Manual: PC200,2001C4 PC21 0,21 Ollhi PC220,22OLC4 PC230,23OLC

SEBMOl 0102
Shop
Manual
PC200,2001C4
PC21 0,21Ollhi
PC220,22OLC4
PC230,23OLC=~
HYDRAULIC EXCAVATOR
PC200/2OOLC-6 - 96514
PC200/2OOLC-6 HYPER GX - 96514
SERIAL NUMBERS PC21 O/21 OK-6 - 30980 and UP
PC220/22OLC-6 - 52852
PC230/23OLC-6 - 10177
This material is proprietary to Komatsu America International Company and is not to be reproduced, used, or
disclosed except in accordance with wriien authorization from Komatsu America International Company.
It is our policy to improve our products whenever it is possible and practical to do so. We reserve the right to make
changes or add improvements at any time without incurring any obligation to install such changes on products sold
previously.
Due to this continuous program of research and development, periodic revisions may be made to this publication.
It is recommended that customers contact their distributor for information on the latest revision.
oo- 1
February 1998 Copyright 1998 Komatsu America International Company
0
CONTENTS
No. of page
01 GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..~. 01-I
IO STRUCTURE AND FUNCTION . . . . .. . . . . . . . . . . . . . . . . . . . . . . . ..*...... 10-l
20 TESTING AND ADJUSTING . . ..m...............m..................... 20-I
30 DISASSEMBLY AND ASSEMBLY n . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . 30-l
40 MAINTENANCE STANDARD .,....................................... 40-I
90 OTHERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-l
00-2
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LIST OF REVISED PAGES
The affected pages are indicated by the use of the

following marks. It is requested that necessary actions Mark Indication Action requirec
be taken to these pages according to the table below.
0 Page to be newly added Add
0 Page to be replaced Replace
Page to be deleted Discard

( 1
Pages having no marks are those previously revised

or made additions.
LIST OF REVISED PAGE
Time oi Time of Time oi Time oi Time of

Mark Page Mark Page Mark Page Wark Page Mark Page
revisior revision revisior revision; revision
l oo- 1 Ol- 3 01-31 IO-19 1o-49
l oo- 2 Ol- 4 01-32 IO-20 1O-50

l oo- 2-l Ol- 5 01-33 IO-21 IO-51
l oo- 2-2 Ol- 6 01-34 10-22 lo-52

$
> l 00- 2-3 Ol- 7 01-35 lo-23 10-53
% 0 00- 2-4 oi- a 01-36 lo-24 10-54
0 00- 2-5 Ol- 9 01-37 IO-25 IO-55
0 00- 2-6 01-10 01-38 IO-26 IO-56
oo- 3 01-11 01-39 IO-27 IO-57
oo- 4 01-12 01-40 lo-28 lo-58 @
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00- 6 01-14 10-30 IO-60
oo- 7 01-15 lo- 1 IO-31 IO-61
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00-18 01-26 IO-14 IO-43 IO-73
00-19 01-27 IO-15 10-44 IO-74
01-28 lo-16 10-45 10-75
Ol- 1 01-29 IO-17 IO-46 IO-76
Ol- 2 01-30 lo-18 lo-48 10-77
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Time o Time D Time o Time o Time of

Mark Page Mark Page Mark Page Mark Page Mark Page
revisior revision revisior revisior revision
IO-78 10-103 IO-150 10-192 IO-232
IO-79 10-104 IO-151 10-193 IO-233
IO-80 IO-106 lo-152 IO-194 lo-234
IO-81 IO-107 IO-153 10-195 IO-235
lo-82 lo-108 10-154 IO-196 IO-236
10-83-I @ IO-109 10-155 IO-197 lo-237
10-83-2 0 10-110 IO-156 IO-198 IO-238
10-83-3 @ IO-Ill 10-157 IO-199 IO-239
10-83-4 @ IO-112 IO-158 10-200 IO-241
10-83-5 @ IO-113 10-159 IO-201 lo-242
10-83-6 @ IO-114 lo-160 IO-202 IO-243
10-83-7 0 IO-115 lo-161 IO-203 lo-244
10-83-8 @ IO-116 lo-162 IO-204 IO-245
10-83-g @ lo-118 lo-164 IO-205
10-83-10 @ IO-119 lo-165 IO-206
10-83-11 @ IO-120 10-166 IO-207 20- 1
10-83-12 @ 10-121 IO-167 lo-208 20- l-l
10-83-13 @ IO-122 IO-168 IO-209 20- 2
10-83-14 @ IO-123 lo-169 IO-210 20- 3
10-83-15 0 IO-124 IO-170 IO-211 20- 4
10-83-16 0 IO-125 IO-171 IO-212 20- 5
IO-84 lo-126 IO-172 lo-213 20- 6
lo-85 IO-127 10-173 IO-214 20- 7
IO-86 lo-128 IO-174 IO-215 20- 8
lo-87 IO-129 IO-175 IO-216 20- 9
IO-88 IO-130 lo-176 lo-217 20-10
IO-89 IO-131 IO-178 IO-218 20-11
10-90 lo-132 IO-179 IO-219 20-12
IO-91 IO-133 IO-180 IO-220 20-13

10-92 10-134 0 lo-181 IO-221 20-14
IO-93 IO-140 lo-182 IO-222 20-15
10-94 IO-141 IO-183 IO-223 20-16
10-95 IO-142 lo-184 lo-224 20-17
lo-96 IO-143 lo-185 lo-225 20-18
10-97 IO-144 IO-186 lo-226 20-19
lo-98 @ IO-145 lo-187 lo-227 20-20
10-99 IO-146 IO-188 lo-228 20-21
10-100 10-147 IO-189 10-229 20-23
10-101 IO-148 IO-190 lo-230 20-24
10-102 IO-149 IO-191 IO-231 20-25
00-2-2
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Time Time Time Time of Time of
revisim revisi revisi revision revision
(20-101) 20-142 @ 20-203 @ 20-245 @ 20-377 @

20-102 @ 20-143 @ 20-204 @ 20-246 @ 20-378 @
20-103 @ 20-144 @ 20-205 @ 20-247 @ 20-379 @
20-104 @ 20-145 @ 20-206 0 20-248 @ 20-380 @
20-105 @ 20-146 @ 20-207 @ 20-249 @ 20-381 @
20-106 @ 20-147 @ 20-208 0 20-250 @ 20-382 @
20-107 0 20-148 @ 20-209 @ 20-251 0 20-383 @

20-108 @ 20-149 @ 20-210 Q) 20-252 @
20-109 0 20-150 0 20-211 0 20-253 @ 20-401 @

20-110 @ 20-151 @ l 20-212 @ 20-254 @ 20-402 @
20-111 @ 20-152 @ 20-214 @) 20-255 @ 20-403 @
20-112 @ 20-153 @ 20-215 @ 20-256 @ 20-404 @
20-113 @ 20-154 0 20-216 @ 20-405 0

20-114 0 20-155 @ 20-217 0 20-301 0 20-406 @
20-115 0 20-156 0 20-218 @ 20-302 @ 20-407 @
20-116 @ 20-157 @ 20-219 @ 20-303 @ 20-408 @

$
> 20-117 @ 20-158 @ 20-220 @ 20-409 @
% 20-118 @ 20-159 @ 20-221 @ 20-351 @ 20-410 @
20-119 0 20-160 @ 20-222 @ 20-352 @ 20-411 @
20-120 @ 20-161 @ 20-223 @ 20-354 @ 20-412 @
20-122 @ 20-162 @ 20-224 @ 20-355 @ 20-413 @
20-123 @ 20-163 @ 20-225 0 20-356 @ 20-414 @
20-124 @ 20-164 @ 20-226 @ 20-357 0 20-415 @
20-125 0 20-165 0 20-227 @ 20-358 @ 20-416 @
20-126 @ 20-166 @ 20-228 @ 20-359 @ 20-417 @
20-127 @ 20-167 @ 20-229 @ 20-360 @ 20-418 @
20-128 @ 20-168 @ 20-230 @ 20-361 @ 20-419 @
l 20-129 @ 20-169 @ 20-231 0 20-362 @ 20-420 @
20-130 @ 20-170 0 20-232 0 20-363 @ 20-421 @
20-131 @ 20-171 a 20-234 @ 20-364 0 20-422 @
20-132 @ 20-172 @ 20-235 @ 20-365 @ 20-423 @
20-133 @ 20-173 @ 20-236 @ 20-366 @
20-134 @ 20-174 @ 20-237 @ 20-367 @ l 20-451 @
20-135 @ 20-175 @ 20-238 @ 20-368 0 20-452 @

20-136 0 20-176 @ 20-239 @ 20-370 @ 20-454 @
20-137 @ 20-177 @ 20-240 @ 20-371 @ 20-455 @
20-138 @ 20-178 @ 20-241 @ 20-372 0 20-456 @
20-139 @ 20-242 @ 20-374 @ 20-457 @
20-140 @ 20-201 @ 20-243 0 20-375 @ 20-458 @
20-141 @ 20-202 @ 20-244 @ 20-376 @ 20-459 @
00-2-3
0
Time of Time oi Time of Time of Time of
Mark Page Vlark Page Mark Page Mark Page Mark Page
revision revisior revision revision revision
20-460 @ 20-511 @ 20-602 @ 20-651 @ 20-693 @

20-461 @ 20-512 @ 20-604 @) 20-652 @ 20-694 @
20-462 @ 20-605 0 20-653 @ 20-695 @
20-463 @ 20-551 @ 20-606 0 20-654 @ 20-696 @

20-464 @ 20-552 @ 20-607 @ 20-655 @ 20-697 @
20-465 @ 20-553 @ 20-608 @ 20-656 @ 20-698 @

20-466 @ 20-554 @ 20-609 @ 20-657 @ 20-699 @
l 20-467 @ 20-555 @ 20-610 0 20-658 @ 20-700 @
20-468 @ 20-556 @ 20-611 @) 20-660 @ 20-701 @
20-469 0 20-557 @ 20-612 @ 20-661 @ 20-702 @

20-470 @ 20-558 @ 20-613 @ 20-662 @ 20-703 @
20-471 @ 20-559 @ 20-614 @ 20-663 @ 20-704 @
20-472 @ 20-560 @ 20-615 0 20-664 @ 20-705 @

20-473 @ 20-561 @ 20-616 0 20-665 @ 20-706 @
20-474 @ 20-562 @ 20-617 0 20-666 @ 20-707 @
20-475 @ 20-564 @ 20-618 @ 20-667 @) 20-708 @

20-476 @ 20-565 @ 20-619 @ 20-668 @ 20-710 ($ g
>
20-477 @ 20-566 @ 20-620 @ 20-669 @
20-711 @ %
20-478 @ 20-567 @ 20-621 @ 20-670 @ 20-712 @
20-479 @ 20-568 @ 20-622 @ 20-671 @ 20-714 @
20-480 @ 20-569 @ 20-623 @ 20-672 @ 20-715 @
20-481 @ 20-570 @ 20-624 @ 20-673 @ 20-716 ($
20-482 @ 20-571 @ 20-625 @ 20-674 @ 20-717 @
20-483 @ 20-572 @ 20-626 @ 20-675 @ 20-718 @

20-484 @ 20-573 0 20-627 0 20-676 @ 20-719 @
20-485 @ 20-574 @ 20-628 @ 20-677 @) 20-720 @
20-486 @ 20-576 @ 20-629 @ 20-678 @ 20-721 @

20-487 @ 20-577 @ 20-630 @ 20-679 @ 20-722 @
20-488 @ 20-578 @ 20-631 @ 20-680 @ 20-723 @

20-579 @ 20-632 @ 20-681 @ 20-724 @
20-501 @ 20-580 @ 20-633 @ 20-682 @) 20-725 @
20-502 @ 20-581 @ 20-634 @ 20-683 0 20-726 @

20-503 @ 20-582 @ 20-635 0 20-684 @
20-504 @ 20-583 @ 20-636 @ 20-685 @ 20-751 @
20-505 @ 20-584 @ 20-637 @ 20-686 @ 20-752 @
20-506 @ 20-585 @ 20-638 @ 20-687 @ 20-753 @

20-507 @ 20-586 @ 20-639 @ 20-688 @ 20-754 @
20-508 @ 20-587 @ 20-640 @ 20-689 @ 20-755 @
20-509 @ 20-641 @ 20-690 @ 20-756 @

20-510 @ 20-601 @ 20-642 @ 20-692 0 20-757 @
00-2-4
0
Time oi Time of Time 01 Time oi Time of

revisior revision revisior revision revision
20-758 20-798 0 30-21 0 30-61 0 30-101 @

20-759 20-799 0 30-22 0 30-62 0 30-102 @
20-760 20-800 0 30-23 0 30-63 0 30-103 @
20-761 20-801 0 30-24 0 30-64 0 30-104 @
20-762 20-802 0 30-25 0 30-65 0 30-105 @
20-763 20-803 0 30-26 0 30-66 0 30-106 @
20-764 20-804 0 30-27 0 30-67 0 30-107 @
20-765 20-805 0 30-28 0 30-68 0 30-108 @
20-766 20-806 0 30-29 0 30-69 0 30-109 @
20-767 20-807 0 30-30 0 30-70 0 30-110 @
20-768 20-808 0 30-31 0 30-71 0 30-111 @
20-769 20-809 0 30-32 0 30-72 0 30-112 @

20-770 20-810 0 30-33 0 30-73 0 30-113 @
20-77 1 20-811 0 30-34 0 30-74 0 30-114 @
20-772 20-812 0 30-35 0 30-75 0 30-115 @
20-773 20-813 0 30-36 0 30-76 0 30-116 @
20-774 20-814 0 30-37 0 30-77 0 30-117 @
20-775 20-815 0 30-38 0 30-78 0 30-118 @
20-776 0 30-39 0 30-79 0 30-119 @

20-777 0 30-40 0 30-80 0 30-120 @
20-778 0 30-I 0 30-41 0 30-81 0 30-121 @
20-779 0 30-2 0 30-42 0 30-82 0 30-122 @
20-780 0 30-3 0 30-43 0 30-83 0 30-123 @
20-781 0 30-4 0 30-44 0 30-84 0 30-124 @
20-782 0 30-5 0 30-45 0 30-85 0 30-125 @
20-783 0 30-6 0 30-46 0 30-86 0 30-126 @
20-784 0 30-7 0 30-47 0 30-87 0 30-127 @
20-785 0 30-B 0 30-48 0 30-88 0 30-128 @
20-786 0 30-9 0 30-49 0 30-89 0 30-129 @
20-787 0 30-10 0 30-50 0 30-90 0 30-130 @
20-788 0 30-I 1 0 30-51 0 30-91 0 30-131 @
20-789 0 30-12 0 30-52 0 30-92 0 30-132 @
20-790 0 30-13 0 30-53 0 30-93 0 30-133 @

20-79 1 0 30-14 0 30-54 0 30-94 0 30-134 @
20-792 0 30-15 0 30-55 0 30-95 0 30-135 @
20-793 0 30-16 0 30-56 0 30-96 0 30-136 @
20-794 0 30-17 0 30-57 0 30-97 0 30-137 @
20-795 0 30-18 0 30-58 0 30-98 0 30-138 @
20-796 0 30-19 0 30-59 0 30-99 0 30-139 @
20-797 0 30-20 0 30-60 0 30-100 0 30-140 @
00-2-5
0
Time of Time oi Time of Time of Time of
revision revisior revision revision revision
0 30-141 @ 0 30-182 @ 0 40-14 go- 5
0 30-142 @ 0 30-183 @ 40-15 go- 7
0 30-143 @ 0 30-184 @ 40-15-l go- 9
0 30-144 @ 0 30-185 @ 40-15-2 90-11
0 30-145 @ 0 30-186 @ 40-16 90-13
0 30-146 @ 0 30-187 @ 40-17 90-15
0 30-147 @ 0 30-188 @ 40-18 90-17
0 30-148 @ 0 30-189 @ 40-19 90-17-2
0 30-149 @ 0 30-190 @ 40-20 90-17-4
0 30-150 @ 0 30-191 @ 40-21 90-17-6
0 30-151 @ 0 30-192 @ 40-22 90-17-8
0 30-152 @ 0 30-193 @ 40-23 90-19
0 30-153 @ 0 30-194 @ 40-24 90-21
0 30-154 @ 0 30-195 @ 40-25 90-23
0 30-155 @ 0 30-196 @ 40-26 90-25
0 30-156 @ 0 30-197 @ 40-27 90-27
0 30-157 @ 0 30-198 @ 40-28 90-29
0 30-158 @ 0 30-199 @ 40-29 90-31
0 30-159 @ 0 30-200 @ 40-30 90-33
0 30-160 @ 0 30-201 @ 40-31 90-35
0 30-161 @ 0 30-202 @ 40-32 90-37
0 30-162 @ 0 30-203 @ 40-33 90-39
0 30-163 @ 0 30-204 @ 40-34 90-41
0 30-164 @ 0 30-205 @ 40-35 90-43
0 30-165 @ 0 30-206 @ 40-36 go-201
0 30-166 @ 0 30-207 @ 40-37
0 30-167 @ 0 30-208 @ 40-38
0 30-168 @ 40-39
0 30-169 @ 40-40
0 30-170 @ 40- 1 40-41
0 30-172 @ 40- 2 40-42
0 30-173 @ 40- 3 40-43
0 30-174 @ 40- 4 40-44
0 30-175 @ 40- 6 40-45
0 30-176 @ 40- 7 40-46
0 30-177 @ 40- 8 40-47
0 30-178 @ 40-10
0 30-179 @ 40-11
0 30-180 @ 40-12 go- 1
0 30-181 @ 40-13 go- 3
00-2-6
0
SAFETY SAFETY NOTICE
SAFETY
SAFETY NOTICE
IMPORTANT SAFETY NOTICE
Proper service and repair is extremely important for safe machine operation. The
service and repair techniques recommended by Komatsu and described in this manual
are both effective and safe. Some of these techniques require the use of tools specially
designed by Komatsu for the specific purpose.
To prevent injury to workers, the symbol A is used to mark safety precautions in this
manual. The cautions accompanying these symbols should always be followed care-
fully. If any dangerous situation arises or may possibly arise, first consider safety, and
take the necessary actions to deal with the situation.
GENERAL PRECAUTIONS 6. Decide a place in the repair workshop to

keep tools and removed parts. Always keep
Mistakes in operation are extremely dangerous. the tools and parts in their correct places.
Read the Operation and Maintenance Manual Always keep the work area clean and make
carefully BEFORE operating the machine. sure that there is no dirt or oil on the floor.
1. Before carrying out any greasing or repairs, Smoke only in the areas provided for smok-
read all the precautions given on the decals ing. Never smoke while working.
which are fixed to the machine.
2. When carrying out any operation, always PREPARATIONS FOR WORK

wear safety shoes and helmet. Do not wear
loose work clothes, or clothes with buttons Before adding oil or making any repairs,
missing. park the machine on hard, level ground, and
. Always wear safety glasses when hitting block the wheels or tracks to prevent the
parts with a hammer. machine from moving.
. Always wear safety glasses when grind-
Before starting work, lower blade, ripper,
ing parts with a grinder, etc.
bucket or any other work equipment to the
3. If welding repairs are needed, always have a ground. If this is not possible, insert the
trained, experienced welder carry out the safety pin or use blocks to prevent the work
work. When carrying out welding work, al- equipment from falling. In addition, be sure
ways wear welding gloves, apron, hand to lock all the control levers and hang warn-
shield, cap and other clothes suited for welding signs on them.
ing work.
9. When disassembling or assembling, support
4. When carrying out any operation with two the machine with blocks, jacks or stands
or more workers, always agree on the oper- before starting work.
ating procedure before starting. Always in-
10. Remove all mud and oil from the steps or
form your fellow workers before starting any
other places used to get on and off the ma-
step of the operation. Before starting work,
chine. Always use the handrails, ladders or
hang UNDER REPAIR signs on the controls
steps when getting on or off the machine.
in the operator’s compartment.
Never jump on or off the machine. If it is
5. Keep all tools in good condition and learn impossible to use the handrails, ladders or
the correct way to use them. steps, use a stand to provide safe footing.
00-3
SAFETY SAFETY NOTICE
PRECAUTIONS DURING WORK 19. Be sure to assemble all parts again in their
original places.
11. When removing the oil filler cap, drain plug Replace any damaged parts with new parts.
or hydraulic pressure measuring plugs, . When installing hoses and wires, be sure
loosen them slowly to prevent the oil from that they will not be damaged by contact
spurting out. with other parts when the machine is be-
Before disconnecting or removing compo- ing operated.
nents of the oil, water or air circuits, first
20. When installing high pressure hoses, make
remove the pressure completely from the
sure that they are not twisted. Damaged
circuit.
tubes are dangerous, so be extremely care-
12. The water and oil in the circuits are hot ful when installing tubes for high pressure
when the engine is stopped, so be careful circuits. Also, check that connecting parts
not to get burned. are correctly installed.
Wait for the oil and water to cool before
21. When assembling or installing parts, always
carrying out any work on the oil or water
use the specified tightening torques. When
circuits.
installing protective parts such as guards,
13. Before starting work, remove the leads from or parts which vibrate violently or rotate at
the battery. Always remove the lead from high speed, be particularly careful to check
the negative H terminal first. that they are installed correctly.
14. When raising heavy components, use a hoist 22. When aligning two holes, never insert your
or crane. fingers or hand. Be careful not to get your
Check that the wire rope, chains and hooks fingers caught in a hole.
are free from damage.
23. When measuring hydraulic pressure, check
Always use lifting equipment which has
that the measuring tool is correctly assem-
ample capacity.
bled before taking any measurements.
Install the lifting equipment at the correct
places. Use a hoist or crane and operate
24. Take care when removing or installing the
slowly to prevent the component from hit-
tracks of track-type machines.
ting any other part. Do not work with any
When removing the track, the track sepa-
part still raised by the hoist or crane.
rates suddenly, so never let anyone stand at
15. When removing covers which are under in- either end of the track.
ternal pressure or under pressure from a
spring, always leave two bolts in position
on opposite sides. Slowly release the pres-
sure, then slowly loosen the bolts to remove.
16. When removing components, be careful not

to break or damage the wiring. Damaged
wiring may cause electrical fires.
17. When removing piping, stop the fuel or oil
from spilling out. If any fuel or oil drips onto
the floor, wipe it up immediately. Fuel or oil
on the floor can cause you to slip, or can
even start fires.
18. As a general rule, do not use gasoline to

wash parts. In particular, use only the mini-
mum of gasoline when washing electrical
parts.
00-4
FOREWORD GENERAL
FOREWORD
GENERAL
This shop manual has been prepared as an aid to improve the quality of repairs by giving the
serviceman an accurate understanding of the product and by showing him the correct way to perform
repairs and make judgements. Make sure you understand the contents of this manual and use it to full
effect at every opportunity.
This shop manual mainly contains the necessary technical information for operations performed in a
service workshop. For ease of understanding, the manual is divided into the following chapters; these
chapters are further divided into the each main group of components.
STRUCTURE AND FUNCTION

This section explains the structure and function of each component. It serves not only to give
an understanding of the structure, but also serves as reference material for troubleshooting.
TESTING AND ADJUSTING

This section explains checks to be made before and after performing repairs, as well as
adjustments to be made at completion of the checks and repairs.
Troubleshooting charts correlating “Problems” to “Causes” are also included in this section.
DISASSEMBLY AND ASSEMBLY

This section explains the order to be followed when removing, installing, disassembling or
assembling each component, as well as precautions to be taken for these operations.
MAINTENANCE STANDARD
This section gives the judgement standards when inspecting disassembled parts.
NOTICE
The specifications contained in this shop manual are subject to change at any
time and without any advance notice. Use the specifications given in the book
with the latest date.
00-5
FOREWORD HOW TO READ THE SHOP MANUAL
HOW TO READ THE SHOP MANUAL
VOLUMES REVISED EDITION MARK
Shop manuals are issued as a guide to carrying When a manual is revised, an edition mark
out repairs. They are divided as follows: (a@@....) is recorded on the bottom of the
Chassis volume: Issued for every machine model pages.
Engine volume: Issued for each engine series
Electrical volume: Each issued as one
Attachments volume: volume to cover all REVISIONS
I models
Revised pages are shown in the LIST OF RE-
These various volumes are designed to avoid VISED PAGES next to the CONTENTS page.
duplicating the same information. Therefore, to
deal with all repairs for any model , it is neces-
sary that chassis, engine, electrical and attach-
SYMBOLS
ment volumes be available.
So that the shop manual can be of ample prac-
DISTRIBUTION AND UPDATING tical use, important safety and quality portions
are marked with the following symbols.
Any additions, amendments or other changes
will be sent to KOMATSU distributors. Get the
most up-to-date information before you start any
work.
FILING METHOD
1. See the page number on the bottom of the Remarks
page. File the pages in correct order.
2. Following examples show how to read the Special safety precautions are
necessary when performing
page number. the work.
Example 1 (Chassis volume):
Special technical precautions
10 - 3
or other precautions for pre-
* Caution serving standards are neces-
Item number (IO. Structure sary when performing the
and Function) work.
Consecutive page number for
Weight of parts of systems.
each item. Caution necessary when se-
Weight lecting hoisting wire, or when
Example 2 (Engine volume): working posture is important,
etc.
Places that require special at-

Tightening
Unit number (1. Engine) tention for the tightening
w torque torque during assembly.
Item number (2. Testing and
Adjusting) Places to be coated with ad-
Consecutive page number for 6 Coat
hesives and lubricants, etc.
each item.
Places where oil, water or fuel
Oil, water must be added, and the ca-
3. Additional pages: Additional pages are indi- pacity.
cated by a hyphen (-1 and number after the
Places where oil or water
page number. File as in the example. - : Drain must be drained, and quan-
Example: tity to be drained.
IO-4 12-203
10-4-I -
> Added pages -c~f:f~~:~
1O-4-2
IO-5 12-204
00-6
FOREWORD HOISTING INSTRUCTIONS
HOISTING INSTRUCTIONS
HOISTING
Slinging near the edge of the hook may
Heavy parts (25 kg or more) must be cause the rope to slip off the hook during
lifted with a hoist, etc. In the DISAS- hoisting, and a serious accident can re-
sult. Hooks have maximum strength at
every part weighing 25 kg or more is the middle portion.
indicated clearly with the symbol &
. If a part cannot be smoothly removed from

the machine by hoisting, the following checks
should be made:
I) Check for removal of all bolts fastening 100% 88% 79% 71% 41%
the part to the relative parts. SAM10479
2) Check for existence of another part caus- 3) Do not sling a heavy load with one rope
ing interference with the part to be re- alone, but sling with two or more ropes
moved. symmetrically wound onto the load.
A Slinging with one rope may cause

turning of the load during hoisting,
untwisting of the rope, or slipping of
WIRE ROPES
the rope from its original winding
1) Use adequate ropes depending on the
position on the load, which can re-
weight of parts to be hoisted, referring to
sult in a dangerous accident.
the table below:
Wire ropes 4) Do not sling a heavy load with ropes form-

(Standard “Z” or “S” twist ropes ing a wide hanging angle from the hook.
without galvanizing) When hoisting a load with two or more
ropes, the force subjected to each rope
Rope diameter T Allowable load will increase with the hanging angles. The
table below shows the variation of allow-
mm kN tons
able load kN {kg) when hoisting is made
10 9.8 1.0 with two ropes, each of which is allowed
11.2 13.7 1.4 to sling up to 9.8 kN 11000 kg) vertically,
at various hanging angles.
12.5 15.7 1.6
When two ropes sling a load vertically, up
14 21.6 2.2
to 19.6 kN (2000 kg) of total weight can be
16 27.5 2.8 suspended. This weight becomes 9.8 kN
18 35.3 3.6 {IO00 kg) when two ropes make a 120”
20 43.1 4.4 hanging angle. On the other hand, two

ropes are subjected to an excessive force
22.4 54.9 5.6
as large as 39.2 kN 14000 kg) if they sling
30 98.1 10.0
a 19.6 kN (2000 kg) load at a lifting angle
40 176.5 18.0 of 150”.
ar, A
50 274.6 28.0
60 392.2 40.0
f The allowable load value is estimated to

be one-sixth or one-seventh of the break-
ing strength of the rope used.
I
2) Sling wire ropes from the middle portion 30 60 90 120 150
of the hook. Lifting mole (deoreel SAD00480
00-7
FOREWORD COATING MATERIALS
COATING MATERIALS
* The recommended coating materials such as adhesives, gasket sealants and greases used for
disassembly and assembly are listed below.
Ir For coating materials not listed below, use the equivalent of products shown in this list.
Category :omatsu code Part No. Q’w Container Main applications, features
l Used to prevent rubber gaskets, rubber

LT-IA 790-129-9030 150 g Tube
cushions, and cock plug from coming out.
l Used in places requiring an immediately

effective, strong adhesive. Used for plas-
790-129-9050 20 9 Polyethylene
LT-1 B tics (except polyethylene, polyprophylene,
(2 pes.) container
tetrafluoroethlene and vinyl chloride), rub-
ber, metal and non-metal.
l Features: Resistance to heat and chemi-

Polyethylene cals
LT-2 09940-00030 50 g container l Used for anti-loosening and sealant pur-
pose for bolts and plugs.
790-129-9060 4dhesive: l Used as adhesive or sealant for metal, glass

(Set of adhe- 1 kg and plastic.
LT-3 sive and iardeninc Can
hardening agent:
agent) 500 g
Adhesives
Polyethylene . Used as sealant for machined holes.
LT-4 790-129-9040 250 g
container
Holtz l Used as heat-resisting sealant for repair-

790-126-9120 75 g Tube
MH 705 ing engine.
l Quick hardening type adhesive

Three bond Polyethylene l Cure time: within 5 sec. to 3 min.
790-129-9140 50 g
1735 container l Used mainly for adhesion of metals, rub-
bers, plastics and woods.
I* Quick
l
hardening type adhesive
Quick cure type (max. strength after 30 min-
Aron-alpha Polyethylene
790-129-9130 29 utes)
201 container
l Used mainly for adhesion of rubbers, plas-
tics and metals.
l Features: Resistance to heat, chemicals

Loctite Polyethylene
r9A-129-9110 50 cc l Used at joint portions subject to high tem-
648-50 container
peratures.
l Used as adhesive or sealant for gaskets

LG-1 790-129-9010 200 g Tube
and packing of power train case, etc.
l Features: Resistance to heat

l Used as sealant for flange surfaces and
Gasket bolts at high temperature locations, used
sealant to prevent seizure.
LG-3 790-129-9070 1 kg Can
l Used as sealant for heat resistance gasket
for high temperature locations such as en-
gine precombustion chamber, exhaust
pipe, etc.
00-8
FOREWORD COATING MATERIALS
Category Komatsu code Part No. Q'W Container Main applications, features
I I I I I l
l
Features: Resistance to water, oil
Used as sealant for flanae surface, thread.
I LG-4
17go-12g-go201 2oo ’ / Tube /
l Also possible to use as sealant for flanges
with large clearance.
I I I I I l Used assealant for mating surfaces of fi-

nal drive case, transmission case.
l Used as sealant for various threads, pipe

Polyethylene joints, flanges.
LG-5 790-129-9080 1 kg container l Used as sealant for tapered plugs, elbows,
nipples of hydraulic piping.
l Features: Silicon based, resistance to heat,

Gasket cold
sealant LG-6 09940-00011 Tube l Used as sealant for flange surface, tread.
l Used as sealant for oil pan, final drive case,
etc.
l Features: Silicon based, quick hardening

type
LG-7 09920-00150 Tube l Used as sealant for flywheel housing, in-
take manifold, oil an, thermostat housing,
etc.
Three bond l Used as heat-resisting sealant for repairing

790-129-9090 1 engine.
1211 loo g / Tube
Used as lubricant for sliding portion (to pre-

LM-G
Molybde- ogg40-ooo51 / ” g / Can 1. vent from squeaking).
num I I I I
disulphide l Used to prevent seizure or scuffling of the
lubricant LM-P 09940-00040 200 g Tube thread when press fitting or shrink fitting.
l Used as lubricant for linkage, bearings, etc.
SYG2-400LI l General purpose type

SYG2-350LI
G2-LI SYG2-4OOLI-A Various Various
SYG2-16OLI
SYGA-16OCNLI
l Used for normal temperature, light load

SYG24OOCA bearing at places in contact with water or
Grease
SYG2-350CA steam.
GP-CA SYG2-4OOCA-A Various Various
SYG2-16OCA
SYGA-16OCNCA
1
Mc$?_!~~ SYG2-400M ~ (!!l{r IRelows type1
l Used for places with heavy load
00-9
FOREWORD STANDARD TIGHTENING TORQUE
STANDARD TIGHTENING TORQUE
STANDARD TIGHTENING TORQUES OF BOLTS AND NUTS

Use these torques for metric bolts and nuts. (Always use torque wrench).
Thread diameter Width

of bolt across flats
I
mm mm Nm Mm
6 10 13.2zk 1.4 1.35kO.15
8 13 31*3 3.2 ?I0.3
IO 17 66k7 6.7 k 0.7
12 19 113k 10 11.5* 1
14 22 177zk 19 18f2
16 24 279 * 30 28.5+3
18 27 382 k 39 39+4
20 30 549 ? 59 56k6
22 32 745k 83 76f 8.5
24 36 927f 103 94.5* 10.5
27 41 1320f 140 135+ 15
30 46 1720+ 190 175+20
33 50 2210f240 225k25
36 2750 f 290 280 k 30
39 3290 + 340 335k35
Threadof diameter
bolt Widthfiats
across 0 07
CDL00313
mm mm Nm krm
6 10 7.85? 1.95 0.8 + 0.2
8 13 18.6f 4.9 1.9-to.5
10 14 40.2 i 5.9 4.1 k 0.6
12 27 82.35f 7.85 8.4 + 0.8
TIGHTENING TORQUE OF HOSE NUTS

Use these torques for hose nuts.
Thread diameter Width across flat Tightening torque
Nominal No.
mm mm Nm kgm
02 14 19 24.5 + 4.9 2.5f 0.5
03 18 24 49f 19.6 5f2
04 22 27 78.5f 19.6 8f2
:: 24
30 3: 137.3f 29.4
176.5f 18f3
14f3
10 33 41 196.1+49 20?5
12 36 46 245.2 f 49 25+ 5
14 42 55 294.2 k 49 30+5
TIGHTENING TORQUE OF SPLIT FLANGE BOLTS

Use these torques for split flange bolts.

I I
mm mm Nm Mm
10 14 65.7 f 6.8 6.7 rt 0.7
12 17 112f9.8 11.5+1
16 22 279 + 29 28.5f3
00-l0
TIGHTENING TORQUE OF O-RING BOSS CONNECTOR

Use these torques for O-ring boss connector

Nominal No.
mm mm Nm kgm
02 14 34.3+ 4.9 3.5kO.5
03,04 20 Varies depending on 93.1k9.8 9.5fl
05,06 24 type of connector. 142.1+ 19.6 14.5f2
IO,12 33 421.4? 58.8 43+6
14 42 877.1k 132.3 89.5k13.5
TIGHTENING TORQUE OF O-RING BOSS CONNECTOR

Nominal No.
Thread diameter Width across flat Tighteni ns3 torque
mm mm Nm kgm
08 8 14 7.35* 1.47 0.75f0.15
10 10 17 11.27+ 1.47 1.15f0.15
12 12 19 17.64+ 1.96 1.8kO.2
14 14 22 22.54f1.96 2.3k0.2
16 16 24 29.4+ 4.9 3f0.5
18 18 27 39.2+ 4.9 4Iko.5
20 20 30 49+ 4.9 5f0.5
24 24 32 68.659.8 7fl
30 30 32 107.8+ 14.7 llf1.5
33 33 - 127.4k19.6 13+2
36 36 36 151.9f24.5 15.5f2.5
42 42 - 210.7f29.4 21.5f3
52 52 - 323.4f44.1 33rt 4.5
-
TIGHTENING TORQUES OF FLARE NUT

SAD00483
Thread diameter 1 Width across flat 1 Tightening toraue
mm mm Nm bm
14 19 24.5f 4.9 2.5kO.5
18 24 49+ 19.6 5f2
22 27 78.5k19.6 8f2
24 32 137.3f29.4 14f3
30 36 176.5f29.4 18f3
33 41 196.1f49 20f5
36 46 245.2f49 2555
42 55 294.2+49 30f5
00-l 1
TIGHTENING TORQUE FOR 102 SERIES ENGINE (BOLT AND NUTS)

Use these torques for metric bolts and nuts of 102 Series Engine.
Thread diameter Tightening torque

mm Nm kgm
6 IO f 2 1.02 f 0.20
8 24 f 4 2.45 f 0.41
10 43 t 6 4.38 f 0.61
12 77 + 12 7.85 f 1.22
TIGHTENING TORQUE FOR 102 SERIES ENGINE (EYE JOINTS)

Use these torques for metric eye joints of 102 Series Engine.

mm Nm kgm
6 8i2 0.81 f 0.20
8 lOi 1.02 f 0.20
10 12i2 1.22 f 0.20
12 24 r!z
4 2.45 f 0.41
14 36 k 5 3.67 +_0.51
TIGHTENING TORQUE FOR 102 SERIES ENGINE (TAPERED SCREWS)

Use these torques for inches tapered screws of 102 Series Engine.

inches Nm kgm
l/If?
., ._ 3fl 0.31 k 0.10
118 8f2 0.81 + 0.20
l/4 12f2 1.22 k 0.20
318 15f2 1.53 f 0.41
112 24 + 4 2.45 f 0.41
314 36 f 5 3.67 f 0.51
1 60 f 9 6.12 f 0.92
00-12
FOREWORD ELECTRIC WIRE CODE
ELECTRIC WIRE CODE
In the wiring diagrams, various colors and symbols are employed to indicate the thickness of wires.
This wire code table will help you understand WIRING DIAGRAMS.
Example: 5WB indicates a cable having a nominal number 5 and white coating with black stripe.
CLASSIFICATION BY THICKNESS
Copper wire
Ca;kzjD. Curre;;rating
Nu,tTaF;sof Dia. T;s$nds Cros;qtion Applicable circuit
0.85 11 0.32 0.88 2.4 12 Starting, lighting, signal etc.

I I I I I I
2 26 0.32 2.09 3.1 20 Lighting, signal etc.
5 65 0.32 5.23 4.6 37 Charging and signal
15 84 0.45 13.36 7.0 59 Starting (Glow plug)
40 I 85 I 0.80 I 42.73 I 11.4 I 135 I Starting
60 127 0.80 63.84 13.6 178 Starting
100 217 0.80 109.1 17.6 230 Starting
CIassi-
\
ication
Circuits
Charging Lighting
I
Instrument Signal Other
1
pri_ Code w I B I B R I y I G I L
mary t Color White I Black I Black Red I Yellow I Green I Blue
2
1Code WR 1 - 1 BW RW I YR I GW I LW
Whit;: Red 1 I /lack;White Red & White Yellow & Red Green &White Blue &White
RB YB GR LR
3
WhitzBlackI I /lack i:lloM Red & Black Yellow & Black Green & Red Blue & Red
RY YG GY LY
;
White & Blue1 - I Black & Red Red & Yellow~ellow & GreenlGreen & YellowlBlue & Yellow
Code WG 1 - 1 - RG I YL I GB I LB
t Color White & Green] - I - Red & Green bellow & BluelGreen & Black1 Blue & Black
6
Code - l-l - RL I YvJ I GL I -
t Color - l-l - Red & Blue tv ellow & WhiteIGreen & Blue1 -
00-l 3
FOREWORD CONVERSION TABLE
CONVERSION TABLE
METHOD OF USING THE CONVERSION TABLE

The Conversion Table in this section is provided to enable simple conversion of figures. For
details of the method of using the Conversion Table, see the example given below.
EXAMPLE
. Method of using the Conversion Table to convert from millimeters to inches
1. Convert 55 mm into inches.
(I) Locate the number 50 in the vertical column at the left side, take this as @, then draw a horizontal
line from @.
(2) Locate the number 5 in the row across the top, take this as @, then draw a perpendicular line
down from @.
(3) Take the point where the two lines cross as 0. This point @ gives the value when converting
from millimeters to inches. Therefore, 55 mm = 2.165 inches.
2. Convert 550 mm into inches.

(I) The number 550 does not appear in the table, so divide by IO (move the decimal point one place
to the left) to convert it to 55 mm.
(2) Carry out the same procedure as above to convert 55 mm to 2.165 inches.
(3) The original value (550 mm) was divided by 10, so multiply 2.165 inches by 10 (move the decimal
point one place to the right) to return to the original value. This gives 550 mm = 21.65 inches.
@
Millimeters to inches 1 mm = 0.03937 in
I I
0 1 2 3 4 5 ; 6 7 8 9
A
0 0 0.039 0.079 0.118 0.157 0.197! 0.236 0.276 0.315 0.354

IO 0.394 0.433 0.472 0.512 0.551 0.591; 0.630 0.669 0.709 0.748
20 0.787 0.827 0.866 0.906 0.945 0.984 i 1.024 1.063 1.102 1.142
30 1.181 1.220 1.260 1.299 1.339 1.378 i 1.417 1.457 1.496 1.536
40 1.575 1.614 1.654 1.693 1.732 1.772 : 1.811 1.850 1.890 1.929
.. . 50
. .. . .. . . ..1.969
. .. . .. . . . ..2.008
.. . . . . . . . .2.047
. . . . . . . .. . .. .. 2.087
. .. . .. .. . . . .2.126
. . . . .. . . 2.205 2.244 2.283 2.323
@- 2.362 2.402 2.441 2.480 2.520 2.598 2.638 2.677 2.717
60
70 2.756 2.795 2.835 2.874 2.913 2.953 2.992 3.032 3.071 3.110
80 3.150 3.189 3.228 3.268 3.307 3.346 3.386 3.425 3.465 3.504
90 3.543 3.583 3.622 3.661 3.701 3.740 3.780 3.819 3.858 3.898
00-l 4
Millimeters to Inches
1 mm = 0.03937 in
0 1 2 3 4 5 6 7 8 9
0 0 0.039 0.079 0.118 0.157 0.197 0.236 0.276 0.315 0.354
IO 0.394 0.433 0.472 0.512 0.551 0.591 0.630 0.669 0.709 0.748
20 0.787 0.827 0.866 0.906 0.945 0.984 1.024 1.063 1.102 1.142
30 1.181 1.220 1.260 1.299 1.339 1.378 1.417 1.457 1.496 1.536
40 1.575 1.614 1.654 1.693 1.732 1.772 1.811 1.850 1.890 1.929
50 1.969 2.008 2.047 2.087 2.126 2.165 2.205 2.244 2.283 2.323
60 2.362 2.402 2.441 2.480 2.520 2.559 2.598 2.638 2.677 2.717
70 2.756 2.795 2.835 2.874 2.913 2.953 2.992 3.032 3.071 3.110
80 3.150 3.189 3.228 3.268 3.307 3.346 3.386 3.425 3.465 3.504
90 3.543 3.583 3.622 3.661 3.701 3.740 3.780 3.819 3.858 3.898
Kilogram to Pound
1 kg = 2.2046 lb
0 1 2 3 4 5 6 9
0 0 2.20 4.41 6.61 8.82 11.02 13.23 15.43 17.64 19.84
IO 22.05 24.25 26.46 28.66 30.86 33.07 35.27 37.48 39.68 41.89
20 44.09 46.30 48.50 50.71 51.91 55.12 57.32 59.53 61.73 63.93
30 66.14 68.34 70.55 72.75 74.96 77.16 79.37 81.57 83.78 85.98
40 88.18 90.39 92.59 94.80 97.00 99.21 101.41 103.62 105.82 108.03
50 110.23 112.44 114.64 116.85 119.05 121.25 123.46 125.66 127.87 130.07
60 132.28 134.48 136.69 138.89 141.10 143.30 145.51 147.71 149.91 152.12
70 154.32 156.53 158.73 160.94 163.14 165.35 167.55 169.76 171.96 174.17
80 176.37 178.57 180.78 182.98 185.19 187.39 189.60 191.80 194.01 196.21
90 198.42 200.62 202.83 205.03 207.24 209.44 211.64 213.85 216.05 218.26
00-l5
FOREWORD CONVERSIONTABLE
Liter to U.S. Gallon

lf = 0.2642 U.S. Gal
5 6 7 8 9
0 0 0.264 0.528 0.793 1.057 1.321 1.585 1.849 2.113 2.378
10 2.642 2.906 3.170 3.434 3.698 3.963 4.227 4.491 4.755 5.019
20 5.283 5.548 5.812 6.076 6.340 6.604 6.869 7.133 7.397 7.661
30 7.925 8.189 8.454 8.718 8.982 9.246 9.510 9.774 10.039 10.303
40 10.567 10.831 11.095 11.359 11.624 11.888 12.152 12.416 12.680 12.944
50 13.209 13.473 13.737 14.001 14.265 14.529 14.795 15.058 15.322 15.586
60 15.850 16.115 16.379 16.643 16.907 17.171 17.435 17.700 17.964 18.228
70 18.492 18.756 19.020 19.285 19.549 19.813 20.077 20.341 20.605 20.870
80 21.134 21.398 21.662 21.926 22.190 22.455 22.719 22.983 23.247 23.511
90 23.775 24.040 24.304 24.568 24.832 25.096 25.361 25.625 25.889 26.153
Liter to U.K. Gallon

I! = 0.21997 U.K. Gal
4- 0
10
0
0
2.200
1
0.220
2.420
2
0.440
2.640
3
0.660
2.860
4
0.880
3.080
5
1.100
3.300
6
1.320
3.520
7
1.540
3.740
8
1.760
3.950
9
1.980
4.179
20 4.399 4.619 4.839 5.059 5.279 5.499 5.719 5.939 6.159 6.379
30 6.599 6.819 7.039 7.259 7.479 7.969 7.919 8.139 8.359 8.579
40 8.799 9.019 9.239 9.459 9.679 9.899 10.119 10.339 10.559 10.778
50 10.998 11.281 11.438 11.658 11.878 12.098 12.318 12.528 12.758 12.978
60 13.198 13.418 13.638 13.858 14.078 14.298 14.518 14.738 14.958 15.178
70 15.398 15.618 15.838 16.058 16.278 16.498 16.718 16.938 17.158 17.378
80 17.598 17.818 18.037 18.257 18.477 18.697 18.917 19.137 19.357 19.577
90 19.797 20.017 20.237 20.457 20.677 20.897 21.117 21.337 21.557 21.777
00-16
kgm to ft. lb
1 kgm = 7.233 ft. lb
0 1 2 3 4 5 6 7 8 9
\
0 0 7.2 14.5 21.7 28.9 36.2 43.4 50.6 57.9 65.1
10 72.3 79.6 86.8 94.0 101.3 108.5 115.7 123.0 130.2 137.4
20 144.7 151.9 159.1 166.4 173.6 180.8 188.1 195.3 202.5 209.8
30 217.0 224.2 231.5 238.7 245.9 253.2 260.4 267.6 274.9 282.1
40 289.3 296.6 303.8 311.0 318.3 325.5 332.7 340.0 347.2 354.4
50 361.7 368.9 376.1 383.4 390.6 397.8 405.1 412.3 419.5 426.8
60 434.0 441.2 448.5 455.7 462.9 470.2 477.4 484.6 491.8 499.1
70 506.3 513.5 520.8 528.0 535.2 542.5 549.7 556.9 564.2 571.4
80 578.6 585.9 593.1 600.3 607.6 614.8 622.0 629.3 636.5 643.7
90 651.0 658.2 665.4 672.7 679.9 687.1 694.4 701.6 708.8 716.1
100 723.3 730.5 737.8 745.0 752.2 759.5 766.7 773.9 781.2 788.4
110 795.6 802.9 810.1 817.3 824.6 831.8 839.0 846.3 853.5 860.7
120 868.0 875.2 882.4 889.7 896.9 904.1 911.4 918.6 925.8 933.1
130 940.3 947.5 954.8 962.0 969.2 976.5 983.7 990.9 998.2 1005.4
140 1012.6 1019.9 1027.1 1034.3 1041.5 1048.8 1056.0 1063.2 1070.5 1077.7
1099.4
,
150 1084.9 1092.2 1106.6 1113.9 1121.1 1128.3 :1135.6 1142.8 1150.0
160 1157.3 1164.5 1171.7 1179.0 1186.2 1193.4 1200.7 11207.9 1215.1 1222.4
L
170 1129.6 1236.8 1244.1 11251.3 1258.5 1265.8 1273.0 11280.1 1287.5 1294.7
180 1301.9 1309.2 1316.4 11323.6 1330.9 1338.1 1345.3 11352.6 1359.8 1367.0
190 1374.3 1381.5 1388.7 11396.0 1403.2 1410.4 1417.7 11424.9 1432.1 1439.4
- - - - -
00-17
kg/cm2 to lb/in*
1 kg/cm* = 14.2233 Ib/in*
0 1 2 3 4 5 6 7 8 9
0 0 14.2 28.4 42.7 56.9 71.1 85.3 99.6 113.8 128.0
10 142.2 156.5 170.7 184.9 199.1 213.4 227.6 241.8 256.0 270.2
20 284.5 298.7 312.9 327.1 341.4 355.6 369.8 384.0 398.3 412.5
30 426.7 440.9 455.1 469.4 483.6 497.8 512.0 526.3 540.5 554.7
40 568.9 583.2 597.4 611.6 625.8 640.1 654.3 668.5 682.7 696.9
50 711.2 725.4 739.6 753.8 768.1 782.3 796.5 810.7 825.0 839.2
60 853.4 867.6 881.8 896.1 910.3 924.5 938.7 953.0 967.2 981.4
70 995.6 1010 1024 1038 1053 1067 1081 1095 1109 1124
80 1138 1152 1166 1181 1195 1209 1223 1237 1252 1266
90 1280 1294 1309 1323 1337 1351 1365 1380 1394 1408
100 1422 1437 1451 1465 1479 1493 1508 1522 1536 1550
110 1565 1579 1593 1607 1621 1636 1650 1664 1678 1693
120 1707 1721 1735 1749 1764 1778 1792 1806 1821 1835
130 1849 1863 1877 1892 1906 1920 1934 1949 1963 1977
140 1991 2005 2020 2034 2048 2062 2077 2091 2105 2119
150 2134 2148 2162 2176 2190 2205 2219 2233 2247 2262
160 2276 2290 2304 2318 2333 2347 2361 2375 2389 2404
170 2418 2432 2446 2460 2475 2489 2503 2518 2532 2546
180 2560 2574 2589 2603 2617 2631 2646 2660 2674 2688
190 2702 2717 2731 2745 2759 2773 2788 2802 2816 2830
200 2845 2859 2873 2887 2901 2916 2930 2944 2958 2973
210 2987 3001 3015 3030 3044 3058 3072 3086 3101 3115
220 3129 3143 3158 3172 3186 3200 3214 3229 3243 3257
230 3271 3286 3300 3314 3328 3343 3357 3371 3385 3399
240 3414 3428 3442 3456 3470 3485 3499 3513 3527 3542
00-l 8
Temperature
Conversion ; a simple way to convert a Fahrenheittemperature reading intoa Centigradetempera-
Fahrenheit-Centigrade
ture reading or vice versa is to enter the accompanying tablein the centeror boldfacecolumn of figures.
These figuresrefertothetemperature in eitherFahrenheit or Centigrade degrees.
Ifitis desired to convert from Fahrenheit to Centigrade degrees, consider the center column as a table of Fahrenheit
temperatures and read the corresponding Centigrade temperature in the column at the left.
IfitisdesiredtoconvertfromCentigradeto Fahrenheitdegrees,considerthecenter column as atable of Centigrade values,
and read the corresponding Fahrenheit temperature on the right.
1°C = 33.8"F
“C “F “C “F “C “F “C “F
-40.4 -40 -40.0 -11.7 11 51.8 7.8 46 114.8 27.2 81 117.8

-37.2 -35 -31.0 -11.1 12 53.6 8.3 47 116.6 27.8 82 179.6
-34.4 -30 -22.0 -10.6 13 55.4 8.9 46 118.4 28.3 63 181.4
-31.7 -25 -13.0 -10.0 14 57.2 9.4 49 120.2 28.9 84 183.2
-28.9 -20 -4.0 -9.4 15 59.0 10.0 50 122.0 29.4 85 185.0
-28.3 -19 -2.2 -8.9 16 60.8 10.6 51 123.8 30.0 86 186.8

-27.8 -18 -0.4 -8.3 17 62.6 11.1 52 125.6 30.6 87 188.6
-27.2 -17 1.4 -7.8 18 64.4 11.7 53 127.4 31.1 88 190.4
-26.7 -16 3.2 -7.2 19 66.2 12.2 54 129.2 31.7 89 192.2
-26.1 -15 5.0 -6.7 20 68.0 12.8 55 131.0 32.2 90 194.0
-25.6 -14 6.8 -6.1 21 69.8 13.3 56 132.8 32.8 91 195.8

-25.0 -13 8.6 -5.6 22 71.6 13.9 57 134.6 33.3 92 197.6
-24.4 -12 10.4 -5.0 23 73.4 14.4 56 136.4 33.9 93 199.4
-23.9 -11 12.2 -4.4 24 75.2 15.0 59 138.2 34.4 94 201.2
-23.3 -10 14.0 -3.9 25 77.0 15.6 60 140.0 35.0 95 203.0
-22.8 -9 15.8 -3.3 26 78.8 16.1 61 141.8 35.6 96 204.8

-22.2 -6 17.6 -2.8 27 80.6 16.7 62 143.6 36.1 97 206.6
-21.7 -7 19.4 -2.2 28 82.4 17.2 63 145.4 36.7 98 208.4
-21.1 -6 21.2 -1.7 29 84.2 17.8 64 147.2 37.2 99 210.2
-20.6 -5 23.0 -1.1 30 86.0 18.3 65 149.0 37.8 166 212.0
-20.0 -4 24.8 -0.6 31 87.8 18.9 66 150.8 40.6 105 221.0

-19.4 -3 26.6 0 32 89.6 19.4 67 152.6 43.3 110 230.0
-18.9 -2 28.4 0.6 33 91.4 20.0 68 154.4 46.1 115 239.0
-18.3 -1 30.2 1.1 34 93.2 20.6 69 156.2 48.9 120 248.0
-17.8 0 32.0 1.7 35 95.0 21.1 70 158.0 51.7 125 257.0
-17.2 1 33.8 2.2 36 96.8 21.7 71 159.8 54.4 130 266.0

-16.7 2 35.6 2.8 37 98.6 22.2 72 161.6 57.2 135 275.0
-16.1 3 37.4 3.3 38 100.4 22.8 73 163.4 60.0 140 284.0
-15.6 4 39.2 3.9 39 102.2 23.3 74 165.2 62.7 145 293.0
-15.0 5 41.0 4.4 40 104.0 23.9 75 167.0 65.6 150 302.0
-14.4 6 42.8 5.0 41 105.8 24.4 76 168.8 68.3 155 311.0

-13.9 7 44.6 5.6 42 107.6 25.0 77 170.6 71.1 160 320.0
-13.3 8 46.4 6.1 43 109.4 25.6 78 172.4 73.9 165 329.0
-12.8 9 48.2 6.7 44 111.2 26.1 79 174.2 76.7 170 338.0
-12.2 10 50.0 7.2 45 113.0 26.7 80 176.0 79.4 175 347.0
00-l 9
01 GENERAL
Specification dimension drawings ............. Ol- 2

Specifications.. .............................................. Ol- 6
Weight table ................................................ 01-22
Fuel, coolant and lubricants.. .................... 01-38
01-l
GENERAL SPECIFICATION DIMENSION DRAWINGS
SPECIFICATION DIMENSION DRAWINGS

PC200,2OOLC-6 Unit: mm
6665 2740
SOP02553
* The figures in ( 1 indicate the PC2OOLC.

Ir The values marked % are for shovel operations.
01-2
GENERAL SPECIFICATION DIMENSION DRAWINGS
PC210,21OLC-6
Unit: mm
6665 2850 -
-1
-2
-3
-4
-5
SBP02554
Ir The figures in ( ) indicate the PCSIOLC.

* The values marked % are for shovel operations.
01-3
GENERAL SPECIFICATION DRAWINGS
PC220,22OLC-6 Unit: mm
6930 2650
/ I/ t 44Ok!600(700)
0 -3
LD
-4
SBP02555
* The figures in ( 1 indicate the PC22OLC.

01-4
GENERAL SPECIFICATION DRAWINGS
PC230,23OLC-6 Jnit: mm
1260 1450
3445 (3830) a
4250 (4640)
SEiPO2556
* The figures in ( ) indicate the PC23OLC.

01-5
GENERAL SPECIFICATIONS
SPECIFICATIONS
PC200-6 STD
PC200-6
Machine model
STD
Serial Number 96514 and up
Bucket capacity m3 0.8
Operating weight f kg 19,100
Max. digging depth mm 6,620
Max. vertical wall depth mm 5,980
Max. digging reach mm 9,875
Max. reach at ground level mm 9,700
Max. digging height mm 9,305
Max. dumping height mm 6,475
Max. digging force

(using power max. function) kN IkgI 125 {12,8001 (137 (14,0001)
Swing speed rpm 12.4
Swing max. slope angle deg. 20
Travel speed km/h Lo: 3.0 Mi: 4. 1 Hi: 5.5
Gradeability deg. 35
Ground pressure
(standard shoe width: 600 mm) Pa {kg/cm* 44.1 (0.45)
Overall length (for transport) mm 9,425
Overall width mm 2,800
Overall width of track mm 2,800
Overall height (for transport) mm 2,970
Overall height to chassis mm 2,905
Ground clearance to bottom of upper structure mm 1,085
Min. ground clearance mm 440
Tail swing radius mm 2,750
Min. swing radius of work equipment mm 3,630
Height of work equipment at min. swing radius mm 7,570
Length of track on ground mm 3,270
Track gauge mm 2,200
Height of machine cab mm 2,255
01-6
PC200-6
Machine model
STD
Serial Number i 96514 and up
Model S6D102-1
Type 4-cycle, water-cooled, in-line, vertical,

direct injection, with turbocharger
No. of cylinders - bore x stroke mm 6-102x 120

Piston displacement e (cc} 5.883 {5,883}
Flywheel horsepower kW/rpm IHP/rpm: 99.3/2,000 {I 33/2,000}
Max. torque Vmlrpm (kgmlrpm 562.9/l ,350 {57.4/l ,350)
Max. speed at no load rpm 2,200 + 60
Min. speed at no load rpm 1,000 + 25
Min. fuel consumption g/kWh (g/HPhI 218 (160)
Starting motor 24V, 4.5 kW
Alternator 24V, 35A
Battery 12V, 110 Ah x 2

Radiator core type Corrugated CWX-4
Carrier roller 2 on each side
Track roller 7 on each side
Track shoe Assembly-type triple grouser, 45 on each side
Type x no. HPV95+95, variable displacement
piston type x 2
Delivery Umin Piston type: 206 x 2

Set pressure MPa {kg/cm? Piston type: 34.8 (3551
Type x No. 6-spool type x 1
Control method Hydraulic
Travel motor HMVI 1O-2, Piston type
(with brake valve, parking brake: x 2
Swing motor KMFSOABE-3, Piston type

(with safety valve, parking brake): x 1
Boom Arm Bucket
Type Double acting Double acting Double acting

piston piston piston
Inside diameter of cylinder mm 120 135 115

Diameter of piston rod mm 85 95 80
Stroke mm 1,285 1,490 1,120
Max. distance between pins mm 3,155 3,565 2,800
Min. distance between pins mm 1,870 2,075 1,680
Hydraulic tank Box-shaped, sealed
Hydraulic filter Tank return side
Hvdraulic cooler CFT-1 (Air cooled)
01-7
PCZOO-6 HYPER GX
‘PC200-6
Machine model
HYPER GX
Operating weight kg 19,200
Max. digging force

(using power max. function) kN {kg} 125 (12,800) (137 (14,000))
Travel speed km/h Lo: 3.0 Mi: 4. 1 Hi: 5.5
Ground pressure
(standard shoe width: 600 mm) kPa {kg/cm* 44.1 (0.45)
01-8
PC200-6
Machine model
HYPER GX
i
Model S6D102-1

No. of cylinders - bore x stroke mm 6- 102 x 120

on displacement e {cc) 5.883 (5,883)
Flywheel horsepower kW/rpm IHP/rpm 99.3/2,000 {133/2,000}
Max. torque Nmlrpm {kgmlrpm 562.9/1,350 {57.4/1,350}
Max. speed at no load rpm 2,200 f 60
Min. speed at no load rpm 1,000 f 25
Min. fuel consumption g/kWh Ig/HPhI 218 (160}
Starting motor 24U, 4.5 kW
Alternator 24U, 35A
Batterv 12U, 110 Ah x 2
ac:k shoe Assembly-type triple grouser, 45 on each side
Type x no. HPU95+95, variable displacement
L piston type x 2
i
L Delivery r?/min Piston type: 206 x 2
Set pressure MPa {kg/cm*) Piston type: 34.8 {355)
Travel motor HMUI 1 O-2, Piston type

Boom Arm Bucket


Stroke mm 1,285 1,490 1,120
Hydraulic cooler CFT-1 (Air cooled)
01-9
PC21O-6 STD
PC21 O-6
Machine model
STD
Max. digging force

(using power max. function) kN {kg) 125 {12,800} (137 {14,000})
Travel speed km/h Lo: 3.0 Mi: 4.1 Hi: 5.5
Ground pressure
(standard shoe width: 600 mm) :Pa {kg/cm*: 49.0 IO.501
01-10
PC21 O-6
Machine model
STD
Model S6D102-1

No. of cylinders - bore x stroke mm 6-102x120

Piston disolacement e {cc1 5.883 (5,883)
Flywheel horsepower kW/rpm {HP/rpm} 99.3/2,000 {133/2,000}
Max. torque Urn/mm {kgm/rpmI 562.9/1,350 (57.4/l ,350)
Min. fuel consumption g/kWh {@-iPhI 218 {160}
Alternator 24V, 35A
-Track shoe Assembly-type triple grouser, 45 on each side

piston type x 2
Delivery Umin Piston type: 206 x 2

Set pressure MPa Ikg/cm*> Piston type: 34.8 (355)
Travel motor HMVI 10-2, Piston type

Boom Arm Bucket


Stroke mm 1,285 1,490 1,120
01-11
PC220-6, 230-6 STD
PC220-6 PC230-6
Machine model
STD STD
Serial Number 52852 and up 10177 and up
Bucket capacity m3 1.0 1.0
Operating weight i kg 22,100 23,300
Max. digging depth mm 6,920 6,920
Max. vertical wall depth mm 6,010 6,010
Max. digging reach mm 10,180 10,180
Max. reach at ground level mm 10,000 10,000
Max. digging height mm 9,380 9,380
Max. dumping height mm 6,515 6,515
Max. digging force

(using power max. function) kN {kg} 46 {14,9001(159 I16,2001) 46 I14,900)(159 I16,2001)
Swing speed rpm 12.4 12.4
Swing max. slope angle deg. 17.5 17.5
Travel speed km/h _o:3.0 Mi: 4.1 Hi: 5.5 Lo: 3.0 Mi: 4.1 Hi: 5.5
Gradeability deg. 35 35
Ground pressure
(standard shoe width: 600 mm) (Pa {kg/cm* 48.1 {0.49} 51 .O (0.52}
Overall length (for transport) mm 9,780 9,780
Overall width mm 2,980 2,980
Overall width of track mm 2,980 2,980
Overall height (for transport) mm 3,160 3,160
Overall height to chassis mm 2,905 2,905
Ground clearance to bottom of upper structure mm 1,085 1,085
Min. ground clearance mm 440 440
Tail swing radius mm 2,860 2,860
Min. swing radius of work equipment mm 3,860 3,860
Height of work equipment at min. swing radius mm 7,760 7,760
Length of track on ground mm 3,445 3,445
Track gauge mm 2,380 2.380
Height of machine cab mm 2,255 2,255
01-12
Machine model
Serial Number
Model S6D102-1
Type 4-cycle, water-cooled, in-line, vertical, direct

injection, with turbocharger, water-cooled aftercooler
No. of cylinders - bore x stroke mm 6 - 102 x 120

on displacement e {cc} 5.883 (5,883)
Flywheel horsepower kW/rpm (HP/rpm: 118/2,100 {I 58/2,000}
Max. torque \lm/rpm Ikgm/rpm 618/l ,400 (63/l ,400)
Min. speed at no load rpm 1,000 f 25
Min. fuel consumption g/kWh {g/HPhI 218 1160)
Alternator 24V, 35A
2
5Q piston type x 2
OE
:z Delivery Urnin Piston type: 216 x 2
L Set pressure MPa {kg/cm*} Piston type: 34.8 (3551
6-spool type x 1
Hydraulic
z Travel motor HMVI 1O-2, Piston type
ig (with brake valve, parking brake: x 2
:s Swing motor KMFSOABE-3, Piston type

Boom Arm Bucket


Stroke mm 1,285 1,635 1,020
Hydraulic cooler SF-3 (Air cooled)
01-13
PC2OOLC-6 STD
PC2OOLC-6
Machine model
STD
Operating weight f kg 20,500
Max. digging force

(using power max. function) kN {kg} 125 {I 2,800) (I 37 {I 4,0001)
Ground pressure
(standard shoe width: 700 mm) Pa {kg/cm* 36.3 {0.37}
01-14
I
PC2OOLC-6
Machine model
STD
Model S6D102-1


Piston displacement e {cc} 5.883 {5,883)
Flywheel horsepower kW/rpm {HP/rpm 99.3/2,000 { 133/2,000}
Max. torque Vm/rpm {kgmlrpm 562.9/l ,350 {57.4/l ,350)
Min. fuel consumption g/kWh (g/HPhI 218 I1601
Starting motor 24U, 4.5 kW
Alternator 24U, 35A
Batterv 12U, 110 Ah x 2
Radiator core tvoe Corrugated CWX-4
-Tr ac:k shoe Assembly-type triple grouser, 49 on each side

Type x no. HPU95+95, variable displacement
i!
L piston type x 2
1
L Delivery e/min Piston type: 206 x 2
Set pressure MPa {kg/cm21 Piston type: 34.8 (3551
Travel motor HMUI 10-2, Piston type

Boom Arm Bucket


Stroke mm 1,285 1,490 1,120
Min. distance between Dins mm 1,870 2,075 1,680
01-15
PCZOOLC-6 HYPER GX
PC2OOLC-6
Machine model
HYPER GX
Operating weight i kg 20,600
Max. digging force

(using power max. function) kN {kg) 125 {12,800) (137 I14,OOO))
Ground pressure
(standard shoe width: 700 mm) k.Pa {kg/cm2 36.3 {0.37}
01-16
PC2OOLC-6
Machine model
HYPER GX
Model S6D102-1


Piston displacement Q {cc} 5.883 {5,883}
Flywheel horsepower kW/rpm {HP/rpm: 99.3/2,000 U33/2,000}
Max. torque Vm/rpm Ikgmlrpm 562.9/1,350 {57.4/1,350)
Min. fuel consumption g/kWh {g/HPhI 218 (1601
Alternator 24V, 35A
Batten, 12V, llOAhx2
piston type x 2
Delivery Q/min Piston type: 206 x 2

Set pressure MPa {kg/cm*} Piston type: 34.8 (3551

Boom Arm Bucket

Stroke mm 1,285 1,490 1,120
01-17
PC21 OLC-6 STD
PC2 1OLC-6
Machine model
STD
Max. digging force

(using power max. function) kN (kg} 125 (12,800) (137 {14,000})
Ground pressure
(standard shoe width: 600 mm) Pa {kg/cm2 46.1 {0.47}
Height of work equipment at min. swing radiu: mm 7,570
01-18
PC2 1OLC-6
Machine model
STD
Model S6D102-1


Piston disolacement Q {ccl 5.883 (5,883)
Flywheel horsepower cW/rpm {HP/mm1 99.3/2,000 {133/2,000}
Max. torque imlrpm Ikgm/rpml 562.9/1,350 {57.4/l ,350)
Min. speed at no load rpm 1,000 +. 25
Min. fuel consumption g/kWh Ig/HPhI 218 {I601
Alternator 24V, 35A
Battery 12V, llOAhx2
piston type x 2
Delivery kY/min Piston type: 206 x 2

Set pressure MPa {kg/cm*} Piston type: 34.8 (355)

Boom Arm Bucket
We Double acting Double acting Double acting


Stroke mm 1,285 1,490 1,120
01-19
PCZZOLC-6,23OLC-6 STD
PC22OLC-6 PC23OLC-6
Machine model
STD STD
Bucket capacity m3 1.0 1.0
Operating weight kg 23,400 24,300
Max. digging depth mm 6,920 6,920
Max. vertical wall depth mm 6,010 6,010
Max. digging reach mm 10,180 10,180
Max. reach at ground level mm 10,000 10,000
Max. digging height mm 9,380 9,380
Max. dumping height mm 6,515 6,515
Max. digging force

(using power max. function) kN {kg) 46 I14,9001(159{16,200)) 46 {I 4,900) (159116,200I)
Swing speed rpm 12.4 12.4
Swing max. slope angle deg. 17.5 17.5
Travel speed km/h Lo:3.0 Mi: 4.1 Hi: 5.5 .o: 3.0 Mi: 4.1 Hi: 5.5
Gradeability deg. 35 35
Ground pressure
(standard shoe width: 600 mm) klPa {kg/cm? 39.2 iO.40) 48.1 {0.49}
Overall length (for transport) mm 9,780 9,780
Overall width mm 3,280 3,180
Overall width of track mm 3,280 3,180
Overall height (for transport) mm 3,160 3,160
Overall height to chassis mm 2,905 2,905
Ground clearance to bottom of upper structure mm 1,085 1,085
Min. ground clearance mm 440 440
Tail swing radius mm 2,860 2,860
Min. swing radius of work equipment mm 3,860 3,860
Height of work equipment at min. swing radiuz; mm 7,760 7,760
Length of track on ground mm 3,830 3,830
Track gauge mm 2,580 2,580
Height of machine cab mm 2,255 2,255
01-20
Machine
Serial
model
Number
T
T
Model SAGDI 02-I
Type 4-cycle, water-cooled, in-line, vertical, direct

njection, with turbocharger, water-cooled aftercooler

Piston displacement e k-6 5.883 15,883)
Flywheel horsepower kW/rpm {HP/rpm: 118/2,100 { 158/2,100}
Max. torque Um/rpm {kgmlrpm 618/l ,400 {63/l ,400)
Min. speed at no load rpm 1,000 * 25
Min. fuel consumption g/kWh {g/HPhI 218 I1601
Alternator 24V, 35A
2
5n piston type x 2
OE
:z Delivery Umin Piston type: 216 x 2
- Set pressure MPa {kg/cm*} Piston type: 34.8 (3551
5s Type x No. 6-spool type x 1
js Control method Hydraulic
?
:i (with brake valve, parking brake: x 2
ig Swing motor KMFSOABE-3, Piston type

Boom Arm Bucket


Stroke mm 1,285 1,635 1,020
Hydraulic cooler SF-3 (Air cooled)
01-21
GENERAL WEIGHT TABLE
WEIGHT TABLE
A This weight table is for use when handling components or when transporting the machine.
PCZOO-6 STD Unit: kg
PC200-6
Machine model
STD
Engine ass’y 742
l Engine 535
l Damper 6
l Hydraulic pump 145
Radiator, oil cooler ass’y 121
Hydraulic tank, filter ass’y (excl. hydraulic oil) 136
Fuel tank (excl. fuel) 122
Revolving frame 1,556
Operator’s cab 287
Operator’s seat 29
Counterweight 3,430
Swing machinery 164
Control valve 169
Swing motor 53
Travel motor 98 x 2
Center swivel joint 42
Track frame ass’y 4,280
Track frame 2,158
Swing circle 276
Idler 140x2
Idler cushion 135 x 2
Carrier roller 21 x 4
Track roller 38 x 14
Final drive (incl. travel motor) 340 x 2
01-22
Unit: kg
PC200-6
Machine model
STD
Track shoe ass’y
Standard triple grouser shoe (600 mm) 1,225 x 2
Wide triple grouser shoe (800 mm) 1,565 x 2
Swamp shoe (860 mm) 1,645 x 2
Flat shoe (610 mm) 1,450 x 2
Road liner (rubber pad type) (600 mm) 1,470 x 2
Boom ass’y 1,334
Arm ass’y 620
Bucket ass’y 619
Boom cylinder ass’y 176 x 2
Arm cylinder ass’y 244
Bucket cylinder ass’y 148
Link ass’y (large) 68
Link ass’y (small) 22 x 2
Boom pin 43 + 10 x 2 + 25 + 10 + 20
Arm pin 10 x 2
Bucket pin 20 x 2
Link pin 13 x 2
01-23
PC200-6 HYPER GX Unit: ka
PC200-6
Machine model
HYPER GX
Engine ass’y 742
l Engine 535
l Damper 6
Revolving frame I ,558
Counterweight 3,430
Swing machinery 164
Control valve I 169
Swing motor I 53
Travel motor 98 x 2
Center swivel ioint I 42
Track frame ass’y
l Track frame 2,158
l Swing circle 276
l Idler
l Idler cushion
l Carrier roller
l Track roller 38x 14
l Final drive (incl. travel motor) I 340 x 2
01-24
Unit: kg
PC200-6
Machine model
HYPER GX
Track shoe ass’y
Flat shoe (610 mm) 1,450 x 2
Boom ass’y 1,334
Arm ass’y 620
Bucket ass’y 619
Boom pin 43 + 10 x 2 + 25 + 10 + 20
Arm pin 10 x 2
Bucket pin 20 x 2
Link pin 13x 2
01-25
PC21 O-6 STD Unit: kg
PC2 1 O-6
Machine model
STD
Engine ass’y 742
l Engine 535
l Damper 6
Radiator, oil cooler ass’y I 121
Operator’s cab I 290
Operator’s seat I 29
Counterweight 4,450
Swing machinery 164
Control valve 169
Swing motor 53
Travel motor 98 x 2
Track frame ass’y
l Track frame 2,164
l Swing circle 280
l idler 140x2
l Idler cushion 135 x 2
l Carrier roller 21 x 4
01-26
Unit: kg
PC2 1 O-6
Machine model
STD
Track shoe ass’y
Standard triple grouser shoe (700 mm) -
Wide triple grouser shoe (800 mm)
Swamp shoe (860 mm)
Flat shoe (610 mm) 1,450 x 2
Road liner (rubber pad type) (600 mm) -
Boom ass’y 1,420
Arm ass’y 758
Bucket ass’y 753
Boom pin 43 + 10 x 2 + 25 + 10 + 20
Arm pin 10 x 2
Bucket pin 20 x 2
Link pin 13 x 2
01-27
PC220-6, 230-6 STD Unit: kg
PC220-6 PC230-6
Machine model
STD STD
Engine ass’y 752 752
l Engine 545 545
l Damper 6 6
l Hydraulic pump 145 145
Radiator, oil cooler ass’y 126 126
Hydraulic tank, filter ass’y (excl. hydraulic oil) 136 136
Fuel tank (excl. fuel) 122 122
Revolving frame 1,838 1,906
Operator’s cab 287 290
Operator’s seat 29 29
Counterweight 4,450 4,880
Swing machinery 164 164
Control valve I 169 -~7169
Swing motor 53 53
Travel motor 98 x 2 98 x 2
Center swivel joint 42 42
Track frame ass’y 4,774 4,780
l Track frame 2,996 2,502
l Swing circle
l idler
l Idler cushion 135 x 2 135 x 2
l Carrier roller 21 x 4 21 x 4
l Track roller 38x 14 38x 14
l Final drive (incl. travel motor) 340 x 2 340 x 2
01-28
Unit: kg
PC220-6 PC230-6
Machine model
STD STD
Track shoe ass’y
Standard triple grouser shoe (600 mm) 1,365 x 2 1,365 x 2
Wide triple grouser shoe (800 mm) 1,630 x 2 1,630 x 2
Wide triple grouser shoe (900 mm) - -
Swamp shoe (860 mm) - -
Flat shoe (610 mm) 1,510 x 2 1,510 x 2
Road liner (rubber pad type) (600 mm) - -
Boom ass’y 1,627 1,627
Arm ass’y 710 871
Bucket ass’y 740 923
Boom cylinder ass’y 203 x 2 203 x 2
Arm cylinder ass’y 286 286
Bucket cylinder ass’y 174 174
Link ass’y (large) 80 80
Link ass’y (small) 22 x 2 22 x 2
Boom pin 51+10x2+31+10+ 26 51+10x2+31+10+ 26
Arm pin 10 x 2 10 x 2
Bucket pin 20 x 2 20 x 2
Link pin 17 x 2 17 x 2
01-29
PC2OOLG6 STD Unit: kg
PC200LC-6
Machine model
STD
Engine ass’y 742
l Engine 535
l Damper 6
Radiator, oil cooler ass’v 121
Onerator’s cab 287
Ooerator’s seat I 29
Counterweight I 3.430
Swing machinery I 164
Control valve 169
Swing motor 53
Travel motor 98 x 2
l Track frame
l Swing circle 276
l Idler 140 x 2
l Carrier roller 21 x4
l Track roller
01-30
Unit: kg
PC2OOLC-6
Machine model
STD
Track shoe ass’y
Flat shoe (610 mm) 1,450 x 2
Boom ass’y 1,334
Arm ass’y 620
Bucket ass’y 619
Boom cylinder ass’y 176x 2
Boom pin 43 + 10 x 2 + 25 -I- IO + 20
Arm pin 10 x 2
Bucket pin 20 x 2
Link pin 13 x 2
01-31
PC2OOLC-6 HYPER GX Unit: ka
Machine model
I PC2OOLC-6
HYPER GX
Engine ass’y 742
l Engine 535
l Damper 6
Fuel tank (excl. fuel) I 122
Counterweight 3,430
Swing machinery 164
Control valve I 169
Swing motor I 53
Travel motor I 98 x 2
l Track frame 2,624
l Swing circle
l Idler
l Final drive (incl. travel motor) 340 x 2
01-32
Unit: kg
PC2OOLC-6
Machine model
HYPER GX
Track shoe ass’y
Flat shoe (610 mm) 1,450 x 2
Boom ass’y 1,337
Arm ass’y 620
Bucket ass’y 619
Boom pin 43 + 10 x 2 + 25 + 10 + 20
Arm pin 10 x 2
Bucket pin 20 x 2
Link pin 13 x 2
01-33
PC21 OLC-6 STD Unit: kg
PC21OLC-6
Machine model
STD

I
Engine ass’y 742
l Engine 535
l Damper 6
Hydraulic tank, filter ass’y (excl. hydraulic oil) I 136
Fuel tank (excl. fuel) I 122
Counterweight 4,450
Swing machinery I 164
Control valve I 169
Swing motor 53
Travel motor 98 x 2
l Track frame 2,630
l Swing circle 280
l Idler 140 x 2
l Final drive (incl. travel motor) 340 x 2
01-34
Unit: kg
PC21OLC-6
Machine model
STD
Track shoe ass’y
Standard triple grouser shoe (700 mm)
Swamp shoe (860 mm)
Flat shoe (610 mm) 1,575 x 2
Road liner (rubber pad type) (600 mm) -
Boom ass’y 1,420

I
Arm ass’y 758

I
Bucket ass’y
Boom cylinder ass’y 176x 2

I

I

I
Boom pin I 43 + 10 x 2 + 25 + 10 + 20
Arm pin
Bucket pin
01-35
PC22OLC-6,23OLCa6 STD Unit: kg
PC22OLC-6 PC23OLC-6
Machine model
STD STD
Engine ass’y 752 752
l Engine
l Damper 6 6
l Hydraulic pump I 145 I 145
Radiator, oil cooler ass’y I 126 I 126
Hydraulic tank, filter ass’y (excl. hydraulic oil) 136 136
Fuel tank (excl. fuel) 122 122
Revolving frame 1,835 1,906
Operator’s cab I 287 1, 290
Operator’s seat I 29 I 29
Counterweight 4,450 4,880
Swing machinery 164 164
Control valve 169 169
Swing motor 53 53
Travel motor I 98 x 2 I 98 x 2
Center swivel joint 42 42
Track frame ass’y 5,294 5,300
l Track frame 2,940 2,946
l Swing circle 280 280
l Idler
l Idler cushion
l Carrier roller
l Track roller 38x 14 38x 14
l Final drive (incl. travel motor) 340 x 2 340 x 2
01-36
Unit: kg
PC22OLC-6 PC23OLC-6
Machine model
STD STD
Track shoe ass’y
Wide triple grouser shoe (800 mm) 1,770 x 2 1,770 x 2
Wide triple grouser shoe (900 mm) - -
Swamp shoe (860 mm) - -
Flat shoe (610 mm) 1,640 x 2 1,640 x 2
Road liner (rubber pad type) (600 mm) - -
Boom ass’y 1,627 1,627
Arm ass’y 710 871
Bucket ass’y 740 923
Boom cylinder ass’y 203 x 2 203 x 2

_
Arm cylinder ass’y 286 286
Bucket cylinder ass’y 174 174
Link ass’y (large) 80 80
Link ass’y (small) 22 x 2 22 x 2
Boom pin 51+10x2+31+10+ 26 51+10x2+31+10+ 26
Arm pin 10 x 2 10 x 2
Bucket pin 20 x 2 20 x 2
Link pin 17 x 2 17 x 2
01-37
GENERAL FUEL, COOLANT AND LUBRICANTS
FUEL, COOLANT AND LUBRICANTS

PC200,2OOLC-6
PC21 0,21 OLC-6
RESERVOIR
KIND OF
AMBIENT
14
TEMPERATURE
32 50 68 86 104°F
T CAPACITY (t)
FLUID Specified Refill
- -10 0 10 20 30 40°C
f
Engine oil pan 26.3 24
Damper case 0.75
Swing machinery case 5.5 5.5
Final drive case (each side) Engine 4.4 4.2

oil
Idler (1 each) 0.07 - 0.08 0.07 - 0.08
Track roller (1 each) 0.19 - 0.21 I3.19 - 0.21
Carrier roller (I each) 0.23 - 0.25 I3.23 - 0.25
Hydraulic system 239 166
Hydraulic
oil
Diesel
Fuel tank 340
fuel
Cooling system Coolant Add antifreeze 22.2 -

-
01-38
PC220,22OLC-6
PC230,23OLC-6
AMBIENT TEMPERATURE CAPACITY (f?,
<IND OF
RESERVOIR -22 -4 14 32 50 68 I
FLUID Specified 1 Refill
-20 -10 0 10 20 :
Engine oil pan 26.3 24
Damper case
Swing machinery case
Final drive case (each side) Engine 4.4 4.2

I
oil
Idler (1 each) 0.07 - 0.08 0.07 - 0.08
Track roller (I each) 0.19 - 0.21 0.19 - 0.21
Carrier roller (I each) 0.23 - 0.25 0.23 - 0.25
Hydraulic system 246 166
iydraulic
oil
Diesel 340 -
Fuel tank
fuel )
Cooling system Coolant Add antifreeze 23.3 -

/
01-39
NOTE:
(I) When fuel sulphur content is less than 0.5%,
change oil in the oil pan every periodic main-
tenance hours described in this manual.
Change oil according to the following table
if fuel sulphur content is above 0.5%.
Change interval of oil in

Fuel sulphur content
engine oil pan
(2) When starting the engine in an atmospheric

temperature of lower than O”C, be sure to
use engine oil of SAEIOW, SAEIOW-30 and
SAE15W-40, even though an atmospheric
temperature goes up to 10°C more or less in
the day time.
(3) Use API classification CD as engine oil and if
API classification CC, reduce the engine oil
change interval to half.
(4) There is no problem if single grade oil is
mixed with multigrade oil (SAEIOW-30, 15W-
40), but be sure to add single grade oil that
matches the temperature in the table on the
left.
(5) We recommend Komatsu genuine oil which
has been specifically formulated and ap-
proved for use in engine and hydraulic work
equipment applications.
* For the H046-HM, use the oil recommended
by Komatsu.
ASTM: American Society of Testing and Material

SAE: Society of Automotive Engineers
API: American Petroleum Institute
Specified capacity: Total amount of oil includ-

ing oil for components and
oil in piping.
Refill capacity: Amount of oil needed to refill
system during normal inspection
and maintenance.
01-40
10 STRUCTURE AND FUNCTION
Engine related parts.. ................................. IO- 2

Radiator oil cooler
l l aftercooler.. ........... IO- 4
Power train ................................................. IO- 7
Final drive ................................................... IO- 8
Swing circle ................................................ IO- 9
Swing machinery ....................................... IO- 10
Track frame l recoil spring.. ...................... IO- 11
Track shoe.. ................................................. IO- 12
Hydraulic piping drawing .......................... IO- 14
Hydraulic circuit drawing .......................... IO- 16
Hydraulic tank.. ........................................... IO- 18
Hydraulic pump .......................................... IO- 19
Line oil filter ................................................ IO- 38
Control valve .............................................. IO- 40
Self-reducing pressure valve .................... IO- 48
CLSS ............................................................ IO- 53
Swing motor. .............................................. IO- 84
Center swivel joint ..................................... IO- 90
Travel motor ............................................... IO- 92
Valve control ............................................... IO-100
Work equipment l swing PPC valve ........ IO-102
Travel PPC valve ........................................ 10-l 10
Service PPC valve ...................................... 10-l 14
Safety lock valve ........................................ 10-l 18
PPC accumulator ........................................ 10-l 18
Straight-travel system.. .............................. 10-l 19
EPC solenoid valve .................................... IO-120
Boom holding valve.. ................................. IO-122
Additional filter for breaker.. ..................... IO-125
Work equipment.. ....................................... IO-126
Air conditioner.. .......................................... IO-127
Electric wiring diagram ............................. IO-128
Electric circuit diagram .............................. IO-132
Engine control system ............................... IO-140
Electronic control system for STD ........... IO-146
Electronic control system
for HYPER GX .......... IO-178
Machine monitor system.. ......................... IO-230
Sensors ....................................................... IO-241
Front window auto pull-up system .......... IO-244
10-l
STRUCTURE AND FUNCTION ENGINE RELATED PARTS
ENGINE RELATED PARTS
A-A
B-B C-C D-D E-E
SAE02598
1. Drive plate OUTLINE

2. Torsion spring . The damper assembly is a wet type.
3. Stopper pin Oil capacity: 0.75 .@
4. Friction plate
5. Damper assembly
6. Air cleaner
7. Intake connector
8. Muffler
9. Rear engine mount
IO. Front engine mount
1o-2
STRUCTURE AND FUNCTION RADIATOR l OIL COOLER l AFTERCOOLER
RADIATOR l OIL COOLER l AFTERCOOLER

PC200, 200LC-6
PC210,21OLC-6
3
\
SAP02599
1. Reservoir tank SPECIFICATIONS

2. Oil cooler Radiator : cwx-4
3. Radiator Oil cooler : CFT-1
4. Fan
5. Radiator inlet hose
6. Radiator outlet hose
7. Radiator cap
8. Net
9. Shroud
1o-4
STRUCTURE AND FUNCTION RADIATOR l OIL COOLER l AFTERCOOLER
PC220,22OLC-6
PC230,23OLC-6
I 2
IF---
.__-
Z SAP03435
1. Reservoir tank 6. Radiator outlet hose SPECIFICATIONS

2. Oil cooler 7. Net Radiator : cwx-4
3. Radiator 8. Radiator inlet hose Oil cooler : SF-3
4. Fan 9. Shroud
5. Radiator cap
1o-5
STRUCTURE AND FUNCTION POWER TRAIN
POWER TRAIN
\
12 SBPO2601
1. Idler 7. Engine (S(A)6D102-1)

2. Center swivel joint 8. Travel speed solenoid valve
3. Control valve 9. Swing brake solenoid valve
4. Final drive 10. Swing motor (KMFgOABE-3)
5. Travel motor (HMVIIO-2) 11. Swing machinery
6. Hydraulic pump (HPV95+95) 12. Swing circle
1o-7
STRUCTURE AND FUNCTION FINAL DRIVE
FINAL DRIVE
1. Level plug
2. Drain plug
3. Cover
4. No. 2 sun gear (No. of teeth: 21)
5. No. 1 sun gear (No. of teeth: IO)
4. No. 1 planetary carrier
6. Cover
8. Sprocket
9. Floating seal
10. Travel motor
11. Hub
12. No. 2 planetary gear (No. of teeth: 36)
13. Ring gear (No. of teeth: 95)
14. No. 1 planetary gear (No. of teeth: 42)
SPECIFICATIONS
Reduction ratio: - (v) x (v) + 1
= -57.000
i2 ‘11
A-A
SAP01244
1O-8
STRUCTURE AND FUNCTION SWING CIRCLE
SWING CIRCLE
A-A
_______________
) ;r-’
B-B
SAP00049
1. Swing circle inner race (No. of teeth: 110) SPECIFICATIONS

2. Ball
Reduction ratio: % = 7.333
3. Swing circle outer race
Amount of grease: 21 .C?
(G2-LI)
a. Inner race soft zone S position
b. Outer race soft zone S position
1o-9
STRUCTURE AND FUNCTION SWING MACHINERY
SWING MACHINERY
1. Swing pinion (No. of teeth: 15)

2. Cover
3. Case
5. No. 2 sun gear
6. No. 1 ring gear
7. No. 1 sun gear
8. Swing motor
9. Oil level gauge
10. No. 1 planetary gear
12. No. 2 planetary gear
13. Drain plug
SPECIFICATIONS
Reduction ratio: 22 ;2101 x 27 + 101

27
= 26.505
IO
7
I1
6
12
13
4
I- A-A
SAP02602
10-10
STRUCTURE AND FUNCTION TRACK FRAME l RECOIL SPRING
TRACK FRAME l RECOIL SPRING

* The diagram shows the PC200-6.
A-A
_-__________
r-----------
----------
----------
SAP02603
1. idler . The dimensions and number of track rollers

2. Track frame may differ according to the model, but the
3. Carrier roller basic structure is the same.
4. Final drive
5. Track roller . No. of track rollers
6. Track shoe
7. Center guard No. of rollers
Model
(each side)
8. Recoil spring
9. Front guard PC200, 21 O-6 7
PC2OOLC-6, PC21 OLC-6 9
PC220, 230-6 8
PC22OLC-6, PC23OLC-6 10
10-11
STRUCTURE AND FUNCTION TRACK SHOE
TRACK SHOE
STANDARD SHOE
PC200-6 PC2OOLC-6 PC220-6 PC22OLC-6

PC210-6 PC2 1OLC-6 PC230-6 PC23OLC-6
Shoe width PC2OOLC: 700 mm PC22OLC: 700 mm
600 mm 600 mm
(triple
shoe) PCPIOLC: 600 mm PC23OLC: 600 mm
Link pitch 190 mm 190 mm 190 mm 190 mm

No. of rollers
(each side) 45 49 47 51
SELECTION OF TRACK SHOE

l Select the most suitable track shoe from the following table.
I PC200-6
Specifications
I
Category
PC2OOLC-6
Specifications
I
Category
PC210-6
Specifications
I
Category
I
PC21 OLC-6
Specifications Category
Standard 600 mm triple A 700 mm triple B 600 mm triple A 600 mm triple A
Option 700 mm triple B 600 mm triple A 610 mm flat D 610 mm flat D
Option I 800 mm triple I c I 800 mm triple ICI - I-1 - l-

Option I 860 mm swamp I C I 900 mm triple ICI - I-1 - I-
Option 1 610 mm flat ) D ) 860 mm swamp ICI - I-l - I-
Option I600 mm rubber pad I E / 610 mm flat 1 D 1 - l-l - I-
Option 600 mm rubber pad E
Option 600 mm road liner E 600 mm road liner E

(rubber pad type) (rubber pad type)
PC220-6 PC22OLC-6 PC230-6 PC23OLC-6
I Specifications ICategory I Specifications ICategory I Specifications ICategory I Specifications Category
Standard 600 mm triple A 700 mm triple B 600 mm triple A 600 mm triple A
Option 700 mm triple B 600 mm triple A 610 mm flat D 610 mm flat D
Option 800 mm triple C 800 mm triple C
Option 610 mm flat D 610 mm flat D
10-12
STRUCTURE AND FUNCTION TRACK SHOE
Category Use Precautions when using
Rocky ground, l Travel in Lo speed when traveling on rough ground with obstacles
A normal river soil such as large boulders and fallen trees.
l Cannot be used on rough ground where there are large obstacles

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

E Paved surface rough ground.
* Categories “B” and “C” are wide shoes, so k When selecting the shoe width, select the
there are restrictions on their use. There- narrowest shoe possible within the range
fore, before using, check the restrictions and that will give no problem with flotation and
consider carefully the conditions of use be- ground pressure.
fore recommending a suitable shoe width. If If a wider shoe than necessary is used, there
necessan/, give the customer guidance in will be a large load on the shoe, and this
their use. may lead to bending of the shoe, cracking of
the links, breakage of the pins, loosening of
the shoe bolts, or other problems.
10-13
1. Bucket cylinder
2. Arm cylinder
3. Boom cylinder
4. Hydraulic tank
5. Hydraulic filter
6. Filter (for breaker)
7. Swing motor
8. R.H. travel motor
9. Hydraulic pump
10. Control valve
11. Oil cooler
12. L.H. travel motor
13. Arm holding valve
I’
14. Boom holding valve
15. PPC safety lock valve
16. L.H. PPC valve
17. R.H. PPC valve
18. Center swivel joint
19. Travel PPC valve
20. Service PPC valve
21. Accumulator
22. Solenoid valve
22A. Active mode solenoid
valve
228. 2-stage relief solenoid
valve
22C. Pump merge-divider
solenoid valve
22D. Travel speed solenoid
valve
22E. Swing brake solenoid
valve
02OYO6
02OYO6
1. Bucket cylinder
2. Arm cylinder
3. Boom cylinder
4. Hydraulic tank
5. Hydraulic filter
7. Swing motor
P
8. R.H. travel motor 8
9. Hydraulic pump 6
10. Control valve
11. Oil cooler
19. Accumulator
20. Solenoid valve
valve
20B. 2-stage relief solenoid
valve
solenoid valve
valve
valve
21. EPC valve
21A. Swing LEFT EPC valve
218. Swing RIGHT EPC valve
21C. Bucket DUMP EPC valve
21D. Bucket CURL EPC valve
21E. Arm OUT EPC valve
21F. Arm IN EPC valve
21G. Boom LOWER EPC valve
21H. Boom RAISE EPC valve
STRUCTURE AND FUNCTION HYDRAULIC CIRCUIT DIAGRAM
HYDRAULIC CIRCUIT DIAGRAM

STD
+ For details of this page, see page 90-7.
I:. - ..-..-.._..:
_ ~_.__..__._..
i7:.-“.T.:r--__:_
...________........~~
lo-16
STRUCTURE AND FUNCTION ELECTRONIC VERSION
ELECTRONIC VERSION
PCZOO-6 HYPER GX
* For details of this page, see page 90-9.
g
STRUCTURE AND FUNCTION HYDRAULIC TANK
HYDRAULIC TANK
SAP02608
1. Sight gauge SPECIFICATIONS

2. Hydraulic tank Tank capacity: 230 L?
3. Bypass valve Amount of oil inside tank: 166 e
4. Filter element Pressure valve
5. Oil filler cap Relief cracking pressure:
6. Hydraulic oil level sensor 16.7 + 3.9 kPa
7. Suction strainer IO.17 r 0.04 kg/cm2}
Suction cracking pressure:
0 - 0.49 kPa
(0 - 0.005 kg/cm21
Bypass valve set pressure:
102.9 + 19.6 kPa
il.05 f 0.2 kg/cm21
lo-18
STRUCTURE AND FUNCTION HYDRAULIC PUMP
HYDRAULIC PUMP
h i k I
l Z
m \
6 SAP02765
1. Front main pump a. PdlF port (pump drain)

2. PC valve b. PenF port (front control pressure detection)
3. LS valve c. PBF port (pump pressure input)
4. Rear main pump d. PAF port (front pump delivery)
5. LS-EPC valve e. PAR port (rear pump delivery)
6. PC-EPC valve f. PenR port (rear control pressure detection)
g. Psig port (LS set selector pilot)
Outline h. Im (PC mode selector current)
l This pump consists of 2 variable capacity i. PLSR port (rear load pressure input)
swash plate piston pumps, a PC valve, LS j. lsig (LS set selector current)
valve, and EPC valve. k. PLSF port (front load pressure input)
I. EPC basic pressure detection port
m. Ps port (pump suction)
10-19
MAIN PUMP
HPV95+95
a b
\ I
1l Z
SAP02786
a. PdlF port (pump drain)

b. PBF port (pump pressure input)
c. PAF port (front pump delivery)
d. PAR ‘port (rear pump delivery)
e. Ps port (suction)
1O-20
0-B c-c SAP02787
1. Shaft (front) 7. Cylinder block

2. Cradle 8. Valve plate
3. Case (front) 9. End cap
4. Rocker cam IO. Shaft (rear)
5. Shoe 11. Case (rear)
6. Piston 12. Servo piston
10-21
SPI ine SPI ine

SAP03438
Function
l The rotation and torque transmitted to the . Rocker cam (4) has flat surface A, and shoe
pump shaft is converted into hydraulic en- (5) is always pressed against this surface
ergy, and pressurized oil is discharged ac- while sliding in a circular movement.
cording to the load. Rocker cam (4) brings high pressure oil at
. It is possible to change the discharge amount cylindrical surface B with cradle (2), which is
by changing the swash plate angle. secured to the case, and forms a static pres-
sure bearing when it slides.
Structure . Piston (6) carries out relative movement in
l Cylinder block (7) is supported to shaft (1) the axial direction inside each cylinder cham-
by a spline, and shaft (I) is supported by the ber of cylinder block (7).
front and rear bearings. . The cylinder block seals the pressure oil to
. The tip of piston (6) is a concave ball, and valve plate (8) and carries out relative rota-
shoe (5) is caulked to it to form one unit. tion. This surface is designed so that the oil
Piston (6) and shoe (5) form a spherical bear- pressure balance is maintained at a suitable
ing. level. The oil inside each cylinder chamber
of cylinder block (7) is sucked in and dis-
charged through valve plate (8).
1o-22
Operation
II Operation of pump
i) Cylinder block (7) rotates together with
I 4
shaft (I), and shoe (5) slides on flat sur- \ \ :A /’
face A.
When this happens, rocker cam (4)
moves along cylindrical surface B, so
angle CLbetween center line X of rocker
cam (4) and the axial direction of cylin-
der block (7) changes. (Angle OLis called
the swash plate angle.)
ii) Center line X of rocker cam (4) main-
tains swash plate angle cx in relation to
the axial direction of cylinder block (71, srJPol4o9
and flat surface A moves as a cam in

relation to shoe (5).
In this way, piston (6) slides on the in- 4 5
\I A/‘F
side of cylinder block (71, so a difference
between volumes E and F is created in-
side cylinder block (7). The suction and
discharge is carried out by this differ-
ence F - E.
In other words, when cylinder block (7)
rotates and the volume of chamber E
becomes smaller, the oil is discharged
during that stroke. On the other hand,
the volume of chamber F becomes larger, SDP01410
and as the volume becomes bigger, the

oil is sucked in.
iii) If center line X of rocker cam (4) is in
line with the axial direction of cylinder
block (7) (swash plate angle = 01, the
difference between volumes E and F in-
side cylinder block (7) becomes 0, so the
pump does not carry out any suction or
discharge of oil.
(In actual fact, the swash plate angle
never becomes 0.) \
7
SDP01411
1O-23
2) Control of discharge amount

. If swash plate angle cx becomes larger,
the difference between volumes E and F
becomes larger and discharge amount
Q increases.
. Swash plate angle c1is changed by servo
piston (12).
. Servo piston (12) moves in a reciprocal
movement (H) according to the signal
pressure from the PC and LS valves. This
straight line movement is transmitted
through rod (13) to rocker cam (41, and
rocker cam (41, which is supported by
the cylindrical surface to cradle (21, slides
ina rotating movement in direction Cc).
l With servo piston (12), the area receiv-
SLIP01412
ing the pressure is different on the left
and right, so main pump discharge pres-
sure (self pressure) PP is always brought
to the chamber receiving the pressure at
the small diameter piston end.
Output pressure Pen of the LS valve is
brought to the chamber receiving the
pressure at the large diameter piston end.
The relationship in the size of pressure
PP at the small diameter piston end and
pressure Pen at the large diameter end,
and the ratio between the area receiving
the pressure of the small diameter pis-
ton and the large diameter piston con-
trols the movement of servo piston (12).
1 O-24
LS VALVE
a b C d e f
SDP01414
a. Port PLS (control valve LS pressure inlet port) 1. Plug

b. Port PA (pump discharge pressure inlet port) 2. Locknut
c. Port PLP (LS valve signal pressure outlet port) 3. Sleeve
d. Port PPL (PC valve signal pressure outlet port) 4. Spring
e. Port Pa (drain pressure outlet port) 5. Seat
f. Port Psig (LS control EPC valve output pressure inlet port) 6. Spool
g. Port PA (pump discharge pressure inlet port) 7. Piston
8. Sleeve
PC VALVE
SDP01415
a. Port Pa (drain pressure outlet port) 1. Piston 7. Piston

b. Port PPL (PC valve signal pressure outlet port) 2. Spring 8. Sleeve
c. Port PA (pump discharge pressure inlet port) 3. Seat 9. Locknut
d. Port PA2 (pump discharge pressure inlet pot-t) 4. Spring 10. Plug
e. Port PM (PC mode selector pressure inlet port) 5. Seat 11. Locknut
6. Spool
1O-25
Function
(I) LS valve
The LS valve detects the load and controls (Q/min)
the discharge amount. 01
This valve controls main pump discharge
amount Q according to differential pressure
APLS (=PP - PLS) [called the LS differential
pressure] (the difference between main
pump pressure PP and control valve outlet
port pressure PLS).
Main pump pressure PP, pressure PLS {called
the LS pressure) coming from the control I I
0.7417.‘51 2. 2(22. 51 lMPa~to/cm’ll

valve output, and pressure PSIG {called the
LS selector pressure) from the proportional LS differential Pressure APLS SAP03439
solenoid valve enter this valve. The relation-

ship between discharge amount Q and dif-
ferential pressure APLS, (the difference be-
tween main pump pressure PP and LS pres-
sure PLS) (= PP - PLS) changes as shown in
the diagram on the right according to LS
selector current isig of the LS-EPC valve.
When isig changes between 0 and IA, the
set pressure of the spring changes accord-
ing to this, and the selector point for the
pump discharge amount changes at the rated
central value between 0.74 t) 2.2 MPa {7.5
H 22.5 kg/cm2).
(21 PC valve
When the pump discharge pressure PPI (self-
pressure) and PP2 (other pump pressure) are
high, the PC valve controls the pump so that
no more oil than the constant flow (in ac-
cordance with the discharge pressure) flows
even if the stroke of the control valve be-
comes larger. In this way, it carries out equal
horsepower control so that the horsepower
absorbed by the pump does not exceed the Pump discharge (PPI+PP2) /2
Pressure average
engine horsepower. SAP03440
In other words, if the load during the opera-
tion becomes larger and the pump discharge
pressure rises, it reduces the discharge
amount from the pump; and if the pump
discharge pressure drops, it increases the
discharge amount from the pump. The rela-
tionship between the average of the front
and rear pump discharge pressures (aver- duces the pump discharge amount to allow
age discharge amount of F, R pumps (PPI + the speed to recover. In other words, when
PP2)/2) and pump discharge amount Q is the load increases and the engine speed
shown on the right, with the current given drops below the set value, the command
to the PC-EPC valve solenoid shown as a current to the PC-EPC valve solenoid from
parameter. The controller senses the actual the controller increases according to the drop
speed of the engine, and if the speed drops in the engine speed to reduce the pump
because of an increase in the load, it re- swash plate angle.
1O-26
OPERATION
Self-Reducino
PreSSUre valve
Minimum direction
SAP03441
(I) LS valve
II When control valve is at neutral position and port C and port D are connected. Pump
l The LS valve is a three-way selector valve, pressure PP enters the large diameter end
with pressure PLS (LS pressure) from the of the piston from port K, and the same
inlet port of the control valve brought to pump pressure PP also enters port J at the
spring chamber B, and main pump discharge small diameter end of the piston, so the
pressure PP brought to port H of sleeve (8). swash plate is moved to the minimum angle
The size of this LS pressure PLS + force 2 of by the difference in area of piston (11).
spring (4) and the main pump pressure (self
pressure) PP determines the position of spool
(6). However, the size of the output pressure
PSIG (the LS selection pressure) of the EPC
valve for the LS valve entering port G also
changes the position of spool (6). (The set
pressure of the spring changes.)
. Before the engine is started, servo piston
(11) is pushed to the right. (See the diagram
on the right)
. When the engine is started and the control
lever is at the neutral position, LS pressure
PLS is 0 MPa (0 kg/cm*). (It is interconnected
with the drain circuit through the control
valve spool.)
At this point, spool (6) is pushed to the left, A-A
1o-27
LS-EPC Valve
D
Main
z
Pump
dv
Maximum direction
SAP03442
21 Operation in maximum direction for pump

discharge amount
. When the difference between main pump For this reason, the pressure at the large
pressure PP and LS pressure PLS, in other diameter end of servo piston (11) becomes
words, LS differential pressure APLS, be- drain pressure PT, and pump pressure PP
comes smaller (for example, when the area enters port J at the small diameter end, so
of opening of the control valve becomes servo piston (I 1) is pushed to the right.
larger and pump pressure PP drops), spool Therefore, the swash plate moves in the di-
(6) is pushed to the right by the combined rection to make the discharge amount larger.
force of LS pressure PLS and the force of If the output pressure of the EPC valve for
spring (4). the LS valve enters port G, this pressure
. When spool (6) moves, port D and port E creates a force to move piston (7) to the left.
are joined and connected to the PC valve. If piston (7) is pushed to the left, it acts to
When this happens, the PC valve is con- make the set pressure of spring (4) weaker,
nected to the drain port, so circuit D - K and the difference between PLS and PP
becomes drain pressure PT. (The operation changes when ports D and E of spool (6) are
of the PC valve is explained later.) connected.
1 O-28
LS-EPC Valve
Self-Reducing
pressure valve
Minimum direction
SAP03443
31 Operation in minimum direction for pump

discharge amount
. The following explains the situation if servo . Main pump pressure PP also enters port J at
piston (11) moves to the left (the discharge the small diameter end of the piston, but
amount becomes smaller). When LS differ- because of the difference in area between
ential pressure APLS becomes larger (for the large diameter end and the small diam-
example, when the area of opening of the eter end of servo piston (I I), servo piston
control valve becomes smaller and pump (I I) is pushed to the left.
pressure PP rises), pump pressure PP pushes As a result, the swash plate moves in the
spool (6) to the left. direction to make angle smaller.
. When spool (6) moves, main pump pressure . If LS selection pressure PSIG enters port G,
PP flows from port C to port D, and from it acts to make the set pressure of spring (4)
port K, it enters the large diameter end of weaker.
the piston.
1O-29
Self-Reducing iii/ ,
pressure valve Main
PUrnP
PEN
SAP03444
4) When servo piston is balanced

. Let us take the area receiving the pressure . At this point, the relationship between the
at the large diameter end of the piston as area receiving the pressure at both ends of
Al, the area receiving the pressure at the piston (11) is A0 : Al = 1 : 2, so the pressure
small diameter end as AO, and the pressure applied to both ends of the piston when it is
flowing into the large diameter end of the balanced becomes PP : Pen = 2 : 1.
piston as Pen. If the main pump pressure PP l The position where spool (6) is balanced and
of the LS valve and the combined force of stopped is the standard center, and the force
force Z of spring (4) and LS pressure PLS of spring (4) is adjusted so that it is deter-
are balanced, and the relationship is A0 x PP mined when PP - PLS = 2.2 MPa (22.5 kg/
= Al x Pen, servo piston (II) will stop in cm*). However, if PSIG (the output pressure
that position, and the swash plate will be of 0 t) 2.9 MPa {O e 30 kg/cm21 of the EPC
kept at an intermediate position. (It will stop valve of the LS valve) is applied to port G,
at a position where the opening of the throt- the balance stop position will change in pro-
tle from port D to port E and from port C to portion to pressure PSIG between PP - PLS
port D of spool (6) is approximately the = 2.2 ++ 0.74 MPa I22.5 ti 7.5 kg/cm2).
same.)
1O-30
Minimum direction Maximum direction
PC prolix switch
PC-EPC Valve
I/ I_ OFF ,, Pump // -
/, I, :I! I
controller //
? ON
SAP03445
PC valve
When pump controller is normal
When the load on the actuator is small and
pump pressures PPI and PP2 are low
@ Movement of PC-EPC solenoid (I)
. The command current from the pump C) output from the PC valve changes ac-
controller flows to PC-EPC solenoid (I). cording to this position.
This command current acts on the PC- The size of command current X is deter-
EPC valve and outputs the signal pres- mined by the nature of the operation
sure. When this signal pressure is re- (lever operation), the selection of the
ceived, the force pushing piston (2) is working mode, and the set value and
changed. actual value for the engine speed.
l On the opposite side to the force push- Other pump pressure
ing this piston (2) is the spring set pres- This is the pressure of the pump at the
sure of springs (4) and (6) and pump opposite end.
pressure PPI (self pressure) and PP2 For the F pump, it is the R pump pres-
(other pump pressure) pushing spool (3). sure
Piston (2) stops at a position where the For the R pump, it is the F pump pres-
combined force pushing spool (3) is bal- sure
anced, and the pressure (pressure of port
10-31
When connected port C. D _
When connected port B.C 1
Maximum direction
PC Prolix switch
PC-EPC Valve
I^ OFF ,, Pump // _
/I controller /I
7 ON
Resister
‘q//&jp
SAP03446
@ Action of spring
. The spring load of springs (4) and (6) in . If the command current input to PC-EPC
the PC valve is determined by the swash valve solenoid (1) changes further, the
plate position. force pushing piston (2) changes, and
. When servo piston (9) moves, piston (7), the spring load of springs (4) and (6)
which is connected to slider (8), also also changes according to the value of
moves to the right or left. the PC-EPC valve solenoid command
. If piston (7) moves to the left, spring (6) current.
is compressed, and if it moves further to
the left, spring (6) contacts seat (5) and
is fixed in position. In other words, the
spring load is changed by piston (5) ex-
tending or compressing springs (4) and
(6).
1O-32
. Port C of the PC valve is connected to

port E of the LS valve (see (I) LS valve).
Self pressure PPI enters port B and the
small diameter end of servo piston (91,
and other pump pressure PP2 enters port
A.
l When pump pressures PPI and PP2 are
small, spool (3) is on the left. At this
point, port C and port D are connected,
and the pressure entering the LS valve
becomes drain pressure PT. If port E and
port G of the LS valve are connected
(see (I) LS valve), the pressure entering
the large diameter end of the piston from
port J becomes drain pressure PT, and
servo piston (9) moves to the right. In
this way, the pump discharge amount
moves in the direction of increase.
. As servo piston (9) moves further, pis-
ton (7) is moved to the left by slider (8).
Springs (4) and (6) expand and the spring
force becomes weaker. When the spring
force becomes weaker, spool (3) moves
to the right, so the connection between
port C and port D is cut, and the pump
discharge pressure ports B and C are
connected. As a result, the pressure at
port C rises, and the pressure at the large
diameter end of the piston also rises, so
the movement of piston (9) to the right
is stopped.
In other words, the stop position for pis-
ton (9) (= pump discharge amount) is
decided at the point where the force of
springs (4) and (6) and the pushing force
from the PC-EPC valve solenoid and the
pushing force created by pressures PPI
and PP2 acting on spool (3) are in bal-
ance.
1o-33
Minimum direction
PC-EPC Valve
SAP03447
b. When load on actuator is large and pump

discharge pressure is high
l When the load is large and pump dis- . If main pump pressure PP increases fur-
charge pressures PPI and PP2 are high, ther and spool (3) moves further to the
the force pushing spool (3) to the left left, main pump pressure PPI flows to
becomes larger and spool (3) moves to port C and acts to make the discharge
the position shown in the diagram above. amount the minimum. When piston (9)
When this happens, as shown in the dia- moves to the left, piston (7) is moved to
gram above, part of the pressurized oil the left. For this reason, springs (4) and
from port A flows out through the LS (6) are compressed and push back spool
valve from port C to port D and the pres- (3). When spool (3) moves to the left,
surized oil flowing from port C to the LS the opening of port C and port D be-
valve becomes approximately half of comes larger. As a result, the pressure
main pump pressure PP. at port C (= J) drops, and piston (9) stops
l When port E and port G of the LS valve moving to the left.
are connected (see (I) LS valve), the pres- The position in which piston (9) stops
sure from port J enters the large diam- when this happens is further to the left
eter end of servo piston (9), and servo than the position when pump pressures
piston (9) stops. PPI and PP2 are low.
1o-34
. The relation of average pump pressure

(PPI + PP2)/2 and the position of servo
piston (9) forms a bent line because of
the double-spring effect of springs (4)
and (6). The relationship between aver-
age pump pressure (PPI + PP2)/2 and
pump discharge amount 0 is shown in
the figure on the right.
Pump discharge CPPI fPP2) /2

PreSSUre average SAP03448
. If command voltage X sent to PC-EPC

valve solenoid (I) increases further, the
relationship between average pump pres-
sure (PPI + PP2)/2, and pump discharge
amount 0 is proportional to the pushing
force of the PC-EPC valve solenoid and
moves in parallel. In other words, the
pushing force of PC-EPC solenoid (I) is
added to the force pushing to the left
because of the pump pressure applied
Pump discharge (PPl +pp21/2
to the spool (3), so the relationship be- pressure average SAP03449
tween the average pump pressure (PPl
+ PP2)/2 and 0 moves from @ to @ in
accordance with the increase in X.
1o-35
Maximum direction
SAP03450
2) When pump controller is abnormal and PC

prolix switch is ON
a. When load on main pump is light
. If there is a failure in the pump control- . At this point, port C is connected to the
ler, turn PC prolix switch ON to switch drain pressure of port D, and the large
to the resistor side. In this case, the diameter end of the piston of servo pis-
power source is taken directly from the ton (9) also becomes the drain pressure
battery. But if the current is used as it is, PT through the LS valve. When this hap-
it is too large, so use the resistor to con- pens, the pressure at the small diameter
trol the current flowing to PC-EPC valve end of the piston is large, so servo pis-
solenoid (I 1. ton (9) moves in the direction to make
l When this is done, the current becomes the discharge amount larger.
constant, so the force pushing piston (2)
is also constant.
. If main pump pressures PPI and PP2 are
low, the combined force of the pump
pressure and the force of PC-EPC valve
solenoid (I) is weaker than the spring
set force, so spool (3) is balanced at a
position to the left.
1 O-36
Large diameter end
Minimum direction
PC prolix switch
PC-EPC Valve
// OFF Pump
II controller
ON
Self-Reducing
Resister 7-T
re valve I
//
// ,I I /I/I
B
b. When main pump load is heavy

. In the same way as in the previous item, discharge amount 0 is determined as
when the PC prolix switch is ON, the shown in the diagram for the value of
command current sent to PC-EPC valve the current sent to the PC-EPC valve so-
solenoid (I) becomes constant. For this lenoid through the resistor.
reason, the force of piston (2) pushing The curve when the PC prolix switch is
spool (3) is constant. ON is curve 0, which is to the left of
. If main pump pressures PPI and PP2 curve @ for when the pump controller is
increase, spool (3) moves further to the normal.
left than when the main pump load is
light, and is balanced at the position in
the diagram above.
. In this case, the pressure from port A
flows to port C, so servo piston (9) moves
to the left (to make the discharge amount
smaller) by the same mechanism as ex-
plained in Item 2)-b, and stops at a posi-
tion to the left of the position when the
load on the pump is light. In other words,
even when the PC prolix switch is ON,
the curve for the pump pressure PP and Pump discharge Pressur PP SAP03452
10-37
STRUCTURE AND FUNCTION LINE OIL FILTER
LINE OIL FILTER

Ir For machine equipped with line oil filter
1. Pressure pick-up plug OUTLINE

2. Element (x2) l One line oil filter is installed to discharge
3. Case side of the main pump to prevent the entry
4. Plug of dirt and dust, and to protect the circuit
and equipment.
A. To control valve
B. To branch hose
C. From pump
1O-38
STRUCTURE AND FUNCTION CONTROL VALVE
CONTROL VALVE
1. 6-spool valve Outline
2. Cover 1 . This control valve consists of the 6-spool
3. Cover 2 valve (an integrated composition) and 3 serv-
4. Merge/flow divider valve ice valves, and a merge/flow divider valve is
5. Service valve installed to this.
6. Service valve . Each valve is formed into one unit by the
7. Service valve connection bolt, and the passages are inter-
nally connected, so the structure is compact
and is very easy to service.
l This control valve consists of one spool for
one item of the work equipment, so it has a
simple structure.
a. Port
PPI (from rear main pump) ee. Port PXI (from 2-stage relief solenoid
b. Port
PP2 (from front main pump) valve)
c. Port
A6 (to arm cylinder head) ff. Port PX2 (from 2-stage relief solenoid
d. Port
B6 (to arm cylinder bottom) valve)
e. Port
A5 (to L.H. travel motor) gg. Port BP3 (from travel PPC valve)
f. Port
85 (to L.H. travel motor) hh. Port BP2 (from travel PPC valve)
g. Port
A4 (to swing motor) ii. Port BP4 (from active mode solenoid
h. Port
84 (to swing motor) valve)
i. Port
A3 (to boom cylinder bottom) jj. Port BP5 (from 2-stage safety valve
j. Port
83 (to boom cylinder head) solenoid valve)
k.Port A2 (to R.H. travel motor) kk. Port SA (pressure sensor mount port)
I.
Port B2 (to R.H. travel motor) mm. Port SB (pressure sensor mount pot-t)
m. Port Al (to bucket cylinder head) pa. Port PI2 (from arm PPC/EPC valve)
n. Port Bl (to bucket cylinder bottom) pb. Port PI1 (from arm PPC/EPC valve)
o. Port A-l (to attachment) pc. Port PI0 (from L.H. travel PPC valve)
p. Port B-l (to attachment) pd. Port P9 (from L.H. travel PPC valve)
q. Port A-2 (to attachment) pe. Port P8 (from swing PPC/EPC valve)
r.Port B-2 (to attachment) pf. Port P7 (from swing PPC/EPC valve)
s.Port A-3 (to attachment) pg. Port P6 (from boom PPC/EPC valve)
t.Port B-3 (to attachment) ph. Port P5 (from boom PPC/EPC valve)
u. Port T (to tank) pi. Port P4 (from R.H. travel PPC valve)
v. Port CPI (to port CP3) pj. Port P3 (from R.H. travel PPC valve)
w. Port CP2 (to port CP4) pk. Port P2 (from bucket PPC/EPC valve)
x.Port CP3 (to port CPI) pl. Port PI (from bucket PPC/EPC valve)
y. Port CP4 (to port CP2) pm. Port P-2 (from service PPC valve)
aa. Port PLSI (to rear pump control) pn. Port P-l (from service PPC valve)
ab. Port PLS2 (to front pump control) po. Port P-4 (from service PPC valve)
bb. Port TS (to tank) pp. Port P-3 (from service PPC valve)
cc. Port PS (from merge/flow divider pq. Port P-6 (from service PPC valve)
solenoid valve) pr. Port P-5 (from service PPC valve)
dd. Port BP1 (boom RAISE PPC output
pressure)
1O-40
9-spool valve
ab
/
”
il nb
Y 'fi
ff Pb pd of kk II iJ mmph pj PI pn PP pr ee
b’b
SAP02609
10-41
Main structure
(l/3)
K-K
SAP02610
1. Spool (arm) 8. Spool (service)

2. Spool (L.H. travel) 9. Spool (service)
3. Spool (swing) IO. Spool return spring
4. Spool (boom) 11. Unload valve (arm end group)
5. Spool (R.H. travel) 12. Main relief valve (arm end group)
6. Spool (bucket) 13. Unload valve (bucket end group)
7. Spool (service) 14. Main relief valve (bucket end group)
1O-42
J-J
/ I
6 5
EE-EE
SAP0261 1
1. LS shuttle valve
2. LS select valve
3. Merge/flow divider valve (main)
4. Merge/flow divider valve (for LS)
5. Return spring
6. Return spring
7. LS bypass valve
1o-43
i D-D 1‘A 5 E-E iA F-F 1A

5 IA 2 IA 2. IA
3’ I’A iA 2’ iA
G-G H-H N-N SAP02612
IA. Pressure compensation valve

IB. Variable pressure compensation valve
2. Safety-suction valve
4. Check valve for regeneration circuit (arm)
5. Suction valve
6. Check valve for regeneration circuit (boom)
10-44
6-spool valve
* For details of the names of the ports and the main structure, see 9-SPOOL VALVE.
C C
e b
ff
/////1/W\\\\
u Db Dd Pf kk Ii JJ mm Dh DJ PI ee
SAP02613
10-45
SAFETY-SUCTION VALVE FOR SERVICE VALVE
1. Suction valve
2. Main valve
3. Piston
4. Piston spring
5. Poppet
6. Poppet spring
7. Suction valve spring
8. Sleeve
9. Adjustment screw
10. Locknut
SPECIFICATION
Part No. Set pressure Use
709-70-74800 20.58 MPa (210 kg/cm*) at 190 e/min For breaker (Okada)
709-70-75100 20.09 MPa (205 kg/cm21 at 5 e/min For breaker (Mitsubishi Krupp)
709-70-75300 1 16.66 MPa (170 kg/cm*) at 190 !J/min 1 For breaker (Matsuda)
709-70-74600 ) 24.5 MP (250 kg/cm*) at 5 e/min For crusher (Okada)
1 O-46
STRUCTURE AND FUNCTION SELF-REDUCING PRESSURE VALVE
SELF-REDUCING PRESSURE VALVE
SAP03258
a. Port PI (from front pump)

b. Port PR (supply to electromagnetic valve, PPC
valve, EPC valve)
c. Port T (to hydraulic tank)
d. Port PC (to front pump LS valve)
1O-48
765 4
A-A
IO ‘9
B-B SAP03259
1. Control valve block 6. Spring (reducing valve pilot)

2. Valve (sequence valve) 7. Spring (reducing valve main)
3. Spring 8. Spring (reducing valve)
4. Screw 9. Spring (safety valve)
5. Poppet 10. Ball
1o-49
Function
. This valve reduces the discharge pressure of
the main pump and supplies it as the control
pressure for the solenoid valve and PPC valve.
Operation
1. When engine is stopped
. Poppet (5) is pushed against the seat by
spring (6), and the passage from port PR +
T is closed.
l Valve (8) is pushed to the left by spring (71,
and the passage from port PI + PR is open. HYDRAULIC CIRCUIT DIAGRM ' SAP03299
. Valve (2) is pushed to the left by spring (31,
so the passage between port PI + P2 is
closed. (See Fig. 1)
lzhjj
(Fig. 1) SAP03300
1O-50
2. At neutral and
When load pressure P2 is low (when moving
down under own weight (boom LOWER or arm
IN11
Note: When load pressure P2 is lower than out-
put pressure PR of the self-reducing pres-
sure valve.
. Valve (2) receives force in the direction to
close the passage from port PI + P2 from
spring (3) and pressure PR (when the engine
is stopped, the pressure is 0 MPa (0 kg/cm2)).
However, when hydraulic oil flows in from
port PI, the pressure is balanced so that
pressure Pl + force of spring (7) + (area @d x
pressure PR), and the opening from port PI
+ P2 is adjusted so that pressure PI is kept
at a certain value above pressure PR.
. When pressure PR goes above the set pres-
sure, poppet (5) opens, and the hydraulic oil
flows in the following circuit: port PR + hole
a inside spool (8) + opening of poppet (5)
+ tank port T.
As a result, a pressure difference is created
on both sides of hole a inside spool (81, so
spool (8) moves in the direction to close the
opening from port PI + PR. Pressure PI is (Fig. 2) SAP03301
reduced to a certain pressure (set pressure)
by the amount of opening at this point, and
is supplied as pressure PR. (See Fig. 2)
3. When load pressure P2 is high CONTROL VALVE1

If load pressure P2 increases and the pump dis-
charge amount also increases because of dig-
ging operations, pressure PI also increases
(pressure PI > force of spring (7) + (area cfd x
pressure PR), so valve (2) moves to the right to
the end of the stroke.
As a result, the amount of opening from port PI
+ P2 increases and the resistance in the pas-
sage is reduced, so the loss of engine horse-
power is reduced.
. If pressure PR goes above the set pressure,

poppet (5) opens and the hydraulic oil flows
in the following circuit: port PR + hole a
inside spool (8) + opening of poppet (5) +
tank port T.
As a result, a pressure difference is created
on both sides of hole a is inside spool (8), so
spool (8) moves in the direction to close the
opening from port PI + PR. Pressure PI is
reduced to a certain pressure (set pressure)
by the amount of opening at this point, and
is supplied as pressure PR. (See Fig. 3)
(Fig. 3) SAP03302
10-51
4. When there is abnormal high pressure -

When pressure PR of the self-reducing pressure
valve becomes abnormally high, ball (IO) pushes
against the force of spring (9), separates from
the seat, and allows hydraulic oil to flow from
output port PR + T, so pressure PR goes down.
This action protects the equipment at the desti-
nation for the hydraulic pressure supply (PPC
valve, electromagnetic valve, etc.) from abnor-
mally high pressure. (See Fig. 4)
IO i
(F i g. 4) SAP03303
1o-52
STRUCTURE AND FUNCTION CLSS
CLSS
OUTLINE OF CLSS
7
Actuators
I I--------------.
1 Control valve
t
Pump
merge-divider valve
____J
4 PC valve
1 ------_-_
.------- LS Valve --------- r---- LS Valve --------_

I6
I
L________/:\ L------------,
I
7-b
I
Servo
SAP03453
Features Structure
. CLSS stands for Closed center Load Sensing l The CLSS consists of a main pump (2
System, and has the following features. pumps), control valve, and actuators for the
work equipment.
1) Fine control not influenced by load . The main pump body consists of the pump
2) Control enabling digging even with fine con- itself, the PC valve and LS valve.
trol
3) Ease of compound operation ensured by flow
divider function using area of opening of
spool during compound operations
4) Energy saving using variable pump control
1o-53
Basic principle
Actuator
1) Control of pump swash plate angle
. The pump swash plate angle (pump dis- @
charge amount) is controlled so that LS dif-
ferential pressure APLS (the difference be-
tween pump pressure PP and control valve
outlet port LS pressure PLS) (load pressure Control valve
of actuator) is constant. ---I
--3
(LS pressure APLS = Pump discharge pres- /J--r I’
sure PP - LS pressure PLS)
1‘PLS
Pu mp Passage I’ u LS Passage
I_---,
L_-_
1
Y
I I I
Servo ‘I
Pistonll
II ,,
’I
I I
APLS ‘I
I II
I
Y&$rse current
SSPO3454
. If LS differential pressure APLS becomes

lower than the set pressure of the LS valve
(when the actuator load pressure is high),
the pump swash plate moves towards the
maximum position; if it becomes higher than
the set pressure of the LS valve (when the
actuator load pressure is low), the pump
swash’ plate moves towards the minimum
position.
0
LS differential pressure APLS
SAP03455
1o-54
2) Pressure compensation
. A pressure compensation valve is installed downstream (outlet port) of the spool of each
to the outlet port side of the control valve to valve the same regardless of the size of the
balance the load. load (pressure).
When two actuators are operated together, In this way, the flow of oil from the pump is
this valve acts to make pressure difference divided (compensated) in proportion to the
AP between the upstream (inlet port) and area of openings Sl and S2 of each valve.
Load
I 1 Load
W
G
#I
W
Actuator Actuator
II Pressure
compensation comwnsation
valve
L
\cI AP
-I A-k-s1
III I I 4-k s2
1
v
Pump
SBP03456
1o-55
OPERATION FOR EACH FUNCTION AND VALVE
Hydraulic circuit diagram for system
1 - 2A
&i8
.
LY
travel
nmor
gj#T CP3 p3 4
/ l7
,.
, , , $------
.3--J---
BP5 4
---- p5
--- BP4
----fT---
---------kn;F;
sm ye& _:
ive
L. H.
travel
w motor
8
IB
28
SAP03693
1 O-56
IA. Main relief valve (bucket end group)

Set pressure: 31.9 MPa (325 kg/cm21
(34.8 MPa (355 kg/cm211
IB. Main relief valve (arm end group)
Set pressure: 31.9 MPa (325 kg/cm*)
(34.8 MPa (355 kg/cm211
2A. Unload valve (bucket end group)
2B. Unload valve (arm end group)
3. Bucket spool
4. Pressure compensation valve
Set pressure: 35.8 MPa 1365 kg/cm21
6. LS shuttle valve
7. R.H. travel spool
8. Suction valve
9. Boom spool
IO. Check valve (for boom regeneration circuit)
11. Swing spool
12. L.H. travel spool
13. Arm spool
14. Check valve (for arm regeneration circuit)
15. LS select valve
$ 16. Merge/flow divider valve
>
E Set pressure: 35.8 MPa (365 kg/cm*)
(28.4 MPa (290 kg/cm21)
A. To bucket cylinder
B. To R.H. travel motor
C. To boom cylinder
D. To swing motor
E. To L.H. travel motor
F. To arm cylinder
1o-57
SYSTEM DIAGRAM
* This shows actuator (6A) at the stroke end
relief in the merge mode.
\
=a3 IOB
\
2A 28
IA
SDPOll02
IA. Main pump 7A. Pump passage

IB. Main pump 7B. Pump passage
2A. Main relief valve 8A. LS circuit
2B. Main relief valve 8B. LS circuit
3A. Unload valve 9A. Tank passage
3B. Unload valve 9B. Tank passage
4. Pump merge-divider valve 1OA. Valve
5A. Control valve IOB. Valve
5B. Control valve 1 IA. Spring
6A. Actuator 11 B. Spring
6B. Actuator 12. LS bypass valve
1 O-58
0
1. Unload valve
8A.8B lOA,lOB 7A,7B
llA,ilB A- d 9;4,9B
SBPOO205
Function
. When all the control valves are at neutral, rized oil in LS circuits (8A, 8B) passes from
the oil discharged when the pump is at the orifice A through port C, and is drained to
minimum swash plate angle is drained. tank passages (9A, 9B). Therefore, when the
When this happens, the pump pressure be- valve is actuated, LS pressure i tank pres-
comes a pressure that matches the set load sure.
of springs (1 IA, 1 IB) inside the valve (PI . When the unload operation is carried out,
pressure). The LS pressure is drained from the differential pressure (pump discharge
LS bypass valve, so LS pressure + tank pres- pressure - LS circuit pressure) is greater than
sure + 0 MPa IO kg/cm21. the pump LS control pressure, so a signal is
sent to move the pump swash plate to the
minimum angle.
Operation
l The pressure in pump passages (7A, 7B) is gA,8B IqA,lOB 747B
received by the end face of valves (IOA, IOB).
The control valve is at neutral, so the pres-
sure in LS circuits (8A. 8B) is 0 MPa (0 kg/
cm2}.
. The pressurized oil in pump passages (7A,
7B) is stopped by valves (IOA, IOB). There is
no way for the pressurized oil discharged by
the pump to escape, so the pressure rises.
When this pressure becomes larger than the
force of springs (1 IA, 11 B), valves (IOA, IOB)
move to the left, ports B and C are con- llA,llB A C 9A,9B SBPOO206
nected and the pump pressure flows to tank
passages (9A, 9B). In addition, the pressu-
1o-59
2. Main relief valve (2-Stage type)
SDPOI 128
1. Poppet Function
2. Spring l The low set pressure and high set pressure
3. Piston can be changed by the external pilot pres-
sure.
l The relief pressure is determined by the
pump pressure acting on poppet (I) and the
set load of spring (2).
l When the pilot pressure is OFF, the system
is set to low pressure.
When the pilot pressure is ON, piston (3) is
pushed fully to the left, so the force of spring
(2) increases and the relief pressure becomes
the high set pressure.
1 O-60
II During cut-off control

Function
This function uses the pump pressure sensor,
pump controller, and PC valve. When pump dis-
charge pressure PP is greater than the set pres-
sure, pump discharge amount Q is the mini-
mum.
Operation
. If the pump pressure sensor detects that _ 1 /mini Relief valve flow (at low set Pressure)
pump discharge pressure PP has become
higher than the set pressure, it informs the
pump controller.
. When the pump controller receives this sig-
nal, it increases the value of the signal cur-
rent going to the PC valve and reduces pump 0
discharge amount Q to the minimum (mini- g “,N_---_______________________-::-~
2
mum swash plate angle). 0 9.6 19. 6
$ When this happens, the oil discharged from (100) (200) :33ppi%
>
l
Pump discharge Pressure P MPa (kc/cm’)

the pump passes through the relief valve
SOP01129
% (low set pressure) and is drained.
21 When power max. is actuated

(When cut-off is canceled) c1 (/min) Relief valve flow (at hieh set Pressure)
Function, operation I I I I \
. In the power max. mode, the torque cut-off
signal is not output, so the torque moves
along the pump discharge curve.
l When this happens, the oil discharged from
the pump is relieved through the reiief valve
g M,N_---------_.--___--
to maintain the overall balance.
2
0 9. 6 19. 6
(100) (200) :3% Go:
Pump discharge Pressure P MPa (kg/cm’)
SOP01 130
10-61
3. Introduction of LS pressure
* The diagram shows the condition for arm
IN.
U Pstream pressure of
P ressure compensation vat\
IIfor spool meter-in downs1
SBPO3457
1. Main pump Function

2. Main spool l The upstream pressure (= spool meter-in
3. Pressure compensation valve downstream pressure) of pressure compen-
4. Valve sation valve (3) is introduced and goes to
5. Ball valve shuttle valve (7) as the LS pressure. When
6. LS circuit this happens, it is connected to port B of the
7. LS shuttle valve actuator through valve (41, and LS pressure
i actuator load pressure. Introduction hole a
inside the spool has a small diameter, so it
also acts as a throttle.
Operation
l When spool (2) is operated, the pump pres-
sure passes through introduction hole a,
enters port C, and is taken to the LS circuit
(6). When the pump pressure rises and
reaches the load pressure of port B, ball valve
(5) opens.
1O-62
4. LS bypass valve
4=
SBPO2617

2. Main spool l The residual pressure in LS circuit (6) is re-
3. Pressure compensation valve leased from orifices a and b.
4. LS shuttle valve l This reduces the speed of the rise in the LS
5. LS bypass valve pressure, and prevents any sudden change
6. LS circuit in the oil pressure. Furthermore, a pressure
loss is generated by the circuit resistance
between LS shuttle valve (4) and throttle c
of main spool (2) according to the bypass
flow from LS bypass valve (5). As a result,
the effective LS differential pressure drops,
and the dynamic stability of the actuator is
increased.
1 O-63
CLSS
5. Pressure compensation valve

2. Valve 1) During independent operation and at maxi-
3. Shuttle valve mum load pressure (during compound op-
4. Piston erations, when load pressure is higher than
5. Spring other work equipment)
6. LS shuttle valve l The pressure compensation valve acts as a
load check valve.
Operation
. If the pump pressure (LS pressure) is lower
than the load pressure at port C, shuttle valve
(3) inside pressure compensation valve pis-
ton (4) moves to interconnect spring cham-
ber E and port C.
From this condition, the force of spring (5)
acts to move piston (4) and valve (2) in the
direction of closing.
1 O-64
From LS shuttle valve for othe r

work eauiument
Upstream Pressure ! of Pressure

comuensation valv
(for SPOOI meter::” downstream)
A4%\ I
SPOOI meter-in upstream Pressure
SEiPO3460
2) When receiving compekation (during com- Operation

pound operations, when load pressure is . Spring chamber E is interconnected with port
lower than other work equipment) D. Piston (4) and valve (2) are actuated by
. The pressure compensation valve is closed the LS circuit pressure from the other work
by the LS pressure of port D, and the spool equipment at port F in the direction of clos-
meter-in downstream pressure of port B being (to the right). In other words, the valve
comes the same as the maximum pressure upstream pressure of port B (= spool meter-
of the other work equipment. in downstream pressure) is controlled by the
The spool meter-in upstream pressure of port LS pressure.
A is the pump pressure, so spool meter-in
differential pressure (upstream pressure
(pressure of port A) - downstream pressure
(pressure of port B)) becomes the same for
all spools that are being operated. There-
fore, the pump flow is divided in proportion
to the area of the meter-in opening.
1O-65
Shattle valve Al
From LS circuit\ TO actuator /
Svool meter-in downstream Pressur e

/
is
F5
SBPO3461 2
<Surface area ratio of pressure compensation <Pressure compensation valve for service
va he> valve>
The condition of the flow division changes ac- l The service valve uses a variable type pres-
cording to the ratio of the area of portion Al sure compensation valve, so it can adjust
and portion A2 of the pressure compensation the division of the oil flow suitably to match
valve. the attachment installed.
Area ratio = A2IAl.
l When area ratio = 1:
Spool meter-in downstream pressure = Max.
load pressure, and oil flow is divided in pro-
portion to area of opening of spool.
l When ratio is more than 1:
Spool meter-in downstream pressure > Max.
load pressure, and oil flow is divided in a
proportion less than area of opening of
spool.
l When ratio is less than 1:
Spool meter-in downstream pressure c Max.
load pressure, and oil flow is divided in a
proportion more than area of opening of
spool.
1O-66
6. Shuttle valve inside pressure compensation

valve
SBPO2621

2. Valve When holding pressure at port A B LS pressure
3. Shuttle valve inside pressure compensation in spring chamber 6
valve . Shuttle valve (3) is pushed to the right by
4. Piston the pressure of port A, and the circuit be-
tween ports A and C is shut off. In this con-
dition, the holding pressure at port A is taken
to spring chamber 6, and pushes piston (4)
to the left to prevent piston (4) and valve (2)
from separating.
1 O-67
7. Variable type pressure compensation valve

