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SEBM027100K

Shop Manual Supplement

PC600LC-6

FOR MACHINES BUILT TO COLD WEATHER SPECIFICATIONS (-50° C) (Use with SEBM017100 and its’ subsequent revisions)

HYDRAULIC EXCAVATOR SERIAL NUMBERS PC600LC-6 – 11064 and up This material is proprietary to Komatsu America International Company and is not to be reproduced, used, or disclosed except in accordance with written authorization from Komatsu America International Company. It is out policy to improve our products whenever it is possible and practical to do so. We reserve the right to make changes or improvements at any time without incurring any obligation to install such changes on products sold previously. Due to this continuous program of research and development, revisions may be made to this publication. It is recommended that customers contact their distributor for information on the latest revision.

CONTENTS No. of page

GENERAL ........................................................................ 01-1

STRUCTURE AND FUNCTION ...................................... 10-1

TESTING AND ADJUSTING .......................................... 20-1

DISASSEMBLY AND ASSEMBLY ................................. 30-1

MAINTENANCE STANDARD ......................................... 40-1

OTHERS........................................................................... 90-1

00-2

PC600-6

SAFETY

SAFETY NOTICE

SAFETY SAFETY NOTICE IMPORTANT SAFETY NOTICE Proper service and repair is extremely important for safe machine operation. The service and repair techniques recommended by Komatsu and described in this manual are both effective and safe. Some of these techniques require the use of tools specially designed by Komatsu for the specific purpose.

To prevent injury to workers, the symbol is used to mark safety precautions in this manual. The cautions accompanying these symbols should always be followed carefully. If any dangerous situation arises or may possibly arise, first consider safety, and take the necessary actions to deal with the situation.

GENERAL PRECAUTIONS Mistakes in operation are extremely dangerous. Read the Operation and Maintenance Manual carefully BEFORE operating the machine. 1. Before carrying out any greasing or repairs, read all the precautions given on the decals which are fixed to the machine. 2. When carrying out any operation, always wear safety shoes and helmet. Do not wear loose work clothes, or clothes with buttons missing. • •

Always wear safety glasses when hitting parts with a hammer. Always wear safety glasses when grinding parts with a grinder, etc.

3. If welding repairs are needed, always have a trained, experienced welder carry out the work. When carrying out welding work, always wear welding gloves, apron, hand shield, cap and other clothes suited for welding work. 4. When carrying out any operation with two or more workers, always agree on the operating procedure before starting. Always inform your fellow workers before starting any step of the operation. Before starting work, hang UNDER REPAIR signs on the controls in the operator's compartment. 5. Keep all tools in good condition and learn the correct way to use them.

6. Decide a place in the repair workshop to keep tools and removed parts. Always keep the tools and parts in their correct places. Always keep the work area clean and make sure that there is no dirt or oil on the floor. Smoke only in the areas provided for smoking. Never smoke while working. PREPARATIONS FOR WORK 7. Before adding oil or making any repairs, park the machine on hard, level ground, and block the wheels or tracks to prevent the machine from moving. 8. Before starting work, lower blade, ripper, bucket or any other work equipment to the ground. If this is not possible, insert the safety pin or use blocks to prevent the work equipment from falling. In addition, be sure to lock all the control levers and hang warning signs on them. 9. When disassembling or assembling, support the machine with blocks, jacks or stands before starting work. 10.Remove all mud and oil from the steps or other places used to get on and off the machine. Always use the handrails, ladders or steps when getting on or off the machine. Never jump on or off the machine. If it is impossible to use the handrails, ladders or steps, use a stand to provide safe footing.

00-3

SAFETY

PRECAUTIONS DURING WORK 11. When removing the oil filler cap, drain plug or hydraulic pressure measuring plugs, loosen them slowly to prevent the oil from spurting out. Before disconnecting or removing components of the oil, water or air circuits, first remove the pressure completely from the circuit. 12.The water and oil in the circuits are hot when the engine is stopped, so be careful not to get burned. Wait for the oil and water to cool before carrying out any work on the oil or water circuits. 13.Before starting work, remove the leads from the battery. Always remove the lead from the negative (–) terminal first. 14.When raising heavy components, use a hoist or crane. Check that the wire rope, chains and hooks are free from damage. Always use lifting equipment which has ample capacity. Install the lifting equipment at the correct places. Use a hoist or crane and operate slowly to prevent the component from hitting any other part. Do not work with any part still raised by the hoist or crane. 15.When removing covers which are under internal pressure or under pressure from a spring, always leave two bolts in position on opposite sides. Slowly release the pressure, then slowly loosen the bolts to remove. 16.When removing components, be careful not to break or damage the wiring. Damaged wiring may cause electrical fires. 17.When removing piping, stop the fuel or oil from spilling out. If any fuel or oil drips onto the floor, wipe it up immediately. Fuel or oil on the floor can cause you to slip, or can even start fires. 18.As a general rule, do not use gasoline to wash parts. In particular, use only the minimum of gasoline when washing electrical parts.

00-4

SAFETY NOTICE

19.Be sure to assemble all parts again in their original places. Replace any damaged parts with new parts. • When installing hoses and wires, be sure that they will not be damaged by contact with other parts when the machine is being operated. 20.When installing high pressure hoses, make sure that they are not twisted. Damaged tubes are dangerous, so be extremely careful when installing tubes for high pressure circuits. Also, check that connecting parts are correctly installed. 21.When assembling or installing parts, always use the specified tightening torques. When installing protective parts such as guards, or parts which vibrate violently or rotate at high speed, be particularly careful to check that they are installed correctly. 22.When aligning two holes, never insert your fingers or hand. Be careful not to get your fingers caught in a hole. 23.When measuring hydraulic pressure, check that the measuring tool is correctly assembled before taking any measurements. 24.Take care when removing or installing the tracks of track-type machines. When removing the track, the track separates suddenly, so never let anyone stand at either end of the track.

FOREWORD

GENERAL

FOREWORD GENERAL This shop manual has been prepared as an aid to improve the quality of repairs by giving the serviceman an accurate understanding of the product and by showing him the correct way to perform repairs and make judgements. Make sure you understand the contents of this manual and use it to full effect at every opportunity.

This shop manual mainly contains the necessary technical information for operations performed in a service workshop. For ease of understanding, the manual is divided into the following chapters; these chapters are further divided into the each main group of components.

STRUCTURE AND FUNCTION This section explains the structure and function of each component. It serves not only to give an understanding of the structure, but also serves as reference material for troubleshooting. In addition, this section may contain hydraulic circuit diagrams, electric circuit diagrams, and maintenance standards. TESTING AND ADJUSTING This section explains checks to be made before and after performing repairs, as well as adjustments to be made at completion of the checks and repairs. Troubleshooting charts correlating "Problems" with "Causes" are also included in this section. DISASSEMBLY AND ASSEMBLY This section explains the procedures for removing, installing, disassembling and assembling each component, as well as precautions for them. MAINTENANCE STANDARD This section gives the judgment standards for inspection of disassembled parts. The contents of this section may be described in STRUCTURE AND FUNCTION. OTHERS This section mainly gives hydraulic circuit diagrams and electric circuit diagrams. In addition, this section may give the specifications of attachments and options together.

NOTICE The specifications contained in this shop manual are subject to change at any time and without any advance notice. Use the specifications given in the book with the latest date.

00-5

FOREWORD

HOW TO READ THE SHOP MANUAL

REVISED EDITION MARK

VOLUMES Shop manuals are issued as a guide to carrying out repairs. They are divided as follows:

W h en a m an u a l is r e vis ed , a n e d itio n ma rk ( ....) is recorded on the bottom of the pages.

Chassis volume: Issued for every machine model Engine volume: Issued for each engine series Each issued as one Electrical volume: Attachments volume: · volume to cover all models

REVISIONS

}

These various volumes are designed to avoid duplicating the same information. Therefore, to deal with all repairs for any model , it is necessary that chassis, engine, electrical and attachment volumes be available. DISTRIBUTION AND UPDATING Any additions, amendments or other changes will be sent to KOMATSU distributors. Get the most up-todate information before you start any work.

FILING METHOD 1. See the page number on the bottom of the page. File the pages in correct order. 2. Following examples show how to read the page number. Example 1 (Chassis volume): 10 - 3 Item number (10. Structure and Function) Consecutive page number for each item. Example 2 (Engine volume): 12 - 5 Unit number (1. Engine) Item number (2. Testing and Adjusting) Consecutive page number for each item. 3. Additional pages: Additional pages are indicated by a hyphen (-) and number after the page number. File as in the example. Example: 12-203 10-4 12-203-1 10-4-1 Added pages 12-203-2 10-4-2 12-204 10-5

00-6

123

Revised pages are shown in the LIST OF REVISED PAGES next to the CONTENTS page.

SYMBOLS So that the shop manual can be of ample practical use, important safety and quality portions are marked with the following symbols.

Symbol

Item

Remarks

Safety

Special safety precautions are necessary when performing the work.

Caution

Special technical precautions or other precautions for preserving standards are necessary when performing the work.

Weight

Weight of parts of systems. Caution necessary when selecting hoisting wire, or when working posture is important, etc.

Tightening torque

Places that require special attention for the tightening torque during assembly.

Coat

Places to be coated with adhesives and lubricants, etc.

Oil, water

Places where oil, water or fuel must be added, and the capacity.

Drain

Places where oil or water m u s t b e d r a i n e d , a nd quantity to be drained.

4 3 2 5 6

FOREWORD

HOISTING INSTRUCTIONS

HOISTING INSTRUCTIONS HOISTING

¤ •

Heavy parts (25 kg or more) must be lifted with a hoist, etc. In the DISASSEMBLY AND ASSEMBLY section, every part weighing 25 kg or more is indicated clearly with the symbol

If a part cannot be smoothly removed from the machine by hoisting, the following checks should be made: 1) Check for removal of all bolts fastening the part to the relative parts. 2) Check for existence of another part causing interference with the part to be removed.

WIRE ROPES 1) Use adequate ropes depending on the weight of parts to be hoisted, referring to the table below: Wire ropes (Standard "Z" or "S" twist ropes without galvanizing) Rope diameter

★

Allowable load

tons

10 11.5 12.5 14 16 18 20 22.4 30 40 50 60

9.8 13.7 15.7 21.6 27.5 35.3 43.1 54.9 98.1 176.5 274.6 392.2

1.0 1.4 1.6 2.2 2.8 3.6 4.4 5.6 10.0 18.0 28.0 40.0

Slinging near the edge of the hook may cause the rope to slip off the hook during hoisting, and a serious accident can result. Hooks have maximum strength at the middle portion.

100%

88%

79%

71%

41% SAD00479

3) Do not sling a heavy load with one rope alone, but sling with two or more ropes symmetrically wound onto the load. Slinging with one rope may cause turning of the load during hoisting, untwisting of the rope, or slipping of the rope from its original winding position on the load, which can result in a dangerous accident.

4) Do not sling a heavy load with ropes forming a wide hanging angle from the hook. When hoisting a load with two or more ropes, the force subjected to each rope will increase with the hanging angles. The table below shows the variation of allowable load kN {kg} when hoisting is made with two ropes, each of which is allowed to sling up to 9.8 kN {1000 kg} vertically, at various hanging angles. When two ropes sling a load vertically, up to 19.6 kN {2000 kg} of total weight can be suspended. This weight becomes 9.8 kN {1000 kg} when two ropes make a 120° hanging angle. On the other hand, two ropes are subjected to an excessive force as large as 39.2 kN {4000 kg} if they sling a 19.6 kN {2000 kg} load at a lifting angle of 150°.

The allowable load value is estimated to be onesixth or one-seventh of the breaking strength of the rope used.

2) Sling wire ropes from the middle portion of the hook.

00-7

FOREWORD

METHOD OF DISASSEMBLING, CONNECTING PUSH-PULL TYPE COUPLER

¤ ¤

Before carrying out the following work, release the residual pressure from the hydraulic tank. For details, see TESTING AND ADJUSTING, Releasing residual pressure from hydraulic tank. Even if the residual pressure is released from the hydraulic tank, some hydraulic oil flows out when the hose is disconnected. Accordingly, prepare an oil receiving container.

Disconnection 1) Release the residual pressure from the hydraulic tan k. Fo r d e tails , se e TES TIN G AN D ADJUSTING, Releasing residual pressure from hydraulic tank. 2) Hold adapter (1) and push hose joint (2) into mating adapter (3). (See Fig. 1) ★ The adapter can be pushed in about 3.5 mm. ★ Do not hold rubber cap portion (4). 3) After hose joint (2) is pushed into adapter (3), press rubber cap portion (4) against (3) until it clicks. (See Fig. 2) 4) Hold hose adapter (1) or hose (5) and pull it out. (See Fig. 3) ★ Since some hydraulic oil flows out, prepare an oil receiving container. Connection 1) Hold hose adapter (1) or hose (5) and insert it in mating adapter (3), aligning them with each other. (See Fig. 4) ★ Do not hold rubber cap portion (4). 2) After inserting the hose in the mating adapter perfectly, pull it back to check its connecting condition. (See Fig. 5) ★ When the hose is pulled back, the rubber cap portion moves toward the hose about 3.5 mm. This does not indicate abnormality, however.

00-8

Type 1

FOREWORD

METHOD OF DISASSEMBLING, CONNECTING PUSH-PULL TYPE COUPLER

Type 3

1) Hold the mouthpiece of the tightening portion and push body (2) in straight until sliding prevention ring (1) contacts contact surface a of the hexagonal portion at the male end.

2) Hold in the condition in Step 1), and turn lever (4) to the right (clockwise).

2) Hold in the condition in Step 1), and push until cover (3) contacts contact surface a of the hexagonal portion at the male end.

3) Hold in the condition in Steps 1) and 2), and pull out whole body (2) to disconnect it.

•

Disassembly

Type 2

Hold the mouthpiece of the tightening portion and push body (2) in straight until sliding prevention ring (1) contacts contact surface a of the hexagonal portion at the male end to connect it.

Connection

Hold the mouthpiece of the tightening portion and push body (2) in straight until sliding prevention ring (1) contacts contact surface a of the hexagonal portion at the male end to connect it.

00-9

FOREWORD

COATING MATERIALS

COATING MATERIALS ★ ★

The recommended coating materials such as adhesives, gasket sealants and greases used for disassembly and assembly are listed below. For coating materials not listed below, use the equivalent of products shown in this list.

Category

Komatsu code

Part No.

Q'ty

Container

LT-1A

790-129-9030

150 g

Tube

LT-1B

790-129-9050

20 g (2 pcs.)

Polyethylene container

LT-2

09940-00030

50 g

Polyethylene container

LT-3

790-129-9060 (Set of adhesive and hardening agent)

Adhesive: 1 kg Hardenin g agent: 500 g

Can

LT-4

790-129-9040

250 g

Polyethylene container

Holtz MH 705

790-126-9120

75 g

Tube

Three bond 1735

790-129-9140

50 g

Polyethylene container

Adhesives

Aron-alpha 201

790-129-9130

Loctite 648-50

79A-129-9110

50 cc

Polyethylene container

LG-1

790-129-9010

200 g

Tube

LG-5

790-129-9070

1 kg

Can

Main applications, featuresr •

Used to prevent rubber gaskets, rubber cushions, and cock plug from coming out.

•

Used in places requiring an immediately effective, strong adhesive. Used for plastics (except polyethylene, polyprophylene, tetrafluoroet hl ene and vi nyl chl or ide) , rubber, metal and non-metal.

• •

Features: Resistance to heat and chemicals Used for anti-loosening and sealant purpose for bolts and plugs.

•

Used as adhesive or sealant for metal, glass and plastic.

•

Used as sealant for machined holes.

•

Used as heat-resisting sealant for repairing engine.

• • •

Quick hardening type adhesive Cure time: within 5 sec. to 3 min. Used mainly for adhesion of metals, rubbers, plastics and woods.

• •

Quick hardening type adhesive Quick cure type (max. strength after 30 minutes) Used mainly for adhesion of rubbers, plastics and metals.

• • •

Resistance to heat, chemicals Used at joint portions subject to high temperatures.

•

Used as adhesive or sealant for gaskets and packing of power train case, etc.

•

Used as sealant for various threads, pipe joints, flanges. Used as sealant for tapered plugs, elbows, nipples of hydraulic piping.

•

Gasket sealant • LG-6

790-129-9020

200 g

Tube

• •

00-10

Features: Silicon based, resistance to heat, cold Used as sealant for flange surface, tread. mab Used as sealant for oil pan, final drive case, etc.

FOREWORD

Category

COATING MATERIALS

Komatsu code

Part No.

Q'ty

Container

Main applications, featuresr •

LG-7

790-129-9070

Tube

Three bond 1211

790-129-9090

100 g

Tube

LM-G

09940-00051

60 g

Can

•

Adhesives

Molybdenum disulphide lubricant

LM-P

09940-00040

200 g

•

Used as heat-resisting sealant for repairing engine.

•

Used as lubricant for sliding portion (to prevent from squeaking).

•

Used to prevent seizure or scuffling of the thread when press fitting or shrink fitting. Used as lubricant for linkage, bearings, etc.

Tube •

G2-LI

SYG2-400LI SYG2-350LI SYG2-400LI-A SYG2-160LI SYGA-160CNLI

G2-CA

SYG2-400CA SYG2-350CA SYG2-400CA-A SYG2-160CA SYGA-160CNCA

Various

Molybdenum disulphide lubricant

SYG2-400M

400 g (10 per case)

Belows type

Grease

Various

Ftures: Silicon based, quick hardening type Used as sealant for flywheel housing, intake manifold, oil an, thermostat housing, etc.

•

General purpose type

•

Used for normal temperature, light load bearing at places in contact with water or steam.

•

Used for places with heavy load

Various

00-11

FOREWORD

STANDARD TIGHTENING TORQUE

STANDARD TIGHTENING TORQUE STANDARD TIGHTENING TORQUE TABLE (WHEN USING TORQUE WRENCH) ★ In the case of metric nuts and bolts for which there is no special instruction, tighten to the torque given in the table below. Thread diameter of bolt

Width across flats

6 8 10 12 14

10 13 17 19 22

16 18 20 22 24

24 27 30 32 36

27 30 33 36 39

41 46 50 55 60

Thread diameter of bolt

Width across flats

6 8 10 12

10 13 14 27

7.85 1.95 18.6 4.9 40.2 5.9 82.35 7.85

kgm

0 0 0 0 0 28.5 0 3 39 0 4 56 0 6 76 0 8.5 94.5 0 10.5 135 0 15 175 0 20 225 0 25 280 0 30 335 0 35

0 1.4 03 07 0 10 0 19 279 0 30 382 0 39 549 0 59 745 0 83 927 0 103 1320 0 140 1720 0 190 2210 0 240 2750 0 290 3290 0 340

1.35 0.15 3.2 0.3 6.7 0.7 11.5 1 18 2

13.2 31 66 113 177

kgm

0 0 0 0

0.8 1.9 4.1 8.4

0 0.2 0 0.5 0 0.6 0 0.8

Sealing surface

TABLE OF TIGHTENING TORQUES FOR FLARED NUTS ★ In the case of flared nuts for which there is no special instruction, tighten to the torque given in the table below.

SAD00483

Thread diameter

Width across flat

kgm

14 18 22 24 30 33 36 42

19 24 27 32 36 41 46 55

24.5 4.9 49 19.6 78.5 19.6 137.3 29.4 176.5 29.4 196.1 49 245.2 49 294.2 49

2.5 0.5 5 2 8 2 14 3 18 3 20 5 25 5 30 5

00-12

Tightening torque

0 0 0 0 0 0 0 0

FOREWORD

STANDARD TIGHTENING TORQUE

TABLE OF TIGHTENING TORQUES FOR SPLIT FLANGE BOLTS ★ In the case of split flange bolts for which there is no special instruction, tighten to the torque given in the table below.

Thread diameter

Width across flat

Tightening torque

kgm

10 12 16

14 17 22

65.7 6.8 112 9.8 279 29

0 0 0

6.7 0.7 11.5 1 28.5 3

0 0

TABLE OF TIGHTENING TORQUES FOR O-RING BOSS PIPING JOINTS ★ Unless there are special instructions, tighten the O-ring boss piping joints to the torque below.

Thread diameter

Width across flat

Tightening torque

kgm

14 20 24 33 42

Varies depending on type of connector.

34.3 4.9 93.1 9.8 142.1 19.6 421.4 58.8 877.1 132.3

0 0 0 0 0

3.5 0.5 9.5 1 14.5 2 43 6 89.5 13.5

Norminal No.

02 03, 04 05, 06 10, 12 14

0 0 0 0 0

TABLE OF TIGHTENING TORQUES FOR O-RING BOSS PLUGS ★ Unless there are special instructions, tighten the O-ring boss plugs to the torque below.

Thread diameter

Width across flat

Tightening torque

kgm

08 10 12 14 16 18 20 24 30 33 36 42 52

14 17 19 22 24 27 30 32 32 n 36 n n

7.35 1.47 11.27 1.47 17.64 1.96 22.54 1.96 29.4 4.9 39.2 4.9 49 4.9 68.6 9.8 107.8 14.7 127.4 19.6 151.9 24.5 210.7 29.4 323.4 44.1

0 0 0 0 0 0 0 0 0 0 0 0 0

0.75 0.15 1.15 0.15 1.8 0.2 2.3 0.2 3 0.5 4 0.5 5 0.5 7 1 11 1.5 13 2 15.5 2.5 21.5 3 33 4.5

Norminal No.

08 10 12 14 16 18 20 24 30 33 36 42 52

0 0 0 0 0 0 0 0 0 0 0 0 0

00-13

FOREWORD

STANDARD TIGHTENING TORQUE

TIGHTENING TORQUE FOR 102 ENGINE SERIES (BOLT AND NUTS) Use these torques for bolts and nuts (unit: mm) of Cummins Engine.

Thread diameter

Tightening torque

6 8 10 12

10 2 24 4 43 6 77 12

kgm

0 0 0 0

1.02 2.45 4.38 7.85

0 0.20 0 0.41 0 0.61 0 1.22

TIGHTENING TORQUE FOR 102 ENGINE SERIES (EYE JOINTS) Use these torques for eye joints (unit: mm) of Cummins Engine.

Thread diameter

Tightening torque

6 8 10 12 14

8 2 10 2 12 2 24 4 36 5

kgm

0 0 0 0 0

0.81 1.02 1.22 2.45 3.67

0 0.20 0 0.20 0 0.20 0 0.41 0 0.51

TIGHTENING TORQUE FOR 102 ENGINE SERIES (TAPERED SCREWS) Use these torques for tapered screws (unit: inch) of Cummins Engine.

Thread diameter

00-14

Tightening torque

1 / 16 1/8 1/4 3/8 1/2 3/4 1

3 1 8 2 12 2 15 2 24 4 36 5 60 9

0 0 0 0 0 0 0

kgm 0.31 0.81 1.22 1.53 2.45 3.67 6.12

0 0.10 0 0.20 0 0.20 0 0.41 0 0.41 0 0.51 0 0.92

FOREWORD

ELECTRIC WIRE CODE

ELECTRIC WIRE CODE In the wiring diagrams, various colors and symbols are employed to indicate the thickness of wires. This wire code table will help you understand WIRING DIAGRAMS. Example: 5WB indicates a cable having a nominal number 5 and white coating with black stripe.

CLASSIFICATION BY THICKNESS

Copper wire Cable O.D. (mm)

Current rating (A)

Applicable circuit

0.88

2.4

Starting, lighting, signal etc.

0.32

2.09

3.1

Lighting, signal etc.

0.32

5.23

4.6

Charging and signal

0.45

13.36

7.0

Starting (Glow plug)

0.80

42.73

11.4

135

Starting

127

0.80

63.84

13.6

178

Starting

100

217

0.80

109.1

17.6

230

Starting

Norminal number

Number of strands

Dia. of strands (mm2)

Cross section (mm 2)

0.85

0.32

CLASSIFICATION BY COLOR AND CODE Circuits Priority Classification

Primary

Charging

Ground

Starting

Lighting

Instrument

Signal

Other

Code

Color

White

Black

Red

Yellow

Green

Blue

Code

2 Color White & Red Code

3 Color White & Black Code 4

Auxiliary

Color White & Blue Code

5 Color White & Green Code 6 Color

n n

n n n n n n n n n n

White & Black Red & White Rellow & Red Green & White Blue & White BY

Black & Yellow Red & Black Yellow & Black Green & Red Blue & Yellow BR

Black & Red Red & Yellow

n n n n

Yellow & Green

Green & Yellow

Blue & Yellow

Red & Green Yellow & Blue Green & Black Blue & Black RL

Red & Blue Yellow & White Green & Blue

n n 00-15

FOREWORD

CONVERSION TABLE

CONVERSION TABLE METHOD OF USING THE CONVERSION TABLE The Conversion Table in this section is provided to enable simple conversion of figures. For details of the method of using the Conversion Table, see the example given below.

EXAMPLE • Method of using the Conversion Table to convert from millimeters to inches 1. Convert 55 mm into inches. (1) Locate the number 50 in the vertical column at the left side, take this as , then draw a horizontal line from . (2) Locate the number 5 in the row across the top, take this as , then draw a perpendicular line down from . (3) Take the point where the two lines cross as . This point gives the value when converting from millimeters to inches. Therefore, 55 mm = 2.165 inches. 2. Convert 550 mm into inches. (1) The number 550 does not appear in the table, so divide by 10 (move the decimal point one place to the left) to convert it to 55 mm. (2) Carry out the same procedure as above to convert 55 mm to 2.165 inches. (3) The original value (550 mm) was divided by 10, so multiply 2.165 inches by 10 (move the decimal point one place to the right) to return to the original value. This gives 550 mm = 21.65 inches.

A B

B Millimeters to inches 1 mm = 0.03937 in

00-16

0 10 20 30 40

0 0.394 0.787 1.181 1.575

0.039 0.433 0.827 1.220 1.614

0.079 0.472 0.866 1.260 1.654

0.118 0.512 0.906 1.299 1.693

0.157 0.551 0.945 1.339 1.732

0.197 0.591 0.984 1.378 1.772

0.236 0.630 1.024 1.417 1.811

0.276 0.669 1.063 1.457 1.850

0.315 0.709 1.102 1.496 1.890

0.354 0.748 1.142 1.536 1.929

50 60 70 80 90

1.969 2.362 2.756 3.150 3.543

2.008 2.402 2.795 3.189 3.583

2.047 2.441 2.835 3.228 3.622

2.087 2.480 2.874 3.268 3.661

2.126 2.520 2.913 3.307 3.701

2.165 2.559 2.953 3.346 3.740

2.205 2.598 2.992 3.386 3.780

2.244 2.638 3.032 3.425 3.819

2.283 2.677 3.071 3.465 3.858

2.323 2.717 3.110 3.504 3.898

FOREWORD

CONVERSION TABLE

Millimeters to Inches 1 mm = 0.03937 in

0.039

0.079

0.118

0.157

0.197

0.236

0.276

0.315

0.354

0.394

0.433

0.472

0.512

0.551

0.591

0.630

0.669

0.709

0.748

0.787

0.827

0.866

0.906

0.945

0.984

1.024

1.063

1.102

1.142

1.181

1.220

1.260

1.299

1.339

1.378

1.417

1.457

1.496

1.536

1.575

1.614

1.654

1.693

1.732

1.772

1.811

1.850

1.890

1.929

1.969

2.008

2.047

2.087

2.126

2.165

2.205

2.244

2.283

2.323

2.362

2.402

2.441

2.480

2.520

2.559

2.598

2.638

2.677

2.717

2.756

2.795

2.835

2.874

2.913

2.953

2.992

3.032

3.071

3.110

3.150

3.189

3.228

3.268

3.307

3.346

3.386

3.425

3.465

3.504

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

2.20

4.41

6.61

8.82

11.02

13.23

15.43

17.64

19.84

22.05

24.25

26.46

28.66

30.86

33.07

35.27

37.48

39.68

41.89

44.09

46.30

48.50

50.71

51.91

55.12

57.32

59.53

61.73

63.93

66.14

68.34

70.55

72.75

74.96

77.16

79.37

81.57

83.78

85.98

88.18

90.39

92.59

94.80

97.00

99.21

101.41

103.62

105.82

108.03

110.23

112.44

114.64

116.85

119.05

121.25

123.46

125.66

127.87

130.07

132.28

134.48

136.69

138.89

141.10

143.30

145.51

147.71

149.91

152.12

154.32

156.53

158.73

160.94

163.14

165.35

167.55

169.76

171.96

174.17

176.37

178.57

180.78

182.98

185.19

187.39

189.60

191.80

194.01

196.21

198.42

200.62

202.83

205.03

207.24

209.44

211.64

213.85

216.05

218.26

00-17

FOREWORD

CONVERSION TABLE

Liter to U.S. Gallon

1 = 0.2642 U.S. Gal

0.264

0.528

0.793

1.057

1.321

1.585

1.849

2.113

2.378

2.642

2.906

3.170

3.434

3.698

3.963

4.227

4.491

4.755

5.019

5.283

5.548

5.812

6.076

6.340

6.604

6.869

7.133

7.397

7.661

7.925

8.189

8.454

8.718

8.982

9.246

9.510

9.774

10.039

10.303

10.567

10.831

11.095

11.359

11.624

11.888

12.152

12.416

12.680

12.944

13.209

13.473

13.737

14.001

14.265

14.529

14.795

15.058

15.322

15.586

15.850

16.115

16.379

16.643

16.907

17.171

17.435

17.700

17.964

18.228

18.492

18.756

19.020

19.285

19.549

19.813

20.077

20.341

20.605

20.870

21.134

21.398

21.662

21.926

22.190

22.455

22.719

22.983

23.247

23.511

23.775

24.040

24.304

24.568

24.832

25.096

25.361

25.625

25.889

26.153

Liter to U.K. Gallon

1 = 0.21997 U.K. Gal

0.220

0.440

0.660

0.880

1.100

1.320

1.540

1.760

1.980

2.200

2.420

2.640

2.860

3.080

3.300

3.520

3.740

3.950

4.179

4.399

4.619

4.839

5.059

5.279

5.499

5.719

5.939

6.159

6.379

6.599

6.819

7.039

7.259

7.479

7.969

7.919

8.139

8.359

8.579

8.799

9.019

9.239

9.459

9.679

9.899

10.119

10.339

10.559

10.778

10.998

11.281

11.438

11.658

11.878

12.098

12.318

12.528

12.758

12.978

13.198

13.418

13.638

13.858

14.078

14.298

14.518

14.738

14.958

15.178

15.398

15.618

15.838

16.058

16.278

16.498

16.718

16.938

17.158

17.378

17.598

17.818

18.037

18.257

18.477

18.697

18.917

19.137

19.357

19.577

19.797

20.017

20.237

20.457

20.677

20.897

21.117

21.337

21.557

21.777

00-18

FOREWORD

CONVERSION TABLE

kgm to ft. lb 1 kgm = 7.233 ft. lb

7.2

14.5

21.7

28.9

36.2

43.4

50.6

57.9

65.1

72.3

79.6

86.8

94.0

101.3

108.5

115.7

123.0

130.2

137.4

144.7

151.9

159.1

166.4

173.6

180.8

188.1

195.3

202.5

209.8

217.0

224.2

231.5

238.7

245.9

253.2

260.4

267.6

274.9

282.1

289.3

296.6

303.8

311.0

318.3

325.5

332.7

340.0

347.2

354.4

361.7

368.9

376.1

383.4

390.6

397.8

405.1

412.3

419.5

426.8

434.0

441.2

448.5

455.7

462.9

470.2

477.4

484.6

491.8

499.1

506.3

513.5

520.8

528.0

535.2

542.5

549.7

556.9

564.2

571.4

578.6

585.9

593.1

600.3

607.6

614.8

622.0

629.3

636.5

643.7

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

00-19

FOREWORD

CONVERSION TABLE

kg/cm2 to lb/in2 1kg/cm2 = 14.2233 lb/in2

14.2

28.4

42.7

56.9

71.1

85.3

99.6

113.8

128.0

142.2

156.5

170.7

184.9

199.1

213.4

227.6

241.8

256.0

270.2

284.5

298.7

312.9

327.1

341.4

355.6

369.8

384.0

398.3

412.5

426.7

440.9

455.1

469.4

483.6

497.8

512.0

526.3

540.5

554.7

568.9

583.2

597.4

611.6

625.8

640.1

654.3

668.5

682.7

696.9

711.2

725.4

739.6

753.8

768.1

782.3

796.5

810.7

825.0

839.2

853.4

867.6

881.8

896.1

910.3

924.5

938.7

953.0

967.2

981.4

995.6

1010

1024

1038

1053

1067

1081

1095

1109

1124

1138

1152

1166

1181

1195

1209

1223

1237

1252

1266

1280

1294

1309

1323

1337

1351

1365

1380

1394

1408

100

1422

1437

1451

1465

1479

1493

1508

1522

1536

1550

110

1565

1579

1593

1607

1621

1636

1650

1664

1678

1693

120

1707

1721

1735

1749

1764

1778

1792

1806

1821

1835

130

1849

1863

1877

1892

1906

1920

1934

1949

1963

1977

140

1991

2005

2020

2034

2048

2062

2077

2091

2105

2119

150

2134

2148

2162

2176

2190

2205

2219

2233

2247

2262

160

2276

2290

2304

2318

2333

2347

2361

2375

2389

2404

170

2418

2432

2446

2460

2475

2489

2503

2518

2532

2546

180

2560

2574

2589

2603

2617

2631

2646

2660

2674

2688

190

2702

2717

2731

2745

2759

2773

2788

2802

2816

2830

200

2845

2859

2873

2887

2901

2916

2930

2944

2958

2973

210

2987

3001

3015

3030

3044

3058

3072

3086

3101

3115

220

3129

3143

3158

3172

3186

3200

3214

3229

3243

3257

230

3271

3286

3300

3314

3328

3343

3357

3371

3385

3399

240

3414

3428

3442

3456

3470

3485

3499

3513

3527

3542

00-20

FOREWORD

CONVERSION TABLE

Temperature Fahrenheit-Centigrade Conversion ; a simple way to convert a Fahrenheit temperature reading into a Centigrade temperature reading or vice versa is to enter the accompanying table in the center or boldface column of figures. These figures refer to the temperature in either Fahrenheit or Centigrade degrees. If it is desired to convert from Fahrenheit to Centigrade degrees, consider the center column as a table of Fahrenheit temperatures and read the corresponding Centigrade temperature in the column at the left. If it is desired to convert from Centigrade to Fahrenheit degrees, consider the center column as a table of Centigrade values, and read the corresponding Fahrenheit temperature on the right. 1°C = 33.8°F

°C

°F

°C

°F

°C

°F

°C

°F

–40.4 –37.2 –34.4 –31.7 –28.9

–40 –35 –30 –25 –20

–40.0 –31.0 –22.0 –13.0 –4.0

–11.7 –11.1 –10.6 –10.0 –9.4

11 12 13 14 15

51.8 53.6 55.4 57.2 59.0

7.8 8.3 8.9 9.4 10.0

46 47 48 49 50

114.8 116.6 118.4 120.2 122.0

27.2 27.8 28.3 28.9 29.4

81 82 83 84 85

117.8 179.6 181.4 183.2 185.0

–28.3 –27.8 –27.2 –26.7 –26.1

–19 –18 –17 –16 –15

–2.2 –0.4 1.4 3.2 5.0

–8.9 –8.3 –7.8 –7.2 –6.7

16 17 18 19 20

60.8 62.6 64.4 66.2 68.0

10.6 11.1 11.7 12.2 12.8

51 52 53 54 55

123.8 125.6 127.4 129.2 131.0

30.0 30.6 31.1 31.7 32.2

86 87 88 89 90

186.8 188.6 190.4 192.2 194.0

–25.6 –25.0 –24.4 –23.9 –23.3

–14 –13 –12 –11 –10

6.8 8.6 10.4 12.2 14.0

–6.1 –5.6 –5.0 –4.4 –3.9

21 22 23 24 25

69.8 71.6 73.4 75.2 77.0

13.3 13.9 14.4 15.0 15.6

56 57 58 59 0

132.8 134.6 136.4 138.2 140.0

32.8 33.3 33.9 34.4 35.0

91 92 93 94 95

195.8 197.6 199.4 201.2 203.0

–22.8 –22.2 –21.7 –21.1 –20.6

–9 –8 –7 –6 –5

15.8 17.6 19.4 21.2 23.0

–3.3 –2.8 –2.2 –1.7 –1.1

26 27 28 29 30

78.8 80.6 82.4 84.2 86.0

16.1 16.7 17.2 17.8 18.3

61 62 63 64 65

141.8 143.6 145.4 147.2 149.0

35.6 36.1 36.7 37.2 37.8

96 97 98 99 100

204.8 206.6 208.4 210.2 212.0

–20.0 –19.4 –18.9 –18.3 –17.8

–4 –3 –2 –1 0

24.8 26.6 28.4 30.2 32.0

–0.6 0 0.6 1.1 1.7

31 32 33 34 35

87.8 89.6 91.4 93.2 95.0

18.9 19.4 20.0 20.6 21.1

66 67 68 69 70

150.8 152.6 154.4 156.2 158.0

40.6 43.3 46.1 48.9 51.7

105 110 115 120 125

221.0 230.0 239.0 248.0 257.0

–17.2 –16.7 –16.1 –15.6 –15.0

1 2 3 4 5

33.8 35.6 37.4 39.2 41.0

2.2 2.8 3.3 3.9 4.4

36 37 38 39 40

96.8 98.6 100.4 102.2 104.0

21.7 22.2 22.8 23.3 23.9

71 72 73 74 75

159.8 161.6 163.4 165.2 167.0

54.4 57.2 60.0 62.7 65.6

130 135 140 145 150

266.0 275.0 284.0 293.0 302.0

–14.4 –13.9 –13.3 –12.8 –12.2

6 7 8 9 10

42.8 44.6 46.4 48.2 50.0

5.0 5.6 6.1 6.7 7.2

41 42 43 44 45

105.8 107.6 109.4 111.2 113.0

24.4 25.0 25.6 26.1 26.7

76 77 78 79 80

168.8 170.6 172.4 174.2 176.0

68.3 71.1 73.9 76.7 79.4

155 160 165 170 175

311.0 320.0 329.0 338.0 347.0

00-21

FOREWORD

UNITS

UNITS In this manual, the measuring units are indicated with Internatinal System of units (SI). As for reference, conventionally used Gravitational System of units are indicated in parentheses { Example: N {kg} Nm {kgm} MPa {kg/cm2} kPa {mmH2O} kPa {mmHg} kW/rpm {HP/rpm} g/kWh {g/HPh}

00-22

01 GENERAL

Specification drawings ................................ 01- 2 Specifications ................................................ 01- 4 Weight table ................................................ 01- 8 Fuel, coolant and lubricants ...................... 01-12

PC600-6

01-1

GENERAL

SPECIFICATION DRAWINGS

01-2

PC600-6

GENERAL

SPECIFICATION DRAWINGS

Unit: mm Machine model

PC600-6

PC600LC-6

Serial number

10001 – 11000

11001 and up

10001 – 11000

11001 and up

12,128

3,900

4,300

3,310

1,365

780

4,250

4,600

3,300

3,195

600

3,070

9,135

3,675

11,880

7,960

8,490

7,510

8,360

2,440

13,020

12,800

5,370

10,020

PC600-6

01-3

GENERAL

SPECIFICATIONS

SPECIFICATIONS PC600-6 Machine model

PC600-6 11001 and up

2.7

Operating weight

56,600

Max. digging depth

8,490

Max. vertical wall depth

7,510

Max. digging reach

13,020

Max. reach at ground level

12,800

Max. digging height

11,880

Max. dumping height

7,960

Max. digging force (using power max. function)

kN{kg}

294.3 {30,000} (316.9 {32,300})

Swing speed

rpm

8.3

Swing max. slope angle

deg.

Travel speed

km/h

Lo: 3.0 Hi: 4.9

Gradeability

deg.

kPa{kg/cm2}

99 {1.01} [600 mm]

80.5 {0.82} [600 mm]

Overall length (for transport)

12,810

Overall width

3,195

Overall width of track

3,900

Overall height (for transport)

4,300

Overall height to top of cab

3,310

Ground clearance of counterweight

1,365

Min. ground clearance

780

Tail swing radius

3,800

Min. swing radius of work equipment

5,370

Height of work equipment at min. swing radius

10,020

Length of track on ground

4,250

Track gauge

3,300

Height of machine cab

3,070

Ground pressure [standard triple grouser shoe width]

Dimensions

10001 – 11000

Bucket capacity

Working ranges

Performance

Serial number

01-4

PC600-6

GENERAL

SPECIFICATIONS

Machine model

PC600-6 10001 – 11000

11001 and up

Model

CUMMINS N14-C420

KOMATSU SA6D140E-3

Type

4-cycle, water-cooled, in-line, vertical, direct injection, with turbocharger and aftercooler (water cooled)

No. of cylinders – bore x stroke

6 – 140 x 152

6 – 140 x 165

Piston displacement

¬ {cc}

14 {14,030}

15.24 {15,240}

Performance

Engine

Serial number

Flywheel horsepower

kW/rpm{HP/rpm} 287/1,800 {384/1,800}

Max. torque

Nm/rpm{kgm/rpm} 1,898/1,400 {194/1,400} 1,755/1,400 {179/1,400}

Max. speed at no load

rpm

2,000

1,950

Min. speed at no load

rpm

800

825

Min. fuel consumption

g/kW.h{g/HP.h}

193 {146}

214 {160}

24V, 8.9 kW

24V, 11 kW

24V, 70A

24V, 50A

Starting motor Alternator Battery

12V, 175 Ah x 2

Radiator core type

CWX-5 3 on each side

Track roller

8 on each side

Track shoe

Assembly-type triple grouser 49 on each side

Hydraulic pump

Carrier roller

Type x No.

Hydraulic system Hydraulic Control Hydraulic cylinder motor valve

Undercarriage

287/1,800 {384/1,800}

Type x No.

Delivery Set pressure

Variable displacement piston type HPV95 + 95 x 2, gear type: SAL(2)56 + (2)8 ¬/min.

Piston type: 410 x 2, gear type: 137 2

MPa{kg/cm }

Piston type: 34.3 {350}, gear type: 2.9 {30} 4-spool + 5-spool type x 1

Control method

Hydraulic

Travel motor

KMV335ADT, Piston type (with brake valve, shaft brake): x 2 KMF90ABE-3, Piston type (with safety valve, shaft brake, reverse prevention valve): x 2

Swing motor

Type Inside diameter of cylinder Diameter of piston rod Stroke Max. distance between pins Min. distance between pins

Hydraulic tank Hydraulic filter Hydraulic cooler PC600-6

mm mm mm mm mm

Boom Arm Bucket Double-acting Double-acting Double-acting piston piston piston 185 200 185 120 140 120 1,725 2,060 1,425 4,182 4,948 3,577 2,457 2,888 2,152 Box-shaped, sealed Tank return side Air cooled

01-5

GENERAL

SPECIFICATIONS

PC600LC-6 Machine model

PC600LC-6 11001 and up

2.7

Operating weight

57,600

Max. digging depth

8,490

Max. vertical wall depth

7,510

Max. digging reach

13,020

Max. reach at ground level

12,800

Max. digging height

11,880

Max. dumping height

7,960

Max. digging force (using power max. function)

kN{kg}

294.3 {30,000} (316.9 {32,300})

Swing speed

rpm

8.3

Swing max. slope angle

deg.

Travel speed

km/h

Lo: 3.0 Hi: 4.9

Gradeability

deg.

kPa{kg/cm2}

94 {0.96} [600 mm]

76.2 {0.78} [600 mm]

Overall length (for transport)

12,810

Overall width

3,195

Overall width of track

3,900

Overall height (for transport)

4,300

Overall height to top of cab

3,310

Ground clearance of counterweight

1,365

Min. ground clearance

780

Tail swing radius

3,800

Min. swing radius of work equipment

5,370

Height of work equipment at min. swing radius

10,020

Length of track on ground

4,600

Track gauge

3,300

Height of machine cab

3,070

Ground pressure [standard triple grouser shoe width]

Dimensions

10001 – 11000

Bucket capacity

Working ranges

Performance

Serial number

01-6

PC600-6

GENERAL

SPECIFICATIONS

Machine model

PC600LC-6 10001 – 11000

11001 and up

Model

CUMMINS N14-C420

KOMATSU SA6D140E-3

Type

4-cycle, water-cooled, in-line, vertical, direct injection, with turbocharger and aftercooler (water cooled)

No. of cylinders – bore x stroke

6 – 140 x 152

6 – 140 x 165

Piston displacement

¬ {cc}

14 {14,030}

15.24 {15,240}

Performance

Engine

Serial number

Flywheel horsepower

kW/rpm{HP/rpm} 287/1,800 {384/1,800}

Max. torque

Nm/rpm{kgm/rpm} 1,898/1,400 {194/1,400} 1,755/1,400 {179/1,400}

Max. speed at no load

rpm

2,000

1,950

Min. speed at no load

rpm

800

825

Min. fuel consumption

g/kW.h{g/HP.h}

193 {146}

214 {160}

24V, 8.9 kW

24V, 11 kW

24V, 70A

24V, 50A

Starting motor Alternator Battery

12V, 175 Ah x 2

Radiator core type

CWX-5 3 on each side

Track roller

9 on each side

Track shoe

Assembly-type triple grouser 52 on each side

Hydraulic pump

Carrier roller

Type x No.

Hydraulic system Hydraulic Control Hydraulic cylinder motor valve

Undercarriage

287/1,800 {384/1,800}

Type x No.

Delivery Set pressure

Variable displacement piston type HPV95 + 95 x 2, gear type: SAL(2)56 + (2)8 ¬/min. MPa{kg/cm2}

Piston type: 410 x 2, gear type: 137 Piston type: 34.3 {350}, gear type: 2.9 {30} 4-spool + 5-spool type x 1

Control method

Hydraulic

Travel motor

KMV335ADT, Piston type (with brake valve, shaft brake): x 2 KMF90ABE-3, Piston type (with safety valve, shaft brake, reverse prevention valve): x 2

Swing motor

Type Inside diameter of cylinder Diameter of piston rod Stroke Max. distance between pins Min. distance between pins

Hydraulic tank Hydraulic filter Hydraulic cooler PC600-6

mm mm mm mm mm

01-7

GENERAL

WEIGHT TABLE

WEIGHT TABLE ¤ This weight table is a guide for use when transporting or handling component. PC600-6

Unit: kg

Machine model Serial number

PC600-6 10001 – 11000

11001 and up

Engine assembly

2,259

• Engine

1,374

• PTO (Including lubricating piping)

258

• Hydraulic pump

327

Radiator, oil cooler assembly

313

Hydraulic tank, filter assembly (excl. hydraulic oil)

425

Fuel tank (excl. fuel)

498

Revolving frame

4,380

4,345

Operator’s cab

330

Operator’s seat

Counterweight

10,750

Swing machinery

724

Control valve

304

Swing motor

61 x 2

Travel motor

268 x 2

Track frame assembly

15,033

• Track frame

4,414

• Swing circle

1,139

• Idler

342 x 2

• Idler cushion

452 x 2

• Carrier roller

50 x 6

• Track roller

105 x 16

• Final drive (incl. travel motor)

957 x 2

Center swivel joint

01-8

PC600-6

GENERAL

WEIGHT TABLE

Unit: kg

Machine model Serial number

PC600-6 10001 – 11000

11001 and up

• Standard triple grouser shoe (600 mm)

5,930

• Wide triple grouser shoe

6,750

Boom assembly

4,704

Arm assembly

3,238

Bucket assembly

2,410

Boom cylinder assembly

643 x 2

Arm cylinder assembly

769

Bucket cylinder assembly

469

Link assembly (large)

584

Link assembly (small)

—

Track shoe assembly

Boom pin

(750 mm)

149 + 26 x 2 + 76 + 104 + 36 149 + 26 x 2 + 76 + 104 + 36

Arm pin

32 + 55

Bucket pin

55 + 62

Link pin

45 x 2

PC600-6

01-9

GENERAL

WEIGHT TABLE

PC600LC-6

Unit: kg

Machine model Serial number

PC600LC-6 10001 – 11000

11001 and up

Engine assembly

2,259

• Engine

1,374

• PTO (Including lubricating piping)

258

• Hydraulic pump

327

Radiator, oil cooler assembly

313

Hydraulic tank, filter assembly (excl. hydraulic oil)

425

Fuel tank (excl. fuel)

498

Revolving frame

4,380

4,345

Operator’s cab

330

Operator’s seat

Counterweight

10,750

Swing machinery

724

Control valve

304

Swing motor

61 x 2

Travel motor

268 x 2

Track frame assembly

15,538

• Track frame

4,709

• Swing circle

1,139

• Idler

342 x 2

• Idler cushion

452 x 2

• Carrier roller

50 x 6

• Track roller

105 x 18

• Final drive (incl. travel motor)

957 x 2

Center swivel joint

01-10

PC600-6

GENERAL

WEIGHT TABLE

Unit: kg

Machine model Serial number

PC600LC-6 10001 – 11000

11001 and up

• Standard triple grouser shoe (600 mm)

6,290

• Wide triple grouser shoe

7,170

Boom assembly

4,704

Arm assembly

3,238

Bucket assembly

2,410

Boom cylinder assembly

643 x 2

Arm cylinder assembly

769

Bucket cylinder assembly

469

Link assembly (large)

584

Link assembly (small)

—

Track shoe assembly

Boom pin

(750 mm)

149 + 26 x 2 + 76 + 104 + 36 149 + 26 x 2 + 76 + 104 + 36

Arm pin

32 + 55

Bucket pin

55 + 62

Link pin

45 x 2

PC600-6

01-11

GENERAL

FUEL, COOLANT AND LUBRICANTS

FUEL, COOLANT AND LUBRICANTS RESERVOIR

KIND OF FLUID –22

AMBIENT TEMPERATURE –4 –20

14 –10

32 0

50 10

68 20

86 30

CAPACITY (¬) 104°F 40°C

Specified

Refill

Final drive case (each)

Hydraulic system

520

360

880

—

–30

SAE 10W Engine oil pan SAE 10W-30

PTO case

Swing machinery case (each)

Engine oil SAE 5W-30

Fuel tank

Cooling system

01-12

Diesel fuel

Water

ASTM D975 No. 2 ASTM D975 No.1

Add antifreeze

PC600-6

10 STRUCTURE AND FUNCTION

Parts related to engine .............................. 10- 2 PTO .............................................................. 10- 4 Radiator, oil cooler ..................................... 10- 5 Power train ................................................. 10- 6 Final drive ................................................... 10- 8 Swing circle ................................................ 10- 9 Swing machinery ....................................... 10- 10 Track frame, recoil spring ......................... 10- 11 Track shoe ................................................... 10- 12 Hydraulic piping drawing .......................... 10- 14 Hydraulic tank, hydraulic filter .................. 10- 16 Hydraulic pump (piston pump) ................ 10- 19 Line oil filter ................................................ 10- 47 Control valve .............................................. 10- 48 Swing motor ............................................... 10- 63 Center swivel joint ..................................... 10- 73 Travel motor ............................................... 10- 74 Valve control ............................................... 10- 84 Work equipment • swing PPC valve ........ 10- 86 Travel PPC valve ........................................ 10- 90 Service PPC valve ...................................... 10- 94 PPC safety lock valve ................................. 10- 97 PPC accumulator ........................................ 10- 97 PPC shuttle valve ........................................ 10- 98 Solenoid valve ............................................ 10- 99 Boom holding valve ................................... 10-102 Boom lower regeneration valve ............... 10-106 Air conditioner ............................................ 10-109 Actual electric wiring diagram .................. 10-110 Engine control ............................................ 10-114 Machine control system ............................ 10-121 Monitor system .......................................... 10-155

PC600-6

10-1

STRUCTURE AND FUNCTION

PARTS RELATED TO ENGINE

10-2

PC600-6

STRUCTURE AND FUNCTION

1. 2. 3. 4. 5.

PARTS RELATED TO ENGINE

Air cleaner Intake connector Muffler Front engine mount Rear engine mount

PC600-6

10-3

STRUCTURE AND FUNCTION

PTO

1. 2. 3. 4. 5. 6. 7.

Connection plate PTO case Driven gear (No. of teeth: 40) Drive gear (No. of teeth: 36) Oil level gauge Main shaft Breather

a. Center of crankshaft (Center of SAL56 shaft) b. Center of HPV95+95 shaft c. Center of HPV95+95 shaft Specifications Lubricating oil: 6 ¬ Reducation ratio: Input shaft (SAL56 shaft) = 1 HPV95+95 shaft =

10-4

36 = 0.9 40

PC600-6

STRUCTURE AND FUNCTION

RADIATOR, OIL COOLER

1. 2. 3. 4. 5. 6.

Oil cooler Radiator Radiator inlet hose Reservoir tank Radiator outlet hose Shroud

PC600-6

7. Radiator cap 8. Fan 9. Radiator sub tank 10. Cushion 11. Collar

Specifications Radiator: CWX-5 Oil cooler: J-5

10-5

STRUCTURE AND FUNCTION

POWER TRAIN

10-6

PC600-6

STRUCTURE AND FUNCTION

1. Idler 2. Center swivel joint 3. Swing motor (KMF90ABE-3) 4. Control valve 5. Final drive, sprocket 6. Travel motor (KMV335ADT) 7. Engine 8. PTO 9. No. 1 pump (HPV95+95) 10. No. 2 pump (HPV95+95)

PC600-6

POWER TRAIN

11. Control pump (SAL56) 12. Swing brake solenoid valve 13. Travel speed solenoid valve 14. Swing machinery 15. Swing circle 16. PTO lubrication pump A: Control valve B: Swing brake solenoid valve

10-7

STRUCTURE AND FUNCTION

FINAL DRIVE

1. Level plug 2. Drain plug 3. No. 1 planetary gear (No. of teeth: 50) 4. No. 1 sun gear (No. of teeth: 12) 5. No. 2 sun gear (No. of teeth: 14) 6. No. 1 planetary carrier 7. No. 2 planetary carrier 8. Cover 9. No. 1 ring gear (No. of teeth: 114) 10. Hub 11. Sprocket 12. Floating seal 13. Travel motor 14. No. 2 planetary gear (No. of teeth: 27) 15. No. 2 ring gear (No. of teeth: 70)

Specifications Reduction ratio: –

14+70 x( +1 (12+114 ) 12 14 )

= – 62.000

10-8

PC600-6

STRUCTURE AND FUNCTION

SWING CIRCLE

1. Swing circle inner race (No. of teeth: 100) 2. Ball 3. Swing circle outer race

Specifications

a. Inner race soft zone ”S” position b. Outer race soft zone ”S” position

Amount of grease: 16.5 ¬ (G2-LI)

PC600-6

Reduction ratio: –

100 = – 7.692 13

10-9

STRUCTURE AND FUNCTION

SWING MACHINERY

SWING MACHINERY 1. Swing pinion (No. of teeth: 13) 2. Cover 3. Case 4. Coupling 5. No. 2 planetary gear (No. of teeth: 36) 6. Ring gear (No. of teeth: 95) 7. No. 1 planetary gear (No. of teeth: 39) 8. Cover 9. Swing motor 10. Oil level gauge 11. No. 1 sun gear (No. of teeth: 16) 12. No. 1 planetary carrier 13. No. 2 sun gear (No. of teeth: 21) 14. No. 2 planetary carrier

Specifications Reduction ratio:

10-10

16+95 21+95 x 16 21 = 38.321

PC600-6

STRUCTURE AND FUNCTION

TRACK FRAME, RECOIL SPRING

TRACK FRAME, RECOIL SPRING ﬂ The diagram shows the PC600-6

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

Idler Track frame Carrier roller Center frame Final drive Track roller Track shoe Recoil spring Center guard

PC600-6

•

The dimensions and number of track rollers may differ according to the model, but the basic structure is the same. No. of track rollers. Model

No. of rollers (each side)

PC600-6

PC600LC-6

10-11

STRUCTURE AND FUNCTION

TRACK SHOE

TRACK SHOE Standard shoe Model Item Shoe width (mm) (triple shoe)

PC600-6

PC600LC-6

600

Link pitch (mm)

228.6

No. of shoes (each side)

Selection of track shoe • Select the most suitable track shoe from the following table PC600-6

Standard

PC600LC-6 CateCateSpecifications gory Specifications gory 600 mm triple A 600 mm triple A

Option

750 mm triple

Option

900 mm triple

Category

Use

Precautions when using

Rocky ground, normal river soil

• Travel in Lo speed when traveling on rough ground with obstacles such as large boulders and fallen trees.

• Cannot be used on rough ground where there are large obstacles such as boulders and fallen trees. Normal soil, soft land • Travel in Hi speed only on flat ground; when it is impossible to avoid traveling over obstacles, lower the travel speed to approx. half of Lo speed.

Extremely soft ground (swampy ground)

• Use only for ground where “A” and “B” sink and are impossible to use. • Cannot be used on rough ground where there are large obstacles such as boulders and fallen trees • Travel in Hi speed only on flat ground; when it is impossible to avoid traveling over obstacles, lower the travel speed to approx. half of Lo speed.

Paved surface

• The shoes are flat, so they have low gradeability

Paved surface

• The shoes are made of rubber, so be careful when traveling on rough ground

ﬂ Categories “B” and “C” are wide shoes, so there are restrictions on their use. Therefore, before using, check the restrictions and consider carefully the conditions of use before recommending a suitable shoe width. If necessary, give the customer guidance in their use.

10-12

ﬂ When selecting the shoe width, select the narrowest shoe possible within the range that will give no problem with flotation and ground pressure. If a wider shoe than necessary is used, there will be a large load on the shoe, and this may lead to bending of the shoe, cracking of the links, breakage of the pins, loosening of the shoe bolts, or other problems.

PC600-6

STRUCTURE AND FUNCTION

HYDRAULIC PIPING DRAWING

1. Bucket cylinder 2. Arm cylinder 3. Boom cylinder 4. Center swivel joint 5. Swing motor 6. Oil cooler 7. Control valve 8. PPC shuttle valve 9. Hydraulic filter 10. Hydraulic pump 11. L.H. travel motor 12. Hydraulic tank 13. PPC safety lock valve 14. L.H. PPC valve 15. R.H. PPC valve 16. Travel PPC valve 17. Boom holding valve 18. Accumulator 19. Active solenoid valve (swing) 20. Solenoid valve assembly 20A. Swing brake solenoid valve 20B. Travel speed solenoid valve 20C. Pump merge/flow divider solenoid valve 20D. Boom Hi 2-stage safety solenoid valve 20E. Active solenoid valve (boom)

10-14

PC600-6

STRUCTURE AND FUNCTION

PC600-6

HYDRAULIC PIPING DRAWING

10-15

STRUCTURE AND FUNCTION

HYDRAULIC TANK, HYDRAULIC FILTER

10-16

PC600-6

STRUCTURE AND FUNCTION

HYDRAULIC TANK, HYDRAULIC FILTER

1. Hydraulic filter 1A. Bypass valve 1B. Strainer 1C. Element 1D. Cooler check valve 2. Hydraulic tank 3. Suction strainer 4. Hydraulic oil level sensor 5. Sight gauge 6. Oil filler cap

Specifications Tank capacity: 500 ¬ Amount of oil inside tank: 380 ¬ (at H level) Safety valve • Relief cracking pressure: 16.7 ± 6.9 kPa {0.17 ± 0.07 kg/cm2} • Suction cracking pressure: 0 – 0.49 kPa {0 – 0.005 kg/cm2} • Bypass valve set pressure: 102.9 ± 19.6 kPa {1.05 ± 0.2 kg/cm2}

PC600-6

10-17

STRUCTURE AND FUNCTION

HYDRAULIC PUMP (PISTON PUMP)

HYDRAULIC PUMP (PISTON PUMP) No. 1 Main pump Type: HPV95+95

PA1 : Front pump discharge port PA2 : Rear pump discharge port PD11 : Drain port PD21 : Drain port PCF : CO selector pilot port PCR : CO selector pilot port PD : Jet sensor downstream pressure IN port PS : Pump suction port PT : Jet sensor upstream pressure IN port PSV : Servo basic pressure IN port PECN : CO+NC valve output pressure detection port

PC600-6

1. 2. 3. 4. 5. 6. 7.

Front pump Front servo valve Front CO+NC valve Rear servo valve Rear CO+NC valve TVC valve Rear pump

10-19

STRUCTURE AND FUNCTION

HYDRAULIC PUMP (PISTON PUMP)

No. 1 main pump

PSV1 : Servo valve basic pressure port PSV2 : Servo valve basic pressure port PSV1A : Servo piston output port PSV1B : Servo valve output port PSV2A : Servo piston output port PSV2B : Servo valve output port

10-20

PC600-6

STRUCTURE AND FUNCTION

1. 2. 3. 4. 5. 6. 7.

Front shaft Front cradle Front case Rocker cam Piston Cylinder block Valve plate

PC600-6

HYDRAULIC PUMP (PISTON PUMP)

8. Front end cap 9. Coupling 10. Impeller 11. Rear end cap 12. Valve plate 13. Cylinder block 14. Piston

15. Rear case 16. Rocker cam 17. Rear cradle 18. Rear shaft 19. Servo piston

10-21

STRUCTURE AND FUNCTION

HYDRAULIC PUMP (PISTON PUMP)

SERVO VALVE 1. Servo valve assembly (No. 1 front)

P1 PE

: Main pump pressure IN port : TVC valve output pressure front, rear interconnection port PCO : CO selector pilot port PD : Jet sensor downstream pressure IN port PT : Jet sensor upstream pressure IN port PAC : Servo actuator port PDR : Servo valve drain OUT port PPO : Servo basic pressure IN port PECN : CO+NC valve output pressure OUT port

10-22

1. CO+NC valve 2. Servo valve

PC600-6

STRUCTURE AND FUNCTION

HYDRAULIC PUMP (PISTON PUMP)

2. Servo valve (No. 1 front)

P2 : Main pump pressure OUT port PDR : CO+NC valve drain IN port PECN : CO+NC valve output pressure IN port

PC600-6

10-23

STRUCTURE AND FUNCTION

HYDRAULIC PUMP (PISTON PUMP)

3. Servo valve assembly (No. 1 rear)

P1 : Main pump pressure IN port P2 : Main pump pressure IN port PCO : CO selector pilot port PAC : Servo actuator port PDR : Servo valve drain OUT port PPO : Servo basic pressure IN port PD : Jet sensor downstream pressure front, rear interconnection port PE : TVC valve output pressure front, rear interconnection port PT : Jet sensor upstream pressure IN port

10-24

1. 2. 3. 4.

TVC valve CO+NC valve Connector Servo valve

PC600-6

STRUCTURE AND FUNCTION

HYDRAULIC PUMP (PISTON PUMP)

4. Servo valve (No. 1 rear)

P1 : Main pump pressure OUT port P2 : Main pump pressure OUT port PDR : CO+NC valve drain port PPO : Servo basic pressure OUT port PECN : CO+NC valve output pressure IN port

PC600-6

10-25

STRUCTURE AND FUNCTION

HYDRAULIC PUMP (PISTON PUMP)

Structure

1. 2. 3. 4. 5. 6.

Plug Locknut Piston Pin Arm Valve body

7. Spring 8. Plug 9. Cover 10. Locknut 11. Locknut 12. Cover

13. Plug 14. Spring 15. Piston 16. Sleeve 17. Cover 18. Locknut

Function Discharge amounts Q1 and Q2 of main pumps PA1 and PA2 are controlled individually by the respective servo valves. The relationship between pump discharge amount Q and input signal PECN to the servo valve is as shown in the graph on the right. Q varies in proportion to PECN.

10-26

PC600-6

STRUCTURE AND FUNCTION

HYDRAULIC PUMP (PISTON PUMP)

1) Operation in direction of increase of pump discharge amount (max. angle)

Operation • The control pump pressure PPO is taken to port a. • Signal pressure PECN from the NC valve is taken from port b to chamber c. • When signal pressure PECN rises, piston (8) is pushed to the right by the pressure in chamber c, and stops at a point where it balances the pressure of springs (4) and (4A). • At the same time, arm (6) uses servo piston (19) as a fulcrum and sways to the right in the same way as piston (8). This moves guide spool (13) to the right. • When guide spool (13) moves, port a and port d are closed and port d is connected to drain chamber e. As a result, servo piston chamber f is also interconnected with drain chamber e through port g and port d.

PC600-6

•

At the same time, port a is interconnected with port h, so the pressure oil flows through port i to servo piston chamber j, pushes servo piston (19) to the right, increases the swash plate angle in the main piston pump and increases the pump discharge amount. When servo piston (19) moves, arm (6) rotates counterclockwise with its center at pin (7) and moves guide spool (13) to the left. Port a, port d and port h close, so the discharge increases by an amount that matches signal pressure PECN.

10-27

STRUCTURE AND FUNCTION

HYDRAULIC PUMP (PISTON PUMP)

2) Operation in direction of decrease of pump discharge amount (min. angle)

Operation • When signal pressure PECN goes down, piston (8) moves to the left and stops at a point where the pressure in chamber c balances the pressure of springs (4) and (4A). • At the same time, arm (6) uses servo piston (19) as a fulcrum and sways to the left in the same way as piston (8). This moves guide spool (13) to the left. • When guide spool (13) moves, port a and port h are closed and port h is connected to drain chamber e. As a result, servo piston chamber j is also interconnected with drain chamber e through port i and port h.

10-28

•

At the same time, port a is interconnected with port d, so the oil flows through port g to servo piston chamber f, pushes servo piston (19) to the left, decreases the swash plate angle in the main piston pump and decreases the pump discharge amount. When servo piston (19) moves, arm (6) rotates clockwise with its center at pin (7). Guide spool (13) is moved to the right and closes port a, port d and port h, so the discharge decreases by an amount that matches signal pressure PECN.

PC600-6

STRUCTURE AND FUNCTION

HYDRAULIC PUMP (PISTON PUMP)

TVC VALVE

PPO : Servo basic pressure IN port P1 : Main pump pressure IN port P2 : Main pump pressure IN port PDR : TVC valve drain OUT port PE : TVC valve output pressure OUT port

PC600-6

1. 2. 3. 4.

Spring Spool Piston Piston

5. 6. 7. 8.

Sleeve Piston Body Solenoid

10-29

STRUCTURE AND FUNCTION

Function • When the power mode is at DH mode or H mode, the pump discharge amount is controlled to the optimum amount by the command current sent from the controller in accordance with the engine speed.

HYDRAULIC PUMP (PISTON PUMP)

•

In G mode or when the pump emergency switch is ON, the pump discharge amount is controlled according to the pump discharge pressure (load) by hydraulic sensing which follows a constant pump absorption torque.

1) When command current value from controller is small in DH and H mode

Operation • The command current sent from the controller actuates solenoid push pin (9) and spool (2) moves. When this happens, spool (2) stops at a point where it balances the total of the force of spring (1), the force of push pin (9), and the force of TVC output pressure PE acting on piston (3). The command current at this point is small, so spool (2) is balanced at the bottom.

10-30

•

As a result, port a and port b are almost completely open, so the pressure oil from the control pump is almost all output as TVC output pressure PE. In this way, the pump discharge amount becomes the maximum.

PC600-6

STRUCTURE AND FUNCTION

HYDRAULIC PUMP (PISTON PUMP)

2) When command current value from controller is large in DH and H mode

Operation • The command current sent from the controller actuates solenoid push pin (9) and spool (2) moves. When this happens, spool (2) stops at a point where it balances the force of spring (1). The command current at this point is large, so spool (2) is balanced at the top.

PC600-6

•

As a result, the flow of oil from the control pump from port a to port b is throttled. At the same time, the area of the opening at port b and port c (drain port) becomes larger. In this way, TVC output pressure PE goes down, and the pump discharge amount decreases.

10-31

STRUCTURE AND FUNCTION

HYDRAULIC PUMP (PISTON PUMP)

3) When pump load is small in G mode (pump emergency switch ON)

Operation • When G mode is selected (pump emergency switch ON) solenoid push pin (9) is pushed up, and keeps spring (1) compressed. • As a result, the pump absorption torque becomes constant, so TVC output pressure PE (= pump discharge amount) is controlled by the pump discharge pressure.

10-32

•

Main pump discharge pressures P1 and P2 are low, so spool (2) is pushed down fully by spring (1). As a result, control pump discharge pressure PPO and TVC valve output pressure PE are equal. At this point, TVC valve output pressure PE becomes the maximum, and the main pump discharge amount is also the maximum.

PC600-6

STRUCTURE AND FUNCTION

HYDRAULIC PUMP (PISTON PUMP)

4) When pump load is large in G mode (pump emergency switch ON)

Operation • When main pump discharge pressure P1 (or P2) increases, spool (2) is moved up by piston (4) or piston (6). As a result, the flow of oil from port a to port b is throttled by the notch in the spool. At the same time, the area of the opening at port b and port c (drain port) becomes larger. In this way, TVC valve output pressure PE goes down, and the main pump discharge amount decreases.

PC600-6

10-33

STRUCTURE AND FUNCTION

HYDRAULIC PUMP (PISTON PUMP)

CO+NC VALVE 1. CO+NC valve (No. 1 front)

P : Main pump pressure IN port PEFR : TVC valve output pressure front, rear interconnection port PE : TVC valve output pressure detection port PCO : CO selector pilot port

10-34

PD : Jet sensor downstream pressure IN port PT : Jet sensor upstream pressure IN port PDR : CO+NC valve drain OUT port PECN : CO+NC valve output pressure OUT port

PC600-6

STRUCTURE AND FUNCTION

HYDRAULIC PUMP (PISTON PUMP)

2. CO+NC valve (No. 1 rear)

P1I : Main pump pressure IN port (front) P1O : Main pump pressure OUT port P2I : Main pump pressure IN port (rear) P2O : Main pump pressure OUT port PEFR : TVC valve output pressure front, rear interconnection port PE1 : TVC valve output pressure IN port PCO : CO selector pilot port

PC600-6

PD : Jet sensor downstream pressure IN port PT : Jet sensor upstream pressure IN port PDRI : TVC valve drain IN port PDRO : CO+NC valve drain OUT port PPOI : Servo basic pressure IN port PPOO : Servo basic pressure OUT port PECN : CO+NC valve output pressure OUT port

10-35

STRUCTURE AND FUNCTION

CO valve 1. Plug 2. Piston 3. Spring 4. Spool 5. Piston 6. Plug

10-36

HYDRAULIC PUMP (PISTON PUMP)

NC valve 7. Plug 8. Sleeve 9. Piston 10. Spool 11. Spring 12. Plug

PC600-6

STRUCTURE AND FUNCTION

HYDRAULIC PUMP (PISTON PUMP)

3. CO valve Function • When the load becomes large during operations and the main pump discharge pressure rises to a point close to relief pressure, the cut-off function of the CO valve acts to reduce the pump discharge in order to reduce relief loss.

•

At the same time, it has a cut-off cancel function actuated by the pilot pressure from the heavy-lift solenoid valve. The CO valve is controlled by balancing the spring with the total of main pump discharge pressure P and CO valve output pressure PEC.

1) When main pump discharge pressure is lower than relief pressure

Operation • Spool (4) is being pushed down fully by spring (3). As a result, port a and port b are fully open and TVC valve output pressure PE and CO valve output pressure PEC are equal. In this way, CO valve output pressure PEC becomes the maximum and the main pump discharge amount also becomes the maximum.

PC600-6

10-37

STRUCTURE AND FUNCTION

HYDRAULIC PUMP (PISTON PUMP)

2) When main pump discharge pressure becomes close to relief pressure

Operation • If the load increases and main pump discharge pressure P comes close to the relief pressure, main pump discharge pressure P pushes piston (5). At the same time, CO valve output pressure PEC pushes piston (5), and spool (4) moves up.

10-38

•

As a result, the flow of oil from port a to port b is throttled by the notch in the spool, and the area of the opening at port b and port c (drain port) becomes larger. In this way, CO valve output pressure PEC goes down, and the pump discharge amount becomes the minimum.

PC600-6

STRUCTURE AND FUNCTION

HYDRAULIC PUMP (PISTON PUMP)

3) When cut-off function is canceled by heavy-lift solenoid valve

Operation • When the heavy-lift solenoid valve is energized and is switched, pilot pressure PCO is sent to the port, and piston (2) is pushed down fully. For this reason, seat (6) contacts seat (7) and spool (4) is locked.

PC600-6

•

As a result, main pump discharge pressure P goes up, but even when it reaches the relief pressure, spool (4) is not actuated, so CO valve output pressure PEC remains at the maximum.

10-39

STRUCTURE AND FUNCTION

HYDRAULIC PUMP (PISTON PUMP)

4. NC valve Function • The NC valve controls the main pump discharge amount according to the amount that the control valve spool is operated. This flow control function reduces the neutral loss and fine control loss.

•

The NC valve is controlled by balancing the total of the jet sensor output pressure PT and the NC valve output pressure PECN with the total of the force of NC valve spring (12) and the jet sensor output pressure PD. The jet sensor detects the flow of oil returning to the tank through the control valve and takes them as PT and PD of the NC valve.

1) When control valve is at neutral

Operation • When the control valve is at neutral, jet sensor differential pressure (PT – PD) becomes the maximum, and the force of jet sensor output pressure PT pushing piston (10) becomes larger than the total of the force of spring (12) and the force of jet sensor output pressure PD pushing the bottom of spool (11).

10-40

•

As a result, spool (11) is pushed down, so the flow from port c to port b is throttled, and the area of the opening of port b and port a (drain port) becomes larger. In this way, NC valve output pressure PECN becomes the minimum, and the main pump discharge amount also becomes the minimum.

PC600-6

STRUCTURE AND FUNCTION

HYDRAULIC PUMP (PISTON PUMP)

2) When control lever is operated

Operation • When the control lever is moved, the jet sensor differential pressure (PT – PD) goes down in accordance with the movement of the control lever. Spool (11) is pushed up, and the area of the opening of port c and port b becomes larger. In this way, NC valve

PC600-6

output pressure PECN becomes larger and the discharge amount from the main pump increases. In other words, the pump discharge amount increases according to the amount that the control lever is operated.

10-41

STRUCTURE AND FUNCTION

HYDRAULIC PUMP (PISTON PUMP)

No. 2 main pump Type: HPV95+95

PA1 : Front pump discharge port PA2 : Rear pump discharge port PD12 : Drain port PD22 : Drain port PS : Pump suction port PSV : Servo basic pressure IN port PECN : CO+NC valve output pressure IN port

10-42

1. 2. 3. 4.

Front pump Front servo valve Rear servo valve Rear pump

PC600-6

STRUCTURE AND FUNCTION

HYDRAULIC PUMP (PISTON PUMP)

No. 2 main pump

PC600-6

10-43

STRUCTURE AND FUNCTION

1. 2. 3. 4. 5. 6. 7.

Front shaft Front cradle Front case Rocker cam Piston Cylinder block Valve plate

10-44

HYDRAULIC PUMP (PISTON PUMP)

8. Front end cap 9. Coupling 10. Impeller 11. Rear end cap 12. Valve plate 13. Cylinder block 14. Piston

15. Rear case 16. Rocker cam 17. Rear cradle 18. Rear shaft 19. Servo piston

PC600-6

STRUCTURE AND FUNCTION

HYDRAULIC PUMP (PISTON PUMP)

SERVO VALVE 1. Servo valve (No. 2 front)

P1 : Main pump pressure IN port P2 : Main pump pressure IN port PAC : Servo actuator port PDR : Servo valve drain OUT port PPO : Servo basic pressure IN port PECN : CO+NC valve output pressure IN port

PC600-6

1. Servo valve

10-45

STRUCTURE AND FUNCTION

HYDRAULIC PUMP (PISTON PUMP)

2. Servo valve (No. 2 rear)

P2 : Main pump pressure IN port PAC : Servo actuator port PDR : Servo valve drain OUT port PPO : Servo basic pressure IN port PECN : CO+NC valve output pressure IN port

10-46

1. Servo valve

PC600-6

STRUCTURE AND FUNCTION

LINE OIL FILTER

1. Cover 2. Element 3. Case A : From main pump B : To control valve

PC600-6

Outline There are two line oil filters installed to the discharge side of the main pump. They protect the circuit and equipment by removing all dirt and dust from the oil.

10-47

STRUCTURE AND FUNCTION

CONTROL VALVE

CONTROL VALVE Outline • This control valve consists of a 4-spool valve and a 5-spool valve, and a travel shuttle valve is also installed to it. Furthermore, a straighttravel valve, arm throttle valve, and swing priority valve are built in. • The 4-spool and 5-spool valves are connected by bolts to form one unit, and internal merging of the oil flow makes it even more compact and easy to maintain.

A1L : To L.H. travel motor PB port A2L : To boom cylinder bottom A3L : To bucket cylinder head A1R : To swing motor MA port A3R : Service A4R : To arm cylinder head A5R : To R.H. travel motor PA port B1L : To L.H. travel motor PA port B2L : To boom cylinder head B3L : To bucket cylinder head B1R : To swing motor MB port B3R : Service B4R : To arm cylinder bottom B5R : To R.H. travel motor PB port NCAL : To rear NC valve NCBL : To rear NC valve NCAR : To front NC valve NCBR : To front NC valve P3 : From arm PPC shuttle valve P4 : From boom, bucket PPC shuttle valve P5 : From swing PPC shuttle valve P6 : Work equipment oil pressure switch

P1AL : From L.H. travel PPC valve P2AL : From boom PPC valve P3AL : From bucket PPC valve P4AL : From arm PPC valve P1AR : From swing PPC valve P3AR : Service P4AR : From arm PPC valve P5AR : From R.H. travel PPC valve P1BL : From L.H. travel PPC valve P2BL : From boom PPC valve P3BL : From bucket PPC valve P1BR : From swing PPC valve P3BR : Service P4BR : From arm PPC valve P5BR : From R.H. travel PPC valve PL : From rear main pump PR : From front main pump PRL : From 2-stage relief solenoid valve PRR : From 2-stage relief solenoid valve T : To tank TS : To tank

1. Travel shuttle valve 2. 4-spool valve (straight-travel valve, arm throttle valve built in) 3. 5-spool valve (swing priority valve built in)

10-48

PC600-6

STRUCTURE AND FUNCTION

CONTROL VALVE

4-spool valve + 5-spool valve (with travel shuttle valve)

PC600-6

10-49

STRUCTURE AND FUNCTION

CONTROL VALVE

Cross-sectional diagram (1/4)

1. 2. 3. 4. 5.

Spool return spring Spool (L.H. travel) Spool (boom Lo) Spool (bucket) Spool (arm Hi)

10-50

6. Jet sensor orifice 7. Jet sensor relief valve 8. Main relief valve 9. Spool (straight-travel) 10. Spool (arm throttle)

PC600-6

STRUCTURE AND FUNCTION

CONTROL VALVE

(2/4)

1. 2. 3. 4. 5.

Spool return spring Spool (swing) Spool (boom Hi) Spool (service) Spool (arm Lo)

PC600-6

6. Spool (R.H. travel) 7. Jet sensor relief valve 8. Jet sensor orifice 9. Main relief valve 10. Spool (swing priority)

10-51

STRUCTURE AND FUNCTION

CONTROL VALVE

(3/4)

1. 2. 3. 4. 5. 6. 7.

Check valve Check valve spring Spool (L.H. travel) Spool (straight-travel) Spool (swing priority) Spool (swing) Suction valve

10-52

8. Spool (boom Lo) 9. Check valve 10. Spool (boom Hi) 11. Suction valve 12. Suction valve 13. Suction valve

PC600-6

STRUCTURE AND FUNCTION

CONTROL VALVE

(4/4)

1. 2. 3. 4. 5. 6.

Suction-safety valve Spool (bucket) Spool (arm throttle) Spool (service) Spool (arm Hi) Check valve

PC600-6

7. Spool (arm Lo) 8. Suction-safety valve 9. Check valve 10. Spool (R.H. travel) 11. Suction-safety valve 12. Suction valve

10-53

STRUCTURE AND FUNCTION

CONTROL VALVE

TRAVEL SHUTTLE VALVE

P0 : To straight-travel valve P1 : From L.H. travel valve A1L port P2 : From L.H. travel valve B1L port P3 : From arm shuttle valve P4 : From boom, bucket shuttle valve P5 : From swing shuttle valve P4A : To arm throttle valve P5A : To swing priority valve T : To tank

10-54

1. 2. 3. 4. 5.

Cover Spool return spring Body Spool Orifice

PC600-6

STRUCTURE AND FUNCTION

CONTROL VALVE

Function • The travel shuttle valve is installed to the top of the 4-spool valve control valve. It brings the PPC valve pressures from the L.H. travel, work equipment, and swing. It also

sends pilot pressure to the straight-travel valve when the travel and work equipment or travel and swing are operated at the same time.

1. When operated independently

Operation • When the travel FORWARD is operated, pilot pressure oil flows from the L.H. travel circuit to port P1 and pushes the spool to the right. Ports P3, P4, and P5 are interconnected with port P0 through the groove in the spool to the straight-travel valve. • However, when the work equipment and swing control levers are at HOLD, the pilot pressure oil from the PPC valve does not flow, so it also does not flow to the straighttravel valve. PC600-6

•

When the travel reverse is operated, the pressure oil is sent to port P2 and pushes the spool to the right.

10-55

STRUCTURE AND FUNCTION

CONTROL VALVE

2. During simultaneous operation

Operation • When the arm and travel FORWARD are operated at the same time, pilot pressure oil flows from the L.H. travel circuit to port P1 and pushes the spool to the right. • When the arm is operated, pilot pressure oil also flows to port P3 from the arm PPC shuttle valve. This passes through the groove in the spool and port P0, and flows to the straight-travel valve.

10-56

•

The pilot pressure oil from the swing PPC shuttle valve flows from port P5 → port P0 → straight-travel valve, and the pilot pressure oil from the boom and bucket PPC shuttle valves flows from port P4 → port P0 → straight-travel valve.

PC600-6

STRUCTURE AND FUNCTION

CONTROL VALVE

STRAIGHT-TRAVEL VALVE Function • When the travel is operated at the same time as the boom, arm, or bucket, the pressure oil flowing to the left and right travel circuits is divided and sent to the boom, arm, or bucket circuit. • If the oil in one travel circuit is divided off, the amount of oil supplied to the travel motor will be less than in the travel circuit which is not divided, so the drop in the supply of oil to the travel motor will cause the machine to deviate.

•

To prevent this, the straight-travel valve is switched to interconnect the left and right travel circuits. This ensures that the amount of oil supplied to the left and right travel motors is equal. As a result, the left and right travel motors both rotate at the same speed, and there is little travel deviation.

1. When travel is operated independently

Operation • No pilot pressure flows from the travel shuttle valve, so the straight-travel valve is not actuated. • Because of this, port PL (L.H. travel circuit) and port PR (R.H. travel circuit) are not interconnected, and each circuit remains independent.

PC600-6

10-57

STRUCTURE AND FUNCTION

CONTROL VALVE

2. When travel and work equipment are operated at same time

Operation • The pilot pressure from the shuttle valve pushes spool (1) of the straight-travel solenoid valve to the right. • Because of this, port PR and port PL are interconnected, and the amount of oil supplied to the left and right travel motors is the same. As a result, the left and right travel motors both rotate at the same speed, so there is little travel deviation.

10-58

PC600-6

STRUCTURE AND FUNCTION

CONTROL VALVE

SWING PRIORITY VALVE Function • When the swing and arm are operated at the same time, a large amount of the pressure oil flows to the arm circuit where the load is small, so little pressure oil flows to the swing circuit. • This makes the arm speed too fast for the swing speed, and causes poor combination in simultaneous operation.

•

To overcome this, the swing priority valve is actuated to throttle the pressure oil flowing to the arm Lo control valve in order to restrict the arm speed and improve the simultaneous operation performance.

1. When swing is at HOLD

Operation • No pilot pressure oil flows from the travel shuttle valve, so the swing priority valve is not actuated. • For this reason, all the pressure oil from the front main pump passes through port PR and flows to the arm Lo control valve.

PC600-6

10-59

STRUCTURE AND FUNCTION

CONTROL VALVE

2. When swing is operated

Operation • When the swing is operated, the pilot pressure oil from the travel shuttle valve pushes spool (1) of the swing priority valve to the left. • As a result, the pressure oil flowing from the front main pump through port PR to the arm Lo control valve is throttled, and the arm speed is restricted to improve the simultaneous operation performance.

10-60

PC600-6

STRUCTURE AND FUNCTION

CONTROL VALVE

ARM THROTTLE VALVE Function When arm and boom are operated at same time • When the arm and boom are operated at the same time, a large amount of the pressure oil flows to the arm circuit where the load is small, so little pressure oil flows to the boom circuit. • This makes the arm speed too fast for the boom speed, and causes poor combination in simultaneous operation. This is a particular problem when the arm OUT and boom RAISE are operated at the same time. • To overcome this, the arm throttle valve is actuated to throttle the pressure oil flowing to the arm Hi control valve in order to restrict the arm speed and improve the simultaneous operation performance.

When arm and bucket are operated at same time • The arm is actuated by the merged flow from two pumps and the bucket is actuated by the oil from one pump. • In this condition, if the arm and bucket are operated at the same time, a large amount of the pressure oil flows to the arm circuit, so little pressure oil flows to the bucket circuit. This makes the arm speed too fast for the bucket speed, and causes poor combination in simultaneous operation. This is a particular problem when the arm OUT and bucket CURL are operated at the same time. • To overcome this, the arm throttle valve is actuated to throttle the pressure oil flowing to the arm Hi control valve in order to restrict the arm speed and improve the simultaneous operation performance.

1. When arm is operated independently

Operation • No pilot pressure oil flows from the travel shuttle valve, so the arm throttle valve is not actuated. • For this reason, all the pressure oil from the rear main pump passes through port PL and flows to the arm Hi control valve.

