Seb D 014203

SEBM014203
PC1100-6
PC1100SP-6
PC1100LC-6
MACHINE MODEL
SERIAL NUMBER
PC1100-6
PC1100SP-6
PC1100LC-6
10001 and up
10001 and up
10001 and up
This shop manual may contain attachments and optional equipment that are not available
in your area. Please consult your local Komatsu distributor for those items you may
require. Materials and specifications are subject to change without notice.
PC1100-6 mount the SAA6D170-2 engine.

For details of the engine, see the 6D170-2 Series Engine Shop Manual.
1998 1
All Rights Reserved
Printed in Japan 03-98(01)01651
00-1
3
CONTENTS
No. of page
01
GENERAL ........................................................................
01-1
10
STRUCTURE AND FUNCTION ......................................
10-1
20
TESTING AND ADJUSTING ..........................................
20-1
30
DISASSEMBLY AND ASSEMBLY .................................
30-1
40
MAINTENANCE STANDARD .........................................
40-1
90
OTHERS...........................................................................
90-1
00-2
2
PC1100-6
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PC1100-6
00-2-5
3
01
GENERAL
Specification drawings .................................. 01-2

Specifications ................................................. 01-4
Weight table .................................................. 01-6
Fuel, coolant and lubricants ........................ 01-8
PC1100-6
01-1
GENERAL
SPECIFICATION DRAWINGS
BACK HOE
PC1100-6
PC1100LC-6
Unit: mm
fl The figures in ( ) show the value for the PC1100LC-6.
01-2
1
PC1100-6
GENERAL
PC1100SP-6
Unit: mm
PC1100-6
01-3
1
GENERAL
SPECIFICATIONS
SPECIFICATIONS
BACK HOE
Machine model
PC1100-6
Performance
Working ranges
Serial Number
Dimensions
PC1100LC-6
10001 and up 10001 and up 10001 and up
Bucket capacity
m3
5.0
6.5
5.0
Weight of machine
kg
103,000
104,000
109,800
Max. digging depth
mm
9,350
7,900
9,350
Max. vertical wall depth
mm
7,610
5,025
7,610
Max. digging reach
mm
15,350
14,070
15,350
Max. reach at ground level
mm
15,000
13,670
15,000
Max. digging height
mm
13,400
13,000
13,400
Max. dumping height
mm
8,680
8,450
8,680
Max. digging force
kN {kg}
478.6 {48,800} 525,6 {53,600} 478.6 {48,800}
Swing speed
rpm
5.8
5.8
5.8
Swing max. slope angle
deg.
12
12
12
Travel speed
km/h
Gradeability
Ground pressure
deg.
35
35
35
kPa {kg/cm2}
132 {1.35}
[700 mm]
133 {1.36}
[700 mm]
84 {0.86}
[1,000 mm]
Overall length
mm
16,020
14,790
16,020
Overall width
mm
5,475
5,475
5,625
Overall width of track (when extended)
mm
4,965
4,965
5,265
Overall height
mm
6,040
6,265
6,040
Overall height to top of machine
mm
4,880
4,880
4,880
Ground clearance of upper structure
mm
1,790
1,790
1,790
Min. ground clearance
mm
990
990
990
Tail swing radius
mm
4,870
4,870
4,870
Min. swing radius of work equipment
mm
7,965
6,415
7,965
Height of work equipment at min. swing radius
mm
11,390
11,020
11,390
Length of track on ground
mm
4,995
4,995
5,970
Track gauge (when extended)
mm
3,900
3,900
3,900
Height of machine cab
mm
3,925
3,925
3,925
[standard double grouser shoe width]
01-4
1
PC1100SP-6
Lo: 2.1 Hi: 3.2 Lo: 2.1 Hi: 3.2 Lo: 2.7 Hi: 3.2
PC1100-6
GENERAL
SPECIFICATIONS
Machine model
PC1100-6
Serial Number
SAA6D170-2
Type
4-cycle, water-cooled, in-line, vertical, direct injection,

with turbocharger and aftercooler (air cooled)
No. of cylinders bore x stroke
mm
6 170 x 170
{cc}
23.15 {23,150}
Flywheel horsepower
kW/rpm {HP/rpm}
611/1,800 {620/1,800}
Max. torque
Nm/rpm {kgm/rpm}
2,756/1,300 {281/1,300}
Max. speed at no load
rpm
2,000
Min. speed at no load
rpm
730
Min. fuel consumption
g/kWh {g/HPh}
209 {156}
Performance
Piston displacement
Starting motor
24V, 7.5 kW x 2
Alternator
24V, 50A
Battery
12V, 170 Ah x 2
CWX-4
Carrier roller
3 on each side
Track roller
8 on each side
Assembly-type double
Assembly-type double
grouser, 48 on each side
grouser, 55 on each side
Track shoe
Hydraulic
motor
Control
valve
Hydraulic
pump
Undercarriage
Radiator core type
Type
Variable displacement piston type:

HPV160+160, HPV95+95 x 2; gear type SAR100+020+010
Delivery
Set pressure
/min
Piston type: 494+494+600, gear type: 158+33+16
MPa {kg/cm2}
Piston type: 31.4 {320}, gear type: 2.9 {30}
Type x No.
4-spool type x 2, + 5-spool type x 1
Control method
Hydraulic
Travel motor
Piston type (with brake valve, shaft brake):

x 2 (MSF340VP)
Swing motor
Piston type (with safety valve, shaft brake):

x 2 (KMF160AB-2)
1 Boom
Hydraulic cylinder
Hydraulic system
PC1100LC-6
10001 and up 10001 and up 10001 and up
Model
Engine
PC1100SP-6
Cylinder type
1, 2 Arm
STD
1, 2 Bucket
STD
SP version
Double-acting piston Double-acting piston
Inside diameter of cylinder
mm
225
250
160
160
Outside diameter of piston rod
mm
160
170
110
110
Stroke
mm
2,390
2,435
1,825
1,950
Max. distance between pins
mm
5,839
3,620
2,535
2,660
Min. distance between pins
mm
3,449
6,055
4,360
4,610
Hydraulic tank
Box-shaped, with breather
Hydraulic filter
Tank return side
Hydraulic cooler
1: Head side with cushion
PC1100-6
Air cooled (J4)

2: Bottom side with cushion
01-5
GENERAL
WEIGHT TABLE
WEIGHT TABLE
This weight table is a guide for use when transporting or handling components
Unit: kg
Machine model
PC1100-6
PC1100SP-6
PC1100LC-6
Serial Number
10001 and up
10001 and up
10001 and up
3,839.5
3,839.5
3,839.5
2,814
2,814
2,814
PTO (incl. lubricating piping)
505
505
505
No. 1 pump
157
157
157
No. 2 pump
148
148
148
No. 3 pump
191
191
191
Control pump (for control, PTO lubrication
24.5
24.5
24.5
Radiator assembly
239
239
239
Oil cooler assembly
321
321
321
Hydraulic tank (excl. hydraulic oil)
776
776
776
9,660
9,660
9,660
370
370
370
Swing machinery
532 x 2
532 x 2
532 x 2
Swing motor assembly
126 x 2
126 x 2
126 x 2
Travel motor assembly
145 x 2
145 x 2
145 x 2
L.H. 5-spool control valve
260
260
260
R.H. 4-spool control valve
253
253
253
Swing 4-spool control valve
240
240
240
Center swivel joint
69
69
69
Counterweight (excl. mounting bolts)
17,400
17,400
17,400
Track frame assembly
27,478
27,478
29,854
Center frame
6,600
6,600
6,600
Track frame
4,342 x 2
4,342 x 2
5,150 x 2
Carrier roller
80 x 6
80 x 6
80 x 6
Track roller
190 x 16
190 x 16
190 x 20
Idler cushion assembly
1,000 x 2
1,000 x 2
1,000 x 2
788 x 2
788 x 2
788 x 2
1,869 x 2
1,869 x 2
1,869 x 2
2,165
2,165
2,165
Engine assembly
Engine
and aftercooler fan drive)
Revolving frame (incl. left and right decks)

Operators cab
Idler
Final drive assembly
Swing circle assembly
01-6
PC1100-6
GENERAL
WEIGHT TABLE
Unit: kg
Machine model
PC1100-6
PC1100SP-6
PC1100LC-6
Serial Number
10001 and up
10001 and up
10001 and up
Standard shoe (700 mm)
10,630
10,630
Wide shoe (1,000 mm)
12,940
12,940
14,820
Wide shoe (1,200 mm)
16,350
Boom assembly (excl. piping)
10,265
10,110
10,265
Arm assembly (excl. piping)
3,520
3,915
3,520
Bucket assembly (excl. piping)
4,579
5,591
4,579
1,174 x 2
1,174 x 2
1,174 x 2
1,538
1,538
1,538
Bucket cylinder assembly
442 x 2
459 x 2
442 x 2
Boom foot pin
71.4 x 2
71.4 x 2
71.4 x 2
Boom cylinder foot pin
43.8 x 2
43.8 x 2
43.8 x 2
Boom cylinder top pin
43.2 x 2
43.2 x 2
43.2 x 2
Boom-arm connecting pin
168.6
168.6
168.6
Arm cylinder foot pin
92.9
101.3
92.9
Arm cylinder top pin
97.9
97.9
97.9
Link-arm connecting pin
103
103
103
Link-bucket connecting pin
110.4
110.4
110.4
Bucket cylinder top pin
37.9
37.9
37.9
Bucket cylinder foot pin
37.9
37.9
37.9
Arm-bucket connecting pin
120.4
120.4
120.4
Link assembly
817
878
817
Link connecting pin
103
103
103
Track shoe assembly
Boom cylinder assembly

Arm cylinder assembly
PC1100-6
01-7
GENERAL
FUEL, COOLANT AND LUBRICANTS

RESERVOIR
KIND OF
FLUID
AMBIENT TEMPERATURE
22
30
4
20
14
10
32
0
50
10
68
20
86
30
CAPACITY ()
104F
40C
Specified
Refill
55
51
13.5
13.5
21.5
21.5
22
22
800
440
SAE 30
SAE 10W
Engine oil pan
SAE 10W-30
SAE 15W-40
PTO case
Engine
oil
SAE 30
SAE 10W
Swing machinery case (each side)

SAE 30
Final drive case (each side)
Hydraulic system
SAE 10W
Idler (1 each)
Track roller (1 each)
0.75 0.83 0.75 0.83

Gear
oil
GO 140B
Carrier roller (1 each)
Fuel tank
Cooling system
01-8
0.80 0.85 0.80 0.85

0.45 0.50 0.45 0.50
Diesel
fuel
Coolant
ASTM D975 No. 2

880
140
ASTM D975A No.1
Add antifreeze
PC1100-6
GENERAL
NOTE:
(1) When fuel sulphur content is less than 0.5%,
change oil in the oil pan every periodic maintenance hours described in this manual.
Change oil according to the following table
if fuel sulphur content is above 0.5%.
Fuel sulphur content
Change interval of oil in

engine oil pan
0.5 to 1.0%
1/2 of regular interval
Above 1.0%
1/4 of regular interval
(2) When starting the engine in an atmospheric

temperature of lower than 0C, be sure to
use engine oil of SAE10W, SAE10W-30 and
SAE15W-40, even though an atmospheric
temperature goes up to 10C more or less in
the day time.
(3) Use API classification CD as engine oil and if
API classification CC, reduce the engine oil
change interval to half.
(4) There is no problem if single grade oil is
mixed with multigrade oil (SAE10W-30, 15W40), but be sure to add single grade oil that
matches the temperature in the table on the
left.
(5) We recommend Komatsu genuine oil which
has been specifically formulated and approved for use in engine and hydraulic work
equipment applications.
ASTM: American Society of Testing and Material
SAE: Society of Automotive Engineers
API:
American Petroleum Institute
Specified capacity: Total amount of oil including oil for components and
oil in piping.
Refill capacity: Amount of oil needed to refill
system during normal inspection
and maintenance.
PC1100-6
01-9
10
STRUCTURE AND FUNCTION
PTO ................................................................ 10- 2

PTO lubrication system ............................... 10- 3
Radiator, oil cooler, aftercooler .................. 10- 4
Power train ................................................... 10- 6
Swing machinery ......................................... 10- 8
Swing circle .................................................. 10- 9
Final drive ..................................................... 10-10
Track frame ................................................... 10-11
Track shoe .................................................... 10-12
Air piping diagram ....................................... 10-13
Air circuit diagram ....................................... 10-14
Air governor ................................................. 10-15
Air tank .......................................................... 10-15
Safety valve .................................................. 10-16
Horn valve .................................................... 10-16
Grease pump ................................................ 10-17
Hydraulic piping drawing ............................ 10-18
Hydraulic circuit diagram ............................ 10-23
Hydraulic tank .............................................. 10-24
Hydraulic pump ............................................ 10-26
NO. 1 pump .................................................. 10-27
NO. 2 pump .................................................. 10-51
NO. 3 pump .................................................. 10-57
Line oil filter ................................................. 10-67
Pilot oil filter ................................................. 10-68
PC1100-6
Return oil filter ........................................... 10- 69

Drain oil filter ............................................. 10- 70
L.H. 5-spool control valve ......................... 10- 72
R.H. 4-spool control valve ......................... 10- 74
Swing. 4-spool control valve .................... 10- 76
Straight-travel valve .................................. 10- 78
Boom lower regeneration valve ............... 10- 82
Swing motor ............................................... 10- 86
Center swivel joint ..................................... 10- 88
Travel motor ............................................... 10- 89
PPC control relief valve ............................. 10- 99
Safety lock valve ........................................ 10-100
Accumulator ............................................... 10-101
Valve control .............................................. 10-102
Work equipment, swing PPC valve .......... 10-104
Travel PPC valve ........................................ 10-108
Solenoid valve ............................................ 10-112
Work equipment ........................................ 10-114
Air conditioner ........................................... 10-115
Actual electric wiring diagram ................. 10-116
Electric circuit diagram .............................. 10-120
Engine control ............................................ 10-126
Machine control system ............................ 10-137
Machine monitor system .......................... 10-168
10-1
PTO
PTO
1.
2.
3.
4.
5.
6.
7.
8.
Driven gear (No. of teeth: 49)

PTO case
Drive gear (No. of teeth: 56)
Main shaft
Hub
Connection plate
Breather
A.
B.
C.
D.
Center
Center
Center
Center
10-2
of
of
of
of
Specifications
Lubricating oil : 13.5
Reduction ratio: SAR100+020+010 shaft = 1
HPV160+160 shaft = 49 = 0.875
56
42
HPV95+95 shaft =
= 0.750
56
HPV160+160 shaft
crankshaft (SAR100+020+010)
HPV95+95 shaft
HPV95+95 shaft
PC1100-6
PTO LUBRICATION SYSTEM
PTO LUBRICATION SYSTEM

Hydraulic circuit diagram
Hydraulic piping diagram
1.
2.
3.
4.
PTO case
Divider block
Lubricating pipe
Control, PTO lubricating, aftercooler fan drive
pump (SAR100+020+010)
5. Oil filter
PC1100-6
Outline
The PTO uses the control and PTO lubricating,
aftercooler fan drive pump (4). The lubricating
oil inside PTO case (1) passes through oil filter
(5), is sent to top divider block (2), and is then
divided to various parts of the PTO to lubricate
and cool the gears.
10-3
RADIATOR, OIL COOLER, AFTERCOOLER
10-4
PC1100-6
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
Aftercooler
Reservoir tank
Aftercooler fan
Fan guard
Fan pulley
Radiator inlet tube
Fan
Radiator upper tank
Oil cooler
Radiator lower tank
Radiator outlet tube
PC1100-6
Specifications
1. Fan
Outside diameter: 1,320 mm
No. of vanes:
6
Rotating speed:
Standard 1,078 rpm
(At rated engine speed of
1,800 rpm)
2. Radiator
Core type:
CWX-4
Fin pitch:
5 mm
Cracking pressure for pressure valve:
49 9.8 kPa
{0.5 0.1 kg/cm2}
Cracking pressure for vacuum valve:
0 4.9 kPa
{0 0.05 kg/cm2}
3. Oil cooler
Core type:
J4
Fin pitch:
3 mm
4. Aftercooler fan
Outside diameter: 620 mm
No. of vanes:
8
Rotating speed:
Standard 1,430 rpm
(At rated engine speed of
1,800 rpm)
10-5
POWER TRAIN
POWER TRAIN
10-6
PC1100-6
1.
2.
3.
4.
5.
6.
7.
8.
Idler
Center swivel joint
Swing motor (KMF160AB-2)
Final drive, sprocket
Travel motor (MSF340VP)
Engine (SAA6D170-2)
PC1100-6
POWER TRAIN
9.
10.
11.
12.
13.
PTO
No. 3 pump (HPV160+160)
No. 1 pump (HPV95+95)
No. 2 pump (HPV95+95)
Control, PTO lubricating,
aftercooler fan drive pump
(SAR100+020+010)
14. Swing 4-spool control valve
15.
16.
17.
18.
Swing
Travel
Swing
Swing
brake solenoid valve

speed solenoid valve
machinery
circle
A. Swing 4-spool control valve

B. Swing brake solenoid valve
10-7
1
SWING MACHINERY
SWING MACHINERY
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
Swing pinion (No. of teeth: 13)

Cover
Case
Coupling
No. 2 planet gear (No. of teeth: 35)
Ring gear (No. of teeth: 92)
Cover
Swing motor
Dipstick
No. 1 sun gear (No. of teeth: 19)
No. 1 planetary carrier
Drain plug
Specification
Reduction ratio: 19 + 92 x 19 + 92
19
19
= 34.130
10-8
PC1100-6
SWING CIRCLE
SWING CIRCLE
1. Swing circle inner race (No. of teeth: 132)

2. Ball
3. Swing circle outer race
Specifications
Reduction ratio: 183 =10.153
13
Amount of grease: 65 (G2-LI)
a. Inner race soft zone S position

b. Outer race soft zone plug position
PC1100-6
10-9
FINAL DRIVE
FINAL DRIVE
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
Level plug
Drain plug
Cover
Drive gear (No. of teeth: 19)
Hub
Sprocket
Floating seal
Case
Coupling
Travel motor
Idler gear (No. of teeth: 27)
No. 1 ring gear (No. of teeth: 68)
No. 2 ring gear (No. of teeth: 63)
Specifications
13 + 68
19 + 69
)(
)
13
19
63
( 13 ) = 139.852
Reduction ratio: (
10-10
PC1100-6
TRACK FRAME
TRACK FRAME
fl
1.
2.
3.
4.
5.
6.
7.
8.
9.
The diagram shows the PC1100-6.
Idler
Track frame
Carrier roller
Center frame
Final drive
Track roller
Track shoe
Idler cushion
Front guard
PC1100-6
The dimensions and number of track rollers

may differ according to the model, but the
basic structure is the same.
No. of track rollers

Model
No. of rollers (each side)
PC1100-6
PC1100SP-6
PC1100LC-6
10
10-11
TRACK SHOE
TRACK SHOE
Standard shoe
Item
Shoe width
(double shoe)
Model
Link pitch
PC1100-6
PC11000SP-6
PC1100LC-6
700 mm
700 mm
1000 mm
280 mm
280 mm
280 mm
48
48
55
No. of shoes
(each side)
Selection of track shoe

Select the most suitable track shoe from the following table
PC1100-6
PC1100SP-6
PC1100LC-6
CateCateSpecifications Category Specifications gory Specifications gory

Standard 700 mm double
700 mm double
1000 mm double
Option
1000 mm double
1200 mm double
1000 mm double
Category
Use
Rocky ground
normal river soil
Travel in Lo speed when traveling on rough ground with obstacles

such as large boulders and fallen trees.
Normal soil,
soft land
Cannot be used on rough ground where there are large obstacles

such as boulders and fallen trees.
Travel in Hi speed only on flat ground; when it is impossible to
avoid traveling over obstacles, lower the travel speed to approx.
half of Lo speed.
Extremely soft
ground (swampy
ground)
Use only for ground where "A" and "B" sink and are impossible
to use.
Cannot be used on rough ground where there are large obstacles
such as boulders and fallen trees.
Travel in Hi speed only on flat ground; when it is impossible to
avoid traveling over obstacles, lower the travel speed to approx.
half of Lo speed.
Paved surface
The shoes are flat, so they have low gradeability.
Paved surface
The shoes are made of rubber, so be careful when traveling on

rough ground.
Precautions when using
fl Categories "B" and "C" are wide shoes, so

there are restrictions on their use. Therefore, before using, check the restrictions are
consider carefully the conditions of use before recommending a suitable shoe width. If
necessary, give the customer guidance in
their use.
10-12
fl When selecting the shoe width, select the

narrowest shoe possible within the range
that will give no problem with flotation and
ground pressure.
If a wider shoe than necessary is used, there
will be a large load on the shoe, and this
may lead to bending of the shoe, cracking of
the links, breakage of the pins, falling out of
the pins, loosening of the shoe bolts, or other
problems.
PC1100-6
AIR PIPING DIAGRAM
AIR PIPING DIAGRAM
1.
2.
3.
4.
5.
6.
7.
8.
9.
Grease gun
Grease reel
Grease pump
Air governor
Air compressor
Safety valve
Air tank
Horn valve
Air horn
PC1100-6
Outline
This machine uses pressurized air to operate
the air horn and automatic greasing system.
The pressurized air is supplied by air compressor (5) installed to the engine and is stored in
air tank (7).
When the pressure in the air tank reaches 0.82
MPa {8.4 kg/cm2}, the air compressor is unloaded;
when the tank pressure drops below 0.72 MPa
{7.3 kg/cm2}, the air compressor again starts to
supply pressurized air.
10-13
AIR CIRCUIT DIAGRAM
AIR CIRCUIT DIAGRAM
1. Air compressor (capacity: 102 /600 rpm)

2. Unloader valve
+0.35
2
3. Air governor (cut-out pressure: 0.82 +0.03
0.005 MPa {8.4 0.05 kg/cm })
+0.03
+0.35
2
(cut-in pressure: 0.72 0.005 MPa {6.0 0.05 kg/cm })
4. Check valve
5. Air tank
0
2
6. Safety valve (set pressure: 0.95 0
0.05 MPa {9.7 0.5 kg/cm })
7. Battery
8. Horn switch
9. Horn valve
10. Air horn
11. Grease pump
12. Grease reel
13. Grease gun
10-14
PC1100-6
AIR GOVERNOR
AIR TANK
AIR GOVERNOR
Function
Port A is connected to the air tank and port
B is connected to the unloader valve of the
air compressor. The air governor maintains
the air pressure inside the air tank within
the specified range. If the pressure exceeds
the specified pressure, it stops the operation
of the air compressor to prevent the air pressure from rising any higher.
1.
2.
3.
4.
5.
6.
7.
Bubble seat
Diaphragm
Body
Sleeve
Adjustment screw
Spring
Cover
A : From air tank

B : To unload valve
Specifications
Cut-out pressure: 0.82 +0.03
0.005 MPa
2
{8.4 +0.35
0.05 kg/cm })
+0.03
Cut-in pressure: 0.72 0.005 MPa
2
{7.3 +0.35
0.05 kg/cm })
AIR TANK
Specifications
Capacity: 15
PC1100-6
10-15
SAFETY VALVE
HORN VALVE
SAFETY VALVE
1.
2.
3.
4.
5.
6.
7.
Cover
Sleeve
Spring
Pin
Cap
Valve
Nipple
0
Set pressure: 0.95 0.05 MPa {9.70.5 kg/cm2})
Function
The safety valve is installed to the air tank,
and if any pressure above the set pressure
is generated in the air circuit, it acts to release the compressed air inside the air tank
to the atmosphere in order to maintain the
safety of the air circuit.
HORN VALVE
1.
2.
3.
4.
5.
6.
7.
8.
Spring
Magnet
Wire
Wire
Coil
Cover
Piston
Body
A : From air tank

B : To horn
10-16
PC1100-6
GREASE PUMP
GREASE PUMP
1.
2.
3.
4.
5.
6.
7.
Silencer
Valve
Cover
Air chamber
Follow plate
Grease chamber
Grease tank
Function
The pump is divided into air chamber (4)
and grease chamber (6). As the amount of
grease in grease chamber (6) goes down,
follow plate (5) is pulled down to push down
the grease stuck to the edge of grease chamber (6).
A : Air inlet port

B : Grease outlet port
PC1100-6
10-17
HYDRAULIC PIPING DRAWING

BACK HOE
(1/2)
10-18
PC1100-6
PC1100-6
10-19
(2/2)
10-20
PC1100-6
PC1100-6
10-21
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
23.
24.
25.
26.
27.
28.
29.
30.
31.
32.
33.
34.
35.
36.
37.
38.
39.
40.
41.
Bucket cylinder
Arm cylinder
Boom cylinder
Swing motor
Aftercooler fan drive motor
Line oil filter (for R.H. 4-spool control valve)
Oil cooler
Line oil filter (for L.H. 5-spool control valve)
Line oil filter (for swing 4-spool control valve)
Return oil filter
L.H. travel motor
Drain oil filter
Hydraulic tank
Center swivel joint
Boom LOWER regeneration valve
Swing holding brake solenoid valve
Travel speed selector solenoid valve
Straight-travel solenoid valve
Machine push-up solenoid valve

Accumulator
Pilot oil filter
No. 3 pump
Control, PTO lubrication, aftercooler fan drive
pump
No. 2 pump
Oil filter
No. 1 pump
Pilot relief valve
PPC control relief valve
CO cancel solenoid valve
Heavy lift solenoid valve
Swing priority selector solenoid valve
Boom shockless control solenoid valve (LOWER)
Boom shockless control solenoid valve (RAISE)
L.H. PPC valve
Travel PPC valve
R.H. PPC valve
10-22
PC1100-6
HYDRAULIC CIRCUIT DIAGRAM

BACK HOE
fl For details of this page, see section 90.
PC1100-6
10-23
HYDRAULIC TANK
HYDRAULIC TANK
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
Hydraulic tank
Strainer
Oil filler cap
Pressure valve
Safety valve
Return filter
Drain filter
Sight guage
Hydraulic oil temperature gauge
Suction strainer
Drain valve
10-24
Specifications
Tank capacity: 1,146
Amount of oil inside tank: 664 (at H level)
Pressure valve
Relief cracking pressure:
38.3 14.7 kPa

{0.39 0.15 kg/cm2}
Suction cracking pressure: 0 4.51 kPa
{0 0.046 kg/cm2}
PC1100-6
HYDRAULIC PUMP
HYDRAULIC PUMP
Outline
The hydraulic pumps consist of three variable
displacement swash plate type piston pumps
and a control pump. The piston pumps have the
valves shown in the table below, and the control pump is used for the PPC valve control,
aftercooler fan drive, and PTO lubrication.
1. No. 3 pump (HPV160+160)

2. Control pump assembly (SAR100+020+010)
2A. For PPC valve control (SAR100)
2B. For aftercooler fan drive motor (SAR020)
2C. For PTO lubrication (SAR010)
3. No. 2 pump (HPV95+95)
4. No. 1 pump (HPV95+95)
Pump No.1 (HPV95+95)

(type)
Front
Rear
Valve
No.2 (HPV95+95)
No.3 (HPV160+160)
Front
Rear
Front
Rear
CO
NC
TVC
Servo
10-26
PC1100-6
NO. 1 PUMP
NO. 1 PUMP
HPV95+95
1.
2.
3.
4.
5.
6.
7.
Front pump
Front servo valve
Front CO, NC valve
Rear servo valve
Rear CO, NC valve
TVC valve
Rear pump
PC1100-6
P3
PA1
PA2
Pd11
Pd21
Pc
:
:
:
:
:
:
Swing pump pressure IN port

Discharge port
Discharge port
Drain port
Drain port
CO selector pilot port
Pd : Jet sensor downstream

pressure IN port
Ps : Suction port
Pt : Jet sensor upstream pressure
IN port
Psv : Servo basic pressure IN port
10-27
NO. 1 PUMP
1. No. 1 main pump
Pac : Servo actuator port

10-28
PC1100-6
1.
2.
3.
4.
5.
6.
7.
Front shaft
Front cradle
Front case
Rocker cam
Piston
Cylinder block
Valve plate
PC1100-6
NO. 1 PUMP
8.
9.
10.
11.
12.
13.
14.
Front end cap

Coupling
Impeller
Rear end cap
Valve plate
Cylinder block
Piston
15.
16.
17.
18.
19.
Rear case
Rocker cam
Rear cradle
Rear shaft
Servo piston
10-29
NO. 1 PUMP
2. No. 1 pump front servo assembly
1. CO, NC valve
2. Servo valve
PA1 : Main pump pressure IN port

Pe1 : TVC valve output pressure detection port
Pe2 : TVC valve output pressure front, rear interconnection port
10-30
Pc :
Pd :
Pt :
Pac :
Pdr :
Psv :
Pecn :

Jet sensor downstream pressure IN port
Jet sensor upstream pressure IN port
Servo actuator port
Servo valve drain OUT port
Servo basic pressure IN port
CO, NC valve output pressure OUT port
PC1100-6
NO. 1 PUMP
No. 1 pump front servo valve
PA2(IN)
PA2(OUT)
Pac
Pdr
PC1100-6
:
:
:
:
Main pump pressure IN port

Main pump pressure OUT port
Servo actuator port
CO, NC valve drain port
Pdr(OUT) : Servo valve drain OUT port

Psv1
: Servo basic pressure IN port
Pecn
: CO, NC valve output pressure IN port
10-31
NO. 1 PUMP
3. No. 1 pump rear servo assembly
1.
2.
3.
4.
TVC valve
CO, NC valve
Connector
Servo valve

Pc : CO selector pilot port
PC1100-6
Pd : Jet sensor downstream pressure IN port

Pe : TVC valve output pressure front, rear interconnection port
Pt : Jet sensor upstream pressure IN port
Pdr : Servo valve drain OUT port
10-33
NO. 1 PUMP
No. 1 pump rear servo valve
PA1(IN)
PA1(OUT)
PA2(IN)
PA2(OUT)
Pac
10-34
:
:
:
:
:
Main pump pressure

Main pump pressure
Main pump pressure
Main pump pressure
Servo actuator port
IN port
OUT port
IN port
OUT port
Pdr
Pdr(OUT)
Psv1
Psv2
Pecn
:
:
:
:
:
CO, NC valve drain port

Servo basic pressure OUT port
CO, NC valve output pressure IN port
PC1100-6
1.
2.
3.
4.
5.
6.
Plug
Locknut
Control piston
Pin
Arm
Valve body
NO. 1 PUMP
7. Spring
8. Plug
9. Cover
10. Locknut
11. Locknut
12. Cover
13.
14.
15.
16.
17.
18.
Plug
Spring
Piston
Sleeve
Cover
Locknut
Function
Discharge amounts Q1 and Q2 of main pumps
PA1 and PA2 are controlled individually by the
respective servo valves. The relationship between pump discharge amount Q and input signal Pecn to the servo valve is as shown in the
graph on the right. Q varies in proportion to
Pecn.
PC1100-6
10-35
NO. 1 PUMP
Operation
1) Operation in direction of increase of pump discharge amount (max. angle)
The control pump pressure Psv is taken to

port a.
Signal pressure Pecn from the NC valve is
taken from port b to chamber c.
When signal pressure Pecn rises, control piston (8) is pushed to the left by the hydraulic
pressure in chamber c, and stops at a point
where it balances the pressure of springs (4)
and (4A).
At the same time, arm (6) uses servo piston
(19) as a fulcrum and sways to the left in the
same way as control piston (8). This moves
guide spool (13) to the left.
When guide spool (13) moves, port a and
port d are closed and port d is connected to
10-36
drain chamber e. As a result, servo piston

chamber f is also interconnected with chamber e through port g and port d.
At the same time, port a is interconnected
with port h, so the oil flows through port i to
servo piston chamber j, pushes servo piston
(19) to the left, increases the swash plate
angle in the main piston pump and increases
the pump discharge amount.
When servo piston (19) moves, arm (6) rotates clockwise with its center at pin (7).
Guide spool (13) is moved to the right and
closes port a, port d and port h, so the discharge increases by an amount that matches
signal pressure Pecn.
PC1100-6
NO. 1 PUMP
2) Operation in direction of decrease of pump discharge amount (min. angle)
When signal pressure Pecn goes down, control piston (8) moves to the right and stops
at a point where the hydraulic pressure in
chamber c balances the pressure of springs
(4) and (4A).
At the same time, arm (6) uses servo piston
(19) as a fulcrum and sways to the right in
the same way as control piston (8). This
moves guide spool (13) to the right.
When guide spool (13) moves, port a and
port h are closed and port h is connected to
drain chamber e. As a result, servo piston
chamber j is also interconnected with chamber e through port i and port h.
PC1100-6
At the same time, port a is interconnected

with port d, so the oil flows through port g
to servo piston chamber f, pushes servo piston (19) to the right, decreases the swash
plate angle in the main piston pump and
decreases the pump discharge amount.
When servo piston (19) moves, arm (6) rotates counterclockwise with its center at pin
(7). Guide spool (13) is moved to the left and
closes port a, port d and port h, so the discharge decreases by an amount that matches
signal pressure Pecn.
10-37
NO. 1 PUMP
4. TVC valve
PA1 :
PA2 :
PA3 :
Pd :
Pe :
Psv :

Swing pump pressure IN port
TVC valve drain OUT port
TVC valve output pressure OUT port
10-38
1.
2.
3.
4.
5.
Spring
Spool
Piston
Piston
Sleeve
6.
7.
8.
9.
10.
Piston
Body
Solenoid
Sleeve
Piston
PC1100-6
NO. 1 PUMP
OPERATION AND FUNCTION OF TVC VALVE

1) When command current value from controller is small in DH and H mode
Function
When the power mode is at DH mode or H
mode, the pump discharge amount is controlled to the optimum amount by the command current sent from the controller in accordance with the variation in the engine
speed.
In G mode or when the pump prolix switch
is ON, the pump discharge amount is controlled according to the pump discharge pressure (load) by hydraulic sensing which follows a constant pump absorption torque.
fl For details, see MACHINE CONTROL SYSTEM.
PC1100-6
Operation
The command current sent from the controller actuates solenoid push pin (9) and
spool (2) moves. When this happens, the
piston stops at a point where it balances the
total of the force of spring (1), the force of
push pin (9), and the force of
TVC output pressure Pe acting on piston (3).
The command current at this point is small,
so spool (2) is balanced at the bottom.
As a result, port a and port b are almost
completely open, so the pressure oil from
the control pump is almost all output as TVC
output pressure Pe.
In this way, the pump discharge amount becomes the maximum.
10-39
NO. 1 PUMP
2) When command current value from controller is large in DH and H mode
Operation
The command current sent from the controller actuates solenoid push pin (9) and
spool (2) moves. When this happens, the
piston stops at a point where it balances the
force of spring (1). The command current at
this point is large, so spool (2) is balanced at
the top.
As a result, the flow of oil from the control
pump at port a and port b is throttled. At the
same time, the area of the opening at port b
and port c (drain port) becomes larger.
In this way, TVC output pressure Pe goes
down, and the pump discharge amount decreases.
10-40
PC1100-6
NO. 1 PUMP
3) When pump load is small in G mode (pump prolix switch ON)
When G mode is selected (pump prolix

switch ON) solenoid push pin (9) is pushed
up, increases the set pressure of spring (1),
and this condition is maintained.
As a result, the pump absorption torque becomes constant, so TVC output pressure Pe
(= pump discharge amount) is controlled by
the pump discharge pressure.
PC1100-6
Main pump discharge pressures PA1 and

PA2 are low, so spool (2) is pushed down
fully by spring (1). As a result, control pump
discharge pressure Psv and TVC valve output pressure Pe are equal.
At this point, TVC valve output pressure Pe
becomes the maximum, and the main pump
discharge amount is also the maximum.
10-41
NO. 1 PUMP
4) When pump load is large in G mode (pump prolix switch ON)
When main pump discharge pressure PA1

(or PA2) increases, spool (2) is moved up by
piston (4) or piston (6). As a result, the flow
of oil from port a to port b is throttled by the
notch in the spool. At the same time, the
area of the opening at port b and port c
(drain port) becomes larger. In this way, TVC
output pressure Pe goes down, and the
pump discharge amount decreases.
10-42
PC1100-6
NO. 1 PUMP
5. No. 1 pump front CO, NC valve
PA1I : Main pump pressure IN port

Pe1 : TVC valve output pressure front, rear
interconnection port
Pe2 : TVC valve output pressure detection port
Pc : CO selector pilot port
PC1100-6

Pt
: Jet sensor upstream pressure IN port
Pdr2 : Servo valve drain OUT port
Pecn : CO, NC valve output pressure OUT port
10-43
NO. 1 PUMP
6. No. 1 pump rear CO, NC valve
PA1I :
PA1o :
PA2I :
PA2o :
Pe1 :

TVC valve output pressure front, rear interconnection port
Pe2 : TVC valve output pressure IN port
Pc
: CO selector pilot port
10-44
Pd
Pt
Pdr1
Pdr2
Psv1
Psv2
Pecn
:
:
:
:
:
:
:

Servo valve drain IN port
Servo basic pressure OUT port
PC1100-6
NO. 1 PUMP
CO
1.
2.
3.
4.
5.
6.
PC1100-6
valve
Plug
Piston
Spring
Spool
Piston
Plug
NC
7.
8.
9.
10.
11.
12.
valve
Plug
Sleeve
Piston
Spool
Spring
Plug
10-45
NO. 1 PUMP
FUNCTION AND OPERATION OF CO VALVE

1) When main pump discharge pressure is lower than relief pressure
Function
When the load becomes large during operations and the main pump discharge pressure rises to a point close to relief pressure,
the cut-off function of the CO valve acts to
reduce the pump discharge in order to reduce relief loss.
At the same time, it has a cut-off cancel
function actuated by the pilot pressure from
the heavy-lift solenoid valve.
The CO valve is controlled by balancing the
spring with the total of main pump discharge
pressure PA and CO valve output pressure
Pec.
10-46
Operation
Spool (4) is being pushed down fully by
spring (3).
As a result, port a and port b are fully open
and TVC valve output pressure Pe and CO
valve output pressure Pec are equal.
In this way, CO valve output pressure Pec
becomes the maximum and the main pump
discharge amount also becomes the maximum.
PC1100-6
NO. 1 PUMP
2) When main pump discharge pressure becomes close to relief pressure
If the load increases and main pump discharge pressure PA comes close to the relief
pressure, main pump discharge pressure PA
pushes piston (5). At the same time, CO valve
output pressure Pec pushes piston (5), and
spool (4) moves up.
As a result, the flow of oil from port a to
port b is throttled by the notch in the spool,
and the area of the opening at port b and
port c (drain port) becomes larger.
In this way, CO valve output pressure Pec
goes down, and the pump discharge amount
becomes the minimum.
PC1100-6
10-47
NO. 1 PUMP
3) When cut-off function is canceled by heavy-lift solenoid valve
When the heavy-lift solenoid valve is excited

and is switched, pilot pressure Pc is sent to
the port, and piston (2) is pushed down fully.
For this reason, seat (6) contacts seat (7)
and spool (4) is locked.
As a result, main pump discharge pressure
PA goes up, but even when it reaches the
relief pressure, spool (4) is not actuated, so
CO valve output pressure Pec remains at the
maximum.
10-48
PC1100-6
NO. 1 PUMP
FUNCTION AND OPERATION OF NC VALVE

1) When control valve is at neutral
Function
The NC valve controls the main pump discharge amount according to the amount that
the control valve spool is operated. This flow
control function reduces the neutral loss and
fine control loss.
The NC valve is controlled by balancing the
total of the jet sensor output pressure Pt
and the NC valve output pressure Pecn with
the total of the force of NC valve spring (12)
and the jet sensor output pressure Pd.
The jet sensor picks up the flow of oil returning to the tank through the control valve
and takes them as Pt and Pd of the NC valve.
PC1100-6
Operation
When control valve is at neutral, jet sensor
differential pressure (Pt Pd) becomes the
maximum, and the force of jet sensor output pressure Pt pushing piston (10) becomes
larger than the total of the force of spring
(12) and the force of jet sensor output pressure Pd pushing the bottom of spool (11).
As a result, spool (11) is pushed down, so
the flow to port c and port b is throttled, and
the area of the opening of port b and port a
(drain port) becomes larger. In this way, NC
valve output pressure Pecn becomes the
minimum, and the main pump discharge
amount also becomes the minimum.
10-49
NO. 1 PUMP
2) When control lever is operated
When the control valve is moved, the jet

sensor differential pressure (Pt Pd) goes
down in accordance with the movement of
the control valve. Spool (11) is pushed up,
and the area of the opening of port c and
port b becomes larger.
In this way, NC valve output pressure Pecn
becomes larger and the discharge amount
from the main pump increases. In other
words, the pump discharge amount increases according to the amount the control
lever is operated.
10-50
PC1100-6
NO. 2 PUMP
NO. 2 PUMP
HPV95+95
1.
2.
3.
4.
Front pump
Front servo valve
Rear servo valve
Rear pump
PC1100-6
PA1 : Discharge port

PA2 : Discharge port
Pd : Jet sensor downstream
pressure IN port
Pd11 : Drain port
Pd21 : Drain port
Ps
: Suction port
Pt
: Jet sensor upstream

pressure IN port
Psv : Servo basic pressure IN
port
Pecn : CO, NC valve output
pressure IN port
10-51
NO. 2 PUMP
1. No. 2 main pump

10-52
PC1100-6
1.
2.
3.
4.
5.
6.
7.
Front shaft
Front cradle
Front case
Rocker cam
Piston
Cylinder block
Valve plate
PC1100-6
NO. 2 PUMP
8.
9.
10.
11.
12.
13.
14.
Front end cap

Coupling
Impeller
Rear end cap
Valve plate
Cylinder block
Piston
15.
16.
17.
18.
19.
Rear case
Rocker cam
Rear cradle
Rear shaft
Servo piston
10-53
NO. 2 PUMP
2. No. 2 pump front servo
1. Servo valve
10-54
PA1 :
PA2 :
Pac :
Pdr :
Psv :
Pecn :

Servo actuator port
PC1100-6
NO. 2 PUMP
3. No. 2 pump rear servo
1. Servo valve
PC1100-6
PA1 :
PA2 :
Pac :
Pdr :
Psv :
Pecn :
Main pump output pressure OUT port

Main pump output pressure IN port
Servo actuator port
10-55
NO. 3 PUMP
NO. 3 PUMP
HPV160+160
1.
2.
3.
4.
5.
Front pump
Front servo valve
Front CO, NC valve
Rear servo valve
Rear pump
PC1100-6
PA1
PA2
Pd11
Pd21
Pc
Pd
:
:
:
:
:
:
Discharge port
Discharge port
Drain port
Drain port
Jet sensor downstream
pressure IN port
Pe : TVC valve output

pressure IN port
Ps : Suction port
Pt : Jet sensor upstream
pressure IN port
Psv : Servo basic pressure
IN port
10-57
NO. 3 PUMP
1. No. 3 main pump
PA1
PA2
Psv1
Psv2
:
:
:
:
Pump
Pump
Servo
Servo
10-58
discharge port
discharge port
valve basic pressure port
valve basic pressure port
Psv1A
Psv1B
Psv2A
Psv2B
:
:
:
:
Servo
Servo
Servo
Servo
piston output port

valve output port
piston output port
valve output port
PC1100-6
1.
2.
3.
4.
5.
6.
7.
Front shaft
Front cradle
Front case
Rocker cam
Piston
Cylinder block
Valve plate
PC1100-6
NO. 3 PUMP
8.
9.
10.
11.
12.
13.
14.
Front end cap

Impeller
Coupling
Rear end cap
Valve plate
Cylinder block
Piston
15.
16.
17.
18.
19.
Rocker cam
Rear case
Rear cradle
Rear shaft
Servo piston
10-59
NO. 3 PUMP
2. No. 3 pump front servo assembly
1. CO, NC valve
2. Servo valve

Pe1 : TVC valve output pressure IN port
Pe2 : TVC valve output pressure front, rear interconnection port
10-60
Pc :
Pd :
Pt :
Pac :
Pdr :
Psv :
Pecn :

Servo actuator port
PC1100-6
NO. 3 PUMP
No. 3 pump front servo valve
PA2(IN)
PA2(OUT)
Pac
Pdr(IN)
PC1100-6
:
:
:
:

Servo actuator port
CO, NC valve drain Pdr IN port
Pdr(OUT) : Servo valve drain OUT port

Psv1
: Servo basic pressure IN port
Pecn
: CO, NC valve output pressure IN port
10-61
NO. 3 PUMP
3. No. 3 pump rear servo
1. Servo valve
10-62
PA1
PA2
Pac
Pdr
Psv
:
:
:
:
:
Main pump output pressure P1 IN port

Main pump output pressure P2 IN port
Servo actuator port
PC1100-6
NO. 3 PUMP
4. No. 3 pump CO, NC valve
PA1I
Pe1
Pe2
Pc
: Main pump pressure IN port

: TVC valve output pressure IN port
: TVC valve output pressure detection port
: CO selector pilot port
10-64

Pt : Jet sensor upstream pressure IN port
Pdr2 : Servo valve drain OUT port
Pecn : CO, NC valve output pressure OUT port
PC1100-6
NO. 3 PUMP
CO
1.
2.
3.
4.
5.
6.
7.
PC1100-6
valve
Plug
Piston
Spool
Spring
Piston
Plate
Plug
NC
8.
9.
10.
11.
12.
13.
valve
Plug
Sleeve
Piston
Spool
Spring
Plug
10-65
NO. 3 PUMP
Function and operation of CO valve for No. 3 pump:

fl Structurally, the CO valve for the No. 3 pump does not function.
Structurally, the CO valve for the No. 3 pump

is set so that it does not function. As a result, when main pump discharge pressure
PA rises and reaches the relief pressure,
spool (4) is not actuated and CO valve output pressure Pec always remains at the maximum.
10-66
PC1100-6
LINE OIL FILTER
LINE OIL FILTER
1. Element
2. Case
3. Cover
A : From main pump
B : To control valve
PC1100-6
Outline
There are three line oil filters installed to the
discharge side of the main pump. They protect
the circuit and equipment by removing all dirt
and dust from the oil.
10-67
PILOT OIL FILTER
PILOT OIL FILTER
1.
2.
3.
4.
Relief valve
Case
Element
Center bolt
10-68
Outline
The pilot oil filter is installed to the discharge
side of the control pump and protects the PPC
valve and other pilot pressure equipment.
PC1100-6
RETURN OIL FILTER
RETURN OIL FILTER
1.
2.
3.
4.
5.
6.
Cover
Spring
Bypass valve
Bypass valve spring
Element
Housing
A : From control valve

B : To hydraulic tank
PC1100-6
Outline
There are two return oil filters installed to the
rear face of the hydraulic tank. They remove the
dirt and dust in the return oil.
Specifications
Bypass valve set pressure:
0.10 0.02 MPa {1.05 0.2 kg/cm2}
10-69
DRAIN OIL FILTER
DRAIN OIL FILTER
1.
2.
3.
4.
Bracket
Safety valve
Cartridge
Filter
Outline
The drain oil filters are installed between the
hydraulic tank and the travel motor, swing motor, and aftercooler fan drive motor. They remove the dirt and dust in the oil from each
motor drain port.
Specifications
Safety valve set pressure:
0.10 MPa {1.05 kg/cm2}
10-70
PC1100-6
L.H. 5-SPOOL CONTROL VALVE
A1 :
A2 :
A3 :
A4 :
A5 :
B1 :
B2 :
B3 :
B4 :
B5 :
Plug
To boom cylinder
To arm cylinder
To bucket cylinder
To L.H. travel motor P2
Plug
Plug
To arm cylinder
To bucket cylinder
To L.H. travel motor P1
10-72
P :
P1 :
T :
PA1 :
PA2 :
PA3 :
PA4 :
PA5 :
PB1 :
PB2 :
From No. 1, No. 2 main pump

To R.H. 4-spool control valve P2
To hydraulic tank
Plug
From R.H. PPC valve
From L.H. PPC valve
From R.H. PPC valve
From L.H. travel PPC valve
Plug
From R.H. PPC valve
PB3 : From L.H. PPC valve

PB4 : From R.H. PPC valve
PB5 : From L.H. travel PPC
valve
PP : 2-stage main relief
solenoid valve
NCA : To NC valve at rear
of No. 1 main pump
NCB : To NC valve at rear
of No. 1 main pump
PC1100-6
1.
2.
3.
4.
5.
Main relief valve

Spool return spring
Spool (L.H. travel)
Spool (bucket Hi)
Spool (arm Lo)
PC1100-6
6.
7.
8.
9.
10.
Spool (boom Hi)

Spool (bottom)
Jet sensor orifice
Jet sensor relief valve
Valve body
11.
12.
13.
14.
15.
Throttle valve
Check valve with orifice
Check valve spring
Suction-safety valve
Suction valve
10-73
R.H. 4-SPOOL CONTROL VALVE
A1 :
A2 :
A3 :
A4 :
B1 :
B2 :
B3 :
B4 :
P :
P1 :
To R.H. travel motor P1

To boom cylinder
To bucket cylinder
To arm cylinder
To R.H. travel motor P2
To boom cylinder
To bucket cylinder
To arm cylinder
10-74
P2 : To L.H. 5-spool control

valve P1
T : To hydraulic tank
PA1 : From R.H. travel PPC valve
PA2 : From R.H. PPC valve
PA3 : From R.H. PPC valve
PA4 : From L.H. travel PPC valve
PB1 : From R.H. travel PPC valve

PP : From control pump
PR : From 2-stage main
relief solenoid valve
PS : From 2-stage safety
solenoid valve
PT : To hydraulic tank
NCA : To NC valve at front
of No. 1 main pump
NCB : To NC valve at front
of No. 1 main pump
PC1100-6
1.
2.
3.
4.
5.
Main relief valve

Spool (R.H. travel)
Spool (boom Lo)
Spool (bucket Lo)
Spool (arm Hi)
PC1100-6
6.
7.
8.
9.
10.
Spool return spring

Valve body
Jet sensor orifice
Check valve
11.
12.
13.
14.
15.
Check valve spring

Straight-travel valve
Suction valve
10-75
SWING 4-SPOOL CONTROL VALVE
A1
A2
A3
A4
B1
B2
B3
B4
: To boom cylinder
: To swing motor MB
: To bucket cylinder
: To arm cylinder
: Plug
: To swing motor MA
: Plug
: To arm cylinder
10-76
P :
T :
PA1 :
PA2 :
PA3 :
PA4 :
PB1 :
PB2 :
From No. 3 main pump

To hydraulic tank
From control pump
From L.H. PPC valve
From L.H. PPC valve
From L.H. PPC valve
From L.H. PPC valve
From L.H. PPC valve

PR : From 2-stage main relief
solenoid valve
NCA : To NC valve at front of
No. 3 main pump
NCB : To NC valve at front of
No. 3 main pump
PC1100-6
1.
2.
3.
4.
5.
Main relief valve

Spool (for swing)
Spool (for boom plus)
Spool (for bucket plus)
Spool (for arm plus)
PC1100-6
6.
7.
8.
9.
10.
Spool return spring

Valve body
Jet sensor orifice
Check valve with orifice
11.
12.
13.
14.
Piston
Check valve spring
Check valve
Safety valve with suction
10-77
STRAIGHT-TRAVEL VALVE
P : From pump at front of No. 1 main pump

P1 : From pump at rear of No. 1 main pump
P2 : To L.H. travel spool of L.H. 5-spool
control valve
P3 : To bucket, boom spool
P4 : To arm spool
PP : From control pump
PT : To hydraulic tank
10-78
Outline
The straight-travel valve is installed to the
R.H. 4- spool control valve. It acts to prevent
any deviation in the direction of travel if the
boom, arm, or bucket are operated when
the machine is traveling.
PC1100-6
1.
2.
3.
4.
5.
6.
7.
Orifice
Check valve
Spring
Spool return spring
Body
Spool
Cover
PC1100-6
10-79
Function
When the travel is operated at the same time
as the boom, arm, or bucket, the pressure
oil flowing to the left and right travel circuits
is divided and sent to the boom, arm, or
bucket circuit. If the oil in one travel circuit
is divided off, the amount of oil supplied to
the travel motor will be less than in the travel
circuit which is not divided, so the drop in
the supply of oil to the travel motor will
cause the machine to deviate.
To prevent this, the straight-travel valve is
switched to interconnect the left and right
travel circuits. This ensures that the amount
of oil supplied to the left and right travel
motors is equal, so the left and right travel
motors both rotate at the same speed, and
this prevents any travel deviation.
Operation
When travel is operated independently (straighttravel solenoid valve de-energized)
The straight-travel solenoid valve is de-energized, so no pilot pressure flows, and spool
(6) remains pushed to the left.
Because of this, port P2 (left travel circuit)
and port P1 (right travel circuit) are not interconnected, and each circuit remains independent.
When travel and work equipment are operated
at same time (straight-travel solenoid valve excited)
The straight-travel solenoid valve is excited,
so the pilot pressure flows and spool (6) is
pushed to the right.
Because of this, port P2 and port P1 are
interconnected, so the amount of oil supplied to the left and right travel motors is
the same. As a result, the left and right travel
motors both rotate at the same speed, so
there is no travel deviation.
10-80
PC1100-6
BOOM LOWER REGENERATION VALVE
T :
PB :
PM :
Pi :
To tank
From boom cylinder bottom
From boom cylinder head
From boom LOWER PPC valve
10-82
PC1100-6
1.
2.
3.
4.
5.
6.
Body
Spool
Check valve
Spring
Spring (small)
Spring (large)
PC1100-6
10-83
Function
When the boom is lowered, some of the oil
drained from the bottom end of the boom
cylinder is circulated to the cylinder head to
increase the lowering speed of the boom.
Operation
1. When control lever (1) is operated to the
LOWER position, PPC pressure flows and
boom Lo spool (2) moves to the LOWER
position. At the same time, regeneration
valve spool (3) is moved by the PPC pressure from port Pi. As a result, the head and
bottom ends of boom cylinder (4) are interconnected through ports PB and PM.
2. When this happens, the oil from the cylinder
bottom passes through the control valve and
returns to tank (5). Some of the oil enters
port PB of the regeneration valve and flows
from port PM to the cylinder head to increase the lowering speed of the boom.
3. The boom cylinder has a large volume, and
during compound operations, the oil flow
from the pump to the cylinder head is insufficient, so this action prevents any vacuum
from forming inside the circuit.
10-84
PC1100-6
SWING MOTOR
SWING MOTOR
KMF160AB-2
1. Swing motor
2. Swing holding brake
B :
S :
T1 :
T2 :
MA :
MB :
From swing holding brake solenoid valve

From tank
To tank
From cooling piping port S
From swing control valve port B1
From Swing control valve port A1
10-86
Specifications
Model: KMF160AB-2
Theoretical discharge: 160.7 cc/rev
Rated speed: 1830 rpm
Brake release pressure:
1.8 0.4 MPa {18.4 4 kg/cm2}
PC1100-6
SWING MOTOR
1. SWING MOTOR
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
Housing
Brake spring (Belleville spring)
Brake piston
Plate
Disc
Brake case
Output shaft
Cylinder block
Piston
Valve plate
Center shaft
2. SAFETY VALVE
1.
2.
3.
4.
Safety valve
Housing
Check valve
Check valve spring
PC1100-6
Specifications
Safety valve set pressure:
27 MPa {275 kg/cm2} (at 300 /min)
Cracking pressure:
Min. 19.6 MPa {200 kg/cm2} (at 5 /min)
Check valve set pressure: 0.03 MPa {0.3 kg/cm2}
10-87
CENTER SWIVEL JOINT
CENTER SWIVEL JOINT
1.
2.
3.
4.
5.
Cover
Body
Slipper seal
Oil seal
Shaft
10-88
A1 :
A2 :
B1 :
B2 :
C1 :
C2 :
D1 :
D2 :
P1 :
P2 :
T1 :
T2 :
From L.H. travel control valve port B5

To L.H. travel motor port P1
From L.H. travel control valve port A5
To L.H. travel motor port P2
From R.H. travel control valve port B1
To R.H. travel motor port P2
From R.H. travel control valve port A1
To R.H. travel motor port P1
From travel speed selector solenoid valve
To L.H., R.H. travel speed selector valve
To hydraulic tank
From L.H. and R.H. travel motor port Dr
PC1100-6
TRAVEL MOTOR
TRAVEL MOTOR
MSF-340VP
1. Travel selector valve

2. Motor
3. Travel brake valve
P1
P2
PI
T
:
:
:
:
From control valve

From control valve
From travel speed solenoid valve
To hydraulic tank
PC1100-6
Specifications
Model
Theoretical delivery
:
:
:
:
:
MSF-340VP
1st 337.2 cc/rev
2nd 228.6 cc/rev
Rated pressure
34.3 MPa {350 kg/cm2}
Rated speed
1st 1,465 rpm
(at 494 /min.)
: 2nd 2,161 rpm
(at 494 /min.)
Brake release pressure : 1.7 MPa {17 kg/cm2}
10-89
TRAVEL MOTOR
1. Travel motor, travel speed selector valve, parking brake
1. Travel speed selector valve

1a. Spool
1b. Spring
2. Relief valve
2a. Shockless piston
2b. Poppet
10-90
PC1100-6
3.
4.
5.
6.
7.
8.
9.
Rear cover
Collar
Valve plate
Cylinder block assembly
Piston assembly
Holder
Retainer
PC1100-6
TRAVEL MOTOR
10.
11.
12.
13.
14.
15.
16.
Piston assembly
Case
Shaft
Steel ball
Rocker cam
Preload spring
Disc
17. Plate
18. Brake piston
19. Spring
10-91
TRAVEL MOTOR
1-1 Motor
There are 9 pistons (7) assembled in cylinder block (6). The end face of the cylinder
block has a spherical surface and is in contact with valve plate (5), which has two halfmoon shaped ports (divider valve for high/
low speed selector).
The fixed surface (contact surface with the

motor case) forming the non-sliding surface
of rocker cam (13) has two faces. The high/
low speed volume selection for this motor is
carried out by fixing each face to provide
large capacity (low speed) or small capacity
(high speed).
The angling operation of rocker cam (14) is
carried out by actuating control piston (10)
with the self-pressure through the speed selector valve when the motor is being driven,
and this angles the rocker cam.
There are two control pistons each for the
high/low pressure divider ports of valve plate
(5), and these provide propulsion force to
the rocker cam.
10-92
PC1100-6
TRAVEL MOTOR
1-2 Speed selector valve

Operation
1) At low speed (pilot pressure PI = 0)
When pilot pressure PI from the control

pump is 0, spool (1a) of travel speed selector valve (1) is not switched.
In this condition, the oil from the chamber
of control piston (10) passes through spool
PC1100-6
(1a) and is drained into the motor case. There

is no angle propulsion force acting on rocker
cam (14), so the low-speed surface is kept in
a static condition.
10-93
TRAVEL MOTOR
2) At high speed (automatic 2nd)
When the pilot signal is ON, pilot pressure

PI from the control pump acts on travel speed
selector valve (1) and the capacity is automatically changed by the drive pressure of
the travel motor.
Balance of force for travel speed selector
valve
F1 [Force pushing spool (1a) to right (highspeed side)] = A (area of spool (1a) receiving pressure) x PI
F2 [Force pushing spool (1a) to left (lowspeed side)] = A (area of spool (1a) receiving pressure) x PH (motor drive pressure) + force of spring (1b)
i)
When traveling on level ground, if the

travel motor drive pressure is low, the
condition becomes F1 > F2, and spool
(1a) is pushed to the right.
10-94
When this happens, the main oil pressure (M1, M2) passes through spool (1a)
and goes to the control piston chamber.
Rocker cam (14) overcomes moment Mx
with hydraulic force from propulsion
force Fc of control piston (10). It rotates
and holds the moment balance at the
high speed surface and is held in position (Mx < Fc, L).
ii) When operating the steering or traveling
uphill, if the motor drive pressure is high,
and it goes above the set pressure, the
condition becomes F1 < F2, and spool
(1a) is pushed to the left.
When this happens, the main oil pressure (M1, M2) passes through spool (1a)
and is drained to the motor case. This
creates the low-speed condition in the
same way as when PI = 0.
PC1100-6
TRAVEL MOTOR
1-3 Parking brake

The parking brake is a hydraulic release, wet
type, multiple disc negative brake. The release pressure employs a self-pressure release method using the travel motor drive
pressure through the oil passage in the counterbalance valve spool of the travel brake
valve.
When the machine is traveling, the drive
pressure is sent to port P of the parking
brake circuit, acts on the piston in the brake
cylinder chamber, overcomes the force of
the spring and releases the brake.
When the machine is parked or stopped, the
counterbalance valve spool returns to neutral, and the oil in the cylinder chamber is
released to the tank through the counterbalance valve spool, so the brake is applied by
the force of the spring to mechanically lock
the motor shaft and hold the machine in
position.
When parking brake is ON
When the travel lever is placed in neutral,
the counterbalance valve spool returns to
the neutral position and parking brake circuit P is closed.
The pressurized oil in chamber e of the brake
piston passes through the counterbalance
valve spool, is drained to the tank, and brake
piston (18) is pushed fully to the left by force
Fs of spring (19), and the brake is applied.
When parking brake is OFF
When the travel lever is operated, the pressurized oil from the pump actuates the counterbalance valve spool, opens the circuit to
the parking brake, and flows into chamber e
of brake piston (18). It overcomes the force
of spring (19), and pushes brake piston (18)
to the right.
When this happens, the force pushing plate
(17) and disc (16) together is lost, so the
plate and disc separate and the brake is released.
PC1100-6
10-95
TRAVEL MOTOR
1-4 Relief valve
1.
2.
a.
b.
c.
Shockless piston
Poppet
Poppet orifice
Relief housing orifice
Piston stroke
Function
In addition to the pressure control function, this
relief valve has a shockless function (2-stage
pressure increase function). This acts to reduce
the shock generated at the beginning when the
speed is reduced (when the machine is stopped).
Operation
1) When relief valve starts to be actuated (1st
stage)
The area receiving the pressure which lifts
poppet (2) becomes area S1 of the poppet
seat.
For this reason, it has a much larger pressure-receiving area than the pressure-receiving area when it is set (S1 S2), so the relief
actuating pressure becomes a low pressure
of approx. 15.7 MPa {160 kg/cm2}.
This condition is maintained until the movement of shockless piston (1) is completed
(approx. 0.25 sec).
2) When movement of shockless piston is completed (2nd stage)
The pressure in the relief valve spring chamber rises, the pressure on both sides of poppet (2) becomes the same, and it becomes
the specified set pressure.
fl Set pressure and amount of adjustment
Amount of adjustment for one turn:
Approx. 7.8 MPa {80 kg/cm2}
10-96
PC1100-6
TRAVEL MOTOR
2. Travel brake valve
Function
The brake valve consists of counterbalance
valve (3) and check valve (5).
The counterbalance valve acts to prevent the
piston motor from stopping or overrunning.
When traveling downhill, the weight of the
machine makes it try to travel at a speed
faster than the rotation of the motor.
For this reason, if the machine is traveling
with the engine running at low speed, the
motor will rotate under no load or may run
away, which is extremely dangerous.
To prevent this, this valve controls the
amount of oil on the return side in order to
keep the valve pressure constant, and makes
it possible to carry out travel operations
which match the oil delivery from the motor.
PC1100-6
1.
2.
3.
4.
5.
6.
a.
Cap assembly
Return spring
Counterbalance valve
Body
Check valve
Check valve spring
Orifice
Specification
Safety valve set pressure: 34 Mpa {350 kg/cm2}
Counterbalance switching pressure:
1.0 0.1 MPa {10 1 kg/cm2}
Check valve switching pressure:
0.02 0.01 MPa {0.2 0.1 kg/cm2}
10-97
TRAVEL MOTOR
Operation when oil is supplied

When the travel lever is operated, the pressurized oil from the control valve is supplied
to port P1. It pushes open check valve (5a)
and flows from motor inlet port M1 to motor outlet port M2.
However, the motor outlet port is closed by
check valve (5b) and spool (3), so the pressure at the supply side rises.
The pressurized oil at the supply side flows

from orifice a in spool (3) to chamber A.
When the pressure in chamber A goes above
the spool switching pressure, spool (3) is
pushed to the left.
As a result, port M2 and port P2 are connected, the outlet port side of the motor is
opened, and the motor starts to rotate.
Operation of brake when traveling downhill

If the machine tries to run away when
traveling downhill, the motor will turn under
no load, so the pressure at the motor inlet
port will drop, and the pressure in chamber
A through orifice a will also drop.
When the pressure in chamber A drops below the spool switching pressure, spool (3)
is returned to the right by spring (2), and
outlet port M2 is throttled.
As a result, the pressure at the outlet port
side rises, resistance is generated to the rotation of the motor, and this prevents the
machine from running away.
In other words, spool (3) moves to a position where the pressure at outlet port M2
balances the pressure at the inlet port and
the force generated by the weight of the
machine. It throttles the outlet port circuit
and controls the travel speed according to
the amount of oil discharged from the pump.
10-98
PC1100-6
PPC CONTROL RELIEF VALVE
1.
2.
3.
4.
Relief valve
Valve body
Check valve spring
Check valve
PC1100-6
A:
B:
C:
D:
E:
F :
P:
T:
From PPC valve

From solenoid valve
From pilot valve
To PPC valve
To accumulator
To solenoid valve
From control pump
To tank
Specifications
+3
2
Set pressure: 3.1 +0.3
+0 MPa {32 +0 kg/cm }
(at 182 /min)
10-99
SAFETY LOCK VALVE
SAFETY LOCK VALVE
1.
2.
3.
4.
5.
Lever
End cap
Ball
Seat
Body
Outline
The safety lock valve is installed between
the PPC valve and the control relief valve in
the PPC circuit. If the work equipment safety
lever is set to the LOCK position, the safety
lock valve is interconnected with the work
equipment safety lever, so it is actuated. It
stops the oil in the PPC circuit and makes it
impossible to operate the work equipment.
10-100
PC1100-6
ACCUMULATOR
ACCUMULATOR
For PPC valve
1.
2.
3.
4.
5.
6.
Gas plug
Shell
Poppet
Holder
Bladder
Oil port
Specifications
Type of gas
:
Gas volume
:
Max. actuating pressure:
Min. actuating pressure :
Nitrogen gas
500 cc
3.1 MPa {32 kg/cm2}
1.2 MPa {12 kg/cm2}
Function
The accumulator is installed between the PPC
control pump and the PPC valve. Even if the
engine is stopped with the work equipment
raised, pilot oil pressure is sent to the main
control valve by the pressure of the nitrogen
gas compressed inside the accumulator, so
it is possible to lower the work equipment
under its own weight.
Operation
After the engine stops, when the PPC valve
is at neutral, chamber A inside the bladder
is compressed by the oil pressure in chamber B.
If the PPC valve is operated, the oil pressure
in chamber B becomes less than 2.9 MPa
{30 kg/cm2}, so the bladder expands under
the pressure of the nitrogen gas in chamber
A. The oil entering chamber B is sent as the
pilot pressure to actuate the main control
valve.
PC1100-6
10-101
VALVE CONTROL
VALVE CONTROL
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.

Accumulator
Safety lock valve
Safety lock lever
Left PPC valve
Left work equipment lever
Travel PPC valve
L.H. travel lever
R.H. travel lever
Right PPC valve
Right work equipment lever
10-102
Lever positions
1 HOLD
2 Boom RAISE
3 Boom LOWER
4 Bucket DUMP
5 Bucket CURL
6 HOLD
7 Arm IN
8 Arm OUT
9
0
A
B
C
D
E
Swing right
Swing left
Neutral
Travel REVERSE
Travel FORWARD
LOCK
FREE
PC1100-6
WORK EQUIPMENT, SWING PPC VALVE
P : From control pump

P1 : Left: Swing right, Right: Bucket DUMP
10-104
P2 : Left: Swing left, Right: Bucket CURL

P3 : Left: Arm OUT, Right: Boom LOWER
P4 : Left: Arm IN, Right: Boom RAISE
PC1100-6
1.
2.
3.
4.
5.
Spool
Metering spring
Centering spring
Piston
Disc
PC1100-6
6.
7.
8.
9.
10.
Nut (for connecting lever)

Joint
Plate
Retainer
Body
10-105
Operation
1) At neutral
Ports A and B of the control valve and ports
P1, P2, P3, and P4 of the PPC valve are connected to drain chamber D at the bottom.
(Fig. 1)
2) Fine control (neutral fine control)

When piston (4) starts to be pushed by disc
(5), retainer (9) is pushed. Spool (1) is also
pushed by metering spring (2) and moves
down.
When this happens, port P1 is shut off from
drain chamber D. At almost the same time,
it is connected to pump pressure chamber
PP, and the pilot pressure of the control
pump is sent from port P1 to port A.
When the pressure at port P1 rises, spool (1)
is pushed back. Fine control hole f is shut
off from pump pressure chamber PP. At almost the same time, it is connected to drain
chamber D, so the pressure at port P1 escapes.
As a result, spool (1) moves up and down
until the force of metering spool (2) is balanced with the pressure of port P1.
The relationship of the positions of spool (1)
and body (10) does not change until retainer
(9) contacts spool (1).
Therefore, metering spring (2) is compressed
in proportion to the travel of the control lever, so the pressure at port P1 also rises in
proportion to the travel of the control lever.
In this way, the spool of the control valve
moves to a position where the pressure of
chamber A (same as pressure at port P1)
and the force of the return spring of the
control valve spool are balanced. (Fig. 2)
10-106
PC1100-6
3) Fine control (control lever returned)

When disc (5) starts to be returned, spool (1)
is pushed up by the force of centering spring
(3) and the pressure at port P1.
Because of this, port P1 is connected to drain
chamber D, and the pressurized oil at port
P1 is released.
If the pressure at port P1 drops too much,
spool (1) is pushed down by metering spring
(2), so port P1 is shut off from drain chamber D. At almost the same time, it is connected to pump pressure chamber PP, so
the pressure at port P1 supplies the pump
pressure until the pressure recovers to a
pressure equivalent to the position of the
lever.
When the control valve returns, oil in drain
chamber D flows in from the valve on the
side that is not moving. It passes through
port P2 and goes to chamber B to charge
the oil. (Fig. 3)
4) At full stroke
When disc (5) pushes down piston (4), and
retainer (9) pushes down spool (1), port P1
is shut off from drain chamber D, and is
connected to pump pressure chamber PP.
Therefore, the pilot pressure oil from the
control pump flows to chamber A from port
P1 to push the control valve spool.
The return oil from chamber B passes from
port P2 and flows to drain chamber D. (Fig.
4)
PC1100-6
10-107
TRAVEL PPC VALVE
TRAVEL PPC VALVE
P : From control pump

P1 : L.H. travel FORWARD
P2 : L.H. travel REVERSE
P3 : R.H. travel FORWARD
P4 : L.H. travel REVERSE
10-108
PC1100-6
1.
2.
3.
4.
Piston
Plate
Collar
Body
PC1100-6
TRAVEL PPC VALVE
5.
6.
7.
8.
Valve
Metering spring
Centering spring
Bolt
10-109
TRAVEL PPC VALVE
Operation
1) At neutral
Ports A and B of the control valve and ports
P1 and P2 of the PPC valve are connected to
drain chamber D through fine control hole f
in spool (1). (Fig. 1)
T
P
1
P2
P1
A
Control valve
(Fig. 1)
SBP00281
2) Fine control (neutral fine control)

When piston (4) starts to be pushed by disc
(5), retainer (9) is pushed. Spool (1) is also
pushed by metering spring (2) and moves
down.
When this happens, fine control hole f is
shut off from drain chamber D. At almost
the same time, it is connected to pump pressure chamber PP, and the pilot pressure of
the control pump is sent from port A through
fine control hole f to port P1.
When the pressure at port P1 rises, spool (1)
is pushed back. Fine control hole f is shut
off from pump pressure chamber PP. At almost the same time, it is connected to drain
chamber D, so the pressure at port P1 escapes.
As a result, spool (1) moves up and down
until the force of metering spool (2) is balanced with the pressure of port P1.
The relationship of the positions of spool (1)
and body (10) (fine control hole f is in the
middle between drain hole D and pump pressure chamber PP) does not change until retainer (9) contacts spool (1).
Therefore, metering spring (2) is compressed
in proportion to the travel of the control lever, so the pressure at port P1 also rises in
proportion to the travel of the control lever.
In this way, the spool of the control valve
moves to a position where the pressure of
chamber A (same as pressure at port P1)
and the force of the return spring of the
control valve spool are balanced. (Fig. 2)
10-110
5
4
9
2
f
T
P
1
PP
P1
A
P2
Control valve
10
B
(Fig. 2)
SBP00282
PC1100-6
3) Fine control (control lever returned)

When disc (5) starts to be returned, spool (1)
is pushed up by the force of centering spring
(3) and the pressure at port P1.
Because of this, fine control hole f is connected to drain chamber D, and the pressurized oil at port P1 is released.
If the pressure at port P1 drops too much,
spool (1) is pushed down by metering spring
(2), so fine control hole f is shut off from
drain chamber D. At almost the same time,
it is connected to pump pressure chamber
PP, so the pressure at port P1 supplies the
pump pressure until the pressure recovers
to a pressure equivalent to the position of
the lever.
When the control valve returns, oil in drain
chamber D flows in from fine control hole f
of the valve on the side that is not moving.
It passes through port P2 and goes to chamber B to charge the oil. (Fig. 3)
TRAVEL PPC VALVE
2
f
T
P
f'
1
PP
P1
A
P2
Control valve
(Fig. 3)
SBP00283
4) At full stroke
Disc (5) pushes down piston (4), and retainer
(9) pushes down spool (1). Fine control hole
f is shut off from drain chamber D, and is
connected to pump pressure chamber PP.
Therefore, the pilot pressure oil from the
control pump passes through fine control
hole f and flows to chamber A from port P1
to push the control valve spool.
The return oil from chamber B passes from
port P2 through fine control hole f and flows
to drain chamber D. (Fig. 4)
5
4
D
9
f
T
P
f'
1
PP
P2
P1
A
Control valve
(Fig. 4)
SBP00284
PC1100-6
10-111
SOLENOID VALVES
SOLENOID VALVES
Solenoid valve A: Swing holding brake, travel speed selector

Solenoid valve B: Straight travel, machine push-up
Solenoid valve C: CO cancel, heavy lift, swing priority selector
Solenoid valve A
1. Front swing solenoid valve
2. Travel speed selector solenoid valve
3. Rear swing solenoid valve
Solenoid valve B
1. Straight-travel solenoid valve
2.
3. Machine push-up solenoid valve
Solenoid valve C
1. CO cancel solenoid valve
2. Heavy lift solenoid valve
3. Swing priority selector solenoid valve
A1
A2
A3
P
T
:
:
:
:
:
See table on right

See table on right
See table on right
From control pump
To hydraulic tank
10-112
Outline
There are three solenoid valves installed. They
respectively control the hydraulic equipment
listed in the table below.
Connected
port
A1
Solenoid
valve
A
Front swing
(Center of
motor
chassis)
StraightB
travel valve
(Center of of R.H. 4chassis) spool control
valve
C
CO valve of
(Rear of
No. 1, 3
hydraulic
pump
tank)
A2
A3
L.H., R.H.
Rear swing
travel motor
motor
Safety valve
at boom
head end of
R.H. 4-spool
control valve
R.H. 4-spool
Swing 4control valve, spool control
L.H. 5-spool
valve
control valve
PC1100-6
SOLENOID VALVES
1.
2.
3.
4.
5.
6.
7.
Connector
Variable iron core
Coil
Push pin
Spring
Spool
Body
Operation
When solenoid is deenergized
No signal current flows from the controller,
so coil (3) is deenergized.
Because of this, spool (6) is pushed fully to
the left by spring (5).
As a result, port P is closed, so pressure oil
from the control pump does not flow to the
actuator.
At the same time, the oil from the actuator
flows from port A to port T and is drained to
the tank.
When solenoid is energized

When the signal current flows from the controller to coil (3), coil (3) is energized.
Because of this, spool (6) is pushed to the
right by push pin (4).
As a result, pressure oil from the control
pump flows from port P to port A, and then
flows to the actuator.
At the same time, port T is closed, so the oil
does not flow to the tank.
PC1100-6
10-113
WORK EQUIPMENT
WORK EQUIPMENT
BACK HOE
1.
2.
3.
4.
5.
6.
Arm
Bucket cylinder
Arm cylinder
Boom
Boom cylinder
Bucket
10-114
PC1100-6
AIR CONDITIONER
AIR CONDITIONER
AIR CONDITIONER PIPING
STD CAB SPECIFICATION
1.
2.
3.
4.
5.
6.
7.
8.
Duct
Condenser
Air conditioner compressor
Hot water return piping
Hot water pickup piping
Refrigerant piping
Receiver tank
Air conditioner unit
PC1100-6
A : Fresh air
B : Recirculated air
C : Hot air/cold air
10-115
ACTUAL ELECTRIC WIRING DIAGRAM

BACK HOE (1/2)
10-116
PC1100-6
PC1100-6
10-117
(2/2)
10-118
PC1100-6
PC1100-6
10-119
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
14.
15.
16.
17.
18.
19.
20.
21.
22.
23.
24.
25.
26.
27.
28.
29.
30.
31.
32.
33.
34.
35.
36.
37.
38.
39.
40.
41.
42.
43.
44.
Boom working lamp

Battery
Battery relay
Fusible link
APS controller
Fuel level sensor
Room lamp
Horn valve
Travel speed selector solenoid valve
Heavy lift solenoid valve
Swing priority solenoid valve
Hydraulic tank level sensor
Hydraulic oil temperature sensor (high
temperature)
Step light
Boom shockless (LOWER) solenoid valve
Washer tank
Boom shockless (RAISE) solenoid valve
Flash light
Wiper motor
Cab front lamp
R.H. working lamp
Swing R.H. PPC oil pressure switch
Swing L.H. PPC oil pressure switch
Arm IN PPC oil pressure switch
Arm OUT PPC oil pressure switch
Bucket CURL PPC oil pressure switch
Bucket DUMP PPC oil pressure switch
Boom RAISE PPC oil pressure switch
Boom LOWER PPC oil pressure switch
L.H. travel REVERSE PPC oil pressure
switch
L.H. travel FORWARD PPC oil pressure
switch
R.H. travel REVERSE PPC oil pressure
switch
R.H. travel FORWARD PPC oil pressure
switch
Air conditioner compressor
electromagnetic clutch
Alternator
Engine water temperature sensor
APS water temperature sensor
10-120
ELECTRICAL CIRCUIT DIAGRAM
45.
46.
47.
48.
49.
50.
51.
52.
53.
54.
55.
56.
57.
58.
59.
60.
61.
62.
63.
64.
65.
66.
67.
68.
69.
70.
71.
72.
73.
74.
75.
76.
77.
78.
79.
80.
81.
82.
83.
84.
85.
86.
87.
88.
89.
Air cleaner clogging sensor

Starting motor
No. 1 engine speed sensor
TVC solenoid valve
Engine oil pressure switch
(low temperature)
Engine oil pressure switch
(high temperature)
Engine oil level sensor
Fuel injection pump
(with electronic governor)
APS nozzle & glow plug
Relay for swing holding brake
Relay for boom shockless
Relay for boom light
Alarm buzzer
Relay for head light
Starting switch
Horn switch
Fuel control dial
Cigar lighter
Radio
Air conditioner controller
APS actuation switch
Pump controller
R.H. speaker
Engine controller
Governor cut relay
Horn valve relay
APS controller relay
Connector for connecting electronic
governor checker
L.H. speaker
Step light timer
Step light switch
Pump prolix resistor
Wiper washer relay box
Monitor panel
Swing prolix switch
Pump prolix switch
Fuse box
Swing lock switch
Wiper washer switch
Light switch
Alarm buzzer cancel switch
Heater switch
Machine push-up switch
Boom shockless switch
PC1100-6

(1/4)
fl For details of this page, see section 90.
PC1100-6
10-121
(2/4)
10-122
PC1100-6
(3/4)
PC1100-6
10-123
(4/4)
10-124
PC1100-6
ENGINE CONTROL
ENGINE CONTROL
1.
2.
3.
4.
5.
6.
7.
8.
Battery
Battery relay
Starting switch
Fuel control dial
Fuel injection pump with electronic governor
Starting motor
Engine controller
Pump controller
10-126
Outline
The engine can be started and stopped simply by using starting switch (3).
With the dial type engine controller, the control signal from fuel control dial (4) is received by engine controller (7). A drive signal is sent to fuel injection pump (5) with
electronic governor, and the rack position is
controlled to control the engine speed.
PC1100-6
ENGINE CONTROL
1. Operation of system
Starting engine
When the starting switch is turned to the
START position, the starting signal flows to
the starting motor, so the starting motor rotates and starts the engine.
When this happens, the engine controller
confirms the signal voltage from the fuel
control dial and sets the engine speed to the
set speed.
PC1100-6
10-127
ENGINE CONTROL
Engine speed control

The fuel control dial sends a signal voltage
that matches the angle position to the engine controller.
The engine controller calculates the engine
speed to match that signal voltage and controls the electronic governor so that the engine runs at that speed.
10-128
PC1100-6
ENGINE CONTROL
Stopping engine
When the starting switch is set to the STOP
position and the power source (ACC terminal) of the engine controller goes OFF, the
engine controller cuts the drive signal to the
electronic governor and stops the engine.
PC1100-6
10-129
ENGINE CONTROL
2. Function
3-mode selector type engine output control

function
The engine controller receives the DH, H and
G mode switch signals from the monitor
through the network signal and controls the
engine output according to each mode.
(For details of the engine output control function for each mode, see the section on the
machine control system.)
Auto-deceleration function
The pump controller receives the auto-deceleration switch from the monitor panel
through the network signal. The pump controller outputs the deceleration actuation/cancel commands to the engine controller according to the signals from the travel and
work equipment control lever oil pressure
switches.
(For details of the auto-deceleration function
for each mode, see the section on the machine control system.)
Automatic engine warming-up, overheat prevention function

The pump controller receives the signal from
the engine water temperature sensor. The
pump controller then sends the engine speed
commands to the engine controller when
carrying out automatic warming up of the
engine and prevention of overheating.
(For details of the engine automatic warming-up function for each mode, see the section on the machine control system.)
Error display function

The engine controller itself has a self-diagnostic display function, but it has the function of displaying on the monitor the overall
errors (user code, service code) for the pump
controller, monitor, and the machine overall.
Note: The error code displayed on the monitor and the error code displayed by
the engine controller itself are not the
same.
10-130
PC1100-6
ENGINE CONTROL
3. Components of system
Fuel control dial
1.
2.
3.
4.
5.
6.
Knob
Dial
Spring
Ball
Potentiometer
Connector
Function
The fuel control dial is installed at the bottom of the monitor panel. A potentiometer
is installed under the knob, and when the
knob is turned, it rotates the potentiometer
shaft.
When the shaft rotates, the resistance of the
variable resistor inside the potentiometer
changes, and the desired throttle signal is
sent to the engine throttle and pump controller.
The hatched area in the graph on the right is
the abnormality detection area and the engine speed is set at low idling.
PC1100-6
10-131
ENGINE CONTROL
FUEL INJECTION PUMP WITH ELECTRONIC GOVERNOR

STRUCTURAL DIAGRAM
1.
2.
3.
4.
5.
Delivery valve
Plunger barrel
Plunger
Hydraulic piston
Hydraulic control valve (adjusting fuel
injection amount)
6. Hydraulic control valve (adjusting fuel
injection timing)
7. Gear pump
As seen from rear
Left: Oil
Right: Fuel
8. Center bearing
9. Camshaft
10. Roller
11. Tappet
12. Pump housing
13. Tappet guide
14. Spring nut
10-132
Function
With control of the fuel injection amount,
the governor actuation hydraulic pressure is
adjusted by the hydraulic control valve according to the command from the engine
controller. It then acts on the piston at the
rear of the rack and moves the control rack
to adjust the fuel injection amount.
The fuel injection timing is adjusted by
changing the length of the plunger of the
fuel injection pump.
The plunger is divided into two parts, and it
is possible to change the free stroke by sending electronically controlled hydraulic pressure between the two parts to change the
length.
The governor solenoid and prestroke solenoid are proportional solenoids, and change
the input current from the controller to a
propulsion force. This propulsion force is
used to control the spool of the hydraulic
control valve (the valve for the governor and
the valve for adjusting the fuel injection timing) to change the hydraulic pressure.
PC1100-6
ENGINE CONTROL
HYDRAULIC CIRCUIT
PLUNGER BARREL VARIABLE PRESTROKE STRUCTURE
1. Hydraulic pump
2. Relief valve
Set pressure: 1.5 MPa {15 kg/cm2}
3. Filter
4. Solenoid valve for controlling rack position
5. Hydraulic cylinder for controlling rack
position
6. Solenoid valve for controlling prestroke
7. Hydraulic cylinder for controller prestroke
8. Filter
9. Fuel injection pump assembly with
electronic governor
PC1100-6
A : From engine main gallery

B : To engine oil pan
10-133
ENGINE CONTROL
Engine throttle, pump controller
10-134
PC1100-6
ENGINE CONTROL
Input and output signals
PC1100-6
10-135
MACHINE CONTROL SYSTEM

CONTROL FUNCTIONS
1
OFF (Cancel)
Auto deceleration function
2
Electronic OLSS function
3
ON
3-mode selector type engine torque control function
3-mode selector type pump torque control
Cut-off control
Flow control
OFF
Heavy-lift function
ON
4
OFF (Digging improvement mode)

2-stage boom pushing force
selector function
ON (Machine push-up mode)
(Machine push-up)
5
Swing control function
Machine
control
system
6
Engine automatic warming up,
overheat prevention function
7
Travel speed selector
function
Travel pressure
rise function
Lo (Low speed) fixed
Travel speed
selector function
Hi (High speed)
Lo (low speed)
automatic gear shift
ON
Boom shockless control
function
Cancel
9
Straight-travel function
10
Swing priority function
11
Boom assurance function
PC1100-6
10-137
MACHINE CONTROL SYSTEM DIAGRAM
10-138
PC1100-6
PC1100-6
10-139
1. Auto deceleration function
Function
If all the control levers are at neutral when
waiting for work or waiting for a dump truck,
the engine speed is automatically reduced
to a midrange speed to reduce fuel consumption and noise.
If any lever is operated, the engine speed
returns immediately to the set speed.
10-140
PC1100-6
Operation
Control levers at neutral
If the engine is running at above the deceleration actuation speed (approx. 1300 rpm),
and all the control levers are returned to
neutral, the engine speed drops immediately
to approx. 100 rpm below the set speed to
the No. 1 deceleration position.
If another 4 seconds passes, the engine
speed is reduced to the No. 2 deceleration
position (approx. 1300 rpm), and is kept at
that speed until a lever is operated.
PC1100-6
When control lever is operated

If any control lever is operated when the
engine speed is at No. 2 deceleration, the
engine speed will immediately rise to the
speed set by the fuel control dial.
10-141
2. Electronic OLSS function

Pump control system
Interconnected control of all pumps is carried out by one TVC valve.

