Professional Documents
Culture Documents
HYDRAULIC HB205 -1
EXCAVATOR
HB215LC -1
HB205- 1001
SERIAL NUMBERS and up
HB215LC- 1001
1
Notice of revision
HB205-1, HB215LC-1 1
(04)
2
Notice of revision
2 HB205-1, HB215LC-1
(04)
3
Notice of revision
HB205-1, HB215LC-1 3
(04)
4
Notice of revision
4 HB205-1, HB215LC-1
(04)
5
Notice of revision
HB205-1, HB215LC-1 5
(04)
6
Notice of revision
6 HB205-1, HB215LC-1
(04)
7
Notice of revision
HB205-1, HB215LC-1 7
(04)
8
Notice of revision
8 HB205-1, HB215LC-1
(04)
0-1
HB205-1, HB215LC-1
HYDRAULIC EXCAVATOR
HB205-1
HB215LC-1
Table of Contents 2
01 Specifications
Specifications .......................................................................................................................... 01- 3 3
Outline of hybrid system ...................................................................................................... 01- 3 3
Specification dimension drawing.......................................................................................... 01- 4 4
Working range diagram........................................................................................................ 01- 5 5
Specifications....................................................................................................................... 01- 6 6
Weight table ......................................................................................................................... 01- 9 9
Table of fuel, coolant and lubricants .................................................................................... 01- 11 11
40 Troubleshooting
General information on troubleshooting .................................................................................. 40- 10 10
Points to remember when troubleshooting .......................................................................... 40- 10
Sequence of events in troubleshooting................................................................................ 40- 11
Checks before troubleshooting ............................................................................................ 40- 12
Classification and procedures for troubleshooting ............................................................... 40- 41
Failure codes table............................................................................................................... 40- 44
Symptom and troubleshooting numbers .............................................................................. 40- 52
Information in troubleshooting table..................................................................................... 40- 55
Troubleshooting method for open circuit in wiring harness of pressure sensor system ...... 40- 57
Connector list and layout ..................................................................................................... 40- 59
Connection table for connector pin numbers ....................................................................... 40- 70
T- branch box and T- branch adapter table ......................................................................... 40- 106
Fuse location table............................................................................................................... 40- 109
Troubleshooting by failure code.............................................................................................. 40-111 111
Failure code [989L00] Engine Controller Lock Caution 1 .................................................... 40- 111
Failure code [989M00] Engine Controller Lock Caution 2 ................................................... 40- 111
Failure code [989N00] Engine Controller Lock Caution 3.................................................... 40- 111-1
Failure code [AA10NX] Air Cleaner Clogging ...................................................................... 40- 111-2
Failure code [AB00KE] Charge Voltage Low ....................................................................... 40- 112
Failure code [B@BAZG] Eng Oil Press Low........................................................................ 40- 114
Failure code [B@BAZK] Eng Oil Level Low......................................................................... 40- 115
Failure code [B@BCNS] Eng Water Overheat .................................................................... 40- 116
Failure code [B@BCZK] Eng Water Level Low ................................................................... 40- 118
Failure code [B@HANS] Hyd Oil Overheat.......................................................................... 40- 120
Failure code [CA111] ECM Critical Internal Failure ............................................................. 40- 121
Failure code [CA115] Eng Ne and Bkup Speed Sens Error ................................................ 40- 121
Failure code [CA122] Chg Air Press Sensor High Error ...................................................... 40- 122
Failure code [CA123] Chg Air Press Sensor Low Error ....................................................... 40- 124
Failure code [CA131] Throttle Sensor High Error ................................................................ 40- 126
Failure code [CA132] Throttle Sensor Low Error ................................................................. 40- 128
Failure code [CA144] Coolant Temp Sens High Error ......................................................... 40- 130
Failure code [CA145] Coolant Temp Sens Low Error.......................................................... 40- 132
Failure code [CA153] Chg Air Temp Sensor High Error ...................................................... 40- 134
Failure code [CA154] Chg Air Temp Sensor Low Error....................................................... 40- 136
Failure code [CA155] Chg Air Temp High Speed Derate .................................................... 40- 138
Failure code [CA187] Sens Supply 2 Volt Low Error ........................................................... 40- 140
Failure code [CA221] Ambient Press Sens High Error ........................................................ 40- 142
Failure code [CA222] Ambient Press Sens Low Error ......................................................... 40- 144
Failure code [CA227] Sens Supply 2 Volt High Error .......................................................... 40- 146
Failure code [CA234] Eng Overspeed ................................................................................. 40- 146
Failure code [CA238] Ne Speed Sens Supply Volt Error..................................................... 40- 147
Failure code [CA271] IMV/PCV1 Short Error....................................................................... 40- 148
Failure code [CA272] IMV/PCV1 Open Error ...................................................................... 40- 150
Failure code [CA322] Inj #1(L#1) Open/Short Error ............................................................ 40- 152
Failure code [CA324] Inj #3(L#3) Open/Short Error ............................................................ 40- 154
Failure code [CA331] Inj #2(L#2) Open/Short Error ............................................................ 40- 156
Failure code [CA332] Inj #4(L#4) Open/Short Error ............................................................ 40- 158
Failure code [CA342] Calibration Code Incompatibility ....................................................... 40- 160
Failure code [CA351] Injectors Drive Circuit Error ............................................................... 40- 161
Failure code [CA352] Sens Supply 1 Volt Low Error ........................................................... 40- 162
Failure code [CA386] Sens Supply 1 Volt High Error .......................................................... 40- 164
Failure code [CA428] Water in Fuel Sensor High Error....................................................... 40- 166
Failure code [CA429] Water in Fuel Sensor Low Error........................................................ 40- 168
Failure code [CA435] Eng Oil Press Sw Error ..................................................................... 40- 170
Failure code [CA441] Battery Voltage Low Error ................................................................. 40- 172
Failure code [CA442] Battery Voltage High Error ................................................................ 40- 174
Failure code [CA449] Rail Press Very High Error ................................................................ 40- 175
Failure code [CA451] Rail Press Sensor High Error ............................................................ 40- 176
Failure code [CA452] Rail Press Sensor Low Error............................................................. 40- 178
Failure code [CA488] Chg Air Temp High Torque Derate ................................................... 40- 180
Failure code [CA553] Rail Press High Error ........................................................................ 40- 181
Failure code [CA559] Supply Pump Press Low Error 1....................................................... 40- 182
Failure code [CA689] Eng Ne Speed Sensor Error ............................................................. 40- 184
Failure code [CA731] Eng Bkup Speed Sens Phase Error.................................................. 40- 186
Failure code [CA757] All Continuous Data Lost Error ......................................................... 40- 187
Failure code [CA778] Eng Bkup Speed Sensor Error.......................................................... 40- 188
Failure code [CA1633] KOMNET Datalink Timeout Error.................................................... 40- 191
Failure code [CA2185] Throt Sens Sup Volt High Error ...................................................... 40- 192
Failure code [CA2186] Throt Sens Sup Volt Low Error ....................................................... 40- 193
Failure code [CA2249] Rail Press Very Low Error............................................................... 40- 194
Failure code [CA2311] IMV Solenoid Error.......................................................................... 40- 195
Failure code [CA2555] Grid Htr Relay Open Circuit Error ................................................... 40- 196
Failure code [CA2556] Grid Htr Relay Short Circuit Error ................................................... 40- 198
Failure code [D19JKZ] Personal Code Relay Abnormality .................................................. 40- 200
Failure code [D862KA] GPS Antenna Open Circuit............................................................. 40- 203
Failure code [DA22KK] Pump Solenoid Power Low Error ................................................... 40- 204
Failure code [DA25KP] 5V Sensor1 Power Abnormality ..................................................... 40- 206
Failure code [DA26KP] 5V Sensor2 Power Abnormality ..................................................... 40- 208
Failure code [DA29KQ] Model Selection Abnormality ......................................................... 40- 210
Failure code [DA2RMC] CAN Discon (Pump Con Detected) .............................................. 40- 212
Failure code [DAF8KB] Camera Power Supply Short Circuit .............................................. 40- 218
Failure code [DAFGMC] GPS Module Error ........................................................................ 40- 220
Failure code [DAFRMC] CAN Discon (Monitor Detected) ................................................... 40- 221
Failure code [DGH2KB] Hyd Oil Sensor Short .................................................................... 40- 228
Failure code [DHPAMA] Pump Press Sensor Abnormality.................................................. 40- 230
Failure code [DHPBMA] R Pump Press Sensor Abnormality .............................................. 40- 232
Failure code [DHS3MA] Arm IN PPC Sen. Abnormality ...................................................... 40- 234
Failure code [DHS4MA] Bucket CURL PPC Press Sensor Abnormality ............................. 40- 236
Failure code [DHS8MA] Boom RAISE PPC Press Sensor Abnormality .............................. 40- 238
Failure code [DHSAKZ] Swing RIGHT PPC pressure sensor system open or short circuit 40- 240
Failure code [DHSBKZ] Swing LEFT PPC pressure sensor system open or short circuit... 40- 242
Failure code [DHSAMA] Swing RH PPC Press Sensor Abnomality .................................... 40- 244
Failure code [DHSBMA] Swing LH PPC Press Sensor Abnomality..................................... 40- 246
Failure code [DHSDMA] Bucket Dump PPC Press Sensor Abnormality ............................. 40- 248
Failure code [DHV3KZ] HYB system arm IN PPC pressure sensor open or short circuit.... 40- 250
Failure code [DHV9KZ] HYB Boom Lower PPC Pr. Sen. Open/Shrt Cir ............................. 40- 252
Failure code [DHVAKZ] HYB Swing-R PPC Pr. Sen. Opn/Short Cir ................................... 40- 254
Failure code [DHVAL8] HYB system swing RIGHT PPC pressure sensor signal
abnormality .......................................................................................................................... 40- 256
Failure code [DHVAMA] HYB system swing RIGHT PPC pressure sensor malfunction ..... 40- 257
Failure code [DHVBKZ] HYB Swing-L PPC Pr. Sen. Opn/short Cir .................................... 40- 258
Failure code [DHVBL8] HYB system swing LEFT PPC pressure sensor signal
abnormality .......................................................................................................................... 40- 260
Failure code [DHVBMA] HYB system swing LEFT PPC pressure sensor malfunction ....... 40- 261
Failure code [DHVCKZ] HYB Arm Dump PPC Pr. Sen. Opn/short Cir ................................ 40- 262
Failure code [DW43KA] Travel Speed Sol Open Circuit...................................................... 40- 264
Failure code [DW43KB] Travel Speed Sol Short Circuit ...................................................... 40- 266
Failure code [DW45KA] Swing holding brake solenoid valve open circuit........................... 40- 268
Failure code [DW45KB] Swing holding brake solenoid valve short circuit........................... 40- 271
Failure code [DW45KK] Swing holding brake solenoid valve power voltage drop............... 40- 274
Failure code [DW45KY] swing holding brake Sol. Val. Pow. Short Cir ................................ 40- 276
Failure code [DW4WKA] Cancel Bucket Dump Open Circuit .............................................. 40- 278
Failure code [DW4WKB] Cancel Bucket Dump Short Circuit .............................................. 40- 280
Failure code [DW91KA] Travel Junction Sol. Disc............................................................... 40- 282
Failure code [DW91KB] Travel Junction Sol. S/C................................................................ 40- 284
Failure code [DWA2KA] Attachment Sol Open Circuit......................................................... 40- 286
Failure code [DWA2KB] Attachment Sol Short Circuit......................................................... 40- 288
Failure code [DWK0KA] 2-stage Relief Sol Open Circuit..................................................... 40- 290
Failure code [DWK0KB] 2-stage Relief Sol Short Circuit..................................................... 40- 292
Failure code [DXA8KA] PC-EPC (F) Sol Open Circuit......................................................... 40- 294
Failure code [DXA8KB] PC-EPC (F) Sol Short Circuit......................................................... 40- 296
Failure code [DXA9KA] PC-EPC (R) Sol Open Circuit ........................................................ 40- 298
Failure code [DXA9KB] PC-EPC (R) Sol Short Circuit ........................................................ 40- 300
Failure code [DXE0KA] LS-EPC Sol Open Circuit............................................................... 40- 302
Failure code [DXE0KB] LS-EPC Sol Short Circuit ............................................................... 40- 304
Failure code [DXE4KA] Service Current EPC Disc.............................................................. 40- 306
Failure code [DXE4KB] Service Current EPC S/C............................................................... 40- 308
Failure code [DXE5KA] Merge-divider Main Sol Open Circuit ............................................. 40- 310
Failure code [DXE5KB] Merge-divider Main Sol Short Circuit ............................................. 40- 312
Failure code [DXE6KA] Merge-divider LS Sol Open Circuit ................................................ 40- 314
Failure code [DXE6KB] Merge-divider LS Sol Short Circuit................................................. 40- 316
Failure code [DY20KA] Wiper Working Abnormality............................................................ 40- 318
Failure code [DY20MA] Wiper Parking Abnormality ............................................................ 40- 320
Failure code [DY2CKA] Washer drive discon ...................................................................... 40- 322
Failure code [DY2CKB] Washer drive short......................................................................... 40- 324
Failure code [DY2DKB] Wiper Drive (Fwd) Short Circuit ..................................................... 40- 326
Failure code [DY2EKB] Wiper Drive (Rev) Short Circuit...................................................... 40- 328
Troubleshooting by failure code [GA****] (code display)......................................................... 40-330 330
Precaution in hybrid device troubleshooting, and common troubleshooting procedures
for high voltage devices ....................................................................................................... 40- 330
Failure code [GA----] Hybrid devices monitoring items list and check sheet........................ 40- 355
Failure code [GA1ZKZ] Booster IGBT Temp. Sens. Opn/Shrt. Circ. ................................... 40- 404-1
Failure code [GA1ZNS] Booster IGBT Temp. Sens. Overheat............................................ 40- 404-2
Failure code [GA21KB] Booster IGBT Short Circuit............................................................. 40- 404-3
Failure code [GA22NS] Booster IGBT Junction Overheat ................................................... 40- 405
Failure code [GA23KZ] Gen. Mot. Dr. Temp. Sens.0 Opn/Short Cir. .................................. 40- 406
Failure code [GA24KZ] Gen. Mot. Dr. Temp. Sens.1 Opn/Short Cir. .................................. 40- 406
Failure code [GA25MA] Gen. Motor Driver IGBT0 Abnormality........................................... 40- 407
Failure code [GA25NS] Gen. Motor Driver IGBT0 overheat ................................................ 40- 407-1
Failure code [GA26MA] Gen. Motor Driver IGBT1 Abnormality........................................... 40- 407-2
Failure code [GA26NS] Gen. Motor Driver IGBT1 overheat ................................................ 40- 408
Failure code [GA27KZ] DC before boosting sensor open or short circuit ............................ 40- 409
Failure code [GA28KZ] DC after boosting sensor open or short circuit ............................... 40- 409
Failure code [GA60MC] Generator Motor Failure ................................................................ 40- 410
Failure code [GA60MD] Gen. Mot. Defective Movement..................................................... 40- 411
Failure code [GA60N1] Generator Motor Overrun ............................................................... 40- 412
Failure code [GA61KZ] Gen. Motor Temp. Sens. Open/Short Cir. ...................................... 40- 414
Failure code [GA61NS] Generator Motor Temp. Sensor Overheat ..................................... 40- 416
Failure code [GA62KY] Gen. Mot. Ph-A Cur. Sen. Power Short Cir.................................... 40- 417
Failure code [GA62KZ] Gen. Mot. Ph-A Cur. Sen. Open/Short Cir ..................................... 40- 418
Failure code [GA62MA] Gen. Mot. Ph-A Current Sen. Malfunction ..................................... 40- 419
Failure code [GA63KY] Gen. Mot. Ph-B Cur. Sen. Power Short Cir.................................... 40- 419
Failure code [GA63KZ] Gen. Mot. Ph-B Cur. Sen. Open/Short Cir ..................................... 40- 420
Failure code [GA63MA] Gen. Mot. Ph-B Current Sen. Malfunction ..................................... 40- 420
Failure code [GA64KY] Gen. Mot. Ph-C Cur. Sen. Power Short Cir.................................... 40- 421
Failure code [GA64KZ] Gen. Mot. Ph-C Cur. Sen. Open/Short Cir. .................................... 40- 422
Failure code [GA64MA] Gen. Mot. Ph-C Current Sen. Malfunction..................................... 40- 422
Failure code [GA70KB] HYB Swing Motor Short Circuit ...................................................... 40- 423
Failure code [GA70MD] HYB Swing Motor Defective Stirr. Motion...................................... 40- 423
Failure code [GA70NS] HYB Swing Motor Overheat........................................................... 40- 424
Failure code [GA71KZ] HYB Swing Mot. Temp. Sens. Opn/Shrt Cir................................... 40- 426
Failure code [GA72MA] HYB Swing Motor Resolver Malfunction........................................ 40- 428
Failure code [GA72MC] HYB Swing Motor Resolver Defect Op.......................................... 40- 430
Failure code [GA81KZ] Swing Motor Power Cable Opn/Shrt Circ. ...................................... 40- 430
Failure code [GAA100] Swing emergency stop switch operated ......................................... 40- 431
Failure code [GAA2KB] Swing Brake sol. Supply Line short cir. ......................................... 40- 432
Troubleshooting of electrical system (E-mode)....................................................................... 40-434 434
E-1 Engine does not start (Engine does not crank) ............................................................. 40- 434
E-2 Preheater does not operate........................................................................................... 40- 440
E-3 When starting switch is turned to ON position, machine monitor displays nothing ....... 40- 445
E-4 When starting switch is turned to ON position (with engine stopped), basic check
monitor lights up................................................................................................................... 40- 448
E-5 Precaution monitor lights up while engine is running .................................................... 40- 449
E-6 Emergency stop monitor lights up while engine is running ........................................... 40- 451
E-7 Fuel level gauge does not indicate properly.................................................................. 40- 452
E-8 Engine coolant temperature gauge does not indicate properly ..................................... 40- 454
E-9 Hydraulic oil temperature gauge does not indicate properly ......................................... 40- 456
E-10 HYB system temperature gauge does not indicate properly ....................................... 40- 458
E-11 Displays on machine monitor are different from those for actual machine.................. 40- 460
E-12 Machine monitor does not display some items ........................................................... 40- 460
E-13 Function switch does not work .................................................................................... 40- 460
E-14 Automatic warm-up system does not operate (in cold season)................................... 40- 461
E-15 Auto-decelerator does not operate normally ............................................................... 40- 462
E-16 Working mode does not change.................................................................................. 40- 463
E-17 Travel speed does not change .................................................................................... 40- 464
60 Maintenance standard
Engine and cooling system ..................................................................................................... 60- 4 4
Engine mount....................................................................................................................... 60- 4 4
Cooling system .................................................................................................................... 60- 5 5
Power train.............................................................................................................................. 60- 7 7
Swing circle.......................................................................................................................... 60- 7 7
Swing machinery ................................................................................................................. 60- 8 8
Swing brake ......................................................................................................................... 60- 10 10
Final drive ............................................................................................................................ 60- 12 12
Sprocket............................................................................................................................... 60- 14 14
80 Appendix
Air conditioner ......................................................................................................................... 80- 3
Precautions for refrigerant ................................................................................................... 80- 3
Air conditioner component ................................................................................................... 80- 4
Configuration and function of refrigeration cycle.................................................................. 80- 6
Outline of refrigeration cycle ................................................................................................ 80- 7
Air conditioner unit ............................................................................................................... 80- 10
Air conditioner controller ...................................................................................................... 80- 15
Compressor ......................................................................................................................... 80- 16
Condenser and Modulator ................................................................................................... 80- 17
Procedure for testing and troubleshooting ........................................................................... 80- 18
Circuit diagram and arrangement of connector pins ............................................................ 80- 20
System diagram ................................................................................................................... 80- 22
Detail of air conditioner unit ................................................................................................. 80- 24
Parts and connectors layout ................................................................................................ 80- 26
Testing air leakage (duct) .................................................................................................... 80- 30
Testing with self-diagnosis function ..................................................................................... 80- 31
Testing temperature control ................................................................................................. 80- 34
Testing vent (mode) changeover ......................................................................................... 80- 36
Testing FRESH/RECIRC air changeover ............................................................................ 80- 39
Testing inner sensor ............................................................................................................ 80- 41
Testing evaporator temperature sensor............................................................................... 80- 42
Testing sunlight sensor ........................................................................................................ 80- 44
Testing (dual) pressure switch for refrigerant ...................................................................... 80- 45
Testing relays....................................................................................................................... 80- 47
Troubleshooting chart 1 ....................................................................................................... 80- 48
Troubleshooting chart 2 ....................................................................................................... 80- 50
Information in troubleshooting table..................................................................................... 80- 52
Troubleshooting for power supply and CAN communication system (Air conditioner
does not operate)................................................................................................................. 80- 53
Troubleshooting for compressor and refrigerant system (Air is not cooled) ........................ 80- 57
Troubleshooting for blower motor system (No air comes out or air flow is abnormal) ......... 80- 60
Troubleshooting for temperature control.............................................................................. 80- 63
Troubleshooting for vent (mode) changeover ...................................................................... 80- 66
Troubleshooting for FRESH/RECIRC air changeover ......................................................... 80- 68
Index ....................................................................................................................................... 1
Safety notice 4
Appropriate servicing and repair are extremely important to ensure safe operation of the machine.
The shop manuals describe the effective and safe servicing and repair methods recommended by
Komatsu. Some of the servicing and repair methods require use of special tools designed by
Komatsu for special purposes.
The symbol mark "k" is indicated for such matters that require special precautions. The work indi-
cated with the warning mark should be performed according to the instructions with special attention
to the precautions. Should a hazardous situation occur or be anticipated during such work, be sure
to keep safe first and take every necessary measure.
6) When removing a cover which is under 5. Precautions for slinging work and making
internal pressure or under pressure by a signals
spring, always leave two bolts in diagonal 1) Only one appointed worker must make
positions. Loosen those bolts gradually and signals and co-workers must communicate
alternately to release the pressure, and then with each other frequently. The appointed
remove the cover. signaler must make specified signals clearly
7) When removing components, be careful not at a place where he is well seen from the
to break or damage the electrical wiring. operator's seat and where he can see the
Damaged wiring may cause electrical fires. working condition easily. The signaler must
8) When removing piping, stop the fuel or oil always stand in front of the load and guide
from spilling out. If any fuel or oil drips onto the operator safely.
the floor, wipe it off immediately. Fuel or oil q Do not stand under the load.
on the floor can cause you to slip and can q Do not step on the load.
even cause fires. 2) Check the slings before starting sling work.
9) As a general rule, do not use gasoline to 3) Keep putting on gloves during sling work.
wash parts. Do not use it to clean electrical (Put on leather gloves, if available.)
parts, in particular. 4) Measure the weight of the load by the eye
10)Be sure to assemble all parts again in their and check its center of gravity.
original places. Replace any damaged parts 5) Use proper sling according to the weight of
and parts which must not be reused with new the load and method of slinging. If too thick
parts. When installing hoses and wires, be wire ropes are used to sling a light load, the
sure that they will not be damaged by contact load may slip and fall.
with other parts when the machine is oper- 6) Do not sling a load with one wire rope alone.
ated. If it is slung so, It may rotate and may slip out
11)When installing high pressure hoses and of the rope. Install two or more wire ropes
tubes, make sure that they are not twisted. symmetrically.
Damaged hoses and tubes are dangerous, k Slinging with one rope may cause
so be extremely careful when installing turning of the load during hoisting, un-
hoses and tubes for high pressure circuits. In twisting of the rope, or slipping of the
addition, check that connections of them are rope from its original winding position
correct. on the load, which can result in a dan-
12)When assembling or installing parts, always gerous accident.
tighten them to the specified torques. When 7) Limit the hanging angle to 60 degree, as a
installing protective parts such as guards, or rule.
parts which vibrate violently or rotate at high Do not sling a heavy load with ropes forming
speeds, be particularly careful to check that a wide hanging angle from the hook.
they are installed correctly. When hoisting a load with two or more ropes,
13)When aligning two holes, never insert your the force subjected to each rope will increase
fingers or hand. Be careful not to get your with the hanging angle. The table below
fingers caught in a hole. shows the variation of allowable load in kN
14)When measuring hydraulic pressure, check {kg} when hoisting is made with two ropes,
that the measuring tools are correctly each of which is allowed to sling up to 9.8 kN
installed. {1,000 kg} vertically, at various hanging
15)Take care when removing or installing the angles. When the two ropes sling a load verti-
tracks of track-type machines. When cally, up to 19.6 kN {2,000 kg} of total weight
removing the track, the track separates can be suspended. This weight is reduced to
suddenly, so never let anyone stand at either 9.8 kN {1,000 kg} when the two ropes make
end of the track. a hanging angle of 120 degree. If the two
16)If the engine is operated for a long time in a ropes sling a 19.6 kN {2,000 kg} load at a
place which is not ventilated well, you may lifting angle of 150 degree, each of them is
suffer from gas poisoning. Accordingly, open subjected to a force as large as 39.2 kN
the windows and doors to ventilate well. {4,000 kg}.
9. Precautions for disconnecting and a For tightening torque, see the precau-
connecting hoses and tubes in an air condi- tions for installation in each section of
tioner circuit "Disassembly and assembly".
1) Disconnection
k Although the refrigerant (refrigerant
gas: R134a) used on the machine's air
conditioner is less destructive to the
ozone layer for environmentally friend-
liness, it is not allowed to be released
into the atmosphere as is. Whenever
disconnecting the air conditioner gas
circuit, be sure to recover the refriger-
ant gas to reuse it.
a Ask a qualified person for collection and
charge of the refrigerant (R134a).
a Never release the refrigerant (R134a) to
the atmosphere.
k If the refrigerant gas gets in your eyes
or contacts your skin, you may lose
your sight or your skin may be frozen.
Whenever recovering or adding refrig-
erant gas, you must put on safety
glasses, safety gloves and long
sleeved clothes.
The refrigerant gas must be recovered
and added by a qualified person.
(Rev. 2010/03)
q Some attachments and optional parts in this shop manual may not be delivered to certain areas. If one of them is
required, consult KOMATSU distributors.
q Materials and specifications are subject to change without notice.
q Shop manuals are divided into the "Chassis volume" and "Engine volume". For the engine unit, see the engine vol-
ume of the engine model mounted on the machine.
01. Specification
This section explains the specifications of the machine.
40. Troubleshooting
This section explains how to find out failed parts and how to repair them. The troubleshooting is divided
by failure modes. The "S mode" of the troubleshooting related to the engine may be also explained in the
Chassis volume and Engine volume. In this case, see the Chassis volume.
80. Appendix
This section explains the structure, function, testing, adjusting, and troubleshooting for the equipment not
classifiable in other sections.
90. Diagrams and drawings (chassis volume) /Repair and replacement of parts (engine volume)
q Chassis volume
This section gives hydraulic circuit diagrams and electrical circuit diagrams.
q Engine volume
This section explains the method of remanufacturing and repairing engine and replacing parts.
3. Filing method
File the revised or added pages in the correct order of the page numbers printed in the LIST OF REVISED
PAGES.
q Revision number
When a manual is revised, revision number of each page is increased by 1.
(Example: (01), (02), (03)...)
q Revisions
The revised pages are shown in the LIST OF REVISED PAGES.
4. Symbol
Important safety and quality portions are marked with the following symbols so that the shop manual will be
used practically.
k
Special safety precautions which are necessary when performing work are
Safety
described.
4
Weight of parts of component or parts are indicated. Caution necessary when
Weight
selecting hoisting wire, or when working posture is important, etc. are described.
3
Places that require special attention for tightening torque during assembly are
Tightening torque
indicated.
2 Coat Places to be coated with adhesives, etc. during assembly are indicated.
5 Oil, coolant Places where oil, etc. must be added, and capacity are indicated.
6 Drain Places where oil, etc. must be drained, and quantity to be drained are indicated.
5. Unit
In this shop manual, the units are indicated with International System of units (SI).
For reference, conventionally used Gravitational System of units is indicated in parentheses { }.
(Rev. 2010/03)
The maintenance standard chapter explains the criteria for replacing or reusing products and parts in the ma-
chine maintenance work. The following terms are used to explain the criteria.
1. Standard dimension and tolerance q When some parts are repaired, the value of
q To be accurate, the finished dimension of performance/function is set to the standard
parts is slightly different from one to another. value.
q To specify the finished dimension of a part, a
certain dimension is set for the part and an al-
lowable difference from that dimension is in-
dicated.
q The above dimension set is called the "stan-
dard dimension" and the range of difference
from the standard dimension is called the
"tolerance".
q The tolerance with the symbols of + or is in-
dicated on the right side of the standard di-
mension.
Example:
Standard dimension Tolerance
-0.022
120
-0.126
a The tolerance may be indicated in the text
and a table as [standard dimension (upper
limit of tolerance/lower limit of tolerance)].
Example) 120 (0.022/0.126)
5. Allowable clearance
q Parts can be used until the clearance be-
tween them is increased to a certain limit.
The limit at which those parts cannot be used
is called the "allowable clearance".
q If the clearance between the parts exceeds
the allowable clearance, they must be re-
placed or repaired.
6. Allowable interference
q The allowable maximum interference be-
tween the hole of a part and the shaft of an-
other part to be assembled is called the
"allowable interference".
q The allowable interference shows the repair
limit of the part of smaller tolerance.
q If the interference between the parts exceeds
the allowable interference, they must be re-
placed or repaired.
(Rev. 2010/03)
With the increase in pressure and precision of hydraulic equipment, the most common cause of failure is dirt
(foreign material) in the hydraulic circuit. Therefore, special precaution is required when adding hydraulic oil,
or when disassembling or assembling hydraulic components.
3. Sealing openings
After any piping or equipment is removed, the
openings should be sealed with caps, tapes, or
vinyl bags to prevent any dirt or dust from
entering. If the opening is left open or is blocked
with a rag, there is danger of dirt entering or of
the surrounding area being made dirty by
leaking oil so never do this. Do not simply drain
oil out onto the ground, but collect it and ask the
customer to dispose of it, or take it back with you
for disposal.
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
performed twice. Primary flushing is performed
by use of flushing oil and secondary flushing is
performed by use of the specified hydraulic oil.
7. Cleaning operations
After repairing the hydraulic equipment (pump,
control valve, etc.) or when running the machine,
perform oil cleaning to remove the sludge or
contaminants in the hydraulic oil circuit. The oil
cleaning equipment can remove the ultra fine
(about 3 m) particles that the filter built in the
hydraulic equipment cannot remove, so it is an
extremely effective device.
(Rev. 2010/03)
k Before performing the following work, loosen the oil filler cap of the hydraulic tank gradually to
release the remaining pressure in the hydraulic tank.
k Even if the remaining pressure is released from the hydraulic tank, some hydraulic oil flows out
when the hose is disconnected. Accordingly, prepare an oil container.
Type 1
1. Disconnection
1) Hold adapter (1) and push hose joint (2) into
mating adapter (3). (Fig. 1)
a The adapter can be pushed in about
3.5 mm.
a Do not hold rubber cap portion (4).
2) With hose joint (2) pushed into adapter (3),
press rubber cap portion (4) against adapter
(3) until it clicks. (Fig. 2)
3) Hold hose adapter (1) or hose (5) and pull it
out. (Fig. 3)
a Since some hydraulic oil flows out, pre-
pare an oil container.
2. Connection
1) Hold hose adapter (1) or hose (5) and insert
it in mating adapter (3), aligning them with
each other. (Fig. 4)
a Do not hold rubber cap portion (4).
2) After inserting the hose fitting in the adapter
on the other side perfectly, pull it back to
check the connecting condition (Fig. 5)
a When the hose is pulled back, the rubber
cap portion moves toward the hose about
3.5 mm. This does not indicate abnormal-
ity, however.
Type 2
1. Disconnection
1) Hold the tightening portion and push body (7)
straight until sliding prevention ring (6)
contacts contact surface (a) of the hexagonal
portion at the male end. (Fig. 6)
2) While holding the condition of Step 1), turn
lever (8) to the right (clockwise). (Fig. 7)
3) While holding the condition of Steps 1) and
2), pull out whole body (7) to disconnect it.
(Fig. 8)
2. Connection
q Hold the tightening portion and push body (7)
straight until sliding prevention ring (6) con-
tacts contact surface (a) of the hexagonal
portion at the male end. (Fig. 9)
Type 3
1. Disconnection
1) Hold the tightening portion and push body (9)
straight until sliding prevention ring (8)
contacts contact surface (b) of the hexagonal
portion at the male end. (Fig. 10)
2) While holding the condition of Step 1), push
cover (10) straight until it contacts contact
surface (b) of the hexagonal portion at the
male end. (Fig. 11)
3) While holding the condition of Steps 1) and
2), pull out whole body (9) to disconnect it.
(Fig. 12)
2. Connection
q Hold the tightening portion and push body (9)
straight until sliding prevention ring (8) con-
tacts contact surface (b) of the hexagonal
portion at the male end. (Fig. 13)
(Rev. 2010/03)
To maintain the performance of the machine over a long period, and to prevent failures or other troubles be-
fore they occur, correct "operation", "maintenance and inspection", "troubleshooting", and "repairs" must be
performed. This section deals particularly with correct repair procedures for mechatronics and is aimed at im-
proving the quality of repairs. For this purpose, it gives sections on "Handling electric equipment".
3) Disconnections in wiring
If the harness is pulled to disconnect the
connector, or components are lifted with a
crane with the harness still connected, or a
heavy object hits the harness, the crimping of
the connector may separate, or the soldering
may be damaged, or the harness may be
broken.
2) Connecting connectors
1] Check the connector visually.
Check that no oil, dirt, or water is stuck to
connector pins (joint portion).
Check that connector pins are free from
deformation, defective contact, corrosion,
or damage.
Check that external surfaces of the
connectors are free from damage or
breakage.
a If there is any oil, water, or dirt stuck to
the connector, wipe it off with a dry
cloth. If any water has got inside the
connector, warm the inside of the con-
nector and harness with a dryer, but
be careful not to make them too hot as
this will cause short circuits.
a If there is any damage or breakage,
replace the connector.
2] Fix the connector securely.
Position the connectors correctly, and
then fit them securely. For connectors
with the lock stopper, push in the
connector until the stopper clicks into
position.
3] Correcting protrusion of the boot and
misalignment of the wiring harness
For connectors fitted with the boot,
correct any extrusion of the boot. In addi-
tion, if the wiring harness is moved in
laying, or the clamp is out of position,
correct it to its right position.
a If the connector cannot be corrected
easily, remove the clamp and adjust
the position.
q If the connector clamp is removed, be
sure to return it to its original position.
Check also that there are no loose
clamps.
Disconnection
1] Slide lock L1 to the right.
2] While pressing lock L2, pull out connector
(1) toward you.
a Even if lock L2 is pressed, connector
(1) cannot be pulled out toward you, if
part (A) does not float. In this case,
float part (A) with a small screwdriver
while pressing lock L2, and then pull
out connector (1) toward you.
Connection
Insert the connector straight until it "clicks".
Connection
Insert the connector straight until it "clicks".
3) Push lock type (1) a If the lock is located on the underside, use
q 95/107/114 series flat-head screwdriver [1] since you cannot
Example) Fuel pressure sensor in insert your fingers.
common rail (BOSCH-03) While pressing up lock (C) of the
connector with flat-head screwdriver [1],
Disconnection pull out connector (3) in the direction of
While pressing lock (C), pull out connector the arrow.
(3) in the direction of the arrow.
q 114 series
Connection
Insert the connector straight until it "clicks".
Disconnection
While pressing lock (D), pull out connector
(4) in the direction of the arrow.
Connection
Insert the connector straight until it "clicks".
Connection
1] Insert the connector to the end, while
setting its groove.
2] Turn housing (H1) in the direction of the
arrow until it "clicks".
Examples) Speed sensor of fuel supply
pump: G (SUMITOMO-3)
a Pull the connector straight up.
Connection
Insert the connector straight until it "clicks".
5. Handling controller
1) The controller contains a microcomputer and
electronic control circuits. These control all of
the electronic circuits on the machine, so be
extremely careful when handling the
controller.
2) Do not place objects on top of the controller.
3) Cover the control connectors with tape or a
vinyl bag. Never touch the connector
contacts with your hand.
4) During rainy weather, do not leave the
controller in a place where it is exposed to
rain.
5) Do not place the controller on oil, water, or
soil, or in a place that can be heated to a high
temperature even for a short time. (Place it
on a suitable dry stand.)
6) Precautions when performing arc welding
When performing arc welding on the
machine body, disconnect all of the wiring
harness connectors connected to the
controller. Fit an arc welding ground to the
place close to the welding point.
(Rev. 2010/11)
Hybrid
a The information about the wires unique to each hybrid machine model is described.
In the electric circuit diagram, the material, thickness, and color of each electric wire are indicated by symbols.
The electric wire code is helpful in understanding the electric circuit diagram.
Example: AEX 0.85 L Indicates blue, heat-resistant, low-voltage wire for automobile, having nominal No.
of 0.85
(Table 1)
Using tempera-
Type Symbol Material Example of use
ture range (C)
Annealed copper for electric
Conductor
Low-voltage wire for appliance General wiring (Nominal
AV
automobile No. 5 and above)
Insulator Soft polyvinyl chloride
30 to +60
Annealed copper for electric AVS: General wiring (Nomi-
Thin-cover Conductor
AVS appliance nal No. 3 to 5)
low-voltage wire for
AVSS AVSS: General wiring
automobile Insulator Soft polyvinyl chloride
(Nominal No. 2)
Annealed copper for electric General wiring in extremely
Heat-resistant Conductor
appliance cold district, wiring at high
low-voltage wire for AEX 50 to +110
Heat-resistant crosslinked ambient temperature place
automobile Insulator
polyethylene
Compressed-conduct Annealed copper for electric
Conductor
or thin-cover appliance General wiring (Nominal
CAVS 30 to +60
low-voltage wire for Plasticized type polyvinyl No. 0.5 to 1.25)
Insulator
automobile chloride
(Table 2)
Using tempera-
Type Symbol Material Example of use
ture range (C)
Annealed copper wire for
Conductor
electric appliance
Insulator Soft polyvinyl chloride
Foil shielded
Sn plated annealed copper For general signal wiring
cable for AVSSCS Drain wire 30 to +60
wire strand (nominal size: 0.5, double core)
automobiles
Shield Aluminum foil
2. Dimensions
AVS, AV, AEX, AVSS
(Table 3)
Nominal No. 0.5f (0.5) 0.75f (0.85) 1.25f (1.25) 2f 2 3f 3 5
Number of
strands/Diame- 20/0.18 7/0.32 30/0.18 11/0.32 50/0.18 16/0.32 37/0.26 26/0.32 58/0.26 41/0.32 65/0.32
ter of strand
Conduc- Sectional area
tor 0.51 0.56 0.76 0.88 1.27 1.29 1.96 2.09 3.08 3.30 5.23
(mm2)
d (approx.) 1.0 1.2 1.5 1.9 1.9 2.3 2.4 3.0
AV Standard - - - - - - - 4.6
AVS Standard - - - - - - - - -
Cover D
AV Standard 5.5 7.0 8.2 10.8 11.4 13.0 13.6 16.0 17.6
AEX Standard 5.3 7.0 8.2 10.8 11.4 13.0 13.6 16.0 17.6
AVSS Standard - - - - - - - - -
CAVS
(Table 4)
Nominal No. 0.5 0.85 1.25
16/Circular compres-
Number of strands 7/Circular compression 11/Circular compression
sion
Conductor Cross-sectional area
0.56 0.88 1.29
(mm2)
d (approx.) 0.9 1.1 1.4
Cover D CAVS Standard 1.6 1.8 2.1
AVSSCS PEXBS
(Table 5) (Table 6)
Nominal No. 0.5f Nominal No. 0.5f
Number of cores 2 Number of cores 3
Construction Construction
19/0.19 20/0.18
(No./mm) (No./mm)
Cross-sectional Cross-sectional
Core conductor 0.54 Core conductor 0.51
area (mm2) area (mm2)
Outside diameter Outside diameter
1.6 2.0
(mm) (mm)
Construction Strand diameter
20/0.18 0.12
(No./mm) (mm)
Drain wire Braided shield
Cross-sectional No. of wires/strands 5/16
0.51
area (mm2) Density (%) Min. 70
Aluminum foil thickness (mm) 0.03 Sheath thickness (mm) 0.5
Sheath thickness (mm) 0.5 Finished outside diameter (mm) 5.9
Finished outside diameter (mm) 4.3
(Table 7)
Color Code Color of wire Color Code Color of wire
B Black LgW Light green & White
Br Brown LgY Light green & Yellow
BrB Brown & Black LR Blue & Red
BrR Brown & Red LW Blue & White
BrW Brown & White LY Blue & Yellow
BrY Brown & Yellow O Orange
Ch Charcoal P Pink
Dg Dark green R Red
G Green RB Red & Black
GB Green & Black RG Red & Green
GL Green & Blue RL Red & Blue
Gr Gray RW Red & White
GR Green & Red RY Red & Yellow
GW Green & White Sb Sky Blue
GY Green & Yellow Y Yellow
L Blue YB Yellow & Black
LB Blue & Black YG Yellow & Green
Lg Light green YL Yellow & Blue
LgB Light green & Black YR Yellow & Red
LgR Light green & Red YW Yellow & White
Remarks: In a color code consisting of 2 colors, the first color is the color of the background and the second
color is the color of the marking.
Example: GW means that the background is Green and marking is White.
(Table 8)
Type of wire AVS, AV AEX
Charge R WG R
Ground B B
Start R R
Light RW RB RY RG RL D
Instrument Y YR YB YG YL YW Y Gr
Signal G GW GR GY GB GL G Br
L LW LR LY LB L
Type of
Br BrW BrR BrY BrB
circuit
Lg LgR LgY LgB LgW
O
Others Gr
P
Sb
Dg
Ch
(Rev. 2010/07)
When removing, installing, disassembling or assembling a unit, be sure to follow the general precautions giv-
en below.
3) If the part is not under hydraulic pressure, the following corks can be used.
Nominal Dimensions
Part No.
number D d L
06 07049 - 00608 6 5 8
08 07049 - 00811 8 6.5 11
10 07049 - 01012 10 8.5 12
12 07049 - 01215 12 10 15
14 07049 - 01418 14 11.5 18
16 07049 - 01620 16 13.5 20
18 07049 - 01822 18 15 22
20 07049 - 02025 20 17 25
22 07049 - 02228 22 18.5 28
24 07049 - 02430 24 20 29
27 07049 - 02734 27 22.5 34
4) Checking muffler, exhaust pipe and their mounts for damage and looseness
1] Visually check the muffler, exhaust pipe and their mounts for a crack and damage.
If any part is damaged, replace it.
2] Check the mounting bolts and nuts of the muffler, exhaust pipe and their mounts for looseness.
If any part is loosened, retighten it.
5) Checking muffler function
Check the muffler for unusual sound and sound different from that of a new muffler.
If any unusual sound is heard, repair the muffler, referring to "Troubleshooting" and "Disassembly and
assembly".
(Rev. 2012/10)
Hybrid
k 1. In order to handle (such as install or remove) the hybrid devices (motor-generator, swing electric
motor, capacitor, inverter) and high-voltage wirings, you must follow the local Industrial Safety
and Health Law concerning electricity. If you touch a device or a wiring carelessly, you may get an
electric shock and may be injured seriously since high-voltage may be stored in that device.
Never disassemble the hybrid devices or high-voltage wirings. If the devices are disassembled
carelessly, their quality assurance will be lost and a serious trouble may occur.
k 2. The hybrid devices and high-voltage wirings (wound with orange conduits) must be replaced by
the assembly.
k 3. When testing, servicing or replacing a hybrid device or a high-voltage wiring, discharge the ca-
pacitor in advance. (For details, see the latter half of this manual)
k 4. The machine is equipped with the capacitor discharge system. If it breaks down, discharge the
capacitor with the capacitor discharger.
k 5. Handling of inverter and capacitor
1) Handling of inverter and capacitor
Handle the inverter and capacitor with extreme care since they have microcomputers and elec-
tronic control circuits in them.
2) Precautions when performing arc welding
When performing arc welding on the body for repair of the machine etc., disconnect all wiring
harness connectors and ground cable connected to the inverter and capacitor. Connect the arc
welding ground cable close to the welding point.
a You cannot swing the upper structure while the 4. Press "F1" to start discharging.
capacitor is being discharged but you can oper- Since the charge in the capacitor is consumed
ate the work equipment. Take care. through the motor-generator by this operation,
the engine speed increases temporarily. This is
1. Turn the key switch ON, start the engine, and set normal.
the engine speed to low idle.
2. While pressing machine monitor switch "4", input
"1+2+3" to enter the service mode.
6. Look into the charge level inspection window at the contactor box above the capacitor and check that the
capacitor charge level indicator LED indicates discharged.
The capacitor is discharged completely now.
a If the capacitor charge ratio does not decrease in 5 minutes, or if the LED does not indicate "UN-
CHARGED" when the capacitor charge ratio is "0%", or "Completed" is not indicated and LED doesn't
indicate "UNCHARGED" when 30 minutes passed after starting discharge, the capacitor is not dis-
charged for some reason. In this case, immediately stop discharging the capacitor with the machine
monitor, and then use the special capacitor discharger.
a If the capacitor is not discharged after discharging by capacitor discharger, leave it until LED lamp goes
out. (Leaving period: maximum 14 days) Stick a piece of sealing tape to the capacitor body and write
down "Discharge is not available" with a felt-tip pen.
a If LED lamp lights up again after discharging and leaving, perform the discharge from Step 1 again, or
leave it until LED lamp goes out. (Leaving period: maximum 14 days)
7. Turn the key switch to the OFF position to stop the engine completely.
a If key switch operation such as the following is performed, capacitor performs electric charge again.
Do not perform the following operation.
q After turning key switch to the OFF position, turn the key switch to the ON position before the engine
stops completely.
q After turning key switch to the OFF position and the engine stops completely, turn key switch to the
ON position to start the engine.
a Even if the capacitor charge ratio is 0, the capacitor voltage has not decreased to 0 V perfectly. Be-
cause of the characteristics of the capacitor, its voltage tends to increase again a little to 0 30 V after
it is discharged. Accordingly, take extreme care when disconnecting the connector or performing other
service work.
(Rev. 2010/03)
1. Table of tightening torques for bolts and nuts
a Unless otherwise specified, tighten metric nuts and bolts to the torque shown in the following table.
Fig. A Fig. B
aValues with ( ) are applied to (*) marked bolt (flange bolt) as the width across flats.
5. Table of tightening torque for hoses (taper seal type and face seal type)
a Unless otherwise specified, tighten the hose fittings (taper seal type and face seal type) to the torque
shown in the following table.
a Apply the following torque when the threads are coated with engine oil (wetted).
Tightening torque (Nm {kgm}) Taper seal Face seal
Nominal Width Nominal No.
number of across Thread
Thread size Number of
hose flats (mm) Range Target diameter (mm)
(mm) threads, type of
(Reference)
thread
34 54 {3.5 5.5} 44 {4.5} 9/16 18UN 14.3
02 19
34 63 {3.5 6.5} 44 {4.5} 14
22 54 93 {5.5 9.5} 74 {7.5} 11/16 16UN 17.5
03
24 59 98 {6.0 10.0} 78 {8.0} 18
04 27 84 132 {8.5 13.5} 103 {10.5} 22 13/16 16UN 20.6
05 32 128 186 {13.0 19.0} 157 {16.0} 24 1 14UNS 25.4
06 36 177 245 {18.0 25.0} 216 {22.0} 30 1-3/16 12UN 30.2
(10) 41 177 245 {18.0 25.0} 216 {22.0} 33
(12) 46 197 294 {20.0 30.0} 245 {25.0} 36
(14) 55 246 343 {25.0 35.0} 294 {30.0} 42
7. Table of tightening torque for 102, 107 and 114 engine series (bolts and nuts)
a Unless otherwise specified, tighten the metric bolts and nuts used for the 102, 107 and 114 engine se-
ries to the torque shown in the following table.
Tightening torque
Thread size
Bolts and nuts
mm Nm kgm
6 10 2 1.02 0.20
8 24 4 2.45 0.41
10 43 6 4.38 0.61
12 77 12 7.85 1.22
14
8. Table of tightening torque for 102, 107 and 114 engine series (eye joints)
a Unless otherwise specified, tighten the metric eye joints used for the 102, 107 and 114 engine series
to the torque shown in the following table.
Thread size Tightening torque
mm Nm kgm
6 82 0.81 0.20
8 10 2 1.02 0.20
10 12 2 1.22 0.20
12 24 4 2.45 0.41
14 36 5 3.67 0.51
9. Table of tightening torque for 102, 107 and 114 engine series (taper screws)
a Unless otherwise specified, tighten NPT screws used for the 102, 107 and 114 engine series to the
torque shown in the following table.
Tightening torque
Material In cast iron or steel In aluminum
Thread size (inch) Nm kgm Nm kgm
1/16 15 2 1.53 0.20 51 0.51 0.10
1/8 20 2 2.04 0.20 15 2 1.53 0.20
1/4 25 3 2.55 0.31 20 2 2.04 0.20
3/8 35 4 3.57 0.41 25 3 2.55 0.31
1/2 55 6 5.61 0.61 35 4 3.57 0.41
3/4 75 8 7.65 0.82 45 5 4.59 0.51
List of Abbreviation 46
(Rev. 2010/03)
q This list of abbreviations includes the abbreviations used in the text of the shop manual for parts, compo-
nents, and functions whose meaning is not immediately clear. The spelling is given in full with an outline
of the meaning.
q Abbreviations that are used in general society may not be included.
q Special abbreviations that appear infrequently are marked in the text with an *.
q This list of abbreviations consists of two parts. The first part is a list of abbreviations used in the text of the
manual, and the second part is a list of abbreviations used in circuit diagrams.
List of abbreviations used in the shop manual
Purpose of use (major
Abbrevia-
Full Spelling applicable machine (*), or Explanation
tion
component/system)
With this function, when the tires skid (wheels stop
Travel and brake
A.B.S. Anti-skid Brake System rotating), the brakes are released, and when the
(HD, HM)
wheels start to rotate, the brakes are applied again.
Automatic Idling Setting
A.I.S.S. Engine This function automatically sets the idle speed.
System
Instead of a steering wheel, a lever is used to per-
Advanced Joystick Steer- Steering
A.J.S.S. form the steering operations as well as to shift gear
ing System (WA)
and change direction (forward or reverse).
When the machine is traveling downhill, if the
Automatic Retarder Accel- Travel and brake accelerator pedal is released, this function auto-
A.R.A.C.
erator Control (HD, HM) matically applies the retarder with a constant brak-
ing force.
When the machine is traveling downhill, if the
accelerator pedal is released, this function auto-
Automatic Retarder Speed Travel and brake
A.R.S.C. matically applies the retarder to ensure that the
Control (HD, HM)
machine speed does not accelerate above the
speed set by the operator.
When the rear wheels spin on soft ground sur-
Travel and brake
A.S.R. Automatic Spin Regulator faces, this function automatically uses the optimum
(HD, HM)
braking force to drive both wheels.
A device that can be fixed onto a machine in order
ATT. Attachment Work equipment
to enable it to do different jobs.
When the retarder is not being used, this valve
Brake Cooling oil control Brake
B.C.V. bypasses part of the brake cooling oil to reduce the
Valve (HD)
load on the hydraulic pump.
Communication and elec- Communications standard standardized as
C.A.N. Controller Area Network
tronic control ISO11898.
System that can simultaneously actuate multiple
Closed-center Load Sens-
C.L.S.S. Hydraulic actuators regardless of the load (provides better
ing System
ease of combined operation than O.L.S.S.).
Uses engine controller to perform electronic control
of supply pump, common rail, and injector. Func-
C.R.I. Common Rail Injection Engine
tions to maintain optimum fuel injection amount
and fuel injection timing.
Electronic control device that uses the signals from
E.C.M. Electronic Control Module Electronic control system the sensors on the machine to indicate to the actu-
ators the optimum actuation. (same as ECU)
Proportional electromagnetic valve that gradually
Electronic Control Modula- Transmission
E.C.M.V. increases oil pressure to engage clutch and
tion Valve (D, HD, WA, etc.)
reduces transmission shock.
System that ensures smooth high-speed travel by
Electronically Controlled Travel
E.C.S.S. using hydraulic spring effect of accumulator to
Suspension System (WA)
absorb vibration of machine during travel
Electronic control device that uses the signals from
E.C.U. Electronic Control Unit Electronic control system the sensors on the machine to indicate to the actu-
ators the optimum actuation. (same as ECM)
Functions to recirculate part of exhaust gas to com-
E.G.R. Exhaust Gas Recirculation Engine bustion chamber in order to reduce combustion
temperature, controls emission of Nox.
Conversion table 50
(Rev. 2010/03)
Method of using the conversion table
The conversion table in this section is provided to enable simple conversion of figures. For details of the meth-
od of using the conversion table, see the example given below.
Example: Method of using the conversion table to convert from millimeters to inches
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
10 0.394 0.433 0.472 0.512 0.551 0.591 0.630 0.669 0.709 0.748
20 0.787 0.827 0.866 0.906 0.945 0.984 1.024 1.063 1.102 1.142
30 1.181 1.220 1.260 1.299 1.339 1.378 1.417 1.457 1.496 1.536
40 1.575 1.614 1.654 1.693 1.732 1.772 1.811 1.850 1.890 1.929
50 1.969 2.008 2.047 2.087 2.126 2.165 2.205 2.244 2.283 2.323
60 2.362 2.402 2.441 2.480 2.520 2.559 2.598 2.638 2.677 2.717
70 2.756 2.795 2.835 2.847 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 7 8 9
0 0 2.20 4.41 6.61 8.82 11.02 13.23 15.43 17.64 19.84
10 22.05 24.25 26.46 28.66 30.86 33.07 35.27 37.48 39.68 41.89
20 44.09 46.30 48.50 50.71 52.91 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
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
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
kgm to ft.lb
1 kgm = 7.233 ft.lb
0 1 2 3 4 5 6 7 8 9
0 0 7.2 14.5 21.7 28.9 36.2 43.4 50.6 57.9 65.1
10 72.3 79.6 86.8 94.0 101.3 108.5 115.7 123.0 130.2 137.4
20 144.7 151.9 159.1 166.4 173.6 180.8 188.1 195.3 202.5 209.8
30 217.0 224.2 231.5 238.7 245.9 253.2 260.4 267.6 274.9 282.1
40 289.3 296.6 303.8 311.0 318.3 325.5 332.7 340.0 347.2 354.4
50 361.7 368.9 376.1 383.4 390.6 397.8 405.1 412.3 419.5 426.8
60 434.0 441.2 448.5 455.7 462.9 470.2 477.4 484.6 491.8 499.1
70 506.3 513.5 520.8 528.0 535.2 542.5 549.7 556.9 564.2 571.4
80 578.6 585.9 593.1 600.3 607.6 614.8 622.0 629.3 636.5 643.7
90 651.0 658.2 665.4 672.7 679.9 687.1 694.4 701.6 708.8 716.1
100 723.3 730.5 737.8 745.0 752.2 759.5 766.7 773.9 781.2 788.4
110 795.6 802.9 810.1 817.3 824.6 831.8 839.0 846.3 853.5 860.7
120 868.0 875.2 882.4 889.7 896.9 904.1 911.4 918.6 925.8 933.1
130 940.3 947.5 954.8 962.0 969.2 976.5 983.7 990.9 998.2 1005.4
140 1012.6 1019.9 1027.1 1034.3 1041.5 1048.8 1056.0 1063.2 1070.5 1077.7
150 1084.9 1092.2 1099.4 1106.6 1113.9 1121.1 1128.3 1135.6 1142.8 1150.0
160 1157.3 1164.5 1171.7 1179.0 1186.2 1193.4 1200.7 1207.9 1215.1 1222.4
170 1129.6 1236.8 1244.1 1251.3 1258.5 1265.8 1273.0 1280.1 1287.5 1294.7
180 1301.9 1309.2 1316.4 1323.6 1330.9 1338.1 1345.3 1352.6 1359.8 1367.0
190 1374.3 1381.5 1388.7 1396.0 1403.2 1410.4 1417.7 1424.9 1432.1 1439.4
kg/cm2 to lb/in2
1 kg/cm2 = 14.2233 lb/in2
0 1 2 3 4 5 6 7 8 9
0 0 14.2 28.4 42.7 56.9 71.1 85.3 99.6 113.8 128.0
10 142.2 156.5 170.7 184.9 199.1 213.4 227.6 241.8 256.0 270.2
20 284.5 298.7 312.9 327.1 341.4 355.6 369.8 384.0 398.3 412.5
30 426.7 440.9 455.1 469.4 483.6 497.8 512.0 526.3 540.5 554.7
40 568.9 583.2 597.4 611.6 625.8 640.1 654.3 668.5 682.7 696.9
50 711.2 725.4 739.6 753.8 768.1 782.3 796.5 810.7 825.0 839.2
60 853.4 867.6 881.8 896.1 910.3 924.5 938.7 953.0 967.2 981.4
70 995.6 1,010 1,024 1,038 1,053 1,067 1,081 1,095 1,109 1,124
80 1,138 1,152 1,166 1,181 1,195 1,209 1,223 1,237 1,252 1,266
90 1,280 1,294 1,309 1,323 1,337 1,351 1,365 1,380 1,394 1,408
100 1,422 1,437 1,451 1,465 1,479 1,493 1,508 1,522 1,536 1,550
110 1,565 1,579 1,593 1,607 1,621 1,636 1,650 1,664 1,678 1,693
120 1,707 1,721 1,735 1,749 1,764 1,778 1,792 1,806 1,821 1,835
130 1,849 1,863 1,877 1,892 1,906 1,920 1,934 1,949 1,963 1,977
140 1,991 2,005 2,020 2,034 2,048 2,062 2,077 2,091 2,105 2,119
150 2,134 2,148 2,162 2,176 2,190 2,205 2,219 2,233 2,247 2,262
160 2,276 2,290 2,304 2,318 2,333 2,347 2,361 2,375 2,389 2,404
170 2,418 2,432 2,446 2,460 2,475 2,489 2,503 2,518 2,532 2,546
180 2,560 2,574 2,589 2,603 2,617 2,631 2,646 2,660 2,674 2,688
190 2,702 2,717 2,731 2,745 2,759 2,773 2,788 2,802 2,816 2,830
200 2,845 2,859 2,873 2,887 2,901 2,916 2,930 2,944 2,958 2,973
210 2,987 3,001 3,015 3,030 3,044 3,058 3,072 3,086 3,101 3,115
220 3,129 3,143 3,158 3,172 3,186 3,200 3,214 3,229 3,243 3,257
230 3,271 3,286 3,300 3,314 3,328 3,343 3,357 3,371 3,385 3,399
240 3,414 3,428 3,442 3,456 3,470 3,485 3,499 3,513 3,527 3,542
Temperature
Fahrenheit-Centigrade conversion: A simple way to convert a Fahrenheit temperature reading into a Centi-
grade temperature reading or vice versa is to enter the accompanying table in the center (boldface column)
of figures. These figures refer to the temperature in either Fahrenheit or Centigrade degrees.
When convert from Fahrenheit to Centigrade degrees, consider the center column to be a table of Fahrenheit
temperatures and read the corresponding Centigrade temperature in the column at the left.
When convert from Centigrade to Fahrenheit degrees, consider the center column to be a table of Centigrade
values, and read the corresponding Fahrenheit temperature on the right.
1C = 33.8F
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 81 177.8
-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 48 118.4 28.3 83 181.4
-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
HYDRAULIC EXCAVATOR
HB205-1
HB215LC-1
01 Specifications 30-1
Contents 0-1
01 Specifications
Specifications.......................................................................................................................... 01- 3 3
Outline of hybrid system ...................................................................................................... 01- 3 3
Specification dimension drawing.......................................................................................... 01- 4 4
Working range diagram........................................................................................................ 01- 5 5
Specifications....................................................................................................................... 01- 6 6
Weight table ......................................................................................................................... 01- 9 9
Table of fuel, coolant and lubricants .................................................................................... 01- 11 11
Specifications 3
This machine is equipped with the hybrid system consisting of an electric motor and a diesel engine to reduce
fuel consumption.
Specifications 6
bottom
Max. ground clearance mm 440 440
Tail swing radius mm 2,750 2,750
Min. swing radius of work equipment mm 3,040 3,040
Top height at min. swing radius of work
mm 8,005 8,005
equipment
Length of track on ground mm 3,275 3,655
Track gauge mm 2,200 2,380
Machine cab height mm 2,390 2,390
Width of standard shoe mm 600 700
Weight table 9
k This weight table is prepared for your reference when handling or transporting the components.
Unit: kg
Machine model HB205-1, HB215LC-1
Serial number 1001 and up
Engine assembly 840 840
q Engine *1 452 452
q Motor-generator *1 225 225
q Hydraulic pump 152 152
Radiator and oil cooler assembly 158 158
Inverter *1 38 38
Capacitor *1 85 85
Hydraulic tank and filter assembly (Not including
123 123
hydraulic oil)
Fuel tank assembly (Not including fuel) 134 134
Revolving frame 1,803 1,803
Cab 480 480
Operator's seat 35 35
Counterweight 3,260 3,260
Swing machinery 229 229
Control valve 235 235
Swing electric motor *1 71 71
Travel motor 93 2 93 2
Center swivel joint 36 36
Track frame assembly (Not including piping) 4,264 4,862
q Track frame 2,260 2,649
q Swing circle 273 273
q Idler 101 2 101 2
q Idler cushion 118 2 129 2
q Carrier roller 14 4 14 4
q Track roller 36 14 36 18
q Final drive (including travel motor) 322 2 322 2
Track shoe assembly
q Standard triple shoe (600 mm) 1,215 2 1,325 2
q Standard triple shoe (700 mm) 1,405 2 1,530 2
Unit: kg
Machine model HB205-1, HB215LC-1
Serial number 1001 and up
Boom assembly 1,393
Arm assembly 633
Bucket assembly 633
Boom cylinder assembly 173 2
Arm cylinder assembly 223
Bucket cylinder assembly 133
Link (large) assembly 83
Link (small) assembly 22 2
Boom pin 42 + 8 2 + 28 + 10 + 26
Arm pin 12 + 8
Bucket pin 20 2
Link pin 13 2
a For details of the notes (Note 1, Note 2... ) in the table, see Operation and Maintenance Manual.
Unit: l
HB205-1, HB215LC-1
Refilling points
Specified capacity Refill capacity
Engine oil pan *1 20 18
Motor-generator case *1 6.5 6.0
Swing electric motor case *1 2.3 1.6
Swing machinery case *1 7.1 7.1
Final drive case
3.5 3.3
(each sides)
Hydraulic system 232 135
Fuel tank 400
Engine cooling system *1 17.3
Hybrid device cooling system *1 6.8 5.4
Note 1: The power train oil and engine oil are different from each other. Use oils recommended for them re-
spectively.
Note 2: When environment preservation is important in river works, marine and shore works, forest works,
etc., recommend use of bio hydraulic oil and bio grease.
Note 3: Hyper white grease (G0-T, G2-T) indicates high-performance white grease.
Recommend use of G0-T or G2-T in the following cases.
(1): Lubrication performance of grease is required to prevent the pins and bushings from creaking.
(2): Outside staining with black grease needs to be prevented.
Note 4: Do not use bio grease to the rolling bearings, including the swing bearing.
Lithium
E Q w Q Q
grease
Synthetic
Bio grease E Q w Q w biodegradable
lithium grease
w: Excellent Q: Satisfactory E: Average : Low
HYDRAULIC EXCAVATOR
HB205-1
HB215LC-1
Contents 10-2
1. Muffler Outline
2. Rear engine mount The motor-generator is mounted.
3. Front engine mount
4. Motor-generator ( )
Cooling system 4
Specifications
Radiator: Corrugated aluminum 5-array
Oil cooler: CF40-1
Aftercooler: Corrugated aluminum
Fuel cooler: Drawn cup type
Radiator for hybrid system: Corrugated aluminum ( )
Hybrid relation 6
1. Motor-generator case
2. Engine
3. Motor-generator high-voltage portion
4. Connector
5. High-voltage wiring
6. Capacitor case
7. Inverter case
8. Swing electric motor case
9. Inverter high-voltage portion
10. Swing electric motor high-voltage portion
11. Capacitor high-voltage portion
12. Swing machinery
13. Machine frame
14. Flexible cable
a. Insulation
b. Shield braid
The values of items marked with * are not measured but estimated from calculation.
2. When an overcurrent is detected in the swing electric motor or motor-generator (including breakage of a
fuse)
Or, when an abnormality is detected in the current sensor
Example of corresponding failure code: [GA62KY] Gen. Mot. Ph-A Cur. Sen. Power Short Cir
[GA62MA] Gen. Mot. Ph-A Current Sen. Malfunction
4. When an abnormality is detected in the high-voltage wiring connector (open circuit, hot short circuit, or
ground fault in the interlock circuit)
Example of corresponding failure code: [GA01KA] Power Cable Interlock Open Circuit
7. When an abnormality is detected in the capacitor or in its high-voltage wiring (including wrong connection)
Example of corresponding failure code: [GA02KZ] DC Line Open & Short Circuit
[GA04KG] Abnormal DC HW Volt. Before Booster
1. High voltage
2. Overcurrent
(swing electric motor, motor-generator)
3. Overcurrent (high-voltage line)
4. Defective connector
5. Emergency stop switch
6. Ground leakage detector (built-in inverter)
7. Fuse is broken when capacitor cable has short
circuit
Since the electrode of the one-touch connector is protected with the insulator and waterproof seal and
cannot be touched easily, safety is secured even while there is charge left in the capacitor.
Interlock function
This function checks for a loose or disconnected connector in the high-voltage wiring (power cable) and out-
puts an error signal to the monitor and stops the hybrid system if it detects an abnormality.
The interlock circuit in the following figure is installed to the high-voltage wiring connectors of the
motor-generator, inverter, and swing electric motor. If any contact in the circuit is disconnected due to reverse
assemble of connector or coming off of connector, interlock function judges it as an abnormality and stops
hybrid system.
This function also checks the interlock circuit and stops the hybrid system if it detects abnormality in the circuit,
outputting the error signal similarly to the above.
The power cable connectors marked with a and connected to the inverter are also equipped with interlock
circuits, which check for loose or disconnected connectors.
Motor-generator 12
Function Specifications
q The motor-generator coverts the rotation and Model: ZG031
torque of the engine into electric power and sup- Lubricating oil:
plies it to the swing electric motor. Specified capacity: 6.5 l
q The motor-generator receives electric power Refill capacity: 6.0 l
from the capacitor and assists the engine output. Oil type: TO10
Weight: 229 kg
Function Specifications
q The swing electric motor converts the electric Model: ZM102
power supplied from the generator and capacitor Specified oil capacity: 2.3 l
into rotation and torque of the motor output shaft Refill capacity: 1.6 l
and transmits it to the swing machinery. Oil type: TO10
q The swing electric motor coverts the kinetic en- Weight: 71 kg
ergy of the upper structure into electric power
and supplies it to the capacitor.
Function Specifications
q The swing electric motor converts the electric Model: ZM103
power supplied from the generator and capacitor Specified oil capacity: 2.5 l
into rotation and torque of the motor output shaft Refill capacity: 1.7 l
and transmits it to the swing machinery. Oil type: TO10
q The swing electric motor coverts the kinetic en- Weight: 65 kg
ergy of the upper structure into electric power
and supplies it to the capacitor.
Function Specifications
q Motor-generator control Inverter model: ZD110
q Swing motor control Fuse rating: 150 A
q Capacitor charge and discharge control Total weight: 123 kg
Inverter weight: 38 kg
Function Specifications
q The high-voltage wiring supplies high-voltage q Waterproof and shield structure
power.
q The high-voltage wiring connectors are distin-
guished with number of block wirings respective-
ly to prevent a wrong connection.
q Each high-voltage wiring connector is equipped
with an interlock switch. If the connector is dis-
connected, the switch is opened and the hybrid
system stops.
Water pump 16
1. Water pump
Function Specifications
q This pump starts when the key is turned to ON q Rated voltage: 24 V
position. q Rated ampere: 2.4 A
q This pump is driven with the electricity from the q Weight: 2.1 kg
battery.
q This pump circulates the coolant for the hybrid
components.
q This pump sucks in the coolant from the hybrid
component radiator and discharges it to the ca-
pacitor.
Power train 18
1. Idler
2. Center swivel joint
3. Control valve
4. Final drive
5. Travel motor (HMV110ADT-2)
6. Hydraulic pump (HPV95 + 95)
7. Motor-generator ( )
8. Engine (SAA4D107E-1)
9. Travel speed solenoid valve
10. Swing brake solenoid valve
11. Swing electric motor (ZM102) ( )
12. Swing machinery
13. Swing circle
Swing circle 19
1. Swing circle inner race (No. of teeth: 96) a. Inner race soft zone "S" position
2. Ball b. Outer race soft zone "S" position
3. Swing circle outer race
Specifications
Reduction ratio 96/13 = 7.385
Grease G2-LI
Amount of filled grease (l) 14.6
Swing machinery 20
Swing brake 2
1. Case
2. No.1 planetary carrier
3. No.1 ring gear
4. No. 2 sun gear
5. No.1 planetary gear
6. Spring
7. No.1 sun gear
8. Brake piston
9. Brake gear
10. Brake plate
11. Brake disc
Final drive 24
1. Level plug
2. No. 1 planetary gear (No. of teeth: 42)
3. Drain plug
4. No. 1 sun gear (No. of teeth: 10)
5. No. 2 sun gear (No. of teeth: 21)
6. No. 1 planetary carrier
7. Cover
8. No. 2 planetary carrier
9. Gear hub (No. of teeth: 95)
10. Sprocket
11. Floating seal
12. Travel motor
13. No. 2 planetary gear (No. of teeth: 36)
Specifications
Reduction ratio: ((10 + 95)/10) x ((21 + 95)/21) + 1 = 57.000
Standard shoe
Models
HB205-1 HB215LC-1
Item
Shoe width (mm) 600 700
Link pitch (mm) 190 190
Q'ty (One side) 45 49
Hydraulic system 28
1. Bucket cylinder
2. Arm cylinder
3. Boom cylinder
4. Right PPC valve
5. Hydraulic tank
6. Hydraulic oil filter
7. R.H. travel motor
8. Main pump
9. Control valve
10. Oil cooler
11. L.H. travel motor
12. Left PPC valve
13. Lock lever
14. Center swivel joint
15. Travel PPC valve
16. Accumulator
17. Solenoid valve assembly
17A. PPC lock solenoid valve
17B. 2-stage relief solenoid valve
17C. Swing brake solenoid valve
17D. Travel speed solenoid valve
17E. Travel junction solenoid valve
Valve control 30
Hydraulic tank 31
CLSS 32
Outline of CLSS
Features Configuration
CLSS stands for Closed center Load Sensing Sys- q CLSS is configured with variable capacity piston
tem, which has the following characteristics: pumps, control valves, and respective actuators.
q The hydraulic pump is configured with pump
q Fine control not influenced by load body, PC valve and LS valve.
q Controllability enabling digging even with fine
control
q Ease of compound operation ensured by flow di-
vider function using area of opening of spool dur-
ing compound operations
q Energy saving using variable pump control
Basic principle
Pump swash plate angle control
q The pump swash plate angle (pump delivery) is q The pump swash plate angle shifts toward the
controlled so that LS differential pressure maximum position if LS differential pressure
(dPLS) (the difference between pump pressure (dPLS) is lower than the set pressure of the LS
(PP) and control valve outlet port LS pressure valve (when the actuator load pressure is high).
(PLS)) (load pressure of actuator) is constant. q If it becomes higher than the set pressure (when
q [LS differential pressure (dPLS) = Pump dis- the actuator load pressure is low), the pump
charge pressure (PP) LS pressure (PLS)] swash plate angle shifts toward the minimum po-
sition.
System diagram
Main pump 36
Type: HPV95+95
Outline
q This pump consists of two variable capacity
swash plate piston pumps, PC valve, LS valve,
and EPC valve.
1. Front pump
2. Rear pump
3. LS valve
4. PC valve
5. LS-EPC valve
6. PC-EPC valve
1. Front shaft
2. Cradle
3. Front case
4. Rocker cam
5. Shoe
6. Piston
7. Cylinder block
8. Valve plate
9. End cap
10. Rear shaft
11. Rear case
12. Servo piston
13. PC valve
Function
q The pump converts the engine torque transmit- q Cylinder block (7) seals the pressurized oil to
ted to its shaft into oil pressure and delivers pres- valve plate (8) and performs relative rotation.
surized oil corresponding to the load. q This surface is designed so that the oil pressure
q It is possible to change the discharge amount by balance is maintained at a suitable level.
changing the swash plate angle. q The oil inside the respective cylinder chambers
of cylinder block (7) is suctioned and discharged
Structure through valve plate (8).
q Cylinder block (7) is connected with shaft (1) on
spline (14).
q Shaft (1) is supported by front and rear bearings
(15).
q Tip of piston (6) is shaped as a concave sphere
and shoe (5) is caulked to it to form one unit.
q Piston (6) and shoe (5) form a spherical bearing.
q Rocker cam (4) has flat surface (A), and shoe (5)
is always pressed against this surface while slid-
ing in a circular movement.
q Rocker cam (4) conducts high pressure oil to the
cylindrical surface (B) with cradle (2), which is
secured to the case, and forms a static pressure
bearing with oil when it pivots.
q Piston (6) performs the reciprocation inside each
cylinder chamber of cylinder block (7).
