Hitachi ZX38U-5A Hydraulic Excavator Technical Manual

PART NO.

TADC-EN-01

ZX38U-5A HYDRAULIC EXCAVATOR TECHNICAL MANUAL

Technical Manual

ZX

38U-5A

Hydraulic Excavator

URL:http://www.hitachi-c-m.com

TADC-EN-01

PRINTED IN JAPAN (K) 2014, 09

Service Manual consists of the following separate Part No. Technical Manual : Vol. No.TADC-EN Workshop Manual : Vol. No.WADC-EN Engine Manual : Vol. No.ETADB-EN, EWADB-EN

INTRODUCTION To The Reader This manual is written for an experienced technician to provide technical information needed to maintain and repair this machine.

The machine specification and description according to destination may be explained on this manual.

 If you have any questions or comments, at if you found any errors regarding the contents of this manual, please contact using “Service Manual Revision Request Form” at the end of this manual. (Note: Do not tear off the form. Copy it for usage.):  Technical Information Center Hitachi Construction Machinery Co., Ltd.  TEL: 81-29-832-7084  FAX: 81-29-831-1162  E-mail: HCM-TIC-GES@hitachi-kenki.com

 Be sure to thoroughly read this manual for correct product information and service procedures.

Additional References Please refer to the other materials (operator’s manual, parts catalog, engine technical material and Hitachi training material etc.) in addition to this manual.

Manual Composition  Information included in the Workshop Manual: Technical information needed for maintenance and repair of the machine, tools and devices needed for maintenance and repair, maintenance standards, and removal / installation and assemble / disassemble procedures.

This manual consists the Technical Manual, the Workshop Manual and the Engine Manual.  Information included in the Technical Manual: Technical information needed for redelivery and delivery, operation and activation of all devices and systems, operational performance tests, and troubleshooting procedures.

 Information included in the Engine Manual: Technical information needed for redelivery and delivery and maintenance and repair of the machine, operation and activation of all devices and systems, troubleshooting and assemble / disassemble procedures.

Page Number Each page has a number, located on the center lower part of the page, and each number contains the following information: Example:  Technical Manual: T 1-3-5 T 1 3 5

 Workshop Manual: W 1-3-2-5 W 1 3 2 5

Technical Manual Section Number Group Number Consecutive Page Number for Each Group

IN-01

Workshop Manual Section Number Group Number Sub Group Number Consecutive Page Number for Each Group

INTRODUCTION Safety Alert Symbol and Headline Notations In this manual, the following safety alert symbol and signal words are used to alert the reader to the potential for personal injury of machine damage.

dCAUTION: Indicates potentially hazardous situation which could, if not avoided, result in personal injury or death.

d This is the safety alert symbol. When you see this

IMPORTANT: Indicates a situation which, if not conformed to the instructions, could result in damage to the machine.

symbol, be alert to the potential for personal injury.

Never fail to follow the safety instructions prescribed along with the safety alert symbol.

The safety alert symbol is also used to draw attention to component/part weights.

To avoid injury and damage, be sure to use appropriate lifting techniques and equipment when lifting heavy parts.

fNOTE: Indicates supplementary technical information or knowhow.

Units Used SI Units (International System of Units) are used in this manual. MKSA system units and English units are also indicated in parentheses just behind SI units.

Example: 24.5 MPa (250 kgf/cm2, 3560 psi) A table for conversion from SI units to other system units is shown below for reference purposes.

Quantity

To Convert From

Into

Multiply By

Length

mm

in

0.03937

mm

ft

0.003281

L

US gal

0.2642

L

US qt

1.057

m3

yd3

1.308

Weight

kg

lb

2.205

Force

N

kgf

0.10197

N

lbf

0.2248

Torque

N·m

kgf·m

Pressure

MPa

kgf/cm

MPa

psi

145.0

kW

PS

1.360

kW

HP

1.341

Temperature

°C

°F

°C×1.8+32

Velocity

km/h

mph

0.6214

min

rpm

1.0

L/min

US gpm

0.2642

mL/rev

cc/rev

1.0

Volume

Power

Flow rate

-1

fNOTE:

The numerical value in this manual might be different from the above-mentioned table.

IN-02

0.10197 2

10.197

SYMBOL AND ABBREVIATION Symbol / Abbreviation TO TT T/M W, W/M E-ECU GSM

GPS CAN

A/C OP, OPT MPDr. A/I WU Li ATT HI, Hi LO, Lo EGR

CSD

Name

Explanation

Technical manual (Operational principle) Technical manual (Troubleshooting) Technical manual Workshop manual

Technical manual (Operational Principle).

Technical manual (Troubleshooting).

Technical manual.

Workshop manual (Removal and Installation, Disassembly and Assembly).

Engine Controller Engine controller. E-ECU controls fuel injection amount according to the machine operating condition.

Global System for Mobile communications Communication controller. GSM is a type of wireless controller communication system, is used in more than on 100 countries around Europe and Asia, and becomes the factual global standards of the mobile telephone.

Global Positioning System Global positioning system.

Controller Area Network CAN communication. CAN is a serial communications protocol internationally-standardized by ISO (International Organization for Standardization).

Air Conditioner Air conditioner.

Option Optional component.

Maintenance Pro Dr. MPDr. is software that troubleshooting, monitoring, and adjustment.

Auto-Idle Auto-idle.

Warming-Up Warming-up.

Low (Slow) Idle Slow idle engine speed.

Attachment Attachment. Attachment is optional parts such as breaker, crusher, and pulverizer in this manual.

High Travel fast position.

Low Travel slow position.

Exhaust Gas Recirculation The EGR control re-circulates a part of exhaust gas in the intake manifold and combines it with intake-air. Therefore, combustion temperature is lowered and generation of oxide of nitrogen (NOx) is controlled.

Cold Start Device Engine start device at low temperature. It increasingly advances the fuel injection timing and increases the fuel injection amount a little when coolant temperature is less than 5 °C. Therefore, the engine starting is improved.

SY-1

SYMBOL AND ABBREVIATION (Blank)

SY-2

SAFETY Recognize Safety Information  These are the SAFETY ALERT SYMBOLS.  When you see these symbols on your machine or in this manual, be alert to the potential for personal injury.  Follow recommended precautions and safe operating practices.

SA-688

Understand Signal Words  On machine safety signs, signal words designating the degree or level of hazard - DANGER, WARNING, or CAUTION - are used with the safety alert symbol.  DANGER indicates an imminently hazardous situation which, if not avoided, will result in death or serious injury.  WARNING indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury.  CAUTION indicates a potentially hazardous situation which, if not avoided, may result in minor or moderate injury.  DANGER or WARNING safety signs are located near specific hazards. General precautions are listed on CAUTION safety signs.  Some safety signs do not use any of the designated signal words above after the safety alert symbol are occasionally used on this machine.  CAUTION also calls attention to safety message in this manual.  To avoid confusing machine protection with personal safety messages, a signal word IMPORTANT indicates a situation which, if not avoided, could result in damage to the machine.

fNOTE:

indicates an additional explanation for an element of information.

SA-1

SA-1223

SAFETY Follow Safety Instructions  Carefully read and follow all safety signs on the machine as well as all safety messages in operator's manual.  Safety signs must be installed, maintained and replaced if damaged.  If a safety sign or operator's manual is damaged or missing, order a replacement from your authorized dealer in the same way you order other replacement parts (be sure to state machine model and serial number when ordering).  Allow only properly trained, qualified, authorized personnel to operate the machine.  Learn how to correctly operate and service the machine.  Keep your machine in proper working condition.  Unauthorized modifications of the machine may impair its function and/or safety and affect machine life.  Do not modify any machine parts without authorization.

Failure to do so may deteriorate the part safety, function, and/or service life. In addition, personal accident, machine trouble, and/or damage to material caused by unauthorized modifications will void Hitachi Warranty Policy.  Do not use attachments and/or optional parts or equipment not authorized by Hitachi. Failure to do so may deteriorate the safety, function, and/or service life of the machine. In addition, personal accident, machine trouble, and/or damage to material caused by using unauthorized attachments and/or optional parts or equipment will void Hitachi Warranty Policy.  The safety messages in this SAFETY chapter are intended to illustrate basic safety procedures of machines. However it is impossible for these safety messages to cover every possible hazardous situation you may encounter. If you have any questions concerning safety, you should first consult your supervisor and/or your authorized dealer before operating or performing maintenance work on the machine.

SA-2

SA-003

SAFETY Prepare For Emergencies  Be prepared if a fire starts or if an accident occurs.  Keep a first aid kit and fire extinguisher on hand.  Thoroughly read and understand the label attached on the fire extinguisher and use it properly.  To ensure that a fire extinguisher can be always used when necessary, check and service the fire extinguisher at the recommended intervals as specified in the fireextinguisher manual.  Establish emergency procedure guidelines to cope with any fire or accidents which may occur.  Keep emergency numbers for doctors, ambulance service, hospitals, and fire department posted near your telephone.

SA-437

Wear Protective Clothing  Wear close fitting clothing and safety equipment appropriate to the job.

You may need: A hard hat Safety belt Safety shoes Safety glasses, goggles, or face shield Heavy gloves Hearing protection Reflective clothing Wet weather gear Respirator or filter mask Be sure to wear the correct equipment and clothing for the job. Do not take any chances.  Avoid wearing loose clothing, jewelry, or other items that can catch on control levers or other parts of the machine.  Operating equipment safely requires the full attention of the operator. Do not wear radio or music headphones while operating the machine.

SA-3

SA-438

SAFETY Protect Against Noise  Prolonged exposure to loud noise can cause impairment or loss of hearing.  Wear a suitable hearing protective device such as earmuffs or earplugs to protect against objectionable or uncomfortably loud noises.

SA-434

Inspect Machine  If any abnormality is found, be sure to repair it immediately before operating the machine.  In the walk-around inspection, be sure to cover all points described in the “Daily Inspection” section in the operator’s manual.

SA-435

SA-4

SAFETY General Precautions for Cab  Always keep inside the cab clean by observing instructions below, to prevent any personal accidents from occurring.  Before entering the cab, thoroughly remove all dirt and/or oil such as mud, grease, soil or stones that may mess up the cab from the soles of your work boots. If any controls such as a pedal is operated while with dirt and/or oil on the soles of the operator’s work boots, the operator’s foot may slip off the pedal, possibly resulting in a personal accident.  Do not mess up around the operator’s seat with parts, tools, soil, stones, obstacles that may fold up or turn over, cans or lunch box. The levers or pedals become inoperable if obstacle jams in operation stroke of the travel levers/pedals, pilot control shut-off lever or control levers, which may result in serious injury or death.  Avoid storing transparent bottles in the cab. Do not attach any transparent type window decorations on the windowpanes as they may focus sunlight, possibly starting a fire.  Refrain from listening to the radio, or using music headphones or mobile telephones in the cab while operating the machine.  Keep all flammable objects and/or explosives away from the machine.  After using the ashtray, always cover it to extinguish the match and/or tobacco.  Do not leave cigarette lighters in the cab. If the temperature in the cab increases, the lighter may explode.  Use proper floor mat dedicated to the machine. If another floor mat is used, it may be displaced and contact with the travel pedals during operation, resulting in serious injury or death.

Use Handrails and Steps  Falling is one of the major causes of personal injury.  When you get on and off the machine, always use the crawler instead of the step for safety. Also get on and off from the position of the crawler that can secure your feet space enough.  When you get on and off the machine, always face the machine.  Maintain a three-point contact with the steps and handrails.  Do not use any controls as handholds.  Never jump on or off the machine. Never mount or dismount a moving machine.  In case adhered slippery material such as oil, grease, or mud is present on steps, handrails, or platforms, thoroughly remove such material.

SA-5

SA-439

SAFETY Adjust the Operator’s Seat  A poorly adjusted seat for either the operator or the work at hand may quickly fatigue the operator leading to misoperation of the machine.  The seat should be adjusted whenever the operator for the machine changes.  The operator should be able to fully depress the pedals and to correctly operate the control levers with his back firmly against the seat back.  If not, readjust the seat forward or backward, and check again.

SA-378

Ensure Safety Before Rising From or Leaving Operator’s Seat  Before rising from the operator’s seat to open/close cab front window or to adjust the seat position, be sure to first lower the front attachment to the ground and then move the pilot control shut-off lever to the LOCK position. Failure to do so may allow the machine to unexpectedly move when a body part unintentionally comes in contact with a control lever, possibly resulting in serious personal injury or death.  Before leaving the machine, be sure to first lower the front attachment to the ground and then move the pilot control shut-off lever to the LOCK position. Turn the key switch OFF to stop the engine.  Before leaving the machine, close all windows, doors, and access covers and lock them up.

SA-6

SAFETY Fasten Your Seat Belt  If the machine should overturn, the operator may become injured and/or thrown from the cab. Additionally the operator may be crushed by the overturning machine, resulting in serious injury or death.  Be sure to remain seated with the seat belt securely fastened whenever operating the machine.  Prior to operating the machine, thoroughly examine webbing, buckle and attaching hardware. If any item is damaged or worn, replace the seat belt or component before operating the machine. Replace the seat belt at least once every 3 years regardless of appearance.

SA-237

Move and Operate Machine Safely  Always be aware that there is a potential danger around the machine while operating the machine.  Take extra care not to run over bystanders. Confirm the location of bystanders before moving, swinging, or operating the machine.  Always keep the travel alarm and horn in working condition (if equipped).  Before starting to move or operate the machine, sound the travel alarm and horn to alert bystanders.  Use a signal person when moving, swinging, or operating the machine in congested areas. Locate the signal person so that the operator can always witness the signal person.  Coordinate the meanings of all safety signs, hand signals and marks before starting the machine. Appoint a person who is responsible to make a signal and/or guidance.  Never allow any persons or obstacles to enter the machine operation areas.  Use appropriate illumination.

SA-7

SA-1291

SAFETY Operate Only From Operator’s Seat  Inappropriate engine starting procedures may cause the machine to runaway, possibly resulting in serious injury or death.  Start the engine only when seated in the operator’s seat.  NEVER start the engine while standing on the tracks or on ground.  Do not start engine by shorting across starter terminals.

A hazardous situation may be created and/or possible damage to the machine may result.  Before starting the engine, confirm that all control levers are in neutral.

SA-444

Jump Starting  Failure to follow correct jump starting procedures could result in a battery explosion or a runaway machine.  If the engine must be jump started, be sure to follow the instructions shown in the “OPERATING ENGINE” chapter.  The operator must be seated in the operator’s seat so that the machine will be under control when the engine starts. Jump starting is a two-person operation.  Never use a frozen battery.  Failure to follow correct jump starting procedures could result in a battery explosion or a runaway machine.

SA-032

Keep Riders Off Machine  Riders on machine are subject to injury such as being struck by foreign objects and being thrown off the machine.  Riders also obstruct the operator’s view, resulting in the machine being operated in an unsafe manner.  Only the operator is allowed on the machine. Keep riders off.

SA-1292

SA-8

SAFETY Precautions for Operations  Thoroughly make certain safety at the work site before starting operations. Especially always observe the following points.  Be sure to wear close fitting clothing and required safety items, such as a hard hat, when operating the machine.  Keep all bystanders and unnecessary objects out of and away from the machine working areas. Always beware of the surroundings while operating the machine. Take care not to allow the rear part of the upperstructure to come in contact with objects when swinging the machine in a small area.  When loading a dump truck, bring the bucket from the rear side of the dump truck to avoid moving the bucket over the dump truck cab or over any co-workers.

M586-12-012

SA-9

SAFETY Investigate Job Site Beforehand  When working at the edge of an excavation or on a road shoulder, the machine could tip over due to collapse of the ground, possibly resulting in serious injury or death.  Investigate the configuration and ground conditions of the job site beforehand to prevent the machine from falling and to prevent the ground, stockpiles, or banks from collapsing.  Make a work plan. Use machines appropriate to the work and job site.  Reinforce ground, edges, and road shoulders as necessary. Keep the machine well back from the edges of excavations and road shoulders.  When working on an incline or on a road shoulder, employ a signal person as required.  Never allow bystanders to enter the working area such as swing radius or traveling range.  When the footing is weak, reinforce the ground before starting work.  When working on frozen ground, be extremely alert. As ambient temperatures rise, footing may become loose and slippery.  When operating the machine near open flame, sparks, and/or dead grass, a fire may easily break out. Use special care not to cause a fire.  Make sure the work site ground has sufficient strength to firmly support the machine. When working close to an excavation or on road shoulders, operate the machine with the tracks positioned perpendicular to the cliff face with travel motors at the rear and with the blade at the front, so that the machine can more easily evacuate if the cliff face collapses.  If working at the bottom of a cliff or on a high bank is required, be sure to investigate the area first and confirm that no danger of the cliff or bank collapsing exists. If any possibility of cliff or bank collapsing exists, do not work in that area.  Soft ground may collapse when operating the machine on it, possibly causing the machine to tip over. When working on a soft ground is required, be sure to reinforce the ground first using large pieces of steel plates strong enough and firm to easily support the machine.  Note that there is always a possibility of machine tipping over when working on rough terrain or on slopes. Prevent machine tipping over from occurring. Operate the machine slowly to ensure safe operation.

SA-10

SA-1293

M586-05-021

SAFETY Equipment of OPG  In case the machine is operated in areas where the possibility of falling stones or debris exists, equip genuine Hitachi OPG guard. Contact your nearest Hitachi dealer for installation method of the OPG guard. Depending on the specifications applied to your machine, modification of the machine to meet ROPS standards will be possible.  To maintain unimpaired operator protection and manufacture’s protective structure.  Damaged ROPS, OPG guard must be replaced, not repaired or revised.  Any alternation to the ROPS or OPG guard must be approved by the manufacturer.

ROPS : Roll Over Protective Structure OPG : Operator Protective Guard SA-490

Provide Signals for Jobs Involving Multiple Machines  In case more than one machine is operated in the same job site, accidental collision between machines may cause serious injury or death.  For jobs involving multiple machines, provide signals commonly known by all personnel involved. Also, appoint a signal person to coordinate the job site. Make sure that all personnel obey the signal person’s directions.

SA-481

Confirm Direction of Machine to be Driven  Incorrect travel pedal/lever operation may result in serious injury or death.  Before driving the machine, confirm the position of the undercarriage in relation to the operator’s position.  If the travel motors are located towards the front of the cab, the machine will move in the reverse direction when travel pedals/levers are operated.

SA-1294

SA-11

SAFETY Drive Machine Safely  Use a signal person when traveling the machine along road shoulders or in congested areas.  Driving the machine in the incorrect direction may result in serious injury or death and/or severe damage to property.  Before driving the machine, always confirm that the travel pedals/levers direction corresponds to the direction you wish to drive.  Be sure to detour around any obstructions.  Avoid traveling over obstructions. Soil, fragments of rocks, and/or metal pieces may scatter around the machine. Do not allow personnel to stay around the machine while traveling.  Driving on a slope may cause the machine to slip or overturn, possibly resulting in serious injury or death.  Never attempt to ascend or descend 30 degrees or steeper slopes.  Be sure to fasten the seat belt.  When driving up or down a slope, keep the bucket facing the direction of travel, approximately 200 to 300 mm (8 to 12 in) (A) above the ground.  If machine starts to skid or becomes unstable, immediately lower the bucket to the ground and stop.  Driving across the face of a slope or steering on a slope may cause the machine to skid or turnover. If the direction must be changed, move the machine to level ground, then, change the direction to ensure safe operation.  Avoid swinging the upperstructure on slopes. Never attempt to swing the upperstructure downhill. The machine may tip over. If swinging uphill is unavoidable, carefully operate the upperstructure and boom at slow speed.  If the engine stalls on a slope, immediately lower the bucket to the ground. Return the control levers to neutral.

Then, restart the engine.  Be sure to thoroughly warm up the machine before ascending steep slopes. If hydraulic oil has not warmed up sufficiently, sufficient performance may not be obtained.

A

SA-1295

A SA-1296

SA-441

WRONG

SA-589

SA-12

SAFETY  When the machine descends a slope at high speed, machine weight accelerates descending speed. It may cause collision accident due to misjudging of braking distance or machine turnover due to running on an unexpected obstacle.

Always ensure that travel mode display (1) on the monitor is , and then reduce the engine speed before descending a slope.  Select a travel route that is as flat as possible. Steer the machine as straight as possible, making small gradual changes repeatedly in direction.  Check the strengths of bridges and road shoulders before traveling on them, and reinforce if necessary.  When the machine is equipped with steel shoes, cover the road surface with wood plates in order not to damage the road surface. Be careful of steering when operating on asphalt roads in summer.  When crossing train tracks, lay wood plates over the tracks not to allow the machine to ride on only the rails.  Check that the machine can pass under a bridge and electric lines before driving the machine.  When crossing a river, drive the machine slowly while measuring the depth of the river using the bucket. Do not cross the river when the depth of the river is deeper than the upper track shoe surface.  Reduce the engine speed when traveling on rough terrains. Select a slow travel speed. Slower speed will reduce possible damage to the machine.  Drive the machine so that the travel motors do not come in contact with loose rocks. If the machine crosses over an obstruction, abnormally large loads may be loaded on the machine. Avoid contact with an obstruction while traveling the machine.  During freezing weather, always clean snow and ice from track shoes before driving the machine on snowy and/or frozen roads, or loading and unloading the machine for transportation, to prevent the machine from slipping.

1

MADB-00-007

Travel Motor

M104-05-008

SA-673

M586-05-002

SA-13

SAFETY Avoid Injury From Rollaway Accidents  Death or serious injury may result if you attempt to mount or try to bodily stop a moving machine.  Park the machine in compliance with the safe parking procedures described in operator's manual to prevent the machine from running away.  Block both tracks and lower the bucket to the ground, thrust the bucket teeth into the ground if you must park on a grade.  Park at a reasonable distance from other machines.

SA-1297

SA-14

SAFETY Avoid Injury From Back-over and Swing Accidents  If any person is present near the machine when backing or swinging the upperstructure, the machine may hit or run over that person, resulting in serious injury or death.

To avoid back-over and swing accidents:  Always look around BEFORE YOU BACK UP AND SWING THE MACHINE. BE SURE THAT ALL BYSTANDERS ARE CLEAR.  Keep the travel alarm in working condition (if equipped).

ALWAYS BE ALERT FOR BYSTANDERS MOVING INTO THE WORK AREA. USE THE HORN OR OTHER SIGNAL TO WARN BYSTANDERS BEFORE MOVING MACHINE.  USE A SIGNAL PERSON WHEN BACKING UP IF YOUR VIEW IS OBSTRUCTED. ALWAYS KEEP THE SIGNAL PERSON IN VIEW. Use hand signals, which conform to your local regulations, when work conditions require a signal person.  No machine motions shall be made unless signals are clearly understood by both signal person and operator.  Learn the meanings of all flags, signs, and markings used on the job and confirm who has the responsibility for signaling.  Keep windows, mirrors, and lights clean and in good condition.  Dust, heavy rain, fog, etc., can reduce visibility. As visibility decreases, reduce speed and use proper lighting.  Read and understand all operating instructions in the operator’s manual.

SA-15

SA-383

SA-384

SAFETY Keep Person Clear From Working Area  If a person is present near the operating machine, the person may come in contact with the swinging front attachment or counterweight and/or may be crushed against an other object, resulting in serious injury or death.  Before operating the machine, set up barriers to the sides and rear area of the bucket swing radius to prevent anyone from entering the work area.  Make sure that no personnel other than the signal person or no obstacles are present in the working area before operating the machine.

SA-667

Never Position Bucket Over Anyone  Never lift, move, or swing bucket above anyone or a truck cab.

Serious injury or machine damage may result due to bucket load spill or due to collision with the bucket.  Never allow the bucket to pass over anyone to avoid personal injury or death.

SA-668

Avoid Undercutting  In order to retreat from the edge of an excavation if the footing should collapse, always position the undercarriage perpendicular to the edge of the excavation with the travel motors at the rear.  If the footing starts to collapse and if retreat is not possible, do not raise the front attachment in a panic.

Lowering the front attachment may be safer in most cases.

SA-1300

SA-16

SAFETY Avoid Tipping  The danger of tipping is always present when operating on a grade, possibly resulting in serious injury or death.

To avoid tipping:  Be extra careful before operating on a grade.  Prepare machine operating area flat.  Keep the bucket low to the ground and close to the machine.  Reduce operating speeds to avoid tipping or slipping.  Avoid changing direction when traveling on grades.  NEVER attempt to travel across a grade steeper than 15 degrees if crossing the grade is unavoidable.  Reduce swing speed as necessary when swinging loads.  Be careful when working on frozen ground.  Temperature increases will cause the ground to become soft and make ground travel unstable.

SA-1301

Never Undercut a High Bank  The edges could collapse or a land slide could occur causing serious injury or death.

SA-1302

SA-17

SAFETY Dig With Caution  Accidental severing of underground cables or gas lines may cause an explosion and/or fire, possibly resulting in serious injury or death.  Before digging check the location of cables, gas lines, and water lines.  Keep the minimum distance required, by law, from cables, gas lines, and water lines.  If a fiber optic cable should be accidentally severed, do not look into the end. Doing so may result in serious eye injury.  Contact your local “diggers hot line” if available in your area, and/or the utility companies directly.

Have them mark all underground utilities.

SA-672

Operate With Caution  If the front attachment or any other part of the machine hits against an overhead obstacle, such as a bridge, both the machine and the overhead obstacle will be damaged, and personal injury may result as well.  Take care to avoid hitting overhead obstacles with the boom or arm.

SA-673

Avoid Power Lines  Serious injury or death can result if the machine or front attachments are not kept a safe distance from electric lines.  When operating near an electric line, NEVER move any part of the machine or load closer than 3 m (10 ft) plus twice the line insulator length.  Check and comply with any local regulations that may apply.  Wet ground will expand the area that could cause any person on it to be affected by electric shock. Keep all bystanders or co-workers away from the site.

SA-1305

SA-18

SAFETY Precautions For Lightning  The machine is vulnerable to lightning strikes.  In the event of an electrical storm, immediately stop operation, and lower the bucket to the ground. Evacuate to a safe place far away from the machine.  After the electrical storm has passed, check all of the machine safety devices for any failure. If any failed safety devices are found, operate the machine only after repairing them.

SA-1805

Object Handling  If a lifted load should fall, any person nearby may be struck by the falling load or may be crushed underneath it, resulting in serious injury or death.  When using the machine for craning operations, be sure to comply with all local regulations.  Do not use damaged chains or frayed cables, sables, slings, or ropes.  Before craning, position the upperstructure with the travel motors at the rear.  When using the machine for craning operations, always park the machine on a solid and level ground.  Move the load slowly and carefully. Never move it suddenly.  Keep all persons well away from the load.  Never move a load over a person’s head.  Do not allow anyone to approach the load until it is safely and securely situated on supporting blocks or on the ground.  Never attach a sling or chain to the bucket teeth. They may come off, causing the load to fall.

SA-19

SA-014

SAFETY Protect Against Flying Debris  If flying debris such as soil, rock fragments or metal pieces hit eyes or any other part of the body, serious injury may result.  Guard against such injuries when working in a job site where possibility of flying pieces of metal or debris exist, or when removing or installing pins using a hammer; wear goggles or safety glasses.  Keep bystanders away from the working area before striking any object.

SA-432

Park Machine Safely  Unless the machine is correctly parked, any hazardous situations such as running away of the machine or damage by vandalism may result, causing the machine to operate unsafely when the engine is restarted. Follow instructions described below when parking the machine.  Park the machine on solid level surface to prevent the machine from running away.  Lower the bucket and/or blade to the ground.  Pull the pilot control shut-off lever to the LOCK position.  Turn the auto-idle switch OFF. Failure to do so may create a hazardous condition as the engine speed may unexpectedly increase.  Run the engine at slow idle speed without load for 5 minutes.  Turn key switch to OFF to stop engine. Remove the key from the key switch.  Before leaving the machine, close all windows, roof vent, and cab door. Lock all access doors and compartments.

SA-20

SA-1306

SAFETY Handle Fluids Safely --- Avoid Fires  Handle fuel with care; it is highly flammable. If fuel ignites, an explosion and/or a fire may occur, possibly resulting in serious injury or death.  Do not refuel the machine while smoking or when near open flame or sparks.  Always stop the engine before refueling the machine.  Fill the fuel tank outdoors.  All fuels, most lubricants, and some coolants are flammable.  Store flammable fluids well away from fire hazards.  Do not incinerate or puncture pressurized containers.  Do not store oily rags; they can ignite and burn spontaneously.  Securely tighten the fuel and oil filler caps.

SA-018

SA-019

SA-21

SAFETY Transport Safely  The danger of tipping is present when loading/unloading the machine onto/from a truck or trailer bed.  Be sure to observe local regulations when transporting the machine on public roads.  Provide an appropriate truck or trailer for transporting the machine.  Be sure to have a signal person.  Take the following precautions when loading/unloading the machine.

1. Select firm level ground.

SA-1307

2. Be sure to use a loading dock or ramp strong enough to support the machine weight.

3. Ramps must be sufficient in width, length, and strength.

Be sure that the incline of the ramp is less than 15 degrees.

4. Loading docks must be sufficient in width and strength to support the machine and have a gradient of less than 15 degrees.

3

2

5. Push auto-idle switch (1) to turn A/I display (2) OFF. 6. Select the slow travel mode for loading or unloading the machine.

Always ensure that travel mode display (3) on the monitor is , before traveling the machine.

7. Avoid steering while driving up or down the ramp as it is extremely dangerous. If steering is unavoidable, first move back to the ground or flatbed, modify traveling direction, and begin to drive again.

8. The top end of the ramp where it meets the flatbed is a sudden bump. Take care when traveling over it.

9. Wedge the front and rear of the tracks. Securely fasten the machine to the trailer bed with chains or cables.

10. Do not operate any levers besides the travel levers when driving up or down the ramp.

11. Prevent possible injury from machine tipping while the upperstructure is rotating.

12. Keep the arm tucked under and rotate the upperstructure slowly for best stability.

Refer to “transporting” chapter in operator's manual for details.

SA-22

1

MADB-00-007

SAFETY Practice Safe Maintenance  Inspection/maintenance work may produce hazardous situations by contacting and/or accessing a part of body to a moving, high pressure, and/or high temperature part of the machine. To avoid serious personal injury or death, follow the instructions described below.  Thoroughly coordinate the working procedures to be taken hereafter with the co-workers before beginning work such as inspecting/servicing the machine, or replacing the attachment.  Safely park the machine in accordance with the instructions for “Park Machine Safely.”  Keep the work area clean and orderly.  Attach a “DO NOT OPERATE” tag in an easy-to-see location such as on a door or a control lever.  If moisture permeates into the electrical system, malfunction and/or erroneous movement of the machine may result. Do not clean sensors, cable connectors, and the cab inside using water and/or steam.  Wait to begin to work until the engine and hydraulic oil temperatures have cooled down to the safety range.  In case inspection/maintenance must be performed with the engine running, be sure to appoint an overseer.  Never lubricate or service the machine while moving it.  Repair the cracked windowpane before servicing the machine. Failure to do so may cause personal injury.  When raising the machine above the ground using the front attachment function, maintain the angle between the boom and the arm in the range of 90 to 110°. Never allow anyone to enter under the machine raised with the front attachment function.  In case working under the machine raised above the ground is unavoidably required, securely hold the machine with stays or blocks strong enough to support the machine weight.  Never work under the raised bucket.  Keep all parts in good condition and properly installed.  Always use the specified tools correctly.  Always use a clean tool.  Fix any damage found immediately. Replace worn or broken parts.  Remove any buildup of grease, oil, or debris.  When cleaning parts, use a non-combustible cleaning solvent. Never use an inflammable fluid such as diesel fuel, or gasoline.

SA-23

SA-028

90 to 110°

M1M7-04-006

SA-527

SAFETY  Disconnect battery ground cable (−) before making adjustments to electrical systems or before welding on the machine.  Sufficiently illuminate the work site. Use a maintenance work light when working under or inside the machine.  Always use a work light protected with a guard. In case the light bulb is broken, spilled fuel, oil, antifreeze fluid, or window washer fluid may catch fire.  When the floor tilt mechanism check and/or maintenance is conducted, the operator’s station is tilted upward.

Before conducting maintenance work, refer to page 7-76 in operator's manual for the detailed operation procedures and correctly operate the machine.  When required to work under the floor, support the raised operator’s station with the fall prevention bars (red color) to ensure safety.  When the inspection/maintenance work is complete, tilt the operator’s station downward after housing the fall prevention bars. Be sure to slowly lower the operator’s station at the time.  Be careful not to allow the operator’s station to tilt down without first stowing the fall prevention bars. Damage to the tilt mechanism may result.

SA-037

M1MW-07-031

Warn Others of Service Work  Unexpected machine movement can cause serious injury.  Before performing any work on the machine, attach a “Do Not Operate” tag in an easy-to-see place such as on the cab door or control lever.  Never attempt to operate the machine with a “Do Not Operate” tag attached.  Make it a rule for the inspection/service person to hold the engine start key during inspection/service work.

SS2045102

SA-24

SAFETY Support Machine Properly  Never attempt to work on the machine without securing the machine first.  Always lower the attachment to the ground before you work on the machine.  If you must work on a lifted machine or attachment, securely support the machine or attachment with stays or blocks strong enough to support the machine and/or attachment weight.

SA-527

Stay Clear of Moving Parts  Contact with moving parts can cause serious injury or death due to amputation or entanglement.  To prevent accidents, care should be taken to ensure that hands, feet, clothing, jewelry and hair do not become entangled when working around rotating parts.

SA-026

SA-2294

SA-25

SAFETY Prevent Parts From Flying  Grease in the track adjuster is under high pressure.

Failure to follow the precautions below may result in serious injury, blindness, or death.  Do not attempt to remove GREASE FITTINGS or VALVE ASSEMBLIES.  As pieces of parts may fly off, be sure to keep body and face away from the valve.  Travel reduction gears are under pressure.  As pieces of parts may fly off, be sure to keep body and face away from AIR RELEASE PLUG to avoid injury.  GEAR OIL is hot. Wait for gear oil to cool, then gradually loosen the air release plug to release pressure.

SA-344

Store Attachments Safely  Stored attachments such as buckets, hydraulic hammers, and blades can fall and cause serious injury or death.  Securely store attachments and implements to prevent falling accidents.  Keep children and bystanders away from storage areas.

SA-034

SA-26

SAFETY Prevent Burns Hot spraying fluids:  After operation, engine coolant is hot and under pressure.

Hot water or steam is contained in the engine, radiator and heater lines.

Skin contact with escaping hot water or steam can cause severe burns.  To prevent possible injury from hot spraying water, stop the engine. Begin to work after the engine and radiator are sufficiently cooled  DO NOT remove the radiator cap until the engine is cool.

When opening, turn the cap slowly to the stop. Allow all pressure to be released before removing the cap.  The hydraulic oil tank is pressurized. Again, be sure to release all pressure by slowly removing the cap.

SA-039

Hot fluids and surfaces:  Engine oil, gear oil and hydraulic oil also becomes hot during operation.

The engine, hoses, lines and other parts become hot as well.  Wait for the oil and components to cool before starting any maintenance or inspection work.

SA-225

SA-27

SAFETY Replace Rubber Hoses Periodically  Rubber hoses that contain flammable fluids such as hydraulic oil or fuel under pressure may break due to aging, fatigue, and abrasion. It is very difficult to gauge the extent of deterioration due to aging, fatigue, and abrasion of rubber hoses by visual inspection alone.  Periodically replace the rubber hoses. (Refer to the Periodical Replacement Parts section in operator's manual.)  Failure to periodically replace rubber hoses may cause a fire, fluid injection into skin, or the front attachment to fall on a person nearby, which may result in severe burns, gangrene, or otherwise serious injury or death.

SA-019

Avoid High-Pressure Fluids  Fluids such as diesel fuel or hydraulic oil under pressure can penetrate the skin or eyes causing serious injury, blindness or death.  Avoid this hazard by relieving pressure before disconnecting hydraulic or other lines. Make sure that all connectors are completely connected before applying pressure.  Search for leaks with a piece of cardboard; take care to protect hands and body from high-pressure fluids. Wear a face shield or goggles for eye protection.  If an accident occurs, see a doctor familiar with this type of injury immediately. Any fluid injected into the skin must be surgically removed within a few hours, or gangrene may result.

SA-031

SA-292

SA-044

SA-28

SAFETY Prevent Fires Check for Oil Leaks:  Fuel, hydraulic oil and lubricant leaks can lead to fires, possibly resulting in personal injury or death.  Check for missing or loose clamps, kinked hoses, lines or hoses that rub against each other, damage to the oilcooler, and loose oil-cooler flange bolts, for oil leaks.  Tighten, repair or replace any missing, loose or damaged clamps, lines, hoses, oil-cooler and oil-cooler flange bolts.  Do not bend or strike high-pressure lines.  Never install bent or damaged lines, pipes or hoses.

Check for Shorts:

SA-019

 Short circuits can cause fires.  Clean and tighten all electrical connections.  Check before each shift or after eight (8) to ten (10) hours operation for loose, kinked, hardened or frayed electrical cables and wires.  Check before each shift or after eight (8) to ten (10) hours operation for missing or damaged terminal caps.  DO NOT OPERATE MACHINE if cable or wires are loose, kinked, etc.

Precautions for Handling Flammables  Spilled fuel and oil, and trash, grease, debris, accumulated coal dust, and other flammables may cause fires.  Prevent fires by inspecting and cleaning the machine daily, and by removing spilled or accumulated flammables immediately.  Do not store flammable fluid near open flames.  Do not burn or crush a pressurized container.  Do not store oily cloths. They are liable to catch fire.  Do not wind easy-to-absorb-oil material around hightemperature parts such as a muffler or exhaust pipe.

SA-29

SAFETY Clean up Flammables:  Spilled fuel and oil, and trash, grease, debris, accumulated coal dust, and other flammables may cause fires.  Prevent fires by inspecting and cleaning the machine daily, and by removing adhered oil or accumulated flammables immediately. Check and clean high temperature parts such as the exhaust outlet and mufflers earlier than the normal interval.  Do not wrap high temperature parts such as a muffler or exhaust pipe with oil absorbents.  Do not store oily cloths as they are vulnerable to catching fire.  Keep flammables away from open flames.  Do not ignite or crush a pressurized or sealed container.  Wire screens may be provided on openings on the engine compartment covers to prevent flammables such as dead leaves from entering. However, flammables which have passed through the wire screen may cause fires.

Check and clean the machine every day and immediately remove accumulated flammables.

Check Heat Shield Covers around Engine Compartment  If the engine compartment heat shield cover becomes broken or lost, fire may break out.  If the engine compartment heat shield cover becomes broken or lost, repair or replace it before operating the machine.

Check Key Switch:  If fire breaks out, failure to stop the engine will escalate the fire, hampering fire fighting.  Always check key switch function before operating the machine every day: 1) Start the engine and run it at slow idle.

2) Turn the key switch to the OFF position to confirm that the engine has stopped.  If any abnormalities are found, be sure to repair them before operating the machine.

SA-30

SAFETY Evacuating in Case of Fire  If fire breaks out during machine operation, evacuate the machine in the following way:  Stop the engine by turning the key switch to the OFF position.  Use a fire extinguisher if there is time.  Exit the machine using handrails and/or steps.  In an emergency, if the cab door or front or rear window can not be opened, break the front or rear window panes with the emergency evacuation hammer to escape from the cab.

Refer to the explanation pages on the Emergency Exit.

SA-393

SS-1510

Beware of Exhaust Fumes  Prevent asphyxiation. Engine exhaust fumes can cause sickness or death.  If you must operate the machine in a building, be sure there is adequate ventilation. Either use an exhaust pipe extension to remove the exhaust fumes or open doors and windows to bring enough outside air into the area.

SA-016

SA-31

SAFETY Precautions for Welding and Grinding  Welding may generate gas and/or small fires.  Be sure to perform welding in a well ventilated and prepared area. Store flammable objects in a safe place before starting welding.  Only qualified personnel should perform welding. Never allow an unqualified person to perform welding.  Grinding on the machine may create a fire hazard. Store flammable objects in a safe place before starting grinding.  After finishing welding and grinding, recheck that there are no abnormalities such as the area surrounding the welded area still smoldering.

SA-818

Avoid Heating Near Pressurized Fluid Lines  Flammable spray can be generated by heating near pressurized fluid lines, resulting in severe burns to yourself and bystanders.  Do not heat by welding, soldering, or using a torch near pressurized fluid lines or other flammable materials.  Pressurized lines can be accidentally cut when heat goes beyond the immediate flame area. Install temporary fire resistant guards to protect hoses or other materials before engaging in welding, soldering, etc.

Avoid Applying Heat to Lines Containing Flammable Fluids SA-030

 Do not weld or flame cut pipes or tubes that contain flammable fluids.  Remove flammable fluids thoroughly with nonflammable solvent before welding or flame cutting pipes or tubes that contained flammable fluids.

Precautions for Handling Accumulator and Gas Damper High-pressure nitrogen gas is sealed in the accumulator and the gas damper. Inappropriate handling may cause explosion, possibly resulting in serious injury or death.

Strictly comply with the following items: Do not disassemble the unit.  Keep the units away from open flames and fire.  Do not bore a hole, do not cut by torch.  Avoid giving shocks by hitting or rolling the unit.  Before disposing the unit, sealed gas must be released.

Consult your nearest Hitachi dealer.

SA-32

SAFETY Remove Paint Before Welding or Heating  Hazardous fumes can be generated when paint is heated by welding, soldering, or using a torch. If inhaled, these fumes may cause sickness.  Remove paint before welding or heating.  Avoid potentially toxic fumes and dust.  Do all such work outside or in a well-ventilated area.

Dispose of paint and solvent properly.  Allow fumes to disperse at least 15 minutes after welding or heating.  Use attention to the following points when removing paint.

1. If you sand or grind paint, avoid breathing the dust which is created.

SA-029

Wear an approved respirator.

2. If you use solvent or paint stripper, remove stripper with soap and water before welding.

3. Remove solvent or paint stripper containers and other flammable material from area.

Beware of Asbestos and Silicon Dust and Other Contamination  Take care not to inhale dust produced in the work site.

Inhalation of asbestos fibers may be the cause of lung cancer.

Inhalation of silicon dust and other contamination may cause sickness.  Depending on the work site conditions, the risk of inhaling asbestos fiber, silicon dust or other contamination may exist.

Spray water to prevent asbestos, silicon dust or other contamination from airborne. Do not use compressed air.  When operating the machine in a work site where asbestos, silicon dust or other contamination might be present, be sure to operate the machine from the upwind side and wear a mask rated to prevent the inhalation of asbestos, silicon dust or other contamination.  Keep bystanders out of the work site during operation.  Asbestos might be present in imitation parts. Use only genuine Hitachi Parts.

SA-33

SA-029

SAFETY Prevent Battery Explosions  Battery gas can explode.  Keep sparks, lighted matches, and flame away from the top of battery.  Never check battery charge by placing a metal object across the posts. Use a voltmeter or hydrometer.  Do not charge a frozen battery; it may explode. Warm the battery to 16 °C (60 °F) first.  Do not continue to use or charge the battery when the electrolyte level is lower than specified. Explosion of the battery may result.  When a terminal becomes loose, it may induce sparks.

Securely tighten all terminals.  Connect terminals to the correct electrical poles. Failure to do so may cause damage to the electrical parts or fire.  Battery electrolyte is poisonous. If the battery should explode battery electrolyte may be splashed into eyes, possibly resulting in blindness. If electrolyte is splashed into eyes, flush your eyes continuously with water for about 15 minutes. Seek medical attention immediately.  Be sure to wear eye protection when checking electrolyte specific gravity.

SA-032

Precautions for Handling Refrigerant  If refrigerant is splashed into eyes or spilled onto skin, blindness or a cold contact burn may result.  Refer to the precautions described on the refrigerant container for handling refrigerant.  Use a recovery and recycling system to avoid venting refrigerant into the atmosphere.  Never allow the skin to directly come in contact with refrigerant.

SA-405

SA-34

SAFETY Handle Chemical Products Safely  Direct exposure to hazardous chemicals can cause serious injury. Potentially hazardous chemicals used with your machine include such items as lubricants, electrolyte, coolants, paints, and adhesives.  A Material Safety Data Sheet (MSDS) provides specific details on chemical products: physical and health hazards, safety procedures, and emergency response techniques.  Check the MSDS before you start any job using a hazardous chemical. Then follow the correct procedures and use recommended equipment.  See your authorized dealer for MSDS. SA-309

Dispose of Waste Properly  Improperly disposing of waste can threaten the environment and ecology. Potentially harmful waste used with HITACHI equipment includes such items as oil, fuel, coolant, brake fluid, filters, and battery.  When draining fluid, use a leakproof container with a capacity larger than the drained fluid volume to receive it.  Do not pour waste onto the ground, down a drain, or into any water source.  Inquire on the proper way to dispose of harmful waste such as oil, fuel, coolant, brake fluid, filters, and battery from your local environmental or recycling center.