(for service valve)
From service Load pressure from

valve SPOOI other work esuioment SOP01
1. Valve Function
2. Spring . It is possible to adjust the division of the oil
3. Sleeve flow to the service valve when the service
4. Poppet valve (for attachment) is operated together
5. Spring with the main control valve (boom RAISE,
6. Screw etc.).
7. Locknut (Variable in proportion to surface area)
8. Plastic cap l The pump pressure leaving the service valve
spool acts on the left end of valve (I), and at
the same time passes through throttle a and
enters chamber g.
The maximum LS pressure passes through
throttle d and enters chamber e. At the same
time, the cylinder port pressure passes
through passage c and throttle f, and goes
to chamber h.
In addition, the force of spring (2) acts on
valve (I), and the force of spring (5) acts on
poppet (4). The force of spring (5) can be
adjusted with screw (6)
1 O-69
Operation
Simultaneous operation with work equipment
under heavy load (boom RAISE, etc.)
1. The pump pressure and LS pressure are de-
termined by the pressure of the other work
equipment, but the cylinder port pressure
becomes the actuating pressure of the at-
tachment.
When the difference between the pump pres-
sure and the cylinder pressure is less than
the force of spring (51, then balance of the t \ \
force acting on valve (I) is as follows. From service CYI inder 5
valve SPOOI port
PxAl=PxA2+LS(A2-Al)+F
SLIP01 132
Al: Cross-sectional area of diameter Dl
A2: Cross-sectional area of diameter D2
F: Force of spring
2. If the difference between pump pressure P

and the cylinder pressure becomes greater
than the force of spring (51, poppet (4) is
pushed to the right and the passage opens,
so the pump passage is connected to the
cylinder port through throttle a, chamber g,
and passages b and c, and the oil flows to
the cylinder port. When this happens, a dif-
ferential pressure is formed between the
upstream and downstream sides of throttle From service CYI inder
a, and the pressure in chamber g goes down, valve SDOOI port
so the force pushing valve (I) to the left is SDPO1133

reduced. In other words, the area ratio be-
comes smaller, so valve (I) moves to the
right and increases the flow from the pump
to the cylinder.
1O-70
8. Boom regeneration circuit
Raise Lower
SBPO3462

2. Main spool 1) Cylinder head pressure < cylinder bottom
3A. Pressure compensation valve pressure (free fail, etc.)
3B. Pressure compensation valve l A return flow circuit is provided from the
4A. Safety-suction valve cylinder bottom to the cylinder head so that
4B. Suction valve when the bottom is lowered, the return flow
5. Check valve can be used to increase the flow of oil from
6. LS shuttle valve the pump to the cylinder bottom.
7. Drain circuit
8. Regeneration circuit Operation
l When the cylinder head pressure c cylinder
bottom pressure, part of the pressurized oil
from the cylinder bottom passes through the
notch in spool (21, goes through port B, and
enters drain circuit (7). The rest of the oil
goes from port C, enters regeneration circuit
(8), opens check valve (51, and passes
through ports C and D to flow back to the
cylinder head.
1o-71
SBPO3463
21 Cylinder head pressure > cylinder bottom

pressure (digging operations, etc.)
. Check valve (5) in regeneration circuit (8)
acts to shut off the flow from the cylinder
head to the cylinder bottom.
1 O-72
9. Arm regeneration circuit
-
IN OUT
38 -
7-
4B’
S0P01134

2. Main spool Cylinder head pressure :, cylinder bottom pres-
3A. Pressure compensation valve sure
3B. Pressure compensation valve . A return flow circuit is provided from the
4A. Safety valve cylinder head to the cylinder bottom so that
4B. Safety valve when the arm is moved in, the flow of oil to
5. Check valve the cylinder becomes the pump discharge
6. LS shuttle valve amount + the return flow, and this increases
7. Regeneration circuit the cylinder speed.
Operation
. When the cylinder head pressure > cylinder
bottom pressure, the pressurized oil from
the cylinder head passes through the notch
in spool (2), enters regeneration circuit (7)
and opens check valve (5), then passes
through ports D and E to flow back to the
cylinder bottom.
1o-73
10. Pump merge-divider valve
PS
‘OFFI
To control
To control valve
P2 PI
SBP03464
1. Main spool Operation
2. Spring I) When merging pump flow (when pilot pres-
3. LS spool sure PS is OFF)
4. Spring . Pilot pressure PS is OFF, so main spool (I)
5. LS circuit (bucket end) is pushed to the left by spring (21, and ports
6. LS circuit (arm end) E and F are interconnected.
7. LS circuit (arm end) Therefore, pressurized oil PI and P2 dis-
8. LS circuit (bucket end) charged from the two pumps is merged at
ports E and F, and is sent to the control
valve that demands the oil.
Function . In the same way, LS spool (3) is also pushed
l This acts to merge or divide (send to its own to the left by spring (41, so the ports are
control valve group) oil flows PI and P2 of connected as follows.
pressurized oil discharged from the two Connected ports: A c-t D, B ++ C
pumps. . Therefore, the LS pressure supplied from the
l At the same time, it also carries out merging spools of each control valve to LS circuits
and dividing of the LS circuit pressure. (5), (61, (71, and (8) is all sent to the pressure
compensation valve and other valve.
1o-74
PS
'ON]
To bucket
$ control valve end
>
%
To arm
control valve end
PI
SBPO3465
2) When dividing pump flow (when pilot pres-

sure PS is ON)
. When pilot pressure PS is ON, main spool
(1) is moved to the right by the PS pressure,
and ports E and F are disconnected.
Therefore, the pressurized oil discharged
from each pump is sent to its own control
valve group.
Pressure PI: To bucket, R.H. travel, boom
group
Pressure P2: To swing, L.H. travel, arm
group
. In the same way, LS spool (3) is also moved
to the right by the PS pressure, and the ports
are connected as follows.
Connected ports: B * D, others are not con-
nected.
Therefore, LS circuits (5), (61, (71, and (8) are
all sent to their own control valve group.
1o-75
11. LS select valve

It The diagram shows the situation when the
swing and left travel are operated at the
same time. (BP pressure ON)
1. Valve
PS 2. Spring
'ON1 3. Piston
4. Piston
5. Swing spool
6. L.H. travel spool
7. Arm spool
8. L.H. shuttle valve
8 9. LS circuit
8
>
9 SBPO2627 %
Function
l This valve is used to increase the ease of
operating the work equipment. It prevents
high pressure from being generated when
the swing is operated. It also prevents the
high LS pressure from the swing circuit from
flowing into any other LS circuit when the
swing is operated together with the work
equipment.
Operation
Ii When pilot pressure BP is OFF
. Pilot pressure BP is OFF, so piston (3) is
To LS shuttle valve
pushed to the left by spring (2). If the swing
SBPO3466
is then operated, swing LS pressure PI
passes through swing spool (5) and enters
port A. It pushes valve (I) to the left and
connects ports A and B. Therefore, swing LS
pressure PI flows to LS shuttle valve (8).
21 When pilot pressure BP is ON
. When pilot pressure BP is ON, piston (3) is
moved to the right against spring (2) by the
BP pressure. It pushes valve (I) to the right
and closes the circuit between ports A and
B. As a result, swing LS pressure PI stops
flowing to LS shuttle valve (81, and even if
To LS shuttle valve
swing LS pressure PI rises to a high pres-
SBPO3467
sure, it does not influence any other LS cir-
cuit.
1 O-76
12. Spool stroke modulation

(I) Boom RAISE modulation
1. Spool
2. Piston
St& Spool stroke
TO
c Boon RAISE
PPC DleSSUle
drain
circuit
---) gq- SDPOI 135
Function Operation
. When the boom RAISE and arm IN are used I) When arm IN is not operated
simultaneously for scooping or other similar l When the boom RAISE is operated, spool .
work, it is possible to achieve well balanced (I) moves to the left by stroke St0 until it
compound operations by controlling the contacts piston (2).
maximum stroke of the boom spool.
st1: Spool stroke

St2: Piston stroke
PPC PreS.s”re in
t
c Boom RAISE
PPC DleSSUle
SDPOll36
2) When arm IN is operated l When the boom RAISE Is operated, spool

. The arm IN PPC pressure passes through (I) moves to the left, but the maximum stroke
port A, acts on the left end of piston (2) and (Stl) of the spool is restricted by the move-
pushes piston (2) to the left. ment (St21 of piston (2).
1o-77
(21 Boom LOWER modulation
1. Spool
2. Piston
Active mode
3. Spring
Pilot ~reeeure 4. Plug
sto: Spool stroke
St2: Piston stroke
Boom LOWER
PPC Press",
t
l-Lz--l SAP03468
Function ODeration
. In the active mode, the maximum stroke of 1)’ When active mode is OFF
the boom LOWER spool is increased and The pilot pressure passes through port A
the flow of oil through the spool is increased, and acts on the right end of piston (21, so $
so the boom LOWER speed increases and it piston (2) is pushed to the left. When this 2
becomes possible to carry out work speed- happens, the maximum stroke of spool (I) g
ily. becomes StO.
Stl: Piston stroke
Active mode
Boom LOWER
PPC DleSSure
SAP03469
2) When active mode is ON When this happens, the maximum stroke of

. Port A is connected to the drain, and the spool (I) becomes greater by the amount
right end of piston (2) becomes the drain (St11 that piston (2) moves, so the amount
pressure, so the force of spring (3) acts on of oil flowing through is increased.
piston (2), and moves it to the right. It stops
when it contacts plug (4).
1 O-78
(3) Arm IN modulation I
1. Spool
2. Piston
sto: Spool stroke
Arm IN
PPC DreSSUre
To
drain
circuit
I f I
\
I 2
SDPOI 139
Function Operation
. If the arm IN is operated when traveling up l When travel is not operated
a steep slope, the arm stroke is restricted in When the arm IN is operated, spool (I)
order to control the flow of oil to the arm moves to the right by stroke St0 until it con-
cylinder so that the pump pressure does not tacts piston (2).
drop. When this happens, the pump merge/
divider valve is in the divide condition, so
the oil from the front pump passes through
the travel junction valve and is supplied to
the left travel motor.
Stl: Spool stroke
St2: Piston stroke
IITravel
(from
pilot
junction
_
Pressure
valve)
Arm IN
PPC Pressure I)
‘LIL
2
St2 SDPOl 140
2) When travel is operated

l The travel PPC pressure passes through l When the arm IN is operated, spool (I)
port A and acts on the right end of pis- moves to the right, but the maximum
ton (2) to push piston (2) to the left. spool stroke (Stl) is restricted by the
amount (St2) that piston (2) moves.
1o-79
(4) Arm IN modulation II
1. Spool
2. Arm timing valve
I I I
I
L_---_-__* I
Pf I
Arm IN Boom RAISE
PPC pressure PPC Pressure SDPOll41
Function
l When the boom RAISE and arm IN are oper-
ated simultaneously (as in scooping opera-
tions), the movement of the arm spool is
delayed to prevent the arm from suddenly
moving out. This makes it easier to operate
the work equipment.
Operation
. If the arm IN and boom RAISE are operated
at the same time, the PPC circuit is throttled
by the arm timing valve, so the hydraulic
pressure actuating spool (I) is momentarily
lowered to delay the movement of the spool.
1 O-80
13. Timing valve
To control valve arm IN PPC port

P1 (output Pressure)
1. Spool
2. Spring
brs IN Boom RAISE

PPC Pressure PI PPC pressure
IinPut oressure) PS
1 B A 2 SEPO1143
Function Operation
l When the arm IN and boom RAISE are oper- 1) When arm IN is operated independently
ated at the same time, the timing valve throt- The PPC pressure acts on port PI and pushes
tles the arm IN PPC pressure supplied to the spool (I) fully to the right against the force
control valve. of spring (2).
Port PI and port P2 are interconnected
through B.
2) Arm IN and boom RAISE operated simulta-

neously
If the boom RAISE is operated, the boom
PPC pressure acts on port P3 and pushes
spool (1) to the left. If the lever is operated
fully for both arm IN and boom RAISE, the
force acting on spool (1) becomes as shown
in the formula below, and spool (I) is pushed
fully to the left.
PI pressure 5 P2 pressure + spring force
When this happens, B is shut off, so the arm
IN PPC pressure passes through throttle A
and is sent from port PI to port PZ.
lo-81
14. 2-stage safety valve (installed to boom cyl-

inder head)
1. Spring
2. Piston
3. Spring
4. Holder
SAW0228
Function
l The set pressure of the safety valve can be
set to two stages and the low pressure set-
ting can be made smaller. Because of this,
when digging with boom, even if high pres-
sure is brought to bear on the boom cylin-
der, it is possible to let the boom escape
without operating the control lever. This
makes it possible to carry out operations
with high efficiency and with little vibration
of the chassis.
Operation
. The set pressure of the safety valve is deter-
mined by the load pressure of spring (I).
II When pilot pressure P is OFF: high pressure
setting (active mode ON)
Pilot pressure P is OFF, so piston (2) is
pushed to the left by spring (3). (Installed
load of spring (I) c installed load of spring
(3)).
When this happens, the installed load of
spring (I) becomes the maximum, and the
set pressure is set to high pressure.
In addition, passage B is connected to the
drain circuit through passage C and cham- SAP03470
ber D.
2) When pilot pressure P is ON: low pressure
setting (active mode OFF)
When pilot pressure P is ON, the pilot pres-
sure goes to portion A through passage B,
and piston (2) acts on the diameter of por-
tion A receiving the pressure (d2 - dl). Pis-
ton (2) is moved to the right against spring
(3) by this pilot pressure.
It moves the full stroke until it contacts holder
(4). As a result, spring (I) extends, the in-
stalled load becomes the minimum, and the
set pressure is set to low pressure.
In addition, an amount of oil equivalent to SAP00230
the piston stroke passes through passage C
and chamber D, and is drained.
1 O-82
STRUCTURE AND FUNCTION SWING MOTOR
SWING MOTOR
KMFSOABE3
SAP02632
a. Port S Specifications
c. Port MB (from control valve) Model : KMFSOABE-3
e. Port MA (from control valve) Theoretical delivery : 87.8 cc/rev
d. Port Tl (to tank) Safety valve set pressure : 27.9 MPa
e. Port B (from swing lock solenoid valve) I285 kg/cm*}
Rated speed : 2,260 rpm
Brake release pressure : 2.1 MPa
I21 kg/cm*}
1 O-84
OPERATION OF CLSS SYSTEM AS A WHOLE

1. When all work equipment is at neutral
Ir The diagram shows the situation when all work equipment is at neutral.
* The valves and circuits that are not connected with the explanation of the operation of the CLSS
hydraulic system have been omitted.
* For details of this page, see page 90-I 1.
10-83-l
0
1. Hydraulic tank Note: Groups of control valves by main pump circuit

2A. Main pump (front) . Bucket group: Bucket, R.H. travel, boom
2B. Main pump (rear) . Arm group: Swing, L.H. travel, arm
3A. PC valve (front)
38. PC valve (rear) Operation
4A. LS valve (front) l When the levers are at neutral, the pump is
4B. LS valve (rear) at the minimum swash plate angle, and the
5A. Pump merge-divider valve (for main) oil flow is drained from unload valve (28A).
5B. Pump merge-divider valve (for LS) l The LS pressure is connected to hydraulic
6. Bucket spool tank (I) by LS bypass valve (31). The LS
7. R.H. travel spool differential pressure APLS (unload pressure
8. Boom spool -tank pressure) at this point is APLS > pump
9. Swing spool LS control pressure, so the pump swash plate
10. L.H. travel spool angle is the minimum.
11. Arm spool
12. Pressure compensation valve (bucket)
13. Pressure compensation valve (without
shuttle valve) (R.H. travel)
14. Pressure compensation valve (boom)
15. Pressure compensation valve (swing)
16. Pressure compensation valve (without
shuttle valve) (L.H. travel)
17. Pressure compensation valve (arm)
18A. Safety-suction valve
g 18B. Safety-suction valve (2-stage)
>
19. Suction valve
% 20. LS shuttle valve (bucket)
21. LS shuttle valve (R.H. travel)
22. LS shuttle valve (boom)
23. LS shuttle valve (L.H. travel)
24. LS shuttle valve (arm)
25. Check valve (for boom regeneration circuit)
26. Check valve (for arm regeneration circuit)
27A. Main relief valve (bucket group)
27B. Main relief valve (arm group)
28A. Unload valve (bucket group)
28B. Unload valve (arm group)
29. LS select valve
30. LS check valve
31. LS bypass valve
32. Self-reducing pressure valve
1 O-83-2
0
2. Pump flow divided, one side actuated, other side neutral

* The diagram shows the independent bucket DUMP operation with pump merge.
1O-83-3
Operation
. Pilot pressure PA of pump merge-divider
valve (5A) ON
I) Bucket group
. When the bucket is operated, pressurized oil
from main pump (2B) flows to the bucket
group. The swash plate angle of main pump
(2B) is controlled to match the operation of
bucket spool (6).
l The LS pressure passing through the inside
of bucket spool (6) goes to unload spool
(28A), and the unload valve is closed.
2) Arm group
. When the pump flow is divided, all spools
are at neutral, so the oil flow from the mini-
mum swash plate angle of main pump (2A)
is all drained from unload valve (288) of the
arm group. All spools in the arm group are
at neutral, so no LS pressure is generated.
. If the pump pressure - LS pressure becomes
greater than the set pressure of unload valve
(28B), the unload valve is actuated and the
oil is drained. The LS differential pressure
APLS at this point is APLS > pump LS con-
trol pressure, so the pump swash plate an-
gle is the minimum.
1O-83-4
0
3. Pump flow merged, arm OUT, standard mode relief (cut-off control)
Ir The diagram shows the arm DUMP and standard mode relief with the pump flow merged.
Ir For details of this page, see page 90-15.
1 O-83-5
0
Operation
1) When pump swash plate angle is controlled
to minimum
. When the arm is operated to OUT, if the
load increases, the LS pressure passing
through the inside of arm spool (II) rises.
. The LS pressure also goes to unload valve
(28) and unload valve (28) is closed. The
main circuit pressure rises and is relieved at
the standard mode relief pressure.
2) When this happens, the pump pressure sen-

sor detects it and increases the PC-EPC cur-
rent (electronic cut-off control) to set the
pump swash plate angle to the minimum.
1 O-83-6
0
4. Pump flow divided, bucket DUMP, power max. relief

* The diagram shows bucket DUMP, relief with the pump flow divided.
1O-83-7
0
Operation
. Pump merge-divider valve (5A) pilot pres-
sure PA ON
Relief valve (27) pilot pressure PB ON.
1) When the bucket is being operated, if the

power max. button is turned ON, pilot pres-
sure PB acts on relief valve (27), so the set
pressure of the relief valve is raised.
2) When the bucket is operated to DUMP and

the load increases, pump pressure PI and
LS pressure PLSI both rise. When this hap-
pens, pilot pressure PB controls relief valve
(27) to the same relief pressure as when the
power max. button is operated.
10-83-8
0
5. Pump flow merged, boom RAISE

* The diagram shows boom RAISE, with the pump flow merged.
* For details of this page, see page 90-17-2.
1 O-83-9
0
Operation
When the boom RAISE is operated, main
pumps (2A) and (2B) are both at the maxi-
mum swash plate angle, and unload valve
(28A) is closed.
At this point, for the meter-in opening of
boom spool (81, even if both pumps are at
the maximum swash plate angle, the LS dif-
ferential pressure is set to be smaller than
the pump LS control pressure.
In other words, LS differential pressure APLS
is APLS c pump LS control pressure, so the
pump swash plate angle becomes the maxi-
mum.
In addition, the flow of main pump (2A)
passes through pump merge-divider valve
(5A) and flows to boom spool (8).
10-83-10
0
6. Pump flow merged, swing operated independently

* The diagram shows the swing operated independently, with the pump flow divided.
10-83-H
0
Operation
. When the swing is operated, unload valve
(28) is closed.
. When this happens, the oil flow from main
pumps (2A, 2B) is controlled by the LS dif-
ferential pressure and is discharged to match
the area of opening of the meter-in of the
swing spool.
10-83-12
0
7. Pump flow divided, travel operated independently

* The diagram shows the travel operated independently with the pump flow divided.
lo-8343
0
Operation
. Pump merge-divider valve (5A) pilot pres-
sure PA ON
1)
. When the straight travel is operated, an oil
flow supplied from the main pump to match
the amount of movement of left and right
travel spools (IO) and (7).
Main pump (2A) oil flow:
To left travel spool (IO) (arm group)
Main pump (2B) oil flow:
To right travel spool (7) (bucket group)
. The ability to travel in a straight line is en-
sured by actuating the pressure compensa-
tion valves and interconnecting the right
travel and left travel through the pistons of
pressure control valves (13) and (16) and
through the external piping.
2)
. From the above condition I), if the steering
control levers are returned (the oil flow is
reduced) or operated in opposite directions
zs (FORWARD and REVERSE), the travel junc-
t tion circuit through the above piston is cut
% off, and the left and right sides are operated
independently to enable the steering to be
operated.
10-83-14
0
8. Pump flow merged, compound operation

Ir The diagram shows boom RAISE + arm IN with the pump flow merged.
Ir For details of this page, see page 90-17-8.
10-83-15
0
Operation
1) When the arm and boom are operated si-
multaneously, the swash plate angle for both
pumps becomes the maximum.
When this happens, the load pressure at the
boom RAISE side is higher than at the arm
side, so the LS pressure passes through ports
E and F of boom spool (8), enters LS shuttle
valve (22) and is sent to the LS circuit. This
LS pressure is transmitted to port G of arm
pressure compensation valve (17), and acts
to increase the set pressure of the pressure
compensation valve. Because of this, the
pressure between port H of arm spool (II)
and port I of pressure compensation valve
(17) rises, and spool meter-in LS differential
pressure (pump pressure - LS pressure =
APLS) becomes the same as that at the boom
end.
2) Because of the above operation, the oil flow

is divided in proportion to the size of the
opening area of boom spool (8) and the
opening area of arm spool (II).
Meter-in LS differential pressure APLS dur-
ing boom RAISE + arm IN is APLS < boom
LS control pressure, so the main pump
swash plate angle is set to maximum.
10-83-16
SWING MOTOR
KMFSOABE3
u e d C
SAP02632
a. Port S Specifications
c. Port MB (from control valve) Model : KMFSOABE-3
e. Port MA (from control valve) Theoretical delivery : 87.8 cc/rev
d. Port Tl (to tank) Safety valve set pressure : 27.9 MPa
e. Port B (from swing lock solenoid valve) (285 kg/cm*]
Rated speed : 2,260 rpm
Brake release pressure : 2.1 MPa
121 kg/cm*}
1 O-84
A-A
c-c
SAP02634
1. Brake spring 11. Cylinder

2. Drive shaft 12. Valve plate
3. Spacer 13. Reverse prevention valve
Case 14. Center shaft
4.
Disc 15. Center spring
5.
Plate 16. Safety valve
6.
Brake ring 17. Check valve
7.
8. Brake piston 18. Check valve spring
Housing 19. Shuttle valve
9.
IO. Piston 20. Shuttle valve spring
1O-85
Operation of swing lock

I) When swing lock solenoid valve is deacti-
vated
When the swing lock solenoid valve is deac-
tivated, the pressurized oil from the main
pump is shut off and port B is connected to
the tank circuit.
Main PUMP
As a result, brake piston (7) is pushed down
by brake spring (I), discs (5) and plates (6)
are pushed together, and the brake is ap-
plied.
SAP0347
2) When swing lock solenoid valve is excited

When the swing lock solenoid valve is ex-
cited, the valve is switched and the pressure
oil from the main pump enters port B and
flows to brake chamber a.
The pressure oil entering chamber a over-
comes brake spring (I) and pushes brake
piston (7) up. As a result, discs (5) and plates
(6) are separated and the brake is released.
- SAP03472
1 O-86
From Port S
RELIEF VALVE PORTION
11 Outline
The relief valve portion consists of check
valves (2) and (31, shuttle valves (4) and (51,
and relief valve (1).
2. Function
When the swing is stopped, the outlet port
circuit of the motor from the control valve is
closed, but the motor continues to rotate
under inertia, so the pressure at the output
side of the motor becomes abnormally high,
and this may damage the motor.
To prevent this, the abnormally high pres-
sure oil is relieved to port S from the outlet
port of the motor (high-pressure side) to pre-
vent any damage to the motor.
3. Operation
1) When starting swing
. When the swing control lever is operated to
swing right, the pressure oil from the pump
passes through the control valve and is sup-
plied to port MA. As a result, the pressure at
(Fig. 1)
g port MA rises, the starting torque is gener- SAP03473
z ated in the motor, and the motor starts to
2 rotate. The oil from the outlet port of the
motor passes from port MB through the con-
trol valve and returns to the tank. (Fig. 1)
21 When stopping swing
. When the swing control lever is returned to
neutral, the supply of pressure oil from the
pump to port MA is stopped. With the oil
from the outlet port of the motor, the return
circuit to the tank is closed by the control
valve, so the pressure at port MB rises. As a
result, rotation resistance is generated in the
motor, so the braking effect starts.
. If the pressure at port MB becomes higher
than the pressure at port MA, it pushes shut-
tle valve A (4) and chamber C becomes the
same pressure as port MB. The oil pressure
rises further until it reaches the set pressure
of relief valve (I). As a result, a high braking
torque acts on the motor and stops the mo-
tor. (Fig. 2)
. When the relief valve (1) is being actuated,
the relief oil and oil from port S passes
through check valve B (3) and is supplied to
9 m
Control valve
port MA. This prevents cavitation at port MA.
(F i LT.2)
SAP03474
1O-87
REVERSE PREVENTION VALVE ::111,1,,111/11/1,11,,,,,,,,,,,,
,
5
Operation
1. Valve body
2. Spool (MA side)
3. Spring (MA side)
4. Plug
5. Spool (MB side)
6. Spring (MB side)
7. Plug
Swind control valve

vv\ NV
SAP03475
Explanation of effect
:wlth reversal PreventIon valve
---------- :without reversal Prevent ion valve
Reversal Pressure
Pressure MA
_, _____._
Pressure MB
Iv,,,;,, /iirsa’ DreSSure
I I
I I
A.,
I I
I
I
\I.-,
I I
-.
’ 1st reversal
Motor speed
ip&nd reverSa’
i/y /’ \\._j,
Start Brake - Reversa I
I I I
--
Time
SAP03476
1O-88
Outline
This valve reduces the swing back gener-
ated in the swing body by the inertia of the
swing body, the backlash and rigidity of the
machinen/ system, and the compression of
the hydraulic oil when the swing is stopped.
This is effective in preventing spillage of the
load and reducing the cycle time when stop-
ping the swing (the positioning ability is
good and it is possible to move swiftly to
the next job).
/
Notch SAP03477
Operation
II When brake pressure is being generated at
port MB
. Pressure MB passes through the notch and
goes to chamber d, spool (5) pushes spring
(6) according to the difference in area Dl >
D2, moves to the left, and MB is connected
to e.
When this happens, pressure MA is below
the set pressure of spring (3), so spool (2)
does not move. For this reason, the pres-
sure oil is closed by spool (2), and the brak-
ing force is ensured.
/
Notch SAP03694
2) After motor stops

l The motor is reversed by the closing pres-
sure generated at port MB. (1st reversal)
When this happens, reversal pressure is gen-
erated at port MA. Pressure MA goes to
chamber a, so spool (2) pushes spring (3)
and moves to the right, and MA is connected
to B. At the same time, b is connected to f
through the drill hole in spool (5). so the
reversal pressure at port MA is bypassed to
port T to prevent the 2nd reversal.
SAP02642
1O-89
STRUCTURE AND FUNCTION CENTER SWIVEL JOINT
CENTER SWIVEL JOINT

4-PORT SWIVEL
Al
Bl
El
‘E2
A-A
Tl T2 D2
B2 A2 c2
SBP00249
1. Cover B2. To. L.H. travel motor pot-t PA

2. Body Cl. From control valve port A2
3. Slipper seal C2. To R.H. travel motor port PA
4. O-ring Dl. From control valve port A5
5. Shaft D2. To L.H. travel motor port PB
El. From travel speed solenoid valve
Al. From control valve port B2 E2. To L.H. and R.H. travel motors port P
A2. To R.H. travel motor port PB Tl. To tank
Bl. From control valve port B5 T2. From L.H. and R.H. travel motors port T
1O-90
STRUCTURE AND FUNCTION CENTER SWIVEL JOINT
6-PORT SWIVEL
Cl
G2
Gl
A-A
Tl
Z
F2 82 A2 E2
SBPO2643
1. Cover C2. To R.H. travel motor port PA

2. Body Dl. From control valve port A5
3. Slipper seal D2. To L.H. travel motor port PB
4. Oil seal El. From control valve port A3
5. Shaft E2. Blind
Fl. From control valve port B3
Al. From control valve port B2 F2. Blind
A2. To R.H. travel motor port PB Gl. From travel speed solenoid valve
Bl. From control valve port B5 G2.To L.H. and R.H. travel motors port P
B2. To. L.H. travel motor port PA Tl. To tank
Cl. From control valve port A2 T2. From L.H. and R.H. travel motors port T
10-91
STRUCTURE AND FUNCTION TRAVEL MOTOR
TRAVEL MOTOR a
HMVllO-2
C
SAP01247
a. Port T (to tank) SPECIFICATIONS

b. Port PB (from control valve)
c. Port P (from travel speed solenoid valve) PC200-6 PC220-6
d. Port PA (from control valve) PC210-6 PC230-6
Type HMVI IO-2

I I I
34.79 MPa
Set pressure I355 kg/cm*)
~
Min.
capacity 2,673 rpm 2,618 rpm
Rated speed
Max.
capacity 1,460 rpm 1,523 rpm
1.18 MPa
Brake releasing pressure
112 kg/cm?
Travel speed Differential 0.78 MPa
switching
pressure I8 kg/cm*)
pressure
1O-92
C-tD ’
\ 9
A-A c-c
D-D SAP02754
1. Regulator piston 9. Check valve spring 17. Valve plate

2. Spring 10. Output shaft 18. Counterbalance valve
3. Regulator valve 11. Swash plate 19. Ring
4. Spring 12. Retainer guide 20. Spool return spring
5. Motor case 13. Pin 21. Brake piston
6. Suction safety valve spring 14. Piston 22. Plate
7. Suction safety valve 15. Retainer 23. Disc
8. Check valve 16. Cylinder 24. Ball
1o-93
OPERATION OF MOTOR
II Motor swash plate angle (capacity) at maxi-
mum
The solenoid valve is deactivated, so the pi- l At the same time, the pressurized oil at regu-
lot pressure oil from the main pump does lator piston (15) passes through orifice c in
not flow to port P. regulator valve (9) and is drained to the
For this reason, regulator valve (9) is pushed motor case.
to the right in the direction of the arrow by l As a result, swash plate (4) moves in the
spring (IO). maximum swash plate angle direction, the
Because of this, it pushes check valve (221, motor capacity becomes maximum.
and the main pressure oil from the control
valve going to end cover (8) is shut off by
regulator valve (9).
Fulcrum a of swash plate (4) is eccentric to
point of force b of the combined force of the
propulsion force of cylinder (6), so the com-
bined force of the piston propulsion force
acts as a moment to angle swash plate (4) in
the direction of the maximum swash plate
angle.
1o-94
2) Motor swash plate angle (capacity) at mini-

mum
Ienoid
1 /Self-Reducing1
1.1.
I rontrnl
/v/v SAP03479
l When the solenoid valve is excited, the pilot

pressure oil from the main pump flows to
port P, and pushes regulator valve (9) to the
left in the direction of the arrow.
. Because of this, the main pressure oil from
the control valve passes through passage d
in regulator valve (91, enters regulator pis-
ton (15) at the bottom, and pushes regulator
piston (15) to the right in the direction of the
arrow.
. As a result, swash plate (4) moves in the
minimum swash plate angle direction, the
motor capacity becomes minimum.
1o-95
OPERATION OF PARKING BRAKE

II When starting to travel
When the travel lever is operated, the pres-
surized oil from the pump actuates counter-
balance valve spool (191, opens the circuit to
the parking brake, and flows into chamber A
of brake piston (12).
It overcomes the force of spring (II), and
pushes piston (12) to the left in the direction
of the arrow.
When this happens, the force pushing plate
(13) and disc (14) together is lost, so plate
(13) and disc (14) separate and the brake is
released.
SAP03480
21 When stopping travel

When the travel lever is placed in neutral,
counterbalance valve spool (19) returns to
the neutral position and the circuit to the
parking brake is closed.
The pressurized oil in chamber A of brake
piston (12) is drained to the case from the
orifice in the brake piston, and brake piston
(12) is pushed to the right in the direction of
the arrow by spring (II).
As a result, plate (13) and disc (14) are
pushed together, and the brake is applied.
A time delay is provided by having the pres-
surized oil pass through a throttle in slow
return valve (22) when the brake piston re-
turns, and this ensures that the brake still
effective after the machine stops.
1O-96
OPERATION OF BRAKE VALVE

l The brake valve consists of a suction safety
valve (18A), counterbalance valve (18) in a
circuit as shown in the diagram on the right.
(Fig. I)
l The function and operation of each compo-
nent is as given below.
1) Counterbalance valve, check valve

Function
l When traveling downhill, the weight of the
machine makes it try to travel faster than
the speed of the motor.
As a result, if the machine travels with the
engine at low speed, the motor will rotate
without load and the machine will run away, (Fib I) SAP03482
which is extremely dangerous.
To prevent this, these valves act to make the
machine travel according to the engine speed
(pump discharge amount).
Operation when pressure oil is supplied

l When the travel lever is operated, the pres- IiIA
surized oil from the control valve is supplied
to port PA. It pushes open suction safety
valve (18A) and flows from motor inlet port
MA to motor outlet port MB.
However, the motor outlet port is closed by
suction safety valve (188) and spool (191, so
the pressure at the supply side rises. (Fig. 2)
-
(F i LI 2) SAP03483
. The pressurized oil at the supply side flows

from orifice El and E2 in spool (19) to cham-
ber Sl. When the pressure in chamber Sl
goes above the spool switching pressure,
spool (19) is pushed to the right in the direc-
tion of the arrow.
As a result, port MB and port PB are con-
nected, the outlet port side of the motor is
opened, and the motor starts to rotate. (Fig.
3)
Sl
I!’
SAP03404
Operation of brake when traveling downhill I I

. If the machine tries to run away when
traveling downhill, the motor will turn under
no load, so the pressure at the motor inlet
port will drop, and the pressure in chamber
Sl through orifices El and E2 will also drop.
When the pressure in chamber Sl drops
below the spool switching pressure, spool
(19) is returned to the left in the direction of
the arrow by spring (20), and outlet port MB
is throttled.
As a result, the pressure at the outlet port
side rises, resistance is generated to the ro-
tation of the motor, and this prevents the
machine from running away.
In other words, the spool moves to a posi-
tion where the pressure at outlet port MB
balances the pressure at the inlet port and 19
the force generated by the weight of the
El E2 SAP03485
machine. It throttles the outlet port circuit
and controls the travel speed according to
the amount of oil discharged from the pump.
(Fi.g 4)
2) Safety valve
Function
. When travel is stopped (or when traveling
downhill), the circuits at the inlet and outlet
ports of the motor are closed by the coun-
terbalance valve, but the motor is rotated by
inertia, so the pressure at the outlet port of
the motor will become abnormally high and
damage the motor or piping. The safety valve
acts to release this abnormal pressure and
send it to the inlet port side of the motor to Sl
prevent damage to the equipment.
Operation
I) When travel is stopped (or when traveling
downhill, rotating to right)
. When the motor inlet port pressure (pres-
sure PA) goes down, the pressure in cham-
ber Sl also goes down. When it goes below
the switching pressure of the spool, spool IF i 0. 5) BI SAP03486
(19) is returned to the left by spring (201,
and outlet port passage Bl is throttled. When
this happens, the motor continues to rotate
under inertia, so the outlet pressure (pres-
sure MB) rises. (Fig. 5)
. If the pressure goes above the set pressure
of suction-safety valve (18A), the poppet
opens. The oil then passes through large
notch Al in counterbalance valve spool (19)
and flows to chamber MA in the circuit on
the opposite side. (Fig. 6)
PoPPet MB
2) When rotating to left
(F i 9. 6) SAP03487
The operation is the reverse of when rotat-
ing to the right.
lo-98
31 When starting travel (or during normal

travel)
. When the travel lever is operated, the pres-
sure oil from the pump moves counterbal-
ance valve spool (19) to the right. When this
happens, the passage to the suction-safety
valve becomes the circuit flowing through
the small notch in the counterbalance valve
spool. As a result, a big difference in pres-
sure is created, and the pump pressure rises
to provide a powerful drawbar pull. (Fig. 7)
(Fie. 7) SAP03488
1o-99
STRUCTURE AND FUNCTION VALVE CONTROL
VALVE CONTROL
STD
SBPO2655
Lever positions
1. Travel PPC valve 9. Accumulator 0 HOLD @ Swing RIGHT
2. Service PPC valve IO. Control valve @ Boom RAISE @ Swing LEFT
3. Service pedal 11. Hydraulic pump @ Boom LOWER @ NEUTRAL
4. L.H. travel lever 12. Junction box @ Bucket DUMP @ Travel REVERSE
5. R.H. travel lever 13. L.H. work equipment @ Bucket CURL @ Travel FORWARD
6. R.H. PPC valve lever @ HOLD @ LOCK
7. R.H. work equipment 14. PPC safety lock valve 0 Arm IN @ FREE
lever 15. L.H. PPC valve @ Arm OUT
8. Solenoid valve 16. Safety lock lever
10-100
STRUCTURE AND FUNCTION VALVE CONTROL
PC200,2OOLC-6 HYPER GX
‘2656
Lever positions
1. Travel PPC valve 9. Control valve @ HOLD @ Swing RIGHT
2. Service PPC valve 10. Hydraulic pump @ Boom RAISE @$ Swing LEFT
3. Service pedal 11. Junction box @ Boom LOWER @ NEUTRAL
4. L.H. travel lever 12. Work equipment, @ Bucket DUMP @ Travel REVERSE
5. R.H. travel lever swing EPC valve @ Bucket CURL @ Travel FORWARD
6. R.H. work equipment 13. L.H. work equipment @ HOLD @ LOCK
lever lever 0 Arm IN @ FREE
7. Solenoid valve 14. PPC safety lock valve @ Arm OUT
8. Accumulator 15. Safety lock lever
10-101
STRUCTURE AND FUNCTION WORK EQUIPMENT l SWING PPC VALVE
WORK EQUIPMENT l SWING PPC VALVE

A-A
b C d e f 0 h I
A4
10
1 2 3 4 5 6 7 0
8-B c-c
~~
Z
SElPOl875
1. Swing LEFT EPC 9. Block a. Port T (to tank)

2. Swing RIGHT EPC 10. Body b. Port Cl (swing LEFT)
3. Bucket CURL EPC 11. Spool c. Port C2 (swing RIGHT)
4. Boom LOWER EPC 12. Spring d. Port C3 (bucket CURL)
5. Bucket DUMP EPC 13. Push pin e. Port C4 (boom LOWER)
6. Arm IN EPC 14. Coil f. Port C5 (bucket DUMP)
7. Arm OUT EPC 15. Plunger g. Port C6 (arm IN)
8. Boom RAISE EPC 16. Connector h. Port C7 (arm OUT)
i. Port C8 (boom RAISE)
i. Port P (from main pump)
10-102
STRUCTURE AND FUNCTION WORK EQUIPMENT. SWING PPC VALVE
Function
l The EPC valve consists of the proportional
solenoid portion and the hydraulic valve
portion.
l When it receives signal current i from the
pump controller, it generates the EPC out-
put pressure in proportion to the size of the
signal, and outputs it to the control valve.
0 200 400 600 800 1000

Current i (mA)
SAP03489
Operation
1. When signal current is 0 (coil deactivated)
. There is no signal current flowing from the
controller to coil (14) is deactivated.
. For this reason, spool (11) is pushed to the
right in the direction of the arrow by spring
(12).
. As a result, port P closes and the pressu-
rized oil from the main pump does not flow
to the control valve.
At the same time, the pressurized oil from
the control valve passes from port C through
port T and is drained to the tank.
10-103
2. When signal current is very small (coil ex-

cited, fine control) Control valve
. When a very small signal current flows to
coil (14), coil (14) is excited, and a propul-
sion force is generated which pushes plunger
(15) to the left in the direction of the arrow.
Push pin (13) pushes spool (I I) to the left in
the direction of the arrow, and pressurized
oil flows from port P to port C.
When the pressure at port C rises and the
load of spring (11) + the force acting on
surface a of spool (11) becomes greater than
the propulsion force of plunger (151, spool
(11) is pushed to the right in the direction of
the arrow. The circuit between port P and
port C is shut off, and at the same time, port T ;
C and port T are connected. /
. :
As a result, spool (I I) is moved to the left or :
right until the propulsion force of plunger :
i:
(15) is balanced with the load of spring (12)
+ pressure at port C.
. Therefore, the circuit pressure between the
EPC valve and the control valve is controlled
in proportion to the size of the signal cur-
rent.
3. When signal current is maximum (coil ex-

Control valve
cited, operated fully)
When the signal current flows to coil (141,
coil (14) is excited.
When this happens, the signal current is at
its maximum, so the propulsion force of
plunger (15) is also at its maximum.
. For this reason, spool (11) is pushed to the
left in the direction of the arrow by push pin
(13).
. As a result, the maximum flow of pressu-
rized oil from port P flows to port C, and the
circuit pressure between the EPC valve and
control valve becomes the maximum.
At the same time, port T closes and stops
the oil from flowing to the tank.
a SBP03492
10-104
WORK EQUIPMENT l SWING PPC VALVE

STD
l-l
SBWO273
a. Port P (from main pump)

b. Port T (to tank)
c. Port P2 (L.H.: Arm IN / R-H.: Boom RAISE)
d. Port P4 (L.H.: Swing LEFT / R.H.: Bucket DUMP)
e. Port PI (L.H.: Arm OUT / R.H.: Boom LOWER)
f. Port P3 (L.H.: Swing RIGHT / R.H.: Bucket CURL)
10-106
1' A-A
D-D
B-B
E-E
SBPoo274
1. Spool 7. Joint
2. Metering spring 8. Plate
3. Centering spring 9. Retainer
4. Piston 10. Body
5. Disc 11. Filter
6. Nut (for connecting lever)
10-107
OPERATION
II At neutral
,Ports A and B of the control valve and ports
PI and P2 of the PPC valve are connected to
drain chamber D through fine control hole f
in spool (I). (Fig. I)
21 During fine control (neutral + fine control)

When piston (4) starts to be pushed by disc
(51, retainer (9) is pushed; spool (I) is also
pushed by metering spring (21, and moves (Fig. 1)
down.
When this happens, fine control hole f is
shut off from drain chamber D, and at al-
most the same time, it is connected to pump
pressure chamber PP, so pilot pressure oil
from the main pump passes through fine
control hole f and goes from port PI to port
A.
When the pressure at port PI becomes
higher, spool (I) is pushed back and fine
control hole f is shut off from pump pres-
sure chamber PP. At almost the same time,
it is connected to drain chamber D to re-
lease the pressure at port PI. When this hap-
pens, spool (I) moves up or down so that
the force of metering spring (2) is balanced
with the pressure at port PI. The relation-
ship in the position of spool (1) and body
(IO) (fine control hole f is at a point midway
between drain hole D and pump pressure
chamber PP) does not change until retainer
(9) contacts spool (I).
Therefore, metering spring (2) is compressed
proportionally to the amount of movement
of the control lever, so the pressure at port
PI also rises in proportion to the travel of
the cqntrol lever. In this way, the control Control valve
valve spool moves to a position where the
pressure in chamber A (the same as the pres- (Fig. ‘2)
SEPO3494
sure at port PI) and the force of the control
valve spool return spring are balanced.
(Fig.2)
lo-108
31 During fine control

(when control lever is returned)
When disc (5) starts to be returned, spool (I)
is pushed up by the force of centering spring
(3) and the pressure at port PI.
connected to drain chamber D and the pres-
sure oil at port PI is released.
If the pressure at port Pl drops too far, spool
(I) is pushed down by metering spring (21,
and fine control hole f is shut off from drain
chamber D. At almost the same time, it is
connected to pump pressure chamber PP,
and the pump pressure is supplied until the
pressure at port Pl recovers to a pressure
that corresponds to the lever position.
When the spool of the control valve returns,
oil in drain chamber D flows in from fine
control hole f’ in the valve on the side that is
not working. The oil passes through port P2
and enters chamber B to fill the chamber
with oil. (Fig. 3)
SBPO3495
$
>
%
41 At full stroke
When disc (5) pushes down piston (4), and
retainer (9) pushes down spool (I), fine con-
trol hole f is shut off from drain chamber D,
and is connected with pump pressure cham-
ber PP. Therefore, the pilot pressure oil from
the main pump passes through fine control
hole f and flows to chamber A from port PI,
and pushes the control valve spool.
The oil returning from chamber B passes
from port P2 through fine control hole f’ and
flows to drain chamber D. (fig. 4)
(Fia.4)
SBPO3496
10-109
STRUCTURE AND FUNCTION TRAVEL PPC VALVE
TRAVEL PPC VALVE
\
e
SAP02660
a. Port P (from main pump)

b. Port T (to tank)
c. Port P2 (L.H. travel FORWARD)
d. Port PI (L.H. travel REVERSE)
e. Port P3 (R.H. travel REVERSE)
f. Port P4 (R.H. travel FORWARD)
10-110
I I
B-0 A-A
c-c D-D
SAP02661
1. Plate 5. Metering spring

2. Body 6. Centering spring
3. Piston 7. Valve
4. Collar 8. Bolt
10-l11
OPERATION
I) At neutral
Ports A and B of the control valve and ports
PI and P2 of the PPC valve are connected to
drain chamber D through fine control hole f
in spool (1). (Fig. 1)
2) Fine control (neutral + fine control)

When piston (4) starts to be pushed by disc
(5), retainer (9) is pushed. Spool (I) is also
pushed by metering spring (2) and moves (Fig. I)
SBPO3497
down.
shut off from drain chamber D. At almost
the same time, it is connected to pump pres-
sure chamber PP, and the pilot pressure of
the main pump is sent from port A through
fine control hole f to port PI. $
>
When the pressure at port PI rises, spool (I)
is pushed back. Fine control hole f is shut %
off from pump pressure chamber PP. At al-
most the same time, it is connected to drain
chamber D, so the pressure at port PI es-
capes.
As a result, spool (I) moves up and down
until the force of metering spool (2) is bal-
anced with the pressure of port PI.
The relationship of the position of spool (I)
and body (IO) (fine control hole f is in the
middle between drain hole D and pump pres-
sure chamber PP) does not change until re-
tainer (9) contacts spool (I).
Therefore, metering spring (2) is compressed
in proportion to the travel of the control le-
ver, so the pressure at port PI also rises in
proportion to the travel of the control lever.
In this way, the spool of the control valve (Fig. 2)
moves to a position where the pressure of SBPO3498
chamber A (same as pressure at port PI)

and the force of the return spring of the
control valve spool are balanced. (Fig.21
10-112
3) Fine control (control lever returned)

When disc (5) starts to be returned, spool (I)
is pushed up by the force of centering spring
(3) and the pressure at port PI.
Because of this, fine control hole f is con-
nected to drain chamber D, and the pressu-
rized oil at port PI is released.
If the pressure at port PI drops too much,
spool (1) is pushed up by metering spring
(2), so fine control hole f is shut off from
drain chamber D. At almost the same time,
it is connected to pump pressure chamber
PP, so the pressure at port PI supplies the
pump pressure until the pressure recovers
to a pressure equivalent to the position of
the lever.
When the control valve returns, oil in drain
chamber D flows in from fine control hole f
of the valve on the side that is not moving.
It passes through port P2 and goes to cham-
ber B to charge the oil. (Fig. 3) (F i 9. 3)
SBPO3499
At full stroke
Disc (5) pushes down piston (41, and retainer
(9) pushes down spool (I). Fine control hole
f is shut off from drain chamber D, and is
connected to pump pressure chamber PP.
Therefore, the pilot pressure oil from the
main pump passes through fine control hole
f and flows to chamber A from port PI to
push the control valve spool. The return oil
from chamber B passes from pot-t P2 through
fine control hole f’ and flows to drain cham-
ber D. (Fig. 4)
Self-f.....
d/,1,
*
% m Î t
9 5
(Fig. 4)
SBPO3695
10-113
STRUCTURE AND FUNCTION SERVICE PPC VALVE
SERVICE PPC VALVE

1. Pin
2. Cam
3. Ball
4. Piston
5. Cover
6. Sleeve
7. Centering spring
8. Metering spring
9. Spool
10. Body
a. Port T (to tank)

b. Port P (from main pump)
c. Port A (to service valve P-l)
d. Port B (to service valve P-2)
SBPOO285
10-114
OPERATION
At neutral
l The pressurized oil from the control pump
enters from port P and is blocked by spool
(9).
. Ports A and B of the control valve and ports
a and b of the PPC valve are connected to
drain port T through fine control hole X of
spool (9).
SElPO3500
$ When operated
g l When cam (2) is moved, metering spring (8)
2 is pushed by ball (31, piston (41, and sleeve
(6), and spool (9) is pushed down by this.
. As a result, fine control hole X is shut off
from the drain circuit. At almost the same
time, fine control portion Y is connected with
port a, and the pressurized oil from port P
flows from port a to port A of the control
valve.
VA
Self-Reducing
Pressure valv
SRPO3501
10-115
. When the pressure at port a becomes higher,

spool (9) is pushed back by the force acting
on the end of the spool. When fine control
portion Y closes, fine control hole X is con-
nected to the drain circuit at almost the same
time.
. As a result, spool (9) moves up and down to
balance the force at port a and the force at
metering spring (8).
. Therefore, metering spring (8) is compressed
in proportion to the amount the control le-
ver is moved. The spring force becomes
larger, so the pressure at port a also in-
creases in proportion to the amount the con-
trol lever is operated.
In this way, the control valve spool moves
to a position where the pressure of port A
(the same as the pressure at port a) is bal-
anced with the force of the return spring of
the control valve spool. SBPO3502
10-116
SAFETY LOCK VALVE
PPC ACCUMULATOR
SAFETY LOCK VALVE
1. Lever
2. Body
3. Seat
4. Ball
5. End cap
SBPOO289
PPC ACCUMULATOR
1. Gas plug
2. Shell
3. Poppet
4. Holder
5. Bladder
6. Oil port
SPECIFICATIONS
Gas capacity: 300 cc
SBPoo290
lo-118
STRUCTURE AND FUNCTION STRAIGHT-TRAVEL SYSTEM
STRAIGHT-TRAVEL SYSTEM
Boom Bucket Junction block
L.H.travel motor R.H.travel motor
_./ III I
Swine / III r--~----@
Arm
I
I
t
III /
; ; I r-;-------j--- Travel
Control valve 1 1
Pump merge- 1
divider valve
/ i--+~~____i___j-__ Bucket DUMP ____
; !I I
Bucket CURL
Travel
PPC valve
i___
;
SAP03503
Function
. This system interconnects the pressure com-
pensation valves for L.H. and R.H. travel
Travel PPC Pressure
FORWARD and REVERSE with external pip-
ing to ensure the ability to travel in a straight /,I,, (right)
line.
. As shown in the diagram on the right, the
left and right ports are interconnected
through passage a inside travel pressure
compensation valve (I 1.
. By setting the throttle in junction circuit a to
a suitable value, it is possible to fulfill the
SAP03504
requirements for steering ability and the abil-
ity to maintain a straight line.
10-119
STRUCTURE AND FUNCTION EPC SOLENOID VALVE
EPC SOLENOID VALVE

FOR ACTIVE MODE, PUMP MERGE-DIVIDER, 2-STAGE RELIEF, TRAVEL SPEED,
SWING BRAKE SOLENOID VALVE
a SAP01251
1. Active mode solenoid valve To tank

2. 2-stage relief solenoid valve ;: To PPC/EPC valve
3. Pump merge-divider solenoid valve c. To main valve (active mode)
4. Travel speed solenoid valve d. To main valve (2-stage relief valve)
5. Swing brake solenoid valve To main valve (pump merge-divider valve)
f”.’ To L.H. and R.H. travel motor
9. To swing motor
h. From main pump
i. To accumulator
10-120
STRUCTURE AND FUNCTION EPC SOLENOID VALVE
1. Connector
2. Variable core
3. Coil
4. Cage
5. Spool
6. Block
7. Spring
SBPOO299
OPERATION
When solenoid is deactivated
. The signal current does not flow from the
controller, so coil (3) is deactivated.
For this reason, spool (5) is pushed to the
right in the direction of the arrow by spring
(6).
As a result, the circuit between ports P and
A closes and the pressurized oil from the
main pump does not flow to the actuator.
At the same time, the pressurized oil from
the actuator flows from port A to port T, and
is then drained to the tank. SEPO3505
When solenoid is excited

l When the signal current flows from the con-
troller to coil (3), coil (3) is excited.
For this reason, spool (5) is pushed to the
left in the direction of the arrow.
As a result, the pressurized oil from the main
pump flows from port P through the inside
of spool (5) to port A, and then flows to the
actuator.
At the same time, port T is closed, and this
stops the oil from flowing to the tank. 3 5 4 SEPO3506
10-121
STRUCTURE AND FUNCTION BOOM HOLDING VALVE
BOOM HOLDING VALVE

Ir For machine equipped with arm holding valve, the structure and function of arm holding valve is
the same as this valve.
A-A
SDP01321
I. Safety-suction valve a. Port T (to tank)

2. Pilot spring b. Port Pi (from boom LOWER PPC valve)
3. Pilot spool c. Port Cy (to boom cylinder bottom)
4. Poppet spring d. Port V (from boom control valve)
5. Poppet
1o-122
OPERATION
1) At boom RAISE
When the boom is raised, the main pressure
from the control valve pushes poppet (5) up
in the direction of the arrow.
Because of this, the main pressure from the
control valve passes through the valve and
flows to the bottom end of the boom cylin-
der.
SBPO3507
2) Boom lever at NEUTRAL

When the boom is raised and the control
lever is returned to NEUTRAL, the circuit for
the holding pressure at the bottom end of
the boom cylinder is closed by poppet (5),
and at the same time, the oil flowing into
poppet (5) through orifice a of poppet (5) is
closed by pilot spool (3).
As a result, the boom is held in position.
SBPO3508
10-123
31 At boom LOWER
When the boom is lowered, the pilot pres-
sure from the PPC valve pushes pilot spool
(3) and the pressurized oil in chamber b in-
side the poppet is drained.
When the pressure at port B rises because
of the pressurized oil from the bottom end
of the boom cylinder, the pressure of the
pressurized oil in chamber b is lowered by
orifice a.
If the pressure in chamber b drops below
Control lever
the pressure at port A, poppet (5) opens the
pressurized oil flows from port B to port A,
s-
and then flows to the control valve.
BoomL
k
If any abnormal pressure is generated in the
circuit at the bottom end of the boom cylin-
der, safety valve (I) is actuated.
SBPO3509
lo-124
STRUCTURE AND FUNCTION ADDITIONAL FILTER FOR BREAKER
ADDITIONAL FILTER FOR BREAKER

* FOR MACHINE EQUIPPED WITH BREAKER
SBPO2669
1. Head cover SPECIFICATIONS

2. Element Rated pressure : 6.86 MPa (70 kg/cm*)
3. Case Flow : 107 !Ymin
4. Drain plug Relief valve cracking pressure:
5. Valve 0.34 + 0.049 MPa
6. Spring (3.5 + 0.5 kg/cm*)
7. Spring set plug Filter mesh size : 6 pm
Filtering area : 3160 cm*
10425
WORK EQUIPMENT
WORK EQUIPMENT
SBPO2670
1. Arm
2. Bucket cylinder
3. Arm cylinder
4. Boom
5. Boom cylinder
6. Bucket
10426
STRUCTURE AND FUNCTION AIR CONDITIONER
AIR CONDITIONER
AIR CONDITIONER PIPING
SBPO2755
1. Hot water pickup piping A. Fresh air

2. Air conditioner compressor B. Recirculated air
3. Refrigerant piping C. Hot air/cold air
4. Condenser
5. Receiver tank
6. Hot water return piping
7. Air conditioner unit
8. Duct
1O-l 27
STRUCTURE AND FUNCTION ELECTRICAL WIRING DIAGRAM
ELECTRICAL WIRING DIAGRAM

STD
Sr For details of this page, see page 90-19.
lo-128
02OYO6
1. Fuel level sensor 38. Heater relay

2. Working lamp 39. Fuse box
3. Hydraulic oil level sensor 40. Alarm buzzer
4. LS control EPC valve 41. Starting switch
5. PC control EPC valve 42. Fuel control dial
6. Rear lamp 43. Cigar lighter
7. Engine speed sensor 44. Swing lock switch
8. Governor motor 45. Wiper, washer switch
9. Engine oil pressure sensor 46. Light switch
(for low pressure) 47. Buzzer cancel switch
10. Rear pump pressure sensor 48. Front window auto pull-up switch
11. Front pump pressure sensor 49. Kerosene mode connector
12. Air cleaner clogging sensor 50. Speaker
13. Radiator water level sensor 51. Air conditioner control panel
14. Window washer motor 52. Governor pump controller
15. Travel alarm 53. Radio
16. Horn (high tone1 54. Prolix resistor
17. Horn (low tone1 55. Wiper motor controller
18. Battery relay 56. Light relay
19. Battery 57. Light relay
20. R.H. front lamp 58. Monitor panel
21. Engine water temperature sensor 59. Swing prolix switch
22. Intake air heater 60. Pump prolix switch
23, Air conditioner compressor magnet 61. Arm OUT oil pressure switch
clutch 62. Arm IN oil pressure switch
24. Engine oil level sensor 63. Travel oil pressure switch
25. Alternator 64. Right swing switch
26. Starting motor 65. Bucket DUMP oil pressure switch
27. Wiper motor 66. Boom RAISE oil pressure switch
28. Horn switch 67. Bucket CURL oil pressure switch
29. R.H. additional front lamp 68. Left swing switch
30. R.H. front lock 69. Boom LOWER oil pressure switch
31. Room lamp 70. Swing brake solenoid valve
32. Auto pull-up motor 71. Travel speed solenoid valve
33. Window limit switch (rear) 72. Merge/flow divider solenoid valve
71 \ 34. L.H. front lock 73. P-stage relief solenoid valve
70 35. Window limit switch (front) 74. Active mode solenoid valve
36. L.H. additional front lamp
w
37. L.H. knob switch
10-130
02OYO6
(I)
_.
1. Bucket cylinder stroke sensor (HYPER GX) 52. Wiper motor
c
2. Arm angle sensor (HYPER GX) 53. R.H. electric lever
3. Working lamp 54. Horn switch 0,
4. Arm cylinder head pressure sensor (HYPER GX) 55. R.H. additional front lamp
56. R.H. front lock “s
-.
5. Arm cylinder bottom pressure sensor (HYPER GX) v)
6. LS control EPC valve 57. Room lamp
6. Hydraulic oil level sensor 58. Auto pull-up motor
59. Rear limit switch x
7. Bucket cylinder head pressure sensor (HYPER GX) cc)
6. Bucket cylinder bottom pressure sensor (HYPER GX) 60. L.H. front lock
?
9. LS control EPC valve 61. Front limit switch
PC control EPC valve 62. L.H. additional front lamp
10.
11. Rear lamp L.H. electric lever
12. Engine speed sensor 8: L.H. knob switch
65: Heater relay x
13. Governor motor fn
14. Engine oil pressure sensor (for low pressure) 66. Fuse box (D
15. Rear pump pressure sensor 67. Alarm buzzer
Front pump pressure sensor 68. Starting switch
16. ?
17. Air cleaner clogging sensor 69. Fuel control dial
18. Radiator water level sensor 70. Cigarette lighter g
Leh swing EPC valve 71. Swing lock switch
19.
20. Right swing EPC valve 72. Wiper, washer switch
21. Window washer motor 73. Light switch
22. Bucket DUMP EPC valve 74. Buzzer cancel switch
23. Bucket CURL EPC valve 75. Auto pull-up switch
24. Arm OUT EPC valve 76. Kerosene mode connector
Arm IN EPC valve 77. Speaker
25.
26. Boom LOWER EPC valve 78. Air conditioner control panel
27. Boom RAISE EPC valve 79. Governor, pump controller
GX controller (HYPER GX) 80. GX panel
28.
29. Valve controller 81. Prolix switch
30. GX automatic operation cancel switch (HYPER GX) 82. Wiper motor controller
31. Boom control switch 83. Light relay
32. Boom prolix switch 84. Light relay
33. Swing motor MA pressure sensor (HYPER GX) 65. EPC relay 2
Swing motor MB pressure sensor (HYPER GX) 86. EPC relay 1
34.
35. Chassis angle sensor (HYPER GX) 87. Monitor panel
36. Travel alarm 88. Swing prolix switch
Boom cylinder head pressure sensor (HYPER GX) 89. Prolix switch
37.
38. Horn (high tone) 90. Arm OUT oil pressure switch
39. Boom cylinder bottom pressure sensor (HYPER GX) 91. Arm IN oil pressure switch
Horn (low tone) 92. Travel oil pressure switch
40.
41. Boom angle sensor (HYPER GX) 93. Right swing switch
42. Battery relay 94. Bucket DUMP oil pressure switch
Battery 95. Boom RAISE oil pressure switch
43.
44. Front lamp 96. Bucket CURL oil pressure switch
45. Fuel level sensor 97. Left swing switch
Engine water temperature sensor 98. Boom LOWER oil pressure switch
46.
47. Intake air heater 99. Swing holding brake solenoid valve
Air conditioner compressor magnet clutch 100. Travel speed selector solenoid valve
48.
49. Engine oil level sensor 101. Merge/flow divider solenoid valve
Alternator 102. 2-stage relief solenoid valve
50.
51. Starting motor 103. Active mode solenoid valve
STRUCTURE AND FUNCTION ELECTRICAL CIRCUIT DIAGRAM
ELECTRICAL CIRCUIT DIAGRAM

STD
* For details of this page, see page 90-27 and 90-29.
1O-l 32
PC200-6 HYPER GX
* For details of this page, see page 90-31 - 90-37.
ELECTRICAL CIRCUIT DIAGRAM FOR AIR CONDITIONER
Blower
Majn blower motor Blower Blower Condensor
relay relay relay relay relay
r ------__ r--------1 r--------
Dual oressure switch
Servo motor
for recycled air
and fresh air
CN- 16
,-----
I -EC
iI iI
r
-_-_-
1
1 25RW 2
I--
I
Condensor
L ,
OnIv elec. conaensor unit.
(Not necessary for board
Amplifier
SAP0351 6
10-134
0
STRUCTURE AND FUNCTION ENGINE CONTROL SYSTEM
ENGINE CONTROL SYSTEM
SBPO2682
1. Battery relay FUNCTION

2. Battery . The engine can be started and stopped sim-
3. Starting switch ply by using the starting switch.
4. Fuel control dial . A dial type engine control is used to control
5. Governor motor the engine speed. The engine throttle l pump
6. Starting motor controller receives the control signal from
7. Engine throttle l pump controller the fuel control dial, sends a drive signal to
8. Fuel injection pump the governor motor, and controls the angle
of the governor lever in the fuel injection
pump.
. At the same time, the engine throttle l pump
controller also receives signals from other
controllers to control the engine speed.
10-140
1. OPERATION OF SYSTEM
Starting engine Start ins
l When the starting switch is turned to the i
START position, the starting signal flows to HI
the starting motor, and the starting motor ,$
turns to start the engine.
When this happens, the engine throttle l
pump controller checks the signal from the

fuel control dial and sets the engine speed
to the speed set by the fuel control dial.
Governor.PumP
Engine speed control

Start ina
l The fuel control dial sends a signal to the Fuel control
engine throttle lpump controller according
to the position of the dial. The engine throt-
tle lpump controller calculates the angle of
the governor motor according to this signal,
and sends a signal to drive the governor
motor so that it is at that angle.
When this happens, the operating angle of
the governor motor is detected by the
potentiometer, and feedback is sent to the
engine throttle lpump controller, so that it
can observe the operation of the governor
motor.
Stopping engine Start ins

. When the starting switch is turned to the
STOP position, the engine throttle l pump
controller drives the governor motor so that
the governor lever is set to the NO INJEC-
TION position.
. When this happens, to maintain the electric
power in the system until the engine stops
completely, the engine throttle l pump con-
troller itself drives the battery relay.
10-141
2. COMPONENTS OF SYSTEM
1) FUEL CONTROL DIAL HIGH
;“\ “zl-
1. Knob
Front of math in 2. Dial
1 3. Spring
4. Ball
5. Potentiometer
6. Connector
y A-/
LOW
A-A
ConPosition of circuit
2
clIll -
3 SBPO3520
FUNCTION
l The fuel control dial is installed at the bot-
tom of the monitor panel. A potentiometer (%) Hi
is installed under the knob, and when the 100
knob is turned, it rotates the potentiometer
shaft.
When the shaft rotates, the resistance of the
variable resistor inside the potentiometer
changes, and the desired throttle signal is ;
sent to the engine throttle l pump control- <::
ler.
The shaded area in the graph on the right is 0 0.25 I 4 4.75 5-w
Characteristics of throttle voltage
the abnormality detection area and the en-
SAP0352 I
gine speed is set at low idling.
lo-142
2) GOVERNOR MOTOR
1. Potentiometer
2. Cover
3. Shaft
4. Dust seal
5. Bearing
6. Motor
7. Gear
8. Connector
A-A
SBPO3696
FUNCTION OPERATON
l The motor is rotated and the governor lever Motor stationary
of the fuel injection pump is controlled by . Both A phase and B phase of the motor are
the drive signal from the engine throttle l continuous, and a holding torque is gener-
pump controller. ated in the motor.
. A stepping motor is used for the motor which Motor rotating
provides the motive power. . A pulse current is applied to the A phase
In addition, a potentiometer for giving feed- and B phase from the engine throttle pump
l
back is installed to allow observation of the controller to give synchronous rotation with
operation of the motor. the pulse.
. The rotation of the motor is transmitted to
the potentiometer through a gear.
10-143
ENGINE THROlTLE l PUMP CONTROLLER
\
w-2 SAP02683
10-144
Input and output signals

CN-1 CN-3 CN-5
Pin ~~ Input/ Pin Input/ Pin Input/
Name of signaloutput Name of signaloutput Name of signaloutput
No. output No. output No. output
1 1Battery relay drive output Output 1 Engine water temperature sensor Input 1 Engine speed sensor GND input
2 Fuel level sensor Input 2 / Engine speed sensor I Input I

3 Pump F pressure input Input 3 GND Input
4 Throttle potentiometer input Input 4 GND Input
I51NC I - I / 51NC I - I 5 1Swing pressure switch I Input I

6 GND Input 6 I Service valve pressure switch I Input I
7 Power source (+24V) Input 7 / NC I-= I
I 8 I Active mode solenoid I output I 8 1Radiator water level sensor1 Input I

I 9 I Travel selector solenoid IOutIJutI 9 Knob switch Input 9 Hydraulic oil level sensor Input
I IO I P-stage relief solenoid I output I 10 NC - 10 Engine speed sensor GND Input
Ill I NC I - I 111 1NC I - I 11 1 Bucket CURL pressure switch / Input I

112jGND I lnout I 12 Batterycharge(alternatorterminal RI Input 12 Bucket DUMP pressure switch Input
113 I Power source (+24V) I Input I 13 Pump R pressure input Input 13 Travel pressure switch Input
CN-2 114 1 Feedback potentiometer input / Input I 14 / NC I - I

Pin Input/ -
Name of signaloutput 15 NC 15 Engine oil pressure sensor L Input
NO. outout
1 Solenoid power source (t24V) Input ~16 Pressure sensor GND Input 16 Engine oil level sensor Input
2 Governor motor phase A (t) Output I17 / Potentiometer GND I Input

I 17 ) Air cleaner clogging sensor I Input I
3 Governor motor phase A (-) Output
4 Governor motor phase B (t) Output
I 5 I Governor motor phase B (-1 1Output I

6 NC -
7 LS-EPC solenoid (+) output
I 8 1PC-EPC solenoid (+I I output I
(IO ( NC I - I
11 PGND Input 26 Model selection 3 Input
12 Solenoid power source (+24V) Input 27 Model selection 5 Input
113 j NC I - I 28 ( Swing prolix switch I Input I

14 NC - 29 Overload sensor (if equiped) Input
15 1 NC - 30 Boom LOWER pressure switch Input
116 j NC I - I 31 Arm OUT pressure switch Input

Input.
17 LS-EPC solenoid (-) output 32 S-NET I+) output
18 PC-EPC solenoid 1-j output 33 Model selection 2 Input
119 I NC I - I 34 Model selection 4 Input
20 NC - 35 Kerosene mode selection input
21 PGND Input 36 Swing lock switch Input
10-145
STRUCTURE AND FUNCTION ELECTRONIC CONTROL SYSTEM FOR STD
ELECTRONIC CONTROL SYSTEM FOR STD

CONTROL FUNCTION
Pump & engine mutual control function
Pump and valve control function
Power maximizing function
Auto-deceleration function
5
Engine automatic warming-up, overheat
prevention function
7
I I
Travel control function
Active mode function
Active power up function
Self-diagnostic function
Ir For details of the self-diagnostic function,

see TROUBLESHOOTING.
10-146
TOTAL SYSTEM DIAGRAM

P ;c
_____.
_.___.
..
1. PUMP & ENGINE MUTUAL CONTROL FUNCTION
p$+----I--
Ensine
1 Work equipment levers
\
injection motor Knob switch
Travel lever
LS valve --i LS valve --7
EC
PC valve
:-----
I
I
I
-7
I_____,
_L___________i
1
‘,_____
PC valve 7 I
I I
1
.J
I
Relay brock
-L
1
LS-EPC
l----J
valve
Fuel contra
dial
Hi
Monitor Panel
Covernor,Pump controller
- (Network signal)
SAP03523
lo-148
FUNCTION
l There are five modes available for selection
with the working mode switch on the moni- L/O H/O
tor panel. These modes are the heavy-duty
operation (H/O) mode, general operation (G/
0) mode, finishing operation (F/O) mode, lift-
ing operation (L/O) mode, and the breaker
operation (B/O) mode. It is possible to select
the most suitable engine torque and pump
absorption torque to match the nature of
Engine speed N
the work.
SAP03524
l The engine throttle l pump controller de-
tects the actual engine speed and the speed
set by the engine governor through the fuel
control dial in accordance with the pump
absorption torque set for each mode, and
carries out control so that the pump absorbs
all of the torque at each output point of the H/O
Power max.
engine.
Engine speed N
SAP03525
CL
" H/O
z
2
L
_
: G/O,F/O,B/O
:
Power max.
"
.II
E
d
Pump discharge amount 0
SAP03526
10-149
1) Control method in each mode

Heavy-duty operation (H/O) mode
Engine speed N Engine speed N Pump disvharae amount Q

SAP03527 SAP03528 SAP03529
. Matching point in heavy-duty operation . When the load on the pump rises and the
mode: 96% partial output point pressure rises, the engine speed goes down.
When this happens, the pump discharge
PC200 PC220 amount is reduced, and the engine speed is
PC210 PC230 controlled so that it becomes near the 96%
partial output point.
Heavy-duty 96 kW/1,800 rpm 114 kW/2,000 rpm
If the reverse happens and the pressure goes
operation (H/O) I128 HP/l,800 rpm} I153 HP/Z000 rpm} down, the system is controlled so that the
pump discharge amount is increased until
the engine speed becomes near the 96%
partial output point.
By repeating this control, the engine can al-
ways be used at near the 96% partial output
point.
General operation (G/O), finishing operation (F/
01, breaker operation (B/O) mode
Enolne speed N Pump discharge amount 0

SAP0353 1 SAP03532
. Matching point in general operation, finish- . When the load on the pump rises and the
ing operation, and breaker operation mode: pressure rises, the engine speed goes down.
80% partial output point When this happens, mutual control of the
engine and pump is used to control the sys-
PC200 PC220
tem so that the pump absorption torque fol-
PC210 PC230
lows the equal horsepower curve of the en-
General operation gine, and the engine speed is lowered while
(G/O), finishing
81 kW/1,700 rpm 96 kW/1,800 rpm keeping the torque constant.
operation (F/O),
breaker ODeration (108 HP/l,700 rpm) {I28 HP/l,800 rpm} In this way, the engine is used in a range
(B/O) ’ I I which provides good fuel efficiency.
1o-150
Liiing operation (L/O) mode
Engine speed N Engine speed N Pump discharge amount 0

SAP03533 SAP03534 SAP03535
. Matching point in lifting operation mode: l When the lifting operation mode is selected,
60% partial output point the engine speed is automatically lowered
to the partial position.
PC220
In this condition, control is carried out in the
PC230
same way as for the general operation, fin-
ishing operation, and breaker operation
76 kW/1,500 rpm
modes to match the load on the pump.
I102 HP/l,500 rpm)
In this way, the fuel consumption is reduced
and the fine control ability is improved.
Power maximizing mode
Ensine speed N Engine speed N

SAP03536 SAP03537
. Matching point in power max. mode: . When the pump load increases, the engine
Rated output point speed drops.
When this happens, the pump discharge is
PC200 PC220 reduced to prevent the engine speed from
PC210 PC230 going down and to ensure that the engine is
used at near the rated output point.
99 kW/2,000 rpm 117 kW/Z,lOOrpm
Power max.
{133HP/2,000rpm) 1158HP/2,100
rpm)
10-151
21 Pump control function when traveling
Engine speed N Pump discharge amount P

SAP03539 SAP03540
. When the machine travels in the heavy-duty

operation (H/O) mode, the engine speed
rises, and the pump is controlled in the same
way as when in the power maximizing mode.
Engine speed N Pump discharse amount 0

SAP03541 SAP03542
. When the machine travels in any mode other

than the heavy-duty operation (H/O) mode,
the working mode and engine speed are kept
as they are, and the pump absorption torque
is increased.
31 Control function when pump prolix switch

is ON
. Even if any abnormality should occur in the l In this case, it is designed to allow a con-
controller or sensor, the pump prolix switch stant current to flow from the battery to the
can be turned ON to provide an absorption PC-EPC valve, so oil pressure sensing is car-
torque more or less equivalent to the gen- ried out only by the PC valve.
eral operation (G/O) mode, thereby allowing
the machine to maintain its functions.
10-152
2. PUMP AND VALVE CONTROL FUNCTION
;-----y------_-_-------------_
I I
I I
merge-divider!
I I I I
Pump meroe-
Z-stage
rel iet
valve
Enoine
Fuel
injection motor
Pump
r-i
I-------
(-------------------_!
I
Fuel control
dial
Hi
c
Lo
=
2 Monitor Panel
.”
P v)
/
Governor,pump controller
I_
’ (Network sianall 1
SAP03545
10-153
FUNCTION
. The following two functions are available to
provide the optimum matching under vari-
ous working conditions: a 2-stage relief func-
tion which increases the digging power, and
a fine control mode function which improves
the ease of fine control.
1) LS control function
. The switching point (LS set differential pres-
sure) for the pump discharge amount inside
the LS valve is changed by changing the
output pressure from the LS control EPC
valve to the LS valve according to the en-
gine speed and operating condition of the
actuator.
. Because of this, the timing for starting the
discharge amount from the pump can be
optimized, to give excellent ease of com- LS set differential pressure
SAP03546
pound operation and fine control.
21 Cut-off function
For details of the operation, see CLSS.
. When the cut-off function is actuated, the

PC-EPC current is increased to near the max.
value. In this way, the flow at relief is made
smaller and the fuel consumption is reduced.
. Actuation conditions for cut-off function
When the front or rear pressure sensor is
above 30.9 MPa 1315 kg/cm? and the power
max. or quick slow-down functions are not
being actuated.
Note: When traveling or when using the lift- Pump Pressure (MPa( ks/cm’l)
SAP03547
ing operation mode, the cut-off is not
actuated.
10-154
31 2-stage relief function

. The relief pressure for normal operations is
31.85 MPa (325 kg/cm?, but when the 2-
stage relief function is actuated, the relief
pressure rises to approx. 34.79 MPa (355 kg/
cm*).
Because of this, the hydraulic pressure is
increased by one stage.
. Actuating conditions for 2-stage relief func-

tion
Conditions Relief pressure

l When traveling
l When swing lock switch 31.85 MPa

is ON 1325 kg/cm*}
l In lifting operation (L/O)

mode G
l When power max. function 34.79 MPa

or swift slow-down function I355 kg/cm*]
are actuated
2
g
8 4) Fine control mode function
l When the finishing operation (F/O) mode is
selected from the working mode, the pump
LS valve is controlled, and the pump dis-
charge amount is reduced to improve the
ease of fine control and the precision when
finishing.
. Relationship between working mode and

pump discharge amount (for independent
operation) (%)
The figures in ( 1 are for the PC220.

The figures in c > are for when arm IN
is operated.
In each working mode, the full flow of
the pump at the set engine speed is taken
as 100%.
10-155
3. POWER MAXIMIZING l SWIFT SLOW-DOWN FUNCTION
Control valve
m - Work equipment lever

PressUre
Engine “alYe knob switch
Monitor Panel
Fuel control
2
pG+---T----7ixq : 7
z
.o I
CnI
z: I 2
!___________ PC-EPC .:
L a
I.? valve
; v)
.-3 .z- .-it
=al -0
cc: G
d ~ ,,
z “g
s c
Governor.uumo controller ti ,:’ J
c
SAP03548
lo-156
FUNCTION
. This function provides an increase in the dig-
ging power for a certain time or switches
the working mode to the lifting operation (L/
0) and reduces the speed. It is operated us-
ing the L.H. knob switch to momentarily
match the operating conditions.
* The power max. function and swift slow-
down function are operated with the same
switch. Only one of these functions can be
selected at any time; they cannot both be
operated together.
1) Power maximizing function

. During digging operations, when that extra
bit of digging power is needed (for example,
when digging up boulders), the L.H. knob
switch can be pressed to raise the hydraulic
pressure by approx. 10% and increase the
digging force.
If the L.H. knob switch is pressed ON when
the working mode is at H/O or G/O, each
function is automatically set as follows.
$
t
% I
Engine, 2-stage Actuating

Working
pump relief
mode time
control function
Actuated Auto-
Matching
Heavy- (31.9 + matically
at rated
duty 34.8MPa canceled
output
operation I325 + after
point
355kg/cm2}) 8.5 set
2) Swift slow-down function

. During normal operations, if it is desired to
carry out lifting operations or finishing op-
erations for a moment, the working mode
can be switched to lifting operation (L/O)
mode by operating the L.H. knob switch.
. If the L.H. knob switch is pressed ON when
the working mode is at H/O or G/O, each
function is automatically set as follows.
Working Actuating time
Lifting operation While switch is kept pressed.
10-157
fl:: If
02OYO6
FUNCTION
. If all the control levers are at neutral when
waiting for work or waiting for a dump truck,
the engine speed is automatically reduced
to a midrange speed to reduce fuel consump-
tion and noise.
. If any lever is operated, the engine speed
returns immediately to the set speed.
OPERATION
Control levers at neutral
. If the engine is running at above the decel-
eration actuation speed (approx. 1400 rpm),
and all the control levers are returned to
neutral, the engine speed drop immediately
to approx. 100 rpm below the set speed to
the No. 1 deceleration position.
. If another 4 seconds passes, the engine
speed is reduced to the No. 2 deceleration
position (approx. 1400 rpm), and is kept at
that speed until a lever is operated.
When control lever is operated

. If any control lever is operated when the
engine speed is at No. 2 deceleration, the
engine speed will immediately rise to the
speed set by the fuel control dial.
Speed (r pm)
100+50 r pm
No. 1 deceleration
No. 2 deceleration
(1400rpm)
4 Less than 2 Less than 1
Time kec)
Levers at neutral Lever operated SAP03550
10-159
5. AUTOMATIC WARNING-UP AND ENGINE OVERHEAT PREVENTION FUNCTION
Governor motor
Fuel control dial
Monitor Panel
I
I
PC-EPC
r
L_________
va I ve
I
zs
Iollo
000
•I
o !~ p(Netnork,;ianal) 4
e, Governor.Pum controller
I
_&“cga J 1 / 22
>
SAP03601
%
lo-160
FUNCTION
. If the coolant temperature is low, this auto-
matically raises the engine speed to warm
up the engine after it is started. (Automatic
warming-up function)
In addition, if the coolant temperature rises
too high during operations, it reduces the
load of the pump to prevent overheating.
(Engine overheat prevention function)
1) Engine automatic warming-up function

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

Engine speed: Less than 1400 rpm
Conditions for cancellation (any one) Cancellation

Coolant temperature: 30°C or above
Auto- I I
matic Automatic warming-up time: 10 minutes or more 1
d 1 Engine speed: As desired
Fuel control dial: Held at more than 70% of

Manual full speed for more than 3 seconds
10-161
2) Engine overheat prevention function

. This function protects the engine by lower-
ing the pump load and engine speed to pre-
vent overheating when the engine coolant
temperature has risen too high.
. This system is actuated in two stages. The
first stage is when the water temperature is
between 102°C and 105”C, and the second
stage is when the water temperature is 105°C
and above.
Normal operation (Coolant temperature below 102°C)

I
Coolant temperature:
,
Below 102°C
(Coolant temperature
gauge: Green range)
1st stage (Coolant temperature between 102°C and 105°C)
r- Actuation condition 1
Working
Actuation
mode
condition
PC200,210 PC220.230
1 Cancel condition
2
Coolant temperature:
Coolant temperature: 66kW 8lkW Below 102’C
Heavy-duty, 189HPI {108HP}
9
tz
Between
105°C
102°C and
general, Flow 57% b When the above condition is
finishing breaker
Mode kept as it is, met, the system returns to the
z (Coolant temperature condition before the overheat
output reduced
gauge: Red range) Lifting operation orevention function was actu-
Lifting ated (automatic reset).
- kept as it is
a
2nd stage (Coolant temperature 105°C and above)
:
Actuation condition Cancel condition

Actuation condition
Coolant temperature: Below 102°C
Working mode In any mode
Fuel control dial: Return temporar-
Q) Coolant temperature: ily to low idling position
g 105°C and above Engine speed Low idling
t; * When the above conditions
z (Coolant temperature are met, the system returns
Monitor caution lamp Lights up
N gauge: Red range) to the condition before the
overheat prevention function
Caution buzzer Sounds
was actuated (manual reset).
lo-162
6. SWING CONTROL FUNCTION
Swing motor
I_____.
s?Y
Work eauipment lever
Engine OFF Id ’ ON
Monitor panel
\
Main Pump
Ioil
0 0 Cl
R
SAP03602
lo-164
FUNCTION
. The system is provided with a swing lock
and swing holding brake function.
1) Swing lock, swing holding brake function Lock

Lock Function Operation
l The swing lock (manual) can be locked at switch lamp
any desired position, and the swing holding Approx. 4 set after swing
brake (automatic) is interconnected with the lever is returned to neutral
Swing swing brake is actuated.
swing, so it prevents any hydraulic drift af- OFF holding When swing lever is oper-
ter the swing is stopped. brake ated, brake is released and
upper structure can swing
freely.
Swing lock is actuated and

swing is held in position.
Swing Even when swing lever is
ON lock operated, swing lock is not
canceled and swing does not
move.
Swing
ON OFF
lock
(when controller (when controller
Operation of swing lock prolix switch prolix
is abnormal) is normal)
If any abnormality should occur in the con- switch
troller, and the swing holding brake is not

actuated normally and the swing cannot be
operated, the swing lock prolix switch can
be operated to cancel the swing lock and
allow the swing to be operated.
Even when the swing lock prolix switch is
turned ON, the swing lock switch stays ON
and the swing brake is not canceled.
When the swing brake is canceled, the swing
has only a hydraulic brake operated by the
safety valve, so if the swing is stopped on a
slope, there may be hydraulic drift.
Hydraulic oil quick warm-up function when

swing lock switch is ON
When the swing lock switch is turned ON,
the pump cut-off function is canceled and
the relief pressure rises from 31.85 MPa (325
kg/cm*) to 34.79 MPa I355 kg/cm*}. w SBPO3603
In this condition, if the work equipment cir-

cuit is relieved, the hydraulic oil tempera-
ture rises more quickly and this makes it
possible to reduce the warming-up time.
10-165
7. TRAVEL CONTROL FUNCTION
Travel lever
& TI .ave I motor
:-
RaQUlatDr
i___________--------J
lp*
Fuel
daial
control
Hi
Engine
Governor,pump controller
Main
Oil
(Oil
.~
Pump
Dressure
Pressure
sensor
se?gor
j1
siani II)
si( tnal)
-
Monitor
I=iIIollo
Panel
SAP03604
10-M
FUNCTION
. When traveling, the pump control is carried
out, and the travel speed can be selected
manually or automatically to give a travel
performance that suits the nature of the work
or the jobsite.
11 Pump control function when traveling

. If the travel is operated in any working mode
other than the heavy-duty operation (H/O)
mode, this increases the pump absorption
torque while keeping the working mode and
engine speed as they are.
* For details, see PUMP & ENGINE MUTUAL
CONTROL SYSTEM.
21 Travel speed selection function

i) Manual selection using travel speed
switch
If the travel speed switch is set to Lo,
Mi, or Hi, the pump controller controls
the pump flow and motor volume at each
speed range as follows to switch the
travel speed.
z!3
>
ii) Automatic selection according to engine
% speed
If the engine speed is reduced to below
1400 rpm by the fuel control dial:
. If the machine is traveling in Lo, it
will not shift even if Mi or Hi are
selected.
. If the machine is traveling in Mi, it
will not shift even if Hi is selected.
. If the machine is traveling in Hi, it
will automatically shift to Mi.
iii) Automatic selection according to pump

discharge pressure
If the machine is traveling with the travel
speed switch at Hi, and the load in-
creases, such as when traveling up a
steep hill, if the travel pressure contin-
ues at 33.32 MPa (340 kg/cm*} for more
than 0.5 set, the motor volume is auto-
matically switched and the travel speed
changes to Mi. 17.6~1801 37.313401
(The travel speed switch stays at Hi.) Travel pressure (MPa(ke/cm'l)
The machine continues to travel in Mi, SAP03605
and when the load is reduced, such as
when the machine travels again on flat
ground or goes downhill, and the travel
pressure stays at 17.64 MPa I180 kg/cm2}
or less for more than 0.5 set, the motor
volume is automatically switched and the
travel speed returns to Hi.
lo-167
8. ACTIVE MODE FUNCTION
I
; Active mood
I
1 solenoid valve
Relf-
Reducing
, /
I
I
,
Fuel control
dial
Z
:--Y
!__ PC-EPC
valve
<
”
.:
i
1
(STD. ESTRAI
(HYPER. HYPER rix)
li
SAP03606
FUNCTION
l When the active mode switch on the moni-
tor panel is turned ON (lamp lights up), it is
possible to increase the speed of the opera-
tion by increasing the speed when there is a
light load and by detecting the load when
there is a heavy load.
l The active mode is actuated only when the
fuel control dial is at the Max. position. If
the fuel control dial is not at the Max. posi-
tion, the load sensing function is actuated
but the pump discharge increase function is
not actuated.
1o-1 68
1) Pump absorption horsepower increase, en-

gine speed increase, cut-off cancel function Active
Heavy-duty (heavy-duty diusina.
. The cycle time is reduced by increasing ooerat ion travel. Power upI
the engine speed and pump absorption
torque and by canceling the cut-off func-
tion. The increase in the absorption
horsepower increases the bucket lifting
height and is effective in loading dump
trucks in hoist and swing operations.
2) 2-stage boom lowering speed, engine speed

up function Engine speed
SAP03607
. When the active mode switch is ON, the
stroke of the boom LOWER spool in the
control valve is switched from 9 mm to
11.5 mm to increase the speed. 1 / H/O 1 Active 1
I
When the engine speed is increased, the 95.6kW/1,800rpm 99kW/2,000rpm

oil flow at light load is increased to in- PC200 ~128HP/1,800rpm~ U33HP/2,000rpm~
crease the rough finishing speed.
3) 2-stage boom cylinder head safety valve

function
. When the active mode switch is ON, the 114kW/2,000rpm 118kW/2,100rpm
boom cylinder head pressure is changed pc23o {153HP/2,000rpmI {158HP/2,100rpm~
$ from 28.4 MPa (290 kg/cm*) + 35.8 MPa
z {365 kg/cm*} to improve the thrusting
z force of the machine.
4) Engine-pump matching point adjustment

function Active mode matching Point
Uni t : MPa (kc/cm’)
. When the active mode switch is ON, the Pump pressure:
engine speed is increased (100 - 200 22.6 (230) or a,bove
rpm) at light load, and the pump dis-

charge is increased to increase the work
equipment speed.
At heavy load, the engine speed is re- Pump pressure:
duced and the load is detected to enable 22.6 (230) or below
operations to be carried out.
Ensine speed
SAP03608
I ) Speed A 1 Speed B 1 Speed C )
1 PC200 1 2,OOOrpm 1 1,800rpm 1 1.700rpm 1

I 1 ,
I I 1
I ~~210 1 2,000rpm 1 1,800rpm 1 1,700rpm I
( ~~220 ( 2,lOOrpm ( l,gOOrpm ( 1,800wm (
/ PC230 1 2,lOORPM 1 1,900rpm 1 1,800rpm. /
lo-169
9. ACTIVE POWER UP FUNCTION
t-stage reli
valve
Ens in
inject ion motor ,

/,
Work equipment lever

knob switch
:____-------------_
Fuel
dial
control i I
C
Lo
Hi L__
i 1PC-EPC
valve
I Monitor Panel
‘2
C====
:
P
‘.
Ciovernor~pump controller
’ (Network signal)
SAP03609
10470
FUNCTION
. In the active mode, if the power max. func-
tion is selected, the left knob switch can be
operated to increase the engine speed and
the digging power and to cancel the engine
speed reduction function under high load. In
this way, it is possible to obtain even Active
speedier production. Heavy-duty (heavy-duty disoina,
. oDerat ion travel. Power UP)
If the fuel control dial is not at the MAX
position, the pump discharge amount is not
increased.
I) Engine speed increase, pump absorption

horsepower increase function
This increases the engine speed and cancels
the engine speed reduction function at high
load to increase the pump absorption horse- Engine speed
SAP03607
power and reduce the cycle time.
21 Power max. function

This increases the hydraulic power by Active Active power max
approx. 10% to increase the digging power. 99.3kWI2,OOOrpm 103kW/2,200rpm
pc2oo {133HP/2,000rpm U38HP/2,200rpmI
99.3kW/2,000rpm 103kW/2,200rpm
$ * This function is automatically canceled after pc21o {133HP/2,000rpm {138HP/2,200rpmI
& 8.5 seconds. 117.7kW/2,100rpm 117.7kW/2,200rpm
3 pc22o {158HP/2,1OOrpmI {158HP/2,200rpmI
117.7kW/2,100rpm 117.7kW/2,200rpm
pc23o {158HP/2,100rpm~ I158HP/2,200rpmI
10-171

1) ENGINE SPEED SENSOR
0 g-z--~
Structure of circuit
SEP02581
FUNCTION
1. Wire . The engine speed sensor is installed to the
2. Magnet ring gear portion of the engine flywheel. It
3. Terminal counts electrically the number of gear teeth
4. Housing that pass in front of the sensor, and sends
5. Connector the results to the engine throttle - pump con-
troller.
l This detection is carried out by a magnet,
and an electric current is generated every
time the gear tooth passes in front of the
21 PPC OIL PRESSURE SWITCH magnet
1. Plug
2. Switch
3. Connector
SPECIFICATIONS
Composition of points : N.O. points
Actuation (ON) pressure : 0.49 + 0.1 MPa
(5.0 f 1.0 kg/cm’)
Reset (OFF) pressure : 0.29 f 0.05 MPa
13.0 f 0.5 kg/cm21
FUNCTION
l There are switches installed to
- the junction box. The operating
0 41 condition of each actuator is de-
--_* 2 tected from the PPC pressure,
Structure of circuit and this is sent to the engine
throttle . pump controller.
SEP02582
lo-172
3) PUMP PRESSURE SENSOR
SEP02584
FUNCTION
InsuIat_lon layer
l Two sensors are mounted in each actuator
circuit of the boom and arm (four sensors in
total). The load pressure on the actuator is
converted to the voltage and sent to the con-
troller.
OPERATION
. When the oil entering from the pressure in-
let applies pressure to the diaphragm of the
steel)
oil pressure detector, the diaphragm is de-
SDP02585
flected and deformed.
l A gauge layer is mounted at the opposite 5
side of the diaphragm and the resistance
value of the gauge converts the deflection
24
of the diaphragm into the output voltage
and sends it to the amplifier (voltage ampli- :
fier). z3
l The voltage is further amplified by the am- z
plifier and sent to the governor and pump
2'2
controller.
l The relational expression of the pressure P 2
(MPa {kg/cm211 and the output voltage (VI: :1

V = 0.008 x P + 1.0 2
ix
0 9.8 19.6 29.4 39.2 49.0

I1001 i2001 I3001 I4001 (5001
Oi I pressure P (MPa ~k.dcm*l) SDP02586
10-173
4) ENGINE THROlTLE l PUMP CONTROLLER
CN-I CN-2 SAP02683
10-174

CN-1 CN-3 CN-5
Pin Input/ Pin Input/ Pin Input/
Name of signaloutput Name of signaloutput Name of signaloutput
NO. output uo. output No. output
1 Battery relay drive output Output 1 1Enaine water temoerature sensor 1 Input
( 2 1Pump merge-divider solenoid 1Output ( 2 ( Fuel level sensor I Input I
3 Swing holding brake solenoid Output 3 1Pump F pressure input I Input I
4 NC - 4 1Throttle ootentiometer inout 1 Input 1 4 GND Input
5 1NC I - I 5 Swing pressure switch Input
I
1 8 1Active mode solenoid /output I
6
8
Pressuresensor power source (t24V) Output
Potentiometer power source (+5V) Output
I Starting switch (ACC) I Input I

6
8
/ Service
7 ) NC
1Radiator
valve pressure switch
water level sensor1

1 Input 1
I -
Input
I
I
9 I Knob switch I Input
I 9 1 Hydraulic oil level sensor I Input I
10 NC - 10 I Engine speed sensor GND / but I
11 NC - 11 Bucket CURL oressure switch
__I lnout I
I12 1GND I but I 12 / Battery charge (alternatorterminal RI j Input I I2 / Bucket DUMP pressure switch I Input 1
13 Power source (+24V) Input 13 Pump R pressure input Input 13 ( Travel pressure switch I but I
CN-2 14 Feedback potentiometer input Input 14 1 NC I - I
Pin Input/ - 1Engine / I
Name of signaloutput 15 NC 15 oil pressure sensor L Input
No. output
1 Solenoid power source (t24V) Input 16 Pressure sensor GND Input 16 I Enaine oil level sensor I InDut I
I 2 / Governor motor phase A (+) /Output / 17 1Potentiometer GND 1 Input I 17 ( Air cleaner clogging sensor 1 input I
3 Governor motor phase A (-) Output 18 Starting switch (terminal C) Input
4 Governor motor phase B (t) Output 19 Automaticgreasingcontrollerabnormality Input
5 Governor motor phase B (-1 /Output I 20 1 NC I - I
6 NC -
7 LS-EPC solenoid (+) output
I 8 I PC-EPC solenoid f+) 1output I 23 1A rm IN pressure switch I Input

I
- Input,
9 NC 24 S-NET (+) output
10 NC - 25 Model selection 1 Input
III I PGND I Input

I 26 / Model selection 3 I Input I
(12 1Solenoid power source (t24V) 1 Input 1 27 I Model selection 5 I InDut I
113 / NC I - I 28 / Swing prolix switch I Input I

14 NC - 29 Overload sensor (if equiped) Input
15 NC - 30 Boom LOWER pressure switch Input
(16 ( NC I - I 31 ( Arm
I
OUT pressure switch 1 Input (
I
Input,
17 LS-EPC solenoid 1-j output 32 S-NET I+) output
18 PC-EPC solenoid (-1 output 33 1 Model selection 2 I Input
I
119 1NC I - I 34 1Model selection 4 I Input I
20 NC - 35 Kerosene mode selection Input
21 1PGND I InDut 36 Swing lock switch Input
10-175
5) PC PROLIX RESISTOR
SBPOO370
FUNCTION
1. Resistor
. This resistor acts to allow a suitable current
2. Connector
to flow to the EPC solenoid when the PC
prolix switch is ON.
SPECIFICATION . No current flows when the PC prolix switch
Resistance: 4012 is OFF.
6) FUEL CONTROL DIAL, GOVERNOR MOTOR, 9) LS CONTROL EPC VALVE

ENGINE THROTTLE . PUMP CONTROLLER PC CONTROL EPC VALVE
* See ENGINE CONTROL SYSTEM. PUMP MERGE-DIVIDER SOLENOID VALVE
P-STAGE RELIEF SOLENOID VALVE
TRAVEL SPEED SOLENOID VALVE
7) MONITOR PANEL SWING BRAKE SOLENOID VALVE
* See ENGINE CONTROL SYSTEM. ACTIVE MODE SOLENOID VALVE
Sr See EPC SOLENOID VALVE.
8) PC VALVE
* See HYDRAULIC PUMP.
lo-176
STRUCTURE AND FUNCTION ELECTRONIC CONTROL SYSTEM FOR HYPER GX
ELECTRONIC CONTROL SYSTEM FOR HYPER GX (l/Z)

PC200, 2OOLC-6 HYPER GX
CONTROL FUNCTION (ADDITIONAL FUNCTIONS ON MONITOR PANEL)
Pump 84 engine mutual control function

I
Pump and valve control function
Power maximizing function
Swift slow-down function
Engine automatic warming-up, overheat prevention function
I I I
- Travel control function
for HYPER GX
Self-diagnostic function
1
, I
Electronic valve control function I
j, For functions surrounded by bold

lines are the additional functions de-
scribed here. Automatic vibration function
For details of the functions sur-
rounded by thin lines, see ELEC- 5
TRONIC CONTROL SYSTEM FOR Soft mode function
STD.
lo-178

10-179
1. ELECTRONIC VALVE CONTROL FUNCTION
EPC valve
Bucket
Ensine
L- n.
I Main PUMP x )
Valve controller IA I
I I Boom Drol ix
Battery
control switch
relay
Fuse
box
boom Drollx switch SAP03612
FUNCTION
. On the electronic
equipment
version machine, the work
and swing are controlled elec-
I Actuator
Electronic
version
tronically, whereas on the hydraulic version I Boom I

machine, control is carried out by a fully I Arm 1 Electronic 1 Hvdraulic
.
hydraulic PPC control system.
In the travel system, a travel PPC valve is
t--GE-. control control
used for both the electronic version and hy- Swing

draulic version.
L.H., R.H. travel Hydraulic control
lo-180
OPERATION outout voltage IV)

An electric signal (voltage) is output to the I
valve controller in accordance with the move-
ment of the electric lever to the front, rear,
left, or right. (Fig. 1)
In the valve controller, this electric signal is Lever
converted into a flow command, and the stroke
) (I)
current for the EPC valve is determined and
output in accordance with this command
value.
(Fig I) SAP03613
. EPC output Pressure (MPa(ke/cm’I)

The EPC valve receives this current value,
and outputs the pilot hydraulic pressure to I-
control the spool of the control valve. (Fig.
2)
* For the functions that are explained on the
following gages, the function is achieved by
changing the flow of the sequence of sig- lo&o 50 100
nals (electric lever + valve controller + EPC EPC Lever
8 valve) and the valve controller automatically current stroke (%I
> value
outputs a current to the EPC valve. (mA)
%
:::
F I ow coyy)d2,va I ve (%)
SAP03614
Boom prolix function

If any abnormality should occur in the valve
controller, the controller shuts off the output
current to each EPC valve and stops the
movement of the work equipment and swing.
If this condition occurs, inspection must be
carried out immediately. In cases where it is
necessary to move the machine temporarily
to a safe place, it is possible to switch the
boom prolix switch under the operator’s seat
to the prolix position and the boom control
switch to a position to raise or lower the
boom.
If there is any abnormality in the electrical
system at the EPC end, the prolix function
does not work. - -
The boom control switch is an auto-return \‘
SBPO3615
type, so it will return automatically to the
neutral position when it is released.
lo-181
2. BOOM/SWING PRIORITY SELECTION FUNCTION
Electric lever
Mon i tor Panel
SAP0361 6
FUNCTION
. By changing the speed (oil flow) for the work
equipment and swing during compound op-
erations, it is possible to obtain the opti-
mum matching dump truck position for
swing and load operations.
lo-182
OPERATION EACH MODE

. The output voltage from each electric lever II Boom boost mode
is converted to a flow command value in- . Compared with the normal situation when
side the valve controller. the priority mode is not used, the flow of oil
When this happens, the converted flow com- sent to the boom is increased, so the bucket
mand value is calculated by the determined lifting speed during swing and load opera-
priority ratio according to the set priority tions is increased.
mode.
. A current value in accordance with the cal- 2) Swing boost mode
culated flow command value is output to . Compared with the normal situation when
the EPC valve. the priority mode is not used, the flow of oil
sent to the swing is increased, so the bucket
Example: When boom mode is selected lifting speed during swing and load opera-
. When the above mode is selected, if both tions is reduced.
the right swing and boom RAISE are oper-
ated to the end of the stroke, the flow com- * With swing and load operations, the posi-
mand value remains at 100% for the boom tion of the matching dump truck is the main
RAISE circuit, but in accordance with the set target, but the actual situation may change
priority ratio, the flow command value for according to the condition of the load, the
the right swing is calculated at 70%. attachment installed, and the method of op-
. As a result, the current value output from eration used by the operator.
the valve controller to the EPC valve is 70% * The priority mode is only used for compound
for the right swing and 100% for the boom operations; with independent operations,
RAISE, so compared with the situation when there is no change in the speed according to
the priority mode is OFF, the lifting speed the mode.
for the bucket is increased. However, with swing boost 2 mode, the
boom and arm speeds become slower with
independent operations.
-Swing boost
SBPO3617
10-183
3. PLAYBACK FUNCTION
/ EPC valve
--------------------____________________--_,
I
I Main relief valve
--f!d-
J.
I
Self-
_
Reducing
PleSSure
Engine valve
1___________1
Electric lever
Monitor valve Valve controller _
SAP03618
FUNCTION
. If the teaching mode is used to teach the
controller the movement of the work equip-
ment, and the system is set to the playback
mode and the L.H. knob switch is operated,
it is possible to carry out the same move-
ment as many times as desired. This means
that it is possible to carry out highly efficient
work in situations where the same opera-
tion is repeated.
lo-184
OPERATION
I) Teaching mode
. When the teaching mode is selected and the
L.H. knob switch is double clicked, the buzzer
will give a short beep, and the teaching is
started.
. From this moment to the point where the
L.H. knob switch is released, all the signals
from the electric levers for the operation of
the boom, arm, and bucket are recorded by
the valve controller.
Ir The memory capacity for teaching is a maxi-
SEPO3619
mum of 50 seconds.
* Teaching cannot be used for the swing and
travel operations.
* To carry out the teaching again, double click
the L.H. knob switch, and the content of the
memory will be rewritten.
* Any teaching that has been stored in
memory remains there until a new teaching
operation is carried out.
The teaching remains in memory even when
the starting switch is turned off. However, if
the battery is replaced, it is deleted.
$
>
21 Playback mode
% . Select the playback mode, and set the work SBPO3620
equipment manually in the posture for start-

ing the playback.
. In this condition, if the L.H. knob switch is
double clicked, the buzzer will give a short
beep, and the lever signals recorded by the
valve controller will be output as a current
command value to the EPC valve to play
back the movement of the work equipment.
* If the work equipment is placed again in the
start posture for teaching, the same opera-
tion can be played back repeatedly simply
by double clicking the L.H. knob switch.
* If the L.H. knob switch is released during the
playback, the operation will stop. Even if the SBPO3621
L.H. knob switch is double clicked again, the
operation will not continue from the point
where it stopped; the teaching will start from
that position and will repeat the whole op-
eration from the beginning, so the move-
ment of the work equipment will be differ-
ent.
lo-185
* If the L.H. knob switch is double clicked dur-

ing teaching, the teaching will start immedi-
ately.
For this reason, even if the lever is not being
operated, it will be recorded as staying in
the neutral position. As a result, if teaching
is not carried out immediately, the start of
the movement may be slow when the play-
back mode is used.
Ir This function plays back the pattern of op-
eration carried out by the operator, so if the
posture when starting the teaching is differ-
ent from the posture when starting the play-
back, the movement of the work equipment
will be different.
If the load is different, this will also influ-
ence the movement.
3) OFF mode
l When not using the playback function, press
OFF switch to return to the standard condi-
tion.
* If the knob button for any other function is
pressed while the playback function is being
used, the playback function will automati-
cally be turned OFF.
* Double clicking L.H. knob switch (caution)

. In functions where the L.H. knob switch is
operated to carry out automatic control, the
movement will not start unless the switch is
double clicked. This is to ensure safety.
. The second click when double clicking the
switch is the signal for starting. Keep the
switch pressed during the operation.
Start of automatic control End of automatic control
If the switch is released, the movement will (double cl ickl
SAP03622
stop immediately.
. Double click:
Press the switch lightly to turn it ON, release
it momentarily, then press it again to turn it
ON, and keep it pressed for the length of the
operation. (The switch must be turned ON
for the second time within 2 seconds of turn-
ing it ON for the first time.)
lo-186
4. AUTOMATIC VIBRATION FUNCTION
EPC valve
I
I
I
I
A.
---------, , Y
I
I
I
-------2
, LA
I
I
____J
li---A
-7 I
I I
I
I
I
L___,+L__,
I
I
-----------~
Self-
Reducins
PleSS"re
Eneine valve
i___________i
Electric lever
Monitor valve Valve controller _
SAP03618
FUNCTION
. Automatic vibration can be -applied to the
selected work equipment simply by select-
ing the mode and operating the L.H. knob
switch.
l There are four types of vibration pattern;
bucket, bucket and arm, boom and arm. Each
of these can be selected at three levels of
vibration amplitude; large, medium, and
small.
1o-1 87
OPERATION
. If the vibration pattern and vibration ampli- RAISE
kxRL)
tude are selected, and the L.H. knob switch
is double clicked, the valve controller out-
puts a signal current in a constant cycle to 2_
the EPC valve of the actuator selected for 20
Time
vibration. :
. The vibration amplitude can be selected at 0
one of three levels, but in actual fact, if a 7 Cycle
large amplitude is selected for the work s
equipment, the controller sends the signal 1b
current for the amplitude, but at the same LOWER
(DUMP) SAP03623
time also outputs a longer cycle.
1) Vibration mode
. If the vibration pattern and vibration ampli-
tude are selected, and the L.H. knob switch
is double clicked, the buzzer gives a short
beep, and the selected work equipment vi-
brates automatically. When the switch is re-
leased, the vibration stops.
. When the boom mode, arm mode, or bucket
mode are selected, the automatic vibration
is carried out independently for the selected
work equipment.
. When the bucket and arm mode is selected,
SBP03624
automatic vibration is carried out for the arm
and bucket simultaneously.
* Depending on the posture of the work equip-
ment and the load, the work equipment may
move in one direction while carrying out vi-
bration. If this happens, operate the work
equipment to compensate for the movement
while continuing the vibration.
21 OFF mode
. When the automatic vibration function is not
being used, press the OFF switch to return
to the standard condition.
* If the lever switch for any other function is
SBPO3625
pressed while the automatic vibration func-
tion is being used, the automatic vibration
function is automatically turned OFF.
Arm
'c
SBPO3626
10-188
5. SOFT MODE FUNCTION
EPC valve
------------------------------------,
:-------
Electric lever
Monitor Panel =C5 ' '
t& ; /--+--j varve controiler B
SAP03616
FUNCTION
. This function changes the operating pattern
to a gentler pattern when the work equip-
ment lever is operated suddenly,
. This function can be used for all the actua-
tors (boom, arm, bucket, swing) that are
operated by the electronic valve control.
SAP03627
1O-l 89
OPERATION
. When the soft mode is ON, even if the work
equipment lever is operated suddenly, the
signal is converted to a gentle flow com-
mand value by the valve controller, and is
output to the EPC valve. E
. When the control lever is operated suddenly, 2
co
if it exceeds the slope set for the soft mode,
the set slope becomes the upper limit, and
the current command value is output to the
EPC valve according to the set slope. Con-
trol is carried out in the same way when Time
SAP03626
stopping in order to reduce the shock to the
actuator.
. If the control lever is operated slowly, and
the slope of the operation does not exceed
the set slope of the soft mode, the controller
outputs the flow command value to the EPC
valve without changing the slope of the op-
eration.
* With this function, the actuator starts to move
smoothly, and when it stops, there is a slight
feeling of overrun.
* This function is used to make the movement
gentle and reduce the shock when stopping
or starting; it is not designed to reduce the
shock at the end of the stroke.
10-190
ELECTRIC LEVER
A-A
A-4
SBPO1941
1. Potentiometer (front-rear direction, for feedback) 6. Nut

2. Potentiometer (left-right direction, for feedback) 7. Disc
3. Potentiometer (front-rear direction, for signal) 8. Body
4. Potentiometer (left-right direction, for signal) 9. Shaft
5. Connector 10. Lever
10-191
FUNCTION
. This is installed to the left and right control Voltaoe WI
For feedback c For signal
stands, and the work equipment and swing
control levers are installed directly above
them.
” The operating angle (stroke) of the control
lever is detected by the potentiometer, and
this is output as a signal voltage to the valve
controller.
l This system is designed with a backup struc-
ture consisting of two potentiometers each
installed for the front-rear direction and left- 0 lOOI
Lever stroke (L) SAP03629
right direction; one of each pair is for the
signal, and the other is for the feedback.
Black For Sil”ll I”

Front 1 1
I c---
front-rear direction 5v
Yellow For“ion”,in
2 fro”+,““,dir”“ti””
Sig
Red For“~“Ilxin
7 left-rioth direction 5v
Yellow For prolix I”

8 left-ril,h direction sig
~-
Black For prolix in
9 left-rioth dirsctio” ma
Black For srolix in

Rear 1 IO front-raar direction 5v
SAP03630
lo-192
2) VALVE CONTROLLER
l-‘--L
0
I:
@
SBPOl944

CN-K03 CN-K04 CN-K05 CN-KO6
7 / Bucket CURL EPC (-) 1 output

8 t Bucket DUMP EPC i-1 / Outwt
14 Boom RAISE EPC (+I output 14 Network circuit 1-j

15 1Arm IN EPC (+) I Outout 15 1Lever potentiometer GND 1 -
16 Left lever leh-nght feedbackSIG Input
21 / EPC power source 24V 1 -

117
18
19
Leftleverfront-rearfeedbackSIG
Rightl&r leh-rightfeedbackSIG
Rightlewr hontwr feedbackSIG Input
10-193
3) BOOM PROLIX RESISTOR
3 SBPOO370
1. Resistor FUNCTION
2. Connector . This resistance is used to send a suitable
current to the boom RAISE and LOWER EPC
valve when the boom prolix switch is ON.
SPECIFICATIONS . When the boom prolix switch is OFF, no
Resistance: 33Q current flows.
4) EPC VALVE
* For details, see WORK EQUIPMENT, SWING
EPC VALUE.
10-194
ELECTRONIC CONTROL SYSTEM FOR HYPER GX (2/2)

CONTROL FUNCTION (ADDITIONAL FUNCTIONS ON MONITOR PANEL)
Pump & engine mutual control function
L
-1 Pump and valve control function I
-1 Power maximizing function
{ Swift slow-down function
-1 Engineautomaticwarming-up,overheatpreventionfunctionI
1 Swing control function
Travel control function
Active mode function
-I Active power up function
-1 Self-diagnostic function
for HYPER GX (2/2)
Electronic valve control function
:
t Priority mode function
Playback function
Automatic vibration function
Soft mode function

1
Bucket monitor function
2
Fully automatic grading function II
3
L
* For functions surrounded by dou- Digging depth warning function
ble lines are the additional func- 4
tions explained here. Bucket cutting angle retention function
t
For details of the functions sur-
5
rounded by thin lines, see ELEC-
TRONIC CONTROL SYSTEM FOR Electronically cushioned cylinder function
STD. 6
For details of the functions sur- Working range setting function
rounded by bold lines, see ELEC-
7
TRONIC CONTROL SYSTEM FOR
HYPER GX (l/2). 1 Boom rock, swing back prevention function
10-l 95

Ii :/
,_____-i._______--_-------j
lo-196
BASIC OPERATION FOR HYPER GX

1) Basic operation
The GX controller receives the switch sig- It also functions to display on the bucket
nals from the GX panel and the signals from monitor the values calculated form the data
the sensors, selects and calculates the GX for the posture and position of the bucket
functions, and sends the EPC valve output cutting edge.
data to the valve controller. In this way, it
carries out various operations, such as auto-
matic operation of the work equipment for
fully automatic grading and bucket cutting
angle retention, limitation of movement such
as electronic cushioning of the cylinder and
setting of ranges, and control of the work
equipment, such as boom lock prevention
and swing back prevention.
GX controller
EPC
Switch signal
II
II II II ; outout I
I
8 I
> !_________________..
WORK MONITOR data
% !_________~ ._________l
I
; Data for work
1eaui Pment Posture.
i hydraulic Pressure
II
Sensor
/ SAP03632
10-197
21 Basic procedure for operation

(I) Operation for starting GX functions [Reason]
To use the GX functions start the engine, To carry out the working range setting func-
and then operate the bucket cylinder to the tions, it is necessary to detect the operating
end of the curl and dump strokes. posture to a high degree of precision. This
[Reason] is necessary for safety reasons.
Stroke sensors are used to detect the bucket The boom and arm angles are detected by
posture. the angle sensor, which consists of a set of
These sensors output the change in position a potentiometer and encoder.
and direction for the cylinder stroke as a The potentiometer outputs a voltage in ac-
pulse signal, but immediately after the start- cordance with the angle, so immediately af-
ing switch is turned on, they cannot judge ter the starting switch is turned ON, it is
the position of the cylinder. Therefore, when possible to detect the angle, but the preci-
the cylinder is operated to the end of the sion is less accurate than that of the en-
stroke at both ends, it becomes possible to coder.
calculate the present stroke of the cylinder On the other hand, the encoder detects the
by counting the number of pulse from the angle from the pulse signal that corresponds
end of the stroke. to the amount of displacement and direction
For this reason, all the functions on the GX of the angle, so precision is high, but it can-
control are OFF until the stroke of the cylin- not detect the angle immediately after the
der can be calculated, but the bucket can be starting switch is turned ON.
operated (this condition is called standby). (Immediately after the starting switch is
* Even at standby, the background modes turned ON, the initial angle for the encoder
(GX monitoring, GX error display, GX is calculated from the potentiometer volt-
adjustment, etc.) can be operated. age, so there is a slight difference from the
* Even when started, the operations in Item actual angle.)
(2) below must be carried out for the However, the encoder has a Z phase output,
working range setting function. which is output only in a fixed range inside
l Bucket cylinder the variable range angle, so when the boom
and arm are operated, it can detect the Z
phase and thereby detect a highly precise
angle.
For this reason, until the initialization of the
encoder (detection of the Z phase) is com-
pleted, even if and attempt is made to set
the working range setting function, the
buzzer sounds three times, and the input is
st rote
end not accepted.
l Boom cylinder and arm cylinder
SBP03633
RAISE
1( stroke
2) Operation for working range setting func-
tion DUMP
To set the working range setting functions, stroke
end
start the engine and raise the boom from III I t Contact3 \
the ground to the end of its stroke, or oper-
ate the arm to the end of the IN and OUT
strokes. (This operation is completed when
the LEDs of the three working range setting
switches stop flashing.)
/
SBPO3634
lo-198
1. BUCKET MONITOR FUNCTION

1. Stroke sensor (bucket cylinder)
2. Encoder (boom top)
3. Potentiometer (boom top)
4. Encoder (boom foot)
5. Potentiometer (boom foot)
6. Inclination sensor
GX Panel
,
/,
GX controller
SBPO3635
FUNCTION
. The GX controller detects the posture of the
work equipment from the signals sent from
the boom angle sensor, arm angle sensor,
bucket cylinder stroke sensor, and chassis
inclination sensor. It calculates these and
displays the depth (height) of the bucket cut-
ting edge, reach, and cutting angle on the
GX panel.
10499
OPERATION
11 Calculation of work equipment posture
. The boom angle sensor detects angle a be-
tween the boom and the horizontal line
through the chassis, and outputs this to the
GX controller.
. The arm angle sensor detects angle b be-
tween the arm and the frame, and outputs
this to the GX controller.
. The bucket cylinder stroke sensor detects
the stroke of the cylinder and outputs this to
the GX controller. “I//,
The controller uses this data to calculate

angle c between the arm and bucket. SElPO3636
. The chassis angle sensor detects angle d

between the horizontal plane and the chas-
sis in the front-rear direction, and outputs
this to the GX controller.
. The GX controller uses the above four sets
of data and the work equipment shape data
to calculate the posture of the work equip-
ment, and displays the selected values on
the GX panel.
2) Cutting angle display

. The display of the bucket cutting angle al-
ways uses the horizontal line as 0.
. If the bucket cutting angle is pointing down
in relation to the horizontal line, the display
is positive (+I.
* The + mark is not displayed on the display
panel.
. If the bucket cutting angle is pointing up in
relation to the horizontal line, the display is
negative (4
* There is a function that allows the standard
SBPO3637
line to be set as desired for the depth dis-
play and reach display, but for the cutting
angle display, the standard line is always
the horizontal plane.
1o-zoo
3) Depth, reach display

(when starting GX function)
l When starting the GX function, the values
are displayed as follows until a new stand-
ard point is set.
. Depth
The horizontal surface from the point where
Center line
the line through the center of the swing ex-
tends to the ground is used as the standard
line, and the vertical distance between this
line and the cutting edge of the bucket is
displayed.
The distance above this line (height) is dis-
played as a positive (+) value.
* The (+) mark is not displayed on the display
panel. The distance below this line (depth)
is displayed as a negative (-1 value. Reach Horizonal
. Reach I
C-1 SBPO3638
The line through the center of the swing is
taken as the standard line, and the horizon-
tal distance to the cutting edge of the bucket
is displayed as positive (+) value.
In this condition, the cutting edge of the
bucket is not to the rear of the line through
the center of the swing, so there can be no
g negative (-1 display.
> 4) Depth, reach display
% (when new standard line is set)
. If the standard setting switch is pressed when
the depth (or reach) are displayed, the posi-
tion of the bucket cutting angle at that point
is taken as the base point, and the horizon-
tal and vertical axes of that point are taken
as the standard line for further displays of
the depth (or reach).
. Depth
This displays the distance in the vertical di-
rection from the set standard line to the
Center line
bucket cutting edge.
The distance above this line (height) is dis-
played as a positive (+I value.
The distance below this line (depth) is dis-
asuremenl Point
played as a negative (-) value.
. Reach
This displays the distance in the front-rear
horizontal direction from the set standard
line to the bucket cutting edge.
The distance in front of this line is displayed
as a positive (+) value. SBPO3639
The distance behind this line (depth) is dis-

played as a negative (-1 value.
Ir If the chassis is at an angle of more than 17”
the measurement cannot be made accu-
rately, so the panel display for the cutting
angle, depth, and reach flash.
(If this happens, set the machine so that it is
horizontal before carrying out the measure-
ment.)
1O-201
2. FULLY AUTOMATIC GRADING FUNCTION 1. Pressure sensor (bucket cylinder head)

2. Pressure sensor (bucket cylinder bottom)
6. Pressure sensor (arm cylinder head)
7. Pressure sensor (arm cylinder bottom)
8. Pressure sensor (boom cylinder head)
9. Pressure sensor (boom cylinder bottom)
12. Pressure sensor (swing left)
13. Pressure sensor (swing right)
, EPC valve
I
II
GX
lllllll
controller
II-- I I t
r
;:
r
r
I
SEPO3640
FUNCTION
. When the desired slope for grading is set
and the L.H. knob switch is kept depressed,
the operation with the bucket-cutting edge
and grading of the floor will be carried out
automatically.
1O-202
Operating pattern
1) When the GX controller receives the start
signal from the L.H. knob switch, it sends a
signal to the engine throttle l pump control-
ler, and sets the working mode to H/O. (But
the display does not change.)
2) It uses the signals from the work equipment
sensors to calculate the present position of
the cutting edge and the cutting angle. (Point I--------
A 0
A)
SBPO1955
3) Based on the present data, it calculates the
ideal cutting edge position and cutting an-
gle after a fixed time.
4) It uses the difference between the present
position and the target position to calculate
the movement of the boom, arm, and bucket
to bring the work equipment to the ideal
condition after a fixed time, and outputs a
command current through the value control-
ler to the appropriate EPC valve. (Point A +
Point B) c-__---- - _--_-ci
5) After moving for the fixed time, it takes the 0 C
cutting edge position and cutting angle as SBPO1956
the present position, and repeats the above

g procedures 2) - 4). (Point B + Point C)
>
6) If the boom or bucket lever is operated dur-
% ing the movement (Point B + Point C’), it
takes the position after the lever is operated
as the present position, and repeats the
above procedures 2) - 4). (Point C’ + Point
D)
7) The GX controller stops the movement if
the operator releases the L.H. knob switch
D
I
or if the work equipment comes near to the
SEiPOl957
end of its stroke.
. In the case of the floor digging mode, it

controls the three axes of the boom, arm,
and bucket to maintain angle a constant be-
tween the bottom face of the bucket and the
ground surface.
. In the cutting edge digging mode, it controls
the two axes of the boom and arm to main-
tain digging angle b constant between the
arm and bucket. SBPO1956
. The pressure sensors installed in the actua-
tor circuits detect the load condition of the
boom, arm, and bucket, and output the data
to the controller.
In the controller, these signals are used when
calculating the current value to send to the
EPC valve.
SBP01959
1 O-203
Slope setting switch

Diaoina Dioaina
l When the bucket monitor is set to the cut- Posture direction
SloDe settina select ion select ion
ting angle display and the bottom face of
the bucket is aligned with the slope, the value
is displayed. In this condition, if the SET
switch is pressed, the angle at that point is
taken as the slope, and is set.
If it is necessary to carry out fine adjustment
of the value, adjust with the up and down
slope switches.
+ It is also possible to set the slope directly
with the slope up and down switches with- SAP036 4’
out bringing the bottom face of he bucket
a
into contact with the slope. Slope
* When carrying out horizontal digging, set

the slope 0.
J, The slope can be set either to units of de-
I
grees or fractions.
However, when setting the slope at near
I. 8
horizontal or perpendicular, the fraction dis-
SAP04642
play cannot be given.
Reference: 1 in 1.8 slope
Digging posture selection switch

l When the GX function started, this is set to
AUTO.
l When the start signal is received from the
L.H. knob switch, bucket cutting edge angle
e and angle f between the arm and bucket
are used to automatically judge if the dig-
ging posture desired by the operator is floor
or cutting edge.
* In the case of an extreme posture, the ma- SBPO3643
chine may not carry out the desired move-

ment, so in such cases, select with manual
operation. Precautions when using
In addition, if it is desired to select one par- Ir To maintain the precision of the function,
ticular mode, select manually. set the fuel control dial to high idling (Max.).
* For the boom and bucket only, it is possible
Digging direction selection switch to operate the control lever during the auto-
l When the GX function is started, this is set matic operation to carry out compensation
to IN. When the start signal from the L.H. for the line being followed. (If this is done,
knob switch is received, grading is carried the controller adds the manual lever signal
out in the arm IN direction. to the automatic control signal and operates
l When the start signal is received from the the work equipment.)
knob switch, if the position of the arm is in * To operate the L.H. knob switch, it is neces-
range g (further from the chassis than the sary to double click it (turn the switch ON,
center of the range of movement for the then release it (turn it OFF), and then turn it
arm), the controller will automatically select ON again).
arm IN, and if it is in range h (closer to the
chassis than the center), it will automatically
select arm OUT.
* If it is desired to select one particular mode,
select manually. Max. Zsec.
SAP03644
1 O-204
3. DIGGING DEPTH WARNING FUNCTION 1. Stroke sensor (bucket cylinder)

Caution buzzer
GXPanel
/,
,,
GX contoroller
SEPO3645
FUNCTION
. If the depth is set to the desired setting,
when the work equipment approaches or
reaches that depth, the buzzer will sound
and alarm.
1O-205
OPERATION
I) Set the cutting edge of the bucket at the
depth to be set, then press the digging depth
alarm switch. The depth at that point is
stored in memory.
2) During operations, the GX controller uses
the signals from the work equipment sen-
sors to calculate the actual position of the
cutting edge, and to compare it with the set
depth.
3) If the cutting edge enters a range of from
350 mm to 250 mm from the set depth, the
buzzer will sound intermittently.
4) If the cutting edge enters the area below the
set depth, the buzzer will sound continuously. SBPO3646
* The buzzer does not sound in the range be-

tween the set depth and the point 250 mm
from the set depth.
* This function observes the depth of the tip
of the bucket cutting edge.
Even if some part of the bucket other than
the cutting edge is lower than the set posi-
tion, the buzzer will not sound.
* This function gives a warning only; the work
equipment does not stop even if it reaches
the set depth.
* If the chassis is at an angle of more than
*17”, the measurement cannot be made ac-
curately, so the digging depth alarm LED
flashes. (In this case, set the chassis hori-
zontal before using it.)
1 O-206
4. BUCKET CUlTING ANGLE RETENTION FUNCTION ,.

Pressure sensor (bucket cylinder head1
2. Pressure sensor (bucket cylinder bottom)
f 11 n 3. Stroke sensor (bucket cylinder)
II - 4. Encoder (boom top)
Bucket
CURL
; Main relief valve

I control valve
I- IDUMP_------ _---- -.
mol
injectia
P”mP
1 SBPO3647
FUNCTION
. If the bucket cutting angle retention switch
is set and the L.H. knob switch is operated,
the bucket cutting angle is kept constant to
the horizontal plane while the switch is be-
ing pressed, even if the boom and arm are
operated.
1 O-207
OPERATION
1) When the GX controller receives the start
signal from the L.H. knob switch, it sends a
signal to the engine throttle l pump control-
ler, and sets the working mode to H/O. (But
the display does not change.)
2) It uses the signals from the work equipment
sensors to calculate the bucket cutting angle
to the horizontal plane when the L.H. knob
switch is pressed, and stores that value as
the set value.
3) After this, it calculates the actual cutting an-
gle at fixed intervals, and compares this with
SBPO3648
the set value.
4) From the compared value, it calculates the
necessary amount of movement of the
bucket to make the cutting angle the set
value, and outputs the command current to
the bucket EPC valve through the valve con-
troller.
5) While the switch is being pressed, it repeats
the above procedures 3) and 4).
. The pressure sensor detects the load condi-
tion of the bucket and outputs the data to
the controller. In the controller, these sig-
nals are used when calculating the current
value to send to the EPC valve.
* While the cutting angle retention function is
being used, the bucket will not move even if
the bucket control lever is operated.
* To maintain the precision of the function,
set the fuel control dial to a midrange speed
or above.
* To operate the L.H. knob switch, it is neces-
sary to double click it (turn the switch ON,
then release it (turn it OFF), and then turn it
ON again).
* After the L.H. knob switch is turned ON, the

amount of change is not compensated for
even if the inclination of the chassis changes.
1O-208
5. ELECTRONICALLY CUSHIONED CYLINDER FUNCTION

r
-
CXPanel
GX controller
L) I’c+$y_ ,;’
+-
0
::‘qg@-
!___!!!Y-__
Electric lever
%i Engine , ,,& Main p$
SBP03649
FUNCTION
l This function reduces the shock at the end
of the cylinder stroke, and also prevents the
generation of any relief peak pressure at the
end of the stroke.
. This function is always used for the boom
and arm; it can be selected for the bucket.
1O-209
OPERATION
. When the movement of the work equipment Electronically cushioned
cylinder enters the electronically cushioned I cylinder function OFF
range, the manual operation command from -z
”
the control lever is compared with the op- 0;
eration command for the speed reduction 2
w
pattern set by the GX controller, and the
smaller of these two values is output to the
EPC valve.
. For this reason, the speed at the end of the
Electronicallv cushioned
cylinder stroke is always that of the speed culinderfunction ON
reduction pattern or less, so the shock can
End
be suppressed. End of cylinder stroke SAP03650
. If the cushion mode is turned OFF, only the
electronically cushioned function for the
bucket is canceled.
* For the boom and arm, the electronically
cushioned cylinder function is always work-
ing, so it cannot be canceled.
Electronically
cushioned
cylinder switch
ON Actuated
Always Always
actuated actuated
OFF Canceled
Ir This function is designed to reduce the shock

at the end of the stroke; it is not designed to
reduce the shock during the movement of
the cylinder at other points. (To reduce the
shock during the movement of the cylinder,
use the soft mode on the monitor panel.)
10-210
6. WORKING RANGE SETTING FUNCTION
Stroke sensor (bucket cylinder)

Encoder (boom top)
Potentiometer (boom top)
Encoder (boom foot)
Potentiometer (boom foot)
EPC valve
I
i---------------______----------------_-____,
/ c--- . PL L________________
&:et@ID-
I
/ I Main relief valve .-

I
9 1control valve
I
I
I
I
L-
KG” I
CURL! Bucket IDUMP
II 4 ‘- :
I-. --_
I____
ih
L_____
;____’ L_____‘I
YL t;;,@+
.________J
I--
I
--I
I I
I I I
I L
I
I L______
_‘I / L__ L_
A
‘________:I‘x_-I,.L-------_-______________l r! t
I GX panel
!E GXcontroller
Self-Reducing
pressure
valve
I
1
;
Boom
RAISE
._________~
Electric lever
Engine Main PUMP
SBPO3651
FUNCTION
. If the desired height, depth, and reach of the
work equipment are set before starting op-
erations, the work equipment is automati-
cally stopped if any part of the work equip-
ment goes outside the set area.
10-211
OPERATION
Setting range
If the work equipment is operated to the
Highest Part at this Posture
desired height, depth, and reach, and the
range setting switches are pressed, the GX
J
controller will store the signal from each
work equipment sensor at that point.
The controller has the shape data for the
boom, arm, link, and bucket, so it calculates
the part of the work equipment that will be
the largest value for the set direction.
It takes that part as the standard point, and
determines the set area.
To set this function, start the GX function, SBPO3652
raise the boom from the ground surface to
the end of its stroke, and operate the arm
from the point where it is fully pulled in to
Speed reduction
the point where it is fully extended. If these Pattern sition
operations are not carried out, this function
cannot be set.
When moving closer

If the work equipment enters a range of 200
mm from the limit of the set range, the LED
for the range setting in that direction will
flash.
In addition, when the work equipment moves
close to the limit of the set range, the con-
troller compares the manual operation com-
Position of work equipment
L- SAP03653
$
t
%
mand from the control lever with the opera-
tion command for the speed reduction pat-
tern set in the controller, and outputs the
smaller value to the EPC valve. It outputs
the bold line in the diagram on the right.
If the work equipment reaches the limit of
the set range, even if the manual operation
command from the control lever is input,
the controller will shut off the flow com-
mand to the EPC valve and will stop the
work equipment.
In this way, the speed of the work equip-
ment when it is near the limit of the set SBPO3654
range is always the speed reduction pattern

or lower, and the work equipment stops with-
out any shock. Set posl t ion
A
When moving away

. In order to improve the operating efficiency,
after the work equipment stops, if it moves
away from the limit of the set range, the
work equipment speed is faster than when it
is moving closer to the limit.
Moving closer
Cancelling setting
l When cancelling the setting, press the set-
Cylinder stroke
ting switch. SAP03655
The LED will go out and the function will be
turned OFF.
1o-21 2
Using other attachments

Arm 2.4m (Standard) 2.9m
. The controller can handle the genuine I
Komatsu attachments given in the table on 0.5m3, 0.8m3 (standard),
the right. 0.9 m3, 1.0m3, 1.17m3
Bucket
Slope finishing, trapezoidal, ditch
cleaning, desired bucket (1 type)
Ir Dimension a of the desired bucket must be

the same as the standard.
Ir If dimension a is different, the value calcu-
lated by the controller will be different from
the actual measured value, so there is dan-
ger that the work equipment may go out-
side the set range.
Standard dimensions a: 374.9 mm
SBPOI 976
t If it is impossible to carry out the setting, try

to operate the boom to the end of the RAISE
stroke and the arm to the end of the IN and
OUT strokes.
zz * This function limits only the operation of the * If the work equipment comes close to set-
>
boom, arm, and bucket. When the swing or ting range less than 200 mm, LED of setting
% travel are operated, the work equipment may range switch starts to flash.
go outside the set range.
(For example, when swinging on slopes or
traveling on soft ground)
* The work equipment will stop 30 - 0 mm
before the set position for the height, depth,
and reach, so allow a margin when setting
the range.
* This function is set so that the work equip-
ment will stop 100 mm before the edge of
the set area when it approaches the edge of
the set area with the boom LOWER oper-
ated independently.
The reason for this is that when carrying out
digging operations along the set limit for SBPO3656
the depth, if the work equipment is stopped

at the set limit, the arm IN movement is
limited. To prevent this problem, the boom
is stopped slightly above the limit.
* If the range is set in two directions without
changing the work equipment posture, the
work equipment will go outside one of the
set ranges whichever way the work equip-
ment is moved, so the work equipment will
not move from that position.
Ir With this function, there is no compensation
for the inclination of the chassis. The set
range is at the same angle as the chassis.
10-213
7. BOOM ROCK, SWING BACK PREVENTION FUNCTION

1. Pressure sensor (boom cylinder head)
2. Pressure sensor (boom cylinder bottom)
3. Pressure sensor (swing left)
4. Pressure sensor (swing right)
II
,,
/ , EPC valve
Bucket
i-----__--------------------_____-----______i
CURL
I I
Main relief valve
GX controller 1
Engine
SBP03657
FUNCTION
l This suppresses the residual vibration when
stopping the boom or swing, and reduces
the unpleasant vibration of the chassis and
operator’s cab.
10-214
OPERATION
. When the control lever is moved from the
operating position to near the neutral posi-
tion, the pressure sensor detects the pres-
sure at both ports of the actuator and sends
the data to the GX controller.
. The controller compares the pressure of both
ports, and sends a command current to the
EPC valve to release the pressure at the port
where the pressure is high.
. The determined command current and the
manual control command from the control
lever are compared, and the larger one is
output to the EPC valve.
. If the manual control command is smaller, it
is taken that the operation is stopping, and
the command current determined by the
controller is output to the EPC valve.
. In this way, there is no closed in pressure
after the lever is operated, so there is no
shock when stopping.
* When this function is being used, if the le-
ver is operated, the control command is
larger than the command current determined
g by the controller, so the manual control sig-
>
nal is output by priority to the EPC valve.
% * This function acts to suppress the residual
vibration after the lever is operated, and does
not function when the lever is being oper-
ated.
It carries out control according to the size of
the change in the load pressure, so if the
change in the load pressure for that opera-
tion is small, it does not function.
If the lever is operated suddenly, the swing
back prevention does not function.
10-215
8. PROLIX FUNCTION
. If any abnormality should occur in the HYPER

GX function, the GX controller displays the
abnormality on the monitor panel and GX
panel, and shuts off the signal current to the
EPC valve to stop the operation of the work
equipment and swing.
If this condition occurs, inspection must be
carried out immediately, but if the GX over-
ride switch under the operator’s seat is set
to the Disconnection position as a tempo-
rary measure, the machine can be operated
as a HYPER function machine.
On the HYPER function machine, it is possi-
ble to operate all the functions except those
on the GX panel.
When this switch is set to the Disconnection SBPO3656
position, F is displayed on the GX monitor
display to inform the operator that the ma-
chine is now a HYPER function machine.
OSLOPEOANGLEODEPTHOREACH
SAP03659
10-216
9. COMBINATIONS OF FUNCTIONS
. The HYPER GX has various functions, but when these functions are used in combination, it must
be remembered that there are limitations and orders of priority.
Newly selected function
Working
mode,
etc.
Can be
Bucket monitor selected
Automatic grading
Can be
Digging depth alarm selected
z
& Cutting angle retention
P
Electronically cushioned Can be
:: cylinder selected
Can be
Range setting selected
Boom rock, swing back Can be
preventin selected
Can be
:z Automatic vibration selected
Es
.,gQ Can be
Playback selected
0: The function that has already been selected Independent Bucket monitor, digging depth alarm,
functions - electronically cushioned cylinder,
and the newly selected function can both be
boom rock, swing back prevention
selected at the same time.
a: The newly selected function is set, and the r
Bucket cutting angle retention, fully
function that has already been selected is automatic grading, automatic
automatically turned OFF. vibration, playback
x: The newly selected function cannot be se- Alternative
(because these are all actuated by
the L.H. knob switch)
lected unless the function that has already - functions
been selected is turned OFF. (Buzzer beeps Working range setting (because it
three times) takes too long to calculate)
(I) When any function is being actuated with
the L.H. knob switch, the boom lock/swing
back prevention function is not actuated. b) With alternative functions, if they are selected
(2) If the automatic vibration or playback mode when another function is already being used,
are selected, the boom rock/swing back pre- the newly selected function is given priority,
vention function does not work. and the function that has already been se-
Note: When the fully automatic grading or lected is turned OFF. (For GX functions, they
bucket cutting angle retention functions become a)
are being actuated, the system is auto- One exception to this is the working range
matically set to H/O and auto-decelera- setting. This function only is not turned off
tion OFF. automatically. (This is X to prevent the range
In addition, the bucket monitor, digging setting from being canceled when the op-
depth alarm, and boom rock/swing back erator does not intend to cancel it.)
do not function. c) When alternative functions on the monitor
a) The functions can be divided into two types: panel and the GX function are selected to-
independent functions, which can be selected gether, the newly selected function cannot
regardless of any other function, and alter- be selected while the other function is still
native functions, where only one of the func- being used. (It becomes X)
tions can be selected.
lo-217

MOUNTING LOCATIONS OF COMPONENTS
SBPOl981
1. Bucket cylinder stroke sensor

2. Arm angle sensor
4. GX automatic operation cancel switch
5. GX panel
6. Boom angle sensor
7. GX controller
8. Actuator pressure sensor
1O-218
1) BOOM, ARM ANGLE SENSOR
1. Connector
2. Cover
3. Potentiometer
4. Joint
5. Encoder
6. Spacer
SBPO1982
FUNCTION Connector signal table

. The angle sensors are installed to the boom
foot and boom top. They detect the angle of No. Name of signal
the work equipment, and output the data to 1 Encoder power source
the GX controller.
. The sensor at the boom foot is for detecting
the boom angle.
The sensor at the boom top is for detecting
the arm angle. 4 Encoder B phase
. The potentiometer and encoder form a pair 5 Encoder Z phase
t i
of sensors and are connected with a cou-
pling. They are designed to provide a backup IS I Potentiometer power source I
function to each other by having the two 1 7 1 Potentiometer GND I
signals compared.
8 Potentiometer output
10-219
a. Potentiometer
FUNCTION
. The 5V voltage of the power source
is converted to a signal voltage by
the resistance of a variable resistor
in accordance with the angle of the
work equipment, and this voltage is
. sent to the GX controller.