Operation of pump
q Cylinder block (7) rotates together with shaft (1), q As center line (X) of rocker cam (4) matches the
and shoe (5) slides on flat surface (A). axis of cylinder block (7) (swash plate angle (a)
q When this happens, rocker cam (4) moves along = 0), the difference between volumes (E) and (F)
cylindrical surface (B), so angle (a) between cen- inside cylinder block (7) becomes 0.
ter line (X) of rocker cam (4) and the axis of cyl- q Suction and discharge of pressurized oil is not
inder block (7) changes. performed in this stage. Namely pumping action
q (a) is named the swash plate angle. is not performed. (Actually, however, the swash
plate angle is not set to 0)
Control of delivery
q If the swash plate angle (a) increases, the differ-
ence between volumes (E) and (F) increases
and also pump delivery (Q) increases.
q Servo piston (12) is used for changing swash
plate angle (a).
q Servo piston (12) performs linear reciprocation
according to the signal pressure from the PC
valve and LS valve.
q This linear movement is transmitted to rocker
cam (4) through slider (13).
q Being supported by cradle (2) on the cylindrical
surface, rocker cam (4) pivots on the surface
while rotating.
q The pressure receiving area of servo piston (12)
are not equal on the left side and right side. Main
pump discharge pressure (self pressure) (PP)
always applies to the pressure chamber of the
small diameter piston side.
q Output pressure (PEN) of the LS valve applies to
the chamber receiving the pressure at the large
diameter piston end.
q "The relationship in the size of pressure (PP) at
the small diameter piston end and pressure
(PEN) at the large diameter piston end" and "the
ratio between the area receiving the pressure of
the small diameter piston and the large diameter
piston" control the movement of servo piston
(12).
LS valve
Function
q The LS (load sensing) valve detects the load of
the actuator and controls the discharge amount.
q This valve controls main pump delivery (Q) ac-
cording to differential pressure (dPLS) [=(PP)
(PLS)] (called the LS differential pressure) (be-
tween main pump discharge pressure (PP) and
control valve outlet port pressure (PLS).
q Main pump pressure (PP) and pressure (PLS)
(called the LS pressure) coming from the control
valve output, and pressure (PSIG) (called the LS
selector pressure) from the proportional solenoid
valve enter this valve.
q The relationship between the "LS differential
pressure (dPLS) between the main pump pres-
sure (PP) and LS pressure (PLS) [=(PP)
(PLS)]" and "the pump delivery (Q)" changes as
shown in the diagram according to LS selector
current (ISIG) of the LS-EPC valve.
q If (ISIG) changes from 0 A to 1 A, setting force of
the spring changes, too. As the result, the spec-
ified median of the pump delivery volume switch-
ing point changes as shown in the diagram. It will
change in the range of 0.27 to 1.7 MPa {2.78 to
17.75 kg/cm2}.
Operation
When the control valve is situated at neutral
q The LS valve is a 3-way selector valve, and pres- q Pump pressure (PP) is conducted to the large di-
sure (PLS) (LS pressure) from the inlet port of ameter end from the port (K).
the control valve applies to spring chamber (B) q The same pump pressure (PP) is conducted to
and main pump discharge pressure (PP) applies the small diameter end from the port (J).
to port (H) of sleeve (8). q According to the difference in the areas on servo
q The relation between the force resulting from piston (12), the pressure moves in such that the
this LS pressure (PLS), force of spring (4) and swash plate angle may be minimized.
the pump delivery pressure (self pressure) (PP)
determine the position of spool (6).
q However, magnitude of the output pressure
(PSIG) (called the LS selector pressure) of the
EPC valve for the LS valve entering port (G) also
changes the position of spool (6). (Setting force
of the spring is changed)
q Before the engine is started, servo piston (12) is
pushed to the left by the spring. (See the figure)
q If the control lever is in the neutral position when
the engine is started, LS pressure (PLS) will be
set to 0 MPa {0 kg/cm2}. (It is interconnected to
the drain circuit through the control valve spool)
q Spool (6) is pushed to the right, and port (C) and
port (D) will be connected.
q When the difference between the main pump q If the output pressure of the EPC valve for the LS
pressure (PP) and LS pressure (PLS), in other valve enters port (G), rightward force is generat-
words, LS differential pressure (dPLS) becomes ed on piston (7).
smaller (for example, when the area of opening q If piston (7) is pushed to the right, setting force of
of the control valve becomes larger and pump spring (4) is weakened, changing the LS differ-
pressure (PP) drops), spool (6) is pushed to the ential pressure (dPLS) [Difference between oil
left by the combined force of LS pressure (PLS) pressures (PLS) and (PP)] when ports (D) and
and the force of spring (4). (E) of spool (6) are connected.
q When spool (6) moves, port (D) and port (E) are
interconnected and connected with the PC
valve.
q The PC valve is connected to the drain port, so
the pressure across circuits (D) and (K) be-
comes drain pressure (PT). (The operation of the
PC valve is explained later.)
q The pressure at the large diameter end of servo
piston (12) becomes drain pressure (PT), and
pump pressure (PP) enters port (J) at the small
diameter end, so servo piston (12) is pushed to
the left side. Therefore, the swash plate is
moved in the direction to make the discharge
amount larger.
q Let us take the area receiving the pressure at the q Force of spring (4) is adjusted in such that the
large diameter end of the piston as (A1), the area position of the balanced stop of this spool (6)
receiving the pressure at the small diameter end may be determined when (PP) (PLS) = 1.7
as (A0), and the pressure flowing into the large MPa {17.75 kg/cm2} at the median of the speci-
diameter end of the piston as (PEN). fied value.
q If the main pump pressure (PP) of the LS valve q If (PSIG) [Output pressure of LS-EPC valve, 0 to
and the "combined force of spring (4) and LS 2.9 MPa {0 to 30 kg/cm2}] is input to port (G), the
pressure (PLS)" are balanced, and the relation- position of the balanced stop is changed in the
ship is (A0) x (PP) = (A1) x (PEN), servo piston range of (PP) (PLS) = 1.7 to 0.27 MPa {17.75
(12) will stop in that position. to 2.78 kg/cm2} in proportion to (PSIG) pressure.
q The swash plate of the pump will be held at the
intermediate position. [Spool (6) will be stopped
at a position where the distance of the opening
from port (D) to port (E) and the distance from
port (C) to port (D) is almost the same.]
q At this point, the relationship between the both
pressure receiving areas of servo piston (12) is
(A0) : (A1) = 3 : 5, so the pressure applied to the
both piston ends when it is balanced becomes
(PP) : (PEN) C 5 : 3.
PC valve
Function
q When the pump discharge pressure (PP1) q If the engine speed goes below the specified val-
(self-pressure) and (PP2) (other pump pressure) ue because of increased load, the controller
are high, the PC valve controls the pump so that sends a command current to PC-EPC valve so-
the volume of oil beyond the discharge pres- lenoid in order to reduce the swash plate angle
sure-based specific flow rate may not be con- in proportion to reduction in the engine speed.
ducted however you may increase the control
valve stroke. Namely it is intended at controlling
the horsepower for the pumps so that it may not
exceed the engine hosepower.
q If the pump discharge pressure (PP) increases
due to increased load during operation, this
valve decreases the pump delivery.
q And if the pump discharge pressure goes low, it
increases the pump delivery.
q In this case, relation between the mean dis-
charge pressure of the front and rear pumps
[(PP1) + (PP2)]/2 and the pump delivery (Q) will
become as shown in the diagram if the relation is
represented as the parameter of the current val-
ue (X) to be given to PC-EPC valve solenoid.
q The controller continues counting the actual en-
gine speed.
q If the engine speed is slowed down due to in-
creased load, the controller reduces the pump
delivery to recover the speed.
Operation
When pump controller is normal
When the load on the actuator is small and pump discharge pressures (PP1) and (PP2) are low
Action of spring
q Load of springs (4) and (6) on the PC valve is de- q Ports (C) and (D) are connected, and the pres-
termined by the swash plate position. sure entering the LS valve becomes drain pres-
q As servo piston (9) moves to right, spring (6) is sure (PT).
compressed. q If port (E) and port (G) of the LS valve are con-
q If the servo piston moves further to right, it will be nected, the pressure entering the large diameter
contacted against seat (5), and spring (6) will be end of the piston from port (J) becomes drain
fixed (solid). pressure (PT), and servo piston (9) moves to the
q After that, spring (4) alone will operate. left side.
q The spring load is changed by servo piston (9) q The pump delivery will be set to the increasing
as it extends or compresses springs (4) and (6). trend.
q If the command current (X) to PC-EPC valve so- q According to the move of servo piston (9),
lenoid (1) changes, so does the force pushing springs (4) and (6) will be expanded and the
piston (2). spring force decreases.
q Spring force of springs (4) and (6) is also affect- q As the spring force decreases, spool (3) moves
ed by the command current (X) to PC-EPC valve to the right, the connecting between port (C) and
solenoid. port (D) is shut off and the pump discharge pres-
q Port (C) of the PC valve is connected to port (E) sure ports (B) and (C) are connected.
of the LS valve. q As a result, the pressure on port (C) increases
q Self-pressure (PP1) enters port (B) and the small and the pressure on the large diameter end of
diameter end of servo piston (9), and other pump the piston also increases. Thus, the leftward
pressure (PP2) enters port (A). move of servo piston (9) is stopped.
q When pump pressures (PP1) and (PP2) are
small, spool (3) will be positioned in the left side.
When load on actuator is large and pump discharge pressure (PP) is high
Outline
q When the load is large and pump discharge q When spool (3) moves to the left, the openings
pressures (PP1) and (PP2) are high, the force of port (C) and port (D) increase.
pushing spool (3) to the right becomes larger q As a result, the pressure on port (C) (= J) is de-
and spool (3) will be moved to the position creased and the rightward move of servo piston
shown in above figure. (9) is stopped.
q Part of the pressure to be conducted from port q The position in which servo piston (9) stops at
(C) to LS valve flows from port (B) to port (C) and this time is further to the right than the position
(D) via LS valve. At the end of this flow, level of when pump pressures (PP1) and (PP2) are low.
this pressure becomes approximately half of
pump pressure (PP2).
Operation
q When port (E) and port (G) of the LS valve are
connected, this pressure from port (J) enters the
large diameter end of servo piston (9), and servo
piston (9) is stopped.
q If pump pressure (PP2) increases further and
spool (3) moves further to the right, pump pres-
sure (PP1) flows to port (C) and acts to make the
pump delivery the minimum.
q When servo piston (9) moves to the right,
springs (4) and (6) are compressed and push
back spool (3).
As the emergency pump drive switch is turned "ON" due to failure of the pump controller
When the main pump is under light load
q If the emergency pump drive switch is in "ON" q The curve resulting when the emergency pump
position as in above, the command current (X) drive switch is ON is situated further to the left
sent to PC-EPC valve solenoid (1) becomes (B) than when the pump controller is normal (A).
constant.
q For this reason, the force of piston (2) pushing
spool (3) is constant.
q If main pump pressures (PP1) and (PP2) in-
crease, spool (3) moves further to the right than
when the main pump load is light, and is bal-
anced at the position in the figure above.
q In this case, the pressure from port (B) flows to
port (C), so servo piston (9) moves to the right
(smaller pump delivery) and stops at a position
to the further to the right than when the load on
the pump is light.
q When the emergency pump drive switch is
turned on, too, the pump pressure (PP) and
pump delivery (Q) have a relationship as shown
with the curve in the figure corresponding to the
current sent to the PC-EPC valve solenoid
through the resistor.
LS (PC)-EPC valve
C: To LS (PC) valve
P: From self-pressure reducing valve
T: To tank
1. Connector
2. Coil
3. Body
4. Spring
5. Spool
6. Rod
7. Plunger
Function Operation
q The EPC valve consists of the proportional sole-
noid portion and the hydraulic valve portion. When signal current is 0 (coil is de-energized)
q When it receives signal current (i) from the con- q When there is no signal current flowing from the
troller, it generates the EPC output pressure in controller to coil (2), coil (2) is de-energized.
proportion to the size of the signal, and outputs it q Spool (5) is pushed to the left by spring (4).
to the LS (PC) valve. q Port (P) closes and the pressurized oil from the
self-pressure reducing valve does not flow to the
LS (PC) valve.
q The pressurized oil from the LS (PC) valve is
drained to the tank through port (C) and port (T).
When signal current is minute (coil is energized) When signal current is maximum (coil is ener-
q When a minute signal current flows to coil (2), gized)
coil (2) is energized, and a thrust toward the right q As the signal current flows to coil (2), coil (2) is
is generated on plunger (7). energized.
q Rod (6) pushes spool (5) to the right, and pres- q When this happens, the signal current is at its
surized oil flows from port (P) to port (C). maximum, so the thrust of plunger (7) is also at
q Pressure on port (C) increases and the force to its maximum.
act on spool (5) surface and the force of spring q Spool (5) is pushed toward right by rod (6).
(4) become larger than the thrust of plunger (7). q The maximum volume of pressurized oil flows
q Spool (5) is pushed to the left, and port (P) is from port (P) to port (C), increasing the circuit
shut off from port (C). pressure across EPC valve and LS (PC) valve to
q Port (C) and port (T) are connected. the maximum level.
q Spool (5) moves so that the thrust of plunger (7) q Since port (T) is closed, the pressurized oil does
may be balanced with pressure of port (C) + the not flow to the tank.
force of spring (4).
q The circuit pressure between the EPC valve and
the LS (PC) valve is controlled in proportion to
the size of the signal current.
Control valve 58
Outline
q This control valve consists of a 6-spool valve
(one body composition) and a set of service
valve. A merge-divider valve, a back pressure
valve and a boom hydraulic drift prevention
valve are installed to it.
q The ports which are used on PC200-8 but not
used on this machine are not indicated.
q Since all the valves are assembled together with
connecting bolts and their passes are connected
to each other inside the assembly, the assembly
is compact and easy to maintain.
q With one spool provided for one work equip-
ment, this control valve is simple in construction.
A1: To bucket cylinder head P6: From boom PPC and EPC valves
A2: To L.H. travel motor P9: From R.H. travel PPC valve
A3: To boom cylinder bottom P10: From R.H. travel PPC valve
A5: To R.H. travel motor P11: From arm PPC and EPC valves
A6: To arm cylinder head P12: From arm PPC and EPC valves
A-1: To attachment 1 P-1: From service 1 and PPC valves
ATT: From attachment P-2: From service 1 and PPC valves
B1: To bucket cylinder bottom PLS1: To rear pump control
B2: To L.H. travel motor PLS2: To front pump control
B3: To boom cylinder head PLSC: LS pressure detection port
B5: To R.H. travel motor PP1: From front pump
B6: To arm cylinder bottom PP2: From rear pump
B-1: To attachment 1 PP2S: Pressure sensor mounting port
BP1: From LS select solenoid valve PPC: Pilot basic pressure detection port
BP5: From attachment selector solenoid valve PPS1: Pressure sensor mounting port
C: To tank PPS2: To front pump control
IS1: From controller PR: To solenoid valve, PPC valve, and EPC valve
IS2: From controller PST: From travel junction valve solenoid valve
P1: From bucket PPC and EPC valves PX1: From 2-stage relief solenoid valve
P2: From bucket PPC and EPC valves PX2: From 2-stage relief solenoid valve
P3: From L.H. travel PPC valve T: To tank
P4: From L.H. travel PPC valve T1: To tank
P5: From boom PPC and EPC valves TS: To tank
General view
(if equipped with one attachment)
Sectional view
(1/5)
(2/5)
(3/5)
1. Unload valve
2. Safety valve (Boom RAISE)
3. Main relief valve
4. Lift check valve
Arm valve
5. Arm check valve
6. LS shuttle valve
7. Quick return valve
8. Pressure compensation valve (OUT)
9. Spool
10. Safety-suction valve (OUT)
11. Back pressure valve
12. Regeneration circuit check valve
13. Suction valve (IN)
13A. Safety-suction valve (IN)
14. Pressure compensation valve (IN)
(4/5)
(5/5)
Service valve 1
1. LS shuttle valve 5. Safety-suction valve
2. Pressure compensation valve 6. Unload valve
3. Spool 7. Main relief valve
4. 2-stage safety-suction valve 8. LS bypass plug
1. Arm valve
2. R.H. travel valve
3. Boom valve
4. L.H. travel valve
5. Bucket valve
6. Service valve 1
7. Arm spool
8. R.H. travel spool
9. Boom spool
10. L.H. travel spool
11. Bucket spool
12. Service spool 1
13. Pressure compensation valve
14. Suction valve
15. Check valve (for boom regeneration circuit)
16. Check valve (for arm regeneration circuit)
17. EPC valve (for switching main spool of merge-divider valve)
18. EPC valve (for switching LS spool of merge-divider valve)
19. LS shuttle valve
20. Merge-divider valve
21. Arm quick return valve
22. Arm check valve (for central safety valve circuit)
23. Self-pressure reducing valve
24. Travel junction valve
25. Back pressure valve
26. Cooler check valve
27. Boom drift prevention valve
28. Main relief valve (bucket side)
Set pressure: 35.4 0.5 MPa {360.5 5 kg/cm2}
When digging force increased:
38.0 0.5 MPa {387 5 kg/cm2}
29. Main relief valve (arm side)
Set pressure: 35.4 0.5 MPa {360.5 5 kg/cm2}
When digging force increased:
38.0 0.5 MPa {387 5 kg/cm2}
30. Unload valve (bucket side)
Cracking pressure:
2.5 0.5 MPa {26 5 kg/cm2}
31. Unload valve (arm side)
Cracking pressure:
2.5 0.5 MPa {26 5 kg/cm2}
32. Safety-suction valve
Set pressure: 24.5 0.5 MPa {250 5 kg/cm2}
33. Safety-suction valve
Set pressure: 31.4 0.5 MPa {320 5 kg/cm2}
34. Safety-suction valve
Set pressure: 38.2 0.5 MPa {397 5 kg/cm2}
35. 2-stage safety-suction valve
Set pressure:
1 stage: 24.5 0.5 MPa {250 5 kg/cm2}
2 stage: 20.6 0.5 MPa {210 5 kg/cm2}
Unload valve
When the unload valve is actuating
Function Operation
q Drains an oil delivery for the portion of the mini- q Pressure of pump circuit (3) is received by the
mum pump swash plate angle while all control end of valve (2).
valves are in the holding. q Since the control valve is in neutral position,
q The pump pressure will correspond to a set load pressure of LS circuit (1) is 0 MPa {0 kg/cm2}.
of spring (5) inside the valve (this pressure will q Pressurized oil of pump circuit (3) stops at valve
be P1). (2), and the pressure rises as no relief is avail-
q Since LS pressure is drained from the LS bypass able.
valve, LS pressure C tank pressure C 0 MPa {0 q When this pressure becomes larger than the
kg/cm2}. force of spring (5), valve (2) moves to the left.
q Ports (b) and (c) are interconnected and the
pump pressure flows to tank circuit (4).
q The pressurized oil of LS circuit (1) passes from
orifice (a) through port (c) and is drained to the
tank circuit (4).
q When actuated, LS pressure C tank pressure.
q Since the pump discharge pressure LS circuit
pressure during unloading is larger than the
pump LS control pressure, the signal is output to
minimize the pump swash plate angle.
Introduction of LS pressure
1. Main pump
2. Main spool
3. Pressure compensation valve
4. Valve
5. Check valve
6. LS circuit
7. LS shuttle valve
Function
q Introduces the upstream pressure (downstream
pressure of the spool meter-in) of pressure com-
pensation valve (3) and leads to LS shuttle valve
(7) as the LS pressure.
q Connected to actuator port (B) through valve (4),
and makes LS pressure C actuator load pres-
sure.
q Inlet pore (a) inside main spool (2) has a small
diameter concurrently serving as a throttle.
Operation
q When main spool (2) is operated, the pump pres-
sure enters port (c) through inlet pore (a) and is
led to the LS circuit.
q When the pump pressure rises to reach the load
pressure of port (B), check valve (5) opens.
LS bypass valve
1. Main pump
2. Main spool
3. Pressure compensation valve
4. LS shuttle valve
5. LS bypass valve
6. LS circuit
Function
q Releases the residual pressure in LS pressure
circuit (6) from orifices (a) and (b).
q Slows down the rising rate of LS pressure to pre-
vent a sudden change of hydraulic pressure.
q Bypass flow from LS bypass valve (5) causes a
pressure loss to be generated due to the circuit
resistance between throttle (c) of main spool (2)
and LS shuttle valve (4).
q Effective LS differential pressure drops to im-
prove a dynamic stability of the actuator.
When compensated
(If the load pressure is lower than other work equipment during a combined operation)
Function
q The pressure compensation valve closes under
LS pressure of port (D), and the spool meter-in
downstream pressure of port (B) becomes
equivalent to the maximum pressure of other
work equipment.
q Since the spool meter-in upstream pressure of
port (A) is the pump pressure, the spool meter-in
differential pressure [upstream pressure port (A)
pressure] downstream pressure [port (B) pres-
sure] becomes equivalent to all the spools in op-
eration.
q Pump flow is divided according to the ratio of the
meter-in opening area.
Operation
q Spring chamber (E) is interconnected to port (D).
q Piston (4) and valve (2) operate in the closing di-
rection (to the right) under the LS circuit pressure
from other work equipment of port (F).
q Valve upstream pressure (= spool meter-in
downstream pressure) of port (B) is controlled
with LS pressure.
Function
q The state of division changes according to the
area ratio of pressure compensation portion (A1)
and (A2). Area ratio = (A2)/(A1)
q If area ratio = 1:
The spool meter-in downstream pressure will be
equal to the maximum load pressure, and the
pressure will be divided according to the opening
area ratio.
q If area ratio = 1 or over:
The spool meter-in downstream pressure will be
greater than the maximum load pressure, and
the pressure will be divided smaller than the
opening area ratio.
q If area ratio = 1 or under:
The spool meter-in downstream pressure will be
smaller than the maximum load pressure, and
the pressure will be divided greater than the
opening area ratio.
1. Main pump
2. Valve
3. Pressure compensation valve inner shuttle valve
4. Piston
Function
q Shuttle valve (3) is pushed to the right by port (A)
pressure and cuts off interconnection between
ports (A) and (C).
q Holding pressure at port (A) is led to the spring
chamber (B) to push piston (4) to the left so that
piston (4) and valve (2) will not be separated.
Outline
q Since no holding pressure is generated at port
(A) of the travel circuit, a pressure compensation
valve without shuttle valve (3) is adopted.
Function Operation
q Provides the regeneration circuit from the cylin- q If the cylinder head pressure is lower than the
der bottom to the cylinder head when the boom bottom pressure, pressurized oil (A) from the cyl-
is lowered and increases flow to the cylinder inder bottom flows to drain circuit (B) from the
head. notch of boom spool (2).
q On the other hand, remaining oil flows to regen-
eration circuit (C), opens check valve (6) and
flows to the cylinder head through circuit (D).
q Flow from regeneration circuit (C) and pump (1)
merges in circuit (E).
If the cylinder head pressure is higher than the bottom pressure (digging work, etc.)
Function
q Check valve (6) provided to regeneration circuit
(C) closes to shut off the flow from the cylinder
bottom to the head.
Function Operation
q During arm digging, regeneration circuit provid- q If the cylinder head pressure is lower than the
ed from the cylinder head to the bottom increas- bottom pressure, pressurized oil (A) from the cyl-
es the cylinder speed as the cylinder flow inder bottom flows to drain circuit (B) from the
involves the pump delivery plus regenerated notch of arm spool (2).
flow. q On the other hand, remaining oil flows to regen-
eration circuit (C), opens check valve (6) and
flows to the cylinder bottom through circuit (D).
q Flow from regeneration circuit (C) and pump (1)
merges in circuit (E).
Function
q Check valve (6) provided to regeneration circuit
(C) closes to shut off the flow from the cylinder
bottom to the head.
Merge-divider valve
When flows from the pumps merge [if merge-divider selector signals (IS1) and (IS2) are OFF]
Function Operation
q Merges pressurized oil (P1) and (P2) discharged q Since selector signal (IS1) is OFF, output pres-
from the two pumps or divides (to respective sure from EPC valve is 0 MPa {0 kg/cm2}.
control valve group). q Main spool (1) is pressed to the right by spring
q Merges and divides LS circuit pressure. (2) and ports (E) and (F) are interconnected.
q Merges pressurized oil (P1) and (P2) discharged
from the two pumps at ports (E) and (F) and
sends to necessary control valve.
q Since selector signal (IS2) is OFF for LS spool
(3), it is pressed to the right by spring (4), and
ports (A) (D) and ports (B) (C) are intercon-
nected.
q Forwards LS pressure led from respective con-
trol valve spools to LS circuits (5), (6), (7) and (8)
to all the pressure compensation valves.
When flows from the pumps divide [if merge-divider selector signals (IS1) and (IS2) are ON]
Operation
q Selector signal (IS1) turns ON, and output pres-
sure from the EPC valve shifts main spool (1) to
the left, and ports (E) and (F) are divided.
q Pressurized oil discharged from the two pumps
are sent to respective control valves.
P1 pressure: To bucket, L.H. travel, and boom
P2 pressure: To swing, R.H. travel, and arm
q When selector signal (IS2) is turned ON, LS
spool (3) also shifts to the left under the output
pressure from the EPC valve, interconnects
ports (A) and (C) and divides other ports.
q Forwards LS pressure led from each control
valve spool to LS circuits (5), (6), (7) and (8) to
respective control valves.
Function
q Reduces the discharge pressure of the main
pump and supplies it as control pressure for the
solenoid valves, EPC valves, etc.
Operation
During neutral and when load pressure (P2) When load pressure (P2) is high
is low q Load pressure (A2) increases with the operation
a When load pressure (A2) is lower than self-pres- of digging, etc., and the pump delivery increases
sure reducing valve output pressure (PR) accordingly.
q Pressure (P2) increases to [(fd area x P2 pres-
q Valve (7) is pressed to the closing direction of sure) > force of spring (8) + (fd area x PR pres-
circuit between ports (P2) and (A2) by spring (8) sure)], and valve (7) moves to the right to the
and under pressure (PR) (which is 0 MPa stroke end.
{0 kg/cm2}). q As a result, opening between ports (P2) and (A2)
q When pressurized oil flows in from port (P2), a increases, and the pass resistance reduces, re-
balance is reached due to [(fd area x P2 pres- ducing the engine horsepower loss.
sure) = force of spring (8) + (fd area x PR pres- q When pressure (PR) rises above the set pres-
sure)]. sure, poppet (11) opens.
q Adjusts valve (7) opening to keep pressure (P2) q Pressurized oil flows from port (PR) to orifice (a)
at a constant level over pressure (PR). in spool (14), then flows to seal drain port (TS)
q When pressure (PR) rises above the set pres- from poppet (11) opening.
sure, poppet (11) opens. q Differential pressure is generated before and af-
q Pressurized oil flows from port (PR) to orifice (a) ter orifice (a) in spool (14) and then spool (14)
in spool (14), then flows to seal drain port (TS) moves to close the pass between ports (P2) and
from poppet (11) opening. (PR).
q Differential pressure is generated before and af- q Pressure (P2) is reduced by the opening at this
ter orifice (a) in spool (14) and then spool (14) time and adjusted to a constant pressure (the set
moves to close the pass between ports (P2) and pressure) and supplied as pressure (PR).
(PR).
q Pressure (P2) is reduced by the opening at this
time and adjusted to a constant pressure (the set
pressure) and supplied as pressure (PR).
Function Operation
q This valve connects the L.H. and R.H. travel cir- q Pilot pressure from the travel junction solenoid
cuits through travel junction valve so that the hy- valve contracts spring (1), and travel junction
draulic oil will be supplied evenly to both travel spool (2) moves to the left to the stroke end.
motors to improve machine's straight travel per- q Junction circuit between port (PTL) (L.H. travel
formance. circuit) and port (PTR) (R.H. travel circuit) is
q When the machine is steered, outside pilot pres- closed.
sure (PST) closes the travel junction valve to im-
prove steering performance.
Operation
q If pilot pressure (PST) from the solenoid valve is q If the oil flow rates to the L.H. and R.H. travel mo-
0 MPa {0 kg/cm2}, travel junction spool (2) is tors become different from each other, the oil
pressed by the force of spring (1) against the flows through the route between port (PTL), trav-
right side and the pass between ports (PTL) and el junction spool (2), and port (PTR) so that the
(PTR) is open. oil flow rates to both motors will be equalized
again.
Function Operation
q Regulates flow to each cylinder by controlling q The oil in stroke regulation signal chamber (a) is
the stroke of each spool of the boom, arm, and drained through orifices (5) and (6) of pistons (3)
bucket using the pilot pressure of travel PPC and (4) in the travel spring case and the travel
valve while climbing a steep grade, operating the PPC valve.
boom RAISE, arm IN and OUT, and bucket q When operated for boom RAISE (or arm IN and
CURL and Dump. OUT, bucket CURL and DUMP), spool (1)
q When controlling the stroke of the boom, arm moves to the left until it makes contact with the
and/or bucket, pilot pressure of travel PPC valve end face of spring casing (2) (st0).
passes through the circuit inside the control
valves to actuate the system.
When traveling
Operation
q If the right travel lever is set in the reverse (or for-
ward) direction, pilot pressure from the PPC
valve presses spool (7) to the left (or right).
q Spool (7) pushes piston (3) to close orifice (5)
and shut off stroke regulation signal chamber (a)
and the drain circuit of the travel PPC valve.
q At this time, the right travel reverse (or forward)
lever is set, PPC pressure is applied through or-
ifice (6) of piston (4) to the left end of piston (8)
to push piston (8) to the right.
q When operated for boom RAISE (or arm IN and
OUT, bucket CURL and DUMP), spool (1) moves
to the left.
q Maximum stroke of the spool is limited to (st1) for
the amount of movement (st2) of piston (8) to the
right.
Function
q This valve prevents the oil in the boom cylinder
bottom from leaking through spool (1) and the
boom from lowering under its weight while the
boom lever is not operated.
Operation
q When the boom is raised, pressurized oil from
the control valve works on the ring-shaped area
(S) caused by the difference between outside di-
ameter (d1) of poppet (5) and seat diameter (d2)
to move it to the left.
q Contracts spring (4) and poppet (5) moves to the
left.
q As a result, pressurized oil from the control valve
passes through the opening of poppet (5) and
flows to the bottom end of the boom cylinder.
Operation
q Moves the lever to neutral with the boom raised.
q Pressurized oil flown inside poppet (5) from ori-
fice (a) of poppet (5) is closed by pilot piston (2).
q Pressurized oil from the control valve and the
holding pressure of the boom cylinder bottom
are shut off.
q The holding pressure of boom cylinder bottom
works on the ring-shaped area (S) caused by the
difference between outside diameter (d1) of pop-
pet (5) and seat diameter (d2) to move it to the
right.
q The sum of this force and the force of spring (4)
closes poppet (5).
q Pressurized oil from the control valve and the
holding pressure of the boom cylinder bottom
are shut off.
Operation
q When the boom is lowered, pilot pressure from
the PPC valve presses pilot piston (2).
q Pressurized oil in chamber (b) inside the poppet
is drained through orifice (c).
q Pressurized oil of the boom bottom flows to ori-
fice (a) o chamber (b) o orifice (c) o drain (T),
and the pressurized oil in chamber (b) lowers.
q As the pressure of chamber (b) lowers under the
pressure of port (B), poppet (5) opens.
q Pressurized oil from port (B) is led to port (A) and
then flows to the control valve.
Function
q This valve prevents the oil in the arm head from
leaking through spool (1) and the boom from
lowering under its weight while the arm lever is
not operated.
Operation
q When the arm OUT is operated, pressurized oil
from the control valve works on the ring-shaped
area (S) caused by the difference between the
outside diameter (d1) of poppet (5) and the seat
diameter (d2) to move it to the left.
q Contracts spring (4) and poppet (5) moves to the
left.
q As a result, pressurized oil from the control valve
passes through the opening of poppet (5) and
flows to the arm cylinder head.
Operation
q Moves the lever to neutral with the arm OUT.
q Pressurized oil flown inside poppet (5) from ori-
fice (a) of poppet (5) is closed by pilot piston (2).
q Pressurized oil from the control valve and the
holding pressure of the arm cylinder head are
shut off.
q The holding pressure of arm cylinder head works
on ring-shaped area (S) caused by the differ-
ence between outside diameter (d1) of poppet
(5) and seat diameter (d2) to move it to the right.
q The sum of this force and the force of spring (4)
closes poppet (5).
q Pressurized oil from the control valve and the
holding pressure of the arm cylinder head are
shut off.
When arm IN
Operation
q When the arm IN is operated, pilot piston (2) is
pushed under the pilot pressure from the PPC
valve.
q Pressurized oil in chamber (b) inside the poppet
is drained through orifice (c).
q Pressurized oil of the arm head flows to orifice
(a) o chamber (b) o orifice (c) o drain (T), and
the pressurized oil in chamber (b) lowers.
q As the pressure of chamber (b) lowers under the
pressure of port (B), poppet (5) opens.
q Pressurized oil from port (B) is led to port (A) and
then flows to the control valve.
Function Operation
q When arm OUT, large volume of oil returns from q When the arm OUT is operated, pilot spool (1) is
the cylinder bottom. pushed under the pilot pressure from the PPC
q Reduces this pressure loss. valve.
q Pressurized oil in chamber (b) inside the valve is
drained through orifice (c).
q Pressurized oil of the arm bottom side flows to
orifice (a) o chamber (b) o orifice (c) o drain
(T), and the pressure in chamber (b) lowers.
q If the pressure of chamber (b) drops lower than
that of port (A), pressure receiving force of the
pressure receiving portion [fd2 area (S2) (seat
diameter area)] on the side of port (A) increases
by the sum of the pressure receiving force of
pressure receiving portion [fd1 area (S1)] on the
chamber (b) side of valve (2) and the spring
force.
q Or (fd2 pressure receiving force > fd1 pressure
receiving force + spring force)
q Valve (2) is pressed to the right and pressurized
oil is led from port (A) to (B).
q From port (B), pressurized oil is drained directly
to the tank.
Operation
q Returning the lever to neutral reduces the pilot
pressure from the PPC valve to 0 MPa {0 kg/cm2}.
q The pressurized oil that has flowed and been
drained through orifice (a) in valve (2) is closed
by pilot piston (1).
q The holding pressure on the arm bottom side
works on the difference between areas (S2) and
(S1) of valve (2) to the left.
q Valve (2) is closed by the total of this force and
the force of spring (3), so ports (A) and (B) are
shut off.
1. Spring
2. Poppet
Function
q Set pressure of the relief valve is in two stages.
q When power is needed, pilot pressure (P) is
turned ON and the set pressure becomes high-
er.
Operation
q The set pressure of relief valve is determined by
spring (1) installed load. (1st stage)
q Respective setting is not required for both the 1st
and 2nd stages. Setting the 1st stage completes
the setting of the 2nd stage.
1. Spring
2. Piston
3. Spring
4. Holder
Operation
q The safety valve set pressure is determined by
spring (1) installed load.
Type: HMV110ADT-2
1. Regulator piston
2. Spring
3. Regulator valve
4. Motor case
5. Suction-safety valve spring
6. Check valve
7. Output shaft
8. Rocker cam
9. Retainer guide
10. Pin
11. Retainer
12. Piston
13. Cylinder block
14. Valve plate
15. Counterbalance valve
16. Ring
17. Brake piston
18. Plate
19. Disc
20. Ball
Operation of motor
At slow speed (motor swash plate angle at maximum)
q As the solenoid valve is de-energized, the pilot q The combined force of the piston propulsion
pressurized oil from the self-pressure reducing forces works as the moment to incline rocker
valve does not flow to port (P). cam (4) toward the maximum swash plate angle.
q Regulator valve (9) is pushed to the right by q The pressurized oil at regulator piston (15) pass-
spring (10). es through orifice (c) of regulator valve (9) and is
q Pressurized oil being transmitted from the con- drained in the motor case.
trol valve to end cover (8) by pressing check q Rocker cam (4) is inclined in the maximum
valve (22) is shut off by regulator valve (9). swash plate angle direction. The motor capacity
q Fulcrum (a) of rocker cam (4) is eccentric to the becomes maximum, turning on the low speed
working point (b) of the combined force of the travel.
propulsion force of cylinder (6).
q The pressurized oil on the supply side flows to Operation of brake during travelling downhill
chamber (S1) through orifice (E1) and orifice q If the machine runaway is sensed while it travels
(E2) of the spool (19). down a slope, the motor will be caused to run
q As the pressure in chamber (S1) goes above the idle and the inlet side oil pressure will be de-
spool selector pressure, spool (19) is pushed to- creased.
ward the right. q Pressure in chamber (S1) is released through or-
q Port (MB) and port (PB) are connected, opening ifices (E1) and (E2).
the motor outlet port side and starting the motor q As the pressure in chamber (S1) become lower
rotating. than the spool selector pressure, spool (19) is re-
turned to the left by spring (20) and outlet port
(MB) is throttled.
q The pressure at the outlet port side rises, gener-
ating rotation resistance on the motor to prevent
the machine from a runaway.
q The spool moves to a position where the pres-
sure on outlet port (MB) can be balanced against
the machine's own weight and the inlet port pres-
sure.
q Oil flow from the outlet circuit is restricted to en-
sure the travel speed corresponded to the pump
delivery.
Operation
During machine stops (or when travelling down-
When starting travel (or when traveling at a con-
hill) (Right turn)
stant speed)
q Reduction of the pressure at motor inlet (PA) de-
q As the travel lever is operated, the pressurized
creases the pressure in chamber (S1).
oil from the pump moves spool (19) toward the
q When it drops beyond the spool selector pres-
right.
sure, spool (19) is returned to the left by spring
q The passage to the suction-safety valve func-
(20), reducing the pressure at outlet passage
tions as a circuit which passes through notch
(B1).
(B2) of spool (19), producing large differential
q The motor tries to continue rotation with inertial
pressure.
force, thus pressure on the outlet port (MB) is in-
q The pump pressure rises, providing a large trac-
creased.
tional force to the valve.
PPC valve 17
1. Spool
2. Piston
3. Disc
4. Nut (for lever connection)
5. Joint
6. Plate
7. Retainer
8. Body
9. Filter
Operation
When in neutral q The relationship of the position of spool (1) and
q Ports (A) and (B) of the control valve and ports body (10) [fine control hole (f) is in the middle be-
(P1) and (P2) of the PPC valve are connected to tween drain chamber (D) and pump pressure
drain chamber (D) through fine control hole (f) in chamber (PP)] does not change until retainer (9)
spool (1). contacts spool (1).
q Metering spring (2) compresses in proportion to
the stroke of the control lever.
q Pressure at port (P1) also rises in proportion to
the stroke of the control lever.
q In this way, the control valve spool moves to a
position where the pressure of chamber (A)
[same as pressure at port (P1)] and the force of
the return spring of the control valve spool are
balanced.
1. Plate 5. Valve
2. Body 6. Damper
3. Piston 7. Steering signal spool
4. Collar
Pressure reducing valve function q The relationship of the position of spool (1) and
Operation body (10) [the position of fine control hole (f) is in
When in neutral the middle between drain chamber (D) and
q Ports (A) and (B) of the control valve and ports pump pressure chamber (PP)] does not change
(P1) and (P2) of the PPC valve are connected to until retainer (9) contacts spool (1).
drain chamber (D) through fine control hole (f) in q Metering spring (2) compresses in proportion to
spool (1). the stroke of the control lever.
q Pressure at port (P1) also rises in proportion to
the stroke of the control lever.
q In this way, the control valve spool moves to a
position where the pressure of chamber (A)
[same as pressure at port (P1)] and the force of
the return spring of the control valve spool are
balanced.
During fine control q Therefore, the pilot pressure oil from the
(When control lever is returned) self-pressure reducing valve passes through fine
q When lever (5) starts to be returned, spool (1) is control hole (f) and flows to chamber (A) from
pushed up by the force of centering spring (3) port (P1) to push the control valve spool.
and pressure at port (P1). q The oil returning from chamber (B) passes from
q Because of this, fine control hole (f) is connected port (P2) through fine control hole (f') and flows
to drain chamber (D), and the pressurized oil at to drain chamber (D).
port (P1) is released.
q If the pressure of port (P1) is lowered excessive-
ly, spool (1) is pushed down by metering spring
(2).
q Fine control hole (f) is shut off from drain cham-
ber (D), and it is almost simultaneously intercon-
nected to pump pressure chamber (PP).
q Pump pressure is supplied until the pressure at
port (P1) recovers to the level equivalent to the
control lever position.
q When the spool of the control valve returns, the
oil in drain chamber (D) flows in from fine control
hole (f') in the valve on the side that is not work-
ing. The oil passes through port (P2) and enters
chamber (B) to replenish the chamber with pres-
surized oil.
Travel signal
q If either of the L.H. or R.H. travel levers is oper-
ated, the higher PPC valve output pressure of
both sides is output as the travel signal.
q Accordingly, whether the machine is traveling is
judged by the signal of port (P5).
Steering signal
q If the operation quantities of both levers are dif-
ferent from each other as in the steering opera-
tion, the higher one of the PPC valve output
pressures of both sides is output as the steering
signal.
At full stroke q Any signal is not output from port (P6) while the
q Lever (5) pushes down piston (4), and retainer machine is travelling straight (forward or re-
(9) moves spool (1) downward. verse) or in the neutral position.
q Fine control hole (f) is shut off from drain cham- q Accordingly, whether the machine is being
ber (D), and is interconnected to pump pressure steered is judged by the signal of port (P6).
chamber (PP).
Operation
At the neutral position
a The Illustration shows the circuit for travelling left forward (slow) and right forward (fast) operation.
q If the operation quantities of both levers are dif- q Port (P4) pressure of the L.H. or R.H. PPC
ferent from each other as in the steering opera- valves, whichever having a higher output pres-
tion (if the difference of the pilot pressure sure, is output to port (P6) as the steering signal.
between both sides is higher than a certain lev-
el), the pilot pressure is output as the steering
signal.
q The pressure in left spring chamber (k) of steer-
ing signal spool (j) is (P2).
q The pressure in right spring chamber (l) is (P4).
q When the pressure reaches [(P4 P2) x (Spool
cross-sectional area) > Spring set load], the
spool shifts to the direction of the arrow.
a The illustration shows the circuit for travelling left reverse and right forward.
a For the details of operation, see the paragraph of Work equipment and swing PPC valve.
1. Spool
2. Piston
3. Lever
4. Plate
5. Retainer
6. Block
7. Body
8. EPC valve
EPC valve
Function Operation
q The EPC valve consists of the proportional sole-
noid portion and the hydraulic valve portion. When signal current is 0
q When it receives signal current (i) from the pump (coil is de-energized)
controller, it generates the EPC output pressure q When there is no signal current flowing from the
in proportion to the size of the signal, and out- controller to coil (14), coil (14) is de-energized.
puts it to the control valve. q Spool (11) is pushed to the right by spring (12).
q Port (P) closes and the pressurized oil from the
front pump does not flow to the control valve.
q The pressurized oil from the control valve is
drained to the tank through port (C) and port (T).
a For the details of operation, see the paragraph of Work equipment and swing PPC valve.
For PPC lock, travel junction, travel speed, swing brake, and 2-stage relief solenoid valves
T: To tank
A1: To PPC valve
A2: To main valve (2-stage relief valve)
A3: To swing motor
A4: To L.H. and R.H. travel motors
A5: To main valve (Travel junction valve)
P1: From main pump
ACC: To accumulator
Operation
When solenoid is de-energized
q Since the signal current does not flow from the
controller, solenoid (8) is de-energized.
For this reason, spool (9) is pushed to the left by
spring (11).
Since the pass from port (P) to port (A) is closed,
pressurized oil from the main pump does not
flow to the actuator.
At this time, the oil from the actuator is drained
through ports (A) and (T) into the tank.
ACC: To accumulator
ATT: To attachment
P1: From attachment selector solenoid valve
T: To hydraulic tank
TS: To hydraulic tank
V: To control valve
1. Spool
2. Spring
For breaker
1. Cover 4. O-ring
2. Slipper seal 5. Shaft
3. Body
Accumulator 143
1. Gas plug
2. Shell
3. Poppet
4. Holder
5. Bladder
6. Oil port
Specifications
Gas capacity: 300 cc (for PPC)
Electrical system 14
Function
q This function allows the machine to select engine torque (T) and pump absorption torque depending on
the type of work. Five modes of P, E, L, B, and ATT (three modes of P, E, and L for machines with "No
ATT" specified) are set as working modes.
q Select working mode with the working mode switch of the machine monitor. The inverter controls the en-
gine speed and pump absorption torque according to the lever operation quantity and operation pattern.
q The inverter controls the pump so that the pump will absorb all the torque at each engine output point ac-
cording to the pump absorption torque set for each mode, speed set with the fuel control dial and actual
engine speed.
Control method in each mode
P mode, E mode and ATT mode
q Matching point:
Function
q The machine is matched to various types of work
properly with the 2-stage relief function to in-
crease the digging force, etc.
Cut-off function
q This function increases PC-EPC current (J) to
reduce the flow rate in the relief state, improving
fuel consumption.
Operating condition for turning on cut-off function
When the average value of the front and rear pressure
sensors is 27.9 MPa {285 kg/cm2} or more with the
one-touch power maximizing function off.
The cut-off function does not work, however, while the
machine is travelling in P mode, swing lock switch is in
the ON position.
Function
q The one-touch power maximizing function al-
lows the operator to increases power for a cer-
tain time by operating the left knob switch.
q This function is used to increase digging force for
a certain period of time (e.g., when digging up a
large rock).
q Pressing the L.H. knob switch in P, E or ATT
mode increases a hydraulic force by approxi-
mately 7% and horsepower by approximately
3%, increasing a digging force.
At this time, each function is automatically set as
shown below.
q These settings are automatically reset after 8.5
seconds when the switch is pressed.
Function Setting
Matching at rated
Engine and pump control
output point
34.8 MPa {355 kg/cm2}
2-stage relief function O
37.2 MPa {380 kg/cm2}
Software cut-off function Cancel
Auto-deceleration function
Function
q The auto-deceleration function automatically re- When any control lever is operated
duces the engine speed to its medium speed q If any control lever is operated while the engine
range when the all control levers are set in the speed is kept at the deceleration speed, the en-
NEUTRAL position while waiting for a dump gine speed increases immediately in accor-
truck or work to reduce the fuel consumption and dance with the lever operation quantity.
noise.
q If the control lever is operated, the engine speed
increases immediately in accordance with the le-
ver operation quantity. At this time, the engine
speed upper limit is set with the fuel control dial.
Operation
When control levers are set in the neutral posi-
tion
q If the all control levers are set in the neutral po-
sition while the machine is working/traveling with
the auto-deceleration function is ON, the engine
speed decreases to the waiting speed
(1,250 rpm) temporarily. If the machine is kept Engine speed when auto-deceleration is ON
under this condition for 4 seconds, the engine Working mode Engine speed
speed decreases further to the deceleration P 1st stage 2nd stage
speed (about 700 rpm) and keeps at that speed E 1,250 rpm o 700 rpm
until any lever is operated. Without deceleration
q If the capacitor voltage decreases during decel- L
function
eration, the engine speed increases to B 1,400 rpm
1,150 rpm to charge the capacitor. After the ca- 1st stage 2nd stage
pacitor is charged, the engine speed decreases ATT
1,250 rpm o 700 rpm
to about 700 rpm.
Auto-warm-up function
Function
q After the engine is started, if the engine coolant temperature is low, the engine speed is raised automati-
cally to warm up the engine
Operating condition (All of following conditions) Operation
Coolant temperature: Below 30C
Engine speed: 1,200 rpm
Engine speed: Max. 1,200 rpm
Function
The swing lock and swing brake function are provid-
ed as a swing control function.
Swing lock and swing holding brake function Quick hydraulic oil warm-up function when
q The swing lock function (manual) is used to lock swing lock switch is in the ON position
machine from swinging at any position. The q If swing lock switch (2) is in the ON position, the
swing holding brake function (automatic) is used pump cut-off function is cancelled and the relief
to prevent hydraulic drift after the machine stops pressure rises from 34.8 MPa {355 kg/cm2} to
swinging. 37.2 MPa {380 kg/cm2}.
q Operation of swing lock switch and swing lock/ If the work equipment circuit is relieved under
swing holding brake this condition, the hydraulic oil temperature rises
Swing quickly and the warm-up time can be shortened.
Swing
lock Function Operation
lock lamp
switch
If swing lever is moved to
the neutral position,
Swing swing brake operates in
OFF OFF holding about 5 sec.
brake If swing lever is operated,
brake is released and
machine can swing freely
Swing lock operates and
machine is locked from
swinging.
Swing
ON ON Even if swing lever is
lock
operated, swing lock is
not reset and machine
does not swing.
Function
q The machine is provided with a function that en-
sures travel performance best fit to the type of
work and jobsite by controlling pumps during
travel or allowing operator to change travel
speed automatically or manually.
Function
q This function is available only with attachment
specification.
q The function acts as follows according to the flow
command and working mode from the monitor.
1) It throttles the attachment PPC pressure and
controls the flow when the pedal is
depressed fully.
2) Attachment operation switches depending on
the working mode as shown below.
Working mode Attachment operation
ATT Double-acting
B Single-acting
CN-CE01 CN-CE02
Signal Signal
Pin No. Signal name Pin No. Signal name
category category
28 NC (*) 13 NC (*)
29 NC (*) 14 NC (*)
30 NC (*) 15 NC (*)
31 NC (*) 16 NC (*)
32 IMA return C 17 NC (*)
33 5 V electric power supply for sensor A 18 NC (*)
34 NC (*) 19 NC (*)
35 NC (*) 20 NC (*)
36 NC (*) 21 NC (*)
37 5 V electric power supply for sensor A 22 Fuel control dial (+5 V) A
38 (GND) C 23 Fuel control dial () C
39 NC (*) 24 NC (*)
40 NC (*) 25 NC (*)
41 NC (*) 26 NC (*)
42 NC (*) 27 NC (*)
43 NC (*) 28 NC (*)
44 Boost pressure sensor B 29 NC (*)
45 Injector #1 (+) D 30 NC (*)
46 Injector #3 (+) D 31 NC (*)
47 Bkup sensor () C 32 NC (*)
48 Ne sensor () C 33 GND C
49 NC (*) 34 NC (*)
50 NC (*) 35 NC (*)
51 NC (*) 36 NC (*)
52 Injector #4 () C 37 NC (*)
53 Injector #1 () C 38 NC (*)
54 NC (*) 39 Key switch (ACC) B
55 Injector #4 (+) D 40 Electrical intake air heater relay drive D
56 NC (*) 41 NC (*)
57 Injector #2 (+) D 42 Electrical intake air heater relay return C
58 NC (*) 43 NC (*)
59 Injector #2 () C 44 NC (*)
60 Injector #3 () C 45 NC (*)
46 CAN(+) E
*: Never connect to NC, or malfunctions or failures will
occur. 47 CAN () E
48 NC (*)
49 PWM OUTPUT D
CN-CE02 50 NC (*)
Signal
Pin No. Signal name *: Never connect to NC, or malfunctions or failures will
category
1 NC (*) occur.
2 NC (*)
3 NC (*) CN-CE03
4 NC (*) Signal
Pin No. Signal name
5 NC (*) category
6 NC (*) 1 GND C
7 NC (*) 2 NC (*)
8 NC (*) 3 Electric power supply (+24 V constantly) A
9 Fuel control dial (+) B 4 NC (*)
10 NC (*)
*: Never connect to NC, or malfunctions or failures will
11 NC (*) occur.
12 NC (*)
Pump controller
CN-C02
Pin No. Signal name Input/output
82 NC (*)
83 NC (*)
84 NC (*)
85 NC (*)
86 ATT circuit selector solenoid Output
87 Travel speed solenoid Output
88 LS-EPC Output
89 Merge-devider (LS) EPC Output
90 NC (*)
91 NC (*)
92 NC (*)
93 NC (*)
94 NC (*)
95 NC (*)
96 PC-EPC (F) Output
97 Service flow adjustment EPC Output
98 NC (*)
99 NC (*)
100 NC (*)
101 Swing holding brake solenoid Output
102 NC (*)
103 NC (*)
104 PC-EPC (R) Output
105 NC (*)
106 NC (*)
107 NC (*)
108 Battery relay Output
109 2-stage relief solenoid Output
110 Travel junction SOL Output
111 NC (*)
112 Merge-divider (main) EPC Output
113 NC (*)
114 Wiper motor () Output
115 Solenoid GND Input
116 Solenoid power Input
117 Solenoid GND Input
118 Solenoid power Input
119 Wiper motor(+) Output
120 Solenoid GND Input
121 Solenoid power supply Input
1. Knob 4. Ball
2. Dial 5. Potentiometer
3. Spring 6. Connector
Function
q The fuel control dial is installed on the machine
monitor side.
q Turning knob (1) rotates the shaft of potentiome-
ter (5).
q The rotation of the shaft changes the resistance
of the variable resistor in potentiometer (5),
sending any throttle signal to the engine control-
ler.
q The hatched area in the graph below is the ab-
normality detection area. If the throttle voltage is
within the area, a fuel control dial error is detect-
ed and the engine speed cannot be controlled
with the dial.
1. Connector
2. Sensor
3. O-ring
Specifications 10-190
Function 10-190
1. Plug
2. Switch
3. Connector
Specifications 10-191
Function 10-191
Inverter
Machine monitor
Input/output signal
070-18P (1) [CN-CM01]
Input/Output Input/Output
Pin No. Signal name Pin No. Signal name
signal signal
1 Unswitched power supply (24 V) Input 10 NC (*)
2 Unswitched power supply (24 V) Input 11 Battery charge Input
3 GND (unswitched power supply) 12 GND (machine analog signal)
4 GND (unswitched power supply) 13 Lamp switch Input
5 Wake-up Input/output 14 Starting switch ACC signal Input
Starting motor cut-out relay (for 15 Starting switch C signal Input
6 Output 16 Preheating Input
personal code)
7 NC (*) 17 NC (*)
8 NC (*) 18 NC (*)
9 Fuel level Input
*: Never connect any cable to NC, or malfunctions or failures will occur.
B60-8P [CN-CM05]
Input/Output Input/Output
Pin No. Signal name Pin No. Signal name
signal signal
1 Camera power supply (8 V) Output 5 GND (Camera power supply)
2 Camera NTSC signal 1 Input 6 GND (Camera signal 1)
3 Camera NTSC signal 2 Input 7 GND (Camera signal 2)
4 Camera NTSC signal 3 Input 8 GND (Camera signal 3)
Display
A: Standard screen
B: All indicators light-up screen
q If problems indicated by monitors (15) to (20) occur after starting the engine, the corresponding monitors
are displayed from the left top in the order of occurrence of the problems.
q If a problem indicated by monitors (15) to (20) occurs while working, the relevant monitor is displayed in
large size for two seconds and then displayed in small size.
q If the hydraulic oil temperature goes High or Low while a monitor is being displayed at the central portion
of the screen, at whitch the hydraulic oil temperature monitor is to be displayed, the screen displays only
hydraulic oil temperature monitor (2b).
C: Screen with maintenance time reminder
D: Screen with emergency swing stop switch operation
Display
NO. Display item Description Remarks
category
Temperature Background q Indicates corresponding temperature
Range (C) color range.
W1 105 Red q Alarm buzzer sounds when the temper-
W2 102 Red ature exceeds 105C.
1a Gauge (*1) q If the monitor background appears
Engine coolant W3 100 Blue white, warm-up the engine.
temperature W4 85 Blue
W5 60 Blue
W6 30 White
1b Caution See the column "Gauge".
Temperature Background q Indicates corresponding temperature
Range (C) color range.
H1 105 Red q Alarm buzzer sounds when the temper-
H2 102 Red ature exceeds 105C.
2a Gauge (*1) q If the monitor background appears
Hydraulic oil H3 100 Blue white, warm-up the hydraulic compo-
temperature H4 85 Blue nents.
H5 40 Blue
H6 20 White
2b Caution See the column "Gauge".
Temperature Background q Indicates corresponding temperature
Range (%) color range.
E1 102 Red q Alarm buzzer sounds when the temper-
E2 100 Red ature exceeds 102%.
3a Gauge (*1) (*2)
Hybrid E3 95 Blue
temperature E4 50 Blue
E5 20 Blue
E6 0 White
3b Caution See the column "Gauge".
q
Quantity (l) Background
Indicates corresponding fuel level.
Range color
F1 230 Blue
F2 195 Blue
4a Gauge (*1) F3 160 Blue
Fuel level
F4 80 Blue
F5 60 Blue
F6 40 Red
4b Caution See the column "Gauge".
Segment Load level q
Indicates average load per minute on a
Light to scale of 1 to 10.
5 ECO gauge Green 18 medium (Indicates when "Default (ECO display
is set to active)" of the service mode is
Orange 9,10 Heavy "ON".)
q Displays the average fuel consumption
of 1 minute.
(*1) q Right end gauge: Latest value
Top of gauge: 30 l/h
Fuel q Left end gauge: Value 5 minutes
6 Gauge Middle of gauge: 18 l/h
consumption before q Graph is erased each time when starting
monitor q Total 5 gauges (1 minute interval)
switch is turned from OFF position to ON
position.
q Indicates accumulated engine operating
Service meter reading 00000h 99999h hours (the alternator is running).
(F4 switch changes it for clock display.)
7
q Displays time.
q 12-hour display (AM/PM)
Clock q 24-hour display
(F4 switch changes it for service meter
display.)
Background (If KOMTRAX is installed.)
Condition
color q The condition of the message is dis-
8 Message Green There is unread message. played.
Blue There is unsent message. (OFF when no message exists.)
Pilot q Indicates air conditioner and air blower
Air conditioner Light ON: ON
9 Light OFF: OFF operating status.
INT: Intermittent q Indicates front glass wiper operating
10 Wiper ON: Continuous condition.
Light OFF: Stop
*1: If the gauge signal is not available due to open circuit in CAN communication line, the gauge pointer goes off.
*2: The hybrid temperature gauge displays in percentage to indicate the temperature load of hybrid equipment.
(See separate page for detail.)
Display
NO. Display item Description Remarks
category
Swing lock Swing brake Monitor q Indicates swing lock operating status.
switch cancel switch display
OFF OFF OFF
11 Swing lock ON OFF ON
OFF ON Blink
ON ON Blink
Elapsed time after turning q Indicates preheat operating status.
Monitor
the starting switch to display
"HEAT (preheat)".
12 Preheating 0 30 sec. ON
30 40 sec. Blink
40 sec. or longer OFF
One-touch q Indicates the operating status of
Pilot power max. Monitor display one-touch power maximizing function.
One-touch switch
13 power max. ON (Goes off if pressed
ON for 8.5 seconds)
OFF Off
Light ON: ON q Indicates auto-decelerator operating
14 Auto-decelerator Light OFF: OFF status.
P: Heavy-duty operation q Displays working mode.
E: Low-fuel consumption operation
15 Working mode L: Fine operation
B: Breaker operation
ATT: Double-acting attachment operation
Lo: Low speed q Displays travel speed setting.
16 Travel speed Med: Medium speed
Hi: High speed
(*3) Light ON: Abnormal range (below the q When an error is detected with the en-
17 Radiator coolant specified value) gine stopped, the monitor lights up on
level Light OFF: Normal range the screen.
Light ON: Defective battery charge q When an error is detected with the en-
(*3)
18 (Charge voltage < Battery voltage) gine running, the monitor lights up on
Battery charge Light OFF: Normal range the screen.
(*3) Light ON: Abnormal range (below the q The monitor lights up on the screen and
19 Engine oil specified value) alarm buzzer sounds, when an error is
pressure Light OFF: Normal range detected with the engine running.
Light ON: Abnormal range (above the q When an error is detected with the en-
Hybrid
20 specified value) gine running, the monitor lights up on
temperature Light OFF: Normal range the screen.
Light ON: Abnormal range (below the q When an error is detected with the en-
(*3)
21 specified value) gine stopped, the monitor lights up on
Engine oil level Light OFF: Normal range the screen.
(*3) Light ON: Abnormal range (above the q When an error is detected with the en-
22 Air cleaner specified value) gine running, the monitor lights up on
clogging Light OFF: Normal range the screen.
Caution Light ON: Abnormal range (water level q When an error is detected with the en-
(*3)
23 is above the specified value) gine running, the monitor lights up on
Water separator Light OFF: Normal range the screen.
q When an error is detected with the en-
Light ON: Hybrid system is abnormal
24 Hybrid gine running, the monitor lights up on
Light OFF: Hybrid system is normal
the screen.
Background q The display changes depending on the
Condition
color time to/after the replacement.
There is a maintenance q After the starting switch is turned to ON
Maintenance item which is 30 hours or position, the monitor turns on if the mon-
25 Yellow itor light-up conditions are met, and then
time less left before next
replacement. goes off in 30 seconds.
There is a replacement
Red overdue item.
q The swing emergency stop function is
Swing Lights up: Swing emergency stop switch operated.
26 q If an error occurs while the swing emer-
emergency stop is turned ON
gency stop is operated, the monitor
changes to display the error.
*3: Included in the start-up check. After the staring switch is turned to ON position, the monitor turns on for two seconds,
and changes to the standard screen if no error is found.
Hybrid equipment Capacitor cell Pressure booster Pressure booster Pressure booster
%
temp. temp. IGBT base temp. IGBT JCT Temp. inductor temp.
A1 102 65 80 130 125
A2 100 63 78 125 120
A3 95 60 75 110 110
A4 50 40 55 90 90
A5 20 0 0 0 0
A6 0 -30 -30 -30 -30
Hybrid equipment Swing motor coil Motor-generator Generator driver Swing inverter JCT
%
temp. temp. temp. temp. temp.
A1 102 140 180 95 134
A2 100 120 170 85 133
A3 95 100 130 60 110
A4 50 80 110 40 90
A5 20 0 0 0 0
A6 0 -30 -30 -30 -30
Switches
*1: When the working mode is changed, the auto-decelerator function turns "ON".
*2: When the front window is open, the windshield wiper and the washer do not operate even if the switch is
pressed.
*3: When the temperature is set to 18.0C or 32.0C, the fan speed is kept at "High". Even if the set temper-
ature is reached, the flow rate remains fixed at "High".
*4: When the fan is set to Stop, the air conditioner does not start even if the switch is pressed.
Guidance
Function switch Role Function
icon
1 Clear Clears selected/displayed item.
*1: The items available in the operator mode fall into the following categories.
A: Display from the time starting switch is turned to ON position until the standard screen appears. Display
after the starting switch is turned to OFF position.
B: Display when the switch on the machine monitor is operated.
C: Display when a certain condition is satisfied
D: Display to requires special operation of the switches.
*2: For the category A, the order in which items are displayed varies depending on the settings and conditions
of the machine as follows:
V: When engine start lock is set effective
W: When engine start lock is disabled
X: When working mode at start is set to "Breaker Mode (B)"
Y: When an error is detected during start-up check.
Z: When a replacement time overdue is detected.
a For how to operate the operator mode functions, see the Operation and Maintenance Manual or "Special
functions of machine monitor" section in Testing and adjusting.
a For how to set the engine start lock on/off, see "Password setting/cancel manual".
Oil flow setting for breaker Oil flow setting for attachment
q Oil flow for the breaker can be changed in the q Oil flow for the 2-way attachment can be
"Breaker/attachment setting" of the user mode. changed in the "Breaker/attachment setting" of
q Oil flow level can be set as follows: the user mode.
Flow level Flow rate (l/min) Remarks q Oil flow level can be set as follows:
1 70 Flow level Flow rate (l/min) Remarks
2 80 1 30
3 90 2 90
4 100 3 115
5 110 4 140
6 120 5 170
7 130 6 250
8 140 7 350
9 150 8 430 Default
10 160
Language setting
11 170
12 180 Default
13 190
14 200
15 210
Monitoring
Mechanical Systems
Abnormality Record Electrical Systems
Air-conditioning System
Maintenance Record
Maintenance Mode Change
Phone Number Entry
Key-on Mode
Unit
With/Without Attachment
Default
Attachment/Maintenance Password
Camera
ECO Display
Pump Absorption Torque (F)
Pump Absorption Torque (R)
Adjustment
Low Speed
Attachment Flow Adjustment
Discharge of capacitor
Cylinder Cut-Out
No Injection
Fuel Consumption
Terminal Status
KOMTRAX Settings GPS & Communication Status
Modem S/N
Service Message
a For how to operate the service mode functions, see "Special functions of machine monitor" section in Test-
ing and adjusting.
(if equipped)
KOMTRAX terminal
Model: TH300
q The KOMTRAX system utilizes satellite communications technology.
AMP-10P [CN-CK02]
Input/Output
Pin No. Signal name
signal
B1 RS232C DCD Output
B2 RS232C RXD Output
B3 RS232C TXD Input
B4 RS232C DTR Input
B5 RS232C SGND Input
B6 RS232C DSR Output
B7 RS232C RTS Input
B8 RS232C CTS Output
B9 RS232C RI Output
B10 NC (*)
*: Never connect any cable to NC, or malfunctions or
failures will occur.
Sensors 192
1. Connector 3. O-ring
2. Sensor
Function
q This sensor is installed in the intake manifold. It detects the boost pressure and intake air temperature,
and outputs signal as a variable voltage for pressure, and a resistance change for temperature.
1. Connector 3. O-ring
2. Sensor
Function
q This sensor, installed on the cylinder head, converts the temperature variation into the change in resis-
tance, and outputs the corresponding signals.
1. Connector 3. O-ring
2. Sensor
Function
q Crankshaft speed sensor and camshaft speed sensor are installed to the adjacency of the gear and the
ring on the cooling fan side of crankshaft and camshaft, respectively, and output pulse voltages due to
gear rotations.
Water-in-fuel sensor
1. Connector 3. Sensor
2. Tube 4. O-ring
Function
q This sensor is installed to the cup of fuel prefilter, and outputs a signal when detecting water exists in the
fuel.
1. Connector 3. Float
2. Bracket 4. Switch
Function
q This sensor is installed on the side face of the oil pan, and turns "OFF" by the lowered float, if the oil level
becomes lower than specified.
Operation
q The oil pressure is applied to the diaphragm of
the oil pressure sensor from the pressure intake
part, the diaphragm is deformed.
q The deformation in the diaphragm causes the re-
sistance of the gauge to change. This causes a
change in the output voltage, which is transmit-
q The amplifier increases output voltage (E) and
ted to the amplifier (voltage amplifier).
transmits it to the pump controller.
Function
q Front pump oil pressure sensor and rear pump
oil pressure sensor are installed to the control
valves, detect the discharge pressures of
pumps, and output the corresponding variable
voltages.
1. Connector 3. Float
2. Bracket 4. Switch
Function
q This sensor is installed on the side face of the hydraulic tank, and turns "OFF" by the lowered float, if the
oil level becomes lower than specified.
1. Float 3. Cover
2. Connector 4. Variable resistor
Function
q This sensor is installed on the side face of the fuel tank. The float moves up and down according to the
fuel level.
The movement of the float rotates the shaft of the variable resistor through the arm. As a result, the source
voltage is changed according to the resistance change due to the arm angle change and is output as a
signal.
1. Boss 4. Wire
2. Switch 5. Connector
3. Conduit
Function
q The sensor is installed on the air cleaner outlet side. It turns "ON", if the air cleaner is clogged and the
pressure level drops to the specified level (negative pressure).
Function
q This sensor is integrated with reservoir tank, and turns "OFF" by the lowered float, if the coolant level be-
comes lower than specified.
HYDRAULIC EXCAVATOR
HB205-1
HB215LC-1
Contents 10-2
Intake pressure q Coolant temperature: operating range kPa Min. 133 107
(boost pressure) q Arm IN relief + Power Max. {mmHg} {Min. 1,000} {800}
At sudden
% Max. 25 35
q Coolant temperature: acceleration
Exhaust gas color
within operating range
At full speed %
q Hydraulic oil temperature: Within operating {kg} {1.6 0.4} {Max. 2.5}
range N 12.7 2.9 Max. 21.6
Bucket control lever
q Engine at full speed {kg} {1.3 0.3} {Max. 2.2}
q Control lever grip at center N 12.7 2.9 Max. 21.6
Swing control lever q Pedal at tip {kg} {1.3 0.3} {Max. 2.2}
q Max. value reading up to stroke end N 24.5 5.9 Max. 39.2
Travel control lever
{kg} {2.5 0.6} {Max. 4.0}
N 74.5 18.6 Max. 107.6
Travel control pedal
{kg} {7.6 1.9} {Max. 11}
Swing 1.
q Hydraulic oil temperature: Within operating
range
q Engine running at full speed
Time taken to swing q Working mode: P mode sec. 24.2 2.5 Max. 30
q Time required for 5 more turns after mak-
ing initial one turn
q For measuring posture, see Swing 1.
q Hydraulic oil temperature: Within operating
range
q Engine stopped
q Keeping upper structure transverse on
Drift of upper struc-
slope of 15, and make a mating mark on mm 0 0
ture
inner and outer races of swing circle
q Mating mark misalignment amount during
5 minutes
q For measuring posture, see Swing 2.
ment 1.
q Hydraulic oil temperature:
Within operating range
q Engine running at full speed RAISE sec. 3.5 0.4 Max. 4.7
q Working mode: P mode
Boom q Time required from RAISE
stroke end till bucket touches
ground LOWER sec. 2.5 0.3 Max. 3.7
q For measuring posture, see
Word equipment 2.
Work equipment speed
Hydraulic pump
See "Performance of hydraulic pump" (next page).
delivery
a As far as possible, measure pump discharge pressure P1 and P2 as close as possible to the average pres-
sure.
Avoid measuring the near turning point of the graph because the error increases there.
a When measuring with the pump mounted on the machine, if it is impossible to set the engine speed to the
specified speed by using the fuel control dial, take the pump delivery and the engine speed at the time of
measurement, and use them as a base for calculating the pump delivery at the specified speed.