SA-226

SA-35

SAFETY Never Ride Attachment ď‚— Never allow anyone to ride attachments or the load. This is an extremely dangerous practice.

Precautions for Communication Terminal Electrical wave transmitted from the communication terminal may cause malfunction of other electronic devices.

Inquire the device manufacturer for electrical wave disturbance upon using an electronic device near the communication terminal.

SA-36

SAFETY Precaution for Communication Terminal Equipment A mobile communication terminal which transmits radio wave is located in the monitor cover at front right of the operator's seat. There is a possibility that a medical device, including an implantable device such as a cardiac pacemaker, would be affected and would malfunction by the electrical waves emitted from the communication terminal equipment.

A person who is using a medical device should adjust the operator's seat before operating the machine so that the distance from the monitor cover with the communication terminal mentioned above to the medical device is 22 centimeters (8.662 inches) or longer. If such condition cannot be met, please contact our company's nearest dealer and have the person in charge stop the communication terminal equipment from functioning completely and confirm that it is not emitting electrical waves.

Specific Absorption Rate ("SAR") (measured by 10 g per unit) of communication terminal equipments: E-GSM900 0.573 W/Kg (914.80 MHz) DCS-1800 0.130 W/Kg (1710.20 MHz) WCDMA Band I 0.271 W/Kg (1950.00 MHz) *This data was measured by having each type of communication terminal equipment, such as the communication terminal equipment used with this machine, and a human body set apart by 3 cm (1.18 inches). * SAR is a measure of the amount of radio frequency energy absorbed by the body when using a wireless application such as a mobile phone.

In Japan: *Under the Japanese Radio Act and other relevant Japanese regulations, the maximum SAR value is 2 W/kg (as of March 2012).

In EU Member nation: *Under the "Council Recommendation 1999/519/EC 12 July 1999"; the maximum SAR value is 2 W/kg (as of March 2010).

SA-37

MADB-00-008

SAFETY  Never attempt to disassemble, repair, modify or displace the communication terminal, antennas or cables. Failure to do so may result in damage and/or fire to the base machine or to the communication terminal. (When required to remove or install the communication terminal, consult your nearest Hitachi dealer.)  Do not pinch or forcibly pull cables, cords or connectors.

Failure to do so may cause short circuit or broke circuit that may result in damage and/or fire to the base machine or to the communication terminal.

Before Returning the Machine to the Customer  After maintenance or repair work is complete, confirm that:  The machine is functioning properly, especially the safety systems.  Worn or damaged parts have been repaired or replaced.

SA-435

SA-38

SECTION AND GROUP SECTION 1 GENERAL Group 1 Specification CONTENTS Group 2 Component Layout Group 3 Component Specifications

SECTION 2 SYSTEM TECHNICAL MANUAL

Group 1 Control System Group 2 Hydraulic System Group 3 Electrical System

SECTION 3 COMPONENT OPERATION Group 1 Pump Device Group 2 Swing Device Group 3 Control Valve Group 4 Pilot Valve Group 5 Travel Device Group 6 Others (Upperstructure) Group 7 Others (Undercarriage)

SECTION 4 OPERATIONAL PERFORMANCE TEST Group 1 Introduction Group 2 Standard Group 3 Engine Test Group 4 Machine Performance Test Group 5 Component Test All information, illustrations and specifications in this manual are based on the latest product information available at the time of publication. The right is reserved to make changes at any time without notice.

SECTION 5 TROUBLESHOOTING Group 1 Diagrosing Procedure Group 2 Monitor Group 3 Troubleshooting A Group 4 Troubleshooting B Group 5 Air Conditioner

COPYRIGHT(C)2014 Hitachi Construction Machinery Co., Ltd. Tokyo, Japan All rights reserved

WORKSHOP MANUAL SECTION 1 GENERAL INFORMATION Group 1 Precautions for Disassembling and Assembling Group 2 Tightening Torque Group 3 Painting Group 4 Bleeding Air from Hydraulic Oil Tank Group 5 Hydraulic Circuit Pressure Release Procedure Group 6 Preparation SECTION 2 MAINTENANCE STANDARD Group 1 Upperstructure Group 2 Undercarriage Group 3 Front Attachment SECTION 3 UPPERSTRUCTURE Group 1 Canopy/Cab Group 2 Counterweight Group 5 Pump Device Group 6 Control Valve Group 7 Swing Device Group 8 Pilot Valve Group 9 Solenoid Valve SECTION 4 UNDERCARRIAGE Group 1 Swing Bearing Group 2 Travel Device Group 3 Center Joint Group 4 Track Adjuster Group 5 Front Idler Group 6 Upper and Lower Roller Group 7 Track Group 8 Blade Cylinder SECTION 5 ATTACHMENT Group 1 Front Attachment Group 2 Cylinder

SECTION 1

GENERAL CONTENTS Group 1 Specifications

Std. Specification................................................................. T1-1-1 Working Ranges................................................................... T1-1-2

Group 2 Component Layout

Main Component................................................................. T1-2-1 Electrical System (Overview)........................................... T1-2-2 Electrical System (Relays) . ............................................... T1-2-3 Electrical System (Relays) (Cab Spec. Machine)........ T1-2-4 Electrical System (Monitor, Switches) . ........................ T1-2-5 Electrical System (Battery Room) .................................. T1-2-6 Engine...................................................................................... T1-2-7 Swing Device......................................................................... T1-2-8 Control Valve......................................................................... T1-2-8 Travel Device......................................................................... T1-2-8 2-Spool Solenoid Valve...................................................... T1-2-9 Torque Control Solenoid Valve (Only machine with the air conditioner (optional) attached)................ T1-2-9

Group 3 Component Specifications

Engine...................................................................................... T1-3-1 Engine Accessories.............................................................. T1-3-5 Hydraulic Component........................................................ T1-3-6 Electrical Component.......................................................T1-3-10

ADCT-1-1

(Blank)

ADCT-1-2

SECTION 1 GENERAL Group 1 Specifications Std. Specification ZX38U-5A A

C

B

F

E D I

J H

G MADG-12-001

Model Specification Type of Front-End Attachment Bucket Capacity (Heaped) Operating Weight Base Machine Weight Engine A: B: C: D: E: F: G: H: I: J:

Overall Width Overall Height Rear End Swing Radius Minimum Ground Clearance Counterweight Clearance Engine Cover Height Undercarriage Length Undercarriage Width Sprocket Center to Idler Center Track Shoe Width

Ground Pressure Swing Speed Travel Speed (fast/slow) Gradeability

ZX38U-5A

Canopy -

Boom Swing Type, 1.72 m (5 ft 8 in) Arm

m (yd ) kg (lb) kg (lb) 3

Cab

0.10 (0.13)

3

3790 (8360) 2930 (6460)

kW/min-1 (PS/rpm) mm (ft·in) mm (ft·in) mm (ft·in)

YANMAR EDM-3TNV88 21.2/2400 (28.8/2400) 1550 (5' 1'') 2480 (8' 2'') 980 (3' 3")

mm (ft·in)

280 (11'')

mm (ft·in)

550 (1' 10'')

mm (ft·in) mm (ft·in) mm (ft·in)

1530 (5') 2110 (6' 11'') 1740 (5' 9'')

mm (ft·in)

1660 (5' 5'')

mm (ft·in) kPa (kgf/cm2, psi) min-1 (rpm) km/h (mph)

34 (0.35, 4.9)

300 (1') 9.1 (9.1) 4.3/2.8 (2.7/1.7) 30° (tan θ = 0.58)

3960 (8730) 3100 (6830)

36 (0.36, 5.2)

fNOTE:  The dimensions do not include the height of the shoe lug. The dimensions of the machine equipped with rubber crawlers are shown.  The specifications include additional counterweight and extra attachment lines.

T1-1-1

SECTION 1 GENERAL Group 1 Specifications Working Ranges ZX38U-5A K (Left) K (Right) H

G

C D E

I J

F A B

MADC-12-004

Category

Item A: B: C: D: E: F: G: H: I: J: K:

Maximum Digging Reach Maximum Digging Depth Maximum Cutting Height Maximum Dumping Height Overall Height Overall Length Minimum Swing Radius Boom Swing Pivot Offset Distance Blade Bottom Highest Position Blade Bottom Lowest Position Offset Distance Maximum Boom-Swing Angle

mm (ft·in) mm (ft·in) mm (ft·in) mm (ft·in) mm (ft·in) mm (ft·in) mm (ft·in) mm (ft·in) mm (ft·in) mm (ft·in) mm (ft·in)

ZX38U-5A Canopy Cab 1.32 m Arm 1.72 m Arm 1.32 m Arm 1.72 m Arm 5210 (17' 1") 5520 (18' 1") 5210 (17' 1") 5520 (18' 1") 3060 (10') 3460 (11' 4") 3060 (10') 3460 (11' 4") 4870 (16') 4950 (16' 3") 4700 (15' 5") 4740 (15' 7") 3460 (11' 4") 3570 (11' 9") 3310 (10' 10") 3390 (11' 2") 2480 (8' 2") 4640 (15' 3") 4760 (15' 7") 4640 (15' 3") 4760 (15' 7") 2080 (6' 10") 2190 (7' 2") 2240 (7' 4") 2300 (7' 7") 100 (4") 360 (1' 2") 400 (1' 4") L610 (2') R735 (2' 5") L610 (2') R700 (2'4") * L450 (1'6") R700 (2'4") * L450 (1'6") R700 (2'4") L72° R62° [52°] L62° R62° [52°] * L62° R45° * L62° R45°

fNOTE:  The dimensions do not include the height of the shoe lug. The dimensions of the machine equipped with rubber crawlers are shown.  L: Left R: Right  Values in the brackets [ ] are dimension of the machine equipped with the House rupture valve.  * Mark indicates the machine with assist pipes.

T1-1-2

SECTION 1 GENERAL Group 2 Component Layout Main Component

1

2

31 30

3

29

4

28

5 6

27 23

26 25 24

7 8

22

13 21

20

19

11

12

10

9

18 17 16 15 14 TADB-01-02-008

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

Coolant Reservoir Radiator/Oil Cooler Air Cleaner Water Separator Filter Engine Front Pilot Valve Pump Device Accumulator (Optional) Travel Device

10- 11- 12- 13- 14- 15- 16- 17- 18-

Lower Roller Pilot Filter Upper Roller Control Valve Track Adjuster Center Joint Front Idler 2-Spool Solenoid Valve Travel Pilot Valve

19- 20- 21- 22- 23- 24- 25- 26- 27-

T1-2-1

Blade Cylinder Boom Cylinder Bucket Cylinder Arm Cylinder Work Light Boom Swing Cylinder Swing Bearing Swing Device Boom Swing Pilot Valve

28- 29- 30- 31-

Fuel Tank Hydraulic Oil Tank Battery Blade Pilot Valve

SECTION 1 GENERAL Group 2 Component Layout Electrical System (Overview)

1 2 3 11 10

9

4

8

7

6

5 TADB-01-02-009

1- 2- 3- 4-

Electrical System (Monitor, Switches) (Refer to T1-2-5.)

Electrical System (Relays) (Refer to T1-2-3, 4.)

Pilot Shut-Off Switch Horn

5- 6-

7- 8-

2-Spool Solenoid Valve Components Related with Control Valve (Refer to T12-8.)

Fuel Sensor Battery

9-

Electrical System (Battery Room) (Refer to T1-2-6.)

10- Torque Control Solenoid Valve (Only machine with the air conditioner (optional) attached)

T1-2-2

11- Components Related with Engine (Refer to T1-2-7.)

SECTION 1 GENERAL Group 2 Component Layout Electrical System (Relays)

TAEA-01-02-003

9

View A 1

2 3

8 A

7

6

1- 2- 3- 4- 5- 6-

5

Travel Mode Selector Relay Pilot Shut-Off Relay Travel Alarm Relay (Optional) Fuse Box R2 Cut Relay (Optional) ACC Cut Relay (Optional)

4

7- 8- 9-

13 12 TAEA-01-02-004

Light Relay Horn Relay Travel Mode Selector Relay Unit 10- Auto Shut-Down Relay (Optional)

10 TAEA-01-02-005

12. Main Relay 13. Rack Actuator Relay

T1-2-3

SECTION 1 GENERAL Group 2 Component Layout Electrical System (Relays) (Cab Spec.

Machine)

TAEA-01-02-003

Machine with Heater

Machine with Air Conditioner 1

1 3 4

Blower Motor Relay (Mid) Compressor Relay

3- 4-

Blower Motor Relay (Low) Blower Motor Relay (High)

3

4

5

TAEA-01-02-010

TAEA-01-02-018

1- 2-

2

5-

T1-2-4

Displacement Angle Selection Relay

SECTION 1 GENERAL Group 2 Component Layout Electrical System (Monitor, Switches) 10

30

1

11

12 13 14

27

15

26

16

25

17

24

18 19

MADB-01-002

2

3

9

4

8 28

23

7

22

21

20 TAEA-01-02-015EN

5 6

TAEA-01-02-014 1- 2- 3- 4- 5- 6- 7-

Horn Switch Engine Control Dial Travel Mode Switch (Optional) Numerical Keypad Lock System (Optional) Key Switch * Heater/Air Conditioner Control Panel Auxiliary Flow Rate Selector Switch (Optional)

8- 9- 10- 11- 12- 13- 14- 15- 16-

*Wiper Switch Work Light Switch Overheat Indicator Engine Oil Pressure Indicator Alternator Indicator Fuel Level Indicator Preheat Indicator Clock Security State Indicator (Optional)

17- Auto Shut-Down Indicator (Optional) 18- Fuel Gauge 19- Hour Meter 20- Overload Alarm (Optional)/ Set Switch 21- ECO/PWR Mode/Selection Switch 22- Auto-Idle/Selection Switch 23- Menu/Back Switch 24- Coolant Temperature Gauge

fNOTE:

The item with mark * is equipped for only the cab spec. machine.

T1-2-5

25- 26- 27- 28- 30-

Travel Mode Indicator Work Light Indicator Auxiliary Travel Mode Switch Travel Alarm Deactivation Switch (Optional)

SECTION 1 GENERAL Group 2 Component Layout Electrical System (Battery Room)

2

3

4

5

1 TADB-01-02-010

TADB-01-02-005

1- 2-

Slow Blow Fuse Travel Alarm (Optional)

3- 4-

Glow Plug Relay E-ECU

5-

T1-2-6

Starter relay 1

SECTION 1 GENERAL Group 2 Component Layout Engine A 3

1

9

5

10

2

4

TADB-01-02-006

View A

6

7

8

1- 2- 3-

Alternator Starter Rack Actuator

TADB-01-02-007

TADB-01-02-011

4- 5- 6-

Engine Speed Sensor Engine Oil Pressure Switch Coolant Temperature Sensor

7- 8- 9-

T1-2-7

Glow Plug Overheat Switch CSD Valve

10- Fuel Feeding Pump

SECTION 1 GENERAL Group 2 Component Layout Swing Device

Travel Device 2

3

1

T1M7-01-02-006 T1M7-01-02-004

Control Valve 5

4

7

6

13 14

1- 2- 3- 4- 5-

Relief Valve Counterbalance Valve Travel Mode Selector Valve Make-Up Valve (Boom Swing (Left)) Overload Relief Valve (Arm Roll-Out)

12

8

11 10

9

TADB-01-02-004

6- 7- 8- 9-

Main Relief Valve (Main Pump P2) Boom Anti-Drift Valve Overload Relief Valve (Bucket Roll-Out) Overload Relief Valve (Bucket Roll-In)

10- Overload Relief Valve (Boom Lower) 11- Overload Relief Valve (Boom Raise) 12- Main Relief Valve (Main Pump P1)

T1-2-8

13- Overload Relief Valve (Arm Roll-In) 14- Main Relief Valve (Main Pump P3)

SECTION 1 GENERAL Group 2 Component Layout 2-Spool Solenoid Valve

Torque Control Solenoid Valve (Only machine with the air conditioner (optional) attached)

4 1

3

T1M7-01-02-008

a 2 TAEA-01-02-009

a-

Machine Front

1- 2- 3-

Pilot Relief Valve Pilot Shut-Off Solenoid Valve Travel Mode Selector Solenoid Valve

4-

Torque Control Solenoid Valve (Only machine with the air conditioner (optional) attached)

T1-2-9

SECTION 1 GENERAL Group 2 Component Layout (Blank)

T1-2-10

SECTION 1 GENERAL Group 3 Component Specifications Engine Manufacturer Model Type Cyl. No.- Bore × Stroke Piston Displacement Rated Output Compression Ratio Dry Weight Firing Order Rotation Direction

YANMAR Co.,Ltd. YANMAR EDM-3TNV88 Diesel, 4-Cycle, Water-cooled, Vertical, Direct Injection Type 3-88.0 mm×90.0 mm (3.46 in×3.54 in) 1642 cm3 (100 in3) 21.2 kW/2400 min-1 (28.8 PS/2400 rpm) 19.1 169+50 kg (375+120 lb) 1-3-2-1 Clockwise (Viewed from fan side)

T1-3-1

SECTION 1 GENERAL Group 3 Component Specifications COOLING SYSTEM

LUBRICATION SYSTEM

STARTING SYSTEM PREHEAT SYSTEM ENGINE STOP SYSTEM ALTERNATOR FUEL SYSTEM

Cooling Fan Fan Pulley Ratio Thermostat Water Pump Lubrication Method Lubrication Pump Type Oil Filter Motor Voltage / Output Preheating Method Stop Method Type Voltage / Output Type Governor Oil Filter Injection Nozzle

Dia. 380 mm (15 in), 7 Blades, Draw-In Type Belt Driven Rotation Ratio : 1.00 Cracking Temperature at Atmospheric Pressure: 71 째C (160 째F) Full Open : 85 째C (185 째F) Centrifugal Belt Driven Type Pressure Lubrication Type Trochoid Pump Type Paper Element Type Magnetic Pinion Shift Reduction Type 12 V/2.3 kW Glow Plug Fuel Shut-Off (Electronic Control) Alternating Current Type (with Built-In IC Regulator) 12 V/40 A Distributor Type YPD-MP2 Electronic All Speed Control Paper Element Type Hole Valve Type

T1-3-2

SECTION 1 GENERAL Group 3 Component Specifications IMPORTANT: This list shows design specifications, which are not servicing standards.

PERFORMANCE

Fuel Consumption Ratio Maximum Output Torque Compression Pressure Valve Clearance (Inlet / Exhaust) No Load Speed

254 g/kW·h (187 g/PS·h) or less (at Rated Point as New) 105.5±4.4 N·m (10.6±0.44 kgf·m 77.8±3.25 lbf·ft) at 1000±100 min-1 3.43 MPa (35 kgf/cm2, 495 psi) at 250 min-1 0.2/0.2 mm (when cool) Slow: 1300±10 min-1 Fast: 2430±10 min-1

T1-3-3

SECTION 1 GENERAL Group 3 Component Specifications Engine Performance Curve (YANMAR EDM-3TNV88) Test Condition: 1. In conformity with JIS D0006 (Performance Test Method for Diesel Engine Used for Construction Machinery) under standard atmospheric pressure.

2. Equipped with the fan and alternator.

N路m 125 100

a

75 kW

50 25

35

0

30

320

25

g/kW路h

300

20

b

280

15

260

10 c

240

5 0

220 200 1000

1200

1400

1600

1800

2000

2200

2400

2600

2800 TADB-01-03-001

min-1 (rpm)

kW: Output

g/kW路h: Fuel Consumption Ratio

N路m: Torque

min-1 (rpm): Engine Speed

a-

Torque

b-

Output

c-

T1-3-4

Fuel Consumption Ratio

SECTION 1 GENERAL Group 3 Component Specifications Engine Accessories Air-Tight Test Pressure Cap Opening Pressure BATTERY

Radiator Oil Cooler 2 981 kPa (10 kgf/cm 2, 140 psi) 137 kPa (1.4 kgf/cm , 20 psi) 2 88.3±14.7 kPa (0.9±0.15 kgf/cm , 13±2.1 psi) − Type Voltage Capacity

80D26L-MF 12 V 55 Ah or more (5-Hour Rate)

T1-3-5

SECTION 1 GENERAL Group 3 Component Specifications Hydraulic Component MAIN PUMP 1, MAIN PUMP 2 MAIN PUMP 3 PILOT PUMP CONTROL VALVE

Type Theoretical Displacement Type Theoretical Displacement Type Theoretical Displacement Type Main Relief Set-Pressure (P1, P2) Main Relief Set-Pressure (P3) Overload Relief Set-Pressure (Boom, Arm, and Bucket)

Swash Plate Type Variable Displacement Axial Plunger Pump 16.0 cm3/rev (1.0 in3/rev)×2 Gear Pump 9.5 cm3/rev (0.6 in3/rev) Gear Pump 4.5 cm3/rev (0.3 in3/rev) Pilot Pressure Operated Type (10-Spool) Normal: 25.2±0.3 MPa (257±3.06 kgf/cm2, 3650±44 psi) at 30 L/min 21.6±0.3 MPa (220±3.06 kgf/cm2, 3130±44 psi) at 22 L/min 27.5+10 MPa (280+10.20 kgf/cm2, 3990+1450 psi) at 20 L/min

T1-3-6

SECTION 1 GENERAL Group 3 Component Specifications SWING DEVICE SWING MOTOR VALVE UNIT SWING PARKING BRAKE TRAVEL DEVICE TRAVEL MOTOR

TRAVEL BRAKE VALVE TRAVEL PARKING BRAKE

Type Reduction Gear Ratio Type Type Relief Set-Pressure Type Release Pressure Type Reduction Gear Ratio Type Theoretical Displacement (Fast/ Slow) Type Type Release Starting Pressure

Two-Stage Reduction Planetary Gear 15.5 Swash Plate Type Fixed Displacement Axial Plunger Motor Non Counterbalance Valve Type 18.6 MPa (190 kgf/cm2, 2700 psi) at 23 L/min Spring Set Hydraulic Released Wet-Type Single-Disk Brake 1.5 MPa (15.3 kgf/cm2, 220 psi) Two-Stage Reduction Planetary Gear 45.2 Swash Plate Type Variable Displacement Axial Plunger Motor 14.16/22.10 cm3/rev (0.9/1.3 in3/rev) Counterbalance Valve Type Spring Set Hydraulic Released Wet-Type Single-Disk Brake 0.98 MPa (10 kgf/cm2, 140 psi)

T1-3-7

SECTION 1 GENERAL Group 3 Component Specifications CYLINDER Rod Diameter Cylinder Bore Stroke Fully Retracted Length Plating Thickness

Boom (Canopy) 50 mm (1.97”) 85 mm (3.35”) 576 mm (1’10.7”) 932 mm (3’0.7”) 30 μm (1.18 μin)

Boom (Cab) 50 mm (1.97”) 85 mm (3.35”) 564 mm (1’10.2”) 932 mm (3’0.7”) 30 μm (1.18 μin)

Arm 45 mm (1.77”) 75 mm (2.95”) 597 mm (1’11.5”) 929 mm (3’0.6”) 30 μm (1.18 μin)

Rod Diameter Cylinder Bore Stroke Fully Retracted Length Plating Thickness

Bucket 40 mm (1.57”) 65 mm (2.56”) 435 mm (1’5.1”) 729 mm (2’4.7”) 30 μm (1.18 μin)

Boom Swing 45 mm (1.77”) 85 mm (3.35”) 525 mm (1’8.7”) 822 mm (2’8.4”) 30 μm (1.18 μin)

Blade 50 mm (1.97”) 95 mm (3.74”) 140 mm (5.51”) 470 mm (1’6.5”) 30 μm (1.18 μin)

CYLINDER

T1-3-8

SECTION 1 GENERAL Group 3 Component Specifications FRONT ATTACHMENT PILOT VALVE TRAVEL PILOT VALVE BOOM SWING / AUXILIARY (Optional) PILOT VALVE BLADE PILOT VALVE 2-SPOOL SOLENOID VALVE UNIT (2-Spool Solenoid Valve with Pilot Relief Valve)

OIL COOLER BYPASS CHECK VALVE

Plunger Stroke Plunger Stroke Plunger Stroke

Plunger Stroke Relief Set-Pressure Rated Voltage Operating Voltage Coil Resistance Solenoid Valve Cracking Pressure

Ports 1, 3: 6.5±0.4 mm (0.26±0.016 in) Ports 2, 4: 8.0±0.4 mm (0.31±0.016 in) Ports 1, 2, 3, 4: 3.4±0.3 mm (0.13±0.012 in) Ports 1, 2: 3.7±0.3 mm (0.15±0.012 in)

Ports 1, 2: 3.2±0.3 mm (0.13±0.012 in) 4.1±0.2 MPa (41.8±2 kgf/cm2, 595±29 psi) DC 12 V DC 10 to 15 V 12.2±0.85 Ω Port A Side: Pilot Shut-Off Solenoid Valve Port B Side: Travel Mode Selector Solenoid Valve 390 kPa (4 kgf/cm2, 57 psi) at 5 L/min

T1-3-9

SECTION 1 GENERAL Group 3 Component Specifications Electrical Component ENGINE OIL PRESSURE SWITCH OVERHEAT SWITCH GLOW PLUG RELAY AIR FILTER RESTRICTION SWITCH FUEL SENSOR

Operating Pressure

49±9.8 kPa (0.5±0.1 kgf/cm2, 7.1±1.4 psi)

Operating Temperature Voltage Operating Pressure

110 °C (230 °F) 12 V 6.22±0.31 kPa (0.063±0.003 kgf/cm2, 0.9±0.045 psi)

Resistance

HORN

Specification Sound Pressure

Empty: 87 Ω Full: 10 Ω 12 V/3 A 108+5-3 dB (A) at 2 m

ILLUMINATION AIR CONDITIONER

Work Light Refrigerant Cooling Ability Cool Air Volume Heating Ability Warm Air Volume Temperature Adjusting System Refrigerant Quantity Compressor Oil Quantity

Halogen 12 V, 55 W 134 a 3.5 kW or More 350 m3/h or More 4 kW or More 330 m3/h or More Electronic Type 650 g (1.43 lb) 100 cm3 (6.1 in3)

T1-3-10

MEMO

MEMO

SECTION 2

SYSTEM CONTENTS Group 1 Control System

Outline..................................................................................... T2-1-1 Engine Control...................................................................... T2-1-4 Pump Control......................................................................T2-1-20 Other Control......................................................................T2-1-22

Group 2 Hydraulic System

Outline..................................................................................... T2-2-1 Pilot Circuit............................................................................. T2-2-2 Main Circuit..........................................................................T2-2-10

Group 3 Electrical System

Outline..................................................................................... T2-3-1 Main Circuit............................................................................ T2-3-2 Electric Power Circuit (Key Switch: OFF)...................... T2-3-4 CAN Circuit............................................................................. T2-3-6 Electric Power Circuit (Key Switch: ON)........................ T2-3-8 Preheating Circuit (Key Switch: ON)............................T2-3-10 Starting Circuit (Key Switch: START)............................T2-3-12 Charging Circuit (Key Switch: ON)...............................T2-3-14 Pilot Shut-Off Circuit (Key Switch: ON).......................T2-3-16 Auto Shut-Down Circuit (OP)........................................T2-3-18 Engine Stop Circuit (Key Switch: OFF)........................T2-3-20

ADCT-2-1

(Blank)

ADCT-2-2

SECTION 2 SYSTEM Group 1 Control System Outline The following controllers are used in order to control the machine operations. ď‚– Monitor Controller ď‚– E-ECU ď‚– Air Conditioner Controller Unit (only Cab Spec.

Machine) The signals from the engine control dial, sensors, and switches are sent to each controller and processed in the logic circuit.

Each controller operates the electronic governor and controls the engine and the valve.

T2-1-1

SECTION 2 SYSTEM Group 1 Control System ď‚— Monitor Controller: When the monitor controller receives the signals from sensors and switches, it displays the hour meter, fuel gauge, and coolant temperature gauge, and lights the indicators on the monitor.

In addition, it sends the signal from the auto-idle switch to E-ECU. ď‚— E-ECU: When E-ECU receives the signals from the engine control dial, electronic governor fuel injection pump, auto-idle switch, and coolant temperature sensor, it operates the electronic governor fuel injection pump and controls the engine speed. ď‚— Air Conditioner Controller Unit (only Cab Spec.

Machine) The signal from the air conditioner switch is sent to the air conditioner controller unit and processed in the logic circuit.

The air conditioner controller unit activates the displacement angle selection relay and controls the pump.

T2-1-2

SECTION 2 SYSTEM Group 1 Control System Engine Control , Pump Control Input Signal

Outout Signal

Key Switch Engine Speed Sensor Rack Actuator CSD Valve Coolant Temperature Sensor

    

E-ECU Engine Control Dial Power Mode Switch Auto-Idle Switch Pilot Shut-Off Switch Auto-Idle Pressure Sensor Air Conditioner Switch

 

Engine Control Engine Control Dial Control Auto-Idle Control Idle Speed-Up Control ECO Mode Control Engine Speed Control EGR Control CSD Control Starter Restraining Control

CAN

Monitor  Controller  



Pump Control Air Conditioner Controller * Power Decrease Control Unit

fNOTE:

*: This control is for only the machine with the optional parts equipped.

T2-1-3

SECTION 2 SYSTEM Group 1 Control System Engine Control The engine control consists of the followings.  Engine Control Dial Control  Auto-Idle Control  Idle Speed-Up Control  ECO Mode Control  Engine Speed Control  EGR Control  CSD Control  Starter Restraining Control

T2-1-4

SECTION 2 SYSTEM Group 1 Control System

7 1

2

3

4

5

6

8 12, 13, 14

9 TADB-02-01-001

11

1- 2- 3- 4- 5-

Engine EGR Valve E-ECU CAN Auto-Idle Switch

6- 7- 8- 9-

10

Monitor Controller Auto-Idle Pressure Sensor Engine Control Dial ECO/PWR Mode Selector Switch

10- Coolant Temperature Sensor 11- Electronic Governor Fuel Injection Pump 12- Engine Speed Sensor 13- Rack Actuator

T2-1-5

14- CSD Valve

SECTION 2 SYSTEM Group 1 Control System Engine Control Dial Control

A

Purpose: The engine control dial control controls the engine speed according to the rotation angle of engine control dial (8).

Operation: 1. The command signal according to the rotation angle of engine control dial (8) is sent to E-ECU (3) directly.

2. E-ECU (3) operates electronic governor fuel injection pump (11) and controls the engine speed according to the command signal.

C A - Engine Speed B - Engine Control Dial Position

T2-1-6

D

B

C - Slow Idle Position D - Fast Idle Position

SECTION 2 SYSTEM Group 1 Control System

7 1

2

3

4

5

6

8 12, 13, 14

9 TADB-02-01-001

11

1- 2- 3- 4- 5-

Engine EGR Valve E-ECU CAN Auto-Idle Switch

6- 7- 8- 9-

10

Monitor Controller Auto-Idle Pressure Sensor Engine Control Dial ECO/PWR Mode Selector Switch

10- Coolant Temperature Sensor 11- Electronic Governor Fuel Injection Pump 12- Engine Speed Sensor 13- Rack Actuator

T2-1-7

14- CSD Valve

SECTION 2 SYSTEM Group 1 Control System Auto-Idle Control Purpose: The auto-idle control reduces the engine speed to the slow idle speed when all control levers are in neutral.

Therefore, fuel consumption and noise level can be reduced.

Operation: 1. The signals from engine control dial (8) and electronic governor fuel injection pump (11) are sent to E-ECU (3). In addition, the signals from autoidle pressure sensor (7) and engine control dial (8) are sent to monitor controller (6).

A F

2. When setting auto-idle switch (5) on the monitor to the ON position, the signals from monitor controller (6) are sent to E-ECU (3).

3. When the idle deactivation signal is not sent from monitor controller (6) for specified time, E-ECU (3) operates electronic governor fuel injection pump (11) and sets the engine speed to auto-idle speed (slow idle speed).

E

C A- B- C- D-

4. The signal from auto-idle pressure sensor (7) is sent to monitor controller (6). Monitor controller (6) detects the lever operation from the neutral position by the signal change from auto-idle pressure sensor (7).

5. If either control lever is operated from the neutral position, the signal from auto-idle pressure sensor (7) is changed. Monitor controller (6) which has detected the signal sends the idle deactivation signal to E-ECU (3).

6. E-ECU (3) operates electronic governor fuel injection pump (11) immediately and increases the engine speed to the original engine speed (the engine speed set by engine control dial (8)).

Auto-idle deactivation condition: ď‚– When the control lever is operated (Signal from autoidle pressure sensor (7): 3.0 V or more) ď‚– When the engine speed is changed by engine control dial (8)

T2-1-8

Engine Speed Engine Control Dial Position Slow Idle Position Fast Idle Position

D E- F-

B

Auto-Idle Speed (Slow Idle Speed) Fast Idle Speed

SECTION 2 SYSTEM Group 1 Control System

7 1

2

3

4

5

6

8 12, 13, 14

9 TADB-02-01-001

11

1- 2- 3- 4- 5-

Engine EGR Valve E-ECU CAN Auto-Idle Switch

6- 7- 8- 9-

10

Monitor Controller Auto-Idle Pressure Sensor Engine Control Dial ECO/PWR Mode Selector Switch

10- Coolant Temperature Sensor 11- Electronic Governor Fuel Injection Pump 12- Engine Speed Sensor 13- Rack Actuator

T2-1-9

14- CSD Valve

SECTION 2 SYSTEM Group 1 Control System Idle Speed-Up Control Purpose: The idle speed-up control increases the slow idle speed of the engine by 200 min-1 during the slow idle speed operation when coolant temperature is 10 °C or less. Therefore, it warms the engine quickly at low temperature.

Operation: 1. E-ECU (3) receives the signals from coolant temperature sensor (10).

2. E-ECU (3) controls the engine speed for the stable engine speed at low temperature.

3. Therefore, the engine is warmed up quickly at low temperature.

4. When coolant temperature reaches the set value, E-ECU (3) returns the engine speed to the slow idle speed.

Condition: ď‚– Engine control dial: Slow idle speed

T2-1-10

SECTION 2 SYSTEM Group 1 Control System

7 1

2

3

4

5

6

8 12, 13, 14

9 TADB-02-01-001

11

1- 2- 3- 4- 5-

Engine EGR Valve E-ECU CAN Auto-Idle Switch

6- 7- 8- 9-

10

Monitor Controller Auto-Idle Pressure Sensor Engine Control Dial ECO/PWR Mode Selector Switch

10- Coolant Temperature Sensor 11- Electronic Governor Fuel Injection Pump 12- Engine Speed Sensor 13- Rack Actuator

T2-1-11

14- CSD Valve

SECTION 2 SYSTEM Group 1 Control System ECO Mode Control Purpose: The ECO mode control reduces the engine speed by the specified ratio in order to reduce fuel consumption.

Operation: 1. When ECO/PWR mode selector switch (9) is in the PWR position, the command signal from engine control dial (8) is sent to E-ECU (3) directly.

A

2. When ECO/PWR mode selector switch (9) is in the ECO position, the command signal from engine control dial (8) is sent to monitor controller (6).

3. The command signal to monitor controller (6) is converted into the signal reduced by the specified ratio and is sent to E-ECU (3).

4. E-ECU (3) controls the engine speed according to the converted command signal.

f

C

NOTE: The engine speed is reduced in proportion to the rotation angle of engine control dial (8).

A - Engine Speed B - Engine Control Dial Position

T2-1-12

D

B

C - Slow Idle Position D - Fast Idle Position

SECTION 2 SYSTEM Group 1 Control System

7 1

2

3

4

5

6

8 12, 13, 14

9 TADB-02-01-001

11

1- 2- 3- 4- 5-

Engine EGR Valve E-ECU CAN Auto-Idle Switch

6- 7- 8- 9-

10

Monitor Controller Auto-Idle Pressure Sensor Engine Control Dial ECO/PWR Mode Selector Switch

10- Coolant Temperature Sensor 11- Electronic Governor Fuel Injection Pump 12- Engine Speed Sensor 13- Rack Actuator

T2-1-13

14- CSD Valve

SECTION 2 SYSTEM Group 1 Control System Engine Speed Control Purpose: The engine speed control operates to maintain the target engine speed even when the engine load is changed.

Operation: 1. E-ECU (3) controls the engine while considering the command signal from engine control dial (8) as the target engine speed.

2. When deflection is generated between actual engine speed and target engine speed according to the change of engine load, E-ECU (3) calculates the rack actuator (13) operation and operates to reduce deflection.

3. Therefore, the target engine speed is maintained.

T2-1-14

SECTION 2 SYSTEM Group 1 Control System

7 1

2

3

4

5

6

8 12, 13, 14

9 TADB-02-01-001

11

1- 2- 3- 4- 5-

Engine EGR Valve E-ECU CAN Auto-Idle Switch

6- 7- 8- 9-

10

Monitor Controller Auto-Idle Pressure Sensor Engine Control Dial ECO/PWR Mode Selector Switch

10- Coolant Temperature Sensor 11- Electronic Governor Fuel Injection Pump 12- Engine Speed Sensor 13- Rack Actuator

T2-1-15

14- CSD Valve

SECTION 2 SYSTEM Group 1 Control System EGR Control

CSD Control

Purpose: The EGR control combines a part of exhaust gas with intake-air so that combustion temperature is lowered and generation of oxide of nitrogen (NOx) is controlled.

Purpose: The CSD control controls CSD valve (14) of electronic governor fuel injection pump (11) and improves the starting of the engine at low temperature.

Operation: 1. E-ECU (3) combines electronic governor fuel injection pump (11) and EGR valve (2) in order to control the exhaust gas recirculation amount according to engine load and engine speed.

Operation: 1. E-ECU (3) receives the signals from coolant temperature sensor (10).

2. E-ECU (3) sends the command signal to CSD valve (14) when starting the engine at low temperature.

2. EGR valve (2) controls intake-air recirculation amount by controlling the opening of the valve according to the signal from E-ECU (3).

3. CSD valve (14) controls the fuel increase amount and the advance of fuel injection timing according to the command signal from E-ECU (3).

4. Therefore, the starting of the engine at low temperature is improved.

fNOTE:

When coolant temperature is 60 °C (140 °F) or lower, EGR valve (2) is controlled not to open.

fNOTE:

The engine speed increases more than the engine speed at normal condition during CSD valve (14) operation.

T2-1-16

SECTION 2 SYSTEM Group 1 Control System

7 1

2

3

4

5

6

8 12, 13, 14

9 TADB-02-01-001

11

1- 2- 3- 4- 5-

Engine EGR Valve E-ECU CAN Auto-Idle Switch

6- 7- 8- 9-

10

Monitor Controller Auto-Idle Pressure Sensor Engine Control Dial ECO/PWR Mode Selector Switch

10- Coolant Temperature Sensor 11- Electronic Governor Fuel Injection Pump 12- Engine Speed Sensor 13- Rack Actuator

T2-1-17

14- CSD Valve

SECTION 2 SYSTEM Group 1 Control System Starter Restraining Control Purpose: The starter restraining control makes starting or restarting starter (6) impossible under the conditions in order to protect the starting circuit and starter (6).

Operation: 1. When current flows through terminals #8 and #24, E-ECU (1) connects terminal #20 to the ground.

2. Therefore, starter relay 1 (5) is turned ON, starter (6) rotates, and the engine starts. (Refer to SYSTEM / Electrical System.)

3. When any following conditions exist, E-ECU (1) disconnects terminal #20 from the ground.

4. Therefore, starter relay 1 (5) is turned OFF, starter (6) does not rotate, and the engine does not start.

Condition:  While the self-diagnosis of E-ECU (1) is made before starting the engine  While the OFF signal from pilot shut-off switch (3) is not sent to E-ECU (1) through pilot shut-off relay (2)  When starter (6) is operated for 30 seconds continuously (Then, starter (6) can not restart for 30 seconds.)  When the engine speed is 700 min-1 or more after the engine starts (Then, starter (6) can not restart until the engine speed is lowered to 350 min-1 or less.)

T2-1-18

SECTION 2 SYSTEM Group 1 Control System

1

a

2

3

b

24 20

8

T1N0-02-01-011

6

5

4

a-

From Battery

b-

From Key Switch

1- 2-

E-ECU Pilot Shut-Off Relay

3- 4-

Pilot Shut-Off Switch Engine Speed Sensor

5- 6-

T2-1-19

Starter Relay 1 Starter

SECTION 2 SYSTEM Group 1 Control System Pump Control Power Decrease Control (only Cab Spec. Machine) Purpose: When the air conditioner is operated, the pump control decreases driving torque of the main pump and controls it so that the total load to the main pump and compressor does not exceed the engine output power. (Refer to COMPONENT OPERATION / Pump Device.)

Operation: 1. When turning air conditioner switch (1) ON, terminal #36 is grounded in air conditioner controller unit (2).

A

0 A- Flow Rate (Q)

2. When displacement angle selection relay (3) is excited, current (a) from fuse #7 flows to torque control solenoid valve (4) and shifts it.

3. Therefore, pressure oil from pilot pump (6) is routed to control piston (7) in main pump (5) through torque control solenoid valve (4).

4. The swash plate of main pump (5) reduces the displacement angle due to control piston (7).

5. Consequently, the driving torque of main pump (5) decreases and is kept below the engine output power.

T2-1-20

B B-

Pressure (P)

SECTION 2 SYSTEM Group 1 Control System

1

2 3

36

4 a

7

6

a-

Current from Fuse #7

1- 2-

Air Conditioner Switch Air Conditioner Controller Unit

3-

Displacement Angle Selection Relay

4- 5-

T2-1-21

T1ND-02-01-001

5

Torque Control Solenoid Valve Main Pump

6- 7-

Pilot Pump Control Piston

SECTION 2 SYSTEM Group 1 Control System Other Control AUX Function Lever (AFL) Control (Only Machine with the Optional Parts Equipped) Purpose: The AUX function lever (AFL) control enable to control with slide switch (3) and switch (4) of AUX function lever when using the attachment such as a breaker.

Operation: 1. When operating slide switch (3) or switch (4) of the AUX function lever, current (a) from fuse #15 flows to AUX function solenoid valve 1 (2) or AUX function solenoid valve 2 (6) through AUX function lever controller (5).

fNOTE:

When operating slide switch (3) or switch (4) at the same time, priority is given to the switch (4) operation. Then, the operation is similar to the operation when slide switch (3) reaches full stroke leftward.

2. When operating switch (4), AUX function lever controller (5) activates AUX function solenoid valve 1 (2) or AUX function solenoid valve 2 (6).

3. When operating slide switch (3), AUX function lever controller (5) activates AUX function solenoid valve 1 (2) or AUX function solenoid valve 2 (6) according to the slide switch (3) operation.

4. Pressure oil from pilot pump (9) is routed to auxiliary spool (7) in the control valve through AUX function solenoid valve 1 (2) or AUX function solenoid valve 2 (6).

5. Consequently, pressure oil from main pump (8) is supplied to each attachment through auxiliary spool (7).

T2-1-22

SECTION 2 SYSTEM Group 1 Control System

1

2

a

10 3 4

5

b

6

7 9

8 T1ND-02-01-002

a-

Current from Fuse #15

b-

To Attachment

1- 2- 3-

Pilot Valve (Right) AUX Function Solenoid Valve 1 Slide Switch

4- 5- 6-

Switch AUX Function Lever Controller AUX Function Solenoid Valve 2

7- 8- 9-

T2-1-23

Auxiliary Spool Main Pump Pilot Pump

10- Hydraulic Oil Tank

SECTION 2 SYSTEM Group 1 Control System Travel Alarm Control (Only Machine with the Optional Parts Equipped) Purpose: The travel alarm control sound the buzzer during travel operation.

Operation: 1. The signal from travel pressure sensor (4) is sent to monitor controller (2) during travel operation.

2. As long as monitor controller (2) receives this signal, it sends the signal to buzzer (3) and sounds buzzer (3).

fNOTE:

The alarm can be deactivated by turning buzzer deactivation switch (1) ON. Buzzer (3) sounds again when resuming traveling.

1

2

3

TADB-02-01-003

4 1-

Buzzer Deactivation Switch

2-

Monitor Controller

3-

T2-1-24

Buzzer

4-

Travel Pressure Sensor

SECTION 2 SYSTEM Group 1 Control System Overload Alarm Control (Only Machines with Optional Parts Equipped) Purpose: The overload alarm control sounds the buzzer when boom raise operation such as suspending is overloaded.

Operation: 1. The signal from boom bottom pressure sensor (4) is sent to monitor controller (1).