DH mode: Total horsepower control by engine speed sensing
H mode: Total horsepower control by engine speed sensing
G Mode: Constant torque control
Prolix circuit: Absorption torque equivalent
to G mode
10-142
PC1100-6
1) Control method in each mode

DH, H mode
Matching point in DH, H mode: Rated output

point
Model
Mode
DH
H
PC1100-6
456 kW/1,800 rpm {611 HP/1,800 rpm}
419 kW/1,730 rpm {562 HP/1,730 rpm}
When the load on the pump rises and the

pressure rises, the engine speed goes down.
When this happens, the pump discharge
amount is reduced, and the engine speed is
controlled so that it becomes close to the
rated speed.
If the reverse happens and the pressure goes
down, the system is controlled so that the
pump discharge amount is increased until
the engine speed reaches close to the rated
speed.
By repeating this control, the engine can always be used at near the rated output point.
Compared with the DH mode, which provides the maximum output, the H mode lowers the engine output to provide matching
at a point which gives better fuel consumption efficiency than the DH mode.
PC1100-6
10-143
G mode
Matching point
Mode
Partial output point
78%
Model
Mode
G
PC1100-6
355 kW/1,740 rpm
{476 HP/1,740 rpm}
When the pump load increases and the pressure rises, the engine speed drops.
When this happens, combined control of the
engine and pump carries out controls so that
the engine speed goes down while the pump
absorption torque is maintained constant
along the equal horsepower curve of the
engine.
Compared with the H mode, the high idling
engine speed is lowered, so the engine can
be used in a good fuel consumption range.
2) Cut-off function
If the load during operation increases and
the pump discharge pressure rises to near
the relief pressure, the main pump cut-off
valve is actuated to reduce the relief loss.
10-144
PC1100-6
3. Heavy lift function
10-146
PC1100-6
Outline
This function increases the boom lifting
power by approx. 10%.
It can be actuated only when the boom
RAISE is being actuated independently. If
the arm IN or bucket CURL are operated at
the same time, the heavy-lift function is automatically canceled.
Operation
Lever operation
Heavy-lift
switch
OFF
ON
Heavy-lift
solenoid
valve
Main relief
valve set
pressure
CO valve
Boom
lifting
force
Deenergized
31.4 MPa
{320 kg/cm2}
Actuated
Normal
Neutral
Excited
34.3 MPa
{350 kg/cm2}
Canceled
10% up
Boom
RAISE
Arm IN or
bucket CURL
Operated
Operated
Operated
If the arm IN or bucket CURL are operated during boom RAISE operations, this function is automatically canceled, and the condition becomes
the same as when the switch is turned OFF.
Normal
fl Heavy-lift solenoid valve

For details of the structure and function, see SOLENOID VALVE.
fl CO valve
For details of the structure and function, see NO. 1 PUMP.
fl Main relief valve
For details of the structure and function, see L.H. 5-SPOOL VALVE.
PC1100-6
10-147
4. 2-stage boom pushing force selector

function
10-148
PC1100-6
Outline
This function switches the pushing force of
the boom. It is aimed to provide both increased digging efficiency by reducing the
digging resistance of the boom, and increased ease of operation by increasing the
thrusting force for excavation, digging square
holes, carrying out twist turns, or escaping
from soft ground.
Operation
This function acts to change the set pressure of the safety valve at the boom cylinder end of the
R.H. 4-spool control valve boom Lo in 2 ways: to low pressure (14.7 MPa {150 kg/cm2) and high
pressure (33.3 MPa {340 kg/cm2}.
Mode
Boom
pushing
force (low
mode)
Boom
pushing
force (high
mode)
Machine
push-up
switch
Machine
Safety valve
push-up
set pressure
solenoid valve
Excited
De-energized
Effect
14.7 MPa
{150 kg/cm2}
By reducing the boom pushing force, it is

made easier for the boom to escape automatically in the RAISE direction and to reduce the number of times that the boom is
operated. At the same time it also makes
the digging operation smoother.
33.3 MPa
{340 kg/cm2}
By increasing the thrust force for boom

LOWER, the ease of operation is improved
for excavation, digging square holes, carrying out twist turns, or escaping from soft
ground.
fl Machine push-up solenoid valve

For details of the structure and function, see SOLENOID VALVE.
fl Boom safety valve
For details of the structure and function, see R.H. 4-SPOOL VALVE.
PC1100-6
10-149
5. Swing control function
Function
The system is provided with a swing lock
and swing holding brake function.
10-150
PC1100-6
1) Swing lock, swing holding brake function

The swing lock (manual) can be locked at
any desired position, and the swing lock and
swing holding brake (automatic) are interconnected with the swing, so they prevent
any hydraulic drift after the swing is stopped.
Actuation
Mode
Swing lock
switch
Swing lock
lamp
fl Swing brake solenoid valve

For details of the structure and function, see
SOLENOID ASSEMBLY.
fl Swing motor
For details of the structure and function, see
SWING MOTOR.
Swing brake
solenoid valve
Actuation
When swing and work equipment levers are placed at
neutral, swing brake is applied after approx. 5 sec;
when any swing or work equipment lever is operated,
brake is canceled and swing can be operated freely
Swing
holding
brake
OFF
OFF
See diagram
on right
Swing
brake
ON
ON
De-energized
2) Operation of swing lock prolix switch

If any abnormality should occur in the controller, and the swing holding brake is not
actuated normally and the swing cannot be
operated, the swing lock prolix switch can
be operated to cancel the swing lock and
allow the swing to be operated.
fl Even when the swing lock prolix switch is
turned ON, the swing lock switch stays ON
and the swing brake is not canceled.
fl When the swing brake is canceled, the swing
has only a hydraulic brake operated by the
safety valve, so if the swing is stopped on a
slope, there may be hydraulic drift.
Swing lock is actuated and swing is held in position.

Even when swing lever is operated, swing lock is not
canceled and swing does not move.
Swing
lock
prolix
switch
ON
(when controller
is abnormal)
OFF
(when controller
is normal)
Swing
lock
switch
ON
OFF
ON
OFF
Swing
brake
Swing lock
applied
Swing lock
canceled
Swing lock
applied
Swing holding brake

applied
3) Hydraulic oil quick warm-up function when

swing lock switch is ON
When the swing lock switch is turned ON,
the pump cut-off is canceled. If the work
equipment is relieved in this condition, the
hydraulic oil temperature will rise more
quickly and the warming-up time can be reduced.
PC1100-6
10-151
6. Automatic warming-up and engine overheat

prevention function
Function
If the water temperature is low, this automatically raises the engine speed to warm
up the engine after it is started. In addition,
if the water temperature rises too high during operations, it automatically lowers engine speed to low idling, and reduces the
load of the pump to prevent overheating.
10-152
PC1100-6
1) Engine automatic warming-up function

After the engine is started, if the engine coolant temperature is low, the engine speed is
automatically raised to warm up the engine.
Conditions for actuation (both are necessary)
Actuation
Coolant temperature: Less than 30C

Engine speed: Less than 1200 rpm
Engine speed: 1200 rpm
Conditions for cancellation (any one)
Cancellation
Coolant temperature: 30*C or above
Automatic
Automatic warming-up time: 10 minutes or more
Manual
Fuel control dial: Held at more than 70% of

full throttle for more than 3 seconds
Engine speed: As desired
2) Engine overheat prevention function

This function protects the engine by lowering the pump load and engine speed to prevent overheating when the engine coolant
temperature has risen too high.
This system is actuated at 105C and above.
Actuation condition
Water temperature:
105C and above
(Water temperature gauge:
Red range)
Actuation, remedy
Working mode
:
Engine speed
:
Monitor warning lamp :
Alarm buzzer
:
In any mode
Low idling
Lights up
Sounds
Cancel condition
Water temperature: Below 105C
Fuel control dial : Return temporarily
to low idling position
When the above conditions are met, the
system returns to the condition before
the overheat prevention function was
actuated (manual reset).
PC1100-6
10-153
7. Travel speed selector function

1) Travel pressure rise function
10-154
PC1100-6
Outline
To maintain the drawbar pull when traveling,
the cut-off is canceled and the main relief
pressure is raised from 31.4 MPa {320 kg/
cm2} to 34.3 MPa {350 kg/cm2}.
Operation
When traveling
When not traveling
PC1100-6
Pressure increase
solenoid valve
Main relief valve

set pressure
Cut-off cancel
solenoid valve
CO valve
Energized
34.3 MPa
{350 kg/cm2}
Energized
Canceled
Deenergized
31.4 MPa
{320 kg/cm2}
Deenergized
Actuated
10-155
2) Travel speed selector function
The travel pressure (self pressure) changes the

swash plate angle of the travel motor and automatically shifts the speed range.
When traveling at high speed with the travel
speed switch at Hi, if the travel pressure
goes above 28.4 MPa {290 kg/cm2}, such as
when starting to travel uphill, the self pressure shifts to low speed travel. If the machine continues to travel at low speed and
then comes again to a flat area, when the
travel pressure drops below 28.4 MPa {290
kg/cm2}, the speed is switched back to high
speed travel.
Travel speed
switch
Travel speed
solenoid valve
Travel motor
swash plate angle
Travel speed
Remarks
Lo
Deenergized
Max.
Low speed
(max 2.1 km/h)
Suitable for traveling on rough

ground or traveling downhill
Hi
Energized
Max.
Min
Low speed (2.1 km/h)

high speed (3.2 km/h)
Suitable for moving

long distances
10-156
PC1100-6
8. Boom shockless control function

This function improves safety by preventing spillage of the load from the bucket and by reducing
the shock when the boom is stopped, thereby reducing operator fatigue.
Actuation
Boom shockless
switch
Cancel solenoid
valve
Boom shockless
control
Remarks
ON
(Contacts open)
De-energized
ON
Suitable for normal operations
OFF
(Contacts closed)
Excited
Canceled
Suitable for compacting or

skeleton work
If the boom is raised, the pilot pressure from the PPC valve is generated in line A. When this
happens, the pressure in line A passes through check valve (2) and pushes the spool of the main
valve in the direction of the arrow. The pilot oil at the left end of the spool passes through line B
and the PPC valve, and returns to the tank. However, when this happens, check valve (4) is being
pushed open by the pressure in line A, so it also allows the oil to pass in the opposite direction.
For this reason, the boom can be raised without any delay in response.
In this condition, if the boom RAISE operation is stopped, the spool of the main valve moves in the
opposite direction to the arrow and drains the oil from line A. However, the action of check valve
(2) means that the oil must pass through orifice (1). As a result, the spool returns slowly to the
neutral position to prevent any shock.
PC1100-6
10-157
9. Straight-travel function
10-158
PC1100-6
Outline
When the travel is operated at the same time
as the boom, arm, or bucket, the pressure
oil flowing to the left and right travel circuits
is divided and sent to the boom, arm, or
bucket circuit.
If the oil in one travel circuit is divided off,
the amount of oil supplied to the travel motor will be less than in the travel circuit which
is not divided, so the drop in the supply of
oil to the travel motor will cause the machine to deviate.
To prevent this, the straight-travel valve is

switched to interconnect the left and right
travel circuits. This ensures that the amount
of oil supplied to the left and right travel
motors is equal, so the left and right travel
motors both rotate at the same speed, and
this prevents any travel deviation.
Operation
Left and right
travel levers
Work equipment
control lever,
swing lever
Straight-travel
solenoid valve
Straight-travel
valve
Remarks
Neutral
De-energize
Not actuated
Left and right travel motor

circuits independent
Operated
Excited
Actuated
Left and right travel motor

circuits actuated
Operation
PC1100-6
10-159
10. Swing priority function
There is a swing priority mode switch on

the monitor panel. By turning this switch
ON/OFF it is possible to change the matching of the boom RAISE and swing. This divides the flow to provide a swing speed
which matches the swing angle, thereby enabling the operator to carry out compound
operations easily.
Swing priority mode OFF:
90 swing and load dump truck
Swing priority mode ON:
180 swing and load dump truck
Solenoid
Swing priority
selector valve
Number of
boom riase
control valve
Swing priority
mode OFF
(standard)
OFF
(de-energized)
OFF
Swing priority
mode ON
(swing priority)
ON
(excited)
ON
10-160
PC1100-6
Operation
When swing priority mode is OFF:
Boom RAISE is driven by 3 control valves (R.H. 4-spool control valve, L.H. 5-spool control valve,
and swing 4-spool control valve).
When swing priority mode is ON:
Swing priority solenoid valve is driven and swing 4-spool control valve is locked. As a result, boom
RAISE is driven by 2 control valves (R.H. 4-spool control valve and L.H. 5-spool control valve). (The
swing and boom RAISE control valves become independent.)
PC1100-6
10-161
11. Swing assurance function
If the swing is operated at the same time as the arm or bucket, the throttle valve in the arm or
bucket circuit acts to ensure the flow of oil to the swing to ensure good performance during
combined operations.
Operation
There is a throttle valve in the arm circuit of the swing 4-spool control valve, and when the swing
PPC pressure goes above 1.5 MPa {15 kg/cm2} (when the control lever is operated approx. half
way), the swing assurance selector valve is actuated and the swing drive pressure locks the pilot
check valve of the bucket throttle valve in the swing 4-spool control valve.
When this condition occurs, the oil in the swing 4-spool control valve forms a parallel circuit, so
the flow of oil to the arm and bucket is throttled by the throttle valve and the drive pressure for the
swing rises. In this way, the drive for the swing is ensured.
10-162
PC1100-6
12. Components of system

1) Pump controller
10-164
PC1100-6
PC1100-6
10-165
2) Engine speed sensor
1.
2.
3.
4.
5.
Wire
Magnet
Terminal
Housing
Connector
Function
The engine speed sensor is installed to the
ring gear portion of the engine flywheel. It
counts electrically the number of gear teeth
that pass in front of the sensor, and sends
the results to the engine throttle and pump
controller.
This detection is carried out by a magnet,
and an electric current is generated every
time the gear tooth passes in front of the
magnet.
3) PPC hydraulic pressure switch

1. Plug
2. Switch
3. Connector
Specifications
Composition of points: N.O. points
Actuation (ON) pressure:
0.5 0.1 MPa (5.0 1.0 kg/cm2)
Reset (OFF) pressure:
0.3 0.05 MPa (3.0 0.5 kg/cm2)
Function
There are 8 switches installed
to the PPC shuttle valve. The
operating condition of each actuator is detected from the PPC
pressure, and this is sent to the
engine throttle and pump controller.
10-166
PC1100-6
4) TVC prolix resistor

1
SBP00370
1. Resistor
2. Connector
Specification
Resistance: 20
Function
This resistor acts to allow a suitable current
to flow to the TVC solenoid when the TVC
prolix switch is ON.
No current flows when the TVC prolix switch
is OFF.
5) Fuel control dial, electronic governor

fl See ENGINE CONTROL.
6) Monitor panel
fl See MACHINE MONITOR SYSTEM.
7) TVC valve
fl See HYDRAULIC PUMP.
PC1100-6
10-167
MACHINE MONITOR SYSTEM
Function
The machine monitor system uses the sensors installed to all parts of the machine to
observe the condition of the machine. It processes this information swiftly, and displays
it on a panel to inform the operator of the
condition of the machine.
The content of the information displayed on
the machine can broadly be divided as follows.
1. Monitor portion
This gives an alarm if any abnormality occurs in the machine.
2. Gauge portion
This always displays the condition of the
machine (coolant temperature, fuel level).
10-168
The monitor panel also has various built-in

mode selector switches, and functions as the
control panel for the machine control system.
PC1100-6
1. Monitor panel
Outline
The monitor panel consists of the switches
for the monitor display functions, mode selector, and electrical components.
It has a built-in CPU (Central Processing Unit),
and processes, displays, and outputs the information.
The monitor display panel uses a liquid crystal display (LCD). The mode switches are flat
sheet switches.
PC1100-6

CN-P01
Pin No.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
CN-P02
Name of signal
NC
NC
NC
N/W signal
Swing lock
Buzzer stop
Buzzer output
Lamp
Key ON signal
Acc signal
N/W signal
NC
NC
N/W GND
NC
NC
NC
Preheating
Start signal
NC
Pin No.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
Name of signal
GND
Washer output
Wiper signal
Wiper SW (ON)
Wiper SW (WASHER)
NC
NC
+VB
GND
Washer output
NC
Wiper SW (INT)
NC
+VB
NC
NC
10-169
MONITOR DISPLAY
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
Clock
Service meter
Fuel level gauge
Fuel level caution lamp
Engine oil level caution lamp
Hydraulic oil level caution lamp
Preheating pilot lamp
Swing holding brake pilot lamp
Oil maintenance pilot lamp
Battery charge caution lamp
Air cleaner clogging caution lamp
Hydraulic oil temperature caution lamp
Engine oil pressure caution lamp
Coolant level caution lamp
Coolant temperature caution lamp
Coolant temperature gauge
10-170
PC1100-6
Content of display
Symbol
Display item
Display range
When engine is stopped
When engine is running
Coolant level
Below low level
Flashes when abnormal
Flashes and buzzer

sounds when abnormal
Engine oil
pressure
Below 1500 rpm:

below 0.05 MPa
{0.5 kg/cm2}
Above 1500 rpm:
above 0.15 MPa
{1.5 kg/cm2}
Lights up when normal

(goes out when engine
starts)
Flashes and buzzer sounds

when abnormal
Air cleaner
clogging
When clogged
OFF
Charge level
When charging is
defective
Lights up when normal

(goes out when engine
starts)
Engine oil level
Below low level
OFF
Hydraulic oil level
Below low level
OFF
Parking
(Swing lock)
When swing is
locked
Lights up when swing lock switch is ON, flashes

when swing lock prolix switch is ON
SAP00519
SAP00520
SAP00521
SAP00522
SAP00523
SAP00524
SAT00098
Oil maintenance
See next page. OIL MAINTENANCE FUNCTION
SAP02732
Preheating
SAP00526
Coolant
temperature
When APS is
actuated
When glow plug is preheating: ON; when glow plug

has completed preheating: OFF; when engine coolant
temperature is above set temperature: Flashes (2 times/
3 seconds), then goes OFF
Flashes when above 102C, flashes and

buzzer sounds when above 105C
SAP00527
Fuel level
Flashes when below low level
SAP00528
SAD01484
PC1100-6
Hydraulic oil
temperature
Above specified
level
OFF
Flashes and buzzer sounds

when abnormal
10-171
OIL MAINTENANCE FUNCTION

1. Function, operation
The oil maintenance function uses LED lamps
on the monitor panel to inform the operator
at a fixed interval after the engine oil is
changed that the oil change interval has been
reached.
At the same time, it also functions to display
the service contact telephone number on the
liquid crystal display.
1) Confirmation of elapsed time
Normally, no display is given until the
elapsed time reaches the point B on the
right diagram after reset. However, if
the buzzer cancel switch is pressed and
the key is turned to the ON position (with
the buzzer cancel switch hold for 2.5 seconds), the elapsed time is displayed on
the service meter display.
2) Oil change display
When the elapsed time has reached or
passed the point B on the right diagram,
the service meter display gives the
elapsed time and the LED flashes when
the key is turned ON.
2. Setting change interval

1) The change interval can be set by using
the interval setting mode. The time that
can be set are [125 h], [250 h], [500 h],
[no setting], and [demo mode]. The default setting is [no setting].
2) To enter the change interval setting
mode, keep the time switch and active
mode switch (swing priority switch)
pressed simultaneously for 2.5 seconds.
3) If the buzzer cancel switch is pressed in
the change interval setting mode, the
time display will change from []
[125] [250] [500] [ d] ([] indicates [no setting] and [ d] indicates
[demo mode]).
4) To save the change interval time, set the
monitor panel display to the desired time
(mode), then keep the time switch and
active mode switch (swing priority
switch) pressed simultaneously for 2.5
seconds.
10-172
PC1100-6
3. Display timing, content

1) Oil change display
After all the lamps light up, the elapsed
time is displayed for 10 seconds. For the
next 10 seconds, the telephone number
is displayed.
However, if no telephone number has
been input, the elapsed time is displayed
for 20 seconds after all the lamps light
up.
2) Elapsed time confirmation
After all the lamps light up, the elapsed
time is displayed for 10 seconds.
4. Elapsed time reset
1) During the oil change interval display and
the elapsed time display, for 10 seconds
after all lamps light up (during the
elapsed time display), if the buzzer cancel switch is pressed and held for 3 seconds, the elapsed time is reset. When
the elapsed time is reset, the elapsed
time shows [0h] for 1 second.
2) When the set time is changed, the
elapsed time is reset to 0h.
5. Demo mode
1) The set time in the demo mode is 250h
and the elapsed time is set to 240h. When
the key is turned ON, the oil change display is given. However, the elapsed time
does not increase.
It is also possible to carry out the reset
operation during this display.
In the demo mode, after the key is turned
ON three times, the interval setting is
automatically set to [no setting] from the
4th time. In addition, the elapsed time is
reset to 0h and the elapsed time count
starts.
PC1100-6
10-173
SWITCHES
1.
2.
3.
4.
5.
Working mode switch

Auto deceleration switch
Swing priority mode switch
Travel speed switch
Knob button switch (Heavy lift)
There are three mode selector switches on

the switch panel. Each time any of these
switches is pressed, the condition of the
machine will change. The LEDs on the switch
panel light up to indicate the condition of
the machine.
Switch actuation table

Item
Working mode
Actuation
DH H G
Heavy lift button
OFF ON
Auto decel
ON OFF
Travel speed
Swing priority
Hi Lo
OFF ON
fl The bold letters indicate the default position

of the switch when the starting switch is
turned ON.
10-174
PC1100-6
20
TESTING AND ADJUSTING
Standard value table .............................................................................................................................. 20-102

Standard value table for engine related parts .............................................................................. 20-102
Standard value table for chassis related parts ............................................................................. 20-103
Standard value table for electrical parts ....................................................................................... 20-111
Testing and adjusting ............................................................................................................................. 20-101
Troubleshooting ...................................................................................................................................... 20-201
fl
Note the following when making judgements using the standard value tables for testing, adjusting, or
troubleshooting.
1.
The standard value for a new machine given in the table is the value used when shipping the machine from
the factory and is given for reference. It is used as a guideline for judging the progress of wear after the
machine has been operated, and as a reference value when carrying out repairs.
2.
The service limit value given in the tables is the estimated value for the shipped machine based on the results
of various tests. It is used for reference together with the state of repair and the history of operation to judge
if there is a failure.
3.
These standard values are not the standards used in dealing with claims.
When carrying out testing, adjusting, or troubleshooting, park the machine on level ground, inset the safety
pins, and use blocks to prevent the machine from moving.
When carrying out work together with other workers, always use signals and do not let unauthorized people
near the machine.
When checking the water level, always wait for the water to cool down. If the radiator cap is removed when
the water is still hot, the water will spurt out and cause burns.
Be careful not to get caught in the fan, fan belt or other rotating parts.
PC1100-6
20-1
1
STANDARD VALUE TABLE FOR ENGINE RELATED PARTS
STANDARD VALUE TABLE FOR ENGINE RELATED PARTS

Machine model
PC1100-6
Engine
SAA6D170-2
Item
Measurement condition
Unit
High idling
Engine speed
Low idling
2,000 50
730 25
730 25
1,800
kPa
{mmHg}
Min. 120 {900}
Min. 96 {720}
Max. 620
Max. 670
Rated speed
At rated output
Exhaust gas pressure
All speed range

(intake air temp.: 20C)
At sudden acceleration
Exhaust gas color

At high idling
Permissible value
2,000 50
rpm
Intake air pressure
Standard value
Bosch
index
Max. 4.5
Max. 5.5
Max. 1.0
Max. 2.0
mm
0.4
1.0
Min. 2.9 {30}
Min. 2.1 {21}
Max. 3.9 {400}
Max. 7.9 {800}
0.39 0.54 {4.0 5.5}
Min. 0.21 {2.1}
(normal temperature)
Valve clearance
Intake valve
Exhaust valve
Oil temperature:
40 60C
Compression pressure
Blow-by pressure
MPa
(Engine speed:
2
210 250 rpm) {kg/cm }
(SAE30 oil)
(Coolant temperature:
within operating range) kPa
(SAE30 oil)
{mmH2O}
At rated output
(Coolant temperature:
Min. 80C)
At high idling (SAE30)
Oil pressure
At low idling
MPa
{kg/cm2}
(SAE30)
Min. 0.12 {1.2}
0.07 {0.7}
0.34 0.49 {3.0 5.0}

Min. 0.1 {1.0}
Min. 0.18 {1.8}

Min. 0.07 {0.7}
80 110
Max. 120
deg.
()
19 0.5
19 0.5
10 15
10 15
At high idling (SAE10W)

At low idling (SAE10W)
Oil temperature
All speed range

(inside oil pan)
Fuel injection timing
B. T. D. C.
Alternator belt tension
Deflection when pressed

with finger force of
approx. 58.8 N {6 kg}
Air conditioner compressor belt tension
Deflection when pressed

with finger force of
approx. 58.8 N {6 kg}
mm
20-2
1
PC1100-6
STANDARD VALUE TABLE FOR CHASSIS RELATED PARTS

Applicable model
Category
Item
Engine speed
All pumps at relief
All pumps at relief

+
heavy lift ON
Swing 4-spool control valve Right 4-spool control valve
Spool stroke
Left 5-spool control valve
Engine speed when

auto-deceleration is
actuated
Bottom dump
Measurement conditions
Engine at full throttle
Hydraulic oil temperature:
45 55C
Engine oil pressure:
Within operating range
Engine water temperature:
Within operating range
In D.H mode
Boom RAISE relief
Standard value
Unit for
new machine
rpm

All control levers at neutral
Engine stopped
Service limit
value
1,850 100
1,850 100
1,800 100
1,800 100
1,300 100
a
12 0.5
b
12 0.5
a
12 0.5
b
12 0.5
16 0.5
16 0.5
16 0.5
16 0.5
16 0.5
16 0.5
16 0.5
16 0.5
16 0.5
16 0.5
16 0.5
16 0.5
Boom Hi
Arm Lo
Bucket Hi
Left travel
Right travel
mm
Boom Lo
Bucket Lo
Arm Hi
Boom Plus
Swing
Bucket Plus
Arm Plus
Boom control lever

Control lever stroke
PC1100-6
Arm control lever

Bucket control lever
Swing control lever
Engine
stopped
Center of
lever knob
Read max.
value to end
of travel
N
RAISE LOWER
N
IN OUT
N
CURL DUMP
N Left
Right swing
85 10
85 10
85 10
85 10
85 10
85 10
85 10
85 10
mm
Travel control lever
N Forward
Reverse (both sides)
115 15
115 15
Control lever
play amount
Work equipment
swing, travel
Max. 10
Max. 10
PC1100-6
20-3
1
Applicable model
Item
Standard value
Unit for
new machine
Service limit
value
15.7 4.9 {1.6 0.5}
15.7 4.9 {1.6 0.5}
15.7 4.9 {1.6 0.5}
N {kg} 12.7 3.9 {1.3 0.4}
12.7 3.9 {1.3 0.4}
Swing control lever
12.7 3.9 {1.3 0.4}
12.7 3.9 {1.3 0.4}
Travel control lever
24.5 5.9 {2.5 0.6}
24.5 5.9 {2.5 0.6}
Arm control lever

Bucket control lever
Engine at full
throttle
Oil temperature:
45 55C
In D.H mode
Relieve only
circuit being
measured
RAISE
15.7 4.9 {1.6 0.5}
Boom
Heavy lift
OFF
Heavy lift
ON
Machine
push-up OFF
31.4
+ 1.0
1.5
{320
+ 10
15 }
31.4
+ 1.0
2.5
{320
+ 10
25 }
33.3
+ 1.0
1.5
{340
+ 10
15}
33.3
+ 1.0
2.5
{340
+ 10
25}
18.6 1.9 {190 20}
Machine
push-up ON
18.6 1.9 {190 20}
31.4
+ 1.0
1.5
{320
+ 10
15 }
31.4
+ 1.0
2.5
{320
+ 10
25 }
31.4
+ 1.0
1.5
{320
+ 10
15 }
31.4
+ 1.0
2.5
{320
+ 10
25 }
Bucket
31.4
+ 1.0
1.5
{320
+ 10
15 }
31.4
+ 1.0
2.5
{320
+ 10
25 }
Travel
34.3
+ 1.0
1.5
{350
+ 10
15 }
34.3
+ 1.0
2.5
{350
+ 10
25 }
Swing
30.4
+ 1.0
1.9
{310
+ 10
20 }
30.4
+ 1.0
2.9
{310
+ 10
30 }
3.1
+ 0.4
0
{32
3.1
+ 0.4
0
{32
Arm
Hydraulic pressure
Engine stopped
Oil temperature: 45 55C
Fit push-pull scale to center of
control lever knob
Measure max. value to end of
travel
LOWER
Boom control lever
Control

Oil temperature: 45 55C
TVC valve output

pressure
All control
Engine at
levers at neutral
full throttle
Oil temperature:
Heavy lift
45 55C
OFF
In D.H mode
Heavy lift
ON
CONC
valve
output
pressure
Jet
sensor
differential
output
pressure
20-4
1
No.1 pump
No.2 pump
No.3 pump
Boom RAISE
relief
Operating effort of control levers
Category
PC1100-6
Engine at
full throttle
Oil temperature:
45 55C
In D.H mode
All control
levers at neutral
Travel under no
load
All control
levers at neutral
Swing under no
load
Left 5-spool
All control
Engine at
control valve
levers at neutral
full throttle
Right 4-spool Oil temperature: Travel under no
control valve
45 55C
load
In D.H mode
All control
Swing 4levers at neutral
spool control
Swing under no
valve
load
MPa
{kg/
cm2}
+3.5
0 }
+3.5
0 }
2.3 0.3 {23 3}
Min. 1.8 {18}
1.13 0.2 {11.5 2}
1.08 0.2 {11 2}
1.03 0.2 {10.5 2}
0.98 0.2 {10 2}
Max. 0.25 {2.6}
Max. 0.4 {4.1}
Min. 1.7 {17}
Min. 1.7 {17}
Max. 0.68 {6.9}
Max. 0.82 {8.4}
Min. 1.7 {17}
Min. 1.7 {17}
1.8 0.2 {18 2}
Min. 1.5 {15}
Max. 0.2 {2}
Max. 0.2 {2}
1.8 0.2 {18 2}
Min. 1.5 {15}
Max. 0.2 {2}
Max. 0.2 {2}
PC1100-6
PC1100-6
Applicable model
Category
Item
Hydraulic pressure
PPC valve output

pressure
Solenoid valve
output pressure
Drop in hydraulic
pressure
Standard value
Unit for
new machine
45 55C
Control lever full stroke
45 55C
Operate only solenoid being
measured
2.9
+ 0.6
0.2
{30 + 5.5
1.5}
Service limit
value
2.9
+ 0.6
0.2
{30 + 5.5
1.5}
2.9 0.6 {30 5.5}
2.9 0.6 {30 5.5}
Max. 2.0 {20}
Max. 2.9 {30}
Max. 60
(Max. 1,275)
Max. 80
(Max.1,700)
90
4.7 0.5
Max. 5.7
180
7.6 0.8
Max. 9.2
52 2.6
Max. 59
MPa
{kg/
cm2}

45 55C
Difference between relief
pressure with engine at full
throttle and relief pressure with
engine at low idling
Work equipment posture
Overrun when
stopping swing

45 55C
In D.H mode
Bucket: No load
Stop after swinging one turn and
measure distance that swing circle
moves
Value in ( ) shows distance at
outside circumference of swing circle
deg.
(mm)
Swing
Time taken to
start swing

45 55C
In D.H mode
Bucket: No load
Time taken to swing 90 and
180 from starting position
Time taken to swing
sec

45 55C
In D.H mode
Bucket: No load
Swing one turn, then measure
time taken to swing next 5 turns
PC1100-6
20-5
1
PC1100-6
Applicable model
Category
Item
Standard value
Unit for
new machine
Service limit
value
deg.
(mm)
0
(0)
0
(0)
/min
Max. 14
Max. 28
95 117
95 117
High speed
65 80
65 80
Low speed
Swing
29 37
29 37
20 25
20 25
Hydraulic drift of
swing
Engine stopped
45 55C
Set machine on 15 slope, and set
upper structure at 90 to the side.
Make match marks on swing circle
outer race and track frame.
Measure distance that match
marks move apart after 5 minutes.
Leakage from swing

motor

45 55C
Relieve swing circuit.
Low speed
sec
Travel speed (1)
Travel

45 55C
In D.H mode
Raise track on one side at a
time, rotate one turn, then
measure time taken for next 5
turns with no load.
sec
45 55C
In D.H mode
Run up for at least 10 m, and
measure time taken to travel
next 20 m on flat ground.
20-6
1
High speed
Travel speed (2)
PC1100-6
Applicable model
Category
Item
PC1100-6
Standard value
Unit for
new machine
Service limit
value
Travel deviation

45 55C
In D.H mode
Use a hard horizontal surface.
Run up for at least 10 m, and
measure deviation () when
traveling next 20 m on flat
ground.
mm
Max. 200
Max. 220
mm
/min
Max. 20
Max. 40
20m
Travel
10m
BKP00107
Work equipment
posture
Hydraulic drift of
travel
Engine stopped
45 55C
Stop machine on 12 slope with
sprocket at uphill end of machine.
Do not place the work equipment on the ground.
Measure the distance the
machine moves in 5 minutes.
Leakage of travel
motor
45 55C
Lock shoes and relieve travel
circuit.
PC1100-6
20-7
1
Applicable model
Category
Item
PC1100-6
Standard value
Unit for
new machine
Service limit
value
Work equipment
Hydraulic drift of work equipment
Total work
equipment
hydraulic drift at
tip of bucket
teeth
Boom cylinder
(amount of
retraction of
cylinder)
Arm cylinder
(amount of
extension of
cylinder)
Bucket cylinder
(amount of
retraction of
cylinder)
Place in above posture and

measure extension or retraction of
each cylinder and downward
movement at tip of bucket teeth.
Engine stopped
45 55C
Horizontal, flat ground
Buket: Rated load or full load of
soil
STD, LC specification:
75.9 kN {7,740 kg}
SP specification:
100.6 kN {10,260 kg}
Start measuring immediately after
setting.
Measure hydraulic drift every 5
minutes, and judge from results
for 15 minutes.
Figures in ( ) are value when
bucket is not loaded.
Max. 50
(Max. 30)
Max. 75
(Max. 45)
Max. 160
(Max. 70)
Max. 240
(Max. 105)
Max. 95
(Max. 45)
Max. 145
(Max. 70)
STD, LC
SP
STD, LC
SP
specification specification specification specification
RAISE
45 55C
In D.H mode
Bucket: No load
6.2 0.7 6.6 0.7
Max. 7.6 Max. 8.0
4.0 0.4 4.4 0.4
Max. 4.8 Max. 5.2
sec
LOWER
Work equipment speed
20-8
[ ]
Cylinder fully
extended
Max. 1,800
(Max. 1,000)
mm
Boom
Bucket teeth in
contact with
ground
Max. 1,200
(Max. 650)
PC1100-6
PC1100-6
Applicable model
Category
Item
Standard value
Unit for
new machine
Service limit
value
STD, LC
SP
STD, LC
SP
specification specification specification specification
IN
4.0 0.4 4.0 0.4 Max. 4.8 Max. 4.8
3.3 0.4 3.5 0.4 Max. 4.1 Max. 4.3
Fully extended
sec

45 55C
In D.H mode
Bucket: No load
DUMP
Bucket
Cylinder fully
retracted
Work equipment

45 55C
In D.H mode
Bucket: No load
OUT
sec
CURL
Fully extended
5.0 0.5 5.0 0.5 Max. 6.0 Max. 6.0
Arm
Cylinder fully
retracted
3.1 0.4 3.3 0.4 Max. 3.9 Max. 4.1
Time lag
Boom
PC1100-6
Engine at low idling

45 55C
Retract arm and bucket cylinder
fully, then lower boom from max.
RAISE point and measure time
taken from point where bucket
contacts ground to point where
chassis rises from ground.
sec
Max. 3
Max. 5
20-9
1
PC1100-6
Applicable model
Category
Item
Standard value
Unit for
new machine
Service limit
value
Time lag
Work equipment
Arm
Internal oil leakage
sec
Max. 3
Max. 5
sec
Max. 3
Max. 5
Max. 7
Max. 28
Max. 10
Max. 100
Bucket
20-10

45 55C
Set top surface of boom horizontal, retract bucket cylinder fully,
then extend arm cylinder and
measure time taken for arm to
start moving again after stopping
at bottom.
Cylinders
Center swivel
joint

45 55C
Set top surface of boom horizontal, retract arm cylinder fully,
then extend bucket cylinder and
measure time taken for bucket to
start moving again after stopping
at bottom.

45 55C
Relieve only circuit being
measured.
cc/min
PC1100-6
STANDARD VALUE TABLE FOR ELECTRICAL PARTS
Fuel control dial
Connector Inspection
No.
method
E06 (male)
E21 (male)
Measure
resistance
Name of
component
Measure
resistance
System
Rack position
sensor
Governor
control
solenoid
Variable prestroke control

solenoid
PC1100-6
E22
E19 (male)
E32 (male)
E20 (male)
Visual
check
M36
Measure
voltage
Electronical governor fuel injection pump
Kerosene mode
selector switch
Measure
resistance
E07
Measure
voltage
No. 2 engine
speed sensor
Measure
resistance
Engine controller system
E07 (male)
Measure
resistance
E21
Measure
voltage
No. 1 engine
speed sensor
Measurement
conditions
Judgment table
If the condition is as shown in the table
below, it is normal.
Between (1) (3)
4 6 k
Between (1) (2)
0.25 7 k
Between (2) (3)
0.25 7 k

Between (1) (2)
500 1,000
Between (1) (2) chassis
Min. 1 M

Between (1) (2)
0.5 3.0 V

Between (1) (2)
500 1,000
Between (1) (2) chassis
Min. 1 M

Between (1) (2)
0.5 3.0 V

N36
connector
Gasoline mode
Disconnect
Kerosene mode
Connect

Between (1) (2)
4.5 5.4 V
Between (3) (2)
0.1 4.5 V

E19
E32
Between (1) (2)
Between (1) (2)
10 21
Between (1) (2)

chassis
Between (1) (2)

chassis
Min. 1 M

Between (1) (2)
10 21
Between (1)(2) chassis
Min. 1 M
1) Turn starting
switch OFF.
2) Disconnect
E06 connector.
1) Turn starting
switch OFF.
2) Disconnect
E21 connector.
1) Start engine.
2) Insert Tadapter.
fl Measure with
the tester in
the AC range.
1) Turn starting
switch OFF.
2) Disconnect
E07 connector.
1) Start engine.
2) Insert Tadapter.
fl Measure with
the tester in
the AC range.
1) Turn starting
switch OFF.
1) Turn starting
switch ON.
2) Insert Tadapter.
1) Turn starting
switch OFF.
2) Disconnect
E19, E32
connector.
1) Turn starting
switch OFF.
2) Disconnect E20
connector.
20-11
1
No.
method
E12
Backup power
source
E12
Solenoid
power source
E13
Measure
voltage
Main power
source
Measurement
conditions
Judgment table
Measure
voltage
Name of
component

Measure
voltage
System

Between (9)(17) (8)(16)
Between (7) (8)(16)
Between (1) (21)
20 30 V
20 30 V
20 30 V
Kerosene
mode
selector
switch
Rack position
sensor
20-12
1
E14
E12
E17
E13
E14
Measure
voltage
Measure
voltage
Measure
voltage
No. 2 engine
speed sensor
E14
Measure
voltage
No. 1 engine
speed sensor
E14
E15
Measure
voltage
Fuel control
dial
Engine controller

Between E14(6) E14(16)
(sensor power source)
Between
E15(11) E14(16)
(Input signal)
Fuel dial
at min.
Fuel dial
at max.
4.75 5.25 V
0.5 3.0 V
0.5 3.0 V

Between
E17(2)
E12(8)(16)
Selector switch
released
Selector switch
connected
1) Turn starting
switch ON.
2) Insert Tadapter.
1) Turn starting
switch ON.
2) Insert Tadapter.
0.25 1.0 V

Between (3) (14)
1) Turn starting
switch OFF.
2) Insert Tadapter.
4.0 4.75 V

Between (2) (14)
1) Turn starting
switch ON.
2) Insert Tadapter.
20 30 V
1) Start engine.
2) Insert Tadapter.
fl Measure with
the tester in
the AC range.
1) Start engine.
2) Insert Tadapter.
fl Measure with
the tester in
the AC range.
1) Turn starting
switch ON.
2) Insert Tadapter.
Max. 1 V

Between E13(16) (21)
4.5 5.4 V
Between E14(7) (14)
0.1 4.5 V
1) Turn starting
switch ON.
2) Insert Tadapter.
PC1100-6
E14
E17
Measurement
conditions
Judgment table
Between
(4) (13)
When normal
20 30 V
When abnormal
Max. 1 V

Check 0
Check 1
Between
E14(1) E14(14)
Between
E17(1) E14(14)
20 30 V
Autodeceleration
signal
E12
E17
Starting
switch
start signal
E12
E17
Between
E17(12)
E12(8)(6)
Lever operated
Max. 1 V
All levers at
neutral
20 30 V

Between E17(18) E12(8)(6)
20 30 V
Continuity
Measure
resistance
P19 (male)
When APS
stopped
When APS
operated
Max. 1 V
20 30 V

Between
(2) (3)
OFF
No continuity
ON
Continuity

Between
terminal
and body
Less than 20C
Max. 0.5
Min. 20C
Min. 1 M
Glow plug

P13 (male)
Measure
resistance
APS water
temperature
sensor
M91 (male)
Between
E18(4)
E12(8)(6)
APS nozzle
Measure
resistance
APS controller system
APS switch
E12
E18
Measure
voltage

APS actuate
signal

PC1100-6
No. 1 glow Between (1) body

0.8 1.3
No. 2 glow Between (4) body
Between nozzle terminal
1) Turn starting
switch ON.
2) Insert Tadapter.
1) Turn starting
switch ON.
2) Insert Tadapter.
Max. 1 V

Measure
voltage
Engine controller
Connector
check signal
E12
Measure
voltage
Governor cut
relay signal
No.
method
Measure
voltage
Name of
component
Measure
voltage
System
1.5 2.5
1) Engine full
throttle.
2) Insert Tadapter.
fl Operate the
lever slightly
(just enough to
turn the PPC
switch ON).
1) Turn starting
switch START.
2) Insert Tadapter.
1) Turn starting
switch ON.
2) Insert Tadapter.
fl See the Note
for actuation of
the APS.
1) Turn starting
switch OFF.
2) Disconnect
M91 connector.
1) Turn starting
switch OFF.
2) Disconnect
P19 connector.
1) Turn starting
switch OFF.
2) Disconnect
P13 connector.
1) Turn starting
switch OFF.
2) Disconnect
connector.
20-13
1
APS controller
APS controller system
Glow plug 1
Glow plug 2
APS nozzle
Starting switch
START signal
E25
E26
E25
E26
E25
E26
E26
Measure
voltage
Measure
voltage
E26
Measure
voltage
APS water
temperature
sensor
E25
E26
Measure
voltage
Power source
voltage
No.
method
Measure
voltage
Name of
component
Measure
voltage
System
Measurement
conditions
Judgment table
Between E25(1) E26(1)
20 30 V

Between
(2) (1)
Less than 20C
Max. 1 V
Min. 20C
7 10 V

Between
E25(2)
E26(1)
When APS
stopped
When APS
operated
Max. 1 V
When APS
stopped
When APS
operated
Max. 1 V
When APS
stopped
When APS
operated
Max. 1 V
10 24 V
E26
Measure
voltage

Preheating
monitor lamp
signal
Between
(4) (1)
When APS
stopped
When APS
operated
1) Turn starting
switch ON.
2) Insert Tadapter.
1) Turn starting
switch ON.
2) Insert Tadapter.
0.4 5 V

Between (3) (1)
1) Turn starting
switch ON.
2) Insert Tadapter.
4 12 V

Between
E25(4)
E26(1)
1) Turn starting
switch ON.
2) Insert Tadapter.
4 12 V

Between
E25(3)
E26(1)
1) Turn starting
switch ON.
2) Insert Tadapter.
Max. 1 V
1) Turn starting
switch START.
2) Insert Tadapter.
1) Turn starting
switch ON.
2) Insert Tadapter.
12 20 V
(Note)
Note: After the starting switch is turned ON,

the voltage is held for 12 seconds, and
then goes down to less than 1 V.
20-14
1
PC1100-6
Name of
component
Swing lock switch
No.
method
X05
(female)
Continuity
System

When FREE
Between (1) (2) No continuity
SW01
(main body)
Continuity
Between (3) (4)
Swing prolix
switch
Measurement
conditions
Judgment table
Continuity
When LOCK
Continuity
No continuity

When OFF
When ON
Continuity
Continuity

C05 (male)
Continuity
Pump prolix
switch
When OFF
When ON
Continuity
No continuity

Between (4) (2)
Continuity

Between (8) (6)
Continuity
C06 (male)
Boom RAISE
S02 (male)
Boom LOWER
S04 (male)
Arm IN
S05 (male)
Arm OUT
S03 (male)
Bucket CURL
S06 (male)
Bucket DUMP
S07 (male)
Left swing
S10 (male)
Right swing
S08 (male)
L.H. travel
FORWARD
L.H. travel
REVERSE
R.H. travel
FORWARD
R.H. travel
REVERSE
S12 (male)
PC1100-6
Continuity
No continuity
Continuity
No continuity
Continuity
No continuity
19 21

Between
(1) (2)
Lever at neutral
Min. 1 M
Lever operated
Max. 1
1) Turn starting
switch OFF.
2) Disconnect C05
connector.
Continuity

Between (1) (2)
1) Turn starting
switch OFF.
2) Disconnect
harness.
Min. 1 M
1) Turn starting
switch OFF.
2) Disconnect
C06 connector.
1) Start the
engine.
(or check with
the accumulator charged)
2) Disconnect the
connector to
be checked.
Measure
resistance
Pump prolix
resistor
Measure
resistance
Between (7) (9)
PPC pressure switch
Pump controller system
Between (3) (1)
1) Turn starting
switch OFF.
2) Disconnect
X05 connector.
S13 (male)
S01 (male)
S11 (male)
20-15
1
Pump controller
CO cancel
solenoid
20-16
1
Main
power source
Solenoid
power source
V06 (male)
V07 (male)
C01
C02
Measure
resistance
Between
(4) (8)
1) Turn starting
switch OFF.
2) Disconnect C09
connector.
Continuity No continuity No continuity No continuity
Measure
resistance
Travel speed
solenoid
V04 (male)
V11 (male)
Between
(3) (8)

Measure
resistance
Swing holding
brake solenoid
(F) (R)
V03 (male)
Between
(2) (8)

Measure
resistance
Straight travel
solenoid
V02 (male)
Between
(1) (8)

Measure
resistance
2-stage relief
solenoid
V01 (male)


Measure
resistance
Swing priority
solenoid
C13 (male)
Measurement
conditions
Judgment table

Measure
resistance
TVC solenoid
C09
(female)

Measure
resistance
Model selection
connector
No.
method
Between (1) (2)
10 22
Min. 1 M
Between (1) (2)
20 60
Min. 1 M
Between (1) (2)
20 60
Min. 1 M
Between (1) (2)
20 60
Min. 1 M
Between (1) (2)
20 60
Min. 1 M
Between (1) (2)
20 60
Min. 1 M

Between (1) (2)
20 60
Min. 1 M
Measure
voltage
Name of
component

Measure
voltage
System

Between (7)(13) (6)(12)
Between (1)(12) (11)(21)
20 30 V
20 30 V
1) Turn starting
switch OFF.
2) Disconnect C13
connector.
1) Turn starting
switch OFF.
2) Disconnect V01
connector.
1) Turn starting
switch OFF.
2) Disconnect V02
connector.
1) Turn starting
switch OFF.
2) Disconnect
connector.
1) Turn starting
switch OFF.
2) Disconnect
V04, V11
connector.
1) Turn starting
switch OFF.
2) Disconnect V06
connector.
1) Turn starting
switch OFF.
2) Disconnect
V07connector.
1) Turn starting
switch ON.
2) Insert Tadapter.
1) Turn starting
switch ON.
2) Insert Tadapter.
PC1100-6
Swing prolix
switch
Pump controller
No.2 engine
speed sensor
PPC pressure
switch
C16
C17
C16
C16
C17
Measure
voltage
C16
C17
Measure
voltage
Swing lock
switch
No.
method
Measure
voltage
Name of
component
Measure voltage
System
Measurement
conditions
Judgment table
Between
C17(16)
C16(3)(4)
Swing lock
switch at FREE
Swing lock
switch at LOCK
20 30 V
Max. 1 V

Between
C17(8)
C16(3)(4)
Swing prolix
switch at OFF
20 30 V
Swing prolix
switch at ON
Max. 1 V

Between (2) (1)
1) Turn starting
switch ON.
2) Insert Tadapter.
0.5 3.0 V
Boom RAISE
Between C17(2) C16(3)(4)
Boom LOWER
Between C17(10) C16(3)(4)
Arm IN
Between C17(3) C16(3)(4)
Arm OUT
Between C17(11) C16(3)(4)
Bucket CURL
Between C16(11) C16(3)(4)
Bucket DUMP
Between C16(12) C16(3)(4)
L.H. swing
Between C17(7) C16(3)(4)
R.H. swing
Between C16(5) C16(3)(4)
L.H. travel
Between C16(6) C16(3)(4)
R.H. travel
Between C16(13) C16(3)(4)
1) Turn starting
switch ON.
2) Insert Tadapter.
1) Start engine.
2) Insert Tadapter.
fl Measure with
the tester in
the AC range.
1) Start engine.
2) Insert Tadapter.
TVC solenoid
PC1100-6
C16
C17
C02
Measure
voltage
Model
selection
connector
Measure
voltage

Control levers at neutral
Levers operated
20 30 V
Max. 1 V

Mode
Between C17(5)
Max.
selection 1
C16(3)(4)
1V
Mode
Between C17(13)
20 30 V
selection 2
C16(3)(4)
Mode
Between C17(6)
20 30 V
selection 3
C16(3)(4)
Mode
Between C17(14)
20 30 V
selection 4
C16(3)(4)
1) Turn starting
switch ON.
2) Insert Tadapter.

1) Turn starting
switch ON.
2) Insert Tadapter.
3) Fuel dial at
MAX.
Between (18) (11)(21)
01V
20-17
1
Travel speed
solenoid
CO cancel
solenoid
Machine push-up system
Autodeceleration
signal
Machine push-up
switch
Machine push-up
solenoid
20-18
1
C01
C01
C01
C01
M38
(female)
V05 (male)
Measure
voltage
Measure
voltage
Measure
voltage
Measure
voltage
Swing holding
brake solenoid
C01
Measure
voltage
Pump controller
Straight travel
solenoid
C01
Measure
voltage
2-stage relief
solenoid
C01
Measure
voltage
Swing priority
solenoid
No.
method
Continuity
Name of
component
Measure
resistance
System
Measurement
conditions
Judgment table
priority switch ON
Between Swing
+ swing lever operated 20 30 V
(5)
All control levers at
(6)(12)
Max. 1 V
neutral

Between
(10)
(6)(12)
Travel lever operated
20 30 V

neutral
Max. 1 V

Between
(2)
(6)(12)
Work equipment + L.H. and

R.H. travel levers operated 20 30 V
Max. 1 V
neutral

Work equipment or
Between
20 30 V
swing lever operated
(3)
5 sec after all control
(6)(12) levers
are placed at neutral Max. 1 V
Between
(9)
(6)(12)
Travel speed switch Hi +

20 30 V
travel lever operated
Max. 1 V
neutral

Between
(8)
(6)(12)
Travel lever operated
20 30 V

neutral
Max. 1 V

Auto-deceleration switch ON
Between + all control levers at neutral 20 30 V

(4)
Auto-deceleration
(6)(12)
Max. 1 V
switch at OFF
Between
(1) (2)
When switch is ON
No
continuity
When switch is OFF
Continuity

Between (1) (2)
20 60
Min. 1 M
1) Start engine.
2) Insert T-adapter.
fl Operate the
lever slightly
(just enough to
turn the PPC
switch ON).
1) Start engine.
fl Operate the
lever slightly
(just enough to
turn the PPC
switch ON).
1) Start engine.
fl Operate the
lever slightly
(just enough to
turn the PPC
switch ON).
1) Start engine.
fl Operate the
lever slightly
(just enough to
turn the PPC
switch ON).
1) Start engine.
fl Operate the
lever slightly
(just enough to
turn the PPC
switch ON).
1) Start engine.
fl Operate the
lever slightly
(just enough to
turn the PPC
switch ON).
1) Start engine.
fl Operate the
lever slightly
(just enough to
turn the PPC
switch ON).
1) Turn starting
switch OFF.
2) Disconnect
M38 connector.
1) Turn starting
switch OFF.
2) Disconnect V05
connector.
PC1100-6
M33
(female)
Boom RAISE
V09 (male)
shockless solenoid
Boom LOWER
shockless solenoid V10 (male)
PC1100-6
Continuity
Boom shockless system
Boom shockless
solenoid
No.
method
Measure
resistance
Name of
component
Measure
resistance
System
Measurement
conditions
Judgment table
No
Between When switch is ON continuity
(1) (3)
When switch is OFF Continuity
1) Turn starting
switch OFF.
2) Disconnect
M33 connector.

1) Turn starting
switch OFF.
2) Disconnect V09
connector.
Between (1) (2)
20 60
Min. 1 M

Between (1) (2)
20 60
Min. 1 M
1) Turn starting
switch OFF.
2) Disconnect V10
connector.
20-19
1
Fuel level sensor
Coolant level
sensor
P07 (male)
P06 (male)
P08 (male)
P20 (male)
Measure
resistance
Coolant
temperature
sensor
No.
method
Measure
resistance
Name of
component
Measure
resistance
System
Measurement
conditions
Judgment table
Between
(1) (2)
Normal temperature
(25C)
100C
Approx.
37 50 k
Approx.
3.5 4.0 k

Between
(1)
body
Position of float upper

limit
Position of float lower
limit
Approx.
Max. 12
Approx.
85 110

Between
(1) (2)
Above LOW water level

in sub tank
Below LOW water level
in sub tank
Max. 1
Measure
resistance
above 0.07 MPa

Between Oil pressure
Min.1 M
{above 0.7 kg/cm2}
terminal
below 0.03 MPa
body Oil pressure
Max. 1
{below 0.3 kg/cm2}
Oil pressure switch for high pressure

Oil pressure above 0.17 MPa
Engine oil level

sensor
Hydraulic oil level

sensor
20-20
1
R terminal
P05 (male)
P09 (male)
Measure
resistance
Alternator
P11 (male)
P12 (female)
Measure
resistance
Air cleaner
clogging sensor
Measure
resistance
Between
Min.1 M
{above 1.7 kg/cm2}
terminal
Oil
pressure
below
0.13
MPa
body
Max. 1
{below 1.3 kg/cm2}
Measure
resistance
Monitor panel system

Between
P11 P12
1) Turn starting
switch OFF.
2) Disconnect P06
connector.
3) Remove
senosr.
1) Turn starting
switch OFF.
2) Disconnect
P08, P20
connector.
Min.1 M

Oil pressure switch for low pressure
Engine oil
pressure switch
1) Turn starting
switch OFF.
2) Disconnect P07
connector.
3) Remove
senosr.
Air cleaner normal
Max. 1
Air cleaner clogged
Min.1 M

Between R terminal chassis 27.5 29.5 V
1) Install oil
pressure
measuring
gauge.
2) Disconnect
sensor harness.
3) Start engine.
fl It is also possible to remove
the sensor and
check as an
individual part.
fl The switch at the
flywheel end is
the low-pressure
switch.
1) Start engine.
2) Disconnect
P11, P12
connector.
1) Start engine.
(at mid-range
speed or
above)
fl If the battery is old, or after starting in

cold areas, the voltage may not rise for
some time.
Between
(1) body

limit
limit
Max. 1
Min.1 M

Between
(1) body

limit
limit
Max. 1
Min.1 M
1) Turn starting
switch OFF.
2) Disconnect P05
connector.
3) Remove
sensor.
1) Turn starting
switch OFF.
2) Disconnect P09
connector.
3) Remove
sensor.
PC1100-6
Name of
component
No.
method
Hydraulic oil
temperature
sensor
P10 (male)
Measure
resistance
System
Measurement
conditions
Judgment table
Between
(1) (2)
Normal temperature
(25C)
100C
Approx.
37 50 k
Approx.
3.5 4.0 k
Pump controller
Right
side
Display
position
All OFF
0.646
0.575 0.342
3.156 3.708
3.422 3.900
3.600 4.349
4.015 5.122
4.728 6.816
6.294 10.744
9.946 36.535
1) Insert a
dummy
resistance with
the starting
switch OFF, or
measure the
resistance of
the sensor.
2) Check the
display with
the starting
switch ON.
33.725
flLevels 8 and 9 flash

Right
side
Display
position
C03
(female)
Between
(2) (16)
Position of
Display level resistance (k)
gauge display (controller input resistance)
Starting switch
Starting switch
ON
OFF
Left
side
Fuel level
sensor
Fuel level
gauge
Confirmation of display measure resistance
C03
(female)
Between
(1) (16)
Position of
Display level resistance (k)
gauge display (controller input resistance)
Starting switch
Starting switch
ON
OFF
Left
side
Coolant
temperature
sensor
Engine water
temperature
gauge
Confirmation of display measure resistance

1) Turn starting
switch OFF.
2) Disconnect P10
connector.
3) Remove
senosr.
All OFF
13.82
11.71 21.25
18.90 28.45
25.82 31.85
29.18 39.91
37.00 44.60
41.77 55.14
50.42 77.07
72.98 691.50
1) Insert a
dummy
resistance with
the starting
switch OFF, or
measure the
resistance of
the sensor.
2) Check the
display with
the starting
switch ON.
63.800
flLevel 1 flashes
PC1100-6
20-21
1
Name of
component
Coolant level
sensor
No.
method
C16
Measure
voltage
System
Measurement
conditions
Judgment table
Above LOW water level
Max. 1 V
in sub tank
Between
(8) (3)(4) Below LOW water level
20 30 V
in sub tank

Oil pressure switch for low pressure
C16
Measure
voltage
Engine oil
pressure
switch
1) Turn starting
switch OFF.
2) Insert Tadapter.
20 30 V
Between
{above 0.7 kg/cm2}
(15) (3)(4) Oil pressure below 0.03 MPa
Max. 1 V
{below 0.3 kg/cm2}
1) Install oil
pressure
measuring
gauge.
2) Insert Tadapter.
3) Start engine.
Oil pressure switch for high pressure

Engine oil
level sensor
Hydraulic oil
level sensor
Starting
switch ON
signal
20-22
1
C16
C16
C03
Measure
voltage
Measure
voltage
C03
Measure
voltage
Alternator
C16
Measure
voltage
Air cleaner
clogging
sensor
Measure
voltage
Pump controller
20 30 V
{above 1.7 kg/cm2}
Between
(7) (3)(4) Oil pressure below 0.13 MPa
Max. 1 V
{below 1.3 kg/cm2}
Between
(17) (3)(4)
Air cleaner normal
Max.1 V
Air cleaner clogged
20 30 V

Between
(12) (16)
Stop engine
Max.1 V
Start engine
20 30 V

Between
(16) (3)(4)

limit
limit
Max. 1 V
20 30 V

Between
(9) (3)(4)

limit
limit
Max. 1 V
20 30 V

Between (8) (16)
20 30 V
1) Start engine.
2) Insert Tadapter.
1) Insert Tadapter.
1) Turn starting
switch ON.
2) Insert Tadapter.
3) Remove
sensor.
1) Turn starting
switch ON.
2) Insert Tadapter.
3) Remove
sensor.
1) Turn starting
switch ON.
2) Insert Tadapter.
PC1100-6
Buzzer cancel
switch
C03
P03
(female)
Measure
voltage
Starting switch
START signal
No.
method
Continuity
Name of
component
Pump controller
System
Measurement
conditions
Judgment table
Between (8) (16)
20 30 V

Between
(1) (2)
Free
No continuity
Push
Continuity
Power source
M18
(female)
P02
Continuity
Wiper washer
switch
Measure
voltage

Switch
Between
(1) (2)
Between
(1) (2)
Between
(1) (4)
WASH II
No
continuity
Continuity
Continuity
INT
No
continuity
No
continuity
Continuity
OFF
No
continuity
No
continuity
No
continuity
ON
Continuity
No
continuity
No
continuity
WASH I
Continuity
Continuity
No
continuity

Between (8)(14) (1)(9)
20 30 V

ON signal
Wiper switch OFF
20 30 V
Wiper switch ON
Max. 1 V
Between Wiper switch OFF

(12) (1)(9)
Wiper switch INT
20 30 V
Wiper washer
switch
1) Turn starting
switch OFF.
2) Insert Tadapter.
1) Turn starting
switch ON.
2) Insert Tadapter.
Max. 1 V
Wiper switch OFF
20 30 V
Wiper switch WASH
Max. 1 V

PC1100-6
1) Turn starting
switch OFF.
2) Disconnect
M18 connector.
WASH signal
Between
(5) (1)(9)
Buzzer cancel
switch
1) Turn starting
switch OFF.
2) Disconnect
connector.
INT signal
P02
Measure
voltage
Monitor panel
Between
(4) (1)(9)
1) Turn starting
switch START.
2) Insert Tadapter.
P01
P02
Between
P01(6)
P02(1)(9)
When buzzer cancel

switch is released
When buzzer cancel
switch is pushed
20 30 V
1) Turn starting
switch ON.
2) Insert Tadapter.
Max. 1 V
20-23
1

Between
P01(5)
P02(1)(9)
Swing lock
switch at OFF
Swing lock
switch at ON
20 30 V

Max. 1 V
P01
P02

Starting
switch ACC
signal
P01
P02

Starting
switch START
signal
P01
P02

P01
P02
Between P01(9) P02(1)(9)
Between P01(10) P02(1)(9)
Between P01(19) P02(1)(9)
20 30 V
20 30 V
20 30 V

Between
P01(18)
P02(1)(9)
Preheating
stopped
Preheating
operated
1) Turn starting
switch ON.
2) Insert Tadapter.
20 30 V
Measure
voltage
Light switch
at OFF
Light switch
at ON
Measure
voltage
Between
P01(8)
P02(1)(9)
1) Turn starting
switch ON.
2) Insert Tadapter.
Max. 1 V
Starting
switch ON
signal
APS
preheating
signal
20-24
P01
P02
Measurement
conditions
Judgment table
Measure
voltage
Monitor panel
Light switch
P01
P02
Measure
voltage
Swing lock
switch
No.
method
Measure
voltage
Name of
component
Measure
voltage
System
Max. 1 V
1) Turn starting
switch ON.
2) Insert Tadapter.
1) Turn starting
switch ON.
2) Insert Tadapter.
1) Turn starting
switch ON.
2) Insert Tadapter.
1) Turn starting
switch ON.
2) Insert Tadapter.
20 30 V
PC1100-6
Step light timer
Step light system
Power source
voltage
Input signal
T21
T21
Continuity
L03 (male)
Measure
voltage
Step light
switch
No.
method
Measure
voltage
Name of
component
Measurement
conditions
Judgment table
Between
(1) (2)
When released
No
continuity
When pressed
Continuity

Between (2) (1)
20 30 V

Between
(3) (1)
Step light switch

released
Step light switch
pressed
Max. 1 V
Output signal
T21
Between
(4) (1)
Step light switch

released
Step light switch
pressed
1) Turn starting
switch OFF.
2) Disconnect L03
connector.
1) Turn starting
switch OFF.
2) Insert Tadapter.
1) Turn starting
switch OFF.
2) Insert Tadapter.
20 30 V

Measure
voltage
System
Max. 1 V
1) Turn starting
switch OFF.
2) Insert Tadapter.
20 30 V
(Note)
Note: After the switch is pressed, the voltage is held for 60 seconds, and then
goes down to less than 1 V.
PC1100-6
20-25
1

Tools for testing, adjusting, and troubleshooting ............................................................................. 20-102
Measuring engine speed ....................................................................................................................... 20-103
Measuring air supply pressure (Boost pressure) ............................................................................... 20-104
Measuring exhaust temperature ........................................................................................................... 20-105
Measuring exhaust color ...................................................................................................................... 20-106
Adjusting valve clearance ..................................................................................................................... 20-107
Measuring compression pressure ........................................................................................................ 20-108
Measuring blow-by pressure ................................................................................................................ 20-109
Testing and adjusting fuel injection timing ........................................................................................ 20-110
Measuring engine oil pressure ............................................................................................................ 20-111
Testing and adjusting fan belt tension ............................................................................................... 20-112
Testing and adjusting alternator belt tension .................................................................................... 20-112
Testing and adjusting belt tension for air conditioner compressor ................................................ 20-113
Adjusting engine speed sensor ............................................................................................................ 20-113
Testing clearance of swing circle bearing .......................................................................................... 20-114
Measuring wear of sprocket ................................................................................................................. 20-115
Testing and adjusting track shoe tension ........................................................................................... 20-116
Testing and adjusting hydraulic pressure in work equipment, swing, travel circuit ..................... 20-117
Testing and adjusting control pump circuit oil pressure .................................................................. 20-122
Testing and adjusting piston pump control pressure ....................................................................... 20-123
Measuring servo piston stroke ............................................................................................................. 20-131
Measuring PPC valve output pressure and testing PPC shuttle valve ............................................ 20-132
Testing solenoid valve output pressure .............................................................................................. 20-136
Adjusting work equipment, swing PPC valve .................................................................................... 20-138
Testing travel deviation ......................................................................................................................... 20-139
Testing locations causing hydraulic drift of work equipment .......................................................... 20-140
Measuring oil leakage ........................................................................................................................... 20-141
Bleeding air ............................................................................................................................................ 20-145
Releasing remaining pressure in hydraulic circuit ............................................................................ 20-147
PC1100-6
20-101
1
TOOLS FOR TESTING, ADJUSTING, AND TROUBLESHOOTING
TOOLS FOR TESTING, ADJUSTING, AND TROUBLESHOOTING

Check or measurement item Symbol
Part No.
Part Name
Remarks
Engine speed
799-203-8001
Multi-tachometer
Digital display
L : 60 2,000 rpm
H : 60 19,999 rpm
Air supply pressure

(boost pressure)
799-201-2202
Boost gauge kit
101 199.9 kPa

{760 1,500 mmHg}
Coolant, oil and exhaust

temperature
799-101-1502
Digital temperature gauge
99.9 1,299C
799-201-9000
Handy Smoke Checker
Commercially
available
Smoke meter
Discoloration 0 70%
(with standard color)
(Discoloration x 1/10 = Bosh index)
795-125-1390
Feeler gauge
For intake : 0.4 mm

For exhaust : 1.0 mm
795-502-1205
Compression gauge
0 6.9 MPa {0 70 kg/cm2}
Exhaust color
Valve clearance
Compression pressure
Blow-by pressure
Fuel injection time
795-502-1350 Adapter
For 170 engine series
799-201-1504
Blow-by checker
0 4.9 MPa {0 500 mmH2O}
795-471-1200
Gauge assembly
799-101-5002
Hydraulic tester
Pressure gauge:
2.5, 5.9, 39.2, 58.8 MPa
{25, 60, 400, 600 kg/cm2}
790-261-1203
Digital hydraulic tester
Pressure gauge:
58.8 MPa {600 kg/cm2}
799-101-5220
Nipple
07002-11023
O-ring
799-401-2320
Hydraulic gauge
0.98 MPa {10 kg/cm2)
799-401-2701
Differential pressure gauge
0 49 MPa {0 500 kg/cm2}
796-827-1120
Wear gauge
1
Oil pressure
10 x 1.25
Measuring wear of sprocket
Operating effort
79A-264-0021 Push-pull scale
0 294N {0 30 kg}
79A-264-0091 Push-pull scale
0 490N {0 50 kg}
Stroke, hydraulic drift
Commercially
available
Commercially
available
Servo piston stroke
566-98-41120
Measuring voltage and

resistance values
79A-264-0211 Tester
Troubleshooting of
wiring harnesses and
sensors
20-102
1
Scale
Disc gauge
Stop watch
799-601-8000
T-adapter assembly
799-601-7360
Adapter
For relay (5 Pin)
PC1100-6
MEASURING ENGINE SPEED
MEASURING ENGINE SPEED

When removing or installing the measuring
equipment, be careful not to touch any high
temperature parts.
fl Measure the engine speed under the following
conditions.
Coolant temperature: Within operating range
Hydraulic oil temperature : 45 55C
1. Remove the cap.