For all models (Posture of machine for measur- Travel 1: Travel speed (run the track idle)
ing performance and measurement procedure)
Work equipment 1: Hydraulic drift of work equipment Work equipment 4: Bucket speed
HYDRAULIC EXCAVATOR
HB205-1
HB215LC-1
Contents 10-2
Testing and adjusting air conditioner compressor belt tension ............................................ 30- 31 31
Testing and adjusting hydraulic oil pressure in work equipment and travel circuits............. 30- 37 37
Testing and adjusting oil pressure in pump PC control circuit ............................................. 30- 41 41
Adjusting play of work equipment and swing PPC valves ................................................... 30- 53 53
Checking parts which cause hydraulic drift of work equipment ........................................... 30- 54 54
Sym-
Testing/Adjusting item Part No. Part name Q'ty Remarks
bol
Testing boost pressure A 799-201-2202 Boost gauge kit 1 -101 200 kPa {-760 1,500 mmHg}
1 799-201-9001 Handy smoke checker 1
Testing exhaust gas color B Commercially Bosch index: 0 9
2 Smoke meter 1
available
1 795-799-1131 Gear 1
Adjusting valve clearance C Commercially
2 Feeler gauge 1 Intake: 0.25 mm, Exhaust: 0.51 mm
available
1 795-502-1590 Compression gauge 1 0 7 MPa {0 70 kg/cm2}
2 795-799-6700 Puller 1 107E-1 engine
Testing compression pres-
D 795-790-4411 Adapter 1 107E-1 engine
sure 3
6754-11-3130 Gasket 1 107E-1 engine
4 795-799-8150 Remover 1
1 799- 201-1504 Blow-by checker 1 0 5 kPa {0 500 mmH2O}
Testing blow-by pressure E
2 795-790-3300 Blow-by tool 1 107E-1 engine
Pressure gauge: 2.5, 6, 40, 60 MPa
799-101-5002 Hydraulic tester 1
{25, 60, 400, 600 kg/cm2}
1
Testing engine oil pressure F Pressure gauge: 60 MPa
790-261-1204 Digital hydraulic tester 1
{600 kg/cm2}
2 799-401-2320 Hydraulic tester 1 Pressure gauge: 1 MPa {10 kg/cm2}
Pressure gauge: 2.5, 6, 40, 60 MPa
799-101-5002 Hydraulic tester 1
{25, 60, 400, 600 kg/cm2}
1
Pressure gauge: 60 MPa
790-261-1204 Digital hydraulic tester 1
{600 kg/cm2}
795-790-4430 Adapter 1
2 101.0 mm o R1/8
Testing fuel system pres- 6215-81-9710 O-ring 1
G
sure Fuel pressure gauge
3 795-790-5200 1
adapter kit
Pressure gauge: 0 254 kPa
4 795-790-1470 Pressure gauge 1
{0 75 inHg}
5
799-201-2202 Boost gauge kit 1
6
795-790-5110 Screw 1
1
795-790-4700 Tester kit 1
2
795-790-6700 Adapter 1
6754-71-5340 Connector 1
Testing fuel return rate and 3
H 6754-71-5350 Washer 1
leakage Commercially
4 Measuring cylinder 1
available
Commercially
5 Stopwatch 1
available
Testing swing circle bear- Commercially
J Dial gauge 1
ing clearance available
Pressure gauge: 2.5, 6, 40, 60 MPa
799-101-5002 Hydraulic tester 1
Testing and adjusting {25, 60, 400, 600 kg/cm2}
1
hydraulic oil pressure in Pressure gauge: 60 MPa
K 790-261-1204 Digital hydraulic tester 1
work equipment and travel {600 kg/cm2}
circuits 799-101-5220 Nipple 3
2 Size: 101.25 mm
07002-11023 O-ring 3
Pressure gauge: 2.5, 6, 40, 60 MPa
799-101-5002 Hydraulic tester 1
{25, 60, 400, 600 kg/cm2}
1
Testing source pressure of Pressure gauge: 60 MPa
L 790-261-1204 Digital hydraulic tester 1
control circuit {600 kg/cm2}
799-101-5220 Nipple 1
2 Size: 101.25 mm
07002-11023 O-ring 1
Sym-
Testing/Adjusting item Part No. Part name Q'ty Remarks
bol
Pressure gauge: 2.5, 6, 40, 60 MPa
799-101-5002 Hydraulic tester 1
{25, 60, 400, 600 kg/cm2}
Testing and adjusting oil 1
Pressure gauge: 60 MPa
pressure in pump PC con- M 790-261-1204 Digital hydraulic tester 1
{600 kg/cm2}
trol circuit
799-101-5220 Nipple 6
2 Size: 101.25 mm
07002-11023 O-ring 6
Pressure gauge: 2.5, 6, 40, 60 MPa
799-101-5002 Hydraulic tester 1
{25, 60, 400, 600 kg/cm2}
1
Pressure gauge: 60 MPa
Testing and adjusting oil 790-261-1204 Digital hydraulic tester 1
{600 kg/cm2}
pressure in pump LS con- N Differential pressure
trol circuit 2 799-401-2701 1 50 MPa {500 kg/cm2}
gauge
799-101-5220 Nipple 6
3 Size: 101.25 mm
07002-11023 O-ring 6
Pressure gauge: 2.5, 6, 40, 60 MPa
799-101-5002 Hydraulic tester 1
{25, 60, 400, 600 kg/cm2}
Testing solenoid valve out- 1
P Pressure gauge: 60 MPa {600
put pressure 790-261-1204 Digital hydraulic tester 1
kg/cm2}
2 799-401-3100 Adapter 1 Size: 02
Pressure gauge: 2.5, 6, 40, 60 MPa
799-101-5002 Hydraulic tester 1
{25, 60, 400, 600 kg/cm2}
1
Testing PPC valve output Pressure gauge: 60 MPa
Q 790-261-1204 Digital hydraulic tester 1
pressure {600 kg/cm2}
2 799-401-3100 Adapter 1 Size: 02
3 799-401-3200 Adapter 1 Size: 03
799-601-4101
or T-adapter assembly 1
799-601-4201
799-601-4130 T-adapter 1 Ne Sensor
799-601-4150 T-adapter 1 For oil pressure sensor
Troubleshooting for engine For DRC60, ECONO (Not included in
controller/sensors/actua- R 799-601-4350 Measurement box 1
799-601-4201)
tors 799-601-4211 q T-adapter 1 Engine controller
799-601-4220 q T-adapter 1 Engine controller
799-601-4250 q T-adapter 1 For boost pressure sensor
799-601-4260 q T-adapter 1 Engine controller
799-601-9040 q T-adapter 1 For injector
Sym-
Testing/Adjusting item Part No. Part name Q'ty Remarks
bol
799-601-2500
or
799-601-2700
or
799-601-2800
or
799-601-2900 T-adapter assembly 1 799-601-2900 is no more available
or
799-601-7100
or
799-601-7400
or
799-601-8000
For ECONO (Not included in
799-601-2600 q T-adapter box 1
799-601-2700)
799-601-4101
or
799-601-4201
or T-adapter assembly 1
799-601-9000
or
799-601-9200
For DRC60, ECONO and DT6P
799-601-4350 q Measurement box 1 (Not included in 799-601-4201,
799-601-9000 and 799-601-9200)
For DT and HD (Not included in
799-601-9320 q Measurement box 1
799-601-4101 and 799-601-4201)
Troubleshooting for chas- 799-601-9020 q Adapter for DT 1 For DT2P
sis sensors/wiring har- S For DT3P (Not included in
nesses 799-601-9030 q Adapter for DT 1
799-601-4010 and 799-601-4201)
For DTP4 (Not included in
799-601-4260 q Adapter for DT 1
799-601-9000 and 799-601-9200)
For DT12P (Not included in
799-601-9110 q Adapter for DT (GR) 1
799-601-4101 and 799-601-4201)
For AMP3P (Not included in
799-601-9420 q Adapter for AMP 1
799-601-9000 and 799-601-9200)
799-601-7000
or
799-601-7100
or T-adapter assembly 1
799-601-7400
or
799-601-8000
For X1P (Not included in
799-601-7010 q Adapter for X 1
799-601-7000 and 799-601-7100)
799-601-7020 q Adapter for X 1 For X2P
For SW6P (Not included in
799-601-7050 q Adapter for SWP 1
799-601-8000)
For SW8P (Not included in
799-601-7060 q Adapter for SWP 1
799-601-8000)
799-601-7090 q Adapter for M For M2P
799-601-7110 q Adapter for M For M3P
799-601-7120 q Adapter for M For M4P
799-601-7130 q Adapter for M For M6P
799-601-7140 q Adapter for S For S8P
Sym-
Testing/Adjusting item Part No. Part name Q'ty Remarks
bol
799-601-7500 T-adapter assembly
799-601-7520 q Adapter for 070 For 070-12P
799-601-7540 q Adapter for 070 For 070-18P
799-601-8980 Adapter for multiple For DT-2, 3, 4/DTM-2P
Troubleshooting for chas-
799-601-4280 Measurement box AMP121P (for pump controller)
sis sensors/wiring har- S
nesses 799-601-7310 Adapter for SWP For SW12P
799-601-7360 Adapter for relay For REL-5P
799-601-7370 Adapter for relay For REL-6P
Socket for CRI-T2
799-601-9410 For YAMAZAKI 2P
engine
Commercially
Testing oil leakage T Measuring cylinder 1
available
566-35-43561 Nipple 1
1
07002-11822 O-ring 1
Diagnosis of cooling cir-
U 2 799-101-5160 Joint 1
cuit for hybrid system
3 799-101-5150 Hose 1
4 799-401-2311 Pressure gauge 1
Testing coolant tempera-
799-101-1502 Digital thermometer 1 -99.9 1,299C
ture and oil temperature
Testing operating effort 79A-264-0021 Push-pull scale 1 0 294 N {0 30 kg}
and depressing effort 79A-264-0091 Push-pull scale 1 0 490 N {0 50 kg}
Testing stroke and hydrau- Commercially
Scale 1
lic drift available
Testing work equipment Commercially
Stopwatch 1
speed available
Testing voltage and resis- Commercially
Circuit tester 1
tance available
Removal and installation of
Commercially 3.26 mm Torx wrench
boost pressure and tem- Hexlobe (TORX) wrench 1
available (KTC Q4T15 or equivalent)
perature sensors
Removal and installation of 27 mm hexagonal deep socket
795-799-6210 Deep socket 1
engine oil pressure sensor (inner diameter: 24.5 mm)
Removal and installation of
19 mm deep socket
engine coolant tempera- 795T-981-1010 Deep socket 1
(MITOLOY 4ML-19 or equivalent)
ture sensor
Socket
5. Testing 2-pump relief and power maximizing 6. Testing the speed when auto-deceleration is
speed (near rated speed) in operation
1) Arm IN relief condition 1) Start the engine, set the fuel control dial to
1] Start the engine and operate the arm the full speed position (MAX), and turn the
cylinder to the IN stroke end. auto-deceleration ON.
2] Set the fuel control dial to the full speed 2) Set all the control levers and pedals for work
(MAX) position and set the working mode equipment, swing, and travel to the neutral
to the power mode (P). and measure the engine speed when the
3] While operating the left work equipment auto-deceleration operates.
control lever to relieve the arm circuit at a If all the control levers and pedals are set to
the IN stroke end and pressing the neutral, the engine speed decreases to the
one-touch power maximizing switch, test waiting speed (1,250 rpm). If the machine is
the engine speed. kept under this condition for 4 seconds or
2) Travel circuit relief condition more, the engine speed decreases further to
1] Start the engine and lock the travel mech- the deceleration speed (approximately 700
anism. For the method of locking the rpm). Check the engine speed at this time.
travel mechanism, see Testing and (Reference: See 10 Structure and function,
adjusting hydraulic oil pressure in work Electrical system, "Auto-deceleration func-
equipment and travel circuits, "5. Testing tion".
travel relief pressure".
2] Set the working mode to power mode (P),
travel speed to Mi (medium) or Hi (high),
and fuel control dial to the full speed
(MAX) position.
k Before operating the travel lever
and pedal, check the lock pin posi-
tion and locking direction (forward
or reverse travel) again.
3] While operating the travel lever to relieve
the travel circuit oil pressure and holding
down the one-touch power maximizing
switch, test the engine speed.
a The one-touch power maximizing function is
reset automatically in approximately 8.5 sec-
onds even if the switch is kept pressed. Ac-
cordingly, test the engine speed in that
period.
a You may check with the swing lock switch
ON (In this case, you do not need to operate
the one-touch power maximizing switch).
9. Install adapter D3 to the injector mounting hole 13. After finishing testing, remove the testing tools
by using the injector holder, and connect and return the removed parts.
compression gauge D1. a Install the injector and high-pressure fuel
a Be sure to install the gasket to the adapter tube according to the following procedure.
tip. 1) Mate protrusion (a) of the injector with notch
a Tighten the holder mounting bolts alternately. (b) of the injector holder, and set the injector
3 Injector holder mounting bolt: to the cylinder head.
8 0.8 Nm {0.8 0.08 kgm} a Set the injector with the above mating po-
a If a little quantity of engine oil is applied to the sition toward the fuel inlet connector
joint of the adapter and gauge, air does not pass-through.
leak easily.
operation
a No-injection cranking means to rotate the engine
23
a Cylinder cut-out test mode operation means to by the starting motor while the fuel injection into
run the engine with the fuel injector of one or all the cylinders are stopped electrically. The
more cylinders disabled electrically to reduce the purpose and effect of this operation are as fol-
number of active cylinders. The purpose and ef- lows.
fect of this operation are as follows. Before the engine is started after it or the
1. This operation is used to find out a cylinder machine has been stored for a long period, the
which does not output power properly (i.e. no-injection cranking is performed to lubricate
combustion in it is abnormal). the engine parts and protect them from seizure.
a See the section of "Special functions of machine
2. When fuel to a cylinder is shut off, if the engine monitor" when performing the no-injection crank-
speed and output do not change from those ing operation.
before cylinder cut-out (all-cylinder operation), a Use the no-injection cranking operation for only
that cylinder has one or more problems. the purpose of troubleshooting.
The possible problems are as follows.
Gas leakage through the cylinder head
gasket
Defective injection from the injector
Defective piston or piston ring
Defective valve mechanism
Defect in electrical system
Testing fuel delivery, return rate 3) Install test hose H1 to the nipple on the
and leakage discharge side of the supply pump.
a Tie the hose with a wire etc.
24
a Testing tools for fuel delivery, return rate and a Put the end as the testing hose in the con-
leakage tainer so that it will not sag.
Symbol Part number Part name
1 795-790-4700 Tester kit
2 795-790-6700 Adapter
6754-71-5340 Connector
3
H 6754-71-5350 Washer
Commercially
4 Measuring cylinder
available
Commercially
5 Stopwatch
available
a Since some fuel flows out during test, prepare a
container of approximately 20 l.
k Stop the machine on level ground and lower
the work equipment to the ground.
4) Crank the engine for 20 seconds and
1. Testing supply pump delivery measure the delivery by using measuring
1) Open the engine hood and remove counter- cylinder H4.
weight upper cover (1). a Do not crank the engine for more than 20
seconds to protect the starting motor in
any case other than this test.
a If the supply pump delivery is in the fol-
lowing standard range, it is normal.
(30-second conversion)
At cranking speed (125
75 cc or more
rpm)
At cranking speed (150
90 cc or more
rpm)
q Delivery [Q]:
Q = Engine speed x 0.6
2. Testing supply pump return rate 4) Run the engine at low idle and measure the
1) Disconnect quick coupler (2) of the supply return rate in 25 sec by using measuring
pump return hose from connector (3) on the cylinder H4.
pump. a If the return rate from the supply pump is
in the following range, it is normal.
At low idle (750 rpm) 400 cc/min or less
3. Testing leakage from pressure limiter 4) Run the engine at low idle and test the return
1) Disconnect quick coupler (4) of the return rate in 1 minute by using measuring cylinder
hose of the pressure limiter from connector H4.
(5) on the pump. a If the leakage from the pressure limiter is
in the following range, it is normal.
0 cc/min.
At low idle
(No leakage)
Handling of controller
high-voltage circuit 30
k Stop the machine on level ground and lower 1. Loosen bolts (1) and (2).
the work equipment to the ground.
2. Move compressor (3) and bracket (4) together to
Checking adjust the belt tension.
1. Open the engine hood and remove the belt
guard (1) from the top of the air conditioner 3. After positioning compressor (3), tighten bolts
compressor. (1) and (2).
a Check each pulley for breakage, wear of the
V-groove, and contact of the V-belt and
V-groove.
a If the V-belt is so elongated that no adjust-
ment allowance remains or it has a cut or a
crack, replace it with a new one.
a If the belt is replaced, adjust the tension
again after operating the machine for 1 hour.
a After tightening the bolts, check the belt ten-
sion again according to the above procedure.
Testing swing circle bearing 4. Set the arm almost perpendicular to the ground
clearance 3
and lower the boom until the front part of the
track floats.
a Testing tools for swing circle bearing clearance a At this time the front of the upper structure
Symbol Part No. Part name rises and the rear lowers.
Commercially
J Dial gauge 5. Under this condition, read dial gauge J.
available
a The value indicated by dial gauge J is the
a When testing the swing circle bearing clearance
clearance of the bearing.
on the complete machine, perform the following
a For the standard value, see Maintenance
procedure.
k Stop the machine on level ground and lower
standard, "Swing circle".
the work equipment to the ground.
k Do not put your hands or feet under the un-
dercarriage during testing.
2. Decreasing tension
1) Loosen valve (2) to discharge grease, and
then tighten valve (2).
k Do not loosen the valve more than one
turn. If it is loosened more, it may
jump out because of the internal
high-pressure grease.
2) To check that the tension is normal, run the
engine at low idle and move the machine
forward by the length of track on ground, then
stop slowly.
3) After adjusting, check the track tension again
according to the above procedure.
Hydraulic system 37
Testing and adjusting hydraulic 2) Install nipples K2 and connect oil pressure
oil pressure in work equipment gauges [1] of hydraulic tester K1.
a Use the oil pressure gauges of 60 MPa
and travel circuits 37
{600 kg/cm2}.
a Testing and adjusting tools for oil pressure in
work equipment and travel circuits.
Symbol Part No. Part name
799-101-5002 Hydraulic tester
1
790-261-1204 Digital hydraulic tester
K
799-101-5220 Nipple (10 1.25 mm)
2
07002-11023 O-ring
k Stop the machine on level ground and lower
the work equipment to the ground. Then, re-
lease the remaining pressure from the hy-
draulic circuit. For details, see "Releasing
remaining pressure from hydraulic circuit".
Testing
a The oil pressure in the work equipment and trav- 2. Combination of pump, actuator, and valve
el circuits (pump discharge pressure) can be a When the oil from the pumps is divided, the
checked by using the monitoring function of the front pump and rear pump act independently
machine monitor, too (For details, see "Special on each actuator. Note that the relieved valve
functions of machine monitor"). varies depending on the actuator.
q Monitoring code: 01100 F pump pressure
a When the work equipment circuit is relieved
q Monitoring code: 01101 R pump pressure
singly, the oils of the pumps are merged.
a Test the oil pressure in the work equipment and When the travel circuit is relieved singly, the
travel circuits under the following condition. oils of the pumps are divided.
q Hydraulic oil temperature: Within operating
a The actuators in the table are arranged in the
range order when the control valve is seen from the
front of the machine (and the service valve is
1. Preparatory for work used for an attachment).
1) Open the side cover of the pump room and Actuator Valve relieved
remove oil pressure pickup port plugs (1) and (R unload valve) (R main relief valve)
Rear pump
Right
F main relief valve
travel
Arm F main relief valve
(F unload valve) (F main relief valve)
(Centralized safety valve) (Back pressure valve)
Testing source pressure of 3. Start the engine, set the working mode to the
control circuit 40
power mode (P), and turn the auto-deceleration
OFF.
a Testing tools for source pressure of control cir-
cuit 4. Run the engine at high idle, set all the levers and
Symbol Part No. Part name pedals for work equipment control and travel
799-101-5002 Hydraulic tester control to the neutral position, and measure the
1 oil pressure.
790-261-1204 Digital hydraulic tester
L
799-101-5220 Nipple (10 1.25 mm)
2
07002-11023 O-ring
k Stop the machine on level ground and lower
the work equipment to the ground. Then, re-
lease the remaining pressure from the hy-
draulic circuit. For details, see "Releasing
remaining pressure from hydraulic circuit".
a Test the source pressure of control circuit under
the following condition.
q Hydraulic oil temperature: Within operating
range
Testing and adjusting oil pressure 2) Install nipples M2 and nipples of hydraulic
in pump PC control circuit 41
tester M1 and connect them to oil pressure
gauges [2].
a Testing and adjusting tools for oil pressure in a Connect the pressure gauge to the mea-
pump PC control circuit suring part of plug (3) by using joint
Symbol Part No. Part name (790-301-1271) and elbow (790-301-
799-101-5002 Hydraulic tester 1530) of hydraulic tester M1 and nipple so
1 that it will not interfere with the drain pip-
790-261-1204 Digital hydraulic tester
M ing.
799-101-5220 Nipple (10 1.25 mm)
2 a Use the oil pressure gauges of 60 MPa
07002-11023 O-ring
k
{600 kg/cm2}.
Stop the machine on level ground and lower
the work equipment to the ground. Then, re-
lease the remaining pressure from the hy-
draulic circuit. For details, see "Releasing
remaining pressure from hydraulic circuit".
Testing
a Before testing the oil pressure in the PC control
circuit, check that the oil pressure in the work
equipment and travel circuits and the source
pressure of the control circuit are normal.
a Test the oil pressure in the pump PC control cir-
cuit under the following condition.
q Hydraulic oil temperature: Within operating
range 3) Start the engine and operate the arm cylinder
to the IN stroke end.
1. Testing PC valve output pressure (servo 4) Set the working mode to the power mode (P)
piston inlet pressure) and turn the swing lock switch ON.
a Test the PC valve output pressure (servo pis- a If the swing lock switch is turned ON, the
ton inlet pressure) and pump discharge pres- main relief valve is set for high-pressure
sure simultaneously and compare them. relief.
1) Open the side cover of the pump room and 5) Run the engine at full speed, operate the left
remove oil pressure pickup port plugs (1), (2), work equipment control lever to relieve the
(3), and (4). arm circuit at the IN stroke end, and measure
q (1): Front pump discharge pressure pick- the oil pressure.
up port plug
q (2): Rear pump discharge pressure pick-
up port plug
q (3): Front PC valve output pressure pick-
up port plug
q (4): Rear PC valve output pressure pick-
up port plug
a Testing condition and method of judg- 2) Install nipples M2 and connect them to oil
ment: If the pressures are in the following pressure gauges [2].
ratio, the PC valve is normal. a Use the oil pressure gauges of 6 MPa
Measured oil Operation of Ratio of oil {60 kg/cm2}.
pressure lever pressures
Pump discharge
1
pressure
Arm IN relief
PC valve output Approx. 0.6
pressure (Approx. 3/5)
a If the PC valve or the servo piston is ab-
normal, the PC valve output pressure
(servo piston inlet pressure) is "the same
as the pump discharge pressure" or "al-
most zero".
6) After finishing test, remove the testing tools
and return the removed parts.
Testing and adjusting oil pressure 2) Install nipples N3 and nipples of hydraulic
in pump LS control circuit 4
tester N1 and connect them to oil pressure
gauges [2].
a Testing and adjusting tools for oil pressure in a Connect the measuring part of plug (3) by
pump LS control circuit using joint (790-301-1271) and elbow
Symbol Part No. Part name (790-301-1530) of hydraulic tester N1
799-101-5002 Hydraulic tester and nipple so that it will not interfere with
1 the drain piping.
790-261-1204 Digital hydraulic tester
N 2 799-401-2701 Differential pressure gauge a Use the oil pressure gauges of 60 MPa
799-101-5220 Nipple (10 1.25 mm) {600 kg/cm2}.
3
07002-11023 O-ring
k Stop the machine on level ground and lower
the work equipment to the ground. Then, re-
lease the remaining pressure from the hy-
draulic circuit. For details, see "Releasing
remaining pressure from hydraulic circuit".
Testing
a Before testing the oil pressure in the PC control
circuit, check that the oil pressure in the work
equipment and travel circuits and the source
pressure of the control circuit are normal.
a Test the oil pressure in the pump LS control cir-
cuit under the following condition. 3) Start the engine and push up the track on the
q Hydraulic oil temperature: Within operating side to be measured by using the work equip-
range ment and prepare for running the track idle.
q When measuring front circuit: Right track
1. Testing LS valve output pressure (servo q When measuring rear circuit: Left track
piston inlet pressure) k Since the raised track runs during test-
a Test the LS valve output pressure (servo pis- ing, secure a sufficient working area.
ton inlet pressure) and pump discharge pres- 4) Set the working mode to the power mode (P)
sure simultaneously and compare them. and set the travel speed to the High.
1) Open the side cover of the pump room and 5) Run the engine at full speed, set all the levers
remove oil pressure pickup plugs (1), (2), (3), and pedals for work equipment control and
and (4). travel control to the neutral position, and
q (1): Front pump discharge pressure pick- measure the oil pressure under this condi-
up port plug tion. Then, operate the travel lever to run the
q (2): Rear pump discharge pressure pick- track idle and measure the oil pressure.
up port plug k While taking extreme care for safety,
q (3): Front LS valve output pressure pick- run the raised track.
up port plug a Do not operate the travel lever to the
q (4): Rear LS valve output pressure pickup stroke end (stop it halfway).
port plug
a Testing condition and method of judg- 2) Install nipples N3 and connect it to differential
ment: If the pressures are in the following pressure gauge N2 or the oil pressure gauge
ratio, the LS valve is normal. of hydraulic tester N1.
Position of levers and pedals a When using differential pressure gauge
Hydraulic pres- Travel lever N2:
sure to be mea- All levers and
moved half- Connect the pump discharge pressure to
sured pedals are at
way (track the high pressure side (back side) and
neutral
idle)
connect the LS pressure to the low pres-
Pump discharge Actual value
pressure is set as 1 sure side (lower side). Since the differen-
Almost same tial pressure gauge needs a 12V power
pressure Approx. 3/5
LS valve output
pressure
of pressure source, connect it to a battery.
above a When using oil pressure gauge (in N1):
6) After finishing test, remove the testing tools Use the oil pressure gauge of 60 MPa
and return the removed parts. {600 kg/cm2} having the unit of 1 MPa
{10 kg/cm2}. Since the differential pres-
2. Testing LS differential pressure sure is about 4 MPa {40 kg/cm2} at
a Test the pump discharge pressure and LS maximum, measure it by installing the
pressure (actuator load pressure) simulta- same gauge to the pickup port plugs
neously and calculate the difference between alternately.
them. q The photo shows the pump discharge
1) Open the side cover of the pump room and pressure side.
remove oil pressure pickup plugs (1), (2), (5),
and (6).
q (1): Front pump discharge pressure pick-
up port plug
q (2): Rear pump discharge pressure pick-
up port plug
4) Set the working mode to the power mode (P) 3) Start the engine.
and set the travel speed to the High. 4) Run the engine at full speed, operate the
5) Run the engine at full speed, set all the levers travel speed switch and travel lever, and
and pedals for work equipment control and measure the output pressure in each case.
travel control to the neutral position, and a Testing condition and method of judg-
measure the oil pressure under this condi- ment: If the output pressures are in the
tion. Then, operate the travel lever to run the following ratio, the LS-EPC valve is nor-
track idle and measure the oil pressure. mal.
k While taking extreme care for safety, Operation of
Travel speed Output pressure
run the raised track. lever
a Do not operate the travel lever to the Travel lever in
Approx.2.9 MPa
stroke end (stop it halfway). Low {Approx.
neutral
30 kg/cm2}
a Testing condition and method of judg-
Travel lever
ment: If the pressures are in the following 0 MPa
High operated a little
ratio, the LS valve is normal. {0 kg/cm2}
(Note)
LS differential Note: Move the travel lever to a degree that the PPC
Operation of lever
pressure
oil pressure switch is turned ON (before the track
All control levers and pedals Specified LS dif-
are at neutral ferential pres- starts moving).
sure (See
Travel lever moved halfway standard values
(track run idle) table)
6) After finishing test, remove the testing tools
and return the removed parts.
Adjusting
Adjusting LS valve
a If the LS differential pressure is abnormal, adjust
the LS valve according to the following proce-
dure.
q (8): Front pump LS valve
q (9): Rear pump LS valve
Testing solenoid valve output a When testing at hoses (2) (6), remove the
pressure 48
undercover of the control valve.
3. Testing oil leakage from bucket cylinder 4. Testing oil leakage from travel motor
1) Move the bucket cylinder to the CURL stroke 1) Remove the travel motor cover.
end and stop the engine. 2) Run the engine, lock the travel mechanism,
k Release the remaining pressure from and stop the engine.
the piping on the bucket cylinder head k Put pin [1] between the sprocket and
side. For details, see "Releasing re- track frame to lock the travel mecha-
maining pressure from hydraulic cir- nism securely.
cuit" (Operate the lever in the bucket
CURL direction only, however).
2) Disconnect hose (3) from the cylinder head
side and block the hose end with a flange.
k Take care not to disconnect the hose
from the cylinder bottom.
a Use the following part to block the hose
end.
07379-00640 (Flange # 06)
pump q q q o q
q Removing suction piping
q Replacing and repairing control valve
q q o q
q Removing control valve piping
q Replacing and repairing cylinder
q q o q
q Removing cylinder piping
q Replacing and repairing travel motor
q o q q
q Removing travel motor piping
q Replacing and repairing swivel joint
q o o q
q Removing swivel joint piping
Note: Bleed air from the travel motors only when the oil in the motor cases is drained.
4. Bleeding air from travel motor 2) Check the oil level by sight gauge on the rear
1) Run the engine at low idle. side of the hydraulic tank.
2) Loosen air bleeder (2) and check that oil a If the oil level is below line L, it is insuffi-
oozes out through the air bleeder. cient. Add oil.
3) After the oil oozes out, tighten air bleeder (2). a The oil level changes according to the oil
3 Air bleeder: temperature. Add oil when the oil level is
27.5 35.3 Nm {2.8 3.6 kgm} out of the following standard ranges.
q When oil temperature is 10 30C:
Between line H and line L
q When oil temperature is 50 80C:
Near line H
[Reference]
q Note that the tightening torque of mounting bolt
(4) of cab tipping stopper (3) is different from that
of a common bolt 30 mm in diameter.
3 Bolt (4): 245 309 Nm {25 31.5 kgm}
Adjusting mirrors 62
Installation and adjustment of mirrors 2) Fold the mirror to position (C) when trans-
1. Installation of foldable mirrors porting the machine.
Install foldable mirrors (a1) and (b1) as shown in 3) Foldable mirror (b1): Install at 33 mm from
the figure. the top of the stay. Install mirror stay (4) so
1) Foldable mirror (a1): Install at 20 mm from that the mirror will be fixed at (A) position out
the bottom of the intermediate stay. Install of the 3 stopping positions where the mirror is
mirror stay (1) so that the mirror will be fixed extended most and at an angle of about 26
at (A) position out of the 3 stopping positions to the side of the machine body.
where the mirror is extended most and at an
angle of about 86 to the intermediate stay.
Angle adjustment of rear view 4. Loosen camera mounting bolts (4) and adjust
camera 65
camera installation angle (A) so that the center
of mounting bolts (4) matches with 4th gradua-
If the image displayed on the monitor is out of posi- tion (B) from the bottom.
tion, remove cover (1) and adjust installation angle a A part of the machine is displayed on the
(A) of the rear view camera. monitor screen.
Angle (A) can be adjusted in the range of 35 80.
5. After adjusting, tighten bolts (4).
3 Camera mounting bolt:
3 5 Nm {0.3 0.5 kgm}
Hybrid relation 6
2. Move the machine to a flat and rigid surface 7. Check the swing lock switch, swing lock solenoid
where there are no obstacles to the swinging valve, etc. in the electrical or hydraulic system
operation. for problems.
8. If there are no problems in the electrical and
3. Turn swing lock switch (1) to the ON position hydraulic systems, the mechanical system can
while keeping the machine in the posture be considered to have a problem. Perform a
described above. disassembly inspection, referring to Disas-
sembly and assembly, "Disassembly and
assembly of swing machinery assembly".
9. If the swing holding brake disc is worn, replace it
with a new one.
10. After replacement, check that the swing holding
brake operates normally according to steps 3
5 described above.
3. Measure the oil pressures of the swing holding 2. Display "09103 Swing motor torque".
brake. Confirm that those pressures are as For details, see "Special functions of machine
follows. monitor".
Output oil
Left work
pressure of swing Monitor screen,
equipment
holding brake etc.
control lever
solenoid valve
Hybrid monitor is
Left swing 0 MPa displayed.
Right swing {0 kg/cm2} Alarm buzzer
sounds.
Electrical system 70
Display of warning after check before starting Display of check of working mode and travel
If any abnormality is detected by the check before speed
starting, the warning monitor is displayed on the If the check before starting is finished normally, the
screen. screen to check the working mode and travel speed
a The following figure shows that the engine oil is displayed for 2 seconds.
level monitor (a) is warning of low of engine oil a After display of check of the working mode and
level. travel speed is finished, the screen changes to
"Display of ordinary screen".
Selection of auto-deceleration
While the ordinary screen is displayed, if the
a u t o- de c e l e r a t i on s w i t c h i s pr e s s e d, l a r g e
auto-deceleration monitor (a) is displayed for 2 sec-
onds and the setting of the auto-deceleration is 2. Operate the function switches or working mode
changed. selector switch to select and confirm the work-
a Each time the auto-deceleration switch is ing mode which you will use.
pressed, the auto-deceleration is turned ON Function switches
and OFF alternately. q [F3]: Move to lower working mode
a If the auto-deceleration is turned ON, large q [F4]: Move to upper working mode
monitor (a) and auto-deceleration monitor (b) q [F5]: Cancel selection and return to ordi-
are displayed simultaneously. nary screen
a If the auto-deceleration is turned OFF, q [F6]: Confirm selection and return to ordi-
auto-deceleration monitor (b) goes off. nary screen
Working mode selector switch
q Press: Move to lower working mode
q Hold down:Confirm selection and return to
ordinary screen
a If you do not touch any of the function
switches and working mode selector
switch for 5 seconds, the selection is con-
firmed and the screen changes to the ordi-
nary screen.
a Heater specification
Operation to display camera mode (if camera is Operation to display clock and service meter
installed) While the ordinary screen is displayed, press [F4],
When a camera is installed, if [F3] is pressed, the and section (a) changes to the service meter and
multi-display changes to the camera image (Set the clock alternately.
connection of the camera in the service mode). a When the clock is selected, adjust the time, set
12-hour or 24-hour display, and set the summer
time with the user mode function.
a To reset the time left after finishing maintenance a There are following items in the user menu.
(oil/filter replacement) more operations are nec- Breaker/Attachment Settings
essary. User Message
Screen Adjustment
Clock Adjustment
Language
Economy Mode Adjustment
Reset Average Fuel Consumption Logs
Auto Decel Setting
Display of automatic judgment of breaker Display of user code and failure code
If the operator performs breaker work in an If an abnormality which displays a user code and a
improper working mode, the breaker automatic failure code occurs on the ordinary screen or cam-
judgment screen is displayed to urge the operator era mode screen, all the information of the abnor-
to select a proper working mode. mality is displayed.
a The breaker automatic judgment is displayed (a): User code (3 digits)
when the following condition is satisfied while (b): Failure code (5 or 6 digits)
the display setting is set effective in the service (c): Telephone mark
mode. (d): Telephone No.
a Condition for display: a This screen is displayed only when an abnor-
When the pump controller measures the rear mality (failure code) for which a user code is
pump pressure for a certain time, the obtained set occurs.
value is similar to the pulsation wave form of a The telephone mark and telephone No. are
breaker operation which is held in the control- displayed only when the telephone No. is reg-
ler in advance. istered in the service mode.
a The breaker automatic judgment function is set a If multiple abnormalities occur simultaneously,
to Not used (Not displayed) when delivered. all the codes are displayed repeatedly in order.
a If this screen is displayed, check the setting of a Since the information of the displayed failure
the working mode. If the breaker is being code is recorded in the abnormality record in
used, select the breaker mode [B]. the service mode, check the details in the ser-
a To return to the ordinary screen, press [F5]. vice mode.
a Remedies given by displayed user codes to operator to take (The following table is an excerpt from the
Operation and Maintenance Manual)
User code Failure mode Action
When emergency pump drive switch is at the upper (emergency)
E02 Pump control system error position, normal operations become possible, but have inspection
carried out immediately.
E03 Swing brake system error Have inspection carried out immediately.
Operate machine to a safe posture and have inspection carried out
E09* Hybrid system error
immediately.
Engine controller power source
error
E10 Engine controller drive system Have inspection carried out immediately.
circuit error
(engine stopped)
Engine controller system error Operate machine to a safe posture and have inspection carried out
E11
Output reduced to protect engine immediately.
Abnormality in throttle system Operate machine to a safe posture and have inspection carried out
E14
(fuel dial abnormality) immediately.
Engine sensor
E15 (coolant temperature, fuel pres- Operations are possible, but have inspection carried out immediately.
sure, oil pressure) system error
Operate machine to a safe posture and have inspection carried out
E0E Network error
immediately.
Operate machine to a safe posture and have inspection carried out
E20 Abnormality in travel system
immediately.
Function of changing attachment/maintenance 3. After the New password input screen is dis-
password played, input a new password with the numeral
When changing the attachment/maintenance pass- input switches and confirm it with the function
word used for the attachment setting function and switch.
maintenance setting function, follow these proce- a Set a new password of 4 6 digits (If it
dures. has only 3 or less digits or has 7 or more
1. While the ordinary screen is displayed, perform digits, it is not accepted).
the following operation with the numeral input q [F5]: Reset input numeral/Return to ordi-
switches. nary screen
q Operation of switches (While pressing [4], q [F6]: Confirm input numeral
perform the operation in order):
[4] + [5] o [5] o [5]
a This operation of the switches is not
accepted until 10 minutes pass after the
starting switch is turned on.
Monitoring
The machine monitor can monitor the condition of
the machine in real time by receiving signals from
various switches, sensors, and actuators installed to
many parts of the machine and the information from
the controllers which are controlling actuators, etc.
1. Selecting menu
Select "Monitoring" on the service menu screen.
4. Deleting abnormality record 3) After the "Electrical Sys. Error Reset" screen
1) While the "Electrical Systems" screen is is displayed, operate the function switches.
displayed, perform the following operation by q [F5]: Return to "Electrical systems"
the numeral input switches. screen (Reset mode)
q Operation of switches (While pressing [4], q [F6]: Perform deletion
perform the operation in order): a The following figure shows the screen
[4] + [1] o [2] o [3] displayed when the items are deleted one
by one (which is a little different from the
screen displayed when all the items are
deleted together).
1. Selecting menu
Select "Phone Number Entry" on the "Service
Menu" screen.
1. Selecting menu
Select "Default" on the "Service Menu" screen.
Adjustment (Swing Motor Starting Torque) 3. After the "Swing motor starting torque"
Various adjustments of the machine can be per- screen is displayed, select a set value on the
formed on the machine monitor. right side with the function switches.
The function of setting the swing starting torque is q Set value: For the actual swing motor torque,
used to finely adjust the maximum swing motor see the table.
torque at the start of swinging. q [F3]: Increase the set value.
The acceleration time at the start of swinging can be q [F4]: Decrease the set value.
adjusted finely with this function. q [F6]: Confirm or enter and return to the ad-
justment menu screen.
1. Selection of menu a The three digits on the left side do not change
Select "Adjustment" on the "Service menu" since they are the code of this function.
screen.
Adjustment (Hoist Swing Adjustment) 3. After the "Hoist swing adjustment" screen is
Various adjustments of the machine can be per- displayed, select a set value on the right side
formed on the machine monitor. with the function switches.
The function of adjusting hoist swing is used to ad- q Set value: For the actual swing motor torque,
just the maximum swing motor torque generated at see the table.
combined operations of swing and boom to adjust q [F3]: Increase the set value.
the hoist swing acceleration finely. q [F4]: Decrease the set value.
q [F6]: Confirm or enter and return to the ad-
1. Selection of menu justment menu screen.
Select "Adjustment" on the "Service menu" a The three digits on the left side do not change
screen. since they are the code of this function.
Check of matching speed Calibration of matching speed Return to initial value Return to value at delivery
Check of matching speed Check of matching speed Setting screen Setting screen
<Operation> <Operation>
Relieve by arm-in operation Relieve by arm-in operation
<Condition> <Condition>
Repeat 3 times
Repeat 3 times
Repeat 3 times
Update setting
2. Selection of menu
Select "Adjustment" on the "Service menu"
screen.
Check of matching speed (4/6 to 6/6) 3) While performing arm-in relief or bucket-curl
relief operation, when the engine speed is
stabilized, hold down "F1" of the machine
monitor to start the calibration.
The screen displays the bar while the
matching speed is being checked. Continue
the relief operation until checking is
completed. (About 10 seconds)
E-3 Engine speed is out of specified range Out of target speed 200 rpm Check engine high idle speed
Out of target torque 100 Nm { 10 Perform troubleshooting for engine
E-4 Engine torque is out of specified range
kgm} and pump
Perform troubleshooting for PC-EPC
E-5 PC-EPC current is out of specified range Out of 400 to 650 mA
current
During bucket-curl relief operation,
bucket-curl PPC pressure is below Below 2.2 MPa {22 kg/cm2} or sensor Check bucket control lever is at FULL
E-6
specified value or in normal range of voltage is out of 0.5 to 4.5 [V] (*1) position
bucket-curl PPC pressure sensor
E-7 Working mode is not P or ATT/P Mode other than P and ATT/P Check working mode is P or ATT/P
Swing emergency stop switch is not Check swing emergency stop switch
E-8 Swing emergency stop switch is not ON
at ON position is ON
Swing lock switch is not at ON
E-9 Swing lock switch is not ON Check swing lock switch is ON
position
*1: When the sensor voltage is other than the standard range (0.5 4.5 V), pump controller recognizes the
voltage as 0 MPa {0 kg/cm2}, perform troubleshooting referring to the section "Troubleshooting" (failure
codes [DHPAMA] and [DHPBMA])
*2: Relief side standard value [35.3 MPa {360 kg/cm2}] 2.0 MPa {20 kg/cm2}
*3: MIN side standard value [3.9 MPa {40 kg/cm2}] 2.0 MPa {20 kg/cm2}
Discharging capacitor
The capacitor can be discharged by operating the
machine monitor.
1. Selecting menu
Select "Discharge capacitor" on the "Service
menu" screen.
2. Discharge operation
See 00 Foreword, Safety, Basic information
"Discharging capacitor" in "Handling hybrid
devices or high-voltage wirings".
Cylinder Cut-Out
The technician can perform "Cylinder Cut-Out" op-
eration by using the machine monitor.
"Cylinder Cut-Out" operation means to run the en-
gine with one or more fuel injectors disabled electri-
cally to reduce the number of active cylinders. This
operation is used to find out a cylinder which does
not output power properly (combustion in it is abnor-
mal).
1. Selecting menu
Select "Cylinder Cut-Out" on the "Service Menu"
screen.
2. Starting measurement
After the screen of "Fuel Consumption" is
displayed, start measurement by the function
switches. 4. Finishing measurement
q [F1]: START Press [F1], and measurement is finished and the
q [F2]: CLEAR data are displayed on the "Stop Time".
q [F5]: Return to Service menu screen
a When "Fuel consumption" screen is dis- 5. Displaying fuel consumption
played, if a data is indicated, it is the data of If the measurement is finished, the hourly fuel
the previous measurement. This data is not consumption obtained from the fuel consump-
an obstacle to new measurement and can be tion calculated by the engine controller and the
deleted by pressing [F2]. elapsed time are displayed.
a If [F1] is pressed, the data is displayed on the
"Start Time" side and measurement starts.
KOMTRAX Settings (GPS & Communication Sta- 3. Contents of display of GPS & communication
tus) status
The setting condition and operating condition of KO- On the screen of "GPS & Communication
MTRAX can be checked with "KOMTRAX Settings". Status", the following items are displayed.
GPS & communication status is used to check the q Positioning: positioning condition by GPS
condition of positioning and communication of the q Communication: communication environ-
KOMTRAX terminal. ment of communication modem and connect-
ing condition of communication modem
1. Selecting menu q Number of message not yet sent: number of
Select "KOMTRAX Settings" on the "Service mails which are stored in the machine moni-
Menu" screen. tor but not transmitted yet
q [F5]: Return to KOMTRAX settings screen
1. Selecting menu
Select "KOMTRAX Settings" on the "Service
Menu" screen.
a While removing the cover, disconnect the 4) Insert or connect test T-adapters into or to
body and operation portion of emergency connectors CM01, CM02, and CM03 of
stop switch (3). machine monitor (7).
a Connectors CM02 and CM03 are the
same type. When returning them, check
the mark plates on the mounting brackets
and exercise care to connect them cor-
rectly.
3. Pump controller
1) Slide the operator seat and seat stand to the
forward end.
2) Remove fuse box cover (6), remove the three
mounting bolts and cover (7).
a Since cover (7) is fixed with a clamp at its
bottom, pull it up to remove.
a Disconnect each pump controller connec-
tor, which has a special locking device, in
the order of (a) (c) in the following figure
and connect in the order of (d) (f).
Disconnection: (a) Unlock (b) Slide
lever (c) Disconnect connector.
Connection: (d) Position connector (e)
Slide lever (f) Engage lock.
8. Supply pump IMV solenoid (FUEL REGU- 9. Common rail pressure sensor (FUEL RAIL
LATOR) PRESS)
a Disconnection and connection of connec- a Disconnection and connection of connec-
tor tor
The connector of the supply pump IMV sole- The connector of the common rail pressure
noid has a special locking device. Disconnect sensor has a special locking device. Discon-
it in the order of steps (a) (b) and connect it nect it in the order of steps (a) (b) and
in the order of steps (c) (d) as shown below. connect it in the order of steps (c) (d) as
Disconnection: (a) Unlock (b) Disconnect shown below.
connector. Disconnection: (a) Unlock (b) Disconnect
Connection: (c) Connect connector (d) connector.
Engage lock. Connection: (c) Connect connector (d)
Engage lock.
Pm Clinic 141
C m
Operator's comment
Visual check
Mechanical equipment system failure record Electrical equipment system failure record
989EKX time/1st time h/last h time/1st time h/last h
AA10NX time/1st time h/last h time/1st time h/last h
AB00KE time/1st time h/last h time/1st time h/last h
B@BAZG time/1st time h/last h time/1st time h/last h
B@BAZK time/1st time h/last h time/1st time h/last h
B@BCNS time/1st time h/last h time/1st time h/last h
B@BCZK time/1st time h/last h time/1st time h/last h
B@HANS time/1st time h/last h time/1st time h/last h
CA234 time/1st time h/last h time/1st time h/last h
Max. range of engine coolant temperature gauge Max. range of hydraulic oil temperature gauge
Check sheet
Model Serial No. Service meter User's name Date of check Inspector
/ /
1. Engine
Checking condition Standard
Good
value for Service Measured
NG
No. Check item Fuel Working Auto- Left Operation Unit
control mode deceler- knob of work new limit value value
dial ation switch equipment machine
1,990 1,990
1 Engine speed All levers in rpm
2,130 2,130
MAX the neutral
Engine oil position MPa Min. 0.29 0.25
2
pressure {kg/cm2} {Min.3.0} {2.5}
OFF
1,000 1,000
3 Engine speed All levers in rpm
1,100 1,100
MIN the neutral
Engine oil position MPa Min. 0.10 0.07
4 OFF
pressure {kg/cm2} {Min.1.0} {0.7}
P
1,700 1,700
5 Engine speed rpm
Arm IN 1,900 1,900
ON
relief kPa Max.0.98 1.96
6 Blowby pressure
{mmH2O} {Max.100} {200}
MAX
1,150 1,150
7 Engine speed All levers in 1,350 1,350
OFF the neutral rpm
8 Engine speed ON position 650 750 650 750
Good
value for Service Measured
NG
No. Check item Fuel Working Unit
control mode Checking posture, etc. new limit value value
dial machine
Work equipment extended
1 Boom RAISE sec. 3.1 3.9 Max. 4.9
P fully
sec. 3.3 4.1 Max. 4.7
3 Arm IN
E sec. 3.4 4.2 Max. 4.6
Boom top horizontal
4 Arm OUT sec. 2.4 3.0 Max. 3.5
Boom top horizontal
6 Bucket CURL MAX sec. 2.3 2.9 Max. 3.3
Arm cylinder retracted fully
Work equipment extended
6 Swing (5 turns) P fully sec. 21.7 26.7 Max. 30
Swing right and left
One side of track LO sec. 46.2 56.4 Max. 60.4
Travel
5 raised and turned MI sec. 33.7 41.3 Max. 45.3
(five idle turns)
forward and backward HI sec. 25.2 27.8 Max. 29.8
4. Hydraulic circuit
[1] [2] [3] [4] [5]
Checking condition 60 MPa 60 MPa 60 MPa 60 MPa 6 MPa
{600 {600 {600 {600 {60
Good
NG
No. Check item kg/cm2} kg/cm2} kg/cm2} kg/cm2} kg/cm2}
Fuel Working Auto- Operation of work F pump R pump F pump R pump
control mode deceler- equipment main main main main Control
dial ation
Self-pressure All levers in the A
1 - - - -
reducing valve neutral position
OFF
Main relief valve B B B B
2 -
(Low pressure)
Arm OUT relief
Main relief valve C C C C
3 ON -
(High pressure)
All levers in the D1 D1 D2 D2
4 Unload valve -
neutral position
Right track driven idle E1 E2
- - -
Lever moved halfway
5 LS valve MAX P
Left track driven idle E1 E2
- - -
Lever moved halfway
Right travel lock F
OFF - - - -
Main relief Right forward relief
valve Right travel lock F
- - - -
Travel motor Right reverse relief
6
Safety valve Left travel lock F
Travel junction - - - -
Left forward relief
valve Left travel lock F
- - - -
Left reverse relief
Checked oil pressure Unit Standard value for new machine Service limit value
A (Control circuit source
2.93 3.43 {30 35} 2.74 3.43 {28 35}
pressure)
Standard value
Good
NG
No. Check item kg/cm2} kg/cm2} kg/cm2} kg/cm2} kg/cm2}
Fuel Working Auto- Operation of work F pump R pump F pump R pump
control mode deceler- equipment main main main main Control
dial ation
H1 H1 H2 H2
7 Servo piston MAX P OFF Arm OUT relief -
Checked oil pressure Unit Standard value for new machine Service limit value
Standard
value
H1: H2 = 1 : 0.6
H (Servo control pressure) -
(Oil pressure ratio)
* Gauge changing work: Change [3] and [4] to 6 MPa {60 kg/cm2} and change hoses of [3], [4], and [5].
[1] [2] [3b] [4b] [5a]
Checking condition 60 MPa 60 MPa 60 MPa 60 MPa 6 MPa
{600 {600 {600 {600 {60
Good
NG
No. Check item kg/cm2} kg/cm2} kg/cm2} kg/cm2} kg/cm2}
Fuel Auto-
control Working deceler- Operation of work F pump R pump F pump R pump LS-EPC
dial mode ation equipment main main (F) (R)
J1 J1
MIN - - -
PC-EPC
P
(F) valve All levers in the J2 J2
8 - - -
PC-EPC neutral position
(R) valve J3 J3
E - - -
Travel speed: LO K1
OFF Travel lever in the - - - -
MAX neutral position
K2
Travel speed: MI
9 LS-EPC valve P - - - -
Travel lever operated
K3
Travel speed: HI
- - - -
Travel lever operated
Checked oil pressure Unit Standard value for new machine Service limit value
J1 (PC-EPC valve output
pressure 1) Approx. 2.9 {Approx. 30}
J2 (PC-EPC valve output
Approx. 0.7 {Approx. 7}
Standard value
pressure 2)
J3 (PC-EPC valve output
pressure 3) Approx. 0.78 {Approx. 8}
MPa
K1 (LS-EPC valve output {kg/cm2}
pressure 1) Approx. 2.45 {Approx. 25}
K2 (LS-EPC valve output
pressure 2) Approx. 0.74 {Approx. 7.5}
K3 (LS-EPC valve output
pressure 3) 0 {0}
HB205-1
HYDRAULIC EXCAVATOR
Shop Manual 4-01
HB205-1
HB215LC-1
40 Troubleshooting 40-1
Contents 40-2
40 Troubleshooting
General information on troubleshooting.................................................................................. 40- 10
Points to remember when troubleshooting .......................................................................... 40- 10
Sequence of events in troubleshooting................................................................................ 40- 11
Checks before troubleshooting ............................................................................................ 40- 12
Classification and procedures for troubleshooting ............................................................... 40- 41
Failure codes table............................................................................................................... 40- 44
Symptom and troubleshooting numbers .............................................................................. 40- 52
Information in troubleshooting table..................................................................................... 40- 55
Troubleshooting method for open circuit in wiring harness of pressure sensor system ...... 40- 57
Connector list and layout ..................................................................................................... 40- 59
Connection table for connector pin numbers ....................................................................... 40- 70
T- branch box and T- branch adapter table ......................................................................... 40- 106
Fuse location table............................................................................................................... 40- 109
Troubleshooting by failure code.............................................................................................. 40- 111
Failure code [989L00] Engine Controller Lock Caution 1 .................................................... 40- 111
Failure code [989M00] Engine Controller Lock Caution 2 ................................................... 40- 111
Failure code [989N00] Engine Controller Lock Caution 3.................................................... 40- 111-1
Failure code [AA10NX] Air Cleaner Clogging ...................................................................... 40- 111-2
Failure code [AB00KE] Charge Voltage Low ....................................................................... 40- 112
Failure code [B@BAZG] Eng Oil Press Low........................................................................ 40- 114
Failure code [B@BAZK] Eng Oil Level Low......................................................................... 40- 115
Failure code [B@BCNS] Eng Water Overheat .................................................................... 40- 116
Failure code [B@BCZK] Eng Water Level Low ................................................................... 40- 118
Failure code [B@HANS] Hyd Oil Overheat.......................................................................... 40- 120
Failure code [CA111] ECM Critical Internal Failure ............................................................. 40- 121
Failure code [CA115] Eng Ne and Bkup Speed Sens Error ................................................ 40- 121
Failure code [CA122] Chg Air Press Sensor High Error ...................................................... 40- 122
Failure code [CA123] Chg Air Press Sensor Low Error ....................................................... 40- 124
Failure code [CA131] Throttle Sensor High Error ................................................................ 40- 126
Failure code [CA132] Throttle Sensor Low Error ................................................................. 40- 128
Failure code [CA144] Coolant Temp Sens High Error ......................................................... 40- 130
Failure code [CA145] Coolant Temp Sens Low Error.......................................................... 40- 132
Failure code [CA153] Chg Air Temp Sensor High Error ...................................................... 40- 134
Failure code [CA154] Chg Air Temp Sensor Low Error ....................................................... 40- 136
Failure code [CA155] Chg Air Temp High Speed Derate .................................................... 40- 138
Failure code [CA187] Sens Supply 2 Volt Low Error ........................................................... 40- 140
Failure code [CA221] Ambient Press Sens High Error ........................................................ 40- 142
Failure code [CA222] Ambient Press Sens Low Error ......................................................... 40- 144
Failure code [CA227] Sens Supply 2 Volt High Error .......................................................... 40- 146
Failure code [CA234] Eng Overspeed ................................................................................. 40- 146
Failure code [CA238] Ne Speed Sens Supply Volt Error..................................................... 40- 147
Failure code [CA271] IMV/PCV1 Short Error....................................................................... 40- 148
Failure code [CA272] IMV/PCV1 Open Error....................................................................... 40- 150
Failure code [CA322] Inj #1(L#1) Open/Short Error............................................................. 40- 152
Failure code [CA324] Inj #3(L#3) Open/Short Error............................................................. 40- 154
Failure code [CA331] Inj #2(L#2) Open/Short Error............................................................. 40- 156
Failure code [CA332] Inj #4(L#4) Open/Short Error............................................................. 40- 158
Failure code [CA342] Calibration Code Incompatibility........................................................ 40- 160
Failure code [CA351] Injectors Drive Circuit Error ............................................................... 40- 161
Failure code [CA352] Sens Supply 1 Volt Low Error ........................................................... 40- 162
Failure code [CA386] Sens Supply 1 Volt High Error .......................................................... 40- 164
Failure code [CA428] Water in Fuel Sensor High Error....................................................... 40- 166
Failure code [CA429] Water in Fuel Sensor Low Error........................................................ 40- 168
Failure code [CA435] Eng Oil Press Sw Error ..................................................................... 40- 170
Failure code [CA441] Battery Voltage Low Error ................................................................. 40- 172
Failure code [CA442] Battery Voltage High Error ................................................................ 40- 174
Failure code [CA449] Rail Press Very High Error ................................................................ 40- 175
Failure code [CA451] Rail Press Sensor High Error ............................................................ 40- 176
Failure code [CA452] Rail Press Sensor Low Error............................................................. 40- 178
Failure code [CA488] Chg Air Temp High Torque Derate ................................................... 40- 180
Failure code [CA553] Rail Press High Error ........................................................................ 40- 181
Failure code [CA559] Supply Pump Press Low Error 1....................................................... 40- 182
Failure code [CA689] Eng Ne Speed Sensor Error ............................................................. 40- 184
Failure code [CA731] Eng Bkup Speed Sens Phase Error.................................................. 40- 186
Failure code [CA757] All Continuous Data Lost Error ......................................................... 40- 187
Failure code [CA778] Eng Bkup Speed Sensor Error.......................................................... 40- 188
Failure code [CA1633] KOMNET Datalink Timeout Error.................................................... 40- 191
Failure code [CA2185] Throt Sens Sup Volt High Error ...................................................... 40- 192
Failure code [CA2186] Throt Sens Sup Volt Low Error ....................................................... 40- 193
Failure code [CA2249] Rail Press Very Low Error............................................................... 40- 194
Failure code [CA2311] IMV Solenoid Error.......................................................................... 40- 195
Failure code [CA2555] Grid Htr Relay Open Circuit Error ................................................... 40- 196
Failure code [CA2556] Grid Htr Relay Short Circuit Error ................................................... 40- 198
Failure code [D19JKZ] Personal Code Relay Abnormality .................................................. 40- 200
Failure code [D862KA] GPS Antenna Open Circuit............................................................. 40- 203
Failure code [DA22KK] Pump Solenoid Power Low Error ................................................... 40- 204
Failure code [DA25KP] 5V Sensor1 Power Abnormality ..................................................... 40- 206
Failure code [DA26KP] 5V Sensor2 Power Abnormality ..................................................... 40- 208
Failure code [DA29KQ] Model Selection Abnormality ......................................................... 40- 210
Failure code [DA2RMC] CAN Discon (Pump Con Detected) .............................................. 40- 212
Failure code [DAF8KB] Camera Power Supply Short Circuit .............................................. 40- 218
Failure code [DAFGMC] GPS Module Error ........................................................................ 40- 220
Failure code [DAFRMC] CAN Discon (Monitor Detected) ................................................... 40- 221
Failure code [DGH2KB] Hyd Oil Sensor Short .................................................................... 40- 228
Failure code [DHPAMA] Pump Press Sensor Abnormality.................................................. 40- 230
Failure code [DHPBMA] R Pump Press Sensor Abnormality .............................................. 40- 232
Failure code [DHS3MA] Arm IN PPC Sen. Abnormality ...................................................... 40- 234
Failure code [DHS4MA] Bucket CURL PPC Press Sensor Abnormality ............................. 40- 236
Failure code [DHS8MA] Boom RAISE PPC Press Sensor Abnormality .............................. 40- 238
Failure code [DHSAKZ] Swing RIGHT PPC pressure sensor system open or short circuit 40- 240
Failure code [DHSBKZ] Swing LEFT PPC pressure sensor system open or short circuit... 40- 242
Failure code [DHSAMA] Swing RH PPC Press Sensor Abnomality .................................... 40- 244
Failure code [DHSBMA] Swing LH PPC Press Sensor Abnomality .................................... 40- 246
Failure code [DHSDMA] Bucket Dump PPC Press Sensor Abnormality ............................. 40- 248
Failure code [DHV3KZ] HYB system arm IN PPC pressure sensor open or short circuit ... 40- 250
Failure code [DHV9KZ] HYB Boom Lower PPC Pr. Sen. Open/Shrt Cir ............................. 40- 252
Failure code [DHVAKZ] HYB Swing-R PPC Pr. Sen. Opn/Short Cir ................................... 40- 254
Failure code [DHVAL8] HYB system swing RIGHT PPC pressure sensor signal abnormality40-256
Failure code [DHVAMA] HYB system swing RIGHT PPC pressure sensor malfunction ..... 40- 257
Failure code [DHVBKZ] HYB Swing-L PPC Pr. Sen. Opn/short Cir .................................... 40- 258
Failure code [DHVBL8] HYB system swing LEFT PPC pressure sensor signal abnormality 40- 260
Failure code [DHVBMA] HYB system swing LEFT PPC pressure sensor malfunction ....... 40- 261
Failure code [DHVCKZ] HYB Arm Dump PPC Pr. Sen. Opn/short Cir ................................ 40- 262
Failure code [DW43KA] Travel Speed Sol Open Circuit...................................................... 40- 264
Failure code [DW43KB] Travel Speed Sol Short Circuit ...................................................... 40- 266
Failure code [DW45KA] Swing holding brake solenoid valve open circuit........................... 40- 268
Failure code [DW45KB] Swing holding brake solenoid valve short circuit........................... 40- 271
Failure code [DW45KK] Swing holding brake solenoid valve power voltage drop............... 40- 274
Failure code [DW45KY] swing holding brake Sol. Val. Pow. Short Cir ................................ 40- 276
Failure code [DW4WKA] Cancel Bucket Dump Open Circuit .............................................. 40- 278
Failure code [DW4WKB] Cancel Bucket Dump Short Circuit .............................................. 40- 280
Failure code [DW91KA] Travel Junction Sol. Disc............................................................... 40- 282
Failure code [DW91KB] Travel Junction Sol. S/C................................................................ 40- 284
Failure code [DWA2KA] Attachment Sol Open Circuit......................................................... 40- 286
Failure code [DWA2KB] Attachment Sol Short Circuit......................................................... 40- 288
Failure code [DWK0KA] 2-stage Relief Sol Open Circuit..................................................... 40- 290
Failure code [DWK0KB] 2-stage Relief Sol Short Circuit..................................................... 40- 292
Failure code [DXA8KA] PC-EPC (F) Sol Open Circuit......................................................... 40- 294
Failure code [DXA8KB] PC-EPC (F) Sol Short Circuit......................................................... 40- 296
Failure code [DXA9KA] PC-EPC (R) Sol Open Circuit ........................................................ 40- 298
Failure code [DXA9KB] PC-EPC (R) Sol Short Circuit ........................................................ 40- 300
Failure code [DXE0KA] LS-EPC Sol Open Circuit............................................................... 40- 302
Failure code [DXE0KB] LS-EPC Sol Short Circuit ............................................................... 40- 304
Failure code [DXE4KA] Service Current EPC Disc.............................................................. 40- 306
Failure code [DXE4KB] Service Current EPC S/C............................................................... 40- 308
Failure code [DXE5KA] Merge-divider Main Sol Open Circuit ............................................. 40- 310
Failure code [DXE5KB] Merge-divider Main Sol Short Circuit ............................................. 40- 312
Failure code [DXE6KA] Merge-divider LS Sol Open Circuit ................................................ 40- 314
Failure code [DXE6KB] Merge-divider LS Sol Short Circuit................................................. 40- 316
Failure code [DY20KA] Wiper Working Abnormality............................................................ 40- 318
Failure code [DY20MA] Wiper Parking Abnormality ............................................................ 40- 320
Failure code [DY2CKA] Washer drive discon ...................................................................... 40- 322
Failure code [DY2CKB] Washer drive short......................................................................... 40- 324
Failure code [DY2DKB] Wiper Drive (Fwd) Short Circuit ..................................................... 40- 326
Failure code [DY2EKB] Wiper Drive (Rev) Short Circuit...................................................... 40- 328
Troubleshooting by failure code [GA****] (code display)......................................................... 40- 330
Precaution in hybrid device troubleshooting, and common troubleshooting procedures for high voltage
devices................................................................................................................................. 40- 330
Failure code [GA----] Hybrid devices monitoring items list and check sheet........................ 40- 355
Failure code [GA00NS] HYB devices overheat ................................................................... 40- 359
Failure code [GA01KA] Power Cable Interlock Open Circuit ............................................... 40- 360
Failure code [GA02KZ] DC Line Open/Short Circuit............................................................ 40- 362
Failure code [GA04KG] Abnormal DC HW Volt. Before Booster ......................................... 40- 363
Failure code [GA05KG] Abnormal DC SW Volt. Before Booster ......................................... 40- 364
Failure code [GA05KP] Low DC SW Output Volt. Bef. Booster........................................... 40- 365
Failure code [GA06KZ] DC Vlt. Sen. Opn./Shrt. Cir. Bef. Booster....................................... 40- 366
Failure code [GA08KG] Abnormal. DC HW Volt. After Booster ........................................... 40- 367
Failure code [GA09KG] Abnormal. DC SW Volt. After Booster ........................................... 40- 368
Failure code [GA09KP] Low DC SW Output Volt. After Booster.......................................... 40- 369
Failure code [GA0AKZ] DC Volt. Sen. Op./Shrt cir. Aft. Booster ......................................... 40- 370
Failure code [GA0BKZ] AC Line Open/Short Circuit............................................................ 40- 371
Failure code [GA12MC] HYB Cont. Pow. Suppl. Failure ..................................................... 40- 372
Failure code [GA12NK] HYB Cont. Pow. Suppl. Not Turn. ON ........................................... 40- 373
Failure code [GA12NL] HYB Cont. Pow. Suppl. Not Turn. OFF .......................................... 40- 374
Failure code [GA13MC] HYB Control. Sen. Power Sup. Failure ......................................... 40- 376
Failure code [GA14KR] HYB Control. KOMNET Comm. Failure ......................................... 40- 378
Failure code [GA15KZ] HYB Cont. Bad Insul. Sen. Opn/Short. Cir ..................................... 40- 379
Failure code [GA17KR] Gen. Mot. Drv. Communication Failure.......................................... 40- 379
Failure code [GA17KY] Gen. Mot Dr. Power Line Short Circuit........................................... 40- 380
Failure code [GA17KZ] Gen. Motor Driver Open/Short Circuit ............................................ 40- 380
Failure code [GA17MB] Gen. Mot. Drv. Function Degraded ............................................... 40- 381
Failure code [GA18MC] Gen.Mo. Dr. Excite. Pow. Sup. Failure ......................................... 40- 381
Failure code [GA19KK] Gen. Mot. Drv. Sub-CPU Low Sup. Volt ........................................ 40- 382
Failure code [GA19KR] Gen. Motor Driver Sub-CPU Comm. Failure ................................. 40- 382
Failure code [GA19KT] Int. Abnorm. Gen. Mot. Drv. Sub-CPU Con. .................................. 40- 383
Failure code [GA19MA] Gen. Mot. Drv. Sub-CPU Malfunction ........................................... 40- 383
Failure code [GA19MC] Gen. Mot. Drv. Sub-CPU Defect. Operation ................................. 40- 384
Failure code [GA19NA] Gen. Mot. Drv. Sub-CPU Start Disabled........................................ 40- 384
Failure code [GA1BMA] Gen. Mot. Dr. DC Vlt. Sens. Malfunction ...................................... 40- 385
Failure code [GA1FKR] Swing Mot. Drv. Communication Failure ....................................... 40- 385
Failure code [GA1FMA] Abnormal Swing Motor Driver ....................................................... 40- 386
Failure code [GA1GKK] Low Sup. Volt. Swing Motor Drv. Sub-CPU .................................. 40- 386
Failure code [GA1GKR] Swing Mot. Driver Sub-CPU Comm. Failure ................................. 40- 387
Failure code [GA1GKT] Swing Mot. Drv. Sub-CPU Cont. Abnormal................................... 40- 387
Failure code [GA1GMA] Swing Motor Drv. Sub-CPU Malfunction ...................................... 40- 388
Failure code [GA1GMB] Swing Mot. Drv. Sub-CPU Funct. Degraded ................................ 40- 388
Failure code [GA1GMC] Swing Mot. Drv. Sub-CPU Defect Op........................................... 40- 389
Failure code [GA1GNA] Swing Mot. Drv. Sub-CPU Start Disabled..................................... 40- 389
Failure code [GA1HKZ] Swg Mot. Dr. Ph-U Tem. Sens Opn/Shrt Cir. ................................ 40- 390
Failure code [GA1JKZ] Swg Mot. Dr. Ph-V Tem. Sens Opn/Shrt Cir. ................................. 40- 390
Failure code [GA1KKZ] Swg Mot. Dr. Ph-W Tem. Sens Opn/Shrt Cir................................. 40- 391
Failure code [GA1LKZ] Swg Mot. Dr. Current. Sens Opn/Shrt Cir. ..................................... 40- 391
Failure code [GA1MKZ] Swg Mot. Dr. DC Vlt. Sen Opn/Shrt Cir......................................... 40- 392
Failure code [GA1NNS] Swing Motor Driver IGBT Overheat .............................................. 40- 393
Failure code [GA1SFS] Contactor Locked........................................................................... 40- 394
Failure code [GA1SMC] Contactor Failure .......................................................................... 40- 394
Failure code [GA1TKP] Capacitor Low Output Voltage....................................................... 40- 395
Failure code [GA1TNS] Capacitor Overheat ....................................................................... 40- 396
Failure code [GA1UKZ] Capacitor Temp. Sensor Opn/Short Cir......................................... 40- 398
Failure code [GA1VFS] Capacitor Contactor Locked .......................................................... 40- 400
Failure code [GA1VMC] Capacitor Contactor Failure.......................................................... 40- 402
Failure code [GA1XKZ] Boost. Ind. Temp. Sens. Open/Shrt. Circ. ..................................... 40- 403
Failure code [GA1YNS] Booster Inductor Overheat ............................................................ 40- 404
Failure code [GA1ZKZ] Booster IGBT Temp. Sens. Opn/Shrt. Circ. ................................... 40- 404-1
Failure code [GA1ZNS] Booster IGBT Temp. Sens. Overheat............................................ 40- 404-2
Failure code [GA21KB] Booster IGBT Short Circuit ............................................................ 40- 404-3
Failure code [GA22NS] Booster IGBT Junction Overheat................................................... 40- 405
Failure code [GA23KZ] Gen. Mot. Dr. Temp. Sens.0 Opn/Short Cir. .................................. 40- 406
Failure code [GA24KZ] Gen. Mot. Dr. Temp. Sens.1 Opn/Short Cir. .................................. 40- 406
Failure code [GA25MA] Gen. Motor Driver IGBT0 Abnormality .......................................... 40- 407
Failure code [GA25NS] Gen. Motor Driver IGBT0 overheat................................................ 40- 407-1
Failure code [GA26MA] Gen. Motor Driver IGBT1 Abnormality .......................................... 40- 407-2
Failure code [GA26NS] Gen. Motor Driver IGBT1 overheat................................................ 40- 408
Failure code [GA27KZ] DC before boosting sensor open or short circuit ............................ 40- 409
Failure code [GA28KZ] DC after boosting sensor open or short circuit............................... 40- 409
Failure code [GA60MC] Generator Motor Failure................................................................ 40- 410
Failure code [GA60MD] Gen. Mot. Defective Movement..................................................... 40- 411
Failure code [GA60N1] Generator Motor Overrun............................................................... 40- 412
Failure code [GA61KZ] Gen. Motor Temp. Sens. Open/Short Cir....................................... 40- 414
Failure code [GA61NS] Generator Motor Temp. Sensor Overheat ..................................... 40- 416
Failure code [GA62KY] Gen. Mot. Ph-A Cur. Sen. Power Short Cir.................................... 40- 417
Failure code [GA62KZ] Gen. Mot. Ph-A Cur. Sen. Open/Short Cir ..................................... 40- 418
Failure code [GA62MA] Gen. Mot. Ph-A Current Sen. Malfunction ..................................... 40- 419
Failure code [GA63KY] Gen. Mot. Ph-B Cur. Sen. Power Short Cir.................................... 40- 419
Failure code [GA63KZ] Gen. Mot. Ph-B Cur. Sen. Open/Short Cir ..................................... 40- 420
Failure code [GA63MA] Gen. Mot. Ph-B Current Sen. Malfunction ..................................... 40- 420
Failure code [GA64KY] Gen. Mot. Ph-C Cur. Sen. Power Short Cir.................................... 40- 421
Failure code [GA64KZ] Gen. Mot. Ph-C Cur. Sen. Open/Short Cir. .................................... 40- 422
Failure code [GA64MA] Gen. Mot. Ph-C Current Sen. Malfunction..................................... 40- 422
Failure code [GA70KB] HYB Swing Motor Short Circuit ...................................................... 40- 423
Failure code [GA70MD] HYB Swing Motor Defective Stirr. Motion...................................... 40- 423
Failure code [GA70NS] HYB Swing Motor Overheat........................................................... 40- 424
Failure code [GA71KZ] HYB Swing Mot. Temp. Sens. Opn/Shrt Cir................................... 40- 426
Failure code [GA72MA] HYB Swing Motor Resolver Malfunction........................................ 40- 428
Failure code [GA72MC] HYB Swing Motor Resolver Defect Op.......................................... 40- 430
Failure code [GA81KZ] Swing Motor Power Cable Opn/Shrt Circ. ...................................... 40- 430
Failure code [GAA100] Swing emergency stop switch operated ......................................... 40- 431
Failure code [GAA2KB] Swing Brake sol. Supply Line short cir. ......................................... 40- 432
Troubleshooting of electrical system (E-mode)....................................................................... 40- 434
E-1 Engine does not start (Engine does not crank) ............................................................. 40- 434
E-2 Preheater does not operate........................................................................................... 40- 440
E-3 When starting switch is turned to ON position, machine monitor displays nothing ....... 40- 445
E-4 When starting switch is turned to ON position (with engine stopped), basic check monitor lights up.
............................................................................................................................................. 40- 448
E-5 Precaution monitor lights up while engine is running .................................................... 40- 449
E-6 Emergency stop monitor lights up while engine is running ........................................... 40- 451
E-7 Fuel level gauge does not indicate properly.................................................................. 40- 452
E-8 Engine coolant temperature gauge does not indicate properly ..................................... 40- 454
E-9 Hydraulic oil temperature gauge does not indicate properly ......................................... 40- 456
E-10 HYB system temperature gauge does not indicate properly ....................................... 40- 458
E-11 Displays on machine monitor are different from those for actual machine.................. 40- 460
E-12 Machine monitor does not display some items ........................................................... 40- 460
E-13 Function switch does not work .................................................................................... 40- 460
E-14 Automatic warm-up system does not operate (in cold season)................................... 40- 461
E-15 Auto-decelerator does not operate normally ............................................................... 40- 462
E-16 Working mode does not change.................................................................................. 40- 463
E-17 Travel speed does not change .................................................................................... 40- 464
E-18 Alarm buzzer does not stop sounding ......................................................................... 40- 465
E-19 When starting switch is at OFF position, service meter is not displayed..................... 40- 465
E-20 Machine monitor cannot be set in service mode ......................................................... 40- 465
E-21 All of work equipment, swing, and travel mechanism do not move or are not locked . 40- 466
E-22 Swing holding brake does not operate properly .......................................................... 40- 469
E-23 One-touch power max. function does not operate ...................................................... 40- 472
E-24 Travel alarm does not sound or does not stop sounding ............................................ 40- 476
E-25 Horn does not sound or does not stop sounding......................................................... 40- 478
E-26 Windshield wiper and window washer do not operate ................................................ 40- 480
E-27 "BOOM LOWER" indicator is not displayed properly with monitoring function ........... 40- 482
E-28 "ARM OUT" indicator is not displayed properly with monitoring function .................... 40- 484
E-29 "ARM IN" indicator is not displayed properly with monitoring function ........................ 40- 486
E-30 "BOOM RAISE" indicator is not displayed properly with monitoring function.............. 40- 486
E-31 "BUCKET CURL" indicator is not displayed properly with monitoring function ........... 40- 486
E-32 "BUCKET DUMP" indicator is not displayed properly with monitoring function .......... 40- 487
E-33 "SWING" indicator is not displayed properly with monitoring function ........................ 40- 487
E-34 "TRAVEL" indicator is not displayed properly with monitoring function....................... 40- 488
E-35 "TRAVEL STEERING" indicator is not displayed properly with monitoring function ... 40- 490
E-36 "SERVICE" indicator is not displayed properly with monitoring function..................... 40- 492
The aim of troubleshooting is to pinpoint the basic cause of the failure, to carry out repairs swiftly, and to pre-
vent reoccurrence of the failure. When carrying out troubleshooting, an important point is of course to under-
stand 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 symp-
toms.
1. When carrying out troubleshooting, do not hurry 3) Make checks of other items.
to disassemble the components. 4) Check other maintenance matters which can
If components are disassembled immediately be checked externally and are considered to
after any failure occurs: be necessary.
q Parts that have no connection with the failure
or other unnecessary parts will be disassem- 4. Confirming failure
bled. Confirm the extent of the failure yourself, and
q It will become impossible to find the cause of judge whether to handle it as a real failure or as
the failure. a problem with the method of operation, etc.