2. When all following conditions exist, monitor controller (1) sounds buzzer (2).

Condition: ď‚– Boom bottom pressure sensor (4): Outputting signal beyond the specified pressure ď‚– Overload alarm switch (3): ON

1

2

3

4

TADB-02-01-005

1-

Monitor Controller

2-

Buzzer

3-

T2-1-25

Overload Alarm Switch

4-

Boom Bottom Pressure Sensor

SECTION 2 SYSTEM Group 1 Control System (Blank)

T2-1-26

SECTION 2 SYSTEM Group 2 Hydraulic System Outline The hydraulic system mainly consists of the pilot circuit and main circuit.

Pilot Circuit: Power Source Pilot Pump

Controller Pilot Valve 2-Spool Solenoid Valve Torque Control Solenoid Valve (Optional)

Supplied to Operation Control Circuit Travel Motor Displacement Angle Control Circuit Swing Parking Brake Release Circuit Pump Control Circuit (Only machine with the air conditioner (optional) attached)

Controller Control Valve

Supplied to Motor Cylinder Attachment (Optional)

Main Circuit: Power Source Main Pump

T2-2-1

SECTION 2 SYSTEM Group 2 Hydraulic System Pilot Circuit Outline: Pressure oil from the pilot pump is used in order to operate the following circuits.    

Operation Control Circuit Travel Motor Displacement Angle Control Circuit Swing Parking Brake Release Circuit Pump Control Circuit (Only machine with the air conditioner (optional) attached)

T2-2-2

SECTION 2 SYSTEM Group 2 Hydraulic System

2

1

10

11

23

3

4

9

5

6

7

8

24

12

23 22

21

20

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

19

Pilot Valve (Left) Pilot Valve (Right) Travel Pilot Valve Boom Swing Pilot Valve Blade Pilot Valve Auxiliary Pilot Valve (Optional) Operation Control Circuit Flow Combiner Valve Control Valve

18

17

16

15

10- Spool 11- Boom Anti-Drift Valve 12- Torque Control Solenoid Valve (Only machine with the air conditioner (optional) attached) 13- Main Pump 14- Pilot Pump

14

13

15- Pump Control Circuit (Only machine with the air conditioner (optional) attached) 16- Pilot Filter 17- Pilot Relief Valve 18- Travel Mode Selector Solenoid Valve 19- Pilot Shut-Off Solenoid Valve

T2-2-3

TADB-02-02-006

20- Swing Motor 21- Swing Parking Brake Release Circuit 22- Travel Motor Displacement Angle Control Circuit 23- Travel Mode Selector Valve 24- Travel Motors (Left, Right)

SECTION 2 SYSTEM Group 2 Hydraulic System Operation Control Circuit The operation control circuit controls the control valve (11) operation.

In response to the control lever stroke, the pilot valve regulates the pressure oil supplied to the spool end in control valve (11).

In addition, during boom lower operation, pressure oil from pilot valve (5) is routed to boom anti-drift valve (13) and the spool end surface in control valve (11).

(Refer to COMPONENT OPERATION / Control Valve.)

fNOTE:

The boom raise operation is explained here.

1. When the pilot shut-off lever is set to Unlock position, the pilot shut-off switch which is located under the pilot shut-off lever is turned ON and pilot shut-off solenoid valve (16) is shifted.

2. When the control lever is moved in the boom raise position, pressure oil from pilot pump (15) is routed to pilot valve (right) (4) through pilot shut-off solenoid valve (16).

3. Pressure oil is reduced by pilot valve (right) (4) to the pressure according to the control lever stroke and is supplied to boom spool end (a) so that the spool is moved in response to the control lever stroke.

4. Pressure oil from main pump (14) is routed to boom anti-drift valve (13) through the boom spool. (Refer to COMPONENT OPERATION / Control Valve.)

5. Pressure oil passing through boom anti-drift valve (13) is routed to the boom cylinder (12) bottom side and extends boom cylinder (12) so that the boom is raised.

T2-2-4

SECTION 2 SYSTEM Group 2 Hydraulic System 1 2

4 5

3

7

6

8

r g

he

f

a

b c

d

j

i

k

q

l 9

12

10

13

o

p

n

m

11

P4 P3 P2

16

15

P1

14 TADB-02-02-002

a- b- c- d- e-

Boom Raise Boom Lower Bucket Roll-In Bucket Roll-Out Swing (Right)

f- g- h- i- j-

Swing (Left) Arm Roll-In Arm Roll-Out Travel (Right Forward) Travel (Right Reverse)

k- l- m- n- o-

Travel (Left Reverse) Travel (Left Forward) Boom Swing (Right) Boom Swing (Left) Blade Lower

p- q- r-

1- 2- 3- 4- 5-

Pilot Valve (Left) Arm Swing Pilot Valve (Right) Boom

6- 7- 8- 9- 10-

Bucket Travel Pilot Valve Auxiliary Pilot Valve (OP) Boom Swing Pilot Valve Blade Pilot Valve

11- 12- 13- 14- 15-

Control Valve Boom Cylinder Boom Anti-Drift Valve Main Pump Pilot Pump

16- Pilot Shut-Off Solenoid Valve

T2-2-5

Blade Raise Auxiliary Auxiliary

SECTION 2 SYSTEM Group 2 Hydraulic System Travel Motor Displacement Angle Control Circuit (9) Travel mode control displacement angle circuit (9) controls the travel mode.

It consists of travel mode selector solenoid valve (2) and travel mode selector valve (8).

In response to travel mode switch position (fast/slow), travel mode selector solenoid valve (2) is shifted so that the travel speed control oil pressure is supplied to travel motor (7). (Refer to COMPONENT OPERATION / Travel Device.)

Swing Parking Brake Release Circuit (6) Swing parking brake release circuit (6) releases the swing parking brake.

It consists of the pilot shut-off lever, the pilot shut-off switch, and pilot shut-off solenoid valve (1).

When the pilot shut-off lever is set to Unlock position (pilot shut-off switch: ON), pilot shut-off solenoid valve (1) is shifted so that the swing parking release oil pressure is supplied to swing motor (4). (Refer to COMPONENT OPERATION / Swing Device.)

T2-2-6

SECTION 2 SYSTEM Group 2 Hydraulic System

1

2

9

7

3

8 4

7

6

5 T1MJ-02-02-010

1- 2- 3- 4-

Pilot Shut-Off Solenoid Valve Travel Mode Selector Solenoid Valve Pilot Pump Swing Motor

5- 6- 7- 8-

Swing Parking Brake Swing Parking Brake Release Circuit Travel Motor Travel Mode Selector Valve

T2-2-7

9-

Travel Motor Displacement Angle Control Circuit

SECTION 2 SYSTEM Group 2 Hydraulic System Pump Control Circuit (Only machine with the air conditioner (optional) attached) When shifting torque control solenoid valve (3), pressure oil from pilot pump (2) is supplied to pump device (1) and the torque control of main pump is performed. (Refer to SYSTEM / Control System.)

1

2

3

1-

Pump Device

2-

T1MJ-02-02-009

Pilot Pump

3-

T2-2-8

Torque Control Solenoid Valve

SECTION 2 SYSTEM Group 2 Hydraulic System (Blank)

T2-2-9

SECTION 2 SYSTEM Group 2 Hydraulic System Main Circuit Outline 1. Main pumps (17) (P1, P2, and P3) draw hydraulic oil from hydraulic oil tank (18) and delivers it to control valve (1).

2. The delivered pressure oil is supplied to the motors and cylinders by shifting the control valve (1) spool.

(Refer to COMPONENT OPERATION / Control Valve.)

3. The returning oil from cylinders and motors returns to control valve (1) and is combined inside it again.

The returning oil from control valve (1) returns to hydraulic oil tank (18) after being cooled in oil cooler (20).

4. In addition, when oil temperature is low (high viscosity) and oil flow resistance increases in oil cooler (20). Bypass check valve (19) is opened and hydraulic oil directly returns to hydraulic oil tank (18).

T2-2-10

SECTION 2 SYSTEM Group 2 Hydraulic System

24

1

12

2 3 23

13

4 5

22

14

6

15 7 8 21

9 10

16

11

20

19

P3

P2

P1

18 17

1- 2- 3- 4- 5- 6- 7-

Control Valve Flow Combiner Valve Blade Spool Swing Spool Boom Swing Spool Auxiliary Spool Arm Spool

8- 9- 10- 11- 12- 13- 14-

Travel (Right) Spool Travel (Left) Spool Boom Spool Bucket Spool Blade Cylinder Boom Swing Cylinder Arm Cylinder

15- 16- 17- 18-

19- 20-

T2-2-11

Travel Motor (Left) Bucket Cylinder Main Pump Hydraulic Oil Tank Bypass Check Valve Oil Cooler

TADB-02-02-003

21- 22- 23- 24-

Boom Cylinder Travel Motor (Right) Attachment Swing Motor

SECTION 2 SYSTEM Group 2 Hydraulic System Neutral Circuit 1. When the control lever is in neutral, pressure oil from main pumps (23) return to hydraulic oil tank (22) through control valve (9).

Single Operation Circuit 1. Pressure oil from main pump (23) (P1) flows to travel (right) spool (16), arm spool (15), and auxiliary spool (14) in control valve (9).

2. Pressure oil from main pump (23) (P2) flows to travel (left) spool (17), boom spool (18), and bucket spool (19) in control valve (9).

3. Pressure oil from main pump (23) (P3) flows to flow combiner valve spool (10), blade spool (11), swing spool (12), boom swing spool (13), and auxiliary spool (14) in control valve (9).

T2-2-12

SECTION 2 SYSTEM Group 2 Hydraulic System

1

2

3

4

5

6

7

8

9

19

18

17

16

15

14

13

12

11

10

20 P3 P2 P1

21

22

23 TADB-02-02-004

1- 2- 3- 4- 5- 6-

Swing Motor Bucket Cylinder Boom Cylinder Blade Cylinder Travel Motor (Left) Travel Motor (Right)

7- 8- 9- 10- 11- 12-

Arm Cylinder Boom Swing Cylinder Control Valve Flow Combiner Valve Blade Spool Swing Spool

13- 14- 15- 16- 17- 18-

T2-2-13

Boom Swing Spool Auxiliary Spool Arm Spool Travel (Right) Spool Travel (Left) Spool Boom Spool

19- 20- 21- 22- 23-

Bucket Spool Bypass Check Valve Oil Cooler Hydraulic Oil Tank Main Pump

SECTION 2 SYSTEM Group 2 Hydraulic System Combined Operation Circuit (Combined Operation of Travel and Front Attachment)

fNOTE:

The combined operation of travel (left, right) and boom lower is explained here.

1. When operating boom lower while traveling, pilot signal circuit (5) is blocked by travel spools (13, 14) and boom spool (15).

2. As pilot signal circuit (5) is blocked, pressure in pilot signal circuit (5) increases and flow combiner valve (9) is shifted.

3. When flow combiner valve (9) is shifted, parallel circuits (10) which are connected to boom spool (15), arm spool (12), and bucket spool (16) from main pump (18) (P3) are provided.

4. Therefore, pressure oil from main pump (18) (P3) flows to each front attachment spool so that the combined operation of travel and front attachment can be operated.

5. Pressure oil from main pump (18) (P3) is supplied to blade spool (8), swing spool (7), and boom swing spool (6) through parallel circuit (10) bypassing flow combiner valve (9).

T2-2-14

SECTION 2 SYSTEM Group 2 Hydraulic System

1

2

3

4

16

15

14

13

12

5

6

11

7

10

P3 P2

17

8

9

P1

18 TADB-02-02-005

1- 2- 3- 4- 5-

Boom Cylinder Travel Motor (Left) Travel Motor (Right) Control Valve Pilot Signal Circuit

6- 7- 8- 9- 10-

Boom Swing Spool Swing Spool Blade Spool Flow Combiner Valve Parallel Circuit

11- 12- 13- 14- 15-

T2-2-15

Auxiliary Spool Arm Spool Travel (Right) Spool Travel (Left) Spool Boom Spool

16- Bucket Spool 17- Pilot Pump 18- Main Pump

SECTION 2 SYSTEM Group 2 Hydraulic System (Blank)

T2-2-16

SECTION 2 SYSTEM Group 3 Electrical System Outline The electrical circuit is broadly divided into the main circuit, monitor circuit, accessory circuit, and control circuit.  Main Circuit: Operates the engine and the accessory related circuits.  Monitor Circuit: Displays the machine operating conditions. Consists of monitor controller, sensors, relays, and switches.  Accessory Circuit: Operates the accessory circuit. Consists of relays and switches.  Control Circuit: Controls the engine. Consists of E-ECU, sensors, and switches.

(Refer to SYSTEM / Control System.)

T2-3-1

SECTION 2 SYSTEM Group 3 Electrical System Main Circuit The major functions and circuits in the main circuit are as follows.  Electric Power Circuit: Supplies all electric power to all electrical systems on the machine. {Key switch, Battery, Fuses (Fuse box, Slow blow fuse)}  CAN Circuit: Performs communication between the monitor controller and E-ECU.  Starting Circuit: Starts the engine.

(Key switch, Starter, Starter relay 1)  Charging Circuit: Supplies electric power to the batteries and charges them. {Alternator, (Regulator)}  Pilot Shut-Off Circuit (Key switch: ON): Supplies pressure oil from the pilot pump to the pilot valve by the pilot shut-off solenoid valve.

(Pilot shut-off solenoid valve, Pilot shut-off lever)  Preheating Circuit: Assists the engine when starting in cold weather. (Key switch, Glow plug relay, Glow plug)  Auto Shut-Down Circuit (OP): Stops the engine automatically when the fixed conditions exist.

(Monitor controller, Auto shut-down relay, ACC cut relay, R2 cut relay)  Engine Stop Circuit (Key switch: OFF): Stops the engine by using E-ECU. (E-ECU)

T2-3-2

SECTION 2 SYSTEM Group 3 Electrical System (Blank)

T2-3-3

SECTION 2 SYSTEM Group 3 Electrical System Electric Power Circuit (Key Switch: OFF) The battery (1) minus terminal is grounded to the body.

Current from the battery (1) plus terminal flows as shown below when key switch (7) is in the OFF position.

Battery (1)

Slow Blow Fuse (3)

Starter Relay 1 (4)

Slow Blow Fuse (2)

Glow Plug Relay (5)

Slow Blow Fuse (10)

Alternator (6) Terminal B Key Switch (7) Terminal B Fuse Box (9)

T2-3-4

Terminal #1

Horn Relay (13) Terminals #1 and #3

Terminal #2

Monitor Controller (8) Terminal M1-13

Terminal #3

Light Relay (12) Terminal #3

Terminal #4

Main Relay (11) Terminals #1 and #2

Terminal #5

Option (14)

SECTION 2 SYSTEM Group 3 Electrical System

2

3

4

5

6

7

8

9 1

10

11

14

12

1- 2- 3- 4-

Battery Slow Blow Fuse Slow Blow Fuse Starter Relay 1

5- 6- 7-

Glow Plug Relay (Power) Alternator Key Switch

13

8-

Monitor Controller (Backup Power) 9- Fuse Box 10- Slow Blow Fuse

T2-3-5

TADB-02-05-001

11- 12- 13- 14-

Main Relay (Power) Light Relay Horn Relay (Power) Option

SECTION 2 SYSTEM Group 3 Electrical System CAN Circuit CAN (Controller Area Network) is ISO Standards of the serial communication protocol.

The communication between monitor controller (4) and E-ECU (5) is performed for this machine.

CAN bus (1) consists of two harnesses, CAN-H (High) (2) and CAN-L (Low) (3).

The controller judges the CAN bus (1) level due to potential difference between CAN-H (High) (2) and CAN-L (Low) (3).

The controller arranges the CAN bus (1) level and sends the signal and data.

T2-3-6

SECTION 2 SYSTEM Group 3 Electrical System

2 1 3 TADB-02-05-013

4

5

2

3

TADB-02-05-002 1- 2-

CAN Bus CAN-H (High)

3- 4-

CAN-L (Low) Monitor Controller

T2-3-7

5-

E-ECU (Engine Controller)

SECTION 2 SYSTEM Group 3 Electrical System Electric Power Circuit (Key Switch: ON) 1. When key switch (3) is set to the ON position, terminal B is connected to terminals BR, R2, and ACC in key switch (3).

2. Current from terminals BR, R2, and ACC in key switch (3) flows as shown below as a power source respectively.

3. In addition, when current from terminal BR in key switch (3) flows to terminal M1-1 in monitor controller (4), monitor controller (4) lights the indicator and displays the alarm on the monitor.

4. When current from terminal ACC in key switch (3) flows to terminal #7 in E-ECU (1), E-ECU (1) connects terminal #34 to the ground and excites main relay (17).

Key Switch (3) Terminal BR Key Switch (3) Terminal R2

Fuse Box (5) Fuse Box (5)

Terminal #11 Terminal #7 Terminal #8 Terminal #9

Key Switch (3) Terminal ACC

Fuse Box (5)

Terminal #10 Terminal #12 Terminal #13 Terminal #14 Terminal #15 Terminal #16

Terminal #17 Terminal #18

Monitor Controller (4) Terminal M1-1 Air Conditioner (Blower Fan) Power (j) (OP) Wiper Motor (i) (OP) Washer Motor (i) (OP) Travel Mode Control Solenoid Valve (h) Light Switch (h) Auxiliary Power (g) (OP) Radio (f ) (OP) Air Conditioner Power Switch (f ) (OP) Beacon Light (e) (OP) Travel Mode Switch (d) Travel Alarm (c) (OP) AUX Function Lever Power (c) (OP) Auxiliary Flow Rate Control Power (c) (OP) Rack Actuator Relay (6) Alternator (2) Terminal IG E-ECU (1) Terminal #7 Fuel Pump (20) Pilot Shut-Off Switch (b) Pilot Shut-Off Relay, Pilot Shut-Off Solenoid Valve (b) Option (a)

T2-3-8

SECTION 2 SYSTEM Group 3 Electrical System

3 2

4

ON B

BR R2 ACC

1 7 8 9 101112 131415161718

5

a b c d e f g h i j

6 20

19 TADB-02-05-003

1- 2-

E-ECU Alternator

3- 4-

Key Switch Monitor Controller

5- 6-

Fuse Box Rack Actuator Relay

19- Main Relay 20- Fuel Pump

a- b-

Option Pilot Shut-Off Switch/Pilot Shut-Off Relay/Pilot Shut-Off Solenoid Valve

c-

Travel Alarm (OP)/AUX Function Lever Power (OP)/ Auxiliary Flow Rate Control Power (OP) Travel Mode Switch Beacon Light (OP)

f-

Radio (OP)/Air Conditioner Power Switch (OP) Auxiliary Power (OP) Travel Mode Control Solenoid Valve/Light Switch

i-

d- e-

g- h-

T2-3-9

j-

Wiper Motor (OP)/Washer Motor (OP) Air Conditioner (Blower Fan) Power (OP)

SECTION 2 SYSTEM Group 3 Electrical System Preheating Circuit (Key Switch: ON) 1. Current from battery (1) flows to terminal B in key switch (5), fuse box (7), and terminal #87 in glow plug relay (3) through slow blow fuse (2).

2. When key switch (5) is set to the ON position, terminal B is connected to terminals BR, R2, and ACC in key switch (5).

3. Current from battery (1) flows to terminal M1-13 in monitor controller (6) through fuse box (7).

4. Current from terminal ACC in key switch (5) flows to terminal #7 in E-ECU (9) through fuse box (7).

5. When current flows to terminal #7 in E-ECU (9), E-ECU (9) detects the signal of coolant temperature sensor (8). E-ECU (9) calculates the exciting time of glow plug relay (3) according to the detected signal of coolant temperature sensor (8), and excites glow plug relay (3).

6. When glow plug relay (3) is excited, the circuit is connected to glow plug (4) and current flows to glow plug (4).

7. When current flows to glow plug (4), it heats air to the engine.

8. In addition, E-ECU (9) sends the signal to monitor controller (6) after glow plug relay (3) is excited.

When monitor controller (6) has received the signal from E-ECU (9), the preheat indicator lights.

9. After the calculated exciting time has passed, E-ECU (9) turns glow plug relay (3) OFF. Therefore, glow plug (4) is turned OFF and preheating is stopped.

T2-3-10

SECTION 2 SYSTEM Group 3 Electrical System

1

2

3

4

5

6

ON B

87

ACC

M1-13

2

M2-16

16

7 16 23

7

9 44

8 TADB-02-05-008

1- 2- 3-

Battery Slow Blow Fuse Glow Plug Relay

4- 5- 6-

Glow Plug Key Switch Monitor Controller

T2-3-11

7- 8- 9-

Fuse Box Coolant Temperature Sensor E-ECU

SECTION 2 SYSTEM Group 3 Electrical System Starting Circuit (Key Switch: START) 9. When current flows to terminals #8 and #24 in E-ECU (12), E-ECU (12) connects terminal #20 to the ground and excites starter relay 1 (3). Consequently, terminals #87 and #30 in starter relay 1 (3) are connected.

1. When key switch (5) is set to the START position, terminal B is connected to terminals BR, C, and ACC in key switch (5).

2. Current from terminal ACC in key switch (5) flows to terminal IG in alternator (4) and fuel pump (10) through fuse box (6) as a power source respectively.

3. Terminal L in alternator (4) is grounded inside when alternator (4) slowly rotates or stops. Therefore, terminal M1-24 in monitor controller (7) is grounded through terminal L in alternator (4) and the alternator indicator lights.

10. Current from battery (1) flows to terminal S in starter (2) through terminals #87 and #30 in starter relay 1 (3). Therefore, the contact in starter (2) is connected.

11. Current from battery (1) flows to the starter motor through terminal B in starter (2) and the contact.

Therefore, the starter motor rotates.

4. Current from terminal BR in key switch (5) flows to terminal M1-1 in monitor controller (7) through fuse box (6).

12. When the engine has started, alternator (4) starts charging electricity and voltage at terminals P and B in alternator (4) increase.

5. Current from terminal C in key switch (5) flows to terminal #86 in starter relay 1 (3) and terminal #8 in E-ECU (12) through fuse box (6).

13. E-ECU (12) detects the engine speed according to the signal from engine speed sensor (11). When the engine speed reaches about 700 min-1, E-ECU (12) turns starter relay 1 (3) OFF. Therefore, the starter motor stops.

6. Current from terminal ACC in key switch (5) flows to terminal #3 in pilot shut-off relay (8), terminal #7 in E-ECU (12), and pilot shut-off switch (9) through fuse box (6).

7. When pilot shut-off switch (9) is OFF, the contact between terminals #3 and #4 in pilot shut-off relay (8) is connected.

8. Therefore, current from terminal ACC in key switch (5) flows to terminal #24 in E-ECU (12) through terminals #3 and #4 in pilot shut-off relay (8).

fNOTE:

In case of engine speed sensor (11) is broken, voltage of terminal P in alternator (4) is detected according to terminal #10 in E-ECU (12). When the voltage reaches the set voltage, E-ECU (12) turns starter relay 1 (3) OFF and continues to operate.

fNOTE:

The circuit is not connected to terminal R1 in key switch (5).

fNOTE:

When the pilot shut-off lever is in the UNLOCK position (pilot shut-off switch (9): ON), the engine does not start. (Refer to Pilot Shut-Off Circuit.)

T2-3-12

SECTION 2 SYSTEM Group 3 Electrical System

1

2

3

4

5

START

86

87 30

B

P

B L IG

6

ACC

BR

C

B S

M1-24

6 7

7

11

16 17

8

10 20 24 12

#4 11

#3

10 9

8 TADB-02-05-004

1- 2- 3-

Battery Starter Starter Relay 1

4- 5- 6-

Alternator Key Switch Fuse Box

7- 8- 9-

T2-3-13

Monitor Controller Pilot Shut-Off Relay Pilot Shut-Off Switch

10- Fuel Pump 11- Engine Speed Sensor 12- E-ECU

SECTION 2 SYSTEM Group 3 Electrical System Charging Circuit (Key Switch: ON) 1. After the engine starts and key switch (4) is released, key switch (4) is returned to the ON position. When key switch (4) is in the ON position, terminal B is connected to terminals BR, R2, and ACC in key switch (4).

2. Current from terminal ACC in key switch (4) flows to terminal IG in alternator (3) as a power source for the regulator inside alternator (3).

3. When the engine runs, alternator (3) starts generating electricity and terminal L in alternator (3) is not grounded inside. Therefore, terminal M124 in the monitor controller is not grounded inside alternator (3). Consequently, the alternator indicator goes off.

4. Constant voltage is generated from terminal B in alternator (3) regardless of the alternator (3) rotating speed and current flows to battery (1) and each circuit through slow blow fuse (2). Therefore, battery (1) is charged.

T2-3-14

SECTION 2 SYSTEM Group 3 Electrical System

1

2

3

4

5

ON B

L

B

ACC

IG

M1-24

TADB-02-05-005

1- 2-

Battery Slow Blow Fuse

3- 4-

Alternator Key Switch

5-

T2-3-15

Monitor Controller

SECTION 2 SYSTEM Group 3 Electrical System Pilot Shut-Off Circuit (Key Switch: ON) 1. When the pilot shut-off lever is set to the UNLOCK position, pilot shut-off switch (7) is turned ON. 2. Current from fuse #17 flows to the ground through pilot shut-off switch (7) and pilot shut-off relay (6) and pilot shut-off relay (6) is excited.

3. Therefore, current from fuse #17 flows to pilot shutoff solenoid valve (5) and pilot shut-off solenoid valve (5) is turned ON. Then, pressure oil from the pilot pump is supplied to the pilot valve. ď‚— Neutral Engine Start Circuit 1. When the pilot shut-off lever is set to the UNLOCK position, pilot shut-off relay (6) is excited.

2. Wnen pilot shut-off relay (6) is excited, current from fuse #17 does not flow to terminal #24 in E-ECU (8) so that starter relay 1 (2) is kept OFF. 3. Therefore, when the pilot shut-off lever is in the UNLOCK position, even if key switch (3) is set to the START position, the starter does not rotate and the engine does not start.

T2-3-16

SECTION 2 SYSTEM Group 3 Electrical System

1

2

3 ON START

ACC

4 17

24

8

7

6

5 TADB-02-05-007

1- 2- 3-

Battery Starter Relay 1 Key Switch

4- 5- 6-

Fuse Box Pilot Shut-Off Solenoid Valve Pilot Shut-Off Relay

7- 8-

T2-3-17

Pilot Shut-Off Switch (Pilot Shut-Off Lever) E-ECU

SECTION 2 SYSTEM Group 3 Electrical System Auto Shut-Down Circuit (OP) 1. When key switch (2) is in the ON position, current from terminal ACC flows to the coils of auto shutdown relay (4), ACC cut relay (6), and R2 cut relay (7) through fuse (3).

fNOTE:

2. In addition, current from terminal ACC flows to terminal M2-9 in monitor controller (5) through auto shut-down relay (4).

3. Monitor controller (5) connects terminal M2-9 to the ground inside.

4. Therefore, auto shut-down relay (4), ACC cut relay (6), and R2 cut relay (7) are turned ON and current from terminals ACC and R2 in key switch (2) flow to fuse box (8).

5. In addition, terminal M2-4 of monitor controller (5) is connected to the ground at this time. Therefore, monitor controller (5) automatically detects that the auto shut-down relay circuit is connected and makes the auto shut-down (A/S) function enable.

6. When all following conditions exist and after the auto shut-down enable time set by the monitor is over, monitor controller (5) disconnects terminal M2-9 from the ground inside.

7. Therefore, auto shut-down relay (4) is turned OFF. ACC cut relay (6) and R2 cut relay (7) are also turned OFF at the same time.

8. Current which flows to terminal #7 in E-ECU (9) from terminal ACC in key switch (2) is blocked.

9. Therefore, this is the same case when key switch (2) is set to the OFF position. E-ECU (9) stops the engine.

Conditions of Auto Shut-Down:  Pilot shut-off lever: LOCK  Auto shut-down function: Enable  Overheat switch: OFF  Engine control dial : Not Operated  Engine: Running

T2-3-18

Return the key switch to the OFF position and reset it to the START position, and the engine can restart.

SECTION 2 SYSTEM Group 3 Electrical System

1

2

3

4

5

ON

ACC R2

M2-4

M2-9

7

9

8

7

6

TADB-02-05-009 1- 2- 3-

Battery Key Switch Fuse

4- 5- 6-

Auto Shut-Down Relay Monitor Controller ACC Cut Relay

7- 8- 9-

T2-3-19

R2 Cut Relay Fuse Box E-ECU

SECTION 2 SYSTEM Group 3 Electrical System Engine Stop Circuit (Key Switch: OFF) 1. When key switch (3) is turned from ON to OFF position, terminal B in key switch (3) is disconnected from terminals BR, R2, and ACC. Therefore, power is shut off to each circuit.

2. When current which flows to terminal #7 in E-ECU (5) from terminal ACC in key switch (3) is stopped, E-ECU (5) stops the engine.

fNOTE:

As terminal B in alternator (2) is directly connected to battery (1), surge voltage is charged to battery (1) until the engine stops.

T2-3-20

SECTION 2 SYSTEM Group 3 Electrical System

1

2

3 OFF ON

B

B

ACC

4 16 7

5 TADB-02-05-010

1- 2-

Battery Alternator

3- 4-

Key Switch Fuse Box

5-

T2-3-21

E-ECU

SECTION 2 SYSTEM Group 3 Electrical System (Blank)

T2-3-22

MEMO

MEMO

SECTION 3

COMPONENT OPERATION CONTENTS Group 1 Pump Device

Outline..................................................................................... T3-1-1 Main Pump P1, Main Pump P2........................................ T3-1-2 Main Pump P3, Pilot Pump P4......................................... T3-1-3 Output Power Control Operation.................................. T3-1-4

Group 2 Swing Device

Outline..................................................................................... T3-2-1 Swing Reduction Gear....................................................... T3-2-2 Swing Motor.......................................................................... T3-2-3 Parking Brake......................................................................... T3-2-4 Valve Unit................................................................................ T3-2-5

Group 3 Control Valve

Outline..................................................................................... T3-3-1 Hydraulic Circuit.................................................................T3-3-10 Arm Regenerative Valve..................................................T3-3-14 Boom Anti-Drift Valve.......................................................T3-3-16 Flow Combiner Valve........................................................T3-3-18 Main Relief Valve................................................................T3-3-20 Overload Relief Valve........................................................T3-3-22 Make-Up Valve....................................................................T3-3-26

Group 4 Pilot Valve

Outline..................................................................................... T3-4-1 Operation (Front Attachment / Swing and Travel Pilot Valves).................................... T3-4-5 Operation (Boom Swing / Blade / Auxiliary (Optional) Pilot Valve).................................................T3-4-11 Shockless Function (Only for Travel Pilot Valve)......T3-4-16 Shuttle Valve (Optional)...................................................T3-4-17

Group 5 Travel Device

Outline..................................................................................... T3-5-1 Travel Reduction Gear........................................................ T3-5-2 Travel Motor........................................................................... T3-5-4 Parking Brake......................................................................... T3-5-6 Travel Brake Valve................................................................ T3-5-8

Group 6 Others (Upperstructure)

2-Spool Solenoid Valve...................................................... T3-6-1 Torque Control Solenoid Valve (Only Machine with the Air Conditioner (Optional) Attached).... T3-6-5

Group 7 Others (Undercarriage)

Swing Bearing....................................................................... T3-7-1 Center Joint............................................................................ T3-7-2 Track Adjuster........................................................................ T3-7-3

ADCT-3-1

(Blank)

ADCT-3-2

SECTION 3 COMPONENT OPERATION Group 1 Pump Device Outline The pump device is a direct-engine-drive type and consists of main pump P1 (1), main pump P2 (2), main pump P3 (3), and pilot pump P4 (4). Main pump P1 (1) and main pump P2 (2) are swash plate type variable displacement axial plunger pumps. Main pump P3 (3) is a gear pump. They supply pressure oil to the control valve.

Main pump P1 (1) and main pump P2 (2) have a dual delivery port design. This allows one pump to function like two pumps. Pilot pump P4 (4) is a gear pump and supplies pressure oil to the pilot circuit.

1,2

3

4

T1ND-03-01-001 1- Main Pump P1

2- Main Pump P2

3- Main Pump P3

T3-1-1

4- Pilot Pump P4

SECTION 3 COMPONENT OPERATION Group 1 Pump Device Main Pump P1, Main Pump P2 Shaft (5) is connected to cylinder block (1) by a spline joint, and plunger (3) is inserted into cylinder block (1).

The engine rotation drives shaft (5) directly, and shaft (5) rotates cylinder block (1) and plunger (3) together.

Plunger (3) slides on swash plate (6) and oscillates in cylinder block (1) due to inclination of swash plate (6).

There are suction and delivery ports on inside and outside of cylinder block (1) alternately. In addition, there are delivery ports on each side (inside and outside) of valve plate (2). Therefore, the dual delivery port design allows one pump to function like two pumps having equal oil displacement.

1

6

5

4

3

T1ND-03-01-001

2

7

12

8 11

2

10

9

1 TADB-03-01-001

1- 2- 3- 4-

Cylinder Block Valve Plate Plunger Shoe

5- 6- 7- 8-

Shaft Swash Plate Suction Port (Inside) Suction Port (Outside)

9- Suction, Delivery Port (Inside) 10- Suction, Delivery Port (Outside) 11- Delivery Port (Outside)

T3-1-2

12- Delivery Port (Inside)

SECTION 3 COMPONENT OPERATION Group 1 Pump Device Main Pump P3, Pilot Pump P4 Drive gear (6) is installed to shaft (1). Drive gear (6) engages driven gear (4). The engine rotation drives shaft (1) directly, and shaft (1) rotates drive gear (6). When drive gear (6) rotates, driven gear (4) also rotates. Hydraulic oil from suction port (5) fills the spaces between gears, flows along the inner surfaces of housing, and is delivered through delivery port (8).

2

3

1

T1ND-03-01-001

5 4

6 1

7

8

1- Shaft 2- Main Pump P3

3- Pilot Pump P4 4- Driven Gear

T137-02-03-005

5- Suction Port 6- Drive Gear

T3-1-3

7- Housing 8- Delivery Port

SECTION 3 COMPONENT OPERATION Group 1 Pump Device Output Power Control Operation The output power control controls delivery flow rate of main pumps P1 (1) and P2 (2) in order to prevent the total load of main pumps P1 (1), P2 (2), and P3 (4) from exceeding the engine torque.

1. When delivery pressure from main pumps P1 (1) and P2 (2) increases, plunger (6) pushes swash plate (7). When the plunger (6) force exceeds the spring (3) force, swash plate (7) reduces the angle at pivot pin (8) and delivery flow rate of main pumps P1 (1) and P2 (2) decrease.

4. Therefore, as delivery flow rate of main pumps P1 (1) and P2 (2) varies depending on changes in load from main pump P3 (4), the total load of three main pumps does not exceed the engine torque.

Only the Cab spec. machine: 1. When the air conditioner switch is turned ON, delivery pressure from pilot pump P4 (5) is routed to rod C (10).

2. Therefore, rod C (10) pushes swash plate (7). When the rod C (10) force exceeds the spring (3) force, swash plate (7) reduces the angle at pivot pin (8) and delivery flow rate of main pumps P1 (1) and P2 (2) decrease.

2. In addition, delivery pressure from main pump P3 (4) is routed to rod G (9) through the inner passage in the pump.

3. Therefore, rod G (9) pushes swash plate (7). When the rod G (9) force exceeds the spring (3) force, swash plate (7) reduces the angle at pivot pin (8) and delivery flow rate of main pumps P1 (1) and P2 (2) decreases.

3

1,2

4

5

11

10 9 8

7 1- Main Pump P1 2- Main Pump P2 3- Spring

4- Main Pump P3 5- Pilot Pump P4 6- Plunger

6

T1ND-03-01-002 7- Swash Plate 8- Pivot Pin

T3-1-4

9- Rod G 10- Rod C 11- Control Piston

SECTION 3 COMPONENT OPERATION Group 2 Swing Device Outline The swing device consists of valve unit (1), swing motor (2), and swing reduction gear (3). Valve unit (1) prevents cavitation and overload in the swing circuit. Swing motor (2) is a swash plate type axial plunger motor (with builtin swing parking brake), which is driven by pressure oil from the pump, and the rotation is transmitted to swing reduction gear (3).

Swing reduction gear (3) converts swing motor (2) output into slow large torque to rotate the shaft. Thereby, the upperstructure is rotated.

1

2

3

TADB-03-02-001 1- Valve Unit

2- Swing Motor

3- Swing Reduction Gear

T3-2-1

SECTION 3 COMPONENT OPERATION Group 2 Swing Device Swing Reduction Gear The swing reduction gear is a two-stage planetary reduction gear.

Ring gear (6) is monolithically built with the housing and does not rotate. The swing motor shaft rotates first stage sun gear (1), whose rotating torque is transmitted to second stage sun gear (3) through first stage planetary gear (8) and first stage carrier (2). The rotating torque of second stage sun gear (3) rotates shaft (5) through second stage planetary gear (7) and second stage carrier (4).

Shaft (5) is engaged with the internal gear of the swing bearing fixed to the undercarriage in order to swing the upperstructure.

1 2

8

3

7 6

4

5

TADB-03-02-002

1- First Stage Sun Gear 2- First Stage Carrier

3- Second Stage Sun Gear 4- Second Stage Carrier

5- Shaft 6- Ring Gear

T3-2-2

7- Second Stage Planetary Gear 8- First Stage Planetary Gear

SECTION 3 COMPONENT OPERATION Group 2 Swing Device Swing Motor Shaft (1) is connected to rotor (7) by a spline joint, and plunger (2) is inserted into rotor (7). When pressure oil is supplied from the pump, plunger (2) is pushed. As plunger (2) is pushed and shoe (3) on the end of plunger (2) slides along swash plate (6) and rotor (7) rotates. As shaft (1), which is connected to rotor (7) by a spline joint, is also connected to first stage sun gear (5) by a spline joint, the rotation of rotor (7) is transmitted to the swing reduction gear.

8

1

7

2 3 4

6

5

TADB-03-02-002 1- Shaft 2- Plunger

3- Shoe 4- Retainer

5- First Stage Sun Gear 6- Swash Plate

T3-2-3

7- Rotor 8- Valve Plate

SECTION 3 COMPONENT OPERATION Group 2 Swing Device Parking Brake 1

The parking brake is a wet-type spring set hydraulic released single-disc brake. The brake is released when the brake release pressure is routed to brake piston chamber (2).

2

3

When the brake is released: 1. When the pilot shut-off lever is in the UNLOCK position, the pilot shut-off switch is turned ON. Therefore, pilot shut-off solenoid valve (6) is turned ON and the spool is shifted.

4

2. As the spool is shifted, the brake release pressure (pilot pressure) is routed to brake piston chamber (2) through inner passage (8) in motor housing (1).

8

3. The brake release pressure pushes brake piston (3) upward and brake piston (3) separates from disc plate (4) which is connected to rotor (5) by a spline joint.

4. Consequently, as disc plate (4) becomes free and rotor (5) can rotate, the brake is released.

5

7 1

When the brake is applied:

T565-03-02-005

6 2

9

3

1. When the pilot shut-off lever is in the LOCK position, the pilot shut-off switch is turned OFF. Therefore, pilot shut-off solenoid valve (6) is turned OFF and the spool returns.

2. As the spool returns, the brake release pressure (pilot pressure) routed to brake piston chamber (2) is routed back to the hydraulic oil tank through the spool in pilot shut-off solenoid valve (6).

4

3. Brake piston (3) pushes disc plate (4) which is connected to rotor (5) by a spline joint to motor housing (1) due to spring (9).

4. Consequently, rotor (5) is secured and the brake is applied.

5

7 1- 2- 3- 4- 5-

T3-2-4

Motor Hosing Brake Piston Chamber Brake Piston Disc Plate Rotor

6 6- 7- 8- 9-

T565-03-02-006

Pilot Shut-Off Solenoid Valve Pilot Pump Inner Passage Spring

SECTION 3 COMPONENT OPERATION Group 2 Swing Device Valve Unit The valve unit consists of make-up valve (3) and relief valve (4). Make-up valve (3) prevents occurrence of cavitation in the circuit. Relief valve (4) protects the circuit from surge pressure and overloading.

Make-Up Valve When the upperstructure is swung downward on a slope, the upperstructure is accelerated by its own weight and moves quicker than the swing motor drive speed developed by the pump oil flow rate. Therefore, cavitation can occur in the circuit. In order to prevent cavitation, when pressure in the circuit is lower than pressure at port M (2) (hydraulic oil tank), poppet (1) opens, draws hydraulic oil into the circuit, and compensates the lack of pump oil flow rate.

4

3

1 a- To Control Valve

b- From Control Valve

1- Poppet

2- Port M

b

2

TADB-03-02-003

a

3- Make-Up Valve

T3-2-5

4- Relief Valve

SECTION 3 COMPONENT OPERATION Group 2 Swing Device Relief Valve The relief valve functions to reduce shocks developed when starting or stopping swing movement (shockless) and to protect the circuit from overloading (relief ). ď‚— Shockless Operation 1. When pressure in the circuit increases, pressure oil at port HP is routed to piston chamber (4) through orifices (2, 8), and moves piston (3) to the left.

1

2

3

4

8

5

LP

2. Pressure in spring chamber (6) is kept low during movement of piston (3).

HP

3. Therefore, poppet (1) is pushed by only the spring (5) force. Poppet (1) opens whenever pressure at port HP is low. Therefore, hydraulic oil is relieved under low pressure .

7

4. Therefore, pressure stops temporally increasing and shocks are reduced when starting or stopping the swing operation.

5. When piston (3) moves to the stroke end, pressure in spring chamber (6) becomes equal to pressure at port HP.

1- 2- 3- 4-

6. Therefore, the relief set pressure becomes the normal pressure and poppet (1) closes.

T3-2-6

Poppet Orifice Piston Piston Chamber

6 5- 6- 7- 8-

T561-02-03-001

Spring Spring Chamber Housing Orifice

SECTION 3 COMPONENT OPERATION Group 2 Swing Device  Relief Operation 1. When pressure in the circuit increases due to the external force and the force applied to poppet (1) (Pressurized Area (S1-S2)×Pressure at Port HP) exceeds the spring force, poppet (1) opens and hydraulic oil is relieved.

1 LP

HP

S1

 Quick Return Operation of Piston (3) 1. This operation is to return piston (3) to the original position. The shockless operation is performed as piston (3) moves from the right to the left.

Therefore, when stopping the swing operation, move piston (3) to the right.

6

S2

T566-03-03-039

3 LP

HP

2. When returning the swing control lever to the neutral position, the back pressure arises in the return circuit due to the swing inertial force. Piston (3) is returned to the original position quickly by the back pressure.

T566-03-03-039 1- Poppet 6- Spring Chamber

T3-2-7

3- Piston

SECTION 3 COMPONENT OPERATION Group 2 Swing Device (Blank)

T3-2-8

SECTION 3 COMPONENT OPERATION Group 3 Control Valve Outline The control valve controls the pressure, flow rate, and flow direction in the hydraulic circuit. The main components are main relief valve, overload relief valve, flow combiner valve (11), boom (2) anti-drift valve, and spools.

1

2

3

4

The spools are operated by pilot oil pressure. Viewed from the machine front side, the spools are arranged as follows: flow combiner valve (11), blade (10), swing (9), boom swing (8), auxiliary (6), arm (5), travel (right) (4), travel (left) (3), boom (2), and bucket (1).