The shaded area in the graph is the
abnormality detection area, and if the
controller receives a signal voltage
in this area, it judges that there is an
abnormality in the potentiometer sys-
tem.
1 RG
2w
3Y
SBPO1963
l Output characteristics for boom . Output characteristics for arm
Vol taoe IV)

Voi taae (VI
35___________________
0. 25 angle
0 End of LOWER stroke End of RAISE stroke
SAP03660 0 End of OUT stroke End of IN stroke
SAP03661
1O-220
b. Encoder
FUNCTION
. This converts the 12V voltage of the power
source to an A-phase, B-phase, or Z-phase
pulse signal in accordance with the change
in the work equipment angle, and outputs
this data to the GX controller.
l One rotation is 2500 pulses.
Actually, there is a limit to the angle at which
the work equipment can turn, so it can never
complete one rotation.
l Output wave shape.
Clockwise rotation as seen from shaft Counterclockwise rotation as seen from shaft
A ohase ",: m
B phase ';;m
Z phase 'ii-1 r
SAP03663
10-221
2) BUCKET CYLINDER STROKE SENSOR
1. Connector
2. Sensor body
3. Sensor head
~~~~w.-~ @
SBP01989
FUNCTION
. This is installed to the head of the bucket l There are two types of pulse: A phase and B
cylinder, and the sensor head is installed in phase. It is possible to know the direction of
such a way that it is in tight contact with the movement of the piston rod from the phase
piston rod. difference of each of these.
. When the piston rod moves, an electric pulse . By counting the number of pulses, it is pos-
signal is generated in accordance with the sible to know the relative movement, so the
movement, and this is output to the GX con- bucket cylinder stroke can be calculated from
troller. this.
. Output wave shape
When cylinder is extended When cylinder is retracted
A phase
'::d-Lr
E phase 'ii m
SAP03664 SAP03665
1o-222
3) INCLINATION SENSOR
1. Sensor
2. Connector
SBPOl992
FUNCTION
l This is installed to the top surface of the VoItaaeN)
revolving frame and detects the inclination
(angle to the ground) of the upper structure.
l The 12V voltage of the power source is con-
verted to a signal voltage by the resistance
of a magnetic resistor in accordance with
the angle of inclination of the upper struc-
ture, and this is output to the GX controller.
-20 0 20
Anale of inclinaition (dea) SAP03666
1 O-223
4) ACTUATOR PRESSURE SENSOR
1. Plug
2. Sensor
3. Connector
SEP02584
FUNCTION
. This is installed to the circuit at the work
equipment inlet port. It converts the circuit
pressure to a voltage, and sends this to the
GX controller.
OPERATION
. For details of the operation, see ELECTRONIC
CONTROL SYSTEM.
1 O-224
5) GX PANEL
2
\
3
I I
1
r-
8 CN-A06
8 0 0
-Y-CN-A06 SBP03667
CN-A06
1. Bucket monitor portion No. Name of signal Input/Output
2. Fully automatic grading control switches 1 Monitor power source -
3. Function setting switches 2 Monitor Dower source -
1 3 1 Buzzer I OutDut I
I 41 - I - I
5 - -
6 Network (+) -
7 Network (+I -
8 Network (-) -
FUNCTION I 9 I LamD I Irmut I
. The GX panel consists of the bucket moni- I 10 I - I - I
tor, fully automatic grading control switches, I 11 I - I - I
and function setting switches. 12 1 - -
. If has a built in CPU (Central Processing Unit), I -
13 I -
and processes, displays, and outputs the data 14 1 - -
from the GX controller. 15 1 GND -
. The monitor display uses a liquid crystal dis- 1 16 I GND I - I
play (LCD).
CN-A07
No. Name of signal Input/Output
1 c24V -
2 GND -
CN-A08
No. Name of signal Input/Output
1 +24V -
2 GND -
1O-225
a. Bucket monitor
1. Display
WORK MONITOR
I 3 I 2. Display selection switch
DEG 3. Standard setting switch
DIS STD
OSLOPEOANGLEO DEPTHOREACH
\
2' 3' SAP03666
b. Fully automatic grading control switches
1. Automatic grading set switch

2. Slope UP/DOWN switch
3. Digging posture selection switch
4. Digging direction selection switch
4
SAP03669
c. Function selection switches
I 4
1. Cutting angle retention switch
/ \ 2. Electronically cushioned cylinder
BUCKET 0 ANGLE 0 OC switch
b 3. Digging depth alarm switch
,
LIMITS(G T I] 0 DEPTH 0 0 REACH 4. Height range setting switch
5. Depth range setting switch
6. Reach setting switch
DAMP 0 BOOM 0 OSWING 0
\ . . 7. Boom rock prevention switch
8. Swing back prevention switch
7 8 SAP03670
1O-226
Condition inside controller and panel display
When GX automatic operation is

disconnected, switch is set to
.%Becomes HYPER function machine
Example: Correct angle cannot be displayed

because of failure in boom angle
sensor
Displayed when controller pow-
* Drop in power source
er source voltage drops to less
*When GX monitoring Keep the [SHIFT] + IO] switches

mode is selected pressed for at least 3 seconds.
The buzzer sounds, the left dis-
play changes, and the d display
When error occurs

Example: when there are 2 errors
Keep the [SHIFT] + [-I switches
pressed for at least 3 seconds.
XAfter displaying number of er-
rors, error code is displayed
* Displays details of To change the code No. press

[UP] or [DOWN]
-When GX adjustment Keep the [Ol + [S] switches

mode is selected
lo-227
6) GX CONTROLLER
I
3
I 0 0 0
L
1
0 0
I 0
f-
CN-40 1 CN-.A03 CNyAO9 CN;A02
sEPo2ool

CN-A01 CN-A02 CN-A03 CN-A09
NO. Name of signal InPutnUtW No. 1 Name of sianal NO. Name of signal InpuVOtipul
1 1Encoder GND - 1 RS232C TX _
2 I- - 2 NETGND -
I
3 1Encoder (boom) B / IllpUt 3 Left knob switch Input
4 I- - 4 Radio controller mode output
5 S-NET (+) -
6 HS-NET (+) -
f 7 Radio controller select Input
11 Starting switch Input

12 Vector mode output
13 S-NET (+) -
14 HS-NET (+) -
15 Option select Input
16 Model select 5 IllpUt
19 1 Ressure
sensor
IR pump1 1 Input
20 1 Potentiometer GND 1 -
1 O-228
INTERNAL SElTING OF GX CONTROLLER

(NON-VOLATILE MEMORY)
. The same part (same part number) is used
for the GX controller on the PC200 and other
models, but if a mistake is made in judging
the model for functions such as the auto-
matic grading function and working range
selection function, there is a possibility that
the movement may be dangerous.
. For this reason, a model selection connector
is used on the GX controller in the same
way as for other controller to provide judge-
ment of the model. The controller has a built- Model (external)
wiring harnessGND or open)
in non-volatile memory which retains the SBPO3673
data even when the power is turned off, and
the model is stored in the memory by using
the GX adjustment mode when it is shipped
from the factory.
. When the starting switch is turned on, the
controller compares the data in the non-vola-
tile memory with the model selection con-
nector, and if it is the same, it allows opera-
tion.
. The types of work equipment attachment are
also stored in the non-volatile memory, and
it is designed so that the functions can be
maintained even if the attachment is * When the GX controller is replaced, or when
changed. However, this applies only to the the work .equipment is replaced, or when
arms and buckets that have been previously the sensors or EPC valves are replaced, it is
set.) possible to use the GX adjustment mode to
. Furthermore, to reduce the variation between rewrite the data in the nonvolatile memory
the sensors and the chassis to the minimum, or to use the GX monitoring mode on the
the input and output values of the sensors GX panel to check the data inside the vola-
and EPC valve were checked when the ma- tile memory.
chine was assembled, and this variation is
also stored in the non-volatile memory. Ir For details, see TESTING AND ADJUSTING.
[Reference] Error that occurs at cutting edge of bucket when there is 0.1” variation in boom angle
sensor
Actu
cutt
Position of edee obtained from seneor signal /

SEiPO3674
1 O-229
STRUCTURE AND FUNCTION MACHINE MONITOR SYSTEM
MACHINE MONITOR SYSTEM

STD
Monitor Panel
Network
-
H/O G/O F/O L/O B/C
0 0 0 0 0
Caution, Coolant temp.,
Fuel level sianal
J
Sensor
Sensor signal
1
Power source Buzzer signal
Buzzer
Battery
SAP03675
1O-230
PC200,2OOLC-6 HYPER GX Monitor vane1
Network
--t-l-
SAP03676
FUNCTION
l The machine monitor system uses the net- each controller, including the moni-
work circuits between the controllers and tor panel itself, are displayed.
sensors installed to all parts of the machine 3) If it is set to the trouble data memory
to observe the condition of the machine. It mode, the trouble data for each con-
processes this information, and displays it troller, including the monitor panel
on a panel to inform the operator of the itself, are displayed.
condition of the machine. 4) It displays that the system has been
. The content of the information displayed on set to the governor motor adjustment
the machine can broadly be divided as fol- mode and automatic vibration offset
lows. adjustment mode.
1. Monitor portion 5) In emergencies, it displays abnor-
This gives an alarm if any abnormality malities in any controller.
occurs in the machine. * For details of the content of the dis-
2. Gauge portion play and the method of operation,
This always displays the coolant tem- see TROUBLESHOOTING.
perature and fuel level. . The monitor panel has various built-in mode
3. Time display selector switches, and also functions as the
I) This normally displays the time. control panel for the electronic control sys-
2) If this is set to the machine data tem.
monitoring mode, internal data from
lo-231
1. MONITOR PANEL
STD
CkPO2
H/O G/O F/O L/O B/O
SAP03677
OUTLINE Input and output signals

. The monitor panel consists of the time dis- CN-PO1 CN-POP
play, monitor display, and mode selector
switches.
. It has a built-in CPU (Central Processing Unit),
and processes, displays, and outputs the data
from the sensors and controllers.
. The monitor display and monitor display
panels use a liquid crystal display (LCD) and
LED lamp.
The mode switches are flat sheet switches.
1 O-232
CN-
“60 G60 F&‘O Lg/O 860
(,,a&
CN-
SAP03678
OUTLINE Input and output signals

. The monitor panel is equipped with a moni- CN-POP
CN-PO1
tor display function and the switch functions
for the mode selection and electrical com-
ponents.
It has a built-in CPU (Central Processing Unit),
which processes, displays, and outputs the
data. The monitor panel uses a liquid crystal
display (LCD). The switches are flat sheet
switches.
* For details of the functions and operation of
the time display and monitor display por-
tions, see the section for the PCZOO, 2OOLC-
6.
lo-233
MONITOR DISPLAY
8 ‘7 SAP02731
1. Clock (displays error when there is an error)

2. Service meter (Displays telephone number when there is an error)
3. Fuel level gauge
4. Fuel level caution lamp
5. Engine oil level caution lamp
6. Hydraulic oil level caution lamp
7. Preheating pilot lamp
8. Swing holding brake pilot lamp
9. Oil maintenance pilot lamp
IO. Battery charge caution lamp
11. Air cleaner clogging caution lamp
12. Engine oil pressure caution lamp
13. Coolant level caution lamp
14. Coolant temperature caution lamp
15. Coolant temperature gauge
1 O-234
Content of display
Symbol Display item Display range When engine is stopped When engine is running
Flashes and buzzer

Coolant level Below low level Flashes when abnormal
sounds when abnormal
SAP00519
Below 1500 rpm:

below 0.05 MPa
Lights up when normal
Engine oil lo.5 kg/cm21 Flashes and buzzer sounds
(goes out when engine
pressure Above 1500 rpm: when abnormal
SAP00520 starts)
above 0.15 MPa
(1.5 kg/cm?
Air cleaner
When clogged Flashes when abnormal OFF
clogging
SAP00521
Lights up when normal

When charging is
Charge level (goes out when engine Flashes when abnormal
defective
SAP00522 starts)
Engine oil level Below low level Flashes when abnormal OFF
SAP00523
Hydraulic oil level Below low level Flashes when abnormal OFF
SAP00524
8 Parking When swing is Lights up when swing lock switch is ON, flashes
6 (Swing lock) locked when swing lock prolix switch is ON
SAT00098
Oil maintenance See next page.

SAP02732
Lights up for 30 seconds when starting switch is at

Preheating During preheating HEAT, then flashes for 10 seconds to indicate that
SAP00526
preheatino is completed
3oYI
Coolant Flashes when above 102°C. flashes and ‘02”< ‘050C
SAP00527
temperature buzzer sounds when above 105°C S,L,P&,529
&lIlMLIMUBl~
Fuel level Flashes when below low level
SAP00528 All light up below appropriate level
1 O-235
OIL MAINTENANCE FUNCTION
1. Function, operation
The oil maintenance function uses LED lamps
on the monitor panel to inform the operator
at a fixed interval after the engine oil is
changed that the oil change interval has been
reached.
At the same time, it also functions to display
the service contact telephone number on the
liquid crystal display.
1) Oil change display
When the elapsed time to the next oil
change is less than 10 hours from the r Set time -1Oh
r
set time, the service meter display gives
the elapsed time and the LED flashes
when the key is turned ON.
Reset
I /- Set time
Elapsed
2) Confirmation of elapsed time l time
Normally, no display is given if the
elapsed time has not reached a time 10 Possible to confirm Oil change interval
elapsed time when display when key is
hours before the change interval. How-
key is ON turned ON
ever, if the buzzer cancel switch is
pressed and the key is turned to the ON
position (with the buzzer cancel switch
held for 2.5 seconds), the elapsed time
is displayed on the service meter dis-
play.
2. Setting change interval

1) The change interval can be set by using
the interval setting mode. The time that
can be set are 1125 hl, 1250 hl, 1500 hl,
[no setting], and [demo model. The de-
fault setting is [no setting].
2) To enter the change interval setting
mode, keep the time switch and active
mode switch (swing priority switch)
pressed simultaneously for 2.5 seconds.
3) If the buzzer cancel switch is pressed in
the change interval setting mode, the
time display will change from [...I +
I1251 + [2501 + [5001 + [ dl ([...I indi-
cates [no setting] and 1 dl indicates
[demo model).
4) To save the change interval time, set the
monitor panel display to the desired time
(mode), then keep the time switch and
active mode switch (swing priority
switch) pressed simultaneously for 2.5
seconds.
lo-236
3. Display timing, content

I) Oil change display All lamps light up 10 set 20 set
After all the lamps light up, the elapsed
w Time
time is displayed for 10 seconds. For the Tel No. :
yj*
next 10 seconds, the telephone number input
/ Elapsed time / Tel No. j
is displayed. : display I displayed :
However, if no telephone number has NoTel I
,-:-:
No. input I
been input, the elapsed time is displayed , Elapsed tim4 display i
for 20 seconds after all the lamps light
up.
2) Elapsed time confirmation
After all the lamps light up, the elapsed
time is displayed for 10 seconds.
4. Elapsed time reset

1) During the oil change interval display and
the elapsed time display, for 10 seconds
after all lamps light up (during the
elapsed time display), if the buzzer can-
cel switch is pressed and held for 3 sec-
onds, the elapsed time is reset. When
the elapsed time is reset, the elapsed
time shows [Oh1 for 1 second.
2) When the set time is changed, the
$ elapsed time is reset to Oh.
&
Z 5. Demo mode
1) The set time in the demo mode is 250h
and the elapsed time is set to 240h. When
the key is turned ON, the oil change dis-
play is given. However, the elapsed time
does not increase.
It is also possible to carry out the reset
operation during this display.
In the demo mode, after the key is turned
ON three times, the interval setting is
automatically set to [no setting] from the
4th time. In addition, the elapsed time is
reset to Oh and the elapsed time count
starts.
1 O-237
SWITCHES
STD
1. Working mode switch

2. Auto-deceleration switch
3. Active mode switch
4. Travel speed switch
5. Power max./Swift slow-down switch
SDP00691
l The switch portion consists of five mode se-

lection switches, and the condition of the
machine changes each time that any switch
is pressed. The LED above the switch lights
up to display the present condition of the
machine.
Switch actuation table
Switch Item Action
WORKING MODE H/O ++ G/O * F/O * L/O tf B/O

SDP00692
(SET) KNOB BUT-TON

Y -T
SDP00693 (POWER UP) (SPEED DOWN) SDP006g4
AUTO DECEL ON f--f OFF

SDP00695
TRAVEL SPEED Hi * Mi ++ Lo
SDP00696
8 ACTIVE MODE OFF ++ ON

SDP00697
* The bold letters indicate the default position

of the switch when the starting switch is
turned ON.
1O-238
1. Working mode switch

2. Boom/swing priority mode switch
3. Power max./swift slow-down switch
9 2 4. Automatic mode selection switch
5. Vibration mode switch
6. Travel speed switch
8 7. Automatic mode OFF switch
3 8. Auto-deceleration switch
9. Soft mode switch
SAP03679
l The switch portion consists of eight mode Switch actuation table

selection switches, and the condition of the
machine changes each time that any switch Item Actuation
is pressed. The LED above the switch lights
WORKING MODE H/O++G/O*F/O~L/O++B/O
up to display the present condition of the
machine. LEVER SWITCH POWER UP + SPEED DOWN
AUTO DECEL ON * OFF
TRAVEL SPEED Hi ++ Mi * Lo
<Boom> ct oFF c+ <Swing>

SWING ACCEL Boost Boost
AUTO DECEL I OFF ++ ON
AUTOMATIC PLAYBACK tf TEACH c+ OFF

MODE c+ BUCKET +, BUCKET*ARM
++ BOOM tf ARM
AMPLITUDE L*M*S
ACTIVE MODE ON ++ OFF
Ir The bold letters indicate the default position

of the switch when the starting switch is
turned ON.
1 O-239
STRUCTURE AND FUNCTION SENSORS
SENSORS
. The signals from the sensors are input di-
rectly to the monitor panel.
The contact type sensors are always con-
nected at one end to the chassis GND.
Name of sensor Type of sensor When normal When abnormal
Coolant level Contact type ON (closed) OFF (open)
Engine oil level Contact type ON (closed) OFF (open)
Hydraulic oil level Contact type ON (closed) OFF (open)
Engine oil pressure Contact type OFF (open) ON (closed)
Coolant temperature I Resistance type I - I -

Fuel level I Resistance type I - I -
Air cleaner clogging Contact type ON (closed) OFF (open)
Coolant level sensor
1. Sub-tank
2. Float
3. Sensor
4. Connector
/’
,
/’
L----”
4
SAP00375
10-241
ENGINE OIL LEVEL SENSOR
1. Connector
2. Bracket
3. Float
4. Switch
A
0
O-
a
0
0
581301487
HYDRAULIC OIL LEVEL SENSOR
1. Connector
2. Plug
3. Switch
4. Float
Comvosion of circuit
SBPO3680
ENGINE OIL PRESSURE SENSOR (COMMON FOR BOTH Lo AND Hi)
1. Plug
2. Contact ring
3. Contact
4. Diaphragm
5. Spring
@
6. Terminal
Actuation (ON) pressure
Lo: 0.05 f 0.02 MPa
SBDOl537 IO.5 2 0.2 kg/cm21 or less
Hi: 0.15 + 0.02 MPa
II.5 + 0.2 kg/cm? or less
1 O-242
COOLANT TEMPERATURE SENSOR
SBOOl538
FUEL LEVEL SENSOR
FULL
1. Float
2. Connector
3. Cover
4. Variable resistor
F EMPTY
E
Y
R
SEP025QO
AIR CLEANER CLOGGING SENSOR

Actuation (OFF) pressure:
-7.47 + 0.49 kPa
j-762 f 50 mmHzO}
f?L
SEP01700
1 O-243
STRUCTURE AND FUNCTION FRONT WINDOW AUTO PULL-UP SYSTEM
FRONT WINDOW AUTO PULL-UP SYSTEM
8
>
%
SBPOO382
1. Front window assemblv 14. Rear cover

2. Bracket assembly (tension roller) 15. Bracket (for motor mount)
3. Right block (roller support) 16. Cable assembly
4. Right geared cable 17. Motor assembly (for lifting)
5. Right return cable 18. Motor output shaft
6. Controller 19. Geared cable assembly
7. Control switch 20. Spoiler cover
8. Right lock assembly 21. Limit switch (rear lock)
9. Right tightening motor 22. Rear lock
IO. Limit switch (front) 23. Left block (dovetail)
11. Right bracket assembly (slide link) 24. Left block (return cable guide)
12. Harness 25. Left block (return cable holder)
13. Right rail 26. Left cover (return cable holder)
1o-244
STRUCTURE AND FUNCTION FRONT WINDOW AUTO PULL-UP SYSTEM
FUNCTION
. An electric motor is used for the front glass
(top) of the operator’s cab. This makes it
possible to open, close, or tighten simply by
operating the switch.
OPERATION
1. Opening front window
1) Press the UP control switch.
2) When left and right front locks (8) are
actuated in the OPEN direction, front
window (I) is moved to the LOWER po-
sition by slide link (I I). When the re-
lease operation is completed, the move-
ment of front lock (8) stops.
3) After the movement of front lock (8) has
been completed, operate lift motor (17)
to the OPEN direction. Geared cable (19),
which is meshed with motor output shaft
(18), will move and pull up front window
(I).
4) Front window (I) is set at the OPEN
position, and lift motor (17) stops oper-
ating at the point where rear lock (12) is
engaged.
2. Closinn front window

I) Press the DOWN control switch, and
push the release lever of rear lock (22) at
the same time.
2) Lift motor (17) moves in the CLOSE di-
rection and moves front window (I)
down.
3) When front window (I) has moved down
fully, lift motor (17) stops.
4) When the movement of lift motor (17)
has been completed, front locks (8) are
moved in the tightening direction by left
and right tightening motors (9). When
the tightening is completed, the motor
stops.
1O-245
20 TESTING AND ADJUSTING
TABLE OF JUDGEMENT STANDARD VALUE

Tools for testing, adjusting, and troubleshooting ....................................................................... 20-102
Measuring engine speed ............................................................................................................... 20-103
Measuring exhaust gas color ........................................................................................................ 20-104
Adjusting valve clearance .............................................................................................................. 20-105
Measuring compression pressure.. ............................................................................................... 20-106
Measuring blow-by pressure ......................................................................................................... 20-106
Testing and adjusting fuel injection timing ................................................................................. 20-107
Measuring engine oil pressure ..................................................................................................... 20-108
Testing and adjusting fan belt tension.. ....................................................................................... 20-109
Testing and adjusting belt tension for air conditioner compressor.. ........................................ 20-109
Measuring speed sensor.. .............................................................................................................. 20-I 10
Testing and adjusting governor motor lever stroke ................................................................... 20-I 11
Testing and adjusting hydraulic pressure in work equipment, swing, travel circuit.. ........... 20-I 12
Testing and adjusting PC valve output pressure (servo piston input pressure) .................... 20-I 15
Testing and adjusting LS valve output pressure
(servo piston input pressure) and LS differential pressure ................................................. 20-I 17
Testing and adjusting control circuit oil pressure ...................................................................... 20-120

Testing solenoid valve output pressure ....................................................................................... 20-122
Measuring PPC valve output pressure ......................................................................................... 20-124
Measuring EPC solenoid valve output pressure and checking EPC shuttle valve ................. 20-126
Adjusting work equipment . swing PPC valve ............................................................................ 20-128
Testing travel deviation ................................................................................................................. 20-129
Testing locations causing hydraulic drift of work equipment ................................................... 20-130

Measuring oil leakage .................................................................................................................... 20-132
Releasing remaining pressure in hydraulic circuit ...................................................................... 20-134
Testing clearance of swing circle bearing ................................................................................... 20-135

Testing and adjusting track shoe tension .................................................................................... 20-136
Bleeding air ..................................................................................................................................... 20-137
zo-1
0
Input/output structure of GX controller.. ...................................................................................... 20-140
Basic operation and GX function .................................................................................................. 20-141
Special function on GX panel (background mode). .................................................................... 20-143
Check procedure when operation of GX automatic function is defective.. .............................. 20-166
Adjusting swing back prevention function (swing teaching mode). ......................................... 20-168
Bucket dimension input mode when using custom bucket.. ..................................................... 20-170
Procedure for replacing sensor ..................................................................................................... 20-173
TROUBLESHOOTING .............................................................................................................................. 20-201
* Note the following when making judgements using the standard value tables for testing, adjusting,
or troubleshooting.
1. The standard value for a new machine given in the table is the value used when shipping the
machine from the factory and is given for reference. It is used as a guideline for judging the
progress of wear after the machine has been operated, and as a reference value when carrying out
repairs.
2. The service limit value given in the tables is the estimated value for the shipped machine based on
the results of various tests. It is used for reference together with the state of repair and the history
of operation to judge if there is a failure.
3. These standard values are not the standards used in dealing with claims.
g When carrying out testing, adjusting, or troubleshooting, park the machine on level ground, insert
the safety pins, and use blocks to prevent the machine from moving.
a When carrying out work together with other workers, always use signals and do not let unauthor-
ized people near the machine.
a When checking the water level, always wait for the water to cool down. If the radiator cap is
removed when the water is still hot, the water will spurt out and cause burns.
g Be careful not to get caught in the fan, fan belt or other rotating parts.
20-l-l
0
TESTING AND ADJUSTING TABLE OF JUDGEMENT STANDARD VALUE
l FOR CHASSIS
* The Standard values and permissible values shown in this table are all values for H/O (heavy-duty
operation) mode.
Applicable model
T PC200, 210, 220, 230-6
Cate-
Item Measurement conditions Unit Standard value Permissible value
gory
Hydraulic oil temperature: ‘C200,210 PC220,230 PC200,210 PC220,230

45 - 55°C
. Coolant temperature:
2 pumps at relief
Within operating range
,950flOO 2,150 - -
2-pump relief: Arm relief
I ,
rpm I
Arm relief
One touch power up 1,000+100 2,100 2,000f100 2,100
. Engine at high idling
Fuel control dial at MAX.

1,400 * 120 1,400 + 120
Control lever at neutral II
I I I I
$ 1 Arm control valve
-el
Bucket control valve
z - Boom Boom - Boom Boom
LOWER LOWER LOWER LOWER
I TBPOO436 only only only only
(11.5~0.5)(11.5~0.5) (11.5?0.5)
(11.5f0.5)
Travel control valve
Boom control lever . Center of lever knob mm
z Read max. value to end of

:-,
: Arm control lever travel
z? Engine stopped
-Yz Bucket control lever Excluding neutral play
E
s
z Swing control lever
z
2 Travel control lever
;
P
?z
t?
Play of control
Boom control
lever
lever Engine at high

Oil temperature:
idling
45 - 55°C
Max
Fit push-pull scale to center
z Arm control lever
z of control lever knob to
8 measure 12.7 f 2.9 Max. 21.6
Bucket control lever
% . Measure max. value to end N {I.3 * 0.3) {Max. 2.21
$ of travel {kg1 12.7 + 2.9 Max. 21.6
z Swing control lever
{I.3 + 0.31 {Max. 2.21
? 24.5 + 5.9 Max. 39.2

I;. Lever
12.5 ? 0.6) {Max. 4.01
E Travel control lever
z 74.5 & 18.6 Max. 107.6
0 Pedal
{7.6 k 1.9) {Max. II}
20-3
0
Applicable model PC200, 210, 220, 230-6
Cate- Measurement conditions Unit Standard value ‘ermissible value

Item
WY
. H/O mode
. Oil temperature: 45 - 55°C 3.9 * 1.0 3.9 l!z 1.0
Unload pressure . Engine at high idling {40 +_ 101 (40 + IO)
. All levers at neutral
. Pump output pressure
. Hydraulic oil temperature:

Boom 45 - 55°C 31.9 + 1.0 Max. 33.8 (3451
. Relief pressure with engine {325 f IO} Min. 30.4 (310}
at high idling (Relieve only
Arm circuit to be measured)
. Figures in I 1 are when +15
1 1Min.
34.8 _,:0 Max. 37.2 13801
power max. function is used +15
[ {355_,,1 33.8 (3451 I
(reference)
. Pump output pressure
Irl: For travel, measure oil
pressure for relief on one MPa Max. 32.8 (3351
side 30.9 ‘1:; (315 -‘;a
{kg/ Min. 29.4 (3001
*2: For swing, measure oil
:m2}
pressure with swing lock
switch on. Max. 37.2 1380)
*3: The boom pressure is the Min. 33.8 (3451
oil pressure at RAISE and
at the high pressure 3.3 + 0.2 Max. 3.4 (351
setting (active mode) (33 & 2) Min. 2.9 (301
2.9 f 1.0 2.9 Ik 1.0

(30 f IO] (30 + 101
LS differential
pressure
2.2 f 0.1 2.2 f 0.1
under no load (22 f I} (22 f I}
1 half
20-4
0
-
Applicable model
T PC200, 210, 220, 230-6
Catf
Item Measurement conditions Unit Standard value ‘ermissible value
gor
-
Work equipment Max. reach czoo, 21t ‘C220, 23C c200, 21c ‘C220, 230
nosture
deg.
Swing brake angle Wax. 100 Max. 130 Vlax. 130 Wax. 160
TKPOl115 mm.
Engine at high idling
Hydraulic oil temperature: 45-55°C
Stop after swinging one turn and
measure distance that swing circle
moves -
Work equipment Max.
posture reach
90’ 3.1 z? 0.3 3.2 + 0.3 Max. 3.7 Max. 3.8
Time taken to
TKPOllIG - sec.
start swing
Hydraulic oil temperature:
45 - 55°C 180 4.4 zb 0.8 4.5 f 0.8 Max. 5.6 Max. 5.7
. In H/O mode + H mode
Time taken to swing 90” and
180” from starting position
-
Work equipment Max. reach
posture
Time taken to swing sec. 24 f 3.5 24 + 3.5 Max. 30 Max. 30

TKPOlIIS
Hydraulic oil temperature: 45-55%
In H/O mode t H mode
Swing one turn, and measure time
taken to swing next 5 turns
Hydraulic drift of swing Engine stopped mm 0 0

Hydraulic oil temperature: 45-55°C
Set machine on 15” slope, and set
upper structure at 90” to the side.
Make match marks on swing circle
outer race and track frame.
Measure distance that match
marks move apart after 5 minutes.

Leakage from swing Hydraulic oil temperature: 45-55°C
lmin Max. 5 Max. 10
motor Swing lock switch ON
Relieve swing circuit.
-
20-5
0
Applicable model PC200, 210, 220, 230-6
Item Measurement conditions Unil Standard value Permissible value

-
‘C200, 21f ‘C220, 23 ‘C200, 21t PC220, 230
STD: STD: STD: STD:

Lc
50 i: 7 52 2 7 41 - 61 45 - 63
Lc: LC: LC: LC:
54.5 f 8 56.5 + 8 16.5 + 66.! 48.5 - 68.5
-
BKP00104
STD: STD: STD: STD:
Travel speed (I) sec.
Engine at high idling M 36.5 * 5.5 38 f 5.5 31 - 44 32.5 - 45.5
Hydraulic oil temperature: LC: LC: LC: LC:
45 - 55°C 39.5 f 5.5 41.5 + 5.5 34 * 47 35.5 - 49
- +
In H/O mode
Raise track on one side at a STD: STD: STD: STD:
time, rotate one turn, then 27.5 A 2 29 * 2 !5.5 - 31.f 27 - 33
Hi
measure time taken for LC: LC: LC: LC:
next 5 turns with no load. 30 + 2.5 31 ? 2.5 27.5 - 35 28.5 - 36
-
Lc 23.5 + 3.5 23.5 & 3.5 20 - 28 20 - 28
Travel speed (2) Engine at high idling M sec. 17 i 2.5 17 + 2.5 14.5 - 21 14.5 - 21 s
Hydraulic oil temperature: g
45 - 55°C - 2
In H/O mode
Run up for at least 10 m,
and measure time taken to Hi 13f 1 13f 1 12- 15 12 - 15
travel next 20 m on flat
ground.
-

45 - 55°C
Run up for at least 10 m, and
Travel deviation measure deviation when mm Max. 200
traveling next 20 m on flat
ground.
t Use a hard horizontal surface.
20m _I
I-
BKP00107
* Measure dimension X.
20-6
0
Applicable model
T PC200, 210, 220, 230-6
Hydraulic drift of travel mm 0 0

. Engine stopped
45 - 55°C
f Stop machine on 12O slope
with sprocket facing straight
up the slope.
. Measure the distance the
machine moves in 5 minutes.
Leakage of travel motor Lock Pin /min 13.6 27.2

TKPOlll7

45 - 55°C
Lock shoes and relieve travel
circuit.
Work equipment posture

Total work equip-
ment Max. 600 Max. 900
[hydraulic drift at
tip of bucket teeth)
Boom cylinder BKPOOllO
[amount of retrac- Max. 18 Max. 27

tion of cylinder)
Place in above posture and
measure extension or retrac-
tion of each cylinder and
downward movement at tip of
mm
Arm cylinder bucket teeth.
(amount of exten- Bucket: Rated load Max. 160 Max. 240
sion of cylinder) Horizontal, flat ground
Levers at neutral
Engine stopped
45 - 55°C
Start measuring immediately
Bucket cylinder
after setting.
(amount of retrac- Max. 35 Max. 53
Measure hydraulic drift every 5
tion of cylinder)
minutes, and judge from
results for 15 minutes.
20-7
0
Applicable model
r PC200, 210, 220, 230-6
e-
Y
T
Item
r Measurement
f
conditions
-
IUnit Standard
-
value
-
‘ermissible
c200 PC21( ‘C22C ‘C230 C200PC210 PC220 PC230

value
Boom
z
Bucket teeth in 3.5 3.9 3.4 3.6 lax. Max. Max. Max.
z
contact with ground :0.4 f0.4 f0.4 to.4 6.3 4.7 4.3 4.7
TKP01118
-
X
Cylinder fully 2
Hydraulic oil temperature: 2.8 2.8 3.1 3.1 lax. Max. Max. Max.
extended
45 - 55°C $ IO.3 f0.3 f0.3 f0.3 3.2 3.2 3.5 3.5
In H/O mode d
-
Arm Z 3.6 3.8 3.8 4.0 lax. Max. Max. Max.

-
:0.4 f0.4 f0.4 +0.5 1.5 4.7 4.1 4.8
Cylinder fully
retracted -
TKPOll19
z
Engine at high idling 2.9 3,0 3.1 3.3 lax. Max.. Max. Max.
Fully extended Hydraulic oil temperature: 2 :0.3 kO.3 f0.3 to.3 3.5 3.6 3.1 3.9
45 - 55°C
In H/O mode
-
Bucket 2.8 2.8 2.9 3.0 lax. Max. Max. Max.

IO.4 f0.4 f0.4 kO.4 3.5 3.5 3.6 3.7
Cylinder fully
retracted -
TKPOIIZO
X
. Engine at high idling 2 set 2.1 2.1 2.2 2.2 lax. Max. Max. Max.
Fully extended . Hydraulic oil temperature: 2.1 2.1 2.8 2.8
:0.3 f0.3 +0.3 kO.3
45 - 55°C 2
. In H/O mode -
t I I I
Boom
,,,, a,,, BKP00114 Max. 1.0 Max. 1.2
. Lower boom and measure time
taken from point where bucket
contacts ground to point where
chassis rises from ground
. Engine at low idling
.
45 - 55°C,
Arm Max. 1.0 Max. 2.8

BKP00115
. Stop arm suddenly and measure

time taken for arm to stop
45 - 55°C
20-8
0
Cat{
Applicable model
r PC200, 210, 220, 230-6

wr
Bucket sec. Max. 1.0 Max. 3.6
. Stop bucket suddenly and

measure time taken for bucket
to stop at bottom and then
start again.
45 - 55°C
Cylinders . Hydraulic oil temperature: 4.5 20

45 - 55°C
c/mir
Center swivel joint . Relieve circuit to be measured 10 50

45 - 55°C
* Use a hard horizontal surface.
Travel deviation when

work equipment + mm Max. 200 Max. 220
travel are operated
C IOm 1 BKP00107
* Measure dimension X.
Piston pump See next page See next page
20-9
0
PC200, 210-6: Discharge amount of main piston pump (in H/O mode)
t?/min
oto1 9. 8(1001 19.6(2001 29.4(3001 34.313501 [MPaika/cm'll
PI+P2
Pump discharee Pressure=2
TKP00736
l Pump speed: At 2000 rpm, PC current 260 mA
Test pump Discharge Average

discharge pressure of pressure q
Check point
pressure other pump
(MPa {kg/cm*)) (MPa Ikn/cm*I) (MPa {kg/cm*))
PI t P2
As desired PI P2 See graph See graph
I I 2
Sr As far as possible, bring pump discharge pressure PI and P2 as close as possible to the
average pressure when measuring.
The error is large near the point where the graph curves, so avoid measuring at this point.
* When measuring with the pump mounted on the machine, if it is impossible to set the engine
speed to the specified speed with the fuel control dial, take the pump discharge amount and
the engine speed at the point of measurement, and use them as a base for calculating the
pump discharge amount at the specified speed.
20-10
0
PC220, 230-6: Discharge amount of main piston pump (in H/O mode)
@/min)
8
t
%
0101 9. 811001 19. 6 2001 29.4(3001 34.3(3501 [MPa( ke/cm'll
PI +P2
Pump discharge pressure=-
2
TKP00737
l Pump speed: At 2100 rpm, PC current 260 mA
Test pump Discharge Average Standard value Judgement

discharge pressure of pressure for discharge standard lower
Check point
pressure other pump amount Q limit Q
(MPa Ikg/cnN) (MPa {kg/cm91 (MPa {kg/cm91 (Urnin) (Urnin)
PI + P2
As desired PI P2 See graph See graph
2
* As far as possible, bring pump discharge pressure PI and P2 as close as possible to the
average pressure when measuring.
The error is large near the point where the graph curves, so avoid measuring at this point.
* When measuring with the pump mounted on the machine, if it is impossible to set the engine
speed to the specified speed with the fuel control dial, take the pump discharge amount and
the engine speed at the point of measurement, and use them as a base for calculating the
pump discharge amount at the specified speed.
20-l 1
0
Flow control characteristics of PC valve (STD)

* The values in this table are used as reference values when carrying out troubleshooting.
?-
Item Measurement conditions Unit PC200, 210 PC220, 230
Y
Time taken for swing

. Engine at high idling 4.2 f 0.4
for boom RAISE +
starting swing
45 - 55°C
. In H/O mode
. Load the bucket with the
rated load and measure the
time taken from the position
of starting the swing to the
point of passing the 90”
position.
20-l 2
0
TESTING AND ADJUSTING STANDARD VALUE TABLE FOR ELECTRICAL PARTS
STANDARD VALUE TABLE FOR ELECTRICAL PARTS
sv
tel
Name of
component
Zonnectol
No. n&hoc
Judgment table
Measurement
conditions
If the condition is within the range shown 1) Turn starting
in the table below, it is normal switch OFF.
2) Disconnect
Between (I) - (2) 0.25 - 7 kQ I connector.
E06
Fuel control dial
(male)
Between (2) - (3) 0.25 - 7 kR
Between (1) - (3) 4-6kR

n the table below, it is normal switch OFF.
2) Disconnect
Between (1) - (2) 0.25 - 7 kR I connector.
E04
Potentiometer
(male)
Between (2) - (3) 0.25 - 7 kQ I
Between (I) - (3) 4-6 kQ
If the condition is as shown in the table 1) Turn starting

aelow, it is normal switch OFF.
2) Disconnect
Motor
E05
(male)
)I connector.
Between (1) - chassis No continuity
Between (3) - chassis No continuity

i n the table below, it is normal switch OFF.
2) Disconnect
Between(male) (1) - (2) 500 - 1,000 R connector.
Between(male)(2) - chassis Min. 1 MR I

_J
Engine speed E07 Fwleasure with AC range 1) Start engine.

sensor 2) Insert
Between (1) - (2) 0.5 - 3.0 v T - adapter.
[
1I) Screw in rotation sensor until it contacts

ring gear, then turn back 1 + l/6 turns.
2!I It must work normally when adjusted
as above.
‘ravel so1 f the condition is as shown in the table 1) Start engine

Ielow, it is normal (or with engine
oomRAISESO2 Nhen boom, arm, and bucket levers are stopped and
operated accumulator
rm OUT SO: charged)
Between All levers at neutral Min. 1 MQ 2) Disconnect
oomLOWER
SO4 (male) connectors
PPC oil pressure (1) - (2) Levers operated Max. 1 R so1 - so9.
switch rm IN SO!
ucketCURLSO6 Between (male)

Min. 1 MQ
(l),(2) - chassis
ucketDUMPSO7
lght swing SO8
:fl swing SO9
20-l 3
Empty
0
Name of Zonnectol n Measurement

Judgment table
component No. d conditions
If the condition is as shown in the table I) Start engine.
below, it is normal 2) Turn fuel
control dial to
CO7 (male) Between (2) - (1) 18-28V MAX position.
Pump pressure (rear) 3) Insert
sensor CO8 ;m$e)) T - adapter.
All levers at neutral 0.5 - 1.5 V
Between
(3) - (1)
At arm IN relief 3.1 - 4.5 v
If the condition is as shown in the table I) Turn starting

below, it is normal switch OFF.
2) Disconnect
x05
Swing lock switch connector C02.
(female)
If the condition is within the range shown I) Turn pump

in the table below, it is normal prolix switch
OFF.
PC-EPC solenoid Cl3 Between (I) - (2) 7-1421 2) Turn starting
valve (male) switch OFF.
Between(l), (2) - chassis Min. 1 MQ 3) Disconnect
connector C13.

Swing holding brake vo4 2) Disconnect
solenoid valve (male) Between (I) - (2) 20 - 60 R connector V04.
Between(l), (2) -chassis Min. 1 MQ
If the condition is within the range shown I) Turn starting

Travel speed VO6 2) Disconnect
solenoid valve [male) Between (1) - (2) 20 - 60 R connector V06.
BetweenU 1, (2) - chassis Min. 1 MQ

vo2 2) Disconnect
2-Stage relief
(male) Between (I) - (2) 20 - 60 Sz connector V02.
solenoid valve
Between(l), (2) - chassis Min. 1 MR

Pump merge/divider vo3 2) Disconnect

Active mode vo5 2) Disconnect
Betweeni 1, (2) - chassis Min. 1 MR
20-14
0
Name of :onnectol lspectiol Measurement

Judgment table
component No. nethoc conditions
2) Disconnect
Cl0
LS-EPC solenoid Between (1) - (2) 7-14R connector CIO.
[male)

in the table below, it is normal switch ON.
2) Insert
T - adapter.
Power source co1
voltage co2

below, it is normal switch ON.
2) Insert
Between (7) - (17) T - adapter.
4.75 - 5.25 V
(power source) I
I
Fuel control dial co3 I I
Between (4) - (17) 4.0 - 4.75 v
(low idling)
I
Between (4) - (17)
0.25 - 1.0 V
(high idling) I

2) Insert
Between (14) - (17) T - adapter.
2.9 - 3.3 v
(low idling)
Governor co3
potentiometer Between (14) - (17)
0.5 - 0.9 v
(high idling) I
Between (7) - (17)

4.75 - 5.25 V
(power source)

2) Disconnect
Coolant 1 Normaltemperature(25°C)1 Approx. 37 - 50 kR 1 connector P07.
PO7 3) Insert
temperature
(male)
sensor 1100°C 1Approx. 3.5 - 4.0 kR I T - adapter.
into connector
at sensor end.

2) Insert
Governor motor co2 Between (2) - (3) 1.8 - 4.6 V I T - adapter.
1 Between (4) - (5) I 1.8 - 4.6 V I

2) Insert
Battery relay co1 Between (I) - (6) 20 - 30 v T - adapter.
* This is only for 2.5 set after the starting

switch is operated ON + OFF; at other
times it must be 0 V.
-
IS- Name of Zonnecto Measurement
Judgment table
m :omponent No. conditions
-
If the condition is as shown in the table 1) Start engine.
b elow, it is normal 2) Turn swing lock
switch OFF.
When either swing 3) Turn swing lock
or work equipment prolix switch
control lever is OFF.
20 - 30 V
operated (solenoid 4) Insert
ON, swing holding T - adapter.
Swing holdinc brake canceled) Sr The lever can
co1
brake solenoi; Between be operated
Approx. 5 set after (3) - slightly
swing lever and (6),(12) (without
work equipment moving
control levers are the equipment).
o-3v
placed at neutral
(solenoid OFF,
swing holding
brake applied)
-
If the condition is as shown in the table ;I z;:tengine.
bselow, it is normal
T - adapter.
With travel speed 3) Turn fuel
switch at Hi or Mi control dial to
(solenoid ON, 20 - 30 v MAX position.
travel motor swash 4) Operate the
Travel speed plate angle MIN) lever slightly
ZOI
solenoid not enough to
When travel speed Between move the
switch is at Lo (9) - machine.
(solenoid OFF, (6),(12) To check that the
travel motor swash solenoid is OFF,
plate angle MAX) neasure with the
‘uel control dial at
;rIU; 200 rpm or
-
bt?low, it is normal switch ON.
?I Insert
Nhen swing lock T - adapter.
switch is OFF, and k The lever can
swing + travel be operated
evers are operated 20 - 30 v slightly
simultaneously (without
Active mode 101
‘solenoid ON, LS Between moving
solenoid
divided) (6) - the equipment).
(6),(12)
Nhen swing lock
iwitch is ON
o-3v
solenoid OFF, LS
lot divided)
the condition is as shown in the table ) Turn starting

tlow, it is normal. switch ON.
!I Insert
Rlhen travel is T - adapter.
operated independ- t The lever can
‘ump merge/ ?ntly (solenoid ON,
20 - 30 v
be operated
divider valve :01 iivided) Between slightly
jolenoid (2) - (without
Yhen levers and (6),(12) moving
medals are at the equipment).
neutral (solenoid
o-3v
IFF, merged)
20-M
0
Name of
component T;
Connector
No.
Judgment table
Measurement
conditions

2) Insert
Swing lock switch ON T - adapter.
2-stage relief (solenoid ON: High 20 - 30 v
co1
solenoid valve
(solenoid OFF: Low o-3v

. H/O mode 2) Turn fuel
PC-EPC I I control dial to
solenoid valve co2 MAX position
(default value) 3) Turn prolix
switch OFF.
4) All levers at
neutral.

LS-EPC . H/O mode 2) Turn fuel
solenoid valve co2 control dial to
(default value) Between (7) - (17) 900 & 80 mA MAX position
3) All levers at
neutral.

2) Insert1
L.H. knob switch co3 When switch is ON Between 20 - 28 V T - adapter.
When switch is OFF (‘I - GND 0- 1V

S-NET Cl7 2) Insert1
Between (4),(12)- GND 4-8V T - adapter.
I
2) Insert1
Kerosene mode Cl7 Standard mode 20 - 28 V T - adapter.
Between
Kerosene mode (I%--GND o_2v
20-17
0
SYS
ten
Name of
comoonent T
L
(Zonnector
No.
Spector
lethod
Judgment table
Measurement
conditions
If the condition is as shown in the table Start engine.

below, it is normal :; Set monitoring
codeto IOor 16
(command
PC200 PC220 value).
3) Operate
Active mode Approx. 2,200 Approx. 2,300 working mode
switch and L.H.
H/O (working) Approx. 2,000 Approx. 2,200 knob switch.
No. 2 throttle Monitoring

signal :ode 16, la
B/O Approx. 1,900 Approx. 2,000
Power max. (H/O)(G/O)Approx. 2,200 Approx. 2,300
(H/O)(G/O)\
) Swiftslow-down Approx.1,650)Approx. 1,680)

2) Disconnect
connector.
3) Connect
T - adapter to
wiring harness
Model Cl7 - co2 end.
selection
1Between selection 4 1C17(14) - CO2(11) 1 No continuity 1

Between selection 5 Cl7171 - CO2(11) No continuity
20-18
0
Name of Zonnector spectior Measurement

Judgment table
component No. lethod conditions

PI1 below, it is normal 2) Disconnect
Air cleaner Pll, P12.
clogging sensor ~~2ale’ Air cleaner normal Between Continuity
(female)
Air cleaner clogged “’ - “* No continuity

3) Disconnect
Between (I) - (2) 500 - 1000 R connector E07.
Between(*) - chassis Min. 1 MR
Engine speed senso E07 Measure with AC range I) Start engine.

2) Insert
1 Between (I) - (2) 1 0.5 - 3.0 V I T - adapter.
I) Screw in rotation sensor until it contacts

ring gear, then turn back 1 ? l/6 turns
2) It must work normally when adjusted
as above.

2) Disconnect
connector P08.
Coolant level PO8 3) Insert
sensor (male) T - adapter into
connector at
sensor end.

2) Disconnect
connector P05.
3) Drain oil, then
w’ Raise float Max. 1 R
Engine oil level PO5 BLPOoo02 remove sensor.
sensor (male)
1 y: Lowerfloat 1 Min. 1 MLII

2) Disconnect
Coolant
PO7
1 Normal temperature (25’0 1 Approx. 37 - 50 kR 1 connector P07.
temperature 3) Insert
(male)
sensor 1OO'C Approx. 3.5 - 4.0 kQ T - adapter.
into connector
at sensor end.
20-19
0
sys- Name of Connector Inspection

Judgment table
Measurement
tern component No. method conditions
If the condition is as shown in the table 1) Install oil

below, it is normal pressure
measurement
gauge.
Engine oil
pressure sensor
Sll “1”6’ I
2) Remove wiring
harness
terminal.
3) Start engine.
4) Put tester in
I contact
betweensensor
terminal screw
and chassis.

2) Disconnect
connector P06.
3) Drain fuel, then
remove sensor.
PO6
Fuel level sensor 4) Insert
(male)
T - adapter into
sensor.
t Connect the
T - adapter to
the connector
and sensor
flanoe.

2) Disconnect
connector PO9.
3) Drain oil, then
remove sensor.
Hydraulic oil level PO9 4) Insert
sensor (male) T - adapter into
sensor.
~ y: Lowerfloat /Min. 1 M*i
If the condition is as shown in the table 1) Start engine.

below, it is normal 2) ;;yon&ect
Air cleaner normal Continuity 3) Put ‘tester in

contact with
1 Air cleaner clogged 1 No continuity 1 connector at
sensor end to
measure.
Air cleaner PI1
clogging sensor PI2
BLwOOO6
20-20
0
Clonnector Inspection Measurement

Name of component Judgment table
- No. I method I conditions
B#etween When engine is running (l/2throttle or above) 1) Start engine.

lternator below, the sensor is defective.
Alternator : zrminal j27.5 - 29.5 V
L and Sr If the battery is old, or after starting in
C hassis cold areas, the voltage may not rise for
some time.
-
Display level resistance kR 1) Insert a

Position of dummy
(Monitor panel input
gauge display resistance with
resistance)
the starting
Starting switch ON Starting switch OFF switch OFF, or
measure the
Min. - Max. resistance of
the sensor.
- 0.646
2) Check the
display with
0.575 - 0.342
the starting
switch ON.
3.156 - 3.708
Measure
resistance
3.422 - 3.900
between
coolant
3.600 - 4.349
temperature
gauge CO3
4.015 - 5.122
(female) (I 1
- co3 4.728 - 6.816
(female) (16:
I
r-l 3 6.294 - 10.774
9.946 - 36.535
Left
side 33.725 -
* Levels 8 and 9 flash.

-
Gauges
Display level resistance kR I) Insert a
Position of dummy
(Monitor panel input
gauge display resistance with
resistance)
the starting
Starting switch ON Starting switch OFF switch OFF, or
measure the
Min. - Max. resistance of
Right the sensor.
side 9 - 13.82
2) Check the
8 display with
11.71 - 21.25
the starting
7 switch ON.
t 18.90 - 28.45
Measure
resistance 6 25.82 - 31.85
between
fuel level 29.18 - 39.91
gauge CO3 Display 5
position 4
cf;ma;;!s(2) 37.00 - 44.60
3 41.77 - 55.14
1
2 50.42 - 77.07
1 72.98 - 691.5
Left
side All OFF(10) 638.00 -
* Level 1 flashes.
20-Z 1
0
TESTING AND ADJUSTING STANDARD VALUES TABLE FOR GX CONTROLLER
STANDARD VALUES TABLE FOR GX CONTROLLER

Name of Zonnectoi Measurement

Judgment table
component No. n&hoc conditions
2) Insert
Boom
A21 Between (6) - (7) 5 rt: 0.2 V T-adapter
potentiometer
3) End of boom
Between (8) - (7) 3.6 - 4.6 V RAISE stroke.

Arm 2) Insert
A19 Between (6) - (7) 5 - 0.2 v T-adapter
potentiometer
3) End of arm
Between (8) - (7) 3.6 - 4.6 V RAISE stroke.

2) Disconnect
Boom A21 connector.
potentiometer (male)
G

2) Disconnect
connector.
Arm A19
potentiometer (male)
,....,‘t:l

below, it is normal 2) Turn fuel
control dial to
Between (2) - (1) 18-28V MAX.
A25 3) Insert
(Boom T-adapter.
bottom) Between (3) - (I) 3.2 - 4.2 V
A26
(At relief)
‘hBe”a”d;”
A27 % See the table when comparing with the
(Arm hydraulic pressure.
bottom)
A28
(Arm
Cylinder head) 6
pressure sensor A29

(Bucket 4
bottom)
3
A30
(Bucket
2
head)
A37 1
(Right
(VI
swing) 0
A38 9. 6 19 6 29 4 39.2 49.0
(lOOI (2001 I3001 I4001 (5001
(Left
swing) MPaIka/cm'l
BKP02305
% Reference: 3.8 ?r0.3 V at 34.8 MPa (335 kg/cm21
20-23
0
$ Name of :onnectol Sp3liOl

Judgment table
Measurement
ter component No. rethoc conditions

2) Insert
T-adapter.
Between A01 (9)(17) - (1hlO) 11.5 - 12.5 V 3) Set chassis
horizontal.
Between Chassis
A03 (4) - A01 (l)(lO) horizontal 2’5 - 3’5 ’
A01
Clinometer A03
If the condition is as shown in the table
(A241 below, it is normal
(A241
Between (I) - (3) 11.5 - 12.5 V
Between (2) - (3) 1;;;;t;tal I2.5-3.5V 1

(AOl) 2) Insert
T-adapter.
Between (9)(17) - (lHl0) Tzzq 3) Run engine
when
operating.
EiActuatedi 6f2V (
Bucket cylinder A01
stroke sensor (A181
(A18)
Between (I) - (2) 111.5- 12.5 VI
Between
l---i
(3) - (2) IA1
Between
(4) - (2) [BI
Actuated
If the condition is as shown in the table

6f2V
1) Turn starting
(A21, 19) 2) Insert
T-adapter.
Between (I) - (2) (11.5 - 12.5 VI 3) Run engine
when
Between operating.
Encoder
A21
(Boom)
A19
(Arm)
l----l
(3) - (2) [Al
Between
(4) - (2) [Bl
(A011
Actuated 6+2V
(A011 Between (9)(17) - (I)(101 11.5 - 12.5 VI
I
I
Actuated 6&2V
20-24
a
SYS- Name of Connector Inspection Measurement

Judgment table
tern component No. I methodI conditions
Em If the condition is as shown in the table 1) Turn starting

Model selection Xm below, it is normal switch ON.
A09 IS 2) Insert
(w/o radio control)
$2 Between (8) - GND O-IV T-adapter.
I I If the condition is as shown in the table

below, it is normal
1) Turn starting
switch ON.
Knob switch
A09
Between (3) - GND
(when ON)
_^^^()IU-LU v
12,Fz:pter.
input signal
Between (3) - GND
O-IV
(when OFF)
I I I
GX controller
c)sis;nection
A0g
I I I ,
I I ’
I 1 If the condition is as shown in the table

below, it is normal
1) Operate in
switch back
/boom rock
During prevention
Remote permitted A02 boom rock mode.
output 18-28V 2) Insert
Between prevention
(IO) - (l)(8) control T-adapter.
I I
1Except above 10 - 1 V 1
?!!a, If the condition is as shown in the table I) Turn starting

Xrn below, it is normal switch ON.
A09 :B 2) Insert
2: Between (5)(13) - (2) 3-9v T-adapter.
Ea If the condition is as shown in the table I) Turn starting

20) below, it is normal switch ON.
A09 “9 2) Insert
3-r,
Between (6)(14) - (2) 3-9v T-adapter.
ZZ’
20-25
0
20-101
TESTING AND ADJUSTING TOOLS FOR TESTING, ADJUSTING, AND TROUBLESHOOTING
TOOLS FOR TESTING, ADJUSTING, AND TROUBLESHOOTING
Check or measurement iten jymbo I Part No. Part Name Remarks

799-203-8001 Multi-tachometer 0 - 3,000 rpm
Engine speed A ~~9-608-1000 Tachometer (electrical Digital display H:
L: 60
60 -- 2,000 rpm
type) 19,999 rpm
Coolant and oil temperature: B 799-101-1502 Digital temperature gauge -99 - 1,299”C
- -
Pressure gauge
799-101-5002 Hydraulic tester 2.5, 5.9, 39.2, 58.8 MPa
I25, 60, 400, 600 ka/cm*I
1
Pressure gauge
790-261-1203 Digital hydraulic tester
69 MPa I700 kg/cm*}
-
2 799-401-2320 Hydraulic gauge 1.0 MPa {IO kg/cm*}
-
Both male and female
~790-261-1311
14 x 1.5 (female PT l/8)
3 l790-261-1321 Adapter
Oil pressure C 18 x 1.5 (female PT l/8)
l790-261-1331
-
4 799-401-2700 1 Differential pressure gauge 1 (IN
- I I

790-261-1360 Adapter
790-261-1370 Nut For 14 x 1.5 blind

5
07003-31419 Gasket For blind
g
07040-I 1409 Plug For 14 x 1.5 blind >
- -
795-502-1205 Compression 0 - 6.9 MPa IO -70 kg/cm*} %
1 gauge
Compression pressure D -
2 795-502-1700 Adapter
-
Blow-by pressure E 799-201-1504 Blow-by checker 0 - 4.9 MPa (0 - 500 mmHzO1
Valve clearance F Commercially Feeler gauge -

available
Discoloration 0 - 70% (with
1
1 799-201-9000 Handy Smoke Checker
standard color)
Exhaust color s (Discoloration % x l/IO =
2 Commercially Smoke meter
available Bosch index)
Air supply pressure

(boost pressure) H 799-401-2201 Pressure gauge 199.9 kPa I-760 - 1,500 mmHg}
79A-264-0020 0 - 294N (0 - 30 kg}

Operating effort J Push-pull scale
79A-264-0090 0 - 490N {O - 50 kg}
Stroke, hydraulic drift K
Commercially Stop watch -

Work equipment speed L available
Measuring voltage and
M 79A-264-0210 Tester -
resistance values
1 1 -
I
799-601-7100 1 T-adapter assembly
Troubleshooting of wiring
u 799-601-7070 For SWP14P
harnesses and sensors 2 Adapter
799-601-7360 For relay 5P
Measuring wear of sprocket P 796-427-l 190 Wear gauge -
Fuel injection timing -

valve clearance 0 795-799-l 130 Adapter
20-102
0
TESTING AND ADJUSTING MEASURING ENGINE SPEED
MEASURING ENGINE SPEED
A When removing
equipment,
or installing the measuring
be careful not to touch any high
temperature parts.
* Measure the engine speed under the following
conditions.
l Coolant temperature: Within operating range
. Hydraulic oil temperature : 45 - 55°C
1. Installation of tachometer
1) Mechanical meter
i) Remove the cover under the front pul- BLPOZ113
ley, then set probe @ of tachometer A
on stand @ facing pulley (I).
ii) Stick silver paper to pulley (I) at one
place.
iii) Connect probe @ and tachometer A with
the cable.
A When measuring the speed, be careful
not to touch any rotating part or high
temperature part.
2) Electric meter
i) Install T-adapter Nl to connector CN-EOI
(2) of the engine speed sensor.
$ ii) Connect the power source cable to the
> BLPO2114
battery (24V).
%
2. Start the engine, and measure the engine speed
when it is set to the conditions for measuring.
1) Measuring at low idling and high idling:
Measure the engine speed with the fuel con-
trol dial set to low idling and high idling.
2) Measuring speed at pump relief:
Run the engine at full throttle and measure
the engine speed when the pump is relieved.
3) Measure the speed at near the rated speed.
Run the engine at full throttle, operate the
arm lever, and measure the speed when the
arm circuit is relieved.
20-l 03
0
TESTING AND ADJUSTING MEASURING EXHAUST GAS COLOR
MEASURING EXHAUST GAS

COLOR
l When measuring in the field when there is no

air or power supply, use smoker checker Gl,
when recording official data, use smoke meter
G2.
* Raise the coolant temperature to the operating
range before measuring.
AWhen removing or installing the measuring
equipment, be careful not to touch any high
temperature parts.
1. Measuring with handy smoke checker Gl

I) Fit filter paper in tool Gl.
2) Insert the exhaust gas intake port into the
exhaust pipe, accelerate the engine suddenly,
and at the same time operate the handle of
tool Gl to catch the exhaust gas on the filter
paper.
3) Remove the filter paper and compare it with
the scale provided to judge the condition.
ELPO2115
2. Measuring with smoke meter G2

1) Insert-probe @ into the outlet port of ex-
haust pipe, then tighten the clip to secure it
to the exhaust pipe.
2) Connect the probe hose, accelerator switch
plug, and air hose to tool G2.
* The pressure of the air supply should be
less than 1.47 MPa (15 kg/cm*}.
3) Connect the power cord to the AC outlet.
* When connecting the port, check first that
the power switch of tool G2 is OFF.
4) Loosen the cap nut of the suction pump, BLPOPIIG
then fit the filter paper.
* Fit the filter paper securely so that the
exhaust gas does not leak.
5) Turn the power switch of tool G2 ON.
6) Accelerate the engine suddenly, and at the
same time, depress the accelerator pedal of
tool 62 and catch the exhaust gas color on
the filter paper.
7) Lay the filter paper used to catch the ex-
haust gas color on top of unused filter pa-
pers (IO sheets or more) inside the filter pa-
per holder, and read the indicated value.
BLPO2117
20-104
0
TESTING AND ADJUSTING ADJUSTING VALVE CLEARANCE
ADJUSTING VALVE
CLEARANCE
1. Remove the cylinder head cover.
2. Using cranking tool Q, rotate the crankshaft in

the normal direction until timing pin (I) enters
the hole in the gear.
Ir This position is the No. 1 cylinder compres-
sion top dead center.
3. When No. 1 cylinder is at compression top dead

Valve arrauoement diagram
center, adjust the valves marked 0. Next, rotate
the crankshaft one turn (360”) in the normal di-
rection and adjust the valve clearance of the
remaining valves marked 0.
* Make match marks on the crankshaft pulley
or damper, then rotate 360”.
$
t 4. To adjust the valve clearance, loosen locknut I TKP00738
% (61, then insert feeler gauge F between rocker

lever (3) and valve stem (41, and turn adjust-
ment screw (5) until the clearance is a sliding fit.
Then tighten locknut (6) to hold the adjustment
screw in position.
w Locknut : 44.1 f 4.9 Nm I4.5 f 0.5 kgm}
* After adjusting No. 1 cylinder at compression

top dead center, it is also possible to turn the
crankshaft 180” each time and adjust the valve
clearance of each cylinder according to the fir-
ing order.
. Firing order : 1 - 5 - 3 - 6 - 2 - 4
t After tightening the locknut, check the valve
clearance again.
* There is no timing mark on the front pulley,
so set to compression top dead center as
follows.
i) If the firing order is followed, the next
cylinder after No. 1 cylinder is No. 5 cyl-
inder, so watch the movement of the
No. 2 cylinder valves and rotate in the
normal direction.
ii) When the clearance of both the intake
and exhaust valves of the No. 2 cylinder
is 0, the No. 5 cylinder is at compression
top dead center. (For the No. 3 cylinder,
watch the movement of the No. 4 cylin-
der valves.)
20- 105
0
MEASURING BLOW-BY PRESSURE
TESTING AND ADJUSTING MEASURING COMPRESSION PRESSURE
MEASURING COMPRESSION
PRESSURE
AWhen measuring the compression pressure, be

careful not to touch the exhaust manifold or
muffler, or to get your clothes caught in the fan,
fan belt or other rotating parts.
1. Adjust the valve clearance.
For details, see ADJUSTING VALVE CLEARANCE.
2. Warm up the engine to make the oil tempera-
ture 40 - 60°C.
3. Remove the nozzle holder assembly from the
cylinder to be measured.
4. Install adapter D2 in the mount of the nozzle
holder, then connect pressure gauge Dl.
5. Set tachometer A in position.
6. Disconnect the fuel control rod, place the gover-
nor lever of the injection pump in the NO IN-
JECTION position, then crank the engine with
the starting motor and measure the compres-
sion pressure.
+ Measure the compression pressure at the point
where the pressure gauge indicator remains
steady.
* When measuring the compression pressure,
measure the engine speed to confirm that it is
within the specified range.
* After measuring the compression pressure, in-
stall the nozzle holder assembly.
MEASURING BLOW-BY
PRESSURE
* Measure the blow-by pressure under the follow-

ing conditions.
. Hydraulic oil temperature: 50 - 80°C.
1. Install the nozzle of blow-by checker E to blow-
by hose. BLPO2122
2. Connect the nozzle and gauge with the hose.
3. Set the working mode to the H/O mode, fit a
block between the sprocket and frame, then run
the engine at high idling and relieve the travel
circuit.
4. Measure the blow-by at the point where the
gauge indicator remains steady.
BLP00304
20- 106
0
TESTING AND ADJUSTING TESTING AND ADJUSTING FUEL INJECTION TIMING

FUEL INJECTION TIMING
1. Testing
I) Using cranking tool 0, rotate the crankshaft
in the normal direction until timing pin (1)
enters the hole in the gear.
2) Remove plug (21, reverse timing pin (31, and
check that pin (3) is meshed with timing pin
pointer (4) at the injection pump side.
2. Adjusting
. If the timing pin does not mesh
i) Remove the fuel injection pump.
For details, see REMOVAL OF FUEL INJEC-
TION PUMP ASSEMBLY.
ii) Rotate the camshaft of the injection pump
and mesh timing pin (3) with timing pin
pointer (4).
iii) Install the fuel injection pump assembly.
For details, see INSTALLATION OF FUEL IN-
8 JECTION PUMP ASSEMBLY.
t
ELP01051 BLPO1052
%
20-l 07
a
TESTING AND ADJUSTING MEASURING ENGINE OIL PRESSURE
MEASURING ENGINE OIL
* Measure the engine oil pressure under the fol-

lowing conditions.
1. Remove engine oil low pressure sensor (I), then

install the adapter of oil pressure gauge kit Cl
and oil pressure gauge C2 (1.0 MPa {IO kg/cm21.
2. Start the engine, and measure the oil pressure

at the low pressure end with the engine at low \ I ELPO2123
idling and at the high pressure end with the
engine at high idling.
/“ __ ELPO2124
20-108
0
TESTING AND ADJUSTING FAN BELT TENSION
TESTING AND ADJUSTING TESTING AND ADJUSTING BELT TENSION FOR AIR CONDITIONER COMPRESSOR

FAN BELT TENSION
Testing
. Check the deflection of the belt when the belt is
pressed with a finger force of approx. 58.8 N {S
kg) at a point midway between the tension pul-
ley and fan pulley.
Adjusting
1. Loosen mounting bolts (2) and (31, bolt (4), nut
(51, and belt tension adjustment bolt (6) of ten-
sion pulley (I).
2. Lever the tension pulley and watch the tension
of the fan belt through the clearance from the
cylinder block. When the tension is correct,
tighten adjustment bolt (6) first, then tighten ten-
sion pulley mounting bolts (2) and (3), and nut
(5).
3. After adjusting the belt tension, check again to
confirm that the belt tension is within the stand-
ard value.
* After adjusting the belt, run the engine for at
least 15 minutes, then measure the deflection of
the belt again.
8
> BKP02126
z
0
TESTING AND ADJUSTING Bar
BELT TENSION FOR AIR

CONDITIONER COMPRESSOR
* If the deflection of the belt when it is pressed at

a point midway between the drive pulley and
the compressor pulley is not within the stand-
ard value, or when carrying out maintenance
after replacing the belt, adjust the belt tension
as follows. TLP00739
1. Loosen bolts (I) and (2).
I
2. Lever with a bar between (3) and (4) to adjust
the belt tension.
3. When the position of the compressor is fixed,
tighten bolts (2) and (I) to secure in position.
54mm
4. After adjusting the belt tension, repeat the above
procedure to check that the belt tension is within
the standard value.
(FD
BLPO2128
TESTING AND ADJUSTING MEASURING SPEED SENSOR
MEASURING SPEED SENSOR
1. Screw in until the tip of sensor (1) contacts gear

(2).
2. When gear (2) contacts sensor (I), turn back
one turn.
3. Tighten locknut (3).
* Be particularly careful when securing the sensor
wiring to ensure that no excessive force is
brought to bear on the wiring.
* Be careful not to let the tip of the sensor be
scratched or to let any iron particles stick to the
sensor tip.
BEP01149
20410
a
TESTING AND ADJUSTING TESTING AND ADJUSTING GOVERNOR MOTOR LEVER STROKE

GOVERNOR MOTOR LEVER
STROKE
1. Testing
* Use the governor motor adjustment mode.
1) Preparatory work
i) In the time mode display, keep the time
switch + travel speed R.H. switch + work-
ing mode R.H. switch pressed for 2.5
seconds.
* On the PC200 Series, the engine out-
put (99 kW I133 HP}) when the en-
gine is running at full throttle is the
output when the power max. switch
in the active mode is ON, so use this
mode instead of turning the power
max. switch ON.
ii) Set the fuel control dial to MAX and the
auto deceleration switch OFF.
Ir Any working mode can be used.
2) In this condition, check that governor lever
(4) is in contact with FULL stopper (5) of the
injection pump.
3) After checking, repeat the procedure in Step
I) to complete the governor motor adjust-
ment mode.
2. Adjusting
1) Turn the starting switch OFF, then remove
the nut and disconnect joint (I) from gover-
nor lever (4).
2) Repeat the procedure in Step 1-I) above to
set to the governor motor adjustment mode.
3) Set governor lever (4) to a position where it
contacts FULL stopper (5) of the injection
pump, then adjust the length of spring as-
sembly (2) and rod (31, and connect joint (I)
with the nut.
4) From the above position, turn rod (3) back
1.5 turns (retract the rod approx. 3.7 mm),
and secure in position with locknuts (6) and
(7).
Caution
When the spring assembly is removed and the
starting switch is at the OFF position, if the gov-
ernor motor lever is moved suddenly, the gov-
ernor motor will generate electricity, and this
may cause a failure in the governor controller.
20-111
0
TESTING AND ADJUSTING HYDRAULIC PRESSURE
TESTING AND ADJUSTING IN WORK EQUIPMENT, SWING, TRAVEL CIRCUIT
TESTING AND ADJUSTING HYD RAULIC PRESSURE IN WORK

EQUIPMENT, SWING, TRAVEL C IRCUIT
1. Measuring
* Oil temperature when measuring: 45 - 55’C
A Lower the work equipment to the ground and
stop the engine. Loosen the oil filler cap slowlv
to release the pressure inside the hydraulic tank.
Then put the safety lock lever in the LOCK posi-
tion.
HYPER GX spedification:
First, turn GX controller disconnectin switch to
OFF.
Remove pressure pick-up plug (I) or (2) (Thread
dia. = 10 mm, Pitch = 1.25 mm) from the circuit
to be measured, then install oil pressure gauge
Cl (58.8 MPa (600 kg/cm*}).
Measuring main unload pressure

. Unload pressure when front and rear pump
flows are merged
Measure the oil pressure in H/O mode with
the engine at full throttle and the control
levers at neutral.
+ With this procedure, the unload pressure of
the unload valve of the left and right control
valves is measured.
2) Measuring sub-unload pressure

* Use this procedure to measure when it is
desired to measure each unload pressure.
. The unload pressure in the circuit which is
not under load when the front and rear pump Table 1 Combination of pumps and actuators
flows are divided. controlled when flow from front and
I) Set to H/O mode. rear pumps is divided
2) Operate the travel lever a little at a time
(or connect a short connector to the
travel oil pressure switch connector (CN-
>
Sol)), then measure the pressure in the
pump circuit on the opposite side when
the arm or bucket circuit is relieved. % l Boom cylinder
Rear pump l Bucket cylinder
* Arm relief + load on front pump, rear l R.H. travel motor
pump unloaded. % The set pressure of the safety valve at the
* Bucket relief + load on rear pump, front head end and the swing motor (active
pump, unloaded. mode OFF) is lower than the set pressure
of the main relief valve.
20-l 12
0
. Measuring pump relief pressure

I) Low setting (oil pressure: 31.9 MPa (325 kg/
cm*11
i) Measure the pressure when each actua-
tor except the travel actuator is relieved
in H/O mode with the engine at full throt-
tle.
* Note that the set pressure of the
safety valve for the swing motor and
head end of the boom is lower than
the main relief low set pressure, so
the value measured will be the relief
pressure of the safety valve.
If the swing lock switch is turned ON,
the pressure will rise, so always keep
the lock switch OFF when measur-
ing.
* When measuring the swing relief
pressure, measure with the swing
lock turned switch ON.
2) High setting (oil pressure: 34.8 MPa {355 kg/

cm*11
i) When travel is operated
Measure the oil pressure when the travel
is relieved on each side separately in
H/O mode with the engine at full throt-
tle.
* To relieve the travel circuit, put block
@ under the track shoe grouser, or
put block @ between the sprocket
and frame to lock the track.
ii) When power max. function is actuated
When measuring the oil pressure in G/O
or H/O mode with the engine at full throt-
tle and the power max. function actu-
ated, relieve one of the boom, arm, or
bucket circuits, and measure the oil pres-
sure.
BLPOO170 BLPO0171
20-113
a
2. Adjusting
. (I): For front pump.
. (2): For rear pump.
1) Adjusting high pressure setting
Loosen locknut (31, then turn holder (4) to
adjust.
* Turn the holder to adjust as follows.
To INCREASE pressure, turn CLOCK-
WISE.
To DECREASE pressure, turn COUNTER-
CLOCKWISE.
* Amount of adjustment for one turn of
holder: Approx. 12.5 MPa 1128 kg/cm*}
w Locknut
: 53.5 f. 4.9 Nm 15.5 f 0.5 kgm}
* When the high pressure setting is ad-
4 6
justed, the low pressure setting will also
change, so adjust the low pressure set-
ting also.
2) Adjusting low pressure setting

Loosen locknut (5), then turn holder (6) to
adjust.
* Turn the holder to adjust as follows.
WISE.
CLOCKWISE.
* Amount of adjustment for one turn of
holder: Approx. 12.5 MPa 1128 kg/cm*}
m Locknut:
53.5 f 4.9 Nm (4.0 f 0.5 kgm}
* Normally, the pressure applied to port
PXI is 0 MPa 10 kg/cm*}; at the high pres-
sure setting, it is 2.9 MPa (30 kg/cm2}.
3) Swing motor safety valve

Loosen locknut (I), then turn adjustment
screw (2) to adjust.
+ Turn the adjustment screw to adjust as
follows.
WISE.
CLOCKWISE.
I
BLPO2306
20-114
0
TESTING AND ADJUSTING PC VALVE OUTPUT
TESTING AND ADJUSTING PRESSURE (SERVO PISTON INPUT PRESSURE)
TESTING AND ADJUSTING PC

VALVE OUTPUT PRESSURE
(SERVO PISTON INPUT
PRESSURE)
Measuring
Ir Oil temperature when measuring: 45 - 55°C
. Measure the oil pressure when the circuit is re-
lieved in the pressure rise mode.
I) Remove pressure measurement plugs (I), (21,

(31, and (4) (Thread dia.=10 mm, Pitch=1.25
mm), and install oil pressure gauge Cl.
* Install a 39.2 MPa (400 kg/cm*} gauge to
the servo valve end, and a 58.8 MPa (600
kg/cm*} gauge to the pump outlet port
end.
2) Turn the swing lock switch ON.
3) Set the working mode to H/O mode.
4) Run the engine at full throttle, turn the knob

switch ON, and measure the oil pressure
when the arm (IN) circuit is relieved.
* Check that the servo piston input pres-
sure is l/2 of the pump discharge pres-
sure.
[Reference]
If there is any abnormality in the LS valve or
servo piston, the servo piston input pressure
will be 0 or almost the same as the pump dis-
charge pressure.
TESTING AND ADJUSTING PC VALVE OUTPUT PRESSURE
TESTING AND ADJUSTING (SERVO PISTON INPUT PRESSURE)
Adjusting
* If the load becomes larger, the engine speed
will drop. Or if the engine speed remains nor-
mal, the work equipment speed will drop. In
such cases, if the pump discharge pressure and
LS differential pressure are normal, adjust the
PC valve as follows.
1) Loosen locknut (41, and if the equipment

speed is slow, turn screw (5) to the right; if
the engine speed drops, turn the screw to
the left. TLP00741
_j, If the screw is turned to the right, the

pump absorption torque will be in-
creased, and if it is turned to the left, the
pump absorption torque will be reduced.
* The adjustment range for the screw is a
maximum of 1 turn to the left and 180”
to the right.
+ Amount of adjustment for one turn of
screw: 1.5 mm movement of servo pis-
ton stroke
2) After completing the adjustment, tighten the

locknuts.
w Locknut (3): BKPOlO15
34.3 f 4.9 Nm 43.5 f 0.5 kgm1

Locknut (4):
100.5 + 12.3 Nm (10.25 + 1.25 kgm}
20-116
0
TESTING AND ADJUSTING LS VALVE OUTPUT PRESSURE
TESTING AND ADJUSTING (SERVO PISTON INPUT PRESSURE) AND LS DIFFERENTIAL PRESSURE
TESTING AND ADJUSTING LS

(SERVO PISTON INPUT
PRESSURE) AND LS
DIFFERENTIAL PRESSURE
* Oil temperature when measuring: 45 - 55°C

1. Measuring LS valve output pressure (servo pis-
ton input pressure)
1) Remove pressure measurement plugs (I),
(2), (31, and (4) (Thread dia.= 10 mm,
Pitch=1.25 mm), and install oil pressure
gauge Cl.
+ Install a 39.2 MPa I400 kg/cm*} gauge to
the servo valve end, and a 58.8 MPa (600
kg/cm*) gauge to the pump outlet port
end.
. Oil pressure when travel is rotating under no
load on one side
i) Set the working mode to H/O mode, and
turn the travel speed selector switch to Hi.
ii) Use the work equipment to raise the track
assembly on one side.
iii) Run the engine at full throttle and operate
$ the travel lever to the end of its stroke and
>
measure the oil pressure with the track ro-
%
tating under no load.
Run the engine at full throttle, operate the
travel lever to the end of its stroke, and meas-
ure the oil pressure when the working mode
and travel speed are switched as shown in
Table 1.
Table 1
2. Measuring LS differential pressure

1) Measuring with a differential pressure gauge
i) Remove oil pressure measurement plugs
(1) and (2) (Thread dia.=10 mm, Pitch=1.25
mm) and hoses (5) and (6), and install
differential pressure gauge C4.
ii) Set to the conditions in Table 2 and
measure the LS differential pressure.
Table 2
Differential
Working c,‘iEto, pressure
Operation
mode MPa {kg/cm21
dial
H/O Levers at neutral 2.9 + 1.0

mode I30 * IO)
Travel speed: Hi
H/O 2.2 f 0.1
MAX Travel circuitunder no load
mode I22 * I}
(lever operated half way)
2) Measuring with oil pressure gauge

* The maximum differential pressure is 2.9
f 1.0 MPa {30 f 10 kg/cm*), so measure
with the same gauge.
i) Remove oil pressure measurement plugs
(I 1and (2) (thread dia.=10 mm, pitch=l.25
mm), and install the plugs inside hydrau-
lic tester Cl.
ii) Install oil pressure gauge Cl (58.8 MPa
I600 kg/cm*}) to the measurement plug
for the pump discharge pressure.
* Use a gauge with a scale in units of
1.0 MPa {IO kg/cm*}.
(If no 58.8 MPa {600 kg/cm21 pres-
sure gauge is available, a 39.2 MPa
{400 kg/cm2) pressure gauge can be
used.)
iii) Set to the conditions in Table 2 and
measure the pump discharge pressure.
* Stand directly in front of the indica-
tor and be sure to read it correctly.
20-118
a
iv) Remove hoses (3) and (41, fit adapter C2,

then install oil pressure gauge Cl.
v) Set to the conditions in Table 2 and
measure the LS pressure.
* Stand directly in front of the indica-
tor and be sure to read it correctly.
(Pump discharge pressure) -
(LS pressure) = Differential pressure
3. Adjusting LS valve
When the differential pressure is measured un-
der the conditions above, and the results show
that the differential pressure is not within the
standard value, adjust as follows.
I) Loosen locknut (4) and turn screw (5) to ad-
just the differential pressure.
. Turn the screw to adjust the differential pres-
sure as follows.
To INCREASE pressure, turn CLOCKWISE
CLOCKWISE
Ir Amount of adjustment (LS differential
pressure) for one turn of screw: RKPOIOl6
1.3 MPa i13.3 kg/cm*1
2) After adjusting, tighten locknut (4).

w Locknut:
56.4 + 7.4 Nm 15.75 f 0.75 kgm}
Note: Always measure the differential pres-
sure while adjusting.
TESTING AND ADJUSTING TESTING AND ADJUSTING CONTROL CIRCUIT OIL PRESSURE

CONTROL CIRCUIT OIL
PRESSURE
Measuring
ALower the work equipment to the ground and
stop the engine. Loosen the oil filler cap slowly
Then set the safety lock lever to the LOCK posi-
tion.
1) Remove circuit pressure measurement plug

(I) and install oil pressure gauge Cl (5.8
MPa {60 kg/cm*}).
2) Start the engine and measure with the en-

gine at full throttle.
ElLPO2143
20- 120
0
TESTING AND ADJUSTING TESTING SOLENOID VALVE OUTPUT PRESSURE
TESTING SOLENOID VALVE

OUTPUT PRESSURE
Measuring
Ir Hydraulic oil temperature when measuring:
45 - 55°C
1. Measuring output pressure of LS-EPC solenoid
valve
1) Disconnect output hose (I) of the LS-EPC
solenoid valve, then use adapter C3 in the
oil pressure gauge kit to install oil pressure
gauge Cl (5.9 MPa I60 kg/cm*)).
2) Measure the output pressure under the con-
ditions in Table 1.
Table 1
l H/O mode or
G/O mode
l Travel circuit at Min , 9e0
. I 0 101
neutral, any
work equipment
lever is operated
* Monitoring code 10 or 40 for engine speed

Monitoring code 15 for LS-EPC current
2. Measuring output pressure of ON/OFF solenoid

va Ive
1) Disconnect outlet hose (2) of the solenoid
valve,. then use adapter C3 in the oil pres-
sure gauge kit to install oil pressure gauge
Cl (5.9 MPa 160 kg/cm*}).
2) Measure the output pressure under the con-
ditions in Table 2.
20- 122
0
TESTING AND ADJUSTING TESTING SOLENOID VALVE OUTPUT PRESSURE
Table 2
Name of Condition
of Oil pressure Remarks
Measurement conditions Operating conditions
solenoid solenoid (MPa{ka/cm21)
Swing or work equipment lever Brake canceled
Swing ooerated
1 brake
solenoid All levers except travel at neutral Brake actuated OFF 0 (01
- (5 set after returning to neutral)
Travel speed switch at Hi or Mi Min. 2.7 Motor swash
Engine speed 1500 rpm or above Travel speed Hi ON (Min. 28} plate angle at
Travel Travel lever operated minimum
2 speed
solenoid Travel speed switch at Lo or engine Travel speed Lo Motor swash
OFF 0 {OI plate angle at
speed 1500 rpm or below maximum
Swing lock switch ON + work Pressure rise ON Min. 2.7
zi?fge equipment lever operated {Min. 281
3
solenoid All levers at neutral Normal pressure OFF 0 101
Min. 2.7
tNoJe 3, Active mode OFF Normal pressure ON (Min. 28)
4 Active
mode
solenoid Active mode ON Active mode OFF 0 (0)
Flow from front Min. 2.7

Pump Travel operated independently and rear pumps ON (Min. 28) LS pum
divided merge- d!.lvlder
5 ;v”i’d9e”; Flow from front valve actuated
solenoid Lever at neutral, or boom, arm, at same time
and rear pumps OFF 0 (0)
bucket operated independently meraed
* Operation of solenoid valve

ON: Continuous (oil pressure generated)
OFF: Not continuous (oil pressure: 0)
* Check at the same time that the solenoid is switched ON/OFF electrically with monitoring code 23.
* The measurement conditions in the table show the typical conditions for measuring the output
pressure.
Ir The solenoid valve may be actuated (ON/OFF) even under conditions not listed for the measure-
ment condition.
A When operating the levers, operate them slightly (not enough to make the machine move).
20-123
0
TESTING AND ADJUSTING MEASURING PPC VALVE OUTPUT PRESSURE
MEASURING PPC VALVE

OUTPUT PRESSURE
(STDI
1. Measuring PPC valve output pressure

1) Disconnect hose (I) ofthe circuit to be meas-
ured.
2) Install adapter C3 between hose (1) and el-
bow (2).
3) Install oil pressure gauge Cl (5.9 MPa {SO
kg/cm*}) to adapter C3.
4) Run the engine at full throttle, operate the
control lever of the circuit to be measured,
and measure the oil pressure.
:.
x If the output at the control valve end is low,
measure the input pressure of the PPC valve.
If it is normal, there is defective actuation of
the PPC valve.
8
t
%
20-124
0
TESTING AND ADJUSTING MEASURING PPC VALVE OUTPUT PRESSURE
Pressure switch piping diagram

Interruption block seen from rear of machine
Arm OUT switch 0

(CN-SO31
Arm IN switch
_ _’ &N-S031
I I
Travel switch _
(CN-SO 1)
Right swing switch
I I (CN-Sl O)
k
Bucket DUMP switch
(CN-SO71
Boom RAISE
(CN-SO21
Bucket CURL switch
(CN-SO71
Left swirls SW
(CN-S IO)
Boom LOWER switch
(CN-SO21
Interruption block
r --a
Arm OUT
------------I
Arm
------------+ IN 7
P Travel signal :
------------+
[
Right Swing :
-__-________I
_Bu_cket_D_U_M_P_j
Boom RAISE:
------------+
Bucket
------------+ CURL 7
Swing LEFT
--------------A r
TKP00743
ZO-125
0
MEASURING EPC SOLENOID VALVE OUTPUT PRESSURE
TESTING AND ADJUSTING AND CHECKING EPC SHUlTLE VALVE
MEASURING EPC SOLENOID

AND CHECKING EPC SHUTTLE
VALVE
(HYPER specification)
* The PPC hose became different after the peri-
odic modification, but the content of the opera-
tion is the same.
Ir Oil temperature when measuring: 45 - 55°C
1. Measuring EPC solenoid valve output pressure BLPO21 48

1) Disconnect hose (I) of the circuit to be meas-
ured.
2) Install adapter C3 between hose (I) and el-
bow (2).
3) Install oil pressure gauge Cl (5.9 MPa I60
kg/cm*}) to adapter C3.
4) Run the engine at full throttle, operate the
control lever of the circuit to be measured,
and measure the oil pressure.
20-126
0
MEASURING EPC SOLENOID VALVE OUTPUT PRESSURE
TESTING AND ADJUSTING AND CHECKING EPC SHUTTLE VALVE
Pressure switch piping diagram

Shuttle block seen from rear of machine
Arm IN SW
(CN-SO31
Swina RIGHT SW
(CN-SOB)
Bucket DUMP SW
(CN-S07)
Bucket CURL SW
(CN-S07)
Swing LEFT SW
(CN-SOB)
O -Boom LOWER SW
I-L- (CN-SO'21
Relay block
ravel sianali
------------,
Bucket CURL i
I I
r-T-- I
TKP00744
20-127
0
TESTING AND ADJUSTING ADJUSTING WORK EQUIPMENT. SWING PPC VALVE
ADJUSTING WORK
EQUIPMENT lSWING PPC
VALVE
* If there is excessive play in the work equipment

or swing lever, adjust as follows.
stop the ennine. Loosen the oil filler cap slowly
Then set the safety lock lever to the LOCK posi-
tion.
1. Remove the PPC valve.

2. Remove boot (I).
3. Loosen locknut (21, then screw in disc (3) until it
contacts the 4 heads of piston (4).
* When doing this, do not move the piston.
4. Screw disc (3) in position, then tighten locknut
(2) to the specified torque.
w Locknut: 107.8 f 9.8 Nm 111 + 1 kgm}
5. Install boot (I).
* With the above adjustment, the clearance
between disc (3) and piston (4) becomes 0.
BLPOO154
20-128
0
TESTING AND ADJUSTING TESTING TRAVEL DEVIATION
TESTING TRAVEL DEVIATION
* When traveling on level ground. Travel Posture

1. Set the machine in the travel posture.
Ir For the travel posture, extend the bucket and
arm cylinder rods fully, and hold the boom
angle at 45”.
2. Travel for 10 m, then measure the deviation A
when traveling for the next 20 m.
* Set to H/O mode and measure with the en-
gine at high idling.
* Install the hydraulic pressure gauge and
measure the pump discharge pressure at the
TOP00328
same time.
Make a mark Make a mark at the Make a mark

10m midway Point
0
Lay out a string 10m midway Point _I
\ I
M?--~ark Mark
Measure the amount of
distance A at this Point
TEP00329
20-129
0
TESTING LOCATIONS CAUSING
TESTING AND ADJUSTING HYDRAULIC DRIFT OF WORK EQUIPMENT
TESTING LOCATIONS CAUSING HYDRAULIC DRIFT OF WORK

EQUIPMENT
* If there is any hydraulic drift in the work equip-
ment (cylinders), check as follows to determine
if the cause is in the cylinder packing or in the
control valve.
1. Checking for defective cylinder packing
I) Checking boom and bucket cylinders
i) Set in the same posture as when meas-
uring hydraulic drift, and stop the en-
gine. \ /
ii) Operate the boom control lever to RAISE
/
/////////////////
or the bucket control lever to CURL.
. If the lowering speed increases, the
TDP00333
packing is defective.
. If there is no change, the boom hold-
ing valve (boom) or the control valve
(bucket) is defective.
2) Checking arm cylinder
i) Operate the arm cylinder to move the
arm in fully, then stop the engine.
ii) Operate the control lever to arm IN.
. If the lowering speed increases, the
packing is defective.
. If there is no change, the control
valve is defective.
* If the pressure in the accumulator
has dropped, run the engine for
approx. 10 seconds to charge the BKP00159
accumulator again before operating.
[Reference] If the cause of the hydraulic drift is
in the packing, and the above op-
erations is carried out, the down-
ward movement becomes faster for
the following reasons.
1) If the work equipment is set to the above
posture (holding pressure applied to the bot-
tom end), the oil at the bottom end leaks to
the head end. However, the volume at the
head end is smaller than the volume at the
bottom end by the volume of the rod, so the
internal pressure at the head end increases
because of the oil flowing in from the bot-
tom end.
2) When the internal pressure at the head end
increases, the pressure at the bottom end
also rises in proportion to this. The balance
is maintained at a certain pressure (this dif-
fers according to the amount of leakage) by
repeating this procedure.
3) When the pressure is balanced, the down-
ward movement becomes slower. If the le-
ver is then operated according to the proce-
dure given above, the circuit at the head
end is opened to the drain circuit (the bot-
tom end is closed by the check valve), so
the oil at the head end flows to the drain
circuit and the downward movement be-
comes faster.
20-130
a
TESTING LOCATIONS CAUSING
TESTING AND ADJUSTING HYDRAULIC DRIFT OF WORK EQUIPMENT
2. Checking boom holding valve

g Set the work equipment at the maximum reach,
and the top of the boom horizontal, then stop
the engine.
Lock the work equipment control levers and re-
lease the pressure inside the hydraulic tank.
ATo prevent danger, never stand under the work
equipment.
1) Disconnect pilot hose (I) of the boom hold-
ing valve, and install a blind plug in the
hose.
* Blind plug: 07376-50315
Ir Leave the boom holding valve end open.
* If any oil leaks from the port that is left
open, the boom holding valve is defec-
tive.
3. Checking PPC valve

If the hydraulic drift differs when the safety lock
lever is in the LOCK or FREE position, (engine
running), the PPC valve is defective.
20-131
0
TESTING AND ADJUSTING MEASURING OIL LEAKAGE
MEASURING OIL LEAKAGE
* Hydraulic oil temperature when measuring: Posture for measuring boom cylinder
45 - 55°C
1. Work equipment cylinder
* If the hydraulic drift of the work equipment is
outside the standard value, measure the leak-
age inside the cylinder as follows, and judge if
the cause of the hydraulic drift is in the cylinder
or in the control valve.
. If the leakage is with in the standard value,
the problem is in the control valve.
. If the leakage is greater then the standard
A TEP00334
value, the problem is in the cylinder.
1) Fully extend the rod of the cylinder to be
measured, then stop the engine.
Posture for measuring arm. bucket cylinder
2) Disconnect piping (I) at the head end, then
block the piping at the chassis end with a
blind plug.
ABe careful not to disconnect the piping
at the bottom end.
3) Start the engine and apply the relief pres-
sure to the bottom end of the cylinder with
the engine at high idling.
4) Continue this condition for 30 seconds, then
measure the oil leakage for the next one
minute.
TEP00335
Arm cylinder
TLP00746
20-132
0
TESTING AND ADJUSTING MEASURING OIL LEAKAGF
Bucket cylinder
I TLP00747
Disconnect
20-133
0
MEASURING OIL LEAKAGE
TESTING AND ADJUSTING RELEASING REMAINING PRESSURE IN HYDRAULIC CIRCUIT
2. Swing motor
1) Disconnect drain hose (I) from the swing
motor, then fit a blind plug at the tank end.
2) Set the swing lock switch ON.
3) Start the engine and operate the swing re-
lief with the engine at high idling.
minute.
Ir After measuring, swing 180” and measure
again.
3. Travel motor
1) Disconnect drain hose (2) from the travel
motor, then fit a blind plug at the hose end.
2) Fit block 0 under the track shoe grouser, or
fit block @ between the sprocket and frame
to lock the track.
3) Start the engine and operate the travel relief
with the engine at high idling.
A When measuring the oil leakage from
the travel motor, mistaken operation of
the control lever may lead to a serious
accident, so always use signals and check
when carrying out this operation.
minute.
Ir When measuring, move the motor slightly
(to change the position between the valve
plate and cylinder, and piston and cylinder),
and measure several times.
RELEASING REMAINING
PRESSURE IN HYDRAULIC
CIRCUIT
Ir If the piping between the hydraulic cylinder and
BLPOO170 BLPOO171
the control valve is disconnected, release the
remaining pressure from the circuit as follows.
The travel ciucuit is an open circuit, so there is
no remaining pressure. It is enough to remove
the oil filler cap.
1. Loosen the oil filler cap slowly to release the
pressure inside the tank.
2. Operate the control levers.
* When the levers are operated 2 - 3 times,
the pressure stored in the accumulator is
removed.
3. Start the engine, run at low idling for approx. 5
minutes, then stop the engine and operate the
control levers.
Ir Repeat the above operation 2 - 3 times to
release all the remaining pressure.
20-134
0
TESTING AND ADJUSTING TESTING CLEARANCE OF SWING CIRCLE BEARING
TESTING CLEARANCE OF
SWING CIRCLE BEARING
1
Method of testing clearance of swing circle bearing
when mounted on machine
1. Fix a magnet-type dial gauge to the outer circle
(or inner circle) of the swing circle, and put the
tip of the probe in contact with the inner circle
(or outer circle). frame
Set the dial gauge at the front or rear.
Di al gauge
TEP00339
2. Extend the work equipment to the maximum

reach, and set the tip of the bucket to the same
height as the bottom of the revolving frame.
When this is done, the upper structure will tilt
forward, so the front will go down and the rear
will rise.
3. Set the dial gauge to the zero point.
BKPO0173
4. Set the arm more or less at right angles to the

ground surface, then lower the boom until the
front of the machine comes off the ground.
When this is done, the upper structure will tilt
back, so the front will rise and the rear will go
down.
5. Read the value on the dial gauge at this point.

The value on the dial gauge is the clearance of
the swing circle bearing.
A When carrying out the measurement, do not

put your hand or feet under the undercarriage.
BKPO0174
6. Return to the condition in Step 2, and check that

the dial gauge has returned to the zero point. If
it has not returned to the zero point, repeat Step
2 to 5.
20- 135
0
TESTING AND ADJUSTING TESTING AND ADJUSTING TRACK SHOE TENSION

TRACK SHOE TENSION
TESTING
1. Raise the track frame using the arm and boom,
and measure the clearance between the bottom
of the track frame and the top of the track shoe.
l Clearance: 303 + 20 mm
Measurement position 0
PC200, 210 : 4th track roller from the
sprocket.
PC2OOLC, 210LC: 5th track roller from the
sprocket.
PC220, 230 : Midway between the 4th and
5th track roller from the a
BLW0175
sprocket.
PC22OLC, 230LC: Midway between the 5th and
6th track roller from the
sprocket.
ADJUSTING
Sr If the track shoe tension is not within the stand-
ard value, adjust as follows.
1 . When the tension is too high:
Loosen plug (I) gradually, and release the
grease.
AThere is danger that the plug may fly out
under the high internal pressure of the
grease, so never loosen plug (I) more than BLP02156
1 turn.
Ir If the grease does not come out easily, move
the machine backwards or forwards slowy.
2. If track is too loose:

Pump in grease through grease fitting (2).
* If the grease cannot be pumped in easily,
move the machine backwards and forwards
slowly.
20- 136
0
TESTING AND ADJUSTING BLEEDING AIR
BLEEDING AIR
Order for operation and porocedure for bleeding air
Air bleeding procedure
1 2 3 4 5 6 7
Bleeding Bleeding
Bleeding Bleeding Between EPC
Start air from air from Start
air from air from solenoid -
engine swing travel operations
pump cylinder control valve
motor motor
* Replace hydraulic oil
* Clean strainer 0 -+ 0 -+ 0 -+ 0 -+ 0 -+ 0
(Note11 (Notell
* Replace return filter element 0 > 0

* Replace, repair pump
l Remove suction piping
0 -+ 0 -+ 0 ) 0
+ Replace, repair control valve

O L O I I I) O I
* Replace cylinder
- Remove cylinder piping 0 -+ 0 ’ 0
* Replace swing motor
* Remove swing motor piping 0 > 0 + 0
. Replace travel motor, swivel
* Remove travel motor, swivel piping 0 ) 0 -+ 0
l Replace EPC solenoid (For HYPER) 0 ) 0

Note 1: Bleed the air from the swing and travel motors only when the oil inside the motor case has been drained.
1. Bleeding air from pump

1) Loosen air bleed plug (I), and check that oil
oozes out from the plug.
2) When oil oozes out, tighten plug (1).
w Plug:
17.15 f 2.45 Nm Il.75 f 0.25 kgml
* If no oil oozes out from the air bleed plug:
3) Leave plug (I) loosened and remove hose
(2) and elbow (3).
4) Pour in oil through the elbow mount hole
until oil oozes out from plug (I).
5) Fit elbow (3) and install hose (2).
6) Tighten air bleed plug (I).
w Plug: k------ BLPO2157
17.15 f 2.45 Nm (I.75 + 0.25 kgm1

* Precautions when staring the engine
After completing the above procedure and
starting the engine, run the engine at low
idling for 10 minutes.
* If the coolant temperature is low and auto-
matic warming-up is carried out, cancel it by
using the fuel control dial after starting the
engine.
ELPO2158
20- 137
0
2. Bleeding air from hydraulic cylinders

1) Start the engine and run at idling for approx.
5 minutes.
2) Run the engine at low idling, then raise and
lower the boom 4 - 5 times in succession.
+ Operate the piston rod to approx. 160
mm before the end of its stroke. Do not
relieve the circuit under any circum-
stances.
3) Run the engine at full throttle and repeat
Step 2). After that, run the engine at low
idling, and operate the piston rod to the end
of its stroke to relieve the circuit.
4) Repeat Steps 2) and 3) to bleed the air from
the arm and bucket cylinders.
* When the cylinder has been replaced, bleed
the air before connecting the piston rod.
Be particularly careful not to operate the cyl-
inder to the end of its stroke when the pis-
ton rod has been connected to the LOWER
end of the boom cylinder.
Bleeding air from hydraulic cylinders

(HYPER GX specification)
I) Turn the starting switch off, then set auto-
matic operation disconnection switch (I) to
the DISCONNECT position.
2) Turn the starting switch ON again.
3) Start the engine and run at idling for approx.
5 minutes.
4) Run the engine at low idling, then raise and
lower the boom 4 - 5 times in succession.
j, Operate the piston rod to approx. 100
mm before the end of its stroke. Do not
relieve the circuit under any circum-
stances.
5) Set to governor adjustment mode (engine at
BLPO2159
full throttle) and repeat Step 4). After that,
run the engine at low idling, and operate the
piston rod to the end of its stroke to relieve
the circuit.
6) Repeat Steps 4) and 5) to bleed the air from
the arm and bucket cylinders.
* When the cylinder has been replaced, bleed
the air before connecting the piston rod.
Be particularly careful not to operate the cyl-
inder to the end of its stroke when the pis-
ton rod has been connected to the LOWER
end of the boom cylinder.
* When the starting switch is turned OFF and
the automatic operation disconnection switch
is turned to AUTOMATIC OPERATION, it acts
as the GX function.
20-138
0
3. Bleeding air from swing motor

1) Run the engine at low idling, loosen air bleed
plug (I), and check that oil oozes out.
* If no oil oozes out from the air bleed plug:
2) Stop the engine, and pour oil into the motor
case from plug (1).
3) Tighten air bleed plug (I).
m Plug : 166.6 f 19.6 Nm (17 f 2 kgm}
4. Bleeding air from travel motor

Run the engine at low idling, loosen air bleed
plug (21, and when oil flows out, tighten the
plug again.
5. Bleeding air between EPC solenoid valve and

control valve
(HYPER, HYPER GX specification)
When the EPC solenoid has been replaced or
removed and installed again, bleed the air from
the circuit as follows.
I) Preparatory work
i) With the starting switch at the OFF posi-
tion before starting the engine, turn the
GX automatic operation disconnection
switch to the OFF position.
Ir HYPER GX specification only
ii) Start the engine.
iii) Turn the swing lock switch to the LOCK
position.
iii) Operate the panel and set to the gover-
nor adjustment mode.
* For details, see TESTING AND AD-
JUSTING, Testing and adjusting gov-
ernor motor stroke.
* If this mode is used, the EPC output
voltage is kept to a maximum of IA.
2) Operation
Work equipment circuit
Operate the control lever slowly to oper-
ate the hydraulic cylinder to the end of
its stroke, then operate the control lever
slowly to the end of its stroke.
Swing circuit
The swing is locked in Step l)-iii), so
operate the control lever slowly to the
end of its stroke.
20-139
0
TESTING AND ADJUSTING INPUT/OUPUT STRUCTURE OF GX CONTROLLER
INPUT/OUPUT STRUCTURE OF GX CONTROLLER
1. Output structure diagram

Network system
sensors r- -_
-- --
Pump controller
(boom. arm)
Potent iometersxl
(boom. arm)
Pressure sansorsX8
(boom. arm. bucketXbottom/head;

sninaXrisht/left)
T I A Knob switch
’4
Model
wirino
harness
~~iA&connection
1
L- _/
ON/OFF inout/output system
TLP00748
2. Mounting position of components
Arm anale sensor
GX controller
Bucket CY Ii nder
stroke sensor
GX automatic ooeration
disconnection switch
Chassis anale sense
TLP00749
zo- 140
0
TESTING AND ADJUSTING BASIC OPERATION AND GX FUNCTION
BASIC OPERATION AND GX FUNCTION

1. Basic operation
The GX controller receives the switch signals from the GX panel and the signals from the sensors.
It then selects the GX function and carries out calculation, and sends the EPC output current data
to the valve controller. It acts to control the work equipment by carrying out automatic operation of
the work equipment, such as automatic grading and cutting angle retention, by restricting the
movement of the work equipment by using an electronic cushion and setting the working range,
and by suppressing the vibration of the boom and swing. It also sends the bucket edge position
and posture data to the GX panel and displaying it (cutting edge monitor).
r GX controller
EPC current
Switch ---------________ ,------------ ,------------
/ : I I
__?puf___, ---I! Education :--)I c-o-:man-oLjZ~
I selection , , Control i--C
I I
Output j---
I________________b ’ I II value :
;
I
I
I
I I
________.-_.----_
’
1
:
I
I
I
I EPC current /
I I
--{ Display data i&--i Calculation/

1 ,Replay /
8
‘____________1I1____________1
4____________..___I
Cutting edge
monitor data A
Work equipment posture, [

pressure data
/ Sensor 1
(Reference)
The reception of the data for the GX controller and GX panel is carried out by the general network
communication (S-NET); the reception of the data for the GX controller and valve controller is
carried out by the special high speed network communication (HS-NET).
2. GX function
GX function Role
This displays the horizontal and perpendicular distance between the bucket cutting
Cutting edge monitor edge and the chassis, and the angle of the bottom of the bucket to the ground.
This saves the data for the cutting edge position at the desired position and sounds
Digging depth alarm
a buzzer when the cutting edge goes below the value in memory.
Electronically cushioned This detects the work equipment angle and,controls the output to throttle the lever
cylinder signal in proportion to the distance from the end of stroke.
This obtains the boom vibration (acceleration) from the cylinder pressure sensor
Boom rock prevention
and suppresses the residual vibration after the lever is operated.
This obtains the swing vibration (acceleration) from the cylinder pressure sensor
Swing back prevention
and suppresses the residual vibration after the lever is operated.
This automatically controls the bucket so that the angle of the bucket to the ground
Cutting angle retention
is kept constant while the knob switch is being operated.
This automatically controls the boom, arm and bucket so that the cutting edge
Automatic grading
moves in a straight line while the knob switch is being operated.
This savesthe data for the areas prohibitedfor operationin the height,depth, and reachdirections,
Working range selection
and throttlesthe leversignalwhen the work equipmentapproachesthe prohibitedarea.
Note: When operating knob switch, double click the switch (press the knob twice quickly)
20-141
0
TESTING AND ADJUSTING BASIC OPERATION AND GX FUNCTION
3. GX function combination table
O.... Combination can be selected.

n .. . .Newly selected function has priority (function now in use is automatically turned off)
X .. .. New function cannot be selected (buzzer gives 3 short beeps, setting cannot be made)
x .. . .Function that are being automatically operated with the knob switch are automatically switched
to the heavy-duty operation mode with the deceleration off. (LED stays as it is)
(When using the cutting angle retention, the system also switches to swing boost speed 2.)
a... During automatic operation with the knob switch, the electronically cushioned cylinder stops
working.
@ . . . During automatic operation with the knob switch, the swing back/boom rock prevention function
stops working.
@ . . . When a HYPER function is in use, the swing back/boom rock prevention function stops working.
a) The functions can be divided into two types: independent selection functions (which can be
selected regardless of other function) and exclusive selection functions (which cannot be used in
combination with other functions)
Independent selection -Cutting edge monitor, digging depth alarm, electronically cushioned cylinder,
functions swing back/ boom rock prevention
Cutting angle retention, automatic .......... these all require exclusive use of the
grading, vibration mode, teaching knob switch, so cannot be used
I Exclusive selection playback together.
functions
1 Working range selection .......... The caluculating and processing takes a long
time, so they connot be used together with
other functions.
b) When exclusive selection functions are selected in combination, the newly selected function is
given priority and the function being used is turned off.
The working range selection is the only exception to this: It cannot be canceled by selecting a
different function. (This is to prevent any danger of the prohibited working area being canceled if
the operator selects another function by mistake.)
c) With the GX functions and the exclusive HYPER functions, if one type has already been selected,
the other type cannot be selected. (This is due to hardware restrictions.)
20-142
0
TESTING AND ADJUSTING SPECIAL FUNCTIONS ON GX PANEL (BACKGROUND MODE)
SPECIAL FUNCTIONS ON GX PANEL (BACKGROUND MODE)
l The following four modes are available as background modes that can be operated from the GX
panel.
l These modes are all operated by switching the functions of the panel switches as shown in the
diagram below.
r
GX monitoring mode ......... This mode displays the internal data in the GX
controller (sensor signals or set values for
attachment).
-GX adjustment mode ......... This mode is used for setting the model and
attachment or for correcting the sensor and EPC
valve.
Note: The GX controller overwrites the data in
GX panel background mode the nonvolatile memory, so read the
operating procedure carefully before
carrying out the operation.
Bucket code set mode ...... .. If the user changes the bucket, this mode is used
to set the bucket code. It is the only background
mode made freely available to the user.
I-
IGX error display mode ...... This mode displays the sub-categories of errors
in the GX controller. The main categories of
errors are displayed on the HYPER monitor. For
details, see TROUBLESHOOTING.
. Normal position of switches and method of reading GX panel
lol TLP00750
. Change the function switches as follows to use in the background mode.
SET UP DOWN
CLEAR SHIFT TLP00751
20-l 43
0
1. GX monitoring mode
Operation Display
1. To move to the GX monitorina mode:

SET UP DOWN
1) Press the m+IQ switches for at leas1
3 seconds.
. When the system changes to the
monitoring mode, the buzzer sounds,
the display switches to the display
on the right, and only the “d” dis-
play flashes.
l The “d” display indicates the moni-
toring mode.
CLEAR SHIFT
\I/
u Display number
Shows GX monitoring mode
Flashes
TLP00752
2) To go onto the next monitoring number

(display number), press the m switch.
% For details of each monitoring number
(display number), see the monitoring
mode display data table. I I
Display number
3) To go back to the previous monitoring
TLP00753
number (display number), press the
vl switch.
4) To display the data inside the monitor-
ing number (display number), press the
m switch. Display pattern for data inside display number
* The data inside the display number

is displayed while the (SETI switch is
i-1
.
being pressed.
If m+H switches are pressed, the
data inside the display number is held
(display) even when the switches are IL t- C Units
B 10s
released. L A 100s
sr When the m or -1 switches

Example of display:
are pressed, the display moves on to Display of data for monitoring No.bO2
the next item or back to the previous
item, and the data being displayed is
canceled.
* Example of display: d02 code for
domestic and overseas specification I shows standard bucket
and attachments (arm, bucket) I shows standard arm
2. To finish and exit the GX monitoring mode, 0 shows domestic specification
carry out the same operations as when mov-
TLP00754
ing to the GX monitoring mode.
20-144
0
GX panel monitoring No. and display data
Jlonitor
No.
- T Setting 1
Content of data
AtlOOs)
Monitoring display data
200: PC200 (GX controller)

B(l0.s) C(units)
% The model or 1 is
1
(PCPOO/observation controller) 1: Observation controller displayed
-
1: Standard bucket
2: Different width
bucket A
Setting 2 1: Japan 1: Standard arm 3: Different width
2 (overseas code/arm attachment/ specification 2: Optional arm bucket B
bucket attachment) 2: Overseas 4: Slope finishing
specification bucket
5:Trapezoidal buckei
6: Ditch bucket
8: Custom bucket
-
GX controller internal mode 0: GX controller 0: Valve controller 0: No monitor panel
(option disconnection switch, valve available output possible error display
3 controller stop, monitor E07 1: GX controller 1: Valve controller all 1: Monitor panel E09
display) disconnected stop display
-
Input signal 1 0: GX controller 0: GX controller
(model, observation wiring har- OPEN disconnected
4
ness, option disconnection switch) 1: PC200 1: Observation 1: GX controller
controller GND available
-
Input signal 2 (Note 2) 0: Radio control not 0: Radio control 0: J/S mode
(Radio control, radio control mode, available switch 0FF”OV”
5 vector mode) 1: Radio control 1: Radio control 1: Vector mode
available switch ON”24V”
-
Input signal 3 0: Starting switch 0: Knob switch 0: Double click not
6 (starting switch, knob switch, OFF 0FF”OV” available
double click) 1:Starting switch ON 1: Knob switch ON”24V 1: Double click OK
-
Output signal 0: No display data 0: Remote prohibited 0: Radio control
(no display, remote output, radio “OV” prohibited(Note 2)
7
control output)(Note 2) 1: Remote permitted 1: Radio control
“24V” permitted(Note 2)
-
Internal judgement 0: Not stroke end 0: Lever switch OFF
8 (bucket stroke end, lever switch 1: Near stroke end 1: Lever switch ON
input)
-
Sensor 0 point pass D:Boom 0 point D:Arm 0 point 0: Bucket 0 point
9 (boom, arm, bucket) before correction before correction before correction
1: Boom 0 point pass 1: Arm 0 point pass 1: Bucket 0 point pass
- -
Note 1: Unit: When IO.02 degl displays 1, it indicates iO.02 degl.

Note 2: Dispaly input signal 2 and output signal indicate machines with radio control specification.
Note 3: When GX operation is disconnected, GX monitoring mode does not function.
BKP02314
20-145
0
Boom potentiometer stroke end

4 deviation IO.02 degl
dl
5 Arm encoder angle [degl
(accuracy + 1 deg)
6 Arm potentionmeter voltage

15 mV1 (accuracy f 40 mV)
7 Arm prolix deviation

IO.02 degl
8 Arm encoder stroke end deviation

LO.02 degl
g Arm potentiometer stroke end

deviation LO.02 degl
Bucket angle [deg]

’ (accuracy f 2 deg)
Bucket stroke length

’ 12 mm1
2 Bucket stroke compensation 1

10.5 mm]
Bucket stroke compensation 2

3 lo.5 mm1
4 Boom stroke length, stroke end

deviation IO.5 mm]
d2
5 Chassis tilt (rear of filter) [deg]
(accuracy + 2 deg)
6 Chassis tilt (voltage) 15 mV]

(accuracy f 40 mmV)
Deviation from chassis tilt 0”

7 IO.02 degl
Deviation from chassis tilt 10”

* LO.02 degl
Deviation from chassis tilt -10”

’ LO.02 degl
Note: When GX operation is disconnected, GX monitoring mode does not function.
20-146
0
Jlonitor Monitoring display data

Content of data
No. A(lOOs) B(lOs) C(units)
Boom bottom pressure

0 [MPa ~kg/cm*ll
(accuracy f 2.5 MPa {26 kg/cm*})
-
Boom head pressure
1 [MPa {kg/cm211
-
Arm bottom pressure
2 [MPa {kg/cm*11
(accuracy + 2.5 MPa {26 kg/cm*))
Arm head pressure

3 [MPa {kg/cm*11
Bucket bottom pressure

4 [MPa {kg/cm*11
(accuracy -+ 2.5 MPa I26 kg/cm*})
Bucket head pressure

5 [MPa (kg/cm*11
(accuracy f 2.5 MPa 126 kg/cm*})
Right swing pressure

6 IMPa Ikg/cm*ll
(accuracy + 2.5 MPa 126 kg/cm*))
-
Left swing pressure
7 IMPa {kg/cm*11
(accuracy + 2.5 MPa 126 kg/cm*11
Custom bucket dimension

Ll [cm]

61 fO.5 degl

62 iO.5 degl

63 LO.5degl

L2 [cm]

L3 [cm]
20-147
0
Monitoring display data

tionito
Content of data
No.
A(lOOs) BflOs) C(unitsI
- -
Corrected value for boom RAISE
0
starting current [mA]
-
Corrected value for boom LOWER
1
-
Corrected value for arm IN
2
starting current [mAI
-
Corrected value for arm OUT
3
starting current [mAl
-
Corrected value for bucket CURL
4
37 -
Corrected value for bucket DUMP
5
starting current ImA]
-
Corrected value for right swing
6
starting current [mAl
-
Corrected value for left swing
7
-
24V power source input voltage
8
WI (accuracy & 1 V)
-
24V power source output voltage
9
[VI (accuracy * 1 V)
- -
GX function prohibited l Boom l Arm l Bucket
6 (cushion: boom, arm, bucket) 0: Permitted 0: Permitted 0: Permitted
1: Prohibited 1: Prohibited 1: Prohibited
-
GX function prohibited l Height l Depth l Reach
7 (working range selection: 0: Permitted 0: Permitted 0: Permitted
height, depth, reach) 1: Prohibited 1: Prohibited 1: Prohibited
-
f6 GX function prohibited l Boom rock l Swing back l Digging depth
(boom rock prevention, prevention prevention alarm
8
swing back prevention, 0: Permitted 0: Permitted 0: Permitted
digging depth alarm) 1: Prohibited 1: Prohibited 1: Prohibited
-
GX function prohibited l Cutting angle l Fully automatic l Radio control
(cutting angle retention, retention grading 0: Permitted
9
fully automatic grading, 0: Permitted 0: Permitted 1: Prohibited
radio control) 1: Prohibited 1: Prohibited
- -
20-148
0
2. GX adjustment mode
Operation Display
I) To set to the GX adjustment mode: SET UP DOWN

i) Check that all the automatic modes
on the HYPER monitor are OFF and
that the LEDs corresponding to GX
panel numeric switches 1 to 8 and
the m switch are out (the switch
is OFF).
ii) Press the fl+m switches for at least
3 seconds, and when the buzzer
sound, press the m switch within
1 second.
. When the system switches to the
GX adjustment mode, the display
changes to the display given on
the right, the [cl display flashes,
and the last two digits are free
for the code to be input. I Adjustment code
* The [cl display indicates the GX C indicates the GX adjustment mode
adjustment mode. The flashing indicates that it is
Possible to input the code
TLP00755
2) To carry out setting and adjustment:

i) Input the operation code correspond- \ I I
ing to numeric switches 1 to 8 in the
diagram on the right, then press the
~ switch.
. The relationship between the opera-
tion and the input code is shown on
the following pages.
% Example of input code display
(When changing to a slope finishing CLEAR SH I FT
bucket) Input 34
The [cl is flashing, so input @I to the
right, and press the m switch.
* If a mistake is made in the input code,
press the (CLEAR) switch before
pressing the ISET/ switch to return (Light UP for 2 seconds
when input is received)
to the original display, then input the
correct code.
Note: If the input is prohibited, the buzzer
will give 3 short beeps. If this hap-
pens, see “Reasons for prohibition
and action to take when input is
prohibited in GX adjustment Press SET / I \
mode”. Returns to orialnal
flashing display
TLP00756
-
zo- 149
0
Operation Display
2) To save input data:

. Input C q with the numeric switches
then press the m switch.
. [cl lights up for 2 seconds (writins
data). The new data is automatically
saved and the screen exits the G>c
adjustment mode.
% After saving the data, turn the start.
ing switch OFF, then turn it ON agair
to load the data that was saved.
4) To exit the GX adjustment mode with-
out saving the data, carry out the same
operation as when entering the GX ad-
justment mode.
20-150
0
Table for order of operations in GX adjustment mode
Order of operations
Nature of operation Remarks
(see the following pages for details ofeach item)
When replacing bucket 1. Set to GX adjustment mode [Operation Al

(2. Input dimensions of bucket) [Operation Ll Order 2 on left is only for
3. Input bucket code [Operation Dl custom bucket
4. Save data [Operation Ql
When replacing clinometer 1. Set to GX adjustment mode [Operation Al Instead of the operation in
When replacing boom 2. Pass sensor 0 point [Operation El Item 3 on the left, operate
angle sensor assembly 3. Correct clinometer [Operation Fl each sensor (H, J, and K).
When replacing arm angle (3. Adjust when replacing (When carrying out
sensor assembly boom angle sensor) [Operation HI operations at same time,
When replacing bucket (3. Adjust when replacing arm follow order F + H + J + K
stroke sensor or bucket angle sensor) [Operation Jl
cylinder assembly (3. Adjust stroke sensor) [Operation Kl
4. Save data [Operation Qj
When replacing control 1. Bleed air from EPC valve, spool [Operation M:
valve spool
When replacing EPC valve 2. Set to GX adjustment mode [Operation Al When not replacing the
3. Pass sensor 0 point [Operation El swing EPC valve or swing
4. Correct current for spool, EPC spool, carry out only
valve [Operation Nl Operation 0 (Correct current
5. Save data [Operation 01 for spool, EPC valve other
6. Set to GX adjustment mode [Operation Al than swing) instead of
7. Learning mode for swing back Operations N, Q, A, P on the
prevention [Operation PI left.
8. Save data [Operation 01
When replacing boom 1. Set to GX adjustment mode [Operation Al

cylinder assembly 2. Pass sensor 0 point [Operation El
When replacing arm 3. Adjust boom angle sensor when When replacing the arm
cylinder assembly replacing controller [Operation Gl cylinder assembly, carry out
(3. Adjust arm angle sensor when Operation I instead of the
replacing controller) [Operation II operation on the left.
When replacing GX 1. Set to GX adjustment mode [Operation Al Before correcting the sensor,
controller 2. Input model [Operation Bl save the data for the model
3. Input arm code [Operation Cl and attachment.
4. Input bucket code [Operation Dl
6. Set to GX adjustment mode [Operation Al When correcting the sensor,
7. Pass sensor 0 point [Operation El follow the order on the left.
8. Correct clinometer [Operation Fl t When correcting the
9. Adjust boom angle sensor when boom angle, because the
replacing controller [Operation Gl clinometer signal is being
10. Adjust arm angle sensor when used.
replacing controller [Operation II
11. Adjust stroke sensor [Operation Kl
12. Adjust when replacing EPC valve [Operation Nl
13. Save data [Operation 01
14. Set to GX adjustment mode [Operation Al Carry out Operations A, P, Q
15. Learning mode for swing back only when the swing back
prevention [Operation PI prevention does not have the
16. Save data [Operation 01 proper effect.
20-l51
0
Reason for prohibition and action to take when input is prohibited in GX adjustment mode
(Use if the buzzer sounds three times and input cannot be carried out)
r-
1
Operation
When setting to GX
T Reason for prohibition
Automatic function on HYPER monitor has

Action
adjustment mode been selected . Turn automatic function OFF

(buzzer sounds but input Automatic function on GX panel has been
cannot be carried out) selected . Turn automatic function OFF
Abnormality has occurred in valve controller . Repair failure first
2 When setting model Non-available code has been selected . Input again
(code other than cl1 to ~14)
3 When setting arm Same as above (code other than ~21, ~22) . Input again
attachment
4 When setting bucket Same as above (code other than c31 to ~38) . Input again
attachment Note: When a bucket code not set for the model
is selected
(Input is permitted, but setting is made for
standard bucket)
5 When correcting
clinometer
(I) (When setting with . Boom, arm have not passed 0 point . Carry out Operation E
C41)
(2) (When teaching . Clinometer signal is far from horizontal . Adjust again. For details,
horizontal) (signal voltage is not within range of 2.6 - 3.4V) see Procedure for
replacing sensor
. Actual tilt input data is not within range of . Input again
-20 - +20 (-2.0 deg - + 2.0 deg)
(3) (When teaching +I0 0
Clinometer signal is in normal direction, and is . Adjust again. For details,
deg) far from 10 deg see Procedure for
(signal voltage is not within range of 3.6 - 4.4V) replacing sensor
.
Actual tilt input data is not within range of . Adjust again. For details,
80 - 120 (8.0 - 12.0 deg) see Procedure for
replacing sensor
6 Adjusting boom angle
sensor when replacing
controller
(I) (When setting with I
Boom, arm have not passed 0 point . Carry out Operation E
c51)
(2) (When teaching .
Potentiometer output is not near horizontal . Adjust again. For details,
horizontal) (signal voltage is not within range of 1.25 - 2.50 V) see Procedure for
replacing sensor
(3) (When teaching end .
Potentiometer output is not at end of RAISE . Adjust again. For details,
of RAISE stroke) stroke see Procedure for
(signal voltage is not within range of 3.10 - 4.70 V) replacing sensor
7 Adjusting when
replacing boom angle
sensor
(I) (When setting with .
Boom, arm have not passed 0 point . Carry out Operation E
~52)
(2) (When teaching end .
Potentiometer output is not at end of RAISE Adjust again. For details,
of RAISE stroke) stroke see Procedure for
(3) (When teaching .
Potentiometer output is not near horizontal . Adjust again. For details,
horizontal) (signal voltage is not within range of 1.25 - 2.50 V) see Procedure for
replacing sensor
-
ZO-152
0
r-
8
Operation
Adjusting arm angle

1 Reason for prohibition Action
sensor when replacing

controller
(1) (When setting with . Boom, arm have not passed 0 point . Carry out Operation E
~61)
(2) (When teaching . No prohibited condition -
perpendicular)
(3) (When teaching end . Potentiometer output is not near end of OUT . Adjust again. For details,
of OUT stroke) stroke see Procedure for
(4) (When teaching end . Potentiometer output is not near end of IN . Adjust again. For details,
of IN stroke) stroke see Procedure for
9 Adjusting when
replacing arm angle
sensor
(1) (When setting with . Boom, arm have not passed 0 point . Carry out Operation E
~62)
(2) (When teaching end . Potentiometer output is not near end of OUT . Adjust again. For details,
of OUT stroke) stroke see Procedure for
(3) (When teaching end . Potentiometer output is not near end of IN . Adjust again. For details,
of IN stroke) stroke see Procedure for
IO Adjusting bucket sensor

(c71)
(1) (When teaching end . Stroke sensor signal is not within 10 mm . Set properly to end of
of DUMP stroke) before end of bucket DUMP stroke stroke
(2) (When teaching end . Stroke sensor signal is not within 10 mm . Set properly to end of
of CURL stroke) before end of bucket DURL stroke stroke
II Inputting dimensions of . Input data is not within range of 0 to 250 . Input again
custom bucket (~77)
(when inputting data)
12 Correcting spool, EPC . Boom, arm have not passed 0 point . Carry out Operation E
valve current
(when setting ~81)
(when setting ~82)
(during automatic . Voltage when starting to move is not found . Check for abnormality,
correction) within determined range mistake in wiring of
pressure sensor, or bleed
air fully
13 In teaching mode for . Soft mode is not ON and mode is not finishing . Change mode
swing back prevention operation mode (PC200) or heavy duty
(when setting ~88) operation mode (PC120)
-
20-l 53
0
3. Adjustment procedure when replacing components or sensors
r Item
1 Posture of machine when correcting
Set to GX adjustment mode No connection
Setting model No connection
Setting arm code No connection
Setting bucket code No connection
End of boom RAISE stroke
Passing sensor 0 point
End of
TLP00757
Set the spirit level facing the front and rear on the top surface of
the revolving frame on the horizontal line of the work equipment
(the direction to jack up the chassis with the work equipment is
the + direction)
Correcting clinometer
Xl IsPirit leve
TLP00758
20- 154
0
Operation of panel or operation of machine (mportior Permissible

Remarks
indicates input operation or portion to be operated) value
HYPER monitor automatic functions:

automatic vibration, playback
GX panel automatic functions:

automatic grading,
- cutting angle retention,
cushion,
digging depth alarm,
working range selection,
boom rock prevention, swing
back prevention
i,jj ‘,‘*‘;!*, .~,i ~ J” ~“,“‘,,^‘ii?
@ When C flashes, #&$$Q:&~$& &:@$~~~,~ Cll: PC120 HYPER GX
(Example: When setting PC200 HYPER GX) C12: PC200 HYPER GX
After C lights up for 2 seconds, the C display - If a non-available code is set, the buzzer
flashes (waiting for next input). will sound 3 times and it will be impossi-
ble to carry out the input.
,, i:i j.ljj,,y #’ &.)%i’,p _I
0 When C flashes, .1~~~::.j,B,.:a,,,~~;:~~.~~~ C21: Standard arm
(Example: When setting standard arm) C22: Optional arm
After C lights up for 2 seconds, the C display - If a non-available code is set, the buzzer
flashes (waiting for next input). will sound 3 times and it will be impossi-
C31: Standard bucket

(Example: When setting standard bucket) C32: Different width bucket A
After C lights up for 2 seconds, the C display C33: Different width bucket B
flashes (waiting for next input). C34: Slope finishing bucket
C35: Trapezoidal bucket
C36: Ditch bucket
C38: Custom bucket
If a non-available code is set, the buzzer

will sound 3 times and it will be impossi-
@ When C flashes, ,~~-~~~ill~~,~,~‘~~~~~~, B With operation @ on the left, if the

The panel display changes to “411”. buzzer sounds 3 times and it is impossi-
ble to carry out the input, it means that
Operation E is not completed.
l When teaching horizontal, the data are

” 1" ,J3”, “_n, “SET’.) -
not accepted -if they are not within a
Measuremeni range of -2 deg to +2 deg. (The direc-
The’ panel display changes to “412”.
accuracy for tion to jack up the chassis with the work
@ With the chassis near IO’,, ~~~~~~~~~~~~~~~~~~~~ chassis tilt: equipment is the + direction)
+@&~; ~~~~~~~~~ ;&&&,;Qf &~~&& “’ ’ ’ 0.1 deg
(Examole: When the tilt anale is 11.0 dea. inout . When teaching lo”, the data are not ac-
uim, ”
“. ,~~~
iln, now, nsET#s.)

cepted if they are not within a range of
After C lights up for 2 seconds, the C display 8” to 12”.
flashes (waiting for next input).
Item Posture of machine when correcting
* Making boom horizontal

Prepare a hose (a plastic hose can be used), fill the hose with
water, then compare the height of the foot pin and top pin.
(See diagram below)
Adjusting boom angle sensor

G when replacing controller
Hoie (water)
TLP00759
Adjusting when replacing

H boom angle sensor
* Making arm perpendicular

Prepare about 3 m of string,
fit a weight to one end, then
let it hang and check if the
line between the arm pins is
perpendicular.
(See diagram)
Adjusting arm angle sensor
I when replacing controller
cl
'LPOO760
Adjusting when replacing arm

J Posture 2 on the right
angle sensor
20-156
0
Operation of panel or operation of machine (EEfportior

indicates input operation or portion to be operated)
Permissible
value
Remarks
With the operation on the left, if the

I
buzzer sounds 3 times and it is impossi-
If the clinometer is corrected at the same

tieasuremen time, carry out Operation F first. (When
rhall be the boom is corrected, the clinometer
within d=fl signal is used.)
:m
This Operation G is needed only when
first writing the boom angle sensor cor-
rection value to the non-volatile memory
of the GX controller.

Vleasuremen If the clinometer is corrected at the same

rhall be time, carry out Operation F first. (When
within d=+l the boom is corrected, the clinometer
:m (can be signal is used.)
:hecked
flashes (waiting for next input). risually) The boom angle sensor 0 point is cor-
rected again based on the corrected an-
gle for the end of the boom RAISE stroke
saved in the non-volatile memory of the
GX controller.

If the clinometer and boom are corrected

aeasuremen at the same time, carry out Operations
;hall be F, G, or H first. (When the arm is cor-
vithin d=fl rected, the clinometer and boom signals
The panel display changes to “613”. :m are used.)
This Operation I is needed only when

first writing the arm angle sensor cor-
rection value to the non-volatile memory
flashes (waiting for next input). of the GX controller.

If the clinometer and boom are corrected

at the same time, carry out Operations
- F, G, or H first. (When the arm is cor-
rected, the clinometer and boom signals
After C lights up for 2 seconds, the C display are used.)
The arm angle sensor 0 point is cor-
rected again based on the corrected an-
gle for the arm OUT saved in the non-
volatile memory of the GX controller.
zo- 157
0
Item Posture of machine when correcting
K Adjusting bucket stroke senso Posture 2 on the right
<Bucket with teeth>
TKP00761
nputting data for dimensions_ <Slope finishing bucket>

L ,f custom bucket
TLP00762
Heeding air from EPC valve,

M ;pool See separate sheet
20-158
0
Operation of panel or operation of machine (~portior Permissible

indicates input operation or portion to be operated) Remarks
value
@ When C flashes, ~~~~~~~~~~~~~~~~~~ l Correct actual stroke length of the cylin-

The panel display changes to “711”. der stroke sensor. (Push securely to both
stroke ends and press SET.)
The panel display changes to “712”.
After C lights up for 2 seconds, the C display

@ When C flashes,.~~~~,~~~~.:~~~~‘~~~~~ With this operation (L), the only action

The panel display changes to “771”. is to save the shape of the custom bucket
to memory.
(When using the GX functions with the
._,,,.,, ,, ., ., custom bucket, it is necessary to input
(Example: For 148.7, input “I”, “4”, “9”, “SET”) “C38” with operation (D) for setting the
The panel display changes to 772. bucket code, and to select the custom
bucket.)
~$!&r@&s1&~@&&&~(Angle in deg x 2) If the input value is not correct, the line

iT.Tm;le: For 92.7 deg, input “I”, “8”, “5”, followed by the bucket will form a wave
n
during automatic grading, or the stop
The panel display changes to 773. position for the working range selection
will go outside the set area, so after set-
@,‘l#$@#$&j~,,~#~&;for the bucket shape data 6% @ ting, check that the GX functions work
:ii;k~:~~~~~~,~~~~ (Angle in deg x 2)
,. > , , Ib, I^,-_ ,.,“, -< normally before carrying out operations.
The panel display changes to 774.
The input value can be checked in the
@~:‘&&f;$$l%@$&e
ii<, i,:,,‘C’ for the bucket shape
.$,*<+.*,>,‘$:‘, data#j@ GX monitoring mode (d64 - d69)
%%W&%A&~
I..“_^<.. ,<,*,“~“,
_>>,,,“^, , (Angle in deg x 2)
The panel display changes to 775. A value from 0 to 250 can be input.
(Any value outside this range is taken
as an error.)
The panel display changes to 776. However, the dimensions for e in the
diagram below must be the same as for
the standard bucket.
After C lights up for 2 seconds, the C display

BKP02323
l Always turn the starting switch OFF be-

fore operating the GX automatic opera-
tion disconnection switch.
(If it is operated when the starting switch
is ON, it will be taken as an error.)
b If the air is not bled properly, the per-

@$#&@;&&i~~~For details, see “Bleading air from formance of the GX will become poor
hydraulic cylinder” when the EPC current is corrected.
@ Turn the starting switch ON.

-
20-159
0
r Item Posture of machine when correcting
Correction of spool, EPC valve

N xrrent (including replacement o
the swing EPC or swing spool)
Set the arm and bucket to the end of the arm OUT
and bucket DUMP stroke.
It 00%200mm
TLP00763
Correction of spool, EPC valve

:urrent (when the swing EPC
0 md swing spool have not been
,eplaced.)
From arm Perpendicular to lo-20’forward

\
Swing back prevention

P
teaching mode
of bucket CURL stroke

TL-PO0764
20-160
0
Operation of panel or operation of machine (mportio~

indicates input operation or portion to be operated)
Permissible
value
Remarks
1
@ Carry out the warming-up operation. (Until the With operation @ on the left, if the
temperature of the oil in the tank is approx. 50°C) buzzer sounds 3 times and it is impossi-
At 30°C or above for 10 minutes ble to carry out the input, it means that
The correction for the swing EPC cur-

rent is carried out, so carry out the teach-
,,; ,>,:,;‘iir ,‘@,‘g*g ,@‘, ing mode for the swing back prevention
@ With the C display flashing,,@@&&:.&:“$&:~~;&J#$~$ (operation P below) at the same time.
The panel display will change to “811”.
.,,, ,,.; (,,_ If the buzzer sounds 3 times between
O~~~~~~~~~~~~~(During this time, “812” and “819” on the left, the correc-
the work equipment will automatically move tion is defective.
slightly.) (Defective pressure sensor or insufficient
The panel display will change in turn from “812” bleeding of air)
(boom RAISE) to “819” (left swing).
The buzzer will sound continuously for 1 second
and the display will return to the flashing C dis-
play. (Release the switch.)
@ _~~liC~~%l~~~,~~~~~~~ ##j@#,~ (Until the

In this mode, the change in the cylinder
temperature of the oil in the tank is approx. 50°C) pressure is seen and the movement of
the work equipment and the EPC cur-
rent are automatically judged.

The correction for the swing EPC cur-

The panel display will change in turn from “822” rent is not carried out, so there is no
to “827”. need to carry out the teaching mode for
The buzzer will sound continuously for 1 second the swing back prevention (operation P
and the display will return to the flashing C dis- below).
play. (Release the switch.)
If the buzzer sounds 3 times between
“812” and “819” on the left, the correc-
tion is defective.
(Defective pressure sensor or insufficient
bleeding of air)
<Reason for need for operation to save

@ With the C display flashing,,&&& ,$@~.?/~~~@f$?$~ data>
The LED for the swing back prevention will iight In the GX adjustment mode, the setting
up and the panel display will change to “880”. and correction values are only written to
the volatile memory, so it is necessary to
write this to the non-volatile memory.
n addition, the data values saved are writ-
:en to the controller once only during the
nstant when the starting switch is turned
When the lever is operated, the value taught for 3N. All corrected data becomes ineffec-
the EPC current in the direction of operation is :ive.
displayed on the panel.
If the soft mode is canceled at the point where the
display value stops changing, the buzzer will sound
continuously for 1 second and the display will
return to the C flashing display. (end of teaching)
20-161
0
r Item
1 Posture of machine when correcting
Q Saving data No connection
Note: During the above adjustment operation, the GX controller may take the situation as a
failure and display an error, but this does not indicate any abnormality. However, if
the error message does not go out when the starting switch is turned OFF, this
indicates that the adjustment is defective.
20-l 62
0
Operation of panel or operation of machine (&I portion Permissible

indicates input operation or portion to be operated) Remarks
value
With the C display flashing, ~%~~e~~~~~~~~~ l Operate the engine throttle to the FULL
[COO: save data1 position.
The C will light up for 2 seconds (writing data) l By setting the soft mode ON and oper-
The system will automatically exit the GX ad- ating the lever suddenly, and equivalent
justment mode. operation to fine control of the lever in
normal conditions is achieved.
(To make the swing operation common
when correcting, operate the lever sud-
denly for all cases.)
20-l 63
0
4. Order of operations for bucket code setting mode (for users)
With this mode, the GX panel is operated directly to set the bucket code when the user has changed
the bucket.
Operation of panel or operation of machine (a portion indicates input operation or portion to be operated)
1L~~~on the G)( panel ~~~~~l~~~~~(The switch marked by the arrow in the diagram
on the right.)
The panel display will change to “C3”.
(If Steps 4 and 5 below are not completed within 10 seconds after the panel display changes to “C3”, the
system will automatically exit the bucket setting mode.)
Based on the table on the right,j~;~~~~~~~,~~~~~~~~~~~~~~

(Example: For slope finishing bucket: Press switch “4”. The panel display will change to “C34”.)
, ^“^
,,,,_%,r;*i
ii~;;
5. ;~~Ic~~~~~~~~~~~~~~~~
C lights up for 2 seconds, the system will automatically return to the original display.
iSIr c;hll j,,, I,<“‘)p# “I”
6. ~~~i~~~~to completely stop the power to the GX panel,~~~~~~:~~~~~~~~~~~~
ompletron of setting)
(The set data is not effective until Step 6 is carried out.)
20-164
a
GX panel display Remarks
HYPER monitor automatic functions:

GX panel
automatic vibration, playback
GX panel automatic functions:

automatic grading, cutting angle retention,
cushion, digging depth alarm, working range
selection, boom rock prevention, swing back
prevention
(Turn all the above functions OFF.)
/ In the bucket code setting mode.

<Komatsu genuine bucket codes>
Reach display use the switches as shorn below. l PC200 Panel display
/ 0.7 m3, 0.8 m3,
1
0.9 m3, 1.0 m3 . . . . . . . . . . . . . . . . . Press switch “1”. “C31 fl
BUCKET ( (I) (2) (3) ) 0.45 m3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . Press switch “2”. “C32”
Slope finishing bucket . ..Press switch “4”. “C34”
LIMITS ( m (5) (6) ) Trapezoidal bucket . . . . . . . . . Press switch “5”. “C35”
Ditch bucket . . . . . . . . . . . . . .._.... Press switch “6”. “C36”
[ DAMP ( (7) (8)
- / l Custom bucket: Press switch “8”. “C38”
Switch’9’
TLPOO765
20-165
a
CHECK PROCEDURE WHEN OPERATION OF
TESTING AND ADJUSTING GX AUTOMATIC FUNCTION IS DEFECTIVE
CHECK PROCEDURE WHEN OPERATION OF GX AUTOMATIC

FUNCTION IS DEFECTIVE
1
.% Condition of chassis
Function Problem Check t Effect
- Remedy
% Chassis angle is too large

* GX automatic function can
Numeral flashes Is chassis tilted? be used but accuracy is pool
= If accuracy is needed, reduce
tilt of chassis
Bucket
3ucket monitor * When fully automatic grading
nonitor display is is being used, display shows
abnormal Suddenly changed Is fully automatic grading being value according to set grade
to strange number used? e Release left knob switch to
measure
[El or [Fl is displayed See next page
l Buzzer gives short beeps Check if following switches are - If any switch is ON, turn it
Are the following switches ON. OFF, then turn the following
ON? Working range selection switch, switches ON.
1)Fully (1) Fully automatic grading playback function switch, (1) SET switch
automatic switch automatic vibration switch. (2) Cutting angle retention
grading (2) Bucket cutting angle switch
in use retention switch
The following functions do not

2) Bucket start.
;;;i,“g (1) Fully automatic grading Was knob switch double = Double click correctly
switch clicked?
retention (2) Bucket cutting angle
retention switch
Fully automatic grading does Is control lever being operated - Return control lever to
not start even when knob when knob switch is double neutral, then double click
switch is double clicked clicked? knob switch
+ When fully automatic grading

jigging is being used, digging depth
depth Digging depth alarm does not Is fully automatic grading being alarm does not sound
alarm sound used? m Release knob switch and
carry out operation
Are playback function switch or - Turn the switch OFF, then

automatic vibration switch turn the working range
turned ON? selection switch ON.
Buzzer gives short beeps and
Vorking working range selection switch Are working range selection - Lower the boom to the
ange cannot be turned ON. lamp flashing? ground, then raise it fully;
ielection move the arm out fully, then
move it in fully.
Became impossible to move Are two or more working range - Turn one of the switch OFF.
work equipment when setting selection lamp flashing?
working range
20-166
0
CHECK PROCEDURE WHEN OPERATION OF
TESTING AND ADJUSTING GX AUTOMATIC FUNCTION IS DEFECTIVE
* If the GX automatic function does not work properly even when the checks on the previous page
are carried out, check the following items.
x Condition of chassis
Problem Check * Effect
- Remedy
Even when GX panel setting Turn the starting switch OFF, then % Control function is abnormal
switch is pressed, the buzzer gives start again and carry out the
short beeps and the switch cannot preparatory operation for * Automatic operation function
be turned ON automatic operation cannnot be used
(setting cannot be carried out)
e Use this manual to carry out
[El displayed on the GX panel Sr If the conditon is still the troubleshooting
display condition on the left
Buzzer gives short beeps and

work equipment stops
l LEO91 is displayed on the HYPER
monitor display
Digging depth alarm switch Does the buzzer sound when x Abnormality in buzzer system
cannot be turned ON and buzzer other switches on the GX panel Ir Operation can be continued if
does not sound are pressed? digging depth alarm is not used
= Use this manual to carry out
troubleshooting
20-167
0
ADJUSTING SWING BACK PREVENTION FUNCTION
TESTING AND ADJUSTING (SWING TEACHING MODE)

(SWING TEACHING MODE)
Ir If the swing EPC solenoid valve or swing spool

have been replaced, the swing back prevention
function may not work as well as before re-
placement because of the variation in the prod-
uct (EPC solenoid valve, swing spool) (this is
not a problem). In such a case, use this adjust-
ment procedure to adjust the swing back pre-
vention function.
+ There is no need to carry out this adjustment if
the performance of the swing back prevention
is normal.
Operation Display
1. Complete the correction of the value for the

current when the EPC valve starts to move,
then turn the starting switch OFF.
2. Turn the starting switch ON, then set the
HYPER monitors switch as follows.
* Adjustment code (wait ina input)

This shows the field adjustment
e Flashino
3. Turn the engine fuel control dial to the FULL

position.
4. Set the GX panel to the GX adjustment mode,

input q, q, then press the ISET] switches.
[m] Display changes to [a]
TKP00766
*rm anale IO’-20
5. Set the chassis horizontal, and set the work Perpendicular

41
equipment to the posture shown in the dia-
gram.
TLP00767
20- 168
0
TESTING AND ADJUSTING (SWING TEACHING MODE)
Operation Display
6. Suddenly operate the swing control lever

fully. Swine control lever at neutral
7. When the swing speed reaches the constant

swing speed range, operate the swing con-
TKP00766
trol lever suddenly to return it to the neutral
position.
* Always operate the lever suddenly.
Sr Swing to the left and right in turn, and
repeat 5 or 6 times until the perform-
ance (function) is stable in both direc-
TKP00769
tions.
8. If the HYPER monitor soft mode is turned

OFF or the working mode is changed, the
GX panel will wait for input tm flashes) to
complete the swing teaching mode.
_
CD
--
r-0 u-1 o-0
I QU_UUJ
Flashes
TKP00770
9. With the q flashing, input q, q, then press
the m switch.
. After the input, the buzzer will sound
g
> (with the GX panel, the q will continue
8 to flash)
0
IO. Turn the starting switch OFF to save the re-

sults of the adjustment (teaching result) to
the GX controller.
11. Turn the starting switch ON again and check

the swing back prevention function of the
GX function.
20-l 69
0
TESTING AND ADJUSTING BUCKET DIMENSION INPUT MODE WHEN USING CUSTOM BUCKET
BUCKET DIMENSION INPUT MODE WHEN USING CUSTOM

BUCKET
PC200,2OOLC- HYPER GX
Dimension Q must be same as for
* To enable a bucket other than a Komatsu genu- Komatsu aenuine bucket
ine bucket to be used with the GX function on a
GX specification machine, it is necessary to
record the bucket shape in the adjustment mode
as C38 for the custom bucket data, and also to
input the shape dimension data.
a If the shape dimensions are not correct, there is
danger that the bucket may move in a com-
pletely unexpected way when the GX function nitorino
is operated, so always input the shape dimen- base Point
sion data correctly. TKP00771
Operation Display
1. Set to the GX adjustment mode

(See the section on the content and display
in the GX adjustment mode).
2. Input q, q, then press the ISET] switch.

l After the value is input, the GX panel
display changes to 17711.
3. With the GX panel displaying 1, input
the bucket dimension L (unit: cm).
Example: When L= 157.6 cm
Input a, H, q, then press the
m switch.
(Round the dimention to the near-
est whole number.)
* Note that it is impossible to install any
bucket with dimention L over 250 cm.
(Afterm. q m is
input. waits for input)

display changes to m.
[Shape dimensions of slope finishing bucket1
itorine
e point
TKP00879
TLP00772
20- 170
0
Operation Display
4. With the GX panel display showing 1,

input bucket angle 91 (unit. 0.5 deg)
Example: When 91 is 95.4 deg
95.4 x 2 = 190.8
(I corresponds to 0.5” on the GX panel
display, so multiply by two)
(Round to the nearest whole number.)
Input q, I%/, ljl, then press the @ switch.
* Note that the bucket cannot be installed
if angle 01 is more than 125”.
. After the value is input, the GX panel


(After 81 is inwt,waits for input)
input cutting edge angle 92 (unit: 0.5 deg).
* The input method is the same for Item 4.
* Note that the bucket cannot be installed
if cutting edge angle 62 is more than
125”.
. After the value is input, the GX panel (After 82 is inputSwaits for input)

input angle 93 (unit: 0.5 deg) at the center of
the floor radius.
* The input method is the same for Item 4.
(After 93 is input,waits for input)

display changes to /.

distance x (unit: cm) at the center of the
input floor radius. I (After x is input, waits for input)
Ir The input method is the same for Item 3.
I_
c-3IO uzu
u=u(After
input floor radius r (unit: cm) . r is input.waits for input)
* The input method is the same for Item 3. I UU_UUJ
TLP00773
. After the value is input, the q flashes on
the GX panel display.
20-171
0
Operation Display
9. With the q flashes on the GX panel, input

q, q then press the /SETI switch.
. After the value is input, the buzzer will
sound (the GX panel, the q will con-
tinue to flash)
IO. Turn the starting switch OFF and save the

data.
* With this operation, the data input above
is recorded as the data for the custom
Example: Check with monitoring mode 64 - 69
bucket.
11. Check if the data input for monitoring mode

64 - 69 is correct.
* If the data is mistaken, input the data
again from Step 1. (After inputting the
data, check again)
12. Turn the starting switch ON again select “8”

for the custom bucket in the bucket set mode
(for user), input “8” then press the JSET/
switch.
* With this operation, the custom bucket $
with the dimensions recorded in Step 11 ELPO2334 t
is selected. %
Note 1: If the shape of a bucket cannot be shown
with the above input method, the bucket
cannot be used.
Example: Clamshell bucket, breaker
Note 2: Bucket cannot be used if dimention E

between the bucket pins is different
from Komatsu genuine buckets.
PC200: &?= 458.1 mm
20-172
0
TESTING AND ADJUSTING PROCEDURE FOR REPLACING SENSOR
PROCEDURE FOR REPLACING

SENSOR
PC200, 2OOLC-6 HYPER GX
1. Boom angle sensor

. Removal procedure
1. Remove sensor wiring cover (I), then remove
wiring connector (2) from the clip, and discon-
nect connector (2).
2. Remove clamp (31, remove bolts (4), then re-

‘
move boom angle sensor assembly (5). BLPO2335 BLP02336
3. Loosen screw (6), and remove lever (7). Mark t his surface wit
* Use indelible ink to mark the cut surface of indeli
shaft (8) at plate (7a) end of lever assembly

(7).
:poo775
. Installation procedure
1. Install lever assembly (7) with screw (6).
Ir Clearance between assembly (7) and cover
assembly (IO).
b: 3 mm
Ir Align plate (7a) of lever assembly (7) with
the cut surface of shaft (8) marked with in-
Surface marked with
delible ink, then assemble.
indelible iyk, I ,i _ !i,il TKP00776
* Be careful to tighten screw (6) so that the
screw is at a right angle to the cut surface of
shaft (8).
m Screw: 24.5 + 9.8 Nm (2.5 f 1.0 kgm}
2. Install boom angle sensor assembly (5) with bolts

(41, then install clamp (3).
3. Connect wiring connector (2), and install cover

(I).
20- 173
0
4. Check that the boom angle sensor is installed

correctly. End of boom RAISE stroke
* If it is not installed correctly, an error will be
given when correcting the sensor, or an er-
ror will occur during operation after the com-
pletion of correction. oom anale sensor
* Method of checking
Set the work equipment in the posture given
below and check the value of the boom an-
gle sensor potentiometer with monitoring
mode dll. (See “Method for the monitoring
display”.) TLP00777
Boom angle sensor (check with monitoring
dll)
* After completing the replacement operation,

adjust the boom angle sensor.
Order of operation: A + E + H + 0
For details, see TESTING AND ADJUSTING, Ta-
ble for order of operations in GX adjustment
mode.
zo- 174
0
2. Arm angle sensor

. Removal procedure
1. Remove cover (2) of encoder assembly (I) and
cover (4) of potentiometer assembly (3). Re-
move connectors (5) and (6) from the clips, then
disconnect them.
2. Remove cover (7) of the lever of encoder as-

sembly (I), then remove mounting bolt (9) of
lever (8).
3. Remove clamp (IO). Remove four mounting

bolts (I I) of encoder assembly (I), then remove