It will also cause a waste of manhours, parts, or a When operating the machine to reenact the
oil or grease, and at the same time, will also lose troubleshooting symptoms, do not perform
the confidence of the user or operator. any inspection or measurement that may
For this reason, when carrying out trouble- make the problem worse.
shooting, it is necessary to carry out thorough
prior investigation and to carry out trouble- 5. Troubleshooting
shooting in accordance with the fixed procedure. Use the results of the investigation and inspec-
tion in Items 2 to 4 to narrow down the causes of
2. Points to ask the user or operator failure, then use the troubleshooting flowchart to
1) Have any other problems occurred apart locate the failure exactly.
from the problem that has been reported? a The basic procedure for troubleshooting is as
2) Was there anything strange about the follows.
machine before the failure occurred? 1] Start from the simple points.
3) Did the failure occur suddenly, or were there 2] Start from the most likely points.
problems with the machine condition before 3] Investigate other related parts or informa-
the failure? tion.
4) Under what conditions did the failure occur?
5) Had any repairs been carried out before the 6. Measures to remove root cause of failure
failure? When were these repairs carried Even if the immediate failure is removed, the
out? same failure may occur again, unless the root
6) Has the same kind of failure occurred cause of the failure is repaired. To prevent this,
before? always investigate why the cause of the failure
occurred. Then, remove the root cause.
3. Check before troubleshooting
1) Is there any sign of irregularities of the
machine?
2) Make checks before starting day's work.
Between H
11 Check of level (in oil pan) and type of engine oil Refill with oil
and L
Between H
12 Check of oil level in motor-generator case Refill with oil
and L
Between H
13 Check of coolant level (in sub tank) Refill with coolant
and L
Dust indi-
cator does
14 Check of air cleaner for clogging Clean or replace
not show
red piston.
1 Check for abnormal sounds and smells Repair
Between H
3 Check of hydraulic oil level Refill with oil
and L
Between H
6 Check of swing machinery case oil level Refill with oil
and L
Between H
7 Check of oil level in electric swing motor case Refill with oil
and L
3 Check of starting motor terminal for looseness and corrosion Retighten or replace
Between H
5 Check of battery electrolyte level Add or replace
and L
6 Check of wiring harness for discoloration, burn and cover peeling Repair or replace
7 Check of wiring harness for release from clamp and sagging Repair
c: Electrical equipment
10 Check of connector pin for corrosion, bends and deformation Repair or replace
Dry, clean or
11 Check for water and foreign matter in connector
replace
Before starting the engine, look around and under the machine to check for any loose nuts or bolts, leakages
of oil, fuel or coolant, and check the condition of the work equipment and hydraulic system.
Check the connectors for looseness, the wiring harnesses for loose arrangement, and the hot parts for accu-
mulated dust.
k Accumulated combustibles around hot engine parts such as the engine muffler and turbocharger,
etc. and fuel or oil leakages may cause a machine fire. Be sure to check thoroughly and repair any
abnormalities.
a a1 and a2, ---, b1, b2, --- refer to the Nos. in the table on the previous page.
a1. and b1. Check for unusual sounds and b3. Check of hydraulic equipment, hydraulic
smells tank, hoses and joints for oil leakage
Check for unusual sounds and smells. Check and repair any oil leaks.
Some causes of unusual sounds and smells can
damage the machine if they are left as they are. c1. Check for dirt around battery
Therefore, stop the machine immediately when Check for and remove any accumulated dirt and
you find such abnormalities. combustibles (dead leaves, twigs, etc.) around
the battery.
a2. Check for dirt around engine
Check for and remove any accumulated dirt c16. Check and cleaning of rear view camera
around the engine and any combustibles (dead Check the rear view camera for any defect, and
leaves, twigs, etc.) on hot engine parts such as repair any failures.
the engine muffler, turbocharger, etc.
e1. Check of undercarriage (track, sprocket,
a3. Check for water leakage around engine idler and guard) for abnormalities, wear,
a4. Check for oil leakage around engine loose bolts and oil leakage from roller.
Check for any oil leaks from the engine and any Repair any failures.
water leaks from the cooling system. If any of
them is defective, repair them. e2. Check of handrails and steps for defect and
loose bolts
a5. Check for leakage from fuel line Repair any failures and retighten any loose
Check for any fuel leaks and damaged hoses bolts.
and tubes. If any of them is defective, repair
them. e3. Check and cleaning of rear view mirrors
Check for and repair any defective and broken
a6. Check of radiator for clogging rear view mirrors.
Check for and remove any accumulated dirt and Clean the mirror surfaces and adjust their angles
combustibles (dead leaves, twigs, etc.) around so that the operator can see the area behind him
the radiator. at the operator's seat.
For removal of dirt from the radiator, see the
Operation and Maintenance Manual, "Cleaning f1. Check of gauges and monitors for defect
and testing of radiator fins, oil cooler fins, after- Check the gauges and monitors inside the oper-
cooler fins, fuel cooler fins and air conditioner ator cab. If any of them is defective, replace it.
condenser fins (machine with the air condi- Clean up the surfaces.
tioner)".
f2. Check of seat belt and mounting hardware
b2. Check of work equipment, cylinders, linkage Check the hooks, locks and hook fittings for
and hoses for breakage, wear and clearance damage. If any of them has a problem, repair it.
Check the work equipment, cylinders, linkage
and hoses for cracks and excessive wear, check
that the clearances in them are within the normal
range, and then repair any failures.
2. If the fuel level is low, open oil filler cap (F) of the
fuel tank and add fuel through the oil filler port to
the necessary level, referring to the position of
float gauge (G).
a Height of tip (a): Approx. 50 mm
3. After adding the fuel, push float gauge (G)
straight down using oil filler cap (F) and tighten
oil filler cap (F) securely while taking care not to
pinch float gauge (G) with pawls (2) of the oil
filler cap (F).
a8. Check for foreign matter in fuel a9. Check of fuel pre-filter
1. Open the side cover on the rear right side of the k Immediately after the engine is stopped, its
machine. parts and oil is still very hot, and may cause
2. Place a container under drain hose (1) to receive burn injury. Accordingly, wait until they have
the drained fuel. cooled down before starting the work.
3. Turn drain valve (2) to the "OPEN" position (O) k High pressure is generated in the engine fuel
to drain the sediment and water in the bottom piping system while the engine is running.
together with the fuel. Wait for at least 30 seconds after stopping
4. When only the clean fuel flows out, turn drain the engine until the internal pressure de-
valve (2) to the "CLOSE" position (S). creases, and then replace the filter.
5. Close the side cover. k Do not bring any open flame near the filter.
a Komatsu genuine fuel filter cartridges use a spe-
cial filter with a high filtration efficiency. When re-
placing, be sure to use a Komatsu genuine
cartridge.
2. Open the side cover on the rear right side of the a If water in transparent cap (2) is frozen, the
machine. water separator monitor may not appear.
q The water separator is integrated with fuel And after the engine starts, if the frozen water
pre-filter (1). is melted into water due to the increased tem-
perature surrounding fuel pre-filter (1), water
3. You can check the water level and pres- separator monitor may suddenly appear.
ence/absence of sediments through transparent Drain water frequently during the cold sea-
cap (2). If water or sediments are found, place a son even if water separator monitor (5) does
container under drain hose (3) to receive the not appear on the machine monitor.
drained water and sediments. a If water in transparent cap (2) is frozen, drain
water only after confirming that it has com-
4. Loosen drain valve (4) to drain the water. pletely melted.
a If you cannot visually check for the presence
5. If drain hose (3) starts to discharge fuel, close of water due to stains on transparent cap (2),
drain valve (4) immediately. clean transparent cap (2) when replacing fuel
pre-filter cartridge (1).
a This machine is equipped with a sensor a When you have removed drain valve (4) for
which detects accumulation of water in trans- the above cleaning process, coat the O-ring
parent cap (2). with grease and tighten the drain valve until it
a If water separator monitor (5) appears in red touches the bottom.
on the machine monitor, it indicates that wa-
ter is accumulated in transparent cap (2).
Drain water from the cap.
Replacing fuel pre-filter cartridge 9. When installing the transparent cap, apply a thin
1. Turn valve (1) at the bottom of the fuel tank to the film of oil to the O-ring, set it against the sealing
"CLOSE" (S) position. surface of filter cartridge (4), and then tighten the
transparent cap 1/4 to 1/2 turn.
a If the transparent cap is over tightened, fuel
will leak because the O-ring will have been
damaged. If the transparent cap is not tight-
ened sufficiently, fuel will also leak through
the clearance around the O-ring. Therefore,
observe the tightening angle.
10. Clean the filter holder, fill the new filter cartridge
with clean fuel, apply a thin film of oil to the
O-ring, and then install the new filter cartridge
with the O-ring on the filter holder.
a Be sure to add fuel through eight small holes
(A) which are on the dirty side of the filter
without removing center cap (B).
a After filling with the fuel, remove center cap
2. Open the side cover on the rear right side of the
(B) before installing the fuel pre-filter.
machine.
a Add clean fuel taking care not to allow dirt to
3. Place a container under the fuel pre-filter
mix in it. Be sure to add fuel without removing
cartridge to receive the fuel.
center cap (B) which is on the clean side of
4. Loosen drain valve (2) and drain water and sedi-
the filter to prevent dirt from entering.
ments from transparent cup (3), and also drain
all the fuel from filter cartridge (4).
5. Disconnect connector (5). Wrap the removed
connector with a vinyl bag or the like to protect it
from being exposed to fuel, oil and water.
6. Using the filter wrench, rotate transparent cap
(3) to remove. (This cap is reused.)
7. Using the filter wrench, rotate filter cartridge (4)
to remove.
8. Install currently removed transparent cap (3) to
the bottom of the new filter cartridge.
a At this time, replace O-ring (6) with a new
one.
11. When installing the fuel pre-filter cartridge, a10. Check of fuel man filter
tighten it by 3/4 turn after the O-ring come in k Immediately after the engine is stopped, its
contact with the sealing surface of the filter parts and oil is still very hot, and may cause
holder. burn injury. Accordingly, wait until they have
a If the filter cartridge is over tightened, fuel will cooled down before starting the work.
leak because the O-ring is damaged. If the fil- k High pressure is generated in the engine fuel
ter cartridge is not tightened sufficiently, fuel piping system while the engine is running.
will also leak through the clearance around Wait for at least 30 seconds after stopping
the O-ring. Therefore, observe the tightening the engine until the internal pressure de-
angle. creases, and then replace the filter.
a When using a filter wrench for tightening, k Do not bring any open flame near the filter.
take care not to damage and dent the filter. a Komatsu genuine fuel filter cartridges use a spe-
12. Make sure that drain valve (2) is securely closed. cial filter with a high filtration efficiency. When re-
13. Remove the vinyl bag wrapping connector (5) placing, be sure to use a Komatsu genuine
and connect connector (5). cartridge.
a If connector (5) is exposed to water, the sen-
sor may malfunction, lighting up the water a The common rail fuel injection system of this ma-
separator monitor. Whenever disconnecting chine consists of parts that are more precise
connector (5), take care not to allow the con- compared with the conventional injection pump
nector to come in contact with water. and nozzle. If a fuel filter cartridge other than Ko-
a If connector (5) does come in contact with matsu genuine one is used, foreign matter may
water, dry it completely prior to connecting it. enter, which can cause a trouble in the injection
system. Never use a substitute.
4. Using the filter wrench, rotate filter cartridge (2) 6. When installing the filter cartridge, tighten it by
to remove. 3/4 turn after the O-ring comes in contact with
the sealing surface of the filter holder.
a If the filter cartridge is over tightened, fuel will
leak because the O-ring is damaged. If the fil-
ter cartridge is not tightened sufficiently, fuel
will also leak through the clearance around
the O-ring. Therefore, observe the tightening
angle.
7. Turn valve (1) at the fuel tank bottom to "OPEN"
(O) position.
8. Bleed air according to the following procedure.
1) Fill the fuel tank up with the fuel (until the float
is in the upper limit position).
2) Loosen feed pump knob (4) and draw it out
once, then push and pull it several times until
its movement becomes stiff.
5. Clean the filter holder. Apply a thin film of oil to
q You do not need to remove the plugs at
the packing of the new filter cartridge and install
the head of the fuel pre-filter and fuel
the cartridge to the filter holder.
main filter.
a Replace inside seal (3) with a new one.
q If fuel is used up, bleed air by operating
feed pump knob (4) in the same manner.
10. Check the filter sealing surface for fuel leakage. 6. If the oil level is above line H, drain the extra
If fuel is leaking, check whether the filter engine oil through drain valve (P) at the bottom
cartridge is appropriately tightened. If fuel of the engine oil pan and check the oil level
leakage recurs after the check, remove the filter again.
cartridge by following the steps 1 to 4 and check 7. If the oil is at the correct level, tighten the oil filler
the O-ring for damage or foreign matter being cap securely and close the engine hood.
caught. If any of the above problems are
detected on the O-ring, replace the cartridge
with a new one. Then, perform step 5 and after.
a12. Check of oil level in motor-generator case 6. After checking the oil level and adding oil, install
k Immediately after the engine is stopped, its dipstick (G) and oil filler cap (F).
parts and oil is still very hot, and may cause
burn injury. Accordingly, wait until they have
cooled down before starting the work.
1. Remove dipstick (G) and wipe off oil on the
dipstick with a cloth.
2. Insert dipstick (G) fully into the guide.
3. Pull out dipstick (G) and check the oil level. If the
oil level is between stamp marks H and L on
dipstick (G), the level is correct.
q Before starting engine: use COLD SIDE
Between stamp marks H and
L
q 15 minutes after engine is stopped: use HOT
SIDE
Between stamp
marks H and L
4. If the oil level is below stamp mark L on dipstick
(G), remove the cap from oil filler port (F) and
add oil.
q Before starting engine: use COLD SIDE
Below stamp mark L
q 15 minutes after engine is stopped: use HOT
SIDE
Below stamp mark
L
5. If the oil level is above stamp mark H on dipstick
(G), loosen drain valve (P) to drain the excessive
oil.
q Before starting engine: use COLD SIDE
Above stamp mark H
q 15 minutes after engine is stopped: use HOT
SIDE
Above stamp mark
H
q When draining the oil, place an oil container
under drain valve (P).
a13. Check of coolant level (in sub tank) a14. Check of air cleaner for clogging
k You do not need to open the radiator cap in k When using compressed air for cleaning, put
the ordinary check. Check the coolant at the on personal protective items such as protec-
sub tank after the engine has cooled down. tive eyeglasses, gloves, dust mask, etc. to
k Immediately after the engine is stopped, the protect yourself from dirt that will fly out.
coolant will be hot and pressure will have ac- k Removing the outer element from the air
cumulated in the radiator. cleaner body forcibly is dangerous .
If the cap is opened under these conditions, When working in high places or on unstable
you may be scalded. If you need to remove footing, you may fall off due to the reaction
the radiator cap, wait until the temperature when you pull out the outer element.
drops before you do. Then rotate the cap
slowly to release the pressure and remove it Checking
with care. Clean the air cleaner element if air cleaner clogging
1. Open the side cover at the rear left side of the monitor (1) appears on the monitor panel.
machine and check whether the coolant level is
between lines FULL and LOW on sub tank (1)
(see following figure). If there is not enough
coolant, add it through the coolant filler port of
sub tank (1) until the level reaches line FULL.
2. After adding the coolant, tighten the cap
securely.
3. If the sub tank is vacant, coolant may have
leaked.
After checking, repair any failures immediately. If
no failure is found, check the coolant level in the
radiator. If the level is low, add coolant to the
radiator first and then to the sub tank.
4. When you cannot check the coolant level due to
stains inside sub tank (1), clean the sub tank.
a Do not clean the element until the air cleaner
clogging monitor appears on the monitor panel.
If the element is cleaned frequently before the air
cleaner clogging monitor appears on the monitor
panel, the true performance of the air cleaner will
not be realized and the filtration efficiency will
decrease.
a If the outer element is checked or cleaned while
the engine is running, the dirt sticking to it may
enter the inner element and damage the engine.
Be sure to stop the engine before cleaning.
a After cleaning, light up the inside of the ele- 11. Install cover (3) according to the following proce-
ment to check it. If the element has a small dure.
hole or a thin component, replace it. 1) Set cover (3) to the element.
a Be sure to install cover (3) so that vacua-
tor (4) is at the bottom (A).
Replacement of element 3. Push the outer element straight into the air
1. Remove outer element (5). For details, see cleaner body while swinging it up, down and
"Cleaning of outer element". laterally.
2. Remove inner element (6) and install new inner a Install the air cleaner element with its bottom
element (6) quickly to air cleaner body (7). (end with no hole) (B) on cover (3) side.
a Do not clean or reuse the inner element. If the air cleaner element is installed in
When replacing the outer element, also re- reverse, it may be broken and the engine
place the inner element. may be damaged seriously.
4. Replace O-ring (8) of cover (3) with a new one.
b. Hydraulic and mechanical equipment 40-27 3. Sit down on the operator's seat and check sight
gauge (G) through the right window. If the oil
b3. Check of hydraulic oil level level is between lines H and L, there is sufficient
k Immediately after the engine is stopped, its oil.
parts and oil is still very hot, and may cause a If the oil level is below line L, add oil through
burn injury. Accordingly, wait until they have oil filter port (F).
cooled down before starting the work. a Do not add oil to above line H. If too much is
k If the oil filler cap is removed quickly, the oil added, it may damage the hydraulic circuit
may spurt out. Loosen the oil filler cap of the and spurt out.
hydraulic tank slowly to release the pressure a If the oil level is higher than line H, swing the
in the hydraulic tank. upper structure so that drain plug (P) at the
1. Set the work equipment in the posture as shown bottom of the tank comes between the left
below and, after stopping the engine, check the and right tracks, and stop the engine. After
oil level and add new oil if necessary. the hydraulic oil has cooled, remove cover (1)
a If the work equipment posture is not as and drain excessive oil through drain plug
shown below, fully retract the cylinder rod for (P).
the arm and bucket while running the engine
at low speed. Then lower the boom and stop
the engine when the bucket teeth touch the
ground.
b4. Check of hydraulic oil strainer b5. Check of hydraulic oil filter
k Immediately after the engine is stopped, its k Immediately after the engine is stopped, its
parts and oil is still very hot, and may cause parts and oil is still very hot, and may cause
burn injury. Accordingly, wait until they have burn injury. Accordingly, wait until they have
cooled down before starting the work. cooled down before starting the work.
k If the oil filler cap is removed quickly, the oil k If the oil filler cap is removed quickly, the oil
may spurt out. Loosen the oil filler cap of the may spurt out. Loosen the oil filler cap of the
hydraulic tank slowly to release the pressure hydraulic tank slowly to release the pressure
in the hydraulic tank. in the hydraulic tank.
1. Stop the engine and remove oil filler cap (F) of
the hydraulic tank to release the internal pres- 1. Park the machine on a level and firm ground, set
sure. the work equipment to the posture as shown
2. Remove the bolts to remove cover (1). below and stop the engine.
When removing the bolts, keep pressing down
cover (1) since it may be flung toward you by
spring (2).
3. Pull out rod (3) from the top, and take out spring
(2) and strainer (4).
4. Remove dirt from strainer (4) and clean it using
cleaning oil. If strainer (4) is damaged, replace it
with a new one.
5. Insert and set strainer (4) in projected portion (5)
of the tank.
6. While pressing down spring (2) with the projec-
tion at the bottom of cover (1), install the bolts.
7. Tighten the mounting bolts.
2. Remove oil filler cap (F) of the hydraulic tank to
release the internal pressure.
b8. Check of final drive case oil level b9. Performing air bleeding
k Since the oil may spurt out due to internal q For the procedure for bleeding air from the fuel
pressure, rotate the plug gradually from its system, see Testing and adjusting, "Bleeding air
side to release the internal pressure and then from fuel circuit".
remove it carefully. q For the procedure for bleeding air from the hy-
k Immediately after the engine is stopped, its draulic equipment, see Testing and adjusting,
parts and oil is still very hot, and may cause "Bleeding air from each part".
burn injury. Accordingly, wait until they have
cooled down before starting the work.
q Refill capacity (each side): 5.2 l
q Prepare the handle.
1. Set the final drive with TOP mark at the top, and
the straight line connecting the mark and plug (p)
is vertical to the ground surface.
2. Place a container under plug (P).
3. Remove plugs (P) and (F) using the handle to
drain oil.
a Check the O-ring attached to the plug for
damage. Replace damaged O-rings.
4. Tighten plug (P).
5. Supply oil through the hole for plug (F).
6. If oil flows out from the hole for plug (F), install
plug (F).
3 Tightening torque of Plugs (P) and (F):
68.6 9.8 Nm {7 1 kgm}
a Plug (F) is provided in two locations. To add
oil, use the hole that is easier to use or the in-
ternal gear can not be seen throught it.
3. After adding the purified water, tighten cap (2) a If you have added purified water above the
securely. U.L. line, take some of it out using a syringe
or similar tool. Neutralize the liquid that has
been taken out with sodium bicarbonate or
other suitable liquid, and wash it out with a
large amount of water.
q Remove control valve upper cover (3). q Check the connection of the following ground
terminals in the operator's cab.
q Terminals (T01) and (T11B)
A/C: Air conditioner unit
q Terminal (T02)
A/C: Air conditioner unit
a Fresh air duct removed
q Terminal (T11A)
a P: Pump controller
c9. Check for loose connector and damaged c10. Check of connector pin for corrosion,
lock bends and deformation
q Pull the male and female connectors of the con- q Disconnect the connector and check the pins for
nector by the hand to check the connection. corrosion, bends and recession. Check that the
q If the connection is defective, fit them with each female pins have not expanded.
other securely. q If any pin is found to be damaged, repair or re-
place it.
a If the pins are not shiny, apply contact restorer to
them and connect and disconnect several times
to shine them. (If the pins do not become shiny,
connect and disconnect the connector 10 times)
q Remove foreign matter in the connector by using Remove the cover at the left rear of the operator
a cloth or other material, and blow compressed seat, and the fuse holder is seen.
air against the inside of the connector.
(Detailed view of F)
1. Procedure for troubleshooting to be taken when user code and failure code are displayed on
machine monitor:
If a user code and a failure code are displayed on the standard screen of the machine monitor, perform
the troubleshooting for the corresponding "Display of code" according to the displayed failure code.
a If multiple failures occur simultaneously, all the failure codes are displayed repeatedly in order. Note
down all the codes.
2. Procedure for troubleshooting when a user code and a failure code are not displayed on machine
monitor:
Check a mechanical system failure code and an electrical system failure code with the abnormality record
function of the machine monitor. (See [*1].)
1) If a code is recorded, carry out troubleshooting for the "Display of code" corresponding to the recorded
code.
a If an electrical system failure code is recorded, delete all the codes once, follow the procedure to
reproduce the failure code, and then see if the failure is still detected. (See [*2].)
a A failure code of the mechanical system cannot be deleted.
a If an air conditioner abnormality record is displayed on the abnormality record screen, perform "In-
spection with self-diagnosis" in "Air conditioner". (See [*3].)
2) If no failure code is found in the abnormality record, a trouble that the machine cannot find out by itself
may have occurred in the electrical system or hydraulic and mechanical system.
In this case, check the phenomenon which appears to be connected with machine trouble again and
select the same phenomenon from the list on the next page, and then perform troubleshooting corre-
sponding to that phenomenon in the "E-mode", "H-mode", or "S-mode" troubleshooting.
[*1], [*2] 5. Press [F3] switch (R) on the panel switch to see
1. While pressing numerical key [4] on the panel if the next failure code is displayed and note
switch on the standard screen, press [1], [2] and down all of the failure codes.
[3] in order. a A failure code of the mechanical system can-
not be deleted.
6. Press [F5] switch (RETURN) on the panel switch
to return to "Abnormality Record" screen.
7. Enter the "Electrical System Abnormality
Record" screen similarly to steps 2 and 3.
8. Press the [F3] switch (R) on the panel switch to
see if the next failure code is displayed and note
down all of the failure codes.
a "E" on the left of a failure code indicates that
the failure is "active" (the failure remains or
restoration to normal has not been con-
firmed). A failure code having no "E" on its
left is a "non-active" one. Since it disappears
at the following clear step, be sure to note it
down.
2. On the Service Menu screen, press [F3] switch
9. While pressing numerical key [4] on the panel
(R) on the panel switch once to select "02
switch, press [1], [2] and [3] in this order to enter
Abnormality Record".
the "Clear mode". (Same as 1)
3. Press [F6] switch ( ) on the panel switch to
10. Press [F2] switch(CLEAR) on the panel switch.
enter the selection and go to "Abnormality
11. Press [F6] switch ( ) on the panel switch to clear
Record" screen.
all the failure codes.
12. Press [F5] switch (RETURN) on the panel switch
to return to "Electrical System Abnormality
Record" screen. See if any failure code is still
displayed and note down the displayed ones.
13. Press [F5] switch (RETURN) on the panel switch
to return to the "Abnormality Record" screen.
[*3]
a See steps 1 to 3 of [*1] and [*2] to enter the "Ab-
normality Record" screen.
1. On the Abnormality Record screen, press [F3]
switch (R) on the panel switch twice to select
"03 Air Conditioner Abnormality Record".
2. Press [F6] switch ( ) on the panel switch to
enter the selection and go to "Air Conditionser
Abnormality Record" screen.
Reference
Component Category of
Failure code Failure (Displayed on screen) User code document
in charge record
page
Electrical
CA322 Inj #1 (L#1) Open/Short Error ENG E11 40-152
system
Electrical
CA324 Inj #3 (L#3) Open/Short Error ENG E11 40-154
system
Electrical
CA331 Inj #2 (L#2) Open/Short Error ENG E11 40-156
system
Electrical
CA332 Inj #4 (L#4) Open/Short Error ENG E11 40-158
system
Electrical
CA342 Calibration code incompatible ENG E10 40-160
system
Electrical
CA351 Injectors drive circuit error ENG E10 40-161
system
Electrical
CA352 Sensor power supply 1 voltage low error ENG E15 40-162
system
Electrical
CA386 Sensor power supply 1 high error ENG E15 40-164
system
Electrical
CA428 Water-in-fuel sensor high error ENG E15 40-166
system
Electrical
CA429 Water-in-fuel sensor low error ENG E15 40-168
system
Electrical
CA435 Engine oil pressure switch error ENG E15 40-170
system
Electrical
CA441 Battery voltage low error ENG E10 40-172
system
Electrical
CA442 Battery voltage high error ENG E10 40-174
system
Electrical
CA449 Common rail pressure sensor very high error ENG E11 40-175
system
Electrical
CA451 Common rail pressure sensor high error ENG E11 40-176
system
Electrical
CA452 Common rail pressure sensor low error ENG E11 40-178
system
Electrical
CA488 Boost temperature high error ENG E11 40-180
system
Electrical
CA553 Common rail pressure high error ENG E15 40-181
system
Electrical
CA559 Supply pump pressure low error 1 ENG E15 40-182
system
Electrical
CA689 Engine Ne speed sensor error ENG E15 40-184
system
Electrical
CA731 Engine Bkup speed sensor phase error ENG E15 40-186
system
Electrical
CA757 All Continuous Data Lost Error ENG E10 40-187
system
Electrical
CA778 Eng Bkup Speed Sensor Error ENG E15 40-188
system
Electrical
CA1633 KOMNET Datalink Timeout Error ENG E0E 40-191
system
Electrical
CA2185 Throttle sensor power supply voltage high error ENG E14 40-192
system
Electrical
CA2186 Throttle sensor power supply voltage low error ENG E14 40-193
system
Electrical
CA2249 Common rail pressure very low error ENG E11 40-194
system
Electrical
CA2311 IMV solenoid error ENG E11 40-195
system
Electrical
CA2555 Grid Htr Relay Open Circuit Error ENG E15 40-196
system
Electrical
CA2556 Grid Htr Relay Short Circuit Error ENG E15 40-198
system
Reference
Component Category of
Failure code Failure (Displayed on screen) User code document
in charge record
page
Electrical
D19JKZ Personal Code Relay Abnormality KOMTRAX E01 40-200
system
Electrical
D862KA GPS Antenna Open Circuit KOMTRAX 40-203
system
Electrical
DA22KK Pump Solenoid Power Low Error PUMP E0E 40-204
system
Electrical
DA25KP 5 V sensor power supply output 1 circuit abnormal. PUMP 40-206
system
Electrical
DA26KP 5V sensor power supply 2 output circuit abnormal PUMP 40-208
system
Electrical
DA29KQ Model Selection Abnormality PUMP 40-210
system
Electrical
DA2RMC CAN Discon (Pump Con Detected) PUMP E0E 40-212
system
Electrical
DAF8KB Camera power supply short circuit MON 40-218
system
Electrical
DAFGMC GPS module defective KOMTRAX 40-220
system
Electrical
DAFRMC CAN Discon (Monitor Detected) MON E0E 40-221
system
Electrical
DGH2KB Hyd Oil Sensor Short PUMP 40-228
system
Electrical
DHPAMA Pump Press Sensor Abnormality PUMP 40-230
system
Electrical
DHPBMA R Pump Press Sensor Abnormality PUMP 40-232
system
Electrical
DHS3MA Arm IN PPC sensor system malfunction PUMP 40-234
system
Bucket CURL PPC pressure sensor system mal- Electrical
DHS4MA PUMP 40-236
function system
Boom RAISE PPC pressure sensor system mal- Electrical
DHS8MA PUMP 40-238
function system
Swing RH PPC pressure sensor system open or Electrical
DHSAKZ PUMP E09 40-240
short circuit system
Swing LH PPC pressure sensor system open or Electrical
DHSBKZ PUMP E09 40-242
short circuit system
Electrical
DHSAMA Swing RH PPC Press Sensor Abnormality PUMP 40-244
system
Electrical
DHSBMA Swing LH PPC Press Sensor Abnormality PUMP 40-246
system
Electrical
DHSDMA Bucket DUMP PPC pressure sensor malfunction PUMP 40-248
system
HYB system arm IN PPC pressure sensor open or Electrical
DHV3KZ HYB E09 40-250
short circuit system
Electrical
DHV9KZ HYB Boom Lower PPC Pr. Sen. Open/Shrt Cir HYB E09 40-252
system
Electrical
DHVAKZ HYB Swing-R PPC Pr. Sen. Opn/Short Cir HYB E09 40-254
system
HYB swing RIGHT PPC pressure sensor signal Electrical
DHVAL8 HYB E09 40-256
abnormal system
Electrical
DHVAMA HYB system swing RH PPC sensor malfunction HYB E09 40-257
system
Electrical
DHVBKZ HYB Swing-L PPC Pr. Sen. Opn/short Cir HYB E09 40-258
system
HYB swing LEFT PPC pressure sensor signal Electrical
DHVBL8 HYB E09 40-260
abnormal system
Electrical
DHVBMA HYB system swing LH PPC sensor malfunction HYB E09 40-261
system
Electrical
DHVCKZ HYB Arm Dump PPC Pr. Sen. Opn/short Cir HYB E09 40-262
system
Reference
Component Category of
Failure code Failure (Displayed on screen) User code document
in charge record
page
Electrical
DW43KA Travel speed selector solenoid system open circuit PUMP 40-264
system
Electrical
DW43KB Travel speed selector solenoid short circuit PUMP 40-266
system
Electrical
DW45KA Swing holding brake solenoid valve open circuit HYB E09 40-268
system
Electrical
DW45KB Swing holding brake solenoid valve short circuit HYB E09 40-271
system
Swing holding brake solenoid valve power voltage Electrical
DW45KK HYB E09 40-274
drop system
Electrical
DW45KY Swing holding brake solenoid valve hot short circuit HYB E09 40-276
system
Electrical
DW4WKA Bucket DUMP prohibit EPC solenoid open circuit PUMP E50 40-278
system
Electrical
DW4WKB Bucket DUMP prohibit EPC solenoid short circuit PUMP 40-280
system
Electrical
DW91KA Travel junction solenoid open circuit PUMP 40-282
system
Electrical
DW91KB Travel junction solenoid short circuit PUMP 40-284
system
Electrical
DWA2KA Attachment Sol Open Circuit PUMP 40-286
system
Electrical
DWA2KB Attachment Sol Short Circuit PUMP 40-288
system
Electrical
DWK0KA 2-stage relief solenoid system open circuit PUMP 40-290
system
Electrical
DWK0KB 2-stage relief solenoid system short circuit PUMP 40-292
system
Electrical
DXA8KA PC-EPC (F) Sol Open Circuit PUMP E02 40-294
system
Electrical
DXA8KB PC-EPC (F) Sol Short Circuit PUMP E02 40-296
system
Electrical
DXA9KA PC-EPC (R) Sol Open Circuit PUMP E02 40-298
system
Electrical
DXA9KB PC-EPC (R) Sol Short Circuit PUMP E02 40-300
system
Electrical
DXE0KA LS-EPC solenoid system open circuit PUMP 40-302
system
Electrical
DXE0KB LS-EPC solenoid system short circuit PUMP 40-304
system
Electrical
DXE4KA Service Current EPC Disc. PUMP 40-306
system
Electrical
DXE4KB Service Current EPC S/C PUMP 40-308
system
Electrical
DXE5KA Merge-divider main solenoid open circuit PUMP 40-310
system
Electrical
DXE5KB Merge-divider main solenoid short circuit PUMP 40-312
system
Electrical
DXE6KA Merge-divider LS Sol Open Circuit PUMP 40-314
system
Electrical
DXE6KB Merge-divider LS Sol Short Circuit PUMP 40-316
system
Electrical
DY20KA Wiper Working Abnormality PUMP 40-318
system
Electrical
DY20MA Wiper Parking Abnormality PUMP 40-320
system
Electrical
DY2CKA Window washer drive system open circuit PUMP 40-322
system
Electrical
DY2CKB Window washer drive system short circuit PUMP 40-324
system
Reference
Component Category of
Failure code Failure (Displayed on screen) User code document
in charge record
page
Electrical
DY2DKB Wiper Drive (Fwd) Short Circuit PUMP 40-326
system
Electrical
DY2EKB Wiper Drive (Rev) Short Circuit PUMP 40-328
system
Electrical
GA00NS HYB device overheat HYB E09 40-359 *
system
Electrical
GA01KA Open circuit in power cable interlock HYB E09 40-360 *
system
Electrical
GA02KZ DC Line Open/Short Circuit HYB E09 40-362 *
system
High power supply voltage error detected by hard- Electrical
GA04KG HYB E09 40-363 *
ware in DC line before booster system
High power supply voltage error detected by soft- Electrical
GA05KG HYB E09 40-364 *
ware in DC line before booster system
Electrical
GA05KP Low DC SW Output Volt. Bef. Booster HYB E09 40-365 *
system
Electrical
GA06KZ DC Vlt. Sen. Opn./Shrt. Cir. Bef. Booster HYB E09 40-366 *
system
High power supply voltage error detected by hard- Electrical
GA08KG HYB E09 40-367 *
ware in DC line after booster system
Low power supply voltage error detected by soft- Electrical
GA09KG HYB E09 40-368 *
ware in DC line after booster system
Electrical
GA09KP Low DC SW Output Volt. After Booster HYB E09 40-369 *
system
Electrical
GA0AKZ DC Volt. Sen. Op./Shrt cir. Aft. Booster HYB E09 40-370 *
system
Electrical
GA0BKZ AC Line Open/Short Circuit HYB E09 40-371 *
system
Electrical
GA12MC Malfunction of HYB controller high power supply HYB E09 40-372 *
system
Failure in voltage increase of HYB controller high Electrical
GA12NK HYB E09 40-373 *
power supply system
Failure in voltage drop of HYB controller high Electrical
GA12NL HYB E09 40-374 *
power supply system
Electrical
GA13MC Malfunction of HYB controller sensor power supply HYB E09 40-376 *
system
Electrical
GA14KR KOMNET communication error of HYB controller HYB E09 40-378
system
Electrical
GA15KZ HYB Cont. Bad Insul. Sen. Opn/Short. Cir HYB E09 40-379
system
Electrical
GA17KR Communication error of motor-generator driver HYB E09 40-379 *
system
Electrical
GA17KY Short circuit in motor-generator driver power line HYB E09 40-380 *
system
Electrical
GA17KZ Gen. Motor Driver Open/Short Circuit HYB E09 40-380 *
system
Electrical
GA17MB Reduced performance of motor-generator driver HYB E09 40-381 *
system
Malfunction of motor-generator driver excitation Electrical
GA18MC HYB E09 40-381 *
power supply system
Motor-generator driver sub-CPU power supply volt- Electrical
GA19KK HYB E09 40-382 *
age drop system
Electrical
GA19KR Gen. Motor Driver Sub-CPU Comm. Failure HYB E09 40-382 *
system
Internal failure of motor-generator driver sub-CPU Electrical
GA19KT HYB E09 40-383 *
controller system
Electrical
GA19MA Malfunction of motor-generator driver sub-CPU HYB E09 40-383 *
system
Electrical
GA19MC Malfunction of motor-generator driver sub-CPU HYB E09 40-384 *
system
Reference
Component Category of
Failure code Failure (Displayed on screen) User code document
in charge record
page
Electrical
GA19NA Startup failure of motor-generator driver sub-CPU HYB E09 40-384
system
Malfunction of motor-generator driver DC voltage Electrical
GA1BMA HYB E09 40-385 *
sensor system
Electrical
GA1FKR Communication failure of swing motor driver HYB E09 40-385 *
system
Electrical
GA1FMA Failure of swing motor driver HYB E09 40-386 *
system
Voltage drop of swing motor driver sub-CPU power Electrical
GA1GKK HYB E09 40-386 *
supply system
Communication failure of swing motor driver Electrical
GA1GKR HYB E09 40-387 *
sub-CPU system
Internal failure of swing motor driver sub-CPU con- Electrical
GA1GKT HYB E09 40-387 *
troller system
Electrical
GA1GMA Malfunction of swing motor driver sub-CPU HYB E09 40-388 *
system
Electrical
GA1GMB Performance drop of swing motor driver sub-CPU HYB E09 40-388
system
Electrical
GA1GMC Malfunction of swing motor driver sub-CPU HYB E09 40-389 *
system
Electrical
GA1GNA Startup failure of swing motor driver sub-CPU HYB E09 40-389 *
system
Electrical
GA1HKZ Swg Mot. Dr. Ph-U Tem. Sens Opn/Shrt Cir. HYB E09 40-390
system
Electrical
GA1JKZ Swg Mot. Dr. Ph-V Tem. Sens Opn/Shrt Cir. HYB E09 40-390
system
Electrical
GA1KKZ Swg Mot. Dr. Ph-W Tem. Sens Opn/Shrt Cir HYB E09 40-391
system
Electrical
GA1LKZ Swg Mot. Dr. Current. Sens Opn/Shrt Cir. HYB E09 40-391 *
system
Electrical
GA1MKZ Swg Mot. Dr. DC Vlt. Sen Opn/Shrt Cir. HYB E09 40-392 *
system
Electrical
GA1NNS Swing Motor Driver IGBT Overheat HYB 40-393
system
Electrical
GA1SFS Contactor locked HYB E09 40-394
system
Electrical
GA1SMC Malfunction of contactor HYB E09 40-394 *
system
Electrical
GA1TKP Capacitor output voltage drop HYB E09 40-395 *
system
Electrical
GA1TNS Capacitor Low Output Voltage HYB 40-396
system
Electrical
GA1UKZ Capacitor Temp. Sensor Opn/Short Cir. HYB E09 40-398
system
Electrical
GA1VFS Capacitor contactor locked HYB E09 40-400
system
Electrical
GA1VMC Malfunction of capacitor contactor HYB E09 40-402 *
system
Open or short circuit in booster inductor tempera- Electrical
GA1XKZ HYB E09 40-403
ture sensor system
Electrical
GA1YNS Booster Inductor Overheat HYB 40-404
system
Electrical
GA1ZKZ Booster IGBT Temp. Sens. Opn/Shrt. Circ. HYB E09 40-404-1
system
Electrical
GA1ZNS Booster IGBT Temp. Sens. Overheat HYB 40-404-2
system
Electrical
GA21KB Short circuit in booster IGBT HYB E09 40-404-3 *
system
Electrical
GA22NS Booster IGBT Junction Overheat HYB 40-405
system
Reference
Component Category of
Failure code Failure (Displayed on screen) User code document
in charge record
page
Electrical
GA23KZ Gen. Mot. Dr. Temp. Sens. Opn/Short Cir. HYB E09 40-406
system
Motor-generator driver temperature sensor 1 open Electrical
GA24KZ HYB E09 40-406
or short circuit system
Electrical
GA25MA Gen. Motor Driver IGBT0 Abnormality HYB E09 40-407 *
system
Electrical
GA25NS Motor-generator driver IGBT 0 overheat HYB 40-407-1
system
Electrical
GA26MA Gen. Motor Driver IGBT1 Abnormality HYB E09 40-407-2 *
system
Electrical
GA26NS Motor-generator driver IGBT 1 overheat HYB 40-408
system
Electrical
GA27KZ DC before boosting sensor open or short circuit HYB E09 40-409
system
Electrical
GA28KZ DC after boosting sensor open or short circuit HYB E09 40-409
system
Electrical
GA60MC Malfunction of motor-generator HYB E09 40-410
system
Electrical
GA60MD Gen. Mot. Defective Movement HYB E09 40-411
system
Electrical
GA60N1 Overrun of motor-generator HYB E09 40-412 *
system
Electrical
GA61KZ Gen. Motor Temp. Sens. Open/Short Cir. HYB E09 40-414
system
Electrical
GA61NS Motor-generator temperature sensor overheat HYB 40-416
system
Short circuit in A-phase current sensor power line Electrical
GA62KY HYB E09 40-417 *
of motor-generator system
Electrical
GA62KZ Gen. Mot. Ph-A Cur. Sen. Open/Short Cir HYB E09 40-418 *
system
Malfunction of motor-generator A-phase current Electrical
GA62MA HYB E09 40-419 *
sensor system
Short circuit in B-phase current sensor power line Electrical
GA63KY HYB E09 40-419 *
of motor-generator system
Electrical
GA63KZ Gen. Mot. Ph-B Cur. Sen. Open/Short Cir HYB E09 40-420 *
system
Malfunction of motor-generator B-phase current Electrical
GA63MA HYB E09 40-420 *
sensor system
Short circuit in C-phase current sensor power line Electrical
GA64KY HYB E09 40-421 *
of motor-generator system
Electrical
GA64KZ Gen. Mot. Ph-C Cur. Sen. Open/Short Cir. HYB E09 40-422 *
system
Malfunction of motor-generator C-phase current Electrical
GA64MA HYB E09 40-422 *
sensor system
Electrical
GA70KB Short circuit in HYB swing motor HYB E09 40-423 *
system
Electrical
GA70MD Malfunction of HYB swing motor HYB E09 40-423
system
Electrical
GA70NS HYB swing motor overheat HYB 40-424 *
system
Electrical
GA71KZ HYB Swing Mot. Temp. Sens. Opn/Shrt Cir. HYB E09 40-426 *
system
Electrical
GA72MA Malfunction of HYB swing motor resolver HYB E09 40-428 *
system
Electrical
GA72MC Malfunction of HYB swing motor resolver HYB E09 40-430 *
system
Electrical
GA81KZ Swing Motor Power Cable Opn/Shrt Circ. HYB E09 40-430 *
system
Electrical
GAA100 Swing emergency stop switch operated HYB 40-431 *
system
Reference
Component Category of
Failure code Failure (Displayed on screen) User code document
in charge record
page
Swing holding brake solenoid power line short cir- Electrical
GAA2KB PUMP E03 40-432 *
cuit system
a In this table, failure codes are arranged in the order of characters from numeric to alphabelic character.
a A component in charge means a controller or the machine monitor that is in charge of the system check.
MON: Machine monitor
ENG: Engine controller
PUMP: Pump controller
HYB: Hybrid controller (inverter)
KOMTRAX: KOMTRAX part of machine monitor
a The failure codes that do not have user codes in the user code columns are not displayed on the standard
screen even if a failure code is generated. They are just recorded in the abnormality record (electrical sys-
tem and mechanical system) on the service menu.
a The "Category of record" shows the abnormality record into which the failure is classified, the electrical
system or mechanical system, when it is recorded in the abnormality record of the service menu.
For details, see "Troubleshooting by failure code (Display of code)".
* If any problem occurs, the swing brake actuates suddenly and this may cause an abnormal wear on the
swing holding brake disc. Always perform the check referring to Testing and adjusting "Testing swing holding
brake".
Troubleshooting
No. Symptom of failure Reference document
Index
page
Symptom related to engine
5 Engine starting performance becomes deteriorated. S-1 40-522
6 Engine does not start. E-1, S-2 40-434, 40-523
7 Engine does not pick up smoothly S-3 40-526
8 Engine stops during operation S-4, H-2 40-527, 40-501
9 Engine does not rotate smoothly (hunting) S-5 40-528
10 Engine lacks power S-6 40-529
11 Exhaust smoke is black (incomplete combustion) S-7 40-530
12 Oil consumption is too much (or exhaust smoke is blue) S-8 40-531
13 Oil becomes contaminated quickly S-9 40-532
14 Fuel consumption is excessive S-10 40-533
15 Oil is in coolant (or coolant spurts back or coolant level goes down) S-11 40-534
16 Oil pressure drops S-12 40-535
17 Oil level rises (coolant or fuel in oil) S-13 40-536
18 Coolant temperature rises too high (overheating) S-14 40-537
19 Unusual noise is heard S-15 40-538
20 Vibration is excessive S-16 40-539
21 Preheater does not operate E-2 40-440
22 Automatic warm-up system does not operate (in cold season) E-14 40-461
23 Auto-decelerator does not operate normally E-15 40-462
Symptom related to hybrid system
24 Motor-generator temperature increases abnormally Y-9 40-552
25 Inverter temperature increases abnormally Y-10 40-553
26 Capacitor temperature increases abnormally Y-11 40-554
Symptom related to work equipment, swing and travel
27 All work equipment, swing and travel do not operate E-21, H-3 40-466, 40-502
28 All work equipment, swing and travel operate slowly or lack power H-1 40-499
29 Engine speed lowers significantly or engine stalls H-2, S-6 40-501, 40-529
30 Working mode does not change E-16 40-463
31 Unusual sound is heard from around hydraulic pump H-4 40-502
32 Fine control performance or response is poor H-5 40-503
Symptom related to work equipment
33 Speed or power of boom is low H-6 40-503
34 Speed or power of arm is low H-7 40-504
Troubleshooting
No. Symptom of failure Reference document
Index
page
35 Speed or power of bucket is low H-8 40-505
36 Work equipment does not move in single operation H-9 40-506
37 Hydraulic drift of work equipment is large H-10 40-506
38 Time lag of work equipment is large H-11 40-507
39 Other wok equipment moves when one of work equipment is relieved H-12 40-509
40 One-touch power maximizing function does not work.
41 Attachment circuit can not be changed E-37 40-494
Symptom related to combined operation
42 Work equipment loaded more is slower during combined operation H-14 40-510
In combined operations of swing and boom RAISE, boom rising speed
43 H-15 40-510
is low
44 Travel speed drops largely in combined operation of swing and travel H-16 40-510
Symptom related to travel
45 Machine deviates during travel H-17 40-511
46 Travel speed is low H-18 40-512
47 Machine is not steered well or steering power is low H-19 40-513
48 Travel speed does not change or travel speed is too low or high H-20, E-17 40-514, 40-464
49 Travel system does not work (only one side) H-21 40-515
50 Travel alarm does not sound or does not stop sounding E-24 40-476
Symptom related to swing
51 Upper structure does not swing H-22, Y-2 40-516, 40-544
52 Swing acceleration is poor or swing speed is low H-23, Y-3 40-516, 40-546
53 Upper structure overruns excessively when it stops swinging H-24, Y-4 40-516, 40-547
54 Large shock is made when upper structure stops swinging H-25, Y-5 40-517, 40-548
55 Large sound is made when upper structure stops swinging H-26, Y-6 40-517, 40-548
Swing brake does not operate properly 40-469, 40-517,
56 E-22, H-27, Y-7
Hydraulic drift of swing is large 40-549
57 Electric swing motor overheats Y-8 40-550
Symptom is related to machine monitor
When starting switch is turned to ON position, machine monitor dis-
58 E-3 40-445
plays nothing
When starting switch is turned to ON position (with engine stopped),
59 E-4 40-448
basic check monitor lights up
60 Precaution monitor lights up while engine is running E-5 40-449
61 Emergency stop monitor lights up while engine is running E-6 40-451
62 Engine coolant temperature gauge does not indicate properly E-8 40-454
63 Hydraulic oil temperature gauge does not indicate properly E-9 40-456
64 Fuel level gauge does not indicate properly E-7 40-452
65 Hybrid temperature gauge does not indicate normally E-10 40-458
Displays on machine monitor are different from conditions of actual
66 E-11 40-460
machine
67 Machine monitor does not display some items E-12 40-460
68 Function switch does not work E-13 40-460
69 Alarm buzzer cannot be canceled E-18 40-465
70 Service meter is not displayed with starting switch at OFF position E-19 40-465
71 Machine monitor cannot be set in service mode E-20 40-465
72 Horn does not sound or does not stop sounding E-25 40-478
73 Windshield wiper and window washer do not operate E-26 40-480
Troubleshooting
No. Symptom of failure Reference document
Index
page
Air conditioner does not operate normally (including air conditioner "Testing and troubleshooting procedure" in
74
abnormality record) Chapter 80
75 Monitoring function does not display lever control signal normally E-2736 40-482 - 40-492
76 Hybrid monitor does not go off Y-1 40-542
Others
77 KOMTRAX system does not operate properly E-38 40-495
a Since pressure sensors consisting not only of resistor but also electronic circuit components such as am-
plifiers have variation in measured value and its own polarities. So troubleshooting must be performed
carefully.
Procedure
1. Measure and record resistance of pressure sensor unit.
1) Disconnect pressure sensor connector (1) and connect socket (2) to the sensor side connector.
2) Measure resistances R1 and R2 between pins.
a If polarities of multimeter probes to apply are reversed, measured values may change. Therefore,
when measuring resistances in steps 1 and 2, apply the multimeter probes to the pressure sensor
connector so that their polarities match these of the sensor.
a If measured value is infinite, take measurements by applying the probes of opposite polarities and
record the finite value obtained as a measured value.
a Since measured values may be dispersed, take several measurements.
Cause of this dispersion appears to be a charge in a sensor. Repeat steps 1 and 2 several times.
Consider this dispersion when judging whether the wiring harness is open in step 3.
2. Measure and record resistance with the wiring harness between the pressure sensor and engine controller
connected.
1) Since 5 V power supply to the pressure sensor is supplied to other sensors, disconnect other sensor
connectors first. (*)
2) With the pressure sensor to measure connected, disconnect connector (3) on engine controller side,
and connect T-adapter (4) to the harness side connector.
3) Connect T-box (5) to T-adapter (4) and measure resistances R1' and R2' between respective pins.
*: In addition to the above, when measuring R2', disconnect the following: (See circuit diagram related to each
failure code)
q When measuring R2' of charge pressure sensor (CA123):
Connectors of common rail pressure sensor, CAM sensor and water-in-fuel sensor (water sepa-
rator)
q When measuring R2' of common rail pressure sensor (CA451):
Connectors of charge pressure sensor, CAM sensor and water-in-fuel sensor (water separator)
Measurement record (For measuring locations, see circuit diagram related to each failure code.)
Sensor + Wiring harness
Sensor unit
(Measuring location on wir-
Sensor (Measuring location on sen- Measured value Measured value
ing harness side connector
sor pin side connetor)
of engine controller)
R2': Between (37) and (47)
Charge pressure sen- R2: between (2) and (4)
(*)
sor
R1: between (1) and (4) R1': Between (44) and (47)
R2': Between (37) and (47)
R2: Between (3) and (1)
Common rail pressure (*)
sensor R1: Between (1) (+) and R1': between (47)(+) and
(2) (-) (25)(-)
Num-
Connector No. Type ber of Equipment name Layout address
pins
A08 SWP 12 Intermediate connector I-1
A13 DT 2 Intermediate connector J-1
A15 DT 2 Intermediate connector K-9
A40 DT 4 Rear view camera I-9
A41 DT 4 Camera 2 S-1
A42 DT 4 Camera 3 S-1
A43 S 8 Rear view camera S-9
AB Terminal 2 Alternator (B terminal) AH-8
AC01 YAZAKI 8 Air conditioner unit X-5
AC02 X 1 Air conditioner compressor electromagnetic clutch AG-4
AIR(AMB. AIR
3 Ambient pressure sensor AF-2
PRESSURE)
BOOST(BOOST
SUMITOMO 4 Boost pressure and boost temperature sensor AF-4
PRESS & IMT)
C01 AMP 81 Pump controller V-9
C02 AMP 40 Pump controller W-9
CAM(CAM SEN-
3 Engine Bkup speed sensor AF-1
SOR)
CAMERA2 DT 4 Camera 2
CAMERA3 DT 4 Camera 3
CE02 DRC 50 Engine controller AF-1
CE03 DTP 4 Engine controller AG-1
CK01 AMP 14 KOMTRAX communication module X-7
CK02 AMP 10 KOMTRAX communication module X-6
CM01 070 18 Machine monitor O-6
CM02 070 12 Machine monitor O-5
CM03 070 18 Machine monitor O-5
CM04 070 12 Machine monitor O-5
CM05 070 8 Machine monitor (for camera connection) O-7
CM06 070 4 Machine monitor (GPS antenna) O-7
CRANK(CRANK
3 Engine Ne speed sensor AF-1
SENSOR)
D01 SWP 8 Diode array M-8
D02 SWP 8 Diode array M-8
D03 SWP 8 Diode array M-9
D10 M 2 Diode W-9
D11 M 2 Diode W-9
E01 Terminal 1 Electrical intake air heater (ribbon heater) AG-5
E08 X 1 Intermediate connector AF-5
E10 D 1 Intermediate connector AE-5
E12 2 Alternator (terminal IG, L) AH-8
ECM(CE01) DRC 60 Engine controller AH-1
F01 Fuse box T-9
F04 L 2 Fusible link (65 A) A-9
Num-
Connector No. Type ber of Equipment name Layout address
pins
F05 M 2 Fusible link (30 A) A-7
GM01 DT 8 Motor-generator K-9, AJ-2
GM02 3 Motor-generator J-9
GM03 3 Motor-generator J-9
GT5 1 GPS antenna
H08 M 4 Intermediate connector
H09 M 8 Intermediate connector X-4
H15A DT 12 Intermediate connector (R.H. console) S-9
H15B DT 12 Intermediate connector (R.H. console) S-9
H16 S 12 Intermediate connector X-3
HB01 2 Capacitor L-4
HC01 DRC 24 Inverter L-4
HC02 DRC 64 Inverter L-7
HC03 3 Inverter L-6
HC04 3 Inverter L-5
HC05 3 Inverter L-5
HC06 2 Inverter L-5
HH05 DT 4 Intermediate connector (for service) X-8
HK01 DT 2 Capacitor L-3
HK02 DT 3 CAN terminating resistor L-8
HP01 DT 12 Capacitor L-4
HP03 AMP 3 Arm OUT pressure sensor A-1
HP04 AMP 3 Swing (L) pressure sensor A-2
HP05 AMP 3 Arm IN pressure sensor A-2
HP06 AMP 3 Swing (R) pressure sensor A-2
HP07 AMP 3 Boom LOWER pressure sensor A-3
HS01 Terminal - Emergency stop switch O-6
INJ1 DT 2 Injector #1 and #2 AF-4
INJ2 DT 2 Injector #3 and #4 AH-5
J01 20 Junction connector (black) X-3
J02 20 Junction connector (black) W-2
J03 20 Junction connector (green) W-3
J04 20 Junction connector (green) X-5
J05 20 Junction connector (pink) X-6
J06 20 Junction connector (orange) X-6
J1939(TOOL
3 CAN AG-1
PORT)
K01 M 2 Pump (PC) resistor O-7
L01 DT 2 Working lamp (boom) E-8
L02 DT 2 Right headlamp E-1
L03 M 2 Room lamp AA-8
Intermediate connector [revolving warning lamp/arm
L05 SWP 2 AB-9
crane specifications]
L09 DT 2 Rear working lamp [rear working lamp specification] J-9
Revolving warning lamp [revolving warning lamp/arm
L15 DT 2 AC-9
crane specifications] AG-9
M01 PA 9 Radio V-2
Num-
Connector No. Type ber of Equipment name Layout address
pins
M02 M 2 Speaker (L.H.) AD-8
M03 M 2 Speaker (L.H.) AC-9
M04 2 Cigarette lighter T-9
M05 M 6 Wiper motor Y-5
M06 KESO 2 Window washer motor L-2
M07 090 2 Horn (high tone) I-1
M08 090 2 Horn (low tone) H-1
M09 M 2 Optional power supply connector (1) X-3
M10 M 2 Optional power supply connector (2) X-5
M11 M 4 DC/DC converter X-4
M12 M 2 Optional power supply connector (12 V) X-4
M13 M 2 12 V socket X-5
M14 D 2 Travel alarm J-1
M40 X 2 Headlamp [machines with headlamps] Z-8
M41 X 2 Headlamp [machines with headlamps] Y-7
N08 D 12 Service connector T-9
N10 SUMITOMO 4 Air conditioner unit X-7
O.P.S(OIL PRES-
Terminal 2 Engine oil pressure switch (low pressure) AI-1
SURE SWITCH)
P01 AMP 3 Bucket CURL PPC pressure sensor C-3
P02 X 2 Boom LOWER PPC pressure switch C-3
P03 AMP 3 Swing LEFT pressure sensor C-2
P04 AMP 3 Arm IN pressure sensor C-2
P05 AMP 3 Bucket DUMP PPC pressure sensor C-2
P06 AMP 3 Boom RAISE PPC pressure sensor C-2
P07 AMP 3 Swing RIGHT pressure sensor C-3
P08 X 2 Arm DUMP PPC pressure switch C-4
P09 X 2 Travel PPC pressure switch P-1
P10 X 2 Travel steering PPC pressure switch Q-1
P13 X 2 Intermediate connector O-4
P14 X 2 Service PPC pressure switch (OP) O-1
P15 X 2 Service PPC pressure switch (OP) P-1
P17 2 Air conditioner high/low pressure switch V-2
P20 M 3 Fuel control dial P-8
P21 X 1 Fuel level sensor G-9
P22 D 2 Hydraulic oil temperature sensor AJ-3
P23 DT 2 Air cleaner clogging switch L-8
P24 X 2 Radiator coolant level switch L-3
P25 AMP 3 F pump pressure sensor K-9
P26 AMP 3 R pump pressure sensor K-9
P31 2 Air conditioner sunlight sensor O-6
P44 DT 2 Engine oil temperature sensor AF-5
P47 DT 2 Water-in-fuel sensor AJ-5
P48 DT Fuel refractive index sensor AJ4
Num-
Connector No. Type ber of Equipment name Layout address
pins
PM01 DT 12 Swing motor H-9
PM02 3 Swing motor H-9
PUMP(PUMP
2 Supply pump solenoid (IMV) AJ-2
REGULATOR)
R01 Terminal 1 Battery relay (terminal E) A-7
R02 Terminal 1 Battery relay (terminal BR) A-8
R03 Terminal 1 Battery relay (terminal M) A-8
R03B Terminal 1 Battery relay
R04 Terminal 1 Battery relay (terminal B) A-7
R05 Relay 5 Lamp relay T-9
R06 Relay 5 Starting motor cut-off relay (PPC lock) N-9
R07 Relay 5 Starting motor cut-off relay (Personal code) N-9
R08 Relay 5 Horn relay U-9
R10 Relay 5 Rear lamp relay [machines with rear lamp] U-9
R12 Relay 5 Cab lamp relay [machines with cab lamp] T-9
Electrical intake air heater (ribbon heater) relay (coil cir-
R15 Terminal 1 B-7
cuit)
Electrical intake air heater (ribbon heater) relay (switch
R16 Terminal 1 D-7
circuit)
R17 X 2 Starting motor safety relay (terminal S, R) B-7
R18 Relay 5 Auto preheater relay V-9
R20 Relay 5 Air conditioner blower relay X-8
R21 Relay 5 Air conditioner compressor relay X-8
R22 Relay 5 Arm crane relay [arm crane specification] V-9
R23 Relay 5 Engine controller relay (1) V-9
R24 Relay 5 Engine controller relay (2) V-9
R28 Terminal 1 Starting motor safety relay (terminal C) D-9
RAIL(FUEL RAIL
3 Common rail pressure sensor AH-5
PRESS)
S01 Terminal 6 Starting switch P-7
S02 SWP 6 Light switch Q-8
S04 SWP 6 Swing lock switch Q-8
Revolving warning lamp switch [machines with revolving
S07 SWP 6 Q-8
warning lamp]
S10 090 2 R.H. knob switch P-8
S11 2 L.H. knob switch V-1
S14 M 3 PPC pressure lock switch U-1
S21 12 Emergency pump drive switch N-9
S22 6 Swing holding brake cancel switch N-9
S25 090 8 Intermediate connector O-9
S30 S 8 Model selection connector U-9
SB Terminal 2 Starting motor (terminal B) AE-7
SC Terminal 1 Starting motor (terminal C) AE-6
T01 Terminal 2 Floor frame ground W-2
T02 Terminal 1 Cab ground AD-3
T03 Terminal 1 Intermediate connector
Num-
Connector No. Type ber of Equipment name Layout address
pins
T03A Terminal 1 Radio body ground
T04 Terminal 1 Revolving frame ground S-1
T05 Terminal 1 Revolving frame ground T-1
T06 Terminal 1 Revolving frame ground T-1
T07 Terminal 1 Revolving frame ground U-1
T08 Terminal 1 Revolving frame ground D-8
T09 Terminal 1 Revolving frame ground U-1
T10 Terminal 1 Revolving frame ground U-1
T11A Terminal 1 Floor frame ground
T11B Terminal 1 Floor frame ground W-2
T12 Terminal 1 Engine cylinder block ground AH-1
T13A Terminal 1 C-1
T13B Terminal 1 Revolving frame ground K-2
TEMP(COOLANT
2 Engine coolant temperature sensor AF-3
TEMP)
V01 D 2 PPC lock solenoid valve G-9
V02 D 2 2-stage relief solenoid valve J-2
V03 D 2 Swing holding brake solenoid valve K-2
V04 D 2 Travel speed selector solenoid valve H-9
V05 D 2 Travel junction solenoid valve K-2
Attachment return selector solenoid valve
V06 D 2 H-9
[machine with provision for attachment]
V11 D 2 F-PC-EPC valve AJ-3
V12 D 2 R-PC-EPC valve AJ-2
V19 D 2 VLS-EPC valve AJ-4
V23 D 2 Pump merge-divider EPC valve (main) I-9
V24 D 2 Pump merge-divider EPC valve (LS) I-9
Oil flow adjuster EPC valve for attachment
V30 DT 2 O-3
[machine with provision for attachment]
W03 M 2 Window rear limit switch AC-9
WIF[E06] DT 2 Intermediate connector AI-1
(2/6)
(3/6)
(4/6)
(5/6)
(6/6)
T-adapter kit
Number of pins
799-601-2500
799-601-2700
799-601-2800
799-601-7000
799-601-7100
799-601-7400
799-601-7500
799-601-8000
799-601-9000
799-601-9100
799-601-9200
799-601-9300
799-601-4101
799-601-4201
Out of kit
Identifi-
Part No. Part name cati-on
symbol
T-adapter kit
Number of pins
799-601-2500
799-601-2700
799-601-2800
799-601-7000
799-601-7100
799-601-7400
799-601-7500
799-601-8000
799-601-9000
799-601-9100
799-601-9200
799-601-9300
799-601-4101
799-601-4201
Out of kit
Identifi-
Part No. Part name cati-on
symbol
T-adapter kit
Number of pins
799-601-2500
799-601-2700
799-601-2800
799-601-7000
799-601-7100
799-601-7400
799-601-7500
799-601-8000
799-601-9000
799-601-9100
799-601-9200
799-601-9300
799-601-4101
799-601-4201
Out of kit
Identifi-
Part No. Part name cati-on
symbol
q Signal from engine coolant temperature sensor is input to engine controller and then data is trans-
mitted to machine monitor through CAN communication system.
Related infor-
q Engine coolant temperature can be checked with monitoring function.
mation
(Code: 04107 Engine coolant temperature)
q Method of reproducing failure code: Start engine.
1 Defect in related system If another failure code appears, perform troubleshooting for it.
Failure code [CA115] Eng Ne and Bkup Speed Sens Error 40-121
User code Failure code Engine Ne and Bkup speed sensor error
Failure
(Engine controller system)
E10 CA115
Detail of failure q Signals from both engine Ne and Bkup speed sensors are abnormal.
Action of con-
q None in particular
troller
Problem on q Engine stops.
machine q Engine does not start
Related infor-
q Method of reproducing failure code: Start engine.
mation
Failure code [CA122] Chg Air Press Sensor High Error 40-12
Failure code [CA123] Chg Air Press Sensor Low Error 40-124
*: See "Troubleshooting method for open circuit in wiring harness of pressure sensor system" of "General in-
formation on troubleshooting".
User code Failure code Engine coolant temperature sensor high error
Failure
(Engine controller system)
E15 CA144
Detail of failure q High voltage appears in signal circuit of coolant temperature sensor .
Action of con-
q Takes coolant temperature to be at fixed value and allows engine to run.
troller
Problem on q Engine does not start easily at low temperature.
machine q Overheat prevention function does not work.
q Input voltage from engine coolant temperature sensor can be checked with monitoring function.
(Code: 04105 (V))
q Temperature sensed by engine coolant temperature sensor can be checked with monitoring func-
tion.
Related infor- (Code: 04107 (C))
mation q Method of reproducing failure code: Turn starting switch to ON position.
q This failure code is displayed if temperature sensor connector is disconnected.
q Because troubleshooting "socket" for this sensor features female connector alone, it is not connect-
able to female connector of sensor wiring harness, and thus not usable for checking open circuit
(not designed as a T-adapter).
User code Failure code Engine coolant temperature sensor low error
Failure
(Engine controller system)
E15 CA145
Detail of failure q Low voltage appears in signal circuit of coolant temperature sensor .
Action of con-
q Takes coolant temperature to be at fixed value and allows engine to run.
troller
Problem on q Engine does not start easily at low temperature.
machine q Overheat prevention function does not work.
q Input voltage from engine coolant temperature sensor can be checked with monitoring function.
(Code: 04105 (V))
q Temperature sensed by engine coolant temperature sensor can be checked with monitoring func-
Related infor- tion.
mation (Code: 04107(C) )
q Method of reproducing failure code: Turn starting switch to ON position.
q If temperature sensor connector is disconnected, this failure code is not displayed but failure code
[CA144] for "High Error" is displayed.
Failure code [CA153] Chg Air Temp Sensor High Error 40-134
Failure code [CA154] Chg Air Temp Sensor Low Error 40-136
Failure code [CA155] Chg Air Temp High Speed Derate 40-138
User code Failure code Boost temperature high enough for speed derate
Failure
(Engine controller system)
E11 CA155
q Boost temperature sensed by boost pressure & temperature sensor exceeds upper limit of temper-
Detail of failure
ature control.
Action of con-
q Limits engine output and allows engine to run.
troller
Problem on q Engine output lowers.
machine q Engine stops.
q Boost temperature can be checked with monitoring function.
Related infor-
(Code: 18500 Boost temperature)
mation
q Method of reproducing failure code: Start engine.
User code Failure code Sensor power supply 2 voltage low error
Failure
(Engine controller system)
E15 CA187
Detail of failure q Low voltage appears in sensor power supply 2 circuit.
Action of con- q Takes boost pressure & temperature to be at fixed values and allows engine to run.
troller q Limits engine output and allows engine to run.
Problem on q Engine output lowers.
machine q Engine starting performance becomes deteriorated.
Related infor-
q Method of reproducing failure code: Turn starting switch to ON position.
mation
User code Failure code Sensor power supply 2 voltage high error
Failure
(Engine controller system)
E15 CA227
Detail of failure q High voltage appears in sensor power supply 2 circuit.
Action of con- q Takes boost pressure and boost temperature to be at fixed values and allows engine to run.
troller q Runs engine with output limited.
Problem on q Engine output lowers.
machine q Engine starting performance becomes deteriorated.
Related infor-
q Method of reproducing failure code: Turn starting switch to ON position.
mation
2 Improper use Machine may be used improperly. Instruct operator on proper way to use.
1 Defect in related system If another failure code is displayed, perform troubleshooting for it.
1 Defect in related system If another failure code is displayed, perform troubleshooting for it.
User code Failure code Sensor power supply 1 voltage low error
Failure
(Engine controller system)
E15 CA352
Detail of failure q Low voltage appears in sensor power supply 1 circuit.
Action of con-
q Takes ambient pressure to be at fixed value and allows engine to run.
troller
Problem on q Engine output lowers.
machine q Engine starting performance becomes deteriorated.
Related infor-
q Method of reproducing failure code: Turn starting switch to ON position.
mation
User code Failure code Common rail pressure sensor very high error
Failure
(Engine controller system)
E11 CA449
Detail of failure q High pressure error (2) occurs in common rail circuit.
Action of con-
q Limits engine output and allows engine to run.
troller
Problem on q Engine sound becomes large when no or light load is applied.
machine q Engine output lowers.
q Common rail pressure can be checked with monitoring function.
Related infor-
(Code: 36400 Common rail pressure)
mation
q Method of reproducing failure code: Start engine.
1 Defect in related system If another failure code is displayed, perform troubleshooting for it.
User code Failure code Common rail pressure sensor high error
Failure
(Engine controller system)
E11 CA451
Detail of failure q High voltage appears in signal circuit of common rail pressure sensor.
Action of con-
q Limits engine output and allows engine to run.
troller
Problem on q Engine speed or output lowers.
machine q Engine does not start.
q Signal voltage of common rail pressure sensor can be checked with monitoring function.
(Code: 36401 Common rail pressure sensor volt)
q Method of reproducing failure code: Turn starting switch to ON position.
Related infor-
q This failure code appears if common rail pressure sensor connector is disconnected.
mation
q Since troubleshooting "socket" for this sensor features female connector alone, it is not usable for
checking open circuit in wiring harness and voltage at sensor connector (not designed as a
T-adapter).
*: See "Troubleshooting method for open circuit in wiring harness of pressure sensor system" of "General in-
formation on troubleshooting".
User code Failure code Common rail pressure sensor low error
Failure
(Engine controller system)
E11 CA452
Detail of failure q Low voltage appears in signal circuit of common rail pressure sensor.
Action of con-
q Limits engine output and allows engine to run.
troller
Problem on q Engine speed or output lowers.
machine q Engine does not start
q Signal voltage of common rail pressure sensor can be checked with monitoring function.
(Code: 36401 Common rail pressure sensor volt)
Related infor-
q Method of reproducing failure code: Turn starting switch to ON position.
mation
q If sensor connector is disconnected even in normal condition, failure code [CA451] for "High Error"
is displayed.
Failure code [CA488] Chg Air Temp High Torque Derate 40-180
1 Defect in related system If another failure code is displayed, perform troubleshooting for it.
Failure code [CA731] Eng Bkup Speed Sens Phase Error 40-186
User code Failure code Engine Bkup speed sensor phase error
Failure
(Engine controller system)
E15 CA731
q Phase error is detected between signals from engine Ne speed sensor and engine Bkup speed
Detail of failure
sensor.
Action of con-
q Continues to control engine by using signal from engine Ne speed sensor.
troller
q Engine does not start at all or does not start easily.
Problem on
q Idle speed is unstable.
machine
q Exhaust gas becomes black.
Related infor-
q Method of reproducing failure code: Start engine.
mation
1 Defect in related system If another failure code is displayed, perform troubleshooting for it.
Reference for troubleshooting of CA778 (107 se- 5. Check mounting bolt (4) of camshaft ring (5) for
ries engine) looseness.
Checking camshaft ring for loose installation 3 Mounting bolt (4):
Remove the front cover and check the camshaft ring 10 2 Nm
for looseness. (DP): Dowel pin
a See "Removal and installation of front seal" in
Disassembly and assembly.
a Keep the front seal, liquid gasket LG-7 and front
seal tool (795-799-6400) on hand.
Removal 40-190
1. Remove the fan and fan belt. For details, see
"Removal and installation of front seal" in Disas-
sembly and assembly.
2. Remove damper assembly (1).
Installation 40-190
a See the figures in "Removal" for installation.
1. Install front cover (2).
2 Front cover: Liquid gasket LG-7
a Refer to the engine shop manual for tighten-
ing order and tightening torque of the mount-
ing bolts.
2. Referring to Disassembly and Assembly,
1) Install the CAM sensor.
3. Remove front cover (2). 2) Install front seal (3).
a Remove the CAM sensor before removing 3) Install the damper assembly with the dowel
the front cover. (To avoid interference be- pin (DP).
tween the sensor and camshaft ring when re- 4) Install fan belt, and install the fan.
moving the cover.) 5) Install the cooling system assembly.
4. Remove front seal (3).
(RING): Ring
Failure code [CA2185] Throt Sens Sup Volt High Error 40-192
User code Failure code Throttle sensor power supply voltage high error
Failure
(Engine controller system)
E14 CA2185
Detail of failure q High voltage (5.25 V or higher) appears in throttle sensor power supply circuit.
Action of con-
q Sets throttle position by using signal other than throttle sensor signal and allows engine to run.
troller
Problem on
q Engine speed cannot be controlled by fuel control dial.
machine
Related infor-
q Method of reproducing failure code: Turn starting switch to ON position.
mation
Failure code [CA2186] Throt Sens Sup Volt Low Error 40-193
User code Failure code Throttle sensor power supply voltage low error
Failure
(Engine controller system)
E14 CA2186
Detail of failure q Low voltage appears in throttle sensor power supply circuit.
