-2 L-2 L-2 K-2 K-3 K-1 K-1 L-1 K-2 L-7 L-5 L-3 L-3 G-1 G-9 I-9

4 4 12 6 14 14 16 8 1 1 1 1 1 1 1 1 1 1 1 1 1 2 1 2 2 2 2 1 1 2

Intermediate connector Intermediate connector Intermediate connector Intermediate connector Intermediate connector Intermediate connector Intermediate connector Intermediate connector Revolving frame ground Revolving frame ground Revolving frame ground Revolving frame ground Revolving frame ground Revolving frame ground Revolving frame ground Battery relay (Terminal E) Battery relay (Terminal BR) Battery relay (Terminal M) Battery relay (Terminal B) Heater relay (Coil) Heater relay (Contact) Starting motor safety relay (Terminals S, R) Starting motor safety relay (Terminals C) Air cleaner clogging switch Radiator coolant level sensor Fusible link (65A) Fusible link (30A) Horn Intermediate connector Travel alarm (If equipped)

1

Working lamp (Right front)

D-9

2 2 3 1 2 3 2 4 2 2 2 2 8

Intermediate connector Windshield washer motor (Tank) Pump oil pressure sensor Fuel level sensor Hydraulic oil temperature sensor Overload alarm pressure sensor (If equipped) Fuel priming pump (If equipped) Spare connector Spare connector Spare connector Spare connector Spare connector Intermediate connector

E-9 E-9 I-9 G-9 K-9 G-9 G-1 R-1 K-8 K-8 L-8 L-8 N-2

Address MGcircuit circuit H-7 I-8 H-7 I-8 H-6 I-6 H-6 H-6 H-4 I-1 I-1 I-1 I-1 I-1 I-1 I-1 J-3 J-2 J-2 J-2 K-3 K-3 K-3 K-3 K-5 K-5 K-7 K-7

I-7 G-1

G-1 H-1

Pcircuit H-8 H-7 H-7 H-7 H-6 H-5 H-5 H-5 I-1

I-1 J-1 J-1

J-4 J-3 K-4 K-3 K-7 K-7 K-5 L-5

L-3 L-3

G-2 K-5 H-1

K-6 K-6 K-5 K-6 A-70

H-3

H-4

20-217 (1)

CONNECTOR ARRANGEMENT DRAWING AND ELECTRIC CIRCUIT DIAGRAM OF EACH SYSTEM

TROUBLESHOOTING

Connector No

Type

No. of pins

C01 C02 C03 C09 D01 D02 D03 E01 E02 E03 E04 E05 E06 E06 E08 E10 E11 E12 F02A F02B FB1 H07 H08 H09 H10 H11 H12 H15 J01 J02 J03 J04 J05 J06 J07 J08 J09 J10 K19 K30 K31 M07 M09 M13 M19 M21 M22 M23 M26 M27 M29

DRC DRC DRC S SWP SWP SWP Terminal Terminal D D D M X X D D X SWP DT — M M S S S S 090 J J J J J J J J J J M DT DT M M — — PA 090 090 SWP — 040

24 40 40 8 8 8 8 1 1 2 2 2 3 1 2 3 4 2 2 2 — 2 8 8 16 16 12 20 20 20 20 20 20 20 20 20 20 20 2 3 3 3 1 2 2 9 6 8 12 16 20

20-218 (1)

Name of device Governor and pump controller Governor and pump controller Governor and pump controller Model selection connector Concentrated diode Concentrated diode Concentrated diode Electrical intake air heater Engine oil pressure switch Engine oil level switch Engine speed sensor Engine coolant temperature sensor Fuel control dial Air conditioner compressor magnetic clutch Intermediate connector Governor potentiometer Governor motor Alternator [35-A alternator specification] Intermediate connector Rotary lamp (If equipped) Fuse box Intermediate connector Intermediate connector Intermediate connector Intermediate connector Intermediate connector Intermediate connector Intermediate connector Junction connector (Black) Junction connector (Black) Junction connector (Green) Junction connector (Green) Junction connector (Pink) Junction connector (Orange) Junction connector (Orange) Junction connector (Pink) Junction connector (Pink) Junction connector (Orange) Pump resistor (For driving pump in emergency) CAN terminal resistance CAN terminal resistance Light switch Working lamp (Boom front) Speaker (Right) Cigarette lighter Radio (If equipped) Right lever knob switch Left lever knob switch Intermediate connector Air conditioner unit Air conditioner control panel

Stereogram U-9 V-9 W-9 U-9 W-9 W-8 W-3 J-9 K-8 K-8 H-9 K-8 O-8 J-8 L-7 J-9 J-8 J-2 AA-9 AA-9 U-2 Y-5 W-6 W-6 S-9 S-9 S-9 N-7 T-9 V-3 V-3 V-3 V-3 W-3 W-4 W-4 W-3 W-3 W-3 W-7 N-4 P-8 F-9 AC-8 N-3 U-2 N-7 T-1 W-4 W-5 U-2

Address MGcircuit circuit A-4 A-8 A-3 A-7 A-3 A-4 C-8 A-8 D-1 A-8 D-1 L-3 L-7 L-4 K-6

Pcircuit A-8 A-7 A-4 G-8

K-9 K-5 F-1 K-4

K-2

I-1 K-6 K-6 L-2

J-9

B-1

D-3

I-9 I-9 I-8

B-9

J-8 J-8 C-7 C-6 C-5 C-3 C-9 C-9 D-9 D-9 E-9 E-9 F-9

E-9 E-9

C-3 C-9 D-9 D-9 E-9 E-9

F-9

E-9

D-9 D-9

F-9 G-9

E-9 G-8

A-3 A-4 B-1 G-1

C-1 L-8

B-8

PC130-7

CONNECTOR ARRANGEMENT DRAWING AND ELECTRIC CIRCUIT DIAGRAM OF EACH SYSTEM

TROUBLESHOOTING

Connector No

Type

No. of pins

M30 M31 M31B M32 M32B M33 M33 M40 M40A M40B M41 M42 M43 M45 M46 M50 M51 M71 M72 M73 M91 M92 P01 P02 P03 P05 P06 P15 P17 P70 R10 R11 R13 R16 R17 R18 R20 R22 R30 R31 S01 S02 S03 S04 S05 S06 S07 S08 S09 S10 S11

— M M M M M SWP SWP SWP SWP SWP X M D 090 AMP AMP M M — M KES0 070 040 M M M Y050 — 040 R R R R R R R R R R X X X X X X X X X X X

16 2 2 2 2 2 8 2 2 2 2 1 1 12 4 8 8 2 4 2 1 4 12 20 2 2 2 2 2 16 5 5 5 5 5 5 5 5 5 5 2 2 2 2 2 2 2 2 2 2 2

PC130-7

Name of device Air conditioner control panel Optional power supply (2) Heated seat (If equipped) Optional power supply (1) Heated seat (If equipped) Heated seat switch (If equipped) Air conditioner unit Headlamp (Left) Intermediate connector Rear lamp (If equipped) Headlamp (Right) Intermediate connector Working lamp (Rear) (If equipped) Network bus connector RS232C junction connector Radio cassette (If equipped) Radio cassette (If equipped) Room lamp DC/DC converter Speaker (Left) Working lamp (Left front) (If equipped) Lower wiper motor Monitor panel Monitor panel Caution buzzer stop switch Rotary lamp switch (If equipped) Lower wiper switch Air conditioner daylight sensor (If equipped) Air conditioner high/low pressure switch Monitor panel Light relay (1) Starting motor cutout relay (PPC lock) Starting motor cutout relay (Personal code) Light relay (2) 12-V selector relay Lower wiper relay Spare connector Spare connector Air conditioner blower relay Air conditioner compressor relay Bucket CURL pressure switch Boom LOWER oil pressure switch Swing LEFT oil pressure switch Arm IN pressure switch Bucket DUMP oil pressure switch Boom RAISE oil pressure switch Swing RIGHT oil pressure switch Arm OUT oil pressure switch Intermediate connector Service 1 (Front) oil pressure switch (If equipped) Service 1 (Rear) oil pressure switch (If equipped)

Stereogram U-2 W-6 U-2 Y-5 V-2 W-2 W-6 Z-8 AA-8 AC-8 Y-7 I-9 I-9 W-8 V-9 AD-8 AD-8 Z-8 W-7 AD-7 H-1 H-1 N-6 N-5 P-9 W-2 W-1 N-6 N-4 N-5 O-8 P-8 Q-9 T-9 W-4 T-9 T-9 U-9 W-6 W-5 L-6 L-4 L-7 L-5 L-6 L-4 L-6 L-5 L-3 L-3 K-3

Address MGcircuit circuit

Pcircuit

K-8 K-8 K-8 K-7 H-2 H-1 B-9

H-8 H-8 A-7 A-6 B-1

L-9 L-9

A-9

F-1

A-5 D-1 D-1 D-1 E-1

L-9 B-9

E-1 C-9 C-9

K-4 K-4 K-3 K-4 K-3 K-5 K-3 K-4 H-3 G-2 G-2

20-219 (1)

CONNECTOR ARRANGEMENT DRAWING AND ELECTRIC CIRCUIT DIAGRAM OF EACH SYSTEM

TROUBLESHOOTING

Connector No

Type

No. of pins

S14 S21 S21 S22 S22 S25 S30 S31 SC T05 T06 T06A T11 T13 T91 T92 V01 V04 V05 V06 V21 V22 V30 W03 W04 X05

M Terminal X Terminal X 090 X X Terminal Terminal Terminal M Terminal D D D D D D D D D X X M M

3 6 2 6 2 16 2 2 1 1 1 1 1 1 1 1 2 2 2 2 2 2 2 2 6 4

20-220 (1)

Name of device Safety lock switch Emergency pump drive switch Service 2 (Front) oil pressure switch (If equipped) Swing holding brake release switch Service 2 (Rear) oil pressure switch (If equipped) Intermediate connector Travel oil pressure switch Spare connector Starting motor (Terminal C) Floor frame ground Radio body ground Intermediate connector Cab ground Intermediate connector Intermediate connector Intermediate connector PPC lock solenoid valve Travel speed shifting solenoid valve Swing holding brake solenoid valve 2-stage relief solenoid PC-EPC solenoid valve LS-EPC solenoid valve Spare connector Window rear limit switch Wiper motor Swing lock switch

Stereogram T-1 R-9 K-3 R-9 K-3 Q-9 O-1 P-1 J-8 V-2 U-2 T-2 AD-3 K-8 K-8 K-8 J-2 J-2 J-3 K-3 K-9 K-9 N-2 AB-9 Y-3 Q-9

Address MGcircuit circuit K-9

K-4 K-4 K-4

Pcircuit F-8 E-2 G-1 F-2 G-1 E-3 A-1 A-1

I-2 I-2 I-1 K-8 K-7 K-7 K-7 K-9 K-8 A-1

K-8 A-9 C-1

C-2

PC130-7

TROUBLESHOOTING

CONNECTOR ARRANGEMENT DRAWING AND ELECTRIC CIRCUIT DIAGRAM OF EACH SYSTEM

STEREOGRAM OF CONNECTORS

20-222 (1)

PC130-7

TROUBLESHOOTING

PC130-7

CONNECTOR ARRANGEMENT DRAWING AND ELECTRIC CIRCUIT DIAGRAM OF EACH SYSTEM

20-223 (1)

TROUBLESHOOTING

20-224 (1)

CONNECTOR ARRANGEMENT DRAWING AND ELECTRIC CIRCUIT DIAGRAM OF EACH SYSTEM

PC130-7

TROUBLESHOOTING

PC130-7

CONNECTOR ARRANGEMENT DRAWING AND ELECTRIC CIRCUIT DIAGRAM OF EACH SYSTEM

20-225 (1)

TROUBLESHOOTING

20-226 (1)

CONNECTOR ARRANGEMENT DRAWING AND ELECTRIC CIRCUIT DIAGRAM OF EACH SYSTEM

PC130-7

TROUBLESHOOTING

CONNECTOR ARRANGEMENT DRAWING AND ELECTRIC CIRCUIT DIAGRAM OF EACH SYSTEM

CIRCUIT DIAGRAM OF MONITOR PANEL SYSTEM (M-CIRCUIT)

20-228 (1)

PC130-7

TROUBLESHOOTING

CONNECTOR ARRANGEMENT DRAWING AND ELECTRIC CIRCUIT DIAGRAM OF EACH SYSTEM

a This circuit diagram is made by excerpting the monitor panel system, engine preheating/starting/charging system, lower wiper system, and light system from the general electric circuit diagram.

PC130-7

20-229 (3)

TROUBLESHOOTING

CONNECTOR ARRANGEMENT DRAWING AND ELECTRIC CIRCUIT DIAGRAM OF EACH SYSTEM

CIRCUIT DIAGRAM OF ENGINE THROTTLE CONTROL SYSTEM OF GOVERNOR AND PUMP CONTROLLER (G-CIRCUIT)

20-230 (1)

PC130-7

TROUBLESHOOTING

CONNECTOR ARRANGEMENT DRAWING AND ELECTRIC CIRCUIT DIAGRAM OF EACH SYSTEM

a This circuit diagram is made by excerpting the governor and pump controller system (engine throttle/power supply/model selection/communication system) from the general electric circuit diagram.

PC130-7

20-231 (1)

TROUBLESHOOTING

CONNECTOR ARRANGEMENT DRAWING AND ELECTRIC CIRCUIT DIAGRAM OF EACH SYSTEM

CIRCUIT DIAGRAM OF PUMP CONTROL SYSTEM OF GOVERNOR AND PUMP CONTROLLER (P-CIRCUIT)

20-232 (1)

PC130-7

TROUBLESHOOTING

CONNECTOR ARRANGEMENT DRAWING AND ELECTRIC CIRCUIT DIAGRAM OF EACH SYSTEM

a This circuit diagram is made by excerpting the governor and pump controller system (pump control), PPC lock system, and travel alarm system from the general electric circuit diagram.

PC130-7

20-233 (1)

TROUBLESHOOTING

CONNECTION TABLE FOR CONNECTOR PIN NUMBERS

CONNECTION TABLE FOR CONNECTOR PIN NUMBERS a The terms male and female refer to the pins, while the terms male housing and female housing refer to the mating portion of the housing.

