01 SK130HDL-8B TRG Text - Complete-1 PDF

SERVICE TRAINING
SK130HDL LX08-T0101~
Customer Support Department

KOBELCO INTERNATIONAL (S) CO., LTD
Book code: 2014-01-KISCO-SK130HDL-TrgText

［2. SPECIFICATIONS］
2.5 SPECIFICATIONS AND PERFORMANCE
2.5.1 SPEED AND CLIMBING CAPABILITY
Item / Model SK130HDL-8B

1
Swing speed : min- {rpm} 11 {11}
Travel speed (1-speed/2-speed)
２
2.1 / 3.5 (1.3 / 2.2)
: km/h (mile/h)
Gradeability : % (degree) 70 (35)
2.5.2 ENGINE
Engine model MITSUBISHI D04FR-74KW

Water-cooled, 4 cycle 4 cylinder direct injection type diesel
Type
engine with inter cooler turbo-charger
4 - 102 dia. mm X 130 mm
Number of cylinders-BoreXStroke
(4.02 in X 5.12 in)
Total displacement 4.249 L (259.27 cu-in)
Net 69.2 kW (94 PS) / 2,000 min-1 (ISO 9249)
Rated output / Engine speed
Net 74 kW (101 PS) / 2,000 min-1 (ISO 14396)
Net 359 N-m (265 lbf-ft)/ 1,600 min-1 (ISO 9249)
Maximum torque / Engine speed
Net 375 N-m (277 lbf-ft)/ 1,600 min-1 (ISO 14396)
Starter 24 V / 5.0kW
Alternator 24 V / 50A
2.5.3 HYDRAULIC COMPONENTS
Hydraulic pump Variable displacement axial piston pump X 2 + gear pump X 1

Hydraulic motor (swing) Axial piston motor X 1
Variable displacement axial piston motor X 2
Hydraulic motor (travel)
(with counterbalance valve)
Control valve 12-spool control valve X 1
Cylinder
Double action cylinder
(Boom, Arm, Bucket)
Oil cooler Air-cooled type
1
2-9
2.8 COMBINATIONS OF ATTACHMENT
２
When the only 2.38m (7ft-10in) arm is using, do not turn the bucket back to front to use as a shovel.
2
2-13

3

2.9 ENGINE SPECIFICATION
2.9.1 SPECIFICATIONS
Applicable machine SK130HDL-8B

Engine model MITSUBISHI D04FR-TAA
Water-cooled, 4 cycle 4 cylinder direct injection type diesel
Type
engine with inter cooler turbo-charger
Number of cylinderXBoreXStroke mm (in) 4 X 102 X 130 (4.02 X 5.12)
Total displacement cc (cu-in) 4,249 (259.27)
Compression ratio 17.8
-1
Rated output kW (PS) at min Net 74 (101) at 2,000 (ISO 14396)
N-m (lb-ft) at
Maximum torque Net 375 (277) at 1,600 (ISO 14396)
min-1
High idling min-1 2,230 ~ 2,250
-1
Low idling min 995 ~ 1,035
Injection starting pressure MPa (psi) -
Start/Full open
Thermostat action 344 (160) / 358 (185)
K (degrees F)
Firing order 1 - 3 - 4 - 2
Starter capacity V X kW 24 X 5.0
Generator capacity (Alternator) V X A 24 X 50
600 dia (23.6") X suction type 6 fans, V-belt drive, pulley
Cooling fan drive method
ratio Crank / Fan= 0.9
Full level 17.5 (4.62)
Engine oil quantity L (gal) Low level 14.5 (3.83)
Total 18.5 (4.89)
Dry weight kg (lbs) 412 (908)
Fuel consumption ratio
g/kW-h (g/ps-h) 233 (171)
(At rated output)
Allowable inclination Front / Rear and Right / Left : 35 degrees
Dimension (LXWXH) mm (in) 911 X 719 X 940 (35.9in X 28.3in X 37.0in)
Rotating direction Counterclockwise seeing from flywheel side
4
2-14
2.9.2 ENGINE CHARACTERISTIC CURVE

Condition to be measured: The net value is indicated, measuring without cooling fan.
5
2-15
［13. MAINTENANCE STANDARD AND TEST PROCEDURE］
13.2 PERFORMANCE INSPECTION STANDARD TABLE
Unless otherwise specified, measure it on "H" mode.
13.2.1 STANDARD VALUE TABLE
13
6
13-5
7
13-6
13.3 MEASUREMENT OF ENGINE SPEED
13.3.1 MEASUREMENT OF ENGINE SPEED

(1) Warming up of engine
Start engine to raise the coolant temperature of engine to 60 to 90C degrees (140 to 194F degrees)
at surface of radiator upper tank.
The E/G coolant tem-perature gauge is used to measure. The range in white color shows the
temperature of approx. 65 to 105 C degrees (149 to 221F degrees), so confirm that the pointer
indicates the temperature within the white range.
(2) Engine speed measured value through service diagnosis (See below Fig.)
1. Turn "ON" the starter switch with the buzzer stop switch pressed.
2. A program No. and an actual engine revolution are displayed as the No.2 Item.
3. The screen advances like No.2, No.3....each time the "Wiper switch" on the gauge cluster is
pushed.
4. The screen returns like No.45, No.44....each time the "Washer switch" is pushed. 13
5. The display does not disappear unless the starter switch is turned to"OFF".
Service diagnosis for E/G speed measuring

(Example)
Switch for E/G speed indication
8
13-7
13.4 MEASUREMENT OF HYDRAULIC PRESSURE
13.4.1 PREPARING TO MEASURE HYDRAULIC PRESSURE

(1) Hydraulic equipment
6.9 MPa (1000psi) pressure gauge: 1unit
49 MPa (7100psi) pressure gauge: 2 units
Pressure measuring equipment and instrument for analysis: 1 set
(2) Measuring cleanliness of hydraulic oil
After releasing air in the hydraulic oil tank, open the cover and sample oil in the hydraulic tank, and
measure with the instrument for analysis. If the measured value is higher than the standard value,
replace the return filter or change the hydraulic oil.
13.4.2 PLACE TO INSTALL PRESSURE GAUGE

(1) Main circuit
After releasing the pressure in hydraulic oil
tank and system, replace plugs PF1/4 of
main pump gauge ports (a1) (a2) with plugs
for pressure measurement, and attach
pressure gauge 49 MPa (7100 psi).
(2) Pilot circuit
Replace pilot gauge plug (a5) with plug
PF1/4 for pressure measurement, and
attach pressure gauge 6.9 MPa (1000 psi).
9
13-8
13.4.3 PRESSURE ADJUSTMENT POSITION

(1) Main control valve
13
Relief valve position on main control valve
10
13-9
(2) Pilot relief valve

The pilot relief valve PR1 is located on the gear pump that is attached to the main pump.
Pilot relief valve position
(3) Swing over load relief

The swing motor is equipped with plugs PA,PB for pressure measurement, but the measurement is
carried out using gauge ports (a1) and (a2). (See "Gauge port on main pump" Fig.)
Swing over load relief position
11
13-10
13.4.4 PROCEDURE FOR ADJUSTING RELIEF VALVE

(1) Pilot relief valve
Adjust it with adjust screw (311).
Tools: Spanner: 24 mm,
Tightening torque : 29.4 N-m (22 lbf-ft)
Tools: Allen wrench: 6 mm
Pilot relief valve
(2)Main relief valve

(Common for travel and ATT sections)
Loosen lock nut (7) and adjust the pressure with adjust screw (6).
Tightening torque : 27~31 N-m (20~23 lbf-ft)
Tools: Spanner: 19 mm, Adjust screw
13
Main relief valve (Travel section, ATT

common section)
12
13-11
(3) Over load relief valve

(Boom, bucket, arm sections)
Loosen lock nut (1) and adjust it with adjust screw (2).
Tools: Spanner: 22 mm,
Tightening torque : 27.4~31.4 N-m (20~23 lbf-ft)
Over load relief valve (Boom, bucket, arm

sections)
(4) Over load relief valve (Swing)

When the pressure adjustment is required, loosen lock nut (1) and adjust the pressure with cap (2).
Tools: Spanner: 30, 38 mm,
Tightening torque: 118 N-m (87 lbf-ft)
Swing over load relief valve
(5) Travel over load relief valve

This valve was adjusted by manufacturer and
shipped. Do not replace the parts except O-ring.
Loosen cap (205) and adjust the pressure with
shim (213).
Tools: Allen wrench: 10 mm Travel over load relief valve
13
13-12
13.5 MEASURING TRAVEL PERFORMANCES
13.5.1 TRAVEL SPEED

(1) Purposes
Measure the travel sprocket revolution and
confirm the performances between the
hydraulic pump and the travel motor of the
travel drive system.
(2) Conditions
Hydraulic oil temperature;
45 to 55C degrees (113 to 131F degrees)
Crawler on the right and left sides are One side lifted position
tensioned evenly.
(3) Preparation
Attach the reflection panel with a magnet to the
travel motor cover.
Swing the swing frame through 90C degrees as
shown in upper right Fig. and make the
crawler on one side take off the ground, using
the attachment.
Adhering position of reflection panel 13

(4) Measurement
Engine revolution; Hi idle
2-speed travel switch; 1st speed and 2nd speed
Measuring points; Right and left
Method, example 1;
Measure revolution with a stroboscope
Method, example 2;
Measure the revolutions per minute visually.
13.5.2 DEVIATION OF TRAVEL

(1) Purpose
Measure the amount of deviation at 20 (66 t)
travel and confirm the horizontal balance
between the hydraulic pump and the travel
motor of the travel drive system.
(2) Condition
Travel position
RH and LH crawler are tensioned evenly.
Firm, level ground
14
13-13
(3) Preparation
1.
Straight course more than 30 m (108 ft)
2.
Travel position in which the bottom of the
bucket is lifted by about 30 cm (1 ft).
Measuring method
(4) Measurement
1.
Measure the max. deviation distance of the
circular arc in the 20 m (66 ft) length, excluding
the preliminary run of 3 to 5 m (10 to 16 ft).
2.
Operate the travel lever at the same time.
13.5.3 PERFORMANCES OF PARKING BRAKE

(1) Purpose
Confirm that the parking brake holds a
stopped condition of the machine in a no-load
travel position and on a 15 degree slope.
(2) Condition
A slope with (Approx. 15 deg) gradient and a
stopped condition in a no-load travel position
(3) Preparation
Place an angle meter on the shoe plate and Parking brake operating position
confirm that it makes an angle more than 15
degree.
Hang a perpendicular in parallel with the guide
frame rib on the track frame and put a mark
(matching mark) on the shoe plate.
(4) Measurement
Five minutes after the engine stops, measure
the movement distance of the matching mark.
Method of measurement
15
13-14
13.5.4 DRAIN RATE OF TRAVEL MOTOR

(1) Purpose
To measure the drain rate of the travel motor
and to confirm the performances of the travel
motor.
(2) Conditions
Engine revolution; Hi idle Location of stopper applied to travel sprocket
(3) Preparation
1.
Place a stopper under the RH and LH travel
sprockets.
2.
Stop the engine and release pressure from the
hydraulic circuit.
3.
Connect a hose with the drain port of the travel
motor and take drain in a container.
Method of measuring the drain rate of travel

motor
13
(4) Measurement ; at Travel Lock
1.
Start the engine and relieve pressure at the
full stroke of the travel lever.
2.
Measure the drain rate for 30 seconds of
relieving.
Unless you observe the rotary force direction at travel lock, rib "A" may be broken by stopper "B" in
some cases. (See Upper right Fig.)
16
13-15
13.6 MEASURING SWING PERFORMANCES
13.6.1 SWING SPEED

(1) Purpose
Measure the swing time and confirm the
performances between the hydraulic pump
and the swing motor of the swing drive
system.
(2) Conditions
Firm, level ground
(3) Preparation
Swing speed measuring position (at the min.
Put the bucket empty and extend the
reach)
boom, arm and bucket cylinder fully.
And the machine becomes a position of
minimum reach.
(4) Measurement
Swing the machine by bringing the swing
lever to its full stroke. Measure the time
required to make two turns after one turn
of preliminary run and calculate the time
required for one turn.
13.6.2 PERFORMANCE OF SWING BRAKE

(1) Purpose
Confirm the braking torque performances by the swing relief valve.
(2) Conditions
Firm, level ground
(3) Preparation
1.
Put the bucket empty, retract the arm cylinder
fully and extend the bucket cylinders fully. And
move the boom so that the arm top pin is
positioned at same height with boom foot pin.
Swing brake performance measuring position
2.
Put a matching mark on the outer
circumference of the swing bearing of the upper
frame side and of the track frame side. Place
two poles (flags) on the front and back of the
extended line of the matching mark.
17
13-16
(4) Measurement
1.
When operating in regular swing speed, by
shifting lever to neutral position at pole position
the swing operation stops.
2.
Calculate the swing drift angle by the following
equation, after the upper swing body stops,
using the amount of deflection (m) of the
matching marks on the swing race and the
length (m) of the circumference of the swing
race:
13.6.3 PERFORMANCE OF SWING PARKING BRAKE

(1) Purpose
To confirm the mechanical performances of the
swing parking brake that is fitted to the inside
of the swing motor.
(2) Conditions
On a slope of 15 degree incline. 13
Stop the machine at right angles with the slope.
Put the bucket empty, retract the arm cylinder Swing parking brake performance measuring
fully and extend the bucket cylinder fully. And position
move the boom so that the arm top pin is
positioned at same height with boom foot pin.
(3) Preparation
Put the angle meter on the shoe plate and
make sure that the angle is more than 15
degree.
Put a matching mark on the outer race side
and on the inner race side.
Measuring position of swing parking brake

performances
(4) Measurement
When five minutes has passed after the
engine stops, measure the length of the
movement of the matching marks.
18
13-17
13.6.4 DRAIN RATE OF SWING MOTOR

(1) Purpose
Measure the drain rate of the swing motor and
confirm the performances of the swing motor.
(2) Conditions
Hydraulic oil temperature; 45 to 55C degrees
(113 to 131F degrees)
Firm, level ground
(3) Preparation
1.
Stop the engine.
2.
Release pressure from inside the hydraulic
circuit.
3.
Disconnect the swing motor drain hose from
its end returning to the hydraulic oil tank and
take oil in a container.
4.
Put a plug to the tank side.
(4) Measurement; at Swing Lock

1.
Start the engine and put the side faces of
bucket against the inside of the right or left
shoe plates.
2.
Relieve the swing motor at full stroke of the
swing motion.
3.
Collect the amount of drained oil in a
container for 30 seconds.
19
13-18
13.7 MEASURING ATTACHMENT OPERATING PERFORMANCES
13.7.1 OPERATING TIME OF CYLINDERS

(1) Purpose
Measure the operating time of the boom, arm
and bucket and confirm the performances
between the hydraulic pump and the cylinder
of the attachment drive system.
Measuring position for bucket digging and

dump
(2) Condition
Hydraulic oil temperature; 45 to 55C degrees
(113 to 131F degrees)
Operating time excluding the cushion stroke
Measuring position for boom up and down

motions
(3) Preparation
Firm level ground with the bucket empty 13
(4) Measurement1; Boom up and down
With the boom operating lever at full stroke,
measure the required operating time of the
bucket between the ground surface and its Measuring position for arm in and out
highest position. motions
Measurement 2; Arm in and out, bucket

digging and dump
In a position in which the tooth of the bucket
rises to a level of about 30 cm (1ft) above
ground, measure the full stroke operating time
required with the arm and bucket operating
levers at full stroke.
When lowering the boom, allow the bucket onto a soft ground or cushioning such as rubber tires ;
never put the bucket against concrete or other solid material.
20
13-19
13.7.2 OIL TIGHTNESS OF CYLINDERS

(1) Purpose
Confirm that the cylinder oil tight by checking the moving length of the cylinder rods.
(2) Condition
Hydraulic oil temperature; 45 to 55C degrees (113 to 131F degrees)
Firm, level ground
After cylinders are replaced, bleed off air from the cylinders, before checking for oil tightness.
Retract the arm cylinder rod 50 mm (2 in) from stroke end so that the piston does not match a
same range of the cushioning mechanism.
(3) Preparation
Put the bucket empty. Extend the arm cylinder rod 50mm (2in) from the most retracted position.
And extend the bucket cylinders fully. Then hold the boom so that the arm top pin is positioned at
same height with boom foot pin.
(4) Measurement
Measure the items five minutes after the engine is turned off.
21
13-20
13.8 MEASURING PERFORMANCES OF SWING BEARING
(1) Purpose
Measure the gap between the lower frame and
the bottom face of the swing bearing and
estimate the degree of wear of the swing
bearing.
(2) Condition
Firm, level ground
The swing bearing mounting bolts are not
loosened. How to measure the axial play of swing
The swing bearing is lubricated well, not making bearing
abnormal sound during turning.
(3) Preparation
1.
Install a dial indicator to the magnetic base and
fix it to the lower frame.
2.
Direct the upper swing body and the lower
frame toward the travel direction, bring the
Measuring position 1
probe of the dial indicator in contact with the
bottom surface of the outer race on the swing
body side and set the reading at zero. 13
(4) Measurement 1 (Measuring position 1 and 2)
1.
Measure the displacement of the outer race in
the axial direction in position 1 [The arm at 90
degrees to 110 degrees and the crawler front is
lifted by attachment about 30cm (1ft)] and in
position 2, using a dial indicator.
22
13-21
(5) Measurement 2 (Measuring position 3)

1.
Retract the arm cylinder fully and extend the
bucket cylinder fully. And move the boom so
that the arm top pin is positioned at same
height with boom foot pin. Then swing the
bucket right and left by man power. But in this
case, the gap of the attachment is included.
23
13-22
［21. MECHATRO CONTROLLER］
21.2 MECHATRO CONTROLLER
21.2.1 SUMMARY OF MULTI DISPLAY

Electro-hydraulic conversion information is displayed on the multi display of the gauge cluster.
(1) Controls
21
(2) Gauge cluster
24
21-31
(3) Screen selection by work mode select switch

The mode after the engine starting is always the start from "S" mode.
The work mode is switched in order of "S" -> "H" each time the work mode select switch is pressed.
Select proper work mode shown below according to the work condition and the purpose.
For the selected work mode, refer to the table shown below.
・ S mode: For standard excavating work

・ H mode: For heavy duty excavating work
S mode
"S mode" is suitable for standard digging and
loading works and is in saving fuel consumption
and is in good balance to the workload.
H mode
"H mode" is suitable for heavy duty digging
work which gives priority to the workload at
the high speed.
25
21-32
(4) Screen selection by attachment mode select switch (Option)

This switch is used for switching the attachment
mode.
The screen is changed from "Digging" to
"Nibbler" to "Breaker" each time the attachment
mode switch (3) is turned to respective position.
Depending on the attachment employed, select
the applicable mode from "Digging", Nibbler",
and "Breaker".
Before the working, confirm whether
appropriate attachment had been selected.
21
26
21-33
(5) Pump flow rate adjustment (Nibbler mode / Breaker mode)

According to some kind of attachment, it is required to change the flow rate for service circuit. Change
the flow rate in accordance with the procedure mentioned below.
In this machine, last set flow rate has been stored and the initial flow rate is 130L/min. The
adjustment (increase or decrease) of flow rate is changeable by 10L/min step.
1: Screen Change Switch

2: Buzzer Stop Switch
3: Work Mode Select Switch
4: Washer Switch
5: Wiper Switch
6: Travel Speed Select Switch
7: Auto Accel Switch
8: Select Switch
9: Attachment Mode Select Switch
(SE Asia : Option)
1. Turn starter key switch on and display main screen (a).

2. The screen is changed from "Digging" to "Nibbler" to "Breaker" each time the attachment mode
select switch (9) is turned when the main screen (a) is displayed.
3. Turn the switch (9) to "B", and "Nibbler mode" screen is displayed. Or turn the switch (9) to "A",
and "Breaker mode” screen is displayed.
4. When the nibbler/breaker select screen (b) or (c) is displayed, press the select switch (8) and the
value of flow rate reverses to black, and the screen is changed to (d). To increase flow, press the
up arrow (4) (washer switch), or to decrease flow, press the down arrow (5) (washer switch).
5. Select the desired setting value and then press select switch (8) and the flow rate is set to the
desired value.
27
21-34
(6) MAINTENANCE SCREEN DISPLAYS

This screen displays the remaining time to the
end of recommended replacement/change
interval specified for filter/oil.
After turning starter key switch ON or starting

engine, the screen is changed in order of "Time
for engine oil change" --> "Time for fuel filter
replacement" --> "Time for hydraulic oil filter
change" --> "Time for hydraulic oil change" -->
"Main screen" each time the screen change
switch (2) is pressed.
With this menu, the time range to the
recommended change time for the filter and oil
in use can be identified.
21
For the initial set value of recommenced replacement/change time, see the following table.
Replacement interval
Item Default
Engine oil 500 Hr
Fuel filter 500 Hr
Hydraulic oil filter 1,000 Hr
Hydraulic oil 2,000 Hr
This menu is available for confirmation of the following items.