2. Install pick-up q of multi-tachometer A, then
connect it to multi-tachometer A.
3. Start the engine, and measure the engine speed
when it is set to the conditions for measuring.
1) Measuring low idling and high idling speeds:
i) Set the working mode switch to DH
mode.
ii) Turn the auto-deceleration switch OFF.
fl When measuring at high idling only.
iii) Measure the engine speed with the fuel
control dial set to low idling (MIN) or
high idling (MAX).
2) Measuring auto-deceleration speed:
i) Turn the auto-deceleration switch ON.
ii) Set the fuel control dial to high idling.
iii) Measure the engine speed with all the
levers at neutral.
3) Measuring speed at all-pump relief:
i) Set the working mode to the DH mode.
ii) Turn the heavy-lift switch OFF.
iii) Set the fuel control dial to high idling.
iv) Measure the speed with arm IN circuit
relieved.
4) Measuring speed at all-pump relief + heavy
lift ON:
i) Set the working mode to the DH mode.
ii) Turn the heavy-lift switch ON.
iii) Set the fuel control dial to high idling.
iv) Measure the speed with boom RAISE circuit relieved.
PC1100-6
20-103
1
MEASURING AIR SUPPLY PRESSURE (BOOST PRESSURE)
MEASURING AIR SUPPLY

PRESSURE (BOOST PRESSURE)
When removing or installing the measuring
equipment or when carrying out the measurements, be careful not to touch any high temperature parts.
fl Measure the air supply pressure under the following conditions.
1. Remove air supply pressure measurement plug

(1) (PT 1/8).
2. Fit nipple q of oil pressure gauge J1, and connect to boost gauge B.
3. Run the engine at a mid-range speed or above,
and bleed the oil from inside the hose.
fl Insert the connection of the pressure gauge
and hose about half way, and repeatedly
open the self-seal portion of the hose to
bleed the oil.
fl If Pm kit (A) is available, use the air bleed
coupling (790-261-1130) inside the kit.
fl The gauge does not work if there is any oil
inside the hose, so always be sure to bleed
all the oil.
4. Set the working mode switch to the DH mode
and turn the heavy-lift switch ON.
5. Run the engine at full throttle, and measure the
air supply pressure when the boom RAISE circuit is relieved.
20-104
1
PC1100-6
MEASURING EXHAUST TEMPERATURE
MEASURING EXHAUST TEMPERATURE

fl Wait for the temperature of the exhaust manifold to go down before removing or installing
the temperature sensor.
fl Measure the exhaust temperature under the following conditions.
1. Remove exhaust temperature measurement plug

(1).
2. Install sensor q of digital temperature gauge C,
then connect to digital temperature gauge C.
fl Clamp the wiring harness of the temperature gauge so that it does not touch any
high temperature part during the measurement.
3. Run the engine at full throttle and measure the
maximum temperature during operation.
PC1100-6
20-105
1
MEASURING EXHAUST COLOR
MEASURING EXHAUST COLOR
When measuring in the field where there is no

air or electric power supply, use Handy Smoke
Checker D1; when recording formal data, use
Smoke Meter D2.
fl Raise the coolant temperature to the operating range before measuring.
Be careful not to touch any hot parts when removing or installing the measuring tools.
1. Measuring with Handy Smoke Checker D1

1) Install filter paper to Handy Smoke Checker
D1.
2) Insert the exhaust gas suction port into the
exhaust pipe, accelerate the engine suddenly,
and operate the handle of Handy Smoke
Checker D1 at the same time to collect the
exhaust gas on the filter paper.
3) Remove the filter paper and compare it with
the scale supplied to judge the condition.
2. Measuring with Smoke Meter D2
1) Insert the probe q of Smoke Meter D2 into
the outlet port of the exhaust pipe, and
tighten the clip to secure it to the exhaust
pipe.
2) Connect the air hose and the socket of the
probe hose and accelerator switch to Smoke
Meter D2.
fl Keep the pressure of the air supply below 1.5 MPa {15 kg/cm2}.
3) Connect the power cord to the AC socket.
fl When connecting the cord, check that
the power switch of Smoke Meter D2 is
OFF.
4) Loosen the cap nut of the suction pump,
and fit the filter paper.
fl Fit the filter paper securely so that the
exhaust gas cannot leak.
5) Turn the power switch of Smoke Meter D2
ON.
6) Accelerate the engine suddenly, and depress
the accelerator pedal of Smoke Meter D2 at
the same time to collect the exhaust gas
color on the filter.
7) Place the filter paper used to catch the exhaust gas color on top of at least 10 sheets
of unused filter paper inside the filter paper
holder, and read the value shown.
20-106
1
PC1100-6
ADJUSTING VALVE CLEARANCE
ADJUSTING VALVE
CLEARANCE
1. Remove the cylinder head cover.
fl For details, see DISASSEMBLY AND ASSEMBLY, REMOVAL OF CYLINDER HEAD ASSEMBLY.
2. Crank the engine to rotate the crankshaft in the
normal direction. Align 1.6TOP line (2) on the
crankshaft pulley with pointer (1), and set the
No. 1 cylinder to the compression top dead
center position. When rotating, check the movement of the valves.
fl Carry out the cranking with the barring device of the flywheel housing.
fl At the compression top dead center, the
rocker arms for both the intake and exhaust
move.
If the rocker arms do not move, the cylinder
is not at compression top dead center, so
rotate the crankshaft one more turn and align
the lines again.
3. When No. 1 cylinder is at compression top dead
center, adjust the valves marked in the valve
arrangement chart. Next, rotate the crankshaft
one turn (360) in the normal direction and adjust the valve clearance of the remaining valves
marked fi.
4. To adjust the valve clearance, loosen locknut
(6), then insert feeler gauge E between rocker
arm (3) and crosshead (4), and turn adjustment
screw (5) until the clearance is a sliding fit. Then
tighten locknut (6) to hold the adjustment screw
in position.
3 Locknut : 57.8 77.4 Nm {5.9 7.9 kgm}
fl After adjusting No. 1 cylinder at compression
top dead center, it is also possible to turn the
crankshaft 120 each time and adjust the valve
clearance of each cylinder according to the firing order.
Firing order : 1-5-3-6-2-4
fl After tightening the locknut, check the valve
clearance again.
PC1100-6
20-107
1
MEASURING COMPRESSION PRESSURE
MEASURING COMPRESSION
PRESSURE
When measuring the compression pressure, be
extremely careful not to touch the exhaust manifold or muffler, or to get your clothes caught in
the fan, fan belt or other rotating parts.
1. Adjust the valve clearance.
For details, see ADJUSTING VALVE CLEARANCE.
2. Warm up the engine to make the oil temperature 40 60C.
3. Remove nozzle holder assembly (1) from the
cylinder to be measured.
fl For details, see DISASSEMBLY AND ASSEMBLY, REMOVAL OF NOZZLE HOLDER ASSEMBLY.
4. Set multi-tachometer A in position.
fl See MEASURING ENGINE SPEED.
5. Install adapter q of compression gauge F, then
connect to compression gauge F.
6. Disconnect fuel injection pump connectors E19
(2) and E32 (3).
fl Always turn the starting switch OFF before
disconnecting or connecting the connectors.
7. Crank the engine with the starting motor and
measure the compression pressure.
fl Measure the compression pressure at the
point where the pressure gauge indicator
remains steady.
fl When measuring the compression pressure,
measure the engine speed to confirm that it
is within the specified range.
20-108
1
PC1100-6
MEASURING BLOW-BY PRESSURE
MEASURING BLOW-BY
PRESSURE
fl Measure the blow-by pressure under the following conditions.
Hydraulic oil temperature: 45 55C
1. Install the nozzle q of blow-by checker G to
blow-by hose (1).
2. Connect nozzle q to blow-by checker G.
3. Set the working mode switch to DH mode.
4. Run the engine at full throttle and measure the
blow-by pressure with the arm IN circuit relieved.
fl Measure the blow-by pressure at the point
where the gauge indicator remains steady.
PC1100-6
20-109
1
TESTING AND ADJUSTING FUEL INJECTION TIMING

FUEL INJECTION TIMING
1. Remove No. 1 cylinder nozzle holder assembly
(1).
fl For details, see DISASSEMBLY AND ASSEMBLY, REMOVAL OF NOZZLE HOLDER ASSEMBLY.
2. Remove the coupling cover of the fuel injection
pump.
3. Crank the engine to rotate the crankshaft in the
normal direction and align 1.6TOP line (3) with
pointer (2) to set the No. 1 cylinder to compression top dead center.
fl Carry out cranking with the barring device
on the flywheel housing.
fl At compression top dead center, line a on
the coupling is near line b on the fuel
injection pump.
If the lines are not near each other, the cylinder is not at compression top dead center,
so rotate one more turn and align the lines
again.
4. Set so that the tip of gauge assembly H contacts the head of the piston.
5. At near the top dead center, rotate the crankshaft in the normal direction and in the reverse
direction to set the top dead center accurately
with the scale of the dial gauge.
fl Set the scale on the dial gauge to 0 when
the piston is at top dead center.
6. Rotate the crankshaft in the reverse direction
from the top dead center position until the scale
on the dial gauge is approx. 10 mm.
7. Rotate the crankshaft again in the normal direction until the scale on the dial gauge shows
stroke c to align the fuel injection timing.
+ 0.31
fl Stroke c: 5.89 0.30 mm (BTDC 19 0.5)
fl Always rotate the crankshaft in the normal
direction to align the position. If stroke c
is passed, carry out the operation again from
Step 6.
8. When doing this, check that line a on the
coupling is aligned with line b on the fuel
injection pump body.
fl If the lines are not aligned, loosen 2 mounting bolts (4) in the oblong holes in the coupling, rotate the coupling to align the lines,
then tighten the mounting bolts.
3 Nut: 147 166 Nm {15 17 kgm}
fl After completion of adjustment, rotate the crankshaft in the normal direction and check again
that when it passes the compression top dead
center, the error on the dial gauge display is
+ 0.31
000
0.30 mm.
If the error is not within the specified range,
carry out the adjustment again from Step 5.
20-110
1
PC1100-6
MEASURING ENGINE OIL PRESSURE
MEASURING ENGINE OIL

PRESSURE
fl Measure the engine oil pressure under the following conditions.
1. Remove engine oil high-pressure switch (1) (PT1/

8).
2. Install the nipple q of oil pressure gauge J1

and connect to oil pressure gauge J2 (0.98 MPa
{10 kg/cm2}).
3. Start the engine, and measure the oil pressure

with the engine at low idling and at high idling.
PC1100-6
20-111
1
TESTING AND ADJUSTING FAN BELT TENSION

TESTING AND ADJUSTING ALTERNATOR BELT TENSION

FAN BELT TENSION
fl An auto-tensioner is used to keep the fan belt
tension constant regardless of the elongation of
the V-belt, so there is no need to adjust the belt
tension until the belt is replaced.
However, if the belt slips or if the belt has been
replaced, adjust the belt tension as follows.
1. Loosen stopper bolt (1), then assemble 3 belts.
2. Tighten stopper bolt (1) until it contacts tension
bracket (2), then tighten a further 2 turns.
3. Secure with locknut (3).
3 Locknut: 245 308.7 Nm {25 31.5 kgm}

ALTERNATOR BELT TENSION
Testing
Measure deflection a of the belt when pressed
with a force of approx. 58.8 Nm {approx. 6 kg}
at a point midway between the water pump pulley and the alternator pulley.
Belt deflection a: 10 15 mm
Adjusting
fl If the deflection of the belt is not normal, adjust
as follows.
1. Loosen mounting bolt (1) and locknut (2).
2. Turn adjustment nut (3) and move alternator
assembly (4) to adjust the belt tension.
3. Tighten locknut (2) and mounting bolt (1).
20-112
1
PC1100-6
TESTING AND ADJUSTING BELT TENSION FOR AIR CONDITIONER COMPRESSOR

ADJUSTING ENGINE SPEED SENSOR

BELT TENSION FOR AIR
CONDITIONER COMPRESSOR
Testing
Measure deflection a of the belt when it is
pressed with a force of approx. 58.8 N {6 kg} at
a point midway between the drive pulley and
the compressor pulley.
Deflection a of belt: 10 15 mm
Adjusting
fl If the belt tension is not correct, adjust as follows.
1. Loosen 4 mounting bolts (1) and locknut (2).
2. Turn adjustment nut (3) and move compressor
assembly (4) together with the bracket to adjust
the tension of the belt.
3. Tighten locknut (2) and 4 mounting bolts (1).
ADJUSTING ENGINE SPEED

SENSOR
fl Adjust both No. 1 engine speed sensor (1) and
No. 2 engine speed sensor (2) in the same way.
1. Screw in until the tip of sensor (3) contacts gear
(4).
fl Be careful not to let the tip of the sensor be
scratched or to let any iron particles stick to
the sensor tip.
2 Tip of sensor thread:
Gasket sealant (LG-6)
2. When sensor (3) contacts gear (4), turn back 1
1/6 turns to make clearance a.
Clearance a: 1.5 0.25 mm
3. Tighten locknut (5).
fl Be particularly careful when handling the sensor wiring to ensure that no excessive force is
brought to bear on the wiring.
PC1100-6
20-113
1
TESTING CLEARANCE OF SWING CIRCLE BEARING
TESTING CLEARANCE OF
SWING CIRCLE BEARING
fl Measure the clearance of the swing circle bearing as follows when it is mounted on the machine.
When carrying out the measurement, do not
put your hand or feet under the undercarriage.
1. Fix a dial gauge to the outer race (or inner race)
of the swing circle, then put the tip of the probe
in contact with the inner race (or outer race).
fl Set the dial gauge at the front or rear.
2. Extend the work equipment to the maximum
reach, and set the tip of the bucket to the same
height as the bottom of the revolving frame.
fl When this is done, the upper structure will
tilt forward, so the front will go down and
the rear will rise.
3. Set the dial gauge to the zero point.
4. Set the arm more or less at right angles to the
ground surface, then lower the boom until the
front of the machine comes off the ground.
fl When this is done, the upper structure will
tilt back, so the front will rise and the rear
will go down.
5. Read the value on the dial gauge at this point.
fl The value on the dial gauge is the clearance
of the swing circle bearing.
6. Return to the condition in Step 2, and check that
the dial gauge has returned to the zero point.
fl If it has not returned to the zero point, repeat Steps 2 to 5.
20-114
1
PC1100-6
MEASURING WEAR OF SPROCKET
MEASURING WEAR OF SPROCKET
1. Align wear gauge K with the portion of the

sprocket not meshed with the track shoe.
fl Align with the datum line, then align the
wave shape of the sprocket with the wave
shape of the wear gauge.
2. Judge the wear of the sprocket.
fl If the sprocket wave pattern is above the
wear limit line, it is possible to use the
sprocket as it is.
fl If the sprocket wave pattern has reached the
wear limit line, replace the sprocket with a
new part.
PC1100-6
20-115
1
TESTING AND ADJUSTING TRACK SHOE TENSION

TRACK SHOE TENSION
Testing
1. Using the boom and arm, jack up the track on
the side to be measured.
2. Measure clearance a between the track roller

tread and top surface of the track link.
Measurement position: 4th track roller from
sprocket.
Standard clearance a : 100 150 mm
Adjusting
fl If the track shoe tension is not within the standard value, adjust as follows.
1. If the track tension is too high:
Loosen plug (1) gradually, and release the
grease.
There is danger that the plug may fly out
under the high internal pressure of the
grease, so never loosen plug (1) more than
1 turn.
fl If the grease does not come out easily, move
the machine backwards or forwards slowly.
2. If the track tension is too low:
Pump in grease through grease fitting (2).
fl If the grease cannot be pumped in easily,
move the machine backwards and forwards
slowly.
20-116
1
PC1100-6
TESTING AND ADJUSTING HYDRAULIC PRESSURE IN WORK

EQUIPMENT, SWING, TRAVEL CIRCUIT

HYDRAULIC PRESSURE IN
WORK EQUIPMENT, SWING,
TRAVEL CIRCUIT
Measuring
fl Oil temperature when measuring: 45 55C
Lower the work equipment to the ground and
stop the engine. Operate the control levers several times to release the remaining pressure in
the hydraulic piping. Then loosen the oil filler
cap slowly to release the pressure inside the
hydraulic tank.
fl The relief pressure of the boom LOWER circuit
can be measured only for the front pump circuit.
fl The relief pressure of the bucket DUMP circuit
cannot be measured for the No. 3 pump circuit.
1. Measuring front pump (No. 1 F + No. 2 F) circuit
pressure
1) Connect oil pressure gauge J1 (58.8 MPa
{600 kg/cm2}) to quick coupler (1) or (2) for
the circuit to be measured.
(1): No. 1 front pump
(2): No. 2 front pump
2) Set the working mode switch to the DH
mode.
3) Run the engine at full throttle and measure
the pressure under each of the following conditions.
4) Measuring main relief pressure when heavy
lift is OFF (normal):
i) Turn the heavy-lift switch OFF.
ii) Measure the oil pressure when the actuator to be measured is relieved.
lift is ON (raised pressure):
i) Turn the heavy-lift switch ON.
ii) Measure the oil pressure with the circuit
relieved at boom RAISE.
6) Measuring boom LOWER relief pressure
when machine push-up is OFF (normal):
i) Turn the machine push-up switch OFF.
relieved at boom LOWER.
fl Under these conditions, the set pressure
of the safety valve for the boom LOWER
circuit is lower than the main relief pressure, so the value measured will be the
relief pressure of the safety valve.
PC1100-6
20-117
1

7) Measuring boom LOWER relief pressure

when machine push-up is ON (raised pressure):
i) Turn the machine push-up switch ON.
relieved at boom LOWER.
fl Under these conditions, the set pressure
of the safety valve for the boom LOWER
circuit is higher than the main relief pressure, so the value measured will be the
relief pressure of the safety valve.
fl Condition of actuatorswhen measuring
For the work equipment, operate each
cylinder to the end of its stroke.
For the travel circuit, put block q between the sprocket and frame to lock
the track, and relieve each side at a time.
2. Measuring rear pump (No. 1 R + No. 2 R) circuit

pressure
(3): No. 1 rear pump
(4): No. 2 rear pump
mode.
the pressure under each of the following conditions.
20-118
1
PC1100-6

fl Condition of actuators when measuring

For the travel circuit, put block q between the sprocket and frame to lock
the track, and relieve each side at a time.
3. Measuring No. 3 pump circuit pressure

(5): Front pump
(6): Rear pump
mode.
the pressure under each of the following
conditions.
fl Under these conditions, the set pressure of
the safety valve for the swing circuit is lower
than the main relief pressure, so the value
measured will be the relief pressure of the
safety valve.
For the swing, turn the swing lock switch
ON to lock the swing.
PC1100-6
20-119
1

Adjusting
fl Adjust only the swing motor safety valve. Never
adjust any other safety valve.
1. Adjusting R.H. 4-spool valve main relief valve
fl If the relief pressure of the front pump circuit is not correct, adjust the main relief valve
of the R.H. 4-spool valve as follows.
1) Disconnect hose (7).
2) Loosen locknut (8) so that elbow (9) can
move.
3) Adjusting high-pressure setting
Loosen locknut (10), then turn holder (11) to
adjust.
fl Turn the holder to adjust as follows.
To INCREASE pressure, turn CLOCKWISE.
To
DECREASE
pressure,
turn
COUNTERCLOCKWISE.
fl Amount of adjustment for one turn of
holder:
3 Locknut: 78 93 Nm {8 9.5 kgm}
fl When the high-pressure setting is
changed, the low-pressure setting will
also change, so adjust the low-pressure
setting also.
4) Adjusting low-pressure setting
Loosen locknut (12), then turn holder (13) to
adjust.
fl Turn the holder to adjust as follows.
To
DECREASE
pressure,
turn
COUNTERCLOCKWISE.
holder:
3 Locknut: 93 123 Nm {9.5 12.5 kgm}
fl After completion of adjustment, repeat
the procedure in above to check the set
pressure again.
2. Adjusting L.H. 5-spool valve main relief valve
fl If the relief pressure of the rear pump circuit
is not correct, adjust the main relief valve of
the L.H. 5-spool valve as follows.
fl Adjust in the same way as for the R.H. 4spool valve.
20-120
1
PC1100-6

3. Adjusting swing 4-spool valve main relief valve

fl If the relief pressure of the No. 3 pump circuit is not correct, adjust the main relief valve
of the swing 4-spool valve as follows.
fl Adjust in the same way as for the R.H. 4spool valve.
4. Adjusting swing motor safety valve

fl If the relief pressure of the swing motor is
not correct, adjust the safety valve of the
swing motor as follows.
1) Loosen locknut (14), then turn adjustment
screw (15) to adjust.
fl Turn the adjustment screw to adjust as
follows.
To DECREASE pressure, turn

COUNTERCLOCKWISE.
adjustment screw:
Approx. 4.7 MPa {47.9 kg/cm2}
3 Locknut: 147 196 Nm {15 20 kgm}
pressure again.
PC1100-6
20-121
1
TESTING AND ADJUSTING CONTROL

PUMP CIRCUIT OIL PRESSURE

CONTROL PUMP CIRCUIT OIL
PRESSURE
Measuring
1. Install oil pressure gauge J1 (5.9 MPa {60 kg/
cm2}) to quick coupler (1).
2. Start the engine run the engine at full throttle,

and measure the oil pressure with all the control levers at neutral.
Adjusting
fl If the relief pressure of the control circuit is not
correct, adjust the control relief valve as follows.
1. Remove cap (2).
2. Loosen locknut (3) and turn adjustment screw
(4) to adjust.
fl Turn the adjustment screw as follows.
To INCREASE pressure, turn CLOCKWISE
To
DECREASE
pressure,
turn
COUNTERCLOCKWISE
fl Amount of adjustment for one turn of adjustment screw:
3 Locknut: 9.8 Nm {1 kgm}
fl After completion of adjustment, repeat the
procedure in above to check the set pressure again.
20-122
1
PC1100-6
TESTING AND ADJUSTING PISTON PUMP CONTROL PRESSURE

PISTON PUMP CONTROL
PRESSURE
Measuring
1. TVC valve output pressure
fl The TVC valve output pressure varies with
the discharge pressure of each valve, so always check that the oil pressure of the work
equipment, swing, and travel circuits is normal before measuring.
fl The TVC valve output pressure uses the control circuit pressure as the basic pressure,
so always check that the oil pressure of the
control circuit is normal before measuring.
1) Remove oil pressure measurement plug (1)
(Thread dia.=10mm, Pitch=1.25mm) of the
No. 3 front pump.
2) Install nipple q of oil pressure gauge J1,
then connect oil pressure gauge J1 (5.9 MPa
{60 kg/cm2}).
3) Set the working mode switch to DH mode.
4) Run the engine at full throttle, and measure
the pressure under the following conditions.
5) Measuring with all control levers at neutral:
Set all the control levers to neutral and measure the output pressure.
6) Measuring with circuit relieved at heavy-lift
OFF + boom RAISE
ii) Measure the output pressure with the
circuit relieved at boom RAISE.
7) Measuring with circuit relieved at heavy-lift
ON + boom RAISE
ii) Measure the output pressure with the
circuit relieved at boom RAISE.
2. Measuring output pressure of No. 1 and No. 2

pump CO and NC valves
1) Remove oil pressure measurement plugs (2)
and (3) (Thread dia.=10mm, Pitch=1.25mm)
of the No. 2 pump.
(2): For front pump circuit
(3): For rear pump circuit
PC1100-6
20-123
1
2) Fit nipple q of oil pressure gauge J1, then

connect oil pressure gauge J1 (5.9 MPa {60
kg/cm2}).
conditions.
4) Measuring when work equipment control levers are at neutral:
i) Set the working mode switch to the DH
mode.
ii) Measure the output pressure when all
control levers area at neutral.
5) Measuring when track is rotating under no
load:
mode.
ii) Using the boom and arm, jack up the
track on the side to be measured.
iii) Measure the output pressure when the
track is rotating under no load.
fl The output pressure of the CO, NC valve
differs according to the jet sensor output
differential pressure, so if the CO, NC valve
output pressure is not normal, always measure the jet sensor output differential pressure.
3. Measuring No. 3 pump CO, NC valve output

pressure
1) Remove oil pressure measurement plug (4)
(Thread dia.=10mm, Pitch=1.25mm).
2) Fit nipple q of oil pressure gauge J1, then
connect oil pressure gauge J1 (5.9 MPa {60
kg/cm2}).
conditions.
20-124
1
PC1100-6
4) Measuring when work equipment control levers are at neutral:

mode.
ii) Measure the output pressure when all
control levers area at neutral.
5) Measuring when upper structure is swinging under no load:
mode.
ii) Measure the output pressure when the
upper structure is swinging under no
load.
fl The output pressure of the CO, NC valve
differs according to the jet sensor output
pressure differential pressure, so if the CO,
NC valve output pressure is not normal, always measure the jet sensor output differential pressure.
4. Measuring R.H. 4-spool valve and L.H. 5-spool

valve jet sensor output differential pressure
Loosen the oil filler cap slowly to release
the pressure inside the hydraulic tank.
1) Remove high-pressure oil pressure measurement plug (5) (PT1/8) and low-pressure oil
pressure measurement plug (6) (PT1/8).
PC1100-6
20-125
1
2) Fit nipple e of oil pressure gauge J1, then

connect differential gauge J3 or oil pressure
gauge J1 (5.9 MPa {60 kg/cm2}).
mode.
4) Start the engine, then using the boom and

arm, jack up the track on the side to be
measured.
the output differential pressure when all levers are at neutral and when the track is
rotating under no load.
5. Measuring swing 4-spool valve jet sensor output differential pressure

Loosen the oil filler cap slowly to release the
pressure inside the hydraulic tank.
1) Remove high-pressure oil pressure measurement plug (7) (PT1/8) and low-pressure oil
pressure measurement plug (8) (PT1/8).
20-126
1
PC1100-6
2) Install nipple e of oil pressure gauge J1,

then connect to differential gauge J3 or oil
pressure gauge J1 (58.8 MPa {600 kg/cm2}).
fl When using oil pressure gauge J1 (58.8
MPa {600 kg/cm2}), exchange with a 0.98
MPa {10 kg/cm2} unit gauge to measure
the high pressure and low pressure.
3) Set the working mode switch to DH mode.
the output differential pressure with all the
control levers at neutral and with the swing
operated under no load.
Adjusting
1. Adjusting TVC valve
fl If the TVC valve output pressure is not correct, adjust the TVC valve of the No. 1 pump
as follows.
1) Loosen locknut (9).
2) Turn adjustment screw (10) to adjust.
follows.

COUNTERCLOCKWISE.
adjustment screw:
3 Locknut: 5.9 9.8 Nm {0.6 1.0 kgm}
pressure again.
PC1100-6
20-127
1
2. Adjusting No. 1 and No. 2 pump CO and NC

valves
fl If the CO, NC valve output pressure is not
correct, adjust the CO, NC valve of the No. 1
pump as follows.
1) Adjusting CO valve
i) Loosen locknut (11).
ii) Turn adjustment screw (12) to adjust.
fl Turn the adjustment screw to adjust
as follows.
To INCREASE pressure, turn

CLOCKWISE.

COUNTERCLOCKWISE.
fl Amount of adjustment for one turn
of adjustment screw:
3 Locknut:
5.9 9.8 Nm {0.6 1.0 kgm}
fl After completion of adjustment, repeat the procedure in above to check
the set pressure again.
2) Adjusting NC valve
i) Loosen locknut (13).
ii) Turn adjustment screw (14) to adjust.
fl Turn the adjustment screw to adjust
as follows.
To INCREASE pressure, turn

CLOCKWISE.

COUNTERCLOCKWISE.
fl Amount of adjustment for one turn
of adjustment screw:
3 Locknut:
5.9 9.8 Nm {0.6 1.0 kgm}
20-128
1
PC1100-6
3. Adjusting No. 3 pump CO and NC valves

fl If the CO, NC valve output pressure is not
correct, adjust the CO, NC valve as follows.
1) Adjusting CO valve
fl Adjust in the same way as for the No. 1
and No. 2 pump CO and NC valves
2) Adjusting NC valve
fl Adjust in the same way as for the No. 1
and No. 2 pump CO and NC valves
4. Adjusting R.H. 4-spool valve and L.H. 5-spool

valve jet sensor
fl If the output differential pressure of the jet
sensor is not correct, adjust the jet sensor
relief valve as follows.
1) Loosen locknut (15).
2) Turn adjustment screw (16) to adjust.
follows.

COUNTERCLOCKWISE.
adjustment screw:
3 Locknut: 59 78 Nm {6 8 kgm}
PC1100-6
20-129
1
5. Adjusting swing 4-spool valve jet sensor

fl If the jet sensor output differential pressure
is not correct, adjust the jet sensor relief
valve as follows.
fl Adjust in the same way as for the R.H. 4spool valve and L.H. 5-spool valve jet sensor.
20-130
1
PC1100-6
MEASURING SERVO PISTON STROKE
MEASURING SERVO PISTON

STROKE
fl When judging the condition of the servo valve,
measure the stroke of the servo valve as follows.
1. Measurement tools to prepare
1) Prepare new servo piston cover (1).
fl The same part is used for the No. 1 pump
and No. 2 pump.
2) Machine a PT1/4 tap hole in the center of cap
(1).
3) Install disk gauge P in cap (1).
2. Measuring stroke
1) Remove the cap at the servo piston spring
chamber end, then install the measuring tool.
fl Install the tool for measuring the cap Oring.
2) Stop the engine, push in the rod of the measurement tool fully, and measure dimension
a1 of the rod.
3) Start the engine and use the work equipment to jack up the track shoe from the
ground on the side to be measured.
4) Run the engine at full throttle, rotate the
track under no load, and measure dimension a2 of the rod.
5) Calculate stroke b of the servo piston from
dimensions a1 and a2.
fl Standard stroke b of servo piston
No. 1 pump, No. 2 pump: 9.37 mm
No. 3 pump: 12.2 mm
3. Pass/Fail judgment
fl If the servo piston stroke is not correct, before judging the condition, remove the servo
valve, servo piston cap, and spring, then
move the servo piston by hand and check
that it moves smoothly.
1) If servo piston stroke is correct:
The servo valve is normal.
2) If servo piston stroke is not correct:
If the servo piston moves smoothly:
The servo valve is defective.
If the servo piston does not move
smoothly: The servo valve is normal.
PC1100-6
20-131
1
MEASURING PPC VALVE OUTPUT PRESSURE AND

TESTING PPC SHUTTLE VALVE
MEASURING PPC VALVE OUTPUT PRESSURE AND TESTING

PPC SHUTTLE VALVE
1. Measuring PPC valve output pressure
1) Disconnect hose (1) of the circuit to be measured.
fl See the diagram on the next page for
details of the hose to disconnect.
2) Install adapter q and nipple w of oil pressure gauge J1, then connect oil pressure
3) Run the engine at full throttle, operate the

control lever of the circuit to be measured,
and measure the oil pressure.
fl Measure with the lever operated fully.
For the work equipment, operate

each cylinder to the end of its stroke.
For the swing, turn the swing lock

switch ON to lock the swing.
For the travel circuit, put block e
between the sprocket and frame to
lock the track.
20-132
1
PC1100-6

2. Measuring swing PPC shuttle valve

1) Disconnect hose (2).
2) Install adapter q and nipple w of oil pressure gauge J1, then connect oil pressure
3) Run the engine at full throttle, swing the

upper structure to the left and right, and
measure the oil pressure in each direction.
fl If the oil pressure is correct for both the
left and right swing, the shuttle valve is
normal.
fl If the oil pressure is not correct for either the left or right swing, the shuttle
valve ball is probably stuck.
PC1100-6
20-133
1
20-134
1

PC1100-6
PC1100-6

20-135
1
TESTING SOLENOID VALVE OUTPUT PRESSURE
TESTING SOLENOID VALVE

OUTPUT PRESSURE
1. Disconnect outlet hose (9) of the solenoid valve
(1) (8) to be measured
(1): Straight-travel solenoid valve
(2): Machine push-up solenoid valve
(3): Swing holding brake R solenoid valve

(4): Travel speed solenoid valve
(5): Swing holding brake F solenoid valve
(6): CO cancel solenoid valve

(7): 2-stage relief solenoid valve
(8): Swing priority solenoid valve
2. Install adapter q and nipple w of oil pressure

gauge J1, then connect oil pressure gauge J1
(5.9 MPa {60 kg/cm2}).
20-136
1
PC1100-6
TESTING SOLENOID VALVE OUTPUT PRESSURE
3. Start the engine and measure the output pressure when set or operated to the conditions in
the table below.
fl When operating the work equipment, swing,
or travel levers, operate slightly (enough for
the PPC pressure switch to be turned ON).
Table
No. Solenoid
Straight
travel
Machine
push-up
Swing
holding
brake R
Travel
speed
Swing
holding
brake F
CO
cancel
2-stage
main
relief
Swing
priority
PC1100-6
Condition of Oil pressure

(MPa {kg/cm2})
solenoid
Operating condition
All levers at neutral
OFF
Flow from front pump circuit

and rear pump circuit divided
Swing or work equipment and travel

control lever operated simultaneously
ON
2.9 0.6
{30 5.5}
Flow from front pump circuit

and rear pump circuit merged
When machine push-up switch is at

high-pressure setting
OFF
Boom LOWER safety valve

at high-pressure setting
When machine push-up switch is at

low-pressure setting
ON
2.9 0.6
{30 5.5}
Boom LOWER safety valve

at low-pressure setting
5 sec after all work equipment and

swing levers are returned to neutral
OFF
Swing holding brake

applied
Swing or work equipment lever

operated
ON
2.9 0.6
{30 5.5}
Swing holding brake

canceled
Travel speed switch at Lo
OFF
Travel motor swash plate

angle at MAX
Travel speed switch at Hi and travel

lever operated
ON
2.9 0.6
{30 5.5}
Travel motor swash plate

angle at MIN
5 sec after all work equipment and

swing levers are returned to neutral
OFF
Swing holding brake

applied
Swing or work equipment lever

operated
ON
2.9 0.6
{30 5.5}
Swing holding brake

canceled
Working mode switch at H or G
OFF
Working mode switch at DH
ON
2.9 0.6
{30 5.5}
When heavy-lift switch is OFF
OFF
Main relief valve at lowpressure setting
When heavy-lift switch is ON and boom

RAISE is operated independently
ON
2.9 0.6
{30 5.5}
Main relief valve at highpressure setting
Swing priority switch OFF
OFF
Boom Plus spool actuated
Swing priority switch ON
ON
2.9 0.6
{30 5.5}
Boom Plus spool stopped
Pump CO function actuated

Pump CO function
canceled
20-137
1
ADJUSTING WORK EQUIPMENT, SWING PPC VALVE
ADJUSTING WORK EQUIPMENT, SWING PPC VALVE

fl If there is excessive play at the tip of the work
equipment or swing lever, adjust at the PPC
valve end as follows.
Standard lever play a: 0.5 3 mm at point 200
mm from rotating center of lever (forward and
reverse, and left and right)
1. Remove boot (1).
2. Loosen locknut (2), then turn disc (3) to adjust
the play of the lever.
fl When doing this, do not move the piston.
3. Secure disc (3) in position, then tighten locknut
(2) to the specified torque.
3 Locknut :
98.07 127.49 Nm {10 13 kgm}
4. Install boot (1).
20-138
1
PC1100-6
TESTING TRAVEL DEVIATION
TESTING TRAVEL DEVIATION

fl When traveling on level ground.
1. Set the machine in the travel posture.
fl For the travel posture, extend the bucket and
arm cylinder rods fully, and hold the boom
angle at 45.
2. Operate with the engine at full throttle, run up
for 10 m, then measure the deviation over the
next 20 m.
fl Install the oil pressure gauge and measure
the pump discharge pressure at the same
time.
PC1100-6
20-139
1
TESTING LOCATIONS CAUSING HYDRAULIC

DRIFT OF WORK EQUIPMENT
TESTING LOCATIONS
CAUSING HYDRAULIC DRIFT
OF WORK EQUIPMENT
fl If there is any hydraulic drift in the work equipment (cylinders), check as follows to determine
if the cause is in the cylinder packing or in the
control valve.
1. Checking boom and bucket cylinders
1) Set in the same posture as when measuring
hydraulic drift, and stop the engine.
2) Operate the boom control lever to RAISE or
the bucket control lever to CURL.
If the lowering speed increases, the packing is defective.
If there is no change, the boom lock valve
(boom) or the control valve (bucket) is
defective.
fl If the pressure in the accumulator has
dropped, run the engine for approx. 10
seconds to charge the accumulator again
before operating.
2. Checking arm cylinder
1) Stop the arm cylinder at a point approx. 100
mm before the end of the IN stroke, then
stop the engine.
2) Operate the control lever to arm IN.
If the lowering speed increases, the packing is defective.
If there is no change, the control valve is
defective.
fl If the pressure in the accumulator has
dropped, run the engine for approx. 10
seconds to charge the accumulator again
before operating.
[Reference]If the cause of the hydraulic drift is in
the packing, and the above operation is
carried out, the downward movement becomes faster for the following reasons.
1) If the work equipment is set to the above
posture (holding pressure applied to the bottom end), the oil at the bottom end leaks to
the head end. However, the volume at the
head end is smaller than the volume at the
bottom end by the volume of the rod, so the
internal pressure at the head end increases
because of the oil flowing in from the bottom end.
2) When the internal pressure at the head end
increases, the pressure at the bottom end
also rises in proportion to this. The balance
is maintained at a certain pressure (this differs according to the amount of leakage) by
repeating this procedure.
3) When the pressure is balanced, the downward movement becomes slower. If the lever is then operated according to the procedure given above, the circuit at the head
end is opened to the drain circuit (the bottom end is closed by the check valve), so
the oil at the head end flows to the drain
circuit and the downward movement becomes faster.
20-140
1
PC1100-6
MEASURING OIL LEAKAGE

1. Work equipment cylinder
1) Fully extend the rod of the cylinder to be
measured, then stop the engine.
2) Disconnect piping (1) at the head end, then
block the piping at the chassis end with a
blind plug.
Be careful not to disconnect the piping
at the bottom end.
3) Start the engine and apply the relief pressure to the bottom end of the cylinder with
the engine at full throttle.
Boom cylinder: RAISE
Arm cylinder: IN
Bucket cylinder: CURL
4) Continue this condition for 30 seconds, then
measure the oil leakage for the next one
minute.
PC1100-6
20-141
1
2. Swing motor
Loosen the hydraulic tank oil filler cap slowly
to release the pressure inside the tank.
1) Disconnect drain hose (2) from the swing
motor, then install a blind plug at the tank
end.
2) Turn the swing lock switch LOCK.
3) Start the engine and operate the swing relief with the engine at full throttle.
minute.
fl After measuring, swing 180 and measure
again.
3. Travel motor
Loosen the hydraulic tank oil filler cap slowly
to release the pressure inside the tank.
1) Disconnect drain hose (3) from the travel
motor, then fit a blind plug at the hose end.
2) Fit block q between the sprocket and frame
to lock the track.
3) Start the engine and operate the travel relief
with the engine at full throttle.
When measuring the oil leakage from
the travel motor, mistaken operation of
the control lever may lead to a serious
accident, so always use signals and check
carefully when carrying out this operation.
minute.
fl When measuring, move the motor slightly
(to change the position between the valve
plate and cylinder, and between the piston
and cylinder), and measure several times.
20-142
1
PC1100-6
4. Center swivel joint

Table (inspection port and measurement port)
Swivel joint
inspection port
Direction of rotation
Swivel joint
measurement port
of travel motor
L.H. FORWARD
TB
L.H. REVERSE
AP
R.H. FORWARD
PD
R.H. REVERSE
TC
Speed selection
BC
1) Put block q between the sprocket and frame

to lock the rotation of the travel motor where
the port is to be inspected, and stop the
engine.
Loosen the hydraulic tank oil filler cap
slowly to release the pressure inside the
tank.
2) Disconnect the hoses at the botom of the
swivel joint for the measurement port at both
sides of the port to be inspected, and fit
blind plugs in the hoses.
fl When measuring at port T, disconnect
and block the hoses at the top of the
swivel joint to prevent the oil from the
other circuits from flowing in. At the bottom, disconnect the hoses, and do not
block them. Catch the oil in an oil pan.
as follows.
i) Ports A, B, C, D
Relieve the travel motor slowly in the
direction of rotation for the port to be
inspected.
If the lever is operated mistakenly, it
may lead to serious injury or damage, so be sure to confirm signals
and signs carefully.
ii) Port P
Set the travel speed switch to Hi.
4) Continue for one minute, then measure the
oil leakage for the next one minute.
PC1100-6
20-143
1
20-144
1
PC1100-6
BLEEDING AIR
BLEEDING AIR
1. Bleeding air from hydraulic pumps
fl If the hydraulic pump or related piping has
been removed and installed again, bleed the
air from the hydraulic pumps as follows.
1) Loosen air bleed plugs (1), (2), and (3) 4
turns.
2) Loosen the oil filler cap of the hydraulic tank
and leave for approx. 10 minutes.
fl The time needed differs according to the
amount of oil remaining inside the pump
case.
3) When oil comes out of air bleed plugs (1)
and (2), tighten air bleed plugs (1) and (2).
4) Start the engine and run at low idling.
fl Set the safety lock lever to the LOCK
position to prevent the work equipment
from moving.
5) When no more cloudy white oil comes out
from air bleed plug (3), tighten air bleed
plug (3).
2. Bleeding air from swing motor

fl If the travel motor, center swivel joint, or
related piping has been removed and installed again, bleed the air from the hydraulic pumps as follows.
1) Loosen air bleed plug (4).
2) Start the engine and use the boom and arm
to jack up the track shoe from the ground
on the side where the air is to be bled.
3) Run the engine at low idling and rotate the
track under no load.
4) When oil comes out from air bleed plug (4),
tighten air bleed plug (4).
PC1100-6
20-145
1
BLEEDING AIR
3. Bleeding air from swing motor

fl When the swing motor has been removed
or installed again, or when the related piping has been disconnected or connected, do
as follows to bleed the air from the swing
motor.
1) Run the engine at low idling, then start and
stop the swing several times.
fl This operation will bleed the air inside
the swing motor automatically.
4. Bleeding air from hydraulic cylinders

fl When the hydraulic cylinders have been removed or installed again, or when the related piping has been disconnected or connected, do as follows to bleed the air from
the hydraulic cylinders.
1) Start the engine and run at idling for approx.
5 minutes.
2) Run the engine at low idling, then raise and
lower the boom 4 5 times in succession.
fl Operate the piston rod to a point approx.
100 mm before the end of its stroke. Do
not relieve the circuit under any circumstances.
3) Keep the engine running at low idling, operate the cylinder slowly (take at least 10 seconds) from a point approx. 100 mm before
the end of the stroke, extend the cylinder to
the end of its stroke to relieve the circuit,
and hold in the relief position for 3 minutes.
4) Run the engine at high idling, operate the
cylinder slowly (take at least 10 seconds) from
a point approx. 100 mm before the end of
the stroke, extend the cylinder to the end of
its stroke to relieve the circuit, and hold in
the relief position for 1 minute.
20-146
1
PC1100-6
RELEASING REMAINING PRESSURE IN HYDRAULIC CIRCUIT
RELEASING REMAINING
PRESSURE IN
HYDRAULIC CIRCUIT
fl If the piping between the hydraulic cylinder and
the control valve is to be disconnected, release
the remaining pressure from the circuit as follows.
The travel circuit is an open circuit, so there is
no remaining pressure. It is enough to remove
the oil filler cap.
1. Loosen the oil filler cap slowly to release the
pressure inside the tank.
2. Operate the control levers.
fl When the levers are operated 2 3 times,
the pressure stored in the accumulator is
removed.
3. Start the engine, run at low idling for approx. 5
minutes, then stop the engine and operate the
control levers.
fl Repeat the above operation 2 3 times to
release all the remaining pressure.
PC1100-6
20-147
1
TROUBLESHOOTING
Points to remember when troubleshooting ........................................................................................ 20-202
Sequence of events in troubleshooting .............................................................................................. 20-203
Points to remember when carrying out maintenance ....................................................................... 20-204
Checks before troubleshooting ............................................................................................................ 20-212
Connector types and mounting locations ........................................................................................... 20-214
Connection table for connector pin numbers .................................................................................... 20-220
Explanation of functions of control mechanism for electrical system ............................................ 20-231
Display method and special functions of monitor panel .................................................................. 20-232
Details of troubleshooting and troubleshooting procedure ............................................................. 20-248
Method of using judgement table ....................................................................................................... 20-250
Method of using troubleshooting charts ............................................................................................ 20-252
Troubleshooting of communication abnormality system (N mode) ............................................... 20-301
Troubleshooting of engine controller & APS controller system (E mode) ..................................... 20-351
Troubleshooting of engine system (S mode) ..................................................................................... 20-401
Troubleshooting of pump controller system (C mode) ..................................................................... 20-451
Troubleshooting of pump controller input signal system (F mode) ............................................... 20-501
Troubleshooting of hydraulic, mechanical system (H mode) ........................................................... 20-551
Troubleshooting of machine monitor system (M mode) .................................................................. 20-601
PC1100-6
20-201
3
TROUBLESHOOTING
POINTS TO REMEMBER WHEN TROUBLESHOOTING
POINTS TO REMEMBER WHEN TROUBLESHOOTING

Stop the machine in a level place, and check that the safety pin, blocks, and parking brake are securely fitted.
When carrying out the operation with two or more workers, keep strictly to the agreed signals, and do not
allow any unauthorized person to come near.
If the radiator cap is removed when the engine is hot, hot water may spurt out and cause burns, so wait for
the engine to cool down before starting troubleshooting.
Be extremely careful not to touch any hot parts or to get caught in any rotating parts.
When disconnecting wiring, always disconnect the negative () terminal of the battery first.
When removing the plug or cap from a location which is under pressure from oil, water, or air, always release
the internal pressure first. When installing measuring equipment, be sure to connect it properly.
The aim of troubleshooting is to pinpoint the basic cause of the failure, to carry out repairs swiftly, and to
prevent reoccurrence of the failure.
When carrying out troubleshooting, and important point is of course to understand the structure and function.
However, a short cut to effective troubleshooting is to ask the operator various questions to form some idea
of possible causes of the failure that would produce the reported symptoms.
1.
2.
3.
When carrying out troubleshooting, do not hurry

to disassemble the components.
If components are disassembled immediately any
failure occurs:
Parts that have no connection with the failure or other unnecessary parts will be disassembled.
It will become impossible to find the cause

of the failure.
It will also cause a waste of manhours, parts, or
oil or grease, and at the same time, will also lose
the confidence of the user or operator.
For this reason, when carrying out troubleshooting, it is necessary to carry out thorough prior
investigation and to carry out troubleshooting in
accordance with the fixed procedure.
Points to ask user or operator
1) Have any other problems occurred apart from
the problem that has been reported?
2) Was there anything strange about the machine before the failure occurred?
3) Did the failure occur suddenly, or were there
problems with the machine condition before
this?
4) Under what conditions did the failure occur?
5) Had any repairs been carried out before the
failure?
When were these repairs carried out?
6) Has the same kind of failure occurred before?
Check before troubleshooting
1) Check the oil level
2) Check for any external leakage of oil from
the piping or hydraulic equipment.
3) Check the travel of the control levers.
20-202
3
4)
5)
4.
5.
6.
Check the stroke of the control valve spool.

Other maintenance items can be checked externally, so check any item that is considered
to be necessary.
Confirming failure
Confirm the extent of the failure yourself,

and judge whether to handle it as a real failure or as a problem with the method of operation, etc.
fl When operating the machine to reenact
the troubleshooting symptoms, do not
carry out any investigation or measurement that may make the problem worse.
Troubleshooting
Use the results of the investigation and inspection in Items 2 4 to narrow down the
causes of failure, then use the troubleshooting flowchart to locate the position of the
failure exactly.
fl The basic procedure for troubleshooting
is as follows.
1) Start from the simple points.
2) Start from the most likely points.
3) Investigate other related parts or information.
Measures to remove root cause of failure
Even if the failure is repaired, if the root cause

of the failure is not repaired, the same failure
will occur again.
To prevent this, always investigate why the
problem occurred. Then, remove the root
cause.
PC1100-6
TROUBLESHOOTING
SEQUENCE OF EVENTS IN TROUBLESHOOTING
SEQUENCE OF EVENTS IN TROUBLESHOOTING

Office, shop
Jobsite
Step 1
Examination, confirmation of symptoms
1) When a request for repairs is received, first
ask the following points.
Name of customer
Type, serial number of machine
Details of jobsite, etc.
2) Ask questions to gain an outline of the problem.
Condition of failure
Work being carried out at the time of the
failure
Operating environment
Past history, details of maintenance, etc.
Step 2
Determining probable location of cause
1) Look at the troubleshooting section of the
shop manual to find locations of possible
causes.
Step 3
Preparation of troubleshooting tools
1) Look at the table of troubleshooting tools in
the shop manual and prepare the necessary
tools.
T-adapter
Hydraulic pressure gauge kit, etc.
2) Look in the parts book and prepare the necessary replacement parts.
Step 7
Pinpoint locations of failure (carry out
troubleshooting)
Decide action to take
1) Before starting troubleshooting, locate and
repair simple failures.
Check before starting items
Other check items
2) See the Troubleshooting Section of the shop
manual, select a troubleshooting flowchart
that matches the symptoms, and carry out
troubleshooting.
Step 6
Re-enacting failure
Step 4
Go to jobsite
Step 5
Ask operator questions to confirm details of
failure.
PC1100-6
Drive and operate the machine to confirm

the condition and judge if there is really a
failure.
Was there anything strange about the machine before the failure occurred?
Did the failure occur suddenly?
Had any repairs been carried out before the
failure?
20-203
3
TROUBLESHOOTING
POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE

To maintain the performance of the machine over a long period, and to prevent failures or other
troubles before they occur, correct operation, maintenance and inspection, troubleshooting, and repairs must be carried out. This section deals particularly with correct repair procedures for mechatronics
and is aimed at improving the quality of repairs. For this purpose, it gives sections on Handling
electric equipment and Handling hydraulic equipment (particularly gear oil and hydraulic oil).
1. POINTS TO REMEMBER WHEN HANDLING

ELECTRIC EQUIPMENT
1) Handling wiring harnesses and connectors
Wiring harnesses consist of wiring connecting
one component to another component, connectors used for connecting and disconnecting one
wire from another wire, and protectors or tubes
used for protecting the wiring.
Compared with other electrical components fitted in boxes or cases, wiring harnesses are more
likely to be affected by the direct effects of rain,
water, heat, or vibration. Furthermore, during
inspection and repair operations, they are frequently removed and installed again, so they
are likely to suffer deformation or damage. For
this reason, it is necessary to be extremely careful when handling wiring harnesses.
Main failures occurring in wiring harness

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

The pins of the male and female connectors
are in contact at the crimped terminal or
soldered portion, but if there is excessive
force brought to bear on the wiring, the plating at the joint will peel and cause improper
connection or breakage.
20-204
3
PC1100-6
TROUBLESHOOTING
3 Disconnections in wiring
If the wiring is held and the connectors are
pulled apart, or components are lifted with a
crane with the wiring still connected, or a
heavy object hits the wiring, the crimping of
the connector may separate, or the soldering may be damaged, or the wiring may be
broken.
4 High-pressure water entering connector

The connector is designed to make it difficult for water to enter (drip-proof structure),
but if high-pressure water is sprayed directly
on the connector, water may enter the connector, depending on the direction of the
water jet.
As already said, the connector is designed
to prevent water from entering, but at the
same time, if water does enter, it is difficult
for it to be drained. Therefore, if water should
get into the connector, the pins will be shortcircuited by the water, so if any water gets
in, immediately dry the connector or take
other appropriate action before passing electricity through it.
5 Oil or dirt stuck to connector
If oil or grease are stuck to the connector
and an oil film is formed on the mating surface between the male and female pins, the
oil will not let the electricity pass, so there
will be defective contact.
If there is oil or grease stuck to the connector, wipe it off with a dry cloth or blow it dry
with compressed air and spray it with a contact restorer.
fl When wiping the mating portion of the
connector, be careful not to use excessive force or deform the pins.
fl If there is oil or water in the compressed
air, the contacts will become even dirtier,
so remove the oil and water from the
compressed air completely before cleaning with compressed air.
PC1100-6
20-205
3
TROUBLESHOOTING
2) Removing, installing, and drying connectors and

wiring harnesses
Disconnecting connectors
1 Hold the connectors when disconnecting.
When disconnecting the connectors, hold the
connectors and not the wires. For connectors held by a screw, loosen the screw fully,
then hold the male and female connectors
in each hand and pull apart. For connectors
which have a lock stopper, press down the
stopper with your thumb and pull the connectors apart.
fl Never pull with one hand.
2 When removing from clips
When removing a connector from a clip, pull
the connector in a parallel direction to the
clip.
fl If the connector is twisted up and down
or to the left or right, the housing may
break.
3 Action to take after removing connectors

After removing any connector, cover it with
a vinyl bag to prevent any dust, dirt, oil, or
water from getting in the connector portion.
fl If the machine is left disassembled for a
long time, it is particularly easy for improper contact to occur, so always cover
the connector.
20-206
3
PC1100-6
TROUBLESHOOTING
Connecting connectors
1 Check the connector visually.
1) Check that there is no oil, dirt, or water
stuck to the connector pins (mating portion).
2) Check that there is no deformation, defective contact, corrosion, or damage to
the connector pins.
3) Check that there is no damage or breakage to the outside of the connector.
fl If there is any oil, water, or dirt stuck to
the connector, wipe it off with a dry cloth.
If any water has got inside the connector, warm the inside of the wiring with a
dryer, but be careful not to make it too
hot as this will cause short circuits.
fl If there is any damage or breakage, replace the connector.
2 Fix the connector securely.
Align the position of the connector correctly,
then insert it securely.
For connectors with lock stopper, push in
the connector until the stopper clicks into
position.
3 Correct any protrusion of the boot and any
misalignment of the wiring harness
For connectors fitted with boots, correct any
protrusion of the boot. In addition, if the
wiring harness is misaligned, or the clamp
is out of position, adjust it to its correct position.
fl If the connector cannot be corrected easily, remove the clamp and adjust the
position.
4 If the connector clamp has been removed,
be sure to return it to its original position.
Check also that there are no loose clamps.
PC1100-6
20-207
3
TROUBLESHOOTING
Drying wiring harness

If there is any oil or dirt on the wiring harness,
wipe it off with a dry cloth. Avoid washing it in
water or using steam. If the connector must be
washed in water, do not use high-pressure water or steam directly on the wiring harness.
If water gets directly on the connector, do as
follows.
1 Disconnect the connector and wipe off the
water with a dry cloth.
fl If the connector is blown dry with compressed air, there is the risk that oil in
the air may cause defective contact, so
remove all oil and water from the compressed air before blowing with air.
2 Dry the inside of the connector with a dryer.

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

After drying, leave the wiring harness disconnected and carry out a continuity test to
check for any short circuits between pins
caused by water.
fl After completely drying the connector,
blow it with contact restorer and reassemble.
20-208
3
PC1100-6
TROUBLESHOOTING
3) Handling control box

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

box.
4 Cover the control connectors with tape or a
vinyl bag.
Never touch the connector contacts with your
hand.
5 During rainy weather, do not leave the control box in a place where it is exposed to
rain.
6 Do not place the control box on oil, water,

or soil, or in any hot place, even for a short
time.
(Place it on a suitable dry stand).
7 Precautions when carrying out arc welding
When carrying out arc welding on the body,
disconnect all wiring harness connectors connected to the control box. Fit an arc welding
ground close to the welding point.
2. Points to remember when troubleshooting electric circuits

1) Always turn the power OFF before disconnecting or connect connectors.
2) Before carrying out troubleshooting, check that all the related connectors are properly inserted.
fl Disconnect and connect the related connectors several times to check.
3) Always connect any disconnected connectors before going on to the next step.
fl If the power is turned ON with the connectors still disconnected, unnecessary abnormality
displays will be generated.
4) When carrying out troubleshooting of circuits (measuring the voltage, resistance, continuity, or
current), move the related wiring and connectors several times and check that there is no
change in the reading of the tester.
fl If there is any change, there is probably defective contact in that circuit.
PC1100-6
20-209
3
TROUBLESHOOTING
3. POINTS TO REMEMBER WHEN HANDLING

HYDRAULIC EQUIPMENT
With the increase in pressure and precision of hydraulic equipment, the most common cause of failure is dirt (foreign material) in the hydraulic circuit.
When adding hydraulic oil, or when disassembling
or assembling hydraulic equipment, it is necessary
to be particularly careful.
1) Be careful of the operating environment.
Avoid adding hydraulic oil, replacing filters, or
repairing the machine in rain or high winds, or
places where there is a lot of dust.
2) Disassembly and maintenance work in the field
If disassembly or maintenance work is carried
out on hydraulic equipment in the field, there is
danger of dust entering the equipment. It is also
difficult to confirm the performance after repairs,
so it is desirable to use unit exchange. Disassembly and main-tenance of hydraulic equipment should be carried out in a specially prepared dustproof workshop, and the performance
should be confirmed with special test equipment.
3) Sealing openings
After any piping or equipment is removed, the
openings should be sealed with caps, tapes, or
vinyl bags to prevent any dirt or dust from entering. If the opening is left open or is blocked
with a rag, there is danger of dirt entering or of
the surrounding area being made dirty by leaking oil so never do this.
Do not simply drain oil out on to the ground,
collect it and ask the customer to dispose of it,
or take it back with you for disposal.
4) Do not let any dirt or dust get in during refilling

operations.
Be careful not to let any dirt or dust get in when
refilling with hydraulic oil. Always keep the oil
filler and the area around it clean, and also use
clean pumps and oil containers. If an oil cleaning device is used, it is possible to filter out the
dirt that has collected during storage, so this is
an even more effective method.
20-210
3
PC1100-6
TROUBLESHOOTING
5) Change hydraulic oil when the temperature is

high.
When hydraulic oil or other oil is warm, it flows
easily. In addition, the sludge can also be drained
out easily from the circuit together with the oil,
so it is best to change the oil when it is still
warm. When changing the oil, as much as possible of the old hydraulic oil must be drained
out. (Drain the oil from the hydraulic tank; also
drain the oil from the filter and from the drain
plug in the circuit.) If any old oil is left, the
contaminants and sludge in it will mix with the
new oil and will shorten the life of the hydraulic
oil.
6) Flushing operations
After disassembling and assembling the equipment, or changing the oil, use flushing oil to
remove the contaminants, sludge, and old oil
from the hydraulic circuit.
Normally, flushing is carried out twice: primary
flushing is carried out with flushing oil, and secondary flushing is carried out with the specified
hydraulic oil.
7) Cleaning operations
After repairing the hydraulic equipment (pump,
control valve, etc.) or when running the machine, carry out oil cleaning to remove the sludge
or contaminants in the hydraulic oil circuit.
The oil cleaning equipment is used to remove
the ultrafine (about 3) particles that the filter
built into the hydraulic equipment cannot remove, so it is an extremely effective device.
PC1100-6
20-211
3
TROUBLESHOOTING
CHECKS BEFORE TROUBLESHOOTING
CHECKS BEFORE TROUBLESHOOTING

Judgement
value
Check fuel level, type of fuel
Add fuel
2.
Check for impurities in fuel
Clean, drain
3.
Check hydraulic oil level
Add oil
4.
Check hydraulic strainer
Clean, drain
5.
Check swing machinery oil level
Add oil
6.
Check engine oil level (oil pan oil level), type of oil
Add oil
7.
Check coolant level
Add water
8.
Check dust indicator for clogging
Clean or replace
9.
Check hydraulic filter
Replace
1.
Check for looseness, corrosion of battery terminal, wiring
Tighten or replace
2.
Check for looseness, corrosion of alternator terminal, wiring
Tighten or replace
3.
Check for looseness, corrosion of starting motor terminal, wiring
Tighten or replace
1.
Check for abnormal noise, smell
Repair
2.
Check for oil leakage
Repair
3.
Carry out air bleeding
Bleed air
1.
Check battery voltage (engine stopped)
20 30V
Replace
2.
Check battery electrolyte level
Add or replace
3.
Check for discolored, burnt, exposed wiring
Replace
4.
Check for missing wiring clamps, hanging wiring
Repair
5.
Check for water leaking on wiring (be particularly careful attention
Disconnect
Electrics, electrical equipment
Lubricating oil, coolant
1.
Electrical
equipment
Action
Hydraulic,
mechanical
equipment
Item
to water leaking on connectors or terminals)

6.
Check for blown, corroded fuses
7.
Check alternator voltage (engine running at 1/2 throttle or above)
8.
Check operating sound of battery (when switch is turned ON/OFF)
20-212
3
connector and dry
Replace
After running Replace

for several
minutes:
27.5 29.5V
Replace
PC1100-6
TROUBLESHOOTING
CONNECTOR TYPES AND MOUNTING LOCATIONS

ConNo.
nector Type of
No.
pins
C01
MIC
13
Mounting location
Address
ConNo.
nector Type of
No.
pins
Pump controller
R4
E26
SWP
Address
Mounting location
APS controller
C2
C02
MIC
21
Pump controller
R8
E27
16
Intermediate connector
M7
C03
AMP040
20
Pump controller
R4
E28
16
M8
C05
10
Pump prolix switch
Q2
E32
Governor control solenoid valve
U2
C06
Pump prolix resistor
Q3
F01
Travel alarm
L7
Flasher timer
M8
M5
C09
Model selection connector
R7
F10
C13
TVC valve
V1
H12
16
C16
MIC
17
Pump controller
R8
H13
16
M6
C17
AMP040
16
Pump controller
R6
H14
M5
CH1
16
Electronic governor checker connector
Q9
H15
M5
D01
KES1
Diode (for washer motor)
L03
Step light switch
R7
D03
KES1
Diode (for heater unit circuit)
M2
Starting motor
X5
D03
KES1
Diode (for V02 solenoid)
M06
Heater switch
N3
D04
KES1
M07
Light switch
N2
D05
KES1
Diode (for V04, V11 solenoid)
M08
Boom working lamp
A6
D06
KES1
M09
1-pin
connector
1-pin
connector
Boom working lamp
A5
D07
KES1
M10
E7
D09
KES1
M11
Fusible link
D7
D11
KES1
Diode (for alarm buzzer)
M12
KES1
Heater unit
R8
D14
KES1
Diode (for battery relay circuit)
M13
KES0
Right speaker
M5
D18
KES1
M14
Fusible link
C7
1-pin
connector
1-pin
connector
Horn valve
H9
Horn valve
H9
D20
KES1
Diode (for V09, V10 solenoid)
M16
D22
KES1
Diode (for travel alarm circuit)
M17
D23
KES1
Diode (for travel alarm circuit)
M18
Wiper washer switch
N2
D26
KES1
Diode (for swing prolix circuit)
M20
1-pin
connector
Cigar lighter
N3
D28
KES1
Diode (for automatic greasing circuit)
M21
PA
Radio
N4
E06
Fuel control dial
N3
M23
Horn switch
R6
E07
X5
M26
G1
E08
SWP
14
V1
M28
KES0
Window washer motor
I2
E12
MIC
17
Engine controller
R8
M33
AMP250
Boom shockless motor
M4
E13
MIC
21
Engine controller
P9
M34
Magnetic clutch for air conditioner compressor
S3
E14
AMP040
20
Engine controller
O9
M36
Kerosene mode selector switch R8
E15
AMP040
16
Engine controller
N9
M38
Machine push-up switch
M3
Option power source
M8
Right working lamp
B3
E16
AMP040
12
Engine controller
O9
M39
1-pin
connector
E17
AMP040
20
Engine controller
P9
M42
E18
AMP040
16
Engine controller
O9
M44
M5
E19
Governor control solenoid valve
T3
M45
Network pass connector
R1
E20
Prestroke control solenoid valve
T2
M62
R7
E21
X5
M66
Auto greasing pilot lamp
O1
E22
Rack sensor
S3
M67
E23
SWP
V1
M69
E25
APS controller
C2
M70
1-pin
connector
1-pin
connector
1-pin
connector
1-pin
connector
20-214
3
16
4
Auto greasing pilot lamp
O1
Option power source connector
M8
Service power source connector
O1
PC1100-6
TROUBLESHOOTING
ConNo.
nector Type of
No.
pins
Mounting location
Address
ConNo.
nector Type of
No.
pins
Address
Mounting location
1-pin
connector
Room lamp
F8
R24
Shinagawa
Governor cut relay
M72
M8
S01
R.H. travel FORWARD PPC pressure switch
J1
M73
KES0
Left speaker
N9
S02
Boom RAISE PPC pressure switch
K2
L2
M71
Q9
M74
D7
S03
Arm OUT PPC pressure switch
M75
Step light
G9
S04
Boom LOWER PPC pressure switch K1
M76
Cab front lamp
D7
S05
Arm IN PPC pressure switch
L2
M77
Cab front lamp
E7
S06
Bucket CURL PPC pressure switch
K2
M79
M5
S07
Bucket DUMP PPC pressure switch
K2
M80
G1
S08
Swing right PPC pressure switch
L2
M81
M8
S09
Service PPC pressure switch
I2
M82
Flash light
E1
S10
Swing left PPC pressure switch
L2
M90
Starting motor
U2
S11
R.H. travel REVERSE PPC pressure switch
J1
M91
KES1
APS switch
N4
S12
L.H. travel FORWARD PPC pressure switch
J1
M93
1-pin
connector
Service power source connector
O2
S13
L.H. travel REVERSE PPC pressure switch
J1
M94
R5
SW01
Swing prolix switch
R2
M95
KES0
Window washer motor
I2
T02
Revolving frame ground connection
M96
Q1
T05
Pump controller ground connection
R4
M97
1-pin
connector
Room lamp
G9
T06
Cab front lamp
D7
M99
G8
T07
Step light
H9
P01
AMP040
20
Monitor panel
O2
T08
Cab front lamp
E7
P02
AMP040
16
Monitor panel
O2
T20
Flash timer
N9
P03
Buzzer cancel switch
N3
T21
Step light timer
O9
P04
Alarm buzzer
O2
V01
Swing priority solenoid valve
L7
P05
Engine oil level sensor
U2
V02
2-stage relief solenoid valve
K8
P06
Fuel level sensor
E8
V03
J9
P07
Coolant temperature sensor W7
V04
J9
P08
Coolant level sensor
F8
V05
J8
P09
Hydraulic oil level sensor
I2
V06
Travel speed solenoid valve
I9
P10
Hydraulic oil temperature sensor
J3
V07
K8
P11
1-pin
connector
1-pin
connector
X7
V09
Boom RAISE shockless solenoid valve
G1
X6
V10
Boom LOWER shockless solenoid valve H1
I9
Wiper, washer relay box
Q3
P12
P13
APS nozzle & glow plug
W7
V11
P19
1-pin
connector
APS water temperature sensor
V8
W08
AMP070
P20
Coolant level sensor
G9
W21
R04
Shinagawa
Room light relay
Q2
X01
MIC
R05
Shinagawa
Head light relay
Q3
X05
R15
Shinagawa
Boom shockless relay
Q2
X07
MIC
R16
Shinagawa
Flash relay
N9
R17
Shinagawa
Step light relay
M9
R18
Shinagawa
Horn valve relay
P9
R20
Shinagawa
Swing holding brake relay
O2
R23
Shinagawa
APS controller relay
P9
PC1100-6
18
4
21
4
17
Wiper motor
E1
N5
Swing lock switch
N2
N4
20-215
3
TROUBLESHOOTING
CONNECTOR ARRANGEMENT DIAGRAM
20-216
3
PC1100-6
TROUBLESHOOTING
PC1100-6
20-217
3
TROUBLESHOOTING
20-218
3
PC1100-6
TROUBLESHOOTING
PC1100-6
20-219
3
TROUBLESHOOTING
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS

fl The terms male and female refer to the pins, while the terms male housing and female housing
refer to the mating portion of the housing.
No.
of
pins
X type connector
Male (female housing)
Female (male housing)
2
TEW00221
TEW00222
2
TEW00223
TEW00224
4
TEW00225
20-220
3
TEW00226
PC1100-6
TROUBLESHOOTING
No.
of
pins
SWP type connector

TEW00235
BLP00033
TEW00237
12
12
TEW00238
12
BLP00035
BLP00034
1 4
11
14 10
11
14
3
7 10 14
TEW00239
4
8
16
12
9
16
13
BLP00036
PC1100-6
TEW00240
12
13
16
BLP00037
20-221
3
TROUBLESHOOTING
No.
of
pins
M type connector

2
BLP00038
BLP00039
1
TEW00243
TEW00244
TEW00246
TEW00245
TEW00248
TEW00247
8
8
5
BLP00040
20-222
3
BLP00041
PC1100-6
TROUBLESHOOTING
No.
of
pins
S type connector
10
TEW00249
10
TEW00250
10
TEW00251
BLP00042
12
(White)
16
(White)
PC1100-6
20-223
3
TROUBLESHOOTING
No.
of
pins
S type connector
10
(Blue)
12
12
(Blue)
12
BLP00043
16
TEW00254
16
(Blue)
20-224
3
16 BLP00044
TEW00256
PC1100-6
TROUBLESHOOTING
No.
of
pins
MIC connector
BLP00045
BLP00046
BLP00048
BLP00047
13
13
13
BLP00049
BLP00050
10
17
17
10
17
BLP00052
BLP00051
12
11
21
12
21
21
TEW00259
PC1100-6
11
TEW00260
20-225
3
TROUBLESHOOTING
No.
of
pins
AMP040 type connector

4

8
5
BLP00053
12
BLP00054
12
12
BLP00055
BLP00056
16
16
16
9
BLP00057
10
TEW00232
20
20
10
11
20
20-226
3
11
BLP00058
TEW00234
PC1100-6
TROUBLESHOOTING
No.
of
pins
AMP070 type connector

1

7
6
1
14
BLP00059
14
6
9
18
BLP00060
12
PC1100-6
18
BLP00061
BLP00062
20-227
3
TROUBLESHOOTING
No.
of
pins
L type type connector

TEW00257
20-228
3
TEW00258
PC1100-6
TROUBLESHOOTING
No.
of
pins
Automobile connector
BLP00063
BLP00064
6
4
BLP00069
6
BLP00070
8
5
PC1100-6
BLP00071
8
BLP00072
20-229
3
TROUBLESHOOTING
No.
of
pins
Relay connector
BLP00073
BLP00074
4
5
BLP00075
20-230
BLP00076
PC1100-6
TROUBLESHOOTING
EXPLANATION OF CONTROL MECHANISM FOR ELECTRICAL SYSTEM
EXPLANATION OF CONTROL MECHANISM FOR ELECTRICAL

SYSTEM
1. Explanation of machine control functions
The control mechanism for the electrical system consists of the monitor panel and governor and
pump controller. The monitor panel and the governor and pump controller input the signals that
are necessary, and together with the signals selected by the monitor panel, the governor and
pump controller outputs or inputs the necessary signals and control the pump absorption torque
and engine output.
PC1100-6
20-231
3
TROUBLESHOOTING
DISPLAY METHOD AND SPECIAL FUNCTIONS OF MONITOR PANEL
DISPLAY METHOD AND SPECIAL FUNCTIONS OF MONITOR

PANEL
1. Troubleshooting function of lamps, gauges, buzzer
When the starting switch is turned on, all the lamps and gauges light up for approx. 3 seconds,
and the buzzer sounds for approx. 1 second. During this time, the monitor itself carries out self
diagnosis, and after it has finished, it gives the normal display (if any lamp does not light up
during the visual check, the lamp bulb is blown).
2. User code display function
All the abnormality data for the engine controller and pump controller are transmitted to the
monitor panel.
Of the abnormality data, items with a high emergency level are displayed as a user code automatically on the time display of the monitor panel to advise the operator of the action to take.
User code display
Example: When user code [E02] is displayed
Table of user codes

User code
User code
Abnormal system
E02
TVC system
E11
Engine control system
E03
Swing holding brake system
E12
Engine speed sensor system
E0E
Network system
E13
Governor cut relay system
E10
Engine emergency stop system
E14
Fuel control dial system
20-232
3
Abnormal system
PC1100-6
TROUBLESHOOTING
2. User code display function

All the abnormality data for the engine controller and pump controller are transmitted to the
monitor panel.
These abnormality data, regardless of whether they are necessary to display as a user code or not,
are all stored inside the monitor panel as service codes.
When the following operations are carried out, the service codes are displayed on the monitor
panel time display and the elapsed time data (time on the service meter) are displayed on the
service meter display panel.
Method of displaying and deleting service codes
1. To switch to the service code display mode, keep the Time switch + L.H. travel speed switch
pressed for at least 2.5 seconds.
Example 1: When the display shows that [E213] occurred 6 hours before
Example 2: When [E213] occurred 6 hours before and the display shows that the abnormality is still
continuing (the letter E appears at the head of the code)
PC1100-6
20-233
3
TROUBLESHOOTING
Method of displaying and deleting service codes

Example 3: When the service code is not recorded
2. To go on to the next service code display, press the Time switch + Working mode right switch.
3. To go back to the previous service code display, press the Time switch + Working mode left
switch.
4. To finish using the service code display mode, keep the Time switch + L.H. travel speed switch
5. To delete the service codes from memory, keep the Time switch pressed and turn the starting
switch OFF. Then turn the starting switch ON again and keep the Time switch pressed for at
least 5 seconds.
Table of service codes

Service code
User code
E101
Abnormality in error history data
E102
Abnormality in clock data
E103
Short circuit with power source, short circuit in buzzer output system
E104
Abnormality in air cleaner clogging sensor detected
E106
Abnormality in engine oil high-pressure sensor detected
E108
Engine water temperature over 105C detected
E113
Short circuit in wiper drive system
E114
Short circuit in window washer drive system
E117
S-NET communications error with engine controller
E0E
E118
S-NET communications error with pump controller
E0E
E201
Short circuit in CO cancel solenoid system
E202
Short circuit in straight-travel solenoid system
E203
Short circuit in swing holding brake solenoid relay system
E204
Short circuit in 2-stage relief solenoid system
E205
Short circuit in swing priority solenoid system
E206
Short circuit in travel speed solenoid system
E211
Disconnection in CO cancel solenoid system
20-234
3
Abnormal system
E03
PC1100-6
TROUBLESHOOTING
Service code
Abnormal system
User code
E212
Disconnection in straight-travel solenoid system
E213
Disconnection in swing holding brake solenoid relay system
E214
Disconnection in 2-stage relief solenoid system
E215
Disconnection in swing priority solenoid system
E216
Disconnection in travel speed solenoid system
E217
Error in pump controller model selection input
E218
S-NET response overtime error with pump controller
E227
Abnormality in No. 2 engine speed sensor system (pump controller)
E228
Abnormality in auto-deceleration output system
E232
Short circuit in TVC solenoid system
E02
E233
Disconnection in TVC solenoid system
E02
E313
Error in automatic greasing controller
E501
Abnormality in engine controller power source system
E10
E502
Abnormality in engine controller
E10
E503
Mistaken connection of engine controller connector
E504
Engine overrun abnormality
E505
Abnormality in fuel control dial system
E14
E507
Abnormality in engine controller S-NET
E508
Abnormality in rack sensor power source system
E11
E511
Abnormality in rack sensor signal system
E11
E513
Abnormality in No. 1 engine speed sensor system
E12
E514
E12
E515
Disconnection in prestroke solenoid system
E11
E516
Short circuit in prestroke solenoid system
E11
E521
Disconnection in governor solenoid system
E10
E522
Short circuit in governor solenoid system
E10
E525
Disconnection in governor cut relay system
E13
E526
Short circuit in governor cut relay system
E13
E531
Abnormality in governor servo
E10
E535
Abnormality in engine controller backup power source system
E536
Abnormality in engine controller switch power source system
E537
Abnormality in engine controller solenoid power source system
E03
E10 ()
E10
If service codes E513 and E514 occur at the same time, user code E10 is displayed.
PC1100-6
20-235
3
TROUBLESHOOTING
3. Monitoring code display function

The input signals from the sensors to each component and the output signals to drive the solenoid
can be checked in real time with the monitoring code.
When the following operations are carried out, the monitoring codes are displayed on the monitor
panel time display and the monitoring data are displayed on the service meter display panel.
Method of displaying monitoring codes
1. To set to the machine data monitoring mode, keep the Time switch + Heavy lift switch pressed
for at least 2.5 seconds.
Example 1: When a numeric display monitoring code (engine speed: 2050 rpm) is displayed
Example 2: When a bit pattern display monitoring code (S-NET component connection condition)
is displayed
20-236
3
PC1100-6
TROUBLESHOOTING
Method of displaying monitoring codes

2. To go on to the next monitoring code display, press the Time switch + Working mode right
switch.
3. To go back to the previous monitoring code display, press the Time switch + Working mode left
switch.
4. To finish using the monitoring code display mode, keep the Time switch + Heavy lift switch
Table of monitoring codes
fl For details of the (6 bit) in the Unit column, see the bit pattern chart.
Code No.
Item
Unit
Name of component
01
Monitor panel model code
Monitor panel
02
Pump controller model code
Pump controller
03
Engine controller model code
Engine controller
08
S-NET component connection condition
10
Engine speed
11
(Spare)
Pump controller
12
(Spare)
Pump controller
13
TVC output current
14
(Spare)
16
No. 2 throttle command
20
(6 bit)
10 rpm
Monitor panel
Pump controller
10 mA
Pump controller
Pump controller
10 rpm
Pump controller
Pump controller switch input condition (1)
(6 bit)
Pump controller
21
Pump controller switch input condition (2)
(6 bit)
Pump controller
22
Pump controller switch condition signal (3)
(6 bit)
Pump controller
23
Pump controller solenoid drive condition
(6 bit)
Pump controller
24
Pump controller chassis warning sensor input condition (1)
(6 bit)
Pump controller
25
Pump controller chassis warning sensor input condition (2)
(6 bit)
Pump controller
26
Pump controller input/output condition
(6 bit)
Pump controller
30
(Spare)
Pump controller
31
(Spare)
Pump controller
32
Battery voltage (VBB voltage)
33
(Spare)
Pump controller
34
(Spare)
Pump controller
35
(Spare)
Pump controller
36
Pump controller input condition
40
100 mV
Pump controller
(6 bit)
Pump controller
Engine speed
10 rpm
Pump controller
41
Coolant temperature sensor input voltage
10 mV
Pump controller
42
Fuel level sensor input voltage
10 mV
Pump controller
PC1100-6
20-237
3
TROUBLESHOOTING
Code No.
Item
Unit
Name of component
43
Alternator (charge) input voltage
100 mV
Pump controller
44
Hydraulic oil temperature sensor input voltage
10 mV
Pump controller
47
Monitor panel output condition (1)
(6 bit)
Monitor panel
48
Monitor panel input condition (1)
(6 bit)
Monitor panel
49
(6 bit)
Monitor panel
4A
(6 bit)
Monitor panel
4C
Monitor panel output condition (2)
(6 bit)
Monitor panel
50
Engine speed (No. 1 speed sensor)
10 rpm
Engine controller
51
Engine speed (No. 2 speed sensor)
10 rpm
Engine controller
52
Fuel control dial input voltage
10 mV
Engine controller
53
Rack sensor input voltage
10 mV
Engine controller
54
Governor solenoid output current
10 mA
Engine controller
55
Prestroke solenoid output current
10 mA
Engine controller
56
(Spare)
60
Engine controller input condition
(6 bit)
Engine controller
61
Engine controller output condition
(6 bit)
Engine controller
62
(Spare)
Engine controller
63
(Spare)
Engine controller
C0
Monitor panel program version
Monitor panel
C1
Pump controller program version
Pump controller
C2
Engine controller program version
Engine controller
20-238
3
Engine controller
PC1100-6
TROUBLESHOOTING
Bit pattern display (bit for applicable No. lights up)
Code
08
Content
Connection of S-NET components
Bit
Details (condition when lighted up)
Pump controller connected
Governor controller connected
Engine controller connected
Engine controller connected
5
6
20
Right swing PPC pressure switch ON
R.H. travel PPC pressure switch ON
Input condition of pump controller
Boom LOWER PPC pressure switch ON
PPC pressure switches
Boom RAISE PPC pressure switch ON
Arm IN PPC pressure switch ON
Arm OUT PPC pressure switch ON
Bucket CURL PPC pressure switch ON
Bucket DUMP PPC pressure switch ON
Swing lock switch ON
Service PPC pressure switch ON
L.H. travel PPC pressure switch ON
Swing prolix switch ON
Model selection 1 GND connected

21
PPC pressure switches and other

switches
22
Pump controller model selection
5
6
PC1100-6
20-239
3
TROUBLESHOOTING
Code
23
24
Content
Bit
CO cancel solenoid ON
Straight-travel solenoid ON
Drive condition of pump controller
Swing holding brake solenoid ON
solenoid
2-stage relief solenoid ON
Swing priority solenoid ON
Travel speed solenoid ON
Engine low-pressure hydraulic sensor OPEN (above specified pressure)
Engine high-pressure hydraulic sensor OPEN (above specified pressure)
Input condition (1) of pump con-
Coolant level sensor OPEN (below low level)
troller monitor alarm sensors
Engine oil level sensor OPEN (below low level)
Hydraulic oil level sensor OPEN (below low level)
Air cleaner clogging sensor OPEN (clogging detected)
1
2
25
Input condition (2) of pump con-
troller monitor alarm sensors
4
5
Overload sensor OPEN
Auto greasing controller abnormal
6
1
2
26
Input/output condition of pump
controller
4
5
Auto-deceleration signal output
Left swing PPC pressure switch ON
6
1
2
36
3
4
5
Starting switch ON
6
1
47
Alarm buzzer OFF
Output condition (1) of monitor
Wiper motor drive (R) OFF
panel
Wiper motor drive (L) OFF
Window washer drive ON
20-240
3
PC1100-6
TROUBLESHOOTING
Code
48
49
Content
Bit
Wiper switch [ON] OFF
Wiper switch [INT] OFF
Input condition (1) of monitor
Wiper switch [WASHER] OFF
panel
(Always ON)
(Always ON)
(Always ON)
Starting switch ON terminal OFF
Terminal BR voltage Hi
Lamp switch ON
panel
Preheating switch ON
Starting switch terminal C sometimes ON
4A
Time switch OFF
PPC oil pressure selection switch OFF
Overload selection switch OFF
panel
4
5
Swing lock switch OFF
Buzzer cancel switch OFF
1
2
4C
Wiper motor reverse relay output OFF or set voltage abnormal
panel
Washer motor drive output OFF or set voltage abnormal
5
6
60
Kerosene mode signal input
Auto-deceleration signal input
Input condition of engine control-
ler
APS actuation signal input
Starting switch terminal C ON
6
1
Governor cut relay output ON
2
61
Output condition of engine con-
troller
4
5
6
PC1100-6
20-241
3
TROUBLESHOOTING
4. Function for setting working mode default

The working mode on the monitor panel is set so that the H mode normally lights up when the
starting switch is turned ON.
If the function for setting the default is used as follows, it is possible to change the setting so that
the system starts with the working mode desired by the operator.
Method of setting default
1. To change to the default setting mode, keep the Time switch + Working mode right switch
fl When the system enters the default setting mode, the working mode LED flashes.
2. To change the default set mode, press the Working mode left switch or Working mode right
switch to light up the LED of the desired working mode.
3. To finish using the default setting mode, keep the the Time switch + Working mode right switch
20-242
3
PC1100-6
TROUBLESHOOTING
5. Displaying and setting oil maintenance function

On machines equipped with the oil maintenance function, the Change engine oil LED lights up
from a point 10 hours before the time set for the oil change and stays lighted up until the system
is reset. The elapsed time is displayed on the service meter and the telephone number is displayed
on the time display and service meter display. (It is displayed for 20 seconds after the starting
switch is turned ON.)
With the oil maintenance function, it is possible to set, change, or cancel the display, or set,
change, or cancel the telephone number.
Oil maintenance function display
Example: Oil change interval setting: 250 h, time elapsed since last oil change: 245 h, telephone
number: 0123456789 are displayed
fl Nothing is displayed until the elapsed time enters the period of 10 hours before the change
interval.
(If you want to see the elapsed time when there is no display, keep the buzzer stop switch
pressed and turn the starting switch ON. The elapsed time will be displayed for 10 seconds.)
fl The telephone number display is not shown if the telephone has not been set.
fl If the telephone number is set, when the starting switch is turned ON, the elapsed time is
displayed for 10 seconds at the top and the telephone number for 10 seconds at the bottom,
then the display returns to the normal display.
fl If the telephone number is not set, when the starting switch is turned ON, the elapsed time is
displayed for 20 seconds (top), then the display returns to the normal display.
PC1100-6
20-243
3
TROUBLESHOOTING
Setting interval and resetting elapsed time
1. Setting interval
1) Keep the Time switch + Swing priority mode switch pressed for at least 2.5 seconds.
2) Press the Buzzer stop switch and select the interval.
Example: Interval: When selecting 250 h
fl Interval display
h: Default mode (oil maintenance function not set)
125h: Interval is set for every 125 hours
dh: Demo mode is set
fl Set the interval according to the Operation and Maintenance Manual.
3) Keep the Time switch + Swing priority mode switch pressed for at least 2.5 seconds to
complete the setting of the interval.
3. Resetting elapsed time after changing oil
Press the Buzzer stop switch and keep it depressed for 3 seconds while the elapsed time and
telephone number are being displayed (for 20 seconds) on the monitor panel. The elapsed time
will be reset and the display will show Elapsed time: 0h for 1 second.
20-244
3
PC1100-6
TROUBLESHOOTING
Setting interval and resetting elapsed time
Demo mode
If the demo mode is used, a demonstration of the oil maintenance function can be carried out
when the machine is delivered.
The following functions can be carried out in the demo mode
1 Elapsed time display (note: this is for demonstration purpose only, so the elapsed time is
fixed at 240h)
2 Telephone number display (note: the telephone number must be set individually)
3 Resetting elapsed time
fl After setting to the demo mode, turn the starting switch ON again to start the demonstration.
Note: If the starting switch is turned ON four times, the demo mode is canceled and the
system automatically switches the default mode.
(If you want to continue the demonstration, it is necessary to set to the demo mode again.)
PC1100-6
20-245
3
TROUBLESHOOTING
Setting, changing telephone number
1. To change to the telephone number setting mode, keep the Time switch + Auto-deceleration
fl The 2 digits on the left will flash and the other 8 digits will light up.
2. To select the 2-digit block to be changed (the number can be set or changed when the 2-digit
block is flashing)
1) To move the flashing to the right, press the Time switch + Working mode right switch.
2) To move the flashing to the left, press the Time switch + Working mode left switch.
3. To set or change the number (to set or change the left or right digits in the flashing 2-digit block)
1) To set or change the number in the left digits, press the Time switch + Travel speed left
switch.
2) To set or change the number in the right digits, press the Time switch + Travel speed right
switch.
fl The available numbers are 0 9 and blank.
If the number is set as a blank, that digit will not light up when the telephone number is
displayed.
fl To stop the telephone number display, set all the numbers to 0.
4. To finish using the telephone number setting mode, keep the Time switch + Auto-deceleration
switch pressed for at least 2.5 seconds.
20-246
3
PC1100-6
TROUBLESHOOTING ORDER OF TROUBLESHOOTING WHEN CARRYING OUT TROUBLESHOOTING
ORDER OF TROUBLESHOOTING WHEN CARRYING OUT

TROUBLESHOOTING
If any abnormality occurs on the machine, use the flow chart below to judge which system has the
problem, go to the judgement table for the engine controller, APS controller, and engine system, and
the judgement table for the pump controller and hydraulic (mechanical) system, and then proceed to
the troubleshooting mode.
E02 is displayed
Go to troubleshooting for
C, F, H mode
E03 is displayed
N mode
E0E is displayed
YES
E10 is displayed
E11 is displayed
E, S mode
E12 is displayed
E13 is displayed
1
E14 is displayed
Is user code
displayed on
monitor panel?
YES
NO
E1fifi is displayed
M mode
E2fifi is displayed
C, F, H mode
E5fifi is displayed
E, S mode
Is service code
displayed on
monitor panel?
Turn starting
switch ON.
Set to service
code display
mode.
3
Is abnormality in
engine,
NO machine, or
monitor panel?
Judge from type
of problem that
has occurred.
20-248
3
Engine
E, S mode
Machine
C, F, H mode
Monitor panel
M mode
PC1100-6
TROUBLESHOOTING
N mode
fl After checking the service code, go directly to N mode.
E, S mode
fl Go to the judgement table for the engine controller, APS controller, and engine system in troubleshooting for E mode, check the type of problem, service code, and APS controller LED display to
determine the problem system, then go to troubleshooting for E mode or S mode as appropriate.
C, F, H mode
fl Go to the judgement table for the pump controller, and hydraulic (mechanical) system in troubleshooting for C mode, check the type of problem, service code, monitoring code display, and
solenoid valve input voltage to determine the problem system, then go to troubleshooting for C
mode, F mode, or H mode as appropriate.
M mode
fl After checking the service code, go directly to M mode.
PC1100-6
20-249
3
TROUBLESHOOTING
METHOD OF USING JUDGEMENT TABLE

1. Judgement table for engine controller and engine
This judgement table is a tool to determine if the problem with the machine is caused by an
abnormality in the electrical system or by an abnormality in the engine. The symptoms are then
used to decide which troubleshooting table (E-fifi, S-fifi) matches the symptoms.
<Method of using judgement table>
1) Locate the problem that has occurred in the failure mode column and go to the right across the
judgement table.
2) If there is a mark or mark, check the service code or APS controller LED display given at
the top of the column.
3) If the display is normal:
Go further to the right across the judgement table, and if all the
marks or marks are normal, go to the troubleshooting code at
the right side of the table.
If the display is not normal: Go to the troubleshooting code at the bottom of the judgement
table.
Failure mode
User code
E10
E11
E12
E13 E14
Service code 501 502 521 522 531 537 508 511 515 516 513 514 525 526 505 503 504 535 536 106 108
Starting performance is poor (starting always takes time)

Engine does not turn

Engine does
Engine turns but no exhaust smoke comes out

not start
Exhaust smoke comes out, but engine does not start
Engine does not pick up smoothly (follow-up is poor)