PC600-6

10-61

STRUCTURE AND FUNCTION

CONTROL VALVE

2. When arm and boom or bucket are operated at same time

Operation • When the arm and boom or bucket are operated at the same time, the pilot pressure oil from the travel shuttle valve pushes spool (1) of the arm throttle valve to the left. • As a result, the pressure oil flowing from the rear main pump to the arm Hi control valve is throttled, and the arm speed is restricted to improve the simultaneous operation performance.

10-62

PC600-6

STRUCTURE AND FUNCTION

SWING MOTOR

SWING MOTOR Type: KMF90ABE-3 (with reverse prevention valve)

T1 : To tank S : From control valve MA : From control valve MB : From control valve B : From swing brake solenoid valve

PC600-6

Specifications Model: KMF90ABE-3 Theoretical delivery: 87.8 cc/rev Safety valve set pressure: 25.5 MPa {260 kg/cm2} Rated speed: 2320 rpm Brake release pressure: 2.06 MPa {21.0 kg/cm2}

10-63

STRUCTURE AND FUNCTION

1. 2. 3. 4. 5. 6. 7.

Drive shaft Spacer Case Disc Plate Brake ring Brake piston

10-64

SWING MOTOR

8. Housing 9. Reverse prevention valve 10. Center spring 11. Cylinder block 12. Valve plate 13. Piston 14. Center shaft

15. Safety valve 16. Check valve 17. Check valve spring 18. Shuttle valve 19. Shuttle valve spring 20. Brake spring

PC600-6

STRUCTURE AND FUNCTION

SWING MOTOR

Type: KMF90ABE-3 (without reverse prevention valve)

T1 : To tank S : From control valve MA : From control valve MB : From control valve B : From swing brake solenoid valve

PC600-6

Specifications Model: KMF90ABE-3 Theoretical delivery: 87.8 cc/rev Safety valve set pressure: 25.5 MPa {260 kg/cm2} Rated speed: 2320 rpm Brake release pressure: 2.06 MPa {21.0 kg/cm2}

10-65

STRUCTURE AND FUNCTION

1. 2. 3. 4. 5. 6. 7.

Drive shaft Spacer Case Disc Plate Brake ring Brake piston

10-66

SWING MOTOR

8. Housing 9. Plate 10. Center spring 11. Cylinder block 12. Valve plate 13. Piston 14. Center shaft

15. Safety valve 16. Check valve 17. Check valve spring 18. Shuttle valve 19. Shuttle valve spring 20. Brake spring

PC600-6

STRUCTURE AND FUNCTION

SWING MOTOR

SWING BRAKE 1. When swing brake solenoid valve is de-energized Operation • If the swing brake solenoid valve is de-energized, the flow of pressurized oil from the control pump is shut off, and port B is connected to the tank circuit. • As a result, brake piston (7) is pushed down by brake spring (8), pushes disc (4) and plate (5) together, and the brake is applied.

2. When swing brake solenoid valve is energized Operation • When the swing brake solenoid valve is energized, the valve is switched, and pressurized oil from the control pump enters port B and flows to brake chamber A. • The pressurized oil entering chamber A overcomes brake spring (8) and brake piston (7) moves up. As a result, disc (4) and plate (5) are separated and the brake is released.

PC600-6

10-67

STRUCTURE AND FUNCTION

SWING MOTOR

SAFETY VALVE Outline • The safety valve portion consists of check valves (2) and (3), shuttle valves (4) and (5), and relief valve (1). Function • When the swing is stopped, the outlet port circuit of the motor is closed by the control valve, but the motor continues to be turned by the inertia of the swing. As a result, the pressure at the outlet port of the motor becomes abnormally high and there is danger that the motor will be damaged. • The safety valve is installed to prevent this problem. It acts to release the abnormally high pressure oil from the outlet port (highpressure side) of the motor and send it to port S and prevent damage to the motor. 1. When starting swing Operation • If the swing control lever is operated to swing to the right, the pressurized oil from the pump passes through the control valve and is supplied to port MA. • When this happens, the pressure at port MA rises and starting force is generated in the motor, so the motor starts to turn. The oil from the outlet port of the motor flows from port MB through the control valve and returns to the tank.

10-68

PC600-6

STRUCTURE AND FUNCTION

SWING MOTOR

2. When stopping swing Operation • When the swing control lever is returned to the neutral position, no more pressurized oil is supplied from the pump to port MA. At the same time, the oil from the outlet port of the motor returns from the control valve to the tank, and the circuit is closed. The pressure at port MB rises, and rotating resistance to the motor is generated, so the brake starts to take effect. • If the pressure at port MB rises higher than the pressure at port MA, shuttle valve (4) is pushed and chamber C becomes the same pressure as port MB. The pressure then rises to the set pressure of relief valve (1). In this way, a high brake torque is generated in the motor, and the motor stops. • When relief valve (1) is being actuated, the relieved oil and oil from port S is supplied to port MA through check valve (3) to prevent cavitation at port MA.

PC600-6

10-69

STRUCTURE AND FUNCTION

SWING MOTOR

REVERSE PREVENTION VALVE

MA : Port T1 : Port MB : Port T2 : Port

10-70

1. 2. 3. 4. 5. 6. 7.

Valve body Spool (MA side) Spring (MA side) Plug (MA side) Spool (MB side) Spring (MB side) Plug (MB side)

PC600-6

STRUCTURE AND FUNCTION

SWING MOTOR

Explanation of effect

PC600-6

10-71

STRUCTURE AND FUNCTION

SWING MOTOR

OPERATION OF THE REVERSE FLOW CHECK VALVE 1. Function When the swing is stopped, this valve reduces the rocking motion of the swing body due to the inertia of the swing body, backlash of the machinery system, the compressibility of the hydraulic oil, etc. This valve is effective to prevent the cargo from being spilled when the swing is stopped as well as to shorten recycle time (excellent in the positioning accuracy and the next operation can be started quickly).

2. Operation 1) When the braking pressure is present at the MB port MB pressure is introduced to d chamber via the notch and spool (5) makes a stroke motion to the left, pressing spring (6) due to the difference in area (D1>D2) and the interconnection of MB to e is established. On this occasion, MA pressure is less than the set pressure of spring (3), so that spool (2) does not make a stoke motion and the pressure oil is closed by spool (2), and the braking force is secured.

2) When the motor stopped temporarily The motor is reversed by the shutoff pressure that occurred at MB port. (First reversal) On this occasion, the reverse pressure is generated at MA port side. This pressure at MA port is introduced to a chamber, and spool (2) makes a stroke motion to the right, pressing spring (3), and the interconnection of MA to b is established. Also, the interconnection of b to f is established through the drill hole and the reverse pressure at port MA port is bypassed to T port, thereby preventing the second reversal.

10-72

PC600-6

STRUCTURE AND FUNCTION

CENTER SWIVEL JOINT

CENTER SWIVEL JOINT Z A

B1 C1 3

A–A

Z SBP00249

1. 2. 3. 4. 5.

Cover Body Slipper seal O-ring Shaft

PC600-6

A1. From control valve port A5R A2. To R.H. travel motor port PB B1. From control valve port A1L B2. To L.H. travel motor port PA C1. From control valve port B5R C2. To R.H. travel motor port PA

D1. From control valve port B1L D2. To L.H. travel motor port PB E1. From travel speed EPC valve E2. To L.H. and R.H. travel motors port P T1. To tank T2. From L.H. and R.H. travel motors port T

10-73

STRUCTURE AND FUNCTION

TRAVEL MOTOR

TRAVEL MOTOR Type: KMV335ADT

P : From travel speed solenoid valve T : To tank PA : From control valve PB : From control valve

10-74

Specifications Model: KMV335ADT Theoretical delivery: Minimum 217 cc/rev Maximum 336 cc/rev Brake release pressure: 1.27 ± 0.39 MPa {13.0 ± 4.0 kg/cm2} Travel speed selector pressure: 0.93 ± 0.25 MPa {9.50 ± 2.50 kg/cm2}

PC600-6

STRUCTURE AND FUNCTION

1. 2. 3. 4. 5. 6. 7.

Output shaft Motor case Piston Cylinder block Valve plate End cover Slow return valve

PC600-6

TRAVEL MOTOR

8. Plug 9. Regulator piston 10. Plate 11. Disc 12. Check valve spring 13. Check valve 14. Counterbalance valve

15. Spool return spring 16. Safety valve 17. Regulator valve 18. Spring 19. Brake spring 20. Brake piston

10-75

STRUCTURE AND FUNCTION

TRAVEL MOTOR

1. At low speed (motor swash plate angle at maximum)

Operation • When the solenoid valve is de-energized, the pilot pressure oil from the control pump does not flow to port P. For this reason, regulator valve (17) is pushed to the right in the direction of the arrow by spring (18). • The main pressure oil from the control valve pushes shuttle valve (7), goes through end cover (6), and acts on chamber a of regulator piston (9). At the same time, the main pressure passes through passage c and acts on chamber b through regulator valve (17).

10-76

•

Because of this, propulsion force equal to the difference in area of chambers a and b (Ab – Aa) of regulator piston (9) acts in a downward direction. As a result, valve plate (5) and cylinder block (4) move in the maximum swash plate angle direction, the motor capacity becomes the maximum, and the system is set to low speed.

PC600-6

STRUCTURE AND FUNCTION

TRAVEL MOTOR

2. At high speed (motor swash plate angle at minimum)

Operation • When the solenoid valve is energized, the pilot pressure oil from the control pump flows to port P, and pushes regulator valve (17) down. • Because of this, the main pressure oil and the oil in chamber d is shut off by regulator valve (17), and the oil in chamber b is drained inside the case. • A propulsion force generated by the pressure oil in chamber a of regulator piston (9) then acts upward.

PC600-6

•

As a result, valve plate (5) and cylinder block (4) move in the minimum swash plate angle direction, the motor capacity becomes the minimum, and the system is set to high speed.

10-77

STRUCTURE AND FUNCTION

TRAVEL MOTOR

PARKING BRAKE 1. When starting to travel

Operation • When the travel lever is operated, the pressurized oil from the pump actuates counterbalance valve spool (14), opens the circuit to the parking brake, and flows into chamber e of brake piston (20). It overcomes the force of spring (19), and pushes piston (20) to the right. • When this happens, the force pushing plate (10) and disc (11) together is lost, so plate (10) and disc (11) separate and the brake is released.

10-78

PC600-6

STRUCTURE AND FUNCTION

TRAVEL MOTOR

2. When stopping travel

Operation • When the travel lever is placed in neutral, counterbalance valve spool (14) returns to the neutral position and the circuit to the parking brake is closed. • The pressurized oil in chamber e of brake piston (20) passes through the throttle of slow return valve (7) until spool (14) of the counterbalance valve returns to neutral. • When spool (14) of the counterbalance valve returns to the neutral position, the oil is drained inside the case from the throttle of brake piston (20) and brake piston (20) is pushed fully to the left by spring (19).

PC600-6

• •

As a result, plate (10) and disc (11) are pushed together, and the brake is applied. A time delay is provided by having the pressurized oil pass through a throttle in slow return valve (7) when the brake piston returns, and this ensures that the brake is applied after the machine stops.

10-79

STRUCTURE AND FUNCTION

TRAVEL MOTOR

Operation of brake valve • The brake valve consists of a check valve, counterbalance valve, and safety valve in a circuit as shown in the diagram on the right. • The function and operation of each component is as given below. 1) Counterbalance valve, check valve Function • When traveling downhill, the weight of the machine makes it try to travel faster than the speed of the motor. As a result, if the machine travels with the engine at low speed, the motor will rotate without load and the machine will run away, which is extremely dangerous. To prevent this, these valves act to make the machine travel according to the engine speed (pump discharge amount).

Operation when pressurized oil is supplied • When the travel lever is operated, the pressurized oil from the control valve is supplied to port PA. It pushes open check valve (13A) and flows from motor inlet port MA to motor outlet port MB. However, the motor outlet port is closed by check valve (13B) and spool (14), so the pressure at the supply side rises.

•

The pressurized oil at the supply side flows from orifice E1 in spool (14) and orifice E2 in the piston to chamber S1. When the pressure in chamber S1 goes above the spool switching pressure, spool (14) is pushed to the right. As a result, port MB and port PB are connected, the outlet port side of the motor is opened, and the motor starts to rotate.

10-80

PC600-6

STRUCTURE AND FUNCTION

TRAVEL MOTOR

Operation of brake when traveling downhill • If the machine tries to run away when traveling downhill, the motor will turn under no load, so the pressure at the motor inlet port will drop, and the pressure in chamber S1 through orifices E1 and E2 will also drop. When the pressure in chamber S1 drops below the spool switching pressure, spool (14) is returned to the left by spring (15), and outlet port MB is throttled. As a result, the pressure at the outlet port side rises, resistance is generated to the rotation of the motor, and this prevents the machine from running away. In other words, the spool moves to a position where the pressure at outlet port MB balances the pressure at the inlet port and the force generated by the weight of the machine. It throttles the outlet port circuit and controls the travel speed according to the amount of oil discharged from the pump. 2) Safety valve (2-direction operation, 2-stage set safety valve) Function • When travel is stopped (or when traveling downhill), the circuits at the inlet and outlet ports of the motor are closed by the counterbalance valve. However, the motor is rotated by inertia, so the pressure at the outlet port of the motor will become abnormally high and will damage the motor or piping. The safety valve acts to release this abnormal pressure and send it to the inlet port side of the motor to prevent damage to the equipment. Operation in both directions 1) When pressure in chamber MB has become high (when rotating clockwise) • When the travel is stopped (or when traveling downhill), chamber MB in the outlet port circuit is closed by the check valve of the counterbalance valve, but the pressure at the outlet port rises because of inertia. • If the pressure goes above the set pressure, the force produced by the difference in area between D1 and D2 [π/4(D12 – D22) x pressure] overcomes the force of the spring and moves the poppet to the left, so the oil flows to chamber MA in the circuit on the opposite side.

PC600-6

10-81

STRUCTURE AND FUNCTION

TRAVEL MOTOR

2) When pressure in chamber MA has become high (when rotating counterclockwise) • When the travel is stopped (or when traveling downhill), chamber MA in the outlet port circuit is closed by the check valve of the counterbalance valve, but the pressure at the outlet port rises because of inertia.

•

If the pressure goes above the set pressure, the force produced by the difference in area between D1 and D3 [π/4(D32 – D12) x pressure] overcomes the force of the spring and moves the poppet to the left, so the oil flows to chamber MB in the circuit on the opposite side.

Operation of mechanism for varying set pressure 1) When starting travel (high-pressure setting) • When the travel lever is operated, the pressurized oil from the pump actuates counterbalance valve spool (14), and opens the pilot circuit to the safety valve. The oil passes from chamber G to passage H and flows into chamber J, pushes the piston to the right, and compresses the spring to make the set load larger. Because of this, the set pressure of the safety valve is switched to the high pressure setting, and a large drawbar pull is made available.

10-82

PC600-6

STRUCTURE AND FUNCTION

TRAVEL MOTOR

2) When stopping travel (low-pressure setting) • When the travel lever is placed at neutral, the pressure in chamber PA drops and counterbalance valve spool (14) returns to the neutral position. While the counterbalance valve spool is returning to the neutral position, the pressurized oil in chamber J passes through passage H, and escapes to chamber PA from chamber G. The piston moves to the left, and the set load becomes smaller. Because of this, the set pressure of the safety valve is switched to the low-pressure setting and relieves the shock when reducing speed. [Set pressure of safety valve] When starting, : High-pressure when traveling setting

}

When stopping: Low-pressure setting

37.8 MPa {385 kg/cm2}

27.5 MPa {280 kg/cm2}

PC600-6

10-83

STRUCTURE AND FUNCTION

VALVE CONTROL

1. 2. 3. 4. 5.

Travel PPC valve L.H. travel lever R.H. travel lever Right PPC valve Right work equipment lever 6. Active solenoid valve (swing) 7. Accumulator

10-84

8. Solenoid block 9. Control valve 10. Hydraulic pump 11. LS control EPC valve 12. Left work equipment lever 13. PPC safety lock valve 14. Left PPC valve 15. Safety lock lever

Lever positions 1 NEUTRAL 2 Boom RAISE 3 Boom LOWER 4 Bucket DUMP 5 Bucket CURL 6 NEUTRAL 7 Arm IN 8 Arm OUT 9 Swing right

@ Swing left A NEUTRAL B Travel REVERSE C Travel FORWARD D LOCK E FREE

PC600-6

STRUCTURE AND FUNCTION

WORK EQUIPMENT • SWING PPC VALVE

P : From control pump T : To tank P1 : L.H.: Arm OUT/R.H.: Boom LOWER

10-86

P2 : L.H.: Arm IN/R.H.: Boom RAISE P3 : L.H.: Right swing/R.H.: Bucket CURL P4 : L.H.: Left swing/R.H.: Bucket DUMP

PC600-6

STRUCTURE AND FUNCTION

1. 2. 3. 4. 5. 6.

Spool Metering spring Centering spring Piston Disc Nut (for connecting lever)

PC600-6

WORK EQUIPMENT • SWING PPC VALVE

7. Joint 8. Plate 9. Retainer 10. Body 11. Filter

10-87

STRUCTURE AND FUNCTION

WORK EQUIPMENT • SWING PPC VALVE

Operation 1) At neutral Ports A and B of the control valve and ports P1 and P2 of the PPC valve are connected to drain chamber D through fine control hole f in spool (1). (Fig. 1) D T

f P

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

Control valve (Fig. 1)

SBP00275

5 4 9 D 2 f

T P

PP P2

Control valve

(Fig. 2) SBP00276

10-88

PC600-6

STRUCTURE AND FUNCTION

3) Fine control (control lever returned) When disc (5) starts to be returned, spool (1) is pushed up by the force of centering spring (3) and the pressure at port P1. Because of this, fine control hole f is connected to drain chamber D, and the pressurized oil at port P1 is released. If the pressure at port P1 drops too much, spool (1) is pushed down by metering spring (2), so fine control hole f is shut off from drain chamber D. At almost the same time, it is connected to pump pressure chamber PP, so the pressure at port P1 supplies the pump pressure until the pressure recovers to a pressure equivalent to the position of the lever. When the control valve returns, oil in drain chamber D flows in from fine control hole f’ of the valve on the side that is not moving. It passes through port P2 and goes to chamber B to charge the oil. (Fig. 3)

WORK EQUIPMENT • SWING PPC VALVE

5 4 3 D 2 f

T P f'

1 PP P2

Control valve (Fig. 3)

SBP00277

4) At full stroke Disc (5) pushes down piston (4), and retainer (9) pushes down spool (1). Fine control hole f is shut off from drain chamber D, and is connected to pump pressure chamber PP. Therefore, the pilot pressure oil from the control pump passes through fine control hole f and flows to chamber A from port P1 to push the control valve spool. The return oil from chamber B passes from port P2 through fine control hole f’ and flows to drain chamber D. (Fig. 4)

5 4 D

T P f'

1 Pp P2

Control valve

(Fig. 4) SBP00278

PC600-6

10-89

STRUCTURE AND FUNCTION

TRAVEL PPC VALVE

P : From main pump T : To tank P1 : L.H. travel REVERSE

10-90

P2 : L.H. travel FORWARD P3 : R.H. travel REVERSE P4 : R.H. travel FORWARD

PC600-6

STRUCTURE AND FUNCTION

1. 2. 3. 4.

Plate Body Piston Collar

PC600-6

TRAVEL PPC VALVE

5. Metering spring 6. Centering spring 7. Valve

10-91

STRUCTURE AND FUNCTION

TRAVEL PPC VALVE

OPERATION 1) At neutral Ports A and B of the control valve and ports P1 and P2 of the PPC valve are connected to drain chamber D through fine control hole f in spool (1). (Fig. 1)

T P

1 P2

10-92

Control valve

(Fig. 1) SBP00281

5 4 9

2 f

T P 1 PP P1 A

Control valve

10 B

(Fig. 2) SBP00282

PC600-6

STRUCTURE AND FUNCTION

TRAVEL PPC VALVE

2 f

T P

1 PP P1 A

Control valve

(Fig. 3)

SBP00283

5 4 D 9 f

T P f' 1 PP P2

P1 A

Control valve

(Fig. 4)

SBP00284

PC600-6

10-93

STRUCTURE AND FUNCTION

SERVICE PPC VALVE

T : To tank P : From main pump P1 : To attachment spool P2 : To attachment spool

10-94

1. 2. 3. 4. 5. 6. 7. 8.

Spool Metering spring Centering spring Piston Lever Plate Retainer Body

PC600-6

STRUCTURE AND FUNCTION

SERVICE PPC VALVE

Opration 1) At neutral Ports A and B of the control valve and ports P1 and P2 of the PPC valve are connected to drain chamber D through fine control hole f of spool (1).

2) Fine control (hold → fine control) When piston (4) starts to be pushed by lever (5), retainer (7) is pushed. Spool (1) is also pushed by metering spring (2) and moves down. When this happens, fine control hole f is shut off from drain chamber D. At almost the same time, it is connected to pump pressure chamber PP, and the pilot pressure of the control pump is sent through fine control hole f and goes from port P1 to port A. When the pressure at port P1 rises, spool (1) is pushed back. Fine control hole f is shut off from pump pressure chamber PP. At almost the same time, it is connected to drain chamber D, so the pressure at port P1 escapes. As a result, spool (1) moves up and down until the force of metering spool (2) is balanced with the pressure of port P1. The relationship of the position of spool (1) and body (8) (fine control hole f is in the middle between drain hole D and pump pressure chamber PP) does not change until retainer (7) contacts spool (1). Therefore, metering spring (2) is compressed in proportion to the travel of the control lever, so the pressure at port P1 also rises in proportion to the travel of the control lever. In this way, the spool of the control valve moves to a position where the pressure of chamber A (same as pressure at port P1) and the force of the return spring of the control valve spool are balanced.

PC600-6

10-95

STRUCTURE AND FUNCTION

SERVICE PPC VALVE

3) Fine control (control lever returned) When lever (5) starts to be returned, spool (1) is pushed up by the force of centering spring (3) and the pressure at port P1. Because of this, fine control hole f is connected to drain chamber D, and the pressurized oil at port P1 is released. If the pressure at port P1 drops too much, spool (1) is pushed up by metering spring (2), so fine control hole f is shut off from drain chamber D. At almost the same time, it is connected to pump pressure chamber PP, so the pressure at port P1 supplies the pump pressure until the pressure recovers to a pressure equivalent to the position of the lever. When the control valve returns, oil in drain chamber D flows in from fine control hole f’ of the valve on the side that is not moving. It passes through port P2 and goes to chamber B to charge the oil.

4) At full stroke Lever (5) pushes down piston (4), and retainer (7) pushes down spool (1). Fine control hole f is shut off from drain chamber D, and is connected to pump pressure chamber PP. Therefore, the pilot pressure oil from the control pump passes through fine control hole f and flows from port P1 to chamber A to push the control valve spool. The return oil from chamber B passes from port P2 through fine control hole f’ and flows to drain chamber D.

10-96

PC600-6

PPC SAFETY LOCK VALVE PPC ACCUMULATOR

STRUCTURE AND FUNCTION

PPC SAFETY LOCK VALVE 1. 2. 3. 4. 5.

Lever Body Seat Ball End cap

1. 2. 3. 4. 5.

Valve guard Cylinder Piston Bottom cover Locknut

PPC ACCUMULATOR

Specifications Actual gas volume: 500 cc

PC600-6

10-97

STRUCTURE AND FUNCTION

PPC SHUTTLE VALVE

PPC SHUTTLE VALVE For arm, swing

1. Plug 2. Body 3. Ball a. b. c. d. e. f. g. h. i. j.

P1B port (right swing) P5 port (travel shuttle valve) P2B port (left swing) P4B port (arm OUT) P6 port (travel shuttle valve) P3B port (arm IN) P2A port (left swing) P1A port (right swing) P3A port (arm IN) P4A port (arm OUT)

1. 2. 3. 4.

Plug assembly Plug Ball Body

a. b. c. d. e. f. g. h. i.

P1A port (bucket DUMP) P3A port (bucket CURL) P4A port (boom LOWER) P2A port (boom RAISE) P5 port (travel shuttle valve) P3B port (bucket CURL) P1B port (bucket DUMP) P2B port (boom RAISE) P4B port (boom LOWER)

For boom, bucket

10-98

PC600-6

STRUCTURE AND FUNCTION

SOLENOID VALVE

SOLENOID VALVE FOR CO CANCEL, 2-STAGE RELIEF, BOOM HI 2-STAGE SAFETY VALVE, TRAVEL SPEED, SWING BRAKE SOLENOID VALVE

1. 2. 3. 4. 5.

CO cancel solenoid valve 2-stage relief solenoid valve Boom Hi 2-stage safety valve solenoid valve Travel speed solenoid valve Swing brake solenoid valve

PC600-6

T : To tank A1 : To No. 1 pump (NC valve) A2 : To left and right travel motors A3 : To boom LOWER 2-stage safety valve A4 : To main valve (relief valve) A5 : To swing motor P1 : From control pump ACC : To accumulator PPC : To PPC valve

10-99

STRUCTURE AND FUNCTION

SOLENOID VALVE

1. 2. 3. 4. 5. 6. 7.

Connector Movable core Coil Cage Spool Block Spring

Operation When solenoid is de-energized • When the signal current does not flow from the PPC lock switch or swing lock switch, solenoid (3) is de-energized. For this reason, spool (5) is pushed fully to the left by spring (6). As a result, the circuit between ports P and A closes and the pressurized oil from the control pump does not flow to the actuator. At the same time, the pressurized oil from the actuator flows from port A to port T, and is then drained to the tank.

When solenoid is energized • When the signal current flows from the PPC lock switch or swing lock switch to solenoid (3), solenoid (3) is energized. For this reason, spool (5) is pushed to the right in the direction of the arrow. As a result, the pressurized oil from the control pump flows from port P through the inside of spool (5) to port A, and then flows to the actuator. At the same time, port T is closed, and this stops the oil from flowing to the tank.

10-100

PC600-6

STRUCTURE AND FUNCTION

SOLENOID VALVE

BUCKET CURL HI CANCEL

1. 2. 3. 4. 5. 6. 7.

Connector Movable iron core Coil Spool Body Spring Plug

Operation When solenoid is de-energized • The signal current does not flow from the controller, so coil (3) is de-energized. For this reason, spool (4) is returned to the neutral position by spring (6). As a result, the circuit between ports P and A is connected, and the pressurized oil from the PPC valve flows to the control valve.

When solenoid is energized • When the signal current flows from the controller to coil (3), coil (3) is energized and movable iron core (2) is pushed to the right in the direction of the arrow. • For this reason, spool (4) is also pushed to the right in the direction of the arrow. As a result, port P is closed, and the pressure oil from the control pump does not flow to the control valve. At the same time, port A and port T are interconnected, and the oil from the control valve is drained to the tank.

PC600-6

10-101

STRUCTURE AND FUNCTION

BOOM HOLDING VALVE

1. 2. 3. 4. 5.

Safety-suction valve Pilot spring Pilot spool Poppet spring Poppet

10-102

T : To tank V : From control valve CY : To boom cylinder bottom PI : From PPC valve (pilot pressure)

PC600-6

STRUCTURE AND FUNCTION

BOOM HOLDING VALVE

1. At boom RAISE

Operation • When the boom is raised, the main pressure from the control valve pushes poppet (5) up. Because of this, the main pressure from the control valve passes through the valve and flows to the bottom end of the boom cylinder.

PC600-6

10-103

STRUCTURE AND FUNCTION

BOOM HOLDING VALVE

2. Boom lever at HOLD

Operation • When the boom is raised and the control lever is returned to HOLD, the circuit for the holding pressure at the bottom end of the boom cylinder is closed by poppet (5). At the same time, the oil flowing into poppet (5) through orifice a of poppet (5) is closed by pilot spool (3). As a result, the boom is held in position.

10-104

PC600-6

STRUCTURE AND FUNCTION

BOOM HOLDING VALVE

3. At boom LOWER

Operation • When the boom is lowered, the pilot pressure flows to port PI from the PPC valve pushes pilot spool (3) and the pressurized oil in chamber b inside the poppet is drained. When the pressure at port CY rises because of the pressurized oil from the bottom end of the boom cylinder, the pressure of the pressurized oil in chamber b is lowered by orifice a. If the pressure in chamber b drops below the pressure at port CY, poppet (5) opens, the pressurized oil flows from port CY to port V, and then flows to the control valve. If any abnormal pressure is generated in the circuit at the bottom end of the boom cylinder, safety valve (1) is actuated and drain oil from port CY to port T.

PC600-6

10-105

STRUCTURE AND FUNCTION

BOOM LOWER REGENERATION VALVE

T : To tank PB : From boom cylinder bottom PM : From boom cylinder head PI : From boom LOWER PPC valve

10-106

PC600-6

STRUCTURE AND FUNCTION

1. 2. 3. 4. 5. 6.

BOOM LOWER REGENERATION VALVE

Body Spool Check valve Spring Spring (small) Spring (large)

PC600-6

10-107

STRUCTURE AND FUNCTION

BOOM LOWER REGENERATION VALVE

Function • When the boom is lowered, some of the oil drained from the bottom end of the boom cylinder is circulated to the cylinder head to increase the lowering speed of the boom.

Operation • When control lever (1) is operated to the LOWER position, PPC pressure flows and boom Lo spool (2) moves to the LOWER position. At the same time, regeneration valve spool (3) is moved by the PPC pressure from port Pi. As a result, the head and bottom ends of boom cylinder (4) are interconnected through ports PB and PM. • When this happens, the oil from the cylinder bottom passes through the control valve and returns to tank (5). Some of the oil enters port PB of the regeneration valve and flows from port PM to the cylinder head to increase the lowering speed of the boom. • The boom cylinder has a large volume, and during compound operations, the oil flow from the pump to the cylinder head is insufficient, so this action prevents any vacuum from forming inside the circuit.

10-108

PC600-6

STRUCTURE AND FUNCTION

AIR CONDITIONER

AIR CONDITIONER AIR CONDITIONER PIPING

1. 2. 3. 4. 5. 6. 7. 8.

Refrigerant piping Receiver tank Condenser Air conditioner compressor Hot water return piping Hot water pickup piping Air conditioner unit Duct

PC600-6

A : Fresh air B : Recirculated air C : Hot air/cold air

10-109

STRUCTURE AND FUNCTION

ACTUAL ELECTRIC WIRING DIAGRAM

ACTUAL ELECTRIC WIRING DIAGRAM (1/2)

10-110

PC600-6

STRUCTURE AND FUNCTION

PC600-6

ACTUAL ELECTRIC WIRING DIAGRAM

10-111

STRUCTURE AND FUNCTION

ACTUAL ELECTRIC WIRING DIAGRAM

(2/2)

10-112

PC600-6

STRUCTURE AND FUNCTION

1. Fuel level sensor 2. Front pump pressure sensor 3. Rear pump pressure sensor 4. Electrical intake air heater 5. Not use 6. Engine oil pressure sensor 7. Engine speed sensor 8. Front pump TVC solenoid 9. Hydraulic oil level sensor 10. Not use 11. Room lamp 12. Additional left head lamp 13. Horn (high tone) 14. Horn (low tone) 15. Battery relay 16. Right head lamp 17. Battery 18. Additional right head lamp 19. Working lamp 20. Air conditioner compressor 21. Engine water temperature sensor (High) 22. Alternator 23. Engine oil level sensor 24. Starting motor 25. Bucket DUMP pressure switch 26. Boom LOWER pressure switch 27. Bucket CURL pressure switch 28. Boom RAISE pressure switch 29. Travel pressure switch 30. Swing pressure switch 31. Arm IN pressure switch 32. Arm OUT pressure switch 33. Bucket Hi cancel solenoid valve 34. Swing brake solenoid valve 35. Travel speed solenoid valve 36. 2-stage relief solenoid valve 37. Boom Hi 2-stage safety solenoid valve 38. CO cancel solenoid valve

PC600-6

ACTUAL ELECTRIC WIRING DIAGRAM

39. Wiper motor 40. Fuse box 41. Alarm buzzer 42. Horn switch 43. Starting switch 44. Fuel control dial 45. Cigarette lighter 46. Swing lock switch 47. Wiper, washer switch 48. Lamp switch 49. Buzzer cancel switch 50. Car heater fan switch 51. Machine push-up switch 52. Front window auto pull-up switch 53. Air conditioner control panel 54. Speaker 55. Kerosene mode connector 56. Pump controller 57. Radio 58. TVC prolix resistor 59. Left knob switch 60. Wiper motor controller 61. Lamp relay 62. Lamp relay 63. Monitor panel 64. Swing holding brake release switch 65. Emergency pump drive switch 66. Engine controller 67. Supply pump 68. G sensor 69. Ne sensor 70. Fuel temperature sensor 71. Injector solenoid valve 72. Engine water temperature sensor (low) 73. Boost pressure sensor 74. Circuit breaker 75. Common rail pressure sensor

10-113

STRUCTURE AND FUNCTION

ENGINE CONTROL

1. 2. 3. 4. 5. 6. 7.

Battery relay Battery Starting switch Fuel control dial Supply pump Starting motor Engine controller

10-114

Function • The engine can be started and stopped simply by using starting switch (3). • Dial type engine control is used. Engine controller (7) receives the operation signal from fuel control dial (4), and controls the engine speed by sending a drive signal to supply pump (5) and controlling the fuel injection pump.

PC600-6

STRUCTURE AND FUNCTION

ENGINE CONTROL

1. Operation of system Starting engine • When the starting switch is turned to the START position, the starting signal flows to the starting motor, and the starting motor turns to start the engine. When this happens, the engine controller checks the signal from the fuel control dial and sets the engine speed to the speed set by the fuel control dial.

Engine speed control • The fuel control dial sends a signal voltage matching the angle of the fuel control dial to the engine controller. The engine controller controls the engine speed by sending a drive signal to the supply pump that matches this signal voltage in order to control the fuel injection pump.

Stopping engine • When the engine controller detects that the starting switch is at the STOP position, it cuts the signal to the supply pump drive solenoid and cuts off the supply of fuel to stop the engine. • When this happens, the engine controller itself drives the battery relay to ensure that there is electricity inside the system until the engine stops completely.

PC600-6

10-115

STRUCTURE AND FUNCTION

2. Components of system Fuel control dial

ENGINE CONTROL

HIGH A

1. 2. 3. 4. 5. 6.

45° Front of machine

Knob Dial Spring Ball Potentiometer Connector

45° A LOW

1 2 3 4

2 3

A–A

Composition of circuit

2 1

Function • The fuel control dial is installed at the bottom of the monitor panel. A potentiometer is installed under the knob, and when the knob is turned, it rotates the potentiometer shaft. When the shaft rotates, the resistance of the variable resistor inside the potentiometer changes, and the desired throttle signal is sent to the engine throttle and pump controller. The shaded area in the graph on the right is the abnormality detection area and the engine speed is set at low idling.

10-116

SBP00324

(%) 100

Accelerator angle

Lo 0.25 1

Characteristics of throttle voltage

4 4.75 5 Voltage (V) SAP00325

PC600-6

STRUCTURE AND FUNCTION

ENGINE CONTROL

Engine controller

10-118

PC600-6

STRUCTURE AND FUNCTION

ENGINE CONTROL

Input and output signals CN1

CN5

CN3

Pin No.

Input/ output

Pin No.

Input/ output

Name of signal

Pin No.

1 2

Common rail press. sensor

Input

Accel sensor (Test mode)

Input

Output

GND

ROM write enable switch

Input

Boost press. sensor

Input

GND

RS-232C TX1

Output

GND

4 5

Sensor power supply 1 (+5V, 50mA MAX.) Output

ROM write switch

Input

Q monitor (Test mode)

Output

Ne sensor (+)

Input

Power mode select 1 (Test mode)

Input

6 7

Fuel dial

Input

Power mode select 2 (Test mode)

Input

RS-232C RX1

Auto decel flag (Test mode)

Input

GND

Auto decel control (Test mode)

Input

CN4

GND

10 NC

Input

Pin No.

10 GND

Input

GND

Starter switch (C)

Input

13 Lever neutral flag (Test mode) Input

Input

14 Signal input 19 (Test mode) Input

Memory clear switch

Input

15 Signal input 20 (Test mode) Input 16 Signal input 21 (Test mode) Input

11 GND 12 Ne sensor (–)

CN2 Pin No.

Name of signal

Input/ output

Name of signal

Input

Input/ output

G sensor (+)

Input

Oil press switch (Low)

Input

Sensor power supply 2 (+5V, 50mA MAX.) Output

Oil press switch (High)

Input

Coolant temp. sensor (Low temp.)

Input

Key switch (Acc)

Input

Coolant temp. sensor (High temp.) Input

GND (Battery earth)

Input

Power supply (+24V)

GND

10 GND Input, output

Network (+)

Input, output

G sensor (–)

Input

10 GND 11 Fuel temp. sensor 12 NC

Input Input

13 NC

Output

14 NC

Output

15 NC

Output

16 NC 17 NC 18 Network (+)

Input, output Input, output

11 GND 12 Engine speed pulse (Test mode) Output

Output

Input/ output

Name of signal

CN6 Pin No.

Input/ output

Name of signal

Input

Output

11 Auto decel signal

Input

Injector 3 (+)

Output

12 NC

Input

Injector 2 (+)

Output

13 Machine select 1

Input

14 Machine select 2

Input

Output

15 Machine select 3

Input

Injector 1 (+)

Output

16 NC

Input

Injector 1 (–)

Output

17 NC

Input

Injector 3 (–)

Output

18 Key switch (Acc)

Input

10 Injector 2 (–)

Output

19 GND (Battery earth)

CN7

20 Power supply (+24)

Pin No.

Input/ output

Name of signal

Injector 5 (+)

Output

Injector 6 (+)

Output

Injector 4 (+)

Output

Supply pump 2 (+)

Output

GND (Battery earth)

Power supply (Injector, supply pump)

Injector 5 (–)

Output

Injector 6 (–)

Output

Injector 4 (–)

Output

10 Supply pump 1 (+)

Output

11 Supply pump 1 (–)

Output

12 Supply pump 2 (–)

Output

13 GND (Battery earth) 14 Power supply (Injector, supply pump)

PC600-6

10-119

STRUCTURE AND FUNCTION

MACHINE CONTROL SYSTEM

MACHINE CONTROL SYSTEM CONTROL FUNCTIONS 1

OFF (Cancel) Auto deceleration function ON

3-mode selector type pump torque control Electronic OLSS function

Cut-off control Flow control

OFF Power max. function ON

OFF Heavy-lift function

Machine control system

ON 5

OFF (Digging improvement mode) 2-stage boom pushing force selector function ON (Machine push-up mode) (Machine push-up)

6 Swing control function ª Turbo protect function ª Split injection function ª PC600, 600LC-6 Serial No.: 11001 and up 7 Engine automatic warming up, overheat prevention function 8

Lo (Low speed) fixed Travel speed selector function

PC600-6

Hi (High speed) → ← Lo (low speed) automatic gear shift

10-121

STRUCTURE AND FUNCTION

MACHINE CONTROL SYSTEM

MACHINE CONTROL SYSTEM DIAGRAM

10-122

PC600-6

STRUCTURE AND FUNCTION

PC600-6

MACHINE CONTROL SYSTEM

10-123

STRUCTURE AND FUNCTION

MACHINE CONTROL SYSTEM

1. Auto deceleration function

10-124

PC600-6

STRUCTURE AND FUNCTION

MACHINE CONTROL SYSTEM

FUNCTION • If all the control levers are at neutral when waiting for work or waiting for a dump truck, the engine speed is automatically reduced to a midrange speed to reduce fuel consumption and noise. • If any lever is operated, the engine speed returns immediately to the set speed. OPERATION Control levers at neutral • If the engine is running at above the deceleration actuation speed (approx. 1400 rpm), and all the control levers are returned to neutral, the engine speed drops immediately to approx. 100 rpm below the set speed to the No. 1 deceleration position. • If another 4 seconds passes, the engine speed is reduced to the No. 2 deceleration position (approx. 1400 rpm), and is kept at that speed until a lever is operated. When control lever is operated • If any control lever is operated when the engine speed is at No. 2 deceleration, the engine speed will immediately rise to the speed set by the fuel control dial.

PC600-6

10-125

STRUCTURE AND FUNCTION

MACHINE CONTROL SYSTEM

2. Electronic OLSS function Pump control system

• •

•

Interconnected control of all pumps is carried out by one TVC valve. DH mode: Total horsepower control by engine speed sensing H mode: Total horsepower control by engine speed sensing G Mode: Constant torque control Emergency pump drive circuit: Absorption torque equivalent to G mode

10-126

PC600-6

STRUCTURE AND FUNCTION

MACHINE CONTROL SYSTEM

1) Control method in each mode DH, H mode

•

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

PC600-6 PC600LC-6

Mode DH

287 kW/1,800 rpm {385 HP/1,800 rpm}

265 kW/1,635 rpm {355 HP/1,635 rpm}

•

When the load on the pump rises and the pressure rises, the engine speed goes down. When this happens, the pump discharge amount is reduced, and the engine speed is controlled so that it becomes close to the rated speed. If the reverse happens and the pressure goes down, the system is controlled so that the pump discharge amount is increased until the engine speed reaches close to the rated speed. By repeating this control, the engine can always be used at near the rated output point.

PC600-6

10-127

STRUCTURE AND FUNCTION

MACHINE CONTROL SYSTEM

G mode

•

Matching point Mode

Partial output point

62%

Model Mode G

PC600-6 PC600LC-6 178 kW/1,550 rpm {240 HP/1,550 rpm}

When the load on the pump rises and the pressure rises, the engine speed goes down. When this happens, mutual control of the engine and pump is used to control the system so that the pump absorption torque follows the equal horsepower curve of the engine, and the engine speed is lowered while keeping the torque constant. In this way, the engine is used in a range which provides good fuel efficiency.

10-128

PC600-6

STRUCTURE AND FUNCTION

MACHINE CONTROL SYSTEM

2) Cut-off (CO) function • If the load becomes larger during operation, and the pump discharge pressure rises too close to the relief pressure, the discharge amount is reduced, thereby reducing the relief loss.

3) CO cancel function • The cut-off cancel function acts to stop the operation of the cut-off function in order to ensure the pump flow when the load becomes larger during operation, and the pump discharge pressure rises too close to the relief pressure, thereby preventing any drop in speed. • The actuation and cancellation of the cutoff function is set automatically by operating the power max. switch, travel lever, and heavy lift switch.

•

Cut-off function and actuation of each switch Power max. switch (Note 1)

CO function

Travel lever

Working mode switch

Heavy lift switch

OFF

Operated

Neutral

OFF

Cancel

Actuate

Cancel

Actuate

Cancel

Actuate

Note 1: Actuated only when the working mode switch is at DH or H. 4) 2-stage relief function When the power max. switch is ON, if the travel lever is operated and the heavy lift switch is ON, the pilot pressure of the 2stage relief valve raises the set pressure of the main relief valve from 31.9 MPa {325 kg/ cm2} to 34.3 MPa {350 kg/cm2} to increase the digging and travel power. Power max. switch (Note 1)

Main relief valve set pressure MPa {kg/cm2}

Travel lever

Heavy lift switch (Note 1)

OFF

Operated

Neutra

OFF

34.3 {350}

31.9 {325}

34.3 {350}

31.9 {325}

34.3 {350}

31.9 {325}

Note 1: Actuated when the heavy lift switch is ON and the boom RAISE is operated independently.

PC600-6

10-129

STRUCTURE AND FUNCTION

MACHINE CONTROL SYSTEM

3. Power max. function

10-130

PC600-6

STRUCTURE AND FUNCTION

MACHINE CONTROL SYSTEM

Function • This is a function to increase the power for a fixed period when the L.H. knob switch is operated. It makes it possible to obtain a sudden burst of power to match the working conditions. • If the knob switch on the work equipment control lever is turned ON with the working mode set to DH or H, the following functions are actuated. Power max. switch Mode, function CO function

OFF

Actuated

Canceled

Main relief valve pressure

31.9 MPa 34.3 MPa {325 kg/cm2} {350 kg/cm2}

Operating time

Canceled after 8.5 sec even when kept pressed

—

ﬂ This function is not actuated when the working mode switch is at G.

PC600-6

10-131

STRUCTURE AND FUNCTION

MACHINE CONTROL SYSTEM

4. Heavy lift function

Outline • This function increases the boom lifting power by approx. 10%. • It can be actuated only when the boom RAISE is being actuated independently. If the arm IN and dump or bucket CURL and dump are operated at the same time, the heavy-lift function is automatically canceled.

PC600-6

10-133

STRUCTURE AND FUNCTION

MACHINE CONTROL SYSTEM

Operation Lever operation Heavy-list switch

OFF

Heavy-lift solenoid valve

Main relief valve set pressure

CO valve switch

Boom lifting force

Boom RAISE

Arm IN or bucket CURL

Operated

—

Deenergized

31.9 MPa {325 kg/cm2}

Actuated

Normal

Neutral

Excited

34.3 MPa {350 kg/cm2}

Canceled

10% up

Operated Operated

If the arm IN or bucket CURL are operated during boom RAISE operations, this function is automatically canceled, and the condition becomes the same as when the switch is turned OFF.

Normal

fl Heavy-lift solenoid valve For details of the structure and function, see SOLENOID VALVE ASSEMBLY. fl CO valve For details of the structure and function, see NO. 1 PUMP. fl Main relief valve For details of the structure and function, see CONTROL VALVE.

10-134

PC600-6

STRUCTURE AND FUNCTION

MACHINE CONTROL SYSTEM

5. 2-stage boom pushing force selector function

Outline • This function switches the pushing force of the boom. It is aimed to provide both increased digging efficiency by reducing the digging resistance of the boom, and increased ease of operation by increasing the thrusting force for excavation, digging square holes, carrying out twist turns, or escaping from soft ground.

PC600-6

10-135

STRUCTURE AND FUNCTION

MACHINE CONTROL SYSTEM

Operation • This function acts to change the set pressure of the safety valve at the boom cylinder end of the control valve boom Lo in 2 ways: to low pressure (14.7 MPa {150 kg/cm2) and high pressure (28.4 MPa {290 kg/cm2}. Mode

Boom pushing force (low mode)

Boom pushing force (high mode)

Machine push-up switch

Machine Safety valve push-up set pressure solenoid valve

Effect

Excited

14.7 MPa {150 kg/cm2}

By reducing the boom pushing force, it is made easier for the boom to escape automatically in the RAISE direction and to reduce the number of times that the boom is operated. At the same time it also makes the digging operation smoother.

De-energized

28.4 MPa {290 kg/cm2}

By increasing the thrust force for boom LOWER, the ease of operation is improved for excavation, digging square holes, carrying out twist turns, or escaping from soft ground.

ﬂ Machine push-up solenoid valve For details of the structure and function, see SOLENOID VALVE ASSEMBLY. ﬂ Boom safety valve For details of the structure and function, see CONTROL VALVE.

10-136

PC600-6

STRUCTURE AND FUNCTION

MACHINE CONTROL SYSTEM

6. Swing control function

Function • The system is provided with a swing lock and swing holding brake function.

10-138

PC600-6

STRUCTURE AND FUNCTION

1) Swing lock, swing holding brake function • The swing lock (manual) can be locked at any desired position, and the swing holding brake (automatic) is interconnected with the swing, so it prevents any hydraulic drift after the swing is stopped.

MACHINE CONTROL SYSTEM

•

Swing lock switch and swing lock, swing holding brake

Lock switch

OFF

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

Lock lamp

Function

Operation

OFF

Swing holding brake

When swing lever is placed at neutral, swing brake is applied after approx. 7 sec; when swing lever is operated, brake is canceled and swing can be operated freely

Swing lock

Swing lock is actuated and swing is held in position. Even when swing lever is operated, swing lock is not canceled and swing does not move.

2) Hydraulic oil quick warm-up function when swing lock switch is ON • When the swing lock switch is turned ON, the pump cut-off is canceled. If the work equipment is relieved in this condition, the hydraulic oil temperature will rise more quickly and the warming-up time can be reduced.

PC600-6

Swing holding ON OFF brake (when controller is abnormal) (when controller is normal) cancel switch switch Swing lock switch

OFF

Swing Swing lock Swing lock brake applied canceled

OFF

Swing lock Swing holdapplied ing brake applied

Prolix Normal SBP00362

10-139

STRUCTURE AND FUNCTION

MACHINE CONTROL SYSTEM

7. Engine automatic warming-up device, overheat prevention function, turbo protect function, split injection function

Function • If the water temperature is low, this automatically raises the engine speed to warm up the engine after it is started. In addition, if the water temperature rises too high during operations, it reduces the load of the pump to prevent overheating. • To protect the turbocharger bearing during cold weather, the engine speed is kept below the fixed speed when the engine is started. In addition, to improve the starting ability, a small amount of fuel is injected two or more times before the main injection. PC600-6

10-141

STRUCTURE AND FUNCTION

MACHINE CONTROL SYSTEM

1) Engine automatic warming-up function • After the engine is started, if the engine coolant temperature is low, the engine speed is automatically raised to warm up the engine. Conditions for actuation (both are necessary)

Actuation

Coolant temperature: Less than 30°C Engine speed: Less than 1200 rpm

Engine speed: 1200 rpm

Conditions for cancellation (any one) Automatic Manual

Cancellation

Coolant temperature: 30°C or above Automatic warming-up time: 10 minutes or more

Engine speed: As desired

Fuel control dial: Held at more than 70% of full throttle for more than 3 seconds

2) Engine overheat prevention function • This function protects the engine by lowering the pump load and engine speed to prevent overheating when the engine coolant temperature has risen too high. • This system is actuated at 105°C and above. Normal operation (water transmission below 102°C)

Actuation condition Water temperature: 105°C and above (Water temperature gauge: Red range)

Actuation, remedy Working mode : Engine speed : Monitor warning lamp : Alarm buzzer :

In any mode Low idling Lights up Sounds

Cancel condition Water temperature: Below 105°C Fuel control dial : Return temporarily to low idling position • When the above conditions are met, the system returns to the condition before the overheat prevention function was actuated (manual reset).

10-142

PC600-6

STRUCTURE AND FUNCTION

MACHINE CONTROL SYSTEM

3) Turbo protection function PC600, 600LC-6 Serial No.: 11001 and up Function to protect turbocharger bearing during cold weather by keeping engine speed below fixed speed when engine is started. Actuation condition Engine water temperature

Turbo protect time (sec)

More than +10°C

+10°C to –10°C

Gradually changes between 0 and 5

Less than –10°C

Engine speed: 1000 rpm Even if the fuel control dial is operated during the above time, the engine speed will not change. After the set time passes, the operation moves to the automatic warming up function in Step 1). 4) Split injection function PC600, 600LC-6 Serial No.: 11001 and up To improve the ease of starting in cold weather, a small amount of fuel is injected two or more times within the set time after calculating in the table below before starting the main injection. As a result, the lower idling speed during this time becomes slightly higher. Actuation condition Water temperature

Split injection time (sec)

More than 20°C

20°C to –30°C

0 – 15

Less than –30°C

PC600-6

10-143

STRUCTURE AND FUNCTION

MACHINE CONTROL SYSTEM

8. Travel control function

Outline • The pump absorption torque is increased when traveling to increase the drawbar pull. • Switching between manual and automatic travel speed selection is used to improve the travel performance.

PC600-6

10-145

STRUCTURE AND FUNCTION

Travel speed selection function 1) Manual selection using travel speed switch If the travel speed switch is set to Lo, Mi, the engine throttle and pump controller controls (ª pump controller) the pump flow and motor volume at each speed range as shown on the right to switch the travel speed. ª PC600, 600LC-6 Serial No.: 11001 and up 2) Automatic selection according to engine speed If the engine speed is reduced to below 1,400 rpm by the fuel control dial: • If the machine is traveling in Lo, it will not shift even if Hi is selected. • If the machine is traveling in Hi, it will automatically shift to Lo. 3) Automatic selection according to pump discharge pressure If the machine is traveling with the travel speed switch at Hi, and the load increases, such as when traveling up a steep hill, if the travel pressure continues at 31.9 MPa (325 kg/cm2) for more than 1.0 sec, the pump volume is automatically switched and the travel speed changes to Lo. (The travel speed switch stays at Hi.) The machine continues to travel in Lo, and when the load is reduced, such as when the machine travels again on flat ground or goes downhill, and the travel pressure stays at 22.6 MPa (230 kg/cm2) or less for more than 1.0 sec, the pump volume is automatically switched and the travel speed returns to Hi.

10-146

MACHINE CONTROL SYSTEM

Travel speed switch

Lo (Low speed)

Hi (High speed)

Motor volume

Max.

Min.

Travel speed (km/h)

3.0

4.9

PC600-6

STRUCTURE AND FUNCTION

MACHINE CONTROL SYSTEM

9. Components of system 1) Engine speed sensor

1. 2. 3. 4. 5.

Wire Magnet Terminal Housing Connector

PC600-6

Function • The engine speed sensor is installed to the ring gear portion of the engine flywheel. It counts electrically the number of gear teeth that pass in front of the sensor, and sends the results to the engine throttle · pump controller (ª engine controller and pump controller). ª PC600, 600LC-6 Serial No.: 11001 and up • This detection is carried out by a magnet, and an electric current is generated every time the gear tooth passes in front of the magnet.

10-147

STRUCTURE AND FUNCTION

MACHINE CONTROL SYSTEM

2) PPC hydraulic switch 1. Plug 2. Switch 3. Connector

Specifications Composition of points: N.O. points Actuation (ON) pressure: 0.5 ± 0.1 MPa (5.0 ± 1.0 kg/cm2) Reset (OFF) pressure: 0.3 ± 0.05 MPa (3.0 ± 0.5 kg/cm2) Function • There are 8 switches installed to the PPC shuttle valve. The operating condition of each actuator is detected from the PPC pressure, and this is sent to the engine throttle · pump controller (ª engine controller and pump controller). ª PC600, 600LC-6 Serial No.: 11001 and up 3) TVC prolix resistor 1

SBP00370

1. Resistor 2. Connector

Specification Resistance: 37 Ω

10-148

Function • This resistor acts to allow a suitable current to flow to the TVC solenoid when the TVC prolix switch is ON. • No current flows when the TVC prolix switch is OFF.

PC600-6

STRUCTURE AND FUNCTION

MACHINE CONTROL SYSTEM

4) Engine throttle · pump controller, ª2 engine controller ª2 PC600, 600LC-6 Serial No.: 11001 and up ﬂ See ENGINE CONTROL.

5) Monitor panel ﬂ See MACHINE MONITOR SYSTEM.

6) TVC valve ﬂ See HYDRAULIC PUMP.

PC600-6

10-149

STRUCTURE AND FUNCTION

MACHINE CONTROL SYSTEM

7) Pump pressure sensor 1. Sensor 2. Connector 3. Amplifier

Insulation layer

Function • This sensor is installed to the inlet port circuit of the control valve. It converts the pump discharge pressure to a voltage and sends this to the governor · pump controller (ª pump controller).

PC600, 600LC-6 Serial No.: 11001 and up

Diaphragm (strainless steel) SAP00368

Sensor output voltage (V)

Operation • When the pressurized oil entering from the pressure introduction portion pressurizes the diaphragm of the pressure detection portion, the diaphragm deflects and changes shape. • A gauge layer is installed to the face opposite the diaphragm, and the resistance of the gauge layer converts the deflection of the diaphragm into an output voltage and sends it to the amp (voltage amplifier). • The voltage is further amplified by the amplifier and is sent to the governor · pump controller (ª pump controller). • Relationship between P pressure (MPa {kg/ cm2}) and output voltage (V). V = 0.008 x P + 1.0

Gauge layer

3 2

9 .8 19 .6 29 .4 39 .2 49 .0 (100) (200) (300) (400) (500) Pressure P (MPa (kg/cm2)) SAP00369

10-150

PC600-6

STRUCTURE AND FUNCTION

MACHINE CONTROL SYSTEM

8) Pump controller

10-152

PC600-6

STRUCTURE AND FUNCTION

MACHINE CONTROL SYSTEM

Input and output signals CN1 Pin No.

CN3 Name of signal

Input/ output

Pin No.

CN4 Name of signal

Input/ output

Pin No.

Name of signal

Input/ output

Step light relay

Output

Input

Bucket curl hi solenoid

Output

Fuel level sensor

Input

F Pump press. sensor

Input

RS232C TXD

Output

RS232C RXD

Input

Input, output

Input

Flash write switch

Input

Swing brake solenoid

Output

Auto decel signal output

Output

GND

Sensor power supply

Power supply

CO cancel solenoid

Output

Start switch (Acc)

Input

Travel hi/lo change solenoid Output

Knob switch

Input

10 2-stage relief solenoid

Output

10 NC

11 Flash light relay

Output

Input

11 Hydraulic oil temp.

Input

12 GND

12 Charging level

Input

13 Power supply

13 R Pump press. sensor

Input

CN2

14 NC

Pin No.

Name of signal

Input/ output

15 NC 16 GND

10 RS232C GND 11 NC

Input, output

12 NC

Input, output

CN7

Power supply

17 GND

18 Start switch (C)

Input

Pin No.

19 (Auto grease-up)

Input

GND (PLUS)

20 NC

Engine speed

21 NC

GND

Power supply relay for step light Output

22 Boom raise switch

Input

GND

23 Arm curl switch

Input

Swing switch

TVC solenoid (+)

24 Network (+)

Input, output

6 7

Step light switch

Input

10 NC

25 Machine select 1

Input

Coolant level

Input

11 GND

26 Machine select 3

Input

Hydraulic oil level

Input

12 Power supply

27 Machine select 5

Input

10 GND (PLUS)

13 NC

28 Swing prolix switch

Input

11 Bucket curl switch

14 NC

29 (Over load sensor)

Input

12 Bucket dump switch

Input

15 NC

30 Boom lower switch

Input

13 Travel switch

Input

16 NC

31 Arm dump switch

Input

14 Service switch

Input

32 Network (+)

Input, output

15 Horn switch

Input

16 Engine oil level

Input

33 Machine select 2

Input

17 Air cleaner

Input

34 Machine select 4

Input

Output

17 NC 18 TVC solenoid (–) 19 NC 20 NC 21 GND

PC600-6

Output

35 Kerosene mode select

Input

36 Swing lock switch

Input

Name of signal

Input/ output Input

Input

10-153

STRUCTURE AND FUNCTION

MONITOR SYSTEM

Function • The monitor system uses the sensors installed to all parts of the machine to observe the condition of the machine. It processes this information swiftly, and displays it on a panel to inform the operator of the condition of the machine. • The content of the information displayed on the machine can broadly be divided as follows. 1. Monitor portion This gives an alarm if any abnormality occurs in the machine. 2. Gauge portion This always displays the condition of the machine (coolant temperature, fuel level). PC600-6

•

The monitor panel also has various built-in mode selector switches, and functions as the control panel for the machine control system.

10-155

STRUCTURE AND FUNCTION

MONITOR SYSTEM

1. Monitor panel

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

PC600-6

Input and output signals CN-P01 Pin No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20

CN-P02 Name of signal NC NC NC N/W signal Swing lock Buzzer stop Buzzer output Lamp Key ON signal Acc signal N/W signal NC NC N/W GND NC NC NC Preheating Start signal NC

Pin No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16

Name of signal GND Washer output Wiper signal Wiper SW (ON) Wiper SW (WASHER) NC NC +VB GND Washer output NC Wiper SW (INT) NC +VB NC NC

10-157

STRUCTURE AND FUNCTION

MONITOR SYSTEM

MONITOR DISPLAY

1. Clock 2. Service meter 3. Fuel level gauge 4. Fuel level caution lamp 5. Engine oil level caution lamp 6. Hydraulic oil level caution lamp 7. Swing holding brake pilot lamp 8. Oil maintenance pilot lamp 9. Battery charge caution lamp 10. Air cleaner clogging caution lamp 11. Hydraulic oil temperature caution lamp 12. Engine oil pressure caution lamp 13. Not use 14. Coolant temperature caution lamp 15. Coolant temperature gauge

10-158

PC600-6

STRUCTURE AND FUNCTION

MONITOR SYSTEM

Content of display Symbol

Display item

Display range

When engine is stopped

When engine is running

Engine oil pressure

Below specified level

Lights up when normal (goes out when engine starts)

Flashes and buzzer sounds when abnormal

Air cleaner clogging

When clogged

OFF

Flashes when abnormal

Charge level

When charging is defective

Lights up when normal (goes out when engine starts)

Flashes when abnormal

Engine oil level

Below low level

Flashes when abnormal

OFF

Hydraulic oil level

Below low level

Flashes when abnormal

OFF

Parking (Swing lock)

When swing is locked

Lights up when swing lock switch is ON, flashes when swing holding brake release switch is ON

SAP00520

SAP00521

SAP00522

SAP00523

SAP00524

SAT00098

Oil maintenance

See next page. OIL MAINTENANCE FUNCTION

SAP02732

Coolant temperature

Flashes when above 102°C, flashes and buzzer sounds when above 105°C

Fuel level

Flashes when below low level

SAP00527

SAP00528

Hydraulic oil temperature SAD01484

PC600-6

Above specified level

OFF when normal (lights up Flashes and buzzer sounds for 3 seconds when startwhen abnormal ing switch is turned ON)

10-159

STRUCTURE AND FUNCTION

MONITOR SYSTEM

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

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

10-160

PC600-6

STRUCTURE AND FUNCTION

MONITOR SYSTEM

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

PC600-6

10-161

STRUCTURE AND FUNCTION

MONITOR SYSTEM

SWITCHES

1. 2. 3. 4.

Working mode switch Auto deceleration switch Travel speed switch Heavy lift switch

•

There are four mode selector switches on the switch panel. Each time any of these switches is pressed, the condition of the machine will change. The LEDs on the switch panel light up to indicate the condition of the machine.

Switch actuation table Item

Actuation

Working mode

DH ↔ H ↔ G

Heavy lift button

OFF ↔ ON

Auto decel

ON ↔ OFF

Travel speed

Hi ↔ Lo

ﬂ The bold letters indicate the default position of the switch when the starting switch is turned ON.

10-162

PC600-6

STRUCTURE AND FUNCTION

MONITOR SYSTEM

2. Sensors •

The signal from the sensor is input to the engine controller and pump controller. The contact type sensor is always connected at one end to the chassis ground. Name of sensor

Type of sensor

When normal

When abnormal

Input controller

Engine oil level

Contact type

ON (closed)

OFF (open)

Pump controller

Hydraulic oil level

Contact type

ON (closed)

OFF (open)

Pump controller

Engine oil pressure

Contact type

OFF (open)

ON (closed)

Engine controller

Resistance type

—

Pump controller

Contact type

OFF (closed)

ON (open)

Pump controller

Hydraulic oil temperature

Resistance type

—

Pump controller

Coolant temperature

Resistance type

—

Engine controller

Fuel level Air cleaner clogging

PC600-6

10-163

STRUCTURE AND FUNCTION

MONITOR SYSTEM

Engine oil level sensor Hydraulic oil level sensor

1. 2. 3. 4.

Connector Bracket Float Switch

Engine oil pressure sensor

1. 2. 3. 4. 5. 6.

10-164

Plug Contact ring Contact Diaphragm Spring Terminal

PC600-6

STRUCTURE AND FUNCTION

MONITOR SYSTEM

Fuel level sensor

1. 2. 3. 4.

Float Connector Cover Variable resistor

Air cleaner clogging sensor

PC600-6

10-165

STRUCTURE AND FUNCTION

MONITOR SYSTEM

Coolant temperature sensor Hydraulic oil temperature sensor

1. Thermistor 2. Body 3. Tube

10-166

4. Tube 5. Wire 6. Connector

PC600-6

20 TESTING AND ADJUSTING Standard value table Standard value table for engine .................................................................................................... 20-102 Standard value table for chassis .................................................................................................... 20-103 Standard value table for electrical parts ....................................................................................... 20-111 Testing and adjusting .............................................................................................................................20-101 Troubleshooting ...................................................................................................................................... 20-201

ﬂ

Note the following when making judgements using the standard value tables for testing, adjusting, or troubleshooting.

The standard value for a new machine given in the table is the value used when shipping the machine from the factory and is given for reference. It is used as a guideline for judging the progress of wear after the machine has been operated, and as a reference value when carrying out repairs.

The service limit value given in the tables is the estimated value for the shipped machine based on the results of various tests. It is used for reference together with the state of repair and the history of operation to judge if there is a failure.

These standard values are not the standards used in dealing with claims.

¤ When carrying out testing, adjusting, or troubleshooting, park the machine on level ground, inset the safety pins, and use blocks to prevent the machine from moving.

¤ When carrying out work together with other workers, always use signals and do not let unauthorized people near the machine.

¤ When checking the water level, always wait for the water to cool down. If the radiator cap is removed when the water is still hot, the water will spurt out and cause burns.

¤ Be careful not to get caught in the fan, fan belt or other rotating parts.

PC600-6

20-1

TESTING AND ADJUSTING

STANDARD VALUE TABLE FOR ENGINE

STANDARD VALUE TABLE FOR ENGINE Machine model

PC600-6, 600LC-6

Engine

SA6D140E-3

Item

Measurement condition

Unit

Standard value

Permissible value

1,950 ± 50

800 ± 25

1,800

—

kPa {mmHg}

Min 127 {Min. 950}

107 {800}

°C

Max. 650

Max. 700

Max. 4.0

6.0

Max. 1.0

2.0

0.35

—

0.57

—

Max. 4.1 {Max. 42}

2.8 {29}

Max. 1.47 {Max. 150}

2.94 {300}

0.34 – 0.54 {3.5 – 5.5}

0.21 {2.1}

0.12 {1.2}

0.07 {0.7}

0.1 {1.0}

0.07 {0.7}

90 – 110

120

13 – 16

—

High idling Engine speed

Low idling

rpm

Rated speed Intake air pressure

At rated output

Exhaust gas pressure

All speed range (intake air temp: 20°C) At sudden acceleration

Exhaust gas color At high idling

Bosch index

(normal temperature) Valve clearance

Intake valve

Exhaust valve Oil temperature: 40 – 60°C Compression pressure

Blow-by pressure

MPa (Engine speed: {kg/cm2} 20 – 250 rpm) (SAE30 oil) (Coolant temperature: within operating range) kPa (SAE30 oil) mmH2O At rated output

Oil pressure

(Coolant temperature: within operating range) At high idling MPa {kg/cm2} At low idling (SAE30) At low idling (SAE10W)

Oil temperature

All speed range (inside oil pan)

Alternator belt tension

Deflection when pressed with finger force of approx. 98 N {10 kg}

°C

mm Fan belt tension

20-2

PC600-6

TESTING AND ADJUSTING

STANDARD VALUE TABLE FOR CHASSIS

STANDARD VALUE TABLE FOR CHASSIS ﬂ The Standard value for new machine and Service limit value in the table below are all values when measured in the DH mode. Applicable model

Engine speed

Category

Item

PC600, 600LC-6

Measurement conditions

All pumps at relief

· Engine water temperature: Within operating range · Hydraulic oil temperature: 45 – 55°C · Engine at full throttle · In DH mode · Arm IN relief

All pumps at relief + heavy lift

· Engine at full throttle · In DH mode · Arm IN relief + heavy lift ON

Engine speed when auto-deceleration is actuated

· Auto-deceleration switch ON · Fuel control dial at MAX. · Control levers at neutral.

Standard value Unit for new machine

1,800 ± 100 (ª1) 1,775 ± 100 (ª2)

1,800 ± 100

1,750 ± 100 (ª1) 1,775 ± 100 (ª2)

1,750 ± 100

1,400 ± 100

rpm

Boom Lo control valve Boom Hi control valve

Service limit value

¬ a b

Spool stroke

Arm Lo control valve Arm Hi control valve 69

Bucket Lo control valve

16±0.5 16±0.5

Bucket Hi control valve Travel control valve

BLP00101

Travel of control levers

Swing control valve · Center of lever knob · Read max. value to end of travel · Engine stopped · Exclude play at neutral.

85 ± 10

Travel control lever

115 ± 15

Swing control lever

85 ± 10

Boom control lever Arm control lever Bucket control lever

ª1: PC600, 600LC-6 Serial No. : 10001 – 11000 ª2: PC600, 600LC-6 Serial No. : 11001 and up

PC600-6

20-3

TESTING AND ADJUSTING

STANDARD VALUE TABLE FOR CHASSIS

Applicable model

Operating effort of control levers

Category

Item Boom control lever Arm control lever Bucket control lever Swing control lever

Measurement conditions · Engine at full throttle · Oil temperature: 45 – 55°C · Fit push-pull scale to center of control lever knob or tip of pedal to measure · Measure max. value to end of travel

Travel control lever

RAISE Boom LOWER

Hydraulic pressure

Arm

Bucket

PC600, 600LC-6

· Engine at full throttle · Oil temperature: 45 – 55°C · Relieve only circuit being measured · In DH mode

15.68 ± 4.9 {1.6 ± 0.4} 15.68 ± 4.9 {1.6 ± 0.4} N {kg} 12.74 ± 3.92 {1.3 ± 0.4} 12.74 ± 3.92 {1.3 ± 0.4} 12.74 ± 3.92 {1.3 ± 0.5} 12.74 ± 3.92 {1.3 ± 0.5} 24.5 ± 5.9 {2.5 ± 0.6}

Normal

31.87 – 0.98 {325 – 10 }

Heavy-lift mode, active power-up

24.5 ± 5.9 {2.5 ± 0.6}

+1.47

+15

31.87 – 0.98 {325 – 10 }

34.32 – 0.98 {350 – 10 }

+1.47

+15

34.32 – 0.98 {350 – 10 }

Normal

19.12±1.96 {195±20}

At machine push-up

31.87 – 0.98 {325 – 10 }

+1.47

+15

31.87 – 0.98 {325 – 10 }

Normal

31.87 – 0.98 {325 – 10 }

+1.47

+15

31.87 – 0.98 {325 – 10 }

Active power-up

34.32 – 0.98 {350 – 10 }

+1.47

+15

34.32 – 0.98 {350 – 10 }

Normal

31.87 – 0.98 {325 – 10 }

+1.47

+15

31.87 – 0.98 {325 – 10 }

34.32 – 0.98 {350 – 10 }

+1.47

+15

34.32 – 0.98 {350 – 10 }

36.28 – 0.98 {370 – 10 }

+1.47

+15

36.28 – 0.98 {370 – 10 }

29.91±0.98 {305±10}

Active power-up

Swing

MPa {kg/ cm2}

+0.29

3.14 0

Control pump

NC valve output pressure

Service limit value

15.68 ± 4.9 {1.6 ± 0.5} 15.68 ± 4.9 {1.6 ± 0.5}

Lever

Travel

TVC valve output pressure

Standard value Unit for new machine

· Engine at full Levers at neutral throttle · Oil tempera- Boom RAISE ture: 45 – 55°C relief (standard) Heavy lift ON, boom RAISE relief Levers at · Engine at full neutral throttle · Oil temperaTravel lever at full, ture: 45 – 55°C tracks rotating · In DH mode under no load (note)

{32 – 0 }

+1.47

+15

+1.47

+15

+1.47

+15

+1.47

+15

+1.47

+15

+1.47

+15

+1.47

+15

+1.47

+15

+0.29

3.14 0

{32 – 0 }

2.25 ± 0.2 {23 ± 2}

Min. 1.76 {Min. 18}

1.42 ± 0.2 {14.5 ± 2}

1.37 ± 0.2 {14 ± 2}

1.23 ± 0.2 {12.5 ± 2}

1.2 ± 0.2 {12 ± 2}

Max. 0.4 {Max. 4}

Max. 0.55 {Max.5.5}

Min. 1.8 {Min. 18}

Note: The measurement is carried out at the NC valve, but neither the CO valve nor the NC valve work, so the measurement is the pressure for the TVC valve.

20-4

PC600-6

TESTING AND ADJUSTING

STANDARD VALUE TABLE FOR CHASSIS

Applicable model

Hydraulic pressure

Category

Item

Jet sensor differential pressure

Control levers at neutral Control levers at end of travel

Drop in hydraulic pressure

Overrun when stopping swing

PC600, 600LC-6

Measurement conditions

Standard value Unit for new machine

· Engine at full throttle · Hydraulic oil temperature: 45 – 55°C (Pump discharge pressure at any value) · Hydraulic oil temperature: 45 – 55°C · Difference between relief pressure with engine at full throttle and relief pressure with engine at low idling (relief pressure: 2-pump relief)

MPa {kg/ cm2}

· Engine at full throttle deg. · Hydraulic oil temperature: <mm> 45 – 55°C · Stop after swinging one turn and measure distance that swing circle moves Value in < > shows distance at outside circumference of swing circle

Swing

90°

Time taken to start swing

· Engine at full throttle · Hydraulic oil temperature: 45 – 55°C · In DH mode 180° · Time taken to swing 90° and 180° from starting position sec

Time taken to swing

Service limit value

1.76 ± 0.2 {18 ± 2}

Min. 1.5 {Min. 15}

Max. 0.2 {Max. 2}

Max. 2.0 {Max. 20}

2.9 {30}

45 <Max. 775>

Max. 60 <Max.1,040>

4.0 ± 0.5

Max. 4.9

5.8 ± 0.7

Max. 7.2

34.0 – 38.0

Max. 40

· Engine at full throttle · Hydraulic oil temperature: 45 – 55°C · In DH mode · Swing one turn, then measure time taken to swing next 5 turns

PC600-6

20-5

TESTING AND ADJUSTING

STANDARD VALUE TABLE FOR CHASSIS

Applicable model Category

Item

PC600, 600LC-6

Measurement conditions

Standard value Unit for new machine

Service limit value

15°

BKP00103

¬ /min

Max. 5

Max. 10

Low speed

54 – 66

High speed

35 – 43

Low speed

Leakage from swing motor

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

23 – 31

High speed

Swing

Hydraulic drift of swing

15 – 19

· Engine at full throttle · Hydraulic oil temperature: 45 – 55°C · Relieve swing circuit.

BKP00104

Travel

Travel speed (1)

· Engine at full throttle · Hydraulic oil temperature: 45 – 55°C · In DH mode · Raise track on one side at a time, rotate one turn, then measure time taken for next 5 turns with no load. 45˚

sec

BKP00105

Travel speed (2)

20-6

· Engine at full throttle · Hydraulic oil temperature: 45 – 55°C · In DH mode · Run up for at least 10 m, and measure time taken to travel next 20 m on flat ground.

PC600-6

TESTING AND ADJUSTING

STANDARD VALUE TABLE FOR CHASSIS

Applicable model Category

Item

PC600, 600LC-6

Measurement conditions

Standard value Unit for new machine

Service limit value

Work equipment posture 45°

BKP00106

Travel deviation

· Engine at full throttle · Hydraulic oil temperature: 45 – 55°C · In DH mode · Travel speed : Hi · Run up for at least 10 m, and measure deviation when traveling next 20 m on flat ground. ﬂ Use a hard horizontal surface.

Max. 200

Max. 10

Max. 20

20m

10m

BKP00107

Travel

ﬂ Measure dimension χ.

12˚ BKP00108

Hydraulic drift of travel

· Engine stopped · Hydraulic oil temperature: 45 – 55°C · Stop machine on 12° slope with sprocket at uphill end of machine. · Measure the distance the machine moves in 5 minutes.

Leakage of travel motor

¬ /min · Engine at full throttle · Hydraulic oil temperature: 45 – 55°C · Lock shoes and relieve travel circuit.

PC600-6

20-7

TESTING AND ADJUSTING

STANDARD VALUE TABLE FOR CHASSIS

Applicable model Category

Service limit value

Max. 1,200

Max. 1,800

Max. 90

Arm cylinder (amount of extension of cylinder)

165

Max. 250

Bucket cylinder (amount of retraction of cylinder)

Max. 75

RAISE

4.9 ± 0.5

—

LOWER

Work equipment posture Back hoe

3.6 ± 0.4

—

Total work equipment (hydraulic drift at tip of bucket teeth)

Standard value Unit for new machine

Measurement conditions

5.3 ± 0.5

—

OUT

Work equipment

Hydraulic drift of work equipment

Item

PC600, 600LC-6

3.9 ± 0.4

—

Loading shovel

BKP00110

Boom cylinder (amount of retraction of cylinder) · Place in above posture and measure extension or retraction of each cylinder and downward movement at tip of bucket teeth. · Rated load of work equipment

Cylinder fully extended

· Engine at full throttle · Hydraulic oil temperature: 45 – 55°C · In DH mode

sec

Arm Cylinder fully retracted

↔

Work equipment speed

↔

Boom Bucket teeth in contact with ground

Fully extended · Engine at full throttle · Hydraulic oil temperature: 45 – 55°C · In DH mode

20-8

PC600-6

TESTING AND ADJUSTING

STANDARD VALUE TABLE FOR CHASSIS

Applicable model

Service limit value

CURL

Bucket Cylinder fully retracted Fully extended

Boom

3.2 ± 0.4

—

· Engine at full throttle · Hydraulic oil temperature: 45 – 55°C · In DH mode

3.5 ± 0.4

—

Max. 3

Max. 5

Max. 20

Max. 10

Max. 100

BKP00114

sec

· Lower boom and measure time taken from point where bucket contacts ground to point where chassis rises from ground · Engine at low idling · Hydraulic oil temperature: 45 – 55°C

Time lag

Work equipment

Standard value Unit for new machine

Measurement conditions

↔

Work equipment speed

Item

DUMP

Category

PC600, 600LC-6

Arm

Oil leakage

Bucket

PC600-6

BKP00115

· Stop arm suddenly and measure time taken for arm to stop · Engine at low idling · Hydraulic oil temperature: 45 – 55°C

Each cylinder Center swivel joint

BKP00116

· Stop bucket suddenly and measure time taken for bucket to stop · Engine at low idling · Hydraulic oil temperature: 45 – 55°C · Hydraulic temperature: 45 – 55°C · Hydraulic oil pressure: 31.4±1.0 MPa {320±10 kg/cm2} cc/min

20-9

TESTING AND ADJUSTING

STANDARD VALUE TABLE FOR CHASSIS

Performance of hydraulic pump

Category Discharge amount of one main piston pump (in H mode)

• TVC current : 0.4A • Pump speed: At 1,929 rpm (Engine at 1,800 rpm)

Check point

As desired

Test pump discharge pressure (MPa {kg/cm2})

Discharge pressure of other pump (MPa {kg/cm2})

Average pressure (MPa {kg/cm2}) P1 + P2 2

Standard value for discharge amount Q (¬/min)

Judgement standard lower limit Q (¬/min)

See graph

ﬂ As far as possible, bring pump discharge pressure P1 and P2 as close as possible to the average pressure when measuring. The error is large near the point where the graph curves, so avoid measuring at this point. ﬂ When measuring with the pump mounted on the machine, if it is impossible to set the engine speed to the specified speed with the fuel control dial, take the pump discharge amount and the engine speed at the point of measurement, and use them as a base for calculating the pump discharge amount at the specified speed.

20-10

PC600-6

TESTING AND ADJUSTING

STANDARD VALUE TABLE FOR ELECTRICAL PARTS

Oil pressure low pressure switch

Oil pressure high pressure switch

Boost pressure sensor

Fuel temperature sensor

Common rail fuel pressure sensor

PC600-6

TWH (male)

PSL (male)

PSH (male)

E11 E12

THL (male)

CN1 CN2

Measure resistance Measure resistance Measure resistance Measure resistance

Water temperature high temperature sensor

TWL (male)

Measure resistance

Engine controller system

Water temperature low temperature sensor

G (male)

Measure resistance

G rotation sensor

NE (male)

Measure voltage

Ne rotation sensor

Connector Inspection No. method

Measure resistance

Name of component

Measure voltage

System

Measurement conditions

Judgment table If the condition is as shown in the table below, it is normal Between 1 – 2

85 – 210 Ω

Between 12 – GND

Min 1 MΩ

If the condition is as shown in the table below, it is normal Between 1 – 2

1.4 k – 3.5 kΩ

Between 12 – GND

Between 1 – 2

9 k – 0.3 kΩ

Between 1 2 – GND

Min 1 MΩ

If the condition is as shown in the table below, it is normal Between 1 – 2

90 k – 3.5 kΩ

Between 12 – GND

Min 1 MΩ

If the condition is as shown in the table below, it is normal Engine stopped

Max.1 Ω

Min 600 rpm

Min. 1 MΩ

If the condition is as shown in the table below, it is normal Between terminal – sensor (GND)

1) Turn starting switch OFF. 2) Disconnect connector G.

Min 1 MΩ

If the condition is as shown in the table below, it is normal

Between terminal – sensor (GND)

1) Turn starting switch OFF. 2) Disconnect connector NE.

Engine stopped

Max.1 Ω

Min 1,300 rpm

Min. 1 MΩ

If the condition is as shown in the table below, it is normal Between E12 2 – ?

4.6 – 5.4 V

Between E113 – CN2?

0.3 – 4.7 V

If the condition is as shown in the table below, it is normal Between 1 – 2

9 k – 0.3 kΩ

Between 12 – GND

Min 1 MΩ

If the condition is as shown in the table below, it is normal Between E12 2 – ?

4.6 – 5.4 V

Between E111 – CN2?

0.3 – 4.7 V

1) Turn starting switch OFF. 2) Disconnect connector TWL. 3) Water temperature: 10 – 100°C 1) Turn starting switch OFF. 2) Disconnect connector TWH. 3) Water temperature: 10 – 100°C 1) Turn starting switch OFF. 2) Disconnect connector PSL.

1) Turn starting switch OFF. 2) Disconnect connector PSH.

1) Connect Tadapter to E11 and E12. 2) Start engine.

1) Turn starting switch OFF. 2) Disconnect connector THL. 3) Fuel temperature: 10 – 100°C 1) Connect Tadapter to E11 and E12. 2) Start engine.

20-11

TESTING AND ADJUSTING

No. 3 fuel injector

No. 4 fuel injector

No. 5 fuel injector

No. 6 fuel injector

Fuel control dial

20-12

E32 (male)

E33 (male)

E34 (male)

E35 (male)

E36 (male)

E11

Measure resistance Measure resistance Measure resistance Measure resistance

Engine controller system

No. 2 fuel injector

E31 (male)

Measure resistance

No. 1 fuel injector

E42 (male)

Measure resistance

Fuel supply pump PCV 2

E41 (male)

Measure resistance

Fuel supply pump PCV 1

Connector Inspection No. method

Measure resistance

Name of component

Measure voltage

System

STANDARD VALUE TABLE FOR ELECTRICAL PARTS

Measurement conditions

Judgment table If the condition is as shown in the table below, it is normal Between 1 – 2

2.3 – 5.3 Ω

Between 12 – GND

Min 1 MΩ

If the condition is as shown in the table below, it is normal Between 1 – 2

2.3 – 5.3 kΩ

Between 12 – GND

Min 1 MΩ

If the condition is as shown in the table below, it is normal Between 1 – 2

0.4 – 1.1 Ω

Between 12 – GND

Min 1 MΩ

If the condition is as shown in the table below, it is normal Between 1 – 2

0.4 – 1.1 Ω

Between 12 – GND

Min 1 MΩ

If the condition is as shown in the table below, it is normal Between 1 – 2

0.4 – 1.1 Ω

Between 12 – GND

Min 1 MΩ

If the condition is as shown in the table below, it is normal Between 1 – 2

0.4 – 1.1 Ω

Between 1 2 – GND

Min 1 MΩ

If the condition is as shown in the table below, it is normal Between 1 – 2

0.4 – 1.1 Ω

Between 12 – GND

Min 1 MΩ

If the condition is as shown in the table below, it is normal Between 1 – 2

0.4 – 1.1 Ω

Between 12 – GND

Min 1 MΩ

If the condition is as shown in the table below, it is normal Between E11 4 – A

4.6 – 5.4 V

Between E11 6 – A

0.3 – 4.7 V

1) Turn starting switch OFF. 2) Disconnect connector E41.

1) Turn starting switch OFF. 2) Disconnect connector E42.

1) Turn starting switch OFF. 2) Disconnect connector E31.

1) Turn starting switch OFF. 2) Disconnect connector E32.

1) Turn starting switch OFF. 2) Disconnect connector E33.

1) Turn starting switch OFF. 2) Disconnect connector E34.

1) Turn starting switch OFF. 2) Disconnect connector E35.

1) Turn starting switch OFF. 2) Disconnect connector E36.

1) Insert Tadapter into connector E11. 2) Turn starting switch ON.

PC600-6

TESTING AND ADJUSTING

Engine controller

Engine controller system

Starting switch ON (ACC) signal

Starting switch start (C) signal

Auto-deceleration signal

E17

E14

Measure voltage Measure voltage

Power source

E14

Measure voltage

Main power source

Connector Inspection No. method

Measure voltage

Name of component

Measure voltage

System

STANDARD VALUE TABLE FOR ELECTRICAL PARTS

Measurement conditions

Judgment table If the condition is as shown in the table below, it is normal Between 9J – 8I

20 – 30 V

If the condition is as shown in the table below, it is normal Between 6D – 5C

20 – 30 V

If the condition is as shown in the table below, it is normal Between H – 8I

20 – 30 V

If the condition is as shown in the table below, it is normal Between 2 – 8I

20 – 30 V

If the condition is as shown in the table below, it is normal Between A – 8I

Control lever at Neutral 18 – 30 V Control lever operated

Max. 1 V

Model selection signal

PC600-6

E14

Measure voltage

If the condition is as shown in the table below, it is normal Between C – 8I

Max. 1 V

Between D – 8I

20 – 30 V

Between E – 8I

Max. 1 V

1) Insert Tadapter into connector E14. 2) Turn starting switch ON. 1) Insert Tadapter into connector E17. 2) Turn starting switch ON. 1) Insert Tadapter into connector E14. 2) Turn starting switch ON.

1) Insert Tadapter into connector E14. 2) Turn starting switch ON.

1) Insert Tadapter into connector E14. 2) Turn starting switch ON. 1) Insert Tadapter into connector E14. 2) Turn starting switch ON.