The maintenance screen changes each time the screen change switch is pressed.
1.
Remaining time display to the engine oil change
This display shows the remaining time to the
coming engine oil change.
28
21-35
2.
Remaining time display to the coming fuel filter
replacement
coming engine fuel filter replacement.
3.
Remaining time display to the coming hydraulic
oil filter replacement
coming hydraulic oil filter replacement.
4.
Remaining time display to the coming hydraulic
oil change
coming hydraulic oil change.
-The display automatically changes to the main screen, if switch is not operated for 30 seconds.
-For the setting procedure of maintenance time to be performed to the coming oil change in each
type and filter replacement, see the 21.2.6 SET PROCEDURE OF MAINTENANCE SCHEDULE.
29
21-36
(7) Gauge cluster display

After key is switched on and logo mark display disappears, screen for operator is displayed on multi
screen. The display functions of multi display are explained below.
1. Display function for operator:

Screen usually displayed during operation
1.1 Clock display function:
Current time is displayed.
1.2 Self-diagnosis display :
When abnormality is detected on mechatro system like sensor, proportional valve, etc., this displays
error code.
1.3 Warning display:
When machine was thrown into dangerous state, or was failed, displays warning contents with the
symbol and statement.
21
Error codes were stored as trouble history, and displayed on the monitor by the trouble history display
function.
1.4 Machine condition display :

Displays machine operating condition.
2. Display function for maintenance:

Displays remaining time up to replacement/change of following items.
(1) Engine oil (2) Fuel filter (3) Hydraulic oil filter (4) Hydraulic oil
3. Failure history display function:

Stores abnormality occurred on mechatro system in the past and displays in order of recent occurrence.
30
21-37
4. Mechatro adjustment display:

Displays procedure for adjustment of mechatro system like output adjustment and unload adjustment,
etc.
5. Service diagnosis display :

Displays information like pressure sensor sensed value, proportional valve command, etc. output by
mechatro controller
6. Failure diagnosis mode display function:

Specifies failed section automatically for failures which are not detected by self diagnosis and displays
the results.
31
21-38
21.2.2 SELF DIAGNOSIS DISPLAY

(1) Outline
This function identifies abnormality of control I/O signal like pressure, proportional valve, etc. during
machine operation through self diagnosis. The failed items are displayed on multi display of gauge
cluster. For connector No. and pin No., refer to the section "C-1 Mechatro controller" explained later.
Electric circuit diagram or harness is available to identify wire No. and wire color.
(2) I/O configuration
(3) Self diagnosis display items

As-displayed clock (Usually main screen). When error occurred, specifies failed section and the failure
type with the aid of error code.
21
32
21-39
33
21-40
21
34
21-41
21.2.3 SERVICE DIAGNOSIS DISPLAY FUNCTION

The current service diagnosis is displayed on multi display based on the data received from mechatro
controller. This section explains the operating procedure and examples of each screen. The values in
display changes according to the conditions like engine speed, attachment position, etc.
(1) Service diagnosis display screen operating procedure

1. Turn starter switch ON keeping buzzer stop switch pressed.
Buzzer stop switch
2. After logo mark is displayed, the screen changes in service diagnosis mode.
The service diagnosis screen "Mode No.1", "Screen No.1" is displayed first.
The service diagnosis is classified into three modes, 1, 2, and 3, and the present mode is displayed in
"Screen No.1".
The screen number each mode can display differs. The screen number displayed by each mode is as
follows.
・ Mode No.1 : Screen No.1 to No.30

・ Mode No.2 : Screen No.1, Screen No.31 to No.40
・ Mode No.3 : Screen No.1, Screen No.41 to No.50
3. The screen changes each time each switch is pressed from now on.
Washer switch
Screen gains by 1 in order.
(No.2-->No.3-->No.4-->...)
Wiper switch
Screen loses by 1 in order.
(No.24-->No.23-->No.22-->...)
Auto idling switch

Service diagnosis number advances from No.3
to No.1, and then returns to No.3.
(No.3-->No.2-->No.1-->No.3-->...)
Travel 1, 2 speed switch

Service diagnosis number advances from No.1
to No.3, and then returns to No.1.
(No.1 No.2 No.3 No.1 ...)
4. Turn key switch OFF and the display of service diagnosis mode is closed.
35
21-42
(2) Service diagnosis display screen (Example)

The service diagnosis display screen list is shown below. The conditions for display are H mode,
engine low speed and lever to neutral position.)
1) Service diagnosis mode No.1
21
36
21-43
37
21-44

21
38
21-45
39
21-46
(3) Service diagnosis data list

Preface and precaution
The following is the data decided as normal status after service diagnosis for every operation. Use
these data to decide normal/abnormal status.
・ The values in following display are reference values with standard attachment attached machine.
・ The value of pressure sensor is calculated taking variation into accounts. When compared to
performance check reference criteria, measure it with the aid of calibrated measuring instrument.
・ The current of proportional valve is not the measured value, but command value. The measured
value should be confirmed by the value in the displayed value for each proportional valve.
・ The current value of pump proportional valve is reference value because it varies according to
pump pressure and adjusted torque value.
・ The value in display during operation shows the value in steady state, rather than, at start of
operation.
・ Check on machine after sufficiently warming up machine.
・ The value in display may differ according to software version. Contact our dealer/distributor.
Operation No.1: No operation Operation No.2: No operation

H mode Hi idle S mode Hi idle
No.32 ARM, SWING No.32 ARM, SWING
C-1 P1-PRES 0.2~1.5 M C-1 P1-PRES 0.2~1.5 M
C-2 P2-PRES 0.2~1.5 M C-2 P2-PRES 0.2~1.5 M
E-1 P1-PSV 350 mA E-1 P1-PSV 350 mA
D-1 P1-UL(BPC) 750 mA D-1 P1-UL(BPC) 750 mA
D-2 P2-UL(BPC) 750 mA D-2 P2-UL(BPC) 750 mA 21
D-3 S-TRAVEL 350 mA D-3 S-TRAVEL 350 mA
D-6 ARM-IN-2 750 mA D-6 ARM-IN-2 750 mA
B-3 ARM OUT 0.0 M B-3 ARM OUT 0.0 M
B-4 ARM IN 0.0 M B-4 ARM IN 0.0 M
B-1 BOOM RAISE 0.0 M B-1 BOOM RAISE 0.0 M
B-7 SWING 0.0 M B-7 SWING 0.0 M
G-3 ENG SPEED 1970~2030 G-3 ENG SPEED 1870~1930
POWER SHIFT 0 mA POWER SHIFT 0 mA
Operation No.3: Operation No.4:

Boom up in full lever operation & relief Boom up in full lever operation & in operation
H mode Hi idle H mode Hi idle
No.31 BOOM No.31 BOOM
C-1 P1-PRES 32.0~35.8 M C-1 P1-PRES 11.0~16.0 M
C-2 P2-PRES 32.0~35.8 M C-2 P2-PRES 11.0~16.0 M
E-1 P1-PSV 385~495 mA E-1 P1-PSV 560~750 mA
E-2 P2-PSV 385~495 mA E-2 P2-PSV 450~550 mA
B-2 BOOM LOWER 0.0 M B-2 BOOM LOWER 0.0 M
40
21-47
Operation No.5:
Boom down in full lever operation & in operation
H mode Hi idle
No.31 BOOM
C-1 P1-PRES 12.5~16.0 M
C-2 P2-PRES 0.2~1.5 M
E-1 P1-PSV 549 mA
E-2 P2-PSV 350 mA
D-1 P1-UL(BPC) 360 mA
D-2 P2-UL(BPC) 750 mA
B-1 BOOM RAISE 0.0 M
B-2 BOOM LOWER 3.0 M
G-3 ENG SPEED 1970~2030
POWER SHIFT 0 mA

Arm-in in full lever operation & relief Arm-in in full lever operation & in operation
C-1 P1-PRES 32.0~35.8 M C-1 P1-PRES 12.0~16.5 M
C-2 P2-PRES 32.0~35.8 M C-2 P2-PRES 12.0~16.5 M
E-1 P1-PSV 385~495 mA E-1 P1-PSV 550~700 mA
E-2 P2-PSV 385~495 mA E-2 P2-PSV 550~750 mA
41
21-48

Arm-out in full lever operation & relief Arm-out in full lever operation & in operation
C-1 P1-PRES 32.0~35.8 M C-1 P1-PRES 12.0~18.0 M
C-2 P2-PRES 32.0~35.8 M C-2 P2-PRES 12.0~18.0 M
E-1 P1-PSV 385~495 mA E-1 P1-PSV 606~750 mA
E-2 P2-PSV 385~495 mA E-2 P2-PSV 606~750 mA
* Measure the values after a lapse of 5 * Measure the values after a lapse of 5
minutes or after release of low temperature minutes or after release of low temperature
mode mode

Swing in full lever operation & relief Swing in full lever operation & in operation
No.32 ARM, SWING No.32 ARM, SWING 21
C-1 P1-PRES 0.2~1.5 M C-1 P1-PRES 0.2~1.5 M
C-2 P2-PRES 28.0~35.8 M C-2 P2-PRES 8.0~13.0 M
E-2 P2-PSV 500~610 mA E-2 P2-PSV 642 mA
42
21-49

Bucket digging in full lever operation & relief Bucket digging in full lever operation & in operation
No.33 BUCKET No.33 BUCKET
C-1 P1-PRES 32.0~35.8 M C-1 P1-PRES 4.0~8.0 M
C-2 P2-PRES 0.2~1.5 M C-2 P2-PRES 0.2~1.5 M
E-1 P1-PSV 500~610 mA E-1 P1-PSV 750 mA
B-5 BUCKET DIG 3.0 M B-5 BUCKET DIG 3.0 M
B-6 BUCKET DUMP 0.0 M B-6 BUCKET DUMP 0.0 M

Bucket dump in full lever operation & relief Bucket dump in full lever operation & in operation
No.33 BUCKET No.33 BUCKET
C-1 P1-PRES 32.0~35.8 M C-1 P1-PRES 6.0~15.0 M
C-2 P2-PRES 0.2~1.5 M C-2 P2-PRES 0.2~1.5 M
E-1 P1-PSV 500~610 mA E-1 P1-PSV 650 mA
B-5 BUCKET DIG 0.0 M B-5 BUCKET DIG 0.0 M
B-6 BUCKET DUMP 3.0 M B-6 BUCKET DUMP 3.0 M
43
21-50

P2 side option in full lever operation & relief P2 side option in full lever operation & relief
Nibbler mode Hi idle Breaker mode Hi idle
No.35 OPT No.35 OPT
C-1 P1-PRES 22.5~26.0 M C-1 P1-PRES 0.2~1.5 M
C-2 P2-PRES 22.5~26.0 M C-2 P2-PRES 22.5~26.0 M
E-1 P1-PSV 480~590 mA E-1 P1-PSV 500 mA
E-2 P2-PSV 480~590 mA E-2 P2-PSV 665~750 mA
E-3 OPT RELIEF 0 mA E-3 OPT RELIEF 0 mA
B-16 P1 OPT 0.0 M B-16 P1 OPT 0.0 M
B-17 P2 OPT 2.0~2.6 M B-17 P2 OPT 2.0~2.6 M
F-4 OPT SELECT NIB F-4 OPT SELECT BRK
DOUBLE FLOW SW. ON DOUBLE FLOW SW. OFF
* Conflux switch is ON. Relief set pressure is * Conflux switch is OFF. Relief set pressure is
value of shipping. value of shipping.
Operation No.18: Operation No.19 :

Travel right in full lever operation & travel idling Travel left in full lever operation & travel idling
No.34 TRAVEL No.34 TRAVLE
C-1 P1-PRES 5.0~12.0 M C-1 P1-PRES 0.2~1.5 M 21
C-2 P2-PRES 0.2~1.5 M C-2 P2-PRES 5.0~12.0 M
B-9 TRAVEL(R) 2.0~2.5 M B-9 TRAVEL(R) 0.0 M
B-10 TRAVEL(L) 0.0 M B-10 TRAVEL(L) 2.0~2.5 M
Pi-P1 0.0 M Pi-P1 0.0 M
Pi-P2 0.0 M Pi-P2 0.0 M
44
21-51
21.2.4 TROUBLE HISTORY DIAGNOSIS

The items of error detected by mechatro controller self diagnosis function are stored in mechatro
controller as one of history. And the errors are able to be indicated on the multi display.
The warning content is stored partially in "Travel history screen".
The error code for self diagnosis is stored.
(1) How to display

1. Turn starter switch on.
2. Press buzzer stop switch for 10 seconds continuously 5 times and the trouble history screen is
displayed.
3. Transmit trouble history data (One or many) and hour meter to gauge cluster.
-Hour meter and 4 failure data are displayed on screen.
-In case of more than 4 failure data, 4 data is displayed at a time for 10 seconds by turns.
4. Paging (Up and down)
-Press washer switch (UP), and the item moves upward.
-Press wiper switch (DOWN), and the item moves downward.
5. Turn starter switch off, and the display is disappeared.
(2) How to delete contents of trouble history

1. Display trouble history screen.
2. Press work mode change switch and buzzer stop switch simultaneously for 10 seconds or more.
3. When "NO ERROR" is displayed, the deletion is completed.
4. Turn starter switch off.
All the stored items are erased. It is impossible to erase data partially.
45
21-52
21.2.5 TROUBLE DIAGNOSIS MODE

The recent control system includes many electrical systems and it makes troubleshooting very difficult.
The failure diagnosis mode is used to automatically specify the failed sections for the failures which
can not be detected through the use of self diagnosis function (the failure can be specified through the
use of error code) like disconnection and abnormal output. This is useful to save the time for
troubleshooting.
(1) Function
There are two types of trouble diagnosis mode.
1. Trouble diagnosis mode 1: Used to diagnose unload system, pump system, travel straight system
and engine system.
2. Trouble diagnosis mode 2: Used to diagnose pilot system.
In any mode, with the attachment not moved, both directional valve and proportional valve are
automatically actuated, the sensor detects the machine status and the mechatro controller
identifies the normal condition or failed condition of the system.
For details of how to use, refer to "Chapter 48 TROUBLESHOOTING TROUBLE DIAGNOSIS MODE".
21
46
21-53
21.2.6 SET PROCEDURE OF MAINTENANCE SCHEDULE

This machine is equipped with multi-display
which allows confirmation of remaining time to
the coming replacement/change time of engine
oil, fuel filter, hydraulic oil filter and hydraulic
oil, therefore when the remaining time reaches
to Zero (0), replace or change engine oil, fuel
filter, hydraulic filter, hydraulic oil, etc. and
perform the initial setting by the following order.
Interval of replacement of parts is mentioned below.

-Engine oil: 250 Hr
-Fuel filter: 500 Hr
-Hydraulic filter: 1,000 Hr
-Hydraulic oil: 2,000 Hr
1. After displaying the display for setting by pressing the display change switch, set the respective
maintenance time for fuel filter, hydraulic oil filter and hydraulic oil while repeating the procedure 2 to 5.
2. The engine oil change time is displayed on the multi-display by 500 hours as a warning, but the
buzzer does not sound.
47
21-54
21.2.7 ADJUSTING PROCEDURE OF DISPLAY

(1) For operator
2) Clock Adjustment Switches
21
1. Turn starter key switch on and display main screen (a) for operator, and then press select switch
(8) and display "SWITCH STATUS CLOCK/CONTRAST" select screen (b).
2. In operations of FEED UP (4) and FEED DOWN (5), move cursor to "CLOCK/CONTRAST"
screen (c) and then press select switch (8) and the "ADJUST CLOCK ADJ CONTRAST" screen
(d) is displayed.
3. In operations of FEED UP (4) and FEED DOWN (5), move cursor to "ADJUST CLOCK" and then
press select switch (8) and the "ADJUST CLOCK" screen (e) is displayed.
4. Select any of "Y-M-D-H-M" in operation of FEED UP (4) and FEED DOWN (5) and vary the
values in operations of FEED UP (4) and FEED DOWN (5).
5. After adjustment, press select switch (8) and the adjusted values are stored as memory and time
setting is completed, and then the screen returns to main screen (a).
48
21-55
2) Contrast Adjustment Switches
1. Turn starter key switch on and display main screen (a), and press select switch (8) and display
"SWITCH STATUS CLOCK CONTRAST" select screen (b).
2. In operations of FEED UP (4) and FEED DOWN (5), move cursor to "SWITCH STATUS CLOCK
CONTRAST" screen (c) and then press select switch (8) and the "ADJUST CLOCK ADJ
CONTRAST" screen (d) is displayed.
3. In operations of FEED UP (4) and FEED DOWN (5), move cursor to "ADJUST CLOCK ADJ
CONTRAST" and then press select switch (8) and the "ADJUST CLOCK ADJ CONTRAST"
screen (e) is displayed.
4. Press select switch (8) and the "ADJ CONTRAST 55555" screen (f) is displayed.
5. Vary the values by pressing the desired figure in operations of FEED UP (4) and FEED DOWN
(5).
The available setting range is in 9 steps from "11111" to "99999".
[Example] 11111 (faint) --> 99999 (clear) * The initial set value is 55555.
6. Press select switch (8) and the adjusted values are stored as a memory and the contrast
adjustment is completed, and then the screen returns to main screen (a).
49
21-56
(2) Function for service

Following items are provided for adjustment of service function.
Item CONTENTS
Language Language selection
Rise-up wiper Wiper control change (When cab is changed)
P1 option pressure sensor ON/OFF of self diagnosis for P1 option pressure sensor
P2 option pressure sensor ON/OFF of self diagnosis for P2 option pressure sensor
Swing alarm ON/OFF of swing alarm (ON/OFF of adjustment for user)
Left pedal for rotation of Does left rotation pedal use?
option attachment (Unload valve does not actuate because P4 pump is equipped in EU.)
Setting of optional Optional flow rate limitation, relief pressure limitation, combination of return selector
equipment adjustment.
Engine speed ON/OFF of engine rpm display
Auto acceleration Adjustment the type of the engine speed of auto deceleration runs up abruptly.
Change of starter mode Change of start mode
Low temperature mode Low temperature mode release
forcible release
Cylinders calibration Injection adjust mode of engine
Pressure release For pressure release
21
50
21-57
21.2.8 MECHATRO CONTROL EQUIPMENT

(1) C-1 Mechatro controller
1) Outside view
2) List of connectors
51
21-58
21
52
21-59
53
21-60
21
54
21-61
55
21-62
(2) Gauge cluster (symbol C-2)

1) General view
2) Connector CN-600 (Harness side)

No. Item name Wire color No. Item name Wire color
Gauge cluster --> Mechatro
GND source (+24V Battery direct
1 controller (RS232C White 5 Yellow / Black
connection)
communication)
Mechatro controller --> Gauge
2
cluster (RS232C communication)
Red 6 GND Black 21
3 Reserved - 7 Source (+24V starter switch ON) White
4 Reserved - 8 GND (RS232C communication) Black
3) Function
a. It processes signals by communication between the gauge cluster and the mechatro controller,
displays them in lamps, displays them in LCDs and actuates the buzzer.
b. It outputs coolant temperature signals, fuel level signals and panel switch signals to the mechatro
controller through the communication port.
4) Summary of display and drive item

No. Item Remarks
1 Monitar display LCD dot 120X168
2 Gauge display (Coolant temp., Fuel level) Stepping motor
3 -
4 Buzzer Piezo-electricity type
5 Screen change switch
6 Buzzer stop switch
7 Work mode select switch
8 Back light LED
56
21-63
(3) Relay & fuse box (symbol E-1)

1) General view
57
21-64
SK200-8 / SK330-8 FUSE BOX CONFIGURATION
YN24S00012P1
Relay x 4pcs 5A 10A 15A 20A
Window Washer A.I.S Relay 1

YN24S00010P1
Motor Relay A.I.S Relay 2 Emergency Relay x 8pcs
Stop Relay
Fuse Removal Tool Alternator Relay Horn Relay
Download
Connector
Wiper Motor Work light Relay

Prevent Sparky Relay Safety Lever Lock Relay
Reversing Relay
Safety Relay
Wiper Motor Relay
2) Circuit diagram
21
58
21-65
59
21-66
21
60
21-67
(4) High pressure sensor : LS52S00015P1
(5) Low pressure sensor : LC52S00019P1
61
21-68
SK200-6E SOLENOD VALVE BLOCK
SOLENOD VALVE BLOCK
Swg P/B SV Travel 1/2 speed SV Travel Straight PSV P2 cut PSV
YB35V00006F1 YN35V00020F1 YT35V00013F1
ATT Boost SV Lever Lock SV