Engine stops during operations
Engine does not rotate smoothly (hunting)
Engine lacks output or lacks power
Exhaust gas is black (incomplete combustion)
50 51 52 53 54 55
fi
fi
S-2
fi
fi
S-3
S-4
fi fi
fi
fi fi fi fi
fi
fi
Oil consumption is excessive or exhaust gas is blue
S-5
S-6
S-7
S-8
Oil becomes contaminated quickly

Fuel consumption is excessive
S-1
E-20
fi fi fi
Troubleshooting code
Prestroke solenoid output voltage
Governor solenoid output voltage
Rack position sensor input voltage
No. 2 engine speed
Checking monitoring code
No. 1 engine speed
Abnormality detected in engine high-pressure oil pressure sensor
Abnormality in controller switch power source system
Engine overrun
Abnormality in controller backup power source system
Mistaken connection of connector
Abnormality fuel control dial system
Checking service code
Abnormality in controller solenoid power source system
The E mark is omitted from

the service code
Abnormality in controller
Abnormality in controller power source system

User code
Service code
Monitoring code
Checking preheating pilot lamp display and APS controller LED display
JUDGEMENT TABLE FOR ENGINE CONTROLLER, APS CONTROLLER, AND ENGINE RELATED PARTS
S-9
fi
S-10
Oil is in cooling water, or water spurts back, or water level goes down
S-11
Oil pressure caution lamp lights up
M-13
Oil level rises (water, fuel mixed with oil)
S-13
Water temperature becomes too high (overheating)
M-13
Abnormal noise is made
S-15
Vibration is excessive
Automatic warming-up function does not work or is not canceled
Engine does not stop
S-16
fi fi fi
E-1 E-2 E-3 E-4 E-5 E-6 E-7 E-8 E-9 E-10 E-11 E-12 E-13 E-14 E-15 E-16 E-17 E-18 E-19 S-12 S-14 E-22
M-18
E-21
: Check the service code display. If there is no display, go to the right; if there is a display, go to the
bottom.
: Check the preheating pilot lamp display and APS controller LED display. If the voltage is normal, go
to the right; if the voltage is abnormal, go to the bottom. (For details of the APS display, see the
next page.)
fi: Monitoring code to use as reference when proceeding with troubleshooting (if necessary, check the
display).
<Example of use>
1) Failure mode Starting performance is poor (starting always takes time) has occurred.
2) Check the display of the service codes [E511], [E515], [E516], and the APS controller LED.
3) If there is a display: Carry out troubleshooting for troubleshooting codes E-8, E-9, E-10, or E-22.
If there is no display: Carry out troubleshooting for troubleshooting code S-1.
20-250
3
PC1100-6
TROUBLESHOOTING
2. Judgement table for pump controller and hydraulic (mechanical) system

This judgement table is a tool to determine if the problem with the machine is caused by an
abnormality in the electrical system or by an abnormality in the hydraulic or mechanical system.
The symptoms are then used to decide which troubleshooting table (C-fifi, F-fifi, H-fifi) matches
the symptoms.
<Method of using judgement table>
1) Locate the problem that has occurred in the failure mode column and go to the right across
the judgement table.
2) If there is a mark, mark, or mark, check the solenoid valve input voltage, service code,
or monitoring code given at the top of the column.
3) If the display is normal:
Go further to the right across the judgement table, and if all the
marks, marks, or marks are normal, go to the troubleshooting code at the right side of the table.
If the display is not normal: Go to the troubleshooting code at the bottom of the judgement
table.
Travel speed solenoid
fi fi fi fi
fi fi fi fi
fi
Swing priority solenoid
2-stage relief solenoid
Swing holding brake solenoid
Straight-travel solenoid
CO cancel solenoid
TVC output current
Engine speed
20
21
26 21
22
23
26
02 10 13 12
1 2 3 4 5 6 1 2 5 5 3
34 1 2 3 4 5 6 3
Swing lock switch
Left swing
L.H. travel
Bucket DUMP (service)
Bucket CURL
Arm OUT
Arm IN
Boom RAISE
Boom LOWER
R.H. travel
Right swing
Boom shockless solenoid
Machine push-up solenoid
Model selection input error
Connector
V05
Connectors
V09, V10
Disconnection in swing holding brake solenoid system
Short circuit in swing holding brake solenoid system

LED E02 E03
OFF 232 233 203 213 201 211 202 212 204 214 205 215 206 216 217 227 228
Solenoid drive condition
fi
fi
H-5
H-6
H-7
H-8
H-9
H-10
H-11
H-12
H-13
Travel system
Swing system
H-1
H-2
H-3
H-4
fi
Work equipment
All work equipment,

swing, travel
User code
Service code
Speeds of all work equipment, swing, travel are slow or lack power
There is excessive drop in engine speed, or engine stalls
No work equipment, travel, swing move
Abnormal noise generated (around pump)
Auto-deceleration does not work
In normal mode
Boom is slow or lacks power
With heavy lift ON
With machine push-up ON
Arm is slow or lacks power
Bucket is slow or lacks power
Boom does not move
Arm does not move
Bucket does not move
Excessive hydraulic drift
Boom
Excessive time lag
Arm, bucket
Boom shockless function does not work or cannot be canceled
Deviates
in
same
direction
in FORWARD and REVERSE
Machine deviates naturally
to one side when traveling Deviates in opposite direction in FORWARD and REVERSE
Only
at
full
stroke
Deviation is excessive
when starting
Both during fine control operations and at full stroke
Deviation is excessive during compound operations
Travel speed is slow or lacks power
Both directions (FORWARD and REVERSE)
Does not travel (one side only)
One direction only (either FORWARD or REVERSE)
Travel speed does not switch
Both left and right
Does not swing
One direction only
Both left and right
Swing acceleration is poor or lacks power
One direction only
During compound operations with bucket, swing speed is slow or acceleration is poor
During compound operations with boom when swing priority is ON, swing speed is slow or acceleration is poor
Both left and right
Excessive overrun when stopping swing
One direction only
Both left and right
Excessive shock when stopping swing
One direction only
Both left and right
Excessive abnormal noise when stopping swing
One direction only
Excessive hydraulic drift of swing
Troubleshooting code of pump controller system
Troubleshooting code of pump controller input signal system
Monitoring code for reference during troubleshooting
PPC pressure switch
Connectors
V04, V11
Failure mode
The E mark is omitted

from the service code
Checking solenoid
inlet port voltage

User code
Service code
Monitoring code
Troubleshooting code for hydraulic, mechanical system
JUDGEMENT TABLE FOR PUMP CONTROLLER AND HYDRAULIC (MECHANICAL) RELATED PARTS
H-14
H-15
fi
fi
H-16
H-17
fi
H-18
fi
H-19
fi
H-20
H-21
H-22
H-23
fi
H-24
fi
H-25
H-26
C-1 C-2 C-3 C-4 C-5 C-6 C-7 C-8 C-9 C-10 C-11 C-12 C-13 C-14 C-15 C-16 C-17 C-18 C-19 C-20 C-21
F-1 F-2 F-3 F-4 F-5 F-6 F-7 F-8 F-9 F-10 F-11
is a display, go to the bottom.
: Check the service code display. If there is no display, go to the right; if there
: Measure the voltage at the solenoid inlet port. If the voltage is normal, go to the right; if the voltage is abnormal, go to the bottom.
: Check the monitoring code display. If the display is normal, go to the right; if the display is abnormal, go to the bottom.
fi: Monitoring code to use as reference when proceeding with troubleshooting (if necessary, check the display).
fi
H-27
<Example of use>
1) Failure mode Speeds of all work equipment, swing, travel are slow or lack power has
occurred.
2) Check the display of the service codes [E232], [E233], [E217], and [E227].
3) If there is a display: Carry out troubleshooting for troubleshooting codes C-2, C-3, C-16, or C-17.
If there is no display: Carry out troubleshooting for troubleshooting code H-1.
PC1100-6
20-251
3
TROUBLESHOOTING
METHOD OF USING TROUBLESHOOTING CHARTS

1. Category of troubleshooting code number
Troubleshooting Code No.
Component
N-fifi
Troubleshooting of network system
E-fifi
Troubleshooting of engine controller & APS controller system
S-fifi
Troubleshooting of engine
C-fifi
Troubleshooting of pump controller
F-fifi
Troubleshooting of pump controller input signal system
H-fifi
Troubleshooting of hydraulic, mechanical system
M-fifi
Troubleshooting of monitor panel system
2. Method of using troubleshooting table for each troubleshooting mode

1) Troubleshooting code number and problem (See Example 1)
The title of the troubleshooting chart gives the troubleshooting code, service code, and failure
mode (problem with the machine).
2) Distinguishing conditions (See Example 2)
Even with the same failure mode (problem), the method of troubleshooting may differ according to the model, component, or problem. In such cases, the failure mode (problem) is further
divided into sections marked with small letters (for example, a)), so go to the appropriate
section to carry out troubleshooting.
If the troubleshooting table is not divided into sections, start troubleshooting from the first
check item in the failure mode.
3) Method of following troubleshooting chart (See Example 3)
Check or measure the item inside
, and according to the answer follow either the YES
line or the NO line to go to the next
. (Note: The number written at the top right corner
of the
is an index number; it does not indicate the order to follow.)
Following the YES or NO lines according to the results of the check or measurement will
lead finally to the Cause column. Check the cause and take the action given in the Remedy
column on the right.
Below the
there are the methods for inspection or measurement, and the judgement
values. If the judgement values below the
are correct or the answer to the question
inside the
is YES, follow the YES line; if the judgement value is not correct, or the
answer to the question is NO, follow the NO line.
Below the
is given the preparatory work needed for inspection and measurement, and
the judgement values. If this preparatory work is neglected, or the method of operation or
handling is mistaken, there is danger that it may cause mistaken judgement, or the equipment may be damaged. Therefore, before starting inspection or measurement, always read
the instructions carefully, and start the work in order from Item 1).
4) General precautions (See Example 4)
When carrying out troubleshooting for the failure mode (problem), precautions that apply to all
items are given at the top of the page and marked with fl.
The precautions marked fl are not given in the
, but must always be followed when
carrying out the check inside the
.
5) Troubleshooting tools
When carrying out the troubleshooting, prepare the necessary troubleshooting tools. For details, see TOOLS FOR TESTING, ADJUSTING, AND TROUBLESHOOTING.
6) Installation position, pin number
A diagram or chart is given for the connector type, installation position, and connector pin
number connection. When carrying out troubleshooting, see this chart for details of the connector pin number and location for inspection and measurement of the wiring connector
number appearing in the troubleshooting flow chart for each failure mode (problem).
20-252
3
PC1100-6
TROUBLESHOOTING
<Example>
1 M-11 When starting switch is turned on and engine is started, basic check items flash
4 fl Before carrying out troubleshooting, check that all the related connectors are properly
inserted.
fl Always connect any disconnected connectors before going on the next step.
fl Check both the alternator system and the engine oil pressure system.
2 a) Alternator system
3
Cause
3 YES
Is voltage
YES between C03

1
Is voltage between
alternator terminal
R and chassis
ground normal?
(12) and chassis

ground normal?
Does monitoring
YES code [43] show a
value of more
2
than 100?
NO
Run engine at
mid-range speed
or above.
Run engine at
mid-range speed NO
or above.
20 30 V
Run engine at
mid-range speed
NO
or above.
20 30 V
Remedy
Defective pump
controller
Replace
Defective monitor panel
Replace
Defective contact,
disconnection, or short
circuit with ground in
wiring harness between
C03 (female) (12) and
alternator terminal R
Repair or
replace
Defective alternator
Replace
M-11 Related electric circuit diagram
PC1100-6
20-253
3
TROUBLESHOOTING OF
COMMUNICATION ABNORMALITY SYSTEM
(N MODE)
Action taken by controller when abnormality occurs and problems on machine ..........................20-302
Electrical circuit diagram of N Mode system ......................................................................................20-304
N-1
[E117, 118 occur at same time] Monitor panel communication abnormality ....................20-305
N-2
[E117, 218 occur at same time] Engine controller communication abnormality ............... 20-307
N-3
[E118, 507 occur at same time] Pump controller communication abnormality .................20-309
PC1100-6
20-301
3
ACTION TAKEN BY CONTROLLER WHEN ABNORMALITY

OCCURS AND PROBLEMS ON MACHINE
TROUBLESHOOTING

User
code
Service
code
Abnormal system
S-NET communication
error with engine
controller
When problem occurs at same time as E118

1. Disconnection, defective contact of monitor panel SNET
2. Wiring harness of monitor panel S-NET short circuiting
with chassis ground
3. Defective monitor panel
1. Disconnection, defective contact in wiring harness of
engine controller S-NET
2. Wiring harness of engine controller S-NET short
circuiting with chassis ground
3. Defective engine controller
E118
S-NET communication
error with pump
controller
When problem occurs at same time as E117: Same as

E117 above
1. Disconnection, defective contact in wiring harness of
pump controller S-NET
2. Wiring harness of pump controller S-NET short
circuiting with chassis ground
3. Defective pump controller
E218
Pump controller S-NET

response overtime error
E507
Abnormality in engine
controller S-NET system
E117
E0E
20-302
3
Nature of abnormality

E117 above

E118 above
PC1100-6
TROUBLESHOOTING
Condition when normal

(voltage, current, resistance)
PC1100-6

Action by controller when Problem that appears on machine

abnormality is detected
when there is abnormality
1. Working mode becomes G
Mode.
2. Displays user code E0E on
monitor panel.
1. Operation is carried out in G Mode.

2. Lacks power or speed is slow.

Mode.
2. Displays user code E0E on
monitor panel.


Mode.


Mode.

20-303
3
TROUBLESHOOTING
ELECTRICAL CIRCUIT DIAGRAM OF N MODE SYSTEM
ELECTRICAL CIRCUIT DIAGRAM OF N MODE SYSTEM
20-304
3
PC1100-6
TROUBLESHOOTING
N-1
N-1 [E117, E118 occur at same time] Monitor panel communication

abnormality
fl This troubleshooting is carried out when there is still an abnormality, so when disconnecting the
connector and inserting the T-adapter, or when removing the T-adapter and returning the connector to its original position, if the service code E is not displayed, the problem has been removed.
fl If the starting switch was turned off after the abnormality occurred, turn the starting switch on and
check that the service code displays E. (If it is not displayed, the problem has been removed.)
fl Before carrying out troubleshooting, check that all the related connectors are properly inserted.
Cause
YES
Has been reset
4 YES
1
YES
3
Is monitoring
code [02], [03]
display normal?
YES
Disconnect P01
and connect
again.
Turn starting
switch ON.
See Table 1.
2
Do bits (1), (2), (3),
and (4) light up in
NO monitoring code
[08]?
Turn starting
switch ON.
See Table 2.
Remedy
NO
When E16 and C17

are disconnected, do
bits (1), (2), (3), and
(4) light up in
monitoring code [08]?
Turn starting
switch ON.
See Table 2.
Is resistance between
P01 (female) (4) (11)
and (12), or between
(4) (11) and chassis
normal?
NO
Disconnect P01,
C17, and E16.
Turn starting switch OFF.
Min. 1 M.
NO
5
Is voltage between E16
(female) (6)(12) and
chassis, and between
C17 (female) (4) (12)
and chassis normal?
YES
6 YES
P01(4) and C17 (female)
(4), and between P01
(female) (11) and E16
(female) (12) normal?
Disconnect E16
and C17.
NO
Turn starting
switch ON.
Disconnect P01, NO
Min. 7.5 V
E16 and C17.
Turn starting
switch OFF.
Max. 1.
Replace
Short circuit in wiring

harness at side where
resistance is not normal,
or short circuit with
ground connection
Repair or
replace
Defective pump
controller, engine
controller
Replace
Defective controller at
side where bit does not
light up in Item 2
Replace
Replace
Defective contact or
disconnection in wiring
resistance is not normal
Repair or
replace
Table 1
Monitoring code
02
03
Display
fl If the controllers are not connected to the network, is displayed. If the correct alphanumerics
are not displayed or another model is displayed, the model selection signal of the controllers is
abnormal.
PC1100-6
20-305
3
TROUBLESHOOTING
N-1
Table 2
Monitoring code
08
Display
Network connection condition
Bits light up when network is connected (12: Pump controller, 34: Engine controller)
fl Checks for disconnection in the network system can be carried out with this monitoring code.
The display does not change when there is a short circuit with the ground. (The normal display is
given.)
N-1 Related electrical circuit diagram
20-306
3
PC1100-6
TROUBLESHOOTING
N-2
N-2 [E117, E218 occur at same time] Engine controller communication

abnormality
fl This troubleshooting is carried out when there is still an abnormality, so when disconnecting
the connector and inserting the T-adapter, or when removing the T-adapter and returning the
connector to its original position, if the service code E is no displayed, the problem has been
removed.
Cause
YES
Has been reset
4 YES
1
YES
3
Is monitoring
code [03] display
normal?
When E16 is
YES disconnected, do bits

Disconnect E16
and M94 and
connect again.
Turn starting
switch ON.
See Table 1.
2
Do bits (3) and (4)
light up in
NO monitoring code
[08]?
Turn starting
switch ON.
See Table 2.
E16 (female) (6) (12)
and (10), or between
(6) (12) and chassis
normal?
NO
Disconnect P01,
C17, and E16.
Min. 1 M.
(3) and (4) light up in

Turn starting
switch ON.
See Table 2.
Remedy
NO
YES
Is voltage between
E16 (female) (6)(12)
and chassis
NO
normal?
Disconnect E16.
Turn starting
NO
switch ON.
Min. 7.5 V
Replace

resistance is not normal,
or short circuit with
ground connection
Repair or
replace
Defective engine
controller
Replace
Defective engine
controller
Replace
6 YES Defective monitor panel

E16 (female) (6) C17
(female) (12), E16
(female) (12) P01
Disconnect P01, NO
E16, and C17.
Turn starting
switch OFF.
Max. 1
and pump controller
Replace
Repair or
replace
Table 1
Monitoring code
03
Display
abnormal.
PC1100-6
20-307
3
TROUBLESHOOTING
N-2
Table 2
Monitoring code
08
Display
Bits light up when network is connected (34: Engine controller)

given.)
20-308
3
PC1100-6
TROUBLESHOOTING
N-3
N-3 [E118, E507 occur at same time] Pump controller communication

abnormality
fl This troubleshooting is carried out when there is still an abnormality, so when disconnecting
the connector and inserting the T-adapter, or when removing the T-adapter and returning the
connector to its original position, if the service code E is not displayed, the problem has been
removed.
Cause
YES
Has been reset
4 YES
1
Is monitoring
code [02] display
normal?
When C17 is
Is resistance
YES between C17
(female) (4) (12) and
3
chassis normal?
YES disconnected, do bits

Disconnect C17
and connect
again.
Turn starting
switch ON.
See Table 1.
NO
Disconnect P01,
C17, and E16.
Min. 1 M.
(1) and (2) light up in

2
Do bits (1) and (2)
light up in
NO monitoring code
[08]?
Turn starting
switch ON.
See Table 2.
Remedy
Turn starting
switch ON.
See Table 2.
NO
YES
Is voltage between
C17 (female) (4)(12)
NO and chassis
normal?
Disconnect C17.
Turn starting
NO
switch ON.
Min. 7.5 V
Replace

Repair or
replace
Defective pump
controller
Replace
Defective pump
controller
Replace
6 YES Defective monitor panel

C17 (female) (4) P01
(female) (4), C17
(female) (12) E16
Disconnect P01, NO
E16, and C17.
Turn starting
switch OFF.
Max. 1
and pump controller
Replace
Repair or
replace
Table 1
Monitoring code
02
Display
abnormal.
PC1100-6
20-309
3
TROUBLESHOOTING
N-3
Table 2
Monitoring code
08
Display
Bits light up when network is connected (12: Pump controller)

given.)
20-310
3
PC1100-6
TROUBLESHOOTING OF ENGINE CONTROLLER

& APS CONTROLLER SYSTEM
(E MODE)
Judgement table for engine controller, APS controller, and engine related parts .........................20-352
Points to remember when carrying out troubleshooting of engine controller system ..................20-355
Electrical circuit diagram of E mode system .......................................................................................20-364
E- 1
[E501] Abnormality in engine controller power supply system is displayed .............. 20-368
E- 2
[E502] Abnormality in engine controller is displayed .....................................................20-369
E- 3
[E521] Disconnection in governor control solenoid system is displayed ..................... 20-370
E- 4
[E522] Short circuit in governor control solenoid system is displayed ........................20-371
E- 5
[E531] Abnormality in governor servo is displayed ........................................................20-372
E- 6
[E537] Abnormality in controller solenoid power supply system is displayed ...........20-373
E- 7
[E508] Abnormality in rack sensor power supply system is displayed ........................20-374
E- 8
[E511] Abnormality in rack sensor signal system is displayed .....................................20-375
E- 9
[E515] Disconnection in prestroke control solenoid system is displayed ....................20-376
E-10
[E516] Short circuit in prestroke solenoid control system is displayed .......................20-377
E-11
[E513] Abnormality in engine speed sensor (1) system is displayed ........................... 20-378
E-12
[E514] Abnormality in engine speed sensor (2) system is displayed ........................... 20-379
E-13
[E525] Disconnection in governor cut relay system is displayed .................................. 20-380
E-14
[E526] Short circuit in governor cut relay system is displayed .....................................20-381
E-15
[E505] Abnormality in fuel control dial voltage is displayed .........................................20-382
E-16
[E503] Mistaken connection of connector is displayed ...................................................20-383
E-17
[E504] Engine overrun is displayed ...................................................................................20-384
E-18
[E535] Abnormality in engine controller backup power supply system is displayed.... 20-385
E-19
[E536] Abnormality in controller power supply system is displayed .............................20-386
E-20
Engine does not start ..........................................................................................................20-388
E-21
Engine does not stop ..........................................................................................................20-391
E-22
Defective actuation of APS .................................................................................................20-392
PC1100-6
20-351
3
JUDGEMENT TABLE FOR ENGINE CONTROLLER, APS

CONTROLLER, APS CONTROLLER, AND ENGINE RELATED PARTS
TROUBLESHOOTING
JUDGEMENT TABLE FOR ENGINE CONTROLLER, APS CONTROLLER, AND ENGINE RELATED PARTS
Failure mode
Abnormality in controller solenoid power source system
The E mark is omitted from

the service code
Abnormality in controller
User code
Service code
Monitoring code
User code
E10
E11
Service code 501 502 521 522 531 537 508 511 515 516
Starting performance is poor (starting always takes time)

Engine does
not start
Engine does not turn

Engine turns but no exhaust smoke comes out
Exhaust smoke comes out, but engine does not start
Engine does not pick up smoothly (follow-up is poor)

Engine stops during operations
Engine does not rotate smoothly (hunting)
Engine lacks output or lacks power
Exhaust gas is black (incomplete combustion)
Oil consumption is excessive or exhaust gas is blue

Oil becomes contaminated quickly
Fuel consumption is excessive
Oil is in cooling water, or water spurts back, or water level goes down
Oil level rises (water, fuel mixed with oil)
Water temperature becomes too high (overheating)
Abnormal noise is made
Vibration is excessive
Automatic warming-up function does not work or is not canceled
Engine does not stop
E-1 E-2 E-3 E-4 E-5 E-6 E-7 E-8 E-9 E-10
: Check the service code display. If there is no display, go to the right; if there is a display, go to the
bottom.
: Check the preheating pilot lamp display and APS controller LED display. If the voltage is normal, go
to the right; if the voltage is abnormal, go to the bottom. (For details of the APS display, see the
next page.)
fi: Monitoring code to use as reference when proceeding with troubleshooting (if necessary, check the
display).
20-352
3
PC1100-6
E12
PC1100-6
E13
E14
513 514 525 526 505 503 504 535 536 106 108
E-11 E-12 E-13 E-14 E-15 E-16 E-17 E-18 E-19 S-12 S-14 E-22
fi
fi fi fi
fi
fi
fi
fi fi
fi
fi fi fi fi
fi
fi
fi
fi fi fi
Prestroke solenoid output voltage
Governor solenoid output voltage
Rack position sensor input voltage
No. 2 engine speed
No. 1 engine speed
Checking preheating pilot lamp display and APS controller LED display
Abnormality detected in engine high-pressure oil pressure sensor
Abnormality in controller switch power source system
Abnormality in controller backup power source system
Engine overrun
Mistaken connection of connector
Abnormality fuel control dial system
TROUBLESHOOTING
50 51 52 53 54 55
E-20
S-1
S-2
S-3
S-4
S-5
S-6
S-7
S-8
S-10
S-9
M-13
S-11
M-13
S-13
S-15
S-16
M-18
E-21
20-353

TROUBLESHOOTING
PREHEATING PILOT LAMP DISPLAY AND APS CONTROLLER LED DISPLAY

Preheating pilot lamp display
fl When the starting switch is turned ON, the preheating pilot lamp display changes as follows
according to whether the condition is normal or abnormal.
When normal
Starting switch
ON
APS switch ON
Water
temperature
below 20C
OFF
Water
temperature
above 20C
OFF
When
abnormal
OFF
Preheating
completed
ON
(for 12 sec)
Engine starts
Water temperature APS switch

switch OFF
OFF
OFF
Flashes
(1 time/sec)
OFF
Flashes (1 time/sec)
OFF
ON
The APS water temperature sensor is switched ON when the water temperature is below 20C and
is switched OFF when the water temperature goes above 20C.
APS controller LED display

fl The APS controller carries out self-diagnosis of disconnections and short circuits with the ground
in glow plug 1 system, glow plug 2 system, and the nozzle system. It gives the following LED
displays according to whether the system is normal or abnormal.
fl If any short circuit or disconnection occurs in the power source system, all the LEDs go out.
fl There is no self-diagnosis for the APS water temperature sensor system (because it is an ON/OFF
switch).
LED No.
LED color
Type of abnormality
Red
Short circuit with ground in glow plug 1 system
Green
Red
Green
Red
Green
20-354
3
Disconnection in glow plug 1 system

Short circuit with ground in glow plug 2 system
Disconnection in glow plug 2 system
Short circuit with ground in nozzle system
Disconnection in nozzle system
When
normal
When
abnormal
fi (OFF)
(ON)
fi (OFF)
(ON)
fi (OFF)
(ON)
(ON)
fi (OFF)
(ON)
fi (OFF)
(ON)
fi (OFF)
PC1100-6
TROUBLESHOOTING
POINTS TO REMEMBER WHEN CARRYING OUT

TROUBLESHOOTING OF GOVERNOR, PUMP CONTROLLER SYSTEM
POINTS TO REMEMBER WHEN CARRYING OUT TROUBLESHOOTING OF ENGINE CONTROLLER SYSTEM

1. Points to remember if abnormality returns to normal by itself:
If the connector is disconnected and the T-adapter is inserted, or if the T-adapter is removed and
the connector is returned to its original position when carrying out troubleshooting of the failure,
and the service code is no longer displayed, or if the monitor display returns to normal, the
abnormality has probably returned to normal.
However, there is a high probability that the same problem will occur again, so it is desirable to
follow up this problem carefully.
2. Handling service code memory retention function:
1) When displaying the abnormality code in memory and carrying out troubleshooting, note
down the content of the display, then erase the display. After trying to re-enact the problem,
carry out troubleshooting according to the failure code that is displayed.
(There are cases where mistaken operation or abnormalities that occur when the connector is
disconnected are recorded by the memory retention function. Erasing the data in this way
saves any wasted work.)
2) After completing troubleshooting, always erase the service code from memory again.
PC1100-6
20-355
3

TROUBLESHOOTING

User
code
Service
code
Abnormal system
controller power supply
system
1. E535 and E536 occur at same time
E501
controller
E502
E521
Disconnection in governor control solenoid

system
1. Disconnection, defective contact inside governor control

solenoid
2. Disconnection, defective contact in wiring harness between
controller E13 (7) and governor control solenoid E19 (1)
(No. 1 (+) side)
3. Disconnection, defective contact in wiring harness between
controller E13 (4) and governor control solenoid E32 (1)
(No. 2 (+) side)
4. Disconnection, defective contact, short circuit with ground
in wiring harness between controller E13 (17) and governor control solenoid E19 (2) (No. 1 () side)
in wiring harness between controller E13 (15) and governor control solenoid E32 (2) (No. 2 () side)
Short circuit in governor

control solenoid system
1. Short circuit, short circuit with ground inside governor

control solenoid
2. Short circuit with ground, short circuit with power source
in wiring harness between controller E13 (7) and governor control solenoid E19 (1) (No. 1 (+) side)
in wiring harness between controller E13 (4) and governor control solenoid E32 (1) (No. 2 (+) side)
4. Short circuit with power source in wiring harness between controller E13 (17) and governor control solenoid
E19 (2) (No. 1 () side)
5. Short circuit with power source in wiring harness between controller E13 (15) and governor control solenoid
E32 (2) (No. 2 () side)
E10
E522
E531
20-356
3
Abnormality in governor
servo
1. Defective governor control solenoid system or rack sensor system

(Governor command value and rack sensor signal do not
match)
2. Abnormality in solenoid power source system
PC1100-6
TROUBLESHOOTING

Same as E535 and E536
Solenoid resistance value: 10 21
PC1100-6


1. Stops engine.
2. Displays user code E10 on
monitor panel.
1. Stops engine during operation.

2. Cannot start engine.
1. Stops engine.
monitor panel.

1. Sets output to governor

control solenoid to 0 (stops
engine)
monitor panel.
fl If the abnormality is restored by the vibration of
the machine, it resets automatically. (However, the
service code display does
not go out.)

1. Sets output to governor

control solenoid to 0 (stops
engine)
monitor panel.
not go out.)

1. Stops engine.
monitor panel.
not go out.)

20-357
3

TROUBLESHOOTING
User
code
E10
Service
code
E537
E508
E511
Abnormal system
Abnormality in controller solenoid power

supply system
Abnormality in rack
sensor signal system
1. Disconnection, defective contact inside governor cut relay
2. Disconnection, defective contact in wiring harness between starting switch terminal ACC and governor cut relay R24 (3)
in wiring harness between controller E13 (1) and rack
sensor R24 (6)
1. Defect inside rack sensor
sensor E22 (1)
3. Disconnection, defective contact in wiring harness between rack sensor E22 (2) and chassis ground
1. Defect inside rack sensor

sensor E22 (3) ((+) side)
sensor E22 (4) (() side)
E11
E515
E516
20-358
3
Disconnection in
prestroke control solenoid system
1. Disconnection, defective contact inside prestroke control

solenoid
2. Disconnection, defective contact in wiring harness between controller E13 (9) and prestroke control solenoid
E20 (1) ((+) side)
in wiring harness between controller E13 (19) and
prestroke control solenoid E20 (2) (() side)
Disconnection in
prestroke control solenoid system
1. Disconnection, defective contact inside prestroke control

solenoid
in wiring harness between controller E13 (9) and prestroke
control solenoid E20 (1) ((+) side)
3. Short circuit with power source in wiring harness between controller E13 (19) and prestroke control solenoid
E20 (2) (() side)
PC1100-6
TROUBLESHOOTING



Voltage between E12 (1) and

chassis: 20 30 V
1. Stops engine.
monitor panel.
not go out.)
1. Feels that there is lack of power.

2. Engine does not pick up smoothly.
3. Starting performance is poor.
Voltage between E13 (1) and

chassis: 4.6 5.4 V
1. Operates with open control with output restricted

to 80%.
monitor panel.
not go out.)

Voltage between
chassis: 0.1 4.5
Voltage between
chassis: 0.1 4.5
1. Operates with open control with output restricted

to 80%.
monitor panel.
not go out.)
1. Sets output to prestroke
control solenoid to 0.
2. Operates with output restricted to 80%.
monitor panel.
not go out.)

3. Large amount of black smoke is
included in exhaust.
1. Sets output to prestroke

control solenoid to 0.
2. Operates with output restricted to 80%.
monitor panel.
not go out.)

3. Large amount of black smoke is
included in exhaust.
E14 (7) and

V
E14 (17) and
V
PC1100-6
20-359
3

TROUBLESHOOTING
User
code
Service
code
E513
Abnormal system
speed sensor (1) system
1. Defect inside No. 1 engine speed sensor or defective

adjustment
in wiring harness between controller E14 (2) and No. 1
engine speed sensor E21 (1)
3. Defective contact, disconnection in wiring harness between No. 1 engine speed sensor E21 (2) and chassis
ground
speed sensor (2) system
1. Defect inside No. 2 engine speed sensor or defective

adjustment
in wiring harness between controller E14 (3) and No. 2
engine speed sensor E07 (1)
3. Defective contact, disconnection in wiring harness between No. 2 engine speed sensor E07 (2) and chassis
ground
E12
E514
E525
1. Disconnection, defective contact inside governor cut relay

in wiring harness between starting switch terminal ACC
and governor cut relay R24 (1)
in wiring harness between controller E12 (4) and governor cut relay R24 (2)
E13
1. Short circuit inside governor cut relay
2. Short circuit with power source in wiring harness between controller E12 (4) and governor cut relay R24 (2)
E526
E14
20-360
3
E505
Short circuit in governor

cut relay system
Abnormality in fuel
control dial system
1. Disconnection, defective contact, short circuit in wiring

harness inside fuel control dial
in wiring harness between controller E14 (6) and fuel
control dial E06 (1) ((+) side)
3. Disconnection, defective contact in wiring harness between controller E14 (16) and fuel control dial E06 (3)
(() side)
in wiring harness between controller E15 (11) and fuel
control dial E06 (2) (signal side)
PC1100-6
TROUBLESHOOTING



3. Engine stops during operation and
cannot be started again.
Sensor resistance value:

500 1000
1. Operates with normal control.

monitor panel.
not go out.)

3. Engine stops during operation and
cannot be started again.
Sensor resistance value:

500 1000

monitor panel.
not go out.)
Relay resistance value: 200 900

monitor panel.
not go out.)
Relay resistance value: 200 900

monitor panel.
not go out.)
Voltage (power source) between E14

(6) and (16): 4.6 5.4 V
Voltage (signal) between E15 (11)
and E14 (16): 0.7 4.3 V
PC1100-6
1. Operates at throttle position before abnormality occurred.

monitor panel.
not go out.)
1. Engine speed does not rise to high

idling.
2. Lacks acceleration.
20-361
3

TROUBLESHOOTING
User
code
Service
code
E503
Abnormal system
Mistaken connection of
connector
in wiring harness between controller E17 (1) and chassis
ground
1. Engine speed has gone above operating range.
20-362
3
E504
E535
E536
Engine overrun
controller backup power
supply system
Abnormality in controller power supply system
1. Backup power source voltage has dropped below 17V.

in wiring harness between fuse box No. 14 and controller
E12 (7)
3. Disconnection, defective contact in wiring harness between controller E12 (8)(16) and chassis ground
1. Switch power source voltage has dropped below 17V.
in wiring harness between starting switch terminal ACC
and controller E12 (9)(17)
3. Disconnection, defective contact in wiring harness between controller E12 (8)(16) and chassis ground
PC1100-6
TROUBLESHOOTING

Resistance between E17 (1) and

chassis: Max. 1


1. Stops engine.
not go out.)
1. Stops fuel injection immediately when overrun occurs (when speed drops to
1500 rpm, operates with
normal control).
not go out.)
Voltage between E12 (7) and (8)(16):

20 30 V

not go out.)
Voltage between E12 (9)(17) and

(8)(16): 20 30 V

not go out.)
PC1100-6
1. Engine speed does not follow fuel

control dial position.
20-363
3
TROUBLESHOOTING
ELECTRICAL CIRCUIT DIAGRAM OF E MODE SYSTEM

ENGINE CONTROLLER SYSTEM
20-364
3
PC1100-6
TROUBLESHOOTING
PC1100-6
20-365
3
TROUBLESHOOTING
APS CONTROLLER & ENGINE STARTING SYSTEM
20-366
3
PC1100-6
TROUBLESHOOTING
PC1100-6
20-367
3
TROUBLESHOOTING
E-1
E-1 [E501] Abnormality in engine controller power source system is

displayed
connector and inserting the T-adapter, or when removing the T-adapter and returning the connector to its original position, if the service code E is not displayed, the problem has been
removed.
Cause
2 YES
Is voltage
between E12 (7)
and chassis
ground normal?
Turn starting
switch OFF.
20 30 V
Is voltage between
YES E12 (9)(17) and
1
chassis ground
normal?
Turn starting
switch ON.
20 30 V
NO
NO
Defective engine
controller
Remedy
Replace
Go to E-19
Go to E-18
E-1 Related electrical circuit diagram
20-368
3
PC1100-6
TROUBLESHOOTING
E-2
E-2 [E502] Abnormality in engine controller is displayed

removed.
Cause
1 YES
Is voltage between
E12 (9)(17) and
chassis ground
normal?
Turn starting
switch ON.
20 30 V
NO
Defective engine
controller
Go to E-19
Remedy
Replace
PC1100-6
20-369
3
TROUBLESHOOTING
E-3
E-3 [E521] Disconnection in governor control solenoid system is displayed

removed.
Cause
YES
3
Is resistance
YES between E13

(female) (4) and
(15) normal?
2
Is resistance
YES between E13
(female) (7) and
(17) normal?
1
Is resistance
between E19, E32
(male) (1) and (2)
normal?
Turn starting
switch OFF.
Disconnect E19
and E32.
10 21
Turn starting
switch OFF.
Disconnect E13.
10 21
Is voltage
between E32 (1)
Turn starting
switch OFF.
NO and chassis
ground normal?
Disconnect E13.
10 21
Turn starting
switch ON.
20 30 V
5 YES
Is voltage
between E19 (1)
NO and chassis
ground normal?
Turn starting
switch ON.
20 30 V
NO
NO
Defective engine
controller
Remedy
Replace
Disconnection, defective
contact, short circuit
4 YES with ground in wiring harness
between E13 (female) (15) and
E32 (female) (2)
Repair or
replace
harness between E13 (female)
NO (4) and E32 (female) (1)
Repair or
replace
contact, short circuit
with ground in wiring harness
E19 (female) (2)
Repair or
replace
harness between E13 (female)
(7) and E19 (female) (1)
Repair or
replace
Defective governor
control solenoid
Replace
20-370
3
PC1100-6
TROUBLESHOOTING
E-4
E-4 [E522] Short circuit in governor control solenoid system is displayed

removed.
Cause
YES
3
Remedy
Defective engine
controller
Replace
Short circuit with power

source in wiring harness
between E13 (female)
Repair or
replace
YES E13 (female) (4)
(15), (4)(15) chassis

ground as shown in
Table 1?
2
E13 (female) (7)
(17), (7)(17) chassis
ground as shown in
Table 1?
YES
1
Is resistance
between E19, E32
(male) (1) (2),(1)(2)
chassis ground as
shown in Table 1?
Turn starting
switch OFF.
NO
Disconnect E13.
When E32 is disconnected,

is resistance and voltage
between E13 (female) (4)
and chassis ground as
shown in Table 2?
Disconnect E13
and E32.
Turn starting
switch OFF.
Turn starting
switch OFF.
Disconnect E13.
5 YES
NO

shown in Table 2?
Disconnect E13
and E19.
Turn starting
switch OFF.
Turn starting
switch OFF.
Disconnect E19
and E32.
4 YES
NO
NO
Table 1
E19 (male)
Between
(1) and (2)
Between
(1)(2) and chassis
Table 2
E13 (female)
Between
(7) and chassis
Short circuit with ground,

short circuit with power
NO between E13 (female) (4)
and E32 (female) (1)
Repair or
replace
Short circuit with ground,

short circuit with power
Repair or
replace
Defective governor
control solenoid
Replace
E32 (male)
E13 (female)
E13 (female)
Between
Between
Between
(1) and (2)
(7) and (17)
(4) and (15)
Between
Between
Between
(1)(2) and chassis (7)(17) and chassis (4)(15) and chassis
E13 (female)
Between
(4) and chassis
Repair or
replace
Resistance
Voltage
Min. 1 M
Max. 1 V
Resistance
10 21
Min. 1 M
PC1100-6
20-371
3
TROUBLESHOOTING
E-5
E-5 [E531] Abnormality in governor servo is displayed

Cause
2 YES
YES
1
Is voltage between
E13 (female) (1)
and chassis
ground normal?
Turn starting
switch ON.
20 30 V
When fuel injection

pump is repaired or
replaced, does
display go off?
Turn starting
switch ON.
NO
NO
Remedy
Defective fuel injection

pump
Replace
Defective engine
controller
Replace
Go to E-6
20-372
3
PC1100-6
TROUBLESHOOTING
E-6
E-6 [E537] Abnormality in controller solenoid power supply system is

displayed
removed.
fl Check that the engine can be cranked (if the engine cannot be cranked, carry out troubleshooting
E-20 first).
Cause
3 YES
Is voltage
YES between R24 (3)
and chassis
1
ground normal?
Is resistance
between R24
(female) (3) (5), (3)
(6) as shown in
Table ?
Turn starting
switch OFF.
Disconnect R24.
Table
R24 (male)
Between
(3) and (5)
Between
(3) and (6)
Turn starting
switch ON.
20 30 V.
Is voltage
YES between E13 (1)
2
and chassis
ground normal?
Turn starting
switch ON.
20 30 V.
NO
NO
NO
Remedy
Defective engine
controller
Replace
Defective contact,
disconnection, short circuit
R24 (female) (6)
Repair or
replace
harness between R24 (female)
(3) and X07 (female) (11)
Repair or
replace
Defective governor
control solenoid
Replace
Resistance
Min. 1 M
Max. 1
PC1100-6
20-373
3
TROUBLESHOOTING
E-7
E-7 [E508] Abnormality in rack sensor power source system is

displayed
removed.
Cause
YES
2
YES E13 (female) (16) and

chassis ground
normal?
1
Is resistance
between E22
(male) (1) and (2)
normal ?
Turn starting
switch OFF.
Disconnect E22.
Min. 500 k.
Is voltage
between E22 (1)
Turn starting
switch OFF.
NO and chassis
ground normal?
Disconnect E13.
Min. 500 k.
Turn starting
switch ON.
4.6 5.4 V.
NO
3 YES
NO
Remedy
Defective engine
controller
Replace
harness between E22
(female) (2) and chassis
ground
Repair or
replace
Defective contact,
E22 (female) (1)
Repair or
replace
Defective rack sensor
Replace
20-374
3
PC1100-6
TROUBLESHOOTING
E-8
E-8 [E511] Abnormality in rack sensor signal system is displayed

removed.
fl If service code [E508] is displayed at the same time, carry out troubleshooting E-7 first.
Cause
3 YES
Is voltage
YES between E14 (7)

1
Is resistance
between E22
(male) (3) (2),
(4) (2) normal ?
Turn starting
switch OFF.
Disconnect E22.
50 k 1 M
and chassis
ground normal?
Turn starting
switch ON.
0.1 4.5 V.
Is voltage
YES between E14 (17)
and chassis
2
ground normal?
Turn starting
switch ON.
0.1 4.5 V.
NO
NO
NO
Remedy
Defective engine
controller
Replace
Defective contact,
E14 (female) (17)
Repair or
replace
Defective contact,
E14 (female) (7)
Defective rack senosr
Repair or
replace
Replace
PC1100-6
20-375
3
TROUBLESHOOTING
E-9
E-9 [E515] Disconnection in prestroke control solenoid system is

displayed
removed.
Cause
YES
2
Is resistance
YES between E13

1
Is resistance
between E20
(male) (1) and (2)
normal ?
Turn starting
switch OFF.
Disconnect E20.
10 21 .
(female) (9) and

(19) normal ?
Is voltage
between E20 (1)
Turn starting
switch OFF.
NO and chassis
ground normal?
Disconnect E13.
10 21 .
Turn starting
switch ON.
20 30 V.
NO
3 YES
NO
Remedy
Defective engine
controller
Replace
harness between E13
(female) (19) and E20 (2)
Repair or
replace
Defective contact,
E20 (female) (1)
Repair or
replace
Defective prestroke
control solenoid
Replace
E-9 Related electric circuital diagram
20-376
3
PC1100-6
TROUBLESHOOTING
E-10
E-10 [E516] Short circuit in prestroke control solenoid system is

displayed
removed.
Cause
YES
2
Remedy
Defective engine
controller
Replace

Repair or
replace
YES E13 (female) (9) -

1
Is resistance
between E20(male)
(1) (2), (1)(2)
chassis ground as
shown in Table 1?
Turn starting
switch OFF.
Disconnect E20.
(19), (9)(19) chassis

ground as shown in
Table 1?
Turn starting
switch OFF.
NO
Disconnect E13.
3 YES
shown in Table 2?
Disconnect E13
and E20.
Turn starting
switch ON.
NO
Defective prestroke
control solenoid
NO
Table 1
E20 (male)
E13 (female)
Between
Between
(1) and (2)
(9) and (19)
Between
Between
(1)(2) and chassis (9)(19) and chassis
Table 2
E13 (female)
Between
(9) and chassis
Short circuit with

ground, short circuit with
power source in wiring
harness between E13
(female) (1)
Repair or
replace
Replace
Resistance
10 21
Min. 1 M
Resistance
Voltage
Min. 1 M
Max. 1 V
PC1100-6
20-377
3
TROUBLESHOOTING
E-11
E-11 [E513] Abnormality in engine speed sensor (1) system is

displayed
removed.
Cause
YES
2
Remedy
Defective engine
controller
Replace
Defective adjustment of
speed sensor
Adjust
Is voltage
YES between E14 (3)
YES
and chassis
ground normal?
Start engine.
0.5 3.0 V.
Is resistance
between E07
(male) (1) and (2)
normal ?
NO
When speed sensor

is adjusted, does
voltage in Item 2
become normal?
Defective contact,
4 YES with ground in wiring harness
NO
Turn starting
switch OFF.
Disconnect E07.
500 1,000 k.
E07 (female) (2) and
chassis ground
normal?
Turn starting
switch OFF.
Disconnect E07.
Max. 1 .
NO

E21 (female) (1)
NO harness between E07
ground
Defective engine speed
sensor (1)
Repair or
replace
Repair or
replace
Replace
20-378
3
PC1100-6
TROUBLESHOOTING
E-12
E-12 [E514] Abnormality in engine speed sensor (2) system is

displayed
removed.
Cause
YES
2
Remedy
Defective engine
controller
Replace
speed sensor
Adjust
Defective contact,
E07 (female) (1)
Repair or
replace
Is voltage
YES between E14 (3)
YES
and chassis
ground normal?
Start engine.
0.5 3.0 V.
Is resistance
between E07
(male) (1) and (2)
normal ?
NO
When speed sensor

is adjusted, does
voltage in Item 2
become normal?
4 YES
NO
Turn starting
switch OFF.
Disconnect E07.
500 1,000 k.
NO
E07 (female) (2) and
chassis ground
normal?
NO harness between E07
Turn starting
switch OFF.
Disconnect E07.
ground
Max. 1 .
sensor (2)
Repair or
replace
Replace
PC1100-6
20-379
3
TROUBLESHOOTING
E-13
E-13 [E525] Disconnection in governor cut relay system is displayed

removed.
fl If service code [E501] is displayed at the same time, carry out troubleshooting E-1 first.
Cause
YES
2
Is voltage
YES between E12 (4)

1
Is resistance
between R24
(male) (1) and (2)
normal ?
Turn starting
switch OFF.
Disconnect R24.
200 900 .
and chassis
ground normal?
Turn starting
switch ON.
20 30 V.
3 YES
Is voltage
between R24 (1)
NO and chassis
ground normal?
Turn starting
switch ON.
20 30 V.
NO
NO
Remedy
Defective engine
controller
Replace
harness between E12
(female) (4) and R24
(female) (2)
Repair or
replace
Defective contact,
between X07 (female) (11)
and R24 (female) (1)
Repair or
replace
Defective rgovernor cut

replay
Replace
20-380
3
PC1100-6
TROUBLESHOOTING
E-14
E-14 [E526] Short circuit in governor cut relay system is displayed

removed.
Cause
2 YES
YES
1
Is resistance
between
R24(male) (1) and
(2) normal?
Turn starting
switch OFF.
Disconnect R24.
200 900 .
When R24 is
disconnected, is voltage
(4) and chassis ground
normal?
Disconnect E12
and R24.
Turn starting
switch ON.
Max. 1 V
NO
NO
Remedy
Defective engine
controller
Replace

Repair or
replace
Defective governor cut

replay
Replace
PC1100-6
20-381
3
TROUBLESHOOTING
E-15
E-15 [E505] Abnormality in fuel control dial voltage is displayed

removed.
fl Before carrying out troubleshooting, check that all the related
connectors are properly inserted.
Cause
Remedy
fl Always connect any disconnected connectors before going
on the next step.
YES
2
Is voltage
YES between E15 (11)
YES
and chassis
ground normal?
Turn starting
switch ON.
0.7 4.3 V
3
Is voltage
between E06 (2)
NO and chassis
ground normal?
Turn starting
switch ON.
0.7 4.3 V
1
Is voltage
between E14 (6)
and (16) normal?
Is resistance
YES between E06
(male) (1) and (3)
normal?
5
Turn starting
switch ON.
4.6 5.4 V
YES
7
Is voltage
between E14 (6)
NO and chassis
ground normal?
harness between E15
(female) (2)
Repair or
replace
Defective fuel control dial
Replace
Repair or
replace
harness between E14
(female) (3)
Repair or
replace
Defective fuel control dial
Replace
harness between E14
(female) (1)
Repair or
replace
NO
Turn starting
switch OFF.
Disconnect E06.
4 6 k
Turn starting
switch ON.
4.6 5.4 V
Replace
Short circuit with ground

in wiring harness
Turn starting switch NO
OFF.
6 YES
Is voltage
between E06 (1)
NO and chassis
ground normal?
NO
Disconnect E15 and E16.

Min. 1 M
Turn starting
switch ON.
4.6 5.4 V
20-382
4 YES
When E06 is
disconnected, is
resistance between E15
(female) (11) and
chassis ground normal?
Defective engine
controller
8 YES Defective engine
NO
When E06 is
disconnected, is
resistance between E14
ground normal?
Turn starting
switch OFF.
Disconnect E15
and E06.
Min. 1 M
controller
in wiring harness E14
NO (female) (6) and E06
(female) (1)
Replace
Repair or
replace
PC1100-6
TROUBLESHOOTING
E-16
E-16 [E503] Mistaken connection of connector is displayed

Cause
1 YES
Is resistance
between E17 (1)
and chassis
ground normal ?
Turn starting
switch OFF.
Disconnect E17.
Max. 1 .
NO
Remedy
Defective engine
controller
Replace
harness between E17
ground
Repair or
replace
PC1100-6
20-383
3
TROUBLESHOOTING
E-17
E-17 [504] Engine overrun is displayed
Cause
4 YES Other abnormality has

YES Is other service
code displayed at
3
same time?
YES Is adjustment of
engine speed
sensor normal?
2
Is resistance
YES between E07

1
Is resistance
between E21
(male) (1) and
(2) normal?
Turn starting
switch OFF.
Disconnect E21.
500 1000
(male) (1) and (2)

normal?
Turn starting
switch OFF.
Disconnect E07.
500 1000
See TESTING
AND
ADJUSTING.
NO
NO
Turn starting
switch ON.
NO
occurred at same time
Defective fuel injection
NO pump
Remedy
Act according
to displayed
service codes
Replace
speed sensor
Adjust
Defective No. 2 engine

speed sensor
Replace
Defective No. 1 engine

speed sensor
Replace
20-384
3
PC1100-6
TROUBLESHOOTING
E-18
E-18 [E535] Abnormality in engine controller backup power supply

system is displayed
removed.
E-20 first).
fl Check that fuse 14 is not blown (if it is blown, check for a short circuit with the ground in the
related circuits for fuse 14).
Cause
2 YES
Is voltage
between E12 (7)
and chassis
ground normal?
Turn starting
switch OFF.
20 30 V.
Is resistance
YES between E12 (8)
1
(16) and chassis
ground normal ?
Turn starting
switch OFF.
Disconnect E12.
Max. 1 .
NO
NO
Remedy
Defective engine
controller
Replace
harness between E12
chassis ground
Repair or
replace
Defective contact,
disconnection, short
fuse 14 and E12
(female) (7)
Repair or
replace
PC1100-6
20-385
3
TROUBLESHOOTING
E-19
E-19 [E536] Abnormality in controller power supply system is

displayed
removed.
Cause
2 YES
YES
1
Is voltage
between E12 (9)
(17) and chassis
ground normal?
Turn starting
switch ON.
20 30 V.
Is resistance
between E12
chassis ground
normal ?
Turn starting
NO
switch OFF.
Disconnect E12.
Max. 1 .
3 YES
NO
Is voltage between
starting switch
terminal ACC and
chassis ground
normal?
Turn starting
switch ON.
20 30 V.
NO
Remedy
Defective engine
controller
Replace
harness between E12
(female) (8) (16) and
chassis ground
Repair or
replace
Defective contact,
with ground in wiring
harness between starting
switch terminal ACC and
E12 (female) (9) (17)
Repair or
replace
Defective starting switch
Replace
20-386
3
PC1100-6
TROUBLESHOOTING
E-20
E-20 Engine does not start

fl Check that fuse 14 is not blown (if it is blown, check for a short circuit with the ground in the
related circuits for fuse 14).
fl Check that the wiring harness between battery relay terminal B battery (+) battery () chassis
is connected securely.
4 YES
YES
Is voltage between
starting motor
terminal B and
chassis ground
normal?
NO
Turn starting
switch ON.
20 30 V
YES
Is there sound of
YES starting motor
pinion engaging?
Is voltage between
YES starting motor
terminal R and
chassis ground
normal?
Starting switch
ON START
Turn starting
switch ON.
Max. 1 V
NO
2
Is voltage between
starting motor
terminal S and
chassis ground
normal?
NO
Disconnect wiring.
Turn starting switch ON.
Max. 1 V
Turn starting
switch to START.
20 30 V
YES Is sound heard

from battery
relay?
7 YES
Is voltage between
alternator terminal
NO R and chassis
ground normal?
8 YES
NO
Starting switch
OFF ON
Is resistance
between starting
switch terminal B
and terminal C
normal?
NO
Turn starting
switch to START.
Disconnect X07. Max. 1
10 YES
YES
Is voltage and
specific gravity of
battery normal?
NO
Turn starting
switch OFF.
Voltage: Min. 24V
Specific gravity:
Min. 1.26
Is resistance
between batery
relay terminal E and
chassis ground
normal?
Turn starting
switch OFF.
Max. 1
Is voltage between
batery relay
terminal BR and
chassis ground
normal?
NO
YES
11
Turn starting
switch ON.
20 30 V
NO
Is voltage between
starting switch
terminal BR and
chassis ground
normal?
Turn starting
switch ON.
20 30 V
12 YES
NO
Is resistance
between starting
switch terminal B
and terminal BR
normal?
NO
Turn starting
switch to START.
Disconnect X07.
Max. 1
NO
20-388
3
PC1100-6
TROUBLESHOOTING
E-20
Cause
PC1100-6
Remedy
Defective starting motor
Replace
motor terminal B and
battery relay terminal M
Repair or
replace
Defective starting motor
Replace

between starting motor
terminal R and D14
(female) (2), or short circuit
of diode D14
Repair or
replace
Replace
switch terminal C and
starting motor terminal S
Repair or
replace
Replace
Defective battery relay
Replace
harness between battery
relay terminal E and
chassis ground
Repair or
replace
switch terminal BR and
battery relay terminal BR
Repair or
replace
switch terminal B and
battery relay terminal B
Repair or
replace
Replace
Insufficient battery
capacity
Charge or
replace
20-389
3
TROUBLESHOOTING
E-20
20-390
3
PC1100-6
TROUBLESHOOTING
E-21
E-21 Engine does not stop

Cause
YES
1
Is voltage
between E12 (9)
(17) and chassis
ground normal?
Turn starting
switch OFF.
Max. 1 V.
2 YES
NO
Is resistance
between starting
switch terminal B
and terminal ACC
normal?
Turn starting
switch OFF.
Disconnect X07.
Min. 1 M
NO
Remedy
Defective engine
controller
Replace

(17) and starting switch
terminal ACC
Repair or
replace
Replace
PC1100-6
20-391
3
TROUBLESHOOTING
E-22
E-22 Defective actuation of APS

a) Preheating lamp switch does not light up when APS switch is ON (controller LED is also OFF)
fl Carry out troubleshooting of the power source system.
E-20 first).
fl Check that fuse 2 is not blown (if it is blown, check for a short circuit with the ground in the related
circuits for fuse 2).
fl Carry out troubleshooting with the APS switch ON.
2 YES
YES
1
Is voltage
between E25 (1)
and chassis
ground normal?
Is resistance
between E26
(female) (1) and
chassis ground
normal ?
NO
Turn starting
switch OFF.
Disconnect E26.
Max. 1 .
YES
YES
Turn starting
switch ON.
20 30 V.
6
Is voltage
NO
YES between R23 (3)
When relay (R23) is

interchanged, does
voltage in Item 1
become normal ?
5
Is there continuity
YES between R23
Turn starting
switch ON.
20 30 V.
(female) (2) and

chassis ground?
4
Is voltage
between R23 (1)
NO and chassis
ground normal?
Turn starting
switch ON.
20 30 V.
Turn starting
switch OFF.
NO
NO
9 YES
Is there continuity
YES between M91

8
(male) (2) and (3)?
NO
Is voltage between
M91 (female) (3)
and chassis ground
normal ?
Turn starting
switch ON.
20 30 V.
7 YES
Is there continuity
between starting
NO switch B and
terminal ACC?
Turn starting
switch OFF.
Disconnect R23.
Turn starting
switch ON.
20 30 V.
20-392
and chassis
ground normal?
Turn starting
NO
switch OFF.
Disconnect M91.
Turn APS switch ON.
NO
PC1100-6
TROUBLESHOOTING
E-22
Cause
PC1100-6
Remedy
Defective APS
controller
Replace
harness between E26
ground
Repair or
replace
Defective APS
controller relay
Replace
Defective contact,
between R23 (female) (5) and
E25 (female) (1)
Repair or
replace
Defective contact,
with ground in wiring
switch terminal ACC and
R23 (female) (5)
Repair or
replace
Replace
harness between R23
ground
Repair or
replace
harness between M91
(female) (2) and R23
(female) (1)
Repair or
replace
Defective APS switch
Replace
harness between fuse 2
and M91 (female) (3)
Repair or
replace
20-393
3
TROUBLESHOOTING
E-22
b) Preheating pilot lamp flashes when water temperature is below 20C when APS switch is ON
(controller LEDs all give normal display)
Preheating pilot lamp lights up when water temperature is above 20C when APS switch is ON
(controller LEDs all give normal display)
fl Carry out troubleshooting with the APS switch ON.
fl Check the engine water temperature.
Cause
2 YES
YES
1
Is resistance
between P19
(male) and chassis
ground normal ?
Is resistance
between E26
(female) (2) and
chassis ground
normal ?
Turn starting
switch OFF.
Disconnect E26.
Same as Item 1.
NO
Turn starting
switch OFF.
NO
Disconnect P19.
Water
temperature
below 20C:
Max. 1
Water
temperature
above 20C:
Min. 1 M
Remedy
Defective APS controller
Replace
Defective contact,
E26 (female) (2) and P19
(female)
Repair or
replace
Defective APS water

temperature sensor
Replace
c) Nozzle does not inject fuel when starting switch is turned to START after completion of
preheating when APS switch is ON (controller LEDs all give normal display)
fl Carry out troubleshooting of start signal (terminal C) system.
fl Check that the injection nozzle stop valve is open.
Cause
YES
1
Is voltage
between E26 (3)
and chassis
ground normal?
Turn starting
switch to
START.
20 30 V
20-394
3
2 YES
NO
Is voltage between
starting switch
terminal C and
chassis ground
normal?
Turn starting
switch ON.
20 30 V
NO
Remedy
Replace
harness between E26
(female) (3) and starting
switch terminal C
Repair or
replace
Replace
PC1100-6
TROUBLESHOOTING
E-22
d) Controller LED 1 (short circuit in glow plug 1 system) gives abnormal display
Cause
2 YES
YES
1
Is resistance
between glow plug
1 terminal and
chassis ground
normal?
Turn starting
switch OFF.
Disconnect plug
terminal.
0.8 1.3
Is resistance
between E25
(female) (2) and
chassis ground
normal?
Turn starting
switch OFF.
Disconnect E25.
0.8 1.3
NO
NO
Remedy
Replace

in wiring harness
and glow plug 1 terminal
Repair or
replace
Defective glow plug 1
Replace
e) Controller LED 2 (disconnection in glow plug 1 system) gives abnormal display
Cause
2 YES
YES
1
Is resistance
between glow plug
1 terminal and
chassis ground
normal?
Turn starting
switch OFF.
Disconnect plug
terminal.
0.8 1.3
PC1100-6
Is resistance
between E25
(female) (2) and
chassis ground
normal?
Turn starting
switch OFF.
Disconnect E25.
0.8 1.3
NO
NO
Remedy
Replace

in wiring harness
Repair or
replace
Replace
20-395
3
TROUBLESHOOTING
f)
E-22
Controller LED 3 (short circuit in glow plug 2 system) gives abnormal display
Cause
2 YES
YES
1
Is resistance
between glow plug
2 terminal and
chassis ground
normal?
Turn starting
switch OFF.
Disconnect plug
2.
0.8 1.3
Is resistance
between E25
(female) (3) and
chassis ground
normal?
Turn starting
switch OFF.
Disconnect E25.
0.8 1.3
NO
Remedy
Replace

in wiring harness
Repair or
replace
Replace
NO
g) Controller LED 4 (disconnection in glow plug 2 system) gives abnormal display
Cause
2 YES
YES
1
Is resistance
between glow plug
2 terminal and
chassis ground
normal?
Turn starting
switch OFF.
Disconnect plug
terminal.
0.8 1.3
20-396
3
Is resistance
between E25
(female) (3) and
chassis ground
normal?
Turn starting
switch OFF.
Disconnect E25.
0.8 1.3
NO
NO
Remedy
Replace

in wiring harness
Repair or
replace
Replace
PC1100-6
TROUBLESHOOTING
E-22
k) Preheating pilot lamp lights up when APS switch is OFF

fl Carry out troubleshooting with the APS switch OFF.
Cause
YES
1
When relay R23 is
interchanged with
another relay, does
condition become
normal?
Turn starting
switch ON.
YES
2
Is voltage
between R23 (1)
NO and chassis
ground normal?
Turn starting
switch ON.
Max. 1 V
3 YES
Is resistance
between M91
NO (male) (2) and (3)
normal?
Turn starting
switch OFF.
Disconnect M91.
Max. 1 M
PC1100-6
NO
Remedy

relay
Replace

Repair or
replace

between R23 (female) (1)
and M91 (female) (2)
Repair or
replace
Defective APS switch
Replace
20-397
3
TROUBLESHOOTING
E-22
20-398
3
PC1100-6
TROUBLESHOOTING OF ENGINE SYSTEM

(S MODE)
Method of using troubleshooting charts .............................................................................................20-402

S- 1
Starting performance is poor (starting always takes time) ..................................................20-406
S- 2
Engine does not start ................................................................................................................20-407

a) Engine turns but no exhaust smoke comes out (fuel is not being injected) ............... 20-407
b) Exhaust smoke comes out, but engine does not start (fuel is being injected) ...........20-408
S- 3
Engine does not pick up smoothly (follow-up is poor) .........................................................20-409
S- 4
Engine stops during operations ...............................................................................................20-410
S- 5
Engine does not rotate smoothly (hunting)............................................................................20-411
S- 6
Engine lacks output (no power) ...............................................................................................20-412
S- 7
Exhaust smoke is black (incomplete combustion) .................................................................20-413
S- 8
Oil consumption is excessive (or exhaust smoke is blue) ....................................................20-414
S- 9
Oil becomes contaminated quickly ..........................................................................................20-415
S-10
Fuel consumption is excessive ................................................................................................20-416
S-11
Oil is in cooling water, or water spurts back, or water level goes down ........................... 20-417
S-12
Oil pressure caution lamp lights up (drop in oil pressure) ..................................................20-418
S-13
Oil level rises ..............................................................................................................................20-419
S-14
Water temperature becomes too high (overheating) ............................................................20-420
S-15
Abnormal noise is made ...........................................................................................................20-421
S-16
Vibration is excessive ................................................................................................................20-422
PC1100-6
20-401
3
TROUBLESHOOTING

This troubleshooting chart is divided into three sections: questions, check items, and troubleshooting.
The questions and check items are used to pinpoint
high probability causes that can be located from the
failure symptoms or simple inspeciton without using troubleshooting tools.
Next, troubleshooting tools or direct inspection are
used to check the high probability causes to make
final confirmation.
[Questions]
Sections A + B in the chart on the right corresponds to the items where answers can be obtained from the user. The items in B are items
that can be obtained from the user, depending
on the users level.
[Check items]
The serviceman carries out simple inspection to
narrow down the causes. The items under C in
the chart on the right correspond to this.
The serviceman narrows down the causes from
information A that he has obtained from the
user and the results of C that he has obtained
from his own inspection.
[Troubleshooting]
Troubleshooting is carried out in the order of
probability, starting with the causes that have
been marked as having the highest probability
from information gained from [Questions] and
[Check items].
Causes
Questions
(1) (2) (3)
(a)
(b)
(c)
(d)
(e)
Check items
Troubleshooting
20-402
3
ii
iii
PC1100-6
TROUBLESHOOTING
The basic method of using the troubleshooting chart

is as follows.
Items listed for [Questions] and [Check items] that
have a relationship with the Cause items are marked
with o, and of these, causes that have a particularly
high probability are marked with T.
Check each of the [Questions] and [Check items] in
turn, and mark the o or T in the chart for items
where the problem appeared. The vertical column
(Causes) that has the highest number of points is
the most probable cause, so start troubleshooting
for that item to make final confirmation of the cause.
1. For [Confirm recent repair history] in the
[Questions] Section, ask the user, and mark
the Cause column with
to use as reference for locating the cause of the failure.
However, do not use this when making calculations to narrow down the causes.
in the Cause column as reference
2. Use the
for [Degree of use (Operated for long period)] in the [Questions] section. As a rule,
do not use it when calculating the points for
locating the cause, but it can be included if
necessary to determine the order for troubleshooting.
Causes
ed t
urbo
cha
Clog
rger
ged
, int
air c
erfe
lean
Wor
renc
er e
n pi
e
lem
ston
ent
ring
Clog
, cyl
ged
inde
, sei
r
zed
Imp
inje
rope
c
tion
r inj
noz
ecti
Defe
zle
on t
ctiv
imin
e in
g
ject
ion
pum
p (e
xces
sive
Seiz
inje
ctio
n)
PC1100-6
Confirm recent repair history
Degree of use
Operatred for long period
20-403
3
TROUBLESHOOTING
Example of troubleshooting when exhaust gas is black

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

General causes why exhaust gas is black
Insufficient intake of air
Improper condition of fuel injection
Excessive injection of fuel
Causes
Legend
: Possible causes (judging from Questions and check items)
: Most probable causes (judging from Questions and Check items)
: Possible causes due to length of use (used for a long period)
: Items to confirm the cause.
Seiz
ed t
Clog urboch
arge
ged
r, in
air
W or
terfe
n pis cleaner
elem rence
ton
Clog
r
ent
in
g, c
ged
y
, se
lind
Imp
er
rope ized inje
r inje
ctio
D efe
n
ctio
ctiv
n tim nozzle
e in
ing
Imp
rope jection
p
r
u
v
mp
alve
Cru
(exc
she
clea
d, c
essiv
ran
logg
Lea
e in
kag
ed m ce
ject
e of
ion)
uffle
Defe
air b
r
ctiv
e
t
w
e co
een
Deff
n
turb
tact
ectiv
o
of v
cha
e in
rger
alve
ject
, va
and
ion
lve
hea
pum
seat
d
p (ra
ck, p
lung
er s
eize
d)

Degree of use
Operated for long period
Questions
Suddenly became black

Color of exhaust gas
Gradually became black

Blue under light load
Engine oil must be added more frequently

Power was lost
Suddenly
Gradually
Non-specified fuel has been used

Noise of interference is heard from around turbocharger
Dust indicator is red
Blow-by gas is excessive
Check items
Engine pickup is poor and combustion is irregular

When exhaust manifold is touched immediately after
starting engine, temperature of some cylinders is low
Match marks on fuel injection pump are out of alignment
Seal on injection pump has come off
Clanging sound is heard from around cylinder head
Exhaust noise is abnormal
Muffler is crushed
Leakage of air between turbocharger and head, loose clamp
When turbocharger is rotated by hand, it is found to be heavy
When air cleaner is inspected directly, it is found to be clogged
Troubleshooting
When compression pressure is measured, it is found to be low

Speed of some cylinders does not change when operating
on reduced cylinders
When check is made using delivery method, injection timing
is found to be incorrect
Injection pump test shows that injection amount is incorrect
When valve clearance is checked directly it is found to be
outside standard value
When muffler is removed, exhaust gas color returns to normal
20-404
3
Replace
Repair
Replace
Adjust
Replace
Adjust
Adjust
Replace
Replace
Clean
Remedy
Replace
When control rack is pushed, it is found to be heavy or does

not return
PC1100-6
TROUBLESHOOTING
Five causes
Step 1
Clarify the relationship between the three
symptoms in the [Questions] and [Check items]
section and the five Cause items in the vertical
column.
Three symptoms
Step 2
Add up the total of and marks where the
horizontal lines for the three symptoms and the
vertical columns for the causes intersect.
(1) Clogged air cleaner element:
(2) Air leakage between turbocharger
and head:
(3) Clogged, seized injection nozzle:
(4) Defective contact of valve, valve seat:
(5) Worn piston ring, cylinder:
Step 3
The calculation in Step 2 show that the closest
relationship is with [Clogged air cleaner
element]. Follow this column down to the
troubleshooting area and carry out the
troubleshooting item marked . The Remedy is
given as [Clean], so carry out cleaning, and the
exhaust gas color should return to normal.
PC1100-6
20-405
3
TROUBLESHOOTING
S-1
S-1 Starting performance is poor (starting always takes time)

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

Degree of use of machine
Gradually became worse
Ease of starting
Starts when warm
Takes time to start again after warming up
Preheating pilot lamp does not light up
Replacement of filters has not been carried out according to Operation Manual
Dust indicator lamp is red
Non-specified fuel is being used
Battery charge lamp is ON
Starting motor cranks engine slowly
Engine does not pick up smoothly, and combustion is irregular
Counter marks on fuel injection pump are out of alignment
Mud is stuck to fuel tank cap
When engine is cranked with starting motor,
1) Little fuel comes out even when fuel injection pump sleeve nut is loosened
2) No fuel comes out even when fuel filter air bleed plug is loosened
Leakage from fuel piping
There is hunting from engine (rotation is irregular)
20-406
3
Clean
Clean
Replace
Replace
Adjust
Replace
Clean
Correct
Replace
Adjust
Replace
Replace
Replace
Replace
Replace
Remedy
Clean

When air cleaner element is inspected directly, it is found to be clogged
When fuel filter, strainer are inspected directly, they are found to be clogged
When priming pump strainer is inspected directly, it is found to be clogged
Glow plug mount does not become warm
Yes
Is voltage 26 30V between alternator terminal
No
B and terminal E with engine at low idling?
Either specific gravity of electrolyte or voltage of battery is low
Speed does not change when operation of certain cylinders is stopped
When check is made using delivery method, injection timing is found to be incorrect
When control rack is pushed, it does not return
(when rack stopper bolt at rear of pump is removed and rack
piston is pushed with clean screwdriver, rack does not move)
When fuel cap is inspected directly, it is found to be clogged
Inspect governor oil pump directly
Inspect governor spool valve directly
When governor oil supply pipe is inspected directly, it is found to be clogged
When governor oil strainer is inspected directly, it is found to be clogged
When overflow valve is inspected, it is found that valve is stiff or open
Clean
Troubleshooting
Check items
Questions
Legend
Correct
Wor
n
Defe piston
Clogctive co ring, c
y
Clogged air ntact o linder
f va
c
g
l
e
e
d
a
Defe
ner lve, v
fue
Defective A l filter, elemen alve se
p
P
at
t
Defective re S devic riming
g
pum
Defective al ulator e
p
stra
t
iner
Defective or ernator
Imp ctive in deterio
rope ject
r
a
Defe
r inj ion n ted ba
c
Lea tive fue ection ozzle ttery
t
kag
l
i
Clog e, clo injectio ming
n
Gov ged fue gging, pump
(r
a
e
Seiz rnor spl tank a ir in fu ack, plu
e
i
n
e
Defe d gove ool val r breath l piping ger stu
v
ck)
c
Defe tive ope rnor oil e stuck er hole
r
Clogctive fu ation of pump g
g
e
Clogged go l inject overnor ear sha
ft
io
oi
ged vern
gov or oi n pum l pump
p ov relie
erno l su
fv
e
r oil pply
p rflow v alve
stra
alve
iner ipe
100% 90% 80% 75% 70%

20C
1.28 1.26 1.24 1.23 1.22
0C
1.29 1.27 1.25 1.24 1.23
10C
1.30 1.28 1.26 1.25 1.24
The specific gravity should exceed the value
for the charging rate of 70% in the above table.
In cold areas the specific gravity must exceed the value for the charging rate of 75%
in the above table.
Replace
Causes
Charging rate
Ambient temperature
PC1100-6
TROUBLESHOOTING
S-2
S-2 Engine does not start

a) Engine turns but no exhaust smoke comes
out (fuel is not being injected)
General causes why engine turns but no exhaust smoke comes out
Supply of fuel impossible
Supply of fuel is extremely small
Improper selection of fuel (particularly in winter)
Standards for use of fuel
Causes
22
30
4
20
14
10
32
0
50
10
68
20
86 104F
30 40C
ASTM D975 No.2

Diesel fuel
ASTM D975 No.1
Legend
Bro
ken
fuel
Defe
inje
ctive
ctio
fu
n pu
Seiz
mp
ed, b el inject
driv
ion p
r
o
ken
Clog
es
ump
feed
ged
(rack haft, ke
p
f
u
u
mp
Clog
,
y
el fi
plun
pisto
lter,
ge
ger
n (g
stra
seize
Lack d primi
e
a
i
n
d)
r
, sha
ng p
e
of
ft, et
ump r
Clog fuel
c
,
.
)
s
ge
train
er
Clog d, leaki
ng f
ged
uel
fu
Imp
pipi
rope el tank
air b ng
r
fuel
Seiz
reat
use
ed
her
d
hole
Defe govern
or o
ctive
il pu
actu
Gov
mp
ation
ern
g
Clog or spoo of gove ear, sha
rnor
ft
ged
l va
oil p
lve
go
Clog
stuc
ump
ged vernor
k
relie
o
gov
f val
erno il supp
ve
ly p
r oil
ipe
stra
iner
Ambient temprature
Type of fluid

Questions
Exhaust smoke suddenly stops coming out (when starting again)

Replacement of filters has not been carried out according
to Operation Manual
When fuel tank is inspected, it is found to be empty
There is leakage from fuel piping
When fuel filter is drained, fuel does not come out
Check items
1) Injection pump coupling does not turn

2) No fuel comes out even when fuel filter air bleed
plug is loosened
3) No fuel spurts out even when injection pipe sleeve
nut is loosened
Rust and water are found when fuel tank is drained
Inspect fuel injection pump directly
Troubleshooting
Control pump does not move

Inspect feed pump directly
Inspect governor spool valve directly
PC1100-6
Clean
Clean
Replace
Replace
Replace
Replace
Correct
Correct
Add
Clean
Clean
Replace
Replace
Remedy
Replace
20-407
3
TROUBLESHOOTING
S-2
b) Exhaust smoke comes out, but engine does

not start (Fuel is being injected)
General causes why exhaust smoke comes out
but engine does not start
Lack of rotating force due to defective electrical system
Improper selection of fuel and oil
Defec
Legend
tive,
broke
Defe
n dyn
ctive
amic
fuel
Wor
injec valve syst
n pi
s
t
on r tion pum em (valve
Clog
, ro
ing,
p ( ra
ge
cyl
ck, p cker lever
Clog d fuel f
,
lung
ilter inder li
ged
er st etc.)
n
, str
feed
u ck)
Clog
aine er
p
ge
ump
r
stra
Defe d air cle
iner
ctiv
ane
e
r
elem
APS
Defe
ent
dev
ctiv
ice
e or
Lea
d
eter
kag
Clog e, clogg iorated
ge
ing,
batt
ery
air i
Clog d inject
n fu
ion
ged
el sy
noz
fuel
Imp
stem
zle,
tank
rop
air b defecti
Visc er fuel
ve s
reat
use
osit
p
her
d
y of
hole ray
eng
ine
oil t
oo h
igh
Causes

Suddenly failed to start
Questions
When engine is cranked, abnormal noise is heard from around head

to Operation Manual
Rust is found when fuel tank is drained
Preheating pilot lamp does not light up
Starting motor cranks engine slowly
Check items
1) Little fuel comes out even when fuel injection pump

sleeve nut is loosened
2) Little fuel comes out even when fuel filter air bleed
plug is loosened
When fuel filter is drained, no fuel comes out
Remove head cover and inspect directly
When control rack is pushed, it is found to be heavy, or does not return
Troubleshooting

When feed pump strainer is inspected directly, it is found to be clogged
Glow plug mount does not become warm
Either specific gravity of electrolyte or voltage of battery is low
When feed pump is operated, operation is too light or too heavy
20-408
3
Replace
Replace
Clean
Clean
Correct
Replace
Correct
Clean
Clean
Clean
Replace
Replace
Remedy
Replace
PC1100-6
TROUBLESHOOTING
S-3
S-3 Engine does not pick up smoothly (follow-up is poor)

General causes why engine does not pick up smoothly
Improper fuel used
Defective fuel injection pump
ge
Clog d air cle
ge
ane
re
Clog d fuel f
ilter lement
ged
, str
feed
Clog
pum ainer
ge
p st
Defe d inject
rain
ion
ctiv
er
n
e
ozzl
f
Wor
eed
e, d
n pi
pum
efec
sto
p
tive
Seiz
ed t n ring,
spra
cylin
urbo
y
Imp
der
cha
rope
r
g
e
r va
r
,
Clog
i
n
lve
terf
ge
clea
ranc erence
Clog d fuel t
e
ank
ged
ai
, lea
Defe
king r breat
ctiv
her
fu
e co
hole
ntac el pipin
g
t of
valv
e an
d va
lve
seat
Clog
Legend
Causes

Questions
Replacement of filters has not been carried out according to

Operation Manual
Engine pick-up suddenly became poor

Black

Check items

High idling speed under no load is normal, but speed
suddenly drops when load is applied
Troubleshooting
When feed pump strainer is inspected directly, it is found to be clogged

Inspect feed pump
When valve clearance is checked directly, it is found to be
PC1100-6
Replace
Correct
Clean
Adjust
Replace
Replace
Replace
Correct
Clean
Clean
Remedy
Clean
20-409
3
TROUBLESHOOTING
S-4
S-4 Engine stops during operations

General causes why engine stops during operations
Seized parts inside engie
Overheating
fl If there is overheating and the engine
stops, carry out troubleshooting for overheating.
Failure in machine
fl If the engine stops because of a failure in
the machine, carry out troubleshooting
for the machine.
Remove oil pan and inspect directly

When gear train is inspected, it does not turn
Turns when pump auxiliary equipment is removed
Inspect feed pump directly
Control rack does not move
Remedy
20-410
3
Carry out troubleshooting for machine.

Abnormal noise was heard and
engine stopped suddenly
Condition
Engine overheated and stopped
when engine
Engine stopped slowly
stopped
There was hunting and engine stopped
Fuel level caution lamp is lighted up
to Operation Manual
Engine runs, but when work equipment control lever is
operated, engine stops
Does not turn at all
Try to turn by
Turns in opposite direction
hand using
Moves amount of backlash
barring tool
Shaft does not turn
Metal particles are found when oil is drained
Replace
Replace
Replace
Replace
Replace
Replace
Add
Clean
Clean
Replace
Correct
Clean
Replace
Replace
Replace
Clean
Clean
Troubleshooting
Check items
Questions
Legend
Bro
k
Bro en, seiz
k
e
Brok en, seiz d pisto
e
e
Bro n dynam d cran n, conn
k
k
e
Bro en, seiz ic valve shaft b cting r
k
s
o
e
e
Bro en pum d gear ystem (v aring d
k
alve
Lack en fuel p or au train
, roc
ker l
x
i
ever
Clog of fuel njectio iliary e
, etc
n pu
quip
g
e
.)
d
Clog
mp
men
f
u
e
l
d
g
t
f
r
e
i
i
l
d
ve s
ter,
Bro
p
r
im
haft
k
s
, key
Clogen, seiz ing pu trainer
e
Clogged, le d gear mp stra
a
,
i
g
k
n
s
i
er
Defe ed fue ng fu haft
e
c
Fail tive fue l tank a l pipin
g
ure
i
l
r
on m injectio breat
Bro
h
k
n
Defe en, seiz achine pump er hole
(rack
ctive
ed g
Clog
, plu
ove
actu
nger
r
g
a
n
e
t
o
i
d
o
Clog
r
n
seize
ged govern of gove oil pum
d)
gov or oi
rnor
p ge
erno l su
o
a
r oil pply il pump r, shaf
p
stra
relie t
iner ipe
f val
ve
Causes
PC1100-6
TROUBLESHOOTING
S-5
S-5 Engine does not rotate smoothly (hunting)

General causes why engine does not rotate
smoothly
Air in fuel system
Defective governor mechanism
Defe
Defe
Adjust
Adjust
Legend
ctiv
e op
erat
ion
ctive
of g
slidin
ove
g of
Defe
rnor
gove
ctiv
rnor
e op
(
s
o
e
Low
leno
ratio
id, sp
idlin
n of
ool)
g sp
con
Lack
trol
eed
rack
is to
of fu
o lo
el
w
Clog
ged
prim
Clog
ing
pum
ged
fuel
p st
rain
Clogg
filte
er
ed, air
r, st
rain
in circ
er
uit be
Clogg
tween
ed, air
fuel ta
in cir
nk an
cuit b
Clog
d prim
etwee
ged
ing pu
n fee
fuel
mp
d pum
Clog
tank
p and
ged
a
i
nozzle
r
gove
brea
rnor
ther
Clog
oil p
ged
hole
ump
gove
scre
rnor
e
oil p
n filt
ump
er
inlet
filter
, pip
e
Causes

Questions
Occurs at a certain speed range

Condition of hunting
Occurs at low idling

Occurs even when speed is raised
Occurs on slopes

Replacement of filters has not been carried out according to Operation Manual
Rust is found when fuel tank is drained
Check items
When priming pump is operated,

1) No response, light, return is quick
2) No response, light, return is normal
Engine speed sometimes rises too far
Engine is sometimes difficult to stop
Movement of governor lever (solenoid plunger) is stiff
Troubleshooting
Movement of spool valve is stiff

When governor oil screen filter is inspected, it is found to be clogged
PC1100-6
Clean
Replace
Clean
Correct
Correct
Clean
Clean
Add
Adjust
Remedy
Adjust
When governor oil inlet filter, oil supply pipe are inspected, they are found to be clogged
20-411
3
TROUBLESHOOTING
S-6
S-6 Engine lacks output (no power)
Legend
Causes
Clog
ge
Seiz d air cle
ed t
ane
urb
r ele
Wor
men
n pi ocharg
t
er, i
s
ton
Clog
nter
ring
ged
fere
,
c
y
fuel
nce
Clog
filte linder
ge
r, st
Clog d primi
rain
ng
er
ge
Seiz d inject pump s
ion
ed f
train
noz
uel
er
Imp
rope injectio zle, def
ecti
r va
n pu
Defe
ve s
lve
mp
cti
pray
cl
p
Clog ve cont earance lunger
act
ged
o
,
f
leak
valv
Clog
ing
e an
ge
d va
Defe d fuel t fuel pip
lve
ank
i
ctiv
seat
air b ng
e va
riab
reat
le p
her
rest
hole
roke
spo
ol, s
olen
oid
Measure the engine speed and judge if the cause is

in the engine or on the machine.
General causes why engine lacks output
Improper fuel used
(if non-specified fuel is used, output drops)
Lack of output due to overheating
fl If there is overheating and insufficient output,
carry out troubleshooting for overheating.