encoder assembly (I) and lever (8) together. Encoder
r I
7
4. As with the encoder assembly, remove cover
9
(15) of the lever of potentiometer assembly (31,
then remove mounting bolt (16) of lever (14). 8
1
5. Remove clamp (17). Remove four mounting
bolts (18) of potentiometer assembly (31, then
11
remove potentiometer assembly (3) and lever
(14) together. 2
5
IO TBP00510
Potentiometer
14
20-175
0
1. Install potentiometer assembly (3) and lever (14)
together to the specified position with four bolts
(181, then install clamp (17).
2. Install lever (14) with mounting bolt (161, then
install cover (15).
3. Connect connector (6) and install cover (4).
4. As with the potentiometer assembly, install en-
coder assembly (I) and lever (8) together to the
specified position with four bolts (II), then in-
stall clamp (IO).
5. Install lever (8) with mounting bolt (91, then in-
stall cover (7).
6. Connect connector (5) and install cover (2).
7. Make sure that the arm angle sensor is installed
normally.
* If the arm angle sensor is not installed nor-
mally, errors may happen when it is cali-
brated or operated after calibration.
Jr Check method
l Check the value of the arm angle sensor
potentiometer in the following positions
in monitoring mode d16. (For the indi-
cation method of monitored values, see
the separate explanation.)
Arm angle sensor (To be confirmed in moni-
toring mode d16)
Arm anale sensor

Position ~confa~Js Of- ind of arm (Potentiometer on left.
NT stroke encoder on right)
slAz”,! M;y;Ed 1 909f30 1 845f30

Voltage (VI 4.44 f 0.15 4.13 f 0.15
z;z;zi M;;;rd / 118+30 / 116f30
Voltage (V) 0.57 f 0.15 0.57 + 0.15
% Standard arm: 2.9m, Long arm: 2.4m

TLP0077f
* After replacing the arm angle sensor assem-

bly, adjust it according to the procedures A,
E, J, and 0 in order, referring to “OPERA-
TION PROCEDURE IN GX ADJUSTMENT
MODE”.
20-176
0
3. Bucket stroke sensor

. Removal procedure
1. Remove cover (1).
BLPO2341
2. Remove clips (21, remove wiring connector (3)

from the clips, then disconnects the connector.
BLPO2342
3. Remove 4 bolts, then remove stroke sensor as-

sembly (4).
BLPO2346
20-177
0
1. Fit an O-ring, then install stroke sensor assem-
bly (4) with 4 bolts.
* Coat the outside circumference, bottom sur-
face, and sensor mount hole of the stroke
sensor body well with hydraulic oil, then
insert the sensor into the mount hole.
* Before securing with the mounting bolts,
shake the stroke sensor assembly lightly to
check that the sensor body is in tight con-
tact with the rod. (There is a possibility that
no signal will be given.)
w Sensor mounting bolt:
30.9 + 2.9 Nm I3.15 + 0.35 kgm) TLP00779
2. Connect wiring connector (31, secure to the clips,

then install clips (2).
Sensor body
3. Install cover (I).
Ir After completing the replacement operation,
Order of operation: A + E + K + 0
For details, see TESTING AND ADJUSTING,
Table for order of operations in GX adjust-
ment mode. -+!!od
Put bottom surface of
sensor in tiGht contact
with rod
TLP00780 TLP00781
4. Clinometer
. Removal procedure
1. Remove the cover at the bottom of the opera-
tor’s compartment.
2. Remove connector (I), then remove clinometer

(2).
BLP02347
l Installation procedure
l Carry out installation in the reverse order to
removal.
* After completing the replacement operation,

Order of operation: A + E + K + Q
Table for order of operations in GX adjust-
ment mode.
20-178
0
TROUBLESHOOTING
Points to remember when troubleshooting ....................................................................................... 20-202

Sequence of events in troubleshooting .............................................................................................. 20-203
Precautions when carrying out maintenance.. ................................................................................... 20-204
Checks before troubleshooting ............................................................................................................ 20-212
Connector types and mounting locations .......................................................................................... 20-214
Connection table for connector pin numbers .................................................................................... 20-222
Explanation of control mechanism of electrical system ................................................................... 20-234
Display method and special functions of monitor panel.. ................................................................ 20-236
Method of using judgement table.. ..................................................................................................... 20-246
Method of using troubleshooting charts ............................................................................................ 20-248
Details of troubleshooting and troubleshooting procedure ............................................................. 20-250
Troubleshooting of communication abnormality system (N mode) ............................................... 20-301
Troubleshooting of engine throttle . pump controller (governor control system) (E mode) ....... 20-351
Troubleshooting of engine system (S mode) .................................................................................... 20-401
Troubleshooting of engine throttle . pump controller (pump control system) (C mode). ........... 20-451
Troubleshooting of engine throttle . pump controller (input signal system) IF mode) ............... 20-501
Troubleshooting of hydraulic and mechanical system (H mode). ................................................... 20-551
Troubleshooting of machine monitor system (M mode). ................................................................. 20-601
Troubleshooting of GX controller system (A mode). ........................................................................ 20-651
Troubleshooting of valve controller system (K mode) ..................................................................... 20-751
20-201
0
TROUBLESHOOTING POINTS TO REMEMBER WHEN TROUBLESHOOTING
POINTS TO REMEMBER WHEN TROUBLESHOOTING
g Stop the machine in a level place, and check that the safety pin, blocks, and parking brake are securely fitted.
A When carrying out the operation with two or more workers, keep strictly to the agreed signals, and do not
allow any unauthorized person to come near.
A If the radiator cap is removed when the engine is hot, hot water may spurt out and cause burns, so wait for
the engine to cool down before starting troubleshooting.
A Be extremely careful not to touch any hot parts or to get caught in any rotating parts.
A When disconnecting wiring, always disconnect the negative (-) terminal of the battery first.
A When removing the plug or cap from a location which is under pressure from oil, water, or air, always release
the internal pressure first. When installing measuring equipment, be sure to connect it properly.
The aim of troubleshooting is to pinpoint the basic cause of the failure, to carry out repairs swiftly, and to
prevent reoccurrence of the failure.
When carrying out troubleshooting, and important point is of course to understand the structure and function.
However, a short cut to effective troubleshooting is to ask the operator various questions to form some idea
of possible causes of the failure that would produce the reported symptoms.
1. When carrying out troubleshooting, do not hurry 4) Check the stroke of the control valve spool.
to disassemble the components. 5) Other maintenance items can be checked ex-
If components are disassembled immediately any ternally, so check any item that is considered
failure occurs: to be necessary.
. Parts that have no connection with the fail- 4. Confirming failure
ure or other unnecessary parts will be disas- . Confirm the extent of the failure yourself,
sembled. and judge whether to handle it as a real fail-
. It will become impossible to find the cause ure or as a problem with the method of op-
of the failure. eration, etc.
It will also cause a waste of manhours, parts, or * When operating the machine to reenact
oil or grease, and at the same time, will also lose the troubleshooting symptoms, do not
the confidence of the user or operator. carry out any investigation or measure-
For this reason, when carrying out troubleshoot- ment that may make the problem worse.
ing, it is necessary to carry out thorough prior 5. Troubleshooting
investigation and to carry out troubleshooting in . Use the results of the investigation and in-
accordance with the fixed procedure. spection in Items 2 - 4 to narrow down the
2. Points to ask user or operator causes of failure, then use the troubleshoot-
1) Have any other problems occurred apart from ing flowchart to locate the position of the
the problem that has been reported? failure exactly.
2) Was there anything strange about the ma- Ir The basic procedure for troubleshooting
chine before the failure occurred? is as follows.
3) Did the failure occur suddenly, or were there 1) Start from the simple points.
problems with the machine condition before 2) Start from the most likely points.
this? 3) Investigate other related parts or in-
4) Under what conditions did the failure occur? formation.
5) Had any repairs been carried out before the 6. Measures to remove root cause of failure
failure? . Even if the failure is repaired, if the root cause
When were these repairs carried out? of the failure is not repaired, the same failure
6) Has the same kind of failure occurred be- will occur again.
fore? To prevent this, always investigate why the
3. Check before troubleshooting problem occurred. Then, remove the root
1) Check the oil level cause.
2) Check for any external leakage of oil from
the piping or hydraulic equipment.
3) Check the travel of the control levers.
TROUBLESHOOTING SEQUENCE OF EVENTS IN TROUBLESHOOTING
SEQUENCE OF EVENTS IN TROUBLESHOOTING
Office, shop
TEW00180 a TEWOO,8, Jobsite
step 1
Examination, confirmation of symptoms 1
When a request for repairs is received, first
ask the following points.
. Name of customer
. Type, serial number of machine
. Details of jobsite, etc.
Ask questions to gain an outline of the prob-
lem.
* Condition of failure
* Work being carried out at the time of the TEW00182
failure
. Operating environment
* Past history, details of maintenance, etc.
step 2
Determining probable location of cause
1) Look at the troubleshooting section of the

shop manual to find locations of
causes.
TEW00184
Step 3
Preparation of troubleshooting tools
I) Look at the table of troubleshooting tools in /

the shop manual and prepare the necessary step 7
toois. * Pinpoint locations of failure (carry out
. T-adapter lx! troubleshooting)
- Hydraulic pressure gauge kit, etc. . Decide action to take
2) Look in the parts book and prepare the nec- e!@
essary replacement parts. 1) Before starting troubleshooting, locate and

repair simple failures.
. Check before starting items
* Other check items
2) See the Troubleshooting Section of the shop
manual, select a troubleshooting flowchan
that matches the symptoms, and carry out
troubleshooting.
TEWOOl87
/step 6
IRe-enacting failure
. Drive and operate the machine to confirm

the condition and judge if there is really a
TEW00198
Was there anything strange about the ma-

chine before the failure occurred?
Did the failure occur suddenly?
. Had any repairs been carried out before the
TEW00189 failure?
TEW0019C
20-203
a
TROUBLESHOOTING POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE
POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE
To maintain the performance of the machine over a long period, and to prevent failures or other
troubles before they occur, correct operation, maintenance and inspection, troubleshooting, and re-
pairs must be carried out. This section deals particularly with correct repair procedures for mechatronics
and is aimed at improving the quality of repairs. For this purpose, it gives sections on “Handling
electric equipment” and “Handling hydraulic equipment” (particularly gear oil and hydraulic oil).
1. POINTS TO REMEMBER WHEN HANDLING

ELECTRIC EQUIPMENT
I) Handling wiring harnesses and connectors

Wiring harnesses consist of wiring connecting
one component to another component, connec-
tors used for connecting and disconnecting one
wire from another wire, and protectors or tubes
used for protecting the wiring.
Compared with other electrical components fit-
ted in boxes or cases, wiring harnesses are more
likely to be affected by the direct effects of rain,
water, heat, or vibration. Furthermore, during
inspection and repair operations, they are fre-
quently removed and installed again, so they
are likely to suffer deformation or damage. For
this reason, it is necessary to be extremely care-
ful when handling wiring harnesses.
TEW00191
Main failures occurring in wiring harness

@ Defective contact of connectors (defective
contact between male and female)
Problems with defective contact are likely to
Improper insertion
occur because the male connector is not
properly inserted into the female connector,
or because one or both of the connectors is
deformed or the position is not correctly
aligned, or because there is corrosion or
oxidization of the contact surfaces.
TEW00192
@ Defective crimping or soldering of connec-

tors
The pins of the male and female connectors
Crimped portion
are in contact at the crimped terminal or
soldered portion, but if there is excessive
force brought to bear on the wiring, the plat-
ing at the joint will peel and cause improper
connection or breakage.
20-204
0
Disconnections in wiring
If the wiring is held and the connectors are
pulled apart, or components are lifted with a
crane with the wiring still connected, or a
heavy object hits the wiring, the crimping of
the connector may separate, or the solder-
ing may be damaged, or the wiring may be
broken.
High-pressure water entering connector

The connector is designed to make it diffi-
cult for water to enter (drip-proof structure),
but if high-pressure water is sprayed directly
on the connector, water may enter the con-
nector, depending on the direction of the
water jet.
As already said, the connector is designed
to prevent water from entering, but at the
same time, if water does enter, it is difficult
for it to be drained. Therefore, if water should
get into the connector, the pins will be short-
TEW00195
circuited by the water, so if any water gets
in, immediately dry the connector or take
other appropriate action before passing elec-
tricity through it.
0 Oil or dirt stuck to connector

If oil or grease are stuck to the connector
and an oil film is formed on the mating sur-
face between the male and female pins, the
oil will not let the electricity pass, so there
will be defective contact.
If there is oil or grease stuck to the connec-
tor, wipe it off with a dry cloth or blow it dry
with compressed air and spray it with a con-
TEWOO196
tact restorer.
* When wiping the mating portion of the
connector, be careful not to use exces-
sive force or deform the pins.
* If there is oil or water in the compressed
air, the contacts will become even dirtier,
so remove the oil and water from the
compressed air completely before clean-
ing with compressed air.
20-205
0
21 Removing, installing, and drying connectors and

wiring harnesses
0 Disconnecting connectors
Hold the connectors when disconnecting.
When disconnecting the connectors, hold the
connectors and not the wires. For connec-
tors held by a screw, loosen the screw fully,
then hold the male and female connectors
in each hand and pull apart. For connectors
which have a lock stopper, press down the
stopper with your thumb and pull the con-
nectors apart.
Ir Never pull with one hand.
When removing from clips

When removing a connector from a clip, pull
the connector in a parallel direction to the
clip.
* If the connector is twisted up and down
or to the left or right, the housing may
break.
TBW00.485
0 Action to take after removing connectors

After removing any connector, cover it with
a vinyl bag to prevent any dust, dirt, oil, or
water from getting in the connector portion.
Ir If the machine is left disassembled for a
long time, it is particularly easy for im-
proper contact to occur, so always cover
the connector.
TEWOOlSB
20-206
a
l Connecting connectors
0 Check the connector visually.
1) Check that there is no oil, dirt, or water
stuck to the connector pins (mating por-
tion).
2) Check that there is no deformation, de- Clicks into position
fective contact, corrosion, or damage to
the connector pins.
3) Check that there is no damage or break-
age to the outside of the connector.
* If there is any oil, water, or dirt stuck to
the connector, wipe it off with a dry cloth. TFWmll99
If any water has got inside the connec-
tor, warm the inside of the wiring with a
dryer, but be careful not to make it too
hot as this will cause short circuits.
* If there is any damage or breakage, re-
place the connector.
0 Fix the connector securely.

Align the position of the connector correctly,
then insert it securely.
For connectors with lock stopper, push in
the connector until the stopper clicks into
position.
Correct any protrusion of the boot and any

misalignment of the wiring harness
For connectors fitted with boots, correct any
protrusion of the boot. In addition, if the
wiring harness is misaligned, or the clamp
is out of position, adjust it to its correct po-
sition.
+ If the connector cannot be corrected eas-
ily, remove the clamp and adjust the
position.
0 If the connector clamp has been removed,

be sure to return it to its original position.
Check also that there are no loose clamps.
20-207
0
l Drying wiring harness

If there is any oil or dirt on the wiring harness,
wipe it off with a dry cloth. Avoid washing it in
water or using steam. If the connector must be
washed in water, do not use high-pressure wa-
ter or steam directly on the wiring harness.
If water gets directly on the connector, do as

follows.
0 Disconnect the connector and wipe off the
water with a dry cloth.
Ir If the connector is blown dry with com-
TEWO0196
pressed air, there is the risk that oil in
the air may cause defective contact, so
remove all oil and water from the com-
pressed air before blowing with air.
@ Dry the inside of the connector with a dryer.

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

After drying, leave the wiring harness dis-
connected and carry out a continuity test to
check for any short circuits between pins
caused by water.
* After completely drying the connector,
blow it with contact restorer and reas-
sem ble. T-adapter
TEW00203
20-208
0
31 Handling control box

a The-control box contains a microcomputer
and electronic control circuits. These control
all of the electronic circuits on the machine,
so be extremely careful when handling the
control box.
0 Do not open the cover of the control box
unless necessary.
TEW00204
Do not place objects on top of the control

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

or soil, or in any hot place, even for a short
time.
(Place it on a suitable dry stand).
0 Precautions when carrying out arc welding
When carrying out arc welding on the body,
disconnect all wiring harness connectors con-
nected to the control box. Fit an arc welding
ground close to the welding point.
II TEWO0206
2. Points to remember when troubleshooting electric circuits

1) Always turn the power OFF before disconnecting or connect connectors.
2) Before carrying out troubleshooting, check that all the related connectors are properly inserted.
* Disconnect and connect the related connectors several times to check.
3) Always connect any disconnected connectors before noinn on to the next steo.
Ir if the power is.turned ON with the connectors still disconnected, unnecessary abnormality
displays will be generated.
4) When carrying out troubleshooting of circuits (measuring the voltage, resistance, continuity, or
current), move the related wiring and connectors several times and check that there is no
change in the reading of the tester.
* If there is any change, there is probably defective contact in that circuit.
20-209
0
3. POINTS TO REMEMBER WHEN HANDLING

HYDRAULIC EQUIPMENT
With the increase in pressure and precision of hy-

draulic equipment, the most common cause of fail-
ure is dirt (foreign material) in the hydraulic circuit.
When adding hydraulic oil, or when disassembling
or assembling hydraulic equipment, it is necessary
to be particularly careful.
11 Be careful of the operating environment.

Avoid adding hydraulic oil, replacing filters, or
repairing the machine in rain or high winds, or
places where there is a lot of dust.
21 Disassembly and maintenance work in the field

If disassembly’or maintenance work is carried
out on hydraulic equipment in the field, there is
danger of dust entering the equipment. It is also
difficult to confirm the performance after repairs,
so it is desirable to use unit exchange. Disas-
sembly and main-tenance of hydraulic equip-
ment should be carried out in a specially pre-
pared dustproof workshop, and the performance
should be confirmed with special test equipment.
TEW00207
31 Sealing openings
After any piping or equipment is removed, the
openings should be sealed with caps, tapes, or
vinyl bags to prevent any dirt or dust from en-
tering. If the opening is left open or is blocked
with a rag, there is danger of dirt entering or of
the surrounding area being made dirty by leak-
ing oil so never do this.
Do not simply drain oil out on to the ground,
collect it and ask the customer to dispose of it,
or take it back with you for disposal.
TEW00208
41 Do not let any dirt or dust get in during refilling

operations.
Be careful not to let any dirt or dust get in when
refilling with hydraulic oil. Always keep the oil
filler and the area around it clean, and also use
clean pumps and oil containers. If an oil clean-
ing device is used, it is possible to filter out the
dirt that has collected during storage, so this is
an even more effective method.
20-210
0
5) Change hydraulic oil when the temperature is

high.
When hydraulic oil or other oil is warm, it flows
easily. In addition, the sludge can also be drained
out easily from the circuit together with the oil,
so it is best to change the oil when it is still
warm. When changing the oil, as much as pos-
sible of the old hydraulic oil must be drained
out. (Drain the oil from the hydraulic tank; also
drain the oil from the filter and from the drain
plug in the circuit.) If any old oil is left, the
contaminants and sludge in it will mix with the
new oil and will shorten the life of the hydraulic
oil.
6) Flushing operations
After disassembling and assembling the equip-
ment, or changing the oil, use flushing oil to
remove the contaminants, sludge, and old oil
from the hydraulic circuit.
Normally, flushing is carried out twice: primary
flushing is carried out with flushing oil, and sec-
ondary flushing is carried out with the specified
hydraulic oil.
$
>
%
71 Cleaning operations
After repairing the hydraulic equipment (pump,
control valve, etc.) or when running the ma-
chine, carry out oil cleaning to remove the sludge
or contaminants in the hydraulic oil circuit.
The oil cleaning equipment is used to remove
the ultrafine (about 3~1) particles that the filter
built into the hydraulic equipment cannot re-
move, so it is an extremely effective device.
20-211
0
TROUBLESHOOTING CHECKS BEFORE TROUBLESHOOTING
CHECKS BEFORE TROUBLESHOOTING
Item i;ec+arnent
1. Check fuel level, type of fuel - Add fuel

2. Check for impurities in fuel - Clean, drain
3. Check hydraulic oil level - Add oil
4. Check hydraulic strainer - Clean, drain
5. Check swing machinery oil level - Add oil
6. Check engine oil level (oil pan oil level), type of oil - Add oil
7. Check coolant level - Add water
8. Check dust indicator for clogging - Clean or replace
9. Check hydraulic filter - Replace
1. Check for looseness, corrosion of battery terminal, wiring - Tighten or replace

2. Check for looseness, corrosion of alternator terminal, wiring - Tighten or replace
3. Check for looseness, corrosion of starting motor terminal, wiring - Tighten or replace
1. Check for abnormal noise, smell - Repair
2. Check for oil leakage - Repair
3. Carry out air bleeding - Bleed air
1. Check battery voltage (engine stopped) 20 - 3OV Replace
2. Check battery electrolyte level - Add or replace
3. Check for discolored, burnt, exposed wiring - Replace
4. Check for missing wiring clamps, hanging wiring - Repair
5. Check for water leaking on wiring (be particularly careful attention - Disconnect
to water leaking on connectors or terminals) connector and dry
3. Check for blown, corroded fuses - Replace

7. Check alternator voltage (engine running at l/2 throttle or above) after running Replace
for several
minutes:
!7.5 - 29.5 v
3. Check operating sound of battery relay (when switch is turned ON/OFF) - Replace
20-212
0
TROUBLESHOOTING CONNECTOR TYPES AND MOUNTING LOCATIONS
CONNECTOR TYPES AND MOUNTING LOCATIONS

l STD
Sr The Address column in the table shows the address in the connector arrangement drawing (3-
dimensional drawing).
Con- No. Add-

iector Type of Mounting location Mounting location
ress
No. / I Dins I
co3 040 20 Engine throttle . pump controller K-2
co5 s IO Pump prolix circuit switch H-l

CO6 M 2 Pump prolix resistor l-2
CO7 IX 3 1Rear pump pressure sensor 1 B-8 1
11 3 Front pump pressure sensor B-9
Cl3 IX 2 1Pump EPC solenoid valve I Ed

Cl6 1MIC 17 1Engine throttle, pump controller 1 K-2
Cl7 040 16 Engine throttle, pump controller J-2

DO1 KESI 2 Window washer circuit L-2
DO3 1KESI 1 2 1Active mode solenoid circuit 1 K-2 1
DO4 I KESI I 2 I Pumpmerge/dividersolenoidcircuit 1 K-2 1
DO8 KESl 2 Heater circuit L-2
Dll KESI 2 Alarm buzzer circuit H-l
D13 I KESI ) 2 I Battery relay drive circuit I K-2 1

D14 I KESI I 2 I Battery relay drive circuit I L-2 I
D17 I KESl I 2 I Heater relay circuit I L-2I
D26 1KESI I 2 I Swing holding brake solenoid1 ~-2 I
E04 X 3 Governor potentiometer -
E05 X 4 Governor motor -
~06 IM 3 I Fuel control dial 1 H-4

E07 IX I 2 I Engine speed sensor I_
~08 IX I I Engine I-
-
I
1 Electrical intake air heater
20-214
0
Con-
Add
Mounting location nector Mounting location
ress
No.
so4 X 2 1Boom LOWER pressure switch 1-

so5 X 2 Arm IN pressure switch -
SO6 X 2 Bucket CURL pressure switch -
so7
SO8
so9
SIO X 2 1Left swing I-
Sll Terminal1 1 IEngine oil pressure switch -

SC Terminal 1 Starting motor terminal C -
TO2 Terminal 1 Revolving frame ground -
TO3 TerminalI 1 1 Revolving frame ground 1-

TO4 Terminal 1 Revolving frame ground -
TO5 Terminal 1 Floor ground F-6
T13 L 2 I Starting motor terminal C I -

vo2 X 2 1Active mode solenoid valve 1-
vo3 X 2 I Pump merge/divider solenoid valve! -
vo4 X 2 Swing holding brake solenoid valve -
vo5 X 2 2-stage relief solenoid valve -
V06 X 2 I Travel speed selector solenoid valve I -

WOI KESI 1 4 I Rightfront lock(withoptionalpowerwindow) I H-9
wo2
wo3
wo4
wo5
W06
wo7
W08
wo9
WI0
x01
x05
x07
TROUBLESHOOTING CONNECTOR ARRANGEMENT DIAGRAM
6
I-
__--- __----
___.-.-
20-216
0
M22
‘29 ’
‘Y___/’
. HYPER GX
* The Address column in the table shows the address in the connector arrangement drawing (3-
dimensional drawing).
Mounting location
Cl7 040 16 Engine throttle, pump controller J-l
DO1 KESI 2 Window washer circuit L-2
DO3 KESI 2 Active mode solenoid circuit K-2
DO4 KESI 2 Pump merge/divider solenoid circuit K-2
DO5 KESI 2 Swing holding brake solenoid circuit K-2
1 DO6 1KESl 1 2 I2-stage relief solenoid circuit 1 K-2 1

DO7 KESI 2 Travel speed selector solenoid circuit K-2
DO8 KESI 2 Heater circuit L-2 K21 040 12 Left control lever 1 J-5
1 Dll 1KESI 1 2 ) Alarm
I
buzzer circuit / G-l 1 K22 1040 I 12 I Riaht control lever 1 H-5
D13 KESI 2 Battery relay drive circuit K-l MO2 X 2 Starting motor relay -
D14 KESI 2 Battery relay drive circuit L-2 MO6 M 3 Heater fan switch (option) l-4
D17 KESI 2 Heater relav circuit L-2 MO7 M 2 Liaht switch l-4
I I / I I I I ”
D26 1KESI 1 2 / Swing holding brake solenoid/ L-2 MO8 M 1 Right front light D-3
I E04 IX I 3 1Governor potentiometer l-l MO9 M 1 Working lamp (boom) A-3
E05 X 4 Governor motor - Ml0 M 1 Working lamp (boom) c-3
E06 M 3 Fuel control dial H-4 Ml1 IL 2 Fusible link I D-3

E07 X 2 Engine speed sensor - Ml2 I KESI I 3 I Heater footion) ( F-6
I ~08 Ix I 14 I Intermediate connector l-l
E 11 Terminal 1 Electrical intake air heater -
El2 X 2 Alternator -
El 3 Terminal 1 Starting motor terminal C -
E 14 Terminal 1 Electrical intake air heater relay -
I El5 I TerminalI 1 I Electrical intake air heater I - I

FOI X 2 Travel alarm (option) D-3
H 12 Sfwhite) 16 Base wiring harness E-8
) HI3 IS(blue) I 16 I Base wiring harness I c-9I
20-218
0
Con- No. Add

nectar Type of Mounting location Mounting location
ress
No. / I pins I
M23 1M 1 2 ( Horn switch I- I RB ITerminal1 1 1 Battery relay terminal B I -
M26 M 6 Air conditioner F-7 RE ITerminalI I I Battery relay terminal E I -
M28 KESO 2 Window washer motor D-9 RM Terminal 1 Battery relay terminal M -
M33 250 3 Auto pull-upswitch(with auto pull-up) l-5 so1 x 2 Travel pressure switch -
M34 X 1 Electromagnetic
clutch
forairconditioner
compressor - SO2 IX I 2 l Boom RAISE pressure switch 1 -
M35 X 2 Condenser for air conditioner E-9 1 SO3 IX 1 2 1Arm OUT pressure switch 1-
M36 IM I 1 I Kerosene mode selector switch I E-9 so4 Ix 1 2 Boom LOWER pressure switch -
M38 M 2 Lamp switch (option) i-4 So5 IX I 2 I Arm IN pressure switch 1-
M39 %%tor 1 Optional power source L-3
M40 M 1 Additional right front lamp (option) G-8
M41 IM 1 1 I Additional left front lamp (option) I G-7
M42 l-pin
connector 1 Rear working lamp (option) A-8
M44 SWP 6 Auto grease (option) D-9
M45 M 3 Network bus G-l Sl 1 Terminal 1 Engine oil pressure switch -
M46 M 3 Troubleshooting
of wipermotorcontroller l-2 SC Terminal 1 Starting motor terminal C -
M47 040 16 Troubleshooting
(foroptional
powerwindow) H-3 1 TO2 ITerminalI 1 I Revolving frame ground I -
M66 :,Z%+,, 1 Automatic lubricationwarning lamp G-2 1 TO3 1Terminal1 1 I Revolving frame ground I -
M67 l-pin 1 Automatic lubricationwarning lamp G-l I TO4 ITerminalI 1 I Revolving frame ground I -
connector
M69 I-Pin
c0nnecr0r
1 Optional power source E-9 I TO5 /TerminalI 1 I Floor ground I F-6
M70 %Fctor 1 Intermediate connector G-2 I% jL 1 2 I Starting motor terminal c I -
M71 l-pin 1 Intermediate connector (room lamp) G-3 I ~02 IX I 2 I Active mode solenoid valve I -
connector
M72 l-pin
connector
1 Additional front lamp (option) E-4 ~03 IX I 2 I Pump merge/divider solenoid valve1 -
M73 KES 2 Speaker (left) L-3 vo4 x 2 Swing holding brake solenoid valve -
PO1 1040 ) 20 I Monitor 1G-3 vo5 x 2 2-stage relief solenoid valve -
PO2 040 16 Monitor G-3 V06 IX I 2 I Travel speed selector solenoid valve I -
PO3 M 2 Buzzer cancel switch l-4 WOI I KESI I 4 1RiahtfrontlockiwithoDtionalDowerwindow)I H-9
~04 IM I 2 I Alarm buzzer 1G-3 W02 j KESI I 4 I Leftfront lock (with optional power window) I L-8
PO5 x 1 Engine oil level sensor - wo3 LKtor

2 Rear limit switch J-9
PO6 X 1 Fuel level sensor c-3 W04 M 6 Wiper motor G-l
PO7 x 2 Engine coolant temperature sensor - w05 I KES 1 I 2 I Power window motor (with optional power windowl I K-9
PO8 X 2 Radiator water level sensor C-9 W06 040 14 Power
window wiring harness[with optional powerwindow)G-3
PO9 x 1 Hydraulic oil level sensor A-5 W07 KESI 2 Frontlimitswitch

(withoptional
power
window) K-9
PI1 l-pin
connector
1 Air cleaner clogging sensor C-9 W08 1070 I 18 I Wiper motor controller I l-l
PI2 l-pin
connector
1 Air cleaner clogging sensor C-9 wo9 070 14 Wiper motor controller (with power window) l-l
R02 Shinagawa 6 EPC valve control relay 1 H-l WI0 M 4 Rear limit switch l-l
R03 IShinagawaI 6 I EPC valve control relay 2 1 H-l X01 I MIC / 21 I Panel wiring harness I l-5
R04 / Shinagawa
I 6 I Light relay 1 H-l X05 M 4 Swing lock switch H-5
R05 I Shinagawa) 6 I Light relay (option) 1 H-l X07 MIC 17 Panel wiring harness L-2
20219
0
BLPO2350
M40
8
M41 ‘>,/\I
i i
i i
i i
‘-Q.. ‘<,T j1
K22' ,/"
‘\..', I/
\
\‘-",,A K21
__-
\' \ co3 DO6
co9
Y\\ \ \ \ \ CO6 Cbl Cl7 i%
M45 Dll CO5 R02 BLP02351

TROUBLESHOOTING CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS

* The terms male and female refer to the pins, while the terms male housing and female housing
refer to the mating portion of the housing.
No. X type connector

of
pins Male (female housing) Female (male housing)
TEW00221 TEW00222
TEWO0223
$-=
4
-
TEW00225 TEW00226
20-222
0
No. SWP type connector

of
3 6
TEW00235 6 3 BLWOO33
4 8
8 4
TEW00237 TEW00238
12
0
0
.___.__
__.-__
ii---l34 1
5
4
9 12
BLPW034 BLpoOO35
1 4 8 11 11 8 4 1
14
3 7 10 14
14 10 7 3
TEW00239 TEWO0240
4 1
5
5 8
16
9 9 2
BLWOO36 13 16 BLpooO37
20-223
0
No. M type connector

of
pins I Male (female housing) Female (male housing)
i Bl PO0038 i Elm39
'1
TEW
3 1
2 4 4 2
TEW 00245 TM’00246
-
1 4
3 ‘6 6 3
TEW ‘00247 TEWC9248
8’
BLF BLPW041
20-224
a
No.
of
T S type connector
4‘ ‘8 TEW00249
8 4
1 6
10
(White
TEW00251
UP30042
12
(White
5 12
BEL00113 EEL00114
16
(White
7
BEL00115 BELOO
20-225
0
No. S type connector

of
IO
(Blue)
5 10
EEL00117 BEL00118
1 6
12
(Blue)
5 12
BLPOOO43
II TEW00254
1 8 8 1
16 0
(Blue: ‘7
i
-
7 16 16 7 TEW00256
BLWO044
20-226
0
No.
of
T MIC connector

1
3
uou
BLFwJo46
I IIII I BLFUOO47
13
8
13
BLRJOO49 BLFWO50
17
I I BLWOO51
11
21
21
1 1 TEW00259
20-227
0
No.
of
T AMP040 type connector
8 4
8
zi I-J
d
BLFWO54
6 12 12 6
12
BLFQCO56
8 16
16 8
16
9 1
1 9
BLPOCQ57 TEW00232
20
1
BLFVJO58 TEW00234
20-228
0
No.
of
T AMP070 type connector
7 7 1
1
6 4
BLPcm59 14 '6 BLWCQ60
12
8
BLPOOO61 BLFGQO62
20-229
0
No.
of
T L type type connector
En
m
TEW00257
20-230
0
No.
of
T Automobile connector
B .l
I
BLPUOO64
2
3
EB BLPOO065
1 2
4 BLWOO67
BLPCOO69
8
rm
I L J
BLF00071 BLwoO72
20-231
0
No. Relay connector

of
2 5
n ,
1 3 6
BLFQOO73 BLmQo74
6 5
Eir
BLwoo75
20-232
0
EXPLANATION OF CONTROL MECHANISM FOR ELECTRICAL
SYSTEM
The control mechanism for the electrical system consists of the monitor panel, and engine throttle
- pump controller. The monitor panel and the engine throttle . pump controller all input the signals
that are necessary, and together with the signals selected by the monitor panel, the engine throttle
. pump controller outputs or inputs the necessary signals and control the pump absorption torque
and engine output.
l STD
Ensine speed sensor
LS-EPC Out nut

Power sorece
PC-EPC out nut -

Power sorece
Work equipment
oil Pressure switch Boom RAISE.LOWER
.
Arm IN.OUT
Swina 011 Bucket CURL,OUMP
Pressure switch
Travel speed oil

8 Swina lock sianal Pressure switch
c
Engine oil level

Engine throttle _F Pump Pressure sensorn
1 sensor sianal . PUMP controller
I
Engine oil pressure
sensor sianal
.
FQ
Air cleaner cloaaed
Air cleaner sensor sianal
.
classed sensor
Battery relay drive -0
Coolant level sianal

r;-;Ty
L____
r----
/3
Governor notention sianal
Coolant temperature sierra
fj--
L-_-1
Governor motor drive /
ra
Power source
Fuel level sensor signal
L___-
Workine oil level
sensor sianal _ Fuet-1
ra I
L-_-2
TKP00782
20-234
a
TROUBLESHOOTING EXPLANATION OF CONTROL MECHANISM FOR ELECTRICAL SYSTEM
. HYPER GX
Net _rk Valve controller

Control lever
_3
EPC solenoid
IIIYIG
_ Engine speed sensor mi
LS-EPC Out Put

Power source
PC-EPC Out Put

Power source
.k
Each solenoid contorol
Illb-tbv
Work equipment
oil Pressure switch Boom RAISE.LOWER
I
Arm IN,OUT
Swing oil Bucket CURL.DUMP
Pressure switch
I
Travel speed oil

8 Swina lock sisnat 1 , Pressure switch
Engine oil level Enaine throt Ie

_F Pump Pressure sensor8
1 sensor signal . num9 control er
I
R Pump Pressure sensor
@ f~;“i,f2f;:~:.‘:.~
Air cleaner sensur signal Startina sianal a
c1099ins sensnr
Coolant level signal

r;-“y Battery relay drive
L____
Coolant temperature siana I

ry
-___- Governor potention signal
r=
Fuel level sensor signal l-
ra I Governor motor drive I
-____ Power source
Hydraulic oil level
senscr signal
ra
L____
_ Fuel dial sianal p /
TKP00783
20-235
0
TROUBLESHOOTING DISPLAY METHOD AND SPECIAL FUNCTIONS OF MONITOR PANEL
DISPLAY METHOD AND SPECIAL FUNCTIONS OF MONITOR

PANEL
1. Display on machine monitor
When the starting switch is turned on, all the monitor and gauge lamps light up for approx. 3
seconds, and the buzzer sounds for approx. 1 second. During this time, the monitor itself carries
out self diagnosis, and after it has finished, it returns to the normal display.
2. Recording of abnormality codes and user code display function

1) All the abnormality data for the engine throttle controller, pump controller, and valve control-
ler are received by the monitor panel. When the monitor panel receives the data, it records the
abnormality data, and at the same time, depending on the nature of the abnormality, it
displays the user code on the time display panel or CALL on the service meter display to
advise the operator of the action to take.
However, in cases of abnormalities which are not urgent and do not require the user code or
CALL to be displayed, only the content of the abnormality is recorded, and no display is given.
2) Types of user code and system

EOI (HYPER automatic mode system)
E02 (PC-EPC system)
E03 (swing holding brake system)
E04 + CALL (HYPER control lever neutral position)
E05 (governor motor system)
E06 + CALL (HYPER EPC solenoid drive system for valve)
E09 (HYPER-GX system stop)
CALL (HYPER lever and EPC solenoid drive system)
3) Displaying user code

If it becomes necessary to display the user code, the time displayed panel is automatically
switched to advise the operator to take the necessary action.
. Actual display (Example: Disconnection in the cancel solenoid system for the swing hold-
ing brake)
OFF
User code
%
OFF 0
olFF al
27
07 OisPlaYs CALL
F
OFF
Y
Teleohone number disDlaY
TKP00784
20-236
0
4) Display of trouble data

The monitor panel records both service codes which are included in the user code, and service
codes which are not included. This data can be displayed on the time display as follows.
Ir For details of the service codes that are not included in the user code, see ACTION TAKEN BY
CONTROLLER WHEN ABNORMALITY OCCURS AND PROBLEMS ON MACHINE or the JUDGE-
MENT TABLE
jervice
Time di
Workin
switch
Working
switch
Travel
Travel s switch
switch
runct 10
STD Monitor Panel front HYPER Monitor Panel rear
TKP ‘00785
i) Method of displaying trouble data

Operation Display
1. To set to the trouble data display 1. On the time display and service meter display, the serv-
mode, ice code and number of hours (service meter hours)
Keep the TIME switch + L.H. travel that have elapsed since the occurrence of the abnor-
speed switch pressed for 2.5 sec- mality are displayed.
onds. . Example of display : When E212 has occurred 12
Note: It is possible to call it up at hours before (service meter)
the following times. 1) Display of service code 2) Display of elapsed time
I) In the normal mode
OFF
2) In the user code display mode I
3) In the machine data monitoring
mode
4) In the time adjustment mode
Service code
time data
2. To go to the next service code dis- TKP00786
play, press the time switch + R.H.
woking mode switch.
3. To go back to the previous service 3) If any abnormality exists at this time, the E mark is
code display, press the time switch displayed.
+ L.H. woking mode switch. OFF
OFF
1 I
time data
If there is an abnomalitu,or the controller
is carrying out self diaenosis,
the output is shut off, and E is displayed.
TKP00787
20-237
0
Operation Display
4. To finish with the trouble data dis- 4) If there is no abnormality code in memory
play mode, keep the TIME switch
+ L.H. travel speed switch pressed OFF OFF
for 2.5 seconds.
5. To erase the memory, keep the
time switch pressed, turn the start-
ing switch from OFF to ON, and
keep the time switch pressed for - is displayed - is displayed OFF
5 seconds. TKP00768
3. Machine data monitoring function

The input signals from the sensors and the output signals to drive the solenoid are displayed on
the time display and service meter display.
Time disc r Service meter
I
Service
Time display
Working mode
switch
Knob button
function swil KI -/
junction switch’
STD HYPER
Monitor Panel front Monitor Panel rear
TLP00789
1) Method of displaying monitoring code
Operation Display
1. To set to the machine data moni- 1. On the time display and service meter display, the moni-
toring mode, do as follows. toring code and data are displayed.
Keep the time switch + knob but- l Example of display
ton function switch pressed for 2.5 I) When engine speed is monitored (monitoring code
seconds. IO)
Note: This is possible at the fol-
OFF OFF
lowing times.
1) During the normal mode 1
2) During the user code display

mode
3) During the time adjustment
Monitorino OFF OFF Monitorina
mode code code data
4) During the trouble data display (example of 1950 ram)
mode TKP00790
20-238
0
Operation Display
2. To go to the next monitoring code 2) When displaying bit pattern

display, press the time switch + . For monitoring codes 08, 20 - 24, 36, 37, 47 -
R.H. working mode switch. 49, 4A, display the bit pattern.
3. To go back to the previous moni- . Example of monitoring code 20
toring code display, press the time
OFF - Ois~lavs OFF
switch + L.H. working mode
switch. 1
4. To finish with the machine data

monitoring code mode, keep the
time switch + knob button func-
tion switch pressed for 2.5 sec-
onds.
. The code No. is displayed in the monitoring

code portion, and the display lights up to dis-
play bit patterns (I) - (6).
2) Table of machine data monitoring codes

* For details of the B in the Unit column, see the bit oattern chart in the next section.
No. Item I Unit I Name of component
01 1Monitor model code I - I Monitor panel

02 1Engine throttle . pump controller model code - 1Enginethrottle. pump controller
03 Engine throttle . pump controller model code - Engine throttle . pump controller
08 S-NET component condition display B Engine throttle . pump controller
Yi$G$AlEngine
&i&i I 10rpm IEngine throttle . pump controller
11 1Pump discharge pressure (F) input ( MPa(kg/cm2)I Engine throttle . pump controller
12 1Pump discharge pressure (R) input 1MPa(kg/cm2)I Engine throttle . pump controller
13 PC-EPC current output 10mA Engine throttle . pump controller
14 Spare IOmA Engine throttle . pump controller
15 1LS-EPC current output IOmA I Engine throttle . pump controller
16 I No. 2 throttle command I wm I Engine throttle . pump controller

20 I Engine throttle . pump controller PPC oil pressure switch input signal (I) I B I Engine throttle . pump controller
21 Engine throttle . pump controller PPC oil pressure switch input signal (2) B Engine throttle . pump controller
22 Engine throttle. pump controller PPC oil pressure switch input signal (3) B Engine throttle . pump controller
23 Engine throttle . pump controller solenoid actuation B Engine throttle . pump controller
24 I Input condition of sensor for engine throttle . pump controller monitor warning B I Engine throttle . pump controller
25 Input condition 2 of sensor for engine throttle . pump controller motor warning B Engine throttle pump controller
30 Fuel control dial input value IOmV Engine throttle . pump controller
20-239
0
* For details of the B in the Unit column, see the bit pattern chart.
NO.1 Item 1 Unit 1 Name of component
31 Governor motor feedback potentiometer input value IOmV Engine throttle. pump controller
32 VBB voltage (battery voltage) IOOmV Engine throttle. pump controller
33 Governor motor A phase current IOmV Engine throttle . pump controller

34 ) Governor motor B phase current IOmV ) Engine throttle . pump controller
35 1Battery relay output voltage IOOmV ) Engine throttle pump controller
36 Engine throttle . pump controller input condition B Engine throttle pump controller
37 Engine throttle . pump controller output condition B Engine throttle. pump controller
40 [ Engine speed _I 10rpm Engrne throttle. pump controller

I,-- ~
41 ) Coolant temperature sensor voltage IOmV 1Engine throttle pump controller
42 ( Fuel sensor input voltage IOmV ( Engine throttle pump controller
43 Battery charge input voltage IOOmV Engine throttle . pump controller

47 Monitor panel output 1 B Monitor panel
48 Monitor panel input 1 B Monitor panel
49 1 Monitor panel input 2 I B I Monitor panel
4A I Monitor panel input 3 I B I Monitor panel
4C Monitor panel input 4 B Monitor panel
50 R.H. front-rear signal input IOmV Valve controller

S
51 R.H. front-rear switch input IOmV Valve controller &
g
52 R.H. left-right signal input IOmV Valve controller
53 I R.H. left-right switch input IOmV ) Valve controller
+ The items from No. 50 are for the HYPER GX specification.
20-240
0
3) Bit pattern chart

As shown in the diagram below, the time display has bit numbers which light up to show that
the signal is being transmitted. (For details, see METHOD OF DISPLAYING MONITORING
CODE.)
OFF OFF
,
OFF OFF Code Portion OFF OFF 0;F
TKP00792
Code b Content Bit Details (condition when lighted up)
(1) Engine throttle - pump controller connected (ID=21

(2) Engine throttle . pump controller connected (ID=31
(3)
08 Connection of S-NET components
(4)
(5)
(6)
(1) Swing switch ON

(2) Travel switch ON
Input condition of engine throttle - (3) Boom LOWER switch ON
20
pump controller PPC switches (4) Boom RAISE switch ON
(5) Arm IN switch ON
(6) Arm OUT switch ON
(I) Bucket CURL switch ON

(2) Bucket DUMP switch ON
Input condition of engine throttle .
(3) Swing lock switch ON
21 pump controller PPC switches and
(4) Service switch ON
other switches
(5) Model selection 5
(6) Swing prolix switch ON
(1) Model selection 1 GND connected

Input condition of engine throttle .
22 pump controller model selection
and other switches
(5) Kerosene mode input GND connected
Drive condition of governor,
(6) Knob switch ON
20-241
a
Code Content Bit

- Details (condition when lighted up)
(I)
(2) [Solenoid ON) Active mode OFF (STD mode)
Engine throttle . pump controller (3) Swing holding brake solenoid ON
23
ON/OFF solenoid valves (4) Pump merge/divider solenoid ON
(5) 2-stage relief solenoid ON

(6) Travel speed selector solenoid ON
-
(1) Above engine oil pressure sensor normal (above set pressure)
(2)
Input condition 1 of sensor for
(3) Radiator water level sensor abnormal
24 engine throttle . pump controller
(4) Engine oil level sensor abnormal
monitor warning
(5) Hydraulic oil level sensor abnormal
(6) Air cleaner clogging sensor abnormal

-
(1)
(2)
Input condition 2 of sensor for
(3)
25 engine throttle . pump controller
(4)
monitor warning
(5) Automatic greasing controller abnormal
(6)
-
(1)
(2)
Input condition of engine throttle - (3)
36
pump controller (4)
(5) Starting switch ON
(6)
-
(1) Battery relay: Actuated
(2)
Output condition of engine throttle (3)
37
. pump controller (4)
(5)
(6)
-
(1)
(2) Alarm buzzer: when machine is operated
(3) Wiper motor drive (R): When actuated

47 Monitor panel output condition 1
(4) Wiper motor drive (L): When actuated
(5) Window washer driver: When actuated
(6)
-
20-242
0
Code Content Bit Details (condition when lighted up)
-
(1) Wiper (ON) OFF

(2) Wiper (INT) OFF
(3) Wiper (washer) OFF
48 Monitor panel input condition 1
(4) Window limit switch OPEN
(5) Limit switch (P) OPEN
(6) Limit switch (WI OPEN
(1) KEY ON SW OFF

(2) Terminal BR Voltage Hi
(3) LIGHT SW OFF
49 Monitor panel input condition 2
(4) Preheating switch OFF
(5) START C Sometimes turns ON
(6) Monitor panel LED lighting output OFF
(1) Time switch OFF

(2) PPC oil pressure selector switch OFF
(3) Overload selector switch OFF
4A Monitor panel input condition 3
(4) STD/DLX selection STD
(5) Swing lock switch OFF

$
> (6) Buzzer cancel switch OFF
z
0
(1)
(2) Wiper motor normal rotation relay output
When specified voltage is abnormal
(3) Wiper motor reverse rotation relay output
4c Monitor panel input condition 4 When specified voltage is abnormal
(4) Window washer motor drive output
When specified voltage is abnormal
(5)
(6)
(1) Knob switch signal 1 ON

12) Knob switch signal 2 ON
Input condition of EPC valve con- 13) Model selection 1 GND connected
68
troller (HYPER specification) (4) Model selection 2 GND connected
16) GX disconnection switch GND connected
[I) Safety relay (I) actuated (output)
2) Safety relay (2) actuated (output)

Input/output condition of EPC valve :31
69
controller (HYPER specification) :41
15)
:6) Remote permission signal (24V input)
20-243
0
4. Governor motor adjustment mode

This is used when adjusting the linkage between the governor motor and the injection pump. (For
details of the procedure, see TESTING AND ADJUSTING.)
Operation Display
1. To set to the governor motor ad- 1. OFF

justment mode, press the time
switch + R.H. travel speed switch
+ R.H. working mode switch.
~/&~~&Q%%ZZ!I!h
TW Displays a-SET XV%

TKP00793
2. To return to the time display mode 2. Buzzer sounds once a second

use the same procedure as in Step
1.
5. Time adjustment mode

To adjust the time, do as follows.
Operation Display
1. To set to the time adjustment 1. The time mark portion flashes

mode, keep the time switch de- OFF ON
pressed for 2.5 seconds.
2. Use the L.H. working mode switch

to advance the hour.
3. Use the R.H. working mode

xc-- Hour QLr
(24-hour clock)
T-x Normal display
TKP00794
switch to advance the minute.
* The example shows the situation when setting to
4. To return to the time display 12:34.
mode use the same procedure as
in Step 1.
20-244
0
6. Telephone number input

To input the telephone number, do as follows.
Operation Display
1. To set to the telephone number

input mode, keep the time switch
+ auto-deceleration switch de-
pressed for 2.5 seconds.
2. When time switch + working

r
mode switch (left) are pressed, Telephone number
position moves two digits to left I--/ ,--J
I---/ Blank or number
Flashing ,--J -
each time, and working mode are displayed in turn
switch (right) are pressed, posi- TKP00795
tion moves two digits to right

each time. The two digits flash.
3. When time switch + travel speed

(right) switch are pressed, the
number in the right digit of the
two flashing digits changes [Ol -
191 - [blank] - 101, and when time
switch + travel speed (left) switch
are pressed, the number in the
left digit of the two flashing dig-
its changes in the same way.
4. After inputting the telephone

number, keep time switch + auto
deceleration switch pressed for
2.5 seconds to return to the time
mode (normal mode). At the
same time, the telephone number
is recorded.
20-245
0
TROUBLESHOOTING METHOD OF USING JUDGEMENT TABLE
METHOD OF USING JUDGEMENT TABLE

This judgement table is a tool to determine if the problem with the machine is caused by an abnormal-
ity in the electrical system or by an abnormality in the hydraulic or mechanical system. The symptoms
are then used to decide which troubleshooting table (E-00, S-00, C-00, F-00, H-00, M-00)
matches the symptoms.
The judgement table is designed so that it is easy to determine from the user code and service code
which troubleshooting table to go to.
* The abnormality display (warning) given by the monitor panel leads directly to troubleshooting of
the machine monitor (M-00). (See troubleshooting of the machine monitor system)
1. When using judgement table for engine throttle - pump controller (governor control system) and
engine related parts
. If a service code is displayed on the monitor panel, go to the troubleshooting code at the
bottom of the judgement table (E-00).
(A 0 mark is put at the places where the failure mode and service code match.)
. If a problem has appeared but no service code is displayed on the monitor panel, go to the
point where the failure mode matches the troubleshooting code on the right of the judgement
table (E-00 or S-00).
<Example> Failure mode “Engine does not start”.
Procedure: Check if the se-vice code is being displayed on the monitor panel.
[Judgementl
1) If a service code is being displayed on the monitor panel . . .. ..go to troubleshooting [E3:001 for the
engine throttle - pump controller (governor control system).
21 If no service code is displayed on the monitor panel, and the engine does not start:
Starting motor rotates .. . . . . . .. . .. . . . . .. Go to troubleshooting S-2 of

l Check that starting
motor rotates mechanical system
-!-
LStarting motor does not rotate.... Go to troubleshooting E-8 of
electrical system
20-246
0
TROUBLESHOOTING METHOD OF USING JUDGEMENT TABLE
2. When using judgement table for engine throttle - pump controller (governor control system) and
hydraulic related parts
If a service code is displayed on the monitor panel, go to the troubleshooting code at the
bottom of the judgement table (C-00).
(A 0 mark is put at the places where the failure mode and service code match.)
If a problem has appeared but no service code is displayed on the monitor panel, go to the
point where the failure mode matches the input signal, and check the display for the input
signal (the display at the place with a 0 mark).
. If it is displayed normally, go to the troubleshooting code on the right of the judgement
table (H-00).
. If the input signal is not displayed on the monitor panel, go to the troubleshooting code at
the bottom of the judgement table (F-00).
<Example> Failure mode “Upper structure does not swing”.

Procedure: Check if the service code is being displayed on the monitor panel.
[Judgementl
1) If a service code is being displayed on the monitor panel...... go to troubleshooting [E2:001 for the
engine throttle . pump controller (pump control system).
2) If no service code is displayed on the monitor panel, and the upper structure does not swing: .
There is a signal.... Go to troubleshooting H-25 of

l Check engine throttle .
mechanical system
controller input signal
(Check in monitoring mode)
There is no signal . Go to troubleshooting F-00 of engine
throttle - pump controller input signal
system
(F mode for applicable system)
20-247
a
TROUBLESHOOTING METHOD OF USING TROUBLESHOOTING CHARTS
METHOD OF USING TROUBLESHOOTING CHARTS

1. Category of troubleshooting code number
Troubleshooting
CodeNo. Component Service code
N-00 Troubleshooting of communication abnormality system E218 group
E-00 Troubleshootingof electricalsystemfor engine throttle . pump controller (governor control system) E3-00 group
s-00 Troubleshooting of engine related parts -
c-00 Troubleshooting of electrical system for engine throttle . pump controller (pump control system) E2-00 group
F-00 Troubleshooting of engine throttle . pump controller (input signal system) -
H-00 Troubleshooting of hydraulic, mechanical system -
K-00 Valve controller electrical system (HYPER) 1E4-00 group
M-00 1Troubleshooting of machine monitor /El-00 group
2. Method of using troubleshooting table for each troubleshooting mode

1) Troubleshooting code number and problem
The title of the troubleshooting chart gives the troubleshooting code, service code, and failure
mode (problem with the machine). (See Example (I))
2) Distinguishing conditions
Even with the same failure mode (problem), the method of troubleshooting may differ accord-
ing to the model, component, or problem. In such cases, the failure mode (problem) is further
divided into sections marked with small letters (for example, a), so go to the appropriate
section to carry out troubleshooting. (See Example (2)) If the troubleshooting table is not
divided into sections, start troubleshooting from the first check item in the failure mode.
3) Method of following troubleshooting chart
l Check or measure the item inside & , and according to the answer follow either the
YES line or the NO line to go to the neg I. (Note: The number written at the top right
corner of the 0 is an index number; it does not indicate the order to follow.)
. Following the YES or NO lines according to the results of the check or measurement will
lead finally to the Cause column. Check the cause and take the action given in the Remedy
column on the right. (See Example (3))
. Below the I there are the methods for inspection or measurement, and the judgement
values. If the judgement values below the I are correct or the answer to the question
inside the / is YES, follow the YES line; if the judgement value is not correct, or the
answer to the question is NO, follow the NO line.
. Below the I is given the preparatory work needed for inspection and measurement, and
the judgement values. If this preparatory work is neglected, or the method of operation or
handling is mistaken, there is danger that it may cause mistaken judgement, or the equip-
ment may be damaged. Therefore, before starting inspection or measurement, always read
the instructions carefully, and start the work in order from Item I).
41 General precautions
When carrying out troubleshooting for the failure mode (problem), precautions that apply to all
items are given at the top of the page and marked with f (See Example (4)) .
The precautions marked Ir are not given in the I, but must always be followed when
carrying out the check inside the I.
5) Troubleshooting tools
When carrying out the troubleshooting, prepare the necessary troubleshooting tools. For de-
tails, see TOOLS FOR TESTING, ADJUSTING, AND TROUBLESHOOTING.
20-248
0
TROUBLESHOOTING METHOD OF USING TROUBLESHOOTING CHARTS
6) Installation position, pin number

A diagram or chart is given for the connector type, installation position, and connector pin
number connection. When carrying out troubleshooting, see this chart for details of the con-
nector pin number and location for inspection and measurement of the wiring connector
number appearing in the troubleshooting flow chart for each failure mode (problem).
<Example>
(1) M-9 When starting switch is turned ON (engine stopped), check item for previous
troubleshooting flashes
(4) * Before carrying out troubleshooting, check that all the related connectors are prop-
erly inserted.
Ir Always connect any disconnected connectors before going on the next step.
* Check that the coolant is at the specified level before carrying out troubleshooting
(2) a) )c)- (coolant level) flashes

SAP00519 Divided into sections a) and b)
(engine oil level) flashes
SAP00523
8
A YES I Defective coolant level
cl sensor system (see M-26
-
0
4 YES Defective engine throttle

Replace
. pump controller
YES ls bit (3) of
- monitoring code -
3
24 lighted up?
. Disconnect P08. Is continuity
YES between Cl6 Defective monitor panel Replace
. Turn starting - - Turn stafiiw NO
- (female ) (8)and
switch ON. switch ON.
chassis as shown
2 Defective contact, or
_ in table? * Set to monitoring
disconnection in wiring
Is there continuity * Turn starting code 24. Repair or
harness between Cl6
_between PO8 - switch OFF. NO replace
(female) (8) - PO8
NIC) (female) (2) and . Disconnect C16, P08.
chassis? (female) (1)
* Connect tt disconnect short
- Turn starting connector to PO8 (female). Defective contact, or
switch OFF. disconnection in wiring Repair or
* Disconnect P08. NO harness between PO8 replace
(female) (2) -chassis
ground
Table
20-249
0
TROUBLESHOOTING DETAILS OF TROUBLESHOOTING AND TROUBLESHOOTING PROCEDURE
DETAILS OF TROUBLESHOOTING AND TROUBLESHOOTING

PROCEDURE
If any abnormality should occur, it is necessary to go to the correct troubleshooting chart in accord-
ance with the judgement table for that type of failure (engine throttle - pump controller (governor
control system) and engine throttle . pump controller (pump control system). For details of the
troubleshooting and troubleshooting procedure, refer to this flow chart.
When carrying out troubleshooting, ask the operator as much as possible about the condition of the
machine, and check the following items before starting.
(I) Condition of controller connection (check with monitoring codes 02 - 03)
(2) Blown fuses
(3) Battery voltage (monitoring mode 32)
(4) Electricity generation (charge input) voltage (monitoring code 43)
The procedure for carrying out check items No. 3 and 4 in the flow chart below is given on the
following pages.
EOl (Automatic mode system for HYPE!?)

E02 (PC * EPC system)
E03 (Swing holding brake system)
E04 + CALL (Control lever neutral system for HYPER) Go to Item 2
E05 (Governor motor system)
E06 + CALL (EPC solenoid drive system for HYPER valve)
E09 (HYPER GX system stop) + go to HYPER GX troubleshooting
CALL (Lever signal and EPC solenoid drive system for HYPER valve)
Elm group: Troubleshooting for
montor panel (M mode)
1 E2a group: Troubleshooting for engine
throttle. pump controller (pump control Carry out troubleshooting in applicable mode
Is user code
displayed on system ) (C mode)
Carry out
monitor panel? E3a group: Troubleshooting for
engine throttle. pump controller
(governor control system 1(E mode) systemfor which
E4a group: Troubleshooting there is no failure
troubleshooting
for
for valve controller (K mode)
E6a group: Troubleshooting
for GX controller (A mode) section
wherethereis
noabnormality
display displavl(El1- E15)
onjudgment
table.
, * After adjusting 1HVdraulic Carry out
- Operate and (mechanical) troubleshooting for
check service ‘I YE hydraulic (mechanical)
1:a~;;t~;;~,,? 1 kng%e speed. system (H mode)
* Is all work equipment slow and
4
* Check using does engine speed drop under
3
monitoring code. heavy load?
Are monitor - Governor _ I Carry out troubleshooting for
controller: 30,31, NO
No codes 02,03, input signal system (F mode).
33.34
04,08 normal?
* Pump controller:
lo-24
* Check
* Valve controller:
connection 50-69
condition of
S-NET in - Carry out troubleshooting
monitoring JO
for communication
codes abnormality system
02, 03, 04, 08. IN comde).
* For details, see engine throttle . pump controller (governor control system) (pump control system)
in the JUDGEMENT TABLE.
20-250
0
If there is no abnormality display in the communications system transmitted in S-NET, it can be taken
that the output signal from the monitor panel has been transmitted. However, even if there is no
abnormality display, if the operation is defective, use the following procedure when checking directly.
If any abnormality occurs in the S-NET system, the system is automatically switched to the following
default mode, so be careful when carrying out troubleshooting.
Default Mode when communications cannot be carried out for the monitor and engine throttle
. pump controller
Set mode Pump control Governor control
Working mode G/O mode H/O mode

Throttle signal FULL FULL
Auto-deceleration ON (deceleration mode ON (deceleration mode)
Coolant temperature signal OFF
Priority mode OFF -
Power max. mode ON (power max. possible)
Travel speed Lo
Automatic warming up - ON (automatic warming-up mode)
1. Procedure for checking monitor panel output signal

* For details of operating the monitoring mode, see MONITOR PANEL DISPLAY AND SPECIAL
FUNCTIONS.
1. Connection condition of components
1) Set to the monitoring mode and display monitoring code 08.
2) The time display (bits) will light up to display the components that are connected.
Ir Engine throttle - pump controller (pump control system) (I) and engine throttle - pump
controller (governor control system) (2) will light up.
2. Checking working mode signal {check No. 2 throttle signal (monitoring code 16) at the same
time)
2) Switch the working mode as shown in Table 1 and check that the engine speed changes.
Table 1
Engine speed (high idling)
20-251
0
TROUBLESHOOTlNG DETAILS OF TROUBLESHOOTING AND TROUBLESHOOTING PROCEDURE
3. Checking travel speed selection signal

2) Change the speed selector switch to Hi or Mi and run the engine at 1500 rpm or above.
Check that bit (6) lights up when traveling at Hi or Mi (front or rear pump oil pressure: 17.7
- 23.5 MPa (180 - 240 kg/cm?
4. Checking swing priority mode signal (HYPER GX only)
Ir If the travel oil pressure switch signal is not input to the controller, the flow from the front
and rear pumps will remain divided.
2) Check that bit (4) lights up when the travel is operated (even when operated slightly).
Ir Check the operating condition of the pump merge/divider solenoid valve
2. Checking input signal of engine throttle - pump controller

Ir Check the input signals for each controller as follows.
. Pump control system
1. Checking input signal
1) Check hydraulic switch
i) Set to the monitoring mode, and display monitoring codes 20 and 21.
ii) Operate each work equipment lever, and check how the bit pattern lights up.
* For details of the bit pattern chart, see MONITOR PANEL DISPLAY AND SPECIAL
FUNCTIONS.
2) Check speed sensor (check engine speed)
i) Set to the monitoring mode, and display monitoring code 10.
ii) Use the fuel control dial to change the speed, and measure the speed when this is
done.
3) Check pump discharge pressure sensor
Ir Code 11 is for the front pump and code 12 is for the rear pump.
ii) Refer to Table 2 and measure the hydraulic pressure at the front or rear pump.
Table 2 Pump merge/flow logic and pumps actuated by control levers
Independent operation Travel operated independ-

ently or compound opera-
(basic flow merged)
tion together with travel%
% Conditions for compound operation with travel.

(1) When measuring the oil pressure for any circuit other than travel, operate the
travel lever slightly or connect a short connector (X-2P) to the travel oil pressure
switch connector (CN-SOI).
(2) The circuits merge when the pressure of the front pump or rear pump is more
than 19.6 MPa (200 kg/cm*).
20-252
0
4) Check kerosene mode input signal

ii) Connect the CN-M36 connector and check that bit (5) lights up.
5) Check knob switch input signal .
ii) Turn the knob switch ON and check that bit (6) lights up.
2. Check output signals

1) Check LS-EPC solenoid output current
ii) Run the engine at high idling with all the levers at neutral and in the G/O or H/O mode,
and measure the current.
* All levers at neutral: 900 + 80 mA
Engine at high idling, any lever operated (other than travel): 0 A
2) No. 2 throttle signal
ii) Use the procedure in Item 2 for checking the monitor panel output signal, and measure
the engine speed.
3) Checking ON ti OFF solenoid condition
ii) Refer to Table 3 and check that the applicable bit lights up.
Table 3 Types of solenoid and conditions for actuation
Name of solenoid Actuation condition Bit that lights up
Active mode Active mode switch OFF (2)
Swing holding brake Swing or work equipment lever operated (3) I
Pump merge/divider Travel operated independently (4)

I I
2-stage relief Travel lever operated (5)
Travel speed selector Travel speed selector switch Hi or Mi (6)
Ir Operate the lever slightly not enough to move the machine.
4) Check PC-EPC solenoid output current

ii) With the starting switch kept at the ON position (G/O mode), measure the current when
the fuel control dial is turned to the MAX position and auto-decel is OFF.
l Current with starting switch ON (G/O mode) and fuel control dial at MAX (auto-decel:
OFF), Kerosene mode: PC200: 550 + 80 (mAI, PC220: 560 + 80 (mA)
20-253
0
. Governor control system

1. Check input signal
1) Check fuel control dial input voltage
ii) Measure the voltage when the fuel control dial is turned from low idling to high idling.
-)r Voltage: 0.25 - 4.75 V
2) Check governor potentiometer voltage
ii) Measure the potentiometer voltage when the fuel control dial is turned from low idling
to high idling.
* Voltage: 0.5 - 4.2 V (auto-decle at OFF)
2. Check output signal

1) Check governor motor drive current
* Code 33 is the A phase and code 34 is the B phase
ii) Measure the governor motor drive current when the fuel control dial is turned in the
acceleration direction and deceleration direction.
* Current: 700 f 70 (mA)
2) Measure battery relay drive output voltage

ii) Measure the battery relay drive output voltage when the starting switch is turned from
ON to OFF.
or
iii) Set to the monitoring mode, and display monitoring code 37.
iv) Check that bit (1) lights up when the starting switch is turned from ON to OFF.
20-254
0
TROUBLESHOOTING SERVICE CODE TABLE
SERVICE CODE TABLE
E424 Abnormality 1 in drive circuit system for left swing EPC solenoid valve
E425 Abnormality 1in drive circuit system for boom RAISE EPC solenoid valve E&CA
E426 Abnormality 1 in drive circuit system for arm OUT EPC solenoid valve
E427 Abnormality 1 in drive circuit system for bucket DUMP EPC solenoid valve CAL
E428 Abnormality 1 in drive circuit system for right swing EPC solenoid valve
E431 Abnormality 2 in drive circuit system for boom LOWER EFC solenoid valve EWA
E432 Abnormality 2 in drive circuit system for arm IN EPC solenoid valve
EOStCA
E433 Abnormality 2 in drive circuit system for bucket CURL EPC solenoid valve
- (CAlLI
E434 Abnormality 2 in drive circuii system for left swing EPC solenoid valve
E435 Abnormaliv 2 in drive circuit system for boom RAISE EPC solenoid valve EObtCA
20-255
0
TROUBLESHOOTING SERVICE CODE TABLE
Service Use1
code Abnormal system codt
E621 Abnormality in starting
Change in wiring harness after starting

E622
Abnormality in controller power source
Abnormality in 12V power source (over-currentdetected)

E623
Abnormality in 24V power source (over-currentdetected)
E09
E624 Abnormality in buzzer drive system (over-current)
E625 Impossible for network to receive signals
E626 Abnormality in non-volatile memory data range
E627 Read error in non-volatile memory
E628 Write error in non-volatile memory
For El01 - El14 see troubleshooting for the

monitor panel system (M mode), for E203 -
E237 see troubleshooting for the engine throt-
tle . pump controller [pump control system] (C
mode), for E306 - E318 see troubleshooting for
the engine throttle - pump controller [governor
control system1 (E mode), for E401 - E458 see
troubleshooting for the valve controller sys-
tem (K mode) and for E601 - E628 see trouble-
shooting for the GX controller system (A mode).
E401 - E458 apply to the HYPER specification
and E601 - E628 apply to the HYPER GX speci-
fication.
For service codes where the user code portion
gives EOG+CALL (CALL) or EOG+CALL (EOI),
when an abnormality occurs, either the user
E603 Abnormality in bucket pressure sensor system code without ( 1 or the user code with ( 1 is
displayed.
E604 Abnormality in swing pressure sensor system
E606 Abnormality in clinometer input value
E607 Abnormality in boom potentiometer system
E608 Abnormality in arm potentiometer system
E611 Abnormality in boom variable angle E09
E612 Abnormality in arm variable angle
E613 Abnormality in bucket variable angle
in comparison of two boom sensor signals

E614 Abnormality
E615 Abnormality in comparison of two arm sensor signals
E616 No change in signal when work equipmentshouldmove
E617 Over-range of cutting edge angle
E618 Abnormality in ROM data
20-256
0
TROUBLESHOOTING OF COMMUNICATION
ABNORMALITY SYSTEM
(N MODE)
N-l [E2181 Communication abnormality . . . . . .. . . . . . . .. . . . . . . . . .. .. . . . . .. . . . . . . . . . .. .. .. . . . . . .. . . . . . . .. . .. . . . . . . .. . . . . . .. . .. . . . . 20-302
20-301
0
TROUBLESHOOTING N-l
N-l [E218] Communications abnormality
This troubleshooting is carried out when there is still an abnormality, so when disconnecting the
connector and inserting the T-adapter, or when removing the T-adapter and returning the connec-
tor to its original position, if an E service code is not displayed, the problem has been removed.
If the starting switch is turned OFF after an abnormality occurs, turn the starting switch ON and
check if an E-service code is displayed. (If it is not displayed, the problem has been removed.)
Before carrying out troubleshooting, check that all the re-
lated connectors are properly inserted. Cause Remedy
Always connect any disconnected connectors before going
on to the next step.
System is reset -
Follow service code -

YE display
. Turn starting
I * See Table 1.
Go to troubleshooting
switch ON. NO K-4 (E451)
* See Table 1.
YES Go to troubleshooting
K-4 (E451k2 Short circuit -
l Disconnect C17. 4 in system
* Turn starting
switch ON.
1Do bits (I ), (2) of 1
monitoring code
I
See Table 1. Defective engine throttle
l
Replace
n 08 light up? . pump controller
* See Table 2.
* Turn starting
switch ON. Defective monitor panel Replace
NoI LZ.Za~~rmal? 11 1sresistance ‘YES
* Turn starting u betwet
switch ON. NOSH
I(12) normal? Disconnection in wiring
* Min. 7.5 V IL
harness between PO1 (4). Replace
* Disconnect Cl7 ,nnc+ POI
* DISCOI...__. NC
(11) and Cl7 (4). (12)
and measure and C17.
voltage at wiring * Max. 1 a
harness end.
/ 1
Table 1 Display . When each controller is not con-
Monitoring code PC200,210 PC220,230 nected to the network, II- - -“
01 1Monitor panel model code 200 220 is displayed. If the correct letter
or number is not displayed (an-
02 Engine throttle . pump controller model code 200 220
other model is displayed), there
03 Engine throttle . pump controller model code 200 220 is an abnormality in the con-
04 EPC valve controller model code 200 - troller model selection.
Table 2
Monitoring code
I I BKP00093
Light up when connected . Checks can be carried out with code 08 only
& Engine throttle . pump controller when there is a disconnection in the network;
@ Engine throttle . pump controller when there is a short circuit with the ground,
@ EPC valve controller the display does not change.
@ GX panel Therefore, the basic situation is to use Table
@ GX controller 1 to check the connection condition when
@ Valve controller for expansion (for radio control) there is a short circuit with the ground.
20-302
N-l
TROUBLESHOOTING
N-l Related electric circuit diagram
H14 Monitor Panel

Engine throttle.pump controller (M5) PO1 (04020)
Cl6 (MIC17)
EPC Vi re controller
(04020)
S-NET (-1
Cl7 (04016)
S-NET (-1
S-NET (+I
S-NET (t)
-I
TKP00796
20-303
0
TROUBLESHOOTING OF ENGINE THROTTLE1
PUMP CONTROLLER
(GOVERNOR CONTROL SYSTEM)
(E MODE)
Points to remember when carrying out troubleshooting of engine throttle .

pump controller system . .. . . . .. . . . .. .. . . . .. . . . . . . .. . .. . . . . . . . . . . .. . . . . . . . . . . .. . . . . . . . .. .. . . . . . . . . .. . .. . . . .. . . . . . . .. . . .. . .. . .. .. . . . . . . .. .. 20-352
Action taken by controller when abnormality occurs and problems on machine . . . . . . .. . . . . . . . . . . .. . . .. . 20-354
Judgement table for engine throttle - pump controller (governor control system)
and engine related parts .. . . . .. . . . . . .. . . . . . . . . . . . .. . . . . . . . . .. . . . . . . . . . . . .. .. . . . . . . .. . .. . . . . . .. . .. . . . .. . . . . . .. . . . . . . .. . .. .. . . . . . . .. .. . .. . . 20-358
Electrical circuit diagram for E mode system . . . . . . . . . . . .. . . . . . . .. . . .. . . . . . . .. . .. . . . . . . . .. . . .. . . . . . . . .. .. .. . . . .. . .. .. . . . . . . .. .. . . . 20-360
E- 1 Abnormality in engine throttle - pump controller power source
(controller LED is OFF) ....................................................................................................... 20-362
E- 2 [E3081 Abnormality in fuel control dial input value is displayed ................................. .20-363
E- 3 [E3171 Abnormality (disconnection) in motor drive system
3 is displayed.. ........................................................................................................................ 20-364
>
z
0
E- 4 IE3181 Abnormality (short circuit) in motor drive system is displayed ....................... 20-365
E- 5 IE3061 Abnormality in feedback potentiometer system is displayed ........................... 20-366
E- 6 IE3151 Abnormality (short circuit) in battery relay output system is displayed ......... 20-367
E- 7 [E3161 Abnormality (step-out) in motor is displayed.. ................................................... .20-368
E- 8 Engine does not start ......................................................................................................... 20-370

E- 9 Engine speed is irregular ................................................................................................... 20-374
a) Idling speed is irregular.. ............................................................................................ .20-374
b) There is hunting ........................................................................................................... 20-376
E-10 Lack of output (engine high idling speed is too low). ................................................... .20-378
E-l 1 Engine does not stop ......................................................................................................... 20-380
E-12 Defective operation of battery relay system (engine does not stop). .......................... 20-382
20-35 1
0
POINTS TO REMEMBER WHEN CARRYING OUT TROUBLESHOOTING
TROUBLESHOOTING OF ENGINE THROTTLE . PUMP CONTROLLER SYSTEM
POINTS TO REMEMBER WHEN CARRYING OUT TROUBLE-

SHOOTING OF ENGINE THROTTLE . PUMP CONTROLLER
SYSTEM
1. Points to remember when there is abnormality which is not displayed by user code
The engine is controlled by the engine throttle . pump controller.
The problems that may occur with this system include the following.
1. Idling speed is too high (too low)
2. High idling speed is too low
3. Auto-deceleration speed is too high (too low)
4. Engine speed for automatic warming-up operation is too high (too low)
5. There is hunting
6. Engine does not stop
If any abnormality occurs, and the abnormality is displayed on the time display portion of the
monitor panel, use the troubleshooting table to determine the appropriate troubleshooting flow
chart from E-l to E-12.However, if there is any abnormality in the machine and no abnormality
display is given, it is necessary to determine whether the problem is in the mechanical system or
in the electrical system. If the linkage between the governor motor and the injection pump is not
properly adjusted, problems 1 to 6 listed above may occur. Therefore, if there is no abnormality
display, but one of problems 1 to 6 above has occurred, carry out troubleshooting as follows.
YES 2
Defective adjustment of governor motor
JlfYbetween
likage See TESTING AND ADJUSTING.
governor motor
1
and injection pump
If linkage between - is disconnected, g
governor motor and does operation of
>
injection pump is governor motor Go to troubleshooting E-9 - E-12 of
disconnected and electrical system %
_ become normal? NO
pump lever is
operated by hand or *With starting switch at ON, operate fuel
is fixed with wire, control dial and working mode switch.
does condition Go to troubleshooting S-l - S-16 of
returen t0 nOrId? NO engine system
* If engine does not stop, push
governor lever to STOP position
and check if engine stops.
Disconnect the linkage as explained above, or check the adjustment and go to the troubleshooting
flow chart for the mechanical system or electrical system.
For details of the procedure for adjusting the linkage, see TESTING AND ADJUSTING.
2. Points to remember if abnormality returns to normal by itself

In the following two cases, there is a high probability that the same problem will occur again, so
it is desirable to follow up this problem carefully.
1) If any abnormality returns to normal by itself, or
2) If the connector is disconnected and the T-adapter is inserted, or if the T-adapter is removed
and the connector is returned to its original position when carrying out troubleshooting of the
failure, and the service code is no longer displayed, or if the monitor display returns to normal.
3) After completing troubleshooting, always erase the service code from memory.
3. User code memory retention function

When displaying the abnormality code in memory and carrying out troubleshooting, note down
the content of the display, then erase ,the display. After trying to re-enact the problem, carry out
troubleshooting according to the failure code that is displayed.
(There are cases where mistaken operation or abnormalities that occur when the connector is
disconnected are recorded by the memory retention function. Erasing the data in this way saves
any wasted work.)
20-352
0
ACTION TAKEN BY CONTROLLER WHEN ABNORMALITY
TROUBLESHOOTING OCCURS AND PROBLEMS ON MACHINE

OCCURS AND PROBLEMS ON MACHINE
User Service
Abnormal system Nature of abnormality
code code
1. Short circuit in wiring harness between CO3 (7) - (14), (7
- (17), (14) - (17)
2. Short circuit in wiring harness between E04 (I) - (21, (I) -
(31, (2) - (3)
3. Short circuit in wiring harness between E06 (1) - (21, (I) -
(31, (2) - (3)
4. Short circuit in wiring harness between CO3 (7) - (41, (4) -
Abnormality in fuel
E308 (17)
control dial input value 5. Disconnection in wiring harness between CO3 (7) - X07
(6) - E06 (I)
6. Disconnection in wiring harness between CO3 (4) - X07
(5) - E06 (2)
7. Disconnection in wiring harness between CO3 (17) - X07
(4) - E06 (3)
8. Defective fuel control dial
9. Defective contact of C03, X07, E06 connectors
1. Disconnection inside governor motor

E05 2. Disconnection in wiring harness between CO2 (2) - E05 (I)
Abnormality
3. Disconnection in wiring harness between CO2 (4) - E05 (3)
E317 (disconnection) in motor
drive system
6. Defective contact of E05 connector
1. Short circuit inside governor motor

2. Wiring harness between CO2 (2) - E05 (I) and between
Abnormality CO2 (4) - E05 (3) short circuiting with wiring harness be-
E318 (short circuit) in motor tween CO2 (3) - E05 (2)
drive system 3. Wiring harness between CO2 (4) - E05 (3) and between
CO2 (2) - E05 (I) short circuiting with wiring harness be-
tween CO2 (5) - E05 (4)
4. Wiring harness in Items 2 and 3 short circuiting with
ground
20-354
0
Condition when normal Action by controller when Problem that appears on machin
(voltage, current, resistance) abnormality is detected when there is abnormality
co3 E06 Resistance

(female) (male) value
(7) - (4) (1) - (2) 0.25 - 7kQ 1. Does not become partial speec
(4) - (17) (2) - (3) 0.25 - 7kQ when set at MAX position
(7) - (17) ~ ‘2 - 3kR Maintains eng’ne speed at 2. Does not reach high idling wher
position of fuel control dial
(1) - (3) 4 - 6kR set at partial speed
immediately before abnor-
3. There are cases of hunting
Between mality occurred
4. Lacks output (max. speed of en
each pin - Min. 1 MQ gine is too low)
and chassis
1. When there is a disconnection ir

both the A phase and B phase ai
the same time, the problem is the
same as for a short circuit in the
governor motor system
2. When there is a disconnection ir
Takes no particular action only one of A phase or B phase
1) Engine does not stop
2) Stops moving at position irn.
mediately before failure, so en
gine speed cannot be control-
Motor drive current: Hold: 0.7 A led
3) There are cases of hunting
Start: 0.84 A
E05 co2 Resistance

(male) (female) value
(1) - (2) (2) - (3) 0.25 - 7.5kR 1. If during operation
1) Set to low idling
(3) - (4) (4) - (5) 0.25 - 7.5kR
2) Engine does not stop
(I) - (3) (2) - (4) Min. 1 Ma 3) There are cases of hunting
(1) - (4) (2) - (5) Min. 1 MR 2. When stopped
Between Between Sets motor drive current to 0 1) Engine starts, but stays at low
idling
pins (I),(21, pins (21, (31,
2) Engine does not stop after start-
(31, (4) and (41, and (5) Min. 1 Ma
ing
chassis and chassis 3) There are cases of hunting
Motor drive current: Hold: 0.7 A
Start: 0.84 A
20-355
0
User Service
code code
1. Short circuit in wiring harness between CO3 (7) - (141, (7)

- (171, (14) - (17)
2. Short circuit in wiring harness between E04 (I) - (2), (1) -
(3). (2) - (3)
3. Short circuit in wiring harness between E06 (I) - (21, (1) -
(31, (2) - (3)
4. Short circuit in wiring harness between CO3 (7) - (4), (4) -
- Abnormality in feedback
E306 (17)
potentiometer system
6. Disconnection in wiring harness between CO3 (14) - E04
(2)
7. Disconnection in wiring harness between CO3 (17) - E04
(3)
8. Defective governor motor potentiometer
9. Defective contact of C03, E04 connectors
Abnormality (short cir- If excess current flows between CO3 (1) and battery relay
- E315 cuit) in battery relay out- * This occurs only when turning starting switch to OFF and
put system stopping engine
1. Defective adjustment of rod or scuffing of loose spring
Abnormality (step-out)
- E316 2. Abnormality in governor motor
in motor
3. Abnormality in engine throttle . pump controller
20-356
0
Condition when normal Action by controller when Problem that appears on machine
1. Precision of engine speed control
may be reduced.
For example:
co3 E04 Resistance 1) Engine does not rise to high
(female) (male) value idling speed (a little too low)
2) Engine does not go down to
(7) - (14) (1) - (2) 0.25 - 7kR
Calculates position of motor low idling speed (a little too
(7) - (17) (2) - (3) 0.25 - 7kQ high)
and carries out control from
(14) - (17) - 2 - 3kR 3) Defective engine speed for auto-
value of voltage immediately
deceleration or automatic
(1) - (3) 4 - 6kfi before abnormality occurred
warming-up
Between 4) Engine may not stop
each pin - Min. 1 MR t The governor motor moves
and chassis in the direction to stop the
engine, but the motor may
not move completely to the
position to stop the engine.
5) There are cases of hunting
between CO3 (1) and chassis: 20 - 30 V

t Holds with the motor in the stop
position for 2 - 2.5 sec. returns to ~~~~t~~ry relay drive cur- Engine does not stop
the low idling position, then turns
the battery relay OFF.
1. Displays when returning

. Linkage adjustment correct from high idling to low
idling
I. Must move lightly when connector * ztt$iuzgain irepeats Engine speed cannot be controlled
is removed (particularly at high idling), so there
2. In some cases it may not
display when returning is hunting
from partial speed to low
1. Normal
idling
20-357
0
JUDGEMENT TABLE FOR ENGINE THROTTLE - PUMP CONTROLLER
TROUBLESHOOTING (GOVERNOR CONTROL SYSTEM) AND ENGINE RELATED PARTS
JUDGEMENT TABLE FOR ENGINE THROTTLE 1 PUMP

CONTROLLER (GOVERNOR CONTROL SYSTEM) AND ENGINE
RELATED PARTS
Engine throttle pump
E controller, engine related parts
m (E3: system1
zi
t Self-diagnostic display t
8
2
Engine rotation is irregular
0 : This shows applicable item for service code

I : This shows item that needs only checking with monitoring
20-358
a
02OYO6
Troubleshooting code if no service code display is given

TROUBLESHOOTING ELECTRICAL CIRCUIT DIAGRAM FOR E MODE SYSTEM
ELECTRICAL CIRCUIT DIAGRAM FOR E MODE SYSTEM
Fuel control dia I uL~

Q+-rting switch
EO6m k@
r;
ineine
:ontrol
throttle.pump
ler
I
j( CO1 (MIC13) !
P,
a
h-’ ’
--_--_--_-__-----_-----------__________
I
~___________________--1~
9
II
,”
PCZOOSTD PC220STD
PCZIOSTD PC230STD
Model selection connector

Cl6 (MIC17)
GND
GND
i -----. -_-_-_-_ J
TKP00797
20-360
0
TROUBLESHOOTING ELECTRICAL CIRCUIT DIAGRAM FOR E MODE SYSTEM
Electric governor actuator

_-_-_-_-
I-----
E04 (X3) Potentiometer /
t
sia
otor
D13 (KESl)
1 0 85RCi1
2 0:85BRl:;
L
14
Fuse box
H15 (L2)
10
P, 5R
Battery -
TKP00798
20-361
0
TROUBLESHOOTING E-l
E-l Abnormality in engine throttle m pump controller power source

(controller LED is OFF)
* This troubleshooting is carried out when there is still an abnormality, so when disconnecting the
tor to its original position, if the service code E is not displayed, the problem has been removed.
Ir Check that fuse 1 is not blown.
+ Before carrying out troubleshooting, check that all the related connectors are properly inserted.
* Always connect any disconnected connectors before going on the next step.
Ir When the starting motor rotates correctly. (If the starting motor also does not rotate, go to E-8.)
Cause Remedy
YES Defective engine throttle

Replace
1 . pumpcontroller
Is voltage
between CO1 (7) Defective contact, or
(13) and CO2 (11) - 2 YES disconnection in wiring Repair or
(21) normal? _ Is voltage harness between fuse 1 replace
between fuse 1 and CO1 (female) (7) (13)
l Turn starting
switch ON. NO and chassis Defective contact, or
*20-30V normal? disconnection in wiring Repair or
harness between fuse replace
* Turn starting NO
l-H15 (2kM14 (2)
switch ON.
(lkbattery relay M
*20-30V
E-l Related electric circuit diagram
Engine throttle.PumP
controller
CO1 (MIC13)
H14 (~6) Fuse H15 (L2)
$J
m
Battery relay Fusible link
Battery
II-I/
TKP00799
20-362
0
TROUBLESHOOTING E-2
E-2 [E308] Abnormality in fuel control dial input value is displayed
tor to its original position, if the service code E is not displaved, the problem has been removed.
Before carrying out troubleshooting, check that all the relsteb connectors are properly inserted.
Always connect any disconnected connectors before going on the next step.

Replace
Is resistance pump controller
between each pin
YES of CO3 (female) (4)
, _ (7) (17). or
between each pin
Is resistance and chassis as
between E06 shown in Table l? Defective wiring harness
(male) (1)42). (2)- - in system with defective Replace
* Turn starting NO
(3) as show in resistance
switch OFF.
* Disconnect C03.
. Turn starting Defective fuel control dial Replace
switch OFF. Ml-l
. Disconnect E06. ‘*”
* If E306 also occurs at the same time, check the wiring harness below.
. Wiring harness between CO3 (female) (7) - E04 (female) (I) short circuiting with ground, or
contact with other wiring harness
Table 1
Between each
pin and Min. 1 MQ
chassis
E-2 Related electric circuit diagram
Engine throttle,
Pump controller
Fuel control
Throttle
command
Throttle Power
source (+I
Feedback
Throttle Power
source (-1
TDP00356
20-363
0
TROUBLESHOOTING E-3
E-3 [E317] Abnormality (disconnection) in motor drive system is

displayed
Ir This troubleshooting is carried out when there is still an abnormality, so when disconnecting the
Ir During operation, if there is
1) a simultaneous disconnection in A phase and B phase:
1) the engine will run at low idling
2) the engine will not stop
2) a disconnection in either A phase or B phase, the engine speed will remain the same as before
the abnormality occurred
+ If the problem occurs when the engine is stopped,
1) the engine can be started, but it stays in low idling, or 2) it will not stop after it is started.
g Check with the engine stopped (push the fuel control lever of the fuel injection pump to the NO
INJECTION position).
* Before carrying out troubleshooting, check that all the related connectors are properly inserted.
Cause Remedy

Replace
. pumpcontroller
Defective wiring harness

~~
in system with defective Replace
resistance
I
switch OFF..
* Disconnect COZ.
- Turn starting Defective governor Replace
switch OFF. NO motor
* Disconnect E05.
Table 1
E05 co2 Resistance
(1) - (2) (2) - (3) 2.5 - 7.5kn
(3) - (4) (4) - (5) 2.5 - 7.5k!LI
controller
CO2 (MIC21) E05 (X4)
, I
20-364
0
TROUBLESHOOTING E-4
E-4 [E318] Abnormality (short circuit) in motor drive system is

displayed
* If the abnormality occurs during operation, because of the force of the spring,
1) the engine will run at low idling
2) the engine will not stop
* If the problem occurs when the engine is stopped,
I) the engine can be stat-ted, but it stays in low idling, or 2) it will not stop after it is started.
Before carrying out troubleshooting, check that all the related connectors are properly inserted.
Cause Remedy

. pumpcontroller Replace
between each pin of
YES coz(female), or
I r between each pin -
between each pin of
1shwon in Table I? 11
in system with defective Replace
* Turn starting NO resistance
between each pin
and chassis as switch OFF.
* Disconnect COZ.
* Turn starting I Defective governor Replace
* Disconnect E05.
Table 1
E05 co2 I Resistance 1
(1) - (2) (2) - (3) 2.5 -. 7.51<52
(3) - (4) (4) - (5) 2.5 - 7.5kQ
(I) - (3) (2) - (4) Min. 1 MQ
(1) - (4) (2) - (5) Min. 1 MQ
Between chassis Between chassis
and pins and pins Min. 1 MC2
(1U)(3)(4) bW)(4)(5)
Engine throttle,Pump
controller
CO2 (MIC21) E05 (X4)
Governor motor
A (+I a 3
Ai-) @ 3
B (+I @ 3
Et-1 ($ -3
TKPOOEOO
20-365
0
TROUBLESHOOTING E-5
E-5 [E306] Abnormality in feedback potentiometer system is displayed
Cause Remedy

Replace
-Is re*,stance
between each pin of
. pump controller
YES p; (~r~;jlt7) _
1 ’
- each pin and chassi Defective wiring harness
Is resistance as shown in Table17
between E06 in system with defective Replace
NO
(male) (i)-(z), (2)- - .Turn starting resistance
(3) as shown in switch OFF.
Table l? * Disconnect C03.
l Turn starting Defective governor
Replace
l Disconnect E04.
* If E308 also occurs at the same time, check the wiring harness below.
. Wiring harness between CO3 (female) (7) - X07 (6) - E06 (female) (I) short circuiting with
ground, or contact with other wiring harness
Table 1
co3 E04 Resistance
(female) (male) value
. (7) - (14) (1) - (2) 0.25 - 7m
(14) - (17) (2) - (3) 0.25 - 7kQ
(7) - (17) - 2-3k!Z
(1) - (3) 4-6kQ
Between each
pin and Min. 1 MQ
chassis
Engine throttle,
Pump controller
603 (04020)
Throttle
Throttle Power Potentiometer

source (+I
Feedback
Throttle Dower
source t-1
TDP00356
20-366
a
TROUBLESHOOTING E-6
E-6 [E315] Abnormality (short circuit) in battery relay output system is

displayed
a Check with the engine stopped (push the fuel control lever of the fuel injection pump to the NO
Ir This only occurs when the engine is stopped and the starting switch is turned OFF.
Cause Remedy

Replace
1 . pump controller
Isresistance
between CO1
(female) (1) and 2 YES
chassis normal? IS Defective battery relay Replace
p CO1ifemale)(1)and
l Between CO1 batteryrelayterminal 1) Contact between
(female) (I) and NO wmng
B9*.a”d benveen
harness and other wiring harness
chassis: Approx. chassisnormal? and wiring harness
1ooa between CO1 (female) Replace
* Between CO1 NO
* Turn starting (female) (1) and (I )-HO2 (9kbattery
8 switch OFF. battery relay BR: relay BR.
z * Disconnect COl. MaxlR 2) When light is
* Beetwaen wiring connected
% harness and
chassis: Min. 1 MQ.
* Turn starting switch
OFF.
* Disconnect CO1 and
battery relay BR.
Fusible link
Engine throttle, Battery relay

Pump controller
TDP00360
20-367
0
TROUBLESHOOTING E-7
E-7 [E316] Abnormality (step-out) in motor is displayed
* If any other service code [E3061- [E3181 has occurred at the same time, start troubleshooting from
the code except codelE3161.
* Check that the fuse is normal.
* Read the precautions given in TESTING AND ADJUSTING, “Adjusting travel of governor motor
lever” before carrying out the troubleshooting.
Cause Remedy
YES Go to applicable failure -

mode
YES Defective engine throttle Replace

II . pump controller
Are E306, E317,
YEiS
!
I) Defective linkage Adjust or
2) Defective injection replace
l Turn starting pump
switch ON. 2
Defective governor Replace
ation OFF. . Disconnect E05 NO motor
* Disconnect
linkage at
*Turn starting governor motor
switch ON. end.
l Turn auto- Adjust (For
deceleration OFF. Defective governor details, see
linkage
* Set to governor N0 TESTING AND
motor ADJUSTING)
adjustment
mode.
* See TESTING
AND
ADJUSTING.
20-368
0
TROUBLESHOOTING E-8
E-8 Engine does not start
+ When starting motor does not rotate.

+ Check that fuse 14 is not blown before starting troubleshooting.
+ Always connect any disconnected connectors before going on the next step.
4 YES
Is voltage between
(ES ; starting motor
terminal B and
chassis normal?
* Turn starting NO
switch ON.
*20-29v
YES
Is there sound of Is voltage between

Yf YI
starting motor
pinion engaging? terminal C and
.X-Same conditions
6 as Item 5.
NO
terminal C and
chassis normal?
x Same conditions
Is voltage between as Item 5.
NC
* Turn starting
switch is turned
switch to START.
OFF, is sound heard *20-29v
NO
* See Table 1.
* Turn starting
switch ON +
OFF.
Yl
specific gravity of 11
there continuity
Is
* Use tester in diode 1
YES between starting
switch terminal B ;+a;;~;ea;“dt;“tan NO
l Min. 24V
10 and BR? starting switch and (4 pole with battev relay.
l Specific gravity:
Min. 1.26 Is voltage of . Disconnect both starting switch and battery relay
l Turn starting ends.
starting switch
- switch ON.
NO terminal 6 IO
* Remove terminal
normal?
B.
)
to H terminal of NO
battery.
*20-29v
IO
20-370
0
TROUBLESHOOTING E-8
Cause Remedy
Defective starting motor Repair or

(starting motor proper) replace
Defective contact of
wiring harness between
battery (+) -battery relay Repair or
B - battery relay M - replace
starting motor terminal 6
(including battery relay)
Defective starting motor Repair or

(magnetic clutch) replace
Defective contact or
VFS
harness between safety Repair or
a relay terminal C - T13 (I) replace
-starting motor terminal
Is voltage between C
safety relay
9 YES
terminal C and Defective safety relay Replace
chassis normal? Is voltage between
safety relay
’ ~~~~~Bnditions NO terminal R and
chassis normal?
I I I
Defective alternator Repair or
* Turn starting NO replace
switch ON.
*Max. 13V
harness between X07 Repair or
(fernale) - MO2 (I) - replace
safety relay terminal S
Defective starting switch

(between terminals B Replace
and C)
Defective battery relay Replace
Defective contact of wiring

harness between battery
relay terminal E and Repair or
revolving frame ground replace
terminal
Defective contact, or
disconnectionin wiring
harness between startina Replace
switch terminal BR - DlT-
battery relay terminal BR
(including diode1
Defective starting switch

Replace
(between B and BR)
harness between battery
terminal I+)- Ml1 - H14
Replace
(l),(5) -X07 (1) -starting
switch terminal B (including
fusible link)
Charge or
Lack of battery capacity
replace
20-371
0
TROUBLESHOOTING E-8
Start ina
Fuse
switch X07 (MIC17) HI4 (MEi)
Start ina
Alternator
motor
pair heater
E08 (Xl)
Battery relay
w----
TKP00801
20-372
0
TROUBLESHOOTING E-9
E-9 Engine speed is irregular
Ir Before carrying out troubleshooting, check that all the related connectors are properly inserted.
a) Idling speed is irregular
4 YES
2 Whenhnkage
betweengovernor
YES motor and pumpis
adjusted, does
Icodiip,n become 11
* See TESTING NO
* Turn starting AND
switch ON. ADJUSTING.
3
Starting motor signal 7 YES
disconnected and Is voltagebetween
N
motor lever is
placed at position
engine low idling?
I
YES ~03 (8) and
* Turn starting
model code as switch ON.
shown in Table
. Turn starting
IY”
switch ON. N& and (17) normal
* Set to monitoring 1 and stable? II
I
code 03 or 02.
. At MIN
: 4.0 - 4.75v
NO
z
0
Table 1
Controller model code

I
PC200
PC210
BKP00414
PC220
PC230
BKP00415
Ir The diagram shows monitoring code 03.
20-374
0
TROUBLESHOOTING E-9
1 F;fe;p adjustment of Adjust
Defective injection pump See S mode
wiring harness between Repair or
starting switch ACC-X07 replace
(17)-CO3 (fernal) (81, or
defective starting switch
See E-5 -
See E-2 -
See C-20 -

Start ins
switch X07biIC17) H14M6) Fuse
Engine throttle,
Pump controller
co3 (04 02
Fuel cant rol
Starting switch _ dial
ON signal
Throttle command
!$$ Governor
Throttle Power
source (4
Feedback
Throttle Power
source 6)
TROUBLESHOOTING E-9
b) There is hunting
NO
* Turn starting
switch ON.
Starting motor signal 7 YES
Ir-
l-l
-Turn starting
switch ON. * thrina ooeration NO
model code as and (17) normal
shown in Table *Turn fuel control %el control dial 5
dial from MIN to
MAX and stop *At MIN
* Turn starting 4
also at midway : 2.9 - 3.3v
switch ON. NO
position. . At MAX
-Set to monitoring
: 0.5 - 0.9v
code 03 or 02. $
* At MIN t
: 4.0 - 4.75v
*At MAX
N’
0 8
0
: 0.25 - l.OV
Table 1
I\ I Controller model code I
PC200
PC210
BKP00414
PC220
PC230
BKP00415
* The diagram shows monitoring code 03.
20-376
0
TROUBLESHOOTING E-9
Remedy
k
Cause
See N mode -
Defective adjustment of hdjust

linkage

motor
Repair or
starting switch ACC -
replace
X07 (17) - CO3 (female)
(8), or defective starting
switch
See E-5
-
See E-2 -
See C-20 -

Start ins
switch X07(MICl7) H14(M6) Fuse
Engine throttle, ---u-J%--

Pump controller
Fuel control
Starting switch
ON signal
Throttle command
E04
,-, (X3) Governor
Throttle Dower
source I+)
Feedback
Throttle Power
source (-)
TROUBLESHOOTING E-10
E-10 Lack of output (engine high idling speed is too low)
‘ES
* Turn starting
. ,r
YES
switch ON. 3
Potentiometer 6
4-l
Does injection
pump lever
NO contact FULL
and (17) normal
stopper? Fuel control dial !
* Start engine.
* At MIN l-
I
* Set fuel control
1 and (17) normal : 2.9 - 3.3v NO
dial to MAX.
I Is controller I *At MAX
+ H/O mode.
: 0.5 - 0.9v
*At MIN
I
: 4.0 - 4.75v
. At MAX
NO
* Turn starting : 0.25 - 1.OV
switch ON.
* Set to monitoring
code 03 or 02.
NO
* See TESTING
AND
ADJUSTING.
Table 1
Controller model code
PC200
03 ZYJo
PC210
BKP00414
PC220
PC230
BKP00415
20-378
0
k
Cause Remedy
See N mode -
Starting motor
signal 7 YES
motor
between CO3 (8)
1normal and wiring harness between
Repair or
stable? starting switch ACC -
replace
NO X07 (17) - CO3 (female)
* Durina
0pera;ion: 20 - (8), or defective starting -
3ov switch
See E-5 -
See E-2 -
Defective adjustment of
governor motor linkage Adjust
See S mode -
See C-20 -

Start ins
switch X07 (MIC17) H14 (M6) Fuse
Engine throttle, -A-

Pump controller
co3 (04 20) x07 (MIC171 E06 (M3)
Fuel control
Starting switch
ON signal
@ D - -3
Throttle command g 3 -3
8 3
-8
E04 (x3! Governor
Throttle Power
a 3 potentiometer 1
source (+I
Feedback @ 3
Throttle Power
@=a%,
source (-)
TDP00362
20-379
0
TROUBLESHOOTING E-II
E-II Engine does not stop
A Check with the engine stopped (push the fuel control lever of the fuel injection pump to the NO
Sr Read the precautions given in TESTING AND ADJUSTING, “Adjusting travel of governor motor
lever” before carrying out the troubleshooting.
YES
2
Does governor YES
Yl lever contact STOP
stopper, and does
engine stop?
3 Potentiometer 6YES
Trun starting
*Whenlinkage is
,
switch ON+ OFF.
adjusted, does
_ condition become R,elay drive ;:a1
Nn normal?
r,orma,r
* When engine i s NO
Is controller * See TESTING stopped
model code as AND * 2.9 - 3.3v
shown in Table ADJUSTING.
l?
NO
. Turn starting N
switch ON. chassis normal?
. Set to * Max. IV
monitoring code
03 or 02. NO
Table 1
PC200, 210 PC220, 230
t7
Controller l? LKI
B&H&¶
model code
BKP00414 BKP00415
I I
Table 2
I
I
Voltage from When ON (Approx. 24V)
starting switch(C03(8))
;To battery relay (BR)

OFF
See note 1 /Voltage output from controller
when starting switch is OFF
When ON
Condition of actuation (ADDrox. 24V)
of controller circuit To battery relay (BRI
OFF; 1
-_Min.4. 0 set
Drive time Max.7sec. (When itis impossible to set to
NO IINJECTION because of failure in motor)
TDP00364
Note 1:When the starting switch is ON, the controller end is OFF, but a voltage of approx. 20 - 30V is
always flowing from starting switch BR, so if the voltage is measured at CO1 (I), there is a
voltage of 20 - 30V.
20-380
0
TROUBLESHOOTING E-II
k
Cause Remedy
. Defective adjustment of
linkage
Defective governor
motor
See E-5 -
Defective engine throttle

Replace
. pump controller
Contact with 24V wiring

harness of wiring
harness between startinS I Replace
switch ACC -X07 (17) -
CO3 (female) (81, or
defective starting switch
See C-20 -
E-l 1 Related electric circuit diagram
Engine throttle,
Pump cant rol ler
CO3 (04020)
Starting switch
ON signal
Feed back
TDP00365
20-381
0
E-12 Defective operation of battery relay system (engine does not

stop)
Ir This only occurs when the engine is stopped and the starting switch is turned OFF.
Cause Remedy
See E-6 -

Replace
pump controller
Defective battery relay Replace
* Turn starting
switch OFF. 1)Disconnection in wiring
*20-30V harness between CO1
(female) (1) -battery Replace
relay BR
2)When light is connected
l Between CO1 (female) (1) and
battery relay BR: Max. 1 R
* Between wiring harness and
chassis: Max. 1 MR
* Turn starting switch OFF.
* Disconnect CO1 and battery relay
BR.
Table 1
Voltage from When ON (Approx. 24V)

starting switch (CO3(8))-1 To batteryre,ay(BR)
OFF
Voltage output from controller when starting switch is OFF
___- - See
- - _ Note 1
When ON
(Approx. 24V)
Condition of actuation
of controller circuit OFF[ 1 Min. 4.0tcqattery re’ayu3R’
co1 (1)
Drive time Max. 7sec. (when it is impossible to set to
NO IINJECTION because of failure in motor)
BKP00206
Note l:When the starting switch is ON, the controller end is OFF, but a voltage of approx. 20 - 30V is
always flowing from starting switch BR, so if the voltage is measured at CO1 (I), there is a
voltage of 20 - 30V.
20-382
0
llC17) H14 (~6) Fuse Ml1 (L2)

&
@ .a
Star
swit 3
Fusible link
Battery relay
Engine throttle.pump
controller
CO3 (04020)
p-&-g@
TKP00802
20-383
0
TROUBLESHOOTING OF ENGINE SYSTEM
(S MODE)
Method of using troubleshooting charts .. .. . .. . . . . . . .. . .. . . .. . .. . . . . . . .. .. . .. . . . .. .. . .. . . . . . . .. .. . . . . . . . . .. . . . . . . .. .. . . . . . . .. . . . .. . . 20-402

s- 1 Starting performance is poor (starting always takes time) ................................................. .20-406
s- 2 Engine does not start ............................................................................................................... 20-407
(I) Engine does not turn .......................................................................................................... 20-407
(2) Engine turns but no exhaust smoke comes out (fuel is not being injected) .............. 20-408
(3) Exhaust smoke comes out, but engine does not start (fuel is being injected) ........... 20-409
s- 3 Engine does not pick up smoothly (follow-up is poor) ....................................................... .20-410
s- 4 Engine stops during operations .............................................................................................. 20-411
s- 5 Engine does not rotate smoothly (hunting) .......................................................................... .20-412
S- 6 Engine lacks output (no power). .............................................................................................. 20-413
s- 7 Exhaust smoke is black ............................................................................................................ 20-414
S- 8 Oil consumption is excessive (or exhaust gas is blue). ....................................................... .20-415
s- 9 Oil becomes contaminated quickly ......................................................................................... 20-416
S-IO Fuel consumption is excessive ................................................................................................ 20-417
S-l 1 Oil is in cooling water, or water spurts back, or water level goes down.. ........................ 20-418
z+? lamp lights up (drop in oil pressure) ................................................. .20-419
s-12 Oil pressure caution
&
: s-13 Oil level rises (water, fuel in oil) ............................................................................................. 20-420
s-14 Water temperature becomes too high (overheating) ........................................................... .20-421
s-15 Abnormal noise is made .......................................................................................................... 20-422
S-16 Vibration is excessive ............................................................................................................... 20-423
20-401
0
TESTING AND ADJUSTING METHOD OF USING TROUBLESHOOTING CHARTS
IMETHOD OF USING TROUBLESHOOTING CHARTS
This troubleshooting chart is divided into three

sections: questions, check items, and troubleshoot-
ing. The questions and check items are used to
pinpoint high probability causes that can be located
from the failure symptoms or simple inspeciton with-
out using troubleshooting tools.
Next, troubleshooting tools or direct inspection
are used to check the high probability causes to
make final confirmation.
[Questions]
Sections @ + GJ in the chart on the right corre-
sponds to the items where answers can be ob-
tained from the user. The items in @I are items
that can be obtained from the user, depending
on the user’s level.
[Check items1
The serviceman carries out simple inspection to
narrow down the causes. The items under @ in
the chart on the right correspond to this.
The serviceman narrows down the causes from
information @ that he has obtained from the
user and the results of Q that he has obtained
from his own inspection.
ITroubleshooting]
Troubleshooting is carried out in the order of
probability, starting with the causes that have
been marked as having the highest probability
from information gained from [Questions] and
[Check items].
20-402
0
The basic method of using the troubleshooting chart

is as follows.
Items listed for [Questions] and [Check items] that
have a relationship with the Cause items are marked
with 0, and of these, causes that have a high prob-
ability are marked with Q.
Check each of the [Questions] and [Check items1 in
turn, and marked the 0 or Q in the chart for items
where the problem appeared. The vertical column
(Causes) that has the highest number of points is
the most probable cause, so start troubleshooting
for that item to make final confirmation of the cause.
%I. For [Confirm recent repair history] in the
[Questions] Section, ask the user, and mark
the Cause column with A to use as reference
for locating the cause of the failure. How-
ever, do not use this when making calcula-
tions to narrow down the causes.
%2. Use the A in the Cause column as reference
for [Degree of use (Operated for long pe-
riod)] in the [Questions] section as reference.
As a rule, do not use it when calculating the
points for locating the cause, but it can be
included if necessary to determine the order
for troubleshooting.
20-403
0
. Example of troubleshooting when exhaust gas is black

Let us assume that [Clogged air cleaner1 is taken to be the cause of black exhaust gas. Three
symptoms have causal relationship with this problem: [Exhaust gas slowly became black], [Power
slowly became weaker], and [Dust indicator is red].
If we look from these three symptoms to find the causes, we find that there is a relationship with
five causes. Let us explain here the method of using this causal relationship to pinpoint the most
probable cause.
Exhaust gas is black (incomplete combustion)

General causes why exhaust gas is black
. Insufficient intake of air
. Improper condition of fuel injection
. Excessive injection of fuel
1 When turbocharger is rotated by hand, it is found to be heavy
20-404
0
rll,,
Five causes
Clarify the relationship between the three

symptoms in the [Questions] and [Check items]
section and the five Cause items in the vertical
column.
Three symptoms
Step 2
Add up the total of Oand 0 marks where the

horizontal lines for the three symptoms and the
vertical columns for the causes intersect.
(I) Clogged air cleaner element: 000
(2) Air leakage between turbocharger
and head: 00
(3) Clogged, seized injection nozzle: 0
(4) Defective contact of valve, valve seat: 0
(5) Worn piston ring, cylinder: 0
Step 3
The calculation in Step 2 show that the closest

relationship is with [Clogged air cleaner
element]. Follow this column down to the
troubleshooting area and carry out the
troubleshooting item marked 0. The Remedy is
given as [Clean], so carry out cleaning, and the
exhaust gas color should return to normal.
20-405
0
TESTING AND ADJUSTING S-l
S-l Starting performance is poor (starting always takes time)

* Check that the monitor panel does not display any
abnormality in the governor control system.
General causes why exhaust smoke comes out but
engine takes time to start
. Defective electrical system
. Insufficient supply of fuel
. Improper selection of fuel
(At ambient temperature of 10°C or below, use
ASTM D975 No. 1)
* Battery charging rate
Ambin”I--
FJ 100% 90% 80% 75% 70%
golltfm
20°C 1.28 1.26 1.24 1.23 1.22
0°C 1.29 1.27 1.25 1.24 1.23
-10°C 1.30 1.28 1.26 1.25 1.24
l The specific gravity should exceed the value
for the charging rate of 70% in the above table.
. In cold areas the specific gravity must ex-
ceed the value for the charging rate of 75%
in the above table.
Legend
0 : Possible causes (judging from Questions and check items)
0 : Most probable causes (judgingfrom Questions and Check items)
A : Possible causes due to length of use (used for a long period)
0 : Items to confirm the cause
Confirm recent repair history I I I I I I I I I I I I I
Degree of use of machine 1Operated for long period I I IAkWl I IAl I I I I
Gradually br
,,l Ease of starting
can be seen that plunger control sleeve does not move)

When fuel cap is inspected directly, it is found to be clogged l
8- mom* _
Remedy%: 5 5 $?~?~~~$ 5
;sd~$~$~~~;~~
20-406
a
TESTING AND ADJUSTING s-2
S-2 Engine does not start

(I) Engine does not turn
General causes why engine does not turn

. Internal parts of engine seized Causes
* If internal parts of the engine are seized,

carry out troubleshooting for “Engine
stops during operations”.
. Defective electrical system
Legend
0: Possible causes (judging from Questions and check items)
0 : Most probable causes (judgingfrom Questionsand Check items)
A: Possible causes due to length of use fused for a long period)
l : Items to confirm the cause.
Confirm recent repair history
Degree of use of machine Operated for long period n n

E
When battery is checked, battery electrolyte is found to be low Q 1
Specific gravity of electrolyte, voltage of battery is low 1

For the following conditions 1) 5). turn the starting switch
OFF, connect the cord, and carry out troubleshooting at ON
I) When terminal Band terminal C of starting switch are
connected, engine starts
2) When terminal B and terminal C of starting motor are
3) When terminal B and terminal C of safety relay are
4)There is no 24V between battery relay terminal M and
terminal E
When ring gear is inspected directly, tooth surface is
found to be chipped
Remedy
20-407
0
(21 Engine turns but no exhaust smoke comes

out (fuel is not being injected)
* Check that the monitor panel does not dis-

play any abnormality in the governor control
system.
General causes why engine turns but no ex-
haust smoke comes out
l Supply of fuel impossible
l Supply of fuel is extremely small
. Improper selection of fuel (particularly in win-
ter)
/ Causes I
Ir Standards for use of fuel
Ambient temprature
Type of fuel
Diesel fuel
Legend
20-408
0
(3) Exhaust smoke comes out but engine does

not start
(Fuel is being injected)
* General causes why exhaust smoke comes

out but engine does not start Causes
. Lack of rotating force due to defective elec-
trical system
. Improper selection of fuel and oil
Legend
0 : Most probable causes (judging from Questions and Check items)
: Possible causes due to length of use fused for a long oeriod)

Degree of use of machine 1 Operated for long period DAL
Suddenly failed to start 00
I 6 Enoine oil must be added more freauentlv I I 101 I I I
www
I I to Operation Manual
When exhaust manifold is touched immediately after I I I I I I I I I Ihl

w I
starting engine, temperature of some cylinders is low III1 I I I I I I I I
I When fuel filter is drained, no fuel comes out I I I I I I I I I I I Ic
Wheninjection nozzle istested as individual part, spray condition isfoundto be poor 11 / 1 1 1 I 1 1 10 I I

When fuel cap is inspected directly, it is found to be clogged 1 1 / I 1 I I I I 1 IO 1
S-3 Engine does not pick up smoothly (follow-up is poor)
J, Check that the monitor panel does not display any

abnormality in the governor control system.
General causes why engine does not pick up smoothly
. Improper fuel used
20-4 10
0
S-4 Engine stops during operations

* Check that the monitor panel fuel level dis-
play shows that there is still fuel remaining.
General causes why engine stops during opera-
tions
. Seized parts inside engie
. overheating
* If there is overheating and the engine stops,
carry out troubleshooting for overheating.
. Failure in main piston pump
* If the engine stops because of a failure in the
main piston pump, carry out troubleshooting
for the hydraulic system (H MODE).
Legend
0 : MOS probable causes (judgingfrom Questionsand Check items)
1: Possible causes due to length of use (used for a long period)
Confirm recent repair history I I I I I I 11-1 I I I
Abnormal noise was heard
Condition when
When oil pan is removed and inspection is made directly,
When head cover is removed and inspection is made directly,
20-411
0
TESTING AND ADJUSTING S-5
S-5 Engine does not rotate smoothly (hunting)

Jr Check that the monitor panel does not dis-
play any abnormality in the governor control
system.
General causes why engine does not rotate
smoothly
. Air in fuel system
. Defective governor mechanism
. Defective electric governor mechanism
* If hunting does not occur when the rod be-
tween the governor motor and the injection
pump is disconnected, troubleshoot by us-
ing the electrical system troubleshooting (E
mode).
Legend
A: Possible causes due to length of use (used for a long period)
0: Items to confirm the cause.
1 Confirm recent repair history I I I I I I I I I
Degree of use of machine I
I
Operated for long period I I I I Ifal I I
Occurs at a certain speed range 0000
Condition of hunting Occurs at low idling 0 00000
Occurs even when speed is raised 000 C
Replacement of filters has not been carried out according
00
to Ooeration Manual
Rust, water are found when fuel tank is drained 00

Leakage from fuel piping 00
When feed pump is operated,
1) No response, light, return is quick
2) No response, light, return is normal
Engine speed sometimes rises too far
Engine is sometimes difficult to stop
Seal on injection pump has come off
When governor lever is moved it is found to be stiff
When injection pump is tested, governor is found to be
improperly adjusted
When control rack is pushed, it is found to be heavy, or
does not return I

When fuel cap is inspected directly, it is found to be clogged
When feed pump strainer is inspected directly, it is found to
be clogged
When fuel filter, strainer are inspected directly, they are
found to be clogged
20-412
0
S-6 Engine lacks output (no power)

* Check that the monitor panel does not display
any abnormality in the governor control system.
Measure the engine speed and judge if the cause is
in the engine or in the chassis. Causes
General causes why engine lacks output
. Improper fuel used
(if non-specified fuel is used, output drops)
. Lack of output due to overheating
* If there is overheating and insufficient output,
carry out troubleshooting for overheating.
Legend
A : Possible causes due to length of use (used for a long period)
_ _.
w : Items to contrrm me cause.
Degree of use of machine
suaaenry
Power was lost
Gradually
I
.o Engine oil must be added more frequently 0
Y Replacement of filters has not been carried out according
0 00
d to Operation Manual
Non-specified fuel is being used 0000
I /I Au cleaner clogging caution lamp flashes

I DI^Î_
DldC;I
0
00
Color of exhaust gas A
Blue under ligh, +I^rA
,oPu w
Noise of interference is heard from around turbocharger 0
Blow-by gas is excessive 0
I I Engine pickup is poor and combustion is irregular I 101 I I 101 I I 00

1 _ ( High idling speed under no load is normal, but speed ^^ I I I
I I I -1,1,1
WUJ
I I I I I I I I I
0
suddenly drops when load is applied
1 ‘5 1 When exhaust manifold is touched immediatelv I after I I I I I I-IL I
starting engine, temperature of some cylinders is low
u I There is huntina from enaine (rotation is irreaular) I I I Ic
I en air cleaner element is insoected directlv. it is found to be cloaaed I
When fuel filter, strainer are inspected directly, they are found to be clogged I I [--I$/
I P I When
I .zL feed pump strainer is inspected directly, it is found to be clogged
121 When control rack is pushed, it is found to be heavy, or does not return
Speed does not change when operation of certain cylinders is stopped I
Whenvalve clearanceis checkeddirectly, it is found to be outside standardvalue

When lever is placed at FULL position, it does not contact stopper
I I When
When feed pump is operated, operation is too light or too heavy
fuel cap is inspected directly, it is found to be clogged
Remedy
20-4 13
0
S-7 Exhaust smoke is black

(incomplete combustion)
General causes why exhaust smoke is black


a: Possible causes due to length of use (used for a long period)
l : items to confirm the cause.
1 Confirm recent reDair histotv
Color of exhaust gas
20-414
0
S-8 Oil consumption is excessive (or exhaust smoke is blue)

* Do not run the engine at idling for more than
20 minutes continuously. (Both low and high
idling)
General causes why oil consumption is exces-
sive
. Abnormal combustion of oil
. External leakage of oil
l Wear of lubrication system
Causes
Legend
0: Most probable causes (judgingfrom Questions and Check items.1
l : Items to confirm the cause. ________
1 Confirm recent repair history I I I I I I I I I I I I Ii
Amount of blow-by gas
found to be dirty with oil
Oil level in PTO chamber rises 1 lo,1 1

Clamps for intake system are loose I I I I I I I I I I I 101
When compression pressure is measured, it is found to be low
When breather element is insoected, it is found to be cloaoed with dirtv oil
There is external leakage of oil from engine
c Pressure-tightness test of oil cooler shows there is leakage

%
(Y Excessive play of turbocharger shaft
6
Inspect rear seal directly
1 When intake manifold is removed, dust is found inside
I When intake manifold is removed, inside is found to be dirty with oil
L Remedy
20-415
0
S-9 Oil becomes contaminated quickly

General causes why oil becomes contaminated
quickly
. Intake of exhaust gas due to internal wear
. Clogging of lubrication passage
. Improper fuel
. Improper oil used
. Operation under excessive load
Legend
0: Items to confirm the cause.
20-4 16
0
TESTING AND ADJUSTING S-IO
S-IO Fuel consumption is excessive

General causes why fuel consumption is exces-
sive
. Leakage of fuel
I Causes /
Condition of fuel
Exhaust smoke Black

lw IO I I lo
color White I lol I
Seal on injection pump has come off IQI I I I I I I
I
There is irregular combustion I 101 I I I I I I
When exhaust manifold is touched immediately after
starting engine, temperature of some cylinders is low I I~lOl I I I 1 I

Match mark on injection pump is misaligned I I I Ial I I I I
There is external leakage of fuel from engine I I I I loI I I I
Engine oil level rises and smells of diesel fuel lol I I I l~l~l I
Engine low idling speed is high loI I I I I I 101
I I I I I I I I I I
20-417
0
TESTING AND ADJUSTING S-l 1
S-11 Oil is in cooling water, or water spurts back, or water level goes down
General causes why oil is in cooling water
. Internal leakage in lubrication system
. Internal leakage in cooling system
Legend
I I Confirm recent repair history
Press&e-tightness test of oil cooler shows there is leakage
Pressure-tightness test of cylinder head shows there is leakage
Remove oil pan and inspect directly
20-418
0
S-12 Oil pressure caution lamp lights up (drop in oil pressure)

* Check that the monitor panel engine oil level lamp is
not lighted up.
* When the oil pressure sensor is normal (see M mode).
General causes why oil pressure lamp lights up
. Leakage, clogging, wear of lubricating system
. Defective oil pressure control
. Improper oil used (improper viscosity)
. Deterioration of oil due to overheating
Ir Standards for engine oil selection
Ambient temperature
Type of oil
-22
-30 -?O -i40 32
0 50
10 20
68 30
86 104°F
40°C
Engine oil
Legend
n : Possible causes due to length of use (used for a long period)
Replacement of filters has not been carried out according
Condition when oil

/ Lights up at low, high idling 000000
pressure lamp lights up
E Sometimes lights up 00 0
C
There is clogging, leakage from hydraulic piping (external) 1 IO,1 1
1 1-1 I I I I I I I I
G Metal particles are found when oil is drained 0
Metal particles are stuck to oil filter element 0 0

Oil is cloudv white or smells of diesel oil
, it is found to be cloaaed
When oil filter is inspected dire ctlv. _” ,-,-
F
._
Remove oil pan and inspect directly r-1-
E
5 Oil pump rotation is heavy, there is play I I
a,
a 3
There is catching of relief valve or regulator valve, spring or . .I I 1.2
z
c valve guide is broken I , =
B
When oil pressure is measured, it is found to be within - f
20-419
0
S-13 Oil level rises (water, fuel in oil)

* If there is oil in the cooling water, carry out
troubleshooting for “Oil is in cooling water”.
General causes why oil level rises
l Water in oil
. Causes
Fuel in oil (diluted, and smells of diesel fuel)
. Entry of oil from other component
Legend
l : items to confirm the cause.
E
2 Degree of use of machine Operated for long period
;;
S When engine is first started, drops of water come from muffler
a
Exhaust smoke is white
There is oil in radiator cooling water
Leave radiator cap open. When engine is run at idling, an
abnormal number of bubbles appear, or water spurts back
g Water pump breather hole is clogged with mud

C
When water pump breather hole is cleaned, water comes out
%
o
Oil level goes down in damper chamber
i;
Oil level ooes down in hvdraulic tank
Engine oil smells of diesel fuel
1 Fuel must be added more frequently
20-420
0
S-14 Water temperature becomes too high (overheating)

* Check that the monitor panel coolant level caution
lamp is not lighted up.
* When the monitor panel water temperature gauge
is normal, go to troubleshooting of machine moni-
tor system (M mode).
General causes why water temperature becomes too
high
. Lack of cooling air (deformation, damage of fan)
. Drop in heat dissipation efficiency
. Defective cooling circulation system
* Carry out troubleshooting for chassis.
Legend
a: Possible causes due to length of use (used for a long period)
tanks is excessive
When function test is carried out on thermostat, it does not
20-42 1
0
S-15 Abnormal noise is made Causes

j, Judge if the noise is an internal noise or an I /I/ I / /////
external noise.
General causes why abnormal noise is made
. Abnormality due to defective parts
l Abnormal combustion
l Air sucked in from intake system
Legend
n : Possible causes due to length of use (used for a long period)
Degree of use of machine 1 Operated for long period
E Gradually occurred
.o Condition of abnormal noise
;; Suddenly occurred
2
d Non-specified fuel is being used
Color of exhaust gas

Black 0 0 0
/ Metal particles are found in oil filter 0 0
Blow-by gas is excessive
Noise of interference is heard from around turbocharger
Engine pickup is poor and combustion is abnormal

E
a¶ When exhaust manifold is touched immediately after
C
% starting engine, temperature of some cylinders is low
0
6 Seal on iniection puma has come off
1 Abnormal noise is loud when accelerating engine
1 Clanging sound is heard from around cylinder head
1 Leakage of air between turbocharger and head, loose clamp 0

( Vibrating noise is heard from around muffler 0
When compression pressure is measured, it is found to be low
When turbocharger is rotated by hand, it is found to be heavy
Remove gear cover and inspect directly
.-? Speed does not change when operation of certain cylinders is stopped
ij
2 When control rack is pushed, it is found to be heavy, or does not return
$ Injection pump test shows that injection amount is incorrect
P
2 Fan is deformed, belt is loose
I-‘
When valve clearance is checked, it is found to be outside standard value
Remove cylinder head cover and inspect directly
When muffler is removed, abnormal noise disappears
Remedy
20-422
0
S-16 Vibration is excessive

* If there is abnormal noise together with the
vibration, carry out troubleshooting for “Ab-
normal noise is made”.
General causes why vibration is excessive
. Defective parts (abnormal wear, breakage)
. Improper alignment
l Abnormal combustion
I Causes /
Legend
I
Degree of use of machine _.
Operatedforlonaoeriod lnlnlnl
1-1-1-1
.o Suddenly incrctased 1 lo 0
5 Condition of vibration lhlhlhl
Gradually increased lUlUlU/
5
Non-specified oil is being used lolol I
Seal on injection pump has come off
I Injection pump test shows that iniectian amaunt is incorrect I I I I I I IO
20-423
0
TROUBLESHOOTING OF ENGINE THROTTLE 1
PUMP CONTROLLER
(PUMP CONTROL SYSTEM)
(C MODE)
Points to remember when troubleshooting pump controller system ............................................. .20-452

Action taken by controller when abnormality occurs and problems on machine.. ....................... 20-454
Judgement table for engine throttle . pump controller (pump control system)
and hydraulic related parts ............................................................................................................... 20-462
Electrical circuit diagram for C mode and F mode ............................................................................ 20-464
C- 1 Abnormality in controller power source system (controller LED is OFF) ........................ 20-466
C- 2 [E232] Short circuit in PC-EPC solenoid system is displayed ........................................... .20-467
C- 3 [E2331 Disconnection in PC-EPC solenoid system is displayed ........................................ .20-468
C- 4 [E2031 Short circuit in swing brake solenoid system is displayed ................................... .20-469
C- 5 [E2131 Disconnection in swing brake solenoid system is displayed ................................ .20-471
C- 6 [E2041 Short circuit in pump merge/divider solenoid system is displayed ..................... 20-473
C- 7 [E2141 Disconnection in pump merge/divider solenoid system is displayed.. ................ 20-474
C- 8 [E2071 Short circuit in active mode solenoid system is displayed ................................... .20-475
C- 9 [E2081 Disconnection in active mode solenoid system is displayed ................................ .20-476
C-IO [E2061 Short circuit in travel speed solenoid system is displayed ................................... .20-477
C-l 1 [E2161 Disconnection in travel speed solenoid system is displayed ................................ .20-478
C-12 [E2051 Short circuit in 2-stage relief solenoid system is displayed.. ................................ .20-479
C-13 [E2151 Disconnection in 2-stage relief solenooid system is displayed ............................ 20-480
C-14 [E2171 Model selection input error is displayed .................................................................. 20-481
C-15 [E2221 Short circuit in LS-EPC solenoid system is displayed.. .......................................... .20-483
C-16 [E2231 Disconnection in LS-EPC solenoid system is displayed ........................................ .20-484
C-17 [E2241 Abnormality in front pump pressure sensor system is displayed.. ...................... 20-485
C-18 [E2251 Abnormality in rear pump pressure sensor system is displayed ......................... 20-486
C-19 IE2261 Abnormality in pressure sensor power source system is displayed.. .................. 20-487
C-20 [E2271 Abnormality in engine speed sensor system is displayed .................................... .20-488
20-451
0
TESTING AND ADJUSTING PUMP CONTROLLER SYSTEM
POINTS TO REMEMBER WHEN TROUBLESHOOTING PUMP

CONTROLLER SYSTEM

I) If any abnormality returns to normal by itself, or
3) After completing troubleshooting, always erase the user code from memory.

the content of the display, then erase the display. After trying to re-enact the problem, carry out
any wasted work.)
20-452
0
TESTING AND ADJUSTING OCCURS AND PROBLEMS ON MACHINE

User Service
code code
1. Short circuit with ground, short circuit inside pump EPC solenoid
2. Short circuit with power source, short circuit with ground in wiring
harness between controller CO2 (8) and solenoid Cl3 (I) ((+I side)
Short circuit in pump 3. Short circuit with power source in wiring harness between control-
E232 ler CO2 (18) and solenoid Cl3 (2) ((-1 side)
EPC solenoid system
4. Defective engine throttle . pump controller
1. Disconnection, defective contact inside pump EPC solenoid

E02 2. Disconnection, defective contact in wiring harness between con-
troller CO2 (8) and solenoid Cl3 (1) ((t) side)
3. Disconnection, defective contact, short circuit with ground in wir-
ing harness between controller CO2 (18) and solenoid Cl3 (2) ((-1
Disconnection in side)
E233 pump EPC solenoid 4. Defective engine throttle . pump controller
system
1. Short circuit with ground, short circuit inside swing holding brake
solenoid
2. Short circuit with ground in wiring harness between controller CO1
Short circuit in swing
(3) and solenoid V04 (2) ((+) side)
E203 holding brake “le- 3. Defective engine throttle . pump controller
noid system
1. Disconnection, defective contact inside swing holding brake sole-

E03
noid
2. Disconnection, defective contact, short circuit with power source in
Disconnection in v$$g harness between controller CO1 (3) and solenoid V04 (2) ((+I
E213 swing holding brake
solenoid system 3. Disconnection, defective contact in wiring harness between sole-
noid V04 (I) and chassis ground ((-) side)
20-454
0
Condition when normal Action by controller when abnor- Problem that appears on machine
(voltage, current, resistance) mality is detected when there is abnormality
1. Makes output to solenoid 0. 1. No current flows to the pump
2. Displays user code E02 on monitor EPC solenoid.
panel. Therefore, when the load is
. Resistance of solenoid: + If the abnormality is restored by the large, there is a big drop in the
7-14R vibration of the machine, it resets the engine speed which may result
power source to restore to the proper in the engine stalling.
condition. (However, the service code
display does not go out.)
1. The current stops flowing to the sole- 1. In the case of 1, it is the same
noid, so no particular action is taken. as E232.
2. If there is a short circuit with the 2. In the case of 2, the current (min.
. Resistance of solenoid: ground at the (-) end, the current (min. IA) continues to flow to the
7-14L2 IA) continues to flow to the solenoid. pump EPC solenoid, so the out-
. Current: 1000 mA 3. It displays user code E02 on the moni- put of the pump EPC valve in-
(H/O mode, auto-decel- tor panel. creases and the overall speed
eration ON, levers at Ir If the abnormality is restored by the becomes slower.
neutral, fuel control dial vibration of the machine, it resets the
at MAX.) power source to restore to the proper
1. Makes output to solenoid 0.

2. Displays user code E03 on monitor
panel. When the swing is operated, the
. Resistance of solenoid: * If the abnormality is restored by the motor brake is not released, so the
20 - 60 .Q vibration of the machine, it resets the upper structure does not swing.
power source to restore to the proper
1. The current stops flowing to the sole-

noid, so no particular action is taken.
2. Displays user code E03 on monitor
. Resistance of solenoid: panel.
20 - 60 .Q * If the abnormality is restored by the Same as display for E203
vibration of the machine, it resets the
20-455
User ;ervice
code code
1. Short circuit with ground, short circuit inside pump merge/divider
solenoid
Short circuit in pump 2. Short circuit with ground in wiring harness between controller CO1
E204 merge/divider sole- (2) and solenoid V03 (2) ((+I side)
noid system 3. Defective engine throttle . pump controller
1. Short circuit with ground, short circuit inside 2-stage relief sole-
noid
Short circuit in 2-
E205 stage relief solenoid
(10) and solenoid V05 (2) ((+I side)
system
1. Short circuit with ground, short circuit inside travel speed solenoid
Short circuit in travel
(9) and solenoid V06 (2) ((+) side)
E206 speed solenoid sys-
tem
1. Short circuit with ground, short circuit inside active mode sole-
Short circuit in active noid.
E207 mode solenoid sys- 2. Short circuit with ground in wiring harness between controller CO1
tem (8) and solenoid V02 (2) ((+I side)
3. Defective engine throttle, pump controller.
1. Defective contact, disconnection inside active mode solenoid.

2. Defective contact, disconnection, contact with power source in wir-
ing harness between controller CO1 (8) and solenoid V02 (2) ((+)
Disconnection in ac-
side)
E208 tive mode solenoid
3. Defective contact, disconnection in wiring harness between sole-
system
noid V02 (1) and chassis ground ((-1 side)
4. Defective engine throttle, pump controller.
1. Disconnection, defective contact inside pump merge/divider sole-

noid
Disconnection in 2. Di_sconnection, defective contact, short circuit with power source in
E214 pump merge/divider ;;;g harness between controller CO1 (2) and solenoid V03 (2) ((+I
solenoid system
3. Disconnection, defective contact in wiring harness between sole-
noid V03 (2) and chassis ground ((-1 side)
1. Disconnection, defective contact inside 2-stage relief solenoid

Disconnection in 2- wiring harness between controller CO1 (IO) and solenoid V05 (2)
E215 stage reliefe solenoid ((+) side)
system 3. Disconnection, defective contact in wiring harness between sole-
noid V05 (I) and chassis ground I(-) side)
20-456
0
Ivoltage, current, resistance) mality is detected when there is abnormality
1. Makes output to solenoid 0. The pump merge/divider valve con-
* If the abnormality is restored by the tinues to merge the oil flow.
vibration of the machine, it resets the 1. In the L/O modes, the work
. i%$s;“,nr$ of solenoid: power source to restore to the proper equipment and swung speeds
condition. (However, the service code become faster.
display does not go out.) 2. The steering is difficult to turn.
1. Makes output to solenoid 0. 1. There is no power when traveling

* If the abnormality is restored by the or when power max. function is
. Resistance of solenoid: vibration of the machine, it resets the used (relief pressure is not in-
20 - 60 CI power source to restore to the proper creased)
1. Makes output to solenoid 0.

* If the abnormality is restored by the Even if the travel speed is switched,
Resistance of solenoid: vibration of the machine, it resets the the travel speed does not change
20 - 60 R power source to restore to the proper KT;;l motor swash plate angle
1. Makes output to solenoid 0. 1. In the standard mode (active

Sr If the abnormality is restored by the mode OFF), the boom LOWER
vibration of the machine, it resets the speed becomes faster.
Resistance of solenoid: power source to restore to the proper
20 - 60 R condition. (However, the service code

* If the abnormality is restored by the
Resistance of solenoid: vibration of the machine, it automati- Same content as display for E208
20 - 60 R tally resets to the proper condition.
(However, the service code display
does not go out.)

* If the abnormality is restored by the
. Resistance of solenoid: vibration of the machine, it resets the Same content as display for E204
20 - 60 Q power source to restore to the proper

li If the abnormality is restored by the
. Resistance of solenoid: vibration of the machine, it resets the Same content as display for E205
20 - 60 R power source to restore to the proper
20-457
0
User Service
code code
1. Disconnection, defective contact inside travel speed solenoid

Disconnection in wiring harness between controller CO1 (9) and solenoid V06 (2) ((+)
- E216 travel speed solenoid side)
system 3. Disconnection, defective contact in wiring harness between sole-
noid V06 (I) and chassis ground ((-1 side)
1. Disconnection, defective contact, short circuit with ground in model

selection wiring harness C17(5) (6) (7) (13) (14)
Model selection input

- E217
error
1. Disconnection, short circuit, short circuit with ground in network

wiring harness
2. Abnormality in governor, pump controller
3. Abnormality in monitor
Network response
- E218
overtime error
1. Short circuit with ground, short circuit inside LS-EPC solenoid

2. Short circuit with power source, short circuit with ground in wiring
Short circuit in LS- harness between controller CO2 (7) and solenoid Cl0 (1) ((+I side)
- E222 EPC solenoid system 3. Short circuit with power source in wiring harness between control-
ler CO2 (17) and solenoid Cl0 (2) ((-1 side)
1. Disconnection, defective contact inside LS-EPC solenoid

2. Disconnection, defective contact in wiring harness between con-
troller CO2 (7) and solenoid Cl0 (I) ((+I side)
ing harness between controller CO2 (17) and solenoid Cl0 (2) (1-J
Disconnection in LS-
- E223 side)
EPC solenoid system
1. Disconnection, defective contact, short circuit, short circuit with

ground inside front pump pressure sensor
2. Disconnection, defective contact, short circuit in wiring harness
Abnormality in front between controller CO3 (6) and pressure sensor CO8 (2) ((+) side)
- E224 pump pressure sen- and between CO3 (16) and CO8 (1) ((-1 side)
sor system 3. Disconnection, defective contact, short circuit with power source,
short circuit with ground in wiring harness between controller CO3
(3) and pressure sensor CO8 (3) (SIG side)
20-458
0
Ivoltage, current, resistance) mality is detected when there is abnormality
t If the abnormality is restored by the
. Resistance of solenoid: vibration of the machine, it resets the
20 - 60 R power source to restore to the proper Same content as display for E206
PC200, 210 Detects abnormality in input 1. Engine stalls, or

. Between Cl7 (6) and 1) Retains data when starting switch is 2. Work equipment, swing, travel
chassis: Max. 1 R ON speeds are all slow, and there
Between Cl7 (5),(7), (13), 2) Functions as PC200 when non-set con- is no power
kIJn a;cQhassis: ditions are input
PC220, 230
. Between Cl7 (5), (6) and
chassis: Max. 1 fi
Between CN (7), (13), (14)
and chassis: Min. 1 MR
1. When communications are impossi- 1. @ Even when travel is oper-

ble with the monitor, control is car- ated, the power max. func-
ried out with the following settings. tion does not work
1 Working mode: G/O @ The swift speed-down func-
2 Priority mode: OFF tion does not wor
3 Travel speed: Lo @ The auto-deceleration cannot
4 Auto-deceleration: ON be canceled
15 Power max. : ON (others are as @ The travel speed does not in-
usual) crease
5 The priority mode has no effect
ti6 The automatic mode has no
effect
1. Makes output to LS-EPC solenoid 0. 1. The Mi and Lo travel speed is

* If the abnormality is restored by the too fast.
. Resistance of solenoid: vibration of the machine, it resets the 2. In L/O and F/O modes, the work
7-14R power source to restore to the proper equipment and swing speed is
condition. (However, the service code too fast.
1. The current stops flowing to the LS- 1. In the case of 1, it is the same
EPC solenoid, so no particular action as E222
is taken. 2. In the case of 2, electric current
2. If there is a short circuit with the (min. IA) continues to flow to
ground at the (-1 end, the current (min. the LS-EPC solenoid, so the
. Current: Approx. 900 mA IA) continues to flow to the LS-EPC work equipment, travel, and
(Levers at neutral, low solenoid. swing speeds are slow
idling) * If the abnormality is restored by the
vibration of the machine, it resets the
. Between CO3 (3) and (16): 1. Takes front pump pressure as 0 MPa 1. The travel speed does not auto-
0.5 - 4.5 v (0 kg/cm2) when actuating. matically shift (it does not
. Between CO3 (6) and (16): * If the abnormality is restored by the change from Hi to Lo).
18-28V vibration of the machine, it resets the * If the button is operated
. Between CO3 (female) (3) power source to restore to the proper manually, the panel display
and (161, (3) and chassis condition. (However, the service code is switched.
. Resistance: Min. 1 MR display does not go out.)
(Disconnect connectors
CO3 and CO8.1
20-459
0
User Service
code code
1. Disconnection, defective contact, short circuit, short circuit with
ground inside rear pump pressure sensor
2. Disconnection, defective contact, short circuit in wiring harness
Abnormality in rear between controller CO3 (6) and pressure sensor CO7 (2) ((+I side)
- E225 pump pressure sen- and between CO3 (16) and CO7 (I) (1-j side)
sor system 3. Disconnection, defective contact, short circuit with power source,
short circuit with ground in wiring harness between controller CO3
(13) and pressure sensor CO7 (3) (SIG side)
1. Short circuit, short circuit with ground inside front pump pressure
sensor or rear pump pressure sensor
Abnormality in pres-
2. Short circuit, short circuit with ground in wiring harness between
- E226 sure sensor power
controller CO3 (6) and front pressure sensor CO8 (2) or rear pres-
source system
sure sensor CO7 (2) ((+I side)
1. Disconnection, defective contact, short circuit inside engine speed

sensor
- E227
Abnormality in speed
ing harness between controller Cl6 (I) and speed sensor E07 (2) ((-
sensor system
) side) and between Cl6 (2) and E07 (I) (SIG side)
20-460
0
‘voltage, current, resistance) mality is detected when there is abnormality
. Between CO3 (13) and (16): 1. Takes rear pump pressure as 0 MPa 1. The travel speed does not auto-
0.5 - 4.5 V (0 kg/cm*) when actuating. matically shift (it does not
. Between CO3 (6) and (16): * If the abnormality is restored by the change from Hi to Lo).
18-28V vibration of the machine, it resets the * If the button is operated
. Between CO3 (female) (13) power source to restore to the proper manually, the panel display
and (16), (13) and chassis condition. (However, the service code is switched.
. Resistance: Min. 1 MQ display does not go out.)
(Disconnect connectors
CO3 and CO7.1
1. Takes front pump and rear pump pres- 1. The travel speed does not auto-
sure as 0 MPa (0 kg/cm21 when actu- matically shift (it does not
. Voltage between CO3 (6) ating. change from Hi to Lo).
and (16): 18 - 28 V * If the button is operated
manually, the panel display
is switched.
. Resistance: 500 - 1000 Q 1. It functions in the equivalent of the G/ It operates about the same as G/O
. Voltage (AC range) : 0 mode (the speed rises) rnn~)(prolix) (the power is slightly
0.5 - 3.0 V (engine
started)
20-46 1
0
JUDGEMENT TABLE FOR ENGINE THROTTLE . PUMP CONTROLLER