X type connector

No.of pins

Male (female housing)

Female (male housing)

T-adapter Part No.

1

Part No.: 08055-00181

Part No.: 08055-00191

799-601-7010

2

799-601-7020

Part No.: 08055-00282

Part No.: 08055-00292

3

799-601-7030

Part No.: 08055-00381

Part No.: 08055-00391

4

799-601-7040

Part No.: 08055-00481

Part No.: 08055-00491

—

Terminal part No.: 79A-222-3370 • Electric wire size: 0.85 • Grommet: Black • Q’ty: 20

Terminal part No.: 79A-222-3390 • Electric wire size: 0.85 • Grommet: Black • Q’ty : 20

—

—

Terminal part No.: 79A-222-3380 • Electric wire size: 2.0 • Grommet: Red • Q’ty: 20

Terminal part No.: 79A-222-3410 • Electric wire size: 2.0 • Grommet: Red • Q’ty: 20

—

20-234 (1)

PC130-7

TROUBLESHOOTING

No.of pins

CONNECTION TABLE FOR CONNECTOR PIN NUMBERS

SWP type connector Male (female housing)

Female (male housing)

6

799-601-7050

Part No.: 08055-10681

Part No.: 08055-10691

8

799-601-7060

Part No.: 08055-10881

Part No.: 08055-10891

12

799-601-7310

Part No.: 08055-11281

Part No.: 08055-11291

14

799-601-7070

Part No.: 08055-11481

PC130-7

T-adapter Part No.

Part No.: 08055-11491

20-235 (1)

TROUBLESHOOTING

CONNECTION TABLE FOR CONNECTOR PIN NUMBERS

SWP type connector

No. of pins

Male (female housing)

Female (male housing)

16

T-adapter Part No.

799-601-7320

Part No.: 08055-11681

Part No.: 08055-11691

—

Terminal part No.: • Electric wire size: 0.85 • Grommet: Black • Q’ty: 20

Terminal part No.: • Electric wire size: 0.85 • Grommet: Black • Q’ty: 20

—

—

Terminal part No.: • Electric wire size: 1.25 • Grommet: Red • Q’ty: 20

Terminal part No.: • Electric wire size: 1.25 • Grommet: Red • Q’ty: 20

—

20-236 (1)

PC130-7

TROUBLESHOOTING

CONNECTION TABLE FOR CONNECTOR PIN NUMBERS

M type connector

No.of pins

Male (female housing)

Female (male housing)

T-adapter Part No.

1

Part No.: 08056-00171

Part No.: 08056-00181

799-601-7080

2

799-601-7090

Part No.: 08056-00271

Part No.: 08056-00281

3

799-601-7110

Part No.: 08056-00371

Part No.: 08056-00381

4

799-601-7120

Part No.: 08056-00471

Part No.: 08056-00481

6

799-601-7130

Part No.: 08056-00671

Part No.: 08056-00681

8

799-601-7340

Part No.: 08056-00871

PC130-7

Part No.: 08056-00881

20-237 (1)

TROUBLESHOOTING

No.of pins

CONNECTION TABLE FOR CONNECTOR PIN NUMBERS

S type connector Male (female housing)

Female (male housing)

8

799-601-7140

Part No.: 08056-10871

Part No.: 08056-10881

10 (White)

799-601-7150

Part No.: 08056-11071

Part No.: 08056-11081

12 (White)

799-601-7350

Part No.: 08056-11271

Part No.: 08056-11281

16 (White)

799-601-7330

Part No.: 08056-11671

20-238 (1)

T-adapter Part No.

Part No.: 08056-11681

PC130-7

TROUBLESHOOTING

No.of pins

CONNECTION TABLE FOR CONNECTOR PIN NUMBERS

S type connector Male (female housing)

Female (male housing)

10 (Blue)

—

—

—

12 (Blue)

799-601-7160

Part No.: 08056-11272

Part No.: 08056-11282

16 (Blue)

799-601-7170

Part No.: 08056-11672

PC130-7

T-adapter Part No.

Part No.: 08056-11682

20-239 (1)

TROUBLESHOOTING

CONNECTION TABLE FOR CONNECTOR PIN NUMBERS

MIC type connector

No.of pins

Male (female housing)

Female (male housing)

T-adapter Part No.

7

Body part No.: 79A-222-2640 (Q’ty: 5)

Body part No.: 79A-222-2630 (Q’ty: 5)

—

11

Body part No.: 79A-222-2680 (Q’ty: 5)

Body part No.: 79A-222-2670 (Q’ty: 5)

—

5

799-601-2710

Body part No.: 79A-222-2620 (Q’ty: 5)

Body part No.: 79A-222-2610 (Q’ty: 5)

9

799-601-2950

Body part No.: 79A-222-2660 (Q’ty: 5)

Body part No.: 79A-222-2650 (Q’ty: 5)

13

799-601-2720

Body part No.: 79A-222-2710 (Q’ty: 2)

20-240 (1)

Body part No.: 79A-222-2690 (Q’ty: 2)

PC130-7

TROUBLESHOOTING

No.of pins

CONNECTION TABLE FOR CONNECTOR PIN NUMBERS

MIC type connector Male (female housing)

Female (male housing)

17

799-601-2730

Body part No.: 79A-222-2730 (Q’ty: 2)

Body part No.: 79A-222-2720 (Q’ty: 2)

21

PC130-7

T-adapter Part No.

799-601-2740

Body part No.: 79A-222-2750 (Q’ty: 2)

Body part No.: 79A-222-2740 (Q’ty: 2)

Terminal part No.: 79A-222-2770 (Q’ty: 50)

Terminal part No.: 79A-222-2760 (Q’ty: 50)

—

20-241 (1)

TROUBLESHOOTING

No.of pins

CONNECTION TABLE FOR CONNECTOR PIN NUMBERS

AMP040 type connector Male (female housing)

Female (male housing)

8

T-adapter Part No.

799-601-7180

—

Housing part No.: 79A-222-3430 (Q’ty: 5)

12

799-601-7190

—

Housing part No.: 79A-222-3440 (Q’ty: 5)

16

799-601-7210

—

Housing part No.: 79A-222-3450 (Q’ty: 5)

20

799-601-7220

—

Housing part No.: 79A-222-3460 (Q’ty: 5)

a Terminal part No.: 79A-222-3470 (No relation with number of pins)

20-242 (1)

PC130-7

TROUBLESHOOTING

No.of pins

CONNECTION TABLE FOR CONNECTOR PIN NUMBERS

AMP070 type connector Male (female housing)

Female (male housing)

10

799-601-7510

—

Part No.: 08195-10210

12

799-601-7520

—

Part No.: 08195-12210

14

799-601-7530

—

Part No.: 08195-14210

18

799-601-7540

—

Part No.: 08195-18210

20

799-601-7550

—

PC130-7

T-adapter Part No.

Part No.: 08195-20210

20-243 (1)

TROUBLESHOOTING

No.of pins

CONNECTION TABLE FOR CONNECTOR PIN NUMBERS

L type connector Male (female housing)

Female (male housing)

2

—

—

No.of pins

—

Connector for PA Male (female housing)

Female (male housing)

9

—

Bendix MS connector Male (female housing)

Female (male housing)

10

(1)

T-adapter Part No.

799-601-3460

—

20-244

T-adapter Part No.

—

—

No.of pins

T-adapter Part No.

—

PC130-7

TROUBLESHOOTING

CONNECTION TABLE FOR CONNECTOR PIN NUMBERS

KES 1 (Automobile) connector

No.of pins

Male (female housing)

Female (male housing)

2

T-adapter Part No.

—

Part No.: 08027-10210 (Natural color) 08027-10220 (Black)

Part No.: 08027-10260 (Natural color) 08027-10270 (Black)

3

—

Part No.:08027-10310

Part No.:08027-10360

4

—

Part No.: 08027-10410 (Natural color) 08027-10420 (Black)

Part No.: 08027-10460 (Natural color) 08027-10470 (Black)

6

—

Part No.: 08027-10610 (Natural color) 08027-10620 (Black)

PC130-7

Part No.: 08027-10660 (Natural color) 08027-10670 (Black)

20-245 (1)

TROUBLESHOOTING

CONNECTION TABLE FOR CONNECTOR PIN NUMBERS

KES 1 (Automobile) connector

No.of pins

Male (female housing)

Female (male housing)

8

—

Part No.: 08027-10810 (Natural color) 08027-10820 (Black)

No.of pins

Part No.: 08027-10860 (Natural color) 08027-10870 (Black)

Connector for relay (Socket type) Male (female housing)

Female (male housing)

5

—

6

799-601-7370

—

20-246

T-adapter Part No.

799-601-7360

—

(1)

T-adapter Part No.

—

PC130-7

TROUBLESHOOTING

No.of pins

CONNECTION TABLE FOR CONNECTOR PIN NUMBERS

F type connector Male (female housing)

Female (male housing)

4

—

—

PC130-7

T-adapter Part No.

—

20-247 (1)

TROUBLESHOOTING

CONNECTION TABLE FOR CONNECTOR PIN NUMBERS

[The pin No. is also marked on the connector (electric wire insertion end)] HD30 Series connector

Type (shell size code)

Body (plug)

Body (receptacle)

Pin (male terminal)

Pin (female termial)

T-adapter Part No.

799-601-9210

18-8 (1)

Part No.: 08191-11201, 08191-11202, 08191-11205, 08191-11206 Pin (female terminal)

Part No.: 08191-14101, 08191-14102, 08191-14105, 08191-14106 Pin (male termial)

799-601-9210

Part No.: 08191-12201, 08191-12202, 08191-12205, 08191-12206 Pin (male terminal)

Part No.: 08191-13101, 08191-13102, 08191-13105, 08191-13106 Pin (female termial)

799-601-9220

Part No.: 08191-21201, 08191-12202, 08191-21205, 08191-12206 18-14 (2) Pin (female terminal)

Part No.: 08191-24101, 08191-24102, 08191-24105, 08191-24106 Pin (male termial)

799-601-9220

Part No.: 08191-22201, 08191-22202, 08191-22205, 08191-22206

20-248 (1)

Part No.: 08191-23101, 08191-23102, 08191-23105, 08191-23106

PC130-7

TROUBLESHOOTING

CONNECTION TABLE FOR CONNECTOR PIN NUMBERS

[The pin No. is also marked on the connector (electric wire insertion end)] Type (shell size code)

HD30 Series connector Body (plug)

Body (receptacle)

Pin (male terminal)

Pin (female termial)

T-adapter Part No.

799-601-9230

18-20 (3)

Part No.:08191-31201, 08191-31202

Part No.:08191-34101, 08191-34102

Pin (female terminal)

Pin (male termial)

799-601-9230

Part No.:08191-32201, 08191-32202

Part No.:08191-33101, 08191-33102

Pin (male terminal)

Pin (female termial)

799-601-9240

18-21 (4)

Part No.:08191-41201, 08191-42202

Part No.:08191-44101, 08191-44102

Pin (female terminal)

Pin (male termial)

799-601-9240

Part No.:08191-42201, 08191-42202

PC130-7

Part No.:08191-43101, 08191-43102

20-249 (1)

TROUBLESHOOTING

CONNECTION TABLE FOR CONNECTOR PIN NUMBERS

[The pin No. is also marked on the connector (electric wire insertion end)] HD30 Series connector

Type (shell size code)

Body (plug)

Body (receptacle)

Pin (male terminal)

Pin (female termial)

T-adapter Part No.

799-601-9250

24-9 (5)

Part No.:08191-51201, 08191-51202

Part No.:08191-54101, 08191-54102

Pin (female terminal)

Pin (male termial)

799-601-9250

Part No.:08191-52201, 08191-52202

Part No.:08191-53101, 08191-53102

Pin (male terminal)

Pin (female termial)

799-601-9260

Part No.: 08191-61201, 08191-62202, 08191-61205, 08191-62206 24-16 (6) Pin (female terminal)

Part No.: 08191-64101, 08191-64102, 08191-64105, 08191-64106 Pin (male termial)

799-601-9260

Part No.: 08191-62201, 08191-62202, 08191-62205, 08191-62206

20-250 (1)

Part No.: 08191-63101, 08191-63102, 08191-63105, 08191-63106

PC130-7

TROUBLESHOOTING

CONNECTION TABLE FOR CONNECTOR PIN NUMBERS

[The pin No. is also marked on the connector (electric wire insertion end)] HD30 Series connector

Type (shell size code)

Body (plug)

Body (receptacle)

Pin (male terminal)

Pin (female termial)

T-adapter Part No.

799-601-9270

24-21 (7)

Part No.: 08191-71201, 08191-71202, 08191-71205, 08191-71206 Pin (female terminal)

Part No.: 08191-74101, 08191-74102, 08191-74105, 08191-74106 Pin (male termial)

799-601-9270

Part No.: 08191-72201, 08191-72202, 08191-72205, 08191-72206 Pin (male terminal)

Part No.: 08191-73101, 08191-73102, 08191-73105, 08191-73106 Pin (female termial)

799-601-9280

Part No.: 08191-81201, 08191-81202 08191-81203, 08191-81204 08191-81205, 08191-80206 24-22 (8) Pin (female terminal)

Part No.: 08191-84101, 08191-84103, 08191-84105,

08191-84102 08191-84104 08191-84106

Pin (male termial)

799-601-9280

Part No.: 08191-82201, 08191-82203, 08191-82205,

PC130-7

08191-82202 08191-82204 08191-82206

Part No.: 08191-83101, 08191-83103, 08191-83105,

08191-83102 08191-83104 08191-83106

20-251 (1)

TROUBLESHOOTING

CONNECTION TABLE FOR CONNECTOR PIN NUMBERS

[The pin No. is also marked on the connector (electric wire insertion end)] HD30 Series connector

Type (shell size code)

Body (plug)

Body (receptacle)

Pin (male termial)

Pin (female terminal)

T-adapter Part No.