Action of con-
q Sets throttle position by using signal other than throttle sensor signal and allows engine to run.
troller
Problem on
q Engine speed cannot be controlled by fuel control dial.
machine
Related infor-
q Method of reproducing failure code: Turn starting switch to ON position.
mation
User code Failure code Common rail pressure very low error
Failure
(Engine controller system)
E11 CA2311
Detail of failure q Low pressure appears in common rail circuit.
Action of con-
q Limits engine output and allows engine to run.
troller
q Engine starting performance becomes deteriorated.
Problem on
q Exhaust gas becomes black.
machine
q Engine output lowers.
q Common rail pressure can be checked with monitoring function.
Related infor-
(Code: 36400 Common rail pressure)
mation
q Method of reproducing failure code: Start engine.
Failure code [CA2555] Grid Htr Relay Open Circuit Error 40-196
User code Failure code Intake air heater relay open circuit
Failure
(Engine controller system)
E15 CA2555
Detail of failure q Open circuit is detected in drive circuit (primary circuit) of preheat relay.
Action of con-
q None in particular
troller
Problem on q Intake air heater does not work in auto preheating (degraded starting performance at low temper-
machine ature and emission of white smokes)
q Temperature sensed by boost temperature sensor can be checked with monitoring function.
(Code: 18500)
q Method of reproducing failure code: Turn starting switch to ON position (when boost temperature
Related infor- is below -4 C)
mation q Troubleshooting for this failure code covers circuit starting from engine controller to primary (coil)
side of preheater relay R18.
q For troubleshooting related to heater relay and secondary side of preheater relay R18, see E-2 in
E-mode.
Failure code [CA2556] Grid Htr Relay Short Circuit Error 40-198
User code Failure code Intake air heater relay short circuit
Failure
(Engine controller system)
E15 CA2556
Detail of failure q Short circuit is detected in drive circuit (primary circuit) of preheater relay.
Action of con-
q None in particular
troller
Problem on q Intake air heater does not work in auto preheating (degraded starting performance at low temper-
machine ature and emission of white smokes)
q Temperature sensed by boost temperature sensor can be checked with monitoring function.
(Code: 18500 )
q Method of reproducing failure code: Turn starting switch to ON position (when boost temperature
Related infor- is below -4 C)
mation q Troubleshooting for this failure code covers circuit starting from engine controller to primary (coil)
side of preheater relay R18.
q For troubleshooting related to heater relay and secondary side of preheater relay R18, see E-2 in
E-mode.
User code Failure code Pump solenoid power supply voltage drop (input)
Failure
(Pump controller system)
E0E DA22KK
Detail of failure q Solenoid power supply voltage of controller is below 20 V.
q Stops generation of failure codes (open circuit and short circuit) for all solenoid systems while this
Action of con-
failure code is active.
troller
q If cause of failure disappears, machine becomes normal by itself.
Problem on
q No solenoid valve is energized properly, so machine does not work properly.
machine
q As T-adapter for pump controller connector is "socket-type box", operating voltage cannot be mea-
Related infor-
sured at pump controller connector.
mation
q Method of reproducing failure code: Turn starting switch to ON position.
User code Failure code 5 V sensor power supply output 1 circuit abnormal.
Failure
(Pump controller system)
DA25KP
Detail of failure q Voltage of 5V sensor power supply output 1 circuit is below 2.5 V or above 6.0 V.
q Stops output from 5V sensor power supply output 1.
Action of con-
q Even if cause of failure disappears, machine does not become normal until starting switch is turned
troller
to OFF position.
q Automatic travel speed selector function does not work (pump pressure sensor system).
Problem on
q Auto-decelerator keeps working and is not canceled or fine control performance of work equipment
machine
is lowered (PPC pressure sensor system).
q As T-adapter for pump controller connector is "socket-type box", operating voltage cannot be mea-
Related infor-
sured at pump controller connector.
mation
q Method of reproducing failure code: Turn starting switch to ON position.
User code Failure code 5V sensor power supply 2 output circuit abnormal
Failure
(Pump controller system)
DA26KP
Detail of failure q Voltage of 5 V sensor power supply output 2 circuit is below 2.5 V or above 6.0 V.
Action of con- q Stops power supply from 5 V sensor power supply output 2.
troller q Even if cause of failure disappears, machine does not become normal until starting switch is turned
Problem on
q All sensor functions do not work properly (arm crane specification machine).
machine
q As T-adapter for pump controller connector is "socket-type box", operating voltage cannot be mea-
Related infor-
sured at pump controller connector.
mation
q Method of reproducing failure code: Turn starting switch to ON position.
3 Short circuit in wiring harness Between C01 (female) (39) and C01 (21) Resistance Min. 1 Mz
Between C01 (female) (39) and C01 (40) Resistance Min. 1 Mz
Between C01 (female) (39) and C01 (58) Resistance Min. 1 Mz
1. Turn starting switch to OFF position.
2. Disconnect connector C01 and connect T-adapters to female side.
Ground fault in wiring harness Between C01 (female) (40) and ground Resistance Min. 1 Mz
4
(contact with ground circuit)
Between C01 (female) (58) and ground Resistance Min. 1 Mz
Between C01 (female) (21) and ground Resistance Min. 1 Mz
If no failure is found by above checks, pump controller is defective. (Since this
5 Defective pump controller
is an internal defect, troubleshooting cannot be performed.)
User code Failure code CAN communication disable (pump controller detected)
Failure
(Pump controller system)
E0E DA2RMC
q Pump controller fails in CAN communication with inverter (hybrid controller) or engine controller.
Detail of failure
1) CAN communication line or ACC line of starting switch is defective.
Failure code [DHS4MA] Bucket CURL PPC Press Sensor Abnormality 40-236
User code Failure code Bucket CURL PPC pressure sensor system malfunction
Failure
(Pump controller system)
DHS4MA
Detail of failure q Signal voltage of bucket CURL PPC pressure sensor circuit is below 0.3 V or above 4.5 V.
Action of con- Controls machine taking bucket CURL PPC pressure to be 0 MPa {0 kg/cm2}.
q
troller q
If cause of failure disappears, machine becomes normal by itself.
q Automatic deceleration cannot be canceled.
Problem on
q Bucket CURL performance lowers.
machine
q Low speed matching function is disabled.
a If 5 V circuit (3) and ground circuit (1) of pressure sensor are connected inversely, pressure sensor
will be broken. Accordingly, take extreme care when checking.
q As T-adapter for pump controller connector is "socket-type box", operating voltage cannot be mea-
Related infor-
sured at pump controller connector.
mation
q Bucket CURL PPC pressure can be checked with monitoring function.
(Code: 07300 Bucket CURL PPC pressure)
q Method of reproducing failure code: Turn starting switch to ON position or start engine.
Failure code [DHS8MA] Boom RAISE PPC Press Sensor Abnormality 40-238
User code Failure code Boom RAISE PPC pressure sensor system malfunction
Failure
(Pump controller system)
DHS8MA
Detail of failure q Signal voltage of boom RAISE PPC pressure sensor circuit is below 0.3 V or above 4.5 V.
Action of con- Controls machine taking boom RAISE PPC pressure to be 0 MPa {0 kg/cm2}.
q
troller q If cause of failure disappears, machine becomes normal by itself.
q Automatic deceleration cannot be canceled.
Problem on
q Boom RAISE performance lowers.
machine
q Low speed matching function is disabled.
a If 5 V circuit (3) and ground circuit (1) of pressure sensor are connected inversely, pressure sensor
will be broken. Accordingly, take extreme care when checking.
q As T-adapter for pump controller connector is "socket-type box", operating voltage cannot be mea-
Related infor-
sured at pump controller connector.
mation
q Boom RAISE PPC pressure can be checked with monitoring function.
(Code: 07400 Boom RAISE PPC pressure)
q Method of reproducing failure code: Turn starting switch to ON position or start engine.
Failure code [DHSAKZ] Swing RIGHT PPC pressure sensor system open
or short circuit 40-240
User code Failure code Swing RIGHT PPC pressure sensor open or short circuit
Failure
(Pump controller system)
E09 DHSAKZ
Detail of failure q Signal voltage of swing RIGHT PPC pressure sensor is below 0.3 V or above 4.5 V.
q Limits swing speed, etc.
Action of con-
q Even if cause of failure disappears, machine does not become normal until starting switch is set to
troller
OFF position.
Problem on
q Swing speed, etc. are limited.
machine
a If 5 V circuit (3) and ground circuit (1) of pressure sensor are connected inversely, pressure sensor
will be broken. Accordingly, take extreme care when checking.
q As T-adapter for pump controller connector is "socket-type box", operating voltage cannot be mea-
Related infor-
sured at pump controller connector.
mation
q Swing RIGHT PPC pressure can be checked with monitoring function.
(Code 09002: Swing RIGHT PPC pressure)
q Method of reproducing failure code: Turn starting switch to ON position or start engine.
Failure code [DHSBKZ] Swing LEFT PPC pressure sensor system open
or short circuit 40-242
User code Failure code Swing LEFT PPC pressure sensor open or short circuit
Failure
(Pump controller system)
E09 DHSBKZ
Detail of failure q Signal voltage of swing LEFT PPC pressure sensor is below 0.3 V or above 4.5 V.
q Limits swing speed, etc.
Action of con-
q Even if cause of failure disappears, machine does not become normal until starting switch is set to
troller
OFF position.
Problem on
q Swing speed, etc. are limited.
machine
a If 5 V circuit (3) and ground circuit (1) of pressure sensor are connected inversely, pressure sensor
will be broken. Accordingly, take extreme care when checking.
q As T-adapter for pump controller connector is "socket-type box", operating voltage cannot be mea-
Related infor-
sured at pump controller connector.
mation
q Swing LEFT PPC pressure can be checked with monitoring function.
(Code 09001: Swing LEFT PPC pressure)
q Method of reproducing failure code: Turn starting switch to ON position or start engine.
User code Failure code Swing RIGHT PPC pressure sensor malfunction
Failure
(Pump controller system)
DHSAMA
Detail of failure q Signal voltage of swing RIGHT PPC pressure sensor is below 0.3 V or above 4.5 V.
Action of con- q Controls machine taking swing RIGHT PPC pressure to be 0 MPa {0 kg/cm2}.
troller q If cause of failure disappears, machine becomes normal by itself.
Problem on q
Automatic deceleration cannot be canceled.
machine q
Poor operatability of right swing operation
a If 5 V circuit (3) and ground circuit (1) of pressure sensor are connected inversely, pressure sensor
will be broken. Accordingly, take extreme care when checking.
q As T-adapter for pump controller connector is "socket-type box", operating voltage cannot be mea-
Related infor-
sured at pump controller connector.
mation
q Swing RIGHT PPC pressure can be checked with monitoring function.
(Code 09002: Swing RIGHT PPC pressure)
q Method of reproducing failure code: Turn starting switch to ON position or start engine.
User code Failure code Swing LEFT PPC pressure sensor malfunction
Failure
(Pump controller system)
DHSBMA
Detail of failure q Signal voltage of swing LEFT PPC pressure sensor is below 0.3 V or above 4.5 V.
Action of con- q Controls machine taking swing LEFT PPC pressure to be 0 MPa {0 kg/cm2}.
troller q If cause of failure disappears, machine becomes normal by itself.
Problem on q
Automatic deceleration cannot be canceled.
machine q
Poor operatability of left swing operation
a If 5 V circuit (3) and ground circuit (1) of pressure sensor are connected inversely, pressure sensor
will be broken. Accordingly, take extreme care when checking.
q As T-adapter for pump controller connector is "socket-type box", operating voltage cannot be mea-
Related infor-
sured at pump controller connector.
mation
q Swing LEFT PPC pressure can be checked with monitoring function.
(Code 09001: Swing LEFT PPC pressure)
q Method of reproducing failure code: Turn starting switch to ON position or start engine.
Failure code [DHSDMA] Bucket Dump PPC Press Sensor Abnormality 40-248
User code Failure code Bucket DUMP PPC pressure sensor malfunction
Failure
(Pump controller system)
DHSDMA
Detail of failure q Signal voltage of bucket DUMP PPC pressure sensor is below 0.3 V or above 4.5 V.
Action of con- Controls machine taking bucket DUMP PPC pressure to be 0 MPa {0 kg/cm2}.
q
troller q
If cause of failure disappears, machine becomes normal by itself.
q Automatic deceleration cannot be canceled.
Problem on
q Bucket DUMP performance lowers.
machine
q Low speed matching function is disabled.
a If 5 V circuit (3) and ground circuit (1) of pressure sensor are connected inversely, pressure sensor
will be broken. Accordingly, take extreme care when checking.
q As T-adapter for pump controller connector is "socket-type box", operating voltage cannot be mea-
Related infor-
sured at pump controller connector.
mation
q Bucket DUMP PPC pressure can be checked with monitoring function.
(Code: 07301 Bucket DUMP PPC pressure)
q Method of reproducing failure code: Turn starting switch to ON position or start engine.
Failure code [DHV3KZ] HYB system arm IN PPC pressure sensor open
or short circuit 40-250
User code Failure code HYB arm IN PPC pressure sensor open or short circuit
Failure
(Hybrid controller system)
E09 DHV3KZ
Detail of failure q Signal voltage of HYB arm IN PPC pressure sensor circuit is below 0.3 V or above 4.5 V.
Action of con- q Controls machine taking arm IN PPC pressure to be 0 MPa {0 kg/cm2}.
q Low speed matching function does not work.
troller
q If cause of failure disappears, machine becomes normal by itself.
Problem on
q Low speed matching function is disabled.
machine
a If 5 V circuit (3) and ground circuit (1) of pressure sensor are connected inversely, pressure sensor
will be broken. Accordingly, take extreme care when checking.
q HYB arm IN PPC pressure sensor voltage can be checked with monitoring function.
Related infor-
(Code: 07202 Arm IN PPC pressure sensor 2 voltage)
mation
q Arm IN PPC pressure can be checked with monitoring function.
(Code: 07200 Arm IN PPC pressure)
q Method of reproducing failure code: Turn starting switch to ON position or start engine.
Failure code [DHV9KZ] HYB Boom Lower PPC Pr. Sen. Open/Shrt Cir 40-252
User code Failure code HYB boom LOWER PPC pressure sensor open or short circuit
Failure
(Hybrid controller system)
E09 DHV9KZ
Detail of failure q Signal voltage of HYB boom LOWER PPC pressure sensor circuit is below 0.3 V or above 4.5 V.
Action of con- q Controls machine taking boom LOWER PPC pressure to be 0 MPa {0 kg/cm2}.
q Disables low speed matching function.
troller
q If cause of failure disappears, machine becomes normal by itself.
Problem on
q Low speed matching function is disabled.
machine
a If 5 V circuit (3) and ground circuit (1) of pressure sensor are connected inversely, pressure sensor
will be broken. Accordingly, take extreme care when checking.
Related infor- q Lever stroke sensed by HYB boom LOWER PPC pressure sensor can be checked with monitoring
mation function.
(Code: 42104 Boom lever stroke)
q Method of reproducing failure code: Turn starting switch to ON position or start engine.
1.
Turn starting switch to OFF position.
Defective 5V sensor power sup- 2.
Disconnect connector HP07 and connect T-adapters to female side.
1
ply 1 system 3.
Turn starting switch to ON position.
a
If power supply voltage is abnormal, proceed to troubleshooting for cause 3.
Power sup-
Between HP07 (female) (3) and (1) Voltage 4.5 5.5 V
ply
1. Turn starting switch to OFF position.
2. Insert T-adapters into connector HP07.
3. Turn starting switch to ON position.
Sensor out-
Between HP07 (2) and (1) Voltage 0.5 4.5 V
put
a If power supply voltage is normal and sensor output voltage is abnormal, it
Defective HYB boom LOWER is difficult to judge whether cause is defective sensor, ground fault or hot
2 PPC pressure sensor (internal fail- short circuit of harness. Check as follows.
ure) 1. Turn starting switch to OFF position.
2. Replace connector HP07 with connector of other PPC pressure sensor.
3. Turn starting switch to ON position and display "Abnormality Record"
screen of electrical system on machine monitor.
4. If E mark is not displayed for this failure code, HYB boom LOWER PPC
pressure sensor is defective.
a After finishing test, return connectors as they were.
1. Turn starting switch to OFF position.
2. Disconnect connectors HC02 and HP07, and connect T-adapters to each
female side.
a If power supply voltage measured in check on
Open circuit in wiring harness cause 1 is normal, this check is not required. Resistance Max. 1 z
3 (wire breakage or defective con- Between HC02 (female) (38) and HP07 (female) (1)
tact of connector)
Between HC02 (female) (20) and HP07 (female) (2) Resistance Max. 1 z
a If power supply voltage measured in check on
cause 1 is normal, this check is not required. Resistance Max. 1 z
Between HC02 (female) (7) and HP07 (female) (3)
Circuit diagram related to HYB boom LOWER PPC pressure sensor 40-253
Failure code [DHVAKZ] HYB Swing-R PPC Pr. Sen. Opn/Short Cir 40-254
User code Failure code HYB swing RIGHT PPC pressure sensor open or short circuit
Failure
(Hybrid controller system)
E09 DHVAKZ
Detail of failure q Signal voltage of HYB swing RIGHT PPC pressure sensor is below 0.3 V or above 4.5 V.
q Controls machine movement and limits swing speed, etc. according to swing RIGHT PPC pressure
Action of con- obtained by pump controller.
troller q Even if cause of failure disappears, machine does not become normal until starting switch is set to
OFF position.
Problem on
q Swing speed, etc. are limited.
machine
a If 5 V circuit (3) and ground circuit (1) of pressure sensor are connected inversely, pressure sensor
will be broken. Accordingly, take extreme care when checking.
Related infor- q Signal voltage from HYB swing RIGHT PPC pressure sensor can be checked with monitoring func-
mation tion.
(Code: 09007 Swing RIGHT PPC pressure sensor 2 voltage)
q Method of reproducing failure code: Turn starting switch to ON position or start engine.
Circuit diagram related to HYB swing RIGHT PPC pressure sensor 40-25
Failure code [DHVAL8] HYB system swing RIGHT PPC pressure sensor
signal abnormality 40-256
User code Failure code HYB swing RIGHT PPC pressure sensor signal abnormal
Failure
(Hybrid controller system)
E09 DHVAL8
q Whie motor-generator is running, difference between measured values from HYB swing RIGHT
Detail of failure PPC pressure sensor and pump controller swing RIGHT PPC pressure sensor exceeds 0.49 MPa
{5.0 kg/cm2}.
q Controls machine using value from pump controller or HYB swing RIGHT PPC pressure sensors
whichever are smaller.
Action of con-
q Limits swing speed, etc.
troller
q Even if cause of failure disappears, machine does not become normal until starting switch is set to
OFF position.
Problem on
q Swing speed, etc. are limited.
machine
a If 5 V circuit (3) and ground circuit (1) of pressure sensor are connected inversely, pressure sensor
will be broken. Accordingly, take extreme care when checking.
q HYB swing RIGHT PPC pressure can be checked with monitoring function.
Related infor-
(Code: 09008 Swing Right PPC Pressure #2)
mation
q Pressure sensed by swing RIGHT PPC pressure sensor can be checked with monitoring function.
(Code 09002: Swing RIGHT PPC pressure)
q Method of reproducing failure code: Start engine.
Failure code [DHVAMA] HYB system swing RIGHT PPC pressure sensor
malfunction 40-257
User code Failure code HYB swing RIGHT PPC pressure sensor malfunction
Failure
(Hybrid controller system)
E09 DHVAMA
q Two failures from among HYB swing RIGHT PPC pressure sensor open or short circuit [DHVAKZ],
Detail of failure HYB swing RIGHT PPC pressure sensor signal abnormal [DHVAL8], KOMNET datalink timeout
error, or pump controller swing RIGHT PPC pressure sensor malfunction occur.
q Stops swing motor and motor-generator control, and applies swing holding brake.
q Disables low speed matching function.
Action of con-
q Hoist matching function does not work.
troller
q Even if cause of failure disappears, machine does not become normal until starting switch is set to
OFF position.
Problem on
q Swing is disabled.
machine
a If 5 V circuit (3) and ground circuit (1) of pressure sensor are connected inversely, pressure sensor
will be broken. Accordingly, take extreme care when checking.
q HYB swing RIGHT PPC pressure sensor voltage can be checked with monitoring function.
Related infor-
(Code: 09007 Swing RIGHT PPC pressure sensor 2 voltage)
mation
q Pressure sensed by swing RIGHT PPC pressure sensor can be checked with monitoring function.
(Code 09002: Swing RIGHT PPC pressure)
q Method of reproducing failure code: Turn starting switch to ON position or start engine.
Failure code [DHVBKZ] HYB Swing-L PPC Pr. Sen. Opn/short Cir 40-258
User code Failure code HYB in swing LEFT PPC pressure sensor open or short circuit
Failure
(Hybrid controller system)
E09 DHVBKZ
Detail of failure q Signal voltage of HYB swing LEFT PPC pressure sensor is below 0.3 V or above 4.5 V.
q Controls machine movement and limits swing speed, etc. according to swing LEFT PPC pressure
Action of con- obtained by pump controller.
troller q Even if cause of failure disappears, machine does not become normal until starting switch is set to
OFF position.
Problem on
q Swing speed, etc. are limited.
machine
a If 5 V circuit (3) and ground circuit (1) of pressure sensor are connected inversely, pressure sensor
will be broken. Accordingly, take extreme care when checking.
Related infor-
q HYB swing LEFT PPC pressure sensor voltage can be checked with monitoring function.
mation
(Code: 09006 Swing LEFT PPC pressure sensor 2 voltage)
q Method of reproducing failure code: Turn starting switch to ON position or start engine.
Failure code [DHVBL8] HYB system swing LEFT PPC pressure sensor
signal abnormality 40-260
User code Failure code HYB swing LEFT PPC pressure sensor signal abnormal
Failure
(Hybrid controller system)
E09 DHVBL8
q Whie motor-generator is running, difference between measured values from HYB swing LEFT PPC
Detail of failure pressure sensor and pump controller swing LEFT PPC pressure sensor exceeds 0.49 MPa
{5.0 kg/cm2}.
q Controls machine using value from pump controller or HYB swing LEFT PPC pressure sensors
whichever are smaller.
Action of con-
q Limits swing speed, etc.
troller
q Even if cause of failure disappears, machine does not become normal until starting switch is set to
OFF position.
Problem on
q Swing speed, etc. are limited.
machine
a If 5 V circuit (3) and ground circuit (1) of pressure sensor are connected inversely, pressure sensor
will be broken. Accordingly, take extreme care when checking.
q Pressure sensed by HYB swing LEFT PPC pressure can be checked with monitoring function.
Related infor-
(Code: 09008 Swing LEFT PPC Pressure #2)
mation
q Pressure sensed by swing LEFT PPC pressure can be checked with monitoring function.
(Code 09001: Swing LEFT PPC pressure)
q Method of reproducing failure code: Start engine.
Failure code [DHVBMA] HYB system swing LEFT PPC pressure sensor
malfunction 40-261
User code Failure code HYB swing LEFT PPC pressure sensor malfunction
Failure
(Hybrid controller system)
E09 DHVBMA
q Two failures from among HYB system swing LEFT PPC pressure sensor open or short circuit [DH-
Detail of failure VBKZ], HYB swing LEFT PPC pressure sensor signal abnormal [DHVBL8], KOMNET datalink tim-
eout error, or pump controller swing LEFT PPC pressure malfunction occur.
q Stops swing motor and motor-generator control, and applies swing holding brake.
q Disables low speed matching function.
Action of con-
q Hoist matching function does not work.
troller
q Even if cause of failure disappears, machine does not become normal until starting switch is set to
OFF position.
Problem on
q Swing is disabled.
machine
a If 5 V circuit (3) and ground circuit (1) of pressure sensor are connected inversely, pressure sensor
will be broken. Accordingly, take extreme care when checking.
q HYB swing LEFT PPC pressure sensor voltage can be checked with monitoring function.
Related infor-
(Code: 09006 Swing LEFT PPC pressure sensor 2 voltage)
mation
q Pressure sensed by swing LEFT PPC pressure can be checked with monitoring function.
(Code 09001: Swing LEFT PPC pressure)
q Method of reproducing failure code: Turn starting switch to ON position or start engine.
Failure code [DHVCKZ] HYB Arm Dump PPC Pr. Sen. Opn/short Cir 40-262
User code Failure code HYB arm OUT PPC pressure sensor open or short circuit
Failure
(Hybrid controller system)
E09 DHVCKZ
Detail of failure q Signal voltage of HYB arm OUT PPC pressure sensor circuit is below 0.3 V or above 4.5 V.
Action of con- q Controls machine taking arm OUT PPC pressure to be 0 MPa {0 kg/cm2}.
q Disables low speed matching function.
troller
q If cause of failure disappears, machine becomes normal by itself.
Problem on
q Low speed matching function is disabled.
machine
a If 5 V circuit (3) and ground circuit (1) of pressure sensor are connected inversely, pressure sensor
will be broken. Accordingly, take extreme care when checking.
Related infor-
q HYB arm OUT PPC pressure sensor voltage can be checked with monitoring function.
mation
(Code: 07602 Arm OUT PPC pressure sensor voltage 2)
q Method of reproducing failure code: Turn starting switch to ON position or start engine.
1.
Turn starting switch to OFF position.
Defective 5V sensor power sup- 2.
Disconnect connector HP03 and connect T-adapters to female side.
1
ply 1 system 3.
Turn starting switch to ON position.
a
If power supply voltage is abnormal, proceed to troubleshooting for cause 3.
Power sup-
Between HP03 (3) and (1) Voltage 4.5 5.5 V
ply
1. Turn starting switch to OFF position.
2. Insert T-adapters into connector HP03.
3. Turn starting switch to ON position.
Sensor out-
Between HP03 (2) and (1) Voltage 0.5 4.5 V
put
a If power supply voltage is normal and sensor output voltage is abnormal, it
Defective arm OUT PPC pressure is difficult to judge whether cause is defective sensor, ground fault or hot
2 short circuit of harness. Check as below.
sensor (internal failure)
1. Turn starting switch to OFF position.
2. Replace connector HP03 with connector of other PPC pressure sensor.
3. Turn starting switch to ON position and display "Abnormality Record"
screen of electrical system on machine monitor.
4. If E mark is not displayed for this failure code, arm OUT PPC pressure
sensor is defective.
a After finishing test, return connectors as they were.
1. Turn starting switch to OFF position.
2. Disconnect connectors HC02 and HP03, and connect T-adapters to each
female side.
a If power supply voltage measured in check on
Open circuit in wiring harness cause 1 is normal, this check is not required. Resistance Max. 1 z
3 (wire breakage or defective con- Between HC02 (female) (38) and HP03 (female) (1)
tact of connector)
Between HC02 (female) (29) and HP03 (female) (2) Resistance Max. 1 z
a If power supply voltage measured in check on
cause 1 is normal, this check is not required. Resistance Max. 1 z
Between HC02 (female) (7) and HP03 (female) (3)
Circuit diagram related to HYB arm OUT PPC pressure sensor 40-263
User code Failure code Travel speed selector solenoid system open circuit
Failure
(Pump controller system)
DW43KA
q When command to drive travel speed selector solenoid is ON, no current flows and open circuit is
Detail of failure
detected.
Action of con- q None in particular (Since no current flows, solenoid is not energized).
troller q If cause of failure disappears, machine becomes normal by itself.
Problem on q "Hi" travel speed is slow. (Although "Hi" is diaplayed on machine monitor, actual travel speed is still
machine "Lo".)
q Controller's command (ON/OFF) to travel speed selector solenoid can be checked with monitoring
function. (If controller sends solenoid ON command, monitoring screen shows ON even if solenoid
Related infor-
is not switched to ON due to open circuit.)
mation
(Code: 02300 Solenoid 1)
q Method of reproducing failure code: Start engine, set travel speed to High and operate travel lever.
User code Failure code Travel speed selector solenoid short circuit
Failure
(Pump controller system)
DW43KB
q When command to drive travel speed selector solenoid is ON, abnormal current flows and short
Detail of failure
circuit is detected.
q Shuts off power supply to travel speed selector solenoid.
Action of con-
q Even if cause of failure disappears, machine does not become normal until starting switch is turned
troller
to OFF position.
Problem on q "Hi" travel speed is slow. (Although "Hi" is diaplayed on machine monitor, actual travel speed is still
machine "Lo".)
q Controller's command (ON/OFF) to travel speed selector solenoid can be checked with monitoring
function. (If controller sends solenoid ON command, monitoring screen shows ON even if solenoid
Related infor-
is not switched to ON due to short circuit.)
mation
(Code: 02300 Solenoid 1)
q Method of reproducing failure code: Start engine, set travel speed to High and operate travel lever.
Failure code [DW45KA] Swing holding brake solenoid valve open circuit40-268
User code Failure code Swing holding brake solenoid valve open circuit
Failure
(Hybrid controller system)
E09 DW45KA
q When command to drive swing holding brake solenoid is ON (to release swing holding brake), no
Detail of failure
current flows (swing holding brake is not released).
Action of con- q None in particular (Since no current flows, solenoid does is not energized).
troller q If cause of failure disappears, machine becomes normal by itself.
Problem on
q Upper structure does not swing (swing holding brake is not released).
machine
q If solenoid and wiring harness are normal, swing operation is possible by setting swing holding
brake cancel switch to RELEASE position. (However, swing holding brake is not released when the
starting switch is in OFF position. Swing holding brake remains applied.)
q Be sure to set both of swing lock switch and swing holding brake cancel switch to OFF position dur-
ing troubleshooting.
Related infor-
q Brake is released when current flows through swing holding brake solenoid.
mation
q Command (ON/OFF) to swing holding brake solenoid can be checked with monitoring function.
(Code: 09700 Hybrid controller relay output)
q Method of reproducing failure code: Turn starting switch to ON position.
q Swing holding brake solenoid circuit is powered from pin (8) of inverter (hybrid controller) connector
HC01 or F01 of fuse box F01.
Failure code [DW45KB] Swing holding brake solenoid valve short circuit40-271
User code Failure code Swing holding brake solenoid valve short circuit
Failure
(Hybrid controller system)
E09 DW45KB
q When command to drive swing holding brake solenoid is ON (to release swing holding brake), ab-
Detail of failure
normal current flows.
q Shuts off power supply swing holding brake solenoid.
Action of con-
q Even if cause of failure disappears, machine does not become normal until starting switch is set to
troller
OFF position.
Problem on
q Upper structure does not swing (swing holding brake is not released).
machine
q If solenoid and wiring harness are normal, swing operation is possible by setting swing holding
brake cancel switch to RELEASE position. (However, swing holding brake is not released when
starting switch is in OFF position. Swing holding brake remains applied.)
q Be sure to set both of swing lock switch and emergency stop switch to OFF position during trouble-
shooting.
Related infor- q Brake is released when current flows through swing holding brake solenoid.
mation q Controller command (ON/OFF) to swing holding brake solenoid can be checked with monitoring
function.
(Code: 09700 Hybrid controller relay output)
q Method of reproducing failure code: Turn starting switch to ON position.
q Swing holding brake solenoid circuit is powered from pin (8) of inverter (hybrid controller) connector
HC01 or F01 of fuse box F01.
User code Failure code Swing holding brake solenoid valve power voltage drop
Failure
(Hybrid controller system)
E09 DW45KK
q Drop in power supply voltage is detected at swing holding brake solenoid drive power circuit in hy-
Detail of failure
brid controller.
Action of con- q None in particular. (Since no current flows, solenoid is not energized.)
troller q If cause of failure disappears, machine becomes normal by itself.
Problem on
q Upper structure does not swing (swing holding brake is not released).
machine
q If solenoid and wiring harness are normal, swing operation is possible by setting swing holding
brake cancel switch to RELEASE position. (However, swing holding brake is not released when
Related infor- starting switch is in OFF position.)
mation q Command (ON/OFF) to swing holding brake solenoid can be checked with monitoring function.
(Code: 09700 Hybrid controller relay output)
q Method of reproducing failure code: Turn starting switch to ON position.
3 Blown fuse No.2 If fuse is blown, circuit probably has grounding fault. (See Cause 6.)
4 Blown fuse No. 17. If fuse is blown, circuit probably has grounding fault. (See Cause 6.)
Connections in circuit from fuses No. 2 and 17, through machine harness, to
hybrid conrtoller may be defective. Check connections directly.
Defective wiring harness connec-
5 q Looseness of connector, breakage of lock, or breakage of seal
tor
q Corrosion, bend, breakage, pushed-in, or expantion of pin
q Moisture or dirt in connector or defective insulation
a If no failure is found by above checks, this check is not required.
1. Prepare with starting switch OFF, then perform troubleshooting without
turning starting switch to ON position.
Between F01-17 and each of HC01 (female) (5) and
Open circuit in wiring harness Resistance Max. 1 z
(11)
6 (wire breakage or defective con-
tact of connector) Between F01-2 and each of HC01 (female) (1) and
Resistance Max. 1 z
(7)
Between H15A (male) (5) and each of HC01
Resistance Max. 1 z
(female) (6) and (12)
Defective inverter (hybrid control- If no falure is found by above checks, inverter (hybrid controller) is defective.
7
ler) (Since this is an internal defect, troubleshooting cannot be performed.)
Failure code [DW45KY] swing holding brake Sol. Val. Pow. Short Cir 40-276
User code Failure code Swing holding brake solenoid valve hot short circuit
Failure
(Hybrid controller system)
E09 DW45KY
q When command to drive swing holding brake solenoid is OFF, controller output voltage to solenoid
Detail of failure
is above standard value.
q Shuts off power supply to swing holding brake solenoid.
Action of con-
q Even if cause of failure disappears, machine does not become normal until starting switch is set to
troller
OFF position.
Problem on
q Swing holding brake does not work if current flows abnormally to swing holding brake solenoid.
machine
q If solenoid and wiring harness are normal, swing operation is possible by setting swing holding
brake cancel switch to RELEASE position. (However, swing holding brake is not released when
starting switch is in OFF position. Swing holding brake remains applied.)
q Be sure to set both of swing lock switch and emergency stop switch to OFF position during trouble-
shooting.
q Brake is released when current flows through swing holding brake solenoid.
Related infor-
(Lower work equipment to ground. Swing holding brake may not work.)
mation
q Controller command (ON/OFF) to swing holding brake solenoid can be checked with monitoring
function.
(Code: 09700 Hybrid controller relay output)
q Method of reproducing failure code: Turn starting switch to ON position.
q Swing holding brake solenoid circuit is powered from pin (8) of inverter (hybrid controller) connector
HC01 or F01 of fuse box F01.
User code Failure code Bucket DUMP prohibit EPC solenoid open circuit
Failure
(Pump controller system)
E50 DW4WKA
q When command to drive bucket DUMP prohibit EPC solenoid is OFF, controller output voltage to
Detail of failure
solenoid is above standard value and open circuit is detected.
Action of con- q None in particular (Since no current flows, solenoid is not energized).
troller q If cause of failure disappears, machine becomes normal by itself.
Problem on
q Bucket DUMP does not work.
machine
q This failure code is subject to be displayed only when arm crane mode (L) is selected for arm crane
Related infor- specification machine.
mation q Method of reproducing failure code: Turn starting switch to ON position and select arm crane mode
(L).
User code Failure code Bucket DUMP prohibit EPC solenoid short circuit
Failure
(Pump controller system)
DW4WKB
q When command to drive bucket DUMP prohibit EPC solenoid is ON, abnormal current flows in cir-
Detail of failure
cuit and short circuit is detected.
q Shuts off power supply to bucket DUMP prohibit EPC solenoid.
Action of con-
q Even if cause of failure disappears, machine does not become normal until starting switch is turned
troller
to OFF position.
Problem on
q Bucket DUMP does not work.
machine
q This failure code is detected only when mode other than arm crane mode (L) is selected for arm
Related infor- crane specification machine.
mation q Method of reproducing failure code: Turn starting switch to ON position and select arm crane mode
(L).
User code Failure code Attachment single/double selector solenoid open circuit
Failure
(Pump controller system)
DWA2KA
q When command to drive attachment return selector solenoid is ON, no current flows and open cir-
Detail of failure
cuit is detected.
Action of con- q None in particular (Since no current flows, solenoid is not energized).
troller q If cause of failure disappears, machine becomes normal by itself.
Problem on
q Attachment hydraulic circuit does not change to single-acting circuit.
machine
q Controller's command (ON/OFF) to attachment return selector solenoid can be checked with mon-
itoring function. (If controller sends solenoid ON command, monitoring screen displays ON even if
Related infor- solenoid is not switched to ON due to open circuit.)
mation (Code: 02301 Solenoid 2)
q Method of reproducing failure code: Turn starting switch ON and set machine in mode other than
breaker mode (B).
User code Failure code Attachment single/double selector solenoid short circuit
Failure
(Pump controller system)
DWA2KB
q When command to drive attachment return selector solenoid is ON, abnormal current flows through
Detail of failure
circuit and short circuit is detected.
q Shuts off power supply to attachment return selector solenoid.
Action of con-
q Even if cause of failure disappears, machine does not become normal until starting switch is turned
troller
to OFF position.
Problem on
q Attachment hydraulic circuit does not change to single-acting circuit.
machine
q Controller's command (ON/OFF) to attachment return selector solenoid can be checked with mon-
itoring function. (If controller sends solenoid ON command, monitoring screen displays ON even if
Related infor-
solenoid is not switched to ON due to short circuit.)
mation
(Code: 02301 Solenoid 2)
q Method of reproducing failure code: Turn starting switch ON and set machine in breaker mode (B).
User code Failure code 2-stage relief solenoid system open circuit
Failure
(Pump controller system)
DWK0KA
q When stop command to drive 2-stage relief solenoid is OFF, controller output voltage to solenoid
Detail of failure
is above standard value and open circuit is detected.
Action of con- q None in particular (Since no current flows, solenoid is not energized).
troller q If cause of failure disappears, machine becomes normal by itself.
Problem on q Travel power is low (main relief valve is not set to high-pressure setting)
machine q One-touch power max. function does not work.
q Controller's command (ON/OFF) to 2-stage relief solenoid can be checked with monitoring func-
tion. (If controller sends solenoid ON command, monitoring screen displays ON even if solenoid is
not switched to ON due to open circuit.)
Related infor- (Code: 02300 Solenoid 1)
mation q As T-adapter for pump controller connector is "socket-type box", operating voltage cannot be mea-
sured at pump controller connector.
q Controller detects open circuit only when command to drive solenoid is OFF.
q Method of reproducing failure code: Turn starting switch to ON position.
User code Failure code 2-stage relief solenoid system short circuit
Failure
(Pump controller system)
DWK0KB
q When command to drive 2-stage relief solenoid circuit is ON, abnormal current flows through circuit
Detail of failure
and short circuit is detected.
q Shuts off power supply to 2-stage relief solenoid circuit.
Action of con-
q Even if cause of failure disappears, machine does not become normal until starting switch is set to
troller
OFF position.
Problem on q Travel power is low (main relief valve is not set to high-pressure setting)
machine q One-touch power maximizing function does not work.
q Controller's command (ON/OFF) to 2-stage relief solenoid can be checked with monitoring func-
tion. (If controller sends solenoid ON command, monitoring screen displays ON even if solenoid is
not switched to ON due to short circuit.)
Related infor-
(Code: 02300 Solenoid 1)
mation
q As T-adapter for pump controller connector is "socket-type box", operating voltage cannot be mea-
sured at pump controller connector.
q Method of reproducing failure code: Turn starting switch to ON position.
User code Failure code Attachment flow rate adjustment EPC open circuit
Failure
(Pump controller system)
DXE4KA
q When driving attachment flow rate adjustment EPC solenoid, no current flows and open circuit is
Detail of failure
detected.
Action of con- q None in particular (Since no current flows, solenoid is not energized).
troller q If cause of failure disappears, machine becomes normal by itself.
Problem on
q Attachment does not move.
machine
q Drive current of attachment flow rate adjustment EPC solenoid can be checked with monitoring
Related infor- function.
mation (Code: 01700 Service solenoid current)
q Method of reproducing failure code: Turn starting switch ON and set machine in breaker mode (B).
User code Failure code Attachment flow rate adjustment EPC short circuit
Failure
(Pump controller system)
DXE4KB
q When driving attachment flow rate adjustment EPC solenoid, abnormal current flows and short cir-
Detail of failure
cuit is detected .
q Shuts off power supply to attachment flow rate adjustment EPC solenoid.
Action of con-
q Even if cause of failure disappears, machine does not become normal until starting switch is turned
troller
to OFF position.
Problem on
q Attachment does not move.
machine
q Drive current of attachment flow rate adjustment EPC solenoid can be checked with monitoring
Related infor- function.
mation (Code: 01700 Service solenoid current)
q Method of reproducing failure code: Turn starting switch ON and set machine in breaker mode (B).
User code Failure code Window washer drive system open circuit
Failure
(Pump controller system)
DY2CKA
q When command to drive window washer drive is OFF, no voltage appears at output pin (pin No. 3)
Detail of failure
of controller and open circuit is detected.
Action of con- q None in particular (washer motor does not work because no current flows).
troller q If cause of failure disappears, machine becomes normal by itself.
Problem on
q Window washer does not operate.
machine
Related infor-
q Method of reproducing failure code: Turn starting switch to ON position.
mation
1 Blown fuse No. 4 of fuse box F01 If fuse is blown, circuit probably has ground fault, etc. (See Cause 6.)
User code Failure code Window washer drive system short circuit
Failure
(Pump controller system)
DY2CKB
Detail of failure q When driving window washer motor, abnormal current flows and short circuit is detected.
User code Failure code Wiper motor drive normal rotation system short circult
Failure
(Pump controller system)
DY2DKB
q When normal rotation command to power wiper motor drive is ON, abnormal current flows through
Detail of failure
circuit and short circuit is detected.
q Shuts off power supply to normal rotation system of wiper motor drive.
Action of con-
q Even if cause of failure disappears, machine does not become normal until starting switch is turned
troller
to OFF position.
Problem on
q Windshield wiper does not operate.
machine
q As T-adapter for pump controller connector is "socket-type box", operating voltage cannot be mea-
Related infor- sured at pump controller connector.
mation q Method of reproducing failure code: Turn starting switch to ON position and and set wiper switch
to INT or ON position.
User code Failure code Wiper motor drive reverse rotation system short circuit
Failure
(Pump controller system)
DY2EKB
q When reverse rotation command to wiper motor drive is ON, abnormal current flows through circuit
Detail of failure
and short circuit is detected.
q Shuts off power supply to reverse rotation system of wiper motor drive.
Action of con-
q Even if cause of failure disappears, machine does not become normal until starting switch is turned
troller
to OFF position.
Problem on
q Windshield wiper does not operate.
machine
q As T-adapter for pump controller connector is "socket-type box", operating voltage cannot be mea-
Related infor- sured at pump controller connector.
mation q Method of reproducing failure code: Turn starting switch to ON position and and set wiper switch
to INT or ON position.
k When testing or adjusting hybrid devices, ensure that you fully understand the following.
k Since the items with the above mark are related to handling of the hybrid devices, ensure that you
understand the descriptions of 00-200 Introduction, safety, and basic information, "Handling of hy-
brid devices and high-voltage wiring", before beginning the work on them.
a For the monitoring items related to hybrid devices troubleshooting, see the list in Failure code [GA----]
(separate sheet 1).
a For the check sheet for recording test results of abnormal hybrid devices, see separate sheet 2 in Failure
code [GA----]. (Use this check sheet when making inquiries to the workshop.)
k Before starting troubleshooting, discharge the capacitor by using capacitor discharge tool (gen-
erator): 796-426-1800 (see previous page).
k After discharging the capacitor, confirm that both capacitor charge LEDs (1) are OFF.
k A voltage not exceeding 30 V will still remain in the capacitor after the discharging process is com-
pleted. Do not work with bare hands. Always wear insulating gloves.
a After disconnecting connector HB01 (at capacitor), cover the connector (both of wiring harness and ca-
pacitor sides) with a plastic bag to prevent entry of foreign matter.
a Perform troubleshooting while the engine is stopped.
a Do not connect the multimeter probe directly to the capacitor side connector (female side of HB01).
Failure codes that not allow capacitor discharging using machine monitor 40-3 1
1. Capacitor troubleshooting
If test results for the failure code indicate a possible problem in the capacitor, proceed with the following trou-
bleshooting procedures.
Cause Procedure, measuring location, criteria and remarks
1. Turn starting switch to OFF position.
2. Disconnect inverter power cable connector HC06.
(Capacitor side connector HB01 must be connected)
a Capacitor enclosure must be wiped clean.
a Take measurement after 1 minute if value is unstable.
a A megohmmeter is recommended to use.
Between HC06 (DC+) (male): red tester probe and
Capacitor system insulation Resistance Min. 10 Mz
1 capacitor enclosure: black tester probe
deteriorated
Between HC06 (DC+) (male): black tester probe and
Resistance Min. 10 Mz
capacitor enclosure: red tester probe
Between HC06 (DC-) (male): red tester probe and
Resistance Min. 10 Mz
capacitor enclosure: black tester probe
Between HC06 (DC-) (male): black tester probe and
Resistance Min. 10 Mz
capacitor enclosure: red tester probe
If no failure is found by check on cause 1, other high voltage devices may be defective.
Proceed to troubleshooting for other suspicious high voltage devices.
If any failure is found, proceed to 5. Capacitor power cable troubleshooting. If power cable is normal, replace capacitor.
Note 1: I*, II*, III*, IIII* indicate the number of lines of the mark.
Note 2: Mark* indicates that "the mark has one to three lines".
Note 3: When connecting connector and the components to be connected, mate the both marked faces and
set the both marks of the same number of lines together. (Harness connector has its top and bottom po-
sitions.)
Note 1: I*, II*, III*, IIII* indicate the number of lines of the mark.
Note 2: Mark* indicates that "the mark has one to three lines".
Note 3: When connecting connector and the components to be connected, mate the both marked faces and
set the both marks of the same number of lines together. (Harness connector has its top and bottom po-
sitions.)
Note 1: I*, II*, III*, IIII* indicate the number of lines of the mark.
Note 2: Mark* indicates that "the mark has one to three lines".
Note 3: When connecting connector and the components to be connected, mate the both marked faces and
set the both marks of the same number of lines together. (Harness connector has its top and bottom po-
sitions.)
If test results for the failure code indicate a possible problem in the electric swing motor power cable, proceed
with the following troubleshooting procedures.
*: *: If connector HB01 is already disconnected.
Cause Procedure, measuring location, criteria and remarks
1. Turn starting switch to OFF position.
2. Disconnect inverter power cable connector HC05 and swing motor power
cable connector PM02.
(Leave capacitor side connector HB01 disconnected)*
1 Open circuit in power cable
Between HC05 (U) (male) and PM02 (U) (male) Resistance Max. 1 z
Between HC05 (V) (male) and PM02 (V) (male) Resistance Max. 1 z
Between HC05 (W) (male) and PM02 (W) (male) Resistance Max. 1 z
1. Turn starting switch to OFF position.
2. Disconnect inverter power cable connector HC05 and swing motor power
cable connector PM02.
(Leave capacitor side connector HB01 disconnected)*
2 Short circuit in power cable
Between HC05 (U) (male) and HC05 (V) (male) Resistance Min. 10 Mz
Between HC05 (V) (male) and HC05 (W) (male) Resistance Min. 10 Mz
Between HC05 (W) (male) and HC05 (U) (male) Resistance Min. 10 Mz
1. Turn starting switch to OFF position.
2. Disconnect inverter power cable connector HC05 and swing motor power
cable connector PM02.
(Leave capacitor side connector HB01 disconnected)*
a Metal part of cable housing must be wiped clean.
a Take measurement after 1 minute if value is unstable.
a A megohmmeter is recommended to use.
Between HC05 (U) (male): red tester probe and cable
Resistance Min. 10 Mz
housing metal part (P): black tester probe
Power cable insulation deterio- Between HC05 (U) (male): black tester probe and Resistance Min. 10 Mz
3 cable housing metal part (P): red tester probe
rated
Between HC05 (V) (male): red tester probe and cable
Resistance Min. 10 Mz
housing metal part (P): black tester probe
Between HC05 (V) (male): black tester probe and
Resistance Min. 10 Mz
cable housing metal part (P): red tester probe
Between HC05 (W) (male): red tester probe and
Resistance Min. 10 Mz
cable housing metal part (P): black tester probe
Between HC05 (W) (male): black tester probe and
Resistance Min. 10 Mz
cable housing metal part (P): red tester probe
If any failure is found by checks on causes 1 to 3, replace swing motor power cable.
Note 1: I*, II*, III*, IIII* indicate the number of lines of the mark.
Note 2: Mark* indicates that "the mark has one to three lines".
Note 3: When connecting connector and the components to be connected, mate the both marked faces and
set the both marks of the same number of lines together. (Harness connector has its top and bottom po-
sitions.)
If test results for the failure code indicate a possible problem in the motor-generator power cable, proceed
with the following troubleshooting procedures.
*: *: If connector HB01 is already disconnected.
Cause Procedure, measuring location, criteria and remarks
1. Turn starting switch to OFF position.
2. Disconnect inverter power cable connectors HC03, HC04 and motor-gener-
ator power cable connectors GM02 and GM03.
(Leave capacitor side connector HB01 disconnected)*
Between HC03 (A1) (male) and GM02 (A1) (male) Resistance Max. 1 z
1 Open circuit in power cable Between HC03 (B1) (male) and GM02 (B1) (male) Resistance Max. 1 z
Between HC03 (C1) (male) and GM02 (C1) (male) Resistance Max. 1 z
Between HC04 (A2) (male) and GM03 (A2) (male) Resistance Max. 1 z
Between HC04 (B2) (male) and GM03 (B2) (male) Resistance Max. 1 z
Between HC04 (C2) (male) and GM03 (C2) (male) Resistance Max. 1 z
1. Turn starting switch to OFF position.
2. Disconnect inverter power cable connectors HC03, HC04 and motor-gener-
ator power cable connectors GM02 and GM03.
(Leave capacitor side connector HB01 disconnected)*
Between HC03 (A1) (male) and HC03 (B1) (male) Resistance Min. 10 Mz
2 Short circuit in power cable Between HC03 (B1) (male) and HC03 (C1) (male) Resistance Min. 10 Mz
Between HC03 (C1) (male) and HC03 (A1) (male) Resistance Min. 10 Mz
Between HC04 (A2) (male) and HC04 (B2) (male) Resistance Min. 10 Mz
Between HC04 (B2) (male) and HC04 (C2) (male) Resistance Min. 10 Mz
Between HC04 (C2) (male) and HC04 (A2) (male) Resistance Min. 10 Mz
1. Turn starting switch to OFF position.
2. Disconnect inverter power cable connectors HC03, HC04 and motor-gener-
ator power cable connectors GM02 and GM03.
(Leave capacitor side connector HB01 disconnected)*
a Metal part of cable housing must be wiped clean.
a Take measurement after 1 minute if value is unstable.
a A megohmmeter is recommended to use.
Between HC03 (A1) (male): red tester probe and
Resistance Min. 10 Mz
cable housing metal part (P): black tester probe
Between HC03 (A1) (male): black tester probe and
Resistance Min. 10 Mz
cable housing metal part (P): red tester probe
Power cable insulation deterio-
3 Between HC03 (B1) (male): red tester probe and
rated Resistance Min. 10 Mz
cable housing metal part (P): black tester probe
Between HC03 (B1) (male): black tester probe and
Resistance Min. 10 Mz
cable housing metal part (P): red tester probe
Between HC03 (C1) (male): red tester probe and
Resistance Min. 10 Mz
cable housing metal part (P): black tester probe
Between HC03 (C1) (male): black tester probe and
Resistance Min. 10 Mz
cable housing metal part (P): red tester probe
Between HC04 (A2) (male): red tester probe and
Resistance Min. 10 Mz
cable housing metal part (P): black tester probe
Between HC04 (A2) (male): black tester probe and
Resistance Min. 10 Mz
cable housing metal part (P): red tester probe
Note 1: I*, II*, III*, IIII* indicate the number of lines of the mark.
Note 2: Mark* indicates that "the mark has one to three lines".
Note 3: When connecting connector and the components to be connected, mate the both marked faces and
set the both marks of the same number of lines together. (Harness connector has its top and bottom po-
sitions.)
Failure code [GA----] Hybrid devices monitoring items list and check
sheet 40-35
List of monitoring items for hybrid devices troubleshooting
(Separate sheet 1)
Motor Electric
Capaci- Unit Re-
No. Monitoring item Code genera- Inverter swing Monitoring item
tor Range marks
tor motor
1 Swing LEFT PPC Sensor2 Volt. 09006 mV
Motor Electric
Capaci- Unit Re-
No. Monitoring item Code genera- Inverter swing Monitoring item
tor Range marks
tor motor
35 Swing LEFT PPC Pressure #2 09009 MPa
A. Failure
Testing Mea-
Display item Code condi- Unit Reference value sured Pass Fail
tions value
-100 100
Swing Lever Stroke 42103 % (Zero with lever at
NEUTRAL)
-100 100
Boom Lever Stroke 42104 % (Zero with lever at
NEUTRAL)
-100 100
Arm Lever Stroke 42105 % (Zero with lever at
NEUTRAL)
-100 100
Bucket Lever Stroke 42106 % (Zero with lever at
NEUTRAL)
Control output of hybrid sys-
09701
tem controller
Hybrid system controller SW
4 input 09702
Swing Motor Rev. Speed 09102 r/min 8311
Swing Motor Target Rev.
09105 r/min 8311
Speed
Starting
switch at
ON,
Bad Insulating Sensor Voltage 09900 mV 4650
before
starting
engine
Assembly part number
---
(Hybrid System Controller)
Serial number
20417 1001 and up
(Hybrid System Controller)
Program part number
20256 787523R400
(Hybrid System Controller)
Program version
20257 4.1.18.0
(Hybrid System Controller)
Defective inverter If no failure is found by checks on causes 1 to 9, inverter (hybrid controller) is defective.
11
(Hybrid controller) (Since this is an internal defect, troubleshooting cannot be performed.)
User code Failure code High power supply voltage error detected by hardware in DC line
Failure before booster
E09 GA04KG (Hybrid controller system)
Defective inverter
3 Since this is an internal defect, troubleshooting cannot be performed.
(hybrid controller)
User code Failure code High power supply voltage error detected by software in DC line
Failure before booster
E09 GA05KG (Hybrid controller system)
Defective inverter
3 Since this is an internal defect, troubleshooting cannot be performed.
(hybrid controller)
User code Failure code Low power supply voltage error detected by software in DC line
Failure before booster
E09 GA05KP (Hybrid controller system)
Defective inverter
3 Since this is an internal defect, troubleshooting cannot be performed.
(hybrid controller)
Failure code [GA06KZ] DC Vlt. Sen. Opn./Shrt. Cir. Bef. Booster 40-36
k Before starting troubleshooting, discharge capacitor by using capacitor discharge tool (genera-
tor): 796-426-1800.
User code Failure code Open or short circuit in voltage sensor in DC line before booster
Failure open or short circuit
E09 GA06KZ (Hybrid controller system)
Defective inverter
1 Since this is an internal defect, troubleshooting cannot be performed.
(hybrid controller)
User code Failure code High power supply voltage error detected by hardware in DC line
Failure after booster
E09 GA08KG (Hybrid controller system)
4 Defective capacitor
User code Failure code High power supply voltage error detected by software in DC line
Failure after booster
E09 GA09KG (Hybrid controller system)
4 Defective capacitor
User code Failure code Low power supply voltage error detected by software in DC line
Failure after booster
E09 GA09KP (Hybrid controller system)
Defective inverter
1 Since this is an internal defect, troubleshooting cannot be performed.
(hybrid controller)
Failure code [GA0AKZ] DC Volt. Sen. Op./Shrt cir. Aft. Booster 40-370
k Before starting troubleshooting, discharge capacitor by using capacitor discharge tool (genera-
tor): 796-426-1800.
User code Failure code Open or short circuit in voltage sensor in DC line after booster
Failure
(Hybrid controller system)
E09 GA0AKZ
Detail of failure q Power train voltage sensor in inverter is abnormal.
q Stops swing motor and motor-generator control, and applies swing holding brake.
q Disables low speed matching function.
Action of con-
q Disables hoist matching function.
troller
q Even if cause of failure disappears, machine does not become normal until starting switch is set to
OFF position.
Problem on q Upper structure does not swing.
machine q Low speed matching function does not operate.
q Voltage of power train can be checked with monitoring function.
Related infor-
(Code: 09200 High current, high voltage system DC voltage)
mation
q Method of reproducing failure code: Turn starting switch to ON position or start engine.
Defective inverter
1 Since this is an internal defect, troubleshooting cannot be performed.
(hybrid controller)
User code Failure code Malfunction of HYB controller high power supply
Failure
(Hybrid controller system)
E09 GA12MC
q Capacitor voltage does not drop below 10 V when discharge operation is completed using machine
Detail of failure
monitor.
q Stops swing motor and motor-generator control, and applies swing holding brake.
q Disables low speed matching function.
Action of con-
q Disables hoist matching function.
troller
q Even if cause of failure disappears, machine does not become normal until starting switch is set to
OFF position.
Problem on q Upper structure does not swing.
machine q Low speed matching function does not operate.
q Capacitor voltage can be checked by using monitoring function.
Related infor-
(Code: 09300 Capacitor voltage)
mation
q Method of reproducing failure code: Turn starting switch to ON position or start engine.
Defective inverter
3 Since this is an internal defect, troubleshooting cannot be performed.
(hybrid controller)
Failure code [GA12NK] HYB Cont. Pow. Suppl. Not Turn. ON 40-373
k Before starting troubleshooting, discharge capacitor by using capacitor discharge tool (genera-
tor): 796-426-1800.
User code Failure code Failure in voltage increase of HYB controller high power supply
Failure
(Hybrid controller system)
E09 GA12NK
Detail of failure q Electrical system in inverter does not start.
q Stops swing motor and motor-generator control, and applies swing holding brake.
q Disables low speed matching function.
Action of con-
q Disables hoist matching function.
troller
q Even if cause of failure disappears, machine does not become normal until starting switch is set to
OFF position.
Problem on q Upper structure does not swing.
machine q Low speed matching function does not operate.
Related infor-
q Method of reproducing failure code: Turn starting switch to ON position or start engine.
mation
Defective inverter
5 Since this is an internal defect, troubleshooting cannot be performed.
(hybrid controller)
Failure code [GA12NL] HYB Cont. Pow. Suppl. Not Turn. OFF 40-374
k Before starting troubleshooting, discharge capacitor by using capacitor discharge tool (genera-
tor): 796-426-1800.
User code Failure code Failure in voltage drop of HYB controller high power supply
Failure
(Hybrid controller system)
E09 GA12NL
Detail of failure q Although a certain time has passed, voltage of power train does not drop below specified level.
q Stops swing motor and motor-generator control, and applies swing holding brake.
q Disables low speed matching function.
Action of con-
q Disables hoist matching function.
troller
q Even if cause of failure disappears, machine does not become normal until starting switch is set to
OFF position.
Problem on q Upper structure does not swing.
machine q Low speed matching function does not operate.
q Voltage of power train can be checked with monitoring function.
Related infor-
(Code: 09200 High current, high voltage system DC voltage)
mation
q Method of reproducing failure code: Turn starting switch to ON position or start engine.
Defective inverter
3 Since this is an internal defect, troubleshooting cannot be performed.
(hybrid controller)
Failure code [GA13MC] HYB Control. Sen. Power Sup. Failure 40-376
User code Failure code Malfunction of HYB controller sensor power supply
Failure
(Hybrid controller system)
E09 GA13MC
Detail of failure q Voltage of 5 V sensor power supply circuit dropps below 2.5 V or exceeds above 6.0 V.
q Shuts off power supply to 5 V sensor.
q Disables low speed matching function.
q Disables hoist matching function.
Action of con-
q Stops swing motor control.
troller
q Applies swing holding brake.
q Even if cause of failure disappears, machine does not become normal until starting switch is turned
to OFF position.
Problem on q Upper structure does not swing.
machine q Low speed matching function does not operate.
Related infor-
q Method of reproducing failure code: Turn the starting switch to ON position.
mation
Detail of failure q Inverter (hybrid controller) fails in CAN communication with pump controller or engine controller.
Defective inverter If no failure is found by above checks, hybrid controller is defective. (Since this is an inter-
3
(hybrid controller) nal defect, troubleshooting cannot be performed.)
Failure code [GA15KZ] HYB Cont. Bad Insul. Sen. Opn/Short. Cir 40-379
User code Failure code Open or short circuit in bad insulation sensor of HYB controller
Failure
(Hybrid controller system)
E09 GA15KZ
Detail of failure q Sensor that detects insulation deterioration between hybrid device and chassis ground is abnormal.
Action of con-
q None in particular.
troller
Problem on
q No current leakage can be detected.
machine
Related infor- q Method of reproducing failure code: Turn starting switch to ON position, or start engine and then
mation turn starting switch to OFF position.
Defective inverter
1 Since this is an internal defect, troubleshooting cannot be performed.
(hybrid controller)
Failure code [GA17KY] Gen. Mot Dr. Power Line Short Circuit 40-380
k Before starting troubleshooting, discharge capacitor by using capacitor discharge tool (genera-
tor): 796-426-1800.
User code Failure code Short circuit in motor-generator driver power line
Failure
(Hybrid controller system)
E09 GA17KY
Detail of failure q Short circuit is detected in power line for motor-generator driver.
q Stops swing motor and motor-generator control, and applies swing holding brake.
q Disables low speed matching function.
Action of con-
q Disables hoist matching function
troller
q Even if cause of failure disappears, machine does not become normal until starting switch is set to
OFF position.
Problem on q Upper structure does not swing.
machine q Low speed matching function does not operate.
Related infor-
q Method of reproducing failure code: Turn starting switch to ON position or start engine.
mation
Defective inverter
1 Since this is an internal defect, troubleshooting cannot be performed.
(hybrid controller)
Defective inverter
1 Since this is an internal defect, troubleshooting cannot be performed.
(hybrid controller)
Defective inverter
1 Since this is an internal defect, troubleshooting cannot be performed.
(hybrid controller)
Failure code [GA18MC] Gen.Mo. Dr. Excite. Pow. Sup. Failure 40-381
k Before starting troubleshooting, discharge capacitor by using capacitor discharge tool (genera-
tor): 796-426-1800.
User code Failure code Malfunction of motor-generator driver excitation power supply
Failure
(Hybrid controller system)
E09 GA18MC
Detail of failure q Electrical system in inverter does not start.
q Stops swing motor and motor-generator control, and applies swing holding brake.
q Disables low speed matching function.
Action of con-
q Disables hoist matching function.
troller
q Even if cause of failure disappears, machine does not become normal until starting switch is set to
OFF position.
Problem on q Upper structure does not swing.
machine q Low speed matching function does not operate.
Related infor-
q Method of reproducing failure code: Turn starting switch to ON position or start engine.
mation
Failure code [GA19KK] Gen. Mot. Drv. Sub-CPU Low Sup. Volt 40-382
k Before starting troubleshooting, discharge capacitor by using capacitor discharge tool (genera-
tor): 796-426-1800.
User code Failure code Motor-generator driver sub-CPU power supply voltage drop
Failure
(Hybrid controller system)
E09 GA19KK
Detail of failure q Abnormal power supply voltage is detected in motor-generator controller.
q Stops swing motor and motor-generator control, and applies swing holding brake.
q Disables low speed matching function.
Action of con-
q Disables hoist matching function.
troller
q Even if cause of failure disappears, machine does not become normal until starting switch is set to
OFF position.
Problem on q Upper structure does not swing.
machine q Low speed matching function does not operate.
Related infor-
q Method of reproducing failure code: Turn starting switch to ON position or start engine.
mation
Failure code [GA19KR] Gen. Motor Driver Sub-CPU Comm. Failure 40-382
k Before starting troubleshooting, discharge capacitor by using capacitor discharge tool (genera-
tor): 796-426-1800.
Failure code [GA19KT] Int. Abnorm. Gen. Mot. Drv. Sub-CPU Con. 40-383
k Before starting troubleshooting, discharge capacitor by using capacitor discharge tool (genera-
tor): 796-426-1800.
User code Failure code Internal failure of motor-generator driver sub-CPU controller
Failure
(Hybrid controller system)
E09 GA19KT
Detail of failure q Inverter internal communication failure 3 is detected by motor-generator controller.
q Stops swing motor and motor-generator control, and applies swing holding brake.
q Disables low speed matching function.
Action of con-
q Disables hoist matching function.
troller
q Even if cause of failure disappears, machine does not become normal until starting switch is set to
OFF position.
Problem on q Upper structure does not swing.
machine q Low speed matching function does not operate.
Related infor-
q Method of reproducing failure code: Turn starting switch to ON position or start engine.
mation
Failure code [GA19MC] Gen. Mot. Drv. Sub-CPU Defect. Operation 40-384
k Before starting troubleshooting, discharge capacitor by using capacitor discharge tool (genera-
tor): 796-426-1800.
Failure code [GA19NA] Gen. Mot. Drv. Sub-CPU Start Disabled 40-384
k Before starting troubleshooting, discharge capacitor by using capacitor discharge tool (genera-
tor): 796-426-1800.
Failure code [GA1BMA] Gen. Mot. Dr. DC Vlt. Sens. Malfunction 40-385
k Before starting troubleshooting, discharge capacitor by using capacitor discharge tool (genera-
tor): 796-426-1800.
Failure code [GA1GKK] Low Sup. Volt. Swing Motor Drv. Sub-CPU 40-386
User code Failure code Voltage drop of swing motor driver sub-CPU power supply
Failure
(Hybrid controller system)
E09 GA1GKK
Detail of failure q Abnormal power supply voltage is detected in swing motor controller power supply.
q Stops swing motor and motor-generator control, and applies swing holding brake.
q Disables low speed matching function.
Action of con-
q Disables hoist matching function.
troller
q Even if cause of failure disappears, machine does not become normal until starting switch is set to
OFF position.
Problem on q Upper structure does not swing.
machine q Low speed matching function does not operate.
Related infor-
q Method of reproducing failure code: Turn starting switch to ON position or start engine.
mation
Failure code [GA1GKR] Swing Mot. Driver Sub-CPU Comm. Failure 40-387
User code Failure code Communication failure of swing motor driver sub-CPU
Failure
(Hybrid controller system)
E09 GA1GKR
Detail of failure q Communication failure is detected in swing motor driver sub-CPU.
q Stops swing motor and motor-generator control, and applies swing holding brake.
q Disables low speed matching function.
Action of con-
q Disables hoist matching function.
troller
q Even if cause of failure disappears, machine does not become normal until starting switch is set to
OFF position.
Problem on q Upper structure does not swing.
machine q Low speed matching function does not operate.
Related infor-
q Method of reproducing failure code: Turn starting switch to ON position or start engine.
mation
Failure code [GA1GKT] Swing Mot. Drv. Sub-CPU Cont. Abnormal 40-387
User code Failure code Internal failure of swing motor driver sub-CPU controller
Failure
(Hybrid controller system)
E09 GA1GKT
Detail of failure q Inverter internal communication failure 3 is detected by swing motor controller.
q Stops swing motor and motor-generator control, and applies swing holding brake.
q Disables low speed matching function.
Action of con-
q Disables hoist matching function.
troller
q Even if cause of failure disappears, machine does not become normal until starting switch is set to
OFF position.
Problem on q Upper structure does not swing.
machine q Low speed matching function does not operate.
Related infor-
q Method of reproducing failure code: Turn starting switch to ON position or start engine.
mation
Failure code [GA1GMB] Swing Mot. Drv. Sub-CPU Funct. Degraded 40-38
User code Failure code Performance drop of swing motor driver sub-CPU
Failure
(Hybrid controller system)
GA1GMB
Detail of failure q Inverter internal communication failure 1 is detected by swing motor controller.
q None in particular.
Action of con-
q Even if cause of failure disappears, machine does not become normal until starting switch is set to
troller
OFF position.
Problem on
q None in particular.
machine
Related infor-
q Method of reproducing failure code: Turn starting switch to ON position or start engine.
mation
Failure code [GA1GMC] Swing Mot. Drv. Sub-CPU Defect Op. 40-389
Failure code [GA1GNA] Swing Mot. Drv. Sub-CPU Start Disabled 40-389
User code Failure code Startup failure of swing motor driver sub-CPU
Failure
(Hybrid controller system)
E09 GA1GNA
Detail of failure q Internal communication initialization failure of inverter is detected by swing motor controller.
q Stops swing motor and motor-generator control, and applies swing holding brake.
q Disables low speed matching function.
Action of con-
q Disables hoist matching function.
troller
q Even if cause of failure disappears, machine does not become normal until starting switch is set to
OFF position.
Problem on q Upper structure does not swing.
machine q Low speed matching function does not operate.
Related infor-
q Method of reproducing failure code: Turn starting switch to ON position or start engine.
mation
Failure code [GA1HKZ] Swg Mot. Dr. Ph-U Tem. Sens Opn/Shrt Cir. 40-390
User code Failure code Open or short circuit in U-phase temperature sensor of swing
Failure motor driver
E09 GA1HKZ (Hybrid controller system)
Detail of failure q Temperature sensor failure is detected in U-phase output circuit of swing motor inverter.
Action of con- q Limits swing speed, etc.
troller q If cause of failure disappears, machine becomes normal by itself.
Problem on
q Swing speed, etc. are limited.
machine
q Swing motor coil temperature can be checked with monitoring function.
Related infor-
(Code: 09500 Swing inverter phase U temperature)
mation
q Method of reproducing failure code: Turn starting switch to ON position or start engine.
Failure code [GA1JKZ] Swg Mot. Dr. Ph-V Tem. Sens Opn/Shrt Cir. 40-390
User code Failure code Open or short circuit in V-phase temperature sensor of swing
Failure motor driver
E09 GA1JKZ (Hybrid controller system)
Detail of failure q Temperature sensor failure is detected in V-phase output circuit of swing motor inverter.
Action of con- q Limits swing speed, etc.
troller q If cause of failure disappears, machine becomes normal by itself.
Problem on
q Swing speed, etc. are limited.
machine
q Swing motor coil temperature can be checked with monitoring function.
Related infor-
(Code: 09501 Swing inverter phase V temperature)
mation
q Method of reproducing failure code: Turn starting switch to ON position or start engine.
Failure code [GA1KKZ] Swg Mot. Dr. Ph-W Tem. Sens Opn/Shrt Cir 40-391
User code Failure code Open or short circuit in W-phase temperature sensor of swing
Failure motor driver
E09 GA1KKZ (Hybrid controller system)
Detail of failure q Temperature sensor failure is detected in W-phase output circuit of swing motor inverter.
Action of con- q Limits swing speed, etc.
troller q If cause of failure disappears, machine becomes normal by itself.
Problem on
q Swing speed, etc. are limited.
machine
q Swing motor coil temperature can be checked with monitoring function.
Related infor-
(Code: 09502 Swing inverter phase W temperature)
mation
q Method of reproducing failure code: Turn starting switch to ON position or start engine.
Failure code [GA1LKZ] Swg Mot. Dr. Current. Sens Opn/Shrt Cir. 40-391
User code Failure code Open or short circuit in swing motor driver current sensor
Failure
(Hybrid controller system)
E09 GA1LKZ
Detail of failure q Open or short circuit is detected in swing motor inverter current sensor.
q Stops swing motor and motor-generator control, and applies swing holding brake.
q Disables low speed matching function.
Action of con-
q Disables hoist matching function.
troller
q Even if cause of failure disappears, machine does not become normal until starting switch is set to
OFF position.
Problem on q Upper structure does not swing.
machine q Low speed matching function does not operate.
Related infor-
q Method of reproducing failure code: Turn starting switch to ON position or start engine.
mation
Failure code [GA1MKZ] Swg Mot. Dr. DC Vlt. Sen Opn/Shrt Cir. 40-392
User code Failure code Open or short circuit in swing motor driver DC voltage sensor
Failure
(Hybrid controller system)
E09 GA1MKZ
Detail of failure q DC voltage sensor failure of swing motor inverter is detected.
q Stops swing motor and motor-generator control, and applies swing holding brake.
q Disables low speed matching function.
Action of con-
q Disables hoist matching function.
troller
q Even if cause of failure disappears, machine does not become normal until starting switch is set to
OFF position.
Problem on q Upper structure does not swing.
machine q Low speed matching function does not operate.
Related infor-
q Method of reproducing failure code: Turn starting switch to ON position or start engine.
mation
q Reference
User code Failure code Open or short circuit in capacitor temperature sensor
Failure
(Hybrid controller system)
E09 GA1UKZ
q Difference between capacitor base temperature and capacitor busbar temperature is more than
Detail of failure
54.4 C.
Action of con- q Limits swing speed, etc.
troller q If cause of failure disappears, machine becomes normal by itself.
Problem on
q Swing speed, etc. are limited.
machine
q Capacitor base temperature and capacitor busbar temperature can be checked with monitoring
Related infor- function.
mation (Code: 09304 Capacitor base temperature, Code: 09305 Capacitor busbar temperature)
q Method of reproducing failure code: Turn starting switch to ON position or start engine.
Failure code [GA1XKZ] Boost. Ind. Temp. Sens. Open/Shrt. Circ. 40-403
User code Failure code Open or short circuit in booster inductor temperature sensor
Failure
(Hybrid controller system)
E09 GA1XKZ
Detail of failure q Abnormality of booster inductor temperature sensor in the inverter is detected.
Action of con- q Limits swing speed, etc.
troller q If cause of failure disappears, machine becomes normal by itself.