TESTING AND ADJUSTING (PUMP CONTROL SYSTEM) AND HYDRAULIC RELATED PARTS
JUDGEMENT TABLE FOR ENGINE THROTTLE . PUMP

CONTROLLER (PUMP CONTROL SYSTEM) AND HYDRAULIC
RELATED PARiS
Failure mode \ >

User code
Service code
Speeds of all work equipment, swing, travel are slow or lack power
There is excessive drop in engine speed, or engine stalls
No work equipment, travel, swing move
Abnormal noise generated (around pump)
Auto-deceleration does not work
Fine control ability is poor or response is poor
Boom is slow or lacks power
Arm is slow or lacks power
Bucket is slow or lacks power
Boom does not move
Arm does not move
Bucket does not move
Excessive hydraulic drift
Excessive time lag (engine at low idling)
Other equipment moves when single circuit is relieved
Lack of power when pressure rises
In L/O, F/O modes, work equipment speed is faster than specified speed
In compound operations, work equipment with larger load is slow
In swing + boom (RAISE), boom is slow
In swing + arm, arm is slow
In swing + travel, travel speed drops excessively
Deviation is excessive during normal travel
Travel deviation
Deviation is excessive when starting
Travel speed is slow
Steering does not turn or lacks power
t Travel speed does not switch or is faster than specified speed

Does not move (one side only)
when stopping swing 1 One direction only

Excessive shock when stopping swing (one direction only)
<
Excessive abnormal noise when stopping swing
Excessive hydraulic When holding brake is released
drift of swing 1 When holding brake is applied
Swing speed is faster than specified swing speed
Troubleshooting code when service code is displayed
Troubleshooting code when there is abnormality in monitoring check
r:This shows applicable item for service code (simultaneous abnormality at ront or rear)
l :This shows applicable item for service code
.X :This shows item that needs only checking with monitoring
o :This shows item to check with monitoring or machine monitor
20-462
0
JUDGEMENT TABLE FOR ENGINE THROlTLE . PUMP CONTROLLER
TESTING AND ADJUSTING (PUMP CONTROL SYSTEM) AND HYDRAULIC RELATED PARTS
* If service code E218 (abnormality in network system) is displayed, go to troubleshooting for N mode.
Check items in monitoring mode

i-i
Pressure switch Ad&n ofsolenoid
Bit pattern
_,7 c_,* c_,gc-20 - - - - - - - - - - - - - - - - - - - - -
- - - - F-l F-2 F-3 F-4 F-5 F-6 F-7 F-8 F-9 F-10F-11 - - - - - - - - - - -
20-463
0
TESTING AND ADJUSTING ELECTRICAL CIRCUIT DIAGRAM FOR C MODE AND F MODE
ELECTRICAL CIRCUIT DIAGRAM FOR C MODE AND F MODE

(l/2)
sta ina switch Swing prolix switch Resistor
lIEi CO6 IMZI
Battery
--
x07
(MICl7)
4F=
-h zl
II 72
Solenoid valve TKP01020
20-464
0
TESTING AND ADJUSTING ELECTRICAL CIRCUIT DIAGRAM FOR C MODE AND F MODE
Engine
E07 (X21 speed sensor
solenoid
L.H.knob Machine select
valve
connector TKPOIOPI
20-465
a
TESTING AND ADJUSTlNG C-l
C-l Abnormality in controller power source system (controller LED is

OFF)
Check that fuse 1 is not blown.
When the starting motor rotates normally. (If the starting motor also does not rotate, go to E-8.)
Cause Remedy

pump controller Replace
Repair or
harness between fuse 1
replace
and CO1 (female) (7) (13)
disconnection in wiring Repair or
harness between fuse 1 - replace
* Turn starting NO
HI5 (2) - Ml4 (2) (1) -
switch ON.
battery relay M
*20-30V
C-l Related electric circuit diagram
controller
CO1 (MIC13)
HI4 (~6) FUSS H15 (L2)
Battery relay Fusible link

n
TKP00799
20-466
a
TESTING AND ADJUSTING c-3
C-3 [E2331 Disconnection in PC-EPC solenoid system is displayed

* If the starting switch is turned OFF after an abnormality occurs, turn the starting switch ON and
check if an E service code is displayed. (If it is not displayed, the problem has been removed.)
* If there is a disconnection in the solenoid or wiring harness, no current flows to the solenoid.
If the No. 2 pin of the solenoid is short circuiting with the ground, the current (approx. 1 A)
continues to flow to the solenoid.
* Always turn the pump prolix switch OFF.
* Always connect any disconnected connectors before going on to the next step.
I Cause Remedy

Short circuit with ground or
short circuit with power source
- in wiring harness between CO2
(femaleN8) - H12 (5) - CO5
CO2 (female) (8) and 4 YEE
(female)(l), or short circuit with Repair or
(18). (18) and chassis power source in wiring harness
es shown in Table 17 between CO2 (female)(l8) - H12
(7) - CO5 (femaM(2l
* Turn starting and chassis as shown Defective pump prolix switch
switch OFF. (internal short circuit with
ground or short circuit with
Replace
* Disconnect C02. (female) I31 and (4). power source)
shown in Table l? . Disconnect C05. Short circuit with ground or

* Turn pump prolix short circuit with oower source
* Turn starting in wiring harness’between CO5 Repair or
l Turn starting switch OFF. (femaleN3) - H12 (3) - Cl3
~female~~l~, or short circuit with replace
switch OFF. * Disconnect CO5 powersource in wiring harness
* Disconnect C13. between CO5 (female)(l) - H12
(4) - Cl3 (femaleM2)
Defective pump EPC Replace

NO solenoid (internal short
circuit or short circuit
with ground)
Table 1
Troubleshooting No. 2 Troubleshooting No. 3 Troubleshooting No. 4 Resistance value
Between Cl3 (male) (1) - (2) Between CO2 (female) (8) - (18) Between CO5 (female) (3) - (4) 7-l4R
Between Cl3 (male) (2) - chassis Between CO2 (female) (18) -chassis Between CO5 (female) (4) -chassis Min. 1 MR
Table 2
Troubleshooting No. 5 Resistance value
Between CO5 (male) (1) - (3). (2) - (4) Max. 1 R
Between CO5 (male) (l)(2)(3)(4) - chassis Min. 1 MR
Related electric circuit diagram
20-468
TKP00803
C-4 [E203] Short circuit in swing brake solenoid system is displayed

Always turn the TVC prolix switch OFF.
Cause Remedy

I II . pump controller
Is resistance
(female) (3) and

chassis normal?
I+ GotoA
-Turn starting
switch OFF.
* Disconnect C02.
* Turn starting
connector with switch OFF.
other solenoid. Is *20-60n
LE2031 displayed? Disconnect C04.
NO
Defective swing holding
* Turn starting I brake soleoid (internal
L Replace
switch OFF. short circuit or short circui:
- Interchange V04 No with ground)
with other
Short circuit with chassai
connector.
5 YES ground in wiring harness
* Start engine. between CO1 (female) (3) -
* Operate swing Is resistance D26(1~(2~-H13(1)-X01(7) Repair or
lever YES between X05 (female) (2) replace
- (male) (4) and - Short circuit with chassai
4
- chassis normal? ground in wiring harness
Is resistance Repair or
between X05 (male) (4) replace
between X05 * Turn starting NO
-X01 (7) - HI3 (7) - V04
A = (female) (3) (4) and - switch OFF. (female) (2)
chassis normal? * Disconnect X05.
~ *20-60R Defective swing lock switch
* Turn starting (internal short circuit with
NO
switch OFF. ground)
* Disconnect X05.
* Turn starting
switch OFF.
* Min. 1 MR
Table 1
Between V04 (male) (I) - (2) 1 20-60 R
Between V04 (male) (2) - chassis Min. 1 MR
20-469
0
C-4 Related electric circuit diagram
Swine prolix switch Swing lock switch
Fuse
I
Engine throttle.oumP controller 1326(KES~)

CO1 (MIC13)
X01 (MIC21) X05 (M4)
Swine holding
e -3 -
I @ gI
DO5 vo4 (X2)
a. L a Swing holding
brake solenoid
a 4, @
m
TKP00804 $
>
g
0
20-470
0
C-5 [E213] Disconnection in swing brake solenoid system is displayed

Always turn the swing lock prolix switch OFF, then turn the swing lock switch OFF before checking.
Always connect any disconnected connectors before going on to the next step.
Note: When the swing prolix switch is operated, error [E213] is detected, but this is not a failure.
Note: If error fE2131 is generated when the swing lock switch is operated, carry out troubleshooting F-
9 for failure in the swing lock signal input-system.
Cause Remedy
3 YES
Is resistance II GotoA
YES between D26 (1)
2 and chassis as
Is resistance shown in Table I? Defective engine throttle
Reolace
YES between V04 _ * Turn starting NO pump controller
(male) (1) and (2) switch ON.
1
_ normal? * Disconnect D26.
Interchange
* Turn starting
connector with
other solenoid. Is -
switch OFF. NO
* Disconnect V04.
LE2131 displayed? Defective swing holding
.20-6012
* Turn starting brake solenoid (internal
! disconnection or short
switch OFF. _,_ Replace
INU circuit with power
* Interchange V04
with other source)
connector.
* Turn starting Defective contact or
switch ON.
YES
harness between D26 replace
!il
(female) (2) - HI3 -X01
(7) -X05 (male) (2)
YE
Short circuit with power
4
chassis normal? source or defective contact
or disconnection in wiring
* Turn starting Repair or
harness between X05
switch OFF. (male) (4) -X01 (6) - H13 replace
*-~~~nd 1
. Disconnect X05. (7) - V04 (female) (2)
*20-60Q
*Turn starting Defective swing lock switch
switch OFF. (internal disconnection or ileplace
* Disconnect X05. short circuit with power
* Max. 1 D source)
Table 1
Troubleshooting No. 3 1 Voltage Measurement conditions 1
o-IOV / 4 - 5 set after all levers placed at neutral
Between D26 (I) - chassis
20 - 30 V 1 Swing or work equipment lever operated slightly (not enough to move swing or work equipment)
20-471
0
TESTING AND ADJUSTING C-5
Swine prolix switch Swing lock switch
Fuse
Engine throt
vo4 (X.2)
DO5
a L a Swine holding
brake solenoid
@ @ valve
TKP00804 22
&
g
20-472
0
C-6 [E2041 Short circuit in pump merge/divider solenoid system is

displayed
Cause Remedy

Replace
pump controller
Is resistance Short circuit with chassis Repair or

ground in wiring harness replace
between CO1 (female ) (2)
and V03 (female) (2)
* Turn starting switch Defective pump

OFF. merge/divider soleoid Replace
. Interchange V03 NO (internal short circuit or
with other short circuit with ground)
connector.
* Start engine.
- Operate travel I
independently.
Table 1
Between V03 (male) (1) - (2) ]20-60R
Between V03 (male) (2) - chassis 1Min. 1 MfI
Ens ine throttle.pump controller

CO1 (MIC13)
a Pump merge
/divider
I _ solenoid
@ valve
I
TKP00805
20-473
0
C-7 [E2141 Disconnection in pump merge/divider solenoid system is

displayed
Ir If the starting switch is turned OFF after an abnormality occurs, turn the starting switch ON and
* Always connect any disconnected connectors before going on to the next step.
Cause Remedy

Replace
Is resistance pump controller
YES between CO1 Short circuit with chassis
2 (female) (2) and ground in wiring harness
Is resistance chassis normal? between CO1 (female) (2) Repair or
YES between V03 _ * Turn starting NO and V03 (female) (2) or replace
(male) (1) and (2) switch OFF. between V03 (female) (1)
1
~ normal? * Disconnect COI. and chassis
interchange
* Turn starting *20-60R
connector with
other solenoid. Is - switch OFF. NO
LE2141 displayed? * Disconnect V03.
*20-60R Defective pump
* Turn starting merge/divider solenoid
I Reolace
switch OFF. (internal disconnection
NO or short circuit with
* Interchange V03
with other power source)
connector.
* Turn starting
switch ON.
Ens i ne throttle.PumP controller

CO1 (MICl3)
Pump merge
/divider
solenoid
valve
TKP00805
20-474
0
C-8 [E2071 Short circuit in active mode solenoid system is displayed

* Always connect any disconnected Connectors before going on the next step.
Remedy

Replace
I Is resistance I . pump controller
YES between CO1
2 - (female) (8) and ’
~Is resistance chassis normal? Short circuit with chassis Repair or
YES between V02 (male) ~ ground in wiring harness replace
NO between CO1 (female) (8)
- (1) and (2). (2) and - ’ Turn Starting
switch OFF.
1 chassis as shown in and V02 (female) (2)
~Interchange Table I? * Disconnect COl.
- Turn starting -20-600
connector with
other solenoid. Is - switch OFF.
NO
IE2071 displayed? * Disconnect V02.
$YxGq 1 Defective active mode

solenoid (internal short
Replace
circuit or short circuit with
l Interchange ~02 NO
ground)
with other
connector.
- Turn starting switch
ON.
-WhenSTD model
switch is ON.
Table 1
Between V02 (male) (I) - (2) ]20-60R
Between V02 (male) (2) - chassis 1Min. 1 MR
Engine throttle.PumP controller

CO1 (MIC13)
Active mode
solenoid
valve
TKPOOB06
20-475
0
C-9 [E2081 Disconnection in active mode solenoid system is displayed

li If the starting switch is turned OFF after an abnormality occurs, turn the starting switch ON and
Cause Remedy

Replace
Is resistance . pump controller
YES between CO1 Defective contact, or
2 (female) (8) and disconnection in wiring
Is resistance chassis normal? harness between CO1 Repair or
YES between VO2 _ *Turn starting NO (female) (8) and V02 replace
(male) (1)and (2) switch OFF. (female) (2) or V02
1 (female) (I) and chassis
P normal? * Disconnect COl.
Interchange *20-6O.Q
connector with l Turn starting
*20-6OD Defective active mode
l Turn starting switch solenoid (internal
Y Replace
OFF. disconnection or short
NO
l Interchange V02 circuit with power source)
with other
connector.
l Turn starting switch
ON.
CO1 (MIC13)
TKP00806
20-476
0
TESTING AND ADJUSTING C-IO
C-10 [E206] Short circuit in travel speed solenoid system is displayed

Cause

Replace
Is resistance . pump controller
YES between CO1
2 (female) (9) and
Short circuit with chassis Repair or
chassis normal?
ground in wiring harness replace
YES between V06 (male) p p
NO between CO1 IfernIe) (8) and
- (1) and (2), (2) and - *Turn starting
chassis as shown in switch OFF. V06 (female) (2)
1
p Table l? * Disconnect COl.
Interchange
* Turn starting *20-60n
connector with
other solenoid. Is - switch OFF.
NO
IE2061 displayed? Disconnect V06.
l

T Defective travel speed
OFF.
solenoid (internal short
* Interchange V06 NO
with other circuit or short circuit
connector. with ground)
* Start engine.
l Travel speed switch
at Mi or Hi
* Operate the lever slightly not
enough to move the machine.
Table 1
Between V06 (male) (1) - (2) ) 20 - 60 R
C-IO Related electric circuit diagram
Engine throttle,
Pump controller
V06 (X2)
co1 (MIC13)
\
@ Travel speed
Trave I solenoid
speed @- va I ve
solenoid
m
m 007
1
2
TOP00379
20-477
0
TESTING AND ADJUSTING C-II
C-II [E2161 Disconnection in travel speed solenoid system is displayed

+ This troubleshooting is carried out when there is still an abnormality, so when disconnecting the
Cause Remedy

1- pump controller Replace
harness between CO1 Repair or
(female) (9) - V06 reolace
(female) (2), or between
V06 (female) (1) and
chassis
El
Interchange
connector with
otehr solenoid. Is
* Disconnect V06. ._-
fE2161 displayed?
.20-60R Defective travel speed
-Turn starting solenoid (internal
Replace
switch OFF. disconnection or short
IO
* Interchange VO6 circuit with power source)
with other
connector.
* Turn starting
switch ON.
C-II Related electric circuit diagram
Engine throttle,
Pump controller
TDP00379
20-478
0
C-12 [E2051 Short circuit in 2-stage relief solenoid system is displayed

Cause Remedy

Replace
. pump controller
(female) (10) and I -

chassis normal? Short circuit with chassis
I
Repair or
YES between V05 (male) ground in wiring harness replace
* Turn starting NO
rll between CO1 (female) (10)
kyh$;as shown in switch OFF. and V05 (female) (2)
* Disconnect COl.
connector with
other solenoid. Is switch OFF.
NO
I
Defective 2-stage relief
. Turn
--- starting switch ‘l
1 solenoid (internal short
wt. circuit or short circuit with
* Interchange ~05 NO
with other ground)
connector.
. Start engine.
*Turn swina lock
switch Odor set to
UO mode.
Table 1
Between V05 (male) (1) - (2) 120 - 60 Q

CO1 (MIC13)
2-stage relief
solenoid valve
Ti-T
TKP00807
20-479
0
C-13 [E215] Disconnection in 2-stage relief solenoid system is displayed

Remedv

. pump controller Replace

ground, defective
contact, or disconnection Repair or
in wiring harness replace
between CO1 (female)
* Disconnect COl. (10) and V05 (female) (2).
Interchange *20-60R or V05 (female) (1) and
connector with lTurn starting chassis
fE2151 displayed? * Disconnect V05.
Defective 2-stage relief
p .20-60R
solenoid (internal
disconnection or short Replace
OFF.
NO circuit with power
. Interchange VO5
with other source)
connector.
- Turn starting switch
ON.
Engine thrOttie.DUmD controller

CO1 (MICl3)
Z-stage relief
solenoid valve
TKP00807
20-480
0
C-14 [E217] Model selection input error is displayed

I Cause Remedy

Replace
pump controller
Is monitoring
mode display as
shown in Table 2 YES
I? I Is voltage between
. Turn starting
Cl7 (516) (7) (
-13)
IS as
switch ON. Defective model selection
In I able 2?
* Set to monitoring connector, or disconnection, Repair or
codes 102, 031 ’:+CArti”q
* Turn U.L.‘..“Y NO short circuit with ground, or replace
and 121, 221. short circuti in witing
switch ON.
harness where voltage is
defective
Table 1 Monitoring code display

Model code display Model selection signal input display
Monitoring codes 02, 03 Monitoring code 21 Monitoring code 22
f _---_ _A.%_
P-P P-L=)
+ + +
BKP00420 BKP00194 BKFU0421
+ +
BKP00422 BKP00194
BKP00423

* Check the bit pattern display marked with t. (Monitoring codes 21, 22)
Table 2 Voltage of wiring harness

Cl7 Between(5) - chassis Between(6) -chassis Between 171 -chassis Between (131-chassis Between (14l- chassis
Pc200,210 20 - 30 v Max. 1 V 20 - 30 v 20 - 30 v 20 - 30 v
Voltage
PC220, 230 Max. 1 V Max. 1 V 20 - 30 v 20 - 30 v 20 - 30 v
20-48 1
0
c-14 Related electric circuit diagram
Eneine throttle,PumP controller Model selection connector

-_-_-_-_-____________
Cl7 (04016) co9 (St31 r I I
-1
3 01 01
02 02
Model selection 5
03 03
Model selection 2
04 04
Model selection 4 I 05 05
06 06
H14 (~6) 07 07
08 c 08 c
I
r-i--r+
PCSOOSTD PC220STD
i PC2lOSTD PC230STD
TKPOOBOB
20-482
a
C-15 [E222] Short circuit in LS-EPC solenoid system is displayed

+ This troubleshooting is carried out when there is still an abnormality, so when disconnecting the
Sr Before carrying out troubleshooting, check that all the related connectors are properly inserted.
Cause Remedy

Replace
I Is resistance II pumpcontroller
Short circuit with ground or short
circuit with power source in
wiring harness between CO2 Repair or
(female) 17) - Cl0 (female) (11, or replace
short circuit with power source in
wiring harness between CO2
(female) (17) - Cl0 (female) (21
* Turn starting I Replace
Defective LS-EPC solenoid
switch OFF. NO
(internal short circuit with
* Disconnect CIO.
ground or short circuit
with power source)
Table 1
Troubleshooting No. 1 I Troubleshooting No. 2 I Resistance value I
Between Cl0 (male) (1) - (2) 1Between CO2 (female) (7) - (17) I 7-14n I
Between Cl0 (male) (1) - chassis I Between CO2 (female) (7) - chassis I Min. I MD 1
Ensine throttle.cums controller

CO2 (MIC21) Cl 0 (x21
TKP00809
20-483
0
C-16 [E223] Disconnection in LS-EPC solenoid system is displayed


2 YES
Is resistance
Defect contact or short circuit
YE ; between CO2
- (female) (7) and (17), - with chassis ground in wiring
1 harness between CO2 (female)
(17) and chassis as
shown in Table l? (7) and Cl0 (female) (I), or Repair or
between Cl0 (male)
- NO defective contact, short circuit replace
(I) and (3, (2) and -Turn starting with ground, or disconnection
switch OFF. in wiring harness between CO2
* Disconnect C02. (female) 117)- Cl0 (female) (2)
l Turn starting Defective LS-EPS Replace
switch OFF. uo solenoid (internal
* Disconnect CIO. disconnection, defective
contact, or short circuit
with ground)
Table 1
Troubleshooting No. 1 Troubleshooting No. 2 Resistance value
Between Cl0 (male) (I) - (2) 1Between CO2 (female) (7) - (17) 7-14n
Between Cl0 (male) (2) - chassis Between CO2 (female) (17) - chassis 1 Min. 1 MR 1
Engine throttle.pump controller
TKP00809
20-484
0
C-17 [E2241 Abnormality in front pump pressure sensor system is

displayed
* If the starting switch is turned OFF after an abnormalitv occurs, turn the startina switch ON and
check if an E service code is displayed. (If it is not displayed, the problem has bien removed.)
Cause Remedy

. pump controller
YES/w 7
and (16) normal? Short circuit with powe
source, defective contact, or Repair or
disconnection in wirina
* Engine at high NO replace
harness between CO3 -
{f3ymale) (3) - CO8 (female)
_ * Operate repeatedly arm IN
and (1) normal? relief- lever NEUTRAL.
Short circuit with ground,
-0.5 - 4.5 v defective contact, or
4 YES Repair 01
1 *Turn starting disconnection in wiring
Is voltage harness between CO3 replace
Interchange switch ON.
between CO8 (2) (female) (16) and CO8
connector with rear l18-28V
NO and chassis (female) (1)
pump pressure -
normal? Short circuit with ground,
sensor. Is [E2241 Repair or
disolaved? defective contact, or
* Disconnect C08. NO replace
l Turn starting * Turn starting harness between CO3(female)
switch OFF. switch ON. (6) and CO8(female) (2)
* Interchange CO7 *18-28:’
with C08. Defective front pump 3eplace
NO pressure sensor (internal
. Engine at high
idling disconnection, defective
contact, short circuit, or
short circuit with ground)
Ensine throttle.PumP controller

CO3 (04020) CO8 (X02)
Front Pump pressure

sensor SIG
Pressure sensor Front Pump
Power source Pressure sensor
TKP00610
20-485
0
C-18 [E225] Abnormality in rear pump pressure sensor system is

displayed
Cause Remedy

Replace
. pump controller
YE FH_ Short circuit with power
source, defective contact, or
Repair or
2 harness between CO3
* Engine at high NO replace
(female) (13) - CO7 (female)
idling (3)
YE bwtween CO7 (2)
l Operate repeatedly arm IN Short circuit with ground,
and (I) normal?
relief-lever NEUTRAL. defective contact, or
f 0.5 - 4.5 v disconnection in wiring
4 YES Repair or
harness bewtween CO3
17
* Turn starting
connector with
pressure sensor. Is
switch ON.
*18-28V
N Oi
1 between CO7 (2)
2,
tl
(female) (16) and CO7 (female;
(1)

defective contact, or
replace
Repair or
tE2251 displayed?
* Disconnect C07. NO disconnection in wiring replace
l Turn starting l Turn starting harness between CO3 (female:
swtich OFF. (6) and CO7(female) (2)
switch ON.
* Interchange CO8 *18-28V Defective rear pump
with C07. pressure sensor (internal Replace
* Engine at high disconnection, defective
idling contact, short circuit, or
short circuit with ground)

CO3 (04020) co7 (X03)
Pressure sensor
Power source
Rear Pump pressure Rear Pump
sensor SIG Pressure sensor
TKPOOB11
20-486
0
C-19 [E226] Abnormality in pressure sensor power source system is

displayed
YES Defective front pump

Replace
2 pressure sensor (internal
short circuit or short
1Is voltage
circuit with ground)
YES between CO3 (6)
and (16) normal? 3 YES Defective rear pump
Replace
7 pressure sensor (internal
l- short circuit or short
between CO3 (6)
* Turn starting
NG and (16) normal? - circuit with ground)
between CO3 switch ON.
(female) (6) and - l Disconnect C08. Defective engine throttle
Replace
(16L (6) (16) and *18-28V NO pump controller
*Turn starting
chassis normal?
switch ON.
*Turn starting * Disconnect C07.
switch OFF. *18-28V Short circuit or short Repair or
* Disconnect C03, circuit with ground in replace
C07, and C08. No wiring harness of system
l Min. 1 MR where resistance value is
defective

CO8 (X3)
Engine throttle.numD controller

CO3 (04020)
Pressure sensor
Front Pump Pressure
sensor SIG
Pressure sensor
Power source
Rear Dump Pressure
sensor SIG
Pressure sensor GND
TKP00812
20-487
0
C-20 [E2271 Abnormality in engine speed sensor system is displayed

Cause Remedy

Is resistance . pump controller Replace
YE j between Cl6 Short circuit with ground,
- (female) (1) and - defective contact, or
(2) normal? disconnection in wirina Repair or
harness between Cl6 - replace
l Turn starting NO (female) (I) - E08 (10) - E07
(male) (I) and (2) switch OFF. (female) (2), or between Cl6
* Disconnect C16. (female) (2) - E08 (9) - E07
l500- 1ooon (female) (1)
l Turn starting
Defective engine speed
switch OFF. L Replace
iJ0 sensor (internal
* Disconnect E07. disconnection, defective
l500-1OOOR contact, or short circuit with
ground)

Cl6 (MIC17)
Speed sensor
Engine
speed
sensor
TKP00813
20-488
0
TROUBLESHOOTING OF ENGINE THROlTLE 1
PUMP CONTROLLER (INPUT SIGNAL SYSTEM)
(F MODE)
F- 1 Bit pattern 20-(l) Swing oil pressure switch does not light up .......................................... .20-502
F- 2 Bit pattern 20-(2) Travel oil pressure switch does not light up .......................................... .20-503
F- 3 Bit pattern 20-(3) Boom LOWER oil pressure switch does not light up.. ........................... 20-504
F- 4 Bit pattern 20-(4) Boom RAISE oil pressure switch does not light up ............................... 20-505
F- 5 Bit pattern 20-(5) Arm IN oil pressure switch does not light up ........................................ .20-506
F- 6 Bit pattern 20-(6) Arm OUT oil pressure switch does not light up.. ................................... .20-507
F- 7 Bit pattern 21-(l) Bucket CURL oil pressure switch does not light up.. ............................. 20-508
F- 8 Bit pattern 21-(2) Bucket DUMP oil pressure switch does not light up ............................. 20-509
F- 9 Bit pattern 21-(3) Swing lock switch does not light up.. ...................................................... .20-510
F-IO Bit pattern 22-(5) Kerosene mode connection does not light up ........................................ .20-511
F-II Bit pattern 22-(6) L.H. knob switch does not light up .......................................................... .20-512
20-50 1
0
TESTING AND ADJUSTING F-l
F-l Bit pattern 20-(l) Swing oil pressure switch does not light up
tor to its original position, if the monitor code display returns to normal, the problem has been
removed.
g Turn the swing lock switch ON before operating the swing lever.
Sr If there is no display when the lever is operated on one side, the PPC shuttle valve is defective.
(See H-5)
(When measuring with the engine stopped, charge the accumulator first.)
Jr Before carrying out troubleshooting, check that all the related connectors are properly inserted.
Cause Remedy

. pump controller
Is voltage disconnection in wiring Repair or
harness between SO8 replace
between Cl6 (5)
(female) (1) and chassis
and chassis YI ground
normal?
Defective contact, short
l Start engine. 2 circuit with ground, or Repair or
. Swing lever at Is resistance between disconnection in wiring replace
neutral SO8(male) II) and (21 *Turn starting switch harness between Cl6
- normal, and is circuit OFF. (female) (5) and SO8
:20-30V
l Swing lever
NO insulated from - Disconnect Cl6 and S08. (female) (2)
opereated
chassis? - Between Cl6 and S08: Max. 1 R
* Disconnect S08. - Between wiring harness and Defective swing oil
: Max. 1V chassis: Min. 1 MR pressure switch
* Start engine.
Replace
- Swing lever at NO (If the condition does
neutral not return to normal
: Min. 1 MR even when the switch
* Swing lever operated: Max. 1 R is replaced, go to H-5.
* See Note 1.
Note 1: It is also possible to fit a short connector

and judge the condition. In this case,
check the voltage between Cl6 (5) and
the chassis.
lIfitis20-30V:GotoYES
* If it is less than 1 V: Go to NO
F-l Related electric circuit diagram
Engine throttle.PumD controller SO8 (X2)

Cl6 (MIC17)
G Swine oil
Swing oi I Pressure switch
g @
Pressure switch
TKP00814
20-502
0
TESTING AND ADJUSTING F-2
F-2 Bit pattern 20-(2) Travel oil pressure switch does not light up
removed.
A Before operating the travel lever, check that the surrounding area is safe.
* If there is no display when the travel lever is operated on one side, the PPC shuttle valve is
defective. (See H-5)
Cause Remedy
‘ES Defective engine throttle

Replace
pump controller
1
Is voltage disconnection in wiring harness Repair 01
between Cl6 (13) between SO1 (female) (1) and replace
Cl6 (female) (13) and
and chassis YES SO1 (female) (2) chassis ground
normal? normal, and is circuit
insulated from Defective contact, short circuit
- Start engine. 2 with ground, or disconnection in Repair or
~ chassis?
* Travel lever at Is resistance between ~NO wiring harness between Cl6 replace
SO1 (male) III and I21 *Turn starting switch (female1 (13) and SO1 (female) (2)
neutral
:20-30V
- normal, and is circuit - DFF,
N 1insulated from
* Travel lever chassis?
*Disconnect Cl6 and Sol.
operated *BetweenCl6 andSol: Max.1 Q
* Disconnect SO1 - Between wiring harness and chassis: Min. 1 MR
: Max. 1 V Defective travel oil
* Start engine.
*Travel lever at pressure switch
NO
neutral
: Min. IMR
- Travel lever operated
: Max: 1 R
* See Note 1.
Note 1: It is also posibble to fit a short connector and

judge the condition. In this case, check the
voltage between Cl6 113) and the chassis.
*Ifitis20-30V:GotoYES
- If it is less than 1 V: Go to NO
F-2 Related electric circuit diagram
Eneine throttle.Dumo controller

so1 (X2)
Cl6 (MIC17)
a
Travel oil Travel oil
Pressure @ @ Pressure switch
switch
TKP00615
20-503
0
F-3 Bit pattern 20-(3) Boom LOWER oil pressure switch does not light up
removed.
a When measuring with the engine running, operate the lever slightly and make sure that the work
equipment does not move.
Cause Remedy

Replace
pump controller
1
R Defective contact, or
PIs resistance between _YES disconnection in wiring harries: Repair or
between Cl7 (10) Cl7 (female) (10) and between SO4 (female) (1) and replace
YES SO4(female) (2) chassis ground
normal, and is circuit
insulated from Defective contact, short circuit with
* Start engine. -
2
chassis? ground, or disconnection in wiring Repair or
* Boom lever at Is resistance between P
NO harness between Cl7 (female) (IO] replace
neutral: 20 - 30V SO4(male) (1) and (2) * Turn starting switch H13(11)-S04(female)(2)
- normal, and is circuit - OFF,
* Boom lever
operated to
NO insulated from * Disconnect Cl7 and S04.
chassis? * Between Cl7 and SO4: Max. 1 R
LOWER: Max. IV
* Disconnect S04. * Between wiring harness and chassis
* Start engine. 1 :Min.l Ma Defective boom LOWER
Replace
* Boom lever at ..-
NO oil pressure switch
neutral
: Min. 1 MR
* Boom lever operated to LOWER: Max. 1 R
* See Note 1.
Note 1: It is also possible to fit a short connector and judge the

condition. In this case, check the voltage between Cl7
(IO) and the chassis.
*IfitisZO-30V:GotoYES
* If it is less than 1 V: Go to NO
Engine throttle,
Pump controller Boom 101 er
Cl7 (04016) ni I ore! sure switch
TOP00391
20-504
0
F-4 Bit pattern 20-(4) Boom RAISE oil pressure switch does not light up
removed.
g When measuring with the engine running, operate the lever slightly and make sure that the work
Cause Remedy

Replace
pump controller
Is voltage Repair or
harness between SO2 replace
between Cl7 (2)
(female) (1) and chassis
and chassis YI ground
normal?
Defective contact. short circuit
* Start engine. 2 Repair or
with ground, or disconnection
- Boom lever at Is resistancebetween in wiring harness between Cl7 replace
neutral: 20 - 30V _ SO2(male)(1) and (2) . * Turn starting switch (female) (2) - H13 (9) - SO2
* Boom lever NO normal, and iscircuit OFF.
- Disconnect Cl7 and S02. (female) (2)
operated to RAISE insulatedfrom chassis?
: Max. 1 V I 4 * Between Cl7 and SO2 : Max. 1 R
* Disconnect SOZ. * Between wiring harness and chassis
* Start engine. : Min. 1 MR - Defective boom RAISE o
Replace
* Boom lever at NO pressure switch
neutral: Min. 1 MR
* Boom lever operated to RAISE
: Max. 1 R.
* See Note 1.
Note 1: It is also possible to fit a short connector

and judge the condition. In this case, check
the voltage between Cl7 (2) and the
chassis.
* If it is 20 - 30V: Go to YES
* If it is less than IV: Go to NO

so2 (X2)
Cl7 (04016)
H13 61 6)
a Boom RAISE oil
Pressure switch
Pressure switch
TKP00616
20-505
0
F-5 Bit pattern 2045) Arm IN oil pressure switch does not light up
removed.
a When measuring with the engine running, operate the lever slightly and make sure that the work
_j, Before carrying out troubleshooting, check that all the related connectors are properly inserted.
Cause Remedy

Replace
pomp controller
1 I 3
1 YES
disconnection in wiring harness Repair or
Is voltage Is resistance between ,
between Cl7 (3) between SO5(female) (11and replace
Iand chassis
normal?
Cl7 (female) (3) and
YES SO5(female) (2)
normal, and is circuit
chassis ground
insulated from Defective contact, short circuit

- chassis? with ground, or disconnection
- Arm lever at Is resistance between P in wiring harness between Cl7 replace
NO
SO5(male) (1) and (2) * Turn starting
neutral: 20 - 30V (female) (31- H13 (10) - SO5
- normal, and is circuit - switch OFF.
* Arm lever
NO insulated from (female) (21
* Disconnect Cl7 and S05.
operated to IN chassis? * Between Cl7 and S05: Max. 1 R
: Max. 1 V * Between wiring harness and chassis
* Disconnect S05.
* Start engine. 1 :Min. 1 MR Defective arm IN oil
Replace
* Arm lever at ..-
NO pressure switch
neutral
: Min. 1 MR
- Arm lever operated to IN: Max. 1 Q
* See Note 1.
Note 1: It is also possible to fit a short connector and

voltage between Cl7 (3) and the chassis.
* If it is less than 1V: Go to NO
Engine throttle,
Pump controller Arm in oi I
so5 (X2)
C17 (04016) Pressure switch
H 13 (S 161
a
@ @
m TDP00433
20-506
0
F-6 Bit pattern 20-(6) Arm OUT oil pressure switch does not light up
removed.
A When measuring with the engine running, operate the lever slightly and make sure that the work
Cause Remedy

Replace
pump controller
harness between SO3 Repair or
between Cl7 (I I) (female) (I) and chassis replace
ground
normal? Defective contact, short
. Start engine. circuit with ground, or Repair or
* Arm lever at replace
SO3(male1(I) and (2) * Turn starting harness between Cl7
neutral: 20 - 30V
switch OFF. (female) (II)-H13(12)-
* Arm lever SO3 (female) (2)
* Disconnect Cl7 and S03.
operated to
* Between Cl7 and SO3: Max. 1 Q
OUT: Max. 1 V
l Start engine. : Min. 1 MR Defective arm OUT oil
* Arm lever at IO pressure switch
neutral
: Min. 1 MR
* Arm lever operated to OUT: Max. 1 R
* See Note 1.
Note 1: It is also possible to fit a short connector and

voltage between Cl7 (II) and the chassis.
* If it is 20 - 3OV: Go to YES
Engine throttle,
Pump controller cn, IVO\ Arm out oil
J”J \*,L,
Cl7 (04016) Pressure switch
H13 (S161 n
a
Pressure 0 @ @
-7h- - -0P0039
20-507
0
F-7 Bit pattern 21-(l) Bucket CURL oil pressure switch does not light up
removed.
Cause

Replace
I pump controller
1
3 disconnection in wiring
Is voltage - YES harness between SO6 Repair or
Is resistance between -
between Cl 6 ( II) replace
Cl6 (female) (II) and (female) (I) and chassis
and chassis YES SO6(female) (2) ground
normal? normal, and is circuit
insulated from Defective contact, short
circuit with ground, or
* Bucket lever at Is chassis? replace
NO disconnection in wiring
neutral: 20 - 30V SO6(male) (1) and (21 s Turn starting
harness between Cl6
* Bucket lever
- normal, and is circuit - switch OFF.
NO insulated from . Disconnect Cl6 and S06. (female) (I I) and SO6
operated to chassis? (female) (2)
. Between Cl6 and S06: Max. 1 D
CURL: Max. 1 V
* Start engine. : Min. 1 MR Defective bucket CURL
Replace
* Bucket lever at in oil pressure switch
neutral: Min. 1
MR
* Bucket lever operated to CURL: Max. 1 R
* See Note 1.

(I I) and the chassis.
Engine throttle,
Pump controller
SF6 /X2),
Cl6 (MIC17)
?
Bucket a Bucket cu rl oil
curl oil m Pressure switch
@
I Pressure I Y
switch
m TDP00394
20-508
0
F-8 Bit pattern 21-12) Bucket DUMP oil pressure switch does not light up
removed.
Cause Remedy

. pump controller
1
Is voltage disconnection in wiring harness Repair or
between Cl6 (12) _ between SO7(female) (2) and replace
and chassis YE chassis ground
normal?
* Start engine. 2 circuit with ground, or Repair or
* Bucket lever at Is resistance between disconnection in wiring replace
neutral: 20 - 30V SO7(male) (1) and (21 *Turn starting switch harness between Cl6
- normal, and is circuit - OFF. (female) (12) and SO7
* Bucket lever
NO insulated from - Disconnect Cl6 and S07. (female) (2)
operated to chassis? * Between Cl6 and 507: Max. 1R
DUMP: Max. 1 V
- Disconnect S07. * Between wiring harness and chassis:
- Start engine. Min. 1 M!J Defective bucket DUMP
Replace
- Bucket lever at 0 oil pressure switch
neutral
: Min. 1 MR
* Bucket lever operated to DUMP: Max. 1 R
* See Note 1.

(12) and the chassis.
* If it is 20 - 3OV: Go to YES
. If it is less than IV: Go to NO

Cl6 (MIC17)
Bucket DUMP oil

Pressure switch
TKPOO617
20-509
0
F-9 Bit pattern 2143) Swing lock switch does not light up
removed.
* If the panel display is normal. (If the swing lock lamp does not light up, go to M-21.)
Cause Remedy

pump controller
Defective contact, short circuit

with ground, or disconnection Repair or
in wiring harness betweenX05
between Cl7 (16) replace
(female) (2)-X01 (51-HI4(6l-
* Turn starting
1 YI chassisground

circuit with ground, or
Repair or
switch ON. replace
mSwing lock * Turn starting
harness between Cl7
switch switch OFF.
(female) (16) -X01 (4) -
ON: Max. IV * Disconnect Cl7 and X05.
* Between Cl7 and X05 : Max. 1 a X05 (male) (I)
OFF: 20 - 30V
l Turn starting * Between wiring harness and chassis
switch OFF. : Min. 1 MR Defective swing lock Replace
* Disconnect X05. IO switch
l Swing lock
switch
ON: Max. 1 R
OFF: Min. 1 MR
Engine throttle, Swing lock

Pump controller switch
Cl7 (04016)
I \ I
Monitor panel
-dT TDP00397
20-510
0
TESTING AND ADJUSTlNG F-10
F-10 Bit pattern 22-(5) Kerosene mode connection does not light up
removed.
Cause Remedy

. pump controller
Is voltage ‘II
between Cl7 (15) Defective contact, or
and chassis 2 YES disconnection in wiring Repair or
normal? harness between M36 replace
Is resistance between
(male) (1) and chassis
* Turn starting L Cl7 (female) 1151and
ground
switch ON. NO M36 (female) (I)
1normal? 11 Defective contact or
* M36 connector Repair or
Connected * Turn starting NO replace
% harness between Cl7
: Max. IV switch OFF. (female) (15) and M36
& Open: 20 - 30V * Disconnect Cl7 (female) (I)
8 and M36.
* Max. 1 R
F-IO Related electric circuit diagram

Kerosene mode connector
Cl7 (04016)
)b
.Diesel oi I mode(oPen)
TKP00818
20-511
a
TESTING AND ADJUSTlNG F-II
F-II Bit pattern 22-16) L.H. knob switch does not light up
removed.
When fuse No. 5 is not blown.
Cause Remedy
YES
r
Replace
pump controller
L
Is voltage 3 YES disconnection in wiring Repair wiring
, harness between knob harness
between CO3 (9)
and chassis I switch outlet - M23 (2) -
normal? M22 (2) - CO3 (female) (9:
I
l Turn starting Defective L.H. knob Replace
switch ON. ~~ switch
* Knob switch
ON: 20 - 30V JO * Disconnect switch terminal.
OFF: Max. 1 V normarc * Knob switch Defective contact, or
ON: Max. 1 n disconnection in wiring
* Turn starting OFF: Min. 1 MR harness between fuse Repair wiring
switch ON. No. 5 - HI2 (16) - M22 (11
NO harness
*20-30V - H23 (I) - knob switch
inlet
F-II Related electric circuit diagram
HI2 616)
d
Engine throttle.
L. H. knob switch
DUrnP controller
1 Knob switch ) q-
TKP00819
20-512
0
TROUBLESHOOTING OF HYDRAULIC AND
MECHANICAL SYSTEM
(H MODE)
Table of failure modes and causes for hydraulic and mechanical system . . . . . . . .. . . . . . .. . .. .. . . . .. .. .. . . .. . .. 20-552
Pump merge/divider logic . .. . .. .. . . .. . . . . . . . . . . . . .. . . . . . .. . . .. . . . . . . .. . . .. . . . .. . .. . . . . . .. . .. . . . . . . .. . . .. . .. . . . .. . .. . . . . . . . .. . .. . . .. . .. . . . . . .. . 20-556
Solenoid actuation table . .. . . . . . .. . .. . . . . . . .. .. . .. . . . . . .. . .. . . . . . .. . . . . . . . .. . . .. . . . . . . .. .. . . . . . . . . .. . .. . . . . . . .. . . . . . . . . .. . . . . . . .. . .. . . . . . . . .. . . 20-557
Troubleshooting flow charts for each failure mode
All work equipment, travel, swing
H-l Speeds of all work equipment, swing, travel are slow or lack power . . .. .. . . . . . . .. . . . . . . .. .. . . . 20-558
H-2 There is excessive drop in engine speed, or engine stalls . . . . . .. . . . . . . .. . .. .. . . . . . .. . .. . . . . . . .. . . . . . .. . 20-560
H-3 No work equipment, travel, swing move . .. . .. . . . . . . .. . . . . . . .. . . .. . . . . . . .. . .. . . . . . .. . .. .. . .. . . . .. . . . .. . . . .. . . . . . .. . 20-561
H-4 Abnormal noise generated (around pump) .. . . . . . .. . .. . . . . . . . . .. . .. . . . .. . .. . . . . . .. . .. .. . .. . . . . . .. . .. . . . .. . .. . . .. . 20-561
H-5 Auto-deceleration does not work (PPC shuttle valve is equipped
only in travel PPC valve) . .. . .. .. . . . . . . .. .. . .. . . . .. . . . .. . . . .. . .. . . . . . . . . .. . .. .. . .. .. .. . . . . .. .. . .. . . . . . . .. . . .. . .. . . . .. . . . . . . .. . . 20-562
H-6 Fine control ability is poor or response is poor . .. .. . .. . . . .. . . . .. . . . . . . .. . . . .. . . . . . .. . . . . . . .. . . . .. . . . .. . . . .. . . . 20-562
Work equipment
H-7 Boom is slow or lacks power .............................................................................................. 20-564
H-8 Arm is slow or lacks power.. ............................................................................................... 20-566
H-9 Bucket is slow or lacks power.. ........................................................................................... 20-568
H-10 Work equipment (boom, arm, bucket) does not move (but travel and
$
swing are normal) ................................................................................................................. 20-569
&
2 H-l 1 Excessive hydraulic drift ...................................................................................................... 20-569
H-12 Excessive time lag (engine at low idling) ......................................................................... -20-570
H-13 Other equipment moves when single circuit is relieved ................................................. .20-570
H-14 Lack of power when pressure rises ................................................................................... .20-571
H-15 In L/O, F/O modes, work equipment speed is faster than specified speed.. ................. 20-572
Compound operations
H-16 In compound operations, work equipment with larger load is slow ............................. 20-572
H-17 In swing + boom RAISE, boom RAISE is slow.. ............................................................... .20-573
H-18 In swing + travel, travel speed drops excessively ........................................................... .20-573
Travel system
H-19 Travel deviation.. ................................................................................................................... 20-574
H-20 Travel speed is slow.. ........................................................................................................... 20-576
H-21 Steering does not turn easily or lacks power.. ................................................................. .20-578
H-22 Travel speed does not switch or is faster than specified speed .................................... .20-580
H-23 Travel does not move (one side only). .............................................................................. .20-580
Swing system
H-24 Does not swing ..................................................................................................................... 20-581
H-25 Swing acceleration is poor or swing speed is slow ......................................................... 20-582
H-26 Excessive overrun when stopping swing .......................................................................... .20-584
H-27 Excessive shock when stopping swing (one direction only). .......................................... .20-585
H-28 Excessive abnormal noise when stopping swing ............................................................. 20-585
H-29 Excessive hydraulic drift of swing ....................................................................................... 20-586
H-30 Swing speed is faster than specified speed in L/O, F/O modes ..................................... .20-587
H-31 Operation of automatic mode function defective (HYPER specification). ...................... 20-587
20-551
0
TABLE OF FAILURE MODES AND CAUSES FOR HYDRAULIC
TESTING AND ADJUSTING AND MECHANICAL SYSTEM

AND MECHANICAL SYSTEM (l/Z)
Parts causing failure
Failure mode
wing acceleration is poor
* In the failure modes, modes for compound operations are used when independent operations are normal.
A: When there is an abnormality for both front and rear
% With ( ) shows for HYPER specification
20-552
0
- -
Control
-
valve
- - - - -
5
T 1”
For For
Y$! F
e c
ump merge
front rear .il 5
iveder valve P
pump pump
E D E
- - - - - - 1 - -
e
I= 3
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z
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- -2 -5 -c_zFL -
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- -(;3
- -w w
-
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-
7
- - - - - - - - - - - - - -
- - - H-l
- - - - - - - - - - - - - - - - 2 H-2
- - - - - - - - - - - - - - - - - - 0
- - - - H-3
- - - - - - - - - - - - - - - - - - - - - H-4
- - - - - - - - - - - - - - 0
- - - - - H-5
- - - 5
- - - - - - - - - H-6
5 - - - - / 0 0 - 5 - - -’ 0 0
- - 0 - - - - - H-7
5 - - - , 0
- -0 - 5
- - - - 0
- 0 - - D - - - - - H-8
5 - - - - ,
- - - - - - - - 0- - - 0 - - - - - H-S
5 - - - - - - - - - - - - - - - 0 - - - -
5 - - - - - - - - - - - - - - - g - - - - - i-10
; - - - - - - - - - - - - - - - - - - -
- - - - I
- - - - - - 0 - - - - - - - - i-l1
- - - - (
- - - - - - - r?
3 - 0- - - - - - - - - i-12
- - I
- - - - - - - - - - - - - - - - - i-13
- -0 - 0- - - - - - - - - - - - - - - - i-14
- - - - - 0
- 0
- - - - - - - - - - - - - - - - i-15
- - - - - (
- - - - - - - - - - - - - - - - - i-16
- - - - - - - - - - - - - - - - - - - - - i-17
- - - - - - - - - - - - - - - - - - - i-18
3 - - - - (
- - - - - - - - - - - 0
- - - - - - i-19
- - - - - - - - - - - - - - - - -
5
- - - ( 5 - - - - 3 - 0
- - - - - - i-20
- 0
- - 5- - (
- o-
?3- - -5 -5 3 - - - - 7
- - - - - - - - l-21
- - - - - - - - - - - - - - - - - - - - - l-22
- - - - - - - - - - - - - - 3-
- - - - - - - - l-23
- - - - - - - - - - - - - - - - - - - -
3 - - - - - - - - - - - - - 0
- - - - - - l-24
- - - - - - - 3 - - - - - -
a
- - - -
” - - - - (
- - - - - - - - - - - - 5- - - - - l-25
-
- - - - - - - - - - - - - - - - - - -
2 - - - - - - - - - - - - - - - CT - - 7 - - l-26
- - - - - - - - - - - - - - - - 5
- - - 3-
- - - l-27
- - - - - - - - - - - - - - - - - - - - - l-28
5 - - - - ( - - - - - - - - - - - - - - - -
- - - - - - - - - - - - - - - - - - - l-29
- - - - - l-
/5 7
- - - - - - - - - - - - - - - - - l-30
-
20-553
0
Parts causing failure
Failure mode
20-554
0
02OYO6
0 Safety valve
0 0 valve I!
I I I I I Counterbalance
0 0
0 0 Boom holding valve
Lift check valve
0 0 0 RAISE
$
0 0 0 LOWER 5
TESTING AND ADJUSTING PUMP MERGE/DIVIDER LOGIC
PUMP MERGE/DIVIDER LOGIC
Flow divided Flow merged
Solenoid ON (excited) Solenoid OFF (de-energized)
* Breaker mode + service switch ON
* In L/O mode, except for Conditions I), 2), or 3) * In L/O mode, under Conditions l), 2), or 3)
1)Any of travel + (boom or arm or bucket or swing) operated 1) Any of travel + (boom or arm or bucket or swing) operated
independently independently
2) Any of travel + (boom or arm or bucket or swing) operated 2)Any of travel + (boom or arm or bucket or swing) operated
simultaneously simultaneously
3)Swing + boom RAISE (hoist swing) 3) Swing + boom RAISE (hoist swing)
l In other modes {(breaker mode + service switch ON or l In other modes {(breaker mode + service switch ON or
any mode except UO mode (including HYPER or HYPER any mode except !_/O mode (including HYPER or
GX specification machine with swing priority mode OFF)} HYPER GX specification machine with swing priority
mode OFF)]
* Independent operation of travel * Compound operation of travel

(Travel + other work equipment)
l With travel OFF * With travel OFF
* Swing lock switch OFF * With swing lock switch ON
* F/O mode + arm IN l With swing lock switch OFF
* With HYPER or HYPER GX specifica- a * Except operation a on left, in active mode

tion, boom priority 2 mode + boom
RAISE + arm OUT l Except operation a on left, and except in
active mode
* Operation except operation a except
in active mode fin standard mode) * With swing ON
+ swing OFF
* With swing OFF
* Arm OUT + service ON +
pressure sensor (F pump b * Except operation b on left.
pressure or R pump pressure)
more than 19.6 MPa (200 kg/cm*)
b HYPER or HYPER GX specification machine with swing * HYPER or HYPER GX specification machine with swing
priority mode ON priority mode ON
* With travel ON * With travel ON
l Any one of boom ON, arm ON, bucket g l Any one of boom ON, arm ON, bucket
ON, or swing ON + condition * ON, or swing ON + service ON or except d
condition *
* Except operation d on right
* With travel OFF
t The higher pressure of the F or R pumps is as follows:

When pressure rises: 19.6 MPa {200 kg/cm?
When pressure goes down: 14.7 MPa I150 kg/cm3
20-556
0
TESTING AND ADJUSTING SOLENOID ACTUATION TABLE
I Name of solenoid I ON (energized) OFF (de-energized) I
I Swing holding brake Brake released Brake applied I
I Travel speed 1 Travel motor swash plate angle at MlN 1 Travel motor swash plate angle at MAX 1
Active mode Standard mode (active mode OFF) Active mode ON
Pump merge/divider valve Divided flow Merged flow
I 2-stage relief valve Pressure rises Pressure does not rise

I
20-557
0
TESTING AND ADJUSTING H-l
H-l Speeds of all work equipment, swing, travel are slow or lack
power
* Carry out troubleshooting in the H/O mode.
* Check that no abnormal noise is being generated from the main pump before carrying out
troubleshooting. (If there is any abnormal noise, carry out troubleshooting for H-4.)
YES
5
Does condition
YE ; become normal
when PC valve is GYES
adjusted? _ Does condition
See TESTING become normal when
AND NO PCvalve assembly is
Is input pressure of
L-t
ADJUSTING. replaced?
YE servo piston
approx. 3/5 of main NO
circuit pressure?
* Engine at high 7 YES

idling
Does condition
* Power max. II
YES become normal when
mode
+ L.H. knob switch NO ~~p~~~~~~mb’y is
normal? ON
* 0.2 f 0.2 MPa * Arm IN relief * Distribution of LS NO
(‘2 +_2 kg/cm? * See Note 1. valve and piston
2
* Engine at high pump (servo piston)
idling
ES g
* Arm IN relief i 0
8
l 30.4 - 33.8 MPa YES

(310 - 345 kg/cm*} 8
* Engine at high
idling
1Foes condition, 1
become nOrmal
I I
* Arm IN relief
h when main relief 9 YES
Is control circuit
I4
pressure normal? Does condition
* 30.4 - 33.8 MPa _ become normal
(310 - 345 NO when unload valvee
* Check and are replaced?
kg/cm9
measure circuit
* Engine at high * 3.9 f 1.0 MPa NO
oil pressure. For
idling (40 f 10 kg/cm21
details, see
TESTING AND
* Arm IN relief *Engine at high idling
ADJUSTING. i
- Arm IN relief
NO
% The PPC control circuit oil pressure is reduced by self-reducing pressure valve
Note 1. Measuring servo piston inlet port pressure in Item No. 4

. Measure the input pressure to the large diameter end of the servo piston when the arm is
relieved in the power max. mode. (Approx. 17.6 MPa (180 kg/cm*})
Basically, the pressure at the large diameter end is approx. 3/5 of the small diameter end.
(For details, see TESTING AND ADJUSTING.)]
20-558
0
TESTING AND ADJUSTING H-l
Cause Remedy
t- Defective adjustment of
PC valve Adjust
Defective PC valve servo Repair or

assembly replace
Repair or
Defective piston pump
replace
Defective LS valve Repair or

assembly replace
Defective piston pump Repair or

(servo piston) replace
Defective operation of
LS-EPC solenoid valve Replace
main relief assembly
(valve which becomes Adjust
normal when adjusted)
unload valve (valve
Replace
which becomes normal
when replaced)
main relief valve
Defective self-reducing Repair or

pressure valve replace
20-559
0
TESTING AND ADJUSTING H-2
H-2 There is excessive drop in engine speed, or engine stalls

-k Check that the main relief pressure is normal.
Cause Remedy
Clogged throttle inside

YES
servo or clogged filter Clean
inside servo
Adjust or
Defective PC valve or
replace servo
defective operation of LS
3 valve
Is throttle inside valve
servo or filter
1Does condition 1 assembly
inside servo Adjust or

clogged? 4YE replace LS
Defective LS valve
valve
become normal assembly
when LS valve
Replace
Defective servo piston (piston pump
at arm IN relief
assembly)
See troubleshooting for

-
engine (S mode)
Note 1:Replace the servo valve assembly on the defective side with a new part, and if the engine
speed is lower than the reference value below, carry out troubleshooting for S mode (engine).
If it is higher, it can be judged that the servo valve is defective, so replace it.
Ir Engine speed (reference) at arm IN relief when engine and pump are normal
Engine speed at arm IN relief Conditions
PC200, 210 Min. 1,900 rpm l Engine at high idling

l Power max. mode
PC220, 230 Min. 2,000 rpm l L.H. knob switch ON
20-560
0
TESTING AND ADJUSTING H-3, 4
H-3 No work equipment, travel, swing move
Defective self-reducing
pressure valve, defective
2 YES control circuit, or Replace
When main pump defective main piston
YEis pressure pickup pump
1 plug is removed, -
does oil come out?
Is safety lock Defective damper Replace
valve working * Crank with NO
properly? starting motor.
i safety lock valve or Adjust
NO safety linkage
$
> H-4 Abnormal noise generated (around pump)
%
Cause Remedy
3 YES
YE/Fl-- Goto4
stopped? I Change
2 I Improper hydraulic oil
NO hydraulic oil
Clogged by external
YES
object (cloth, etc.) Remove
4
(strainer)
Is suction strainer
1
Repair or
Defect inside pump
Is hydraulic tank replace
oil level normal?
Operate for a short time Inspect again
and watch for any (depending on
change in symptoms changes in
symptoms)
Lack of hydraulic oil Add hydraulic

NO oil
20-56 1
0
H-5 Auto-deceleration does not work (PPC shuttle valve is equipped

only in travel PPC valve)
* The control pressure for the travel passes through the PPC shuttle valve and is supplied to the
pressure switch.
Cause Remedy
1 YES Defective pressure

Replace
Does condition switch
become normal
when pressure
switch is replaced? Repair or
PPC shuttle valve with
ND replace
travel PPC valve
H-6 Fine control ability is poor or response is poor
Cause
2 YES Clogged throttle in LS

circuit Clean
YES Is throttle in LS
1 circuit clogged?
Defective LS valve, or
Is output Replace
defective servo piston
NO
pressure of LS- -
EPC normal?
Repair or
l Engine speed: _ Defective LS-EPC valve
replace
Max. 1300 rpm NO
l Output pressure:
2.2 f 0.2 MPa
(22 f 2 kg/cm?
20-562 .
0
H-7 Boom is slow or lacks power

+ When travel and swing speeds are normal.
YES
Does LS shuttle
YI
* Check LS shuttle
for R.H. travel NO
5
and bucket
Y
pumps normal when
boom RAISE circuit
+ 30.4 - 33.8 MPa - Front is low -
!
310 - 345 kg/cm2
* Engine at high
4 idling
Is pressure
l-l
YI j compensation
valve for
boom normal, or does
pressure compensation
piston move sJlwttlh/;)
* It is also possible
to interchange
N I
_ Both front and

rear are low
with other
compensation
valve.
* See Note 2.
N0
NO
* Min. 2.7 MPa I28
Is pressure switch kg/cm2~
for boom RAISE, * Engine at high
idling
* Operate boom. NO
* See judgement
Table. (Bit pattern
20 (3)(4))
* See Note 1. NO
Note 1: If auto-deceleration is canceled when boom RAISE or boom LOWER is operated, system is
normal.
Note 2: After inspection, do not forget to return the interchanged valves to the original position.
Note 3: For HYPER and HYPER-GX specification machines, carry out troubleshooting as PPC valve +
EPC valve.
20-564
a
Cause Remedy
7 YES Defective operation of Correct or

boom lock valve replace
Is operating
pressure normal
when boom RAISE
is being operated? Defective boom cylinder Correct or
. ~~200: I 4.7 k I .5 NO piston packing replace
MPa (150 * 15 kg/cm21
PC220: 16.7 + 1.5 MPa (170 + 15 kg/cm*)
. Engine at higt idling
Defective operation of LS Correct or
. At max. reach, no load
shuttle valve (LS shuttle
replace
for R.H. travel or bucket)
a YES pump merge/divider valve Correct or
or LS pump merge/divider replace
Is pump
valve)
merge/divider
solenoidvalve output
pressurenormal? Defective operation of
Correct or
pump merge/divider
replace
*When boom is NO solenoid valve
raised: 0 MPa (0
kg/cm*) Defective boom lock valve
or suction valve for boom Replace
in control valve
Defective operation of Correct or

boom regenration valve replace
I50 + 30 kg/cm*)
-Engine at high Defeaive operatjonof boom
pressurecompensationvalve or
idling Correct or
pressurecompensationpiston
(for boom PAlSEend, check replace
boom Hi also)
boom Hi spool also)
Defective PPC valve Replace
Defective boom RAISE or

boom LOWER pressure Replace
switch
20-565
a
H-8 Arm is slow or lacks power

Ir When travel and swing speeds are normal.
t Carry out troubleshooting in the H/O mode.
YES
a-
6l-
; Does LS shuttle
YE
valve move
smoothly?
* Check LS shuttle
for L.H. travel, NO
5 boom, R.H. travel
and bucket
relief pressure of
Is
YES front and rear pumps
normal when arm
circuit is relieved? - Rear is low -
4
- 30.4 - 32.4 MPa
(310 - 330 kg/cm*}
Ispreswre * Engine at high
YES compensationvalvefor
arrnmnnal,wdces - idling
pressurecompensation
pistonmovesmcothly? Both front and
=l - rear are low -
*, + It is also possible 1
to interchange
with other
compensation
valve. NO
* See Note 2.
YES Is output
- pressure of PPC -
valve normal? NO
1
* Min 2.7 MPa
Is pressure switch (28 kg/cm*}
for arm IN, OUT - * Engine at high NO
normal? idling
I * Operate arm.
* See judgement
Table. (Bit pattern
20 (5). (6)) r.,n
* See Table 1. I’”
Note 1: If the auto-deceleration is canceled when arm IN or arm OUT is operated, the system is
normal.
EPC valve.
20-566
a
7 YES Defective operation of arm Correct or

regeneration valve replace
Is leakage from
- arm cylinder
normal?
Defective arm cylinder Correct or
. Max. 20 cc/min NO piston packing replace
- Engine at high
idling Defective operation of LS
shuttle valve (LS shuttle Correct or
for L.H. travel, boom, R.H. replace
travel or bucket)
8 YES pump merge/divider valve Correct or
Is pump or LS pump merge/divider replace
merge/divider valve
adenoid valve output
pressurenormal? Defective operation of
Correct or
pump merge/divider
NO replace
* 0 MPa {O kg/cm?} solenoid valve
* Arm lever operated
* Engine at high idling
Defective operation of arm
Replace
safety-suction valve
:I Defective PPC valve leplace
20-567
0
H-9 Bucket is slow or lacks power

* When travel and swing speeds are normal.
Cause Remedy
3 YES
H
I Does control I GotoA
YES valve spool for
YES
2 bucket move
smoothly? Correct or
Is output control valve spool for
NO replace
pressure of PPC _ bucket
1 valve normal?
Is pressure
switch for bucket * Min. 2.7 MPa
CURL, DUMP - 128 kg/cm21 NO
normal? * Engine at high
idling
* See Judgement Defective bucket CURL or
* Operate bucket.
Table. (Bit bucket DUMP pressure
pattern 21 (I), No switch
(2))
- See Note 1 Defective operation of
5YE S Repair or
safety-suction valve for
replace
bucket
4
ns pressure I
compensationvalve Defective bucket cylinder Repair or
From A for bucketnormal,or * Max. 20 cc/min NIQ Ipiston packing replace

-i doespressure * Engine at high
idling Defective operation of
Ipressure compensation Repair or
* If 1salso posslole NO valve for bucket or replace
to interchange Ipressure compensation
with other Ipiston
compensation
valve.
* See Note 2.
Note 1: If the auto-deceleration is canceled when bucket CURL or bucket DUMP is operated, the
system is normal.
EPC valve.
20-568
0
H-10 Work equipment (boom, arm, bucket) does not move (but travel
and swing are normal)
Cause Remedy
+ When boom, arm, and bucket are each operated inde-
pendently.
1 YES Defective control valve Correct or

spool replace
Isoutput
pressureof PPC -
valve normal?
- Min. 2.7 MPa NO
(28 kg/cm21
* Engine at high
idling
Note 1: For HYPER and HYPER-GX specification machines, carry out troubleshooting as PPC valve + EPC valve.
H-l 1 Excessive hydraulic drift

I) Excessive hydraulic drift of boom
Cause Remedy
YES Defective hydraulic

Replace
1 cylinder piston packing
Does speed of
Replace
safety-suction valve

boom lock valve replace
to measure
leakage of
cylinder.
* Max. 20 cc/min
* At relief
* Engine at high
idling
2) Excessive hydraulic drift of arm or bucket Cause Remedy
YES Defective hydraulic

cylinder piston packing
1
Does speed of
downward movement _ YES Defective operation of
become faster when Reolace
2 safety-suction valve
lever is operated?
~ Does condition
* See TESTING become normal 3
AND NO when safety- YES Defective control valve
Is slipper seal of
ADJUSTING. suction valve is spool Replace
pressure
* It is also possible interchanged? compensation valve
to measure Nc damaged? Damaged slipper seal of
leakage of Or does pressure pressure compensation Correct or
cylinder. compensation piston valve, or defective
* Max. 20 cc/min move smoothlv? NO replace
operation of pressure
*At relief compensation piston
* It is also possible to interchange with
* Engine at high
other compensation valve.
idling
. See Note 1.
20-569
0
H-l 2 Excessive time lag (engine at low idling)
Cause Remedy
Defective safety-suction
valve, or defective Replace
regeneration valve
2
Is pressure Defective safety-suction
YES compensationvalve Bucket Replace
valve
- normal,or does
1 pressurecompensation
p piston move smoothly? Defective operation of
Is output pressure compensation
* It is also possible Correct or
pressure of LS- valve or pressure
- tointerchange NO replace
EPC solenoid compensation piston
valve normal? with other
compensation valve.
* See Note 1. l See Note 2. Defective operation of Correct or
NO LS-EPC solenoid valve replace
Note 1: Output pressure of LS-EPC solenoid

2.2 f 0.2 MPa 122 C 2 kg/cm*) is output from the LS-EPC solenoid when the engine is at low
l
idling (approx. 1300 rpm or below) regardless of the working mode.

H-13 Other equipment moves when single circuit is relieved
Cause Remedy
valve slipper seal
(The slipper seal in the Replace
valve of the circuit that
moved is defective.)
20-570
0
H-14 Lack of power when pressure rises

. If condition is normal except when pressure rises
I Cause Remedy
2 YES
Defective main relief
valve
YE
I I I Defective operation of Eorrect or

Is pressure switch . Min. 2.7 MPa (28 NO 2-stage relief solenoid ,eplace
kg/cm21 valve
* UO mode
. Operate each
Defective pressure switch Replace
control lever, and
if auto-deceleration is canceled, condition is normal
(note: if shuttle valve with PPC valve is normal)
20-571
0
H-15 In L/O, F/O modes, work equipment speed is faster than

specified speed
Cause Remedy
2 YES Xorrect or
Defective LS valve
.eplace

LS-EPC solenoid valve replace
IJeKJYl
Is oil pressure
normal when 4 YES Correct or
pump is relieved? Defective operation of LS
Does main pump replace
pump merge/divider
YES_ merge/divider valve
l At arm relief 3 valve move
F pump: Approx. -
smoothly? Defective operation of Correct or
34.8 MPa {355 Is output pressureof I
_ pump merge/divider _ . See Note 2 NO main pump replace
kg/cm21 merge/divider valve
R pump: Approx. NO scFii; Valve below.
5.9 MPa 160
kg/cm21 . Min. 2.7 MPa I28 Defective operation of Correct or
* At bucket relief kg/cm21 NO pump merge/divider replace
F pump: Approx. * L/O mode solenoid valve
5.9 MPa (60 * See Note 2
kg/cm? below.
R pump: Approx.
34.8 M Pa (355
kg/cm*)
* L/O mode
* See Note 2
Note 1: Output pressure of LS-EPC solenoid (travel OFF)

Approx. 1.3 MPa {approx. 13 kg/cm*) is output from the LS-EPC solenoid when the lever is
operated in the L/O and F/O modes, regardless of the engine speed.
Note 2: Troubleshooting items 3 and 4 apply only for the L/O mode.
H-16 In compound operations, work equipment with larger load is

slow
Cause Remedy
Defective operation of pressure Replace (replace pressure compensation

compensation valve valve on side where load is lower)
Combination of compound operation Side where load is larger

1 Boom RAISE + arm IN Boom RAISE
2 Boom RAISE + arm OUT Arm OUT
3 Boom RAISE + bucket CURL Boom RAISE
4 Arm OUT + bucket CURL Arm OUT
5 Boom LOWER + arm OUT Arm OUT
20-572
0
H-17 In swing + boom RAISE, boom RAISE is slow

Ir If swing and boom RAISE work normally when operated
independently.
Cause Remedy
Defective operation of LS Correct or

select valve replace
H-18 In swing + travel, travel speed drops excessively

* If swing and boom RAISE work normally when operated
independently. Remedy
Cause
Defective operation of LS
Correct or
shuttle valve (LS shuttle
replace
for L.H. travel or swing)
20-573
0
H-19 Travel deviation

Jr When swing and work equipment speeds are normal
a) When there is deviation in normal travel
Cause Remedy
4YEI Defective travel motor Correct or

assembly replace
Does control
YES- valve spool move _
3 smoothly?
Does travel
control valve spool replace
YES pressure NC
compensation valve
2 move smoothly?
Is travel speed Defective operation of
* Check as an Correct or
YE 1when operated travel pressure
replace
under no load
- individual part. NO compensation valve
1
Is difference in output
% See Standard Adjust or
Value Table. Defective LS valve replace
NO
-Output pressure:
5 YES
Min 2.7 MPa Defective PPC valve Replace
(28 kg/cm*} Is output pressure
*Difference in of self-reducing
output pressure N , pressure valve
normal? Defective self-reducing
between left and
Replace
right: Within 0.4 NO pressure valve
. Min 3.3 MPa
MPa I4 kg/cm21 {34 kg/cm*}
. Engine at high . Engine at high
idling idling
20-574
0
H-20 Travel speed is slow

* Check that the spool of the travel PPC valve is moving the full stroke before carrying out trouble-
shooting.
* When the swing and work equipment speeds are normal.
3 YES
Is output
YES pressure of LS-
2 - EPC solenoid
valve normal?
Slow in both Is pressure
FORWARD and - - See Note 2. NO
switch normal?
REVERSE
7YES
Does condition
,I become normal
u-
L
both FORWARD and YE
REVERSE,or is it 6
direction onlv? compensationvalve

NO
* See Note 1.
pressurecompensation
YE - It is also possible s
to interchange
1move smoothly? 1 with other
compensation valve.
* See Note 4.
pressurenormal?
- Difference in 8 YES
output pressure
I
0.4 MPa _ Min 3,_ ._^ LI_
3 Mra
{4kg/cm*I
(34 kg /cm21
- Output pressure:
* Engine ar ’nls
‘gh
Min. 2.7 MPa
idling
(28 kg/cm21
* Engine at high
idling
* Travel relief
Note 1: Measure the travel speed when operated under no load or the specified time for 20 m. (See
l
Standard Value Table for Engine related parts.)

Measurement
l of travel motor speed when rotated under no load 0 Remove the connector
of the LS-EPC solenoid, then measure the travel speed in Hi and Lo.
Note 2: Output pressure of LS-EPC solenoid
In H/O mode, 0.2 f 0.2 MPa {2 + 2 kg/cm21 is output regardless of the engine speed.
l
20-576
0
Cause Remedy
k Defective operation of LS
shuttle valve (for bucket)
Correct or
replace

LS-EPC solenoid valve replace
Defective travel pressure

Replace
switch
Correct or
travel suction valve of
replace
control valve
Defective travel motor Correct or

assembly replace
Defective pressure
compensation valve, or
Correct or
defective operation of
replace
piston

control valve travel spool replace
Defective self-reducing
I3eplace
pressure valve
Note 4: lRemove the PPC shuttle block inlet hose, fit an adapter, and block the tip.
lIf the adapter for blocking the circuit is not available, interchange the travel PPC hoses with
the PPC hoses for the bucket (CURL, DUMP), boom (LOWER), or arm (IN) at both the inlet
and outlet ports of the shuttle block.
Note 5: For HYPER and HYPER-GX specification machines, carry out troubleshooting as PPC valve -+
EPC valve.
20-577
0
H-21 Steering does not turn easily or lacks power

Pressure high
only on side not
being relieved
I
4 YES
Difficult to turn pressure of front Both left and

. toboth left and right high
when relieved on +jj$?lH
right
NO
Pressure high
onlyon side
being relieved
(oil pressure is
to both left and
normal)
right, or is it difficult
to turn in one Both left and
direction only? right high
Neither front nor

rear reach relief
pressure
5 b
1How is relief I 8
Difficult to turn
- to turn in one
direction only
YEiS
-
6
When steering,
drive side is low
(opposite side is
normal) power max. is ON?
* 34.8 Z::,”MPa
1355 $ kg/cm*)
* Engine at high
idling
-Arm IN relief -
NO
20-578
0
Cause Remedy
Mistaken connection of
Connect or
LS pilot hose (F and R
:orrect
are connected in reverse]
main merge-divider Repair or
valve or defective LS replace
merge-divider valve
Repair or
Ipump merge-divider
replace
solenoid valve
IDefective operation of
Repair or
1travel pressure
replace
,comoensation valve
IDefective operation of LS 3epair or

,circuit check valve replace
IDefective operation of
qepair or
,:ontrol valve main circuit
,eplace
,:heck valve (remains
,3pen)
YES IDefective control valve 3eplace

juction valve
IDefective travel motor 3epair or

,:heck valve .eplace
I
Jefective travel motor Replace
NO safety valve
See troubleshooting for

Does not turn -
H-14 Lack of power wher
to left or right
pressure rises
c
9 YES
H
II
Does bucket LS
Does not turn
shuttle valve
to left only
move smoothly?
Defective operation of LI Repair or
NO shuttle valve for bucket replace
Defective travel oil

Replace
pressure switch
20-579
0
H-22 Travel speed does not switch or is faster than specified speed
i-
* Carry out troubleshooting in the H/O mode. Cause Remedy
4YE: S
travel speed selector Replace
Is output servo piston
YES pressure of travel
3 speed solinoid
valve normal? Defective operation of Repair or
Is output
travel speed solenoid replace
YES pressure of LS - Min 2.74 MPa N( 1 valve
control EPC valve - {28 kg/c&
_
2
normal?
- Travel speed switch:
- Mi,Hi
* See Table 1 - Travel lever operated Defective operation of LS Repair or
Is pumppressure
control EPC valve
NO replace
sensor normal?
Defective pump pressure Replace

NO sensor
I
* See JUDGEMENT
TABLE (Bit pattern Defective travel oil
Replace
20 (2)). IO pressure
- Note:
If auto-deceleration
is canceled when
travel is operated,
system is normal.
Table 1 Output pressure of LS control EPC valve

Lo Mi Hi
PC200 2.5 ? 0.2 MPa 2.5 f 0.2 MPa 0.2 k 0.2 MPa
PC210 I25 f 2 kg/cm*) (25 ? 2 kg/cm*} 12 + 2 kg/cm?
1.9 f 0.2 MPa

119 f 2 kg/cm3
l Engine at high idling

Remarks
l Trave lever at fine control position (auto-deceleration canceled)
H-23 Travel does not move (one side only)

Cause Remedy
Repair or
Defective final drive
replace
suction valve of control Replace
in final drive
valve
Defective counterbalance
valve, or defective
Replace
operation of travel motor
safety valve
. Max: 30elmin I Defective travel motor

- Engine at high NO
idling
*At travel relief
20-580
0
H-24 Does not swing

a) Does not swing to either left or right
I Cause Remedy
3 YES Defective swing Repair or

machinery replace
Is any foreign
YES material found in
2 oil drained from
~Is output pressure , swing machinery? Defective swing holding Repair or
YES of swing holding brake or swing motor replace
NO
brake solenoid
1
_ valve normal?
holding brake solenoid Correct or
Is swing pressure . Min. 2.7 MPa
valve replace
switch normal? - I28 kg/cm? NO
. Operate swing
lever (or operate work
* See Judgement equipment lever). Defective swing pressure
Replace
Table. (Bit switch
NO
pattern 20 (1))
* If auto-
deceleration is
canceled when
swing is
operated, system
is normal.
b) Does not swing in one direction
I Cause Remedy
Defective swing motor

2 YES safety valve or suction Replace
Does control valve
YES valve spool for
1 swing move
smoothly? Correct or
control valve spool for
Is PPC valve replace
NO swing
output pressure -
normal?
1 I
* Min. 2.7 MPa I Defective PPC valve Replace
(28 kg/cm? NO
* Operate swing
lever for operate
work equipment
lever).
EPC valve.
20-581
0
H-25 Swing acceleration is poor or swing speed is slow

f Carry out troubleshooting in the H/O mode.
* When individual operation of the work equipment is normal.
a) Swing acceleration is poor
2 YES
I II
I I I
NO
1
Is swing 5 YES
acceleration poor in
Is pressurecompensa-
both directions or in YES tion valve normal, or
one direction only? 4 I- does pressurecompen--
sation piston move
smoothly?
Does control
YES valve swing _ * It is also possible to NO
spool move interchange with
3 smoothly? other compensation valve.
p *SeeNotel.
Is PPC valve
One direction
- output pressure - NO
- only
normal?
* Min. 2.7 MPa I28
* Engine at high
idling 0
* Operate swing.
Note 1: After checking, always return the interchanged valves to their original positions.
20-582
0
Remedy
Defective swing motor Replace

assembly
Defective operation of LS
Correct or
shuttle valve (all LS
shuttles) replace

Correct or
safety valve or suction
valve
Defective pressure
compensation valve, or Correct or
defective operation of replace
compensation piston
Correct or
control valve swing
replace
spool
Defective PPC valve
20-583
0
H-26 Excessive overrun when stopping swing

a) One direction only
Cause Remedy
3 YES Defective swing PPC Correct or

slow return valve replace
1Does control
I Defective swing motor
Replace
NO safety valve
control valve spool for Correct or
swing replace
Note 1: For HYPER and HYPER-GX specification machines, carry out troubleshooting as PPC valve + g
EPC valve.
&
z
b) Both directions
I Cause I Remedy I
1 Defective swina motor 1 ReDair or reolace 1
20-584
0
H-27 Excessive shock when stopping swing (one direction only)
Cause Remedy
1
Defective swing PPC
1 YES Correct or
slow return valve (check
Does condition replace
valve)
become when left
and right swing PPC
Replace
EPC valve.
H-28 Excessive abnormal noise when stopping swing
Cause
YES swing motor safety or Jean
suction valve
1
Doescondition beccme
normal when swing
YES Defective swing motor
motor safety or suction 3eplace
2 safety or suction valve
valve is cleaned?
~ Doesconditionbecome
normalwhenswing
NO motorsafetyor suction 3 YES Defective swing Repair or
valveis replaced? machinery replace
Is foreign
material found in
NO swing
machinery? Defective back pressure Correct or
NO valve replace
20-585
0
H-29 Excessive hydraulic drift of swing

a) When swing holding brake is released
Cause Remedy
2 YES Defective swing motor Correct or

safety or suction valve replace
r
,~~H~
One direction only Defective pressure
compensation valve for Correct or
swing, or defective replace
NO
operation of pressure
excessive in both compensation piston
L
directions or one
3 YES Defective control valve Replace
spool for swing
Both left and right. j$LjFjH-
Repair or
NO replace
* 10 Q/min
* Engine at high
idling
*At swing relief
b) When swing holding brake is applied
Remedy
F
Cause
1 YES Defective operation of Repair or

Is output pressure swing holding brake replace
of swing holding
brake solenoid
swing holding brake replace
l0.2 f 0.2 MPa NO
solenoid valve
(2 f 2 kg/cm?
lWhen4-5
seconds have
passed after all
swing and work
equipment
control levers
have been
returned to
neutral.
20-586
0
H-30 Swing speed is faster than specified speed in L/O and F/O
modes
*
2 YES . Defective operation of LS Replace servo
Is LS control EPC valve assembly
YES solenoid valve
output pressure
1 normal? Defective operation of Repair or
Is discharge . See Table 1. NO EPC valve replace
pressure of rear * In UO and F/O
pump normal when modes Defective operation of
swing is relieved? 3 YES main merge-divider Repair or
* 5.9 - 7.8 MPa Is pump merge- valve or LS merge- replace
(60 - 80 kg/cm21 divider solenoid divider valve
* Engine at high NO valve output
idling pressure normal? Repair or
pump merge-divider
* At bucket relief replace
* 3.0 + 0.2 MPa NO solenoid valve
131 * 2 kg/cm21
*Turn swing lock
switch ON.
* In L/O mode only
Table 1 Output pressure of LS control EPC valve

l Engine at high idling
H/O mode G/O mode F/O mode L/O mode
PC200 0.2 f 0.2 MPa 0.2 k 0.2 MPa 1.5 f 0.2 MPa 1.5 k 0.2 MPa
PC210 IO.2 + 2.0 kg/cm*} IO.2 & 2.0 kg/cm*) I15.5 + 2.0 kg/cm*} (15.5 + 2.0 kg/cm*)
PC220 0.2 & 0.2 MPa 0.2 & 0.2 MPa 0.2 i 0.2 MPa 1.5 k 0.2 MPa
PC230 IO.2 * 2 kg/cmz) IO.2 + 2.0 kg/cm*} IO.2 f 2.0 kg/cm*} (15.5 + 2.0 kg/cm3
H-31 Operation of automatic mode is defective (HYPER specification)
Cause Remedy
YES Defective operation of

Correct
control valve spool
r Is output
pressure (control
‘II
valve end) of EPC 2 YES Correct or
EPC shuttle, or excessive
valve normal? replace
_ Is output pressure leakage
. Engine at high _ (solenoid outlet _
idling NO port) of EPC valve
normal? Defective operation of
Replace
* Engine at high NO EPC solenoid valve
idling
20-587
0
TROUBLESHOOTING OF MACHINE
MONITOR SYSTEM
(M MODE)
Action taken by monitor panel when abnormality occurs and problems on machine.. ............... 20-604
Electrical circuit diagram for M mode system .................................................................................... 20-606
M-l [El011 Abnormality in error data is displayed
[El021 Error in clock data is displayed ................................................................................... 20-608
M-2 [El031 Short circuit in buzzer output or contact of 24V wiring harness
with buzzer drive harness is displayed.. ................................................................................. 20-609
M-3 [El041 Air cleaner clogging detected is displayed.. .............................................................. .20-610
M-4 [El081 Engine water temperature 105’C detected is displayed ........................................... .20-610
M-5 When starting switch is turned ON, none of lamps on monitor panel
light up for 3 seconds.. ............................................................................................................. 20-61 1
a) None of lamps on monitor panel light up ....................................................................... 20-611
b) Some of lamps on monitor panel do not light up.. ....................................................... .20-61 1
M-6 When starting switch is turned ON, monitor panel lamps all stay lighted up
and do not go out ..................................................................................................................... 20-613
M-7 When starting switch is turned ON, items lighted up on monitor panel are different
g
> from actual machine (model). .................................................................................................. 20-613
% M-8 When starting switch is turned ON (engine stopped), basic check items flash.. .............. 20-614
a) ,9,, (coolant level) flashes .................................................................................................. 20-614
b) ,!$& (engine oil level) flashes .............................................................................................. 20-615
c) a (hydraulic oil level) flashes.. ........................................................................................ 20-616
M-9 Prerlating is not being used but ,ez. (preheating monitor) lights up.. .............................. .20-617
M-10 When starting switch is turned ON and engine is started, basic check items flash ........ 20-618
a) Alternator system ......................................... . ..................................................................... 20-618
b) Engine oil pressure system ............................................................................................... 20-619
M-l 1 When starting switch is turned ON (engine stopped), caution items,
emergency stop items flash (battery, engine oil pressure lamps do not light up) .......... 20-620
a) Alternator system ............................................................................................................... 20-620
b) Engine oil pressure sensor system.. ................................................................................. 20-621
M-12 When starting switch is turned ON and engine is started, caution items,
emergency items flash (when there is no abnormality in engine or items
to check before troubleshooting) ............................................................................................ 20-622
(engine oil pressure) flashes ....................................................................................... 20-622
(coolant level) flashes .................................................................................................. 20-622
(battery charge) flashes ............................................................................................... 20-622
(coolant temperature) flashes ..................................................................................... 20-623
(fuel level) flashes ........................................................................................................ 20-623
(air cleaner clogging) flashes ...................................................................................... 20-624
20-601
Cc
M-13 When starting switch is turned ON (engine stopped), buzzer does not sound
for 1 second
Caution item flashes but buzzer does not sound ................................................................. .20-625
M-14 No abnormality is displayed on monitor but buzzer sounds.. ............................................ .20-625
M-15 Night lighting on monitor panel does not light up (liquid crystal display is normal) ...... 20-626
M-16 Coolant temperature gauge does not rise.. ........................................................................... .20-627
M-17 Coolant temperature gauge does not give any display
(none of gauge lamps light up during operation) ................................................................ .20-627
M-18 Fuel level gauge always displays FULL.. ................................................................................ 20-628
M-19 Fuel level gauge does not give any display.. ........................................................................ .20-628
M-20 Swing lock switch is turned ON (LOCK) but
‘._
6” (swing lock monitor) does not light up.. ......................................................................... 20-629
M-21 Swing prolix switch is turned ON (prolix), but
__
6” (swing lock monitor) does not flash.. .............................................................................. 20-629
M-22 Service meter does not advance while engine is running .................................................. .20-630
M-23 When starting switch is at OFF and time switch is pressed,
time and service meter are not displayed.. ............................................................................ 20-630
M-24 Defective fuel level sensor system .......................................................................................... 20-631
M-25 Defective coolant temperature sensor system ....................................................................... 20-632
M-26 Defective engine oil level sensor system ............................................................................... 20-633
M-27 Defective coolant level sensor system.. .................................................................................. 20-634
M-28 Defective hydraulic oil level sensor system ........................................................................... 20-635
M-29 Wiper does not work or switch is not being used but wiper is actuated.. ........................ 20-636
a) Wiper does not work.. ........................................................................................................ 20-636
b) Wiper switch is not being operated but wiper is actuated ............................................ 20-639
M-30 Washer motor does not work, or switch is not being used but
washer motor is actuated ... ...................................................................................................... 20-641
a) Washer motor does not work ........................................................................................... 20-641
b) Switch is not being operated but washer is actuated ................................................... .20-642
20-602
a
ACTION TAKEN BY MONITOR PANEL WHEN ABNORMALITY

User Service
code code
1. Abnormality in internal memory

- Abnormality in error 2. Excess voltage (more than 36V) has occurred
El01
data 3. Low voltage (less than 12V) has occurred
4. Connector has separated
1. Abnormality in internal clock function

- El02 Abnormality in clock 2. Excess voltage (more than 36V) has occurred
data 3. Low voltage (less than 12V) has occurred
4. Connector has separated
1. Short circuit inside buzzer

- El03 Short circuit in buzzer 2. Power line in contact with wiring harness between monitor (PO1 (7)
output system pin) and buzzer
3. Abnormality in monitor panel
- Air cleaner clogging

El04 1. Air cleaner clogging sensor has detected clogging
detected is displayed
Engine water 1. Coolant temperature gauge has detected water temperature of

- El08 temperature 105°C 105’C
detected is displayed
1. Short circuit with ground, short circuit inside wiper motor

Short circuit in wiper 2. Short circuit with ground, short circuit inside relay box
- El12 motor drive normal 3. Short circuit with ground, short circuit in wiring harness between
rotation system monitor PO2 (11) and relay box W08 (21, or between W08 (6) and
wiper motor W04 (3)
1. Short circuit with ground, short circuit inside wiper motor

Short circuit in wiper 2. Short circuit with ground, short circuit inside relay box
-
El13 motor drive reverse 3. Short circuit with ground, short circuit in wiring harness between
rotation system monitor PO2 (3) and relay box W08 (3), or between W08 (7) and
wiper motor W04 (1)
1. Short circuit inside washer motor

Short circuit in win- 2. Short circuit inside relay box
-
El14 dow washer drive 3. Short circuit with power source in wiring harness between monitor
system PO2 (2),(10) and relay box W08 (171, or between W08 (16) and M28
(1)
20-604
a
voltage, current, resistance) abnormality is detected when there is abnormality
- 1. Service code cannot be cleared

2. Time becomes 0O:OO.
When starting switch is
turned ON, keep time
switch pressed for 5
seconds to actuate clear 1. Service code cannot be cleared
function - 2. Time becomes 0O:OO.
3. Clock does not advance.
Voltage between PO1 (7)

- chassis
Buzzer ON: Max. IV
Buzzer OFF: 20 - 30V
* When there is a discon- - 1. Buzzer does not sound
nection, El03 is not
displayed and the buzzer
does not sound
Resistance between PI1 1. If abnormality detection contin-

(male) - PI2 (male): - ues, air cleaner clogging caution
Min. 1 Q (engine stat-ted) lamp flashes and buzzer sounds
1. If abnormality detection contin-

ues, coolant temperature cau-
Resistance between PO7 tsi;;r$ssmp flashes and buzzer
(I) - (2): -
Min. 3.156 kR (engine 2. If abnormality detection contin-
stat-ted) ues, engine speed is reduced to
low idling
1 Voltage between W04 (3) 1. Sets output to relay box to 0 1. Operation of wiper stops
and (5) : Max. 3 V
T
20 - 30 v
t Repeats in regular cycle
1 Voltage between W04 (I)

and (5) : Max. 3 V
Same as El 12 Same as El 12
20 :30 v
Lr Repeats in regular cycle
Resistance of motor : 1. Sets output to washer motor to 0 1. Operation of window washer

stops
20-605
0
TESTING AND ADJUSTING ELECTRICAL CIRCUIT DIAGRAM FOR M MODE SYSTEM
ELECTRICAL CIRCUIT DIAGRAM FOR M MODE SYSTEM
Right front
lamp
Boom working RL-
lamp H12 (~516)
m
”
P
L
2
I--
Ml4
CL21
H 15 (L2)
-
L
+z@==
n)r I
Window washer
M28 (KESO) HI4 (~6)
2P _?P
D14 (KES~)
Doi (KESI) :
I
Alarm
buzzer
I I
Air
conditioner
Ai r?aner L-I
HYdrauIlc
cloeeino Radiator water Fuel level level
aaneor level eenaor aenaor aanaor TKP00820
28-606
0
TESTING AND ADJUSTING ELECTRICAL CIRCUIT DIAGRAM FOR M MODE SYSTEM
Light switch Swing lock switch Wiper, washer switch Swine prolix switch
l--lWiper
motor
troubleshootins
/ 1 11 Engine throttIe.pump
I I II controller
I I Start ina
Heater re!a~
StartIn motor
safety relay l I -1-h
Electrical intake
air heater
Engine oil level sensor
Engine water temoerature sensor
Ensine oil Pressure switch

TKP0082 I
20-607
0
TESTING AND ADJUSTING M-l
M-l [El011 Abnormality in error data is displayed

[El021 Error in clock data is displayed
* This is not an abnormality. It occurs during troubleshooting when disconnecting and connecting
connector PO2 (for the monitor panel electrical system), fuse No. 13, connector M14, connector
Mll, battery relay terminal B, or the battery terminal.
(When the monitor panel power source circuit is shut off with the starting switch turned OFF.)
* If the service code display appears again after the system has been reset, carry out troubleshoot-
ing as follows.
Remedy
2 YES
Defective monitor panel Replace
I. II I
Disconnection, defective
contact, short circuit with
ground in wiring harness
Repair or
between battery - battery
relay B - Ml1 (l)(2) - HI4 replace
(lb-fuse No. 13-PO2
(female) (8)(14)
l After resetting Normal -

system, carry out NO
normal
operations for a
short time and
watch the
condition. (See
Note 1.)
Note 1: Resetting operation:

Turn the starting switch OFF. Then keep the time switch at the back of the monitor panel
depressed, switch the starting switch ON again, and keep the time switch depressed for 5
seconds to return the system to normal.
(With this operation, all the service codes in the internal memory are erased.)
M-l Related electric circuit diagram

Engine throttle,
Pump controller
PO2 (04016)
I Ml1 (L2)
Fuse
14 (~6)
GND
Power source -----c&o
(+24)
GND
Power source
(+24) fusible link
Battery relay
TDP00405
20-608
0
TESTING AND ADJUSTING M-2
M-2 [El031 Short circuit in buzzer output or contact of 24V wiring

harness with buzzer drive harness is displayed
+ If the starting switch is turned OFF after an abnormality occurs, turn the starting switch ON and
check if an E service code is displayed. (If it is not displayed, the system has been reset.)
Sr Always connect any disconnected connectors before going on the next step.
Cause Remedy
2 YES
Defective monitor panel
Is voltage
YES between ~04 (2) _
source in wiring harness
1 and chassis
H*
between PO1 (femaleH7) Repair or
normal?
and PO4 (femaleI(2) or replace
PO4(male) (1) - (21,(2) Turn starting NO short circuit in wiring
- chassis as shown in switch ON. harness between PO4 (I)
* Buzzer ON: Max. 1 V and (2)
. Turn starting + Buzzer OFF: 20 - 30 V

Defective buzzer Replace
switch OFF. NO
* Disconnect P04.
Table 1
PO4 (male) / Resistance value 1
I Between (I) and (2) 1 200- 300 Q 1

1 Between (2) and chassis / Min. 1 MR I
M-2 Related electric circuit diagram
Monitor Panel PO4 (hi21

PO 1 (04020)
a
Buzzer
a
Fuse
TDP00406
20-609
0
TESTING AND ADJUSTING M-3, 4
M-3 [El041 Air cleaner clogging detected is displayed
Cause Remedy
YES -
See M-12 f)
‘I I
Failure in engine system

-
NO (See Note 1)
l Turn starting
switch ON.
Note 1: The monitor panel display has returned to normal, but the air cleaner clogging sensor has
detected symptoms of clogging in the past, so carry out troubleshooting of the engine to g
remove the problem. z
8
M-4 [El081 Engine water temperature 105°C detected is displayed
Cause Remedy
See M-12 d) -
Doescoolant
temperaturegaugeon
monitor paneldisplay -
2 YES
red rangeand is caution Defective monitor panel Replace
lampflashing?
Is “E” service
NO code displayed?
Failure in engine system
(See Note 1)
l Turn starting NO
switch ON.
Note 1: The monitor panel display has returned to normal, but the coolant temperature sensor has
detected symptoms of the coolant temperature reaching 105°C in the past, so carry out
troubleshooting of the engine to remove the problem.
20-610
0
M-5 When starting switch is turned ON, none of lamps on monitor

panel light up for 3 seconds
* Check that fuses No. 10 and 13 are not blown.
a) None of lamps on monitor panel light up
I Cause Remedy 1
YES Defective monitor panel Replace

2
Is voltage Disconnection, defective
YES between PO1 (9) contact, short circuit with
and chassis 3 YES ground in wiring harness Repair or
normal? between PO1 (female) (9) replace
Is voltage
and fuse No. 10
. Turn starting between fuse No.
1
switch ON. ND 10 and chassis Disconnection,defective
Is voltage normal? contact,short circuitwith
*20-30V Repair or
between PO2 ground in wiring harness
* Turn starting NO replace
(8K14) - (l)(9) between fuse No. IO- HO5(2)
normal? switch ON. - Ml4 (2l(l)- battery relay M
*20-30V
* Turn starting Disconnection, defective
4 YES Repair or
switch ON. contact, short circuit with
Is voltage ground in wiring harness replace
*20-30V
_ between fuse No. between PO2 (female)
NO 13 and chassis (8)(14) and fuse No. 13
normal? Disconnection, defective Repair or
* Turn starting NO contact, short circuit with replace
switch ON. ground in wiring harness
*20-30V between fuse No. 13 - H14
(2) - Ml1 (2)(l) - batter-v
I relay B
b) Some of lamps on monitor panel do not light up
Cause Remedy
20-611
0
M-5 a) Related electric circuit diagram
Monitor Panel
PO 1 (04020) Ml4 (L2)
I
I Starting switch Fuse H15 (L2)
GND
Power source
(+24)
GND
Power source
relay
TDP00407
20-612
0
M-6 When starting switch is turned ON, monitor panel lamps all stay
lighted up and do not go out
Cause Remedy
M-7 When starting switch is turned ON, items lighted up on monitor

panel are different from actual machine (model)
* Immediately after replacing the monitor panel, turn the starting switch OFF, then turn it ON again
and check.
Cause Remedy
1 YES
Is display of
monitoring code
01 as shown in
table I? Go to troubleshooting for
-
* Turn starting NO C mode (See C-16)
switch ON.
* Set to monitoring
code 01.
Table 1
BKP00432
20-6 13
0
M-8 When starting switch is turned ON (engine stopped), basic check

items flash
a) b@ (coolant level) flashes

SAP00519
* Check that the coolant is at the specified level before carrying out troubleshooting.
Cause Remedy
Defective coolant level

sensor system (see M-261
-

connector is
YES iS bit (3) Of
~connected to PO8
ffwmal~l? t - monitoring code -
3
~ 24 lighted up?
* Disconnect P08. I.5continuity
YES between Cl6 Defective monitor panel Replace
. Turn starting - (female j (8)and - - Turn starting NO
switch ON. switch ON.
chassis as shown
_ in table l? * Set to monitoring
Is there continuity * Turn starting code 24. Repair or
harness between Cl6
between PO8 replace
- switch OFF. NO (female) (8) - PO8
n (female) (2) and
. Disconnect C16, P08.
chassis? (female) (1)
- Connect ++ disconnect short
- Turn starting connector to PO8 (female). Defective contact, or
switch OFF. disconnection in wiring Repair or
* Disconnect P08. NO harness between PO8 replace
(female) (2) -chassis
ground
Table 1
Short connector 1 Continuity 1
Engine throttle,
Monitor Pump controller
Pane I Cl6 (MIC17)
P38 (X3)
Coolant
level
sensor
TOP00408
20-614
0
b) 0 6 (engine oil level) flashes

SAP00523
Ir Check that the engine oil is at the specified level before carrying out troubleshooting.
Cause Remedy
YES Defective engine oil level

sensor system (see M-27)
H
Does display 90 out 3 YES Defective engine throttle
when PO5(female) (1) Replace
pump controller
is connected to
YEiS
chassis ground? Pi_
2
I
* Turn starting NO
switch ON.
* Set to monitoring code 24. Defective contact, or
* Turn starting
harness between Cl6 replace
switch OFF. NO
(female) (16) - E08 (5) -
* Disconnect C16,
PO5 (female) (I)
PO5.
*Connects disconnect shortconnectorto
PO5 (female) (1).
Table 1
M-8 b) Related electric circuit diagram
Engine throttle,
Engine oil
level sensor
Pane I Cl6 (MIC17)
TDP00409
20-615
0
cl a 0
SAP00524
(hydraulic oil level) flashes
* Check that the hydraulic oil is at the specified level before carrying out troubleshooting.
Cause Remedy
Defective hydraulic oil

level sensor system (see -
M-29)
1
Does display go out 3 YES Defective engine throttle
when PO9(female) (11 _ Replace
pump controller
is connected to
YE
chassis ground? FH-
2
- Disconnect PO9. Is continuiw between
- Turn starting Defective monitor panel Replace
Cl6 (female) (9) and - Turn starting NO
switch ON.
NO chassis as shown in switch ON.
table l? . Set to monitoring code 24. Defective contact, or
*Turn starting harness between Cl6 replace
switch OFF. 0 (female) (9) and PO9
* Disconnect C16, (female) (1)
PO9.
- Connect++ disconnect short connector to
PO9 (female) (I).
Table 1
1 Chassis ground 1Continuity 1
M-8 c) Related electric circuit diagram
Engine th rott le,

Hydraul ic oi I
Monitor Pump cant roller
level sensor
Pane I Cl6 (M IC17)
I I PO9 (Xl)
TDP00410
20-616
0
M-9 Preheating is not being used but 088 (preheating monitor)

lights up SAP00526
Y=
Remedy
2 YES Defective monitor panel Replace

Is voltage
YES between PO1 (18) _ Short circuit with power
1 and chassis source in wiring harness
normal? between starting switch
Is voltage between ~ s Repair or
Rl-X07(3)-H13(6)-
starting switch _ *Turn starting NO replace
PO1 (femaleI(l8) or E08
terminal Rl and switch ON.
(3) - HI3 (femaleI(6)
chassis normal? * Max. 1 V
* Disconnect Defective starting switch Replace
terminal Rl. NO
*Turn starting
switch ON.
* Max. 1 V
Starting switch
24V-
Heater relay
Electrical intake
TKP00822
20-6 17
0
TESTING AND ADJUSTING M-IO
M-10 When starting switch is turned ON and engine is started, basic

check items flash
* Check both the alternator system and the engine oil pressure system.
a) Alternator system
Cause Remedy

r . pump controller
Replace
Does monitoring
YES code 43 show a _
2 value of greater
Is voltage 1 than lOO?
YES between CO3 (12) _ estartengineand NO
and chassis run at mid-range
1 normal? Defective contact, or
or above. disconnection in wiring
Is voltage between * Set to monitoring code 43.
l Start engine and harness between Repair or
alternator terminal
- run at mid-range NO alternator terminal R - replace
R and chassis
or above. E08 (2) - CO3 (female)
normal?
*20-30V (12)
* Start engine and
run at mid-range Defective alternator Replace
or above.
NO
*20-30V
Engine throttle,
Pane I Alternator
TDP00412
20-618
0
M-10
b) Engine oil pressure system

* When engine oil pressure is normal.
1) Low-pressure sensor
Cause Remedy
Defective oil pressure

sensor (for low pressure)
Contact of chassis
ground with wiring Repair or
harness beteen Cl6 repalce
(female) (15) - E08 (8) -
sensor
. Engine at low
idling (female) (15) and 3 YES Defective engine throttle
N
. pump controller
*Turn starting &HP

switch OFF. h
* Disconnect Defective monitor panel
sensor wiring * Engine at low NO
harness C16. idling
*Set to monitoring
code 24.
Ensine throttIe.Pums controller

Monitor Panel Cl6 (MIC17)
Network Engine oil

Pressure sensor
TKP00823
20-619
0
TESTING AND ADJUSTING M-II
M-II When starting switch is turned ON (engine stopped), caution

items, emergency items flash
(battery, engine oil pressure lamps do not light up)
* Before carrying out troubleshooting, check that all the related connectors are properly inset-ted.
Ir Check both the alternator system and the engine oil pressure system.
a) Alternator system
I Cause I Remedy

Replace
pump controller
Yf jJz$z%JH_
2
Is voltage
YES between ~03 * Start engine and NO
1 (female) (12) and run at mid-range
p chassis normal? speed or above. Short circuit with power
Is voltage between ~
* Disconnect C03. * Set to monitorina code 43. source in wiring harness Repair or
alternator terminal
* Turn starting JO between CO3 replace
Rand chassis
switch ON. (femaleHl2) - E08 (1) -
normal?
* Max. 1V El2 (1) -alternator R
* Disconnect
I Defective alternator Replace
terminal R.
NO
* Turn starting
switch ON.
l Max. 1 V
M-II a) Related electric circuit diagram
Engine throttle.DumP controller

CO3 (04020) Alternator
Monitor Dane1
Battery
Network @
charge
TKP00824
20-620
0
TESTING AND ADJUSTING M-II
b) Engine oil pressure sensor system

Ir When engine oil pressure is normal.
1) Low-pressure sensor
Cause Remedy

Replace
. pump controller
l-l
’ 124lighted up? 11
Is there continuity Defective monitor panel
Replace
YES between Cl6 (female) NO
* Engine at low
- (15 land sensor wiring -
1 idling Defective contact, or
harness?
* Set to monitoring code disconnection in wiring
Is there continuity 24. Repair or
* Turn starting harness between Cl6
between sensor _ replace
switch OFF. NO (female) (I 5) - E08 (8) -
terminal and
l Disconnect Cl6 sensor
chassis?
- and sensor
*Turn starting wiring harness. Defective oil pressure
switch OFF. Replace
NO sensor flow pressure)
* Remove sensor
wiring hanrness.
2) High-pressure sensor
Remedy

Replace
pump controller
YES Is bit (2) of
2 7 monitoring code -
p 24 lighted up?
Is there continutiy
~ Defective monitor panel Replace
YES betweenCl6 ffemle) _ #Engine at high NO
(7) and sensorwiring ilding
harness? Defective contact, or
* Set to monitoring code 24.
* Turn starting harness between Cl6 Repair or
between sensor
switch OFF. NO (female) (7) - E08 (7) - replace
* Disconnect Cl6 sensor
1
l Turn starting
switch OFF. Replace
l Remove sensor
wiring harness.

Monitor Panel Cl6 (MIC17)
Sl 1
Engine oil
Network
Pressure Eneine oil
Pressure sensor
TKP00823
20-621
0
M-12 When starting switch is turned ON and engine is started,

caution items, emergency items flash
(when there is no abnormality in engine or items to check
before troubleshooting)
a) 0 6 (engine oil pressure) flashes

SAW0520
* Check that the engine oil pressure is normal before

carrying out troubleshooting. Cause Remedy
b)
SAW0519
*
(coolant level) flashes
Check that the coolant

out troubleshooting.
level is normal before carrying
See M-II b)
I -
Remedy
c)
SAP00522
(battery charge) flashes
See M-9 a)
Cause
I -
Remedy
See M-l 1 a) -
20-622
0
d) a-
SAP00527
(coolant temperature) flashes
Ir Check that the coolant temperature is normal before car-

rying out troubleshooting.
temperature sensor -
system (see M-26)
Yf disconnected,
. does only level 1 - 3 YES Defective engine throttle
Replace
(left end) of gauge
Is resistance
. pump controller
1 display light up? between CO3
- (female) (1) - (16). -
Short circuit of wiring
* Start engine. NO (1) (16) -chassis harness between CO3
normal? (female) (1)- E08 (6) - Repair or
PO7 (female) (I) and replace
*Turn starting NO
switch OFF. CO3 (female) (16) - E08
* Start engine and . Disconnect CO3 and P07. (1 I) -PO7 (female) (2)
run at mid-range * Max. 1 MR
or above. . Defective monitor panel Replace
hIO
M-13 d) Related electric circuit diagram
Enoine throttle,pump Fontroller

CO3 (04020) Alternator
Monitor Panel
TKP00824
e) (fuel level) flashes Cause Remedy

SAP00528
t
* Check that there is fuel before carrying out trouble-

shooting.
When PO6 (femaleI (1) is

YES connected to chassis
- ground, do all lamps10 -
level 14 (right end) of Replace
gaugedisplay light up? pump controller
l- Is voltage
* Start engine. - between CO3 (2) - Defective contact or
Is fuel gauge in a Wait for aPProx. NO and (16) normal7
red range? - 2 minutes.
harness between CO3 replace
(The fuel level *Connect PO6(female) NO (female) (2) and PO6
may vary, so the (1) to chassisground.
-Start engine. (female) (1)
display is given a -TurnstartingswitchON.
time delay.) . Max. 0.3 V Defective monitor panel Replace
NO
M-13 e) Related electric circuit diagram
Engine throttle,
Pane I CO3 (04020)
Fuel level
sensor
TOP0041 5
20-623
0
f)
*
a
,--.I
SAP00521
(air cleaner clogging) flashes
Ir Check that the air cleaner is not clogged before carrying out troubleshooting.
Cause Remedy
Defective air cleaner

clogging sensor Replace
1 4 YEI Defective engine throttle

Replace
pump controller
Does display go out YES Is bit (6) of
when Pll (female) _ monitoring code _
is connected to PI2 _ 3 24 lighted up?
Is continuitybetween
YES Cl6 Ifemale)117)and _ - Start engine. NC
- Start engine.
r chassisas shownin * Set to monitoring
2 table l? Defective contact or
code 24.
Is there continuity Repair or
* Turn starting harness between Cl6
between P12 replace
- switch OFF. NO (female) (17) and PI 1
h (male) and
- Disconnect C16, PI 1, and P12. (female)
chassis?
- Connectetdisconnect PI 1 (female) to
-Turn starting PI2 (male). Repair or
switch OFF. replace
NO harness between PI2
-Disconnect P12.
(male) and chassis
ground
M-12 f) Related electric circuit diagram
Monitor Panel Cl6 (MICl7)

Pll
Network
Air c leaner
P12 c I eggins sensor
TKP00825
Table 1
PI1 (female) and PI2 (male) PI1 (female) and PI2 (male)
Cl6 (female) (17) - chassis connected disconnected
Continuity No continuity
20-624
0
M-13 When starting switch is turned ON (engine stopped), buzzer

does not sound for 1 second
Caution item flashes but buzzer does not sound
* Of the caution items, the buzzer will not sound even if
there is an abnormality in the battery charge or fuel level.
* Before carrying out troubleshooting, check that all the
related connectors are properly inserted. Cause Remedy
* Always connect any disconnected connectors before going
on the next step.
YES
2
When PO1(female) Defective contact or
YE ; (7) and chassis are disconnection in wiring
connected, does 3 YES harness between PO1 Repair or
buzzer sound? Is voltage (female) (7) and PO4 replace
1 (female) (2)
. Disconnect POI. _ between PO4
. Turn starting NO (female) (I) and Disconnection, defective
switch ON. chassis normal? contact, short circuit with Repair or
(male) (I) and (2) ground in wiring harness replace
* Disconnect ~04. NO
between PO4 (female) (I)
*Turn starting
* Turn starting and fuse No. 13
switch ON.
switch OFF. *20-30V
* Disconnect P04. Defective buzzer Replace
*200-300 R NO
M-14 No abnormality is displayed on monitor but buzzer sounds

* When the buzzer sounds continuously.
If the buzzer sounds intermittently, carry out troubleshoot-
ing M-13.)
related connectors are properly inserted. Remedy
Cause
on the next step.
Contact of chassis
ground with wiring
1 YES Repair or
harness between PO1
(female) (7) and PO4 replace
When PO1 is
disconnected, (female) (2), or defective
does buzzer buzzer
sound?
* Disconnect POl. NO
- Turn starting
switch ON.
M-13, 14 Related electric circuit diagram

Monitor Panel
Pp4 ,(M2),
PO1 (04020)
Fuse
Liz+-- TKP00826
20-625
0
M-15 Night lighting on monitor panel does not light up (liquid crystal
display is normal)
+ When the front lamp and working lamp light up normally.
Cause Remedy
Blown bulb or defective Replace bulb,

YES contact of bulb or clean
(defective
1 contact)
Is bulb blown, or
is there defective - YES
contact? 2
l Remove bulb. Does bit (3) of

* ;ire;;oznu;;.sb. NO ;9o;z$yg code - 3 YES
- Is voltage
. Turn starting - between PO1 (8) - Defective contact, or
switch ON. NO and (12) normal? disconnection in wiring
* Set to monitoring harness between PO1 Repair or
code 49. * Turn starting NO (female) (8) -X01 (1) - replace
switch ON. MO7 (female) (1)
*Turn light switch
ON.
*20-30V
Monitor Panel
PO I (040201 Light switch
x01 (MIC31) MO7 (M2)
[OFF] ON 1
a QI
8 02
_
TDP00419
20-626
0
M-16 Coolant temperature gauge does not rise

* If the coolant temperature actually does not rise, check
the engine system.
on the next step.
Defective coolant
YES temperature sensor -
system (see M-26)
When short
connector is 3 YES
connected to PO7
(female), do level Does monitoring
lamps on gauge go
YES _ code 41 show a _
uo in turn and then value of less than
2 500? Defective engine throttle
Replace
. Disconnect P07. Is therecontinuity *Connect short connector N 0 pump controller
* Turn starting between CO3 (female) to PO7 (female).
I - (I) and (16) when Short - *Turn starling switchON. Defective contact, or
switch ON.
NO connectorisconnected *Set to monitoring code 41. disconnection in wiring
to PO7 (female)? 4 YES harness between CO3 Repair or
. Turn starting Is there continuity (female) (16) - E08 (11) - replace
switch OFF. between CO3 PO7 (female) (2)
* Disconnect CO3 NO (female) (I) and
and P07. PO7 (female) (I)? Repair or
replace
*Turn starting switch NO harness between CO3
OFF. (female) (1) - E08 (6) -
* Disconnect CO3 and PO7 (female) (1)
PO7.
Es
& M-17 Coolant temperature gauge does not give any display
8 (none of gauge lamps light up during operation)
)
+ Always connect any disconnected connectors before going
on the next step.
Defective coolant
temperature sensor
-
system (see M-26)
1
When PO7 is Contact of chassis
disconnected, does ground with wiring
coolant temperature - YES qepair or
gauge display harness between CO3
2 splace
appear? (female) (1) - E08 (6) -
Is there continuity PO7 (female) (1)
l Disconnect P07. between CO3
* Turn starting NO (female) (I) and 3 Defective engine throttle
switch ON. f3eplace
chassis?
Does monitoring . pump controller
* Turn starting _ code 41 show a
switch OFF. NO value of less than
- Disconnect C03, 500?
Defective monitor panel f3eplace
PO7. * Turn starting switch
ON.
* Set to monitoring
code 41.

Engine throttle.Pumo controller
Monitor Panel CO3 (04020) Alternator
E08 (Xl)
I r--r- I
/I Network
Battery
@ 3 .
charge
TKP00824
20-627
0
M-18 Fuel level gauge always displays FULL

Ir Check if the tank is actually full before carrying out
troubleshooting.
on the next step.
YES Defective fuel level

sensor system (see M-251/
1
When PO6is
disconnected,do Contact of chassis
level lamps on ground with wiring
gauge go down in YES Repair or
turn and then all 2 harness between CO3 replace
lamps go out? (female) (2) and PO6
p Is there continuity
* Turn starting (female) (I)
_ between CO2
switch ON.
. Wait for approx NO (female)(2) and 3
chassis? Does monitoring
2 minutes. (The p
fuel level may *Turn starting code 42 show a _
vary, so the switch OFF. NO value of greater
display isgiven a * Disconnect C02, than 40? Defective engine throttle
time delay.) PO6. * Turn starting pump controller
switch ON.
* Set to monitoring
code 42.
M-19 Fuel level gauge does not give display

Ir Check that there is actually no fuel before carrying out
troubleshooting.
+ Before carrying out troubleshooting, check that all the
Ir Always connect any disconnected connectors before going
on the next step.
YES Defective fuel level
sensor system (see -
M-25)
1
Doesdisplayappear 3 YES Defective engine throttle
Replace
when PO6(femaleHI) Does monitoring . pump controller
and chassisground YES code 42 show a
are connected? 2 value of less than
Is therecontrnurty 408?
l Disconnect PO& betweenCO3(female) p p Defective monitor panel Replace
*Turn starting (2) andchassiswhen _ *Turn starting switch NO
switch ON. Nc RI6 (female)(l)and
chassrsgroundare ON. Defective contact, or
connected? *Set to monitoring code disconnection in wiring
*Turn starting 42. harness between CO3 Repair or
switch OFF. NO (female) (2) and PO6 replace
* Disconnect C03, (female) (1)
PO6.
Engine throttle,
Pane I CO3 (04020)
PO6 (Xl)
Fuel level
etwor9 Fuel level sensor
TDP00415
20428
0
M-20 Swing lock switch is turned ON (LOCK) but 8 (swing lock

monitor) does not light up 6
SAT00098
+ Carry out this troubleshooting only if the swing lock is actually being actuated.
Ir Before carrying out troubleshooting, check that all the
related connectors are properly inserted.
on the next step.
*
1 YES
Is voltage
between PO1 (5)
and chassis as Defective contact or
shown in table l? disconnection in wiring Repair or
harness between PO1 replace
+ Turn starting NO
(female) (5) -X01 (4) -
switch ON. - X05 (male)

Monitor Panel Swing lock switch
PO1 (04020)
x01,
Table 1
Swing lock switch ON Max. 1 V
Swing lock switch OFF 20 - 30 V
8 M-21 Swing prolix switch is turned ON (prolix), but &J (swing lock
monico;) does not flash
SA%OO98
Carry out this troubleshooting only if the swing prolix is
actually being actuated.
Cause Remedy
Before carrying out troubleshooting, check that all the
related connectors are properly inserted.
Always connect any disconnected connectors before going
on the next step. 2 YES
monitoring code
’ 121 lighted up? 1)
Is voltage Defective engine throttle
Replace
between Cl7 (8) _ NO pump controller
*Turn starting
and chassis as switch ON.
shown in table l? * Set to monitoring code Defective contact or
- Turn starting 21. disconnection in wiring Repair or
switch ON. NO harness between Cl7 replace
(female) (8) and prolix
switch (4)
Table 1
Swing prolix switch ON Max. 1 V
Engine throttle. Swing prolix switch
Swing prolix switch OFF 20 - 30 V Pump controller
Monitor
^^^^ I Cl7 (04016) 1
jn
Swine
PO0422
20-629
0
M-22 Service meter does not advance while engine is running
Cause Remedy
YES
See M-13 d) -
il
Defective monitor oanel
* Start engine and

* Start engine and pump controller
run at mid-range
or above.
* Set to monitoring code 43.
M-23 When starting switch is at OFF and time switch is pressed, time
and service meter are not displayed
Cause Remedy
1 YES
When starting
switch is ON, is _
panel display
normal?
See M-6
l Turn starting NO
switch ON.
20-630
0
M-24 Defective fuel level sensor system

* Remove the fuel level sensor when carrying out the troubleshooting.
1 Cause Remedy
3 YES Interference with sensor Replace (See

inside tank Note 2)
YES Is there any large
- crack, chip, or -
2
~ damage to float? Clean
connector or
YES Does arm move NO connector
replace
smoothly?
1
Defective sensor (See
When float is I Replace
Note 2)
moved up and NO
down, is resistance
between connector
(1) and flange as
shown in table l?
Disconnection in wiring
4 YES harness (See Note 3)
Replace sensor
(defective clamp)
Check wiring
(external force applied)
harness visually. -
’ Is it broken?
Defective sensor Replace
NO
8
>
Ei
0
Table 1
Top (FULL) stopper position Approx. 12 R or below

Bottom (EMPTY) stopper position Approx. 85 - 110 Q
w \ Top (ful I)
- 1 Bottom (empty)
TEP00423
Note 1: Difference between fuel level and gauge display

For gauge display position 14 (FULL), the amount of fuel is 78-100%; and for display position
1 (EMPTY) it is below 14.5%. If the chassis is at an angle, the displayed amount of fuel will be
different from the actual amount. Therefore, when checking, stop the machine at a horizontal
place and wait for at least 2 minutes before checking the gauge. (The display is given a time
delay so that the gauge can deal with sudden changes in the fuel level.)
Note 2: There is the possibility of defective installation or interference with the sensor inside the tank,
so be careful when installing.
Note 3: Check for vibration at the connector mount. If there is excessive vibration, take the appropri-
ate action.
20-63 1
0
M-25 Defective coolant temperature sensor system
I Cause Remedy
‘ES Clean
connector or
connector (See Note 1)
replace sensor
temperaturesensor
connector(male)(1)and 2 YES
harness (See Note 2) Replace
121asshown in table l?
Check wiring (defective clamp) sensor
- harness visually. - (external force applied)
N ’ Is it broken?
NO
Table 1
INormal temperature (25°C) 1 Approx. 37 - 50 ki2 1

IOO'C 1Approx. 3.5 - 4.0 ka
SKP00291
Note 1: If the problem occurs again, the connector (female) at the chassis end is probably defective, so
check the connector and wiring harness at the chassis end.
Note 2: Check for vibration at the connector mount. If there is excessive vibration, take the appropriate
action.
20-632
0
M-26 Defective engine oil level sensor system

* Remove the engine oil level sensor when carrying out troubleshooting.
Cause Remedy
Defective movement of
Clean
float due to dirt
Resonance of mount Replace sensor

(See Note 2) (See Note 4)
Clean
and down, is resistance Defective contact of
connector or
betweenconnector(1) NO connector (See Note 2)
replace
and flange as shown in
4 YES
harness (See Note 3) Replace sensor
(defective clamp)
Check wiring
L harness visually. -
NO IS it broken?
NO
s
z Table 1
8 Float UP Max. 1 L2
Float DOWN Min. 1 MQ
Note 1: Variations in oil level

The oil level may change according to the angle of the machine, the engine speed, or the
temperature of the oil, so if there is any display, check the oil level again with the machine at
a horizontal place.
Note 2: If the problem occurs again, the connector (female) at the chassis end is probably defective,
so check the connector and wiring harness at the chassis end.
ate action.
Note 4: Defective installation is a possible cause, so be careful when installing. If the problem occurs
again, check for any vibration of the mount, and if there is excessive vibration, take the
appropriate action.
20-633
0
M-27 Defective coolant level sensor system

* Remove the coolant level sensor when carrying out troubleshooting.
Cause Remedy
Clean
float due to dirt
YE Replace
Resonance of mount
(See Note 2) sensor (See
Note 4)
1
When float is moved UPI
NOI damage to float? 11 Clean
1and down, is resistance I I I
connector or
between connector (1) NO connector (See Note 2)
replace
and I21asshown in
Table17 t
4 YES Replace
harness (See Note 3)
sensor
(defective clamp)
Table 1
Float
V
Down
t
@ TDP00425
Note 1: Variations in coolant level

The coolant level may change according to the angle of the machine, or the swaying of the
machine, so if there is any display, check the coolant level again with the machine at a
horizontal place.
ate action.
appropriate action.
20-634
0
M-28 Defective hydraulic oil level sensor system

* Remove the hydraulic oil level sensor when carrying out troubleshooting.
Cause Remedy
Clean
float due to dirt
YE Replace
Resonance of mount
sensor (See
(See Note 2)
Note 4)
1
Whenfloat is moved up Clean
and down, is resistance
connector or
between connector (1) connector (See Note 2)
replace
Replace
harness (See Note 3)
sensor
(defective clamp)
I I I
NO
Table 1
UP
t
Down
TEP00424
Note 1: Variations in hydraulic oil level

The hydraulic oil level may change according to the angle of the machine, or the swaying of
the machine, so if there is any display, check the hydraulic oil level again with the machine at
a horizontal place.
ate action.
appropriate action.
20435
a
M-29 Wiper does not work, or switch is not being used but wiper is
actuated
+ Always connect any disconnected connectors before going on to the next step.
al Wiper does not work
Jr Check that fuse 7 is normal.

Ir Carry out this troubleshooting if service code [El121 or [El131 is displayed.
YES
4
Is voltage
x
YEg between pins of _
W04 as shown in 5 YES
Table 11 1S
pins of PO2 (female),
*Turn starting - W04 (male), and WOB -
3 switch ON. NO (female) as shown in
Do bits (3) or (4) of Table Z?
IES monitoring code 1471 * Turn starting NO
light up under same switch OFF.
conditions as Item 2? * Disconnect P02, W04, W08.
. Same as Item 2. YES
code f4.81 go out
switch is turned
mode. * Turn starting switch ON.
to ON or INT?
*Turn wiper switch OFF.
* Turn starting * Set to monitoring code f4Cl.
switch ON. 9 YES
*Turn wiper Is resistance between
switch to ON or YES pins of PO2(female)
INT. and W04 (male) as
3r
* Set to monitoriq 1 1 shown in Table 2?
code I481.
pins of Ml8 (female) * Turn starting ‘.
switch OFF.
* Disconnect P02,
WOA
*Turn starting
l Front window:
switch OFF.- NO
Closed position
* Disconnect M18.
* Turn starting
switch ON.
11 YES
l Set to monitoring
Is resistance
between
code [481.
YES WlOi”Uk+)(3)-P%
ma,?
(femalelU3). WlO (male) -
(4)- PO2(female) (11
between WlO * Turn starting NO

(female) (3) and switch OFF.
* Disconnect W04, P02.
* Max. 1 R
* Turn starting
switch OFF.
* Disconnect
WlO.
20-636
0
Remedy
harness with defective replace
resistance
source in wiring harness Repair or
between PO2 (female) (3) replace
and WO8 (female) (3). or
between PO2 (female) (11)
and WO8 (female) (2)
Defective contact or Repair or
disconnection in above replace
wiring harness
,~I Defective monitor panel Replace
1 Defective monitor panel 1 Replace
1 :;:;;;ive wiper, washer 1 Replace
Defective monitor panel 1 Replace

harness between PO2
(female) (13) and WlO 1 Repair or
(male) (3). or between PO2 replace
(female) (1) - H14 (2) -
chassis, or between WlO
(male) (4) - H15 (1) -
chassis
Defective rear limit Inspect or
switch, or front window replace
is open
20-637
0
Table 1
Timing chart when wiper switch is at ON
\ctuat ion ON hem

If wiper
Iwltch OFF
Length of pause until
I
next actuation
Safety circuit during op-

eration of wiper [safety Tsa
function (l)]
Length of pause when

stowing wiper blade
Safety circuit during

stowing of wiper [safety
function (2)I
TKP00827
Timing chart when wiper switch is at INT
Actuation ON Item Symbol Set time
Length of pause until

Tla 4sec
next actuation
Safety circuit during op-

eration of wiper [safety Tsa 1 Osec
function (l)l
Length of pause when

TIP 1.5sec
stowing wiper blade
Safety circuit during

stowing of wiper [safety Tsp 1Osec
function (2)1
OFF: Max. 3 V
TKP00828
ON: 20 - 30 V
Table 2 Table 3
Resistance
value
Between W04 (female) (1) and W08 (female) (7)
Between W04 (female) (3) and W08 (female) (6)
Between W04 (female) (5) and PO2 (female) (1)
1 Between W04 (female) (6) and PO2 (female) (6) 1

1 Between W04 (female) (l),(3),(4),(5),(6) and GND 1Min. 1 Ma 1
Max. 1 Q
20-638
0
b) Wiper switch is not being operated but wiper is actuated
Cause Remedy
4YE
(female), W04 (male),
Defective contact or Repair or

between pins of disconnection in wiring replace
Ml8 (female) (1). harness with defective
(2). (4) as shown in
resistance
Defective wiper, washer
IES Replace
switch OFF. switch
code [481 go out?
* Disconnect M18.
* Turn starting
switch ON.
* Set to
monitoring code
[481.
monitoring code
* Turn starting
switch ON. YES
* Set to monitorin<
code 1481. Short circuit with ground
1Do bits (3) or (4)
‘--- in wiring harness
ey
I-i YES between PO2 (female) (3) Repair or
* Turn starting
-l Do bits (2) or (3)
6 and W08 (female) (3). or
between PO2 (female)
(11) and W08 (female) (2)
replace
_~ of monitoring
switch ON. NO code [4cl light 7Y
* Set to up? Defective relay box Replace
Is voltage between
monitoring code
W06 (female) (11 and
1471. * Turn starting
(6). or between (1)
switch ON. NO and (7) normal? Short circuit with power
* Set to I source in wiring harness Repair or
monitoring code between W08 (female) (6) replace
. Disconnect W06. Nt
l4Cl. and W04 (male) (I), or
* Turn starting
between W08 (female) (7)
switch ON.
and W04 (male) (3)
+ Max. 1 V
Table 2 Table 3
Resistance Wiper switch 1 Ml8 (female) 1 PO2 (female) 1 Resistance 1

value Between (I) - (2) Between (1) - (4) Min. 1 MR
Between W04 (female) (I) and WO8 (female) (7)
)I
INT mode Between (1) - (4) Between (1) - (12) Max. 1 R
Between W04 (female) (3) and W08 (female) (6) Between (2) - (4) Between (4) - (12) Min. 1 MD
Between W04 (female) (4) and PO2 (female) (5) Max.lR Between (I) - (2) Between (1) - (4)
Between WO4 (female) (5) and PO2 (female) (I
Between W04 (female) (l),(3),(4),(5),(6) and GND

1
Min. 1 MD
Between (2) - (4)
Between (1) - (2)

Between (4) - (12)
Between (1) - (4) Max. 1 R

I
Between W08 (female) (2) and PO2 (female) (11) ON mode Between (1) - (4) 1 Between (1) - (12) 1
Max. 1 R Min. 1 MR
Between W08 (female) (3) and PO2 (female) (3) Between (2) - (4) Between (4) - (12)
20439
0
046)
Monitor panel
r
or reverse rotation I Fuse
et switch WASHER
1
Limit switch W
1
Power source l+24V)
Washer output
Motor normal rotation
Wiper switch INT
Window limit switch
Power source (+24V)
Limit switch P
H12
(S16)
DO1 M28
HI5 (L2) CKESl) (X21
Rear limit switch
Washer motor
WO8 (070 I
Ml8 CM41
Wiper. washer
switch
slay box
TKP00829
20-640
0
M-30 Washer motor does not work, or switch is not being used but
washer motor is actuated
Ir Always connect any disconnected connectors before going
on to the next step. Cause Remedy
a) Washer motor does not work

* Check that fuse 5 is normal.
al-1 When El14 is displayed
2 YES
YES Is resistance of
- washer motor
1 normal? Defective washer motor
Replace
Is-- (internal short circuit)
* Turn starting NO
PO2 (female) (2).
(10). M28 (female) - switch OFF.
(I) and chassis * Disconnect W28.
normal? * Check as
nindividual part. Short circuit in wiring
harness between PO2 Replace
switch OFF.
(female) (2), (9) and M28
* Disconnect POZ, No
(female) (1)
M28.
* Connect T-adapter to PO2 (female) or M28
(female).
*Turn starting switch to ON or OFF. Cause Remedy
* Max. 1 V
al-2 When El14 is not displayed

YES Defective monitor panel Replace
3
Is voltage
YI between PO2
(female) (5) and 4 ToL
(9) normal? Is resistance
* Turn starting between Ml8
switch OFF. NO (female) (1) and
* Insert T-adapter (3) normal? Defective wiper washer
in PO2. switch
* Turn starting
* Turn starting switch OFF.
2 switch ON. . Disconnect M18.
* Wiper washer - Check as
YE switch at [WASH individual part.
(female) (2). (IO) II or [WASH III: *Wiper washer
and (9) normal? Max. 1 V switch at [WASH
*Wiper washer II or [WASH III:
* Turn starting
switch at [OFF]: Max. 1 R
switch OFF.
20-30V *Wiper washer
* Insert T-adapter
in PO2. switch at [OFFI:
Short circuit with ground
*Turn starting Min. 1 MQ
or disconnection in
6 YES Repair or
switch ON. wiring harness between
replace
box W08 (16) and + Wiper washer PO2 (female) (21, (IO) and
switch at [WASH M28 (1)
II or [WASH III: f EH_
* Turn starting
Max. 1 V Short circuit with ground Repair or
switch OFF.
*Wiper washer or disconnection in replace
* Disconnect W08. * Disconnect M28. NO
switch at [OFF]: wiring harness between
* Max. 1 R * Connect T-adapter.
20-30V fuse 5 and M28 (16)
*Turn starting switch ON.
.20-30V Defective relay box
0 (internal disconnection)

5YEI source or defective Repair or
contact in wiring harness replace
between PO2 (5) - X01
From A]w[ (10) - Ml8 (3)
Disconnection in wiring Repair or

harness between Ml8 replace
* Turn starting N(
(male) -X01 (21) -
switch OFF.
chassis ground
* Disconnect M18.
* Max. 1 R
20-641
a
b) Switch is not being operated but washer is actuated
* For this failure mode, El14 is not displayed.
*
1 YES
Is resistance
between PO2
(female) (3). Ml8
Short circuit with ground
in wiring harness Repair or
between PO2 (female) (5) replace
- Turn starting NO
switch OFF. - Ml8 (male) - W08
l Disconnect P02, M18, W08. (female) (13)
- Min. 1 MR Cause Remedy
M-30 Related electric circuit diagram r 1

1 Wiper motor 1
wo4 046)
Moni tar Dane1 pO2 (04016) HI4 (M6)
CND I/
Washer output
Motor reverse rotation
Wieer switch ON
Wiper switch WASHER
Limit switch W
NC
Power source lt24V)
GNO
Washer outout
Motor normal rotation
Wioer switch INT
Window limit switch
Power source (t24V)
Limit switch P
INC
M28
(X2)
Rear limit switch III II II IIIIIIIIIII “E-=i
Washer motor
W08 (07018)
A GA fi x01 (NIC21)
s-tll Ill
Relay box
TKP00829
20-642
0
TROUBLESHOOTING OF GX CONTROLLER SYSTEM
(A MODE)
Points to remember when troubleshooting GX controller system.. ................................................ .20-653

Procedure for troubleshooting HYPER GX .......................................................................................... 20-654
Operation of GX error code display mode and content of display.. ................................................ 20-657
Action taken by controller when abnormality occurs, and problems on machine.. ...................... 20-660
Electrical wiring diagram for GX controller ........................................................................................ 20-668
A- 1 E6:01, E6:02, E6:03, and E6:04 are displayed at the same time.. ...................................... .20-670
A- 2 E6:Ol (GX panel 011, 012) [Abnormality in boom (RAISE) pressure sensor system]
is displayed .............................................................................................................................. 20-672
A- 3 E6:Ol (GX panel 013, 014) [Abnormality in boom (LOWER) pressure sensor system]
is displayed .............................................................................................................................. 20-674
A- 4 E6:02 (GX panel 021, 022) [Abnormality in arm (IN) pressure sensor system
is displayed .............................................................................................................................. 20-676
A- 5 E6:02 (GX panel 023, 024) [Abnormality in arm (OUT) pressure sensor system1
is displayed .............................................................................................................................. 20-678
A- 6 E6:03 (GX panel 031, 032) [Abnormality in bucket (CURL) pressure sensor system]
is displayed .............................................................................................................................. 20-680
A- 7 E6:03 (GX panel 033, 034) [Abnormality in bucket (DUMP) pressure sensor system]
is displayed .............................................................................................................................. 20-682
A- 8 E6:04 (GX panel 041, 042) [Abnormality in swing (RIGHT) pressure sensor system1
is displayed .............................................................................................................................. 20-684
A- 9 E6:04 (GX panel 043, 044) [Abnormality in swing (LEFT) pressure sensor system1
is displayed .............................................................................................................................. 20-686
8 A-10 E6:06 (GX panel 061, 063) [Abnormality in clinometer input value1 is displayed .......... 20-688
>
% A-l 1 E6:07 and E6:08 [Abnormality in potentiometer power source] are displayed
at the same time ..................................................................................................................... 20-690
A-12 E6:07 (GX panel 071, 072) [Abnormality in boom potentiometer system1
is displayed .............................................................................................................................. 20-692
A-13 E6:08 (GX panel 081, 082) [Abnormality in arm potentiometer system1 is displayed ... 20-694
A-14 E6:ll (GX panel; 111, 112) [Abnormality in boom variable angle1 is displayed ............. 20-696
A-15 E6:12 (GX panel 121, 122) [Abnormality in arm variable angle1 is displayed.. ............... 20-698
A-16 E6:13 (GX panel 131, 132) [Abnormality in bucket variable angle] is displayed ............ 20-701
A-17 E6:14 (GX panel 141) [Abnormality in comparison of two boom sensor signals]
is displayed .............................................................................................................................. 20-702
A-18 E6:15 (GX panel 151) [Abnormality in comparison of two arm sensor signals]
is displayed .............................................................................................................................. 20-703
A-19 E6:16 (GX panel 163) [No change in signal when work equipment should move]
is displayed .............................................................................................................................. 20-704
A-20 E6:17 (GX panel 171, 172) [Cutting edge position out of range] is displayed ................ 20-705
A-2 1 E6:18 (GX panel 181, 182) [Abnormality in data ROM1 is displayed.. ............................... 20-705
A-22 E6:21 (GX panel 211, 212, 213, 214) [Abnormality in engine pick-up] is displayed ....... 20-706
A-23 E6:22 (GX panel 221) [Change in wiring harness after engine picks up]
is displayed
(GX panel 222) [Automatic operation disconnection switch signal does not match
in valve controller and GX controller is displayed
(GX panel 223) [Abnormality in controller power source1 is displayed.. ......................... 20-710
20-65 1
0
A-24 E6:23 (GX panel 231) [Abnormality in remote signal1 is displayed
(GX panel 235) [Abnormality in 12V power source (overcurrent detection)]
is displayed
(GX panel 236) [Abnormality in 24V power source (overcurrent detection)]
is displayed . . . . . . . .. . . .. . . . .. . . . . . . .. . . . . . . .. . .. . . . . . . .. . . . . . . . . . .. . . . . . .. . .. . . . . . . .. . . . .. . . . . . . .. . . . . .. . . . .. .. . . . . . . . . .. . . . . . . .. . . ...... 20-714
A-25 E6:24 (GX panel 241) [Abnormality in buzzer drive system1 is displayed . . .. . . .. . . . . . .. . .. . . . . . 20-717
A-26 E6:25 (GX panel 251, 252) [Impossible to receive network (S-NET) signal
is displayed . . . . . . . .. . . . . .. . .. . . . . . . .. . . . . . . .. .. . . . . . . .. . . . . . .. . .. . . . . . . . .. . . . . . . . . . .. . . . . . . . . . . .. . . . . . .. . . . .. .. . . . .. . . .. . . . . . . . .. . . ...... 20-718
A-26 E6:25 (GX panel 253) [Impossible to receive network (HS-NET) signal]
is displayed . . . . .. . . . . . . . .. . .. . . . . . . .. . . . . .. . . . . . . .. . .. . . . . . .. . . .. . . . . . . . .. . . . . . .. . .. . . . . . . . . . .. .. . . . . . .. . . .. . . . . . . .. . .. . . . . . .. . .. . . ...... 20-720
A-27 E6:26 (GX panel 261, 262, 263, 264) [Abnormality in non-volatile memory
data range1 is displayed . . . . . .. .. . . . . . .. .. . . .. . . . .. . . . .. .. . . . . .. . . . .. . . .. . .. . .. .. . . . . . . . . .. . . . . . . . . . . . .. . . . . . . .. . .. . . . . . . .. . . . . . . 20-723
A-28 E6:27 [Non-volatile read error1 is displayed . . . . . .. . .. .. . . . .. . .. .. . . . . . . . .. . . . . . . . .. . .. . . . . . . . . .. .. . . . . . . .. . .. . . . . . .. 20-724
A-29 E6:28 [Non-volatile write error1 is displayed . . .. .. . . . . . . . . .. . .. . . . . . . . . .. . . . .. . . . .. . . . . . . . . . . .. . . .. . . . .. . . . . . . . . .. .. 20-724
A-30 Buzzer does not sound (when there is no abnormal displayed) . .. . . . .. .._............................ 20-725
A-31 Automatic mode is not actuated when knob switch is pressed
(when there is no abnormal display) . . . . . . .. . . . . . . .. . .. . . . . . .. .. . .. . . . . . . . . .. . . . . . . . . .. . . . . . . .. . .. .. .. . . .. .. . . . . . . . .. . .. 20-726
20-652
0
TROUBLESHOOTING GX CONTROLLER SYSTEM
POINTS TO REMEMBER WHEN TROUBLESHOOTING GX

CONTROLLER SYSTEM

1) If any abnormality returns to normal by itself, or
3) After completing troubleshooting, always erase the user code from memory.

any wasted work.)
3. If any abnormality that occurred during operation returns to normal (before the starting switch is
turned OFF), the error code displayed on the HYPER monitor or GX panel will continue to be
displayed until the starting switch is turned OFF.
4. % If the GX controller has been replaced, see Table for order of operations in GX adjustment mode
when carrying out operations.
20-653
0
TROUBLESHOOTING PROCEDURE FOR TROUBLESHOOTING HYPER GX
PROCEDURE FOR TROUBLESHOOTING HYPER GX
Judge if the problem is a failure peculiar to the

HYPER GX specification machine.
. If the problem is a failure peculiar to GX ma-

chines, the system will display one of the follow-
ing conditions.
a “E09” is displayed on the HYPER monitor, and
all parts of the work equipment stop.
Note: With E09, CALL is not displayed.
0 “E” is displayed on the GX panel, and the bucket
monitor functions cannot be used.
0 If an attempt is made to select an automatic func-
tion on the GX panel, the buzzer sounds 3 times
and the selection cannot be made.
Note: The following cases are not failure.
1) Before the GX is started, the GX functions
cannot be selected.
2) Before the preparatory, the working range TKP00830
selection cannot be selected.

3) Functions which cannot be selected together
according to the function combination table
cannot be used together.
TKP00831 2
In the case of a failure peculiar to the GX

specification machine, ask the user to carry out
the following operation and confirmation.
. When the work equipment is completely stopped

and does not move, if all the functions on the GX
panel (excluding the bucket monitor) are turned
OFF, EO9 goes out and the all-stop is canceled.
l Turn the starting switch OFF, then start again,
and check if the machine returns to normal or
not. TKP00832
(If it does not return to normal, it is possible to

select only GX functions which are not related to
the failure.)
Reference: If the GX automatic operation disconnec-
tion switch at the rear right of the opera-
tor’s seat is set to the DISCONNECTION
position, and the starting switch is turned
ON, the machine starts as a normal
HYPER specification machine.
TKP00833
(In this case, “F” is displayed on the GX
panel.)
20-654
0
Check error code at jobsite
. There are the following three types of error codes

for the GX machine.
0 Emergency error code (E09)
This is the only error code informed to the user.
When there is a failure in the GX, it is displayed
only when it is dangerous to continue opera-
tions. At the same time, a buzzer sounds inter-
mittently and all the work equipment stops.
0 HYPER monitor error codes (E6:Ol - E6:28)
When the monitor is switched to the error dis-
play mode, it displays the error codes.
E6: shows that it is an error for the GX related
system, and the final two digits (01 - 28) show
the main categories of error.
Note: For details of the relationship between
the error code and the nature of the fail- TKP00834
ure and the behavior of the machine, see

Large category
“Action taken by controller when abnor-
mality occurs, and problems on ma-
chine”.
Note: Only these error codes are not deleted
even when the starting switch is turned
OFF.
0 GX panel error codes (-011 to -284)
These are displayed when the GX panel is set to
the GX error display mode. The first two digits Detailed content
(01 - 28) show the main type of error, and the TKP00835
last digit shows the detailed code for the error.
Note: With the error codes in @ and @ above,
even if the failure disappears, the display
continues until the starting switch is
turned OFF.
TKPOO836
r
Investigate the system with the failure from the
items corresponding to the code in “Action
taken by controller when abnormality occurs,
1 and problems on machine”. - 1
Example: If the monitor error code is “601” and

the panel error code is “OOI”, it can be
seen from the item in “Action taken by
controller when abnormality occurs, and
problems on machine” that there is an
abnormality in the boom pressure sen-
sor system (defective bottom sensor, or
7 short circuit in signal, disconnection in
ground connection).
20-655
0
aPinpoint the location of the failure from the

corresponding item in the troubleshooting flow
chart
Example: With the error above, look at troubleshoot-

ing flow chart A-2 (E6:01, and 011,012) to
II investigate the location of the failure.
Repair the location of the failure, replace parts.

1
Start the GX and check that the error does not

occur (completed)
20-656
0
OPERATION OF GX ERROR CODE DISPLAY MODE
TROUBLESHOOTING AND CONTENT OF DISPLAY
OPERATION OF GX ERROR CODE DISPLAY MODE AND

CONTENT OF DISPLAY
If the switches on the GX panel are operated as follows, it is possible to know the details of the error.
Operation Display
1. To set to the error code displav mode:

1) Press the m + q
’ switches for at
least 3 seconds.
. When the system switches to the er-
ror code display mode, the number
of errors now occurring is displayed
(2 seconds), then the error code is
displayed.
2) Example of display SET UP DOWN

If connector (A19) is disconnected, it is
judged that there is a disconnection in
the power source system, so E6:08, E6:12
are generated.
i) There are two errors, so (E02) is dis-
played for 2 seconds.
ii) Following this, the panel error code
(082) is displayed.
For details of the correspondence be-
CLiAR SHIFT
tween the service code displayed
HYPER monitor display and the error code
displayed on the GX panel, see “Action
on the
I
taken by controller when abnormality When there are two errors
1-1 (E6:08 and E6:lZ)
occurs, and problems on machine”.
After 2 Number of errors displayed

3) To go on to the next error code, press seconds
I for 2 seconds
the m switch. In this case, the display
changes to 11221.
4) To go back to the previous error code,

press the jDOWNl switch.
5) To exit the error code display mode:

I
I
- -
Error code (abnormality
potentiometer
(-1 indicates the error
in
Power source)
code
Use the same operation as for setting to display mode
Press the UP switch
the error code display mode. I
- Error code (abnormalitv in

encoder Power source)
TKP00837
20-657
0
OPERATION OF GX ERROR CODE DISPLAY MODE
TROUBLESHOOTING AND CONTENT OF DISPLAY
Troubleshooting GX, example 1
Buzzer sounds during fully automatic grading operation, all work equipment stops and “E09” is
displayed on HYPER monitor.
Display is E09, indicating failure peculiar to GX. [lnstru,ctions are, given Jar operation.1
1
When fully automatic grading LED is turned OFF, E09 goes out and work equipment can be
operated, but automatic grading cannot be selected again. Even when starting switch is turned off
and then started again, it cannot be selected again.
1 ISe@iceinan
iiivestigates error code at jobsite.
When HYPER monitor is set to error display mode, service code E6:03 is displayed.
When GX panel is set to GX error display mode, -034 is displayed.
See “Action taken by controller when abnormality occurs, and problems on machine” and
11 investigate failad system?
Monitor code E603: Abnormality in bucket pressure sensor system

Panel code 034: Head sensor signal is below normal voltage (GND end)
1 See troubleshooting flow chart and [determine iocation of failure.]

Applicable troubleshooting flow is “A7”, voltage between A30 connector (2) - (I) is abnormal.
1 IReplace wiring harness] between A30 and A05.

.
Turn the starting switch ON, and start the GX, then set to the GX error display mode and Ichecq
Iftiat the erro,r @& not 0acuy.j
Troubleshooting GX, example 2
When starting switch is turned ON and GX is started, “E” is displayed on GX panel.
1 GX display is “E”, indicating failure peculiar to GX. Instructions are given for operation:
Even when starting switch is turned off and then started again, “E” does not go out.
1 ISetiitieman investigates,errot code at jobsite.]

When HYPER monitor is set to error display mode, service codes E6:07 and E6:14 are displayed.
If GX panel is set to GX error display mode, -071 and -141 are displayed.
See “Action taken by controller when abnormality occurs, and problems on machine” and
1 1investigate failed syste,m,
,,
. Monitor code E607: Abnormality in boom potentiometer system
Panel code 071: As above; signal is above normal voltage (power source)
. Monitor code E614: Abnormality in boom angle sensor prolix (2-sensor comparison) system
Panel code 141: As above; difference too great between potentiometer and encoder angle
signals
1 See troubleshooting flow chart and ]det&hin6
The main cause is probably E607, so when Troubleshooting

location of failure.]
“A-14” is carried out first, abnormality
is found in resistance between A21 connector (8) and (9).
1 Replace boom potentiometer and use GX adjustment mode to correct sensor.
Turn the starting switch ON, and start the GX, then set to the GX error display mode and/m
bhat the error does not occur.]
20-658
0
TROUBLESHOOTING OCCURS, AND PROBLEMS ON MACHINE

OCCURS, AND PROBLEMS ON MACHINE
HYPER monitor GX panel

User Service Service
code code code
Abnormality in pres- 1) Disconnection, short circuit with ground in power

E6:Ol sure sensor power source wiring harness between A02 (2) (12) - pressure
I source system sensor.
E6:04 2) Defective sensor (one of 8 sensors is defective)
Boom % If the power source wiring harness between A02 (2)
displayed Arm Power source (12) - pressure sensor is short circuiting with the
at same Bucket for all sensors ground, [E6:231 is displayed at the same time.
Swing I
time
x Voltage between A25 (3) and (I) stays at 4.5 V or above

5 2 1) Defective boom (bottom) pressure sensor
t;; 011
ZE 2) Short circuit in A25 (3) (signal wiring harness)
v)a
t mz 3) Disconnection in A25 (I) (GND wiring harness)
z zr
n.m
z x Voltage between A25 (3) and (1) stays at 0.5 V or below
2 :i I) Defective boom (bottom) pressure sensor
z$ 012
2 ou, 2) Disconnection in A25 (2) (power source wiring harness)
m 3) Disconnection or short circuit with ground in A25 (3)
z
E6:Ol
: (signal wiring harness)
:
displayed
x Voltage between A26 (3) and (1) stays at 4.5 V or above
alone
1) Defective boom (head) pressure sensor
013
:s 2) Short circuit in A26 (3) (signal wiring harness)
q 3) Disconnection in A26 (I) (GND wiring harness)
Fv,
QL I Voltage between A26 (3) and (1) stays at 0.5 V or below
0s I) Defective boom (head) pressure sensor
EC
1: 014 2) Disconnection in A26 (2) (power source wiring harness)
3) Disconnection or short circuit with ground in A26 (3)
(signal wiring harness)
% Voltage between A27 (3) and (I) stays at 4.5 V or

above.
?? 1) Defective arm (bottom) pressure sensor
XE 021
$B 2) Short circuit in A27 (3) (signal wiring harness)
C0
3) Disconnection in A27 (I) (GND wiring harness)
g,r
gi % Voltage between A27 (3) and (I) stays at 0.5 V or below

z: 1) Defective arm (bottom) pressure sensor
ou, 022 2) Disconnection in A27 (2) (power source wiring harness)
m
E6:02
% Voltage between A28 (3) and (I) stays at 4.5 V or above
1) Defective arm (head) pressure sensor
023
2) Short circuit in A28 (3) (signal wiring harness)
%
3% 3) Disconnection in A28 (I) (GND wiring harness)
z
Ev,
aL x Voltage between A28 (3) and (I) stays at 0.5 V or below
oP 1) Defective arm (head) pressure sensor
$8 024 2) Disconnection in A28 (2) (power source wiring harness)
1:
20-660
0
Action by controller Problem that appears

Condition when normal
when abnormality on machine when
(voltage, current, resistance)
is detected there is abnormality
Between A02(2)(12) - (7)(13): 18 - 28 V I) Stops all output when 1) All movement stops when
automatic grading, automatic grading, working
working range selection, range selection, cutting angle
cutting angle retention retention are selected.
are selected, and dis- % Movement becomes possible
plays [E091on the when the function is
HYPER monitor. canceled.
2) Automatically cancels the (Cannot be reset)
boom rock and swing 2) The boom rock and swing back
back prevention func- prevention functions are
tions. canceled, so the boom rock and
swing back prevention functions
do not work.
1) Stops all output when 1) All movement stops when

:e!:zwI: 22: izi 1 1:; Voltage: 18 - 28 V
automatic grading is automatic grading is selected.
selected, and displays % Movement becomes possible
~~~~~~ 2%: 1;; 1 1:; Voltage: 3.2 - 4.1 V
iE091on the HYPER when the function is
(at relief)
monitor. canceled.
X See the table when measuring in 2) Automatically cancels the (Cannot be reset)
contrast with the hydraulic pressure. boom rock prevention 2) The boom rock prevention
function. function is canceled, so the
boom rock prevention function
5
does not work.
4
(VI
IF
0
9. 8 19. 6 29. 4 39. 2 49. 0
I1001 (2001 (3001 (4001 15001
MPa( kg/cm']
BKP02305
1) Stops all output when 1) All movement stops when