799-601-9290

24-31 (9)

Part No.: 08191-91203, 08191-91204, 08191-91205, 08191-91206 Pin (female terminal)

Part No.: 08191-94103, 08191-94104, 08191-94105, 08191-94106 Pin (male termial)

799-601-9290

Part No.: 08191-92203, 08191-92204, 08191-92205, 08191-92206

20-252 (1)

Part No.: 08191-93103, 08191-93104, 08191-93105, 08191-93106

PC130-7

TROUBLESHOOTING

CONNECTION TABLE FOR CONNECTOR PIN NUMBERS

[The pin No. is also marked on the connector (electric wire insertion end)] DT Series connector

No.of pins

Body (plug)

Body (receptacle)

2

T-adapter Part No.

799-601-9020

Part No.: 08192-12200 (normal type) 08192-22200 (fine wire type)

Part No.: 08192-12100 (normal type) 08192-22100 (fine wire type)

3

799-601-9030

Part No.: 08192-13200 (normal type) 08192-23200 (fine wire type)

Part No.: 08192-13100 (normal type) 08192-23100 (fine wire type)

4

799-601-9040

Part No.: 08192-14200 (normal type) 08192-24200 (fine wire type)

Part No.: 08192-14100 (normal type) 08192-24100 (fine wire type)

6

799-601-9050

Part No.: 08192-16200 (normal type) 08192-26200 (fine wire type)

PC130-7

Part No.: 08192-16100 (normal type) 08192-26100 (fine wire type)

20-253 (1)

TROUBLESHOOTING

CONNECTION TABLE FOR CONNECTOR PIN NUMBERS

[The pin No. is also marked on the connector (electric wire insertion end)] DT Series connector

No.of pins

Body (plug)

Body (receptacle)

8GR: 8B: 8G: 8BR:

8

Part No.: 08192-1820 08192-2820

(normal type) Part No.: 08192-1810 (fine wire type) 08192-2810

799-601-9060 799-601-9070 799-601-9080 799-601-9090

(normal type) (fine wire type)

12GR: 12B: 12G: 12BR:

12

Part No.: 08192-1920 08192-2920

20-254 (1)

T-adapter Part No.

(normal type) Part No.: 08192-1910 (fine wire type) 08192-2910

799-601-9110 799-601-9120 799-601-9130 799-601-9140

(normal type) (fine wire type)

PC130-7

TROUBLESHOOTING

CONNECTION TABLE FOR CONNECTOR PIN NUMBERS

[The pin No. is also marked on the connector (electric wire insertion end)] DTM Series connector

No.of pins

Body (plug)

Body (receptacle)

T-adapter Part No.

799-601-9010

2

Part No.: 08192-02200

Part No.: 08192-02100

[The pin No. is also marked on the connector (electric wire insertion end)] DTHD Series connector

No.of pins

Body (plug)

Body (receptacle)

2

T-adapter Part No.

—

Part No.: 08192-31200 (Contact size#12) Part No.: 08192-31100 (Contact size#12) 08192-41200 (Contact size #8) 08192-41100 (Contact size #8) 08192-51200 (Contact size #4) 08192-51100 (Contact size #4)

PC130-7

20-255 (1)

TROUBLESHOOTING

CONNECTION TABLE FOR CONNECTOR PIN NUMBERS

[The pin No. is also marked on the connector (electric wire insertion end)] No.of pins

DRC26 Series connector Body (plug)

Body (receptacle)

24

799-601-9360

—

Part No.: 7821-93-3110

40 (A)

799-601-9350

—

Part No.: 7821-93-3120

40 (B)

799-601-9350

—

20-256 (1)

T-adapter Part No.

Part No.: 7821-93-3130

PC130-7

TROUBLESHOOTING

T-BRANCH BOX AND T-BRANCH TABLE

T-BRANCH BOX AND T-BRANCH TABLE

799-601-2600 799-601-3100 799-601-3200 799-601-3300 799-601-3360 799-601-3370 799-601-3380 799-601-3410 799-601-3420 799-601-3430 799-601-3440 799-601-3450 799-601-3460 799-601-3510 799-601-3520 799-601-3530 799-601-2910 799-601-3470 799-601-2710 799-601-2720 799-601-2730 799-601-2740 799-601-2950 799-601-2750 799-601-2760 799-601-2770 799-601-2780 799-601-2790 799-601-2810 799-601-2820 799-601-2830 799-601-2840 799-601-2850 799-601-7010 799-601-7020 799-601-7030 799-601-7040 799-601-7050 799-601-7060 799-601-7310 799-601-7070 799-601-7320 799-601-7080 799-601-7090 799-601-7110 799-601-7120 799-601-7130 799-601-7340

PC130-7

Measurement box Measurement box Measurement box Measurement box Plate Plate Plate BENDIX (MS) BENDIX (MS) BENDIX (MS) BENDIX (MS) BENDIX (MS) BENDIX (MS) BENDIX (MS) BENDIX (MS) BENDIX (MS) BENDIX (MS) Case MIC MIC MIC MIC MIC ECONO ECONO ECONO ECONO ECONO DLI DLI DLI Additional cable Case X X X X SWP SWP SWP SWP SWP M M M M M M

—

799-601-9300

799-601-9200

799-601-9100

799-601-9000

799-601-8000

799-601-7500

799-601-7400

799-601-7100

799-601-7000

799-601-6500

799-601-6000

799-601-5500

799-601-3000

799-601-2900

799-601-2800

Connector type or No. of pins part name

799-601-2700

Part No.

799-601-2500

a The vertical column shows part number of T-Branch Box or T-Branch, and horizontal column shows part number of Harness Checker Ass'y.

Econo-21P MS-37P MS-37P Econo-24P For MS box For MS box For MS box 24P 24P 17P 17P 5P 10P 5P 14P 19P 14P 5P 13P 17P 21P 9P 2P 3P 4P 8P 12P 8P 12P 16P

1P 2P 3P 4P 6P 8P 12P 14P 16P 1P 2P 3P 4P 6P 8P

20-257 (1)

799-601-7140 799-601-7150 799-601-7160 799-601-7170 799-601-7330 799-601-7350 799-601-7180 799-601-7190 799-601-7210 799-601-7220 799-601-7230 799-601-7240 799-601-7270 799-601-7510 799-601-7520 799-601-7530 799-601-7540 799-601-7550 799-601-7360 799-601-7370 799-601-7380 799-601-9010 799-601-9020 799-601-9030 799-601-9040 799-601-9050 799-601-9060 799-601-9070 799-601-9080 799-601-9090 799-601-9110 799-601-9120 799-601-9130 799-601-9140 799-601-9210 799-601-9220 799-601-9230 799-601-9240 799-601-9250 799-601-9260 799-601-9270 799-601-9280 799-601-9290 799-601-9310 799-601-9320 799-601-9330 799-601-9340 799-601-9350 799-601-9360 799-601-9410

S S S S S S AMP040 AMP040 AMP040 AMP040 Short connector Case Case 070 070 070 070 070 Relay connector Relay connector JFC connector DTM DT DT DT DT DT DT DT DT DT DT DT DT HD30 HD30 HD30 HD30 HD24 HD30 HD30 HD30 HD30 Plate Measurement box Case Case DRC DRC For NE, G sensor For fuel, boost 799-601-9420 press. 799-601-9430 PVC socket

20-258 (1)

—

799-601-9300

799-601-9200

799-601-9100

799-601-9000

799-601-8000

799-601-7500

799-601-7400

799-601-7100

799-601-7000

799-601-6500

799-601-6000

799-601-5500

799-601-3000

799-601-2900

799-601-2800

Connector type or No. of pins part name

799-601-2700

Part No.

T-BRANCH BOX AND T-BRANCH TABLE

799-601-2500

TROUBLESHOOTING

8P 10P-White 12P-Blue 16P-Blue 16P-White 12P-White 8P 12P 16P 20P X-2

10P 12P 14P 18P 20P 5P 6P 2P 2P 2P 3P 4P 6P 8P-Gray 8P-Black 8P-Green 8P-Brown 12P-Gray 12P-Black 12P-Green 12P-Brown 18-8 18-14 18-20 18-21 24-9 24-16 24-21 24-23 24-31 For HD30 For DT, HD

40P 24P 2P 3P 2P

PC130-7

TROUBLESHOOTING WHEN ERROR CODE IS DISPLAYED (DISPLAY OF ERROR CODE) BEFORE CARRYING OUT TROUBLESHOOTING WHEN CODE IS DISPLAYED .................................. 20-302 INFORMATION IN TROUBLESHOOTING TABLE .................................................................................... 20-307 Error code [104] (Clogging of air cleaner) .................................................................................................. 20-310 Error code [108] (Overheating of engine coolant) .......................................................................................20-311 Error code [112] (Short circuit in wiper motor drive forward system) ......................................................... 20-312 Error code [113] (Short circuit in wiper motor drive reverse system) ......................................................... 20-314 Error code [114] (Short circuit in windshield washer drive system) ............................................................ 20-316 Error code [115] (Trouble in operation of windshield wiper) ....................................................................... 20-318 Error code [116] (Trouble in storage of windshield wiper) .......................................................................... 20-320 Error code [203] (Short circuit in swing holding brake solenoid) ................................................................ 20-322 Error code [205] (Short circuit in 2-stage relief solenoid) ........................................................................... 20-324 Error code [206] (Short circuit in travel speed shifting solenoid) ................................................................ 20-326 Error code [213] (Disconnection in swing holding brake solenoid) ............................................................ 20-328 Error code [215] (Disconnection in 2-stage relief solenoid) ....................................................................... 20-330 Error code [216] (Disconnection in travel speed shifting solenoid) ............................................................ 20-332 Error code [217] (Abnormality in input model code) ................................................................................... 20-334 Error code [218] (Disconnection in S-NET signal line) ............................................................................... 20-336 Error code [222] (Short circuit in LS-EPC solenoid) ................................................................................... 20-338 Error code [223] (Disconnection in LS-EPC solenoid) ............................................................................... 20-339 Error code [224] (Abnormality in pump pressure sensor) .......................................................................... 20-340 Error code [226] (Abnormality in pressure sensor power supply) .............................................................. 20-342 Error code [227] (Abnormality in engine speed sensor) ............................................................................. 20-344 Error code [232] (Short circuit in PC-EPC solenoid) .................................................................................. 20-346 Error code [233] (Disconnection in PC-EPC solenoid) .............................................................................. 20-348 Error code [251] (Abnormality in overload pressure sensor) ..................................................................... 20-350 Error code [301] (Engine low idling speed out of standard range) ............................................................. 20-352 Error code [302] (Engine high idling speed out of standard range) ............................................................ 20-352 Error code [306] (Abnormality in governor potentiometer) ......................................................................... 20-354 Error code [308] (Abnormality in fuel control dial) ...................................................................................... 20-356 Error code [315] (Short circuit in battery relay output line) ......................................................................... 20-358 Error code [316] (Step-out of governor motor) ........................................................................................... 20-360 Error code [317] (Disconnection in phases A and B of governor motor) .................................................... 20-362 Error code [318] (Short circuit in phases A and B of governor motor) ....................................................... 20-364

PC130-7

20-301 (1)

Error code

218

315

(1)

q

20-302 217

q

203

q

205

q

206

q

213

q

215

q

216

q

104

q

108

q

112

q q

113

q q

114

q

115

q q

116

q q

316

q

317

q

q

318

q

q

q

222

q q

223

q q

226

q

224

q

227

q

232

q

q

q

233

q

q

q

251

q

301

q

q

302

q

q

306

q

q

308

q

q q

q

q

q

q

Defective travel speed shifting solenoid

Defective 2-stage relief solenoid valve

Defective swing holding brake solenoid

Defective LS-EPC solenoid

Defective PC-EPC solenoid

Clogging of air cleaner

Overheating of engine

Defective fuel control of engine

Defective adjustment of governor lever

Defective mechanical system of engine

Defective air cleaner clogging switch

Defective engine coolant temperature sensor

Defective engine speed sensor (including adjustment)

Defective governor potentiometer

Defective governor motor

Defective fuel control dial

Defective emergency pump drive switch

Defective swing lock switch

Defective windshield washer motor

Defective wiper motor

Defective sensor power supply (5 V)

Defective governor and pump controller

Defective monitor panel

Defective fuse or fusible link

Defective battery relay

TROUBLESHOOTING BEFORE CARRYING OUT TROUBLESHOOTING WHEN CODE IS DISPLAYED

BEFORE CARRYING OUT TROUBLESHOOTING WHEN CODE IS DISPLAYED

Error codes and possible causes of them Possible causes

q

q

q

q q

q q

q q

q q

q q

q

q

q

q

q

PC130-7

q

q

q

PC130-7 q

q

q q q

q

q

q

q Short circuit with power source in wiring harness

Grounding fault in wiring harness

Disconnection in wiring harness

Defective assembled-type diode

Overload pressure sensor

Pump pressure sensor

TROUBLESHOOTING

q q

q q

q q

q

q

q

q

q

q

q

q

q

BEFORE CARRYING OUT TROUBLESHOOTING WHEN CODE IS DISPLAYED

Possible causes

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q

q q

q

q q

q

q

q

q

q q

q

q

q

q

q

q

q

q

20-303

(1)

TROUBLESHOOTING

BEFORE CARRYING OUT TROUBLESHOOTING WHEN CODE IS DISPLAYED

Connection table of fuse box a This connection table shows the devices to which each power supply of the fuse box (FB1) supplies power (A switch power supply is a device which supplies power while the starting switch is at the ON position and a constant power supply is a device which supplies power while the starting switch is at the OFF position). a When carrying out troubleshooting related to the electrical system, you should check the fuse box and fusible link to see if the power is supplied normally. Type of power supply

Fuse No.