5

6

8

9

10

11

a

TADB-03-03-007

a-

Machine Front

1- Bucket 2- Boom 3- Travel (Left)

4- Travel (Right) 5- Arm 6- Auxiliary

8- Boom Swing 9- Swing 10- Blade

T3-3-1

11- Flow Combiner Valve

SECTION 3 COMPONENT OPERATION Group 3 Control Valve

26

27

33 36

28

35

29

34 30

1

25

2

3

4

5

24 23 22 21

6

7

8 9

20

10 11 12

13

14

P2

2- 3- 4- 5- 6- 7- 8-

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

Load Check Valve (Arm Parallel Circuit) Arm Regenerative Valve Load Check Valve (Auxiliary Parallel Circuit) Check Valve (Orifice) (Auxiliary Parallel Circuit) Load Check Valve (Main Pump P3 Parallel Circuit) Load Check Valve (Boom Swing Parallel Circuit) Load Check Valve (Swing Parallel Circuit) Load Check Valve (Blade Parallel Circuit)

17- Main Relief Valve (Main Pump P3) 18- Make-Up Valve (Boom Swing: Bottom Side) 19- Overload Relief Valve (Arm: Bottom Side) 20- Overload Relief Valve (Arm: Rod Side) 21- Overload Relief Valve (Boom: Rod Side) 22- Overload Relief Valve (Boom: Bottom Side) 23- Load Check Valve (Bucket Parallel Circuit) 24- Overload Relief Valve (Bucket: Rod Side)

T3-3-2

17

P1

31 Load Check Valve (Bucket Tandem Circuit) Boom Anti-Drift Valve (Selector Valve) Boom Anti-Drift Valve (Check Valve) Load Check Valve (Boom Parallel Circuit) Load Check Valve (Boom Tandem Circuit) Main Relief Valve (Main Pump P2) Main Relief Valve (Main Pump P1) Load Check Valve (Arm Tandem Circuit)

16

18

19

P3

1-

15

TADB-03-03-002 25- Overload Relief Valve (Bucket: Bottom Side) 26- Travel Motor (Left) 27- Travel Motor (Right) 28- Arm Cylinder 29- Boom Swing Cylinder 30- Flow Combiner Valve 31- Main Pump 33- Swing Motor 34- Bucket Cylinder 35- Boom Cylinder 36- Blade Cylinder

SECTION 3 COMPONENT OPERATION Group 3 Control Valve

18 A

B

C

D

20 F

6 H

G

2,3 I

J

24 K

L

J

a

17

19

7

22

21

25

TADB-03-03-001

a- Machine Front

Section A (Flow Combiner Valve)

Section B (Blade)

16

T1LA-03-03-015

T3-3-3

T1LA-03-03-016

SECTION 3 COMPONENT OPERATION Group 3 Control Valve

26

27

33 36

28

35

29

34 30

1

25

2

3

4

5

24 23 22 21

6

7

8 9

20

10 11 12

13

14

P2

2- 3- 4- 5- 6- 7- 8-

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

Load Check Valve (Arm Parallel Circuit) Arm Regenerative Valve Load Check Valve (Auxiliary Parallel Circuit) Check Valve (Orifice) (Auxiliary Parallel Circuit) Load Check Valve (Main Pump P3 Parallel Circuit) Load Check Valve (Boom Swing Parallel Circuit) Load Check Valve (Swing Parallel Circuit) Load Check Valve (Blade Parallel Circuit)

17- Main Relief Valve (Main Pump P3) 18- Make-Up Valve (Boom Swing: Bottom Side) 19- Overload Relief Valve (Arm: Bottom Side) 20- Overload Relief Valve (Arm: Rod Side) 21- Overload Relief Valve (Boom: Rod Side) 22- Overload Relief Valve (Boom: Bottom Side) 23- Load Check Valve (Bucket Parallel Circuit) 24- Overload Relief Valve (Bucket: Rod Side)

T3-3-4

17

P1

31 Load Check Valve (Bucket Tandem Circuit) Boom Anti-Drift Valve (Selector Valve) Boom Anti-Drift Valve (Check Valve) Load Check Valve (Boom Parallel Circuit) Load Check Valve (Boom Tandem Circuit) Main Relief Valve (Main Pump P2) Main Relief Valve (Main Pump P1) Load Check Valve (Arm Tandem Circuit)

16

18

19

P3

1-

15

TADB-03-03-002 25- Overload Relief Valve (Bucket: Bottom Side) 26- Travel Motor (Left) 27- Travel Motor (Right) 28- Arm Cylinder 29- Boom Swing Cylinder 30- Flow Combiner Valve 31- Main Pump 33- Swing Motor 34- Bucket Cylinder 35- Boom Cylinder 36- Blade Cylinder

SECTION 3 COMPONENT OPERATION Group 3 Control Valve Section D (Boom Swing)

Section C (Swing)

15 M

14 M

Section M-M

13

T1LA-03-03-017

T1LA-03-03-018

Section F (Auxiliary)

12

11

T1ND-03-03-005

T3-3-5

SECTION 3 COMPONENT OPERATION Group 3 Control Valve

26

27

33 36

28

35

29

34 30

1

25

2

3

4

5

24 23 22 21

6

7

8 9

20

10 11 12

13

14

P2

2- 3- 4- 5- 6- 7- 8-

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

Load Check Valve (Arm Parallel Circuit) Arm Regenerative Valve Load Check Valve (Auxiliary Parallel Circuit) Check Valve (Orifice) (Auxiliary Parallel Circuit) Load Check Valve (Main Pump P3 Parallel Circuit) Load Check Valve (Boom Swing Parallel Circuit) Load Check Valve (Swing Parallel Circuit) Load Check Valve (Blade Parallel Circuit)

17- Main Relief Valve (Main Pump P3) 18- Make-Up Valve (Boom Swing: Bottom Side) 19- Overload Relief Valve (Arm: Bottom Side) 20- Overload Relief Valve (Arm: Rod Side) 21- Overload Relief Valve (Boom: Rod Side) 22- Overload Relief Valve (Boom: Bottom Side) 23- Load Check Valve (Bucket Parallel Circuit) 24- Overload Relief Valve (Bucket: Rod Side)

T3-3-6

17

P1

31 Load Check Valve (Bucket Tandem Circuit) Boom Anti-Drift Valve (Selector Valve) Boom Anti-Drift Valve (Check Valve) Load Check Valve (Boom Parallel Circuit) Load Check Valve (Boom Tandem Circuit) Main Relief Valve (Main Pump P2) Main Relief Valve (Main Pump P1) Load Check Valve (Arm Tandem Circuit)

16

18

19

P3

1-

15

TADB-03-03-002 25- Overload Relief Valve (Bucket: Bottom Side) 26- Travel Motor (Left) 27- Travel Motor (Right) 28- Arm Cylinder 29- Boom Swing Cylinder 30- Flow Combiner Valve 31- Main Pump 33- Swing Motor 34- Bucket Cylinder 35- Boom Cylinder 36- Blade Cylinder

SECTION 3 COMPONENT OPERATION Group 3 Control Valve Section H (Travel (Right))

Section G (Arm)

9 O

O

10

N

N

Section N-N

T1ND-03-03-003

T1M7-03-03-015

Section O-O (Travel (Right))

Section I (Travel (Left))

8

T1LA-03-03-010

P

Section P-P (Travel (Left))

P

5

T1LA-03-03-010

T1ND-03-03-004

T3-3-7

SECTION 3 COMPONENT OPERATION Group 3 Control Valve

26

27

33 36

28

35

29

34 30

1

25

2

3

4

5

24 23 22 21

6

7

8 9

20

10 11 12

13

14

P2

2- 3- 4- 5- 6- 7- 8-

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

Load Check Valve (Arm Parallel Circuit) Arm Regenerative Valve Load Check Valve (Auxiliary Parallel Circuit) Check Valve (Orifice) (Auxiliary Parallel Circuit) Load Check Valve (Main Pump P3 Parallel Circuit) Load Check Valve (Boom Swing Parallel Circuit) Load Check Valve (Swing Parallel Circuit) Load Check Valve (Blade Parallel Circuit)

17- Main Relief Valve (Main Pump P3) 18- Make-Up Valve (Boom Swing: Bottom Side) 19- Overload Relief Valve (Arm: Bottom Side) 20- Overload Relief Valve (Arm: Rod Side) 21- Overload Relief Valve (Boom: Rod Side) 22- Overload Relief Valve (Boom: Bottom Side) 23- Load Check Valve (Bucket Parallel Circuit) 24- Overload Relief Valve (Bucket: Rod Side)

T3-3-8

17

P1

31 Load Check Valve (Bucket Tandem Circuit) Boom Anti-Drift Valve (Selector Valve) Boom Anti-Drift Valve (Check Valve) Load Check Valve (Boom Parallel Circuit) Load Check Valve (Boom Tandem Circuit) Main Relief Valve (Main Pump P2) Main Relief Valve (Main Pump P1) Load Check Valve (Arm Tandem Circuit)

16

18

19

P3

1-

15

TADB-03-03-002 25- Overload Relief Valve (Bucket: Bottom Side) 26- Travel Motor (Left) 27- Travel Motor (Right) 28- Arm Cylinder 29- Boom Swing Cylinder 30- Flow Combiner Valve 31- Main Pump 33- Swing Motor 34- Bucket Cylinder 35- Boom Cylinder 36- Blade Cylinder

SECTION 3 COMPONENT OPERATION Group 3 Control Valve Section K (Boom)

*Section J-J (Boom) 2

4

3

T1LA-03-03-023

T1ND-03-03-002

Section L (Bucket)

23

1

T1LA-03-03-024

T3-3-9

SECTION 3 COMPONENT OPERATION Group 3 Control Valve Hydraulic Circuit The hydraulic circuit in control valve is divided into main circuit and pilot signal circuit.

Control Valve Hydraulic Circuit

Main circuit Pilot Signal Circuit

Main Circuit Pressure oil from main pumps (P1, P2, and P3) flow to the control valve respectively. When the spool is in neutral (control lever is in neutral), pressure oil from the main pump returns to hydraulic oil tank (25) through neutral circuits (6, 9, and 10). When the spool is operated (control lever is operated), pressure oil from the main pump flows to the actuator through the spool. (When the combined operation of travel and front attachment is done, flow combiner valve (12) is shifted.) The main circuit has parallel circuits (13, 15, 16, and 26). The combined operation of actuator becomes possible by using this circuit.

Pressure in the main circuit (between pump and actuator) is controlled by main relief valves (11, 17) and is prevented from exceeding the set pressure when the spool (control lever) is operated. Pressure in the actuator circuit (between control valve and actuator) is controlled by overload relief valves (8, 20) and is prevented from exceeding the set pressure by external force when the spool (control lever) is in neutral.

T3-3-10

SECTION 3 COMPONENT OPERATION Group 3 Control Valve 1

2

21 24

3

23

4

22

5

6

20

7

17

8

9

16 15

26

25

11

10

12

13

14

18 19

1- 2- 3- 4- 5- 6- 7-

Travel Motor (Left) Travel Motor (Right) Arm Cylinder Boom Swing Cylinder Boom Anti-Drift Valve Neutral Circuit Arm Regenerative Valve

8- 9- 10- 11- 12- 13- 14-

Overload Relief Valve Neutral Circuit Neutral Circuit Main Relief Valve Flow Combiner Valve Parallel Circuit Engine

TADB-03-03-003

15- 16- 17- 18- 19- 20- 21-

T3-3-11

Parallel Circuit Parallel Circuit Main Relief Valve Oil Cooler Bypass Check Valve Overload Relief Valve Swing Motor

22- 23- 24- 25- 26-

Bucket Cylinder Boom Cylinder Blade Cylinder Hydraulic Oil Tank Parallel Circuit

SECTION 3 COMPONENT OPERATION Group 3 Control Valve Pilot Signal Circuit The pilot signal circuit is connected to the hydraulic oil tank through each spool (travel (right), travel (left), auxiliary, arm, boom, and bucket). During the combined operation of front attachment (boom, arm, and bucket) and travel, the pilot signal circuit is blocked so that pressure in the circuit increases.

Consequently, the flow combiner valve is shifted.

During the combined operation of travel and front attachment, pressure oil from main pump P3 flows to the front attachment spool located after the travel spool so that the combined operation of travel and front attachment can be operated. When operating the swing, boom swing, and blade, the flow combiner valve is not shifted. But, as pressure oil from main pumps P1 and P2 flows to travel (right) and travel (left) respectively, the combined operation of swing, boom swing, blade, and travel can be operated.

T3-3-12

SECTION 3 COMPONENT OPERATION Group 3 Control Valve 1

2

8 4

3

5 6

7

9

10 14

13

12

11

15

TADB-03-03-004

a - b - c - d - e - f -

Boom Raise Boom Lower Bucket Roll-In Bucket Roll-Out Swing (Right) Swing (Left)

g - h - i - j - k - l -

Arm Roll-In Arm Roll-Out Travel (Right Forward) Travel (Right Reverse) Travel (Left Reverse) Travel (Left Forward)

m - n - o - p - q - r -

Boom Swing (Right) Boom Swing (Left) Blade Lower Blade Raise Auxiliary (Optional) Auxiliary (Optional)

DR1 - Returning to Hydraulic Oil Tank DR2 - Returning to Hydraulic Oil Tank

1- 2- 3- 4-

Pilot Valve (Left) Pilot Valve (Right) Swing Motor Boom Cylinder

5- 6- 7- 8-

Travel Motor Auxiliary Pilot Valve (Optional) Blade Pilot Valve Travel Pilot Valve

9- 10- 11- 12-

Boom Swing Pilot Valve Flow Combiner Valve Pilot Pump Pilot Filter

13- Pilot Signal Circuit 14- Control Valve 15- Hydraulic Oil Tank

T3-3-13

SECTION 3 COMPONENT OPERATION Group 3 Control Valve Arm Regenerative Valve 4. Pressure oil which has pushed and has opened the poppet (arm regenerative valve) (4) flows to the arm cylinder (1) bottom side through port B5 and passage F (d) so that cavitation is prevented.

The arm regenerative valve supplies returning oil from the arm cylinder rod side to the arm cylinder bottom circuit when the arm is rolled in. This control increases the arm roll-in speed and prevents the occurrence of cavitation.

5. In addition, pressure in the arm cylinder (1) bottom side becomes higher than that in the rod side during digging operation.

1. When rolling in the arm with the arm raised, pressure in the arm cylinder (1) bottom side circuit becomes lower than that in the rod side circuit due to the arm and bucket weight while the arm is lowered.

6. In this case, the poppet (arm regenerative valve) (4) is not opened. Therefore, the returning oil from the arm cylinder (1) rod side does not flow to the bottom side, but returns to hydraulic oil tank (2).

2. Pressure oil from the cylinder rod side flows to port A5 and is routed to the poppet (arm regenerative valve) (4) through passage E (c).

3. Pressure oil from the cylinder rod side pushes and opens the poppet (arm regenerative valve) (4).

fNOTE:

Orifice (3) in passage E (c) makes pressure oil easily flow to the cylinder bottom side by regulating returning oil from the cylinder rod side.

1

a

d A5 B5

b

4 C

3

TADB-03-03-005

2 a-

Rod Side

1- Arm Cylinder 2- Hydraulic Oil Tank

b-

Bottom Side

3- Orifice

c-

Passage E

4- Poppet (Arm Regenerative Valve)

T3-3-14

d-

Passage F

SECTION 3 COMPONENT OPERATION Group 3 Control Valve When Arm Spool is in Neutral A5

B5

T577-03-03-005

When Operating Arm Roll-In X

A5

B5

4

5 X

Section X-X

a 3

T577-03-03-006

a-

To Hydraulic Oil Tank

3- Orifice

4- Poppet

(Arm Regenerative Valve)

5- Arm Spool

T3-3-15

SECTION 3 COMPONENT OPERATION Group 3 Control Valve Boom Anti-Drift Valve A boom anti-drift valve is provided in the boom cylinder bottom side circuit in order to reduce boom cylinder drift.

When Boom Spool is in Neutral

When Operating Boom Lower

1. When the engine is stopped with the boom raised, oil pressure in the boom cylinder bottom side increases by the front attachment weight.

1. During boom lower operation, pressure oil from boom spool (5) is supplied to the boom cylinder rod side.

2. At this time, pressure in the bottom side circuit is routed to the spring (3) side of check valve (4) through spool (2) of the anti-drift valve and pushes check valve (4).

2. At this time, boom lower pilot pressure pushes piston (1) and moves spool (2) of the boom antidrift valve.

3. Therefore, check valve (4) blocks pressure oil in the bottom side and the cylinder drift is reduced.

3. Therefore, pressure oil in spring chamber (3) of check valve (4) returns to the hydraulic oil tank through spool (2).

4. At this time, returning oil pressure from the boom cylinder bottom side is routed to the stepped part of check valve (4) and opens check valve (4).

When Operating Boom Raise 1. During boom raise operation, pressure oil from boom spool (5) pushes and opens check valve (4) and flows to the boom cylinder bottom side.

5. Consequently, pressure oil in the bottom side returns to boom spool (5) through check valve (4).

T3-3-16

SECTION 3 COMPONENT OPERATION Group 3 Control Valve

When Boom Spool is in Neutral

When Operating Boom Lower

1

2

1

2 f

d 3

6

3

4

c e

e

5

b

4

c

5

b

TADB-03-03-008

a- b-

To Hydraulic Oil Tank To Boom Spool

c- d-

Rod Side Boom Lower Pilot Pressure

e- f-

Bottom Side Hydraulic Oil Tank

1- 2-

Piston Spool

3- 4-

Spring Check Valve

5- 6-

Boom Spool Boom Cylinder

T3-3-17

TADB-03-03-009

SECTION 3 COMPONENT OPERATION Group 3 Control Valve Flow Combiner Valve 4. As parallel circuits (7) (passage G (c) and passage E (d)) are provided, pressure oil from main pump P3 is supplied to each front attachment spool. Then, the front attachment can be operated while traveling.

1. When operating the front attachment while traveling, pilot signal circuit (5) is blocked by each spool (8, 9, 10, 11, 12, and 13).

2. As pilot signal circuit (5) is blocked, pressure in the circuit increases and flow combiner valve (6) is shifted.

5. Pressure oil from main pump P3 is supplied to to spools of blade (4), swing (3) and boom swing (2) through parallel circuit (7) (passage F (f )) bypassing flow combiner valve (6).

3. When flow combiner valve (6) is shifted, parallel circuits (7) (passage G (c) and passage E (d)) to spools of boom (12), arm (9), bucket (13), and auxiliary (8) are provided.

a 1

e

13

12

11

10

9

2

4

3

7

8

5

d

g

6

f

c

b

TADB-03-03-006

a- b-

From Main Pump P1 From Main Pump P3

c- d-

Passage G Passage E

e- f-

From Main Pump P2 Passage F

g-

1- 2- 3- 4-

Control Valve Boom Swing Swing Blade

5- 6- 7- 8-

Pilot Signal Circuit Flow Combiner Valve Parallel Circuit Auxiliary

9- 10- 11- 12-

Arm Travel (Right) Travel (Left) Boom

13- Bucket

T3-3-18

From Pilot Pump

SECTION 3 COMPONENT OPERATION Group 3 Control Valve When Flow Combiner Valve is in Neutral a

b

c

T577-03-03-003

When Operating Flow Combiner Valve a

b

c

d

e

a- b-

From Main Pump P3 Passage E

c- d-

Passage G Pilot Signal Pressure

e-

T3-3-19

Flow Combiner Valve Spool

T577-03-03-004

SECTION 3 COMPONENT OPERATION Group 3 Control Valve Main Relief Valve The main relief valve prevents that pressure in main circuit exceeds the set pressure.

Operation 1. Pressure in port HP (actuator circuit) is routed to pilot poppet (5) through orifices (2, 4) in main poppet (1).

2. When pressure in port HP reaches the set pressure, pilot poppet (5) is opened and small amount of pressure oil flows to port LP (hydraulic oil tank) through passage (7).

3. At this time, pressure difference between port HP and spring chamber (8) occurs due to orifice (2).

4. When this pressure difference overcomes the spring (3) force, main poppet (1) is opened and pressure oil from port HP flows to port LP.

T3-3-20

SECTION 3 COMPONENT OPERATION Group 3 Control Valve During Normal Operation

1

2

3

4

5

6

HP

LP 8

TADB-03-03-010

7

During Relief Operation 1

2

3

4

5

6

HP

LP 8

HP- Main Circuit

LP- Hydraulic Oil Tank

1- 2-

3- 4-

Main Poppet Orifice

Spring Orifice

7

5- 6-

T3-3-21

Pilot Poppet Spring

T554-02-06-011

7- 8-

Passage Spring Chamber

SECTION 3 COMPONENT OPERATION Group 3 Control Valve Overload Relief Valve The overload relief valve prevents the actuator circuit pressure from exceeding the set pressure (relief operation) and prevents occurrence of cavitation (makeup operation).

Relief Operation Flows pressure oil to the hydraulic oil tank when pressure in the actuator increases due to external force.

1. Pressure in port HP (actuator circuit) is routed to pilot poppet (4) through orifice (8) in piston (9).

2. When pressure in port HP reaches the set pressure, pilot poppet (4) is opened and small amount of pressure oil flows to port LP (hydraulic oil tank) through passage (6) of seat (3).

3. At this time, pressure difference between port HP and spring chamber (7) occurs due to orifice (8).

When this pressure difference overcomes the spring (2) force, main poppet (1) is opened and pressure oil from port HP flows to the hydraulic oil tank through port LP.

T3-3-22

SECTION 3 COMPONENT OPERATION Group 3 Control Valve During Normal Operation: 8

1

9

2

3

4

5

HP

LP

10

7

6

TADB-03-03-011

During Relief Operation: 8

1

9

2

3

4

5

HP

LP

HP- Main Circuit

LP- Hydraulic Oil Tank

1- Main Poppet 2- Spring 3- Seat

4- Pilot Poppet 5- Spring 6- Passage

10

7

6

7- Spring Chamber 8- Orifice 9- Piston

T3-3-23

TADB-03-03-012

10- Sleeve

SECTION 3 COMPONENT OPERATION Group 3 Control Valve Make-Up Operation When lowering the boom suddenly, the actuator circuit is lack of pressure oil from the pump. At this time, oil is supplied to the actuator circuit from the hydraulic oil tank.

When operating the relief operation due to external force, which is explained on the previous page, pressure in the opposite side circuit decreases. At this time, oil is supplied to the actuator circuit from the hydraulic oil tank.

1. As pressure in port HP is routed to spring chamber (7) through the passage of poppet (9), pressure in port HP and spring chamber (7) become equal.

2. Therefore, when pressure in port HP is higher, the force to close main poppet (1) [Pressure in Spring Chamber (7) Ă— Pressurized Area S2 + Spring (2) Force] becomes larger than the force to open main poppet (1) [Port HP Ă— Pressurized Area S1] so that main poppet (1) is closed.

3. When pressure in port HP is lower than pressure in port LP and the force to open main poppet (1) [Pressure in Port LP x (Pressurized Areas S2 - S1)] becomes larger than the force to close main poppet (1) [Spring (3) Force], main poppet (1) is opened and hydraulic oil is supplied to port HP from port LP. 4. Therefore, cavitation at the port HP side is prevented.

T3-3-24

SECTION 3 COMPONENT OPERATION Group 3 Control Valve During Normal Operation:

8

1

9

2

3

4

5

HP

LP

10

6

7

TADB-03-03-011

During Make-Up Operation: 8

1

9

2

3

4

5

HP

LP S1

10 S2

HP- Main Circuit

LP- Hydraulic Oil Tank

1- Main Poppet 2- Spring 3- Seat

4- Pilot Poppet 5- Spring 6- Passage

TADB-03-03-013

6

7

7- Spring Chamber 8- Orifice 9- Piston

T3-3-25

10- Sleeve

SECTION 3 COMPONENT OPERATION Group 3 Control Valve Make-Up Valve The make-up valve prevents cavitation in the main circuit.

The make-up valve is provided in the bottom side circuit in boom swing.

1. As pressure in port HP is routed to spring chamber (4) through passage (1) in poppet (2), pressures in port HP and spring chamber (4) become equal.

1

2. Therefore, when pressure in port HP is higher, the force to close poppet (2) [Pressure in Spring Chamber (4) Ă— Pressurized Area S2 + Spring (3) Force] becomes larger than the force to open poppet (2) [Port HP Ă— Pressurized Area S1] so that poppet (2) is closed.

3

4

HP

3. When pressure in port HP is lower than pressure in port LP and the force to open poppet (2) [Pressure in Port LP x (Pressurized Areas S2 - S1)] becomes larger than the force to close poppet (2) [Spring (3) Force], poppet (2) is opened and hydraulic oil is supplied to port HP from port LP. 4. Therefore, cavitation at the port HP side is prevented.

2

LP

S1 1- Passage 2- Poppet

T3-3-26

S2

T1LA-03-03-028

3- Spring 4- Spring Chamber

SECTION 3 COMPONENT OPERATION Group 4 Pilot Valve Outline The pilot valve controls pilot pressure oil in order to move the spool in the control valve.

The pilot valve outputs pressure according to the control lever stroke by PPC (Pressure Proportional Control Valve) function and moves the spool in the control valve.

The 4-port pilot valves for front attachment / swing and for travel are standard.

The 2-port pilot valve is for boom swing, blade, and auxiliary (optional).  Front Attachment / Swing Pilot Valve Port No. ISO Control Pattern

Right

Left

1 2 3 4 1 2 3 4

Bucket Roll-In Boom Raise Bucket Roll-Out Boom Lower Swing (Left) Arm Roll-In Swing (Right) Arm Roll- Out

Hitachi Pattern     Arm Roll- Out Swing (Left) Arm Roll-In Swing (Right)

P TADB-03-04-001

A View A

4

Hydraulic Symbol P

T

1 3

1

3 2

T

4

2

TADB-03-04-006 P-

T3-4-1

Port P (Pressure Oil from Pilot Pump)

T1M9-03-05-002 T-

Port T (To Hydraulic Oil Tank)

SECTION 3 COMPONENT OPERATION Group 4 Pilot Valve ï‚— Travel Pilot Valve Port No. 1 2 3 4

Travel (Left Forward) Travel (Left Reverse) Travel (Right Reverse) Travel (Right Forward)

T P

Hydraulic Symbol P

T TADB-03-04-002

B 1

2 3

View B

4 T1M9-03-05-006

3

4

2

1 TADB-03-04-003

P-

T3-4-2

Port P (Pressure Oil from Pilot Pump)

T-

Port T (To Hydraulic Oil Tank)

SECTION 3 COMPONENT OPERATION Group 4 Pilot Valve  Travel Pilot Valve (Optional) Port No. 1 2 3 4 a

Travel (Left Forward) Travel (Left Reverse) Travel (Right Reverse) Travel (Right Forward) Pressure Sensor

T P

Hydraulic Symbol P

a

T

T1M9-03-05-007

1

2

3

4

2

1

4 T1M7-03-04-020

a a-

3

Pressure Sensor

T1M9-03-05-008 P-

a-

Port P (Pressure Oil from Pilot Pump) Pressure Sensor

T-

Port T (To Hydraulic Oil Tank)

 Boom Swing / Auxiliary (Optional) Pilot Valve Boom Swing Auxiliary

Port No. 1 2 1 2

Left Right Open Close

T P

Hydraulic Symbol

P

T

1 1

2 T1CF-03-04-001

P-

T3-4-3

Port P (Pressure Oil from Pilot Pump)

2 T-

TADB-03-04-004

Port T (To Hydraulic Oil Tank)

SECTION 3 COMPONENT OPERATION Group 4 Pilot Valve  Blade Pilot Valve  without Travel Mode Switch Port No. 1 2

Blade

Lower Raise T

Hydraulic Symbol

P

T

P

1

2 T1CF-03-04-001

1 P-

Port P (Pressure Oil from Pilot Pump)

2 T-

TADB-03-04-004

Port T (To Hydraulic Oil Tank)

 with Travel Mode Switch (Optional) Port No. 1 2

Blade Raise Blade Lower T

Hydraulic Symbol

P T

T

P

P 1 1

2

2

T554-02-07-009

1

T3-4-4

2

TADB-03-04-011

SECTION 3 COMPONENT OPERATION Group 4 Pilot Valve Operation (Front Attachment / Swing and Travel Pilot Valves)

Front Attachment / Swing Pilot Valve 1

The spool (7) head comes in contact with the upper surface of spring guide (4). Spring guide (4) is kept raised by return spring (6).

2

f

NOTE: Total lever strokes for front attachment and swing controls are determined by stroke dimension (E) of pusher (2). Total lever stroke for travel control is determined by stroke dimension (E) of cam (1).

3 4 5 6 E

7 8

TPPP-03-04-005

Travel Pilot Valve 1

E

2 3 4 5 6

7 8

TPPP-03-04-010 1- 2-

Cam Pusher

3- 4-

Casing Spring Guide

5- 6-

T3-4-5

Balance Spring Return Spring

7- 8-

Spool Hole

SECTION 3 COMPONENT OPERATION Group 4 Pilot Valve Neutral (Output Curve: A to B):

Front Attachment / Swing Pilot Valve

1. When in neutral, spool (7) completely blocks pressure oil from port P (pilot pump). In addition, the output port is opened to port T (hydraulic oil tank) through the inner passage in spool (7).

a D

2. Therefore, pressure in the output port is equal to that in port T. 3. When the control lever is slightly tilted, cam (1) is tilted and pusher (2) is pushed downward. Pusher (2) compresses return spring (6) along with spring guide (4) together.

C

A

4. At this time, as pressure in the output port is equal to that in port T, spool (7) moves downward due to the balance spring (5) force while keeping the lower surface of the spool (7) head in contact with spring guide (4).

a-

B

Pilot Pressure

b b-

T1F3-03-09-004 Control Lever Stroke

Travel Pilot Valve E

a

5. This status continues until hole (8) on spool (7) is connected to port P.

F D

C

A

b

B

T523-02-05-001 a-

T3-4-6

Pilot Pressure

b-

Control Lever Stroke

SECTION 3 COMPONENT OPERATION Group 4 Pilot Valve Front Attachment / Swing Pilot Valve 1

1

2

2

3

3

4

4

5

5

6

6

7 T

8 P a

7

T

7

T

8

P

8

P

a

a TPPP-03-04-015

TPPP-03-04-006

Travel Pilot Valve 1

1

2

2

3

T

3

7

4

4

8

5

5

6

6

a

T

7

T

7 P

8

P

P

8

a

a TPPP-03-04-016

TPPP-03-04-011

P-

Port P

T-

Port T

a-

Output Port

1- 2-

Cam Pusher

3- 4-

Casing Spring Guide

5- 6-

Balance Spring Return Spring

T3-4-7

7- 8-

Spool Hole

SECTION 3 COMPONENT OPERATION Group 4 Pilot Valve During Metering or Decompressing (Output Curve: C to D)

Front Attachment / Swing Pilot Valve

1. When the control lever is further tilted and pusher (2) is moved downward further, hole (8) on spool (7) is connected to port P and pressure oil in port P flows to the output port.

a D

2. Pressure in the output port acts on the bottom surface of spool (7) so that spool (7) is pushed upward.

C

3. When the force to move spool (7) upward is smaller than the balance spring (5) force, balance spring (5) is not compressed so that spool (7) is not raised and pressure in the output port increases.

4. As pressure in the output port increases further, the force to move spool (7) upward increases. When this force overcomes the balance spring (5) force, spool (7) compresses balance spring (5) and moves upward.

A a-

B

Pilot Pressure

b b-

T1F3-03-09-004 Control Lever Stroke

Travel Pilot Valve E

a

F

D

5. As spool (7) is moved upward, hole (8) is closed so that pressure oil from port P stops flowing to the output port and pressure in the output port stops increasing.

C

6. As spool (7) is moved downward and balance spring (5) is compressed, pressure acting on the bottom surface of spool (7) increases until pressure balances with the increasing spring force. This increasing pressure becomes pressure in the output port.

A

b

B

T523-02-05-001 a-

T3-4-8

Pilot Pressure

b-

Control Lever Stroke

SECTION 3 COMPONENT OPERATION Group 4 Pilot Valve Front Attachment / Swing Pilot Valve 1

1

2

2

7

3

7

3

T

T

4

4

8

5

8

5 6

6

P

P

7

7

T

T P

8

P

8

a

a TPPP-03-04-007

TPPP-03-04-008

Travel Pilot Valve 1

1

2

2 T

7

3

3 P

4

P

4

8

5

T

7

8

5

6

6 a

a

T

7

T

7

P

P

8

8 a

a TPPP-03-04-012

TPPP-03-04-013

P-

Port P

T-

Port T

a-

Output Port

1- 2-

Cam Pusher

3- 4-

Casing Spring Guide

5- 6-

Balance Spring Return Spring

T3-4-9

7- 8-

Spool Hole

SECTION 3 COMPONENT OPERATION Group 4 Pilot Valve Full Stroke (Output Curve: E to F) (Only for Travel Pilot Valve) 1. When the control lever is fully stroked, cam (1) moves downward until it comes in contact with casing (3).

E

a

F

D

2. At this time, the bottom surface of pusher (2) directly pushes spool (7). Therefore, even if pressure in the output port increases further, hole (8) on spool (7) is kept open.

C

3. Consequently, pressure in the output port is equal to that in port P. A

b

B

T523-02-05-001 a-

Pilot Pressure

b-

Control Lever Stroke

Travel Pilot Valve 1

2

3 4 5 6

T

7

P

8 a TPPP-03-04-014 P-

Port P

T-

Port T

a-

Output Port

1- 2-

Cam Pusher

3- 4-

Casing Spring Guide

5- 6-

Balance Spring Return Spring

T3-4-10

7- 8-

Spool Hole

SECTION 3 COMPONENT OPERATION Group 4 Pilot Valve Operation (Boom Swing / Blade / Auxiliary (Optional) Pilot Valve) The spool (7) head comes in contact with the upper surface of spring guide (4). Spring guide (4) is kept raised by return spring (6).

1

fNOTE:

E

Total lever stroke is determined by stroke dimension (E) of cam (1).

2 3 4 5 6 7 8

TADB-03-04-007

1- 2-

Cam Pusher

3- 4-

Plate Spring Guide

5- 6-

T3-4-11

Balance Spring Return Spring

7- 8-

Spool Hole

SECTION 3 COMPONENT OPERATION Group 4 Pilot Valve ď‚— Boom Swing / Blade / Auxiliary (Optional) Pilot Valve Neutral (Output Curve: A to B): 1. When the control pedal is in neutral, spool (7) completely blocks pressure oil from port P. In addition, the output port is opened to port T (hydraulic oil tank) through the inner passage in spool (7).

a D

2. Therefore, pressure in the output port is equal to that in port T.

C

3. When the control pedal is slightly depressed, cam (1) is moved and pusher (2) is pushed downward.

Pusher (2) compresses return spring (6) along with spring guide (4) together.

A

b

B

T1F3-03-09-004

4. At this time, as pressure in the output port is equal to that in port T, spool (7) moves downward due to the balance spring (5) force while keeping the lower surface of the spool (7) head in contact with spring guide (4).

a-

5. This status continues until hole (8) on spool (7) is connected to port P.

fNOTE:

The pusher stroke while hole (8) on spool (7) is connected to port P is play.

T3-4-12

Pilot Pressure

b-

Pusher Stroke

SECTION 3 COMPONENT OPERATION Group 4 Pilot Valve

1 2

4

3

5 T

6 P

7

8

a

TADB-03-04-007

1 7

2

T

8 3

P

4 a

5 T

6 P

8

7 a

TADB-03-04-008

P-

Port P

T-

Port T

a-

Output Port

1- 2-

Cam Pusher

3- 4-

Plate Spring Guide

5- 6-

Balance Spring Return Spring

T3-4-13

7- 8-

Spool Hole

SECTION 3 COMPONENT OPERATION Group 4 Pilot Valve During Metering or Decompressing (Output Curve: C to D) 1. When the control pedal is further depressed and pusher (2) is moved downward further, hole (8) on spool (7) is connected to port P and pressure oil in port P flows to the output port.

a D

2. Pressure in the output port acts on the bottom surface of spool (7) so that spool (7) is pushed upward.

C

3. When the force to move spool (7) upward is smaller than the balance spring (5) force, balance spring (5) is not compressed so that spool (7) is not raised and pressure in the output port increases.

4. As pressure in the output port increases further, the force to move spool (7) upward increases. When this force overcomes the balance spring (5) force, balance spring (5) is compressed so that spool (7) is moved upward.

A

b

B

T1F3-03-09-004 a-

5. As spool (7) is moved upward, hole (8) is closed so that pressure oil from port P stops flowing to the output port and pressure in the output port stops increasing.

6. As spool (7) is moved downward and balance spring (5) is compressed, pressure acting on the bottom surface of spool (7) increases until pressure balances with the increasing spring force. This increasing pressure becomes pressure in the output port.

T3-4-14

Pilot Pressure

b-

Pusher Stroke

SECTION 3 COMPONENT OPERATION Group 4 Pilot Valve

1 7

2

T

8 P

3 4 5

a

T

P

6

7

8 a

TADB-03-04-009

1 7

2

T

8 P

3 4 5

a

T

6 P

7 8 a TADB-03-04-010

P-

Port P

T-

Port T

a-

Output Port

1- 2-

Cam Pusher

3- 4-

Plate Spring Guide

5- 6-

Balance Spring Return Spring

T3-4-15

7- 8-

Spool Hole

SECTION 3 COMPONENT OPERATION Group 4 Pilot Valve Shockless Function (Only for Travel Pilot Valve) The travel pilot valve has damper (1) enabling damping of the speed change shock by travel control lever (4).

Damper (1) is composed of support (5), gear 1 (9), gear 2 (8), and others. Gear 1 (9) is connected to support (5).

Support (5) is secure to bracket (6) by spring pin (2). Travel control lever (4) and travel pedal (3) are secure to bracket (6). Therefore, support (5) rotates transversely around pin (7) according to movement of travel control lever (4).

1

3

2 A

4

Operation 5

1. If travel control lever (4) is released while traveling, spring force of the return spring returns travel control lever (4) to the neutral position.

6 7

2. At this time, gear 1 (9) and gear 2 (8) inside damper (1) receive opposing force due to friction.

8

3. Consequently, as travel control lever (4) gradually returns to the neutral position, the extent of sudden stop at the time of abrupt release of travel control lever (4) is reduced.

9

A

T1M7-03-04-002

Section A-A

2

5

1

7 1- 2- 3- 4- 5-

T3-4-16

Damper Spring Pin Travel Pedal Travel Control Lever Support

T1M7-03-04-003 6- 7- 8- 9-

Bracket Pin Gear 2 Gear 1

SECTION 3 COMPONENT OPERATION Group 4 Pilot Valve Shuttle Valve (Optional)

Travel Pilot Valve (Optional)

The shuttle valve is for selecting necessary pilot pressure for traveling and leads pressure oil to the pressure sensors.

TADB-03-04-005

b a-

T3-4-17

Shuttle Valve

a b-

To Pressure Sensor

SECTION 3 COMPONENT OPERATION Group 4 Pilot Valve (Blank)

T3-4-18

SECTION 3 COMPONENT OPERATION Group 5 Travel Device Outline The travel device consists of travel motor (3), travel reduction gear (2), and travel brake valve (1).

Travel motor (3) is a swash plate type variable displacement axial plunger motor and equipped with a parking brake (a wet-type spring set hydraulic released multi-disc brake). Travel motor (3) is driven by pressure oil from the pump and transmits the rotation power to travel reduction gear (2).

Travel reduction gear (2) is a two-stage planetary reduction gear, converts the travel motor (3) rotation power to a slow-large torque, and rotates sprocket (4) and the track.

Travel brake valve (1) prevents the machine from running away.

3

2

1

4

1-

Travel Brake Valve

2-

Travel Reduction Gear

TADB-03-05-008

3-

T3-5-1

Travel Motor

4-

Sprocket

SECTION 3 COMPONENT OPERATION Group 5 Travel Device Travel Reduction Gear The travel reduction gear is a two-stage planetary reduction gear.

The travel motor rotates shaft (5) and the rotation is transmitted to first stage sun gear (8). The rotation of first stage sun gear (8) is reduced by first stage planetary gear (2) and first stage carrier (7), and is transmitted to second stage sun gear (6). The rotation of second stage sun gear (6) is reduced by second stage planetary gear (3) and second stage carrier (4) (united with the travel motor housing).

1

2

3

As second stage carrier (4) and travel motor housing is united into one part, the rotation of second stage planetary gear (3) is transmitted to sprocket (9) via ring gear (1).

4

5

8

7

6

9 TADB-03-05-008

1- 2- 3-

Ring Gear First Stage Planetary Gear Second Stage Planetary Gear

4- 5- 6-

Second Stage Carrier Shaft Second Stage Sun Gear

7- 8- 9-

T3-5-2

First Stage Carrier First Stage Sun Gear Sprocket

SECTION 3 COMPONENT OPERATION Group 5 Travel Device (Blank)

T3-5-3

SECTION 3 COMPONENT OPERATION Group 5 Travel Device Travel Motor The travel motor is a swash plate type variable displacement axial plunger motor, and consists of valve plate (6), swash plate (4), rotor (2), plunger (5), and shaft (1).

Shaft (1) is connected to rotor (2) by a spline joint into which plunger (5) is inserted.

1

4

1- 2-

Shaft Rotor

3- 4-

Shoe Swash Plate

When pressure oil is supplied from the pump, plunger (5) is pushed. As swash plate (4) is inclined, shoe (3) on the end of plunger (5) slides along swash plate (4) and rotor (2) rotates.

2

6

5

3

5-

T3-5-4

Plunger

T1ND-03-05-002

6-

Valve Plate

SECTION 3 COMPONENT OPERATION Group 5 Travel Device Operation 1. Pressure oil flows to port B in valve plate (6), enters one side in rotor (2), and pushes plunger (5).

2. This force and inclination of swash plate (4) make shoe (3) slide on swash plate (4) in order to rotate rotor (2) and output shaft (7).

3. As rotor (2) rotates, when plungers (5) reach port A, pressure oil is returned to the hydraulic oil tank.

4. Whether forward travel or reverse travel depends on whether pressure oil is supplied to port A or port B.

A

A

B

B

6 2 5

7

4

6

3

T183-03-05-009 A- Port A

(Pressure oil from main pump or returning oil to hydraulic oil tank)

B-

Port B (Pressure oil from main pump or returning oil to hydraulic oil tank)

2- 3-

4- 5-

Swash Plate Plunger

Rotor Shoe

6-

T3-5-5

Valve Plate

7-

Output Shaft

SECTION 3 COMPONENT OPERATION Group 5 Travel Device Parking Brake The parking brake is a wet-type spring set hydraulic released multi-disc brake. The brake is released when the brake release pressure oil is routed to brake piston chamber (a).

The parking brake is automatically applied unless the travel function is operated.

Friction plates (2) and plates (3) are connected to rotor (4) and housing (1) of the travel motor by a spline joint respectively.

When brake is released

When brake is applied

1. When the travel control lever is operated, pressure oil from the main pump is routed to port AV or BV in the travel motor through the control valve.

1. When the travel control lever is returned to neutral, counterbalance valve spool (7) in the travel brake valve is returned to neutral.

2. This pressure oil shifts counterbalance valve spool (7) in the travel brake valve and is routed to brake piston (5) through the notch on counterbalance valve spool (7).

2. As pressure oil routed to brake piston (5) is returned to the drain circuit, brake piston (5) is returned by spring (6).

3. Consequently, the spring force acts on friction plate (2), which is engaged with the external circumference of rotor (4), and on plate (3), which is engaged with the inside of housing (1) of the travel motor through brake piston (5). Therefore, the external circumference of rotor (4) is secured with friction force.

3. Consequently, as brake piston (5) is pushed, plates (3) and friction plates (2) become freed each other so that the brake is released.

T3-5-6

SECTION 3 COMPONENT OPERATION Group 5 Travel Device

When brake is applied:

2

3

When brake is released:

4

a

1

5

T1LA-03-05-007

6

Section A-A AV

b

BV

7 A

A

TADB-03-05-003

T1ND-03-05-003

AV- Port AV

(Pressure oil from main pump)

BV- Port BV

(Pressure oil from main pump)

a-

Brake Piston Chamber

b-

To Brake Piston

1- 2-

3- 4-

5- 6-

Brake Piston Spring

7-

Counterbalance Valve Spool

Housing Friction Plate

Plate Rotor

T3-5-7

SECTION 3 COMPONENT OPERATION Group 5 Travel Device Travel Brake Valve The travel brake valve is located on the travel motor head and consists of the following valves.  Counterbalance Valve (2): Counterbalance valve (2) ensures smooth start / stop travel operation and prevents the machine from running away when traveling on a down slope. In addition, counterbalance valve (2) routes the travel motor operating pressure oil in the high-pressure port (AV or BV) to the parking brake.  Check Valve (4): Check valve (4) assists the counterbalance valve (2) operation.  Travel Mode Selector Valve (5): Travel mode selector valve (5) is switched by pressure oil from the travel mode selector solenoid valve and switches the travel speed by the control piston.  Orifice (3) (for slow / fast speed): Orifice (3) makes the travel mode control (displacement angle control) smooth.

T3-5-8

SECTION 3 COMPONENT OPERATION Group 5 Travel Device

1

A

A

3

2

Section A-A

4

T1ND-03-05-003

5

4 TADB-03-05-003

1- 2-

Travel Brake Valve Counterbalance Valve

3- 4-

Orifice Check Valve

5-

T3-5-9

Travel Mode Selector Valve

SECTION 3 COMPONENT OPERATION Group 5 Travel Device Counterbalance Valve ď‚— While Traveling 1. When pressure oil from the control valve enters port BV (12), pressure oil flows through the inside of spool (2), unseats check valve BC (9), and flows further to motor port BM (8).

2. On the other hand, returning oil from the travel motor is routed to motor port AM (7). However, its passage is blocked by check valve AC (6) and spool (2).