Problem on
q Swing speed, etc. are limited.
machine
q Booster inductor temperature can be checked with monitoring function.
(Code: 09402 Booster inductor temperature)
q Method of reproducing failure code: Turn starting switch to ON position or start engine.
q If any of the failure code [GA00NS] or [GA1YNS] or [GA1NNS] or [GA1ZNS] or [GA22NS] or
Related infor-
[GA25NS] or [GA26NS] which indicates the overheat in the inverter is displayed at the same time,
mation
hybrid system cooling circuit may be defective.
q Inductor temperature which can be checked with monitoring function is at normal level (the tem-
perature is equal to ambient temperature or higher. The temperature range is 16 C to 190 C), hy-
brid system cooling circuit may be deactive.
Failure code [GA1ZKZ] Booster IGBT Temp. Sens. Opn/Shrt. Circ. 40-404
User code Failure code Open or short circuit in booster IGBT temperature sensor
Failure
(Hybrid controller system)
E09 GA1ZKZ
Detail of failure q Abnormality of booster IGBT temperature sensor in inverter is detected.
Action of con- q Limits swing speed, etc.
troller q If cause of failure disappears, machine becomes normal by itself.
Problem on
q Swing speed, etc. are limited.
machine
q Booster IGBT base temperature can be checked with monitoring function.
Related infor-
(Code: 09403 Booster IGBT base temperature)
mation
q Method of reproducing failure code: Turn starting switch to ON position or start engine.
Failure code [GA23KZ] Gen. Mot. Dr. Temp. Sens.0 Opn/Short Cir. 40-406
User code Failure code Open or short circuit in motor-generator driver temperature sen-
Failure sor 0
E09 GA23KZ (Hybrid controller system)
Detail of failure q Open or short circuit is detected in motor-generator driver temperature sensor 0.
Action of con- q Limits swing speed, etc.
troller q If cause of failure disappears, machine becomes normal by itself.
Problem on
q Swing speed, etc. are limited.
machine
Related infor-
q Method of reproducing failure code: Turn starting switch to ON position or start engine.
mation
Failure code [GA24KZ] Gen. Mot. Dr. Temp. Sens.1 Opn/Short Cir. 40-406
User code Failure code Open or short circuit in motor-generator driver temperature sen-
Failure sor 1
E09 GA24KZ (Hybrid controller system)
Detail of failure q Open or short circuit is detected in motor-generator driver temperature sensor 1.
Action of con- q Limits swing speed, etc.
troller q If cause of failure disappears, machine becomes normal by itself.
Problem on
q Swing speed, etc. are limited.
machine
Related infor-
q Method of reproducing failure code: Turn starting switch to ON position or start engine.
mation
User code Failure code Open or short circuit in DC current sensor before booster
Failure
(Hybrid controller system)
E09 GA27KZ
Detail of failure q Open or short circuit is detected in DC current sensor before booster.
Action of con-
q Limits swing speed, etc.
troller
Problem on
q Swing speed, etc. are limited.
machine
q Capacitor current can be checked with monitoring function.
Related infor-
(Code: 09307 Capacitor current)
mation
q Method of reproducing failure code: Turn starting switch to ON position or start engine.
Failure code [GA28KZ] DC after boosting sensor open or short circuit 40-409
User code Failure code Open or short circuit in DC current sensor after booster
Failure
(Hybrid controller system)
E09 GA28KZ
Detail of failure q Open or short circuit is detected in DC current sensor after booster.
Action of con-
q Limits swing speed, etc.
troller
Problem on
q Swing speed, etc. are limited.
machine
q Swing motor DC can be checked with monitoring function.
Related infor-
(Code: 09100 Swing motor DC)
mation
q Method of reproducing failure code: Turn starting switch to ON position or start engine.
q Reference 3. Tools [1] and [2] are needed to replace rotor (1)
1. Speed sensor (2) is installed on rotor (1) of of motor-generator (see "Disassembly and
motor-generator. Speed sensor (2) can be assembly").
replaced individually by removing plate (3). a Tool [1] is needed when replacing mo-
2. Wiring harness (4) is connected to connector tor-generator rotor (1) together with housing
GM01. assembly (2) (see "Disassembly and assem-
a Pump assembly is removed in the drawing. bly").
Failure code [GA61KZ] Gen. Motor Temp. Sens. Open/Short Cir. 40-414
User code Failure code Open or short circuit in motor-generator temperature sensor
Failure
(Hybrid controller system)
E09 GA61KZ
Detail of failure q Open or short circuit is detected in motor-generator temperature sensor.
Action of con- q Limits swing speed, etc.
troller q If cause of failure disappears, machine becomes normal by itself.
Problem on
q Swing speed, etc. are limited.
machine
q For replacement procedure of motor-generator temperature sensor, see failure code [GA61NS].
q Method of reproducing failure code: Turn starting switch to ON position or start engine.
q Generator motor temperature can be checked with monitoring function.
(Code: 09600 Generator Motor Temperature)
Related informa- q If any of the failure code [GA00NS] or [GA1YNS] or [GA1NNS] or [GA1ZNS] or [GA22NS] or
tion [GA25NS] or [GA26NS] which indicates the overheat in the inverter is displayed at the same time,
hybrid system cooling circuit may be defective.
q If generator motor temperature which can be checked with monitoring function is at normal level
(the temperature is equal to ambient temperature or higher, the temperature range is 16 C to
190 C), hybrid system cooling circuit may be defective.
q Reference
a To replace the motor-generator temperature
sensor, motor-generator (1) housing must be re-
placed (see Disassembly and assembly).
1. Install tool [1] to remove motor-generator
housing (1) and rotor (2) assembly.
2. Remove plate (3) and disconnect the connector
for wiring harness (4) at the inside.
3. With tool [1] still installed, remove rotor (2).
Failure code [GA62KY] Gen. Mot. Ph-A Cur. Sen. Power Short Cir 40-417
k Before starting troubleshooting, discharge capacitor by using capacitor discharge tool (genera-
tor): 796-426-1800.
User code Failure code Short circuit in A-phase current sensor power line of motor-gen-
Failure erator
E09 GA62KY (Hybrid controller system)
Failure code [GA62KZ] Gen. Mot. Ph-A Cur. Sen. Open/Short Cir 40-418
k Before starting troubleshooting, discharge capacitor by using capacitor discharge tool (genera-
tor): 796-426-1800.
User code Failure code Open or short circuit in A-phase current sensor of motor-genera-
Failure tor
E09 GA62KZ (Hybrid controller system)
Failure code [GA62MA] Gen. Mot. Ph-A Current Sen. Malfunction 40-419
k Before starting troubleshooting, discharge capacitor by using capacitor discharge tool (genera-
tor): 796-426-1800.
Failure code [GA63KY] Gen. Mot. Ph-B Cur. Sen. Power Short Cir. 40-419
k Before starting troubleshooting, discharge capacitor by using capacitor discharge tool (genera-
tor): 796-426-1800.
User code Failure code Short circuit in B-phase current sensor power line of motor-gen-
Failure erator
E09 GA63KY (Hybrid controller system)
Failure code [GA63KZ] Gen. Mot. Ph-B Cur. Sen. Open/Short Cir 40-420
k Before starting troubleshooting, discharge capacitor by using capacitor discharge tool (genera-
tor): 796-426-1800.
User code Failure code Open or short circuit in B-phase current sensor of motor-genera-
Failure tor
E09 GA63KZ (Hybrid controller system)
Failure code [GA63MA] Gen. Mot. Ph-B Current Sen. Malfunction 40-420
k Before starting troubleshooting, discharge capacitor by using capacitor discharge tool (genera-
tor): 796-426-1800.
Failure code [GA64KY] Gen. Mot. Ph-C Cur. Sen. Power Short Cir. 40-421
k Before starting troubleshooting, discharge capacitor by using capacitor discharge tool (genera-
tor): 796-426-1800.
User code Failure code Short circuit in C-phase current sensor power line of motor-gen-
Failure erator
E09 GA64KY (Hybrid controller system)
Failure code [GA64KZ] Gen. Mot. Ph-C Cur. Sen. Open/Short Cir. 40-42
k Before starting troubleshooting, discharge capacitor by using capacitor discharge tool (genera-
tor): 796-426-1800.
User code Failure code Open or short circuit in C-phase current sensor of motor-genera-
Failure tor
E09 GA64KZ (Hybrid controller system)
Failure code [GA64MA] Gen. Mot. Ph-C Current Sen. Malfunction 40-42
k Before starting troubleshooting, discharge capacitor by using capacitor discharge tool (genera-
tor): 796-426-1800.
Failure code [GA70MD] HYB Swing Motor Defective Stirr. Motion 40-423
k Before starting troubleshooting, discharge capacitor by using capacitor discharge tool (genera-
tor): 796-426-1800.
Circuit diagram related to hybrid system swing motor temperature sensor 40-424
Failure code [GA71KZ] HYB Swing Mot. Temp. Sens. Opn/Shrt Cir. 40-426
User code Failure code Open or short circuit in hybrid swing motor temperature sensor
Failure
(Hybrid controller system)
E09 GA71KZ
Detail of failure q Abnormality of swing motor temperature sensor is detected.
Action of con- q Limits swing speed, etc.
troller q If cause of failure disappears, machine becomes normal by itself.
Problem on
q Swing speed, etc. are limited.
machine
q Swing motor coil temperature can be checked with monitoring function.
(Code: 09101 Swing motor coil temperature)
q Method of reproducing failure code: Turn starting switch to ON position or start engine.
q If any of the failure code [GA00NS] or [GA1YNS] or [GA1NNS] or [GA1ZNS] or [GA22NS] or
Related infor-
[GA25NS] or [GA26NS] which indicates the overheat in the inverter is displayed at the same time,
mation
hybrid system cooling circuit may be defective.
q If swing motor coil temperature which can be checked with monitoring function is at normal level
(the temperature is equal to ambient temperature or higher. The temperature range is 16 C to
190 C), hybrid system cooling circuit may be defective.
Hot short circuit in wiring harness Between HC02 (female) (6) and ground Voltage Max. 1 V
3
(contact with 24 V circuit) Between HC02 (female) (15) and ground Voltage Max. 1 V
Between HC02 (female) (16) and ground Voltage Max. 1 V
Between HC02 (female) (26) and ground Voltage Max. 1 V
Between HC02 (female) (36) and ground Voltage Max. 1 V
Failure code [GA72MC] HYB Swing Motor Resolver Defect Op. 40-430
Failure code [GA81KZ] Swing Motor Power Cable Opn/Shrt Circ. 40-430
User code Failure code Open or short circuit in swing motor power cable
Failure
(Hybrid controller system)
E09 GA81KZ
Detail of failure q Open or short circuit is detected in swing motor power cable.
q Stops swing motor and motor-generator control, and applies swing holding brake.
q Disables low speed matching function.
Action of con-
q Disables hoist matching function.
troller
q Even if cause of failure disappears, machine does not become normal until starting switch is set to
OFF position.
Problem on q Upper structure does not swing.
machine q Low speed matching function does not operate.
Related infor-
q Method of reproducing failure code: Turn starting switch to ON position or start engine.
mation
Failure code [GAA2KB] Swing Brake sol. Supply Line short cir. 40-432
User code Failure code Swing holding brake solenoid power line short circuit
Failure
(Pump controller system)
E03 GAA2KB
Detail of failure q When command to drive swing holding brake solenoid is ON, short circuit is detected.
q Shuts off power supply to swing holding brake solenoid.
Action of con-
q Even if cause of failure disappears, machine does not become normal until starting switch is set to
troller
OFF position.
Problem on
q Upper structure does not swing (swing holding brake is not released).
machine
q If solenoid and wiring harness are normal, swing operation is possible by setting swing holding
brake cancel switch to RELEASE position. (However, swing holding brake is not released when
starting switch is in OFF position.
q Be sure to set swing lock switch and emergency stop switch to OFF position during troubleshoot-
ing.
q Brake is released when current flows through swing holding brake solenoid.
Related infor-
q Controller's command (ON/OFF) to swing holding brake solenoid can be checked with monitoring
mation
function. (If controller sends solenoid ON command, monitoring screen displays ON even if sole-
noid is not switched to ON due to short circuit.)
(Code: 09700 Hybrid controller relay output)
q Method of reproducing failure code: Turn starting switch to ON position.
q Swing holding brake solenoid is powered from pin (8) of inverter (hybrid controller) connector HC01
or F01 of fuse box F01.
Defective fuse No. 3 in fuse box If fuse is blown, circuit probably has ground fault. (See troubleshooting on
5
F01 cause 22).
1. Turn starting switch to ON position (to connect ACC).
6 Defective battery relay system a If battery relay operation sound is not heard, go to troubleshooting on cause
19.
1. Turn starting switch to OFF position. Remove fuse No. 3 in fuse box F01.
2. Turn starting switch to ON position (to connect ACC).
Defective fusible link F04, defec-
7 Between input terminal (1A) of fuse box F01-3 and
tive wiring harness Voltage 20 30 V
ground
a If voltage is abnormal, go to troubleshooting on cause 10.
1. Turn starting switch to OFF position.
2. Remove fuse No. 19 in fuse box F01. (To prevent engine start during trou-
Defective starting switch, lock bleshooting)
lever switch, starting motor cut-off 3. Insert T-adapters into connector R17.
8 relay R06, personal code relay 4. Turn starting switch to START position and hold (two persons required for
R07, battery relay, or wiring har- this check).
ness Between R17 (1) and ground Voltage 20 30 V
a If voltage is abnormal, go to cause 13.
Failure 3) While preheater is operating, preheating monitor does not light up.
q "Automatic preheating" and "Manual preheating" functions are available. When either function is
Related informa-
operated, preheating monitor lights up.
tion
q Check if manual preheating functions first.
E-8 Engine coolant temperature gauge does not indicate properly 40-454
1) While engine coolant temperature is rising properly, temperature gauge indicator does not rise
above white range (C).
Failure
2) While engine coolant temperature remains in normal range, temperature gauge indicator rises to
red range (H).
q Signal of engine coolant temperature sensor is input to engine controller and then data is trans-
Related infor- mitted to machine monitor through CAN communication system.
mation q Engine coolant temperature can be checked with monitoring function
(Code: 04107 Engine coolant temperature)
3) Indication of engine coolant temperature gauge is different from actual engine coolant tempera-
ture.
Failure
4) Indication of engine coolant temperature gauge is different from display of engine coolant temper-
ature monitor.
q Signal voltage of engine coolant temperature sensor is input to engine controller and then data is
Related infor- transmitted to machine monitor through CAN communication system.
mation q Engine coolant temperature can be checked with monitoring function.
(Code: 04107 Engine coolant temperature)
E-9 Hydraulic oil temperature gauge does not indicate properly 40-456
(1) While hydraulic oil temperature is rising properly, temperature gauge indicator does not rise above
white range (C).
Failure
(2) While hydraulic oil temperature remains in normal range, temperature gauge indicator rises to red
range (H).
q Signal of hydraulic oil temperature sensor is input to pump controller and then the data is transmit-
Related infor- ted to machine monitor through CAN communication system.
mation q Hydraulic oil temperature can be checked with monitoring function
(Code: 04401 Hydraulic oil temperature)
(3) Indication of hydraulic oil temperature gauge is different from actual hydraulic oil temperature.
Failure (4) Indication of hydraulic oil temperature gauge is different from display of hydraulic oil temperature
monitor.
q Signal of hydraulic oil temperature sensor is input to pump controller and then the data is transmit-
Related infor- ted to machine monitor through CAN communication system.
mation q Hydraulic oil temperature can be checked with monitoring function
(Code: 04401 Hydraulic oil temperature)
Hydraulic oil temperature gauge and hydraulic oil temperature monitor 40-457
E-10 HYB system temperature gauge does not indicate properly 40-458
1) While hybrid system temperature is rising normally, temperature gauge indicator does not rise
above white range (C).
Failure
2) While hybrid system temperature remains in normal range, temperature gauge indicator rises to
red range (H).
q Signal voltage of hybrid system temperature sensors are input to hybrid controller and then data
is transmitted to machine monitor.
q Hybrid temperatures can be checked with monitoring function.
Related infor- (Code: 09306: Capacitor cell temperature, 09403: Booster IGBT base temperature, 09404:
mation Booster IGBT junction temperature, 09402: Booster inductor temperature, 09101: Swing motor
coil temperature, 09600: Motor-generator temperature, 09607: Generator driver IGBT base
temperature #0, 09608: Generator driver IGBT base #1, 09507: Swing driver IGBT junction
temperature)
a Hybrid system temperature gauge indicates in % to show temperature load of hybrid devices (see next
page for details).
Booster
Hybrid device Capacitor cell Booster Booster
% IGBT junction tem-
temperature temperature IGBT base temperature inductor temperature
perature
A1 102 65 80 130 125
A2 100 63 78 125 120
A3 95 60 75 110 110
A4 50 40 55 90 90
A5 20 0 0 0 0
A6 0 -30 -30 -30 -30
a If gauge signal is not obtained due to open circuit in CAN communication line, indicator disappears.
E-11 Displays on machine monitor are different from those for actual
machine 40-460
Failure q Displays on machine monitor are different from those for actual machine
Related information
Defective machine monitor If no failure is found by check on cause 1, machine monitor may be defective.
2
(body) (Since this is an internal defect, troubleshooting cannot be performed.)
E-14 Automatic warm-up system does not operate (in cold season) 40-461
Failure q Automatic warm-up system does not operate (in cold weather).
q Automatic warm-up function increases engine speed to 1,200 rpm when engine coolant tem-
perature is below 30 C.
q With starting switch at ON position or after engine is started, if fuel control dial is kept at 70%
throttle position or higher for 3 seconds, automatic warm-up operation is canceled.
q If machine is equipped with air conditioner, when blower is turned on, ambient temperature is
Related information
below 5 C and engine coolant temperature is below 55 C, automatic warm-up function in-
creases engine speed to 1,300 rpm. If engine coolant temperature reaches 60 C, automatic
warm-up function is canceled.
q If engine coolant temperature is below 10 C, turbocharger protection function works to keep
engine speed below 1,000 rpm for up to 5 seconds after engine is started.
Engine coolant temperature gauge and engine coolant temperature monitor 40-461
Failure 2) Auto-decelerator is not operated or canceled interlocking with work equipment lever.
q Since auto-deceleration set speed is 1,050 rpm, auto-deceleration is not operated or canceled if
Related infor-
engine speed higher than this speed is set by fuel control dial.
mation
q Auto-deceleration does not function in arm crane mode (L) for arm crane specification machines.
Failure 2) When working mode is changed, setting of engine and hydraulic pump is not changed.
Related information
Failure 2) When selection of travel speed is changed, actual travel speed does not change.
q When failure due to cause 1 occurs, actual travel speed does not decrease when travel speed set-
Related infor- ting is changed to "Lo".
mation q As T-adapter for pump controller connector is "socket-type box", operating voltage cannot be mea-
sured at pump controller connector.
E-21 All of work equipment, swing, and travel mechanism do not move
or are not locked 40-46
Failure 1) All of work equipment, swing, and travel mechanism do not move.
Related infor-
mation
Failure 2) All of work equipment, swing, and travel mechanism are not locked.
Related infor-
mation
Failure 2) When swing brake cancel switch is set to Normal position, swing holding brake does not operate.
Related infor-
mation
Failure 3) When L.H. knob switch is released, work equipment power is not returned to normal.
Related informa- q Signal of L.H. knob switch can be checked with monitoring function.
tion (Code: 02200 Switch input 1)
E-24 Travel alarm does not sound or does not stop sounding 40-476
Failure 1) Alarm does not sound during travel.
q Output to travel alarm can be checked with monitoring function.
(Code: 03701 Controller output 2)
q Travel pressure switch signal (ON/OFF) can be checked with monitoring function.
Related infor-
(Monitoring code: 01900 Pressure switch 1)
mation
q Use "short connector" 799-601-7230 for 2-pin X connector in troubleshooting for cause 3.
q As T-adapter for pump controller connector is "socket-type box", operating voltage cannot be mea-
sured at the pump controller connector.
E-25 Horn does not sound or does not stop sounding 40-478
Failure 1) Horn does not sound.
Related infor-
mation
Failure 2) When wiper switch is operated, windshield wiper does not operate.
q Signal of window rear limit switch can be checked with monitoring function.
Related infor- (Code: 02204 Switch input 5)
mation q Wiper motor is checked and its failure is expressed in failure code [DY20KA], [DY20MA],
[DY2DKB], or [DY2EKB].
Failure 3) When window washer switch is operated, window washer does not operate.
q Signal of window washer switch can be checked with monitoring function.
Related infor-
(Code: 04504 Monitor 1st, 2nd row switches)
mation
q Window washer is checked and its failure is expressed in failure codes [DY2CKA] or [DY2CKB].
E-29 "ARM IN" indicator is not displayed properly with monitoring func-
tion 40-486
Failure "Arm IN" operation signal is not displayed properly on monitoring sceen.
Related information q Monitoring code: 01900 Pressure switch 1
Defective PPC pressure switch If "Service" operation signal displayed on monitoring screen changes to "ON",
1 (P14) for front end of attachment front service PPC pressure switch (P14) is defective (Note 1).
control pedal
B. If "Service" operation signal displayed on monitoring screen is ON" when
starting switch is turned to ON position
1. Turn starting switch to OFF position.
2. Disconnect connector P14.
3. Turn starting switch to ON position.
Defective PPC pressure switch If "Service" operation signal displayed on monitoring screen changes to "ON",
2 (P15) for rear end of attachment rear service PPC pressure switch (P15) is defective (Note 1).
control pedal
B. If "Service" operation signal displayed on monitoring screen is ON" when
starting switch is turned to ON position
1. Turn starting switch to OFF position.
2. Disconnect connector P15.
3. Turn starting switch to ON position.
Note 1: If "Service" operation signal displayed on monitoring screen is "OFF" while voltage between C01 (52)
and ground is below 1 V, pump controller is defective.
Note 2: If "Service" operation signal displayed on monitoring screen is "ON" while voltage between C01 (52)
and ground is approximately 7 V, pump controller is defective.
a This system diagram is a rough general hydraulic circuit diagram made as reference material for trouble-
shooting of the hydraulic and mechanical systems.
(Rev. 2010/03)
a The following information is summarized in the troubleshooting table. Before carrying out troubleshooting,
understand that information fully.
Failure Problem on machine
Related infor-
Information related to the detected failure or troubleshooting
mation
2
Probable Probable causes for trou- <Contents of description>
causes and cri- ble (Given numbers are q Standard value in normal condition to judge probable
teria 3
reference numbers, which causes
do not indicate priority.) q Remarks on judgment
4
H-1 Speed or power of all work equipment and travel is low 40-49
Failure q Speed or power of all work equipment and travel is low.
Related infor-
q Perform all troubleshooting in power mode (P) of working mode.
mation
H-3 All work equipment and travel systems do not work 40-502
Failure q All work equipment and travel systems do not work.
Related infor-
q Perform all troubleshooting in power mode (P) of working mode.
mation
H-4 Unusual noise comes out from around hydraulic pump 40-502
Failure q Unusual noise comes out from around hydraulic pump.
Related infor-
mation
H-10 Work equipment does not move in its single operation 40-506
(1) Boom does not move independently.
Failure (2) Arm does not move independently.
(3) Bucket does not move independently.
Related infor-
q Perform all troubleshooting in power mode (P) of working mode.
mation
H-13 When part of work equipment is relieved singly, other parts of work
equipment move 40-509
Failure q When part of work equipment is relieved singly, other parts of work equipment move.
Related infor-
mation
H-20 Travel speed does not shift or travel speed is low or high 40-514
Failure q Travel speed does not change or travel speed is too low or high
Related infor-
q Perform all troubleshooting in power mode (P) of working mode.
mation
H-21 Travel system does not work (only one side) 40-515
Failure q Travel system does not work (only one side).
Related infor-
q Perform all troubleshooting in power mode (P) of working mode.
mation
See "Troubleshooting for hybrid system (Y mode)" and troubleshoot since this failure is related to hybrid system.
Failure (2) Upper structure does not swing in only one direction.
Related infor-
q Perform all troubleshooting in power mode (P) of working mode.
mation
See "Troubleshooting for hybrid system (Y mode)" and troubleshoot since this failure is related to the hybrid system.
See "Troubleshooting for hybrid system (Y mode)" and troubleshoot since this failure is related to the hybrid system.
Failure (2) Swing acceleration performance is poor or swing speed is slow in only one direction.
Related infor-
q Perform all troubleshooting in power mode (P) of working mode.
mation
See "Troubleshooting for hybrid system (Y mode)" and troubleshoot since this failure is related to hybrid system.
See "Troubleshooting for hybrid system (Y mode)" and troubleshoot since this failure is related to the hybrid system.
Failure (2) Upper structure overruns excessively when it stops swinging in only one direction.
Related infor-
q Perform all troubleshooting in power mode (P) of working mode.
mation
See "Troubleshooting for hybrid system (Y mode)" and troubleshoot since this failure is related to hybrid system.
H-25 Large shock is made when upper structure stops swinging 40-517
Failure q Large shock is made when upper structure stops swinging
Related infor-
q Perform all troubleshooting in power mode (P) of working mode.
mation
See "Troubleshooting for hybrid system (Y mode)" and troubleshoot since this failure is related to hybrid system.
H-26 Large sound is made when upper structure stops swinging 40-517
Failure q Large sound is made when upper structure stops swinging
Related infor-
q Perform all troubleshooting in power mode (P) of working mode.
mation
See "Troubleshooting for hybrid system (Y mode)" and troubleshoot since this failure is related to hybrid system.
See "Troubleshooting for hybrid system (Y mode)" and troubleshoot since this failure is related to hybrid system.
Failure (2) Upper structure lowers largely by its own weight (when parking brake is released).
q When swing brake cancel switch is set to RELEASE position, swing holding brake is released and
Related infor- swinging motion of upper structure is held with swing electric motor. (However, this applies only
mation while hybrid system is operating normally)
q Perform all troubleshooting in power mode (P) of working mode.
See "Troubleshooting for hybrid system (Y mode)" and troubleshoot since this failure is related to hybrid system.
This troubleshooting chart marks the content of the questions and check items with E, Q or w according to
their closer relationship with the causes.
E: Reference information for estimation of the cause
Q: Information and inspection result that indicate the cause of the failure
w: A cause particularly probable among those marked with Q above.
a Count the priority level of each marking as w > Q when determining the cause.
Don't count E when determining the cause. The item with this marking may be counted, however, if no
difference is present than this and the cause cannot be determined.
There is a causal relationship between 3 items in the [Questions] and [Check items] sections and 6 items in
the [Causes] sections.
The method of pinpointing the [cause] from the causal relationship and approaching the [troubleshooting] is
explained according to Step 1 Step 3 shown below.
Defective injector
Check recent repair history
Degree of use
Operated for long period E E E
of machine
It becomes worse gradually Q w w Q
Questions
Startability:
Engine starts easily when warm w w
Fuel other than specified one is used Q Q Q
Filters are not replaced as indicated in the Operation and Maintenance w w Q Q
Engine oil must be added more frequently w
When engine is preheated or when temperature is low, preheating w
During operation, charge level monitor indicates abnormal charge w w
Dust indicator indicates a red zone w
Air breather hole in fuel tank cap is clogged w
Fuel is leaking from fuel piping w Q
No response or heavy resistance is felt when operating the priming w Q
Starting motor rotates engine slowly w
Even if air bleeding plug of fuel filter head is removed,
w
While engine is fuel does not flow out
cranked: If spill hose from injector is disconnected, little fuel
Check items
w
spills
When exhaust manifold is touched immediately after starting engine,
w
temperature of some cylinders is low
Engine does not pick up smoothly and combustion is irregular Q Q w
Engine hunts Q w Q
Blowby gas is excessive w
Inspect air cleaner directly q
When compression pressure is measured, it is found to be low q q
When air bleeding operation for fuel system is performed, air comes q
Troubleshooting
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Clean
Clean
Clean
Remedy
Replace
Replace
Replace
Replace
Correct
Rem-
edy
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Add
Remedy
c) Exhaust smoke comes out but engine does not start (Fuel is being Causes
injected)
When air bleeding operation for fuel system is performed, air comes out q
Inspect fuel filter directly q
Perform troubleshooting for error "Rail Press Low" or "Rail Press Very
q
Low" (*1) indicated by failure code
Engine can be started cylinder cutout mode q
Specific gravity of electrolyte and voltage of battery are low q
Coolant temperature gauge does not indicate normally q
During pre-heating operation, intake air heater mount is cold q
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Clean
Clean
Clean
Remedy
gas Black w Q w w
When engine is cranked, unusual noise is generated around cylinder head w
When engine is cranked, interference sound is generated around turbocharger w
High idle speed is normal, but speed suddenly drops when load is applied Q w
Engine hunts Q Q Q
Blowby gas is excessive w
Inspect air cleaner directly q
When compression pressure is measured, it is found to be low q q
Troubleshooting
Replace
Replace
Replace
Replace
Correct
Adjust
Clean
Clean
Clean
Remedy
Metal particles are found when oil is drained from oil pan w w w Q
Does not turn at all w w
When engine is Turns in opposite direction only w
rotated by hand Moves by amount of gear backlash w w
Supply pump shaft does not turn w
Engine operates, but stops when load is applied to machine w
Inspect valve system directly q
Perform troubleshooting in H-mode
Replace
Replace
Replace
Replace
Correct
Clean
Clean
Add
Remedy
machine
Occurs at a certain speed range Q Q
Occurs at low idle Q Q Q Q Q
Condition of hunting
Occurs even when speed is raised Q Q Q
Occurs on slopes w
Filters are not replaced as indicated in the Operation and Maintenance Manual w
When fuel tank is inspected, it is found to be empty w
Air breather hole in fuel tank cap is clogged w
Troubleshooting Check items
When air bleeding operation for fuel system is performed, air comes out q
Inspect fuel filter or strainer directly q
When a certain cylinder is cut out, engine speed does not change q
Perform troubleshooting for "Eng Ne speed sensor error" according to failure code (*1) q
Perform troubleshooting for "Eng Backup speed sensor error" according to failure code
q
(*2)
Replace
Replace
Replace
Replace
Replace
Clean
Add
Remedy
(air leakage)
Check recent repair history
Degree of use of
Operated for long period E E E E
machine
Questions
Suddenly Q w Q Q Q Q
Power was lost
Gradually Q Q Q Q Q Q
Fuel other than specified one is used Q Q Q
Filters are not replaced as indicated in the Operation and Maintenance Manual w w
Engine oil must be added more frequently Q Q
Dust indicator indicates a red zone w w
Air breather hole in fuel tank cap is clogged w w
Fuel is leaking from fuel piping w
Output power becomes insufficient after short stop of operation w
Color of exhaust Black w w
gas Blue under light load w
When exhaust manifold is touched immediately after starting engine, tempera-
w w
ture of some cylinders is low
Check items
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Correct
Adjust
Clean
Clean
Remedy
wiring harness
cylinder head
q Controller is controlling in derate mode.
(limiting injection rate (power) because of an error in electrical system)
Color of exhaust
Gradually becomes black w Q Q
gas
Blue under light load w
Fuel other than specified one is used Q Q
Oil must be added more frequently w
Suddenly w Q Q Q
Power was lost
Gradually Q Q Q Q
Dust indicator indicates a red zone w
Muffler is crushed w
Air leaks between turbocharger and cylinder head, clamp worked
w
loose
Engine is operated in low-temperature mode at normal temperature Q Q Q
When exhaust manifold is touched immediately after starting engine,
Q w
temperature of some cylinder is low
When engine is cranked, interference sound is generated around tur-
w
Check items
bocharger
When engine is cranked, unusual noise is generated around cylinder
w
head
Pump relief speed is high (Fuel is injected excessively) Q
Exhaust sound is abnormal Q w Q
Engine does not pick up smoothly and combustion is irregular Q Q Q Q Q w
Blowby gas is excessive w
If spill hose from injector is disconnected, abnormally much fuel spills w
Inspect air cleaner directly q
When turbocharger is rotated by hand, it is found to be heavy q
When compression pressure is measured, it is found to be low q q
Troubleshooting
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Adjust
Adjust
Clean
Rem-
edy
Turbocharger
Oil in coolant w
Oil level in damper chamber of installed machine is high w
Exhaust gas is blue under light load w w
Amount of blowby Excessive Q Q w w
gas None w
When intake manifold is removed, dust is found inside q
When intake manifold is removed, inside is found to be dirty abnor-
q
Troubleshooting
mally
Excessive play of turbocharger shaft q q
Check breather or breather hose directly q
When compression pressure is measured, it is found to be low q q
Inspect rear oil seal directly q
Pressure-tightness test of oil cooler shows oil leakage q q
External leakage of oil from engine q q q q
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Correct
Correct
Correct
Correct
Correct
Clean
Remedy
See S-7.
Check breather or breather hose directly q
Inspect oil cooler directly q
Inspect oil filter directly q
Spring of oil filter safety valve is stuck or broken q
Inspect turbocharger lubrication oil drain tube directly q
Replace
Replace
Replace
Replace
Replace
Clean
Clean
Clean
Remedy
Perform troubleshooting for "Supply pump pressure low error according to failure
q
code (*1)
When a certain cylinder is cut out, engine speed does not change q
If spill hose from injector is disconnected, much fuel spills q
Perform troubleshooting for error "Coolant Temp Sens High" or "Coolant Temp Sens
q
Low" according to failure code (*2)
Check by using monitoring function q q
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Correct
Remedy
S-11 Oil is in coolant (or coolant spurts or coolant level goes down) 40-534
Remedy
Replace
Correct
Adjust
Clean
Clean
Clean
Clean
Add
Remedy
Degree of use of
Operated for long period E EE E
machine
Fuel must be added more frequently w w
Coolant must be added more frequently Q Q
Oil in coolant QQ QQ w
Oil smells of diesel fuel w w
Oil is milky Q Q
When engine is started, drops of water come from muffler Q
When radiator cap is removed and engine is run at low idle, an abnormal number of bub-
w Q
Check items
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Remedy
Malfunction of thermostat
Holes caused by pitting
Replace
Replace
Replace
Replace
Correct
Correct
Correct
Add
Remedy
machine
Condition of Gradually occurred Q Q
unusual noise Suddenly occurred Q Q Q
Fuel other than specified one is used Q
Oil must be added more frequently w
Metal particles are found when oil filter is drained w w
Air leaks between turbocharger and cylinder head w
When engine is cranked, interference sound is heard from turbocharger w
When engine is cranked, unusual noise is generated around cylinder
w w
head
When engine is cranked, beat noise is generated around muffler w
Check items
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Adjust
Remedy
q Abnormal combustion
a If unusual noise is made and vibration is excessive, perform troubleshooting for S-15
Unusual noise is heard, too.
Replace
Adjust
Remedy
k When testing or adjusting hybrid devices, ensure that you fully understand the following.
1. Disassemble of hybrid devices (motor-generator, capacitor, inverter, electric swing motor etc.) and
high-voltage wiring must be performed by whom finished special education for low-voltage electric
handling.
2. Never disassemble the hybrid devices, even if you are the qualified person for the work. This is from quality
assurance reason.
3. The hybrid devices and high-voltage wirings (wound with orange conduits) must be replaced by the unit.
4. When handling hybrid devices, be sure to discharge the capacitor completely first.
(For details, see Testing and adjusting, Special functions of machine monitor, "Discharge of capacitor".)
a Discharge of capacitor by using machine monitor is only performed when hybrid system is normal.
a When the failure code of "GA ****" appears and hybrid system is abnormal, discharge can not be done
although discharge display appears on the machine monitor. (The condition to consume the electric
charge of capacitor is not established.) Accordingly, use the generator dedicated to discharge capacitor :
796-426-1800. (For details, see Failure code [GA****] hybrid related precautions, common troubleshooting
procedure for high voltage system.)
k Since the items with the above mark are related to handling of the hybrid devices, ensure that you
understand the descriptions of 00-200 Introduction, safety, and basic information, "Handling of hy-
brid devices and high-voltage wiring", before beginning the work on them.
a For the monitoring items applied to troubleshooting for the hybrid devices, see the list in "Separate sheet
1" of failure code [GA****].
a For the check sheet to record the inspection result when any hybrid device is abnormal, see "Separate
sheet 2" of failure code [GA****].
k Before starting troubleshooting, discharge the capacitor by using capacitor discharge tool (gen-
erator): 796-426-1800 (see previous page).
k After discharging the capacitor, confirm that both capacitor charge LEDs (1) are OFF.
k A voltage not exceeding 30 V will still remain in the capacitor after the discharging process is com-
pleted. Do not work with bare hands. Always wear insulating gloves.
a After disconnecting connector HB01 (at capacitor), cover the connector (both of wiring harness and ca-
pacitor sides) with a plastic bag to prevent entry of foreign matter.
a Perform troubleshooting while the engine is stopped.
a Do not connect the multimeter probe directly to the capacitor side connector (female side of HB01).
3 Defective hybrid system If error of user code E09 is displayed, troubleshoot it first.
Defective assembly of swing Operation section and contact section of swing emergency stop
4
emergency stop switch switch may be coupled defectively. Check them directly.
Swing emergency stop switch may have internal defect. Check it
directly.
Probable Defective swing emergency 1. Turn starting switch OFF.
5
causes and cri- stop switch a Turn swing emergency stop switch OFF.
teria Resis-
Between terminals HS01 (11) and HS01(12) Max. 1 z
tance
1. Turn starting switch OFF.
2. Disconnect No.17 in fuse box F01.
3. Disconnect connector HC01 and HC02, then connect T-adapter
Open circuit in wiring har- to female side.
ness Between HS01 (female) (11) and HC01 Resis-
6 Max. 1 z
(wire breakage or defective (female) (5), (11) tance
contact of connector) Resis-
Between HS01 (female) (11) and F01 - 17 Max. 1 z
tance
Resis-
Between HS01 (12) and HC02 (female) (3) Max. 1 z
tance
If no failure is found by check on causes 1 to 6, hybrid controller
Defective inverter (hybrid
7 may be defective. (Since this is an internal defect, troubleshooting
controller)
cannot be performed.)
Failure (1) Upper structure swings neither to the right nor left
Related infor-
q Perform all troubleshooting with working mode in power mode (P).
mation
Failure (2) Upper structure does not swing in only one direction.
Related infor-
q Perform all troubleshooting with working mode in power mode (P).
mation
Failure (1) Swing acceleration performance is poor or swing speed is slow in both right and left directions.
q Capacitor voltage can be checked by using monitoring function.
Related infor- (Code: 09300 capacitor voltage)
mation q Method of reproducing failure code: Turn starting switch to ON or start the engine. Perform all trou-
bleshooting with the working mode set to the Power Mode (P).
Failure (2) Swing acceleration performance is poor or swing speed is slow in only one direction.
Related infor-
q Perform all troubleshooting with working mode in power mode (P).
mation
Failure (1) Upper structure overruns excessively when stop swinging in both right and left directions.
Related infor-
q Perform all troubleshooting with working mode in power mode (P).
mation
Failure (2) Upper structure overruns excessively when stop swinging in only one direction.
Related infor-
q Perform all troubleshooting with working mode in power mode (P).
mation
Y-5 Large shock is made when upper structure stops swinging 40-548
Y-6 Large unusual noise is made when upper structure stops swinging 40-548
Failure q Large unusual noise is made when upper structure stops swinging in both directions.
Related infor-
q Perform all troubleshooting with working mode in power mode (P).
mation
Failure (1) Swing drift on a slope is large (when swing holding brake is being applied)
q If swing lock switch is ON or swing brake cancel switch is in normal position, swing holding brake
Related infor-
operates and upper structure is fixed by disc brake.
mation
q Perform all troubleshooting with working mode in power mode (P).
Failure (2) Swing drift on a slope is large (when swing brake is being released).
q If swing lock switch is ON or swing brake cancel switch is in normal position, swing holding brake
Related infor-
operates and upper structure is fixed by disc brake.
mation
q Perform all troubleshooting with working mode in power mode (P).
Failure q Electric swing motor overheats and failure code [GA70NS] is displayed.
q Electric swing motor coil temperature can be checked with monitoring function.
Related infor-
(Code: 09101 electric swing motor coil temperature)
mation
q Method of reproducing failure code: Turn starting switch to ON position or start the engine.
Failure q Inverter overheats and failure code(s) [GA1ZNS] and/or [GA1YNS] displayed.
q Inverter booster IGBT temperature and booster inductor temperature can be checked with monitor-
Related infor- ing function.
mation (Code: 09401 booster IGBT temperature, code: 09042 booster inductor temperature)
q Method of reproducing failure code: Turn starting switch to ON position or start the engine.
HB205-1, HB205LC-1
HYDRAULIC EXCAVATOR
Shop Manual 5-01
HB205-1
HB215LC-1
Contents 50-2
50 Disassembly and assembly
General information on disassembly and assembly ............................................................... 50- 4
How to read Disassembly and Assembly............................................................................. 50- 4
Precautions related to hybrid machine................................................................................. 50- 6
Coating materials list............................................................................................................ 50- 7
Special tools list ................................................................................................................... 50- 10
Sketches of special tools ..................................................................................................... 50- 15
Engine and cooling system ..................................................................................................... 50- 20
Removal and installation of fuel supply pump assembly ..................................................... 50- 20
Removal and installation of fuel injector assembly .............................................................. 50- 25
Removal and installation of cylinder head assembly ........................................................... 50- 32
Removal and installation of radiator assembly .................................................................... 50- 55
Removal and installation of hydraulic oil cooler assembly................................................... 50- 57
Removal and installation of aftercooler assembly................................................................ 50- 59
Removal and installation of engine front seal ...................................................................... 50- 62
Removal and installation of engine rear seal ....................................................................... 50- 64
Removal and installation of fuel cooler assembly ................................................................ 50- 68
Removal (and installation) of engine, motor generator, and main pump assembly ............. 50- 70
Removal and installation of fuel tank assembly ................................................................... 50- 86
Hybrid...................................................................................................................................... 50- 89
Draining adding coolant and bleeding air for hybrid system ................................................ 50- 89
Removal and installation of hybrid radiator assembly.......................................................... 50- 93
Removal and installation of water pump assembly for hybrid system ................................. 50- 96
Removal and installation of inverter assembly..................................................................... 50- 99
Removal and installation of inverter and capacitor assembly .............................................. 50- 103
Draining and adding generator lubricating oil ...................................................................... 50- 108
Removal and installation of tandem pump assembly........................................................... 50- 110
Removal and installation of motor-generator housing assembly ......................................... 50- 113
Removal and installation of swing electric motor assembly................................................. 50- 122
Power train.............................................................................................................................. 50- 129
Removal and installation of final drive assembly ................................................................. 50- 129
Disassembly and assembly of final drive ............................................................................. 50- 131
Removal and installation of sprocket ................................................................................... 50- 140
Removal and installation of swing motor and swing machinery assembly .......................... 50- 141
Disassembly and assembly of swing machinery assembly ................................................. 50- 145
Removal and installation of swing circle assembly .............................................................. 50- 160
Undercarriage and frame ........................................................................................................ 50- 161
Separation and connection of track shoe assembly ............................................................ 50- 161
Disassembly and assembly of idler...................................................................................... 50- 164
Disassembly and assembly of idler cushion assembly ........................................................ 50- 167
Disassembly and assembly of track roller............................................................................ 50- 169
Disassembly and assembly of carrier roller ......................................................................... 50- 171
Removal and installation of revolving frame assembly ........................................................ 50- 175
Removal and installation of counterweight assembly .......................................................... 50- 177
Hydraulic system..................................................................................................................... 50- 179
Removal and installation of center swivel joint assembly .................................................... 50- 179
Disassembly and assembly of center swivel joint assembly................................................ 50- 181
Removal and installation of hydraulic tank assembly .......................................................... 50- 183
Removal and installation of main pump assembly............................................................... 50- 188
Removal and installation of main pump input shaft oil seal ................................................. 50- 193
Removal and installation of control valve assembly ............................................................ 50- 194
Removal 50-4
q In Removal section, the work procedures, pre-
cautions and know-how to do the work, and the
amount of oil and coolant to be drained are de-
scribed.
q Common tools that are necessary for removal
are described as [1], [2] etc. and their part
numbers, part names and quantities are not de-
scribed.
q Various symbols used in Removal section are
explained and listed below.
k : Precautions related to work safety are
described.
a : Know-how or precautions for work are de-
scribed.
Disassembly 50-5
q In Disassembly section, the work procedures,
precautions and know-how to do the work, and
the amount of oil and coolant to be drained are
described.
q Common tools that are necessary for disassem-
bly are described as [1], [2] etc. and their part
numbers, part names and quantities are not de-
scribed.
q The meanings of the symbols used in "Disas-
sembly" section are as follows.
k : Precautions related to work safety are
described.
a : Know-how or precautions for work are de-
scribed.
6 : Amount of oil or coolant drained.
Polyethyl-
LT-4 790-129-9040 250 g ene con- q Use to seal plugs for blank holes.
tainer
Holtz
790-129-9120 75 g Tube q Heat-resistant seal used to repair engines
MH 705
q Instanetaneous adhesive
Polyethyl-
ThreeBond q Curing time: From 5 sec. to 3 min.
790-129-9140 50 g ene con-
1735 q Use mainly to bond metals, rubbers, plastics, and
tainer
woods.
q Instanetaneous adhesive
Polyethyl-
q Quick-curing type (max. strength is obtained after
Aron-alpha 201 790-129-9130 2g ene con-
30 minutes)
tainer
q Use mainly to bond rubbers, plastics, and metals.
Polyethyl-
q Features: Resistance to heat and chemicals
Loctite 648-50 79A-129-9110 50 cc ene con-
q Use for fitted portions used at high temperatures.
tainer
q Use to seal various threaded portions, pipejoints,
Polyethyl-
and flanges.
LG-5 790-129-9080 1 kg ene con-
q Use to seal taper plugs, elbows, and nipples for
tainer
hydraulic piping.
q Features: Silicon-based heat and cold-resistant
sealant.
LG-6 790-129-9160 200 g Tube
q Use to seal threaded portions on flange surface
q Use to seal oil pan, final drive case, etc.
Liquid gasket
Cate-
Komatsu code Part No. Capacity Container Main features and applications
gory
LG-10 q Use as lubricant/sealant when installing the radia-
ThreeBond 790-129-9320 200 g Tube tor hoses to the water tubes.
Liquid gasket
LC-G
Can q Use for the mounting bolt in the high temperature
NEVER-SEEZ
area of the exhaust manifold and the turbocharg-
er, etc.
SYG2-400LI
SYG2-350LI
SYG2-400LI-A
G2-LI
SYG2-160LI
G0-LI (*) q Feature: Lithium grease with extreme pressure lu-
SYGA-160CNLI Various Various
*: For cold dis- brication performance, general purpose type.
SYG0-400LI-A
trict
(*)
SYG0-16CNLI
(*)
q Use for parts under heavy load.
Bel- Caution:
Molybdenum
SYG2-400M 400 g x 10 lows-type q Do not use this grease for rolling bearings like
disulphide
SYG2-400M-A 400 g x 20 container swing circle bearings, etc. and spline.
grease
SYGA-16CNM 16 kg q Use this grease for work equipment pins only
LM-G (G2-M)
Can when installing them, but do not use it after-
ward.
Grease
SYG2-400T-A
Hyper White
SYG2-16CNT Bel- q Seizure resistance, heat resistance and water re-
G2-T
SYG0-400T-A 400 g lows-type sistance higher than molybdenum disulphide
G0-T (*)
(*) 16 kg container grease.
*: For cold dis-
SYG0-16CNT Can q Not conspicuous on machine since color is white.
trict
(*)
Biogrease
SYG2-400B
G2-B
SYGA-16CNB Bel-
G2-BT (*) q Since this grease is biodegradable in short period,
SYG2-400BT 400 g lows-type
*: For use at it has less impact on microorganisms, animals,
(*) 16 kg container
high tempera- and plants.
SYGA-16CNBT Can
ture and under
(*)
high load
q Feature: Silicone grease with wide usable temper-
G2-S ature range, high resistance to thermal-oxidative
ThreeBond 200 g Tube degradation and performance to prevent deterio-
1855 ration of rubber and plastic parts.
q Use for oil seals of the transmission, etc.
Cate-
Komatsu code Part No. Capacity Container Main features and applications
gory
q Feature: Urea (organic system) grease with heat
resistance and long life, can be packed into the
Grease
G2-U-S
427-12-11871 2 kg Can confined space and left intact until next overhaul.
ENS grease
q Use for rubber, bearing and oil seal in damper.
Caution: Do not mix with lithium grease.
SUNSTAR q Use as primer for painted cab sheet metal
PAINT Glass con- surface.
20 ml
PRIMER580 tainer (Effective period: four months after date of
SUPER manufacture)
417-926-3910
SUNSTAR
q Use as primer for glass.
GLASS Glass con-
20 ml (Effective period: four months after date of
W" manufacture)
Polyethyl- q Use as adhesive for glass.
Sika Japan,
For adhered window glass
20Y-54-39850 310 ml ene con- (Effective period: six months after date of
Sikaflex 256HV
tainer manufacture)
SUNSTAR Ecocart q Use as adhesive for glass.
PENGUINE 22M-54-27210 320 ml (Special (Effective period: six months after date of
SUPER 560 container) manufacture)
SUNSTAR Polyethyl- q Use to seal glass-to-glass joints.
PENGUINE 417-926-3920 320 ml ene con- (Effective period: four months after date of
Caulking material
a Part Nos. of special tools starting with 79*T-***-**** mean that they are not available from Komatsu Ltd.
(i.e. tools to be made locally).
a Necessity:
t:Special tools that cannot be substituted and should always be used.
q:Special tools that will be useful if available and are substitutable with tools available on the market.
a New/redesign:
N: Tools newly developed for this model, newly assigned with unique part numbers.
R: Tools made available by redesigning the existing tools which were developed for other models. Each
of them has a new part number assigned by setting forward the part number of the existing tool.
BlankTools already available for other models, can be used without any modification
a Tools marked with Q in the sketch column are presented in the sketches of the special tools. (See "Sketch-
es of special tools")
New/redesign
Necessity
Sketch
Q'ty
Work Symbol Part number Part name Nature of work, remarks
New/redesign
Necessity
Sketch
Q'ty
Work Symbol Part number Part name Nature of work, remarks
New/redesign
Necessity
Sketch
Q'ty
Work Symbol Part number Part name Nature of work, remarks
New/redesign
Necessity
Sketch
Q'ty
Work Symbol Part number Part name Nature of work, remarks
New/redesign
Necessity
Sketch
Q'ty
Work Symbol Part number Part name Nature of work, remarks
Note: Komatsu does not take any responsibility for special tools manufactured according to these sketches.
A8 Plate 50-15
Note: Komatsu does not take any responsibility for special tools manufactured according to these sketches.
B1-2 Plate 50-16
Note: Komatsu does not take any responsibility for special tools manufactured according to these sketches.
F1 Plate 50-17
Note: Komatsu does not take any responsibility for special tools manufactured according to these sketches.
J2 Push tool 50-18
Note: Komatsu does not take any responsibility for special tools manufactured according to these sketches.
S Push tool 50-19
New/redesign
Necessity
Sketch
Q'ty
Symbol Part number Part name
A 13 795-799-6130 Support t 1
Removal 50-20
k Park the machine on a level place, lower the
work equipment to the ground completely,
and stop the engine.
k Disconnect the cable from the negative (-)
terminal of the battery.
1. Close fuel stop valve (1). 4. Remove counterweight maintenance cover (5).
2. If the fuel level is above the hose adapter (supply 5. Disconnect the wiring and hoses from the fuel
pump portion) going to the fuel cooler, open right supply pump as follows. [*1]
inspection cover (2) and open fuel drain valve (3) a Remove mud from the joints in advance.
to drain the fuel until the fuel level lowers below (since locks (L) may become hard because of
the hose adapter going to the fuel cooler. mud)
a While pressing lock (L) from both sides, pull
out each hose.
a When disconnecting the hoses, fuel will flow
out. Plug the fittings, to prevent fuel from
flowing out.
a Do not use a wooden plug because wooden
chips may enter the fuel line.
a Record the disconnected and clamped por-
tions of each hose.
a Cover the ends of the disconnected hoses
and high pressure pipes with cloths.
1) Disconnect connector PUMP (6). 7. Remove high-pressure pipe clamps (13) and
2) Disconnect quick couplers (8) and (9) of the (14). [*7]
fuel return tubes. [*2]
3) Disconnect quick coupler (9) of the hose
coming from the fuel filter. [*3]
(Parts A: Indicate the pump mounting positions.) 3) Install puller [3] on puller [2] and the shaft.
4) Turn center bolt [4] until the gear comes off
the shaft.
5) Remove pullers [2] and [3].
[*5]
3 Joint bolt:
19.6 29.4 Nm {2.0 3.0 kgm}
[*6]
a Install the boots with the slits out and down.
a The boots are installed so that fuel does not
spout over the hot parts of the engine and catch
fire when it leaks for some reason.
3 High-pressure pipe mounting bolt:
24 4 Nm {2.45 0.4 kgm}
[*13]
q Install gear (20) according to the following proce-
dure.
q Bleeding air
Bleed air from the fuel system. For details, see
Testing and adjusting, "Bleeding air from fuel
system".
New/redesign
Necessity
Sketch
Q'ty
Symbol Part number Part name
1 795-799-1131 Gear t 1
A 2 795-799-8150 Remover q 1
3 795-799-6700 Puller t 1
Removal 50-25
k Park the machine on a level place, lower the
work equipment to the ground completely,
and stop the engine.
k Disconnect the cable from the negative (-)
terminal of the battery. 4. Remove the fuel injection pipe according to the
following procedure. [*1]
1. Close fuel stop valve (1). 1) Disconnect wiring connector (5).
(This is not necessary when removing only
the No. 4 cylinder injector assembly.)
a Since you cannot hold each connector,
disconnect it by using 2 flat-head screw-
drivers according to the following proce-
dure.
1] Keep pressing lock (a) of the connector
with flat-head screwdriver [1].
2] Insert flat-head screwdriver [2] in the
clearance between the connectors on the
right and left sides of lock (a) and move it
to the right and left to pry out the
connector gradually.
2) Remove boot (6) from the common rail and 6. Remove mounting bolts (13) and blow-by duct
cylinder head. (14). [*3]
9. Disconnect wiring (28). 13. Remove mounting bolts (34) of the fuel injector
assembly.
10. Loosen locknut (29) and loosen adjustment
screw (30) thoroughly.
Installation 50-28 4) When installing, direct the fuel inlet hole (inlet
1. Fuel injector assembly connector mounting hole) toward the air
a When replacing the fuel injector assembly intake manifold.
with a new one, be sure to replace the inlet 5) Install fuel injector assembly (35) to the fuel
connector as well. injector sleeve and tighten mounting bolts
a Check that fuel injector sleeve (36) is free (34) at least three - four turns.
from flaw and dirt.
7) While setting part (B) of inlet connector (27) 8) Install the inlet connector and tighten
to the groove (upper side) on the head, insert retaining nut (26) temporarily.
the inlet connector completely. 3 Retaining nut:
2 O-ring (41) and inlet connector 15 5 Nm {1.5 0.5 kgm}
mounting bore: Engine oil (For de-
tails, see "List of lubricant and wa-
ter".)
2. Rocker arm assembly 2) Install rocker arm assembly (32) and tighten
1) Install crosshead (33). mounting bolts (31).
a Install each crosshead in the position and a Ensure that adjustment screws (30) are
direction (the shape of parts (a)) and (b)) thoroughly loosened.
recorded when removed. a Check that the ball of adjustment screw
(30) is fitted in the push rod socket se-
curely, and then tighten mounting bolt
(31).
3 Rocker arm mounting bolt (31):
36 5 Nm {3.7 0.51 kgm}
3) Adjust the valve clearance. For details, see
Testing and adjusting, Adjusting valve clear-
ance.
a Use tool A1 to rotate the engine.
4) After adjusting the valve clearance, ensure
that locknut (12) is tighten to the specified
torque.
3 Locknut (29):
24 4 Nm {2.4 0.4 kgm}
5) Install wirings (28) and wiring nuts.
a Check that the wirings do not interfere
with the rocker arm.
a Mounted position of wirings
Cable color Cylinder No.
White 1, 3
Black 2, 4
[*1] [*2]
a Precautions for installing fuel injection pipe a If injector harness connector (IHC) is removed,
k Do not reuse the fuel injection pipe by apply liquid gasket LG-7 to O-ring (o) and flange
bending it. ((p) of the connector.
k Be sure to use genuine fuel injection pipe Apply a bead of LG-7 f3 mm in diameter to the
clamps and tighten them to the specified O-ring so that the ring groove is completely
torque. sealed.
k After installing the fuel injection pipe, be If the O-ring is damaged, replace it and the
sure to install the boot to the sleeve nut. harness assembly as a unit.
k When installing the boot, direct it out 3 Connector flange mounting bolt (45):
down. 10 2 Nm {1 0.2 kgm}
a Before installing the fuel injection pipe, check the
following.
q If the fuel injection pipe has a fault, it may
leak the fuel. Accordingly, replace it with a
new one.
q Taper seal section (j): Check that there is no
visible streaky slits (k) and spotty dimples (l)
in the 2 mm distance area from the end.
q Portion (m): Check that there is no steps (de-
formation) that your nail can feel in the 2 mm
distance area from the end of the taper seal
section.
3 Sleeve nut:
35 3.5 Nm {3.57 0.36 kgm}
[*3]
a When installing the blowby duct, check that the
O-ring is fitted.
3 Blowby duct mounting bolt:
7 2 Nm {0.71 0.2 kgm}
[*4]
3 Cylinder head cover mounting nut:
24 4 Nm {2.4 0.4 kgm}
q Bleeding air
Bleed air from the fuel system. For details, see
Testing and adjusting, "Bleeding air from fuel
system".
New/redesign
Necessity
Symbol Part number Part name
Q'ty
1 795-799-1131 Gear t 1
2 795-799-8150 Remover q 1
3 795-799-6700 Puller t 1
A
Wrench
6 790-331-1120 q 1
(Angle)
7 795-790-4510 Gauge q 1
Removal 50-32
k Park the machine on a level place, lower the
work equipment to the ground completely, 4. Open engine hood (4).
and stop the engine.
k Disconnect the cable from the negative (-)
terminal of the battery.
5) Similarly, remove fuel injection pipes (30), 9) Remove fuel high-pressure pipe mounting
(31), and (32) in the order of the No. 3, No. 2, sleeve nuts (39) from the supply pump and
and No. 1 cylinders. common rail and remove high-pressure pipe
(40).
17)Loosen sleeve nut (60) and disconnect inlet 12. Remove eight exhaust manifold mounting bolts
hose (61) of the turbocharger lubricating oil. (69a) and remove exhaust manifold assembly
[*10] (69). [*13]
a Fix connector (62) on the turbocharger
side by using a wrench to prevent it from
being dragged.
18)Remove turbocharger mounting nut (63) and
place the turbocharger on stud bolt (64).
[*11]
19)Remove two hexagon socket head bolts (65)
and disconnect outlet tube (66) of the turbo-
charger lubricating oil. [*12]
20)Remove turbocharger (67).
16. Remove fan guards (76) and (77). 4) Remove the alternator mounting bolts and
disconnect alternator assembly (83).
18. Remove the alternator assembly according to 20. Remove two bolts (85) and blow-by duct (86).
the following procedure. [*15] [*16]
1) Disconnect wiring (79) and (80).
2) Insert wrench [1] in hole (A) (width across 21. Remove joint bolt (87a) and disconnect fuel
flats: T12.7 mm) of tensioner assembly (81) return tube (87). [*17]
and rotate it counterclockwise (R), seeing
from the front of the engine, to loosen fan belt 22. Remove clamp (87b) of the fuel return tube.
(82).
3) Remove fan belt (82) from alternator 23. Remove cylinder head cover (88). [*18]
assembly (83).
k Set wrench [1] securely to hole (A) of
the tensioner assembly before rotating
the tensioner assembly. (The spring of
the tensioner assembly is strong. If
wrench [1] is set incompletely and ro-
tated, it comes off and that is very dan-
gerous.))
k Rotate the tensioner assembly. While
rotating, take care that wrench [1] will
not come off.
k After removing fan belt (82), loosen
wrench [1] slowly and carefully.
k Take care not to catch your finger be-
24. Remove the fuel injector and rocker arm housing
tween the pulley and fan belt during according to the following procedure.
the work. 1) Disconnect wiring (89) from the fuel injector.
1) Install O-ring (107) and gasket (108) to fuel 6) Apply engine oil to O-ring (91a) of inlet
injector (106). connector (91) and the inlet connector
a Replace the O-ring and gasket with new mounting hole (on the cylinder head side).
ones. a Check the inlet connector visually. If it
2) Apply engine oil to O-ring (107) of fuel has any of the following faults, replace it
injector (106) and the fuel injector mounting and fuel injector assembly together.
bore. q There is a burr or a worn part at front end
2 O-ring (107) and fuel injector (a) or rear end (b) of the inlet connector.
sleeve: Engine oil (For details, see q Foreign material is collected in the edge
"List of lubricant and water".) filter at rear end (c) of the inlet connector.
3) Engage the male and female parts at (A) to q Cracks or deterioration is recognizable in
install holder (109) to fuel injector (106). O-ring of the inlet connector upper (d)
portion.
q Sealing surface (e) on the edge of the in-
let connector is worn or has uneven con-
tact pattern.
a If high-pressure fuel leaks through the in-
let connector, the sealing surface has fine
streaks or cracks.
7) Insert inlet connector (91) completely, while
matching its part (b) with the groove (upper)
on the head side.
2 O-ring (91a) and inlet connector
mounting bore: Engine oil (For de-
tails, see "List of lubricant and wa-
ter".)
4) When installing, direct the fuel inlet hole (inlet
connector mounting hole) toward the air
intake manifold.
5) Install fuel injector assembly (99) to fuel
injector sleeve. Finger tighten mounting bolts
(98) at least three or four turns.
6) Install the wirings and tighten them with the 9. Connect turbocharger cooling tube (84).
nuts.
a Check that the wirings do not interfere
with the rocker arm.
a Installed positions of wires
Cable color Cylinder No.
White 1, 3
Black 2, 4
3 Wiring mounting nut (89):
1.5 0.25 Nm {0.15 0.03 kgm}
3] Install the clamp to the clamp mark 16)Install covers (46) and (51).
made on the hose.
3 Clamp bolt:
Min. 6 Nm {0.6 kgm}
q When using a new hose
4] Tighten until dimension BDG
becomes as follows.
Part (z):7 10 mm
19. Install the fuel injection pipe and fuel high-pres- a The common rail assembly is finally tight-
sure pipe according to the following procedure. ened after step 6).
[*4], [*5], [*7]
a Do not reuse the fuel injection pipe or fuel
high-pressure pipe by bending it.
k Be sure to use genuine fuel injection
pipe clamps and tighten them to the
specified torque.
k Be sure to use genuine fuel injection
pipe clamps and tighten them to the
specified torque.
k After installing the fuel injection pipe
or fuel high-pressure pipe, be sure to
install the boot to the sleeve nut.
k When installing the boot, direct it out
down.
a Before installing the fuel injection pipe or fuel 2) Install the fuel injection pipe between the
high-pressure pipe, check the following. common rail and cylinder head and tighten it
q If the fuel injection pipe has a fault, it may
with sleeve nut (39) temporarily.
3 Sleeve nut:
leak the fuel. Accordingly, replace it with
a new one. 0.2 0.8 Nm {0.02 0.08 kgm}
q Taper seal section (j) at the connecting
3) Install the fuel injection pipe and tighten
end: Check that there is no visible streaky sleeve nut (39) to the specified torque
slits (k) or spotty dimples (l) in the 2 mm according to the following procedure.
3 Sleeve nut:
distance area from the end.
q (Check that portion (m) (the end of the ta-
35 3.5 Nm {3.57 0.36 kgm}
per seal section: 2 mm from the end) is 1] #1 cylinder head side
not stepped (deformed) that your nail can 2] #4 cylinder head side
feel. 3] #4 common rail side
4] #1 common rail side
5] #2 cylinder head side
6] #3 cylinder head side
7] #2 common rail side
8] #3 common rail side
4) Install fuel high-pressure pipe (40) between 8) Install the boots to all the fuel high-pressure
the fuel supply pump and common rail and pipes.
tighten it with sleeve nut (39) temporarily. k Install the boots with the slits out and
3 Sleeve nut: down.
0.2 0.8 Nm {0.02 0.08 kgm} a The boots are installed so that fuel does
5) Tighten the sleeve nut on the fuel supply not spout over the hot parts of the engine
pump side first, and then tighten that on the and catch fire when it leaks for some rea-
common rail side to the specified torque. son.
3 Sleeve nut: 9) Install quick couplers (33), (34), and (35) of
35 3.5 Nm {3.57 0.36 kgm} the fuel return tube.
6) Install fuel high-pressure pipe clamps (37) a Handling of fuel pressure sensor and fuel re-
and (38). lief valve
3 Mounting bolt: 1) Procedure for installing fuel pressure sensor
24 4 Nm {2.4 0.4 kgm} (a)
If fuel pressure sensor (a) was removed from
common rail assembly (42), be sure to
replace it with a new one.
1] Check the fuel pressure sensor connector
for cracking/breakage, damage of seal,
foreign matter at pin, corro-
sion/bend/breakage of pin, etc.
2] Install a new fuel high-pressure sensor.
a Apply clean gear oil (#90) to the
threaded portion.
3 Fuel pressure sensor:
70 5 Nm {7.1 0.5 kgm}
5) Install wiring clamps (8) and (9). 24. Close engine hood (4).
6) Install wiring connector AC02 (7).
q Refilling of oil
Tighten the drain plug and supply diesel fuel
through the filler port.
5 Fuel tank:
400 l
q Bleeding air
a Bleed air from the fuel system. For details,
see Testing and adjusting, "Bleeding air from
fuel system".
[*1], [*2]
q Insert each hose to the position marked when re-
moved.
a Insertion depth: 45 mm (upper and lower)
3 Radiator hose mounting clamp:
10.8 11.8 Nm {1.1 1.2 kgm}
a Align the clamp to the original position.
[*3]
a Ensure that the heat insulation sealant (sponge)
around the radiator is not damaged.
11. Lift off radiator assembly (11). [*3] If the heat insulation sealant (sponge) is
4 Radiator assembly:
damaged, replace it.
15 kg a Check that convex part (A) at the radiator bottom
is matched with concave part (B) from the under-
cover side.
q Refilling of coolant
5 Radiator:
17.3 l
a Run the engine to circulate the coolant
through the system and then check the cool-
ant level again. If the coolant level is low, add
coolant.
Removal 50-57
k Park the machine on a level place and swing
the upper structure 90 deg., and then lower
the work equipment to the ground complete-
ly and stop the engine. 4. Open the engine hood.
k Loosen the hydraulic tank oil filler cap grad-
ually to release the pressure inside the tank 5. Remove the mounting bolts of cover (5).
and then set the lock lever to the LOCK posi-
tion.
k Disconnect the cable from the negative (-)
terminal of the battery.
[*1]
a Ensure that the heat insulation sealant (sponge)
around the hydraulic oil cooler is not damaged.
If the heat insulation seal (sponge) is damaged,
replace it.
a Check that convex part (A) at the oil cooler bot-
tom is matched with concave part (B) from the
undercover side.
Installation 50-61
q Perform installation in the reverse order to re-
moval.
[*1]
a Replace the O-ring with a new one.
[*2]
q If the U-clamp (11) was loosened or removed, in-
stall it and tighten to the following torque.
3 Mounting nut:
10.8 19.6 Nm {1.1 2.0 kgm}
[*4]
a Ensure that the heat insulation sealant (sponge)
around the aftercooler is not damaged.
If the heat insulation sealant (sponge) is
damaged, replace it.
a Check that convex part (A) at the aftercooler bot-
tom is matched with concave part (B) from the
undercover side.
[*3]
q Install hose (12) according to the following pro-
cedure.
a Use a new MIKALOR clamp.
1) Insert each hose to the position marked
when removed.
(Hose insertion length)
Aftercooler side: 60 mm
Removed tube side: 67 mm
2) MIKALOR clamp at 30 mm from the marked
position.
3) Place bridge (BR) under the clamp bolt and
set overlap (b) between bridge (BR) and
band to the following dimension.
Dimension (b): Min. 5 mm
2 Threaded portion of clamp bolt
(part BC):
Lubricating oil (THREEBOND, PAN-
DO 18B)
4) Tighten the clamp bolt to the following
torque.
(When reusing hose)
a Install the clamp to the clamp mark made
on the hose.
3 Clamp bolt:
Min. 6 Nm {0.6 kgm}
New/redesign
a Replace the engine front oil seal.
Necessity
Symbol Part number Part name a Before installing the engine front oil seal,
Sketch
check that crankshaft end corners and seal
Q'ty
lip sliding surfaces are free from a housing
4 795-799-6400 Seal puller t 1 flaw, burr, fin, rust, etc.
A
6 790-331-1120
Wrench
q 1 a When installing the engine front oil seal, do
(Angle) not apply oil or grease to the crankshaft and
seal lip. Thoroughly wipe off oil and grease
Removal 50-62 from the crankshaft.
1. Remove the engine, motor-generator, and main
pump assembly referring to the section of
"Removal (and installation) of engine,
motor-generator, and main pump assembly".
New/redesign
2) Sling flywheel (4) and remove the remaining
mounting bolts.
Necessity
Symbol Part number Part name 3) Pull out flywheel (4) toward you.
Sketch
4) Remove guide bolts [1] and lift off flywheel
Q'ty
(4).
4 Flywheel: 15 kg
A 5 795-799-6500 Seal puller t 1
Removal 50-64
1. Remove the engine, motor-generator, and main
pump assembly by referring to "Removal (and
installation) of engine, motor-generator, and
main pump assembly".
Removal 50-68 3. Remove two mounting bolts (6) of the fuel cooler
k Park the machine on a level place, lower the mounting bracket.
work equipment to the ground completely,
and stop the engine. 4. Remove fuel cooler assembly (7) and bracket (8)
k Disconnect the cable from the negative (-) together.
terminal of the battery.
Installation 50-69
q Perform installation in the reverse order to re-
moval.
[*1]
a When tightening each fuel hose, hold elbow on
the fuel cooler side using a wrench.
q Bleeding air
After adding fuel, bleed air from the fuel system.
For details, see Testing and adjusting, "Bleeding
air from fuel system".
8 796T-401-1110 Plate q 1
9 795-790-9300 Lifting tool q 1
10 796-460-1210 Oil stopper q 1
A
11 796-770-1320 Adapter q 1
12 Commercially Megaohm tester t 1
available
Removal 50-70
k Park the machine on a level place, lower the
work equipment to the ground completely,
and stop the engine.
k While draining the coolant, take care that the 3. Disconnect two one-touch wiring connectors
coolant does not stick to your skin or enter HB01 (CC) (cable terminals of (+) and (-)) from
your eye. the capacitor.
Super Coolant mixed in the coolant is toxic. a While pressing the lock portion of the con-
If the coolant splashes on your skin or enters nector with your thumb to unlock the connec-
your eye, wash it away immediately with tor, pull out the connectors.
plenty of water and then consult a doctor.
a Record the installed positions, connector Nos.,
or hose band colors of the disconnected wires
and pipes so that you do not make a mistake in
their connection positions.
10. Remove the covers and frames according to the 6) Remove frame (28).
following procedure. 7) Remove heat insulation plate (29).
1) Remove cover (20). a Remove rubber partition (29a) and heat
2) Remove partitions (21) and (22). insulation plate (29) together.
a To remove partition (21), remove cover
(20) and remove bolt (21a), and the re- 11. Disconnect prefilter (30) and bracket (31)
move two bolts (21b) from the control together from frame (32).
valve side.
a Remove bolt (23) to remove partition (22).
3) Remove two bolts (24) and partition (25).
a Remove bolt (24) from the control valve
side.
a Remove partition (25) by pulling it up.
4) Remove cover (26).
5) Remove frame (27).
13. Disconnect fuel filter (35) and bracket (36) 16. Disconnect the following seven hoses
together from frame (37). connected to the main pump.
a Place fuel filter (35) and bracket (36) together (40) Rear load pressure input port hose
on the engine. (Collar band color: None)
(41) EPC source pressure port hose
14. Disconnect lubricating oil filter (38) of the gener- (Collar band color: Yellow)
ator motor from bracket (36). (42) Front load pressure input port hose
a Bind lubricating oil filter (38) of the mo- (Collar band color: Red)
tor-generator to the engine/ motor-generator (43) Pump pressure input port hose
/ main pump assembly. (Collar band color: Blue)
(44) Drain port hose
(45) Pump discharge port hose (2 pieces)
(45a) Branch hoses (2 pieces)
31. Disconnect starting motor wiring (75) and wiring 37. Remove connector cover (84) of the
connector E10 (76) high-voltage wiring (power cable).
41. Disconnect wiring connectors CE02 (91) and 47. Disconnect wiring connector K02 (101).
CE03 (92) from the engine controller.
48. Disconnect engine controller ground strap T12
(102).
Installation 50-81
q Perform installation in the reverse order to re-
moval.
[*1]
q If mounting bolts (MB) of the air conditioner com-
pressor were loosened, tighten them to the fol-
lowing torque.
a Tightening to too high torque can damage
the internal bearings. Observe the specified
torque strictly.
3 Mounting bolt:
24.5 29.4 Nm {2.5 3.0 kgm}
[*2], [*5]
q If a hose is equipped with a MIKALOR clamp, in-
stall it according to the following procedure.
a Use a new MIKALOR clamp.
1) Set the hose to the original position (marked
when the hose was removed).