Fuse capacity

Destination of power Governor and pump controller (Controller power supply)

1

10A

PC-EPC solenoid (Emergency pump drive switch circuit) Swing holding brake solenoid (Swing holding brake release switch circuit)

2

20A

3

10A

Governor and pump controller (Solenoid power supply) PPC oil pressure lock solenoid Starting motor cutout relay (For PPC lock) Cigarette lighter

4

10A Windshield washer motor

Switch power supply (Fusible link: A34)

5

10A

Horn

6

10A

Lower wiper motor [If equipped]

7

10A

Rotary lamp [If equipped], DC/DC converter [If equipped]

8

10A

Working lamp (Boom and right front) Working lamp (Left front and rear) [If equipped] 9

10A

One-touch power maximizing switch circuit

10

10A

Fuel priming pump [If equipped]

11

20A

Air conditioner unit

12

20A

Starting motor cutout relay (For personal code) Monitor panel (Switch power supply) Light relay 1 13

20A

Light relay 2 Panel night light signal circuit

14

10A

15

10A

Heated seat [If equipped] Heated seat [If equipped] Travel alarm [If equipped]

Constant power supply (Fusible link: A35)

20-304 (3)

16

10A

Radio back up (Constant power supply)

17

20A

Monitor panel (Constant power supply)

18

10A

Starting switch

19

10A

Room lamp

20

10A

(Spare)

PC130-7

TROUBLESHOOTING

BEFORE CARRYING OUT TROUBLESHOOTING WHEN CODE IS DISPLAYED

Troubles which occur when controller power supply of governor and pump controller is defective a The controller power supply (FB1-1) of the governor and pump controller drives the controller system. a Accordingly, if the controller power supply is turned off, the controller cannot control the governor motor and battery relay and the following troubles occur. 1) The engine can be started but cannot be stopped. 2) The engine speed cannot be controlled with the fuel control dial. a If the above problems occur, check the related fuse (FB1-1) and "green LED" of the governor and pump controller to see if the power is supplied normally. • Lighting: The controller power is supplied (There is not an error and the power supply is normal). • Flashing: The controller power is supplied (There is an error). • Put out: The controller power is not supplied. a Green LED of governor and pump controller (GREEN)

PC130-7

20-305 (1)

TROUBLESHOOTING

BEFORE CARRYING OUT TROUBLESHOOTING WHEN CODE IS DISPLAYED

Troubles which occur when solenoid power supply of governor and pump controller is defective a The solenoid power supply (FB1-2) of the governor and pump controller is used by the controller to drive the solenoids and relays. a Accordingly, if the solenoid power supply is turned off, when the controller outputs the power to the solenoids or relays, the power is not supplied to any of the solenoids and relays and all or some of the following error codes are displayed simultaneously. • [E213]: Disconnection in swing holding brake solenoid • [E215]: Disconnection in 2-stage relief solenoid • [E216]: Disconnection in travel speed shifting solenoid • [E222]: Disconnection in LS-EPC solenoid • [E223]: Disconnection in PC-EPC solenoid a If the above problems occur, check the related fuse (FB1-2) and inlet voltage of the governor and pump controller. 1) Disconnect connector C03 of the controller and connect a T-adapter to the wiring harness side. 2) Turn the starting switch ON. 3) Measure the voltage between each of pins (2) and (12) and each of pins (31), (32), and (33). • Pins (2) and (3) are the power supply pins and pins (31), (32), and (33) are the ground pins. • Pins (2) and (3) are the power supply and pins (31), (32), and (33) are the chassis ground. • If the voltage is 20 – 30 V, it is normal. a Power supply connector (C03) of governor and pump controller

20-306 (1)

PC130-7

INFORMATION IN TROUBLESHOOTING TABLE

TROUBLESHOOTING

INFORMATION IN TROUBLESHOOTING TABLE a The following information is summarized in the troubleshooting table and the related electrical circuit diagram. Before carrying out troubleshooting, understand that information fully. User code Error code Display on panel Display on panel

Trouble

Trouble indicated by error code

Contents of Condition at the time when the monitor panel or controller detects the trouble trouble Action of monitor The action taken by the monitor panel or controller to protect the system or devices when the monitor panel or panel or controller detects the trouble controller Problem that appears on machine Related information

The problem that appears on the machine as a result of the action taken by the monitor panel or controller (shown above) Information related to the detected trouble or troubleshooting Cause

Standard value in normal state/Remarks on troubleshooting • Standard value in normal state to judge possible causes • Remarks on judgment

1

2 Possible causes and standard value in normal state

3

4

PC130-7

• Disconnection Connector is connected imperfectly or harness is broken. • Grounding fault Harness which is not connected to chassis ground circuit is in contact with chassis ground circuit. • Short circuit with power source Harness which is not connected to power source (24-V) circuit is in contact with power source (24-V) circuit. Possible causes of trouble (Given numbers are refer- ence numbers, which do not 1) Method of indicating connector No. and handling of T-adapter Insert or connect T-adapter as explained below for troubleshooting, indicate priority) unless otherwise specified. • If connector No. has no marks of "male" and "female", disconnect connector and insert T-adapters in both male side and female side. • If connector No. has marks of "male" and "female", disconnect connector and connect T-adapter to only male side or female side. 2) Entry order of pin Nos. and handling of circuit tester leads Connect positive (+) lead and negative (-) lead of circuit tester as explained below for troubleshooting, unless otherwise specified. • Connect positive (+) lead to pin No. or harness entered on front side. • Connect negative (-) lead to pin No. or harness entered on rear

20-307 (1)

TROUBLESHOOTING

INFORMATION IN TROUBLESHOOTING TABLE

Related circuit diagram

This is a circuit diagram of the part related to troubleshooting. • Connector No.: Shows the "Type-Number of pin" and "Color". • Branching/Merging point: Shows that there is a branching/merging point in the electric circuit to be checked. • Arrow ( ): Roughly shows the location on the machine.

20-308 (1)

PC130-7

[104]

TROUBLESHOOTING

Error code [104] (Clogging of air cleaner) User code – Contents of trouble Action of monitor panel Problem that appears on machine Related information

Error code

Trouble Clogging of air cleaner(Monitor panel system) 104 • The signal circuit of the air cleaner clogging switch is opened (disconnected from the chassis ground) while the engine is running. • None in particular. • If the machine is operated as it is, the engine may be damaged. • If the air cleaner clogging monitor of the monitor panel flashes while the engine is running, this error code is recorded. • The input state (ON/OFF) from the air cleaner clogging switch can be checked with the monitoring function. (Code: 046, Right of upper line) Cause Clogging of air cleaner 1 (When system is normal) Defective air cleaner clog2 ging switch (Internal disconnection)

Possible causes and standard value in normal state

Standard value in normal state/Remarks on troubleshooting Check the air cleaner. If it is clogged, clean or replace it. aPrepare with starting switch OFF, then start engine and carry out troubleshooting. A31 (male) Between (1) and (2)

Air cleaner When normal

Resistance Max.1 z

When clogged Min.1 Mz aPrepare with starting switch OFF, then carry out troubleshooting without turning starting switch. Disconnection in wiring harness (Disconnection in Wiring harness between P02 (female) (5) and Resistance Max.1 z 3 wiring harness or defective A31 (female) (1) contact in connector) Wiring harness between P11 (female) (2) and Resistance Max.1 z chassis ground (A15) aPrepare with starting switch OFF, then start engine and carry out troubleshooting. 4 Defective monitor panel

P02 Between (5) and chassis ground

Air cleaner When normal

Voltage Max. 1 V

When clogged

20 – 30 V

Circuit diagram related to air cleaner clogging switch

20-310 (1)

PC130-7

[108]

TROUBLESHOOTING

Error code [108] (Overheating of engine coolant) User code – Contents of trouble Action of monitor panel Problem that appears on machine Related information

Error code

Trouble Overheating of engine coolant (Monitor panel system) 108 • The signal circuit of the engine coolant temperature sensor inputs 99 o or higher temperature while the engine is running. • None in particular. • If the machine is operated as it is, the engine may be seized. • If the engine coolant temperature monitor of the monitor panel flashes while the engine is running, this error code is recorded. • The input state (ON/OFF) from the engine coolant temperature sensor can be checked with the monitoring function. (Code: 041, by 10 mV) Cause Overheating of engine 1 (When system is normal)

Defective engine coolant 2 temperature sensor (Internal short circuit) Possible causes and standard value in normal state

Short circuit with chassis ground in wiring harness 3 (Contact with ground circuit)

Standard value in normal state/Remarks on troubleshooting The engine may have overheated. Find the cause and check the engine for damage, and then repair. aPrepare with starting switch OFF, then carry out troubleshooting without turning starting switch. E05 (male)

Engine coolant temperature

Resistance

Between (1) and (2) 3.5k – 90 kz 10 – 100 °C Between (2) and Min. 1 Mz chassis ground aPrepare with starting switch OFF, then carry out troubleshooting without turning starting switch. Between P02 (female) (1) – E05 (female) (2) wiring harness and chassis ground

Resistance Min. 1 Mz

aPrepare with starting switch OFF, then carry out troubleshooting without turning starting switch. 4 Defective monitor panel

P02

Engine coolant temperature

Between (1) and (13) Between (1) and chassis ground

Resistance 3.5k – 90 kz

10 – 100 °C

Min. 1 Mz

Circuit diagram related to engine coolant temperature sensor

PC130-7

20-311 (1)

[112]

TROUBLESHOOTING

Error code [112] (Short circuit in wiper motor drive forward system) User code

Error code

– Contents of trouble Action of monitor panel

112

Problem that appears on machine Related information

Trouble

• When the signal is output to the wiper motor drive forward circuit, an abnormal current flows. • Turns the output to the wiper motor drive forward circuit OFF. • Windshield wiper stops.

Cause Defective wiper motor 1 (Internal short circuit or grounding fault) Possible causes and standard value in normal state

Short circuit in wiper motor drive forward system (Monitor panel system)

Short circuit with chassis ground in wiring harness 2 (Contact with ground circuit)

3 Defective monitor panel

Standard value in normal state/Remarks on troubleshooting aPrepare with starting switch OFF, then carry out troubleshooting without turning starting switch. W04 (male) Continuity/Resistance Between (3) and (1) Between (3) and chassis ground

aPrepare with starting switch OFF, then carry out troubleshooting without turning starting switch. Between P01 (female) (9) – W03 (female) (3) wiring harness and chassis ground

(1)

Resistance Min. 1 Mz

aPrepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. P01 Wiper switch Resistance Between (9) and chassis ground

20-312

There is continuity Min. 1 Mz

OFF

Max. 3 V

ON

Max. 3 V 20 – 30 V (Constant period)

PC130-7

TROUBLESHOOTING

[112]

Circuit diagram related to wiper motor

PC130-7

20-313 (1)

[113]

TROUBLESHOOTING

Error code [113] (Short circuit in wiper motor drive reverse system) User code

Error code

– Contents of trouble Action of monitor panel

113

Problem that appears on machine Related information

Trouble

• When the signal is output to the wiper motor drive reverse circuit, an abnormal current flows. • Turns the output to the wiper motor drive reverse circuit OFF. • Windshield wiper stops.

Cause Defective wiper motor 1 (Internal short circuit or grounding fault) Possible causes and standard value in normal state

Short circuit in wiper motor drive reverse system (Monitor panel system)

Short circuit with chassis ground in wiring harness 2 (Contact with ground circuit)

3 Defective monitor panel

Standard value in normal state/Remarks on troubleshooting aPrepare with starting switch OFF, then carry out troubleshooting without turning starting switch. W04 (male) Continuity/Resistance Between (1) and (3) Between (1) and chassis ground

aPrepare with starting switch OFF, then carry out troubleshooting without turning starting switch. Between P01 (female) (10) – W03 (female) (1) wiring harness and chassis ground

(1)

Resistance Min. 1 Mz

aPrepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. P01 Wiper switch Resistance Between (10) and chassis ground

20-314

There is continuity Min. 1 Mz

OFF

Max. 3 V

ON

Max. 3 V 20 – 30 V (Constant period)

PC130-7

TROUBLESHOOTING

[113]

Circuit diagram related to wiper motor

PC130-7

20-315 (1)

[114]

TROUBLESHOOTING

Error code [114] (Short circuit in windshield washer drive system) User code – Contents of trouble Action of monitor panel Problem that appears on machine Related information

Error code

Short circuit in windshield washer drive system Trouble (Monitor panel system) 114 • When the windshield washer drive circuit is connected to the ground circuit (the output is turned ON), an abnormal current flows. • Turns the ground output of the windshield washer motor circuit OFF. • The windshield washer stops.

1

Possible causes and standard value in normal state

Cause

Standard value in normal state/Remarks on troubleshooting

Defective washer motor (Internal short circuit)

aPrepare with starting switch OFF, then carry out troubleshooting without turning starting switch. A50 (male) Resistance

Short circuit with power 2 source in wiring harness (Contact with 24-V circuit)

3 Defective monitor panel

20-316 (1)

Between (1) and (2) 5 – 20 z aPrepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Between P01 (female) (3) – A50 (female) (2) or D02 (female) (8) wiring harness and chassis Voltage Max. 1 V ground aPrepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Windshield washer P01 Voltage switch OFF 20 – 30 V Between (3) and chassis ground ON Max. 1 V

PC130-7

TROUBLESHOOTING

[114]

Circuit diagram related to windshield washer motor

PC130-7

20-317 (1)

[115]

TROUBLESHOOTING

Error code [115] (Trouble in operation of windshield wiper) User code

Error code

– Contents of trouble Action of monitor panel

115

Problem that appears on machine Related information

Trouble

Trouble in operation of windshield wiper (Monitor panel system)

• When the wiper operates, the W-signals of both ends of the operating range are not input. • Turns the operation signal to the wiper motor OFF. • The windshield wiper does not operate. • The input state (ON/OFF) from the W-signals of the wiper operating range can be checked with the monitoring function. (Code: 049, Center of lower line) Cause

1

Defective wiper motor (Internal disconnection)

Standard value in normal state/Remarks on troubleshooting aPrepare with starting switch OFF, then carry out troubleshooting without turning starting switch. W04 (male) Wiper blade Resistance

Top of operating range Max. 1 z Other than top of Min. 1 Mz operating range aPrepare with starting switch OFF, then carry out troubleshooting without turning starting switch. Disconnection in wiring harness (Disconnection in Wiring harness between P01 (female) (5) and Resistance Max. 1 z 2 wiring harness or defective W04 (female) (6) contact in connector) Wiring harness between W04 (female) (5) and Resistance Max. 1 z chassis ground (A11, A12) Between (6) and (5)

Possible causes and standard value in normal state

aPrepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. 3 Defective monitor panel

P01 Between (5) and chassis ground

20-318 (1)

Wiper blade Top of operating range

Voltage Max. 1 V

Other than top of operating range

20 – 30 V

PC130-7

TROUBLESHOOTING

[115]

Circuit diagram related to wiper motor

PC130-7

20-319 (1)

[116]

TROUBLESHOOTING

Error code [116] (Trouble in storage of windshield wiper) User code

Error code

– Contents of trouble Action of monitor panel

116

Problem that appears on machine Related information

Trouble

• When the wiper stored, the P-signals of the storage range is not input. • Turns the storage signal to the wiper motor OFF. • The wiper is not stored. • The input state (ON/OFF) from the P-signals of the wiper operating range can be checked with the monitoring function. (Code: 049, Left of upper line) Cause

1

Possible causes and standard value in normal state

Trouble in storage of windshield wiper (Monitor panel system)

Defective wiper motor (Internal disconnection)

Standard value in normal state/Remarks on troubleshooting aPrepare with starting switch OFF, then carry out troubleshooting without turning starting switch. W04 (male) Wiper blade Resistance Between (4) and (5)

(1)

Max. 1 z Min. 1 Mz

aPrepare with starting switch OFF, then carry out troubleshooting without turning starting switch.