20-13

TESTING AND ADJUSTING

Connector Inspection No. method

PPC pressure switch

Boom RAISE Boom LOWER Arm IN Arm OUT Bucket CURL Bucket DUMP Swing Travel

Pump controller system

Pump pressure sensor

Swing lock switch

Swing emergency switch

S02 (male) S04 (male) S05 (male) S03 (male) S06 (male) S07 (male) S08 (male) S01 (male)

C07 (rear) C08 (front)

X05 (female)

SW01

Measure resistance

—

Adjust Measure voltage

ENE

Measure with AC range

Measure resistance

Engine speed sensor

Measure voltage

ENE (male)

Measurement conditions

Judgment table If the condition is within the range shown in the table below, it is normal.

Measure continuity

Name of component

Measure continuity

System

STANDARD VALUE TABLE FOR ELECTRICAL PARTS

Between 1 – 2

500 – 1,000 Ω

Between 12 – chassis

Min 1 MΩ

Between 1 – 2

0.5 – 3.0 V

If the condition is as shown in the table below, it is normal All levers at neutral Min. 1 MΩ One or more levers operated Max. 1 Ω Between 12 – chassis Min. 1 MΩ Between 1–2

If the condition is within the range shown in the table below, it is normal. Between 2 – 1 chassis Between 3–1

18 – 28 V

All levers at neutral

0.5 – 1.5 V

At arm IN relief

3.1 – 4.5 V

If the condition is as shown in the table below, it is normal FREE LOCK Between 1 – 2 No continuity

Continuity

Between 3 – 4

No continuity

Continuity

If the condition is as shown in the table below, it is normal OFF ON Between 1 – 3 No continuity

Continuity

Between 4 – 6 No continuity

Continuity

Model selection connector

20-14

C09 (female)

Measure resistance

C06 (male)

Measure continuity

Pump emergency resistor

Measure continuity

Between 3 – 1 C05 (male)

1) Start engine. 2) Insert Tadapter.

1) Screw in rotation sensor until it contacts ring gear, then turn back 1±1/6 turns. 2) It must work normally when adjusted as above.

If the condition is as shown in the table below, it is normal OFF ON

Pump emergency switch

1) Turn starting switch OFF. 2) Disconnect connector ENE.

Continuity

No continuity

Between 3 – 5 No continuity

Continuity

Between 4 – 2

Continuity

No continuity

Between 4 – 9 No continuity

Continuity

Between 8 – 6

No continuity

Continuity

Between 8 – ? No continuity

Continuity

Between 7 – 9

No continuity

Continuity

If the condition is within the range shown in the table below, it is normal. Between 1 – 2

36 – 38 Ω

If the condition is as shown in the table below, it is normal Between Between Between Between Between Between Between 1–8 2–8 3–8 4–8 5–8 6–8 7–8 No No No No No Continuity Continuity Continuity Continuity Continuity Continuity Continuity

1) Start engine (or with accumulator charged if engine is stopped). 2) Disconnect connector to be checked. 1) Start engine. 2) Set fuel control dial to FULL. 3) Insert Tadapter.

1) Turn starting switch OFF. 2) Disconnect connector X05.

1) Turn starting switch OFF. 2) Disconnect wiring harness.

1) Turn starting switch OFF. 2) Disconnect connector C05.

1) Turn starting switch OFF. 2) Disconnect connector C06. 1) Turn starting switch OFF. 2) Disconnect connector C09.

PC600-6

TESTING AND ADJUSTING

CO cancel solenoid valve

Bucket Hi cancel solenoid valve

Step light

Controller

Flashing lamp

PC600-6

Main power source

Solenoid power source

V05 (male)

V02 (male)

V08 (male)

M75

M82

C01

C02

Measure resistance Measure resistance Measure resistance Measure resistance Measure resistance

Main 2-stage relief solenoid valve

V06 (male)

Measure resistance

Pump controller system

Travel speed solenoid valve

V04 (male)

Measure resistance

Swing holding brake solenoid valve

V05 (male)

Measure voltage

2-stage relief solenoid

C13 (male)

Measure voltage

TVC solenoid

Connector Inspection No. method

Measurement conditions

Judgment table If the condition is within the range shown in the table below, it is normal. Between 1 – 2

10 – 22 Ω

Between 12 – chassis

Min 1 MΩ

If the condition is within the range shown in the table below, it is normal. Between 1 – 2

20 – 60 Ω

Between 12 – chassis

Min 1 MΩ

If the condition is within the range shown in the table below, it is normal. Between 1 – 2

20 – 60 Ω

Between 2 – chassis

Min 1 MΩ

If the condition is within the range shown in the table below, it is normal. Between 1 – 2

20 – 60 Ω

Between 2 – chassis

Min 1 MΩ

If the condition is within the range shown in the table below, it is normal. Between 1 – 2

20 – 60 Ω

Between 2 – chassis

Min 1 MΩ

If the condition is within the range shown in the table below, it is normal. Between 1 – 2

20 – 60 Ω

Between 2 – chassis

Min 1 MΩ

If the condition is within the range shown in the table below, it is normal. Between 1 – 2

20 – 60 Ω

Between 2 – chassis

Min 1 MΩ

If the condition is within the range shown in the table below, it is normal. Between 1 – revolving frame

20 – 30 V

If the condition is within the range shown in the table below, it is normal. Between 1 – revolving frame

20 – 30 V

If the condition is within the range shown in the table below, it is normal. Between 1B – AK

1) Turn starting switch OFF. 2) Disconnect connector V05.

1) Turn starting switch OFF. 2) Disconnect connector V04.

1) Turn starting switch OFF. 2) Disconnect connector V06.

1) Turn starting switch OFF. 2) Disconnect connector V05.

1) Turn starting switch OFF. 2) Disconnect connector V02.

1) Turn starting switch OFF. 2) Disconnect connector V08.

1) Turn step light switch ON. 2) Turn step light switch OFF.

1) Turn horn switch ON. 2) Turn horn switch OFF.

0–3V

If the condition is within the range shown in the table below, it is normal. Between 7C – 6B

1) Turn starting switch OFF. 2) Disconnect connector C13.

0–3V

Measure voltage

Name of component

Measure voltage

System

STANDARD VALUE TABLE FOR ELECTRICAL PARTS

20 – 30 V

1) Turn starting switch ON. 2) Insert Tadapter. 1) Turn starting switch ON. 2) Insert Tadapter.

20-15

TESTING AND ADJUSTING

Swing emergency switch

Engine speed sensor

C16 C17

C16

C16 C17

Measure voltage

Measurement conditions

Judgment table If the condition is within the range shown in the table below, it is normal. Between C17F – C1634

Swing lock switch at FREE 20 – 30 V Swing lock switch at LOCK Max. 1 V

If the condition is within the range shown in the table below, it is normal. Between C17F – C1634

1) Turn starting switch ON. 2) Insert Tadapter.

Swing lock switch at FREE 20 – 30 V

1) Turn starting switch ON. 2) Insert Tadapter.

Swing lock switch at LOCK Max. 1 V

If the condition is within the range shown in the table below, it is normal. Between 2 – 1

0.5 – 3.0 V

Boom RAISE

Between C172 – C1634

Boom LOWER

Between C17? – C1634

Arm IN

Between C173 – C1634

Arm OUT

Between C17A – C1634

Bucket CURL

Between C16A – C1634

Bucket DUMP

Between C16B – C1634

Swing

Between C165 – C1634

Travel

Between C16C – C1634

1) Turn starting switch ON. 2) Insert T-adapter. ﬂ Measure with the tester at the AC range. 1) Start engine. 2) Insert Tadapter.

If the condition is within the range shown in the table below, it is normal.

No. 2 throttle signal

Monitoring code 10 or 16

Engine speed

Controller

Pump controller system

PPC pressure switch

C16 C17

Measure voltage

Swing lock switch

Connector Inspection No. method

Measure voltage

Name of component

Measure voltage

System

STANDARD VALUE TABLE FOR ELECTRICAL PARTS

Control lever at neutral

Control lever operated

20 – 30 V

Max. 1 V

If the condition is as shown in the table below, it is normal High idling (rpm) DH (excluding travel)

Approx. 1,950

Approx. 1,900

Approx. 1,700

Model selection connector

C16 C17

Measure voltage

If the condition is within the range shown in the table below, it is normal. Model selection 1 Between C175 – C1634 Max. 1 V

1) Start engine. 2) Set monitoring code to 10 or 16 (command value) 3) Operate working mode switch. 1) Turn starting switch ON. 2) Insert Tadapter.

Model selection 2 Between C17C – C1634 20 – 30 V Model selection 3 Between C176 – C1634 20 – 30 V Model selection 4 Between C17D – C1634 20 – 30 V

S-NET

20-16

C03

C17

Measure voltage

Left knob switch

Measure voltage

Model selection 5 Between C177 – C1634 20 – 30 V If the condition is within the range shown in the table below, it is normal. Switch ON Switch OFF

Between 9 – chassis

20 – 28 V 0–1V

If the condition is within the range shown in the table below, it is normal. Between 4, B – chassis

1) Turn starting switch ON. 2) Insert Tadapter.

4–8V

1) Turn starting switch ON. 2) Insert Tadapter.

PC600-6

TESTING AND ADJUSTING

TVC solenoid valve (initial setting)

TVC solenoid

C17

Monitoring code 13

C02

Measure voltage

Kerosene mode

Connector Inspection No. method

Measure ampere

Name of component

Measure voltage

System

STANDARD VALUE TABLE FOR ELECTRICAL PARTS

Measurement conditions

Judgment table If the condition is within the range shown in the table below, it is normal. Standard mode Between E – 20 – 28 V chassis Kerosene mode 0–2V If the condition is as shown in the table below, it is normal G code

600 ± 80 mA

If the condition is within the range shown in the table below, it is normal. Between H – AK

0–1V

C01

One of swing or work equipment control levers 20 – 30 V operated(Solenoid ON: Swing holding brake released) Between 5 sec. after all swing and work 3– equipment control levers 6, B returned to Neutral 0–3V (Solenoid ON: Swing holding brake applied) If the condition is within the range shown in the table below, it is normal.

Travel speed solenoid

C01

Measure voltage

Controller

Pump controller system

Swing holding brake solenoid

Measure voltage

If the condition is within the range shown in the table below, it is normal.

Travel speed switch at Hi 20 – 30 V (solenoid ON: travel motor swash plate angle at min.) Between 9– Travel speed switch at Lo 6, B (solenoid OFF: travel motor 0–3V swash plate angle at max.)

Bucket Hi cancel solenoid

PC600-6

C01

Measure voltage

CO cancel solenoid

C01

Measure voltage

Main 2-stage relief solenoid

Measure voltage

If the condition is within the range shown in the table below, it is normal. Travel operated (ª) 20 – 30 V (solenoid ON) Between Working mode [G mode] + ?– travel lever OFF (not 0–3V 6, B operated), heavy lift switch OFF (solenoid OFF)

1) Turn starting switch ON. 2) Insert Tadapter.

1) Turn starting switch ON. 2) Set fuel control dial to FULL. 3) Turn pump emergency switch OFF. 1) Turn starting switch ON. 2) Insert Tadapter. 3) Set fuel control dial to FULL. 1) Start engine. 2) Turn swing lock switch ON. 3) Operate swing emergency switch OFF. 4) Insert Tadapter. ﬂ It is also possible to operate the lever slightly (not enough to move the machine). 1) Start engine. 2) Insert Tadapter.

1) Start engine. 2) Insert Tadapter. ﬂ It is also possible to operate the travel lever slightly (not enough to move the machine).

If the condition is within the range shown in the table below, it is normal. Working mode 20 – 30 V DH mode (solenoid ON) Between 8– Working mode H or G 6, B 0–3V mode (solenoid OFF)

1) Start engine. 2) Insert Tadapter.

If the condition is within the range shown in the table below, it is normal.

1) Start engine. 2) Insert Tadapter. 3) Set fuel control dial to FULL. ﬂ It is also possible to operate the lever slightly to bucket CURL (not enough to move the machine).

Except bucket CURL operated independently 20 – 30 V Between (solenoid ON) 2– Bucket CURL operated 6, B 0–3V independently (solenoid OFF)

20-17

TESTING AND ADJUSTING

Flashing lamp drive relay

Machine push-up system

Machine pushup solenoid valve (controller does not perform control)

Machine push-up switch

Machine push-up solenoid

20-18

C02

C01

V03 (male)

V03

M38 (female)

V05 (male)

Measure voltage Measure voltage Measure voltage Measure voltage

Step light power source retention relay

C01

Measure voltage

Controller

Pump controller system

Controller power source (key OFF)

C01

Measure resistance

Step light drive relay

C01

Measure voltage

Auto-deceleration signal

Connector Inspection No. method

Measure continuity

Name of component

Measure resistance

System

STANDARD VALUE TABLE FOR ELECTRICAL PARTS

Measurement conditions

Judgment table If the condition is within the range shown in the table below, it is normal.

Between 4 – 6, B

Auto-deceleration switch ON + all levers at Neutral Auto-deceleration switch OFF

20 – 30 V Max. 1 V

If the condition is within the range shown in the table below, it is normal. 20 – 30 V Between 1 – 6

1) Start engine. 2) Insert Tadapter. ﬂOperate the lever slightly (enough to turn the PPC pressure switch ON). 1) Turn step light switch ON. 2) Step light switch OFF

0–3V If the condition is within the range shown in the table below, it is normal. 20 – 30 V Between 7 – 6

1) Turn step light switch ON. 2) Step light switch OFF

0–3V If the condition is within the range shown in the table below, it is normal. 20 – 30 V Between 6 – C016

1) Turn step light ON. 2) Turn step light OFF.

0–3V If the condition is within the range shown in the table below, it is normal. 20 – 30 V Between A – 6

1) Turn horn switch ON. 2) Turn horn switch OFF.

0–3V If the condition is within the range shown in the table below, it is normal. Between 1 – 2

20 – 60 Ω

Between 2 – chassis

Min 1 MΩ

1) Turn starting switch OFF. 2) Disconnect connector V03.

If the condition is within the range shown in the table below, it is normal. Machine push-up switch Between 20 – 30 V ON (solenoid ON) 2– Machine push up switch chassis 0–3V OFF (solenoid OFF)

1) Start engine. 2) Insert Tadapter.

If the condition is as shown in the table below, it is normal.

1) Turn starting switch OFF. 2) Disconnect connector M38.

Between 1–2

No continuity

OFF

Continuity

If the condition is within the range shown in the table below, it is normal. Between 1 – 2

20 – 60 Ω

Between 12 – chassis

Min 1 MΩ

1) Turn starting switch OFF. 2) Disconnect connector V05.

PC600-6

TESTING AND ADJUSTING

Engine oil level sensor

OL (male)

V10 (male)

Monitor system

Hydraulic oil temperature sensor

Measure continuity

P11 (male)

Measure resistance

Air cleaner clogging sensor

Connector Inspection No. method

Measure continuity

Name of component

Measurement conditions

Judgment table If the condition is as shown in the table below, it is normal.

Fuel level sensor

P06 (male)

Continuity Between Air cleaner clogged 1 – 2 No continuity If the condition is as shown in the table below, it is normal. Engine oil above low level Engine oil below low level

Between 1 – chassis

Max. 1 Ω

Normal temperature (25°C)

Continuity

Above 120°C

No continuity

BLP00004

PC600-6

Measure resistance

P09 (male)

1) Turn starting switch ON. 2) Insert Tadapter into OL.

Min. 1 MΩ

If the condition is as shown in the table below, it is normal

BLP00005

Hydraulic oil level sensor

1) Start engine. 2) Disconnect P11.

Air cleaner normal

If the condition is as shown in the table below, it is normal

Measure resistance

System

STANDARD VALUE TABLE FOR ELECTRICAL PARTS

Raise float to stopper

Approx. 12 Ω or below

Lower float to stopper

Approx. 85 – 110 Ω

If the condition is as shown in the table below, it is normal Raise float

Max. 1 Ω

Lower float

Min. 1 MΩ

BLP00002

1) Turn starting switch OFF. 2) Disconnect connector P10. 3) Insert Tadapter into connector at sensor end. 1) Turn starting switch OFF. 2) Disconnect connector P06. 3) Drain fuel, then remove sensor. 4) Insert Tadapter into sensor. ﬂ Connect the Tadapter to the connector and sensor flange. 1) Turn starting switch OFF. 2) Disconnect connector P09. 3) Drain oil, then remove sensor. 4) Insert Tadapter into sensor.

BLP00003

20-19

TESTING AND ADJUSTING

Connector Inspection No. method

]

If the condition is as shown in the table below, it is normal.

1) Insert a dummy resistance with the starting switch OFF, or measure the resistance of the sensor. 2) Check the display with the starting switch ON. ﬂ The engine water temperature sensor (low temperature) signal is not used for the engine water temperature gauge.

Right side

Position of Display level resistance (kΩ) gauge display (controller input resistance) Starting switch Starting switch ON OFF

➝

Monitor system

[

1) Start engine.

➝

Engine water temperature sensor E12 (High temperature) (female) Between Engine water (4) – (10) temperature gauge

Measurement conditions

When engine is running (1/2 throttle or above) → 27.5 – 29.5 V ﬂ If the battery is old, or after starting in cold areas, the voltage may not rise for some time.

Display position

Alternator

Judgment table

Left side

Between alternator terminal R and chassis

Measure voltage

Name of component

Confirmation of display · measure resistance

System

STANDARD VALUE TABLE FOR ELECTRICAL PARTS

All OFF

– 0.646

0.575 – 0.342

3.156 – 3.708

3.422 – 3.900

3.600 – 4.349

4.015 – 5.122

4.728 – 6.816

6.294 – 10.744

9.946 – 36.535

33.725 –

ﬂLevels 8 and 9 flash

]

Right side

➝ Display position

[

C03 (female) Between (2) – (16)

Position of Display level resistance (kΩ) gauge display (controller input resistance) Starting switch Starting switch ON OFF

➝ Left side

Fuel level sensor Fuel level gauge

Confirmation of display · measure resistance

If the condition is as shown in the table below, it is normal.

All OFF

– 13.82

11.71 – 21.25

18.90 – 28.45

25.82 – 31.85

29.18 – 39.91

37.00 – 44.60

41.77 – 55.14

50.42 – 77.07

72.98 – 691.50

63.800 –

1) Insert a dummy resistance with the starting switch OFF, or measure the resistance of the sensor. 2) Check the display with the starting switch ON.

ﬂLevel 1 flashes

20-20

PC600-6

TESTING AND ADJUSTING ﬂ For details of inspection and maintenance of the Cummins N14-C420 engine, see the engine shop manual. This section gives information only for the Komatsu SA6D140E-3 engine. Tools for testing, adjusting, and troubleshooting .............................................................................. 20-102 Measuring intake air pressure (boost pressure) ................................................................................. 20-103 Measuring exhaust temperature ........................................................................................................... 20-104 Measuring exhaust color ....................................................................................................................... 20-105 Adjusting valve clearance ...................................................................................................................... 20-106 Measuring compression pressure ......................................................................................................... 20-107 Measuring blow-by pressure ................................................................................................................. 20-107 Measuring engine oil pressure ............................................................................................................. 20-108 Handling equipment in fuel circuit ....................................................................................................... 20-109 Releasing remaining pressure in fuel system ..................................................................................... 20-109 Measuring fuel pressure ........................................................................................................................ 20-110 Reduced cylinder mode operation for engine ..................................................................................... 20-111 Bleeding air from fuel system ............................................................................................................... 20-113 Check for leakage in fuel system .......................................................................................................... 20-114 Adjusting engine speed sensor ............................................................................................................. 20-115 Testing and adjusting alternator belt tension ..................................................................................... 20-116 Testing and adjusting fan belt tension ................................................................................................ 20-117 Handling engine controller high voltage circuit .................................................................................. 20-118 Testing wear of sprocket ....................................................................................................................... 20-119 Inspection and adjustment of track shoe tension ............................................................................... 20-120 Testing clearance of swing circle bearing ........................................................................................... 20-121 Testing and adjusting hydraulic pressure in work equipment, swing, travel circuit ...................... 20-122 Testing and adjusting control pump circuit oil pressure ................................................................... 20-125 Testing and adjusting piston pump control oil pressure ................................................................... 20-127 Measuring PPC valve output pressure ................................................................................................. 20-133 Testing solenoid valve output pressure ............................................................................................... 20-134 Adjusting work equipment, swing PPC valve ..................................................................................... 20-135 Testing travel deviation .......................................................................................................................... 20-136 Testing locations causing hydraulic drift of work equipment ........................................................... 20-137 Measuring oil leakage ............................................................................................................................ 20-138 Bleeding air ............................................................................................................................................. 20-141 Releasing remaining pressure in hydraulic circuit ............................................................................. 20-143 Procedure for checking diode ............................................................................................................... 20-144

PC600-6

20-101

TESTING AND ADJUSTING

TOOLS FOR TESTING, ADJUSTING, AND TROUBLESHOOTING

TOOLS FOR TESTING, ADJUSTING, AND TROUBLESHOOTING Check or measurement item Symbol

Part No.

Part Name

Remarks

Air supply pressure (boost pressure)

799-201-2202

Pressure gauge

Water and oil temperatures

799-101-1502

Digital temperature gauge –99.9 to +1,299°C

799-101-5002

Hydraulic tester

790-261-1203

Digital hydraulic tester

Oil pressure

PT1/8

799-101-5220

Nipple

10 x 1.25

07002-11023

O-ring

• 790-261-1311

1.0 MPa {10 kg/cm2}

Differential pressure gauge

799-201-9000

Handy Smoke Checker

Commercially available Commercially available

Smoke meter Feeler gauge

Discoloration 0 – 70% (with standard color) (Discoloration % x 1/10 = Bosch index) SA6D140E-3 Engine Intake: 0.35 mm, Exhaust: 0.57 mm

795-502-1590

Compression gauge

6.9 MPa {70 kg/cm2}

795-471-1310

Adapter

For SA6D140E-3 Engine

6217-71-6110

Gasket

799-201-1504

Blow-by checker

79A-264-0021

0 – 49 MPa {0 – 500 mmH2O} 0 – 294 N {0 – 30 kg}

Push-pull scale

Work equipment speed

Measuring voltage and resistance values

20-102

Male, female both 10 x 1.25 (female PT 1/8)

799-401-2701

Measuring wear of sprocket

• 790-261-1340

Stroke, hydraulic drift

Troubleshooting of wiring harnesses and sensors

Male, female both 22 x 1.5 (female PT 1/8)

Hydraulic gauge

1 Operating effort

• 790-261-1331

799-401-2320

Blow-by pressure

Male, female both 18 x 1.5 (female PT 1/8) • Adapter

Compression pressure

2.5, 5.9, 39.2, 58.8 MPa {25, 60, 400, 600 kg/cm2}

Male, female both 14 x 1.5 (female PT 1/8)

• 790-261-1321

Valve clearance

Pressure gauge:

• 790-101-5160 • Nipple

Exhaust color

–101.3 – 200 kPa (–760 – 1500 mmHg)

79A-264-0091

0 – 490 N {0 – 50 kg}

Commercially available Commercially available Commercially available

Scale

799-601-8000

T-adapter kit

799-601-9000

T-adapter kit

HD30, T-adapter for DT, box

799-601-7370

Adapter

For 6-pin relay

799-601-7050

Adapter

SWP-6P

799-601-7080

Adapter

M-1P

799-601-7310

Adapter

SWP-12P

799-601-7320

Adapter

SWP-16P

799-601-7340

Adapter

M-16P

799-601-7540

Adapter

070-18P

796-627-1140

Wear gauge

Stop watch Tester

PC600-6

TESTING AND ADJUSTING

MEASURING INTAKE AIR PRESSURE

MEASURING INTAKE AIR PRESSURE (BOOST PRESSURE) ¤ When installing or removing the measuring equipment, be careful not to touch high-temperature parts. fl Measure the air supply pressure under the following conditions. • Coolant temperature: Within operating range • Hydraulic oil temperature : 45 – 55°C 1. Remove air intake pressure measurement plug (1). 2. Install nipple 1 of boost gauge kit A, then connect to boost gauge kit A. 3. Run the engine at a mid-range speed or above, and bleed the oil from inside the hose. fl Insert the pressure gauge and hose connection about half way, and repeatedly open the self-seal portion at the hose end to bleed the oil. fl If Pm kit (A) is available, it is possible to use the air bleed coupling (790-261-1130) inside the kit. 4. Set the working mode to the DH mode, then set the heavy lift switch to ON. 5. Run the engine at full throttle, and measure the speed when the boom RAISE circuit is relieved. 6. After completing the measurement, remove the measurement equipment and set to the original condition.

PC600-6

20-103

TESTING AND ADJUSTING

MEASURING EXHAUST TEMPERATURE

MEASURING EXHAUST TEMPERATURE ¤ Wait for the exhaust manifold temperature to go down before removing or installing the measuring equipment. ﬂ Measure the exhaust temperature under the following conditions. • Coolant temperature: Within operating range • Hydraulic oil temperature : 45 – 55°C 1. Remove exhaust temperature measurement plug (1).

2. Fit sensor 1 of digital temperature gauge B, then connect to the digital temperature gauge. ﬂ Clamp the wiring harness of the temperature gauge so that it does not touch any high temperature part during the measurement. 3. Run the engine at full throttle and measure the maximum temperature during operation. 4. After completing the measurement, remove the measurement equipment and set to the original condition.

20-104

PC600-6

TESTING AND ADJUSTING

MEASURING EXHAUST COLOR

MEASURING EXHAUST COLOR •

When measuring in the field where there is no air or electric power supply, use Handy Smoke Checker D1; when recording formal data, use Smoke Meter D2. ﬂ Raise the coolant temperature to the operating range before measuring. ¤ Be careful not to touch any hot parts when removing or installing the measuring tools.

1. Measuring with Handy Smoke Checker D1 1) Install filter paper to Handy Smoke Checker D1. 2) Insert the exhaust gas suction port into the exhaust pipe, accelerate the engine suddenly, and operate the handle of Handy Smoke Checker D1 at the same time to collect the exhaust gas on the filter paper. 3) Remove the filter paper and compare it with the scale supplied to judge the condition. 2. Measuring with Smoke Meter D2 1) Insert the probe q of Smoke Meter D2 into the outlet port of the exhaust pipe, and tighten the clip to secure it to the exhaust pipe. 2) Connect the air hose and the socket of the probe hose and accelerator switch to Smoke Meter D2. fl Keep the pressure of the air supply below 1.5 MPa {15 kg/cm2}. 3) Connect the power cord to the AC socket. fl When connecting the cord, check that the power switch of Smoke Meter D2 is OFF. 4) Loosen the cap nut of the suction pump, and fit the filter paper. fl Fit the filter paper securely so that the exhaust gas cannot leak. 5) Turn the power switch of Smoke Meter D2 ON. 6) Accelerate the engine suddenly, and depress the accelerator pedal of Smoke Meter D2 at the same time to collect the exhaust gas color on the filter. 7) Place the filter paper used to catch the exhaust gas color on top of at least 10 sheets of unused filter paper inside the filter paper holder, and read the value shown.

PC600-6

20-105

TESTING AND ADJUSTING

ADJUSTING VALVE CLEARANCE

ADJUSTING VALVE CLEARANCE 1. Remove cylinder head cover (1).

2. Rotate the crankshaft in the normal direction to set No. 1 cylinder at compression top dead center, and align pointer (2) with the [1.6] mark a on the damper. ﬂ Crank the crankshaft with the hexagonal portion at the tip of the water pump drive shaft. ﬂ At compression top dead center, the valve rocker arm can be moved by hand by the amount of the valve clearance. If the rocker arm does not move, the crankshaft is not at compression dead center, so rotate it one more turn.

3. To adjust the valve clearance, insert the feeler gauge into clearance b between rocker arm (3) and crosshead (4), and adjust the valve clearance with adjustment screw (5). fl Insert the feeler gauge and turn adjustment screw (5) until the clearance is a sliding fit. fl Valve clearance Intake valve: 0.35 mm Exhaust valve: 0.57 mm 4. Tighten locknut (6) to hold adjustment screw (5) in position. 3 Locknut: 53.0 – 64.7 Nm {5.4 – 6.6 kgm} fl After tightening the locknut, check the clearance again. 5. Turn the crankshaft 120° each time in the normal direction and repeat the procedure in Steps 2 to 4 to adjust the valves of each cylinder according to the firing order. fl Firing order: 1–5–3–6–2–4 6. After completing the measurement, set to the original condition. 3 Cylinder head cover mounting bolt: 29.4 – 34.3 Nm {3.0 – 3.5 kgm}

20-106

PC600-6

TESTING AND ADJUSTING

MEASURING COMPRESSION PRESSURE MEASURING BLOW-BY PRESSURE

MEASURING COMPRESSION PRESSURE ﬂ For details of the method of measuring the compression pressure, see the engine shop manual for the 140-3 Series.

MEASURING BLOW-BY PRESSURE ﬂ Measure the blow-by pressure under the following conditions. • Coolant temperature: Within operating range • Hydraulic oil temperature: 45 – 55°C 1. Remove blow-by tube (1). ﬂ For the type where a hose is installed to the tip of the blow-by tube, the measurement can be made at the tip of the hose, so there is no need to remove the blow-by tube.

2. Install nozzle 1 of blow-by checker G, then connect to the blow-by checker. 3. Set the working mode to the DH mode. 4. Run the engine at full throttle, and measure the speed when the arm IN circuit is relieved. 5. After completing the measurement, remove the measurement equipment and set to the original condition.

PC600-6

20-107

TESTING AND ADJUSTING

MEASURING ENGINE OIL PRESSURE

MEASURING ENGINE OIL PRESSURE ﬂ Measure the engine oil pressure under the following conditions. • Coolant temperature: Within operating range 1. Remove oil pressure low-pressure switch (1) or oil pressure high-pressure switch (2). ﬂ Wrap the wiring harness of the disconnected switch with tape to prevent it from touching the cylinder block.

2. Install nipple 1 of oil pressure gauge C2, then connect the oil pressure gauge. 3. Start the engine and measure the oil pressure when the engine is running at low idling and high idling. 4. After completing the measurement, remove the measurement equipment and set to the original condition. 3 Oil pressure switch: 2.9 – 5.9 Nm {0.3 – 0.6 kgm}

20-108

PC600-6

TESTING AND ADJUSTING

HANDLING EQUIPMENT IN FUEL CIRCUIT RELEASING REMAINING PRESSURE IN FUEL SYSTEM

HANDLING EQUIPMENT IN FUEL CIRCUIT

RELEASING REMAINING PRESSURE IN FUEL SYSTEM

ﬂ Precaution for inspection and maintenance of fuel system With the common rail type fuel injection system, more precise equipment is used than with the conventional fuel injection pump and nozzle, so problems may occur if dirt or dust get in. When carrying out installation and maintenance of the fuel system, pay more attention than usual to prevent dirt or dust from getting in. If there is any dirt stuck to any part, use clean fuel to wash it off completely. ﬂ Precautions when replacing fuel filter cartridge Always use a genuine Komatsu part for the fuel filter cartridge. With the common rail type fuel injection system, more precise equipment is used than with the conventional fuel injection pump and nozzle, so a special filter with high efficiency filtering ability is used to prevent dirt or dust from getting in. For this reason, if any filter is used as a substitute for the genuine filter, there is danger that problems will occur with the fuel system. To prevent this, never use such filters.

fl When the engine is running, pressure is generated both the low-pressure circuit and highpressure circuit of the fuel line. Low-pressure circuit: Feed pump – fuel filter – fuel supply pump High-pressure circuit: Fuel supply pump – common rail – fuel injector fl For both the low-pressure circuit and highpressure circuit, the pressure automatically goes down to a safe level 30 seconds after the engine is stopped. fl The remaining pressure in the fuel system must be completely released before carrying out inspection of the fuel system or removal or installation of the equipment. Always follow the following precautions when carrying out the operation. ¤ When inspecting the fuel line or removing or installing equipment, wait for at least 30 seconds after the engine is stopped to release the remaining pressure in the fuel system before staring the operation. (There is still pressure remaining in the circuit, so do not start operations immediately after the engine is stopped).

PC600-6

20-109

TESTING AND ADJUSTING

MEASURING FUEL PRESSURE

MEASURING FUEL PRESSURE ﬂ Measure the fuel pressure only for the low-pressure circuit between the feed pump – fuel filter – fuel supply pump. ¤ The high-pressure circuit between the fuel supply pump – common rail – fuel injector is under extremely high pressure, so it cannot be measured. 1. Remove fuel pressure measurement plug (1).

2. Install nipple 1 of oil pressure gauge C2, then connect the oil pressure gauge. 3. Start the engine and measure the fuel pressure at high idling. 4. After completing the measurement, remove the measurement equipment and set to the original condition.

20-110

PC600-6

TESTING AND ADJUSTING

REDUCED CYLINDER MODE OPERATION FOR ENGINE

REDUCED CYLINDER MODE OPERATION FOR ENGINE ﬂ Reduced cylinder mode operation for the engine means setting the fuel injectors of a single cylinder or multiple cylinders electrically to the NO INJECTION condition to run the engine on a reduced number of cylinders. The reduced cylinder mode operation is used when it is thought that one of the engine cylinders is not giving normal output (combustion). It is a method to determine which cylinder is not operating normally (for details, see the shop manual for the 1403 Series). ﬂ The reduced cylinder mode operation is carried out by using the reduced cylinder mode operation setting function on the monitor panel. For details of the functions of the monitor panel, see the TROUBLESHOOTING, Monitor panel display and special functions.

1. Turn the starting switch ON. 2. Keep time switch (1), R.H. travel speed switch (2), and R.H. working mode switch (3) pressed at the same time for at least 2.5 seconds. fl The monitor panel will switch to the reduced cylinder mode operation, time display (4) will show the engine speed, and service meter display (5) will show the cylinder number. fl The engine speed is displayed in units of 10 rpm. 3. Start the engine, then measure the low idling speed and high idling speed. fl When carrying out the reduced cylinder mode operation, note down the engine speed when the reduced cylinder mode operation is not used in order to use it as the standard for judgment. 4. Use the following procedure to set the cylinder for the reduced cylinder mode operation. fl It is possible to set the reduced cylinder mode operation for a single cylinder or multiple cylinders. 1) Keep time mode switch (1) pressed, operate working mode switches (3) and (6), and select the number of the cylinder for the reduced cylinder mode operation. fl The number for the selected cylinder flashes on the display. 2) Keep time mode switch (1) pressed and operate heavy lift switch (7) to select the reduced cylinder mode operation. fl When the reduced cylinder mode operation is set, the liquid crystal segment for the cylinder number changes the display gradually from a flashing number, and finally two segments (top and bottom) light up.

PC600-6

20-111

TESTING AND ADJUSTING

REDUCED CYLINDER MODE OPERATION FOR ENGINE

fl During the time that the cylinder number changes the display gradually from a flashing number to the lighted up top and bottom segments, the monitor panel and engine controller are sending and receiving signals, so check that the change to the top and bottom segments lighting up has completely finished before going on to the next operation. 3) When multiple cylinders have been set, repeat Steps 1) and 2). 5. Measure the low idling speed and high idling speed during reduced cylinder mode operation. fl Compare the engine speed during reduced cylinder mode operation with the engine speed noted down in Step 3 (when the reduced cylinder mode operation was not being used). Determine the abnormal cylinder from this. 6. Use the following procedure to cancel the cylinder set for the reduced cylinder mode operation. 1) Keep time mode switch (1) pressed, operate working mode switches (3) and (6), and select the segment of the cylinder to be canceled for the reduced cylinder mode operation. fl The two top and bottom segments for the selected cylinder flash on the display. 2) Keep time mode switch (1) pressed and operate heavy lift switch (7) to cancel the reduced cylinder mode operation. fl When the reduced cylinder mode operation is canceled, the liquid crystal segment for the cylinder number changes the display gradually from the two flashing segments (top and bottom) and finally become a flashing number. fl During the time that the cylinder number changes the display gradually from two flashing top and bottom segments to the flashing number, the monitor panel and engine controller are sending and receiving signals, so check that the change to the flashing number has completely finished before going on to the next operation. 3) When multiple cylinders have been set, repeat Steps 1) and 2). 7. After completing the measurement, keep time switch (1), R.H. travel speed switch (2), and R.H. working mode switch (3) pressed at the same time for at least 2.5 seconds to finish the reduced cylinder mode.

20-112

PC600-6

TESTING AND ADJUSTING

BLEEDING AIR FROM FUEL SYSTEM

fl Bleed the air as follows if the engine has run out of fuel or the fuel circuit equipment has been removed and installed. 1. Remove fuel filter (1), fill with fuel, then install again. fl When filling with fuel, always use clean fuel and be careful not to let any dirt or dust get in. fl Add fuel through inlet port portion a (8 places) of the filter. Portion b is the outlet port after filtering (clean side), so fuel must not be added from portion b. fl If clean fuel is not available, do not remove the filter. Operate the priming pump to fill the inside of the filter with fuel. 2. Remove air bleed plug (2) of the fuel filter and operate priming pump (3). fl Continue operating the priming pump until fuel flows out from the plug hole. When fuel comes out, install the pug. 3 Air bleed plug: 7.8 – 9.8 Nm {0.8 – 1.0 kgm}

PC600-6

3. Loosen air bleeder (4) of the fuel supply pump and operate priming pump (3) 90 – 100 times. ﬂ Operate the priming pump until fuel flows out from the bleeder. When the fuel flows out, tighten the bleeder, then operate the priming pump several times until the pump becomes stiff. 3 Air bleeder: 4.9 – 6.9 Nm {0.5 – 0.7 kgm}

20-113

TESTING AND ADJUSTING

BLEEDING AIR FROM FUEL SYSTEM CHECK FOR LEAKAGE IN FUEL SYSTEM

4. Crank the engine with the starting motor and start the engine. ﬂ When the high-pressure circuit is cranked with the engine, the air is automatically bled. ﬂ If the engine does not start, the air has probably not properly bled from the lowpressure circuit, so repeat the procedure from Step 2.

CHECK FOR LEAKAGE IN FUEL SYSTEM ¤ With the fuel system, the high-pressure circuit is under extremely high pressure, so if fuel leaks when the engine is running, there is danger of fire. Check for fuel leakage as follows then checking the fuel circuit or when equipment has been removed and installed. fl To make it easier to check for fuel leakage, wipe the engine itself and the surrounding area clean and remove all oil and grease before starting the inspection. 1. Spray the fuel supply pump, common rail, fuel injector, and high-pressure piping connections with a color checker (developing solution). 2. Start the engine, run it at under 1000 rpm, and when the speed stabilizes, stop the engine. 3. Check the fuel piping and equipment for fuel leakage. fl Check the high-pressure circuit for fuel leakage, particularly at the places sprayed with color checker. fl If there is fuel leakage, carry out repairs, then repeat the check from Step 2.

6. Start the engine and run it at high idling. 7. Check the fuel piping and equipment for fuel leakage. fl Check the high-pressure circuit for fuel leakage, particularly at the places sprayed with color checker. fl If there is fuel leakage, carry out repairs, then repeat the check from Step 2. 8. Start the engine, run it at high idling, then apply load to the engine. fl If this inspection is carried out with the engine mounted on the machine, stall the torque converter or relieve the hydraulic pump. 9. Check the fuel piping and equipment for fuel leakage. fl Check the high-pressure circuit for fuel leakage, particularly at the places sprayed with color checker. fl If there is fuel leakage, carry out repairs, then repeat the check from Step 2. fl If no fuel leakage is found, the check is complete.

4. Start the engine and run it at low idling. 5. Check the fuel piping and equipment for fuel leakage. ﬂ Check the high-pressure circuit for fuel leakage, particularly at the places sprayed with color checker. ﬂ If there is fuel leakage, carry out repairs, then repeat the check from Step 2.

20-114

PC600-6

TESTING AND ADJUSTING

ADJUSTING ENGINE SPEED SENSOR

ADJUSTING ENGINE SPEED SENSOR fl Adjust the engine speed sensor for the pump controller as follows. fl The engine G rotation sensor and engine Ne rotation sensor for the engine controller cannot be adjusted. 1. Screw in sensor (1) until the tip contacts the tip of the tooth of flywheel ring gear (2). fl Check that there is no damage or metal powder on the tip of the sensor when installing. 2 Thread: Hydraulic sealant 2. Turn sensor (1) back 1/2 – 2/3 turns. fl This makes a clearance a of 0.75 – 1.00 mm between the tip of the sensor and the tip of the gear tooth. 3. Hold sensor (1) in position with nut (3). 2 Nut: 69 – 74 Nm {7.0 – 7.5 kgm}

PC600-6

20-115

TESTING AND ADJUSTING

TESTING AND ADJUSTING ALTERNATOR BELT TENSION

TESTING AND ADJUSTING ALTERNATOR BELT TENSION 1. Inspecting Measure deflection a when the belt is pressed with a finger at a point midway between the alternator pulley and drive pulley. ﬂ Pushing force: Approx. 98 Nm {approx. 10 kg} ﬂ Deflection (one belt): 13 – 16 mm

2. Adjusting fl If the deflection is not within the specified range, adjust as follows. 1) Loosen 2 mounting bolts of alternator (1) and 1 lock bolt of the bar. 2) Loosen locknut (2), move alternator (1) with adjustment nut (3), and adjust the tension of belt (4). fl Deflection (one belt): 13 – 16 mm 3) Tighten locknut (2). 4) Tighten 2 mounting bolts of alternator (1) and 1 lock bolt of the bar. fl After adjusting, check the belt tension again.

20-116

PC600-6

TESTING AND ADJUSTING

TESTING AND ADJUSTING FAN BELT TENSION

1. Inspection With the fan belt tension, there is no need to inspect until the belt is replaced. 2. Adjustment 1) Install 2 belts (1). ﬂ Loosen the stopper bolt when installing the belts. 2) Tighten stopper bolt (2) until it contacts bracket (3). 3) Tighten stopper bolt (2) a further 2 turns and hold in position with locknut (4). 3 Locknut : 245.0 – 308.7 Nm {25.0 – 31.5 kgm}

PC600-6

20-117

TESTING AND ADJUSTING

HANDLING ENGINE CONTROLLER HIGH VOLTAGE CIRCUIT

HANDLING ENGINE CONTROLLER HIGH VOLTAGE CIRCUIT ¤ With the controller, a high voltage circuit (110 – 130 V) is used for the fuel injector drive. As a result, a high voltage circuit is connected to the wiring harness and connector from the controller to the fuel injector. ﬂ Normally, high voltage is output from the controller to the fuel injector only when the engine is running. When the engine is stopped, the output stops. ¤ If the high voltage circuit is touched directly, there is danger of electrocution, so observe the following precautions when carrying out inspection. 1. The connectors, including those for the high voltage circuit, are as follows. • Controller connector: E16, E17 • Intermediate connector: E22 • Injector connector: E31, E32, E33, E34, E35, E36 • Terminal at head of injector (inside head cover) 2. When disconnecting or connecting the applicable connector, always turn the starting switch OFF before starting. 3. When a T-adapter has been inserted or connected to the applicable connector to carry out troubleshooting, never start the engine. ﬂ If the starting switch is operated, operate it only to OFF or ON. Never turn it to the START position.

20-118

PC600-6

TESTING AND ADJUSTING

TESTING WEAR OF SPROCKET

1. Remove the track shoe assembly. fl For details, see TESTING AND ADJUSTING, REMOVAL OF TRACK SHOE ASSEMBLY. 2. Align wear gauge P with the sprocket. fl Align the datum line, then align the sprocket wave pattern and wear gauge wave pattern. 3. Judge the wear of the sprocket. fl If the sprocket wave pattern is above the wear limit line, it is possible to use the sprocket as it is. fl If the sprocket wave pattern has reached the wear limit line, replace the sprocket with a new part.

PC600-6

20-119

TESTING AND ADJUSTING

INSPECTION AND ADJUSTMENT OF TRACK SHOE TENSION

INSPECTION AND ADJUSTMENT OF TRACK SHOE TENSION Inspection 1. Travel the machine forward by the length of track on ground, keeping the engine at low idling, and stop the machine slowly. 2. Place straight bar 1 on the track shoe between the idler and the 1st carrier roller. fl L beam is recommended for bar 1, because of its deflection-free nature. 3. Measure max. clearance a between bar 1 and the track shoe. • Max. standard clearance a: 10 – 30 mm Adjustment fl If the track shoe tension is not proper, adjust it in the following manner. 1. When the tension is too strong Discharge grease by loosening valve (1). ¤ Do not loosen valve (1) by more than one turn, because grease will spurt out due to its internal high pressure. 2. When the tension is too weak Add grease through grease fitting (2). fl If the normal track shoe tension is not restored even after greasing, move the machine slowly back and forth.

20-120

PC600-6

TESTING AND ADJUSTING

TESTING CLEARANCE OF SWING CIRCLE BEARING

TESTING CLEARANCE OF SWING CIRCLE BEARING ﬂ Measure the clearance of the swing circle bearing as follows when it is mounted on the machine. 1. Fix a magnet-type dial gauge to the outer race (or inner race) of the swing circle, then put the tip of the probe in contact with the inner race (or outer race). Set the dial gauge at the front or rear.

2. Extend the work equipment to the maximum reach, and set the tip of the bucket to the same height as the bottom of the revolving frame. When this is done, the upper structure will tilt forward, so the front will go down and the rear will rise. 3. Set the dial gauge to the zero point. 4. Set the arm more or less at right angles to the ground surface, then lower the boom until the front of the machine comes off the ground. When this is done, the upper structure will tilt back, so the front will rise and the rear will go down.

BKP00173

5. Read the value on the dial gauge at this point. The value on the dial gauge is the clearance of the swing circle bearing. ¤ When carrying out the measurement, do not put your hand or feet under the undercarriage. 6. Return to the condition in Step 2, and check that the dial gauge has returned to the zero point. If it has not returned to the zero point, repeat Steps 2 to 5.

PC600-6

BKP00174

20-121

TESTING AND ADJUSTING

TESTING AND ADJUSTING HYDRAULIC PRESSURE IN WORK EQUIPMENT, SWING, TRAVEL CIRCUIT

TESTING AND ADJUSTING HYDRAULIC PRESSURE IN WORK EQUIPMENT, SWING, TRAVEL CIRCUIT Measuring 1. Measuring at normal pressure ﬂ Oil temperature when measuring: 45 – 55˚C ¤ Lower the work equipment to the ground and stop the engine. Operate the control levers several times to release the remaining pressure in the hydraulic piping. Loosen the oil filler cap slowly to release the pressure inside the hydraulic tank. Then put the safety lock lever in the LOCK position. 1) Install oil pressure gauge C1 (58.8 MPa {600 kg/cm2}) to quick couplers (1) and (2). 2) Start the engine, set to the D.H mode, then measure the main relief pressure with the engine at full throttle. • Set the actuator to be measured to the following condition. i) For the work equipment, operate the respective cylinder to the end of its stroke. ii) For the swing, turn the swing lock switch ON. iii) For the travel, fit block q between the sprocket and the frame to lock the track shoe, then measure one side at a time.

2. Measuring when pressure rises 1) When main relief valve pressure rises i) Turn the heavy-lift switch ON. ii) Relieve the boom RAISE circuit and measure the oil pressure.

20-122

PC600-6

TESTING AND ADJUSTING

TESTING AND ADJUSTING HYDRAULIC PRESSURE IN WORK EQUIPMENT, SWING, TRAVEL CIRCUIT

2) When safety valve pressure at boom LOWER end rises i) Turn the machine push-up switch ON. ii) Relieve the boom LOWER circuit and measure the oil pressure. fl The set pressure when the pressure rises is higher than the main relief set pressure, so if the measurement is the main relief pressure of 31.4 MPa {320 kg/cm2}, the situation is normal. fl If the pressure does not rise, the pressure is 19.12 ± 1.96 MPa {190 ± 20 kg/cm2} (cracking pressure), so this pressure is measured. Adjusting 1. Main relief valve of left and right control valves • (5): Main relief valve for L.H. 4-spool control valve • (6): Main relief valve for R.H. 5-spool control valve 1) Adjusting high-pressure setting i) Loosen locknut (7), then turn holder (8) to adjust. fl Turn the holder to adjust as follows. To INCREASE pressure, turn CLOCKWISE. To DECREASE pressure, turn COUNTERCLOCKWISE. fl Amount of adjustment for one turn of holder: Approx. 21.78 MPa (222 kg/cm2} 3 Locknut : 107.8 ± 14.7 Nm {11 ± 1.5 kgm} fl When the high-pressure setting is changed, the low-pressure setting will also change, so adjust the lowpressure setting also. 2) Adjusting low-pressure setting i) Loosen locknut (10) of elbow (9) of the high-pressure setting connecting hose. fl Check that elbow (9) moves. ii) Loosen locknut (11), then turn holder (12) to adjust. fl Turn the holder to adjust as follows. To INCREASE pressure, turn CLOCKWISE. To DECREASE pressure, turn COUNTERCLOCKWISE. fl Amount of adjustment for one turn of holder: Approx. 21.78 MPa (222 kg/cm2} 3 Locknut : 85.75 ± 7.35 Nm {8.75 ± 0.75 kgm} fl After completion of adjustment, repeat the procedure in Item 1 to check the set pressure again. PC600-6

20-123

TESTING AND ADJUSTING

TESTING AND ADJUSTING HYDRAULIC PRESSURE IN WORK EQUIPMENT, SWING, TRAVEL CIRCUIT

3. Swing motor safety valve 1) Loosen locknut (2) of safety valve (1), then turn adjustment screw (3) to adjust. fl Carry out the adjustment with the valve assembly installed to the motor. fl Turn the adjustment screw to adjust as follows. • To INCREASE pressure, turn CLOCKWISE. • To DECREASE pressure, turn COUNTERCLOCKWISE. fl Amount of adjustment for one turn of adjustment screw: Approx. 3.9 MPa {39.5 kg/cm2} 3 Locknut : 132.3 ± 14.7 Nm {13.5 ± 1.5 kgm}

20-124

PC600-6

TESTING AND ADJUSTING

TESTING AND ADJUSTING CONTROL PUMP CIRCUIT OIL PRESSURE

TESTING AND ADJUSTING CONTROL PUMP CIRCUIT OIL PRESSURE Measuring ﬂ Oil temperature when measuring: 45 – 55°C 1. Remove pressure pick-up plug (1) (Thread dia.=10mm, Pitch=1.25mm), and install oil pressure gauge C1 (5.88 MPa {60 kg/cm2}). 2. Start the engine and measure with the engine at full throttle. ﬂ When testing for internal leakage of the equipment in the control circuit, use the parts given below to shut off the circuit for the following sections when measuring the relief pressure. No.

Section of hydraulic circuit shut off

Component that can be checked

Piston pump inlet port

Piston pump

Solenoid valve inlet port

Solenoid valve

L.H. PPC valve inlet port

L.H. PPC valve

Travel PPC valve inlet port

Travel PPC valve

R.H. PPC valve inlet port

R.H. PPC valve

ﬂ Items No. 2 and below can be checked if the equipment in the previous number is normal. ﬂ Use the following parts to shut off the circuit. • For elbow Sleeve nut : 07221-20315 Plug : 07222-00315 • For hose Plug : 07376-50315

PC600-6

20-125

TESTING AND ADJUSTING

TESTING AND ADJUSTING CONTROL PUMP CIRCUIT OIL PRESSURE

Adjusting 1. Remove cap (2). 2. Loosen locknut (3) and turn adjustment screw (4) to adjust. ﬂ Turn the adjustment screw as follows. • To INCREASE pressure, turn CLOCKWISE • To DECREASE pressure, turn COUNTERCLOCKWISE 3 Locknut : 9.8 Nm {1 kgm} ﬂ After completion of adjustment, repeat the procedure in “Measuring” Item to check the set pressure again.

20-126

PC600-6

TESTING AND ADJUSTING

TESTING AND ADJUSTING PISTON PUMP CONTROL OIL PRESSURE

TESTING AND ADJUSTING PISTON PUMP CONTROL OIL PRESSURE 1. TVC valve output pressure Measuring fl Oil temperature when measuring: 45 – 55˚C fl Measure the control pump relief pressure first and check that it is normal. fl The output pressure of TVC valve (1) varies according to the average for the pump discharge pressure ( P1+P2 2

= Average pres-

sure), so always adjust the main relief pressure to the set pressure before measuring. 1) Remove output pressure pickup plug (2) (Thread dia.=10mm, Pitch=1.25mm) of the TVC valve at the No. 1 pump rear end, then install oil pressure gauge C1 (5.88 MPa {60 kg/cm2}). 2) Start the engine, set to the D.H mode, run the engine at full throttle, and measure the output pressure at 2-pump relief (No. 1 pump + No. 2 pump).

Adjusting fl If the result of the measurement shows that the pressure is not within the standard value, adjust as follows. 1) Loosen locknut (3). 2) Turn adjustment screw (4) to adjust. fl If the adjustment screw is stiff and it is turned by force, the tip may be damaged, so in this case, remove the TVC valve assembly, then remove the cover assembly and apply lubricant to the screw portion before moving it. 3) Turn the adjustment screw to adjust as follows. To INCREASE pressure, turn CLOCKWISE. To DECREASE pressure, turn COUNTERCLOCKWISE. fl Amount of adjustment of pump pressure for one turn of adjustment screw: Approx. 14.36 MPa {146.4 kg/cm2} 3 Locknut : 5.9 – 9.8 Nm {0.6 – 1.0 kgm} fl After completion of adjusting the adjustment screw, repeat the procedure in Item 1 to check the output pressure again.

PC600-6

20-127

TESTING AND ADJUSTING

TESTING AND ADJUSTING PISTON PUMP CONTROL OIL PRESSURE

2. Output pressure of CO valve and NC valve • The output pressure of the NC valve goes to the servo valve and controls the amount of oil discharged from the piston pump. The oil flows as follows: TVC valve → CO valve → NC valve → servo valve. The output pressure varies as follows according to the operation of the control lever for work equipment. 1) Control levers at neutral Because of the differential pressure of the jet sensor, the NC valve is actuated and the output pressure drops below 0.54 MPa {5.5 kg/cm2}. (The pump discharge becomes the minimum.) 2) Hydraulic cylinder relieved The CO valve moves and reduces the pressure below 0.54 MPa {5.5 kg/cm2} before the oil enters the NC valve. The NC valve supplies the oil at this pressure to the servo valve. (The pump discharge amount in this case is also the minimum.) 3) Work equipment, swing, travel operated The output pressure of the TVC valve is not influenced by the CO valve or the NC valve, and supplies oil as it is to the servo valve. (The pump discharge amount varies from the maximum to the point where the CO valve is actuated.) 4) CO cancel operated In the D.H mode, the CO valve is not actuated even near the relief pressure. Therefore, in the same way as in Item 3), the output pressure of the TVC valve is supplied as it is to the servo valve.

Measuring ﬂ Oil temperature when measuring: 45 – 55˚C • Disconnect CO + NC valve output pressure hose (5) or (6), install oil adapter C3, then install oil pressure gauge C1 (5.88 MPa {60 kg/cm2}). • For front pump: (5) • For rear pump: (6)

20-128

PC600-6

TESTING AND ADJUSTING

TESTING AND ADJUSTING PISTON PUMP CONTROL OIL PRESSURE

1) Oil pressure when NC valve is actuated i) NC valve for No. 1 pump Start the engine, set to the D.H mode, run the engine at full throttle, and measure the oil pressure when all the control levers are at neutral. fl Turn the auto deceleration switch OFF. fl If the output pressure is more than 0.54 MPa {5.5 kg/cm2}, measure the differential pressure of the jet sensor. 2) Oil pressure when CO valve is actuated Measure at the same time as measuring the TVC valve output pressure. i) No. 1 pump, No. 2 pump Run the engine at full throttle, set to the D.H mode, and measure the oil pressure when the boom (except LOWER), arm, and bucket circuits are relieved. 3) Oil pressure when CO valve and NC valve are not actuated i) When CO valve is not actuated Set to the DH mode, heavy-lift mode, and the end of the boom RAISE stroke, run the engine at full throttle, and relieve the circuit (at CO cancel). fl Measure from the beginning of the operation to the point of relief. ii) When NC valve is not actuated Set to D.H mode, run the engine at full throttle, and operate the travel to rotate the track under no load. fl Always operate the lever fully to the end of its travel. ¤ When measuring with the tracks rotating under no load, check carefully that the surrounding area is safe. fl When measuring the TVC valve output pressure at the same time, if the difference is large (0.1 MPa {1 kg/cm2} or more), the operation of the CO valve or NC valve is probably defective.

PC600-6

20-129

TESTING AND ADJUSTING

TESTING AND ADJUSTING PISTON PUMP CONTROL OIL PRESSURE

Adjusting 1) CO valve fl If the CO valve set pressure is high, the discharge amount is not reduced at relief, so the relief pressure becomes higher. For this reason, always adjust to the set pressure. 1) Loosen locknut (7), then turn adjustment screw (8) to adjust. fl Turn the adjustment screw to adjust as follows. To INCREASE pressure, turn CLOCKWISE. To DECREASE pressure, turn COUNTERCLOCKWISE. fl Amount of adjustment for one turn of holder: Approx. 4.05 MPa {41.25 kg/cm2} fl If the oil pressure does not go down even when the adjustment screw is turned, there is probably a defect inside the CO valve. 3 Locknut : 7.84 ± 1.96 Nm {0.8 ± 0.2 kgm} ii) After completion of adjusting the adjustment screw, repeat the procedure in “Measuring” Item 1 to check the set pressure again.

2) NC valve fl The NC valve is actuated by the differential pressure of the jet sensor, so always check that the differential pressure of the jet sensor is normal before adjusting. 1) Loosen locknut (9), then turn adjustment screw (10) to adjust. fl Turn the adjustment screw to adjust as follows. To INCREASE pressure, turn CLOCKWISE. To DECREASE pressure, turn COUNTERCLOCKWISE. fl Amount of adjustment for one turn of holder: Approx. 0.42 MPa (4.3 kg/cm2} 3 Locknut : 7.84 ± 1.96 Nm {0.8 ± 0.2 kgm}

20-130

PC600-6

TESTING AND ADJUSTING

TESTING AND ADJUSTING PISTON PUMP CONTROL OIL PRESSURE

3. Differential pressure of jet sensor High pressure and low pressure (high pressure low pressure = differential pressure) is formed at the outlet port of the control valves, and this differential pressure controls the NC valve. The differential pressure is at the maximum when the control levers are at neutral, and at the minimum when the control levers are operated fully. Measuring ¤ Release the pressure inside the hydraulic tank. fl Oil temperature when measuring: 45 – 55°C 1) Disconnect pressure pickup plugs (11) and (13) (PT 1/8), or the hoses. fl Use adapter C3 at the point where hoses (12) and (14) are disconnected, and connect again. • Plug (11): No. 1 front pump high-pressure end • Plug (12): No. 1 front pump low-pressure end • Plug (13): No. 1 rear pump high-pressure end • Plug (14): No. 1 rear pump low-pressure end 2) Install oil pressure gauge C1 (high-pressure end: 5.88 MPa {60 kg/cm2}, low-pressure end: 2.45 MPa {25 kg/cm2}. 3) Measuring with control levers at neutral (differential pressure at maximum) Run the engine at full throttle, set to the D.H mode, and measure the differential pressure with the control levers at neutral. fl High pressure (Pt) – Low pressure (Pd) = Differential pressure fl The differential pressure is the maximum. 4) Measuring with control levers operated (differential pressure at minimum) i) No. 1 pump, No. 2 pump Using the work equipment, push up the track frame on one side and measure the differential pressure with the track rotating under no load (with the control levers operated fully).

PC600-6

20-131

TESTING AND ADJUSTING

TESTING AND ADJUSTING PISTON PUMP CONTROL OIL PRESSURE

Adjusting fl If the result of the measurement shows that the differential pressure is not within the standard value, adjust as follows. • Plug (17): For L.H. 4-spool control valve • Plug (18): For R.H. 5-spool control valve 1) Loosen locknut (19), then turn adjustment screw (20) to adjust. fl Turn the adjustment screw to adjust as follows. To INCREASE pressure, turn CLOCKWISE. To DECREASE pressure, turn COUNTERCLOCKWISE. fl Amount of adjustment for one turn of holder: Approx. 1.628 MPa (16.6 kg/cm2} 3 Locknut : 68.6 ± 9.8 Nm {7.0 ± 1.0 kgm} fl After completion of adjusting the adjustment screw, repeat the procedure in “Measuring” Item 1 to check the set pressure again.

20-132

PC600-6

TESTING AND ADJUSTING

MEASURING PPC VALVE OUTPUT PRESSURE

MEASURING PPC VALVE OUTPUT PRESSURE ﬂ Oil temperature when measuring: 45 – 55°C 1. Disconnect hose (1) of the circuit to be measured (see diagram below). 2. Install adapter C3 between the hose and elbow. 3. Install oil pressure gauge C1 (5.88 MPa {60 kg/ cm2}) to adapter C3. 4. Run the engine at full throttle, operate the control lever of the circuit to be measured, and measure the oil pressure.

PC600-6

20-133

TESTING AND ADJUSTING

TESTING SOLENOID VALVE OUTPUT PRESSURE

TESTING SOLENOID VALVE OUTPUT PRESSURE Measuring output pressure of ON/OFF solenoid valve 1. Disconnect outlet hoses (1) – (5) of the solenoid valve to be measured, then use adapter C3 in the oil pressure gauge kit to install oil pressure gauge C1 (5.88 MPa {60 kg/cm2}). 2. Measure the solenoid valve output pressure under the conditions in Table 1.

Table 1 Hose Solenoid

2-stage main relief

Machine push-up

Travel speed

Swing holding brake

CO cancel

20-134

Measurement conditions

Operating conditions Condition of Oil pressure2 solenoid (MPa {kg/cm })

Operate boom RAISE independently with Pump discharge pressure power max actuated or heavy-lift switch ON at high-pressure setting

Min. 2.74 MPa {28 kg/cm2}

In DH or H mode, when power max. is OFF Pump discharge pressure (and travel and all except above are OFF) at low-pressure setting

OFF

When machine push-up switch is at Safety valve at highhigh-pressure setting pressure setting

OFF

When machine push-up switch is at Safety valve at lowlow-pressure setting pressure setting

Min. 2.74 MPa {28 kg/cm2}

Travel speed switch at Hi

Travel motor swash plate angle at MIN

Min. 2.74 MPa {28 kg/cm2}

Travel speed switch at Lo

Travel motor swash plate angle at MAX

OFF

Swing or work equipment lever operated

Brake canceled

Min. 2.74 MPa {28 kg/cm2}

Approx. 7 sec after all levers except travel lever are returned to neutral Brake applied

OFF

In D.H mode

CO cancel

Min. 2.74 MPa {28 kg/cm2}

In H or G mode

CO valve actuated

OFF

Remarks

If pressure reaches high pressure of more than 22.56 MPa {230 kg/cm2}, speed is switched inside motor to Lo

PC600-6

TESTING AND ADJUSTING

ADJUSTING WORK EQUIPMENT, SWING PPC VALVE

ADJUSTING WORK EQUIPMENT, SWING PPC VALVE fl If there is excessive play in the work equipment or swing lever, adjust as follows. ¤ Lower the work equipment to the ground and stop the engine. Operate the control levers several times to release the remaining pressure in the hydraulic piping. Loosen the oil filler cap slowly to release the pressure inside the hydraulic tank. Then put the safety lock lever in the LOCK position. fl Lever play: 0.5 – 3 mm at point 200 mm from center of lever installation pin 1. Loosen locknut (1), then turn disc (2) to adjust the play of the lever. fl When doing this, do not move the piston. 2. Secure disc (2) in position, then tighten locknut (1) to the specified torque. 3 Locknut : 117.7 ± 9.8 Nm {12 ± 1 kgm}

PC600-6

20-135

TESTING AND ADJUSTING

TESTING TRAVEL DEVIATION

TESTING TRAVEL DEVIATION fl When traveling on level ground. 1. Set the machine in the travel posture. fl For the travel posture, extend the bucket and arm cylinder rods fully, and hold the boom angle at 45˚. 2. Travel for 10 m, then measure the deviation when traveling for the next 20 m. fl Set to DH mode and measure with the engine at full throttle. fl Measure on a flat, firm road surface or concrete road surface (surface with little travel resistance).

20-136

PC600-6

TESTING AND ADJUSTING

TESTING LOCATIONS CAUSING HYDRAULIC DRIFT OF WORK EQUIPMENT

TESTING LOCATIONS CAUSING HYDRAULIC DRIFT OF WORK EQUIPMENT ﬂ If there is any hydraulic drift in the work equipment (cylinders), check as follows to determine if the cause is in the cylinder packing or in the control valve. 1. Checking for defective cylinder packing 1) Checking boom and bucket cylinders i) Set in the same posture as when measuring hydraulic drift, and stop the engine. ii) Operate the boom control lever to RAISE or the bucket control lever to CURL. • If the lowering speed increases, the packing is defective. • If there is no change, the boom lock valve (boom) or the control valve (bucket) is defective. 2) Checking arm cylinder i) Operate the arm cylinder to move the arm in fully, then stop the engine. ii) Operate the control lever to arm IN. • If the lowering speed increases, the packing is defective. • If there is no change, the control valve is defective. ﬂ If the pressure in the accumulator has dropped, run the engine for approx. 10 seconds to charge the accumulator again before operating. [Reference] If the cause of the hydraulic drift is in the packing, and the above operation is carried out, the downward movement becomes faster for the following reasons. 1) If the work equipment is set to the above posture (holding pressure applied to the bottom end), the oil at the bottom end leaks to the head end. However, the volume at the head end is smaller than the volume at the bottom end by the volume of the rod, so the internal pressure at the head end increases because of the oil flowing in from the bottom end. 2) When the internal pressure at the head end increases, the pressure at the bottom end also rises in proportion to this. The balance is maintained at a certain pressure (this differs according to the amount of leakage) by repeating this procedure. 3) When the pressure is balanced, the downward movement becomes slower. If the lever is then operated according to the procedure given above, the circuit at the head end is opened to the drain circuit (the bottom end is closed by the check valve), so the oil at the head end flows to the drain circuit and the downward movement becomes faster. PC600-6

BKP00159

20-137

TESTING AND ADJUSTING

MEASURING OIL LEAKAGE

MEASURING OIL LEAKAGE fl Oil temperature when measuring: 45 – 55˚C 1. Work equipment cylinder fl If the hydraulic drift of the work equipment is not within the standard value, measure the leakage inside the cylinder as follows, and judge if the cause of the hydraulic drift is in the cylinder or in the control valve. • If the leakage is within the standard value, the problem is in the control valve. • If the leakage is greater than the standard value, the problem is in the cylinder. 1) Fully extend the rod of the cylinder to be measured, then stop the engine. 2) Disconnect pipings (1), (2) and (3) at the head end, then block the piping at the chassis end with a blind plug. (1): Boom cylinder head piping (2): Arm cylinder head piping (3): Bucket cylinder head piping ¤ Be careful not to disconnect the piping at the bottom end. 3) Start the engine and apply the relief pressure to the bottom end of the cylinder with the engine at full throttle. fl Boom cylinder: RAISE Arm cylinder: IN Bucket cylinder: CURL 4) Continue this condition for 30 seconds, then measure the oil leakage for the next one minute.

20-138

PC600-6

TESTING AND ADJUSTING

MEASURING OIL LEAKAGE

2. Swing motor 1) Disconnect drain hose (1) or (2) from the swing motor. fl Disconnect hose (1) between the left swing motor and right swing motor, and install a blind plug in the elbow at the right swing motor end and in the elbow at the tank end of hose (2) at the tank end. 2) Turn the swing lock switch ON. 3) Start the engine and operate the swing relief with the engine at full throttle. 4) Continue this condition for 30 seconds, then measure the oil leakage for the next one minute. fl After measuring, swing 180° and measure again. 3. Travel motor 1) Disconnect drain hose (3) from the travel motor, then fit a blind plug at the hose end. 2) Fit block 1 between the sprocket and frame to lock the track. 3) Start the engine and operate the travel relief with the engine at full throttle. ¤ When measuring the oil leakage from the travel motor, mistaken operation of the control lever may lead to a serious accident, so always use signals and check carefully when carrying out this operation. 4) Continue this condition for 30 seconds, then measure the oil leakage for the next one minute. fl When measuring, move the motor slightly (to change the position between the valve plate and cylinder, and between the piston and cylinder), and measure several times.

PC600-6

20-139

TESTING AND ADJUSTING

MEASURING OIL LEAKAGE

4. Center swivel joint • If there is any abnormality when traveling (travel deviation, lack of travel speed), and there is no abnormality in the hydraulic pumps or control valves, check as follows. Table 1 Swivel joint inspection port

Direction of rotation Swivel joint measurement port of travel motor

L.H. FORWARD

B·T

R.H. FORWARD

A·C

L.H. REVERSE

B·D

R.H. REVERSE

C·P

Speed selection

1) Put block (1) between the sprocket and frame to lock the rotation of the travel motor where the port is to be inspected, and stop the engine. ¤ Loosen the hydraulic tank oil filler cap slowly to release the pressure inside the tank. 2) Disconnect the hoses at the top of the swivel for the measurement port at both sides of the port to be inspected, and fit blind plugs in the hoses. fl For the combination of inspection port and measurement port, see Table 1. fl Use the following parts as blind plugs. • Main hose: Flange (07379-01044) Split flange (07371-31049) Drain hose: Plug (07376-50315) (07376-50628) 3) Start the engine, run the engine at full throttle, and use a measuring cylinder to catch the oil that leaks out from the measurement port as follows. i) Ports A, B, C, D Relieve the travel motor slowly in the direction of rotation for the port to be inspected. fl For the direction of rotation for the port to be inspected, see Table 1. ii) Port P Set the travel speed switch to Hi. 4) Continue for one minute, then measure the oil leakage for the next one minute.

20-140

PC600-6

TESTING AND ADJUSTING

BLEEDING AIR

BLEEDING AIR Air bleeding procedure

Air bleeding item

Nature of work

Bleed air from pump

Start engine

Bleed air from cylinder

Bleed air from swing motor

Start operations

• Change hydraulic oil • Clean strainer

(note)

• Replace return filter element • Replace, repair pump • Remove suction piping • Replace, repair control valve • Replace cylinder • Remove cylinder piping • Reoplace swing motor • Remove swing motor piping • Replace travel motor, swivel • Remove travel motor, swivel piping

Note: Bleed the air from the swing motor only when the oil inside the motor case has been drained.

1. Bleeding air from pump 1) Loosen air bleed plugs (1) and (2), and check that oil oozes out from the plugs. 2) When oil oozes out, tighten plugs (1) and (2). 3 Air bleed plug: 8.82 ± 0.98 Nm {0.9 ± 0.1 kgm} fl If no oil oozes out from the air bleed plug: 3) Leave plugs (1) and (2) loosened and remove drain hoses (3), (4) and elbows (5) and (6). 4) Pour in oil through the elbow mount hole until oil oozes out from plugs (1) and (2). 5) Fit elbows (5) and (6), and install drain hoses (3) and (4). 6) Tighten air bleed plugs (1) and (2). 3 Air bleed plug: 8.82 ± 0.98 Nm {0.9 ± 0.1 kgm} fl Precautions when starting the engine After completing the above procedure and starting the engine, run the engine at low idling for approx. 10 minutes. fl If the coolant temperature is low and automatic warming-up is carried out, cancel it by using the fuel control dial.

PC600-6

20-141

TESTING AND ADJUSTING

BLEEDING AIR

2. Bleeding air from hydraulic cylinders 1) Start the engine and run at idling for approx. 5 minutes. 2) Run the engine at low idling, then raise and lower the boom 4 – 5 times in succession. ﬂ Operate the piston rod to a point approx. 100 mm before the end of its stroke. Do not relieve the circuit under any circumstances. 3) Run the engine at full throttle and repeat Step 2). After that, run the engine at low idling, and operate the piston rod to the end of its stroke to relieve the circuit. 4) Repeat Steps 2) and 3) to bleed the air from the arm and bucket cylinders. ﬂ When the cylinder has been replaced, bleed the air before connecting the piston rod. Be particularly careful not to operate the cylinder to the end of its stroke when the piston rod has been connected to the LOWER end of the boom cylinder.

3. Bleeding air from swing motor 1) Inside motor case Run the engine at low idling for approx. 5 minutes. ﬂ This operation will bleed the air inside the motor case automatically. 2) Inside brake case ﬂ Normally, the air inside the brake case is bled automatically, but if it feels that the brake is dragging when operating the swing, bleed the air as follows. Loosen the mouthpiece of brake hose (1), start the engine, turn the swing holding brake cancel switch ON and OFF repeatedly, and tighten the mouthpiece when oil oozes out.

20-142

PC600-6

TESTING AND ADJUSTING

RELEASING REMAINING PRESSURE IN HYDRAULIC CIRCUIT

RELEASING REMAINING PRESSURE IN HYDRAULIC CIRCUIT fl If the piping between the hydraulic cylinder and the control valve is to be disconnected, release the remaining pressure from the circuit as follows. The travel circuit is an open circuit, so there is no remaining pressure. It is enough to remove the oil filler cap. 1. Loosen the oil filler cap slowly to release the pressure inside the tank. 2. Operate the control levers. fl When the levers are operated 2 – 3 times, the pressure stored in the accumulator is removed. 3. Start the engine, run at low idling for approx. 5 minutes, then stop the engine and operate the control levers. fl Repeat the above operation 2 – 3 times to release all the remaining pressure.

PC600-6

20-143

TESTING AND ADJUSTING

PROCEDURE FOR CHECKING DIODE

PROCEDURE FOR CHECKING DIODE •

•

Use the following procedure to check the diode as individual part and the wiring harness including the diode. Use a digital tester with a range for measuring diodes.

1. Put the red (+) end of the test pin in contact with the anode (P) of the diode, and the black (–) end in contact with the cathode (N). ﬂ There is a mark showing the direction of continuity on the surface of the diode. ﬂ If a normal tester is switched to the diode range, the voltage of the internal battery is displayed. The value indicates the following. • No change: No continuity • Changes: There is continuity (normal) (Note) • Value is 0 or near 0: Short circuit inside diode Note: In the case of silicon diodes, a value between 400 and 600 is displayed. Depending on the type of tester, a value between 0.4 and 0.6 is displayed.

20-144

PC600-6

TROUBLESHOOTING Points to remember when troubleshooting ........................................................................................ 20-202 Sequence of events in troubleshooting ............................................................................................... 20-203 Points to remember when carrying out maintenance ....................................................................... 20-204 Checks before troubleshooting ............................................................................................................. 20-212 Connector types and mounting locations ........................................................................................... 20-214 Connection table for connector pin numbers ..................................................................................... 20-222 Explanation of control mechanism for electrical system................................................................... 20-245 Display method and special functions of monitor panel ................................................................... 20-247 Method of using judgement table ........................................................................................................ 20-261 Method of using troubleshooting charts ............................................................................................. 20-263 Details of troubleshooting and troubleshooting procedure .............................................................. 20-268 Troubleshooting of communication abnormality system (N mode) ................................................ 20-301 Troubleshooting of engine controller system (E mode) .................................................................... 20-351 Troubleshooting of pump controller system (C mode) ..................................................................... 20-451 Troubleshooting of pump controller [input signal system] (F mode) .............................................. 20-551 Troubleshooting of hydraulic, mechanical system (H mode) ........................................................... 20-601 Troubleshooting of machine monitor system (M mode)................................................................... 20-651

PC600-6

20-201

TROUBLESHOOTING

POINTS TO REMEMBER WHEN TROUBLESHOOTING

POINTS TO REMEMBER WHEN TROUBLESHOOTING ¤ Stop the machine in a level place, and check that the safety pin, blocks, and parking brake are securely fitted. ¤ When carrying out the operation with two or more workers, keep strictly to the agreed signals, and do not allow any unauthorized person to come near.

¤ If the radiator cap is removed when the engine is hot, hot water may spurt out and cause burns, so wait for the engine to cool down before starting troubleshooting.

¤ Be extremely careful not to touch any hot parts or to get caught in any rotating parts. ¤ When disconnecting wiring, always disconnect the negative (–) terminal of the battery first. ¤ When removing the plug or cap from a location which is under pressure from oil, water, or air, always release the internal pressure first. When installing measuring equipment, be sure to connect it properly. The aim of troubleshooting is to pinpoint the basic cause of the failure, to carry out repairs swiftly, and to prevent reoccurrence of the failure. When carrying out troubleshooting, and important point is of course to understand the structure and function. However, a short cut to effective troubleshooting is to ask the operator various questions to form some idea of possible causes of the failure that would produce the reported symptoms. 1.

When carrying out troubleshooting, do not hurry to disassemble the components. If components are disassembled immediately any failure occurs: • Parts that have no connection with the failure or other unnecessary parts will be disassembled. • It will become impossible to find the cause of the failure. It will also cause a waste of manhours, parts, or oil or grease, and at the same time, will also lose the confidence of the user or operator. For this reason, when carrying out troubleshooting, it is necessary to carry out thorough prior investigation and to carry out troubleshooting in accordance with the fixed procedure. Points to ask user or operator 1) Have any other problems occurred apart from the problem that has been reported? 2) Was there anything strange about the machine before the failure occurred? 3) Did the failure occur suddenly, or were there problems with the machine condition before this? 4) Under what conditions did the failure occur? 5) Had any repairs been carried out before the failure? When were these repairs carried out? 6) Has the same kind of failure occurred before? Check before troubleshooting 1) Check the oil level 2) Check for any external leakage of oil from the piping or hydraulic equipment. 3) Check the travel of the control levers.

20-202

4) 5)

Check the stroke of the control valve spool. Other maintenance items can be checked externally, so check any item that is considered to be necessary. Confirming failure • Confirm the extent of the failure yourself, and judge whether to handle it as a real failure or as a problem with the method of operation, etc. ﬂ When operating the machine to reenact the troubleshooting symptoms, do not carry out any investigation or measurement that may make the problem worse. Troubleshooting • Use the results of the investigation and inspection in Items 2 – 4 to narrow down the causes of failure, then use the troubleshooting flowchart to locate the position of the failure exactly. ﬂ The basic procedure for troubleshooting is as follows. 1) Start from the simple points. 2) Start from the most likely points. 3) Investigate other related parts or information. Measures to remove root cause of failure • Even if the failure is repaired, if the root cause of the failure is not repaired, the same failure will occur again. To prevent this, always investigate why the problem occurred. Then, remove the root cause.

PC600-6

TROUBLESHOOTING

SEQUENCE OF EVENTS IN TROUBLESHOOTING

SEQUENCE OF EVENTS IN TROUBLESHOOTING Office, shop

Jobsite

Step 1 Examination, confirmation of symptoms 1) When a request for repairs is received, first ask the following points. • Name of customer • Type, serial number of machine • Details of jobsite, etc. 2) Ask questions to gain an outline of the problem. • Condition of failure • Work being carried out at the time of the failure • Operating environment • Past history, details of maintenance, etc.

Step 2 Determining probable location of cause 1) Look at the troubleshooting section of the shop manual to find locations of possible causes.

Step 3 Preparation of troubleshooting tools 1) Look at the table of troubleshooting tools in the shop manual and prepare the necessary tools. • T-adapter • Hydraulic pressure gauge kit, etc. 2) Look in the parts book and prepare the necessary replacement parts.

Step 7 • Pinpoint locations of failure (carry out troubleshooting) • Decide action to take 1) Before starting troubleshooting, locate and repair simple failures. • Check before starting items • Other check items 2) See the Troubleshooting Section of the shop manual, select a troubleshooting flowchart that matches the symptoms, and carry out troubleshooting.

Step 6 Re-enacting failure •

Step 4 Go to jobsite

Step 5 Ask operator questions to confirm details of failure. • • •

PC600-6

Drive and operate the machine to confirm the condition and judge if there is really a failure.

Was there anything strange about the machine before the failure occurred? Did the failure occur suddenly? Had any repairs been carried out before the failure?

20-203

TROUBLESHOOTING

POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE

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

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

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

2 Defective crimping or soldering of connectors The pins of the male and female connectors are in contact at the crimped terminal or soldered portion, but if there is excessive force brought to bear on the wiring, the plating at the joint will peel and cause improper connection or breakage.

20-204

PC600-6

TROUBLESHOOTING

POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE

3 Disconnections in wiring If the wiring is held and the connectors are pulled apart, or components are lifted with a crane with the wiring still connected, or a heavy object hits the wiring, the crimping of the connector may separate, or the soldering may be damaged, or the wiring may be broken.

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

PC600-6

20-205

TROUBLESHOOTING

POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE

2) Removing, installing, and drying connectors and wiring harnesses ‡

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

3 Action to take after removing connectors After removing any connector, cover it with a vinyl bag to prevent any dust, dirt, oil, or water from getting in the connector portion. ﬂ If the machine is left disassembled for a long time, it is particularly easy for improper contact to occur, so always cover the connector.

20-206

PC600-6

TROUBLESHOOTING

‡

POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE

Connecting connectors 1 Check the connector visually. 1) Check that there is no oil, dirt, or water stuck to the connector pins (mating portion). 2) Check that there is no deformation, defective contact, corrosion, or damage to the connector pins. 3) Check that there is no damage or breakage to the outside of the connector. fl If there is any oil, water, or dirt stuck to the connector, wipe it off with a dry cloth. If any water has got inside the connector, warm the inside of the wiring with a dryer, but be careful not to make it too hot as this will cause short circuits. fl If there is any damage or breakage, replace the connector. 2 Fix the connector securely. Align the position of the connector correctly, then insert it securely. For connectors with lock stopper, push in the connector until the stopper clicks into position. 3 Correct any protrusion of the boot and any misalignment of the wiring harness For connectors fitted with boots, correct any protrusion of the boot. In addition, if the wiring harness is misaligned, or the clamp is out of position, adjust it to its correct position. fl If the connector cannot be corrected easily, remove the clamp and adjust the position. 4 If the connector clamp has been removed, be sure to return it to its original position. Check also that there are no loose clamps.

PC600-6

20-207

TROUBLESHOOTING

‡

POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE

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

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

3 Carry out a continuity test on the connector. After drying, leave the wiring harness disconnected and carry out a continuity test to check for any short circuits between pins caused by water. ﬂ After completely drying the connector, blow it with contact restorer and reassemble.

20-208

PC600-6

TROUBLESHOOTING

POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE

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

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

6 Do not place the control box on oil, water, or soil, or in any hot place, even for a short time. (Place it on a suitable dry stand). 7 Precautions when carrying out arc welding When carrying out arc welding on the body, disconnect all wiring harness connectors connected to the control box. Fit an arc welding ground close to the welding point.

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

PC600-6

20-209

TROUBLESHOOTING

POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE

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

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

20-210

PC600-6

TROUBLESHOOTING

POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE

5) Change hydraulic oil when the temperature is high. When hydraulic oil or other oil is warm, it flows easily. In addition, the sludge can also be drained out easily from the circuit together with the oil, so it is best to change the oil when it is still warm. When changing the oil, as much as possible of the old hydraulic oil must be drained out. (Drain the oil from the hydraulic tank; also drain the oil from the filter and from the drain plug in the circuit.) If any old oil is left, the contaminants and sludge in it will mix with the new oil and will shorten the life of the hydraulic oil. 6) Flushing operations After disassembling and assembling the equipment, or changing the oil, use flushing oil to remove the contaminants, sludge, and old oil from the hydraulic circuit. Normally, flushing is carried out twice: primary flushing is carried out with flushing oil, and secondary flushing is carried out with the specified hydraulic oil.

7) Cleaning operations After repairing the hydraulic equipment (pump, control valve, etc.) or when running the machine, carry out oil cleaning to remove the sludge or contaminants in the hydraulic oil circuit. The oil cleaning equipment is used to remove the ultrafine (about 3µ) particles that the filter built into the hydraulic equipment cannot remove, so it is an extremely effective device.

PC600-6

20-211

TROUBLESHOOTING

CHECKS BEFORE TROUBLESHOOTING

CHECKS BEFORE TROUBLESHOOTING Judgement value

Check fuel level, type of fuel

—

Add fuel

Check for impurities in fuel

—

Clean, drain

Check hydraulic oil level

—

Add oil

Check hydraulic strainer

—

Clean, drain

Check swing machinery oil level

—

Add oil

Check engine oil level (oil pan oil level), type of oil

—

Add oil

Check coolant level

—

Add water

Check dust indicator for clogging

—

Clean or replace

Check hydraulic filter

—

Replace

Check for looseness, corrosion of battery terminal, wiring

—

Tighten or replace

Check for looseness, corrosion of alternator terminal, wiring

—

Tighten or replace

Check for looseness, corrosion of starting motor terminal, wiring

—

Tighten or replace

Check for abnormal noise, smell

—

Repair

Check for oil leakage

—

Repair

Carry out air bleeding

—

Bleed air

Check battery voltage (engine stopped)

20 – 30V

Replace

Check battery electrolyte level

—

Add or replace

Check for discolored, burnt, exposed wiring

—

Replace

Check for missing wiring clamps, hanging wiring

—

Repair

Check for water leaking on wiring (be particularly careful attention

—

Disconnect

Electrics, electrical equipment

Lubricating oil, coolant

Electrical equipment

Action

Hydraulic, mechanical equipment

Item

to water leaking on connectors or terminals) 6.