AVR PSV P1 cut SV
4. P2 Unload PSV - PSV-B 5. ATT Boost SV 6. Travel 1/2 Speed SV

(Unload + P2 cut) SV-2 SV-3 YN35V00049F1 YN35V00048F1 YN35V00050F1 YN35V00050F1
3. Travel Priority PSV Arm 2 PSV P1 Unload PSV ATT Boost SV Travel 1/2 Speed SV
- PSV-C PSV-A PSV-D SV-2 SV-3
2. P1 Unload PSV
- PSV-D
( l d P1 )
1. Arm 2 PSV
- PSV-A
(AVR function)
Engine Side Swing Motor

side
A8 A7 A6 A5 A4 A3 A2 A1
A1
7. Swing P/B SV 8. Lever Lock SV
SV-1 SV-4
Travel Priority PSV P2 Unload PSV Swing P/B SV Lever Lock SV
SK200-8 SOLENOID VALVE BLOCK - PSV-CD - PSV-B SV-1 SV-4
YN35V00048F1 YN35V00048F1 YN35V00051F1 YN35V00050F1

［22. HYDRAULIC SYSTEM］
22.2.1 STANDARD
22
62 22-5
22.2.2 N&B SPECIFICATION (OPTION)
63
22-6
22.3 COLOR CODING STANDARD 22.4 NEUTRAL CIRCUIT (2) Principle: spool sleeve is closed.
The current command I to the pump's solenoid
FOR HYDRAULIC CIRCUITS
This section describes the following. proportional valve controls the delivery rate of the 22.4.4 PUMP P-Q CURVE CONTROL
Blue pump. OPERATION
(1) Bypass cut valve and unload valve control (3) Operation: (1) Type:
Feed, drain circuit
(2) Safety lock lever and pilot circuit Electrical flow control type variable pump
less than 0.44 MPa (64 psi)
(3) Pump positive flow control 1. Flow rate rise operation (Eg. P1 pump) (2) Principle:
Green
(4) Pump P-Q (Pressure-Quantity) curve control By operating any of control levers, the operating Perform an operation of the value from pump high
Return, make up circuit, secondary pressure of pilot valve rises, and the pressure sensor to P-Q curve control value, and
0.44~0.59 MPa (64~86 psi) 22.4.1 OPERATION OF BY-PASS CUT rising pressure is transformed to the rise of output send a command to the pump solenoid
Purple VALVE AND UNLOADING VALVE voltage corresponding to the pressure input by the proportional valve.
Secondary pilot pressure, HOUSED IN CONTROL VALVE low pressure sensor. Mechatro controller (3) Operation:
(including proportional vlave) (1) By-pass cut valve signal-processes this change of voltage, resulting The pump high pressure sensor converts the
On starting engine, P1 and P2 unloading in rise of command current value I to the pump pressure to the output voltage corresponding to
0.59~5 MPa (86~725 psi)
proportional valves (PSV-D, PSV-B) output proportional solenoid valve and consequently the the pump delivery pressure.
Red
secondary pressure according to the command pump flow rate rises. This is called "Positive The mechatro controller converts the voltage
Primary pilot pressure,
output by mechatro controller, and this pressure Control System". output by the high pressure sensor to the P-Q
(including proportional vlave) exerts on PBp1 and PBp2 ports, and As the pump command current value rises, the curve control value. On the other hand, select the
5 MPa (725 psi) consequently the by-pass cut spool is switched secondary pressure of proportional solenoid valve pump positive control command current value from
Orange to CLOSE side. also rises. On the regulator attached on the the low pressure sensor in lower order, and the
Main pump drive pressure, The by-pass cut spool is usually held on CLOSE pump, the spool (652) through piston (643) is values are output to respective pump proportional
side after the engine started. And it is switched to pushed leftward, and stops at the position where valve as a command current.
5~34.3 MPa (725~4970 psi)
OPEN side only when failure occurred on pump being in proportion to the force of pilot spring With this operation, the pump power is controlled
Blue tone
proportional valve and mechatro controller. (646). so as not to be exceed the engine power,
At valve operation
(2) Unloading valve The tank port connected to the large bore of therefore engine dose not stall.
Red valve On starting engine, like by-pass cut valve, the servo piston (532) opens, and the piston moves
When solenoid proportional valve (reducing) is secondary pressures output by P1 and P2 leftward by delivery pressure P1 of the small bore
operating unloading proportional valves (PSV-D, PSV-B) resulting in the increase of tilt angle (α).
Red solenoid exert on PCb and PCa ports, consequently the The servo piston and spool (652) are connected
In active and exciting P1 and P2 unloading valves are switched to to feedback lever (611). Therefore when servo
Displaying the flow circuit and standby circuit when OPEN side. piston moves leftward, the spool (652) also moves
operating. rightward by means of feedback lever. With this
Regarding the electrical symbols in this manual, refer to 22.4.2 SAFETY LOCK LEVER AND PILOT movement, the opening of spool sleeve closes
the electric circuit diagram. CIRCUIT gradually, and the servo piston stops at the
(1) Purpose: position the opening closed completely.
To protect attachment from unexpected 2. Flow rate reduction operation
movement for safety. As the current value I of mechtro controller
(2) Principle: reduces, the secondary pressure of solenoid
Cut pressure source of pilot valve for operation. proportional valve reduces, and spool (652) is
(3) Operation: moved rightward by the force of pilot spring (646).
If the safety lock lever (red) is pushed forward With the movement of spool, the delivery pressure
after the engine starts, the limit switch (SW-11) P1 usually flows into the large bore of piston
is turned on. The timer relay is actuated one through the spool.
second later which causes the solenoid (SV-4) of The delivery pressure P1 flows in the small bore
the solenoid valve block (13) to be energized of servo piston, but the servo piston moves
and makes the pilot operating circuit to stand by. rightward due to the difference of area, resulting
in the reduction of tilt angle. Similarly, when the
22.4.3 PUMP POSITIVE FLOW CONTROL servo piston moves rightward, the spool (652) is
(1) Type: moved leftward by the feedback lever.
Electric flow controlled variable displacement pump. The operation is maintained until the opening of
22-8 64
22
NEUTRAL CIRCUIT : Positive control function at safety lock lever down (unlocked position)
65
22-9
22.5 TRAVEL CIRCUIT switches the unloading spool in CLOSE side.
This section describes the following. 22.5.2 2-SPEED TRAVEL SOLENOID

COMMAND CIRCUIT AND AUTO 1st
(1) Travel forward pilot simultaneous operation circuit SPEED RETURN FUNCTION
(2) 2 speed travel solenoid command circuit and (1) Purpose:
auto 1-speed return function Change travel motor speed with switch.
(3) Travel main circuit (2) Principle:
(4) Travel motor function If the switch is turned, an electric signal is
issued. It excites the 2-speed travel solenoid
22.5.1 TRAVEL FORWARD PILOT which in turn converts the primary pilot pressure
SIMULTANEOUS OPERATION and the self pressure to a tilting angle of the
CIRCUIT variable displacement motor.
(1) Purpose: (3) Operation:
Light operating force and shockless operation If the rabbit marked switch on the gauge cluster
(2) Mechatronics: is pressed, the solenoid (SV-3) of the
proportional valve block (13) is excited and
1. If the travel lever with damping mechanism is changes the proportional valve. Then the
operated for travel right, left and forward solenoid command pressure is issued from port
motions, the secondary pilot proportional pressure A3, enters the P port of the travel motor (4),
comes out of the 3, 1 ports of P/V (10). The opens the oil passage to the 2nd speed select
higher of the pressures is selected, comes out of piston, and causes the motor to run in the 2nd
the 6, 5 ports and acts upon the low pressure speed tilting mode by its self pressure. However,
sensors (SE-9) (SE-10). when the main circuit pressure rises above 27.3
2. The pilot secondary pressure flows to PBr and MPa (3960 psi), the motor's self pressure pushes
PBL ports of the control valve (2), moves the the 2nd speed select piston back to the 1st
travel spool, and switches the main circuit. speed.
3. The low pressure sensor output voltage is input
into mechatro controller. The mechatro controller 22.5.3 TRAVEL MAIN CIRCUIT
performs signal processing and outputs current (1) Operation:
corresponding to the increase of flow rate to P1 The delivery oil from Pump A1 and A2 ports by
pump proportional valve (PSV-P1) and P2 pump changing the travel spool with the operation of
proportional valve (PSV-P2), and at the same time travel pilot flows in each A,B port on the left
the command current is output to P1 unloading side of travel motor (4) through C,D ports of
valve (PSV-D) and P2 unloading valve (PSV-B). swivel joint (8) from AL, AR ports of C/V, and
4. The secondary pressures output by P1 pump rotates the travel motor.
proportional valve (PSV-P1) and P2 pump
proportional valve (PSV-P2) exert on pump 22.5.4 TRAVEL MOTOR FUNCTION
regulator, actuating the pump on the delivery (1) Function:
flow rate increase side.
5. The secondary pressure delivered in P1 unloading 1. Prevents the motor from over running on a slope.
valve (PSV-D) and P2 unloading valve (PSV-B) 2. Check valve that prevents cavitation of the
is fed to PBp1, Pcb, PBp2 and PCa ports hydraulic motor.
provided in control valve (2). 3. Shockless relief valve and anti cavitation valve
The secondary pressure from proportional valve when inertia force stops.
which has exerted on PBp1 and PBp2 ports holds 4. High/Low 2 step speed change mechanism and
the by-pass cut spool on CLOSE side, like the auto 1st speed return at high load.
operation in the lever neutral position. 5. Travel parking brake.
The secondary pressure from proportional valve
which has exerted on PCb and PCa ports
22-10 66
22
TRAVEL CIRCUIT : Travel 2nd speed, RH & LH simultaneous operation.
67 22-11
22.6 BUCKET CIRCUIT <When lever is set to neutral position>

In the event where the sensor does not receive
This section describes the following. signal for 4 seconds or more even though the
acceleration dial is set to MAX position, the
(1) Bucket digging pilot circuit engine speed should be raised to 1000 rpm.
(2) Auto accel operation <When lever is operated>
(3) Flow control in the work mode When the pressure 0.6 MPa (87 psi) is input to
low pressure sensor in STD specification (travel,
22.6.1 PILOT CIRCUIT FOR BUCKET bucket, swing, arm), proportional voltage from
DIGGING low pressure sensor inputs in mechatro
(1) Mechatronics: controller, and then the engine speed returns to
the dial set position corresponding to the lever
1. When the operation for bucket digging is operation.
performed, the pilot proportional secondary
pressure is delivered through port 1 of the right 22.6.3 STAND-BY CURRENT CONSTANT
pilot V (9), flows to PAc port, and acts on the CONTROL
low pressure sensor (SE-1), and at the same time (1) Principle:
the bucket spool is switched. When the engine speed is intermediate speed or
2. The voltage output by low pressure sensor lower, command current value to have the pump
inputs in mechatro controller. The mechatro delivery rate constant is output.
controller performs signal processing and outputs (2) Operation:
current corresponding to the increase of pump Even if the engine speed specified by acceleration
flow rate to pump proportional valves (PSV-P1) on potentiometer is low speed, as the delivery rate
the P1 pump sides, and at the same time the corresponds to the intermediate speed, the
command current is output to P1 unloading valve actuator moves earlier than the movement
(PSV-D). equivalent to the control lever angle rate in light
In the following pages, the relation of operation of load operation.
low pressure sensor to both the increase of pump
flow rate and unloading proportional valve is the
same. Therefore the explanation is omitted.
3. The secondary pressure output by P1 pump
proportional valve (PSV-P1) exerts on pump
regulator, actuating the pump onto the delivery
flow increase side.
4. The secondary pressure delivered in P1 unloading
valve (PSV-D) is led to PBp1 and PCb ports
provided in control valve (2).
which has exerted on PBp1 ports holds the
by-pass cut spool on CLOSE side, like the
operation in the lever neutral position.
which has exerted on PCb ports switches the
unloading spool in CLOSE side.
22.6.2 AUTO ACCELERATION OPERATION

(1) Principle:
Auto acceleration actuates according to signals
from low pressure sensor.
(2) Operation:
22-12 68
22
BUCKET CIRCUIT : Bucket digging, Auto-accelation and Standby flow rate constant control
69 22-13
22.7 BOOM CIRCUIT into tank circuit through boom spool from C/V (2)
Bb port.
This section describes the boom raise conflux
operation.
(1) Boom up pilot circuit

(2) Boom up 2 pumps conflux main circuit in C/V
22.7.1 BOOM RAISE PILOT CIRCUIT

(1) Operation:
1. If boom up operation is performed, the

secondary pilot proportional pressure from the
right pilot valve (9) gets out of port 3 and acts
upon the low pressure sensor (SE-3). At the
same time, the pressure acts upon the PAb and
PB1 ports.
2. The secondary pressure which enters the PAb
port of C/V (2) shifts the boom spool. The
secondary pressure which enters the PB1 port
shifts the boom conflux spool.
22.7.2 BOOM UP 2 PUMPS CONFLUX

MAIN CIRCUIT IN C/V
(1) Purpose:
Boom up speed up
(2) Principle:
Confluxing oil from 2 pumps
(3) Operation:
1. The oil delivered through A1 port of P1 pump

flows into C/V (2) P1 port, and branches into
bypass circuit and parallel circuit. Since P1
unloading valve is closed, the boom spool is
moved and bypass circuit is closed, the oil
opens load check valve LCb through parallel
circuit and flows into boom spool.
2. Then the oil passes through boom spool, opens
lock valve of boom lock valve CRb, and is led
into H side of boom cylinder through C/V (2) Ab
port.
3. Meanwhile, the oil delivered from the A2 port of
the P2 pump enters the P2 port of C/V (2) and
due to shut off the P2 unloading valve, the oil
then passes through the parallel circuit and via
the restrictor on the circumference of the boom
conflux spool, pushes the load check valve CCb
open from the boom conflux circuit, and combines
the oil delivered by the P1 pump internally.
4. The return oil from boom cylinder R side flows
22-14 70
22
BOOM CIRCUIT : Boom up operation, Confluence function.
71 22-15
This section describes boom lower operation. 22.7.5 CONSTANT RECIRCULATION

(1) Boom down pilot circuit FUNCTION OF BOOM DOWN MAIN
(2) Prevention of natural fall by lock valve and CIRCUIT
actuation at lowering (1) Purpose:
(3) Constant recirculation function of boom down main Prevention of cavitation during boom lowering
circuit motion.
(2) Principle:
22.7.3 BOOM DOWN PILOT CIRCUIT The oil returning from the boom cylinder head (H)
(1) Operation: is recirculated to the rod (R).
(3) Operation:
1. If the boom down operation is performed, the When the oil is supplied to the boom cylinder
secondary pilot proportional pressure comes out of rod (R) side during boom down operation, the
porta4 of the right pilot valve (9) and acts upon boom moves faster than it should do in some
the low pressure sensor (SE-4). cases by the self weight of the attachment.
At the same time, the pressure acts upon the On that occasion, the circuit pressure on the rod
PBb port of C/V (2). (R) side is on the negative side.
2. The voltage output of the low pressure sensor The oil supplied to the boom cylinder rod (R)
(SE-4) enters the mechatro controller and flows into the A1 port of the P1 pump and the
processed in it. P1 port of C/V. The oil then passes through the
3. Then, the proportionl secondary pressure fed into boom spool and goes out of the Bb port.
C/V (2) PBb port and branches off in two lines On that occasion, the oil returning from the head
and switches boom spool and releases boom lock (H) goes through the recirculation path in the
valve. boom spool, pushes the check valve in the spool
open, is recirculated to the Bb port and is
22.7.4 PREVENTION OF NATURAL FALL supplied to the rod (R). When the (R) pressure
BY LOCK VALVE AND ACTUATION is larger than the head (H) pressure, the check
AT LOWERING valve in spool closes.
(1) Purpose: Thereupon, the recirculation is stopped.
Prevention of natural fall when the lever is neutral.
(2) Principle:
The oil is prevented from returning to the boom
spool by the poppet seat of the boom lock valve.
(3) Operation:
In the boom down action, the selector valve is
changed over by the secondary proportional
pressure of PBb port. Then the poppet spring
chamber of the lock valve CRb gets through the
drain line (Dr) and makes the lock valve poppet
open.
When the boom lever is at neutral, the drain line
on the lock valve CRb poppet spring chamber is
closed which causes the poppet closed.
The result is that the oil returning from the boom
cylinder head (H) to the boom spool is held and
makes the leak from the boom spool zero.
Thus the boom cylinder is prevented from
making a natural fall.
22-16 72
22
BOOM CIRCUIT : Boom down operation & Prevention of natural boom falling.
73 22-17
22.8 SWING CIRCUIT 22.8.3 SWING MAIN CIRCUIT

(1) Operation:
This section describes the following operations. The oil delivered from the A2 port of the P2
(1) Swing left pilot circuit pump enters the P2 port of C/V (2) and is
(2) Swing auto parking brake branched off into the bypass line and the parallel
(3) Swing main circuit circuit. However, since the bypass line is closed
(4) Swing motor circuit as the swing spool is shifted, the oil pushes the
load check valve LCs open through the parallel
22.8.1 PILOT CIRCUIT FOR LEFT SWING circuit, enters the B port of the swing motor via
(1) Operation: the As port of C/V (2), and rotates the swing
motor counterclockwise.
1. When the left swing operation is performed, the
pilot proportional secondary pressure is delivered 22.8.4 SWING MOTOR CIRCUIT
through port (5) of left pilot V (9), and the (1) Anti cavitation circuit at swing deceleration
secondary pressure acts on PAs port of C/V (2), (2) Shockless relief valve that prevents the swing
and simultaneously flows out from Pss port of motor from being reversed.
C/V and acts on low pressure sensor (SE-5).
2. The voltage output by the low pressure sensor is
input in the mechatro controller, and is
signal-processed.
3. Then, the secondary pressure led into PAs port of
C/V (2) switches the swing spool.
22.8.2 SWING AUTO PARKING BRAKE

(1) Purpose:
Swing lock in neutral position and parking
(2) Principle:
Release mechanical brake only when required to
operate swing and arm in.
(3) Operation:
1. The swing parking system excites the swing

parking SOL (SV-1) usually if the key switch is
turned on and works by the action of the
mechanical brake.
2. The mechanical brake is released if the swing
parking solenoid is de-excited only when the
secondary operating pressure in the swing and
arm in actions acts upon any of the low
pressure sensors (SE-5, 7).
3. The swing parking solenoid (SV-1) is excited five
seconds after the pressure of the swing low
pressure sensors (SE-5) is reduced to zero. In
the case of arm in operation, the swing parking
solenoid (SV-1) is excited the moment the
pressure of the arm in low pressure sensor
(SE-7) is reduced to zero. This causes the
mechanical brake to operate.
22-18 74
22
SWING CIRCUIT : Swing operation (LH)
75 22-19
22.9 ARM CIRCUIT section and travel right tandem path. Then
because arm 2 spool was switched, the delivery
This section describes the following operations. oil opens load check valve LCAT2, goes through
arm 2 spool, and confluences with P2 pump
(1) Arm in, light-load operating pilot circuit delivery oil in the valve section, and then is
(2) Arm in, light-load variable normal recirculation flowed into arm cylinder head (H) side through Aa
main circuit / internal conflux main circuit port of C/V (2).
3. The return oil from arm cylinder (R) side flows in
22.9.1 ARM IN, LIGHT-LOAD Ba port of C/V (2) and passes through the Ba
OPERATING PILOT CIRCUIT port because the arm lock valve CRa is open,
(1) Purpose: and is flowed into arm 2 spool through arm 1
Speed-up and Anticavitation when the arm is at spool.
light loaded. 4. Because arm 2 spool is switched to normal
(2) Principle: recirculation position, causing restriction of
The oil returning from the arm cylinder rod (R) is passage to tank, the return oil from arm cylinder
recirculated variably to the head (H) at arm 2 (R) side flows into arm cylinder (H) side.
spool in C/V. -Because, at light load, the pressure in cylinder
(3) Operation: rod (R) side is higher than that in the head (H)
side, it opens the check valve housed-in arm 2
1. When the arm in operation is performed, the spool and is recirculated in the head (H) side,
secondary pilot proportional pressure gets out of resulting in the speed up of arm-in operation at
port 7 of the left pilot valve (9) and acts upon the light load.
low pressure sensor (SE-7). 5. Cavitations prevention control in arm-in operation
At the same time, the pressure is branched off Command current is output to arm 2 solenoid
in two flows, acts upon the PAa1 port and the proportional valve by signal processing of E/G
PLc2 port, changes over the arm spool and the speed and arm-in pilot pressure, accordingly the
arm lock valve CRa. releases. arm 2 spool is switched to neutral (cavitations
2. The output voltage by the low pressure sensor is prevention) position, resulting in cavitations
input into mechatro controller, and is pilot prevention.
signal-processed, and is output to P1, P2 pump
proportional valve (PSV-P1), (PSV-P2) and arm 2 Position of arm 2 spool
inverse proportional valve (PSV-A).
3. The secondary pressure from pilot proportional
valve, which is reduced by arm 2 inverse
proportional valve (PSV-A) switches arm 2 spool.
22.9.2 ARM-IN, LIGHT-LOAD VARIABLE