Disconnection in wiring harness (Disconnection in Wiring harness between P01 (female) (12) and Resistance Max. 1 z 2 wiring harness or defective W04 (female) (4) contact in connector) Wiring harness between W04 (female) (5) and Resistance Max. 1 z chassis ground (A11, A12) aPrepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. P01 Wiper blade Voltage 3 Defective monitor panel Between (12) and chassis ground

20-320

Storage range Operating range

Storage range Operating range

Max. 1 V 20 – 30 V

PC130-7

TROUBLESHOOTING

[116]

Circuit diagram related to wiper motor

PC130-7

20-321 (1)

[203]

TROUBLESHOOTING

Error code [203] (Short circuit in swing holding brake solenoid) User code

Error code

E03 Contents of trouble

203

Action of controller Problem that appears on machine Related information

Trouble

• When the signal is output to the swing holding brake solenoid circuit, an abnormal current flows. • Turns the output to the swing holding brake solenoid circuit OFF. • Even if the cause of the failure disappears, the system does not reset itself until the starting switch is turned OFF. • The machine cannot swing (The swing holding brake is not released). • The operation state (ON/OFF) of the swing holding brake solenoid can be checked with the monitoring function. (Code: 023, Center of upper line) • If the solenoid and wiring harness are normal, the machine can swing by setting the swing holding brake release switch in the FREE position. (The swing holding brake does not operate when the machine stops swinging, however.) Cause Defective swing holding 1 brake solenoid (Internal short circuit)

Possible causes and standard value in normal state

Short circuit in swing holding brake solenoid (Governor and pump controller system)

Short circuit with chassis ground in wiring harness 2 (Contact with ground circuit)

3

Defective governor and pump controller

Standard value in normal state/Remarks on troubleshooting aPrepare with starting switch OFF, then carry out troubleshooting without turning starting switch. V05 (male) Between (1) and (2)

Between (2) and chassis ground Min. 1 Mz aPrepare with starting switch OFF, then carry out troubleshooting without turning starting switch. Between C03 (female) (37) – D01 – J02 – X05 Resistance Min. 1 Mz – V05 (female) (1) or S25 (female) (8) wiring harness and chassis ground aPrepare with starting switch OFF, then start engine and carry out troubleshooting. Left work equipment C03 Voltage control lever Between (37) and chassis ground

20-322 (1)

Resistance 20 – 60 z

Neutral position Swing position

Max. 1 V 20 – 30 V

PC130-7

TROUBLESHOOTING

[203]

Circuit diagram related to swing holding brake solenoid

PC130-7

20-323 (1)

[205]

TROUBLESHOOTING

Error code [205] (Short circuit in 2-stage relief solenoid) User code

Error code

– Contents of trouble

205

Action of controller Problem that appears on machine Related information

Trouble

• When the signal is output to the 2-stage relief solenoid circuit, an abnormal current flows. • Turns the output to the 2-stage relief solenoid circuit OFF. • Even if the cause of the failure disappears, the system does not reset itself until the starting switch is turned OFF. • The one-touch power maximizing function does not work (The main relief valve is not set to high pressure). • The operation state (ON/OFF) of the 2-stage relief solenoid can be checked with the monitoring function. (Code: 023, Left of upper line) Cause Defective 2-stage relief 1 solenoid (Internal short circuit)

Possible causes and standard value in normal state

Short circuit in 2-stage relief solenoid (Governor and pump controller system)

Short circuit with chassis ground in wiring harness 2 (Contact with ground circuit)

Standard value in normal state/Remarks on troubleshooting aPrepare with starting switch OFF, then carry out troubleshooting without turning starting switch. V06 (male) Between (1) and (2)

Between (2) and chassis ground Min. 1 Mz aPrepare with starting switch OFF, then carry out troubleshooting without turning starting switch. Between C03 (female) (28) – V06 (female) (1) Resistance Min. 1 Mz wiring harness and chassis ground aPrepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting.

3

Defective governor and pump controller

C03 Between (37) and chassis ground

20-324 (1)

Resistance 20 – 60 z

One-touch power maximizing switch Released Kept pressed

Voltage Max. 1 V 20 – 30 V (With 8.5-sec timer)

PC130-7

TROUBLESHOOTING

[205]

Circuit diagram related to 2-stage relief solenoid

PC130-7

20-325 (1)

[206]

TROUBLESHOOTING

Error code [206] (Short circuit in travel speed shifting solenoid) User code

Error code

– Contents of trouble

206

Action of controller Problem that appears on machine Related information

Trouble

• When the signal is output to the travel speed shifting solenoid circuit, an abnormal current flows. • Turns the output to the travel speed shifting solenoid circuit OFF. • Even if the cause of the failure disappears, the system does not reset itself until the starting switch is turned OFF. • The travel speed is not set to HI (The swash plate angle of the travel motor is not set to the minimum). • The operation state (ON/OFF) of the travel speed shifting solenoid can be checked with the monitoring function. (Code: 023, Left of lower line) Cause Defective travel speed 1 shifting solenoid (Internal short circuit)

Possible causes and standard value in normal state

Short circuit travel speed shifting solenoid (Governor and pump controller system)

Short circuit with chassis ground in wiring harness 2 (Contact with ground circuit)

Standard value in normal state/Remarks on troubleshooting aPrepare with starting switch OFF, then carry out troubleshooting without turning starting switch. V04 (male) Between (1) and (2)

Resistance 20 – 60 z

Between (2) and chassis ground Min. 1 Mz aPrepare with starting switch OFF, then carry out troubleshooting without turning starting switch. Between C03 (female) (27) – V04 (female) (1) Resistance Min. 1 Mz wiring harness and chassis ground aPrepare with starting switch OFF, then start engine and carry out troubleshooting.

3

20-326 (1)

Defective governor and pump controller

C03

Travel speed switch and travel lever

Voltage

Between (27) and chassis ground

Lo + Neutral Hi + Travel position

Max. 1 V 20 – 30 V

PC130-7

TROUBLESHOOTING

[206]

Circuit diagram related to travel speed shifting solenoid

PC130-7

20-327 (1)

[213]

TROUBLESHOOTING

Error code [213] (Disconnection in swing holding brake solenoid) User code

Error code

E03 Contents of trouble Action of controller

213

Problem that appears on machine

Related information

Trouble

Disconnection in swing holding brake solenoid (Governor and pump controller system)

• When the signal is output to the swing holding brake solenoid circuit, no current flows. • None in particular (Since no current flows, the solenoid does not operate). • If the cause of the failure disappears, the system resets itself. • The machine cannot swing (The swing holding brake is not released). • The operation state (ON/OFF) of the swing holding brake solenoid can be checked with the monitoring function. (Code: 023, Center of upper line) • If the solenoid and wiring harness are normal, the machine can swing by setting the swing holding brake release switch in the FREE position. (The swing holding brake does not operate when the machine stops swinging, however.) • During troubleshooting, keep the swing lock switch in the OFF position and the swing holding brake release switch in the RELEASE position. • Since the controller detects disconnection while the solenoid output is turned ON, be sure to turn the solenoid output ON when checking for reproduction of the failure after repair. (For the method of turning the solenoid output ON and OFF, see troubleshooting for error code [203].) Cause Defective swing holding 1 brake solenoid (Internal disconnection)

2

Defective swing lock switch (Internal disconnection)

Standard value in normal state/Remarks on troubleshooting aPrepare with starting switch OFF, then carry out troubleshooting without turning starting switch. V05 (male) Resistance Between (1) and (2) 20 – 60 z aPrepare with starting switch OFF, then carry out troubleshooting without turning starting switch. X05 (female) Between (3) and (4)

Possible causes and standard value in normal state

harness (Disconnection in Wiring harness between D01 (female) (3) and wiring harness or defective J02 and X05 (male) (3) contact in connector) Wiring harness between X05 (male) (4) and V05 (female) (1)

Short circuit with power 5 source in wiring harness (Contact with 24-V circuit)

6

(1)

Resistance Max. 1 z

ON Min. 1 Mz aPrepare with starting switch OFF, then carry out troubleshooting withDefective assembled-type out turning starting switch. 3 diode D01 (Internal disconD01 (male) Digital circuit tester Continuity nection) Between (7) and (3) Diode mode There is continuity aPrepare with starting switch OFF, then carry out troubleshooting without turning starting switch. Wiring harness between C03 (female) (37) and Resistance Max. 1 z D01 (female) (7) Disconnection in wiring 4

20-328

Swing lock switch OFF

Defective governor and pump controller

Resistance

Max. 1 z

Resistance

Max. 1 z

Wiring harness between C03 (female) (3), (13), Resistance Max. 1 z (23) and V05 (female) (2) aPrepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Between C03 (female) (37) – D01 (female) (7) Voltage Max. 1 V wiring harness and chassis ground aPrepare with starting switch OFF, then carry out troubleshooting without turning starting switch. C03 (female) Disconnect D01 and Between (37) and (3), connect (3) and (7) on female side. (13), (23)

Resistance 20 – 60 z

PC130-7

TROUBLESHOOTING

[213]

Circuit diagram related to swing holding brake solenoid

PC130-7

20-329 (1)

[215]

TROUBLESHOOTING

Error code [215] (Disconnection in 2-stage relief solenoid) User code

Error code

– Contents of trouble Action of controller

215

Trouble

Disconnection in 2-stage relief solenoid (Governor and pump controller system)

• When the signal is output to the 2-stage relief solenoid circuit, no current flows. • None in particular (Since no current flows, the solenoid does not operate). • If the cause of the failure disappears, the system resets itself.

Problem that appears on machine

• The one-touch power maximizing function does not work (The main relief valve is not set to high pressure).

Related information

• The operation state (ON/OFF) of the 2-stage relief solenoid can be checked with the monitoring function. (Code: 023, Left of upper line) • Since the controller detects disconnection while the solenoid output is turned ON, be sure to turn the solenoid output ON when checking for reproduction of the failure after repair. (For the method of turning the solenoid output ON and OFF, see troubleshooting for error code [205].) Cause

Possible causes and standard value in normal state

Standard value in normal state/Remarks on troubleshooting

aPrepare with starting switch OFF, then carry out troubleshooting withDefective 2-stage relief out turning starting switch. 1 solenoid (Internal short cirV06 (male) Resistance cuit) Between (1) and (2) 20 – 60 z aPrepare with starting switch OFF, then carry out troubleshooting without turning starting switch. Disconnection in wiring harness (Disconnection in Wiring harness between C03 (female) (28) and Resistance Max. 1 z 2 wiring harness or defective V06 (female) (1) contact in connector) Wiring harness between C03 (female) (3), (13), Resistance Max. 1 z (23) and V06 (female) (2) Short circuit with power 3 source in wiring harness (Contact with 24-V circuit)

Defective governor and 4 pump controller

aPrepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Between C03 (female) (28) – V06 (female) (1) wiring harness and chassis ground

(1)

Max. 1 V

aPrepare with starting switch OFF, then carry out troubleshooting without turning starting switch. C03 (female) Resistance Between (37) and (3), (13), (23)

20-330

Voltage

20 – 60 z

PC130-7

TROUBLESHOOTING

[215]

Circuit diagram related to 2-stage relief solenoid

PC130-7

20-331 (1)

[216]

TROUBLESHOOTING

Error code [216] (Disconnection in travel speed shifting solenoid) User code

Error code

– Contents of trouble

216

Action of controller

Trouble

Disconnection in travel speed shifting solenoid (Governor and pump controller system)

• When the signal is output to the travel speed shifting solenoid circuit, no current flows. • None in particular (Since no current flows, the solenoid does not operate). • If the cause of the failure disappears, the system resets itself.

Problem that appears on machine

• The travel speed is not set to HI (The swash plate angle of the travel motor is not set to the minimum).

Related information

• The operation state (ON/OFF) of the travel speed shifting solenoid can be checked with the monitoring function. (Code: 023, Left of lower line) • Since the controller detects disconnection while the solenoid output is turned ON, be sure to turn the solenoid output ON when checking for reproduction of the failure after repair. (For the method of turning the solenoid output ON and OFF, see troubleshooting for error code [206].) Cause Defective travel speed 1 shifting solenoid (Internal disconnection)

Possible causes and standard value in normal state

Standard value in normal state/Remarks on troubleshooting aPrepare with starting switch OFF, then carry out troubleshooting without turning starting switch. V04 (male) Resistance Between (1) and (2) 20 – 60 z aPrepare with starting switch OFF, then carry out troubleshooting without turning starting switch.