3. When pressure in port BV (12) increases further, pressure oil is routed to chamber B (10) through orifice (11) and moves spool (2) to the right.

4. Consequently, returning oil from the travel motor flows to port AV (1) through notch (4) of spool (2).

As pressure oil starts flowing at this stage, the travel motor starts rotating.

5. When the travel control lever is returned to neutral, spool (2) is returned to the original position by the spring force and blocks the oil passage so that the travel motor rotation is stopped. ď‚— While Descending a Slope 1. When the machine descends a slope, the travel motors are forcibly rotated by the machine self weight like a pump.

2. If the travel motor draws oil, oil pressure in port BV (12) and chamber B (10) decrease. Spool (2) moves to the left so that returning oil from the travel motor is reduced.

3. Therefore, oil pressure in motor port AM (7) increases and functions the travel motor brake.

4. Once pressure oil is reduced, pressure in port BV (12) increases again and moves spool (2) to the right.

By repeating this (hydraulic brake operation), the machine is prevented from running away.

T3-5-10

SECTION 3 COMPONENT OPERATION Group 5 Travel Device During travel operation:

12

1 2

11

3

10

4

5 9 6

8

7 TADB-03-05-006

1- 2- 3- 4-

Port AV Spool (Counterbalance Valve) Orifice Notch

5- 6- 7- 8-

Chamber A Check Valve AC Motor Port AM Motor Port BM

9- 10- 11- 12-

T3-5-11

Check Valve BC Chamber B Orifice Port BV

SECTION 3 COMPONENT OPERATION Group 5 Travel Device Travel Mode Selector Valve  When Engine Stops 1. When the engine stops, pressure oil acting on control piston (4) returns to the hydraulic oil tank through the travel mode selector valve.

 Slow Speed Operation 1. When the travel is at slow speed, pressure oil from travel mode selector solenoid valve (6) is not supplied to spool (1) of the travel mode selector valve. As spool (1) does not move to the right, pressure oil is not supplied to control piston (4).

2. Consequently, surface (a) of the swash plate makes contact with the housing by spring (5) force in the rotor.

2. Therefore, surface (a) of the swash plate makes contact with the housing by pressure oil acting on plunger (2) and spring (5) force in the rotor.

3. Consequently, the angle of swash plate increases and makes the stroke of plunger (2) longer.

4. As a consequence, the motor capacity becomes larger and the travel motor rotates at slow speed.  Fast Speed Operation 1. When the travel is at fast speed, pressure oil from travel mode selector solenoid valve (6) flows through the inner passage and switches spool (1) of the travel mode selector valve.

2. Therefore, pressure oil in travel circuit A or B is supplied to control piston (4) through notch (7) on spool (1).

3. The swash plate is pushed by control piston (4) due to pressure oil, which makes surface (b) contact with the housing.

4. Consequently, the angle of swash plate decreases and makes the stroke of plunger (2) shorter.

5. As a consequence, the motor capacity becomes smaller and the travel motor rotates at fast speed.

T3-5-12

SECTION 3 COMPONENT OPERATION Group 5 Travel Device Slow Speed Operation:

1 A

B

b

2

6

a

5

Fast Speed Operation:

A

1

3

4

TADB-03-05-009

4

TADB-03-05-010

B

7

b

2

6

5 a-

Surface (a)

1- Spool 2- Plunger

b-

a

3

Surface (b)

3- Ball 4- Control Piston

5- Spring 6- Travel Mode Selector Solenoid Valve

T3-5-13

7- Notch

SECTION 3 COMPONENT OPERATION Group 5 Travel Device Auto Swash Angle Control At fast speed position (at small swash plate angle), switching to slow speed position (at large swash plate angle) is made automatically due to motor load.

1. When turning the travel mode switch to FAST, the travel motor rotates at fast speed.

2. Motor operating pressure always acts on travel mode selector valve (6) through counterbalance valve (3).

3. As load to the motor increases, the forces acting on piston 1 (8) and piston 2 (5) also increase.

4. Pressurized areas of piston 1 (8) and piston 2 (5) are different. When the sum of pressure difference between piston 1 (8) and piston 2 (5) plus spring force exceeds pilot pressure from the travel mode selector solenoid valve, spool (9) in travel mode selector valve (6) moves to the left.

5. Consequently, as pressure oil is not supplied to control piston (7), the swash plate angle increases.

Therefore, the motor capacity also increases and the travel motor rotates at slow speed.

6. In addition, when motor load decreases, pressures acting on piston 1 (8) and piston 2 (5) decrease.

As pressure difference between piston 1 (8) and piston 2 (5) is small, the force moving spool (9) in travel mode selector valve (6) to the right prevails.

Therefore, spool (9) in travel mode selector valve (6) moves to the right.

7. Consequently, pressure oil is supplied to control piston (7), the motor capacity is reduced, and the motor speed returns to fast speed.

T3-5-14

SECTION 3 COMPONENT OPERATION Group 5 Travel Device At Fast Speed:

At Slow Speed:

a

1 2

3

a

9

1 2

3

9 4

4

5

5

8

8

6

6

DR

7

DR 7

TADB-03-05-007

8

TADB-03-05-004

b

4

5

a c e

6 9

d

TADB-03-05-005

a- Pilot Pressure (Pilot Port PP) from Travel Mode Selector Solenoid Valve

b- From Port A c- Pressurized Area of Piston 2

d- To Control Piston e- Pressurized Area of Piston 1

1- 2- 3-

4- 5- 6-

7- 8- 9-

Port A Port B Counterbalance Valve

Spring Piston 2 Travel Mode Selector Valve

T3-5-15

Control Piston Piston 1 Spool

SECTION 3 COMPONENT OPERATION Group 5 Travel Device (Blank)

T3-5-16

SECTION 3 COMPONENT OPERATION Group 6 Others (Upperstructure) 2-Spool Solenoid Valve 1

There are two kinds of solenoid valves in the 2-spool solenoid valve; one is pilot shut-off solenoid valve (1) in order to turn pilot pressure ON or OFF, the other is travel mode selector solenoid valve (2) in order to shift travel speed.

NOTE: The structures of pilot shut-off solenoid valve (1) and travel mode selector solenoid valve (2) are same.

2

f

3

TADB-03-06-001 1- 2-

T3-6-1

Pilot Shut-Off Solenoid Valve Travel Mode Selector Solenoid Valve

3-

Pilot Relief Valve

SECTION 3 COMPONENT OPERATION Group 6 Others (Upperstructure)  Pilot Shut-Off Solenoid Valve  Pilot Shut-Off Lever: LOCK Position 1. When the pilot shut-off lever is set to the LOCK position, the pilot shut-off relay is turned OFF and the pilot shut-off solenoid valve is turned OFF. (Refer to SYSTEM / Electrical System.)

Pilot Shut-Off Lever: LOCK Position

2. Pressure oil from the pilot pump is blocked by spool (1) in the pilot shut-off solenoid valve.

3. Therefore, even if the control / travel control lever is operated, the pilot valve is not activated.

P 1

 Pilot Shut-Off Lever: UNLOCK Position 1. When the pilot shut-off lever is set to the UNLOCK position, the pilot shut-off relay is turned ON and the pilot shut-off solenoid valve is turned ON. (Refer to SYSTEM / Electrical System.)

T

a

2. Therefore, spool (1) in the pilot shut-off solenoid valve is pushed down and pressure oil from the pilot pump flows to the pilot valve.

TADB-03-06-004

3. Consequently, when the control / travel control lever is operated, the pilot valve is activated.

Pilot Shut-Off Lever: UNLOCK Position

P

1 a

TACC50-03-06-003

P- a-

From Pilot Pump To Pilot Valve

1-

Spool

T3-6-2

T-

Returning Oil to Hydraulic Oil Tank

SECTION 3 COMPONENT OPERATION Group 6 Others (Upperstructure)  Travel Mode Selector Solenoid Valve  Slow Speed Position 1. When the travel mode switch is turned OFF (set to slow speed position), the travel mode selector relay is turned OFF and the travel mode selector solenoid valve is turned OFF. (Refer to SYSTEM / Electrical System.)

Slow Speed Position

P

2. Pressure oil from the pilot pump is blocked by spool (1) in the travel mode selector solenoid valve.

3. Consequently, the travel mode selector valve in travel motor is not shifted and the travel motor rotates at slow speed.

1 a T

 Fast Speed Position 1. When the travel mode switch is turned ON (set to fast speed position), the travel mode selector relay is turned ON and the travel mode selector solenoid valve is turned ON. (Refer to SYSTEM / Electrical System.)

TACC50-03-06-003

2. Therefore, spool (1) in the travel mode selector solenoid valve is pushed down and pressure oil from the pilot pump flows to both right and left travel motors.

Fast Speed Position

3. Consequently, the travel mode selector valve in travel motor is shifted and travel motor rotates at fast speed.

P

1 a

TACC50-03-06-004 P- a-

From Pilot Pump To Travel Motor

1-

Spool

T3-6-3

T-

Returning Oil to Hydraulic Oil Tank

SECTION 3 COMPONENT OPERATION Group 6 Others (Upperstructure) ď‚— Pilot Relief Valve The pilot circuit of 2-spool solenoid valve has a pilot relief valve which prevents the circuit pressure from rising more than the set pressure.

1. Pressure oil from the pilot pump is always routed to relief cap (1). When this pressure increases more than the set pressure (spring (2) force), relief cap (1) is moved and pressure oil is relieved.

1

a b

2 TADB-03-06-003

a-

From Pilot Pump

b-

To Hydraulic Oil Tank

1-

Relief Cap

2-

Spring

T3-6-4

SECTION 3 COMPONENT OPERATION Group 6 Others (Upperstructure) Torque Control Solenoid Valve (Only Machine with the Air Conditioner (Optional) Attached) The torque control solenoid valve controls pressure oil from the pilot pump and controls delivery flow rate of the main pump.

B

P

T

B T1M9-03-07-003 Section B-B

1 A

T1M9-03-07-004

A- Port A (Torque Control Solenoid Valve: Main Pump) P- Port P (From Pilot Pump) 1-

T3-6-5

Spool

T-

Port T (To Hydraulic Oil Tank)

SECTION 3 COMPONENT OPERATION Group 6 Others (Upperstructure)  Torque Control Solenoid Valve  Air Conditioner Switch: OFF 1. When the air conditioner switch is OFF, the torque control solenoid valve is turned OFF.

Air Conditioner Switch: OFF

2. Pressure oil from the pilot pump is blocked by spool (1) in the torque control solenoid valve.

3. Consequently, pressure oil is not supplied to the control piston of main pump.  Air Conditioner Switch: ON 1. When the air conditioner switch is ON, the torque control solenoid valve is turned ON.

a

2. Therefore, spool (1) in the torque control solenoid valve is pushed down and pressure oil from the pilot pump is supplied to the control piston of main pump.

1 A

3. Consequently, the control piston tilts the swash plate of main pump and controls the pump delivery flow rate.

T1M9-03-07-004

Air Conditioner Switch: ON

a 1 A

TADB-03-06-007 A- Port A (To Control Piston of Main Pump) 1-

T3-6-6

Spool

a-

From Pilot Pump

SECTION 3 COMPONENT OPERATION Group 7 Others (Undercarriage) Swing Bearing The swing bearing supports the upperstructure on the undercarriage and allows the upperstructure to swing smoothly.

This bearing is a single row type ball bearing and consists of outer race (1), inner race (3), ball (6), support (5), and seals (2, 4).

Outer race (1) is bolted to the upperstructure. Inner race (3) is bolted to the undercarriage. The internal gear of inner race (3) meshes with the output shaft of the swing reduction gear.

1 2

5 3

4 6

TADB-03-07-001

1- 2-

Outer Race Seal

3- 4-

Inner Race Seal

5- 6-

T3-7-1

Support Ball

SECTION 3 COMPONENT OPERATION Group 7 Others (Undercarriage) Center Joint The center joint is a 360 ° rotating joint. When the upperstructure swings, the center joint eliminates twisting of the hoses and allows hydraulic oil to flow the travel motors and the blade cylinder.

Spindle (1) and body (2) are secured to the upperstructure and to the swing center of the undercarriage respectively.

Pressure oil flows to the right and left travel motors and the blade cylinder through spindle (1) and each oil port of body (2). Seals (3) prevent oil leaks between spindle (1) and body (2).

c

d

a

b

1

f h

g e

d

2

b

3

c

3 a

TADB-03-07-002

a b- c-

Travel (Left Reverse) Travel (Right Reverse) Travel (Left Forward)

d- e- f-

Travel (Right Forward) Blade Lower Blade Raise

g- h-

Drain Pilot Pressure for Travel Mode Control

1-

Spindle

2-

Body

3-

Seal

T3-7-2

TADB-03-07-003

SECTION 3 COMPONENT OPERATION Group 7 Others (Undercarriage) Track Adjuster The track adjuster located on the side frame consists of spring (3) and adjuster cylinder (1).

Spring (3) absorbs the loads applied to the front idler (4) part. Track sag is adjusted by adjuster cylinder (1). ď‚— When grease is supplied through grease fitting (5), grease fills chamber (a) in adjuster cylinder (1), pushes piston rod (2), and reduces track sag.

Detail A

5

TADB-03-07-004

4

2

1

3

A

a

TADB-03-07-005 1- 2-

Adjuster Cylinder Piston Rod

3- 4-

Spring Front Idler

5-

T3-7-3

Grease Fitting

SECTION 3 COMPONENT OPERATION Group 7 Others (Undercarriage) (Blank)

T3-7-4

MEMO

MEMO

SECTION 4

OPERATIONAL PERFORMANCE TEST CONTENTS Group 1 Introduction

Operational Performance Tests....................................... T4-1-1 Preparation for Performance Tests................................ T4-1-2

Group 2 Standard

Operational Performance Standard Table.................. T4-2-1 Main Pump P1, Main Pump P2 P-Q Diagram............. T4-2-7 Main Pump P-Q P3 Diagram............................................ T4-2-9 Sensor Activating Range.................................................T4-2-10

Group 3 Engine Test

Engine Speed........................................................................ T4-3-1

Group 4 Machine Performance Test

Travel Speed.......................................................................... T4-4-1 Track Revolution Speed..................................................... T4-4-2 Mistrack Check...................................................................... T4-4-3 Travel Parking Leakage...................................................... T4-4-4 Swing Speed.......................................................................... T4-4-5 Swing Function Drift Check............................................. T4-4-6 Swing Motor Leakage........................................................ T4-4-8 Maximum Swingable Slant Angle................................T4-4-10 Swing Bearing Play............................................................T4-4-12 Hydraulic Cylinder Cycle Time.......................................T4-4-14 Dig Function Drift Check.................................................T4-4-17 Control Lever Operating Force......................................T4-4-19 Control Lever Stroke.........................................................T4-4-20 Combined Operation of Boom Raise / Swing Function Check.....................T4-4-21 Clearance of Front Attachment Connecting Part.......................T4-4-22

Group 5 Component Test

Primary Pilot Pressure......................................................... T4-5-1 Secondary Pilot Pressure................................................... T4-5-3 Main Relief Set Pressure.................................................... T4-5-4 Relief Pressure (when relieving swing)........................ T4-5-7 Overload Relief Valve Set Pressure................................ T4-5-8 Pump Driving Torque.......................................................T4-5-10 Swing Motor Drainage.....................................................T4-5-11 Travel Motor Drainage.....................................................T4-5-13

ADCT-4-1

(Blank)

ADCT-4-2

SECTION 4 OPERATIONAL PERFORMANCE TEST Group 1 Introduction Operational Performance Tests Use operational performance test procedure to quantitatively check all system and functions on the machine.

The machine performance does not always deteriorate as the working hours increase. However, the machine performance is normally considered to reduce in proportion to the increase of the operation hours.

Accordingly, restoring the machine performance by repair, adjustment, or replacement shall consider the number of the machine’s working hours.

Purpose of Performance Tests 1. To comprehensively evaluate each operational function by comparing the performance test data with the standard values.

2. According to the evaluation results, repair, adjust, or replace parts or components as necessary to restore the machine’s performance to the desired standard.

Definition of “Performance Standard” 1. Operation speed values and dimensions of the new machine.

2. Operational performance of new components adjusted to specifications. Allowable errors will be indicated as necessary.

3. To economically operate the machine under optimal conditions.

Kinds of Tests 1. Base machine performance test is to check the operational performance of each system such as engine, travel, swing, and hydraulic cylinders.

2. Hydraulic component unit test is to check the operational performance of each component such as hydraulic pump, motor, and various kinds of valves.

Performance Standards “Performance Standard” is shown in tables to evaluate the performance test data.

Precautions for Evaluation of Test Data 1. To evaluate not only that the test data are correct, but also in what range the test data are.

2. Be sure to evaluate the test data based on the machine operation hours, kinds and state of work loads, and machine maintenance conditions.

T4-1-1

SECTION 4 OPERATIONAL PERFORMANCE TEST Group 1 Introduction Preparation for Performance Tests Observe the following rules in order to carry out performance tests accurately and safely.

THE MACHINE 1. Repair any defects and damage found, such as oil or water leaks, loose bolts, cracks and so on, before starting to test.

TEST AREA 1. Select a hard and flat surface.

2. Secure enough space to allow the machine to run straight more than 20 m (65 ft 7 in), and to make a full swing with the front attachment extended.

3. If required, rope off the test area and provide signboards to keep unauthorized personnel away.

PRECAUTIONS 1. Before starting to test, agree upon the signals to be employed for communication among coworkers.

Once the test is started, be sure to communicate with each other using these signals, and to follow them without fail.

2. Operate the machine carefully and always give first priority to safety.

3. While testing, always take care to avoid accidents due to landslides or contact with high-voltage power lines. Always confirm that there is sufficient space for full swings.

4. Avoid polluting the machine and the ground with leaking oil. Use oil pans to catch escaping oil. Pay special attention to this when removing hydraulic pipings.

T105-06-01-003

MAKE PRECISE MEASUREMENT 1. Accurately calibrate test instruments in advance to obtain correct data.

2. Carry out tests under the exact test conditions prescribed for each test item.

3. Repeat the same test and confirm that the test data obtained can be produced repeatedly. Use mean values of measurements if necessary.

T105-06-01-004

T4-1-2

SECTION 4 OPERATIONAL PERFORMANCE TEST Group 2 Standard Operational Performance Standard Table The standard Performance values are listed in the table below.

Refer to the Group T4-3 to T4-5 for performance test procedures.

Values indicated in parentheses are reference values.

Performance Test Designation

Unit

ENGINE SPEED Slow Idle Speed Fast Idle Speed Fast Idle Speed (Main Pump P1 Relief Operation) Fast Idle Speed (Main Pump P2 Relief Operation) Fast Idle Speed (Main Pump P3 Relief Operation) Auto-Idle Speed (Slow Idle Speed) ENGINE COMPRESSION PRESSURE

min-1

VALVE CLEARANCE (IN, EX) NOZZLE INJECTION PRESSURE

INJECTION TIMING

The following switch positions shall be selected and the hydraulic oil temperature shall be maintained as indicated below as the preconditions of performance tests unless otherwise instructed in each performance test procedure:  Engine Control Dial : Fast Idle  Power Mode : PWR  Auto-Idle Switch: OFF  Hydraulic Oil Temperature : 50±5 °C (122±9 °F)

Performance Standard

Remarks

Reference Page T4-3-1

1300±50 2400±50 2400±50 2400±50 2200±50 1300±50 MPa(kgf/cm2, 3.43 (35, 495) ±0.1 Measure after warming up psi) (1, 15) the engine. mm 0.15 to 0.25 Measure with the engine cold.

MPa(kgf/cm2, 19.6 to 20.6 (200 psi) to 210, 2840 to 2990) Before TDC 4.5 °

T4-2-1

Refer to Engine Manual.

Refer to Engine Manual.

Refer to Engine Manual.

Refer to Engine Manual.

SECTION 4 OPERATIONAL PERFORMANCE TEST Group 2 Standard Performance Test Designation

Unit

TRAVEL SPEED Fast Speed Mode (Rubber Crawler/Steel Crawler) Slow Speed Mode (Rubber Crawler/Steel Crawler) TRACK REVOLUTION SPEED Fast Speed Mode (Rubber Crawler/Steel Crawler) Slow Speed Mode (Rubber Crawler/Steel Crawler) MISTRACK (With fast and slow travel speed modes) (Rubber Crawler/Steel Crawler) TRAVEL PARKING LEAKAGE SWING SPEED SWING FUNCTION DRIFT CHECK SWING MOTOR LEAKAGE MAXIMUM SWINGABLE SLANT ANGLE SWING BEARING PLAY

sec/20 m

Performance Standard

Remarks

Reference Page T4-4-1

16.6±1.5/17.1±1.5 25.9±1.5/26.7±1.5 sec/3 rev

T4-4-2 11.2±1.5/11.5±1.5 17.5±1.5/17.9±1.5

mm/20 m

200/350 or less

T4-4-3

mm/3 min sec/3 rev mm/90° mm/5 min deg mm

about 0 19.8±1.5 140 or less 0 20 or more 0.3 or less

T4-4-4 T4-4-5 T4-4-6 T4-4-8 T4-4-10 T4-4-12

T4-2-2

Bucket: loaded Bucket: loaded Allowable limit: 1.5

SECTION 4 OPERATIONAL PERFORMANCE TEST Group 2 Standard Performance Test Designation

Unit

HYDRAULIC CYLINDER CYCLE TIME Boom Raise (Canopy/Cab) Boom Lower (Canopy/Cab)

sec

Arm Roll-In Arm Roll-Out Bucket Roll-In Bucket Roll-Out Boom Swing (Right) (Canopy/Cab) Boom Swing (Left) (Canopy/Cab) Blade Raise Blade Lower DIG FUNCTION DRIFT CHECK Boom Cylinder Arm Cylinder Bucket Cylinder Bucket Bottom Blade Cylinder Blade Cylinder (With the track jacked up) Boom Swing Cylinder

Performance Standard

Remarks

Reference Page T4-4-14

2.7±0.3/2.6±0.3 2.4±0.3/2.3±0.3 3.3±0.3 2.8±0.3 2.4±0.3 1.6±0.3 6.2±0.5/5.9±0.5 8.2±0.5/7.7±0.5 2.1±0.5 2.8±0.5 mm/5 min

Bucket: loaded 5 or less 8 or less 5 or less 100 or less 3 or less 15 or less 3 or less

T4-2-3

T4-4-17

SECTION 4 OPERATIONAL PERFORMANCE TEST Group 2 Standard Performance Test Designation

Unit

CONTROL LEVER/PEDAL OPERATING FORCE Front and Rear at Right Side

N(kgf, lbf )

Remarks

Reference Page T4-4-19

15(1.5, 3.38) or less 15(1.5, 3.38) or less 15(1.5, 3.38) or less 15(1.5, 3.38) or less 23(2.3, 5.18) or less 22(2.2, 4.95) or less 60(6.1, 13.5) or less

Right and Left at Left Side Right and Left at Right Side Front and Rear at Left Side Travel Control Lever Blade Control Lever Boom Swing Pedal CONTROL LEVER/PEDAL STROKE Front and Rear at Right Side Right and Left at Left Side Right and Left at Right Side Front and Rear at Left Side Travel Control Lever Blade Control Lever Boom Swing Pedal BOOM RAISE/SWING (Bucket: Empty) Height Time

Performance Standard

mm

T4-4-20 88±10 73±10 73±10 88±10 94±10 49±10 18±5 T4-4-21

mm sec

2400 or more 2.0±0.3

T4-2-4

SECTION 4 OPERATIONAL PERFORMANCE TEST Group 2 Standard PERFORMANCE TEST DESIGNATION Clearance of Front Attachment Connecting Part Swing Post and Boom Foot

Unit

Performance Standard

Remarks

1.0 or less

Swing Post

mm

Boom Foot Pin Boom and Arm

Reference Page T4-4-22

1.0 or less

Boom Arm Pin

T4-2-5

max 45.02 min 45.00 max 45.14 including Bushing min 44.97 including Bushing max 44.97 min 44.95 max 45.03 min 45.00 max 45.14 including Bushing min 44.97 including Bushing max 44.97 min 44.95

SECTION 4 OPERATIONAL PERFORMANCE TEST Group 2 Standard Performance Test Designation HYDRAULIC SYSTEM PRIMARY PILOT PRESSURE SECONDARY PILOT PRESSURE MAIN RELIEF VALVE SET PRESSURE

Unit

Performance Standard

MPa(kgf/cm2, psi) MPa(kgf/cm2, psi) MPa(kgf/cm2, psi)

4.1±0.5(42±5, 595±73) 2.9±0.5(30±5, 420±73)

Main Pump P1, Main Pump P2

Travel Swing MPa(kgf/cm2, psi)

T4-5-1 T4-5-3 Measure at machine.

T4-5-4

Measured at test stand.

T4-5-8

27.5±1.0(280±10, 3990±145) 18.6±1.0(190±10, Effective Pressure 2700±145)

Swing SWING MOTOR DRAINAGE With constant speed TRAVEL MOTOR DRAINAGE With constant speed (With fast and slow travel speed modes) PUMP DELIVERY PRESSURE (Control Lever in Neutral) Fast Idle Slow Idle

Reference Page

25.4±1.0(259±10, 3680±145) 21.9±1.0(223±10, 3180±145) 25.4±1.0(259±10, 3680±145) 20.4±1.0(208±10, 2960±145)

Main Pump P3

OVERLOAD RELIEF VALVE SET PRESSURE Boom, Arm, Bucket

Remarks

L/min (gpm)

T4-5-11 (0.5 (0.13) or less)

L/min (gpm)

T4-5-13 (0.7 (0.18)/0.7 (0.18) or less)

Reference Value

2.4(24.5, 350) 2.1(21.4, 305)

Reference Value Reference Value

MPa(kgf/cm2, psi)

T4-2-6

SECTION 4 OPERATIONAL PERFORMANCE TEST Group 2 Standard Main Pump P1, Main Pump P2 P-Q Diagram  P-Q Control (Torque Control) (Air Conditioner: OFF) (Reference: Calculated Valve)  Rated Pump Speed: 2400 min-1 (rpm)  Hydraulic Oil Temperature: 50±5 °C (122±9 °F)  Pilot Pump Pressure: 4.1 MPa(42 kgf/cm2, 595 psi)  Points on P-Q Line (P3=20.6 MPa (210 kgf/cm2, 2990 psi))

 Points on P-Q Line (P3=0.98 MPa (1.0 kgf/cm2, 140 psi)) Delivery Pressure MPa (kgf/cm2, psi) 0 (0, 0) 9.3 (94.8, 1350) 17.2 (175, 2490) 24.5 (250, 3550)

A B C D

L/min

Flow Rate L/min (gpm) 38.4 (10.1) 37.4 (9.87) 21.6 (5.70) 12.7 (3.35)

Delivery Pressure MPa (kgf/cm2, psi) 0 (0, 0) 3.0 (30.6, 435) 11.8 (120, 1710) 21.6 (220 3130) 24.5 (250, 3550)

A E F G H

Flow Rate L/min (gpm) 38.4 (10.1) 38.0 (10.0) 19.2 (5.07) 7.9 (2.08) 7.3 (1.93)

Q

40 A

E

B

35 30 25

C

F

20 15

D

10

G

5 0 0

5(51)

10(102)

15(153)

20(204)

H

25(255) MPa (kgf/cm2)

P-

Delivery Pressure

Q- Flow Rate

T4-2-7

P TADB-04-02-001

SECTION 4 OPERATIONAL PERFORMANCE TEST Group 2 Standard  P-Q Control (Torque Control) (Air Conditioner: ON) (Reference: Calculated Valve)  Rated Pump Speed: 2400 min-1 (rpm)  Hydraulic Oil Temperature: 50±5 °C (122±9 °F)  Pilot Pump Pressure: 4.1 MPa(42 kgf/cm2, 595 psi)  Points on P-Q Line (P3=20.6 MPa (210 kgf/cm2, 2990 psi))

 Points on P-Q Line (P3=0.98 MPa (1.0 kgf/cm2, 140 psi)) Delivery Pressure MPa (kgf/cm2, psi) 0 (0, 0) 6.9 (70.4, 1000) 16.7 (170, 2420) 24.5 (250, 3550)

A B C D

L/min

Flow Rate L/min (gpm) 38.4 (10.1) 37.8 (9.97) 18.2 (4.80) 8.6 (2.27)

A E F G H

Delivery Pressure MPa (kgf/cm2, psi) 0 (0, 0) 1.6 (16.3, 230) 10.5 (107, 1520) 17.6 (179, 2550) 24.5 (250, 3550)

Flow Rate L/min (gpm) 38.4 (10.1) 38.2 (10.1) 16.7 (4.41) 8.6 (2.27) 7.3 (1.93)

Q

40 A

E

B

35 30 25 20

F

C

15 10

G

D H

5 0 0

5(51)

10(102)

15(153)

20(204)

25(255) MPa (kgf/cm2)

P-

Delivery Pressure

Q- Flow Rate

T4-2-8

P TADB-04-02-002

SECTION 4 OPERATIONAL PERFORMANCE TEST Group 2 Standard Main Pump P-Q P3 Diagram  Auxiliary Section P-Q Control (Torque Control) (Reference: Calculated Valve)  Rated Pump Speed: 2400 min-1 (rpm)  Hydraulic Oil Temperature: 50±5 °C (122±9 °F)  Pilot Pump Pressure: 4.1 MPa(42 kgf/cm2, 595 psi)  Points on P-Q Line (Air Conditioner: OFF (Flow Combination of P2 and P3)

A B C D E F

Delivery Pressure MPa (kgf/cm2, psi) 0 (0, 0) 5.0 (51.0, 725) 10.0 (102, 1450) 15.0(153, 2180) 20.6(210, 2990) 24.5(250, 3550)

 Points on P-Q Line (Air Conditioner: ON (Flow Combination of P2 and P3)

Flow Rate L/min (gpm) 61.2 (16.1) 59.4 (15.7) 52.0 (13.7) 40.0 (10.6) 30.6 (8.07) 7.3 (1.93)

Delivery Pressure MPa (kgf/cm2, psi) 0 (0, 0) 5.0(51.0, 725) 10.0 (102, 1450) 15.0 (153, 2180) 20.6 (210, 2990) 24.5 (250, 3550)

A G H I J F

Flow Rate L/min (gpm) 61.2 (16.1) 58.5 (15.4) 47.0 (12.4) 36.2 (9.55) 29.6 (7.81) 7.3 (1.93)

Q

L/min

70 60

A

B G

C

50 H D

40 I 30

E J

20 10 F 0 0

5(51)

10(102)

15(153)

20(204)

P 25(255) MPa (kgf/cm2) TADB-04-02-003

P-

Delivery Pressure

Q- Flow Rate

T4-2-9

SECTION 4 OPERATIONAL PERFORMANCE TEST Group 2 Standard Sensor Activating Range 1. Checking Method  Hydraulic Oil Temperature: 50±5 °C (122±9 °F)  Unless specified: Engine Control Dial Fast Idle

2.

Power Mode

Auto-Idle Switch

PWR

OFF

Sensor Activating Range

Item Engine Control Dial Auto-Idle Pressure Sensor

Operation Slow Idle Fast Idle Control Lever: Neutral Pilot Shut-Off Lever: LOCK Control Lever: Full Stroke Pilot Shut-Off Lever: UNLOCK

T4-2-10

Specification 0.6±0.1 V 4.0±0.1 V 0.64 MPa (6.5 kgf/cm2, 93 psi) or less 3.0 MPa (30.6 kgf/cm2, 435 psi) or more

SECTION 4 OPERATIONAL PERFORMANCE TEST Group 3 Engine Test Engine Speed Summary: 1. Measure the engine speed by using the monitor.

2. Measure the engine speeds in each mode.

fNOTE:

If the engine speed is not adjusted correctly, all other performance data will be unreliable. Therefore, measure the engine speed before performing all other tests in order to check that the engine speed meets specification.

Preparation: 1. Select Monitoring of the monitor.

2. Warm up the machine until coolant temperature reaches 50 °C (122 °F) or more, and hydraulic oil temperature is 50±5 °C (122±9 °F).

T4-3-1

SECTION 4 OPERATIONAL PERFORMANCE TEST Group 3 Engine Test Measurement:

Remedy:

1. Measure the items as shown in the table below.

Refer to Troubleshooting B.

2. When measuring, set the switch and test condition as shown in the table below in response to the engine speed to be measured.

Evaluation: Refer to Operational Performance Standard.

Item Slow Idle Fast Idle (Relief operation) Auto-Idle Speed

Engine Control Dial

Power Mode

Auto-Idle Switch

Min. Speed

PWR

OFF

Max. Speed

PWR

OFF

Max. Speed

PWR

ON

T4-3-2

Test Conditions

Measure engine speed while relieving the boom raise circuit.

Measure engine speed in 4 seconds after returning all control levers to neutral.

SECTION 4 OPERATIONAL PERFORMANCE TEST Group 3 Engine Test

1

MADB-01-002 1-

Engine Control Dial

2-

Auto-Idle/Selection Switch

T4-3-3

2 3-

3

MADB-01-035

ECO/PWR Mode/Selection Switch

SECTION 4 OPERATIONAL PERFORMANCE TEST Group 3 Engine Test (Blank)

T4-3-4

SECTION 4 OPERATIONAL PERFORMANCE TEST Group 4 Machine Performance Test Travel Speed Summary: 1. Measure the time required for the machine to travel a test track and check the performance of the travel device systems (from main pump to travel motor).

Preparation: 1. Adjust the track sag of both tracks equally.

c b

2. Provide a flat, solid test yard 20 m (65.6 ft) in length, with extra length of 3 to 5 m (10 to 16 ft) on both ends for machine acceleration and deceleration.

d

a

3. With the arm and the bucket cylinders fully extended, hold the bucket 0.3 to 0.5 m (12 to 20 in) above the ground.

d

e TADB-04-04-001

4. Maintain the hydraulic oil temperature at 50±5 °C (122±9 °F). a - Bucket Height: 0.3 to 0.5 m (12 to 20 in) b - Start c - End

Measurement: 1. Measure in both fast and slow travel modes.

2. Select the following conditions.

Travel Mode Engine Switch Control Dial

Power Mode Auto-Idle Switch

Slow Mode

Fast Idle

PWR

OFF

Fast Mode

Fast Idle

PWR

OFF

3. Start traveling the machine in the acceleration zone with the travel levers to full stroke.

4. Measure the time required to travel 20 m (65.6 ft).

5. After measuring the forward travel speed, turn the upperstructure 180° and measure the reverse travel speed in the same way.

6. Repeat the measurement three times and calculate the mean values.

Evaluation: Refer to Operational Performance Standard.

Remedy: Refer to Troubleshooting B.

T4-4-1

d - Acceleration/Deceleration Zone: 3 to 5 m (10 to 16 ft) e - 20 m (65.6 ft)

SECTION 4 OPERATIONAL PERFORMANCE TEST Group 4 Machine Performance Test Track Revolution Speed Summary: 1. Measure the track revolution cycle time with the track raised off ground and check the performance of the travel device systems (from main pump to travel motor). a

Preparation: 1. Adjust the track sag of both tracks equally.

2. On the track to be measured, put the mark on one shoe by using a piece of chalk or cloth.

3. Raise the track to be measured as illustrated.

TADB-04-04-002 a - 90 to 110 °

Securely support the raised machine dCAUTION: using blocks.

4. Maintain the hydraulic oil temperature at 50±5 °C (122±9 °F).

Measurement: 1. Measure on both tracks at slow and fast travel modes during forward and reverse travel.

2. Select the following conditions.

Travel Mode Engine Switch Control Dial

Power Mode Auto-Idle Switch

Slow Mode

Fast Idle

PWR

OFF

Fast Mode

Fast Idle

PWR

OFF

3. Operate the travel control lever of the track to be measured to full stroke.

4. Measure the time required for 3 revolutions after a constant track revolution speed is obtained.

5. Repeat the measurement three times and calculate the mean values.

Evaluation: Refer to Operational Performance Standard.

NOTE: The measurement data obtained through the raised track revolution test may have wide variations.

Therefore, the evaluation based on the results obtained from the 20 m (65.6 ft) travel speed check described before is more recommendable.

f

Remedy: Refer to Troubleshooting B.

T4-4-2

SECTION 4 OPERATIONAL PERFORMANCE TEST Group 4 Machine Performance Test Mistrack Check Summary: 1. Allow the machine to travel 20 m (65.6 ft). Measure the maximum tread deviation from the tread chord drawn between the travel start and end points and check the performance of travel device systems (from main pump to travel motor).

2. If measured on a concrete surface, the tread deviation has a trend to decrease.

Preparation: 1. Adjust the track sag of both tracks equally.

a

2. Provide a flat, solid test yard 20 m (65.6 ft) in length, with extra length of 3 to 5 m (10 to 16 ft) on both ends for machine acceleration and deceleration.

3. With the arm and bucket cylinders fully extended, hold the bucket 0.3 to 0.5 m (8 to 12 in) above the ground.

c

a - Maximum Distance b - Acceleration Zone: 3 to 5 m (10 to 16 ft)

4. Maintain the hydraulic oil temperature at 50±5 °C (122±9 °F).

Measurement: 1. Measure in both fast and slow travel modes.

2. Select the following conditions.

Travel Mode Engine Switch Control Dial

Power Mode Auto-Idle Switch

Slow Mode

Fast Idle

PWR

OFF

Fast Mode

Fast Idle

PWR

OFF

b TADB-04-04-003

3. Start traveling the machine in the acceleration zone with the travel levers to full stroke.

4. Measure maximum distance between a straight 20 m (65.6 ft) tread chord and the tread made by the machine.

5. After measuring the tracking in forward travel, turn the upperstructure 180° and measure in reverse travel.

6. Repeat the measurement three times and calculate the mean values.

Evaluation: Refer to Operational Performance Standard.

Remedy: Refer to Troubleshooting B.

T4-4-3

c - 20 m (65.6 ft)

SECTION 4 OPERATIONAL PERFORMANCE TEST Group 4 Machine Performance Test Travel Parking Leakage Summary: 1. Measure the parking brake function on a specified slope.

Preparation: 1. Measure on a flat slope with a gradient of 20 % (11.31°).

2. With the arm and bucket cylinders fully extended, hold the bucket 0.2 to 0.3 m (8 to 12 in) above the ground.

a

3. Maintain the hydraulic oil temperature at 50±5 °C (122±9 °F).

TADB-04-04-004 a - 0.2 to 0.3 m (8 to 12 in)

Measurement: 1. Measure the travel parking brake slip amount while parked.

2. Climb the slope and set the travel lever in neutral.

3. Stop the engine.

4. After the machine stops, put the matching marks on track link or shoe, and the track side frame.

5. After 3 minutes, measure the distance between marks on the track link or the shoe and the track frame.

Evaluation: Refer to Operational Performance Standard.

b T505-06-03-005 b - Displacement measured after 3 minutes.

T4-4-4

SECTION 4 OPERATIONAL PERFORMANCE TEST Group 4 Machine Performance Test Swing Speed Summary: 1. Measure the time required to swing three complete turns and check the performance of the swing device systems (from main pump to swing motor).

Preparation: 1. Check lubrication of the swing gear and the swing bearing.

2. Place the machine on flat and solid ground with ample space for swinging. Do not conduct this test on a slope.

a

3. Fully retract the arm cylinder. Fully extend the bucket cylinder. Hold the boom so that the arm end pin height is the same as the boom foot pin height.

Empty the bucket.

TADB-04-05-007 a - The height as boom foot pin height

fNOTE:

In case a sufficient space for the measurement is difficult to find, carry out the measurement with the boom fully raised and the arm fully rolled-in.

4. Maintain the hydraulic oil temperature at 50±5 °C (122±9 °F).

Prevent personal injury. Always make dCAUTION: sure that the area is clear and that coworkers are out of the swing area before starting the measurement.

Measurement: 1. Select the following conditions.

Engine Control Dial

Power Mode

Auto-Idle Switch

Fast Idle

PWR

OFF

2. Operate the swing control lever fully.

3. Measure the time required to swing 3 turns in one direction.

TADB-04-04-018

4. Check in both clockwise and counterclockwise directions.

5. Repeat the measurement three times and calculate the mean values.

Evaluation: Refer to Operational Performance Standard.

Remedy: Refer to Troubleshooting B.

T4-4-5

SECTION 4 OPERATIONAL PERFORMANCE TEST Group 4 Machine Performance Test Swing Function Drift Check Summary: 1. Measure the swing drift on the swing bearing outer circumference when stopping after a 90° full-speed swing and check the performance of the swing brake valve.

a

2. The mechanical brake for the swing parking brake is equipped for the swing motor.

Preparation:

TADB-04-04-015

1. Check lubrication of the swing gear and the swing bearing.

2. Place the machine on the flat and solid ground with ample space for swinging. Do not conduct this test on a slope.

a - Put the matching marks on swing bearing outer circumference and track

frame.

3. With the arm cylinder fully retracted and the bucket cylinder fully extended, hold the bucket so that height of the arm end pin is the same as the boom foot pin. Empty the bucket. b

4. Put the matching marks on the swing bearing outer circumference (upperstructure side) and the track frame.

5. Swing the upperstructure 90°.

TADB-04-04-016

6. Maintain the hydraulic oil temperature at 50±5 °C (122±9 °F).

Prevent personal injury. Always make dCAUTION: sure that the area is clear and that coworkers

b - Before starting the measurement, swing the upperstructure 90°.

are out of the swing area before starting the measurement.

T4-4-6

SECTION 4 OPERATIONAL PERFORMANCE TEST Group 4 Machine Performance Test Measurement: 1. Select the following conditions.

Engine Control Dial

Power Mode

Fast Idle

PWR

Auto-Idle Switch a

OFF

2. Operate the swing control lever fully and return it to the neutral position when the mark on upperstructure aligns with that on track frame after swinging the upperstructure 90°.

b

3. Measure the distance between the two marks.

c

4. Check in both clockwise and counterclockwise directions.

5. Repeat the measurement three times and calculate the mean values.

T105-06-03-010 a - Measure difference between marks. b - Mark on Track Frame

Evaluation: Refer to Operational Performance Standard.

Remedy: Refer to Troubleshooting B.

T4-4-7

c - Mark on Swing Bearing

SECTION 4 OPERATIONAL PERFORMANCE TEST Group 4 Machine Performance Test Swing Motor Leakage Summary: 1. Measure the upperstructure drift while suspending a load on a specified slope and check the performance of the swing parking brake.

(The mechanical brake for the swing parking brake is equipped for the swing device.)

Preparation: 1. Check lubrication of the swing gear and the swing bearing.

2. Load the bucket with either soil or a weight equivalent to the weight standard.

Weight:165 kg (365 lb) 3. With the arm cylinder fully retracted and the bucket cylinder fully extended, hold the bucket so that height of the arm end pin is the same as the boom foot pin.

4. Park the machine on a smooth slope with a gradient of 26.8 % (15°).

5. Climb a slope and swing the upperstructure to position it 90° to the slope. Put the matching marks on the outer circumference of the swing bearing (upperstructure side) and track frame by using the tape.

6. Maintain the hydraulic oil temperature at 50±5 °C (122±9 °F).

T4-4-8

TADB-04-04-006

SECTION 4 OPERATIONAL PERFORMANCE TEST Group 4 Machine Performance Test Measurement: 1. Select the following conditions.

Power Mode

Auto-Idle Switch

PWR

OFF

a

2. Maintain the engine at slow idle. After five minutes, measure the difference between the marks on the swing bearing outer circumference and the track frame.

b

3. Measure the difference respectively when the brake is applied (pilot shut-off lever: LOCK position) and when the brake is released (pilot shut-off lever: UNLOCK position).

4. Check in both clockwise and counterclockwise directions.

c T105-06-03-010 a - Measure difference between marks. b - Mark on Track Frame

5. Repeat the measurement three times and calculate the mean values.

Evaluation: Refer to Operational Performance Standard.

Remedy: Refer to Troubleshooting B.

T4-4-9

c - Mark on Swing Bearing

SECTION 4 OPERATIONAL PERFORMANCE TEST Group 4 Machine Performance Test Maximum Swingable Slant Angle Summary: 1. With the upperstructure swung 90° to the slope, check the maximum slant angle on which the upperstructure can swing to the uphill side.

Preparation: 1. Check lubrication of the swing gear and the swing bearing.

2. Load the bucket with either soil or a weight equivalent to the weight standard.

Weight:165 kg (365 lb) 3. With the arm cylinder fully retracted and the bucket cylinder fully extended, hold the bucket so that height of the arm end pin is the same as the boom foot pin.

4. Climb a slope and swing the upperstructure 90° to the slope.

5. Maintain the hydraulic oil temperature at 50±5 °C (122±9 °F).

T4-4-10

TADB-04-04-006

SECTION 4 OPERATIONAL PERFORMANCE TEST Group 4 Machine Performance Test Measurement: 1. Select the following conditions.