Check for blown, corroded fuses

Check alternator voltage (engine running at 1/2 throttle or above)

Check operating sound of battery (when switch is turned ON/OFF)

20-212

connector and dry —

Replace

After running Replace for several minutes: 27.5 – 29.5V —

Replace

PC600-6

TROUBLESHOOTING

CONNECTOR ARRANGEMENT DIAGRAM

CONNECTOR TYPES AND MOUNTING LOCATIONS ConNo. nector Type of No. pins

Mounting location

Address

ConNo. nector Type of No. pins

Address

Mounting location

B01

HD30

Circuit breaker box

D03

YSKD

Collector diode

B02

Circuit breaker box

D06

YSKD

Collector diode

B03

Circuit breaker box

D08

KES1

Diode

B11

terminal

Circuit breaker (80A)

D11

KES1

Diode

B12

terminal

Circuit breaker (20A)

D14

KES1

Diode

B13

terminal

Circuit breaker (20A)

D17

KES1

Diode

B14

terminal

Circuit breaker (20A)

D22

KES1

Diode

B15

terminal

Circuit breaker (20A)

D26

KES1

Diode

B16

terminal

Circuit breaker (20A)

D28

KES1

Diode

B17

terminal

Circuit breaker (20A)

D29

KES1

Diode

B18

terminal

Circuit breaker (20A)

D30

KES1

Diode

B19

terminal

Circuit breaker (20A)

D31

KES1

Diode

B1A

terminal

Circuit breaker (20A)

D32

KES1

Diode

B21

terminal

Circuit breaker (80A)

D33

KES1

Diode

B22

terminal

Circuit breaker (20A)

D34

KES1

Diode

B23

terminal

Circuit breaker (20A)

D35

KES1

Diode

B24

terminal

Circuit breaker (20A)

E06

Fuel control dial

B25

terminal

Circuit breaker (20A)

E09

Model selection connector

B26

terminal

Circuit breaker (20A)

E11

070

Engine controller

B27

terminal

Circuit breaker (20A)

E12

070

Engine controller

B28

terminal

Circuit breaker (20A)

E13

040

Engine controller

B29

terminal

Circuit breaker (20A)

E14

070

Engine controller

B2A

terminal

Circuit breaker (20A)

E15

040

Engine controller

C01

MIC

Pump controller

E16

070

Engine controller

C02

MIC

Pump controller

E17

070

Engine controller

C03

040

Pump controller

E21

HD30

Intermediate connector

C05

Emergency pump drive switch

E22

HD30

Intermediate connector

C06

Emergency pump drive resistor

E31

No. 1 fuel injector

C07

Rear pump pressure sensor

E32

No. 2 fuel injector

C08

Front pump pressure sensor

E33

No. 3 fuel injector

C09

Model selection connector

E34

No. 4 fuel injector

C13

TVC valve

E35

No. 5 fuel injector

C16

MIC

Pump controller

E36

No. 6 fuel injector

C17

040

Pump controller

E41

DENSO

Fuel supply pump PSV1

D01

KESI

Diode

E42

DENSO

Fuel supply pump PSV2

20-214

PC600-6

TROUBLESHOOTING

ConNo. nector Type of No. pins

CONNECTOR ARRANGEMENT DIAGRAM

Mounting location

Address

ConNo. nector Type of No. pins

Address

Mounting location

E60

Intermediate connector

M21

Radio

ENE

Engine speed sensor

M22

Intermediate connector

F01

Travel alarm

M23

Intermediate connector

DENSO

Engine G rotation sensor

M26

Air conditioner unit

G01

Grease gun

M28

KES0

Window washer motor

H07

Intermediate connector

M33

250

Boom sway control switch

H12

S (white)

Intermediate connector

M34

Air conditioner compressor clutch

H13

S (blue)

Intermediate connector

M36

Kerosene mode switch

H14

Intermediate connector

M37

terminal

Horn (high tone)

H15

Intermediate connector

M38

terminal

Horn (low tone)

terminal

Intake air heater relay

M38

Machine push-up switch

Service connector

J01

Junction connector

1-pin M39 connector

J02

Junction connector

M42

Right front lamp

J03

Junction connector

M44

Intermediate connector

J04

Junction connector

M45

Network bus connector

J05

Junction connector

M50

Intermediate connector

Engine room lamp

—

Service power source connector

Intermediate connector

J06

Junction connector

M58

J07

Junction connector

M69

J08

Junction connector

M70

J09

Junction connector

M71

1-pin connector 1-pin connector 1-pin connector 1-pin connector

J10

Junction connector

M72

Intermediate connector

L03

Step light switch

M73

KES0

Left speaker

M06

Heater switch

M73

Intermediate connector

M07

Lamp switch

M74

Cab top light

M09

Working lamp

M75

Step light

M09

Rear working lamp

—

M76

Cab top light

M09L

Additional working lamp (left)

—

M80

Intermediate connector

M09R

Additional working lamp (right)

—

M81

Intermediate connector

M10

Intermediate connector

M82

Flashing lamp

—

M12

KES1

Heater unit

M91

KES1

Lower wiper switch

M13

KES0

Right speaker

1-pin M93 connector

Service power source connector

M16

terminal

Horn (high tone)

M94

Intermediate connector

M17

terminal

Horn (low tone)

DENSO

Engine Ne rotation sensor

—

M18

Wiper, washer switch

Engine oil level sensor

M20

1-pin connector

Cigar lighter

P01

040

Monitor panel

PC600-6

20-215

TROUBLESHOOTING

ConNo. nector Type of No. pins

CONNECTOR ARRANGEMENT DIAGRAM

Mounting location

Address

ConNo. nector Type of No. pins

Mounting location

Address

P02

040

Monitor panel

T06

terminal

Revolving frame ground

—

P03

Buzzer cancel switch

T06

terminal

Ground

P04

Alarm buzzer

T07

terminal

Pump controller ground

P06

Fuel level sensor

T07

terminal

Ground

—

P09

Hydraulic oil level sensor

T08

terminal

Engine controller ground

P10

Hydraulic oil temperature sensor

T09

terminal

Revolving frame ground

P11

Air cleaner clogging sensor

THL

Spill fuel temperature sensor

V5 V1 U1

PFUEL DENSO

Fuel common rail pressure sensor

TWH

PIM

DENSO

Boost pressure sensor

TWL

Engine water temperature high temperature sensor Engine water temperature low temperature sensor

PSH

terminal

Engine oil pressure high pressure sensor

V02

CO cancel solenoid

PSL

terminal

Engine oil pressure low pressure sensor

V03

Machine push-up solenoid

R04

Shinagawa

Head lamp relay

V04

Swing holding brake solenoid

R05

Shinagawa

Boom lamp relay

V05

2-stage relief solenoid

R11

Shinagawa

Lower wiper relay

V06

Travel speed solenoid

R15

Shinagawa

Boom sway control valve relay

V08

Bucket Hi cancel solenoid

Window rear limit switch

R16

Shinagawa

Flashing lamp relay

1-pin W03 connector

R17

Shinagawa

Step light relay

W04

Wiper motor

R18

Shinagawa

Horn switch relay

W08

070

Relay box (for wiper)

R24

Shinagawa

Engine controller power source relay

W10

Intermediate connector

R25

Shinagawa

Step light relay

W15

KES0

Lower wiper

—

S01

Travel PPC oil pressure switch

X01

MIC

Intermediate connector

S02

Boom RAISE PPC oil pressure switch

X05

Swing lock switch

S03

Arm OUT PPC oil pressure switch

X07

MIC

Intermediate connector

S04

Boom LOWER PPC oil pressure switch

S05

Arm IN PPC oil pressure switch

S06

Bucket CURL PPC oil pressure switch

S07

Bucket DUMP PPC oil pressure switch

S08

Swing PPC oil pressure switch

S09

Service PPC oil pressure switch

Starting motor

SWI

terminal

Swing emergency switch

T02

terminal

Revolving frame ground

T03

terminal

Revolving frame ground

T04

terminal

Revolving frame ground

T05

terminal

Revolving frame ground

20-216

PC600-6

TROUBLESHOOTING

CONNECTOR ARRANGEMENT DIAGRAM

20-218

PC600-6

TROUBLESHOOTING

PC600-6

CONNECTOR ARRANGEMENT DIAGRAM

20-219

TROUBLESHOOTING

20-220

CONNECTOR ARRANGEMENT DIAGRAM

PC600-6

TROUBLESHOOTING

PC600-6

CONNECTOR ARRANGEMENT DIAGRAM

20-221

TROUBLESHOOTING

CONNECTION TABLE FOR CONNECTOR PIN NUMBERS

CONNECTION TABLE FOR CONNECTOR PIN NUMBERS ﬂ The terms male and female refer to the pins, while the terms male housing and female housing refer to the mating portion of the housing. X type connector

No. of pins

Male (female housing)

Female (male housing)

T-adapter Part No.

Part No.: 08055-00181

Part No.: 08055-00191

799-601-7010

799-601-7020

Part No.: 08055-00282

Part No.: 08055-00292

799-601-7030

Part No.: 08055-00381

Part No.: 08055-00391

799-601-7040

Part No.: 08055-00481

Part No.: 08055-00491

—

Terminal part No.: 79A-222-3370 • Electric wire size: 0.85 • Grommet: Black • Q’ty: 20

Terminal part No.: 79A-222-3390 • Electric wire size: 0.85 • Grommet: Black • Q’ty : 20

—

Terminal part No.: 79A-222-3380 • Electric wire size: 2.0 • Grommet: Red • Q’ty: 20

Terminal part No.: 79A-222-3410 • Electric wire size: 2.0 • Grommet: Red • Q’ty: 20

—

20-222

PC600-6

TROUBLESHOOTING

No. of pins

CONNECTION TABLE FOR CONNECTOR PIN NUMBERS

SWP type connector Male (female housing)

Female (male housing)

799-601-7050

Part No.: 08055-10681

Part No.: 08055-10691

799-601-7060

Part No.: 08055-10881

Part No.: 08055-10891

799-601-7310

Part No.: 08055-11281

Part No.: 08055-11291

799-601-7070

Part No.: 08055-11481

PC600-6

T-adapter Part No.

Part No.: 08055-11491

20-223

TROUBLESHOOTING

No. of pins

CONNECTION TABLE FOR CONNECTOR PIN NUMBERS

SWP type connector Male (female housing)

Female (male housing)

T-adapter Part No.

799-601-7320

Part No.: 08055-11681

Part No.: 08055-11691

—

Terminal part No.: • Electric wire size: 0.85 • Grommet: Black • Q’ty: 20

—

Terminal part No.: • Electric wire size: 1.25 • Grommet: Red • Q’ty: 20

Terminal part No.: • Electric wire size : 1.25 • Grommet: Red • Q’ty: 20

—

20-224

PC600-6

TROUBLESHOOTING

CONNECTION TABLE FOR CONNECTOR PIN NUMBERS

M type connector

No. of pins

Male (female housing)

Female (male housing)

T-adapter Part No.

Part No.: 08056-00171

Part No.: 08056-00181

799-601-7080

799-601-7090

Part No.: 08056-00271

Part No.: 08056-00281

799-601-7110

Part No.: 08056-00371

Part No.: 08056-00381

799-601-7120

Part No.: 08056-00471

Part No.: 08056-00481

799-601-7130

Part No.: 08056-00671

Part No.: 08056-00681

799-601-7390

Part No.: 08056-00871 PC600-6

Part No.: 08056-00881

20-225

TROUBLESHOOTING

No. of pins

CONNECTION TABLE FOR CONNECTOR PIN NUMBERS

S type connector Male (female housing)

Female (male housing)

799-601-7140

Part No.: 08056-10871

Part No.: 08056-10881

10 (White)

799-601-7150

Part No.: 08056-11071

Part No.: 08056-11081

12 (White)

799-601-7350

Part No.: 08056-11271

Part No.: 08056-11281

16 (White)

799-601-7330

Part No.: 08056-11671

20-226

T-adapter Part No.

Part No.: 08056-11681

PC600-6

TROUBLESHOOTING

No. of pins

CONNECTION TABLE FOR CONNECTOR PIN NUMBERS

S type connector Male (female housing)

Female (male housing)

—

10 (Blue)

—

12 (Blue)

799-601-7160

Part No.: 08056-11272

Part No.: 08056-11282

16 (Blue)

799-601-7170

Part No.: 08056-11672

PC600-6

T-adapter Part No.

Part No.: 08056-11682

20-227

TROUBLESHOOTING

No. of pins

CONNECTION TABLE FOR CONNECTOR PIN NUMBERS

MIC type connector Male (female housing)

Female (male housing)

Body part No.: 79A-222-2640

Body part No.: 79A-222-2630

(Q’ty: 5)

Body part No.: 79A-222-2680

Body part No.: 79A-222-2670

(Q’ty: 5)

—

799-601-2710

Body part No.: 79A-222-2620 (Q’ty: 5)

Body part No.: 79A-222-2610 (Q’ty: 5)

799-601-2950

Body part No.: 79A-222-2660 (Q’ty: 5)

Body part No.: 79A-222-2650 (Q’ty: 5)

799-601-2720

Body part No.: 79A-222-2710 (Q’ty: 2)

20-228

T-adapter Part No.

Body part No.: 79A-222-2690 (Q’ty: 2)

PC600-6

TROUBLESHOOTING

No. of pins

CONNECTION TABLE FOR CONNECTOR PIN NUMBERS

MIC type connector Male (female housing)

Female (male housing)

799-601-2730

Body part No.: 79A-222-2730 (Q’ty: 2)

Body part No.: 9A-222-2720 (Q’ty: 2)

PC600-6

T-adapter Part No.

799-601-2740

Body part No.: 79A-222-2750 (Q’ty: 2)

Body part No.: 79A-222-2740 (Q’ty: 2)

Terminal part No.: 79A-222-2770 (Q’ty: 50)

Terminal part No.: 79A-222-2760 (Q’ty: 50)

—

20-229

TROUBLESHOOTING

No. of pins

CONNECTION TABLE FOR CONNECTOR PIN NUMBERS

AMP040 type connector Male (female housing)

Female (male housing)

T-adapter Part No.

799-601-7180

—

Housing part No.: 79A-222-3430 (Q’ty: 5)

799-601-7190

—

Housing part No.: 79A-222-3440 (Q’ty: 5)

799-601-7210

—

Housing part No.: 79A-222-3450 (Q’ty: 5)

799-601-7220

—

Housing part No.: 79A-222-3460 (Q’ty: 5)

ﬂ Terminal part No.: 79A-222-3470 (No relation with number of pins)

20-230

PC600-6

TROUBLESHOOTING

No. of pins

CONNECTION TABLE FOR CONNECTOR PIN NUMBERS

AMP070 type connector Male (female housing)

Female (male housing)

799-601-7510

—

Part No.: 08195-10210

799-601-7520

—

Part No.: 08195-12210

799-601-7530

—

Part No.: 08195-14210

799-601-7540

—

Part No.: 08195-18210

799-601-7550

—

PC600-6

T-adapter Part No.

Part No.: 08195-20210

20-231

TROUBLESHOOTING

No. of pins

CONNECTION TABLE FOR CONNECTOR PIN NUMBERS

L type connector Male (female housing)

Female (male housing)

—

No. of pins

—

Connector for PA Male (female housing)

Female (male housing)

—

Bendix MS connector Male (female housing)

Female (male housing)

T-adapter Part No.

799-601-3460

—

20-232

T-adapter Part No.

—

No. of pins

T-adapter Part No.

—

PC600-6

TROUBLESHOOTING

No. of pins

CONNECTION TABLE FOR CONNECTOR PIN NUMBERS

KES 1 (Automobile) connector Male (female housing)

Female (male housing)

—

Part No.: 08027-10210 (Natural color) 08027-10220 (Black)

Part No.: 08027-10260 (Natural color) 08027-10270 (Black)

—

Part No.: 08027-10310

Part No.: 08027-10360

—

Part No.: 08027-10410 (Natural color) 08027-10420 (Black)

Part No.: 08027-10460 (Natural color) 08027-10470 (Black)

—

Part No.: 08027-10610 (Natural color) 08027-10620 (Black)

PC600-6

T-adapter Part No.

Part No.: 08027-10660 (Natural color) 08027-10670 (Black)

20-233

TROUBLESHOOTING

CONNECTION TABLE FOR CONNECTOR PIN NUMBERS

KES 1 (Automobile) connector

No. of pins

Male (female housing)

Female (male housing)

T-adapter Part No.

—

Part No.: 08027-10810 (Natural color) 08027-10820 (Black)

20-234

Part No.: 08027-10860 (Natural color) 08027-10870 (Black)

PC600-6

TROUBLESHOOTING

No. of pins

CONNECTION TABLE FOR CONNECTOR PIN NUMBERS

Connector for relay (Socket type) Male (female housing)

Female (male housing)

799-601-7360

—

799-601-7370

—

PC600-6

T-adapter Part No.

—

20-235

TROUBLESHOOTING

No. of pins

CONNECTION TABLE FOR CONNECTOR PIN NUMBERS

F type connector Male (female housing)

Female (male housing)

—

20-236

T-adapter Part No.

—

PC600-6

TROUBLESHOOTING

CONNECTION TABLE FOR CONNECTOR PIN NUMBERS

[The pin No. is also marked on the connector (electric wire insertion end)] Type (shell size code)

HD30 Series connector Body (plug)

Body (receptacle)

Pin (male terminal)

Pin (female termial)

T-adapter Part No.

799-601-9210

18-8 (1)

Part No.: 08191-11201, 08191-11202, 08191-11205, 08191-11206

Part No.: 08191-14101, 08191-14102, 08191-14105, 08191-14106

Pin (female terminal)

Pin (male termial)

799-601-9210

Part No.: 08191-12201, 08191-12202, 08191-12205, 08191-12206

Part No.: 08191-13101, 08191-13102, 08191-13105, 08191-13106

Pin (male terminal)

Pin (female termial)

799-601-9220

18-14 (2)

Part No.: 08191-21201, 08191-12202, 08191-21205, 08191-12206

Part No.: 08191-24101, 08191-24102, 08191-24105, 08191-24106

Pin (female terminal)

Pin (male termial)

799-601-9230

Part No.: 08191-22201, 08191-22202, 08191-22205, 08191-22206

PC600-6

Part No.: 08191-23101, 08191-23102, 08191-23105, 08191-23106

20-237

TROUBLESHOOTING

CONNECTION TABLE FOR CONNECTOR PIN NUMBERS

[The pin No. is also marked on the connector (electric wire insertion end)] Type (shell size code)

HD30 Series connector Body (plug)

Body (receptacle)

Pin (male terminal)

Pin (female termial)

T-adapter Part No.

799-601-9230

18-20 (3)

Part No.: 08191-31201, 08191-31202

Part No.: 08191-34101, 08191-34102

Pin (female terminal)

Pin (male termial)

799-601-9230

Part No.: 08191-32201, 08191-32202

Part No.: 08191-33101, 08191-33102

Pin (male terminal)

Pin (female termial)

799-601-9240

18-21 (4)

Part No.: 08191-41201, 08191-42202

Part No.: 08191-44101, 08191-44102

Pin (female terminal)

Pin (male termial)

799-601-9240

Part No.: 08191-42201, 08191-42202

20-238

Part No.: 08191-43101, 08191-43102

PC600-6

TROUBLESHOOTING

CONNECTION TABLE FOR CONNECTOR PIN NUMBERS

[The pin No. is also marked on the connector (electric wire insertion end)] Type (shell size code)

HD30 Series connector Body (plug)

Body (receptacle)

Pin (male terminal)

Pin (female termial)

T-adapter Part No.

799-601-9250

24-9 (5)

Part No.: 08191-51201, 08191-51202

Part No.: 08191-54101, 08191-54102

Pin (female terminal)

Pin (male termial)

799-601-9250

Part No.: 08191-52201, 08191-52202

Part No.: 08191-53101, 08191-53102

Pin (male terminal)

Pin (female termial)

799-601-9260

24-16 (6)

Part No.: 08191-61201, 08191-62202, 08191-61205, 08191-62206

Part No.: 08191-64101, 08191-64102, 08191-64105, 08191-64106

Pin (female terminal)

Pin (male termial)

799-601-9260

Part No.: 08191-62201, 08191-62202, 08191-62205, 08191-62206

PC600-6

Part No.: 08191-63101, 08191-63102, 08191-63105, 08191-63106

20-239

TROUBLESHOOTING

CONNECTION TABLE FOR CONNECTOR PIN NUMBERS

[The pin No. is also marked on the connector (electric wire insertion end)] Type (shell size code)

HD30 Series connector Body (plug)

Body (receptacle)

Pin (male terminal)

Pin (female termial)

T-adapter Part No.

799-601-9270

24-21 (7)

Part No.: 08191-71201, 08191-71202, 08191-71205, 08191-71206

Part No.: 08191-74101, 08191-74102, 08191-74105, 08191-74106

Pin (female terminal)

Pin (male termial)

799-601-9270

Part No.: 08191-72201, 08191-72202, 08191-72205, 08191-72206

Part No.: 08191-73101, 08191-73102, 08191-73105, 08191-73106

Pin (male terminal)

Pin (female termial)

799-601-9280

24-22 (8)

Part No.: 08191-81201, 08191-81202, 08191-81203, 08191-81204, 08191-81205, 08191-80206

Part No.: 08191-84101, 08191-84102, 08191-84103, 08191-84104, 08191-84105, 08191-84106

Pin (female terminal)

Pin (male termial)

799-601-9280

Part No.: 08191-82201, 08191-82202, 08191-82203, 08191-82204, 08191-82205, 08191-82206

20-240

Part No.: 08191-83101, 08191-83102, 08191-83103, 08191-83104, 08191-83105, 08191-83106

PC600-6

TROUBLESHOOTING

CONNECTION TABLE FOR CONNECTOR PIN NUMBERS

[The pin No. is also marked on the connector (electric wire insertion end)] Type (shell size code)

HD30 Series connector Body (plug)

Body (receptacle)

Pin (male terminal)

Pin (female termial)

T-adapter Part No.

799-601-9290

24-31 (9)

Part No.: 08191-91203, 08191-91204, 08191-91205, 08191-91206

Part No.: 08191-94103, 08191-94104, 08191-94105, 08191-94106

Pin (female terminal)

Pin (male termial)

799-601-9290

Part No.: 08191-92203, 08191-92204, 08191-92205, 08191-92206

PC600-6

Part No.: 08191-93103, 08191-93104, 08191-93105, 08191-93106

20-241

TROUBLESHOOTING

CONNECTION TABLE FOR CONNECTOR PIN NUMBERS

[The pin No. is also marked on the connector (electric wire insertion end)] DT Series connector

No. of pins

Body (plug)

Body (receptacle)

T-adapter Part No.

799-601-9020

Part No.: 08192-12200 (normal type) Part No.: 08192-12100 (normal type) 08192-22200 (fine wire type) 08192-22100 (fine wire type)

799-601-9030

Part No.: 08192-13200 (normal type) Part No.: 08192-13100 (normal type) 08192-23200 (fine wire type) 08192-23100 (fine wire type)

799-601-9040

Part No.: 08192-14200 (normal type) Part No.: 08192-14100 (normal type) 08192-24200 (fine wire type) 08192-24100 (fine wire type)

799-601-9050

Part No.: 08192-16200 (normal type) Part No.: 08192-16100 (normal type) 08192-26200 (fine wire type) 08192-26100 (fine wire type)

20-242

PC600-6

TROUBLESHOOTING

CONNECTION TABLE FOR CONNECTOR PIN NUMBERS

[The pin No. is also marked on the connector (electric wire insertion end)] No. of pins

DT Series connector Body (plug)

Body (receptacle)

T-adapter Part No.

8GR: 799-601-9060 8B: 799-601-9070 8G: 799-601-9080 8BR: 799-601-9090

Part No.: 08192-1820 (normal type) Part No.: 08192-1810 (normal type) 08192-2820 (fine wire type) 08192-2810 (fine wire type)

12GR:799-601-9110 12B: 799-601-9120 12G: 799-601-9130 12BR:799-601-9140

Part No.: 08192-1920 (normal type) Part No.: 08192-1910 (normal type) 08192-2920 (fine wire type) 08192-2910 (fine wire type)

PC600-6

20-243

TROUBLESHOOTING

CONNECTION TABLE FOR CONNECTOR PIN NUMBERS

[The pin No. is also marked on the connector (electric wire insertion end)] No. of pins

DTM Series connector Body (plug)

Body (receptacle)

T-adapter Part No.

799-601-9010

Part No.: 08192-02200

Part No.: 08192-02100

[The pin No. is also marked on the connector (electric wire insertion end)] No. of pins

DTHD Series connector Body (plug)

Body (receptacle)

—

Part No.: 08192-31200 (Contact size#12) 08192-41200 (Contact size #8) 08192-51200 (Contact size #4)

20-244

T-adapter Part No.

Part No.: 08192-31100 (Contact size#12) 08192-41100 (Contact size #8) 08192-51100 (Contact size #4)

PC600-6

TROUBLESHOOTING

EXPLANATION OF CONTROL MECHANISM FOR ELECTRICAL SYSTEM

EXPLANATION OF CONTROL MECHANISM FOR ELECTRICAL SYSTEM The control structure of the electrical system consists of the monitor panel, engine controller, and pump controller. The monitor panel, engine controller, and pump controller input the necessary signals, and match them with the signals selected on the monitor panel. The engine controller and pump controller output or input the necessary data to control the engine output and pump absorption torque.

PC600-6

20-245

TROUBLESHOOTING

DISPLAY METHOD AND SPECIAL FUNCTIONS OF MONITOR PANEL

The functions of the monitor panel include the normal observation and display functions for the condition of the machine and the switch functions for the control system. The monitor panel also has the following special functions. 1. Troubleshooting functions for lamps, gauges, and buzzer (monitor display troubleshooting) 2. Display functions for user codes 3. Display functions for service codes 4. Display functions for monitoring codes 5. Setting function for reduced cylinder mode operation 6. Setting function for working mode default 7. Setting function for oil maintenance display 8. Adjustment function for time display 1. Troubleshooting functions for lamps, gauges, and buzzer (monitor display troubleshooting) When the starting switch is turned on, all of the lamps and gauges on the monitor panel light up for approx. 3 sec and the alarm buzzer sounds for approx. 1 sec, the monitor panel itself carries out troubleshooting, and after that, it returns to the normal display (if any lamp does not light up, the bulb is blown).

PC600-6

20-247

TROUBLESHOOTING

DISPLAY METHOD AND SPECIAL FUNCTIONS OF MONITOR PANEL

2. Display functions for user codes The abnormality data for the engine controller and pump controller are all transmitted to the monitor panel by the network signals. Among these abnormality data, those items that have a high level of emergency are automatically displayed on the time display (1) of the monitor panel as user codes to recommend the action for the operator to take. Example: The figure on the right shows the situation when user code [E02] is displayed. User code

System with abnormality

E02

TVC system

E03

Swing holding brake system

E0E

Network system

E10

Engine emergency stop system

E11

Engine control system

E14

Fuel control dial system

E15

Engine controller minor failure

3. Display functions for service codes The abnormality data for the engine controller and pump controller are all transmitted to the monitor panel by the network signals. Among these abnormality data, those items for which it is necessary to display the user code and those items for which it is not necessary to display the user code are all saved in memory as service codes inside the monitor panel. When the next operation is carried out, the service codes are displayed on time display (1) of the monitor panel and elapsed time (service meter time) is displayed on the service meter display (2). 1) To switch to the service code display mode: Keep time switch (3) and L.H. travel speed switch (4) pressed at the same time for at least 2.5 seconds. Example of display A: When display shows that service code [E213] occurred six hours ago.

20-248

PC600-6

TROUBLESHOOTING

DISPLAY METHOD AND SPECIAL FUNCTIONS OF MONITOR PANEL

B: When an abnormality still exists, an [E] mark is displayed at the head of the service code. C: If there is no service code in memory, only the center segment is displayed. To go to the next service code display: Keep time switch (3) and R.H. press working mode switch (5). To go back to the previous service code display: Keep time switch (3) and press L.H. working mode switch (6). To end the service code display mode: Keep time switch (3) and L.H. travel speed switch (4) pressed at the same time for at least 2.5 seconds. To delete a service code from memory: Keep time switch (3) pressed, turn the starting switch OFF and then ON again, and keep time switch (3) pressed for at least 2.5 seconds.

Table of service codes Service code

Abnormal system

User code

E101

Abnormality in error history data

—

E102

Abnormality in clock data

—

E103

Short circuit in buzzer output system

—

E104

Air cleaner clogging sensor abnormality detection

—

E108

Engine water temperature 105°C detection

—

E112

Short circuit in wiper motor drive normal rotation system

—

E113

Short circuit in wiper motor drive reverse rotation system

—

E114

Short circuit in window washer drive system

—

E117

S-NET communication error between engine controllers

E0E

E118

S-NET communication error between pump controllers

E0E

E201

Short circuit in CO cancel solenoid system

—

E203

Short circuit in swing holding brake solenoid relay system

E03

E204

Short circuit in 2-stage relief solenoid system

—

E206

Short circuit in travel speed solenoid system

—

E207

Short circuit in flashing lamp relay system

—

E211

Short circuit in CO cancel solenoid system

—

E213

Disconnection in swing holding brake solenoid relay system

E03

PC600-6

20-249

TROUBLESHOOTING

DISPLAY METHOD AND SPECIAL FUNCTIONS OF MONITOR PANEL

Service code

Abnormal system

User code

E214

Disconnection in 2-stage relief solenoid system

—

E216

Disconnection in travel speed solenoid system

—

E217

Error in pump controller model selection input

—

E218

S-NET response overtime error

—

E224

Abnormality in front pump pressure sensor system

—

E225

Abnormality in rear pump pressure sensor system

—

E226

Abnormality in pressure sensor power source system

—

E227

Abnormality in engine speed sensor system

—

E228

Abnormality in auto-deceleration output system

—

E231

Abnormality in step light power source retention output system

—

E232

Short circuit in TVC solenoid system

E02

E233

Disconnection in TVC solenoid system

E02

E302

Short circuit in step light relay drive system

—

E311

Short circuit in bucket CURL Hi cancel solenoid system

—

E312

Disconnection in bucket CURL Hi cancel solenoid system

—

E313

Error in automatic greasing controller system

—

E91b

Abnormality in engine Ne rotation sensor system

E11, E10 (Note 1)

E91C

Abnormality in engine G rotation sensor system

E11, E10 (Note 1)

E920

Abnormality in engine controller model selection system

E11

E922

Engine overrun

—

E924

Drop in engine oil pressure

E11

E931

Abnormality in fuel control dial system

E14

E934

Abnormality in engine water temperature high temperature sensor system

E15

E936

Abnormality in engine oil pressure switch system

E15

E93C

Abnormality in boost pressure sensor system

E11

E93d

Abnormality in fuel temperature sensor system

E15

E954

Short circuit in starting switch terminal C

—

E955

Abnormality in engine controller network

E0E

E956

Abnormality 1 in engine controller power source system

E10

E957

Abnormality 2 in engine controller power source system

E15

E95A

Abnormality in engine controller fuel injection quantity control switch signal

—

E96A

Abnormality in engine water temperature low temperature sensor system

E15

E970

Overcurrent in fuel supply pump PCV1 system

E11, E10 (Note 2)

E971

Overcurrent in fuel supply pump PCV2 system

E11, E10 (Note 2)

E974

Disconnection in fuel supply pump PCV1 system

E11, E10 (Note 2)

E975

Disconnection in fuel supply pump PCV2 system

E11, E10 (Note 2)

E977

Abnormality in common rail fuel pressure sensor system

E11

E979

Abnormality 1 in common rail fuel high pressure

E11

20-250

PC600-6

TROUBLESHOOTING

Service code

DISPLAY METHOD AND SPECIAL FUNCTIONS OF MONITOR PANEL

Abnormal system

User code

E97A

Abnormality 2 in common rail fuel high pressure

E10

E97b

Fuel supply pump non-force feed 1

E11

E97C

Fuel supply pump non-force feed 2

E10

E97d

Abnormality in common rail fuel pressure

E11

E980

Abnormality in engine controller

E11, E10 (Note 3)

E981

Disconnection in No. 1 fuel injector system

E11, E10 (Note 4)

E982

Disconnection in No. 2 fuel injector system

E11, E10 (Note 4)

E983

Disconnection in No. 3 fuel injector system

E11, E10 (Note 4)

E984

Disconnection in No. 4 fuel injector system

E11, E10 (Note 4)

E985

Disconnection in No. 5 fuel injector system

E11, E10 (Note 4)

E986

Disconnection in No. 6 fuel injector system

E11, E10 (Note 4)

E98A

Short circuit in No. 1, No. 2, No. 3 fuel injector system

E11, E10 (Note 4)

E98b

Short circuit in No. 4, No. 5, No. 6 fuel injector system

E11, E10 (Note 4)

Note 1: If a single abnormality occurs, user code [E11] is displayed. If the abnormality occurs at the same time in both the Ne rotation sensor and G rotation sensor, user code [E10] is displayed. Note 2: If a single abnormality occurs, user code [E11] is displayed. If the abnormality occurs at the same time in both PCV1 and PCV2, user code [E10] is displayed. Note 3: If a single abnormality occurs, user code [E11] is displayed. If the abnormality is serious and the controller all stop is generated, user code [E10] is displayed. Note 4: If a single abnormality occurs, user code [E11] is displayed. If the abnormality occurs at the same time in another injector, user code [E10] is displayed.

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

PC600-6

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TROUBLESHOOTING

DISPLAY METHOD AND SPECIAL FUNCTIONS OF MONITOR PANEL

4. Display functions for monitoring codes The input signals from the sensors to the engine controller and pump controller and the signals to drive the solenoids can be checked in real time as monitoring data by the monitoring code. The monitoring data that can be displayed include numerical values, such as the engine speed, oil pressure, voltage, or current, and items that are displayed by bits, such as the actuation status of the oil pressure switches or solenoids. With the following operation, the monitoring code can be displayed on time display (1) of the monitor panel and the monitoring data can be displayed on service meter display (2). 1) To switch to the monitoring code of display mode: Keep time switch (3) and heavy lift switch (4) pressed at the same time for at least 2.5 seconds. Example of display: A (numerical display): This shows the case when the engine speed is displayed with monitoring code [10].

B (bit display): This shows the case when the S-NET connection status is displayed with monitoring code [08]. 2) To go to the next monitoring code display: Keep time switch (3) pressed and press R.H. working mode switch (5). 3) To go back to the previous monitoring code display: Keep time switch (3) pressed and press L.H. working mode switch (6). 4) To finish with the monitoring code display mode: Keep time switch (3) and heavy lift switch (4) pressed at the same time for at least 2.5 seconds.

20-252

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TROUBLESHOOTING

DISPLAY METHOD AND SPECIAL FUNCTIONS OF MONITOR PANEL

Table 1 of monitoring codes (all codes) ﬂ For details of the code displayed as (6 bit) in the Unit column, see Details of bit pattern code. Monitoring code 01 02

Monitoring data Monitor panel model code Pump controller model code

Unit

Controller

— —

Monitor panel Pump controller

03 08

Engine controller model code S-NET component connection status

— (6 bit)

Engine controller Monitor panel

10 11

Engine speed Front pump discharge pressure input

10 rpm kg/cm2

Pump controller Pump controller

12 13

Rear pump discharge pressure input TVC output current

kg/cm2 10 mA

Pump controller Pump controller

16 20

No. 2 throttle command value Input status 1 of pump controller switch

10 rpm (6 bit)

Pump controller Pump controller

21 22

Input status 2 of pump controller switch Input status 3 of pump controller switch

(6 bit) (6 bit)

Pump controller Pump controller

23 24

Drive status 1 of pump controller solenoid, relay Input status 1 of sensor for pump controller warning monitor

(6 bit) (6 bit)

Pump controller Pump controller

25 26

Input status 2 of sensor for pump controller warning monitor Drive status 2 of pump controller solenoid, relay

(6 bit) (6 bit)

Pump controller Pump controller

27 32

Input status 4 of pump controller switch Battery voltage

(6 bit) 100 mV

Pump controller Pump controller

42 43

Fuel level sensor input voltage Alternator (battery charge) input voltage

10 mV 100 mV

Pump controller Pump controller

44 47

Hydraulic oil temperature sensor input voltage Monitor panel output status 1

10 mV (6 bit)

Pump controller Monitor panel

48 49

Monitor panel input status 1 Monitor panel input status 2

(6 bit) (6 bit)

Monitor panel Monitor panel

4A 4C

Monitor panel input status 3 Monitor panel output status 2

(6 bit) (6 bit)

Monitor panel Monitor panel

50 71

Engine speed Accelerator angle

10 rpm 1%

Engine controller Engine controller

72 73

Fuel injection level command (qfin) Common rail pressure command (qfin)

mm3/st 1 MPa

Engine controller Engine controller

74 75

Fuel injection timing command (tfin) Common rail fuel pressure

0.1 CA 1 MPa

Engine controller Engine controller

76 77

Boost pressure Engine water temperature (high temperature sensor)

1 kPa 1°C

Engine controller Engine controller

78 79

Engine water temperature (low temperature sensor) Fuel temperature

1°C 1°C

Engine controller Engine controller

80 81

Engine control mode Converted torque (load output)

— 1%

Engine controller Engine controller

82 83

Fuel control dial input voltage R.H. fuel injection quantity control switch

10 mV —

Engine controller Engine controller

84 85

L.H. fuel injection quantity control switch Engine controller input status

— (6 bit)

Engine controller Engine controller

C0 C1

Monitor panel program version Pump controller program version

— —

Monitor panel Pump controller

Engine controller program version

—

Engine controller

PC600-6

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TROUBLESHOOTING

DISPLAY METHOD AND SPECIAL FUNCTIONS OF MONITOR PANEL

Table 2 of monitoring codes (details of bit pattern code) ﬂ Bits 1 to 6 in the diagram on the right light up or go out to display the monitoring data.

Monitoring code

20-254

Item

Bit No.

1 2 3 Connection of S-NET components 4 5 6 1 2 Input status 1 of pump controller 3 switch 4 5 6 1 2 Input status 2 of pump controller 3 switch 4 5 6 1 2 Input status 3 of pump controller 3 switch 4 5 6 1 2 Drive status 1 of pump controller 3 solenoid, relay 4 5 6 1 2 Input status 1 of sensor for pump 3 controller monitor 4 5 6

Details (status when bit is lighted up Pump controller: When connected Engine controller: When connected

Swing PPC oil pressure switch: When ON Travel PPC oil pressure switch: When ON Boom RAISE PPC oil pressure switch: When ON Boom LOWER PPC oil pressure switch: When ON Arm IN PPC oil pressure switch: When ON Arm OUT PPC oil pressure switch: When ON Bucket CURL PPC oil pressure switch: When ON Bucket DUMP PPC oil pressure switch: When ON wing lock switch: When ON Service PPC oil pressure switch: When ON Swing holding brake cancel switch: When ON Model selection signal 1: When connected to GND Model selection signal 2: When connected to GND Model selection signal 3: When connected to GND Model selection signal 4: When connected to GND Kerosene mode: When selected Left knob switch: When ON CO cancel solenoid: When ON Bucket CURL Hi cancel solenoid: When ON Swing holding brake solenoid: When ON 2-stage relief solenoid: When ON Travel speed solenoid: When ON Step light switch: When ON Horn switch: When OFF Coolant level sensor: When open (when abnormal) Engine oil level sensor: When open (when abnormal) Hydraulic oil temperature sensor: When open (when abnormal) Air cleaner clogging sensor: When open (when abnormal) PC600-6

TROUBLESHOOTING

Monitoring code

DISPLAY METHOD AND SPECIAL FUNCTIONS OF MONITOR PANEL

Item

Input status 2 of sensor for pump controller warning monitor

Drive status 2 of pump controller solenoid, relay

Input status 4 of pump controller switch

Monitor panel output status 1

Monitor panel input status 1

Monitor panel input status 2

PC600-6

Monitor panel input status 3

Monitor panel output status 2

Bit No.

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

Details (status when bit is lighted up Overload sensor: When OPEN (only when equipped) Automatic greasing controller: When abnormal (only when equipped)

Flashing lamp relay: When driven Step light relay: When driven Auto-deceleration signal: When output Step light power supply retention relay: When driven

Model selection signal 5: When connected to GND

Starting switch C signal: When ON Starting switch ACC signal: When ON

Alarm buzzer: When OFF Wiper motor drive (R): When OFF Wiper motor drive (L): When OFF Window washer drive: When ON Wiper, washer switch ON: When OFF Wiper, washer switch INT: When OFF Wiper, washer switch WASHER: When OFF Window limit switch: When open Limit switch W: When open Limit switch P: When open Starting switch ACC signal: When OFF Starting switch BR signal: When voltage Hi Lamp switch: When ON Preheating switch: When ON Starting switch C signal: When checking ON Time switch: When ON PPC oil pressure selector switch: When OFF Overload selector switch: When OFF Swing lock switch: When OFF Buzzer cancel switch: When OFF Wiper motor normal rotation relay output: When OFF or voltage is abnormal Wiper motor reverse rotation relay output: When OFF or voltage is abnormal Washer motor drive output: When OFF or voltage is abnormal

20-255

TROUBLESHOOTING

Monitoring code

DISPLAY METHOD AND SPECIAL FUNCTIONS OF MONITOR PANEL

Item

Engine controller input status

Bit No.

1 2 3 4 5 6

Details (status when bit is lighted up Starting switch C signal: When ON Auto-deceleration signal: When connected to GND Model selection signal 1: When connected to GND Model selection signal 2: When connected to GND Model selection signal 3: When connected to GND

5. Setting function for reduced cylinder mode operation This is used when setting the engine to reduced cylinder mode operation. fl For details, see TESTING AND ADJUSTING, Reduced cylinder mode operation for engine. With the following operation, the engine speed can be displayed on time display (1) of the monitor panel and the cylinder number can be displayed on service meter display (2). fl The engine speed is displayed in units of 10 rpm. fl It is possible to set the reduced cylinder mode operation for a single cylinder or multiple cylinders. 1) To switch to reduced cylinder mode operation: Keep time switch (3), R.H. travel speed switch (4), and R.H. working mode switch (5) pressed at the same time for at least 2.5 seconds. 2) To select the cylinder to set or cancel for reduced cylinder mode operation: Keep time mode switch (3) pressed and press R.H. working mode switch (5) or L.H. working mode switch (6). 3) To set or cancel reduced cylinder mode operation: Keep time switch (3) pressed and press heavy lift switch (7). 4) To finish reduced cylinder mode operation: Keep time switch (3), R.H. travel speed switch (4), and R.H. working mode switch (5) pressed at the same time for at least 2.5 seconds.

20-256

PC600-6

TROUBLESHOOTING

DISPLAY METHOD AND SPECIAL FUNCTIONS OF MONITOR PANEL

6. Setting function for working mode default The working mode on the monitor panel is set so that the H mode normally lights up when the starting switch is turned ON. If the function for setting the default is used as follows, it is possible to change the setting so that the system starts with the working mode desired by the operator. 1) To switch to the default setting mode: Keep time switch (1) and R.H. working mode switch (2) pressed at the same time for at least 2.5 seconds. ﬂ When it enters the default setting mode, the working mode LED flashes. 2) To change the setting of the working mode default: Press L.H. working mode switch (3) or R.H. working mode switch (2) to make the LED of the desired working mode flash. 3) To finish using the default setting mode: Keep time switch (1) and R.H. working mode switch (2) pressed at the same time for at least 2.5 seconds. 4) To checking after changing working mode default setting: Turn the starting switch OFF, then turn it ON again and check the LED of the working mode switch.

PC600-6

20-257

TROUBLESHOOTING

DISPLAY METHOD AND SPECIAL FUNCTIONS OF MONITOR PANEL

7. Setting function for oil maintenance display On machines equipped with the oil maintenance function, the oil maintenance display is given from 10 hours before the set oil change time until it is reset. Oil maintenance lamp (1) lights up for 20 seconds after the starting switch is turned ON, the elapsed time is displayed on service meter display (2), and then the telephone number is displayed on time display (3) and service meter display (2). With the oil maintenance function, it is possible to set, change, or cancel the display, or to set, change, or cancel the telephone number. Example: When the oil change interval is set to 250 hours, the following are displayed. • Time elapsed after oil change: 245 hours • Telephone number: 0123456789 fl Nothing is displayed until the elapsed time reaches 10 hours before the change interval. To check the elapsed time in this condition, keep buzzer cancel switch (4) pressed and turn the starting switch ON. The elapsed time is displayed for 10 seconds. fl The telephone number is not displayed if no telephone number has been set. fl If the telephone number has been set, when the starting switch is turned ON, the elapsed time is displayed for 10 seconds, and then the telephone number is displayed for 10 seconds. After that, the display switches to the normal display. If no telephone number has been set, the elapsed time is displayed for 20 seconds after the starting switch is turned on, and the display then switches to the normal display. 1) To set the interval: i) Keep time switch (5) and switch I (6) pressed at the same time for at least 2.5 seconds to switch to the interval setting mode. ii) Press buzzer cancel switch (4) to set the time for the interval. Example: When interval 250 hours is selected iii) Keep time switch (5) and switch I (6) pressed at the same time for at least 2.5 seconds to finish the interval setting mode.

20-258

PC600-6

TROUBLESHOOTING

DISPLAY METHOD AND SPECIAL FUNCTIONS OF MONITOR PANEL

fl Interval display - - -h: Default mode (oil maintenance function not set) 125h: Interval is set for every 125 hours 250h: Interval is set for every 250 hours 500h: Interval is set for every 500 hours dh: Demo mode is set ª If the demo mode is used, a demonstration of the oil maintenance function can be carried out when the machine is delivered. The following functions can be carried out in the demo mode. 1 Elapsed time display (this is for demonstration purposes only, so the elapsed time is fixed at 240h) 2 Telephone number display (the telephone number must be input before using the demo) 3 Resetting elapsed time After setting to the demo mode, turn the starting switch OFF, and then turn it ON again to start the demonstration. After setting the demo mode, it can be carried out four times. After that, it is automatically canceled. 2) Resetting elapsed time after changing oil Press buzzer cancel switch (4) and keep it depressed for 3 seconds while the monitor panel is displaying the oil maintenance. The elapsed time will be reset and the display will show [Elapsed time: 0h] for 1 second. 3) To set or correct telephone number: i) Keep time switch (5) and auto-deceleration switch (7) pressed at the same time for at least 2.5 seconds to switch to the telephone number mode. ii) Press time switch (5) and L.H. working mode switch (8) or R.H. working mode switch (9) to select the number to be set or corrected. fl Two digits are chosen at the same time for the number. fl When the display of the telephone number is canceled, all numbers are set to [0]. iii) Press time switch (5) and L.H. travel speed switch (10) and select the numbers on the left. iv) Press time switch (5) and R.H. travel speed switch (11) and select the numbers on the right. v) Keep time switch (5) and auto-deceleration switch (7) pressed at the same time for at least 2.5 seconds to finish the telephone number mode. PC600-6

20-259

TROUBLESHOOTING

DISPLAY METHOD AND SPECIAL FUNCTIONS OF MONITOR PANEL

8. Adjustment function for time display When setting the time on the time display, do as follows. 1) When correcting time manually: i) Keep time switch (1) pressed for at least 2.5 seconds to switch to the time adjustment mode. ii) Press L.H. working mode switch (H) (2) to adjust the hours; press R.H. working mode switch (M) (3) to adjust the minutes. ﬂ If the switch is kept pressed for at least 2.5 seconds, the numbers advance rapidly. iii) Keep time switch (1) pressed for at least 2.5 seconds to finish the time adjustment mode. 2) When correcting the hour according to time signal: i) Keep time switch (1) pressed for at least 2.5 seconds to switch to the time adjustment mode. ii) Press L.H. working mode switch (H) (2) to adjust the hours; press R.H. working mode switch (M) (3) to adjust the minutes to prepare to set according to the time signal. ﬂ When setting according to the time signal, if the minute display is 14 minutes or less, the time will return to 0 minutes; if the minute display is 45 minutes or more, the time will advance to 0 minutes and the hour will advance by 1. When preparing to set according to the time signal, set the minute display either to less than 14 or more than 45. iii) When the time signal sounds, press heavy lift switch (4). iv) Keep time switch (1) pressed for at least 2.5 seconds to finish the time adjustment mode.

20-260

PC600-6

TROUBLESHOOTING

METHOD OF USING JUDGEMENT TABLE

METHOD OF USING JUDGEMENT TABLE This judgement table is a tool to determine if the problem with the machine is caused by an abnormality in the electrical system or by an abnormality in the hydraulic or mechanical system. The symptoms are then used to decide which troubleshooting table (E–fifi, S–fifi, C–fifi, F–fifi, H–fifi, M–fifi) matches the symptoms. The judgement table is designed so that it is easy to determine from the user code and service code which troubleshooting table to go to. fl The abnormality display (warning) given by the monitor panel leads directly to troubleshooting of the machine monitor (M–fifi). (See troubleshooting of the machine monitor system) 1. When using judgement table for engine controller and engine related parts • If a service code is displayed on the monitor panel, go to the troubleshooting code at the bottom of the judgement table (E–fifi). (A ● mark is put at the places where the failure mode and service code match.) • If a problem has appeared but no service code is displayed on the monitor panel, go to the point where the failure mode matches the troubleshooting code on the right of the judgement table (E–fifi or S–fifi). <Example> Failure mode “Engine does not start”. Procedure: Check if the service code is being displayed on the monitor panel. Short circuit in No. 1, No. 2, No. 3 fuel injector system

Short circuit in No. 4, No. 5, No. 6 fuel injector system

User code

E11 E11 — E10 E10 E11 — E11 E14 E15 E15 E11

E11 E11 E11 E11 E11 E11 E11 E11 E11 E11 E11 E11 E11 E15 — E0E E10 E15 — E15 E10 E10 E10 E10 E11 E11 E10 E11 E10 E11 E10 E10 E10 E10 E10 E10 E10 E10 E10

Service code

108 91B 91C 920 922 924 931 934 936 93C

93d 954 955 956 957 95A 96A 970 971 974 975 977 979 97A 97b 97C 97d 980 981 982 983 984 985 986 98A 98b

Does starting motor turn?

Disconnection in No. 6 fuel injector system

Disconnection in No. 3 fuel injector system

Disconnection in No. 4 fuel injector system

Disconnection in No. 5 fuel injector system

Abnormality in controller

Disconnection in No. 1 fuel injector system

Disconnection in No. 2 fuel injector system

Supply pump non-force feed abnormality 2

Abnormality in common rail fuel pressure

Common rail fuel high-pressure abnormality 1

Common rail fuel high-pressure abnormality 2

Supply pump non-force feed abnormality 1

Disconnection in fuel supply pump PCV1 system

Abnormality in common rail fuel pressure sensor system

Abnormality in engine water temperature (low- temperature) sensor system

Overcurrent in fuel supply pump PCV1 system

Overcurrent in fuel supply pump PCV2 system

Power source system abnormality 1

Power source system abnormality 2

Abnormality in fuel injection quantity control switch signal

Abnormality in fuel temperature sensor system

Short circuit in starting switch C signal system

Abnormality in network system

Abnormality in engine water temperature (high- temperature) sensor system

Abnormality in engine oil pressure switch system

Abnormality in boost pressure sensor system

Drop in engine oil pressure

Abnormality in fuel control dial system

Abnormality in engine G rotation sensor system

Abnormality in machine model selection system

Overrun

Overheat

Self-diagnostic display

Troubleshooting code when no service code is displayed

Failure mode

No. 1 Engine does not start

‡ ‡‡

‡ ‡ ‡

Starting ability Exhaust gas is emitted but engine does not start, or is difficult to start is poor No exhaust gas is emitted

Engine stops during operation

Lack of engine output

Acceleration is poor Engine speed stays at Exhaust gas is normal low idling, and does not follow fuel control dial Exhaust gas is extremely black

Abnormality in engine Ne rotation sensor system

Self-diagnostic display

Disconnection in fuel supply pump PCV2 system

RELATED PARTS

Accelerates at high idling

Accelerated at same time as abnormality display was given

Low idling does not work according to operation

Does not switch to low idling

‡ ‡ ‡

‡ ‡ ‡ ‡

‡ ‡‡‡ ‡

‡ ‡ ‡ ‡ ‡

‡ ‡

‡ ‡‡‡ ‡ ‡‡‡ ‡ ‡‡‡ ‡ ‡‡‡

‡ ‡‡ ‡ ‡ ‡ ‡

‡ ‡ ‡ ‡‡ ‡ ‡‡ ‡ ‡‡ ‡

See engine volume

‡ ‡‡‡ ‡ ‡‡ ‡

See engine volume See engine volume

‡ ‡‡‡ ‡ ‡‡ ‡ See engine volume

Accelerated after abnormality display was given Does not switch to high idling

‡ ‡

‡ ‡ ‡

‡

See engine volume

Exhaust gas is normal

Fuel consumption is excessive Exhaust gas is extremely black High idling does not Does not rise to high idling work according to Switches to high idling but returns to low idling operation Warming-up operation is defective

Auto-deceleration does not work

Engine speed does not change even when working mode is switched

Engine does Engine remains accelerated not stop Remains at low idling even when starting switch is turned OFF

See engine volume

There is hunting of engine (low idling speed is irregular)

See engine volume

Oil consumption is excessive, or exhaust gas is blue

See engine volume

Oil becomes dirty prematurely

Oil is mixed in coolant

Engine oil pressure caution lamp lights up

Oil level rises

Coolant temperature rises too high

Abnormal noise is generated

There is excessive vibration

9 10

‡ ‡

‡

‡ ‡‡‡ ‡ ‡‡ ‡ ‡

‡

See engine volume See engine volume

‡

See engine volume See engine volume

‡

See engine volume

‡ ‡‡‡ ‡ ‡‡ ‡ ‡ ‡‡‡ ‡ ‡‡ ‡ Troubleshooting M-00 E-1 E-2 E-3 E-4 E-5 E-6 E-7 E-8 E-9 code

E-10 E-11 E-12 E-13 E-14 E-15 E-16 E-17 E-18 E-19 E-20 E-21 E-22 E-22 E-23 E-23 E-24 E-25 E-26 E-27 E-28 E-29 E-30 E-31 E-32 E-33

[Judgement] 1) If a service code is being displayed on the monitor panel...... go to troubleshooting [E9:ﬁﬁ] for the engine controller. 2) If no service code is displayed on the monitor panel, and the engine does not start: •

Check that starting motor rotates

Starting motor rotates .................. Go to troubleshooting S-2 of mechanical system Starting motor does not rotate .... Go to troubleshooting E-8 of electrical system

PC600-6

20-261

TROUBLESHOOTING

METHOD OF USING JUDGEMENT TABLE

2. When using judgement table for pump controller and hydraulic related parts • If a service code is displayed on the monitor panel, go to the troubleshooting code at the bottom of the judgement table (C–fifi). (A ● mark is put at the places where the failure mode and service code match.) • If a problem has appeared but no service code is displayed on the monitor panel, go to the point where the failure mode matches the input signal, and check the display for the input signal (the display at the place with a fi mark). • If it is displayed normally, go to the troubleshooting code on the right of the judgement table (H–fifi). • If the input signal is not displayed on the monitor panel, go to the troubleshooting code at the bottom of the judgement table (F–fifi). <Example> Failure mode “Upper structure does not swing”. Procedure: Check if the service code is being displayed on the monitor panel.

ﬂ If service code E218 (abnormality in network system) is displayed, go to troubleshooting for N mode.

Work equipment

224 225 226 227 ●

●

Front pump discharge pressure input

TVC current output

H-1

Rear pump discharge pressure input

Monitoring code 02 10 11 12 13 ª ª ª ª

Model code

Travel speed (6)

●

Engine speed input

Bucket CURL Hi cancel (4)

Swing holding brake (3)

Bit pattern 21 22

2-stage relief (5)

Bucket DUMP (2)

Kerosene mode (5)

Knob switch (6)

CO cancel (1)

Arm IN (5)

Arm OUT (6)

Swing (1)

Travel (2)

Boom LOWER (3)

Boom RAISE (4)

—

● ● ●

Solenoid drive condition

Pressure switch

Abnormality in engine speed sensor system

Abnormality in front pump pressure sensor system

Abnormality in rear pump pressure sensor system

Short circuit in bucket CURL Hi cancel solenoid system

Model selection input error

Disconnection in bucket CURL Hi cancel solenoid system

Disconnection in 2-stage relief solenoid system

Short circuit in travel speed solenoid system

E03

Disconnection in travel speed solenoid system

Short circuit in swing holding brake solenoid system

Short circuit in 2-stage relief solenoid system

Disconnection in swing holding brake solenoid system

Short circuit in CO cancel solenoid system

—

Service code OFF 232 233 201 211 203 213 204 214 206 216 311 312 217 ▲ ▲ ●

There is excessive drop in engine speed, or engine stalls

Machine push-up solenoid

LED E02

Disconnection in CO cancel solenoid system

Short circuit in TVC solenoid system

Disconnection in TVC solenoid system

Abnormality in controller power source

User code

Speeds of all work equipment, swing, travel are slow or lack power

Check items in monitoring mode

Troubleshooting code if no service code is displayed

All work equipment, travel, swing

Failure mode

Abnormality in pressure sensor power source system

Pump controller (E2:XX system) Self-diagnostic display

Self-diagnostic display

Bucket CURL (1)

Pump controller (E2:XX system)

H-3

Abnormal noise generated (around pump) Auto-deceleration does not work

H-4

●

fi fi fi fi fi fi fi fi

H-5

● ●

Fine control ability is poor or response is poor Boom is slow or lacks power

● ●

Arm is slow or lacks power

● ●

Bucket is slow or lacks power

● ●

H-6

ﬁ ﬁ

● ●

fi fi fi fi

ª ª

H-7

ª ª

H-8

ª ª

H-9

Boom does not move Arm does not move

H-10

Bucket does not move Excessive hydraulic drift

H-8

ﬁ

Excessive time lag (engine at low idling)

ﬁ

H-9

ﬁ

Machine push-up function does not work

Travel system

H-2

No work equipment, travel, swing move

In compound operations with swing, work equipment speed is slow

H-11

In compound operations with bucket, swing and work equipment speeds are slow

H-12

In compound operations, speed drops excessively

H-13

Travel deviation

Deviation is excessive during normal travel

H-14

Deviation is excessive when starting Travel speed is slow Travel speed does not switch or is faster than set speed

H-15

● ●

ﬁ ﬁ

● ●

●

● ●

● ● ● ●

H-16 ª

ª ª ª

H-17

Does not move (one side only) Does not swing

H-18

ﬁ

● ●

Both left and right

ﬁ

H-19

One direction only Swing system

C-19 H-10

Swing acceleration is poor

Both left and right

or swing speed is slow

One direction only

Excessive overrun when

Both left and right

H-20 H-21

stopping swing

One direction only Excessive shock when stopping swing (one direction only)

H-22

Excessive abnormal noise when stopping swing Excessive hydraulic

H-23

When swing holding brake is released ª

drift of swing

When swing holding brake is applied Troubleshooting code when service code is displayed Troubleshooting code when there is abnormality in monitoring code check

C-1 C-2 C-3 C-4 C-5 C-6 C-7 C-8 C-9 C-10 C-11 C-12 C-13 C-14

C-15 C-16 C-17 C-18 –

–

ª ª ª ª ª ª –

–

H-24

ª – – –

–

– F-1 F-2 F-3 F-4 F-5 F-6 F-7 F-8 F-9 F-11 – – –

– –

–

▲ :This shows applicable item for service code (simultaneous abnormality at front or rear)

‡ :This shows applicable item for service code ª :This shows item that needs only checking with monitoring

ﬁ :This shows item to check with monitoring or machine monitor

[Judgement] 1) If a service code is being displayed on the monitor panel...... go to troubleshooting [E2:fifi, E3:fifi] for the pump controller. 2) If no service code is displayed on the monitor panel, and the upper structure does not swing: . •

Check pump controller input signal (Check in monitoring mode)

20-262

There is a signal .... Go to troubleshooting H-25 of mechanical system There is no signal . Go to troubleshooting F–ﬁﬁ of pump controller input signal system (F mode for applicable system)

PC600-6

TROUBLESHOOTING

METHOD OF USING TROUBLESHOOTING CHARTS

METHOD OF USING TROUBLESHOOTING CHARTS 1. Category of troubleshooting code number Troubleshooting Code No.

Component

Service code

N-

Troubleshooting of communication abnormality system

E218

E-

Troubleshooting of electrical system for engine controller

E9-

group

Troubleshooting of electrical system for pump controller (pump control system)

E2-

group

C-

E3-

group

F-

Troubleshooting of pump controller (input signal system)

—

H-

Troubleshooting of hydraulic, mechanical system

—

M-

Troubleshooting of machine monitor

PC600-6

E1-

group

20-263

TROUBLESHOOTING

METHOD OF USING TROUBLESHOOTING CHARTS

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

20-264

PC600-6

TROUBLESHOOTING

METHOD OF USING TROUBLESHOOTING CHARTS

<Example> (1) M-8 When starting switch is turned ON (engine stopped), standard check item flashes (4) fl Before carrying out troubleshooting, check that all the related connectors are properly inserted. fl Always connect any disconnected connectors before going on the next step. fl Check that the coolant is at the specified level before carrying out troubleshooting (2) a)

(engine oil level) flashes

Divided into section a)

SAP00523

(3)

Cause

YES

Defective coolant level sensor system (see M-26)

Remedy

—

1 4 YES Defective engine throttle

Does display go out when short connector is connected to P08 (female)? Is continuity

• Disconnect P08. • Turn starting

YES between C16

• Turn starting

• Set to monitoring

switch ON. Is there continuity between P08 NO (female) (2) and chassis? • Turn starting

switch OFF. • Disconnect P08.

(female ) (8) and chassis as shown in table?

• Turn starting

switch ON. code 24.

NO switch OFF. • Disconnect C16, P08. disconnect short • Connect connector to P08 (female). NO

& pump controller

Replace

Defective monitor panel

Replace

Defective contact, or disconnection in wiring harness between C16 (female) (8) – P08 (female) (1)

Repair or replace

YES Is bit (3) of monitoring code 3 24 lighted up?

Defective contact, or disconnection in wiring harness between P08 (female) (2) – chassis ground

Repair or replace

Table Short connector

Continuity

Connected

Yes

Disconnected

PC600-6

20-265

TROUBLESHOOTING

•

DETAILS OF TROUBLESHOOTING AND TROUBLESHOOTING PROCEDURE

Governor control system 1. Check input signal 1) Check fuel control dial input voltage i) Set to the monitoring mode, and display monitoring code 30. ii) Measure the voltage when the fuel control dial is turned from low idling to high idling. fl Voltage: 0.25 – 4.75 V 2) Check governor potentiometer voltage i) Set to the monitoring mode, and display monitoring code 31. ii) Measure the potentiometer voltage when the fuel control dial is turned from low idling to high idling. fl Voltage: 0.5 – 2.3 V 2. Check output signal 1) Check governor motor drive current i) Set to the monitoring mode, and display monitoring codes 33 and 34. fl Code 33 is the A phase (engine speed acceleration direction) and code 34 is the B phase (engine speed deceleration direction) ii) Measure the governor motor drive current when the fuel control dial is turned in the acceleration direction and deceleration direction. fl Current: 700 ± 70 (mA) 2) Measure battery relay drive output voltage i) Set to the monitoring mode, and display monitoring code 35. ii) Measure the battery relay drive output voltage when the starting switch is turned from ON to OFF. or iii) Set to the monitoring mode, and display monitoring code 37. iv) Check that bit (1) lights up when the starting switch is turned from ON to OFF.

PC600-6

20-267

TROUBLESHOOTING

DETAILS OF TROUBLESHOOTING AND TROUBLESHOOTING PROCEDURE

DETAILS OF TROUBLESHOOTING AND TROUBLESHOOTING PROCEDURE If any abnormality should occur, it is necessary to go to the correct troubleshooting chart in accordance with the judgement table for that type of failure (engine controller and pump controller). For details of the troubleshooting and troubleshooting procedure, refer to this flow chart. When carrying out troubleshooting, ask the operator as much as possible about the condition of the machine, and check the following items before starting. (1) Condition of controller connection (check with monitoring codes [01] – [08]) (2) Blown fuses (3) Battery voltage (monitoring mode [32]) (4) Electricity generation (charge input) voltage (monitoring code [43]) The procedure for carrying out check items No. 3 and 4 in the flow chart below is given on the following pages.

YES

E02 (TVC system) E10 (Engine stop system) E15 (Engine system) E03 (Swing brake system) E11 (Engine control system) E0E (Network system) E14 (Fuel dial system)

YES

Is user code displayed on monitor panel?

E100 group: Monitor panel system (M mode) E200 group: Pump controller system (C mode) E300 group: Pump controller system (C mode) E400 group: Engine controller system (E mode)

Go to Item 2

Carry out troubleshooting in applicable mode (Note: For E117, E118, E218, carry out troubleshooting of the communication abnormality system (N mode).) 6 YES Carry out

Engine system 5

Is problem in

YES engine system

Is service code displayed on NO monitor panel?

of hydraulic (mechanical) system?

• Operate and

Are pump

check service code.

YES controller input and output signals normal?

20-268

}

• Check using monitoring code.

troubleshooting for engine

Carry out troubleshooting for engine electrical system. NO • Go to flow chart for (Use flow chart for section where there is items where there is no abnormality display no display) on judgment table.

Carry out • After adjusting Hydraulic oil pressure, (mechanical) troubleshooting for hydraulic (mechanical) judge from system system engine speed. • Is all work equipment slow and does engine speed drop under heavy load?

Are monitor codes 02, 03, 08 normal?

• Check connection condition of S-NET in monitoring codes 02, 03, 08.

Carry out troubleshooting for communication abnormality system (N comde).

Is engine electrical system for which there is no failure code display normal?

Carry out troubleshooting for input signal system (F mode).

PC600-6

TROUBLESHOOTING

DETAILS OF TROUBLESHOOTING AND TROUBLESHOOTING PROCEDURE

If there is no abnormality display in the communications system transmitted by S-NET, it can be taken that the output signal from the monitor panel has been transmitted. However, even if there is no abnormality display, if the operation is defective, use the following procedure when checking directly. If any abnormality occurs in the S-NET system, the system is automatically switched to the following default mode, so be careful when carrying out troubleshooting. Defaults when communications cannot be carried out for the monitor panel and engine controller and pump controller Set mode 1 2 3 4 5 6 7

Working mode Throttle signal Auto-deceleration Coolant temperature signal Heavy lift Travel speed Automatic warming up

Pump controller

Engine controller

G mode FULL ON (deceleration mode) OFF OFF Lo —

DH mode FULL ON (deceleration mode) — — — ON (automatic warming-up mode)

1. Procedure for checking monitor panel output signal ﬂ For details of operating the monitoring mode, see MONITOR PANEL DISPLAY AND SPECIAL FUNCTIONS. 1. Connection status of components 1) Set to the monitoring mode and display monitoring code [08]. 2) The time display (bits) will light up to display the components that are connected. ﬂ Engine controller (3) and pump controller (1) will light up. 2. Checking working mode signal {check No. 2 throttle signal (monitoring code [16]) at the same time} 1) Set to the monitoring mode and display monitoring code [16]. 2) Switch the working mode as shown in Table 1 and check that the engine speed changes. Table 1

PC600-6

Working mode

High idling speed (rpm) [The figures in ( ) are the rated speed]

Approx. 2000 <during operation> (1800) Approx. 1750 <idling>

Approx. 1900 (1620)

Approx. 1700 (1550)

20-269

TROUBLESHOOTING

DETAILS OF TROUBLESHOOTING AND TROUBLESHOOTING PROCEDURE

3. Checking travel speed selection signal 1) Set to the monitoring mode and display monitoring code [23]. 2) Change the speed selector switch to Hi or Mi and run the engine at 1400 rpm or above. Check that bit (6) lights up when traveling at Hi or Mi (front or rear pump oil pressure: 22.56 – 31.78 MPa {230 – 325 kg/cm2}) 2. Checking input signal of pump controller fl Check the input signals for controller as follows. 1. Checking input signal 1) Check oil pressure switch i) Set to the monitoring mode, and display monitoring codes [20] and [21]. ii) Operate each work equipment lever, and check how the bit pattern lights up. fl For details of the bit pattern chart, see MONITOR PANEL DISPLAY AND SPECIAL FUNCTIONS. 2) Check speed sensor (check engine speed) i) Set to the monitoring mode, and display monitoring code [10]. ii) Use the fuel control dial to change the speed, and measure the speed when this is done. 3) Check pump discharge pressure sensor i) Set to the monitoring mode, and display monitoring codes [11] and [12]. fl Code [11] is for the front pump and code [12] is for the rear pump. ii) Measure the oil pressure at the front or rear pump. 4) Check knob switch input signal i) Set to the monitoring mode, and display monitoring code [22]. ii) Turn the knob switch ON and check that bit (6) lights up.

20-270

PC600-6

TROUBLESHOOTING

DETAILS OF TROUBLESHOOTING AND TROUBLESHOOTING PROCEDURE

2. Check output signals 1) No. 2 throttle signal i) Set to the monitoring mode, and display monitoring code [16]. ii) Use the procedure in Item 2 for checking the monitor panel output signals, and measure the engine speed. 2) Checking ON ↔ OFF solenoid status i) Set to the monitoring mode, and display monitoring code [23]. ii) Refer to Table 3 and check that the applicable bit lights up.

Table 3 Types of solenoid and conditions for actuation Name of solenoid

Actuation condition

Bit that lights up

CO cancel

Travel lever operated (ON)

Swing holding brake

Swing or work equipment lever operated

Bucket CURL Hi cancel

Bucket CURL Hi operated independently

Travel speed selector

Travel speed selector switch at Hi or Mi

2-stage relief

Travel lever operated (ON)

ﬂ Operate the lever slightly (not enough to move the machine). 3) Check TV solenoid output current i) Set to the monitoring mode, and display monitoring code [13]. ii) With the starting switch kept at the ON position (G mode), measure the current when the fuel control dial is turned to the MAX position. • Current with starting switch ON (G mode) and fuel control dial at MAX : 600 ± 80 (mA)

3. Checking input signal of engine controller 1. Check input signal 1) Check fuel control dial input voltage i) Set to the monitoring mode, and display monitoring code [82]. ii) Measure the voltage when the fuel control dial is turned from low idling to high idling. ﬂ Voltage: 0.25 – 4.75 V

PC600-6

20-271

TROUBLESHOOTING OF COMMUNICATION ABNORMALITY SYSTEM (N MODE)

Action taken by controller when abnormality occurs and problems on machine ......................... 20-302 Electrical circuit diagram of N Mode system ...................................................................................... 20-304 N-1

[E117, 118 occur at same time] Monitor panel communication abnormality ................... 20-305

N-2

[E117, 218 occur at same time] Engine controller communication abnormality .............. 20-307

N-3

[E118, 955 occur at same time] Pump controller communication abnormality ................ 20-309

PC600-6

20-301

ACTION TAKEN BY CONTROLLER WHEN ABNORMALITY OCCURS AND PROBLEMS ON MACHINE

TROUBLESHOOTING

ACTION TAKEN BY CONTROLLER WHEN ABNORMALITY OCCURS AND PROBLEMS ON MACHINE User code

Service code

Abnormal system

Nature of abnormality

S-NET communication error with engine controller

• When problem occurs at same time as E118 1. Disconnection, defective contact of monitor panel SNET 2. Wiring harness of monitor panel S-NET short circuiting with chassis ground 3. Defective monitor panel • When problem occurs at same time as E218 1. Disconnection, defective contact in wiring harness of engine controller S-NET 2. Wiring harness of engine controller S-NET short circuiting with chassis ground 3. Defective engine controller

E118

S-NET communication error with pump controller

• When problem occurs at same time as E117: Same as E117 above • When problem occurs at same time as E955 1. Disconnection, defective contact in wiring harness of pump controller S-NET 2. Wiring harness of pump controller S-NET short circuiting with chassis ground 3. Defective pump controller

E218

Pump controller S-NET response overtime error

E955

Abnormality in engine controller S-NET system

E117

E0E

—

E0E

20-302

• When problem occurs at same time as E117: Same as E117 above

• When problem occurs at same time as E118: Same as E118 above

PC600-6

TROUBLESHOOTING

Condition when normal (voltage, current, resistance)

PC600-6

ACTION TAKEN BY CONTROLLER WHEN ABNORMALITY OCCURS AND PROBLEMS ON MACHINE

Action by controller when Problem that appears on machine abnormality is detected when there is abnormality 1. Working mode becomes G Mode. 2. Displays user code E0E on monitor panel.

1. Operation is carried out in G Mode. 2. Lacks power or speed is slow.

1. Working mode becomes G Mode. 2. Displays user code E0E on monitor panel.

1. Operation is carried out in G Mode. 2. Lacks power or speed is slow.

1. Working mode becomes G Mode.

1. Operation is carried out in G Mode. 2. Lacks power or speed is slow.

1. Working mode becomes G Mode.

1. Operation is carried out in G Mode. 2. Lacks power or speed is slow.

20-303

TROUBLESHOOTING

ELECTRICAL CIRCUIT DIAGRAM OF N MODE SYSTEM

20-304

PC600-6

TROUBLESHOOTING

N-1

N-1 [E117, E118 occur at same time] Monitor panel communication abnormality fl This troubleshooting is carried out when there is still an abnormality, so when disconnecting the connector and inserting the T-adapter, or when removing the T-adapter and returning the connector to its original position, if the service code E is not displayed, the problem has been removed. fl If the starting switch was turned off after the abnormality occurred, turn the starting switch on and check that the service code displays E. (If it is not displayed, the problem has been removed.) fl Before carrying out troubleshooting, check that all the related connectors are properly inserted. fl Always connect any disconnected connectors before going on the next step. Cause

YES

Is resistance between YES P01 (female) (4) (11) and (14), or between 3 (4) (11) and chassis When E12 and C17 normal? YES are disconnected, do NO • Disconnect P01, bits (1), (2), (3), and C17, and E12. (4) light up in • Turn starting switch OFF. monitoring code [08]? • Min. 1 MΩ.

Is monitoring code [02], [03] display normal? • Disconnect P01 and connect again. • Turn starting switch ON. • See Table 1.

Has been reset

4 YES

2 Do bits (1) and (3) light up in NO monitoring code [08]? • Turn starting switch ON. • See Table 2.

Remedy

• Turn starting switch ON. • See Table 2.

5 Is voltage between E12 (female) (8)(18) and chassis, and between NO C17 (female) (4) (12) and chassis normal?

• Disconnect E12 and C17. • Turn starting switch ON. • Min. 7.5 V

YES

6 YES

Is resistance between P01(4) and C17 (female) (4), and between P01 NO (female) (11) and E12 (female) (18) normal?

• Disconnect P01, NO E12 and C17. • Turn starting switch OFF. • Max. 1Ω.

Defective monitor panel

Replace

Short circuit in wiring harness at side where resistance is not normal, or short circuit with ground connection

Repair or replace

Defective pump controller, engine controller

Replace

Defective controller at side where bit does not light up in Item 2

Replace

Defective monitor panel

Replace

Defective contact or disconnection in wiring harness at side where resistance is not normal

Repair or replace

Table 1 Monitoring code 02

Pump controller model code

Engine controller model code

Display

ﬂ If the controllers are not connected to the network, “– – –” is displayed. If the correct alphanumerics are not displayed or another model is displayed, the model selection signal of the controllers is abnormal.

PC600-6

20-305

TROUBLESHOOTING

N-1

Table 2 Monitoring code

Display

Network connection condition

• Bits light up when network is connected (12: Pump controller, 34: Engine controller) ﬂ Checks for disconnection in the network system can be carried out with this monitoring code. The display does not change when there is a short circuit with the ground. (The normal display is given.)

N-1 Related electrical circuit diagram

20-306

PC600-6

TROUBLESHOOTING

N-2

N-2 [E117, E218 occur at same time] Engine controller communication abnormality fl This troubleshooting is carried out when there is still an abnormality, so when disconnecting the connector and inserting the T-adapter, or when removing the T-adapter and returning the connector to its original position, if the service code E is no displayed, the problem has been removed. fl If the starting switch was turned off after the abnormality occurred, turn the starting switch on and check that the service code displays E. (If it is not displayed, the problem has been removed.) fl Before carrying out troubleshooting, check that all the related connectors are properly inserted. fl Always connect any disconnected connectors before going on the next step. Cause

YES

Has been reset

4 YES

1 Is monitoring code [03] display normal? • Disconnect E16 and M94 and connect again. • Turn starting switch ON. • See Table 1.

When E12 is

Is resistance between YES E12 (female) (8) (18) and (10), or between 3 (8) (18) and chassis normal?

YES disconnected, do bits (3) light up in monitoring code [08]?

2 Do bits (3) light NO up in monitoring code [08]? • Turn starting switch ON. • See Table 2.

Remedy

• Turn starting switch ON. • See Table 2.

NO • Disconnect P01, C17, and E12. • Turn starting switch OFF. • Min. 1 MΩ. NO

5 Is voltage between E12 (female) (8)(18) and chassis NO normal?

YES

Replace

Short circuit in wiring harness at side where resistance is not normal, or short circuit with ground connection

Repair or replace

Defective engine controller

Replace

Defective engine controller

Replace

6 YES Defective monitor panel

Is resistance between E12 (female) (8) – C17 • Disconnect E12. (female) (12), E12 • Turn starting NO (female) (18) – P01 switch ON. (female) (11) normal?

• Min. 7.5 V

Defective monitor panel

• Disconnect P01, NO E12, and C17. • Turn starting switch OFF. • Max. 1Ω

and pump controller

Replace

Defective contact or disconnection in wiring harness at side where resistance is not normal

Repair or replace

Table 1 Monitoring code

Display

Engine controller model code

PC600-6

20-307

TROUBLESHOOTING

N-2

Table 2 Monitoring code

Display

Network connection condition

• Bits light up when network is connected (34: Engine controller) ﬂ Checks for disconnection in the network system can be carried out with this monitoring code. The display does not change when there is a short circuit with the ground. (The normal display is given.)

N-2 Related electrical circuit diagram

20-308

PC600-6

TROUBLESHOOTING

N-3

N-3 [E118, E955 occur at same time] Pump controller communication abnormality fl This troubleshooting is carried out when there is still an abnormality, so when disconnecting the connector and inserting the T-adapter, or when removing the T-adapter and returning the connector to its original position, if the service code E is not displayed, the problem has been removed. fl If the starting switch was turned off after the abnormality occurred, turn the starting switch on and check that the service code displays E. (If it is not displayed, the problem has been removed.) fl Before carrying out troubleshooting, check that all the related connectors are properly inserted. fl Always connect any disconnected connectors before going on the next step. Cause

YES

Has been reset

4 YES

Is resistance

YES between C17 (female) (4) (12) and 3

Is monitoring code [02] display normal?

YES • Disconnect C17 and connect again. • Turn starting switch ON. • See Table 1.

2 Do bits (1) light NO up in monitoring code [08]?

When C17 is disconnected, do bits (1) light up in monitoring code [08]?

• Turn starting switch ON. • See Table 2.

chassis normal?

NO • Disconnect P01, C17, and E12. • Turn starting switch OFF. • Min. 1 MΩ. NO

5 • Turn starting switch ON. • See Table 2.

Remedy

Is voltage between C17 (female) (4)(12) NO and chassis normal?

YES

Replace

Short circuit in wiring harness at side where resistance is not normal

Repair or replace

Defective pump controller

Replace

Defective pump controller

Replace

6 YES Defective monitor panel

Is resistance between C17 (female) (4) – P01 • Disconnect C17. (female) (4), C17 (female) • Turn starting NO (12) – E12 (female) (8) switch ON. normal?

• Min. 7.5 V

Defective monitor panel

• Disconnect P01, NO E12, and C17. • Turn starting switch OFF. • Max. 1Ω

and pump controller

Replace

Defective contact or disconnection in wiring harness at side where resistance is not normal

Repair or replace

Table 1 Monitoring code

Display

Pump controller model code

PC600-6

20-309

TROUBLESHOOTING

N-3

Table 2 Monitoring code

Display

Network connection condition

• Bits light up when network is connected (12: Pump controller) ﬂ Checks for disconnection in the network system can be carried out with this monitoring code. The display does not change when there is a short circuit with the ground. (The normal display is given.)