Disconnection in wiring harness (Disconnection in Wiring harness between C03 (female) (27) and Resistance 2 wiring harness or defective V04 (female) (1) contact in connector) Wiring harness between C03 (female) (3), (13), Resistance (23) and V04 (female) (2) Short circuit with power 3 source in wiring harness (Contact with 24-V circuit)

4

Defective governor and pump controller

(1)

Max. 1 z

aPrepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Between C03 (female) (27) – V04 (female) (1) Voltage Max. 1 V wiring harness and chassis ground aPrepare with starting switch OFF, then carry out troubleshooting without turning starting switch. C03 (female) Resistance Between (27) and (3), (13), (23)

20-332

Max. 1 z

20 – 60 z

PC130-7

TROUBLESHOOTING

[216]

Circuit diagram related to travel speed shifting solenoid

PC130-7

20-333 (1)

[217]

TROUBLESHOOTING

Error code [217] (Abnormality in input model code) User code

Error code

– Contents of trouble

217

Action of controller Problem that appears on machine Related information

Trouble

Abnormality in input model code (Governor and pump controller system)

• A model code signal for a model which is not registered in the controller is input. • Uses the default model (PC200-7) for control. • Even if the cause of the failure disappears, the system does not reset itself until the starting switch is turned OFF. • The engine does not output sufficient power or may stall. • The model name (number) recognized by the controller can be checked with the monitoring function. (Code: 002, 003) • The input state (ON/OFF) of the model selection signal can be checked with the monitoring function. (Code: 027, Other than left of lower line) Cause

Standard value in normal state/Remarks on troubleshooting

aPrepare with starting switch OFF, then carry out troubleshooting without turning starting switch. Defective model selection C09 (female) Resistance 1 connector (Internal disconnection or short circuit) Between (1), (2) and (8) Max. 1 z Between (3), (4), (7) and (8) Min. 1 Mz aPrepare with starting switch OFF, then carry out troubleshooting without turning starting switch. Disconnection in wiring harness (Disconnection in 2 wiring harness or defective contact in connector) Possible causes and standard value in normal state Short circuit with chassis ground in wiring harness 3 (Contact with ground circuit)

Wiring harness between C02 (female) (37) and Resistance C09 (male) (1)

Wiring harness between C02 (female) (27) and Resistance Max. 1 z C09 (male) (2) Wiring harness between C09 (female) (8) and Resistance Max. 1 z chassis ground (A13) aPrepare with starting switch OFF, then carry out troubleshooting without turning starting switch. Between C02 (female) (17) – C09 (male) (3) Resistance Min. 1 Mz wiring harness and chassis ground Between C02 (female) (7) – C09 (male) (4) wirResistance Min. 1 Mz ing harness and chassis ground Between C02 (female) (13) – C09 (male) (7) wiring harness and chassis ground

4

20-334 (1)

Defective governor and pump controller

Max. 1 z

Resistance Min. 1 Mz

aPrepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. C02 (female) Voltage Between (7), (13), (17) and chassis ground

20 – 20 V

Between (27), (37), and chassis ground

Max. 1 V

PC130-7

TROUBLESHOOTING

[217]

Circuit diagram related to model selection connector

PC130-7

20-335 (1)

[218]

TROUBLESHOOTING

Error code [218] (Disconnection in S-NET signal line) User code – Contents of trouble

Error code

• •

Action of controller • • Problem that appears on machine

• • •

Related information

•

Disconnection in S-NET signal line Trouble (Governor and pump controller system) 218 A trouble has occurred in the S-NET communication between the monitor panel and controller (It has been repaired when this error code is displayed). Uses the following default items for control until the trouble is repaired. 1) Working mode: E 2) Travel speed: Lo 3) Auto-decelerator: ON Even if the cause of the failure disappears, the system does not reset itself until the starting switch is turned OFF. The working mode cannot be changed (The working mode displayed in the monitor panel changes normally). The travel speed cannot be changed (The travel speed displayed in the monitor panel changes normally). The auto-decelerator cannot be reset (The auto-decelerator displayed in the monitor panel is reset normally.) This error code is displayed to notify the operator that a trouble has occurred when the S-NET communication between the monitor panel and governor and pump controller becomes normal. The system is normal when the error code is displayed. Check the related devices and circuits and remove the cause of the trouble, however, to prevent reoccurrence of the trouble. Cause

Possible causes and standard value in normal state

Standard value in normal state/Remarks on troubleshooting

aPrepare with starting switch OFF, then carry out troubleshooting without turning starting switch. Disconnection in wiring harness (Disconnection in Wiring harness between P02 (female) (9), (10) Resistance Max. 1 z 1 wiring harness or defective and C02 (female) (21). contact in connector) Wiring harness between P02 (female) (20) and Resistance Max. 1 z C02 (female) (31) aPrepare with starting switch OFF, then carry out troubleshooting withShort circuit with chassis out turning starting switch. ground in wiring harness 2 (Contact with ground cirBetween P02 (female) (9), (10) – C02 (female) Resistance Min. 1 Mz cuit) (21) wiring harness and chassis ground Short circuit with power 3 source in wiring harness (Contact with 24-V circuit)

4 Defective monitor panel

5

Defective governor and pump controller

aPrepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Between P02 (female) (9), (10) – C02 (female) Voltage Max. 1 V (21) wiring harness and chassis ground aPrepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. P02 Voltage Between (9), (10) and (20) 6–9V aPrepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. C02 Voltage Between (21) and (31)

20-336 (1)

6–9V

PC130-7

TROUBLESHOOTING

[218]

Circuit diagram related to S-NET

PC130-7

20-337 (1)

[222]

TROUBLESHOOTING

Error code [222] (Short circuit in LS-EPC solenoid) User code

Error code

– Contents of trouble

222

Action of controller Problem that appears on machine Related information

Trouble

Short circuit in LS-EPC solenoid (Governor and pump controller system)

• An abnormal current flows in the LS-EPC solenoid circuit • Reduces the output to the LS-EPC solenoid circuit 0. • Even if the cause of the failure disappears, the system does not reset itself until the starting switch is turned OFF. • The travel speed is fast at Lo. Amount of flow is large at model B. (The set pressure of the LS valve cannot be controlled) • The output state (current) to the LS-EPC solenoid can be checked with the monitoring function. (Code: 015, by 10 mA) Cause

Standard value in normal state/Remarks on troubleshooting aPrepare with starting switch OFF, then carry out troubleshooting without turning starting switch.

1

Possible causes and standard value in normal state

Defective LS-EPC solenoid (Internal short circuit)

Short circuit with chassis ground in wiring harness 2 (Contact with ground circuit)

V22 (male) Between (1) and (2)

Resistance 7 – 14 z

Between (1) and chassis ground Min. 1 Mz aPrepare with starting switch OFF, then carry out troubleshooting without turning starting switch. Between C03 (female) (6) – V22 (female) (1) Resistance Min. 1 Mz wiring harness and chassis ground aPrepare with starting switch OFF, then carry out troubleshooting without turning starting switch.

3

Defective governor and pump controller

C03 Between (6) and (3), (13), (23)

Resistance 7 – 14 z

Between (6) and chassis ground

Min. 1 Mz

Circuit diagram related to LS-EPC solenoid

20-338 (1)

PC130-7

[223]

TROUBLESHOOTING

Error code [223] (Disconnection in LS-EPC solenoid) User code

Error code

– Contents of trouble Action of controller

223

Problem that appears on machine Related information

Trouble

Disconnection in LS-EPC solenoid (Governor and pump controller system)

• No current flows in the LS-EPC solenoid circuit • None in particular (Since no current flows, the solenoid does not operate). • If the cause of the failure disappears, the system resets itself. • The travel speed is fast at Lo. Amount of flow is large at model B. (The set pressure of the LS valve cannot be controlled) • The output state (current) to the LS-EPC solenoid can be checked with the monitoring function. (Code: 015, by 10 mA) Cause

1

Possible causes and standard value in normal state

Defective LS-EPC solenoid (Internal short circuit)

Standard value in normal state/Remarks on troubleshooting aPrepare with starting switch OFF, then carry out troubleshooting without turning starting switch. V22 (male) Resistance

Between (1) and (2) 7 – 14 z aPrepare with starting switch OFF, then carry out troubleshooting without turning starting switch. Disconnection in wiring harness (Disconnection in Wiring harness between C03 (female) (6) and Resistance Max. 1 z 2 wiring harness or defective V22 (female) (1) contact in connector) Wiring harness between C03 (female) (3), (13), Resistance Max. 1 z (23), and V22 (female) (2) Short circuit with power 3 source in wiring harness (Contact with 24-V circuit)

Defective governor and 4 pump controller

aPrepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Between C03 (female) (6) – V22 (female) (1) wiring harness and chassis ground

Voltage

Max. 1 V

aPrepare with starting switch OFF, then carry out troubleshooting without turning starting switch. C03 Resistance Between (6) and (3), (13), (23)

7 – 14 z

Circuit diagram related to LS-EPC solenoid

PC130-7

20-339 (1)

[224]

TROUBLESHOOTING

Error code [224] (Abnormality in pump pressure sensor) User code

Error code

– Contents of trouble Action of controller

224

Problem that appears on machine Related information

Trouble

Abnormality in pump pressure sensor (Governor and pump controller system)

• The signal voltage from the pump pressure sensor is below 0.3 V or above 4.72 V. • Sets the pump pressure to 0 MPa {0 kg/cm2} for control. • If the cause of the failure disappears, the system resets itself. • The travel speed does not change automatically (The travel load pressure cannot be sensed). • Cut-off function dose not work (The work equipment pressure can not be detected.) • If the 5-V circuit (B) and ground circuit (A) of the pressure sensor are connected inversely, the pressure sensor will be broken. Accordingly, take extreme care when checking. • The input state (ON/OFF) from the pump pressure sensor can be checked with the monitoring function. (Code: 011, 012, by 1 kg/cm2) Cause Defective sensor power 1 supply

Standard value in normal state/Remarks on troubleshooting If error code [226] is displayed, carry out troubleshooting for it first. aPrepare with starting switch OFF, then hold starting switch ON or start engine and carry out troubleshooting.

Defective pump pressure 2 sensor (Internal defect)

A51 Between (B) and (A)

Power supply

Voltage 4.5 – 5.5 V

Between (C) and (A) Signal 0.5 – 4.5 V The pressure sensor voltage is measured with the wiring harness connected. Accordingly, if the voltage is abnormal, check the wiring harness and controller, too, for another cause of the trouble, and then judge. aPrepare with starting switch OFF, then carry out troubleshooting without turning starting switch.

Possible causes and standard value in normal state

Disconnection in wiring harness (Disconnection in 3 wiring harness or defective contact in connector)

Short circuit with chassis ground in wiring harness 4 (Contact with ground circuit)

Short circuit with power 5 source in wiring harness (Contact with 24-V circuit)

6

20-340 (1)

Defective governor and pump controller

Wiring harness between C01 (female) (22) and Resistance J07 and A51 (female) (B)

Max. 1 z

Wiring harness between C01 (female) (10) and Resistance Max. 1 z A51 (female) (A) Wiring harness between C01 (female) (8) and Resistance Max. 1 z A51 (female) (C) aPrepare with starting switch OFF, then carry out troubleshooting without turning starting switch. Between C01 (female) (8) – A51 (female) (C) Resistance Min. 1 Mz wiring harness and chassis ground aPrepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Between C01 (female) (22) – J07 – A51 (female) (B) wiring harness and chassis ground

Voltage

Max. 1 V

Between C01 (female) (8) – A51 (female) (C) Voltage Max. 1 V wiring harness and chassis ground aPrepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. C01 Voltage Between (22) and (10) Between (8) and (10)

Power supply Signal

4.5 – 5.5 V 0.5 – 4.5 V

PC130-7

TROUBLESHOOTING

[224]

Circuit diagram related to pump pressure sensor

PC130-7

20-341 (1)

[226]

TROUBLESHOOTING

Error code [226] (Abnormality in pressure sensor power supply) User code

Error code

– Contents of trouble

226

Action of controller Problem that appears on machine Related information

Trouble

• An abnormal current flows in the power supply (5 V) circuit of the pressure sensor or potentiometer. • Turns the output to the power supply (5 V) circuit OFF. • Even if the cause of the failure disappears, the system does not reset itself until the starting switch is turned OFF. • The signals of the pressure sensor and potentiometer are not input normally. • The error codes of abnormality in the pressure sensor and abnormality in the potentiometer are displayed simultaneously.

Cause

Defective pressure sensor 1 or potentiometer (Internal short circuit)

Possible causes and standard value in normal state

Abnormality in pressure sensor power supply (Governor and pump controller system)

Short circuit with chassis ground in wiring harness 2 (Contact with ground circuit)

Standard value in normal state/Remarks on troubleshooting aDisconnect connector with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Fuel control dial Connector E06 Disconnect the devices Governor Connector E10 at right in order. If the potentiometer error code disappears Pump pressure when a device is disConnector A51 sensor connected, that device Overload pressure has a defect in it. Connector A70 sensor (If installed) aPrepare with starting switch OFF, then carry out troubleshooting without turning starting switch. Between C01 (female) (22) – J07 – E06 (female) (1) wiring harness and chassis ground Resistance Min. 1 Mz [Fuel control dial system] Between C01 (female) (22) – J07 – E10 (female) (A) wiring harness and chassis ground Resistance Min. 1 Mz [Governor potentiometer system] Between C01 (female) (22) – J07 – A51 (female) (B) wiring harness and chassis ground Resistance Min. 1 Mz [Pump pressure sensor system] Between C01 (female) (22) – J07 – A70 (female) (B) wiring harness and chassis ground Resistance Min. 1 Mz [Overload pressure sensor system: If installed]

Defective governor and 3 pump controller

20-342 (1)

aPrepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. C01 Between (22) and (10)

Voltage 4.5 – 5.5 V

PC130-7

TROUBLESHOOTING

[226]

Circuit diagram related to sensor power supply

PC130-7

20-343 (1)

[227]

TROUBLESHOOTING

Error code [227] (Abnormality in engine speed sensor) User code

Error code

– Contents of trouble Action of controller

227

Problem that appears on machine Related information

Trouble

• Normal pulse signals are not input to the signal circuit of the engine speed sensor. • Controls as if in the E-mode. • If the cause of the failure disappears, the system resets itself. • The output power is a little low (The engine speed cannot be sensed). • The input state (ON/OFF) from the engine speed sensor can be checked with the monitoring function. (Code: 010, by 10 rpm) Cause Defective engine speed 1 sensor (Internal short circuit or disconnection)

2

Possible causes and standard value in normal state

Abnormality in engine speed sensor (Governor and pump controller system)

Defective adjustment of engine speed sensor

Standard value in normal state/Remarks on troubleshooting aPrepare with starting switch OFF, then carry out troubleshooting without turning starting switch. E04 (male) Resistance Between (1) and (2) Between (1) and chassis ground

500 – 1,000 z Min. 1 Mz

See TESTING AND ADJUSTING, Adjusting engine speed sensor. aPrepare with starting switch OFF, then carry out troubleshooting without turning starting switch.