Engine Control Dial

Power Mode

Auto-Idle Switch

Fast Idle

PWR

OFF

2. Operate the swing control lever to full stroke to swing the upperstructure to the uphill side.

3. If the machine can swing, measure the cab floor slant angle.

4. When the machine can swing, increase the slant angle. Check in both clockwise and counterclockwise directions.

5. Repeat the measurement three times.

Evaluation: Refer to Operational Performance Standard.

Remedy: Refer to Troubleshooting B.

T4-4-11

SECTION 4 OPERATIONAL PERFORMANCE TEST Group 4 Machine Performance Test Swing Bearing Play Summary: 1. Measure the swing bearing play and check the wear of the swing bearing races and the balls.

Preparation 1. Check the swing bearing mounting bolts for looseness.

1 1-

2. Check lubrication of the swing bearing. Confirm that bearing rotation is smooth without noise.

Magnetic Base

2 2-

T105-06-03-014

Dial Gauge

3. Secure dial gauge (2) on round trunk (3) of the track frame by using magnetic base (1).

4. Position the upperstructure so that the boom aligns with the tracks facing towards the front idlers.

5. Position dial gauge (2) so that its needle point comes into contact with the bottom surface of the swing bearing outer race.

3

6. The bucket should be empty.

fNOTE:

The measured value will vary depending on where magnetic base (1) is secured. Secure magnet base (1) onto round trunk (3) or in a position as close to the swing bearing as possible.

T105-06-03-015 3-

T4-4-12

Round Trunk

SECTION 4 OPERATIONAL PERFORMANCE TEST Group 4 Machine Performance Test Measurement: 1. With the arm cylinder fully retracted and the bucket cylinder fully extended, hold the bucket at the height as boom foot pin height. Record dial gauge reading (h1).

a

TADB-04-05-007

2. Lower the bucket to the ground and raise the front idler 0.5 m (20 in) by using the front attachment.

Record dial gauge (2) reading (h2).

a - The height as boom foot pin height

3. Calculate bearing play (H) from these data (h1 and h2) as follows: H=h2-h1 Evaluation: Refer to Operational Performance Standard.

b TADB-04-04-019 b-

T4-4-13

0.5 m (20 in)

SECTION 4 OPERATIONAL PERFORMANCE TEST Group 4 Machine Performance Test Hydraulic Cylinder Cycle Time Summary: 1. Measure the cycle time of boom, arm and bucket cylinders and check the performance of the front attachment systems (from main pump to each cylinder).

2. The bucket should be empty.

Preparation: 1. Measurement is made for the following positions.  Measurement of the cycle time of the boom cylinder: With the bucket cylinder fully extended and the arm cylinder fully retracted, lower the bucket onto the ground.

TADB-04-04-008

 Measurement of the cycle time of the arm cylinder: With the bucket cylinder fully extended, adjust the boom height so that the arm oscillation center faces vertically to the ground while holding the bucket bottom height at approx. 0.5 m (20 in) above the ground.

 Measurement of the cycle time of the bucket cylinder: Adjust the boom and arm cylinders so that the bucket oscillation center faces vertically to the ground.

a TADB-04-04-009 a - 0.5 m (20 in)

T105-06-03-020

T4-4-14

SECTION 4 OPERATIONAL PERFORMANCE TEST Group 4 Machine Performance Test  Measurement of the cycle time of the boom swing cylinder: Set the boom swing cylinder in either the right or left swing stroke end position.  Measurement of the cycle time of the blade cylinder: Raise the machine by using the front attachment in order to be able to move the blade cylinder to fully stroke.

2. Maintain the hydraulic oil temperature at 50±5 °C (122±9 °F).

TADB-04-04-010

TADB-04-04-019

T4-4-15

SECTION 4 OPERATIONAL PERFORMANCE TEST Group 4 Machine Performance Test Measurement: 1. Select the following conditions.

Engine Control Dial Fast Idle

Power Mode

Auto-Idle Switch

PWR

OFF

2. Measure the cylinder cycle times as follows:

(Cylinder full stroke includes cylinder cushioning zone.)

 Measurement of the cycle time of the boom cylinder: Operate the boom control lever to full stroke.

Measure the time to raise and lower the boom.  Measurement of the cycle time of the arm cylinder: Operate the arm control lever to full stroke. Measure the time to roll in and roll out the arm.  Measurement of the cycle time of the bucket cylinder: Operate the bucket control lever to full stroke.

Measure the time to roll in and roll out the bucket.  Measurement of the cycle time of the boom swing cylinder: Operate the boom swing pedal to full stroke.

Measure the time to swing the front attachment from right to left or vice versa.  Measurement of the cycle time of the blade cylinder: Operate the blade control lever to full stroke.

Measure the time to raise and lower the blade.

3. Repeat the measurement three times and calculate the mean values.

Evaluation: Refer to Operational Performance Standard.

Remedy: Refer to Troubleshooting B.

T4-4-16

SECTION 4 OPERATIONAL PERFORMANCE TEST Group 4 Machine Performance Test Dig Function Drift Check Summary: 1. Measure dig function drift, which can be caused by oil leakage in the control valve and boom, arm and bucket cylinders, with the bucket loaded.

b

a

2. When measuring the drift just after cylinder replacement, slowly operate the cylinder for ten minutes and bleed air from the cylinder.

a

Preparation: d

1. Load the bucket with either soil or a weight equivalent to the weight standard.

c

Weight:165 kg (365 lb) b

2. With the arm cylinder fully retracted and the bucket cylinder fully extended, hold the bucket so that height of the arm end pin is the same as the boom foot pin. Fully retract the blade cylinder.

a - Retracted Distance b - Extended Distance c - Dig Function Drift Amount

TADB-04-04-011 d - The height is the same as boom foot pin.

3. When measuring the boom swing cylinder, climb the slope with a gradient of 26.8 % (15°) and swing the upperstructure 90° to the slope.

4. Position the arm cylinder and the bucket cylinder with the rod 50 mm (2 in) away from the full stroke end position.

5. Maintain the hydraulic oil temperature at 50±5 °C (122±9 °F).

TADB-04-04-006

T4-4-17

SECTION 4 OPERATIONAL PERFORMANCE TEST Group 4 Machine Performance Test Measurement: 1. Stop the engine.

a

b

2. Five minutes after the engine has been stopped, measure the change in position of bottom of the bucket, as well as the boom, arm and bucket cylinders.

b

Boom and Bucket Cylinders: Retraction: a a=A-B Arm Cylinder: Extension: c

T110-06-03-002

c=B-A

a - Boom and Bucket Cylinders: Retraction

Blade Drift Amount: e

b - Mark

e=A-B 3. When measuring the boom swing cylinder, measure the boom swing cylinder retraction and extension in left and right direction to the slope.

c

4. Repeat the measurement three times and calculate the mean values.

d

Evaluation: Refer to Operational Performance Standard.

Remedy: Refer to Troubleshooting B. T110-06-03-001 c - Arm Cylinder: Extension

d - Mark

e

A

B

e - Blade Drift Amount

TDAD-04-04-001

f

f -

T4-4-18

Boom Swing Cylinder: Extension and Retraction

T506-06-03-001

SECTION 4 OPERATIONAL PERFORMANCE TEST Group 4 Machine Performance Test Control Lever Operating Force Summary: 1. Measure a play and operating condition of each control lever.

2. Measure the maximum operating force of the front attachment control lever.

3. Measure the lever stroke at the grip center of each control lever.

T107-06-03-003

Preparation: 1. Maintain the hydraulic oil temperature at 50±5 °C (122±9 °F).

Prevent personal injury. Always make dCAUTION: sure that the area is clear and that coworkers are out of the swing area before starting the measurement.

Measurement: 1. Measure the force of each control lever.

T107-06-03-004

2. Select the following conditions.

Engine Control Dial

Power Mode

Auto-Idle Switch

Fast Idle

PWR

OFF

3. In case of boom (raise), arm, and bucket control lever, measure the maximum operating force for each with each actuator relieved.

4. In case of boom (lower) control lever, measure the maximum operating force with the boom (lower) relieved by raising the machine in a stable area.

5. In case of swing control lever, measure the maximum operating force with swing relieved after securing the front attachment to prevent turning.

6. In case of travel control lever, raise the track to be measured. Measure the maximum operating force required.

7. Repeat the measurement three times and calculate the mean values.

Evaluation: Refer to Operational Performance Standard.

T4-4-19

SECTION 4 OPERATIONAL PERFORMANCE TEST Group 4 Machine Performance Test Control Lever Stroke Summary: 1. Check play and operating condition and measure each control lever stroke.

2. Measure the lever stroke at the grip center of each control lever. As for the boom swing pedal, measure the stroke from the center position to the stopper.

3. In case lever stroke play is present in the neutral position, add half (1/2) the play present to both side lever strokes.

Preparation:

T107-06-03-005

1. Maintain the hydraulic oil temperature at 50±5 °C (122±9 °F).

Blade Control Lever

Measurement: 1. Stop the engine.

2. Measure each lever stroke from neutral to the stroke end of each control lever of boom, arm, bucket, swing, travel, and blade.

3. As for the boom swing pedal, measure the straight distance between the center and fully depressed positions at tip of the pedal.

4. Measure the chord length from neutral to the stroke end.

5. Repeat the measurement three times and calculate the mean values.

Evaluation: Refer to Operational Performance Standard.

T4-4-20

TADB-04-04-017

SECTION 4 OPERATIONAL PERFORMANCE TEST Group 4 Machine Performance Test Combined Operation of Boom Raise / Swing Function Check Summary: 1. Check boom raise and swing movement and speeds while operating both functions simultaneously.

2. Check if the cylinders do not hesitate while operating the cylinder with the engine running at fast idle.

TADB-04-04-012

Preparation: 1. With the arm cylinder fully retracted and the bucket cylinder fully extended, lower the bucket onto the ground. Lower the bucket onto the ground. Empty the bucket.

2. Maintain the hydraulic oil temperature at 50±5 °C (122±9 °F).

Prevent personal injury. Always make dCAUTION: sure that the area is clear and that coworkers are out of the swing area before starting the measurement.

TADB-04-04-013

Measurement: 1. Select the following conditions.

Engine Control Dial

Power Mode

Auto-Idle Switch

Fast Idle

PWR

OFF

H

2. Raise the boom and swing the upperstructure in full stroke at the same time. Measure the time required to swing the upperstructure 90° and height (H) of the bucket teeth. (The bucket should be empty.)

3. Repeat the measurement three times and calculate the mean values.

T107-06-03-011

Evaluation: Refer to Operational Performance Standard.

Remedy: Refer to Troubleshooting B.

T4-4-21

SECTION 4 OPERATIONAL PERFORMANCE TEST Group 4 Machine Performance Test Clearance of Front Attachment Connecting Part

1

2

Summary: 1. Measure the clearance of pin and pin hole, and check the clearance of pins bushings in each connecting part of swing post (5), boom (1), and arm (6).

Preparation: 1. Secure dial gauge (3) on the side surface of boom (1) or arm (6) by using magnetic base (2).

5

2. Position the upperstructure so that the boom aligns with the tracks facing towards the front idlers.

1- 2- 3-

Boom Magnetic Base Dial Gauge

3. Position dial gauge (3) so that needle point (4) comes into contact with the upper surface of swing post (5) or the arm (6) connecting part of boom (1) tip.

4 4- 5-

1

3

TDCK-04-04-001

Needle Point Swing post

3

4 6

Measurement: 1. Set arm (6) so that the center of arm (6) operation is vertical. Hold the bucket 50 mm (1.97 in) above the ground. Record reading (h1) of dial gauge (3).

2. Rraise the front idler with arm (6) set in vertical position. Raise the machine 50 mm (1.97 in) as illustrated. Record reading (h2) of dial gauge (3).

2

3. Calculate clearance (H) from these data (h1 and h2) as follows:

H=h2-h1

1 - Boom 2 - Magnetic Base 3 - Dial Gauge

TDCK-04-04-002

4 - Needle Point 6 - Arm

Measurement of (h1)

Evaluation: Refer to Operational Performance Standard.

a TADB-04-04-020

a - 50 mm (1.97 in) Measurement of (h2)

a a - 50 mm (1.97 in)

T4-4-22

TADB-04-04-021

SECTION 4 OPERATIONAL PERFORMANCE TEST Group 5 Component Test Primary Pilot Pressure Preparation: 1. Stop the engine.

2. Slowly loosen the cap of the hydraulic oil tank and bleed air.

3. Remove hose (9/16-18UNF) (3) at the pilot filter (4) connection part. Install the tee (ST 6450), the adapter (ST 6069), and the pressure gauge assembly (ST 6932) to the pressure check port.

1

2

j : 19 mm 4. Start the engine. Confirm that no oil leakage is observed at the pressure gauge connection.

5. Maintain the hydraulic oil temperature at 50±5 °C (122±9 °F) Measurement:

T1M7-04-05-001

1. Select the following conditions: Engine Control Dial Fast Idle

Power Mode PWR

OFF

Slow Idle

PWR

OFF

4

Auto-Idle Switch 1- 2-

2. Measure pilot pressure in each specified setting above without load.

3. Repeat each measurement three times and calculate the mean values.

Evaluation: Refer to Operational Performance Standard.

T4-5-1

Control Valve Pump Device

3- 4-

3 Hose (9/16-18UNF) Pilot Filter

SECTION 4 OPERATIONAL PERFORMANCE TEST Group 5 Component Test Primary Pilot Pressure Adjustment Procedure Adjustment: Adjust the relief valve set pressure of 2-spool solenoid valve if necessary.

1. Loosen lock nut (1). j : 17 mm 2. Turn adjusting screw (2) in order to adjust pressure. l : 6 mm 3. Tighten lock nut (1). j : 17 mm m : 15 to 20 N·m (1.5 to 2.0 kgf·m, 11 to 15 lbf·ft) 4. After adjustment, check the set pressures.

fNOTE:

Standard Change in Pressure (Reference)

Adjusting Screw Turns 1/4 kPa 182 Change in (kgf/cm2) (1.85) Pressure (psi) (26)

1/2 363

3/4 545

1 726

(3.70)

(5.55)

(7.40)

(53)

(79)

(105)

1

1-

T4-5-2

Lock Nut

2

TADB-03-06-003 2-

Adjusting Screw

SECTION 4 OPERATIONAL PERFORMANCE TEST Group 5 Component Test Secondary Pilot Pressure Preparation: 1. Stop the engine.

2. Slowly loosen the cap of the hydraulic oil tank and bleed air.

3. Install tee (5) (ST 6450), adapter (7) (ST 6069), and pressure gauge (6) (ST 6942) to the pilot port for spool operation in the circuit to be measured. j : 19 mm 4. Start the engine. Confirm that no oil leakage is observed at the pressure gauge (6) connection.

5. Maintain the hydraulic oil temperature at 50±5 °C (122±9 °F).

Measurement: Always make sure that the area is dCAUTION: clear and that co-workers are out of the swing area

5

6

7

before starting the measurement.

When measuring the boom lower secondary pilot pressure, the machine should be raised off the ground. Do not allow the machine to come in contact with the ground, and lay down the machine as the machine become unbalanced.

1. Select the following conditions:

Engine Control Dial Fast Idle

Power Mode

Auto-Idle Switch

PWR

OFF

Slow Idle

PWR

OFF

5- 6-

2. Measure pilot pressure by using pressure gauge (6) with the corresponding control lever operated to full stroke.

3. Repeat each measurement three times and calculate the mean values.

Evaluation: Refer to Operational Performance Standard.

Remedy: Refer to Troubleshooting B.

T4-5-3

Tee Pressure Gauge

7-

Adapter

SECTION 4 OPERATIONAL PERFORMANCE TEST Group 5 Component Test Main Relief Set Pressure Main Circuit

2

1

3

Summary: Measure the main relief valve set pressure at the delivery port in main pump.

4

Preparation: 1. Stop the engine.

2. Slowly loosen the cap of the hydraulic oil tank and bleed air.

3. Remove plug (2) from the port to be measured.

Install the adapter (ST 6069) and the pressure gauge assembly (ST 6933). j : 19 mm 4. Start the engine. Confirm that no oil leakage is observed at the pressure gauge connection.

T1MJ-04-05-001 1- 2-

5. Maintain the hydraulic oil temperature at 50±5 °C (122±9 °F).

T4-5-4

Port P2 Plug

3- 4-

Port P1 Port P3

SECTION 4 OPERATIONAL PERFORMANCE TEST Group 5 Component Test Measurement: 1

1. Select the following conditions: Engine Control Dial Fast Idle

Power Mode

Auto-Idle Switch

PWR

OFF

2. Operate control levers and pedals slowly to the stroke end and relieve the pressure.

3. When measuring main relief valve (P1) (2), operate the arm control lever and relieve the pressure.

4. When measuring main relief valve (P2) (1), operate the bucket control lever and relieve the pressure.

5. When measuring main relief valve (P3) (3), operate the blade control lever and relieve the pressure.

6. When measuring main relief valves (P1) (2) and (P2) (1) at the same time, operate the arm and bucket control levers and relieve the pressure.

7. When measuring main relief valves (P1) (2), (P2) (1), and (P3) (3) at the same time, operate the arm, bucket, and blade control levers and relieve the pressure.

3 1- 2-

8. As for the swing, secure the upperstructure so it is immovable. Slowly operate the swing control lever and relieve the pressure. Measure the relief pressure of swing by using the pressure gauge in main pump P3.

9. As for the travel, secure the tracks against an immovable object. Slowly operate the travel control lever and relieve the pressure.

10. Repeat each measurement three times and calculate the mean values.

Evaluation: Refer to Operational Performance Standard.

T4-5-5

Main Relief Valve (P2) Main Relief Valve (P1)

2 3-

TADB-04-05-001

Main Relief Valve (P3)

SECTION 4 OPERATIONAL PERFORMANCE TEST Group 5 Component Test Adjustment: Adjust the main relief valve set pressure if necessary.

The main relief valves are installed on the position as illustrated.

1. Loosen lock nut (4).

1

j : 17 mm IMPORTANT: Adjust the pressure so that the pressure does not exceed the upper limit of standard.

2. Turn adjusting screw (5) in order to adjust pressure. l : 6 mm 3. Tighten lock nut (4). j : 17 mm m : 28 to 32 N·m (2.8 to 3.2 kgf·m, 20.5 to 23.5 lbf·ft) 4. After adjustment, check the set pressures.

fNOTE:

3

2

TADB-04-05-001

Standard Change in Pressure (Reference)

4

Adjusting Screw Turns 1/4 1/2 3/4 1 MPa 4.45 8.9 13.35 17.8 Change in (kgf/cm2) (45.4) (91) (136) (182) Pressure (psi) (645) (1290) (1940) (2580)

5

TADB-04-05-002

4

5

a

b

a - Pressure Increase

b - Pressure Decrease T505-06-04-007

1- 2- 3-

4- 5-

T4-5-6

Main Relief Valve (P2) Main Relief Valve (P1) Main Relief Valve (P3)

Lock Nut Adjusting Screw

SECTION 4 OPERATIONAL PERFORMANCE TEST Group 5 Component Test Relief Pressure (when relieving swing) Adjustment: 1. Loosen lock nut (3).

1

1

j : 17 mm 2. Turn adjusting screw (2) in order to adjust pressure. l : 4 mm 3. Tighten lock nut (3). j : 17 mm m : 16±1 N·m(1.6±0.1 kgf·m, 12±0.7 lbf·ft) 4. After adjustment, check the set pressures.

fNOTE:

Standard Change in Pressure (Reference)

Adjusting Screw (2) Turns 1/4 MPa 2.45 Change in 2 (kgf/cm ) (25) Pressure (psi) (355)

1/2 4.9

3/4 7.4

1 9.8

(50)

(75)

(100)

(710) (1070) (1420)

TADB-04-05-003

3 2

TADB-04-05-006

2

a

b

W107-02-05-129 a - Pressure Increase

b - Pressure Decrease

1- 2-

3-

T4-5-7

Swing Relief Valve Adjusting Screw

Lock Nut

SECTION 4 OPERATIONAL PERFORMANCE TEST Group 5 Component Test Overload Relief Valve Set Pressure Summary: 1. The circuit pressure must be increased by applying an external force while blocking the return circuit from the control valve. This measuring method is hazardous and the results obtained with this method are unreliable.

2. The oil flow rate used to set the overload relief pressure is far less than that used to set the main relief pressure. Therefore, measuring the overload pressure in the main circuit by increasing the main relief set pressure more than the overload valve setpressure is not a proper method. In addition, main relief valve may be designed to leak a small quantity of oil before reliving. In this case, its pre-leaking start pressure must be increased more than the overload relief valve set pressure.

However, the pre-leaking start pressure is not always increased more than the overload relief valve set-pressure as the adjustable upper limit of the main relief valve set-pressure is provided.

Accordingly, the overload relief valve assembly should be removed from the machine and checked on a specified test stand at a correct oil flow rate.

Some overload relief valves come in contact with the control valve body to block the oil passage.

When this type of overload relief valve is checked, the control valve body must be precisely finished as the test unit. Provide one control valve other than that on the machine as a test kit.

3. If the overload relief valve performance must be checked on the machine, however, measure the main relief pressure while releasing each front function respective to the measuring overload relief valve. And, assume that the overload relief valve is functioning correctly if the obtained main relief pressure is within the specified value range.

T4-5-8

SECTION 4 OPERATIONAL PERFORMANCE TEST Group 5 Component Test Overload Relief Valve Pressure Adjustment Procedure

fNOTE:

In principle, adjust the overload relief valve pressure on a test stand.

1

2

Loosen lock nut (7) and adjust pressure by using adjusting screw (8).

1. Loosen lock nut (7). j : 17 mm 2. Turn adjusting screw (8) in order to adjust pressure. l : 6 mm 3. Tighten lock nut (7). j : 17 mm m : 28 to 32 N·m (2.8 to 3.2 kgf·m, 20.5 to 23.5 lbf·ft)

6

5

4. After adjustment, check the set pressures.

fNOTE:

4

3

TADB-04-05-001

7 8

Standard Change in Pressure (Reference)

Adjusting Screw (8) 1/4 1/2 3/4 1 Turns MPa 7.1 14.2 21.3 28.4 Change in 2 (kgf/cm ) (72) (145) (217) (290) Pressure (psi) (1030) (2060) (3090) (4120)

TADB-04-05-004

7

8

a

b

a - Pressure Increase

b - Pressure Decrease T505-06-04-007

1-

5-

2- 3- 4-

T4-5-9

Overload Relief Valve (Arm: Rod Side) Overload Relief Valve (Bucket: Rod Side) Overload Relief Valve (Bucket: Bottom Side) Overload Relief Valve (Boom: Rod Side)

6- 7- 8-

Overload Relief Valve (Boom: Bottom Side) Overload Relief Valve (Arm: Bottom Side) Lock Nut Adjusting Screw

SECTION 4 OPERATIONAL PERFORMANCE TEST Group 5 Component Test Pump Driving Torque Summary: The adjustment of pump driving torque is not recommended. If the adjustment of pump driving torque is necessary, perform the following procedures.

However, do not increase the torque.

1

Adjustment: 1. Loosen lock nut (2). j : 13 mm

T575-04-04-003

2. Turn adjusting screw (1) in order to adjust pressure. l : 4 mm 3. Tighten lock nut (2).

fNOTE:

2

Replace the washer of lock nut (2) after every adjustment. If not, oil leaks may occur.

1

j : 13 mm m : 10 to 14 N·m (1 to 1.4 kgf·m, 7.4 to 10 lbf·ft)

fNOTE:

a

Standard Change in Pressure (Reference)

Adjusting Screw (1) Turns 1/4 kPa 123 Change in Pressure (kgf/cm2) (1.25) (difference (18) from point A) (psi)

1/2 245

3/4 368

1 490

(2.5)

(3.75)

(5)

(36)

(53)

(71)

TABA50-04-05-005 A c

a

b a - Torque Decrease b - Pressure ((P1 + P2)/2)

c - Flow Rate (Q1 = Q2)

1-

2-

T4-5-10

Adjusting Screw

Lock Nut

SECTION 4 OPERATIONAL PERFORMANCE TEST Group 5 Component Test Swing Motor Drainage a

Summary: 1. Measure amount of oil draining from the swing motor while swinging the upperstructure and check the swing motor performance.

2. Secure absolute safety for the measuring persons as well as for the surrounding while measuring.

3. The amount of drain oil from the swing motor will change depending on hydraulic oil temperature.

Preparation: 1. Maintain the hydraulic oil temperature at 50±5 °C (122±9 °F). Rotate the swing motor and warm inside of the motor.

2. Stop the engine. Slowly loosen the cap of the hydraulic oil tank and bleed air.

3. Disconnect the drain hose of swing motor at the motor end. Install the plug (7/16-20UNF) to the disconnected hose. Connect the hose to drain port (a) of the swing motor.

TADB-04-05-003

j : 17, 22 mm

a-

m : 40 N·m (4 kgf·m, 29.5 lbf·ft) Preconditions for Measurement: 1. Select the following conditions: Engine Control Dial Fast Idle

Power Mode

Auto-Idle Switch

PWR

OFF

T4-5-11

Drain Port

SECTION 4 OPERATIONAL PERFORMANCE TEST Group 5 Component Test Measurement: Always make sure that the area is dCAUTION: clear and that co-workers are out of the swing area before starting the measurement. Also, take care not to fall off the machine while the measuring.

 Amount of Oil Drained While Swinging the Upperstructure 1. Fully retract the arm cylinder. Fully extend the bucket cylinder. Hold the boom so that the arm tip pin height is the same as the boom foot pin height.

The bucket must be empty.

2. Start the engine. Operate and hold the swing lever full stroke. After the swing speed reaches a constant maximum speed, start draining oil measurement when drain oil starts coming out of the drain hose end.

3. Repeat the measurement at least three times in both clockwise and counterclockwise directions, and calculate the mean values.

a

TADB-04-05-007 a - The same height as boom foot pin height

4. The measuring time should be more than 45 seconds.  Amount of Oil Drained While Relieving Swing Motor Circuit 1. Thrust the bucket teeth into the ground so that the upperstructure does not rotate.

2. Start the engine. Operate and hold the swing lever full stroke. Start draining oil measurement when drain oil starts coming out of the drain hose end.

3. Repeat the measurement at least three times in both clockwise and counterclockwise directions, and calculate the mean values.

4. The measuring time should be more than 45 seconds.

Evaluation: Refer to Operational Performance Standard. * Conversion of amount of drain oil measured into the per-minute value First measure amount of drain oil using a calibrated container. Then, convert the measured drain oil into the per-minute value using the formula below: ∆Q =60×q/t ∆Q : Amount of drain oil per minute (L/min) t : Measured time (seconds) q : Total amount of drain oil (L)

T4-5-12

SECTION 4 OPERATIONAL PERFORMANCE TEST Group 5 Component Test Travel Motor Drainage Summary: 1. While rotating the travel motor with the track to be measured jacked up, measure amount of oil draining from the travel motor and check travel motor performance.

2. Secure absolute safety for the measuring persons as well as for the surrounding while measuring.

3. Judge travel motor performance from the results including travel speed, mistrack and so on overall.

4. The amount of drain oil from the travel motor will change depending on hydraulic oil temperature.

Preparation: 1. Maintain the hydraulic oil temperature at 50±5 °C (122±9 °F). Rotate the travel motor and warm inside of the motor.

1

2. Stop the engine. Slowly loosen the cap of the hydraulic oil tank and bleed air.

3. Disconnect drain hose (1) of the travel motor at the travel motor end. Install the plug (9/16UNF-ORS) to the disconnected hose.

Connect the drain hose (9/16-18UNF-ORF) to the drain port of travel motor. j : 19 mm m : 45 N·m (4.5 kgf·m, 33 lbf·ft) Preconditions for Measurement: 1. Select the following conditions: Engine Control Dial Fast Idle

Power Mode

T571-04-04-004

Auto-Idle Switch 1-

PWR

OFF

T4-5-13

Drain Hose

SECTION 4 OPERATIONAL PERFORMANCE TEST Group 5 Component Test Measurement: When working around moving parts dCAUTION: is unavoidable, pay special attention to ensure that hands, feet, and clothing do not become entangled. Securely support the raised track by using the blocks.

a

1. Start the engine. Jack up the track to be measured.

2. Rotate the track to be measured. Start drain oil measurement when drain oil starts coming out of the drain hose (1) end.

3. Repeat the measurement at least three times in both forward and reverse directions, and calculate the mean values.

TADB-04-04-002 a - 90 to 110 º

4. The measuring time should be more than 45 seconds.

1

Evaluation: Refer to Operational Performance Standard.

Conversion of amount of drain oil measured into the per-minute value

First measure amount of drain oil using a calibrated container. Then, convert the measured drain oil into the per-minute value using the formula below: ∆Q =60×q/t ∆Q : Amount of drain oil per minute (L/min) t : Measured time (seconds) q : Total amount of drain oil (L)

TADB-04-05-005 1-

T4-5-14

Drain Hose

MEMO

MEMO

SECTION 5

TROUBLESHOOTING CONTENTS Group 1 Diagnosing Procedure

Introduction........................................................................... T5-1-1 Diagnosis Procedure........................................................... T5-1-2 Electric System Inspection................................................ T5-1-5 Precautions for Inspection and Maintenance .......... T5-1-6 Instructions for Disconnecting Connectors............... T5-1-8 Fuse Inspection...................................................................T5-1-10 Slow Blow Fuse Inspection.............................................T5-1-12 Battery Voltage Check......................................................T5-1-13 Alternator Check................................................................T5-1-14 Continuity Check...............................................................T5-1-15 Voltage Inspection Method...........................................T5-1-16 Check by False Signal.......................................................T5-1-18

Group 5 Air Conditioner

Air Conditioner Troubleshooting................................... T5-5-1 Troubleshooting................................................................... T5-5-3 Work after Replacing Components.............................T5-5-14 Charge Air Conditioner with Refrigerant..................T5-5-15

Group 2 Monitor

Outline..................................................................................... T5-2-1 Operating Procedures of Service Menu....................... T5-2-2 Inspection of Fuel Gauge, Battery Voltage, Hour Meter, and Destination No. . .........................T5-2-19 Fuel Gauge and Coolant Temperature Gauge.........T5-2-20 Factory Setting....................................................................T5-2-21

Group 3 Troubleshooting A

Troubleshooting A (Base Machine Diagnosis

By Using Fault Codes) Procedure.............................. T5-3-1 Fault Code List....................................................................... T5-3-3 Fault Code W: 1304.............................................................. T5-3-4 Fault Code W: 1310.............................................................. T5-3-5 Fault Code W: 2304.............................................................. T5-3-7 Fault Code W: 2306.............................................................. T5-3-8 Fault Code W: 2307.............................................................. T5-3-9

Group 4 Troubleshooting B

Troubleshooting B (Machine Diagnosis by Using Troubleshooting Symptom) Procedure.................. T5-4-1 Engine System Troubleshooting.................................... T5-4-3 All Actuator System Troubleshooting.........................T5-4-10 Front Attachment System Troubleshooting.............T5-4-15 Swing System Troubleshooting....................................T5-4-20 Travel System Troubleshooting....................................T5-4-22 Blade System Troubleshooting.....................................T5-4-29 Boom Swing System Troubleshooting.......................T5-4-30 How to Lower Boom in Case of Emergency and When Engine Stops.....................................................T5-4-31

ADCT-5-1

(Blank)

ADCT-5-2

SECTION 5 TROUBLESHOOTING Group 1 Diagnosing Procedure Introduction Refer to the inspection and troubleshooting procedures after any machine trouble has occurred. The inspection and troubleshooting procedures are presented in an orderly fashion in this section to quickly find the cause of the machine trouble and solution.

The troubleshooting section in this manual consists of five groups; Diagnosing Procedure, Monitor, Troubleshooting A (base machine diagnosis by using fault codes), Troubleshooting B (base machine diagnosis starting with inspection of abnormal operational status), and air conditioner.  Diagnosing Procedure This group explains procedures of troubleshooting and precautions and/or information for the electrical system inspection.

Example: Fuse Inspection  Monitor This group contains the display screen of monitor and the operating procedures of service menu.

 Troubleshooting A (base machine diagnosis by using fault codes) Refer to these procedures if any fault codes are displayed when each controller is diagnosed by using the service menu of monitor.

IMPORTANT: The monitor controller receives and retains a record of the electrical signal system malfunction of engine controller in the form of fault codes by using the CAN communication. In addition, the self-diagnosing function records the electrical signal system malfunction in the form of fault codes.

Example: Fault Code 00276-02: Abnormal EEPROM in ECU (Checksum)  Troubleshooting B (base machine diagnosis starting with inspection of abnormal operational status) Refer to troubleshooting B for diagnosis by using trouble symptom.

Refer to these procedures when no fault codes are displayed after diagnosing the machine by using the service menu of monitor.

Example: Even if engine control dial is rotated, engine speed does not change.  Air Conditioner This group explains air conditioner system, troubleshooting, and charge air conditioner with refrigerant.

T5-1-1

SECTION 5 TROUBLESHOOTING Group 1 Diagnosing Procedure Diagnosis Procedure These six basic steps are essential for efficient troubleshooting: 1. Study the system  Study the machine's technical manuals.  Know the system and how it works, and what the construction, functions and specifications of the system components are.

(Construction and functions) 2. Ask the operator Before inspecting, get the full story of malfunctions from the operator below.  Operating condition: How is the machine being used? (Find out if the machine is being operated correctly.)  Trouble identification: When was the trouble noticed, and what type of work was the machine doing at that time?  Trouble symptom: What are the details of the trouble? Did the trouble slowly get worse, or did it appear suddenly for the first time?  Trouble history: Did the machine have any other troubles previously? If so, which parts were repaired before?

3. Inspect the machine Before starting the troubleshooting procedure, check the machine's daily maintenance points, as shown in the operator's manual.

Also, check the electrical system, including the batteries, as troubles in the electrical system such as low battery voltage, loose connections and blown fuses will result in malfunction of the controllers, causing total operational failure of the machine.

If troubleshooting is started without checking for blown fuses, a wrong diagnosis may result, wasting time. Check for blown fuses before troubleshooting.

Even if a fuse looks normal by visual inspection, a fine crack is difficult to find.

Always use a circuit tester when checking the fuses.

T107-07-01-001

T107-07-01-002

4. Operate the machine yourself Reproduce the trouble on the machine and make sure the actual phenomenon.

If the trouble cannot be confirmed, stop the engine and obtain further details of the malfunction from the operator. Also, check for any incomplete connections of the wire harnesses corresponding to the trouble.

T107-07-01-003

T5-1-2

SECTION 5 TROUBLESHOOTING Group 1 Diagnosing Procedure 5. Perform troubleshooting Do not disconnect harnesses or dCAUTION: hydraulic lines while the engine is running. The

machine may malfunction or pressurized oil may spout, possibly resulting in personal injury. Stop the engine before disconnecting harnesses or hydraulic lines.

Perform diagnosis by using the service menu of monitor.

In case any fault code has been displayed by diagnosis by using the service menu of monitor, check the cause of the trouble by referring to Troubleshooting A in this section. In case any fault code has been displayed by diagnosis by using the service menu of monitor, write the fault code. Delete the fault code once and retry self-diagnosis again. If the fault code is displayed again, check the cause of the trouble by referring to Troubleshooting A in this section. After the machine trouble has been corrected, the fault code (displayed by the service menu of monitor) will be deleted.

In case the fault code is not displayed, check operating condition of each component by referring to Troubleshooting B in this section and by using the service menu of monitor.

NOTE: Note that the fault codes displayed do not necessarily indicate machine trouble. The controller stores even temporary electrical malfunctions, such as a drop in battery output voltage or disconnection of the switches, sensors, etc., for inspections. For this reason, the "RETRIAL" is required to erase the accumulated fault codes from the controller memory and to confirm if any fault codes are indicated after the "RETRIAL".

f

T5-1-3

SECTION 5 TROUBLESHOOTING Group 1 Diagnosing Procedure 6. Trace possible causes Before reaching a conclusion, check the most suspect causes again.

Try to identify the actual cause of the trouble.

Based on your conclusion, make a plan for appropriate repairs to avoid consequent malfunctions.

T107-07-01-007

T5-1-4

SECTION 5 TROUBLESHOOTING Group 1 Diagnosing Procedure Electric System Inspection The precautions and information for the electrical system inspection are explained here. The electrical system inspection contains as follows.          

Precautions for Inspection and Maintenance Instructions for Disconnecting Connectors Fuse Inspection Fusible Link Inspection Battery Voltage Check Alternator Check Continuity Check Voltage and Current Measurement Check by False Signal Test Harness

T5-1-5

SECTION 5 TROUBLESHOOTING Group 1 Diagnosing Procedure Precautions for Inspection and Maintenance 1. Disconnect the power source.

Disconnect the harness from the negative terminal side in battery first when taking wire harnesses and connectors off for repair or replacement work.

Failure to do so can result in damage to the wire harnesses, fuses and fusible links and, in some cases, cause fire due to short circuiting. In addition, even when the key switch is turned OFF, the controller may be operated for a specified time. Therefore, disconnect the harness from the negative terminal side in battery after setting the key switch to the OFF position and waiting one minute or more.

2. Color coding of wire harnesses.

As for the color codes of wire harnesses in the electrical system, refer to the table. In cases on the design sheet where two colors are indicated for one wire, the left initial stands for base color, while the right initial stands for marking color.

Code Color Code Color

R Red Or Orange

W White Lg Light green

L Blue Br Brown

G Green P Pink

Y Yellow Gr Gray

B Black V Violet

fNOTE:  Code BW indicates a black base wire with white fineline marking.  Initials "O" and "Or" both stand for the color orange.  Wires with longitudinal stripes printed on them are not color coded. Do not confuse them with color coded wires.

T5-1-6

SECTION 5 TROUBLESHOOTING Group 1 Diagnosing Procedure 3. Precautions for connecting and disconnecting terminal connectors.  When disconnecting the harnesses, grasp them by their connectors. Do not pull on the wire itself. Release the lock first before attempting to separate connectors, if a lock is provided. (Refer to Instructions for Disconnecting Connector on T5-1-8.)  The water-resistant connectors keep water out.

If water enters them, water will not easily drain from them. When checking the water-resistant connectors, take extra care not to allow water to enter the connectors. In case water should enter the connectors, reconnect only after the connectors are thoroughly dried.  Before connecting the terminal connectors, check that no terminals are bent (3) or coming off. In addition, as most connectors are made of brass, check that no terminals are rusting (2).  When connecting terminal connectors provided with a lock, insert them together until the lock "clicks."  Pull the harness near the connector in order to check if it is correctly connected.

TDAA-05-08-002

1 2 3

4 TDAA-05-08-003 1- 2-

Correct Rust

3- 4-

Incorrect (Deformation) Incorrect (Deformation)

4. Precaution for using a circuit tester.  Before using a circuit tester, refer to the instructions in the circuit tester manual. Then, set the circuit tester to meet the object to be measured, voltage range and current polarity.  Before starting the connector test, always check the connector terminal numbers, referring to the circuit diagram. When the connector size is very small, and the standard probe size is too large to be used for testing, wind a fine piece of sharpened wire or a pin around the probe to make the test easier.  When checking the connector by using a circuit tester, insert a tester probe from the harness end of connector in order not to damage the terminal inside connector.

TDAA-05-08-004

T5-1-7

SECTION 5 TROUBLESHOOTING Group 1 Diagnosing Procedure Instructions for Disconnecting Connectors  Push, Unlock, and Separate Type  Connectors will not be easily separated even if the lock is pushed while being pulled.  The lock is located on female side connector (harness end side).

T107-04-05-002

 Raise Lock, Pull, and Separate Type

T107-04-05-003

T5-1-8

SECTION 5 TROUBLESHOOTING Group 1 Diagnosing Procedure (Blank)

T5-1-9

SECTION 5 TROUBLESHOOTING Group 1 Diagnosing Procedure Fuse Inspection Cracks in a fuse are so fine that it is very difficult or impossible to find by visual inspection. Use a circuit tester in order to correctly inspect fuse continuity. Use a circuit tester in order to correctly inspect fuse continuity by following the instructions described below.

1. Set the key switch to the ON position. When the key switch is in the ON position, current from key switch terminal BR, R2, and ACC is supplied to all circuits except fuse #6. (Refer to the circuit diagram.)

2. Remove the fuse box cover. Set a circuit tester.

(Measurement Range: 0 to 14.5 V) 3. Ground the negative probe of circuit tester to the body. Touch the terminals located away from center of the fuse box with the positive probe of circuit tester one at a time. When normal continuity of a fuse is intact, the circuit tester will indicate 12 V (battery voltage).

11 12 13 14 15 16 17 18

1 2 3 4 5 6 7 8 9 10

T1N0-05-05-001

T5-1-10

SECTION 5 TROUBLESHOOTING Group 1 Diagnosing Procedure Fuse No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18

Capacity 5A 5A 25 A 10 A 5A 5A 25 A 10 A 5A 20 A 5A 5A 20 A 5A 10 A 5A 5A 5A

Connected to Horn Relay Monitor Controller (Backup Power), Radio (Backup Power) (OP) Light Relay Main Relay Option Starter Relay 1 Air Conditioner (Blower Fan) Power (OP) Wiper Motor (OP)/Washer Motor (OP) Travel Mode Selector Relay, Travel Mode Control Solenoid Valve, Light Switch Auxiliary Power (OP) Monitor Controller Radio (OP)/Air Conditioner Power Switch (OP) Beacon Light (OP) Travel Mode Switch Travel Alarm (OP), AUX Function Lever Power (OP), Auxiliary Flow Rate Control Power (OP) Rack Actuator Relay, Alternator, E-ECU, Fuel Pump Pilot Shut-Off Switch, Pilot Shut-Off Relay, Pilot Shut-Off Solenoid Valve Option

T5-1-11

SECTION 5 TROUBLESHOOTING Group 1 Diagnosing Procedure Slow Blow Fuse Inspection Inspection 1. Visually inspect slow blow fuse (1).

Replacement 1. Disconnect the negative cable from the battery.

2. Pull out slow blow fuse (1). Replace slow blow fuse (1).

3. Connect the negative cable to the battery.

1

MADB-07-022

1

1-

T5-1-12

Slow Blow Fuse

TADB-05-01-003

SECTION 5 TROUBLESHOOTING Group 1 Diagnosing Procedure Battery Voltage Check 1. Turn the key switch OFF. Check voltage between the battery positive terminal and the body (ground).

Normal Voltage: 12 V

fNOTE:

If voltage is abnormal, recharge or replace the battery.

2. Start the engine. Check voltage between the battery positive terminal and the body (ground).

Normal Voltage: 14.5 V

fNOTE:

system.

If voltage is abnormal, check the charging

T505-07-01-002

T5-1-13

SECTION 5 TROUBLESHOOTING Group 1 Diagnosing Procedure Alternator Check

1

Generally, if the alternator has generated electricity, alternator indicator (1) will disappear. If alternator indicator (1) is displayed while the engine is running, the alternator might be defective.

How to Check Alternator 1. Set the key switch to the ON position. Confirm that alternator indicator (1) is displayed.

2. Measure voltage between terminal B of the alternator and the body. If the measured voltage is around 12 V, the alternator circuit can be considered normal. If the measured voltage is low, a shortage in battery capacity or looseness of the wire connectors of alternator circuit might be the cause of the malfunction. When voltage is 0 V, the wiring between fuse box and alternator might be loose or disconnected. Also, the alternator cannot generate electricity if the ground line is disconnected.

MADB-00-007 1-

Alternator Indicator

3. Next, start the engine and measure voltage generated while the alternator rotates. As described above, measure voltage between terminal B on the alternator side and the body.

If voltage is around 13.5 V, the alternator is operating normally. If the rated voltage is not being generated (around 12 V), there is some trouble with the alternator or the regulator.

B

TADB-05-01-004

T5-1-14

SECTION 5 TROUBLESHOOTING Group 1 Diagnosing Procedure Continuity Check IMPORTANT: Before continuity check, set the key switch to the OFF position.

A

 Single-line continuity check Disconnect both end connectors of the harness and check continuity between both ends:  If the ohm-meter reading is: ∞ Ω = Discontinuity  0 Ω = Continuity

A

a

a

 When the one end connector is far apart from the other, connect one end of connector (A) to the body by using a clip. Then, check continuity of the harness through the body as illustrated.  If the ohm-meter reading is: ∞ Ω = Discontinuity  0 Ω = Continuity A

 Single-line short-circuit check Disconnect both end connectors of the harness and check continuity between one end connector of the harness and the body:  0 Ω = Short-circuit is present.  ∞ Ω = No short-circuit is present.

a

T107-07-05-003

 Multi-line continuity check Disconnect both end connectors of the harness, and short-circuit two terminals, (A) and (B), at one end connector, as illustrated. Then, check continuity between terminals (a) and (b) at the other connector.