N-3 Related electrical circuit diagram

20-310

PC600-6

TROUBLESHOOTING OF ENGINE CONTROLLER SYSTEM (E MODE) Action taken by controller and condition of machine when error code is displayed ................... 20-352 Judgement table for engine controller and engine related parts ..................................................... 20-360 Electrical circuit diagram of E mode system ...................................................................................... 20-362 E- 1 [E91b] (Abnormality in engine speed Ne sensor system) is displayed ............................. 20-364 E- 2 [E91C] (Abnormality in engine G rotation sensor system) is displayed............................ 20-365 E- 3 [E920] (Abnormality in model selection system) is displayed ............................................ 20-366 E- 4 [E922] (Engine overrun) is displayed ..................................................................................... 20-367 E- 5 [E924] (Drop in engine oil pressure) is displayed ................................................................ 20-368 E- 6 [E931] (Abnormality in fuel control dial sensor system) is displayed ............................... 20-369 E- 7 [E934] (Abnormality in engine water temperature (high) sensor system) is displayed ................................................................................................................................ 20-370 E- 8 [E936] (Abnormality in engine oil pressure switch system) is displayed ......................... 20-371 E- 9 [E93C] (Abnormality in boost pressure sensor system) is displayed .................................20-372 E-10 [E93d] (Abnormality in fuel temperature sensor system) is displayed ............................. 20-373 E-11 [E954] (Short circuit in starting switch C system) is displayed ........................................... 20-374 E-12 [E955] (Abnormality in network system) is displayed .......................................................... 20-374 E-13 [E956] (Power source system abnormality 1) is displayed .................................................. 20-375 E-14 [E957] (Power source system abnormality 2) is displayed .................................................. 20-376 E-15 [E95A] (Abnormality in fuel injection quantity control switch signal) is displayed.......... 20-377 E-16 [E96A] (Abnormality in engine water temperature (low) sensor system) is displayed ................................................................................................................................ 20-378 E-17 [E970] (Excess current in fuel supply pump PCV1 system) is displayed .......................... 20-379 E-18 [E971] (Excess current in fuel supply pump PCV2 system) is displayed .......................... 20-380 E-19 [E974] (Disconnection in fuel supply pump PCV1 system) is displayed ........................... 20-381 E-20 [E975] (Disconnection in fuel supply pump PCV2 system) is displayed ........................... 20-382 E-21 [E977] (Abnormality in common rail fuel pressure sensor system) is displayed ............ 20-383 E-22 [E979] (Common rail fuel high pressure abnormality 1) is displayed [E97A] (Common rail fuel high pressure abnormality 2) is displayed ............................... 20-384 E-23 [E97b] (Fuel supply pump non-force feed 1) is displayed [E97C] (Fuel supply pump non-force feed 2) is displayed ................................................... 20-385 E-24 [E97d] (Abnormality in common rail fuel pressure) is displayed ....................................... 20-387 E-25 [E980] (Defective engine controller) is displayed ................................................................. 20-387 E-26 [E981] (Disconnection in No. 1 fuel injector system) is displayed ..................................... 20-388 E-27 [E982] (Disconnection in No. 2 fuel injector system) is displayed ..................................... 20-389 E-28 [E983] (Disconnection in No. 3 fuel injector system) is displayed ..................................... 20-390 E-29 [E984] (Disconnection in No. 4 fuel injector system) is displayed ..................................... 20-391 E-30 [E985] (Disconnection in No. 5 fuel injector system) is displayed ..................................... 20-392 E-31 [E986] (Disconnection in No. 6 fuel injector system) is displayed ..................................... 20-393 E-32 [E98A] (Short circuit in No. 1, No. 2, No. 3 fuel injector system) is displayed ................ 20-394 a) Determining location of problem ...................................................................................... 20-394 b) Troubleshooting No. 1 fuel injector system .................................................................... 20-394 c) Troubleshooting No. 2 fuel injector system .................................................................... 20-395 d) Troubleshooting No. 3 fuel injector system .................................................................... 20-395 E-33 [E98b] (Short circuit in No. 3, No. 4, No. 5 fuel injector system) is displayed ................................................................................................................................ 20-397 a) Determining location of problem ...................................................................................... 20-397 b) Troubleshooting No. 4 fuel injector system .................................................................... 20-397 c) Troubleshooting No. 5 fuel injector system .................................................................... 20-398 PC600-6

20-351

ACTION TAKEN BY CONTROLLER AND CONDITION OF MACHINE WHEN ERROR CODE IS DISPLAYED

TROUBLESHOOTING

ACTION TAKEN BY CONTROLLER AND CONDITION OF MACHINE WHEN ERROR CODE IS DISPLAYED User code

E11 E12

E11 E10

Service code

E91b

E91C

System with abnormality

Nature of abnormality

Abnormality in engine Ne rotation sensor system

1. Defective contact, disconnection, short circuit, or short circuit with ground in wiring harness inside Ne rotation sensor 2. Defective contact, disconnection, or short circuit with ground in wiring harness between controller E11 (5) (+) and Ne rotation sensor NE (1) 3. Defective contact, disconnection, or short circuit with ground in wiring harness between controller E11 (12) (–) and Ne rotation sensor NE (2) 4. Defective engine controller

Abnormality in engine G rotation sensor system

1. Defective contact, disconnection, short circuit, or short circuit with ground in wiring harness inside G rotation sensor 2. Defective contact, disconnection, or short circuit with ground in wiring harness between controller E12 (1) (+) and G rotation sensor G (1) 3. Defective contact, disconnection, or short circuit with ground in wiring harness between controller E12 (9) (–) and G rotation sensor G (2) 4. Defective engine controller

E11

E920

Abnormality in machine model selection system

1. Defective machine model selection connector 2. Defective contact, disconnection, or short circuit with ground in wiring harness between controller E14 (13) and machine model selection connector E09 (1) 3. Defective contact, disconnection, or short circuit with ground in wiring harness between controller E14 (14) and machine model selection connector E09 (2) 4. Defective contact, disconnection, or short circuit with ground in wiring harness between controller E14 (15) and machine model selection connector E09 (3) 5. Defective engine controller

—

E922

Overrun

1. Engine speed goes above operating range 2. Defective engine controller

Drop in engine oil pressure

1. Engine oil pressure goes below operating range 2. Defective engine oil pressure low-pressure sensor 3. Defective engine oil pressure high-pressure sensor 4. Short circuit with chassis ground in wiring harness between controller E14 (5) and oil pressure low-pressure sensor PSL 5. Short circuit with chassis ground in wiring harness between controller E14 (6) and oil pressure low-pressure sensor PSH 6. Defective engine controller

Abnormality in fuel control dial system

1. Defective fuel control dial 2. Defective contact, disconnection, or short circuit with ground in wiring harness between controller E11 (4) (power source) and fuel control dial E06 (1) 3. Defective contact, disconnection, or short circuit with ground in wiring harness between controller E11 (6) (signal) and fuel control dial E06 (2) 4. Defective contact, disconnection, or short circuit with ground in wiring harness between controller E11 (11) (GND) and fuel control dial E06 (3) 5. Defective engine controller

Abnormality in engine water temperature high- temperature sensor system

1. Defective engine water temperature high-temperature sensor 2. Defective contact, disconnection, or short circuit with ground in wiring harness between controller E12 (4) (signal) and water temperature hightemperature sensor TWH (1) 3. Defective contact or disconnection in wiring harness between controller E12 (10) (GND) and water temperature high-temperature sensor TWH (2) 4. Defective engine controller

Abnormality in engine oil pressure switch system

1. Defective oil pressure low-pressure sensor 2. Defective oil pressure high-pressure sensor 3. Defective contact, disconnection, or short circuit with ground in wiring harness between controller E14 (5) and oil pressure low-pressure sensor PSL 4. Defective contact or disconnection in wiring harness between controller E14 (6) and oil pressure low-pressure sensor PSH 5. Defective engine controller

Abnormality in boost pressure sensor system

1. Defective boost pressure sensor 2. Defective contact, disconnection, or short circuit with ground in wiring harness between controller E12 (2) (power source) and boost pressure sensor PIM (1) 3. Defective contact, disconnection, or short circuit with ground in wiring harness between controller E11 (3) (signal) and boost pressure sensor PIM (2) 4. Defective contact, disconnection, or short circuit with ground in wiring harness between controller E12 (10) (GND) and boost pressure sensor PIM (3) 5. Defective engine controller

E11

E14

E15

E11

20-352

E924

E931

E934

E936

E93C

PC600-6

TROUBLESHOOTING

ACTION TAKEN BY CONTROLLER AND CONDITION OF MACHINE WHEN ERROR CODE IS DISPLAYED

Action by controller

Problem that appears on machine

• Sensor resistance value Between NE (1) and (2): 85 – 210 Ω

1. Displays user code [E11] (when occurring independently) or [E10] (when E91C occurs at same time) 2. Limits output for operation (when problem occurs independently) 3. Control of the system becomes impossible (when E91C occurs at same time)

1. Reduces output (when problem occurs independently) 2. Engine stops during operation (when E91C occurs at same time) 3. Engine cannot be started (when E91C occurs at same time)

• Sensor resistance value Between G (1) and (2): 1.4 k – 3.5 kΩ

1. Displays user code [E11] (when occurring independently) or [E10] (when E91b occurs at same time) 2. Limits output for operation (when problem occurs independently) 3. Control of the system becomes impossible (when E91C occurs at same time)

1. Output is reduced (when problem occurs independently) 2. Engine stops during operation (when E91b occurs at same time) 3. Engine cannot be started (when E91C occurs at same time)

• Resistance in ground connection circuit Between E14 (female) (13)(15) and ground: Max. 1 Ω • Resistance in ground cut-off circuit Between E14 (female) (14) and ground: Min. 1 MΩ

1. Displays user code [E11] 2. Carries out operation under normal control

1. Output is reduced

1. Stops fuel injection until engine speed goes down to operating range

1. Engine speed varies abnormally

• Low-pressure switch resistance value Between PSL and ground Engine stopped: Max. 1 Ω Engine above 600 rpm: Min. 1 MΩ • High-pressure switch resistance value Between PSH and ground Engine stopped: Max. 1 Ω Engine above 1300 rpm: Min. 1 MΩ

1. Displays user code [E11] 1. Limits output for operation

1. Runs at low idling.

• Sensor power source voltage Between E11 (4) and (11): 4.6 – 5.4 V • Sensor signal voltage Between E11 (6) and (11): 0.3 – 4.7 V

1. Displays user code [E14] 2. Actuated with throttle signal 100% (when problem occurs independently and simultaneously) 3. Actuated with throttle signal 0% (when E924 and E936 occur at same time)

1. Fixed at high idling (when problem occurs independently) 2. Fixed at low idling (when E924 and E936 occur at same time)

• Sensor resistance value (water temperature: 10 – 100°C) Between TWH (1) and (2): 90 k – 3.5 kΩ

1. Displays user code [E15] 2. Carries out operation under normal control

1. Fixes water temperature signal output to machine at 90°C

1. Displays user code [E15] 2. Carries out operation under normal control

1. Operates normally

• Sensor power source voltage Between PIM (1) and (3): 4.6 – 5.4 V • Sensor signal voltage Between PIM (2) and (3): 0.3 – 4.7 V

1. Displays user code [E11]

1. Operates normally

Condition when normal

PC600-6

20-353

ACTION TAKEN BY CONTROLLER AND CONDITION OF MACHINE WHEN ERROR CODE IS DISPLAYED

TROUBLESHOOTING

User code

Service code

System with abnormality

Nature of abnormality 1. Defective fuel temperature sensor 2. Defective contact, disconnection, or short circuit with ground in wiring harness between controller E12 (11) (signal) and fuel temperature sensor THL (1) 3. Defective contact or disconnection in wiring harness between controller E12 (10) (GND) and fuel temperature sensor THL (2) 4. Defective engine controller

E15

E93d

Abnormality in fuel temperature sensor system

—

E954

1. Defective starting switch Short circuit in starting 2. Short circuit with power source in wiring harness between controller switch C signal system E14 (2) and starting switch terminal C 3. Defective engine controller

E0E

E955

Abnormality in network system

E10

E956

Power source system abnormality 1

1. Defective power source relay 2. Defective contact, disconnection, or short circuit with ground in wiring harness between starting switch terminal ACC and power source relay R24 (1) 3. Defective contact or disconnection in wiring harness between power source relay R24 (2) and ground 4. Defective contact, disconnection, or short circuit with ground in wiring harness between battery relay – circuit breaker 8 – power source relay R24 (3) 5. Defective contact, disconnection, or short circuit with ground in wiring harness between controller E17 (6)(14) and power source relay R24 (5) 6. Defective engine controller

E15

E957

Power source system abnormality 2

1. Defective power source relay 2. Short circuit with power source in wiring harness between controller E17 (6)(14) and power source relay (5) 3. Defective engine controller

—

E95A

Abnormality in fuel injection quantity control switch signal

1. Defective setting of fuel injection quantity control switch 2. Defective engine controller

E96A

Abnormality in engine water temperature low-temperature sensor system

1. Defective engine water temperature low-temperature sensor 2. Defective contact, disconnection, or short circuit with ground in wiring harness between controller E12 (3) (signal) and water temperature lowtemperature sensor TWL (1) 3. Defective contact or disconnection in wiring harness between controller E12 (10) (GND) and water temperature low-temperature sensor TWL (2) 4. Defective engine controller

E970

Overcurrent in fuel supply pump PCV1 system

1. Defective fuel supply pump PCV1 2. Short circuit with chassis ground or short circuit with power source in wiring harness between controller E17 (10) and PCV1 solenoid E41 (1) 3. Short circuit with power source in wiring harness between controller E17 (11) and PCV1 solenoid E41 (2) 4. Defective engine controller

E971

Overcurrent in fuel supply pump PCV2 system

1. Defective fuel supply pump PCV2 2. Short circuit with chassis ground or short circuit with power source in wiring harness between controller E17 (4) and PCV2 solenoid E42 (1) 3. Short circuit with power source in wiring harness between controller E17 (12) and PCV2 solenoid E42 (2) 4. Defective engine controller

E974

Disconnection in fuel supply pump PCV1 system

1. Defective fuel supply pump PCV1 2. Defective contact or disconnection in wiring harness between controller E17 (10) and PCV1 solenoid E41 (1) 3. Defective contact, disconnection, or short circuit with ground in wiring harness between controller E17 (11) and PCV1 solenoid E41 (2) 4. Defective engine controller

E975

Disconnection in fuel supply pump PCV2 system

1. Defective fuel supply pump PCV2 2. Defective contact or disconnection in wiring harness between controller E17 (4) and PCV2 solenoid E42 (1) 3. Defective contact, disconnection, or short circuit with ground in wiring harness between controller E17 (12) and PCV2 solenoid E42 (2) 4. Defective engine controller

E15

E10 E11

20-354

PC600-6

TROUBLESHOOTING

ACTION TAKEN BY CONTROLLER AND CONDITION OF MACHINE WHEN ERROR CODE IS DISPLAYED

Problem that appears on machine

Condition when normal

Action by controller

•

Sensor resistance value (fuel temperature: 10 – 100°C) Between THL (1) and (2): 9 k – 0.3 kΩ

1. Displays user code [E15] 2. Carries out operation under normal control

1. Operates normally.

•

Starting switch C signal voltage Between E14 (2) and ground Starting switch at ON: Max. 1 V Starting switch at START: 20 – 30 V

1. Carries out operation under normal control

1. Operates normally 10 seconds after engine starts

1. Displays user code [E0E] •

Power source voltage Between E17 (6)(14) and (5)(13) Starting switch at ON: 20 – 30 V

1. Displays user code [E10]

1. Engine stops during operation 2. Engine cannot be started.

•

Power source voltage Between E17 (6)(14) and (5)(13) Starting switch at OFF: Max. 8 V

1. Displays user code [E15] 2. Carries out operation under normal control

1. Operates normally

•

Either fuel injection quantity control switch 1 or 2 of controller is set to [F]

1. Carries out operation under normal control

1. Fuel injection quantity control setting cannot be changed

•

Sensor resistance value (water temperature: 10 – 100°C) Between TWL (1) and (2): 9 k – 0.3 kΩ

1. Displays user code [E15] 2. Carries out operation under normal control

1. Exhaust gas color at low temperatures is poor. 2. Starting ability at low temperatures is poor.

•

Solenoid resistance value Between E41 (1) and (2): 2.3 – 5.3 Ω

1. Displays user code [E11] (when occurring independently) or [E10] (when E971 occurs at same time) 2. Stops output to PCV1 (when problem occurs independently) 3. Stops output to PCV1 and PCV2 (when E971 occurs at same time)

1. Operates normally (when problem occurs independently) 2. Stops engine (when E971 occurs at same time)

•

Solenoid resistance value Between E42 (1) and (2): 2.3 – 5.3 Ω

1. Displays user code [E11] (when occurring independently) or [E10] (when E970 occurs at same time) 2. Stops output to PCV2 (when problem occurs independently) 3. Stops output to PCV1 and PCV2 (when E970 occurs at same time)

1. Operates normally (when problem occurs independently) 2. Stops engine (when E970 occurs at same time)

•

Solenoid resistance value Between E41 (1) and (2): 2.3 – 5.3 Ω

1. Displays user code [E11] (when occurring independently) or [E10] (when E975 occurs at same time) 2. Stops output to PCV1 (when problem occurs independently) 3. Stops output to PCV1 and PCV2 (when E975 occurs at same time)

1. Operates normally (when problem occurs independently) 2. Stops engine (when E975 occurs at same time)

•

Solenoid resistance value Between E42 (1) and (2): 2.3 – 5.3 Ω

1. Displays user code [E11] (when occurring independently) or [E10] (when E974 occurs at same time) 2. Stops output to PCV2 (when problem occurs independently) 3. Stops output to PCV1 and PCV2 (when E974 occurs at same time)

1. Operates normally (when problem occurs independently) 2. Stops engine (when E974 occurs at same time)

PC600-6

20-355

ACTION TAKEN BY CONTROLLER AND CONDITION OF MACHINE WHEN ERROR CODE IS DISPLAYED

TROUBLESHOOTING

User code

Service code

System with abnormality

E11

E977

Abnormality in common rail fuel pressure sensor system

E11

E979

Common rail fuel highpressure abnormality 1

E10

E97A

Common rail fuel highpressure abnormality 2

E11

E97b

Supply pump non-force feed abnormality 1

E10

E97C

Supply pump non-force feed abnormality 2

E97d

Abnormality in common rail fuel pressure

Nature of abnormality 1. Defective common rail fuel pressure sensor 2. Defective contact, disconnection, or short circuit with ground in wiring harness between controller E12 (2) (power source) and fuel pressure sensor PFUEL (1) 3. Defective contact, disconnection, or short circuit with ground in wiring harness between controller E11 (1) (signal) and fuel pressure sensor PFUEL (2) 4. Defective contact, disconnection, or short circuit with ground in wiring harness between controller E12 (10) (GND) and fuel pressure sensor PFUEL (3) 5. Defective engine controller 1. Viscosity of fuel is too high (unsuitable fuel) 2. Defective overflow valve 3. Defective pressure limiter 4. Defective common rail fuel pressure sensor 5. Clogged overflow piping ﬂ See E979

1. Defective fuel low-pressure circuit (etc.) 2. Defective fuel supply pump PSV 3. Defective pressure limiter 4. Defective common rail fuel pressure sensor 5. Defective fuel injector 6. Leakage from fuel high-pressure piping ﬂ See E97b

ﬂ See E979 E11

1. Defective contact or disconnection in wiring harness between controller E17 (5)(13) and ground 2. Defective engine controller E11 E10

E11 E10

20-356

E980

E981

E982

E983

Abnormality in controller

Disconnection in No. 1 fuel injector system

Disconnection in No. 2 fuel injector system

Disconnection in No. 3 fuel injector system

1. Defective No. 1 fuel injector solenoid 2. Defective contact or disconnection in wiring harness between controller E16 (7) (–) and No. 1 injector E31 (1) 3. Defective contact or disconnection in wiring harness between controller E16 (8) (+) and No. 1 injector E31 (2) 4. Defective engine controller

1. Defective No. 2 fuel injector solenoid 2. Defective contact or disconnection in wiring harness between controller E16 (4) (–) and No. 2 injector E32 (1) 3. Defective contact or disconnection in wiring harness between controller E16 (10) (+) and No. 2 injector E32 (2) 4. Defective engine controller

1. Defective No. 3 fuel injector solenoid 2. Defective contact or disconnection in wiring harness between controller E16 (3) (–) and No. 3 injector E33 (1) 3. Defective contact or disconnection in wiring harness between controller E16 (9) (+) and No. 3 injector E33 (2) 4. Defective engine controller

PC600-6

TROUBLESHOOTING

Condition when normal • •

Sensor power source voltage Between PFUEL (1) and (3): 4.6 – 5.4 V Sensor signal voltage Between PFUEL (2) and (3): 0.3 – 4.7 V

ACTION TAKEN BY CONTROLLER AND CONDITION OF MACHINE WHEN ERROR CODE IS DISPLAYED

Action by controller

Problem that appears on machine

1. Displays user code [E11] 2. Limits output with open control

1. Output is reduced

1. Displays user code [E11] 2. Operation carried out with limited output

1. Output is reduced

1. Displays user code [E10] 2. Stops output to fuel supply pump 3. Limits output to fuel injector

1. Output is reduced

1. Displays user code [E11] 2. Sets engine output to delayed 3. Operation carried out with limited output

1. Output is reduced

1. Displays user code [E10] 2. Stops output to fuel supply pump 3. Limits output to fuel injector

1. Engine stops

1. Displays user code [E11] 2. Carries out operation under normal control

1. Engine does not run at high idling speed when there is no load 2. Engine stops when a large load is applied

1. Displays user code [E11] (when occurring independently) or [E10] (when E98A, E98b occur at same time) 2. Operation carried out with limited output

1. Engine does not run at high idling speed when there is no load 2. Engine stops when a large load is applied 3. Engine stops during operation 4. Engine cannot be started

•

No. 1 injector resistance value Between E31 (1) and (2): 0.4 – 1.1 Ω

1. Displays user code [E11] (when occurring independently) or [E10] (when E982 to E986 occur at same time) 2. Stops output to No. 1 injector (when problem occurs independently) 3. Stops output to fuel supply pump, all fuel injectors (when E982 to E986 occur at same time)

1. Output is reduced (when problem occurs independently) 2. Engine stops (when E982 to E986 occur at same time)

•

No. 2 injector resistance value Between E32 (1) and (2): 0.4 – 1.1 Ω

1. Displays user code [E11] (when occurring independently) or [E10] (when E981 to E986 occur at same time) 2. Stops output to No. 2 injector (when problem occurs independently) 3. Stops output to fuel supply pump, all fuel injectors (when E981 to E986 occur at same time)

1. Output is reduced (when problem occurs independently) 2. Engine stops (when E981 to E986 occur at same time)

•

No. 3 injector resistance value Between E33 (1) and (2): 0.4 – 1.1 Ω

1. Displays user code [E11] (when occurring independently) or [E10] (when E981 to E986 occur at same time) 2. Stops output to No. 3 injector (when problem occurs independently) 3. Stops output to fuel supply pump, all fuel injectors (when E981 to E986 occur at same time)

1. Output is reduced (when problem occurs independently) 2. Engine stops (when E981 to E986 occur at same time)

PC600-6

20-357

ACTION TAKEN BY CONTROLLER AND CONDITION OF MACHINE WHEN ERROR CODE IS DISPLAYED

TROUBLESHOOTING

User code

E11 E10

Service code

E984

E985

E986

E98A

System with abnormality

Disconnection in No. 4 fuel injector system

Disconnection in No. 5 fuel injector system

Disconnection in No. 6 fuel injector system

Short circuit in No. 1, No. 2, No. 3 fuel injector system

Nature of abnormality 1. Defective No. 4 fuel injector solenoid 2. Defective contact or disconnection in wiring harness between controller E17 (3) (–) and No. 4 injector E34 (1) 3. Defective contact or disconnection in wiring harness between controller E17 (9) (+) and No. 4 injector E34 (2) 4. Defective engine controller

1. Defective No. 5 fuel injector solenoid 2. Defective contact or disconnection in wiring harness between controller E17 (1) (–) and No. 5 injector E35 (1) 3. Defective contact or disconnection in wiring harness between controller E17 (7) (+) and No. 5 injector E35 (2) 4. Defective engine controller

1. Defective No. 6 fuel injector solenoid 2. Defective contact or disconnection in wiring harness between controller E17 (2) (–) and No. 6 injector E36 (1) 3. Defective contact or disconnection in wiring harness between controller E17 (8) (+) and No. 6 injector E36 (2) 4. Defective engine controller

1. Defective No. 1 fuel injector 2. Defective No. 2 fuel injector 3. Defective No. 3 fuel injector 4. Short circuit with chassis ground or short circuit with power source in wiring harness between controller E16 (7) (+) and No. 1 injector E31 (1) 5. Short circuit with chassis ground or short circuit with power source in wiring harness between controller E16 (8) (–) and No. 1 injector E31 (2) 6. Short circuit with chassis ground or short circuit with power source in wiring harness between controller E16 (4) (+) and No. 2 injector E32 (1) 7. Short circuit with chassis ground or short circuit with power source in wiring harness between controller E16 (10) (–) and No. 2 injector E32 (2) 8. Short circuit with chassis ground or short circuit with power source in wiring harness between controller E16 (3) (+) and No. 3 injector E33 (1) 9. Short circuit with chassis ground or short circuit with power source in wiring harness between controller E16 (9) (–) and No. 3 injector E33 (2) 10. Defective contact or disconnection in wiring harness between controller E17 (5)(13) and ground 11. Defective engine controller 1. 2. 3. 4.

E11 E10

20-358

E98b

Short circuit in No. 4, No. 5, No. 6 fuel injector system

Defective No. 4 fuel injector Defective No. 5 fuel injector Defective No. 6 fuel injector Short circuit with chassis ground or short circuit with power source in wiring harness between controller E17 (3) (+) and No. 4 injector E34 (1) 5. Short circuit with chassis ground or short circuit with power source in wiring harness between controller E17 (9) (–) and No. 4 injector E34 (2) 6. Short circuit with chassis ground or short circuit with power source in wiring harness between controller E17 (1) (+) and No. 5 injector E35 (1) 7. Short circuit with chassis ground or short circuit with power source in wiring harness between controller E17 (7) (–) and No. 5 injector E35 (2) 8. Short circuit with chassis ground or short circuit with power source in wiring harness between controller E17 (2) (+) and No. 6 injector E36 (1) 9. Short circuit with chassis ground or short circuit with power source in wiring harness between controller E17 (8) (–) and No. 6 injector E36 (2) 10. Defective contact or disconnection in wiring harness between controller E17 (5)(13) and ground 11. Defective engine controller

PC600-6

TROUBLESHOOTING

ACTION TAKEN BY CONTROLLER AND CONDITION OF MACHINE WHEN ERROR CODE IS DISPLAYED

Problem that appears on machine

Condition when normal

Action by controller

•

No. 4 injector resistance value Between E34 (1) and (2): 0.4 – 1.1 Ω

1. Displays user code [E11] (when occurring independently) or [E10] (when E981 to E986 occur at same time) 2. Stops output to No. 4 injector (when problem occurs independently) 3. Stops output to fuel supply pump, all fuel injectors (when E981 to E986 occur at same time)

1. Output is reduced (when problem occurs independently) 2. Engine stops (when E981 to E986 occur at same time)

•

No. 5 injector resistance value Between E35 (1) and (2): 0.4 – 1.1 Ω

1. Displays user code [E11] (when occurring independently) or [E10] (when E981 to E986 occur at same time) 2. Stops output to No. 5 injector (when problem occurs independently) 3. Stops output to fuel supply pump, all fuel injectors (when E981 to E986 occur at same time)

1. Output is reduced (when problem occurs independently) 2. Engine stops (when E981 to E986 occur at same time)

•

No. 6 injector resistance value Between E36 (1) and (2): 0.4 – 1.1 Ω

1. Displays user code [E11] (when occurring independently) or [E10] (when E981 to E985 occur at same time) 2. Stops output to No. 6 injector (when problem occurs independently) 3. Stops output to fuel supply pump, all fuel injectors (when E981 to E985 occur at same time)

1. Output is reduced (when problem occurs independently) 2. Engine stops (when E981 to E985 occur at same time)

•

No. 1 injector resistance value Between E31 (1) and (2): 0.4 – 1.1 Ω No. 2 injector resistance value Between E32 (1) and (2): 0.4 – 1.1 Ω No. 3 injector resistance value Between E33 (1) and (2): 0.4 – 1.1 Ω

1. Displays user code [E11] (when occurring independently) or [E10] (when E98b occurs at same time) 2. Stops output to No. 1, No. 2, No. 3 fuel injectors (when problem occurs independently) 3. Stops output to fuel supply pump, all fuel injectors (when E98b occurs at same time)

1. Output is greatly reduced (when problem occurs independently) 2. Engine stops (when E98b occurs at same time)

No. 4 injector resistance value Between E34 (1) and (2): 0.4 – 1.1 Ω No. 5 injector resistance value Between E35 (1) and (2): 0.4 – 1.1 Ω No. 6 injector resistance value Between E36 (1) and (2): 0.4 – 1.1 Ω

1. Displays user code [E11] (when occurring independently) or [E10] (when E98A occurs at same time) 2. Stops output to No. 4, No. 5, No. 6 fuel injectors (when problem occurs independently) 3. Stops output to fuel supply pump, all fuel injectors (when E98A occurs at same time)

1. Output is greatly reduced (when problem occurs independently) 2. Engine stops (when E98A occurs at same time)

• •

• • •

PC600-6

20-359

JUDGEMENT TABLE FOR ENGINE CONTROLLER AND ENGINE RELATED PARTS

TROUBLESHOOTING

Abnormality in engine oil pressure switch system

Abnormality in boost pressure sensor system

Abnormality in engine water temperature (high- temperature) sensor system

Drop in engine oil pressure

Abnormality in fuel control dial system

Overrun

Abnormality in engine G rotation sensor system

Abnormality in machine model selection system

Overheat

E11 E11 — E10 E10 E11 — E11 E14 E15 E15 E11

Service code

108 91b 91C 920 922 924 931 934 936 93C

‡ ‡ ‡

Starting ability Exhaust gas is emitted but engine does not start, or is difficult to start is poor No exhaust gas is emitted

Engine stops during operation

Lack of engine output

Acceleration is poor Engine speed stays at Exhaust gas is normal low idling, and does not follow fuel control dial Exhaust gas is extremely black

Accelerates at high idling

Accelerated at same time as abnormality display was given

Low idling does not work according to operation

Does not switch to low idling

Fuel consumption is excessive

Exhaust gas is normal

‡ ‡ ‡

‡ ‡ ‡ ‡

‡ ‡ ‡ ‡ ‡

‡ ‡

Accelerated after abnormality display was given

‡ ‡

Does not switch to high idling

Exhaust gas is extremely black High idling does not Does not rise to high idling work according to Switches to high idling but returns to low idling operation Warming-up operation is defective

Auto-deceleration does not work

Engine speed does not change even when working mode is switched

Engine does Engine remains accelerated not stop Remains at low idling even when starting switch is turned OFF

There is hunting of engine (low idling speed is irregular)

Oil consumption is excessive, or exhaust gas is blue

Oil becomes dirty prematurely

Oil is mixed in coolant

Engine oil pressure caution lamp lights up

Oil level rises

Coolant temperature rises too high

Abnormal noise is generated

There is excessive vibration

User code

Failure mode

No. 1 Engine does not start

Abnormality in engine Ne rotation sensor system

JUDGEMENT TABLE FOR ENGINE CONTROLLER AND ENGINE RELATED PARTS Self-diagnostic display

‡ ‡ ‡

‡ ‡ Troubleshooting M-4 E-1 E-2 E-3 E-4 E-5 E-6 E-7 E-8 E-9 code

20-360

PC600-6

‡ ‡

PC600-6

‡ ‡‡

‡ ‡‡ ‡ ‡ ‡ ‡

‡ ‡ ‡‡‡

‡ ‡ ‡‡‡ ‡ ‡‡‡ ‡ ‡‡‡ ‡ ‡‡‡ ‡ ‡ ‡ ‡‡ ‡ ‡‡ ‡ ‡‡ ‡

E11 E11 E11 E11 E11 E11 E11 E11 E11 E11 E11 E11 E11 E15 — E0E E10 E15 — E15 E10 E10 E10 E10 E11 E11 E10 E11 E10 E11 E10 E10 E10 E10 E10 E10 E10 E10 E10

93d 954 955 956 957 95A 96A 970 971 974 975 977 979 97A 97b 97C 97d 980 981 982 983 984 985 986 98A 98b

‡ ‡‡‡ ‡ ‡‡ ‡

Does starting motor turn?

Short circuit in No. 4, No. 5, No. 6 fuel injector system

Short circuit in No. 1, No. 2, No. 3 fuel injector system

Disconnection in No. 6 fuel injector system

Disconnection in No. 5 fuel injector system

Disconnection in No. 4 fuel injector system

Disconnection in No. 3 fuel injector system

Disconnection in No. 2 fuel injector system

Disconnection in No. 1 fuel injector system

Abnormality in controller

Abnormality in common rail fuel pressure

Supply pump non-force feed abnormality 2

Supply pump non-force feed abnormality 1

Common rail fuel high-pressure abnormality 2

Common rail fuel high-pressure abnormality 1

Abnormality in common rail fuel pressure sensor system

Disconnection in fuel supply pump PCV2 system

Disconnection in fuel supply pump PCV1 system

Overcurrent in fuel supply pump PCV2 system

Overcurrent in fuel supply pump PCV1 system

Abnormality in engine water temperature (low- temperature) sensor system

Abnormality in fuel injection quantity control switch signal

Power source system abnormality 2

Power source system abnormality 1

Abnormality in network system

Short circuit in starting switch C signal system

Abnormality in fuel temperature sensor system

TROUBLESHOOTING JUDGEMENT TABLE FOR ENGINE CONTROLLER AND ENGINE RELATED PARTS

Self-diagnostic display

Troubleshooting code when no service code is displayed

See engine volume

‡ ‡‡‡ ‡ ‡‡ ‡ See engine volume

‡ ‡ ‡ See engine volume

‡ ‡‡‡ ‡ ‡‡ ‡

‡

See engine volume

‡ ‡‡‡ ‡ ‡‡ ‡ ‡ ‡‡‡ ‡ ‡‡ ‡

E-10 E-11 E-12 E-13 E-14 E-15 E-16 E-17 E-18 E-19 E-20 E-21 E-22 E-22 E-23 E-23 E-24 E-25 E-26 E-27 E-28 E-29 E-30 E-31 E-32 E-33

20-361

TROUBLESHOOTING

ELECTRICAL CIRCUIT DIAGRAM FOR E MODE SYSTEM

20-362

PC600-6

TROUBLESHOOTING

PC600-6

ELECTRICAL CIRCUIT DIAGRAM FOR E MODE SYSTEM

20-363

TROUBLESHOOTING

E-1

E-1 [E91b] (Abnormality in engine speed Ne sensor system) is displayed Cause

Remedy

1 • Turn starting switch OFF. • Disconnect NE.

Is resistance between NE (male) NO (1) and (2), between (1)(2) and ground as shown in Table 1?

Defective engine speed Ne sensor

Replace

YES 2 • Turn starting switch OFF. • Disconnect E11.

Is resistance between E11 (female) (5) and (12) 85 – 210 Ω?

Defective contact or disconnection in wiring harness between E11 (female) Repair or replace (5) and NE (female) (1) or between E11 (female) (12) and NE (female) (2)

YES 3 • Turn starting switch OFF. • Disconnect E11 and NE.

Is resistance between E11 (female) (5)(12) and ground more than 1 MΩ? YES

Short circuit with ground in wiring harness between E11 (female) (5) and NE (female) (1) or between E11 (female) (12) and NE (female) (2)

Repair or replace

Defective engine controller

Replace

Table 1 NE (male) Between (1) and (2) Between (1)(2) and ground

Resistance value 85 – 210 Ω Min. 1 MΩ

E-1 Related electrical circuit diagram

20-364

PC600-6

TROUBLESHOOTING

E-2

E-2 [E91C] (Abnormality in engine G rotation sensor system) is displayed Cause

Remedy

1 • Turn starting switch OFF. • Disconnect G.

Is resistance between G (male) (1) and (2), between (1)(2) and ground as shown in Table 1?

Defective engine G rotation sensor

Replace

YES 2 • Turn starting switch OFF. • Disconnect E12.

Is resistance between E12 (female) (1) and (9) 1 k – 2 kΩ?

Defective contact or disconnection in wiring harness between E12 (female) Repair or replace (1) and G (female) (1) or between E12 (female) (9) and G (female) (2)

YES 3 • Turn starting switch OFF. • Disconnect E12 and G.

Is resistance between E12 (female) (1)(9) and ground more than 1 MΩ? YES

Short circuit with ground in wiring harness between E12 Repair or (female) (1) and G (female) (1) replace or between E12 (female) (9) and G (female) (2) Defective engine controller

Replace

Table 1 G (male) Between (1) and (2) Between (1)(2) and ground

Resistance value 1 k – 2 kΩ Min. 1 MΩ

E-2 Related electrical circuit diagram

PC600-6

20-365

TROUBLESHOOTING

E-3

E-3 [E920] (Abnormality in model selection system) is displayed

Cause

Remedy

1 • Turn starting switch OFF. • Disconnect E09.

Is resistance between E09 (female) (1)(2)(3) and (8) as shown in Table 1?

Defective model selection connector

Replace

YES 2 • Turn starting switch OFF. • Disconnect E14.

Is resistance between E14 (female) (13)(15) and (8)(19) less than 1 Ω?

Defective contact or disconnection in wiring harness between E14 (female) Repair or replace (13) and E09 (male) (1) or between E14 (female) (15) and E09 (male) (3)

YES 3 • Turn starting switch OFF. • Disconnect E14 and E09.

Is resistance between E14 NO (female) (14) and ground more than 1 MΩ?

Short circuit with ground in wiring harness between E14 (female) (14) and E09 (male) (2)

Repair or replace

Defective engine controller

Replace

YES

Table 1 E09 (female) Between (1) and (8) Between (2) and (8) Between (3) and (8)

Resistance value Max 1 Ω Min. 1 MΩ Max. 1 Ω

E-3 Related electrical circuit diagram

20-366

PC600-6

TROUBLESHOOTING

E-4

E-4 [E922] (Engine overrun) is displayed

• Turn starting switch ON.

Is another error code displayed at same time? YES

Was machine used in a way that would cause engine to overrun?

Can engine speed be read correctly?

Remedy

—

Go to troubleshooting for service code displayed

2 NO

YES

• Start engine.

Cause 1 NO

—

3 NO

—

YES Defective engine controller

PC600-6

Check cause of problem and repair damage to engine Go to troubleshooting for service codes [E91b], [E91C] Replace

20-367

TROUBLESHOOTING

E-5

E-5 [E924] (Drop in engine oil pressure) is displayed Cause 1 • See TESTING AND ADJUSTING.

Is engine oil pressure normal?

Drop in engine oil pressure

YES • Insert T-adapter to E14. • Engine at low idling.

2 Is voltage between E14 (5) and NO ground 20 – 30 V?

Remedy Check cause of problem and repair damage to engine

YES

• Turn starting switch OFF. • Disconnect E14 and PSL.

3 Is resistance between E14 (female) (5) and ground more than 1 MΩ?

YES

• Insert T-adapter to E14. • Run engine at midrange speed (1300 rpm or more)

Repair or replace

Defective engine oil pressure (low) switch

Replace

Defective engine controller

Replace

Short circuit with ground in wiring harness between E14 (female) (6) and PSH.

Repair or replace

Defective engine oil pressure high-pressure switch

Replace

4 Is voltage between E14 (6) and NO ground 20 – 30 V? YES

• Turn starting switch OFF. • Disconnect E14 and PSH.

Short circuit with ground in wiring harness between E14 (female) (5) and PSL

5 Is resistance between E14 (female) (6) and ground more than 1 MΩ? YES

E-5 Related electrical circuit diagram

20-368

PC600-6

TROUBLESHOOTING

E-6

[E931] (Abnormality in fuel control dial sensor system) is displayed Cause

Remedy

1 • Insert T-adapter to E06. • Turn starting switch ON.

Is voltage between E06 (1) and NO (3) 4.6 – 5.4 V? YES

2 • Insert T-adapter to E11. • Turn starting switch ON.

Is voltage between E11 (4) and NO (11) 4.6 – 5.4 V?

Defective contact, disconnection, or short circuit with ground in wiring harness between E11 (female) (4) and E06 (female) (1) or E11 (female) (11) and E06 (female) (3)

YES

3 • Turn starting switch OFF. • Disconnect E06.

Is resistance between E06 (male) (1) and (3), between (2) and (3), and between (1)(2) and ground as shown in Table 1?

Defective engine controller

Replace Repair or replace

Defective fuel control dial

Replace

Defective contact, disconnection, or short circuit with ground in wiring harness between E11 (female) (6) and E06 (female) (2)

Repair or replace

Defective engine controller

Replace

YES 4 • Turn starting switch OFF. • Disconnect E11.

Is resistance between E11 (female) (4) and NO (11), between (6) and (11), and between (4)(6) and ground as shown in Table 2?

YES

Table 1 E06 (male) Between (1) and (3) Between (2) and (3) Between (1)(2) and ground

Table 2 Resistance value 4.0 k – 6.0 kΩ 0.24 – 7.0 kΩ Min. 1 MΩ

E11 (male) Between (4) and (11) Between (6) and (11) Between (4)(6) and ground

Resistance value 4.0 k – 6.0 kΩ 0.24 – 7.0 kΩ Min. 1 MΩ

E-6 Related electrical circuit diagram

PC600-6

20-369

TROUBLESHOOTING

E-7

E-7 [E934] (Abnormality in engine water temperature (high) sensor system) is displayed Cause • Turn starting switch OFF. • Disconnect TWH. • Water temperature: 10 – 100°C

Remedy

1 Is resistance between TWH NO (male) (1) and (2), between (1) and ground as shown in Table 1?

Defective engine water temperature (high) sensor

Replace

YES • Turn starting switch OFF. • Disconnect E12. • Water temperature: 10 – 100°C

2 Is resistance between E12 (female) (4) and (10) 90 k – 3.5 kΩ?

Defective contact or disconnection in wiring harness between E12 (female) Repair or replace (4) and TWH (female) (1) or between E12 (female) (10) and TWH (female) (2)

YES • Turn starting switch OFF. • Disconnect E12 and TWH.

3 Is resistance between E12 (female) (4) and ground more than 1 MΩ?

Short circuit with ground in wiring harness between E12 Repair or (female) (4) and TWH (female) replace (1)

YES Defective engine controller

Replace

Table 1 TWH (male) Between (1) and (2) Between (1) and ground

Resistance value 90 k – 3.5 kΩ Min. 1 MΩ

E-7 Related electrical circuit diagram

20-370

PC600-6

TROUBLESHOOTING

E-8

E-8 [E936] (Abnormality in engine oil pressure switch system) is displayed Cause

Remedy

1 • Insert T-adapter to E14.

Is voltage between E14 (5) and NO ground as shown in Table 1? YES

2 • Disconnect PSL.

Is resistance between PSL (switch end) and ground as shown in Table 2?

YES

• Insert T-adapter to E14.

3 Is voltage between E14 (6) and NO ground as shown in Table 3? YES

Defective engine oil pressure (low) switch

Replace

Defective contact, Repair or disconnection, or short circuit replace with ground in wiring harness between E14 (female) (5) and PSL

Defective engine controller

Replace

Defective engine oil pressure high-pressure switch

Replace

4 • Disconnect PSH.

Is resistance between PSH (switch end) and ground as shown in Table 4?

Defective contact or Repair or disconnection in wiring harness between E14 (female) replace (6) and PSH

YES

Table 2

Table 1 E14 (male)

Engine

Voltage

Between (5) and ground

When stopped At 600 rpm or more

Max. 1 V 20 – 30 V

PSL

Engine

When stopped Between PSL (switch) and ground At 600 rpm or more

Resistance value Max. 1 Ω Min. 1 MΩ

Table 4

Table 3 E14 Between (6) and ground

Resistance Engine value When stopped Max. 1 V At 1,300 rpm or more 20 – 30 V

Resistance value When stopped Max. 1 Ω Between PSH (switch) and ground At 1,300 rpm or more Min. 1 MΩ PSH

Engine

E-8 Related electrical circuit diagram

PC600-6

20-371

TROUBLESHOOTING

E-9

E-9 [E93C] (Abnormality in boost pressure sensor system) is displayed Cause • Connect T-adapter to E12. • Turn starting switch ON.

Remedy

1 Is voltage between E12 (2) and NO (10) 4.6 – 5.4 V? YES

2 • Disconnect PIM. • Turn starting switch ON.

NO Is voltage between PIM (female) (1) and (3) 4.6 – 5.4 V? YES

• Connect T-adapter to E11 and E12. • Turn starting switch ON.

Defective boost pressure sensor

Replace

3 Is voltage between E11 (3) and NO E12 (10) 0.3 – 4.7 V? YES

Defective engine controller 4

• Disconnect E11 and PIM. • Turn starting switch ON.

Defective contact, disconnection, or short circuit with ground in wiring harness Repair or between E12 (female) (2) and PIM (female) (1) or E12 (female) replace (10) and PIM (female) (3)

Is resistance between E11 (female) (3) and NO PIM (female) (2), and between E11 (female) (3) and ground as shown in Table 1?

Defective contact, disconnection, or short circuit with ground in wiring harness Repair or between E11 (female) (3) and replace PIM (female) (2)

YES Defective boost pressure sensor

Replace

Table 1 E11, PIM (female) Between E11 (3) and PIM (2) Between E11 (3) and ground

Resistance value Max. 1 Ω Min. 1 MΩ

E-9 Related electrical circuit diagram

20-372

PC600-6

TROUBLESHOOTING

E-10

E-10 [E93d] (Abnormality in fuel temperature sensor system) is displayed Cause • Turn starting switch OFF. • Disconnect THL. • Water temperature: 10 – 100°C

1 Is resistance between THL (male) NO (1) and (2), between (1) and ground as shown in Table 1?

Defective fuel temperature sensor

Remedy Replace

YES • Turn starting switch OFF. • Disconnect E12. • Water temperature: 10 – 100°C

2 Is resistance between E12 (female) (11) and (10) 9 k – 0.3 kΩ?

Defective contact or disconnection in wiring harness between E12 (female) Repair or replace (11) and THL (female) (1) or E12 (female) (10) and THL (female) (2)

YES • Turn starting switch OFF. • Disconnect E12 and THL.

3 Is resistance between E12 NO (female) (11) and ground more than 1 MΩ?

Short circuit with ground in wiring harness between E12 Repair or (female) (11) and THL (female) replace (1)

YES Defective engine controller

Replace

Table 1 THL (male) Between (1) and (2) Between (1) and ground

Resistance value 9 k – 0.3 kΩ Min. 1 MΩ

E-10 Related electrical circuit diagram

PC600-6

20-373

TROUBLESHOOTING

E-11, E-12

E-11 [E954] (Short circuit in starting switch C system) is displayed Cause • Connect T-adapter to E14. • Turn starting switch ON.

Remedy

1 Is voltage between E14 (2) and NO ground less than 1 V? YES Defective engine controller

Replace

Defective starting switch

Replace

Short circuit with power source in wiring harness between E14 (female) (2) and starting switch terminal C

Repair or replace

2 • Disconnect starting switch terminal C. • Turn starting switch ON.

Is voltage between starting switch terminal C and ground less than 1 V? YES

E-11 Related electrical circuit diagram

E-12 [E955] (Abnormality in network system) is displayed ﬂ Carry out troubleshooting for N Mode.

20-374

PC600-6

TROUBLESHOOTING

E-13

E-13 [E956] (Power source system abnormality 1) is displayed ﬂ Before carrying out troubleshooting, check that circuit breaker 8 has not shut off the circuit. (If the breaker has shut off the circuit, there has probably been a surge of current caused by a short circuit with the ground, so check the circuits related to circuit breaker 8.)

Cause

Remedy

1 • Insert T-adapter to E17. • Turn starting switch ON.

Is voltage between E17 (6)(14) and (5)(13) 20 – 30 V? YES

Defective engine controller

Replace

Defective power source relay (coil end)

Replace

2 • Turn starting switch OFF. • Disconnect R24.

Is resistance between R24 (male) (1) and (2) 200 – 900 Ω? YES

3 • Turn starting switch OFF. • Insert T-adapter to R24.

Is voltage between R24 (1) and NO ground 20 – 30 V? YES

4 • Turn starting switch OFF. • Disconnect R24.

Is resistance between R24 (female) (2) and ground less than 1 Ω?

YES

5 • Insert T-adapter to R24. • Turn starting switch ON.

Is voltage between R24 (3) and NO ground 20 – 30V? YES

• Turn starting switch OFF. • Insert T-adapter to R24.

6 Is voltage between R24 (5) and NO ground 20 – 30 V? YES

PC600-6

Defective contact, disconnection, or short circuit with ground in wiring harness Repair or replace between starting switch terminal ACC and R24 (female) (1)

Defective contact or Repair or disconnection in wiring harness between R24 (female) replace (2) and ground

Defective contact, disconnection, or short circuit with ground in wiring harness Repair or replace between battery relay terminal B – circuit breaker 8 – R24 (female) (3)

Defective power source relay (contact end)

Replace

Defective contact, disconnection, or short circuit Repair or with ground in wiring harness replace between E17 (female) (6)(14) and R24 (female) (5)

20-375

TROUBLESHOOTING

E-13, E-14

E-13 Related electrical circuit diagram

E-14

[E957] (Power source system abnormality 2) is displayed

Cause

Remedy

1 • Insert T-adapter to E17. • Turn starting switch OFF.

Is voltage between E17 (6)(14) and (5)(13) less than 8 V? YES

• Disconnect R24. • Insert T-adapter to E17. • Turn starting switch OFF.

Replace

Defective power source relay (contact end)

Replace

Short circuit with power source in wiring harness between E17 (female) (6)(14) and R24 (female) (5)

Repair or replace

2 Is voltage between E17 (6)(14) and (5)(13) less than 8 V? YES

20-376

Defective engine controller

PC600-6

TROUBLESHOOTING

E-14, E-15

E-14 Related electrical circuit diagram

E-15 [E95A] (Abnormality in fuel injection quantity control switch signal) is displayed

Cause

Remedy

1 Are both fuel injection quantity NO control switches 1 and 2 set to [F]? YES

PC600-6

Defective engine controller

Replace

Adjust Defective fuel injection quantity control switch setting again

20-377

TROUBLESHOOTING

E-16

E-16 [E96A] (Abnormality in engine water temperature (low) sensor system) is displayed

Cause • Turn starting switch OFF. • Disconnect TWL. • Water temperature: 10 – 100°C

Remedy

Is resistance between TWL NO (male) (1) and (2), between (1) and ground as shown in Table 1?

Defective engine water temperature (low) sensor

Replace

YES • Turn starting switch OFF. • Disconnect E12. • Water temperature: 10 – 100°C

Is resistance between E12 (female) (3) and (10) 9 k – 0.3 kΩ?

Defective contact or disconnection in wiring harness between E12 (female) Repair or replace (3) and TWL (female) (1) or between E12 (female) (10) and TWL (female) (2)

YES • Turn starting switch OFF. • Disconnect E12 and TWL.

Is resistance between E12 (female) (3) and ground more than 1 MΩ?

Short circuit with ground in wiring harness between E12 (female) (3) and TWL (female) (1)

Repair or replace

Defective engine controller

Replace

YES

Table 1 TWL (male) Between (1) and (2) Between (1) and ground

Resistance value 9 k – 0.3 kΩ Min. 1 MΩ

E-16 Related electrical circuit diagram

20-378

PC600-6

TROUBLESHOOTING

E-17

E-17 [E970] (Excess current in fuel supply pump PCV1 system) is displayed Cause

Remedy

1 • Turn starting switch OFF. • Disconnect E41.

Is resistance between E41 (male) NO (1) and (2), between (1)(2) and ground as shown in Table 1?

Defective fuel supply pump PCV1

Replace

YES

2 • Turn starting switch OFF. • Disconnect E17.

Is resistance between E17 (female) (10) – (11), (10)(11) – ground as shown in Table 2? YES

Short circuit with ground, or short circuit with power source in wiring harness between E17 Repair or (female) (10) and E41 (female) replace (1) or between E17 (female) (11) and E41 (female) (2) Defective engine controller

Replace

Table 1 E41 (male) Between (1) and (2) Between (1)(2) and ground

Resistance value 2.3 – 5.3 Ω Min. 1 MΩ

Table 2 E17 (male) Between (10) and (11) Between (10)(11) and ground

Resistance value 2.3 – 5.3 Ω Min. 1 MΩ

E-17 Related electrical circuit diagram

PC600-6

20-379

TROUBLESHOOTING

E-18

E-18 [E971] (Excess current in fuel supply pump PCV2 system) is displayed Cause

Remedy

1 • Turn starting switch OFF. • Disconnect E42.

Is resistance between E42 (male) NO (1) and (2), between (1)(2) and ground as shown in Table 1?

Defective fuel supply pump PCV2

Replace

YES

2 • Turn starting switch OFF. • Disconnect E17.

Is resistance between E17 (female) (4) – (12), (4)(12) – ground as shown in Table 2? YES

Short circuit with ground, or short circuit with power source in wiring harness between E17 Repair or (female) (4) and E42 (female) replace (1) or between E17 (female) (12) and E42 (female) (2) Defective engine controller

Replace

Table 1 E42 (male) Between (1) and (2) Between (1)(2) and ground

Resistance value 2.3 – 5.3 Ω Min. 1 MΩ

Table 2 E17 (male) Between (4) and (12) Between (4)(12) and ground

Resistance value 2.3 – 5.3 Ω Min. 1 MΩ

E-18 Related electrical circuit diagram

20-380

PC600-6

TROUBLESHOOTING

E-19

E-19 [E974] (Disconnection in fuel supply pump PCV1 system) is displayed Cause

Remedy

1 • Turn starting switch OFF. • Disconnect E41.

Is resistance between E41 (male) (1) and (2) 2.3 – 5.3 Ω

Defective fuel supply pump PCV1

Replace

Defective contact, disconnection, or short circuit with ground in wiring harness between E17 (female) (10) and E41 (female) (1) or between E17 (female) (11) and E41 (female) (2)

Repair or replace

Defective engine controller

Replace

YES

2 • Turn starting switch OFF. • Disconnect E17.

Is resistance between E17 (female) (10) – (11), (11) – ground as shown in Table 1? YES

Table 1 E17 (male) Between (10) and (11) Between (11) and ground

Resistance value 2.3 – 5.3 Ω Min. 1 MΩ

E-19 Related electrical circuit diagram

PC600-6

20-381

TROUBLESHOOTING

E-20

E-20 [E975] (Disconnection in fuel supply pump PCV2 system) is displayed Cause

Remedy

1 • Turn starting switch OFF. • Disconnect E42.

Is resistance between E42 (male) (1) and (2) 2.3 – 5.3 Ω?

Defective fuel supply pump PCV2

Replace

Defective contact, disconnection, or short circuit with ground in wiring harness between E17 (female) (4) and E42 (female) (1) or between E17 (female) (12) and E42 (female) (2)

Repair or replace

Defective engine controller

Replace

YES

2 • Turn starting switch OFF. • Disconnect E17.

Is resistance between E17 (female) (4) – (12), (12) – ground as shown in Table 1? YES

Table 1 E17 (male) Between (4) and (12) Between (12) and ground

Resistance value 2.3 – 5.3 Ω Min. 1 MΩ

E-20 Related electrical circuit diagram

20-382

PC600-6

TROUBLESHOOTING

E-21

E-21 [E977] (Abnormality in common rail fuel pressure sensor system) is displayed Cause

Remedy

1 • Connect T-adapter to E12. • Turn starting switch ON.

Is voltage between E12 (2) and NO (10) 4.6 – 5.4 V? YES

• Disconnect PFUEL. • Turn starting switch ON.

2 NO Is voltage between PFUEL (female) (1) and (3) 4.6 – 5.4 V? YES

• Connect T-adapter to E11 and E12. • Turn starting switch ON.

Defective common rail fuel pressure sensor

Replace

Defective engine controller

Replace

3 Is voltage between E11 (1) and NO E12 (10) 0.3 – 4.7 V? YES

4 • Disconnect E11 and PFUEL. • Turn starting switch ON.

Defective contact, disconnection, or short circuit with ground in wiring harness between E12 (female) (2) and PFUEL (female) (3) or between Repair or E12 (female) (10) and PFUEL replace (female) (1)

Is resistance between E11 (female) (1) and NO PFUEL (female) (2), and between E11 (female) (1) and ground as shown in Table 1?

Defective contact, disconnection, or short circuit with ground in wiring harness Repair or between E11 (female) (1) and replace PFUEL (female) (2)

YES Defective common rail fuel pressure sensor

Replace

Table 1 E11, PFUEL (female) Between E11 (1) and PFUEL (2) Between E11 (1) and ground

Resistance value Max. 1 Ω Min. 1 MΩ

E-21 Related electrical circuit diagram

PC600-6

20-383

TROUBLESHOOTING

E-22

E-22 [E979] (Common rail fuel high pressure abnormality 1) is displayed [E97A] (Common rail fuel high pressure abnormality 2) is displayed Cause

Remedy

—

Go to troubleshooting for service code displayed

1 • Turn starting switch ON.

Is another error code displayed at same time? YES

2 NO

Is fuel being used suitable for ambient temperature?

Unsuitable fuel being used

Change

YES

Repair or replace

3 • Loosen joint of fuel supply pump overflow valve.

When priming pump is operated, does fuel leak out from connection of joint?

YES

4 • Disassemble fuel supply pump overflow valve.

In overflow valve, is spring broken, seat worn, or ball stuck?

—

Go to Troubleshooting No. 7

YES Defective overflow valve

Replace

Defective pressure limiter

Replace

Defective electrical system of common rail fuel pressure sensor

Repair or replace

Defective mechanical system of common rail fuel pressure sensor

Replace

Clogged overflow pipe

Clean or replace

5 • Loosen joint of common rail pressure limiter.

When engine is started, does fuel leak out from connection of joint?

YES

6 When troubleshooting for error NO code [E977] is carried out, does any problem occur in electrical system? YES

7 Is overflow pipe clogged?

YES

20-384

PC600-6

TROUBLESHOOTING

E-23

E-23 [E97b] (Fuel supply pump non-force feed 1) is displayed [E97C] (Fuel supply pump non-force feed 2) is displayed Cause

Remedy

—

Go to troubleshooting for service code displayed

1 • Turn starting switch ON.

Is another error code displayed at same time? YES

2 NO

Does fuel being used match ambient temperature?

Unsuitable fuel being used

Change

Fuel leakage in high-pressure circuit

Repair or replace

Filter or strainer clogged

Clean or replace

Defective equipment in lowpressure circuit (See Note 2)

Repair or replace

Defective pressure limiter

Replace

Defective fuel injector

Replace

Defective common rail fuel pressure sensor

Replace

Defective fuel supply pump

Replace

Defective electrical system of fuel supply pump PCV

Repair or replace

YES • Check visually with engine stopped, then check visually with engine at low idling.

3 Is there any leakage of fuel from fuel pump, NO high- pressure primary piping, common rail, or high-pressure secondary piping?

YES

4 NO

Is filter or strainer clogged? (See Note 1) YES

• Measure fuel pressure (see TESTING AND ADJUSTING). • Engine at high idling.

5 Is fuel low-pressure circuit pressure 0.15 – 0.3 MPa {1.5 – 3 kg/cm2}?

YES • Disconnect outlet piping of common rail pressure limiter. • Start engine.

6 Is drain amount from pressure NO limiter less than 10 cc/min? YES

• Disconnect pressure compensation valve connector on one side. • Start engine.

7 Does engine stop when PCV connector NO is disconnected from one side of fuel pump and engine is run on one lung?

YES

• Disconnect hose at portion collecting spill from injector. • Start engine.

8 NO

Is spill flow from injector normal? (See Note 3) YES

9 Carry out troubleshooting for service NO codes [E970], [E971], [E974], [E975]. Does any problem occur with electrical system?

YES

PC600-6

20-385

TROUBLESHOOTING

E-23

Note 1: Carry out inspection, cleaning, and replacement of the filter and strainer as follows. 1) Gauze filter Disassemble and inspect. Clean it if it is clogged. 2) Strainer at upstream side of gauze filter If the gauze filter is clogged, clean the upstream strainer also. 3) Fuel filter If the problem is not solved even after carrying out Steps 1) and 2) above, replace the fuel filter. Note 2: If the equipment in the low-pressure circuit is defective, inspect the following points. 1) Remaining amount of fuel 2) Stuck, worn feed pump 3) Leakage, clogged low-pressure fuel piping 4) Defective actuation of bypass valve, incorrect assembly with other parts (See Fig. 1) 5) Fuel entering oil pan (fuel leakage inside head cover) Fig. 1 Installation positions of overflow valve (1), bypass valve (2), and fuel inlet port joint (with gauze filter) (3)

20-386

PC600-6

TROUBLESHOOTING

E-23, E-24, E-25

Note 3: Method of measuring amount of fuel spill flow ¤ The fuel in the spill line is at high temperature (up to 90°C), so be careful not to burn yourself during the operation. 1) Disconnect the hose connected to the spill tube return collection portion (rear of engine). 2) Connect another hose to the tip of the spill tube, and collect the spill fuel in a container. 3) Start the engine, stall the engine at each speed, and measure the spill fuel amount for 1 minute.

Limits for fuel spill amount (total for 6 cylinders) Stall speed (rpm)

Spill limit (cc/min)

1,600

960

1,700

1,020

1.800

1,080

1,900

1,140

2,000

1,200

E-24 [E97d] (Abnormality in common rail fuel pressure) is displayed ﬂ Go to Troubleshooting of error codes [E979] and [E97A].

E-25 [E980] (Defective engine controller) is displayed

Cause 1 • Turn starting switch OFF. • Disconnect E17.

Is resistance between E17 (female) (5)(13) and ground less than 1 Ω?

Remedy

Defective contact or Repair or disconnection in wiring harness between E17 (female) replace (5)(13) and ground

YES Defective engine controller

Replace

E-25 Related electrical circuit diagram

PC600-6

20-387

TROUBLESHOOTING

E-26

E-26 [E981] (Disconnection in No. 1 fuel injector system) is displayed ¤ A high voltage (110 – 130 V) is used in the electrical circuit for the fuel injector, so be careful of electrocution or electric leakage. For details, see TESTING AND ADJUSTING, Handling engine controller high voltage circuit.

Cause

Remedy

1 • Disconnect E31 • Turn starting switch OFF.

Is resistance between E31 (male) (1) and (2) 0.4 – 1.1 Ω?

Defective No. 1 fuel injector

Replace

YES

2 • Turn starting switch OFF. • Disconnect E16.

NO Is resistance between E16 (female) (7) and (8) 0.4 – 1.1 Ω? YES

Defective contact or disconnection in wiring harness between E16 (female) Repair or (7) and E31 (female) (1) or replace between E16 (female) (8) and E31 (female) (2) Defective engine controller

Replace

E-26 Related electrical circuit diagram

20-388

PC600-6

TROUBLESHOOTING

E-27

E-27 [E982] (Disconnection in No. 2 fuel injector system) is displayed ¤ A high voltage (110 – 130 V) is used in the electrical circuit for the fuel injector, so be careful of electrocution or electric leakage. For details, see TESTING AND ADJUSTING, Handling engine controller high voltage circuit.

Cause

Remedy

1 • Turn starting switch OFF. • Disconnect E32.

Is resistance between E32 (male) (1) and (2) 0.4 – 1.1 Ω?

Defective No. 2 fuel injector

Replace

YES

2 • Turn starting switch OFF. • Disconnect E16.

NO Is resistance between E16 (female) (4) and (10) 0.4 – 1.1 Ω? YES

Defective contact or disconnection in wiring harness between E16 (female) Repair or (4) and E32 (female) (1) or replace between E16 (female) (10) and E32 (female) (2) Defective engine controller

Replace

E-27 Related electrical circuit diagram

PC600-6

20-389

TROUBLESHOOTING

E-28

E-28 [E983] (Disconnection in No. 3 fuel injector system) is displayed ¤ A high voltage (110 – 130 V) is used in the electrical circuit for the fuel injector, so be careful of electrocution or electric leakage. For details, see TESTING AND ADJUSTING, Handling engine controller high voltage circuit.

Cause

Remedy

1 • Turn starting switch OFF. • Disconnect E33.

Is resistance between E33 (male) (1) and (2) 0.4 – 1.1 Ω?

Defective No. 3 fuel injector

Replace

YES

2 • Turn starting switch OFF. • Disconnect E16.

NO Is resistance between E16 (female) (3) and (9) 0.4 – 1.1 Ω? YES

Defective contact or disconnection in wiring harness between E16 (female) Repair or (3) and E33 (female) (1) or replace between E16 (female) (9) and E33 (female) (2) Defective engine controller

Replace

E-28 Related electrical circuit diagram

20-390

PC600-6

TROUBLESHOOTING

E-29

E-29 [E984] (Disconnection in No. 4 fuel injector system) is displayed ¤ A high voltage (110 – 130 V) is used in the electrical circuit for the fuel injector, so be careful of electrocution or electric leakage. For details, see TESTING AND ADJUSTING, Handling engine controller high voltage circuit.

Cause

Remedy

1 • Turn starting switch OFF. • Disconnect E34.

Is resistance between E34 (male) (1) and (2) 0.4 – 1.1 Ω?

Defective No. 4 fuel injector

Replace

YES

2 • Turn starting switch OFF. • Disconnect E17.

NO Is resistance between E17 (female) (3) and (9) 0.4 – 1.1 Ω? YES

Defective contact or disconnection in wiring harness between E17 (female) Repair or (3) and E34 (female) (1) or replace between E17 (female) (9) and E34 (female) (2) Defective engine controller

Replace

E-29 Related electrical circuit diagram

PC600-6

20-391

TROUBLESHOOTING

E-30

E-30 [E985] (Disconnection in No. 5 fuel injector system) is displayed ¤ A high voltage (110 – 130 V) is used in the electrical circuit for the fuel injector, so be careful of electrocution or electric leakage. For details, see TESTING AND ADJUSTING, Handling engine controller high voltage circuit.

Cause

Remedy

1 • Turn starting switch OFF. • Disconnect E35.

Is resistance between E35 (male) (1) and (2) 0.4 – 1.1 Ω?

Defective No. 5 fuel injector

Replace

YES

2 • Turn starting switch OFF. • Disconnect E17.

NO Is resistance between E17 (female) (1) and (7) 0.4 – 1.1 Ω? YES

Defective contact or disconnection in wiring harness between E17 (female) Repair or (1) and E35 (female) (1) or replace between E17 (female) (7) and E35 (female) (2) Defective engine controller

Replace

E-30 Related electrical circuit diagram

20-392

PC600-6

TROUBLESHOOTING

E-31

E-31 [E986] (Disconnection in No. 6 fuel injector system) is displayed ¤ A high voltage (110 – 130 V) is used in the electrical circuit for the fuel injector, so be careful of electrocution or electric leakage. For details, see TESTING AND ADJUSTING, Handling engine controller high voltage circuit.

Cause

Remedy

1 • Turn starting switch OFF. • Disconnect E36.

Is resistance between E36 (male) (1) and (2) 0.4 – 1.1 Ω?

Defective No. 6 fuel injector

Replace

YES

2 • Turn starting switch OFF. • Disconnect E17.

NO Is resistance between E17 (female) (2) and (8) 0.4 – 1.1 Ω? YES

Defective contact or disconnection in wiring harness between E17 (female) Repair or (2) and E36 (female) (1) or replace between E17 (female) (8) and E36 (female) (2) Defective engine controller

Replace

E-31 Related electrical circuit diagram

PC600-6

20-393

TROUBLESHOOTING

E-32

E-32 [E98A] (Short circuit in No. 1, No. 2, No. 3 fuel injector system) is displayed ¤ A high voltage (110 – 130 V) is used in the electrical circuit for the fuel injector, so be careful of electrocution or electric leakage. For details, see TESTING AND ADJUSTING, Handling engine controller high voltage circuit. a) Determining location of problem • Turn starting switch OFF. • Disconnect E16.

Cause

1 Is resistance between E16 (female) NO (7) and (8), between (7)(8) and ground as shown in Table 1?

Remedy

Abnormality in No. 1 fuel injector system

Go to troubleshooting procedure b).

Abnormality in No. 2 fuel injector system

Go to troubleshooting procedure c).

Abnormality in No. 3 fuel injector system

Go to troubleshooting procedure d).

YES

• Turn starting switch OFF. • Disconnect E16.

2 Is resistance between E16 (female) NO (4) and (10), between (4)(10) and ground as shown in Table 1?

YES 3 • Turn starting switch OFF. • Disconnect E16.

Is resistance between E16 (female) NO (3) and (9), between (3)(9) and ground as shown in Table 1?

YES

4 • Turn starting switch OFF. • Disconnect E17.

Is resistance between E17 (female) (5)(13) and ground less than 1 Ω?

Defective contact or disconnection in wiring Repair or harness between E17 (female) replace (5)(13) and ground

YES

Defective engine controller

Replace

Table 1 E16 E16 E16 (female) (female) (female) Between (7) and (8) Between (4) and (10) Between (3) and (9) Between (7)(8) and ground Between (4)(10) and ground Between (3)(9) and ground

Resistance value 0.4 – 1.1 Ω Min. 1 MΩ

b) Troubleshooting No. 1 fuel injector system Cause

Remedy

1 • Turn starting switch OFF. • Disconnect E31.

Is resistance between E31 (male) (1) and (2), between (1)(2) and ground as shown in Table 2? YES

Table 2 E31 (female) Between (1) and (2) Between (1)(2) and ground

20-394

Resistance value 0.4 – 1.1 Ω Min. 1 MΩ

Defective No. 1 fuel injector

Replace

Short circuit with ground or short circuit with power source in wiring harness between E16 (female) (7) and E31 (female) (1) or between E16 (female) (8) and E16 (female) (2)

Repair or replace

PC600-6

TROUBLESHOOTING

E-32

c) Troubleshooting No. 2 fuel injector system Cause

Remedy

1 • Turn starting switch OFF. • Disconnect E32.

Is resistance between E32 (male) (1) and (2), between (1)(2) and ground as shown in Table 3?

YES

Table 3 E32 (female) Between (1) and (2) Between (1)(2) and ground

Resistance value 0.4 – 1.1 Ω Min. 1 MΩ

Defective No. 2 fuel injector

Replace

Short circuit with ground or short circuit with power source in wiring harness between E16 (female) (4) and E32 (female) (1) or between E16 (female) (10) and E16 (female) (2)

Repair or replace

d) Troubleshooting No. 3 fuel injector system Cause

Remedy

1 • Turn starting switch OFF. • Disconnect E33.

Is resistance between E33 (male) (1) and (2), between (1)(2) and ground as shown in Table 4? YES

Table 4 E33 (female) Between (1) and (2) Between (1)(2) and ground

Resistance value 0.4 – 1.1 Ω Min. 1 MΩ

Defective No. 3 fuel injector

Replace

Short circuit with ground or short circuit with power source in wiring harness between E16 (female) (3) and E33 (female) (1) or between E16 (female) (9) and E33 (female) (2)

Repair or replace

E-32 a) b) Related electrical circuit diagram

PC600-6

20-395

TROUBLESHOOTING

E-32

E-32 a) c) Related electrical circuit diagram

E-32 a) d) Related electrical circuit diagram

20-396

PC600-6

TROUBLESHOOTING

E-33

E-33 [E98b] (Short circuit in No. 3, No. 4, No. 5 fuel injector system) is displayed ¤ A high voltage (110 – 130 V) is used in the electrical circuit for the fuel injector, so be careful of electrocution or electric leakage. For details, see TESTING AND ADJUSTING, Handling engine controller high voltage circuit. a) Determining location of problem • Turn starting switch OFF. • Disconnect E17.

Cause

1 Is resistance between E17 (female) NO (3) and (9), between (3)(9) and ground as shown in Table 1?

Remedy

Abnormality in No. 4 fuel injector system

Go to troubleshooting procedure b).

Abnormality in No. 5 fuel injector system

Go to troubleshooting procedure c).

Abnormality in No. 6 fuel injector system

Go to troubleshooting procedure d).

YES

• Turn starting switch OFF. • Disconnect E17.

2 Is resistance between E17 (female) NO (1) and (7), between (1)(7) and ground as shown in Table 1?

YES 3 • Turn starting switch OFF. • Disconnect E17.

Is resistance between E17 (female) NO (2) and (8), between (2)(8) and ground as shown in Table 1?

YES

4 • Turn starting switch OFF. • Disconnect E17.

Is resistance between E17 (female) (5)(13) and ground less than 1 Ω?

Defective contact or disconnection in wiring Repair or harness between E17 (female) replace (5)(13) and ground

YES

Defective engine controller

Replace

Table 1 E17 E17 E17 (female) (female) (female) Between (3) and (9) Between (1) and (7) Between (2) and (8) Between (3)(9) and ground Between (1)(7) and ground Between (2)(8) and ground

Resistance value 0.4 – 1.1 Ω Min. 1 MΩ

b) Troubleshooting No. 4 fuel injector system Cause

Remedy

1 • Turn starting switch OFF. • Disconnect E34.

Is resistance between E34 (male) (1) and (2), between (1)(2) and ground as shown in Table 2? YES

Table 2 E34 (female) Between (1) and (2) Between (1)(2) and ground

PC600-6

Resistance value 0.4 – 1.1 Ω Min. 1 MΩ

Defective No. 4 fuel injector

Replace

Short circuit with ground or short circuit with power source in wiring harness between E17 (female) (3) and E34 (female) (1) or between E17 (female) (9) and E34 (female) (2)

Repair or replace

20-397

TROUBLESHOOTING

E-33

c) Troubleshooting No. 5 fuel injector system Cause

Remedy

1 • Turn starting switch OFF. • Disconnect E35.

Is resistance between E35 (male) (1) and (2), between (1)(2) and ground as shown in Table 3?

YES

Table 3 E35 (female) Between (1) and (2) Between (1)(2) and ground

Resistance value 0.4 – 1.1 Ω Min. 1 MΩ

Defective No. 5 fuel injector

Replace

Short circuit with ground or short circuit with power source in wiring harness between E17 (female) (1) and E35 (female) (1) or between E17 (female) (7) and E35 (female) (2)

Repair or replace

Cause

Remedy

d) Troubleshooting No. 6 fuel injector system 1 • Turn starting switch OFF. • Disconnect E36.

Is resistance between E36 (male) (1) and (2), between (1)(2) and ground as shown in Table 4? YES

Table 4 E36 (female) Between (1) and (2) Between (1)(2) and ground

Resistance value 0.4 – 1.1 Ω Min. 1 MΩ

Defective No. 6 fuel injector

Replace

Short circuit with ground or short circuit with power source in wiring harness between E17 (female) (2) and E36 (female) (1) or between E17 (female) (8) and E36 (female) (2)

Repair or replace

E-33 a) b) Related electrical circuit diagram

20-398

PC600-6

TROUBLESHOOTING

E-33

E-33 a) c) Related electrical circuit diagram

E-33 a) d) Related electrical circuit diagram

PC600-6

20-399

TROUBLESHOOTING OF PUMP CONTROLLER SYSTEM (C MODE)

Points to remember when carrying out troubleshooting of pump controller system .................. 20-452 Action taken by controller when abnormality occurs and problems on machine ......................... 20-454 Judgement table for pump controller and hydraulic related parts .................................................. 20-462 Electrical circuit diagram of C mode system ...................................................................................... 20-464 Troubleshooting flow charts for each failure mode ........................................................................... 20-466 C- 1 Abnormality in controller power source (controller LED is OFF) ...................................... 20-466 C- 2 [E232] (Short circuit in pump TVC solenoid system) is displayed ....................................20-467 C- 3 [E233] (Disconnection in pump TVC solenoid system) is displayed .................................20-469 C- 4 [E203] (Short circuit in swing holding brake solenoid system) is displayed ................... 20-471 C- 5 [E213] (Disconnection in swing holding brake solenoid system) is displayed................ 20-473 C- 6 [E201] (Short circuit in CO cancel solenoid system) is displayed ..................................... 20-475 C- 7 [E211] (Disconnection in CO cancel solenoid system) is displayed ..................................20-476 C- 8 [E204] (Short circuit in 2-stage relief solenoid system) is displayed ............................... 20-477 C- 9 [E214] (Disconnection in 2-stage relief solenoid system) is displayed ............................ 20-478 C-10 [E206] (Short circuit in travel speed solenoid system) is displayed..................................20-479 C-11 [E216] (Disconnection in travel speed solenoid system) is displayed ............................. 20-480 C-12 [E311] (Short circuit in bucket CURL Hi cancel solenoid system) is displayed ............... 20-481 C-13 [E312] (Disconnection in bucket CURL Hi cancel solenoid system) is displayed ............ 20-482 C-14 [E217] (Model selection input error) is displayed ................................................................ 20-483 C-15 [E224] (Abnormality in front pump pressure sensor system) is displayed ..................... 20-485 C-16 [E225] (Abnormality in rear pump pressure sensor system) is displayed ....................... 20-486 C-17 [E226] (Abnormality in pressure sensor power source system) is displayed ................. 20-487 C-18 [E227] (Abnormality in engine speed sensor system) is displayed ...................................20-488 C-19 Abnormality in machine push-up solenoid system (no service code displayed) ........... 20-489 C-20 [E207] Short circuit in flashing light relay drive system is displayed .............................. 20-491 C-21 Flashing light relay does not work........................................................................................ 20-492 C-22 [E231] Abnormality (short circuit) in step light power source retention relay output system is displayed .................................................................................................... 20-493 C-23 Step light switch does not work............................................................................................ 20-494 C-24 [E302] Short circuit in step light relay drive system is displayed ..................................... 20-495 C-25 Step light does not light up ................................................................................................... 20-496 C-26 [E228] Abnormality in auto-deceleration output system is displayed .............................. 20-497

PC600-6

20-451

TROUBLESHOOTING

POINTS TO REMEMBER WHEN TROUBLESHOOTING CONTROLLER SYSTEM

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

20-452

PC600-6

TROUBLESHOOTING

ACTION TAKEN BY CONTROLLER WHEN ABNORMALITY OCCURS AND PROBLEMS ON MACHINE

ACTION TAKEN BY CONTROLLER WHEN ABNORMALITY OCCURS AND PROBLEMS ON MACHINE User Service code code

E232

Abnormal system

Short circuit in TVC solenoid system

E02

E233

E203

Disconnection in TVC solenoid system

Short circuit in swing holding brake solenoid system

E03

—

20-454

E213

Disconnection in swing holding brake solenoid system

E201

Short circuit in CO cancel solenoid system

E211

Disconnection in CO cancel solenoid system

Nature of abnormality 1. Short circuit with ground, short circuit inside pump TVC solenoid 2. Short circuit with power source, short circuit with ground in wiring harness between controller C02 (8) and TVC solenoid C13 (1) ((+) end) 3. Short circuit with power source in wiring harness between controller C02 (18) and TVC solenoid C13 (2) ((–) end) 4. Defective pump controller 1. Disconnection, defective contact inside pump TVC solenoid 2. Disconnection, defective contact in wiring harness between controller C02 (8) and TVC solenoid C13 (1) ((+) end) 3. Disconnection, defective contact, short circuit with ground in wiring harness between controller C02 (18) and TVC solenoid C13 (2) ((–) end) 4. Defective pump controller

1. Short circuit with ground, short circuit inside swing holding brake solenoid 2. Short circuit with ground in wiring harness between controller C01 (3) and solenoid V04 (2) ((+) end) 3. Defective pump controller

1. Disconnection, defective contact inside swing holding brake solenoid 2. Disconnection, defective contact, short circuit with power source in wiring harness between controller C01 (3) and solenoid V04 (2) ((+) end) 3. Disconnection, defective contact in wiring harness between solenoid V04 (1) and chassis ground ((–) end) 4. Defective pump controller 1. Short circuit with ground, short circuit inside CO cancel solenoid 2. Short circuit with ground in wiring harness between controller C01 (8) and solenoid V02 (2) ((+) end) 3. Defective pump controller

1. Disconnection, defective contact inside CO cancel solenoid 2. Disconnection, defective contact, short circuit with power source in wiring harness between controller C01 (8) and solenoid V02 (2) ((+) end) 3. Disconnection, defective contact in wiring harness between solenoid V02 (1) and chassis ground ((–) end) 4. Defective pump controller

PC600-6

TROUBLESHOOTING

Condition when normal (voltage, current, resistance)

· ·

ACTION TAKEN BY CONTROLLER WHEN ABNORMALITY OCCURS AND PROBLEMS ON MACHINE

Action by controller when abnormality is detected

Problem that appears on machine when there is abnormality

Resistance of solenoid: 10 – 22 Ω

1. Makes output to TVC solenoid 0. 2. Displays user code E02 on monitor panel. ﬂ If the abnormality is restored by the vibration of the machine, the power source is reset to restore to the proper condition. (However, the service code display does not go out.)

1. No current flows to the TVC solenoid. Therefore, when the load is large, there is a big drop in the engine speed, which may result in the engine stalling. 2. The swing acceleration is poor

Resistance of solenoid: 10 – 22 Ω Current: 1000 mA (DH mode, auto-deceleration ON, levers at neutral, fuel control dial at MAX.)

1. The current stops flowing to the TVC solenoid, so no particular action is taken. 2. If there is a short circuit with the ground at the (–) end, the current (min. 1A) continues to flow to the TVC solenoid. 3. It displays user code E02 on the monitor panel. ﬂ If the abnormality is restored by the vibration of the machine, it resets automatically to restore to the proper condition. (However, the service code display does not go out.)

1. In the case of 1, it is the same as E232. 2. In the case of 2, the current (min. 1 A) continues to flow to the TVC solenoid, so the output of the TVC valve increases and the overall speed becomes slower.

When the swing is operated, the motor brake is not released, so the upper structure does not swing.

Resistance of solenoid: 20 – 60 Ω

1. Makes output to solenoid 0. 2. Displays user code E03 on monitor panel. ﬂ If the abnormality is restored by the vibration of the machine, the power source is reset to restore to the proper condition. (However, the service code display does not go out.)

Resistance of solenoid: 20 – 60 Ω

PC600-6

1. The current stops flowing to the solenoid, so no particular action is taken. 2. Displays user code E03 on monitor panel. ﬂ If the abnormality is restored by the vibration of the machine, it resets automatically to restore to the proper condition. (However, the service code display does not go out.)

Same as display for E203

1. Makes output to TVC solenoid 0. ﬂ If the abnormality is restored by the vibration of the machine, the power source is reset to restore to the proper condition. (However, the service code display does not go out.)

Lack of power in DH mode or heavy lift

1. The current stops flowing to the solenoid, so no particular action is taken. ﬂ If the abnormality is restored by the vibration of the machine, it resets automatically to restore to the proper condition. (However, the service code display does not go out.)

Same as display for E201

20-455

TROUBLESHOOTING

ACTION TAKEN BY CONTROLLER WHEN ABNORMALITY OCCURS AND PROBLEMS ON MACHINE

User Service code code

Abnormal system

Nature of abnormality

E204

Short circuit in 2stage relief solenoid system

1. Short circuit with ground, short circuit inside 2-stage relief solenoid 2. Short circuit with ground in wiring harness between controller C01 (10) and solenoid V05 (2) ((+) end) 3. Defective pump controller

——

E214

Disconnection in 2stage relief solenoid system

1. Disconnection, defective contact inside 2-stage relief solenoid 2. Disconnection, defective contact, short circuit with power source in wiring harness between controller C01 (10) and solenoid V05 (2) ((+) end) 3. Disconnection, defective contact in wiring harness between solenoid V05 (1) and chassis ground ((–) end) 4. Defective pump controller

——

E206

Short circuit in travel speed solenoid system

1. Short circuit with ground, short circuit inside travel speed solenoid 2. Short circuit with ground in wiring harness between controller C01 (9) and solenoid V06 (2) ((+) end) 3. Defective pump controller 1. Disconnection, defective contact inside travel speed solenoid 2. Disconnection, defective contact, short circuit with power source in wiring harness between controller C01 (9) and solenoid V06 (2) ((+) end) 3. Disconnection, defective contact in wiring harness between solenoid V06 (1) and chassis ground ((–) end) 4. Defective pump controller

——

E216

Disconnection in travel speed solenoid system

——

E217

Model selection input error

——

20-456

E218

Network response overtime error

1. Disconnection, defective contact, short circuit with ground in model selection wiring harness C17(5)(6)(7)(13)(14) 2. Defective pump controller 1. Disconnection, short circuit, short circuit with ground in network wiring harness 2. Abnormality in pump controller 3. Abnormality in monitor panel 4. Abnormality in engine controller

PC600-6

TROUBLESHOOTING

Action by controller when abnormality is detected

Problem that appears on machine when there is abnormality

Resistance of solenoid: 20 – 60 Ω

1. Makes output to solenoid 0. ﬂ If the abnormality is restored by the vibration of the machine, the power source is reset to restore to the proper condition. (However, the service code display does not go out.)

Power does not increase in boom RAISE (operated independently) in heavy lift mode

Resistance of solenoid: 20 – 60 Ω

Same as display for E204

Even if the travel speed is switched, the travel speed does not change (remains at Lo)

Same as display for E206

Condition when normal (voltage, current, resistance)

ACTION TAKEN BY CONTROLLER WHEN ABNORMALITY OCCURS AND PROBLEMS ON MACHINE

Resistance of solenoid: 20 – 60 Ω

Between C17 (7),(13) and chassis: Max. 1 Ω Between C17 (5),(6),(14) and chassis: Min. 1 MΩ

Detects abnormality in input 1. Retains data when starting switch is ON. 2. Functions as PC300 when non-set conditions are input.

1. Engine stalls, or 2. Work equipment, swing, travel speeds are all slow or lack power

1. When communications are impossible with the monitor, engine controller, control is carried out with the following settings. (1) Working mode: G (2) Travel speed: Lo (3) Auto-deceleration: ON (4) Heavy lift: OFF (others are as normal)

1. (1) Even when travel is operated, power does not increase (2) Auto-deceleration cannot be canceled (3) Travel speed does not increase

PC600-6

20-457

TROUBLESHOOTING

User Service code code

——

20-458

E224

E225

Abnormal system

Nature of abnormality

Abnormality in front pump pressure sensor system

1. Disconnection, defective contact, short circuit, short circuit with ground inside front pump pressure sensor 2. Disconnection, defective contact, short circuit in wiring harness between controller C03 (6) and pressure sensor C08 (2) ((+) end) and between C03 (16) and C08 (1) ((–) end) 3. Disconnection, defective contact, short circuit with power source, short circuit with ground in wiring harness between controller C03 (3) and pressure sensor C08 (3) (SIG end) 4. Defective pump controller

Abnormality in rear pump pressure sensor system

1. Disconnection, defective contact, short circuit, short circuit with ground inside rear pump pressure sensor 2. Disconnection, defective contact, short circuit in wiring harness between controller C03 (6) and pressure sensor C07 (2) ((+) end) and between C03 (16) and C07 (1) ((–) end) 3. Disconnection, defective contact, short circuit with power source, short circuit with ground in wiring harness between controller C03 (13) and pressure sensor C07 (3) (SIG end) 4. Defective pump controller

E226

Abnormality in pressure sensor power source system

E227

Abnormality in engine speed sensor system

E311

E312

ACTION TAKEN BY CONTROLLER WHEN ABNORMALITY OCCURS AND PROBLEMS ON MACHINE

Short circuit in bucket CURL Hi cancel solenoid system

Disconnection in bucket CURL Hi cancel solenoid system

1. Short circuit, short circuit with ground inside front pump pressure sensor or rear pump pressure sensor 2. Short circuit, short circuit with ground in wiring harness between controller C03 (6) and front pressure sensor C08 (2) or rear pressure sensor C07 (2) ((+) end) 3. Defective pump controller

1. Disconnection, defective contact, short circuit with ground inside engine speed sensor 2. Disconnection, defective contact, short circuit with ground in wiring harness between controller C16 (1) and speed sensor ENE (2) ((–) end) and between C16 (2) and ENE (1) (SIG end) 3. Defective pump controller 1. Short circuit with ground, short circuit inside bucket CURL Hi cancel solenoid 2. Short circuit with ground in wiring harness between controller C01 (2) and solenoid V08 (2) ((+) end) 3. Defective pump controller

Disconnection, defective contact inside bucket CURL Hi cancel solenoid ?? 1. Disconnection, defective contact inside straight- travel solenoid ?? 2. Disconnection, defective contact, short circuit with power source in wiring harness between controller C01 (2) and solenoid V08 (2) ((+) end) 3. Disconnection, defective contact in wiring harness between solenoid V08 (1) and chassis ground ((–) end) 4. Defective pump controller

PC600-6

TROUBLESHOOTING

Condition when normal (voltage, current, resistance) · · ·

· · ·

· ·

ACTION TAKEN BY CONTROLLER WHEN ABNORMALITY OCCURS AND PROBLEMS ON MACHINE

Action by controller when abnormality is detected

Problem that appears on machine when there is abnormality

Voltage between C03 (3) and (16): 0.5 – 4.5 V Voltage between C03 (6) and (16): 18 – 28 V Resistance between C03 (female) (3) and (16), (3) and chassis: Min. 1 MΩ (Disconnect connectors C03 and C08.)

1. Takes front pump pressure as 0 MPa (0 kg/cm2) when actuating. ﬂ If the abnormality is restored by the vibration of the machine, it resets automatically to restore to the proper condition. (However, the service code display does not go out.)

1. The travel speed does not automatically shift (it does not change from Hi to Lo). ﬂ If the button is operated, the panel display is switched.

Voltage between C03 (13) and (16): 0.5 – 4.5 V Voltage between C03 (6) and (16): 18 – 28 V Resistance between C03 (female) (13) and (16), (13) and chassis: Min. 1 MΩ (Disconnect connectors C03 and C07.)

1. Takes rear pump pressure as 0 MPa (0 kg/cm2) when actuating. ﬂ If the abnormality is restored by the vibration of the machine, it resets automatically to restore to the proper condition. (However, the service code display does not go out.)

1. The travel speed does not automatically shift (it does not change from Hi to Lo). ﬂ If the button is operated, the panel display is switched.

1. Takes front pump and rear pump pressure as 0 MPa (0 kg/cm2) when actuating. 2. When abnormality is detected, it switches the output OFF, and when all levers are returned to neutral, it outputs again. ﬂ This automatic resetting is repeated up to 3 times.

1. The travel speed does not automatically shift (it does not change from Hi to Lo). ﬂ If the button is operated, the panel display is switched.

1. It functions in the equivalent of the G mode (the speed rises)

It operates about the same as G mode (emergency) (the power is lower)

When other work equipment is operated together with bucket CURL, speed of work equipment other than bucket CURL becomes slow

Voltage between C03 (6) and (16): 18 – 28 V

Resistance: 500 – 1000 Ω Voltage (AC range) : 0.5 – 3.0 V (engine started)

Resistance of solenoid: 20 – 60 Ω

PC600-6

Same as display for E311

20-459

TROUBLESHOOTING

User Service code code

——

20-460

ACTION TAKEN BY CONTROLLER WHEN ABNORMALITY OCCURS AND PROBLEMS ON MACHINE

Abnormal system

Nature of abnormality

E207

Short circuit in flashing light relay drive system

1. Short circuit or short circuit with ground inside flashing light relay 2. Short circuit with ground or short circuit with power source in wiring harness between controller C01 (11) and flashing light relay R16 (1) 3. Defective pump controller

E231

Abnormality (short circuit) in step light power source holding relay output system

1. Failure in power source retention relay for step light 2. Short circuit with power source in wiring harness between controller C02 (6) and step light power source retention relay R25 (2) 3. Defective pump controller

E302

Short circuit in step light relay drive system

1. Short circuit or short circuit with ground inside step light relay 2. Short circuit with ground or short circuit with power source in wiring harness between controller C01 (1) and step light relay R17 (1) 3. Defective pump controller

E228

Abnormality in autodeceleration output system

1. Defective contact, disconnection, or short circuit with ground in wiring harness between pump controller C01 (4) and engine controller E14 (11) 2. Defective pump controller

PC600-6

TROUBLESHOOTING

ACTION TAKEN BY CONTROLLER WHEN ABNORMALITY OCCURS AND PROBLEMS ON MACHINE

Condition when normal (voltage, current, resistance)

Action by controller when abnormality is detected

Problem that appears on machine when there is abnormality

1. Makes output to solenoid 0. ﬂ If the abnormality is restored by the vibration of the machine, the condition will return to normal when the power source is reset. (However, the service code does not go out.)