(Hose insertion depth)
q Air intake manifold side (58)
Tube side: (x) 80 mm
Manifold side (y): 80 mm
q Aftercooler side (72)
Aftercooler side: 60 mm
Tube side: (z) 67 mm
q Hose (72) between aftercooler and turbo-
charger
Tube side: 85 mm a If air intake connector (108) was removed, re-
Aftercooler side: 80 mm place the O-ring with a new one.
2) Place bridge (BR) under the clamp bolt and 3 Air intake connector mounting bolt :
set overlap (b) between bridge (BR) and 8.8 10.8 Nm {1.1 1.2 kgm}
band to the following dimension.
Dimension (b): Min. 5 mm
2 Threaded portion of clamp bolt
(BC):
Lubricating oil (THREEBOND PAN-
DO 18B)
a Do not use an impact wrench.
[*4]
3 Air hose clamp bolt:
10.0 11.0 Nm {1.02 1.12 kgm}
[*6]
a Insert each hose to the position marked when re-
moved.
(Reference) Hose insertion length: 45 mm
3 Hose clamp bolt:
10.8 11.8 Nm {1.1 1.2 kgm}
[*7]
q Install the connector of the high-voltage wiring
(power cable) according to the following proce-
dure.
a Before installing the connector of the
high-voltage wiring (power cable), measure
the insulation resistance of the generator mo-
tor according to the following procedure.
(Criteria)
a Insulation resistance between phase A
and case phase: Min. 5 Mz
a Insulation resistance between phase B
and case phase: Min. 5 Mz
a Insulation resistance between phase C
and case phase: Min. 5 Mz
q Refilling of coolant
Add engine coolant through the coolant filler to
the specified level. Run the engine to circulate
the coolant through the system. Then, check the
coolant level again and add coolant if it is low.
5 Coolant:
17.3 l
a For the precautions for mixing proportion of
water and Super Coolant, see "Removal (and
installation) of radiator assembly".
q Bleeding air
See Testing and adjusting, Bleeding air from
each part.
Removal 50-86
k Park the machine on a level place, lower the
work equipment to the ground completely,
and stop the engine.
k Disconnect the cable from the negative (-)
terminal of the battery.
8. Remove two upper mounting bolts (10) of cover 10. Remove lower cover (13).
(8) and remove cover (8).
Installation 50-8
q Perform installation in the reverse order to re-
moval.
[*1]
3 Fuel tank mounting bolt:
245 309 Nm {25.0 31.5 kgm}
q Bleeding air
After adding fuel, bleed air from the fuel system.
For details, see Testing and adjusting, "Bleeding
air from fuel system".
Hybrid 50-89
Draining adding coolant and bleeding air for hybrid system 50-89
Drain 50-89
k Park the machine on a level place, lower the
work equipment to the ground completely,
and stop the engine.
k When opening the coolant filler cap or drain-
a Removal (and installation) procedures in this
section can be carried out by personnel other ing the coolant, ensure that coolant tempera-
than those who have finished a special training ture is low and it does not scald you.
k While draining the coolant, take care that the
course for handling low voltage electrical appli-
ances. coolant does not stick to your skin or enter
k
your eye.
Never disconnect the high-voltage wiring Super Coolant mixed in the coolant is toxic.
(power cable) during the removal and instal- If the coolant splashes on your skin or enters
lation work in this section. your eye, wash it away immediately with
plenty of water and then consult a doctor.
3. Add coolant to the full level through filler port (6) 4. Tighten the radiator cap and turn the key switch
of the hybrid radiator slowly (taking approxi- to the ON position to run the water pump. And
mately 5 minutes). (approximately 3.8 l) turn the key switch to the OFF position after 2
a Add coolant through the coolant filler of the minutes to stop the water pump.
hybrid radiator, taking care not to spill it. k Never start the engine.
a The minimum necessary volumetric percent- a If too long time passes before the starting
age of Super Coolant is 30%. switch is turned to the ON position after the
a Decide the mixing proportion of the coolant to coolant is added, air may be trapped on the
the water according to the past minimum suction side of the water pump and the water
temperature and the following mixing propor- pump may have a suction trouble. According-
tion table. ly, turn the starting switch to the ON position
Actually, set the proportion for a temperature immediately after adding the coolant.
about 10 C lower than the past minimum a Judge if hybrid system water pump (WP) is
temperature. running by directly touching water pump
Mixing proportion of city water and Super Coolant (WP) with the hand. (Since the drive sound of
(Refill capacity of hybrid system radiator: 5.4 l) the pump is low, it is difficult to judge by the
Min. temperature ( C) drive sound.)
Abo
ve-1 -15 -20 -25 -30 (-35) (-40)
0
Quantity
Mixing proportion(l)
Replacement of all hybrid coolant 50-92 a Decide the mixing proportion of the cool-
a When changing the mixing proportion of Super ant to the water according to the past min-
Coolant or replacing all the coolant because of imum temperature and the following
entry of swing motor lubricating oil into it, replace mixing proportion table.
the coolant according to the following procedure. Actually, set the proportion for a tempera-
ture about 10 C lower than the past
1. See the preceding procedure of "drain" and drain minimum temperature.
from the draining part of capacitor. Mixing proportion of city water and Super Coolant
2. Install capacitor drain bolt and cover according (Refill capacity of hybrid system radiator: 5.4 l)
to "Refilling coolant and bleeding air", steps 1 Min. temperature ( C)
and 2.
Abo
3. Loosen clamp (10) of the tube (11) and hose (12)
ve-1 -15 -20 -25 -30 (-35) (-40)
returning from the swing motor and disconnect 0
tube (11).
Quantity
Mixing proportion(l)
a Before disconnecting tube (11), prepare a of Super 1.6 1.9 2.2 2.5 2.7 (2.9) (3.1)
container to receive the drained coolant un- Coolant
der the disconnecting point of the hose. Quantity
3.6 3.3 3.1 2.8 2.6 2.4 2.2
4. Install a thick vinyl bag, etc. to the tube (11) to be of water
disconnected to prevent the coolant from Volumet-
splashing around. ric ratio 30 36 41 46 50 (54) (58)
(%)
5. Close coolant filler cap (2) and supply 2) Open the radiator cap (2) and turn the key
compressed air (for an impact wrench, etc.) into switch to the ON position to run the water
the disconnected hose (12) to discharge all the pump. Turn the key switch to the OFF posi-
coolant forcibly. (For prevention of splashing of tion after 2 minutes to stop the water pump.
coolant) 3) Since the coolant level lowers after running
a Be sure to close the radiator cap before sup- the water pump, fill the tank with coolant.
plying compressed air. 4) Close the radiator cap (2) and turn the key
5 Quantity of drained coolant: switch to the ON position to run the water
6.8 l pump. Turn the key switch to the OFF posi-
6. Connect the disconnected hose and tighten the tion after 20 minutes to stop the water pump.
clamp temporarily. 5) Open the radiator cap (2) and fill the tank with
7. Add the specified quantity of coolant according coolant if the coolant level lowers.
to the procedure of "Refilling coolant and 6) Close the radiator cap (2) and complete the
bleeding air", steps 3 to 6, and wash the circuit. air bleeding work.
8. Repeat above steps 1 to 5. Then wash inside 7) Since air may remain in coolant circuit, check
and discharge. Repeat steps 7 to 8 if necessary, the coolant level of hybrid radiator again after
depending on the stain of the inside. performing work (after approximately 8
9. Insert the disconnected hose to the original posi- hours) and fill it with coolant if the coolant
tion of tube and fasten the clamp to the specified level lowers.
torque.
3 Tightening torque:
3.9 4.9 Nm {0.4 0.5 kgm}
10. Perform the following steps 1) to 7) (refilling
coolant and bleeding air after draining
completely), then add the specified quantity of
coolant and bleed air.
1) Add coolant through filler port (6) of the
hybrid radiator slowly taking approximately 5
minutes. (5.4 l)
a Add coolant through the coolant filler of
the hybrid radiator, taking care not to spill
it.
a The minimum necessary volumetric per-
centage of Super Coolant is 30%.
k When opening the coolant filler cap or drain- 3) Remove lower cover (3).
ing the coolant, ensure that coolant tempera-
ture is low and it does not scald you.
k While draining the coolant, take care that the
coolant does not stick to your skin or enter
your eye.
Super Coolant mixed in the coolant is toxic.
If the coolant splashes on your skin or enters
your eye, wash it away immediately with
plenty of water and then consult a doctor.
2. Remove three nuts (5) from the top of inverter 5. Disconnect overflow hose (10).
and remove cover (6).
6. Loosen clamp (11) and disconnect coolant hose
(12) from the radiator.
Installation 50-95
q Perform installation in the reverse order to re-
moval.
[*1]
3 Hose mounting bolt:
34 74 Nm {3.5 7.5 kgm}
[*2]
3 Hybrid radiator mounting bolt:
14.7 34.0 Nm {1.5 3.5 kgm}
Removal and installation of water pump assembly for hybrid system 50-96
Removal 50-96
4) Remove capacitor drain bolts (4) to drain the 8. Remove overflow tank (13).
coolant.
6 Hybrid radiator:
5.2 l
2. Remove three nuts (5) from the top of inverter 10. Remove three mounting bolts (16) and washer
and remove cover (6). tank (17).
3. Remove three bolts (7) and bracket (8). 11. Disconnect hose (18) between the water pump
and radiator.
4. Disconnect one-touch wiring connectors HB01
(9a) and (9b) from the capacitor. 12. Disconnect hose (19) between the water pump
a While pressing the lock portion of the con- and inverter.
nector with your thumb to unlock the connec-
tor, pull out the connectors.
Removal 50-9
4) Remove capacitor drain bolts (4) to drain the 6. Remove three nuts (10) from the top of inverter
coolant. and remove cover (11).
6 Coolant:
3.5 l
Installation 50-102
q Perform installation in the reverse order to re-
moval.
[*1]
q Install the connector of the high-voltage wiring
(power cable) according to the following proce-
dure.
1) Check plug (P) on the cable side for dirt and
flaw.
2) Thinly apply grease (G2-LI) to insertion
sealing portion (R) of the flange.
(For protection of the seal from the inserted
flange)
3) Insert plug (P) on the cable side straight into
power feed terminal socket (S) on the motor
side.
a Direct the black mark up.
a When inserting the plug, set disconnec-
tion detection contact (Q) of the power ca-
ble under the cable.
3 Mounting bolt of high-voltage wir-
ing (power cable) plug:
8.8 10.8 Nm {0.9 1.1 kgm}
[*2]
3 Tightening torque of inverter mounting
bolt:
59 74 Nm {6.0 7.6 kgm}
Sketch
Sym-
Q'ty
Removal 50-103
4) Remove capacitor drain bolts (4) to drain the 6. Remove three nuts (10) from the top of inverter
coolant. and remove cover (11).
2. Open the engine hood. 7. Remove three bolts (12) and bracket (13).
3. Remove two mounting bolts 5a to remove net
(5). 8. Disconnect coolant level sensor wiring
4. Remove covers (6) and (7). connector P24 (14).
14. Disconnect connectors (21) to (24) of the 17. Remove bolt (30), loosen hose clamp (30), and
high-voltage wiring (power cable). [*1] disconnect radiator lower hose (32). [*2]
(Connector No.): (From left)
(21): HC06 18. Remove bolt (33) and disconnect hose (34) from
(22): HC05 inverter (35).
(23): HC04
(24): HC03 19. Disconnect hose (36) from inverter (35).
[*1]
3 Connector mounting bolt:
8.8 10.8 Nm {0.9 1.1 kgm}
[*2]
3 Tightening torque of coolant hose clamp
screw:
3.9 4.9 Nm {0.4 0.5 kgm}
[*3]
a Replace four mounting nuts (01596-01211) of
the "capacitor and inverter assembly" with new
ones.
25. Using the hanging bolts at the four capacitor (Replace the nuts once they are used since they
are loosened and the torque decreases.)
3 Tightening torque:
lower corners, lift off inverter and capacitor
assembly (39).
a Put cloths, etc. between the "inverter and ca- 35 44 Nm{3.5 4.5 kgm}
pacitor assembly" and sling to protect the "in- Tighten the mounting bolts diagonally in the order of
verter and capacitor assembly". [1] to [4] as shown below.
4 Inverter and capacitor assembly:
123 kg
[*4]
a If the mounting bolts of the rubber mounts were
a Do not loosen mounting bolts (45) of four rub- loosened, position the rubber mounts according
ber mounts (44). [*4] to the following procedure.
1) Install rubber mount (44) and tighten
mounting bolt (46) with the fingers.
Drain 50-108
k Park the machine on a level place, lower the
work equipment to the ground completely,
and stop the engine.
k Disconnect the cable from the negative (-)
terminal of the battery.
2. Install generator motor lower cover (1).
1. Remove generator motor lower cover (1).
4. Remove plug (6) of oil supply port (5) and add oil
to the specified level.
5 Generator housing:
6 l(TO10)
a Check the oil level with oil level gauge (7).
a Run the engine to circulate the oil in the lubri-
cation circuit, and then check the oil level and
add oil as necessary.
Check oil level
1) Remove oil level gauge (7) and wipe off oil on
the gauge with a cloth.
2) Insert oil level gauge (7) fully into the guide.
3) Pull out oil level gauge (7). When the oil level
is in the range shown in the figure, it is
normal.
q Before starting the engine: between (H)
and (L) marks on COLD SIDE
q 15 minutes after atopping the engine: be-
tween (H) and (L) marks on HOT SIDE
4) If the level is below (L) of oil level gauge (7),
add oil.
5) If the level is above (H) of oil level gauge (7),
loosen drain plug (3) to discharge the excess
oil.
Removal 50-1 0
k Park the machine on a level place, lower the
work equipment to the ground completely, 4. Referring to "Draining and adding lubricating oil",
and stop the engine. loosen oil drain plug (5) to drain the oil. [*1]
k Disconnect the cable from the negative (-) 6 Generator oil tank:
[*5]
3 Hose clamp bolt:
19.6 29.4 Nm {2.0 3.0 kgm}
New/redesign
1) Remove the parts.
Necessity
Sketch
Part q Muffler assemblyAss'y (1)
Q'ty
Symbol Part number q Dipstick pipe (2)
name
q Oil filter assembly (3)
a Bind the oil filter assembly and hose
1 796T-401-1210 Stand q 1 N Q
together to the engine
2 796T-401-1220 Plate q 1 N Q
1 3 01010-81690 Bolt q 2
4 01580-11613 Nut q 2
5 01643-31645 Washer q 4
B 1 796-410-1000 Guide t 1 N
2 796-410-1040 Bar t 1 N
3 796-410-1050 Plate t 1 N
2
4 01010-81030 Bolt t 2
5 01643-31032 Washer t 6
6 01010-81035 Bolt t 4
a When removing the generator motor and hous-
ing assembly, set the engine horizontally.
Removal 50-1 3
1. Remove the engine, motor-generator and main
pump assembly referring to the section of
"Removal and installation of engine,
motor-generator and main pump assembly".
5) Install plate (16) to the flange temporarily. 2) Insert tool B2-2 (bar) in the guide hole of tool
10. Remove seven mounting bolts (19b) of the rotor B2-1 (guide).
and flange assembly, leaving two mounting bolts 3) Tighten tools B2-4 (bolts) to the specified
(19a). torque.
a Press tool B2-1 (guide) against crank bar
center (C) securely and align it, and then
fix it with tools B2-4 (bolts).
2) Install hanging bolts [J] (M10 x 1.5) to two 6) Lift off generator motor housing assembly
hanging bolt holes (G) of the housing, and (12).
sling generator motor housing assembly 4 Motor-generator housing assem-
(12). bly:
3) Remove the following mounting bolts and 120 kg
mounting nuts from the portions shown in the
following figure.
q Mounting bolts [1] - [15]
q Mounting nuts [16] - [18]
4) Install two guide pins [H] to the places of
guide bolts [3] and [5].
Installation 50-1 9
(Installation of generator motor housing assembly)
(Installation of rotor and flange assembly) 3) Pass tool B2-2 (bar) through the shaft hole
of rotor and flange assembly (18) and insert
1. Install the rotor and flange assembly according it until it reaches center (C) of the crankshaft.
to the following procedure. 4) While tool B2-2 (bar) is aligned, tighten tool
1) Install tool B2-1 (guide) to housing (12) and B2-4 (bolts) to the specified torque to fix tool
tighten two tools B2-4 (bolts) and B2-5 B2-1 (guide) to housing (12).
(washers) with the fingers. 5) Install tool B2-3 (bar fixing plate) and fix it
with tools B2-6 (bolt).
6) Remove sling [5].
7) Insert rotor and flange assembly (18) in the q Perform the subsequent installation in the re-
motor-generator housing along tool B2-2 verse order to removal.
(bar).
a When inserting rotor and flange assembly [*1]
(18), take care not to damage the follow- 3 Drain plug :
ing portions. 58.8 78.4 Nm {6.0 8.0 kgm}
q Coil insulation portion (D) on housing
side [*2]
q Core end portion (E) on housing side 3 Plate mounting bolt :
q Core portion (F) on rotor side 5.8 8 Nm {0.6 0.8 kgm}
[*3]
a Clean the mounting face of the starting motor as-
sembly and apply gasket sealant to it.
(R: Periphery L = 4mm apart from end face)
2 Starting motor assembly mounting face:
Liquid gasket (LG-7)
q Refilling of oil
Add oil to the generator motor housing.
5 Motor-generator housing:
6.5 l
(Power line oil TO10)
a Check the oil level with oil level gauge.
a Run the engine to circulate the oil in the lubri-
8) Install flange mounting bolts (19).
cation circuit, and then check the oil level and
9) Remove tool B2.
add oil as necessary.
New/redesign
Necessity
Sketch
Sym-
Q'ty
Part number Part name
bol
Removal 50-12
16. Remove clamp (21) and disconnect two coolant 22. Sling the swing electric motor and remove six
hoses (22). [*9] mounting bolts (28). [*12]
a Make marks on the hoses so that you do not a Before removing the bolts, make a match
mistake them for each other. mark (X) between the swing electric motor
and swing machinery
17. Disconnect lubricating oil outlet hose (23). [*10]
Installation 50-126
q Perform installation in the reverse order to re- [*7]
moval. 3 Delivery hose sleeve nut:
54 93 Nm {5.5 9.5 kgm}
[*1]
3 Cover mounting bolt: [*8]
98 123 Nm {10.0 12.5 kgm} 3 Bracket mounting bolt:
59.7 74 Nm {6.0 7.5 kgm}
[*2]
3 Oil drain plug: [*9]
58.8 78.4 Nm {6.0 8.0 kgm} a When connecting the coolant hoses, check their
Target value: 68.6 Nm {7.0 kgm} marks made when they were removed.
(Left side): Outlet hose from swing electric motor
[*3] (Right side): Inlet hose to swing electric motor
3 Plate fixing bolt:
27 34 Nm {2.8 3.5 kgm} [*10]
3 Sleeve nut of lubricating oil outlet hose:
[*4] 84 132 Nm {8.5 13.5 kgm}
3 Cover mounting bolt:
27 34 Nm {2.8 3.5 kgm} [*11]
3 Sleeve nut of lubricating oil drain hose:
[*5] 84 132 Nm {8.5 13.5 kgm}
3 Mounting bolt of travel hose bracket:
27 34 Nm {2.8 3.5 kgm}
[*6]
q Install the connector of the high-voltage wiring
(power cable) according to the following proce-
dure.
1) Check plug (P) on the cable side for dirt and
flaw.
2) Thinly apply grease (G2-LI) to insertion
sealing portion (R) of the flange.
(For protection of the seal from the inserted
flange)
3) Insert plug (P) on the cable side straight into
power feed terminal socket (S) on the motor
side.
a Direct the black mark up.
a When inserting the plug, set disconnec-
tion detection contact (Q) of the power ca-
ble under the cable.
3 Mounting bolt of high-voltage wir-
ing (power cable) plug:
8.8 10.8 Nm {0.9 1.1 kgm}
q Refilling of oil
Add oil through the oil filler to the specified level.
Run the engine to circulate the oil through the
piping. Then, check the oil level again.
5 Swing machinery case:
6 l(TO30)
5 Swing electric motor case:
1.6 1.8 l(TO10)
(Refill capacity):
1.6 l(TO10)
Serial No.: 2635 and up 1. Open left side inspection cover (1).
Special tools
Necessity
Sym-
Q'ty
Part No. Part name
bol
Removal
k Place the machine on a level ground, lower 3. Disconnect one-touch wiring connectors HB01
the work equipment to the ground, and stop (CC) ((+) and (-) cable terminals) (2 pieces) of
the engine. the capacitor.
k Release the remaining pressure in the hy- a Pull out the connector by pressing the lock
draulic circuit and set the lock lever to LOCK part of the connector with your thumb to re-
position. For details, see "Releasing remain- lease the lock.
ing pressure in hydraulic circuit" in Testing
and adjusting.
k Disconnect the cable from the negative (-)
terminal of the battery.
k Before opening the water filler cap or drain-
ing coolant, check that the coolant tempera-
ture cools down to the temperature safe
enough for anyone not to get burn.
k When draining coolant, be careful not to let
coolant contact your skin or enter your eye.
The super coolant mixed in the coolant is
poisonous. If the coolant sticks to your skin
or enters your eye, immediately rinse with
water thoroughly and see a doctor.
k Drain the coolant for hybrid.
[*3]
3 Bracket fixing bolt:
27 to 34 Nm {2.8 to 3.5 kgm}
[*4]
3 Cover mounting bolts:
27 to 34 Nm {2.8 to 3.5 kgm}
[*5]
3 Travel hose bracket mounting bolt:
27 to 34 Nm {2.8 to 3.5 kgm}
[*6]
q Install the connector of the high voltage wiring
(power cable) according to the following proce-
dure.
1) Check that there is no stain or scratch on the
cable side plug (P).
2) Apply grease (G2-LI) lightly on insertion seal
part (R) of the flange.
(To protect the seal from damage during
insertion)
3) Insert the cable side plug straight into the
motor side power supply terminal socket (S).
a Make sure that black marking faces up-
ward.
a Insert power cable removal and installa-
tion detection contact (Q) with having the
cable facing the bottom.
3 High voltage wiring (power cable)
plug mounting bolt:
8.8 to 10.8 Nm {0.9 to 1.1 kgm}
[*8]
3 Delivery hose sleeve nut:
54 to 93 Nm {5.5 to 9.5 kgm}
[*9]
a Install the coolant hoses by checking right and
left hoses recorded during removal.
(Left side): Outlet hose from the swing electric
motor
(Right side): Inlet hose from the swing electric
motor
[*10]
3 Lubricating oil outlet hose sleeve nut: 3) Install swing electric motor assembly (29) to
84 to 132 Nm {8.5 to 13.5 kgm} the swing machinery assembly along with the
matchmarks (x) put before removal.
[*11] a When installing a new swing electric mo-
3 Lubricating oil drain hose sleeve nut: tor, match the oil filler pipe mounting sur-
84 to 132 Nm {8.5 to 13.5 kgm} face (S) and swing electric motor piping
port surface (T), and use tool F4 to install
[*12] swing electric motor assembly (29).
q Install the swing electric motor assembly to the
swing machinery according to the following pro-
cedure.
1) Degrease the mating face (Q) of the swing
electric motor and No.1 ring gear (30).
Installation 50-130
q Perform installation in the reverse order to re-
moval.
[*1]
3 Mounting bolt:
245 309 Nm {25.0 31.5 kgm}
q Refilling of oil
Fill power train oil (TO30) through the oil filler
port to the specified level. Start the engine to
circulate the oil through the pipings and recheck
the oil level.
q Bleeding air
See Testing and adjusting, Bleeding air from
each part.
New/redesign
Necessity
5. No. 1 carrier assembly
Sketch
Q'ty
Symbol Part number Part name 1) Remove No. 1 carrier assembly (3).
Wrench assem-
796-427-1400 t 1 N
bly
1 796-427-1410 q Wrench 1 N
796-427-1140 q Pin 3
01314-20612 q Screw 3
796T-427-1510 Push tool t 1 N Q
790-101-2510 Block t 1
790-101-3310 Block t 1
790-101-2610 Rod t 2
J
790-101-2730 Adapter t 2
01580-11613 Nut t 2
2
790-101-2570 Plate t 2
01643-31645 Washer t 2
Puller
790-101-2102 (294 kN {30 t 1 2) Disassemble No. 1 carrier assembly as
ton}) follows.
790-101-1102 Pump t 1 1] Push in pin (4) and drive out shaft (5) from
3 796-427-1520 Installer t 1 N
carrier (6).
a After removing the shaft, remove pin
Disassembly 50-131 (4).
1. Draining oil 2] Remove thrust washer (7), planetary gear
Remove the drain plug to drain the oil from the (8), bearing (9), and thrust washer (10)
final drive case. from carrier (6).
6 Final drive case:
3.5 l
6. Remove No. 1 sun gear shaft (11). 3) Disassemble No. 2 carrier assembly as
follows.
7. Remove thrust washer (12). 1] Push in pin (18) and drive out shaft (17)
from carrier (19).
8. Remove No. 2 sun gear (13). a After removing the shaft, remove pin
(16).
2] Remove thrust washer (19), planetary
gear (20), bearing (21), and thrust washer
(22).
10. Nut
1) Remove lock plate (23).
2) Use tool J1 to remove nut (24).
a Use bar [2] to hold.
11. Hub assembly 13. Use puller [3] and push tool [4] to remove
1) Sling hub assembly (25) and remove from bearing (32).
travel motor. a Bearing may come off without using the pull-
2) Remove bearing (26). er.
5. Install bearing (26) by tapping it lightly with the 7] Measure the size (a) under the condition
push tool. described in 6] above.
2] Align the pin holes on shaft (5) and the 2) Install No. 1 carrier assembly (3).
carrier, and install shaft (5) by tapping it
lightly with a plastic hammer. 13. Thrust washer
a Install the shaft, rotating the planetary Install thrust washer (2).
gear (8). Take care so the thrust a After installing washer (2), measure dimen-
washer is not damaged. sion (i) from the upper end face of planetary
3] Insert pin (4). gear (8) to that of ring gear assembly (25) to
a When inserting the pin, take care that check for the correct assembly condition.
the 3 claws (parts f) on the periphery a If dimension (i) is 0.6 mm or larger, it is not
of the pin will not be placed on the thin assembled correctly. Check the assembling
parts of the carrier (parts g). The thin condition.
wall part may be on the opposite side
depending on carriers, however.
Check each carrier and avoid setting
any claw of the pin to the thin wall part.
If there is a groove, avoid the groove.
a After assembling the carrier assem-
bly, check that gear (8) rotates
smoothly.
14. Cover
Install cover (1).
2 Cover mounting face:
Liquid gasket (LG-6)
3 Mounting bolt:
98 123 Nm {10.0 12.5 kgm}
4. Remove lower cover (4). [*1] 8. Remove mounting bolt (9) to remove plate (10).
[*3]
7. Pull out swing machinery drain block (7) and 12. Remove mounting bolt (16) to disconnect power
drain hose (8) from the hole of the revolving cable connector (17). [*6]
frame.
13. Disconnect power cable fixing clamp (18) from
bracket (19).
17. Loosen clamp (23) and disconnect two coolant 23. Remove twelve mounting bolts (29). [*12]
hoses (24). [*9]
a Make marks on the hoses so that you do not
mistake them for each other.
24. Install eyebolt [1] and sling [2] to three places (P)
on the periphery.
[*1] [*8]
3 Cover mounting bolt: 3 Bracket mounting bolt:
98 123 Nm {10.0 12.5 kgm} 59.7 74 Nm {6.0 7.5 kgm}
[*2] [*9]
3 Oil drain plug: a When connecting the coolant hoses, check their
19.6 24.5 Nm {2.0 2.5 kgm} marks made when they were removed.
(Left side): Outlet hose from swing electric motor
[*3] (Right side): Inlet hose to swing electric motor
3 Plate fixing bolt:
27 34 Nm {2.8 3.5 kgm} [*10]
3 Sleeve nut of lubricating oil outlet hose:
[*4] 84 132 Nm {8.5 13.5 kgm}
3 Cover mounting bolt:
27 34 Nm {2.8 3.5 kgm} [*11]
3 Sleeve nut of lubricating oil drain hose:
[*5] 84 132 Nm {8.5 13.5 kgm}
3 Mounting bolt of travel hose bracket:
27 34 Nm {2.8 3.5 kgm} [*12]
3 Swing machinery assembly mounting
[*6] bolt:
q Install the connector of the high-voltage wiring 490 608 Nm {50 62 kgm}
(power cable) according to the following proce-
dure. q Refilling of oil
1) Check plug (P) on the cable side for dirt and Add oil through the oil filler of the swing electric
flaw. motor to the specified level. Run the engine to
2) Thinly apply grease (G2-LI) to insertion circulate the oil through the piping. Then, check
sealing portion (R) of the flange. the oil level again.
(For protection of the seal from the inserted 5 Swing electric motor case:
flange) 1.6 1.8 l (TO10)
3) Insert plug (P) on the cable side straight into q Refilling coolant and bleeding air
power feed terminal socket (S) on the motor a Add coolant and bleed air. For details, see
side. "Draining adding coolant and bleeding air for
a Direct the black mark up. hybrid system".
a When inserting the plug, set disconnec-
tion detection contact (Q) of the power ca-
ble under the cable.
3 Mounting bolt of high-voltage wir-
ing (power cable) plug:
8.8 10.8 Nm {0.9 1.1 kgm}
Serial No.: 2635 and up 1. Open left side inspection cover (1).
Special tool
Necessity
Sym-
Q'ty
Part No. Part name
bol
F 11 7875-35-2910 Cap t 1
Removal
12. Disconnect clip (15) and disconnect connector 17. Loosen clamps (22) and (23) and disconnect
CN-P01 (16). coolant hoses (24) and (25) (2 pieces). [*8]
a Make matchmarks on the hoses to prevent
13. Remove mounting bolts (17) and disconnect any mistake of right and left.
high voltage wiring connector (18). [*5]
a After disconnecting the high voltage wiring, 18. Disconnect lubricating oil outlet hose (26). [*9]
make sure to install tool F11.
a Tool F11 prevents water and dust from enter- 19. Remove cover (27).
ing into the connector part.
[*3]
3 Cover mounting bolts:
27 to 34 Nm {2.8 to 3.5 kgm}
[*4]
3 Travel hose bracket mounting bolt:
27 to 34 Nm {2.8 to 3.5 kgm}
[*5]
q Install the connector of the high voltage wiring
(power cable) according to the following proce-
dure.
1) Check that there is no stain or scratch on the
cable side plug (P).
2) Apply grease (G2-LI) lightly on insertion seal
part (R) of the flange.
(To protect the seal from damage during
insertion)
3) Insert the cable side plug straight into the
motor side power supply terminal socket (S).
a Make sure that black marking faces up-
ward.
a Insert power cable removal and installa-
tion detection contact (Q) with having the
cable facing the bottom.
3 High voltage wiring (power cable)
plug mounting bolt:
8.8 to 10.8 Nm {0.9 to 1.1 kgm}
[*6]
3 Bracket mounting bolt:
59.7 to 74 Nm {6.0 to 7.5 kgm}
[*7]
3 Delivery hose sleeve nut:
54 to 93 Nm {5.5 to 9.5 kgm}
[*8]
a Install the coolant hoses by checking right and
left hoses recorded during removal.
(Left side): Outlet hose from the swing electric
motor
(Right side): Inlet hose from the swing electric
motor
[*9]
3 Lubricating oil outlet hose sleeve nut:
84 to 132 Nm {8.5 to 13.5 kgm}
[*10]
3 Swing machinery assembly mounting
bolt:
490 to 608 Nm {50 to 62 kgm}
New/redesign
Necessity
tric swing motor drain hose (3).
Sketch
Q'ty
Symbol Part number Part name 2) Remove the oil level gauge according to the
following procedure.
1] Remove clamp mounting bolt (4) and
796T-426-1130 Plate t 1 Q remove hose (5).
1 790-101-5421 Push tool t 1 2] Remove two mounting bolts (6a) and two
01010-81240 Bolt t 1 mounting bolts (6b) to remove bracket
2 796-426-1120 Push tool t 1
F 3 796T-426-1410 Plate t 1 Q
(7).
4 01124-51490 Guide bolt t 3 3] Remove four mounting bolts (8a) and oil
1 796-426-1710 Collet t 1 filler pipe (8).
5 2 796-426-1720 Tapered cone t 1
3 796-426-1730 Collar t 1 4. Electric swing motor
1) Remove six mounting bolts (9a).
Disassembly 50-145 a Make match mark (P) between the case
1. Set the swing electric motor and swing of the electric swing motor assembly (9)
machinery assembly to a block. and swing machinery assembly (10).
2) Lift off electric swing motor assembly (9). 8. Remove six mounting bolts (15) of the No. 1 ring
4 Electric swing motor assembly: gear.
71 kg
2) Disassemble the No. 1 carrier assembly 11. Using air gun [1], apply air pressure through
according to the following procedure. swing holding brake port (Q) to remove piston
1] Reverse carrier assembly (17). (29).
2] Remove Spirolock (18). k Use air pressure of 5-6 kg/cm .
2
a While lifting up the abutment joint of k When applying air pressure, hold piston
Spirolock (18) with a thin flat-head (29) to prevent it from jumping out.
screwdriver, move the screwdriver
around clockwise to remove Spirolock
(18).
q While lifting up the abutment joint of
Spirolock (18) with the fingers, move
the screwdriver around clockwise to
remove Spirolock (18).
3] Remove ring (19).
4] Remove shaft (20) from the carrier
assembly by using the push tool.
q Shaft pressing force (reference):
12.2 30.0 N {1,240 3,050 kg}
5] Remove plate (21), planetary gear (22),
bearing (23), plate (24), and ring (25).
6] Reverse No. 1 carrier assembly (17).
7] Remove holder (26).
a Take care not to lose ball (27).
14. Remove six mounting bolts (36) and lift off case
(37).
3) Using push tool [1], remove shaft (47) from 2) Disassemble the No. 3 carrier assembly
carrier (46). according to the following procedure.
q Shaft pressing force (reference): 1] Push in pin (52) and drive out shaft (53)
11.2 - 25.8 kN {1,140 - 2,630 kg} from carrier (54).
a After removing the shaft, remove pin
(52).
2] Remove thrust washer (55), planetary
gear (56), and bearing (57).
3] Remove plate (58).
19. Remove holder mounting bolt (50). 21. Shaft and case assembly
1) Reverse shaft and case assembly (59).
20. No. 3 carrier assembly 2) Remove cover mounting bolts (60).
1) Remove No. 3 carrier assembly (51).
3) Reverse shaft and case assembly (59) again 22. Shaft assembly
and set it to the press. 1) Using push tools [3] and [4], remove shaft
4) Using push tool [2], remove shaft assembly (62).
(61) from shaft and case assembly (59). 2) Remove bearing (64) and oil seal (65) from
cover (63).
Assembly 50-151 2. Using push tool [5], press fit bearing (64) to case
a Clean all the parts thoroughly, check them for (66).
dirt and flaw, and apply power train oil to the slid- a Use a new bearing.
ing parts before assembling.
a Do not reuse the removed bearings and oil seals
but replace them with new ones.
1. Oil seal
Using tool F1, install oil seal (65) to cover (63).
a Take care of the direction (top and bottom) of
the oil seal.
2 Outer periphery of oil seal:
Liquid gasket (LG-6)
a Take care that the liquid gasket (LG-6) does
not stick to the oil seal lip at the time of
press-fitting.
5. Bearing
Using tool F3 and push tool [11], press fit bearing
(67).
a Press the inner race and outer race of the
bearing simultaneously. Do not press only
the inner race.
q Bearing press fit force (reference):
9.4 35.5 kN {960 3,620 kg}
a After press-fitting the bearing, ensure that the
case rotates smoothly.
4] Match the pin holes of shaft (53) and 7. No. 3 sun gear
carrier with each other by lightly hitting Install No. 3 sun gear (48).
with a plastic hammer, and then install
shaft (53). 8. No. 2 ring gear
a When installing the shaft, rotate the Using eyebolts (M10 x 1.5), install No. 2 ring
planetary gear so that the thrust wash- gear (49).
ers are not damaged. a Degrease mating faces of No. 2 ring gear
5] Insert pin (52). (49) and case (66).
a When inserting the pin, take care that a Do not stick gasket sealant to the mating fac-
the 3 claws (parts a) on the periphery es of the No. 2 ring gear and case.
of the pin will not be placed on the thin a When installing the No. 2 ring gear, set its
parts of the carrier (parts b). match mark (c) to convex part (d) of the
The thin wall part may be on the oppo- flange as shown in the figure.
site side depending on carriers, 3 Mounting bolt:
however. Check each carrier and 157 196 Nm {16 20 kgm}
avoid setting any claw of the pin to the
thin wall part. 9. Install O-ring (71).
a After inserting the pin, caulk two plac-
es (c) around the pin hole of the carri-
er.
11. Case
Install case (37) according to the following
procedure.
1) When installing case (37), match its notch (a)
with bolt (c) next to convex part (b) of the
flange as shown in the figure.
a Degrease mating faces of No. 2 ring gear
(49) and case (37).
a Do not stick liquid gasket to the mating
faces of No. 2 ring gear (49) and case
3] Install plate (44) to carrier (46). (37).
4] Install thrust washer (43), bearing (42), 2) Install six mounting bolts (36).
planetary gear (41), thrust washer (40), 3 Mounting bolt:
and snap ring (39) in this order. 59 74 Nm {6.0 7.5 kgm}
12. Install three plates (34) and two discs (35). 13. No. 2 sun gear
a Do not clean the discs with trichloroethylene 1) Assemble No. 2 sun gear (30) according to
or denatured alcohol or blow air strongly the following procedure.
against it. 1] Install swing holding brake gear (33) to
a When installing the discs, apply clean lubri- No. 2 sun gear (30).
cating oil (TO30) to their surfaces. 2] Install plate (32) to No. 2 sun gear (30)
a Install the plates and discs in the order shown and install snap ring (31).
in the figure. a Take care not to install swing holding
brake gear (33) upside down.
a Take care not to install plate (32) up-
side down.
20. Install cover (13) with seven mounting bolts (12). 2) Sling electric swing motor assembly (9) while
matching the match marks that were made
21. Install No. 1 sun gear (11). on the electric swing motor and No. 1 ring
a Before installing No. 1 sun gear (11), check gear at disassembly.
to see if there is the plate.
a If there is not the plate, install it before install-
ing No. 1 sun gear (11).
a When installing No. 1 sun gear (11), apply oil
(TO30) to the plate.
a When installing the plate, do not bruise or
scratch its face to be in contact with the ball.
23. Fix oil fuller pipe (8) with four mounting bolts
(8a).
3 Mounting bolt:
27 34 Nm {2.8 3.5 kgm}
New/redesign
Necessity
ment, lift the track shoes.
Sketch
Sym
Q'ty
Part number Part name 2) Locate master pin (2) at around the center of
bol
lower track shoes and between 2 track
rollers.
791-630-3000 Remover and installer t 1 3) Put blocks [1] under the track below the idler
Cylinder and sprocket.
R 790-101-1300 t 1
(980 kN {100 ton})
790-101-1102 Pump t 1
5. Set the location of guide pin (GP). Installation of track shoe 50-162
1) Pushing against ground with the work equip- q Perform connection in the reverse order to sep-
ment, lift the track shoes. aration.
2) Move away blocks [1] that were set under the
track below the idler and sprocket. [*1]
3) Move guide pin (GP) to the front of the idler. a Refer to the Checking and adjusting track shoe
4) Relieve the work equipment, and lower the tension section in the Testing and adjusting
machine. chapter of this manual.
5) Place block [1] under track (3) in front of the
idler. [*2]
1. Apply grease to master pin (2). (in the area
where bushing (4) and master pin (2) come
contact: shown hatched)
2 Between bushing and master pin
(hatched area):
Grease
NIGTIGHT LYK-2 from Nippon Grease
Co., Ltd.: part no. 44392708 or equiva-
lent
[*3]
1. Using bar [2], roll up track shoes (3) while the
machine moves forward slowly.
Special tools 50-164 3. Remove idler (4) from the assembly of shaft (5)
and support (7).
New/redesign
a Since 250 cc of oil is filled in, drain it at this
Necessity
Sketch
Sym-
Q'ty
Part number Part name timing, or underlay some cloth to prevent any
bol
careless smearing.
Assembly 50-165
q Structural illustration
4. Install the assembly of shaft (5) and support (7) 6. Install support (2) with the O-ring to the shaft by
to idler (4). using dowel pin (1).
a See structural illustration.
Special tools 50-167 1. Remove piston assembly (2) from idler cushion
assembly (1).
New/redesign
Necessity
Sketch
Sym-
Q'ty
Part number Part name 2. Disassembling idler cushion assembly
bol
1) Set tool M1 to idler cushion assembly (1).
k The tool must be installed correctly as
791-600-2001 Compressor (A) the load at installed length of the
or t 1 spring is large and dangerous.
791-685-8006 Compressor (B) a Load at installed length of spring:
790-201-2780 Spacer
109.2 kN {11,150 kg}
1 791-635-3160 Extension t 1
Cylinder
790-101-1600
(686 kN {70 ton})
790-101-1102 Pump t 1
M 790-640-2180 Guide bolt t 1
790-101-5201 Push tool kit (B) q 1
790-101-5241 q Plate 1
2
790-101-5221 q Grip 1
01010-51225 q Bolt 2
790-201-1500 Push tool kit q 1
790-201-1620 q Plate 1
3
790-101-5021 q Grip 1
01010-50816 q Bolt 1
Disassembly 50-167
q Structural illustration
2) Apply hydraulic pressure gradually to
compress the spring and remove lock plate
(3) and nut (4).
a Compress the spring up to the point
where the nut gets loose.
a Release the hydraulic pressure slowly to
release the tension of the spring.
a Free length of spring: 531 mm
3) Remove yoke (6) and cylinder (7) from spring
(5).
4) Remove snap ring (8), dust seal (9) and
bushing (10), in turn from cylinder (7).
Assembly 50-168
q Structural illustration
4) Install cylinder (7) and yoke (6) to spring (5).
Install the assembly to tool M1.
2 Sliding surface of cylinder:
Grease (G2-LI)
New/redesign
Necessity
(10) to roller (4).
Sketch
Sym-
Q'ty
Part number Part name
bol
2. Install collar (8) with the O-ring to shaft (5), and
install pin (7).
L 2 796-670-1020 Installer t 1
Disassembly 50-169
1. Remove pin (1), then remove collar (2).
5. Remove pin (7) and then collar (8) from shaft (5).
3. Using tool L2 install floating seal (6a) to collar 5. Install shaft (5) to roller (4).
(8).
a Completely clean, degrease and dry the con- 6. Turn over the assembly of roller (4) and shaft (5).
tact surfaces (hatched area in the drawing) of
the floating seal and the O-ring. And take
care not to have any dirt stuck on the contact
surfaces.
a After inserting the floating seal, verify that the
inclination of the seal is less than 1 mm per
its diameter and that the protrusion height
shown as (a) in the illustration falls within the
range of 7 to 11 mm.
4. Using tool L2, install floating seals (6b) and (3b)
to roller (4).
a As to precautions for installation of floating
seals (6b) and (3b), refer to a marked com-
ments in step 3.
7. Using tool L2, install floating seal (3a) to collar
(2).
a For precautions for installing floating seal
(3a), see a mark in step 3.
a Apply oil to the sliding surface of the floating
seal, and take care not to have any dirt stuck
on it.
Special tools 50-171 2. Using push tool [1], push the end surface of the
shaft to remove shaft (2) from carrier roller (1) to
New/redesign
Necessity
separate followings.
Sketch
Sym-
Q'ty
Part number Part name q The assembly of roller (4) and ring (5), shaft
bol
(2) and cover (3).
q Press fit force (reference): 59 kN {6,000 kg}or
L 1 790-434-1660 Installer t 1 more.
a The press fit between shaft (2) and ring (5),
q Sectional view and also between roller (4) and cover (3) are
a A number in the drawing is the number shown in disengaged.
the text. a Shaft (2) and cover (3) under the shaft are re-
moved as a unit.
Disassembly 50-171
1. Remove plug (9) and drain the oil from carrier 3. Remove ring (5) from roller (4).
roller (1).
6 Carrier roller:
4. Remove floating seal (6) from ring (5).
75 85 cc a Take care not to damage the sealing surface.
Assembly 50-173
1. Using push tools [3] and [4], press fit bushing (8)
to roller (4).
a Press fit it from the side of cover (3)
2. Floating seal
1) Using tool L1, install floating seal (7) to roller
(4).
2) Using tool L1, install floating seal (6) to roller
(5)
a Completely clean, degrease and dry the
contact surfaces (hatched area in the
drawing) of the floating seal and the
O-ring. And take care not to have any dirt
stuck on the contact surfaces.
3. Install roller (4) and ring (5) to shaft (2).
a When installing floating seals, use tool L1
a Apply oil to the sliding surface of the floating
and make sure to press the O-ring.
seal, and take care not to have any dirt stuck
a After inserting the floating seal, verify that
on it.
the inclination of the seal is less than 1
mm per its diameter and that the protru-
sion height shown as (a) in the illustration
falls within the range of 7 to 11 mm.
4. Place washers [7] between push tool [6] and 6. Fill carrier roller assembly (1) with oil and tighten
roller (4). Press fit ring (5) to shaft (2) until the plug (9).
height difference between roller (4) and ring (5) 5 Carrier roller:
becomes 1.8 0.2 mm. 75 85 cc(E030-CD)
a Thickness of washer [7] = 1.8 0.2 mm 3 Plug:
a Use push tool [5] to support shaft (2) on it. 15 5 Nm {1.5 0.5 kgm}
Removal 50-175
k Safely lower the work equipment to the
ground by extending the arm and the bucket
completely. Set the lock lever in the lock po-
sition.
3. Disconnect 4 boom cylinder hoses (1). 6. From center swivel joint assembly, disconnect 6
a Put an oil stopper to the hose. hoses (8) to (13).
q (8): Center swivel joint (port D) to
Swing motor (T port)
q (9): Center swivel joint (port E) to
Solenoid valve
q (10): Center swivel joint (port B) to
L.H. travel control valve (A2 port)
q (11): Center swivel joint (port D) to
R.H. travel control valve (B5 port)
q (12): Center swivel joint (port A) to
L.H. travel control valve (B2 port)
q (13): Center swivel joint (port C) to
R.H. travel control valve (A5 port)
q Bleeding air
Bleed air from the travel motor referencing the
"Bleeding air from each part" section in the
Testing and adjusting chapter of this manual.
New/redesign
Necessity
Sketch
Sym-
Q'ty
Part number Part name
bol
Commer-
cially avail- Impact wrench q 1
able
Z
Commer- Socket wrench
cially avail- (Width across flats : q 1
able 46 mm)
Removal 50-17
k Park the machine on a level place and swing
the upper structure 90 deg., and then lower
the work equipment to the ground complete-
ly and stop the engine.
k Disconnect the cable from the negative (-)
terminal of the battery.
[*1]
2 Mounting bolt:
Adhesive (LT-2)
3 Counterweight mounting bolt:
1.52 1.91 kNm {155 195 kgm}
[*2]
a Installation and adjustment of counterweight
1) Adjust the level difference from the exterior
parts (horizontal clearance) with shims.
a Shims: 1 mm(205-46-25150)
2) Fix the counterweight so that the clearances
6. Sling and remove counterweight assembly (10). in the direction of front and rear are even and
[*2] within the limit of 10 5 mm for both from the
q Counterweight assembly: 3,450 kg
doors and from the revolving frame.
3) The difference in level in left to right direction
between the exterior of door (D) and counter-
weight (C)
(a): 10 4 mm
The difference in level in left to right direction
between revolving frame (R) and counter-
weight (C)
(b): 5 mm or less
The difference in level in up and down direc-
tion between exterior upper cover (UC) and
counterweight (C)
c: 0 5 mm
are the respective limits for the mounting
adjustment.
a Rear view (Enlarged drawing for right
hand side)
[*1]
Install the center swivel joint (CSJ) facing in the di-
rection shown in the figure. (The figure shows the
machine body as seen from above.)
a S: Sprocket
A to D: Port name
q Bleeding air
See Testing and adjusting, Bleeding air from
each part.
Special tools 50-181 1. Remove elbows (1), (2) and tee (3).
New/redesign
2. Remove cover (4).
Necessity
Sym-
Part number Part name
Sketch
bol
3. Remove snap ring (5) and ring (6).
Q'ty
790-101-2501 Push-puller q 1 4. Using tool T1, pull out swivel shaft (8) from swivel
790-101-2510 q Block 1 rotor (7).
790-101-2520 q Screw 1
791-112-1180 q Nut 1
A 790-101-2540 q Washer 1
790-101-2630 q Leg 2
790-101-2570 q Plate 4
790-101-2560 q Nut 2
790-101-2650 q Adapter 2
Disassembly 50-181
Assembly 50-182
a See figure at left.
1. Install seal (9) and O-ring (10) to swivel rotor (7).
3) Remove two upper mounting bolts (9) of 2) Remove four bolts (15) from hinge (14) and
cover (7) and remove cover (7). lift off engine hood (12).
a Make marks of (x) and (y) to hinges (14)
to indicate their installed positions.
2) Remove frames (18) and (19). 8. Disconnect pre-filter (23) and bracket (24)
3) Remove partition (20). together from frame (25).
4) Remove partition (21).
9. Disconnect drain hoses (26) - (28).
12. Disconnect suction hose (35). [*2] 14. Remove six mounting bolts (37). [*3]
a Put marks on the hose and tube to indicate
their fitting positions.
New/redesign
Necessity
Sym-
Part number Part name
Sketch
bol
Q'ty
10 796-460-1210 Oil stopper q 1
A
11 796-770-1320 Adapter q 1
Removal 50-18
k Park the machine on a level place, lower the
work equipment to the ground completely,
and stop the engine.
k Referring to Testing and adjusting, "Releas-
ing remaining pressure in hydraulic circuit",
release the pressure inside the hydraulic cir-
cuit and then set the lock lever to the LOCK
position.
k Disconnect the cable from the negative (-)
terminal of the battery.
a Record the installed positions, connector
Nos., or hose band colors of the disconnect-
ed wires and pipes so that you do not make a
mistake in their connection positions.
4. Loose drain plug (4) to drain oil from the 5. Remove the engine hood according to the
hydraulic oil tank. [*1] following procedure.
6 Hydraulic tank: 1) Open engine hood (6) and sling it.
232 l(Specified amount of oil) 2) Remove pins (7) and (8) and disconnect two
135 l (Refill capacity) gas springs (9) on the right and left sides.
a If you do not drain the oil from the tank, skip 3) Remove four bolts (11) from hinge (10) and
steps 1, 2, and 4, and install the stopper by lift off engine hood (6).
using tool A10 according to the following pro- a Make marks of (x) and (y) to hinges (10)
cedure. to indicate their installed positions.
1) Remove cover (HC). 4 Engine hood:
2) Remove the strainer. 45 kg
3) Assemble tool A10 (oil stopper) and A11
(adapter).
4) Install tools A10 and A11 together to the
position of the removed strainer.
5) Install cover (5).
a Tighten with several bolts temporarily.
7. Remove frames (13) and (14). 12. Disconnect the following five hoses connected to
the main pump.
8. Remove partition plate(15). (23): Rear load pressure input port hose
(Collar band color: None)
(24): EPC source pressure port hose
(Collar band color: Yellow)
(25): Front load pressure input port hose
(Collar band color: Red)
(26): Pump pressure input port hose
(Collar band color: Blue)
(27): Drain port hose
a When using tool A10 without draining oil from
the hydraulic tank, prepare a large container
if the oil level in the tank is higher than the
drain port for the main pump.
(Oil will flow out when the drain hose is
disconnected.)
9. Disconnect prefilter (16) and bracket (17)
together from frame (18).
17. Disconnect the four hoses connected to the 21. Sling main pump assembly (40).
main pump.
(33): Pump discharge port hose (2 pieces) 22. Remove twelve mounting bolts (41).
(33a): Branch hose (2 pieces)
23. Lift and remove main pump assembly (40).
18. Remove four bolts (34) and disconnect suction 4 Main pump assembly:
tube (35) from the main pump assembly. 165 kg
Installation 50-192
q Perform installation in the reverse order to re-
moval.
k If the main pump is replaced or adjusted, per-
form pump calibration according to "Special
function of machine monitor".
[*1]
3 Hydraulic tank drain plug:
58.8 78.5 Nm {6.0 8.0 kgm}
Removal and installation of main pump input shaft oil seal 50-193
New/redesign
moval.
Necessity
Sym-
Part number Part name
Sketch
bol
[*1]
2
Q'ty
Oil seal lip:
S 796T-467-2410 Push tool t 1 N Grease (G2-LI)
2 Oil seal outer periphery:
Removal 50-193 Grease (G2-LI)
1. Remove the main pump assembly. For details, a Apply a thin film of the grease on the oil seal out-
see "Removal (and installation) of main pump er circumference.
assembly". a By using tool S and tools [1] and [2], press fit oil
2. Remove snap ring (1) and then remove spacer seal (3).
(2).
3. By using a screwdriver, pry off oil seal (3).
[*1]
a Take care not to damage the shaft when re-
moving the oil seal.
q (20): Port B6 (arm bottom) (above-men- 5) Disconnect wiring connectors P25 (27) and
tioned) P26 (28).
q (21): Port T1 (drain hose) 6) Disconnect hoses (29) to (33).
q (29): Port PP1 hose (from rear pump)
q (30): Port PP2 hose (from front pump)
q (31): Port T hose (to hydraulic tank)
q (32): Port PPS2 hose (to front pump con-
trol)
q (33): Port PR hose (to solenoid valve)
11. Disconnect the hoses on the left side of the 14. Disconnect following six connectors (58).
control valve according to the following proce- (From top)
dure. q V06
1) Disconnect PPC hoses (41) to (48). q V05
q (41): (Attachment) q V04
q (42): Port P2 hose (bucket CURL PPC) q V03
q (43): Port P4 hose (left travel PPC) q V02
q (44): Port P6 hose (boom LOWER PPC) q V01
q (45): Port P10 hose (right travel PPC)
q (46): Port P12 hose (arm IN PPC) 15. Disconnect clamp (59).
q (47): (Attachment)
q (48): Port P2 hose (bucket CURL PPC) 16. Keep away solenoid valve assembly (60) from
2) Disconnect port PST hose (solenoid valve) control valve bracket (B).
(49).
17. Remove four mounting bolts (62) of the control
valve.
Installation 50-198
q Perform installation in the reverse order to re-
moval.
[*1]
3 Hydraulic tank drain plug:
58.8 78.5 Nm {6.0 8.0 kgm}
q Bleeding air
See Testing and adjusting, Bleeding air from
each part.
a This section explains only the precautions for as- Replacement of pressure compensation valve
sembling the contol valve assembly. seal 50-19
a Since there are many types of pressure compen-
Special tools 50-19 sation valve, put a mark and note the installed
position when removing it.
New/redesign
1. Remove piston (2), plug (3) and spring (4) from
Necessity
Sym-
Part number Part name pressure compensation valve (1).
Sketch
bol
Q'ty
2. Remove seals (5) and (6) from piston (2).
796-946-1310 Guide f21.8
t 1
(For 723-46-40100)
796-946-1610 Guide f21.4
t 1
(For 723-46-41100)
796-946-1810 Guide f21.2
(For 723-46-43100 and t 1
2 723-46-43400)
796-946-1910 Guide f21.0
(For 723-46-46101 and t 1
723-46-46300)
796-946-2210 Guide f20.6
(For 723-46-45100 and t 1
723-46-45700)
796-946-1320 Guide f21.8
t 1
(For 723-46-40100)
796-946-1620 Guide f21.4
t 1
(For 723-46-41100) a There are many types of pistons.
796-946-1820 Guide f21.2
(For 723-46-43100 and t 1
723-46-43400) 3. Install tool T2 on piston (2), put the seal on the
3 tool and slowly push seal (5) down by hand so
T 796-946-1920 Guide f21.0
(For 723-46-46101 and t 1 that it evenly expands.
723-46-46300)
796-946-2220 Guide f20.6 a You may put the seal on the tool and push it
t 1
(For 723-46-45100) down to the flat part of the tool, and them in-
796-946-1420 Guide f21.6
t 1 stall the tool to the pistion to install the seal in
(For 723-46-42700)
796-946-1330 Sleeve position.
t 1
(For 723-46-40100)
796-946-1630 Sleeve
t 1
(For 723-46-41100)
796-946-1830 Sleeve
(For 723-46-43100 and t 1
723-46-43400)
4
796-946-1930 Sleeve
(For 723-46-46101 and t 1
723-46-46300)
796-946-2230 Sleeve
t 1
(For 723-46-45100)
796-946-1430 Sleeve
t 1
(For 723-46-42700)
4. Likewise, set tool T3 to piston (2) in the same 6. Fit plug (3) and spring (4) to piston (2), then
direction and push it slowly by hand so that install pressure compensation valve (1).
another seal (6) may be spread out evenly. a After the installation, push the piston by hand
a You may put the seal on the tool and push it and check that the piston returns only with
down to the flat part of the tool, and them in- spring force.
stall the tool to the pistion to install the seal in
position.
a Only precautions for assembling the work equipment PPC valve assembly are described below.
a When installing springs (6) and (7), note that a Apply grease (G2-LI) to the sliding parts of joint
they are different by hydraulic port to install. (12) and contact surfaces of disc (13) and piston
q Installed height: 31.9 mm (all) (8).
q Load at installed length of spring 2 Quantity of grease (G2-LI)
Spring (6) (P1, P2): 35.3 N {3.6 kg} 1) Rocking parts of joint: 2 to 4 cc/entire
Spring (7) (P3, P4): 21.6 N {2.2 kg} periphery
2) Contact parts of disc and piston:
a When installing piston (8), apply grease (G2-LI) 0.3 to 0.8 cc/part
to its outside and the inside of the body (1) hole.
3 Bolt (11): a Install disc (13) according to the following proce-
11.8 14.7 Nm {1.2 1.5 kgm} dure. Adjust the disc so that the play at the lever
a When installing joint (12) to valve body (1), apply end is within the following range.
Loctite according to the following procedure. Lever play:
1) When installing the joint, apply a drop 0.5 to 3 mm (at 200 mm from lever pivot point)
(approximately 0.02 g) of Loctite (No. 262) to a See Testing and adjusting, "Adjusting play of
each female thread portion (A) (2 places) of work equipment and swing PPC valve".
the valve body. Before installing the joint, a Tighten nut (14) to the following tightening
degrease its male threads and the female torque.
threads of the valve body with Drysol and dry 3 Nut (14):
them. 69 88 Nm {7 9 kgm}
2) Drop LOCTITE to the following positions.
2 Female thread (A) of valve body:
Loctite No. 262
3 Joint (12):
39 49 Nm {4 5 kgm}
Special tools 50-205 5. Remove mounting bolt (19) to remove plate (22).
a Note the thickness and installed position of
New/redesign
Necessity
Sym
a Remove pin (23) from body (1).
Q'ty
2. Remove mounting bolt (21) to remove case (12), 8. Remove valves (2) from valve body (1).
shaft (14) and lever (15) assembly.
Special tools 50-208 5. Start the engine and then retract the piston rod.
a Bind the piston rod with wire etc. and put it
New/redesign
Necessity
down on the blocking tools so that the piston
Sketch
Sym-
Q'ty
Part number Part name rod does not slip out, or allot a support so that
bol
the cylinder doesn't fall down to the bottom
side. If a support is allotted, remove the
796-900-1200 Remover t 1 grease fitting at the bottom side.
796-900-1210 q Sleeve 1 a Remove the boom cylinder on the opposite
792-900-1520 q Plate 1
side in the same way.
799-900-1230 q Screw 1
796-900-1240 q Adapter 1
a If bumping of the lifting hook against the work
V equipment lamp is anticipated in lifting the
01643-33080 q Washer 1
01803-13034 q Nut 1 work equipment, the lamp must be removed.
Puller
790-101-4000 t 1
(490 kN {50 ton}, long) 6. Disconnect 2 pieces of bucket cylinder hose (6)
790-101-1102 Pump (294 kN 30 ton}) t 1
and 2 pieces of arm cylinder hose (7).
a Apply the oil restraining plug and then fix the
Removal 50-208 hoses to the valve side by use of ropes.
k Safely lower the work equipment to the
ground by extending the arm and the bucket 7. Disconnect intermediate connector for working
completely. Set the lock lever in the lock po- lamp A13 (8).
sition.
k Release the residual pressure in the hydrau-
lic circuit. Refer to the "Releasing residual
pressure from hydraulic circuit" section in
the Testing and adjusting chapter of this
manual.
[*2]
2 Inside surface of bushing when installing
pin:
Antifriction compound (LM-P)
2 Greasing after installing pin:
Grease (LM-G)
a Set the clearance (c) between the foot end face
of boom (13) and bracket (14) to 1 mm or less by
shimming.
Standard shim thickness: 2.0, 2.5, 3.0, 3.5 mm
q Bleeding air
See Testing and adjusting, Bleeding air from
each part.
New/redesign
Necessity
Sym-
Part number Part name
Sketch
bol
Q'ty
790-502-1003 Cylinder repair stand q 1
1
790-101-1102 Pump q 1
790-102-4300 Wrench assembly t 1
2
790-102-4310 Pin t 2
3 790-720-1000 Expander q 1
Rubber band
796-720-1670 q 1
(for boom and arm)
07281-01279 Clamp q 1
4
Rubber band
796-720-1660 q 1
(for bucket)
07281-01159 Clamp q 1 4) Disassemble the piston rod assembly as
790-201-1702 Push tool kit t 1 follows.
q Push tool 1] Place piston rod assembly (2) on tool U1.
790-201-1831 1
(for bucket)
q Push tool
790-201-1930 1
U 5 (For arm)
q Push tool
790-201-1940 1
(for boom)
790-101-5021 q Grip 1
01010-50816 q Bolt 1
Push tool kit (for
790-201-1500 q 1
bucket)
790-201-1640 q Push tool 1
790-101-5021 q Grip 1
01010-50816 q Bolt 1
6 Plate
790-201-1980 q 1
(for boom)
Plate
790-201-1990 q 1
(For arm)
790-101-5021 Grip q 1 2] Remove stopper screw (3) of piston
01010-50816 Bolt q 1
assembly.
a Common to the boom, arm and bucket
Disassembly 50-21 cylinder.
1. Piston rod assembly Screw size: M12 x pitch 1.75
1) Remove the piping from the cylinder
assembly.
2) Remove the mounting bolts and disconnect
cylinder head assembly (1).
3) Pull out piston rod assembly (2).
a Place an container under the cylinder to
receive the oil.
a If the caulking of screw (3) is too 7] Remove cap (8), and pull 12 balls (9),
strong and it cannot be removed, then remove plunger (10).
tighten the screw fully, then use tap q Arm cylinder only
(T) to the threads and remove the
screw.
5) Set plunger (10) on the piston rod, assemble 2] Tighten screw (3).
12 balls (9) to it and secure with cap (8). 2 Screw part female screw side:
a Check that there is a small amount of play Loctite No. 262
at the tip of the plunger. 3 Screw:
a Put a mark on the end face of the rod so 58.9 73.6 Nm {6 7.5 kgm}
that the processing hole position of cap 3] Caulk thread at 4 places (a) of screw (3)
(8) is visual from outside. with punch.
q Arm cylinder only
q When using piston rod assembly (2) a For the rod with bottom cushion, put a
and piston assembly (4) again mark to indicate the position of the cap
a Wash the parts thoroughly and remove all on the end surface of the rod. (See
the metal particles and dirt. step 3.5.)
1] Screw in piston assembly (4) by using tool q Arm cylinder only
U2, and tighten piston assembly (4) until 1] Screw in until piston assembly (4)
the position of the screw thread hole (H1) contacts end surface (B) of rod, then
which is in piston rod assembly (2) use tool to tighten.
halfway matches. 3 Piston assembly:
a Remove any burr on the threaded por- 294 29.4 Nm {30 3.0 kgm}
tion with a file. a After tightening the piston, check that
there is play in plunger (5).
q Boom, arm cylinder only
2] Make a threaded hole to install screw 8) Assemble the cylinder tube to piston rod
(3). assembly (2).
a With a drill aligned with the V groove a Align axial center of the cylinder tube,
where the threads of piston assembly then insert.
(4) and piston rod assembly (2) are a Check that the ring is not broken and has
mated, drill a hole straight. not come out, then push in fully.
a For the arm cylinder, avoid the cap
machining holes position when ma-
chining. (See step 3.5.)
q Screw machining dimension (mm)
10)Install piping.
6. Remove cover and duct assembly (7). 10. Remove duct (14).
20. Disconnect antenna cable (32) from KOMTRAX 26. Disconnect window washer hose (43).
communication module (K).
27. Disconnect harness clamp (44).
21. Disconnect connectors CK01(33) and CK02(34)
from KOMTRAX communication module (K). 28. Haul in antenna line (42).
32. Remove six mounting bolts (47) and four Installation 50-2 0
mounting nuts (48). q Perform installation in the reverse order to re-
a Check the bolt length beforehand. moval.
[*1]
3 Mounting bolt (44) of lock plate (45):
98 123 Nm {10 12.5 kgm}
[*2]
3 Bolt (44):
245 309 Nm {25 31.5 kgm}
a Among the panes of window glass on the four (1): Right side window glass
sides of the operator's cab, five panes (1) to (4) (2): Left side rear window glass
and (18) are adhered. (3): Door lower window glass
a In this section, the procedure for replacing the (4): Front window glass
adhered glasses is explained. (5): Front window assembly
a When replacing front window glass (4), remove (Front window glass and front frame)
front window assembly (5). (6): Dam rubber
(It is impossible to replace only the front window (17): Center trim seal
glass while the front window assembly is (18): Rear glass
installed to the operators cab.)
a For the procedure for replacing the front window
assembly, see Removal and installation of front
window assembly.
New/redesign
Necessity
remaining adhesive and dam rubber from the
Sketch
Sym-
Q'ty
Part number Part name sheet metal (adhesion surfaces) of the oper-
bol
ators cab.
a Remove the adhesive and dam rubber to a
2 793-498-1210 Lifter (Suction cup) t 2 degree that they will not affect adhesion of
X
3 20Y-54-13180 Stopper rubber t 2 the new adhesive. Take care not to scratch
the painted surfaces.
Removal 50-2 2 (If the painted surfaces are damaged, adhe-
a Remove the window glass to be replaced ac- sion will be lowered.)
cording to the following procedure.
1. Use seal cutter [1] to cut the adhesive between
broken window glass (7) and operator cab
(metal sheet) (8).
a Never apply the wrong primer. 4. Install dam rubber (double-faced tape)(6) along
If the glass primer, etc. is applied by the inside edge of the glass sticking section.
mistake, wipe it off with white gasoline. a Do not remove the release tape of dam rub-
ber on the glass sticking side before sticking
4) Evenly apply the glass primer to the adhe- the glass.
sion surfaces of window glass (9). a When installing the dam rubber, do not touch
2 Primer for glass: the cleaned surface.
SUNSTAR GLASS PRIMER 580 SU- a Care should be taken not to slacken the dam
PER rubber of each sticking corner.
a Do not apply the primer more than two
times.
(If it is applied more than two times, its
performance will be lowered.)
a When adhering dam rubber (6) goes around, 2) Stick dam rubber (6) for left side rear window
mind not to overlap dam rubber at the both glass (2) to the position as shown in the
ends. Or, provide a clearance of approxi- figure.
mately 5 mm at the mating portion (e).
1) Install dam rubber (6) for right side window
glass (1) to the position as shown in the
figure.
4) Stick dam rubber (6) for front window glass a Do not remove the tapes left on the win-
(4) to the position as shown in the figure. dow glass and the operator's cab before
installing the window glass.
a Apply adhesive (15) to dam rubber (6) of 7. Install the window glass.
operator's cab (8) in the (s) and (t) dimen- 1) Install window glass (9), with the alignment of
sions shown in the figure. the lines of the positioning tapes drawn in
q Dimension (s): 10 mm step 5.
q Dimension (t): 15 mm a Since the window glass cannot be re-
a Apply adhesive (15) thicker than dam rub- moved and adhered again, adhere it with
ber (6). utmost care.
a Apply the adhesive evenly with same a Adhere the glass within 5 minutes after
height level. applying the adhesive.
2) After adhering window glass (9), press all
around the glass until it adheres to the dam
rubber.
a Press the corners of the window glass
firmly.
a After installing front window glass (4) fill 8. Fix the window glass.
the clearances between it and center trim 1) After installing right window glass (1) to the
seal (16) with caulking material in range operator's cab, insert stopper rubbers X3 to 2
(s) with dimensions (t) and (u). places (v) at the bottom of the glass to fix the
After applying the primer to the part of glass.
window glass (4) shown in section A-A,
apply the adhesive as caulking material.
q Caulking dimension (t): 2 mm
q Caulking dimension (u): 5 mm
a When caulking, apply masking to the
glass side and form the adhesive with a
rubber spatula as shown in the figure.
a Wipe off the squeezed adhesive.
2 Primer for glass:
SUNSTAR GLASS PRIMER 580 SU-
PER
2 Adhesive:
SUNSTAR penguine seal 580 super
"S" or "W", or equivalent
Removal 50-231
1. Pull up the front window assembly over the
ceiling and fix it with the rear locks (on the right
and left sides).
Installation 50-23 3. Pull up the front window assembly and fix it with
q Perform installation in the reverse order to re- the rear locks (on the right and left).
moval. a Check that the locks in the rear of the opera-
tor's cab securely fasten.
[*1]
q Adjust opening and closing of the front window 4. Install right corner block (2).
assembly according to the following procedure. a Fully tighten the block after adjusting the
1. Open and close the front window to check that it "Close" position in the following step 6.
does not interfere with the rails and that the a Install right corner block (2) so that clearance
rollers are not caught. (a) between the rail and right corner block (2)
2. If there is any problem in opening and closing of becomes 0 to 2.0 mm.
the front window, loosen the mounting bolt of a Install right corner block (2) so that there is no
roller adjustment bracket (13) and adjust the level difference on rail surface (R) of the roll-
condition of the front window, and then tighten er.
the mounting bolt again.
a Make sure that bracket (13) is not slanted
when mounted.
3 Mounting bolt:
34.3 Nm {3.5 kgm}
5. Install left corner block (1). 2) Check the working condition of right and left
a Fully tighten the block after adjusting the locks (17) and (16) when opening and
"Close" position in the following step 6. closing the front window assembly.
a Install left corner block (1) so that clearance q If right and left locks (17) and (16) do not
(b) between the rail and left corner block (1) work normally;
becomes 0 to 2.0 mm. 1] Loosen lock fixing bolt (18), move lock
a Install left corner block (1) so that there is no (16) forward, and then tighten the bolt
level difference on rail surface (R) for the roll- again.
er. (See the figure above.) a The same applies to the right side.
2] After moving the lock, check the fitness of
the front window glass (14) and cab-side
trim seal (15) which is checked in step 1).
3] Repeat the work in 1] and 2] until the
fitness of the front window glass and the
working condition of locks (16) and (17)
are both acceptable, and then tighten the
mounting bolts of the right and left corner
blocks.
7. After the adjustment, splash water heavily over q When adjustment is necessary after the
the front window glass and check that the water above check
does not leak into the cab. 3) Close front window assembly (10).
4) Loosen locknut (20) of right and left side of
8. Adjust the "Open" position of the front window rubber stoppers (18), and then pull back both
assembly lock. rubber stoppers (18) so that they won't
1) After adjusting the "Close" position of the contact with the front window assembly when
front window assembly lock in steps 6 and 7, it is in "Open" position.
pull up the front window assembly to the
ceiling.
2) Set the front window assembly locks on the
both sides of rear of the operator's cab to the
Open" position, and then check the following
items.
q Check the working condition of right and
left locks (16) and (17) (as explained
above).
q Front window assembly must be in con-
tact with the right and left rubber stoppers
(18), and furthermore, must be pushing
them backward by 1.5 to 3.0 mm.
q The front window assembly must be
pushing the limit switch (19) backward by 5) Loosen both sides of locknuts (22), and
4 to 7 mm. adjust the position of striker bolts (21).
a The position of limit switch (19) cannot be a Striker bolt (21): M10, inner diameter of
adjusted. Therefore, the "Open" position plate (23): f14.5 mm
of the front window assembly is set within
the range where this switch works.
a The limit switch (19) prevents wiper oper-
ation if the wiper switch is accidentally
turned on when the front window assem-
bly is in "Open" position. If the wiper is op-
erated when the front glass is missing,
the wiper will fall inside the cab and may
fail.
To check whether limit switch (19) is
working, turn the key switch on and see
that, even if the wiper switch is turned on,
the wiper does not operate when the front
window assembly is in "Open" position.
1] The front window assembly (10) (in 2] Close front window assembly (10).
"Open" position) must be pushing the limit 3] Turn right and left rubber stoppers (18) to
switch (19) backward by 4 to 7 mm. the left one and a half rotation.
2] Working condition of lock (17). a One turn of rubber stopper (18) to the
left is equivalent to squashing the rub-
ber for approximately 1.5 mm.
a When the front window assembly is in
"Open" position, the front window as-
sembly must be pushing right and left
rubber stoppers (18) by 1.5 to 3.0 mm.
13. Disconnect connector P17 (14) from the air 18. Remove mounting bolt (19) and disconnect air
conditioner tube. conditioner tubes (20). [*1]
14. Remove the clamp and spacer (15). 19. Remove clamps (21) and (22). [*2]
23. Disconnect connectors N10 (27) and AC01 (28). 30. Disconnect the clamp of wiring harness (35).
24. Disconnect connectors ECU10 and ECU11 (29) 31. Move plates (36) and (37) together with wiring
from the air conditioner controller (ACCONT). harness (35) to the boom side.