Questions
Power was lost

Suddenly
Gradually

to Operation Manual
Black

Check items
High idling speed under no load is normal, but speed

suddenly drops when load is applied
High idling speed of engine is low
Troubleshooting

When valve clearance is checked directly, it is found to be outside standard value
When priming pump is operated, operation is too light or too heavy
20-412
3
Replace
Clean
Correct
Replace
Adjust
Replace
Correct
Clean
Clean
Replace
Replace
Remedy
Clean
Inspect sliding of spool valve, solenoid at variable prestroke end
PC1100-6
TROUBLESHOOTING
S-7
S-7 Exhaust smoke is black

(incomplete combustion)
General causes why exhaust smoke is black
Legend
Seiz
ed
Clog turboch
ge
arg
Wor d air cle er, inte
n pi
r
ston aner ele ferenc
Clog
e
men
ring
ged
,
t
cyli
, se
Imp
rope ized in nder
ject
r in
Imp
rope jection ion no
zzle
r va
timi
Cru
lve
she
clea ng
d
,
ranc
clog
Lea
ged
e
kag
muf
Defe e of air
betw fler
ctiv
e co
Defe
ntac een tur
ctiv
boc
t
h
Defe e fuel in of valv
e an arger a
jecti
ctiv
nd h
on p
d va
e va
ump
ead
riab
lve
s
le p
(
e
r
a
at
ck, p
rest
lung
roke
er se
spo
iz
ol, s
olen ed)
oid
Causes

Questions
Suddenly became black

Gradually became black


Power was lost
Suddenly
Gradually

Check items

Exhaust noise is abnormal
Muffler is crushed
Leakage of air between turbocharger and head, loose clamp
Troubleshooting

When check is made using delivery method, injection
timing is found to be incorrect
When valve clearance is checked directly it is found to be
When muffler is removed, exhaust color returns to normal
PC1100-6
Replace
Replace
Replace
Correct
Replace
Adjust
Adjust
Replace
Replace
Clean
Remedy
Replace
20-413
3
TROUBLESHOOTING
S-8
S-8 Oil consumption is excessive (or exhaust smoke is blue)

fl To prevent leakage of oil in the cylinders, do
not run the engine at idling for more than 20
minutes continuously. (Both low and high
idling)
General causes why oil consumption is excessive
Abnormal combustion of oil
External leakage of oil
Wear of lubrication system
Bro
Legend
ken
pist
Wor
on r
np
ing
Clog iston ri
ng,
ged
cylin
brea
Lea
de
t
kag
e fro her or b r liner
Lea
reat
m
kag
o
her
i
l fi
e fro
Lea
m o lter or o hose
kag
i
il co
l
p
e fro
oler
Lea
m o iping
kag
i
l
drai
e fro
Bro
n
m
p
ken
lu
oil p
oil c
an o g
oole
r cy
Turb
r
lind
er h
och
arge
ead
r
Wor
Wor
n se
n, b
al a
roke
Wor
t tur
Dus
n re
n se
bin
t su
ar s
al a
c
k
eal,
ed i
t blo e end
Wor
n fro
seal
wer
n va
m in
s
end
lve
Too
take urface
muc (stem,
s
yste
guid
h en
m
e)
gine
oil a , broke
n se
dde
al
d
Causes

Questions
Oil consumption suddenly increased

Engine oil becomes contaminated quickly
Exhaust smoke is blue under light load
Amount of blow-by gas
Excessive
Check items
None
Area around engine is dirty with oil
There is oil in engine cooling water
When exhaust pipe is removed, inside is found to be dirty with oil
When turbocharger air supply pipe is removed, inside is
found to be dirty with oil
Oil is accumulated inside flywheel housing
Oil level is above H mark on oil level gauge
Clamps for intake system are loose
Troubleshooting
When breather element is inspected, it is found to be

clogged with dirty oil
There is external leakage of oil from engine
Pressure-tightness test of oil cooler shows there is leakage
Excessive play of turbocharger shaft
Inspect rear seal directly
When intake manifold is removed, dust is found inside
When intake manifold is removed, inside is found to be dirty with oil
20-414
3
Correct
Correct
Correct
Correct
Replace
Replace
Replace
Correct
Correct
Correct
Correct
Clean
Replace
Remedy
Replace
PC1100-6
TROUBLESHOOTING
S-9
S-9 Oil becomes contaminated quickly

General causes why oil becomes contaminated
quickly
Intake of exhaust gas due to internal wear
Clogging of lubrication passage
Incomplete combustion
Improper oil used
Operation under excessive load
Too long between oil changed

Non-specified oil is being used
Amount of blow-by gas

Black
Excessive
Carry out troubleshooting for "Exhaust smoke is black".
Check items
None
When oil filter is inspected, metal particles are found
When exhaust pipe is removed, inside is found to be dirty with oil
Engine oil temperature rises quickly
Troubleshooting
When breather element is inspected directly, hose is found to

be broken or clogged with dirty oil
When oil filter is inspected directly, it is found to be clogged
When oil cooler is inspected directly, it is found to be clogged
Turbocharger drain tube is clogged
Excessive play of turbocharger shaft
When safety valve is directly inspected, spring is found to be
catching or broken
PC1100-6
Correct
Replace
Replace
Clean
Clean
Replace
Replace
Clean
Remedy
Replace
Questions
Legend
Wor
n pi
Clog ston rin
g
ged
brea , cylinde
Clog
ther
ged
, bre r
oil
athe
Wor
r tub
n va filter
e
lve,
Clog
v
alve
ged
g
u
o
ide
il co
Clog
oler
ged
turb
Defe
o
char
ctiv
ger
drai
Defe e seal a
n pip
tt
ctive
e
safe urbocha
Too
t
rger
y
muc
valv
turb
h en
e
Exha
ine e
ust s gine oil
nd
mok
adde
e is
d
blac
k
Causes
20-415
3
TROUBLESHOOTING
S-10
S-10 Fuel consumption is excessive

General causes why fuel consumption is excessive
Leakage of fuel
Legend
Defe
ctive
fuel in
jectio
Defe
n pum
ctiv
p (ex
e no
cessiv
zzle
Defe
e inje
hold
ctiv
ction
e fu
er s
)
pray
el in
Defe
j
e
ctiv
c
t
i
o
e fu
n
p
ump
el in
Exte
ject
plun
rnal
ion
leak
ger
timi
age
Lea
ng
from
kag
e of
fuel
pipin
fuel
Defe
g, fu
insi
ctive
de h
el fil
varia
ter
ead
ble p
c
ove
restr
r
oke
spoo
l, so
leno
id
Causes
Questions

More than for other machines
Condition of fuel
of same model
consumption
Gradually increased
Suddenly increased
Exhaust smoke color
Black
White
Check items
There is irregular combustion

There is external leakage of fuel from engine
Engine oil level rises and smells of diesel fuel
Engine low idling speed is high
Troubleshooting
Injection pump measurement shows that injection amount is excessive

When check is made using delivery method, injection
timing is found to be incorrect
20-416
3
Replace
Correct
Correct
Adjust
Replace
Replace
Remedy
Adjust
PC1100-6
TROUBLESHOOTING
S-11
S-11 Oil is in cooling water, or water spurts back, or water level goes down
General causes why oil is in cooling water
Internal leakage in lubrication system
Internal leakage in cooling system
ken
Replace
ken
Bro
Bro
Replace
Legend
oil c
oole
r co
re, O
cylin
-ring
der
Insu
hea
ffici
d, h
ent
e
p
ad g
r
Bro
otru
aske
ken
sion
t
pow
o
f lin
er tr
Dam
er
ain
aged
oil c
liner
oole
O-rin
Inte
r
g, ho
rnal
les c
crac
ause
ks in
Dam
d by
aged
cylin
pittin
wate
der
g
r pum
bloc
p sea
k
l (clo
gged
brea
ther)
Causes
Questions

Oil level

Suddenly increased
Gradually increased
Check items
(or corrosion resistor valve is closed)
Troubleshooting
Hard water is being used as cooling water
Engine oil level has risen, oil is cloudy white

Excessive air bubbles inside radiator, spurts back
Pressure-tightness test of cylinder head shows there is leakage

Remove cylinder head and inspect directly
PC1100-6
Replace
Replace
Replace
Replace
Remedy
Replace
When water pump is inspected, it is found to be abnormal
20-417
3
TROUBLESHOOTING
S-12
S-12 Oil pressure caution lamp lights up (drop in oil pressure)

General causes why oil pressure caution lamp lights up
Leakage, clogging, wear of lubricating system
Defective oil pressure control
Improper oil used (improper viscosity)
Deterioration of oil due to overheating
fl Standards for engine oil selection
Ambient temperature
Type of fulid
22
30
4
20
14
10
32
0
50
10
68
20
Causes
86 104F
30 40C
SAE 10W
Engine oil
SAE 10W-30
SAE 15W-40
Legend
Clog
ged
oil f
ilter
Wor
n be
arin
g, jo
Clog
urna
ged
l
suct
Bro
i
o
n
ken
pipe
suct
insi
ion
de o
Bro
pipe
ken
il pa
insi
suct
n
d
i
o
e
Defe
n pi
o
i
l
pan
pe b
ctiv
e oi
razi
l pu
ng
Lack
mp
of o
il in
Defe
oil p
ctiv
an
e re
gula
Lea
tor v
king
, cru
alve
she
Defe
d hy
ctiv
drau
e oi
lic p
l lev
Defe
ipin
el se
ctiv
g
nso
e oi
r
l pre
Clog
ssur
ged
e se
oil c
nso
Wat
oole
r
er, f
r
uel
in o
il
SAE 30
Questions

to Operation Manual
Lights up at low idling
Condition when oil pressure
Lights up at low, high idling
caution lamp lights up
Occurs on slopes
Check items
Sometimes lights up
Leaking, crushed hydraulic piping (external)
Oil level caution lamp lights up
When oil level in oil pan is checked, it is found to be low
Metal particles are stuck to oil filter element
Troubleshooting
When oil filter is inspected directly, it is found to be clogged

Oil pump rotation is heavy, or there is play
There is catching of relief valve, spring or valve guide is broken
Oil level caution lamp goes out when oil level sensor is replaced
When oil pressure is measured, it is found to be within standard value
20-418
3
Replace
Replace
Replace
Correct
Correct
Add
Replace
Correct
Replace
Replace
Clean
Remedy
Replace
Remove oil cooler and inspect directly
Carry out troubleshooting for "Oil level rises".
Oil is cloudy white or smells of diesel fuel
PC1100-6
TROUBLESHOOTING
S-13
S-13 Oil level rises

fl If there is oil in the cooling water, carry out
troubleshooting for Oil is in cooling water
also.
General causes why oil level rises
Water in oil
Fuel in oil (diluted, and smells of diesel fuel)
Entry of oil from other component
Check items
Questions
Legend
Bro
ken
Defe oil coo
ler
cti
Broke ve nozz core, O
n cyli
l
-r
e ho
lder ing
Clog nder head,
slee
head
ged
ve
gaske
wa
Wor
n, d ter pum t (includin
g prec
a
p
m
b
Defe
age
ombu
d re reather
ctiv
e se
ar s
hole stion cham
Lea
eal
al o
ber)
, de
kag
surf
f pu
fect
ac
ive s
m
Defe e of fue
eal
ctive
l fro p auxili e
ary
mn
part
Defe
equ
ozzl
insid
ctiv
i
e ho
pme
e fue
e th
lde
l in
Dam
nt
erm
age
osta jection p r retain
d
t se
ing
ump
line
Crac
a
c
r O(flan
ks in
ring t
ge ty ap
side
pe)
cylin , holes
der
mad
bloc
e by
k
pitti
ng
Causes

There is oil in radiator cooling water
Exhaust smoke is white
When engine is first started, drops of water come from muffler
When radiator cap is left open and engine is run at idling,
abnormal number of bubbles appear, or water spurts back
Water pump breather hole is clogged with mud
When water pump breather hole is cleaned, water comes out
Oil level goes down in PTO
Oil level goes down in hydraulic tank
Engine oil smells of diesel fuel
Fuel must be added more frequently
Troubleshooting

Remove water pump and inspect directly
Inspect rear seal directly
When pump auxiliary equipment is removed,
seal is found to be damaged
Remove nozzle holder and inspect directly
Remove fuel injection pump and inspect directly
Thermostat seat valve contact is defective
PC1100-6
Replace
Replace
Correct
Replace
Correct
Replace
Correct
Replace
Replace
Replace
Remedy
Replace
Remove oil pan and check directly
20-419
3
TROUBLESHOOTING
S-14
S-14 Water temperature becomes too high (overheating)

General causes why water temperature becomes too
high
Lack of cooling air (deformation, damage of fan)
Drop in heat dissipation efficiency
Defective cooling circulation system
Bro
ken
wat
er p
Clog
ump
ged
, cru
she
Clog
d ra
ged
diat
radi
or fi
ator
Defe
ns
core
ctiv
e th
erm
Defe
osta
ctiv
t (do
ew
ater
es n
Lack
ot o
tem
of c
pen
pera
ooli
)
ture
ng w
Fan
gau
belt
ater
g
e
slip
ping
Clog
, wo
ged
rn fa
, bro
n pu
ken
Defe
lley
oil c
ctiv
e pr
oole
essu
r
Bro
ken
re v
alve
hea
d, h
Dam
e
a
aged
d ga
liner
sket
O-rin
Crac
g, ho
ked
les m
cylin
ade
der
by p
bloc
itting
k
Legend
Causes

Condition of overheating

Suddenly overheated
Questions
Always tends to overheat

Water temperature gauge
Rises quickly
Does not go down from red range
Radiator water level caution lamp lights up

Fan belt whines under sudden load
Cloudy white oil is floating on cooling water
Cooling water flows out from overflow hose
Check items
Excessive air bubbles inside radiator, water spurts back

Engine oil level has risen, oil is cloudy white
Radiator shroud, inside of underguard are clogged with dirt or mud
When light bulb is held behind radiator, no light passes through
Water is leaking because of cracks in hose or loose clamps
When belt tension is inspected, it is found to be loose
Temperature difference between top and bottom radiator tanks is excessive
Temperature difference between top and bottom radiator tanks is slight
Troubleshooting
When water filler port is inspected, core is found to be clogged

When function test is carried out on thermostat, it does
not open even at cracking temperature
When water temperature is measured, it is found to be room temperature
When oil cooler is inspected directly, it is found to be clogged
When measurement is made with radiator cap tester, set
pressure is found to be low
20-420
3
Replace
Replace
Replace
Replace
Replace
Correct
Add
Replace
Replace
Correct
Correct
Remedy
Replace
PC1100-6
TROUBLESHOOTING
S-15
S-15 Abnormal noise is made

fl Judge if the noise is an internal noise or an
external noise.
General causes why abnormal noise is made
Abnormality due to defective parts
Abnormal combustion
Air sucked in from intake system
Exc
Legend
essi
Seiz ve wea
ed t
r
urbo of pist
Mis
o
cha
sing
rger n ring,
cylin
, int
Clog , seize
er
d bu
d
ge
shin ference er line
Defe d, seize
r
g
d in
ctive
ject
fuel
Defe
i
o
i
n
n
ctiv
ject
no
Defo e fuel in ion pum zzle
jecti
p
rme
(ra
on p
df
Imp
ump ck, plun
rope an, fan
ger
(exc
belt
r ad
s e iz e
ess
Brok
just
en d
men interfer ive injec d)
y
n
enc
amic
tion
t of
Imp
e,
)
valv
rope
valv
e sys
e c l e slippin
r ge
Lea
t
g
a
a
e
m (v
r tra
ranc
kag
alve
in b
e
,
Defe e of air
a
ct in
betw cklash rocker le
side
ver,
e
Lea
e
muff
n tu
etc.)
kag
rboc
ler (d
harg
ividi
Seiz e from
ng b
e
air c
ed c
r an
oard
ond
rank
d he
out o
it
sha
ad
fp
ft be ioner c
omp osition)
arin
g
ress
or p
ipin
g
Causes
Questions

Condition of abnormal nois

Gradually occurred
Suddenly occurred

Black
Metal particles are found in oil filter
Check items

Engine pickup is poor and combustion is abnormal
Seal on fuel injection pump has come off
Abnormal noise is loud when accelerating engine
Leakage of air between turbocharger and head
Vibrating noise is heard from around muffler
Troubleshooting
Remove gear cover and inspect directly

Fan is deformed, belt is loose
When valve clearance is checked, it is found to be outside standard value
Remove cylinder head cover and inspect directly
When muffler is removed, abnormal noise disappears
Check for leakage from air conditioner compressor piping
PC1100-6
Replace
Replace
Replace
Correct
Correct
Replace
Adjust
Correct
Adjust
Replace
Replace
Replace
Replace
Remedy
Replace
Remove oil pan and inspect
20-421
3
TROUBLESHOOTING
S-16
S-16 Vibration is excessive

fl If there is abnormal noise together with the
vibration, carry out troubleshooting for Abnormal noise is made.
General causes why vibration is excessive
Defective parts (abnormal wear, breakage)
Improper alignment
Abnormal combustion
Wor
Replace
n co
Wor
Replace
Legend
nne
ctin
g ro
n ba
d, m
lanc
ain
er, c
Wor
bea
am
n su
ring
bus
ppo
hing
rt pi
Loos
lot p
e en
ortio
gine
n
mou
Bro
ken
nt b
o
part
lts, b
insi
roke
Mis
de o
alig
n cu
utpu
nme
shio
n
n
t
Imp
t be
sha
ft (d
rope
twe
en e
amp
r ge
ngin
er)
ar tr
Defec
e an
ain
tive d
bac
d PT
ynam
k
l
O
ic
a
Defe
sh
valve
ctive
syste
fuel
m (va
injec
Clog
lv
e, roc
tion
ged
ker le
pum
inje
p (ex
ver, e
ctio
Defe
c
tc.)
e
ssive
n no
ctiv
injec
zzle
e vi
tion)
brat
ion
dam
per
Causes
Questions


Suddenly increased
Condition of vibration
Gradually increased
Metal particles are found in oil filter
Check items
Oil pressure is low at low idling

Vibration occurs at mid-range speed
Vibration follows engine speed
Exhaust smoke is black
Seal on fuel injection pump has come off
Remove side cover and inspect directly
Troubleshooting
Check directly for wear, play in support pilot portion

When engine mount bolts are inspected directly, loose
bolts are found; check for broken cushion
Inspect inside of output shaft (damper) directly
Radial, face runout are found to be outside range
Remove front cover and inspect directly
20-422
3
Replace
Replace
Adjust
Replace
Correct
Correct
Replace
Replace
Remedy
Replace
Remove vibration damper and inspect directly
PC1100-6
TROUBLESHOOTING OF PUMP
CONTROLLER SYSTEM
(C MODE)
Judgement table for pump controller and hydraulic (mechanical) related parts ........................... 20-452
Points to remember when carrying out troubleshooting of pump controller system ...................20-455
Electrical circuit diagram for C mode system .....................................................................................20-462
C- 1 Abnormality in controller power source (controller LED is OFF) ...........................................20-465
C- 2 [E232] Short circuit in TVC solenoid system is displayed ......................................................20-466
C- 3 [E233] Disconnection in TVC solenoid system is displayed ...................................................20-468
C- 4 [E203] Short circuit in swing holding brake solenoid relay system is displayed ................ 20-470
C- 5 [E213] Disconnection in swing holding brake solenoid relay system is displayed .............20-472
C- 6 [E201] Short circuit in CO cancel solenoid system is displayed ............................................20-474
C- 7 [E211] Disconnection in CO cancel solenoid system is displayed .........................................20-475
C- 8 [E202] Short circuit in straight-travel solenoid system is displayed ......................................20-476
C- 9 [E212] Disconnection in straight-travel solenoid system is displayed .................................. 20-477
C-10 [E204] Short circuit in 2-stage relief solenoid system is displayed .......................................20-478
C-11 [E214] Disconnection in 2-stage relief solenoid system is displayed ....................................20-479
C-12 [E205] Short circuit in swing priority solenoid system is displayed .....................................20-480
C-13 [E215] Disconnection in swing priority solenoid system is displayed .................................. 20-481
C-14 [E206] Short circuit in travel speed solenoid system is displayed ........................................20-482
C-15 [E216] Disconnection in travel speed solenoid system is displayed .....................................20-483
C-16 [E217] Model selection input error is displayed .......................................................................20-484
C-17 [E227] Abnormality in engine speed sensor (2) system is displayed ....................................20-486
C-18 [E228] Abnormality in auto-deceleration output system is displayed ...................................20-487
C-19 Abnormality in swing holding brake system is displayed (no service code is displayed) .... 20-488
C-20 Abnormality in machine push-up solenoid system (no service code is displayed) ............20-489
C-21 Abnormality in boom shockless solenoid system (no service code is displayed) ............... 20-492
PC1100-6
20-451
3
JUDGEMENT TABLE FOR FOR PUMP CONTROLLER

AND HYDRAULIC (MECHANICAL) RELATED PARTS
TROUBLESHOOTING
JUDGEMENT TABLE FOR PUMP CONTROLLER AND

HYDRAULIC (MECHANICAL) RELATED PARTS
Failure mode
Model selection input error
Disconnection in swing holding brake solenoid system

LED E02 E03
OFF 232 233 203 213 201 211 202 212 204 214 205 215 206 216 217 227
Swing system
Travel system
Work equipment
All work equipment,

swing, travel
User code
Service code
Abnormal noise generated (around pump)
Auto-deceleration does not work
In normal mode
With heavy lift ON
Boom does not move
Arm does not move
Boom
Excessive time lag
Arm, bucket
Machine deviates naturally Deviates in same direction in FORWARD and REVERSE
to one side when traveling Deviates in opposite direction in FORWARD and REVERSE
Deviation is excessive Only at full stroke
when starting
Does not travel (one side only)
Both left and right
Does not swing
One direction only
Both left and right
Swing acceleration is poor or lacks power
One direction only
Both left and right
One direction only
Both left and right
One direction only
Both left and right
One direction only
Troubleshooting code of pump controller system
Troubleshooting code of pump controller input signal system
Short circuit in swing holding brake solenoid system
The E mark is omitted

from the service code

User code
Service code
Monitoring code
C-1 C-2 C-3 C-4 C-5 C-6 C-7 C-8 C-9 C-10 C-11 C-12 C-13 C-14 C-15 C-16 C-17

is a display, go to the bottom.
: Check the service code display. If there is no display, go to the right; if there
: Measure the voltage at the solenoid inlet port. If the voltage is normal, go to the right; if the voltage is abnormal, go to the bottom.
: Check the monitoring code display. If the display is normal, go to the right; if the display is abnormal, go to the bottom.
fi: Monitoring code to use as reference when proceeding with troubleshooting (if necessary, check the display).
20-452
3
PC1100-6
TROUBLESHOOTING
Travel speed solenoid
Swing priority solenoid
Straight-travel solenoid
TVC output current
Engine speed
Swing lock switch
Left swing
L.H. travel
Bucket DUMP (service)
Bucket CURL
Arm OUT
Arm IN
Boom RAISE
Boom LOWER
R.H. travel
Right swing
Boom shockless solenoid
Machine push-up solenoid
Connectors
V04, V11
Connector
V05
Connectors
V09, V10
228
Solenoid drive condition
Monitoring code for reference during troubleshooting
PPC pressure switch
CO cancel solenoid
Checking solenoid
inlet port voltage
20
21
26 21
22
23
26
02 10 13 12
1 2 3 4 5 6 1 2 5 5 3
34 1 2 3 4 5 6 3
fi fi fi fi
fi fi fi fi
fi
Troubleshooting code for hydraulic, mechanical system

H-1
H-2
H-3
H-4
fi
fi
fi
H-5
H-6
H-7
H-8
H-9
H-10
H-11
H-12
H-13
H-14
H-15
fi
fi
H-16
H-17
fi
H-18
fi
H-19
fi
H-20
H-21
H-22
H-23
fi
H-24
fi
H-25
H-26
fi
C-18 C-19 C-20 C-21
F-1 F-2 F-3 F-4 F-5 F-6 F-7 F-8 F-9 F-10 F-11
PC1100-6
H-27
20-453
3
TROUBLESHOOTING

Method of measuring solenoid inlet voltage

fl The pump controller observes the circuit between swing holding brake relay R20 and swing
holding brake solenoid V04, V11 (secondary side) of the swing holding brake solenoid circuit, the
circuit for machine push-up solenoid V05, and the circuit for boom shockless solenoids V09 and
V10. Even if a short circuit or disconnection occurs in these circuits, no service code is displayed.
For this reason, measure the solenoid inlet voltage as follows to judge if the problem is in the
electrical system or in the hydraulic or mechanical system.
1. Measuring swing holding brake solenoid inlet voltage
1) Insert T-adapters into swing holding brake solenoids V04 and V11.
2) Start the engine and turn the swing lock switch ON.
3) If the voltage between V04 and V11 pins (1) and (2) is as shown in the table below, the
condition is normal.
Between V04, V11 Swing lever operated
(1) (2)
5 sec after returning all levers to Neutral
20 30 V
Max. 1 V
2. Measuring machine push-up solenoid inlet voltage

1) Insert a T-adapter into machine push-up solenoid V05.
2) Turn the starting switch ON.
3) If the voltage between V05 pins (1) and (2) is as shown in the table below, the condition is
normal.
Between V05
(1) (2)
Machine push-up switch OFF
20 30 V
Machine push-up switch ON
Max. 1 V
3. Measuring boom shockless solenoid inlet voltage

1) Insert T-adapters into boom shockless solenoid V09 and V10.
2) Turn the starting switch ON.
3) If the voltage between V09 and V10 pins (1) and (2) is as shown in the table below, the
condition is normal.
Between V09, V10
(1) (2)
20-454
3
Boom shockless switch OFF
20 30 V
Boom shockless switch ON
Max. 1 V
PC1100-6
TROUBLESHOOTING

TROUBLESHOOTING OF PUMP CONTROLLER SYSTEM

TROUBLESHOOTING OF PUMP CONTROLLER SYSTEM
1. Points to remember if abnormality returns to normal by itself:
If the connector is disconnected and the T-adapter is inserted, or if the T-adapter is removed and
the connector is returned to its original position when carrying out troubleshooting of the failure,
and the service code is no longer displayed, or if the monitor display returns to normal, the
abnormality has probably returned to normal.
However, there is a high probability that the same problem will occur again, so it is desirable to
follow up this problem carefully.
2. Handling service code memory retention function:
1) When displaying the abnormality code in memory and carrying out troubleshooting, note
down the content of the display, then erase the display. After trying to re-enact the problem,
carry out troubleshooting according to the service code that is displayed.
(There are cases where mistaken operation or abnormalities that occur when the connector is
disconnected are recorded by the memory retention function. Erasing the data in this way
saves any wasted work.)
2) After completing troubleshooting, always erase the service code from memory again.
PC1100-6
20-455
3
TROUBLESHOOTING


User Service
code code
E232
Abnormal system
Short circuit in TVC

solenoid system
E02
E233
E203
Disconnection in
TVC solenoid
system
Short circuit in
swing holding brake
solenoid relay
system
1. Short circuit with ground, short circuit inside TVC solenoid
2. Short circuit with power source, short circuit with ground in wiring
harness between controller C02 (8) and TVC solenoid C13 (1) ((+)
side)
3. Short circuit with power source in wiring harness between controller C02 (18) and TVC solenoid C13 (2) (() side)
1. Disconnection, defective contact inside TVC solenoid
2. Disconnection, defective contact in wiring harness between controller C02 (8) and TVC solenoid C13 (1) ((+) side)
3. Disconnection, defective contact, short circuit with ground in wiring harness between controller C02 (18) and TVC solenoid C13 (2)
(() side)
1. Short circuit with ground, short circuit inside swing holding brake
relay
2. Short circuit with ground in wiring harness between controller C01
(3) and relay R20 (1) ((+) side)
E03
E213
E201
20-456
3
Disconnection in
swing holding brake
solenoid relay
system
Short circuit in CO
cancel solenoid
system
1. Disconnection, defective contact inside swing holding brake relay

2. Disconnection, defective contact, short circuit with power source in
wiring harness between controller C01 (3) and relay R20 (1) ((+)
side)
3. Disconnection, defective contact in wiring harness between relay
R20 (2) and chassis ground (() side)
1. Short circuit with ground, short circuit inside CO cancel solenoid

(8) and solenoid V07 (2) ((+) side)
PC1100-6
TROUBLESHOOTING


Action by controller when abnormality is detected
Problem that appears on machine

1. Makes output to TVC solenoid 0.

2. Displays user code E02 on monitor
panel.
fl If the abnormality is restored by the
vibration of the machine, it resets the
power source to restore to the proper
condition. (However, the service code
display does not go out.)
1. No current flows to the TVC solenoid. Therefore, when the TVC

valve output pressure goes
down and the load is large, there
is a big drop in the engine speed
which may result in the engine
stalling.
1. The current stops flowing to the TVC

solenoid, so no particular action is
taken.
2. If there is a short circuit with the
ground at the () end, the current (min.
1 A) continues to flow to the TVC solenoid.
3. It displays user code E02 on the monitor panel.
1. In the case of Action 1, it is the

same as E232.
2. In the case of Action 2, the current (min. 1 A) continues to flow
to the TVC solenoid, so the output of the TVC valve increases
and the overall speed becomes
slower.
Resistance of relay:
200 400
fl When the swing holding
brake system is seen from
the controller, the relay is
the primary circuit and the
solenoid is the secondary
circuit, so observe the relay circuit of the primary
circuit.
1. Makes output to relay 0.

1. When the swing is operated, the

swing holding brake is not released, so the upper structure
does not swing.
1. The current stops flowing to the relay,

so no particular action is taken.
1. When the swing is operated, the

swing holding brake is not released, so the upper structure
does not swing.
2. If there is a short circuit with
the power source, the solenoid
remains actuated.
1. Makes output to solenoid 0.

1. If load becomes large in heavy

lift mode, boom RAISE speed
becomes low.
2. In heavy lift mode, lifting force
of boom is weak.
3. When traveling uphill in Low
speed, the travel speed becomes
slow.
Resistance of solenoid:
10 22
10 22
Current: 1000 mA
(DH mode, auto-deceleration ON, fuel control dial
at MAX., all levers at
neutral)
Resistance of relay:
200 400
fl When the swing holding
brake system is seen from
the controller, the relay is
the primary circuit and the
solenoid is the secondary
circuit, so observe the relay circuit of the primary
circuit.
20 60
PC1100-6
20-457
3
TROUBLESHOOTING
User Service
code code
E202
Short circuit in
straight-travel
solenoid system
E204
Short circuit in
2-stage relief
solenoid system
E205
Short circuit in
swing priority
solenoid system
E206
E211
E212
E214
20-458
3
Abnormal system
Short circuit in
travel speed
solenoid system
Disconnection in CO
cancel solenoid
system

1. Short circuit with ground, short circuit inside straight- travel solenoid
1. Short circuit with ground, short circuit inside heavy lift solenoid
1. Short circuit with ground, short circuit inside swing priority solenoid
1. Short circuit with ground, short circuit inside travel speed solenoid
1. Disconnection, defective contact inside CO cancel solenoid

wiring harness between controller C01 (8) and solenoid V07 (2) ((+)
side)
3. Disconnection, defective contact in wiring harness between solenoid V07 (1) and chassis ground (() side)
Disconnection in
travel straight
solenoid system
1. Disconnection, defective contact inside travel straight solenoid

side)
Disconnection in
2-stage relief
solenoid system
1. Disconnection, defective contact inside heavy lift solenoid

wiring harness between controller C01 (10) and solenoid V02 (2)
((+) side)
PC1100-6
TROUBLESHOOTING

20 60

1. When travel is operated at same

time as work equipment or
swing, travel deviation occurs.
20 60


of boom is weak.
2. Drawbar pull is weak.
20 60

1. When swing + boom RAISE is

operated at same time in boom
priority mode, boom rises too
far.
1. Travel speed does not switch to

Hi.
20 60

1. The current stops flowing to the solenoid, so no particular action is taken.
1. In heavy lift mode, boom RAISE

speed becomes slower when
load becomes larger.
of boom is weak.
3. Travel speed becomes slow
when traveling uphill in Low
travel speed range.
4. When there is short circuit with
power source, solenoid remains
actuated.

1. When travel is operated at same

time as work equipment or
swing, travel deviation occurs.
actuated.


of boom is weak.
2. Drawbar pull is weak.
actuated.


20 60
20 60
20 60
PC1100-6
20-459
3
TROUBLESHOOTING
User Service
code code
E215
E208
E216
Abnormal system

Disconnection in
swing priority
solenoid system
1. Disconnection, defective contact inside swing priority solenoid

side)
3. Disconnection, defective contact in wiring harness between solenoid V01 (1) and chassis ground () side)
Disconnection in
travel speed
solenoid system
1. Disconnection, defective contact inside travel speed solenoid

side)
3. Disconnection, defective contact in wiring harness between solenoid V06 (1) and chassis ground () side)
Model selection
input error
1. Disconnection, defective contact, short circuit with ground in model

selection wiring harness (C17(5)(6)(13)(14))
E227
Abnormality in
engine speed
sensor (2) system
1. Disconnection, defective contact, short circuit with ground inside

engine speed sensor
2. Disconnection, defective contact, short circuit with ground in wiring
harness between controller C16 (2) and controller E07 (1) (SIG
side) or between C16 (1) and E07 (2) (() side)
E228
Abnormality in
auto-deceleration
output system
1. Disconnection, defective contact, short circuit with ground in wiring

harness between pump controller C01 (4) and engine controller
E17 (12)
E313
Abnormality in auto
greasing controller
system
20-460
3
PC1100-6
TROUBLESHOOTING

20 60



1. When swing + boom RAISE is

operated at same time in boom
priority mode, boom rises too
far.
actuated.

1. Travel speed does not switch to

Hi.
actuated.
20 60
Between C17 (female) (5)

and chassis: Max. 1
Between C17 (female)
(6),(13),(14) and chassis:
Min. 1 M
Detects abnormality in input

1. Retains data when starting switch is
ON
2. Functions as PC1100 when non-set
conditions are input
1. Speed is slow for all work equipment, swing, and travel, or engine stalls.
2. Work equipment, swing, travel
speeds are all slow, or lacks
power.
Resistance of sensor:
500 1000
Voltage of sensor:
0.5 3.0 V
(Engine started, AC range)
1. Operates in equivalent to G Mode.
1. Operates in equivalent to G
Mode, so speed is slightly
slower.
1. Functions with signal from network

(S-NET) circuit.
1. No abnormality appears.
(However, if an abnormality occurs at the same time in the network, the auto-deceleration cannot be actuated.)
Resistance between C01

(female) (4) and E17 (female) (12): Max. 1
PC1100-6
20-461
3
TROUBLESHOOTING
ELECTRICAL CIRCUIT DIAGRAM FOR C MODE SYSTEM
20-462
3
PC1100-6
TROUBLESHOOTING
PC1100-6
20-463
3
TROUBLESHOOTING
C-1
C-1 Abnormality in controller power source system (controller LED is

OFF)
fl Check that fuse 1 is not blown. (If it is blown, check for a short circuit with the ground in the related
circuits for fuse 1.)
fl When the starting motor starts normally. (If the engine does not start, carry out E-20 first.)
fl Always connect any disconnected connectors before going on to the next step.
Cause
2 YES
YES
1
Is voltage between
C01 (7)(13) and
chassis ground
normal?
Turn starting
switch ON.
20 30V
C02 (female) (11)(21)
and chassis ground
normal?
Turn starting
NO
switch OFF.
Disconnect C02.
Max. 1
3 YES
Is voltage
between fuse 1
NO outlet and
chassis normal?
Turn starting
switch ON.
20 30V
NO
Remedy
Defective pump
controller
Replace
harness between C02
chassis ground
Repair or
replace
Defective contact, or
outlet and C01 (female)
(7)(13)
Repair or
replace
harness between battery
relay terminal M and
fuse 1 inlet
Repair or
replace
C-1 Related electrical circuit diagram
PC1100-6
20-465
3
TROUBLESHOOTING
C-2
C-2 [E232] Short circuit in TVC solenoid system is displayed

connector and inserting the T-adapter, or when removing the T-adapter and returning the connector to its original position, if an E service code is not displayed, the problem has been removed.
fl If the starting switch is turned OFF after an abnormality occurs, turn the starting switch ON and
check if an E service code is displayed. (If it is not displayed, the problem has been removed.)
fl Carry out troubleshooting with the TVC prolix switch OFF.
Cause
YES
Defective pump
controller
3
YES
2
YES
1
Is resistance
between C13 (male)
(1) and (2), (1) and
chassis ground as
shown in Table 1?
When C13 is disconnected,

between C02 (female) (8)
shown in Table 2?
When C13 is
disconnected, is
voltage between
C02 (female) (18)
and chassis normal?
Disconnect C02
and C13.
Turn starting
switch ON.
4 YES
Go to A
Is resistance
between C05
Disconnect C02
and C13.
Defective TVC prolix
normal?
Turn starting
switch
switch ON.
NO
Turn starting
Max. 1 V
switch OFF.
YES
5
NO
Is resistance
between C05 (male)
(1) and (3), (1)(3) and
chassis ground as
shown in Table 3?
Turn starting
switch OFF.
Disconnect C05.
When C05 is disconnected,

shown in Table 2?
Disconnect C02
and C05.
Turn starting
switch ON.
NO
NO

between C05 (female)(3)
and C13 (female) (1)
When C05 is
disconnected, is
voltage between C02
(female) (18) and
chassis normal1?
NO
Table 1
Replace
Repair or
replace

or short circuit with power
NO source in wiring harness
and C05 (male) (1)
Repair or
replace

switch
Replace
Defective TVC solenoid

(internal short circuit
with ground)
Replace

and C13 (female)(2)
between C02
(female)(18) and C05
(female)(2)
1 YES
Disconnect C02
and C05.
Turn starting
switch ON.
Max. 1 V
Replace

Disconnect C05.
or short circuit with power
Max. 1
6 YES
Turn starting
switch OFF.
Disconnect C13.
Remedy
Repair or
replace
Repair or
replace
Table 2
Between C13 (male) (1) (2)
10 22
Between C13 (male) (1) chassis
Min. 1 M
Resistance
Voltage
Between C02 (female) (8) chassis Min. 1 M Max. 1 V
Table 3
Max. 1
Between C05 (male) (1)(3) chassis Min. 1 M
20-466
3
PC1100-6
TROUBLESHOOTING
C-2
PC1100-6
20-467
3
TROUBLESHOOTING
C-3
C-3 [E233] Disconnection in TVC solenoid system is displayed

fl Carry out troubleshooting with the TVC prolix switch OFF.
Cause
Remedy
Defective pump
controller
YES
3
Replace
Is voltage
YES between C02 (18)

and chassis
ground normal?
Turn starting
switch ON.
0.8 1.0 V.
Is voltage between
YES C13 (female) (1)
and chassis
ground normal?
1
Is resistance
between C13 (male)
(1) and (2), (2) and
chassis ground as
shown in Table 1?
Disconnect C13.
Turn starting
switch ON.
20 30 V
Turn starting
switch OFF.
Disconnect C13.
4 YES
NO
Repair or
replace
Disconnect C05. NO harness between C02
(female) (8) and C05
Turn starting
(male) (1)
switch ON.
20 30 V
Repair or
replace
Replace
switch
NO
Defective TVC solenoid

(internal disconnection
or defective contact)
Replace
contact, short circuit with
ground in wiring harness
and C13 (female) (2)
7 YES
Is voltage
between C05 (4)
and chassis
ground normal?
Turn starting
switch ON.
0.8 1.0 V
Replace
chassis ground
normal ?
NO
Go to A

NO switch
Turn starting
switch OFF.
Disconnect C05.
6 YES harness between C05
(female) (3) and C13
Is voltage between
YES C05 (female) (1) and
(female) (1)
Is resistance
between C05
normal?
Turn starting
switch OFF.
Disconnect C05
Max. 1
Is resistance
between C05 (male)
(2) and (4), (2)(4)
and chassis as
shown in Table 2?
between C02 (female)
(18) and C05 (male) (2)
NO
Table 1
Repair or
replace
Repair or
replace
Table 2
10 22
Max. 1
Between C13 (male) (2) chassis
Min. 1 M
Between C05 (male) (2)(4) chassis
Min. 1 M
20-468
3
PC1100-6
TROUBLESHOOTING
C-3
PC1100-6
20-469
3
TROUBLESHOOTING
C-4
C-4 [E203] Short circuit in swing holding brake solenoid relay system
is displayed
fl When carrying out troubleshooting, always turn the swing lock switch and the swing prolix switch
OFF.
Cause
YES
Defective pump
controller
Interchange relay
R20 with other
relay. Is [E203]
displayed?
Start engine.
Operate swing
lever.
20 30 V
NO
YES
3
Is resistance
between X05
(female) (3)(4) and
chassis ground
normal?
Turn starting
switch OFF.
Disconnect X05.
Min. 1 M
Start engine.
Operate swing
lever.
20-470
4 YES in wiring harness
NO
Replace
Is voltage
YES between R20 (1)
and chassis
ground normal?
Remedy
Is resistance
between X05
(female) (3) and
chassis ground
normal?
Turn starting
switch OFF.
Disconnect X05.
Min. 1 M
NO
between X05 (male) (4)

in wiring harness between
C01 (female) (3) and X05
NO
(male) (3) or between X05
(male) (3) and SW1 (1)
Repair or
replace
Repair or
replace
Defective swing lock

switch (internal short
circuit with ground)
Replace
Defective swing holding

brake relay (internal
short circuit or short
circuit with ground)
Replace
PC1100-6
TROUBLESHOOTING
C-4
PC1100-6
20-471
3
TROUBLESHOOTING
C-5
C-5 [E213] Disconnection in swing holding brake solenoid relay system

is displayed
fl When carrying out troubleshooting, always turn the swing lock prolix switch OFF.
a) When [E213] is displayed with swing lock switch OFF
fl Carry out troubleshooting with the swing lock switch OFF.
Cause
Defective pump
controller
3 YES
Is resistance
between R20
(female) (2) and
chassis ground
normal?
YES
Is voltage
YES between R20 (1)

and chassis
ground normal?
1
Interchange relay
R20 with other
relay. Is [E213]
displayed?
NO
Turn starting
switch OFF.
Disconnect R20.
Min. 1 M
Start engine.
Operate swing
lever.
20 30 V
NO
When C01 is
disconnected, is
voltage between X05
(male) (3) and chassis
ground norma?
YES Is there continuity

between X05
4
(male) (3) and (4)?
OFF.
Turn swing lock
switch OFF.
NO
YES
1
3 YES
Turn starting
Is there continuity
switch OFF.
between X05
Disconnect C17.
NO (female) (1) and
Max. 1
(2)?
Turn starting
switch OFF.
Disconnect X05.
20-472
3
Is resistance
between X05 (male)
(2) and chassis
ground normal?
Turn starting
switch OFF.
Disconnect X05.
Max. 1
NO
harness between C01
(female) (3) D26 X05
(male) (3)

disconnection or
defective contact)
b) When [E213] is displayed with swing lock switch at LOCK

fl Carry out troubleshooting with the swing lock switch at LOCK.
YES
2

harness between X05 (male)
(4) and R20 (female) (1)

switch (internal
Disconnect X05.
NO disconnection or
Turn starting switch
defective contact)
NO
chassis ground
normal?
Replace
Repair or
replace
5 YES contact, short circuit with
Disconnect C01
and X05.
Turn starting
switch ON.
Max. 1 V
Turn starting
switch ON.
harness between R20
ground
Remedy
NO
Cause
Repair or
replace
Replace
Repair or
replace
Replace
Remedy
Defective pump
controller
Replace
harness between C17
(female) (16) and X05
(male) (1)
Repair or
replace
harness between X05
ground

switch (internal
disconnection or
defective contact)
Repair or
replace
Replace
PC1100-6
TROUBLESHOOTING
C-5
PC1100-6
20-473
3
TROUBLESHOOTING
C-6
C-6 [E201] Short circuit in CO cancel solenoid system is displayed

Cause
3 YES
YES
2
YES
1
Interchange V07
with other
solenoid. Is [E201]
dislayed?
Start engine.
Turn heavy lift
switch ON.
Operate boom
RAISE.
V07 (male) (1) and
(2), (2) and chassis as
shown in table?
Turn starting
switch OFF.
Disconnect V07.
Is residence
between C01
(female) (8) and
chassis ground
normal?
Turn starting
switch OFF.
Disconnect C01.
20 60
NO
Remedy
Defective pump
controller
Replace

in wiring harness
and V07 (female) (2)
Repair or
replace
Defective CO cancel
solenoid (internal short
circuit or short circuit
with ground)
Replace
NO
NO
Table
Between V07 (male) (1) (2)
20 60
Between V07 (male) (2) chassis
Min. 1 M
20-474
3
PC1100-6
TROUBLESHOOTING
C-7
C-7 [E211] Disconnection in CO cancel solenoid system is displayed

Cause
4 YES Defective pump

Is voltage between
and chassis
ground normal?
3
YES
2
Is resistance
YES between V07

1
Interchange V07
with other
solenoid. Is
[E211] displayed?
Turn starting
switch ON.
Turn heavy lift
switch OFF.
(male) (1) and (2)

normal?
Turn starting
switch OFF.
Disconnect V07.
20 60
Is resistance
between C01
(female) (8) and
chassis ground
normal?
controller
NO
Disconnect C01.
Turn starting
switch OFF.
Max. 1 V
5 YES disconnection in wiring
Is resistance
Turn starting
between V07
switch OFF.
(female) (1) and
Disconnect C01. NO chassis ground
20 60
normal?
NO
Turn starting
switch OFF.
Disconnect V07.
Max. 1
harness between C01

(female) (8) and V07
(female) (2)
harness between V07
ground
Remedy
Replace
Repair or
replace
Repair or
replace
Repair or
replace
NO
NO
Defective CO cancel
solenoid (internal
disconnection or
defective contact)
Replace
PC1100-6
20-475
3
TROUBLESHOOTING
C-8
C-8 [E202] Short circuit in straight-travel solenoid system is displayed

Cause
3 YES
YES
2
YES
1
Interchange V03
with other
solenoid. Is
[E202] displayed?
Start engine.
Operate left and
right travel
levers and work
equipment at
same time.
Is resistance
between V03 (male)
(1) and (2), (2) and
chassis as shown in
table?
Turn starting
switch OFF.
Disconnect V03.
Is resistance
between C01
(female) (2) and
chassis ground
normal?
Turn starting
switch OFF.
Disconnect C01.
20 60
NO
Remedy
Defective pump
controller
Replace

in wiring harness
Repair or
replace
Defective straight-travel
with ground)
Replace
NO
NO
Table
20 60
Min. 1 M
20-476
3
PC1100-6
TROUBLESHOOTING
C-9
C-9 [E212] Disconnection in straight-travel solenoid system is displayed

Cause

Is voltage between
YES C01 (male) (2) and
chassis ground
normal?
3
YES
2
Is resistance
YES between V03

1
Interchange V03
with other
solenoid. Is
[E212] displayed?
(male) (1) and (2)

normal?
Turn starting
switch OFF.
Disconnect V03.
20 60
Is resistance
between C01
(female) (2) and
chassis ground
normal?
controller

Disconnect C01. NO
Turn starting
switch ON.
Max. 1 V
5 YES disconnection in wiring
harness between C01
Is resistance
Turn starting
between V03
switch OFF.
(female) (2)
(female) (1) and
20 60
normal?
NO harness between V03
Turn starting
switch OFF.
ground
Disconnect V03.
Max. 1
Remedy
Replace
Repair or
replace
Repair or
replace
Repair or
replace
NO
Turn starting
switch ON.
NO
Defective straight-travel
solenoid (internal
disconnection or
defective contact)
Replace
PC1100-6
20-477
3
TROUBLESHOOTING
C-10
C-10 [E204] Short circuit in 2-stage relief solenoid system is displayed

Cause
3 YES
YES
2
YES
1
Interchange V02
with other
solenoid. Is
[E204] displayed?
Start engine.
Turn heavy lift
switch ON.
Operate boom
RAISE.
Is resistance
between V02 (male)
(1) and (2), (2) and
chassis as shown in
table?
Turn starting
switch OFF.
Disconnect V02.
Is resistance
between C01
(female) (10) and
chassis ground
normal?
Turn starting
switch OFF.
Disconnect C01.
20 60
NO
Remedy
Defective pump
controller
Replace

in wiring harness
(10) and V02 (female) (2)
Repair or
replace
Defective 2-stage relief

with ground)
Replace
NO
NO
Table
20 60
Min. 1 M
20-478
3
PC1100-6
TROUBLESHOOTING
C-11
C-11 [E214] Disconnection in 2-stage relief solenoid system is displayed

Cause

Is voltage between
and chassis
ground normal?
3
YES
2
Is resistance
YES between V02

1
Interchange V02
with other
solenoid. Is
[E214] displayed?
(male) (1) and (2)

normal?
Turn starting
switch OFF.
Disconnect V02.
20 60
Is resistance
between C01
(female) (10) and
chassis ground
normal?
controller

Disconnect C01. NO (10) and V02 (female) (2)
Turn starting
switch ON.
Max. 1 V
5 YES
Is resistance
Turn starting
between V02
switch OFF.
(female) (1) and
20 60
normal?
harness between C01

(female) (2)
Turn starting
switch OFF.
ground
Disconnect V02.
Remedy
Replace
Repair or
replace
Repair or
replace
Repair or
replace
Max. 1
NO
Turn starting
switch ON.
NO
Defective 2-stage relief

solenoid (internal
disconnection or
defective contact)
Replace
PC1100-6
20-479
3
TROUBLESHOOTING
C-12
C-12 [E205] Short circuit in swing priority solenoid system is displayed

Cause
3 YES
YES
2
YES
1
Interchange V01
with other
solenoid. Is
[E205] displayed?
Start engine.
Turn swing
priority mode
switch ON.
Operate swing.
Is resistance
between V01 (male)
(1) and (2), (2) and
chassis as shown in
table?
Turn starting
switch OFF.
Disconnect V01.
Is resistance
between C01
(female) (5) and
chassis ground
normal?
Turn starting
switch OFF.
Disconnect C01.
20 60
NO
Remedy
Defective pump
controller
Replace

in wiring harness
Repair or
replace
Defective swing priority

with ground)
Replace
NO
NO
Table
20 60
Min. 1 M
20-480
3
PC1100-6
TROUBLESHOOTING
C-13
C-13 [E215] Disconnection in swing priority solenoid system is

displayed
Cause

Is voltage between
and chassis
ground normal?
3
YES
2
Is resistance
YES between V01

1
Interchange V01
with other
solenoid. Is
[E215] displayed?
(male) (1) and (2)

normal?
Turn starting
switch OFF.
Disconnect V01.
20 60
Is resistance
between C01
(female) (5) and
chassis ground
normal?
controller

Disconnect C01. NO and V01 (female) (2)
Turn starting
switch ON.
Max. 1 V
5 YES
harness between C01
Is resistance
Turn starting
between V01
(female) (2)
switch OFF.
(female) (1) and
20 60
normal?
Turn starting
switch OFF.
ground
Disconnect V01.
Max. 1
Remedy
Replace
Repair or
replace
Repair or
replace
Repair or
replace
NO
Turn starting
switch ON.
NO
Defective swing priority

solenoid (internal
disconnection or
defective contact)
Replace
PC1100-6
20-481
3
TROUBLESHOOTING
C-14
C-14 [E206] Short circuit in travel speed solenoid system is displayed

Cause
3 YES
YES
2
YES
1
Interchange V06
with other
solenoid. Is
[E206] displayed?
Start engine.
Set travel speed
switch to Hi.
Operate travel
lever.
Is resistance
between V06 (male)
(1) and (2), (2) and
chassis as shown in
table?
Turn starting
switch OFF.
Disconnect V06.
Is resistance
between C01
(female) (9) and
chassis ground
normal?
Turn starting
switch OFF.
Disconnect C01.
20 60
NO
Remedy
Defective pump
controller
Replace

in wiring harness
Repair or
replace
Defective travel speed

with ground)
Replace
NO
NO
Table
20 60
Min. 1 M
20-482
3
PC1100-6
TROUBLESHOOTING
C-15
C-15 [E216] Disconnection in travel speed solenoid system is displayed

Cause

Is voltage between
and chassis
ground normal?
3
YES
2
Is resistance
YES between V06

1
Interchange V06
with other
solenoid. Is
[E216] displayed?
(male) (1) and (2)

normal?
Turn starting
switch OFF.
Disconnect V06.
20 60
Is resistance
between C01
(female) (9) and
chassis ground
normal?
controller

Disconnect C01. NO and V06 (female) (2)
Turn starting
switch ON.
Max. 1 V
5 YES
harness between C01
Is resistance
Turn starting
between V06
(female) (2)
switch OFF.
(female) (1) and
20 60
normal?
Turn starting
switch OFF.
ground
Disconnect V06.
Max. 1
Remedy
Replace
Repair or
replace
Repair or
replace
Repair or
replace
NO
Turn starting
switch ON.
NO
Defective travel speed

solenoid (internal
disconnection or
defective contact)
Replace
PC1100-6
20-483
3
TROUBLESHOOTING
C-16
C-16 [E217] Model selection input error is displayed

Cause
Remedy
Defective pump
controller
YES
Replace
1
Is display for
monitoring codes
[02][22] as shown
in Table 1?
Turn starting
switch ON.
YES
2
NO
Is voltage between
C17 (5)(6)(13)(14)
and chassis ground
as shown in Table
2?
Turn starting
switch ON
Defective contact,
circuit with ground, or
short circuit in wiring
harness in circuit where
voltage is defective in
Item 2.
3 YES
NO
Is resistance
between C09
(female) (8) and
(1)(2)(3)(4) as shown
in Table 3?
Turn starting
switch OFF.
Disconnect C09.
Defective model
selection connector
(internal disconnection,
defective contact, short
circuit)
NO
Monitoring code
Repair or
replace
Replace
Display
02
22

input condition
Table 2
C17
Between (5) chassis
Between (6) chassis
Between (13) chassis Between (14) chassis
Voltage
Max. 1 V
20 30 V
20 30 V
20 30 V
C09 (female)
Between (8) (1)
Between (8) (2)
Between (8) (3)
Between (8) (3)
Resistance
Max. 1
Min. 1 M
Max. 1
Min. 1 M
Table 3
20-484
3
PC1100-6
TROUBLESHOOTING
C-16
PC1100-6
20-485
3
TROUBLESHOOTING
C-17
C-17 [E227] Abnormality in engine speed sensor (2) system is

displayed
Cause
3 YES
YES
2
Is resistance
YES between C16
(female) (2) and

chassis ground as
shown in table?
1
Is resistance
between E07 (male)
(1) and (2), (1)(2)
and chassis ground
as shown in table?
Turn starting
switch OFF.
Disconnect E07.
Turn starting
switch OFF.
Disconnect C16.
500 1000
Is resistance
between C16
(female) (1) and
chassis ground
normal?
Turn starting
switch OFF.
Disconnect C16.
Max. 1
NO
NO
Defective pump
controller
harness between C16
ground
sensor (2) (internal
disconnection, defective
contact, short circuit)
NO
Remedy
Replace
Repair or
replace
Repair or
replace
Replace
Table
E07 (male)
Resistance
Between (1) (2)
500 1000
Min. 1 M
20-486
3
PC1100-6
TROUBLESHOOTING
C-18
C-18 [E228] Abnormality in auto-deceleration output system is

displayed
Cause
YES
Remedy
Defective pump
controller
Replace
Defective engine
controller
Replace
harness between C01
(female) (12)
Repair or
replace

in wiring harness
Replace
1
Is voltage
between C01 (4)
and chassis
ground normal?
Turn starting
switch ON.
Turn autodeceleration
switch OFF.
Min. 5 V
3 YES
YES
2
NO
Is resistance
between C01
(female) (4) and
chassis ground
normal?
Turn starting
switch OFF.
Disconnect C01
and E17.
Min. 1 M
Is resistance
between C01
(female) (12)
normal?
Turn starting
NO
switch OFF.
Disconnect C01 and E17.
Max. 1
NO
PC1100-6
20-487
3
TROUBLESHOOTING
C19
C-19 Abnormality in swing holding brake system (no service code is

displayed)
fl Even if an abnormality occurs in the swing holding brake system, the service code is not displayed
on the monitor panel.
a) When swing holding brake is not actuated (short circuit)
Cause
YES
1
Interchange R20
with other relay.
Does condition
become normal?
2 YES
Start engine.
NO
Interchange swing
holding brake solenoid
with other solenoid.
Does condition become
normal?
NO
Start engine.
Remedy

short circuit or short
Replace

V04 (female) (2) and
V11 (female) (2)
Repair or
replace

brake solenoid (spool
stuck)
Repair or
replace
b) When swing holding brake cannot be released (disconnection)

Cause

disconnection or defective
contact)
YES
2
Interchange R20
YES with other relay.
Does condition
become normal?
Start engine.
Is resistance
between V04 and
V11 (male) (1) (2),
(2) chassis ground
as shown in table?
4 YES harness between R20

Is resistance
YES between V04 and
V11 (female) (1) and
3
chassis ground
Is voltage
normal?
between R20 (3)
OFF.
NO and chassis
Disconnect V04 and
ground normal?
V11.
Max. 1
Turn starting
switch ON.
20 30 V
Turn starting
switch OFF.
Disconnect V04
and V11.
NO
(female) (5) V04 (female)

(2) or V11 (female) (2)
NO
harness between V04
(female) (1) or V11 (female)
(1) chassis ground
between fuse 2 outlet and
R20 (female) (3)
brake solenoid (internal
contact, internal short circuit,
or short circuit with ground)
NO
Remedy
Replace
Repair or
replace
Repair or
replace
Repair or
replace
Repair or
replace
Table
Between V04, V11 (male) (1) (2)
20 60
Between V04, V11 (male) (2) chassis ground
Min. 1 M
20-488
3
PC1100-6
TROUBLESHOOTING
C19
PC1100-6
20-489
3
TROUBLESHOOTING
C-20
C-20 Abnormality in machine push-up solenoid system (no service

code is displayed)
fl Even if an abnormality occurs in the machine push-up solenoid system, the service code is not
displayed on the monitor panel.
a) When machine push-up switch is set to low-pressure setting, system does not switch to lowpressure setting (disconnection)
fl Carry out troubleshooting with the machine push-up switch at the low-pressure setting position.
Cause
harness between V05
ground
YES
2
Is resistance
between V05
(male) (1) and (2)
normal?
4 YES contact, short circuit with

Is resistance
Disconnect V05.
Is voltage
Turn starting
between M38 (2)
switch ON.
and chassis
NO
20 30 V
ground normal?
YES
between M38 (1)
3
and (2) normal?
Disconnect M38.
Turn starting
switch ON.
20 30 V
Turn starting
switch OFF.
Disconnect V05.
20 60
NO
Repair or
replace
Is voltage
YES between V05 (2)
and chassis
ground normal?
Remedy

OFF.
Disconnect M38.
Set to low pressure.
Max. 1
NO

between M38 (male) (1) and
V05 (female) (2)
Defective machine push-
NO up switch
between fuse 2 and M38
(male) (2)
Defective machine pushup switch (internal
contact, or short circuit
with ground)
Repair or
replace
Repair or
replace
Repair or
replace
Replace
b) When machine push-up switch is set to high-pressure setting, system does not switch to highpressure setting (short circuit)
fl Carry out troubleshooting with the machine push-up switch at the high-pressure setting position.
Cause
1 YES
Is resistance
between M38
(female) (1) and
(2) normal?
Turn starting
NO
Remedy

between M38 (male) (1)
Repair or
replace
Defective machine pushup switch (internal short

circuit)
Replace
switch OFF.
Disconnect M38.
Set to high
pressure.
Min. 1 M
20-490
3
PC1100-6
TROUBLESHOOTING
C-20
PC1100-6
20-491
3
TROUBLESHOOTING
C-21
C-21 Abnormality in boom shockless solenoid system (no service code

is displayed)
fl Even if an abnormality occurs in the boom shockless solenoid system, the service code is not
displayed on the monitor panel.
a) When boom shockless switch is turned OFF, shockless mode is not canceled (disconnection)
fl Carry out troubleshooting with the boom shockless switch OFF.
YES
YES
Interchange R15
YES with other relay.
Does condition
become normal?
YES
Start engine.
3
Is voltage
YES between R15 (1)
and chassis
ground normal?
Is voltage between
V09, V10 (2) and
NO chassis ground
normal?
Disconnect V09
and V10.
Turn starting
switch ON.
20 30 V
1
Is resistance
between V09,
V10 (male) (1)
and (2) normal?
5
Is resistance
YES between R15

4
Is voltage
between R15 (3)
NO and chassis
ground normal?
Turn starting
switch OFF.
Disconnect V09
and V10.
20 60
Turn starting
switch ON.
20 30 V
NO
(female) (2) and

chassis ground
normal?
Turn starting
switch OFF.
Disconnect R15.
Max. 1
NO
Turn starting
switch ON.
20 30 V
NO
NO
20-492
3
PC1100-6
TROUBLESHOOTING
C-21
Cause
8 YES
Is resistance
YES between M33
(female) (1) and
7
(3) normal?
Is voltage between
M33 (female) (1)
and chassis
ground normal?
Disconnect M33.
Turn starting
switch ON.
20 30 V
Turn starting
NO
switch OFF.
Disconnect M33.
Turn boom shockless switch OFF.
Max. 1
NO
Defective boom
shockless relay (internal
disconnection or
defective contact)
Replace
harness between V09
(female) (1) and V10 (female)
(1) chassis ground
Repair or
replace
harness between R15
(female) (5) V09 (female)
(2) and V10 (female) (2)
between M33 (female) (3)
Defective boom shockless
switch (internal
disconnection or defective
contact)
M33 (female) (1)
Repair or
replace
Repair or
replace
Replace
Repair or
replace
harness between R15
ground
Repair or
replace
R15 (female) (3)
Repair or
replace
Defective boom shockless

solenoid at side where
resistance is defective
(internal disconnection or
defective contact)
PC1100-6
Remedy
Replace
20-493
3
TROUBLESHOOTING
C-21
b) When boom shockless switch is turned ON, shockless mode is not actuated (short circuit)
fl Carry out troubleshooting with the boom shockless switch ON.
Cause
Defective boom
shockless relay (internal
short circuit)
YES
1
Interchange R15
with other relay.
Does condition
become normal?
Start engine.
Short ciruit with power

V09 (female) (2) or V10
(female) (2)
YES
2
Is voltage
between R15 (1)
NO and chassis
ground normal?
Turn starting
switch ON.
Max.1 V
3 YES
Is resistance
between M33 (1)
NO and (3) normal?
Turn starting
switch OFF.
Disconnect M33.
Min. 1 M
NO
Remedy
Replace
Repair or
replace
Short ciruit with power

between M33 (female)
(3) and R15 (female) (1)
Repair or
replace
Defective boom
shockless switch
(internal short circuit)
Replace
20-494
3
PC1100-6
TROUBLESHOOTING OF PUMP CONTROLLER

INPUT SIGNAL SYSTEM
(F MODE)
Electrical circuit diagram of F mode ....................................................................................................20-502

F- 1
[Bit pattern 20-(1)] (Swing to right oil pressure switch) does not light up ........................... 20-504
F- 2
[Bit pattern 20-(2)] (R.H. travel oil pressure switch) does not light up .................................20-505
F- 3
[Bit pattern 20-(3)] (Boom LOWER oil pressure switch) does not light up ........................... 20-506
F- 4
[Bit pattern 20-(4)] (Boom RAISE oil pressure switch) does not light up .............................20-507
F- 5
[Bit pattern 20-(5)] (Arm IN oil pressure switch) does not light up .......................................20-508
F- 6
[Bit pattern 20-(6)] (Arm OUT oil pressure switch) does not light up ...................................20-509
F- 7
[Bit pattern 21-(1)] (Bucket CURL oil pressure switch) does not light up .............................20-510
F- 8
[Bit pattern 21-(2)] (Bucket DUMP oil pressure switch) does not light up ............................ 20-511
F- 9
[Bit pattern 21-(5)] (L.H. travel oil pressure switch) does not light up .................................. 20-512
F-10 [Bit pattern 26-(5)] (Swing to left oil pressure switch) does not light up .............................20-513
F-11 [Bit pattern 21-(3)] (Swing lock switch) does not light up ......................................................20-514
PC1100-6
20-501
3
TROUBLESHOOTING
ELECTRICAL CIRCUIT DIAGRAM OF F MODE
20-502
3
PC1100-6
TROUBLESHOOTING
PC1100-6
20-503
3
TROUBLESHOOTING
F-1
F-1 [Bit pattern 20-(1)] (Swing to right oil pressure switch) does not
light up
connector and inserting the T-adapter, or when removing the T-adapter and returning the connector to its original position, if the monitoring mode display returns to normal, the problem has
been removed.
When operating the swing with the engine started, set the swing lock switch to LOCK.
(When operating the swing with the engine stopped, charge the accumulator first.)
Cause
YES
1
Is voltage
between C16 (5)
and chassis
ground normal?
3 YES
Is resistance
YES between S08

(female) (1) and
2
chassis ground
Start engine.
normal?
Swing lever at
S08 (male) (1) and (2)
Turn starting
normal, and is circuit
neutral: 20 30V
switch OFF.
NO insulated from
Swing lever
Disconnect S08.
chassis?
operated to right:
Max. 1
Max. 1 V Disconnect S08.
Start engine.
NO
Swing lever at
neutral: Min. 1 M
Swing lever
operated to right:
Max. 1
NO
Remedy
Defective pump
controller
Replace
and S08 (female) (2)
Repair or
replace
harness between S08
ground
Defective right swing
pressure switch (internal
Repair or
replace
Replace
F-1 Related electrical circuit diagram
20-504
3
PC1100-6
TROUBLESHOOTING
F-2
F-2 [Bit pattern 20-(2)] (R.H. travel oil pressure switch) does not light
up
been removed.
When operating the travel with the engine started, check that the area around the machine is safe.
(When operating the travel with the engine stopped, charge the accumulator first.)
Cause
Defective pump
controller
YES
1
Is voltage
between C16 (13)
and chassis
ground normal?
3 YES
YES
2
Is resistance
between S01, S11
(female) (1) and
chassis ground
normal?
Start engine.
R.H. travel lever
S01, S11 (male) (1)
Turn starting
NO
at neutral:
and (2) normal, and
switch OFF.
20 30V NO is circuit insulated
Disconnect S01 and S11.
from chassis?
R.H. travel lever
Max. 1
Disconnect S01
operated:
and S11.
Max. 1 V
NO
Start engine.
R.H. travel lever at
neutral: Min. 1 M
R.H. travel lever
operated: Max. 1
S01 (female) (2) or S11
(female) (2)
harness between S01
(female) (1) or S11 (female)
(1) chassis ground
Defective R.H. travel
FORWARD pressure switch
or R.H. travel REVERSE
Remedy
Replace
Repair or
replace
Repair or
replace
Replace
PC1100-6
20-505
3
TROUBLESHOOTING
F-3
F-3 [Bit pattern 20-(3)] (Boom LOWER oil pressure switch) does not
light up
been removed.
When operating the work equipment with the engine started, check that the area around the
machine is safe and move the work equipment only slightly.
(When operating the boom LOWER with the engine stopped, charge the accumulator first.)
Cause
YES
1
Is voltage
between C16 (10)
and chassis
ground normal?
3 YES
YES
2
Is resistance
between S04
(female) (1) and
chassis ground
normal?
Start engine.
Boom lever at
S04 (male) (1) and (2)
Turn starting
neutral: 20 30V
switch OFF.
NO
insulated from
Boom lever
Disconnect S04.
chassis?
operated to
Max. 1
Disconnect S04 .
LOWER: Max. 1 V
Start engine.
NO
Boom lever at
neutral: Min. 1 M
Boom lever
operated to
LOWER: Max. 1
NO
Remedy
Defective pump
controller
Replace
Repair or
replace
harness between S04
ground
Repair or
replace
Defective boom LOWER

Replace
20-506
3
PC1100-6
TROUBLESHOOTING
F-4
F-4 [Bit pattern 20-(4)] (Boom RAISE oil pressure switch) does not
light up
been removed.
(When operating the boom RAISE with the engine stopped, charge the accumulator first.)
Cause
YES
1
Is voltage
between C17 (2)
and chassis
ground normal?
3 YES
YES
2
Is resistance
between S02
(female) (1) and
chassis ground
normal?
Start engine.
Boom lever at
S02 (male) (1) and (2)
Turn starting
neutral: 20 30V
switch OFF.
NO
insulated from
Boom lever
Disconnect S02.
chassis?
operated to
Max. 1
RAISE: Max. 1 V
Disconnect S02 .
Start engine.
NO
Boom lever at
neutral: Min. 1 M
Boom lever
operated to RAISE:
Max. 1
NO
Remedy
Defective pump
controller
Replace
Repair or
replace
harness between S02
ground
Defective boom RAISE
Repair or
replace
Replace
PC1100-6
20-507
3
TROUBLESHOOTING
F-5
F-5 [Bit pattern 20-(5)] (Arm IN oil pressure switch) does not light up
been removed.
Cause
YES
1
Is voltage
between C17 (3)
and chassis
ground normal?
3 YES
YES
2
Is resistance
between S05
(female) (1) and
chassis ground
normal?
Start engine.
Arm lever at
S05 (male) (1) and (2)
Turn starting
neutral: 20 30V
switch OFF.
NO
insulated from
Arm lever
Disconnect S05.
chassis?
operated to IN:
Max. 1
Disconnect S05 .
Max. 1 V
Start engine.
NO
Arm lever at
neutral: Min. 1 M
Arm lever
operated to IN:
Max. 1
NO
Remedy
Defective pump
controller
Replace
Repair or
replace
harness between S05
ground
Repair or
replace
Defective arm IN pressure

switch (internal
Replace
20-508
3
PC1100-6
TROUBLESHOOTING
F-6
F-6 [Bit pattern 20-(6)] (Arm OUT oil pressure switch) does not light
up
been removed.
Cause
YES
1
Is voltage
between C17 (11)
and chassis
ground normal?
3 YES
YES
2
Is resistance
between S03
(female) (1) and
chassis ground
normal?
Start engine.
Arm lever at
S03 (male) (1) and (2)
Turn starting
neutral: 20 30V
switch OFF.
NO
insulated from
Arm lever
Disconnect S03.
chassis?
operated to OUT:
Max. 1
Max. 1 V Disconnect S03 .
Start engine.
NO
Arm lever at
neutral: Min. 1 M
Arm lever
operated to OUT:
Max. 1
NO
Remedy
Defective pump
controller
Replace
Repair or
replace
harness between S03
ground
Defective arm OUT
Repair or
replace
Replace
PC1100-6
20-509
3
TROUBLESHOOTING
F-7
F-7 [Bit pattern 21-(1)] (Bucket CURL oil pressure switch) does not
light up
been removed.
Cause
YES
1
Is voltage
between C16 (11)
and chassis
ground normal?
3 YES
YES
2
Is resistance
between S06
(female) (1) and
chassis ground
normal?
Start engine.
Bucket lever at
S06 (male) (1) and (2)
Turn starting
neutral: 20 30V
switch OFF.
NO insulated from
Bucket lever
Disconnect S06.
chassis?
operated to
Max. 1
CURL: Max. 1 V
Disconnect S06 .
Start engine.
NO
Bucket lever at
neutral: Min. 1 M
Bucket lever
operated to CURL:
Max. 1
NO
Remedy
Defective pump
controller
Replace
Repair or
replace
harness between S06
ground
Defective bucket CURL
Repair or
replace
Replace
20-510
3
PC1100-6
TROUBLESHOOTING
F-8
F-8 [Bit pattern 21-(2)] (Bucket DUMP oil pressure switch) does not
light up
been removed.
fl If service PPC pressure switch is equipped, check the circuit at the same time.
Cause
YES
1
Is voltage
between C16 (12)
and chassis
ground normal?
3 YES
YES
2
Is resistance
between S07
(female) (1) and
chassis ground
normal?
Start engine.
Bucket lever at
S07 (male) (1) and (2)
Turn starting
neutral: 20 30V
switch OFF.
NO insulated from
Bucket lever
Disconnect S07.
chassis?
operated to
Max. 1
Disconnect S07 .
DUMP: Max. 1 V
Start engine.
NO
Bucket lever at
neutral:Min. 1 M
Bucket lever
operated to
DUMP: Max. 1
NO
Remedy
Defective pump
controller
Replace
Repair or
replace
harness between S07
ground
Repair or
replace
Defective bucket DUMP

Replace
PC1100-6
20-511
3
TROUBLESHOOTING
F-9
F-9 [Bit pattern 21-(5)] (L.H. travel oil pressure switch) does not light
up
been removed.
When operating the travel with the engine started, check that the area around the machine is safe.
Cause
Defective pump
controller
YES
1
Is voltage
between C16 (6)
and chassis
ground normal?
3 YES
YES
2
Start engine.
L.H. travel lever
S12, S13 (male) (1)
at neutral:
and (2) normal, and
20 30V NO is circuit insulated
from chassis?
L.H. travel lever
Disconnect S12
operated to IN:
and S13.
Max. 1 V
Start engine.
L.H. travel lever
at neutral:
Min. 1 M
L.H. travel lever
operated :
Max. 1
Is resistance
between S12,S13
(female) (1) and
chassis ground
normal?
Turn starting
NO
switch OFF.
Disconnect S12 and S13.
Max. 1
NO
S12 (female) (2) or S13
(female) (2)
harness between S12
(female) (1) or S13 (female)
(1) and chassis ground
Defective L.H. travel
FORWARD pressure switch
or L.H. travel REVERSE
Remedy
Replace
Repair or
replace
Repair or
replace
Replace
20-512
3
PC1100-6
TROUBLESHOOTING
F-10
F-10 [Bit pattern 26-(5)] (Swing to left oil pressure switch) does not
light up
been removed.
When operating the swing with the engine started, set the swing lock switch to LOCK.
Cause
YES
Defective pump
controller
1
Is voltage
between C17 (7)
and chassis
ground normal?
3 YES
YES
2
Start engine.
Swing lever at
S10 (male) (1) and (2)
neutral: 20 30V
NO insulated from
Swing lever
chassis?
operated to left:
Disconnect S10 .
Max. 1 V
Start engine.
Swing lever at
neutral:
Min. 1 M
Swing lever
operated to left:
Max. 1
Is resistance
between S10
(female) (1) and
chassis ground
normal?
Turn starting
switch OFF.
Disconnect S10.
Max. 1
NO
NO
Remedy
Replace
Repair or
replace
harness between S10
ground
Repair or
replace
Defective left swing

Replace
PC1100-6
20-513
3
TROUBLESHOOTING
F-11
F-11 [Bit pattern 21-(3)] (Swing lock switch) does not light up
been removed.
fl Check that the swing lock lamp display on the monitor panel is normal.
(If the swing lock lamp does not light up, carry out troubleshooting for M-fifi first.)
Cause
Defective pump
controller
YES
1
Is voltage
between C17 (16)
and chassis
ground normal?
3 YES
Is resistance
YES between X05
(male) (2) and
2
chassis ground
Turn starting
normal?
switch ON.
X05 (female) (1) and
Turn starting
(2) normal, and is
Swing lock
switch OFF.
NO circuit insulated from
switch ON:
Disconnect X05
chassis?
Max. 1V
Max. 1
Turn starting
Swing lock
switch OFF:
20 30 V
switch OFF
NO
Disconnect X05.
Swing lock
switch ON:
Max. 1
Swing lock
switch OFF:
Min. 1 M
NO
and X05 (male) (2)
harness between X05
ground
switch (internal
Remedy
Replace
Repair or
replace
Repair or
replace
Replace
20-514
3
PC1100-6
TROUBLESHOOTING OF HYDRAULIC,
MECHANICAL SYSTEM
(H MODE)
Table of failure modes and causes ......................................................................................................20-552

Before carrying out troubleshooting of hydraulic system (H Mode) ................................................20-554
H- 1 Speeds of all work equipment, swing, travel are slow or lack power .................................. 20-560
H- 2 There is excessive drop in engine speed, or engine stalls .....................................................20-562
H- 3 No work equipment, travel, swing move ..................................................................................20-564
H- 4 Abnormal noise generated (from around pump) .....................................................................20-565
H- 5 Boom is slow or lacks power .....................................................................................................20-566
H- 6 Arm is slow or lacks power ........................................................................................................20-568
H- 7 Bucket is slow or lacks power ....................................................................................................20-568
H- 8 Boom does not move ..................................................................................................................20-569
H- 9 Arm does not move .....................................................................................................................20-569
H-10 Bucket does not move .................................................................................................................20-569
H-11 Excessive hydraulic drift .............................................................................................................20-570
H-12 Excessive time lag .......................................................................................................................20-570
H-13 Boom shockless function is not actuated or cannot be canceled ..........................................20-571
H-14 Machine deviates naturally to one side during travel operations .........................................20-572
H-15 Deviation is excessive when starting ........................................................................................20-574
H-16 Travel deviation is excessive during compound operations ..................................................20-575
H-17 Travel speed is slow or lacks power .........................................................................................20-575
H-18 Travel does not move (one side only) ......................................................................................20-576
H-19 Travel speed does not switch .....................................................................................................20-577
H-20 Does not swing ............................................................................................................................20-578
H-21 Swing speed is slow or swing acceleration is poor ................................................................20-579
H-22 In compound operations with bucket, swing speed is
slow or swing acceleration is poor .....................................................................................20-580
H-23 In compound operations with boom when boom priority is ON,
swing speed is slow or swing acceleration is poor ..........................................................20-580
H-24 Excessive overrun when stopping swing ..................................................................................20-581
H-25 Excessive shock when stopping swing .....................................................................................20-582
H-26 Excessive abnormal noise when stopping swing ....................................................................20-583
H-27 Excessive hydraulic drift of swing .............................................................................................20-583
PC1100-6
20-551
3
TROUBLESHOOTING
TABLE OF FAILURE MODES AND CAUSES

Control valve
Hydraulic pump
All work equipment,

swing, travel
Jet sensor valve
Suction valve
Safety-suction valve
Swing compensation valve
Straight-travel valve
Spool
Main relief valve
Abnormal noise generated (from around pump)
In normal mode
Work equipment system
Valve
TVC valve
CO NC valve
Servo valve
Failure mode
Pump
Hydraulic oil tank strainer
Parts causing failure
With heavy lift ON

Boom does not move
Arm does not move

Excessive time lag
Boom
Arm, bucket
Travel system

Machine deviates naturally
to one side when traveling
Deviates in same direction in FORWARD and REVERSE
Deviation is excessive
when starting
Only at full stroke
Deviates in opposite direction in FORWARD and REVERSE


Does not travel
(one side only)


Does not swing
Swing system
Swing speed is slow or swing acceleration is poor
Both left and right

One direction only
Both left and right

One direction only
Both left and right

One direction only
Both left and right

One direction only
Both left and right
One direction only
20-552
3
PC1100-6
PC1100-6
Engine
Final drive
Swing machinery
PTO
Swing priority
Swing holding brake
Travel speed
Straight-travel
Boom shockless
Control
pump
Machine push-up
2-stage relief
CO cancel
Swing compensation pilot valve
Swing PPC shuttle valve
Boom shockless valve
PPC valve
Relief valve
Travel motor
Pump
Parking brake
Speed selector servo valve
Safety valve
Counterbalance valve
Swing motor
Travel motor proper, internal leakage
Back pressure compensation valve
Swing holding brake
Suction valve
Safety valve
Swing motor proper, internal leakage
Center swivel joint
Hydraulic cylinder
Boom LOWER regeneration valve
Jet sensor orifice
TROUBLESHOOTING
Solenoid valve
H-1
H-2
H-3
H-4
H-5
H-6
H-7
H-8
H-10
H-9
H-11
H-12
H-13
H-14
H-15
H-16
H-17
H-18
H-19
H-20
H-21
H-22
H-23
H-24
H-25
H-26
H-27
20-553
TROUBLESHOOTING
BEFORE CARRYING OUT TROUBLESHOOTING