Flashing lamp does not light up

When horn is ON, relay contacts repeatedly switch ON/ OFF

When step light switch is ON, step light power source retention relay contacts turn ON

1. Makes output to solenoid 0. ﬂ If the abnormality is restored by the vibration of the machine, the condition will automatically return to normal. (However, the service code does not go out.)

When key is at OFF, step lamp does not light up

1. Makes output to solenoid 0. ﬂ If the abnormality is restored by the vibration of the machine, the condition will automatically return to normal. (However, the service code does not go out.)

Flashing lamp does not light up

When step light switch is ON, step light relay contacts turn ON

1. Functions with signal from network (S-NET) circuit side

The abnormality does not occur. (However, if an abnormality occurs at the same time in the network, the auto-deceleration cannot be actuated.)

Resistance between C01 (female) (4) and E14 (female) (11): Max. 1 Ω

PC600-6

20-461

JUDGEMENT TABLE FOR PUMP CONTROLLER AND HYDRAULIC RELATED PARTS

TROUBLESHOOTING

JUDGEMENT TABLE FOR PUMP CONTROLLER AND HYDRAULIC RELATED PARTS Pump controller (E2:XX system)

Work equipment

All work equipment, travel, swing

User code

Speeds of all work equipment, swing, travel are slow or lack power

E03

Disconnection in bucket CURL Hi cancel solenoid system

Model selection input error

Disconnection in travel speed solenoid system

Short circuit in bucket CURL Hi cancel solenoid system

Disconnection in 2-stage relief solenoid system

Short circuit in travel speed solenoid system

Disconnection in swing holding brake solenoid system

Short circuit in 2-stage relief solenoid system

Disconnection in CO cancel solenoid system

—

Short circuit in swing holding brake solenoid system

Disconnection in TVC solenoid system

LED E02

Short circuit in CO cancel solenoid system

Abnormality in controller power source

Failure mode

Short circuit in TVC solenoid system

Self-diagnostic display

—

Service code OFF 232 233 201 211 203 213 204 214 206 216 311 312 217 ▲ ▲ ●

There is excessive drop in engine speed, or engine stalls

● ● ●

●

No work equipment, travel, swing move Abnormal noise generated (around pump) Auto-deceleration does not work

● ● ●

Fine control ability is poor or response is poor Boom is slow or lacks power

● ●

Arm is slow or lacks power

● ●

Bucket is slow or lacks power

● ●

Boom does not move Arm does not move Bucket does not move Excessive hydraulic drift Excessive time lag (engine at low idling) Machine push-up function does not work In compound operations with swing, work equipment speed is slow In compound operations with bucket, swing and work equipment speeds are slow

Travel system

In compound operations, speed drops excessively Travel deviation

Deviation is excessive during normal travel

Deviation is excessive when starting Travel speed is slow Travel speed does not switch or is faster than set speed

●

● ●

Does not move (one side only) Does not swing

● ●

Both left and right

Swing system

One direction only Swing acceleration is poor

Both left and right

or swing speed is slow

One direction only

Excessive overrun when

Both left and right

stopping swing

One direction only Excessive shock when stopping swing (one direction only) Excessive abnormal noise when stopping swing Excessive hydraulic

When swing holding brake is released

drift of swing

When swing holding brake is applied Troubleshooting code when service code is displayed

C-1 C-2 C-3 C-4 C-5 C-6 C-7 C-8 C-9 C-10 C-11 C-12 C-13 C-14

Troubleshooting code when there is abnormality in monitoring code check

–

▲ :This shows applicable item for service code (simultaneous abnormality at front or rear) ‡ :This shows applicable item for service code

ª :This shows item that needs only checking with monitoring

ﬁ :This shows item to check with monitoring or machine monitor

20-462

PC600-6

JUDGEMENT TABLE FOR PUMP CONTROLLER AND HYDRAULIC RELATED PARTS

TROUBLESHOOTING

ﬂ If service code E218 (abnormality in network system) is displayed, go to troubleshooting for N mode.

Machine push-up solenoid

Troubleshooting code if no service code is displayed

Rear pump discharge pressure input

Engine speed input ª

TVC current output

H-1

●

Front pump discharge pressure input

Travel speed (6)

Model code

Bucket CURL Hi cancel (4)

2-stage relief (5)

CO cancel (1)

Swing holding brake (3)

Swing lock switch (3)

Knob switch (6)

Bucket CURL (1)

Bit pattern 21 22

Monitoring code 02 10 11 12 13 ª ª ª ª

Solenoid drive condition

Bucket DUMP (2)

Arm IN (5)

Arm OUT (6)

Boom LOWER (3)

224 225 226 227 ●

Boom RAISE (4)

Swing (1)

Travel (2)

Abnormality in pressure sensor power source system

Check items in monitoring mode Pressure switch

Abnormality in engine speed sensor system

Abnormality in front pump pressure sensor system

Abnormality in rear pump pressure sensor system

Pump controller (E2:XX system) Self-diagnostic display

H-2

H-3 H-4 ●

fi fi fi fi fi fi fi fi

H-5 H-6

fi fi fi fi fi fi

ª ª

H-7

ª ª

H-8

ª ª

H-9 H-10 H-8

ﬁ

H-9

ﬁ

C-19 H-10

H-11 H-12 H-13 H-14 H-15

ﬁ ﬁ

● ● ● ●

H-16 ª

ª ª ª

H-17 H-18

ﬁ

H-19

H-20 H-21 H-22 H-23

ª C-15 C-16 C-17 C-18 – –

–

ª ª ª ª ª ª

– – –

–

– F-1 F-2 F-3 F-4 F-5 F-6 F-7 F-8 F-9 F-11 – – –

–

PC600-6

–

H-24

ª – –

20-463

TROUBLESHOOTING

ELECTRICAL CIRCUIT DIAGRAM FOR C MODE

20-464

PC600-6

TROUBLESHOOTING

PC600-6

ELECTRICAL CIRCUIT DIAGRAM FOR C MODE

20-465

TROUBLESHOOTING

C-1

C-1 Abnormality in controller power source system (controller LED is OFF) fl This troubleshooting is carried out when there is still an abnormality, so when disconnecting the connector and inserting the T-adapter, or when removing the T-adapter and returning the connector to its original position, if an E service code is not displayed, the problem has been removed. fl Check that fuse 1 is not blown. fl Before carrying out troubleshooting, check that all the related connectors are properly inserted. fl Always connect any disconnected connectors before going on to the next step. fl When the starting motor rotates normally. (If the starting motor also does not rotate, go to E-8.)

Cause

YES 1 Is voltage between C01 (7) (13) and C02 (11) (21) normal? • Turn starting switch ON. • 20 – 30V

2 YES Is voltage between circuit NO breaker 5 and chassis normal? • Turn starting switch ON. • 20 – 30V

Remedy

Defective pump controller

Replace

Defective contact, or disconnection in wiring harness between circuit breaker and C01 (female) (7) (13)

Repair or replace

Defective contact, or disconnection in wiring harness between circuit breaker – battery relay M

Repair or replace

C-1 Related electrical circuit diagram

20-466

PC600-6

TROUBLESHOOTING

C-2

C-2 [E232] (Short circuit in pump TVC solenoid system) is displayed fl This troubleshooting is carried out when there is still an abnormality, so when disconnecting the connector and inserting the T-adapter, or when removing the T-adapter and returning the connector to its original position, if an “E” service code is not displayed, the problem has been removed. fl If the starting switch is turned OFF after an abnormality occurs, turn the starting switch ON and check if an “E” service code is displayed. (If it is not displayed, the problem has been removed.) fl Always turn the emergency pump drive switch OFF. fl Before carrying out troubleshooting, check that all the related connectors are properly inserted. fl Always connect any disconnected connectors before going on to the next step.

Cause

YES

Is resistance YES between C02 (female) (8) and (18), (8) and chassis as shown in Table 1?

1 Is resistance between C13 (male) (1) and (2), (1) and chassis as shown in Table 1?

Is resistance • Turn starting between C05 (female) (3) and (4), switch OFF. • Disconnect C02. NO (3) and chassis as shown in Table 1?

• Turn starting switch OFF. • Disconnect C05.

4 YES

Is resistance between C05 (male) (1) and (3), (2) and (4), (1) (2) (3) (4) and chassis as shown in Table 2? • Turn starting NO switch OFF. • Disconnect C05. • Turn TVC emergency switch OFF.

• Turn starting switch OFF. • Disconnect C13.

Remedy

Replace

Defective pump controller Short circuit with ground or short circuit with power source in wiring harness between C02 (female)(8) – H12 (5) – C05 (female)(1), or short circuit with power source in wiring harness between C02 (female)(18) – H12 (6) – C05 (female)(2)

Repair or replace

Defective emergency pump drive switch (internal short circuit, short circuit with power source)

Replace

Short circuit with ground or short circuit with power Repair or source in wiring harness replace between C05 (female)(3) – H12 (3) – C13 (female) (1), or short circuit with power source in wiring harness between C05 (female) (4) – H12 (4) – C13 (female)(2) Defective TVC solenoid (internal short circuit or short circuit with ground)

Replace

Table 1 Troubleshooting No. 1

Troubleshooting No. 2

Troubleshooting No. 3

Resistance value

Between C13 (male) (1) – (2)

Between C02 (female) (8) – (18)

Between C05 (female) (3) – (4)

10 – 22 Ω

Between C13 (male) (1) – chassis

Between C02 (female) (8) – chassis

Between C05 (female) (3) – chassis

Min. 1 MΩ

Table 2 Troubleshooting No. 4

Resistance value

Between C05 (male) (1) – (3), (2) – (4)

Max. 1 Ω

Between C05 (male) (1)(2)(3)(4) – chassis

Min. 1 MΩ

PC600-6

20-467

TROUBLESHOOTING

C-2

C-2 Related electrical circuit diagram

20-468

PC600-6

TROUBLESHOOTING

C-3

C-3 [E233] (Disconnection in pump TVC solenoid system) is displayed fl This troubleshooting is carried out when there is still an abnormality, so when disconnecting the connector and inserting the T-adapter, or when removing the T-adapter and returning the connector to its original position, if an “E” service code is not displayed, the problem has been removed. fl If the starting switch is turned OFF after an abnormality occurs, turn the starting switch ON and check if an “E” service code is displayed. (If it is not displayed, the problem has been removed.) fl If there is a disconnection in the solenoid or wiring harness, no current flows to the solenoid. If the No. 2 pin of the solenoid is short circuiting with the ground, the current (approx. 1 A) continues to flow to the solenoid. fl Always turn the emergency pump drive switch OFF. fl Before carrying out troubleshooting, check that all the related connectors are properly inserted. fl Always connect any disconnected connectors before going on to the next step.

Cause

YES

Is resistance YES between C02 (female) (8) and (18), (18) and chassis as shown in Table 1?

1 Is resistance between C13 (male) (1) and (2), (1) and chassis as shown in Table 1?

Is resistance • Turn starting between C05 (female) (3) and (4), switch OFF. • Disconnect C02. NO (3) and chassis as shown in Table 1?

• Turn starting switch OFF. • Disconnect C05.

4 YES

Is resistance between C05 (male) (1) and (3), (2) and (4), (1) (2) (3) (4) and chassis as shown in Table 2? • Turn starting NO switch OFF. • Disconnect C05. • Turn TVC emergency switch OFF.

• Turn starting switch OFF. • Disconnect C13.

Remedy

Defective pump controller Defective contact or disconnection in wiring harness between C02 (female) (8) – H12 (5) – C05 (female) (1), or defective contact, disconnection, or short circuit with ground in wiring harness between C02 (female) (18) – H12 (6) – C05 (female) (2) Defective emergency pump drive switch (internal defective contact, disconnection, or short circuit with ground)

Repair or replace

Replace

Defective contact or Repair or disconnection in wiring harness between C05 (female) replace (3) – H12 (3) – C13 (female) (1), or defective contact, disconnection, or short circuit with ground in wiring harness between C05 (female) (4) – H12 (4) – C13 (female) (2) Defective TVC solenoid (internal disconnection or defective contact)

Replace

Table 1 Troubleshooting No. 2

Troubleshooting No. 1

Troubleshooting No. 3

Between C13 (male) (1) – (2)

Between C02 (female) (8) – (18)

Between C05 (female) (3) – (4)

Between C13 (male) (2) – chassis

Between C02 (female) (18) – chassis Between C05 (female) (4) – chassis

Resistance value 10 – 22 Ω Min. 1 MΩ

Table 2 Troubleshooting No. 4

Resistance value

Between C05 (male) (1) – (3), (2) – (4)

Max. 1 Ω

Between C05 (male) (1)(2)(3)(4) – chassis

Min. 1 MΩ

PC600-6

20-469

TROUBLESHOOTING

C-3

C-3 Related electrical circuit diagram

20-470

PC600-6

TROUBLESHOOTING

C-4

C-4 [E203] (Short circuit in swing holding brake solenoid system) is displayed fl This troubleshooting is carried out when there is still an abnormality, so when disconnecting the connector and inserting the T-adapter, or when removing the T-adapter and returning the connector to its original position, if an “E” service code is not displayed, the problem has been removed. fl If the starting switch is turned OFF after an abnormality occurs, turn the starting switch ON and check if an “E” service code is displayed. (If it is not displayed, the problem has been removed.) fl Before carrying out troubleshooting, check that all the related connectors are properly inserted. fl Always connect any disconnected connectors before going on to the next step. fl Always turn the swing holding brake cancel switch OFF, then turn the swing lock switch OFF before checking.

Cause

3 YES

Is resistance

YES between V04 1 Interchange connector with other solenoid. Is [E203] displayed?

• Turn starting switch OFF. • Interchange V04 with other connector. • Start engine. • Operate swing lever.

(male) (1) and (2), (2) and chassis as shown in Table 1?

• Turn starting switch OFF. • Disconnect V04.

Is resistance YES between C01 2 (female) (3) and chassis normal? • Turn starting switch NO OFF. • Disconnect C01. • Turn swing lock switch OFF. • 20 – 60 Ω

5 YES

• Turn starting switch OFF. • Disconnect X05. • Turn swing lock switch OFF. • Min. 1 MΩ

Defective pump controller

Replace

Defective swing holding brake solenoid

Replace

Short circuit with chassis ground in wiring harness between C01 (female) (3) – D26 (2)(1) – H13 (1) – X01 (7) – X05 (male) (3)

Repair or replace

Go to A

Is resistance between X05 (female) (3)(4) and chassis normal?

Remedy

Is resistance YES between X05 (male) (4) and 4 chassis normal? • Turn starting switch OFF. • Disconnect X05. • 20 – 60 Ω

Short circuit with chassis ground in wiring harness between X05 (male) (4) – X01 (6) – H13 (7) – V04 (female) (2) Defective swing lock switch

Repair or replace

Replace

Table 1 Between V04 (male) (1) – (2)

20 – 60 Ω

Between V04 (male) (2) – chassis

Min. 1 MΩ

PC600-6

20-471

TROUBLESHOOTING

C-4

C-4 Related electrical circuit diagram

20-472

PC600-6

TROUBLESHOOTING

C-5

C-5 [E213] (Disconnection in swing holding brake solenoid system) is displayed fl This troubleshooting is carried out when there is still an abnormality, so when disconnecting the connector and inserting the T-adapter, or when removing the T-adapter and returning the connector to its original position, if an “E” service code is not displayed, the problem has been removed. fl If the starting switch is turned OFF after an abnormality occurs, turn the starting switch ON and check if an “E” service code is displayed. (If it is not displayed, the problem has been removed.) fl Always turn the swing holding brake cacnel switch OFF, then turn the swing lock switch OFF before checking. fl Before carrying out troubleshooting, check that all the related connectors are properly inserted. fl Always connect any disconnected connectors before going on to the next step. Note 1: When the swing holding brake cancel switch is operated, this error [E213] is detected, but it does not indicate a failure. Note 2: When the swing lock switch is operated and error [E213] is generated, carry out troubleshooting of the swing lock signal input system. Cause

3 YES

Is resistance

Is voltage YES between D26 (2) and chassis as 2 shown in Table 1?

YES between V04 1 Interchange connector with other solenoid. Is [E213] displayed?

• Turn starting switch OFF. • Interchange V04 with other connector. • Turn starting switch ON.

(male) (1) and (2) normal? • Turn starting switch OFF. • Disconnect V04. • 20 – 60 Ω

• Turn starting switch ON. • Disconnect D26.

YES 5 Is resistance

YES between X05 4 A

• Turn starting switch OFF. • Disconnect X05. • Max. 1 Ω

Go to A

Defective pump controller

Replace

Defective swing holding brake solenoid

Replace

• Defective contact or disconnection in wiring harness between D26 (female) (1) – H13 (1) – X01 (7) – X05 (male) (3) • Defective contact or disconnection in wiring harness between V04 (female) (1) – J06 (3) (7) – GND (Revolving frame)

Repair or replace

Is resistance between X05 (female) (3) and (4) normal?

Remedy

(male) (4) and chassis normal? • Turn starting switch OFF. • Disconnect X05. • 20 – 60 Ω

Short circuit with power source, defective contact, or disconnection in wiring harness between X05 (male)(4) – X01 (6) – H13 (7) – V04 (female)(2)

Defective swing lock switch

Repair or replace

Replace

Table 1 Troubleshooting No. 3 Between D26 (1) – chassis

PC600-6

Voltage

Measurement condition

0 – 10 V

4 – 5 seconds after all levers are returned to neutral

20 – 30 V

Swing lever or work equipment lever operated slightly

20-473

TROUBLESHOOTING

C-5

C-5 Related electrical circuit diagram

20-474

PC600-6

TROUBLESHOOTING

C-6

C-6 [E201] (Short circuit in CO cancel solenoid system) is displayed fl This troubleshooting is carried out when there is still an abnormality, so when disconnecting the connector and inserting the T-adapter, or when removing the T-adapter and returning the connector to its original position, if an “E” service code is not displayed, the problem has been removed. fl If the starting switch is turned OFF after an abnormality occurs, turn the starting switch ON and check if an “E” service code is displayed. (If it is not displayed, the problem has been removed.) fl Before carrying out troubleshooting, check that all the related connectors are properly inserted. fl Always connect any disconnected connectors before going on to the next step.

Cause

3 YES Is resistance YES between C01 (female) (8) and 2 chassis normal?

YES 1 Interchange connector with other solenoid. Is [E204] displayed? • Turn starting switch OFF. • Interchange V02 with other connector. • Start engine.

Is resistance between V02 (male) (1) and (2), (2) and chassis as shown in Table 1?

• Turn starting switch OFF. • Disconnect V02.

• Turn starting switch OFF. • Disconnect C01. • 20 – 60 Ω

Remedy

Defective pump controller

Replace

Short circuit with chassis ground in wiring harness between C01 (female) (8) and V02 (female) (2)

Repair or replace

Defective CO cancel solenoid

Replace

Table 1 Between V02 (male) (1) – (2)

20 – 60 Ω

Between V02 (male) (2) – chassis Min. 1 MΩ

C-6 Related electrical circuit diagram

PC600-6

20-475

TROUBLESHOOTING

C-7

C-7 [E211] (Disconnection in CO cancel solenoid system) is displayed fl This troubleshooting is carried out when there is still an abnormality, so when disconnecting the connector and inserting the T-adapter, or when removing the T-adapter and returning the connector to its original position, if an “E” service code is not displayed, the problem has been removed. fl If the starting switch is turned OFF after an abnormality occurs, turn the starting switch ON and check if an “E” service code is displayed. (If it is not displayed, the problem has been removed.) fl Before carrying out troubleshooting, check that all the related connectors are properly inserted. fl Always connect any disconnected connectors before going on to the next step.

Cause

4 YES Defective pump

Is resistance YES between C01 (female) (8) and 2 chassis normal? Is resistance YES between V02 (male) (1) and (2) 1 normal? Interchange connector with other solenoid. Is [E211] displayed? • Turn starting switch OFF. • Interchange V02 with other connector. • Turn starting switch ON.

• Turn starting switch OFF. • Disconnect V02. • 20 – 60 Ω

• Turn starting switch OFF. • Disconnect C01. • 20 – 60 Ω

Is voltage between YES V02 (female) (2) and chassis as shown in 3 Table 1?

controller

Short circuit with power source in wiring harness • Disconnect C01 and NO between C01 (female)(8) – V02 (female)(2) V02. • Turn starting switch ON. • Max. 1 V

Defective contact or disconnection in wiring harness between C01 (8) and V02 (2), or between V02 (female) (1) – J06 (1) (7) and chassis ground

Remedy

Replace

Repair or replace

Defective CO cancel solenoid

Replace

C-7 Related electrical circuit diagram

20-476

PC600-6

TROUBLESHOOTING

C-8

C-8 [E204] (Short circuit in 2-stage relief solenoid system) is displayed fl This troubleshooting is carried out when there is still an abnormality, so when disconnecting the connector and inserting the T-adapter, or when removing the T-adapter and returning the connector to its original position, if an “E” service code is not displayed, the problem has been removed. fl If the starting switch is turned OFF after an abnormality occurs, turn the starting switch ON and check if an “E” service code is displayed. (If it is not displayed, the problem has been removed.) fl Before carrying out troubleshooting, check that all the related connectors are properly inserted. fl Always connect any disconnected connectors before going on to the next step.

Cause

3 YES Is resistance YES between C01 (female) (10) and 2 chassis normal?

YES 1 Interchange connector with other solenoid. Is [E204] displayed? • Turn starting switch OFF. • Interchange V05 with other connector. • Start engine. • Operate travel independently.

Is resistance between V05 (male) (1) and (2), (2) and chassis as shown in Table 1?

• Turn starting switch OFF. • Disconnect V05.

• Turn starting switch OFF. • Disconnect C01. • 20 – 60 Ω

Remedy

Defective pump controller

Replace

Short circuit with chassis ground in wiring harness between C01 (female) (10) and V05 (female) (2)

Repair or replace

Defective 2-stage relief solenoid

Replace

Table 1 Between V05 (male) (1) – (2)

20 – 60 Ω

Between V05 (male) (2) – chassis Min. 1 MΩ

C-8 Related electrical circuit diagram

PC600-6

20-477

TROUBLESHOOTING

C-9

C-9 [E214] (Disconnection in 2-stage relief solenoid system) is displayed fl This troubleshooting is carried out when there is still an abnormality, so when disconnecting the connector and inserting the T-adapter, or when removing the T-adapter and returning the connector to its original position, if an “E” service code is not displayed, the problem has been removed. fl If the starting switch is turned OFF after an abnormality occurs, turn the starting switch ON and check if an “E” service code is displayed. (If it is not displayed, the problem has been removed.) fl Before carrying out troubleshooting, check that all the related connectors are properly inserted. fl Always connect any disconnected connectors before going on to the next step.

Cause

4 YES Defective pump

Is resistance YES between C01 (female) (10) and 2 chassis normal? Is resistance YES between V05 (male) (1) and (2) 1 normal? Interchange connector with other solenoid. Is [E214] displayed? • Turn starting switch OFF. • Interchange V05 with other connector. • Turn starting switch ON.

• Turn starting switch OFF. • Disconnect V05. • 20 – 60 Ω

• Turn starting switch OFF. • Disconnect C01. • 20 – 30 Ω

Is voltage between YES C01 (female) (10) and chassis ground 3 approx. 0V?

controller

Short circuit with power source in wiring harness • Turn starting switch NO between C01 (female) (10) – V05 (female)(2) ON.

Remedy

Replace

Repair or replace

• Disconnect C01.

Defective contact or disconnection in wiring harness between C01 (female) (10) and V05 (female) (2), or between V05 (female) (1) – J06 (4) (7) and chassis ground

Defective 2-stage relief solenoid (internal disconnection or short

Repair or replace

Replace

C-9 Related electrical circuit diagram

20-478

PC600-6

TROUBLESHOOTING

C-10

C-10 [E206] (Short circuit in travel speed solenoid system) is displayed fl This troubleshooting is carried out when there is still an abnormality, so when disconnecting the connector and inserting the T-adapter, or when removing the T-adapter and returning the connector to its original position, if an E service code is not displayed, the problem has been removed. fl If the starting switch is turned OFF after an abnormality occurs, turn the starting switch ON and check if an E service code is displayed. (If it is not displayed, the problem has been removed.) fl Before carrying out troubleshooting, check that all the related connectors are properly inserted. fl Always connect any disconnected connectors before going on to the next step.

Cause

3 YES Is resistance YES between C01 (female) (9) and 2 chassis normal? Is resistance YES between V06 (male) • Turn starting (1) and (2), (2) and switch OFF. chassis as shown in 1 • Disconnect C01. Table 1? • 20 – 60 Ω • Turn starting

Interchange connector with other solenoid. Is [E206] displayed?

switch OFF. • Disconnect V06.

Defective pump controller Short circuit with chassis ground in wiring harness between C01 (femle) (9) and V02 (female) (2)

Remedy

Replace

Repair or replace

• Interchange V06 with other NO connector. • Start engine. • Travel speed switch at Hi • Operate the lever slightly not enough to move the machine.

Defective travel speed solenoid (internal short circuit or short circuit with ground)

Replace

Table 1 Between V06 (male) (1) – (2)

20 – 60 Ω

Between V06 (male) (2) – chassis Min. 1 MΩ

C-10 Related electrical circuit diagram

PC600-6

20-479

TROUBLESHOOTING

C-11

C-11 [E216] (Disconnection in travel speed solenoid system) is displayed fl This troubleshooting is carried out when there is still an abnormality, so when disconnecting the connector and inserting the T-adapter, or when removing the T-adapter and returning the connector to its original position, if an E service code is not displayed, the problem has been removed. fl If the starting switch is turned OFF after an abnormality occurs, turn the starting switch ON and check if an E service code is displayed. (If it is not displayed, the problem has been removed.) fl Before carrying out troubleshooting, check that all the related connectors are properly inserted. fl Always connect any disconnected connectors before going on to the next step. Cause

4 YES YES 3 Is resistance YES between V06 (female) (1) and 2 chassis normal? Is resistance

YES between V06 1 Interchange connector with other solenoid. Is [E216] displayed? • Interchange V06 with other connector. • Turn starting switch ON.

(male) (1) and (2) normal? • Turn starting switch OFF. • Disconnect V06. • 20 – 60 Ω

• Turn starting switch OFF. • Disconnect C01 and V06. • Max. 1 Ω

When V06 (female) (2) is grounded to chassis, is resistance between C01 (female) (9) and chassis normal?

• Turn starting switch OFF. • Disconnect V06. • Max. 1 Ω

Go to A

Defective contact or disconnection in wiring harness between C01 NO (female) (9) and V06 (female) (2) Defective contact or disconnection in wiring harness between V06 (female) (1) – J06 (5) (7) and chassis

Remedy

Repair or replace

NO Defective pump merge/divider solenoid (internal disconnection)

5 YES Defective pump From A

controller

Is voltage between C01 (female) (9) – V06 (female) (2) normal? • Turn starting switch OFF. • Disconnect C01 and V06. • Max. 1 V

Short circuit with power source in wiring harness between C01 (female) (9) and V06 (female) (2)

Replace

Repair or replace

C-11 Related electrical circuit diagram

20-480

PC600-6

TROUBLESHOOTING

C-12

C-12 [E311] (Short circuit in bucket CURL Hi cancel solenoid system) is displayed fl This troubleshooting is carried out when there is still an abnormality, so when disconnecting the connector and inserting the T-adapter, or when removing the T-adapter and returning the connector to its original position, if an “E” service code is not displayed, the problem has been removed. fl If the starting switch is turned OFF after an abnormality occurs, turn the starting switch ON and check if an “E” service code is displayed. (If it is not displayed, the problem has been removed.) fl Before carrying out troubleshooting, check that all the related connectors are properly inserted. fl Always connect any disconnected connectors before going on to the next step.

Cause

3 YES Is resistance YES between C01 (female) (2) and 2 chassis normal? Is resistance YES between V08 (male) • Turn starting (1) and (2), (2) and switch OFF. chassis as shown in 1 • Disconnect C01. Table 1? • 20 – 60 Ω • Turn starting

Interchange connector with other solenoid. Is [E204] displayed?

switch OFF. • Disconnect V08.

Defective pump controller

Remedy

Replace

Short circuit with chassis ground in wiring harness between C01 (female) (2) and V08 (female) (2)

Repair or replace

Defective bucket CURL Hi cancel solenoid

Replace

• Turn starting switch OFF. NO • Interchange V08 with other connector. • Start engine. • Operate bucket CURL independently.

Table 1 Between V08 (male) (1) – (2)

20 – 60 Ω

Between V08 (male) (2) – chassis Min. 1 MΩ

C-12 Related electrical circuit diagram

PC600-6

20-481

TROUBLESHOOTING

C-13

C-13 [E312] (Disconnection in bucket CURL Hi cancel solenoid system) is displayed fl This troubleshooting is carried out when there is still an abnormality, so when disconnecting the connector and inserting the T-adapter, or when removing the T-adapter and returning the connector to its original position, if an “E” service code is not displayed, the problem has been removed. fl If the starting switch is turned OFF after an abnormality occurs, turn the starting switch ON and check if an “E” service code is displayed. (If it is not displayed, the problem has been removed.) fl Before carrying out troubleshooting, check that all the related connectors are properly inserted. fl Always connect any disconnected connectors before going on to the next step. Cause

4 YES Is resistance between YES C01 (female) (2) and chassis normal when 3 V08 (female) (2) is grounded to chassis?

Is resistance

YES between V08 2 Is resistance

YES between V08 1 Interchange connector with other solenoid. Is [E214] displayed? • Turn starting switch OFF. • Interchange V08 with other connector. • Turn starting switch ON.

(male) (1) and (2) normal? • Turn starting switch OFF. • Disconnect V08. • 20 – 60 Ω

(female) (1) and chassis normal? • Turn starting switch OFF. • Disconnect C01. • Max. 1 Ω

• Turn starting switch OFF. • Disconnect V08. • Max. 1 Ω

Remedy

Go to A

Defective contact or disconnection in wiring harness between C01 NO (female) (2) and V08 (female) (2) Defective contact or disconnection in wiring harness between V08 (female) (1) – J06 (6) (7) and chassis

Repair or replace

NO Defective bucket CURL Hi cancel solenoid (internal disconnection)

5 YES Defective pump From A

Is voltage between C01 (female) (2), V08 (female) (2) chassis normal?

• Turn starting switch OFF. • Disconnect C01 and V08. • Turn starting switch ON.

controller Short circuit with power source in wiring harness NO between C01 (female)(2) – V08 (female)(2)

Replace

Repair or replace

C-13 Related electrical circuit diagram

20-482

PC600-6

TROUBLESHOOTING

C-14

C-14 [E217] (Model selection input error) is displayed fl This troubleshooting is carried out when there is still an abnormality, so when disconnecting the connector and inserting the T-adapter, or when removing the T-adapter and returning the connector to its original position, if an E service code is not displayed, the problem has been removed. fl If the starting switch is turned OFF after an abnormality occurs, turn the starting switch ON and check if an E service code is displayed. (If it is not displayed, the problem has been removed.) fl Before carrying out troubleshooting, check that all the related connectors are properly inserted. fl Always connect any disconnected connectors before going on to the next step.

Cause

YES

Defective pump controller

1 Is monitoring mode display as shown in Table 1?

Remedy

Replace

2 YES

Is voltage between C17 (5) (6) (7) (13) • Turn starting switch ON. NO (14) and chassis as shown in Table 2? • Set to monitoring codes [02, 03] • Turn starting and [21, 22]. switch ON.

Defective model selection connector, or disconnection, short circuit with ground, or short circuti in witing harness where voltage is defective

Repair or replace

Table 1 Monitoring code display Model code display

Model selection signal input display

Monitoring codes 02, 03

Monitoring code 21

Monitoring code 22

ﬂ The diagram shows monitoring code 02. ﬂ Check the bit pattern display marked with ↑.

Table 2 Voltage of wiring harness C17 Voltage

PC600-6

Between (5) – chassis Between (6) – chassis Between (7) – chassis Between (13) – chassis Between (14) – chassis 20 – 30 V

20 – 30 V

Max. 1 V

20 – 30 V

20-483

TROUBLESHOOTING

C-14

C-14 Related electrical circuit diagram

20-484

PC600-6

TROUBLESHOOTING

C15

C-15 [E224] (Abnormality in front pump pressure sensor system) is displayed fl This troubleshooting is carried out when there is still an abnormality, so when disconnecting the connector and inserting the T-adapter, or when removing the T-adapter and returning the connector to its original position, if an E service code is not displayed, the problem has been removed. fl If the starting switch is turned OFF after an abnormality occurs, turn the starting switch ON and check if an E service code is displayed. (If it is not displayed, the problem has been removed.) fl Before carrying out troubleshooting, check that all the related connectors are properly inserted. fl Always connect any disconnected connectors before going on to the next step.

Cause

3 YES Is voltage YES between C03 (3) and (16) normal?

2 Is voltage

YES between C08 (2) and (1) normal?

1 Interchange connector with rear pump pressure sensor. Is [E224] displayed? • Interchange C07 with C08. • Engine at high idling

• Turn starting switch ON. • 18 – 28 V

NO • Engine at high ilding • Operate repeatedly arm IN relief lever NEUTRAL. • 0.5 – 4.5 V 4 YES

Is voltage between C08 (2) NO and chassis normal? • Disconnect C08. • Turn starting switch ON. • 18 – 28 V

Defective pump controller Short circuit with powe source, defective contact, or disconnection in wiring harness between C03 (female) (3) – C08 (female) (3) Short circuit with ground, defective contact, or disconnection in wiring harness between C03 (female) (16) and C08 (female) (1) Short circuit with ground, defective contact, or disconnection in wiring harness between C03 (female) (6) and C08 (female) (2) Defective front pump pressure sensor (internal disconnection, defective contact, short circuit, or short circuit with ground)

Remedy

Replace

Repair or replace

Replace

C-15 Related electrical circuit diagram

PC600-6

20-485

TROUBLESHOOTING

C-16

C-16 [E225] (Abnormality in rear pump pressure sensor system) is displayed fl This troubleshooting is carried out when there is still an abnormality, so when disconnecting the connector and inserting the T-adapter, or when removing the T-adapter and returning the connector to its original position, if an E service code is not displayed, the problem has been removed. fl If the starting switch is turned OFF after an abnormality occurs, turn the starting switch ON and check if an E service code is displayed. (If it is not displayed, the problem has been removed.) fl Before carrying out troubleshooting, check that all the related connectors are properly inserted. fl Always connect any disconnected connectors before going on to the next step.

Cause

3 YES Is voltage YES between C03 (13) and (16) normal?

2 Is voltage

YES bwtween C07 (2) and (1) normal?

1 Interchange connector with front pump pressure sensor. Is [E225] displayed?

• Turn starting switch OFF. • Interchange C08 with C07. • Engine at high idling

• Turn starting switch ON. • 18 – 28 V

NO • Engine at high idling • Operate repeatedly arm IN relief lever NEUTRAL. • 0.5 – 4.5 V

• Disconnect C07. • Turn starting switch ON. • 18 – 28 V

Defective pump controller

Replace

Short circuit with power source, defective contact, or disconnection in wiring harness between C03 (female) (13) – C07 (female) (3)

Repair or replace

4 YES

Short circuit with ground, defective contact, or disconnection in wiring harness bewtween C03 (female) (16) and C07 (female) (1)

Short circuit with ground, defective contact, or disconnection in wiring harness between C03 (female) (6) and C07 (female) (2)

Is voltage between C07 (2) NO and chassis normal?

Remedy

Defective rear pump pressure sensor (internal disconnection, defective contact, short circuit, or short circuit with ground)

Repair or replace

Replace

C-16 Related electrical circuit diagram

20-486

PC600-6

TROUBLESHOOTING

C-17

C-17 [E226] (Abnormality in pressure sensor power source system) is displayed fl This troubleshooting is carried out when there is still an abnormality, so when disconnecting the connector and inserting the T-adapter, or when removing the T-adapter and returning the connector to its original position, if an E service code is not displayed, the problem has been removed. fl If the starting switch is turned OFF after an abnormality occurs, turn the starting switch ON and check if an E service code is displayed. (If it is not displayed, the problem has been removed.) fl Before carrying out troubleshooting, check that all the related connectors are properly inserted. fl Always connect any disconnected connectors before going on to the next step.

Cause

Defective front pump pressure sensor (internal short circuit or short circuit with ground)

YES 2 Is voltage

YES between C03 (6) and (16) normal?

1 Is resistance between C03 (female) (6) and (16), (6) (16) and chassis normal? • Turn starting switch OFF. • Disconnect C03, C07, and C08. • Min. 1 MΩ

3 YES Is voltage between C03 (6) and (16) normal?

• Turn starting switch ON. NO • Disconnect C08. • 18 – 28 V • Disconnect C07. • Turn starting switch ON. • 18 – 28 V

Defective rear pump pressure sensor (internal short circuit or short circuit with ground) Defective pump controller

Short circuit or short circuit with ground in wiring harness of system where resistance value is defective

Remedy

Replace

Repair or replace

C-17 Related electrical circuit diagram

PC600-6

20-487

TROUBLESHOOTING

C-18

C-18 [E227] (Abnormality in engine speed sensor system) is displayed fl This troubleshooting is carried out when there is still an abnormality, so when disconnecting the connector and inserting the T-adapter, or when removing the T-adapter and returning the connector to its original position, if an E service code is not displayed, the problem has been removed. fl If the starting switch is turned OFF after an abnormality occurs, turn the starting switch ON and check if an E service code is displayed. (If it is not displayed, the problem has been removed.) fl Before carrying out troubleshooting, check that all the related connectors are properly inserted. fl Always connect any disconnected connectors before going on to the next step.

Cause

2 YES Is resistance YES between C16 (female) (1) and 1 (2) normal? Is resistance between E07 (male) (1) and (2) normal? • Turn starting switch OFF. • Disconnect E07. • 500 – 1000 Ω

• Turn starting switch OFF. • Disconnect C16. • 500 – 1000 Ω

Remedy

Defective pump controller

Replace

Short circuit with ground, defective contact, or disconnection in wiring harness between C16 (female) (1) – ENE (female) (2), or between C16 (female) (2) – ENE (female) (1)

Repair or replace

Defective engine speed sensor (internal disconnection, defective contact, or short circuit with ground)

Replace

C-18 Related electrical circuit diagram

20-488

PC600-6

TROUBLESHOOTING

C-19

C-19 Abnormality in machine push-up solenoid system (no service code displayed) fl Even if any abnormality occurs in the machine push-up solenoid system, the service code is not displayed on the monitor panel. fl Before carrying out troubleshooting, check that all the related connectors are properly inserted. fl Always connect any disconnected connectors before going on to the next step. a) If solenoid is not actuated (turned ON) when machine push-up switch is set to low-pressure setting fl Check that fuse No. 2 is not blown. fl Carry out troubleshooting with the machine push-up switch at the low-pressure setting position. Cause

Defective contact or disconnection in wiring harness between V03 (female) (1) and chassis ground

2 YES Is resistance

YES between V03 (male) (1) and (2) normal?

1 Is voltage between V03 (2) and chassis normal? • Turn starting switch ON. • 20 – 30 V

• Turn starting switch OFF. • Disconnect V05. • 20 – 60 Ω

4 YES Is resistance YES between M38 (female) (1) and 3 (2) normal?

Is voltage between M38 (2) NO and chassis normal? • Turn starting switch ON. • 20 – 30 V

NO • Turn starting switch OFF. • Disconnect M38. • Switch ON: Max. 1 Ω • Switch OFF: Min. 1MΩ NO

Defective machine push-up solenoid (internal disconnection or defective contact) Short circuit with ground, defective contact, or disconnection in wiring harness between M38 (male) (1) – X01 (16) –H13 (3) – V03 (female) (2) Defective machine push-up switch (internal disconnection, defective contact, or short circuit with ground) Defective fuse 2 or short circuit with ground, defective contact, or disconnection in wiring harness between fuse 2 – X01 (12) –M38 (male) (2)

Remedy

Repair or replace

Replace

Repair or replace

Replace

Repair or replace

C-19 Related electrical circuit diagram

PC600-6

20-489

TROUBLESHOOTING

C-19

b) If solenoid is not canceled (turned OFF) when machine push-up switch is set to high-pressure setting ﬂ Carry out troubleshooting with the machine push-up switch at the high-pressure setting position.

Cause

YES

Defective machine push-up solenoid

Replace

2 YES

Defective machine push-up switch (internal short circuit with power source)

Replace

Short circuit with power source in wiring harness between M38 (male) (1) – X01 (16) – H13 (3) – V03 (female) (2)

1 Is voltage between V03 (2) and chassis normal? • Turn starting switch ON. • Max. 1 V

Is voltage between M38 (1) NO and chassis normal? • Turn starting switch ON. • Max. 1 V

Remedy

Repair or replace

C-19 Related electrical circuit diagram

20-490

PC600-6

TROUBLESHOOTING

C-20

C-20 [E207] Short circuit in flashing light relay drive system is displayed fl This troubleshooting is carried out when there is still an abnormality, so when disconnecting the connector and inserting the T-adapter, or when removing the T-adapter and returning the connector to its original position, if an E service code is not displayed, the problem has been removed. fl If [E207] is not displayed, but the flashing light does not light up, go to C-21 Flashing light relay does not work. fl Before carrying out troubleshooting, check that all the related connectors are properly inserted. fl Always connect any disconnected connectors before going on to the next step.

Cause

YES 1 Interchange with other relay. Is [E207] displayed? • Turn starting switch OFF. • Interchange relay. • Start engine. • Turn flashing light switch ON.

2 YES Is resistance between chassis and wiring harness between C01 NO (female) (2) and R16 (female) (1) normal?

NO • Turn starting switch OFF. • Disconnect C01 and R16. • Between wiring harness and chassis: Min. 1 MΩ

Remedy

Defective flashing light drive relay

Replace

Defective pump controller

Replace

Short circuit with ground in wiring harness between C01 (2) and R16 (1)

Repair or replace

C-20 Related electrical circuit diagram

PC600-6

20-491

TROUBLESHOOTING

C-21

C-21 Flashing light relay does not work fl First, check monitoring code: bit pattern 24-(2) to see if the horn switch input is normal. (F-13: When horn switch is ON, bit pattern 24-(2) does not go out.) fl If [E207] is displayed, go to C-20 [E207] Short circuit in flashing light relay drive system. fl Before carrying out troubleshooting, check that all the related connectors are properly inserted. fl Always connect any disconnected connectors before going on to the next step. Cause

Defective flashing light drive relay

YES

4 YES

When horn switch YES is ON, do relay contacts making 3 clicking sound?

Interchange with other relay. Is movement normal?

Is resistance YES between R16 NO • Turn starting • Turn starting (female) (2) and switch ON. switch OFF. 2 chassis normal? • Interchange R16 Is resistance relay. • Turn starting between C01 • Turn engine NO switch OFF. NO (female) (2) and R16 starting horn • Disconnect R16. (female) (1) normal? switch ON. • Between R16 (2) and chassis : Max. 1 Ω • Turn starting switch OFF. NO • Disconnect C01 and R16. • Between C01 (2) 6 YES and R16 (1): Is resistance between Max. 1 Ω R16 (male) (5) – M80

YES – M82 (female) normal, and is circuit 5

Is voltage of R16 (3) normal?

insulated from chassis? • Turn starting switch NO OFF. • Disconnect R16 and M82. • Between R16 and M82: Max. 1 Ω • Between wiring harness and chassis: Min. 1 Ω

• Turn starting switch ON. NO • Voltage of R16 (3): 20 – 30 V

To A

Remedy

Replace

—

Defective pump controller

Replace

Defective contact or disconnection in wiring harness between R16 (2) and chassis

Repair or replace

Defective contact or disconnection in wiring harness between C01 (2) and R16 (1)

Repair or replace

Blown flashing light bulb or defective contact of flashing light GND

Repair or replace

Defective contact, disconnection, or short circuit with ground in wiring harness between R16 (5) – M80 – M82

Repair or replace

Defective contact, disconnection, or short circuit with ground in wiring harness between fuse 6 – H12 (13) – R16 (3)

Repair or replace

C-21 Related electrical circuit diagram

20-492

PC600-6

TROUBLESHOOTING

C-22

C-22 [E231] Abnormality (short circuit) in step light power source retention relay output system is displayed fl This troubleshooting is carried out when there is still an abnormality, so when disconnecting the connector and inserting the T-adapter, or when removing the T-adapter and returning the connector to its original position, if an E service code is not displayed, the problem has been removed. fl If [E231] is not displayed, and the step light does not light up only when the key is OFF (the step light can light up when the key is ON), go to C-25 Step light does not light up. fl Before carrying out troubleshooting, check that all the related connectors are properly inserted. fl Always connect any disconnected connectors before going on to the next step.

Cause

YES 1 Interchange with other relay. Is [E231] displayed? • Turn starting switch OFF. • Interchange relay. • Leave key switch at OFF position and turn step light switch ON.

2 YES Is resistance between chassis power source and wiring harness C02 NO between (female) (6) and R25 (female) (2) normal?

NO • Turn starting switch OFF. • Disconnect C02 and R25. • Between wiring harness and chassis power source: Min. 1 MΩ

Remedy

Defective step light power source drive relay

Replace

Defective pump controller

Replace

Short circuit with power source in wiring harness between C02 (6) and R25 (2)

Repair or replace

C-22 Related electrical circuit diagram

PC600-6

20-493

TROUBLESHOOTING

C-23

C-23 Step light switch does not work fl The step light can light up when the key is ON, but when the key is OFF, the step light does not light up continuously for 60 seconds when the switch is pressed. fl First, check monitoring code: bit pattern 24-(1) to see if the step light switch input is normal. (F-12: When step light switch is ON, bit pattern 24-(1) does not go out.) fl If [E231] is displayed, go to C-22 [E231] Abnormality (short circuit) in power source retention relay drive for step light. fl Before carrying out troubleshooting, check that all the related connectors are properly inserted. fl Always connect any disconnected connectors before going on to the next step. Cause

Defective step light power source retention relay

YES

4 YES

When step light YES switch is ON, do 3 relay contacts move?

Interchange with other relay. Is movement normal?

Is voltage YES between R25 • Leave key switch NO • Turn starting (female) (1) and at OFF position switch OFF. 2 chassis normal? and turn step • Interchange Is resistance between light switch ON relay. C02 (female) (6) and • Turn starting R25 (female) (2) • Leave key switch switch OFF. NO normal, and is circuit at OFF position NO insulated from • Leave key switch at OFF position and turn step chassis? and turn step light switch ON. • Turn starting light switch ON. • Voltage between R25 (2) and chassis: 20 – 30 V switch OFF. • Disconnect C02 NO and R25. • Between C02 (6) and R25 (2): Max. 1 Ω • Between wiring harness and chassis: Min. 1 MΩ

20-494

Defective pump controller Defective contact, disconnection, or short circuit with ground in wiring harness between fuse 14 – H14 (6) – R25 (1) Defective contact, disconnection, or short circuit with ground in wiring harness between C02 (6) and R25 (2)

Replace

—

Replace

Repair or replace

Defective contact,

5 YES disconnection, or short A

C-23 Related electrical circuit diagram

To A

Remedy

Is voltage of R25 (3) normal? • Leave key switchNO at OFF position and turn step light switch ON. • Voltage of R25 (3): 20 – 30 V

circuit with ground in wiring harness between R25 (5) – D34 (2)(1) – C01 (7)(13)

Defective contact, disconnection, or short circuit with ground in wiring harness between fuse 14 – H14 (6) – R25 (3)

Repair or replace

PC600-6

TROUBLESHOOTING

C-24

C-24 [E302] Short circuit in step light relay drive system is displayed fl This troubleshooting is carried out when there is still an abnormality, so when disconnecting the connector and inserting the T-adapter, or when removing the T-adapter and returning the connector to its original position, if an E service code is not displayed, the problem has been removed. fl If [E302] is not displayed, but the step light does not light up, go to C-25 Step light does not light up. fl Before carrying out troubleshooting, check that all the related connectors are properly inserted. fl Always connect any disconnected connectors before going on to the next step.

Cause

YES 1 Interchange with other relay. Is [E302] displayed? • Turn starting switch OFF. • Interchange relay. • Start engine. • Turn step light switch ON.

2 YES Is resistance between chassis and wiring harness C01 NO between (female) (1) and R17 (female) (1) normal?

NO • Turn starting switch OFF. • Disconnect C01 and R17. • Between wiring harness and chassis: Min. 1 MΩ

Remedy

Defective step light drive relay

Replace

Defective pump controller

Replace

Short circuit with ground in wiring harness between C01 (1) and R17 (1)

Repair or replace

C-24 Related electrical circuit diagram

PC600-6

20-495

TROUBLESHOOTING

C-25

C-25 Step light does not light up fl First, check monitoring code: bit pattern 24-(1) to see if the step light switch input is normal. (F-13: When step light switch is ON, bit pattern 24-(1) does not go out) fl If the step light can light up when the key is ON, but when the key is OFF, the step light does not light up continuously for 60 seconds when the switch is pressed, go to C-23 Step light switch does not work. fl If [E302] is displayed, go to C-24 [E302] Short circuit in step light relay drive system is displayed. fl Before carrying out troubleshooting, check that all the related connectors are properly inserted. Cause Remedy fl Always connect any disconnected connectors before going on to the next step. Defective step light drive relay

YES

4 YES

1 Interchange with other relay. Is movement normal?

Is resistance

When step light YES switch is ON, is 3 voltage of C01 (1) normal?

YES between R17 • Turn starting switch NO • Turn starting ON. (female) (2) and switch OFF. • When step light switch is 2 chassis normal? • Interchange R17 ON, voltage between C01 Is resistance (1) and chassis: 20 – 30 V relay. • Turn starting between C01 • Start engine. NO switch ON. (female) (1) and R17 • Turn step light NO (female) (1) normal? • Disconnect R17. switch ON. • Between R17 (2) and chassis: Max. 1 Ω • Turn starting switch OFF. NO • Disconnect C01 and R17. • Between C01 (1) 6 YES and R17 (1): Max. Is resistance between 1Ω R17 (female) (5) – M72 YES (3) – M73 (3) – M75 (female) normal, and is 5 circuit insulated from chassis?

Is voltage of R17 (3) normal?

• Turn starting switch NO OFF. • Disconnect R17 and M75. • Between R17 (5) and M75: Max. 1 Ω • Between wiring harness and chassis: Min. 1 Ω

• Turn starting switch ON. NO • Voltage of R17 (3): 20 – 30 V

C-25 Related electrical circuit diagram

20-496

To A

Replace

—

Defective pump controller

Replace

Defective contact or disconnection in wiring harness between R17 (2) and chassis

Repair or replace

Defective contact or disconnection in wiring harness between C01 (1) and R17 (1)

Repair or replace

Blown step light bulb or defective contact of step light GND

Repair or replace

Defective contact, disconnection, or short circuit with ground in wiring harness between R17 (5) – M72 (3) – M73 (3) – M75 Defective contact, disconnection, or short circuit with ground in wiring harness between fuse 14 – H14 (6) – R17 (3)

Repair or replace

PC600-6

TROUBLESHOOTING

C-26

C-26 [E228] Abnormality in auto-deceleration output system is displayed fl This troubleshooting is carried out when there is still an abnormality, so when disconnecting the connector and inserting the T-adapter, or when removing the T-adapter and returning the connector to its original position, if an “E” service code is not displayed, the problem has been removed. fl If the starting switch is turned OFF after an abnormality occurs, turn the starting switch ON and check if an “E” service code is displayed. (If it is not displayed, the problem has been removed.) fl Always turn the emergency pump drive switch OFF. fl Before carrying out troubleshooting, check that all the related connectors are properly inserted. fl Always connect any disconnected connectors before going on to the next step.

Cause

YES

Remedy

Defective pump controller

Replace

Defective engine controller

Replace

Defective contact or disconnection in wiring harness between C01 (female) (4) and E14 (female) (11)

Repair or replace

Short circuit with ground in wiring harness between C01 (female) (4) and E14 (female) (11)

Replace

1 3 YES

Is voltage between C01 (4) and ground normal? • Turn starting switch ON. • Turn autodeceleration switch OFF. • Min. 5 V

Is resistance YES between C01 (female) (4) and E14 (female) (11) 2 normal?

Is resistance between C01 NO (female) (4) and ground normal? • Turn starting switch OFF. • Disconnect C01 and E14. • Min. 1 Ω

NO • Turn starting switch OFF. • Disconnect C01 and E14. • Max. 1 Ω

C-26 Related electrical circuit diagram

PC600-6

20-497

TROUBLESHOOTING OF PUMP CONTROLLER (INPUT SIGNAL SYSTEM) (F MODE)

Electrical circuit diagram of F mode system ....................................................................................... 20-552 F- 1

Bit pattern 20-(1) (Swing oil pressure switch) does not light up ........................................... 20-554

F- 2

Bit pattern 20-(2) (Travel oil pressure switch) does not light up ........................................... 20-555

F- 3

Bit pattern 20-(3) (Boom LOWER oil pressure switch) does not light up ............................ 20-556

F- 4

Bit pattern 20-(4) (Boom RAISE oil pressure switch) does not light up ............................... 20-557

F- 5

Bit pattern 20-(5) (Arm IN oil pressure switch) does not light up ......................................... 20-558

F- 6

Bit pattern 20-(6) (Arm OUT oil pressure switch) does not light up ..................................... 20-559

F- 7

Bit pattern 21-(1) (Bucket CURL oil pressure switch) does not light up............................... 20-560

F- 8

Bit pattern 21-(2) (Bucket DUMP oil pressure switch) does not light up ............................. 20-561

F- 9

Bit pattern 22-(4) (Service valve oil pressure switch) does not light up .............................. 20-562

F-10 Bit pattern 21-(3) (Swing lock switch) does not light up ........................................................ 20-563 F-11 Bit pattern 22-(6) (L.H. knob switch) does not light up ........................................................... 20-564 F-12 When step light switch is ON, bit pattern 24-(1) does not go out......................................... 20-565 F-13 When horn switch is ON, bit pattern 24-(2) does not go out ................................................. 20-566

PC600-6

20-551

TROUBLESHOOTING

ELECTRICAL CIRCUIT DIAGRAM FOR F MODE

20-552

PC600-6

TROUBLESHOOTING

PC600-6

ELECTRICAL CIRCUIT DIAGRAM FOR F MODE

20-553

TROUBLESHOOTING

F-1

F-1 Bit pattern 20-(1) (Swing oil pressure switch) does not light up fl This troubleshooting is carried out when there is still an abnormality, so when disconnecting the connector and inserting the T-adapter, or when removing the T-adapter and returning the connector to its original position, if the monitor code display returns to normal, the problem has been removed. ¤ Turn the swing lock switch ON before operating the swing lever. fl If there is no display when the lever is operated on one side, the PPC shuttle valve is defective. (See H-5) (When measuring with the engine stopped, charge the accumulator first.) fl Before carrying out troubleshooting, check that all the related connectors are properly inserted. fl Always connect any disconnected connectors before going on to the next step.

Cause

YES

1 Is voltage between C16 (5) and chassis normal? • Start engine. • Swing lever at neutral : 20 – 30 V • Swing lever opereated : Max. 1V

YES

Is resistance between C16 (female) (5) and YES S08 (female) (2) normal, and is circuit insulated from 2 chassis? Is resistance between NO S08 (male) (1) and (2) • Turn starting switch normal, and is circuit OFF. NO insulated from • Disconnect C16 and S08. chassis? • Between C16 and S08: Max. 1 Ω • Between wiring harness and • Disconnect S08. chassis: Min. 1 MΩ • Start engine. • Swing lever at NO neutral : Min. 1 MΩ • Swing lever operated: Max. 1 Ω • See Note 1.

Remedy

Defective pump controller

Replace

Defective contact, or disconnection in wiring harness between S08 (female) (1) – J 04 (3) (4) – J05 (6) (7) and chassis ground

Repair or replace

Defective contact, short circuit with ground, or disconnection in wiring harness between C16 (female) (5) and S08 (female) (2) Defective swing oil pressure switch (If the condition does not return to normal even when the switch is replaced, go to H-5.

Repair or replace

Replace

Note 1: It is also possible to fit a short connector and judge the condition. In this case, check the voltage between C16 (5) and the chassis. • If it is 20 – 30 V: Go to YES • If it is less than 1 V: Go to NO

F-1 Related electrical circuit diagram

20-554

PC600-6

TROUBLESHOOTING

F-2

F-2 Bit pattern 20-(2) (Travel oil pressure switch) does not light up fl This troubleshooting is carried out when there is still an abnormality, so when disconnecting the connector and inserting the T-adapter, or when removing the T-adapter and returning the connector to its original position, if the monitor code display returns to normal, the problem has been removed. ¤ Before operating the travel lever, check that the surrounding area is safe. fl If there is no display when the travel lever is operated on one side, the PPC shuttle valve is defective. (See H-5) (When measuring with the engine stopped, charge the accumulator first.) fl Before carrying out troubleshooting, check that all the related connectors are properly inserted. fl Always connect any disconnected connectors before going on to the next step.

Cause

YES

1 Is voltage between C16 (13) and chassis normal? • Start engine. • Travel lever at neutral : 20 – 30V • Travel lever operated : Max. 1 V

YES

Is resistance between C16 (female) (13), S01 YES (2) and S50 (female) (2) normal, and is circuit insulated from 2 chassis? Is resistance between NO S50 (male) (1) and (2) • Turn starting switch normal, and is circuit OFF. NO insulated from • Disconnect C16 and S50. chassis? • Between C16 and S50: Max. 1 Ω • Disconnect S50 • Between wiring harness and chassis: Min. 1 MΩ • Start engine. • Travel lever at NO neutral : Min. 1MΩ • Travel lever operated : Max: 1 Ω • See Note 1.

Remedy

Defective pump controller

Replace

Defective contact, or disconnection in wiring harness between S50 (female) (1), S01 (1) – J 02 (3) (5) – J05 (5) (7) and chassis ground

Repair or replace

Defective contact, short circuit with ground, or disconnection in wiring harness between C16 (female) (13), S01 (2) and S50 (female) (2)

Repair or replace

Defective travel oil pressure switch (If the condition does not returen to normal even when the switch is replaced, go to H-5.)

Replace

Note 1: It is also posibble to fit a short connector and judge the condition. In this case, check the voltage between C16 (13) and the chassis. • If it is 20 – 30 V: Go to YES • If it is less than 1 V: Go to NO

F-2 Related electrical circuit diagram

PC600-6

20-555

TROUBLESHOOTING

F-3

F-3 Bit pattern 20-(3) (Boom LOWER oil pressure switch) does not light up fl This troubleshooting is carried out when there is still an abnormality, so when disconnecting the connector and inserting the T-adapter, or when removing the T-adapter and returning the connector to its original position, if the monitor code display returns to normal, the problem has been removed. ¤ When measuring with the engine running, operate the lever slightly and make sure that the work equipment does not move. (When measuring with the engine stopped, charge the accumulator first.) fl Before carrying out troubleshooting, check that all the related connectors are properly inserted. fl Always connect any disconnected connectors before going on to the next step.

Cause

YES

1 Is voltage between C17 (10) and chassis normal? • Start engine. • Boom lever at neutral: 20 – 30V • Boom lever operated to LOWER: Max. 1V

YES

Is resistance between C17 (female) (10) and YES S04 (female) (2) normal, and is circuit insulated from 2 chassis? Is resistance between NO S04 (male) (1) and (2) • Turn starting switch normal, and is circuit OFF. • Disconnect C17 and S04. NO insulated from chassis? • Between C17 and S04: Max. 1 Ω • Between wiring harness and chassis • Disconnect S04. : Min. 1 MΩ • Start engine. • Boom lever at NO neutral : Min. 1 MΩ • Boom lever operated to LOWER: Max. 1 Ω • See Note 1.

Remedy

Defective pump controller

Replace

Defective contact, or disconnection in wiring harness between S04 (female) (1) – J 04 (1) (4) – J05 (6) (7) and chassis ground

Repair or replace

Defective contact, short circuit with ground, or disconnection in wiring Repair or harness between C17 (female) (10) – replace H13 (11) – S04 (female) (2) Defective boom LOWER oil pressure switch (If the condition does not return to normal even when the switch is replaced, go to H-5.)

Replace

Note 1: It is also possible to fit a short connector and judge the condition. In this case, check the voltage between C17 (10) and the chassis. • If it is 20 – 30 V: Go to YES • If it is less than 1 V: Go to NO

F-3 Related electrical circuit diagram

20-556

PC600-6

TROUBLESHOOTING

F-4

F-4 Bit pattern 20-(4) (Boom RAISE oil pressure switch) does not light up fl This troubleshooting is carried out when there is still an abnormality, so when disconnecting the connector and inserting the T-adapter, or when removing the T-adapter and returning the connector to its original position, if the monitor code display returns to normal, the problem has been removed. ¤ When measuring with the engine running, operate the lever slightly and make sure that the work equipment does not move. (When measuring with the engine stopped, charge the accumulator first.) fl Before carrying out troubleshooting, check that all the related connectors are properly inserted. fl Always connect any disconnected connectors before going on to the next step.

Cause

YES

1 Is voltage between C17 (2) and chassis normal?

3 Is resistance between C17 (female) (2), D28 YES (2), (1) S02 (female) (2) normal, and is circuit insulated from 2 chassis?

YES

• Start engine. • Boom lever at Is resistance between NO • Turn starting switch neutral: 20 - 30V S02 (male) (1) and (2) OFF. • Boom lever NO normal, and is circuit • Disconnect C17 and S02. operated to RAISE insulated from chassis? • Between C17 and S02 : Max. 1 Ω : Max. 1 V • Between wiring harness and chassis • Disconnect S02. : Min. 1 MΩ • Start engine. • Boom lever at NO neutral: Min. 1 MΩ • Boom lever operated to RAISE : Max. 1 Ω. • See Note 1.

Remedy

Defective pump controller

Replace

Defective contact, or disconnection in wiring harness between S02 (female) (1) – J05 (1) (7) and chassis ground

Repair or replace

Defective contact, short circuit with ground, or disconnection in wiring harness between C17 (female) (2) – H13 (9) – D28 (2), (1) – S02 (female) (2) Defective boom RAISE oil pressure switch (If the condition does not return to normal even when the switch is replaced, go to H-5.)

Repair or replace

Replace

Note 1: It is also possible to fit a short connector and judge the condition. In this case, check the voltage between C17 (2) and the chassis. • If it is 20 – 30V: Go to YES • If it is less than 1V: Go to NO

F-4 Related electrical circuit diagram

PC600-6

20-557

TROUBLESHOOTING

F-5

F-5 Bit pattern 20-(5) (Arm IN oil pressure switch) does not light up fl This troubleshooting is carried out when there is still an abnormality, so when disconnecting the connector and inserting the T-adapter, or when removing the T-adapter and returning the connector to its original position, if the monitor code display returns to normal, the problem has been removed. ¤ When measuring with the engine running, operate the lever slightly and make sure that the work equipment does not move. (When measuring with the engine stopped, charge the accumulator first.) fl Before carrying out troubleshooting, check that all the related connectors are properly inserted. fl Always connect any disconnected connectors before going on to the next step.

Cause

YES

1 Is voltage between C17 (3) and chassis normal?

YES

Is resistance between C17 (female) (3) and YES S05 (female) (2) normal, and is circuit insulated from 2 • Start engine. chassis? Is resistance between • Arm lever at NO S05 (male) (1) and (2) • Turn starting neutral: 20 – 30V normal, and is circuit switch OFF. • Arm lever NO insulated from • Disconnect C17 and S05. operated to IN chassis? • Between C17 and S05: Max. 1 Ω : Max. 1 V • Between wiring harness and chassis • Disconnect S05. : Min. 1 MΩ • Start engine. • Arm lever at NO neutral : Min. 1 MΩ • Arm lever operated to IN: Max. 1 Ω • See Note 1.

Remedy

Defective pump controller

Replace

Defective contact, or disconnection in wiring harness between S05 (female) (1) – J 04 (2) (4) – J05 (6) (7) and chassis ground

Repair or replace

Defective contact, short circuit with ground, or disconnection in wiring harness between C17 (female) (3) – H13 (10) – S05 (female) (2) Defective arm IN oil pressure switch (If the condition does not return to normal even when the switch is replaced, go to H-5.)

Repair or replace

Replace

Note 1: It is also possible to fit a short connector and judge the condition. In this case, check the voltage between C17 (3) and the chassis. • If it is 20 – 30V: Go to YES • If it is less than 1V: Go to NO

F-5 Related electrical circuit diagram

20-558

PC600-6

TROUBLESHOOTING

F-6

F-6 Bit pattern 20-(6) (Arm OUT oil pressure switch) does not light up fl This troubleshooting is carried out when there is still an abnormality, so when disconnecting the connector and inserting the T-adapter, or when removing the T-adapter and returning the connector to its original position, if the monitor code display returns to normal, the problem has been removed. ¤ When measuring with the engine running, operate the lever slightly and make sure that the work equipment does not move. (When measuring with the engine stopped, charge the accumulator first.) fl Before carrying out troubleshooting, check that all the related connectors are properly inserted. fl Always connect any disconnected connectors before going on to the next step.

Cause

YES

1 Is voltage between C17 (11) and chassis normal?

YES

Is resistance between C17 (female) (11) and YES S03 (female) (2) normal, and is circuit insulated from 2 • Start engine. chassis? Is resistance between • Arm lever at NO S03 (male) (1) and (2) • Turn starting neutral: 20 – 30V normal, and is circuit switch OFF. • Arm lever NO insulated from • Disconnect C17 and S03. operated to chassis? • Between C17 and S03: Max. 1 Ω OUT: Max. 1 V • Between wiring harness and chassis • Disconnect S03. : Min. 1 MΩ • Start engine. • Arm lever at NO neutral : Min. 1 MΩ • Arm lever operated to OUT: Max. 1 Ω • See Note 1.

Remedy

Defective pump controller

Replace

Defective contact, or disconnection in wiring harness between S03 (female) (1) – J05 (2) (7) and chassis ground

Repair or replace

Defective contact, short circuit with ground, or disconnection in wiring harness between C17 (female) (11) – H13 (12) – S03 (female) (2) Defective arm OUT oil pressure switch (If the condition does not return to normal even when the switch is replaced, go to H-5.)

Repair or replace

Replace

Note 1: It is also possible to fit a short connector and judge the condition. In this case, check the voltage between C17 (11) and the chassis. • If it is 20 – 30V: Go to YES • If it is less than 1V: Go to NO

F-6 Related electrical circuit diagram

PC600-6

20-559

TROUBLESHOOTING

F-7

F-7 Bit pattern 21-(1) (Bucket CURL oil pressure switch) does not light up fl This troubleshooting is carried out when there is still an abnormality, so when disconnecting the connector and inserting the T-adapter, or when removing the T-adapter and returning the connector to its original position, if the monitor code display returns to normal, the problem has been removed. ¤ When measuring with the engine running, operate the lever slightly and make sure that the work equipment does not move. (When measuring with the engine stopped, charge the accumulator first.) fl Before carrying out troubleshooting, check that all the related connectors are properly inserted. fl Always connect any disconnected connectors before going on to the next step.

Cause

YES

Is voltage between C16 (11) and chassis normal?

YES

Is resistance between C16 (female) (11) and YES S06 (female) (2) normal, and is circuit insulated from 2 • Start engine. chassis? Is resistance between • Bucket lever at NO S06 (male) (1) and (2) • Turn starting neutral: 20 – 30V normal, and is circuit switch OFF. • Bucket lever NO insulated from • Disconnect C16 and S06. operated to chassis? • Between C16 and S06: Max. 1 Ω CURL: Max. 1 V • Between wiring harness and chassis • Disconnect S06. : Min. 1 MΩ • Start engine. • Bucket lever at NO neutral: Min. 1 MΩ • Bucket lever operated to CURL: Max. 1 Ω • See Note 1.

Remedy

Defective pump controller

Replace

Defective contact, or disconnection in wiring harness between S06 (female) (1) – J05 (3) (7) and chassis ground

Repair or replace

Defective contact, short circuit with ground, or disconnection in wiring harness between C16 (female) (11) and S06 (female) (2) Defective bucket CURL oil pressure switch (If the condition does not return to normal even when the switch is replaced, go to H-5.)

Repair or replace

Replace

Note 1: It is also possible to fit a short connector and judge the condition. In this case, check the voltage between C16 (11) and the chassis. • If it is 20 – 30V: Go to YES • If it is less than 1V: Go to NO

F-7 Related electrical circuit diagram

20-560

PC600-6

TROUBLESHOOTING

F-8

F-8 Bit pattern 21-(2) (Bucket DUMP oil pressure switch) does not light up fl This troubleshooting is carried out when there is still an abnormality, so when disconnecting the connector and inserting the T-adapter, or when removing the T-adapter and returning the connector to its original position, if the monitor code display returns to normal, the problem has been removed. ¤ When measuring with the engine running, operate the lever slightly and make sure that the work equipment does not move. (When measuring with the engine stopped, charge the accumulator first.) fl Before carrying out troubleshooting, check that all the related connectors are properly inserted. fl Always connect any disconnected connectors before going on to the next step.

Cause

YES

Is voltage between C16 (12) and chassis normal?

YES

Is resistance between C16 (female) (12) and YES S07 (female) (2) normal, and is circuit insulated from 2 • Start engine. chassis? Is resistance between • Bucket lever at NO S07 (male) (1) and (2) • Turn starting switch neutral: 20 – 30V normal, and is circuit OFF. • Bucket lever NO insulated from • Disconnect C16 and S07. operated to chassis? • Between C16 and S07: Max. 1 Ω DUMP: Max. 1 V • Between wiring harness and chassis: • Disconnect S07. Min. 1 MΩ • Start engine. • Bucket lever at NO neutral : Min. 1 MΩ • Bucket lever operated to DUMP: Max. 1 Ω • See Note 1.

Remedy

Defective pump controller

Replace

Defective contact or disconnection in wiring harness between S07 (female) (1) – J05 (4) (7) and chassis ground

Repair or replace

Defective contact, short circuit with ground, or disconnection in wiring harness between C16 (female) (12) and S07 (female) (2) Defective bucket DUMP oil pressure switch (If the condition does not return to normal even when the switch is replaced, go to H-5.)

Repair or replace

Replace

Note 1: It is also possible to fit a short connector and judge the condition. In this case, check the voltage between C16 (12) and the chassis. • If it is 20 – 30V: Go to YES • If it is less than 1V: Go to NO

F-8 Related electrical circuit diagram

PC600-6

20-561

TROUBLESHOOTING

F-9

F-9 Bit pattern 21-(2) (Service valve oil pressure switch) does not light up fl This troubleshooting is carried out when there is still an abnormality, so when disconnecting the connector and inserting the T-adapter, or when removing the T-adapter and returning the connector to its original position, if the monitor code display returns to normal, the problem has been removed. ¤ When measuring with the engine running, operate the lever slightly and make sure that the work equipment does not move. (When measuring with the engine stopped, charge the accumulator first.) fl Before carrying out troubleshooting, check that all the related connectors are properly inserted. fl Always connect any disconnected connectors before going on to the next step.

Cause

YES

Is voltage between C16 (14) and chassis normal?

YES

Is resistance between C16 YES (female) (14) and S09 (female) (2) normal, and is circuit insulated 2 • Start engine. from chassis? Is resistance • Bucket lever at NO between S09 (male) • Turn starting switch HOLD: 20 – 30V (1) and (2) normal, OFF. is circuit • Bucket lever NO and insulated from • Disconnect C16 and S09. operated to chassis? • Between C16 and S09: Max. 1 Ω

DUMP: Max. 1 V

• Between wiring harness and chassis: Min. 1 MΩ • Disconnect S09. • Start engine. • Bucket lever at NO HOLD: Min. 1 MΩ • Bucket lever operated to DUMP: Max. 1 Ω • See Note 1.

Remedy

Defective pump controller

Replace

Defective contact or disconnection in wiring harness between S09 (female) (1) – J 02 (4) (5) – J05 (5) (7) and chassis ground

Repair or replace

Defective contact, short circuit with ground, or disconnection in wiring harness between C16 (female) (14) and S09 (female) (2)

Defective bucket DUMP oil pressure switch (If the condition does not return to normal even when the switch is replaced, go to H-5.)

Repair or replace

Replace

Note 1: It is also possible to fit a short connector and judge the condition. In this case, check the voltage between C16 (14) and the chassis. • If it is 20 – 30V: Go to YES • If it is less than 1V: Go to NO

F-9 Related electrical circuit diagram

20-562

PC600-6

TROUBLESHOOTING

F-10

F-10 Bit pattern 21-(3) (Swing lock switch) does not light up fl This troubleshooting is carried out when there is still an abnormality, so when disconnecting the connector and inserting the T-adapter, or when removing the T-adapter and returning the connector to its original position, if the monitor code display returns to normal, the problem has been removed. fl If the panel display is normal. (If the swing lock lamp does not light up, go to M-21.) fl Before carrying out troubleshooting, check that all the related connectors are properly inserted. fl Always connect any disconnected connectors before going on to the next step.

Cause

YES

1 Is voltage between C17 (16) and chassis normal? • Turn starting switch ON. • Swing lock switch ON: Max. 1V OFF: 20 – 30V

YES Is resistance between C17 YES (female) (16) and X05 (1) normal, and is circuit insulated 2 from chassis? Is resistance between NO X05 (female) (1) and • Turn starting (2) normal, and is switch OFF. NO circuit insulated from • Disconnect C17 and X05. chassis? • Between C17 and X05 : Max. 1 Ω • Turn starting • Between wiring harness and chassis switch OFF. : Min. 1 MΩ • Disconnect X05. NO • Swing lock switch ON: Max. 1 Ω OFF: Min. 1 MΩ

Remedy

Defective pump controller

Replace

Defective contact, short circuit with ground, or disconnection in wiring harness between X05 (male) (2) – X01 (5) – H14 (7) – chassis ground

Repair or replace

Defective contact, short circuit with ground, or disconnection in wiring harness between C17 (female) (16) – X01 (4) – X05 (male) (1) Defective swing lock switch

Repair or replace

Replace

F-10 Related electrical circuit diagram

PC600-6

20-563

TROUBLESHOOTING

F-11

F-11 Bit pattern 22-(6) (L.H. knob switch) does not light up fl This troubleshooting is carried out when there is still an abnormality, so when disconnecting the connector and inserting the T-adapter, or when removing the T-adapter and returning the connector to its original position, if the monitor code display returns to normal, the problem has been removed. fl When fuse No. 5 is not blown. fl Before carrying out troubleshooting, check that all the related connectors are properly inserted. fl Always connect any disconnected connectors before going on to the next step.

Cause

YES

1 3 YES

Is voltage between C03 (9) and chassis normal? • Turn starting switch ON. • Knob switch ON: 20 – 30V OFF: Max. 1 V

Is resistance YES between terminals of knob 2 switch normal? Is voltage between knob switch inlet NO terminal and chassis normal? • Turn starting switch ON. • 20 – 30V

NO • Turn starting switch OFF. • Disconnect switch terminal. • Knob switch ON: Max. 1 Ω OFF: Min. 1 MΩ NO

Remedy

Defective pump controller

Replace

Defective contact, or disconnection in wiring harness between knob switch outlet – M22 (2) – C03 (female) (9)

Repair wiring harness

Defective L.H. knob switch

Replace

Defective contact, or disconnection in wiring harness between fuse No. 5 – H12 (14) – M22 (1) – knob switch inlet

Repair wiring harness

F-11 Related electrical circuit diagram

20-564

PC600-6

TROUBLESHOOTING

F-12

F-12 When step light switch is ON, bit pattern 24-(1) does not go out fl This troubleshooting is carried out when there is still an abnormality, so when disconnecting the connector and inserting the T-adapter, or when removing the T-adapter and returning the connector to its original position, if the monitor code display returns to normal, the problem has been removed. fl If the step light does not light up, check this item, then go to C-25 Step light does not light up. fl Before carrying out troubleshooting, check that all the related connectors are properly inserted. fl Always connect any disconnected connectors before going on to the next step.

Cause

YES

Defective pump controller

1 Is voltage between C16 (7) and chassis normal?

3 YES Is resistance between C16 (female) (7) and YES L03 (female) (1) normal, and is circuit insulated from 2 chassis?

• Start engine. Is resistance • Step light switch between L03 (1) and OFF: 20 – 30 V (2) normal, and is • Step light switch NO circuit insulated ON: Max. 1 V from chassis? • Disconnect L03. • Start engine. • Step light switch OFF: Min. 1 MΩ • Step light switch ON: Max. 1 Ω • See Note 1.

NO • Turn starting switch OFF. • Disconnect C16 and L03. • Between C16 and L03: Max. 1 Ω • Between wiring harness and chassis: Min. 1 MΩ NO

Defective contact or disconnection in wiring harness between L03 (female) (2) – M81 (2) – ground Defective contact, disconnection, or short circuit with ground in wiring harness between C16 (female) (7) and M81 (female) (1) Defective swing oil pressure switch (If the condition does not return to normal even when the switch is replaced, go to H-5.)

Remedy

Replace

Repair or replace

Replace

Note 1: It is also possible to fit a short connector and judge the condition. In this case, check the voltage between C16 (7) and the chassis. • If it is 20 – 30V: Go to YES • If it is less than 1V: Go to NO

F-12 Related electrical circuit diagram

PC600-6

20-565

TROUBLESHOOTING

F-13

F-13 When horn switch is ON, bit pattern 24-(2) does not go out fl This troubleshooting is carried out when there is still an abnormality, so when disconnecting the connector and inserting the T-adapter, or when removing the T-adapter and returning the connector to its original position, if the monitor code display returns to normal, the problem has been removed. fl If the flashing light does not light up, check this item, then go to C-21 Flashing light does not light up. fl Before carrying out troubleshooting, check that all the related connectors are properly inserted. fl Always connect any disconnected connectors before Cause Remedy going on to the next step.

YES

Defective pump controller

Replace

Defective horn switch relay R18

Replace

1 Is voltage between C16 (15) and chassis normal?

YES 2

• Start engine. Interchange horn 4 YES • Horn switch OFF: switch relay R18. Is resistance between 20 – 30 V Does condition C16 (female) (15) – NO • Horn switch ON: YES D35 – R18 (female) return to normal? (5) normal, and is Max. 1 V 3 circuit insulated from • Interchange R18 Is resistance chassis? relay with other between M23 (1) • Turn starting switch NO relay. OFF. and (2) normal, and • Disconnect C16 and R18. NO is circuit insulated • Start engine. • Between C16 and R18: Max. 1Ω • When horn from chassis? • Between wiring harness and • Disconnect M23. switch is pressed, chassis: Min. 1 MΩ • Start engine. does bit pattern NO • Horn switch OFF: 24-(2) go out? Min. 1 MΩ • Horn switch ON: Max. 1 Ω

6 YES

Is resistance between R18 (female) (1) and YES M23 (female) (2) normal, and is circuit 5 insulated from chassis? Is resistance • Turn starting switch NO between R18 OFF. (female) (3)(2) and • Disconnect R18 and M23. chassis normal? • Between R18 and M23: Max. 1 Ω • Between wiring harness and chassis: Min. 1 MΩ

• Turn starting switch OFF. • Disconnect R18. • Both R18 (3) and (2): Max. 1 Ω

To A Defective contact, disconnection, or short circuit with ground in wiring harness between C16 (female) (15) – D35 – R18 (female) (5)

Defective horn switch (including wiring harness up to M23) Defective contact, disconnection, or short circuit with ground in wiring harness between M23 (female) (1) – H12 (13) – fuse 6 Defective contact, disconnection, or short circuit with ground in wiring harness between R18 (female) (1) and M23 (female) (2) Defective contact or disconnection in wiring harness between R18 (female) (3) and chassis, between R18 (female) (2) and chassis

—

Repair or replace

Replace

Repair or replace

F-13 Related electrical circuit diagram

20-566

PC600-6

TROUBLESHOOTING OF HYDRAULIC, MECHANICAL SYSTEM (H MODE)

Table of failure modes and causes ...................................................................................................... 20-602 Before carrying out troubleshooting of hydraulic system (H mode) ............................................... 20-604 Troubleshooting flow charts for each failure mode ........................................................................... 20-607 All work equipment, travel, swing H-1

Speeds of all work equipment, swing, travel are slow or lack power ........................... 20-607

H-2

There is excessive drop in engine speed, or engine stalls .............................................. 20-608

H-3

No work equipment, travel, swing move ........................................................................... 20-610

H-4

Abnormal noise generated (around pump) ....................................................................... 20-611

H-5

Auto-deceleration does not work ........................................................................................ 20-611

Work equipment system H-6

Work equipment (boom, arm, bucket) is slow or lacks power ........................................ 20-612

H-7

Work equipment (boom, arm, bucket) does not move (but travel and swing are normal) ...................................................................................... 20-613

H-8

Excessive hydraulic drift ...................................................................................................... 20-613

H-9

Excessive time lag ................................................................................................................ 20-614

H-10 Defective actuation of machine push-up function ............................................................. 20-614 H-11 In compound operations with swing, work equipment speed is slow .......................... 20-615 H-12 In compound operations with bucket CURL, swing and other work equipment speeds are slow .................................................................................................................... 20-615 Travel system H-13 Travel deviation is excessive during compound operations ............................................ 20-615 H-14 Machine deviates naturally to one side during travel operations ..................................20-616 H-15 Deviation is excessive when starting.................................................................................. 20-620 H-16 Travel speed is slow ............................................................................................................. 20-622 H-17 Travel speed does not switch .............................................................................................. 20-623 H-18 Travel does not move (one side only)................................................................................ 20-623 Swing system H-19 Does not swing ..................................................................................................................... 20-624 H-20 Swing speed is slow or swing acceleration is poor ......................................................... 20-625 H-21 Excessive overrun when stopping swing ........................................................................... 20-626 H-22 Excessive shock when stopping swing .............................................................................. 20-627 H-23 Excessive abnormal noise when stopping swing ............................................................. 20-627 H-24 Excessive hydraulic drift of swing ...................................................................................... 20-628

PC600-6

20-601

TROUBLESHOOTING

TABLE OF FAILURE MODES AND CAUSES

TABLE OF FAILURE MODES AND CAUSES Pump

Control valve

TVC

All work equipment, travel, swing

Speeds of all work equipment, swing, travel are slow or lack power There is excessive drop in engine speed, or engine stalls No work equipment, travel, swing move Abnormal noise generated (around pump)

Swing priority valve

Valve proper

Bucket CURL Hi valve

Straight-travel valve

Safety valve

ﬁ

Auto-deceleration does not work

fi fi fi fi fi fi fi

Arm is slow or lacks power Bucket is slow or lacks power Boom does not move Arm does not move Bucket does not move Excessive hydraulic drift

fi fi fi fi fi fi

fi fi fi

ﬁ ﬁ

Excessive time lag

ﬁ

Defective actuation of machine push-up function In compound operations with swing, work equipment speed is slow

ﬁ

ﬁ ﬁ

In compound operations with bucket CURL, swing and work equipment speeds are slow

ﬁ

Travel deviation is excessive in compound operations

Travel system

Suction valve

Spool

Main relief valve

Solenoid

Spool

Strainer

PTO

Pump proper

fi fi fi fi fi fi fi fi fi fi fi fi fi

Boom is slow or lacks power

Work equipment

Control pump, relief valve

CO, NC valve

Failure mode

Servo valve

Parts causing failure

Machine deviates to one Deviates in same direction when traveling in FORWARD and REVERSE side when traveling Deviates in different direction when traveling in FORWARD and REVERSE

fi fi fi

Deviation is excessive when starting

ﬁ ﬁ

ﬁ

fi fi fi

Travel speed is slow Travel speed does not switch or is faster (slower) than set speed Does not move (one side only) Both left and right

Swing system

Does not swing

One direction only

Swing speed is slow or swing acceleration is poor Excessive overrun when stopping swing

ﬁ

Both left and right One direction only

ﬁ

Both left and right One direction only

ﬁ

Excessive shock when stopping swing Excessive abnormal noise when stopping swing Excessive hydraulic drift of swing

20-602

When swing holding brake is canceled

ﬁ

When swing holding brake is applied

PC600-6

Jet sensor (relief valve, orifice)

fi fi fi fi fi fi

PC600-6

fi fi fi fi fi fi fi fi

ﬁ

ﬁ Internal leakage

ﬁ

fi fi fi fi

fi fi fi fi fi fi fi fi fi

ﬁ

ﬁ ﬁ

fi fi fi H-20

fi fi fi fi fi fi fi fi fi

H-21

ﬁ ﬁ

fi fi fi fi

ﬁ

fi fi fi

ﬁ

Engine system

Lift check valve

Hydraulic cylinder

Final drive

Swing machinery

Travel speed selector servo

Brake

Internal leakage

Motor proper

Swing motor

Safety valve

Motor proper

Suction valve

Safety valve

Solenoid

Brake

Bucket CURL Hi cancel

Swing holding brake

Machine push-up

CO cancel

Travel speed

2-stage relief

Center swivel joint

PPC valve

TROUBLESHOOTING TABLE OF FAILURE MODES AND CAUSES

Travel motor

Troubleshooting code

ﬁ ﬁ H-1

H-2

H-3

H-4

H-5

H-6

H-7

H-8

H-10 H-9

H-11

H-12

H-13

H-14

H-15

H-16

H-17

H-18

H-19

H-22

H-23

H-24

20-603

TROUBLESHOOTING

BEFORE CARRYING OUT TROUBLESHOOTING OF HYDRAULIC SYSTEM (H MODE)

BEFORE CARRYING OUT TROUBLESHOOTING OF HYDRAULIC SYSTEM (H MODE) 1. Actuation and combination of main pumps One each of piston pumps HPV160+160 and HPV95+90 are used in the work equipment and travel circuits. The oil from the No. 1 front pump and No. 2 front pump merges and flows to the R.H. 4-spool valve; and the oil from the No. 1 rear pump and No. 2 rear pump merges and flows to the L.H. 5-spool valve. The No. 2 pump is controlled by the control pressure (NC valve output pressure) from the No. 1 pump, so it is controlled in the same way as the No. 1 pump. If the differential pressure of the jet sensor is defective or the NC valve output pressure is defective, the No. 1 front pump (rear pump) and No. 2 front pump (rear pump) are affected at the same time. Therefore, if the work equipment and travel speed is slow or lacks power, or there is travel deviation, check using the following procedure and the troubleshooting chart to determine if the problem is in the pump system (and to find which of the four pump systems has the problem) or if the problem is in the control valve system. 2. Judgement procedure If the work equipment is slow and the machine deviates to the left, the cause is probably one of the following: 1) Drop in main relief pressure of L.H. 5spool control valve 2) Defective jet sensor differential pressure of L.H. 5-spool control valve 3) Defective NC valve output pressure for No. 1 rear pump 4) Defective No. 1 rear pump or No. 2 rear pump It is possible to judge if the main relief pressure, jet sensor differential pressure, and NC valve output pressure are correct by measuring the oil pressure. However, as explained in Item 1 above, in the case of the pumps, the No. 2 pump is simultaneously controlled by the output pressure of the NC valve installed to the No. 1 pump, so it is impossible to judge if the problem is in the No. 1 front pump or the No. 2 front pump. If the outlet port hoses of the No. 1 pump are interchanged between the front and rear, it is possible to judge which pump is defective.