automatic grading is automatic grading is selected.
irs:twEi 24: iz; 1 ii,’ Voltage: 18 - 28 V
selected, and displays % Movement becomes possible
[E091 on the HYPER when the function is
~~r~~~~ izi izl 1 iil Voltage: 3.2 - 4.1 V
monitor. canceled.
(at relief)
(Cannot be reset)
X See the table when measuring in
contrast with the hydraulic pressure.
(VI
0l!IL
9. a 19.6 29.4 39 2 49 0
I1001 (2001 (3OOl 14001 (5001
MPa[ kg/cm')
BKP02305

code code code
1) Defective sensor (potentiometer) (including mount)

2) Short circuit with ground in wiring harness between
A03 (I) (11) - sensor (power source)
E6:07, 3) Disconnection in wiring harness between A03 (I) (11) -
E6:08 are Al 1 (14) (power source)
Potentiometer power
displayed 4) Disconnection in wiring harness between A03 (IO) (20)
source system
at same - All (15) (GND)
time
% Signal voltage stays at 4.75 V or above

1) Short circuit in wiring harness between A03 (3) - A21
(8) (signal)
071
& 2) Disconnection in wiring harness between A21 (7) - A04
z (11) (GND)
E
.g
E6:07 5 I Signal voltage stays at 0.25 V or below

5 1) Disconnection or short circuit with ground in wiring
F harness between A03 (3) - A21 (8) (signal)
2) Disconnection in wiring harness between A21 (6) - A04
: 072
m (IO) (power source)
(11) (GND)
% Signal voltage stays at 4.75 V or above

I) Short circuit in wiring harness between A03 (3) - A19
(8) (signal)
081
&I 2) Disconnection in wiring harness between A19 (7) - A04
5 (11) (GND)
E 3) Defective sensor (potentiometer) (including mount)
E6:08 .$
: I Signal voltage stays at 0.25 V or below
5 I) Short circuit with ground in wiring harness between
A03 (3) - A19 (8) (signal)
F 2) Disconnection in wiring harness between A19 (6) - A04
< 082
(IO) (power source)
(11) (GND)
% When end of boom LOWER stroke is exceeded

I) Mistake in setting for model, attachment or defective
“,
correction of sensor
F
m 2) Defective encoder (broken) (including defective mount)
a, 111
CI) l If the mount is defective, the angle becomes misaligned.
z
.E : 3) 12 V power source (disconnection, short circuit with
zz
a ground)
&I
Lu.E E 4) 2 phase (disconnection, short circuit with ground)
E6:ll E’ 8
$ m ?% When end of boom RAISE stroke is exceeded
2& 1) Mistake in setting for model, attachment, or defective
a,
a:B correction of sensor
2 F 2) Defective encoder (broken) (including defective mount)
0 m
112 l If the mount is defective, the angle becomes misaligned.
2 3) 12 V power source (disconnection, short circuit with
ground)
4) Z phase (disconnection, short circuit with ground)
20-662
0
Condition when normal Action by controller Problem that appears

(voltage, current, resistance) when abnormality on machine when
I) Voltage between A03 (I) (11) - (IO) 1) Stops all output when @ 1) All movement stops when
(20): 5.0 * 0.2 v automatic grading, @ functions @ to @ on the left are
cutting angle retention, selected.
@ working range selec- X Movement becomes possible
tion, @ digging depth when the function is
alarm are selected, and canceled.
displays [E091 on the (Cannot be reset)
HYPER monitor. 2) The electronically cushioned
2) Automatically cancels the cylinder funciton is canceled, so
electronically cushioned there is shock at the end of the
cylinder function. cylinder stroke.
1) Between A21 (8) - (7) (A03 (3) - (IO) 1) Stops all output when @ 1) All movement stops when
(20)) (signal) automatic grading, @ functions @ to @ on the left are
Voltage: (End of boom RAISE stroke) cutting angle retention, selected.
3.6 - 4.6 V @ working range selec- % Movement becomes possible
2) Between A21 (6) - (7) (A03 (1) (11) - tion, @ digging depth when the function is
(IO) (20)) (power source) alarm are selected, and canceled.
Voltage: 5.0 f 0.2 V displays LEO91 on the (Cannot be reset)
1) Between A19 (8) - (7) (A03 (3) - (IO) 1) Stops all output when @ I) All movement stops when
(20)) (signal) automatic grading, @ functions @ to @ on the left are
Voltage: (End of arm IN stroke) cutting angle retention, selected.
3.6 - 4.6 V @ working range selec- X Movement becomes possible
2) Between A19 (6) - (7) (A03 (I) (11) - tion, @ digging depth when the function is
(IO) (20)) (power source) alarm are selected, and canceled.
Voltage: 5.0 + 0.2 V displays LEO91 on the (Cannot be reset)
I) Power source I) Stops all output when @ 1) All movement stops when
Between A19 (A211 (1) - (2) (A01 (9) automatic grading, 0 functions @ to @ on the left are
(17) - (1) (10)) cutting angle retention, selected.
Voltage: 11.5 - 12.5 V @ working range selec- X Movement becomes possible
!I Signal tion, @ digging depth when the function is
l Between boom A21 (3) (4) - (2) alarm are selected, and canceled.
(A01 (3) (12) - (1) (IO)) displays [E091 on the (Cannot be reset)
l Between arm A19 (3) (4) - (2) HYPER monitor. 2) The electronically cushioned
(A01 (6) (14) - (1) (10)) 2) Automatically cancels the cylinder funciton is canceled, so
l Between bucket Al8 (3) (4) - (2) electronically cushioned there is shock at the end of the
(A01 (8) (16) - (1) (IO)) cylinder function. cylinder stroke.
Voltage: 6 f 2 V (when actuated)
20-663
0

code code code
Abnormality in internal calculation

Horizontal
171
position
Cutting
edge
E6:17
position out
Abnormality in internal calculation
of range
Perpen-
dicular 172
position
Abnormality in data ROM
SIN
181
function
Abnormality
E6:18 in data
ROM
Abnormality in data ROM
Others 183
% When starting switch is ON, voltage between A09 (8) -

GND is different from value on right
Abnormality 1) Mistaken model input to non-volatile memory
211
in model 2) Disconnection, short circuit with ground in wiring
harness between A09 (8) - controller (model selection
3)
Abnormality Abnormality
E6:21 m engine in observa-
% When starting switch is ON, voltage between A09 (16) -
212
pick-up tion function GND is different from value on right
x When starting switch is ON, GX panel switch signal is

Panel
213 input
switch
1) GX panel switch stuck
Knob. % When starting switch is ON, left knob switch is pressed

214
switch 1) Knob switch stuck
I When voltage between A09 (8) (15) - GND changes

after starting switch is turned ON
1) Disconnection, short circuit with ground in wiring
Change in wiring harness between A09 (8) - GND (model selection 3)
harness after engine 221 2) Disconnection or short circuit with ground in wiring
picks up harness between A09 (15) - controller (GX controller
disconnection switch)
3) When starting switch is turned ON, GX controller
disconnection switch is operated
E6:22
Automatic operation dis- % Network data from valve controller is different from
connection switch signal judgement of GX controller
222
does not match in valve 1) Disconnection, short circuit with ground in wiring
controller and GX controller harness between A09 (15) - A02 (1) (6)
% When voltage between A02 (I) - (21, A09 (11) - GND

Abnormality in continues at less than 15 V for more than 10 seconds
223 Disconnection in wiring harness between A02 (2) (9) -
controller power source
fuse (11)
20-664
0

1) Stops all output when @ I) All movement stops when

automatic grading, @ functions 0 to @ on the left are
@ working range selec- % Movement becomes possible
- alarm are selected, and canceled.
I) Stops all output when @ I) All movement stops when

automatic grading, @ functions @ to @ on the left are
@ working range selec- x Movement becomes possible
- alarm are selected, and canceled.
Voltage between A09 (8) - chassis: 1) Stops all output when @ 1) All movement stops when
0 - 0.3 v automatic grading, 0 functions @ to @ on the left are
working range selection, selected.
displays fE091 on the (Cannot be reset)
Voltage between A09 (16) - GND: HYPER monitor. 2) The electronically cushioned
18-28V 2) Automatically cancels the cylinder funciton is canceled, so
When starting switch is ON, panel switch cylinder function. cylinder stroke.
signal input is [Ol 3) Automatically cancels the 3) The boom rock and swing back
boom rock and swing prevention functions are
back prevention func- canceled, so the boom rock and
When starting switch is ON tions. swing back prevention fucntions
Voltage between A09 (3) - GND: 0 V do not work.
I) Voltage between A09 (8) - GND: 1) Stops all output when @ 1) All movement stops when
0 - 0.3v automatic grading, @ functions @ to @ on the left are
2) Voltage between A09 (15) - GND working range selection, selected.
lGX controller connected: 0 - 0.3 V @ working range selec- % Movement becomes possible
lGX controller disconnected: 18 - 28 V tion, @ digging depth when the function is
Voltage between A09 (15) - GND cylinder function. cylinder stroke.
l GX controller connected: 0 - 0.3 V 3) Automatically cancels the 3) The boom rock and swing back
l GX controller disconnected: 18 - 28 V boom rock and swing prevention functions are
tions. swing back prevention fucntions
Voltage between A09 (II) - (2) (BR do not work.
signal): 18 - 28 V
20-665
0

code code code
% If value in memory for EPC starting current is not

within range of 400 & 120 mmA when engine picks up
EPC correction value 263
E6:26
c If the value of the data in memory for the custom
bucket is not within the range below when the engine
picks up
Others (custom bucket) 264 1) Angle: 0 - 125”
2) Length: 0 - 2500 mm
x Abnormality in SUM when reading data in non-volatile

Abnormality in memory block 1
block 1 SUM 271 1) Abnormality in non-volatile memory data
check 2) Mistaken setting in memory
,r
SO
p,s % Abnormality in SUM when reading data in non-volatih

‘L E Abnormality in
memory block 2
E6:27 ‘f ,” block 2 SUM 272 1) Abnormality in non-volatile memory data
.E -‘z check 2) Mistaken setting in memory
57
=r
wo Data saved to above two places is not the same
c
Data for block
273
1, 2 do not
match
x Abnormality in SUM when reading data in non-volatile

Abnormality in memory block 1
check 2) Mistaken setting in memory
% Abnormality in SUM when reading data in non-volatile

?T Abnormality in memory block 2
SO
F: check 2) Mistaken setting in memory
‘G E
E6:28 ‘fg _
.E k- % Number of times of writing has exceeded 10,000 time!
:P EPC correction or abnormality in timing
b& 283
wo value
c
% Data written to memory has exceeded range

1) Defective correction
Others 284
20-666
0

Value for EPC starting current: I) Stops all output when @ I) All movement stops when
400 + 120 mmA automatic grading, @ functions @to @ on the left are
displays fE091on the (Cannot be reset)
1) Angle: 0 - 125”
2) Length: 0 - 2500 mm
3) Automatically cancels the 3) The boom rock and swing back
do not work.
1) Stops all output when @ I) All movement stops when

automatic grading, @ functions @ to @ on the left are
-
displays LEO91 on the (Cannot be reset)
- HYPER monitor. 2) The electronically cushioned
- back prevention func- canceled, so the boom rock and
do not work.
1) Stops all output when @ 1) All movement stops when

automatic grading, @ functions 0 to @ on the left are
-
working range selection, selected.
@ working range selec- .% Movement becomes possible
- HYPER monitor. 2) The electronically cushioned
- back prevention func- canceled, so the boom rock and
do not work.
20-667
TROUBLESHOOTING ELECTRICAL WIRING DIAGRAM FOR GX CONTROLLER
ELECTRICAL WIRING DIAGRAM FOR GX CONTROLLER
Bucket
CY I inde
stroke
sensor
Arm angle
sensor
(boom top) 11
Boom i
sensor
(boom
I
L-__“L-I I
8QOm bottom
Pressure Sensor
&!AlSEl
Boom head
eressure SSQSQl
(LOWER1
Arm bottom
Pressure sensor
(INI
Arm head
Prassure sensor
(OUT1
Bucket bottoln
Pressure sensor
(CURLI
Bucket head
PlMS”lS SS”SQr
MJMPI
Swins WA
Pressure sensor
(RIGHT)
Swina MB
eressure sensor
(LEFT1
Base harness
TKP00838
20-668
0
TROUBLESHOOTING ELECTRICAL WIRING DIAGRAM FOR GX CONTROLLER
er-*et GX controller
Valve controller harness
/ Radio-control harness
AntennaA
TKP00839
20-669
0
TROUBLESHOOTING A-l
A-l E6:01,E6:02, E6:03, and E6:04 are displayed at the same time
* The error code displayed on the HYPER monitor or GX panel does not go out until the starting
switch is turned OFF.
4 YES
I II
YES Is voltage
- between A25 (2) -
and (1) normal?
3
Is voltage *18-28V NO
YEF between A05 (5) _ * Turn starting
and (4) normal? switch ON.
5 YES
*18-28V Is voltage
* Turn starting between A02
2 switch ON. NO (6)(12) and
(7H13) normal?
E6:23 not Is 012 displayed *18-28V NO
displayed on GX panel? * Turn starting
switch ON.
7 YES
. Turn starting
switch ON. YES Is voltage
% GX panel error z GND writing
- between A25 (2) -
display mode harness 6
- and (I) normal?
Is voltage
- between A05 (5) - * 18 - 28V NO
displayed at same NO and (4) normal7 -Turn starting
switch ON.
-18-28V
I HYPER monitor * Turn starting NO
Service code switch ON.
display mode
YES
a
Start from A25 and
1 Ey3:!3 alyo disconnect one
A25 (X3) L dlsplayed at - connector at a time. - YES
same time Dose E6:23 display
go out? 9
- Does E6:23
* Turn starting
display go off
switch ON.
NO when A05 is 10 YES
I There are 8
removed? Is resistancebetween
connectors.
A02 Ifemale)(61(12)
* Turn starting
- and l7)(131,and
switch ON. NO between(6)(12)and
chassisnormal?
* Min. 1 MQ NO
* Turn starting
switch OFF.
+ Disconnect A02
and A05.
Iki-J A-l Related electric circuit diagram
A02 IM I Cl 3)
Press, sensor Power (24V)
TKPOO840
20-670
0
TROUBLESHOOTING A-l
Remedy
Replace wiring
harness between A05
harness
(male) (5) and each sensor
connector
Defective contact ,or
disconnection in wiring Replace wiring
harness between A02 harness
(female) (6)(12) and A05
(female) (5)
Defective GX controller Replace
Replace wiring
harness
Replace wiring
harness
(female) (7)(13) and A05
(female) (4)
Defect inside connector Reolace

where display goes out
Wiring harness between

A05 (male) (5) and each Replace wiring
sensor connector short harness
circuiting with chassis
ground or other point

A02 (female) (6H12) and
Replace wiring
A05 (femaleN5) short
harness
ground, short circuiting
% When the GX controller has been replaced, carry out the operation in the TABLE FOR ORDER OF
OPERATIONS IN GX ADJUSTMENT MODE.
20-671
0
TROUBLESHOOTING A-7
A-Z E6:Ol (GX panel 011, 012) [Abnormality in boom (RAISE) pressure
sensor system] is displayed
* If [E6:021 - [E6:041 are displayed at the same time, go to Troubleshooting A-l.
When GX panel displays 011

I GX panel error display mode
YES
4
_ Is voltage
YES between A03 (5)
and A02 (7)
3
- normal?
Is resistance
When GX panel displays 012 . Min. 0.5 V
between A25
% GX panel error display mode (female)(3) - (IL (3) * Turn starting NO
-chassis normal? switch ON.
between A25(2)
and (1) normal? * Min. 1 MQ
* Turn starting I
NO
switch OFF.
when sensor is * Disconnect A25,
interchanged with AOZ, and A03.
NO
z After
interchanging
sensors
* Turn starting
NO
switch ON.
% HYPER monitor
Service code
display mode
A-2 Related electric circuit diagram
A02 (MICl3)
6 Pressure sensor Dower

(24V)
I 7 CND
To other DreSsure sensors
Pressure sensor power
A I
(24V)
Pressure senscr
(boom bottom) A25 (X3) A05tSWPl4) 13 GND
GND
24V A03 (040201
Press.sensor SIG
TKP00841
20-672
0
TROUBLESHOOTING A-2
Cause Remedy
5 YES Already reset -

% See Note in Contents.
l-!kzFlII
- monioring d30
display (RAISE relief
pressure) normal?
. 27.0 - 39.2 MPa NO
{270 - 400 kg/cm’>
* Engine at full throttle,
boom RAISE relief. Disconnection in wiring
.X GX monitorin mode
harness between A25 Replace wiring
(female) (3) - A05(6) - A03 harness
(female) (5)
A25 (femaleN3) - A05(6) -
Replace wiring
A03 (female) (5) short
harness
ground
Replace wiring
(female) (2)(l) and A05 (5)
(4)
Defective pressure
sensor
20-673
0
TROUBLESHOOTING A-3
A-3 E6:Ol (GX panel 013, 014) [Abnormality in boom (LOWER)

pressure sensor system] is displayed
Sr Before carrying out troubleshooting, check that all the related connectors are properly inserted.
* If [E6:021 - [E6:041 are displayed at the same time, go to Troubleshooting A-l.
+ The error code displayed on the HYPER monitor or GX panel does not go out until the starting

% GX panel error display mode
YES
YE between A03 (17)

z GX panel error display mode * Turn startina NO
switch ON. -
and (1) normal?
* Min. 1 MR
* Turn starting
*18-28V switch OFF.
Is E6:Olstill displayed * Turn starting
when sensor is
- Disconnect A26,
- switch ON. A02, and A03.
interchangedwith
other pressuresensor?
NO
% After
interhanging
sensors
* Turn starting NO
switch ON.
% HYPER monitor
Service code
display mode

A02 (MI Cl 31
Press. sensor POWer

(24V)
GND
To other Pressure sensors
I I P\;;tj sensor Pcvier

Pressure sensor
(boom head) A26 (X3) A05 (SWP14) 13 CND
GND 4
24V 5 A03 (04020)
SIG Pressure sensor SIG
TKP00842
20-674
0
TROUBLESHOOTING A-3
I Cause Remedy

1At boom LOWER 1I % See Note in Contents.
(female) (3) - A05 (7) - A03 harness
(female) (17)
A26 ffemaM(3) - A05 (7) - Replace wiring
harness
ground
Defective contact .or
Replace wiring
(4)
Defective pressure Replace
sensor
20-675
0
TROUBLESHOOTING A-4
A-4 E6:02 (GX panel 021, 022) [Abnormality in arm (IN) pressure
$i If [E6:011, [E6:031, or [E6:041 are displayed at the same time, go to Troubleshooting A-l.
Ir The error code displayed on the HYPER monitor or GX panel does not go out until the starting
r tp;pGX ynel displays 021

ane error drsplay mode p
YES
4
Is voltage
YES between A03 (6)
and A02 (7)
3
- normal?
I
Is resistance
When GX panel displays 022 * Min. 0.5V
between A27
YES Is voltage
% GX panel error display mode (femalel(3) - II), (31 - *Turn starting NO
-chassis normal? switch ON.
- between A27(2) -
and (1) normal? * Min. 1 MR
1- *Turn starting
- *18-28V NO
switch OFF.
Is E&02 still displayed * Turn starting * Disconnect A27
even when sensor is _ switch ON. A02, and A03.
interchangedwith
other pressuresensor?
NO
% After
interhanging
sensors
* Turn starting
NO
switch ON.
%%HYPER monitor
Service code
display mode
A02 (MI C 13)

* Press. senscr ~cvrer
Pressure sensor
A A (24V)
(arm bottom1 A27 (X3) A05 (SWPl4) 13 GND
GND
!
24y 2 5' A03 (04020)
SIG 3 8 Press.sensor SIG
TKP00843
20-676
0
TROUBLESHOOTING A-4
Cause Remedy
Already reset -
.x See Note in Contents.
At arm IN relief, is
GX monitoring d32
- display (IN relief
pressure) normal?
* 27.0 - 39.2 MPa NO
1275- 400 kg/cm*}
*Engine at full throttle,
arm IN relief. Disconnection in wiring
mnni+nrinn harness between A27 Replace wiring
(female) (31- A05 (8) - A03 harness
(female) (6)
A27 (female) (3) - A05 (8) - Replace wiring
A03 (female) (6) short harness
ground
20-677
0
TROUBLESHOOTING A-5
A-5 E6:02 (GX panel 023, 024) [Abnormality in arm (OUT) pressure
Ir If [E6:011, [E6:031, [E6:041 are displayed at the same time, go to Troubleshooting A-l.
r
x GX panel error display mode p
+
YES
YES
II
Is resistance
H
2 * Min. 0.5V
When GX panel displays 024 between A26
x GX panel error display mode lfemale)(3) - (I), I(3) * Turn starting
‘;;;;;;;;;;I? 1[ switch ON.
NO
switch OFF.
IS E6:02 still displayed
even when sensor is * Disconnect A28,
A02, and A03.
I
NO
I After
interhanging
sensors
* Turn starting
switch ON.
% HYPER monitor
Service code
display mode
A02 (MICl3)
6 I Press. sensor Power

(24V)
7 GND
12 Press. sensor Power
A (24V)
Pressure sensor
(arm head) A28 (X3) A05 iSWPl4) 13 CND
GND
24V A03 (04020)
w Press. sensor SIG
TKPOO’344
20-678
0
TROUBLESHOOTING A-5
Cause Remedy
!i YES Already reset -

I See Note in Contents.

. 27.0 - 39.2 MPa NO
(275 - 400 kg/cm’)
* Engine at full throttle,
arm OUT relief. Disconnection in wiring
.X GX monitoring mode harness between A28 Replace wiring
(female) (3) - A05 (9) - A03
harness
(female) (7)
A28 (female) (3) - A05 (9) -
A03 (female) (7) short Replace wiring
circuiting with chassis harness
ground
(4)

sensor
20-679
0
TROUBLESHOOTING A-6
A-6 E6:03 (GX panel 031, 032) [Abnormality in bucket (CURL) pressure
* If [E6:011, [E6:02], or [E6:04] are displayed at the same time, go to Troubleshooting A-l.

r .%GX panel error display mode [
YES
YES
*I",,".
U.3"
d
. II Is resistance
ilL H
When GX panel displays 032 between A29
I,_
ID
.,Î.^^_
““lwyc
.%GX panel error display mode (female)(3) - (1). (3)
YE? between A29(2) -
I- chassis normal7 1 1 switchUN.
and (1) normal? *Min. 1 MR
1 - Turn starting
NO
- *18-28V switch OFF.
Is E&03 still displayed -Turn starting
even when sensor is * Disconnect A29,
_ switch ON. A02, and A03.
interchanged with
other pressure sensor?
NO
Cx After
interhanging
sensors
* Turn starting
switch ON.
% HYPER monitor
Service code
display mode
3% When the GX controller has been replaced, carry out the operation in the TABLE FOR ORDER OF

A02 (MIC13)
Pressure sensor Power

(24Vl
GND
To other pressure sensors
12 P;;ye sensor Power
A A
Pressure sensor
(bucket bottom) A29 (X3) A0 5 (SWP 14) GND
GND
24V A03 (04020)
SIG ~ @pb ( Pressure sensor SIG ’
TKP00845
20-680
0
TROUBLESHOOTING A-6
Cause Remedy

At bucket OURL .%See Note in Contents.
relief, is GX
- monitoring d34 -
display (CURL relief
pressure) normal?
Defective GX controller
-27.0 - 39.2 MPa NO
1275- 400 kg/cm21
. Engine at full throttle,
bucket CURL relief. Disconnection in wiring
I GX monitoring mode harness between A29 Replace wiring
(female) (3) - A05flO) - A03 harness
(female) (8)
Wiring harness between 1
A29 (femalej(3) - A05flO) -
Replace wiring
harness
ground
Defective pressure 1 Replace
20-681
0
TROUBLESHOOTING A-7
A-7 E6:03 (GX panel 033, 034) [Abnormality in bucket (DUMP) pressure
sensor system1 is displayed
+ If [E6:011, [E6:021, or [E6:041 are displayed at the same time, go to Troubleshooting A-l.
Sr The error code displayed on the HYPER monitor or GX panel does not go out until the starting

r % GX panel error display mode
YES
2 When GX panel displays 034

- % GX panel error display mode
Is voltage
YE
between A30(2) - 1 I
and (1) normal? . Min. 1 MR
- Turn starting
*18-28V NO
switch OFF.
* Turn starting * Disconnect A30,
switch ON. A02, and A03.
k
.XAfter
interhanging
sensors
* Turn starting
0
switch ON.
.% HYPER monitor
Service code
display mode
Z When the GX controller has been replaced, carry out the operation in the TABLE FOR ORDER OF

A02 (MI Cl 3)
Press. sensor Power

(24V)
GND
12 Press. sensor power
Pressure sensor (24V)
(bucket head)
A30 (X3) I t A05 (SWP14) 13 GND
GND
24v A03 (04020)
SIG Press. sensor SIG
TKP00846
20-682
0
TROUBLESHOOTING A-7
Cause Remedy

At bucketDUMPrelief,
is GX monitoringd35
display(DUMPrelief
pressure)normal?
Defective GX controller 3eplace
.27.0 - 39.2 MPa NO
{275 - 400 kg/cm’)
- Engine at full throttle, Disconnection in wiring
bucket DUMP relief.
harness between A30 3eplace wiring
.%GX monitoring mode
(female) (3) - A05 Ill) - iarness
I,
A03 (female) (9)
A30 (female) (3) - A05 (11) 3eplace wiring
- A03 (female) (9) short harness
ground
(4)

sensor
20-683
0
TROUBLESHOOTING A-8
A-8 E6:04 (GX panel 041, 042) [Abnormality in swing (RIGHT) pressure
t Before carrying out troubleshooting, check that all the related connectors are properly inserted.
Ir If [E6:011 - [E6:031 are displayed at the same time, go to Troubleshooting A-l.

- .%GX panel error display mode
YES
4r
YE between A03 (12)

3
_ When GX panel displays 042 * Turn starting NO

I GX panel error display mode switch ON.
* Min. 1 MR
* Turn starting
*18-28V switch OFF.
* Turn starting * Disconnect A37
% After
interhanging
sensors
* Turn starting
switch ON.
% HYPER monitor
Service code
display mode
9% When the GX controller has been replaced, carry out the operation in the TABLE FOR ORDER OF

A02 (M IC13)
6 Press.sensor Power
(24V)
7 GNO
Pressure sensor
(risht swing) A37 (X3)
GND
24V
Press. sensor SIG
TKP00847
20-684
0
TROUBLESHOOTING A-8
Cause Remedy
5 YES Already reset

At swingRIGHTrelief,
is GX monitoring
d36
- display(swingRIGHT -
reliefpressure)
normal?
NO
(female) (3) - AO5(12) - AO: harness
(female) (12)
A37 (fern&)(31 - A05(12) -
Replace wiring
harness
ground
(4)

sensor
20-685
0
TROUBLESHOOTING A-9
A-9 E6:04 (GX panel 043, 044) [Abnormality in swing (LEFT) pressure
Ir If [E6:011 - [E6:031 are displayed at the same time, go to Troubleshooting A-l.
+ The error code displayed on the HYPER monitor or GX panel does not go out until the starting

% GX panel error display mode
YES
4
_ Is voltage
YES between A03 (13)
and A02 (7)
3
~ normal?
Is resistance
When GX panel displays 044 between A38 * Min. 0.5V
I GX panel error display mode ffemale)(3) - (1). (3) *Turn starting NO
YE -chassis normal7 switch ON.
between A38 (2)
and (1) normal? * Min. 1 MR
-Turn starting
*18-28V NO
switch OFF.
* Turn starting * Disconnect A38,
NO
%After
interhanging
sensors
* Turn starting 0
switch ON.
I HYPER monitor
Service code
display mode
A02 (MICl3)

(24V)
1 GND
A A
Pressure sensor (24V)
(left swine) A35 (X3) A0 5 (SWP 14) 13 GND
GND
24V A03 (04020)
13 Press. sensor SIG
TKP00848
20-686
0
TROUBLESHOOTING A-9

1AtswingLEFT relief, is 11 I See Note in Contents. I
GX mkitoring d37
- display (swingLEFT -
relief pressure)
normal? Replace
NO
(female) (3) - A05(13) - A03 harness
(female) (13)
A38 (femaleM3) - A05(13) -
Replace wiring
ground
Defective contact. or
Replace wiring
harness
/ F;kf;tp pressure Rep,ace
20-687
0
TROUBLESHOOTING A-10
A-10 E6:06 (GX panel 061, 063) [Abnormality in clinometer input

value] is displayed
* If [E6:231 is displayed at the same time, go to Troubleshooting A-24.
YES
YES Is voltage
- between A24 (2) -
and (3) normal?
3
Is resistance * 2.5 - 3.5V

ES_ between A24
- (chassis
(female) (2) - (3). (2) horizontal) NO
-chassis normal?
-Turn starting
* Min. 1 MR switch ON.
E6:23 displayed * Turn starting

switch OFF. NO
alone A24(female) (1)
* Disconnect A24,
AOI. and A03.
* 11.5 - 12.5V 7 YES
*Turn starting Is voltage
switch ON. between A01 (9),
displayed at same NO (17) -(l), (10)
normal?
NO
E6 :23 also displayed

at same time

A01 (MICl7)
1 GND
A04 (SWPI 6) 10 GND
I I 9 Sensor Power (IZV)

2 17 Sensor Power (12V)
Clinometer A24 (X3) A05 (SWPl4)
12v 1 I A03 (04020)
SIG 2 2 Clinometer SIG

I \ I
GND 3 3
TKP00849
20-688
0
Cause Remedy

lis GX monitoring
YE _ d26 display
5 klinometer gauge
voltaae) normal?
1 Defective GX controller Replace
between A03 - * 500 - 700 (unit: 5mV) NO
(chassis horizontal)
-Turn starting switch ON. Defective contact, or
% GX monitoring mode disconnection in wiring
Replace wiring
l 2.5 - 3.5v harness between A24
Nl harness
(chassis (female) (2) - AO5(2) - A03
horizontal) (female) (4)
* Turn starting
switch ON.
Defective clinometer Replace

A24lfemale) (2) - A05 (2) -
A03 (female) (4) short Replace wiring
ground
(female) (I), (3) - A05 (1).
(3) - A01 (female) (9). ( 17).
(1). (10)
Go to Troubleshooting -
A-24 (GX panel 235)
20-689
0
A-II E6:07 and E6:08 [Abnormality in potentiometer power source]

are displayed at the same time
Remedy

Is voltage
7” between A21 (6) _ Defective contact, or
- and (7) normal? disconnection in wiring
YES Is voltage
(female) (II( (IOh20) - harness
- between A03(1) - * 4.8 - 6.2V NO
* Turn starting A04fIOI,fll)-All
and (IO) normal?
switch ON. (femaleI(llI, (15)
*4 8 - 5.2V
1
* :I urnstarting NO
Is resistance switch ON.
between A03
(female)(l) - (IO). (1)
-chassis normal? 5 YES A03 (female) (IHllI - A04
Replace wiring
(IO) -AI I (female) (14)
Is resistance harness
l Min. 1 MR short circuiting with
* Turn starting
YES between Al 9 chassis ground
4 (male)(b) and (7)
switch OFF.
normal? Defective arm
* Disconnect A03. Is resistance Replace
_ between A21 *Min. I kR NO potentiometer
NO fmaleh6) and (7) * Turn starting
normal? switch OFF.
* Disconnect Al9.
* Min. 1 kR Defective boom
* Turn starting Replace
NO potentiometer
switch OFF.
* Disconnect A21.
% When the GX controller or boom, arm angle sensor assembly have been replaced, carry out the
operation in the TABLE FOR ORDER OF OPERATIONS IN GX ADJUSTMENT MODE.
A-II Related electric circuit diagram
Boom potentiometer A2 I (SWPB)
5v
GND
SIG
Arm Potentiometer Al 9 (SWP6) Al 1 (SWPI 6) A04 (SWP16) A03 (04020)
5v 6 14 IO I Potentio dower &VI
GND g @$ a- 3 Boom SIG
SIG . a I6 12 2 Arm SIG
16 - 11 Potent io power (5V)
0 10 GND
20 GND
TKP00850
20-690
0
A-12 E6:07 (GX panel 071, 072) [Abnormality in boom potentiometer

system] is displayed
* If [E6:081 is displayed at the same time, go to Troubleshooting A-II.
* Check that there is no play or deformation in the sensor mount or linkage.
* If the display of monitoring mode dll (boom potentiometer voltage) on the GX panel changes to
more than “40” when the boom is operated, the potentiometer mount is defective (loose mount,
play, etc.)
% Carry out the troubleshooting in this flow chart only if the above change has not occurred.
5 YES
Dpes voltage
YES between A03 (3) -
- (10)(20) match
GX monitoring
4 display dll?
When GX panel .%GX monitoring NO
YI
i Is voltage
mode.
. between A03 (3) - -
% GX panel error * Operate boom.
(10)(20) normal?
YE 6 YES
* 0.25 - 4.75V Is resistance
*Turn starting between A03
switch ON. N6 (femalej(3) - (10) -
* Start engine and (20) normal?
display mode
operate boom. * Min. 10 R NO
l Min. 1 MR Max. 10 kR
* Turn starting - Turn starting
switch OFF.
switch OFF.
* Disconnect A03.
* Disconnect A21
between A21 (6) IO
and A03.
Iand (7)normal?
I
* 4.8 - 5.2V 7 YES
* Turn starting
When GX panel Is voltage
1 switch ON.
displays 071 between A03( 11,
Isresistance (11) - (IO), (20) -
between A2 1 normal?
Imale)i6) - (7), (61- I
(8), (8) - (7) normal? - 4.8 - 5.2V NO
*Turn starting
L
* Min. 10 C2 When GX panel switch ON.
Max. 10 kQ displays 072
* Turn starting z GX panel error
switch OFF. display mode
* Disconnect A21.
A A03 (04020)
Boom potentiometer A21 (sWP8) A04 (SWP 16) Potent io Power &VI
5V Potent io Power &VI
GND Boom SIG
SIC IO CND
@ \GND
TKP00851
20-692
0
Remedy
-
E See Note in Contents.
(female) (8) - A04 (16) - harness
A03 (female) (3)
A21 (female) (8) - A04 (16) Replace wiring
- A03 (female) (3) short harness
ground
Defective contact, or Replace wiring
disconnection inwiring
harness
harness between A21
(female) (7) and A04
(male)(ll)
I disconnection in wirina Replace wiring
harness
(maleMl0)
Defective boom
potentiometer or Replace
defective mount
20-693
a
A-13 E6:08 (GX panel 081, 082) [Abnormality in arm potentiometer

system] is -displayed
+ If [E6:071 is displayed at the same time, go to Troubleshooting A-11.
* Check that there is no play or deformation in the sensor mount or linkage.
* If the display of monitoring mode d16 (arm potentiometer voltage) on the GX panel changes to
more than “40” when the arm is operated, the potentiometer mount is defective (loose mount,
play, etc.)
c% Carry out the troubleshooting in this flow chart only if the above change has not occurred.
5 YES
.,4-u-
When GX panel .%GX monitoring

displays 081 mode.
r x GX oanel error * Operate arm.
dispiay mode normal? 6 YES
3
* 0.25 - 4.75V
IL When GX panel
displays 082
% GX panel error (female)W - (7). (8)
*Turn starting
switch ON.
* Start engine and
display mode -chassis normal?
operate arm. . Min. 10 Cl NO
* Min. 1 MR Max. 10 kQ
. Turn starting switch
* Turn starting
OFF.
switch OFF. . Disconnect A03.
between A19 (6) * Disconnect A19 .^
NU
and (7) normal? and A03.
7 YES
Is voltage
between A03t 1).
(II)-(10).(20) -
normal?
* 4.8 - 5.2 V NO
I I NO * Turn starting
* Min. 10 R
Max. 10 kR
* Turn starting
switch OFF.
1 When GX panel
displays 082
.%GX panel error
display mode
switch ON.
* Disconnect A19.
NW
I 1
A03 (04020)
Arm potentiometer Al 9 (SWPB) Al 1 (SWPI 6) A04 (SWP I 6) Potent io Power (5V)
5v Potent io Power (5V)
GND Arm SIG
SIG GND
GND
TKP00852
20-694
0
x When the GX controller has been replaced, carry out the operation in the TABLE FOR ORDER OF
rAlready
% See
Cause
reset
Note in Contents.
Remedy
harness between A19 3eplace wiring
(female) (8) -All (16) - 7arness
A04 (12) - A03 (female) (2)
Wiring harness between A19
(femaleH8) - Al 1 (16) - A04
3eplace wiring
(12) - A03 (female) (21 short
larness
ground
disconnection in wiring 3eplace wiring
harness between A19 narness
(female) (7) -Al l(15) -
A04 h-nale)(l I)

(female) (6) -Al l(14) - AO,
(maieKl0)
Defective arm
Replace
potentiometer
20-695
0
A-14 E6:ll (GX panel 111, 112) [Abnormality in boom variable angle]
is displayed
If [E6:141 may or may not be displayed at the same time, but even if it is displayed at the same
time, carry out the troubleshooting according to the flow chart on this page first.
The error code displayed on the HYPER monitor or GX panel does not go out until the starting
ES
YES
L+ld
YES
NO
YES
*I
Is voltage
between A01 (I 1)
- (l)(lO) normal?
* 11.5- 12.5V
l Boom at end of
stroke.
* Turn starting
switch ON. NO
*When boom is
being actuated.
YES
?/
between A21 (I)
I
* 11.5- 12.5V
mode: d01, d02
* Turn starting
switch ON.
NO
20-696
0
% When the GX controller or boom angle sensor assembly has been replaced, carry out the opera-
tion in the TABLE FOR ORDER OF OPERATIONS IN GX ADJUSTMENT MODE.
Cause Remedy
Defective GX controller Correct or

replace
Go to Troubleshooting
A-24
A-10
A-12
for appropriate code No.
9 YES Go back to Item 1 and

Is GX monitoring start troubleshooting
display d13 (error again
- from stroke end of -
encoder angle) Correct again
normal? Defective correction, or
Check mount
defective sensor mount
* Start engine and NO again
ooerate boom.
11 YES Replace wiring
harness between A21
harness
Is voltage (female) (5) - A04 (15) -
YEx between A21 (5) - A01 (female) (I 1)
~ 10 and (2) normal?
Is resistance Defective encoder Replace
betweenA01 _ % Same conditions NO
(female) (I I) and as in item 8. Wiring harness between
chassis normal?
A21 (femaleH5) - A04
. Min. 1 MR (15) -A01 (female) (11) Replace wiring
* Turn starting NO short circuiting with harness
switch OFF. chassis ground
* Disconnect A01 Defective contact, or
and A21. disconnection in wiring
YES Replace wiring
13 harness between A21 harness
Is voltage (female) (3)(4) - A04 (13)
between A21 (3) - (14) -AOlffemale) (12)(3)
(2), (4) - (2) 14 YES
normal? Defective encoder Replace
_ Is resistancebetween
.%Same conditions _ A01 (female)(12)- _ Wiring harness between
as in Item 7. NO chassis,(3) -chassis. A21 tfemale)(3)(4) - A04
(11) -chassis normal?
(13)(14) -A01 (female) Replace wiring
NO (12)(3) short circuiting with harness
* Min. 1 MR
chassis ground
*Turn starting switch OFF.
* Disconnect A21 and AOl. Defective contact, or
(male) (1)
Earry out
Defective encoder
jetting again
20-697
0
A-15 E6:12 (GX panel 121, 122) [Abnormality in arm variable angle] is
displayed
+ If IE6:151 may or may not be displayed at the same time, but even if it is displayed at the same
time, carry out the troubleshooting according to the flow chart on this page first.
Is E6:23
displayed at YES
same time? 4
I
Is E6:06
I\ j displayed at 5 YES
same time?
- Is E6:08
i displayed at
NO same time?
NO
YES
other than E6:15

displayed at same
switch ON. NO
7
fl)flO) normal?
*When boom is
being actuated.
YES
attachment
between A19 (1)
* GX panel
monitoring
mode: dol. d02
NO
NO
20-698
0
% When the GX controller or arm angle sensor assembly has been replaced, carry out the operation
in the TABLE FOR ORDER OF OPERATIONS IN GX ADJUSTMENT MODE.
Cause Remedy
Defective linkager Correct or

replace
A-24
A-IO
A-13
for appropriate code No.
9 YES Go back to Item 1 and

start troubleshooting
Is GX monitoring
again
display d18 (error
- from stroke end of -
encoder angle)
* Correct again
normal? Defective correction or
defective sensor mount
* Check mount
* Start engine and NO again
operate arm.
harness between A19
harness
YES Is voltage (female) (5) -Al 1 (13) -
-between A19t5) - A04(9) -AOl(female) (131
IO
~ and (2) normal?
Is resistance Replace
Defective encoder
_ batwean AOl(13) _ z Same conditions NO
and chassis as in item 8.
normal? Wiring harness between
A19 (female) (5) -Al 1 (13)
* Min. 1 MD - A04(9) -A01 (female) (13 Replace wiring
* Turn starting NO short circuiting with harness
switch OFF. chassis ground
* Disconnect A01 Defective contact, or
and A21. YES disconnection in wiring Replace wiring
13 harness between A19
harness
(female1 (3)(4)-All (11)
Is voltage
(12) -A04 (8) - AOl(female
between A19(3) -
(14)(6)
(21, (4) - (2) 14 YES
Defective encoder Replace
Is resistance between
A01 (female) (141 - Wiring harness between
.x- Same conditions chassis,(3) -chassis, - A19 (female) (3)(4) -Al 1
as in Item 7. No (ll)-chassis fllH12) - A04(7)(8) - A01
normal? Replace wiring
(femaleNl4)(6) short
* Min. 1 MR NO circuiting with chassis harness
. Turn starting switch OFF. ground
- Disconnect A19 and AOI. Defective contact, or
(female) (1) -Al l(9) -
A04 (male) (1)
Carry out
Defective setting
setting again
20499
0
A-14, 15 Related electrical circuit diagram
Arm encoder Al9 (SWP8) All (SWP16) A04 (SWP 161 A01 (p 17)
-
12V
Boom encoder A21 (SWPB)

I I I
I Arm encoder
I4-----l+
GND
II 12v
GND
I
A
I
B B Boom encoder
I
TKP00653
20-700
0
A-16 E6:13 (GX panel 131, 132) [Abnormality in bucket variable angle]
is displayed
Cause Remedy
YES Go to Troubleshooting -
.l ,
L A-24
YE
r-l
Is E6:23
displayed at
same time?
3 YES Go to Troubleshooting
A-10
-
I I I Go to Troubleshooting -
NO for appropriate code No.
code displayed at 6 YES Skipped reading of -

same time as stroke sensor pulse
Is voltage
YES between A01 (8) - _ Defective contact, or
5 (IL (16) - (1) disconnection in wiring
Is voltage normal? harness between A01 Replace wiring
YE between Al8 (3) - _ k Same conditionsNO (female) (8) - A04 (4) -Al 1 harness
(2). and between (4) or A01 (female) (16) -
tl
as in Item 5.
(4) - (2) normal? A04(3)-AllB-Al8
(female) (3)
*6+2V Defective stroke sensor Replace
*When operating NO
at constant speed Defective contact, or
within variable disconnection in wiring
* 11.5- 12.5V angle for bucket. harness between A01 Replace wiring
*Turn starting (female) (l)(lO) -A04 (2) -
harness
switch ON. Al 1 (2) - A18 (female) (2).
(9)(17)-A04(1)-All (l)-
A18 (female) (1)
A-16 Related electrical circuit diagram
Stroke sensor Al 8 (SWPG) Al 1 (SWPI 6) A04 (SWP 1 6)
12V I 1 I A01 (MIC17)
CND 2 -2 2 CNO
1
TKP00854
A-17 E6:14 (GX panel 141) [Abnormality in comparison of two boom

sensor signals] is displayed _
Cause Remedy
1 YES Go to A-12 Boom -

protentiometer system
Is E6:07
displayed at
same time?
Go to A-14 Boom -
NO varianle angle system
zs
&
% When the GX controller has been replaced, carry out the operation in the TABLE FOR ORDER OF :
20-702
0
A-18 E6:15 (GX panel 151) [Abnormality in comparison of two arm

sensor signals] is displayed _
Cause Remedy
1 YES Go to A-13 Arm -

potentiometer system
Is E6:08
displayed at
same time?
Go to A-15 Arm varianle -
NO angle system
g
>
% 3% When the GX controller has been replaced, carry out the operation in the TABLE FOR ORDER OF
20-703
0
A-19 E6:16 (GX panel 163) [No change in signal when work equipment
should move1 is displayed
* When only E6:16 is displayed. (If E6:23 is displayed at the same time, go to Troubleshooting A-24.)
Remedy
Replace
YES
‘II
Is voltage
normal?
x Same conditions
I
NO
harness between
(female) (16H8) -
A01
A04
Replace wiring
harness
(3)(4) - Al 1 (3)(4) - Al8
r- between A18 (3). - as in Item 2.
(female)
(4) - (2) normal?
4 YES
Defective stroke sensor Replace
* Operate bucket Is resistance
cylinder between Al8
between CURL NO (female) (3)(4) -
and DUMP. chassis normal?
* Min. 10 R NO (female) (16)(S) - A04 (3)(4) - harness
* Turn starting Al l(3)(4) - A18 (female)W(4)
switch OFF.
-
r
(female) (9)(17) - A04 (1) harness
Only E&16 is Al 1 (1) - A18 (female) (I)
displayed Defective contact, or
r
Replace wiring
harness between A01
*11.5-12.5V (female) rllf10) -A04 (2) - harness
* Turn starting , All (2) - A18 (female) (2)
NO switch ON. Defective contact, or
f disconnection in wiring Replace wiring
(female) (9)(17), fl)(lOl -A04
(female) (1). (2)
* Turn starting
switch OFF.
- Disconnect A01
and A04.
Stroke sensor Al6 (SWPGI Al 1 (SWPI 6) A04 (SWP16)
12v I I I = A01 (MIC17)
CND 2 .2 2 1 GND
A 3 3 3 8 Stroke sensor B
A
a @ 3 @ -& 12v
- IO GND
A05 (SWPl4) I6 Stroke sensor A
l- - 17 12v
3-
TKP00855
20-704
0
TROUBLESHOOTING A-20, A-21
A-20 E6:17 (GX panel 171, 172) [Cutting edge position out of range] is
displayed
Cause Remedy
Abnormality in internal calculation Replace GX controller
A-21 E6:18 (GX panel 181, 182) [Abnormality in data ROM] is

displayed
Cause Remedy
Abnormality in data ROM Replace GX controller
20-705
0
A-22 E6:21 (GX panel 211, 212, 213, 214) [Abnormality in engine pick-
up] is displayed
* Before carrying out troubleshooting, check that all the related connectors
are properly inserted.
* E4:02 may also be displayed at the same time.
4 YES
(Model selection 3) 2
GX panel
- displays 211 or * Turn starting
NO
212 switch ON.
* Max. 0.5V
* Turn starting
switch ON. NO
(GX panel) 5 YES

Is dispay given
GX panel when starting
- displays 213 switch is turned
displayed on GX
on again?
I Operate the NO
starting switch
without touching
the GX panel. YES
7
Is voltage
YES between K09 (3)
and chassis 6 YES
normal?
(Knob switch) 6 ~ Is resistance
Is dispay given * L& knob switch between K07
ON: 18 - 28V NO (male)(g) and (10)
GX panel when starting
: - OFF:Max. 1V normal?
displays 214 switch is turned
* Turn starting
on again? switch ON. * Left knob switch NO
ON: Max. 1 R
% Operate the
OFF: Min. 1 MQ
starting switch
. Turn starting switch OFF.
without touching
the left knob NO * Discnnect K07
switch.
% When the GX controller has been replaced or the model has been set (GX controller non-volatile
memory), carry out the operation in the TABLE FOR ORDER OF OPERATIONS IN GX ADJUST-
MENT MODE.
20-706
0
Cause Remedy
Defective GX controller I Replace

A09 (16) and A40 (male)
Replace wiring
(13) short circuiting with
harness
chassis ground
Abnormality in wiring
harness between A09 (8) Replace wiring
- A39 (8) - K06 (female) harness
(9)
Defective GX panel Replace

I
Replace wiring
harness
Replace
20-707
0
EPC valve
CDtltrOllEZr K06(04016) KOl (S16) CO9 (S8)
:1
3
GX controller AO9(04016)
A40 (Sl6)
TKP00856
Knob switch
K07 M22 H13 Al0 A31
(M2) (SlGBlue) (S12) (S16) A09 (04016)
TKP00857
20-708
0
A-23 E6:22 (GX panel 221) [Change in wiring harness after engine
picks up] is displayed
(GX panel 222) [Automatic operation disconnection switch
signal does not match in valve controller
and GX controller] is displayed
(GX panel 223) [Abnormality in controller power source] is
displayed
* If the display goes out when the starting switch is turned on again, the system has been reset.
YES
2
Was GX automatic
GX panel operation
-displays 221 disconnection 3 YES E&21 (GX panel 211)
switch operated? is displayed
~ What code is
_ displayed when
NO starting switch is
turned on again? E&22 (GX panel 222)
NO is displayed
YES
5
1 Does voltage
YI ; between K06 (I 1 -
IWhat code is
displayed on GX
4
K04(4) match
condition of switch? P
Is resistance
between terminals
6 YES
~
% Same
- of disconnection -
GX panel conditions as in NO switch as shown
displays 222 Item 4. in Table l?
*Check switch as NO
individual part.
* Operation
. Turn starting
position: MAX.lV
switch OFF.
* Disconnection
position: 18 - 28V JO
* Turn starting
switch ON.
GX panel Is E3:15 dispayed

-displays 223 at same time ? a YES
- Is voltage
- between A09 (11) _
NO and (2) normal?
I I I
*20-30V NC-I
* Turn starting
Table 1 switch ON.
Operation Disconnection
Terminal
position position
Between
Max. 1 Q Min. 1 MR
(1) - (3)
Between
Max. 1 R Min. 1 MR
(4) - (6)
20-710
0
Cause Remedy
Mistaken operation of Operate with

GX automatic operation starting switch
disconnection switch OFF
A-22
I Defective contact, or
I
switch
Defective contact, or I
Replace wiring
harness between A09
harness
(female) (15) - A41 (3) -
switch terminal (4)
E-9
Replace wiring
harness between A09
harness
(female) (11) - A39 (7) -
KOl (fernale)
20-711
0
CX controller
GX controller A02 (MIC :13)
disconnection switch I
1 GND
- 8 GND
- I
A39 (SIO)
A09
(040____I
16)
GND
Model selection 3
Starting switch signal
Option controller
:
t 1 Valve controller
K01 (Sl6) )I 6)
3- Option controller
I1 - Starting switch ON
Starting switch
X07 (MlC17) H13 (Sl6Blue) Model selection 3
Starting snitch signal
Battery relay K04 (MICS
Q BR
A40 (S 16)
Radio-control harness
TKP00858
20-712
0
A-24 E6:23 (GX panel 231) [Abnormality in remote sirrnall is disr>layed

(GX panel 235) [Abnormality in 12V pow& source m
(overcurrent detection)] is displayed
(GX panel 2361 [Abnormality in 24V power source
(overcurrent detection)] is displayed
* Turn the starting switch OFF before disconnecting the connector.
sr The error code displayed on the HYPER monitor or GX panel does not go out until the starting
2 YES
Is resistance
3X panel between A02
displays 231 (fernale) and
chassis normal?
* Min. 1 MR NO
* Turn starting
switch OFF.
* Disconnect A02
and K06.
3
3X panel ‘FS
displays 235 disconnect one
connector at a time.
12V power
Does E&23 display
iource system)
* Turn starting
switch ON.
displayed on GX % There are 4 YES
connectors 6--
YES Is E6:23 go out

* Turn starting - when Al 1 is
switch ON. removed ?
5’
* Turn starting
Is E6:23 go out switch ON. NO
- when A04 is
I removed ?
8 YES
* Turn starting Is resistance r
switch ON. between A01 (9)(17)
.N~ -(l)(lOl, and
between (9)(171-
chassis normal?
. Min. 10 R NO
OFF.
GX panel a Disconnect AOl,
displays 236
124V power
source system)
20-714
0
Cause Remedy
Defective GX controlier Replace

A02 (fernale) - A39
(2) - K06 (fernale) qeplace sense
short circuiting with assembly
chassis ground
Defective sensor where Teplace wiring

display goes out. iarness

A05 (male)(l) and A24
<eplace wiring
(female)(l) short circuiting
larness
with chassis ground

A19 (female)(l)-All (1) -
7 YES qeplace wiring
A04(femalehl) short
Is resistance larness
between Al8 circuiting with chassis
- (female) (1) - (2). - ground
and behveen (1) - Wiring harness between
chassis normal? Al8 (female)(l)-All(g)- qeplace wiring
* Min. 1 MR NO A04 (male)(l) short iarness
* Turn starting circuiting with chassis
switch OFF.
* Disconnect Al8 and All.
A21 (female)(l) and A04 qeplace wiring
(male)(l) short circuiting larness
with chassis ground
Defective GX controller ?eplace

A01 ffemale)f9)(17) and Replace wirin!
A05 (female)(l) short harness
ground
Start troubleshooting -
from A-l Item 5
20-715
0

GXcontroller
EPC valve controller A39 (SIO) A02 (MICl3)
K06 (04016)
@ Remote
Permission
TKP00859
Bucket stroke A18 Al 1

sensor (SWPG) (SWPl 6)
TKP00660
A25 1x3)
A02 (MIC131
A05(SWP14) Press.sensor Dower 124V)
A36 (X3)
TKP00840
20-716
0
A-25 E6:24 (GX panel 241) [Abnormality in buzzer drive System] is

displayed
* This is the same system as the El:03 display, but displays the side which first drives the buzzer
when the abnormality occurs.
Cause Remedy
2 YES Defective HYPER monitor

Replace
Is voltage or GX panel
YES between ~04 (2) Contact of 24V wiring
1 harness with wiring harness
and chassis
between PO1 Ifemale) (13) -
Is resistance normal?
PO4 (femle) (2). or between Replace wiring
between PO4 Imale) / i
* Turn starting NO A06 (female) (3) - A10 (9) - harness
(ll- (2). and between -
(21-chassis as switch ON. PO1 (female) (13). or contact
shown in Table 17 * Buzzer ON: Max.lV of wiring harness between
PO4 (1) and (21
* Buzzer OFF: 20 - 30V
Defective buzzer
NO % Operate the HYPER monitor and GX panel.
Table 1
I PO4 (male) Resistance value
Between (I)- (2) 200 - 300R
Between (2) -chassis Min. 1 MR
HYPER monitor
_-__-__-__
PO4 (M
1
DTl
I Warning buzzer 7
L_________--_-_J
A06 (04016) A10 (S12) 1

GX panel
TKP00661
20-717
0
A-26 E6:25 (GX panel 251, 252) [Impossible to receive network (S-NET)
signal] is displayed
YES
% Short circuit
,s,-
1 YE
Yl
* Connectors POZ, mode 08 all light
C03, A06, A09. * Min. 1 MR
* After removing NO
* After inserting * Turn starting switch OFF.
* Turn starting connectors, turn
connectors again, * Disconnect P02, EOl, C03, K05,
turn starting switch ON. starting switch
% HYPER ON. A06, and A07.
switch ON.
2 monitoring IO
mode
mode displays 02 -
N 7 YES
Is voltage
* Turn starting YI between CO1
switch ON. (lO)(ll) -(l)(2)
% HYPER normal?
monitoring *20-30V NO
mode * Turn starting
6 switch ON.
ES
* Turn starting
switch ON.
% HYPER
monitoring I Disconnection 8
Monitoring display (time display portion) mode
/Doesmonitoring
YES
t
I I
(11 Pumpcontrollerconnected * Turn starting
switch ON.
* HYPER
monitorring
mode
I Monitoring display I
I 02 I Pump controller model display
03 Governorcontrollermodel display
t 04 Valve controller model display
% With the 04 model display, if the GX automatic operation disconnection switch is at the automatic
operation position, the last digit will change to [El.
Example: PC200GX is displayed as 20E.
20-718
0
I Cause Remedy
Defective connection of -
connector
Defective controller
where voltage became
Replace
normal when connector
was disconnected
Defective HYPER monito Replace
Short circuit with chassis

ground at some point
with network (+) wiring Replace wiring
harness harness
% See network circuit
diagram
Defective HYPER monito, Replace
Defective pump
Replace
controller
. Blown fuse 1 - Replace fuse

* Defective contact, or mReplace wiriq
harness
harness between fuse 1
and CO1 (female) (lO)(ll)
harness between PO2 harness
(female) (7) - KOl (5)(g) -
K05 (female) (3)(4)
12 YES
Defective GX controller qeplace
Is voltage
S between A02 * Blown fuse 11 5Replace fuse
(Z)(9) -(t)(8) - Defective contact, or *Replace wiring
normal? disconnection in wiring harness
*20-30V NO harness between A02
* Turn starting (female) (2)(g) - A31 (5)
switch ON. - A10 (7) - fuse 11
Defective GX panel qeplace
* Blown fuse 11 Replace fuse

- Defective contact, or Replace wiring
disconnection in wiring harness
harness between A06
.20-30V NO (fern&l (ll(2) - A10 (7) -
. Turn starting fuse 11
switch ON. Defective contact, or
disconnection in wiring 3eplace wiring
harness between A6 (female: larness
W(7) and A10 (female) (l)(2)
3eplace wiring
harness between PO2
(female) (71 -AlO (l)(2) -
larness
A31(1)(2) -AOS(female)
(5N13)
20-719
0
A-26 E6:25 (GX panel 253) [Impossible to receive network (HS-NET)

signal] is displayed
YES
5 YES
[Is voltage
Does E6:25 go out YE4 betwe&K06

after connector is
* Connectors A09, YEiS

K05. (l)(2) - (llH12)
+ After inserting switch ON.
connectors
again, turn
starting switch
* Turn starting I
switch ON. NO
ON.
YES
R
*4-8V
* Turn starting
switch ON.
(female) (6)(141 -
*Min. 1 MR + Turn starting

* Turn starting switch ON.
switch OFF.
* Disconnect NO
A09 and K05.
?% When the GX controller has been replaced, carry out the operation in the TABLE FOR ORDER OF
20-720
0
I Cause Remedy
Defective connection of -
connector
Defective valve controller Replace
* Blowfuse 12
* Defective contact, or
harness between K04 Replace wiring
(female) H9l- KOl (7) - harness
fuse 12
harness between K06
harness
(femaleM4)(12) - KOl (11) -
X07 (femaleH2)
(femaleN6N14) - A39 (3)(4) -
K05 (female) (l)(2)
Defective valve controller qeplace
Defective GX controller qeplace
* Blow fuse 11
. Defective contact, or
harness between A02 Seplace wiring
(female) (2)(9) - A31 (5) - ttarness
A10 (7) -fuse 11
Wiring between
harness
A09 (female) (6K14) - A39
(3)(4) - K05 (female) (l)(2)
short circuiting with
chassis ground
20-721
0
tiXcontroller
GX Panel A06 (04016) A31 (5161 A09 (0 16)
I
(+I
(+) S-NET
1
(GND) J
Valve controller
1
K05 (04020)
(t)
(+I HS-NET
(GND)J
S-NET
HS-NET Engine throttle,

Pump controller
Cl7 (04016)
TKP00862
tuse
12
11
Pump controller CO1 (MICl3) Al0 (S12) A31 (S16) A02(MIC13) GX controller
1 5 2 24V
“y’ ’ $/I61 i:iGXDanej
TKP00863
20-722
0
A-27 E6:26 (GX panel 261, 262, 263, 264) [Abnormality in non-volatile
memory data range] is displayed
% Displayed when the GX controller is replaced and the starting switch is turned ON.
Cause Remedy
GX panel Defective model,

Set again
-displays 261 attachment setting
I GX monitor
code dol. d02
* Model PC200:
GX panel 200. Defective correction of
Correct again
-displays 262 * Clinometer sensor
* Boom sensor,
arm sensor
* Bucket sensor
GX panel Check EPC Defective correction of

Correct again
-displays 263 current value EPC current value
I I
I GX monitor code
d70 - d76
GX panel Defective input of

Input again
-displays 264 dimensions of bucket
20-723
0
TROUBLESHOOTING A-20, A-29
A-28 E6:27 [Non-volatile read error] is displayed
% Displayed when the GX controller is replaced and the starting switch is turned ON.
1 When displayed in any other case, the GX controller is defective.
A-29 E6:28 [Non-volatile write error] is displayed
a) If the GX panel displays 281, 282, or 283, the GX controller is defective.

$
b) If the GX panel displays 284 k
% This display is given if an attempt is made to write the wrong data when correcting the sensor. z
20-724
0
A-30 Buzzer does not sound (when there is no abnormal display)

f When the HYPER monitor and GX panel light up normally.
t Before carrying out troubleshooting, check that all the related connectors are properly inserted.
f Always connect any disconnected connectors before going on the next step.
Cause Remedy
4YES
Defective GX panel Beplace
dr
YES
sound when
attempt is made
Is voltage Already reset -
YES between PO6 (3) z See Note in Contents.
and chassis panel.
- normal?
Is voltage qeplace wiring
.20-30V qarness between A06
YES_ between P04 (2) _ larness
* Turn starting NO Ifemale) (3) - A10 (7) -
and chassis
1 switch ON. fuse 11
normal?
Is voltage *20-30V
between PO4 (1) Defective buzzer Replace
- l Turn starting
and chassis NO
switch ON.
normal?
.20-30V disconnection in wiring Replace wiring
l Turn starting harness between fuse13 harness
switch ON. NO
and PO4 (female) (1)
HYPER monitor
_-__-.---- Warnine buzzer
ower source
TKP00861
20-725
0
A-31 Automatic mode is not actuated when knob switch is pressed

(when there is no abnormal dipslay)
Cause Remedy
3 YES
Is voltage
YES between A09 (3) Defective contact, or
2 and chassis disconnection in wiring
normal? harness between K07 Replace wiring
Is voltage (female) (9) - M22 (2) - HO1
YIES between K07 (9) harness
!
_ * Same NO (16)-AlO(A31(7)-
and chassis conditions as in A09 (female) (3)
normal? Item 2.
Contact of 24V line with
1 * Switch ON: _24V even when wiring harness between Replace wiring
18-28V switch is OFF K07 (female) (9) - M22 (2) - harness
* Switch OFF: HO1 (16)-AlO(A31
between K07 (IO)
Max. 1V NO (7) - A09 (female) (3)
Less than IV when
Defective knob switch Replace
switch is ON
*18-28V
l Turn starting * Blown fuse 5 * Replace fuse
switch ON. l Defective contact, or - Replace wiring
disconnection in wiring harness
NO harness between K07
(female) (IO) - M22 (1) -
HO4 (16) - fuse 5
% Precautions when operating knob switch

1) It must be double clicked for it be actuated. (Keep the switch depressed after double clicking it.)
2) It does not work when the work equipment has reached the end of its stroke.
3) The double click operation of the knob switch does not work when the boom, arm, bucket, or
swing levers are being operated.
Knob switch K07 M22 HI3 A10 A3 1

(SIO) (M2) (SlGBlue) (Sl2) (S 16) A09 (040 16)
Knob switch sional
HI2 (SlGwhite)
TKP00864
20-726
0
TROUBLESHOOTING OF VALVE CONTROLLER
SYSTEM (K MODE)
* This troubleshooting applies only to HYPER GX mode.
Points to remember when troubleshooting pump controller system ............................................. .20-753

Action taken by controller when abnormality occurs and problems on machine.. ....................... 20-754
Judgement table for valve controller system ..................................................................................... 20-772
Electrical circuit diagram of valve controller system ........................................................................ .20-774
K- 1 [LED OFF] Controller power source system ........................................................................ .20-775
K- 2 [E4:021 L.H. knob switch OFF system is displayed ............................................................. .20-776
K- 3 [E4:071 Abnormality in model code input is displayed ....................................................... 20-777
K- 4 [E4:51] Abnormality in S-NET communications is displayed.. ........................................... 20-778
1. Disconnection related ...................................................................................................... 20-778
2. Short circuit related ......................................................................................................... 20-780
K- 5 [E4:561 Abnormality in teaching, playback RAM data is displayed .................................. .20-780
K- 6 [E4:571 Abnormality in knob switch is displayed ............................................................... .20-781
K- 7 [E4:011 Abnormality in control lever neutral system is displayed.. .................................. .20-782
K- 8 [E4:041 Abnormality in control lever potentiometer power source system
is displayed ................................................................................................................. 20-784
K- 9 IE4:lll Short circuit in EPC relay 1 drive power source system is displayed ................. 20-785
K-10 [E4:121 Contact between chassis power source and EPC relay 1 drive power
source system is displayed ....................................................................................... 20-786
8 K-II [E4:131 Short circuit in EPC relay 2 drive power source system is displayed ................. 20-787
t K-12 [E4:141 Contact between chassis power source and EPC relay 2 drive
% power source system is displayed ........................................................................... 20-788
K-13 [E4:151 Disconnection in EPC relay 1, 2 solenoid power source system
is displayed ................................................................................................................. 20-789
K-14 [E4:16] EPC relay 1 points melted or short circuit in solenoid power source
system is displayed
[E4:171 EPC relay 2 points melted or short circuit in solenoid power source
system is displayed.. .................................................................................................. 20-791
1) When E4:16 is displayed independently.. ...................................................................... 20-791
2) When E4:16, E4:17 are displayed simultaneously ........................................................ 20-791
K-15 [E4:171 EPC relay 2 points melted or short circuit in solenoid power source
system is displayed
[E4:161 EPC relay 1 points melted or short circuit in solenoid power source
system is displayed .................................................................................................... 20-793
1) When E4:17 is displayed independently.. ...................................................................... 20-793
2) When E4:16, E4:17 are displayed simultaneously ....................................................... .20-793
K-16 [E4-181 Abnormality in lever signal input delay circuit system is displayed.. ................. 20-795
K-17 [E4:211 Abnormality 1 in drive circuit system for boom LOWER EPC valve
is displayed
[E4:251 Abnormality 1 in drive circuit system for boom RAISE EPC valve
is displayed ................................................................................................................. 20-796
K-17 [E4:211 IE4:311 Abnormality 1, 2 in drive circuit system for boom LOWER EPC
valve is displayed
[E4:251 [E4:351 Abnormality 1, 2 in drive circuit system for boom RAISE EPC
valve is displayed .......................................................................................... 20-798
K-18 [E4:311 Abnormality 2 in drive circuit system for boom L,OWER EPC valve
is displayed
[E4:35] Abnormality 2 in drive circuit system for boom RAISE EPC valve
is displayed ................................................................................................................. 20-800
20-751
0
K-18 [E4:211 [E4:311 Abnormality 1, 2 in drive circuit system for boom LOWER EPC
valve is displayed
[E4:251 [E4:351 Abnormality 1, 2 in drive circuit system for boom RAISE EPC
valve is displayed .. . . . . . . .. .. . . . . . . .. . . . . . . .. .. . .. . . . .. .. . .. . . . . . . .. .. .. . . . . . . .. . .. .. . . . .. . .. .. . . . . . . .. . . . . 20-802
K-19 [E4:321 Abnormality 2 in drive circuit system for arm IN EPC valve is displayed
[E4:331 Abnormality 2 in drive circuit system for bucket CURL EPC valve is
displayed
[E4:341 Abnormality 2 in drive circuit system for swing LEFT EPC valve is
displayed
[E4:361 Abnormality 2 in drive circuit system for arm OUT EPC valve is
displayed
[E4:371 Abnormality 2 in drive circuit system for bucket DUMP EPC valve is
displayed
[E4:381 Abnormality 2 in drive circuit system for swing RIGHT EPC valve is
displayed . .. . . .. . . . . .. . .. . . . .. . .. . . . . . . . .. . . . . .. . . .._..............................................._......................._. 20-804
K19 [E4:221 [E4:323 Abnormality 1, 2 in drive circuit system for arm IN EPC valve
is displayed
[E4:231 [E4:331 Abnormality 1, 2 in drive circuit system for bucket CURL EPC
valve is displayed
lE4:241 lE4:341 Abnormality 1, 2 in drive circuit system for swing LEFT EPC valve
is displayed
[E4:261 [E4:361 Abnormality 1, 2 in drive circuit system for arm OUT EPC valve
is displayed
lE4:271 [E4:371 Abnormality 1, 2 in drive circuit system for bucket DUMP EPC valve
is displayed
[E4:281 [E4:381 Abnormality 1, 2 in drive circuit system for swing RIGHT EPC valve
is displayed . . . . . .. . . . . . . .. . .. . . . . . .. . . . . .. .. . .. . . . . . .. . . . . . . .. . .. .. . . . . . . .. .. . .. . . . .. .. . .. . . . .. . .. . . . . . . . . .. .. . 20-806
K20 tE4:411 [E4:421 [E4:431 tE4:441 Over-range in control lever potentiometer signal
system is displayed .. .. .. . . .._................................................_. 20-808
K21 [E4:451 [E4:461 [E4:471 IE4:481 Excessive error in signal SIG and switch SIG of
control lever potentiometer is displayed . . . . . . . .. . . . . . . . . . . .. . .. . 20-810
K-22 [E4:551 Abnormality in ROM, RAM of CPU is displayed .. . . . . . . .. . .. . . . . . . .. . . .. . . . . .. .. . . . . . . . . .. . .. .. . . . . 20-812
K-23 [E4:581 Abnormality in interlock PLD is displayed . .. . .. .. . . . . . .. . .. . . . . . . .. .. . .. . . . . . . .. ..__.._................ 20-812
K-24 [E4:221 Abnormality 1 in drive circuit system for arm IN EPC valve is displayed
[E4:231 Abnormality 1 in drive circuit system for bucket CURL EPC valve is
displayed
[E4:241 Abnormality 1 in drive circuit system for swing LEFT EPC valve is
displayed
[E4:261 Abnormality 1 in drive circuit system for arm OUT EPC valve is displayed
[E4:271 Abnormality 1 in drive circuit system for bucket DUMP EPC valve is
displayed
[E4:281 Abnormality 1 in drive circuit system for swing RIGHT EPC valve is
displayed . . . . . . . .. . . . . . . . .. . . . . . . .. . . . . . . .. . .. . . . . .. . . . . . . .. . . .. . . . . .. .. . . . . . .. . . .. . . . . . .. . .. .. . . . . .. . . .. . . . . . . .. . . . . . . .. .. .. . 20-813
K-24 [E4:221 [E4:321 Abnormality 1, 2 in drive circuit system for arm IN EPC valve
is displayed
[E4:231 [E4:331 Abnormality 1, 2 in drive circuit system for bucket CURL EPC valve
is displayed
[E4:241 [E4:341 Abnormality 1, 2 in drive circuit system for swing LEFT EPC valve
is displayed
[E4:261 [E4:361 Abnormality 1, 2 in drive circuit system for arm OUT EPC valve is
displayed
[E4:271 [E4:371 Abnormality 1, 2 in drive circuit system for bucket DUMP EPC valve
is displayed
[E4:281 [E4:381 Abnormality 1, 2 in drive circuit system for swing RIGHT EPC valve
is displayed . .. . .. . . . . . . .. . . . . . .. . .. . . .._..................................................._................... 20-815
20-752
0
TROUBLESHOOTING VALVE CONTROLLER SYSTEM
POINTS TO REMEMBER WHEN TROUBLESHOOTING VALVE

CONTROLLER SYSTEM

I) If any abnormality returns to normal by itself, or
3) After completing troubleshooting, always erase the service code from memory.
2. User service memory retention function

troubleshooting according to the service code that is displayed.
any wasted work.)
20-753
0

User Service
code Abnormal system Nature of abnormality
code
Abnormality in L.H. L.H. knob switch control signal is being input when starting switch is
knob switch OFF at ON
E4:02
system
_
Abnormality in 1. When model code is switched during use
model code input (disconnection, short circuit with ground, short circuit in wiring I
E4:07 harness of model selection)
2. When non-set model code is input
Abnormality in S- . Impossible to networking with monitor panel

EOl NET networking 1. Disconnection, short circuit with ground, short circuit in wiring
harness between K05(3)(4) - KOl(5) - PO2(7)
E4:51 2. Disconnection, short circuit with ground, short circuit in wiring
harness between K05(13)(14) - K01(14)(15) -PO2(16)
Abnormality in teach- * Abnormality inside controller

E4:56
ing, playback RAM data
Abnormality in L.H. l When signals of K06(5) and (13) are different

E4:57 knob switch
Abnormality in l When control lever operation signal is input with starting switch
control lever neutral ON
system 1. Mistaken operation of lever
2. Misalignment of potentiometer mount or defective potentiometer
E04
E4:Ol
CA+LL
Abnormality in * When power source of control lever potentiometer has dropped

E4:04 control lever below 4.5V
potentiometer power 1. K05(10)(20) (power source wiring harness) short circuiting with
source system ground
E06 Short circuit in EPC 1. Short circuit with ground or short circuit between wires in wiring
relay [II drive power harness between K04(1)(6) - KOl(18) - R02(1)
E4:ll
source system 2. Short circuit in relay [II
CA+LL
Abnormality in EPC 1. Defective transistor (short circuit) inside controller

relay [II drive power 2. Contact of 24V wiring harness with wiring harness between K04(1)(6)
E4:12
source system - KOl(8) - R02(1)
20-754
0
tween K06(2)(10) - GND: of 2, PC120 is selected.

layed on monitor panel.
mode and priority mode are pos-
If the L.H. knob switch is turned OFF, it is
tarting switch is turned
After display on panel goes out com-
Voltage between K05(10) - (5): l Only travel works

5 + 0.25V s EPC solenoid power source relay
Voltage between K05(20) - (15):
between relay (1) - (2):
3. Displays E06 w CALL on monitor panel.
20-755
User Service
code
1. Short circuit with ground or short circuit between wires in wiring

Short circuit in EPC
E4:13 harness between K04(2)(7) - KOl(13) - R03(1)
relay [21 drive
2. Short circuit in relay 121
power source
system
Abnormality in EPC 1. Defective transistor (short circuit) inside controller

relay I21 drive 2. Contact of 24V wiring harness with wiring harness between K04(2)(7)
E4:14 - KOl(13) - R03(1)
power source
system
Abnormality (dis- 1. Short circuit with ground, disconnection in wiring harness between
connection) in EPC K03(11)(21) - KOl(4) - R03(5)(3) - R02(5)(3)
E4:15 relay [II, 121sole- 2. Defective contact of relays [II and f21
noid power source 3. Disconnection, defective contact in wiring harness between relay
system [l](3) - X07(11) - starting switch ACC
1. Relay [I] points melted

Abnormality (short
2. Contact of 24V wiring harness with wiring harness between R02(5)
circuit) in EPC relay
E4:16 - R03(3)
[II solenoid power
source system
1. Relay I21 points melted

Abnormality (short
2. Contact of 24V wiring harness with wiring harness between
E4:17 circuit) in EPC relay
K03(11)(21) - KOl(4) - R03(5)
121solenoid power
source system
E06
+
CALL
Abnormality in lever Abnormality inside controller
E4:18 signal input delay
circuit system
1. Wiring harness on output side short circuiting with ground

Wiring harness between K03(13) - K17(4) - boom prolix switch -
E4:21 K17(9) - KlO(1) - EPC solenoid short circuiting with ground
Abnormality 1 in 2. Short circuit between output and return wiring harness
occurs boom LOWER EPC Contact between output wiring harness (K03(13) - K17(4) - boom
indenpend-
ently drive circuit prolix switch - K17(9) - KlO(1) - EPC solenoid) and return wiring
harness (K03(2) - K17(3) - boom prolix switch - K17(10) - KlO(2) -
EPC solenoid)
3. Short circuit inside solenoid
1. Disconnection in output wiring harness

Disconnection in wiring harness between K03(13) - K17(4) - boom
prolix switch - K17(9) - KlO(1) - EPC solenoid
Abnormality 1 in 2. Disconnection, short circuit with ground in return wiring harness
E4:21 boom LOWER EPC Disconnection or short circuit with ground in wiring harness K03(2)
E4:31 drive circuit - K17(3) - boom prolix switch - K17(10) - KlO(2) - EPC solenoid
Occur + 3. Disconnection inside solenoid
simulta- Abnormality 2 in 4. Short circuit in return wiring harness power source
neOUslY boom LOWER EPC Contact of 24V power source and wiring harness between K03(2) -
drive circuit K17(3) - boom prolix switch - K17(10) - KlO(2) - EPC solenoid
1. Voltage between K04(2)(7) - (4)(5): 1. Stops all output. l Only travel works
20 - 3ov 2. Turns EPC solenoid power source
2. Resistance between relay [21(l) - relay OFF.
(2): 200 - 300R 3. Displays E06 ++ CALL on monitor
panel.
1. Voltage between K04(2)(7) - (4)(5): 1. Stops all output. l Only travel works
20 - 3ov 2. Turns EPC solenoid power source
relay OFF.
3. Displays E06 ++ CALL on monitor
panel.
1. Voltage between K03(11)(21) - 1. Stops all output. l Only travel works

(1)(12): 20 - 3ov 2. Turns EPC solenoid power source
relay OFF.
3. Displays E06 * CALL on monitor
panel.

relay OFF.
3. Displays E06 u CALL on monitor
panel.

relay OFF.
panel.
1. Stops all output. l Only travel works

2. Turns EPC solenoid power source
- relay OFF.
panel.
1. Resistance of EPC solenoid: 7 - 15fi 1. Stops all output when abnormal- 1. Stops all systems when
2. Solenoid current (full current value) ity occurs. abnormality occurs
PC200: 910 + 30mA (monitoring 2. Resets when lever is returned to 2. When lever is returned
code. 61) neutral, but stops output for to neutral, it becomes
system where abnormality possible to operate any
occurred. system except system
where failure occurred.
3. Operation of travel is
possible.
1. Resistance of EPC solenoid: 7 - 15R 1. Stops all output when abnormal- 1. Stops all systems when
2. Solenoid current (full current value) ity occurs. abnormality occurs
PC200: 910 + 30mA (monitoring 2. For Item 1 - 3, resets when lever 2. For items 1 - 3, when
code. 61) is returned to neutral, but stops lever is returned to
output for system where abnor- neutral, it becomes
mality occurred. possible to operate any
3. For Item 4, safety relay is turned system except system
OFF and all systems stop. where failure occurred.
3. For Item 4, all systems
remain stopped.
possible.
20-757
0
User Service
code code
1. Abnormality in circuit inside controller

E4:31 2. Short circuit in output wiring harness power source
Abnormality 2 in
occ”rs boom LOWER EPC Contact between 24V power source and wiring harness between
indenpend-
drive circuit K03(13) - K’l7(4) - boom prolix switch - Kl7(9) - KlO(4) - EPC
ently
solenoid

Wiring harness between K03(14) - K17(6) - boom prolix switch -
K17(7) - Kg(l) - EPC solenoid short circuiting with ground
E4’25 Abnormality 1 in
2. Short circuit between output and return wiring harness
occurs boom RAISE EPC
indenpend- Contact between output wiring harness (K03(14) - K17(6) - boom
drive circuit
ently prolix switch - K17(7) - Kg(l) - EPC solenoid) and return wiring
harness (K03(3) - K17(5) - boom prolix switch - K17(8) - K912)
EPC solenoid)

Disconnection in wiring harness between K03(14) - K17(6) - boom
Abnormality 1 in prolix switch - K17(7) - Kg(l) - EPC solenoid
E4:25 boom RAISE EPC 2. Disconnection, short circuit with ground in return wiring harness
~4~35 drive circuit Disconnection or short circuit with ground in wiring harness K03(3)
Occur + - K17(5) - boom prolix switch - K17(8) - K9(2) - EPC solenoid
simulta- Abnormality 2 in 3. Disconnection inside solenoid
neously boom RAISE EPC 4. Short circuit in return wiring harness power source
drive circuit Contact between 24V power source and wiring harness between
K03(3) - K17(5) - boom prolix switch - K17(8) - K9(2) - EPC sole-
E06
noid
+
CALL

E4:35 Abnormality 2 in 2. Short circuit in output wiring harness power source
Occurs boom RAISE EPC Contact between 24V power source and wiring harness between
indenpend- drive circuit K03(14) - K17(6) - boom prolix switch - K17(7) - Kg(l) - EPC
ently
solenoid

E4:32 Abnormality 2 in
Occurs 2. Short circuit in output wiring harness power source
arm IN EPC drive
indenpend- circuit Contact between 24V power source and wiring harness between
ently K03(15) - Kll(1) - EPC solenoid
~4~2 Abnormality 1 in arm 1. Short circuit in return wiring harness power source
IN EPC drive circuit Contact between 24V power source and wiring harness between
E4:32
+ K03(4) - Kl l(2) - EPC solenoid
Occur
simulta- Abnormality 2 in arm
neously IN EPC drive circuit

E4:33 2. Short circuit in output wiring harness power source
Abnormality 2 in
occurs bucket CURL EPC Contact between 24V power source and wiring harness between
indenpend- K03(17) - K13(1) - EPC solenoid
drive circuit
ently
20-758
0
Condition when normal Action by controller when Problem that appears on machini
1. Resistance of EPC solenoid: 1. Stops all output 1. All systems stop.

7- l5R 2. Turns safety relay OFF and stops 2. Operation of travel is
2. Solenoid current (full current value) all system possible
PC200: 910 2 30 mA (monitoring
code. 61)
1. Resistance of EPC solenoid: 1. Stops all output when abnormal- 1. Stops all axes when
7- 1552 ity occurs. abnormality occurs.
2. Solenoid current (full current value) 2. Resets when lever is returned to 2. When lever is returned
PC200: 910 + 30 mA (monitoring neutral, but stops output for to neutral, it becomes
code. 60) system where abnormality possible to operate any
occurred. axis except axis where
failure occurred.
possible.
1. Resistance of EPC solenoid: 1. Stops all output when abnormal- 1. Stops all systems when
7- 15R ity occurs. abnormality occurs
2. Solenoid current (full current value) 2. For Item 1 - 3, resets when lever 2. For items 1 - 3, when
PC200: 910 + 30 mA (monitoring is returned to neutral, but stops lever is returned to
code. 60) output for system where abnor- neutral, it becomes
mality occurred. possible to operate any
3. For Item 4, safety relay is turned system except system
OFF and all systems stop. where failure occurred.
3. For Item 4, all systems
remain stopped.
possible.
1. Resistance of EPC solenoid: 1. Stops all output 1. All systems stop.

7- 15R 2. Turns safety relay OFF and stops 2. Operation of travel is
2. Solenoid current (full current value) all systems possible
PC200: 910 + 30 mA (monitoring
code. 60)
1. Resistance of EPC solenoid: 1. Stops all output and is not reset 1. All systems stop and
7-15R until starting switch is turned operation becomes
2. Solenoid current (full current value) OFF. impossible.
PC200: 910 + 30 mA (monitoring 2. Safety relay is turned OFF 2. Operation of travel is
code. 62) possible
7- 15R until starting switch is turned operation becomes
PC200: 910 2 30 mA (monitoring 2. Safety relay is turned OFF 2. Operation of travel is
code. 62) possible
PC200: 910 t 30 mA (monitoring 2. Safety relay is turned OFF 2. Operation of travel is
code. 64) possible
20-759
0

I
I
E4:23 Abnormality 1 in bucket 1. Short circuit in return wiring harness power source
E4:33 CURL EPC drive circuit Contact between 24V power source and wiring harness between
Occur + K03(7) - K13(2) - EPC solenoid
simulta- Abnormality 2 in bucket
neously CURL EPC drive circuit

E4:34
2. Short circuit in output wiring harness power source
Occurs Abnormality 2 in swing
Contact of 24V wiring harness with wiring harness between K03(19)
indenpend- LEFT EPC drive circuit
- K16(1) - EPC solenoid
ently
1. Short circuit in return wiring harness power source

Contact between 24V power source and wiring harness between
+ K03(9) - K16(2) - EPC solenoid
Abnormality 2 in swing
LEFT EPC drive circuit

E4:36
Occurs Abnormality 2 in arm
Contact of 24V wiring harness with wiring harness between K03(16)
indenpend-OUT EPC drive circuit
- K12(1) - EPC solenoid
ently
I I
I
E4:26 Abnormality 1 in arm 1. Short circuit in return wiring harness power source
E06 E4:36 OUT EPC drive circuit Contact between 24V power source and wiring harness between
+ Occur K03(5) - K12(2) - EPC solenoid
CALL simulta- Abnormality+2 in arm
neously OUT EPC drive circuit
I

Contact between 24V power source and wiring harness between
K03(18) - K14(1) - EPC solenoid
E4:27 Abnormality 1 in bucket 1. Short circuit in return wiring harness power source
E4:37 DUMP EPC drive circuit Contact between 24V power source and wiring harness between
Occur t K03(8) - K14(2) - EPC solenoid
simulta- Abnormality 2 in bucket
neously DUMP EPC drive circuit
I
E4:38 1. Abnormality in circuit inside controller

Occurs Abnormality 2 in swing 2. Short circuit in output wiring harness power source
indenpend- RIGHT EPC drive circuit Contact between 24V power source and wiring harness between
ently K03(20) - K15(1) - EPC solenoid
I I I I
/ E4:28 ) Abnormality I, in sying 1 1. Short circuit in r-‘.._- . . .._~-_ L______

eturn wlrlng narness power source
Ed:38 RIGHT EPC drwe ctrcult rnntart hdwczo,
__, ..-._.. .-...-,I 24V power source and wiring harness between
I I Occur I t I l/ncs,,n\ II1c,*)\ - EPC solenoid
Abnormality 2 in swing
RIGHT EPC drive circuit
I
20-760
a
Condition when normal Action by controller when Problem that appears on machins
PC200: 910 + 30mA (monitoring 2. Safety relay is turned OFF. 2. Operation of travel is
code. 64) possible.
7- 1552 until starting switch is turned operation becomes
PC200: 910 e 30mA (monitoring 2. Safety relay is turned OFF. 2. Operation of travel is
code. 67) possible.
PC200: 910 r 30mA (monitoring 2. Safety relay is turned OFF. 2. Operation of travel is
code. 67) possible.
PC200: 910 2 30mA (monitoring 2. Safety relay is turned OFF. 2. Operation of travel is
code. 63) possible.
8
>
Ei
0
1. Resistance
7- 15R
of EPC solenoid: 1. Stops all output and is not reset
until starting switch is turned
1. All systems stop and
operation becomes
code. 63) possible.
code. 65) possible.
code. 65) possible.
code. 66) possible.
code. 66) possible.
20-76 1
0
User Service
code
l Over-range for output signal for SIG system or SWITCH system

1. Defective potentiometer
2. Disconnection, short circuit with ground in wiring harness between
Abnormality in boom K22(2)(3) - K05(19)(5) or K22(11)(12) - K05(9)(5), or contact with
E4:41 lever potentiometer other wiring harness
system
l Excessive error in output signal for SIG system or SWITCH system

Abnormality in boom K22(2)(3) - K05(19)(5) or K22(11)(12) - K05(9)(5), or contact with
E06 E4:45 lever potentiometer other wiring harness
system
CLLL
Abnormality inside controller
Abnormality in ROM,
E4:55
RAM of CPU
Abnormality inside controller

Abnormality in
E4:58
interlock PLD
20-762
0
1. Stops all output when abnormal- 1. When abnormality

ity occurs. occurs, all systems
Voltage 2. Resets when lever is returned to stop.
g Monitoring neutral, but output remains 2. After lever is returned
8 measured
by tester (V) “‘Itage (‘I stopped for only system where to neutral, only boom
; K22 K05 z abnormality occurred. cannot be operated.
3
= At full 3. Displays E06 * CALL on monitor (there is a prolix switch)
; At full 2
5 stroke = stroke panel. * Only travel works
z 2 z normally
25 3.87 0.66 2.5 4.15 0.85 1. Stops all output when abnormal- 1. When abnormality
50 (Z)-(3) (191-151+ - - f +0.15 +0.07 ity occurs. occurs, all systems
0.25 4.52 0.97 0.1 4.07 4.15
2. Resets when lever is returned to stop.
25 3.87 0.66 2.5 4.15 0.85 neutral, but output remains 2. After lever is returned
51 llll-(121 (9H5) f - - f +0.15 +0.07 stopped for only system where to neutral, only boom
0.25 4.52 0.97 0.1 4.07 -0.15 abnormality occurred. cannot be operated.
3. Displays E06 ~1 CALL on monitor (there is a prolix switch)
panel. * Only travel works
normally
1. Stops all output l Only travel works

2. Turns EPC solenoid power source
- relay OFF.
3. Displays E06 u CALL on monitor
panel.
8
>
1. Stops all output. l Only travel works
% 2. Turns EPC solenoid power source
- relay OFF.
panel.
20-763
0
User Service
code

Wiring harness between K03(15) - Kll(1) - EPC solenoid short
E4:22 circuiting with ground
Occurs Abnormality 1 in arm 2. Short circuit between output and return wiring harness
indenpend- IN EPC drive circuit Contact between output wiring harness (K03(15) - Kll(1) - EPC
ently solenoid) and return wiring harness (K03(4) - Kll(2) - EPC sole-
noid)

Abnormality 1 in arm Disconnection in wiring harness between K03(15) - Kl l(1) - EPC
E4:22
IN EPC drive circuit solenoid
E4:32 + 2. Disconnection, short circuit with ground in return wiring harness
pccur Abnormality 2 in arm Disconnection in wiring harness between K03(4) - Kll(2) - EPC
f,r$$$ IN EPC drive circuit solenoid
3. Disconnection inside solenoid

Wiring harness between K03(17) - K13(1) - EPC solenoid short
E4:23 Abnormality 1 in circuiting with ground
Occurs bucket CURL EPC 2. Short circuit between output and return wiring harness
indenpend- drive circuit Contact between output wiring harness (K03(17) - K13(1) - EPC
ently solenoid) and return wiring harness (K03(7) - K13(2) - EPC sole-
noid)
Abnormality 1 in 1. Disconnection in output wiring harness

E4:23 bucket CURL EPC Disconnection in wiring harness between K03(17) - K13(1) - EPC
~4~33 drive circuit solenoid
CALL Occur + 2. Disconnection, short circuit with ground in return wiring harness
simulta- Abnormality 2 in Disconnection in wiring harness between K03(7) - K13(2) - EPC
neously bucket CURL EPC solenoid
drive circuit 3. Disconnection inside solenoid

Wiring harness between K03(19) - K16(1) - EPC solenoid short
circuiting with ground
E4:24 Abnormality 1 in
2. Short circuit between output and return wiring harness
Occurs swing LEFT EPC
Contact between output wiring harness (K03(19) - K16(1) - EPC
indenpend- drive circuit
ently solenoid) and return wiring harness (K03(9) - K16(2) - EPC sole-
noid)
Abnormality 1 in 1. Disconnection in output wiring harness

E4:24 swing LEFT EPC drive Disconnection in wiring harness between K03(19) - K16(1) - EPC
E4:34 circuit solenoid
Occur + 2. Disconnection, short circuit with ground in return wiring harness
simulta- Abnormality 2 in Disconnection in wiring harness between K03(9) - K16(2) - EPC
neouslY swing LEFT EPC drive solenoid
circuit 3. Disconnection inside solenoid

Wiring harness between K03(16) - KlZ(1) - EPC solenoid short
E4:26 circuiting with ground
Occurs Abnormality 1 in arm 2. Short circuit between output and return wiring harness
indenpend- OUT EPC drive circuit Contact between output wiring harness (K03(16) - KlZ(1) - EPC
ently solenoid) and return wiring harness (K03(5) - KlZ(2) - EPC sole-
noid)
20-764
0
1. Resistance of EPC solenoid: 7 - 15fi 1. Stops all output momentarily 1. All systems stop mo-
2. Solenoid current (full current value) when abnormality occurs. mentarily.
PC200: 910 -+ 30mA (monitoring 2. When lever is returned to neutral, 2. When lever is returned
code. 62) it is possible to operate any to neutral, it becomes
system except system where possible to operate any
failure occurred. system except system
1. Resistance of EPC solenoid: 7 - 15.Q 1. Stops all output momentarily 1. All systems stop mo-
PC200: 910 2 30mA (monitoring 2. When lever is returned to neutral, 2. When lever is returned
1. Resistance of EPC solenoid: 7 - 15Q 1. Stops all output momentarily 1. All systems stop mo-
PC200: 910 + 30mA (monitoring 2. When lever is returned to neutral, 2. When lever is returned
1. Resistance of EPC solenoid: 7 - 15R 1. Stops all output momentarily 1. All systems stop mo-
PC200: 910 t 30mA (monitoring 2. When lever is returned to neutral, 2. When lever is returned
PC200: 910 t 30mA (monitoring 2. When lever is returned to neutral, 2. When lever is returned
1. Resistance of EPC solenoid: 7 - 15Q 1. Stops all output momentarily 1. All systems stop mo-
PC200: 910 2 30mA (monitoring 2. When lever is returned to neutral, 2. When lever is returned
PC200: 910 + 30mA (monitoring 2. When lever is returned to neutral, 2. When lever is returned
20-765
a
User Service
code code
E4:26 Abnormality 1 in arm 1. Disconnection in output wiring harness

E4:36 OUT EPC drive circuit Disconnection .in wiring harness between K03(16) - K12(1) - EPC solenoid
simulta- Abnormality 2 in arm Disconnection in wiring harness between K03(5) - K12(2) - EPC solenoid
neOUSly OUT EPC drive circuit 3. Disconnection inside solenoid
_
Wiring harness between K03(18) - K14(1) - EPC solenoid short circuiting
E4:27 Abnormality 1 in with ground
occurs bucket DUMP EPC 2. Short circuit between output and return wiring harness
indenpend-
drive circuit Contact between output wiring harness (K03(18) - K14(1) - EPC solenoid)
ently
and return wiring harness (K03(8) - K14(2) - EPC solenoid)
E4:27 Abnormality 1 in bucket I. Disconnection in output wiring harness

E4:37 DUMP EPC drive circuit Disconnection in wiring harness between K03(18) - K14(1) - EPC solenoid
simujta- Abnormality 2 in bucket Disconnection in wiring harness between K03(8) - K14(2) - EPC solenoid
neously DUMP EPC drive circuit 3. Disconnection inside solenoid

Wiring harness between K03(20) - K15(1) - EPC solenoid short circuiting
E4:28
Abnormality 1 in with ground
occurs swing RIGHT EPC 2. Short circuit between output and return wiring harness
indenpend-
ently drive circuit Contact between output wiring harness (K03(20) - K15(1) - EPC solenoid)
and return wiring harness (K03(10) - K15(2) - EPC solenoid)
8
>
%
E4:28 Abnormality 1 in swing 1. Disconnection in output wiring harness
~4~36 RIGHT EPC drive circuit Disconnection in wiring harness between K03(20) - K15(1) - EPC solenoid
+ 2. Disconnection, short circuit with ground in return wiring harness
CALL Occur
simulta- ABnormality 2 in swing Disconnection in wiring harness between K03(10) - K15(2) - EPC solenoid
neously RIGHT EPC drive circuit 3. Disconnection inside solenoid

K21(2)(3) - K05(17)(5) or K21(11)(12) - K05(7)(5), or contact with
other wiring harness
Abnormality (1) in
arm lever
E4:42
potentiometer
system
. Over-range for output signal for SIG system or SWITCH system

Abnormality (I) in
bucket lever
E4:43
potentiometer
system
0 f 30mA (monitoring
id current (full current value)

910 t 30mA (monitoring
2. When lever is returned to neutral, it is neutral, it becomes possible to

code. 66) possible to operate any system except operate any system except
system where failure occurred. systemwhere failure occurred.
8
t
%
1. Resistance of EPC solenoid: 7 - 15R 1. Stops all output momentarily when 1. All systems stop momentarily.
2. Solenoid current (full current value) abnormality occurs. 2. When lever is returned to
PC200: 910 + 30mA (monitoring 2. When lever is returned to neutral it is
1. When abnormality
occurs, all systems
2. Resets when lever is returned to
neutral, but output remains 2. After lever is returned
stopped for only system where to neutral, only arm
abnormality occurred. cannot be operated.
3. Displays E04 ++ CALL on monitor t Only travel works
stopped for only system where to neutral, only bucket

3. Displays E04 t--t CALL on monitor Sr Only travel works
20-767
0
User Service
code

Abnormality (1) in
swing lever
E4:44
potentiometer
system

Abnormality (2) in
arm lever
E4:46
potentiometer
system

CALL 1. Defective potentiometer
Abnormality (2) in
bucket lever
E4:47
potentiometer
system

Abnormality (2) in other wiring harness
E4:48 swing lever

potentiometer
system
1. Defective controller.
LED Controller power 2. Disconnection in wiring harness between fuse (12) - KOl(7) - K04(8)(9)
OFF source system 3. Disconnection, defective contact in wiring harness between starting
switch BR - X07(2) - KOl(11) - K06(4)(12).
1. Stops all output when abnormal- 1. When abnormality

occurs, all systems
2. Resets when lever is returned to
neutral, but output remains 2. After lever is returned
stopped for only system where to neutral, only swing
neutral, but output remains

stopped for only system where
3. Displays E04 ++ CALL on monitor * Only travel works
stopped for only system where to neutral, only bucket

3. Displays E04 ++ CALL on monitor t Only travel works
er lever is returned
stopped for only system where 0 neutral, only swing
3. Displays E04 t-t CALL on monitor
etween K04(8)(9) - (4H5): Stops all output. Only travel works normally.
20-769
0
User Service
code
1. Remote permission signal is ON when starting switch is ON.