Disconnection in wiring harness (Disconnection in Wiring harness between C01 (female) (40) and Resistance Max. 1 z 3 wiring harness or defective E04 (female) (1) contact in connector) Wiring harness between C01 (female) (29), Resistance Max. 1 z (39) and E04 (female) (2) aPrepare with starting switch OFF, then turn starting switch ON and carShort circuit with power ry out troubleshooting. 4 source in wiring harness Between C01 (female) (40) – E04 (female) (1) (Contact with 24-V circuit) Voltage Max. 1 V wiring harness and chassis ground aPrepare with starting switch OFF, then carry out troubleshooting without turning starting switch. 5

20-344 (1)

Defective governor and pump controller

C02 Between (40) and (29), (39)

Resistance 500 – 1,000 z

Between (40) and chassis ground

Min. 1 Mz

PC130-7

TROUBLESHOOTING

[227]

Circuit diagram related to engine speed sensor

PC130-7

20-345 (1)

[232]

TROUBLESHOOTING

Error code [232] (Short circuit in PC-EPC solenoid) User code

Error code

E02 Contents of trouble

232

Action of controller Problem that appears on machine Related information

Trouble

Short circuit in PC-EPC solenoid (Governor and pump controller system)

• An abnormal current flows in the PC-EPC solenoid circuit. • Turns the output to the LS-EPC solenoid circuit OFF. • Even if the cause of the failure disappears, the system does not reset itself until the starting switch is turned OFF. • If the pump load increases, the engine speed lowers largely and the engine may stall (The pump absorption torque cannot be controlled). • The output state (current) to the PC-EPC solenoid can be checked with the monitoring function. (Code: 013, by 10 mA) Cause

Standard value in normal state/Remarks on troubleshooting aPrepare with starting switch OFF, then carry out troubleshooting without turning starting switch.

1

Possible causes and standard value in normal state

Defective PC-EPC solenoid (Internal short circuit)

V21 (male) Between (1) and (2)

Resistance 7 – 14 z

Between (1) and chassis ground Min. 1 Mz aPrepare with starting switch OFF, then carry out troubleshooting without turning starting switch. Emergency pump drive Defective emergency pump S25 (male) Resistance switch 2 drive switch (Internal short circuit or disconnection) Between (3) and (4) Min. 1 Mz Normal Between (3) and Min. 1 Mz chassis ground aPrepare with starting switch OFF, then carry out troubleshooting without turning starting switch. Short circuit with chassis ground in wiring harness Between C03 (female) (16) – S25 (female) (3) Resistance Min. 1 Mz 3 (Contact with ground cirwiring harness and chassis ground cuit) Between S25 (female) (2) – V21 (female) (1) Resistance Min. 1 Mz wiring harness and chassis ground aPrepare with starting switch OFF, then carry out troubleshooting without turning starting switch. 4

20-346 (1)

Defective governor and pump controller

C03 (female) Between (16) and (3), (13), (23)

Resistance 7 – 14 z

Between (16) and chassis ground

Min. 1 Mz

PC130-7

TROUBLESHOOTING

[232]

Circuit diagram related to PC-EPC solenoid

PC130-7

20-347 (1)

[233]

TROUBLESHOOTING

Error code [233] (Disconnection in PC-EPC solenoid) User code

Error code

E02 Contents of trouble Action of controller

233

Problem that appears on machine Related information

Trouble

Disconnection in PC-EPC solenoid (Governor and pump controller system)

• No current flows in the PC-EPC solenoid circuit. • None in particular (Since no current flows, the solenoid does not operate). • If the cause of the failure disappears, the system resets itself. • If the pump load increases, the engine speed lowers largely and the engine may stall (The pump absorption torque cannot be controlled). • The output state (current) to the PC-EPC solenoid can be checked with the monitoring function. (Code: 013, by 10 mA) Cause

Standard value in normal state/Remarks on troubleshooting

aPrepare with starting switch OFF, then carry out troubleshooting without turning starting switch. Defective PC-EPC solenoid 1 (Internal short circuit) V21 (male) Resistance Between (1) and (2) 7 – 14 z aPrepare with starting switch OFF, then carry out troubleshooting without turning starting switch. Emergency pump drive S25 (male) Resistance Defective emergency pump switch 2 drive switch (Internal short Normal Max. 1 z circuit or disconnection) Between (2) and (3) Emergency Min. 1 Mz Normal Max. 1 z Between (5) and (6) Emergency Min. 1 Mz aPrepare with starting switch OFF, then carry out troubleshooting without turning starting switch. Possible causes and standard value in normal state

Disconnection in wiring harness (Disconnection in 3 wiring harness or defective contact in connector)

Short circuit with power 4 source in wiring harness (Contact with 24-V circuit)

5

20-348 (1)

Defective governor and pump controller

Wiring harness between C03 (female) (16) and Resistance S25 (female) (3)

Max. 1 z

Wiring harness between S25 (female) (2) and V21 (female) (1)

Max. 1 z

Resistance

Wiring harness between C03 (female) (3), (13), Resistance Max. 1 z (23) and S25 (female) (6) Wiring harness between S25 (female) (5) and Resistance Max. 1 z V21 (female) (2) aPrepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Between C03 (female) (16) – S25 (female) (3) Voltage Max. 1 V wiring harness and chassis ground Between S25 (female) (2) – V21 (female) (1) wiring harness and chassis ground

Voltage

Max. 1 V

aPrepare with starting switch OFF, then carry out troubleshooting without turning starting switch. C03 (female) Between (16) and (3), (13), and (23)

Resistance 7 – 14 z

PC130-7

TROUBLESHOOTING

[233]

Circuit diagram related to PC-EPC solenoid

PC130-7

20-349 (1)

[251]

TROUBLESHOOTING

Error code [251] (Abnormality in overload pressure sensor) User code

Error code

– Contents of trouble Action of controller

251

Problem that appears on machine Related information

Trouble

Abnormality in overload pressure sensor (Governor and pump controller system)

• The signal voltage from the overload pressure sensor is below 0.3 V or above 4.72 V. • Sets the boom cylinder bottom pressure to 0 MPa {0 kg/cm2} for control. • If the cause of the failure disappears, the system resets itself. • The overload caution function does not operate (The load pressure on the boom cylinder bottom side cannot be sensed). aIf the 5-V circuit (B) and ground circuit (A) of the pressure sensor are connected inversely, the pressure sensor will be broken. Accordingly, take extreme care when checking. Cause Defective sensor power 1 supply system

Standard value in normal state/Remarks on troubleshooting If error code [226] is displayed, carry out troubleshooting for it first. aPrepare with starting switch OFF, then hold starting switch ON or start engine and carry out troubleshooting. A70 Voltage

Defective overload pres2 sure sensor (Internal defect)

Possible causes and standard value in normal state

Between (B) and (A) Between (C) and (A)

Power supply Signal

4.5 – 5.5V 0.5 – 4.5V

The pressure sensor voltage is measured with the wiring harness connected. Accordingly, if the voltage is abnormal, check the wiring harness and controller, too, for another cause of the trouble, and then judge. aPrepare with starting switch OFF, then carry out troubleshooting without turning starting switch. Wiring harness between C01 (female) (22) and Resistance Max. 1 z J07 and A70 (female) (B)

Disconnection in wiring harness (Disconnection in 3 wiring harness or defective Wiring harness between C01 (female) (10) and Resistance contact in connector) A70 (female) (A) Wiring harness between C01 (female) (7) and A70 (female) (C) Short circuit with chassis ground in wiring harness 4 (Contact with ground circuit)

Short circuit with power 5 source in wiring harness (Contact with 24-V circuit)

Resistance

Max. 1 z Max. 1 z

aPrepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Between C01 (female) (7) - A70 (female) (C) Resistance Min. 1 Mz wiring harness and chassis ground aPrepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Between C01 (female) (22) – J07 – A70 Voltage Max. 1 V (female) (B) wiring harness and chassis ground Between C01 (female) (7) – A70 (female) (C) wiring harness and chassis ground

Voltage

Max. 1 V

aPrepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. 6

Defective governor and pump controller

C01 Between (22) and (10) Between (7) and (10)

20-350 (1)

Power supply

Voltage 4.5 – 5.5 V

Signal

0.5 – 4.5 V

PC130-7

TROUBLESHOOTING

[251]

Circuit diagram related to overload pressure sensor

PC130-7

20-351 (1)

[301], [302]

TROUBLESHOOTING

Error code [301] (Engine low idling speed out of standard range) User code

Error code

– Contents of trouble Action of controller

301

Problem that appears on machine Related information

Trouble

• Engine speed below 500 rpm is sensed for continuous 10 seconds while the engine is running. • None in particular. • If the cause of the failure disappears, the system resets itself. • If the machine is operated as it is, the engine may be damaged. • The input state (rpm) from the engine speed sensor can be checked with the monitoring function. (Code: 010, by 10 rpm) Cause

Possible causes and standard value in normal state

Engine low idling speed out of standard range (Governor and pump controller system)

Standard value in normal state/Remarks on troubleshooting

Check for external and internal factors that have lowered the engine low Abnormality in mechanical 1 idling speed, and then carry out troubleshooting for the mechanical syssystem of engine tem of the engine. 2

Defective governor and pump controller

Troubleshooting cannot be carried out since the defect is in the governor and pump controller. (If there is not any visible trouble in the machine, the controller may be used as it is.)

Error code [302] (Engine high idling speed out of standard range) User code – Contents of trouble Action of controller Problem that appears on machine Related information

Error code 302

20-352 (1)

Engine high idling speed out of standard range (Governor and pump controller system)

• Engine speed above 2,600 rpm is sensed for continuous 10 seconds while the engine is running. • None in particular. • If the cause of the failure disappears, the system resets itself. • If the machine is operated as it is, the engine may be damaged. • The input state (rpm) from the engine speed sensor can be checked with the monitoring function. (Code: 010, by 10 rpm) Cause

Possible causes and standard value in normal state

Trouble

Standard value in normal state/Remarks on troubleshooting

Check for external and internal factors that have heightened the engine Abnormality in mechanical 1 high idling speed, and then carry out troubleshooting for the mechanical system of engine system of the engine. Troubleshooting cannot be carried out since the defect is in the goverDefective governor and 2 nor and pump controller. (If there is not any visible trouble in the pump controller machine, the controller may be used as it is.)

PC130-7

[306]

TROUBLESHOOTING

Error code [306] (Abnormality in governor potentiometer) User code

Error code

– Contents of trouble

306

Action of controller

Problem that appears on machine Related information

Trouble

Abnormality in governor potentiometer (Governor and pump controller system)

• The signal voltage from the governor potentiometer is below 0.4 V or above 4.6 V. • Calculates the motor position from the voltage just before occurrence of the trouble and uses it for control. • Even if the cause of the failure disappears, the system does not reset itself until the starting switch is turned OFF. • • • • • •

The high idling speed is not obtained (it is a little low). The low idling speed is not obtained (it is a little high). The auto-decelerator or automatic warm-up system does not operate. The engine stalls. The engine does not stop. The input state (voltage) from the governor potentiometer can be checked with the monitoring function. (Code: 031, by 10 mV) Cause

Defective sensor power 1 supply system

Standard value in normal state/Remarks on troubleshooting If error code [226] is displayed, carry out troubleshooting for it first. aPrepare with starting switch OFF, then carry out troubleshooting without turning starting switch.

2

Possible causes and standard value in normal state

Defective governor potentiometer (Internal defect)

E10 (male) Between (A) and (C)

Resistance 4.0 – 6.0 z

Between (B) and (A) Between (B) and (C)

0.25 – 5.0 z 0.25 – 5.0 z

aPrepare with starting switch OFF, then carry out troubleshooting without turning starting switch. Wiring harness between C01 (female) (22) and Disconnection in wiring Resistance Max. 1 z harness (Disconnection in J07 and E10 (female) (A) 3 wiring harness or defective Wiring harness between C01 (female) (21) and Resistance Max. 1 z contact in connector) E10 (female) (C) Wiring harness between C01 (female) (13) and Resistance Max. 1 z E10 (female) (B) Short circuit with chassis ground in wiring harness 4 (Contact with ground circuit)

Short circuit with power 5 source in wiring harness (Contact with 24-V circuit)

6

Defective governor and pump controller

aPrepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Between C01 (female) (13) – E10 (female) (B) wiring harness and chassis ground

aPrepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Between C01 (female) (22) – J07 – E10 Voltage Max. 1 V (female) (A) wiring harness and chassis ground Between C01 (female) (13) – E10 (female) (B) Voltage Max. 1 V wiring harness and chassis ground aPrepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. C01 Between (22) and (21) Between (13) and (21)

20-354 (1)

Resistance Min. 1 Mz

Power supply

Voltage 4.5 – 5.5 V

Signal

0.5 – 4.5 V

PC130-7

TROUBLESHOOTING

[306]

Circuit diagram related to governor motor and potentiometer

PC130-7

20-355 (1)

[308]

TROUBLESHOOTING

Error code [308] (Abnormality in fuel control dial) User code

Error code

E05 Contents of trouble

308

Action of controller Problem that appears on machine Related information

Trouble

Abnormality in fuel control dial (Governor and pump controller system)

• The signal voltage from the fuel control dial is below 0.23 V or above 4.77 V. • Calculates the fuel control dial position from the voltage just before occurrence of the trouble and uses it for control. • If the cause of the failure disappears, the system resets itself. • If the output was set in the full mode before occurrence of the failure, it is not set in the partial mode. • If the output was set in the partial mode before occurrence of the failure, it is not set in the full mode. • The engine hunts. • The high idling speed is not obtained and the output is insufficient. • The input state (voltage) from the fuel control dial can be checked with the monitoring function. (Code: 030, by 10 mV) Cause Defective sensor power 1 supply system

Standard value in normal state/Remarks on troubleshooting If error code [226] is displayed, carry out troubleshooting for it first. aPrepare with starting switch OFF, then carry out troubleshooting without turning starting switch.