20-604

1) If deviation is to left, No. 2 rear pump is defective 2) If deviation is to right, No. 1 rear pump is defective 3) If the travel speed is slow on both the left and right, the output pressure for the No. 1 rear pump NC valve is defective or the jet sensor of the L.H. 5-spool control valve is defective (if the relief pressure is normal when both the left and right travel are relieved). In addition, if it is judged that the No. 1 rear pump or No. 2 rear pump is defective and the NC valve output pressure is normal, the next step is to check if the defect is in the servo valve or in the pump itself. To make this judgement, remove the servo valve and carry out a test on the individual part to judge if the servo valve is defective or not. ª When testing the servo valve as an individual part, carry out the test at the specified maintenance work shop. ﬂ If the work equipment speed is slow and the machine deviates to the right when traveling, replace “front” for “rear” in the above explanation.

PC600-6

BEFORE CARRYING OUT TROUBLESHOOTING OF HYDRAULIC SYSTEM (H MODE)

TROUBLESHOOTING

Work equipment is slow or lacks power

Troubleshooting No. Remedy

Causes

l m n o p

Defective L.H. travel motor

L.H. 5- R.H. 4spool spool control control valve valve

Defective R.H. travel motor

Front Rear pump pump

Defective servo valve

Rear pump

Defective servo valve

No. 2 pump

Defective pump

Defective CO, NC valve

Front pump

Drop in main relief valve set pressure

No. 1 pump

g h

Defective jet sensor

Drop in main relief valve set pressure

Jet sensor defective

Defective servo valve

Defective pump

Defective servo valve

ﬂ There is also travel deviation (there is no abnormality in the auto-deceleration) 1) If there is a big drop in speed and it seems that there is an abnormality in the pump, check the line filter. 2) If there is only a small drop in speed and the problem is not corrected by adjusting the equipment, check the line filter. 3) To judge if the servo valve is defective or not, remove the servo valve and carry out a test on the individual part, or see TESTING AND ADJUSTING, Measuring servo piston stroke. 4) To check the actuation of the servo piston, remove both caps and move the piston by hand.

A A A A

X X X X X X X X X X X X X X X X

ﬁ ﬁ

1 There is travel deviation to left, and work equipment and swing speeds are slow 2 There is travel deviation to left, and swing speed when operated independently is particularly slow

ﬁ

fi fi fi

ﬁ

3 There is travel deviation to left, but swing speed when operated independently is normal

ﬁ ﬁ

4 There is travel deviation to right, and work equipment speed is also slow 5 There is travel deviation to right, and bucket DUMP speed is particularly slow

ﬁ

fi fi fi

ﬁ

6 There is travel deviation to right, but bucket DUMP is normal

ﬁ

7 In Item 1, relief pressure is low

ﬁ

8 In Item 4, relief pressure is low 9 Item 7 is normal, and when No. 1 Machine deviates to left (no change) 10 pump outlet hoses are interMachine deviates to right (opposite direction) changed between front and rear 11 Left and right travel speeds both become slow ﬁ

ﬁ

fi fi fi

12 In Item 11, jet sensor differential pressure is defective (L.H. 5-spool control valve) 13 Item 12 is normal, but rear NC valve output pressure is defective [ª1] 14 Item 8 is normal, and when No. 1

Machine deviates to right (no change)

15 pump outlet hoses are interchanged between front and rear 16

Machine deviates to left (opposite direction)

fi fi fi

Left and right travel speeds both become slow

ﬁ ﬁ

17 In Item 16, jet sensor differential pressure is defective (R.H. 4-spool control valve)

ﬁ

18 Item 17 is normal, but front NC valve output pressure is defective 19 Item 13 is normal, and No. 1 rear pump servo valve is also normal

ﬁ ﬁ

20 Item 19 is normal, and No. 1 rear pump servo valve is also normal 21 Item 18 is normal, and No. 1 front pump servo valve is also normal 22 Item 21 is normal, and No. 2 front pump servo valve is also normal

ﬁ

ﬁ ﬁ

Remedy A: Adjust X: Repair or replace ª1: Remember that there is an NC valve installed to No. 2 rear pump.

PC600-6

20-605

TROUBLESHOOTING BEFORE CARRYING OUT TROUBLESHOOTING OF HYDRAULIC SYSTEM (H MODE)

•

Hydraulic circuit diagram after interchanging hoses

20-606

PC600-6

TROUBLESHOOTING

H-1

H-1 Speeds of all work equipment, swing, travel are slow or lack power ﬂ Carry out troubleshooting in the D.H mode. ﬂ Check that no abnormal noise is being generated from the main pump before carrying out troubleshooting. (If there is any abnormal noise, carry out troubleshooting for H-4.)

Cause

YES

Carry out troubleshooting in H-14

4 YES 1

Go to A

Is main relief YES pressure normal at CO cancel?

Is there travel deviation?

• Max. 220 mm/20 m travel • Engine at high idling • Lever operated fully

Remedy

Is output YES pressure of TVC solenoid valve normal?

• See Table 1. • Engine at high idling

Is control pump relief pressure NO normal?

Go to B +1.47 NO • 31.87 –0.98 MPa +15 2 {325 –10 kg/cm } • Engine at high idling 7 YES Defective adjustment of TVC solenoid valve Does condition

Adjust

become normal

NO when TVC solenoid valve is adjusted?

Defective TVC solenoid

NO valve

Replace

+029

• 3.13 0 MPa {32 +30 kg/cm2} • Engine at high idling

Carry out troubleshooting from Item 2 in H-3

5 YES From A Table 2 DH mode

1,780 ± 100 rpm

Is engine speed at arm relief normal? • See Table 2. • Engine at high idling

6 YES From B

Is output pressure of CO cancel solenoid valve normal? • Min. 2.74 MPa {28 kg/cm2} • Engine at high idling

Table 1

Pump body

Replace

Defective engine system (Refer to CUMMINS ENGINE Shop Manual.)

Defective main relief valve

Adjust or replace

Defective operation of CO cancel solenoid valve

Correct or replace

Control lever at neutral Min. 1.76 MPa {18 kg/cm2} H mode, boom RAISE relief

1.37

0.2 MPa {14

2 kg/cm2}

Heavy lift ON, boom RAISE relief

1.2

0.2 MPa {12

2 kg/cm2}

PC600-6

20-607

TROUBLESHOOTING

H-2

H-2 There is excessive drop in engine speed, or engine stalls ﬂ Carry out troubleshooting in the D.H mode.

YES 2 Is CO valve output pressure normal at relief?

YES

Does output • At normal relief: pressure become Max. 0.54 MPa {5.5 kg/cm2} NO normal when CO valve is adjusted? • At CO cancel: Same pressure as TVC pressure • Engine at high idling

1 Is TVC valve set pressure normal? • See Table 1. • Engine at high idling

4 Does condition become normal NO when TVC valve set pressure is adjusted?

ª Same conditions as Item 1.

• Output pressure becomes normal. • Problem does not change. • Output pressure becomes normall. • Condition becomes normal. • Output pressure does not become normal.

• Set pressure becomes normal. • Problem does not change. • Set pressure becomes normal. • Condition becomes normal. • Set pressure does not become normal.

Table 1 Control levers at neutral

Min. 1.76 MPa {18 kg/cm2}

H mode, boom RAISE relief

1.37 ± 0.2 MPa {14 ± 2 kg/cm2}

Heavy lift ON, boom RAISE relief

1.2 ± 0.2 MPa {12 ± 2 kg/cm2}

20-608

PC600-6

TROUBLESHOOTING

PC600-6

H-2

Cause

Remedy

See Engine Shop Manual

–

Defective adjustment of CO valve

Adjust

Defective CO valve

Replace

Defective adjustment of TVC solenoid valve

Adjust

Defective TVC solenoid valve

Replace

20-609

TROUBLESHOOTING

H-3

H-3 No work equipment, travel, swing move fl Carry out troubleshooting in the D.H mode. fl When auto-deceleration is normal. fl Check operation of safety valve before starting troubleshooting.

Cause

YES 3 Is control pump YES relief pressure normal when (1) – (6) in Fig. 1 is blocked?

When control

YES pump pressure 1

measurement plug is removed, does oil come out?

When main pump pressure measurement plug is removed, does oil come out?

+029

• 3.13 0 MPa {32 +30 kg/cm2} • Engine at high idling

4 YES Is foreign material found in strainer at NO outlet port of control pump?

Remedy

Excessive leakage inside equipment of applicable system

Replace

Defective control pump

Replace

Defective control pump

Adjust or replace

NO relief valve • Defective PTO • Defective gear pump (broken shaft, etc.)

Repair or replace

Defective PTO

Repair

ª For both Items 1 and 2, if oil does not come out, the PTO is defective.

H-3 Related hydraulic circuit diagram

20-610

PC600-6

TROUBLESHOOTING

H-4, H-5

H-4 Abnormal noise generated (around pump) Cause

YES

Remedy

Clogged strainer

Clean

Loose piping clamp

Tighten

Defective pump

Replace

2 YES Is strainer

YES

clogged?

3 Is problem removed when piping between NO tank and pump is tightened?

1 Is hydraulic tank oil level normal?

4 YES Are metal wear particles found in NO drained hydraulic oil?

Operate for a short time and watch for any NO change in symptoms

Inspect again depending on change in symptoms

Lack of hydraulic oil

Add hydraulic oil

H-5 Auto-deceleration does not work

Cause

1 YES Does autodeceleration not work for all levers or only for some levers?

PC600-6

Remedy

All levers

Go to E3, E4

–

Some levers

Go to F1 - F9

–

20-611

TROUBLESHOOTING

H-6

H-6 Work equipment (boom, arm, bucket) is slow or lacks power ﬂ When travel and swing speeds are normal. (If there is also travel deviation, and the speed is slow when operating the bucket DUMP (front pump independent) or swing (rear pump independent), carry out troubleshooting first for H-14 Machine deviates to one side when traveling.) ﬂ Carry out troubleshooting in the DH mode.

Cause

3 YES Is actuating

YES pressure of cylinder 2 abnormally high?

YES Is output

pressure of PPC valve normal?

1 Is hydraulic drift of slow cylinder within standard range?

• Engine at high idling • Lever operated fully

• Min. 2.74 MPa {28 kg/cm2} • Engine at high idling

YES

mm/15min Does speed of downward Boom Max. 60 movement become Arm Max. 165 NO faster when lever is operated? Bucket Max. 50 Does condition become normal ª See TESTING when safety AND NO (suction) valve is ADJUSTING. interchanged? ª It is also possible See Note 1. to measure leakage of cylinder. • Max. 20 cc/min • Engine at high idling

5 YES

Remedy

Abnormality inside hydraulic cylinder (port clogged, etc.)

Repair

Defective operation of control valve spool

Correct or replace

Defective PPC valve

Replace

Defective hydraulic cylinder piston packing

Repair or replace

Defective safety (suction) valve

Repair

Defective control valve or spool

Repair

Note 1: The mounts for the safety & suction valves are interchangeable, but the setting is different according to the cylinder, so do not forget to return the interchanged valves to their original position. ª There is a pilot hose only for the boom LOWER.

20-612

PC600-6

TROUBLESHOOTING

H-7, H-8

H-7 Work equipment (boom, arm, bucket) does not move (but travel and swing are normal) ﬂ When boom, arm, and bucket are each operated independently.

Cause

1 YES

Defective control valve spool

Correct or replace

Defective PPC valve

Replace

Is output pressure of PPC valve normal?

• Min. 2.74 MPa {28 kg/cm2} • Engine at high idling

Remedy

H-8 Excessive hydraulic drift Cause

YES 1 Does speed of downward movement become faster when lever is operated?

• See TESTING AND ADJUSTING • It is also possible to measure leakage of cylinder. • Max. 20 cc/min • At relief • Engine at high idling

2 YES Does condition become normal when safety-suction NO valve is interchanged?

See Note 1.

Remedy

Defective hydraulic cylinder piston packing

Replace

Defective operation of safety-suction valve

Replace

Defective operation of control valve spool

Replace

Note 1. The safety-suction valves have common mounts. However, the settings are different for each cylinder, so be sure to replace the valves in their original positions after completion of the troubleshooting. ª There is a pilot hose only at the boom LOWER end.

PC600-6

20-613

TROUBLESHOOTING

H-9, H-10

H-9 Excessive time lag ﬂ When the work equipment speed is normal. (If the work equipment speed is also slow, carry out troubleshooting first from Item 2 of H-6.) Cause

Defective operation of suction valve

Remedy

Time lag

unit: sec

Boom

Max. 3.0

Arm

Max. 3.0

Bucket

Max. 3.0

Replace

H-10 Defective actuation of machine push-up function ﬂ When electrical system is normal.

Cause

1 YES Is output pressure of machine pushup solenoid valve normal?

• At low pressure setting: Min. 2.74 MPa {28 kg/cm2} • At high pressure setting: 0 • Engine at high idling

20-614

Remedy

Defective safety valve

Replace

Defective operation of solenoid valve

Correct or replace

PC600-6

TROUBLESHOOTING

H-12, H-13, H-14

H-11 In compound operations with swing, work equipment speed is slow ﬂ Carry out troubleshooting in the DH mode. ﬂ If condition is normal when operated independently. Cause

Defective swing priority valve(defective operation of spool)

Remedy

Repair or replace

H-12 In compound operations with bucket CURL, swing and other work equipment speeds are slow ﬂ Carry out troubleshooting in the DH mode. ﬂ If condition is normal when operated independently.

1 YES Is output pressure of bucket CURL Hi cancel solenoid normal?

• Max. 0.2 MPa {Max. 2 kg/cm2} • When swing and work equipment are operated at same time. • Engine at high idling

Cause

Remedy

Defective bucket CURL Hi valve (defective operation of spool)

Correct or replace

Defective bucket CURL Hi cancel solenoid valve

Replace

H-13 Travel deviation is excessive during compound operations ﬂ Carry out troubleshooting in the DH mode. ﬂ If condition is normal when operated independently.

1 YES Is output pressure of shuttle valve normal? +029

NO • 3.13 0 MPa {32 +30 kg/cm2} • Measure output pressure of circuit when travel is operated together with swing or work equipment. (It is enough to operate lever so that travel moves slightly.) • Engine at high idling

PC600-6

Cause

Remedy

Defective travel shuttle valve or straight-travel valve

Repair or replace

Defective shuttle valve

Repair or replace

20-615

TROUBLESHOOTING

H-14

H-14 Machine deviates naturally to one side during travel operations ﬂ When travel speed is normal. ﬂ Carry out troubleshooting in the D.H mode. a) Direction of deviation is same in FORWARD and REVERSE

YES

YES 4 Are metal particles YES found in oil drained from final drive on side of deviation?

1 Was it possible to locate abnormality in troubleshooting chart on page 20555?

Is output pressure of PPC NO valve normal? • Min. 2.74 MPa {28 kg/cm2} • Engine at high idling • Measure travel circuit PPC pressure (output pressure)

20-616

5 Does condition return to normal when travel deviation is adjusted NO according to specified procedure?

Is amount of oil YES drained from travel motor normal?

YES

ª See TESTING AND ADJUSTING.

• Max. 20 ¬/min • Engine at high idling

YES 6 Is leakage from swivel joint NO packing normal? • Min. 100 cc/min • Engine at high NO idling ª See TESTING AND ADJUSTING.

PC600-6

TROUBLESHOOTING

7 YES Does direction of deviation change when hoses between swivel joint and motor are interchanged?

PC600-6

H-14

Cause

Remedy

See Cause column in troubleshooting chart on page 20-455

Adjust, repair, or replace

Defective final drive

Repair or replace

Defective adjustment of pump

Adjust

Defective control valve

Replace

Defective travel motor

Repair or replace

Defective swivel joint packing

Repair

Excessive leakage inside motor

Replace

Defective PPC valve

Replace

20-617

TROUBLESHOOTING

H-`4

b) Direction of deviation is different in FORWARD and REVERSE Cause

YES

Remedy

Defective swivel joint packing

Repair

Defective operation of control valve spool

Replace

Defective PPC valve

Replace

Drop in set pressure of travel motor safety valve

Adjust

1 3 YES

Is deviation as shown in Fig. 1?

Is output YES pressure of PPC 2 valve normal? Is relief pressure at travel motor NO relief normal? +1.47

• 31.89 –0.98 MPa 2 {325 +15 –10 kg/cm } • Engine at high idling

• Min. 2.74 MPa {28 kg/cm2} • Engine at high idling

Fig. 1 Location of defective swivel joint packing and direction of travel deviation

20-618

PC600-6

TROUBLESHOOTING

H-15

H-15 Deviation is excessive when starting fl When travel speed is normal. fl If there is also deviation during travel, see H-14 Machine deviates naturally to one side during travel operations. If there is deviation during compound operations with the work equipment, carry out troubleshooting first for H-13 Travel deviation excessive during compound operations. fl Bleed the air from the circuit before the operation. fl Carry out troubleshooting in the D.H mode.

YES 2 Deviation only when lever is operated fully

Is direction of deviation reversed when pump outlet hoses are interchanged between front and rear?

4 YES

Is direction of deviation reversed when hoses are NO interchanged at swivel outlet port?

Is direction of YES deviation reversed when hoses are 3 interchanged at swivel inlet port?

Is there deviation when lever is operated fully or when lever is operated a small amount?

• Max. 220 mm/20 m travel • Engine at high idling • Lever operated fully

6 YES Is output YES pressure of NC valve normal on fast side? 5 Deviation when starting for following lever operation: both N → small amount and N → full distance

Is differential pressure normal for jet sensor on fast side (outside of turn)?

• Control lever at NO neutral: Max. 0.55 MPa {5.5 kg/cm2} • Track rotated under no load: Min. 1.8 MPa {18 kg/cm2} • Engine at high idling

7 YES

Is direction of deviation Control levers at neutral Min. 1.76 ± 0.2 MPa {18 ± 2 kg/cm } reversed when jet sensor relief valves are Lever operated fully Max. 0.2 MPa {2 kg/cm2} NO interchanged or • Engine at high idling adjusted? 2

20-620

PC600-6

TROUBLESHOOTING

H-15

Cause

PC600-6

Remedy

Defective operation of servo valve

Replace

Defective operation of control valve spool

Replace

Defective swivel joint

Correct or replace

Defective travel motor (motor proper, safety valve, parking brake)

Replace

Defective operation of servo valve

Replace

Defective adjustment of NC valve

Correct or replace

Defective jet sensor relief valve

Correct or replace

Defective jet sensor orifice

Replace

20-621

TROUBLESHOOTING

H-16

H-16 Travel speed is slow ﬂ When there is no travel deviation. ﬂ Carry out troubleshooting in the DH mode. ª If the main relief valve pressure has dropped, there will also be lack of power for normal operations of the work equipment.

Cause

3 YES

Is output

YES pressure of CO 1 Is output pressure of PPC valve normal? • Min. 2.74 MPa {28 kg/cm2} • Engine at high idling

20-622

cancel solenoid valve normal? • Min. 2.74 MPa {28 kg/cm2} • Engine at high idling

Is output pressure YES of 2-stage relief solenoid valve 2 normal?

• Min. 2.74 MPa {28 kg/cm2} • Engine at high idling

Remedy

Drop in main relief pressure

Adjust

Defective operation of 2-stage relief solenoid valve

Replace

Defective operation of CO cancel solenoid valve

Repair or replace

Defective PPC valve

PC600-6

TROUBLESHOOTING

H-17, H-18

H-17 Travel speed does not switch ﬂ When travel speed is normal in Hi or Lo. ª If the fuel control dial is set to 1,400 rpm or below, the speed is fixed in Lo. ﬂ Carry out troubleshooting in the D.H mode.

1 YES Is oil pressure at travel speed solenoid outlet port normal?

NO • At Hi: Min. 2.74 MPa {28 kg/cm2} • At Lo: 0 MPa {0 kg/cm2} • Engine at high idling

Cause

Remedy

Defective travel motor • Speed selector servo valve

Replace motor assembly

Defective travel speed solenoid valve

Replace

H-18 Travel does not move (one side only) ﬂ Carry out troubleshooting in the D.H mode.

Cause

2 YES Is any foreign YES material found in oil drained from final drive? 1 Is main relief pressure at motor relief normal?

3 YES

Is oil pressure at • At travel relief: motor relief normal 31.89 +1.47 –0.98 MPa +15 2 {325 –10 kg/cm } NO when safety valve is interchanged? • Engine at high idling NO ª See Item 1 for the standard value.

PC600-6

Remedy

Defective final drive

Correct or replace

Travel motor brake dragging

Replace motor assembly

Defective travel motor safety valve

Replace safety valve

Defective travel motor

Replace motor assembly

20-623

TROUBLESHOOTING

H-19

H-19 Does not swing fl When other work equipment and travel are normal. fl Carry out troubleshooting in the D.H mode. fl Turn the swing lock switch OFF.

Cause

3 YES

[Both left and right]

Is oil pressure of swing brake solenoid valve outlet port normal?

Is any foreign YES material found in oil drained from 2 swing machinery?

• Min. 2.74 MPa {28 kg/cm2} • Engine at high idling

1 Is problem with swing in both left and right directions or in one direction only?

5 YES Is problem reversed

Remedy

Drop swing machinery

Repair or replace

Defective swing motor brake or swing motor

Replace

Defective operation of swing brake solenoid valve

Correct or replace

Defective safety valve

Replace

YES when left and right safety valves are 4 interchanged?

[One direction only]

Is output pressure of PPC valve normal?

• Min. 2.74 MPa {28 kg/cm2} • Engine at high idling

6 YES From A

Does control valve spool move smoothly?

20-624

Go to A

Defective PPC valve

Replace

Defective swing motor suction valve

Replace

Defective operation of control valve spool

Correct or replace

PC600-6

TROUBLESHOOTING

H-20

H-20 Swing speed is slow or swing acceleration is poor ﬂ When other work equipment and travel are normal. (However, if there is travel deviation (deviation to right), carry out troubleshooting first for H-14 Machine deviates naturally to one side during travel operations. ﬂ Carry out troubleshooting in the D.H mode. Cause

3 YES Is foreign material YES found in oil drained from 2 swing machinery?

[Both left and right]

Is drain amount from swing motor normal

• 10 ¬/min • Engine at high idling

1 Is swing speed slow in both directions or in one direction only?

[One direction only]

Is output pressure of PPC valve normal?

ª It is also possible to NO measure relief oil pressure. 2 • 3.14 +0.29 MPa {32 +3 –0 kg/cm } –0 • Engine at high idling

• Min. 2.74 MPa {28 kg/cm2} • Engine at high idling

From A

Repair or replace

Swing motor brake dragging or internal defect

Repair or replace

Excessive leakage inside swing motor

Repair or replace

Defective safety valve

Adjust or replace

Go to A

Defective PPC valve

Replace

6 YES

Defective swing motor suction valve

Replace

Defective operation of control valve spool

Replace

Does control valve spool move smoothly?

PC600-6

Defective swing machinery

5 YES Is problem reversed YES when left and right safety valves are 4 interchanged?

Remedy

20-625

TROUBLESHOOTING

H-21

H-21 Excessive overrun when stopping swing a) Both left and right Cause

Remedy

Excessive leakage inside swing motor Repair or replace

b) One direction only Cause

2 YES Is problem reversed YES when left and right PPC valve output 1 hoses are interchanged?

Does swing spool of control valve move smoothly?

20-626

Remedy

Defective PPC valve

Replace

Defective swing motor safety valve

Replace

Defective operation of swing spool of control valve

Correct or replace

PC600-6

TROUBLESHOOTING

H-22, H-23

H-22 Excessive shock when stopping swing ﬂ When swing speed is normal.

Cause

3 YES Defective swing

Is oil pressure at swing brake solenoid valve outlet port normal?

[Both left and right]

1 Is shock excessive in both left and right directions or in one direction only?

machinery

Is foreign material YES found in oil 2 drained from swing machinery?

Defective swing motor

NO brake

• When lever is operated: 2.74 NO MPa {28 kg/cm2} • When lever is at neutral: 0 MPa {0 kg/cm2} • Engine at high idling [One direction only]

Remedy

Repair

Replace

Defective swing brake solenoid valve

Replace

Defective safety valve

Replace

ª When the swing has been operated and the lever is returned to the neutral position, the oil pressure becomes 0 after approx. 4 sec.

H-23 Excessive abnormal noise when stopping swing

Cause

YES 1 Does condition become normal when swing motor safety-suction valve is cleaned?

YES 2 Does condition become normal when swing motor NO safety-suction valve is replaced?

3 YES Is foreign material found in oil NO drained from swing machinery?

PC600-6

Remedy

Defective operation of swing motor safetysuction valve

Clean

Defective swing motor safety-suction valve

Replace

Defective swing machinery

Repair or replace

Defective back pressure valve

Correct or replace

20-627

TROUBLESHOOTING

H-24

H-24 Excessive hydraulic drift of swing a) When swing holding brake is released

Cause

2 YES [One direction only]

Is problem reversed when left and right safety valves are interchangedl?

Is hydraulic drift excessive in both left and right directions or in one direction only?

3 YES [Both left and right]

Is drain amount from swing motor normal? • 10 ¬/min • Engine at high idling • At swing relief

Remedy

Defective swing motor safety valve

Replace

Defective swing motor suction valve

Correct or replace

Defective control valve swing spool

Replace

Excessive leakage inside swing

Repair or replace

b) When swing holding brake is applied

Cause

1 YES Is output pressure of swing holding brake solenoid valve norma?

• Min. 2.74 MPa {28 kg/cm2} • When 7 seconds has passed after all swing and work equipment control levers have been returned to neutral. • Engine at high idling

20-628

Remedy

Defective operation of swing holding brake

Repair or replace

Defective operation of swing holding brake solenoid valve

Correct or replace

PC600-6

TROUBLESHOOTING OF MACHINE MONITOR SYSTEM (M MODE)

Action taken by monitor panel when abnormality occurs and problems on machine ................................................................................................................ 20-654 Electrical circuit diagram for M mode system .................................................................................... 20-656 M-1

[E101] Abnormality in error data) or [E102] (Abnormality in clock data) is displayed .................................................................. 20-658

M-2

[E103] (Short circuit in buzzer output system) is displayed ............................................... 20-659

M-3

[E104] (Air cleaner clogging detection) is displayed ........................................................... 20-660

M-4

[E108] (Engine water temperature 105°C) is displayed ....................................................... 20-660

M-5

When starting switch is turned on, none of lamps on monitor panel light up for 3 seconds ............................................................................. 20-661

M-6

When starting switch is turned ON, monitor panel lamps all stay lighted up and do not go out ................................................................................................................... 20-663

M-7

When starting switch is turned on, items lighted up on monitor panel are different from actual machine ......................................................................................... 20-663

M-8

When starting switch is turned on (engine stopped), basic check items flash ............... 20-664 a) Engine oil level caution lamp flashes............................................................................. 20-664 b) Hydraulic oil level caution lamp flashes ........................................................................ 20-665

M-9

Preheating is not being used but preheating display monitor lamp lights up ............... 20-666

M-10 When engine is started, basic check items flash................................................................. 20-667 M-11 When starting switch is turned ON (engine stopped), CAUTION items and EMERGENCY STOP items flash ..................................................................................... 20-668 M-12 When engine is started, CAUTION items and EMERGENCY STOP items flash .............. 20-669 a) Engine oil pressure caution lamp flashes ...................................................................... 20-669 b) Charge caution lamp flashes ........................................................................................... 20-669 c) Engine water temperature caution lamp flashes .......................................................... 20-670 d) Fuel level caution lamp flashes ....................................................................................... 20-670 e) Air cleaner clogging caution lamp flashes .................................................................... 20-671 f)

Hydraulic oil temperature caution lamp flashes ........................................................... 20-672

M-13 Operation of alarm buzzer is not normal ............................................................................. 20-674 a) When starting switch is turned ON (engine stopped), buzzer does not sound for 1 second. ............................................................................. 20-674 b) No abnormality is displayed on monitor but buzzer sounds ...................................... 20-674 M-14 Night lighting on monitor panel does not light up ............................................................. 20-676 M-15 Engine water temperature display is not normal ................................................................ 20-677 a) Gauge does not go up ..................................................................................................... 20-677 b) Gauges do not give display (no stage is displayed) .................................................... 20-677

PC600-6

20-651

M-16 Fuel level gauge display is not normal ................................................................................ 20-678 a) Fuel level gauge always displays FULL ......................................................................... 20-678 b) Fuel level gauge does not give display (no stage is displayed) ................................. 20-678 M-17 Swing lock switch is turned ON but swing lock monitor lamp does not light up ......... 20-680 M-18 When swing brake cancel switch is set to CANCEL (EMERGENCY), swing lock monitor lamp does not flash .............................................................................. 20-681 M-19 Service meter does not give normal display ....................................................................... 20-682 a) Service meter does not advance when engine is running .......................................... 20-682 b) When starting switch is OFF, service meter does not give display when time switch is pressed ........................................................................................... 20-682 M-20 Defective fuel level sensor system ........................................................................................ 20-683 M-21 Defective engine oil level sensor system ............................................................................. 20-684 M-22 Defective hydraulic oil level sensor system ......................................................................... 20-685 M-23 Wiper is not actuated when wiper switch is operated or wiper is actuated when wiper switch is not operated ....................................................................... 20-686 a) Wiper is not actuated when switch is operated (including when service code [E112], [E113] are displayed) .......................................................... 20-686 b) Wiper switch is not being operated, but wiper is actuated ......................................... 20-688 M-24 Electric grease gun does not work (machines equipped with electric grease gun) ....... 20-691

20-652

PC600-6

ACTION TAKEN BY MONITOR PANEL WHEN ABNORMALITY OCCURS AND PROBLEMS ON MACHINE

TROUBLESHOOTING

ACTION TAKEN BY MONITOR PANEL WHEN ABNORMALITY OCCURS AND PROBLEMS ON MACHINE User Service code code

—

E101

E102

Abnormal system

Abnormality in error data

Abnormality in clock data

Nature of abnormality 1. 2. 3. 4.

Abnormality in internal memory Excess voltage (more than 36V) has occurred Low voltage (less than 12V) has occurred Defective connection of connector

1. 2. 3. 4.

Abnormality in internal clock function Excess voltage (more than 36V) has occurred Low voltage (less than 12V) has occurred Defective connection of connector

1. Short circuit inside buzzer 2. Short circuit with power source in wiring harness between monitor panel P01 (7) and alarm buzzer P04 (2) 3. Defective monitor panel ﬂ If there is a disconnection, [E103] is not displayed and the buzzer does not sound.

—

E103

Short circuit in buzzer output system

—

E104

Air cleaner clogging detection

E108

Engine water temperature 105˚C detection

E112

Short circuit in wiper drive normal rotation system

1. Short circuit or short circuit with ground inside wiper motor 2. Short circuit or short circuit with ground inside relay box 3. Short circuit or short circuit with ground in wiring harness between monitor panel P02 (11) and relay box W08 (17), or between relay box W08 (7) and wiper motor W04 (3)

—

E113

Short circuit in wiper drive reverse rotation system

1. Short circuit or short circuit with ground inside wiper motor 2. Short circuit or short circuit with ground inside relay box 3. Short circuit or short circuit with ground in wiring harness between monitor panel P02 (3) and relay box W08 (18), or between relay box W08 (6) and wiper motor W04 (1)

—

E114

Short circuit in window washer drive system

1. Short circuit inside washer motor 2. Short circuit with power source in wiring harness between monitor panel P02 (2)(10) and washer motor M28 (1)

1. Air cleaner clogging sensor has detected clogging

—

20-654

1. Engine water temperature sensor has detected water temperature of 105°C pressure

PC600-6

TROUBLESHOOTING

Condition when normal

ACTION TAKEN BY MONITOR PANEL WHEN ABNORMALITY OCCURS AND PROBLEMS ON MACHINE

Action by controller when abnormality is detected

Problem that appears on machine when there is abnormality

•

When starting switch is OFF, press time switch. Keep pressed, turn starting switch ON, and keep time switch pressed for at least another 5 seconds to reset (if it is reset, it is normal)

1. Service code cannot be cleared 2. Time becomes 00:00.

•

When starting switch is OFF, press time switch. Keep pressed, turn starting switch ON, and keep time switch pressed for at least another 5 seconds to reset (if it is reset, it is normal).

1. Service code cannot be cleared 2. Time becomes 00:00. 3. Clock does not advance.

•

Voltage between P01 (7) and ground Buzzer ON: Max. 1V Buzzer OFF: 20 – 30V

1. Buzzer does not sound

•

Resistance between P11 (male) and P12 (female) When engine is running: Max. 1 Ω

1. If this is continuously detected, air cleaner clogging caution lamp flashes and alarm buzzer sounds

•

See section on Engine controller

1. Engine water temperature caution lamp flashes and alarm buzzer sounds 2. Overheat prevention function is actuated and engine speed is set to low idling

•

Voltage between W04 (3) and (5) : More than 3 V ↔ 20 – 30 V ﬂ Repeated in a constant cycle

1. Sets output to relay box to 0

1. Wiper operation stops

•

Voltage between W04 (1) and (5) : More than 3 V ↔ 20 – 30 V ﬂ Repeated in a constant cycle

1. Sets output to relay box to 0

1. Wiper operation stops

•

1. Sets output to washer motor to 0

1. Window washer operation stops

Resistance between P02 (2)(10) and W08 (15): Max. 1Ω

PC600-6

20-655

TROUBLESHOOTING

ELECTRICAL CIRCUIT DIAGRAM FOR M MODE SYSTEM

20-656

PC600-6

TROUBLESHOOTING

PC600-6

ELECTRICAL CIRCUIT DIAGRAM FOR M MODE SYSTEM

20-657

TROUBLESHOOTING

M-1

M-1 [E101] Abnormality in error data) or [E102] (Abnormality in clock data) is displayed ﬂ When the wiring is disconnected to carry out troubleshooting and this temporarily shuts off the power supply to the monitor panel, a service code is displayed, but this is not an abnormality. ﬂ Before carrying out troubleshooting, check that circuit breaker 9 has not shut off the circuit. (If the breaker has shut off the circuit, there has probably been a surge of current caused by a short circuit with the ground, so check the circuits related to circuit breaker 9.)

Cause • See Note 1. • Operate for a short time and watch for any change in symptoms.

Remedy

1 After reset operation is carried NO out, is service code displayed again? YES

Normal

—

2 • Turn starting switch OFF.

Is voltage between P02 (8)(14) and ground 20 – 30 V? YES

Defective monitor panel

3 • Turn starting switch OFF. • Disconnect B19.

Is voltage between B19 and ground 20 – 30 V? YES

Defective contact or disconnection in wiring harness between battery relay terminal B and B19 Defective contact or disconnection in wiring harness between P02 (female) (8)(14) and B29

Replace

Repair or replace Repair or replace

Note 1: Resetting operation: With the starting switch OFF, press the time switch, keep it pressed and turn the starting switch ON, then keep the time switch pressed for at least another 5 seconds.

M-1 Related electrical circuit diagram

20-658

PC600-6

TROUBLESHOOTING

M-2

M-2 [E103] (Short circuit in buzzer output system) is displayed

Cause

Remedy

1 • Turn starting switch OFF. • Disconnect P04.

Is resistance between P04 (male) (1) – (2), between (2) – ground as shown in Table 1? YES

2 • Turn starting switch ON.

Is voltage between P04 (2) and NO ground as shown in Table 1? YES

Defective alarm buzzer

Replace

Short circuit with power source in wiring harness between P01 (female) (7) and P04 (female) (2) or short circuit in wiring harness between P04 (1) and (2) Defective monitor panel

Repair or replace Replace

Table 1 P04 (male)

Resistance value

Between (1) and (2)

200 – 300 Ω

Between (2) and ground

Min. 1 MΩ

M-2 Related electrical circuit diagram

PC600-6

20-659

TROUBLESHOOTING

M-3, M-4

M-3 [E104] (Air cleaner clogging detection) is displayed Cause

Remedy

1 Is air cleaner clogging caution lamp on monitor panel flashing? YES

Go to M-12 f)

—

Defective air cleaner (See Note 1)

—

2 Is [E] displayed at head of service code?

YES Defective monitor panel

Replace

Note 1: The monitor panel display has been reset, but in the past, the air cleaner clogging sensor may have detected clogging, so clean the air cleaner thoroughly. For details, see the Operation and Maintenance Manual.

M-4 [E108] (Engine water temperature 105°C) is displayed Cause

Remedy

1 Does water temperature on NO monitor panel display red range, and is caution lamp flashing? YES Go to M-12 d)

—

Failure in engine (See Note 1)

—

2 Is [E] displayed at head of service code?

YES Defective monitor panel

Replace

Note 1: The monitor panel display has been reset, but in the past, the engine water temperature sensor may have detected a water temperature of 105°C, so carry out troubleshooting of the engine to locate the cause and remove the problem.

20-660

PC600-6

TROUBLESHOOTING

M-5

M-5 When starting switch is turned on, none of lamps on monitor panel light up for 3 seconds ﬂ Check that the engine starts normally. (If it does not start, carry out troubleshooting for E Mode first.) ﬂ Before carrying out troubleshooting, check that circuit breakers 9 and 10 have not shut off the circuit, and that fuse 10 is not blown. (If the breaker has shut off the circuit or the fuse is blown, there has probably been a surge of current caused by a short circuit with the ground, so check the circuits related to circuit breakers 9 and 10 and fuse 10.)

a) None of lamps on monitor panel light up Cause

Remedy

1 • Turn starting switch ON.

• Turn starting switch OFF. • Disconnect P02.

Is voltage between P02 (8)(14) and ground 20 – 30 V? YES

2 Is resistance between P02 (1)(9) NO and ground less than 1 Ω? YES

• Turn starting switch ON.

Defective contact, disconnection, or short circuit with ground in wiring harness between P02 (female) (8)(14) Repair or and battery relay terminal B, replace or defective circuit breaker 9 Defective contact or disconnection in wiring harness between P02 (female)(1)(9) and ground

Repair or replace

Defective monitor panel

Replace

3 Is voltage between P01 (9) and NO ground 20 – 30 V? YES

4 • Turn starting switch ON.

Is voltage between fuse 10 inlet and ground 20 – 30 V? YES

Defective contact, disconnection, or short circuit with ground in wiring harness Repair or between fuse 10 inlet and replace battery relay terminal M, or defective circuit breaker 1 Defective contact, disconnection, or short circuit Repair or with ground in wiring harness replace between P01 (female) (9) and fuse 10

b) Some of lamps on monitor panel do not light up ﬂ Defective monitor panel

PC600-6

20-661

TROUBLESHOOTING

M-5

M-5 Related electrical circuit diagram

20-662

PC600-6

TROUBLESHOOTING

M-6, M-7

M-6 When starting switch is turned ON, monitor panel lamps all stay lighted up and do not go out ﬂ Defective monitor panel

M-7 When starting switch is turned on, items lighted up on monitor panel are different from actual machine ﬂ If this problem occurs immediately after the monitor panel has been replaced, turn the starting switch OFF, then turn it ON and check again.

Cause

Remedy

1 • Turn starting switch ON. • Set monitoring code to [01].

Is display of monitoring code [01] as shown in Table 1?

YES

Defective monitor panel

Replace

Go to troubleshooting of C-14 (error code [E217] displayed)

Replace

Table 1 Monitoring code 01

Detail of display

Monitor panel model code

PC600-6

20-663

TROUBLESHOOTING

M-8

M-8 When starting switch is turned on (engine stopped), basic check items flash a) Engine oil level caution lamp flashes ﬂ Check that the engine oil is at the specified level before carrying out troubleshooting Cause

Remedy

1 • Disconnect OL. • Turn starting switch ON.

Does display go out when OL (female) (1) is connected to ground? YES

NO Defective engine oil level sensor system (go to M-21) 2

• Turn starting switch OFF. • Disconnect C16 and OL.

Is resistance between C16 (female) (16) and ground as shown in Table 1? YES

Replace

Defective contact or Repair or disconnection in wiring harness between C16 (female) replace (16) and OL (female) (1)

3 • Turn starting switch ON. • Set monitoring code to [24].

Is bit (4) of monitoring code [24] lighted up? YES

Table 1 OL (female) (1) and ground

Defective monitor panel

Replace

Defective pump controller

Replace

Resistance value

Connected

Max. 1 Ω

Disconnected

Min. 1 MΩ

M-8 a) Related electrical circuit diagram

20-664

PC600-6

TROUBLESHOOTING

M-8

b) Hydraulic oil level caution lamp flashes ﬂ Check that the hydraulic oil is at the specified level before carrying out troubleshooting Cause

Remedy

1 • Disconnect P09. • Turn starting switch ON.

Does display go out when P09 (female) (1) is connected to ground? YES

NO Defective hydraulic oil level sensor system (go to M-23) 2

• Turn starting switch OFF. • Disconnect C16 and P09.

Is continuity between C16 (female) (9) and ground as shown in Table 1? YES

• Turn starting switch ON. • Set monitoring code to [24].

Is bit (5) of monitoring code [24] lighted up?

Replace

Defective contact or Repair or disconnection in wiring harness between C16 (female) replace (9) and P09 (female) (1)

3 NO

Defective monitor panel

Replace

Defective pump controller

Replace

YES

Table 1 P09 (female) (1) and ground

Resistance value

Connected

Max. 1 Ω

Disconnected

Min. 1 MΩ

M-8 b) Related electrical circuit diagram

PC600-6

20-665

TROUBLESHOOTING

M-9

M-9 Preheating is not being used but preheating display monitor lamp lights up

Cause

Remedy

1 • Disconnect starting switch R1. • Turn starting switch ON.

Is voltage between starting NO switch terminal R1 and ground less than 1 V? YES 2

• Turn starting switch ON.

Is voltage between P01 (18) and ground less than 1 V? YES

Defective starting switch

Replace

Short circuit with power source in wiring harness Repair or between starting switch terminal R1 – P01 (female) (18) replace – heater relay HT Defective monitor panel

Replace

M-9 Related electrical circuit diagram

20-666

PC600-6

TROUBLESHOOTING

M-10

M-10 When engine is started, basic check items flash

• Turn starting switch ON.

Cause

Remedy

Carry out troubleshooting of displayed service code (go to E Mode)

—

1 Is service code [E924] or [E936] NO displayed at same time? YES

2 • Run engine at a midrange speed.

Is voltage between alternator terminal R and ground 20 – 30 V? YES

3 • Run engine at a midrange speed.

Is voltage between C03 (12) and ground 20 – 30 V?

YES

• Run engine at a midrange speed. • Set monitoring code to [43].

Defective alternator

Replace

Defective contact, disconnection, or short circuit Repair or with ground in wiring harness replace between C03 (female) (12) and alternator terminal R

4 Is alternator input voltage for monitoring code [43] displayed as more than 100? YES

Defective monitor panel

Replace

Defective pump controller

Replace

M-10 Related electrical circuit diagram

PC600-6

20-667

TROUBLESHOOTING

M-11

M-11 When starting switch is turned ON (engine stopped), CAUTION items and EMERGENCY STOP items flash

• Turn starting switch ON.

Cause

Remedy

Carry out troubleshooting of displayed service code (go to E Mode)

—

1 Is service code [E924] or [E936] NO displayed at same time? YES

2 • Run engine at a midrange speed.

Is voltage between alternator terminal R and ground less than 1 V? YES

3 • Run engine at a midrange speed.

Is voltage between C03 (12) and ground less than 1 V?

YES

• Run engine at a midrange speed. • Set monitoring code to [43].

Defective alternator

Replace

Defective contact, disconnection, or short circuit Repair or with ground in wiring harness replace between C03 (female) (12) and alternator terminal R

4 Is alternator input voltage for monitoring code [43] displayed as more than 100? YES

Defective monitor panel

Replace

Defective pump controller

Replace

M-11 Related electrical circuit diagram

20-668

PC600-6

TROUBLESHOOTING

M-12

M-12 When engine is started, CAUTION items and EMERGENCY STOP items flash a) Engine oil pressure caution lamp flashes ﬂ Check that the engine oil pressure is normal before carrying out troubleshooting.

Cause

Remedy

1 • Turn starting switch ON.

Is service code [E924] or [E936] NO displayed at same time? YES

Defective monitor panel Carry out troubleshooting of displayed service code (go to E Mode)

—

Replace

b) Charge caution lamp flashes ﬂ Carry out troubleshooting for M-10

PC600-6

20-669

TROUBLESHOOTING

M-12

c) Engine water temperature caution lamp flashes ﬂ Check that the engine water temperature is normal before carrying out troubleshooting.

Cause

Remedy

1 • Turn starting switch ON.

Is service code [E934] displayed at same time? YES

Defective monitor panel Carry out troubleshooting of displayed service code (go to E Mode)

Replace

—

d) Fuel level caution lamp flashes ﬂ Check that there is enough fuel before carrying out troubleshooting. Cause • Start engine.

1 Does fuel gauge show E range NO (left end)?

Defective monitor panel

Remedy Replace

YES

• Disconnect P06. • Turn starting switch ON.

2 When P06 (female) (1) is connected NO to ground, does fuel gauge display to F range (right end)? YES

3 • Disconnect C03. • Turn starting switch ON.

Is voltage between C03 (female) (2) and ground less than 1 V? YES

Defective fuel level sensor system (go to M-20)

—

Short circuit with power source in wiring harness between C03 (female) (2) and P06 (female) (1)

Repair or replace

Defective pump controller

Replace

M-12 d) Related electrical circuit diagram

20-670

PC600-6

TROUBLESHOOTING

M-12

e) Air cleaner clogging caution lamp flashes ﬂ Check that the air cleaner is not clogged before carrying out troubleshooting.

Cause

Remedy

1 • Disconnect P11. • Start engine.

When P11 (female) (1) and (2) are connected, does display disappear? YES

Defective air cleaner clogging sensor 2

• Disconnect P11. • Turn starting switch OFF.

Is resistance between P11 (female) (2) and ground less than 1 Ω? YES

• Turn starting switch OFF. • Disconnect C16 and P11.

Is resistance between C16 (female) (17) and ground as shown in Table 1? YES

• Turn starting switch ON. • Set monitoring code to [24].

Is bit (6) of monitoring code [24] lighted up?

3 NO

Replace

Defective contact or Repair or disconnection in wiring harness between P11 (female) replace (2) and ground

Defective contact or Repair or disconnection in wiring harness between C16 (female) replace (17) and P11 (female) (1)

4 NO

Defective monitor panel

Replace

Defective engine controller

Replace

YES

Table 1 P11 (female) (1) and (2)

Resistance value

Connected

Max. 1 Ω

Disconnected

Min. 1 MΩ

M-12 e) Related electrical circuit diagram

PC600-6

20-671

TROUBLESHOOTING

M-12

Hydraulic oil temperature caution lamp flashes ﬂ Check that the hydraulic oil temperature is normal before carrying out troubleshooting

Cause

Remedy

1 • Disconnect P10. • Start engine.

When P10 is disconnected, does display disappear?

YES

Defective hydraulic oil temperature sensor system (go to M-23)

Replace

• Turn starting switch OFF. • Disconnect C03 and P10.

2 Is resistance between C03 (female) NO (11) – (16), between (11)(16) – ground more than 1 MΩ? YES

Short circuit with ground in wiring harness between C03 (female) (11) and P10 (female) Repair or replace (1) or contact with wiring harness between C03 (female) (16) and P10 (female) (2)

• Turn starting switch ON. • Set monitoring code to [44].

3 Is more than 21 displayed for NO hydraulic oil temperature sensor input voltage of monitoring code [44]? YES

Defective monitor panel

Replace

Defective pump controller

Replace

M-12 f) Related electrical circuit diagram

20-672

PC600-6

TROUBLESHOOTING

M-13

M-13 Operation of alarm buzzer is not normal a) When starting switch is turned ON (engine stopped), buzzer does not sound for 1 second. Caution item is flashing, but alarm buzzer does not sound. ﬂ Of the caution items, the buzzer will not sound even if the lamp lights up for the battery charge or fuel level. Cause

Remedy

1 • Turn starting switch OFF. • Disconnect P04.

Is resistance between P04 (male) (1) and (2) 200 – 300 Ω?

Defective alarm buzzer

Replace

Defective monitor panel

Replace

YES 2 • Disconnect P01. • Turn starting switch ON.

• Turn starting switch ON.

When P01 (female) (7) is connected to ground, does buzzer sound? YES

3 Is voltage between P04 (1) and NO ground 20 – 30 V? YES

Defective contact or disconnection in wiring harness between battery relay terminal B and P04 (female) (1) Defective contact or disconnection in wiring harness between P01 (female) (7) and P04 (female) (2)

Repair or replace Repair or replace

b) No abnormality is displayed on monitor but buzzer sounds ﬂ If the buzzer sounds continuously, carry out this troubleshooting. (If it sounds intermittently, carry out troubleshooting for a).)

Cause

Remedy

1 • Turn starting switch OFF. • Disconnect P04.

Is resistance between P04 (male) (2) and ground more than 1 MΩ? YES

• Disconnect P01. • Turn starting switch ON.

When P01 is disconnected, does buzzer stop?

YES

20-674

Defective alarm buzzer

Replace

Short circuit with ground in wiring harness between P01 (female) (7) and P04 (female) (2)

Repair or replace

Defective monitor panel

Replace

PC600-6

TROUBLESHOOTING

M-13

M-13 Related electrical circuit diagram

PC600-6

20-675

TROUBLESHOOTING

M-14

M-14 Night lighting on monitor panel does not light up ﬂ Check that front lamps and working lamp light up before carrying out troubleshooting.

Cause

Remedy

1 • Remove bulb. • Check bulb visually.

Is bulb blown, or is there defective contact? YES

• Turn starting switch ON. • Set monitoring code to [49]. • Turn light switch ON.

Replace

Defective monitor panel

Replace

2 NO

Is bit (3) of monitoring code [49] out? YES

3 • Turn starting switch ON. • Turn light switch ON.

Is bulb blown, or is there defective contact?

Is voltage between P01 (8) and NO ground 20 – 30 V? YES

Defective contact or disconnection in wiring Repair or harness between P01 (female) replace (8) and M07 (male) (1) Defective monitor panel

Replace

M-14 Related electrical circuit diagram

20-676

PC600-6

TROUBLESHOOTING

M-15

M-15 Engine water temperature display is not normal a) Gauge does not go up

Cause

Remedy

1 • Turn starting switch ON.

Is service code [E934] or [E96A] displayed at same time? YES

Defective monitor panel

Replace

Carry out troubleshooting of displayed service code (go to E Mode)

—

Cause

Remedy

b) Gauges do not give display (no stage is displayed)

1 • Turn starting switch ON.

PC600-6

Is service code [E934] or [E96A] displayed at same time? YES

Defective monitor panel Carry out troubleshooting of displayed service code (go to E Mode)

Replace

—

20-677

TROUBLESHOOTING

M-16

M-16 Fuel level gauge display is not normal a) Fuel level gauge always displays FULL ﬂ Check the level in the fuel tank before carrying out troubleshooting. Cause

Remedy

1 • Turn starting switch ON.

When P06 is disconnected, does NO gauge go down slowly to E range (left side) and finally flash? YES

2 • Turn starting switch OFF. • Disconnect C03 and P06.

Is resistance between C03 (female) (2) and ground more than 1 MΩ? YES

• Turn starting switch ON. • Set monitoring code to [42].

Is less than 408 displayed for fuel level sensor input voltage of monitoring code [42]? YES

Defective fuel level sensor system (go to M-20)

Replace

Short circuit with ground in wiring harness between C03 (female) (2) and P06 (female) (1)

Repair or replace

Defective monitor panel

Replace

Defective pump controller

Replace

3 NO

b) Fuel level gauge does not give display (no stage is displayed) ﬂ Check the level in the fuel tank before carrying out troubleshooting. Cause • Disconnect P06. • Turn starting switch ON.

• Turn starting switch OFF. • Disconnect C03 and P06. • Connect P06 (female) (1) to ground.

1 When P06 (female) (1) is connected NO to ground, does display go up slowly to F range (right side)? YES

2 Is resistance between C03 (female) (2) and ground less than 1 Ω? YES

Remedy

Defective fuel level sensor system (go to M-20)

Replace

Short circuit with ground in wiring harness between C03 (female) (2) and P06 (female) (1)

Repair or replace

Defective monitor panel

Replace

Defective pump controller

Replace

3 • Turn starting switch ON. • Set monitoring code to [42].

20-678

Is less than 408 displayed for fuel level sensor input voltage of monitoring code [42]? YES

PC600-6

TROUBLESHOOTING

M-16

M-16 Related electrical circuit diagram

PC600-6

20-679

TROUBLESHOOTING

M-17

M-17 Swing lock switch is turned ON but swing lock monitor lamp does not light up ﬂ Check that the swing lock is actually being actuated before carrying out troubleshooting.

Cause 1 • Turn starting switch ON.

Is voltage between P01 (female) (5) and ground as shown in Table 1? YES

Defective contact or disconnection in wiring Repair or harness between P01 (female) replace (5) and X05 (male) (1) Defective monitor panel

Table 1 Swing lock switch

Voltage

Max. 1 V

OFF

20 – 30 V

Remedy

Replace

M-17 Related electrical circuit diagram

20-680

PC600-6

TROUBLESHOOTING

M-18, M-19

M-18 When swing brake cancel switch is set to CANCEL (EMERGENCY), swing lock monitor lamp does not flash ﬂ Check that the swing brake is released before carrying out troubleshooting.

Cause • Turn starting switch ON.

1 Is voltage between C17 (8) and NO ground as shown in Table 1? YES

Remedy

Defective contact or disconnection in wiring Repair or harness between C17 (female) replace (8) and SW1 (4)

2 • Turn starting switch ON. • Set monitoring code to [21].

Is bit (6) of monitoring code [21] lighted up?

Defective pump controller

Replace

Defective monitor panel

Replace

YES

Table 1 Swing brake cancel switch

Voltage

Max. 1 V

OFF

20 – 30 V

M-18 Related electrical circuit diagram

PC600-6

20-681

TROUBLESHOOTING

M-19

M-19 Service meter does not give normal display a) Service meter does not advance when engine is running

Cause

Remedy

Go to Troubleshooting M-10

—

1 • Run engine at midrange speed.

Is charge caution lamp flashing? YES

• Run engine at midrange speed. • Set monitoring code to [43].

2 Is more than 100 displayed for NO alternator input voltage of monitoring code [43]? YES

Defective pump controller

Replace

Defective monitor panel

Replace

b) When starting switch is OFF, service meter does not give display when time switch is pressed Cause

Remedy

1 • Turn starting switch ON.

20-682

When starting switch is ON, does monitor panel give normal display? YES

Go to Troubleshooting M-5

Replace

Defective monitor panel

Replace

PC600-6

TROUBLESHOOTING

M-20

M-20 Defective fuel level sensor system ﬂ Remove the fuel level sensor when carrying out the troubleshooting.

Cause

Remedy

1 When float is moved up and down, NO is resistance between connector (1) and flange as shown in table? YES 2 NO

Does arm move smoothly?

Defective sensor (See Note 2)

Replace

YES 3 Is there any large crack, chip, or damage to float?

YES

Clean Defective contact of connector connector or replace Interference with sensor inside tank

Replace (See Note 2)

Defective sensor

Replace

Disconnection in wiring harness (See Note 3) (defective clamp) (external force applied)

Replace sensor

4 Check wiring harness visually. Is it broken?

YES

Table Top (FULL) stopper position

Approx. 12 Ω or below

Bottom (EMPTY) stopper position

Approx. 85 – 110 Ω

TOP (FULL) Bottom (EMPTY) BLP00290

Note 1: Difference between fuel level and gauge display For gauge display position 9 (FULL), the amount of fuel is 78-100%; and for display position 1 (EMPTY) it is below 14.5%. If the chassis is at an angle, the displayed amount of fuel will be different from the actual amount. Therefore, when checking, stop the machine at a horizontal place and wait for at least 2 minutes before checking the gauge. (The display is given a time delay so that the gauge can deal with sudden changes in the fuel level.) Note 2: There is the possibility of defective installation or interference with the sensor inside the tank, so be careful when installing. Note 3: Check for vibration at the connector mount. If there is excessive vibration, take the appropriate action.

PC600-6

20-683

TROUBLESHOOTING

M-21

M-21 Defective engine oil level sensor system ﬂ Remove the engine oil level sensor when carrying out troubleshooting.

Cause

Remedy

1 Check wiring harness visually. NO Is it broken? YES

Disconnection in wiring harness (See Note 3) (defective clamp) (external force applied)

Replace sensor

Defective movement of float due to dirt

Clean

2 Is any foreign material (dirt) stuck to moving part of float?

YES

3 NO

Is there any large crack, chip, or damage to float?

Defective contact of connector Clean connector (See Note 2) or replace

YES 4 Is there any resonance of mount? YES

Defective sensor

Replace

Resonance of mount (See Note 2)

Replace sensor (See Note 4)

Note 1: Variations in oil level The oil level may change according to the angle of the machine, the engine speed, or the temperature of the oil, so if there is any display, check the oil level again with the machine at a horizontal place. Note 2: If the problem occurs again, the connector (female) at the chassis end is probably defective, so check the connector and wiring harness at the chassis end. Note 3: Check for vibration at the connector mount. If there is excessive vibration, take the appropriate action. Note 4: Defective installation is a possible cause, so be careful when installing. If the problem occurs again, check for any vibration of the mount, and if there is excessive vibration, take the appropriate action.

20-684

PC600-6

TROUBLESHOOTING

M-22

M-22 Defective hydraulic oil level sensor system ﬂ Remove the hydraulic oil level sensor when carrying out troubleshooting. Cause

Remedy

1 When float is moved up and down, NO is resistance between connector (1) and flange as shown in Table? YES 2 Is any foreign material (dirt) stuck to moving part of float?

YES

Defective movement of float due to dirt 3

Is there any large crack, chip, or damage to float?

YES

4 Check wiring harness visually. NO Is it broken? YES

Table Float UP

Max. 1 Ω

Float DOWN

Min. 1 MΩ

Clean

Defective contact of connector Clean connector (See Note 2) or replace Resonance of mount (See Note 2)

Replace sensor (See Note 4)

Defective sensor

Replace

Disconnection in wiring harness (See Note 3) (defective clamp) (external force applied)

Replace sensor

DOWN

BLP00292

Note 1: Variations in hydraulic oil level The hydraulic oil level may change according to the angle of the machine, or the swaying of the machine, so if there is any display, check the hydraulic oil level again with the machine at a horizontal place. Note 2: If the problem occurs again, the connector (female) at the chassis end is probably defective, so check the connector and wiring harness at the chassis end. Note 3: Check for vibration at the connector mount. If there is excessive vibration, take the appropriate action. Note 4: Defective installation is a possible cause, so be careful when installing. If the problem occurs again, check for any vibration of the mount, and if there is excessive vibration, take the appropriate action.

PC600-6

20-685

TROUBLESHOOTING

M-23

M-23 Wiper is not actuated when wiper switch is operated or wiper is actuated when wiper switch is not operated a) Wiper is not actuated when switch is operated (including when service code [E112], [E113] are displayed) ﬂ Before carrying out troubleshooting, check that circuit breakers 2 or 9 have not shut off the circuit. (If the breaker has shut off the circuit, there has probably been a surge of current caused by a short circuit with the ground, so check the circuits related to circuit breakers 2 and 9.) Cause

Remedy

Defective rear limit switch or front window is open

Repair or replace

1 • Turn starting switch ON. • Set monitoring code to [48].

When front window is closed, NO does bit (4) of monitoring code [48] light up? YES

• Turn starting switch OFF. • Disconnect W10. • Close front window.

Is resistance between W10 (female) (3) and (4) more than 1 MΩ? YES

• Turn starting switch OFF. • Disconnect W10 and P02.

• Turn starting switch ON. • Set monitoring code to [48].

2 NO

3 Is resistance between W10 (female) (3) NO and P02 (female) (13), between W10 (female) (4) and ground less than 1 Ω? YES

Defective contact or disconnection in wiring harness between W10 Repair or (female) (3) and P02 (female) (13), between W10 (female) (4) replace and ground Defective monitor panel

Replace

Defective wiper and washer switch

Replace

Defective contact or disconnection in wiring harness with defective resistance value

Repair or replace

Defective monitor panel

Replace

Short circuit with power source in wiring harness between P02 (female) (3) and W08 (female) (18) or between P02 (female) (11) and W08 (female) (17)

Repair or replace

4 When wiper switch is turned to NO ON or INT, does bit (1) or (2) of monitoring code [48] go out? YES

5 • Turn starting switch OFF. • Disconnect M18.

• Turn starting switch OFF. • Disconnect P02 and W04.

Is resistance between pins of M18 (female) (1)(2)(4) as shown in Table 3? YES

6 Is resistance between each pin NO of P02 (female), W04 (male) as shown in Table 2? YES

• Turn starting switch ON. • Set monitoring code to [47].

7 When wiper switch is turned to NO ON or INT, does bit (3) or (4) of monitoring code [47] light up? YES

• Turn starting switch ON. • Set service code to display mode.

Is service code [E112] or [E113] NO being displayed?

YES

• Turn starting switch ON. • Set monitoring code to [4C]

9 When wiper switch is turned NO to OFF, does bit (2) or (3) of monitoring code [4C] light up? YES

To A

20-686

Defective monitor panel Replace Defective contact or disconnection in wiring harness between P02 (female) Repair or (3) and W08 (female) (18) or replace between P02 (female) (11) and W08 (female) (17)

PC600-6

TROUBLESHOOTING

M-23

Cause

Remedy

10 • Turn starting switch ON.

Is voltage of each pin of W04 as shown in Table 1?

YES

• Turn starting switch OFF. • Disconnect P02, W04, and W08.

11 Is resistance between each pin of NO P02 (female), W04 (male), W08 (female) as shown in Table 2? YES

Defective wiper motor

Replace

Defective contact or disconnection in wiring harness with defective resistance value

Repair or replace

Defective relay box

Replace

Table 1 Timing chart when wiper switch is at ON Item

Symbol

Set time

Length of pause until next actuation

Tla

0.13sec

Safety circuit during operation of wiper [safety function (1)]

Tsa

10sec

Length of pause when stowing wiper blade

Tlp

1.5sec

Safety circuit during stowing of wiper [safety function (2)]

Tsp

10sec

Item

Symbol

Set time

Length of pause until next actuation

Tla

4sec

Safety circuit during operation of wiper [safety function (1)]

Tsa

10sec

Length of pause when stowing wiper blade

Tlp

1.5sec

Safety circuit during stowing of wiper [safety function (2)]

Tsp

10sec

Timing chart when wiper switch is at INT

OFF: Max. 3 V ON: 20 – 30 V

Table 2

Table 3 Resistance value

Between W04 (female) (1) and W08 (female) (6)

Wiper switch

INT mode

Between W04 (female) (3) and W08 (female) (7) Between W04 (female) (4) and W08 (female) (15)

Max. 1 Ω

Between W04 (female) (5) and P02 (female) (1)

OFF mode

Between W04 (female) (6) and P02 (female) (6) Between W04 (female) (1),(3),(5),(6) and GND

Min. 1 MΩ

Between W08 (female) (17) and P02 (female) (11) Between W08 (female) (18) and P02 (female) (3)

PC600-6

Max. 1 Ω

ON mode

M18 (female)

P02 (female)

Resistance

Between (1) – (2)

Between (1) – (4)

Min. 1 MΩ

Between (1) – (4)

Between (1) – (12)

Max. 1 Ω

Between (2) – (4)

Between (4) – (12)

Min. 1 MΩ

Between (1) – (2)

Between (1) – (4)

Between (1) – (12)

Between (2) – (4)

Between (4) – (12)

Between (1) – (2)

Between (1) – (4)

Between (1) – (12)

Between (2) – (4)

Between (4) – (12)

Min. 1 MΩ

Max. 1 Ω Min. 1 MΩ

20-687

TROUBLESHOOTING

M-23

b) Wiper switch is not being operated, but wiper is actuated

Cause

Remedy

1 • Turn starting switch ON. • Set monitoring code to [48].

Is bit (4) of monitoring code [48] lighted up? YES

2 • Turn starting switch ON. • Set monitoring code to [47].

Is bit (3) or (4) of monitoring code [47] lighted up? YES

Defective monitor panel

Replace

3 • Turn starting switch ON. • Set monitoring code to [4C].

Is bit (2) or (3) of monitoring code [4C] lighted up? YES

4 • Disconnect W08. • Turn starting switch ON.

Is voltage between W08 (female) (1) and (6), between (1) and (7) less than 1 V? YES

Short circuit with ground in wiring harness between P02 (female) (3) and W08 (female) (18) or between P02 (female) (11) and W08 (female) (17) Short circuit with power source in wiring harness between W08 (female) (7) and W04 (male) (3) or between W08 (female) (6) and W04 (male) (1) Defective relay box

Repair or replace

Repair or replace Replace

5 • Turn starting switch ON. • Set monitoring code to [48].

Has bit (1) or (4) of monitoring NO code [48] gone out?

Go to Troubleshooting No. 5

—

YES

• Turn starting switch OFF. • Disconnect M18.

6 Is resistance between each pin NO of M18 (female) (1)(2)(4) as shown in Table 1? YES

Defective wiper and washer switch

Replace

• Turn starting switch OFF. • Disconnect P02, W04, and W08.

7 Is resistance between each pin NO of P02 (female), W04 (male) as shown in Table 2? YES

Defective contact or disconnection in wiring harness with defective resistance value

Repair or replace

Defective monitor panel

Replace

20-688

PC600-6

TROUBLESHOOTING

M-23

Table 1

Table 2 Resistance value

Between W04 (female) (1) and W08 (female) (6)

Wiper switch

INT mode

Between W04 (female) (3) and W08 (female) (7) Between W04 (female) (4) and W08 (female) (15)

Max. 1 Ω

Between W04 (female) (5) and P02 (female) (1)

OFF mode

Between W04 (female) (6) and P02 (female) (6) Between W04 (female) (1),(3),(5),(6) and GND

Min. 1 MΩ

Between W08 (female) (17) and P02 (female) (11) Between W08 (female) (18) and P02 (female) (3)

PC600-6

Max. 1 Ω

ON mode

M18 (female)

P02 (female)

Resistance

Between (1) – (2)

Between (1) – (4)

Min. 1 MΩ

Between (1) – (4)

Between (1) – (12)

Max. 1 Ω

Between (2) – (4)

Between (4) – (12)

Min. 1 MΩ

Between (1) – (2)

Between (1) – (4)

Between (1) – (12)

Between (2) – (4)

Between (4) – (12)

Between (1) – (2)

Between (1) – (4)

Between (1) – (12)

Between (2) – (4)

Between (4) – (12)

Min. 1 MΩ

Max. 1 Ω Min. 1 MΩ

20-689

TROUBLESHOOTING

M-23

M-23 Related electrical circuit diagram

20-690

PC600-6

TROUBLESHOOTING

M-24

M-24 Electric grease gun does not work (machines equipped with electric grease gun) ﬂ Before carrying out troubleshooting, check that circuit breaker 4 has not shut off the circuit. (If the breaker has shut off the circuit, there has probably been a surge of current caused by a short circuit with the ground, so check the circuits related to circuit breaker 4.)

Cause • Turn starting switch ON.

1 Is voltage between G01 (1) and NO ground 20 – 28V? YES 2

• Turn starting switch OFF. • Disconnect G01.

Is resistance between G01 (male) (2) and ground less than 1 Ω? YES

Remedy

Defective contact or disconnection in wiring Repair or harness between battery relay replace terminal M and G01 (male) (1)

Defective contact or disconnection in wiring harness between G01 (male) (2) and ground

Repair or replace

Defective monitor panel

Replace

M-24 Related electrical circuit diagram

PC600-6

20-691

30 DISASSEMBLY AND ASSEMBLY

METHOD OF USING MANUAL ............... 30- 2 PRECAUTIONS WHEN CARRYING OUT OPERATION ........................................ 30- 5 SPECIAL TOOL LIST ................................. 30- 7 SKETCHES OF SPECIAL TOOLS ............... 30- 14 RADIATOR, HYDRAULIC COOLER ASSEMBLY Removal and Installation ................... 30- 22 ENGINE, PTO, HYDRAULIC PUMP ASSEMBLY Removal and Installation ................... 30- 25 PTO ASSEMBLY Removal and Installation ................... 30- 29 Disassembly and Assembly .............. 30- 30 FUEL TANK ASSEMBLY Removal and Installation ................... 30- 34 FINAL DRIVE ASSEMBLY Disassembly and Assembly .............. 30- 35 TRAVEL MOTOR ASSEMBLY Disassembly and Assembly .............. 30- 48 REVOLVING FRAME ASSEMBLY Removal and Installation ................... 30- 64 SWING MOTOR ASSEMBLY Removal and Installation ................... 30- 66 Disassembly and Assembly .............. 30- 67 SWING MACHINERY ASSEMBLY Removal and Installation ................... 30- 78 Disassembly and Assembly .............. 30- 79 SWING CIRCLE ASSEMBLY Removal and Installation ................... 30- 88 TRACK SHOE ASSEMBLY Removal and Installation ................... 30- 89 ONE LINK IN FIELD Disassembly and Assembly .............. 30- 91 IDLER, RECOIL SPRING ASSEMBLY Removal and Installation ................... 30- 95 IDLER Disassembly and Assembly .............. 30- 96 RECOIL SPRING ASSEMBLY Disassembly and Assembly .............. 30-100 TRACK ROLLER ASSEMBLY Removal and Installation .................. 30-102 Disassembly and Assembly .............. 30-103

PC600-6

CARRIER ROLLER ASSEMBLY Removal and Installation .................. 30-106 Disassembly and Assembly .............. 30-107 HYDRAULIC TANK ASSEMBLY Removal and Installation .................. 30-110 MAIN RELIEF VALVE ASSEMBLY Disassembly and Assembly .............. 30-112 MAIN CONTROL VALVE, SOLENOID VALVE ASSEMBLY Removal and Installation .................. 30-114 MAIN CONTROL VALVE ASSEMBLY Disassembly and Assembly .............. 30-116 NO. 1 AND NO. 2 PUMP ASSEMBLY Removal and Installation .................. 30-120 HYDRAULIC PUMP ASSEMBLY Disassembly and Assembly .............. 30-122 CONTROL, PTO LUBIRCATION PUMP ASSEMBLY Removal and Installation .................. 30-148 CENTER SWIVEL JOINT ASSEMBLY Removal and Installation .................. 30-149 Disassembly and Assembly .............. 30-150 WORK EQUIPMENT, PPC VALVE ASSEMBLY Disassembly and Assembly .............. 30-151 TRAVEL PPC VALVE ASSEMBLY Disassembly and Assembly .............. 30-153 BUCKET CYLINDER ASSEMBLY Removal and Installation .................. 30-155 ARM CYLINDER ASSEMBLY Removal and Installation .................. 30-157 BOOM CYLINDER ASSEMBLY Removal and Installation .................. 30-159 HYDRAULIC CYLINDER ASSEMBLY Disassembly and Assembly .............. 30-161 BUCKET ASSEMBLY Removal and Installation .................. 30-168 ARM ASSEMBLY Removal and Installation .................. 30-170 BOOM ASSEMBLY Removal and Installation .................. 30-172 OPERATOR’S CAB ASSEMBLY Removal and Installation .................. 30-174 COUNTERWEIGHT ASSEMBLY Removal and Installation .................. 30-176

30-1

DISASSEMBLY AND ASSEMBLY

METHOD OF USING MANUAL

METHOD OF USING MANUAL 1. When removing or installing unit assemblies 1 When removing or installing a unit assembly, the order of work and techniques used are given for the removal operation; the order of work for the installation operation is not given. 2 Any special techniques applying only to the installation procedure are marked 1, and the same mark is placed after the relevant step in the removal procedure to indicate which step in the installation procedure it applies to. (Example) REMOVAL OF ASSEMBLY ............ Title of operation ¤ ...................................................................... Precautions related to safety when carrying out the operation 1. X X X X (1) ..................................................... Step in operation fl ................................................................... Technique or important point to remember when removing XXXX (1). 2. (2): ...............................................1 Indicates that a technique is listed for use during installation 3. assembly (3) 6 ............................................................ Quantity of oil or water drained INSTALLATION OF ASSEMBLY ....Title of operation • Carry out installation in the reverse order to removal. 1 .............................................................. Technique used during installation fl ................................................................... Technique or important point to remember when installing (2). • Adding water, oil ................................. Step in operation fl ............................................................ Point to remember when adding water or oil -......................................................... Quantity when filling with oil and water 2. General precautions when carrying out installation or removal (disassembly or assembly) of units are given together as PRECAUTIONS WHEN CARRYING OUT OPERATION, so be sure to follow these precautions when carrying out the operation. 3. Listing of special tools 1 For details of the description, part number, and quantity of any tools (A1, etc.) that appear in the operation procedure, see the SPECIAL TOOLS LIST given in this manual.

30-2

PC600-6

DISASSEMBLY AND ASSEMBLY

METHOD OF USING MANUAL

4. Standard tightening torques of bolts and nuts Use these torques for metric bolts and nuts. (Always use torque wrench). Thread diameter of bolt

Width across flats

kgm

6 8 10 12 14

10 13 17 19 22

13.2 ± 1.4 31 ± 3 66 ± 7 113 ± 10 177 ± 19

1.35 ± 0.15 3.2 ± 0.3 6.7 ± 0.7 11.5 ± 1 18 ± 2

16 18 20 22 24

24 27 30 32 36

279 ± 30 382 ± 39 549 ± 59 745 ± 83 927 ± 103

28.5 ± 3 39 ± 4 56 ± 6 76 ± 8.5 94.5 ± 10.5

27 30 33 36 39

41 46 50 55 60

1320 ± 140 1720 ± 190 2210 ± 240 2750 ± 290 3290 ± 340

135 ± 15 175 ± 20 225 ± 25 280 ± 30 335 ± 35

Thread diameter of bolt

Width across flats

kgm

6 8 10 12

10 13 14 27

7.85 ± 1.95 18.6 ± 4.9 40.2 ± 5.9 82.35 ± 7.85

0.8 ± 0.2 1.9 ± 0.5 4.1 ± 0.6 8.4 ± 0.8

Thread diameter mm

Width across flat mm

Tightening torque Nm

kgm

14 18 22 24 30 33 36 42

19 24 27 32 36 41 46 55

24.5 ± 4.9 49 ± 19.6 78.5 ± 19.6 137.3 ± 29.4 176.5 ± 29.4 196.1 ± 49 245.2 ± 49 294.2 ± 49

2.5 ± 0.5 5±2 8±2 14 ± 3 18 ± 3 20 ± 5 25 ± 5 30 ± 5

5. Tightening torque of hose nuts Use these torques for hose nuts. Nominal No. 02 03 04 05 06 10 12 14

6. Tightening torque of split flange bolts Use these torques for split flange bolts. Tightening torque

Thread diameter

Width across flat

kgm

10 12 16

14 17 22

65.7 ± 6.8 112 ± 9.8 279 ± 29

6.7 ± 0.7 11.5 ± 1 28.5 ± 3

PC600-6

30-3

DISASSEMBLY AND ASSEMBLY

METHOD OF USING MANUAL

7. Tightening torque of O-ring boss connector Use these torques for O-ring boss connector Nominal No. 02 03, 04 05, 06 10, 12 14

Thread diameter mm 14 20 24 33 42

Width across flat mm Varies depending on type of connector.

Tightening torque Nm

kgm

34.3 ± 4.9 93.1 ± 9.8 142.1 ± 19.6 421.4 ± 58.8 877.1 ± 132.3

3.5 ± 0.5 9.5 ± 1 14.5 ± 2 43 ± 6 89.5 ± 13.5

8. Tightening torque of O-ring boss connector Use these torques for O-ring boss connector Nominal No. 08 10 12 14 16 18 20 24 30 33 36 42 52

30-4

Tightening torque

Thread diameter mm

Width across flat mm

kgm

8 10 12 14 16 18 20 24 30 33 36 42 52

14 17 19 22 24 27 30 32 32 — 36 — —

7.35 ± 1.47 11.27 ± 1.47 17.64 ± 1.96 22.54 ± 1.96 29.4 ± 4.9 39.2 ± 4.9 49 ± 4.9 68.6 ± 9.8 107.8 ± 14.7 127.4 ± 19.6 151.9 ± 24.5 210.7 ± 29.4 323.4 ± 44.1

0.75 ± 0.15 1.15 ± 0.15 1.8 ± 0.2 2.3 ± 0.2 3 ± 0.5 4 ± 0.5 5 ± 0.5 7± 1 11 ± 1.5 13 ± 2 15.5 ± 2.5 21.5 ± 3 33 ± 4.5

PC600-6

DISASSEMBLY AND ASSEMBLY

PRECAUTIONS WHEN CARRYING OUT OPERATION

PRECAUTIONS WHEN CARRYING OUT OPERATION [When carrying out removal or installation (disassembly or assembly) of units, be sure to follow the general precautions given below when carrying out the operation.] 1. Precautions when carrying out removal work • If the coolant contains antifreeze, dispose of it correctly. • After disconnecting hoses or tubes, cover them or fit blind plugs to prevent dirt or dust from entering. • When draining oil, prepare a container of adequate size to catch the oil. • Confirm the match marks showing the installation position, and make match marks in the necessary places before removal to prevent any mistake when assembling. • To prevent any excessive force from being applied to the wiring, always hold the connectors when disconnecting the connectors. Do not pull the wires. • Fit wires and hoses with tags to show their installation position to prevent any mistake when installing. • Check the number and thickness of the shims, and keep in a safe place. • When raising components, be sure to use lifting equipment of ample strength. • When using forcing screws to remove any components, tighten the forcing screws uniformly in turn. • Before removing any unit, clean the surrounding area and fit a cover to prevent any dust or dirt from entering after removal. ﬂ Precautions when handling piping during disassembly Fit the following blind plugs into the piping after disconnecting it during disassembly operations. 1) Hoses and tubes using sleeve nuts Nominal number

Plug (nut end)

Sleeve nut (elbow end) Use the two items below as a set

02 03 04 05 06 10 12

07376-50210 07376-50315 07376-50422 07376-50522 07376-50628 07376-51034 07376-51234

07221-20210 (Nut), 07222-00210 (Plug) 07221-20315 (Nut), 07222-00312 (Plug) 07221-20422 (Nut), 07222-00414 (Plug) 07221-20522 (Nut), 07222-00515 (Plug) 07221-20628 (Nut), 07222-00616 (Plug) 07221-21034 (Nut), 07222-01018 (Plug) 07221-21234 (Nut), 07222-01219 (Plug)

2) Split flange type hoses and tubes Nominal number

Flange (hose end)

Sleeve head (tube end)

Split flange

04 05

07379-00400 07379-00500

07378-10400 07378-10500

07371-30400 07371-30500

Part Number

06 08 10 12 14 16 18 20 22 24 27

07049-00608 07049-00811 07049-01012 07049-01215 07049-01418 07049-01620 07049-01822 07049-02025 07049-02228 07049-02430 07049-02734

PC600-6

Dimensions D d L 6 5 8 8 6.5 11 10 8.5 12 12 10 15 14 11.5 18 16 13.5 20 18 15 22 20 17 25 22 18.5 28 24 20 30 27 22.5 34

Taper 1/8

ød

Nominal number

øD

3) If the part is not under hydraulic pressure, the following corks can be used.

L DEW00401

30-5

DISASSEMBLY AND ASSEMBLY

2. • • • • • • • • • • • • •

PRECAUTIONS WHEN CARRYING OUT OPERATION

Precautions when carrying out installation work Tighten all bolts and nuts (sleeve nuts) to the specified (KES) torque. Install the hoses without twisting or interference. Replace all gaskets, O-rings, cotter pins, and lock plates with new parts. Bend the cotter pins and lock plates securely. When coating with adhesive, clean the part and remove all oil and grease, then coat the threaded portion with 2 – 3 drops of adhesive. When coating with gasket sealant, clean the surface and remove all oil and grease, check that there is no dirt or damage, then coat uniformly with gasket sealant. Clean all parts, and correct any damage, dents, burrs, or rust. Coat rotating parts and sliding parts with engine oil. When press fitting parts, coat the surface with anti-friction compound (LM-P). After fitting snap rings, check that the snap ring is fitted securely in the ring groove. When connecting wiring connectors, clean the connector to remove all oil, dirt, or water, then connect securely. When using eyebolts, check that there is no deformation or deterioration, screw them in fully, and align the direction of the hook. When tightening split flanges, tighten uniformly in turn to prevent excessive tightening on one side.

fl When operating the hydraulic cylinders for the first time after reassembling cylinders, pumps and other hydraulic equipment removed for repair, always bleed the air as follows: 1. Start the engine and run at low idling. 2. Operate the work equipment control lever to operate the hydraulic cylinder 4 – 5 times, stopping the cylinder 100 mm from the end of its stroke. 3. Next, operate the hydraulic cylinder 3 – 4 times to the end of its stroke. 4. After doing this, run the engine at normal speed. fl When using the machine for the first time after repair or long storage, follow the same procedure. 3. Precautions when completing the operation • If the coolant has been drained, tighten the drain valve, and add water to the specified level. Run the engine to circulate the water through the system. Then check the water level again. • If the hydraulic equipment has been removed and installed again, add engine oil to the specified level. Run the engine to circulate the oil through the system. Then check the oil level again. • If the piping or hydraulic equipment have been removed, always bleed the air from the system after reassembling the parts. fl For details, see TESTING AND ADJUSTING, Bleeding air. • Add the specified amount of grease (molybdenum disulphide grease) to the work equipment parts.

30-6

PC600-6

DISASSEMBLY AND ASSEMBLY

SPECIAL TOOL LIST

SPECIAL TOOL LIST fl Tools with part number 79 T- - cannot be supplied (they are items to be locally manufactured). fl Necessity: ■: Cannot be substituted, should always be installed (used). ●: Extremely useful if available, can be substituted with commercially available part. fl New/remodel: N: Tools with new part numbers, newly developed for this model. fl R: Tools with upgraded part numbers, remodeled from items already available for other models. fl Blank: Tools already available for other models, used without any modification. fl Tools marked in the Sketch column are tools introduced in special sketches (See SKETCHES OF SPECIAL TOOLS). Component

Symbol

Disassembly, F assembly of swing machinery assembly

Part No.

Part Name

796T-626-1110

Push tool

■

790-331-1110

Wrench

■

790-501-5200

Unit repair stand

●

790-901-2110

Bracket

●

790-901-2290

Plate

●

796-730-2120

Screwdriver

■

796-720-2220

Socket

■

796T-660-1510

Pump adapter

■

• 790-101-1430

• Coupler assembly

■

• 799-660-1490

• Nipple

■

• 799-101-5130

• Gauge

■

• 799-101-5160

• Nipple

■

• 790-301-1190

• Nipple

■

• 790-301-1660

• Tee

■

• 205-70-51390

• Nipple

■

• 790-301-1210

• Joint

■

• 07002-01423

• O-ring

■

790-101-1102

Pump

■

790-201-2740

Spacer

■

790-201-2730

Spacer

■

796-730-2000

Wrench

■

796T-466-1110

Push tool

■

790-201-2740

Spacer

■

Oil leak tester

■

Disassembly, assembly of swing motor

3 FF

9 10 799-301-1600

PC600-6

Neces- Q’ty New/ Sketch sity remodel 9

Nature of work, remarks Press fitting of bearing Tightening of ring gear bolt For overseas Disassembly, assembly of motor Removal, installation of retainer mounting screw

Releasing brake

Press fitting of main bearing inner race Press fitting of sub bearing inner race Measuring rotating torque of drive shaft N

9 Press fitting of oil seal Removal of brake piston

30-7

DISASSEMBLY AND ASSEMBLY

Component

Symbol

SPECIAL TOOL LIST

790-501-5000

Unit repair stand

●

AC100V

790-501-5200

Unit repair stand

●

AC100V, 220V

790-901-4110

Bracket

●

796T-627-1510

Plate

●

796T-627-1520

Plate

●

970-431-1031

Block

■

791-730-1130

Bolt

■

790-101-2360

Plate

■

01643-32060

Washer

■

01580-12016

Nut

■

796-627-1420

Adapter

■

790-201-2790

Spacer

■

790-201-2690

Plate

■

790-101-2102

Puller (294N{30ton})

■

790-101-1102

Pump

■

796-627-1020

Installer

■

790-101-2510

Block

■

791-830-1320

Rod

■

790-101-2570

Washer

■

01643-31645

Washer

■

01580-11613

Nut

■

796-627-1410

Adapter

■

796T-627-1330

Push tool

●

790-101-2102

Puller

■

790-101-1102

Pump

■

791-575-1520

Installer

■

791-601-1000

Oil pump assembly

●

790-701-3600

Adapter

●

791-560-1520

Installer

■

791-601-1000

Oil pump assembly

●

790-701-3600

Adapter

●

791-651-1510

Installer

■

791-601-1000

Oil pump assembly

●

AC110 – 220V, AC220 – 240V Installation of floating seal Filling with oil, check sealing

790-701-3600

Adapter

●

AC110 – 220V, AC220 – 240V

Disassembly, assembly of idler assembly

Disassembly, assembly of track roller assembly

Disassembly, assembly of carrier roller

30-8

Nature of work, remarks

Part Name

Disassembly, assembly of final drive assembly

NecesNew/ sity Q’ty remodel Sketch

Part No.