Abnormality in
E4:03 remote permission
signal
1. Disconnection, short circuit with ground or other point in K05(1)(2)

Abnormality in HS- (+ wiring harness)
E4:52 NET communica- 2. Disconnection in K05(11)(12) (GND wiring harness)
tions % E6:25 (GX panel 253) displayed at same time.
EOI
Abnormality 1 in
K06(5)(13) - knob switch
optional controller
E4:53 2. Defective knob switch
procedure (knob
switch)

Abnormality 2 in
A02(10) - K06(11)
optional controller
E4:54 %C E6:23 (GX panel 231) is displayed at the same time.
procedure (remote
permission signal)
20-770
0
Condition when normal Action by controiler when Problem that appears on machine
Voltage between K06(3)(11) - chassis Stops automatic mode Normal lever operations
ground possible
: During boom rock/swing back control
18-28V
: Except above 0 - 0.3V
Voltage between K05(1)(2) - (11)(12): Stops all axes Nothing except travel
: 3-9v works. (When GX control-
ler disconnection switch is
ON, acts as HYPER specifi-
cation machine)
Voltage between K06(5)(13) - chassis Stops automatic mode After all axes are stopped
ground and control levers are
: Knob switch ON: 18 - 28V returned to neutral, it
: Knob switch OFF: Max. IV becomes possible to carry
out normal lever operation
Voltage between K06(3)(1 I) - chassis Stops automatic mode After all axes are stopped
ground and control levers are
: During boom rock/swing back control returned to neutral, it
18 - 28V becomes possible to carry
: Except above 0 - 0.3V out normal lever operation
20-771
0
TROUBLESHOOTING JUDGEMENT TABLE FOR VALVE CONTROLLER SYSTEM
JUDGEMENT TABLE FOR VALVE CONTROLLER SYSTEM

or !r
User code
Failure mode
Service code
Speeds of all work equipment, swing, travel are slow or lack power
; There is excessive drop in engine speed, or engine stalls
;,E No work equipment, travel, swing move
:Z Abnormal noise generated (around pump)
:g Auto-deceleration does not work
2 Fine control ability is poor or response is poor
No work equipment, swing move (travel is normal)
Speed is slow in H/O mode
Boom RAISE is slow or lacks power
Boom LOWER is slow or lacks power I i i i i i i i i i
Arm IN is slow or lacks power
Arm OUT is slow or lacks power
Bucket CURL is slow or lacks power
z Bucket DUMP is slow or lacks power
E Boom RAISE does not move
% Boom LOWER does not move
5 Arm IN does not move
z Arm OUT does not move
2 Bucket CURL does not move
= Bucket DUMP does not move
Excessive hydraulic drift
Excessive time lag (engine at low idling)
Lack of power when pressure rises (Z-stage relief)
Other equipment moves when one circuit is relieved
In UO or F/O mode, work equipment speed is faster than set speed
- In comoound ooeratlons. work eaumment with larger load IS slow
Deviation is excessive when starting
Steering does not turn or lacks power

E Travel speed does not switch or is faster than set speed
- Does not move (one side only) I I I
Does not swing (LEFT)
Does not swing (RIGHT)
Swing acceleration is poor (LEFT)
i Swing acceleration is poor (RIGHT)
; Excessive overrun Both left and right
; when stopping swing One direction only
Excessive shock when stopping swing (one direction only)
i Excessive abnormal noise when stopping swing
Excessive hydraulic When brake is ON
drift of swing When brake is OFF
Swing speed is faster than specified swing speed
Does not change to soft mode
$ Does not carry out automatic vibration
z Cannot carry out teaching
; Cannot carry out playback
Does not change to boom priority mode 1
i Does not change to boom priority mode 2
c Does not change to swing priority mode 1
Does not change to swing priority mode 2
Troubleshootmg code when servxe code IS dlsplayed
. : This shows applicable item for service code
%: This shows item that needs only checking with monitoring
20-772
02OYO6
Ahormallty 121 in swing RIGHT EPC valve drive circuit sptem
Abnormality 111in boom lever potentiometer system

Abnormality 121in boom lever potentiometer system
-1
Abnormality 111 in arm OUT EPC valve drive circuit system
Abnormalih tll in sting RIGHT EPC valve drive circuit system
Abnormality 121 in sting LEFT EPC valve dwe urcult system
Abnormality 121 in arm OUT EPC valve drive circuit system
Abnormality 121 in bucket DUMP EPC valve drive clrcufi system
normalib 121 in swing RIGHT EPC valve drive circuit system
I I I I I I I I I I t
z SIG
Swing
Y SWITCH
:: code when no service code is displayed
Troubleshooting
:i
TROUBLESHOOTING ELECTRICAL CIRCUIT DIAGRAM OF VALVE CONTROLLER SYSTEM
ELECTRICAL CIRCUIT DIAGRAM OF VALVE CONTROLLER

SYSTEM
Ir For details of this page, see page 90-201.
20-774
0
TROUBLESHOOTING K-l
K-l [LED OFF] Controller power source system

Ir Check that fuse 12 is not blown.
Cause Remedy
2 YES
harness between starting Replace wiring
NO switch BR -X07 (2) - KOI harness
(II)- K06 (female) (4)(12)
normal! 3 YES Replace wiring
Is voltage I harness
H
-2O-30V ‘II harness between fuse
-Turn starting between fuse 12 inlet - HO5 (6) - Ml 1
switch ON. (l)(2)- battery relay
Defective contact, or Replace wiring
*20-30V NO disconnection in wiring harness
* Turn starting harnessbetweenfuse12
switch ON. - KOl (7) - K04 (8)(g)
K-l Related electric circuit diagram
Ml 1 (L2)
K04 (MIC9)
Fuse HO5 (~6)
K04 (04016) X07 (MICl7) Startine switch
Start sianal 4 $j) @

Start signal 12
TKP00866
20-775
0
TROUBLESHOOTING K-2
K-2 [E4:02] L.H. knob switch OFF system is displayed

Sr Turn the starting switch ON and check if E4:02 is displayed. (If it is not displayed, the system has
been reset.)
Cause Remedy
2 YES
1
YE
* Turn starting
I1 NO
Mistaken operation by
operator
-
switch ON. Contact of 24V wiring

harness with wiring
in Table 17 3 YES harness between K06 teplace wiring
I I (female) (5), (13) - K01
l Turn starting Is resistance of rarness
(12) - HOI (16) - M22 (2)
switch ON. L.H. knob switch - K07 (9) - L.H. knob
* Engine stopped. N switch
* Set monitoring
Defective L.H. knob Replace
code to 68. * Switch ON: NO switch
Max. ID
* Switch OFF: Min. 1 MR
* Check L.H. knob switch
as an individual part.
Table 1 Monitoring mode display (Time display portion)
Lights up when safety relay is ON

Goes out when safety relay is OFF
K-2 Related electric circuit diagram
HO4 61 6)
TKP00867
20-776
0
TROUBLESHOOTING K-3
K-3 [E4:07] Abnormality in model code input is displayed

connector and inserting the T-adapter, or when removing the T-adapter and returning the con-
nector to its original position, if the service code is not displayed, the problem has been removed.
* Turn the starting switch ON and check if E4:07 is displayed. (If it is not displayed, the system has
been reset.)
Cause Remedy
YES
1
Is input condition
of valve controller
as shown in Table 2 YES
I? Is resistance
~ between K06
-Turn starting - (female) (3, (9). (10) - Defective model selection
switch ON. NO and GND as shown :onnector, or disconnection, * Replace
* Set monitoring in Table 2? short circuit with ground, or connector
code to 04,68. * Turn starting NO short circuit in applicable *Replace wiring
switch OFF. ,Niring harness harness
- Disconnect K06.
(1:ON
Table 1 Monitoring mode display
(Time display portion) I:_;; : OFF Table 2 Resistance value
Condition of valve Valve controller Applicable wiring harness PC200
controller input model code
Between K06 (female) (2) and GND Min. 1 MQ
Max. 1 R
I I
p ,-, 0 c_:2 c-1-J <_-_2 ,-,, (0 1, ,-,,-, Between K06 (female) (9) and GND
PC200
Ei r! o (I :---; ;---‘ 1-i 7 o I!! f!_( r,l Between K06 (female) (10) and GND Min. 1 MR
c__* .__1
K-3 Related electric circuit diagram
Model selection
K01 (Sl 6) co9 68) connector
IA I I
K06 (040 16)
I
3 3
selection 3
6 6
iii:
PC200 (STD) PC210
TKP00868
20-777
0
TROUBLESHOOTING K-4
K-4 [E4:51] Abnormality in S-NET communications is displayed

connector and inserting the T-adapter, or when removing the T-adapter and returning the con-
nector to its original position, if the monitor code display returns to normal, the problem has
been removed.
* If the starting switch is turned ON when there is a disconnection in the wiring harness between the
monitor panel and the controller, or the positive end (+I of the network wiring harness or the
inside of the controller are short circuited, the controller cannot carry out communications, so the
monitor panel does not display any abnormality.
* This includes cases where the E lights up and goes out repeatedly.
1. Disconnection related
2 YES
Are error codes
YES E301, E218
generated at
same trme?
1-i
NO
Is monitoring
code 04 display -
normal? YES
3
* See Table 1.
* Turn starting With monitoring
switch ON. code 08, is EPC
NO valve controller YES
connection normal? 4
* See Table 2, Item Do all lamps go

- out in monitoring _
0.
NO code 08? 5 YES
* Turn starting
switch ON. - Is voltage
* See Table 2 (all _ between K05 (3),
lamps OFF). NO (4) and (13L (14)
* Turn starting normal?
switch ON.
*4-8V NO
* Turn starting
switch OFF.
Table 1 Table 2
TKP00869
. Light up when connected

@ Engine throttle a pump controller
. @ Engine throttle . pump controller
When each controller is not connected to the
@ EPC valve controller
network, n- - -n is displayed.
@ GX panel
If the correct letter or number is not displayed @ GX controller
(another model is displayed), there is an ab- @ Valve controller for expansion (for radio control)
normality in the controller model selection. . Checks can be carried out with code 08 only
when there is a disconnection in the network;
when there is a short circuit with the ground,
the display does not change.
Therefore, the basic situation is to use Table 1
to check the connection condition when there
is a short circuit with the ground.
20-778
0
TROUBLESHOOTING K-4
k
Cause Remedy
Defective mating of Correct or

connector PO2 or replace
defective monitor panel
Defective mating of
connector K05 or Correct or
defective EPC valve replace
controller
Go to Short circuit -
related (next page)
Defective monitor panel Correct or

or defective mating of replace
connector PO2
Defective EPC valve

Replace
controller
Defective network wiring

harness between
Replace
monitor panel and EPC
valve controller
20-779
0
TROUBLESHOOTING K-4, K-5
Cause Remedy
2. Short circuit related
YES
Defective pump controlle Replace
1
Is monitoring
code 03,04 YES Defective engine throttle
Replace
display normal? controller
2
l Disconnect C03. Is monitoring

- Turn starting J- code 02,04 YES Defective EPC valve Replace
switch ON. NO display normal? 3 controller
* See Table 1.
- Disconnect EOI. Is monitoring
* Turn starting L code 02,03
4 YEI
switch ON. NO display normal? Defective monitor panel Replace
- See Table 1. p Isresistance
* Disconnect K05. between PO2
- Turn starting NO (fe”lak) (7). (8) and
switch ON. chassis normal?
Defective wiring harness Replace
- See Table 1 NO
* Min. 1 MQ
- Turn starting
switch OFF.
* Disconnect POZ,
C03, EOI, and
K05.
Table 1
I Monitorina code I Model /
1No. 1 Item I Pc200.210 I 230I
PCZZO.
(01 IMTrpanelmodelcode 1 iii 1 t 1
02 Enginethrottle pump controllermodel code
03 Enginethrottle pump controllermodel code
04 EPC valve controller model code
. When each controller is not connected to the

network, “- - -n is displayed.
If the correct letter or number is not displayed
(another model is displayed), there is an ab-
normality in the controller model selection.
K-5 [E4:561 Abnormality in teaching, playback RAM data is displayed
Cause Remedy
k
Note: When the chassis battery is removed or when fuse (12) is reolaced. and the Dower to the valve
controller is cut, all the data is cleared from memory, so this error message is given.
This case does not indicate an error, so there is no need to replace the controller assembly.
20-780
0
TROUBLESHOOTING K-6
K-6 [E4:57] Abnormality in knob switch is displayed

* This troubleshooting is carried out when there is still an abnormality, so when disconnecting
the connector and inserting the T-adapter, or when removing the T-adapter and returning the
connector to its original position, if the service code is not displayed, the problem has been
removed.
* Turn the starting switch ON and check if E4:57 is displayed. (If it is not displayed, the system has
been reset.)
Cause
2 YES
VEIL-
Defective knob switch Replace
as an individual part.
1l::::I:‘,::;‘;;zAal? * Switch 0N:Max. 1 Q
* Switch 0FF:Min. 1 MD
Short circuit with
ground, disconnection in
-Turn starting wiring harness between
Replace
switch OFF. NO K06 (female) (5) and KOl
- Disonnect KOI (female) (12), or between
and K06. K06 (female) (13) and
- Max.1 fi KOI (female) (12)
K-6 Related electrical circuit diagram
HO4 El 6) Fuse
5
@
K07 (Sl 0) M22 (M2) K06 (04016)

Knob switch
HO1 (S16) KOI (Sl6) Knob switch
@ g- 3 signal 2
@ @ @ @ 3 Knob switch
signal 1
TKP00867
20-781
0
TROUBLESHOOTING K-7
K-7 [E4:01] Abnormality in control lever neutral system is displayed

This troubleshooting is carried out when there is still an abnormality, so when disconnecting
removed.
Place the control levers securely in neutral before starting.
Turn the starting switch ON and check if E4:Ol is displayed. (If it is not displayed, the system has
been reset.)
Cause Remedy
YES Go to troubleshooting for -

code that is displayed
ld
, 1 I
3 YES
Are other service Defective valve controller Replace
codes displayed?
YES Is E4:Ol
2 displayed?
* Turn starting Mistaken operation by
Is the voltage -
switch ON. when the lever is operator
* Turn starting NO
NO at neutral as switch ON.
shown in Table l?
------I
* Turn starting
switch ON. NO
Defective control lever Replace
* Set monitoring
code to 50 - 57.
Table 1 Monitoring display
20-782
0
TROUBLESHOOTING K-7
K22 (04012) K 3 (S8)
L I
I I I1
Valve controller
K05 (04020)
_ _
I
a- CD
L.ii.
front-rear NSW signal
- a-, R.H. left-right NSW sianal
R. H. front-rear NSW signal
Potentiometer Power
Potentiometer GND
TKPD0871
20-783
0
TROUBLESHOOTING K-8
K-8 [E4:041 Abnormality in control lever potentiometer power source

system is displayed
removed.
Turn the starting switch ON and check if E4:04 is displayed. (If it is not displayed, the system has
been reset.)
Cause Remedy
1 YES
Is voltage
Wiring harness between K05
between K05 (10) _
(female) (10) - K07 (1). KOHlI
(20) and (5) (15) - CN21(1)(10), CN22
normal? Ifemale)( or between Replace wiring
NO K05 (female) (20) - K07 (5). harness
* 5 k 0.25V
K08L5) - CN21(4)(7), CN22
* Turn starting
(female) l4)(7) short
switch ON. circuiting with chassis
ground
K2 EPC Valve controller

KO 5 (04020)
r--
Lever Potentiometer
Power source (5V)
Lever Potentiometer GND
K2 104012)
-
K07 (St 0) @ Lever potentiometer GND
G
L. H. control @ a
I ever Lever Potentiometer
@ @ power source (5V)
I
TKP00872
20-784
0
TROUBLESHOOTING K-9
K-9 [E4:1 II Short circuit in EPC relay 1 drive power soure system is
displayed
removed.
Turn the starting switch ON and check if E4:ll is displayed. (If it is not displayed, the system has
been reset.)
Cause Remedy
2 YES
Is resistance
YES betweeen K04
(female)(l)(d) and Wiring harness between
GND normal? K04 (female) (l)(6) -
Is resistance KOlf8) - relay 1 (I) short Replace wiring
betweeen EPC * Min. 1 MD NO harness
relay 1 (I) and (2) . Turn starting
ground.
normal? switch OFF.
* Disconnect K04 and EPC relay 1.
*200-300 R Defective EPC relay 1 Replace
* Check relay as an NO
individual part.
$
EPC Valve controller EPC Valve controller

zlav 1 relay 2
I
n
r I 2 3 5 6
K02 (Si 6)
-3
-4
@
@
K04
EPC Valve
(MIC9)
Safety
Safety
GND
relay
relay
controller
I
1
drive
drive
4-3 GND
m
TKP00873
20-785
0
TROUBLESHOOTING K-10
K-10 [E4:12] Contact between chassis power source and EPC relay 1
drive power source system is displayed
removed.
been reset.)
harness between K04 harness

Is voltage
(l)(6) - KOl(8) -relay 1
betweeen K04
(1)
(female)(l)(b) and
(4)(5) 20 - 3OV?
*Turn starting NO
switch ON.
* Disconnect K04.
K-IO Related electrical circuit diagram

relay 1 relay 2
r I I I
EPC Valve controller
K02 (Sl 6) K04 (MIC9)
)B 3 Safety relay I drive

3 Safety relay I drive
77T -4 GND
a-3 CND
n-r
TKPOOB73
20-786
0
TROUBLESHOOTING K-l 1
K-II [E4:131 Short circuit in EPC relay 2 drive power source system is
displayed
removed.
been reset.)
Cause Remedy
2 YES
is resistance
YE ; betweeen K04
1 (female) (1) - (2). (7)
- GND normal? K04 (female) (2)(7) -
KOl(13) - relay 2 short Replace wiring
* Min. 1 MR NO harness
betweeen EPC circuiting with chassis
*Turn starting
switch ON. ground.
* Disconnect K04
and EPC relay 2.
*200-300 R Defective EPC relay 2 Replace
* Check relay as an 10
individual part.
$
2
8
K-l 1 Related electrical circuit diagram

relay 1 relay 2
K02 61 6) K04 (MIC9)
3 3 Safety relay 2 drive
3 Safety relay 2 drive
7-i-r -3 GND
--@ GND
m
TKP00874
20-787
0
K-12 [E4:14] Contact between chassis power source and EPC relay 2
drive power source system is displayed
removed.
been reset.)
Before carrying out troubleshooting, check that all the related connectors are properly inset-ted.
Cause Remedy
Contact of 24V wiring

1 YES harness with wiring Replace wiring
harness between K04 harness
Is voltage
(female)(2)(7) - KOlU3) -
betweeen K04
relay 2 (1)
(female)(2)(7) and
(4)(5) 20 - 3OV?
Defective valve controlk Replace
* Turn starting NO
switch ON.
* Disconnect K04.

relay 1 relay 2
K02 (Sl 6) K04 (MIC9)

A
3 Safety relay 2 drive
I
Safety relay 2 drive
GND
GND
I
T/r ’ ’
TKP00874
20-788
0
K-13 [E4:15] Disconnection in EPC relay 1, 2 solenoid Dower source

system is displayed _
removed.
been reset.)
Cause Remedy
YES Defective relay on side

Replace
where display goes out
1 4YE: GotoA
!S resista,nce
of wiring r
YES “Z”eSS DetWW”
Replay relay, and
- relay 1 (2) and GND, -
I _ 3 and between relay 2 Disconnection in wiring
Is voltage (2) and GND normal? harness between R02 Replace wiring
YES between relay 2 _ . Max. 1 f2 Nf (female) (2) and GND or harness
f Turn starting *Turn starting switch R03 female (2)
(I) and GND
switch ON. 3% 2 OFF.
I normal? Short circuit with ground,
Note: - Disconnect relay 1
Is voltage and 2. Replace wiring
It is also possible *20-30V harness between K04
_ between relay 1 _ harness
to check the * Turn starting NO (female) (2)(7) - KOl (13) -
actuation of the
F l(l) and GND
switch ON. R03 (female) (1)
normal?
relay. In that case, Short circuit with ground,
YES and NO are *20-30V
* Turn starting
I disconnection in wiring Replace wiring
reversed. harness between K04 harness
NO
switch ON. (female) (l)(6) - KOl (8) -
R02 (female) (1)
I See the next page for details.
7 YES
Is resistanceof

Replace wiring
harness between K03
harness
(female) fll)(Zl) - KOl (4) -
relay2 (5)
Replace wiring
between relay 1 disconnection in wiring
harness
* Between wiring harness
harness between relay 1
and GND: Min. lM0 (5) and relay 2 (3)
*Turn starting switch OFF.
. Remove relays 1 and 2.
. “... “.“....‘J
switch ON. NO harness between relay 1 narness
(3) - X07 (I 1) - starting
switch ACC
* Checking relay
Connect 24V with relay pin (I), and pin (2) with the ground. If the resistance between pins (3) and
(5) is less than 1 12, the relay is normal.
20-789
a

relay I relay 2 X07 (MIC17) Starting switch
z
z EPC Valve controller

m
:
c
.-
z
2
CT
Safety relay 1 drive
Safety relay I drive
TKP00875
% In troubleshooting items 2 and 3, when the wiring harness is replaced, if an abnormality occurs,
the voltage will become 20 - 30V momentarily (approx. 0.5 set), and after that it will return to OFF,
so it is impossible to measure with a digital tester.
0.2sec 0.4sec 0. 5sec

Starting switch ON I
I
A. Relay I drive sional- I
(CN-RO2 (1) 1 II
I
I
I
I I
I
_______________1____--_
8. Relay 2 drive signal
(CN-R03 (1))
Relay drive sequence
TKP00876
20-790
0
K-14 [E4:161 EPC relay 1 points melted or short circuit in solenoid

power source system is displayed
[E4:171 EPC relay 2 points melted or short circuit in solenoid
removed.
When E4:16 is displayed independently
Turn the starting switch ON and check if E:16 is displayed. (If it is not displayed, the system has
been reset.)
Cause Remedy
YES
Defective EPC relay 1 Replace
1
When relays 1
and 2 are Contact of 24V wiring
interchanged, is harness with wiring
E4:17 displayed? harness between R02
Is voltage harness
(female) (5) and R03
* Turn starting between R02 (female) (3)
switch OFF. NO (female) (5) and
* Interchange GND20-30V?
relays. Defective valve controller Replace
* Turn starting NO
* Turn starting
switch ON.
switch ON.
* Disconnect R02.
2) When E4:16, E4:17 are displayed simultaneously
* Turn the starting switch ON and check if E:16 and E4:17 are displayed. (If they are not displayed,
the system has been reset.)
1
J
2 YES harness with wiring
harness between K03 Replace
Is voltage between
(female) (I 1)(21) - KOl(4)
YES K03 (female) (11).
- R03 (female) (5)
1 - (21) and (1). (12) -
p 20-3OV?
Is voltage between Defective EPC relay 1 and Replace
K03 (female) (ll), * Turn starting NO 2
(21) and (1). (12) switch ON.
20-3OV? . Disconnect K03,
R02, and R03.
* Turn starting Defective valve controller Replace
switch ON. NO
* Disconnect K03.
20-791
0

relay I relay 2 X07 (MIC17) Start ine switch
I II 1 1 I
TKP00875
20-792
0
K-15 [E4:17] EPC relay 2 points melted or short circuit in solenoid

power s&r&e system is displayed
[E4:16] EPC relay 1 points melted or short circuit in solenoid
removed.
When E4:17 is displayed independently
Turn the starting switch ON and check if E:17 is displayed. (If it is not displayed, the system has
been reset.)
YES I Defective EPC relay 2 Replace
1 When relavs 2 11 I
I and 1 are
interchanged, is 2 YES
I
* Turn startina between R03 Contact of wiring

switch OFF- sle) (3) and harness between K03
* Interchange jemal? (female) (1 I), (21) - Replace wiring
relays. KOl(4) - R03 (female) (5)
- Turn r+?.rt;ng
=Lal LI NO harness
* Turn starting and betweeen R02
switch OFIF.
switch ON. (female) (5) and R03
* Disconnec t K03. R02. R03.
* Between R03 (female) (3) and (5): Min. 1 MR (female) (3)
2) When E4:16, E4:17 are displayed simultaneously
removed.
* Turn the starting switch ON and check if E:16 and E4:17 are displayed. (If they are not displayed,
the system has been reset.)
I Cause Remedy
Contact of 24V wiring

harness with wiring
2 YES
- harness between K03 Replace
Is voltage between (female) (llH21) - KOl(4)
YES K03 (female) (I I), - R03 (female) (5)
1 r (21) and (1). (12)
II y Defective EPC relav 1 and Replace
K03 (female) (11). NO 2
I
(21) and (1). (12)
* Disconnect K03,
I
-Turn starting
’ R02, and R03.
switch ON. NO
* Disconnect K03.
20-793
0

relay 1 relay 2 X07 (MIC17) Starting switch
z
a
z EPC Valve controller
: K03 (M I C2 1)
.-:
3 EPC GND
sl
0
@ EPC GND
z
W 11 EPC Power source
m
EPC Power source
K01 (Sl 6)
I K04 (MIC9)
3
1 Safety relay I drive
gI 6 Safety relay I drive
m 2 Safety relay 2 drive
Q 7 Safety relay 2 drive
TKP00875
20-794
0
K-16 [E4:18] Abnormality in lever signal input delay circuit system is

displayed
Cause Remedy
1
I Defective valve controller Replace
20-795
0
K-17 [E4:21] Abnormality 1 in drive circuit system for boom LOWER

EPC valve is displayed
[ E4:25] Abnormality 1 in drive circuit system for boom RAISE EPC
valve is displayed
removed.
Turn the starting switch ON, operate according to the conditions in the table, and check if the
service code is displayed. (If it is not displayed, the system has been reset.)
Always turn the boom prolix switch OFF.
When E4:21 or E4:25 are displayed independently
. - : Applicable connector No.

0 : Applicable pin No.
Cause Remedy
3 YES
17
Defective valve controk Replace
Contact of wiring harness
between K03 (female) 0 -
K170 - boom prolix switch -
K170 -K. . (I) - solenoid,
Replace
Yf NO and between K03 (female) 0
ltroubleshooting 2 in 11 switch OFF. - K170 - boom prolix switch
1 - K170 - K a. (2) -solenoid
the Table 1 normal? 1 - Disconnect K03 and
apphcable connector Wiring harness between K03
* Turn starting (female) 0 - K17@ - boom
between each for Replace
troubleshooting 1 in switch OFF. NO prolix switch - K170 - K . s
the Table 1 normal? - Disconnect (1) - solenoid short circuiting
applicable with chassisground
* Turn starting connector
switch OFF. Short circuit inside Replace
- Disconnect solenoid
applicable
connector
Table 1
Service Measurement location
Condition
code Troubleshooting 1 Troubleshooting 2 Ttroubleshooting 3
Between KlO Between KIO
E4:21
(male) (1) and (2) ’ - l5 * (female) (1) and GNDI Min. ’ MR ~~~“e;(!)t&d (2) 1Min. ’ MR op~%&om
Between K09 Between K09 Between K09 Operate boom
E4:25
(male) (1) and (2) ’ - l5 R (female) (1) and GND Min. ’ Mn (female) (1) and (2) Min. ’ MR RAISE
20-796
0
K-17 [E4:211, [E:251 Related electrical circuit diagram
Boom prolix switch
Valve controller
MIC21)
EPC GND
Boom LOWER(-)
Boom RAISE(-)
EPC Power source
12 EPC GND
13 Boom LOWER(+)
14 Boom RAISE(+)
21 EPC Power source

%
TKP00877
20-797
0
K-17 [E4:21] [E4:311 Abnormality 1, 2 in drive circuit system for boom

LOWER EPC valve is displayed -
[E4:25] [E4:35] Abnormality 1, 2 in drive circuit system for boom
RAISE EPC valve is displayed
removed.
When E4:21 l E&31 or E4:25 l E4:35 are displayed simultaneously
- - : Applicable connector No.

Cause Remedy
3 YES
I Isresistance IIA
YES between each pin
I Miring harness between
- fortroubleshooting -
2. E:03 (female) 0 - K170 -
3 in the Table 2
Is resistance “OmXll? t ,oom prolix switch - K170 Replace wiring
YES between each pin Km. (2) -solenoid short narness
* Turn starting NO
- for troubleshooting - c:ircuiting with chassis
switch OFF.
2 in the Table 2
* Disconnect K03 and Elround
“O”lXll?
1 - applicable connector IDisconnection inside
* Turn starting
switch OFF. NO ;olenoid
Is safety relay ON
f Disconnect t :ontact of power source
as shown in
applicable 1 !4V wiring harness with
Table l?
connector ~ YES ” viring harness between
- E:03 (female) 0 - K17@ -
Replace wiring
* Turn starting harness
t loom prolix switch - K170
switch ON. K . . (2) -solenoid
rble 2 normal? i YES

- IIefective valve controller Replace
&
ON. - tContact EPC power source
. Check needed ”viring harness with wiring
because there is normal? _ ttarness between K03 Replace wiring
also contact with * Turn starting NO harness
(female) 0 - K170 -boom
wiring harness switch OFF. )rohx switch - K17@ -K -.
which is 24V only
when fixed
* Disconnect K03. F2) -solenoid
operation is carried
out, such as for light
switch.
4 YES Replace
Defective valve controller
H
Is resistance II
between each pin for Disconnection in wiring
A troubleshooting 4 in harness between K03
the Table 2 normal? (female) 0 - K170 - boom
I Replace wiring
I
prolix switch - K170 - K . s
* Turn starting NO 0 -solenoid,or between harness
switch OFF. K03 (female) 0 - K170 -
* Disconnect K03 boom prolix switch - K17~
and applicable - KS. (2) -solenoid
CO”“ecbX.
* Connect short
connector to applicable
connector (female).
20-798
0
Table 1 Monitoring mode display (time display portion)

Table 2
Condition
code Troubleshooting 2 Troubleshooting 3 Ttroubleshooting 4 Troubleshooting 5 Troubleshooting 6
Between KlO BetweenKlO Between K03 BetweenK03 BetweenK03 Operate
E4:21 (male) 7 - 15 Q (female) Min.1 MR (female) Max. 1 n (2) 20 -30 V (female)
(female) (21 Min.1 MR boom
E4:31 (1)and (2) (2)andGND 113)and (2) and(I).
(12) and (11).
(21) LOWER
K-17 [E4:211 [E4:311, [E:251 [E4:351 Related electrical circuit diagram
Boom prolix switch
= EPC Valve controller

K17 I--'
MIC21)
(SlO) @@($(i)(
K9 (X2) EPC GND
Boom LOWER (-1

Boom 3
RAISE EPC A Boom RAISE(-)
solenoid
y\i EPC Power source
1
EPC GND
KIO (X 2'
Boom LOWER(+)
Boom RAISE(+)
bkk-/- 1
EPC Power source
TKP00877
20-799
0
K-18 [E4:31] Abnormality 2 in drive circuit system for boom LOWER

[E4:35] Abnormality 2 in drive circuit system for boom RAISE EPC
valve is displayed
removed.
* Turn the starting switch ON, operate according to the conditions in the table, and check if the
* Stop the engine, turn the swing lock switch ON, then set the safety lock lever to the LOCK nosition.
* Always turn the boom prolix switch OFF.
When E4:31 or E4:35 are displayed independently -a : Applicable connector No.

Cause Remedy
Contact of power source

24V wiring harness with
YES Replace wiring
K03 (female) 0 - K170 -
1 I boom prolix switch - K17 -

K . . (1) -solenoid
harness
3 YES 24V wiring harness with Replace wiring

Is voltage between wiring harness between harness
YES each pin for K03 (female) 0 - K17@ -
L 1 2 troubleshooting 3 in boom prolix switch K17@
*Turn starting - the Table 1 normal?
NO - K * . (2) -solenoid
Is resistance
switch ON. _ *A
between each pin
* Disconnect K03. _ for troubleshooting _ *Turn startingswitchON. Stopengine.Disconnect K03.
* Check needed NI 1 2 in the Table 1 * Checkneededbecausethereis alsocontactwithwiring Contact of EPC power
because there is normal? harness which is 24V onlywhen fixed operationis source wiring harness with
also contact with - carriedout,suchas for lightswitch.
* Turn starting wiring harness between Replace wiring
wiring harness K03 (female) 0 - K170 -
switch OFF. NO harness
which is 24V only boom prolix switch - K170
* Disconnect K03.
when fixed -K..(l)-solenoid
operation is
carried out, such
as for light switch.
4 YES
Defective valve controller qeplace
Is resistance II
between each pin
A for troubleshooting - Contact of EPC power
4 in the Table 1 source wiring harness
normal? with wiring harness qeplace wiring
* Turn starting NO between K03 (female) 0 - larness
switch OFF. K170 - boom prolix switch
* Disconnect K03. - K170 -K . . (2) - solenoid
Table 1
code 1 1 Condition
Troubleshooting 1 Troubleshooting 2 Ttroubleshooting 3 Troubleshooting 4
Between K03 Between K03 Between K03 Operate
E4:31 (female) (13) 20 - 30V (female) (13) Min. 1 MD (female) (2) 20 - 3ov boom
and (1). (12) and (ll), (21) and (1). (12) LOWER
Between K03 Between K03 Between K03 Between K03 Operate

E4:35 (female) (14) 20 - 30V (female) (14) Min. 1 MR (female) (3) 20 - 3ov (female) (3) Min. 1 MR boom
and (1). (12) and (ll), (21) and (l), (12) and (11). (21) RAISE
20-800
0
K-18 [E&31], [E4:351 Related electrical circuit diagram
Boom prolix switch
I 1 EPC Valve controller

K17 1
K03 (MICLI)
610) 1 @(g(i;>(i)(i)(g(g@ 1 r- I
K9 (X2) EPC GND
Boom LOWER (-)

Boom 3
RAISE EPC Boom RAISE(-)
solenoid 3
EPC power source
EPC GND
Boom LOWER(+)
Boom RAISE(+)
EPC Power source
20-801
0
K-18 [E4:21] [E4:31] Abnormality 1, 2 in drive circuit system for boom

LOWER EPC valve is displayed
[E4:25] [E4:35] Abnormality 1, 2 in drive circuit system for boom
RAISE EPC valve is displayed
removed.
service code is displayed. (if it is not displayed, the system has been reset.)
When E&21 l E4:31 or E4:25 l E4:35 are displayed simultaneously
. . : Applicable connector No.

Cause Remedy
3 YES
Is resistance
. I I---- GotoA
K03 (female) 0 - K170 -
boom prolix switch - K17G1 IReplace wiring
YE - K . . (2) -solenoid short Iharness
ground
1 Disconection inside
Reolace
switch OFF. NO solenoid
L-t
Is safety relay ON
* Disconnect Contact of power source
as shown in
applicable 24V wiring harness with
Table I?
connector wiring harness between
5 Replace wiring
K03 (female) 0 - K170 -
El
switch ON.
Is voltagebetween boom prolix switch - K17C
each pin for - K . * (2) - solenoid
*Set monitoring troubleshooting5 in
h i YES
code to 69. the Table 2 normal? Defective valve controlle r Replace
*Turn starting switch
ON. Contact EPC power source
* Check needed h wiring harness with wiring
because there is normal? harness between K03 Replace wiring
also contact with * Turn starting (female) 0 - K170 - boom harness
wiring harness switch OFF. prolix switch - K170 - K. .
which is 24V only (2) -solenoid
* Disconnect K03.
when fixed
switch.
4 YES
Defective valve controlle r
Is resistance
between each pin Disconnection in wiring
A- for troubleshooting -
harness between K03
4 in the Table 2
(female) 0 - K170 - boom
Lnormal? . .^ prolix switch - K170 - KS Replace wiring
*Turn starting NW (1) -solenoid, or between harness
switch OFF. K03 (female) 0 - K170 -
- Disconnect K03 boom prolix switch - K17~
and applicable - K . + (2) -solenoid
connector.
*Connect short
connector to applicable
connector (female).
20-802
0

Table 2
code Troubleshooting 2 Troubleshooting 3 Ttroubleshooting 4
Between KIO Between KIO Between K03
54:2I (male) 7 - I5 R (female) Min. I MD (female) Max. I R
54:3I (I) and (2) (21 and GND 113) and (2)
E4:25
54:35
Between K09
imale
111 and (21
7 - I5 R
Between K09
(female)
121 and GND
Min.
Between K03
1 MQ (female)
(14) and (31
Max. I R
-7
Min. 1 MG
K-18 [E&21 . E4:31 I, [E:25 l E&351 Related electrical circuit diagram
Boom prolix switch
Norma I
lalve controller
llC21)
EPC GND
Boom LOWER 1-j
Boom RAISE 1-j
EPC Power source
EPC GND
Boom LOWER (+I
Boom RAISE (t)
EPC power source
20-803
0
K-19 [E4:32] Abnormality 2 in drive circuit system for arm IN EPC valve
is displayed
[E4:331 Abnormality 2 in drive circuit system for bucket CURL EPC
valve is displayed
[E4:34] Abnormality 2 in drive circuit system for swing LEFT EPC
valve is displayed
[E4:36] Abnormality 2 in drive circuit system for arm OUT LEFT
[E4:37] Abnormality 2 in drive circuit system for bucket DUMP
[E4:38] Abnormality 2 in drive circuit system for swing RIGHT EPC
valve is displayed
removed.
Stop the engine, turn the swing lock switch ON, then set the safety lock lever to the LOCK position.
When E&32, E4:33, E4:34, E4:36, E4:37, E4:38 are displayed independently

Cause Remedy

24V wiring harness with
YES Replace wiring
K03 (female)@ - K.. (1) - narness
solenoid
1
Is voltage between 3 YES 24V wiring harness with qeplace wiring
each pin for wiring harness between
Is voltage between
7arness
troubleshooting 1 in
YES each pin for
K03 (female10 - K . . (2) -
the Table 1 normal?
troubleshooting3 in solenoid
2
- Turn starting ~Is resistance the Table 1 normal? NO
switch ON. -A
between each pin
* Disconnect K03. _ for troubleshooting _ *Turn startingswitchON. Stopengine.Disconnect
K03.
* Check needed NO 2 in the Table 1 *Check needed because there is also contact with wiring
because there is normal? harnesswhichis 24V onlywhenfixedoperationis Contact of EPC power
also contact with carriedout,suchasfor lightswitch. source wiring harness
. Turn starting qeplace wiring
wiring harness with wiring harness
switch OFF. NO iarness
which is 24V only between K03 (female) 0
* Disconnect K03. - K -. (1) -solenoid
when fixed
operation is
carried out, such
as for light switch.
Defective valve controlle r Replace

Is resistance
between each pin
A- for troubleshooting Contact of EPC power
4 in the Table 1 source wiring harness
normal? Replace wiring
with wiring harness
. Turn starting NO harness
between K03 (female) 0
switch OFF. - K . . (2) -solenoid
* Disconnect K03.
20-804
0
Table 1
jervice Measurement location
Condition
code Troubleshooting 1 ) Troubleshooting 2 Ttroubleshooting 3 1 Troubleshooting 4
E4:32 (female) (15) 20 - 30V (female) 115) 20 - 30V (female) (4) Min. 1 MR arm
and (11). (21) IN
Operate
E4:33 Min. 1 MQ bucket
CURL
Operate
E4:34 Min. 1 MR swing
LEFT
Between K03 Between K03 Operate

E4:36 (female) (16) 20 - 30V (female) (16) Min. 1 MR (female)(51 20 - 3OV (female)(5) Min. 1 MQ arm
and (l), (12) and (II), (21)
E4:37
E4:38
:
K-19 [E4:321, [E4:331, [E4:341, [E4:361, [E4:371, [E4:381 Related electrical circuit diagram
tro1 Ier
K12 (X21 K03 (MIC21)
Arm OUT EPC 3 Arm IN(-)

solenoid _ 3 Arm OUT(-)
3 Bucket CURL(-)
K13 (X2)
8 Bucket DUMP(-)
Bucket 9 Suing LEFT(-)

CURL EPC
n Suing RIGHT(-)
solenoid
I I I IjjJ Arm IN(t)
Kl4 (X2)
@ Arm OUT(+)
Bucket .I7 Bucket CURL(+)

DUMP EPC
&$ Bucket DUMP(+)
solenoid
.j$ Swins LEFT(t)
Swine RIGHT(+)
Swne 0
LEFT EPC
solenoid @
K15 (X2)
Swine 3
RIGHT EPC
solenoid a
TKPOPB78
20-805
0
K-19 [E4:22] [E4:32] Abnormality 1, 2 in driye circuit system for arm IN

[E4:23] [E4:331 Abnormality 1, 2 in drive circuit system for bucket
CURL EPC valve is displayed
[ E4:24] [ E4:34] Abnormality 1, 2 in drive circuit system for swing
LEFT EPC valve
[E4:26] [E4:36] Abnormality 1, 2 in drive circuit system for arm
OUT EPC valve is displayed
[E4:27] [E4:37] Abnormality 1, 2 in drive circuit system for bucket
DUMP EPC valve is displayed
RIGHT EPC valve is displayed
removed.
* Turn the startino switch ON, operate accordina to the conditions in the table, and check if the
service code is displayed. (If-it is not displayed,-the system has been reset.)
* Before carrying out troubleshooting, check that all the re-
. . : Applicable connector No.
lated connectors are properly inserted.
* Always connect any disconnected connectors before going ’ ’ App’icab’epi” No’
on the next step. Cause Remedy
r
When E4:22 . E432, E4:23 E4:33, E4:24 lE&34, E4:26 E4:36, l l
E4:27 l E4:37 or E4:28 E4:38 are displayed simultaneously

l
3 YES
Is resistance IIA
H
for troubleshooting
2 Wiring harness between
rl 3 in the Table 2
K03 (female) 0 - K . . (2) - Replace wiring
normal? II
solenoid short circuiting harness
loorlng
* Turn startino switch NO with chassis ground
OFF. -
2 in the Tabl-e2_ l-l
normal? * Disconnect K03 and
I applicable connector.
* Turn starting Disconnection inside
Replace
switch OFF. NO solenoid
* Disconnect
applicable Contact of power source
connector. 24V wiring harness with
YES
I I wiring harness between Replace wiring
l Turn starting
switch ON.
L
I Is voltage between II I K03 (female) 0 - KS. (2) -
solenoid
harness
l Set monitoring
code to 69. h
Contact EPC power source

wiring harness with wiring
because there is normal? Replace wiring
harness between K03
also contact with
* Turn starting (female) 0 - K . . (2) - harness
wiring harness
switch OFF. solenoid
which is 24V only
when fixed * Disconnect K03.
switch.
4 YES
Is resistance
between each pin
A - for troubleshooting - Disconnection in wiring
4 in the Table 2 harness between K03
normal? II Ifemale)@-K..(l)- Replace wiring
* Turn starting NO solenoid, or between K03
switch OFF- (female) 0 - K +. (2) -
* Disconnect K03 and applicable connector. solenoid
+ Connect short connector to applicable connector (female)
20-806
0

Table 2
service Measurement locatior
Condition
code Troubleshooting 2 Troubleshooting 3 Ttroubleshooting 4 Troubleshooting 5 1 Troubleshooting 6
E4.22 Between Kll Between Kll Between K03 Between K031 1Between K03 1 Ooerate
B4132 (male) 7 - 15 R (female) Min. 1 MQ (female) Max. 1 R
’ (1)and (2) (2) and GND (15) and (4)
E4:26 Between K12 Between K12 Between K03

(male1 7 - 15 n (female) Min. 1 MQ (female) Max. 1 G
E4’36 (11 and (2) (21 and GND (161 and (5)
Between K14 Between K14 Between K03
E!g: (male) 7 - 15 D (female) Min. 1 MR (female) Max. 1 Q
’ (1) and (2) (2) and GND (18) and (8)
E4:28 Between K15 Between K15 Between K03
8
>
s
E4’38
(male)
(1) and (2)
7 - 15 G (female)
(21 and GND
Min. 1 MQ (female)
120) and (10)
Max. 1 R
1
0
K-19 [E4:22 . E4:321, [E4:23 E4:331, [E4:24l l E4:341, [E4:26 l E4:361, IE4:27 l E4:371 or [E4:28 l E4:381
Related electrical circuit diagram
Kll (X2)
Bucket CURL (-)

Bucket DUMP (-)
Swine LEFT (-1
Swine RIGHT(-)
Bucket CURL f+)

Bucket DUMP(+)
Swing RIGHT(+)
TKP00678
20-807
0
K-20 [E4:41] [E4:421 [E4:43] [E4:441 Over-range in control lever

potentiometer signal system is displayed
removed.
When E4:45, E4:46, E4:47 or E4:48 are displayed at the same time, there is probably a short circuit
with the ground or a disconnection in the wiring harness for the power source, or there is contact
with the 24V wiring harness, or there is a disconnection in the GND line wiring harness.
Cause Remedy
YES
Defective lever assembly Replace
1 1
Is there any II I
change when left
and right levers 2 YES
are interchanfgd?
- Is voltage measured
* Turn starting _ at T-adapter as
switch OFF. ~0 shown in the Table
* Interchange levers. 17 Replace wiring
*Turn starting NO
switch ON.
switch ON.
* Insert T-adapter in
K05.
Table 1
Monitoring display
Example
Service Voltage measured by tester (V)

K22 K21 K05
code At neutral At full stroke
Between Between
E&41 (2) and (3) - (19) and (5)
I I
Boom
Between 1 1 Between
(11) and (12) - (9) and (5)
Between Between
E4:42 - (2) and (3) (17) and (5)
Arm
Between Between
(11) and Cl’21 (7) and (5)
2.5 t 0.25 3.87 - 4.52 0.66 - 0.97
Between Between
(5) and (6) - (18) and (15)
E4:43
Bucket Between Between
Is) and (9) - (8) and (15)
Between Between
E4:44 - (5) and (6) (16) and (15)
Swing
Between Between
(8) and (9) (6) and (15)
20-808
0
K2 2'LO4012) K0t 3 68)
- K21 (04012)
I
KC
Valve controller
L. H. left-right
L. H. front-rear
R. Ii. left-right
R. H. front-rear
NSW siclna
NSW signa
NSW signa
NSW signa
Potentiometer Power
Potentiometer GND
L. H. left-right SIC sisna
L. H. front-rear SIC signa
R.H. left-right SIC signa
TKP00871
20-809
0
K-21 [E4:45] [E4:46] [E4:47] [E4:48] Excessive error in signal SIG and
switch SIG of control lever potentiometer is displayed
removed.
When E4:41, E4:42, E4:43 or E4:44 are displayed at the same time, there is probably a short circuit
with the ground or a disconnection in the wiring harness for the power source, or there is contact
with the 24V wiring harness, or there is a disconnection in the GND line wiring harness.
Cause
YES Defective lever assembly Replace

1 I
change when left

are interchanged?
- Turn starting
switch OFF. N
* Interchange levers.
-Turn starting I II Defective wiring harness Replace
*Turn starting NO
switch ON.
switch ON.
* Insert T-adapter in
K05.
I
Table 1
Monitoring display
Example
sm: g$yM x%:”
E4:48 (5) and (6) (16) and (15)

Swing
Between Between
(8) and (9) (6) and (15)
20-810
0
K2 01qS8'
Valve controller
K05 (04020)
:
3 Potentiometer GND
-3 L. H. left-right NSY signal
-3 L. H. front-rear NSY signal
-3 R. H. left-right NSW sional
-8 R. H. front-rear NSY signal

04012) )7
Potentiometer Power
source (5V)
Potentiometer CND
L. H. left-right SIG signal
L. H. front-rear SIC signal
R.H. left-right SIG signal
TKP00871
20-811
0
TROUBLESHOOTING K-22, 23
K-22 [E4:55] Abnormality in ROM, RAM of CPU is displayed
Cause Remedy
1 YES Failure in lever controller Replace

When battery is
charged and starting
switch is turned again -
to ON, does problem
appear agin? Charge battery
Drop in battery voltage
* Turn starting NO or replace
switch ON.
Start engine.
* Raise engine speed and maintain
for approx. 1 min.
*Turn starting switch ON again.
Note: This error message may appear when cranking the engine if the chassis battery voltage drops
considerably (approx. IOV or below).
K-23 [E4:58] Abnormality in interlock PLD is displayed
Cause Remedy
Defect inside controller Replace
20-812
0
K-24 [E4:22] Abnormality 1 in drive circuit system for arm IN EPC valve
is displayed
[ E4:23] Abnormality 1 in drive circuit system for bucket CURL EPC
valve is displayed
[ E4:24] Abnormality 1 in drive circuit system for swing LEFT EPC
valve is displayed
[ E4:26] Abnormality 1 in drive circuit system for arm OUT EPC
valve is displayed
[E4:27] Abnormality 1 in drive circuit system for bucket DUMP
[ E4:28] Abnormality 1 in drive circuit system for swing RIGHT EPC
valve is displayed
removed.
When E&22, E&23, E&24, E&26, E4:27, E4:28 are displayed independently

Cause Remedy
3 YES
Is resistance
- for troubleshooting - Contact of wiring harness
2
~ 3 in the Table 1 between K03 (female) 0 - K
Is resistance IVXrllal?
YES between each pin - * 11)-solenoid, and Replace wiring
- for troubleshooting -
* Turn starting NO between K03 (female) 0 -K harness
switch OFF. - . (2) -solenoid
1 2 in the Table 1
~ normal? * Disconnect K03 and
Is resistance Wiring harness between K03
applicable connector
between each pin * Turn starting (female) 0 - K . . (I b- Replace wiring
for troubleshooting - switch ON. NO solenoid short circuitingwith harness
1 in the Table 1 l Disconnect K03 and chassis ground
normal?
applicable connector
- Turn starting
Short circuit inside
switch OFF. Replace
NO solenoid
* Disconnect
applicable
connector
20-813
0
Table 1
service Measurement location
code Troubleshooting 1 1 Troubleshooting 2
Between Kll Between Kll
E4:22 (male) 7 - 15 R (female) Min. 1 Ma (female) 1Min. 1 MR 1 arm
(1) and (2) (I) and GND iI) and .(2) IN

E4:23 (male) 7-l5R (female) Min. 1 MR (female) Min. 1 MR bucket
(1) and (2) (1) and GND (I) and (2) I I CURL
Between K16 Between K16

E4:24 (male) 7 - 15 R (female) Min. 1 MR
II) and (2) (I) and GND

E4:26 (male) 7 - 15 Q (female) Min. 1 MQ
(I) and (2) (1) and GND

E4:28 (male) 7 - 15 Q (female) Min. 1 MR (female) Min. 1 Ma Ang
(I) and (2) (I) and GND (1) and (2) RIGHT
K-24 [E4:22], [E4:23], [E4:241, [E4:261, [E4:271, [E4:281 Related electrical circuit diagram
Kll (X2)
Arm IN EPC
solenoid
Bucket CURL (-)

Bucket DUMP (-)
Swing LEFT (-)
Swing RIGHT(-)
K14 (X2)
Bucket Bucket CURL(+)

DUMP EPC
Bucket DUMP (+)
solenoid
SW i ne LEFT (+I
Swing RIGHT(+)
Swine
LEFT EPC
solenoid
I I I \I
K15 (X2)
I I I II I
Swing
RIGHT EPC
solenoid
TKP00878
20-814
0
K-24 [ E4:22] [ E4:32] Abnormality 1, 2 in drive circuit system for arm IN

[ E4:23] [ E4:33] Abnormality 1, 2 in drive circuit system for bucket
CURL EPC valve is displayed
LEFT EPC valve
[ E4:26] [ E4:36] Abnormality 1, 2 in drive circuit system for arm
OUT EPC valve is displayed
[ E4:27] [ E4:37] Abnormality 1, 2 in drive circuit system for bucket
DUMP EPC valve is displayed
RIGHT EPC valve is displayed
* If two or more codes occur simultaneously, see K-19 for details of the troubleshooting flow chart.
20-815
0
Table 1
i&i7 - Measurement location
code Troublesh’ oot:ing 1 1 TroubleshI ting 2 T Ttroubleshooting 3
Condition
Between Kll Between Kll Between Kll Operate

E4:22 (male) 7-15n (female) Min. 1 MR (female) Min. 1 MD arm
(I) and (2) (I) and GND (I) and (2) IN

E4:23 (male) 7-15R (female) Min. 1 MD (female) Min. 1 MR bucket
(1) and (2) (I) and GND (I) and (2) CURL
E4:24 (male) 7-15R (female) Min. 1 Ma (female) Min. 1 MQ swing
(I) and (2) (1) and GND (I) and (2) f LEFT

E4:26 (male) 7-15a (female) Min. 1 MQ (female) Min. 1 MD arm
iI) anb (2) and (II), (21) (I) and (2) OUT

E4:27 (male) 7-15R (female) Min. 1 MD
(1) and (2) (I) and GND

E4:28 (male) 7-15n (female) Min. 1 MQ
(1) and (2) (I) and GND
K-24 [E4:221, [E&231, [E4:241, [E4:261, [E4:271, [E4:281 Related electrical circuit diagram
20-816
0
K-24 [E4:221 [E4:321 Alonormality 1, 2 in drive circuit system for arm IN

EF‘C valve is displayed
[E4:23] [E4:331 Dnormality 1, 2 in drive circuit system for bucket
:I JRL EPC valve is displayed
[ E4:24] [ E4:34] AlDnormality 1, 2 in drive circuit system for swing
LE:FT EPC valve
[ E4:26] [ E4:361 AlDnormality 1, 2 in drive circuit system for arm
01UT EPC valve is displayed
[ E4:27] [ E4:37] AlDnormality 1, 2 in drive circuit system for bucket
DIUMP EPC valve is displayed
[ E4:281 [E4:381 AlDnormality 1, 2 in drive circuit system for swing
RI GHT EPC valve is displayed
* If two or more codes occur simultaneously, see K-19 for details of the troubleshooting flow chart.
20-817
0
30 DISASSEMBLY AND ASSEMBLY
METHOD OF USING MANUAL . . . . . . .. . . . .. . .. . .. 30- 3 CENTER SWIVEL JOINT

PRECAUTIONS WHEN CARRYING OUT Removal and Installation ................... 30- 65
OPERATION . . .. . .. . . . . . . . .. .. . . . . . . .. . . . . . . .. .. . . . . . . .. 30- 4 Disassembly and Assembly.. ............ 30- 67
SPECIAL TOOL LIST . . . . . . .. . . . . . . .. . . . .. . .. .. . . . .. . . . . . 30- 6 FINAL DRIVE
SKETCHES OF SPECIAL TOOLS . .. . .. . . . . . .. . . 30-10 Removal and Installation ................... 30- 68
STARTING MOTOR Disassembly ......................................... 30- 69
Removal and Installation . .. . . . . . . . . .. . . . . . . . 30-I 1 Assembly .............................................. 30- 72
ALTERNATOR SPROCKET
Removal and Installation . . . . . . .. . . . . . . .. .. . . 30-12 Removal and Installation ................... .30- 77
AIR CONDITIONER COMPRESSOR SWING MOTOR AND SWING MACHINERY
Removal and Installation . . . . . . . .. . . .. . . . . . . . 30-13 Removal ................................................ 30- 78
CONDENSER Installation ............................................ 30- 79
Removal and Installation . .. . .. . . .. . .. .. . . . . . 30-14 Disassembly ......................................... 30- 80
DRY RECEIVER Assembly .............................................. 30- 84
Removal and Installation . . . . . . .. . . . . . .. . . .. . 30-16 REVOLVING FRAME
ENGINE OIL COOLER CORE Removal ................................................ 30- 89
Removal and Installation .. . . . . . . .. . .. . . . . . .. 30-17 Installation ............................................ 30- 90
FUEL INJECTION PUMP SWING CIRCLE
Removal . .. . . . .. . . . . . . . . .. . .. . . . . . .. . .. . . . . .. .. . . . . . .. . . . 30-18 Removal ................................................ 30- 91
Installation . . .. . . . . . . . . .. . . . . . . .. .. . . . . .. .. . . . .. . .. . .. . 30-21 Installation ............................................ 30- 92
WATER PUMP IDLER RECOIL SPRING
l
Removal and Installation .. . . . . . . .. .. . . . . . . .. 30-28 Removal and installation ................... .30- 93

NOZZLE HOLDER RECOIL SPRING
Removal and Installation . . .. .. . . . . . . . .. . . . . . 30-30 Disassembly ......................................... 30- 94
TURBOCHARGER Assembly .............................................. 30- 95
Removal and Installation . . . . . . .. . . . . . . . . . . .. 30-31 IDLER
THERMOSTAT Disassembly ......................................... 30- 96
Removal and Installation .. . . . .. .. . . . .. . . . . . . 30-32 Assembly .............................................. 30- 97
GOVERNOR MOTOR TRACK ROLLER
Removal and Installation . . .. . . .. . . . . .. . . . . . . 30-34 Removal and Installation ................... .30- 99
CYLINDER HEAD Disassembly ........................................ .30-100
Removal . .. .. . . . .. .. . .. . . . .. . . . .. . . . . . .. . . . . . . . . . .. . . . . . . 30-35 Assembly .............................................. 30-I 02
Installation . . . . . . .. . . . . . . .. .. . . . . . . .. . . . . . . .. . .. . . . . . .. 30-39 CARRIER ROLLER
HYDRAULIC OIL COOLER Removal and Installation ................... .30-l 04
Removal and Installation . .. . . . . . . . . .. . . . . .. . 30-50 Disassembly ........................................ .30-105
RADIATOR HYDRAULIC OIL COOLER
l Assembly .............................................. 30-I 07
Removal .. . . . . . . .. .. . . . . . .. . . . . . .. .. .. . . .. . . .. . . . .. . . . .. . 30-52 TRACK SHOE
Installation . .. . . . . . . . . .. . . . . . . .. . . . . . .. . .. . . . . . . .. . . . . . 30-54 Removal and Installation ................... .30-109
ENGINE MAIN PUMP
l HYDRAULIC TANK
Removal . . .. .. . . . . . . . .. . . . .. . . . .. . .. .. . . . . . . .. . . . . . .. . .. . 30-58 Removal ................................................ 30-I IO
Installation . .. . . . .. . . . . .. . . . . . . .. . . . . .. . .. . . . . . . .. . . . . . 30-62 Installation .......................................... ..30-111
DAMPER MAIN PUMP
Removal and Installation . . . . . . . .. . . . . .. . .. . . 30-63 Removal ................................................ 30-I 12
FUEL TANK Installation ............................................ 30-I 14
Removal and Installation . .. . . . . .. . . .. . . . . .. . 30-64
30-l
0
MAIN PUMP INPUT SHAFT OIL SEAL OPERATOR’S CAB
Removal and Installation .................. ..30-115 Removal .. . . . . . . .. . .. . . . . . .. . . . . .. .. .. . . . . . . .. . . . . . . .. . . 30-168
CONTROL VALVE Installation . . . . . . . .. . . . . . .. .. . . . . . . .. . . .. . . .. . .. . . . . . . . 30-169
Removal ................................................ 30-I 16 COUNTERWEIGHT
Installation .......................................... ..30-118 Removal and Installation . . .. . .. . . . . . .. . .. . . . 30-170
Disassembly ....................................... 30-I 19 WORK EQUIPMENT ELECTRIC LEVER UNIT
Assembly .............................................. 30-124 Removal and Installation . . . . . .. . .. . . . .. . . . .. 30-172
PUMP MERGE/DIVIDER VALVE ENGINE THROTTLE PUMP CONTROLLER
l
Disassembly and Assembly.. ............ 30-130 Removal and Installation .. . . . . . . .. . .. . . . . . .. 30-173

MAIN RELIEF VALVE CONTROL STAND CASE
Disassembly and Assembly.. ............. .30-131 Removal . .. . . . .. . .. .. . .. .. . . . . . . .. . .. . . . .. . . .. . . . . . . . . . . 30-174
WORK EQUIPMENT EPC VALVE Installation . . . . . . . .. . ..._.............................. 30-175
Removal and Installation ................... .30-132 VALVE CONTROLLER
PC VALVE Removal and Installation . .. . .. . . .. . . . .. . .. . . 30-176
Removal ................................................ 30-I 33 MONITOR
Installation .......................................... 30-134 Removal and Installation . .. . .. .. . . . . . . .. .. . . 30-177
LS VALVE
Removal and Installation ................... .30-135 ITEMS FOR HYPER GX
PC LS-EPC VALVE SWING MOTOR
Removal and Installation ................... .30-136 Removal and Installation ................... .30-l 78
SOLENOID VALVE CONTROL STAND CASE
Removal and Installation ................... .30-137 Removal and Installation ................... .30-179
WORK EQUIPMENT lSWING PPC VALVE WORK EQUIPMENT EPC VALVE
Removal and Installation ................... .30-138 Removal and Installation ................... .30-181
Disassembly ........................................ .30-139 BOOM CYLINDER
Assembly ............................................. -30-I 40 Removal ................................................ 30-182
TRAVEL PPC VALVE Installation ........................................... .30-183
Removal and Installation .................. ..30-14 1 ARM CYLINDER
Disassembly ........................................ .30-l 42 Removal ............................................... .30-184
Assembly .............................................. 30-I 43 Installation ........................................... .30-185
BOOM LOCK VALVE BUCKET CYLINDER
Removal and Installation ................... .30-144 Removal ................................................ 30-186
BOOM CYLINDER Installation ........................................... .30-187
Removal ................................................ 30-I 45 Disassembly ....................................... 30-188
Installation ............................................ 30-I 46 Assembly .............................................. 30-190
ARM CYLINDER WORK EQUIPMENT
Removal ................................................ 30-I 47 Removal ................................................ 30-194
Installation ............................................ 30-I 48 Installation ............................................ 30-196
BUCKET CYLINDER BUCKET
Removal ................................................ 30-I 49 Removal ................................................ 30-197
Installation ............................................ 30-I 50 Installation ............................................ 30-198
HYDRAULIC CYLINDER ARM
Disassembly ....................................... 30-I 51 Removal ............................................... .30-199
Assembly .............................................. 30-I 54 Installation ........................................... .30-200
WORK EQUIPMENT BUCKET ARM l
Removal ................................................ 30-I 58 Removal ............................................... .30-201

Installation ........................................... .30-159 Installation ............................................ 30-202
BUCKET BOOM
Removal ................................................ 30-160 Removal ............................................... -30-203
Installation ............................................ 30-I 61 Installation ........................................... .30-205
ARM VALVE CONTROLLER
Removal ................................................ 30-162 Removal and Installation ................... .30-206
Installation ............................................ 30-163 GX CONTROLLER
BUCKET ARM
l Removal and Installation ................... .30-207
Removal ................................................ 30-I 64 GX PANEL
Installation ........................................... .30-165 Removal and Installation ................... .30-208
BOOM
Removal ................................................ 30-166
Installation ............................................ 30-I 67
30-2
0
DISASSEMBLY AND ASSEMBLY METHOD OF USING MANUAL
METHOD OF USING MANUAL
1. When removing or installing unit assemblies

@ When removing or installing a unit assembly, the order of work and techniques used are given
for the removal operation; the order of work for the installation operation is not given.
@ Any special techniques applying only to the installation procedure are marked m, and the
same mark is placed after the relevant step in the removal procedure to indicate which step in
the installation procedure it applies to.
(Example)
REMOVAL OF 0 0 0 0 ASSEMBLY . . .. . .. . . . . . Title of operation
g . . . . . .. . . . . . . .. .. . . . . . . . . .. . . . . . . . . .. . . . . . . . .. . .. . . . . . .. .. . . . . . . . . .. . . Precautions related to safety when carrying out
the operation
1. XXXX(1) . . . . . . . .. . . . . . . . . . .. . . . . . . .. .. . . . . . . .. . . .. . . . . . . . .. . . Stepinoperation
* . . .. . . .. . . . . . .. . . . . . . . . .. . . . . . . .. . . .. . . . . . . . .. . . . . . . . .. . . . .. . . . . .. . Technique or important point to remember
when removing XXXX (1).
2. n a a a (2): . . . . . .. .. . . . . . .. . .. . . . . . . .. . . .. . . . . . .. . . .. . . .. . a Indicates that a technique is listed for use
during installation
3. 0 0 0 0 assembly (3)
.. . . . . . .. . .. . . . . . .. . .. . . . . .. . . .. . . . . . .. . .. . . . . . . .. . . . . . . .. .. Quantity of oil or water drained
l
INSTALLATION OF 0 0 0 0 ASSEMBLY .. ..Title of operation
Carry out installation in the reverse order to removal.
p .._. ...... ............ .................. ............. ..... .... Technique used during installation
. . .. . .. . . . . . . .. . . .. . . . . . .. . . . . . . .. . . .. . . .. . . .. . .. . . . . . .. . . .. . . .. .. . Technique or important point to remember when
installing a a fI n (2).
. Adding water, oil .. . . . . . .. . .. . . . . . . . .. . . . . . .. .. . . . Step in operation
Ir .. . . . . . . . . . . .. . . . . . . . . . .. . . . . . . .. . .. . . . . . . .. . . . . . .. . . .. . . . . . Point to remember when adding water or oil
%# . .. .. . .. . . . . . .. . .. . . . . . .. . .. .. . .. . .. .. . . . . . . .. .. . . . . . . .. . Quantity when filling with oil and water
2. General precautions when carrying out installation or removal (disassembly or assembly) of units
are given together as PRECAUTIONS WHEN CARRYING OUT OPERATION, so be sure to follow
these precautions when carrying out the operation.
3. Listing of special tools

@ For details of the description, part number, and quantity of any tools (Al, etc.) that appear in
the operation procedure, see the SPECIAL TOOLS LIST given in this manual.
30-3
0
DISASSEMBLY AND ASSEMBLY PRECAUTIONS WHEN CARRYING OUT OPERATION
PRECAUTIONS WHEN CARRYING OUT OPERATION

[When carrying out removal or installation (disassembly or assembly) of units, be sure to follow the
general precautions given below when carrying out the operation.]
1. Precautions when carrying out removal work
. If the coolant contains antifreeze, dispose of it correctly.
. After disconnecting hoses or tubes, cover them or fit blind plugs to prevent dirt or dust from
entering.
. When draining oil, prepare a container of adequate size to catch the oil.
. Confirm the match marks showing the installation position, and make match marks in the neces-
sary places before removal to prevent any mistake when assembling.
. To prevent any excessive force from being applied to the wiring, always hold the connectors when
disconnecting the connectors. Do not pull the wires.
. Fit wires and hoses with tags to show their installation position to prevent any mistake when
installing.
. Check the number and thickness of the shims, and keep in a safe place.
. When raising components, be sure to use lifting equipment of ample strength.
. When using forcing screws to remove any components, tighten the forcing screws uniformly in
turn.
. Before removing any unit, clean the surrounding area and fit a cover to prevent any dust or dirt
from entering after removal.
* Precautions when handling piping during disassembly
Fit the following blind plugs into the piping after disconnecting it during disassembly operations.
1) Hoses and tubes using sleeve nuts
Nominal
Plug (nut end) Sleeve nut (elbow end) Use the two items below as a set
number
02 07376-50210 07221-20210 (Nut),07222-00210 (Plug)
03 07376-50315 07221-20315 (Nut),07222-00312 (Plug)
04 07376-50422 07221-20422 (Nut), 07222-00414 (Plug)
05 07376-50522 07221-20522 (Nut),07222-00515 (Plug)
06 07376-50628 07221-20628 (Nut),07222-00616 (Plug)
IO 07376-51034 07221-21034 (Nut), 07222-01018 (Plug)
12 07376-51234 07221-21234 (Nut), 07222-01219 (Plug)
2) Split flange type hoses and tubes
Nominal
Flange (hose end) Sleeve head (tube end) Split flange
number
04 07379-00400 07378-10400 07371-30400
05 07379-00500 07378-10500 07371-30500
3) If the part is not under hydraulic pressure, the following corks can be used.
Part Number
30-4
0
DISASSEMBLY AND ASSEMBLY PRECAUTIONS WHEN CARRYING OUT OPERATION
2. Precautions when carrying out installation work

. Tighten all bolts and nuts (sleeve nuts) to the specified (KES) torque.
. Install the hoses without twisting or interference.
. Replace all gaskets, O-rings, cotter pins, and lock plates with new parts.
. Bend the cotter pins and lock plates securely.
. When coating with adhesive, clean the part and remove all oil and grease, then coat the threaded
portion with 2 - 3 drops of adhesive.
. When coating with gasket sealant, clean the surface and remove all oil and grease, check that there
is no dirt or damage, then coat uniformly with gasket sealant.
l Clean all parts, and correct any damage, dents, burrs, or rust.
. Coat rotating parts and sliding parts with engine oil.
l When press fitting parts, coat the surface with anti-friction compound (LM-P).
. After fitting snap rings, check that the snap ring is fitted securely in the ring groove.
. When connecting wiring connectors, clean the connector to remove all oil, dirt, or water, then
connect securely.
. When using eyebolts, check that there is no deformation or deterioration, screw them in fully, and
align the direction of the hook.
. When tightening split flanges, tighten uniformly in turn to prevent excessive tightening on one
side.
* When operating the hydraulic cylinders for the first time after reassembling cylinders, pumps and
other hydraulic equipment removed for repair, always bleed the air as follows:
1. Start the engine and run at low idling.
2. Operate the work equipment control lever to operate the hydraulic cylinder 4 - 5 times,
stopping the cylinder 100 mm from the end of its stroke.
3. Next, operate the hydraulic cylinder 3 - 4 times to the end of its stroke.
4. After doing this, run the engine at normal speed.
* When using the machine for the first time after repair or long storage, follow the same
procedure.
3. Precautions when completing the operation

. If the coolant has been drained, tighten the drain valve, and add water to the specified level. Run
the engine to circulate the water through the system. Then check the water level again.
. If the hydraulic equipment has been removed and installed again, add engine oil to the specified
level. Run the engine to circulate the oil through the system. Then check the oil level again.
. If the piping or hydraulic equipment have been removed, always bleed the air from the system
after reassembling the parts.
Ir For details, see TESTING AND ADJUSTING, Bleeding air.
. Add the specified amount of grease (molybdenum disulphide grease) to the work equipment parts.
30-5
0
DISASSEMBLY AND ASSEMBLY SPECIAL TOOL LIST
SPECIAL TOOL LIST
Tools with part number790T-0000000cannot be supplied (they are items to be locally manufac-
tured).
Necessity: W: Cannot be substituted, should always be installed (used)
0: Extremely useful if available, can be substituted with commercially available part
New/remodel:N: Tools with new part numbers, newly developed for this model.
R: Tools with upgraded part numbers, remodeled from items already available for
other models.
Blank: Tools already available for other models, used without any modification.
Tools marked 0 in the Sketch column are tools introduced in special sketches (See SKETCHES OF
SPECIAL TOOLS).
Component Symbol
1
l Removal, installa- 1
tion of cylinder nder head bolt
assembly
l Removal, installa- 2
tion of fuel injection
pump assembly
l Removal, installa-
tion of nozzle holder
assembly
l Engine, main pump

assembly
l Radiator, hydraulic
cooler assembly
l Control pump
assembly 796-460-1210 Oil stopper W 1
l Main pump assem-
bly
l Removal, installa-
tion of servo valve
assembly
Disassembly
of center swivel joint
assembly
.790-101-2560 .Nut 2
.790-101-2650 .Adapter 2
Disassembly, F 796-426-l 120 Push tool n 1 Press fitting of

assembly of swing
machinery
30-6
0
Nature of work,
Component Symbol Part No. Part Name rz$el Sketch
remarks
Removal, installa-
1 796-427-1200 Wrench n 1
tion of round nut
2
Disassembly, assem- Press fitting of
bly of final drive G bearing inner race
assembly
3 790-331-I 110 Wrench n 1 Tightening of final

drive cover mount-
ing bolt
4 791-545-1510 Installer n 1 Installation of
floating seal
pin
Removal, installation
of recoil spring H
assembly
Installation of dust
seal on recoil
of track shoe fitting of master pin
of road liner (rubber
pad type)
Assembly of idler
assembfy
Disassembly, assem-
bly of track roller
assembly
Tightening of track
roller assembl
Nature of work,
Component Symbol Part No. Part Name .t!$el Sketclh
r remarks
Removal, installa-
1 797-101-I 121 Wrench n 1 i- tion of nut
Press fitting of
Disassembly, assem- 2 796-430-I 110 Push tool n 1 bearing
bly of carrier roller L
assembly Installation of
3 791-434-1650 Installer n 1 floating seal
Chargingwith oil,
checkingfor air leakage
Installation of track Tightening of track
roller roller bolt
Replacement of pump , 791-463-1141 Push tool 1 n ( 1

N I I I
shaft oil seal
---I-- Removal, installation

of piston’ assembly
Replacement pin for
wrench assembly
Removal, installa-
tion of piston nut
(for PC200 HYPER-
GX bucket cylinder)
Expansion of piston
ring
PC220 Arm
PC200 Boom
PC220 Boom
Disassembly, assem- PC220 Bucket
bly of hydraulic 0
cylinder PC200 Bucket
790-201-1702 Push tool kit W 1 PC200 Bucket
I
.790-201-1831 .Push tool 1
~790-101-5021 -Grip 1
.OlOlO-50816 .Bolt 1
790-201-1702 Push tool kit W 1 PC220 Boom
.790-201-1841 .Push tool 1 PC220 Bucket

5
~790-101-5021 -Grip 1
790-201-1702 Push tool kit n 1 PC220 Arm

.790-201-1851 -Push tool 1
~790-101-5021 .Grip 1
30-8
0
-
eces New/ Nature of work,
Component Symbol Part No. Part Name QY\ ;ketcl
sily emode remarks
- - - -
790-201-1702 Push tool kit W 1 PC200 Arm
~790-201-1930 *Push tool 1
~790-101-5021 *Grip 1
5 ~01010-50816 -Bolt 1
790-201-1702 Push tool kit n 1 PC200 Boom

-790-201-1940 .Push tool 1
~790-101-5021 .Grip 1
~01010-50816 -Bolt 1
-
790-201-1500 Push tool kit 0 1 PC200 Bucket
.790-201-1640 *Push tool 1
-790-101-5021 -Grip 1
~01010-50816 .Bolt 1
Disassembly, assem- 790-201-1500 Push tool kit 0 1 PC220 Boom
bly of hydraulic 0
cylinder .790-201-1650 .Push tool 1 PC220 Bucket
-790-101-5021 *Grip 1
~01010-50816 *Bolt 1
-
790-201-1500 Push tool kit 0 1 PC220 Arm
6
.790-201-1660 .Push tool 1
~790-101-5021 .Grip 1
~01010-50816 .Bolt 1
790-201-1980 Plate 0 1 PC200 Boom

790-101-5021 Grip 1
01010-50816 Bolt 1
790-201-1990 Plate 0 1 PC200 Arm
790-101-5021 Grip 1
01010-50816 Bolt 1
l Removal, installatior 796-900-I 200 Remover n 1 Removal of boom

of work equipment Foot pin
P 790-101-4000 Puller (49OkN @ton) long n 1
assembly
l Boom assembly 790-101-1102 Pump (294kN I3Otonll n 1
-
30-9
0
DISASSEMBLY AND ASSEMBLY SKETCHES OF SPECIAL TOOLS
SKETCHES OF SPECIAL TOOLS

Note: Komatsu cannot accept any responsibility for special tools
manufactured according to these sketches.
G2 Push tool
150
CKP04076
v 1 796T-427-1220 n
30-10
0
DISASSEMBLY AND ASSEMBLY STARTING MOTOR
REMOVAL OF STARTING
a Disconnect the cable from the negative (-1 ter-

minal of the battery.
1. Open engine hood.
2. Disconnect 3 wires (I).
3. Remove 2 bolts (2). a
4. Remove starting motor assembly (3). m CLPO3201
INSTALLATION OF STARTING
MOTOR ASSEMBLY

removal.
w Starting motor mounting bolt :

43 f 6 Nm 14.38 + 0.61 kgm)
& Both faces of starting motor gasket :

Gasket sealant (LG-1)
30-l 1
0
DISASSEMBLY AND ASSEMBLY ALTERNATOR
REMOVAL OF ALTERNATOR
ASSEMBLY
A Disconnect the cable from the negative (-1 ter-

2. Remove fan guard (1) and right fan guard mount-

ing bracket (2).
3. Disconnect wiring (3) and connector (41, and re-

move X-connector (5) from bracket.
4. Using wrench 0, raise tensioner (6) and remove

belt (7).
A Be extremely careful not to get your fingers
caught when removing the belt.
II I I I CLPO3205
5. Remove alternator mounting bolts (8) and (9),

then remove alternator assembly (IO).
INSTALLATION OF
ALTERNATOR ASSEMBLY

removal. LPO3206
DISASSEMBLY AND ASSEMBLY AIR CONDITIONER COMPRESSOR
REMOVAL OF AIR
ASSEMBLY
A Loosen the flange mounting bolts of the air

conditioner hose, and release the refrigerant (R-
134a) slowly.
2. Remove fan guard (1).
3. Disconnect connector (2).
4. Disconnect hoses (3) and (4). m
5. Loosen adjustment bolt (5) and remove belt (6).

m
6. Remove 4 mounting bolts (71, then remove com-

pressor assembly (8).
Ir Spacer (9) is used at the bolt for the connec-
tor mounting bracket.
INSTALLATION OF AIR
ASSEMBLY
. Carry out installation in the reverse order to
removal.
pJ
* When installing the hoses, check that the O-
rings are not damaged or deteriorated, then
connect the hoses.
m
* Adjust the belt tension.
Testing and adjusting air conditioner belt ten-
sion.
. Fill with refrigerant (R-134a).
30-l 3
0
DISASSEMBLY AND ASSEMBLY CONDENSER
REMOVAL OF CONDENSER
ASSEMBLY (~c200,210-6)
1. Open engine hood (I) and side cover (2) at left

side of chassis.
2. Remove cover (3) on top of condenser.
CLPO3210
3. Disconnect air conditioner hose (41, then dis-

connect tube (5) at condenser end. m
* Loosen the sleeve nut slightly and release
the refrigerant (R-134a) completely before
disconnecting hoses (4) and tube (5).
+ Fit blind plugs into the hoses and tubes to
prevent the entry of moisture, dust or dirt.
4. Remove dry receiver (6) together with bracket.
5. Remove condenser assembly (7). I’( I \ CLPO3211
INSTALLATION OF
CONDENSER ASSEMBLY
(PC200, 210-6)

removal.
Ir Check that the O-rings are not damaged or

deteriorated, then connect the hoses.
30-14
0
DISASSEMBLY AND ASSEMBLY CONDENSER
REMOVAL OF AIR
CONDITIONER CONDENSER
1. Open engine hood, then open both side covers

at left side of chassis.
2. Remove cover (I) on top of condenser.
WI 5 I t CLPO3721
3. Disconnect electrical wiring connectors (2) and

(3) of condenser.
4. Disconnect air conditioner hose (4) and tube (5).

Ir Loosen the sleeve nut slightly and release
the refrigerant (R-134a) completely before
disconnecting hoses (4) and tube (5).
Ir Fit blind plugs into the hoses and tubes to
5. Remove intermediate clamp (6) of air conditioner

tube (5). remove bolt at drv receiver, then re-
move tube (5).
6. Remove condenser mounting bolts, then remove

condenser assembly (7).
CLP03723
INSTALLATION OF AIR
CONDITIONER CONDENSER

removal.
* Check that the O-ring is not damaged or

deteriorated, then connect the tubes.
30-15
0
DISASSEMBLY AND ASSEMBLY DRY RECEIVER
REMOVAL OF DRY RECEIVER

ASSEMBLY (pc220,230-6)
1. Open both side covers at left side of chassis.
2. Disconnect hose (I) and tube (2) of dry receiver.

* Loosen the mounting bolt slightly and re-
lease the refrigerant (R134a) completely be-
fore disconnecting hoses (I) and tube (2).
* Fit blind plugs into the hose and tube to
m
3. Remove mounting U-bolt (3), then remove dry

receiver assembly (4). m
INSTALLATION OF DRY
RECEIVER ASSEMBLY
(PC220, 230-6)

removal.
Ir Check that the O-rings are not damaged or

deteriorated, then connect the hoses and
tubes.
m Dry receiver mounting U-bolt :

18.6 t 7.9 Nm II.9 2 0.8 kgm}
l Fill with refrigerant W134a).
30-16
0
DISASSEMBLY AND ASSEMBLY ENGINE OIL COOLER CORE
REMOVAL OF ENGINE OIL

COOLER CORE ASSEMBLY
2. Remove adiabatic cover (1).
3. Remove turbocharger lubrication hose (2) and

oil filter (3). m
4. Disconnect connector (4) with alternator wiring,

and remove connector bracket (5) of intermedi-
ate clamp. CLPO3213
5. Remove oil cooler cover assembly (6). m
6. Remove cooler core (7) from oil cooler cover

assembly (6).
CLP03214
INSTALLATION OF ENGINE OIL

COOLER CORE ASSEMBLY

removal.
m Sleeve nut (2) of turbocharger lubrica-

tion hose :
24 2 4 Nm I2:45 t 0.41 kgm}
w Oil filter (3) : 13 5 2 Nm (1.33 t 0.20 kgm} I u CLP03228
* Or bring the seal surface into contact, then

tighten 314 turns.
L
* Tighten in the order (I) - (14) as shown in
the diagram.
w Mounting bolt (6) of oil cooler cover as-
sembly : 24 2 4 Nm 12.45 2 0.41 kgm}
CLPO3215
30-l 7
0
DISASSEMBLY AND ASSEMBLY FUEL INJECTION PUMP
REMOVAL OF FUEL INJECTION

PUMP ASSEMBLY (~c200,210-6)

2. Remove cover (I) on top of condenser, then

remove stay (2) at counterweight.
3. Remove fan guard (3) and left bracket (4).
4. Disconnect water temperature sensor connector

(5).
5. Remove bracket (6) for compressor hose clamp.

* Tighten together with the fuel inlet hose
clamp.
6. Remove lock clips (8) (2 places) and lock bracket

(7) of dipstick guide.
7. Disconnect governor motor rod (9) at governor

end. a,
r _.
* Rotate the shaft of tne governor motor and
do not stop it suddenly.
* Always disconnect the guide motor connec-
tor before disconnecting the rod.
a. Disconnect 6 delivery tubes (IO). m
9. Disconnect fuel supply hose (I I) and return hose

(12).
* Fuel will flow out when the hoses are dis-
connected, so insert wooden plugs in the
hoses to prevent the fuel from leaking.
\
CLP03219
30-18
0
IO. Disconnect tube clamp (15) (4 places) and tubes

(13) and (14) between fuel filter and fuel injec-
tion pump.
11. Remove lubrication tube (16).
12. Remove mounting bolt (17) of support bracket

at bottom of fuel injection pump.
I,
CLPO3794
13. Using tool A2, rotate engine in normal direc-

tion, and push No. 1 cylinder compression top
dead center positioning pin (18) into gear.
* Push the pin lightly‘ against the-gear and
rotate the engine slowly.
* After determining the TDC position, check if
the meshing of the timing pin has come out.
$
>
zi
0
14. Remove 2 fan belts (19), then move fan tension

pulley (20) and adjustment bar (21) towards fan
shaft. a
* Loosen mounting bolt (23) of adjustment bolt
bottom bracket (221, then loosen adjustment
bolt (24).
15. Turn cap (25) and remove.
CLPO3226
16. Remove washer (27) and nut (26) inside case.

m
* Be extremely careful not to drop the nut and
washer inside the case when removing.
17. Using tool A3, pull drive gear of fuel injection

pump and loosen from shaft.
CLPO3229
18. Remove 4 nuts (28), then remove fuel injection

pump assembly (29). m
30-20
0
INSTALLATION OF FUEL
INJECTION PUMP ASSEMBLY
(PC200, 210-6)

removal.
Ir Adjust the governor lever.

Adjusting governor motor lever stroke.
m Delivery tube sleeve nut (IO) :

24 + 4 Nm I2.45 = 0.41 kgm}
m
Testing and adjusting fan belt tension.
m Drive nut (26) :

95 2 10 Nm 19.7 +. 1.01 kgm}
m
. Install the fuel injection pump assembly as
follows.
I) Check that the No. 1 cylinder is at compres-
* For details, see Removal Step 13.
2) Remove plug (301, then remove timing pin

(31).
3) Reverse the position of timing pin (311, align

the timing pin groove with pointer (32) in-
side the pump, then temporarily tighten plug
(30).
* If the tooth of pointer (32) cannot be
aligned with the timing pin hole, rotate
the shaft of the fuel injection pump to
align the pointer tooth.
30
CLPO3232 CLPO3233
4) Align pump camshaft with pump drive gear

and install fuel injection pump assembly (29),
then tighten nut (28).
w Nut (28) :
43 + 6 Nm I4.38 + 0.61 kgm}
5) Assemble washer (27), and tighten nut (26)

temporarily.
Ir Be extremely careful not to drop the nut
and washer inside the case when install-
ing.
w Temporary tightening of nut (26) :
12.5 t 2.5 Nm Il.27 + 0.25 kgm1
j, This is not the final torque value.
* To prevent damage to the timing pin, be
careful not to tighten the nut to more
than the above tightening torque.
6) Remove meshing of engine timing pin (18).
7) Remove plug (30), reverse position of tim-

ing pin (311, then assemble and install plug
to fuel injection pump.
m Plug : 14.7 Nm Il.5 kgm}
8) Tighten nut (26) of fuel injection pump fully.

m Nut (26) :
95 + 10 Nm (9.7 + 1.01 kgm}
9) For remaining installation, carry out in re-

verse order to removal.
. Bleeding air CLPO3236

* Bleed the air from fuel system.
30-22
REMOVAL OF FUEL INJECTION

PUMP ASSEMBLY (pc220,230-6)
A Disconnect the cable from the negative (-) ter-

2. Remove cover (I) in front of radiator, then re-

move stay (2) at counterweight.
3. Remove fan guard (3) and left bracket (4).
4. Disconnect connector of water temperature sen-

sor wiring (5).
5. Remove bracket (6) for compressor hose clamp.

* This is tightened together with the fuel inlet
hose clamp.
6. Disconnect governor motor rod (7) at governor

end. m
* Rotate the shaft of the governor motor and
Ir Always disconnect the guide motor connec-
tor before disconnecting the rod.
7. Remove lock clip (9) (2 places) and lock bracket

(8) of dipstick guide.
8. Disconnect 6 delivery tubes (IO). m
9. Disconnect fuel supply hose (I I) and return hose

(12).
Ir Fuel will flow out when the hoses are dis-
connected, so insert a wooden plug into the
hoses to prevent leakage.
10. Disconnect tube clamps (15) (4 places) and tubes

(13) and (14) between fuel filter and fuel injec-
tion pump.
CLPO3737
11. Remove lubrication tube (16).
30-23
0
12. Using tool A2, rotate engine in normal direc-

tion, and push No. 1 cylinder compression top
dead center positioning pin (18) into gear.
* Push the pin lightly against the gear and
rotate the engine slowly.
* After determining the TDC position, check if
the meshing of the timing pin has matched.
13. Remove 2 fan belts (191, and move fan tension

pulley (20) and adjustment bar (21) towards fan
shaft. m
Ir Loosen mounting bolt (23) of adjustment bolt
bottom bracket (22), then loosen adjustment
bolt (24).
14. Turn cap (25) and remove.
CLPO3226
15. Remove washer (27) and nut (26) inside case.

m
* Be extremely careful not to drop the nut and
washer inside the case when removing.
16. Using tool A3, pull drive gear of fuel injection

pump, and loosen from shaft.
30-24
0
17. Remove mounting bolts (28) of mounting bracket

at bottom of fuel injection pump assembly, re-
move 4 nuts (291, then remove fuel injection
pump assembly (30). m
30-25
0
INSTALLATION OF FUEL
INJECTION PUMP ASSEMBLY
(PC220, 230-6)

removal.
* Adjust the governor lever.

Adjusting governor motor lever stroke.
m Delivery tube sleeve nut (IO) :

24 t 4 Nm 12.45 + 0.41 kgml

Testing and adjusting fan belt tension.
m Drive nut (25) :

95 + 10 Nm {9.7 = 1.01 kgm}
m
. Install the fuel injection pump assembly as
follows.
1) Check that the No. 1 cylinder is at compres-
+r For details, see Removal Step 12.
2) Remove plug (311, then remove timing pin

(32).
3) Reverse the position of timing pin (32), align

the timing pin groove with pointer (33) in-
side the pump, then temporarily tighten plug
(31).
Ir If the tooth of pointer (33) cannot be
aligned with the timing pin hole, rotate
the shaft of the fuel injection pump to
align the pointer tooth.
30-26
0
4) Align pump camshaft with pump drive gear

and install fuel injection pump assembly (30),
tighten bolt (281, nuts (29).
w Nut (29) :
43 z 6 Nm 14.38 z 0.61 kgm}
Mounting bolt (28) :
43 + 6 Nm I 4.38 + 0.61 kgm}
5) Assemble washer (271, and tighten nut (26)

temporarily.
Jr Be extremely careful not to drop the nut
and washer inside the case when install-
ing.
N Temporary tightening of nut (26) :
12.5 2 2.5 Nm il.27 + 0.25 kgm1
* This is not the final torque value.
Ir To prevent damage to the timing pin, be
careful not to tighten the nut to more
than the above tightening torque.
CLPO3234
6) Remove meshing of engine timing pin (18).
I CLPO37.35
7) Remove plug (301, reverse position of tim-

ing pin (311, then assemble and install plug
to fuel injection pump.
w Plug : 14.7 Nm Il.5 kgm}
8) Tighten nut (26) of fuel injection pump fully.

w Nut (26) :
95 + 10 Nm 19.7 + 1.01 kgm}
9) For remaining installation, carry out in re-

verse order to removal.
. Bleeding air CLPO4081

* Bleed the air from fuel system.
30-27
0
DISASSEMBLY AND ASSEMBLY WATER PUMP
REMOVAL OF WATER PUMP

ASSEMBLY
1. Drain coolant.
3. Remove fan guard (I), then remove left and right

side covers (2) and (3) of fan guard mount.
4. Using wrench 0, raise tensioner (41, then re-

move belt (5).
A Be extremely careful not to get your fingers
5. Loosen adjustment bar (7) of fan tension pulley

(61, then loosen fan belt (8). m
CLPO3240
6. Loosen mounting bolt (11) of fan pulley (IO) and

fan shaft (9) 2 - 3 mm, then move towards ra-
diator.
30-28
0
DISASSEMBLY AND ASSEMBLY WATER PUMP
7. Remove water pump assembly (12).
INSTALLATION OF WATER
PUMP ASSEMBLY

removal.
?!r Adjust the belt tension

For details, see TESTIN’G AND ADJUSTING,
Testing and adjusting of fan belt tension.
l Refilling with water

* Add water through the water filler to the
specified level.
Run the engine to circulate the water through
the system. Then check the water level again.
30-29
0
DISASSEMBLY AND ASSEMBLY NOZZLE HOLDER
REMOVAL OF NOZZLE
HOLDER ASSEMBLY
2. Disconnect delivery tube (I) at nozzle holder as-

sembly end. m
3. Remove spill tube (2). a
4. Remove nozzle holder assembly (3). m

* If it is difficult to remove the nozzle holder
assembly, use tool A4 to remove it. CLPO3.243
* Be careful not to let dirt or dust get into the
nozzle holder assembly mount.
INSTALLATION OF NOZZLE
HOLDER ASSEMBLY

removal.
CLP03244
mB Delivery tube sleeve nut :

30 f 5 Nm (3.06 + 0.51 kgm1
B Joint bolt : 8 + 2 Nm IO.81 + 0.20 kgm}
mu Nozzle holder assembly :

60 t 5 Nm (6.12 I 0.51 kgm)
& Nozzle holder assembly thread portion :
Seizure prevention compound
(Molycoat 1000)
* When assembling the nozzle holder, clean
the nozzle holder mount, and check that there
is no dirt or dust inside the sleeve before
assembling.
30-30
0
DISASSEMBLY AND ASSEMBLY TURBOCHARGER
REMOVAL OF
TURBOCHARGER ASSEMBLY
1. Open engine hood, and remove adiabatic cover

(I) of turbocharger assembly.
2. Remove air cleaner intake connector (2) and air

supply tube (3) between turbocharger and
aftercooler. m
3. Remove connector clamp (4).
4. Remove lubrication inlet tube (5) and lubrica- CL603245

tion return tube (61, then remove turbocharger
assembly (7). m
* After removing the lubrication tube, close
all the ports to prevent the entry of mud or
dirt.
CLP03246
INSTALLATION OF
TURBOCHARGER ASSEMBLY

removal.
m&l 8wm Inat ke tube band clip .

10 t. 2 Nm’ Il.02 + 0.21 kgm)
m Lubrication inlet tube sleeve nut :

35 + 5 Nm (3.6 + 0.5 kgm1
m Lubrication return tube mounting bolt :
24 + 4 Nm 12.45 2 0.41 kgm1
m Turbocharger assembly mounting nut :
10 t 2 Nm Il.02 2 0.20 kgm}
30-3 1
0
DISASSEMBLY AND ASSEMBLY THERMOSTAT
REMOVAL OF THERMOSTAT
ASSEMBLY
1. Drain coolant.
2. Open engine hood, and remove fan guard (I)

and right side guard mounting bracket (2).
3. Using wrench 0, raise tensioner (3), then re-

move fan belt (4).
g Be extremely careful not to get your fingers
4. Remove alternator assembly top mounting bolt

(5) from bracket, then move alternator assembly
(6) towards partition plate end.
j, Loosen the mounting bolts at the bottom of
the alternator assembly.
.,
CLPO3250
5. Disconnect radiator inlet hose (7) and aeration

hose (8).
6. Remove alternator bracket (9).
30-32
0
DISASSEMBLY AND ASSEMBLY THERMOSTAT
7. Remove thermostat housing (IO).
CLP03252
8. Remove thermostat (I IL
CLP03253
INSTALLATION OF
THERMOSTAT ASSEMBLY

removal.
w Thermostat housing mounting bolt :

24 z 4 Nm 12.45 + 0.41 kgm}
. Refilling with water

specified level.
30-33
0
DISASSEMBLY AND ASSEMBLY GOVERNOR MOTOR
REMOVAL OF GOVERNOR
MOTOR ASSEMBLY
g Disconnect the cable from the negative (-) ter-

2. Disconnect wiring (I 1.
* Disconnect 2 connectors at the bottom of
governor motor mounting bracket (2).
3. Remove motor rod (3). 'CLPO325.i
4. Remove governor motor assembly (4). m

Ir Rotate the shaft of the governor motor and
CLP03255
INSTALLATION OF GOVERNOR
MOTOR ASSEMBLY

removal.
-k Adjust the rod.

Testing and adjusting of governor motor le-
ver stroke.
30-34
0
DISASSEMBLY AND ASSEMBLY CYLINDER HEAD
REMOVAL OF CYLINDER HEAD

a Disconnect the cable from the negative (-) ter-

1. Drain coolant.
3. Remove fan guard (I), then remove left and right

4. Remove turbocharger assembly.

For details, see REMOVAL OF TURBOCHARGER
ASSEMBLY.
5. Remove exhaust manifold cover (4).
6. Remove adiabatic plate mounting bracket (5) for

turbocharger.
* In order to remove mounting bolt (6), do as
follows.
1) Remove muffler drain pipe. (main pump
end)
2) Loosen muffler mounting U-bolt. a
3) Rotate connector (7) at the muffler end
up slightly to a position where it is pos-
sible to remove the mounting bolts.
7. Remove exhaust manifold (8). m
8. Disconnect electrical intake air heater wiring (9),

water temperature sensor connector (IO), and
compressor connector (II).
9. Remove mounting bracket (12) of intermediate

clamp for wiring and air conditioner hose at
engine end.
10 Remove air conditioner belt (13), then remove

compressor assembly (14) together with bracket,
and move towards counterweight. m
11 Remove mounting plate (16) and clamp (15) of CLPO3256

dipstick guide.
30-35
0
12. Disconnect radiator inlet hose (171, heater hose

t18), and aeration hose (19).

move belt (21).
g Be extremely careful not to get your fingers
+ Before removing the belt, loosen 4 mount-
ing bolts of air conditioner pulley (22).
14. Remove air conditioner pulleys (22).

(23) from bracket, then move alternator assem-
bly (24) towards partition plate.
* Loosen the mounting bolts at the bottom of
16. Remove alternator bracket (251, pulley hub (26)

and tensioner (20) together with bracket (27).
m
30-36
0
17. Remove intake connector (28).
18. Remove 6 delivery tubes (29). m
19. Disconnect tubes (30) and (31) between fuel fil-

ter and fuel injection pump, then disconnect fuel
return hose (32) at fuel filter end. m
20. Remove fuel filter assembly (33) together with

bracket.
CLP03264
21. Remove intermediate clamps (34) (3 places) of

fuel return hose (321, then remove spill tube
(35). m
22. Remove nozzle holder assembly (36). m
23. Remove head cover (37).

24. Remove rocker arm assembly (38).
25 Remove push rod (39).
Remove mounting bolts of cylinder head in or-

der shown in diagram.
CEW00394
27. Lift off cylinder head assembly (40).
A kg Cylinder head assembly: 52 kg
28. Remove cylinder head gasket (41).
CLPO326Q
30-38
0
INSTALLATION OF CYLINDER
HEAD ASSEMBLY (PCZOO, 21 O-6)

removal.
w
w Muffler mounting U-bolt :
12 + 2.5 Nm (I.22 f 0.26 kgm)
pJ
* Tighten the mounting bolts in the order @ -
@ shown in the diagram on the right. CDWOO396
m Exhaust manifold mounting bolt :
43 e 6 Nm I4.38 + 0.61 kgm}

sion.
/KJ
w Pulley hub mounting bolt :
33 + 5 Nm 13.37 2 0.51 kgm}
$ w Tensioner bracket mounting bolt :
z 24 2 4 Nm 12.45 + 0.41 kgm}
2
m
w Exhaust hose clamp :
10 + 2 Nm {I .02 = 0.20 kgm)
m Sleeve nut at injection pump end :

24 + 4 Nm 12.45 e 0.41 kgm}
m Sleeve nut at nozzle holder end :
30 t 5 Nm I3.06 t 0.51 kgm}
m Fuel tube joint bolt (30), (31) :

24 t 4 Nm 12.45 + 0.41 kgm}
m Fuel hose joint bolt (32) :
30 + 5 Nm I3.06 2 0.51 kgm}
30-39
0
Spill tube joint bolt :

8 f 2 Nm to.81 + 0.20 kgm}
Nozzle holder assembly :

60 F 9 Nm i6.12 + 0.92 kgm}
Head cover mounting bolt :

24 t 4 Nm (2.45 2 0.41 kgm}
. Install the rocker arm assembly and cylinder

head assembly as follows.
* Check that there is no dirt or dust on the
cylinder mount surface or inside the cylin-
der.
1) Set cylinder head gasket (41) to cylinder
block.
* Check that the gasket is aligned correctly
with the holes in the block.
2) Raise cylinder head assembly (40) and set to

cylinder block.
3) Assemble push rod (39).

6 Add engine oil (15W-40) to the push
rod socket portion.
4) Fit rocker arm assembly (381, and tighten

mounting bolts by hand.
* Check that the ball portion of the adjust-
ment screw is fitted securely in the socket
portion of the push rod.
6 Put engine oil (15W-401 on the seat
surface and thread of the 8 mm and
12 mm diameter mounting bolts.
30-40
0
5) Tighten cylinder head mounting bolts in or-

6 Put engine oil (15W-40) on the seat
surface and thread of the mounting
bolts.
w Cylinder ‘head mounting bolt :
1st step: Tighten in order @ - @ to 90 f 5 Nm

t9.18 + 0.51 kgml.
2nd step: Tighten in order a,@, 0, @I, @, @to
120 f 5 Nm I12.24 + 0.51 kgml.
3rd step: i) When using tool Al
l Using angle tightening wrench
(tool Al), tighten bolts a further
90” in order @ - @.
ii) When not using tool Al
l Make match marks with a felt
pen on bolt and head, then
tighten bolt a further 90”.
CLPO4084
6) Tighten rocker arm assembly mounting bolts

(diameter: 8 mm). Make marks on cylinder
6hea; boll
w Rocker arm mounting bolt :
24 + 4 Nm 12.25 f 0.41 kgm}
7) Adjust valve clearance.

Adjusting valve clearance.
DKP00485

* Refill to the specified level, and run the
engine to circulate the water through the
system. Then check the water level again.
REMOVAL OF CYLINDER HEAD


1. Drain coolant.
3. Remove fan guard (I), then remove left and right 2

4. Loosen clamp of hose (41, then remove hose (4)

and air connector portion (5) of aftercooler.
5. Disconnect tube (6) and hose (7).
6. Remove turbocharger assembly.

For details, see REMOVAL OF TURBOCHARGER
ASSEMBLY.
7. Remove exhaust manifold cover (8).
8. Remove adiabatic plate mounting bracket (9) for

turbocharger.
* In order to remove mounting bolt (IO), do as
follows.
1) Remove muffler drain pipe. (main pump
end)
2) Loosen muffler mounting U-bolt. m
3) Rotate connector (11) at the muffler end
up slightly to a position where it is pos-
sible to remove the mounting bolts.
9. Remove exhaust manifold (12). m
30-42
0
10. Disconnect electrical intake air heater wiring (13)

and (141, water temperature sensor wiring con-
nector (15).
I5
CLPO3743
11. Disconnect compressor wiring connector (161,

and remove mounting bracket (17) of intermedi-
ate clamp for wiring and air conditioner hose at
engine end.
12. Remove air conditioner belt (181, remove com-

pressor assembly (19) together with bracket, then
move towards counterweight end. a
13. Remove clamp (20) of engine oil level gauge

$ guide and mounting plate (21).
&
g
14. Disconnect radiator inlet hose (221, heater hose

(231, and aeration hose (24).

move belt (26).
a Be extremely careful not to get your fingers
* Before removing the belt, loosen 4 mount-
ing bolts of air conditioner pulley (22).
16. Remove air conditioner pulleys (27).

CYLINDER HEAD

(28) from bracket, then move alternator assem-
bly (29) towards partition plate.
* Loosen the mounting bolts at the bottom of
D
C
18. Remove alternator bracket (301, pulley hub (31)

and tensioner (25) together with bracket (32).
m
19. Remove intermediate clamp (331, and discon-

nect fuel return hose (34). m
20. Remove intermediate clamps (35) (4 places), then

remove tubes (36) and (37) between fuel filter
and fuel injection pump. m
21. Remove fuel filter assembly (38) and bracket

(39).
22. Disconnect ground connection (40).
23. Remove 6 delivery tube (41). a
24. Remove aftercooler assembly (421, then remove

gasket (43). m
CLPO3750
30-44
0
25. Remove intermediate clamps (44) (3 places) of

fuel return hose, then remove spill tube (45).
m
26. Remove nozzle holder assembly (46). 11101
27. Remove head cover (47).
28. Remove rocker arm assembly (48).
29. Remove push rod (49).

30. Remove mounting bolts of cylinder head in or-

der shown in diagram. m
CEW00394
31. Lift off cylinder head assembly (50).
A kg Cylinder head assembly : 52 kg
32. Remove cylinder head gasket (51). m
30-46
0
INSTALLATION OF CYLINDER
HEAD ASSEMBLY (pc220,230-6)

removal.
m Muffler mounting U-bolt :

12 + 2.5 Nm (1.22 + 0.26 kgm}
m
* Tighten the mounting bolts in the order @ -
@ shown in the diagram on the right. CDW00396
w Exhaust manifold mounting bolt :

43 f 6 Nm I4.38 f 0.61 kgm}

sion.
Pulley hub mounting bolt :

33 = 5 Nm (3.37 2 0.51 kgml
Tensioner bracket mounting bolt :
24 t 4 Nm 12.45 f 0.41 kgml
Fuel hose joint bolt (34) :

10 + 2 Nm Il.02 + 0.20 kgml
Sleeve nut at injection pump end :

24 + 4 Nm i2.45 t 0.41 kgml
Sleeve nut at nozzle holder end :
30 2 5 Nm I3.06 2 0.51 kgml
Fuel tube joint bolts (361, (37) :

24 2 4 Nm (2.45 I 0.41 kgml
Aftercooler assembly mounting bolt :

24 f 4 Nm I2.45 + 0.41 kgm}
30-47
0
?&I kml Sp’llI tube joint bolt :

8 f 2 Nm IO.81 = 0.20 kgm}
mw Nozzle holder assembly :

60 * 9 Nm 16.12 + 0.92 kgm1
m Head cover mounting bolt :

24 t 4 Nm 12.45 + 0.41 kgm}
piqFiqpiq%q
. Install rocker arm assembly and cylinder
head assembly as follows.
* Check that there is no dirt or dust on the
cylinder mount surface or inside the cylin-
der.
1) Set cylinder head gasket (51) to cylinder
block.
f Check that the gasket is aligned correctly
with the holes in the block.
2) Raise cylinder head assembly (50) and set to

cylinder block.
3) Assemble push rod (49).

& Add engine oil (15W-40) to the push
rod socket portion.
CLPO3800
4) Fit rocker arm assembly (48) and tighten

mounting bolts by hand.
Ir Check that the ball of the adjustment
screw is fitted securely in the socket of
the push rod.
& Put engine oil (15W-40) on the seat
surface and thread of the 8 mm and
12 mm diameter mounting bolts.
30-48
0
5) Tighten cylinder head mounting bolts in or-

& Put engine oil (15W-40) on the seat
surface and thread of the mounting
bolts.,
m Cylinder head mounting bolt :
1st step: Tighten in order @ - @ to 90 t 5 Nm

19.18 f 0.51 kgm}.
2nd step: Tighten in order @,a, 0, @I, @I, @to
120 + 5 Nm 112.24 + 0.51 kgm}.
3rd step: i) When using tool Al CEW00394
Using angle tightening wrench
l
(tool Al), tighten bolts a further

90” in order 0 - @.
ii) When not using tool Al
Make match marks with a felt
l
pen on bolt and head, then

tighten bolt a further 90”.
$
> CLPO4084
%
6) Tighten rocker arm assembly mounting bolts
(diameter: 8 mm).
m Rocker arm mounting bolt :
24 = 4 Nm t2.25 t 0.41 kgm}
7) Adjust valve clearance.

Adjusting valve clearance.

* Refill to the specifiedlevel, and run the
engine to circulate the water through the
system. Then check the water level again.
CLPOl522
DISASSEMBLY AND ASSEMBLY HYDRAULIC OIL COOLER
REMOVAL OF HYDRAULIC OIL

COOLER ASSEMBLY (~c200,210-61
1. Remove condenser assembly.

For details, see REMOVAL OF CONDENSER AS-
SEMBLY.
2. Remove tool box and undercover, and set oil

container under chassis.
3. Disconnect connector (I ), and remove reservoir

tank (2).
4. Remove bracket (3) and right side bracket (4).
5. Disconnect oil cooler inlet hose (5) and outlet

hose (6).
* After disconnecting the hoses, insert blind
plugs.
CLPO3273
6. Remove 4 mounting bolts (7) at bottom of hy-

draulic cooler assembly.
7. Sling hydraulic cooler assembly (81, remove left

and right mounting bolts, then lift off hydraulic
cooler assembly (8).
+ There is a guide pin on the left side of the
hydraulic cooler assembly (counterweight
side), so be careful when lifting off.
r+ kg Hydraulic cooler assembly : 47 kg
7 7
CLP03274
INSTALLATION OF HYDRAULIC
OIL COOLER ASSEMBLY (~c200,210-6)

removal.
. Refilling with oil (hydraulic tank)

* Add oil through the oil filler to the specified
level.
Run the engine to circulate the oil through CLPO32
the system. Then check the oil level again.
30-50
0
DISASSEMBLY AND ASSEMBLY HYDRAULIC OIL COOLER
REMOVAL OF HYDRAULIC OIL

COOLER ASSEMBLY (pc220,230-6)
1. Open engine hood and remove top cover (1). F

2. Remove tool box,and undercover (21, and set oil
container under chassis.
3. Disconnect oil cooler inlet hose (3) and outlet

hose (4).
* After disconnecting
plugs.
the hoses, insert blind
L
PO3725
4. Remove 4 mounting bolts (5) at bottom of hy-

draulic cooler assembly
CLPO3726
5. Sling hydraulic cooler assembly (61, remove 4

left and right mounting bolts, then lift off hy-
draulic cooler assembly.
* There is a guide pin on the left side of the
hydraulic cooler assembly (counterweight
side), so be careful when lifting off.
&I ka Hydraulic cooler assembly : 59 kg
CLP03727
OIL COOLER ASSEMBLY (~~220.230-6)
removal.

level.
Run the engine to circulate the oil through
30-51
0
DISASSEMBLY AND ASSEMBLY RADIATOR l HYDRAULIC OIL COOLER
REMOVAL OF RADIATOR,
HYDRAULIC OIL COOLER
A Lower the work equipment completely to the

ground and stop the engine. Then loosen the oil
filler cap slowly to release the pressure inside
the hydraulic tank.
. Remove the hydraulic tank strainer, and using

tool B, stop the oil.
l When not using tool B, remove the drain
plug, and drain the oil from the hydraulic - CLP03276
tank and inside the system.
:
w Hydraulic tank : Approx. 170 J?
1. Drain coolant.
2. Remove condenser assembly.

For details, see REMOVAL OF CONDENSER AS-
SEMBLY.
3. Remove undercover under radiator.
4. Disconnect connector (I), then disconnect hose

(21, and remove reservoir tank (3).
5. Disconnect oil cooler hoses (4) and (5).
CLP03276
7. Disconnect radiator upper hose (7). a
30-52
0
8. Remove clamps (9) (2 places) of heater hose (8).
’
LCLPO3280
9. Disconnect radiator support rods (IO) and (11).
10. Disconnect radiator lower hose (12) and heater

hose (131, then remove intermediate clamp (14)
of radiator lower hose. a
11. Sling radiator and hydraulic cooler assembly

(151, remove bottom mounting bolts, then lift
off radiator and hydraulic cooler assembly.
* When raising the radiator and hydraulic
cooler assembly, check the position carefully
and do not let it hit the fan when removing I5
it.
c+kg Radiator, hydraulic cooler assembly:
112 kg
283
INSTALLATION OF RADIATOR,

removal.
WI 1121
m Radiator hose band clip :
8.83 t 0.98 Nm IO.9 + 0.1 kgm}

Ir Add water through the water filler to the
specified level.

level.
30-54
0
REMOVAL OF RADIATOR,
ASSEMBLY (pc220,230-6)
g Lower the work equipment completely to the

B
the hydraulic tank.

. When not using tool B, remove the drain
CLPO3.276
plug, and drain the oil from the hydraulic
6 tank and inside the system.
.(. Hydraulic tank : Approx. 170 f?
1. Drain coolant.
2. Open engine hood, remove top cover (I) and

tool box and undercover (21, then set oil con-
tainer under chassis.
3. Remove undercover under radiator.
$ 4. Disconnect connector of reservoir tank wiring

> (3) and hose (4), then remove reservoir tank (5).
%
5. Disconnect oil cooler hoses (6) and (7).
7. Disconnect radiator upper hose (9). m
8. Remove clamps (II) (2 places) of heater hose

(IO).
’
I CLPO3730
30-55
0
9. Disconnect radiator support rods (12) and (13).
10. Disconnect radiator lower hose (14) and heater

hose (151, then remove intermediate clamp (16)
of radiator lower hose. a
11. Sling radiator and hydraulic cooler assembly

(171, remove bottom mounting bolts, then lift
off radiator and hydraulic cooler assembly.
Ir When raising the radiator and hydraulic
cooler assembly, check the position carefully
and do not let it hit the fan when removing
it.
&I kg Radiator, hydraulic cooler assembly :
116 kg
30-56
0
DISASSEMBLY AND ASSEMBLY RADIATOR . HYDRAULIC OIL COOLER
IINSTALLATION OF RADIATOR,

removal.
m Radiator hose band clip :

8.83 2 0.98 Nm IO.9 z 0.1 kgm}

specified level.
l Refilling with oil (hydraulic tank)

level.
30-57
0
DISASSEMBLY AND ASSEMBLY ENGINE l MAIN PUMP
REMOVAL OF ENGINE, MAIN

PUMP ASSEMBLY

the hydraulic tank.
I - CLP03276
:
w Hydraulic tank : Approx. 170 e
* Mark all the piping with tags to prevent mis-

takes in the mounting Dosition when installing.
I
1. Drain coolant.
2. Remove engine hood 1).
CLPO3299
3. Remove main pump top cover (2).

f
4. Remove right side cover (3) together with cover
mounting frame (4).
* Remove the cover at the bottom of the main
pump and the cover at the bottom of the
engine, and set a container under the main
pump to catch the oil.
5. Remove connectors (5) and (6) from bracket and

disconnect.
I I,
CLPO3292
30-58
0
DISASSEMBLY AND ASSEMBLY ENGINE . MAIN PUMP
6. Disconnect F and R pump discharge hoses (7)

and (8), F and R LS pressure hoses (9) and (IO),
and EPC basic pressure hose (II).
* Protect with the sleeve nut to prevent dam-
age to the n/pple or elbow taper seal por-
tion.
7. Disconnect pump servo pressure hose (12) and

pump drain hose (131, and remove intermediate
clamp (14) of hose.
Ir Protect with the sleeve nut to prevent dam-
age to the nipple or elbow taper seal por-
tion.
8. Disconnect suction tube (15) at pump end.

Ir Cover the suction tube port portion with plas-
tic.
$
z
8
9. Remove engine partition plates (161, (171, and

(18).
10. Remove bracket (19) at counterweight end.
11. Remove fan guard (201, then remove left and

right side brackets (21) of fan guard mount.
12. Disconnect oil level sensor connector (22) of oil (Counterweight)

pan, wiring (23) for oil pressure sensor, and
ground connection (24).
13. Remove intermediate clamp (25) of heater hose.
II II (Engine oil van) DLP00486
14. Disconnect governor motor connectors (26) (2

places) and speed sensor connector (27).
8
>
%
15. Disconnect starting motor wiring (28) and start-

ing motor connectors (29) and (301, and remove
from clamp.
16. Disconnect fuel supply hose (31) and fuel return

hose (321, then remove intermediate clamp (33).
,/ I’\ w-/ ,, =lYlJ//

=32----- 31- CLPO3755
30-60
0
17. Disconnect electrical intake air heater wiring (34)

and air conditioner connector (35).
18. Remove compressor assembly (36).

For details, see REMOVAL OF AIR CONDITIONER
COMPRESSOR ASSEMBLY.
* After removing the compressor assembly,
put it on top of the counterweight.
19. Remove fan (37), and move towards radiator.
20. Remove radiator upper hose (381, radiator lower

hose (391, heater hose (401, and air cleaner con-
nector (41).
21. Remove mount bolt, then raise engine and main

pump assembly (42) slowly, and lift off.
Ir When removing the engine and main pump
assembly, check that all the wiring and pip-
ing has been disconnected. m
r+ k9 Engine, main pump assembly : 770 kg
CLPO3759
INSTALLATION OF ENGINE,
MAIN PUMP ASSEMBLY
removal.
./
* Set the engine mount rubber as shown in

the diagram, then install the engine and main
pump assembly.
m Engine mount bolt :
277 2 32 Nm t28.3 = 3.3 kgm} Engine rear side Engine front side
DKP00487
specified level.

level.
. Bleeding air
* Bleed the air from the main pump.
Bleeding air.
30-62
0
DISASSEMBLY AND ASSEMBLY DAMPER
REMOVAL OF DAMPER
ASSEMBLY
1. Remove main pump assembly.

For details, see REMOVAL OF MAIN PUMP AS-
SEMBLY.
2. Remove damper assembly (1).
INSTALLATION OF DAMPER
ASSEMBLY
removal.
30-63
0
DISASSEMBLY AND ASSEMBLY FUEL TANK
REMOVAL OF FUEL TANK

ASSEMBLY

1. Loosen drain valve (I) of fuel tank and drain

fuel.
w
: Fuel tank :
Approx. 340 .Q(when tank is full)
2. Disconnect fuel supply hose (2) and return hoses

(3) and (4).
3. Remove handrail (51, battery case (61, and cover

(7).
el ks Battery case : 28 kg
4. Disconnect fuel sensor connector (81, then re-

move wiring from clamp.
5. Sling fuel tank assembly (91, then remove mount-

ing bolts, and lift off fuel tank assembly (9).
m
&I ks Fuel tank assembly : 122 kg
INSTALLATION OF FUEL TANK

ASSEMBLY

removal.
w Fuel tank mounting bolt :

277 + 32 Nm (28.3 + 3.2 kgml
. Refilling with fuel (fuel tank)

Add fuel.
30-64
DISASSEMBLY AND ASSEMBLY CENTER SWIVEL JOINT
REMOVAL OF CENTER SWIVEL

JOINT ASSEMBLY
g Release the remaining pressure in the hydraulic
circuit. For details, see TESTING AND ADJUST-
ING, Releasing remaining pressure from hydrau-
lic circuit.
* Mark all the piping with tags to prevent mis-
takes in the mounting position when installing.
1. Disconnect hoses (I), (2), (3), and (4) and tubes
(5) and (61, and remove filter and bracket as-
sembly.
+ Machines equipped with additional attach-
ment circuit.
&l kg Filter, bracket assembly : 95 kg
2. Disconnect hoses (71, (81, (91, and (IO) between

travel motor and swivel joint.
3. Remove elbow (I I).
\ ’ wri1-J/ ”
CLPO3837
4. Disconnect drain hose (12).

5. Disconnect hoses (13) and (14) between control
valve and swivel joint.
6. Disconnect travel speed selector hose (15).
7. Disconnect plate (16).
8. Remove center swivel joint assembly (17). m
&I kg Center swivel joint assembly : 45 kg
I” (’ CLP0383d
30-65
0
INSTALLATION OF CENTER
SWIVEL JOINT ASSEMBLY
removal.
m
Ir Assemble the center swivel as shown in the
Center swivel
diagram below. joint
Sprocket
Ir Add oil through the oil filler to the specified
level. Run the engine to circulate the oil
through the system. Then check the oil level
again. @ b DKP00488
l Bleeding air
* Bleed the air form the travel motor. For de-
tails, see TESTING AND ADJUSTING, Bleed-
ing air.
30-66
0
DISASSEMBLY OF CENTER
2. Remove snap ring (2).
3. Using tool D, pull out swivel rotor (4) and ring

(3) from swivel shaft (5).
4. Remove O-ring (6) and slipper seal (7) from

swivel rotor.
ASSEMBLY OF CENTER
1. Assemble slipper seal (7) and O-ring (6) to swivel

rotor.
2. Set swivel shaft (5) to block, then using push

tool, tap swivel rotor (4) with a plastic hammer
$ to install.
& CLPO3841
& Contact surface of rotor, shaft :
g Grease (G2-LI)
* When installing the rotor, be extremely care-
ful not to damage the slipper seal and the
O-ring.
3. Install ring (3) and secure with snap ring (2).
4. Fit O-ring and install cover (1).

m Mounting bolt :
31.36 + 2.94 Nm 13.2 + 0.3 kgm)
CLPO3842
30-67
0
DISASSEMBLY AND ASSEMBLY FINAL DRIVE
REMOVAL OF FINAL DRIVE

ASSEMBLY
1. Remove sprocket. For details, see REMOVAL OF

SPROCKET.
the hydraulic tank.
2. Remove cover (I).
3. Disconnect 4 travel motor hoses (21, and lift off CLPO1413
final drive assembly (3). m

Ir Be extremely careful not to damage the nip-
ple tool surface of the hose mount.
r&lks Final drive assembly : 300 kg
* Never use tap hole for cover when slinging
final drive assembly.
INSTALLATION OF FINAL
DRIVE ASSEMBLY

removal.
m Final drive mounting bolt:

276.8 f 31.8 Nm (28.25 A 3.25 kgm}
. Bleeding air
* Bleed the air from the travel motor. For de-
tails, see TESTING AND ADJUSTING, Bleed-
ing air.

again.
30-68
0
DISASSEMBLY OF FINAL
DRIVE ASSEMBLY
1. Draining oil
Remove drain plug and drain oil from final drive
case.
:
w Final drive case : Approx. 4.2 .t
2. Cover
Remove mounting bolts, then remove cover (I)
using eyebolts 0.
* When raising ring gear (12) and cover (1) as CLP01427
one unit, tap the ring gear with a wooden
hammer to remove the ring gear.
3. Spacer
Remove spacer (2).
CLPO1417
4. No. 1 carrier assembly

1) Remove No. 1 carrier assembly (3).
CLPO1418
2) Disassemble No. 1 carrier assembly as fol-

lows.
i) Push in pin (41, and pull out shaft (5)
from carrier (6).
* After removing the shaft, remove pin
(4).
ii) Remove thrust washer (71, gear (81, bear-
ing (9), and thrust washer (IO).
CLPOl419
30-69
0
5. No. 1 sun gear shaft

Remove No. 1 sun gear shaft (11).
CLPO1428 1
6. Ring gear
Remove,ring gear (12).
7. Thrust washer
Remove thrust washer (13).
8. No. 2 sun gear

Remove No. 2 sun gear (14).
CLPO1429 1
9. Thrust washer
Remove thrust washer (15).

I) Remove No. 2 carrier assembly (16).
CLPO1430 1

lows.
i) Push in pin (17) and pull out shaft (18)
from carrier (19).
(17).
ii) Remove thrust washer (201, gear (211,
bearing (22), and thrust washer (23).
CLPOl431
30-70
0
11. Nut
I) Remove lock plate (24).
2) Using tool Gl, remove nut (25).
CLPO1432 CLPO1433
12. Hub assembly

I) Using eyebolts 0, remove hub assembly (26)
from travel motor.
CLPO1434
2) Disassemble hub assembly as follows.

i) Remove floating seal (27).
ii) Remove bearings (28) and (29) from hub
(30).
Sr When removing bearing (28), do not hit
the resin retainer of the bearing.
3) Remove floating seal (31) from travel motor

(32).
CLPO1436
30-71
0
ASSEMBLY OF FINAL DRIVE

ASSEMBLY
* Clean all parts, and check for dirt or damage.

Coat the sliding surfaces of all parts with engine
oil before installing.
1. Hub assembly
I) Using push tool, press fit bearings (28) and
(29) to hub (30).
2) Using tool G4, install floating seal (26).

* Remove all oil and grease from the O-
ring and O-ring contact surface, and dry G4
the parts before installing the floating \
seal.
* After installing the floating seal, check
that the angle of the floating seal is
within 1 mm.
+ After installing the floating seal, coat the
sliding surface thinly with engine oil.
CKP03843
3) Using tool 64, install floating seal (31) to

travel motor (32).
* The procedure for installation is the same
as in Step 2) above.
CLPOi436
4) Using eyebolts 0, set hub assembly (26) to

travel motor, then using push tool, tap to
press fit bearing portion.
CLPO1434
30-72
0
2. Nut G2
1) Install nut as follows.
i) Using tool G2, push bearing inner race
portion.
* Do not heat the bearing with a
burner, or directly push or hit the a
resin retainer.
Sr Pushing force:
8.82 - 12.74 kN IO.9 - 1.3 ton)
* Rotate the hub 2 - 3 times before
applying the pushing force to the
bearing inner race. CLP03844
ii) Measure dimension a in the condition in
Step i) above.
iii) Measure thickness b of nut itself.
G!
iv) Calculate a - b = c.
v) Using tool Gl, tighten nut (25) to a point
where dimension d is c!,,,.
CLPO1437
vi) Using push-pull scale 0, measure tan-

gential force in direction of rotation of
hub in relation to motor case.
* Tangential force : Max. 294 N (30 kg}
* The tangential force is the maximum
force when starting rotation.
vii) Install lock plate (24).
CLPO1438
30-73
0
* Install the lock plate as shown in the

diagram.
& Thread of mounting bolt:
GOOD
Thread tightener (LT-2)
* Do not coat the tap portion of the
nut with thread tightener (LT-2). &jg$q
0LPO0489

I) Assemble No. 2 carrier assemblv as follows.
Replace thrust washers (20),‘(23) and pin
(17) with new ones.
There are the remains of the caulking
when the pin is inserted at the end face
of hole h at the side of the carrier, so
remove the caulked metal from the in-
side diameter of the hole before starting
to assemble. h
Assemble bearing (22) to gear (211, fit
top and bottom thrust washers (20) and CLPO1439
(231, and set gear assembly in carrier
(191.
Align position of pin holes of shaft and
carrier, then tap with a plastic hammer
to install shaft (18).
* When installing the shaft, rotate the
planetary gear. Be careful not to dam-
age the thrust washer.
iii) Insert pin (17).
* After inserting the pin, caulk the pin
portion of the carrier.
Ir After assembling the carrier assembly,
check that gear (21) rotates smoothly.
CLPO1440
2) Install No. 2 carrier assembly (16).

* Align the position so that the three tips
of the gear shafts of carrier assembly
(16) enter the three hollows in the end
face of the motor case, then install.
CLPOl441
30-74
0
4. Thrust washer
Install thrust washer (15).
5. No. 2 sun gear

Install No. 2 sungear (14).
6. Thrust washer
Install thrust washer (13).
7. No. 1 sun gear shaft

Install No. 1 sun gear shaft (II).
CLP01442

I) Assemble No. 1 carrier assembly as follows.
* Replace thrust washers (71, ilO) and pin
(4) with new ones.
sr There are the remains of the caulking
of hole h at the side of the carrier, so
side diameter of the hole before starting
to assemble.
i) Assemble bearing (9) to gear (8), fit top
and bottom thrust washers (7) and (IO), CLP01422
and set gear assembly in carrier (6).
ii) Align position of pin holes of shaft and

carrier, then tap with a plastic hammer
to install shaft (5).
planetary gear. Be careful not to dam-
age the thrust washer.
* After assembling the carrier assembly,
check that gear (8) rotates smoothly.
CLP01423
9. Spacer
Install spacer (2).
CLPO1443
30-75
0
10. Ring- gear

-
Fit O-ring to hub end, then using eyebolts 0,
align position of bolt holes of hub and ring gear
(121, and install.
* Remove all grease and oil from the mating
surface of the ring gear and hub.
* Do not put any gasket sealant on the mating
surface of the ring gear and hub under any
circumstances.
CLPO1444
11. Cover
Using eyebolts 0, fit cover (I), then tighten
mounting bolts with angle tightening wrench
63.
& Mounting surface of cover :
w Mounting bolt :
1st pass: 98 Nm {IO kgm}
2nd pass: Turn 80 - 90”
CLPO1445
12. Refilling with oil

Tighten drain plug and add engine oil through
oil filler.
Q# Final drive case : Approx. 4.2 e

Ir Carry out a final check of the oil level at the
determined position after installing the final
drive assembly to the chassis.
CLPO1446
30-76
0
DISASSEMBLY AND ASSEMBLY SPROCKET
REMOVAL OF SPROCKET
1. Remove track shoe assembly. For details, see

REMOVAL OF TRACK SHOE ASSEMBLY.
2. Swing work equipment 90”, then push up chas-

sis with work equipment and set block @ be-
tween track frame and track shoe.
3. Lift off sprocket (I).
INSTALLATION OF SPROCKET

removal.
& Thread mounting bolt :

of sprocket
Gasket sealant (LG-61
m Sprocket mounting bolt :
465.5 + 24.5 Nm (47.5 f 2.5 kgm}
30-77
0
DISASSEMBLY AND ASSEMBLY SWING MOTOR AND SWING MACHINERY
REMOVAL OF SWING MOTOR,

SWING MACHINERY
ASSEMBLY

stop the engine. Loosen the hydraulic tank oil
the hydraulic tank. Then set the safety lock lever
to the LOCK position.
1. Remove hose clamps (I) and (2) (2 places each).
2. Disconnect swing motor inlet and outlet hoses

(3) and (41, and disconnect suction hose (5).
3. Remove hose clamp (6).
4. Disconnect drain hoses (7) and (81, then discon-

nect pilot hose (9).
5. Remove 12 mounting bolts (IO) at swing ma-

chinery end, then lift off swing motor and swing
machinery assembly (11). m
* When removing the swing motor and swing
machinery assembly, be careful not to dam-
age the hoses, and lift off slowly.
& kg Swing motor, swing machinery assem-
bly : 225 kg
CLP03763
30-78
0
DISASSEMBLY AND ASSEMBLY SWING MOTOR AND SWING MACHINERY
INSTALLATION OF SWING
MOTOR, SWING MACHINERY
ASSEMBLY

removal.
w Swing machinery mounting bolt :

549 + 59 Nm {56 + 6 kgm1

level.
. Bleeding air
-k Bleed the air from the swing motor.
Bleeding air.
30-79
0
DISASSEMBLY AND ASSEMBLY SWING MACHINERY
DISASSEMBLY OF SWING
MACHINERY ASSEMBLY
1. Draining oil
Loosen drain plug and drain oil from swing ma-
chinery case.
:
w Swing machinery case : Approx. 5.5 Q
2. Swing motor assembly

I) Set swing motor and swing machinery as-
sembly to block 0. CLPO2923
2) Remove mounting bolts, then remove swing
motor assembly (I).
3. No. 1 thrust washer

Remove No. 1 thrust washer (2).
CLPO2924
4. No. 1 sun gear


I) Remove No. 1 carrier assembly (4).
CLP02926
30-80
0

lows.
Knock pin (5), and remove shaft (61, gear (7),
bearing (8), and thrust washer (9).
Ir After rem,oving shaft (61, remove pin (5)
from the shaft.
CLPO2927
6. Ring gear
Remove ring gear (IO).

Remove No. 2 thrust washer (I I).
8. No. 2 sun gear

30-81
0
9. Bolt
Remove holder mounting bolt (13). I3

1) Remove No. 1 carrier assembly (14).
.PO2931
21 Disassemble No. 2 carrier assembly as fol-

lows.
i) Push in pin (151, and knock shaft (16) out
from carrier (17). 18
I!
(15).
ii) Remove thrust’washer (181, gear (19),
20
bearing (201, and thrust washer (21).
iii) Remove plate (22). 21
22 I5
CLPO2932
11. Shaft assembly

1) Remove mounting bolts (23).
2) Set shaft and case assembly to press, then
using push tool 0, remove shaft assembly
(24) from case assembly (25).
CLPO2933 CLPO2934
3) Disassemble shaft assembly as follows.

i1 Using push tool 0, remove cover as-
sembly (26) and bearing (27) from shaft
(28).
u
ii) Remove oil seal (29) from cover (30).
CLPO2935 CLPO2936
30-82
0
12. Bearing
Using push tool, remove bearing (31) from case
(32).
:LPo2937
30-83
0
ASSEMBLY OF SWING
MACHINERY ASSEMBLY
* Clean all parts and check for dirt or damage.

Coat the sliding surfaces of all parts with engine
oil before installing.
1. Bearing
Using push tool 0, press fit bearing (27) to case
(32).
CLPO2938
2. Cover assembly
1) Using push tool 0, press fit oil seal (29) to
cover (30).
6 Outside circumference of oil seal :
* Be careful not to let the gasket sealant
(LG-6) get on the oil seal lip when press
fitting.
2) Fit cover assembly (26) to case (321, and

tighten mounting bolts (23).
6 Cover mounting surface :
m Mounting bolt :
66.2 2 7.4 Nm 16.75 + 0.75 kgm}
& Lip of oil seal : Grease (G2-LI)
LIIiE5b CLPO2940
3. Case Assembly
Set case assembly (25) to shaft (281, then using
push tool @, press fit bearing inner race por-
tion.
* When setting the case assembly to the shaft,
be extremely careful not to damage the oil
seal.
CLPO2941
30-84
0
4. Bearing
Using tool F, press fit bearing (31).
* Press the bearing inner race and outer race
at the same time when press fitting. Do not
press only the inner race when press fitting.
* After press fitting the bearing, check that the -31
case rotates smoothly.
CLPO2942

1) Assemble No. 2 carrier assembly as follows.
17 19
There are the remains of the caulking
of hole h at the side of the carrier, so 19
side diameter of the hole before starting 20
to assemble.
i) Assemble plate (22) to carrier (17).
ii) Assemble bearing (20) to gear (191, fit 21
top and bottom thrust washers (18) and
(21) and set gear assembly to carrier (17).
iii) Align with position of pin holes of shaft
I 22.
CLPO2943
and carrier, then tap with a plastic ham-

mer to install shaft (16).
planetary gear, and be careful not to
damage the thrust washer.
iv) Insert pin (15).
‘h
CLPO2944

13
6. Bolt
Tighten bolt (13).
& Mounting bolt :
m Mounting bolt :
176.5 +. 19.6 Nm I18 2 2.0 kgm}
30-85
0
7. No. 2 sun gear

Install No. 2 sun gear (12).

Install No. 2 thrust washer (11).
9. Ring gear
Install ring gear (IO).
& Case side mounting surface :

I) Assemble No. 1 carrier assembly as follows.
* There are the remains of the caulking at
the end face of carrier side hole k made
when inserting the pin, so remove the
remains of the caulking on the inside
diameter of the hole before starting as-
sembly.
i) Assemble bearing (8) to gear (71, then fit
top and bottom thrust washers (9) and
set gear assembly to carrier.
CLPO2945
30-86
0
ii) Align pin hole position of carrier and

shaft, then tap with plastic hammer and
install shaft (6).
* Rotate the planet gear when install-
ing the shaft, and be careful not to
damage the thrust washer.
j, After inserting the pin, caulk the pin
CLPO.2946
iv) Install No. 1 carrier assembly (4).
/I
CLPO2926
11. No. 1 sun gear

Install No. 1 sun gear (3).

Install No. 1 thrust washer (2).
CLPO2924
13. Swing motor assembly

Install swing motor assembly (1).
& Ring gear side mounting surface :
* Coat the outside diameter of the hole only

at the hole in the ring gear where there is a
distinguishing protrusion on the case. (See
the diagram on the right.)
w Mounting bolt :
176.5 + 19.6 Nm I18 + 2.0 kgml
14. Refilling with oil

Proj
Tighten drain plug and add engine oil through iden
oil filler to specified level.
30-88
0
DISASSEMBLY AND ASSEMBLY REVOLVING FRAME
REMOVAL OF REVOLVING
FRAME ASSEMBLY
1. Remove 2 boom cylinder assemblies. For de-

tails, see REMOVAL OF BOOM CYLINDER AS-
SEMBLY.
2. Remove work equipment assembly. For details,

see REMOVAL OF WORK EQUIPMENT ASSEM-
BLY.
3. Remove counterweight assembly. For details, see

REMOVAL OF COUNTERWEIGHT ASSEMBLY.
4. Disconnect top mounting hoses (I), (21, and (3)

of swivel joint assembly at swivel joint assem-
bly end.
5. Remove stopper link (4).
6. Remove mounting bolts, then lift off revolving

frame assembly (5). m
* Leave 2 bolts @ each at the front and rear,
use a lever block to adjust the balance of the
revolving frame assembly to the front and
rear, and left and right, then remove the
remaining bolts, and lift off.
a When removing the revolving frame as-
sembly, be careful not to hit the center
swivel joint assembly.
& kg Revolving frame assembly: 5,200 kg CLPO3849
30-89
0
DISASSEMBLY AND ASSEMBLY REVOLVING FRAME
INSTALLATION OF REVOLVING
FRAME ASSEMBLY

removal.
6 Mating of swing circle :

surface
& Thread of revolving frame mounting
bolt : Thread tightener (LT-2)
w Revolving frame mounting bolt :
PC220-6 1st: 294 (30)

22-110 32
PC230-6 2nd: Tighten 60”

* Add oil through the oil filler to the speci-
fied level. Run the engine to circulate
the oil through the system. Then check
the oil level again.
l Bleeding air
* Bleed the air. For details, see TESTING
AND ADJUSTING, Bleeding air.
30-90
0
DISASSEMBLY AND ASSEMBLY SWING CIRCLE
REMOVAL OF SWING CIRCLE

ASSEMBLY
1. Remove revolving frame assembly. For details,

see REMOVAL OF REVOLVING FRAME ASSEM-
BLY.
2. Remove swing circle mounting bolts (I), leaving

1 bolt each in front and rear direction. m
* Swing circle assembly mounting bolts: 32
3. Sling swing circle assembly (2) at three points,

I-1
then remove remaining mounting bolts. CLPO3850
4. Lift off swing circle assembly (2). m
&I La Swing circle assembly : 280 kg
30-91
0
DISASSEMBLY AND ASSEMBLY SWING CIRCLE
l Carry out installation in the reverse order to Swine circle start mark
removal.
Socket
start mark
6 Thread of swing circle mounting bolt :

Thread tightener(LT-2) Socket ~~oS~of~rk
w Swing circle mounting bolt : swine circle
1st pass: end mark Socket start mark
Tighten to 191.2 z 19.6 Nm (19.5 + 2 kgm}
2nd pass: DKP00491
i) Using the angle of the bolt head as the

base, make start marks on the swing cir-
cle and socket.
Inner race
2) Make an end mark at a point (on swing #soft zone
circle) 48*5” from the start mark.
3) Tighten so that the start mark on the
socket is aligned with the end mark on
the swing circle at the 48*5” position.
a
* Set the soft zone S mark on the inside ring
of the inner race facing the right side as
shown in the diagram, then install to the
track frame. DLP00492
& Swing circle : Grease (G2-LI) 21&
30-92
0
DISASSEMBLY AND ASSEMBLY IDLER l RECOIL SPRING
REMOVAL OF IDLER l RECOIL

SPRING ASSEMBLY
1. Remove track shoe assembly. For details, see

REMOVAL OF TRACK SHOE ASSEMBLY.
2. Sling idler and recoil spring assembly (I), and

pull out to the front to remove.
el kg Idler l recoil spring assembly : 275 kg
3. Disconnect recoil spring assembly (3) from idler

assembly (2). m CLPO3854
r+ kg Idler assembly : 140 kg
&I kg Recoil spring assembly : 135 kg
INSTALLATION OF IDLER l
RECOIL SPRING ASSEMBLY

removal.
cLPo3855
* When installing the idler assembly and re-

coil spring assembly, assemble so that the
position of the greasing plug on the idler is
on the outside for the right side of the ma-
chine and on the inside for the left side of
the machine.
30-93
0
DISASSEMBLY AND ASSEMBLY RECOIL SPRING
DISASSEMBLY OF RECOIL
SPRING ASSEMBLY
L_____-____.________-.-_-.-_-_~L-_____.____-Ll_-_/
CLPO3856
1. Remove piston assembly (2) from recoil spring

assembly (I).
2. Disassembly of recoil spring assembly

1) Set recoil spring assembly (I) to tool HI.
a The recoil spring is under large installed
load, so be sure to set the tool properly.
Failure to do this is dangerous.
* Installed load of spring
PC200, 210 : 108.8 kN {II,100 kg}
PC2OOLC, 21OLC, 220, 220LC, 230, 230LC :
126.5 kN {12,900 kg} CLP03857
2) Apply hydraulic, pressure slowly to compress

spring, and remove lock plate (31, then re-
move nut (4).
* Compress the spring to a point where
the nut becomes loose.
* Release the hydraulic pressure slowly
and release the tension of the spring.
* Free length of spring
PC200, 210 : 558 mm
PC2OOLC, 21OL, 220, 22OLC, 230, 230LC :
603.5 mm
3) Remove yoke (61, cylinder (71, and dust seal

(8) from spring (5).
3. Disassembly of piston assembly

I) Remove lock plate (IO) from piston (91, then
remove valve (1 I).
2) Remove snap ring (121, then remove U-pack-
ing (13) and ring (14).
30-94
0
DISASSEMBLY AND ASSEMBLY RECOIL SPRING
ASSEMBLY OF RECOIL SPRING

ASSEMBLY
1. Assembly of piston assembly

1) Assemble ring (14) and U-packing (13) to
piston (9), and secure with snap ring (12).
2) Tighten valve (11) temporarily, and secure
with lock plate (IO).
2. Assembly of recoil spring assembly

1) Using tool H2, install dust seal (8) to cylin-
der (7).
CLPO3858
2) Assemble cylinder (7) and yoke (6) to spring
(51, and set in tool HI.
& Sliding portion of cylinder :
Grease (G2-LI)
3) Apply hydraulic pressure slowly to compress

spring, and tighten nut (4) so that installed
length of spring is dimension “a”, then se-
cure with lock plate (3).
* Installed length “a” of spring
PC200, 210 : 437 mm _--
PC2OOLC, 21OLC, 220,22OLC, 230,230LC :
466 mm
CLPO3859
4) Remove recoil spring assembly (I) from tool
HI.
3. Assemble piston assembly (2) to recoil spring

assembly (I 1.
& Sliding portion of piston, wear ring:
Grease (G2-LII
* Assemble the cylinder assembly so that the
mounting position of the valve is 90” to the
side.
* Fill the inside of the cylinder with 300 cc of
grease (G2-LI), then bleed the air and check
that grease comes out of the grease hole.
30-95
0
IDLER
DISASSEMBLY OF IDLER
ASSEMBLY
1. Remove dowel pin (I), then remove support (2).
2. Remove floating seal (3) from support (2) and

idler (4).
3. Pull out idler (4) from shaft (5) and support (7)
assembly.
* It is filled with 80 cc. of oil, so drain the oil at
this point or lay a cloth to prevent the area
from becoming dirty.
CLPO3660
4. Remove floating seal (6) on opposite side from

idler (4) and shaft (5) and support (7) assembly.
' CLPO3861
5. Remove dowel pin (81, then remove support (7)

from shaft (51.
6. Remove bushings (9) and (IO) from idler (4).
CLPO3662 CLP03663
30-96
0
DISASSEMBLY AND ASSEMBLY IDLER
ASSEMBLY OF IDLER
ASSEMBLY
1. Press fit bushings (9) and (IO) to idler (4).
IO
CLPO2209 CLPO2210
2. Fit O-ring and install support (7) to shaft (5) with

dowel pin (8).
3. Using tool Jl, install floating seal (6) to idler (4)

and shaft (5) and support (7) assembly.
Sr Coat the sliding surface of the floating seal
with oil, and be careful not to let any dirt or
dust get stuck to it.
* Remove all grease and oil from the contact
surface of the O-ring and the floating seal.
Jl
I I
I CKP03867
4. Assemble shaft (5) land support (7) assembly to

idler (4).
CLPO3868
30-97
0
DISASSEMBLY AND ASSEMBLY IDLER
5. Using tool Jl, install floating seal (3) to idler (4)

and support (2).
* Coat the sliding surface of the floating seal
with oil, and be careful not to let any dirt or
dust get stuck to it.
* Remove all grease and oil from the contact
surface of the O-ring and the floating seal.
CKP03870
6. Install O-ring, then install support (2) with dowel

pin (1).
7
7. Add oil and tighten plug.
%z Oil : Approx. 80 cc (SAE30)
w Plug : 205.8 f 49 Nm I21 t. 5 kgm1

5
\
O\
2
CLP03860
30-98
0
DISASSEMBLY AND ASSEMBLY TRACK ROLLER
REMOVAL OF TRACK ROLLER

ASSEMBLY
v
1. Lower work equipment, then loosen lubricator
(I), and relieve track tension. m
g The adjustment cylinder is under extremely
high pressure. Never loosen the lubricator
more than one turn. If the grease does not
come out easily, move the machine back-
wards and forwards. I ’
2. Remove mounting bolts of track roller, then
swing work equipment 90”, jack up machine,
and remove track roller assembly (2) towards CLPO3872
outside of machine. m
&I kg Track roller assembly : 40 kg
INSTALLATION OF TRACK
ROLLER ASSEMBLY

removal.
23 a
>
* Adjust the track tension. For details, see
% TESTING AND ADJUSTING, Testing and ad-
justing track tension.
m
* Place the plug on the outside of the chassis,
and set the track roller assembly in the
mounting position.
* Operate the work equipment levers to lower
the machine slowly, then tighten the mount-
ing bolts temporarily.
* Operate the work equipment levers to lower
the machine completely to the ground, then
tighten the mounting bolts fully.
CLPO3874
QKI Track roller assembly mounting bolt:
1st pass :
Tighten to 196 z 19.6 Nm I20 + 2 kgm1
2nd pass :
Track roller
1. When using tool M. start mark
. Using an angle tightening
Socket I
wrench, tighten bolt 90 + 5”. start
2. When not using tool M.
1) Using the angle of the bolt head
as the base, make start marks on
the track roller and socket.
2) Make an end mark at a point 90 f track roller
5” from the start mark. end mark Socket start mark
3) Tighten so that the start mark on Socket
DLP00493
the socket is aligned with the end
mark on the track roller at the
90+5” position.
30-99
0
DISASSEMBLY OF TRACK
ROLLER ASSEMBLY t
1. Remove pin (I), then remove collar (2).
II
3 H CLPO2218
CLPO2219
2. Remove floating seal (3) from collar (2) and roller

(4).
CLPO2220 CLP02221
3. Pull out roller (4) from shaft (5).