NORMAL RECIRCULATION,
INTERNAL CONFLUX MAIN CIRCUIT
(1) Operation:
Reference:
1. The P2 pump delivery oil flows in travel left In light-load arm-in operation (normal recirculation,
section through P2 port of C/V (2) and is conflux), when the attachment to which the circuit in
branched off in by-pass circuit and parallel P1 pump side is applied is operated, the meter-in
circuit, but because arm 1 spool is switched, the path of arm 2 spool is closed, resulting in single flow
delivery oil which goes through parallel circuit operation.
opens load check valve LCa and is flowed into
arm 1 spool.
2. On the other hand, P1 pump delivery oil flows in
P1 port of C/V (2), and the flows in travel straight
22-20 76
22
ARM CIRCUIT : Arm in (Light load) operation, Arm variable recirculation & Anti cavitation function
77
22-21
This section describes the following operations. valve, but because the arm lock valve is open,
the return oil goes through arm lock valve CRa
(3) Arm in, heavy load operating pilot circuit and flows in arm 2 spool.
(recirculation cut) 4. The return oil returns directly into tank circuit
(4) Arm in, heavy load operating sequence confluxed because arm 2 spool is switched to recirculation
main circuit cut position.
22.9.3 ARM IN, HEAVY LOAD Position of arm 2 spool

OPERATING PILOT CIRCUIT
(1) Operation:
1. In arm-in operation, when the heavy loading is

applied to arm and the P2 pump pressure
increases to the set pressure, the voltage output
by P2 pump pressure sensor (SE-23) is converted
to signal (signal processing) by mechatro
controller, consequently the current of arm 2
solenoid proportional valve is controlled according
to the load pressure and the arm variable
recirculation is cut.
When the recirculation is cut, internal confluence
is held similarly to that in light load operation.
2. Left pilot valve actuation due to arm-in operation
is equivalent to that at light load operation.
22.9.4 ARM IN, HEAVY LOAD

OPERATING RECIRCULATION CUT
MAIN CIRCUIT
(1) Purpose:
Power up for arm in operation
(2) Principle:
Cut the recirculation and reduce rod pressure.
(3) Operation:
1. P2 pump delivery oil flows in the travel left

section through P2 port of C/V (2) and branched
off in by-pass circuit and parallel circuit.
Consequently the arm spool is switched and
pushes and opens load check valve LCa through
parallel circuit, and flows in the arm spool.
2. On the other hand, P1 pump delivery oil flows in
P1 port of C/V (2), and flow in travel right
tandem passage through travel straight section.
Then because arm 2 spool was switched, the
delivery oil opens load check valve LCAT2, and
confluences with P2 pump delivery oil in the valve
section, and is flowed into arm cylinder head (H)
side through Aa port of C/V(2).
3. The return oil from arm cylinder (R) side flows in
Ba port of C/V(2) and is flowed to arm lock
22-22 78
22
ARM CIRCUIT : Arm in (Heavy load) operation, Arm confluence & recirculation cut function
79 22-23
This section describes the following operations. weight of the arm and bucket.
(5) Arm out pilot circuit (2) Principle:
(6) Arm out 2 pumps conflux main circuit Complete seat of the return circuit against the
(7) Natural fall protection with arm lock valve arm spool of the arm cylinder (R) side circuit.
(3) Operation:
22.9.5 ARM OUT PILOT CIRCUIT
(1) Operation: 1. When the secondary pressure for arm operation
disappears and the arm cylinder stops, the
1. When the arm out operation is performed, the pressure on the rod (R) side passes through the
secondary pilot proportional pressure gets out of selector of the lock valve from the Ba port of C/V
port 8 of the left pilot valve (9), and acts upon (2), acts the back pressure on the lock valve CRa
the low pressure sensor (SE-8). At the same and seats the lock valve.
time, the oil is branched off in two flows and act 2. Since the oil flow into the arm spool from the
upon the PBa1 and PBa2 ports of C/V (2). lock valve is shut off completely, natural fall of
2. The operating proportional secondary pressure the arm due to oil leaks through the arm spool is
flowed in Pba1 port of C/V (2) switches the arm prevented.
1 spool.
3. Then, the operating secondary pressure flowed in
PBa2 port of C/V (2) switches the arm 2 spool
valve.
22.9.6 ARM OUT 2 PUMPS CONFLUX

MAIN CIRCUIT
(1) Purpose:
Arm out operation speed up.
(2) Principle:
The oil delivered by the P1 pump is confluxed
with that delivered by the P2 pump in C/V (2).
(3) Operation:
1. P1 pump delivery oil opens load check valve

(LCAT2) by switching arm 2 spool and confluxes
with P2 pump delivery oil just short of the arm
lock valve.
2. And, P2 pump delivery oil flows through arm 1
spool and confluences with P1 delivery oil,
opens lock valve of arm lock valve CRa with
free flow and is flowed into arm cylinder rod (R)
side through Ba port of C/V(2).
3. On the other hand, the return oil from arm
cylinder (H) side flows in Aa port, and returns into
tank circuit through arm 1 spool and arm 2 spool.
The return line which does not pass through
boost check valve is used for this return circuit
to reduce the pressure loss.
22.9.7 NATURAL FALL PROTECTION

WITH ARM LOCK VALVE
(1) Purpose:
To prevent the arm from falling naturally by the
22-24 80
22
ARM CIRCUIT : Arm out operation, Confluence function
81 22-25
22.10 COMBINED CIRCUIT P2 pump flows in left travel spool to travel

leftward.
This section describes only the difference in combined The delivery oil flowed into travel straight spool of
operation. P2 pump flows in right travel spool because the
travel straight spool is shifted and exerts on the
(1) Boom up / travel, pilot circuit right travel operation.
(2) Boom up / travel, main circit (In travel straight operation, P2 pump delivery oil
exerts on travel operation.)
22.10.1 BOOM UP / TRAVEL, PILOT 4. However, a portion of the flow is led to the
CIRCUIT travel straight spool notch restriction. The speed
(1) Operation: of attachments like travel, boom, etc. is adjusted
<Operation: Different point of pilot circuit from by the circuit of restriction.
independent operation >
1. The mechatro controller outputs command current

to travel straight solenoid proportional valve
(PSV-C) after signal processing, and the solenoid
valve outputs secondary pressure and acts on
PTb port of C/V (2).
2. Then the pressure of PTb port switches the travel
straight valve.
22.10.2 BOOM UP / TRAVEL, MAIN

CIRCUIT
(1) Purpose:
To insure straight travel movement during travel
operation even if the attachment is operated.
(2) Principle:
The travel action and the attachment action are
actuated by separate pumps.
(3) Operation:
1. P1 pump delivery oil flows through P1 port of

C/V(2) and branches off in P1 parallel circuit and
travel straight spool.
P2 pump delivery oil flows through P2 port of
C/V(2) and branches off in P2 tandem circuit
and travel straight spool.
2. The delivery oil flowed into P1 parallel circuit of
P1 pump opens check valve CT1 and LCb and
flows in boom spool, which exerts on boom up
operation.
The delivery oil flowed into travel straight spool of
P1 pump opens check valve CT2 because the
travel straight spool is shifted, and flows in boom
conflux spool and exerts on boom up operation
with the internal oil conflux.
(In travel straight operation, P1 pump delivery oil
exerts on swing operation of attachment.)
3. The delivery oil flowed into P2 tandem circuit of
22-26 82
22
COMBINED CIRCUIT : Boom up & Travel forward 1st speed operation, Travel straight function.
83 22-27
In this section, the independent operation is omitted This operation is called "Swing Priority Circuit".
and describes difference in combined operation.
(3) Swing / Arm in light load, pilot circuit Position of arm 2 spool
(4) Swing / Arm in, swing priority main circuit
22.10.3 SWING / ARM IN LIGHT LOAD,

PILOT CIRCUIT
(1) Operation:
1. On operating swing (left) and arm in motions

simultaneously, mechatro controller outputs
command current to travel straight solenoid
proportional valve (PSV-C) and arm 2 solenoid
inverse proportional valve (PSV-A) according to
signal processing, and this proportional valve
outputs secondary pressure, which acts on PTb
port and PAa2 port of C/V(2).
2. PTb port pressure switches the travel straight
spool 2 steps, and the PAa2 port pressure
switches the arm 2 spool to the forced
recirculation position.
22.10.4 SWING / ARM IN, SWING

PRIORITY MAIN CIRCUIT
(1) Purpose:
Stable swing speed.
(2) Principle:
Raise the oil pressure flowing to arm cylinder,
and give a priority of the delivery of P2 pump to
swing operation.
(3) Operation:
1. The swing main circuit operates with P2 pump

flow. But on P2 pump circuit side, the flow goes
to the swing circuit and arm circuit
simultaneously because the swing circuit and
arm circuit are parallel. Then since the return oil
from arm cylinder rod (R) side is restricted in the
arm 2 spool because the arm 2 spool is switched
to forced recirculation position, the pressure of
return oil is raised, causing the rise of circuit
pressure on the arm cylinder head (H) side.
2. At the same time meter-in of arm 2 spool closes
and arm in conflux is therefore cancelled, and
delivery oil from P2 pump and P1 pump are
combined in the parallel circuit on P2 pump side
because the travel straight spool was switched.
The conflux oil of P1 and P2 delivery oil in high
pressure flows in swing side taking priority over
all others.
22-28 84
22
COMBINED CIRCUIT : Swing / Arm in operation, swing priority function
85 22-29
22.11 PRESSURE DRAINING 2. Unloading proportional valves (PSV-D, PSV-B)

output secondary pressure and the secondary
This section describes the following operations. pressure flows in PCb, PCa ports of C/V(2) and
switches the P1, P2 unloading valves to OPEN
(1) Pressure drain (releasing) pilot circuit position.
(2) Pressure drain (releasing) main circuit
22.11.2 PRESSURE RELEASE MAIN
22.11.1 PRESSURE RELIEVING PILOT CIRCUIT
CIRCUIT
(1) Purpose:
To release the pressure in main circuit for piping
repair works. When the hydraulic pressure releasing is performed,
(2) Principle: make sure to place bucket on the ground.
After the mode is switched to "Pressure Relief
Mode" with switch on gauge cluster, mechatro (1) Operation:
controller outputs the following commands. When the operating lever is shifted to neutral
during engine running, "DRAINING HYD.
1. Minimum tilting command value to pump PRESS." is displayed on the gauge cluster while
proportional valve (PSV-P1, PSV-P2). the mode switch is changed to pressure relieving
2. Output "Pressure relief control speed command mode. In this time the intermittent buzzer sounds
value" at ECU. (Electric system) continuously. When right and left operating levers
3. Stand-by command value to P1, P2 unloading are operated 4 or 5 times to their full stroke,
proportional valves pressure is relieved.
After draining pressure is completed, turn off the
How to switch to "Pressure release mode" starter key and buzzer sound stops. If the pump
1. Select the service diagnosis mode. pressure is determined to be more than 1 MPa
(Keeping pressing of the "BUZZER STOP (145 psi) by the output value of the high pressure
SWITCH" on gauge cluster, turn the starter key sensor or the high pressure sensors (SE-22,23)
on.) are broken, "FAIL DRAIN HYD. PRESS" is
2. Select the service adjustment mode 1. displayed and the buzzer sounds continuously. In
(Under the condition that "Screen No.1" of that case, also the buzzer is not stopped unless
"Service diagnosis mode 1" is indicated, keeping the engine key is turned to OFF. Repeat the
pressing of the "BUZZER STOP SWITCH", press pressure releasing procedure once again.
the "SELECT SWITCH" 3 times. When (2) Hydraulics :
"LANGUAGE/LOGO", "ADJUSTING MODE 1" Unload spool is switched to open position, and
and "PRESET BY FACTORY" are displayed, the oil delivered by each pump is unloaded to the
press [▲] or [▼] switch, and highlight tank passage.
"ADJUSTING MODE 1", and then press "Selector If the spools are switched by pilot operation, the
Switch" again.) remaining pressure from the actuators may be
3. When "ADJUSTING MODE 1" screen is displayed, relieved to the tank circuit, i.e. the main circuit
press [▲] or [▼] switch, and "DRAIN HYD. pressure may be released.
OFF" screen appears.
4. Press "Selector Switch" and highlight "OFF", and
press [▲] switch to change to "DRAIN HYD. ON",
and then press "Selector Switch" again.
(3) Operation:
1. Pump proportional valve reduces the pump flow

rate to the minimum.
22-30 86
22
PRESSURE DRAIN (RELEASE) CIRCUIT : At pressure release mode.
87 22-31
［23. ELECTRICAL SYSTEM］
23.1 ELECTRIC CIRCUIT DIAGRAM
23
88 23-3
23-4 89
23
90 23-5
23-6 91
23.2 ELECTRICAL EQUIPMENT &

HARNESS
23-10 92
23.3.2 INSTRUMENT PANEL ASSY
23-12 93
23.3.3 CONTROLLER INSTALL
23
94 23-13
23.3.4 OPERATOR'S CONTROL (SWITCH

INSTALL)
23-14 95
23.3.5 UPPER ELECTRIC ASSY
23
96 23-15
23.3.6 UPPER HARNESS ASSY (1/6)
23-16 97
23
98 23-17
23-18 99
23
100 23-19
23-20 101
23
102 23-21
［24. COMPONENTS SYSTEM］
24.2 ELECTRICAL EQUIPMENT
24.2.1 ELECTRICAL EQUIPMENT LIST
Group Code Part Name Part No.

C - 1 Mechatro controller YN22E00425F1
C - 2 Gauge cluster YN59S00032F1
(C) Controller
C - 4 Air-con controler (including panel) YN20M01468P4
C - 8 Engine controller 32G87-01020
D - 4 Diode YN02D01001P1
D - 5 Diode Accessory of relay box
D - 6 Diode
D - 9 Diode
D - 10 Diode
D - 12 Diode
D - 13 Diode
D - 14 Diode
(D) Diode
D - 15 Diode
D - 16 Diode
D - 17 Diode
D - 18 Diode
D - 19 Diode
D - 20 Diode
D - 21 Diode
D - 32 Diode YN02D01001P1
E - 1 Fuse and Relay box YY24E00008F2
E - 2 Alternator 32G68-00100
E - 3 Hour meter YT58S00006P1
E - 5 Horn high LC53S00001D1
E - 6 Horn low LC53S00001D2
E - 10 Receiver dryer LQ54S00005P1
(E) Electric fittings
E - 11 Air-con compressor YX91V00001F1
E - 12 Battery LP72S00002P1
E - 14 Cigaratte lighter YN81S00003P1
E - 15 Fusible link YY73S00003P1
E - 27 Accel redumdant volume -
E - 38 Resister LC22E01001D1
24
L - 1 Boom work light (LH) YW80S00001F1
(L) Light L - 2 Frame work light (RH) YT80S00002F2
L - 5 Room light LQ02C00031S020
24-103
103

M - 1 Starter motor 32G66-00100
(M) Motor M - 3 Wiper motor YN53C00012F2
M - 4 Washer motor (Tank assy) YT54C00003F1
PSV - A Arm 2 speed inverse propo. valve YN35V00049F1
PSV - B P2 unload propo. valve (YY35V00013F2) YN35V00048F2
(P) Proportional PSV - C Travel straight propo. valve Solenoid valve assy
solenoid valve PSV - D P1 unload propo. valve
PSV - P1 P1 pump propo. valve (LP10V00006F1) YN35V00054F1
PSV - P2 P2 pump propo. valve Pump accesory
R - 1 Battery relay YN24S00008F1

R - 2 Starter relay Engine accessory
R - 3 Glow relay 34390-00601
R - 4 Safety relay Accessor of relay box
R - 5 Horn relay YN24S00010P1
R - 6 Working light relay
R - 23 Auto idle stop relay 1
R - 24 Auto idle stop relay 2
(R) Reray
R - 25 Engine emergency stop relay
R - 26 Lever lock relay
R - 28 Alternator relay
R - 29 Wiper motor relay (Normal rotation) YN24S00012P2
R - 30 Wiper motor relay (Reverse rotation)
R - 31 Prevent spark relay
R - 32 Washer motor relay
R - 53 Glow relay (ECU)
SE - 1 Pressure sensor : Bucket digging LC52S00019P1
SE - 2 Pressure sensor : Bucket dump
SE - 3 Pressure sensor : Boom up
SE - 4 Pressure sensor : Boom down
SE - 5 Pressure sensor : Swing
SE - 7 Pressure sensor : Arm in
SE - 8 Pressure sensor : Arm out
SE - 9 Pressure sensor : Travel RH
(SE) Sensor SE - 10 Pressure sensor : Travel LH
SE - 11 Pressure sensor : P2 OPT.
SE - 13 E/G speed sensor Engine accessory
SE - 15 Fuel sensor YN52S00045F1
SE - 16 Accel potentiometer YN52S00075P1
SE - 20 Pressure sensor : P1 OPT. LC52S00019P1
SE - 22 Pressure sensor : Pump P1 LS52S00015P1
SE - 23 Pressure sensor : Pump P2
SE - 29 Opt. selector detect sensor LC52S00019P1
24-104
104

SV - 1 Swing parking brake SOL. YN35V00051F1
SV - 2 - (YY35V00013F2) -
(SV) Solenoid
SV - 3 Two speed select SOL Solenoid valve assy YN35V00050F1
SV - 4 Safety lock lever SOL YN35V00061F1
SW - 1 Key switch YN50S00026F1
SW - 4 Swing parking brake release switch YN50S00047P1
SW - 5 Horn switch (RH) -
SW - 8 Air filter clogging switch YY11P00008S007
SW - 10 Horn switch (LH) YN50E00017P1
SW - 11 Safety lock lever switch YN50S00041F1
(SW) Switch SW - 15 Conflux/single select switch YN50S00040DD
SW - 17 Skylight wiper switch YN50S00040D9
SW - 19 Wiper interlock switch YT50S00004P1
SW - 22 KPSS release switch YX50S00001F1
SW - 36 Water separator restrlction switch 32G90-00300
SW - 55 Boom work light switch YN50S00040D1
SW - 111 Attachment mode select switch PY50S00003P2
24
24-105
105
23.3.7 UPPER HARNESS ASSY (FLOOR) (3/3)
23-34 106
23.3.9 CAB INSTALL

23.3.9.1-1 CAB ASSY : YN02C00289F1
23-42 107
23.3.11 CAB HARNESS ASSY
23-44 108
23.3.12 IT KIT HARNESS ASSY (1/2)
23
109 23-47
23.3.12 IT KIT HARNESS ASSY (2/2)
23-48 110
24.1 HYDRAULIC COMPONENTS
24.1.1 HYDRAULIC PUMP - REGULATOR

24.1.1.1 SUMMARY
(1) Outside view and Hydraulic port
24
Hydraulic pump - regulator
24-3
111
(2) Hydraulic circuit diagram
Hydraulic circuit diagram of pump
(3) Specifications
24-4
112
SK130 STD VS SK130HDL-8E MAIN PUMP ASSY
MAIN PUMP ASSY NO: YY10V00009F3 MAIN PUMP ASSY NO: LP10V00006F1
SK130-8 Main Pump Assy - Regulator SK130HDL-8E Main Pump Assy - Regulator
24.1.1.2 HYDRAULIC PUMP

24.1.1.2.1 CONSTRUCTION
(1) Main pump
24
24-5
113
(2) Gear pump (For pilot)
No. Parts Q'TY No. Parts Q'TY

307 Poppet 1 361 Front case 1
308 Seat 1 433 Flange socket; M8X40 2
309 Ring 1 434 Flange socket; M8X55 2
310 Spring 1 435 Flange socket; M8X20 4
311 Adjust screw 1 466 VP plug; PF1/4 1
312 Lock nut; M14X1.5 1 700 Ring 1
351 Gear case 1 710 O-ring; 1B G95 1
353 Drive gear 1 725 O-ring; 1B P11 1
354 Driven gear 1 732 O-ring; 1B P16 1
355 Filter 1 850 Locking ring 1
24-6
114
(3) PTO gear case (OPT)
No. Parts Q'TY No. Parts Q'TY