2

Defective fuel control dial (Internal defect)

E06 (male) Between (A) and (C)

Resistance 4.0 – 6.0 z

Between (B) and (A) Between (B) and (C)

0.25 – 5.0 z 0.25 – 5.0 z

aPrepare with starting switch OFF, then carry out troubleshooting without turning starting switch.

Possible causes and standard value in normal state

Disconnection in wiring harness (Disconnection in 3 wiring harness or defective contact in connector)

Short circuit with chassis ground in wiring harness 4 (Contact with ground circuit)

Short circuit with power 5 source in wiring harness (Contact with 24-V circuit)

6

20-356 (1)

Defective governor and pump controller

Wiring harness between C01 (female) (22) and Resistance J07 and E06 (female) (1)

Max. 1 z

Wiring harness between C01 (female) (21) and Resistance Max. 1 z E06 (female) (3) Wiring harness between C01 (female) (19) and Resistance Max. 1 z E06 (female) (2) aPrepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Between C01 (female) (19) – E06 (female) (2) Resistance Min. 1 Mz wiring harness and chassis ground aPrepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Between C01 (female) (22) – J07 – E06 (female) (1) wiring harness and chassis ground

Voltage

Max. 1 V

Between C01 (female) (19) – E06 (female) (2) Voltage Max. 1 V wiring harness and chassis ground aPrepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. C01 Voltage Between (22) and (21) Between (19) and (21)

Power supply Signal

4.5 – 5.5 V 0.5 – 4.5 V

PC130-7

TROUBLESHOOTING

[308]

Circuit diagram related to fuel control dial

PC130-7

20-357 (1)

[315]

TROUBLESHOOTING

Error code [315] (Short circuit in battery relay output line) User code

Error code

– Contents of trouble

315

Action of controller Problem that appears on machine Related information

Trouble

Abnormality in battery relay output (Governor and pump controller system)

• When the signal is output to the battery relay drive circuit, an abnormal current flows. • Turns off the output to the battery relay drive circuit OFF. • Even if the cause of the failure disappears, the system does not reset itself until the starting switch is turned OFF. • The engine does not stop (The controller power supply cannot be maintained until the engine stops). • The operation state (ON/OFF) of the battery relay can be checked with the monitoring function. (Code: 037, Right of upper line) Cause

Standard value in normal state/Remarks on troubleshooting aPrepare with starting switch OFF, then carry out troubleshooting without turning starting switch.

1

Possible causes and standard value in normal state

Short circuit with chassis ground in wiring harness 2 (Contact with ground circuit)

3

20-358 (1)

Defective battery relay (Internal short circuit)

Defective governor and pump controller

Battery relay (unit) Between A21 (BR) and A20 (E)

Resistance Approx. 100 z

Between A21 (BR) and chassis ground

Min. 1 Mz

aPrepare with starting switch OFF, then carry out troubleshooting without turning starting switch. Between C03 (female) (4) – D01 – J01 – A21 Resistance Min. 1 Mz (BR) wiring harness and chassis ground aPrepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. C03 Starting switch Voltage Between (4) and chassis ground

ON o OFF

20 – 30 V (For 4 – 7sec)

PC130-7

TROUBLESHOOTING

[315]

Circuit diagram related to battery relay

PC130-7

20-359 (1)

[316]

TROUBLESHOOTING

Error code [316] (Step-out of governor motor) User code

Error code

– Contents of trouble

316

Action of controller Problem that appears on machine Related information

Trouble

• The input signal from the governor potentiometer is much different from the set value in the controller. • Repeats the control operation (steps out). • Even if the cause of the failure disappears, the system does not reset itself until the starting switch is turned OFF. • The engine speed cannot be controlled. • The engine hunts. • The engine does not stop.

Cause

Possible causes and standard value in normal state

(1)

Standard value in normal state/Remarks on troubleshooting

1

Defective fuel control dial system

2

Defective governor potentiIf error code [306] is displayed, carry out troubleshooting for it first. ometer system

Defective governor motor system (Disconnection) Defective governor motor 4 system (Short circuit) Defective adjustment of 5 governor lever Defective fuel control sys6 tem of engine 3

7

20-360

Step-out of governor motor (Governor and pump controller system)

Defective governor and pump controller

If error code [308] is displayed, carry out troubleshooting for it first.

If error code [317] is displayed, carry out troubleshooting for it first. If error code [318] is displayed, carry out troubleshooting for it first. See TESTING AND ADJUSTING, Special functions of monitor panel See Shop Manual for 95-3 Series engine. Troubleshooting cannot be carried out since the defect is in the controller (If none of causes 1 – 6 is the cause of the trouble, the controller is defective).

PC130-7

[317]

TROUBLESHOOTING

Error code [317] (Disconnection in phases A and B of governor motor) User code

Error code

E05 Contents of trouble Action of controller

317

Problem that appears on machine Related information

Trouble

Disconnection in phases A and B of governor motor (Governor and pump controller system)

• When the signal is output to the governor motor, no current flows. • None in particular. • If the cause of the failure disappears, the system resets itself. • • • • •

The engine speed is set to low idling. The engine hunts. The engine does not stop. The governor motor steps out. The operation state (current) of the governor motor can be checked with the monitoring function. (Code: 033 - Phase A, 034 - Phase B, by 10 mA) Cause

Standard value in normal state/Remarks on troubleshooting aPrepare with starting switch OFF, then carry out troubleshooting without turning starting switch.

1

Possible causes and standard value in normal state

(1)

E11 (male) Between (1) and (2)

Resistance 2.5 – 7.5 z

Between (3) and (4) 2.5 – 7.5 z aPrepare with starting switch OFF, then carry out troubleshooting without turning starting switch. Wiring harness between C03 (female) (5) and Resistance Max. 1 z E11 (female) (1)

Disconnection in wiring harness (Disconnection in Wiring harness between C03 (female) (15) and Resistance 2 wiring harness or defective E11 (female) (2) contact in connector) Wiring harness between C03 (female) (25) and Resistance E11 (female) (3)

3

20-362

Defective governor motor (Internal disconnection)

Defective governor and pump controller

Max. 1 z Max. 1 z

Wiring harness between C03 (female) (35) and Resistance Max. 1 z E11 (female) (4) aPrepare with starting switch OFF, then carry out troubleshooting without turning starting switch. C03 (female) Resistance Between (5) and (15) Between (25) and (35)

2.5 – 7.5 z 2.5 – 7.5 z

PC130-7

TROUBLESHOOTING

[317]

Circuit diagram related to governor motor and potentiometer

PC130-7

20-363 (1)

[318]

TROUBLESHOOTING

Error code [318] (Short circuit in phases A and B of governor motor) User code

Error code

E05 Contents of trouble Action of controller

318

Problem that appears on machine Related information

Trouble

Short circuit in phases A and B of governor motor (Governor and pump controller system)

• When the signal is output to the governor motor, an abnormal current flows. • None in particular. • If the cause of the failure disappears, the system resets itself. • • • • •

The engine speed cannot be controlled. The engine speed is set to low idling. The engine hunts. The engine does not stop. The operation state (current) of the governor motor can be checked with the monitoring function. (Code: 033 - Phase A, 034 - Phase B, by 10 mA) Cause

Standard value in normal state/Remarks on troubleshooting aPrepare with starting switch OFF, then carry out troubleshooting without turning starting switch.

Defective governor motor 1 (Internal disconnection)

Possible causes and standard value in normal state

Short circuit with chassis ground in wiring harness 2 (Contact with ground circuit)

E11 (male) Between (1) and (2)

Resistance 2.5 – 7.5 z

Between (3) and (4) Between (1) and chassis ground

2.5 – 7.5 z Min. 1 Mz

Between (3) and chassis ground Min. 1 Mz aPrepare with starting switch OFF, then carry out troubleshooting without turning starting switch. Between C03 (female) (5) – E11 (female) (1) Resistance Min. 1 Mz wiring harness and chassis ground Between C03 (female) (15) – E11 (female) (2) wiring harness and chassis ground

Resistance Min. 1 Mz

Between C03 (female) (25) – E11 (female) (3) wiring harness and chassis ground

Resistance Min. 1 Mz

Between C03 (female) (35) – E11 (female) (4) Resistance Min. 1 Mz wiring harness and chassis ground aPrepare with starting switch OFF, then carry out troubleshooting without turning starting switch. C03 (female) Resistance Defective governor and 3 pump controller

20-364 (1)

Between (5) and (15) Between (25) and (35)

2.5 – 7.5 z 2.5 – 7.5 z

Between (5) and chassis ground Between (15) and chassis ground

Min. 1 Mz Min. 1 Mz

Between (25) and chassis ground Between (35) and chassis ground

Min. 1 Mz Min. 1 Mz

PC130-7

TROUBLESHOOTING

[318]

Circuit diagram related to governor motor and potentiometer

PC130-7

20-365 (1)

TROUBLESHOOTING FOR ELECTRICAL SYSTEM (E-MODE) BEFORE CARRYING OUT TROUBLESHOOTING WHEN CODE IS DISPLAYED................................... 20-402 INFORMATION IN TROUBLESHOOTING TABLE ..................................................................................... 20-403 E- 1 Engine does not start......................................................................................................................... 20-404 E- 2 Engine stops during operation........................................................................................................... 20-408 E- 3 Engine speed is unstable or engine hunts......................................................................................... 20-410 E- 4 Engine does not stop......................................................................................................................... 20-412 E- 5 Auto-decelerator does not operate .................................................................................................... 20-414 E- 6 Automatic warm-up system does not operate ................................................................................... 20-415 E- 7 Preheater does not operate............................................................................................................... 20-416 E- 8 Work equipment, swing, and travel system do not operate ............................................................... 20-418 E- 9 One-touch power maximizing system does not operate.................................................................... 20-420 E-10 No items of monitor panel light up ..................................................................................................... 20-421 E-11 7-segment LED's of monitor panel does not light up partially............................................................ 20-422 E-12 Monitor lamp of monitor panel is different from mounted model........................................................ 20-422 E-13 When starting switch is turned ON, basic check items light up or flash ............................................ 20-423 E-14 While engine is running, caution items flash ..................................................................................... 20-424 E-15 While engine is running, emergency stop items flash ....................................................................... 20-428 E-16 Engine coolant thermometer is abnormal.......................................................................................... 20-430 E-17 Fuel level gauge is abnormal............................................................................................................. 20-431 E-18 Swing lock monitor is abnormal......................................................................................................... 20-432 E-19 When monitor switch is operated, display by lamp does not change ................................................ 20-434 E-20 Windshield wiper and windshield washer do not operate.................................................................. 20-436 E-21 Lower windshield wiper does not operate ......................................................................................... 20-440 E-22 Caution buzzer does not stop............................................................................................................ 20-442 E-23 Monitoring function does not display "Boom RAISE" normally .......................................................... 20-444 E-24 Monitoring function does not display "Boom LOWER" normally ....................................................... 20-446 E-25 Monitoring function does not display "Arm IN" normally .................................................................... 20-448 E-26 Monitoring function does not display "Arm OUT" normally ................................................................ 20-450 E-27 Monitoring function does not display "Bucket CURL" normally ......................................................... 20-452 E-28 Monitoring function does not display "Bucket DUMP" normally ........................................................ 20-454 E-29 Monitoring function does not display "Swing" normally ..................................................................... 20-456 E-30 Monitoring function does not display "Travel" normally ..................................................................... 20-458 E-31 Monitoring function does not display "service" normally.................................................................... 20-460 E-32 Troubleshooting of air conditioner ..................................................................................................... 20-464 E-33 Travel alarm does not sound or does not stop sounding................................................................... 20-475

PC130-7

20-401 (1)

TROUBLESHOOTING

BEFORE CARRYING OUT TROUBLESHOOTING WHEN CODE IS DISPLAYED

BEFORE CARRYING OUT TROUBLESHOOTING WHEN CODE IS DISPLAYED Connection table of fuse box

a This connection table shows the devices to which each power supply of the fuse box (FB1) supplies power (A switch power supply is a device which supplies power while the starting switch is at the ON position and a constant power supply is a device which supplies power while the starting switch is at the OFF position). a When carrying out troubleshooting related to the electrical system, you should check the fuse box and fusible link to see if the power is supplied normally. Type of power supply

Fuse No.

Fuse capacity

Destination of power Governor and pump controller (Controller power supply)

1

10A

PC-EPC solenoid (Emergency pump drive switch circuit) Swing holding brake solenoid (Swing holding brake release switch circuit)

Switch power supply (Fusible link: A34)

2

20A

3

10A

Governor and pump controller (Solenoid power supply) PPC oil pressure lock solenoid Starting motor cutout relay (For PPC lock) Cigarette lighter

4

10A Windshield washer motor

Switch power supply (Fusible link: A34)

5

10A

Horn

6

10A

Lower wiper motor [If equipped]

7

10A

Rotary lamp [If equipped]

8

10A

Working lamp (Boom and right front) Working lamp (Left front and rear) [If equipped] 9

10A

One-touch power maximizing switch circuit

10

10A

Fuel priming pump [If equipped]

11

20A

Air conditioner unit

12

20A

Starting motor cutout relay (For personal code) Monitor panel (Switch power supply) Light relay 1 Switch power supply (Fusible link: A34)

13

20A

Light relay 2 Panel night light signal circuit

14

10A

15

10A

Heated seat [If equipped] Heated seat [If equipped] Travel alarm [If equipped]

Constant power supply (Fusible link: A35)

20-402 (1)

16

10A

DC/DC converter (Power supply to 12-V devices)

17

20A

Monitor panel (Constant power supply)

18

10A

Starting switch

19

10A

Room lamp

20

10A

(Spare)

PC130-7

INFORMATION IN TROUBLESHOOTING TABLE

TROUBLESHOOTING

INFORMATION IN TROUBLESHOOTING TABLE a The following information is summarized in the troubleshooting table and the related electrical circuit diagram. Before carrying out troubleshooting, understand that information fully. Trouble Related information

Trouble which occurred in the machine Information related to the detected trouble or troubleshooting Cause