OF HYDRAULIC SYSTEM (H MODE)
BEFORE CARRYING OUT TROUBLESHOOTING OF HYDRAULIC

SYSTEM (H MODE)
20-554
3
PC1100-6
TROUBLESHOOTING
1. Actuation and combination of hydraulic

pumps
Three tandem pumps (total of 6 pumps)
are used in the work equipment, travel,
and swing circuits: No. 1 pump
(HPV95+95), No. 2 pump (HPV95+95), and
No. 3 pump (HPV160+160)
The oil from the No. 1 front pump and
No. 2 front pump merges and flows to
the R.H. 4-spool valve; the oil from the
No. 1 rear pump and No. 2 rear pump
merges and flows to the L.H. 5-spool
valve; and the oil from the No. 3 front
rear pump and No. 3 rear pump merges
and flows to the swing 4-spool valve.
The TVC control for the No. 1 pump, No.
2 pump, and No. 3 pump is all carried
out in the same way by the TVC valve
installed to the No. 1 rear
The CO NC control for the No. 1 front
pump and No. 2 front pump is carried
out in the same way by the CO NC valve
installed to the No. 1 front pump and by
the jet sensor installed to the R.H. 4-spool
control
The CO NC control for the No. 1 rear
pump and No. 2 rear pump is carried out
in the same way by the CO NC valve
installed to the No. 1 rear pump and by
the jet sensor installed to the L.H. 5-spool
control
The CO NC control for the No. 3 front
rear pump and No. 3 rear pump is carried out in the same way by the CO NC
valve installed to the front pump and by
the jet sensor installed to the swing 4spool valve.
PC1100-6

2. Judgement procedure if work equipment is

slow and there is travel deviation to the
left:
The cause is probably one of the following:
1) Defective main relief of L.H. 5-spool
control valve
2) Defective jet sensor of L.H. 5-spool
control valve
3) Defective CO NC valve of No. 1 rear
pump
4) Defective servo valve of No. 1 rear
pump
5) Defective No. 1 rear pump
pump
If the problem occurs, measure the following to judge if the related part is defective.
1) Measure relief pressure to judge
main relief valve
2) Measure differential pressure to
judge jet sensor
3) Measure output pressure to judge
CO NC valve
As mentioned above, the oil flow in the
No. 1 pump and No. 2 pump merges, so
to judge if the problem is in the No. 1
pump servo valve and pump proper or
in the No. 2 pump servo valve and pump
proper, interchange the outlet port hoses
of the No. 2 pump between the front
and rear. It is then possible to judge as
follows which pump is defective.
1) If deviation is to left (no change), No.
1 rear pump is defective
2) If deviation is to right (opposite direction), No. 2 rear pump is defective
3) If the travel speed becomes slow, the
jet sensor is defective or the CO NC
valve is defective (if the left and right
relief pressures are normal).
Next, to judge if the problem is in the
servo valve or the pump proper, remove
the servo valve and test the individual
part, or judge from the stroke of the servo
piston.
fl For the actual procedure for judgement,
follow the Troubleshooting chart for
judgement when work equipment is slow
and there is travel deviation to the left.
20-555
3
TROUBLESHOOTING


slow and there is travel deviation to the
right:
fl For this problem, use the explanation
given 2. Judgement procedure if work
equipment is slow and there is travel
deviation to the left, but replace as follows.
Use R.H. 4-spool control valve instead of
L.H. 5-spool control valve; and use front
pump instead of rear pump.
For all other points, the judgement procedure is the same.
slow and swing is also slow (but travel
speed is normal):
The cause is probably one of the following:
1) Defective main relief valve of swing
4-spool control valve
2) Defective jet sensor of swing 4-spool
control valve
3) Defective CO NC valve of No. 3 pump
4) Defective servo valve of No. 3 front
pump
5) Defective No. 3 front pump
pump
If the problem occurs, measure the following to judge if the related part is defective.
1) Measure relief pressure to judge
main relief valve
2) Measure differential pressure to
judge jet sensor
3) Measure output pressure to judge
CO NC valve
To judge if the problem is in the servo
valve or the pump proper of the No. 3
front pump, or in the servo valve or the
pump proper of the No. 3 rear pump,
remove the servo valve and test the individual part, or judge from the stroke of
the servo piston.
fl It is impossible to judge if the problem
is in the front pump or the rear pump
while the pumps are mounted on the
machine, so remove the No. 3 pump assembly and test individually.
20-556
3
PC1100-6

TROUBLESHOOTING
Troubleshooting chart for judgement when work

equipment is slow and there is travel deviation
to the left
fl Use this troubleshooting chart to judge if
the location of the problem is in the No. 1
pump system or in the No. 2 pump system.
1. To judge if the servo valve is defective or
not, remove the servo valve and carry out a
test on the individual part, or measure the
servo piston stroke.
fl Carry out the individual test on the servo
piston at the specified repair shop.
2. If there is a big drop in speed and it seems
that there is an abnormality in the pump,
check the line filter also.
3. If there is only a small drop in speed and the
problem is not corrected by adjusting the
equipment, check the line filter also.
Causes
4
5
6
7
8
Item 2 is normal, and when No. 2 pump

outlet hoses are interchanged
between front and rear
16
17
18
Travel deviates to right
15
l m n
L.H. 5- R.H. 4spool spool

control control
valve
valve
A A A A
Left and right travel speeds both become slow
In Item 3, No. 1 rear servo valve is normal
In Item 4, No. 2 rear servo valve is normal
In Item 5, jet sensor differential pressure of L.H. 5-spool control valve is defective
Travel relief pressure of front pump is low

Item 11 is normal, and when No. 2 pump Machine deviates to right (no change)
outlet hoses are interchanged
Machine deviates to left (opposite direction)
between front and rear
Left and right travel speeds both become slow
In Item 12, No. 1 front servo valve is normal
In Item 13, No. 2 front servo valve is normal
In Item 14, jet sensor differential pressure of R.H. 4-spool control valve is defective
Item 15 is normal, but No. 1 rear NC valve output pressure is defective
fl Start troubleshooting from the top, and judge that the item with the most
fl Remedy
PC1100-6
A: Adjust
Defective jet sensor
Defective main relief valve
Defective jet sensor
Defective main relief valve
Defective pump
Defective servo valve
Front Rear
pump pump
Defective pump
Defective pump
Defective CO NC valve
Defective pump
g h
No. 2 pump
Rear
pump
Machine deviates to left (no change)
There is travel deviation to right, and work equipment speed is slow
14
Machine deviates to right (opposite direction)
10
13
Travel relief pressure of rear pump is low
Item 6 is normal, but No. 1 rear NC valve output pressure is defective
12
X X X X X X X X X X X X X X
9
11
There is travel deviation to left, and work equipment speed is slow

Travel deviates to left
Front
pump
Remedy
No. 1 pump
No. Troubleshooting
1
marks is the cause of the failure.
X: Repair or replace
20-557
3
TROUBLESHOOTING

Interchange method of No. 2 pump outlet hoses between front and rear
Hyrdraulic circuit after interchanging hoses
20-558
3
PC1100-6
TROUBLESHOOTING
H-1
H-1 Speeds of all work equipment, swing, travel are slow or lack
power
fl Measure the speeds of the work equipment, travel, and swing, and confirm that they are all slow
(or lack power).
fl Check that no abnormal noise is being generated from the hydraulic pump before carrying out
troubleshooting.
fl Carry out all troubleshooting in the DH mode.
Cause
YES
See H-14
YES
1
Is there travel
deviation?
Max. 220 mm/
20 m
Engine at high
idling
See S Mode
YES Is output
pressure of TVC
valve normal?
2
Is control pump
relief pressure
NO normal?
See Table.
Engine at high
idling
4 YES Defective adjustment of
YES
NO
3.1 +0.4
0
{32 +3.5
0
MPa
kg/cm2}
Engine at high
idling
7 YES
Defective TVC valve
Repair or
replace
Internal leakage in
equipment in control
system
See Note
NO
5
Is control relief
pressure normal
when 1 5 in
diagram are
blocked?
6 YES Defective adjustment of
NO
control relief valve
Does relief pressure

become normal
when control relief
valve is adjusted?
3.1 +0.4
MPa
0
{32 +3.5
kg/cm2}
0
Engine at high
idling
Adjust
TVC valve
Does output
pressure become
NO normal when TVC
valve is adjusted?
See Table.
Engine at high
idling
3.1 +0.4
MPa
0
{32 +3.5
kg/cm2}
0
Engine at high
idling
Defective engine
Remedy
NO
Are metal
particles found
inside pilot filte?
NO
Adjust
Go to A
Defective control pump
Repair or
replace
Defective control relief

valve
Repair or
replace
Table
TVC valve output pressure
Min. 1.8 MPa {Min. 18 kg/cm2}
Heavy lift OFF + boom RAISE relief
1.08 0.2 MPa {11 2 kg/cm2}
Heavy lift ON + boom RAISE relief
0.98 0.2 MPa {10 2 kg/cm2}
Note: Block 1, 4, 6 C in diagram individually, measure the control relief pressure, decide which
equipment is defective, then repair or replace.
20-560
3
PC1100-6
TROUBLESHOOTING
PC1100-6
H-1
20-561
3
TROUBLESHOOTING
H-2
H-2 There is excessive drop in engine speed, or engine stalls

YES
Output pressure
becomes normal.
Condition does not
become normal.
Is CO NC valve
output pressure
of No. 1 pump
normal?
YES
See Table 2
Engine at high
idling
3
Does output
pressure become
NO normal when CO
valve is adjusted?
Output pressure
becomes normal.
Condition also
becomes normal
See Table 2
Engine at high
idling
1
Output pressure
does not become
normal.
Condition does not
become normal.
Is output
pressure of TVC
valve normal?
See Table 1
Engine at high
idling
Output pressure
becomes normal.
Condition does not
become normal.
NO
Do output pressure
and condition
become normal
when TVC valve is
adjusted?
Output pressure
becomes normal.
Condition also
becomes normal
See Table 1
Engine at high
idling
Output pressure
does not become
normal.
Condition does not
become normal.
Table 1
TVC valve output pressure
1.08 0.2 MPa {11 2 kg/cm2}
0.98 0.2 MPa {10 2 kg/cm2}
20-562
3
PC1100-6
TROUBLESHOOTING
H-2
Cause
Remedy
Defective engine
See S Mode
CO NC valv
Adjust
Repair or
replace
TVC valve
Adjust
Defective TVC valve
Repair or
replace
Table 2
CO NC valve output pressure
+2.0
2
1.10 +0.20
0.58 MPa {11 5.9 kg/cm }
0.98 0.2 MPa {10 2 kg/cm2}
PC1100-6
20-563
3
TROUBLESHOOTING
H-3
H-3 No work equipment, travel, swing move

fl Check that the safety lock valve linkage is normal.
Cause
YES
3
YES
2
YES
1
Does oil come out
when main pump
pressure
measurement plug
is removed?
Does oil come out

when control pump
pressure
measurement plug
is removed?
Crank engine
with barring
device at
flywheel portion.
Crank engine
with barring
device at
NO
flywheel portion.
Is control relief
pressure normal
when 1 5 in
diagram are
blocked?
3.1 +0.4
MPa
0
{32 +3.5
kg/cm2}
0
Engine at high
idling
4 YES
Remedy
Internal leakage in
equipment in control
system
See Note
Defective control pump
Repair or
replace
Defective control relief
Repair or
replace
Are metal
particles found
NO inside pilot filter?
NO valve
Defective PTO
Repair or
replace
Defective PTO
Repair or
replace
NO
Note: Block 1, 4, 6 C in diagram individually, measure the control relief pressure, decide which
equipment is defective, then repair or replace.
20-564
3
PC1100-6
TROUBLESHOOTING
H-4
H-4 Abnormal noise generated (from around pump)
Cause
YES
2
YES Is strainer
YES
clogged?
NO
Is oil level in
hydraulic tank
normal?
Is problem removed
when piping
between tank and
pump is tightened?
Clogged hydraulic tank

strainer
Clean
Loose piping clamp
Tighten
4 YES Defective hydraulic

Are metal wear
particles found in
NO drained hydraulic
oil?
Remedy
pump
Operate for a short time

and watch for any
NO change in symptoms
Lack of oil
Repair or
replace
Inspect again
(depending on
changes in
symptoms)
Add oil
NO
PC1100-6
20-565
3
TROUBLESHOOTING
H-5
H-5 Boom is slow or lacks power

fl Check that the arm, bucket, travel, and swing speeds are normal, and that there is no deviation
when traveling.
a) In normal mode, boom is slow or lacks power.
fl Normal mode means the following conditions: Heavy lift OFF, swing priority OFF, machine
push-up OFF.
Cause
4 YES Defective boom LOWER

Does control
regeneration valve
Remedy
Repair or
replace
YES valve spool move

3
smoothly?
Is swing priority
Defective operation of
YES solenoid valve

2
YES
1
Is hydraulic drift
of boom cylinder
normal?
Is output
pressure of PPC
valve normal?
2.9 +0.6
0.2 MPa
{30 +5.5
kg/cm2}
1.5
Engine at high
idling
NO control valve spool
Repair or
replace
outlet pressure
normal?
See Table.
Engine at high
idling
NO
NO
YES
At rated load:
5
Max. 75 mm/
Does speed of
downward
15 minutes
movement become
At no load:
6 YES
NO
faster when boom
Max. 45 mm/
Does hydraulic drift
lever is operated?
15 minutes
become normal when
See TESTING
Engine stopped
safety-suction valve is
AND
NO interchanged with other
ADJUSTING
safety-suction valve?
It is also possible
NO
For standard
to measure
values, see Item 1.
leakage from
See Note
cylinder.
Max. 28 cc/min
Engine at high
idling
swing priority solenoid
valve
Repair or
replace
Defective PPC valve
Repair or
replace
Defective hydraulic
cylinder seal
Repair or
replace
Defective control valve

safety-suction valve
Replace
Replace
Table
Solenoid valve outlet pressure
Swing priority switch OFF
0 MPa {0 kg/cm2}
Swing priority switch ON
2.9 0.6 MPa {30 5.5 kg/cm2}
Note: The set pressure for the boom safety-suction valve is different from the set pressure for the arm
and bucket safety-suction valves, so interchange the valves temporarily for the purpose of
testing. A hose is installed at the head end, so fit a blind plug when disconnecting, and be sure
to replace the valves in their original positions after completion of the troubleshooting.
20-566
3
PC1100-6
TROUBLESHOOTING
H-5
b) When heavy lift is ON, boom RAISE speed is slow or lacks power
Cause
2 YES
Is CO cancel
solenoid valve
outlet pressure
normal?
Is 2-stage relief
YES solenoid valve
outlet pressure
1
normal?
See Table.
Engine at high
idling
See Table.
Engine at high
idling
NO
NO
Remedy

main relief valve (highpressure side)
Repair or
replace
valve
Repair or
replace
Repair or
replace
Table

0 MPa {0 kg/cm2}
Heavy lift switch OFF

Heavy lift switch ON + boom RAISE
2.9 0.6 MPa {30 5.5 kg/cm2}
c) When machine push-up is ON, boom LOWER speed is slow or lacks power
Cause
1 YES
Is machine pushup solenoid valve
outlet pressure
normal?
See Table.
Engine at high
idling
NO
Remedy

boom LOWER safetysuction valve (highpressure side)
Repair or
replace
machine push-up
solenoid valve
Repair or
replace
Table
Machine push-up switch OFF
2.9 0.6 MPa {30 5.5 kg/cm2}
Machine push-up switch ON
0 MPa {0 kg/cm2}
PC1100-6
20-567
3
TROUBLESHOOTING
H-6, H-7
H-6 Arm is slow or lacks power

fl Check that the boom, bucket, travel, and swing speeds are normal.
Cause
2 YES
YES
Is output
pressure of PPC
valve normal?
1
2.9 +0.6
0.2 MPa
{30 +5.5
kg/cm2}
1.5
Engine at high
idling
Is hydraulic drift
of arm cylinder
normal?
NO
YES
3
At rated load:
Does speed of
Max.240 mm/
downward
15 minutes
movement become
NO faster when arm
4 YES
At no load:
lever is operated?
Max.105 mm/
become normal when
15 minutes
See TESTING
Engine stopped
AND
ADJUSTING
It is also possible
For standard
NO
to measure
values, see Item 1.
leakage from
Interchange with
cylinder.
safety-suction
Max. 28 cc/min
valve for bucket
Engine at high
idling
Remedy
control valve spool
Repair or
replace
Defective PPC valve
Repair or
replace
Defective hydraulic
cylinder seal
Repair or
replace

Replace
Replace
H-7 Bucket is slow or lacks power

fl Check that the boom, bucket, travel, and swing speeds are normal.
Cause
2 YES
Is output
Remedy
control valve spool
Repair or
replace
Defective PPC valve
Repair or
replace
Defective hydraulic
cylinder seal
Repair or
replace

Replace
Replace
YES pressure of PPC

valve normal?
1
Is hydraulic drift
of bucket
cylinder normal?
2.9 +0.6
0.2 MPa
{30 +5.5
kg/cm2}
1.5
Engine at high
idling
NO
YES
3
At rated load:
Does speed of
Max.145 mm/
downward
15 minutes
movement become
NO faster when bucket
4 YES
At no load:
lever is operated?
Max.70 mm/
become normal when
15 minutes
See TESTING
Engine stopped
AND
ADJUSTING
It is also possible
For standard
NO
to measure
values, see Item 1.
leakage from
Interchange with
cylinder.
safety-suction
Max. 28 cc/min
valve for arm
Engine at high
idling
20-568
3
PC1100-6
TROUBLESHOOTING
H-8, H-9, H-10
H-8 Boom does not move

fl Check that the arm, bucket, travel, and swing move normally.
Cause
1 YES
Is output
pressure of PPC
valve normal?
2.9 +0.6
0.2 MPa
{30 +5.5
kg/cm2}
1.5
Engine at high
idling
NO
Remedy
control valve spool
Repair or
replace
Defective PPC valve
Repair or
replace
H-9 Arm does not move

fl Check that the boom, bucket, travel, and swing move normally.
Cause
1 YES
Is output
pressure of PPC
valve normal?
2.9 +0.6
0.2 MPa
{30 +5.5
kg/cm2}
1.5
Engine at high
idling
NO
Remedy
control valve spool
Repair or
replace
Defective PPC valve
Repair or
replace
H-10 Bucket does not move

fl Check that the boom, arm, travel, and swing move normally.
Cause
1 YES
Is output
pressure of PPC
valve normal?
2.9 +0.6
0.2 MPa
{30 +5.5
kg/cm2}
1.5
Engine at high
idling
PC1100-6
NO
Remedy
control valve spool
Repair or
replace
Defective PPC valve
Repair or
replace
20-569
3
TROUBLESHOOTING
H-11, H-12
H-11 Excessive hydraulic drift

Cause
YES
1
Does speed of
downward
movement become
faster when lever is
operated?
2 YES
Does condition become
normal when safetysuction valve is
interchanged with other
See TESTING
NO
AND
ADJUSTING.
It is also possible
NO
For standard
to measure
values, see Item 1.
leakage of
See Note
cylinder.
Max. 28 cc/min
Engine at high
idling
Remedy
Defective hydraulic
cylinder seal
Repair or
replace
control valve safetysuction valve
Replace
Defective control valve,

defective oil tightness of
spool
Replace
Note: The set pressure for the boom safety-suction valve is different from the set pressure for the arm
and bucket safety-suction valves, so interchange the valves temporarily for the purpose of
testing. A hose is installed at the head end, so fit a blind plug when disconnecting, and be sure
to replace the valves in their original positions after completion of the troubleshooting.
The set pressure of the safety-suction valves for the arm and bucket is the same.
H-12 Excessive time lag

a) Boom
Cause
1 YES
Does spool and
check valve of
boom regeneration
valve move
smoothly?
NO
Remedy
Replace
boom regeneration valve
Repair or
replace
b) Arm, bucket
Cause
20-570
3
Remedy
Replace
PC1100-6
TROUBLESHOOTING
H-13
H-13 Boom shockless function is not actuated or cannot be canceled

Cause
1 YES
Is operation of
boom shockless
solenoid valve
normal?
See Note
NO
Remedy
boom shockless valve
Repair or
replace
boom shockless solenoid
valve
Repair or
replace
Note: Remove the solenoid valve as an individual part from the block, then connect the connector.
Turn the starting switch ON, then turn the boom shockless switch ON-OFF. If the spool moves,
it is normal.
PC1100-6
20-571
3
TROUBLESHOOTING
H-14
H-14 Machine deviates naturally to one side during travel operations

fl Check that the travel speed is normal.
a) Direction of deviation is same in FORWARD and REVERSE
YES
YES
4
1
Are metal
YES particles found in
oil drained from
final drive?
Was it possible to
locate abnormality
in troubleshooting
chart?
YES
6
Does direction of deviation
YES change when left and right
Carry out
troubleshooting
with
troubleshooting
chart in BEFORE
CARRYING OUT
TROUBLESHOOTING OF
HYDRAULIC
SYSTEM.
Is amount of oil
Is leakage from
swivel joint
NO normal?
YES drained from

travel motor
normal?
Is output
pressure of PPC
NO valve normal?
Max. 40 /min
Engine at high
idling
2.9 +0.6
0.2 MPa
{30 +5.5
kg/cm2}
1.5
Engine at high
idling
hoses between swivel joint

and travel motor are
interchanged?
Max.100 cc/min
Engine at high
idling
NO
NO
NO
NO
b) Direction of deviation is different in FORWARD and REVERSE

Cause
YES
Remedy
Dfective swivel joint seal
Repair or
replace
control valve spool
Repair or
replace
Defective PPC valve
Repair or
replace
Drop in set pressure of

travel motor safety valve
Replace
1
Is deviation as
shown in 1, 2,
5, 6 in diagram
on right?
3 YES
YES Is output
pressure of PPC
2
valve normal?
Is relief pressure
at travel relief
NO normal?
34.3 +1.0
2.5 MPa
{35 +10
kg/cm2}
25
Engine at high
idling
20-572
3
2.9 +0.6
0.2 MPa
{30 +5.5
kg/cm2}
1.5
Engine at high
idling
NO
NO
PC1100-6
TROUBLESHOOTING
H-14
Cause
7 YES
Remedy
See Cause column in

troubleshooting chart
Follow
instructions in
troubleshooting
chart
Defective final drive
Repair or
replace
control valve spool
Replace
Repair or
replace
Defective travel motor
Repair or
replace
Defective swivel joint

seal
Repair or
replace
Internal leakage in travel

motor
Repair or
replace
Defective PPC valve
Repair or
replace
Does control
valve spool move
smoothly?
NO
Fig.: Location of defective swivel joint seal and direction of travel deviation
PC1100-6
20-573
3
TROUBLESHOOTING
H-15
H-15 Deviation is excessive when starting

fl Check that there is no deviation during normal travel.
a) Deviation when starting occurs only when control lever is operated fully
Cause
YES
Remedy
pump servo valve
Repair or
replace
control valve spool
Repair or
replace
Defective swivel joint

seal
Repair or
replace
Repair or
replace
1
Does direction of
deviation change when
No. 2 pump outlet
hoses are interchanged
between front and rear?
3 YES
YES
2
NO

change when left and right
hoses between swivel joint
and travel motor are
interchanged?

change when left and right
hoses between control
valve and swivel joint are
interchanged?
NO
NO
b) Deviation when starting occurs both when control lever is

operated a small amount and when it is operated fully
YES
2
Cause
Remedy
pump servo valve
Repair or
replace
CO NC valve
Adjust
Repair or
replace
control valve jet sensor
relief valve
Adjust

jet sensor relief valve
Repair or
replace

jet sensor orifice
Repair or
replace
Is output pressure
YES of CO NC valve
normal on fast
side?
1
Is differential
pressure of jet
sensor normal on
fast side?
See Table
Engine at high
idling
3 YES
NO
Does output
pressure become
normal when
CO NC valve is
adjusted?
NO
See Table
Engine at high
idling
See Table.
Engine at high
idling
YES
4
NO
Does differential
pressure become
normal when jet
sensor relief valve is
adjusted?
See Table
Engine at high
idling
NO
5 YES
Does differential
pressure become
normal when relief
valves are interchanged
on opposite sides?
See Table
Engine at high
idling
NO
Table
Jet sensor differential pressure CO NC valve output pressure

Min. 1.5 MPa {Min. 15 kg/cm2} Max. 0.4 MPa {Max. 4.1 kg/cm2}
Travel levers operated fully (track rotating under no load) Max. 0.2 MPa {Max. 2 kg/cm2}
20-574
3
PC1100-6
TROUBLESHOOTING
H-16, H-17
H-16 Travel deviation is excessive during compound operations

fl Check that there is no travel deviation during independent operation.
Cause
1 YES
Is output pressure
of straight-travel
solenoid valve
normal?
See Table.
Engine at high
idling
NO
Remedy
control valve straighttravel valve
Repair or
replace
straight-travel solenoid
valve
Repair or
replace
Table

0 MPa {0 kg/cm2}

Work equipment, swing + left and right travel levers operated
2.9 0.6 MPa {30 5.5 kg/cm2}
H-17 Travel speed is slow or lacks power

fl Check that there is no travel deviation.
Cause
1 YES
Is output
pressure of CO
cancel solenoid
valve normal?
See Table.
Engine at high
idling
NO
Remedy
valve
Repair or
replace
Repair or
replace
Table
Travel levers at neutral
0 MPa {0 kg/cm2}
Travel levers operated
2.9 0.6 MPa {30 5.5 kg/cm2}
PC1100-6
20-575
3
TROUBLESHOOTING
H-18
H-18 Travel does not move (one side only)

a) Does not move in either direction (FORWARD and REVERSE)
Cause
1 YES
Are metal
particles found in
oil drained from
final drive?
NO
Remedy
Defective final drive
Repair or
replace
travel motor parking
brake or defective travel
motor
Repair or
replace
b) Does not move in one direction (FORWARD or REVERSE)
Cause
YES
2
YES Is travel relief
YES
pressure normal?
1
Is output
pressure of PPC
valve normal?
34.3 +1.0
2.5 MPa
{35 +10
kg/cm2}
25
Engine at high
idling
2.9 +0.6
0.2 MPa
{30 +5.5
kg/cm2}
1.5
Engine at high
idling
NO
20-576
3
NO

become normal
when safety valve is
interchanged?
travel motor
counterbalance valve
Repair or
replace

safety valve
Replace
4 YES Defective operation of

become normal
when safety valve is
interchanged?
Remedy
control valve suction

valve
34.3 +1.0
2.5 MPa
{350 +10
kg/cm2} NO
25
Engine at high
idling
NO control valve spool
34.3 +1.0
2.5 MPa
{350 +10
kg/cm2}
25
Engine at high
idling
Defective PPC valve
Repair or
replace
Repair or
replace
Repair or
replace
PC1100-6
TROUBLESHOOTING
H-19
H-19 Travel speed does not switch

fl Check that travel speed is normal in Hi or Lo.
fl If the engine speed is 1400 rpm or below, and the travel actuation pressure is 28.4 MPa {290 kg/
cm2} or more, the speed is automatically fixed in Lo.
Cause
1 YES
Is output pressure
of travel speed
solenoid valve
normal?
See Table.
Engine at high
idling
NO
Remedy
travel motor servo valve
Repair or
replace
travel speed solenoid
valve
Repair or
replace
Table
Travel speed switch at Lo
Travel operated with travel speed switch at Hi
PC1100-6

0 MPa {0 kg/cm2}
2.9 0.6 MPa {30 5.5 kg/cm2}
20-577
3
TROUBLESHOOTING
H-20
H-20 Does not swing

fl Check that the work equipment and travel are normal.
fl Carry out all troubleshooting in the DH mode with the swing lock switch OFF.
a) Does not swing in either direction (left and right)
Cause
2 YES
Are any metal
oil drained from
1
swing machinery?
Is output pressure
of swing holding
brake solenoid
valve normal?
See Table.
Engine at high
idling
NO
NO
Remedy
Defective swing
machinery
Repair or
replace

brake or swing motor
Repair or
replace
swing holding brake
solenoid valve
Repair or
replace
Table
5 sec after returning swing lever to Neutral
0 MPa {0 kg/cm2}
2.9 0.6 MPa {30 5.5 kg/cm2}
Swing lever operated
b) Does not swing in one direction (either left or right)

Cause
YES
2
Remedy
Defective swing motor

safety valve
Repair or
replace

suction valve
Repair or
replace
control valve spool
Repair or
replace
Defective PPC valve
Repair or
replace
Is problem reversed
YES when left and right

safety valves are
interchanged?
1
Is output
pressure of PPC
valve normal?
2.9 +0.6
0.2 MPa
{30 +5.5
kg/cm2}
1.5
Engine at high
idling
20-578
3
Check front and

rear individually. NO
3 YES
Is problem reversed
when left and right
suction valves are
interchanged?
Check front and

rear individually.
NO
NO
PC1100-6
TROUBLESHOOTING
H-21
H-21 Swing speed is slow or swing acceleration is poor

fl Check that the work equipment and travel are normal.
a) Swing speed is slow in both directions (left and right)
Cause
2 YES
Are any metal
oil drained from
1
swing machinery?
Is leakage of oil
from motor
normal?
NO
Max. 28 /min.
Engine at high
idling
NO
Remedy
Defective swing
machinery
Repair or
replace

Repair or
replace
Oil leakage from swing

motor
Repair or
replace
b) Swing speed is slow in one direction (either left or right)

Cause
YES
2
Remedy

safety valve
Repair or
replace

suction valve
Repair or
replace
control valve spool
Repair or
replace
Defective PPC valve
Repair or
replace
Is problem reversed
YES when left and right

safety valves are
interchanged?
1
Is output
pressure of PPC
valve normal?
2.9 +0.6
0.2 MPa
{30 +5.5
kg/cm2}
1.5
Engine at high
idling
Check front and

See Note.
3 YES
Is problem reversed
when left and right
suction valves are
interchanged?
Check front and

rear individually.
See Note.
NO
NO
Note: Instead of checking the problem, it is possible to measure the swing relief pressure.
+10
2
Swing relief pressure: 30.4 +1.0
2.9 MPa {310 30 kg/cm }
PC1100-6
20-579
3
TROUBLESHOOTING
H-22, H-23
H-22 In compound operations with bucket, swing speed is slow or

swing acceleration is poor
Cause
2 YES
Does swing
YES compensation
pilot valve spool
1
move smoothly?
Is output pressure
of swing PPC
shuttle valve
normal?
2.9 +0.6
0.2 MPa
{30 +5.5
kg/cm2}
1.5
Engine at high
idling
Operate swing.
NO
NO
Remedy
control valve swing
compensation valve
Repair or
replace
swing compensation
pilot valve
Repair or
replace
Defective swing PPC

shuttle valve
Repair or
replace
H-23 In compound operations with boom when swing priority is ON,

swing speed is slow or swing acceleration is poor
Cause
swing priority solenoid
valve
20-580
3
Remedy
Repair or
replace
PC1100-6
TROUBLESHOOTING
H-24
H-24 Excessive overrun when stopping swing

a) Both directions (left and right)
Cause
Internal leakage of swing

motor
Remedy
Repair or
replace
b) One direction only (either left or right)

Cause
YES
Defective PPC valve
Repair or
replace

safety valve
Repair or
replace

suction valve
Repair or
replace
control valve spool
Repair or
replace
1
Is problem reversed
when left and right
PPC hoses are
interchanged?
YES
2
NO
Is problem reversed
when left and right
safety valves are
interchanged?
Check front and

See Note.
3 YES
Is problem reversed
when left and right
suction valves are
interchanged?
Check front and

rear individually.
See Note.
NO
Remedy
Note: Instead of checking the problem, it is possible to measure the swing relief pressure.
+10
2
Swing relief pressure: 30.4 +1.0
2.9 MPa {310 30 kg/cm }
PC1100-6
20-581
3
TROUBLESHOOTING
H-25
H-25 Excessive shock when stopping swing

a) Shock excessive in both directions (left and right)
Cause
2 YES
Are metal particles
YES found in oil
drained from
1
swing machinery?
Is outlet pressure
of swing holding
brake solenoid
valve normal?
See Table.
Engine at high
idling
NO
NO
Remedy
Defective swing
machinery
Repair or
replace

Repair or
replace
swing holding brake
solenoid valve
Repair or
replace
Table
0 MPa {0 kg/cm2}
2.9 0.6 MPa {30 5.5 kg/cm2}
b) Shock excessive in one direction only (either left or right)

Cause

safety valve
20-582
3
Remedy
Repair or
replace
PC1100-6
TROUBLESHOOTING
H-26, H-27
H-26 Excessive abnormal noise when stopping swing

a) Abnormal noise in both directions (left and right)
Cause
1 YES
Is foreign material
found in oil
drained from
swing machinery?
NO
Remedy
Defective swing
machinery
Repair or
replace
Defective back pressure

compensation valve
Repair or
replace
b) Abnormal noise in one direction only (either left or right)

Cause
1 YES
Is problem reversed
when left and right
safety valves are
interchanged?
Check front and

rear individually.
NO
Remedy
swing motor safety valve
Repair or
replace

suction valve
Repair or
replace
H-27 Excessive hydraulic drift of swing

Cause
1 YES
Is output pressure
of swing holding
brake solenoid
valve normal?
See Table.
Engine at high
idling
NO
Remedy

brake
Repair or
replace
swing holding brake
solenoid valve
Repair or
replace
Table
0 MPa {0 kg/cm2}
PC1100-6
2.9 0.6 MPa {30 5.5 kg/cm2}
20-583
3
TROUBLESHOOTING OF MACHINE
MONITOR SYSTEM
(M MODE)
Action taken by monitor panel when abnormality occurs and problems on machine ..................20-602
Electrical circuit diagram for M mode system ....................................................................................20-606
M- 1 [E101] Abnormality in error data is displayed
[E102] Abnormality in clock data is displayed .........................................................................20-608
M- 2 [E103] Short circuit in buzzer output system is displayed ......................................................20-609
M- 3 [E104] Air cleaner clogging detected is displayed ...................................................................20-610
M- 4 [E106] Drop in engine oil Hi pressure detected is displayed .................................................20-610
M- 5 [E108] Engine water temperature 105 detected is displayed ................................................20-611
M- 6 When starting switch is turned on, none of lamps on monitor panel
light up for 3 seconds .................................................................................................................20-612
M- 7 When starting switch is turned on, monitor panel lamps all stay lighted up
and do not go out ........................................................................................................................20-614
M- 8 When starting switch is turned on, items lighted up on monitor panel
are different from machine .........................................................................................................20-614
M- 9 When starting switch is turned on (engine stopped), basic check items flash ....................20-615
M-10 When starting switch is turned on (engine stopped),
preheating monitor display is not normal ................................................................................20-618
M-11 When engine is started, basic check items flash .....................................................................20-619
caution items, emergency stop items flash ..............................................................................20-621
M-13 When engine is started, caution items, emergency stop items flash
(but there is no abnormality in any item) .................................................................................20-623
M-14 When starting switch is turned on (engine stopped), buzzer does not sound for 1 second
Caution item flashes but buzzer does not sound ....................................................................20-628
M-15 No abnormality is displayed on monitor but buzzer sounds .................................................20-628
M-16 Night lighting on monitor panel does not light up .................................................................20-629
M-17 Engine water temperature gauge does not rise .......................................................................20-630
M-18 Engine water temperature gauge does not give any display
(gauge does not even display 1st level) ...................................................................................20-630
M-19 Fuel level gauge always displays FULL ....................................................................................20-631
M-20 Fuel level gauge does not give any display (gauge does not even display 1st level) ........ 20-631
M-21 Swing lock switch is turned ON, but swing lock monitor does not light up .......................20-632
M-22 Swing prolix switch is turned ON (prolix), but swing lock monitor does not flash ............20-633
M-23 Service meter does not advance while engine is running .....................................................20-634
M-24 When starting switch is at OFF and time switch is pressed,
service meter does not give display ..........................................................................................20-634
M-25 Defective fuel level sensor system ............................................................................................20-635
M-26 Defective engine water temperature sensor system and
defective hydraulic oil temperature sensor system .................................................................20-636
M-27 Defective engine oil level sensor system and defective
hydraulic oil level sensor system ...............................................................................................20-637
M-28 Defective radiator water level sensor system ..........................................................................20-638
M-29 Defective operation of wiper (including cases where [E113] is displayed) ..........................20-639
M-30 Defective operation of window washer
(including cases where service code [E114] is displayed) ......................................................20-642
PC1100-6
20-601
3
TROUBLESHOOTING
ACTION TAKEN BY MONITOR PANEL WHEN ABNORMALITY


User Service
code code
Abnormal system
1. Abnormality in internal memory
E101
Abnormality in error
2. Excess voltage (more than 36 V) has occurred
data
3. Low voltage (less than 12 V) has occurred

4. Defective connection of connector
1. Abnormality in internal clock function
E102
Abnormality in clock
2. Excess voltage (more than 36 V) has occurred
data
3. Low voltage (less than 12 V) has occurred

4. Defective connection of connector
1. Short circuit inside buzzer
Short circuit in
E103
buzzer output
system
2. Short circuit with power source in wiring harness between monitor

P01 (7) and alarm buzzer P04 (2)
fl If there is a disconnection, E103 is also displayed.
E104
Air cleaner clogging
1. Air cleaner clogging sensor has detected clogging
detected
1. Engine oil pressure Hi sensor has detected drop in oil pressure
E106
Drop in engine oil

pressure Hi detected
1. Engine water temperature gauge has detected water temperature

of 105C
Engine water
E108
temperature 105C
detected

Disconnection, short
E113
circuit in wiper drive

system
2. Defective wiper, washer relay box

3. Defective contact or disconnection in wiring harness between monitor panel P02 (3) and wiper, washer relay box W08 (2)
4. Short circuit with ground in wiring harness between monitor panel
P02 (3) wiper, washer relay box W08 (2)
20-602
3
PC1100-6
TROUBLESHOOTING

Turn the starting switch

OFF. Then keep the time


1. Service code cannot be cleared.
2. Time becomes [00:00].
switch pressed, turn the

starting switch ON again,
and keep the time switch
pressed for a further 5 seconds to reset. (If the sys.
tem is reset, it is normal)
Voltage between P01 (7)
1. Service code cannot be cleared.

2. Time becomes [00:00].
3. Clock does not advance.
1. Buzzer does not sound.
chassis ground
Buzzer ON: Max. 1 V
Buzzer OFF: 20 30 V
Resistance between P11
1. If abnormality detection contin-
(male) P12 (female):
ues, air cleaner clogging caution
Max. 1 (engine running)
lamp flashes and buzzer sounds.
Resistance between
1. If abnormality detection contin-
sensor terminal and
ues, engine oil pressure caution
chassis:
lamp flashes and buzzer sounds.
Min. 1 M (engine at
mid-range speed or
above)
1. If abnormality detection continues, engine water temperature
caution lamp flashes and buzzer
(1) (2):
sounds.
Min. 3.156 k
(engine running)
2. If abnormality detection continues, overheat prevention function is actuated, and engine

speed is reduced to low idling.
1. Wiper does not work.
2. Wiper does not stop.

(3) W08 (2): Max. 1
PC1100-6
20-603
3
TROUBLESHOOTING
User Service
code code
Abnormal system

Disconnection, short
E114
circuit in washer
drive system
2. Defective wiper, washer relay box

3. Defective contact or disconnection in wiring harness between monitor panel P02 (2)(10) and wiper, washer relay box W08 (15)
4. Short circuit with ground in wiring harness between monitor panel
P02 (2)(10) wiper, washer relay box W08 (15)
20-604
3
PC1100-6
TROUBLESHOOTING



1. Washer does not work.
2. Washer does not stop.

(2)(10) W08 (15):
Max. 1
PC1100-6
20-605
3
TROUBLESHOOTING
ELECTRICAL CIRCUIT DIAGRAM FOR M MODE SYSTEM
20-606
3
PC1100-6
TROUBLESHOOTING
PC1100-6
20-607
3
TROUBLESHOOTING
M-1
M-1 [E101] Abnormality in error data is displayed or

[E102] Abnormality in clock data is displayed
fl This is not an abnormality. It occurs during troubleshooting when disconnecting and connecting
connector P02 (for the monitor panel electrical system), fuse 13, connector H14, connector M11,
battery relay terminal B, or the battery terminal. This action temporarily shuts off the monitor
panel power source circuit, so a service code is displayed.
fl Check that fuse 13 is not blown. (If it is blown, check for a short circuit with the ground in the
related circuits for fuse 13.)
Cause
YES
2
Is voltage between
YES P02 (8)(14) and

1
Does service code
display appear
again after system
has been reset?
chassis ground
normal?
Turn starting
switch OFF.
20 30 V
Reset. For details,

see Note.
After resetting
system, carry out NO
normal
operations for a
short time and
watch the
condition.
3 YES
Is voltage
between fuse 13
NO inlet and chassis
ground normal?
Turn starting
switch OFF.
20 30 V
NO
Remedy
Replace
between fuse 13 outlet
and P02 (female) (8)(14)
Repair or
replace
between battery terminal
B and fuse 13
Normal
Repair or
replace
Note:
Resetting operation: Turn the starting switch OFF. Then keep the time switch depressed, turn the
starting switch ON again, and keep the time switch depressed for 5 seconds to
reset the system.
M-1 Related electrical circuit diagram
20-608
3
PC1100-6
TROUBLESHOOTING
M-2
M-2 [E103] Short circuit in buzzer output system is displayed

check if an E service code is displayed. (If it is not displayed, the system has been reset.)
Cause
2 YES
When P01 is
YES disconnected,
does buzzer
1
stop?
Is resistance
between P04 (male)
(2) chassis ground
normal?
Turn starting
switch OFF.
Disconnect P04.
Min. 1 M
Turn starting
switch ON.
NO
NO
Remedy
Replace

in wiring harness
between P01 (female) (7)
and P04 (female) (2)
Repair or
replace
Defective alarm buzzer
Replace
PC1100-6
20-609
3
TROUBLESHOOTING
M-3, M-4
M-3 [E104] Air cleaner clogging detected is displayed

Cause
YES
See M-13 f)
1
Is air cleaner
clogging caution
lamp on monitor
panel flashing?
2 YES
Remedy
Replace
Is [E] displayed at
head of service
NO code?
NO
Defective air cleaner

(See Note)
Note: The monitor panel display has returned to normal, but the air cleaner clogging sensor has
detected symptoms of clogging in the past, so clean the air cleaner properly. For details, see the
Operation and Maintenance Manual.
M-4 [E106] Drop in engine oil Hi pressure detected is displayed
Cause
YES
See M-11 b)
1
Is engine oil
pressure caution
lamp on monitor
flashing?
2 YES
Remedy
Replace
Failure in engine system

(See Note)
Is [E] displayed at
head of service
NO code?
NO
Note: The monitor panel display has returned to normal, but the engine oil pressure Hi sensor has
detected symptoms of a drop in the oil pressure in the past, so carry out troubleshooting of the
engine to remove the problem.
20-610
3
PC1100-6
TROUBLESHOOTING
M-5
M-5 [E108] Engine water temperature 105C detected is displayed

Cause
YES
See M-13 d)
1
Does engine water
temperature gauge on
monitor panel display
red range and is
caution lamp flashing?
2 YES
Remedy
Replace
Failure in engine system

(See Note)
Is [E] displayed at
head of service
NO code?
NO
Note: The monitor panel display has returned to normal, but the engine water temperature sensor has
detected symptoms of the engine water temperature reaching 105C in the past, so carry out
troubleshooting of the engine to remove the problem.
PC1100-6
20-611
3
TROUBLESHOOTING
M-6
M-6 When starting switch is turned on, none of lamps on monitor

panel light up for 3 seconds
fl Check that fuses 10 and 13 are not blown. (If they are blown, check for a short circuit with the
ground in the related circuits for fuses 10 and 13.)
fl Check that the engine starts properly. (If it does not start, carry out Troubleshooting E-20 first.)
a) None of lamps on monitor panel light up
Cause
YES
2
Is voltage between
YES P01 (9) and

3 YES
chassis ground
normal?
1
Is voltage
between P02
(8)(14) chassis
ground normal?
Turn starting
switch ON.
20 30 V
Is voltage
between fuse 10
NO inlet and chassis
ground normal?
Turn starting
switch ON.
20 30 V
Turn starting
switch ON.
20 30 V
NO
4 YES
Is resistance
between P02
NO (1)(9) and chassis
ground normal?
Turn starting
switch OFF.
Disconnect P02.
Max. 1
NO
b) Some of lamps on monitor panel do not light up
Replace
P01 (female) (9)
Repair or
replace
between battery relay
terminal M and fuse 10 inlet
Repair or
replace
P02 (female) (8)(14)
Repair or
replace
harness between P02
(female) (1)(9) and chassis
ground
Cause
20-612
3
Remedy
Repair or
replace
Remedy
Replace
PC1100-6
TROUBLESHOOTING
M-6
PC1100-6
20-613
3
TROUBLESHOOTING
M-7, M-8
M-7 When starting switch is turned on, monitor panel lamps all stay
lighted up and do not go out
Cause
Remedy
Replace
M-8 When starting switch is turned on, items lighted up on monitor

panel are different from machine
fl Immediately after replacing the monitor panel, turn the starting switch OFF, then turn it ON again
and check.
Cause
1 YES
Is display of
monitoring code
[01] normal?
Turn starting
switch ON.
See Table.
Go to troubleshooting
for C mode (See C-16)
NO
Remedy
Replace
Table
Monitoring code
01
Monitor panel model selection code
20-614
3
Display
PC1100-6
TROUBLESHOOTING
M-9
M-9 When starting switch is turned ON (engine stopped), basic check

items flash
a)
(radiator water level) flashes

SAP00519
fl Check that the radiator water level is at the specified

level before carrying out troubleshooting.
YES
Cause
Remedy
Defective radiator water

level sensor system
(see M-28)
1
Does display go out
when short
connector is
connected to P08,
P20 (female)?
Is resistance
YES between C16
Disconnect P08
and P20.
2
Turn starting
Is resistance
switch ON.
between P20 (2)
Check P08 and
P20 individually. NO and chassis
ground normal?
(female) (8) and

chassis ground as
shown in table?
Turn starting
switch OFF.
Disconnect C16
and P20.
Turn starting
Is resistance
switch OFF.
between P08
Disconnect P20.
(female) (2) and
NO
Max. 1
chassis ground
Turn starting
switch ON.
NO
5 YES
normal?
Turn starting
switch OFF.
Disconnect P08.
Max. 1
controller
Is bit (3) of
YES
monitoring code
3
[24] lighted up?
NO
NO

harness between C16
(female) (8) and P20
(female) (1)
harness between P20
(female) (1)
harness between P08
ground
Replace
Replace
Repair or
replace
Repair or
replace
Repair or
replace
Table
Connection between P20 (female) (1) and chassis
Resistance
Connected
Max. 1
Disconnected
Min. 1 M
M-9 a) Related electrical circuit diagram
PC1100-6
20-615
3
TROUBLESHOOTING
b)
M-9
(engine oil level) flashes

SAP00523
fl Check that the engine oil is at the specified level before carrying out troubleshooting.
YES
Cause
Remedy
Defective engine oil level

sensor system
(see M-27)
1
Does display go out
when P05 (female)
(1) is connected to
chassis ground?
Disconnect P05.
Turn starting
switch ON.
3 YES
NO
Is resistance
between C16
(female) (16) and
chassis ground
normal?
Turn starting
switch OFF.
Disconnect C16,
P05.
Is bit (4) of
YES
monitoring code
2
[24] lighted up?
Turn starting
switch ON.
NO
NO
Defective pump
controller
Replace
Replace
harness between C16
(female) (1)
Repair or
replace
Table
Resistance
Connected
Max. 1
Disconnected
Min. 1 M
M-9 b) Related electrical circuit diagram
20-616
3
PC1100-6
TROUBLESHOOTING
c)
M-9
(hydraulic oil level) flashes

SAP00524
fl Check that the hydraulic oil is at the specified level before carrying out troubleshooting.
YES
Cause
Remedy
Defective engine oil level

sensor system
(see M-27)
1
Does display go out
when P09 (female)
(1) is connected to
chassis ground?
Disconnect P09.
Turn starting
switch ON.
3 YES
Is bit (5) of
NO
Is resistance
between C16
(female) (9) and
chassis ground
normal?
Turn starting
switch OFF.
Disconnect C16,
P09.
Defective pump
controller
Replace
Replace
harness between C16
(female) (1)
Repair or
replace
YES monitoring code

2
[24] lighted up?
Turn starting
switch ON.
NO
NO
Table
Resistance
Connected
Max. 1
Disconnected
Min. 1 M
M-9 c) Related electrical circuit diagram
PC1100-6
20-617
3
TROUBLESHOOTING
M-10

(preheating monitor) display is not normal
SAP00526
a) When APS switch is turned ON, lamp does not light up
(APS is actuated)
YES
Cause
Remedy
Replace
Replace
1
Is voltage
between P01 (18)
and chassis
ground normal?
3 YES
Is voltage
YES between E26 (4)
and chassis
2
ground normal?
Turn starting
When E26 is
switch ON.
disconnected, is
Turn starting
NO
resistance between P01
Turn APS switch
switch ON.
NO (female) (18) and
ON.
Turn APS switch ON.
20 30 V
20 30 V
Turn starting
switch OFF.
NO
Disconnect P01
and E26.
Min. 1 M
b) When APS switch is turned OFF, lamp lights up

(APS is not actuated)
YES
1
Is voltage
between P01 (18)
and chassis
ground normal?
2 YES
When E26 is
disconnected, is
voltage between
P01 (18) and chassis
ground normal?
Turn starting
switch ON.
NO
Turn APS switch
OFF.
Turn starting
Max.1 V
switch OFF.
NO
harness between P01
(female) (4)
in wiring harness
between P01 (female)
Cause
Repair or
replace
Repair or
replace
Remedy
Replace
Replace

in wiring harness
between P01 (female)
Repair or
replace
Disconnect P01
and E26.
Max.1 V
20-618
3
PC1100-6
TROUBLESHOOTING
M-11
M-11 When engine is started, basic check items flash

a) Alternator system
Cause
3 YES
Is voltage
YES between C03

1
Is voltage between
alternator terminal
R and chassis
ground normal?
(12) and chassis

ground normal?
Does monitoring
value of more
2
than 100?
NO
Run engine at
mid-range speed
or above.
Run engine at
mid-range speed NO
or above.
20 30 V
Run engine at
mid-range speed
NO
or above.
20 30 V
Remedy
Defective pump
controller
Replace
Replace
Defective contact,
Repair or
replace
Replace
PC1100-6
20-619
3
TROUBLESHOOTING
M-11
b) Engine oil pressure system

fl Check that the engine oil pressure is normal before carrying out troubleshooting.
Cause
Remedy
Low-pressure sensor
YES
Defective engine oil

pressure low-pressure
sensor
Replace
Defective pump
controller
Replace
Replace

in wiring harness
(15) and low-pressure
sensor
Repair or
replace
1
at low idling and wiring
harness of oil pressure
sensor is removed,
does display go out?
3 YES
Engine at low
Is resistance
idling
between C16
(female) (15) and
Disconnect lowpressure sensor NO chassis ground
normal?
wiring harness.
Turn starting
switch OFF.
Disconnect lowpressure sensor
wiring harness
and C16.
Min. 1 M
Is bit (1) of
YES
monitoring code
2
[24] lighted up?
Engine at low
idling
NO
NO
Cause
Remedy
High-pressure sensor
YES

pressure high-pressure
sensor
Replace
Defective pump
controller
Replace
Replace

in wiring harness
and high-pressure
sensor
Repair or
replace
1
at high idling and wiring
harness of oil pressure
sensor is removed,
does display go out?
3 YES
Is bit (2) of
YES
monitoring code
2
[24] lighted up?
Engine at high
Is resistance
idling
between C16
(female) (7) and
Disconnect highNO
chassis ground
pressure sensor
normal?
wiring harness.
Turn starting
switch OFF.
Disconnect highpressure sensor
wiring harness
and C16.
Min. 1 M
Turn starting
switch ON.
NO
NO
20-620
3
PC1100-6
TROUBLESHOOTING
M-12
M-12 When starting switch is turned on (engine stopped), caution

items, emergency stop items flash
a) Alternator system
Cause
3 YES
Is voltage
YES between C03

1
Is voltage between
alternator terminal
R and chassis
normal?
Disconnect
wiring harness.
Turn starting
switch ON.
Max. 1 V
(12) and chassis

normal?
Turn starting
switch ON
Max. 1 V
Does monitoring
value of more
2
than 100?
Turn starting
switch ON.
NO
NO
NO
Remedy
Defective pump
controller
Replace
Replace

between C03
(female)(12) and
Repair or
replace
Replace
PC1100-6
20-621
3
TROUBLESHOOTING
M-12
b) Engine oil pressure sensor system

Cause
Low-pressure sensor
3 YES
Is resistance
YES between C16

1
Is there continuity
between lowpressure sensor
terminal and
chassis ground?
(female) (15) and

chassis ground
normal?
Turn starting
switch OFF
Disconnect C16.
Max. 1
Turn starting
switch OFF.
Remove lowpressure sensor
wiring harness.
Is bit (1) of
YES
monitoring code
2
[24] lighted up?
Turn starting
switch ON.
NO
NO
NO
Remedy
Defective pump
controller
Replace
Replace
harness between C16
(female) (15) and lowpressure sensor
Repair or
replace

pressure low-pressure
sensor
Replace
Cause
Remedy
High-pressure sensor
3 YES
Is resistance
YES between C16

1
Is there continuity
between highpressure sensor
terminal and
chassis ground?
Turn starting
switch OFF.
Remove highpressure sensor
wiring harness.
(female) (7) and

chassis ground
normal?
Turn starting
switch OFF
Disconnect C16.
Max. 1
Is bit (2) of
YES monitoring code
2
[24] lighted up?
Turn starting
switch ON.
NO
NO
NO
Defective pump
controller
Replace
Replace
harness between C16
(female) (7) and highpressure sensor
Repair or
replace

pressure high-pressure
sensor
Replace
20-622
3
PC1100-6
TROUBLESHOOTING
M-13
M-13 When engine is started, caution items, emergency stop items

flash (but there is no abnormality in any item)
a)
(engine oil pressure) flashes

SAP00520
Cause
See M-11 b)
b)
Remedy
(radiator water level) flashes

SAP00519
fl Check that the radiator water level is normal before carrying out troubleshooting.
Cause
See M-9 a)
c)
Remedy
(battery charge) flashes

SAP00522
Cause
See M-11 a)
PC1100-6
Remedy
20-623
3
TROUBLESHOOTING
d)
M-13
(engine water temperature) flashes

SAP00527
fl Check that the engine water temperature is normal before carrying out troubleshooting.
Cause
Defective engine water

temperature sensor
system (see M-26)
YES
2
YES
1
Is engine water
temperature in
red range?
Run engine at
mid-range or
above.
When P07 is
disconnected, does
only level 1 (left
end) of gauge
display light up?
Run engine at
mid-range or
above.
3 YES
NO
Is resistance
between C03
(female) (1) (16),
(1)(16) chassis
ground normal?
NO
Turn starting
switch OFF.
Disconnect C03 and P07.
Min. 1 M
NO
Defective pump
controller
Short circuit with ground in
wiring harness between C03
(female) (1) and P07 (female)
(1), or short circuit in wiring
harness between C03
(female) (2)
Remedy
Replace
Repair or
replace
Replace
M-13 d) Related electrical circuit diagram
20-624
3
PC1100-6
TROUBLESHOOTING
e)
M-13
(fuel level) flashes

SAP00528
fl Check that there is ample fuel before carrying out troubleshooting.
Cause
Defective fuel level

sensor system (see
M-25)
YES
2
When P06 (female)(1) is
Remedy
YES connected to chassis

1
Is fuel gauge in
red range?
ground, do all lamps to

level 14 (right end) of
gauge display light up?
3 YES
Is voltage
between C03 (2)
Disconnect P06.
Turn starting
NO and chassis
ground normal?
switch ON
Disconnect C03.
Turn starting
switch ON
Max. 1 V
Start engine.
NO
Defective pump
controller
Replace
harness between C03
(female) (1)
Repair or
replace
Replace
NO
M-13 e) Related electrical circuit diagram
PC1100-6
20-625
3
TROUBLESHOOTING
f)
M-13
(air cleaner clogging) flashes

SAP00521
fl Check that the air cleaner is not clogged before carrying out troubleshooting.
Cause
Defective air cleaner

clogging switch
YES
Is bit (6) of
YES monitoring code
3
[24] lighted up?
When P11 (female)

is connected to
P12 (male), does
display go out?
Disconnect P11
and P12.
Start engine.
Is resistance
YES between C16

2
Is resistance
between P12
NO (male) and chassis
ground normal?
Turn starting
switch OFF.
Disconnect P12.
Max. 1
NO
(female) (17) and

chassis ground as
shown in table?
Turn starting
switch OFF.
Disconnect C16,
P11, and P12
NO
Replace
controller
Replace
Replace
harness between C16
(female)
Repair or
replace
harness between P12
(male) and chassis
ground
NO
Remedy
Repair or
replace
Table
Connection between P11 (female) and P12 (male)
Resistance
Connected
Max. 1
Disconnected
Min. 1 M
M-13 f) Related electrical circuit diagram
20-626
3
PC1100-6
TROUBLESHOOTING
g)
M-13
(hydraulic oil temperature) flashes

SAD01484
fl Check that the hydraulic oil temperature is normal before carrying out troubleshooting.
Cause
Defective hydraulic oil

temperature sensor
system (See M-26)
YES
Remedy
1
When P10 is
disconnected,
does display go
out?
3 YES
Start engine.
NO
Is resistance
between C03
(female) (11) (16),
(11)(16) chassis
ground normal?
Turn starting
switch OFF.
Disconnect C16
and P10.
Min. 1 M
Does monitoring
2
value of more
than 21?
Turn starting
switch ON
NO
Defective pump
controller
Replace
Replace

C03 (female) (11) and P10
(female) (1), or short circuit
C03 (female) (16) and P10
(female) (2)
Repair or
replace
NO
M-13 g) Related electrical circuit diagram
PC1100-6
20-627
3
TROUBLESHOOTING
M-14, M-15
M-14 When starting switch is turned on (engine stopped), buzzer does

not sound for 1 second
Caution item flashes but buzzer does not sound
fl Of the caution items, the buzzer will not sound even if there is an abnormality in the battery charge
or fuel level.
fl Before carrying out troubleshooting, check that all
Cause
Remedy
the related connectors are properly inserted.
fl Always connect any disconnected connectors before
going on to the next step.
YES
2
Replace
Repair or
replace
When P01 (female)
YES (7) and chassis

1
Is resistance
between P04
(male) (1) and (2)
normal?
Turn starting
switch OFF.
Disconnect P04.
200 300
ground are
connected, does
buzzer sound?
3 YES
Is voltage
between P04 (1)
Disconnect P01.
Turn starting
NO and chassis
ground normal?
switch ON
Turn starting
switch ON
20 30 V
NO
harness between P01
(female) and P04
(female) (1)
NO
Repair or
replace
Replace
M-15 No abnormality is displayed on monitor but buzzer sounds

fl When the buzzer sounds continuously. (If the buzzer sounds intermittently, carry out troubleshooting M-14.)
Cause
Remedy
2 YES
YES When P01 is
disconnected,
1
Is resistance
between P04
(male)(2) and
chassis ground
normal?
Turn starting
switch OFF.
Disconnect P04.
Min. 1 M
does buzzer stop?
Turn starting
switch ON
NO
NO
Replace

in wiring harness
between P01 (female) (7)
Repair or
replace
Replace
M-14, 15 Related electrical circuit diagram
20-628
3
PC1100-6
TROUBLESHOOTING
M-16
M-16 Night lighting on monitor panel does not light up

fl Check that the head lamps and working lamps light up normally before carrying out troubleshooting.
Cause
YES
1
Is bulb blown or
is there defective
contact?
YES
2
Does bit (3) of

Remove bulb.
monitoring code
Check visually
for blown bulb. NO [49] go out?
Remedy
Blown bulb or defective

contact of bulb
Replace
Replace
harness between P01
(female) (8) and M07
(male) (1)
Repair or
replace
3 YES
Is voltage
between P01 (8)
Turn starting
switch ON
NO and chassis
ground norma?
Turn light switch
ON.
Turn starting
switch ON
Turn light switch
ON.
20 30 V
NO
PC1100-6
20-629
3
TROUBLESHOOTING
M-17, M-18
M-17 Engine water temperature gauge does not rise

fl If the engine water temperature actually does not rise, check the engine system.
Cause
Remedy

temperature sensor
system (see M-26)
YES
1
3 YES
When short connector is

connected to P07 (female),
do level lamps on gauge go
up in turn and then all
lamps go out?
Does monitoring
value of more
than 500?
2
Disconnect P07.
Turn starting
switch ON.
NO
When short connector

is connected to P07
(female), is resistance
(1) and (16) normal?
NO
Turn starting
switch ON
4 YES
Is voltage
Turn starting
between P07 (1)
switch OFF
Disconnect C03 NO and chassis
ground normal?
and P07.
Max. 1
Turn starting
switch ON
20 30 V
NO
Replace
Defective pump
controller
Replace
harness between C03
(female) (2)
Repair or
replace
harness between C03
(female) (1)
Repair or
replace
M-18 Engine water temperature gauge does not give any display
(gauge does not even display 1st level)
Cause

temperature sensor
system (see M- 26)
YES
Remedy
1
When P07 is
disconnected, does
engine water
temperature gauge
display appear?
3 YES
Turn starting
switch ON.
NO
Is resistance
between C03
(female) (1) and
chassis ground
normal?
Does monitoring
value of more
2
than 500?
Disconnect C03 .
Turn starting
switch OFF.
Min. 1 M
Turn starting
switch ON
NO
NO
Defective pump
controller
Replace
Replace

in wiring harness
Repair or
replace
20-630
3
PC1100-6
TROUBLESHOOTING
M-19, M-20
M-19 Fuel level gauge always displays FULL

YES
Cause
Remedy

sensor system (see M-25)
1
When P06 is
disconnected, do level
lamps on gauge go
down in turn and then
all lamps go out?
3 YES
Turn starting
switch ON.
Is resistance
between C03
(female) (2) and
chassis ground
normal?
NO
Does monitoring
value of more
2
than 40?
Disconnect C03
and P06.
Turn starting
switch OFF.
Min. 1 M
NO
Turn starting
switch ON
NO
Defective pump
controller
Replace
Replace

in wiring harness
Repair or
replace
M-20 Fuel level gauge does not give any display (gauge does not even
display 1st level)
YES
Cause
Remedy

sensor system (see M-25)
1
When P06 (female)(1)
is connected to
chassis ground, does
display appear on
gauge?
3 YES
Does monitoring
value of more
2
than 400?
When P06 (female)(1) is
Turn starting
switch ON.
NO
connected to chassis
ground, is resistance
(2) and chassis normal?
Disconnect C03.
Turn starting
switch OFF.
Max. 1
Turn starting
switch ON
NO
NO
Defective pump
controller
Replace
Replace
harness between C03
(female) (1)
Repair or
replace
PC1100-6
20-631
3
TROUBLESHOOTING
M-21
M-21 Swing lock switch is turned ON, but

does not light up
(swing lock monitor)

SAT00098
fl Check that the swing lock switch is actually being actuated before carrying out troubleshooting.
Cause
1 YES
Is voltage between
P01 (female) (5) and
chassis ground as
shown in table?
Turn starting
switch ON
NO
Remedy
Replace
harness between P01
(female) (5) and X05
(male) (1)
Repair or
replace
Table
Swing lock switch ON
Max. 1 V
Swing lock switch OFF
20 30 V
20-632
3
PC1100-6
TROUBLESHOOTING
M-22
M-22 Swing prolix switch is turned ON (prolix), but

lock monitor) does not flash
(swing
SAT00098
fl Check that the swing prolix function is actually being actuated before carrying out troubleshooting.
Cause
2 YES
Remedy
Replace
Defective pump
controller
Replace
harness between C17
(female) (8) and SW1 (4)
Repair or
replace
Is bit (6) of
YES
monitoring code
1
[21] lighted up?
Is voltage between
C17 (8) and
chassis ground as
shown in table ?
Turn starting
switch ON
Turn starting
switch ON
NO
NO
Table
Swing prolix switch ON
Max. 1 V
Swing prolix switch OFF
20 30 V
PC1100-6
20-633
3
TROUBLESHOOTING
M-23, M-24
M-23 Service meter does not advance while engine is running

Cause
YES
Run engine at
mid-range or
above.
2 YES
Does monitoring
code [43] show a
NO value of more
than 100?
Run engine at
mid-range or
above.
See M-11 a)
1
Does battery
charge caution
lamp flash?
Remedy
NO
Replace
Defective pump
controller
Replace
M-24 When starting switch is at OFF and time switch is pressed,

service meter does not give display
Cause
1 YES
When starting
switch is ON, is
panel display
normal?
Turn starting
switch ON
20-634
3
NO
See M-6
Remedy
Replace
PC1100-6
TROUBLESHOOTING
M-25
M-25 Defective fuel level sensor system

fl If it is judged from all the troubleshooting that the fuel level sensor is defective, check the sensor
as an individual part as follows.
fl Remove the fuel level sensor when carrying out the troubleshooting.
Cause
3 YES
Is there any large
Interference with sensor

inside tank (See Note 2)
Install
correctly
Defective contact of
connector
Clean or
replace
connector
Defective sensor (See

Note 2)
Replace
sensor
Disconnection in wiring
harness (See Note 3)
Replace
sensor
Defective sensor
Replace
sensor
YES
crack, chip, or
2
damage to float?
YES Does arm move
NO
smoothly?
1
When float is moved up
and down, is resistance
between connector (1)
and flange as shown in
table?
NO
4 YES
Check wiring
harness visually.
NO Is it broken?
NO
Remedy
Table
Top (FULL) stopper position
Bottom (EMPTY) stopper position
Approx. 12 or below
Approx. 85 110
Note 1: Difference between fuel level and gauge display

For gauge display position 9 (FULL), the amount of fuel is 78 100%; and for display position
1 (EMPTY) it is below 14.5%.
If the chassis is at an angle, the displayed amount of fuel will be different from the actual
amount. Therefore, when checking, stop the machine at a horizontal place and wait for at
least 2 minutes before checking the gauge. (The display is given a time delay so that the
gauge can deal with sudden changes in the fuel level.)
Note 2: There is the possibility of defective installation or interference with the sensor inside the tank,
so be careful when installing.
Note 3: Check for vibration at the connector mount. If there is excessive vibration, take the appropriate action.
PC1100-6
20-635
3
TROUBLESHOOTING
M-26
M-26 Defective engine water temperature sensor system and defective

hydraulic oil temperature sensor system
fl If it is judged from all the troubleshooting that the engine water temperature sensor is defective,
check the sensor as an individual part as follows.
fl Remove the engine oil temperature sensor or hydraulic oil temperature sensor when carrying out
troubleshooting.
Cause
YES
1
Is resistance
between connector
(1) and (2) as shown
in table?
2 YES
Check wiring
harness visually.
NO Is it broken?
NO
Remedy
connector (See Note 1)
Clean or repair
connector
Replace
sensor
Defective sensor
Replace
sensor
Table
Normal temperature (25C)
Approx. 37 50
100C
Approx. 3.5 4.0
BKP00291
Note 1: If the problem occurs again, the connector (female) at the chassis end is probably defective,
so check the connector and wiring harness at the chassis end.
20-636
3
PC1100-6
TROUBLESHOOTING
M-27
M-27 Defective engine oil level sensor system and defective hydraulic
oil level sensor system
fl If it is judged from all the troubleshooting that the engine oil level sensor or hydraulic oil level
sensor is defective, check the sensor as an individual part as follows.
fl Remove the engine oil level sensor or hydraulic oil level sensor when carrying out troubleshooting.
Cause
YES
2
Remedy
Defective movement of
float due to dirt
Clean
Resonance of mount
(See Note 4)
Repair
Clean or repair
connector
Replace
sensor
Defective sensor
Replace
sensor
Is any foreign
YES material (dirt)

stuck to moving
part of float?
1
and flange as shown in
table?
3 YES
Is there any large
crack, chip, or
NO damage to float?
NO
4 YES
Check wiring
harness visually.
NO Is it broken?
NO
Table
Max. 1
Min. 1 M
Note 1: Variations in oil level

The oil level may change according to the angle of the machine, the engine speed, or the
temperature of the oil, so check the oil level with the machine at a horizontal place.
Note 4: Defective installation is a possible cause, so be careful when installing.
If the problem occurs again, check for any vibration of the mount, and if there is excessive
vibration, take the appropriate action.
PC1100-6
20-637
3
TROUBLESHOOTING
M-28
M-28 Defective radiator water level sensor system

fl If it is judged from all the troubleshooting that the radiator water level sensor is defective, check
the sensor as an individual part as follows.
fl Remove the radiator water level sensor when carrying out troubleshooting.
Cause
YES
2
Remedy
Defective movement of
float due to dirt
Clean
Resonance of mount
(See Note 4)
Repair
Clean or repair
connector
Replace
sensor
Defective sensor
Replace
sensor
Is any foreign
YES material (dirt)

stuck to moving
part of float?
1
and (2) as shown in
table?
3 YES
Is there any large
crack, chip, or
NO damage to float?
NO
4 YES
Check wiring
harness visually.
NO Is it broken?
NO
Table
Max. 1
Min. 1 M
Note 1: Variations in radiator sub tank water level

The sub tank water level may change according to the angle of the machine, or the swaying
of the machine, so check the water level with the machine at a horizontal place.
Note 4: Defective installation is a possible cause, so be careful when installing.
If the problem occurs again, check for any vibration of the mount, and if there is excessive
vibration, take the appropriate action.
20-638
3
PC1100-6
TROUBLESHOOTING
M-29
M-29 Defective operation of wiper (including cases where [E113] is

displayed)
a) Wiper does not work when wiper, washer switch is at ON or INT
Cause
3 YES
Is resistance
YES between W08
(male) (2) and (4)
2
normal?
Is voltage between
YES W08 (female) (4)
Turn starting
switch OFF.
Disconnect W08.
25.6 31.4
and chassis
ground normal?
Turn starting
switch ON.
20 30 V
NO
NO
6 YES
1
YES
Is service code
[E113] displayed?
5
Is voltage
YES between W21 (1)
and chassis
ground normal?
Turn starting
switch ON.
4
Is voltage
between P02 (3)
NO and chassis
ground normal?
Is resistance
between W21
(female) (2) and
chassis ground
normal?
9 YES
A
When resistance between

W08 (female) (1) and W21
(female) (1) is normal, and
is it properly insulated from
chassis?
Turn starting
switch OFF.
Disconnect W08
and W21.
Max. 1
PC1100-6
NO
harness between W08
(female) (3)
Replace or
replace
Defective wiper, washer

relay box
Repair
Defective contact,
fuse 7 and W08 (female)
(4)
Replace or
replace
Defective wiper motor
Repair
harness between W21
NO (female) (2) and chassis
ground
Turn starting
switch OFF.
Disconnect W21.
Max. 1
7 YES
Go to A
Turn starting
Is resistance
between W08
switch ON.
(female) (8) and
Turn wiper
NO chassis ground
switch to ON or
normal?
INT.
harness between W08
20 30 V
OFF.
Disconnect W08.
ground
Turn starting
Max. 1
switch ON.
8 YES
Turn wiper
Is resistance
switch to ON or
between M18 (male)
INT.
NO (1) and chassis
Max. 1 V
ground normal?
Turn starting
switch OFF.
Disconnect M18.
Max. 1
NO
Remedy
Replace or
replace
Replace or
replace
Repair
harness between M18
ground
Replace or
replace

relay box
Repair
Defective contact,
W08 (female) (1) and
W21 (female) (1)
Replace or
replace
20-639
3
TROUBLESHOOTING
M-29
b) Wiper does not work when wiper, washer switch is

at one position (ON or INT)
Cause
YES
2
Is voltage between
At ON P02 (female) (4)

and chassis
ground normal?
1
Does wiper not
work at ON or at
INT?
3 YES
Is resistance
between M18
NO (female) (1) and
(2) normal?
Turn starting
switch ON.
Turn wiper
switch ON.
Max. 1 V

ON.
Turn wiper switch ON.
Max. 1
YES
4
Is voltage between
P02 (female) (12)
At INT and chassis
ground normal?
Turn starting
switch ON.
Turn wiper
switch to INT.
Max. 1 V
5 YES
1
Is service code
[E113] displayed?
When P02 is
disconnected, is
resistance between
NO
YES
4
and chassis
ground normal?
3
Is voltage
between P02 (3)
NO and chassis
ground normal?
Turn starting
switch ON.
Turn wiper
switch OFF.
20 30 V
Turn starting
switch ON.
Max. 1 V
5 YES
Is resistance
between W08
normal?
Turn starting
switch OFF.
Disconnect W08.
Min. 1 M
YES
6
NO
Is voltage between
P02 (4) and chassis
ground, between
(12) and chassis
ground normal?
Turn starting
switch ON.
Turn wiper
switch OFF.
20 30 V
Repair or
replace

switch
Replace
Replace
Repair or
replace
Replace
Remedy

in wiring harness
between W08 (female)
(2) and P02 (female) (3)
Repair or
replace

relay box
Replace
Replace

(1) and W21 (female) (1)
Repair or
replace

relay box
Replace
Replace
Is voltage
YES between W21 (1)
20-640
harness between P02
(male) (2)
Cause
2 YES
Turn starting
switch OFF.
Disconnect P02
and W08.
Min. 1 M
Replace

switch
Turn starting
NO
switch ON.
Turn wiper switch to INT.
Max. 1
c) Wiper is actuated when wiper, washer switch is OFF
YES
harness between P02
(male) (4)
Is resistance
between M18
NO (female) (1) and
(4) normal?
Remedy
NO

in wiring harness
7 YES between M18 (male) (2)
and P02 (female) (4) or
Is resistance
between M18
NO (female) (1) (2),
(1) (4) normal?
Turn starting
NO switch
switch OFF.
Turn wiper
switch OFF.
Min. 1 M
Repair or
replace
Replace
PC1100-6
TROUBLESHOOTING
M-29
PC1100-6
20-641
3
TROUBLESHOOTING
M-30
M-30 Defective operation of window washer (including cases where

service code [E114] is displayed)
fl Check that the wiper works properly before carrying out troubleshooting. (If the wiper also does
not work, carry out Troubleshooting M-29 first.)
a) Window washer does not work when wiper, washer switch is at WASH I at WASH II
Cause
harness between W08
(female) (2)(10)
2 YES
Is resistance
YES between W08
(male) (4) and
(15) normal?
NO
Turn starting
switch OFF.
Disconnect W08.
25.6 31.4
YES
3
Is voltage between
P02 (2)(10) and
NO chassis ground
normal?
Turn starting
switch OFF.
Turn wiper
switch to WASH
I, II
Max. 1 V
Is resistance
between M28, M95
(female) (1) and
chassis ground
normal?
Repair or
replace

relay box
Replace
Replace
Is voltage between
YES M28, M95 (female)
(2) and chassis
ground normal?
4
Is service code
[E114] displayed?
20-642
5 YES
Remedy
Defective contact,
Disconnect M28 and NO wiring harness between
M95.
fuse 7 M28, M95
(female) (2)
ON.
20 30 V
6 YES Defective wiper, washer

Is resistance
relay box
Disconnect M28
between W08
and M95.
(female) (12) M28,
Turn starting
NO M95 (female) (1)
switch ON.
normal?
harness between M28,
Turn wiper
M95 (female) (1) W08
switch WASH I,
OFF.
(female) (8)
Disconnect W08,
II.
Repair or
replace
Replace
Repair or
replace
M28, and M95.

Max. 1
NO
Replace
PC1100-6
TROUBLESHOOTING
M-30
b) Washer is actuated when wiper, washer switch is OFF
Cause
2 YES
YES
1
Is service code
[E114] displayed?
When P02 is
disconnected, is
resistance between
NO
Turn starting
switch OFF.
Disconnect P02
and W08.
Min. 1 M
YES
4
YES
3
Is voltage between
P02 (2)(10) and
NO chassis ground
normal?
Turn starting
switch ON.
Turn wiper
switch OFF.
20 30 V
Is resistance
between M29, M95
(female) (1)
chassis ground
normal?
Is resistance
between W08
Disconnect M29
and M95.
NO (male) (12) and
(8) normal?
Turn starting
switch ON.
Turn starting
switch OFF.
Turn wiper
Disconnect W08.
switch OFF.
Min. 1 M
Min. 1 M
NO
YES
6
Is voltage
between P02 (5)
NO and chassis
ground normal?
Turn starting
switch ON.
Turn wiper
switch OFF.
20 30 V
PC1100-6
5 YES
Remedy

in wiring harness
(15) and P02 (female)
(2)(10)
Repair or
replace

relay box
Replace
Replace

in wiring harness
(12) M28, M95 (female)
(1)
Repair or
replace

relay box
Replace
Replace
7 YES in wiring harness

Is resistance
between M18
NO (female) (1) and
(3) normal?
Turn starting
switch OFF.
Turn wiper
switch OFF.
Min. 1 M
NO

switch
Repair or
replace
Replace
20-643
3
TROUBLESHOOTING
M-30
20-644
3
PC1100-6
30 DISASSEMBLY AND ASSEMBLY
METHOD OF USING MANUAL .................