115 Idle shaft 1 435 Flange socket; M10X20 4
117 2nd gear 1 468 VP plug; PF3/4 1
118 3rd gear 1 710 O-ring; 1B G80 1
125 Ball bearing 2 711 O-ring; 1B G85 1
126 Roller bearing 1 728 O-ring; 1B P24 1
128 Bearing spacer 2 825 Snap ring 1
262 Cover 2 826 Snap ring 1
326 Gear case 1 885 Sprig pin 1
414 Capscrew; M10X20 4 886 Pin 2
24
24-7
115
24.1.1.2.2 OPERATION
The pump assy is equipped with two pumps
arranged on the same axis that are connected
with gear (116) and distribute the rotating power
to the gear trains on a different axis. Thus the
engine rotation is transmitted to front shaft (111)
that drives the two pumps and, at the same
time, drives the auxiliary pump (OPT) arranged
on another shaft.
The pump assy consists largely of the rotary
group, the main part of the pump that makes
rotary on; the swash plate group that changes
the delivery rate; the valve block group that
selects between oil suction and delivery and the
PTO group (OPT) that transmits the drive power
to the auxiliary pump.
Construction of hydraulic pump
(1) Rotary group

The rotary group consists of shaft(111) (113), cylinder block (141), piston (151), shoe (152), plate
(153), spherical bushing (156), bearing spacer (127), and cylinder spring (157).
The shaft is supported by bearings (123) and (124) at its both ends. The shoe, which is caulked to
the piston, forms a spherical joint and relieves it of thrust force that is generated by load pressure.
Further, the piston is provided with a pocket so it moves lightly on shoe plate (211), taking hydraulic
balance.
The sub group of the piston-shoe is pressed against the shoe plate by the cylinder spring, via the
retainer plate and the spherical bushing, so that it moves smoothly over the shoe plate. The cylinder
block (141) is also pressed against valve plate (314) by the action of cylinder spring (157).
Rotary group
24-8
116
(2) Swash plate group

The swash plate group consists of swash plate
(212), shoe plate (211), swash plate support
(251), lock pin (255), set spring (256), tilting
bushing (214), tilting pin (531), and servo piston
(532). The swash plate is the cylindrical part
that is formed on the opposite side of the
shoe sliding surface and is supported by the
swash plate support.
The hydraulic force controlled by the regulator
flows into the hydraulic chamber that is
provided on both sides of the servo piston. This
moves the servo piston to the right and left.
The result is that the swash plate swings on Swash plate group
the swash plate support via the spherical part
of the tilting pin and changes the tilting angle
(a).
(3) Valve block group

The valve block group consists of valve block
(312), valve plates (313 or 314), and spring
pin (886). The valve plates having two
crescent-shaped ports are installed to valve
block (312) to feed oil and recycle it from
cylinder block (141). The oil switched over by
the valve plate is connected with the external
pipe by way of the valve block.
Valve block group
24
24-9
117
(4) PTO group (OPT)

The PTO group is composed of 1st gear
(116), 2nd gear (117) and 3rd gear (118). The
2nd and the 3rd gear are supported by
bearings (125) and (126) respectively and
installed to the valve block.
Now, if the shaft is driven by the engine, the
cylinder block rotates together by the spline
linkage. If the swash plate is inclined, the
pistons arranged in the cylinder block make
reciprocating motion with respect to the
cylinder while rotating with the cylinder block.
If we keep an eye on a single piston, it
makes a motion away from the valve plate (oil
suction process) in the first 180?and a motion
toward the valve plate (oil delivery process) in PTO group
the remaining 180?. If the swash plate is not
inclined (zero tilting angle), the piston does not
stroke i.e. delivers no oil.
The shaft rotation is taken up by the 1st gear
(116) and transmitted to the 2nd gear (117) and
the 3rd gear (118), in that order, to drive the
gear pump that is linked to the 3rd gear.
24-10
118
24.1.1.3 REGULATOR
24.1.1.3.1 CONSTRUCTION
24-12
119
24
24-13
120
24
Regulator operation
24-15
121
24.1.2 CONTROL VALVE

24.1.2.1 SPECIFICATIONS
24.1.2.1.1 OUTSIDE VIEW
Outside view
24-20
122
24.1.2.1.3SPECIFICATIONS
Item Specifications
Model KMX13YD/B44001A
Maximum flow rate [L/min (gal/min)] 130 (34) X 2
Maximum set pressure [MPa (psi)] 37.8 (5480) (Pump port)/ 39.7 (5760) (Actuator port)
Main relief valve set pressure [MPa (psi)] Std 34.3 (4970) [at 30 X 2L/min (8 X 2gal/min)]
Overload relief valve set pressure [MPa (psi)] 37.8 (5480) [at 30L/min (8gal/min)]
24-22
123
24.1.3 PILOT VALVE (ATT)

24.1.3.1 OUTLINE
(1) Outside view
24
124
24-57
24.1.3.2 CONSTRUCTION
Pilot valve (ATT)
Tightening torque Tightening torque

No. NAME Q'TY No. NAME Q'TY
N-m (lbf-ft) N-m (lbf-ft)
101 Casing 1 *218-1 Seat 2
151 Plate 1 *218-2 Seat 2
201-1 Spool 2 221 Spring 4
201-2 Spool 2 241-1 Spring 2
211 Plug 4 241-2 Spring 2
212 Push rod 4 *246 Spring 4
213 Seal 4 47.1 (34.7) 301 Joint: M14 1
214 O-ring: 1B P20 4 302 Circular plate 1
216-1 Spring seat 2 68.6 (50.6) 312 Adjust nut: M14 1
216-2 Spring seat 2 501 Boots 1
217 Washer 2 (Shim) 4
Note) The parts marked * may not be equipped depending on valve type.
125
24-58
24.1.4 PILOT VALVE (TRAVEL)

24.1.4.1 OUTLINE
(1) Outside view
(2) Specifications
(3) Performance characteristics
24
24-61
126
24.1.5 SWING MOTOR UNIT

24.1.5.1 SPECIFICATION
(1) General view
127
24-64
(2) Specifications
Swing motor unit part No. YY15V00016F1
Type M2X63CHB-13A-36/285-60
Part No. YY15V00018F1
Displacement cm3 (in3) / rev 60 (3.66)
Rated pressure MPa (psi) 28.0 (4060)
Hydraulic motor
Braking torque N-m (lbf-ft) 314 (232)
Release pressure MPa (psi) 2.3 (334)
Relief set pressure MPa (psi) 28.0 (4060) at 110L/min (29 gal/min)
Weight kg (lbs) 29 (64)
Type RG06D19J2
Part No. YY32W00004F1
Gear oil SAE#90~#140 (API class GL-3~4
Lubicate oil
grade)
Reduction unit
Lubicate oil volume L (gal) 1.65 (0.44)
Grease Extreme pressure lithum base #2 grease
Grease volume cm3 (in3) 500 (30.5)
Weight kg (lbs) 79 (174)
Total weight kg (lbs) 113 (249)
24
128
24-65
24.1.5.2 CONSTRUCTION
(1) Swing motor
129
24-66
［33. UPPER SLEWING STRUCTURE］
33.2.6 SWIVEL JOINT

33.2.6.1 CONSTRUCTION VIEW 33
Construction of swivel joint
No. Part name Q'TY No. Part name Q'TY

1 Body 1 7 O-ring (G95 1A) 1
2 Stem 1 8 Socket bolt (M8X20) 2
3 Thrust plate 1 9 Socket bolt (M8X30) 3
4 Cover 1 12 Plug 1
5 Seal 5 13 O-ring (P80) 2
6 Seal assy 1
33-173
130
［34. TRAVEL SYSTEM］
34.2 REMOVAL AND INSTALLATION OF TRAVEL MOTOR UNIT
34.2.1 CONSTRUCTION OF TRAVEL MOTOR

34.2.1.1 CROSS-SECTIONAL VIEW OF TRAVEL MOTOR ASSEMBLY
34
34-41
131
［34. TRAVEL SYSTEM］
132
34-42
133

134
GENERAL
Table 1-1 Main specifications (2 / 3)

Engine model D04FR-TAA
Forced circulation type
Lubricating method
(pressure feed by oil pump)
Standard API classification CF-4 or above class
Engine oil
Engine oil capacity Engine total: approx. 17.5 L [4.62 US gallons]
Type Gear type oil pump
Oil pump 40 L [10.57 US gallons]/min
Delivery capacity
Lubrication (at pump rotation of 1800 min-1)
system Type Piston valve type
Relief valve 0.35 ± 0.05 MPa
Valve opening pressure
{3.5 ± 0.5 kgf/cm²} [50 ± 7 psi]
Oil cooler Type Water-cooled, multi-plate type
Oil filter Type Cartridge type paper element
1.1 MPa
Safety valve Opening pressure
{11 kgf/cm²} [157 psi]
Cooling method Water-cooled, forced circulation
Coolant capacity (Engine water jacket) 6 L [1.6 US gallons] approx.
Type Centrifugal
Water pump 133 L [35 US gallons]/min
Discharge capacity
(at pump rotation of 1800 min-1)
Cooling
Water pump pulley Speed ratio Varies depending on the specifications
system
Fan belt Type Ribbed belt
Fan Type ø600 mm [23.62 in.]
Type Wax type
Thermostat Valve opening
71 ± 2°C [160 ± 3.6°F]
temperature
Inlet and Model number TD04HL
exhaust Turbocharger
system Qty 1
Control ECU Model number EDC16UC40

system (Electronic Control Unit) Manufacturer Bosch Corporation
1-8 135
GENERAL
1. External view
Oil filler
Exhaust manifold
Front hanger Turbocharger
Thermostat
Fan Rear hanger
Front Rear
Alternator
Crankshaft pulley
Starter
Belt
Oil pan
Engine left view
Inlet manifold
Breather
Oil level gauge
Air heater
Oil filter Water pump
Rear Front
Common rail
Fuel pump
Flywheel housing Oil pump
Flywheel
Engine right view
1-2 134
136
GENERAL
2. System flow diagrams

2.1 Fuel system - flow diagram
Injector
Common rail
Fuel pump
To fuel tank
From fuel tank
Fuel system - flow diagram
2.2 Lubrication system - flow diagram
Tappet Turbocharger Valve mechanism
Piston
Camshaft
Piston cooling nozzle
Oil filter
Main gallery
Oil cooler
Timing gear
Relief valve
Oil pump
Crankshaft
Oil strainer
Safety valve
Lubrication system - flow diagram
137
135 1-3
GENERAL
2.3 Cooling system - flow diagram
Outlet
Thermostat
Cylinder head
Bypass pipe
Inlet
Oil cooler Water pump
Water jacket
Cooling system - flow diagram
2.4 Inlet and exhaust system - flow diagram
Inlet
Exhaust Turbocharger
Muffler
Cylinder
Inlet and exhaust system - flow diagram
1-4 138
GENERAL
2.5 Electrical system - wiring diagram
Injector power supply

Air heater relay
Inlet manifold pressure sensor
Water temperature sensor
Common rail
Common rail pressure sensor
Speed/timing sensor
(Camshaft side)
Speed/timing sensor
(Crankshaft side)
High pressure pump
High pressure pump

Engine oil pressure switch solenoid sensor (MPROP)
Connector
Electronic control unit
Electrical system - wiring diagram

133
139 1-5
2.Engine General
Boost Pressure Sensor P.A-2-3
Mechatro -Rpm Sensor VA329000700
VA32G9000100 Water Temp Sensor
VA32G9000200
Cam Sensor
VA32G9000600
ECU Rpm
Sensor
VA32G9000600
Oil Pressure Switch

VA3439040200
1
Mechatro -Rpm Sensor VA32G9000100
GENERAL
3. Engine serial number location

The engine serial number is stamped on the side of the
crankcase.
Engine serial number
Stamp location of engine serial number
1-6 140
GENERAL
Table 1-1 Main specifications (3 / 3)

Engine model D04FR-TAA
Manufacturer Nikko Electric Industry
Type 0-24000-0188
Pinion meshing type Pinion shift
Output 24V - 5kW
Qty 1
Ring gear and pinion ratio 10/127
Voltage 23V
Starter No-load
Current 85A or below
characteristics
Speed 3300 min-1 or more
Voltage 9V
Load
Current 1400A or below
characteristics
Torque 88.26 N·m {9.0 kgf·m} [65 lbf·ft] or above
Minimam operating
16V or below
Electrical voltage
system Minimam holding voltage 8V or below
Manufacturer Nikko Electric Industry
Model number 0-35000-4838
Output 24V - 50A
Rated speed 5000 min-1
Direction of rotation Clockwise when viewed from pulley side
Alternator
Drive system PK type, V ribbed, 12 ribs
Ground system One conductor (-) side
Regulated voltage 28.5V ± 1V
Temperature range
-30 to +100°C [-22 to +212°F]
tolarance
Type Electric heater
Air heater
Capacity 2.1kW
Heater relay Fuse capacity 127A
141 1-9
Fuel system
SK130HDL
2.1 - MHI
Removing D04FR(Part
fuel system ENGINE
1) FUEL SYSTEM
Replace: Sealing washer 8

B
O-ring
Gasket
Leak off hose 6
10
2
3
4 1
5 11
16
A
18 14
17 D
15 7 9
B
C 13
C
21
22
12
23
19
D
A 20
Removing fuel system (Part 1)

Removing sequence
1 Pipe clamp 9 Fuel pipe 17 Nozzle ground

2 No.1 injection pipe 10 Bracket 18 Injector
3 No.2 injection pipe 11 Bolt 19 Fuel pump nut
4 No.3 injection pipe 12 Hose clamp 20 Fuel pump flange, fuel pump
5 No.4 injection pipe 13 Fuel hose 21 Head assembly
6 Leak off hose 14 Fuel return pipe 22 Fuel filter element
7 Fuel hose 15 Common rail 23 Water sedimenter
8 Pipe clamp 16 Hexagon bolt
142 8-3
［46. TROUBLE SHOOTING (BY ERROR CODES)］
46.2 CLASSIFICATION OF FAILURE AND TROUBLESHOOTING
Classify failures into the following 3 types and carry out the troubleshooting.
No. Classes of failure Troubleshooting

A When error code after self-diagnosis is displayed Carry out troubleshooting according to the error code.
on gauge cluster
B When no failure is detected currently but error When it is hard to recreate the failure situation,
code after self diagnosis is remained in trouble cancel the data in the history and reproduce the
history failed situation or suppose the cause according to
the troubleshooting by error code, and then repair it.
C When error code after self diagnosis is not -Carry out troubleshooting according to instructions in
displayed or is not remained in the history Chapter 47 "TROUBLESHOOTING BY TROUBLE".
-Carry out troubleshooting according to instructions in
Chapter 48 "TROUBLE DIAGNOSIS MODE".
143
46-4
46.3 THE BLOWN FUSE OF MECHATRO CONTROLLER
If the fuse of mechatro controller has blown, the following display appears on the gauge cluster.
(1) The blown fuse of mechatro controller
a. Blown fuse 5A of mechatro controller :

"DATA COMMUNICATION ERROR" is displayed on the gauge cluster in the condition where the
controller program is not executed.
b. Blown fuse 20A of mechatro controller
The controller functions normally but the power supply applied when the controller drives the
solenoid, etc. stops.
Many error codes are displayed on the gauge cluster.
D013, D023, D033, D063,
E013, E023, F021
46
46-5
144
46.4 TROUBLESHOOTING BY ERROR CODE
When error code was displayed on the gauge cluster with the aid of self-diagnosis display function,
carry out the troubleshooting referring to applicable page in the contents of error codes.
Error Code Trouble

A025 Pump propo. valve adjustment (B adjustment) is not adjusted yet or is failed.
A035 Unload valve adjustment (C adjustment) is not adjusted yet or is failed.
A215 Written data of ROM adjustment data is incorrect.
A225 Writing of ROM adjustment data is incorrect.
A235 Written data of ROM hour meter data is incorrect.
A245 Writing of ROM hour meter data is incorrect.
A255 Writing of proportional valve adjustment data is incorrect.
B012 Incorrect output of boom up pressure sensor
B013 Disconnection of boom up pressure sensor
B014 Short-circuit of boom up pressure sensor
B022 Incorrect output of boom down pressure sensor
B023 Disconnection of boom down pressure sensor
B024 Short-circuit of boom down pressure sensor
B032 Incorrect output of arm out pressure sensor
B033 Disconnection of arm out pressure sensor
B034 Short-circuit of arm out pressure sensor
B042 Incorrect output of arm in pressure sensor
B043 Disconnection of arm in pressure sensor
B044 Short-circuit of arm in pressure sensor
B052 Incorrect output of bucket digging pressure sensor
B053 Disconnection of bucket digging pressure sensor
B054 Short-circuit of bucket digging pressure sensor
B062 Incorrect output of bucket dump pressure sensor
B063 Disconnection of bucket dump pressure sensor
B064 Short-circuit of bucket dump pressure sensor
B072 Incorrect output of swing pressure sensor
B073 Disconnection of swing pressure sensor
B074 Short-circuit of swing pressure sensor
B092 Incorrect output of travel right pressure sensor
B093 Disconnection of travel right pressure sensor
B094 Short-circuit of travel right pressure sensor
B102 Incorrect output of travel left pressure sensor
B103 Disconnection of travel left pressure sensor
B104 Short-circuit of travel left pressure sensor
B113 Disconnection of pressure sensor of optional selector positioning
B114 Short-circuit of pressure sensor of optional selector positioning
46-6
145
Error Code Trouble

B162 Incorrect output of P1 optional side pressure sensor
B163 Disconnection of P1 side optional pressure sensor
B164 Short-circuit of P1 side optional pressure sensor
B172 Incorrect output of P2 optional side pressure sensor
B173 Disconnection of P2 side optional pressure sensor
B174 Short-circuit of P2 side optional pressure sensor
C012 Incorrect output of P1 pump pressure sensor
C013 Disconnection of P1 pump pressure sensor
C014 Short-circuit of P1 pump pressure sensor
C022 Incorrect output of P2 pump pressure sensor
C023 Disconnection of P2 pump pressure sensor
C024 Short-circuit of P2 pump pressure sensor
C033 Disconnection of boom head pressure sensor
C034 Short-circuit of boom head pressure sensor
D012 Failure of output transistor ON at P1 unload proportional valve
D013 Disconnection of P1 unload proportional valve
D022 Failure of output transistor ON at P2 unload proportional valve
D023 Disconnection of P2 unload proportional valve
D032 Failure of output transistor ON at travel straight proportional valve
D033 Disconnection of travel straight proportional valve
D062 Failure of output transistor ON at arm in high speed proportional valve
D063 Disconnection of arm in high speed proportional valve
E012 Failure of output transistor ON at P1 pump proportional valve
E013 Disconnection of P1pump proportional valve
E022 Failure of output transistor ON at P2 pump proportional valve
E023 Disconnection of P2 pump proportional valve
F021 Failure of output transistor OFF and GND short of swing parking SOL valve 46
F023 Failure of output transistor ON and disconnection of swing parking SOL valve
F031 Failure of output transistor OFF and GND short of travel 1-2 speed SOL valve
F033 Failure of output transistor ON and disconnection of travel 1-2 speed SOL valve
F041 Failure of output transistor OFF and GND short of optional selector SOL valve
F043 Failure of output transistor ON and disconnection of optional selector SOL valve
G032 Overrun of speed sensor of direct input Mechatro-controller
G033 Disconnection of speed sensor of direct input Mechatro-controller
G042 Overrun of speed sensor of direct input Mechatro-controller and received data from E/G controller.
Disconnection of speed sensor of direct input Mechatro-controller and received data from E/G
G043
controller.
H013 Disconnection of acceleration potentio
H014 Power short-circuit of acceleration potentio
H091 Failure of GND short-circuit of fuel sensor
H093 Disconnection of fuel sensor
46-7
147
Error Code Trouble

I111 Received error of CAN1 communication (passive error)
I113 Received error of CAN1 communication (time-out)
I313 Received error of cluster communication (time-out error)
K014 Adhesion of battery relay terminal
R014 Failure of arc prevention relay of wiper motor
R024 Failure of normal rotation relay of wiper motor
R034 Failure of reverse rotation relay of wiper motor
R044 Failure of washer motor relay
R134 Failure of swing right flasher relay
R144 Failure of swing left flasher relay
R154 Failure of travel alarm relay
R164 Failure of auto idling stop relay 2
R174 Failure of engine forcible stop relay
R184 Failure of lever lock relay
46-8
147
TROUBLESHOOTING
4. Diagnosis code cross reference