If the ohm-meter reading is ∞ Ω, either line (A) - (a), or (B) - (b) is in discontinuity. To find out which line is discontinued, conduct the single line continuity check on both lines individually, or, after changing the shortcircuit terminals from (A) - (B) to (A) - (C), check continuity once more between terminals (a) and (c). By conducting the multi-line continuity check twice, it is possible to find out which line is discontinued. With terminals (A) and (C) short-circuited, check continuity between terminals (a) and (c).  0 Ω = Line (B) - (b) has discontinuity.  ∞ Ω = Line (A) - (a) has discontinuity.  Multi-line short-circuit check Disconnect both end connectors of the harness, and check continuity between terminals (A) and (B) or (C).  0 Ω = Short-circuit exists between the lines.  ∞ Ω = No short-circuit exists between the lines.

A B C

a b c

T107-07-05-004

A B C

a b c

T107-07-05-005

T5-1-15

SECTION 5 TROUBLESHOOTING Group 1 Diagnosing Procedure Voltage Inspection Method Turn switches ON so that the specified voltage is supplied to the check point. Measure voltage. Diagnose the circuit between power source and the check point by checking that specified voltage is supplied or not.

Start checking the circuit in order up to the location to be measured from either power source or actuator side.

Thereby, the faulty location in the circuit will be found.

Key Switch: ON (check point (4) to check point (8)) Relay: ON (check point (9), check point (10)) Black (negative) probe terminal of circuit tester: To ground to the body Red (Positive) probe terminal of circuit tester: To check point Power source: Batteries (12 V) * If the measured voltage is 0.5 V less than the battery voltage, some incorrect contacts may exist at connectors.

a

e

d

f TADB-05-01-002 a- Key Switch d- Relay

e- Battery f- Check Order (Horn Circuit)

T5-1-16

SECTION 5 TROUBLESHOOTING Group 1 Diagnosing Procedure 5-Volt Circuit  Voltage between terminal #1 and the body Disconnect the connector with the key switch OFF. Measure voltage between terminal #1 on the body harness end connector and the body (ground).

Two Polarities 1

2

 Key Switch: ON  Black (negative) probe terminal of circuit tester: To ground to the body  Red (Positive) probe terminal of circuit tester: To terminal #1 T107-07-05-006

Evaluation: If the measuring voltage is within 5 ± 0.5 volts, the circuit up to terminal #1 is normal.

Three Polarities 1

2

3

T107-07-05-007

 Voltage between terminal #1 and the ground terminal Turn OFF the key switch, and disconnect the sensor connector. Measure the voltage between terminal #1 (5 V power supply) on the body harness end connector and the ground terminal (terminal #2 for two-polarities or terminal #3 for three-polarities connector) under the following conditions.

Two Polarities 1

2

 Key Switch: ON  Black (negative) probe terminal of circuit tester: To ground terminal (Terminal #2 or #3)  Red (Positive) probe terminal of circuit tester: To terminal #1

T107-07-05-008

Evaluation: If the measuring voltage is within 5 ± 0.5 volts, the circuit up to terminal #1 or the ground terminal (terminal #2 or #3) is normal.

Three Polarities 1

2

3

T107-07-05-009

T5-1-17

SECTION 5 TROUBLESHOOTING Group 1 Diagnosing Procedure Check by False Signal Two Polarities

Turn the key switch OFF. Disconnect the sensor connector.

Turn the key switch ON. Connect terminal #1 (power source) of the body harness end connector to terminal #2 (signal). (Power voltage is used as a false signal.)

Check this state by using the service menu of monitor.

When the maximum value is displayed, the circuit up to the body harness end connector is normal. If "ON" is displayed, the pressure switch circuits are normal.

IMPORTANT: Do not connect terminal #1 or #2 to terminal #3 or to the body (ground) when checking a three-polarity connector.

1

2

T107-07-05-010

fNOTE:

Some kinds of sensors can be monitored by the service menu of monitor.

Three Polarities 1

2

3

T107-07-05-011

T5-1-18

SECTION 5 TROUBLESHOOTING Group 2 Monitor Outline Basic Screen

1

2

3

4

5

18

6

17

7

16

8

15 9

10

14

13

12

11 TADB-05-02-039EN

1- 2- 3- 4- 5-

Overheat Indicator Engine Oil Pressure Indicator Alternator Indicator Fuel Level Indicator Preheat Indicator

6- 7- 8- 9- 10-

Clock Security State Display (OP) Auto Shut-Down Display (OP) Fuel Gauge Hour Meter

11- Overload Alarm/Set Switch 12- ECO/PWR Mode/Selection Switch 13- Auto-Idle/Selection Switch 14- Menu/Back Switch

T5-2-1

15- 16- 17- 18-

Coolant Temperature Gauge Travel Mode Display Work Light Display Auxiliary

SECTION 5 TROUBLESHOOTING Group 2 Monitor Operating Procedures of Service Menu IMPORTANT: The service menu is provided only for maintenance activity. Do not explain this function to your customers.

The following items can be displayed on the monitor.  Monitoring: The information of sensors and switches are displayed.  Setting: The settings as engine speed adjustment, is adjusted.  Issued Warning Record: Twenty alarms which were issued recently are displayed.

T5-2-2

SECTION 5 TROUBLESHOOTING Group 2 Monitor How to display service menu 1. Set the key switch to the ON or START position while pushing menu/back switch (1). Therefore, the service menu is added to the MENU screen.

2. When pushing menu/back switch (1), the MENU screen is displayed.

3. When pushing select switches (2, 3), the service menu (Monitoring (5), Setting (6), and Trouble Code Record (7)) are displayed.

4. When pushing menu/back switch (1), the previous screen appears.

1

4

2

3

TADB-05-02-002

5 6 7

1

4

2

T5-2-3

3

TADB-05-02-003EN

SECTION 5 TROUBLESHOOTING Group 2 Monitor (Blank)

T5-2-4

SECTION 5 TROUBLESHOOTING Group 2 Monitor Monitoring 1. When pushing select switches (2, 3), select Monitoring (5) from MENU. When pushing set switch (4), the Monitoring screen is displayed.

(Figure A) 2. When pushing select switches (2, 3), select the item for monitoring. When pushing set switch (4), the selected monitoring items are displayed. (Figure B) (Refer to List of Monitoring Item.)

5

3. When pushing menu/back switch (1), the previous screen appears.

1

4

2

3

TADB-05-02-003EN

A

1

4

2

3

TADB-05-02-006EN

B

1

4

2

T5-2-5

3

TADB-05-02-007EN

SECTION 5 TROUBLESHOOTING Group 2 Monitor List of Monitoring Item Switch Item

Unit

Data

Pilot Control Shut-Off Lever SW

ON/OFF

Pilot shut-off switch ON/OFF status

Travel alarm cancel SW

ON/OFF

Travel alarm deactivation switch ON/OFF status

Item

Unit

Data

Engine Speed Control Dial

V

Input signal from engine control dial

Sensor

C/V Pressure Sensor

V

Input signal from auto-idle pressure sensor

Travel Pi Pressure Sensor

V

Input signal from travel pressure sensor

Boom Bottom Pressure Sensor

V

Input signal from boom bottom pressure sensor

Engine Controller Item

Unit

Data

Engine Speed

min

Input signal (actual engine speed) from E-ECU

Engine Coolant Temperature

ยบC

Input signal from coolant temperature sensor

Accelerator pedal position

%

Target engine speed signal to E-ECU

Engine gross load ratio

%

Input signal from E-ECU

-1

T5-2-6

SECTION 5 TROUBLESHOOTING Group 2 Monitor Monitor Item

Unit

Data

Battery Voltage

V

Input signal from battery

Fuel Gauge

%/Ω

Input signal from fuel sensor

Battery output Relay

ON/OFF

Battery relay ON/OFF status

Regulator

ON/OFF

Alternator (regulator) ON/OFF status

Alarm Output

ON/OFF

Travel alarm ON/OFF status

CTRL1*

ON/OFF

Connected controller ON/OFF status

CTRL2*

ON/OFF

Connected controller ON/OFF status

CTRL3*

ON/OFF

Connected controller ON/OFF status

Auto-shutdown count level*

sec

Remaining time until starting auto-shutdown

Frequency of Auto-shutdown*

-

Frequency of engine stopping due to auto-shutdown

Monitor Controller Version

-

Version of monitor controller (software)

Number of engine starts

-

Frequency of engine starting

fNOTE:

*: Optional

T5-2-7

SECTION 5 TROUBLESHOOTING Group 2 Monitor Setting 1. When pushing select switches (2, 3), select Setting (5) from MENU. When pushing set switch (4), the Setting screen is displayed. (Figure A) 2. When pushing select switches (2, 3), select the item for setting. When pushing set switch (4), the Setting screen for selected item is displayed. (Figure B) (Refer to List of Setting Item.)

fNOTE: here.

5

Engine Speed (6) is explained as an example

4

1

2

3

TADB-05-02-003EN

A

6

1

4

2

3 TADB-05-02-008EN

B

TADB-05-02-009EN

T5-2-8

SECTION 5 TROUBLESHOOTING Group 2 Monitor 3. When pushing set switch (4), the color of selected item data is changed. Push select switches (2, 3), change the data, and push set switch (4). (Figure C)

C

4. The setting has been completed.

5. When pushing menu/back switch (1), the previous screen appears.

1

4

2

3 TADB-05-02-010EN

T5-2-9

SECTION 5 TROUBLESHOOTING Group 2 Monitor List of Setting Item Item A/S

Detail Repeat

Overload warning Function buzzer Engine Speed E mode

Unit Enabled/ Disabled Enabled/ Disabled %

Data Setting of auto-shutdown function.

Initial Value Enabled

Setting of overload alarm function.

Disabled

Setting of engine speed at the ECO mode.

76.0

Minimum Adjustment 0.4

Adjustable Range

Initial Value

OFF/50.0 to 100

76.0

ï‚— Engine Speed (List of Adjustment) Item

Unit

E mode

%

T5-2-10

SECTION 5 TROUBLESHOOTING Group 2 Monitor (Blank)

T5-2-11

SECTION 5 TROUBLESHOOTING Group 2 Monitor Issued Trouble Cord Record (Warning Record) ï‚— Trouble Code Record Clear 1. When pushing select switches (2, 3), select Trouble Code Record (5) from MENU. When pushing set switch (4), the Trouble Code Record screen is displayed. (Figure A) 2. When pushing select switches (2, 3), select Record Clear (6). When pushing set switch (4), the Record Clear screen is displayed. (Figure B)

5

3. When pushing select switches (2, 3), select YES (7). When pushing set switch (4), the trouble code record is deleted.

1

4. When pushing menu/back switch (1), the previous screen appears.

4

2

3

TADB-05-02-011EN

A

6

1

4

2

3

TADB-05-02-012EN

B

7

1

4

2

T5-2-12

3

TADB-05-02-013EN

SECTION 5 TROUBLESHOOTING Group 2 Monitor ï‚— Issued Trouble Code Record 1. When pushing select switches (2, 3), select Trouble Code Record (5) from MENU. When pushing set switch (4), the Trouble Code Record screen is displayed. (Figure A) 2. When pushing select switches (2, 3), select Record (6). When pushing set switch (4), the Trouble Code Record screen is displayed. (Figure B)

5

3. Maximum twenty alarm logos and descriptions which were issued recently are displayed. (Refer to List of Alarm.)

4. When pushing menu/back switch (1), the previous screen appears.

1

4

2

3

TADB-05-02-011EN

A

6

1

4

2

3

TADB-05-02-014EN

B

1

4

2

3 TADB-05-02-015EN

T5-2-13

SECTION 5 TROUBLESHOOTING Group 2 Monitor List of Alarm IMPORTANT: When the fault code of Engine Failure is displayed, check the details (fault code) by using List of Alarm or Issued Warning Record.

Engine Failure Logo

Fault Code E: 1100

Alarm

Description

Remedy

Engine Trouble Alarm Engine or engine related parts are abnormal.

Refer to Engine Manual.

W: 1100

Engine Warning

Engine or engine related parts are abnormal.

Stop operation. Check the details (fault code) and inspect it.

Refer to Engine Manual.

W: 2201

Overheat Alarm

Coolant temperature is abnormally high. Stop operation. Run the engine at slow idle to cool coolant temperature.



W: 2202

Engine Oil Pressure Alarm

Engine oil pressure is low. Immediately stop the engine. Check engine oil system and oil level.



W: 1206

Air Filter Restriction Alarm

Air cleaner filter is clogged. Clean the air cleaner filter or replace it.



W: 1207 W: 2207

Coolant Temperature Coolant temperature sensor is broken or Sensor Failure abnormal. Repair or replace it.

Refer to Engine Manual.

W: 1208

Engine Speed Sensor Engine or engine related parts are abnormal.

Failure

Refer to Engine Manual.

TADB-05-02-028

TADB-05-02-029

TADB-05-02-030

TADB-05-02-031

TADB-05-02-032

TADB-05-02-033

TADB-05-02-033

T5-2-14

SECTION 5 TROUBLESHOOTING Group 2 Monitor Machine Failure Logo

Fault Alarm Code W: 1304 Engine Control Dial Failure (CAN Signal)

Description

W: 2304 Fuel Sensor Failure

Fuel sensor is broken or abnormal. Repair or replace it.

Refer to Troubleshooting A.

W: 2306 Boom Bottom Pressure Sensor Failure

Boom bottom pressure sensor is broken or abnormal. Repair or replace it.

Refer to Troubleshooting A.

W: 2307 Engine Control Dial Failure (Analog)

Engine control dial is broken or abnormal. Repair Refer to or replace it.

Troubleshooting A. The communication system is abnormal.

Replace the controller.

TADB-05-02-033

Engine control dial is broken or abnormal. Repair Refer to or replace it.

Troubleshooting A.

TADB-05-02-033

TADB-05-02-033

TADB-05-02-035

W: 2310 EEPROM Failure

Remedy

TADB-05-02-036

T5-2-15

SECTION 5 TROUBLESHOOTING Group 2 Monitor CAN Communication Failure Logo

TADB-05-02-037

Fault Code Alarm W: 1310 CAN Communication Failure

Description CAN communication device is abnormal. Stop operation. Check if the sensor or controller is abnormal.

Remedy Refer to Troubleshooting A.

Controller Failure Logo

TADB-05-02-038

Fault Code Alarm Description Remedy W: 0001 CMOS Communication CMOS communication device is abnormal.

Replace the Error Stop operation. Check if any part or system is controller. abnormal.

T5-2-16

SECTION 5 TROUBLESHOOTING Group 2 Monitor Fault Code List Monitor ENG: xxxxx-xx 0001D-02 0001D-03 0001D-04 0001D-08 0005B-02 0005B-03 0005B-04 00064-01 00064-04 0006E-00 0006E-02 0006E-03 0006E-04 0009E-00 0009E-01 000A7-01 000A7-04 000BE-00 00274-02 00274-02 00274-0C 00276-02 00276-0C 0027E-02 0027E-03 0027E-04 0027E-07 0027F-0C

Engine Fault Code

Cause

P0224 P0223 P0222 P1227 P0124 P0123 P0122 P1198 P1192 P0217 P0119 P0118 P0117 P0563 P0562 P1568 P1562 P0219 P1605 P1606 P0605 P1601 P0601 P1214 P1213 P1212 P1211 U0001

Spare accelerator sensor intermittent failure Spare accelerator sensor error (high voltage) Spare accelerator sensor error (low voltage) Spare accelerator sensor error (pulse communication) Accelerator sensor intermittent failure Accelerator sensor error (high voltage) Accelerator sensor error (low voltage) Oil pressure descend error Oil pressure switch error Cooling water temperature rise alarm Cooling water temperature sensor intermittent failure Cooling water temperature sensor error (high voltage) Cooling water temperature sensor error (low voltage) Power supply voltage error (high voltage) Power supply voltage error (low voltage) Charge alarm Charge switch error Overspeed error ECU internal flash ROM error (checksum B) ECU internal flash ROM error (checksum C) ECU internal flash ROM error (checksum A) ECU internal EEPROM error (checksum) ECU internal EEPROM error (read/write error) Engine error Rack actuator error (high current) Rack actuator error (low current) Rack actuator mechanical failure CAN communication error

T5-2-17

SECTION 5 TROUBLESHOOTING Group 2 Monitor

Monitor ENG: xxxxx-xx 00436-04 00437-02 00437-03 00437-04 00470-00 00470-02 00470-03 00470-04 004BA-03 004BA-04 005CD-04 7F801-02 7F801-03 7F801-04 7F802-02 7F802-03 7F802-04 7F803-02 7F803-03 7F803-04 7F84A-00 7F853-00 7F8A2-04 7F9E7-0C 7F9E7-0C 7F9E7-0C 7F9E8-0C

Engine Fault Code

Cause

P0340 P1644 P0643 P0642 P0634 P1664 P0669 P0668 P1203 P1202 P0686 P1224 P1223 P1222 P1244 P1243 P1242 P1234 P1233 P1232 P1217 P1101 P1340 P1610 P1611 P1612 P1620

Speed sensor error Sensor 5V intermittent failure Sensor 5V error (high voltage) Sensor 5V error (low voltage) ECU temperature rise alarm ECU temperature sensor intermittent failure ECU temperature sensor error (high voltage) ECU temperature sensor error (low voltage) Rack position sensor error (high voltage) Rack position sensor error (low voltage) Main relay error Rack actuator relay intermittent failure Rack actuator relay error B Rack actuator relay error A CSD solenoid valve intermittent failure CSD solenoid valve error B CSD solenoid valve error A Start assist relay intermittent failure Start assist relay error B Start assist relay error A Abnormal water temperature Air cleaner clogging alarm Spare speed sensor error ECU internal sub CPU error A ECU internal sub CPU error B ECU internal sub CPU error C ECU internal map format error

T5-2-18

SECTION 5 TROUBLESHOOTING Group 2 Monitor Inspection of Fuel Gauge, Battery Voltage, Hour Meter, and Destination No. Inspection Method 2

1. In case pushing menu/back switch (1) for a while with the key switch set in the OFF position, fuel gauge (2), battery voltage (3), hour meter (4), and destination No. (5) can be checked.

3 4

2. When releasing menu/back switch (1), the monitor display disappears in three seconds.

fNOTE:

5

Refer to Factory Setting for destination No. (5).

1

TADB-05-02-016

T5-2-19

SECTION 5 TROUBLESHOOTING Group 2 Monitor Fuel Gauge and Coolant Temperature Gauge Fuel Gauge B

A

C D E

No. A B C D E F

Fuel Level (%) 87 71 53 31 15 0 (EMPTY)

Fuel Sensor (Ω) 18±1 26±1 33±1 44±2 59±2 840-4

No.

Coolant Temperature (ºC) 20 50 80 100 105 113

Coolant Temperature Sensor (kΩ) 2.45+0.14-0.13 0.318±0.008 (0.1836) -

F TADB-05-02-024

Coolant Temperature Gauge E

A B C D E F

F

D C B A

TADB-05-02-026

T5-2-20

SECTION 5 TROUBLESHOOTING Group 2 Monitor Factory Setting IMPORTANT: When the monitor has been replaced and icon (a) which has not been set is displayed, set it to the factory setting.

a

1

4

2

3

TADB-05-02-002

A

TADB-05-02-040

1. Set the key switch to the ON position while pushing menu/back switch (1) and set switch (4) at the same time. The Shipment Setup screen is displayed.

(Figure A)

5

2. When pushing select switches (2, 3), select Destination (5). Push set switch (4).

3. When pushing select switches (2, 3), select the destination. Push set switch (4).

ZX33U-5A ZX38U-5A ZX48U-5A ZX55U-5A ZX65USB-5A

1

Destination No. 41 42 43 44 45

4

2

3

1

4

2

T5-2-21

TADB-05-02-017

3

TADB-05-02-018

SECTION 5 TROUBLESHOOTING Group 2 Monitor 4. When pushing select switches (2, 3), select Model (6). Push set switch (4).

5. When pushing select switches (2, 3), select the machine model (t). Push set switch (4).

6

1

4

2

3

1

4

2

T5-2-22

TADB-05-02-019

3

TADB-05-02-020

SECTION 5 TROUBLESHOOTING Group 2 Monitor ï‚— Setting of Overload Warning Buzzer (OP) 6. When pushing select switches (2, 3), select Option (7). Push set switch (4).

7. When pushing select switches (2, 3), select O/L Warning BZ (8). Push set switch (4).

8. When pushing select switches (2, 3), select Enabled (9). Push set switch (4).

9. When pushing menu/back switch (1), the previous screen appears.

7

1

4

2

3

TADB-05-02-021

8

1

4

2

3

TADB-05-02-022

9

1

4

2

T5-2-23

3

TADB-05-02-023

SECTION 5 TROUBLESHOOTING Group 2 Monitor (Blank)

T5-2-24

SECTION 5 TROUBLESHOOTING Group 3 Troubleshooting A Troubleshooting A (Base Machine Diagnosis

by Using Fault Codes) Procedure Refer to troubleshooting A procedure in case any fault codes are displayed after diagnosing by using the service menu of the monitor.

fNOTE:

 Diagnosis Procedure  The diagnosis procedures for the displayed fault codes are explained in this group.  In case more than one fault code are displayed at the same time, the controller may be faulty or the power/ground of the sensor system may be faulty.  When the controller fault code is displayed with other fault code, replace the controller.  In case more than one fault code other than those described above are displayed at the same time, diagnose for each fault code.  It may be required that the machine is operated or the test harness is connected at inspection.

Check the items of preparation and perform inspection according to the procedures when diagnosing.

fNOTE:

Harness end connector viewed from the open end side by the all connectors image shown in this section.

1 2

T6L4-05-03-001

1-

Harness End Connector

2-

Harness

T5-3-1

After repairing, perform Record Clear of the monitor. Then, delete the warning record. (Refer to TROUBLESHOOTING / Monitor.)

SECTION 5 TROUBLESHOOTING Group 3 Troubleshooting A Contents Of Diagnosis

Fault Code Preparation Tools for a diagnosis and contents needing inspection beforehand are explained.

How to Read Table Fault Code

Trouble

(A)

(B)

    

A: B: C, F: D, G: E, H:

Inspection Method (C) (F)

Evaluation

Cause

(D) (G)

(E) (H)

Fault code Trouble details Inspection method for trouble cause Evaluation specification of check results Trouble cause for the fault code

Procedure: 1. Check an applicable line depending on displayed Fault Cord (A).

2. After checking or measuring on Inspection Method (C), refer to Evaluation (D) and judge the results.

3. In case the results are satisfied with Evaluation (D), the trouble cause becomes Cause (E).

In case the results are not satisfied with Evaluation (D), go to the next procedure, Inspection Method (F).

Circuit Diagram of Test Harness A connection point of the test harness and a point to check are explained.

(Only Pressure Sensor System Troubleshooting)

T5-3-2

SECTION 5 TROUBLESHOOTING Group 3 Troubleshooting A Fault Code List Fault Code

Trouble

Cause

W: 1304

Engine Control Dial Faulty monitor controller Failure (CAN Signal) Faulty CAN harness

W: 1310

CAN Communication Failure

Faulty CAN harness

W: 2304

Fuel Sensor Failure

Faulty fuel float Faulty fuel float harness

W: 2306

Boom Bottom Pressure Sensor Failure

W: 2307

Engine Control Dial Failure (Analog)

Faulty boom bottom pressure sensor Faulty boom bottom pressure sensor harness Faulty engine control dial Faulty harness

T5-3-3

Symptoms in Machine Remedy Operation When Trouble Occurs.

Power mode is not shifted. Check the monitor Auto-idle is not operated. controller.

Check the CAN harness.

Power mode is not shifted. Check the CAN harness.

Auto-idle is not operated.

All segments of coolant temperature gauge blink.

Fuel segment blinks.

Replace the fuel sensor.

Correct value of fuel Check the harness. gauge is not displayed.

Overload alarm (OP) Replace the boom continues to sound within bottom pressure sensor. the allowable lifting load Check the harness. range.

Replace the engine Although the engine control dial. control dial is operated, Check the harness. the engine speed does not change.

SECTION 5 TROUBLESHOOTING Group 3 Troubleshooting A Fault Code W: 1304 Preparation  Check the wiring connections first.

Fault Code W: 1304

Trouble Engine Control Dial Failure (CAN Signal)

Inspection Method Measure resistance between E-ECU#40 and terminal M1-20 in monitor controller.

Measure resistance between E-ECU#39 and monitor controller terminal M1-21.

-

Evaluation 0/∞ Ω

0/∞ Ω

The check mentioned above is normal.

Cause Faulty CAN (High side) harness between E-ECU and monitor controller Faulty CAN (Low side) harness between E-ECU and monitor controller Faulty monitor controller

Connector (Harness end)  E-ECU

 Monitor Controller M1

TADB-05-03-001

T5-3-4

TADB-05-03-002

SECTION 5 TROUBLESHOOTING Group 3 Troubleshooting A Fault Code W: 1310 Preparation  Check the wiring connections first.

Discontinuity check (shorted circuit) Fault Code W: 1310

Trouble CAN Communication Failure

Inspection Method Measure resistance between CAN (High side) harness and CAN (Low side) harness in E-ECU. Measure resistance between CAN (High side) harness and CAN (Low side) harness in monitor controller.

Measure resistance between CAN harness end #1 and #2.

Measure resistance between YDT harness end #2 and #3.

Evaluation The value is lower than the normal value.

(Normal value: 120 Ω)

Cause Shorted circuit between CAN (High side) harness and CAN (Low side) harness in E-ECU.

The value is lower than Shorted circuit between CAN the normal value.

(High side) harness and CAN (Normal value: 120 Ω) (Low side) harness in E-ECU. The value is lower than the normal value.

(Normal value: 120 Ω) The value is lower than the normal value.

(Normal value: 120 Ω)

Shorted circuit in CAN harness #1 and #2.

Shorted circuit in YDT harness #2 and #3.

Continuity check (open circuit) Fault Code W: 1310

Trouble CAN Communication Failure

Inspection Method Measure resistance in CAN (High side) harness between E-ECU and monitor controller.

Measure resistance in CAN (Low side) harness between E-ECU and monitor controller.

Measure resistance between High side in E-ECU and CAN #1.

Measure resistance between High side in E-ECU and YDT #2.

Measure resistance between Low side in E-ECU and CAN #2.

Measure resistance between Low side in E-ECU and YDT #3.

Measure resistance between E-ECU #30 and CAN #2.

T5-3-5

Evaluation ∞Ω

∞Ω

∞Ω

∞Ω ∞Ω ∞Ω ∞Ω

Cause Open circuit in CAN (High side) harness between E-ECU and monitor controller.

Open circuit in CAN (Low side) harness between E-ECU and monitor controller.

Open circuit in harness #1 in CAN. Open circuit in harness #2 in YDT. Open circuit in harness #2 in CAN. Open circuit in harness #3 in YDT. Open circuit in harness #30 in E-ECU.

SECTION 5 TROUBLESHOOTING Group 3 Troubleshooting A Connector (Harness end)  E-ECU

 Monitor Controller M1

TADB-05-03-001

 CAN TDCD-05-06-010

 YDT

TADB-05-03-004

T5-3-6

TADB-05-03-002

SECTION 5 TROUBLESHOOTING Group 3 Troubleshooting A Fault Code W: 2304 Fault Code W: 2304

Trouble Fuel Sensor Failure

Inspection Method Measure resistance between sensor #1 and #2.

Evaluation Cause The value is not within the Faulty sensor normal values. (Refer to the table.)

0V Open circuit in harness #2.

Measure voltage between sensor harness end #2 and the body.

Measure resistance between ∞ Ω sensor harness end #1 and the body.

The check mentioned above is normal.

Fuel Gauge B

No. A B C D E F

A

C D E

Fuel Level (%) 87 71 53 31 15 0 (EMPTY)

F TADB-05-02-024

Connector (Harness end)  Fuel Sensor

TDCD-05-06-010

T5-3-7

Fuel Sensor (Ω) 18±1 26±1 33±1 44±2 59±2 840-4

Open circuit in harness #1.

Shorted circuit in harness #1 and #2.

SECTION 5 TROUBLESHOOTING Group 3 Troubleshooting A Fault Code W: 2306 Preparation  Check the wiring connections first.

Fault Code W: 2306

Trouble Boom Bottom Pressure Sensor Failure

Inspection Method Measure resistance in boom bottom pressure sensor end.

Evaluation Cause The value is not within the Faulty sensor normal values. (Normal value: between #1 and #2: 166 kΩ, between #1 and #3: 2.7 kΩ, between #2 and #3: 81.5 kΩ) 0Ω Shorted circuit in Measure resistance between harness #1 and #2. harness end #1 and #2 in boom bottom pressure sensor.

Measure resistance between ∞Ω Open circuit in harness end #3 in boom bottom harness #3. pressure sensor and terminal M1-14 in monitor controller. ∞Ω Open circuit in Measure resistance between harness #2. harness end #2 in boom bottom pressure sensor and terminal M1-16 in monitor controller.

The check mentioned above Open circuit in is normal. harness #1.

Connector (Harness end)  Boom Bottom Pressure Sensor

 Monitor Controller M1

TADB-05-03-005

T5-3-8

TADB-05-03-002

SECTION 5 TROUBLESHOOTING Group 3 Troubleshooting A Fault Code W: 2307 Engine Control Dial Voltage Specification (V) Slow Idle

0.6±0.1

Fast Idle

4.0±0.1

Preparation  Check the wiring connections first.

Fault Code W: 2307

Trouble Engine Control Dial Failure (Analog)

Inspection Method Monitor EC Dial (V) and operate the engine control dial.

Evaluation The value is not within the normal values.

(Normal value: Slow idle: 0.6±0.1 V, Fast idle: 4.0±0.1 V)

Cause -

Evaluation The value is not within the normal values.

(Normal value: between #1 and #2: 0.5 Ω, between #1 and #3: 5 kΩ, between #2 and #3: 5 kΩ) ∞Ω

Cause Faulty engine control dial

∞Ω

Open circuit in harness #1.

The check mentioned above is normal.

Open circuit in harness #3.

When the value is lower than standard voltage: Fault Code W: 2307

Trouble Engine Control Dial Failure (Analog)

Inspection Method Measure resistance in engine control dial end.

Measure resistance between harness end #2 in engine control dial and E-ECU #35.

Measure resistance between harness end #1 in engine control dial and E-ECU #38.

-

T5-3-9

Open circuit in harness #2.

SECTION 5 TROUBLESHOOTING Group 3 Troubleshooting A When the value is higher than standard voltage: Fault Code W: 2307

Trouble Engine Control Dial Failure (Analog)

Inspection Method Measure resistance in engine control dial end.

-

Evaluation The value is not within the normal values.

(Normal value: between #1 and #2: 0.5 Ω, between #1 and #3: 5 kΩ, between #2 and #3: 5 kΩ) The check mentioned above is normal.

Cause Faulty engine control dial

Shorted circuit in harness #1 and #2.

Connector (Harness end)  Engine Control Dial

 E-ECU

TADB-05-03-003

TADB-05-03-001

T5-3-10

SECTION 5 TROUBLESHOOTING Group 4 Troubleshooting B Troubleshooting B (Machine Diagnosis by Using Troubleshooting Symptom) Procedure Refer to troubleshooting B procedures for diagnosis by using trouble symptom when no fault codes are displayed.  Diagnosis Procedure  The diagnosis procedures for the displayed fault codes are explained in this group.  Perform diagnosis by using the service menu of monitor first.  In case any fault code has not been displayed by diagnosis, perform inspection according to the procedures when diagnosing.  When the fault code is displayed, refer to the troubleshooting A group and diagnose.

fNOTE:

Harness end connector viewed from the open end side by the all connectors image shown in this section.

1 2

T6L4-05-03-001 1-

Harness End Connector

2-

Harness

T5-4-1

SECTION 5 TROUBLESHOOTING Group 4 Troubleshooting B Contents of Diagnosis

Trouble Symptom Preparation Viewpoints for a diagnosis and contents needing inspection beforehand are explained.

How to Read Table Procedure (A) (F)

Inspection Method (B) (G)

Condition

Evaluation

Cause

(C) (H)

(D) (I)

(E) (J)

 A, F: Inspection order  B, G: Inspection method for trouble cause  C, H: Conditions for inspection  D, I: Evaluation specification of check results  E, J: Trouble cause for trouble symptom

Procedure: 1. Perform inspection according to Inspection Method (B) and Condition (C) of Procedure (A).

2. In case the results are applied to Evaluation (D), the trouble cause becomes Cause (E).

In case the results are not applied to Evaluation (D), go to the next procedure, Procedure (F).

T5-4-2

SECTION 5 TROUBLESHOOTING Group 4 Troubleshooting B Engine System Troubleshooting E-1 Starter does not rotate.

Preparation  The engine unit or E-ECU may be faulty. Refer to Engine Manual.  The starter restraining control may prevents the starter from rotating. (Refer to SYSTEM / Control System.)  Check the wiring connections first.

OFF Starter Terminal B 12 V or more Starter Terminal S 0

Procedure Inspection Method Condition 1 Measure battery voltage and electrolyte density.

Cause Faulty battery

2

Switch starter relay 1 with glow plug relay.

Faulty starter relay 1

3

Measure voltage at E-ECU harness end #24.

Measure voltage at starter relay 1 harness end #87.

4

5 6

7 8 9 10

Measure voltage at starter relay 1 harness end #86.

Check continuity in harness between starter relay 1 #85 and E-ECU #20.

Measure voltage at starter terminal B. Measure voltage at starter terminal S. Check continuity between key switch #1 and #6.

-

Evaluation The measured values are not within the normal values (Normal value: Voltage: 12 V or more, Electrolyte density: 1.25 to 1.28) Set the key switch The symptom to START after disappears. switching relays.

Key Switch: ON 0V

ON 12 V or more 0

Key Switch: OFF

0V

Key Switch: START 0 V -

∞Ω

-

0V

START 12 V or more 12 V or more

Faulty pilot shut-off circuit (Refer to A-2.)

Open circuit in harness between starter relay 1 and slow blow fuse, or faulty slow blow fuse.

Open circuit in harness between starter relay 1 and #6 fuse.

Open circuit in harness between starter relay 1 and E-ECU.

Key Switch: START ∞ Ω

Open circuit in harness between battery and starter.

Open circuit in harness between starter and starter relay 1.

Faulty key switch

-

Faulty starter or faulty E-ECU

Key Switch: START 0 V

The check mentioned above is normal.

T5-4-3

SECTION 5 TROUBLESHOOTING Group 4 Troubleshooting B Connector (Harness end)  E-ECU

 Starter Relay 1

TADB-05-04-001 TADB-05-03-001

T5-4-4

SECTION 5 TROUBLESHOOTING Group 4 Troubleshooting B E-2 Even if starter rotates, engine does not start.

Preparation  The engine unit or E-ECU may be faulty. Refer to Engine Manual.  Check that #4 fuse is normal.  Check the wiring connections first.

Procedure Inspection Method 1 Switch main relay with other general relay.

2

-

Condition Set the key switch to START after switching relays.

-

T5-4-5

Evaluation The engine starts.

Cause Faulty main relay

The check mentioned Faulty E-ECU or engine unit above is normal.

SECTION 5 TROUBLESHOOTING Group 4 Troubleshooting B E-3 Auto-idle system is faulty.

Auto-Idle Speed

Specification (min−1) 1300±50

Remark

 Even if the control lever is set to neutral, auto-idle system is not operated.

Preparation  In case other trouble symptoms occur, perform troubleshooting of these troubles first.

 Refer to SYSTEM / Control System / Auto-Idle Control.  Check the wiring connections first.

Procedure Inspection Method 1 Monitor C/V Pressure Sensor.

Condition Control lever in neutral

Evaluation 0.5 V

2

Measure resistance between terminals of auto-idle pressure sensor.

-

3

-

-

The measured values are not within the normal values (Normal value: between #1 and #2: 10 kΩ, between #1 and #3: 38 kΩ, between #2 and #3: 20 kΩ) The check mentioned Shorted circuit in harness above is normal. between sensor harness #1 and #2 of auto-idle pressure sensor.

Connector (Harness end)  Auto-Idle Pressure Sensor

TADB-05-04-002

 Even if the auto-idle switch is in the OFF position, autoidle system is operated.  In case auto-idle system is operated with the autoidle switch set in the OFF position, the monitor controller, E-ECU, or CAN harness may be faulty.

Check the fault code.

T5-4-6

Cause Faulty monitor controller, faulty E-ECU, or faulty CAN harness Faulty auto-idle pressure sensor

SECTION 5 TROUBLESHOOTING Group 4 Troubleshooting B E-4 Engine is difficult to start at low temperature.

(During cold weather or in cold districts, engine is difficult to start or does not start even if preheated.)

Preparation  The engine unit or E-ECU may be faulty. Refer to Engine Manual.  Check the battery.  Check the wiring connections first.

Procedure Inspection Method Condition Evaluation 1 Switch glow plug relay with Key Switch: START Starter does not starter relay 1. rotate.

2 Measure voltage at glow plug 0V relay harness end #87.

3

-

-

The check mentioned above is normal.

Connector (Harness end)  Glow Plug Relay

TADB-05-04-001

T5-4-7

Cause Faulty glow plug relay Open circuit in harness between glow plug relay and battery, or faulty slow blow fuse.

Open circuit in harness between glow plug relay and E-ECU, or faulty E-ECU.

SECTION 5 TROUBLESHOOTING Group 4 Troubleshooting B E-5 ECO mode is faulty.

Fast Idle Speed (ECO mode)

Specification (min−1) 2200

Remark Reference Value

Preparation  In case other trouble symptoms occur, perform troubleshooting of these troubles first.  Refer to SYSTEM / Control System / ECO Mode Control.  Check the wiring connections first.

Procedure Inspection Method 1 Operate the ECO/PWR mode selector switch and select ECO mode.

Condition Key Switch: ON

2

-

-

Evaluation Even if ECO is displayed on the monitor, engine speed does not decreases.

The check mentioned above is normal.

T5-4-8

Cause Faulty monitor controller

Faulty E-ECU or faulty CAN harness

SECTION 5 TROUBLESHOOTING Group 4 Troubleshooting B E-6 Auto shut-down is not activated.

Preparation  In case all actuators do not work, the fuse in auto shut-down relay circuit may be faulty.  Refer to SYSTEM / Electrical System / Auto ShutDown Relay Circuit (OP).  Check the wiring connections first.

Procedure Inspection Method 1 Monitor Pilot Control Shut-Off Lever SW. 2 Monitor Engine Coolant temperature.

Condition Pilot Shut-Off Lever: UNLOCK Position Key Switch: ON

3

-

4 5 6

Switch auto shut-down relay with other general relay.

Switch R2 cut relay with glow plug relay.

Switch ACC cut relay with glow plug relay.

-

-

Evaluation ON is displayed.

Cause Faulty pilot shut-off switch

Engine overheating occurs or all segments blink.

The symptom disappears.

Faulty CAN harness or faulty overheat switch

The symptom disappears.

The symptom disappears.

The check mentioned above is normal.

Faulty R2 cut relay

T5-4-9

Faulty auto shut-down relay

Faulty ACC cut relay Faulty monitor controller or faulty auto shut-down harness

SECTION 5 TROUBLESHOOTING Group 4 Troubleshooting B All Actuator System Troubleshooting A-1 All actuator speeds are slow and power is weak.

Primary Pilot Pressure (MPa)

Specification 4.1±0.5

Remark Engine Control Dial: Fast Idle

Preparation  In case the trouble occurs only when the hydraulic oil temperature is low, high viscosity of hydraulic oil may be the cause.  As the main circuit consists of 3 systems (3 main relief valves are located), the possibility of failure in all main relief valve is small.  In case more than one actuators are abnormal, the load check valves in the related circuits may be faulty.

Procedure Inspection Method 1 Monitor Engine Speed.

2

3 4

Measure primary pilot pressure.

Check that pilot filter is clogged.

-

Condition Refer to OPERATIONAL PERFORMANCE TEST / Engine Test.

-

Evaluation The measured values are not within the normal values

Cause Faulty engine unit

The measured values are not within the normal values Correct

To Procedure No. 3.

-

There is abnormality.

Find out cause of trouble by tracing other trouble symptoms.

Clogged pilot filter

-

The check mentioned above is normal.

Faulty pilot relief valve or faulty pilot pump

T5-4-10

SECTION 5 TROUBLESHOOTING Group 4 Troubleshooting B A-2 All actuators do not work.

Preparation  As the main circuit consists of 3 systems (3 main relief valves are located), the possibility of failure in all main relief valve is small.  Refer to SYSTEM / Electrical System.  Check the wiring connections first.

Procedure Inspection Method Condition 1 Monitor Pilot Control Shut-Off Pilot Shut-Off Lever: Lever SW. UNLOCK Position Key Switch: ON

Evaluation OFF is displayed.

2

Switch pilot shut-off relay with other general relay.

The symptom disappears.

3

Measure resistance between pilot shut-off solenoid valve #1 and #2.

Measure voltage between pilot shut-off solenoid valve harness end #1 and body.

-

Pilot Shut-Off Lever: UNLOCK Position Key Switch: ON -

Pilot Shut-Off Lever: UNLOCK Position Key Switch: ON -

0V

4

5

Connector (Harness end)  Pilot Shut-Off Solenoid Valve

T2BC-05-03-031

T5-4-11

Cause Faulty pilot shut-off switch or open circuit in harness between pilot shut-off switch and #17 fuse Faulty pilot shut-off relay

∞ Ω (Normal value: Faulty pilot shut-off solenoid 12.2±0.85 Ω) valve

The check mentioned above is normal.

Open circuit in harness between pilot shut-off relay and pilot shut-off solenoid valve Faulty ground circuit in pilot shut-off solenoid valve

SECTION 5 TROUBLESHOOTING Group 4 Troubleshooting B A-3 Actuator does not stop even if control lever is set to neutral.

Preparation ď‚– Stuck spool in the pilot valve or stuck main spool in the control valve is suspected. ď‚– Refer to T5-4-13 in case the actuator does not stop even if control lever is returned to neutral.

Procedure Inspection Method 1 Set the pilot shut-off lever to the LOCK position.

2 -

Condition -

Evaluation Actuator stops.

Cause Faulty pilot valve (stuck spool)

-

The check mentioned above is normal.

Faulty control valve (stuck spool)

T5-4-12

SECTION 5 TROUBLESHOOTING Group 4 Troubleshooting B A-4 Actuator does not stop even if control lever is set to neutral.

Boom, Arm, Bucket, Boom Swing Procedure Inspection Method 1 Switch corresponding overload relief valve and make-up valve with normal ones.

2 -

Condition -

Evaluation Actuator stops.

Cause Faulty overload relief valve or faulty make-up valve

-

The check mentioned above is normal.

Faulty control valve (stuck spool) or faulty pilot valve (stuck spool)

Evaluation The measured values are not within the normal values (Normal value: 20.4Âą1.0 MPa) The check mentioned above is normal.

Cause Faulty swing relief valve

Evaluation There is abnormality.

Cause Faulty counterbalance valve

The check mentioned above is normal.

Faulty control valve (stuck spool) or faulty pilot valve (stuck spool)

Swing Procedure Inspection Method Condition 1 Measure relief pressure when When relieving relieving swing. swing

2

-

-

Faulty control valve (stuck spool) or faulty pilot valve (stuck spool)

Travel Procedure Inspection Method Condition 1 Disassemble and inspect the counterbalance valve in travel device.

2 -

T5-4-13

SECTION 5 TROUBLESHOOTING Group 4 Troubleshooting B A-5 Front attachment is not operated during combined operation of travel and front attachment.

Preparation ď‚– Pressure oil from main pump P2 flows to each spool of travel (left), boom, and bucket. Pressure oil from main pump P1 flows to each spool of travel (right), arm, and auxiliary. As the travel spool is located in front of other spools in each circuit, pressure oil does not flow to other spools when travel operation is made. Therefore, pressure oil from main pump P3 is supplied to the front attachment spool located after the travel spool through the flow combiner valve, so that the front attachment can be operated when travel operation is made. In case the front attachment can not be operated when travel operation is made, the flow combiner valve may be faulty (stuck spool). Therefore, pressure oil from main pump P3 is not supplied to the front attachment spool.

T5-4-14

SECTION 5 TROUBLESHOOTING Group 4 Troubleshooting B Front Attachment System Troubleshooting F-1 All front attachment actuator power are weak.

Preparation ď‚– Not only the front attachment but also other functions will have the problem. In case the travel function is also abnormal, refer to All actuator speeds are slow and power is weak on T5-4-10. In case only the front attachment is abnormal, check the pilot valve.