PRECAUTIONS WHEN CARRYING OUT
OPERATION ..........................................
SPECIAL TOOL LIST ..................................
SKETCHES OF SPECIAL TOOLS ...............
STARTING MOTOR ASSEMBLY
Removal and Installation ....................
ALTERNATOR ASSEMBLY
NOZZLE HOLDER ASSEMBLY
ENGINE OIL COOLER ASSEMBLY
FUEL INJECTION PUMP ASSEMBLY
Removal ................................................
Installation ............................................
WATER PUMP ASSEMBLY
TURBOCHARGER ASSEMBLY
THERMOSTAT ASSEMBLY
AIR COMPRESSOR ASSEMBLY
ENGINE FRONT SEAL
ENGINE REAR SEAL
CYLINDER HEAD ASSEMBLY
Removal ................................................
Installation ............................................
AFTERCOOLER
RADIATOR, HYDRAULIC COOLER
ASSEMBLY
Removal ................................................
Installation ............................................
HYDRAULIC COOLER ASSEMBLY
ENGINE, PTO, HYDRAULIC PUMP
ASSEMBLY
Removal ................................................
Installation ............................................
PC1100-6
30- 3
30- 5
30- 7
30-12
30-19
30-20
30-21
30-22
30-23
30-24
30-25
30-26
30-27
30-28
30-29
30-31
30-33
30-37
30-39
30-40
30-41
30-42
30-43
30-46
PTO ASSEMBLY
Removal ................................................
Installation ............................................
Disassembly .........................................
Assembly ..............................................
FUEL TANK ASSEMBLY
FINAL DRIVE ASSEMBLY
Disassembly .........................................
Assembly ..............................................
REVOLVING FRAME ASSEMBLY
SWING MACHINERY ASSEMBLY
Disassembly .........................................
Assembly ..............................................
SWING CIRCLE ASSEMBLY
TRACK SHOE ASSEMBLY
Removal ................................................
Installation ............................................
SPROCKET
IDLER ASSEMBLY
Disassembly .........................................
Assembly ..............................................
IDLER ADJUSTMENT CYLINDER
ASSEMBLY
Disassembly and Assembly ...............
RECOIL SPRING ASSEMBLY
Disassembly .........................................
Assembly ..............................................
CARRIER ROLLER ASSEMBLY
Disassembly .........................................
Assembly ..............................................
TRACK ROLLER ASSEMBLY
Disassembly .........................................
Assembly ..............................................
30-47
30-48
30-49
30-51
30-53
30-54
30-55
30-59
30-67
30-68
30-69
30-73
30-78
30-79
30-80
30-81
30-82
30-83
30-85
30-87
30-88
30-90
30-91
30-92
30-93
30-94
30-95
30-96
30-97
30-1
2
HYDRAULIC TANK ASSEMBLY

Removal ................................................ 30-99
Installation .......................................... 30-100
TVC VALVE ASSEMBLY
Removal and Installation .................. 30-101
SERVO VALVE ASSEMBLY
HYDRAULIC PUMP ASSEMBLY
MAIN PUMP INPUT SHAFT OIL SEAL
MAIN RELIEF VALVE ASSEMBLY
Disassembly and Assembly ............. 30-106
PILOT RELIEF VALVE ASSEMBLY
5-SPOOL CONTROL VALVE ASSEMBLY
Removal .............................................. 30-108
Installation .......................................... 30-109
4-SPOOL CONTROL VALVE ASSEMBLY
Removal .............................................. 30-110
Installation .......................................... 30-111
CONTROL VALVE ASSEMBLY
Disassembly ....................................... 30-114
Assembly ............................................ 30-115
SWING MOTOR ASSEMBLY
CENTER SWIVEL JOINT ASSEMBLY
Disassembly and Assembly ............. 30-127
TRAVEL MOTOR ASSEMBLY
WORK EQUIPMENT PPC VALVE
ASSEMBLY
Disassembly ....................................... 30-130
Assembly ............................................ 30-131
TRAVEL PPC VALVE ASSEMBLY
Disassembly ....................................... 30-133
Assembly ............................................ 30-134
BUCKET CYLINDER ASSEMBLY
Removal .............................................. 30-135
Installation .......................................... 30-136
ARM CYLINDER ASSEMBLY
Removal .............................................. 30-137
Installation .......................................... 30-138
BOOM CYLINDER ASSEMBLY
Removal .............................................. 30-139
Installation .......................................... 30-140
30-2
2
BUCKET ASSEMBLY
Removal ..............................................
Installation ..........................................
ARM ASSEMBLY
Removal ..............................................
Installation ..........................................
BOOM ASSEMBLY
Removal ..............................................
Installation ..........................................
BUCKET, ARM ASSEMBLY
Removal ..............................................
Installation ..........................................
WORK EQUIPMENT ASSEMBLY
Removal ..............................................
Installation ..........................................
CAB ASSEMBLY
Removal ..............................................
Installation ..........................................
COUNTERWEIGHT ASSEMBLY
Removal and Installation ..................
RECEIVER TANK ASSEMBLY
AIR CONDITIONER CONDENSER
ASSEMBLY
AIR CONDITIONER COMPRESSOR
ASSEMBLY
AIR CONDITIONER UNIT ASSEMBLY
Removal ..............................................
Installation ..........................................
SOLENOID VALVE ASSEMBLY
GOVERNOR CONTROLLER ASSEMBLY
MONITOR PANEL ASSEMBLY
PUMP CONTROLLER ASSEMBLY
BOOM ROCK PREVENTION VALVE
ASSEMBLY
ACCUMULATOR ASSEMBLY
ASSEMBLY
30-141
30-142
30-143
30-144
30-145
30-146
30-147
30-148
30-149
30-150
30-151
30-152
30-153
30-154
30-155
30-156
30-157
30-158
30-159
30-160
30-161
30-162
30-163
30-164
30-165
PC1100-6
DISASSEMBLY AND ASSEMBLY
METHOD OF USING MANUAL

1. When removing or installing unit assemblies
1 When removing or installing a unit assembly, the order of work and techniques used are given
for the removal operation; the order of work for the installation operation is not given.
2 Any special techniques applying only to the installation procedure are marked 1, and the
same mark is placed after the relevant step in the removal procedure to indicate which step in
the installation procedure it applies to.
(Example)
REMOVAL OF o o o o ASSEMBLY ............ Title of operation
...................................................................... Precautions related to safety when carrying out
the operation
1. X X X X (1) ..................................................... Step in operation
fl .................................................................. Technique or important point to remember
when removing XXXX (1).
2. # # # # (2): ............................................... 1 Indicates that a technique is listed for use
during installation
3. l l l l assembly (3)
6 ............................................................ Quantity of oil or water drained
INSTALLATION OF o o o o ASSEMBLY ....Title of operation
Carry out installation in the reverse order to removal.
1 ............................................................. Technique used during installation
fl .................................................................. Technique or important point to remember when
installing # # # # (2).
Adding water, oil ................................. Step in operation
fl ............................................................ Point to remember when adding water or oil
-......................................................... Quantity when filling with oil and water
2. General precautions when carrying out installation or removal (disassembly or assembly) of units
are given together as PRECAUTIONS WHEN CARRYING OUT OPERATION, so be sure to follow
these precautions when carrying out the operation.
3. Listing of special tools
1 For details of the description, part number, and quantity of any tools (A1, etc.) that appear in
the operation procedure, see the SPECIAL TOOLS LIST given in this manual.
PC1100-6
30-3
2
4. General tightening torque table (when using torque wrench)

fl In the case of metric nuts and bolts for which there is no special instruction, tighten to the torque
given in the table below.
Thread diameter
Width across flats

SAD00481
mm
6
8
10
12
14
16
18
20
22
24
27
30
33
36
39
mm
10
13
17
19
22
24
27
30
32
36
41
46
50
55
60
kgm
1.35 0.15
3.2 0.3
6.7 0.7
11.5 1.0
18.0 2.0
28.5 3
39 4
56 6
76 8
94.5 10
135 15
175 20
225 25
280 30
335 35
SAD00482
Nm
13.2 1.4
31.4 2.9
65.7 6.8
112 9.8
177 19
279 29
383 39
549 58
745 78
927 98
1320 140
1720 190
2210 240
2750 290
3280 340
Seal surface
SAD00483
5. Table of tightening torques for flared nuts

fl In the case of flared nuts for which there is no special instruction, tighten to the torque given in the
table below.
Thread diameter
mm
14
18
22
24
30
33
36
42
Width across flats

mm
19
24
27
32
36
41
46
55
Tightening torque
kgm
Nm
2.5 0.5
24.5 4.9
52
49 19.6
82
78.5 19.6
14 3
137.3 29.4
18 3
176.5 29.4
20 5
196.1 49
25 5
245.2 49
30 5
294.2 49
6. Table of tightening torques for split flange bolts

fl In the case of split flange bolts for which there is no special instruction, tighten to the torque given
in the table below.
Thread diameter
mm
10
12
16
30-4
2
Width across flats

mm
14
17
22
Tightening torque
kgm
Nm
6.7 0.7
65.7 6.8
11.5 1
112 9.8
28.5 3
279 29
PC1100-6
PRECAUTIONS WHEN CARRYING OUT OPERATION

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

Nominal
number
Flange (hose end)
Sleeve head (tube end)
Split flange
04
05
07379-00400
07379-00500
07378-10400
07378-10500
07371-30400
07371-30500
Part Number
06
08
10
12
14
16
18
20
22
24
27
07049-00608
07049-00811
07049-01012
07049-01215
07049-01418
07049-01620
07049-01822
07049-02025
07049-02228
07049-02430
07049-02734
PC1100-6
Dimensions
D
d
L
6
5
8
8 6.5 11
10 8.5 12
12 10 15
14 11.5 18
16 13.5 20
18 15 22
20 17 25
22 18.5 28
24 20 30
27 22.5 34
Taper 1/8
Nominal
number
3) If the part is not under hydraulic pressure, the following corks can be used.
DEW00401
30-5
2
2.
Precautions when carrying out installation work

Tighten all bolts and nuts (sleeve nuts) to the specified (KES) torque.
Install the hoses without twisting or interference.
Replace all gaskets, O-rings, cotter pins, and lock plates with new parts.
Bend the cotter pins and lock plates securely.
When coating with adhesive, clean the part and remove all oil and grease, then coat the threaded
portion with 2 3 drops of adhesive.
When coating with gasket sealant, clean the surface and remove all oil and grease, check that there
is no dirt or damage, then coat uniformly with gasket sealant.
Clean all parts, and correct any damage, dents, burrs, or rust.
Coat rotating parts and sliding parts with engine oil.
When press fitting parts, coat the surface with anti-friction compound (LM-P).
After fitting snap rings, check that the snap ring is fitted securely in the ring groove.
When connecting wiring connectors, clean the connector to remove all oil, dirt, or water, then
connect securely.
When using eyebolts, check that there is no deformation or deterioration, screw them in fully, and
align the direction of the hook.
When tightening split flanges, tighten uniformly in turn to prevent excessive tightening on one
side.
fl When operating the hydraulic cylinders for the first time after reassembling cylinders, pumps and
other hydraulic equipment removed for repair, always bleed the air as follows:
1. Start the engine and run at low idling.
2. Operate the work equipment control lever to operate the hydraulic cylinder 4 5 times,
stopping the cylinder 100 mm from the end of its stroke.
3. Next, operate the hydraulic cylinder 3 4 times to the end of its stroke.
4. After doing this, run the engine at normal speed.
fl When using the machine for the first time after repair or long storage, follow the same
procedure.
3. Precautions when completing the operation
If the coolant has been drained, tighten the drain valve, and add water to the specified level. Run
the engine to circulate the water through the system. Then check the water level again.
If the hydraulic equipment has been removed and installed again, add engine oil to the specified
level. Run the engine to circulate the oil through the system. Then check the oil level again.
If the piping or hydraulic equipment have been removed, always bleed the air from the system
after reassembling the parts.
fl For details, see TESTING AND ADJUSTING, Bleeding air.
Add the specified amount of grease (molybdenum disulphide grease) to the work equipment parts.
30-6
2
PC1100-6
SPECIAL TOOL LIST
SPECIAL TOOL LIST

fl Tools with part number 79o T- ooo- oooo can not be supplied (they are items to be locally
manufactured).
fl Necessity: : Cannot be substituted, should always be prepared (used).
Extremely useful if available, can be substituted with commercially available part.
fl New/remodel: N: Tools with new part numbers, newly developed for this model.
fl
R: Tools with upgraded part numbers, remodeled from items already available for
other models.
fl
Blank: Tools already available for other models, can be used without any modification.
fl Tools marked 9 in the Sketch column are tools introduced in special sketches (See SKETCHES OF
SPECIAL TOOLS).
Component
Symbol
Part No.
Part Name
790-331-1110
Wrench
790-471-1001
Lifting tool
795-902-1430
Push tool
01050-32235
Bolt
795-902-1410
Sleeve
01050-32240
Bolt
795-902-1440
Push tool
01050-32050
Bolt
795-902-1420
Sleeve
795-902-1450
Bolt
01582-02016
Nut
795T-871-1110
Adapter
790-701-5401
Push tool kit
790-101-5541
Plate
790-101-5421
Grip
01010-51240
Bolt
796T-826-1110
Plate
796T-826-1130
Push tool
796T-826-1120
Push tool
790-331-1110
Wrench
Angle tightening
Removal, installation of
round nut
4
A
5
Removal,
installation of
cylinder head
Press fitting of front
seal
Press fitting of front
sleeve
Press fitting of rear
seal
Press fitting of rear

sleeve
2
Disassembly,
assembly of
final drive
796-627-1200
Wrench assembly
796T-827-1130
Spacer
01017-52450
Bolt
01580-12419
Nut
790-201-2820
Spacer
790-101-5401
Push tool kit (C)
790-101-5491
Push tool
790-101-5421
Grip
01010-51240
Bolt
PC1100-6
injection pump
Press fitting of oil

seal
1
Disassembly,
assembly of
swing
machinery
Nature of work,
remarks
Disassembly,
assembly of
engine
New/
Necessity Qty remodel Sketch
Press fitting of main

bearing
Press fitting of sub
bearing
Press fitting of pinion
shaft
9
Pulling out of No. 1
carrier pin holder
Pulling out of No. 1
carrier pin
Press fitting of No. 1

carrier gear bearing
outer race
30-7
2
Component
Symbol
New/
Nature of work,
remarks
Press fitting of needle

bearing
Plate
No. 2 carrier
790-101-5061
Plate
No. 3 carrier
790-101-5021
Grip
01010-50816
Bolt
796-627-1030
Push tool
790-101-2300
790-101-5001
Push tool kit
790-101-5151
Press fitting of outer

race
Push-puller
790-101-2310
Block
Measurement depth
of hub bearing
inner race
790-101-2350
Leg
790-101-2360
Plate
02215-11622
Nut
791-181-1010
Adapter
796T-627-1340
Push tool
790-101-2102
Puller
(290 kN {30 ton})
790-101-1102
Hydraulic pump
796-627-1050
Installer
796-660-1560
Guide bolt
791-685-8501
Compressor
791-635-3160
Extension
796T-830-1110
Plate
796T-830-1120
Spacer
01010-61640
Bolt
790-101-1600
Cylinder
(690 kN {70 ton})
790-101-1102
Hydraulic pump
790-101-5401
Push tool kit (C)
790-101-5441
Plate
790-101-5421
Grip
01010-51240
Bolt
796T-830-1130
Push tool
796T-830-1140
Adapter
796-570-1020
Installer
790-101-5401
Push tool kit (C)
790-101-5521
Plate
790-101-5421
Grip
Disassembly,
assembly of
recoil spring
Part Name
Disassembly,
assembly of
final drive
Part No.
SPECIAL TOOL LIST
Installation of floating
seal
travel motor
Disassembly,
assembly of recoil
spring
Press fitting of
carrier roller bearing
outer race
Disassembly,
assembly of
carrier roller,
track roller,
idler
30-8
2
Press fitting of carrier roller

bearing inner race
Press fitting of shaft

and roller
Installation of carrier
roller floating seal
PC1100-6
Component
Symbol
Part No.
SPECIAL TOOL LIST
Part Name
01010-51240
Bolt
790-434-1620
Installer
Installation of track
roller floating seal
790-401-1700
Lifting tool
790-401-1761
Adapter
Removal, installation
of track roller
assembly
790-401-1540
Shackle
790-401-1770
T-bolt
790-101-5401
Push tool lit
790-101-5541
Plate
790-101-5421
Grip
01010-51240
Bolt
796-675-1510
Installer
791-601-1000
Oil pump
10 791-646-8002
Oil lubricator
790-701-3000
Seal checker
796-832-1110
Remover & Installer
791-685-9510
Frame
791-685-9520
Frame
791-685-9530
Rod
791-685-9540
Rod
791-685-9550
Nut
791-685-9560
Bolt
791-126-0150
Adapter
791-680-5520
Guide
791-632-1150
Pusher
791-632-1140
Adapter
791-832-1110
Adapter
790-434-1610
Grip
01010-51440
Bolt
791-685-9620
Extension
791-632-1160
Guide
791-680-5543
Adapter
791-680-5551
Guide
796-832-1120
Adapter
791-632-1170
Guide
PC1100-6
Press fitting of idler

bushing
Disassembly,
assembly of
track
Nature of work,
remarks
Disassembly,
assembly of
carrier roller,
track roller,
idler
New/
Installation of idler
floating seal
Filling with oil and

checking seal
N
Pulling out and

insertion of master
pin
N
30-9
2
Component
Disassembly,
assembly of
track
Symbol
Part No.
SPECIAL TOOL LIST
Part Name
New/
791-680-9630
Adapter
790-101-4300
790-101-4200
Cylinder
(1,500 kN {150 ton})
Puller
(290 kN {30 ton})
790-101-1102
Hydraulic pump
796-770-1301
Oil stopper
790-101-5001
Push tool kit (A)
790-101-5151
Plate
790-101-5021
Grip
01010-50816
Bolt
790-101-5201
Push tool kit (B)
790-101-5221
Grip
01010-51225
Bolt
791-222-1310
Plate
790-502-1003
Repair stand
Disassembly, assembly
of hydraulic cylinder
790-201-1702
Push tool kit (C)
790-201-1861
Push tool
Press fitting of coil

bushing
(Bucket cylinder)
790-201-5021
Grip
01010-50816
Bolt
790-201-1910
Push tool
(Arm cylinder)
790-863-1110
Push tool
(Boom cylinder)
790-101-5421
Grip
01010-51240
Bolt
Boom & arm

cylinder
790-201-1500
Push tool kit
790-201-1670
Plate
790-101-5021
Grip
01010-50816
Bolt
792-715-1400
Push tool
790-201-1920
Push tool
790-101-5421
Grip
01010-51240
Bolt
790-720-1000
Expander
796-720-1680
Ring
07281-01589
Clamp
2
Removal,
installation of
hydraulic pump
and replacement
of pump input
shaft oil seal
3,4
U
5
6,7
8
9
30-10
2
pump
Replacement of input
shaft seal of No. 1, 2
pump
Disassembly,
assembly of
hydraulic
cylinder
Nature of work,
remarks
Replacement of input
shaft seal of No. 3
pump
Press fitting of dust

seal
(Bucket cylinder)
(Boom & arm cylinder)
Installation of piston
ring
(Bucket cylinder)
PC1100-6
Component
Symbol
Disassembly,
assembly of
hydraulic
cylinder
10
Part No.
SPECIAL TOOL LIST
Part Name
796-720-1710
Ring
07281-02709
Clamp
796-702-1720
Ring
07281-02429
Clamp
796T-870-1130
Sleeve
796T-870-1140
Sleeve
790-445-4130
Screw
01643-32780
Washer
02215-11622
Nut
790-101-4200
Puller
(290 kN {30 ton})
790-101-1102
Hydraulic pump
790-445-4120
Sleeve
790-445-4140
Sleeve
02215-11622
Nut
01643-32780
Washer
790-101-4200
Puller
(290 kN {30 ton})
790-101-1102
Hydraulic pump
796T-870-1120
Sleeve
796-870-1110
Adapter
796-900-1230
Screw
01643-33080
Washer
01582-03024
Nut
790-101-4000
Puller
(500 kN {50 ton})
790-101-1102
Hydraulic pump
796T-870-1150
Sleeve
790-438-1110
Screw
796-775-1110
Adapter
791-112-1180
Nut
790-101-2540
Washer
U
11
Disassembly,
assembly of
work equipment
Charging air
conditioner with
gas
PC1100-6
New/
Puller
790-101-2102 (290 kN {30 ton})
790-101-1102
Hydraulic pump
799-703-1200
Service tool kit
799-703-1100
Vacuum pump
799-703-1110
Vacuum pump (220 V)
799-703-1400
Gas leak tester
Nature of work,
remarks
(Arm cylinder)
(Boom cylinder)
Pulling out of boom

foot pin
Pulling out of boom

cylinder head pin
and bottom pin
Pulling out of boom

top pin
Pulling out of arm

cylinder head pin
and bottom pin
Charging with new

freon gas
799-703-1120 (240 V)
30-11
2
SKETCHES OF SPECIAL TOOLS

Note:
A7 Adapter
Komatsu cannot accept any responsibility for special tools

manufactured according to these sketches.
F2 Plate
30-12
2
PC1100-6
F3 Push tool
F4 Push tool
PC1100-6
30-13
2
J2 Spacer
J7 Push tool
30-14
2
PC1100-6
M1 Plate
M1 Spacer
PC1100-6
30-15
2
L2 Push tool
L3 Adapter
30-16
2
PC1100-6
V1 Sleeve
V1 Sleeve
PC1100-6
30-17
2
V3 Sleeve
V4 Sleeve
30-18
2
PC1100-6
STARTING MOTOR
REMOVAL OF STARTING
MOTOR ASSEMBLY
Disconnect the cable from the negative ()
terminal of the battery.
A. Removal of R.H. starting motor assembly
1. Open cover (1) and use a ladder to enter into
side face of engine.
2. Disconnect wiring connector (2) (M2).
3. Disconnect terminal B wiring (3) (tightened
together with 3 wires).
4. Remove mounting bolt (4), then remove starting
motor assembly (5).
B.
1.
2.
3.
Removal of L.H. starting motor assembly

Open doors (1).
Disconnect wiring connector (2) (M90).
Disconnect terminal B wiring (3) (tightened
together with 3 wires).
4. Remove mounting bolt (4), then remove starting
motor assembly (5).
INSTALLATION OF STARTING
MOTOR ASSEMBLY
Carry out installation in the reverse order to

removal.
PC1100-6
30-19
2
ALTERNATOR
REMOVAL OF ALTERNATOR
ASSEMBLY
2. Disconnect wiring (2) (terminals B and R).
3. Loosen lock bolt (3).
4. Loosen locknuts (4) and lock bolt (5), and remove
fan belt (6) from pulley.
1
5. Remove lock bolts (3) and (5), then remove
alternator assembly (7).
INSTALLATION OF
ALTERNATOR ASSEMBLY

removal.
1
fl Adjust the fan belt tension.
For details, see TESTING AND ADJUSTING,
Adjusting fan belt tension.
30-20
2
PC1100-6
NOZZLE HOLDER
REMOVAL OF NOZZLE
HOLDER ASSEMBLY
1. Open engine hood.
2. Remove fuel injection tubes (1).
3. Remove spill tube (2).
4. Remove connection (3).

5. Remove head cover (4).
3
fl Remove nozzle seal (5) from the head cover.
6. Remove 2 holder bolts (6), then remove nozzle
assembly (7).
4
INSTALLATION OF NOZZLE
HOLDER ASSEMBLY

removal.
1
3 Fuel injection tube:
22.7 3.0 Nm {2.3 0.3 kgm}
2
3 Spill tube: 15.8 2.0 Nm {1.0 0.2 kgm}
3
3 Head cover:
32.5 3.0 Nm {3.3 0.3 kgm}
4
3 Holder bolt:
27.5 3.0 Nm {2.8 0.3 kgm}
PC1100-6
30-21
2
ENGINE OIL COOLER
REMOVAL OF ENGINE OIL

COOLER ASSEMBLY
1. Drain coolant.
2. Remove engine hood (1).
4 Engine hood assembly: 60 kg
3. Remove adiabatic plates (2), (3), and (4).
4. Remove brackets (5) together with oil cooler
mounting bolts.
5. Disconnect wiring harness clamp (6).
6. Remove water pipe (7).
7. Remove turbocharger drain tube (8).
8. Remove 26 mounting bolts (9), then remove oil
cooler assembly (10).
9. Remove core (12) from cover (11).
INSTALLATION OF ENGINE OIL

COOLER ASSEMBLY

removal.
Refilling with water

Add water to the mouth of the radiator filler
port. Tighten the cap and run the engine to
circulate the water through the system. Then
check the water level in the reserve tank.
(Check if the water level goes up or down.)
30-22
2
PC1100-6
FUEL INJECTION PUMP
REMOVAL OF FUEL INJECTION

PUMP ASSEMBLY
1. Close fuel valve.
3. Open engine side doors (2).
4. Remove cover (3), and disconnect wiring

connectors for injection pump.
fl Connectors for governor control solenoid:
E19, E32
fl Connector for variable prestroke control
solenoid: E20
fl Connector for rack sensor: E22
5. Disconnect hose (5) between hand priming pump

and feed pump.
6. Disconnect hose (6) between feed pump and
fuel filter.
7. Disconnect hose (7) between fuel injection pump
and fuel filter.
8. Disconnect hose (8) between fuel injection pump
and fuel tank.
9. Remove inlet tube (9) for fuel injection pump
lubrication.
10. Disconnect fuel injection tubes (10).

1
11. Remove U-bolt (11), then remove bracket (12).
12. Disconnect outlet tube (13) for fuel injection
pump lubrication.
13. Remove cover (14).
PC1100-6
30-23
2
FUEL INJECTION PUMP
14. Loosen coupling bolts (15).
15. Remove 4 mounting bolts (16), then remove fuel

injection pump assembly (17).
4 Fuel injection pump assembly: 45 kg
INSTALLATION OF FUEL
INJECTION PUMP ASSEMBLY

removal.
1
3 Fuel injection tube:
23.66 0.98 Nm {2.4 0.1 kgm}
fl Adjust the fuel injection timing.
Testing and adjusting fuel injection timing.
fl Bleed the air from the fuel system.
30-24
2
PC1100-6
WATER PUMP
REMOVAL OF WATER PUMP

ASSEMBLY
1. Drain coolant.
3. Remove 4 mounting bolts (2).
4. Remove bracket (3).
5. Remove connector tube (4) between oil cooler

and water pump.
fl Move the alternator wiring towards the
engine.
6. Remove mounting bolt (5) of water bypass pipe.
7. Remove 4 mounting bolts (6), then remove water
pump assembly (7).
fl Pull out the water bypass pipe while
removing the water pump assembly down
to the rear.
INSTALLATION OF WATER
PUMP ASSEMBLY

removal.
1
fl Tighten the bracket mounting bolts in turn
at the top and bottom.

PC1100-6
30-25
2
TURBOCHARGER
REMOVAL OF
1. Open engine hood (1).
2. Disconnect bracket (2).
3. Remove 4 joint tube mounting bolts (3), and
disconnect joint tube (6) from air cleaner
assembly (4).
4. Remove lock bracket, and pull out joint tube (6)
from turbocharger.
5. Remove adiabatic plate (7).
fl Disconnect the exhaust temperature sensor
connector.
6. Disconnect turbocharger lubrication oil outlet
tube (8).
7. Disconnect clamp (9).
8. Remove clamps (10) (2 places), and pull out tube
(11) between aftercooler and turbocharger from
turbocharger.
9. Disconnect turbocharger lubrication oil inlet hose
(12).
10. Remove 4 mounting bolts, then remove
turbocharger assembly (13).
1
INSTALLATION OF

removal.
1
3 Turbocharger assembly mounting bolt:
67.0 7.9 Nm {6.8 0.8 kgm}
30-26
2
PC1100-6
THERMOSTAT
REMOVAL OF THERMOSTAT
ASSEMBLY
1. Drain coolant.
3. Remove hose (2) between radiator and
thermostat.
4. Remove aeration tube (3).
5. Disconnect tension pulley lubrication grease
tubes (4) and (5).
6. Remove pin (7), and move water pipe (8) towards
rear of engine, then disconnect from cover (6).
7. Remove mounting bolts, then remove cover (6).
8. Remove thermostats (10) and seals (11) from
thermostat housing (9).
INSTALLATION OF
THERMOSTAT ASSEMBLY

removal.

PC1100-6
30-27
2
AIR COMPRESSOR
REMOVAL OF AIR
COMPRESSOR ASSEMBLY
1. Drain engine cooling water to level of thermostat
housing.
2. Open engine room door.

3. Remove suction tube (1).
4. Remove tube (2) going to air tank.
5. Remove tube (3) going to air governor.
6. Remove lubrication tube (4).
7. Disconnect tube (5) coming from thermostat
housing.
8. Disconnect tube (6) going to engine oil cooler.
9. Remove mounting bolts, then remove air
compressor assembly (7).
INSTALLATION OF AIR
COMPRESSOR ASSEMBLY

removal.
30-28
2
PC1100-6
ENGINE FRONT SEAL
REMOVAL OF ENGINE FRONT

SEAL
1. Remove radiator guard assembly.
For details, see REMOVAL OF RADIATOR,
HYDRAULIC COOLER ASSEMBLY.
2. Remove crankshaft pulley and damper (1).1
3. Remove front seal (2).
INSTALLATION OF ENGINE
FRONT SEAL

removal.
1
fl Align the dowel pin when installing the
crankshaft pulley.
fl Tighten the mounting bolts in the order
shown in the diagram on the right.
3 Crankshaft pulley mounting bolt:
1st step: 73.5 19.6 Nm {7.5 2 kgm}
2nd step: 245 19.6 Nm {25 2 kgm}
3rd step: 637 19.6 Nm {65 2 kgm}
2
Procedure for assembling standard seal
fl Fill the lip portion with approx. 5 cc of lithium
grease (G2-LI).
fl Press fit front seal (2) to front cover (3).
fl After press fitting, check mounting dimension
a.
Front seal mounting dimension a:
66 mm (standard)
PC1100-6
30-29
2
ENGINE FRONT SEAL
Procedure for assembling front seal with sleeve

(for maintenance)
1) Using tool A4, guide bolt 1, and nut 2,
press fit sleeve (4) to crankshaft (5).
fl Tighten 3 nuts 2 uniformly.
fl Press fit until tool A4 contacts the end
face of the crankshaft.
fl After press fitting, check that mounting
dimension b of the sleeve is the
specified dimension.
Sleeve mounting dimension b:
68 0.1 mm
2) Press fit front seal (6) to front cover (3).

fl Fill the lip portion with approx. 5 cc of
lithium grease (G2-LI).
fl After press fitting, check mounting
dimension c.
Front seal mounting dimension c:
66 mm (standard)
30-30
2
PC1100-6
ENGINE REAR SEAL
REMOVAL OF ENGINE REAR

SEAL
1. Remove damper assembly.
For details, see REMOVAL OF DAMPER ASSEMBLY.
2. Remove 1 mounting bolt of flywheel (1), and
install guide bolt 1.
3. Using eyebolts 2, sling flywheel (1), then
remove remaining mounting bolts.
1
4. Move flywheel (1) out to front and lift off.
The flywheel pilot is shallow and it may come
off suddenly, so be careful not to get your
fingers caught.
2
4
Flywheel: 75 kg
5. Remove rear seal (2).
INSTALLATION OF ENGINE
REAR SEAL

removal.
1
fl Coat the thread and seat surface of the
flywheel mounting bolts with anti-friction
compound (LM-P).
fl Secure the flywheel and housing with
stopper 3, then tighten the mounting bolts.
fl Tighten the flywheel mounting bolts in the
order shown in the diagram on the right.
3 Flywheel mounting bolt
1st step: 98 19.6 Nm {10 2 kgm}
2nd step: 294 19.6 Nm {30 2 kgm}
3rd step: 539 19.6 Nm {55 2 kgm}
PC1100-6
30-31
2
ENGINE REAR SEAL
fl After installing the flywheel, use dial gauge

4 to measure the radial and face runout of
the flywheel.
Face runout: Max. 0.15 mm
Radial runout: Max. 0.20 mm
2
Procedure for assembling standard seal
fl Press fit the rear seal until it contacts the
flywheel housing.
Procedure for assembling rear seal with sleeve

(for maintenance)
1) Using tool A5, guide bolts 5, and nuts 6,
press fit sleeve (3) to crankshaft (4).
fl Tighten 2 nuts 6 uniformly.
fl Press fit until tool A5 contacts the
crankshaft.
fl After press fitting, check that mounting
dimension a of sleeve is the specified
dimension.
Sleeve mounting dimension a:
27 1 mm
2) Press fit rear seal (5) until it contacts flywheel

housing (6).
30-32
2
PC1100-6
CYLINDER HEAD
REMOVAL OF CYLINDER HEAD

ASSEMBLY
1. Open engine side doors (1).
2. Remove engine hoods (2).
3. Drain coolant.
4. Disconnect clamp (3) of turbocharger lubrication

oil inlet hose.
5. Remove U-bolt (4), then remove tube (5) between
aftercooler and turbocharger.
7. Disconnect tube (7) between aftercooler and
intake manifold.
8. Disconnect muffler end (8) and air cleaner end
(9) of Komaclone tube.
fl Remove it after removing the fuel injection
tube.
9. Disconnect turbocharger lubrication inlet hose
(10).
10. Disconnect wiring connector (11) (P13) for auto
priming.
11. Disconnect hose (12) for auto priming.
12. Disconnect hoses (13), and remove fuel filter
assembly (14).
13. Remove fuel injection tubes (15).
1
14. Remove inlet and outlet tubes (16) of corrosion

resistor.
15. Remove corrosion resistor assembly (17).
16. Disconnect fuel return hoses (18) and (19), then
remove bracket (20).
17. Disconnect hose (21) between compressor and
intake manifold.
PC1100-6
30-33
2
CYLINDER HEAD
18. Remove mounting bolts, then lift off intake

manifold assembly (22).
2
4 Intake manifold assembly: 30 kg
19. Disconnect water temperature sensor wiring

connector (23) (P7).
20. Disconnect water temperature sensor wiring (24)
at connector end.
21. Remove ground connection wiring (25).

23. Remove exhaust temperature sensor (27), then
remove adiabatic plate (28).
25. Disconnect air cleaner clogging switch wiring

connectors (30) (P11, 12).
26. Remove air cleaner mounting bracket (31), then
remove air cleaner assembly (32).
27. Remove bracket (33), then remove joint tube
(34).
28. Disconnect heater hose (35).
29. Disconnect exhaust temperature sensor wiring
clamp (36).
30. Disconnect water temperature sensor wiring
connector (37) (P19).
30-34
2
PC1100-6
CYLINDER HEAD
33. Lift off muffler assembly (40).

4 Muffler assembly: 90 kg
34. Disconnect turbocharger lubrication outlet tube

(41).
35. Lift off turbocharger and exhaust manifold

assembly (42).
3
4 Turbocharger, exhaust manifold assembly:
60 kg

37. Remove spill hose (44) and eye joint (45).
38. Remove cylinder head cover (46).
4
PC1100-6
30-35
2
CYLINDER HEAD
39. Remove rocker arm assembly (47).

5
fl Loosen the locknut and turn the adjustment
screw back 2 3 turns.
40. Remove crosshead (48) and pushrod (49). 6

41. Remove holder (50), then remove nozzle holder
assembly (51).
7
42. Remove pin (52), and use a bar to move water

manifold (53).
43. Remove mounting bolts, then remove rocker arm
housing (54).
8
44. Using eyebolts 1, remove cylinder head

assembly (55).
9
4 Cylinder head assembly: 40 kg
30-36
2
PC1100-6
CYLINDER HEAD
INSTALLATION OF CYLINDER
HEAD ASSEMBLY

removal.
1
3 Fuel injection tube sleeve nut:
23.66 0.98 Nm {2.4 0.1 kgm}
2
3 Intake manifold assembly mounting bolt:
66.15 7.35 Nm {6.75 0.75 kgm}
3
3 Turbocharger, exhaust manifold assembly
mounting bolt:
110.25 12.25 Nm {11.25 1.25 kgm}
4
3 Cylinder head cover mounting bolt :
31.85 2.45 Nm {3.25 0.25 kgm}
5
fl Clean the oil holes of the mounting bolts
before installing.
fl Check that the ball of the adjustment screw
is fitted properly into the socket of the push
rod.
fl Adjust the valve clearance.
Testing and adjusting valve clearance.
3 Rocker arm assembly mounting bolt :
98 4.9 Nm {10 0.5 kgm}
3 Locknut : 67.62 9.8 Nm {6.9 1 kgm}
6
fl Adjust the crosshead as follows.
1) Loosen the locknut and turn back the
adjustment screw.
2) Press down lightly on the top of the
crosshead and screw in the adjustment
screw.
PC1100-6
30-37
2
CYLINDER HEAD
3) When the adjustment screw contacts the

valve stem, tighten it a further 20.
4) Tighten the locknut to hold the
adjustment screw in position.
3 Locknut:
58.8 5.88 Nm {6 0.6 kgm}
7
fl Assemble so that the nozzle holder counter
marks are facing the front of the engine.
3 Holder mounting bolt:
27.5 3.0 Nm {2.8 0.3 kgm}
8
3 Rocker arm housing mounting bolt:
98 4.9 Nm {10 0.5 kgm}
9
fl Check that there is no dirt or dust on the
cylinder head mounting surface or inside the
cylinder.
fl Check that the grommet does not come out
when installing the gasket.
fl Tighten the cylinder head mounting bolts in
the order shown in the diagram on the right.
2 Mounting bolt:
Anti-friction compound (LM-P)
3 Cylinder head mounting bolt
1st step: 98 9.8 Nm {10 1 kgm}
2nd step: 186.2 4.9 Nm {19 0.5 kgm}
3rd step: Make marks with paint on the
bolt and head, then tighten bolt
a further 60 +150.
fl After tightening, make one punch mark on
the bolt head to indicate the number of times
it has been tightened.
If any bolt already has five punch marks, do
not reuse it. Replace it with a new bolt.

Add water to the specified level, and run the
engine to circulate the water through the system.
Then check the water level again.
30-38
2
PC1100-6
AFTERCOOLER
REMOVAL OF AFTERCOOLER
ASSEMBLY
2. Remove handrail (2).
3. Remove step (3).
fl Remove the guard at the front of the
aftercooler.
4. Disconnect aftercooler outlet hose (4).
5. Disconnect aftercooler inlet hose (5).
6. Disconnect outlet hose (6) of aftercooler cooling
fan motor.
7. Disconnect inlet hose (7) of aftercooler cooling
fan motor.
8. Disconnect lubrication grease tube (8) of
aftercooler cooling fan motor.
9. Remove mounting bolts, then lift off aftercooler
assembly (9).
4 Aftercooler assembly: 1,060 kg
fl Sling the aftercooler before removing the
mounting bolts.
INSTALLATION OF
AFTERCOOLER ASSEMBLY

removal.
PC1100-6
30-39
2
REMOVAL OF RADIATOR,
HYDRAULIC COOLER
ASSEMBLY
Lower the work equipment completely to the
1.
2.
3.
4.
ground and stop the engine. Then loosen the oil

filler cap slowly to release the pressure inside
the hydraulic tank.
Drain coolant.
Remove radiator mask (1).
Remove radiator guards (2).
Remove condenser (3).
fl Remove the condenser, then let it hang at
the front face.
5. Disconnect radiator bottom hose (4).

6. Disconnect aeration hose (5).
7. Disconnect make-up line hose (6).
10. Disconnect radiator upper hose (9).

11. Disconnect lubrication grease tubes (10) (aftercooler motor), (11) (tension pulley), and (12) (fan
pulley).
12. Disconnect hose (13) between reserve tank and
radiator.
14. Remove tube (15) between aftercooler and
turbocharger.
16. Remove guard (17).
17. Disconnect oil cooler inlet hose (18).
18. Remove clamp (19).

19. Loosen locknut (20), and return adjustment bolt
(21) fully to bracket.
20. Insert bar of approx. 50 cm in portion a, pull to
outside and hold in position while removing fan
belt (22).
30-40
2
PC1100-6
21. Disconnect oil cooler outlet hose (23).

fl The oil inside the cooler will flow out when
the hose is disconnected, so prepare an oil
pan or other container to catch the oil.
6 Oil inside cooler: 30
22. Remove left and right cushions (24).
23. Remove mounting bolts (25), then lift off radiator
and hydraulic cooler assembly (26).
fl Sling the radiator and oil cooler assembly
before removing the mounting bolts.
4 Radiator, hydraulic cooler assembly:
560 kg
INSTALLATION OF RADIATOR,
HYDRAULIC COOLER
ASSEMBLY

removal.

Refilling with oil

Add oil to the hydraulic tank to the specified
level. Run the engine to circulate the oil through
the system. Then check the oil level again.
Adjust the fan belt tension.

Adjusting fan belt tension.
PC1100-6
30-41
2
HYDRAULIC COOLER
REMOVAL OF HYDRAULIC
COOLER ASSEMBLY
the hydraulic tank.
1. Remove radiator mask (1).
2. Remove radiator guards (2).
3. Remove condenser (3).
fl Remove the condenser, then let it hang at
the front face.
4. Disconnect hydraulic oil inlet hose (4).
5. Disconnect hydraulic oil outlet hose (5).
fl The oil inside the cooler will flow out when
the hose is disconnected, so prepare an oil
pan or other container to catch the oil.
6
Oil inside cooler: 28
6. Remove mounting bolts, then lift off hydraulic

cooler assembly (6).
4 Hydraulic cooler assembly: 221 kg
fl Sling the hydraulic cooler assembly before
removing the mounting bolts.
INSTALLATION OF HYDRAULIC
COOLER ASSEMBLY

removal.
Refilling with oil

30-42
2
PC1100-6
REMOVAL OF ENGINE, PTO,

HYDRAULIC PUMP ASSEMBLY
the hydraulic tank.
1. Drain coolant.
6 Coolant: Approx. 160
2. Drain hydraulic oil.
6 Hydraulic oil: Approx. 650
3. Remove engine side doors (1).
4. Remove engine hoods (2).
5. Remove counterweight assembly.
For details, see REMOVAL OF COUNTERWEIGHT
ASSEMBLY.
6. Remove brackets (3) and (4).
7. Remove bracket (5) and support (6).
8. Remove frames (7).
9. Remove tube (8) between aftercooler and

turbocharger.
10. Remove tube (9) between aftercooler and intake
manifold.
12. Disconnect radiator upper hose (11).
13. Disconnect air compressor wiring connector (12)

(M34).
15. Loosen belt tension adjustment bolt (14).
fl Loosen the lock bolt.
fl Loosen the adjustment bolt and remove the
drive belt.
16. Remove 4 mounting bolts (15), then lower air
conditioner compressor assembly (16) to outside
of frame.
17. Disconnect air compressor unload tube (17).
18. Disconnect fuel return hose (18).
PC1100-6
30-43
2
19. Remove hose clamp bracket (19).

20. Disconnect hose (20) between fuel tank and
strainer.
21. Disconnect fuel return hose (21).
22. Disconnect hose (22) between air compressor
and air tank.
23. Disconnect air hose clamp (23).
24. Disconnect water hose clamp (24).

25. Disconnect lubrication grease hose (25).
26. Remove fan belt (26).
fl For details, see REMOVAL OF RADIATOR,
OIL COOLER ASSEMBLY.
27. Disconnect heater return hose (27).
28. Remove heater hose clamp (28).

29. Remove ground connection wiring (29).
30. Disconnect wiring connectors (30), (31), and (32)
(E08).
31. Disconnect cable (33) from starting motor.
32. Disconnect heater outlet hose (34).
33. Disconnect heater hose clamp (35).
34. Disconnect hose (36) between hydraulic tank and

filter.
35. Disconnect hose (37) between No. 1 pump and
filter.
36. Disconnect hose (38) between PPC pump and
filter.
37. Remove pilot filter assembly (39).
38. Disconnect PTO filter (40), and remove bracket
(41) from PTO housing.
39. Install lifting jig 1 to PTO housing.
30-44
2
PC1100-6
40. Disconnect No. 3 pump suction tube (42), No. 2

pump suction tube (43), and No. 1 pump suction
tube (44).
41. Disconnect pilot pump suction hoses (45).
42. Disconnect No. 3 pump discharge hose (46).
43. Disconnect hose (47) between pilot pump and
pilot filter.
44. Disconnect hoses (48) between pilot pump and
aftercooler fan motor.
45. Disconnect No. 2 pump discharge hoses (49).

46. Disconnect No. 1 pump discharge hose (50).
47. Disconnect hoses (51) between pilot filter and
No. 1 pump.
48. Disconnect hose (52) between control valve and
No. 1 pump.
49. Remove hose clamp (53), then disconnect hose
between block and No. 1 pump.
50. Remove mount (54), then lift off engine, PTO,

and hydraulic pump assembly (55).
1
4 Engine, PTO, hydraulic pump assembly:
Approx. 4,500 kg
fl While lifting off the engine, PTO, and
hydraulic pump assembly, check that all the
piping and wiring has been removed.
PC1100-6
30-45
2
INSTALLATION OF ENGINE,
PTO, HYDRAULIC PUMP
ASSEMBLY

removal.
1
3 Mount bolt :
823.7 1,029.7 Nm {84 105 kgm}
Refilling with oil

Add oil to the specified level. Run the engine to
circulate the oil through the system. Then check
the oil level again.

Bleeding air
Bleed the air from the main pump.
Bleeding air from main pump.
Adjusting drive belt tension.

Adjust the air conditioner compressor drive belt
and fan belt.
Adjusting belt tension.
30-46
2
PC1100-6
PTO
REMOVAL OF PTO ASSEMBLY

1. Remove engine hood, side cover, frame, and
underguard.
For details, see REMOVAL OF ENGINE, PTO,
HYDRAULIC PUMP ASSEMBLY.
ASSEMBLY.
3. Remove air cleaner (1) together with bracket.

fl Disconnect the Komaclone tube.
pilot filter and hose (3) between No. 1 pump
and pilot filter, remove pilot filter (4), then move
towards engine.
5. Disconnect hose (5) coming from pilot pump,
remove PTO lubrication oil filter (6), then remove
bracket (7).
fl Disconnect the hose coming from the PTO
lubrication oil block.
6. Disconnect hose (8) coming from block.
7. Disconnect hoses (9) coming from control valve.
10. Disconnect hose (12) going to pilot filter.
11. Disconnect suction tubes (13) and (14) and hose
of each pump.
12. Disconnect PTO suction hose (17), then remove
filter (17a).
13. Disconnect hose (18) coming from PPC pump.
14. Disconnect connection hoses (19) and (20)
between pumps.
aftercooler cooling fan motor.
17. Disconnect branch hoses (23) and (24).
18. Disconnect hose (25) between PPC pump and
No. 1 pump.
19. Disconnect hose (26) going to PTO lubrication
oil block.
20. Disconnect branch hose (27).
PC1100-6
30-47
2
PTO
21. Remove mounting bolts of No. 1 pump (28),

pilot pump (29), No. 2 pump (30), and No. 3
pump (31), then lift off.
4 No. 1 pump assembly: Approx. 200 kg
No. 2 pump assembly: Approx. 150 kg
No. 3 pump assembly: Approx. 140 kg
Pilot pump assembly: Approx. 90 kg
22. Disconnect bracket (32) from PTO.
23. Remove drain plug (33) and drain lubrication
oil.
6 Lubrication oil : 13.5
24. Disconnect hose (34) between flywheel housing
and PTO.
25. Remove mounting bolts of left and right mounts
(35).
26. Set supports 1 under flywheel housing (36) on
left and right, and adjust height with jack.
fl The part is high, so be extremely careful.
27. Disconnect PTO lubrication oil tubes (37).
28. Remove 22 mounting bolts (38), then lift off PTO
assembly (39).
1
4 PTO assembly: 440 kg
29. Remove shaft (40).
30. Remove bolts (41), then remove hub (42). 2
31. Remove bolts (43), then remove plate (44). 3
INSTALLATION OF PTO
ASSEMBLY

removal.
1
3 Mounting bolt:
98 123 Nm {10 12.5 kgm}
2
3 Mounting bolt:
245 309 Nm {25 31.5 kgm}
3
3 Mounting bolt:
98 123 Nm {10 12.5 kgm}
30-48
2
PC1100-6
PTO
DISASSEMBLY OF PTO
ASSEMBLY
1. Front cover
1) Remove mounting bolts (1), then remove
front cover (2) using forcing screws 1.
fl Use a bar to adjust in the up-down
direction to reduce the load on the
forcing screw, and when a clearance is
made, insert wooden sheets.
2) Remove snap ring (3) from cover (2), then

remove bearing (4).
2. Gear assembly
1) Remove 2 gears (6) (for No. 1, 2 pump drive).
2) Remove gear (7) (for No. 3 pump drive).
fl If the gear assembly will not come out,

remove nipple (8), then use a puller to
remove the gear assembly.
PC1100-6
30-49
2
PTO
3. Removal of bearing
Using puller 2, remove bearing from each gear.
4. Rear cover
1) Remove snap ring (9) from rear cover (5).
2) Using push tool 3, pull out gear (10).
3) Remove snap ring (11) from rear cover (5),

then remove bearing (12).
fl After pulling out gear (10), turn over rear
cover (5).
30-50
2
PC1100-6
PTO
ASSEMBLY OF PTO
ASSEMBLY
1. Rear cover
1) Press fit bearing (12) to rear cover (5), then
install snap ring (11).
fl Coat the rolling surface with grease.
2 Bearing: Lubrication oil (G2-LI)
2) Using push tool 4, press fit gear (10).
3) After press fitting gear (10), install snap ring

(9).
2. Press fitting bearing

1) Using tool 5, press fit bearing to gear (6)
for No. 1, 2 pump drive.
PC1100-6
30-51
2
PTO
2) Using tool 5, press fit bearing to gear (7)

for No. 3 pump drive.
3. Gear assembly
1) Install nipples (8).
2) Press fit 2 gears (6) to rear cover (5).
3) Press fit gear (7) to rear cover.
fl Before press-fitting, coat the rolling
surface of the bearing with grease.
fl Put wooden sheet 6 in contact with the
gear, and tap lightly with a hammer to
press fit.
4. Front cover
1) After coating front cover (2) and bearing (4)
with grease, press fit, then install snap ring
(3).
2) Set guide bolts 7 (2 places) to rear cover

(5), then align front cover (2), and lower
slowly.
fl Coat the mating surface of the rear cover
with gasket sealant.
2 Mating surface of cover:
3) Tighten mounting bolts (1) in turn on
diagonally opposite sides.
3 Mounting bolt:
98 123 Nm {10 12.5 kgm}
30-52
2
PC1100-6
FUEL TANK
REMOVAL OF FUEL TANK

ASSEMBLY
1. Drain fuel.
6 Fuel tank: 1,000
2. Remove handrails (1).
3. Remove steps (2) and (3).
4. Disconnect fuel level sensor wiring connector
(4) (P06).
5. Disconnect fuel injection pump return hose (5).
6. Disconnect injector return hose (6).
7. Disconnect hose (7) between fuel tank and
strainer.
8. Remove mounting bolts, then lift off fuel tank
assembly (8).
4 Fuel tank assembly: 740 kg
INSTALLATION OF FUEL TANK

ASSEMBLY

removal.
PC1100-6
30-53
2
FINAL DRIVE
REMOVAL OF FINAL DRIVE

ASSEMBLY
1. Remove track shoe assembly.
For details, see REMOVAL OF TRACK SHOE
ASSEMBLY.
2. Remove covers (1) and (2).
3. Disconnect hose (3) for travel speed selector
valve.
4. Disconnect drain hose (4).
6. Remove sprocket (6).
4 Sprocket assembly: 195 kg
7. Sling final drive assembly (7), then remove
mounting bolts and lift off final drive assembly.
1
4 Final drive assembly: 1,530 kg
INSTALLATION OF FINAL
DRIVE ASSEMBLY

removal.
1
2 Mounting bolt : Thread tightener (LT-2)
3 Mounting bolt:
882 1,030 Nm {90 105 kgm}
Bleeding air
fl Bleed the air from the travel motor.
Bleeding air.
30-54
2
PC1100-6
FINAL DRIVE
DISASSEMBLY OF FINAL
DRIVE ASSEMBLY
1. Draining oil
Remove drain plug and drain oil from final drive
case.
6 Final drive case : Approx. 21
2. Put travel motor at bottom and set on block
(height approx. 350 mm).
3. Cover
Using forcing screws and eyebolts 1, remove
cover (1).
4. No. 3 carrier assembly
1) Remove thrust washer (50).
2) Using eyebolts 2, remove No. 3 carrier
assembly (2).
3) Disassemble No. 3 carrier assembly as

follows.
i) Remove mounting bolts (3).
ii) Using tool J2, remove holder (4).
iii) Turn over carrier assembly (2) and set to

press, then using tool J3, pull out pin (5)
and remove gear assembly (6).
PC1100-6
30-55
2
FINAL DRIVE
iv) Remove bearing (7) and spacer (8) from

gear assembly (6).
fl If the parts are to be used again,
make counter marks to prevent any
change in the combination with the
outer race.
v) Remove outer race (9) from gear
assembly (6).
5. No. 3 sun gear

1) Remove thrust washer (11) from No. 3 sun
gear (10).
2) Remove No. 3 sun gear (10).
6. No. 3 ring gear

Using eyebolts 3, remove No. 3 ring gear (12).
7. Hub assembly
1) Remove lock plate (13).
2) Using tool J4, remove nut (14).
30-56
2
PC1100-6
FINAL DRIVE
3) Using eyebolts 4, remove hub assembly (15)

together with bearing (16) from shaft (41).
4) Remove bearing (16) from hub (49).
5) Remove floating seal (17a) from hub (49).

fl If the seal is to be used again, be careful
not to damage the contact surface, and
keep in a safe place.
6) Remove outer races (18).
8. Spacer
Remove spacer (19) from shaft (41).

assembly (20).
follows.
i) Knock pin (21) into shaft (22).
ii) Push shaft (22) from pin side to remove.
fl Remove the pin from the shaft.
iii) Pull out gear (23) from carrier (27), then

remove thrust washer (24) and bearing
(25).
iv) Remove thrust assembly (26) from carrier
(27).
PC1100-6
30-57
2
FINAL DRIVE
10. No. 2 sun gear

Remove No. 2 sun gear (28).
11. No. 2 ring gear
Remove No. 2 ring gear (30).
12. Spacer
Remove spacer (31).

assembly (32).
follows.
i) Knock pin (33) into shaft (34).
ii) Pull out shaft (34) towards pin end.
fl Remove the pin from the shaft.
iii) Pull out gear (35) from carrier (36), then

remove thrust washer (37) and bearing
(38).
14. No. 1 ring gear

Remove No. 1 ring gear (39).
15. No. 1 sun gear
Remove No. 1 sun gear (40).
fl Note: If the travel motor is removed, the
gear will fall off when it is put in the posture
for disassembly.
16. Thrust washer
Remove thrust washer (48) from travel motor.
17. Floating seal
Remove floating seal (17b) from shaft (41).
fl If the seal is to be used again, be careful not
to damage the contact surface, and keep in
a safe place.
30-58
2
PC1100-6
FINAL DRIVE
ASSEMBLY OF FINAL DRIVE

ASSEMBLY
fl 1) Clean all parts, check for dirt or damage,
and correct all dents and burrs.
2) Coat the bearings and surfaces of all parts
with engine oil before installing.
1. Thrust washer
1) Set shaft assembly on block (height: approx.
350 mm).
2) Install thrust washer (48) of travel motor.
2. No. 1 sun gear

Install No. 1 sun gear (40).
3. No. 1 ring gear
Install No. 1 ring gear (39).
fl Set with the side with the cut outside
circumference facing the motor.
4. Spacer
Install spacer (31).

1) Assemble No. 1 carrier assembly as follows.
fl There are the remains of the caulking
when the pin is inserted at the end face
of hole h at the side of the carrier, so
remove the caulked metal from the inside
diameter of the hole before starting to
assemble.
i) Assemble bearing (38) to gear (35), put
thrust washers (37) in contact at both
sides, then set to carrier (36).
PC1100-6
30-59
2
FINAL DRIVE
ii) Align position of pin holes of carrier and

shaft, then tap with a plastic hammer to
install shaft (34).
fl When installing the shaft, rotate the
planetary gear, and be careful not to
damage the thrust washer.
iii) Install pin (33).
fl Check that the pin groove and
protruding part of the pin are not
fatigued. If the pin is defective,
replace it with a new part.
fl When assembling the pin again,
avoid the position previously used
for caulking.
fl After inserting the pin, caulk the pin
portion (marked by arrows) of the
carrier.
fl After assembling the carrier
assembly, check that gear (35) rotates
smoothly.
2) Using eyebolts 6, install No. 1 carrier
assembly (32).
6. No. 2 sun gear

1) Press fit button (29) to No. 2 sun gear (28).
2) Install No. 2 sun gear (28).
7. No. 2 ring gear
Install No. 2 ring gear (30).

i) Press fit thrust washer (44) to plate (43).
ii) Press fit thrust assembly (26) to carrier
(27).
30-60
2
PC1100-6
FINAL DRIVE
fl There are the remains of the caulking

when the pin is inserted at the end face
of hole h at the side of the carrier, so
remove the caulked metal from the inside
diameter of the hole before starting to
assemble.
iii) Assemble bearing (25) to gear (23), put
thrust washers (24) in contact at both
sides, then set to carrier (27).
iv) Align position of pin holes of carrier and
shaft, then tap with a plastic hammer to
install shaft (22).
gear, and be careful not to damage
the thrust washer.
v) Install pin (21).
fl Check that the pin groove and
protruding part of the pin are not
fatigued. If the pin is defective,
replace it with a new part.
fl When assembling the pin again,
avoid the position previously used
for caulking.
portion (marked by arrows) of the
carrier. (See Step 5-1)-iii).)
fl After assembling the carrier assembly,
check that gear (23) rotates smoothly.
assembly (20).
9. Spacer
Align protruding portion with protruding portion
of shaft (41), and install spacer (19).
fl Set the spacer with the shallow protruding
part facing the motor.
10. Hub assembly

1) Floating seal at shaft end
Using tool J8, install floating seal (17b) to
shaft (41).
fl Remove all oil and grease from the Oring and O-ring contact surface, and dry
the parts before installing the floating
seal.
PC1100-6
30-61
2
FINAL DRIVE
fl After installing the floating seal, check

that the angle of the floating seal is
within 1 mm.
fl After installing the floating seal, coat the
sliding surface thinly with engine oil.
2) Inside bearing
Shrink fit bearing (16) to shaft (41), or use
tool J3 to install.
fl When using tool J7, see the drawing on the

right.
3) Outer race at hub end

Expand fit outer race (18) to hub (49), or use
tool J2 to install.
fl When using tool J2, see the drawing on
the right.
4) Floating seal at hub end

Using tool J8, install floating seal (17a) to
hub (49).
fl For precautions and details of the tool,
see Step 10-1).
fl When turning over the hub, the floating
seal will be at the bottom, so install it
temporarily with several of bolts 8.
5) Installation of hub assembly
Using eyebolts 4, install hub assembly (15)
to shaft (41).
30-62
2
PC1100-6
FINAL DRIVE
6) Outside bearing
Install bearing (16).
7) Install nut as follows.

i) Set tool J7 in position.
ii) Push bearing inner race portion with
specified force.
fl Pushing force:
34.3 38.2 kN {3.5 3.9 ton}
iii) Rotate hub assembly 2 3 times to settle
bearing.
iv) Measure dimension a in the condition

above.
v) Measure thickness b of nut (14) as an

individual part.
vi) Calculate a b = c.
vii) Using tool J1, tighten nut (14) to a point
where dimension c = +0.15
0.05 mm.
PC1100-6
30-63
2
FINAL DRIVE
8) Install lock plate (13).

Install the lock plate as shown in the diagram
on the right.
2 Thread of mounting bolt :
Thread tightener (LT-2)
3 Mounting bolt:
59 74 Nm {6 7.5 kgm}
11. No. 3 ring gear

1) Install O-ring to shaft end.
2) Using eyebolts 3, install No. 3 ring gear
(12).
fl Align the bolt holes.
fl Install the ring gear with the machined
outside circumference facing up (outside).

i) Using tool J4, press fit outer race (9) to
gear (46).
ii) Assemble bearing (7) and spacer (8) to

gear (46), and set to carrier (47).
fl Align the carrier and bearing and
spacer holes accurately.
30-64
2
PC1100-6
FINAL DRIVE
iii) Expand fit shaft (5) or press fit with a

press.
fl Do not move the gear until the tip of
shaft (5) enters the carrier. Be
particularly careful with the spacer.
fl When press fitting the shaft, be
careful of the angle of the shaft, and
press fit so that there is no clearance
between the pin and end face m of
the bearing.
fl After press fitting the pin, check that
the gear rotates smoothly.
iv) Assemble holder (4) to shaft (5).
v) Tighten bolt (3).
2 Bolt: Thread tightener (LT-2)
3 Bolt:
931 1,030 Nm {90 105 kgm}
vi) Install thrust washer (50).

assembly (2).
fl Align the low portion (4 places) of spacer
(19) and shaft (41) with the carrier
assembly holder.
fl Align the bolt holes also.
13. No. 3 sun gear

1) Install thrust washer (11) to No. 3 sun gear
(10).
2) Install No. 3 sun gear (10).
fl Be careful not to get your fingers caught.
PC1100-6
30-65
2
FINAL DRIVE
14. Cover
Using eyebolts 1, install cover (1).
2 Mounting surface: Gasket sealant (LG-6)
2 Bolt: Thread tightener (LT-2)
3 Bolt: 982 1,030 Nm {90 105 kgm}
30-66
2
PC1100-6
REVOLVING FRAME
REMOVAL OF REVOLVING
FRAME ASSEMBLY
ASSEMBLY.
2. Remove work equipment assembly.
For details, see REMOVAL OF WORK EQUIPMENT
ASSEMBLY.
3. Disconnect hose (1) coming from filter.
4. Disconnect hoses (2) and (3) coming from swing
motor.
5. Disconnect hoses (4) coming from 5-spool
control valve.
control valve.
7. Disconnect hose (6) coming from travel speed
selector solenoid valve.
8. Disconnect stopper link (7).
9. Leave 4 mounting bolts (8) at front and rear,
and remove remaining mounting bolts. 1
10. Lift off revolving frame assembly (9).
4 Revolving frame assembly:
Approx. 20,300 kg
INSTALLATION OF REVOLVING
FRAME ASSEMBLY

removal.
fl Remove the mounting bolts of the swing motor,

raise the swing gear enough for it to be free,
then set on a block.
1
2 Mounting bolt: Thread tightener (LT-2)
3 Mounting bolt:
1,960 2,450 Nm {200 250 kgm}
PC1100-6
30-67
2
SWING MACHINERY
REMOVAL OF SWING
MACHINERY ASSEMBLY
the hydraulic tank.
fl Center of chassis
1. Disconnect hoses (1), (2), (3), and (4) coming
from control valve.
2. Disconnect hoses (5) and (6) going to swing
motor at front of chassis.
4. Disconnect swing brake release hose (8).
fl Front of chassis
motor at center of chassis.
4. Disconnect hose (13) going to boom LOWER
regeneration valve.
6. Remove mounting bolts (15), then lift off swing
motor assembly (16).
4 Swing motor assembly: 81 kg
7. Remove mounting bolts, then lift off swing
machinery assembly (17).
1
4 Swing machinery assembly: 532 kg
INSTALLATION OF SWING
MACHINERY ASSEMBLY

removal.
1
3 Mounting bolt :
824 1,030 Nm {84 105 kgm}
Refilling with oil

30-68
2
PC1100-6
SWING MACHINERY
DISASSEMBLY OF SWING
MACHINERY ASSEMBLY
1. Draining oil
Loosen drain plug and drain oil from swing
machinery case.
6 Swing machinery case: Approx. 21.5

2. Cover
Remove mounting bolts, then lift off cover (1).
CEP00205

CEP00206
3) Remove No. 1 carrier assembly (4).
CEP00207
4. Disassemble No. 1 carrier assembly as follows.

1) Push in pin (5) and knock out shaft (6) from
carrier (7).
fl After removing the shaft, remove pin (5).
2) Remove thrust washer (8), gear (9), bearing
(10), and thrust washer (11).
10
11
CEP00208
PC1100-6
30-69
2
SWING MACHINERY
5. Ring gear
Lift off ring gear (12).
12
CEP00209
6. No. 1 sun gear

1) Remove thrust washer (13) and collar (14).
14
13
15
CEP00210
16
CEP00211

Lift off No. 2 carrier assembly (17).
17
CEP00212
30-70
2
PC1100-6
8. Disassemble No. 2 carrier assembly as follows.

1) Push in pin (18), and knock out shaft (19)
from carrier (17).
fl After removing the shaft, remove pin
(18).
2) Remove thrust washer (20), gear (21), bearing
(22), and thrust washer (23).
SWING MACHINERY
19
22
17
20
21
23
18
9. Pinion shaft assembly

1) Remove bolt (24), then remove holder (25).
2) Remove gear (26).
CEP00213
24
26
25
CEP00214
3) Turn over case and pinion assembly, then

remove mounting bolts (28) of cover
assembly (27).
27
28
CEP00215
4) Turn over case and pinion assembly (29),

and set on press stand, then using push tool
F4, remove pinion shaft assembly (30) with
press.
fl Set a wooden block under the press, and
be careful not to damage the pinion shaft
assembly when removing it.
PC1100-6
30-71
2
SWING MACHINERY
10. Disassemble pinion shaft assembly as follows.

1) Using push tool 1, remove cover assembly
(27) and bearing (31) from shaft (32).
2) Remove oil seal (33) from cover (27).
33
27
31
32
27
CEP00218
11. Bearing
Using push tool, remove bearing (34) from case
(35).
35
CEP00219
34
CEP00220
30-72
2
PC1100-6
SWING MACHINERY
ASSEMBLY OF SWING
MACHINERY ASSEMBLY
fl Clean all parts, and check for dirt or damage.
Coat the sliding surfaces of all parts with engine
oil before installing.
1. Bearing
Using push tool F2, press fit bearing (31) to case
(35).
2. Cover assembly
1) Using push tool F1, press fit oil seal (33) to
cover (27).
2 Outside circumference of oil seal:
fl Be careful not to let the gasket sealant
(LG-6) get on the oil seal lip when press
fitting.
2) Fit cover assembly (27) to case (35), and

tighten mounting bolts (28).
2 Cover mounting surface:
2 Lip of oil seal: Grease (G2-LI)
fl Be careful not to let the gasket sealant
(LG-6) get on the oil seal lip when press
fitting.
27
28
35
CEP00223
3. Case assembly
1) Set case assembly (35) to shaft (32), then
using push tool 2, press fit bearing inner
race portion.
fl When setting the case assembly to the
shaft, be extremely careful not to damage
the oil seal.
PC1100-6
30-73
2
SWING MACHINERY
2) Bearing
Using tool F3, press fit bearing (34).
fl Push the bearing inner race and outer
race at the same time when press fitting.
Do not push only the inner race when
press fitting.
fl After press fitting the bearing, check that
the case rotates smoothly.
3) Gear, holder
Assemble gear (26), then fit holder (25) and
tighten bolt (24).
2 Mounting bolt:
3 Mounting bolt:
343 427 Nm {35 43.5 kgm}
24
26
25
CEP00214
4. Assemble No. 2 carrier assembly as follows.

fl There are the remains of the caulking when
the pin is inserted at the end face of hole h
at the side of the carrier, so remove the
caulked metal from the inside diameter of
the hole before starting to assemble.
1) Assemble bearing (22) to gear (21), fit top
and bottom thrust washers (23) and (20) and
set gear assembly to carrier (17).
22
17
20
21
23
h
CEP00226
2) Align position of pin holes of shaft and

carrier, then tap with a plastic hammer to
install shaft (19).
3) Insert pin (18).
portion of the carrier.
fl After assembling the carrier assembly, check
that gear (21) rotates smoothly.
30-74
2
21
18
19
CEP00227
PC1100-6

Raise No. 2 carrier assembly (17) and install.
SWING MACHINERY
17
CEP00212
6. No. 2 sun gear

1) Assemble thrust washer (16).
16
CEP00211
2) Install No. 2 sun gear (15) to No. 2 carrier,

then install collar (14) and thrust washer (13).
14
13
15
CEP00210
7. Ring gear
Raise ring gear (12) and install.
fl Align with the drain hole and assemble.
2 Mating surface of ring gear and case:
12
CEP00209
PC1100-6
30-75
2
8. Assemble No. 1 carrier assembly as follows.

fl There are the remains of the caulking when
the pin is inserted at the end face of hole h
at the side of the carrier, so remove the
caulked metal from the inside diameter of
the hole before starting to assemble.
1) Assemble bearing (10) to gear (9), fit top
and bottom thrust washers (8) and (11) and
set gear assembly to carrier (7).
SWING MACHINERY
10
11
CEP00228
2) Align position of pin holes of shaft and

carrier, then tap with a plastic hammer to
install shaft (6).
3) Insert pin (5).
portion of the carrier.
fl After assembling the carrier assembly, check
that gear (9) rotates smoothly.
6
CEP00229

Install No. 1 carrier assembly (4).
CEP00207
10. No. 1 sun gear

1) Assemble No.1 sun gear (3) to carrier
assembly.
2) Install thrust washer (2).
CEP00206
30-76
2
PC1100-6
11. Cover
Install cover (1).
2 Cover mounting surface:
3 Mounting bolt:
1st pass: 98 Nm {10 kgm}
2nd pass: 120 5
SWING MACHINERY
CEP00205
12. Refilling with oil

Tighten drain plug and add oil through oil filler.
5 Swing machinery case: Approx. 21.5
PC1100-6
30-77
2
SWING CIRCLE
REMOVAL OF SWING CIRCLE

ASSEMBLY
1. Remove revolving frame assembly.
For details, see REMOVAL OF REVOLVING FRAME
ASSEMBLY.
2. Remove grease tubes (1).
3. Remove mounting bolts (2).
4. Pass a round bar through revolving frame

mounting bolt holes, then fit wire and lift off
swing circle assembly (3).
2
4 Swing circle assembly: 2,169 kg
5. Remove seal (4).
INSTALLATION OF SWING
CIRCLE ASSEMBLY

removal.
1
3 Mounting bolt:
1,960 2,450 Nm {200 250 kgm}
2
2 Mounting surface of swing circle:
Gasket sealant (LG- 6)
fl Amount of grease (G2-LI) to fill oil bath:
Approx. 75
fl Coat the inner teeth with grease (G2-LI).
fl Set the soft zone S mark on the inner race
facing the left side of the machine, then
install.
30-78
2
PC1100-6
TRACK SHOE
REMOVAL OF TRACK SHOE

ASSEMBLY
1. Positioning master pin
fl Move the track so that the master pin is
midway between the idler and the carrier
roller. The track shoe is opened to the rear,
so be sure that there is enough space to lay
it out.
2. Loosen track shoe tension.
1
Never loosen lubricator (1) more than one
turn.
fl If the track tension is not relieved even when
the lubricator is loosened, move the machine
backwards and forwards.
3. Using tool R1, pull out master pin.
4. Fit block or hydraulic jack 1 (100 kN {10 t})

under shoe at idler end, then remove guide pin
2.
2
5. Raise tip of track shoe with crane, and move

machine slowly to rear to open track shoe
assembly (3).
PC1100-6
30-79
2
TRACK SHOE
INSTALLATION OF TRACK
SHOE ASSEMBLY

removal.
1
fl Adjust the track shoe tension.
Adjusting track shoe tension.
3 Lubricator:
73.5 14.7 Nm {7.5 1.5 kgm}
2
fl Assemble spacer (4) and washer (5) to the
link, connect to the bottom link, then install
the guide pin.
30-80
2
PC1100-6
SPROCKET
REMOVAL OF SPROCKET
ASSEMBLY.
2. Swing work equipment 90, push up chassis with
work equipment, set block 1 on top of track
shoe, then lower chassis slowly.
ground.
3. Remove mounting bolts (1), and lift off sprocket
(2).
1
4 Sprocket: 194 kg
INSTALLATION OF SPROCKET

removal.
1
3 Mounting bolt:
824 1,030 Nm {84 105 kgm}
PC1100-6
30-81
2
IDLER
REMOVAL OF IDLER
ASSEMBLY
ASSEMBLY.
2. Remove idler assembly (1).
fl Pull out the idler assembly, then lift off the
idler and adjustment cylinder.
4 Idler assembly: 1,000 kg
INSTALLATION OF IDLER
ASSEMBLY

removal.
30-82
2
PC1100-6
IDLER
DISASSEMBLY OF IDLER
ASSEMBLY
1. Remove plug and drain oil.
6 Idler: Approx. 750 830 cc
2. Set idler assembly (1) on block 1, remove bolt
and nut (2), then remove support (3).
3. Remove O-ring (4).

4. Remove plate (5), then remove dowel pin (6)
from plate.
5. Remove floating seal (7).
6. Turn over idler assembly, remove bolt and nut

(8), then remove support (9).
7. Remove O-ring (10).

8. Remove plate (11), then remove dowel pin (12)
from plate.
9. Remove floating seal (7).
PC1100-6
30-83
2
IDLER
10. Remove shaft (13) from idler.
11. Remove bushings (14) and (15) from idler.
12. Remove floating seal (7) from supports (3) and

(9).
30-84
2
PC1100-6
IDLER
ASSEMBLY OF IDLER
ASSEMBLY
fl Clean all parts, and check for dirt or damage.
1. Using tool L2, assemble floating seals (7) to
supports (3) and (9).
fl Check that the angle of the seal is less than
1 mm.
2. Using tool L1, press fit bushings (14) and (15) to

idler (1).
Press-fitting force:
114 200 kN {11.6 20.4 t}
3. Using tool L2, assemble floating seal (7) to idler

(1).
1 mm.
4. Install shaft (13) to idler assembly (1).

fl Assemble the shaft so that the UP mark at
the end face of the shaft is at the top.
fl Assemble so that the oil filler plug is facing
the right side of the machine
PC1100-6
30-85
2
IDLER
5. Assemble plate (5) to idler (1).

6. Install dowel pin (6) to plate (5).
7. Fit O-ring (4) to shaft (13).
8. Assemble plate (11) to idler (1).

9. Assemble dowel pin (12) to plate (11).
10. Fit O-ring (10) to shaft (13).
11. Assemble support (9) to shaft (13).

fl Align the dowel pin with the hole at the
support end.
12. Install bolt and nut (8), and secure support (9).
13. Turn over idler, and assemble support (3) to

shaft (13).
fl Align the dowel pin with the hole at the
support end.
14. Install bolt and nut (2), and secure support (3).
15. Using tool J3, add oil to specified level, then
tighten plug.
5
Idler: 750 830 cc (GO140)
3 Plug: 274.4 367.5 Nm {28 37.5 kgm}
30-86
2
PC1100-6
IDLER ADJUSTMENT CYLINDER
DISASSEMBLY OF IDLER
ADJUSTMENT CYLINDER
ASSEMBLY
1. Remove plunger assembly (1).
2. Remove snap ring (3), then remove packing (4),
backup ring (5), and wear ring (6) from plunger
(2).
3. Remove dust seal (7).
ASSEMBLY OF IDLER
ADJUSTMENT CYLINDER
ASSEMBLY
1. Install wear ring (6) to plunger (2).
2. Assemble backup ring (5) and packing (4) to
plunger (2), then install snap ring (3).
3. Fill inside with grease (G2-LI), then assemble
plunger assembly (1) to piston.
4. Install dust seal (7).
PC1100-6
30-87
2
RECOIL SPRING
REMOVAL OF RECOIL SPRING

ASSEMBLY
fl The coil portion of the recoil spring assembly is
hooked on the rib inside the track frame, so
prepare a special tool for disassembly.
ASSEMBLY.
2. Remove idler assembly.
For details, see REMOVAL OF IDLER ASSEMBLY.
3. Recoil spring assembly
1) Remove No. 2 and No. 3 track roller
assemblies.
For details, see REMOVAL OF TRACK ROLLER
ASSEMBLY.
2) After removing track roller assembly, install
tool 1.
fl When making tool 1, see Fig. 1.
fl Lower the track frame on top of the track
shoe.
3) Using eyebolts (Thread dia. = 16 mm, Pitch
= 2.0 mm), pull out recoil spring assembly
(1) and lift off.
4
Recoil spring assembly: 1,000 kg
INSTALLATION OF RECOIL
SPRING ASSEMBLY

removal.
fl To check that the spring is securely fitted
inside the track frame, look through the side
hole on the inside (at the 5th track roller
from the front).
30-88
2
PC1100-6
RECOIL SPRING
Fig. 1 (for tool 1)
PC1100-6
30-89
2
RECOIL SPRING
DISASSEMBLY OF RECOIL
SPRING ASSEMBLY
1. Set recoil spring assembly (1) to tool M1.
The recoil spring is under a large installed
load, so be sure to set the tool properly.
Failure to do this is dangerous.
fl Installed load of spring: 578 kN {58,957 kg}
2. Apply hydraulic pressure slowly to compress
spring, then remove lock plate, and remove nut
(2).
3. Release hydraulic pressure gradually to relieve
tension of spring, then remove recoil spring
assembly (1) from tool M1.
4. Remove rear pilot (4) and rod (5) from spring
(3).
30-90
2
PC1100-6
RECOIL SPRING
ASSEMBLY OF RECOIL SPRING

ASSEMBLY
1. Install tool M1 to tip of rod (5).
fl Tool M1 is to prevent damage to the thread
when inserting the rear pilot.
2. Install rod (5) to spring (3).
Assemble rear pilot (4), and set to tool M1.
The recoil spring is under a large installed
load, so be sure to set the parts properly.
Failure to do this is dangerous.
3. Apply hydraulic pressure slowly to compress
spring so that installed length of spring is
standard dimension.
fl Installed length a of spring: 1,280 mm
4. Fit nut (2) and secure with lock plate.
5. Release hydraulic pressure gradually to relieve
tension of spring, then remove recoil spring
assembly (1) from tool M1.
PC1100-6
30-91
2
CARRIER ROLLER
REMOVAL OF CARRIER
ROLLER ASSEMBLY
1. Loosen track shoe slightly.
Adjusting track shoe tension.
2. Using hydraulic jack 1, push up track shoe.
3. Remove 4 mounting bolts (1).
4. Lift off carrier roller assembly (2).
fl Pull the carrier roller assembly to the outside
to a point where it does not fall.
4 Carrier roller assembly: 80 kg
INSTALLATION OF CARRIER
ROLLER ASSEMBLY

removal.
30-92
2
PC1100-6
CARRIER ROLLER
DISASSEMBLY OF CARRIER
ROLLER ASSEMBLY
6 Carrier roller assembly:
Approx. 450 500 cc
2. Set carrier roller assembly (1) on press stand.
fl When support (2), shaft (3), and roller (4)
come away from roller (4), they will fall, so
set something to catch them under the roller.
3. Push with press, and remove support (2), shaft
(3), and roller (4) as one unit.
fl Remove floating seal (5) from support (2).
4. Remove shaft (3) and bearing (6) as one unit
from support (2).
5. Remove roller (4) and floating seal (5) (on top of

support (2)) as one unit.
6. Remove floating seal (5) from support (2).
7. Remove bearing (6) from support (2).
8. Remove floating seal (5) from roller (4).

9. Using tool L2, remove bearing (6) from shaft (3).
10. Remove bearing outer race (7) from support (2).

11. Using tool 1 , remove bushing (8) from support
(2).
PC1100-6
30-93
2
CARRIER ROLLER
ASSEMBLY OF CARRIER
ROLLER ASSEMBLY
1. Using tool 1, press fit bushing (8) to support
(2).
fl Press fit so that the protrusion is the same
on the left and right.
2. Using tool L1, press fit bearing outer race (7) to
support (2).
3. Using tool L2, press fit bearing (6) to shaft (3).

fl Push in approx. 80 mm from the end face of
the shaft.
4. Install bearing (6) to shaft (3), install bushing (8)
to support (2), then press fit shaft (3) to support
(2).
fl Check that the inner race of the bearing is in
contact with bushing (8).
5. Using tool L4, install floating seal (5) to roller
(4).
1 mm.
fl Wash the O-ring and O-ring contact surface,
remove all oil and grease, then dry
thoroughly.
6. Assemble floating seal (5) to roller (4), then set
roller (4) on tool L3.
7. Assemble floating seal (5) to support (2), then
press fit support (2) and shaft (3) as one unit to
roller (4).
fl Make sure that there is no dirt stuck to the
seal surface.
8. Press fit bearing (6) to shaft (3).
9. Install floating seal (5) to support (2).
10. Assemble floating seal (5) to roller (4), then press
fit roller (4) to shaft (3).
fl Press fit roller (4) to the end face of the
shaft, then use tool L3 to press fit finally.
fl Ensure that the press-fitting force for the
shaft and each roller is at least 230 kN {23
tons}.
11. After assembling carrier roller assembly (1), fill
with oil.
5
Lubricating oil: 450 500 cc (GO140)
12. After filling carrier roller assembly with oil,
tighten plug.
3 Plug: 157 255 Nm {16 26 kgm}
30-94
2
PC1100-6
TRACK ROLLER
REMOVAL OF TRACK ROLLER

ASSEMBLY
1. Loosen track shoe tension.
ASSEMBLY.
2. Remove track roller guards (1) and (2).
4 Track roller guard: 170 kg
3. Using work equipment, push up track frame on
side which is to be removed.
After jacking up the chassis, set a block on
the track shoe.
4. Using tool L7, remove track roller assembly (2).
1
4 Track roller assembly (S flange): 140 kg
INSTALLATION OF TRACK
ROLLER ASSEMBLY

removal.
1
3 Roller mounting bolt:
137.2 98 Nm {140 10 kgm}
PC1100-6
30-95
2
TRACK ROLLER
DISASSEMBLY OF TRACK
ROLLER ASSEMBLY
fl Rotate the shaft while draining the oil.
6 Track roller: Approx. 800 850 cc
2. Remove pin (1), then remove collar (2).
3. Remove floating seal (3) from collar (2) and roller

(4).
1
2
4. Pull out roller (4) from shaft (5).

fl It is filled with 800 850 cc. of oil, so drain
the oil at this point or lay a cloth to prevent
the area from becoming dirty.
CEP00085
CEP00086
CEP00088
CEP00087
5. Remove floating seal (6) on opposite side from

roller (4) and collar (8).
9, 10
6. Remove pin (7), then remove collar (8) from

shaft (5).
7. Remove bushings (9) and (10) from roller (4).
5
6
8
4
7
30-96
2
CEP00089
CEP00090
PC1100-6
TRACK ROLLER
ASSEMBLY OF TRACK ROLLER

ASSEMBLY
1. Using tool 1, press fit bushings (9) and (10) to
roller (4).
2. Assemble collar (8) to shaft (5), and install pin
(7).
3. Using tool L6, install floating seal (6) to shaft
(5).
fl When assembling the floating seal, clean the
contact surface of O-ring (6c) and floating
seal (6a), remove all grease and oil, and dry
it. Make sure that no dirt or dust sticks to
the contact surface of the floating seal.
fl After inserting the floating seal, check that
the angle of the seal is less than 1 mm.
Remove all oil and

grease from
hatched portion.
Protrusion of seal
57mm
CEP00093
4. Using tool L6, install floating seals (6) and (3) to

roller (4).
fl For details of the precautions when installing
floating seals (6b) and (6d), and (3b) and
(3d), see the precautions marked fl for Step
3.
CEP00094
5. Assemble shaft (5) to roller (4).
CEP00096
6. Turn over roller (4) and shaft (5) assembly.

7. Using tool L6, install floating seal (3) to collar
(2).
fl For details of the precautions when installing
floating seals (3a) and (3c), see the
precautions marked fl for Step 3.
CEP00097
PC1100-6
30-97
2
TRACK ROLLER
8. Assemble collar (2) to shaft (5), and install pin

(1).
5
CEP00099
9. Using tool L10, apply standard pressure to roller

oil filler port, and check for leakage of air from
seal.
fl Standard pressure: 0.1 MPa (1 kg/cm2)
fl Method of checking
The standard pressure shall be maintained
for 10 seconds and the indicator of the gauge
shall not go down.
10. Using tool L10, fill track roller assembly with oil,
then tighten plug (11).
L10
5
Track roller oil: 800 850 cc (EO30-CD)
3 Plug: 17 37 Nm {1.7 3.8 kgm}
To oil pump
To vacuum tank
CEP00201
11
CEP00202
30-98
2
PC1100-6
HYDRAULIC TANK
TANK ASSEMBLY
Swing the frame and set the position of the
hydraulic tank between the left and right tracks.

the hydraulic tank.
1. Drain oil from hydraulic tank.
6 Hydraulic tank: 650
2. Disconnect wiring connectors (1) (from top:
V7=CO cancel, V1=swing priority selector,
V2=main 2-stage relief valve).
3. Disconnect hose (2) coming from oil cooler.
4. Disconnect hose (3) coming from main pump
CO valve.
5. Disconnect hoses (4) and (5) coming from control
valve main relief.
6. Disconnect hose (6) coming from 4-spool control
valve (boom RAISE).
7. Disconnect wiring connector (7) (P1=hydraulic

oil high temperature sensor).
8. Disconnect tube (8) going to hydraulic tank.
9. Disconnect motor drain hose (9).
10. Disconnect pump drain hose (10).
11. Disconnect tube (11) coming from pilot pump.
12. Disconnect hose (12) coming from accumulator.
13. Disconnect clamps (13) and (14).