33. Disconnect clamp (39). 36. Sling and remove floor frame assembly (42).
a Check that the hoses, connectors, clamps,
34. Disconnect PPC hose (40) of the work equip- and so on are disconnected without fail.
ment. 4 Floor frame assembly:
From the top, the color of the band is: 250 kg
White
Brown
None
Blue
Black
Green
Red
Yellow
a Prepare an oil sump.
Installation 50-242
q Perform installation in the reverse order to re-
moval.
[*1]
a When installing the air conditioner hose, take
care so that dust, dirt or water does not enter the
hose.
a Make sure before the installation that there is
O-ring at the piping connector of the air condi-
tioner hose.
a Check that there is no defect or deterioration on
the O-ring.
a When connecting the refrigerant piping, coat the
O-ring with compressor oil for new refrigerant
(R134a) (Denso: ND-OIL8, VALEO THERMAL
SYSTEMS: ZXL100PGZXL100PG (PAG 46 or
equivalent)).
3 Mounting bolt:
8 12 Nm {0.8 1.2 kgm}
[*2]
a Make sure that the hoses do not lap over.
q Refilling of coolant
Supply coolant through the coolant filler port to
the specified level. Run the engine to circulate
the coolant through the system. Then, check the
coolant level again.
5 Coolant:
17.3 l
Removal 50-243 8. Pull down opening and closing lever (8) of the
k Disconnect the cable from the negative (-) fresh air filter cover.
terminal of the battery.
k If you drain the coolant or disconnect the 9. Remove fresh air filter (9).
heater hose when the coolant temperature in
the radiator is high, you may be scalded. In
this case, wait until the coolant temperature
lowers and then disconnect the heater hose.
13. Remove plate (16). 18. Disconnect connectors N10 (27) and AC01 (28).
14. Remove lock pin (17) and remove duct (18). 19. Disconnect connectors ECU10 and ECU11 (29)
from the air conditioner controller (ACCONT).
22. Remove mounting bolt (33) and air conditioner Installation 50-245
tubes (34). [*1] q Perform installation in the reverse order to re-
moval.
23. Disconnect heater hoses (35).
a Check the connecting point. [*1]
a When installing the air conditioner hose, take
care so that dust, dirt or water does not enter the
hose.
a Make sure before the installation that there is
O-ring at the piping connector of the air condi-
tioner hose.
a Check that there is no defect or deterioration on
the O-ring.
a When connecting the refrigerant piping, coat the
O-ring with compressor oil for new refrigerant
(R134a) (Denso: ND-OIL8, VALEO THERMAL
SYSTEMS: ZXL100PGZXL100PG (PAG 46 or
equivalent)).
3 Mounting bolt:
24. Remove the seven mounting bolts and remove 8 12 Nm {0.8 1.2 kgm}
air conditioner unit assembly (36).
q Refilling with refrigerant
Refill the air conditioner circuit with refrigerant
(R134a).
a Quantity of refrigerant: 870 50 g
q Refilling of coolant
Supply coolant through the coolant filler port to
the specified level. Run the engine to circulate
the coolant through the system. Then, check the
coolant level again.
5 Coolant:
17.3 l
Removal 50-246
k Disconnect the cable from the negative (-)
terminal of the battery.
Installation 50-247
q Perform installation in the reverse order to re-
moval.
[*1]
q Check that there is no sand, dust or water inside
the controller connecter (especially on the bot-
tom). If any of them is found, completely remove
them using a blower, etc. (Sand, dust or water
may cause defective contact in connectors or
defects by entering water.)
a Reference
q Method of replacing the O-ring seal of power
supply connector (4).
O-ring seal: 1010-074-0406 (NIHON-DEUTSCH
Ltd.) or equivalent
a Reference
1. Procedure for removing connector cover (1)
1) Cut and remove cable tie (2).
2) Move lever (3) up.
k Park the machine on a level place, lower the a Disconnect the body and control part of
work equipment to the ground completely, swing emergency stop switch (8) as follows.
and stop the engine. 1] While pressing right and left tabs (A) up,
k Disconnect the cable from the negative (-) pull lock part (B) toward the harness.
terminal of the battery. 2] Turn lock part (B) 45 deg. in the direction
of arrow (a).
1. Remove cover (1) according to the following
procedure.
1) Remove cap (2) and bolt.
2) Remove mounting bolts (3) and (4).
3) Remove cover (1).
4) While removing, disconnect connector P31
(5) of the sunlight sensor.
HYDRAULIC EXCAVATOR
HB205-1
HB215LC-1
Contents 60-2
60 Maintenance standard
Engine and cooling system ..................................................................................................... 60- 4 4
Engine mount....................................................................................................................... 60- 4 4
Cooling system .................................................................................................................... 60- 5 5
Power train .............................................................................................................................. 60- 7 7
Swing circle.......................................................................................................................... 60- 7 7
Swing machinery.................................................................................................................. 60- 8 8
Swing brake ......................................................................................................................... 60- 10 10
Final drive ............................................................................................................................ 60- 12 12
Sprocket............................................................................................................................... 60- 14 14
Undercarriage and frame ........................................................................................................ 60- 16 16
Track frame and idler cushion.............................................................................................. 60- 16 16
Idler ...................................................................................................................................... 60- 18 18
Track roller ........................................................................................................................... 60- 20 20
Carrier roller ......................................................................................................................... 60- 21 21
Track shoe ........................................................................................................................... 60- 22 22
Hydraulic system..................................................................................................................... 60- 28 28
Main pump ........................................................................................................................... 60- 28 28
Control valve ........................................................................................................................ 60- 32 32
Travel motor......................................................................................................................... 60- 41 41
PPC valve ............................................................................................................................ 60- 44 44
Solenoid valve...................................................................................................................... 60- 54 54
Attachment circuit selector valve ......................................................................................... 60- 55 55
Center swivel joint................................................................................................................ 60- 56 56
Work equipment...................................................................................................................... 60- 58 58
Work equipment................................................................................................................... 60- 58 58
Dimension of work equipment.............................................................................................. 60- 60 60
Work equipment cylinder ..................................................................................................... 60- 64 64
Engine mount 4
Cooling system 5
Power train 7
Swing circle 7
Unit: mm
No. Item Criteria Remedy
Standard clearance Allowable clearance
Axial clearance of bearing
1 (when installed on machine) Replace
0.5 1.6 3.2
Swing machinery 8
Unit: mm
No. Item Criteria Remedy
Standard clearance Allowable clearance
Backlash between No. 2 planetary
1 gear and No. 2 ring gear 0.18 0.59 1.10
Backlash between No. 2 planetary
2 carrier and No. 3 sun gear
0.39 0.71 1.20
Backlash between No. 3 planetary
3 gear and No. 2 ring gear
0.18 0.59 1.00
Replace
Backlash between No. 3 sun gear
4 and No. 3 planetary gear
0.16 0.50 0.90
Backlash between swing pinion
5 and No. 3 planetary carrier
0.07 0.23
Backlash between swing pinion
6 and swing circle
0.22 1.32 2.00
Standard dimension Repair limit Apply hard
Wear of swing pinion surface
7 chrome plating or
contacting with oil seal f125 (0/0.100) replace
Standard clearance Allowable clearance
Clearance between No. 3 sun
8 gear and plate 1.66 2.94
Replace
Clearance between plate and
9 No. 3 planetary carrier
0.66 1.14
Swing brake 10
Unit: mm
No. Item Criteria Remedy
Standard clearance Allowable clearance Replace
Backlash between swing motor
1 shaft and No. 1 sun gear 0.07 0.18
Backlash between No. 1 sun gear
2 and No.1 planetary gear
0.12 0.31 0.80
Backlash between No. 1 planetary
3 gear and ring gear
0.14 0.43 0.90
Backlash between No. 1 planetary
4 carrier and No. 2 sun gear
0.07 0.21
Backlash between No. 2 sun gear
5 and No. 2 planetary gear
0.16 0.50 1.00
Final drive 12
Unit: mm
No. Item Criteria Remedy
Standard clearance Allowable clearance
Backlash between No. 2 sun gear
1 and No. 2 planetary gear 0.13 0.47 1.00
Backlash between No. 1 planetary
2 gear and gear hub
0.17 0.57 1.10
Backlash between No. 2 planetary
3 carrier and motor
0.06 0.25
Replace
Backlash between No. 1 sun gear
4 and No. 1 planetary gear
0.14 0.46 1.00
Backlash between No. 2 planetary
5 gear and gear hub
0.16 0.56 1.10
Backlash between No. 1 planetary
6 carrier and No. 2 sun gear
0.38 0.66 1.00
Sprocket 14
Unit: mm
No. Item Criteria Remedy
Standard dimension Repair limit
1 Wear of tooth tip
294.5 282.5
Build-up welding
2 Thickness of tooth root 17 11 for rebuilding or
replace
3 Width of tooth 71 68
Repair limit: 6
4 Wear of tooth shape
(use a full-size drawing of sprocket tooth shape to judge)
Unit: mm
No. Item Criteria Remedy
Standard
Tolerance Repair limit
dimension
Vertical width of +3
1 Track frame 107 111
idler guide 1
Build-up welding
Idler support 105 0.5 103 for rebuilding or
replace
+4
Track frame 250 1 255
Horizontal width of
2 idler guide
Idler support 247.4 245.4
Standard dimension Repair limit
Free length
x Outside Installed Installed Free length Installed
length load load
diameter
3 Recoil spring Replace
109.3 kN 87.4 kN
HB205-1 558 x 238 417 531.4
{11,150 kg} {8,920 kg}
HB215LC-1 561.4 x 237 433 126.5 kN 534 101 kN
{12,900 kg} {10,300 kg}
Idler 18
Unit: mm
No. Item Criteria Remedy
Standard dimension Repair limit
1 Outside diameter of protrusion
538
Track roller 20
Unit: mm
No. Item Criteria Remedy
Standard dimension Repair limit
1 Outside diameter of flange
188
Carrier roller 21
Unit: mm
No. Item Criteria Remedy
Standard dimension Repair limit
1 Outside diameter of flange
145
3 Width of tread 43
4 Thickness of tread 23 16
5 Width of flange 14
Tolerance Replace
Standard Standard Allowable
Clearance between shaft and dimension Shaft Hole clearance clearance
6 bushing
40 0.170 +0.301 0.338
0.190 +0.168 0.491
Standard Tolerance Standard Allowable
Interference between roller and dimension Shaft Hole interference interference
7 bushing +0.061 0 0.016
47
+0.016 0.040 0.101
Standard clearance Allowable clearance
8 End play in axial direction
0.44 0.76
Track shoe 2
Unit: mm
No. Item Criteria Remedy
Standard dimension Repair limit
1 Link pitch
190.3 193.3
Standard dimension Reverse
Reverse or replace
2 Outside diameter of bushing
59.3 54.3
6 160.4
8 62
Inside
9 width
84.8
Overall
10 Link width
45.4
Tread
11 width
39.6
Regular 2.5
12 Protrusion of pin
Master 2.5 Adjust or replace
Regular 4.85
13 Protrusion of bushing
Master 0.0
Regular 212
14 Overall length of pin
Master 212
Regular 138.5
15 Overall
bushing
length of
Master 128.7
16 Thickness of spacer
Unit: mm
No. Item Criteria Remedy
Tightening torque Retightening angle
(Nm {kgm}) (deg.)
a. Regular Triple grouser 490 49 120 10
link shoe {50 5}
Road liner 549 59
20 Shoe bolt (Rubber pad type) {56 6}
Retighten
Tightening torque Retightening angle Lower limit torque
b. Master (Nm {kgm}) (deg.) (Nm {kgm})
link
Standard Tolerance Standard
dimension interference
21 Interference
link
between bushing and Shaft Hole
+0.434 +0.074
59 0.320 0.434
+0.394 0
22 Interference
and link
between regular pin
38
+0.222
+0.162
0.138
0.200
0.300 0.422
Standard Tolerance Standard
dimension clearance
23 Clearance between regular pin
and bushing
Shaft Hole
+0.222 +0.902
38 0.180 0.740 Adjust or replace
+0.162 +0.402
Standard Tolerance Standard
24 Interference between master pin dimension Shaft Hole interference
(*) and link +0.280 +0.062
37.8 0.188 0.280
+0.250 0
Standard Tolerance Standard
25 Clearance between master pin dimension Shaft Hole clearance
(*) and bushing 0.150 +0.902
38 0.552 1.252
0.350 +0.402
* Dry type track link
Swamp shoe
Road liner
Unit: mm
No. Item Criteria Remedy
Standard dimension Repair limit
1 Height
26 16
10
2 Thickness
(*) 8.5
3 Length of base 26
4 Length of base 19
5 Length at tip 20
Build-up welding
or replace
6 Length at tip 14
7 Length at tip 19
Standard dimension Repair limit
36 26
8 Thickness
(*) 34.5 24.5
10 Thickness 17 5
11 Height 70 Replace
Hydraulic system 28
Main pump 28
Type: HPV95+95
LS (PC)-EPC valve
Control valve 32
General view
(If equipped with one attachment)
Sectional view
(1/5)
Unit: mm
No. Check item Criteria Remedy
Standard dimension Repair limit
Free length
Installed Installation Installation
x Outside Free length
1 Spool return spring
diameter
length load load
(2/5)
Unit: mm
No. Check item Criteria Remedy
Standard dimension Repair limit
Free length
Installed Installation Installation
x Outside Free length
1 Suction valve spring
diameter
length load load If damaged or
deformed, replace
46.8 x 7.5 40.6 5.5 N 4.4 N spring.
{0.56 kg} {0.45 kg}
1.5 N 1.2 N
2 Check valve spring 11.5 x 4.6 8.5
{0.15 kg}
{0.12 kg}
(3/5)
Unit: mm
No. Check item Criteria Remedy
Standard dimension Repair limit
Free length
Installed Installation Installation
x Outside Free length
1 Check valve return spring
diameter
length load load
(4/5)
Unit: mm
No. Check item Criteria Remedy
Standard dimension Repair limit
Free length
Installed Installation Installation
x Outside Free length
1 Spool return spring
diameter
length load load
(5/5)
Travel motor 41
Type: HMV110ADT-2
Unit: mm
No. Check item Criteria Remedy
Free length
Installed Installation Installation
x Outside Free length
length load load
1 Check valve spring diameter
7.16 N 5.69 N
32.5 6.5 24.2
{0.73 kg} {0.58 kg} If damaged or
1.96 N 1.57 N deformed, replace
2 Check valve spring 13.0 6.5 9.5
{0.2 kg}
{0.16 kg} spring
427 N 341 N
3 Spool return spring 58.4 30 42
{43.5 kg}
{34.8 kg}
54.9 N 43.9 N
4 Regulator valve spring 21.5 11.1 17.1
{5.6 kg}
{4.48 kg}
PPC valve 4
Unit: mm
No. Check item Criteria Remedy
Standard dimension Repair limit
Free length
Installed Installation Installation
Centering spring x Outside Free length
1 (for ports P3 and P4) diameter
length load load
If damaged or
42.5 15.5 34.0 17.7 N 14.1 N deformed, replace
{1.80 kg} {1.44 kg}
spring
Centering spring 29.4 N 23.5 N
2 (for ports P1 and P2)
44.5 15.5 34.0
{3.0 kg}
{2.40 kg}
16.7 N 13.3 N
3 Metering spring 26.5 8.15 24.9
{1.70 kg}
{1.36 kg}
Unit: mm
No. Check item Criteria Remedy
Standard dimension Repair limit
Free length
Installed Installation Installation
x Outside Free length
1 Centering spring
diameter
length load load
If damaged or
48.6 15.5 32.5 108 N 86.3 N deformed, replace
{11.0 kg} {8.8 kg}
spring
16.7 N 13.3 N
2 Metering spring 26.5 8.15 24.9
{1.7 kg}
{1.36 kg}
8.83 N 7.06 N
3 Steering signal spring 12.8 7.3 8.5
{0.9 kg}
{0.72 kg}
Unit: mm
No. Check item Criteria Remedy
Standard dimension Repair limit
Free length
Installation Installation Installation
x Outside Free length
1 Centering spring
diameter
length load load If damaged or
deformed, replace
33.9 x 15.3 28.4 125 N 100 N spring.
{12.7 kg} {10.2 kg}
16.7 N 13.3 N
2 Metering spring 22.7 x 8.10 22.0
{1.70 kg}
{1.36 kg}
EPC valve
Unit: mm
No. Check item Criteria Remedy
Standard dimension Repair limit
If damaged or
Installation Installation Installation
Free length Free length deformed, replace
1 Return spring length load load
EPC valve
3.1 N assembly.
9.0 8.4
{0.32 kg}
Unit: mm
No. Check item Criteria Remedy
Standard dimension Repair limit
Free length
Installation Installation Installation
x Outside Free length
1 Centering spring
diameter
length load load If damaged or
deformed, replace
33.9 x 15.3 28.4 125 N 100 N spring.
{12.7 kg} {10.2 kg}
16.7 N 13.3 N
2 Metering spring 22.7 x 8.10 22.0
{1.70 kg}
{1.36 kg}
Solenoid valve 54
For PPC lock, travel junction, travel speed, swing brake, and 2-stage relief solenoid valves
Unit: mm
No. Check item Criteria Remedy
Standard dimension Repair limit
Free length
Installation Installation Installation If damaged or
x Outside Free length
1 Spool return spring diameter length load load deformed, replace
spring.
834 N 667 N
132 x 29 114.5 {85.0 kg} {68.0 kg}
Unit: mm
No. Item Criteria Remedy
Standard dimension Standard clearance Allowable clearance
Clearance between rotor and
1 shaft
Replace
80
Work equipment 58
Work equipment 58
Unit: mm
No. Item Criteria Remedy
Standard Tolerance Standard Allowable
Clearance between pin connecting dimension clearance clearance
Shaft Hole
1 "boom and revolving frame" and
bushing 0.036 +0.135 0.110
90 1.0
0.071 +0.074 0.206
Clearance between pin connecting 0.036 +0.137 0.113
2 "boom and arm" and bushing
90
0.071 +0.077 0.208
1.0
Clearance between pin connecting 0.030 +0.158 0.108 Replace
3 "arm and link" and bushing
70
0.076 +0.078 0.234
1.0
Clearance between pin connecting 0.030 +0.137 0.104
4 "arm and bucket" and bushing
80
0.076 +0.074 0.213
1.0
Clearance between pin connecting 0.030 +0.166 0.116
5 "link and bucket" and bushing
80
0.076 +0.086 0.242
1.0
Clearance between pin connecting 0.030 +0.154 0.104
6 links and bushing
70
0.076 +0.074 0.230
1.0
Arm
Unit: mm
HB205-1, HB215LC-1
No.
Standard dimension Tolerance
+0.1
1 f80
0
+1.5
2 109.3
0
0
3 305.5
0.5
+0.054
4 f90
0
5 402.1 1
6 187.2 0.5
7 829.1 1
8 2,919
9 2,630.5 1
10 410 1
11 640 0.2
12 600 0.5
13 458.1
14 1,486
+0.1
15 f80
0
16 325 0.5
+0.1
17 f80
0
0
Arm boss (without bushing) 311
0.5
18
When press-fitting bushing
325
(with bushing)
Min. 1,680
19
Max. 2,800
Bucket
Unit: mm
HB205-1, HB215LC-1
No.
Standard dimension Tolerance
1 457.6 0.5
2 22 0.5
3 9245'
4 458.1
5 1,477.3
6 158.6
8 1554'
+0.1
9 f80
0
10 326.5 1
11 56
12 106
13 470
14 f23.5
15 f140
16 f190
17 133.2
18 131.6
19 107
20 85
+2
21 348.5
0
22 38
Boom cylinder
Arm cylinder
Bucket cylinder
Unit: mm
No. Item Criteria Remedy
Standard Tolerance Standard Allowable
Cylinder
dimension Shaft Hole clearance clearance
0.036 +0.222 0.083
Boom 85 0.412
Clearance between 0.090 +0.047 0.312
1 piston rod and bushing
Replace bushing
0.036 +0.222 0.083
Arm 95 0.412
0.090 +0.047 0.312
0.030 +0.222 0.077
Bucket 80 0.398
0.076 +0.047 0.298
0.030 +0.190 0.100
Boom 80 1.0
0.060 +0.070 0.250
Clearance between
0.030 +0.190 0.100
2 piston rod support Arm 80
0.076 +0.070 0.266
1.0
shaft and bushing
0.030 +0.170 0.100
Bucket 70 1.0
0.076 +0.070 0.246 Replace pin or
0.030 +0.165 0.075 bushing
Boom 70 1.0
Clearance between 0.060 +0.045 0.225
cylinder bottom 0.030 +0.190 0.100
3 support shaft and
Arm 80
0.076 +0.070 0.266
1.0
bushing 0.030 +0.165 0.075
Bucket 70 1.0
0.060 +0.045 0.225
HB205-1
HYDRAULIC EXCAVATOR
Shop Manual 8-01
HB205-1
HB215LC-1
80 Appendix 80-1
Contents 80-2
80 Appendix
Air conditioner ......................................................................................................................... 80- 3
Precautions for refrigerant ................................................................................................... 80- 3
Air conditioner component ................................................................................................... 80- 4
Configuration and function of refrigeration cycle.................................................................. 80- 6
Outline of refrigeration cycle ................................................................................................ 80- 7
Air conditioner unit ............................................................................................................... 80- 10
Air conditioner controller ...................................................................................................... 80- 15
Compressor ......................................................................................................................... 80- 16
Condenser and Modulator ................................................................................................... 80- 17
Procedure for testing and troubleshooting ........................................................................... 80- 18
Circuit diagram and arrangement of connector pins ............................................................ 80- 20
System diagram ................................................................................................................... 80- 22
Detail of air conditioner unit ................................................................................................. 80- 24
Parts and connectors layout ................................................................................................ 80- 26
Testing air leakage (duct) .................................................................................................... 80- 30
Testing with self-diagnosis function ..................................................................................... 80- 31
Testing temperature control ................................................................................................. 80- 34
Testing vent (mode) changeover ......................................................................................... 80- 36
Testing FRESH/RECIRC air changeover ............................................................................ 80- 39
Testing inner sensor ............................................................................................................ 80- 41
Testing evaporator temperature sensor............................................................................... 80- 42
Testing sunlight sensor ........................................................................................................ 80- 44
Testing (dual) pressure switch for refrigerant ...................................................................... 80- 45
Testing relays....................................................................................................................... 80- 47
Troubleshooting chart 1 ....................................................................................................... 80- 48
Troubleshooting chart 2 ....................................................................................................... 80- 50
Information in troubleshooting table..................................................................................... 80- 52
Troubleshooting for power supply and CAN communication system (Air conditioner does not operate)
............................................................................................................................................. 80- 53
Troubleshooting for compressor and refrigerant system (Air is not cooled) ........................ 80- 57
Troubleshooting for blower motor system (No air comes out or air flow is abnormal) ......... 80- 60
Troubleshooting for temperature control.............................................................................. 80- 63
Troubleshooting for vent (mode) changeover ...................................................................... 80- 66
Troubleshooting for FRESH/RECIRC air changeover ......................................................... 80- 68
Troubleshooting for temperature sensor system ................................................................. 80- 70
Troubleshooting with gauge pressure.................................................................................. 80- 71
Connection of service tool.................................................................................................... 80- 74
Precautions for disconnecting and connecting air conditioner piping .................................. 80- 76
Handling of compressor oil .................................................................................................. 80- 78
Desiccant replacement procedure ....................................................................................... 80- 80
Over-cooling (Freezing) prevention 80-1 a 5 A fuse for the air conditioner unit is attached to
q The resistance of the evaporator temperature the wiring harness.
sensor (12) changes in response to tempera- a The door is the same as the damper.
ture.
q The air conditioner controller detects the temper-
ature of the evaporator (1) by converting the
changes in the resistance of the evaporator tem-
perature sensor (12) into voltage changes.
q The air conditioner controller performs control to
prevent freezing of the evaporator (1) by operat-
ing the compressor clutch relay (*) to stop the
compressor.
*: See "Parts and connectors layout" for details re-
garding the compressor clutch relay.
Functions of major components 80-12 q When the potential difference fails to reach a
Evaporator 80-12 predefined voltage for control of the servomotor,
q Evaporator (1) is cooled by the low-pressure, the air conditioner controller notifies the machine
low-temperature refrigerant gas being sent from monitor of an abnormality. "A/C Controller Error"
expansion valve (3). Air from blower motor (4) is is displayed in red on the air conditioner opera-
cooled and dehumidified when passing through tion screen of machine monitor.
the evaporator fins. a FRESH/RECIRC air changeover servo motor
does not feature a variable resistance, and
Heater core 80-12 therefore, does not have a self-diagnosis
q Heater core (2) is warmed by the hot water (en- function.
gine coolant) being sent from the engine. Air a When attempting to operate a servomotor during
from blower motor (4) is warmed when passing inspecting, do not supply power directly between
through the heater core fins. servomotor terminals (6) and (7).
Servomotors 80-12
Compressor 80-16
Specifications 80-16
Number of cylinder Bore x
Stroke 10 - 32 x 20.8
(mm)
Piston capacity
157.3
(cc/rev)
Allowable maximum speed
6,000
(rpm)
Denso: ND-OIL8 (For
Compressor oil
R134a)
Compressor oil refill capacity
180
(cc)
The air conditioner is provided with self-diagnosis functionality in order to provide for inspection of its main
components. Specifically, the operation of sensors and servomotors can be examined.
If a troubled section is detected, every part of that section must be inspected.
1. After basic check, find the troubled section according to the detected trouble of the air conditioner.
2. Narrow down the sections with the self-diagnosis function (See Check with self-diagnosis).
If, however, the entire air conditioner unit fails to operate, inspect for problems with the supply of power to
the air conditioner controller and with CAN communication between the machine monitor and the air condi-
tioner controller.
If any part of the air conditioner unit can operate, it will indicate that the air conditioner controller is
receiving power normally and that CAN communication between the machine monitor and the air condi-
tioner controller is normal.
3. After finding out the troubled section, inspect the component parts in that section and repair the troubled
part.
*1: By error display or abnormal display on "Abnormality Record" screen on machine monitor.
*2: Simple checking of refrigerant volume through sight glass.
Start up the engine, set the air conditioner switch to ON, and then wait for five minutes before proceeding
with the inspection.
A) If the continuous stream of bubbles can be seen, the system contains insufficient refrigerant.
B) If the bubbles can be seen intermittently, the refrigerant volume is sufficient.
C) If no bubbles can be seen (i.e., the liquid is perfectly clear), the system contains too much refrigerant
or no refrigerant at all.
The above should be treated as general guidelines as certain exceptions do exist.
See "Troubleshooting with gauge pressure" and use gauge pressure to determine whether or not the
condition is normal.
*3: If any leakage of refrigerant is occurring, the compressor oil circulating within the air conditioner circuit will
definitely be leaking from the same point.
In such a case, retighten in accordance with the table of retightening torques from "Precautions for discon-
necting and connecting air conditioner piping."
*4: Start the engine and perform the check with the air conditioner switch set to ON.
a BLOW OUT (MODE) SERVOMOTOR means BLOW OUT (MODE) CHANGEOVER SERVOMOTOR.
Input/output signals of the air conditioner con- q Operation of air conditioner controller
troller (CNT) 80-23 1. Performing CAN communication with the
Controller side connector: AMP 040 - 36PM machine monitor, the air conditioner controller
Harness side connectors: [1], [2] controls the air conditioner unit by inputting
[1] AMP040 - 16PF switches associated with air conditioning.
Pin Input/o 2. The air conditioner controller controls three
Symbol Signal name servomotors located inside the air conditioner
No. utput
1 unit in order to adjust the temperature (airmix),
A/M servo potentiometer volt- perform vent (mode) changeover, and perform
2 A/MP Input
age FRESH/RECIRC air changeover.
Servo potentiometer 5 V 3. The air conditioner controller controls the
3 POT 5 V Output
power supply ON/OFF condition of the blower main relay (i.e.,
PRESS (Dual) pressure switch
4 Input a switch for blowing air) and of the compressor
SW (Refrigerant pressure)
5 clutch relay (i.e., a switch for activating the
6 +24 V Power supply Input compressor).
7 BLOW F/B Blower feedback signal Input 4. The air conditioner controller controls the air flow
Power transistor control sig- volume using the power transistor.
8 PTR B Output
nal a The power transistor has an overcurrent pre-
Blow out (mode) servo poten- vention fuse in it.
9 MODE P Input
tiometer voltage 5. The air conditioner controller detects the evapo-
10
11 THI Inside air temperature sensor Input
rator temperature using the evaporator tempera-
Evaporator temperature sen- ture sensor.
12 THEVA Input 6. In order to prevent freezing of the evaporator,
sor
13 the air conditioner controller controls the
14 compressor by turning the compressor clutch
15 SS Sunlight sensor Input relay ON and OFF.
16 GND GND Input a When the dual pressure switch detects a
[2]AMP040 - 20PF pressure abnormality (i.e., turns OFF), the air
Pin Input/o conditioner controller turns the compressor
Symbol Signal name clutch relay OFF, and therefore, the com-
No. utput
Input/ pressor stops operating.
17 CAN (+) CAN communication +
output 7. When performing automatic air conditioning, the
Input/ air conditioner controller controls the inside air
18 CAN (-) CAN communication -
output temperature to the set temperature based on
Fresh/Recirculated air servo data from the sunlight sensor and the inner
19 F/RA Output
terminal A sensor (inside air temperature sensor).
Fresh/Recirculated air servo
20 F/RB Output 8. The air conditioner controller has the self-diag-
terminal B
21 A/MA A/M servo terminal A Output nosis function. If any abnormality is detected, the
22 A/MB A/M servo terminal B Output control amplifier notifies it to the machine
Blow out (mode) servo termi- monitor by the CAN communication. Then, the
23 MODE A Output
nal A letters of "A/C Controller Error" are displayed in
Blow out (mode) servo termi- red on the air conditioner operation screen of the
24 MODE B Output
nal B machine monitor.
25
26
27 GND S Sensor GND Input
28
29
30
31
32
33
34
35 CCRL Compressor clutch relay Output
36 BLOW RL Blower main relay Output
q A/M: Air mix
q F/B: Feedback
q F/R: Fresh/Recirculated air
q Evaporator
Temperature sensor installation position
a Fu5A is installed inside the holder. a Bottom of the air conditioner unit
Part No. of fuse [4]: Power transistor (PTR) connector
Fu5A: ND93950-05003 [7]: FRESH/RECIRC air changeover servo-
motor (R/FS) connector
[8]: Inner sensor (inside air temperature
sensor) connector
H: Air conditioner unit wiring harness
PTR: Power transistor
q Reference
Remove cover (4) as described below. [*1]
1] Insert a flat-head screwdriver into the slit
(SL) and lift it up.
2] Release lock (L) and remove cover (4).
8. Rear duct
Check ducts (12) and (13) for disconnection.
7. Foot duct
a Duct to under operator seat
1) Check duct (11) for disconnection.
2) Check the seal between duct (11) and cover
(11-1).
3) Remove duct (11) and cover (11-1).
4) Check that packing (A) is attached.
(See figure bottom)
2. Setting : Abnormal
The air conditioner controller software and the
monitor software are not compatible. Confirm
the part number of each.
a Plate (P1) and lever 1 (L1) to lever 4 (L4) are not q When lever 5 (L5) and lever 6 (L6) do not move
seen from outside. smoothly between the points shown in the figure:
1) Disconnect connectors (5) and [6] of the
servomotor.
2) Apply a match mark to the servomotors (5)
and (6) to identify later on which side they
were attached. (It might be required later to
install servomotors (5) and (6) after swapping
their mutual positions.)
3) Remove servo motors (5) and (6).
q MODES: Vent (mode) servomotor
q A/MS: Temperature control (air mix) ser-
vomotor
4) Remove cover (7).
Outline 80-36
The vent (mode) is selected by changing the angles
of the four doors (dampers) provided inside. The
servomotor changes the angles of the doors (damp-
ers) through plate (P2), rod for differential (RODD),
rod for front face (RODF) and lever 7 (L7) to lever 12
(L12). Rod for differential (RODD), rod for front face
(RODF), and levers 7 (L7) and 8 (L8) alone are seen
from outside. (See Item 5 for the figure.) Visually
check the opening and closing operation of the front
face and rear face doors (dampers) and the position
of these levers.
The servo motor changes the angle of the rear face
door (damper) through lever (13) and rod (RODR).
Lever (L11) of the front face, lever (13) of the rear
face and rod (RODR) are not seen from outside. Ac-
cordingly, remove the duct and check the rotation of
the door (damper) directly.
a To reset the self-diagnosis system (to clear the
"A/C Controller Error" displayed on the air condi-
tioner screen of the machine monitor), the start-
ing switch must be turned OFF (While "A/C
Controller Error" is displayed with self-diagnosis
system, no signals are output to the servomo-
tor).
Reference
q How to remove fresh air duct.
1. Remove plate (6). (See the previous figure)
Connection 80-43
1. Install the evaporator temperature sensor to the
position shown in the previous figure with the
holder.
2. Carry out the following installation in the reverse
order to removal.
2. During cooling, the blower fan motor is normal but the flow of air is very light.
Probable cause Check method Remedy
Large duct resistance Check the filter for clogging and the duct for crushing. Repair
Check duct joints.
Air leakage through duct joints Repair
See "Testing air leakage (duct)".
Remove obstruc-
Obstruction at evaporator inlet Check evaporator for stain and obstruction
tion and clean
Evaporator is frozen.
Defective evaporator tempera-
Sensor fixing clip inspection, sensor contaminated
ture sensor, defective contact of
Inspect the air conditioner hose around the pressure switch for Repair or replace
evaporator temperature sensor,
frost.
defective expansion valve*
(when freezing has advanced even further)
*: The evaporator temperature sensor and expansion valve are located inside the air conditioner unit.
5. During heating, blower fan motor is normal but air flow alone is insufficient.
Probable cause Check method Remedy
Large duct resistance Check the filter for clogging and the duct for crushing. Repair
Check the duct joints by referring to "Testing air leakage
Air leakage through duct joints Repair
(duct)."
Clogging of heater core fins Check heater core fins for clogging Clean
8. Other abnormalities
Probable cause Check method Remarks
Temperature cannot be con- See "Testing temperature control" and "Troubleshooting for
trolled temperature control"
Vent (mode) changeover is not "Testing vent (mode) changeover" Common to cooling and
possible. See "Troubleshooting vent (mode) changeover." heating
FRESH/RECIRC air cannot be See "Testing FRESH/RECIRC air changeover" and "Trouble-
changed over shooting for FRESH/RECIRC air changeover"
Excessive compressor oil See "Handling compressor oil".
Cooling only
Water leakage into the cab Clogging of drain hole
Circuit diagram related to compressor and pressure switch for refrigerant 80-59
Troubleshooting for blower motor system (No air comes out or air flow
is abnormal) 80-60
Failure No air comes out or air flow is abnormal due to blower motor system failure.
q LCD of machine monitor on air conditioner operation screen lights up normally but air does not come
Problem on
out.
machine
q Air flow does not match fan switch setting on air conditioner operation screen.
q This failure is not checked with self-diagnosis function.
q In cases where the blown-air volume begins to behave in an unpredictable manner after a certain
while during cooling, freezing of the evaporator is a likely cause.
This may be due to the followings.
1) Defective compressor clutch relay (i.e., stuck in ON position) (see item 4 A from "Trouble-
shooting for compressor and refrigerant system")
2) Evaporator temperature sensor mounting holder has come off. (Remove and disassemble air
conditioner unit.)
3) Incorrect adjustment of the expansion valve. (Remove air conditioner unit and replace expan-
sion valve.)
Related infor-
q If air comes out, fuse and relay are normal and wiring harness is seldom abnormal.
mation
q For each connector, relay, and power transistor, see "Parts and connectors layout".
a Since the power transistor is located at the bottom of the air conditioner unit, its troubleshooting or
troubleshooting by disconnecting connector (4) is not available as long as it is installed on the ma-
chine.
q In cases where air is discharged but with unpredictable volumes even during heating, the power
transistor has failed, and therefore, the air conditioner unit must be replaced.
a The power transistor and blower motor cannot be replaced unless the air conditioner unit is once
removed.
q T-adapter for connector [1]: 799-601-7210, T-adapter for connector [2]: 799-601-7220
a T-adapter is not prepared for other connectors.
Defective air conditioner wiring a When test result for cause 1 is abnormal, perform following procedure.
2
harness Check with circuit diagram.
1. Turn starting switch to OFF position.
2. Disconnect connectors [1] and [2] and insert the T-adapter.
3. Turn starting switch to ON position.
4. Operate FRESH/RECIRC air selector switch on air conditioner operation
screen, and prepare by setting RECIRC.
5. Operate FRESH/RECIRC air selector switch on air conditioner operation
screen, and set to FRESH.
a Voltage will be output between connectors [1] (6) and [2] (20) for approxi-
mately 3 seconds (only while door moves to the fresh-air position).
Defective control amplifier or
Between connector [1] (6) (+) and connector [2] (20) Approx. 24
3 defective FRESH/RECIRC air Voltage
(-) V
changeover servo motor
See1. 3. above.
4. Operate FRESH/RECIRC air selector switch on air conditioner operation
screen, and prepare by setting FRESH.
5. Operate FRESH/RECIRC air selector switch on air conditioner operation
screen to RECIRC.
a Voltage will be output between connectors [1] (6) and [2] (20) for approxi-
mately 3 seconds (only while door moves to the fresh-air position).
Between connector [1] (6) (+) and connector [2] (19) Approx. 24
Voltage
(-) V
a When test result for cause 1 is abnormal and that for cause 2 is normal.
Defective FRESH/RECIRC air
4 (If all test results for causes 1, 2 and 3 are normal, cause may be mechan-
changeover servo motor
ical trouble such as hitch.)
a When test result for cause 1 is normal and that for cause 2 is normal and
5 Defective air conditioner controller
that for cause 3 is abnormal, air conditioner controller is defective.
1. Turn starting switch to ON position.
Defective machine monitor 2. Display the air conditioner operation screen on the machine monitor.
6
(defective switch) Display of Recirc/Fresh
Press FRESH/RECIRC air selector switch.
changes.
Indicated gauge
Cause Check method Remedy
pressure
Air conditioner cycle is operating normally.
If there is any trouble (cooling trouble), there is another cause.
Pressure is normal
High-pressure: Approx. 1.5 - 1.7 MPa {15 - 17 kg/cm2}
Low-pressure: Approx. 0.13 - 0.2 MPa {1.3 - 2.0 kg/cm2}
Collect refrigerant, then
Bubble can be seen through sight glass. *1, fill up with proper quan-
Insufficient refrigerant
*3 tity of refrigerant again
*2
There is a temperature difference between
Replace
Clogging of receiver drier inlet and outlet pipes of receiver drier.
*2
Tank is frosty
Clean or replace
Both high-pressure Clogging of expansion valve Expansion valve is frosted
*2
and low-pressure
Gas leakage at thermoprobe of expan- Replace
are too low> Low-pressure gauge reads vacuum
sion valve *2
Repair or replace
Low-pressure gauge Evaporator is frozen
Replace receiver drier
reads vacuum Defective evaporator temperature sensor Flow rate of refrigerant is reduced due to
Collect refrigerant, then
or defective contact of sensor (coming off freezing.
fill up with proper quan-
of mounting clip) (At Cool Max. and HI speed of fan, later it
tity of refrigerant again
becomes not to cold.)
*2
Piping between receiver drier and com-
pressor is clogged or crushed. Clean or replace
Clogged or crushed piping
If clogged completely, low-pressure gauge *2
reads vacuum
Collect refrigerant, then
fill up with proper quan-
Filling too much with refrigerant Connect gauge manifold
tity of refrigerant again
*2
Clean, repair fins, or
Dirty condenser, clogging or crushing of repair or replace con-
<Both high-pres- Defective cooling of condenser
fins, or defective rotation of cooling fan denser
sure and low-pres-
*2
sure are too high>
Improper adjustment of expansion valve Replace
Bubble can be seen through sight glass. *3
(Valve is opened too wide) *2
Evacuate and then fill up
with proper quantity of
Air in cycle parts Bubble can be seen through sight glass. *3
refrigerant again
*2
<High-pressure is Clean inside of cycle or
Clogged or crushed piping between com- There is a remarkable temperature differ-
too high and low- replace
pressor and condenser ence across clogged part
pressure is too low> *2
<High-pressure is Both high-pressure and low-pressure are
too low and Defective compressor (Compression balanced while compressor is in operation. Replace
low-pressure is too trouble of compressor) Compressor has seized and is extremely *2
high> hot.
*1: If refrigerant leaks, compressor oil in the air conditioner circuit always leaks, too. So perform the check
mainly on pipe joints and dirty parts with oil.
*2:
k When replacing a cooling cycle part, see Caution about refrigerant and collect refrigerant. After
replacing it, fill up the air conditioner system with refrigerant again.
*3: Sight glass is on the air conditioner hose near the condenser.
A: From Cab
B: To Condenser
k Collect the refrigerant (Air conditioner gas: q When connecting piping, apply compressor oil
R134a) from air conditioner circuit before (ND-OIL8) for R134a to its O-rings. (See item 4
disconnecting air conditioner hose to re- of "Handling compressor oil")
place air conditioner unit, air conditioner Do not apply oil to the threads of a bolt, nut or
compressor or receiver drier and so on. union, however.
a Ask a gualified person for collecting, adding and q Once an O-ring is used, it is deformed and dete-
filling operations of the refrigerant (R134a). riorated. Accordingly, do not reuse it. When re-
a Never release the refrigerant (R134a) to the at- moving it, use a soft tool (such as a toothpick) so
mosphere. that the piping will not be damaged.
k If refrigerant gas (R134a) gets in your eyes, q Push in each pipe to the stopper and tighten the
you may lose your sight. And if it touches bolt or nut fully with your fingers.
your skins, you may suffer from frostbite. Ac- q Be sure to use two wrenches to tighten each nut.
cordingly, put on the protective eyeglasses, Use one wrench to fix and tighten the nut with
gloves and working suits with long sleeves the other wrench to the specified torque (Use a
while you are collecting the refrigerant torque wrench for tightening).
(R134a) or filling the air conditioner circuit
with the refrigerant (R134a). Collecting and
filling work must be conducted by a qualified
person.
1. Engine
2. Compressor
3. Condenser
4. Modulator
5. Air conditioner unit
q In case of compressor seizure or breakage. Whenever connecting piping or hoses, the com-
Metal chips will circulate through the air condi- pressor oil (ND-OIL8) must be applied to O-rings in
tioner circuit and contaminate the compressor oil order to prevent the leakage of refrigerant.
extremely.
In this case, flush the air conditioner circuit and
replace the compressor and receiver drier.
The compressor oil is removed from the air
conditioner circuit by flushing. Accordingly,
install a new compressor with the oil of the spec-
ified quantity (180 cc) filled in it.
q Other cases
a New compressor contains compressor oil of 180
cc in it.
1) Prepare an oil container and drain oil from
the old compressor.
2) Measure the quantity of the drained oil with a
measuring cylinder, and note the quantity or
mark the level.
HYDRAULIC EXCAVATOR
HB205-1
HB215LC-1
Contents 0-1
(Rev. 2010/03)
HB205-1, HB215LC-1
HB205-1, HB215LC-1
a This figure covers the equipment and devices that are unavailable as optional items in some areas.
(Rev. 2010/03)
(Standard spec.)
(Standard spec.) HB205-1, HB215LC-1
HB205-1, HB215LC-1
a This figure covers the equipment and devices that are unavailable as optional items in some areas.
(Standard spec.)
(Standard spec.) HB205-1, HB215LC-1
HB205-1, HB215LC-1
a This figure covers the equipment and devices that are unavailable as optional items in some areas.
(Standard spec.)
(Standard spec.) HB205-1, HB215LC-1
HB205-1, HB215LC-1
a This figure covers the equipment and devices that are unavailable as optional items in some areas.
(Standard spec.)
(Standard spec.) HB205-1, HB215LC-1
HB205-1, HB215LC-1
a This figure covers the equipment and devices that are unavailable as optional items in some areas.
(Standard spec.)
(Standard spec.) HB205-1, HB215LC-1
HB205-1, HB215LC-1
a This figure covers the equipment and devices that are unavailable as optional items in some areas.
(Standard spec.)
(Standard spec.) HB205-1, HB215LC-1
HB205-1, HB215LC-1
a This figure covers the equipment and devices that are unavailable as optional items in some areas.
Index 0 -1
HB205-1, HB215LC-1
B E
Bleeding air from each part 30-59 E-1 Engine does not start (Engine does not
Bleeding air from fuel circuit 30-28 crank) 40-434
E-2 Preheater does not operate 40-440
C E-3 When starting switch is turned to ON
Carrier roller 60-21 position, machine monitor displays nothing 40-445
Center swivel joint 10-142, 60-56 E-4 When starting switch is turned to ON
Checking cab tipping stopper 30-61 position (with engine stopped), basic check
Checking exhaust gas color 30-12 monitor lights up. 40-448
Checking parts which cause E-5 Precaution monitor lights up while engine
hydraulic drift of work equipment 30-54 is running 40-449
Checks before troubleshooting 40-12 E-6 Emergency stop monitor lights up while
Circuit diagram and arrangement of connector engine is running 40-451
pins 80-20 E-7 Fuel level gauge does not indicate properly 40-452
Classification and procedures for troubleshooting 40-41 E-8 Engine coolant temperature gauge does
Cleaning and replacement of not indicate properly 40-454
oil filter of swing electric motor 30-67 E-9 Hydraulic oil temperature gauge does not
CLSS 10-32 indicate properly 40-456
Coating materials list 50-7 E-10 HYB system temperature gauge does not
Compressor 80-16 indicate properly 40-458
Condenser and Modulator 80-17 E-11 Displays on machine monitor are different
Configuration and function of refrigeration cycle 80-6 from those for actual machine 40-460
Configuration and safety functions of E-12 Machine monitor does not display some
hybrid system 10-6 items 40-460
Connection of service tool 80-74 E-13 Function switch does not work 40-460
Connection table for connector pin numbers 40-70 E-14 Automatic warm-up system does not
Connector list and layout 40-59 operate (in cold season) 40-461
Control valve 10-58, 60-32 E-15 Auto-decelerator does not operate
Conversion table 00-50 normally 40-462
Cooling system 10-4, 60-5 E-16 Working mode does not change 40-463
Cooling system of hybrid component 10-10 E-17 Travel speed does not change 40-464
Cylinder cut-out test mode operation 30-23 E-18 Alarm buzzer does not stop sounding 40-465
E-19 When starting switch is at OFF position,
D service meter is not displayed 40-465
Desiccant replacement procedure 80-80 E-20 Machine monitor cannot be set in
Detail of air conditioner unit 80-24 service mode 40-465
Dimension of work equipment 60-60 E-21 All of work equipment, swing, and travel
Disassembly and assembly of carrier roller mechanism do not move or are not locked 40-466
assembly 50-171 E-22 Swing holding brake does not operate
Disassembly and assembly of center swivel properly 40-469
joint assembly 50-181 E-23 One-touch power max. function does not
Disassembly and assembly of control valve operate 40-472
assembly 50-199 E-24 Travel alarm does not sound or does not
Disassembly and assembly of final drive 50-131 stop sounding 40-476
Disassembly and assembly of idler assembly 50-164 E-25 Horn does not sound or does not stop
Disassembly and assembly of idler cushion sounding 40-478
assembly 50-167 E-26 Windshield wiper and window washer do
Disassembly and assembly of swing machinery not operate 40-480
assembly 50-145
HB205-1, HB215LC-1 1
(01)
2
Index
E-27 "BOOM LOWER" indicator is not Failure code [CA154] Chg Air Temp Sensor
displayed properly with monitoring function 40-482 Low Error 40-136
E-28 "ARM OUT" indicator is not displayed Failure code [CA155] Chg Air Temp High
properly with monitoring function 40-484 Speed Derate 40-138
E-29 "ARM IN" indicator is not displayed Failure code [CA187] Sens Supply 2 Volt Low
properly with monitoring function 40-486 Error 40-140
E-30 "BOOM RAISE" indicator is not displayed Failure code [CA221] Ambient Press Sens
properly with monitoring function 40-486 High Error 40-142
E-31 "BUCKET CURL" indicator is not Failure code [CA222] Ambient Press Sens
displayed properly with monitoring function 40-486 Low Error 40-144
E-32 "BUCKET DUMP" indicator is not Failure code [CA227] Sens Supply 2 Volt High
displayed properly with monitoring function 40-487 Error 40-146
E-33 "SWING" indicator is not displayed Failure code [CA234] Eng Overspeed 40-146
properly with monitoring function 40-487 Failure code [CA238] Ne Speed Sens Supply
E-34 "TRAVEL" indicator is not displayed Volt Error 40-147
properly with monitoring function 40-488 Failure code [CA271] IMV/PCV1 Short Error 40-148
E-35 "TRAVEL STEERING" indicator is not Failure code [CA272] IMV/PCV1 Open Error 40-150
displayed properly with monitoring function 40-490 Failure code [CA322] Inj #1(L#1) Open/Short
E-36 "SERVICE" indicator is not displayed Error 40-152
properly with monitoring function 40-492 Failure code [CA324] Inj #3(L#3) Open/Short
E-37 Attachment hydraulic circuit cannot be Error 40-154
changed 40-494 Failure code [CA331] Inj #2(L#2) Open/Short
E-38 KOMTRAX system does not operate Error 40-156
properly 40-495 Failure code [CA332] Inj #4(L#4) Open/Short
Electric control unit 10-14 Error 40-158
Electrical circuit diagram 90-13 Failure code [CA342] Calibration Code Incom
Electrical control system 10-144 patibility 40-160
Engine and cooling system 50-20 Failure code [CA351] Injectors Drive Circuit
Engine mount 60-4 Error 40-161
Engine related parts 10-3 Failure code [CA352] Sens Supply 1 Volt Low
Explanation of terms for maintenance standard 00-11 Error 40-162
Failure code [CA386] Sens Supply 1 Volt High
F Error 40-164
Failure code [989L00] Engine Controller Lock Failure code [CA428] Water in Fuel Sensor
Caution 1 40-111 High Error 40-166
Failure code [989M00] Engine Controller Lock Failure code [CA429] Water in Fuel Sensor
Caution 2 40-111 Low Error 40-168
Failure code [989N00] Engine Controller Lock Failure code [CA435] Eng Oil Press Sw Error 40-170
Caution 3 40-111-1 Failure code [CA441] Battery Voltage Low
Failure code [AA10NX] Air Cleaner Clogging 40-111-2 Error 40-172
Failure code [AB00KE] Charge Voltage Low 40-112 Failure code [CA442] Battery Voltage High
Failure code [B@BAZG] Eng Oil Press Low 40-114 Error 40-174
Failure code [B@BAZK] Eng Oil Level Low 40-115 Failure code [CA449] Rail Press Very High
Failure code [B@BCNS] Eng Water Overheat 40-116 Error 40-175
Failure code [B@BCZK] Eng Water Level Low 40-118 Failure code [CA451] Rail Press Sensor High
Failure code [B@HANS] Hyd Oil Overheat 40-120 Error 40-176
Failure code [CA111] ECM Critical Internal Failure code [CA452] Rail Press Sensor Low
Failure 40-121 Error 40-178
Failure code [CA115] Eng Ne and Bkup Speed Failure code [CA488] Chg Air Temp High
Sens Error 40-121 Torque Derate 40-180
Failure code [CA122] Chg Air Press Sensor Failure code [CA553] Rail Press High Error 40-181
High Error 40-122 Failure code [CA559] Supply Pump Press
Failure code [CA123] Chg Air Press Sensor Low Error 1 40-182
Low Error 40-124 Failure code [CA689] Eng Ne Speed Sensor
Failure code [CA131] Throttle Sensor High Error 40-184
Error 40-126 Failure code [CA731] Eng Bkup Speed Sens
Failure code [CA132] Throttle Sensor Low Phase Error 40-186
Error 40-128 Failure code [CA757] All Continuous Data Lost
Failure code [CA144] Coolant Temp Sens Error 40-187
High Error 40-130 Failure code [CA778] Eng Bkup Speed Sensor
Failure code [CA145] Coolant Temp Sens Error 40-188
Low Error 40-132 Failure code [CA1633] KOMNET Datalink
Failure code [CA153] Chg Air Temp Sensor Timeout Error 40-191
High Error 40-134
2 HB205-1, HB215LC-1
(03)
3
Index
Failure code [CA2185] Throt Sens Sup Volt Failure code [DHVBL8] HYB system swing
High Error 40-192 LEFT PPC pressure sensor signal
Failure code [CA2186] Throt Sens Sup Volt abnormality 40-260
Low Error 40-193 Failure code [DHVBMA] HYB system swing
Failure code [CA2249] Rail Press Very Low LEFT PPC pressure sensor malfunction 40-261
Error 40-194 Failure code [DHVCKZ] HYB Arm Dump PPC
Failure code [CA2311] IMV Solenoid Error 40-195 Pr. Sen. Opn/short Cir 40-262
Failure code [CA2555] Grid Htr Relay Open Failure code [DW43KA] Travel Speed Sol
Circuit Error 40-196 Open Circuit 40-264
Failure code [CA2556] Grid Htr Relay Short Failure code [DW43KB] Travel Speed Sol
Circuit Error 40-198 Short Circuit 40-266
Failure code [D19JKZ] Personal Code Relay Failure code [DW45KA] Swing holding brake
Abnormality 40-200 solenoid valve open circuit 40-268
Failure code [D862KA] GPS Antenna Open Failure code [DW45KB] Swing holding brake
Circuit 40-203 solenoid valve short circuit 40-271
Failure code [DA22KK] Pump Solenoid Power Failure code [DW45KK] Swing holding brake
Low Error 40-204 solenoid valve power voltage drop 40-274
Failure code [DA25KP] 5V Sensor1 Power Failure code [DW45KY] swing holding brake
Abnormality 40-206 Sol. Val. Pow. Short Cir 40-276
Failure code [DA26KP] 5V Sensor2 Power Failure code [DW4WKA] Cancel Bucket Dump
Abnormality 40-208 Open Circuit 40-278
Failure code [DA29KQ] Model Selection Failure code [DW4WKB] Cancel Bucket Dump
Abnormality 40-210 Short Circuit 40-280
Failure code [DA2RMC] CAN Discon (Pump Failure code [DW91KA] Travel Junction Sol.
Con Detected) 40-212 Disc. 40-282
Failure code [DAF8KB] Camera Power Supply Failure code [DW91KB] Travel Junction Sol.
Short Circuit 40-218 S/C 40-284
Failure code [DAFGMC] GPS Module Error 40-220 Failure code [DWA2KA] Attachment Sol Open
Failure code [DAFRMC] CAN Discon (Monitor Circuit 40-286
Detected) 40-221 Failure code [DWA2KB] Attachment Sol Short
Failure code [DGH2KB] Hyd Oil Sensor Short 40-228 Circuit 40-288
Failure code [DHPAMA] Pump Press Sensor Failure code [DWK0KA] 2-stage Relief Sol
Abnormality 40-230 Open Circuit 40-290
Failure code [DHPBMA] R Pump Press Sensor Failure code [DWK0KB] 2-stage Relief Sol
Abnormality 40-232 Short Circuit 40-292
Failure code [DHS3MA] Arm IN PPC Sen. Failure code [DXA8KA] PC-EPC (F) Sol Open
Abnormality 40-234 Circuit 40-294
Failure code [DHS4MA] Bucket CURL PPC Failure code [DXA8KB] PC-EPC (F) Sol Short
Press Sensor Abnormality 40-236 Circuit 40-296
Failure code [DHS8MA] Boom RAISE PPC Failure code [DXA9KA] PC-EPC (R) Sol Open
Press Sensor Abnormality 40-238 Circuit 40-298
Failure code [DHSAKZ] Swing RIGHT PPC Failure code [DXA9KB] PC-EPC (R) Sol Short
pressure sensor system open or short circuit 40-240 Circuit 40-300
Failure code [DHSAMA] Swing RH PPC Press Failure code [DXE0KA] LS-EPC Sol Open
Sensor Abnomality 40-244 Circuit 40-302
Failure code [DHSBKZ] Swing LEFT PPC Failure code [DXE0KB] LS-EPC Sol Short
pressure sensor system open or short circuit 40-242 Circuit 40-304
Failure code [DHSBMA] Swing LH PPC Press Failure code [DXE4KA] Service Current EPC
Sensor Abnomality 40-246 Disc. 40-306
Failure code [DHSDMA] Bucket Dump PPC Failure code [DXE4KB] Service Current EPC
Press Sensor Abnormality 40-248 S/C 40-308
Failure code [DHV3KZ] HYB system arm IN Failure code [DXE5KA] Merge-divider Main
PPC pressure sensor open or short circuit 40-250 Sol Open Circuit 40-310
Failure code [DHV9KZ] HYB Boom Lower Failure code [DXE5KB] Merge-divider Main
PPC Pr. Sen. Open/Shrt Cir 40-252 Sol Short Circuit 40-312
Failure code [DHVAKZ] HYB Swing-R PPC Failure code [DXE6KA] Merge-divider LS Sol
Pr. Sen. Opn/Short Cir 40-254 Open Circuit 40-314
Failure code [DHVAL8] HYB system swing Failure code [DXE6KB] Merge-divider LS Sol
RIGHT PPC pressure sensor signal Short Circuit 40-316
abnormality 40-256 Failure code [DY20KA] Wiper Working
Failure code [DHVAMA] HYB system swing Abnormality 40-318
RIGHT PPC pressure sensor malfunction 40-257 Failure code [DY20MA] Wiper Parking
Failure code [DHVBKZ] HYB Swing-L PPC Abnormality 40-320
Pr. Sen. Opn/short Cir 40-258 Failure code [DY2CKA] Washer drive discon 40-322
HB205-1, HB215LC-1 3
(03)
4
Index
Failure code [DY2CKB] Washer drive short 40-324 Failure code [GA1BMA] Gen. Mot. Dr. DC Vlt.
Failure code [DY2DKB] Wiper Drive (Fwd) Sens. Malfunction 40-385
Short Circuit 40-326 Failure code [GA1FKR] Swing Mot. Drv.
Failure code [DY2EKB] Wiper Drive (Rev) Communication Failure 40-385
Short Circuit 40-328 Failure code [GA1FMA] Abnormal Swing Motor
Failure code [GA----] Hybrid devices monitoring Driver 40-386
items list and check sheet 40-355 Failure code [GA1GKK] Low Sup. Volt. Swing
Failure code [GA00NS] HYB devices overheat 40-359 Motor Drv. Sub-CPU 40-386
Failure code [GA01KA] Power Cable Interlock Failure code [GA1GKR] Swing Mot. Driver
Open Circuit 40-360 Sub-CPU Comm. Failure 40-387
Failure code [GA02KZ] DC Line Open/Short Failure code [GA1GKT] Swing Mot. Drv.
Circuit 40-362 Sub-CPU Cont. Abnormal 40-387
Failure code [GA04KG] Abnormal DC HW Failure code [GA1GMA] Swing Motor Drv.
Volt. Before Booster 40-363 Sub-CPU Malfunction 40-388
Failure code [GA05KG] Abnormal DC SW Failure code [GA1GMB] Swing Mot. Drv.
Volt. Before Booster 40-364 Sub-CPU Funct. Degraded 40-388
Failure code [GA05KP] Low DC SW Output Failure code [GA1GMC] Swing Mot. Drv.
Volt. Bef. Booster 40-365 Sub-CPU Defect Op. 40-389
Failure code [GA06KZ] DC Vlt. Sen. Opn./Shrt. Failure code [GA1GNA] Swing Mot. Drv.
Cir. Bef. Booster 40-366 Sub-CPU Start Disabled 40-389
Failure code [GA08KG] Abnormal. DC HW Failure code [GA1HKZ] Swg Mot. Dr. Ph-U
Volt. After Booster 40-367 Tem. Sens Opn/Shrt Cir. 40-390
Failure code [GA09KG] Abnormal. DC SW Failure code [GA1JKZ] Swg Mot. Dr. Ph-V
Volt. After Booster 40-368 Tem. Sens Opn/Shrt Cir. 40-390
Failure code [GA09KP] Low DC SW Output Failure code [GA1KKZ] Swg Mot. Dr. Ph-W
Volt. After Booster 40-369 Tem. Sens Opn/Shrt Cir 40-391
Failure code [GA0AKZ] DC Volt. Sen. Op./Shrt Failure code [GA1LKZ] Swg Mot. Dr. Current.
cir. Aft. Booster 40-370 Sens Opn/Shrt Cir. 40-391
Failure code [GA0BKZ] AC Line Open/Short Failure code [GA1MKZ] Swg Mot. Dr. DC Vlt.
Circuit 40-371 Sen Opn/Shrt Cir. 40-392
Failure code [GA12MC] HYB Cont. Pow. Suppl. Failure code [GA1NNS] Swing Motor Driver
Failure 40-372 IGBT Overheat 40-393
Failure code [GA12NK] HYB Cont. Pow. Suppl. Failure code [GA1SFS] Contactor Locked 40-394
Not Turn. ON 40-373 Failure code [GA1SMC] Contactor Failure 40-394
Failure code [GA12NL] HYB Cont. Pow. Suppl. Failure code [GA1TKP] Capacitor Low Output
Not Turn. OFF 40-374 Voltage 40-395
Failure code [GA13MC] HYB Control. Sen. Failure code [GA1TNS] Capacitor Overheat 40-396
Power Sup. Failure 40-376 Failure code [GA1UKZ] Capacitor Temp.
Failure code [GA14KR] HYB Control. KOMNET Sensor Opn/Short Cir. 40-398
Comm. Failure 40-378 Failure code [GA1VFS] Capacitor Contactor
Failure code [GA15KZ] HYB Cont. Bad Insul. Locked 40-400
Sen. Opn/Short. Cir 40-379 Failure code [GA1VMC] Capacitor Contactor
Failure code [GA17KR] Gen. Mot. Drv. Failure 40-402
Communication Failure 40-379 Failure code [GA1XKZ] Boost. Ind. Temp.
Failure code [GA17KY] Gen. Mot Dr. Power Sens. Open/Shrt. Circ. 40-403
Line Short Circuit 40-380 Failure code [GA1YNS] Booster Inductor
Failure code [GA17KZ] Gen. Motor Driver Overheat 40-404
Open/Short Circuit 40-380 Failure code [GA1ZKZ] Booster IGBT Temp.
Failure code [GA17MB] Gen. Mot. Drv. Function Sens. Opn/Shrt. Circ. 40-404-1
Degraded 40-381 Failure code [GA1ZNS] Booster IGBT Temp.
Failure code [GA18MC] Gen.Mo. Dr. Excite. Sens. Overheat 40-404-2
Pow. Sup. Failure 40-381 Failure code [GA21KB] Booster IGBT Short
Failure code [GA19KK] Gen. Mot. Drv. Circuit 40-404-3
Sub-CPU Low Sup. Volt 40-382 Failure code [GA22NS] Booster IGBT Junction
Failure code [GA19KR] Gen. Motor Driver Overheat 40-405
Sub-CPU Comm. Failure 40-382 Failure code [GA23KZ] Gen. Mot. Dr. Temp.
Failure code [GA19KT] Int. Abnorm. Gen. Mot. Sens.0 Opn/Short Cir. 40-406
Drv. Sub-CPU Con. 40-383 Failure code [GA24KZ] Gen. Mot. Dr. Temp.
Failure code [GA19MA] Gen. Mot. Drv. Sens.1 Opn/Short Cir. 40-406
Sub-CPU Malfunction 40-383 Failure code [GA25MA] Gen. Motor Driver
Failure code [GA19MC] Gen. Mot. Drv. IGBT0 Abnormality 40-407
Sub-CPU Defect. Operation 40-384 Failure code [GA25NS] Gen. Motor Driver
Failure code [GA19NA] Gen. Mot. Drv. IGBT0 overheat 40-407-1
Sub-CPU Start Disabled 40-384
4 HB205-1, HB215LC-1
(03)
5
Index
Failure code [GA26MA] Gen. Motor Driver H-3 All work equipment and travel systems do
IGBT1 Abnormality 40-407-2 not work 40-502
Failure code [GA26NS] Gen. Motor Driver H-4 Unusual noise comes out from around
IGBT1 overheat 40-408 hydraulic pump 40-502
Failure code [GA27KZ] DC before boosting H-5 Auto-decelerator does not operate 40-503
sensor open or short circuit 40-409 H-6 Fine control performance or response is
Failure code [GA28KZ] DC after boosting low 40-503
sensor open or short circuit 40-409 H-7 Speed or power of boom is low 40-504
Failure code [GA60MC] Generator Motor H-8 Speed or power of arm is low 40-505
Failure 40-410 H-9 Speed or power of bucket is low 40-506
Failure code [GA60MD] Gen. Mot. Defective H-10 Work equipment does not move in its
Movement 40-411 single operation 40-506
Failure code [GA60N1] Generator Motor H-11 Hydraulic drift of work equipment is large 40-507
Overrun 40-412 H-12 Time lag of work equipment is large 40-509
Failure code [GA61KZ] Gen. Motor Temp. H-13 When part of work equipment is relieved
Sens. Open/Short Cir. 40-414 singly, other parts of work equipment move 40-509
Failure code [GA61NS] Generator Motor H-14 Power maximizing function does not work 40-510
Temp. Sensor Overheat 40-416 H-15 In combined operation of work equipment,
Failure code [GA62KY] Gen. Mot. Ph-A Cur. speed of part loaded more is low 40-510
Sen. Power Short Cir 40-417 H-16 When machine swings and travels
Failure code [GA62KZ] Gen. Mot. Ph-A Cur. simultaneously, travel speed is low 40-510
Sen. Open/Short Cir 40-418 H-17 Machine deviates during travel 40-511
Failure code [GA62MA] Gen. Mot. Ph-A H-18 Travel speed is low 40-512
Current Sen. Malfunction 40-419 H-19 Machine is not steered well or sterring
Failure code [GA63KY] Gen. Mot. Ph-B Cur. power is low 40-513
Sen. Power Short Cir. 40-419 H-20 Travel speed does not shift or travel
Failure code [GA63KZ] Gen. Mot. Ph-B Cur. speed is low or high 40-514
Sen. Open/Short Cir 40-420 H-21 Travel system does not work (only one
Failure code [GA63MA] Gen. Mot. Ph-B side) 40-515
Current Sen. Malfunction 40-420 H-22 Upper structure does not swing 40-516
Failure code [GA64KY] Gen. Mot. Ph-C Cur. H-23 Swing acceleration or swing speed of
Sen. Power Short Cir. 40-421 upper structure is low 40-516
Failure code [GA64KZ] Gen. Mot. Ph-C Cur. H-24 Upper structure overruns remarkably
Sen. Open/Short Cir. 40-422 when it stops swinging 40-516
Failure code [GA64MA] Gen. Mot. Ph-C H-25 Large shock is made when upper
Current Sen. Malfunction 40-422 structure stops swinging 40-517
Failure code [GA70KB] HYB Swing Motor H-26 Large sound is made when upper
Short Circuit 40-423 structure stops swinging 40-517
Failure code [GA70MD] HYB Swing Motor H-27 Upper structure lowers largely by its own
Defective Stirr. Motion 40-423 weight 40-517
Failure code [GA70NS] HYB Swing Motor Handling fuel system parts 30-20
Overheat 40-424 Handling of compressor oil 80-78
Failure code [GA71KZ] HYB Swing Mot. Temp. Handling of controller high-voltage circuit 30-30
Sens. Opn/Shrt Cir. 40-426 Handling of electric equipment 00-18
Failure code [GA72MA] HYB Swing Motor Handling of hybrid devices and
Resolver Malfunction 40-428 high-voltage wirings 00-36
Failure code [GA72MC] HYB Swing Motor Handling of hydraulic components 00-13
Resolver Defect Op. 40-430 Handling voltage circuit of engine controller 30-132
Failure code [GA81KZ] Swing Motor Power High-voltage wiring (power cable) 10-15
Cable Opn/Shrt Circ. 40-430 How to read Disassembly and Assembly 50-4
Failure code [GAA100] Swing emergency stop How to read electric wire code 00-28
switch operated 40-431 How to read the shop manual 00-9
Failure code [GAA2KB] Swing Brake sol. How to read this manual 50-4
Supply Line short cir. 40-432 Hydraulic circuit diagram 90-7
Failure codes table 40-44 Hydraulic components layout drawing 10-28
Final drive 10-24, 60-12 Hydraulic tank 10-31
Functions and operation by valve 10-70
Fuse location table 40-109 I
Idler 60-18
H Information in troubleshooting table (H mode) 40-498
H-1 Speed or power of all work equipment and Information in troubleshooting table 40-55
travel is low 40-499 Information in troubleshooting table 80-52
H-2 Engine speed lowers significantly or engine
stalls 40-501
HB205-1, HB215LC-1 5
(03)
6
Index
6 HB205-1, HB215LC-1
(03)
7
Index
S-8 Oil consumption is excessive (or exhaust Testing oil leakage 30-57
gas is blue) 40-531 Testing PPC valve output pressure 30-51
S-9 Oil becomes contaminated quickly 40-532 Testing relays 80-47
S-10 Fuel consumption is excessive 40-533 Testing solenoid valve output pressure 30-48
S-11 Oil is in coolant (or coolant spurts or Testing source pressure of control circuit 30-40
coolant level goes down) 40-534 Testing sunlight sensor 80-44
S-12 Oil pressure drops 40-535 Testing swing circle bearing clearance 30-33
S-13 Oil level rises (coolant or fuel in oil) 40-536 Testing swing holding brake 30-66
S-14 Coolant temperature rises too high Testing temperature control 80-34
(overheating) 40-537 Testing vent (mode) changeover 80-36
S-15 Unusual noise is made 40-538 Testing with self-diagnosis function 80-31
S-16 Vibration is excessive 40-539 Tools for testing, adjusting and troubleshooting 30-4
Safety notice 00-4 Track frame and idler cushion 10-26, 60-16
Sensor 10-192 Track roller 60-20
Separation and connection of track shoe Track shoe 60-22
assembly 50-161 Travel motor 10-107, 60-41
Sequence of events in troubleshooting 40-11 Troubleshooting chart 1 80-48
Sketches of special tools 50-15 Troubleshooting chart 2 80-50
Solenoid valve 10-136, 60-54 Troubleshooting for blower motor system
Special functions of machine monitor 30-70 (No air comes out or air flow is abnormal) 80-60
Special tools list 50-10 Troubleshooting for compressor and refrigerant
Specification dimension drawing 01-4 system (Air is not cooled) 80-57
Specifications 01-6 Troubleshooting for FRESH/RECIRC air
Sprocket 60-14 changeover 80-68
Standard tightening torque table 00-42 Troubleshooting for power supply and CAN
Standard value table for engine 20-3 communication system (Air conditioner
Standard value table for machine 20-4 does not operate) 80-53
Swing brake 10-22, 60-10 Troubleshooting for temperature control 80-63
Swing circle 10-19, 60-7 Troubleshooting for temperature sensor system 80-70
Swing electric motor 10-13 Troubleshooting for vent (mode) changeover 80-66
Swing machinery 10-20, 60-8 Troubleshooting method for open circuit in
Symbols used in electric circuit diagrams 90-9 wiring harness of pressure sensor system 40-57
Symbols used in hydraulic circuit diagrams 90-3 Troubleshooting with gauge pressure 80-71
Symptom and troubleshooting numbers 40-52
System diagram 80-22 V
System diagram of hydraulic and mechanical Valve control 10-30
system 40-496
W
T Water pump 10-16
T- branch box and T- branch adapter table 40-106 Weight table 01-9
Table of contents 00-2 Work equipment 60-58
Table of fuel, coolant and lubricants 01-11 Work equipment cylinder 60-64
Testing (dual) pressure switch for refrigerant 80-45 Working range diagram 01-5
Testing air leakage (duct) 80-30
Testing and adjusting air conditioner compressor Y
belt tension 30-31 Y-1 Hybrid monitor does not go out 40-542
Testing and adjusting hydraulic oil pressure in Y-2 Upper structure does not swing 40-544
work equipment and travel circuits 30-37 Y-3 Swing acceleration or swing speed is low 40-546
Testing and adjusting oil pressure in pump Y-4 Upper structure overruns largely when
LS control circuit 30-44 stop swinging 40-547
Testing and adjusting oil pressure in pump Y-5 Large shock is made when upper structure
PC control circuit 30-41 stops swinging 40-548
Testing and adjusting track tension 30-34 Y-6 Large unusual noise is made when upper
Testing blowby pressure 30-18 structure stops swinging 40-548
Testing boost pressure 30-11 Y-7 Swing drift on a slope is large 40-549
Testing compression pressure 30-15 Y-8 Electric swing motor temperature increases
Testing engine oil pressure 30-19 abnormally 40-550
Testing engine speed 30-9 Y-9 Motor-generator temperature increases
Testing evaporator temperature sensor 80-42 abnormally 40-552
Testing FRESH/RECIRC air changeover 80-39 Y-10 Inverter overheats 40-553
Testing fuel circuit for leakage 30-29 Y-11 Capacitor overheats 40-554
Testing fuel delivery, return rate and leakage 30-24
Testing fuel system pressure 30-21
Testing inner sensor 80-41
HB205-1, HB215LC-1 7
(03)
HB205-1, HB215LC-1 HYDRAULIC EXCAVATOR
2013 KOMATSU
All Rights Reserved
Printed in Japan 03-13 (01)
(04)