* It is filled with 190 - 215 cc. of oil, so drain
the oil at this point or lay a cloth to prevent
the area from becoming dirty.
4. Remove floating seal (6) on opposite side from

roller (4) and shaft (5).
CLPO2222 CLP02223
30-l 00
0
5. Remove pin (71, then remove collar (8) from

shaft (5).
0
&
6. Remove bushings (9) and (IO) from roller (4).
i
5
0, 0 8
7’
CLP02224 CLPO2225
30-101
0
ASSEMBLY OF TRACK ROLLER

ASSEMBLY
1. Using push tool 0, press fit bushings (9) and
(IO) to roller (4).
2. Assemble collar (81 to shaft (51, and install pin

(7).
3. Using tool Kl, install floating seal (6) to shaft

(5).
Jr When assembling the floating seal, clean the
contact surface of O-ring (6~) and floating
CLPOO803
seal (6a), remove all grease and oil, and dry
it. Make sure that no dirt or dust sticks to
the contact surface of the floating seal.
4. Using tool Kl, install floating seals (6) and (3) to

roller (4).
* For details of the precautions when install-
ing floating seals (6b) and (6d), and (3b) and
(3d), see the precaution for Step 3.
5. Assemble shaft (5) to roller (4).
6. Turn over roller (4) and shaft (5) assembly.
CLP02226 CLPO3885
7. Using tool Kl, install floating seal (3) to collar
(2).
* For details of the precautions when install-
ing floating seals (3a) and (3~1, see the pre-
caution for Step 3.
CLP03887
Kl.
CLP03888 CLP03689
30- 102
0
8. Assemble collar (2) to shaft (5), and install pin

(I).
CLPO3890
9. Using tool K2, apply basic pressure to roller oil

filler port, and check for leakage of air from
seal.
K2
* Basic pressure : 0.1 MPa {I kg/cm21
The basic pressure shall be maintained for
IO seconds and the indicator of the gauge
shall not go down.
CLPO3891
10. Using tool K2, fill track roller assembly with oil,
K2
then tighten plug (II).
m Plug : 14.7 t 4.9 Nm Il.5 2 0.5 kgm1
G Track roller oil : 190 - 215 cc (SAE30)
To oi I PUIIIP I
To vacuum tank
DLP00529
30-l 03
0
DISASSEMBLY AND ASSEMBLY CARRIER ROLLER
REMOVAL OF CARRIER
ROLLER ASSEMBLY
-
v
A The adjustment cylinder is under extremely
more than one turn. If the grease does not
come out, move the machine backwards and
forwards. I ’
2. Using hydraulic jack 0, push up track to a posi-
tion where carrier roller assembly can be re- CLPO3872
moved, then remove carrier roller assembly (2).
B
INSTALLATION OF CARRIER
ROLLER ASSEMBLY

removal.
Adjust the track tension. For details, see CLPO3894
TESTING AND ADJUSTING, Testing and ad-

Thread of carrier roller assembly mounting bolt:

30- 104
0
DISASSEMBLY OF CARRIER
ROLLER ASSEMBLY
’ I.
i ‘P
1. Remove plug (I) and drain oil.
:
_ Carrier roller assembly : 230 - 250 cc
2. Set carrier roller assembly on stand 0.

4. Remove ring (3).
CLPO3895
CLPO3896 CLPO3697
5. Using tool Ll, remove nut (4).

6. Using push tool 0, pull out shaft assembly (5)
from roller (6) with press, then remove inner
race (7).
CLPO3896 CLPO3699
7. Remove outer races (8) and (9) from roller (6).
8. Disassembly of shaft assembly

1) Using puller 0, remove inner race (IO). i
8
CLPO3900 CLPO3901
30-105
0
2) Remove floating seals (II).

3) Using push tool 0, remove collar (12) from
Liz
shaft (13). 0
13
12
r.-
-%03903
30-l 06
0
ASSEMBLY OF CARRIER
ROLLER ASSEMBLY I
$
1. Using push tool 0, press fit outer races (8) and 0
(9) to roller (6).

0
2. Assembly of shaft assembly
1) Using push tool 8, press fit collar (12) to
-
shaft (13).
Ir When press fitting, be careful that there 13 12
is no scuffing.
& Fitting portion of shaft : SAE30 Es---HP
2) Using tool L3, assemble floating seals (II). CLPO3904 - +-cLPo3905
+ When assembling the floating seal, clean
the contact surface of O-ring (11~) and
floating seal (1 la), remove all grease and
oil, and dry it. Make sure that no dirt or
dust sticks to the contact surface of the
floating seal.
3) Assemble floating seals (I I), then using tool
L2, press fit inner race (IO).
IO
+r For details of the precautions when in-
11
stalling floating seals (I 1 b) and (I Id), see
the precaution for Step 2). lb I
- CLPO1447
3. Assemble roller (6) to shaft assembly (5).
4. Using tool l2, press fit inner race (7).

* When press fitting the bearing, rotate the
roller, and press fit to a point where the
rotation becomes slightly heavier.
5. Using tool Ll, tighten nut (4) to a point where

drill hole in shaft is aligned with drill hole in
nut.
l-l
1 CLPO1448 CLPO3898
6. Install ring (3).

3
7. Using push-pull scale 0, check that it rotates
smoothly.
<
u . ”
@
CLPO3897 CLPO3QO9
8. Fit O-ring and install cover (2).

1
CCPO3910
9. Using tool L4, apply basic pressure to roller oil

filler port, and check for leakage of air from
seal.
* Basic pressure : 0.1 MPa (1 kg/cm?
The basic pressure shall be maintained for
10 seconds and the indicator of the gauge
shall not go down.
CLPO3911
10. Using tool L4, fill carrier roller assembly with

oil, then tighten plug (I).
sb Carrier roller oil : 230 - 250 CC (SAE30)
To oi I PUMP I
To vacum tank
DLP00494
30408
0
DISASSEMBLY AND ASSEMBLY TRACK SHOE
REMOVAL OF TRACK SHOE
1. Stop machine at a point where master pin is

midway between idler and carrier roller, and
where there is space to lay out track assembly
on ground.

g The adjustment cylinder is under extremely
more than one turn. If the grease does not CLP03872
come out, move the machine backwards and
forwards.
3. Using tool I, pull out master pin (2). m
4. Remove tool I, and move machine forward so

that position of temporary pin @ is at front of
idler, and set block 0 in position.
5. Remove temporary pin 0, and remove dust seal,

then drive machine in reverse to lay out track
(3).
m
CLPO3913
INSTALLATION OF TRACK
SHOE ASSEMBLY
Adjust the track tension. For details, see

TESTING AND ADJUSTING, Testing and ad-
Use tool I and press fit so that the protru-

sion of the master pin is dimension “a”.
Protrusion “a” of master pin : 4 f 2 mm .PO3914
When assembling the dust seal, coat the

bushing contact surface with grease (G2-LI).
Sr Replace the shoes with new ones when rubber
pads get worn to the same height (or lower) as
the heads of their mounting bolts.
It is impossible to remove or install mounting
bolts once the heads get damaged, crushed or
deformed.
DISASSEMBLY AND ASSEMBLY HYDRAULIC TANK
REMOVAL OF HYDRAULIC
TANK ASSEMBLY
1. Drain oil from hydraulic tank.
:
w Hydraulic tank : Approx. 170 e
2. Remove engine hood (I), pump top cover (2),

and control valve top cover (3).

mounting frame (5).
4. Remove engine partition plates (6) and (7) and

mounting bracket for partition plate on hydrau-
lic tank side.
5. Disconnect hydraulic oil return tube (8).
6. Remove pump suction tube (9) together with

joint hose (IO).
7. Disconnect oil level sensor connector (11) and

remove LS pressure hose clamp (12).
8. Disconnect 7 hydraulic tank return hoses (13).

* After disconnecting the hoses, fit tags to dis-
tinguish them.
tion.
II
:LPo3286
9. Sling hydraulic tank assembly (14), then remove

mounting bolts, and lift off hydraulic tank as-
sembly. m
& kg Hydraulic tank assembly : 136 kg
CLPO3287 I
30410
0
DISASSEMBLY AND ASSEMBLY HYDRAULIC TANK
TANK ASSEMBLY

removal.
QKI Hydraulic tank drain plug :

68.5 2 10 Nm i6.98 + 1.01 kgml
w Hydraulic tank mounting bolt :

277 ~32 Nm 128.3 + 3.2 kgml

level.
Q Hydraulic tank : Approx. 170 e
. Bleeding air
* Bleed the air.
Bleeding air.
30-l 11
0
DISASSEMBLY AND ASSEMBLY MAIN PUMP
REMOVAL OF MAIN PUMP

ASSEMBLY
a Disconnect the cable from the negative (-) ter-

the hydraulic tank.

I - CLP03276
:
w Hydraulic tank : Approx. 170 J?
. Drain oil from damper case.
1. Remove engine hood cover (I).
2. Remove main pump top cover (2).

mounting frame (4).
4. Remove connectors (5) and (6) from bracket and

disconnect.
I I,
CLPO3292
5. Disconnect F and R pump discharge hoses (7)

and (8), F and R LS pressure hoses (9) and (IO),
and EPC basic pressure hose (11).
Ir Protect with the sleeve nut to prevent dam-
tion.
30-l 12
0
6. Disconnect pump servo pressure hose (12) and

pump drain hose (13), and remove intermediate
clamp (14) of hose.
age to the njpple or elbow taper seal por-
tion.
7. Disconnect suction tube (15) at pump end.

* Cover the suction tube port portion with plas-
tic.
8. Remove engine partition plates (161, (17, and

(18).
9. Remove muffler drain pipe (19) and clamp

mounting bracket (20).
10. Remove main pump assembly (21) as follows.

1) Leaving 2 - 3 mounting bolts, remove other
mounting bolts.
2) Sling main pump assembly and install 2
guide bolts @ on diametrically opposite
sides.
3) Remove remaining mounting bolts, then pull
out slowly until main pump assembly sepa-
rates from spline shaft.
4) Lift off main pump assembly. m
&I kg Main pump assembly : 150 kg
30-113
0
INSTALLATION OF MAIN
PUMP ASSEMBLY

removal.
6 Involute spline of main pump :

Anti-friction compound (LM-GI
& Mating surface of main pump case :
. Refilling with oil (damper)

* Add engine oil through the oil filler to the
specified level. Run the engine to circulate
the oil through the system. Wait for at least
15 minutes, then check the oil level again.
%z Damper : Approx. 0.7 e

level.
l Bleeding air
* Bleed the air from main pump.
Bleeding air.
30-114
0
DISASSEMBLY AND ASSEMBLY MAIN PUMP INPUT SHAFT OIL SEAL
REMOVAL OF MAIN PUMP

INPUT SHAFT OIL SEAL
1. Remove main pump assembly. For details, see

REMOVAL OF MAIN PUMP ASSEMBLY.
2. Remove snap ring (I), then remove spacer (2).
3. Lever up oil seal (3) with a screwdriver to re-

move. m
* When removing the oil seal, be extremely
careful not to damage the shaft.
CLPO3916
INSTALLATION OF MAIN
PUMP INPUT SHAFT OIL SEAL
removal.
& Lip of oil seal : Grease (G2-LI)

& Coat the outside circumference of the oil
seal with grease (G2-LI) thinly, then press
fit.
* Using tool N, press fit oil seal (3).
CLPO3917
30-l 15
0
DISASSEMBLY AND ASSEMBLY CONTROL VALVE
REMOVAL OF CONTROL
VALVE ASSEMBLY
A Run the engine at low idling, operate the cylin-

der to the end of its stroke without relieving the
circuit, then lower the work equipment to the
ground.
For details, see TESTING AND ADJUSTING, Re-
leasing pressure in hydraulic circuit.
After stopping the engine, do as follows.
. Loosen the oil filler cap slowly to release the

pressure inside the tank.
. Operate the control levers.
* Operate the control levers several times to
release the pressure in the accumulator.
. Start the engine and run at low idling for approx.
5 seconds, then stop the engine and operate the
control levers.
* Repeat the above operation several times to
release the remaining pressure completely.
1. Open engine hood, and remove valve top cover

(I) and air cleaner top cover (2).
2. Remove partition plate covers (3) and (4) be-

tween engine and control valve, move partition
plate cover (5) under intake hose towards en-
gine.
3. Disconnect 2 connectors (6) of pressure sensor

and remove from holder.
CLP03766
4. Disconnect pump discharge hoses (7) and (8),

and remove hose clamp (9).
5. Remove self-reducing pressure valve (IO).

* The length of the mounting bolts is differ-
ent. See below.
Left side mounting bolts (2 bolts) :
L = 120 mm
Right side mounting bolts (2 bolts) :
L = 125 mm
30-116
0
6. Disconnect 5 hoses (1 I) between control valve

and relay block, hose (12) between control valve
and timing valve, travel valve pilot hose (131, 2
boom valve pilot hoses (141, and 2 relief valve
pilot hoses (15).
tinguish them.
tion.
7. Disconnect 2 travel valve junction hoses (16).
8. Disconnect 2 LS pressure pilot hoses (17).

t After disconnecting the hoses, fit tags to dis-
tinguish them.
9. Remove timing valve (18) and drain tube (19).
10. Disconnect 4 hoses (20) between control valve

and relay block, hose (21) between control valve
and timing valve, travel valve junction hose (221,
travel valve pilot hoses (231, and pilot hose (24)
between arm and bucket.
tinguish them.
tion.
11. Disconnect 2 each of bucket valve tube (251,

boom valve tube (261, and arm valve tube (27).
12. Disconnect 2 each of right travel valve hose (281,

swing valve hose (29), and left travel valve hose
(30).
13. Disconnect 2 LS select valve pilot hoses (31).

14. Sling control valve assembly (321, then remove

mounting bolts, and lift off control valve assem-
bly.
&I kg Control valve assembly : 170 kg
INSTALLATION OF CONTROL
VALVE ASSEMBLY
removal.

level.
. Bleeding air
* Bleed the air from the circuit between the
valve and the hydraulic cylinder.
Bleeding air.
30-118
0
DISASSEMBLY OF CONTROL
VALVE ASSEMBLY
(l/3)
Service
Bucket
R. H.trave
Boom
Swins
L. H. trave
Arm
16
t
Z
22 23
21 24
25
20
I! 26
27
DKP00495
30-119
I I
/ / ’ \
L-L 43 42 H-H 41
34 33 Bucket valve 12 ’ 31 Swino valve
IO 44 45 46
II
12
13
14 / I- \\
50 49 G-G 48 47
Travel valve
I5
.57
J-J
Boom valve
DKP00496
30-120
0
(3/3)
N-N \
2
24
25 ‘20
26 19
‘18 ‘80
c-c
D-D
/ I \ \
50 49 K-K 40 i7
DKP00497
30-121
0
* The set pressure of the safety valve cannot be

adjusted when it is installed on the machine, so
do not disassemble.
. This section explains the procedure for the 6-
spool valve.
1. Main relief valve

Remove main relief valve (2).
2. Unload valves, safety-suction valves, suction

valves
I) Remove unload valves (I) and (17).
2) Remove safety-suction valves (231, (22), (271,
(181, and (20).
3) Remove suction valves (25), (241, (211, (26),
and (19).
3. Pressure compensation valves

* Before removing any pressure compensa-
tion valve, check and mark its mounting po-
sition.
I) Remove bucket DUMP pressure compensa-
tion valve (8), R.H. travel REVERSE pressure
compensation valve (71, boom RAISE pres-
sure compensation valve (61, right swing
pressure compensation valve (51, L.H. travel
REVERSE pressure compensation valve (41,
and arm OUT pressure compensation valve
(3).
2) Remove bucket CURL pressure compensa-
tion valve (IO), R.H. travel FORWARD pres-
sure compensation valve (I I), boom LOWER
pressure compensation valve (12), left swing
pressure compensation valve (131, L.H. travel
FORWARD pressure compensation valve
(141, and arm IN pressure compensation
valve (15).
Ir After removing the pressure compensation
valves, remove check valve (35) from each
pressure compensation valve mount.
4. LS select valve
Remove LS select valve (38).
30-122
0
5. LS shuttle valves, pump merge/divider valve, 10. Boom control valve

boom regeneration valve I) Remove case (571, then remove spring
I) Remove LS shuttle valves (79) and (81). (55) and retainer (60).
2) Remove pump merge/divider valve as- 2) Remove plug (581, then remove piston
sembly (80), then remove boom regen- (59) and spring (56).
eration spring (61) and boom regenera- 3) Remove case (641, then remove spring
tion valve (62). (53) and retainer (63).
4) Remove spool assembly (54).
6. Remove covers (9) and (16). * Do not disassemble spool assembly
(54).
7. Arm control valve
1) Remove case (701, then remove spring 11. Bucket control valve
(74) and retainer (69). 1) Remove case (30), then remove spring
2) Remove case (661, then remove spring (31) and retainer (32).
(67) and retainer (78). 2) Remove case (341, then remove spring
3) Remove spool assembly (68). (28) and retainer (33).
* Do not disassemble spool assembly 3) Remove spool assembly (29).
(68). Ir Do not disassemble spool assembly
(29).
8. Swing control valve
I) Remove case (401, then remove spring 12. Arm regeneration valve
(39) and retainer (41). Remove plate (751, then remove arm regen-
2) Remove case (431, then remove spring eration spring (76) and arm regeneration
(36) and retainer (42). valve (77).
$ 3) Remove spool assembly (37).
>
* Do not disassemble spool assembly
% (37).
9. R.H. travel, L.H. travel control valves

I) Remove case (471, then remove spring
(46) and retainer (48).
2) Remove case (501, spring (441, and re-
tainer (49).
3) Remove spool assembly (45).
* Do not disassemble spool assembly
(45).
30- 123
0
ASSEMBLY OF CONTROL
VALVE ASSEMBLY
(l/3)
J
Swing J
L. H. travel ;----&
1Arm
22 23
21 24
25
20
19 26
\
/ \
I8 27
DKP00495
30-124
0
43 42 H-H il
34 33 Bucket valve 32 31 Swine valve
44 45 $6
IO
II
12
13
I4 G-G
48 47
Travel valve
I5
A-A
64 63 Si 61 1 :-r( 60 56
7756’ 7j ArmF-Fvalve 7:
J-J
Boom valve
DKP00496
30-125
0
(3/3)
Bucket
R. H. tra
Boom
Swine
I 2
L.H.tra
Arm
B-B
e-
24 21
25 ‘20
26 19
50 49 K-K 40 i7
DKP00497
30-126
0
. Coat the sliding surfaces of all parts with 3) Assemble retainer (41) and spring (391,
engine oil before installing. then fit O-ring to case (40) and install.
w Case mounting bolt :
1. Bucket control valve spool 30.87 t 3.43 Nm I3.15 + 0.15 kgm1
1) Assemble spool assembly (29) to valve
body. 5. Arm control valve
2) Assemble retainer (33) and spring (281, 1) Assemble spool assembly (68) to valve
then fit O-ring to case (34) and install. body.
w Case mounting bolt : 2) Assemble retainer (78) and spring (67),
30.87 + 3.43 Nm 13.15 + 0.35 kgm1 then fit O-ring to case (66) and install.
3) Assemble retainer (32) and spring (31) m Case mounting bolt :
to spool, then fit O-ring to case (30) and 30.87 t 3.43 Nm 13.15 * 0.15 kgm}
install. 3) Assemble retainer (69) and spring (741,
m Case mounting bolt : then fit O-ring to case (70) and install.
30.87 t 3.43 Nm 13.15 + 0.35 kgm} w Case mounting bolt :
30.87 + 3.43 Nm 13.15 t 0.15 kgm1
2. Boom control valve spool
1) Assemble spool assembly (54) to valve
body.
2) Assemble retainer (63) and spring (531,
then fit O-ring to case (64) and install.
m Case mounting bolt :
30.87 I 3.43 Nm i3.15 + 0.35 kgm}
3) Assemble spring (56) and piston (591,
then install plug (58).
m Plug :
107.8 = 14.7 Nm (II.0 + 1.5 kgm)
then install case (57).
30.87 2 3.43 Nm 13.15 2 0.15 kgm}
3. R.H. travel, L.H. travel control valves

I) Assemble spool assembly (45) to valve
body.
30.87 + 3.43 Nm I3.15 z 0.15 kgm}
3) Assemble retainer (48) and spring (46)
to spool, then fit O-ring to case (47) and
install.
m Case mounting bolt :
30.87 2 3.43 Nm 13.15 + 0.15 kgm)
4. Swing control valve spool

I) Assemble spool assembly (37) to valve
body.
2) Assemble retainer (42) and spring (36).
30.87 f; 3.43 Nm I3.15 t. 0.15 kgml
30-127
0
6. Covers
1) Fit O-ring to cover (161, then install.
2) Fit O-ring to cover (91, then install.
6 Mating surface of covers (161, (9) :
Seal end 242 or equivalent
Ir Tighten the mounting bolts in the order
shown in the diagram on the right.
m Mounting bolt :
166.6 = 9.8 Nm {I7 2 1 kgm1
7. LS shuttle valves, pump merge/divider valve,

CKPO0820
boom regeneration valve
I
1) Assemble boom regeneration valve (62) and
spring (61) to valve body, then install pump
merge/divider valve assembly (80).
shown in the diagram on the right.
w Mounting bolt :
166.6 f 9.8 Nm {I7 + 1 kgml
2) Install LS shuttle valves (81) and (79).
m Mounting bolt :
66.15 f 7.35 Nm (6.75 2 0.75 kgml
8. LS select valve
Install LS select valve (38).
w LS select valve :
127.4 + 19.6 Nm (13 + 2 kgml
9. Pressure compensation valves

. Check the marks made on each pressure
compensation valve during disassembly, and
install in the correct position.
1) Before installing pressure compensation
valves below, install check valve (35).
2) Fit O-ring, then install arm IN pressure com-
pensation valve (15), L.H. travel FORWARD
pressure compensation valve (14), left swing
pressure compensation valve (131, boom
LOWER pressure compensation valve (121,
R.H. travel FORWARD pressure compensa-
tion valve (II), and bucket CURL pressure
compensation valve (IO).
m Pressure compensation valves :
392 t 19.6 Nm (40 + 2 kgm)
3) Fit O-ring, then install arm OUT pressure
compensation valve (31, L.H. travel REVERSE
pressure compensation valve (41, right swing
pressure compensation valve (51, boom
RAISE pressure compensation valve (61, R.H.
travel REVERSE pressure compensation
valve (71, and bucket DUMP pressure com-
pensation valve (8).
QKl Pressure compensation valves :
392 z 19.6 Nm I40 t 2 kgm}
30- 128
IO. Arm regeneration valve

. Install arm regeneration valve (77) and spring
(761, then install plate (75).
shown in, the diagram on the right.
w Mounting bolt :
66.15 2 7.35 Nm 16.75 f 0.75 kgm1
11. Unload valves, safety-suction valves, suction

valves
1) Fit O-rings and install suction valves (19),
(26), (21), (24), and (25). CKP00820
m Suction valve :
147 + 9.8 Nm {I5 2 1 kgm1
2) Fit O-rings and install safety-suction valves
(18), (27), (22), and (23).
m Safety-suction valve :
147 + 9.8 Nm {I5 t 1 kgm}
3) Fit O-rings and install unload valves (17) and
(I).
m Unload valve assembly :
166.6 2 19.6 Nm 117 L. 2 kgm1
12. Main relief valve

8 . Fit O-ring and install main relief valve as-
t
sembly (2).
% QECl Main relief valve :
53.9 2 4.9 Nm I5.5 + 0.5 kgml
30-129
0
DISASSEMBLY AND ASSEMBLY PUMP MERGE-DIVIDER VALVE
DISASSEMBLY OF PUMP
MERGE-DIVIDER VALVE
ASSEMBLY
CLPO3918
1. Remove plug (2) from valve body (I), then re-

move spring (3) and spool (4).
2. Remove plate (5).
3. Remove plug (61, then remove spring (7) and
spool (8).
4. Remove plug (9).
* After disassembling, if there is any abnormality
in body (1) or spools (4) or (8), replace the whole
pump merge-divider valve assembly.
ASSEMBLY OF PUMP MERGE-

DIVIDER VALVE ASSEMBLY
. Before assembling, coat the sliding surface with

engine oil.
1. Fit O-ring to plug (9) and install to valve body

(I).
m Plug (9) : 39.2 2 5.88 Nm j4.0 2 0.6 kgm}
2. Assemble spool (8) and spring (7), then fit O-
ring to plug (6) and install.
w Plug (6) : 39.2 2 5.88 Nm I4.0 t 0.6 kgm1
3. Fit O-ring to plate (5) and install to valve body.
4. Assemble spool (4) and spring (31, then fit O-
ring to plug (2) and install.
w Plug (2) :
151.9 t 24.5 Nm (15.5 t 2.5 kgm)
30- 130
0
DISASSEMBLY AND ASSEMBLY MAIN RELIEF VALVE
DISASSEMBLY OF MAIN
RELIEF VALVE ASSEMBLY
CKP03919
1. Loosen locknut (91, remove plug (8), then re-

move retainer (6).
2. Loosen locknut (IO), then remove holder (71,
spring (II), seat (121, and poppet (5).
3. Remove ring (I), then remove valve (3) and
spring (4).
* If any abnormality is found in any part after
disassembly, replace the whole main relief valve
assembly.
$
t
s
0
ASSEMBLY OF MAIN RELIEF

VALVE ASSEMBLY
. Coat the sliding surfaces with engine oil.
1. Assemble spring (4) and valve (3), then install

ring (I).
2. Install seat (121, poppet (51, spring (II), and
holder (71, and secure in position with locknut
(IO).
m Locknut : 53.9 + 4.9 Nm 15.5 t 0.5 kgm}
3. Fit retainer (61, then install plug (8) and secure
in position with locknut (9).
w Locknut : 39.7 2 4.9 Nm (4.0 t 0.5 kgm}
Ir After installing main relief valve to control valve
assembly, adjust pressure referring to section
TESTING AND ADJUSTING, testing and adjust-
ing hydraulic pressure in work equipment, swing,
travel circuit.
30-131
0
DISASSEMBLY AND ASSEMBLY WORK EQUIPMENT EPC VALVE
REMOVAL OF WORK
EQUIPMENT EPC VALVE
ASSEMBLY
0
PC200,2OOLC-6 HYPER GX 0
g Disconnect the cable from the negative (-1 ter-

minal of the battery. 0
1. Open left side cover.
2. Disconnect wiring harness clamp (I), then re-

move 8 wiring connectors (2) from holder and
disconnect.
3
;:
0
I
Ir Mark the mounting position of the connec-
tors.
3. Disconnect hoses (3) and (4).
4. Remove EPC valve assembly (5).

. When EPC solenoid is removed as an indi-
vidual part
Disconnect connector (21, remove mounting
bolts (7), then remove EPC solenoid (6).
a
INSTALLATION OF WORK
EQUIPMENT EPC VALVE
ASSEMBLY

removal.
w Solenoid mounting bolt:

11.76 + 1.96 Nm (I.2 + 0.2 kgm}
* Tighten the EPC solenoid mounting bolts

gradually in turn.
CLPO3923
30- 132
0
DISASSEMBLY AND ASSEMBLY PC VALVE
REMOVAL OF PC VALVE
ASSEMBLY

a
the hydraulic tank.

. When not using tool B, remove the drain CLP03276
:
w Hydraulic tank : Approx. 170 fi
. There are PC valve assemblies installed to both

the front pump and the rear pump, but the pro-
cedure for removal is the same.
1. Remove nut (I), then remove hose assembly

(2). m
2. Install locknut @ (708-2L-28290).

w Locknut :
100.5 2 12.5 Nm (IO.25 t 1.25 kgm}
3. Turn nut (3) in direction of loosening, then

tighten at locknut @ end.
* Angle of turning for nut (3): Approx. 30”
4. Fit tool to width across flats (22 mm) of hexago-

nal portion of sleeve (41, then loosen and re-
move PC valve assembly 6). a
CKP03719
30- 133
0
DISASSEMBLY AND ASSEMBLY PC VALUE
I’NSTALLATION OF PC VALVE
ASSEMBLY

removal.
w Nut (2) :
100.5 z 12.5 Nm (IO.25 + 1.25 kgml
If
+ After installing the PC valve assembly, re-
move locknut 0.
* Adjust the PC valve assembly.

Testing and adjusting PC valve output pres-
sure (servo piston inlet pressure).
N Nut (3) :
100.5 = 12.5 Nm (IO.25 + 1.25 kgm)

level.
30- 134
0
DISASSEMBLY AND ASSEMBLY LS VALVE
REMOVAL OF LS VALVE
ASSEMBLY
g Disconnect the cable from the negative (4 ter-

the hydraulic tank.

l When not using tool B, remove the drain - CLP03276
:
w Hydraulic tank : Approx. 170 a
. There are LS valve assemblies installed to both

the front pump and the rear pump, but the pro-
cedure for removal is the same.
1. Disconnect hose (1).
2. Fit tool to width across flats (30 mm) of hexago-

nal portion of sleeve, then loosen and remove
LS valve assembly (2). m
INSTALLATION OF LS VALVE
ASSEMBLY

removal.
* Adjust the LS valve assembly.

Testing and adjusting LS valve output pres-
sure (servo piston inlet pressure) and LS dif-
ferential pressure.
m Sleeve :
139.7 + 12.3 Nm 114.75 2 1.25 kgm}

level.
30-135
0
DISASSEMBLY AND ASSEMBLY PC, LS-EPC VALVE
REMOVAL OF PC, LS-EPC

VALVE ASSEMBLY

the hydraulic tank.
1. Remove the main pump bottom cover.
2. Disconnect wiring connectors (I) (2 places).

* After disconnecting the connectors, fit tags
to distinguish them.
3. Disconnect hoses (2) and (3). m
4. Remove PC-EPC valve assembly (4) and LS-EPC

valve assembly (5). m
INSTALLATION OF PC, LS-EPC

VALVE ASSEMBLY
removal.
m Hose sleeve nut :

24.5 t. 4.9 Nm 12.5 + 0.5 kgm}
m PC, LS-EPC valve assembly mounting

bolt : 13.3 + 1.5 Nm II.35 + 0.15 kgm}
30- 136
0
DISASSEMBLY AND ASSEMBLY SOLENOID VALVE
REMOVAL OF SOLENOID
VALVE ASSEMBLY

1. Remove 5 solenoid wiring connectors (II from

clip and disconnect.
* Mark the male and female ends of each con-
nector with tags to prevent mistakes when
connecting.
2. Disconnect 3 hoses (2) installed to bottom of

valve.
tinguish them.
3. Disconnect 7 hoses (3) installed to top of valve.

+ After disconnecting the hoses, fit tags to dis-
tinguish them.
4. Remove mounting bolts, then remove solenoid

valve assembly (4).
. When removing solenoid valve as an individual

part
i) When washino valve, loosen mounting bolt
(5) and remove.
CKP01453
INSTALLATION OF SOLENOID
VALVE ASSEMBLY

removal.
-w Bolt : 3.9 + 0.39 Nm IO.4 + 0.04 kgm1
30- 137
0
DISASSEMBLY AND ASSEMBLY WORK EQUIPMENT l SWING PPC VALVE
REMOVAL OF WORK
EQUIPMENT SWING l PPC
VALVE ASSEMBLY

the hydraulic tank.
1. Remove control stand case.

For details, see REMOVAL OF CONTROL STAND
CASE.
CLPOO82
2. Remove joint bolt (I), and disconnect hose (2).

m
3. Remove mounting bolts, raise PPC valve assem-

bly (31, then disconnect hoses (4) and (51, and
remove. m
Ir Before disconnecting the hoses, make match
marks to show the connecting position.
EQUIPMENT SWING PPC l
VALVE ASSEMBLY

removal.
w Hose mount joint bolt :

29.4 2 4.9 Nm I3.0 + 0.5 kgm}
m Hose mount joint bolt :

39.2 2 4.9 Nm I4.0 z 0.5 kgm}
* If there is excessive play in the control le-
vers, adjust the PPC valve.
Adjusting PPC valve.
30- 138
0
DISASSEMBLY OF WORK
VALVE ASSEMBLY
1. Remove nut (I), then remove disc (2) and boot

(3).
2. Remove bolts, then remove plate (5).

* Do not remove joint (4) unless it is to be
replaced.
3. Remove seal (6) and collar (7).
4. Pull out piston (81, and remove retainer (91,

springs (IO) and (II), and shim (12). 8 -0
* Spring (IO) consists of a set of two types of
a-9
springs with different
check the mounting
installed loads, so
position (oil port) and I2-10
mark with tags to prevent mistakes when o---- II
installing. O-12
d -13
5. Pull out valve (13) from body (14). “&
I&
*-a- -14
.
0
.0 I
k!G
CLP03924
30- 139
0
ASSEMBLY OF WORK
VALVE ASSEMBLY
1. Assemble valve (13) to body (14).
2. Assemble shim (12) and spring (11) to valve

(13).
* When assembling spring (II), set the end
with the small coil diameter (inside diam-
eter) at shim (12) end.
3. Assemble spring (IO), retainer (9), and piston (8).

Ir The number of loops in the coil for spring
(IO) is different for each of the hydraulic
ports below, so be careful when installing.
* The position of each port is marked on the

bottom of the valve body.
& Piston : Grease (G2-LI)
+ When assembling piston (8), coat the out-
side of the piston and the inside of the hole
in the body with grease.
4. Fit O-ring to collar (7) and assemble in body , 5-7mm

(141, then install seal (6).
I
5. Install plate (5).

w Mounting bolt :
13.23 + 1.47 Nm Il.35 t 0.15 kgm}
6. Install joint (4).

6 Sliding portion of joint :
Grease (G2-LII, 2 - 4 cc
CKP03925
& Female thread of body :
Ir Coat two places on the female thread with
one drop each of Loctite as shown in the
diagram.
m Joint : 44.1 + 4.9 Nm I4.5 t 0.5 kgm}
Ir Keep strictly to the tightening torque.
7. Assemble boot (3) and disc (21, and tighten with

nut (I).
& Contact surface of piston and disc :
Grease (G2-LI), 0.3 - 0.8 cc
m Nut : 112.7 2 14.7 Nm ill.5 + 1.5 kgm}
* After assembling the disc, adjust the height
of the disc. For details, see TESTING AND
ADJUSTING, Adjusting PPC valve.
30-140
0'
DISASSEMBLY AND ASSEMBLY TRAVEL PPC VALVE
REMOVAL OF TRAVEL PPC

VALVE ASSEMBLY
a Lower the work equipment completely to the

the hydraulic tank.
1. Remove travel PPC valve undercover.
2. Remove floor mat.
3. Remove pedals (I) and levers (2).
4. Remove cover (3). m
5. Remove covers (4), then remove springs (5).
6. Disconnect 6 PPC hoses (7), then remove travel

PPC valve assembly (6). m
CEF’O0427
INSTALLATION OF TRAVEL
PPC VALVE ASSEMBLY

removal.
Cover mounting bolt :

19.6 z 1.96 Nm I2.0 t. 0.2 kgm1 5 CEP00428
Hose mount joint bolt :

(width across flats : 30 mm) :
39.2 + 4.9 Nm I4.0 L 0.5 kgm}
Hose mount elbow :
(width across flats : 22 mm) :
34.3 + 4.9 Nm 13.5 + 0.5 kgm1
.8
Hose mount joint bolt :
(width across flat : 17 mm) :
24.5 + 4.9 Nm 12.5 + 0.5 kgm}
CEFO0429
30-141
0
DISASSEMBLY OF TRAVEL PPC
r
VALVE ASSEMBLY
1. Remove screws (I), then remove levers (2).
2. Remove mounting bolts (3), then remove case

and shaft assembly (4).
3. Remove mounting bolts (5), then remove plate

(6) and damper assembly (7) as one unit.
* Check the thickness and mounting position
of washer (18).
Ir Never disassemble damper assembly (7).
4. Remove mounting bolts (8), then remove damper

assembly (7) from plate (6).
5. Remove seal (9) and collar (10).
6. Pull out piston (II), and remove retainer (12),

springs (13) and (14), and shims (15).
* Check the number and thickness of shims
(15) for each mounting position, and keep in
a safe place.
7. Pull out valve (16) from body (17).
CLP03926
30-l 42
0
ASSEMBLY OF TRAVEL PPC

VALVE ASSEMBLY
1. Assemble valve (16) in body (17).
2. Assemble shim (15) and spring (14) to valve

(16).
Ir Assemble the same number and thickness
of shim (15) as was removed during disas-
sembly.
Standard shim thickness : 0.3 mm
* Spring (14) is not symmetrical at the top
and bottom, so assemble with the small coil
diameter (inside diameter) at the shim end.
3. Assemble spring (13), retainer (12), and piston

(II).
& Outside circumference of piston,
body hole : Grease (G2-LI)
4. Fit O-ring to collar (IO) and assemble in body

(171, then install seal (9).
5. Install damper assembly (7) to plate (6), then

tighten mounting bolts (8).
$ & Mounting bolt : Thread tightener (LT-2)
>
m Mounting bolt:
% 4.41 + 0.49 Nm IO.45 2 0.05 kgm}
6. Install plate (6) and damper assembly (7) as one

unit, then tighten mounting bolts (5).
* Check the thickness of washer (18) and as-
semble in the position checked during dis-
assembly.
m Mounting bolt:
30.87 t 3.43 Nm t3.15 + 0.35 kgm)
7. Install case and shaft assembly (4), then tighten

mounting bolts (3).
* Check that the out-of-parallel of shaft and
CLP03926
damper assembly (7) of case and shaft as-
sembly (4) is less than 0.5.
6 Rocking portion of shaft,
connection of lever and piston :
Grease (G2-LI)
m Mounting bolt:
27.93 2 3.43 Nm (2.85 r. 0.35 kgm}
8. Install levers (2), then tighten screws (1).

* Adjust so that lever (2) can slightly move.
& Rocking portion of lever pin and plate :
Grease (G2-LI)
m Screw : 8.82 + 0.98 Nm (0.9 2 0.1 kgm}
30-l 43
0
DISASSEMBLY AND ASSEMBLY BOOM LOCK VALVE
REMOVAL OF BOOM LOCK

VALVE ASSEMBLY
a Lower the work equipment completely to the

ground, then release the remaining pressure in
the hydraulic circuit. For details, see TESTING
AND ADJUSTING, Releasing remaining pressure
in hydraulic circuit.
1. Disconnect tube (I) and hoses (2).
2. Disconnect tube (3).
3. Remove mounting bolts of bracket (41, then re-

move boom lock valve (5) together with bracket
(4).
INSTALLATION OF BOOM
LOCK VALVE ASSEMBLY
removal.
CLPO3928
Jr Add oil through the oil filler to the specified
again.
l Bleeding air
Ir Bleed the air. For details, see TESTING AND
ADJUSTING, Bleeding air.
30-l 44
0
DISASSEMBLY AND ASSEMBLY BOOM CYLINDER
REMOVAL OF BOOM
CYLINDER ASSEMBLY
A Extend the arm and bucket fully, lower the work

equipment completely to the ground, and put
the safety lock lever in the LOCK position.
1. Disconnect grease hose (I).
2. Sling boom cylinder assembly (2), and remove

lock bolt (3). a
3. Remove plate, then remove head pin (4). 112)

* There are shims installed, so check the
number and thickness, and keep in a safe
place.
4. Start engine, and retract piston rod, then tie

piston rod with wire to prevent it from coming
out.
* Set stand @ under the cylinder assembly,
and adjust the position for slinging.
g Release the remaining pressure in the hy-
draulic circuit. For details, see TESTING AND
ADJUSTING, Releasing remaining pressure
5. Disconnect hoses (5).
6. Remove plate, then using forcing screws 0, re-

move bottom pin (61, and remove boom cylin-
der assembly (2). m
place.
&I kg Boom cylinder assembly

: PC200, 210-6: 190 kg
: PC220, 230-6: 220 kg
30-l 45
0
CYLINDER ASSEMBLY
removal.
a
* When tightening the locknut, tighten so that
clearance a between the plate and nut is 0.5
- 1.5 mm.
;:
-+-
-_
0
_+-_-_
I
-
a
& Inside surface of bushing when CKP03932
assembling pin :
Anti-friction compound (LM-PI
6 Greasing after assembling pin :
Grease (LM-G)
A When aligning the position of the pin hole,
never insert your fingers in the pin hole.
Ir Adjust the shim thickness so that clearance
b between cylinder rod (7) and plate (8) is
below 1 mm.
* Standard shim thickness : 0.8 mm, 1.5
mm
& Inside surface of bushing when CLPO3933

assembling pin :
Anti-friction compound (LM-P)
& Greasing after assembling pin :
Grease (LM-G)
* Adjust the shim thickness so that clearance
c between cylinder bottom (9) and bracket
(IO) is below 1 mm.
mm

j, Add oil through the oil filler to the specified CLPO3934
again.
l Bleeding air
j, Bleed the air from the cylinder. For details,
see TESTING AND ADJUSTING, Bleeding air
from hydraulic cylinder.
30-146
0
DISASSEMBLY AND ASSEMBLY ARM CYLINDER
REMOVAL OF ARM CYLINDER

ASSEMBLY I
a Extend the arm cylinder piston rod approx. 200
mm, lower the work equipment completely to
the ground, then set the remaining safety lock
lever to the LOCK position.
1. Set block @) between arm cylinder and boom.
2. Remove plate, then remove head pin (1). m
3. Start engine, and retract piston rod, then tie CLPO3935

out.
a Release the remaining pressure in the hy-
5. Disconnect grease hose (3).
6. Raise arm cylinder assembly, remove plate, re-

move bottom pin (41, then remove arm cylinder
assembly (5). m
place.
l&lkg Arm cylinder assembly

: PC200, 210-6: 265 kg
: PC220, 230-6: 300 kg
30- 147
0
INSTALLATION OF ARM
CYLINDER ASSEMBLY

removal.
Inside surface of bushing when

assembling pin :
Greasing after assembling pin :
Grease (LM-G)
g When aligning the position of the pin hole, CLPO.?Q?fi
& Inside surface of bushing when

assembling pin :
a Greasing after assembling pin :
Grease (LM-GI
g When aligning the position of the pin hole,
a between cylinder bottom (6) and bracket
(7) is below 1 mm.
+ Standard shim thickness : 0.8 mm, 1.5
mm

again.
. Bleeding air
* Bleed the air from the cylinder. For details,
30- 148
0
DISASSEMBLY AND ASSEMBLY BUCKET CYLINDER
REMOVAL OF BUCKET
CYLINDER ASSEMBLY
A Extend the bucket cylinder piston rod approx.

200 mm, lower the work equipment completely
to the ground, then set the safety lock lever to
the LOCK position.
1. Set block @ under arm top.

2. Set block @ between link and arm, and block @
between bucket cylinder and arm.
3. Remove lock bolt (I). m
4. Remove plate, then remove head pin (2). a CLPD3937
t There are shims installed, so check the
place.
piston rod with wire to prevent it from coming 4
out.
A Release the remaining pressure in the hy-
6. Disconnect 2 hoses (3).
7. Raise bucket cylinder assembly, remove plate,
$ remove bottom pin (41, then remove bucket cyl-
>
inder assembly (5). m CIP0393A
% * There are shims installed, so check the
place.
&I kg Bucket cylinder assembly
: PC200, 21 O-6: 165 kg
: PC220, 230-6: 195 kg
30-l 49
0
INSTALLATION OF BUCKET
CYLINDER ASSEMBLY

removal.
a
Sr When tightening the locknut, tighten so that
- 1.5 mm.
-+- I
a
assembling pin :
6 Grease after assembling pin :
b
Grease (LM-G)
b between link (6) and link (7) is below 1
mm.
Standard shim thickness : 0.8 mm, 1.5
mm
Inside surface of bushing when CLPO3939

assembling pin :
Grease after assembling pin :
Grease (LM-G)
a When aligning the position of the pin hole,
(9) is below 1 mm.
mm

* Add oil through the oil filler to the specified CLPO3940
again.
l Bleeding air
30- 150
0
DISASSEMBLY AND ASSEMBLY HYDRAULIC CYLINDER
DISASSEMBLY OF HYDRAULIC
CYLINDER ASSEMBLY
1. Piston rod assembly

1) Remove piping kom cylinder assembly.
2) Remove mounting bolts and disconnect head
assembly (I).
3) Pull out piston rod assembly (2).
* Place a container under the cylinder to
catch the oil.
CLPO3941
4) Disassemble piston rod assembly as follows.

i) Set piston rod assembly (2) in tool 01.
CLPO3778
ii) Remove stopper screw (3) of piston as-

sembly.
* Common screw size for boom, arm,
and bucket cylinder: Ml2 x Pitch 1.75
CLPO3779
* If the caulking of screw (3) is too

strong and it cannot be removed,
tighten the screw fully, then fit a tap
to the thread and remove the screw.
DKP00498
30-l 51
0
iii) Using tool 02, remove piston assembly

(4).
. When not using tool 02, use the drill
holes (0 10, 4 places) and loosen the
piston assembly.
DLPOO499
iv) Remove plunger (5).

Boom and arm cylinder only
v) kemove collar (6).
Boom and arm cylinder only
vi) Remove head assembly (7).
CLP03782
vii) Remove cap (81, and pull out 12 balls

(91, then remove plunger (IO).
. Boom and arm cylinder only
CKP03783

1) Remove rings (1 I).
2) Remove wear rings (12).
3) Remove piston ring (13).
4) Remove O-ring and backup ring (14).
CLPO3784
30-l 52
0
3. Disassembly of cylinder head assembly

1) Remove O-ring and backup ring (15).
2) Remove snap ring (16), then remove dust 20
seal (17). I5
3) Remove rod packing (18).
4) Remove buffer ring (19).
I!
5) Remove bushing (20). 17
18
CLPO2322
30-153
0
ASSEMBLY OF HYDRAULIC
CYLINDER ASSEMBLY
* Be careful not to damage the packings, dust

seals, and O-rings.
* Do not try to force the backup ring into position.
Warm it in warm water (50 - SOT) before fitting
it.
1. Assemblv of head assemblv

1) Using tool 05, press fit-bushing (20).
2) Assemble buffer ring (19).
3) Assemble rod packing (18). CLP03766
CLPO3787
4) Using tool 06, install dust seal (171, and se-
cure with snap ring (16).
5) Install backup ring and O-ring (15).
CLP02322
2. Assembly of piston assembly 1

1) Using tool 03, expand piston ring (13).
Ir Set the piston ring on tool 03, and turn
the handle 8 - 10 times to expand the
ring.
2) Set tool 04 in position, and compress piston
ring (13).
CKP03768 CLPO3789

4) Assemble wear ring (12).
5) Assemble ring (11).
Ir Be careful not to open the end gap of
the ring too wide.
& Ring groove : Grease (G2-LI)
CLPO3764
30- 154
0

1) Set piston rod assembly (2) to tool 01.
CLPO3778
2) Assemble head assembly (7).
3) Fit O-ring and backup ring to collar (61, then

assemble.
4) Assemble plunger (5).

* Check that there is a small amount of
play at the tip of the plunger.
. Arm cylinder only
CLPO3782
Set cushion plunger (IO) to piston rod, then

assemble 12 balls (9) and secure with cap
(8).
. Arm cylinder only
I 1- CKP03783
6) Assemble piston assembly (4) as follows.

. When using rod and piston again:
* Wash thoroughly and remove all
metal particles and dirt.
i) Screw in piston assembly (41, then
use tool 02 to tighten piston assem-
bly (2) so that position of screw
thread hole matches.
* Remove all burrs and flashes with
a file.
ii) Tighten screw (3).
m Screw (3) : DLP00499
66.2 + 7.35 Nm i6.75 T 0.75 kgm)
iii) Caulk thread at 2 places with punch.
. When using a new part for either or both

of rod or piston assembly (2)
* For the rod with bottom cushion,
mark the cushion plug position on
Punch
the end face of the rod.
. Arm cylinder only
DKP00500
i) Screw in until piston assembly (4)

contacts end face of rod, then use Contact
tool 02 to tighten. surface
m Piston assembly (4):
294 z 29.4 Nm I30 + 3.0 kgm}
* After tightening the piston, check
that there is play in plunger (5).
. Boom, arm cylinder only
DKP00501
ii) Machine one of holes used to install

screw (3).
Ir Align a drill horizontal with the
V-groove of the thread of rod (2)
and piston (41, then carry out
machining.
* For the cylinder with bottom
cushion (arm cylinder), avoid the
cushion plug position when ma-
chining.
l Screw machining dimension
(mm)
CLPO3792
iii) After machining, wash thoroughly to

remove all metal particles and dust.
iv) Tighten screw (3).

m Screw (3) :
66.2 2 7.35 Nm 16.75 t 0.75 kgml
VI Caulk thread at 2 places with punch.
CLPO3779
30-156
0
7) Assemble piston rod assembly (2).

& Seal portion : Grease (G2-LI)
* Set the end gap of the ring horizontal (at
side position), align axial center of cylin-
der tube, then insert.
* After inserting, check that the ring is not
broken and has not come out, then push
in fully.
DLPOO502
8) Tighten head assembly (I) with mounting

bolts.
m Mounting bolt :
I I I
Cylinder 1 Tightening torque
Bucket 270k39Nm {27.5&4.0kgmI
Arm 373+_54Nm {38.0+5.5kgml
Boom 1 270&39Nm {27.5r4.0kgm}
9) Install piping.
CLP03941
30-157
0
DISASSEMBLY AND ASSEMBLY WORK EQUIPMENT
REMOVAL OF WORK
EQUIPMENT ASSEMBLY

equipment to the ground, and set the safety
lock-lever to the LOCK position.
2. Sling boom cylinder assembly (21, and remove

lock bolt (3). m
3. Remove plate, then remove head pin (4) m CLPO3929

place.

out, and lower it onto block.
* Disconnect the boom cylinder on the oppo-
site side in the same way.
gs
\
5. Disconnect hoses (5) and (6), and secure it to

valve with rope.
* Hoses (6) are for machines equipped with
an additional attachment circuit.
6. Disconnect wiring connector (7) for working

lamp.
7. Sling work equipment assembly, remove plate,

then remove foot pin (8) using tool P, and re-
move work equipment assembly (9). m
Sr There are shims installed, so check the
place. CLPO3945
& kg Work equipment assembly :

PC200-6: 3,300 kg
PC210-6: 3,650 kg
PC220-6: 3,850 kg
PC230-6: 4,250 kg
CLPO3946
30-158
0
EQUIPMENT ASSEMBLY
Carry out installation in the reverse order to
-@)I
l
removal.
pJ
-- -i------r
- 1.5 mm.
--I-- I
a
assembling pin :
Grease (LM-G)
b between cylinder rod (IO) and plate (II) is
below 1 mm.
mm
I

assembling pin :
Grease (LM-G)
c between boom (12) and bracket (13) is be-
low 1 mm.
* Standard shim thickness :
0.8 mm, 1.0 mm, 1.5 mm
C
* Add oil through the oil filler to the specified CLPO3948
again.
. Bleeding air
30-l 59
0
DISASSEMBLY AND ASSEMBLY BUCKET
REMOVAL OF BUCKET
ASSEMBLY
a Set the back of the bucket facing down, lower

the work equipment completely to the ground,
and set the safety lock lever to the LOCK posi-
tion.
1. Remove lock bolt (1). m
2. Remove connecting pin (2) between link and

bucket. a
* There are shims installed, so check the CLPO3949
place.

out.
4. Remove lock bolt (3). a
5. Remove plate (41, the remove connecting pin (5)

between arm and bucket. m
place.
6. After raising work equipment, swing to discon-

nect bucket assembly (6).
& kg Bucket assembly : PC200-6: 650 kg

PC210-6: 800 kg
PC220-6: 750 kg
PC230-6: 950 kg
Cl PO3951
30- 160
0
ASSEMBLY

removal.
pi7-j pi -
- 1.5 mm.
-+- I
a
assembling pin :
& Grease after assembling pin :
Grease (LM-G) b

b between bucket boss (7) and link (8) is
below 1 mm.
Ir Standard shim thickness : 0.8 mm, 1.5
mm

assembling pin :
Grease (LM-G)
* Set the O-ring at the end face of the bucket
boss securely.
m
c between arm top (9) and spacer (IO) is 0.5
- 1.0 mm.
mm
10 9
CLPO3953
30-l 61
0
DISASSEMBLY AND ASSEMBLY ARM
REMOVAL OF ARM ASSEMBLY
1. Remove bucket assembly. For details, see RE-

MOVAL OF BUCKET ASSEMBLY.
2. Secure front link to arm with wire.
3. Pull in arm so that it is easy to remove pin at

arm cylinder head, then lower arm and bucket
assembly (I) on to block 0.
Set the safety lock lever to the LOCK posi-
tion.
CLPO3954
4. Set block @ between arm cylinder and boom.
5. Remove plate, then remove arm cylinder head

pin (2). m

out.
7. Disconnect 2 hoses (3) and 2 hoses (4).

* Install blind plugs at the male end and in the
disconnected hoses.
8. Remove plate, then remove connecting pin (5)

between arm and boom. m
place.
9. After raising boom, swing to remove arm and

bucket cylinder assembly (I).
&I ke Arm, bucket cylinder assembly :

PC200-6: 950 kg
PC210-6: 1,100 kg
PC220-6: 1,100 kg
PC230-6: 1,250 kg
30-162
0
INSTALLATION OF ARM
ASSEMBLY
removal.

assembling pin :
Grease (LM-G)
A When aligning the position of the pin hole, CLP03955

assembling pin :
Grease (LM-GI
a between boom top (6) and arm bottom (7)
is below 1.0 mm.
* Standard shim thickness : 0.8 mm

again.
. Bleeding air
30-l 63
0
DISASSEMBLY AND ASSEMBLY BUCKET l ARM
REMOVAL OF BUCKET l ARM

ASSEMBLY

the ground, then set the safety lock lever to the
LOCK position.
1. Set block 0 between arm cylinder and boom.

pin (I). m
CLPO3956

out.
4. Disconnect 2 hoses (2) and 2 hoses (3).

Jr Install blind plugs at the male end and in the
disconnected hoses.
CLPO3957
5. Raise bucket and arm assembly, remove plate,
then remove connecting pin (4) between arm
and boom, and remove bucket and arm assem-
bly (5). m
t There are shims installed, so check the
place.
&I kg Bucket, arm assembly :

PC200-6: 1,650 kg
PC210-6: 1,900 kg
PC220-6: 1,900 kg
PC230-6: 2,250 kg
30- 164
0
INSTALLATION OF BUCKET l
ARM ASSEMBLY
removal.

assembling pin :
Grease (LM-G)
g When aligning the position of the pin hole, CLPO3955

assembling pin :
Grease (LM-G)
a between boom top (6) and arm bottom (7)
is below 1 mm.

again.
. Bleeding air
30-165
0
DISASSEMBLY AND ASSEMBLY BOOM
REMOVAL OF BOOM
ASSEMBLY
1. Remove bucket and arm assembly. For details,

see REMOVAL OF BUCKET, ARM ASSEMBLY.
2. Lower boom assembly completely to ground,

and set safety lock lever to LOCK position.

lock bolt (3). a CLPO3929
5. Remove plate, then remove head pin (4). a

* There are shim installed, so check the
place.

out, and lower it onto block.
* Disconnect the boom cylinder on the oppo-
g Release the remaining pressure in the hy- \
draulic circuit. For details, see TESTING AND \
7. Disconnect hoses (5) and (61, and secure to valve

with rope.

lamp.
9. Raise boom assembly and remove plate, remove

foot pin (8) using tool P, then remove boom
assembly (9). m
Ir There are shims installed, so check the CLP03945
place.
r+Ikg Boom assembly : PC200-6: 1,650 kg

PC210-6: 1,750 kg
PC220-6: 1,950 kg
PC230-6: 2,000 kg
3958
30-166
0
ASSEMBLY

removal.
m
-- -i------1-
clearance a between the plate and nut is 0.5 -=@
- 1.5 mm.
+ I
a
assembling pin :
Grease (LM-G)
b between cylinder rod (IO) and plate (11) is
below 1 mm.
mm

assembling pin :
Grease (LM-G)
12 I3
low 1 mm.
Ir Standard shim thickness :
0.8 mm, 1.0 mm, 1.5 mm
C
Ir Add oil through the oil filler to the specified CLPO3948
again.
. Bleeding air
30-l 67
0
DISASSEMBLY AND ASSEMBLY OPERATOR’S CAB
REMOVAL OF OPERATOR’S
CAB ASSEMBLY
I:
1. Remove floor mat.
2. Remove operator’s seat (1).

+ Be careful not to damage the covers.
CEP00438
3. Remove knob (2).
4. Remove 4 bolts and 1 clip, then remove panels

(3) and (4).
5. Disconnect window washer hose (5).
6. Remove plate (61, then remove left cover (7).
CEPO0440 CEPO0441
7. Disconnect hose (8) and speaker wiring connec-

tor, then remove right cover (9).
* Lift up right cover (9) slightly before discon-
necting the speaker wiring connector.
‘. -8
CEPU0442
30- 168
0
DISASSEMBLY AND ASSEMBLY OPERATOR’S CAB
8. Remove cover (IO) and duct (II).
9. Disconnect air conditioner cable (12).
IO. Disconnect duct (13) at front.
11. Disconnect 11 connectors (I 4).

* Panel : CN-X07 (MIC21)
* Controller : CN-CO1 (MIC131
: CN-CO2 (MIC21)
: CN-CO3 (MIC20)
: CN-Cl6 (MIC17)
j, Wiring harness intermediate
: CN-HI2 (S16) White
: CN-H.13 (S16) Blue
: CN-HI4 (M6)
: CN-HI5 (L2)
* Speaker : CM-Ml3 (KES-2)
* Air conditioner : No connector No.
* PC200-6 HYPER only : KOI (S16)
$
>
%
12. Remove 4 mounting nuts and 6 mounting bolts,

then lift off operator’s cab assembly (151.
& kg Operator’s cab assembly : 300 kg

. % : Nut A: Bolt
j, Check the length of the bolts.
INSTALLATION OF
OPERATOR’S CAB ASSEMBLY
removal.
m Mounting nut :
276.85 + 31.85 Nm (28.25 t 3.25 kgm}
u CEW0446
DISASSEMBLY AND ASSEMBLY COUNTERWEIGHT
REMOVAL OF
COUNTERWEIGHT ASSEMBLY
1. Set eyebolts @ to counterweight assembly (I),
and sling.
2. Remove mounting bolts (2) and (3). m

Ir Be careful not to lose the shims when re-
moving.
3. Lift off counterweight (I) horizontally with wire

or chain block. 1121
Ir Be careful not to hit the engine, radiator and
cooler assembly.
k-*2% CLPO3959
& ks Counterweight assembly :

PC200-6: 3,430 kg
PC2 1O-6: 4,450 kg
PC220-6: 4,450 kg
PC230-6: 4,880 kg
INSTALLATION OF
COUNTERWEIGHT ASSEMBLY
removal.
m
xcly Thread of counterweight mounting bolt:
QFI Counterweight mounting bolt :
1,323 + 147 Nm I135 t 15 kgml
(12
Ir Installing and adjusting counteweight
1) Sling counterweight with crane and set
in position on frame.
2) Push counterweight and install shim and
mounting bolts (2) and (31, and adjust to
following dimensions.
. Clearance from revolving frame :
10 + 5 mm (left and right) Door Unit:mm
. Clearance from bodywork door :
10 + 5 mm (left and right) -Counterweight
. 2
Stepped difference b from revolving I:
frame in left-to right direction :
Max. 5 mm ___ a=10*4
. Stepped difference a from bodywork
door in left-to right direction :
10 +4mm
. Stepped difference c from bodywork
top cover in up-down direction :
Revolvino frame DKP00503
Max. 5 mm
30- 170
0
DISASSEMBLY AND ASSEMBLY WORK EQUIPMENT ELECTRIC LEVER UNIT
REMOVAL OF WORK
EQUIPMENT ELECTRIC LEVER
UNIT ASSEMBLY
g Lower the work equipment to the ground.

1. Remove control stand case.

For details, see REMOVAL OF CONTROL STAND
CASE.
2. Remove mounting bolts, raise work equipment

electric lever unit assembly (I), then disconnect
wiring connector (2), and remove. m
EQUIPMENT ELECTRIC LEVER 8
>
UNIT ASSEMBLY
%

removal.
m
Ir Check that there is no oil or dust stuck to the
connector joint, then connect the wiring se-
curely.
30-172
0
DISASSEMBLY AND ASSEMBLY ENGINE THROTTLE l PUMP CONTROLLER
REMOVAL OF ENGINE
THROTTLE PUMP l
CONTROLLER ASSEMBLY

1. Slide operator’s seat fully forward.
2. Remove plate (I), then remove left cover (2).
CEP00105
3. Disconnect hose (3) and speaker wiring connec-

tor, then remove right cover (4).
Ir Lift up the cover slightly before disconnect-
ing the speaker wiring connector.
4. Remove 5 connectors (5).
5. Remove engine throttle and pump controller

assembly (6). m
INSTALLATION OF ENGINE
THROTTLE PUMP l
CONTROLLER ASSEMBLY

removal.
* Check the performance of the work equip-

ment, travel, and swing. For details, see
TESTING AND ADJUSTING.
30-173
0
DISASSEMBLY AND ASSEMBLY CONTROL STAND CASE
REMOVAL OF CONTROL
STAND CASE
1. Tray
1) Insert a thin flat-headed screwdriver into
notch at rear of tray (I) and lever up lightly
to release rear claw (2).
* The claw can only be released from the
rear.
CEPO608 ( ( ‘2 CKP00832
2) Pull tray (1) to rear to remove. m
-
/
CEPO0609
2. Boot
1) Insert a thin flat-headed screwdriver between
boot (3) and upper case (41, remove claw (5)
at front of boot from upper case, then raise
front.
2) Pull boot (3) to front to remove claw at rear

of boot. a
CEW0604 CEFQ0605
3) Disconnect wiring connector (7) from hole

for removed tray.
4) Push boot (3) up, remove bolt (8), then re-

move lever (9) and boot (3).
It Check the direction of the lever.
30- 174
0
DISASSEMBLY AND ASSEMBLY CONTROL STAND CASE
3. Upper case
1) Remove 4 upper case mounting screws (IO).
CEP00421 CKP00832
2) Push bottom center of upper case (1 I) from

both sides, and lift up to release claws at
both sides.
I CEPO0423
3) Use a screwdriver from control lever hole at

front of upper case (I I) to release claws (12)
at front of case.
4) Remove upper case (I I). m
I I CEP00602
STAND CASE
removal.
When installing the tray and upper case, in-

sert the claws at the front first.
When installing the boot, insert the claw at

the rear first. CEPU0603
30-175
0
DISASSEMBLY AND ASSEMBLY VALVE CONTROLLER
REMOVAL OF VALVE
CONTROLLER ASSEMBLY

1. Remove plate (I), then remove cover (2).
2. Disconnect air conditioner hose (3) and speaker

wiring connector, then remove cover (4).
* When removing cover (41, the speaker wir-
ing connector cannot be seen, so be careful.
3. Disconnect wiring connectors (51, then remove

valve controller assembly (6).
CLP03962
INSTALLATION OF VALVE
CONTROLLER ASSEMBLY

removal.
30- 176
0
DISASSEMBLY AND ASSEMBLY MONITOR
REMOVAL OF MONITOR
ASSEMBLY
a Disconnect the cable from the negative I-1 ter-

1. Remove screws (I), then lift up monitor assem-

bly (2).
2. Disconnect wiring connectors (31, then remove

monitor assembly (2).
CLPO3964
L
INSTALLATION OF MONITOR
ASSEMBLY

removal.
l Check the mode setting and display function.

For details, see TESTING, ADJUSTING AND
TROUBLESHOOTING.
30- 177
0
DISASSEMBLY AND ASSEMBLY SWING MOTOR
REMOVAL OF SWING MOTOR

ASSEMBLY

ground and stop the engine. Loosen the oil filler
cap slowly to release the pressure inside the
hydraulic tank. Then set the safety lock lever to
the LOCK position.

CLP03966 CLPO3967
2. Disconnect wiring connectors (2).
3. Remove hose clamps (3) and (4).
4. Disconnect swing motor inlet and outlet hoses

(51, (61, and (7).
5. Remove bracket (8).
6. Disconnect drain hoses (9) and (IO).
7. Disconnect pilot hose (I I).
8. Remove swing motor assembly (12).
& kg Swing motor assembly : 65 kg
MOTOR ASSEMBLY

removal.

again.
. Bleeding air
see TESTING AND ADJUSTING, Bleeding air.
30-178
0
REMOVAL OF CONTROL
VALVE ASSEMBLY
g Run the engine at low idling, operate the cylin-

der to the end of its stroke without relieving the
circuit, lower the work equipment to the ground,
then stop the engine. For details, see TESTING
AND ADJUSTING, Releasing pressure in hydrau-
lic circuit. After stopping the engine, do as fol-
lows.
. Loosen the oil filler cap slowly to release
the pressure inside the tank.
l Operate the control levers.
* Operate the control levers several times
to release the pressure in the accumula-
tor.
l Start the engine and run at low idling for
approx. 5 seconds, then stop the operation
and operate the control levers.
Ir Repeat the above operation several times
to release the remaining pressure com-
pletely.
1. Open engine hood, and remove divider covers

(I), then disconnect intake connector.
CLFUO606
2. Disconnect hoses (21, (31, and (41, remove 2 con-
nectors (5) from holder, then disconnect.
* Remove the hose mounting elbow from the
valve body.
3. Remove block (6).
4. Disconnect hoses (7) and (81, block (9) and tim-

ing valve (19).
Ir When disconnecting block (91, loosen the
mounting bolts of the block tube flange first.
5. Disconnect tubes (IO), (II), and (12), and hoses

(131, (l4), and (15).
* Disconnect 6 tubes and 7 hoses.
* With hoses (15) there is another hose under
each of the hoses.
CONTROL VALVE
7. Sling control valve assembly (181, then remove

mounting bolts, and lift off control valve assem-
bly.
&I kg Control valve assembly : 170 kg
VALVE ASSEMBLY
PC200,200LC-6 HYPER GX

removal.

again.
. Bleeding air
* Bleed the air from the circuit between the
valve and the hydraulic cylinder. For details,
see TESTING AND ADJUSTING, Bleeding air.
* When control valve has been replaced

After completing all operations, carry out ad-
justment in the order given below. For details,
see TESTING AND ADJUSTING, Table for order
of operations in GX adjustment mode.
i) When replacing control valve assembly or
replacing spool including swing spool
Order of operation: M+A+E+N+Q+A+P-+Q
ii) When replacing spools other than swing
spool
Order of operation: M+A+E+O+Q
30-180
0
DISASSEMBLY AND ASSEMBLY WORK EQUIPMENT EPC VALVE
REMOVAL OF WORK
EQUIPMENT EPC VALVE
ASSEMBLY
0
(:
PCZOO, 2OOLC-6 HYPER GX 0

minal of the battery. 0
1. Open left side cover.
2. Disconnect wiring harness clamp (I), then re-

move 8 wiring connectors (2) from holder and
disconnect.
* Mark the mounting position of the connec-
3 0
tors.
4. Remove EPC valve assembly (5).

. When removing the EPC solenoid as an in-
dividual part:
Disconnect connector (2), remove mounting
bolts (71, then remove EPC solenoid (6).
m
EQUIPMENT EPC VALVE
ASSEMBLY

removal.
m
m Solenoid mounting bolt :
11.76 +. 1.96 Nm II.2 z 0.2 kgm}
* Tighten the EPC solenoid mounting bolts in
turn slowly.
Sr When work equipment EPC valve has been re-

placed
i) When replacing work equipment EPC valve
assembly or replacing EPC valve including
swing EPC valve
Order of operation : M+A+E+N+Q+A+P+Q
ii) When replacing EPC valves other than swing
EPC valve
CLPO3923
Order of operation : M+A+E+O+Q
REMOVAL OF BOOM
CYLINDER ASSEMBLY

equipment completely to the ground, and put
the safety lock lever in the LOCK position.

lock bolt (3). m
CLPO3929
3. Remove plate, then remove head pin (4). a

Ir There are shims installed, so check the
place.

out.
* Set stand @ under the cylinder assembly,
and adjust the position for slinging.
5. Disconnect hoses i5).
6. Remove plate, then using forcing screws 0, re-

move bottom pin (6). and remove boom cylin-
der assembly (2). a
place.
&I kg Boom cylinder assembly : 190 kg
30- 182
0
CYLINDER ASSEMBLY
-=Q:
removal.
m
-- -i----r-
- 1.5 mm. ---I--- I
a
CKP03932
assembling pin :
Grease (LM-G)
Adjust the shim thickness so that clearance
below 1 mm.
mm
CLP03933
assembling pin :
Grease (LM-G)
(IO) is below 1 mm.
0.8 mm, 1.5 mm
. Refilling with oil (hydraulic tank) CLPO3934

again.
. Bleeding air
* When boom cylinder assembly has been re-
placed
justment in the following order: A+E+G+Q
mode.
30-183
0
REMOVAL OF ARM CYLINDER

ASSEMBLY

the ground, then set the remaining safety lock
lever to the LOCk position.

CLP03935
out.
6. Raise arm cylinder assembly, remove plate, re-

move bottom pin (4), then remove arm cylinder
assembly (5). a
place.
&I kg Arm cylinder assembly : 265 kg
30- 184
0
INSTALLATION OF ARM
CYLINDER ASSEMBLY

removal.

assembling pin :
Grease (LM-G) CLPO3936

assembling pin :
Grease (LM-G)
a between cylinder bottom (6) and bracket
(7) is below 1 mm.
0.8 mm, 1.5 mm

again.
. Bleeding air
* When arm cylinder assembly has been replaced
justment in the following order: A+E+I+Q
mode.
30- 185
0
REMOVAL OF BUCKET
CYLINDER ASSEMBLY
PCZOO,2OOLC-6 HYPER GX
g Extend the bucket cylinder piston rod approx.

200 mm, lower the work equipment completely
the LOCK position.
1. Remove cover (I).

CLPO3971
2. Remove clamp (21, then remove wiring connec-

tor (3) from clip and disconnect.
3. Set block @ under arm top.
4. Set block @ between link and arm, and block @

between bucket cylinder and arm.
5. Remove lock bolt (4). m

place. CLPO3972

out.
9. Raise bucket cylinder assembly, remove plate,

remove bottom pin (71, then remove bucket cyl-
inder assembly (8). m CLPO3937
+ When raising the bucket cylinder assembly,
wrap the sling around the cylinder. Be care-
ful not to wrap it around the wiring.
Ir There are shims installed, so check the
number and thickness, and keep in a safe 7
place.
&I k# Bucket cylinder assembly : 170 kg,
CLP03973
30-186
0
CYLINDER ASSEMBLY

removal.
m
- 1.5 mm.
a
w CKP03932
6 inside surface of bushing when
assembling pin :
Grease (LM-G)
b between link (9) and link (IO) is below 1
mm.
mm
$
2- IO
Ei CLPO3974
0 Inside surface of bushing when
assembling pin :
Grease (LM-G)
(12) is below 1 mm.
0.8 mm, 1.5 mm
. Refilling with oil (hydraulic tank) CLPO3975

again.
. Bleeding air
+ When bucket cylinder assembly has been re-
placed
justment in the following order: A+E+K+Q
mode.
30- 187
0
DISASSEMBLY OF BUCKET
CYLINDER ASSEMBLY
1. Plate, sensor
1) Remove plate (I), then remove piping (2).
2) Remove sensor (3).
CLPO3976

(4).
assembly (5).
3) Pull out piston rod assembly (6).
* Place a container under the cylinder to
catch the oil.
5
CLPO3977
4) Disassemble piston rod assemblv as follows.

i) Set piston rod assembly (6)to tool 01.
ii) Using tool 02, remove nut (7).
* Width across flats: 85 mm
iii) Remove piston assembly (8).
iv) Remove head assembly (5) and head (4).
CJl
CLPO3978

1) Remove rings (9).
2) Remove wear rings (IO). IO
3) Remove piston ring (II).
II
IO
CLPO3979
30- 188
0
4. Disassembly of cylinder head assembly

I) Remove O-ring and backup ring (12).
2) Remove snap ring (13), then remove dust 17
seal (14). 12
3) Remove rod packing (15).
4) Remove buffer ring (16).
5) Remove bushing (17).
I4
15
CLPO3980
5. Disassembly of head
1) Remove O-ring (18).
2) Remove snap ring (19), then remove dust
seal (20).
3) Remove bushing (21).
30-189
0
ASSEMBLY OF BUCKET
CYLINDER ASSEMBLY
* Be careful not to damage the packing, dust seals,

or O-rings.
+ Do not try to force the backup ring into position.
Warm it in warm water (50 - 60°C) before fitting
it.
CKP03982 CKP03983
1. Assembly of head assembly

1) Using tool 05, press fit bushing (21).
I! 20
2) Using tool 06, install dust seal (20), and se-

3) Install O-ring (18).
2. Assembly of cylinder head assembly

1) Using tool-05, press fit bushing-(17).
2) Assemble buffer ring (16).
3) Assemble rod packing (15).
4) Using tool 06, install dust seal (141, and se-


CKP03984 CKP03985
CLPO3980
30- 190
0
3. Assembly of piston assembly

1) Using tool 03, expand piston ring (11).
* Set the piston ring on tool 03 and turn
the handle 8 - 10 times to expand the
ring.
2) Set tool 04 in position, and compress piston

ring (11).
CKP03987 cLPo398a
3) Assemble wear rings (IO).
4) Assemble rings (9).

Ir Be careful not to open the end gap of
the ring too far.
& Groove of ring: Grease (G2-LI)
CLPO3979

I) Assemble piston rod assembly as follows.
i) Assemble head (4), cylinder head assem-
bly (5), and piston assembly (8).
ii) Set piston rod assembly (6) to tool 01,
then using tool 02, tighten nut (7).
e :IJ: : Thread tightener (LT-2)
Lwn u :
7,056 2 705.6 Nm (720 2 72 kgm}
up03978
2) Assemble piston rod assembly (6) in cylin-

der.
[u
6 Seal : Grease (G2-LI)
Ir Set the end gap of the ring in the hori-
zontal (side) position, then align with the
center of the cylinder tube, and push in.
Ir After inserting, check that the ring is not
damaged or missing, then push in fully.
End B~P in rina
DLP00504
30-191
0
3) Fit cylinder head assembly (51, and tighten

mounting bolts.
CLPO3990
* Set the cylinder head with the holes for

the bolts with countersunk head in the Direction of botto_m port
position shown in the diagram, then
Direction of head port
tighten the bolts to the cylinder.
B Mounting bolt :
269.5 t 39.2 Nm i27.5 f 4.0 kgml
CYI inder head CYI inder

\
Holes for bolts with
countersunk head
(4 Places) DKP00505
4) Fit head (4) and tighten mounting bolts.
CLPO3991
+ Set the notch in the head to the position

shown in the diagram, then install to the Holes for bolts with
cylinder. countersunk head (4 places)
\
w Mounting bolt :
@ik
269.5 = 39.2 Nm I27.5 + 4.0 kgml 080 0
0
ho I
0
- 37
Head Cylinder head
\
Bolt holes& places)
DKP00506
30- 192
0
5. Sensor, plate
1) Fit O-ring and install sensor (3).
* Coat the outside circumference, bottom
face, and sensor mount hole well with
engine oil (SAEIOW-CD), then install.
* Before tightening the mounting bolts,
shake the sensor assembly lightly to
check that the sensor is in tight contact
with the rod.
2) Set piping (21, guard plate, and pipe band in
position and install.
3) Secure cable of sensor to plate with clip. CLPO3976
4) Install plate (1).
When
DLP00507
30- 193
0
REMOVAL OF WORK
EQUIPMENT ASSEMBLY
g Extend the arm and the bucket fully, lower the

work equipment completely to the ground, then
set the safety lock lever to the LOCK position.


CLPO3929

lock bolt (3). m

* Check the number and thickness of the
shims, and keep in a safe place.
4. Start engine and retract piston rod, then tie pis-

ton rod with wire to prevent it from coming out, 7
and lower it onto stand.
Sr Disconnect the boom cylinder on the oppo-
A Release the remaining pressure from the
hydraulic circuit. For details, see TESTING CLPO3995
AND ADJUSTING, Bleeding remaining pres-

sure from hydraulic circuit.
6. Remove clamps (6), then remove wiring con-

nector (7) from clip and disconnect.
7. Disconnect hoses (8), and secure to valve end

with rope.

lamp.
9. Remove wiring cover (IO).
10. Remove wiring connector (11) for boom angle

sensor from clip and disconnect.
11. Remove clamp (12), then remove boom angle

sensor assembly (13).
CLPO3998
CLPO3997
30-194
0
13. Raise work equipment assembly, and using tool

P, remove foot pin (151, then remove work equip-
ment assembly (16). a
&l kg Work equipment assembly : 3,300 kg
CLPO3999
cLP04000
30-195
0
EQUIPMENT ASSEMBLY
-=a:

removal.
u -- -t------r
- 1.5 mm.
a
CKP03932
assembling pin :
Grease (LM-G)
below 1 mm.
mm 8
DLP00508
assembling pin :
Grease (LM-G)
low 1 mm.
0.8 mm, 1.0 mm, 1.5 mm C
. Refilling with oil (hydraulic tank) DLP00509

again.
. Bleeding air
Sr Bleed the air from the cylinder. For details,
* After completing all operations, carry out ad-

justment in the following order: A+E+H+Q
mode.
30- 196
0
REMOVAL OF BUCKET
ASSEMBLY
A Set the back of the bucket facing down, lower

the work equipment completely to the ground,
and set the safety lock lever to the LOCK posi-
tion.
1. Remove lock bolt (I). m
2. Remove connecting pin (2) between link and

bucket. 112
place.

out.
4. Remove lock bolt (3).
5. Remove plate (41, then remove connecting pin

(5) between arm and bucket. m
place.
6. After raising work equipment, swing to discon-

nect bucket assembly (6).
&I kg Bucket assembly : 650 kg
CLPO3951
30- 197
0
ASSEMBLY

removal.
-- _+-_-__~_
m fij
* When tightening the locknut, tighten so that =@
- 1.5 mm. _I-
a
CKP03932
assembling pin :
Grease (LM-G)
, b

b between bucket boss (7) and link (8) is
below 1 mm.
mm
7 0
I CLPO3952
assembling pin :
Grease (LM-G)
Ir Set the O-ring at the end face of the bucket
boss securely.
c between arm top (9) and spacer (IO) is 0.5
- 1.0 mm.
+ Standard shim thickness :
0.5 mm, 1.0 mm CLPO3953
* When bucket has been replaced (when replac-

ing and changing specifications)
i) When replacing and changing specifications
with bucket set as attachment
Order of operation : A+D+Q
ii) When replacing with other bucket
Order of operation : A+L+D+Q
30- 198
0
REMOVAL OF ARM ASSEMBLY


1. Remove bucket assembly.

For details, see REMOVAL OF BUCKET ASSEM-
BLY.
2. Secure front link to arm with wire.
3. Fold in arm and set arm and bucket cylinder

- CLPO4001
assembly on block @ so that it is easy to re-
move pin at arm cylinder head end.
A Set the safety lock lever to the LOCK posi-
tion.

pin (1). m

ton rod with wire to prevent it from coming out.
hydraulic circuit. For details, see TESTING
CLPO4002
7. Remove bucket cylinder wiring cover.

li After disconnecting the hoses, install blind
plugs in the hoses and male end.
9. Remove clamp (41, then remove wiring connec-

tor (5) from clip and disconnect.
10. Remove wiring cover (6).
CLPO4003
11. Remove wiring connector (7) for arm angle sen-
sor from clip and disconnect.
12. Remove 4 clamps (81, then remove arm angle

13. Remove brackets (IO) and (I I), them remove

connecting pin (12) of arm and boom. m
14. Raise boom and remove arm and bucket cylin-

der assembly (13).
& kg Arm, bucket cylinder assembly : 950 kg
30- 199
0
INSTALLATION OF ARM
ASSEMBLY

removal.

assembling pin :
Grease (LM-G)

assembling pin :
Grease (LM-G)
a between boom top (14) and arm bottom
(15) is below 1.0 mm.
\\ -
CLPO4006

again.
l Bleeding air
CLPO4007
Sr After completing all operations for installing the
bucket assembly, carry out adjustment in the
order given below. For details, see TESTING AND
ADJUSTING, Table for order of operations in
GX adjustment mode.
i) When replacing or removing and installing
again without changing specifications
Order of operation : A+E+J+Q
ii) When replacing and changing specifications
with arm set as attachment
Order of operation : A+C+Q+A+E+I+Q
30-200
0
REMOVAL OF BUCKET l ARM

ASSEMBLY
A Extend the arm cylinder piston rod approx. 200

mm and lower the work equipment completely
the LOCK position.

1. Set block @ between arm cylinder and boom. CLPO4008
2. Remove plate, then remove arm cvlinder head

pin (1).

ton rod with wire to prevent it from coming out.
4. Remove bucket cylinder wiring cover (2).

$
z 5. Disconnect 2 hoses (3).
2 * After disconnecting the hoses, install blind
plugs in the hoses and male end.
6. Remove clamps (41, then remove wiring con-

8. Remove wiring connector (7) for arm angle sen-

sor from clip and disconnect.
9. Remove 4 clamps (81, then remove arm angle

16. Remove brackets (IO) and (II).
11. Raise bucket and arm assembly, then remove

connecting pin (12) of arm and boom, and re-
move bucket and arm assembly (13). m
shims, and keep in a safe place
&I kg Bucket, arm assembly : 1,650 kg
CLPO4004
DISASSEMBLY AND ASSEMBLY BUCKET. ARM
INSTALLATION OF BUCKET l
ARM ASSEMBLY
PCZOO, 2OOLC-6 HYPER GX

removal.

assembling pin :
Grease (LM-G)

assembling pin :
Grease (LM-G)
a between boom top (14) and arm bottom
(15) is below 1 mm.
Refilling with oil (hydraulic tank)

again.
Bleeding air
After completing all operations, carry out ad- CLPO4007

justment in the following order : A+E+J+Q
mode.
30-202
0
REMOVAL OF BOOM
ASSEMBLY

1. Remove bucket and arm assembly.

For details, see REMOVAL OF BUCKET, ARM
ASSEMBLY.
2. Lower boom assembly completely to ground and

set safety lock lever to LOCK position. CLPO3929

lock bolt (3). a
5. Remove plate, then remove head pin (4). 1121


ton rod with wire to prevent it from coming out,
$ and lower it onto stand.
>
* Disconnect the boom cylinder on the oppo- Ll CLPO3995
% site side in the same way.
8. Remove clamps (6), then remove wiring con-

9. Disconnect hoses (81, and secure to valve end

with rope.
IO. Disconnect wiring connector (9) for working

lamp.
12. Remove wiring connector (11) for boom angle

sensor from clip and disconnect.
13. Remove clamp (121, then remove boom angle

CLP03997 CLP03998
30-203
0
15. Raise boom assembly, and using tool P, remove

foot pin (151, then remove boom assembly (16).

&I kg Boom assembly : 1,650 kg
CLPO3999
PO4010
30-204
0
ASSEMBLY
PCZOO, 2OOLC-6 HYPER GX

removal.
-
-- -i-----
M
* When tightening the locknut, tighten so that -=@
- 1.5 mm. --t-- I
a
CKP03932
assembling pin :
Grease (LM-G)
Adjust the shim thickness so that clearance
below 1 mm.
0.8 mm, 1.5 mm
DLPOO508
assembling pin :
Grease (LM-G)
low 1 mm.
0.8 mm, 1.0 mm, 1.5 mm C
. Refilling with oil (hydraulic tank) DLP00509

again.
. Bleeding air
* After completing all operations for installing the

bucket and arm assembly, carry out adjustment
in the following order : A-+E+H+J+Q
mode.
30-205
0
DISASSEMBLY AND ASSEMBLY VALVE CONTROLLER
REMOVAL OF VALVE
CONTROLLER ASSEMBLY
1. Remove GX controller assembly.

For details, see REMOVAL OF GX CONTROLLER
ASSEMBLY.
2. Disconnect wiring connectors (I), and remove

valve controller assembly (2).
CLPO4011
INSTALLATION OF VALVE
CONTROLLER ASSEMBLY

removal.
30-206
0
DISASSEMBLY AND ASSEMBLY GX CONTROLLER
REMOVAL OF GX
CONTROLLER ASSEMBLY

1. Remove plate (I), then remove cover (2).
2. Disconnect air conditioner hose (3) and speaker

wiring connector, then remove cover (4).
* When removing cover (4), the speaker wir-
ing connector cannot be seen, so be careful.
3. Disconnect wiring connectors (5), then remove

GX controller assembly (6).
INSTALLATION OF GX
CONTROLLER ASSEMBLY
g
& l Carry out installation in the reverse order to
8 removal.
* When GX controller has been replaced

justment in the following order :
A-+B~CjD~Q~A~E~F~G~I~K~N~Q
mode.
However, if the only problem is that the swing
back prevention does not have the proper ef-
fect, use the order given below to adjust again.
Order of operation : A+P+Q
30-207
0
DISASSEMBLY AND ASSEMBLY GX PANEL
REMOVAL OF GX PANEL
ASSEMBLY
PCZOO,2OOLC-6 HYPER GX

1. Disconnect 2 wiring connectors (1).
2. Remove caps (21, then remove mounting screw

panel assembly (31.
I
3. Disconnect wiring connector (41, and remove &PO4012
panel assembly (3).
4. Disconnect lamps (5) for panel night lighting.
5. Remove 4 mounting bolts of GX panel assem-

bly, disconnect wiring connector (61, then re-
move GX panel assembly (7).
INSTALLATION OF GX PANEL
CLPO4013
ASSEMBLY

removal.
5 cLPo:o14
\
CLPO4015
30-208
0
40 MAINTENANCE STANDARD
Swing machinery ......................................... 40- 2

Swing circle ................................................. 40- 4
Final drive .................................................... 40- 6
Track frame l Recoil spring.. ...................... 40- 8
Idler.. .............................................................. 40-I 0
Carrier roller ................................................ 40-12
Track roller.. ................................................. 40-13
Track shoe.. .................................................. 40-14
Hydraulic pump.. ........................................ 40-18
Control valve ............................................... 40-19
Safety-suction valve for service valve ..... ..40-2 6
Self-reducing pressure valve ..................... .40-27
Swing motor.. .............................................. 40-28
Travel motor ................................................ 40-29
Work equipment l Swing PPC valve.. ....... -40-30
Work equipment l Swing EPC valve.. ....... .40-31
Travel PPC valve .......................................... 40-32
Service PPC valve ........................................ 40-33
EPC solenoid valve ..................................... .40-34
Center swivel joint ..................................... 40-35
Boom holding valve.. ................................... 40-37
Hydraulic cylinder ...................................... 40-38
Work equipment.. ....................................... 40-42
Dimension of work equipment ................. 40-44
40- 1
MAINTENANCE STANDARD SWING MACHINERY
SWING MACHINERY
SAP02735
40-2
MAINTENANCE STANDARD SWING MACHINERY
Unit: mm
Backlash between swing motor

shaft and No. 1 sun gear
and No. 1 planetary gear
Backlash between No. 1 planetary
Backlash between No. 2 planetary
Backlash between swing pinion and

0.22 - 1.32
8 Clearance between plate and

0.68 - 1.12 -
planetary carrier
Apply hard
Standard size Repair limit chrome
,. Wear of swing pinion surface
plating
contacting with oil seal
recondition,
125-:.100 124.7
or replace
40-3
MAINTENANCE STANDARD SWING CIRCLE
SWING CIRCLE
m
1st :191.3?r19.6Nm 1 st :294.2+29.4Nm
(19.5fZksml (30+3kQml
2nd :4Bi5’ 2nd :60f6°
A-A
SAP02736
Unit: mm
No. Check item Criteria Remedy
Standard clearance Clearance limit

Axial clearance of bearing
1 Replace
(when mounted on chassis)
0.5 - 1.6 3.2
40-4
MAINTENANCE STANDARD FINAL DRIVE
FINAL DRIVE
_-__-__-..-__ L_~--J____--_*_LL_,__I_-_--_..-_-_--____
I::-- ___I
SAP01252
40-6
MAINTENANCE STANDARD FINAL DRIVE
Unit: mm

Backlash between No. 1 sun gear and
1
No. 1 planetary gear
0.15 - 0.49 1.oo
2 Backlash
gear between
and ring gear No. 1 planetary 0.17 - 0.57 1.10
3 Backlashandbetween
carrier motor No. 1 planetary 0.06 - 0.25 -
Replace
Backlash between No. 2 sun gear and
4 No. 2 planetary gear 0.14 - 0.46 1 .oo
5 Backlash
gear between
and ring gear No. 2 planetary 0.17 - 0.57 1.10
6 Backlashandbetween
carrier 2 planetary
No.gear
No. 1 sun 0.38 - 0.66 1.00
7 End play of sprocket shaft 0 - 0.10 -
8 Amount of wear on sprocket tooth Repair limit: 6
Rebuild or
Standard size Repair limit replace
9 Width of sprocket tooth
I 71 68
I
40-7
MAINTENANCE STANDARD TRACK FRAME l RECOIL SPRING
TRACK FRAME l RECOIL SPRING

* Figure shows PC200-6.
_-_____-____
__-__-__
~______..____.._______.._______..____..-____.-__-__-__-_~
SAP02737
Unit: mm
I I
NC Check item Criteria Remedy
I
I
I
I
Standard Repair
Tolerance
size limit
1 Vertical width of idler guide Track frame 107
Rebuild or
Idler support 105
replace
-
Track frame 250

2 Horizontal width of idler guide
Idler support 247.4
Standard size Repair limit
Free length 1 Installation I Installation Free 1 Installation

x 0.0: length load length load
3 Recoil spring 108.8 kN Replace
PC200 558 x 238 437 534 87.3 kN
PC210 {II,100 kg} (8.900 kg}
PCZOOLC,
PC220, 23021OLC 603.5 x 239 466 126.5 kN 100.9 kN
112,900 kg} 576
PC22OLC. 230LC {IO,300 kg}
40-8
MAINTENANCE STANDARD IOLER
IDLER
I- --
I- -’
i’ I
7
/
_- 11
4
SBP02738
40-l 0
MAINTENANCE STANDARD IDLER
Unit: mm
NO Check item Criteria Remedy

$
> -
% 1 Outside diameter of protruding
-
2 Outside diameter of tread
-
3 Width of protrusion
-
4 Total width 164 -

-
5 Width of tread
-
Clearance between shaft and

6
bushing
-
Clearance between shaft and 65 -0.250 -0.110 0.03 -
7
support -0.290 -0.220 0.180
-
Interference between idler and

8 bushing
Replace
bushing
-
Standard clearance Clearance limit I

I
9 Side clearance of idler (each)
0.39 - 1.00 1.5
40-11
MAINTENANCE STANDARD CARRIER ROLLER
CARRIER ROLLER
$
&
SBP02739
:
Unit: mm
No Check item Criteria Remedy

-

1 Outside diameter of flange
(outside)
165 -
Rebuild or
replace
2 Outside diameter of tread 140 130
I
3 Width of tread 43 50
II
I I I
Tolerance
Standard Standard Interference
size interference limit
Interference between shaft and
4 Shaft Hole
bearing
Replace
Interference between roller and f
5
bearing

6 Side clearance of roller
I
0.01 - 0.18 -
-
I
40-12
MAINTENANCE STANDARD TRACK ROLLER
TRACK ROLLER
l-J---u SBPO2740
Unit: mm

Outside diameter of flange
1 (outside)
188 -
Rebuild or
2 Outside diameter of tread 156 144 replace
3 Width of tread 44.5 52
4 Width of flange 25.5 -

I I
I I I I
Tolerance
Standard Standard Clearance
Clearance between shaft and size clearance limit
5
bushing Shaft Hole
-0.215 +0.195 0.215 -

60 1.5
-0.315 0 0.510
Replace
bushing
Tolerance
Standard Standard Interference
size interference limit
6 Interference between roller and
Shaft Hole
bushing
67 +0.153 +0.030 0.023 - -

+0.053 0 0.153
I
7 Side clearance of roller Replace
0.5 - 1.0 1.5
40-l 3
MAINTENANCE STANDARD TRACK SHOE
TRACK SHOE
TRIPLE GROUSER SHOE, SWAMP SHOE, FLAT SHOE, RUBBER PAD SHOE, ROAD LINER
(l/2)
14 8 23 22 21 Ii 5 12 II 24
I
/ I \Ill
/ I I
IO 2 I8 7 I7 25 I9
Xl 1% /
SBPO4III
* P portion shows the link of bushing press fitting end.
X+1. Triple-grouser shoe x4. Rubber pad shoe

n2. Swamp shoe %5. Road liner
~3. Fiat shoe
40-14
0
Unit: mm

-

I
1 Link pitch
Reverse or
replace
2 Bushing outside diameter

Rpair or
3 Link height
replace
105 97
Thickness of link metal

4 28.5
g -
(bushing press-fitting portion) I
>
5
% Replace
6 Shoe bolt pitch
8 Inside width 84.8
Rpair or
9 Link Overall width 45.5
replace
10 Tread width 40.3
11 Protrusion of pin 4
12 Protrusion of regular bushing 4.85

I
13 Overall length of pin 220
I Adjust or
replace
14 Overall length of bushing 128.7
15 Thickness of bushing metal 10.4
16 Thickness of spacer -
I
17 Bushing 88.2 - 245 kN {9 - 25 ton}
I
18 Press-fitting force Regular pin 127.4 - 274.4 kN {I3 - 28 ton) -
q Master pim 78.4 - 147 kN 18 - 15 ton)

-
% : Dry type track link
40-15
0
x4 x5
L
SBPO4lll
Ir P portion shows the link of bushing press fitting end.
%I. Triple-grouser shoe %4. Rubber pad shoe

%2. Swamp shoe %5. Road liner
Z-3. Flat shoe
40-15-l
a
Unit: mm
Tightening torque Additinal tightening

(Nm {kgm)) angle (deg.)
Triple shoe
Swamp shoe
a. Regular link
Flat shoe
Shoe bolt Retighten

20
b. Master link
- - -
PC200, 210-6: 45 PC2OOLC, 21OLC-6: 49

No. of shoes teach side)
I PC220. 230-6: 47 PC22OLC. 23OLC-6: 51
Tolerance
Standard Standard
size interference
Interference between
21 Shaft Hole
bushing and link
+0.304 +0.074
59 0.190 - 0.314
+0.264 0
Interference between +0.222 -0.138

22 38 0.210 - 0.422
regular pin and link +0.072 -0.200
Clearance between
23
regular pin and bushing
Adjust or
replace
-
E
Interference between
24
master pin and link
+0.230 +0.062
37.8 0.138 - 0.230
+0.200 0
.X
Clearance between
25
master pin and bushing
Standard size Repair limit Lw3

welding,
a. Flat shoe
rebuild or
- - replace
26 Height of grouser
b. Rubber
- -
pad shoe
Replace
1 c. Road liner 1 70 I 25
- I I I
% : Dry type track link
40-15-2
0
TRIPLE GROUSER SHOE
SDDOI 629
Unit: mm
No Criteria Remedy

1 Height
26 16
2 Thickness 10
3 27
Rebuild or
- Length of base replace
4 22
5 21
6 Length at tip 14
7 19
-
40-l 6
SWAMP SHOE
\\ // t
W’ A-A
SED01630
Unit: mm

1 Height
Rebuild or
102.5 90.5 replace
2 Thickness 17 5
-
40-l 7
MAINTENANCE STANDARD HYDRAULIC PUMP
HYDRAULIC PUMP
HPV95 + 95
144.5*12.5Nm
14.75*1.25kml
7 30.5*3.5Nm
(3.15*0.35kml
SAP02742
40-18
MAINTENANCE STANDARD CONTROL VALVE
CONTROL VALVE
* Figure shows 9-spool control valve (with 3 service valve).
(l/6)
SAP02743
40-19
SAP02744
Unit: mm
-
No. Check item
1 Spool return spring

-
393.2 N 314.6 N
4 Spool return spring (40.1 kg} - (32.1 kg}
54.5 x 34.8 51.2
*When installing
40 x 12.3 3638.0 *50.0 N 40.2 N to valve, spring
5 Stroke selector spring is free, so judge
315.1 kg} - (4.1 kg1 from test
heiaht.
40-20
(3/6)
K-K
SAP02745
Unit: mm
D-D E-E
lOO.O*lO.ONm
lO*lkPml
iI
F-F G-G
SAP02746
40-22
W6)
H-H N-N
SAP02147
Unit: mm
Check item Criteria Remedy
Free length Installed Installed Free Installed

Regeneration valve spring
x O.D. length load length load
31.5 x 10.3 19.5 5.9 N 4.4 N

{0.6 kg} - iO.45 kg}
23.5 N
Piston return spring Replace
36.9 x 11.1 28 13 kg)N
29.4 - (2.4 kg1 spring if
17.6 N 13.7 N any
Piston return spring 48.1 x 10.8 28 damages
{I.8 kg} - il.4 kg}
or defor-
428.3 N 343 N mations
Load spring 30.4 x 16.7 27 143.7 kg} - (35.0 kg} are found.
1.5 N
Check valve spring 13.6 x 5.5 10 IO.15 kg}
158.8 N 127.4 N
Piston return spring 50.4 x 17 39
c16.2 kg} - I13 kg1
40.8 x 22.4 21 17.6 N 13.7 N

Piston return spring Il.8 kg) - II.4 kg}
40-23
7.4Nm
0.75kpml EE-EE \
I
3
JJ-JJ
SDP01125
Unit: mm
1 Check valve spring

-
2.0 N 1.5 N
3 Spool return spring 13.6 x 5.5 10
iO.2 kg} - fO.15 kg} I
40-24
VARIABLE PRESSURE COMPENSATION VALVE
SDPO1124
Unit: mm
Replace
Free length Installed Installed Free Installed spring if
1 Piston return spring
x 0 .D. length load length load
any
damages
9.8 N 7.8 N
32.76 x 8.5 20.5 or defor-
il.0 kg} - W.8 kg}
mations
74.5 N 59.8 N are found.
2 Relief valve spring 17.1 x 9 15.5
{7.6 kg} - IS.1 kg}
40-25
SAFETY-SUCTION VALVE (FOR SERVICE VALVE)
SAP02140
Unit: mm
Free length installed Installed Free Installed

1 Suction valve spring length load
x 0 .D. length load
- Replace
2.1 N 1.6 N
16.3 x 21.3 9.5
IO.21 kg} - (0.16 kg}
2.1 N 1.6 N
2 Piston spring 20 x 7 14
fO.21 kg} - IO.16 kg}
40-26
0
MAINTENANCE STANDARD SELF-REDUCING PRESSURE VALVE
SELF-REDUCING PRESSURE VALVE
I 4
A-A
SAP03294
Unit: mm
I I
I
I I
1 Spring
(reducing pressure valve, main)
Spring
2 (reducing pressure valve, pilot)
are found.
199.8 N 186.2 N
3 Spring
71 x 18 59 t20.4 kg} - 119 kg}
-
61.7 N 58.8 N
4 Spring (safety valve)
16.1 x 7.8 13.4 (6.3 kg} - 16 kg)
-
40-27
MAINTENANCE STANDARD SWING MOTOR
SWING MOTOR
KMFSOABE3
SAP02749
Unit: mm

Replace
Free length Free spring if
Installed Installed Installed
x O.D. length load length load any
damages
3.5 N 2.8 N or defor-
62.5 x 20.0 35.0
IO.36 kg} - CO.29 kg) mations
are found.
13.7 N 10.8 N
2 Shuttle valve spring 16.4 x 8.9 11.5
cl.4 kg) - (I.1 kg}
40-28
MAINTENANCE STANDARD TRAVEL MOTOR
TRAVEL MOTOR
HMVllO-2
A-A
L m 74!05*&35Nm
\ 17.55*0.85kPml
3
B-B c-c
SAP02750
Unit: mm
Free length Installed Installed Free Installed Replace

x O.D. length load length load spring if
any
2.55 N 2.06 N
31.6 x 6.5 24.2 damages
CO.26 kg} - IO.2 kg) or defor-
1.96 N 1.57 N mations
2 Check valve spring 13.0 x 6.5 9.5 are found.
IO.2 kg} - CO.16 kg}
3 Return spring 58.43 x 30 42.6 411 N - 329 N

(41.9 kg} 133.5 kg)
40-29
MAINTENANCE STANDARD WORK EQUIPMENT l SWING PPC VALVE
WORK EQUIPMENT . SWING PPC VALVE

STD
A-A
D-D
E-E SAP0275 I
Unit: mm
Free length Installed Installed Free Installed Replace

1 Centering spring (for P3, P4) x O.D. length load length load spring if
any
17.6 N 13.7 N
42.4 x 15.5 34 damages
Il.8 kg} - Il.4 kg1 or defor-
29.4 N 23.5 N mations
2 - 12.4 kg} are found.
Centering spring (for PI, P2) 44.4 x 15.5 34 13.0 kg)
16.7 N 13.7 N
3 Metering spring 26.5 x 8.2 24.9 Il.7 kg} - (1.4 kg)
40-30
MAINTENANCE STANDARD WORK EQUIPMENT. SWING EPC VALVE
WORK EQUIPMENT l SWING EPC VALVE

PC200 .2OOLC-6 HYPER GX
m 113*1.5Nm
(1 15*0.15bm1
B-B c-c
SBPO2012
Unit: mm
I I I
Standard size Repair limit Replace

EPC valve
Free length Installed Installed Free Installed ass’y if any
1 Return spring damages
or defor-
3.1 N mations
9.0 x 11.4 7.9 -
(0.32 kg) - are found.
40-3 1
MAINTENANCE STANDARD TRAVEL PPC VALVE
TRAVEL PPC VALVE
SAP02752
Unit: mm

I
I -
tree length Installed
I
Installed Free Installed
Replace
1 Metering spring
x 0 .D. length length 1 . spring if
load load
any
127 hl damages
I”., I.
- or defor-
26.5 x 8.15 24.7 {I.7
16.7 kg}
N Il.4 kg}
mations
2 Centering spring 48.1 x 15.5 32.5 107.8 N - 86.2 N are found.
111 kg} (8.8 kg}
40-32
MAINTENANCE STANDARD SERVICE PPC VALVE
SERVICE PPC VALVE
78.5Nm
(8.0kgm)
SBPOO436
Unit: mm
Replace
1 Centering spring
x 0 .D. length load length load
_ any
damages
46.1 N 44.1 N
64.8 x 16.6 40.5 (62.9) or defor-
14.7 kg} (4.5 kg}
mations
25.5 N 24.5 N are found.
2 Metering spring 26.0 x 10.5 25.0 (25.2)
12.6 kg} 12.5 kg1
40-33
MAINTENANCE STANDARD EPC SOLENOID VALVE
EPC SOLENOID VALVE
SBP00438
Unit: mm
Standard size Repair limit Replace

EPC valve
ass’y if any
Free length Installed Installed Free Installed
1 Return spring
damages
or defor-
3.1 N mations
9.0 x 11.4 7.9 -
IO.32 kg) - are found.
-
40-34
MAINTENANCE STANDARD CENTER SWIVEL JOINT
CENTER SWIVEL JOINT

4 PORT SWIVEL JOINT
SBP00439
Unit: mm
Standard size Standard clearance Clearance limit

1 Clearance between rotor and shaft - Replace
90 0.056 - 0.105 0.111
40-35
MAINTENANCE STANDARD CENTER SWIVEL JOINT
6 PORT SWIVEL JOINT
S8PO2753
Unit: mm
Standard size Standard clearance Clearance limit

1 Clearance between rotor and shaft Replace
100 0.056 - 0.105 0.111
40-36
MAINTENANCE STANDARD BOOM HOLDING VALVE
BOOM HOLDING VALVE

* For machine equipped with arm holding valve, the Maintenance Standard of arm holding valve is
the same as this valve.
w 39* 5Nm
{4.0*0.5koml
\ \
SDP01354
Unit: mm

Replace
1 Pilot valve spring
x O.D. length load length load any
- damages
4.7 N 3.7 N or defor-
26.5 x 11.2 25.0
(0.48 kg} - (0.38 kg) mations
are found.
35.3 N 28.4 N
2 Check valve spring 37.2 x 16.2 30.0
13.6 kg} - (2.9 kg}
40-37
MAINTENANCE STANDARD HYDRAULIC CYLINDER
HYDRAULIC CYLINDER
PC200,2OOLC-6
PC210, 210LC-6
BOOM CYLINDER
SAP02756
ARM CYLINDER
66.25*7.35Nm
(6.75*0.75kPml SAP02757
BUCKET CYLINDER
SAP02758
40-38
Unit: mm
-
-
Tolerance
Cylinder
size clearance limit
Shaft Hole
Clearance between
1 piston rod and
bushing Boom 85
-0.036
-0.090
+0.222
+0.047
0.083 - Replace
0.312 0.412
bushing
+0.222 0.083 -
Arm 95 -0.036 0.412
-0.090 +0.047 0.312
-
Bucket 80 -0.030 +0.258 0.078 0.434
-0.076 +0.048 0.334
-
Boom 80 -0.030 +0.457 0.400 1.0
-0.060 +0.370 0.517
Clearance between
-0.030 +0.457 0.400 -
2 oiston rod ,support Arm 80 1.0
-0.076 +0.370 0.533
oin and bushing
-
Bucket I 70 -0.030
-0.076
+0.424
+0.350
0.380 1.0 Replace
0.500
pin or
- bushing
Boom 70 -0.030 +0.211 0.380 1.0
tIearance between -0.060 +0.124 0.484
:ylinder bottom -0.030 +0.457 0.400 -
3 support pin and Arm 80 -0.076 +0.370 0.523 1.0
mshing
40-39
PC220,22OLC-6
PC230, 230LC-6
BOOM CYLINDER
SAP02759
ARM CYLINDER
w 373*54Nm
f38*5.5kml
SAP02760
BUCKET CYLINDER
SAP02761
40-40
Unit: mm
No.
I Check item
I Criteria
Tolerance
Cylinder clearance limit
size
Shaft Hole
Clearance between
1 piston rod and -0.036 +0.257 0.084 - Replace
bushing Boom 90 -0.090 +0.048 0.347 0.447 bushing
-
Arm 100 -0.036 +0.257 0.083 0.447
-0.090 +0.047 0.347
-
Bucket 90 -0.030 +0.257 0.084 0.447
-0.090 +0.048 0.347
-
Boom 80 -0.030 io.457 0.400 1.0
-0.060 +0.370 0.517
Clearance between
2 piston rod support Arm 80 -0.030 +0.457 0.400 -
-0.076 +0.370 0.533 1.0
pin and bushing
-
Bucket 80 -0.030
-0.076 +0.457
io.370 0.400
0.533 1.0 Replace
pin or
Boom 80 -0.030 +0.211 0.400 - 1.0 bushing
Clearance between -0.076 +0.124 0.533
cylinder bottom -
3 support pin and Arm 80 -0.030 +0.457 0.400 1.0
-0.076 +0.370 0.533
bushing
-
Bucket 80 -0.030 +0.457 0.400 1.0
-0.076 +0.370 0.533
40-41
MAINTENANCE STANDARD WORK EQUIPMENT
WORK EQUIPMENT
F-F
I II
A-A
G-G
c-c
D-D
E-E K-K
SAP02 763
40-42
MAINTENANCE STANDARD WORK EQUIPMENT
SBPO2762
Unit: mm
Clearance between connecting pin

1 and bushing of revolving frame
and boom
-0.036 +0.342 0.305 -
so -0.07 1 +0.269 0.412 1.0 I
Clearance between connecting pin -0.036 +0.153 0.133 -
2 and bushing of boom and arm so -0.071 +0.097 0.224
1.0
-
Clearance between connecting pin 70 (PC200) -0.030 +0.335 0.305 -
3 and bushing of arm and link 80 (PC220) -0.076 +0.275 0.41 I 1.0
-
4 and bushing of arm and bucket 80 1.0
-0.076 +0.273 0.413
-
5 and bushing of link and bucket 80 -0.076 +0.273 0.413 1.0 I
Clearance between connecting pin
6 and bushing of link and link 80 (PC2201 -0.076 +0.275 0.411 1.0
70 (PC2001 -0.030 +0.335 0.303 - I
40-43
MAINTENANCE STANDARD DIMENSION OF WORK EQUIPMENT
DIMENSION OF WORK EQUIPMENT

1. ARM PORTION
12
z-z
-
Y-Y x-x SAP02764
40-44
Unit: mm
2. BUCKET PORTION
_, 2 ,_ 5
21 2
I-
4
--i----
11
15
d CL_
:-I--
A-A
I II
D I5
SAP02765
40-46
Unit: mm
PC200-6 PC210-6 PC220-6 PC230-6
1 457.620.5 457.6e0.5 442.4~05 442.4k0.5
2 22kO.5 22t0.5 59.2kO.5 59.220.5
3 92045 92045 97"37' 97037'
4 458.1 458.1 446.3 446.3

I I I I
5 1,477.4 1,489.g 1,540.5 1.561.7
6 159.8 158.4 185.7 208.2
7 - - - -
8 0 0 7"37' 7"37'
9
I 080+'.~
0 I 080
+0.2
o
I
080+".2
0 I
000
+0.2
O
10 326.5+1 326.5+1 326.5tl 326.5&l
11 56 50 59 56
12 106 112 104 107
13 I 470 I 470 I 470 I 470
14 022 022 022 022
15 0140 0140 0140 0140
16 0190 0190 0190 0190
17 132 132 155 155

I I I
18 129 129 135 135
19 107 107 107 107
20 82 82 a2 82
21
I 348.5+; 348.5+;
I
348.5 +;
I
348.c;
22 38 34 37 37
40-47
90 OTHERS
Hydraulic piping drawing

STD.. ....................................................................................................... .90- 3
PC200, 2OOLC-6 HYPER GX.. ................................................................ 90- 5
Hydraulic circuit diagram
STD.. ....................................................................................................... .90- 7
PC200, 200LC-6 HYPER GX.. ................................................................ 90- 9
Operation of CLSS system as a whole
1. When all work equipment is at neutral ....................................... ..90-1 1
2. Pump flow divided, one side actuated, other side neutral.. ...... ..90-13
3. Pump flow merged, arm OUT, standard mode relief
(cut-off controll) ............................................................................ 90-15
4. Pump flow divided, bucket DUMP, power max. relief.. .............. .90-17
5. Pump flow merged, boom RAISE.. ............................................. .90-17-2
6. Pump flow merged, swing operated independently ................ .90-17-4
7. Pump flow divided, travel operated independently ................. .90-17-6
8. Pump flow merged, compound operation ................................ .90-17-8
Electrical wiring diagram
STD (l/2) ................................................................................................ 90-19
STD (2/2) ................................................................................................ 90-21
PC200, 2OOLC-6 HYPER GX (l/2) ......................................................... 90-23
PC200, 2OOLC-6 HYPER GX (2/2) ......................................................... 90-25
Electrical circuit diagram
STD (l/2) ................................................................................................ 90-27
STD (2/2) ................................................................................................ 90-29
PC200, 2OOLC-6 HYPER GX (l/4) ......................................................... 90-31
PC200, 2OOLC-6 HYPER GX (2/4) ......................................................... 90-33
PC200, 2OOLC-6 HYPER GX (3/4) ......................................................... 90-35
PC200, 2OOLC-6 HYPER GX (4/4) ......................................................... 90-37
Electronic control system diagram for STD
Total system diagram .......................................................................... 90-39
Electronic control system diagram for HYPER GX (l/2)
Electronic control system diagram for HYPER GX (2/2)
Electrical circuit diagram of valve controller system ............................ 90-201
90- 1
0
Komatsu America international Company
440 North Fairwav Drive I 1
Vernon Hills, IL 66061-8112 U.S.A.
Attn: Technical Publications PROPOSAL FOR MANUAL REVlslON
Fax No. (847) 970-4186
FOR INTERNAL USE ONLY -- No. PMR
2 NAME OF COMPANY: LOCATION:
: PHONE NO:
:
S DEPARTMENT: DATE:
E
R NAME:
MANUAL NAME:
MANUAL NO:
MACHINE MODEL:
S/N IF APPLICABLE:
PAGE NO:
PROBLEM:
Attach photo or sketch.

If more space is needed, use another sheet.
1 FOR INTERNAL USE ONLY

CORRECTIVE ACTION:
PFMRl 081696
STRUCTURE AND FUNCTION HYDRAULIC PIPING DRAWING
HYDRAULIC PIPING DRAWING

STD
1. Bucket cylinder
2. Arm cylinder
3. Boom cylinder
4. Hydraulic tank
5. Hydraulic filter
7. Swing motor
9. Hydraulic pump
10. Control valve
11. Oil cooler
12. L.H. travei motor
16. L.H. PPC valve
17. R.H. PPC valve
21. Accumulator
22. Solenoid valve
valve
valve
solenoid valve
valve
SEPO2604 valve
90-3

1. Bucket cylinder
2. Arm cylinder
3. Boom cylinder
4. Hydraulic tank
5. Hydraulic filter
7. Swing motor
9. Hydraulic pump
10. Control valve
11. Oil cooler
19. Accumulator
20. Solenoid valve
va Ive
12
va Ive
solenoid valve
1218 valve
valve
21. EPC valve
21A. Swing LEFT EPC valve
21B. Swing RIGHT EPC valve
21C. Bucket DUMP EPC valve
21D. Bucket CURL EPC valve
21E. Arm OUT EPC valve
21F. Arm IN EPC valve
21G. Boom LOWER EPC valve
SBPO2605
21H. Boom RAISE EPC valve
90-5
HYDRAULIC CIRCUIT DIAGRAM
ELECRONIC VERSION
r-_-__-________________________________T~---- ~____________________.._____.____, ----------------------------------------------------------------------------------------------------------------------------
,_____~___~__________________________----__________________----_-________---_________________________________________________________ :
SOLENOIO I 1___~__________________._______----_-__________________--____________________________________________________________________, / j
VALVE :__-_~--"__________--_-_--_-__________~________~_.________________._-_-_________________________.___________________-_________________-_________----------_._-__--_-_-~ ! ! !
._
L__________________------__*_________----~~--_-______---_-_____________
._. ____ .____________________________________________--.-_--____-_______-__------.____________‘
.-_-__________________________I _______, RELIEF VALAE OPTION(ST0 FOR OEMOLITiON)
-)- MA,,, REL,F”ALVE
{ SETTING PRESSURE:
SUEUNLOAO VALVE RELIEF PRESSUURE:2O.6MPB(210kg/C~l
CRACKING PRESSURE:
I 31.9MPa(325k9/cm'~
CONTROL VALVE
CYL I NDER
____P-4_ ____.
I BOOM HOLOING VALVE

CRACKING PRESSURE:
2. (LEFT)
P P C L E V E R LOCI PRESSURE SENSOR I
:
P-4' ----A
r---
I
(ARM DIGGING1 -----I BOOM CYLINDER
-
I
I 1
PRESSURE
I SENSOR (RIGHT)
: i axNT.~AL."ALYE
(RIGHT SWING1 P-i ____
_____ i 01&N&? (IVER PRE!s"RE: TRAVEL MOTOR:HMVllO-2
,EPC VALVE
T -1 i
O.@M'B,8.7kQ/m'I
RIGHT
~~_~~~~~~~~~__~___.~~_
~_-__---_----______________________~-~._
:P FORWARD
(BUCKET OUMPIPI
/’
i i L___________________
L__________________~__...__________
(LEFT SWING) :
I
:
I
I :
: I
SWIVEL JOINT
’ ; / ,_&----- .___________________-_----------__-_”_
,,i ,:I (LEFT TRAVEL FORWARD)!'10
:: :I
/---.._____________________________________ I I
(RIGHT TRAVEL FORWAROjP4
'RESSURE : I
tENSOR I I
-!!
I--__-__..---______-__-__----t
FORWARD
SELF PRESSURE 1
A R M HOLOING VALVE
MAIN PUMP:HPVS CRACK I HG PRESSURE. PRESSURE
A R M CYLiNOER
L--J4%;;
“X PUMP) ; SLOW RETURN VALVE
E P C VALVI
CAP
SAFETY YALVE BYPASS CHECK VALVE
ORENING PiEiSURE, CRACKING PRESSURE:
16 1!6.3KPB 103f19.6KPal1.05f0.2k~~cm'~
lO.11!0 O?kmtl COOLER CHECK
CHECK VALVE
CRACKING PRESSURE
-0 MKPa MAIN RELIEF VALVE
I-a.wJ-Otq/cm'l SETTING PRESURE:
31.9MPal325km~f~ $1
(34.8MP81355k9/Ctill
‘I
SAP02607
90-9
OPERATION OF CLSS SYSTEM AS A WHOLE

1. When all work equipment is at neutral
* The diagram shows the situation when all work equipment is at neutral.
Sr The valves and circuits that are not connected with the explanation of the operation of the CLSS hydraulic system have been omitted.
rr 11 Max\
Min
I
“ii jdax
26 2BB l!A !’ II ,I7
278 1BA I! 24 16 23 15 29 l8B 22 I3 IBA 21 12 20 I] 27A 31
SAP04095
. Connection of ports when pump
flow is merged
Connected ports: A - D, B - C
2. Pump flow divided, one side actuated, other side neutral

* The diagram shows the independent bucket DUMP operation with pump merge.
-
I’
ii-3
II ma I
7”
I
I’
i,
5A
. Connection of ports when

pump flow is divided
Connected ports: B - D
Disconnected ports: A, C
3. Pump flow merged, arm OUT, standard mode relief (cut-off control)
* The diagram shows the arm DUMP and standard mode relief with the pump flow merged.
PLSl j2
L’ I
I I’
I \\ / ,\
,I
h’~““““““““““““““““““’ .” d
SAP04097
flow is merged
90-l 5
0
4. Pump flow divided, bucket DUMP, power max. relief

Ir The diagram shows bucket DUMP, relief with the pump flow divided.
Min “i/ /Max
Max\ I
/
27B
I
I I I I
90-17
0
5. Pump flow merged, boom RAISE

* The diagram shows boom RAISE, with the pump flow merged.
Min Max
t-Y
2A
Sh r PLSl P
(
Pl P2
SAP04099
flow is merged
90-17-2
0
6. Pump flow merged, swing operated independently

* The diagram shows the swing operated independently, with the pump flow divided.
lAin Max
WI
28 26
Pl 81 P 2
I (
SAP04100
7. Pump flow divided, travel operated independently

* The diagram shows the travel operated independently with the pump flow divided.
T-l Max
Iri
lAin Min
i-wMax
28 2A
Pl P2

90- 17-6
0
8. Pump flow merged, compound operation

* The diagram shows boom RAISE + arm IN with the pump flow merged.
-
Min Max
b
PLSl PLSP
Connection of ports when pump

flow is merged
90-17-8
0
90AOZO

STD (2/2)
1. Fuel level sensor 38. Heater relay

2. Working lamp 39. Fuse box
3. Hydraulic oil level sensor 40. Alarm buzzer
4. LS control EPC valve 41. Starting switch
5. PC control EPC valve 42. Fuel control dial
6. Rear lamp 43. Cigar lighter
7. Engine speed sensor 44. Swing lock switch
8. Governor motor 45. Wiper, washer switch
9. Engine oil pressure sensor 46. Light switch
(for low pressure) 47. Buzzer cancel switch
10. Rear pump pressure sensor 48. Front window auto pull-up switch
11. Front pump pressure sensor 49. Kerosene mode connector
12. Air cleaner clogging sensor 50. Speaker
13. Radiator water level sensor 51. Air conditioner control panel
14. Window washer motor 52. Governor pump controller
15. Travel alarm 53. Radio
I\ \ 57
-56
61
16.
17.
18.
19.
Horn (high tone)
Horn (low tone)
Battery relay
Battery
54.
55.
56.
57.
Prolix resistor
Wiper motor controller
Light relay
Light relay
62 20. R.H. front lamp 58. Monitor panel
21. Engine water temperature 59. Swing prolix switch
63 sensor 60. Pump prolix switch
22. Intake air heater 61. Arm OUT oil pressure switch
64 23. Air conditioner compressor 62. Arm IN oil pressure switch
magnet clutch 63. Travel oil pressure switch
65 24. Engine oil level sensor 64. Right swing switch
25. Alternator 65. Bucket DUMP oil pressure switch
66 26. Starting motor 66. Boom RAISE oil pressure switch
27. Wiper motor 67. Bucket CURL oil pressure switch
67 28. Horn switch 68. Left swing switch
29. R.H. additional front lamp 69. Boom LOWER oil pressure switch
66 30. R.H. front lock 70. Swing brake solenoid valve
31. Room lamp 71. Travel speed solenoid valve
72 \ 32. Auto pull-up motor 72. Merge/flow divider solenoid valve
69
71 \ 33. Window limit switch (rear) 73. 2-stage relief solenoid valve
70 34. L.H. front lock 74. Active mode solenoid valve
35. Window limit switch (front)
W 36. L.H. additional front lamp
SBP02672
37. L.H. knob switch
90-21

PC200, 2OOLC-6 HYPER GX (l/2)
13
16
17
18
19
20
22’ 57 co
SEPO2673
90-23

PC200,2OOLC-6 HYPER GX (2/2)
1. Bucket cylinder stroke sensor (HYPER GX) 52. Wiper motor

2. Arm angle sensor (HYPER GX) 53. R.H. electric lever
3. Working lamp 54. Horn switch
4. Arm cylinder head pressure sensor (HYPER GX) 55. R.H. additional front lamp
5. Arm cylinder bottom pressure sensor (HYPER GX) 56. R.H. front lock
6. LS control EPC valve 57. Room lamp
6. Hydraulic oil level sensor 58. Auto pull-up motor
7. Bucket cylinder head pressure sensor (HYPER GX) 59. Rear limit switch
8. Bucket cylinder bottom pressure sensor (HYPER GX) 60. L.H. front lock
9. LS control EPC valve 61. Front limit switch
10. PC control EPC valve 62. L.H. additional front lamp
11. Rear lamp 63. L.H. electric lever
12. Engine speed sensor 64. L.H. knob switch
13. Governor motor 65. Heater relay
14. Engine oil pressure sensor (for low pressure) 66. Fuse box
15. Rear pump pressure sensor 67. Alarm buzzer
16. Front pump pressure sensor 68. Starting switch
17. Air cleaner clogging sensor 69. Fuel control dial
18. Radiator water level sensor 70. Cigarette lighter
19. Left swing EPC valve 71. Swing lock switch
20. Right swing EPC valve 72. Wiper, washer switch
21. Window washer motor 73. Light switch
22. Bucket DUMP EPC valve 74. Buzzer cancel switch
23. Bucket CURL EPC valve 75. Auto pull-up switch
24. Arm OUT EPC valve 76. Kerosene mode connector
25. Arm IN EPC valve 77. Speaker
26. Boom LOWER EPC valve 78. Air conditioner control panel
27. Boom RAISE EPC valve 79. Governor, pump controller
28. GX controller (HYPER GX) 80. GX panel
29. Valve controller 81. Prolix switch
30. GX automatic operation cancel switch (HYPER GX) 82. Wiper motor controller
31. Boom control switch 83. Light relay
32. Boom prolix switch 84. Light relay
33. Swing motor MA pressure sensor (HYPER GX) 85. EPC relay 2
34. Swing motor MB pressure sensor (HYPER GX) 86. EPC relay 1
35. Chassis angle sensor (HYPER GX) 87. Monitor panel
36. Travel alarm 88. Swing prolix switch
37. Boom cylinder head pressure sensor (HYPER GX) 89. Prolix switch
38. Horn (high tone) 90. Arm OUT oil pressure switch
39. Boom cylinder bottom pressure sensor (HYPER GX) 91. Arm IN oil pressure switch
40. Horn (low tone) 92. Travel oil pressure switch
41. Boom angle sensor (HYPER GX) 93. Right swing switch
42. Battery relay 94. Bucket DUMP oil pressure switch
43. Battery 95. Boom RAISE oil pressure switch
44. Front lamp 96. Bucket CURL oil pressure switch
45. Fuel level sensor 97. Left swing switch
46. Engine water temperature sensor 98. Boom LOWER oil pressure switch
47. Intake air heater 99. Swing holding brake solenoid valve
48. Air conditioner compressor magnet clutch 100. Travel speed selector solenoid valve
49. Engine oil level sensor 101. Merge/flow divider solenoid valve
W
SBPO2674 50. Alternator 102.2-stage relief solenoid valve
51. Starting motor 103. Active mode solenoid valve
90-25
STD (l/2)
FUSE BOX CONNECTION TABLE

RADIO CONNECTION TABLE
I SWING
- - REDUNDANCY
p - e -SWITCH
- l
RE TER
,~-----__---_--_____, /
i---PUMP REDUNOANCY C I R C U I T SwiTCH-----j

0N:PUMP CONTROLLER REDUNOANCY
RELAY FOR OFF’NORUAL
O P T LiGHT /
--
rm%6EriiiECTIONl
/ CONNECTOR
‘IGHT)
/ ~OVERNOR.PUMP CONTROLLER
ima - - - . -p - p
-
3
/ I /
_---J
r------
P A N E -___
L ASS’ Y
r----
ROOM L A M P
( T O 2/2)
SAP02675
90-27
STD (Z/Z)
BATTERY
606
BATTERY RELAY
--~___
ELECTRIC GOVERNOR ACTUATOR
I I I II
INE O I L L E V E L S E N S O R
(TO l/2)
7
PANEL ASS'
WINOOW WASHER
LA4 N
:OPT )’
/
SAP02676
90-29
PC200,2OOLC-6 HYPER GX (l/4)
F U S E BOX C O N N E C T I O N TABLE r---- SWING REDUNDANCY SWITCH 1

RAOIO C O N N E C T I O N TA8LE ’
ON:?“MP CONTROLLER REOUNOANCY

OFF NORMAL
OPT LIGHT
lTZlO(STU)
_A HYPER
-
-
-
7
/
(TO 2/3)
SAP02677
BATTERY
6OB
-___-
..i I I / / I ELECTRIC GOVERNOR ACTUATOR
LEVEL SENSOR
(TO 11
-
-
- PRESSURE SWITCH
-
-
r - - - -
WINDOW WASHER
SAP02678
PCZOO, 2OOLC-6 HYPER GX (3/4)
HORN SWITCH
TO AUTO LEVEL CONTROLLER
0 . 85WG
EPC VALVE CONTROLLER
0. 85WG
0 . 85LR 0 . a5LR r-----
C O N T R O L L E V E R (R. H)
m i
1 CN-KOG
BOOM REDUNDANCY
OPERATION REGISTER
(33n)
OPERATION SWITCH
;,..~....~..____‘_..........._._____________._________----._.----....---...-..-.....-...-..~
SWING
EPC
R~GHTSOLENOIO
EPC
UP
SOLENOI 0
I_
BOOM w CN-KIO
CN-401 GX CONTROLLER
BUCKET CY L I NDE
SENSOR
BOOM TOP I
SENSOR
(ARM)
I
CN-402
BOOM FOOT
SENSOR
(BOOM)
INCLINATION
SENSOR
BOOM CLY I NLIER

BOTTOM
(RAISE)
BOOM CLYINDER GX CONTROLLER

HEAD (LOWER)
” OFF” SWITCH
r---- - 1
ARM CLYINDER
BOTTOM (DIG)
CN&A28
II I
ARM CLYINDER
HEAD (DUMP)
BUCKET CLYINDER
B O T T O M (DIG)
B U C K E T CLYINOER
HEAD ( DUMP) GX PANEL
CN-A07 cNGA3g ELECTRICAL VERSION HARNESS
CN931 ‘7
DRESS SENSOR MA
(RIGHT SWING)
PRESS SENSOR MB
(LEFT SWING)
i_-.--
PANEL HARNESS
AIR
CON0 I T O N E R
BASE HARNESS RADIO
i’
ANTENNA&
STRUCTURE AND FUNCTION ELECTRONIC CONTROL SYSTEM DIAGRAM FOR STD
ELECTRONIC CONTROL SYSTEM DIAGRAM FOR STD

1
I I Work eouippment lever
Solenoid valve i
$-
.jl-
I eu-
/ ;--------------------------‘:‘---A+-, s.,no Arm Boo’ttet
r~+;+-------------; / r I
/5
&CL%2 E%dcL
I I -wzz
“LLIaz
Oz~OO a<==
3-.3zx
d-Urn
i-
I LLLL
I
icci IL ic II IL
-Lb __ _ ____
: r--------- ------~+;~>-~+-------~++,
I
/
,+-------- ------~~~-~-------~~~~ 1
I I I j / :------- ------~+i’t-i+---f--! 1 ; ;
,
I
,_ ------_+_c~-_+----~--~-!; ;
I
I / I ,-+ ------‘+;+>i, I
I
I
I
,_______-----------------------------------_____-______------,~~-! I I I ,+-+ _-_---t+-+ ; I =

Swing
brake
,I ,I ,I ,++~L --y--J I 1 / I ;
I --&+-! 1 1
____________________----------------------------------------------------------------------~ I j/ ;I 1 I II II ;A-I I z
~ ~~~~~:~~
_______________-_-_------------------------------------------------------------------------- ,/,,,, ”
____________________-------------------------------------------------------------------------~ 1I / 1I
_______________-------------------------------------------------------------------------------. ,,,, z
____________________--------------------------------------------------------------------_______~
____________________-------------------------------------------------------------------_________~, ,,I ,,, :
:
r<r
1I --------- ~‘~--------,.----------,~,-_---_-__-------------------------------------------------------------------------------__-____________ -.-
’i
II
I L___________________----------------------------------------------------------------------_-____________~
I II 1
1 I r
I II
4
I
I
HYPER monitor
II
I
I
T------,1
I
III Buzzer cansel switch
Buzzer Covernor.Dume Swing ProI
3
ix
L_____# L_____________, ~~~~~~~~~~~~_~~_________, stop controller
Caution
buzzer
Swing
I
Pump ProI ix Fuel control dial
Starting
switch I
inject ion
PumP
I. I
SAP03522
90-39
STRUCTURE AND FUNCTION ELECTRONIC CONTROL SYSTEM DIAGRAM FOR HYPER GX (l/Z)
ELECTRONIC CONTROL SYSTEM DIAGRAM FOR HYPER GX (l/2)

r Bucket
CURL
HYPER monitor
Buzzer cancel switch

Governor Pump
controller
Caution
buzzer
Swing lock switch I IF 1 I
Pump prolix Fuel control dial
Start
switch
ins
--gE connector
Resister RAISE
Boom prolix switch
Boom ProI ix LOWER -_

control snitch
SAP0361 1
90-41
STRUCTURE AND FUNCTION ELECTRONIC CONTROL SYSTEM DIAGRAM FOR HYPER GX (2/2)
ELECTRONIC CONTROL SYSTEM DIAGRAM FOR HYPER GX (2/2)

1. Pressure sensor (bucket cylinder head) 4. Encoder (boom top) 7. Pressure sensor (arm cylinder bottom) 10. Encoder (boom foot) 13. Pressure sensor (swing right)
2. Pressure sensor (bucket cylinder bottom) 5. Potentiometer (boom top) 8. Pressure sensor (boom cylinder head) 11. Potentiometer (boom foot) 14. Inclination sensor
3. Stroke sensor (bucket cylinder) 6. Pressure sensor (arm cylinder head) 9. Pressure sensor (boom cylinder bottom) 12. Pressure sensor (swing left)
GXcontroller
Governor,oumo 1 1 Swine prolix switcl

L-_--A L_____________, .--_-___________________, controller
I
GX
Q
I
P autodrive
switch
I
I
Caution
buzzer
Swine lock switch
” Fuel control
dial ,,
Electric lever
Starting switch
- Valve
control Ier -
Battery
TROUBLESHOOTING ELECTRICAL CIRCUIT DIAGRAM OF VALVE CONTROLLER SYSTEM
ELECTRICAL CIRCUIT DIAGRAM OF VALVE CONTROLLER SYSTEM
CN-X11
R. H.control lever 104012) To GX control Ier
8
t
%
prolix switch
TKP00865
90-201
0

Manual: PC200,2001C4 PC21 0,21 Ollhi PC220,22OLC4 PC230,23OLC

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SEBMOl 0102

IO STRUCTURE AND FUNCTION . . . . .. . . . . . . . . . . . . . . . . . . . . . . . ..*...... 10-l

20 TESTING AND ADJUSTING . . ..m...............m..................... 20-I

30 DISASSEMBLY AND ASSEMBLY n . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . 30-l

40 MAINTENANCE STANDARD .,....................................... 40-I

The affected pages are indicated by the use of the

0 Page to be newly added Add

0 Page to be replaced Replace

Page to be deleted Discard

Pages having no marks are those previously revised

LIST OF REVISED PAGE

Time oi Time of Time oi Time oi Time of

l oo- 1 Ol- 3 01-31 IO-19 1o-49

l oo- 2 Ol- 4 01-32 IO-20 1O-50

l oo- 2-2 Ol- 6 01-34 10-22 lo-52

% 0 00- 2-4 oi- a 01-36 lo-24 10-54

0 00- 2-5 Ol- 9 01-37 IO-25 IO-55

0 00- 2-6 01-10 01-38 IO-26 IO-56

oo- 3 01-11 01-39 IO-27 IO-57

oo- 4 01-12 01-40 lo-28 lo-58 @

oo- 5 01-13 IO-29 IO-59

00- 6 01-14 10-30 IO-60

oo- 7 01-15 lo- 1 IO-31 IO-61

oo- a 01-16 IO- 2 IO-32 IO-62

oo- 9 01-17 lo- 4 IO-33 IO-63

00-10 01-18 lo- 5 IO-34 IO-64

00-11 01-19 lo- 7 IO-35 IO-65

00-12 01-20 IO- a lo-36 IO-66

00-13 01-21 IO- 9 IO-37 IO-67

00-14 01-22 10-10 lo-38 lo-69

00-15 01-23 IO-11 10-40 10-70

00-16 01-24 IO-12 10-41 10-71

00-17 01-25 IO-13 lo-42 lo-72

00-18 01-26 IO-14 IO-43 IO-73

00-19 01-27 IO-15 10-44 IO-74

01-28 lo-16 10-45 10-75

Ol- 1 01-29 IO-17 IO-46 IO-76

Ol- 2 01-30 lo-18 lo-48 10-77

Time o Time D Time o Time o Time of

IO-78 10-103 IO-150 10-192 IO-232

IO-79 10-104 IO-151 10-193 IO-233

IO-80 IO-106 lo-152 IO-194 lo-234

IO-81 IO-107 IO-153 10-195 IO-235

lo-82 lo-108 10-154 IO-196 IO-236

10-83-I @ IO-109 10-155 IO-197 lo-237

10-83-2 0 10-110 IO-156 IO-198 IO-238

10-83-3 @ IO-Ill 10-157 IO-199 IO-239

10-83-4 @ IO-112 IO-158 10-200 IO-241

10-83-5 @ IO-113 10-159 IO-201 lo-242

10-83-6 @ IO-114 lo-160 IO-202 IO-243

10-83-7 0 IO-115 lo-161 IO-203 lo-244

10-83-8 @ IO-116 lo-162 IO-204 IO-245

10-83-g @ lo-118 lo-164 IO-205

10-83-10 @ IO-119 lo-165 IO-206

10-83-11 @ IO-120 10-166 IO-207 20- 1

10-83-12 @ 10-121 IO-167 lo-208 20- l-l

10-83-13 @ IO-122 IO-168 IO-209 20- 2

10-83-14 @ IO-123 lo-169 IO-210 20- 3