The P code shown in the table below is displayed by connecting the scan tester to the service connector.
The vehicle side code is displayed on the vehicle monitor. Check the corresponding codes by following chart.
For the detail and treatment of diagnosis codes, refer to "Troubleshooting reference chart".
Note: The word "DBV" in the table is an abbreviation of pressure limiting valve.
Table 14-1 Diagnosis code cross reference (2 / 4)

Table 14-1 Diagnosis code cross reference (1 / 4)
J1939 Vehicle
J1939 Vehicle P
P Item code side
Item code side code
code (DTC) code
(DTC) code
Shut off
Discrepancy between P0215 1110-2 1110-4
P0016 228-3 228-1 pass test
crank and cam signal
Shut off
Backup control using P0215 1110-12 1110-8
P0021 635-3 635-1 pass test
cam side signal
MPROP power stage
P0089 DBV valve opening 2041-3 2041-1 P0230 2001-3 2001-1
short-circuit to battery
P0089 DBV kick off 2042-4 2042-2 MPROP power stage
P0231 2002-4 2002-2
P0090 DBV closed sticking 2043-2 2043-4 short-circuit to ground
P0091 DBV pressure is too low 2045-4 2045-2 MPROP power stage open
P0252 2000-2 2000-4
circuit
P0092 DBV pressure is too high 2044-3 2044-1
MPROP power stage over-
P0117 Water temperature sensor 110-4 110-2 P0252 2000-12 2000-8
load
P0118 Water temperature sensor 110-3 110-1 Inlet manifold pressure
P0235 102-12 102-8
sensor
Accelerator signal
P0121 383-12 383-8
diagnosis Inlet manifold pressure
P0237 102-4 102-2
sensor
P0122 Accelerator sensor 1 29-4 29-2
Inlet manifold pressure
P0123 Accelerator sensor 1 29-3 29-1 P0238 102-3 102-1
sensor
Rail pressure governor
P0191 2013-3 2013-1 P0261 Injector No.1 657-2 657-4
deviation
P0262 Injector No.1 657-3 657-1
Rail pressure governor
P0191 2014-3 2014-1
deviation P0263 Injector No.1 657-12 657-8
Rail pressure governor P0264 Injector No.2 659-2 659-4
P0191 2015-3 2015-1
deviation
P0265 Injector No.2 659-3 659-1
P0192 Rail pressure SRC 2011-4 2011-2
P0266 Injector No.2 659-12 659-8
P0193 Rail pressure SRC 2011-3 2011-1
P0267 Injector No.3 661-2 661-4
Rail pressure sensor
P0192 2012-4 2012-2 P0268 Injector No.3 661-3 661-1
offset monitoring
Rail pressure sensor P0269 Injector No.3 661-12 661-8
P0193 2012-3 2012-1
offset monitoring P0270 Injector No.4 663-2 663-4
P0194 Rail pressure governor 2016-3 2016-1 P0271 Injector No.4 663-3 663-1
P0194 Rail pressure governor 2017-3 2017-1 P0272 Injector No.4 663-12 663-8
P0201 Injector No.1 658-2 658-4 Speed/timing sensor
P0336 637-4 637-2
P0202 Injector No.2 660-2 660-4 (crankshaft side)
P0203 Injector No.3 662-2 662-4 Speed/timing sensor

P0339 637-3 637-1
(crankshaft side)
P0204 Injector No.4 664-2 664-4
Speed/timing sensor
P0341 636-4 636-2
Shut off (camshaft side)
P0215 1110-4 1110-2
pass test
Speed/timing sensor
P0344 636-3 636-1
(camshaft side)
14-14 148
TROUBLESHOOTING
Table 14-1 Diagnosis code cross reference (3 / 4) Table 14-1 Diagnosis code cross reference (4 / 4)
J1939 Vehicle J1939 Vehicle
P P
Item code side Item code side
code code
(DTC) code (DTC) code
Air heater relay P060B ADC monitoring 2008-4 2008-2
P0540 677-12 677-8
power stage
P060B ADC monitoring 2008-2 2008-4
Air heater relay
P0541 677-4 677-2 P060B ADC monitoring 2008-12 2008-8
power stage
P060D CAN accelerator 91-2 91-4
Air heater relay
P0542 677-3 677-1
power stage P060E APPREQ message time out 1674-2 1674-4
Air heater relay P061C Engine speed 2005-3 2005-1
P0543 677-2 677-4
power stage
Injector
P062D 651-12 651-8
Power supply unit voltage drive bank 1
P0562 1543-4 1543-2
too low
Injector
P062E 653-12 653-8
Power supply unit voltage drive bank 2
P0563 1542-3 1542-1
too high
P062F EEPROM 1235-4 1235-2
P0600 CAN transmitting time out 2028-2 2028-4
P062F EEPROM 1235-2 1235-4
P0600 CAN (A) pass off 1671-3 1671-1
P062F EEPROM 1235-12 1235-8
P0600 CAN (C) pass off 1673-3 1673-1
P0933 Oil pressure switch 19-12 19-8
P0606 SPI communication error 1231-3 1231-1
P0933 Oil pressure switch 100-12 100-8
P0606 Super vision 1484-12 1484-8
Injector
P2047 652-2 652-4
P0607 Recovery occurred 1668-12 1668-8 drive bank 1
P0607 Recovery occurred 1670-12 1670-8 Injector
P2048 651-4 651-2
drive bank 1
P0607 SPI watch dog error 2010-12 2010-8
Injector
P0611 Injector IC 655-3 655-1 P2049 651-3 651-1
drive bank 1
P0611 Injector IC 655-4 655-2
Injector
P2050 654-2 654-4
P0611 Injector IC 655-2 655-4 drive bank 2
P0611 Injector IC 655-12 655-8 Injector
P2051 653-4 653-2
drive bank 2
P0611 Injector IC 656-3 656-1
Injector
P0611 Injector IC 656-4 656-2 P2052 653-3 653-1
drive bank 2
P0611 Injector IC 656-2 656-4
Atmospheric pressure sen-
P2228 108-4 108-2
P0611 Injector IC 656-12 656-8 sor
Sensor supply voltage Atmospheric pressure sen-

P0642 1079-4 1079-2 P2229 108-3 108-1
monitoring 1 sor
Sensor supply voltage

P0643 1079-3 1079-1
monitoring 1
P0652 1080-4 1080-2
monitoring 2
P0653 1080-3 1080-1
monitoring 2
P0698 620-4 620-2
monitoring 3
P0699 620-3 620-1
monitoring 3
P060A TPU monitoring 2009-12 2009-8
P060B ADC monitoring 2008-3 2008-1
149 14-15
TROUBLESHOOTING
5. Troubleshooting reference chart

5.1 Troubleshooting with diagnosis code
Note: The diagnosis codes which has * mark in the "Recovery" column recovers when the cause of fault has deleted and the
engine has restarted.
P0016 : Discrepancy between speed/timing sensor P0117 : Water temperature sensor

(crankshaft side/camshaft side) signal Vehicle side code : 110-2
Vehicle side code : 228-1 Faulty part Water temperature sensor
Speed/timing sensor The ECU detects a faulty operation of
Faulty part
(crankshaft side/camshaft side) the water temperature sensor (open cir-
Detail
The ECU detects a discrepancy between cuit, short circuit). The input voltage
Detail speed/timing sensor (crankshaft side/ falls below the limiting value.
camshaft side) signal. Recovery *
Recovery * When engine is operated, the ECU con-
The ECU controls the engine using trols the engine as overheated
speed/timing sensor (crankshaft side) with fixing the temperature 120°C
Control signal. Control (warm mode). When starting the engine,
The ECU limits the maximum power of the ECU controls the engine with fixing
the engine. the water temperature -20°C (cold
mode).
Power limit The maximum power is limited to 50%.
When the water temperature is 100°C or
Inspection Contact a Mitsubishi dealer. Power limit above, the ECU controls the engine as
overheated.
P0021 : Backup control using camshaft side signal
Water temperature sensor, and wiring of
Vehicle side code : 635-1 Inspection
water temperature sensor.
Speed/timing sensor
Faulty part
(crankshaft side) P0118 : Water temperature sensor
The engine is operating without speed/ Vehicle side code : 110-1
timing sensor (crankshaft side) signal. Faulty part Water temperature sensor
Detail
The ECU controls the engine using cam-
shaft side signal only. The input voltage exceeds the limiting
Detail
value.
Recovery *
Recovery *
The ECU limits the maximum power of
Control When engine is operated, the ECU con-
the engine.
trols the engine as overheated
Power limit The maximum power is limited to 50%. with fixing the temperature 120°C
Speed/timing sensor (crankshaft side) Control (warm mode). When starting the engine,
Inspection and wiring of speed/timing sensor the ECU controls the engine with fixing
(crankshaft side). the water temperature -20°C (cold
mode).
When the water temperature is 100°C or
Power limit above, the ECU controls the engine as
overheated.
Water temperature sensor, and wiring of
Inspection
water temperature sensor.
14-16 150
TROUBLESHOOTING
P0121 : Accelerator signal diagnosis P0191 : Rail pressure governor deviation

Vehicle side code : 383-8 Vehicle side code : 2013-1
Accelerator signal (CAN signal, analog Faulty part Common rail
Faulty part
signal)
The rail pressure control is abnormal.
Detail
The ECU compares the CAN signal and The target pressure is not achieved.
Detail analog signal, and detects a discrepancy
Recovery *
between them.
The ECU limits the maximum power of
When a discrepancy is deleted, it recov- Control
Recovery the engine.
ers automatically.
Control The ECU warns to the operator.
Inspection Damage on the common rail.
Power limit -
Inspection CAN signal and analog signal wiring.
Vehicle side code : 2014-1
P0122 : Accelerator sensor 1
Faulty part Common rail
The rail pressure control is abnormal.
Faulty part Accelerator signal (analog signal)
Detail The target pressure is not achieved even
The ECU detects a faulty analog signal fully pressured by fuel pump.
Detail input from vehicle controller. The input
Recovery *
voltage falls below the limiting value.
Control Engine stop
When the input voltage recovers to the
Recovery specified value, it recovers automati- Power limit -
cally.
When operating by CAN signal, the
ECU warns to the operator. When oper- P0192 : Rail pressure sensor offset monitoring
Control ating by analog signal, the ECU warns
to the operator and the engine operation
switches to the redundancy operation. Faulty part Rail pressure sensor
Power limit - The input voltage falls below the limit-
Detail
ing value.
Inspection Accelerator signal (analog signal)
Recovery *
P0123 : Accelerator sensor 1 Accelerator opening ratio is fixed to
Vehicle side code : 29-1 Control
12%.
Faulty part Accelerator signal (analog signal) Power limit -
The ECU detects a faulty analog signal Rail pressure sensor, and wiring of rail
Detail input from vehicle controller. The input Inspection
pressure sensor.
voltage exceeds the limiting value.
When the input voltage recovers to the
Recovery specified value, it recovers automati-
cally.
When operating by CAN signal, the
ECU warns to the operator. When oper-
Control ating by analog signal, the ECU warns
to the operator and the engine operation
switches to the redundancy operation.
Power limit -
Inspection Accelerator signal (analog signal)
151 14-17
TROUBLESHOOTING
P0193 : Rail pressure sensor offset monitoring P0202 : Injector No.2

Faulty part Rail pressure sensor Faulty part Injector No.2
The input voltage exceeds the limiting The ECU detects an open circuit of the
Detail Detail
value. injector and/or injector harness.
Recovery * Recovery *
Accelerator opening ratio is fixed to The engine keeps operating if only one
Control
12%. Control injector is faulty. The engine stops if
two or more injectors are faulty.
Power limit -
There is no specific control by the ECU,
Rail pressure sensor, and wiring of rail Power limit
Inspection but the engine power decreases.
pressure sensor.
Inspection Injector, and wiring of injector.
P0194 : Rail pressure governor
Vehicle side code : 2016-1 P0203 : Injector No.3
Faulty part Injector No.3
The rail pressure falls below the limiting
Detail
value. The ECU detects an open circuit of the
Detail
injector and/or injector harness.
Recovery *
Recovery *
Control Engine stop
The engine keeps operating if only one
Power limit -
Control injector is faulty. The engine stops if two
Inspection Damage on the common rail. or more injectors are faulty.
P0201 : Injector No.1 Power limit
but the engine power decreases.
The ECU detects an open circuit of the P0204 : Injector No.4
Detail
injector and/or injector harness. Vehicle side code : 664-4
Recovery * Faulty part Injector No.4
The engine keeps operating if only one The ECU detects an open circuit of the
Detail
Control injector is faulty. The engine stops if two injector and/or injector harness.
or more injectors are faulty.
Recovery *
Power limit The engine keeps operating if only one
Control injector is faulty. The engine stops if two
Inspection Injector, and wiring of injector. or more injectors are faulty.
Power limit
14-18 152
TROUBLESHOOTING
P0215 : Shut off pass test P0235 : Inlet manifold pressure sensor
Faulty part ECU Inlet manifold pressure sensor power
Faulty part
supply line
The emergency injection stop circuit
Detail does not operate. The shut-off by watch The ECU detects an open circuit or short
Detail
dog is disabled. circuit of the sensor power supply (5V).
Control The ECU warns to the operator. The ECU controls the engine fixing the
Control value to the backup data.(Approx. 1013
Power limit -
hpa)
Inspection Contact a Mitsubishi dealer.
Inlet manifold pressure sensor power
Inspection
Vehicle side code : 1110-4 supply line wiring
Faulty part ECU P0237 : Inlet manifold pressure sensor

The emergency injection stop circuit Vehicle side code : 102-2
Detail does not operate. The shut off by high
Faulty part Inlet manifold pressure sensor
voltage monitoring is disabled.
The ECU detects the faulty operation of
Recovery *
the inlet manifold pressure sensor (open
Control The ECU warns to the operator. Detail circuit, short circuit, characteristic
fault). The input voltage falls below the
Power limit - limiting value.
Inspection Contact a Mitsubishi dealer. Recovery *
The ECU controls the engine using the
Control
backup data.
Faulty part ECU
Inlet manifold pressure sensor, and wir-
The emergency injection stop circuit Inspection
ing of inlet manifold pressure sensor.
Detail does not operate. The shut off by low
voltage monitoring is disabled.
P0238 : Inlet manifold pressure sensor
Recovery * Vehicle side code : 102-1
Control The ECU warns to the operator. Faulty part Inlet manifold pressure sensor
Power limit - The input voltage exceeds the limiting
Detail
Inspection Contact a Mitsubishi dealer. value.
Recovery *
P0231 : MPROP power stage short-circuit to ground
Vehicle side code : 2002-2 Control
backup data.
Faulty part MPROP
The ECU detects a short circuit on the
Detail Inlet manifold pressure sensor, and wir-
ground line of the MPROP harness. Inspection
ing of inlet manifold pressure sensor.
Recovery *
Accelerator opening ratio is fixed to
Control
12%.
Power limit -
Inspection MPROP, and wiring of MPROP.
153 14-19
TROUBLESHOOTING
P0261 : Injector No.1 P0265 : Injector No.2

Faulty part Injector No.1 Faulty part Injector No.2
The ECU detects a short circuit of the The injector is faulty. The low side is a
Detail
injector and/or injector harness. There short circuit to the battery (+).
Detail
are short circuits on the high side and
Recovery *
low side.
Control Engine stop
Recovery *
Power limit -
Control Engine stop
Power limit -
Inspection Injector, and wiring of injector. P0266 : Injector No.2
P0262 : Injector No.1
Unclassifiable error in the injector and/
Detail or the injector harness. The injector is
The injector is faulty. The low side is a disabled.
Detail
short circuit to the battery (+).
Recovery *
Recovery *
Control Engine stop
Control Engine stop
Power limit -
Power limit -
P0263 : Injector No.1 Vehicle side code : 661-4
The ECU detects a short circuit of the
Unclassifiable error in the injector and/ injector and/or injector harness. There
Detail
Detail or the injector harness. The injector is are short circuits on the high side and
disabled. low side.
Control Engine stop Control Engine stop
Power limit - Power limit -
Inspection Injector, and wiring of injector. Inspection Injector, and wiring of injector.
P0264 : Injector No.2 P0268 : Injector No.3

Faulty part Injector No.2 Faulty part Injector No.3
The ECU detects a short circuit of the The injector is faulty. The low side is a
Detail
injector and/or injector harness. There short circuit to the battery (+).
Detail
Recovery *
low side.
Control Engine stop
Recovery *
Power limit -
Control Engine stop
Power limit -
14-20 154
TROUBLESHOOTING
P0269 : Injector No.3 P0336 : Speed/timing sensor (crankshaft side)

Faulty part Injector No.3 Speed/timing sensor
Faulty part
(crankshaft side)
Detail or the injector harness. The injector is The ECU detects the fault of speed/tim-
disabled. ing sensor (crankshaft side)(open cir-
Detail cuit, short circuit, tooth breakage). The
Recovery *
number of crank pulse and/or crank
Control Engine stop pulse position are faulty.
Power limit - Recovery *
Inspection Injector, and wiring of injector. The ECU controls the engine using the
Control speed/timing sensor (camshaft side) sig-
P0270 : Injector No.4 nal.
Vehicle side code : 663-4 The maximum power is limited to 50%
Power limit
only when starting the engine.
Speed/timing sensor (crankshaft side),
Inspection and wiring of speed/timing sensor
injector and/or injector harness. There
Detail (crankshaft side).
low side.
P0339 : Speed/timing sensor (crankshaft side)
Recovery * Vehicle side code : 637-1
Control Engine stop Speed/timing sensor
Faulty part
Power limit - (crankshaft side)
Inspection Injector, and wiring of injector. The speed/timing sensor (crankshaft

Detail side) is faulty. The ECU is not receiving
P0271 : Injector No.4 the crank pulse.
Vehicle side code : 663-1 Recovery *
Faulty part Injector No.4 The ECU controls the engine using the
Control speed/timing sensor (camshaft side) sig-
The injector is faulty. The low side is a
Detail nal.
short circuit to the battery (+).
The maximum power is limited to 50%
Recovery * Power limit
only when starting the engine.
Control Engine stop
Speed/timing sensor (crankshaft side),
Power limit - Inspection and wiring of speed/timing sensor
(crankshaft side).