14. Disconnect wiring connector (15) (P09=oil level
sensor).
PC1100-6
30-99
2
HYDRAULIC TANK
16. Remove filter assembly (17) from hydraulic tank,

and disconnect together with hose (18) from
hydraulic tank.
17. Disconnect hose (19) coming from 5-spool
control valve.
18. Disconnect hoses (20) going to oil cooler.

control valve.
20. Disconnect hydraulic tank bottom suction tube
(21).
21. Lift off hydraulic tank assembly (22).
4 Hydraulic tank assembly: 780 kg
TANK ASSEMBLY

removal.
1
3 Hydraulic tank mounting bolt:
490 608 Nm {50 62 kgm}
Refilling with oil (hydraulic tank)

Run the engine to circulate the oil through the
system. Then check the oil level again.
5
Hydraulic tank: 650
Bleeding air
Bleed the air.
Bleeding air.
30-100
2
PC1100-6
TVC VALVE
REMOVAL OF TVC VALVE

ASSEMBLY
1. Open door of pump room.
2.
Disconnect TVC valve wiring connector (1) (C13).
3. Disconnect hose (2) coming from swing pump

inlet.
4. Remove mounting bolts, then remove TVC valve
assembly (3).
1
INSTALLATION OF TVC VALVE

ASSEMBLY

removal.
1
3 Mounting bolt:
31.4 2.9 Nm {3.2 0.3 kgm}
PC1100-6
30-101
2
SERVO VALVE
REMOVAL OF SERVO VALVE

ASSEMBLY
1. Remove external parts around hydraulic pump.
2. Disconnect discharge hoses (2) of No. 3 pump
(1).
3. Disconnect discharge hoses (4) of No. 1 pump
(3).
4. Disconnect jet sensor (upstream) hose (5).
5. Disconnect jet sensor (downstream) hose (6).
6. Disconnect TVC valve output pressure inlet hose
(7).
7. Disconnect hose (8) for C/O selector pilot.
fl Disconnect the C/O selector pilot hose and
the jet sensor (upstream and downstream
pressure) hose from the CO.NC valve of the
front pump of the No. 1 pump.
fl Disconnect the C/O selector pilot hose and
the jet sensor (upstream and downstream
pressure) hose from the CO.NC valve of the
rear pump of the No. 1 pump.
fl Disconnect the hose between the swing
pump inlet and the TVC valve.
8. Disconnect hose (9) between front and rear of
No. 3 pump servo valve.
1
9. Disconnect TVC valve wiring connector (10)
(C13).
10. Disconnect tube (11) between outside pumps
from front pump of No. 1 pump.
2
11. Remove servo valves (12), (13), (14), and (15)
together with CO.NC valve.
3
12. Disconnect CO + NC valve output pressure hoses
at front (16) and at rear (17).
13. Remove servo valves (18) and (19).
4
INSTALLATION OF SERVO
VALVE ASSEMBLY

removal.
1
3 Hose mounting bolt:
19.6 29.4 Nm {2 3 kgm}
2
3 Tube mounting bolt:
15.7 19.6 Nm {1.6 2 kgm}
34
3 Mounting bolt:
27 34 Nm {2.8 3.5 kgm}
30-102
2
PC1100-6
HYDRAULIC PUMP
PUMP ASSEMBLY

the hydraulic tank.
1. Remove external parts around hydraulic pump.

2. Disconnect piping and wiring.
For details, see REMOVAL OF ENGINE, PTO,
HYDRAULIC PUMP ASSEMBLY.
3. Remove hydraulic tank strainer, and using tool
S, stop oil.
4. When not using tool S, drain hydraulic oil.
6 Hydraulic tank: 650
5. Remove No. 3 pump assembly (1).
4 No. 3 pump assembly: Approx. 200 kg
4 No. 1 pump assembly: 156 kg
4 No. 2 pump assembly: 146 kg
8. Remove pilot pump (4).
4 Pilot pump: Approx. 90 kg
PUMP ASSEMBLY

removal.

Add oil through the oil filler to the specified
Bleeding air
Bleed the air from all parts.
Bleeding air.
PC1100-6
30-103
2
MAIN PUMP INPUT SHAFT OIL SEAL
REMOVAL OF MAIN PUMP

INPUT SHAFT OIL SEAL
,
1. Remove main pump assembly.

For details, see REMOVAL OF MAIN PUMP
ASSEMBLY.
fl Be careful not to lose shims (2) and (3).
3. Remove oil seal (4) from cover (1).
INSTALLATION OF MAIN
PUMP INPUT SHAFT OIL SEAL

removal.
1
2 Lip of oil seal: Grease (G2-LI)
2 Coat the outside circumference of the oil
seal with grease (G2-LI) thinly, then press
fit.
fl Using tool 1, press fit oil seal (4).
30-104
2
PC1100-6
MAIN RELIEF VALVE
REMOVAL OF MAIN RELIEF

VALVE ASSEMBLY
the hydraulic tank.
1. Disconnect hoses (1) (coming from solenoid for
2-stage main relief valve) from 4-spool control
valve and 5-spool control valve main relief valve.
fl 4-spool control valve x 2, 5-spool control
valve x 1
2. Remove main relief valve (2).
12
INSTALLATION OF MAIN
RELIEF VALVE ASSEMBLY

removal.
1
3 Main relief valve:
321 46.6 Nm {32.8 4.8 kgm}
2
fl Check the relief pressure.
Measuring oil pressure in work equipment,
swing, and travel circuits.
PC1100-6
30-105
2
MAIN RELIEF VALVE
DISASSEMBLY OF MAIN
1. Remove sleeve assembly (1) from sleeve (2).
2.
Remove springs (3) and (4), pistons (5) and (6),

and sleeve (7).
3. Disassembly of sleeve assembly

fl Do not disassemble except when replacing
parts. When disassembling, measure the
protrusion dimensions of sleeves (9) and (12).
fl Loosen locknut (8), and remove sleeve (9)
and piston (10).
fl Loosen locknut (11), and remove sleeve (12),
spring (13), and piston (14) from sleeve (15).
ASSEMBLY OF MAIN RELIEF

VALVE ASSEMBLY
1. Assembly of sleeve assembly
fl Set sleeves (12) and (9) to the protrusion
dimensions measured before disassembly,
then assemble. After installing the control
valve, adjust the relief pressure.
For details, see TESTING AND ADJUSTING,.
1) Assemble piston (14) and spring (13) to
sleeve (15), screw in sleeve (12), then tighten
locknut (11).
3 Locknut:
107.8 14.7 Nm {11 1.5 kgm}
2) Assemble piston (10) and sleeve (9) to sleeve
(12), then tighten locknut (8).
3 Locknut:
85.75 7.35 Nm {8.75 0.75 kgm}
2. Assemble sleeve (7), pistons (6) and (5), and
springs (4) and (3) to sleeve (2).
3. Install sleeve assembly (1).
3 Sleeve: 186.2 9.8 Nm {19 1 kgm}
30-106
2
PC1100-6
PILOT RELIEF VALVE
REMOVAL OF PILOT RELIEF

VALVE ASSEMBLY
1. Disconnect hose (1) coming from electromagnetic valve.
2. Disconnect hose (2) coming from pilot filter.
3. Disconnect drain tube (3).
4. Disconnect hose (4) coming from pilot valve.
5. Disconnect hoses (5) and (6) going to electromagnetic valve.
6. Disconnect tube (7) going to safety valve.
7. Disconnect hose (8) going to relay joint.
8. Remove pilot relief valve assembly (9).
1
INSTALLATION OF PILOT

removal.
1
3 Mounting bolt: 78.5 Nm {8 kgm}
PC1100-6
30-107
2
5-SPOOL CONTROL VALVE
REMOVAL OF 5-SPOOL
(NO. 1)

the hydraulic tank.
Release the remaining pressure inside the
hydraulic circuit.
Releasing remaining pressure from hydraulic
circuit.
fl After disconnecting the PPC hoses, make counter

marks to distinguish the mounting positions.
fl After disconnecting the hoses and tubes, fit blind
plugs.
1. Disconnect wiring connector (1).
2. Disconnect tube (2) coming from line filter.
3. Disconnect branch hoses (3) and (4).
4. Remove clamp (5), then disconnect tube (6)
coming from main pump.
5. Disconnect R.H. PPC hoses (7) (L.H. travel), (8)
(bucket Hi), (9) (arm Lo), and (10) (boom Hi).
6. Disconnect hoses (11) going to 4-spool main
relief valve and hose between 2-stage main relief
solenoid valve and main relief valve.
7. Disconnect L.H. PPC hoses (12) (boom Hi), (13)
(arm Lo), (14) (bucket Hi), and (15) (L.H. travel).
8.
9.
10.
11.
12.
13.
Disconnect tube (16) for boom (RAISE) control.

Disconnect tube (17) for arm (OUT) control.
Disconnect tube (18) for bucket (CURL) control.
Disconnect tube (19) for arm (IN) control.
Disconnect tube (20) for bucket (DUMP) control.
Disconnect tube (21) for L.H. travel (FORWARD)
control.
14. Disconnect tube (22) for L.H. travel (REVERSE)
control.
15. Disconnect hose (23) going to filter.
fl Disconnect 2 hoses between the bottom of
the control valve and the main pump.
16. Remove mounting bolts and lift off 5-spool
control valve assembly (24).
1
4 5-spool control valve assembly: 260 kg
30-108
2
PC1100-6
INSTALLATION OF 5-SPOOL
(NO. 1)

removal.
1
fl Check the hydraulic pressure and speed of
the work equipment, travel, and swing
circuits. For details, see TESTING AND
ADJUSTING.
Aligning position when installing valve.

1) Install jig bolts 1 and 2 as shown in
the diagram on the right.
2) Install tube 3 (normal piping).
3) Replace jig bolts with normal bolts.

level. Run the engine to circulate the oil
through the system. Then check the oil level
again.
PC1100-6
30-109
2
REMOVAL OF 4-SPOOL
(NO. 2)
fl
fl
1.
2.
3.
4.

the hydraulic tank.
hydraulic circuit.
circuit.
After disconnecting the PPC hoses, make counter
After disconnecting the hoses and tubes, fit blind
plugs.
Disconnect wiring connector (1).
Disconnect tube (2) coming from main pump.
Disconnect branch hoses (3) and (4).
Disconnect hose (5) between main relief valve
and solenoid valve of 2-stage safety valve.
5. Disconnect drain hose (straight travel valve) (6).

6. Disconnect R.H. PPC hoses (7) (R.H. travel), (8)
(boom Lo), (9) (bucket Lo), and (10) (arm Hi).
7. Disconnect hose (11) from solenoid valve of 2stage safety valve.
8. Disconnect hose (12) from straight travel valve
solenoid.
9. Disconnect L.H. PPC hoses (13) (R.H. travel), (14)
(boom Lo), (15) (bucket Lo), and (16) (arm Hi).
10. Disconnect tube (17) from line filter.

11. Disconnect tube (18) going to 5-spool control
valve (L.H. travel).
12. Disconnect tube (19) for R.H. travel (FORWARD)
control.
13. Disconnect tube (20) for R.H. travel (REVERSE)
control.
14. Disconnect tube (21) for boom (LOWER) control.
15. Disconnect tube (22) for boom (RAISE) control.
16. Disconnect tube (23) for bucket (CURL) control.
17. Disconnect tube (24) for bucket (DUMP) control.
18. Disconnect tube (25) for arm (IN) control.
19. Disconnect tube (26) for arm (OUT) control.
20. Remove step (27).
fl Disconnect 2 hoses between the bottom of
the control valve and the main pump.
21. Remove mounting bolts and lift off 4-spool
control valve assembly (28).
1
30-110
2
PC1100-6
(NO. 2)

removal.
1
fl Check the hydraulic pressure and speed of
the work equipment, travel, and swing
circuits. For details, see TESTING AND
ADJUSTING.
Aligning position when installing valve.

1) Install jig bolts 1 and 2 as shown in
the diagram on the right.
2) Install tube 3 (normal piping).
3) Replace jig bolts with normal bolts.

again.
PC1100-6
30-111
2
REMOVAL OF 4-SPOOL
(NO. 3)

the hydraulic tank.
hydraulic circuit.
circuit.
fl After disconnecting the PPC hoses, make counter

fl After disconnecting the hoses and tubes, fit blind
plugs.
1. Disconnect
valves.
2. Disconnect
3. Disconnect
4. Disconnect
5. Disconnect
6. Disconnect
7. Disconnect
8. Disconnect
9. Disconnect
10. Disconnect
tubes (1) going to No. 1, 2 control

return line tubes (2).
tube (3) for arm control.
tube (4) for bucket control.
tube (5) for arm control.
tube (6) for bucket control.
tube (7) for swing control.
tube (8) for boom control.
hose (9) from hydraulic pump.
hose (10) from hydraulic valve.
11. Disconnect PPC hoses (arm control (11), bucket

control (12), swing control (13), boom control
(14)).
12. Disconnect PPC hoses (arm control (15), (bucket
control (16), swing control (17), boom control
(18)).
13. Disconnect inlet hose (19) of main 2-stage relief
solenoid valve.
14. Disconnect hoses (20) and (21) coming from No.

3 pump.
15. Remove 4-spool control valve (No. 3) assembly
(22).
30-112
2
PC1100-6
(NO. 3)

removal.

Bleeding air
Bleed the air from the circuit between the valve
and hydraulic pressure cylinder.
Bleeding air.
PC1100-6
30-113
2
CONTROL VALVE
DISASSEMBLY OF CONTROL
VALVE ASSEMBLY (NO. 1)
1. Remove bolt (2) from valve body (1), then
remove case (3).
2. Remove O-ring (4) from case (3).
3. Remove spring (5), tube (6), and retainer (9) from
bottom control valve mount, then pull out spool
(10).
4. Remove tube (7) and retainer (9) from boom Hi
control valve mount.
5. Remove springs (5) and (8), and retainer (9) from
boom Hi control valve mount, then pull out spool
(11).
6. Remove springs (5) and (8), and retainer (9) from
arm Lo, bucket Hi, and L.H. travel control valve
mount.
7. Pull out arm Lo spool (12), bucket Hi spool (13),
and L.H. travel spool (14).
8.
9.
10.
11.
12.
13.
14.
15.
Remove 2 suction valves (15).

Remove 5 suction-safety valves (16).
Remove main relief valve (17).
Remove plug (18), then remove (19) (O-ring,
backup ring, and O-ring).
Remove orifice (20).
Remove jet sensor relief valve (21).
Remove plug (22), then remove O-ring (23) from
plug.
Remove plug (24), then remove backup ring and
O-ring from plug.
16. Remove bolts (25), remove plate (26), then

remove O-ring (27), spring (28), and check valve
(29).
17. Remove plug (30), then remove backup ring (31)
and O- ring (32).
18. Remove nut (35), then remove sleeve (36).
19. Remove spring (33) and check valve (34) from
sleeve (36).
20. Remove backup ring (37) and O-ring (38) from
sleeve (36).
30-114
2
PC1100-6
CONTROL VALVE
ASSEMBLY OF CONTROL
1. Fit backup ring (37) and O-ring (38) to sleeve
(36), then assemble to valve body (1).
2 Sleeve: Thread tightener (Seal end 242)
3 Sleeve: 177 216 Nm {18 22 kgm}
2. Assemble nut (35) to sleeve (36).
3 Nut: 177 216 Nm {18 22 kgm}
3. Assemble check valve (34) and spring (33) to
sleeve (36).
4. Fit backup ring (31) and O-ring (32) to plug (30),
then assemble to sleeve (36).
3 Plug: 29.4 39.2 Nm {3 4 kgm}
5. Insert check valve (29) in valve body (1), then
assemble spring (28).
6. Fit O-ring to plate (26) and tighten to valve body
(1) with bolt.
3 Mounting bolt: 78.5 98 Nm {8 10 kgm}
7. Fit backup ring and O-ring to plug (24), then
assemble to valve body (1).
2 Plug: Thread tightener (Loctite No. 638)
3 Plug:
117.7 161.8 Nm {12.0 16.5 kgm}
8. Fit O-ring (23) to plug (22), then assemble to
valve body (1).
3 Plug: 58.8 78.5 Nm {6 8 kgm}
9. Assemble jet sensor relief valve (21) to valve
body (1).
3 Jet sensor relief valve:
177 196 Nm {18 20 kgm}
10. Assemble orifice (20) to valve body (1).
3 Orifice: 127 177 Nm {13 18 kgm}
11. Fit O-ring, backup ring, and O-ring (19) to plug
(18), then assemble to valve body (1).
12. Assemble main relief valve (17) to valve body
(1).
275 368 Nm {28 37.5 kgm}
PC1100-6
30-115
2
CONTROL VALVE
13. Assemble suction-safety valve (16) to valve body

(1).
3 Suction-safety valve:
216 235 Nm {22 24 kgm}
14. Assemble suction valve (15) to valve body (1).
3 Suction valve:
294 314 Nm {30 32 kgm}
15. Assemble spools (10) (bottom), (11) (boom Hi),
(12) (arm Lo), (13) (bucket Hi), and (14) (L.H.
travel) to valve body (1).
fl Coat the spool with engine oil.
fl Be careful not to mistake the location and
direction of the spool.
16. Assemble retainer (9), tube (6), and spring (5) to
bottom control valve mount.
17. Fit O-ring (4) to case (3) and tighten to valve
body (1) with bolt (2).
18. Assemble retainer (9) and tube (7) to boom Hi
control valve mount.
20. Assemble retainer (9) and springs (8) and (5) to
spool (12) (boom Lo control valve mount), spool
(13) (bucket Hi control valve mount), and spool
(14) (L.H. travel control valve mount).
30-116
2
PC1100-6
CONTROL VALVE
1. Remove mounting bolts (2) and (3) from valve
body (1), then remove straight travel valve (4).
2. Remove O-rings (5) and (6) from straight travel
valve (4).
3. Remove spring (7) and check valve (8) from each

port of valve body (1).
4. Remove seat (9), spring (10), and check valve
(11) from valve body (1).
5. Remove mounting bolts (12) from each control

valve mount, then remove case (13).
6. Remove O-ring (14) from each case (13).
7. Remove springs (15) and (16) from each control
valve mount, then remove retainer (17).
8. Pull out spool (18) for R.H. travel, spool (19) for
boom Lo, spool (20) for bucket Lo, and spool
(21) for arm Hi from valve body.
9. Remove 2 suction valves (22).
10. Remove suction-safety valves (23) and (24) (1
each) and 4 suction-safety valves (25).
11. Remove orifice (26).
12. Remove jet sensor relief valve (27).
14. Remove plug (29).
15. Remove backup ring and O-ring (30) from plug
(29).
PC1100-6
30-117
2
CONTROL VALVE
17. Disassembly of straight travel valve assembly

cover (33).
2) Remove plug (34).
3) Remove backup ring and O-ring (35) from
plug (34).
4) Loosen nut (46) and remove sleeve (47).
5) Remove plug (44), spring (48), and check
valve (49) from sleeve (47).
6) Remove backup ring and O-ring (45) and
(50) from plug (44) and sleeve (47).
flange (38) and O-ring (40).
8) Remove spring (41) and spool (42).
9) Remove plug and O-ring (43) from spool (42).
ASSEMBLY OF CONTROL
1. Assembly of straight travel valve
1) Fit O-ring and plug (43), assemble to spool
(42), then insert together with spring (41) in
valve body (4).
2) Fit O-ring to flanges (38) and (39), and tighten
with mounting bolts (37) from left and right.
2 Flange: Liquid sealant (Seal end 242)
3) Fit backup ring and O-ring (50) to sleeve
(47), then assemble to valve body.
2 Sleeve: Liquid sealant (Seal end 242)
3 Sleeve: 177 216 Nm {18 22 kgm}
4) Tighten nut (46) in sleeve (47).
3 Nut: 177 216 Nm {18 22 kgm}
5) Fit backup ring and O-ring (45) to plug (44).
6) Insert check valve (49) and spring (48) in
sleeve (47), then assemble plug (44).
3 Plug: 29.4 39.2 Nm {3 4 kgm}
30-118
2
PC1100-6
CONTROL VALVE
7) Fit backup ring and O-rings (35) and (36) to

plug (34), then insert in valve body (4).
8) Install cover (32), then install bolt (51).
2 Cover: Liquid sealant (Seal end 242)
3 Bolt: 27.5 34.3 Nm {2.8 3.5 kgm}
9) Put cover (33) on valve body, fit washer to
bolt (32), then insert into valve body (4).
2. Fit O-ring to plug (31) and install.
3 Plug: 58.8 78.5 Nm {6 8 kgm}
3. Fit backup ring and O-ring (30) to plug (29) and
install.
3 Plug: 118 162 Nm {12 16.5 kgm}
4. Install main relief valve (28).
275 368 Nm {28 37.5 kgm}
5. Install jet sensor relief valve (27).
177 196 Nm {18 20 kgm}
6. Install orifice (26).
3 Orifice: 127 177 Nm {13 18 kgm}
7. Install suction-safety valves (23), (24), and (25).
216 235 Nm {22 24 kgm}
8. Install suction-safety valve (22).
294 314 Nm {30 32 kgm}
9. Insert spools (18) (R.H. travel), (19) (boom Lo),
(20) (bucket Lo), and (21) (arm Hi) in valve body
(1).
fl Coat the spool with engine oil, then insert.
10. Assemble retainer (17) and springs (15) and (16).
11. Fit O-ring (14) to case (13), and tighten with bolt
(12).
PC1100-6
30-119
2
CONTROL VALVE
12. Insert check valve (8) and spring (7) in valve

body (1).
13. Insert check valve (11), spring (10), and seat (9)
in valve body (1).
14. Fit O-rings (5) and (6) to straight travel valve (4),
and set to valve body (1).
15. Fit washers to mounting bolts (2) and (3) and

tighten.
fl Tighten in the order shown in the diagram
on the right.
3 Mounting bolt (2) x 12:
78.5 98.1 Nm {8 10 kgm}
157 177 Nm {16 18 kgm}
30-120
2
PC1100-6
CONTROL VALVE
1. Remove mounting bolts (2) and (3) from valve
body (1), then remove swing priority valve (4).
2. Remove O-rings (5) and (6) from swing priority
valve (4).
3. Remove spring (7) and check valve (8) from each

port of valve body (1).
4. Remove spring (9), seat (10), and check valve
(11) from valve body (1).
5. Remove spring (12) and check valve (13) from
valve body (1).
6. Remove mounting bolts (14) from each control

valve mount on left side (main relief valve mount
side), then remove case (15).
7. Remove O-ring (16) from each case (15).
8. Remove bolt (14) from each control valve mount
(Boom Plus), then remove case (15), tube (20),
and retainer (19).
9. Pull out spool (22) for Boom Plus.
10. Remove bolt (14), then remove case (15), springs
(17) and (18), and retainer (19).
11. Pull out swing spool (23).
12. Remove bolt (14), then remove case (15), tube
(21), and retainer (19).
13. Pull out spool (24) for Bucket Plus.
14. Remove bolt (14), then remove case (15), springs
(17) and (18), and retainer (19).
15. Pull out spool (25) for Arm Plus.
16. Remove O-ring (16) from each case.
17. Remove 6 plugs (26) from valve body (1).
18. Remove O-ring (27) and backup ring and O-ring
(28) from plug (26).
19. Remove 2 suction-safety valves (29).
20. Remove orifice (30).
21. Remove jet sensor relief valve (31).
24. Remove backup ring and O-ring (34) from plug
(33).
PC1100-6
30-121
2
CONTROL VALVE
26. Disassembly of swing priority valve assembly

cover (37).
2) Remove O-ring (38) from cover (37).
3) Remove plug (39).
4) Remove backup ring, O-ring (40), and O-ring
(41) from plug (39).
5) Loosen nut (42), and remove sleeve (43).
6) Remove plug (44), spring (45), and check
valve (46) from sleeve (43).
7) Remove backup ring and O-rings (47) and
(58) from plug (44) and sleeve (43).
flange (50) and O-ring (51).
ASSEMBLY OF CONTROL
1. Assembly of swing priority valve
1) Fit washer to bolt (49), then install O-ring
(51) and flange (50) to valve body (4).
2) Fit backup ring and O-ring (48) to sleeve
(43), and assemble to valve body.
2 Sleeve: Liquid sealant (Seal end 242)
3 Sleeve: 177 216 Nm {18 22 kgm}
3) Tighten nut (42) to sleeve (47).
3 Nut: 177 216 Nm {18 22 kgm}
4) Fit backup ring and O-ring (47) to plug (44).
5) Insert check valve (46) and spring (45) in
sleeve (43), then assemble plug (44).
3 Plug: 29.4 39.2 Nm {3 4 kgm}
6) Fit backup ring and O-ring (40) and O-ring
(41) to plug (39), then insert in valve body
(4).
7) Fit O-ring, then set cover (37) together with
bolt (36) to valve body (4).
30-122
2
PC1100-6
CONTROL VALVE
2. Fit O-ring to plug (35) and install.

3 Plug: 58.8 78.5 Nm {6 8 kgm}
3. Fit backup ring and O-ring (34) to plug (33) and
install.
3 Plug: 118 162 Nm {12 16.5 kgm}
4. Install main relief valve (32).
275 368 Nm {28 37.5 kgm}
5. Install jet sensor relief valve (31).
177 196 Nm {18 20 kgm}
6. Install orifice (30).
3 Orifice: 127 177 Nm {13 18 kgm}
7. Install suction-safety valve (29).
216 235 Nm {22 24 kgm}
8. Fit O-ring (27) and backup ring and O-ring (28)
to plug (26), then install.
3 Plug: 177 196 Nm {18 20 kgm}
9. Insert spools (22) (Boom Plus), (23) (swing), (24)

(Bucket Plus), and (25) (Arm Plus) in valve body
(1).
fl Coat the spool with engine oil, then insert.
10. Assemble retainer (19) and spring (20).
11. Fit O-ring (16) to case (15), and tighten with bolt
(14).
13. Fit O-ring to case (17) and tighten with bolt (14).
14. Assemble retainer (19) and tube (21).
15. Fit O-ring to case (15) and tighten with bolt (14).
17. Fit O-ring (16) to case (15) and tighten with bolt
(14).
18. Assemble main relief valve in same way.
PC1100-6
30-123
2
CONTROL VALVE
19. Insert check valve (8) and spring (7) in valve

body (1).
20. Fit spring (9) to check valve (11) and seat (10),
then set to valve body (1).
21. Set check valve (13) and spring (12) to valve
body.
22. Fit O-rings (5) and (6) to swing priority valve
assembly (4), then set to valve body assembly
(1).
23. Fit washers to bolts (2) and (3), then tighten.

fl Tighten in the order shown in the diagram
on the right.
78.5 98.1 Nm {8 10 kgm}
157 177 Nm {16 18 kgm}
30-124
2
PC1100-6
SWING MOTOR
REMOVAL OF SWING MOTOR

ASSEMBLY
stop the engine. Then loosen the oil filler cap
hydraulic tank.
fl Center of chassis
1. Disconnect hoses (1), (2), (3), and (4) coming
from control valve.
2. Disconnect hoses (5) and (6) going to swing
motor at front of chassis.
fl Front of chassis
motor at center of chassis.
4. Disconnect hose (13) going to boom LOWER
regeneration valve.
6. Remove mounting bolts (15), then lift off swing

motor assembly (16).
4 Swing motor assembly: 130 kg
INSTALLATION OF SWIVEL
MOTOR ASSEMBLY

removal.
Refilling with oil

PC1100-6
30-125
2
CENTER SWIVEL JOINT
REMOVAL OF CENTER SWIVEL

JOINT ASSEMBLY
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.

hydraulic tank.
Disconnect piping and wiring crossing at top of
center swivel joint.
Disconnect hose (1) between swivel joint bottom
L.H. and R.H. travel motors.
Disconnect travel speed selector hose (2)
between swivel joint bottom and L.H. and R.H.
travel motors.
Disconnect tubes (3) and (4) between swivel joint
bottom and L.H. travel motor.
fl Remove the clamps.
Disconnect tubes (5) and (6) between swivel joint
bottom and R.H. travel motor.
fl Disconnect the clamps.
Disconnect hoses (7) and (8) between 4-spool
control valve and swivel joint.
Disconnect hose (9) between travel speed
selector solenoid valve and swivel joint.
Pull out pin and remove stopper link (10).
Disconnect hoses (11) and (12) between 5-spool
control valve and swivel joint.
Disconnect hose (13) going to filter.
Disconnect inside and outside swing motor drain
hoses (14) and (15).
Lift off center swivel joint assembly (16).
4 Center swivel joint assembly: 70 kg
INSTALLATION OF CENTER
SWIVEL JOINT ASSEMBLY

removal.
fl Add oil to replace the oil that leaked out during
the removal operation.
30-126
2
PC1100-6
CENTER SWIVEL JOINT
DISASSEMBLY OF CENTER
2. Remove snap ring (2).
3. Using puller 1, pull out swivel rotor (4) and
ring (3) from swivel shaft (5).
4. Remove O-ring (6) and slipper seal (7) from
swivel rotor.
2
3
ASSEMBLY OF CENTER
1. Assemble slipper seal (7) and O-ring (6) to swivel
rotor.
2. Set swivel shaft (5) on block, and using push
tool 2, tap swivel rotor (4) with a plastic
hammer, and install.
2 Contact surface of rotor, slipper seal:
Grease (G2LI)
fl When installing the rotor, be extremely
careful not to damage the lips of the slipper
seal and the O-ring.
CEP00381
3. Install ring (3) and secure with snap ring (2).

4. Fit O-ring and install cover (1).
3 Mounting bolt:
66.15 7.35 Nm {6.75 0.75 kgm}
CEP00382
PC1100-6
30-127
2
TRAVEL MOTOR
REMOVAL OF TRAVEL MOTOR

ASSEMBLY
Swing the work equipment 90, then lower it
completely to the ground and stop the engine.

1. Remove covers (1) and (2).
2. Disconnect travel speed selector hose (3).
5. Remove mounting bolts on diagonally opposite
sides, set guide bolts 1 in position, then lift off
travel motor assembly (6).
fl Set guide bolts 1 in position, sling the travel
motor, then remove the mounting bolts, and
use forcing screws to pull out the motor
assembly.
4 Travel motor assembly: 60 kg
INSTALLATION OF TRAVEL
MOTOR ASSEMBLY

removal.
fl Be sure to install the thrust rings and O-rings.
30-128
2
PC1100-6
REMOVAL OF WORK
EQUIPMENT PPC VALVE
ASSEMBLY
the hydraulic tank.
1. Remove boots (1), then disconnect levers (2)
from PPC valve.
fl On the right side, disconnect horn wiring
connector (M23).
fl Remove the boots together with the levers.
2. Remove case covers (3).
3. Disconnect 6 hoses (4).
fl The hoses are distinguished by different
colored marks, but if oil gets on the marks,
the color may change.
4. Remove mounting bolts (5), then remove PPC
valve assembly (6).
1
INSTALLATION OF WORK
EQUIPMENT PPC VALVE
ASSEMBLY

removal.
1
fl If there is excessive play in the control levers,
adjust the PPC valve.
Adjusting PPC valve.
PC1100-6
30-129
2
DISASSEMBLY OF WORK
EQUIPMENT PPC VALVE
ASSEMBLY
1. Remove nut (1), then remove disc (2) and boot
(3).
2. Remove bolts, then remove plate (5).
fl Do not remove joint (4) unless it is to be
replaced.
3. Remove seal (6) and collar (7).
4. Pull out piston (8), then remove retainer (9),
springs (10) and (11), and shim (12).
fl Spring (10) consists of two each of two types of
springs with different installed loads, so check
the mounting position (oil pressure port) and
mark with tags to prevent mistakes when
installing.
5. Pull out valve (13) from body (14).
30-130
2
PC1100-6
ASSEMBLY OF WORK
EQUIPMENT PPC VALVE
ASSEMBLY
1. Assemble valve (13) to body (14).
2. Assemble shim (12) and spring (11) to valve
(13).
fl When assembling spring (11), set the end
with the small coil diameter (inside diameter)
at shim (12) end.
3. Assemble spring (10), retainer (9), and piston
(8).
fl The number of loops in the coil for spring
(10) is different for each of the hydraulic
ports below, so be careful when installing.
Position of port
Free length of spring (mm)
P1, P2
38.71
P3, P4
42.48
fl The position of each port is marked on the

bottom of the valve body.
2 Piston: Grease (G2-LI)
fl When assembling piston (8), coat the outside
of the piston and the inside of the hole in
the body with grease.
4. Fit O-ring to collar (7) and assemble in body
(14), then install seal (6).
5. Install plate (5).
3 Mounting bolt:
13.23 1.47 Nm {1.35 0.15 kgm}
6. Install joint (4).
2 Rocking portion of joint: Grease (G2-LI)
2 Female thread of body:
fl Coat two places on the female thread with
one drop each of Loctite as shown in the
diagram on the right.
3 Joint: 44.1 4.9 Nm {4.5 0.5 kgm}
fl Keep strictly to the tightening torque for the
joint.
7. Assemble boot (3) and disc (2), and tighten with
nut (1).
3 Nut: 112.7 14.7 Nm {11.5 1.5 kgm}
fl After assembling the disc, adjust the height
of the disc.
Adjusting PPC valve.
PC1100-6
57mm
CEP00425
30-131
2
TRAVEL PPC VALVE
REMOVAL OF TRAVEL PPC

VALVE ASSEMBLY
the hydraulic tank.
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
Remove cover under travel PPC valve.

Remove floor mat.
Remove pedals (1) and levers.
Remove cover (3).
1
Remove covers (4), then remove springs (5).
Disconnect left and right FORWARD hoses (6).
2
Disconnect left and right REVERSE hoses (7).
Disconnect drain hose (8).
Disconnect hose (9) coming from pilot pump.
Remove mounting bolts, then remove travel PPC
valve assembly (10).
INSTALLATION OF TRAVEL
PPC VALVE ASSEMBLY
CEP00427

removal.
1
3 Cover mounting bolt:
19.6 1.9 Nm {2.0 0.2 kgm}
2
3 Hose mount joint bolt
(width across flats: 30mm):
39.2 4.9 Nm {4.0 0.5 kgm}
3 Hose mount joint bolt
(width across flats: 22mm):
29.4 4.9 Nm {3.0 0.5 kgm}
30-132
2
CEP00428
PC1100-6
TRAVEL PPC VALVE
DISASSEMBLY OF TRAVEL PPC

VALVE ASSEMBLY
1. Remove screws (1), then remove levers (2).
2. Remove mounting bolts (3), then remove case
and shaft assembly (4).
3. Remove 4 mounting bolts (5), then remove plate
and damper assembly (6).
fl Check the thickness and mounting position
of washer (7).
4. Remove mounting bolts (8), then remove damper
assembly (9) from plate (10).
5. Remove seal (11) and collar (12).
6. Pull out piston (13), then remove retainer (14),
springs (15) and (16), and shim (17).
fl Check the number and thickness of shim (17)
for each mounting position, and keep in sets
in a safe place.
7. Remove valve (18) from body (19).
8. Disassembly of case, shaft assembly
1) Knock pin (20) into shaft, and remove shaft
(21).
2) Remove lever (22).
3) Pull out pin (20) from shaft (21).
PC1100-6
30-133
2
TRAVEL PPC VALVE
ASSEMBLY OF TRAVEL PPC

VALVE ASSEMBLY
1. Assemble valve (18) in body (19).
2. Assemble shim (17) and spring (16) to valve
(18).
fl Check the number and thickness of shim (17)
for each mounting position, and assemble
in the same position as before disassembly.
Standard thickness of shim: 0.3 mm
fl The top and bottom of spring (16) are not
symmetrical, so set the small coil diameter
(inside diameter) at the shim end when
assembling.
3. Assemble spring (15), retainer (14), and piston
(13).
2 Outside circumference of piston, hole in
body: Grease (G2-LI)
4. Fit O-ring to collar (12) and assemble in body
(19), then install seal (11).
5. Install damper assembly (9) to plate (10) and
3 Mounting bolt:
4.41 0.49 Nm (0.45 0.05 kgm)
6. Install plate and damper assembly (6), and
fl Temporarily assemble a standard washer (1.6
mm) for washer (7).
After the completion of assembly, measure
the difference in the angle when the left and
right levers are operated fully. If the
difference in angle is greater than 0.7,
change the thickness of washer (7) to make
the difference less than 0.7.
Thickness of washer: 1.0, 1.3, 1.6 mm
fl If the thickness of the washer is reduced
by 0.3 mm, the angle when the lever is
fully operated will be increased by 0.39.
3 Mounting bolt:
30.87 3.43 Nm (3.15 0.35 kgm)
7. Install case and shaft assembly (4) and tighten
mounting bolts (3).
2 Rocking portion of shaft, connection of
lever and piston: Grease (G2-LI)
3 Mounting bolt:
27.93 3.43 Nm (2.85 0.35 kgm)
8. Install levers (2) and tighten screws (1).
2 Rocking portion of lever pin and plate:
Grease (G2-LI)
3 Screw: 8.82 0.98 Nm (0.9 0.1 kgm)
30-134
2
PC1100-6
BUCKET CYLINDER
REMOVAL OF BUCKET
CYLINDER ASSEMBLY
Backhoe specification
Set mounting pin (1) and link (2) at the bucket
cylinder rod end to a position where there is no

interference, then set the back face of the bucket
on a block.
Stop the engine, then operate the bucket control
lever to release the remaining pressure in the
hydraulic circuit.
1. Remove stopper, then remove rod pin (1) from

link (2).
1
fl After removing the pin, start the engine, and
retract the piston rod, then tie the piston rod
with wire to prevent it from coming out.
fl Extend the arm and set block 1 between
the cylinder and the arm.
fl The bucket and link are still installed, so be
careful when extending the arm.
fl There are shims installed, so check the
number and thickness, and keep in a safe
place.
2. Disconnect 2 left and right cylinder bottom
grease hoses (3).
3. Disconnect right cylinder bottom hose (4) and
head hose (5).
4. Disconnect left cylinder bottom hose (6) and
head hose (7).
fl If there is remaining pressure in the hydraulic
circuit, the oil may spurt out, so check while
disconnecting.
fl Fit blind plugs in the hoses after
disconnecting them.
5. Sling right bucket cylinder assembly (8) and
remove lock plate (9), then remove pin (10). 2
fl Pull out pin (10) to a position where the
right cylinder comes off.
place.
6. Lift off right bucket cylinder assembly (8).
7. Remove the cylinder assembly on the left side
in the same way.
4 Bucket cylinder assembly: 700 kg
PC1100-6
30-135
2
BUCKET CYLINDER
INSTALLATION OF BUCKET
CYLINDER ASSEMBLY

removal.
1
2 Inside surface of bushing when assembling
pin: Anti-friction compound (LM-P)
2 Grease after assembling pin:
Grease (LM-G)
When aligning the position of the pin hole,
never insert your fingers in the pin hole.
fl Adjust with shims so that clearance a
between link (2) and the end face of the
head of cylinder (8) is 2 3 mm.
Shim thickness: 0.8 mm (STD)
1.0 mm (SP)
2
Grease (LM-G)
fl Adjust with shims so that clearance b
between the end face and the bottom of
cylinder (8) and bracket (9) is 2 3 mm.
Shim thickness: 0.8 mm (STD)
1.0 mm (SP)
Bleeding air
fl Bleed the air.
Bleeding air.

fl Add oil through the oil filler to the specified
again.
30-136
2
PC1100-6
ARM CYLINDER
REMOVAL OF ARM CYLINDER

ASSEMBLY
Retract the arm cylinder fully and set block 1

under the tip of the arm.
Stop the engine and operate the control levers

to release the remaining pressure in each
cylinder.
1. Disconnect piston rod grease hose (1).
2. Remove lock plate, then remove piston rod pin
(2).
1
fl Set block 2 between the arm cylinder and
the boom.
3. Disconnect 2 bottom hoses (3).
4. Disconnect head hose (4).
fl After disconnecting the hoses, fit blind plugs
to prevent the entry of dirt or dust.
5. Disconnect bottom grease hose (5).

6. Remove lock plate, then remove pin (6). 2
fl Sling arm cylinder assembly (7).
place.
7. Lift off arm cylinder assembly (7).

4 Arm cylinder assembly: 610 kg
PC1100-6
30-137
2
ARM CYLINDER
INSTALLATION OF ARM
CYLINDER ASSEMBLY

removal.
1
Grease (LM-G)
2
Grease (LM-G)
fl Adjust with shims (9) so that clearance a
between the end face of the bottom of
cylinder (7) and bracket (8) is 2 3 mm.
Shim thickness: 0.8 mm
Bleeding air
fl Bleed the air.
Bleeding air.

again.
30-138
2
PC1100-6
BOOM CYLINDER
REMOVAL OF BOOM
CYLINDER ASSEMBLY
Extend the arm and bucket cylinder rods fully,
lower the work equipment completely to the

ground, and put the safety lock lever in the LOCK
position.
Stop the engine and operate the control levers
to release the remaining pressure in the
hydraulic circuit.
1. Disconnect grease hose (1).

2. Remove lock plate, then remove pin (2).
fl Sling the boom cylinder assembly.
3. Retract rod (3).

4. Lower boom cylinder slowly, and insert wedge
1 between cylinder bottom and revolving frame.
fl Insert so that the cylinder is horizontal.
5. Disconnect head hose (4).
6. Disconnect bottom hose (5).
7. Sling boom cylinder assembly (7) and remove

lock plate, then remove pin (7).
2
fl Use forcing screws when removing.
4
PC1100-6
Boom cylinder assembly: 1,049 kg
30-139
2
BOOM CYLINDER
INSTALLATION OF BOOM
CYLINDER ASSEMBLY

removal.
1
Grease (LM-G)
2
Grease (LM-G)
between the end face of the bottom of boom
cylinder (7) and bracket (8) is less than 1
mm.
Shim thickness: 1.0, 1.5 mm
Bleeding air
fl Bleed the air.
Bleeding air.

again.
30-140
2
PC1100-6
BUCKET
REMOVAL OF BUCKET
ASSEMBLY
Set the back face of the bucket facing down,

lower the work equipment completely to the
ground, and set the safety lock lever to the LOCK
position.
1. Remove 3 link pin lock bolts (2) of bucket (1),
then remove stopper (3).
2. Remove link pin (4).

1
fl If it is difficult to remove the pin, raise the
bucket and move it backward and forward
to find a position where it is easier to remove
the pin.
fl If the bucket is not in contact with the ground,
set a block under the back face of the bucket.
fl After removing the pin, retract the bucket
cylinder and lift up link (5).
3. Remove 3 lock bolts (6) of connecting pin
between arm and bucket, then remove stopper
(7).
4. Loosen 4 cover lock bolts (8).
5. Remove connecting pin (9) between arm and
bucket.
2
fl If it is difficult to remove the pin, move the
arm up and down a small amount to find a
position where it is easier to remove the
pin.
6. Remove 4 cover lock bolts (8) and cover (10)
from bucket (1), then remove shim (11), bushing
(12), and O-ring (13).
place.
7. Start engine, then raise work equipment to
disconnect arm (14) from bucket.
4 Bucket assembly: 4,600 kg
PC1100-6
30-141
2
BUCKET
INSTALLATION OF BUCKET
ASSEMBLY

removal.
1
Grease (LM-G)
2
Grease (LM-G)
fl Insert the O-ring at the end face of the bucket
boss securely.
fl Adjustment of bucket clearance
1) Measure clearance a between arm (14)
and bushing (12).
fl Put the edge of the arm boss and
the edge of the bucket boss in
contact, and measure clearance a.
2) After removing the shims, take out shims
equal to clearance a, and fit the
remaining shims.
fl Shim thickness: 0.5, 1.0 mm
fl If clearance a is smaller than the
thickness of one shim, do not carry
out any adjustment.
3) Tighten bolt (8) and bolt (6).
30-142
2
PC1100-6
ARM
REMOVAL OF ARM ASSEMBLY

1. Remove bucket assembly.
For details, see REMOVAL OF BUCKET
ASSEMBLY.
fl Secure the bucket link to the arm.
3. Disconnect 4 bucket cylinder hoses (2).
fl Disconnect at the tip of the boom.
4. Sling arm cylinder assembly (3) and remove pin
(4).
1
the boom.
5. Sling arm assembly (6) and remove pin (5). 2
fl If it is difficult to remove the pin, operate the
swing to move the boom slightly to the left
and right, and knock out the pin at a point
where the forcing screw becomes lighter.
6. Lift off arm assembly (6).
4 Arm assembly: 4,000 kg
PC1100-6
30-143
2
ARM
INSTALLATION OF ARM
ASSEMBLY

removal.
1
Grease (LM-G)
2
Grease (LM-G)
between the end face of the bottom of arm
(6) and boom (7) is less than 1 mm.
Bleeding air
fl Bleed the air.
Bleeding air.

again.
30-144
2
PC1100-6
BOOM
REMOVAL OF BOOM
ASSEMBLY
1. Remove bucket and arm assembly.
For details, see REMOVAL OF BUCKET, ARM
ASSEMBLY.
2. Set tip of boom on support 1 and stop engine,
then operate boom control lever to release any
remaining pressure in boom cylinder.
3. Sling boom cylinder (1) and remove pin (2). 1
fl Lower the boom cylinder slowly and insert a
wedge between the cylinder bottom and the
frame.
4. Disconnect 7 hoses (3) for bucket and arm.
5. Disconnect wiring connector (4) for working

lamp.
6. Sling boom assembly (7).
7. Remove lock plate (5), then remove boom foot
pins (6).
2
fl Use forcing screws.
8. Lift off boom assembly (7) slowly.

fl Boom assembly (7) will rock when the crane
is operated, so fit rope 2 to the tip of the
boom and apply tension to control the boom
and prevent it from rocking.
4 Boom assembly: 9,000 kg
PC1100-6
30-145
2
BOOM
ASSEMBLY

removal.
1
Grease (LM-G)
2
Grease (LM-G)
between the end face of the foot of boom
(7) and bracket (8) is less than 1 mm.
Bleeding air
fl Bleed the air.
Bleeding air.

again.
30-146
2
PC1100-6
BUCKET, ARM
REMOVAL OF BUCKET, ARM

ASSEMBLY
2. Disconnect 4 bucket cylinder hoses (2).
fl Disconnect at the tip of the boom.
3. Sling arm cylinder assembly (3) and remove pin
(4).
1
the boom.
4. Raise bucket and arm assembly (6) a little and

remove pin (5).
2
fl If it is difficult to remove the pin, operate the
swing to move the boom slightly to the left
and right, and knock out the pin at a point
where the forcing screw becomes lighter.
5. Drive machine in reverse and separate bucket
and arm assembly (6) from boom.
6. Set support under arm and lower bucket and
arm assembly (6) slowly.
4 Bucket, arm assembly: 8,500 kg
PC1100-6
30-147
2
BUCKET, ARM
INSTALLATION OF BUCKET,
ARM ASSEMBLY

removal.
1
Grease (LM-G)
2
Grease (LM-G)
between the end face of the bottom of arm
(7) and boom (8) is less than 1 mm.
Bleeding air
fl Bleed the air.
Bleeding air.

again.
30-148
2
PC1100-6
WORK EQUIPMENT
REMOVAL OF WORK
EQUIPMENT ASSEMBLY
1. Sling boom cylinder (1) and remove pin (2). 1
fl Lower the boom cylinder slowly and insert a
wedge between the cylinder bottom and the
frame.
2. Disconnect 7 bucket and arm hoses (3).
3. Disconnect wiring connector (4) for working

lamp.
4. Sling work equipment assembly (7).
5. Remove lock plate (5), then remove boom foot
pins (6).
2
fl Use forcing screws.
6. Start engine and drive machine slowly in reverse.
7. Set support under boom foot, then operate crane
and lower work equipment slowly.
4 Work equipment assembly: 18,000 kg
PC1100-6
30-149
2
WORK EQUIPMENT
INSTALLATION OF WORK
EQUIPMENT ASSEMBLY

removal.
1
Grease (LM-G)
2
Grease (LM-G)
between the end face of the foot of boom
(8) and bracket (9) is less than 1 mm.
Bleeding air
fl Bleed the air.
Bleeding air.

again.
30-150
2
PC1100-6
CAB
REMOVAL OF CAB ASSEMBLY

1. Remove floor mat.
2. Remove covers (1), (2), and (3).
3. Disconnect window washer hoses (4).

4. Disconnect wiper motor wiring connector (5)
(W21).
5. Remove base mounting bolts (6) and (7).
6. Remove plate (8).

8. Open door (10), and disconnect speaker wiring
connector (M13).
PC1100-6
30-151
2
CAB
10. Remove base mounting bolts (12) and (13).
11. Remove wiring clamp (14) installed to cab.

fl Disconnect wiring connector (M72) for cab
head lamp and wiring connectors (M71, 97)
for room lamp.
12. Remove mounting bolts (15), then lift off cab

assembly (16).
fl When raising the cab assembly, check that
all the wiring and connectors have been
disconnected, then lift off slowly.
4 Cab assembly: 300 kg
INSTALLATION OF CAB
ASSEMBLY

removal.
30-152
2
PC1100-6
COUNTERWEIGHT
REMOVAL OF
1. Sling counterweight assembly (1).
2. Remove mounting bolts (2).
3. Lift off counterweight assembly (1).

4 Counterweight assembly: 17,500 kg
INSTALLATION OF

removal.
1
3 Counterweight mounting bolt:
3,822 392 Nm {390 40 kgm}
PC1100-6
30-153
2
RECEIVER TANK
REMOVAL OF RECEIVER TANK

ASSEMBLY
Set tool X1 to the gas charging plug of the air

conditioner compressor and collect the air
conditioner gas (R134a).
1. Open door at rear of cab.
2. Disconnect hose (1) coming from air conditioner
condenser.
3. Disconnect hose (2) going to air conditioner unit.
4. Remove U-bolt (3), then remove receiver tank
assembly (4).
1
INSTALLATION OF RECEIVER
TANK ASSEMBLY

removal.
1
fl Be careful not to let dirt, dust, or water get
inside the hoses of the air conditioner circuit
when installing the hoses.
fl Check that there are O-rings at the
connections of the air conditioner hoses
when installing.
fl Check that the O-rings are not damaged or
deteriorated, then connect the hoses.
Charging with air conditioner gas

Using tool X1, charge the air conditioner circuit
with air conditioner gas (R134a).
30-154
2
PC1100-6
AIR CONDITIONER CONDENSER
REMOVAL OF AIR
CONDITIONER CONDENSER
ASSEMBLY

1. Open radiator mask.
2. Disconnect hose (1) coming from air conditioner
compressor.
3. Disconnect hose (2) going to receiver tank.
4. Remove 4 mounting bolts (3), then remove air
conditioner condenser assembly (4).
1
INSTALLATION OF AIR
CONDITIONER CONDENSER
ASSEMBLY

removal.
1
fl Be careful not to let dirt, dust, or water get
inside the hoses of the air conditioner circuit
when installing the hoses.
fl Check that there are O-rings at the
connections of the air conditioner hoses
when installing.

Using tool X1, charge the air conditioner circuit
with air conditioner gas (R134a).
PC1100-6
30-155
2
AIR CONDITIONER COMPRESSOR
REMOVAL OF AIR
ASSEMBLY

1. Loosen lock bolt (1) of air conditioner compressor
mounting bracket.
2. Disconnect wiring connector (2) (M34).
3. Disconnect hoses (3).
1
fl Fit blind plugs in the hoses after
disconnecting.
5. Loosen locknut (5).
6. Loosen adjustment bolt (6) and remove drive
belt.
2
7. Remove mounting bolt (7), then remove air
conditioner compressor assembly (8).
INSTALLATION OF AIR
ASSEMBLY

removal.
1
2
fl Adjust the belt tension.
Testing and adjusting tension of air
conditioner compressor drive belt.

fl Using tool X1, charge the air conditioner
circuit with air conditioner gas (R134a).
30-156
2
PC1100-6
REMOVAL OF AIR
CONDITIONER UNIT
ASSEMBLY

AIR CONDITIONER UNIT
1
2
1. Close valve of heater hose (outlet).

fl It is installed to the engine water manifold.
CEP00105
2. Slide operators seat fully forward.

3. Remove plate (1), then remove cover (2).
4. Disconnect speaker wiring connector (3) (M13),
then disconnect cover (4).
fl Lift up the cover slightly before disconnecting
the speaker wiring connector.
5. Remove bellows hose (5).

6. Remove ducts (6) and (7).
PC1100-6
30-157
2
AIR CONDITIONER UNIT
7. Disconnect governor controller wiring connectors

(8).
fl Connectors (E12, 13, 14, 15, 16, 17, 18)
8. Remove governor controller (9).
9. Remove relays (10), (11), and (12).
fl Relays (R18, 23, 24)
10. Disconnect wiring harness clamps (13) and (14)
from cover.
11. Disconnect wiring connector (15) (M26) for air

conditioner unit.
12. Tie wiring harnesses (16) together and move
towards cab.
14. Disconnect heater hoses (18) and (19).
fl Fit blind plugs in the hoses.
15. Disconnect refrigerant hoses (20) and (21).
fl The clamp is weak, so always hold with one
wrench while using the other to turn.
16. Disconnect wiring connectors (22), (23), (24), and

(25).
17. Disconnect 4 relays (26).
18. Remove filter (27).
19. Remove mounting bolts, then remove air
conditioner unit (28).
INSTALLATION OF AIR
CONDITIONER UNIT
ASSEMBLY

removal.

fl Add water through water filler to the
specified level.
Run the engine to circulate the water through
the system. Then check the water level again.

fl Using tool X1, charge the air conditioner
circuit with air conditioner gas (R134a).
30-158
2
PC1100-6
SOLENOID VALVE
REMOVAL OF SOLENOID
VALVE ASSEMBLY
1. Boom rock prevention valve
1) Open door at rear of cab.
2) Disconnect wiring connectors (1) (V9, 10).
3) Remove nuts (2), then remove solenoids (3).
fl V9, V10: Boom rock prevention solenoid
valve
2. Swing priority valve, main 2-stage relief valve,

CO cancel valve
1) Open door at side of hydraulic tank.
2) Disconnect wiring connectors (1) (V1, 2, 7).
fl V1: Swing priority valve
V2: Main 2-stage relief valve
V3: CO cancel valve
3. Straight travel valve, swing lock valve, boom

head 2-stage safety valve, travel speed selector
valve, swing lock valve
1) Remove step at center of chassis.
2) Disconnect wiring connectors (1) (V3, 4, 5, 6,
11).
fl V3: Straight travel valve
V4: Swing lock valve
V5: Boom head 2-stage safety valve
V6: Travel speed selector valve
V11: Swing lock valve
INSTALLATION OF SOLENOID
VALVE ASSEMBLY

removal.
fl Be careful not to let dirt get stuck to the coil
insertion portion.
PC1100-6
30-159
2
GOVERNOR CONTROLLER
REMOVAL OF GOVERNOR
CONTROLLER ASSEMBLY
1. Open air conditioner unit covers (1).
2. Disconnect wiring connectors (2) (E12, 13, 14,

15, 16, 17, 18).
3. Remove 4 mounting bolts (3), then remove
governor controller assembly (4).
INSTALLATION OF GOVERNOR
CONTROLLER ASSEMBLY

removal.
30-160
2
PC1100-6
MONITOR PANEL
REMOVAL OF MONITOR
PANEL ASSEMBLY
1. Remove 4 screws (1), then disconnect monitor
panel assembly (2) from bracket.
2. Disconnect wiring connectors (3) (P01, 02), and
remove monitor panel assembly (2).
1
INSTALLATION OF MONITOR
PANEL ASSEMBLY

removal.
1
Check the mode setting and display function.
For details, see TESTING, ADJUSTING, AND
TROUBLESHOOTING.
CEP00437
PC1100-6
30-161
2
PUMP CONTROLLER
REMOVAL OF PUMP
CONTROLLER ASSEMBLY
1

1. Slide operators seat fully forward.

2. Remove plate (1), then remove left cover (2).
3. Disconnect hose (3) and speaker wiring
connector (M13), then remove right cover (4).
fl Lift up the cover slightly before disconnecting
the speaker wiring connector.
CEP00105
4. Remove 5 connectors (5) (C01, 02, 03, 16, 17).

5. Remove pump controller assembly (6).
4
3
CEP00106
INSTALLATION OF PUMP
CONTROLLER ASSEMBLY

removal.
1
Check the performance of the work equipment,
travel, and swing. For details, see TESTING AND
ADJUSTING.
30-162
2
CEP00435
PC1100-6
BOOM ROCK PREVENTION VALVE
REMOVAL OF BOOM ROCK

PREVENTION VALVE
ASSEMBLY
Release the remaining pressure from the PPC

circuit.
1. Open door (1) at rear of cab.
2. Disconnect solenoid wiring connectors (2) (V9,
10).
3. Disconnect 4 hoses (3) and (4) between solenoid
valve and rock prevention valve.
fl Disconnect the hose between the rock
prevention valve and the right PPC valve
and the hose between the rock prevention
valve and the relay joint.
4. Remove mounting bolts, then remove rock
prevention valve assembly (5).
ROCK PREVENTION VALVE
ASSEMBLY

removal.
Bleeding air.
Bleed the air fromx the PPC piping circuit.
Bleeding air.
PC1100-6
30-163
2
ACCUMULATOR
REMOVAL OF ACCUMULATOR
ASSEMBLY
Release the remaining pressure from the PPC

circuit.
1. Remove step (1).
2. Disconnect hose (2) coming from pilot relief
valve.
3. Remove mounting bolts,
accumulator assembly (3).
then
remove
INSTALLATION OF
ACCUMULATOR ASSEMBLY

removal.
Bleeding air.
Bleed the air from the PPC piping circuit.
Bleeding air.
30-164
2
PC1100-6
REMOVAL OF BOOM LOWER

REGENERATION VALVE
ASSEMBLY

hydraulic tank.
Release the remaining pressure from the
hydraulic circuit. For details, see TESTING AND
ADJUSTING, Releasing remaining pressure from
hydraulic circuit.
1. Disconnect tube (1) coming from boom control

block.
2. Disconnect hose (2) coming from front swing
machinery.
3. Disconnect hose (3) coming from control valve,
then remove mounting bolts, and remove boom
LOWER regeneration valve (4).
LOWER REGENERATION
VALVE ASSEMBLY

removal.
Bleeding air.
Bleed the air from the boom LOWER regeneration
valve.
Bleeding air.
PC1100-6
30-165
2
40
MAINTENANCE STANDARD
Engine mount ............................................... 40- 2

PTO ............................................................... 40- 3
Swing circle ................................................. 40- 4
Swing machinery ........................................ 40- 6
Final drive .................................................... 40- 8
Track frame .................................................. 40-10
Idler ............................................................... 40-12
Carrier roller ................................................ 40-14
Track roller ................................................... 40-15
Track shoe ................................................... 40-16
Hydraulic pump ........................................... 40-20
Control, PTO lubricating,
aftercooler fan drive pump ................. 40-22
L.H. 5-spool control valve .......................... 40-24
R.H. 4-spool control valve .......................... 40-26
Swing 4-spool control valve ...................... 40-28
Staight-travel valve ..................................... 40-31
Boon lower regeneration valve ................. 40-32
Swing motor ................................................ 40-33
Travel motor ................................................ 40-34
Center swivel joint ...................................... 40-36
PPC control relief valve .............................. 40-37
Work equipment swing PPC valve ......... 40-38
Travel PPC valve ......................................... 40-39
Hydraulic cylinder ....................................... 40-40
Work equipment ......................................... 40-42
Dimensions of work equipment ................ 40-44
PC1100-6
40-1
1
ENGINE MOUNT
ENGINE MOUNT
Unit: mm
No.
Check item
Free height of front mount

rubber
Criteria
Remedy
Standard size
Repair limit
141
Replace
Free height of rear mount

rubber
40-2
141
PC1100-6
PTO
PTO
Unit: mm
No.
Check item
Backlash between drive

gear and driven shaft
(for HPV160+160)

gear and driven gear
(for SAR100+020+010)
Criteria
Remedy
Standard clearance
Clearance limit
0.07 0.18
0.273 0.374
Adjust
Backlash between
drive gear and driven gear
0.2 0.74

gear and driven shaft
(for HPV95+95)
0.07 0.18
PC1100-6
40-3
SWING CIRCLE
SWING CIRCLE
Unit: mm
No.
Check item
Clearance of bearing in
axial direction (when
mounted on machine)
40-4
Criteria
Remedy
Standard clearance
Repair limit
0.5 2
Replace
PC1100-6
SWING MACHINERY
SWING MACHINERY
40-6
PC1100-6
SWING MACHINERY
Unit: mm
No.
Check item
Backlash between swing

motor shaft and No. 1 sun
gear
Criteria
Remedy
Standard clearance
Clearance limit
0.19 0.29
Backlash between No. 1 sun

gear and No. 1 planet gear
0.19 0.56
0.90
Backlash between No. 1

planet gear and ring gear
0.24 0.70
0.90

planet gear and coupling
0.06 0.24

planet carrier and No. 2
sun gear
0.40 0.71
1.10

gear and No. 2 planet gear
0.19 0.56
1.00

planet gear and ring gear
0.24 0.70
1.10
Backlash between coupling

and swing pinion
0.08 0.25
Backlash between swing

pinion and swing circle
0 1.13
2.00
0.06 0.86
Standard size
Repair limit
0
150 0.100
Clearance between plate

10 and coupling
Wear of swing pinion oil
11 seal contact surface
PC1100-6
Replace
Repair hard
chrome plating
or replace
40-7
FINAL DRIVE
FINAL DRIVE
40-8
PC1100-6
FINAL DRIVE
Unit: mm
No.
Check item
Criteria
Remedy
Standard clearance
Clearance limit

planetary carrier and case
0.08 0.27
Backlash between drive gear

and No. 1 planetary carrier
0.21 0.57
0.24 0.71
0.23 0.68
0.28 0.87
3
4
5

sun gear and No. 1
planetary carrier
sun gear and No. 2
planet gear
planetary carrier and No. 2
ring gear
Backlash between coupling

and drive gear
0.38 0.72

ring gear and case
0.08 0.26

sun gear and travel motor
coupling
0.07 0.18

gear and idler gear
0.15 0.53
Backlash between No.1

10 ring gear and idler gear
0.19 0.62
Backlash between driven

11 gear and No. 1 planet gear
0.19 0.62
12 Wear of sprocket tooth shape
Repair limit: 6
Standard size
13 Sprocket tooth width
PC1100-6
Replace
114
Repair limit
108
Rebuild or
replace
40-9
TRACK FRAME
TRACK FRAME
Unit: mm
No.
Check item
Criteria
Remedy
Standard size Tolerance

1
Top-to-bottom width of
idler guide
Left-to-right width of idler

guide
Track frame
200
2002
205
Rebuild or
replace
Idler support
195
1951.2
185
Replace
Track frame
395
3952
405
Rebuild or
replace
Idler support
391
Standard size
3
Recoil spring
391
+1.4
0.8
383
Repair limit
Free length Installation Installation

Installation
Free length
x O.D.
length
load
load
1,508 x 351
40-10
Repair limit
1,280
578.2 kN
{58,957 kg}
Replace
460.9 kN
{47,000 kg}
PC1100-6
PC1100-6
40-11
IOLER
IDLER
40-12
PC1100-6
IDLER
Unit: mm
No.
Check item
Criteria
Remedy
Standard size
Repair limit
962
Outside diameter of
protruding part
Outside diameter of tread

surface
920
908
Depth of tread
21
Overall width
290
Width of tread
77
Clearance between shaft

and bushing
Interference between idler

and bushing
Standard
size
Shaft
Hole
Standard
clearance
Clearance
limit
125
0.080
0.120
+0.313
+0.273
0.353
0.433
1.5
Standard
size
Shaft
Hole
+0.096
+0.042
0.098
0.148
135
PC1100-6
Tolerance
Rebuild or
replace
Tolerance
Replace
bushing
Standard Interference
interference
limit
0.140
0.244
40-13
CARRIER ROLLER
CARRIER ROLLER
Unit: mm
No.
Check item
Criteria
Remedy
Standard size
Repair limit
220
Outside diameter of flange
205
185
Width of tread
79
Thickness of tread
67.6
Width of foange
17
Interference between
bearing and roller
bearing and shaft
Play of roller in axial

direction
40-14
Tolerance
Replace
Standard
size
Shaft
Hole
interference
limit
125
+0.039
+0.020
0
0.015
0.020
0.040
70
+0.390
+0.020
0.059
0.015
0.020
0.054
Standard size
Clearance limit
0 0.110
0.3
PC1100-6
TRACK ROLLER
TRACK ROLLER
Unit: mm
No.
Check item
Criteria
Remedy
Standard size
Repair limit
320
Outside diameter of flange

surface
275
263
Thickness of tread
77.5
Rebuile or
replace
Overall width
370
Inside width
136
Width of tread
82
Width of flange
35
Clearance between shaft

and bushing
Standard
size
110
Interference between roller

and bushing
Standard
size
129
PC1100-6
Tolerance
Shaft
Hole
Standard
clearance
Clearance
limit
0.120
0.207
+0.360
+0.260
0.380
0.567
1.5
Tolerance
Shaft
Hole
+0.087
+0.037
+0.020
0.015
Replace
bushing
interference
limit
0.017
0.102
40-15
TRACK SHOE
TRACK SHOE
fl P portion shows the link of bushing press fitting end.
40-16
PC1100-6
TRACK SHOE
Unit: mm
No.
Check item
Criteria
Remedy
Standard size
1
Repair limit
Link pitch
280.3
283.3
Bushing outside diameter

98.5
Normal load
Impact load
93.5
Standard size
3
Link height
Thickness of link metal

(bushing press-fitting portion)
Repair limit
168
181
Reverse or
replace
When turned
Standard size
Repair or
replace
56
256.6
Replace
Shoe bolt pitch
79.5
8
9
183
Link
10
Inside width
135
Overall width
86.1
Tread width
75
11
Protrusion of pin
4.5
12
Protrusion of regular bushing
8.7
13
Overall length of pin
324.4
14
Overall length of bushing
225.6
15
Thickness of bushing metal
18.8
16
Thickness of spacer
10.93
17
18
Press-fitting
force
19
Bushing
215 304 kN {22 31 ton}
Regular pin
637 745 kN {65 76 ton}
Master
235 294 kN {24 30 ton}
Repair or
replace
Adjust or
replace
: Dry type track link
PC1100-6
40-17
TRACK SHOE
Unit: mm
No.
Check item
a. Regular link
Criteria
Tightening torque
(Nm {kgm})
Additional tightening
angle (deg.)
1,372137 {14014}
15010
Retighten
Shoe bolt
20
b. Master link
Tightening torque
(Nm {kgm})
Additional tightening Lower limit torque

angle (deg.)
(Nm {kgm})
No. of shoes (each side)
21
22
23
bushing and link
regular pin and link
Clearance between
regular pin and bushing
24
master pin and link
Standard
size
25
Clearance between
master pin and bushing
Tolerance
Standard
interference
Shaft
Hole
98
+0.622
+0.522
+0.087
0
0.435 0.622
60
+0.426
+0.326
0.126
0.200
0.452 0.626
Standard
size
Standard
size
60
48
60.5
Remedy
Standard
size
60.5
Tolerance
Shaft
0.174
0.074
Hole
+0.666
+0.166
Tolerance
Shaft
Hole
+0.228
+0.198
0.126
0.200
Tolerance
Shaft
Hole
0.51
0.61
+0.666
+0.166
Standard
clearance
0.340 0.740
Adjust or
replace
Standard
interference
0.324 0.428
Standard
clearance
0.676 1.276
: Dry type track link
40-18
PC1100-6
TRACK SHOE
DOUBLE SHOE
Unit: mm
No.
Check item
Criteria
Standard size
Height
Height
Thickness
Repair limit
50
25
50
25
25
39
Remedy
Rebuild or
replace
Length at bottom
30
6
Length at top
7
PC1100-6
30
40-19
HYDRAULIC PUMP
HYDRAULIC PUMP
HPV95 + 95 (No.1 main pump)
40-20
PC1100-6
HYDRAULIC PUMP
PC1100-6
40-21
CONTROL, PTO LUBRICATING, AFTERCOOLER FAN DRIVE PUMP
CONTROL, PTO LUBRICATING, AFTERCOOLER FAN DRIVE PUMP

SAR100+020+010
Unit: mm
No.
Check item
Clearance
between gear
case and side
plate
Clearance
between bearing
inner diameter
and gear shaft
outer diameter
Criteria
Type
Standard clearance
SAR100
0.10 0.15
0.19
SAR020
0.10 0.15
0.19
SAR010
0.10 0.15
0.19
SAR100
0.06 0.149
0.20
SAR020
0.06 0.144
0.20
SAR010
0.06 0.144
0.20
Clearance limit
Replace
3
Pin insertion depth
4
Standard size
Tolerance
Repair limit
14
0
0.5
10
0
0.5
Spline shaft rotating

torque
Remedy
10.9 21.6 Nm {1.1 2.2 kgm}

Rotating speed Delivery pressure Standard delivery amount Delivery amount limit
(MPa {kg/cm2})
(/min)
(/min)
(rpm)
Delivery
Oil: EO10-CD
Oil temp.:
45 50C
40-22
1
SAR100
2,500
2.9 {30}
15.1
138
SAR020
2,500
6.9 {70}
18
16
SAR010
2,500
2.9 {30}
23
20
PC1100-6
40-24
PC1100-6
Unit: mm
No.
Check item
Criteria
Standard size
Main relief valve, main

valve spring
Remedy
Repair limit

Installation
Free length
x O.D.
length
load
load
34.7 x 10.4
32.5
394.2 N
{40.2 kg}
315.2 N
{32.2 kg}
Jet sensor relief valve,

pilot poppet spring
34.5 x 10.8
29.4
30 N
{3.1 kg}
24.3 N
{2.5 kg}

main valve spring
37.4 x 11.4
33
49 N
{5.0 kg}
39.2 N
{4.0 kg}
Spool return spring
69.9 x 57
63
431 N
{44 kg}
345 N
{35.2 kg}
Spool return spring
75 x 37
74.5
0N
{0 kg}
0N
{0 kg}
Throttle valve spring
31.8 x 7.6
26.5
1N
{0.1 kg}
0.78 N
{0.08 kg}
Check valve spring
78.2 x 26.6
52
18.8 N
{1.92 kg}
15.1 N
{1.54 kg}
PC1100-6
Replace
spring if
damaged or
deformed
40-25
40-26
PC1100-6
Unit: mm
No.
Check item
Criteria
Standard size

valve spring
Remedy
Repair limit

Installation
Free length
x O.D.
length
load
load
34.7 x 10.4
32.5
394.2 N
{40.2 kg}
315.2 N
{32.2 kg}

pilot poppet spring
34.5 x 10.8
29.4
30 N
{3.1 kg}
24.3 N
{2.5 kg}

main valve spring
37.4 x 11.4
33
49 N
{5.0 kg}
39.2 N
{4.0 kg}
Spool return spring
69.9 x 57
63
431 N
{44 kg}
345 N
{35.2 kg}
Spool return spring
75 x 37
74.5
0N
{0 kg}
0N
{0 kg}
Check valve spring
78.2 x 26.6
52
18.8 N
{1.92 kg}
15.1 N
{1.54 kg}
Check valve spring
53.6 x 31
39
18.8 N
{1.92 kg}
15.1 N
{1.54 kg}
PC1100-6
Replace
spring if
damaged or
deformed
40-27

(1/2)
40-28
PC1100-6
(2/2)
PC1100-6
40-29
Unit: mm
No.
Check item
Criteria
Standard size

valve spring
Remedy
Repair limit

Installation
Free length
x O.D.
length
load
load
34.7 x 10.4
32.5
394.2 N
{40.2 kg}
315.2 N
{32.2 kg}

pilot poppet spring
34.5 x 10.8
29.4
30 N
{3.1 kg}
24.3 N
{2.5 kg}

main valve spring
37.4 x 11.4
33
49 N
{5.0 kg}
39.2 N
{4.0 kg}
Spool return spring
69.9 x 57
63
431 N
{44 kg}
345 N
{35.2 kg}
Spool return spring
75 x 37
74.5
0N
{0 kg}
0N
{0 kg}
31.8 x 7.6
26.5
1N
{0.1 kg}
0.78 N
{0.08 kg}
Check valve spring
78.2 x 26.6
52
18.8 N
{1.92 kg}
15.1 N
{1.54 kg}
Check valve spring
65.3 x 14
46
18.8 N
{1.92 kg}
15.1 N
{1.54 kg}
Check valve spring
41.3 x 35.5
25.5
18.8 N
{1.92 kg}
15.1 N
{1.54 kg}
40-30
Replace
spring if
damaged or
deformed
PC1100-6
Unit: mm
No.
Check item
Criteria
Standard size
Spool return spring
PC1100-6
Remedy
Repair limit

Installation
Free length
x O.D.
length
load
load
117.5 x 27.9
68
156.9 N
{16 kg}
31.8 x 7.6
26.5
0.98 N
{0.1 kg}
Replace
spring if
damaged or
deformed
40-31
Unit: mm
No.
Check item
Criteria
Standard size
Spring (check valve)
Remedy
Repair limit

Installation
Free length
x O.D.
length
load
load
83.5 x 25.5
22
29.4 N
{3 kg}
23.5 N
{2.4 kg}
Spool return spring (large)
49.4 x 25.7
47
206.4 N
{21.1 kg}
165.1 N
{16.9 kg}
Spool return spring (small)
41.1 x 9.6
35
58.5 N
{6 kg}
46.8 N
{4.8 kg}
40-32
Replace
spring if
damaged or
deformed
PC1100-6
SWING MOTOR
SWING MOTOR
KMF160AB-2
Unit: mm
No.
Check item
Criteria
Standard size
Check valve spring
Repair limit

Installation
Free length
x O.D.
length
load
load
66.5 x 25.6
PC1100-6
Remedy
45
7.0 N
{0.71 kg}
5.6 N
{0.57 kg}
Replace
spring if
damaged or
deformed
40-33
TRAVEL MOTOR
TRAVEL MOTOR
MSF-340VP
TRAVEL MOTOR, SPEED CHANGE VALVE, RELIEF VALVE
40-34
PC1100-6
TRAVEL MOTOR
TRAVEL BRAKE VALVE
PC1100-6
40-35
CENTER SWIVEL JOINT
CENTER SWIVEL JOINT
Unit: mm
No.
Check item
Clearance between rotor
and shaft
40-36
Criteria
Remedy
Standard size
Standard clearance
Clearance limit
110
0.056 0.105
0.111
Replace
PC1100-6
Unit: mm
No.
Check item
Criteria
Standard size
Check valve spring
Repair limit

Installation
Free length
x O.D.
length
load
load
56 x 21.4
PC1100-6
Remedy
37
6.9 N
{0.7 kg}
Replace
3.9 N
{0.4 kg}
40-37
WORK EQUIPMENT SWING PPC VALVE
WORK EQUIPMENT SWING PPC VALVE
Unit: mm
No.
Check item
Criteria
Standard size
Centering spring
(for P3, P4)
Remedy
Repair limit

Installation
Free length
x O.D.
length
load
load
42.48 x 15.5
34
17.6 N
{1.8 kg}
13.7 N
{1.4 kg}
Metering spring
26.7 x 8.14
24.9
16.6 N
{1.69 kg}
13.2 N
{1.35 kg}
Centering spring
(for P1, P2)
38.71 x 15.5
34
9.8 N
{1 kg}
7.8 N
{0.8 kg}
40-38
Replace
spring if
damaged or
deformed
PC1100-6
TRAVEL PPC VALVE
TRAVEL PPC VALVE
Unit: mm
No.
Check item
Criteria
Standard size
Metering spring
Centering spring
PC1100-6
Remedy
Repair limit

Installation
Free length
x O.D.
length
load
load
Replace
spring if
16.7 N
13.7 N
26.7 x 8.14
24.9
damaged or
{1.7 kg}
{1.4 kg}
deformed
48.1 x 15.5
32.5
108 N
{11 kg}
86.3 N
{8.8 kg}
40-39
HYDRAULIC CYLINDER
HYDRAULIC CYLINDER
BACK HOE
Boom
Arm
Bucket
40-40
1
PC1100-6
Unit: mm
No.
Check item
Name of
cylinder
Tolerance
Hole
Standard
clearance
Clearance
limit
160
0.043
0.106
+0.256
+0.039
0.082
0.362
0.662
170
0.043
0.106
+0.255
+0.038
0.081
0.361
0.661
Bucket
110
0.036
0.090
+0.261
+0.047
0.083
0.351
0.651
Boom
140
+0.025
+0.370
1.0
160
+0.025
+0.370
1.0
100
+0.457
+0.370
1.0
Clearance between piston rod Arm

support shaft
and bushing
Bucket
Boom
Clearance between cylinder
bottom support Arm
shaft and
bushing
Bucket
Standard
size
Remedy
Shaft
Boom
Clearance between piston rod
and bushing
Arm
PC1100-6
Criteria
Replace
bushing
Replace pin,
bushing
140
+0.025
+0.370
1.0
160
+0.245
+0.145
1.0
100
+0.475
+0.370
1.0
40-41
1
WORK EQUIPMENT
WORK EQUIPMENT
40-42
PC1100-6
WORK EQUIPMENT
Unit: mm
No.
Check item
Clearance between bushing

and mounting pin of boom
and revolving frame
2
3
4
5
6
7

and mounting pin of boom
and arm
and mounting pin of arm
and link
and mounting pin of arm
and bucket
and mounting pin of link
and link
and mounting pin of link
and bucket
Bucket clearance
PC1100-6
Criteria
Standard
size
Tolerance
Remedy
Shaft
Hole
Standard
clearance
Clearance
limit
160
0.043
0.106
+0.436
+0.350
0.393
0.542
1.5
160
0.043
0.106
+0.172
+0.085
0.128
0.278
1.5
140
0.043
0.106
+0.404
+0.321
0.364
0.510
1.5
140
0.043
0.106
+0.397
+0.312
0.355
0.503
1.5
140
0.043
0.106
+0.397
+0.312
0.355
0.503
1.5
140
0.043
0.106
+0.404
+0.321
0.364
0.510
1.5
0.5 1.0
Replace
Adjust
shims
40-43
DIMENSIONS OF WORK EQUIPMENT

1. ARM
40-44
PC1100-6
Unit: mm
Model
PC1100SP-6
with 3.4 m
with 4.5 m
with 3.4 m
heavy-duty arm heavy-duty arm heavy-duty arm
No.
18
PC1100-6
PC1100LC-6
with 3.4 m
arm
with 4.5 m
arm
160
160
160
160
160
120
120
120
120
120
636
636
636
636
636
160
160
160
160
160
489
550
496
489
550
635
635
635
635
635
1,348
1,326
1,348
1,348
1,326
3,340
4,455
3,340
3,340
4,455
4,108
4,087
4,274
4,108
4,087
10
610
610
590
610
610
11
1,223
1,223
1,290
1,223
1,223
12
977
977
1,028
977
977
13
840
840
915
840
840
14
2,650
2,650
2,630
2,600
2,600
15
140
140
140
140
140
16
636
636
636
636
636
17
140
140
140
140
140
637
637
637
637
637
653
653
653
653
653
Min.
2,535
2,535
2,660
2,535
2,535
Max.
4,360
4,360
4,610
4,360
4,360
20
20
20
Arm as individual
part
When pressfitting bushing
19
20
PC1100-6
40-45
2. BUCKET
40-46
PC1100-6
Unit: mm
Model
PC1100-6
PC1100SP-6
PC1100LC-6
4.0 m3 bucket 5.0 m3 bucket 5.6 m3 bucket 4.0 m3 bucket 5.0 m3 bucket
No.
1
837
837
911
837
837
76
76
82
76
76
95
95
95
95
95
840
840
915
840
840
2,576 (2,618)
2,576 (2,618)
2,601 (2,638)
2,576 (2,618)
2,576 (2,618)
353 (403)
353 (403)
389 (443)
353 (403)
353 (403)
170
170
170
170
170
170
170
170
170
170
637.5
637.5
637.5
637.5
637.5
100
100
100
100
100
10
100
100
100
100
100
11
280
280
280
280
280
12
310
310
310
310
310
13
70.6
70.6
84.6
70.6
70.6
14
126.5
126.5
128
126.5
126.5
15
174
174
174
174
174
16
160
160
160
160
160
17
679.5
679.5
679.5
679.5
679.5
18
83
83
83
83
83
fl The figures in ( ) show the value for the long life tooth.
PC1100-6
40-47
90
OTHERS
Hydraulic circuit diagram ............................................................................ 90- 3

Electrical circuit diagram (1/4) .................................................................... 90- 5
Electrical circuit diagram (4/4) .................................................................... 90-11
PC1100-6
90-1
PC1100-6
90-3
ELECTRICAL CIRCUIT DIAGRAM (1/4)
PC1100-6
90-5
PC1100-6
90-7
PC1100-6
90-9
PC1100-6
90-11

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SEBM014203

PC1100-6 mount the SAA6D170-2 engine.

STRUCTURE AND FUNCTION ......................................

TESTING AND ADJUSTING ..........................................

DISASSEMBLY AND ASSEMBLY .................................

MAINTENANCE STANDARD .........................................

LIST OF REVISED PAGES

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LIST OF REVISED PAGE

LIST OF REVISED PAGES

LIST OF REVISED PAGES

LIST OF REVISED PAGES

LIST OF REVISED PAGES

Specification drawings .................................. 01-2

fl The figures in ( ) show the value for the PC1100LC-6.

10001 and up 10001 and up 10001 and up

Max. digging depth

Max. vertical wall depth

Max. digging reach

Max. reach at ground level

Max. digging height

Max. dumping height

Max. digging force

478.6 {48,800} 525,6 {53,600} 478.6 {48,800}

Swing max. slope angle

Overall width of track (when extended)

Overall height to top of machine

Ground clearance of upper structure

Min. ground clearance

Tail swing radius

Min. swing radius of work equipment

Height of work equipment at min. swing radius

Length of track on ground

Track gauge (when extended)

Height of machine cab

[standard double grouser shoe width]

4-cycle, water-cooled, in-line, vertical, direct injection,

No. of cylinders bore x stroke

Max. speed at no load

Min. speed at no load

Min. fuel consumption

Radiator core type

Variable displacement piston type:

Piston type: 494+494+600, gear type: 158+33+16

Piston type: 31.4 {320}, gear type: 2.9 {30}

4-spool type x 2, + 5-spool type x 1

Piston type (with brake valve, shaft brake):

Piston type (with safety valve, shaft brake):

10001 and up 10001 and up 10001 and up

Double-acting piston Double-acting piston

Inside diameter of cylinder

Outside diameter of piston rod

Max. distance between pins

Min. distance between pins

Box-shaped, with breather

Tank return side

Air cooled (J4)

PTO (incl. lubricating piping)

Control pump (for control, PTO lubrication

Oil cooler assembly

Hydraulic tank (excl. hydraulic oil)