T5-4-15

SECTION 5 TROUBLESHOOTING Group 4 Troubleshooting B F-2 Some cylinders are not operated or speeds are slow.

Specification

Remark

Secondary Pilot Pressure (MPa)

2.9±0.5

When the control lever is fully operated

Overload Relief Pressure (MPa) Boom, Arm, Bucket

Specification

Remark

27.5±1.0

Preparation  The main circuit consists of 3 systems (3 main relief valves are located). Incase one of main relief valves is faulty, it may lead to failure in the actuator operation of the corresponding system.

Main Pump P1: Main Pump P2: Main Pump P3:

Travel (Right), Arm, Auxiliary Travel (Left), Boom, Bucket Blade, Swing, Boom Swing

Procedure Inspection Method 1 Measure secondary pilot pressure of corresponding cylinder.

2

Measure relief pressure of corresponding cylinder.

3

-

Condition Fully operate the control lever of corresponding cylinder.

-

-

Evaluation The measured value is not within the normal value.

Cause Faulty pilot valve of corresponding cylinder

The measured value is not within the normal value.

The check mentioned above is normal.

Faulty overload relief valve of corresponding cylinder

T5-4-16

Stuck control valve spool or faulty cylinder (faulty seal kit)

SECTION 5 TROUBLESHOOTING Group 4 Troubleshooting B F-3 Arm roll-in operation speed is slow.

Arm Roll-In (sec)

Specification (3.3±0.3)

Remark

Preparation  The arm regenerative valve is provided in the arm roll-in circuit so that the arm roll-in speed increases.

In case only the arm roll-in speed is slow, the arm regenerative valve may be faulty.

T5-4-17

SECTION 5 TROUBLESHOOTING Group 4 Troubleshooting B F-4 Front attachment drifts remarkably. ď‚— Boom Cylinder Internal Leakage Check 1. With the bucket cylinder fully retracted and the arm cylinder slightly extended from the fully retracted position, lower the bucket tooth tips onto the ground.

2. Disconnect the hoses from the boom cylinder rod side. Drain oil from the hoses and cylinders. (Plug the disconnected hose ends.)

3. Retract the arm cylinder and lift the bucket off the ground. If oil flows out of the hose disconnected piping ends and the boom cylinders are retracted at this time, oil leaks in the boom cylinders. If no oil flows out of the hose disconnected piping ends but the boom cylinders are retracted, oil leaks in the control valve.

Procedure Inspection Method 1 Set the pilot shut-off lever to the LOCK position.

2 Measure main relief pressure.

3 Disassemble and inspect the boom anti-drift valve.

4 Disassemble and inspect the cylinder.

5 -

Condition -

TADB-05-04-003

-

Evaluation The symptom disappears.

There is abnormality.

There is abnormality.

-

There is abnormality. Faulty cylinder (seal kit)

-

The check mentioned Scored control valve spool, above is normal. broken spring, or loose spool end

T5-4-18

Cause Faulty pilot valve Faulty overload relief valve Faulty boom anti-drift valve

SECTION 5 TROUBLESHOOTING Group 4 Troubleshooting B F-5 When boom raise or arm roll-out is operated, boom or arm starts to move after moving slightly down.

When the load check valve is faulty:

Preparation (B)

ď‚– During the initial stage of operation, oil pressure and flow rate from the pump is low. Therefore, if the load check valve is faulty, the oil in the bottom side of the boom cylinder flows back into the circuit through the load check valve. Therefore, the boom cylinder is temporarily retracted. ď‚– As oil pressure and flow rate from the pump is low, if oil leaks from bottom side (A) to rod side (B) due to faulty boom cylinder piston or cylinder barrel, the boom cylinder is temporarily retracted during the initial stage of operation. In addition, cylinder force is reduced. The boom cylinder drift increases in this case.

Procedure Inspection Method 1 Disassemble and inspect the load check valve.

2 Disassemble and inspect the boom anti-drift valve.

3 -

(A)

T105-07-04-012

Condition -

Evaluation There is abnormality.

Cause Faulty load check valve

-

There is abnormality.

Faulty boom anti-drift valve

-

The check mentioned above is normal.

Faulty cylinder (seal kit)

T5-4-19

SECTION 5 TROUBLESHOOTING Group 4 Troubleshooting B Swing System Troubleshooting S-1 Swing is slow or unmoving.

Swing Speed (sec/3 rev)

Specification 19.8±1.5

Remark The bucket should be empty.

Preparation  In case the blade and boom swing cylinders, along with the swing function move slowly, its power is weak, or they are not operated, the main relief valve for main pump P3 may be faulty.

Procedure Inspection Method 1 Measure secondary pilot pressure of swing.

2 3

Measure delivery pressure of main pump P3.

Measure relief pressure of swing.

4

Measure the swing motor drainage.

5

-

Condition Evaluation When fully operating The measured value is swing not within the normal value.

(Normal value: 2.9±0.5 MPa) When fully operating approx. 2 MPa swing When relieving swing The measured value is not within the normal value.

(Normal value: 20.4±1.0 MPa) With constant speed The measured value is not within the normal value.

(Normal value: 0.5 L/min or less) The check mentioned above is normal.

T5-4-20

Cause Faulty pilot valve

Faulty control valve (stuck spool) Faulty swing relief valve

Faulty swing motor

Faulty swing parking brake or faulty swing reduction gear

SECTION 5 TROUBLESHOOTING Group 4 Troubleshooting B S-2 Swing drifts remarkably when swinging is stopped.

Swing Function Drift Check (mm/90 °)

Specification 140 or less

Remark The bucket should be empty.

Preparation  In case pressure oil does not flow smoothly, the valves may be faulty. In case pressure oil flows smoothly, the spools may be faulty.

Procedure Inspection Method 1 Measure relief pressure of swing.

Condition When relieving swing

2

-

3

Disassemble and inspect the control valve spool.

-

-

Evaluation Cause The measured value is Faulty swing relief valve not within the normal value.

(Normal value: 20.4±1.0 MPa) There is abnormality.

Stuck control valve spool The check mentioned above is normal.

T5-4-21

Faulty swing device

SECTION 5 TROUBLESHOOTING Group 4 Troubleshooting B Travel System Troubleshooting T-1 Machine does not travel, travel slowly, or power is weak.  Both right and left travel motors are unlikely to be faulty at the same time.  This is used when both right and left travel motors are faulty. In case only one travel motor is faulty, refer to Machine mistracks.  In case travel speed does not become fast, refer to Fast travel is not selected or Travel mode does not change from slow mode to fast mode.  In case the machine does not travel, refer to All actuators do not work.  In case power is weak, refer to All actuator speeds are slow and power is weak.

T5-4-22

SECTION 5 TROUBLESHOOTING Group 4 Troubleshooting B T-2 Fast travel is not selected. Travel mode does not change from slow mode to fast mode.

Preparation  In case the work light does not light, #9 fuse may be faulty.  Check the wiring connections first.

Procedure Inspection Method 1 Measure voltage at travel mode switch (panel) harness end #2.

2 Measure voltage at travel mode switch (lever) (OP) harness end #2.

3 Measure voltage at travel mode selector relay #3.

Condition Key Switch: ON

Key Switch: ON

-

4

Measure voltage at travel Key Switch: ON mode selector relay Travel Mode Switch: harness end #1.

Fast Speed Position

5

Switch travel mode selector relay with other general relay.

Measure voltage at travel mode selector solenoid valve harness end #1.

Key Switch: ON Travel Mode Switch: Fast Speed Position Key Switch: ON Travel Mode Switch: Fast Speed Position

Measure resistance between travel mode selector solenoid valve #1 and #2.

-

-

6

7

8

-

Evaluation Cause 0 V (Normal value: 12 V) Open circuit in harness between travel mode switch (panel) and #14 fuse 0 V (Normal value: 12 V) Open circuit in harness between travel mode switch (lever) (OP) and #14 fuse 0 V (Normal value: 12 V) Open circuit in harness between travel mode selector relay and #9 fuse 0 V (Normal value: 12 V) Faulty travel mode switch (panel), faulty travel mode selector relay unit (OP), or open circuit in harness between travel mode switch (panel) and travel mode selector relay The symptom Faulty travel mode selector relay disappears.

0 V (Normal value: 12 V) Open circuit in harness between travel mode selector relay and travel mode selector solenoid valve ∞ Ω (Normal value: Faulty travel mode selector 12.2±0.85 Ω) solenoid valve The check mentioned above is normal.

T5-4-23

Open circuit in harness #2 of travel mode selector solenoid valve

SECTION 5 TROUBLESHOOTING Group 4 Troubleshooting B

1

2

7

4

6

3 TADB-05-04-007EN

5

1- 2- 3-

Key Switch Fuse Box Travel Mode Switch (Panel)

4-

Travel Mode Switch (Lever) (OP)

5- 6-

Travel Mode Selector Relay Unit (OP) Travel Mode Selector Relay

7-

Travel Mode Selector Solenoid Valve

Connector  Travel Mode Selector Solenoid Valve

 Travel Mode Selector Relay

TADB-05-04-005 T2BC-05-03-031

 Travel Mode Switch (Lever) (OP)

TADB-05-04-004

T5-4-24

 Travel Mode Switch (panel)

TADB-05-04-008

SECTION 5 TROUBLESHOOTING Group 4 Troubleshooting B T-3 Slow travel is not selected. Travel mode does not change from fast mode to slow mode.

Preparation ď‚– Check the wiring connections first.

Procedure Inspection Method 1 Disconnect a connector from the travel mode selector solenoid valve.

2 Disconnect a connector from the travel mode switch (Panel or lever (OP)).

3 Disconnect travel mode selector relay.

4 -

Condition -

Evaluation The symptom does not disappear.

Cause Faulty travel mode selector solenoid valve (stuck spool)

Key Switch: ON

The symptom disappears.

Faulty travel mode switch (Panel or lever (OP))

Key Switch: ON

The symptom disappears.

The check mentioned above is normal.

Faulty travel mode selector relay

-

T5-4-25

Shorted circuit in harness between travel mode selector solenoid valve and travel mode selector relay or faulty travel mode selector relay unit

SECTION 5 TROUBLESHOOTING Group 4 Troubleshooting B

1

2

7

4

6

3 TADB-05-04-007EN

5

1- 2- 3-

Key Switch Fuse Box Travel Mode Switch (Panel)

4-

Travel Mode Switch (Lever) (OP)

5- 6-

T5-4-26

Travel Mode Selector Relay Unit (OP) Travel Mode Selector Relay

7-

Travel Mode Selector Solenoid Valve

SECTION 5 TROUBLESHOOTING Group 4 Troubleshooting B T-4 One side track does not rotate or rotates slowly. Machine mistracks.

Track Revolution Speed (sec/3 rev) Remark Specification Fast Mode 11.2±1.5/11.5±1.5 (Rubber Crawler / Steel Crawler) Slow Mode 17.5±1.5/17.9±1.5 (Rubber Crawler / Steel Crawler)

Hydraulic Cylinder Cycle Time (sec) Specification Boom Raise 2.7±0.3/2.6±0.3 (Canopy/Cab) Boom Lower 2.4±0.3/2.3±0.3 (Canopy/Cab) Arm Roll-In 3.3±0.3 Arm Roll-Out 2.8±0.3 Bucket Roll-In 2.4±0.3 Bucket Roll-Out 1.6±0.3

Remark

Preparation  In case the machine mistracks to the right (only the travel (right) operation is slow, power is weak, or machine does not move), the main relief valve of main pump P1 may be faulty.

Procedure Inspection Method 1 Measure the cycle time of boom or bucket cylinders.

Condition -

2

Measure the cycle time of arm cylinder.

-

3

Measure secondary pilot pressure of travel.

-

4

Switch right and left travel line hoses each other at the bottom of center joint.

-

-

5

-

 In case the machine mistracks to the left (only the travel (left) operation is slow, power is weak, or machine does not move), the main relief valve of main pump P2 may be faulty.

Evaluation The measured values are not within the normal values.

The measured values are not within the normal values.

The measured values are not within the normal values.

(Normal value: 2.9±0.5 MPa) Symptom is reversed.

The check mentioned above is normal.

T5-4-27

Cause Faulty main pump P2

Faulty main pump P1

Faulty travel pilot valve

Faulty center joint or faulty control valve (stuck spool) Faulty travel motor or travel motor displacement angle control mechanical part

SECTION 5 TROUBLESHOOTING Group 4 Troubleshooting B Relationship between Faulty Seal Location and Mistrack Direction Serial No.

When traveling straight

When pivot turn is performed

1

1

d

2

c

2

3

b

4

a

5

3 4

TADB-03-07-003

5 a- c-

T5-4-28

Travel (Left Reverse) Travel (Left Forward)

b- d-

Travel (Right Reverse) Travel (Right Forward)

SECTION 5 TROUBLESHOOTING Group 4 Troubleshooting B Blade System Troubleshooting Blade is not operated or moves slowly. ď‚– As each actuator of blade, swing, and boom swing is operated by pressure oil from main pump P3, the main relief valve of main pump P3 may be faulty.

Procedure Inspection Method 1 Measure secondary pilot pressure of blade.

2 3

4

Measure delivery pressure of main pump P3.

Remove the rod pin of blade cylinder. Retract the blade cylinder fully. Remove the cylinder bottom side hose.

Plug the disconnected hose ends.

-

Condition Evaluation Fully operate the The measured value is blade control lever. not within the normal value.

(Normal value: 2.9Âą0.5 MPa) Fully operate the approx. 2 MPa blade control lever.

When operating Oil leaks from the blade raise bottom side port of blade cylinder.

-

The check mentioned above is normal.

a b c d

TADB-03-07-003 a- c-

For Travel Mode Control Blade Lower

b- d-

Blade Raise Travel (Right Forward)

T5-4-29

Cause Faulty blade pilot valve

Faulty control valve (stuck spool) Faulty seal of cylinder

Faulty center joint

SECTION 5 TROUBLESHOOTING Group 4 Troubleshooting B Boom Swing System Troubleshooting Boom swing is not operated or moves slowly. ď‚– As each actuator of blade, swing, and boom swing is operated by pressure oil from main pump P3, the main relief valve of main pump P3 may be faulty.

Procedure Inspection Method 1 Measure secondary pilot pressure of boom swing.

Condition Fully operate the boom swing pedal.

2

Fully operate the boom swing pedal.

-

3

Measure delivery pressure of main pump P3.

-

T5-4-30

Evaluation The measured values are not within the normal values.

(Normal value: 2.9Âą0.5 MPa) approx. 2 MPa The check mentioned above is normal.

Cause Faulty boom swing pilot valve

Faulty control valve (stuck spool) Faulty seal of cylinder

SECTION 5 TROUBLESHOOTING Group 4 Troubleshooting B How to Lower Boom in Case of Emergency and When Engine Stops Prevent personal injury. Confirm dCAUTION: that no one is under the front attachment before

starting the procedure below.

Lower the boom in the following procedures in case the engine stops with the boom raised and is impossible to restart by some reason.

In case the front attachment is not loaded: Loosen overload relief valve (1) dCAUTION: slowly. In case it is loosened rapidly, the boom

may lower rapidly. Do not loosen it more than 3/4 turns as hydraulic oil may spout.

1. Loosen overload relief valve (1) slowly by checking the movement of the boom.

TADB-04-05-001

j : 24 mm

1

m : 70 to 80 N·m (7 to 8 kgf·m, 52 to 59 lbf·ft)

1-

Overload Relief Valve (Blade Raise)

2. After checking that boom has been lowered completely, tighten overload relief valve (1).

In case the front attachment is loaded: 1. Put the matching marks on lock nut (2), adjusting screw (3), and body (4) of overload relief valve (1) at the boom raise side (cylinder bottom side).

4

Loosen adjusting screw (3) slowly. In dCAUTION: case it is loosened rapidly, the boom may lower

2 3

rapidly.

2. Loosen lock nut (2). Loosen adjusting screw (3) slowly by checking the movement of the boom. j : 17 mm (Lock Nut)

TADB-04-05-004

m : 28 to 32 N·m (2.8 to 3.2 kgf·m, 20.5 to 23.5 lbf·ft)

2- 3-

l : 6 mm (Adjusting Screw) 3. After checking that boom has been lowered completely, fit the matching marks and tighten lock nut (2).

IMPORTANT: After completing the work, check the set pressure of overload relief valve (1). (Refer to OPERATIONAL PERFORMANCE TEST / Standard.)

T5-4-31

Lock Nut Adjusting Screw

4-

Body

SECTION 5 TROUBLESHOOTING Group 4 Troubleshooting B (Blank)

T5-4-32

SECTION 5 TROUBLESHOOTING Group 5 Air Conditioner Air Conditioner Troubleshooting

fNOTE:

For handling of the air conditioner, refer to Operator’s Manual .

4

1

5

3

2

MADB-01-003

MADC-01-013

4

6

7

12

11 10

1- 2- 3-

Right Front Air Vent 1 (Defroster) Foot Air Vent Right Front Air Vent 2

4- 5- 6- 7-

Control Panel Right Rear Air Vent Blower Switch Air Conditioner Switch

8- 9- 10- 11-

T5-5-1

Air Conditioner Power Switch Temperature Control Switch Defroster Switch Mode Switch

9

8

MADB-01-066

12- Circulation/Fresh Air Mode Switch

SECTION 5 TROUBLESHOOTING Group 5 Air Conditioner Air Conditioner Electrical Circuit Diagram 1

2

3

4

5 b 6 a 7 15

14 8 13

12

11

10

a-

Fuse #7

b-

Fuse #12

1- 2- 3-

Control Panel Evaporator Sensor Fresh / Re-circulated Air Damper Servo Motor Air Mix Damper Servo Motor

5- 6- 7- 8-

Air Vent Damper Servo Motor Blower Motor Register Displacement Angle Selection Relay

4-

9- 10- 11- 12- 13-

T5-5-2

9

Blower Motor Relay (Low) Blower Motor Relay (Mid) Blower Motor Relay (High) Compressor Relay Pressure Switch

TAEBJ0-05-05-004

14- Compressor 15- Torque Control Solenoid Valve

SECTION 5 TROUBLESHOOTING Group 5 Air Conditioner Troubleshooting IMPORTANT:  When replacing the compressor due to the breakage of compressor from internal lock, sufficiently clean the air conditioner circuit or replace all the parts.  When cleaning is insufficient or all the parts are not replaced, the air conditioner may be broken due to contaminants remaining in the circuit.  Using deteriorated LLC (coolant) or lowconcentration LLC, the heater core will receive a bad influence and it may lead water leaks and shorten the service life of machine.

Replace coolant and manage LLC concentration according to the Operator's Manual.

T5-5-3

SECTION 5 TROUBLESHOOTING Group 5 Air Conditioner Faulty cooling Condition: ď‚– Airflow volume: Normal ď‚– Compressor: Compressor rotates normally ď‚– Compressor pressure: Abnormal Low-pressure side is high

High-pressure side is high

Pressure is low on both sides of highpressure and lowpressure

After cooling at fast speed continuously, cooling power is reduced or air flow volume is reduced

Overcharge air conditioner with refrigerant Faulty compressor

Remove refrigerant thoroughly and recharge refrigerant to proper level after purging Breakage of head gasket Replace compressor Breakage of inlet valve Replace compressor Clogged foreign matter into inlet Replace compressor valve Faulty valve Replace valve

Excessive open of expansion valve Improper water stop valve wire adjustment and/or faulty stop valve Lack of condenser cooling Clogged fin with dirt or mud Cleaning of fin (washing) Overcharge air conditioner Remove refrigerant thoroughly and recharge refrigerant to proper with refrigerant level after purging Clogged high pressure Remove clog or replace parts circuit before receiver Faulty expansion valve Clogged valve (foreign matter) Replace valve Temporary clogged due to freezing Thoroughly perform purging valve (water intrusion) after replacing valve and receiver Lack of refrigerant Normal leakage of refrigerant from Charge air conditioner with hoses refrigerant Gas leaks from pipe joints and/or Re-tighten or replace parts parts Faulty thermistor

T5-5-4

SECTION 5 TROUBLESHOOTING Group 5 Air Conditioner (Blank)

T5-5-5

SECTION 5 TROUBLESHOOTING Group 5 Air Conditioner Air conditioner is not operated. Air conditioner control panel does not light at all. ď‚– Check the wiring connections first.

Procedure Inspection Method Condition 1 Measure voltage at control panel Key Switch: ON harness end #21.

Evaluation 0V

2

The check mentioned above is normal.

-

-

Connector (Harness end) ď‚– Control Panel

TAEBJ0-05-05-001

T5-5-6

Cause (check point) Open circuit in harness between fuse #12 and control panel.

Faulty control panel

SECTION 5 TROUBLESHOOTING Group 5 Air Conditioner Air vent air temperature control is impossible.  Check the wiring connections first.

Procedure Inspection Method Condition 1 Check if any foreign substance prevents operation of air mix damper servo motor.

2 Check continuity in harness between control panel #8 and air mix damper servo motor #1.

Evaluation There is abnormality.

3

Check continuity in harness between control panel #7 and air mix damper servo motor #2.

4

Check continuity in harness between control panel #18 and air mix damper servo motor #5.

5

Measure voltage at air mix Key Switch: ON damper servo motor harness end Air Conditioner Switch: #4.

ON

6

Measure voltage at air mix Key Switch: ON damper servo motor harness end Air Conditioner Switch: #6.

ON

7

-

-

-

Cause (check point) Foreign substance or failure of parts prevents operation. ∞Ω Open circuit in harness between control panel #8 and air mix damper servo motor #1 ∞Ω Open circuit in harness between control panel #7 and air mix damper servo motor #2 ∞Ω Open circuit in harness between control panel #18 and air mix damper servo motor #5 0V Open circuit in harness between control panel #25 and air mix damper servo motor #4 0V Open circuit in harness between control panel #22 and air mix damper servo motor #6 The check Faulty control panel or mentioned faulty air mix damper servo above is normal. motor

Connector (Harness end)  Control Panel

 Air Mix Damper Servo Motor

TAEBJ0-05-05-001

T5-5-7

TAEBJ0-05-05-002

SECTION 5 TROUBLESHOOTING Group 5 Air Conditioner Compressor clutch is not turned ON.  Check the wiring connections first.  Check that air conditioner has been charged with refrigerant.  Check that temperature in the cab is 2 ˚C or more.

Procedure Inspection Method 1 Switch compressor relay with blower motor relay (Mid).

2 Measure voltage at compressor relay harness end #3.

Condition Key Switch: ON Blower Switch: Min. Key Switch: ON

Evaluation The symptom disappears.

0V

3

Measure voltage at compressor relay harness end #1.

Key Switch: ON

0V

4

Check continuity in harness between compressor relay #2 and control panel #40.

Measure voltage at compressor clutch harness end.

-

∞Ω

6

Check the thermistor.

-

7

-

-

5

0V Key Switch: ON Air Conditioner Switch: ON

Cause (check point) Faulty compressor relay Open circuit in harness between compressor relay #3 and fuse #7 Open circuit in harness between compressor relay #1 and fuse #7 Open circuit in harness between compressor relay #2 and control panel #40.

Open circuit in harness between compressor relay and compressor clutch or faulty pressure switch Faulty thermistor

There is abnormality.

The check Faulty compressor clutch mentioned above or faulty control panel is normal.

Connector (Harness end)  Control Panel

 Compressor Relay

TAEBJ0-05-05-001

 Pressure Switch TADB-05-04-005

T2BC-05-04-031

T5-5-8

SECTION 5 TROUBLESHOOTING Group 5 Air Conditioner Blower motor does not rotate.  Check the wiring connections first.  If the blower motor is definitely abnormal, check it first.  Check the display change of blower switches (I), (II), and (III).  Check that the compressor is operated normally.

Procedure Inspection Method 1 Check continuity in harness between blower motor #1 and #2.

2 Check if any foreign substance prevents rotation of blower fan.

3 Check continuity in harness between register #3 and #2 and between register #3 and #1.

4 Switch blower motor relay in failure position with other blower motor relay.

5 Check continuity in harness between harness end #3 of blower motor relay in failure position and register.

6 Check continuity in harness between harness end #2 of blower motor relay in failure position and control panel.

7 -

Condition -

Evaluation ∞Ω

Cause (check point) Faulty blower motor

-

There is abnormality. ∞Ω

Stall of blower motor due to foreign substance Faulty register

-

Key Switch: ON The symptom Air Conditioner Switch: disappears.

ON ∞Ω -

Faulty blower motor relay

Open circuit in harness between blower motor relay and register

-

∞Ω

-

The check Faulty control panel mentioned above is normal.

Open circuit in harness between blower motor relay and control panel

Connector (Harness end)  Control Panel

 Blower Motor Relay

TAEBJ0-05-05-001

 Blower Motor

 Register TADB-05-04-005

T1M9-05-03-008 TAEBJ0-05-05-003

T5-5-9

SECTION 5 TROUBLESHOOTING Group 5 Air Conditioner Air flow volume is not shifted.  Check the wiring connections first.  Check the display change of blower switches (I), (II), and (III) on the control panel.

Air flow volume (I) and (II) are not shifted. (Air flow volume (I) and (II) are the same.)

Procedure Inspection Method 1 Switch blower motor relay (Low) or blower motor relay (Mid) with blower motor relay (High).

2 Check continuity in harness between register #2 and #3.

3 Check continuity in harness between register harness end #2 and #3.

4 -

Condition Key Switch: ON Air Conditioner Switch: ON -

Evaluation The symptom disappears.

-

0Ω

Shorted circuit in harness #2 and #3

-

The check mentioned above is normal.

Faulty control panel

Condition Key Switch: ON Air Conditioner Switch: ON -

Evaluation The symptom disappears.

Cause (check point) Faulty blower motor relay (Low) or faulty blower motor relay (High) Faulty register

-

0Ω

Shorted circuit in harness #1 and #2

-

The check mentioned above is normal.

Faulty control panel

0Ω

Cause (check point) Faulty blower motor relay (Low) or faulty blower motor relay (Mid) Faulty register

Air flow volume (I) and (III) are not shifted. (Air flow volume (I) and (III) are the same.)

Procedure Inspection Method 1 Switch blower motor relay (Low) or blower motor relay (High) with blower motor relay (Mid).

2 Check continuity in harness between register #1 and #2.

3 Check continuity in harness between register harness end #1 and #2.

4 -

Connector (Harness end)  Register

TAEBJ0-05-05-003

T5-5-10

0Ω

SECTION 5 TROUBLESHOOTING Group 5 Air Conditioner Air flow volume (II) and (III) are not shifted. (Air flow volume (II) and (III) are the same.)

Procedure Inspection Method 1 Switch blower motor relay (High) or blower motor relay (Mid) with blower motor relay (Low).

2 Check continuity in harness between register #1 and #3.

3 Check continuity in harness between register harness end #1 and #3.

4 -

Condition Key Switch: ON Air Conditioner Switch: ON -

Evaluation The symptom disappears.

Cause (check point) Faulty blower motor relay (High) or faulty blower motor relay (Mid) Faulty register

0Ω

-

0Ω

Shorted circuit in harness #1 and #3

-

The check mentioned above is normal.

Faulty control panel

Air flow volume (I), (II), and (III) are not shifted. (Air flow volume (I), (II), and (III) are the same.)

Procedure Inspection Method 1 Switch blower motor relay (Low), blower motor relay (Mid), and blower motor relay (High).

Condition Key Switch: ON Air Conditioner Switch: ON

2

-

-

Connector (Harness end)  Register

TAEBJ0-05-05-003

T5-5-11

Evaluation Cause (check point) Air flow volume Faulty blower motor relay is shifted.

(Low), faulty blower motor relay (Mid), or blower motor relay (High) The check Faulty control panel mentioned above is normal.

SECTION 5 TROUBLESHOOTING Group 5 Air Conditioner Air vent cannot be shifted.  Check the wiring connections first.

Procedure Inspection Method Condition 1 Check if any foreign substance prevents operation of air vent damper servo motor.

2 Check continuity in harness between air vent damper servo motor #1 and control panel #10.

Evaluation There is abnormality.

Cause (check point) Foreign substance or failure of parts prevents operation.

∞Ω

Open circuit in harness between air vent damper servo motor #1 and control panel #10 Open circuit in harness between air vent damper servo motor #2 and control panel #9 Open circuit in harness between air vent damper servo motor #4 and control panel #25 Open circuit in harness between air vent damper servo motor #5 and control panel #19 Open circuit in harness between air vent damper servo motor #6 and control panel #22 Faulty control panel or faulty air vent damper servo motor

3

Check continuity in harness between air vent damper servo motor #2 and control panel #9.

-

∞Ω

4

Check continuity in harness between air vent damper servo motor #4 and control panel #25.

∞Ω

5

Check continuity in harness between air vent damper servo motor #5 and control panel #19.

∞Ω

6

Check continuity in harness between air vent damper servo motor #6 and control panel #22.

∞Ω

7

-

The check mentioned above is normal.

-

Connector (Harness end)  Air Vent Damper Servo Motor

 Control Panel

TAEBJ0-05-05-001

T5-5-12

TAEBJ0-05-05-002

SECTION 5 TROUBLESHOOTING Group 5 Air Conditioner Air vent selection is impossible.  Check the wiring connections first.

Procedure Inspection Method 1 Check if any foreign substance prevents operation of fresh/ re-circulated air damper servo motor.

2 Check continuity in harness between fresh/re-circulated air damper servo motor #1 and control panel #11.

3 Check continuity in harness between fresh/re-circulated air damper servo motor #2 and control panel #12.

4 Check continuity in harness between fresh/re-circulated air damper servo motor #4 and control panel #27.

5 -

Condition -

Evaluation There is abnormality.

-

∞Ω

Cause (check point) Foreign substance or failure of parts prevents operation.

Open circuit in harness between fresh/re-circulated air damper servo motor #1 and control panel #11 ∞Ω Open circuit in harness between fresh/re-circulated air damper servo motor #2 and control panel #12 ∞Ω Open circuit in harness between fresh/re-circulated air damper servo motor #4 and control panel #27 The check Faulty control panel or mentioned faulty fresh/re-circulated air above is normal. damper servo motor

-

-

-

Connector (Harness end)  Fresh / Re-circulated Air Damper Servo Motor

 Control Panel

TAEBJ0-05-05-001

T5-5-13

TAEBJ0-05-05-005

SECTION 5 TROUBLESHOOTING Group 5 Air Conditioner Work after Replacing Components The following work is required after replacing compressor, high pressure hose, low pressure hose, condenser, receiver tank, liquid hose, and air conditioner unit. The same work is required when gas leakage is found.

1. Refill Compressor Oil

Amount Of Oil : 100 cm3

2. Charge Air Conditioner with Refrigerant    

Purging Charge air conditioner with refrigerant Warm-up operation Inspection

T5-5-14

SECTION 5 TROUBLESHOOTING Group 5 Air Conditioner Charge Air Conditioner with Refrigerant Necessity of Purging Be sure to purge the air conditioner circuit with a vacuum before charging with refrigerant (HFC-134a) because the following problems can arise if air or other gases remain in the A/C circuit.

1. Pressure rise in the high pressure side If air remains in the air conditioner circuit, this disturbs the heat exchange between refrigerant and air in the condenser, causing pressure to rise in the high pressure side (compressor side).

Usually, refrigerant gas is easily liquefied; however, air cannot be liquefied and remains as a gas in the condenser because the temperature at which air liquefies is extremely low. That is, liquidation of the refrigerant gas in the condenser decreases by the amount of air in the circuit, and the gas pressure in the high pressure side increases accordingly.

W115-02-10-001

2. Metal corrosion If air remains in the air conditioner circuit, a chemical reaction between refrigerant and moisture in the air takes place, and as a result, hydrochloric acid, that corrodes metals such as aluminum, copper and iron, is produced.

W115-02-10-002

3. Plugging of the expansion valve by moisture When high pressure refrigerant gas passes through the expansion valve, gas pressure decreases and temperature drops. Moisture included in high pressure refrigerant gas in the air conditioner circuit freezes at the expansion valve orifice, plugging refrigerant flow.

Operation of the air conditioner becomes unstable and cooling efficiency lowers.

W115-02-10-003

T5-5-15

SECTION 5 TROUBLESHOOTING Group 5 Air Conditioner Procedures for charging air conditioner with refrigerant

1 7

IMPORTANT: Do not mistake the charge hose connections.

1. Close high pressure valve (2) and low pressure valve (7) on manifold gauge (1). Connect high-pressure side charge hose (3) and low-pressure side charge hose (6) on manifold gauge (1) to the high-pressure side charge valve (“D” marked) and to the lowpressure side charge valve (“S” marked) located on the compressor, respectively. Connect charge hose (5) located on the center of manifold gauge (1) to vacuum pump (4).

6 2 3 5 4

W115-02-10-005

IMPORTANT: Remove refrigerant remained in the air conditioner circuit and operate the vacuum pump.

2. Open high pressure valve (2) and low pressure valve (7) on manifold gauge (1). Perform purging for 10 minutes or more by operating vacuum pump (4).

12

S D

T142-02-05-018

1 7

2

4

W115-02-10-005

T5-5-16

SECTION 5 TROUBLESHOOTING Group 5 Air Conditioner IMPORTANT: If the pointer returns to 0, retighten the line connections and perform purging again.

3. When the low pressure gauge reading falls below -0.1 MPa (-750 mmHg), close high pressure valve (2) and low pressure valve (7) and stop vacuum pump (4). Wait for approximately five minutes and confirm that the pointer does not return to 0.

7

2

4

4. With highpressure valve (2) and lowpressure valve (7) on manifold gauge (1) closed, connect charge hose (5) to refrigerant container (8).

W115-02-10-005

7

1

2

5. Open valve (9) of refrigerant container (8). Push air bleed valve (10) on manifold gauge (1) to purge air in charge hose (5) with the refrigerant pressure.

When draining refrigerant, immediately release air bleed valve (10).

5

8

W115-02-10-007

10

9

1

5

8

W115-02-10-007

T5-5-17

SECTION 5 TROUBLESHOOTING Group 5 Air Conditioner IMPORTANT:  Always stop the engine when charging the air conditioner with refrigerant.  Do not position the refrigerant container upside down during charging operation.  When changing the refrigerant container during charging operation, be sure to purge air from the charge hose, as shown in step 10.  Charge the low-pressure side hose first.

6. Fully tighten charge hose (5) connection to gauge manifold (1). Open high pressure valve (2) and valve (9) of refrigerant container (8). Charge with refrigerant (R134a). Close high pressure valve (2) and valve (9) of refrigerant container (8) when high pressure gauge (11) reading reaches 98 kPa (1 kgf/ cm2).

W115-02-10-008

fNOTE:

Use warm water of 40˚C or less to warm refrigerant container (8) to aid in charging operation.

1

11 2

5 9

For inspection of refrigerant leakage, dCAUTION: use a leakage tester for HFC-134a.Do not use a halide lamp used for leakage inspection of refrigerant CFC-12 (R-12).HFC-134a, if exposed to fire, dissolves and generates toxic gas.

7. After charging, check the line connections for gas leaks using leak tester.

T5-5-18

8

W115-02-10-007

SECTION 5 TROUBLESHOOTING Group 5 Air Conditioner 8. Confirm that high pressure valve (2) and low pressure valve (7) on gauge manifold (1) and valve (9) of refrigerant container (8) are closed. Start the engine and operate the air conditioner.

1 7

Operating Conditions of the Air Conditioner  Engine Speed: Slow Idle  Cab Window: Fully Open  Air Conditioner: ON  Airflow volume: Maximum  Temperature Control Switch: Maximum cool

2

9 8

W115-02-10-007

IMPORTANT: Do not open high pressure valve (2) on manifold gauge (1).

9. Open low pressure valve (7) on manifold gauge (1) and valve (9) of refrigerant container (8) to charge with refrigerant.

1 7

fNOTE:

Required refrigerant quantity: 650 g 10. If refrigerant container (8) becomes empty during the charging work, replace refrigerant container (8) with a new refrigerant container as follows:  Close high pressure valve (2) and low pressure valve (7) on manifold gauge (1).  Replace the empty container with new refrigerant container (8).  Tighten, then slightly loosen refrigerant container (8) joint.  Slightly open low pressure valve (7) on manifold gauge (1).  When refrigerant container (8) joint starts to leak, immediately tighten refrigerant container (8) joint and close low-pressure valve (7) on manifold gauge (1).

11. After charging, close low pressure valve (7) on manifold gauge (1) and valve (9) of refrigerant container (8), and stop the engine.

T5-5-19

2

9 8

W115-02-10-007

SECTION 5 TROUBLESHOOTING Group 5 Air Conditioner IMPORTANT: If the air conditioner is operated with very low refrigerant, a bad load will be exerted on the compressor. If the air conditioner is overcharged with refrigerant, cooling efficiency will lower and abnormal high pressure will arise in the air conditioner circuit, causing danger.

12. Start the engine and operate the air conditioner again. Check that cold air blow out from the vents.

13

Operating Conditions of the Air Conditioner  Engine Speed: Slow Idle  Cab Window: Fully Open  Air Conditioner: ON  Airflow volume: Maximum  Temperature Control Switch: Maximum cool

14

fNOTE:

As the bubbles in sight glass (13) vary depending on the ambient temperature, check refrigerant quantity confirming the changes in pressure. Stop the air conditioner and wait until refrigerant returns to the balanced pressure. Then, start the air conditioner again.

Refrigerant Quantity

13- Sight Glass

W115-02-10-009 14- Receiver Tank

Refrigerant Flow in Sight Glass (13) Explanation for Refrigerant Flow in Sight Glass (13) (approx. 1 min. after air conditioner switch is turned ON)

Adequate W115-02-10-016

Overcharged

Immediately after the air conditioner is turned ON, few bubbles are seen. Then, the flow becomes transparent and shows thin milk white color.

No bubbles are seen after the air conditioner is turned ON.

W115-02-10-017

Not Enough

Bubbles are seen continuously after the air conditioner is turned ON. W115-02-10-018

Bubbles exist:

Bubbles are seen in refrigerant flow as both liquid refrigerant and refrigerant gas exist, being mixed.

W115-02-10-019

Transparent: Refrigerant flow is transparent as only liquid refrigerant exists.

W115-02-10-020

T5-5-20

Milk Refrigerant flow shows thin milk white white: as oil and refrigerant are separated.

W115-02-10-019

SECTION 5 TROUBLESHOOTING Group 5 Air Conditioner When attempting to disconnect the dCAUTION: high-pressure-side charge hose, refrigerant and

compressor oil may spout. Disconnect the highpressure side charge hose after the high-pressure side pressure drops to less than 980 kPa (10 kgf/ cm2).

13. After checking refrigerant quantity, disconnect the low-pressure-side charge hose first. Disconnect the low-pressure-side charge hose. Wait for the highpressure-side pressure to drop to less than 980 kPa (10 kgf/cm2, 142 psi). Disconnect the high-pressureside charge hose.

fNOTE:

Do not discharge refrigerant in the charge hose in order not to discharge refrigerant into the atmosphere for the environmental protection.

T5-5-21

SECTION 5 TROUBLESHOOTING Group 5 Air Conditioner Warm-up Operation After charting the air conditioner, carry out warmup operation five minute to lubricate system with compressor oil.

Operating Conditions of the Air Conditioner  Engine Speed: Slow Idle  Cab Window: Fully Open  Air Conditioner: ON  Airflow volume: Maximum  Temperature Control Switch: Maximum cool Inspection After warm-up operation, carry out gas leak check and performance check.

CAUTION: Refrigerant will produce poisonous material if exposed to heat of 1000 °C or more.

Never bring refrigerant close to a fire.

1. Check the air conditioner for gas leaks using a leak tester.

d

 Perform checking under well-ventilated conditions.  Thoroughly wipe off dust from the charge hose connections of the compressor.  Pay special attention to check the line connections.  If any gas leaks are found, retighten the line connections.

2. Performance Check. Carry out performance check of the air conditioner after checking each air conditioner component.     

Check each component for abnormalities.

Carry out ON-OFF check of the compressor clutch.

Check compressor fan belt tension.

Check the coolant level in the radiator.

Operate the air conditioner and check the performance.

W115-02-10-013

W115-02-10-014

T5-5-22

SECTION 5 TROUBLESHOOTING Group 5 Air Conditioner 3. The checklist before the summer season is as follows:  Check each air conditioner component for abnormalities.  Check the line connections for oil leaks.  Check refrigerant quantity.  Check the engine cooling circuit.  Check V belt for wear. Replace if necessary.  Check for clogged condenser.

4. Off-Season Maintenance  During off-season, operate the idler pulley and compressor at least once a month for a short time to check for any abnormal sounds.  Do not remove the compressor belts during offseason. Operate the compressor occasionally at slow speed for 5 to 10 minutes with the belt slightly loosened in order to lubricate the machine parts.

T5-5-23

SECTION 5 TROUBLESHOOTING Group 5 Air Conditioner * Please fill in all sections and return this AIR CONDITIONER TROUBLE REPORT to Hitachi Works Quality Assurance Dept. after experi-encing a problem with your machine’s air conditioning system. < AIR CONDITIONER TROUBLE REPORT >

File No

(1) What Model Operation Type Delivery Date (2) When Date Time Frequency (3) Where Job Site Address Access Road Condition (4) How (Operating Conditions)

Manual

Semi-Auto Year Month

Year Morning Every Day

Month

(Serial No. Full-Auto

Day Daytime Once a Week

State Paved

)

Checked by:

Operating Hour ( Evening Once a Month

County Not Paved (Gravel

Sand

h) Night Times per

Town Soil)

Weather Fine Cloudy Rain Snow Atmospheric Temperature Very Hot Hot Cold Very Cold Operating Conditions Parking Traveling Working Control Panel Temperature Control Paint blanks equal to red indicators. / Fill in set-temperature when full-auto operation A/C ON OFF Air Induction Re-Circulation Fresh Air Circulation AUTO ON OFF Not Available Fill following items when operated in manual mode or when manual control type unit is used.

Vent Position Front Front / Rear Front / Foot Foot Front / Rear and Foot Fan First Second Third Fourth Fifth Sixth (5) How (Problem Symptom) Abnormal Compressor Operation Symptom Not turned ON Not turned OFF Others Uncontrollable air temperature Symptom No cool air No warm air Others Uncontrollable air volume Symptom Air flows in Hi mode only No air flows Small air volume Others Uncontrollable vent hole Symptom Vent hole isn’t selected Others Abnormal panel indication Faulty Indicator Vent Hole A/C AUTO Fresh Air Circulation Fan OFF Fan (Lo • • • Hi) Temperature Control Symptom Stays OFF Stays ON Blinks Others

<Check Result> (1) Is problem reproducible ?

Reproducible Not reproducible (2) Pressure (To be measured at gauge manifold) Low Pressure High Pressure (3) Which parts have been replaced ?

1 2 * Before replacing the control amplifier, be sure to check that the connectors are correctly connected while repeatedly disconnecting and reconnecting connectors.

T5-5-24

MEMO

MEMO

Hitachi Construction Machinery Co., Ltd. Attn: Technical Information Center Tel: 81-29-832-7084 Fax: 81-29-831-1162 E-mail: HCM-TIC-GES@hitachi-kenki.com

Hitachi Ref. No.

SERVICE MANUAL REVISION REQUEST FORM COMPANY NAME: YOUR NAME: DATE: FAX: E-mail:

MODEL: PUBLICATION PART NO.:

(Located at the left top corner in the cover page)

PAGE NO.:

(Located at the bottom center in the page. If two or more revisions are requested, use the comment column)

YOUR COMMENTS / SUGGESTIONS: Attach photo or sketch if required.

If your need more space, please use another sheet.

REPLY:

(Copy this form for usage)

The Attached Diagram List The following diagrams are attached to this manual.

1. ELECTRICAL CIRCUIT DIAGRAM (STANDARD) ELECTRICAL CIRCUIT DIAGRAM (AIR CONDITIONER) (OPTIONAL) 2. ELECTRICAL CIRCUIT DIAGRAM (AUTO SHUT-DOWN) (OPTIONAL) 3. FLOOR HARNESS MAIN HARNESS 4. LIGHT HARNESS CAB HARNESS (OPTIONAL) 5. AIR CONDITIONER FLOOR HARNESS (OPTIONAL) HEATER HARNESS (OPTIONAL) 6. AIR CONDITIONER COMPRESSOR HARNESS (OPTIONAL) AUTO SHUT-DOWN HARNESS (OPTIONAL) 7. OVERLOAD ALARM HARNESS 1 (OPTIONAL) 8. TRAVEL ALARM FLOOR HARNESS (OPTIONAL) 9. ELECTRIC LEVER HARNESS (OPTIONAL) BEACON LIGHT HARNESS (CAB) (OPTIONAL) 10. HYDRAULIC CIRCUIT DIAGRAM