Detail or the injector harness. The injector is
disabled.
Recovery *
Control Engine stop
Power limit -
156 14-21
TROUBLESHOOTING
P0341 : Speed/timing sensor (camshaft side) P0541 : Air heater relay power stage
Speed/timing sensor Faulty part Air heater relay
Faulty part
(camshaft side)
The air heater relay and/or connecting
Detail
The ECU detects the fault of speed/tim- harness are short circuits to the ground.
ing sensor (camshaft side) (open circuit,
Recovery *
Detail short circuit, tooth breakage). The num-
ber of cam pulse and/or cam pulse posi- The air heater is disabled. The ECU
tion are faulty. Control
warns to the operator.
Recovery * Power limit -
The ECU controls the engine using Inspection Air heater relay, and wiring of air heater.
Control speed/timing sensor (crankshaft side)
signal. The ECU warns to the operator. P0542 : Air heater relay power stage
Power limit - Vehicle side code : 677-1
Speed/timing sensor (camshaft side), Faulty part Air heater relay
Inspection and wiring of speed/timing sensor (cam-
The air heater relay is faulty. The air
shaft side).
Detail heater relay is a short circuit to the bat-
tery.
P0344 : Speed/timing sensor (camshaft side)
Vehicle side code : 636-1 Recovery *
Speed/timing sensor The air heater is disabled. The ECU

Faulty part Control
(camshaft side) warns to the operator.
The speed/timing sensor (camshaft side) Power limit -

Detail is faulty. The ECU is not receiving the Inspection Air heater relay, and wiring of air heater.
cam pulse.
Recovery * P0543 : Air heater relay power stage
The ECU controls the engine using
Control speed/timing sensor (crankshaft side) Faulty part Air heater relay
signal. The ECU warns to the operator.
The ECU detects an open circuit of air
Detail
Power limit - heater relay and/or connecting harness.
Speed/timing sensor (camshaft side), Recovery *
Inspection and wiring of speed/timing sensor (cam-
The air heater is disabled. The ECU
shaft side). Control
P0540 : Air heater relay power stage Power limit -
Vehicle side code : 677-8 Inspection Air heater relay, and wiring of air heater.
Faulty part Air heater relay
P0562 : Power supply unit voltage too low
The ECU detects an overload of air
Detail Vehicle side code : 1543-2
heater relay and/or connecting harness.
Faulty part ECU
Recovery *
The voltage of the power supply unit
The air heater is disabled. The ECU
Control Detail inside the ECU falls below the limiting
value.
Power limit -
Recovery *
Inspection Air heater relay, and wiring of air heater.
Control Engine stop
Power limit -
Inspection Replace the ECU.
14-22 156
TROUBLESHOOTING
P0563 : Power supply unit voltage too high P0600 : CAN (C) pass off
Faulty part ECU Faulty part CAN communication line
The voltage of the power supply unit The CAN communication is faulty. The
Detail
Detail inside the ECU exceeds the limiting ECU detects the CAN (C) pass off.
value.
Recovery *
Recovery *
The ECU uses the analog signal for
Control Engine stop Control backup control. The ECU warns to the
operator.
Power limit -
Power limit -
Inspection CAN communication line, and ECU.
P0600 : CAN transmitting time out
Vehicle side code : 2028-4 P0606 : SPI communication error
Faulty part CAN communication line
Faulty part ECU
The CAN message cannot be transmit-
Detail
ted. There are serial communication errors
Detail
between CPU and other IC.
Recovery *
Recovery *
Control
backup control. Control Engine stop
Inspection CAN communication line, and ECU. Inspection Replace the ECU.
P0600 : CAN (A) pass off P0606 : Super vision

Faulty part CAN communication line Faulty part ECU
The CAN communication is faulty. The The ECU detects an abnormality by
Detail
Detail ECU detects an open circuit or short cir- using self-diagnosis function.
cuit of CAN line.
Recovery *
Recovery *
Control Engine stop
Power limit -
Control backup control. The ECU warns to the
operator. Inspection Replace the ECU.
Power limit -
P0607 : Recovery occurred
Inspection CAN communication line, and ECU. Vehicle side code : 1668-8
Faulty part ECU
The recovery occurred by the fault of the
Detail
ECU.
Recovery *
Power limit -
Inspection -
157 14-23
TROUBLESHOOTING

Faulty part ECU Faulty part ECU
The recovery occurred by the fault of the The injector control IC inside the ECU
Detail Detail
ECU. is faulty.
Control The ECU warns to the operator. Control Engine stop
Inspection - Inspection Replace the ECU.
P0607 : SPI watch dog error

The ECU detects an abnormality by The injector control IC inside the ECU
Detail
Detail using self-diagnosis function. Watch dog is faulty.
error.
Recovery *
Recovery occurs. It recovers automati-
Control Engine stop
cally if an error occurs three times in
Recovery two seconds. The engine stops if an Power limit -
error occurs four times or more in two
seconds. Inspection Replace the ECU.
Control Engine stop

Inspection Replace the ECU. Faulty part ECU

The injector control IC inside the ECU
P0611 : Injector IC Detail
is faulty.
Recovery *
Faulty part ECU
Control Engine stop
Detail Power limit -
is faulty.
Recovery * Inspection Replace the ECU.
Control Engine stop

Inspection Replace the ECU. Faulty part ECU

Detail
is faulty.
Recovery *
Faulty part ECU
Control Engine stop
Detail Power limit -
is faulty.
Recovery * Inspection Replace the ECU.
Control Engine stop

Power limit -
14-24 158
TROUBLESHOOTING
P0652 : Sensor supply voltage monitoring 2

The injector control IC inside the ECU The 5V power supply to the inlet mani-
Detail
is faulty. fold pressure sensor is faulty. The sup-
Detail
ply voltage falls below the limiting
Recovery *
value.
Control Engine stop
Recovery *
Power limit -
Control
Inspection Replace the ECU. backup data.
Vehicle side code : 656-8 Inspection Replace the ECU.
Faulty part ECU P0653 : Sensor supply voltage monitoring 2

The injector control IC inside the ECU Vehicle side code : 1080-1
Detail
is faulty.
Faulty part ECU
Recovery *
The 5V power supply to the inlet mani-
Control Engine stop Detail fold pressure sensor is faulty. The sup-
ply voltage exceeds the limiting value.
Power limit -
Recovery *
Control
P0642 : Sensor supply voltage monitoring 1 backup data.
Vehicle side code : 1079-2 Power limit The maximum power is limited to 75%.
Faulty part ECU Inspection Replace the ECU.
The 5V power supply to the PTO accel-
Detail erator signal is faulty. The supply volt- P0698 : Sensor supply voltage monitoring 3
age falls below the limiting value. Vehicle side code : 620-2
Recovery * Faulty part ECU
Control The ECU warns to the operator. The 5V power supply to the rail pressure
Detail sensor is faulty. The supply voltage falls
Power limit - below the limiting value.
Inspection Replace the ECU. Recovery *
P0643 : Sensor supply voltage monitoring 1 Control The ECU warns to the operator.
Vehicle side code : 1079-1 Power limit -
The 5V power supply to the PTO accel-
Detail erator signal is faulty. The supply volt-
age exceeds the limiting value.
Recovery *
Power limit -
159 14-25
TROUBLESHOOTING
P0699 : Sensor supply voltage monitoring 3

The 5V power supply to the rail pressure The AD converter inside the ECU is
Detail sensor is faulty. The supply voltage Detail faulty. The standard voltage falls below
exceeds the limiting value. the limiting value.
Recovery * Recovery occurs. It recovers automati-
cally if an error occurs three times in two
Recovery seconds. The engine stops if an error
Power limit - occurs four times or more in two sec-
onds.
Control Engine stop
P060A : TPU monitoring Power limit -
Faulty part ECU
The ECU detects a fault of rotating pulse
Detail Vehicle side code : 2008-4
arithmetic circuit inside the ECU.
Recovery occurs. It recovers automati- Faulty part ECU
The AD converter inside the ECU is
Recovery two seconds. The engine stops if an
Detail faulty. The ECU detects the conversion
error by using a test pulse.
seconds.
Control Engine stop
Power limit - Recovery two seconds. The engine stops if an
Inspection Replace the ECU. seconds.
P060B : ADC monitoring Control Engine stop

Vehicle side code : 2008-1 Power limit -
Detail faulty. The standard voltage exceeds the
limiting value. Vehicle side code : 2008-8
Recovery occurs. It recovers automati- Faulty part ECU
Recovery two seconds. The engine stops if an Detail
faulty. The conversion time is abnormal.
seconds. Recovery occurs. It recovers automati-
Control Engine stop
Power limit - error occurs four times or more in two
seconds.
Control Engine stop
Power limit -
14-26 160
TROUBLESHOOTING
P060D : CAN accelerator P062D : Injector drive bank 1

Faulty part ECU communication circuit Faulty part ECU
The ECU detects a fault of accelerator The ECU detects the short circuit of the
Detail
Detail opening (APPREQ) receiving from injector drive circuit inside the ECU.
CAN.
Recovery *
Recovery *
Control Engine stop
Power limit -
operator. Inspection Replace the ECU.
Power limit -
P062E : Injector drive bank 2
Inspection CAN communication circuit Vehicle side code : 653-8
P060E : APPREQ message time out Faulty part ECU

Vehicle side code : 1674-4 The ECU detects the short circuit of the
Detail
injector drive circuit inside the ECU.
Faulty part ECU communication circuit
Recovery *
The ECU cannot receive the accelerator
Detail
opening (APPREQ) signal. Control Engine stop
Recovery * Power limit -
The ECU uses the analog signal for Inspection Replace the ECU.
operator. P062F : EEPROM
Inspection CAN communication circuit Faulty part ECU

The ECU detects a read-write error of
P061C : Engine speed Detail the data memory bank inside the ECU.
Vehicle side code : 2005-1 The ECU cannot read the data.
Faulty part ECU Recovery *
The ECU is faulty. The engine speed Control The ECU warns to the operator.
Detail
data is faulty.
Power limit -
cally if an error occurs three times in Inspection Replace the ECU.
seconds. Vehicle side code : 1235-4
Control The ECU warns to the operator. Faulty part ECU
Power limit - The ECU detects a read-write error of
the data memory bank inside the ECU.
Inspection Replace the ECU. Detail
The ECU cannot write to the data mem-
ory.
Recovery *
Power limit -
161 14-27
TROUBLESHOOTING
P2047 : Injector drive bank 1

The ECU detects a read-write error of The ECU detects an open circuit of the
Detail
Detail the data memory bank inside the ECU. injector drive circuit inside the ECU.
The ECU is using the substitute data.
Recovery *
Recovery *
Control Engine stop
Power limit -
Power limit -
P2048 : Injector drive bank 1
P0933 : Oil pressure switch Vehicle side code : 651-2
Faulty part ECU
Faulty part Oil pressure switch
Detail
The oil pressure switch remains OFF injector drive circuit inside the ECU.
Detail position even the engine speed reaches
Recovery *
500min-1.
Control Engine stop
Recovery *
Power limit -
Control The ECU keeps the engine low idling.
Power limit -
Oil pressure switch, and wiring of oil P2049 : Injector drive bank 1
Inspection
pressure switch. Vehicle side code : 651-1
Faulty part ECU
Vehicle side code : 100-8 The ECU detects a short circuit of the
Detail
Faulty part Oil pressure switch
Recovery *
The oil pressure switch remains OFF
position for 30 second after engine start- Control Engine stop
Detail
ing. The oil pressure switch remains
Power limit -
OFF position during engine operation.
Recovery *
Control Engine stop P2050 : Injector drive bank 2
Oil pressure switch, and wiring of oil Faulty part ECU

Inspection
pressure switch. The ECU detects an open circuit of the
Detail
Recovery *
Control Engine stop
Power limit -
14-28 162
TROUBLESHOOTING
P2051 : Injector drive bank 2 P2229 : Atmospheric pressure sensor

The ECU detects a short circuit of the The ECU detects a faulty operation of
Detail
injector drive circuit inside the ECU. the atmospheric pressure sensor (open
Detail circuit, short circuit, characteristic
Recovery *
fault). The input voltage exceeds the
Control Engine stop limiting value.
Inspection Replace the ECU. The ECU controls the engine fixing the
Control
value to the backup data.
P2052 : Injector drive bank 2 Power limit The maximum power is limited to 75%.
Faulty part ECU
Detail
Recovery *
Control Engine stop
Power limit -
P2228 : Atmospheric pressure sensor

Faulty part ECU
The ECU detects a faulty operation of
the atmospheric pressure sensor (open
Detail circuit, short circuit, characteristic
fault). The input voltage falls below the
limiting value.
Recovery *
The ECU controls the engine fixing the
Control
value to the backup data.
163 14-29
TROUBLESHOOTING
5.2 Related diagnosis code

There are diagnosis codes which are caused by other diagnosis codes, for example, the diagnosis code generated by the fault of
the common rail causes the diagnosis code related to the DBV (pressure limiting valve). These codes can be recovered by
eliminating the fault of the causal diagnosis code.
Causal diagnosis code in the following table must be checked when Related diagnosis code is generated.
Related diagnosis code can be recovered by eliminating the fault of Causal diagnosis code.
Also Related diagnosis code B can be generated by Related diagnosis code A. In this case, Causal diagnosis code and Related
diagnosis code A must be checked.
Table 14-2 Related diagnosis code (1 / 2)

Causal diagnosis Related diagnosis Related diagnosis
Cause A Cause B Remark
code code A code B
There is an open cir-
cuit on the MPROP.
P0089 The MPROP is fully
Vehicle side code : opened and the com-
- - -
P0252 2041-1 mon rail receives
Vehicle side code : DBV opening excessive pressure.
2000-4 The DBV will be
MPROP open circuit opened.
P0089 P0090
The ECU clears P0089
Vehicle side code : MPROP was fully Vehicle side code : The DBV does not
when P0090 is gener-
2042-2 opened for 2 seconds. 2043-4 open.
ated.
DBV kick off DBV closed sticking
There is an overload
on the MPROP. The
P0089 MPROP is fully
- - -
P0252 2041-1 mon rail receives
MPROP overload opened.
P0089 P0090
ated.
There is a short circuit
on the MPROP. The
P0089 MPROP is fully
P0230 - - -
2041-1 mon rail receives
MPROP power stage opened.
short circuit to battery
P0089 P0090
ated.
The pressure in the
P0089 common rail keeps The ECU clears
Vehicle side code : exceeding the limiting P0089(2042-2) when
- -
P0089 2041-1 value, the engine P0089(2041-1) is gen-
Vehicle side code : DBV opening operation switches to erated.
2042-2 the limp home mode.
DBV kick off P0090
Vehicle side code : The DBV does not
- - when P0090 is gener-
2043-4 open.
ated.
DBV closed sticking
14-30 164
TROUBLESHOOTING
Table 14-2 Related diagnosis code (2 / 2)

Causal diagnosis Related diagnosis Related diagnosis
Cause A Cause B Remark
code code A code B
The pressure in the
P0089 common rail keeps
Vehicle side code : exceeding the limiting
P0191 - - -
2041-1 value, the engine
Vehicle side code : DBV opening operation switches to
Rail pressure gover-
nor deviation P0089 P0090
ated.
The pressure in the
P0089 common rail keeps
If DBV does not open,
Vehicle side code : exceeding the limiting
- - the ECU generates
P0194 2041-1 value, the engine
P0090, not 0089.
Vehicle side code : DBV opening operation switches to
Rail pressure governor P0089 P0090
ated.
An error is detected
by SRC. The ECU
cannot control the
P0192 P0089 engine by feedback
In this case, P0192 and
Vehicle side code : Vehicle side code : from the common rail
- - P0089 are generated at
2011-2 2041-1 pressure sensor. The
the same time.
Rail pressure SRC DBV opening DBV will be opened.
The ECU controls the
engine using backup
data.
An error is detected
by SRC. The ECU
cannot control the
P0193 P0089 engine by feedback
In this case, P0192 and
Vehicle side code : Vehicle side code : from the common rail
- - P0089 are generated at
2011-1 2041-1 pressure sensor. The
the same time.
Rail pressure SRC DBV opening DBV will be opened.
The ECU controls the
engine using backup
data.
After the ECU deter-
P0091 mined that DBV has
Vehicle side code : been opened, the
P0091 is not gener-
2045-2 common rail pressure - -
ated separately.
DBV pressure is too exceeds the limiting
P0089 high value during backup
Vehicle side code : operation.
2041-1 After the ECU deter-
DBV opening P0092 mined that DBV has
Vehicle side code : been opened, the
P0092 is not gener-
2044-1 common rail pressure - -
ated separately.
DBV pressure is too exceeds the limiting
high value during backup
operation.
165 14-31
TROUBLESHOOTING
P0089 : DBV valve opening P0092 : DBV pressure is too high.

Faulty part DBV Faulty part DBV
Detail The DBV is opening. The DBV pressure is abnormal. (too
Detail
high)
Recovery *
Recovery *
Control
12%. Control Engine stop
Inspection Contact a Mitsubishi dealer. Inspection Contact a Mitsubishi dealer.
P0089 : DBV kick off P0191 : Rail pressure governor deviation

Faulty part DBV Faulty part Common rail
Pressure shock requested The rail pressure control is abnormal.
Detail Detail
to apply limp home mode. The pressure exceeds the target value.
Accelerator opening ratio is fixed to Accelerator opening ratio is fixed to
Control Control
12%. 12%.
Inspection Contact a Mitsubishi dealer. Inspection Damage on the common rail.
P0090 : DBV closed sticking P0192 : Rail pressure sensor SRC (Signal Range
Vehicle side code : 2043-4 Check)
Faulty part DBV Vehicle side code : 2011-2
The DBV does not open. Closed stick- Faulty part Rail pressure sensor
Detail
ing. The ECU detects an open or short circuit
Recovery * of rail pressure sensor and/or sensor har-
Detail
ness. The input voltage falls below the
Control Engine stop limiting value.
Inspection Contact a Mitsubishi dealer. Accelerator opening ratio is fixed to
Control
12%.
P0091 : DBV pressure is too low
Power limit -
Rail pressure sensor, and wiring of rail
Faulty part DBV Inspection
pressure sensor.
The DBV pressure is abnormal. (too
Detail
low)
Recovery *
Control Engine stop
Power limit -
Inspection Contact a Mitsubishi dealer.
14-32 167
TROUBLESHOOTING
P0193 : Rail pressure sensor SRC (Signal Range P0252 : MPROP power stage overload
Check) Vehicle side code : 2000-8
Vehicle side code : 2011-1 Faulty part MPROP
Faulty part Rail pressure sensor The ECU detects an overload of
Detail
The input voltage exceeds the limiting MPROP and/or MPROP harness.
Detail
value. Recovery *
Recovery * Accelerator opening ratio is fixed to
Control
Accelerator opening ratio is fixed to 12%.
Control
12%. Power limit -
Power limit - Inspection MPROP, and wiring of MPROP.
Rail pressure sensor, and wiring of rail
Inspection
pressure sensor.
P0194 : Rail pressure governor

The rail pressure exceeds the limiting
Detail
value.
Recovery *
Control
12%.
Power limit -
P0230 : MPROP power stage short-circuit to battery

Faulty part MPROP
The ECU detects a short circuit on the
Detail
battery line of the MPROP harness.
Recovery *
Control
12%.
Power limit -
P0252 : MPROP power stage open circuit

Faulty part MPROP
The ECU detects an open circuit of the
Detail
MPROP and/or MPROP harness.
Recovery *
Control
12%.
Power limit -
167 14-33
TROUBLESHOOTING
6. Inspecting sensors
6.1 Speed/timing sensor (crank, cam)
Measure the resistance between terminal A - B.
Standard value : 860±86Ω
If measured value is out of standard, replace the sensor with
a new one.
C B A
Speed/timing sensor
(crank, cam)
6.2 Inlet manifold pressure sensor
With applying pressure using an air compressor, measure
the voltage between terminal B - C.
Standard value
C A
• at 0 MPa {0 kgf/cm²} : 0.5V
• at 0.34 MPa {3.5 kgf/cm²} : 4.5V
If measured value is out of standard, replace the sensor with
a new one. B
Air compressor
Inspecting inlet manifold pressure sensor (1)
0.5
Air pressure MPa
0.4
0.3
0.2
0.1
0
0.5 1 1.5 2 2.5 3 3.5 4 4.5 5 5.5

Output voltage Vdc
Inspecting inlet manifold pressure sensor (2)

6.3 Water temperature sensor
Put the water temperature sensor to the container filled with
water, measure the output resistance between terminal 1 - 2.
Standard value
• 20°C : 2.38 ～ 2.63kΩ
• 80°C : 0.30 ～ 0.36kΩ
If the sensor is an open circuit, its resistance is infinity. If
measured value is out of standard, replace the sensor with a
new one. 1 2
Inspecting water temperature sensor
14-34 168
TROUBLESHOOTING
6.4 Engine oil pressure switch

Apply 50±10 kPa {0.5±0.1 kgf/cm²} [7.11±1.42 psi]
pressure to the sensor using an air compressor.
Check that the micro switch is in ON position. Air compressor
If the switch is not operate, replace the engine oil pressure 50 ± 10 kPa
switch with a new one. {0.5 ± 0.1 kgf/cm²}
[7.11 ± 1.42 psi]
On-Off differences
30 kPa
{0.3 kgf/cm²}
[4.27 psi]
Inspecting oil pressure switch

6.5 Common rail pressure sensor
Apply 5V between terminal A - C, and measure the voltage
at terminal B.
Standard value : Approx. 0.5V
If measured value is out of standard, replace the common
A B C
rail with a new one.
Inspecting common rail pressure sensor

6.6 Injector solenoid
Measure the resistance between terminal 1 - 2.
Standard（at 20 to 70°C [68 to 158 °F]）: 0.215 to 0.295 Ω
If measured value is out of standard, replace the injector
with a new one.
2 1
Inspecting injector solenoid

6.7 High pressure pump solenoid sensor
(MPROP)
Measure the resistance between terminal 1 - 2.
Standard （at 20°C [68 °F]）: 2.6 to 3.15 Ω
If measured value is out of standard, replace the fuel pump
with a new one.
2 1
Inspecting high pressure pump solenoid sensor

(MPROP)
169 14-35
TROUBLESHOOTING
7. Inspecting wiring
7.1 Inspecting connector and harness
When the ECU generates the diagnosis code for the sensors,
the ECU and the relays, check the wiring that connects these
parts.
The looseness of the harness connection and/or poor
connection of connector may cause the electrical faults. In
these cases, reconnecting the connector and/or the repairing
the harness deletes the fault. Inspect the wiring connecting
to the sensor which causes diagnosis code.
7.1.1 Inspecting the intermittent fault

Wiggle the harness and connector in order to reproduce the Inspecting intermittent fault
intermittent fault.
If the diagnosis code is generated, reset the ECU and repeat
the above procedure. If the intermittent fault exists, replace
the connector and harness.
Ensure locking
7.1.2 Inspecting connectors
(1) Disconnect the connector and inspect the connector for
moisture and wear.
(2) Inspect that the terminals are correctly located in the
connector. Inspect that the terminals are not lost.
Inspect that the terminals does not rattle.
(3) Inspect that the locking wedge works correctly. Inspecting connector
7.1.3 Inspecting harness

(1) Inspect harness visually for wear, nicks and cuts.
Especially the part which is exposed to the engine must
be inspected. Nick
(2) Inspect the harness for pinch point caused by cramp.
7.1.4 Inspect open circuit and short circuit

(1) Remove the connector from either end of the harness. Pinch point
Measure the resistance between both ends of the
harness using tester. If measured value is between 0.1～
0.3 Ω, it is normal. If measured value is not in this Inspecting harness
range, it is an open circuit.
(2) Remove the connector from either end of the harness.
Measure the resistance between all terminals in the
connector. If measured value is 100kΩ or more, it is
normal. If measured value is 100kΩ or less, it is a short
circuit.
Inspecting open circuit and short circuit
14-36 170
TROUBLESHOOTING
7.2 Pin location of the ECU connector and extension harness connector
The wirings of the sensors, the injectors and the fuel pump are connected to the ECU through the extension harness connector.
Inspect the pin of the ECU connector and extension harness connector when inspecting the wiring of the sensors, the injectors
and the fuel pump.
ECU terminal A ECU terminal K
46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 91 92 93 94
5 6
31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72
3 4
16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50
1 2
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28
1‫ޓ‬Injector 3, + 1‫ޓ‬ECU power supply, +㧔1㧕

2‫ޓ‬Injector 2, + 2‫ޓ‬ECU ground, -㧔1㧕
7‫ޓ‬Speed/timing sensor (crankshaft side), shield 3‫ޓ‬ECU power supply, +㧔2㧕
8‫ޓ‬Rail pressure sensor, ground 4‫ޓ‬ECU ground, -㧔2㧕
10‫ޓ‬Speed/timing sensor (camshaft side) 5‫ޓ‬ECU power supply, +㧔3㧕
12‫ޓ‬Speed/timing sensor (crankshaft side) 6‫ޓ‬ECU ground, -㧔3㧕
14‫ޓ‬Inlet manifold pressure sensor, power supply 9‫ޓ‬Accelerator㧔1㧕
15‫ޓ‬Heater relay 12‫ޓ‬PTO accelerator, ground
16‫ޓ‬Injector 1, 23‫ޓ‬PTO accelerator, power supply
17‫ޓ‬Injector 4, 25‫ޓ‬K-LINE
19‫ޓ‬MPROP, + 28‫ޓ‬Ignition switch
20‫ޓ‬Speed/timing sensor (camshaft side), shield 36‫ޓ‬PTO accelerator
23‫ޓ‬Inlet manifold pressure sensor, ground 41‫ޓ‬Signal, ground
24‫ޓ‬Heater relay, power supply 54‫ޓ‬Oil pressure switch
26‫ޓ‬Rail pressure sensor, power supply 61‫ޓ‬CAN-L1
27‫ޓ‬Speed/timing sensor (crankshaft side) 62‫ޓ‬CAN-H1
31‫ޓ‬Injector 2, - 72‫ޓ‬Main relay
33‫ޓ‬Injector 4, - 73‫ޓ‬24V power supply
40‫ޓ‬Inlet manifold pressure sensor
41‫ޓ‬Water temperature sensor, ground
43‫ޓ‬Rail pressure sensor
46‫ޓ‬Injector 3, -
47‫ޓ‬Injector 1, -
49‫ޓ‬MPROP, - Point of view
50‫ޓ‬Speed/timing sensor (camshaft side)
58‫ޓ‬Water temperature sensor
Pin location of ECU connector
171 14-37
TROUBLESHOOTING
Extension harness connector, 16 terminals Extension harness connector, 12 terminals
4 3 2 1
4 3 2 1
8 7 6 5
8 7 6 5
12 11 10 9
12 11 10 9
16 15 14 13
1ࠉSpeed/timing sensor (camshaft side), power supply 1ࠉInjector 1, +

2ࠉSpeed/timing sensor (camshaft side) 2ࠉInjector 1, -
3ࠉSpeed/timing sensor (camshaft side), shieldࠉ 3ࠉInjector 4, +
5ࠉSpeed/timing sensor (crankshaft side), power supply 4ࠉInjector 4, -
6ࠉSpeed/timing sensor (crankshaft side) 5ࠉInjector 3, +
7ࠉSpeed/timing sensor (crankshaft side), shield 6ࠉInjector 3, -
8ࠉMPROP, - 7ࠉInjector 2, +
9ࠉRail pressure sensor, power supply 8ࠉInjector 2, -
10ࠉRail pressure sensor 9ࠉWater temperature sensor
11ࠉRail pressure sensor, ground 10ࠉWater temperature sensor, ground
12ࠉMPROP, + 11ࠉOil pressure switch
13ࠉInlet manifold pressure sensor, power supply 12ࠉOil pressure switch
14ࠉInlet manifold pressure sensorࠉ
16ࠉInlet manifold pressure sensor, ground
Point of view for 16 terminals Connector location Point of view for 12 terminals
Pin location of extension harness connector
14-38 172
［4. MAINTENANCE］
4.3 LUBRICANT, FUEL & COOLANT SPECIFICATIONS
The following chart provides information on the specification of oils, grease, fuels and coolant to be
used in various climates and working conditions.
4-11
173
4.4 USE OF BIO-DEGRADABLE OILS
When using Bio-degradable Oil (BIO OIL), refer to the following information.
A. Recommended Oil
Maker Mobil
Brand MOBIL EAL Envirosyn 46H
B. Precaution for the Use of Oil

1. When filling the former machine in which mineral oil is charged with BIO oil, try to flush the
machine three times.
The mineral oil will be left in the circuit of the machine without flushing, resulting in the reduction
of effect of biodegradation ability.
2. When you use BIO OIL, slewing and travel parking brake performance will be reduced because
of lower friction factor of BIO OIL compared to that of mineral oil.
C. Flushing Procedure
1. Drain mineral oil from the hydraulic tank completely.
2. Drain mineral oil from the cylinder completely.
3. Fill hydraulic oil tank with new BIO oil.
4. After starting engine, move every cylinder 10 strokes respectively.
４
The abrupt operation may cause burning of seal because of trapped air in the cylinder.
Try to operate first 4 strokes slowly at engine low idling to charge hydraulic oil in the entire cylinder.
5. Idle travel motor right and left for about 3 minutes.

6. Repeat swing operation 10 rotations.
7. Drain BIO oil from hydraulic tank completely.
8. Drain BIO oil from each cylinder completely.
9. Fill hydraulic tank with new BIO oil. Similarly, repeat the procedure 4. to 9. two times.
10. For hydraulic oil in final condition, analyze the hydraulic oil and be sure of amount of remaining
mineral oil.
D. Bio Oil Change Interval

The BIO oil change interval is 2,000 hours.
For the changing procedure, refer to the section "4.17.B Change Hydraulic Oil".
4-13
174
4.5 MAINTENANCE PARTS
A. Filters & Elements, and Bucket

Replace parts, such as filters and elements, during the periodical maintenance or before the service
life.
The machine can be used economically if the parts are changed properly and timely.
When you place an order of parts, confirm the parts number on parts manual.
System Part Number Parts Name Q'ty Replacement Interval

Return filter element kit After 50 hours (first change)
YN52V01016R610 1
(STD. Breaker) Every 1000 hours (from 2nd change)
(ZD11G19000) (O-ring) 1 (Breaker specification : Every 250 hours)
Hydraulic oil tank
YN50V00025F1 Suction strainer 1
Every 2000 hours
(ZD11G20000) (O-ring) 1
Air breather YN57V00010S002 Element 1 Every 1000 hours
After 6 times of cleaning or one
YY11P00008S003 Element (Outer) 1
year whichever comes first.
Air cleaner For machines equipped with W (double)
YY11P00008S002 Element (Inner) 1 element the inner element must be
replaced together with the outer element.
After 50 hours (first change)

Engine oil filter VA34240-11101 Cartridge 1
Every 250 hours
Fuel filter (Main) VA32G62-00100 Cartridge 1 Every 500 hours
Fuel third filter VA34362-04100 Cartridge 1 Every 1000 hours
Fuel pre-filter YN21P01068R100 Element kit 1 Every 500 hours
YN50V01015P3 Air-con filter (Outer) 1 Every 10 times cleanings
Air conditioner When heavy clogging of filter occurs,
YN50V01014P1 Air-con filter (Inner) 1 clean or replace.
Pilot line filter YN50V00020F1 Line filter 1 Every 2000 hours (Cleaning)
Radiator YN05P00010S006 Radiator cap 1 Every 1000 hours
2412N278D11 Side cutter (R.H) 1
2412N278D21 Side cutter (L.H) 1
Bucket (STD) ZS13C20050 Bolt 8

When required
(0.45 m3) ZN13C20016 Nut 8
2412U16F1 Tooth assy (Outer side) 2
2412U112F1 Tooth assy (Inner side) 3
Internal battery for
communication YN22E00469S001 Battery 1 Every 1 year
controller
- Items enclosed in parenthesis ( ) are the parts to be changed at the same time.
- The internal battery for communication controller should be replaced in once a year. When
replacement is required, ask us or our authorized dealer/distributor to replace the battery.
4-14
175
4.9 INSPECTION & MAINTENANCE CHART
Follow the chart below for recommended intervals of regular inspection and maintenance procedures.
Perform inspection and maintenance according to the calendar time or operation time shown by the
hour meter, whichever comes first.
See the inspection and maintenance procedure mentioned below for details.
See "4.3 LUBRICANT, FUEL & COOLANT SPECIFICATIONS" for detail specification for lubricant,
coolant, fuel and etc.
LLC: KOBELCO genuine antifreeze/coolant.
4-22
176
When the machine works at dusty site, clean the filter and the core of radiator often. Clean the filter
and core depending on their dirt.
4-23
177
-Contact our dealer/distributor for checking and adjustment shown by asterisk *2.
-*1-Break-in (After first 50, 100, 500 Hours) Inspection & Maintenance Required.
4-24
178
4-25
179
4-26
D. Track Tension
-Support lower frame with suitable blocks.

-Before inspecting and greasing, completely wash and remove the mud and dusts attaching to the
truck.
1. Operate swing, arm, bucket and boom

controls until machine is set up as shown
in.
2. In center of track, measure the distance
between the bottom of frame rails and
surface of shoe.
3. Perform steps 1 and 2 on right track.
4. To increase track tension, set machine as
shown in figure and with grease gun inject
extreme pressure No.2 grease into idler
adjustment grease nipple (1) until proper
tension is reached. Perform this procedure
on both tracks.
Slack:
Proper Tension (A):
270 to 300 mm (7.9 to 11.8 inches)
After injecting grease, operate the travel control forward and reverse for the track being adjusted. This
will balance the tension between the idler and the sprocket. Then remeasure as shown in figure.
5. To decrease track tension, set machine up

as shown in figure.
6. Carefully loosen the adjusting grease

nipple (1) to allow grease to escape.
7. Tighten grease nipple (1), measure track
tension as shown in figure.
Tightening torque:
49 to 69 N-m (36.6 to 51.4 lbf-ft)
8. If necessary, perform steps 5 through 7
on other track.
Grease in track tensioning mechanism is under extreme pressure and can penetrate skin causing
severe injury. Keep face and body away from grease nipple area. Never loosen grease nipple more
than one complete turn. If grease does not release after one turn of the nipple, call an authorized
KOBELCO service dealer for assistance.
4-42
181
［3. MACHINE OPERATION］
E. Machine Operation in Water
Be careful not to immerse the slewing bearing, slewing pinion and swivel joint into the water or mud.
If the machine is operated in water or mud, the slewing bearing and others may be worn abnormally.
If water or mud comes up to the slewing bearing level, put grease in slewing bearing unit the old
grease comes out. If water or mud goes higher than the upper frame level, contact the
dealer/distributor for cleaning or repair.
1. Where a bottom is flat and water flow is

slow, the machine may be operated in a
water-depth (A) to the center of upper roller.
2. Make sure careful operation of machine in
water. Use the bucket to check for stability
of the riverbed. Do not operate the machine
in water that is deeper than depth (A).
3. On soft ground or mud the machine may
sink slowly. Make sure constantly of
undercarriage condition and depth of water.
4. After machine operation in seawater,
thoroughly wash the machine to remove
salt.
5. Using grease gun and inject grease into
the part immersed to water until grease
comes out.
3-28
182
B. Refilling engine oil

1. Make sure that the engine oil drain plug is
closed.
2. Remove the oil pan with specified engine
oil to the specified.
3. Fill the engine oil pan with specified
engine oil to the specified level.
Fill it with specified engine oil through oil filler cap (1) referring to the section "4.3 LUBRICANT,
FUEL & COOLANT SPECIFICATIONS" in Chapter 4.
4. Check the oil level in the oil pan as follows: Pull out the oil level gauge (2), and wipe it with a
cloth.
5. Insert the oil level gauge fully into the oil level gauge guide, then pull the gauge out again. The
oil level should be between the H and L marks on the oil level gauge. If the oil level is low, add
engine oil of the specified type.
6. Check the oil pan and other parts for oil leakage. Repair any oil leakage found.
7. Shut off the fuel supply and crank the engine for about 10 seconds or less using the starters, and
wait for about 1 minute.
8. Perform the above cranking operation again to cir culate oil in the engine.
9. Check the oil level with the oil level gauge (2) again, and add oil to the specified level.
To crank the engine, shut off the fuel supply to the engine and operate the starters.
C. Replacing the oil filter
Do not use any oil filter that has dents, as the filter may be damaged during operation, resulting in a
fuel leakage and possible fire.
4-46
183
To avoid damage to the filter, do not use a filter wrench. Tighten the filter by hand.
1. Clean around the oil filter (1).

2. Place a drip pan under the oil filter.
3. Loosen the oil filter drain cock (2) and
drain oil from the oil filter.
4. Using a filter wrench, remove oil filter.
Filter wrench of parts number :
YW01T01014P1
5. Thoroughly wipe off oil on the mounting

surface of oil filter with a cloth.
6. Check the new oil filter for proper seating
of gasket.
7. Apply clean engine oil to gasket on the
new oil filter.
8. Install the new filter. Turn the filter until
the gasket comes into contact with the filter
４
head then tighten an extra three quarters
turn by hand.
Filter wrench of parts number :
YW01T01014P1
4-47
184
B. Bleeding the fuel system
If air vent plugs, the thread portion of the bracket, or sealing washers are damaged, replace them with
new ones.
４
1. Loosen the air vent plug (1) on the fuel
filter intake for the left bank cylinder about
1.5 turns.
2. Turn the priming pump cap (2)
counterclockwise to unlock, and priming
the fuel filter
3. When the fuel from the air vent plug
becomes free from air bubbles, stop priming
and tighten the air vent plug (1) to the
specified torque.
4. After completing the air bleeding from the
fuel filter, move the priming pump cap (2)
in and out 36 times continuously. Or
continue the air bleeding work until the air
level in the transparent fuel filter cup (3)
rises and disappears.
5. Start the engine and push the priming
pump cap (2) back into place. And turn it
to the right to tighten.
4-61
185
K. Cleaning or Replacement of Radiator Cap
To avoid being burned, be careful when removing the radiator cap. Coolant is under high pressure
when hot.
-Do not remove the radiator cap when the system is hot.
-Allow enough time for the machine to cool down before removing the radiator cap.
A loose radiator cap will let hot steam and coolant escape from the cooling system. Allow the radiator
cap/cooling system enough time to cool before tightening the loose cap.
1. After the radiator cap/cooling system has

cooled so it can be touched with a bore
hand, slowly loosen the cap (1) to release
the pressure.
After all pressure is released, remove the
radiator cap.
2. Inspect locations A through C for debris
and damage to the cap (1). Use a clean
cloth to wipe the cap (1) clean. Replace
the cap if necessary.
４
Inspection locations:
A. Contact surface between the negative
pressure valve (2) and gasket (5)
B. Both surfaces of the pressure valve (3)
and gasket (5)
C. Both surfaces of the external lid (4)
and gasket (6)
Radiator cap (1)
3. Securely tighten the cap (1).
If grooves are worn into the surface of the gasket after years of use, steam will escape and pressure
cannot be maintained. Replace the worn gasket with a new one.
4-57
186
4.18 MACHINE STORAGE
A. Machine Storage
The following procedure applies when the machine is to be stored for a month or more.
1. Perform all inspection and maintenance procedures as previously described in this section.
2. Thoroughly clean the machine, inspect for damaged or worn parts and components and replace
or repair all damaged or worn parts.
3. Completely fill fuel tank with fresh, clean fuel to aid in preventing condensation of moisture inside
the fuel tank.
4. Move machine to an indoor location for storage.
5. Operate bucket and arm completely "IN" extending cylinders. Then lower boom until attachment is
resting on the floor.
6. Coat cylinder rods with a heavy coat of grease to prevent corrosion during storage.
7. Remove batteries and store in a well ventilated, warm area.
Protect CPU and all electrical components from water and steam when cleaning the machine.
４
B. Care During Storage
1. Every 30 days during storage, it will be necessary to start and run the machine to circulate the
fluids through the systems. Before starting clean cylinder rods and after running re-grease cylinder
rods.
Run and operate machine for approximately 1 hour to allow all fluids to circulate well and reach
normal operating temperatures.
C. Strage Up After
1. Perform all Inspection and maintenance procedures as described in this section before bringing
machine out of storage for normal operation.
2. Remove drain plugs from travel motor and slewing gear reduction units to drain off any moisture
which may have accumulated during storage.
3. Carefully and closely inspect all hydraulic hoses after long periods of storage for signs of
deterioration. Replace all hoses showing these signs.
4-81
187

01 SK130HDL-8B TRG Text - Complete-1 PDF

Uploaded by

Copyright:

Available Formats

You might also like

01 SK130HDL-8B TRG Text - Complete-1 PDF

Uploaded by

Document Information

Original Description:

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

01 SK130HDL-8B TRG Text - Complete-1 PDF

Uploaded by

Copyright:

Available Formats

SERVICE TRAINING

Customer Support Department

Book code: 2014-01-KISCO-SK130HDL-TrgText

2.5 SPECIFICATIONS AND PERFORMANCE

2.5.1 SPEED AND CLIMBING CAPABILITY

Item / Model SK130HDL-8B

Engine model MITSUBISHI D04FR-74KW

2.5.3 HYDRAULIC COMPONENTS

Hydraulic pump Variable displacement axial piston pump X 2 + gear pump X 1

2.8 COMBINATIONS OF ATTACHMENT

2.9 ENGINE SPECIFICATION

Applicable machine SK130HDL-8B

2.9.2 ENGINE CHARACTERISTIC CURVE

13.2 PERFORMANCE INSPECTION STANDARD TABLE

Unless otherwise specified, measure it on "H" mode.

13.2.1 STANDARD VALUE TABLE

13.3 MEASUREMENT OF ENGINE SPEED

13.3.1 MEASUREMENT OF ENGINE SPEED

Service diagnosis for E/G speed measuring

Switch for E/G speed indication

13.4 MEASUREMENT OF HYDRAULIC PRESSURE

13.4.1 PREPARING TO MEASURE HYDRAULIC PRESSURE

13.4.2 PLACE TO INSTALL PRESSURE GAUGE

13.4.3 PRESSURE ADJUSTMENT POSITION

Relief valve position on main control valve

(2) Pilot relief valve

Pilot relief valve position

(3) Swing over load relief

Swing over load relief position

13.4.4 PROCEDURE FOR ADJUSTING RELIEF VALVE

Pilot relief valve

(2)Main relief valve

Main relief valve (Travel section, ATT

(3) Over load relief valve

Over load relief valve (Boom, bucket, arm

(4) Over load relief valve (Swing)

Swing over load relief valve

(5) Travel over load relief valve

13.5 MEASURING TRAVEL PERFORMANCES

13.5.1 TRAVEL SPEED

Adhering position of reflection panel 13

13.5.2 DEVIATION OF TRAVEL

13.5.3 PERFORMANCES OF PARKING BRAKE

13.5.4 DRAIN RATE OF TRAVEL MOTOR

Method of measuring the drain rate of travel

13.6 MEASURING SWING PERFORMANCES

13.6.1 SWING SPEED

13.6.2 PERFORMANCE OF SWING BRAKE

13.6.3 PERFORMANCE OF SWING PARKING BRAKE

Measuring position of swing parking brake

13.6.4 DRAIN RATE OF SWING MOTOR

(4) Measurement; at Swing Lock

13.7 MEASURING ATTACHMENT OPERATING PERFORMANCES

13.7.1 OPERATING TIME OF CYLINDERS

Measuring position for bucket digging and

Measuring position for boom up and down

Measurement 2; Arm in and out, bucket