2 3 L 4 5 6

Disassembly, assembly of final drive

Removal of travel motor

Press fitting of floating seal

Press fitting of bearing N 9

Installation of floating seal Filling with oil, check sealing AC110 – 220V, AC220 – 240V Installation of floating seal Filling with oil, check sealing

PC600-6

DISASSEMBLY AND ASSEMBLY

Component

Symbol

Disassembly, assembly of recoli M spring assembly

SPECIAL TOOL LIST

NecesNew/ sity Q’ty remodel Sketch

Part No.

Part Name

791-685-8006

Compressor

■

791-635-3160

Extension

■

790-101-1600

Cylinder (686N{70ton}) ■

Pump

■

790-501-5200

Unit repair stand (for 100V) Unit repair stand (for 220V, 240V)

790-901-2110

Bracket

790-901-1331

Plate

790-345-1020

Plate

790-201-3330

Bolt

792-422-1120

Washer

01643-32460

Washer

01643-31845

Washer

01580-01815

Nut

790-201-2180

Plate

790-201-2740

Spacer

790-201-2840

Spacer

796-720-2210

Screwdriver

796-730-2120

Screwdriver

796-720-2220

Socket

795-630-1804

Torque wrench

796-867-1200

Gauge

796-767-1100

Gauge

790-201-2160

Plate

790-201-2730

Spacer

790-201-2190

Plate

790-201-2740

Spacer

790-101-5001

Push tool kit

790-101-5151

• Plate

790-101-5021

• Grip

01010-50816

• Bolt

01435-01225

Bolt

790-101-1102 790-501-5000

Disassembly, assembly of hydraulic pump assembly HPV95+95

P 4

10 Commercially available Torque wrench

PC600-6

Nature of work, remarks

Disassembly, assembly of recoli spring

Disassembly, assembly of pump assembly

Disassembly, assembly of cylinder block assembly

Removal of roller bearing

Disassembly, assembly of impeller, and disassembly, assembly of cradle

For minimum Adjustment of servo piston For maximum swash plate angle Press fitting of roller bearing Press fitting of shaft assembly

Press fitting of oil seal

Inspection of shaft rotating torque

30-9

DISASSEMBLY AND ASSEMBLY

Component

Travel motor assembly

End cover

Travel motor

Retainer screw

Symbol

Part No.

SPECIAL TOOL LIST

Part Name

NecesNew/ sity Q’ty remodel Sketch

1 790-501-5000

Unit repair stand

For Japan

2 790-501-5200

Unit repair stand

For Overseas

3 790-901-2110

Bracket

4 790T-901-1480

Plate

Disassembly, assembly

1 796T-660-1590

Plate

2 01050-82450

Bolt

3 04530-11222

Eyebolt

4 01601-22450

Washer

1 796-720-2250

Screwdriver

2 796-720-2220

Socket

Raising end cover

Tightening retainer screw

Brake piston

799-301-1600

Oil leak tester

Drive shaft

796T-660-1310

Push tool

Main bearing

791-685-8310

Push tool

Sub bearing inner race

790-201-2700

Push tool kit

31 • 790-101-2750

• Spacer

1 796T-660-1320

Guide

2 04530-10815

Eyebolt

1 796T-660-1330

Plate

2 01580-11008

Nut

790-201-3200

Bolt kit

• 790-201-3240

• Bolt

1 796-660-1350

Positioner

2 796-660-1360

Plate

3 796-660-1370

4 796-660-1380

Drive shaft assembly

Nature of work, remarks

Removing brake piston Disassembly, pulling out drive shaft Press fitting of main bearing Press fitting of sub bearing inner race

S 32

Assembly of drive shaft assembly

3 3

Brake piston

Dowel pin

796T-660-1570

Push tool

Valve plate

796-660-1390

Case and end cover

796-660-1580

796T-660-1480

Pump adapter

• 790-101-1430

• Coupler assembly

• 796-660-1490

• Nipple

• 799-101-5130

• Gauge

• 799-101-5160

• Nipple

• 790-301-1190

• Nipple

• 790-301-1660

• Tee

• 205-70-51390

• Nipple

Brake

30-10

Positioning of brake piston

37 1

Knocking in dowel pin Securing valve plate

Assembly of case and end cover

N Releasing brake

PC600-6

DISASSEMBLY AND ASSEMBLY

Component

Symbol

Part No.

SKETCHES OF SPECIAL TOOLS

Part Name

Neces- Q’ty New/ Sketch sity remodel

Nature of work, remarks

• 790-301-1271

• Joint

• 07002-01023

• O-ring

Pump

01435-01016

Bolt

790-101-5201

Push tool kit (B)

• 790-101-5291

• Plate

• 790-101-5221

• Grip

• 01010-51225

• Bolt

790-101-2501

Push-puller

• 790-101-2510

• Block

• 790-101-2520

• Screw

• 791-112-1180

• Nut

• 790-101-2540

• Washer

• 790-101-2630

• Leg

• 790-101-2570

• Washer

• 790-101-2560

• Nut

• 790-101-2650

• Adapter

790-502-1003

Cylinder repair stand

Disassembly, assembly of hydraulic cylinder

790-720-1000

Expander

Expansion of piston ring

796-720-1690

Ring

07281-01919

Clamp

790-201-1702

Push tool kit

• 790-101-5021

• Grip

• 01010-50816

• Bolt

• 790-201-1871

• Push tool

790-201-1702

Push tool kit

• 790-101-5021

• Grip

• 01010-50816

• Bolt

• 790-201-1881

• Push tool

1 37

Travel motor

Brake

2 790-101-1102 38

Drive shaft S

Oil seal

Disassembly, assembly of center swivel joint assembly

Press fitting of oil seal

PC600-6

Disconnection of rotor and shaft

Installation of piston ring

Disassembly, assembly of U hydraulic cylinder assembly

Measuring drive shaft rotating torque

Boom cylinder Bucket cylinder

Press fitting of cylinder head bushing

Arm cylinder

30-11

DISASSEMBLY AND ASSEMBLY

Component

Disassembly, assembly of hydraulic cylinder assembly

Symbol

SPECIAL TOOL LIST

Part Name

790-201-1500

Push tool kit

• 790-101-5021

• Grip

• 01010-50816

• Bolt

• 790-201-1680

• Plate

790-201-1500

Push tool kit

• 790-101-5021

• Grip

• 01010-50816

• Bolt

• 790-201-1690

• Plate

790-102-4300

Wrench

■

790-102-4310

■

796T-670-1210

Sleeve

■

796T-670-1220

Sleeve

■

791-775-1130

Plate

■

796-670-1130

Screw

■

796-870-1110

Adapter

■

01643-33080

Washer

■

01803-13034

Nut

■

790-101-4000

Puller (490N{50ton})

■

790-101-1102

Pump

■

5 U

Removal of boom assembly

30-12

■

799-703-1120

■

799-703-1400

Gas leak tester

■

799-703-1110

Nature of work, remarks Boom cylinder Bucket cylinder Press fitting of dust seal

Service tool kit

799-703-1100 X

■

Vacuum pump (100V) Vacuum pump (220V) Vacuum pump (240V)

799-703-1200 Removal, installation of radiator, hydraulic cooler assembly

NecesNew/ sity Q’ty remodel Sketch

Part No.

Arm cylinder

Removal, installation of piston

Removal of boom foot pin

Collecting and charging refrigerant

PC600-6

DISASSEMBLY AND ASSEMBLY

Component

Symbol

Removal of track shoe assembly Disassembly, assembly of one link in field

PC600-6

NecesNew/ sity Q’ty remodel Sketch

Part No.

Part Name

796-632-1200

Remover, installer

• 791-685-9510

• Frame

• 791-685-9520

• Frame

• 04530-12030

• Eyebolt

• 791-685-9530

• Shaft

• 791-685-9540

• Shaft

• 791-685-9550

• Nut

• 791-685-9560

• Bolt

• 791-126-0150

• Adapter

• 791-675-5520

• Guide

• 01010-81030

• Bolt

• 791-675-5530

• Pin

• 791-685-9620

• Extension

• 791-670-3270

• Guide

• 791-675-5550

• Guide

• 796-632-1230

• Adapter

• 796-632-1210

• Adapter

• 796-632-1220

• Guide

• 01010-81440

• Bolt

• 796-632-1240

• Adapter

• 796-632-1250

• Guide

• 796-632-1260

• Adapter

• 796-632-1270

• Adapter

• 796-632-1280

• Adapter

• 796-632-1290

• Guide

■

790-101-4200

Cylinder (1470N{150ton}) Cylinder (294N{30ton})

■

790-101-1102

Pump

■

796-660-2010

Oil stopper

●

790-101-4300

Removal, installation of engine, PTO, hydraulic pumps, No. 1, No. 2 pumps, control, PTO lubrication pump

SPECIAL TOOL LIST

Nature of work, remarks

Removal, installation of master pin, regular pin, press fitting of bushing

Stopping hydraulic oil

30-13

DISASSEMBLY AND ASSEMBLY

SKETCHES OF SPECIAL TOOLS

SKETCHES OF SPECIAL TOOLS Note:

Komatsu cannot accept any responsibility for special tools manufactured according to these sketches.

φ190.7

φ122±0.5

φ112±0.5

F1 Push tool

C0.5

C0.5 70 100 CDP00506

HEAT TREATMENT

MATERIAL STKM13A

PART NAME PUSH TOOL

QTY 1

796T-626-1110 FF-1 Plate

30-14

PC600-6

DISASSEMBLY AND ASSEMBLY

SKETCHES OF SPECIAL TOOLS

160

FF-3 Pump adapter

P T 1/8 P T 1/4

P F 1/4 3/8 - 18NPTF

P T 1/8

14 X 1.5

PC600-6

CKP00551

30-15

DISASSEMBLY AND ASSEMBLY

SKETCHES OF SPECIAL TOOLS

FF-9 Push tool

J2 Plate

30-16

PC600-6

DISASSEMBLY AND ASSEMBLY

SKETCHES OF SPECIAL TOOLS

J3 Plate

J6 Push tool

100

)

150 CDP00509

HEAT TREATMENT

MATERIAL STKM13A

PART NAME PUSH TOOL

QTY 1

796T-627-1330 PC600-6

30-17

DISASSEMBLY AND ASSEMBLY

SKETCHES OF SPECIAL TOOLS

S25-4 Plate

S26-1 Plate

30-18

PC600-6

DISASSEMBLY AND ASSEMBLY

SKETCHES OF SPECIAL TOOLS

ø 200

ø 180 +0.2 0

S29 Push tool

CKP00784

S32-1 Guide

12 C1 8

C1 ø 304

ø 284±0.2

ø 161±0.2

CKP00785

C1 6

PC600-6

30-19

DISASSEMBLY AND ASSEMBLY

SKETCHES OF SPECIAL TOOLS

ø 180

11 DRILL

S32-3-1 Plate

CKP00786

S34 Push tool

30-20

PC600-6

DISASSEMBLY AND ASSEMBLY

SKETCHES OF SPECIAL TOOLS

V1 Sleeve

PC600-6

30-21

DISASSEMBLY AND ASSEMBLY

RADIATOR, HYDRAULIC COOLER

REMOVAL OF RADIATOR, HYDRAULIC COOLER ASSEMBLY ¤ Lower the work equipment completely to the ground and stop the engine. Then, loosen the oil filler cap slowly to release the pressure inside the hydraulic tank. ¤ Connect tool X to the valve of the air conditioner compressor hose to collect Freon gas (R134a). 1. Drain oil from hydraulic tank. 6 Hydraulic tank: 379 ¬ 2. Drain coolant. 3. Remove radiator top cover and two radiator side covers. 4. Remove engine upper cover. 5. Remove cover frame (1). 6. Disconnect air conditioner pipes (2), (3), and (4). 7. Remove receiver tank (5). 8. Remove bracket (6). 9. Disconnect air conditioner condenser (7). 10. Disconnect fuel cooler pipings (8) and (9), then remove fuel cooler assembly (10).

11. Disconnect inlet hose (11) and outlet hose (12) of hydraulic cooler.

30-22

PC600-6

DISASSEMBLY AND ASSEMBLY

RADIATOR, HYDRAULIC COOLER

12. Remove radiator upper hose (13) and radiator lower hose (14). 1 13. Disconnect reservoir tank hose and aeration hose from radiator. 14. Remove two brackets (15) on both sides of radiator. 2 15. Remove four mounting bolts (16) from underside of radiator. 3 16. Lift off radiator and hydraulic cooler assembly (17). ﬂ Take care not to damage the radiator core. 4 Radiator oil cooler assembly: 320 kg

INSTALLATION OF RADIATOR, HYDRAULIC COOLER ASSEMBLY •

Carry out installation in the reverse order to removal.

1 2 Inserting part of radiator hose: Gasket sealant (PERMATEX 98D manufactured by NIHON LOCKTIGHT or equivalent) 3 Hose clamp: 8.3 – 9.3 Nm {0.85 – 0.95 kgm} 2 3 Radiator mounting bolt (Upper side): 98 –123 Nm {10 – 12.5 kgm} 3 3 Radiator mounting bolt (Lower side): 245 – 309 Nm {25 – 31.5 kgm}

PC600-6

30-23

DISASSEMBLY AND ASSEMBLY

•

Refilling with water Add water through water filler to the specified level. Run the engine to circulate the water through the system. Then, check the water level again.

•

Refilling with oil (Hydraulic tank) Add oil through oil filler to the specified level. Run the engine to circulate the oil through the system. Then, check the oil level again. -

•

RADIATOR, HYDRAULIC COOLER

Hydraulic tank: 360 ¬ (EO10-CD)

Charging air conditioner with gas Using tool X, charge the air conditioner circuit with refrigerant (R134a).

30-24

PC600-6

DISASSEMBLY AND ASSEMBLY

ENGINE, PTO, HYDRAULIC PUMP

REMOVAL OF ENGINE, PTO, HYDRAULIC PUMP ASSEMBLY ¤ Lower the work equipment completely to the ground and stop the engine. Then, loosen the oil filler cap slowly to release the pressure inside the hydraulic tank. ¤ Connect tool X to the valve of the air conditioner compressor hose to collect new Freon gas (R134a). ¤ Disconnect the cable from the negative (–) terminal of the battery. fl Mark all the piping with tags to prevent mistakes in the mounting position when installing. fl Plug all of the disconnected tubes and hoses. 1. Remove hydraulic tank strainer, then using tool S, stop oil. fl When not using tool S, remove the drain plug, then drain oil. 6 Hydraulic tank: 379 ¬ 2. Drain coolant. 3. Remove counterweight. For details, see REMOVAL OF COUNTERWEIGHT. 4. Remove radiator and hydraulic cooler assembly. For details, see REMOVAL OF RADIATOR, HYDRAULIC COOLER ASSEMBLY. 5. Remove engine hood. 4 Engine hood assembly: 110 kg 6. Remove engine guard from top of engine. 7. Remove muffler top cover. 8. Remove hydraulic pump upper cover and cover between engine and hydraulic pump. 9. Remove cover between engine and main valve. 10. Disconnect hose (1), then remove reservoir tank (2). fl Disconnect the wiring connector (P08) from the reservoir tank. 11. Disconnect two heater hoses (3). 12. Disconnect air hoses (4) and (5).

13. Remove band, then remove air cleaner case (6). 2 4 Air cleaner case: 50 kg

PC600-6

30-25

DISASSEMBLY AND ASSEMBLY

ENGINE, PTO, HYDRAULIC PUMP

14. Disconnect wiring connectors (E21, E22) (7).

15. Disconnect terminal B wire (8) from starting motor. 16. Disconnect ground wire (9). 17. Disconnect air conditioner compressor wiring connector (10).

18. Disconnect three fuel hoses (11). ﬂ Plug the fuel hoses to prevent the fuel from leaking.

19. Disconnect upper hose (12) and lower hose (13) from the radiator. 3 20. Disconnect aeration hose and reservoir tank hose from the radiator. 21. Remove the fan guard. 22. Remove radiator fan (14).

30-26

PC600-6

DISASSEMBLY AND ASSEMBLY

ENGINE, PTO, HYDRAULIC PUMP

23. Disconnect wiring connector (CO13) (15) from No. 1 pump assembly.

24. Disconnect all of pump discharge hoses (16), suction hose (17), and hose (18) from No. 1 and No. 2 pump assemblies. 25. Disconnect discharge hose (19) and suction hose (20) from the control PTO lubrication pump.

26. Lift off engine, PTO, and hydraulic pump assembly (21). 5 ﬂ Check that the all wires and pipes have been disconnected. 4 Engine, PTO, hydraulic pump assembly: 2,500kg

PC600-6

30-27

DISASSEMBLY AND ASSEMBLY

ENGINE, PTO, HYDRAULIC PUMP

INSTALLATION OF ENGINE, PTO, HYDRAULIC PUMP ASSEMBLY •

Carry out installation in the reverse order to removal.

1 3 Air hose clamps (5): 8.3 – 9.3 Nm {0.85 – 0.95 kgm} 2 3 Band: 17.6 – 21.6 Nm {0.85 – 2.2 kgm} 3 2 Inserting part of radiator hose: Gasket sealant (PERMATEX 98D manufactured by NIHON LOCKTIGHT or equivalent) 3 Hose clamp: 8.3 – 9.3 Nm {0.85 – 0.95 kgm} 4 3 Radiator fan mounting bolt: 44 – 59 Nm {4.5 – 6 kgm} 5 3 Engine mounting bolt: 823.7 – 1029.7 Nm {84 – 105 kgm} •

Refilling with oil (Hydraulic tank) Add oil through oil filler to the specified level. Run the engine to circulate the oil through the system. Then, check the oil level again. -

Hydraulic tank: 379 ¬ (EO10-CD)

•

Refilling with water Add water through water filler to the specified level. Run the engine to raise the water temperature. Then, check the water level again.

•

Bleeding air Bleed air from the pump. For details, see TESTING AND ADJUSTING, Bleeding air from each part.

•

Charging air conditioner with gas Using tool X, charge the air conditioner circuit with refrigerant (R134a).

30-28

PC600-6

DISASSEMBLY AND ASSEMBLY

PTO

REMOVAL OF PTO ASSEMBLY 1. Remove engine, PTO, and hydraulic pump assembly. For details, see REMOVAL OF ENGINE, PTO, HYDRAULIC PUMP ASSEMBLY. 2. Disconnect hoses and lift off No. 1 pump assembly (1). 4 No. 1 pump assembly: 170 kg 3. Lift off No. 2 pump assembly (2). 4 No. 2 pump assembly: 160 kg 4. Disconnect hoses and lift off control, PTO, and lubrication pump assembly (3). 5. Disconnect all lubrication tubes (4). 6. Remove block (5). 7. Lift off PTO assembly (6).

4 PTO assembly: 210 kg

8. Remove shaft (7).

Note: Do not remove coupling (8) as an individual part from hub assembly (9). When replacing coupling (8), replace the whole hub assembly (9). When installing hub assembly (9) again, align the positions of the 6 spot facings on behind (✩) and 6 engine flywheel bolts (✩✩).

INSTALLATION OF PTO ASSEMBLY •

Carry out installation in the reverse order to removal.

1 3 PTO mounting bolt: 98 – 123 Nm {10 – 12.5 kgm} 2 3 Hub ass’y mounting bolt: 98 – 123 Nm {10 – 12.5 kgm}

PC600-6

30-29

DISASSEMBLY AND ASSEMBLY

PTO

DISASSEMBLY OF PTO ASSEMBLY 1. Draining lubrication oil Loosen drain plug to drain lubrication oil from PTO case. 6 Lubrication oil: Approx. 6 ¬ 2. Case Remove mounting bolts, then remove case (1) by using forcing screw. fl Check the number and thickness of the shims. 3. Gear assembly Remove gear assemblies (2), (3), and (4). fl Use a puller to remove each gear assemblies. fl To remove gear assemblies (2) and (3), remove nipples (5) and (6) first, then use a puller. 4. Bearings 1) Using puller 1, remove bearing (7) from gears (2) and (3).

2) Remove snap ring (8). 3) Using puller 1, remove bearings (9) and (10) from gear (4).

4) Remove snap ring (11) from case (1). 5) Remove outer race (12).

30-30

PC600-6

DISASSEMBLY AND ASSEMBLY

PTO

5. Oil seal Remove oil seal (13) from case (14).

PC600-6

30-31

DISASSEMBLY AND ASSEMBLY

PTO

ASSEMBLY OF PTO ASSEMBLY fl Clean all parts, and check for dirt or damage. Coat the sliding surfaces of all parts with engine oil before installing. 1. Oil seal Press fit oil seal (13) to case (14). 2 Fitting surface of oil seal: Adhesive (LG-6) fl Do not apply the adhesive to the oil seal lip and shaft. fl Supply grease (G2-LI) by about 40 – 60%. 2. Bearings 1) Press fit outer race (12) to case (1). 2) Install snap ring (11). 2 Pin: Grease (G2-LI)

3) Press fit bearings (9) and (10) to gear (4). 4) Install snap ring (8).

5) Press fit bearing (7) to gears (2) and (3).

30-32

PC600-6

DISASSEMBLY AND ASSEMBLY

PTO

3. Gears 1) Install nipples (5) and (6) to case (14). 3 Nipple: 2.9 – 5.9 Nm {0.4 – 0.6 kgm} 2) Install gears (4), (3), and (2). ﬂ Rotate gears and check that each gear rotates smoothly, then coat with red lead to check tooth contact. 2 Rolling surface of bearing: Grease (G2-LI)

4. Case Install case (1). 2 Fitting face of case: Gasket sealant (LG-1) 3 Mounting bolt: 73.5 – 98 Nm {7.5 – 10.0 kgm} •

Refilling with oil (PTO case) Tighten the drain plug, then add oil through oil filler to the specified level. ﬂ Use oil EO30-CD in summer and EO10-CD in winter. -

PC600-6

PTO case: Approx. 6 ¬

30-33

DISASSEMBLY AND ASSEMBLY

FUEL TANK

REMOVAL OF FUEL TANK ASSEMBLY ¤ Disconnect the cable from the negative (–) terminal of the battery. 1. Open drain plug to drain fuel. 6 Fuel tank: 880 ¬ (When full) 2. Remove handrail (1), then remove cover assembly (2). 4 Cover assembly: 80 kg 3. Disconnect wiring connector (P06) from the fuel tank. 4. Disconnect fuel feed hose (3) and fuel return hose (4). 5. Lift off fuel tank assembly (5).

4 Fuel tank assembly: 500 kg

INSTALLATION OF FUEL TANK •

Carry out installation in the reverse order to removal.

1 3 Fuel tank mounting bolt: 319 – 608 Nm {32.5 – 62 kgm}

30-34

PC600-6

DISASSEMBLY AND ASSEMBLY

FINAL DRIVE

DISASSEMBLY OF FINAL DRIVE ASSEMBLY 1. Draining oil Set drain plug (1) at bottom and remove it to drain oil from final drive case. 6 Final drive case: 10.5 ¬ (Each side)

2. Cover 1) Using tools J1 and J2, support final drive assembly. ﬂ Install by using the sprocket mounting bolt holes on the hub.

2) Using eyebolts 1, lift off cover (2).

3. Spacer Remove spacer (3). 4. No. 1 sun gear shaft Remove No. 1 sun gear shaft (4).

PC600-6

30-35

DISASSEMBLY AND ASSEMBLY

FINAL DRIVE

5. No. 1 carrier assembly 1) Lift off No. 1 carrier assembly (5).

2) Disassemble No. 1 carrier assembly as follows. i) Push pin (6) in shaft (7). ii) Remove shaft (7) from carrier (8).

iii) Remove two thrust washers (9), planetary gear (10), and bearing (11).

6. No. 1 ring gear Using eyebolts 2, lift off No. 1 ring gear (12).

30-36

PC600-6

DISASSEMBLY AND ASSEMBLY

FINAL DRIVE

7. No. 2 ring gear Using eyebolt 3, lift off No. 2 ring gear (13).

8. Thrust washer Remove thrust washer (14). 9. No. 2 sun gear Remove No. 2 sun gear (15).

10. Thrust washer Remove thrust washer (16).

11. No. 2 carrier assembly 1) Lift off No. 2 carrier assembly (17).

PC600-6

30-37

DISASSEMBLY AND ASSEMBLY

FINAL DRIVE

2) Disassemble No. 2 carrier assembly as follows. i) Push pin (18) in shaft. ii) Remove shaft (19) from carrier (20).

iii) Remove two thrust washers (21), planetary gear (22), and bearing (23).

12. Retainer 1) Sling the final drive assembly and remove it temporarily. 2) Remove tool J2 and install tool J3, then install final drive assembly to tool J3. ﬂ Install tool J3 to the surface of the travel motor case.

3) Remove 22 mounting bolts (24) and 14 mounting bolts (25), then remove retainer (26).

30-38

PC600-6

DISASSEMBLY AND ASSEMBLY

FINAL DRIVE

4) Remove spacer (27).

13. Hub assembly 1) Using tool J4, remove hub assembly (28) from travel motor assembly (29). 2) Using eyebolts 4, lift off hub assembly (28).

3) Disassemble hub assembly as follows. i) Remove floating seal cover assembly (30) from hub (31).

ii) Remove bearings (32) and (33) from hub (30).

PC600-6

30-39

DISASSEMBLY AND ASSEMBLY

FINAL DRIVE

14. Floating seal 1) Remove floating seal (34) from cover (35).

2) Remove floating seal (36) from travel motor (37).

30-40

PC600-6

DISASSEMBLY AND ASSEMBLY

FINAL DRIVE

ASSEMBLY OF FINAL DRIVE ASSEMBLY ﬂ Clean all parts, and check for dirt or damage. Coat the sliding surfaces of all parts with engine oil before installing. 1. Travel motor assembly Install travel motor assembly to tools J1 and J3.

2. Floating seal 1) Using tool J5, install floating seal (36) to travel motor (37). fl Remove all oil and grease from the Oring and O-ring contact surface, and dry the parts before installing the floating seal. fl After installing the floating seal, check that the angle of the floating seal is within 1 mm. 2) Using tool J5, install floating seal (34) to cover (35). fl Observe the precautions for installation in 1) above. 3. Hub assembly 1) Assemble the hub assembly as follows. i) Using push tool 5, press fit bearing (32) to hub (29). fl Similarly, press fit bearing (33). fl Press fit the bearing until it fits to the hub.

ii) Install floating seal cover assembly (30) to hub (31). 2 Cover fitting face: Gasket sealant (LG-6) 3 Mounting bolt: 98 – 123 Nm {10 – 12.5 kgm}

PC600-6

30-41

DISASSEMBLY AND ASSEMBLY

FINAL DRIVE

2) Using eyebolts, sling and install hub assembly (28) to travel motor assembly . 3) Using tool J6, press fit the inner race of bearing (32). fl Before press fitting, rotate the hub assembly by two – three turns on the travel motor. 4) Under the condition of 3) above, measure distance a between the inner race of the bearing and retainer fitting face with depth gauge or caliper 6. fl Press fitting force: 22 – 25 kN {2.2 – 2.6 ton} fl Calculate the thickness of spacer (27) by the following formula. Thickness of spacer = Distance a – (0.10 to 0.15) fl Distance a (Standard): 3.5 mm fl Thickness of spacer (Standard): t = 3.4 mm fl Thicknesses of spacer: t = 3.25, t = 3.3, t = 3.35, t = 3.4, t = 3.45, t = 3.5, t = 3.55

3. Retainer 1) Install spacer (27) selected by step 2)-4) above.

2) Install retainer (26) and tighten 22 mounting bolts (24) and 14 mounting bolts (25). 2 Mounting bolts (24), (25): Thread tightener (LT-2) 3 Mounting bolts (24), (25): 853 – 931 Nm {87 – 95 kgm}

30-42

PC600-6

DISASSEMBLY AND ASSEMBLY

FINAL DRIVE

4. Measurement of tangential force Using push-pull scale 7, measure tangential force of hub in its rotating direction on motor case. fl Measure the tangential force at the sprocket mounting hole on the hub. fl Tangential force: 620 N {63 kg} max. fl Measure the maximum tangential force when the hub starts rotating.

5. No. 2 carrier assembly 1) Sling the final drive assembly and move it temporarily. 2) Remove tool J3 from tool J1 and install it to tool J2, then install final drive assembly to tool J2. ﬂ Install by using the sprocket mounting bolt holes on the hub.

3) Assemble No. 2 carrier assembly as follows. ﬂ There is caulking left at the pin fitting part of the carrier. Remove the swelled part inside the hole in advance. i) Install bearing (23) and two thrust washers (21) to planetary gear (22), then install them to carrier (20).

ii) Tap shaft (19) to install it to carrier (20). ﬂ When installing shaft (19), rotate planetary gear (22), and take care not to damage the thrust washers. iii) Insert pin (18). ﬂ For precautions when inserting the pin, see the next page.

PC600-6

30-43

DISASSEMBLY AND ASSEMBLY

FINAL DRIVE

fl When inserting the pin, assemble so that the 3 notched parts (portion a) on the circumference on the pin do not overlap the thin metal part (portion b) of the carrier. (Basically, the inside of the chassis (direction A) is the thin metal side). However, with the actual part, the thin metal may be on the opposite side, so check the part and make sure when assembling that the protruding parts of the pin is not at the same place as the thin metal. fl After inserting the pin, caulk the pin portion of the carrier. fl After assembling the carrier assembly, check that planetary gear (22) rotates smoothly. 4) Sling and install No. 2 carrier assembly (17).

6. Thrust washer Install thrust washer (16).

7. No. 2 sun gear Install No. 2 sun gear (15). 8. Thrust washer Install thrust washer (14).

30-44

PC600-6

DISASSEMBLY AND ASSEMBLY

FINAL DRIVE

9. No. 2 ring gear 1) Install O-ring to hub. 2) Using eyebolts 3, sling and install No. 2 ring gear (13). ﬂ Do not apply gasket sealant to the fitting faces of the hub and No. 2 ring gear. ﬂ Degrease the fitting faces of the hub and No. 2 ring gear.

ﬂ Install the ring gear with the identification cut b up.

10. No. 1 ring gear Using eyebolts 2, sling and install No. 1 ring gear (12). 2 Fitting faces of No. 1 ring gear and No. 2 ring gear: Gasket sealant (LG-6)

11. No. 1 carrier assembly 1) Assemble No. 1 carrier assembly as follows. ﬂ Caulking remains at the pin fitting part of the carrier. Remove the swelled part inside the hole in advance. i) Install bearing (11) and two thrust washers (9) to planetary gear (10), then install them to carrier (8). ii) Tap shaft (7) to install it to carrier (8). ﬂ When installing shaft (7), rotate planetary gear (10), and take care not to damage the thrust washers.

PC600-6

30-45

DISASSEMBLY AND ASSEMBLY

FINAL DRIVE

iii) Insert pin (6). fl When inserting the pin, assemble so that the 3 notched parts (portion c) on the circumference on the pin do not overlap the thin metal part (portion d) of the carrier. (Basically, the inside of the chassis (direction B) is the thin metal side). However, with the actual part, the thin metal may be on the opposite side, so check the part and make sure when assembling that the protruding parts of the pin is not at the same place as the thin metal. fl After inserting the pin, caulk the pin portion of the carrier. fl After assembling the carrier assembly, check that planetary gear (10) rotates smoothly.

2) Sling and install No. 1 carrier assembly (5).

12. No. 1 sun gear shaft Install No. 1 sun gear shaft (4). 13. Spacer Install spacer (3).

30-46

PC600-6

DISASSEMBLY AND ASSEMBLY

FINAL DRIVE

14. Cover 1) Using eyebolts 1, sling and install cover (2). 2 Fitting face of cover: Gasket sealant (LG-6) 2) Tighten the cover mounting bolts in the following order. 3 Cover mounting bolt: First time: 98 Nm {10 kgm} Second time: Tighten by 150 degrees. (Make marks on each bolt and the cover with paint, then tighten the bolt by 144 – 155 degrees with tool J7.) •

Refilling with oil 1) Tighten drain plug (1) and remove oil filler plug (38). 3 Drain plug: 59 – 78 Nm {6 – 8 kgm} 2) Set cover with ”TOP” position up, and supply oil up to bottom of oil filler. -

Final drive case (Each side): Approx. 10.5 ¬ (EO30-CD) 3) Tighten oil filler plug (38). 3 Oil filler plug: 59 – 78 Nm {6 – 8 kgm} ﬂ After installing the final drive assembly to the machine, check the oil level again by the above method.

PC600-6

30-47

DISASSEMBLY AND ASSEMBLY

TRAVEL MOTOR

DISASSEMBLY OF TRAVEL MOTOR ASSEMBLY S25

1. Travel motor assembly Set travel motor assembly (1) to tool S25.

CLP00726

2. Plugs, valve 1) Remove plug (2), then remove spring (3) and check valve (4). 2) Remove plug (5), then remove spring (6), piston (7), spring (7-1), piston (7-2) and spool (8). 3) Remove plug (8-1), then remove spring (8-2) and spool (8-3). 4) Remove safety valve (9).

30-48

PC600-6

DISASSEMBLY AND ASSEMBLY

TRAVEL MOTOR

5) Remove plug (10), then remove regulator valve (11) and spring (12). 6) Remove plug (13). 7) Remove plug (14), then remove ball (15). 8) Remove plug (16), then remove valve (17). 9) Remove plug (18). 10) Remove plugs (20), (21), and (22), then remove bleeder (24).

3. End cover assembly Using tool S26, lift off end cover assembly (25). ﬂ The valve plate may be stuck to the rear face, so be careful not to drop it.

4. Regulator piston Remove screw (26), pull out pin (27), then remove regulator pistons (28).

28 27

26 CKP00777

5. Valve plate, spring 1) Remove valve plate (29). ﬂ When using again, keep in a safe place and be careful not to scratch or damage the cylinder block contact surface. 2) Remove brake pistons (30).

30 CLP00730

PC600-6

30-49

DISASSEMBLY AND ASSEMBLY

TRAVEL MOTOR

6. Center shaft, piston 1) Remove cylinder block (31). 2) Remove spring (32) and center ring (33).

CLP00731

3) Using tool S27, remove 7 mounting screws, then remove retainer (34), center shaft (35), and pistons (36) as one assembly. 4) Remove center shaft (35) and pistons (36) from retainer (34).

CLP00732

S27 36

7. Brake piston, discs, plates 1) Set tool S28 to port hole for brake piston. 2) Apply pressure gradually until brake piston (37) comes up. ﬂ Be careful that the air pressure is not too high. The brake piston will fly out. 3) Lift off brake piston (37).

S28

37 37

CLP00734

4) Remove plates (38) and discs (39) in order. ﬂ Plates : 5 ﬂ Discs : 4

CLP00733

CLP00735

CLP00736

30-50

PC600-6

DISASSEMBLY AND ASSEMBLY

8. Oil seal 1) Turn over tool S25. 2) Remove snap ring (40), then remove cover (41). 3) Remove oil seal (42) from cover (41).

TRAVEL MOTOR

41 40

42 41 CLP00737

CLP00738

9. Drive shaft, bearing assembly 1) Rotate tool S25 90° and set opening of motor case facing side. 2) Tap end face of drive shaft with plastic hammer to remove drive shaft and bearing assembly (43).

10. Disassembly of drive shaft, bearing assembly 1) Remove snap ring (44), then remove 2 spacers (45).

CKP00740

2) Set drive shaft and bearing assembly (43) to tool S29. 3) Set push tool 1 to drive shaft, then push with press to remove drive shaft and main bearing inner race assembly.

q 43

S29

CLP00741

PC600-6

30-51

DISASSEMBLY AND ASSEMBLY

4) Remove sub bearing inner race (46), outer race (47), retainer (48), and main bearing outer race (49).

TRAVEL MOTOR

46 47

48 49

CKP00742

5) Remove main bearing inner race (51) from drive shaft (50). 50 51

CLP00743

30-52

PC600-6

DISASSEMBLY AND ASSEMBLY

TRAVEL MOTOR

ASSEMBLY OF TRAVEL MOTOR ASSEMBLY S30

Precautions when assembling 1) Clean all parts, remove all burrs, and check for dirt or damage. 2) Coat the rotating and sliding surfaces of all parts with engine oil (EO10-CD) before installing. 3) Before coating any part with thread tightener, remove all oil and grease from the thread and tap hole, and dry completely.

CKP00744

1. Drive shaft assembly 1) Using tool S30, press fit main bearing (51) to drive shaft (50). ﬂ Press fit until the end face of the inner race is in tight contact with the end face of the drive shaft. ﬂ Press-fitting load : 47.6 kN {4,850 kg} 2 Press-fitting surface of bearing : Lubricating oil (EO10-CD) 2) Install main bearing outer race (49), retainer (48), and sub bearing outer race (47).

47 48 49

CKP00745

3) Using tool S31, press fit sub bearing inner race (46) to drive shaft (50). ﬂ Press fit until the roller of the inner race is in tight contact with the outer race. ﬂ Press-fitting load : 21.7 kN {2,208 kg} 2 Press-fitting surface of bearing : Lubricating oil (EO10-CD)

S31 46

CKP00746

2. Adjusting end play of shaft 1)

Select 2 spacers (45) as follows, and adjust clearance “t” between retainer (48) and sub bearing outer race (47) to make clearance of 0.05 – 0.25 mm.

45 47 48

CKP00747

PC600-6

30-53

DISASSEMBLY AND ASSEMBLY

TRAVEL MOTOR

2) Measure dimension “a” between sub bearing inner race (46) and snap ring (44), and select 2 spacers (45) from table below. ﬂ Check that snap ring (44) is fitted securely in the mounting groove.

44 46

Unit: mm Necessary spacer Measurement thickness No. of dimension (including “a” thickness of 2 spacers)

Spacer thickness: 2.9

5.850 – 6.049

5.8

ﬁ

6.050 – 6.244

6.0

6.250 – 6.449

6.2

6.450 – 6.649

6.4

6.650 – 6.849

6.6

Part No. of spacer

Necessary spacers: 2 spacers marked with ﬁ in table below 3.1

3.3

ﬁ ﬁ

CKP00748

ﬁ ﬁ

ﬁ

706-88-40440 706-88-40450 706-88-40460

3) Install selected spacers (45), then install snap ring (44). ﬂ Check that snap ring (44) is fitted securely in the mounting groove.

CKP00740

4) Push out drive shaft as follows. i) Support main bearing outer race (49) with tool S29. ii) Apply load to drive shaft (50) until top surface of sub bearing inner race (46), spacer (45), and snap ring (44) are all in tight contact with each other. ﬂ Load when pushing out: 21.7 kN {2,208 kg} iii) Check that 2 spacers (45) are in tight contact and cannot be rotated by hand. ﬂ If the spacers can be rotated or are not fully in tight contact, adjust again from Step 2).

30-54

44 46

S29 CKP00749

PC600-6

DISASSEMBLY AND ASSEMBLY

TRAVEL MOTOR

3. Shaft, center shaft, cylinder block 1) Set center shaft (35) and pistons (36) in position on retainer (34), then install drive shaft (43).

43 CLP00750

2) Using tool S27, tighten mounting screws. ﬂ Replace the mounting screws with new parts. 2 Mounting screw : Thread tightener (LT-2) 3 Mounting screw: 1st step : Max. 0.98 Nm {0.1 kgm} 2nd step: 7.8 – 9.8 Nm {0.8 – 1.0 kgm} 3rd step: 22.6 – 26.5 Nm {2.3 – 2.7 kgm}

fl Order for tightening: 1-4-7-3-6-2-5 Tighten in three steps as shown above. fl After tightening, wipe off any adhesive that has been squeezed out. fl Check that the large ball of the piston and the center shaft move smoothly.

S27

CLP00751

t r CKP00752

3) Measure play of piston (36) in axial direction. ﬂ Standard play of piston in axial direction: Max. 0.8 mm

PC600-6

30-55

DISASSEMBLY AND ASSEMBLY

4) Assemble spring (32) and center ring (33) in turn in center shaft hole of cylinder block (31).

TRAVEL MOTOR

32 CKP00754

5) Turn over drive shaft assembly (43), and use eyebolt 2 (10 x 1.5 mm, length below head: approx. 85 mm) to raise drive shaft assembly. 6) Align center shaft and piston with each hole in cylinder block (31), then install drive shaft (43).

31 CLP00755

4. Drive shaft, cylinder block assembly 1) Set motor case (52) to tool S25. 2) Raise drive shaft and cylinder block assembly (53) with tool S32-2 and install motor case (52). ﬂ Align the protrusions on the retainer (4 places around circumference) with the oil grooves in the case (4 places around circumference) and install.

S32-2 53 S25

52 CLP00756

3) Set tool S32-1 in position and hold cylinder block (31) at center position.

31 S32-1

CLP00757

30-56

PC600-6

DISASSEMBLY AND ASSEMBLY

TRAVEL MOTOR ASSEMBLY

4) Install tool S32-3 to drive shaft, then press fit until end face of main bearing outer race is in tight contact with case. ﬂ Press-fitting load: 13.3 kN {1,360 kg}

S32-3

CLP00758

5. Plate, disc, piston 1) Assemble plates (38) and discs (39) in order. fl Plates : 5 fl Discs : 4 fl Do not wash the discs in trichlene or drizol, or blow strongly with air. 2 Front face of disc: Lubricating oil (EO10-CD)

•

Method of placing plates and discs on top of each other. i) Align cutout arc teeth areas G, H, and I of discs (39). ii) Protrusions A, B, C, D, E, and F on plates (38) can be set at any position in relation to positions G, H, and I of discs.

2) Fit O-ring and backup ring to brake piston (37). ﬂ Assemble the backup ring in the direction shown in the diagram.

PC600-6

30-57

DISASSEMBLY AND ASSEMBLY

3) Install brake piston (37) to motor case (52), and determine position with tool S33. ﬂ Install tool S33 in the position shown in the diagram on the right in relation to port hole “a” for the brake piston.

TRAVEL MOTOR

S33 CLP00762

4) Install 6 brake springs (30). 30

30 CLP00763

6. Dowel pin Using tool S34, press fit dowel pin (54) to end cover (25) to dimension shown in diagram. ﬂ Install with the groove end at the brake piston end.

30-58

PC600-6

DISASSEMBLY AND ASSEMBLY

TRAVEL MOTOR

7. Regulator piston Insert regulator piston (28) in piston hole, then assemble pin (27) and secure with screw (26). fl Assemble pin (27) from the opposite side to regulator piston counterbore “a”. fl Apply one drop of adhesive to screw (26) at the point shown in the diagram on the right. fl Be careful not to apply too much adhesive. 2 Screw: Thread tightener (LT-2) 3 Screw: 25.5 – 31.4 Nm {2.6 – 3.2 kgm} fl After assembling the screw, check dimension L between the end face of the piston and the rear end of the screw. fl Dimension L : 63.8 mm

8. Valve plate 1) Remove plugs (22) from end cover assembly (25).

22 25

CKP00778

2) Install valve plate (29) to end cover assembly (25). ﬂ Align the hole in the valve plate exactly with pin (27) of the regulator piston. ﬂ Check that the valve plate moves smoothly in the end cover mounting groove. 3) Pass tool S35 through plug hole and secure valve plate (29) in position.

S35 S35 25 CLP00779

PC600-6

30-59

DISASSEMBLY AND ASSEMBLY

9. End cover 1) Set tool S36 to center shaft (35).

TRAVEL MOTOR

S36 35

CLP00780

2) Using tool S26, raise end cover assembly (25). 3) Lower end cover assembly (25) and pass tool S36 through hole in pin (27) of regulator piston. fl Check that the valve plate is in tight contact with the end cover. 4) Check that valve plate does not slip out of position and lower end cover assembly until it is in tight contact with cylinder block, then temporarily tighten 4 mounting bolts (55) on opposite sides to secure in position. 5) Tighten mounting bolts (55) uniformly until clearance “a” at mating surface is approx. 12 mm. fl Measure the clearance at several places around the circumference to check that the motor case and end cover are parallel. 6) Remove tools S35 and S36. fl When doing this, check that the valve plate moves to the maximum end and makes a sound of contact. fl Check that the regulator piston moves to the maximum end. 7) Tighten mounting bolts (55) uniformly until the plate is fixed firmly. fl If the mounting bolts become heavy before they contact the seat, repeat the procedure again from Step 2). 8) Remove tool S26. 9) Tighten all mounting bolts (55). fl Tighten the mounting bolts uniformly on opposite sides. 3 Mounting bolt : 520 – 618 Nm {53 – 63 kgm}

30-60

PC600-6

DISASSEMBLY AND ASSEMBLY

TRAVEL MOTOR

10. Valve, plugs 1) Install bleeder (24). 3 Bleeder: 27.4 – 35.3 Nm {2.8 – 3.6 kgm} 2) Install plug (22). 3 Plug : 7.8 – 13.7 Nm {0.8 – 1.4 kgm} 3) Install plug (21). 2 Plug : Thread tightener (Loctite 638 or 648) 3 Plug : 186 – 245 Nm {19 – 25 kgm} 4) Install plugs (20). 2 Plug : Thread tightener (Loctite 638 or 648) 3 Plug : 147 – 186 Nm {15 – 19 kgm} 5) Assemble valve (17), then tighten plugs (18) and (16). 2 Plug : Thread tightener (Loctite 638 or 648) 3 Plug : 19.6 – 27.5 Nm {2 – 2.8 kgm} 6) Assemble ball (15), then tighten plug (14). 2 Plug : Thread tightener (Loctite 638 or 648) 3 Plug : 19.6 – 27.5 Nm {2 – 2.8 kgm}

PC600-6

30-61

DISASSEMBLY AND ASSEMBLY

TRAVEL MOTOR

7) Install plug (13). 2 Plug : Thread tightener (Loctite 638 or 648) 3 Plug : 873 – 1,099 Nm {89 – 112 kgm} 8) Assemble spring (12) and regulator valve (11), then tighten plug (10). 3 Plug : 93.2 – 245 Nm {9.5 – 25 kgm} 9) Install safety valve (9). 3 Safety valve assembly : 294 – 343 Nm {30 – 35 kgm} 10) Assemble spool (8), piston (7-2), spring (71), piston (7), and spring (6), then tighten plug (5). 2 Plug : Thread tightener (Loctite 638 or 648) 3 Plug : 373 – 466 Nm {38 – 47.5 kgm} 11) Assemble spool (8-3) and spring (8-2), then tighten plug (8-1). 2 Plug : Thread tightener (Loctite 638 or 648) 3 Plug : 98 – 123 Nm {10 – 12.5 kgm} 12) Assemble check valve (4) and spring (3), then tighten plug (2). 2 Plug : Thread tightener (Loctite 638 or 648) 3 Plug : 324 – 402 Nm {33 – 41 kgm}

11. Measuring drive shaft rotating torque 1) Using tool S37, apply pressure through port B to release brake. ﬂ Brake release pressure : 2.5 ± 0.5 MPa {25 ± 5 kg/cm2}

2) Using tool S38, rotate drive shaft at low speed (5 sec/1 turn) and measure rotating torque and variation. ﬂ Standard value for rotating torque : 7.8 – 19.6 Nm {0.8 – 2.0 kgm} ﬂ Variation range : Max. 1.5 Nm {0.15 kgm}

S38

CLP00768

30-62

PC600-6

DISASSEMBLY AND ASSEMBLY

12. Oil seal 1) Using tool S39, press fit oil seal (42) to cover (41). 2 Lip of oil seal : Grease (G2-LI-S) 2) Install cover (41), and secure with snap ring (40). ﬂ Check that the snap ring is fitted securely in the mounting groove.

TRAVEL MOTOR

S39 40

41 42

41 CKP00769

CLP00737

13. Checking performance Carry out a bench test to check the performance.

PC600-6

30-63

DISASSEMBLY AND ASSEMBLY

REVOLVING FRAME

REMOVAL OF REVOLVING FRAME ASSEMBLY 1. Remove work equipment assembly from chassis. For details, see REMOVAL OF WORK EQUIPMENT ASSEMBLY. 2. Remove counterweight assembly. For details, see REMOVAL OF COUNTERWEIGHT ASSEMBLY. 3. Disconnect grease tube from swing circle. 4. Leave 3 or 4 mounting bolts (1) each at front and rear of revolving frame, and remove other mounting bolts. 1 ﬂ Start the engine and swing the revolving frame while removing the bolts. ﬂ If you do not start the engine, remove the swing motor and use a crane to swing the revolving frame. 5. Disconnect all of swivel joint top pipes (2). 6. Pull out pin (3), and move link (4) towards frame.

7. Revolving frame assembly 12 1) Fit wires to counterweight mounting frame and boom mount, then sling revolving frame assembly. 2) Remove remaining mounting bolts and lift off revolving frame assembly (5). ﬂ Check that the wire is not damaged before using it, and put protective material at the corners. ﬂ Adjust the tilt of the revolving frame with a lever block. 4 Revolving frame assembly: Approx. 11,000 kg

30-64

PC600-6

DISASSEMBLY AND ASSEMBLY

REVOLVING FRAME

INSTALLATION OF REVOLVING FRAME ASSEMBLY •

Carry out installation in the reverse order to removal.

1 2 Mounting bolt: Thread tightener (LT-2) 3 Mounting bolt: 1,520 – 1,910 Nm {155 – 195 kgm} 2 2 Swing circle top surface: Gasket sealant (LG-6)

PC600-6

30-65

DISASSEMBLY AND ASSEMBLY

SWING MOTOR

REMOVAL OF SWING MOTOR ASSEMBLY ¤ Lower the work equipment completely to the

1. 2.

3. 4. 5. 6.

ground and stop the engine. Then, loosen the oil filler cap slowly to release the pressure inside the hydraulic tank. Remove step (1). Disconnect four hoses (2) between control valve and swing motor. ﬂ Mark all the hoses with tags and plug them. Disconnect two suction hoses (3). Disconnect three swing brake hoses (4). Disconnect two drain hoses (5). Remove hose (6).

7. Lift off swing motor assembly (7).

4 Swing motor assembly: 60 kg (1 unit)

INSTALLATION OF SWING MOTOR ASSEMBLY •

Carry out installation in the reverse order to removal.

1 ﬂ When installing the swing motor assembly, apply gasket sealant. (Apply the gasket sealant around the bolt hole “a” for checking oil among the bolt holes, but do not apply around the other bolt holes.) ﬂ Take care when applying the gasket sealant to the ring gear side. 2 Fitting faces of swing motor assembly: Gasket sealant (LG-6) •

Refilling with oil (Hydraulic tank) Add oil to the specified level from oil filler, and run the engine to circulate the oil through the system. Then, check the oil level.

•

Bleeding air Bleed air from the swing motor. For details, see TESTING AND ADJUSTING, Bleeding air from each part.

30-66

PC600-6

DISASSEMBLY AND ASSEMBLY

SWING MOTOR

DISASSEMBLY OF SWING MOTOR ASSEMBLY 1. Housing assembly 1) Set swing motor assembly (1) to tool FF-1. 2) Remove O-rings (3) and (4) of reverse flow check valve assembly (2).

3) Remove plugs (7) and (8). 4) Remove relief valve assembly (9). 5) Remove plug (10), then remove spring (11) and valve (12). 6) Remove plug (42), then remove spring (43) and valve (44). 7) Rotate tool FF-1 approx. 25° so that mounting surface of safety valve assembly is at bottom.

8) Lift off housing assembly (13). ﬂ The brake spring will fall out, so be careful when removing.

9) Remove valve plate (14) from housing assembly (13). ﬂ If the part is to be used again, keep it in a safe place and be careful not to damage the surface in contact with the cylinder block. 10) Remove bearing (15).

PC600-6

30-67

DISASSEMBLY AND ASSEMBLY

SWING MOTOR

2. Cylinder block Remove cylinder block (16).

3. Spring, center ring Remove spring (17) and center ring (18).

4. Brake piston Using tool FF-10, pump in air and remove brake piston (19). ﬂ If the air is at high pressure, the brake piston may fly out, so hold down the brake piston while carrying out the operation.

5. Piston 1) Using tool FF-2, remove screw. 2) Remove piston (20), center shaft (21), and retainer (22). ﬂ It is prohibited to use the screw again.

30-68

PC600-6

DISASSEMBLY AND ASSEMBLY

SWING MOTOR

6. Brake ring Remove brake ring (23).

7. Discs, plates Remove 4 plates (24), 3 discs (25), and plate (26).

8. Oil seal 1) Remove snap ring (27), then remove plate (28). 2) Remove oil seal (29).

9. Drive shaft 1) Using tool 1, push drive shaft and bearing assembly (30) with press and remove.

PC600-6

30-69

DISASSEMBLY AND ASSEMBLY

SWING MOTOR

2) Disassemble drive shaft assembly as follows. i) Remove snap ring (31) from drive shaft (32). ii) Remove spacer (33). iii) Remove bearing (34) and outer race (35). iv) Remove seat (36), 2 springs (37), and spacer (38). v) Remove outer race (39) and bearing (40).

30-70

PC600-6

DISASSEMBLY AND ASSEMBLY

SWING MOTOR

ASSEMBLY OF SWING MOTOR ASSEMBLY • •

Clean all parts and correct any burrs. Coat the rotating surfaces and sliding surfaces of all parts with engine oil (EO10-CD) before assembling.

1. Drive shaft assembly 1) Assemble drive shaft assembly as follows. i) Using tool FF-5, press fit bearing (40) to drive shaft (32) with press. fl Press fit until the end face of the bearing inner race is in tight contact with the drive shaft. fl Press-fitting load: 5.12 – 26.1 kN {522 – 2660 kg} ii) Assemble outer race (39). iii) Install spacer (38), 2 springs (37), and seat (36). fl Install the two springs so that they both face the outside. iv) Assemble outer race (35). v) Using tool FF-6, press fit bearing (34) to drive shaft (32) with press. fl Press fit until seat (36) is in tight contact with spacer (38). fl Press-fitting load: 14.8 kN {1505 kg} vi) Measure clearance a between end face of inner race of bearing (34) and snap ring groove of shaft, and select spacer (33) from chart below. Dimension a (mm)

Spacer thickness (mm)

– 3.45

3.1

3.45 – 3.85

3.4

3.85 –

3.7

vii) Assemble spacer (33) selected in Step vi). ﬂ Standard thickness: 3.4 mm viii)Install snap ring (31). ﬂ Check that the snap ring is fitted securely in the groove.

PC600-6

30-71

DISASSEMBLY AND ASSEMBLY

SWING MOTOR

2) Pushing out drive shaft i) Support outer race (39) of drive shaft and bearing assembly (30). ii) Using tool 1, push out drive shaft with a press until end face of inner race of bearing (34) and spacer (33) and snap ring (31) are in tight contact. ﬂ Load when pushing-out: 4.19 – 16.0 kN {427 – 1630 kg} ﬂ Check that spacer (33) is in tight contact and cannot be rotated by hand.

3) Put drive shaft and bearing assembly (30) on case (41), and using tool 2, press fit with press. ﬂ Press fit until end face of outer race (39) is in tight contact with case (41). ﬂ Press-fitting load: 10.2 kN {1.037 kg}

2. Measurement of drive shaft rotation torque 1) Coat bearing thoroughly with grease. 2) Using tool FF-8, rotate drive shaft at approx. 1 turn per 5 seconds, and measure rotation torque of drive shaft. ﬂ Rotation torque : 0.98 – 1.57 Nm {0.1 – 0.16 kgm} ﬂ If the rotation torque of the drive shaft is not within the above range, replace bearing (40) and outer race (39) with new parts.

3. Oil seal 1) Using tool FF-9, install oil seal (29) to case (41). ﬂ Press fit until the depth of the oil seal from the end face of the cover is 14 ± 0.1 mm. ﬂ Clean the oil seal lip. 2 Oil seal lip : Grease (G2-LI-S)

30-72

PC600-6

DISASSEMBLY AND ASSEMBLY

SWING MOTOR

2) Assemble plate (28). 3) Install snap ring (27).

4. Discs, plates Assemble plate (26), then assemble discs (25) and plates (24) in order. ﬂ Do not wash the discs in trichloroethylene or drizol, or blow strongly with air. 2 Front face of disc : Lubricating oil (EO10-CD)

•

Method of placing plates and discs on top of each other. 1) Align spline teeth notches G, H, and I of the discs. 2) Protrusions A, B, C, D, E, and F on the outside of the plates can be set at any position in relation to positions G, H, and I of discs.

5. Brake ring Fit O-ring and install brake ring (23).

PC600-6

30-73

DISASSEMBLY AND ASSEMBLY

SWING MOTOR

6. Piston assembly 1) Assemble piston assembly (20) and center shaft (21) to retainer (22), then install as one unit to drive shaft. 2) Using tool FF-2, tighten screws. 2 Screw: Thread tightener (LT-2, Loctite No. Adhesive (Loctite 262), or equivalent) 3 Screw: 1st step:Tighten temporarily to max. 0.98 Nm {0.1 kgm} 2nd step: 3.92 – 5.88 Nm {0.4 – 0.6 kgm} 3rd step: 11.77 – 14.71 Nm {1.2 – 1.5 kgm} (Target: 13.24 Nm {1.35 kgm}) fl Remove all oil and grease from the threads (male and female). fl Order for tightening: 1-4-7-3-6-2-5 fl After tightening, wipe off any thread tightener that is squeezed out. fl After tightening, check that the large ball portion of piston assembly (20) and center shaft (21) move smoothly. fl After tightening, check that play of piston assembly (20) in axial direction is 0.35 mm or less.

7. Brake piston Fit O-ring and install brake piston (19). ﬂ Assemble so that the groove in the piston is aligned with the dowel pin in the housing. 8. Center ring, spring Assemble center ring (18) and spring (17) to center shaft (21).

30-74

PC600-6

DISASSEMBLY AND ASSEMBLY

SWING MOTOR

9. Housing assembly 1) Press fit bearing (15) to housing assembly (13). 2) Align valve plate (14) with dowel pin and install. ﬂ Check that there is no play between the housing and mounting surface.

3) Install cylinder block (16). 4) Install brake spring (45).

10. Brake case assembly 1) Support with block 3 so that housing assembly (13) is at an angle of approx. 25° with relief valve assembly at top. 2) Fit O-ring and align dowel pin with brake piston groove, then using eyebolts and nut 4, raise brake case assembly (46) and install. 3) After tightening brake case mounting bolts temporarily, install swing motor assembly to tool FF-1. ﬂ Be careful not to damage the dowel pin, brake piston, and bearing. ﬂ Tighten the mounting bolts uniformly. If the mounting bolts become heavy, do not forcibly tighten; remove the brake case assembly and start again. 2 Mating surface of brake case : Gasket sealant (LG-7 (Three Bond 1207C), or Seal End No. 242, or Loctite No. 572, No. 575) 3 Mounting bolt : 157 – 196 Nm {16 – 20 Nm}

PC600-6

30-75

DISASSEMBLY AND ASSEMBLY

SWING MOTOR

4) Assemble valve (44) and spring (43), then fit O-ring and install plug (42). 3 Plug : 58 – 78 Nm {6 – 8 kgm} 5) Assemble valve (12) and spring (11), then fit O-ring and install plug (10). • Remove all oil and grease from the plug and thread end (housing), then dry. • Position for coating with thread tightener: Coat with 2 drops (approx. 0.04 g) at position b (2 – 3 mm from tip of plug thread) 2 : Thread tightener (Loctite No. 638 or No. 648) 3 Plug : 324 – 402 Nm {33 – 41 kgm} 6) Fit backup ring and O-ring, and install relief valve assembly (9). 3 Relief valve : 226 – 284 Nm (23 – 29 kgm} 7) Fit O-ring and install plug (8). ﬂ For details of the procedure for coating with thread tightener, see Step 5) above. 2 Plug : Thread tightener (Loctite No. 638 or No. 648) 3 Plug : 34.3 – 44.1 Nm {3.5 – 4.5 kgm} 8) Fit O-ring and install plug (7). 3 Plug : 59 – 186 Nm {6 – 19 kgm}

11. Swing lock valve assembly Fit O-rings (3) and (4), then install swing lock valve assembly (2). 2 Mating face of swing lock valve: (Loctite No. 222 or Seal End No. 242) 3 Mounting bolt: 1st step 15 – 20 Nm {1.5 – 2.0 kgm} 2nd step 27 – 34 Nm {2.8 – 3.5 kgm} fl Tighten the mounting bolts slowly in turn. fl Check that there are no burrs, flashes, or dirt on the mating surface. fl Check that O-rings (3) and (4) have not come out.

30-76

PC600-6

DISASSEMBLY AND ASSEMBLY

SWING MOTOR

12. Measurement of rotation torque of swing motor assembly Set tool FF-8 to drive shaft spline portion, then using tool FF-3, release brake, rotate at approx. 1 turn per 5 seconds, and measure rotation torque. ﬂ The swing motor assembly must rotate at the correct rotation torque and within the range of variation. • Variation : Within 1.47 Nm {0.15 kgm} • Rotation torque : 3.9 – 9.8 Nm {0.4 – 1.0 kgm} • Oil pressure : 2.94 ± 0.49 MPa {30 ± 5 kg/cm2}

PC600-6

30-77

DISASSEMBLY AND ASSEMBLY

SWING MACHINERY

REMOVAL OF SWING MACHINERY ASSEMBLY ¤ Lower the work equipment completely to the ground and stop the engine. Then, loosen the oil filler cap slowly to release the pressure inside the hydraulic tank. 1. Remove step (1). 2. Disconnect four hoses (2) between control valve and swing motor. ﬂ Mark all the hoses with tags and plug them. 3. Disconnect two suction hoses (3). 4. Disconnect three swing brake hoses (4). 5. Disconnect two drain hoses (5). 6. Remove hose (6). 7. Using two forcing screws 1, lift off swing motor and swing machinery assembly (7). 1 4 Swing motor and swing machinery assembly: 440 kg (1 unit)

INSTALLATION OF SWING MACHINERY ASSEMBLY •

Carry out installation in the reverse order to removal.

1 3 Swing motor, swing machinery assembly mounting bolt: 824 – 1,030 Nm {84 – 105 kgm} •

Refilling with oil (Hydraulic tank) Add oil to the specified level from oil filler, and run the engine to circulate the oil through the system. Then, check the oil level.

•

Bleeding air Bleed air from the swing motor. For details, see TESTING AND ADJUSTING, Bleeding air from each part.

30-78

PC600-6

DISASSEMBLY AND ASSEMBLY

SWING MACHINERY

DISASSEMBLY OF SWING MACHINERY ASSEMBLY 1. Draining oil Loosen drain plug and drain oil from swing machinery. 6 Swing machinery case: Approx. 12.8 – 13.1 ¬ 2. Cover Remove mounting bolts, then lift off cover (1).

3. No. 1 carrier assembly. 1) Remove thrust washer (2). 2) Remove No. 1 sun gear (3).

3) Remove No. 1 carrier assembly (4).

4. Disassembly of No. 1 carrier assembly 1) Push in pin (5), and knock out shaft (6) from carrier (7). ﬂ After removing the shaft, remove pin (5). 2) Remove thrust washer (8), gear (9), bearing (10), and thrust washer (11).

CEP00208

PC600-6

30-79

DISASSEMBLY AND ASSEMBLY

SWING MACHINERY

5. Ring gear Lift off ring gear (12).

6. No. 1 sun gear 1) Remove thrust washer (13). 2) Remove button (36) and spacer (14). 3) Remove No. 1 sun gear (15).

3) Remove thrust washer (16). ﬂ Remove No. 2 carrier assembly (17) before removing the thrust washer.

7. No. 2 carrier assembly Lift off No. 2 carrier assembly (17).

30-80

PC600-6

DISASSEMBLY AND ASSEMBLY

8. Disassembly of No. 2 carrier assembly 1) Push in pin (18), and knock out shaft (19) from carrier (17). ﬂ After removing the shaft, remove pin (18). 2) Remove thrust washer (20), gear (21), bearing (22), and thrust washer (23).

SWING MACHINERY

20 21 23 18

9. Pinion shaft assembly 1) Remove bolt (24), then remove holder (25). 2) Remove gear (26).

CEP00213

24 26 25

CEP00214

3) Turn over case and pinion assembly, then remove mounting bolts (28) of cover assembly (27).

CEP00215

4) Turn over case and pinion assembly (29), and set on press stand, then using push tool 1, remove pinion shaft assembly (30) with press. ﬂ Set a wooden block under the press, and be careful not to damage the pinion shaft assembly when removing it.

PC600-6

30-81

DISASSEMBLY AND ASSEMBLY

SWING MACHINERY

10. Disassembly of pinion shaft assembly 1) Using push tool 2, remove cover assembly (27) and bearing (31) from shaft (32). 2) Remove oil seal (33) from cover (27).

27 31 32

27 CEP00218

11. Bearing Using push tool, remove bearing (34) from case (35).

CEP00219

CEP00220

30-82

PC600-6

DISASSEMBLY AND ASSEMBLY

SWING MACHINERY

ASSEMBLY OF SWING MACHINERY ASSEMBLY ﬂ Clean all parts, and check for dirt or damage. Coat the sliding surfaces of all parts with engine oil before installing. 1. Bearing Using push tool 3, press fit bearing (31) to case (35).

2. Cover assembly 1) Using push tool 4, press fit oil seal (33) to cover (27). 2 Outside circumference of oil seal: Gasket sealant (LG-6) ﬂ Be careful not to let the gasket sealant (LG-6) get on the oil seal lip when press fitting.

2) Fit cover assembly (27) to case (35), and tighten mounting bolts (28). fl Be careful not to let the gasket sealant (LG-6) get on the oil seal lip when press fitting. fl Take care that gasket sealant will not be projected into the oil pass. 2 Cover mounting surface: Gasket sealant (LG-6) 3 Mounting bolt: 66.2 ± 7.4 Nm {6.75 ± 0.75 kgm} 2 Oil seal lip: Supply grease (G2-LI) by about 40 – 60%. 3. Case assembly 1) Set case assembly (35) to shaft (32), then using push tool 5, press fit bearing inner race portion. fl When setting the case assembly to the shaft, be extremely careful not to damage the oil seal.

PC600-6

30-83

DISASSEMBLY AND ASSEMBLY

SWING MACHINERY

2) Bearing Using tool F1, press fit bearing (34). ﬂ Press the bearing inner race and outer race at the same time when press fitting. Do not press only the inner race when press fitting. ﬂ After press fitting the bearing, check that the case rotates smoothly.

3) Gear, holder Assemble gear (26), then fit holder (25) and tighten bolt (24). 2 Mounting bolt: Thread tightener (LT-2) 3 Mounting bolt: 179 – 196 Nm {16 – 20 kgm}

24 26 25

CEP00214

4. Assembly of No. 2 carrier assembly ﬂ There are the remains of caulking after fitting the pin at the end of side hole h of the carrier. Remove the swelled part inside the hole in advance. 1) Install bearing (22), upper and lower thrust washers (23) and (20) to gear (21), then install gear assembly to carrier (17).

20 21 23

h CEP00226

2) Align with position of pin holes of shaft and carrier, then tap with a plastic hammer to install shaft (19). fl When installing the shaft, rotate the planetary gear, and be careful not to damage the thrust washer. 3) Insert pin (18). fl After inserting the pin, caulk the pin portion of the carrier. fl After assembling the carrier assembly, check that gear (21) rotates smoothly.

30-84

CEP00227

PC600-6

DISASSEMBLY AND ASSEMBLY

SWING MACHINERY

5. No. 2 carrier assembly Raise No. 2 carrier assembly (17) and install. ﬂ Align the position so that the tip of the gear shaft enters at 4 places, then install.

6. No. 2 sun gear 1) Assemble thrust washer (16). ﬂ Assemble thrust washer (16) before installing No. 2 carrier assembly (17).

2) Install No. 2 sun gear (15) to No. 2 carrier. 3) Install spacer (14) and button (36). 4) Install thrust washer (13).

7. Ring gear Raise ring gear (12) and install.

PC600-6

30-85

DISASSEMBLY AND ASSEMBLY

SWING MACHINERY

ﬂ Apply the gasket sealant around the hole “a” for checking oil, but do not apply around the other holes.) 2 Fitting faces of ring gear and case: Gasket sealant (LG-6)

8. Assembly of No. 1 carrier assembly ﬂ There are the remains of the caulking when the pin is inserted at the end face of hole h at the side of the carrier, so remove the caulked metal from the inside diameter of the hole before starting to assemble. 1) Install bearing (10), upper and lower thrust washers (8) and (11) to gear (9), then install gear assembly to carrier (7).

11 CEP00228

2) Align position of pin holes of shaft and carrier, then tap with a plastic hammer to install shaft (6). fl When installing the shaft, rotate the planetary gear, and be careful not to damage the thrust washer. 3) Insert pin (5). fl After inserting the pin, caulk the pin portion of the carrier. fl After assembling the carrier assembly, check that gear (9) rotates smoothly.

6 CEP00229

9. No. 1 carrier assembly Install No. 1 carrier assembly (4).

30-86

PC600-6

DISASSEMBLY AND ASSEMBLY

SWING MACHINERY

10. No. 1 sun gear 1) Assemble No. 1 sun gear (3) to carrier assembly. 2) Install thrust washer (2).

11. Cover Using tool F2, install cover (1). ﬂ When coating gasket sealant, follow the precautions in item 7. 2 Cover mounting surface: Gasket sealant (LG-6) 3 Mounting bolt: 1st pass: 98 Nm {10 kgm} Second time: Tighten by 80 – 90 degrees. (Make marks on each bolt and the cover with paint, then tighten the bolt by 80 – 90 degrees.)

12. Refilling with oil Tighten drain plug and add engine oil through oil filler. 5

PC600-6

Swing machinery case: Approx. 12.8 ¬ (low level) Approx. 13.1 ¬ (high level)

30-87

DISASSEMBLY AND ASSEMBLY

SWING CIRCLE

REMOVAL OF SWING CIRCLE ASSEMBLY 1. Remove revolving frame assembly. For details, see REMOVAL OF REVOLVING FRAME ASSEMBLY. 2. Remove grease tube from swing circle. 3. Remove mounting bolts (1).

4. Using eyebolts and nut 1, lift of swing circle assembly (2). 2 4 Swing circle assembly: 1,150 kg 5. Remove seal assembly (3).

INSTALLATION OF SWING CIRCLE ASSEMBLY •

Carry out installation in the reverse order to removal.

1 2 Mounting bolt: Thread tightener (LT-2) 3 Mounting bolt: 1,180 – 1,470 Nm {120 – 150 kgm} 2 2 Swing circle mounting surface : Gasket sealant (LG-6) fl Amount of grease (G2-LI) in oil bath: Approx. 31 ¬ fl Coat inside teeth with grease (G2-LI). fl Install the inner ring soft zone position (Smark), directing it to the right side of the machine.

30-88

PC600-6

DISASSEMBLY AND ASSEMBLY

TRACK SHOE

REMOVAL OF TRACK SHOE ASSEMBLY 1. Position master pin ﬂ Move the master pin so that it is midway between the idler and the carrier roller. The track shoe is opened to the rear, so be sure that there is enough space. 2. Loosen track shoe tension. 1 ¤ Never loosen lubricator (1) more than one turn. ﬂ If the track tension is not relieved even when the lubricator is loosened, move the machine backwards and forwards. 3. Using tool R, pull out master pin and insert guide pin. 2

4. Fit block or hydraulic jack 1 (10 ton) under shoe at idler end, then remove guide pin 2. 3 5. Raise tip of track shoe with crane, and move machine slowly to rear to open track shoe assembly (2).

PC600-6

30-89

DISASSEMBLY AND ASSEMBLY

TRACK SHOE

INSTALLATION OF TRACK SHOE ASSEMBLY •

Carry out installation in the reverse order to removal.

1 fl Adjust the track shoe tension. For details, see TESTING AND ADJUSTING, Adjusting track shoe tension. 2 fl Using tool R, press fit the master pin so that it will be projected from the track shoe by 3.7 ± 2 mm. 3 fl Fit seal (3) to the link and couple it with the lower link, then install the guide pin.

30-90

PC600-6

DISASSEMBLY AND ASSEMBLY

ONE LINK

DISASSEMBLY OF ONE LINK IN FIELD 1. Remove shoe of link to be disassembled. 2. Using two bolts (2), install tool R (adapter, guide, bolt) to link (1). ﬂ It is also possible to use two track shoe bolts for bolt (2).

3. Assemble tool R (pump, cylinder 1471 kN {150 t}) and tool R (frame, rod, adapter, bolt x 1, eyebolt), then raise chassis and set on track.

4. Insert rod of tool R from cylinder end, and install with two nuts. ﬂ Pass the rod through the hole in link (1) to install.

5. Set tool R (adapter, guide, pusher) in position, then apply hydraulic pressure and remove pin (3). When the cylinder reaches the end of its stroke, insert extension R between the adapter and guide, and repeat the operation.

PC600-6

30-91

DISASSEMBLY AND ASSEMBLY

ONE LINK

6. Set tool R (294 kN {30 ton} puller) and spacer 1 to center of roller tread of link to be disassembled, then apply hydraulic pressure to puller and open link so that dimension a becomes 5 – 6 mm.

30-92

PC600-6

DISASSEMBLY AND ASSEMBLY

ONE LINK

FIELD ASSEMBLY OF ONE LINK 1. Assemble link sub-assembly. 1) Set tool R to end face of link, then press fit bushing (1). 2) Set tool R to end face of link (pin end), and press fit pin (2).

2. Set link sub-assembly (3) on link to be connected.

3. Set link (4) on opposite side, and support with tool R (guide).

4. Set tools R and R in same way as for operation to remove pin, then use tool R (adapter, extension, guide, adapter, bolt) for press fitting pin, and tool R (extension, guide, adapter, bolt) for press fitting bushing, and press fit in turn.

PC600-6

30-93

DISASSEMBLY AND ASSEMBLY

ONE LINK

5. Use tool R (294 kN {30 t} puller) in same way as when disassembling, and push open link (5) at bushing end.

6. Set link (6) at pin end to link (5) at bushing end, connect with tool R (guide), then remove tool R (puller).

7. Set tool R at pin (7) end, then use tool R (adapter, bolt, and guide) to press fit pin (7). fl Supply grease between bushing and pin to 100%. 2 Between bushing and pin: Grease (NIGTITE LYK-2 manufactured by NIHON GREASE CO., LTD. or equivalent) fl Press fit the pin so that it will be projected from the track shoe by 3.7 ± 2 mm. 8. Install shoe to link. 3 Shoe mounting bolt: First time: Tighten four bolts to 789 ± 79 Nm {80 ± 8 kgm}. fl Check that the fitting surfaces are fitted. Second time: Using angle tightening wrench R15, tighten bolt by 120 ± 10 degrees.

30-94

PC600-6

DISASSEMBLY AND ASSEMBLY

IDLER, RECOIL SPRING

REMOVAL OF IDLER, RECOIL SPRING ASSEMBLY 1. Remove track shoe assembly. For details, see REMOVAL OF TRACK SHOE ASSEMBLY. ﬂ Remove lubricator (1).

2. Sling idler and recoil spring assembly (2), and pull out to the front to remove. 4 Idler, recoil spring assembly: Approx. 800 kg

3. Disconnect recoil spring assembly (4) from idler assembly (3). 1 4 Idler assembly: 350 kg 4 Spring assembly: 460 kg

INSTALLATION OF IDLER, RECOIL SPRING ASSEMBLY •

Carry out installation in the reverse order to removal.

1 3 Mounting bolt between idler and recoil spring: 824 – 1,030 Nm {84 – 105 kgm}

PC600-6

30-95

DISASSEMBLY AND ASSEMBLY

IDLER

DISASSEMBLY OF IDLER ASSEMBLY 1. Remove plug (1) and drain oil. 6 Idler : Approx. 400 – 500 cc

2. Set idler assembly (2) on block 1, remove pin (3), then remove support (5). 3. Remove floating seal (4).

4. Turn over idler assembly, remove pin (6), then remove support (7). 5. Remove shaft (8) from idler.

6. Remove two floating seals (4) from idler (7).

30-96

PC600-6

DISASSEMBLY AND ASSEMBLY

IDLER

7. Remove bushings (9) and (10) from idler.

8. Remove floating seals (4) from supports (5) and (7).

PC600-6

30-97

DISASSEMBLY AND ASSEMBLY

IDLER

ASSEMBLY OF IDLER ASSEMBLY fl Clean all parts, and check for dirt or damage. 1. Using tool L1, assemble floating seals (4) to supports (6) and (3). fl When installing the floating seal, clean, degrease and completely dry the contact faces of the O-ring and floating seal (hatched parts in the figure at right). Take care that dirt does not stick to the contact face of the floating seal. fl After installing the floating seal, check that its angle is within 1 mm and its projection “a” is 9 – 11 mm.

2. Using tool 1, press fit bushings (10) and (9) to idler.

3. Using tool L1, assemble floating seal (4) to idler. ﬂ For precautions for installing the floating seal, see 1.

30-98

PC600-6

DISASSEMBLY AND ASSEMBLY

IDLER

4. Turn over idler and using tool L1, assemble floating seal (4). ﬂ For precautions for installing the floating seal, see 1.

5. Install shaft (8) to idler. 6. Assemble support (7) to shaft. ﬂ When installing the support to the shaft, align their pin hole with each other. 7. Install pin (6) to secure support (7).

8. Turn over idler, and assemble support (5) to shaft. ﬂ When installing the support to the shaft, align their pin hole with each other. 9. Install pin (3) to secure support (5).

10. Using tool L2, supply oil by specified quantity, then tighten plug (1). Idler: Approx. 400 – 500 cc (EO30-CD) 3 Plug: 16.66 – 37.86 Nm {1.7 – 3.8 kgm}

PC600-6

30-99

DISASSEMBLY AND ASSEMBLY

RECOIL SPRING

DISASSEMBLY OF RECOIL SPRING ASSEMBLY

8 7

5 3

14 12 13

9 11

1. Remove piston assembly (2) from recoil spring assembly (1). 2. Disassembly of recoil spring assembly 1) Set tool M1 to recoil spring assembly (1). ¤ The recoil spring is under large installed load, so be sure to set the tool properly. Failure to do this is dangerous. fl Installed load of spring: 291.8 kN {29,770 kg} 2) Apply hydraulic pressure slowly to compress spring, then remove lock plate (3), and remove nut (4). fl Compress the spring to a point where the nut becomes loose. fl Free length of spring: Approx. 859 mm 3) Remove yoke (6), cylinder (7) and dust seal (8) from spring (5).

CEP00054

CEP00055

3. Disassembly of piston assembly 1) Remove lock plate (10) from piston (9), then remove valve (11). 2) Remove snap ring (12), then remove U-packing (13) and ring (14).

30-100

PC600-6

DISASSEMBLY AND ASSEMBLY

RECOIL SPRING

ASSEMBLY OF RECOIL SPRING ASSEMBLY 1. Assembly of piston assembly 1) Assemble ring (14) and U-packing (13) to piston (9), and secure with snap ring (12). 2) Tighten valve (11) temporarily, and secure with lock plate (10). 2. Assembly of recoil spring assembly 1) Using tool 1, assemble dust seal (8) to cylinder (7). 2) Assemble cylinder (7), and yoke (6) to spring (5), then set to tool M1. 2 Sliding portion of cylinder: Grease (G2-LI) 3) Apply hydraulic pressure slowly to compress spring, and tighten nut (4) so that installed length of spring is dimension “a”, then secure with lock plate (3). fl Installed length “a” of spring: 715 mm 4) Remove recoil spring assembly (1) from tool M1. 3. Assemble piston assembly (2) to recoil spring assembly (1). 2 Piston sliding portion and wear ring: Grease (G2-LI) fl Assemble the cylinder assembly so that the mounting position of the valve is 90° to the side. fl Fill the inside of the cylinder with approx. 200 cc of grease (G2-LI), then bleed the air and check that grease comes out of the grease hole.

PC600-6

30-101

DISASSEMBLY AND ASSEMBLY

TRACK ROLLER

REMOVAL OF TRACK ROLLER ASSEMBLY 1. Lower work equipment to ground, then loosen lubricator (1), and relieve track tension. 1 ¤ The adjustment cylinder is under extremely high pressure, so never loosen the lubricator more than one turn. If the grease does not come out easily, move the machine backwards and forwards. 2. Remove mounting bolts of track roller guard (2), then swing work equipment 90°, jack up machine with work equipment, and remove track roller guard (2) towards outside of machine.2 4 Track roller guard: Approx. 50 kg 3. Lower chassis completely, remove mounting bolts of track roller assembly (3), then jack up machine with work equipment, and remove track roller assembly (3) to outside of machine. 3 4 Track roller assembly: Approx. 110 kg

INSTALLATION OF TRACK ROLLER ASSEMBLY •

Carry out installation in the reverse order to removal.

1 ﬂ Adjust the track tension. For details, see TESTING AND ADJUSTING, Testing and adjusting track tension. 2 2 Roller guard mounting bolt: Thread tightener (LT-2) 3 Roller guard mounting bolt: 1,180 – 1,470 Nm {120 – 150 kgm} 3 2 Track roller assembly mounting bolt: Thread tightener (LT-2) 3 Track roller assembly mounting bolt: 980 – 1,176 Nm {100 – 126 kgm}

30-102

PC600-6

DISASSEMBLY AND ASSEMBLY

TRACK ROLLER

DISASSEMBLY OF TRACK ROLLER ASSEMBLY 7

5 6 10 4 9 3 1 2 11 CEP00084

1. Remove pin (1), then remove collar (2). 3 2. Remove floating seal (3) from collar (2) and roller (4).

1 2

3. Pull out roller (4) from shaft (5). ﬂ It is filled with 540 – 660 cc. of oil, so drain the oil at this point or lay a cloth to prevent the area from becoming dirty. 4. Remove floating seal (6) on opposite side from roller (4) and collar (8).

CEP00085

CEP00086

CEP00087

5. Remove pin (7), then remove collar (8) from shaft (5).

CEP00088

9, 10

6. Remove bushings (9) and (10) from roller (4).

5 6 8 4

PC600-6

CEP00089

CEP00090

30-103

DISASSEMBLY AND ASSEMBLY

TRACK ROLLER

ASSEMBLY OF TRACK ROLLER ASSEMBLY 1. Using push tool 1, press fit bushings (9) and (10) to roller (4). 5

2. Assemble collar (8) to shaft (5), and install pin (7).

L3 6a

3. Using tool L3, install floating seal (6) to shaft (5). ﬂ When installing the floating seal, clean, degrease and completely dry the contact faces of the O-ring (6c) and floating seal (6a) (hatched parts in the figure at right). Take care that dirt does not stick to the contact face of the floating seal. ﬂ After installing the floating seal, check that its angle is within 1 mm and its projection “a” is 5 – 7 mm.

4. Using tool L3, install floating seals (6) and (3) to roller (4). ﬂ For precautions for installing the floating seals (6b), (6d), (3b), and (3d), see 3 above.

4 10 7

8 CEP00092

CEP00091

3b 3 3d

5. Assemble shaft (5) to roller (4).

6d 6 6b

CEP00096

CEP00095

6. Turn over roller (4) and shaft (5) assembly. 7. Using tool L3, install floating seal (3) to collar (2). ﬂ For precautions for installing the floating seals (3a) and (3c), see 3 above.

4 3

CEP00097

30-104

3a 3b

CEP00098

PC600-6

DISASSEMBLY AND ASSEMBLY

TRACK ROLLER

8. Assemble collar (2) to shaft (5), and install pin (1).

5 CEP00099

9. Using tool L4, apply standard pressure to roller oil filler port, and check for leakage of air from seal. ﬂ Standard pressure: 0.1 MPa {1 kg/cm2} ﬂ Method of checking The standard pressure shall be maintained for 10 seconds and the indicator of the gauge shall not go down.

CEP00100

10. Using tool L4, fill track roller assembly with oil, then tighten plug (11). 5

Track roller oil: 540 – 660 cc (EO30-CD)

3 Plug: 16.66 – 37.86 Nm {1.7 – 3.8 kgm}

To oil pump To vacuum tank CEP00201

CEP00202

PC600-6

30-105

DISASSEMBLY AND ASSEMBLY

CARRIER ROLLER

REMOVAL OF CARRIER ROLLER ASSEMBLY 1. Lower work equipment to ground, then loosen lubricator (1), and relieve track tension. 1 ¤ The adjustment cylinder is under extremely high pressure, so never loosen the lubricator more than one turn. If the grease does not come out, move the machine backwards and forwards.

2. Using hydraulic jacks, push up track to a position where carrier roller assembly can be removed, then remove carrier roller assembly (2). 2 4 Carrier roller assembly: 50 kg

INSTALLATION OF CARRIER ROLLER ASSEMBLY •

Carry out installation in the reverse order to removal.

1 ﬂ Adjust the track tension. For details, see TESTING AND ADJUSTING, Testing and adjusting track tension.

2 3 Carrier roller assembly mounting bolt: 490 – 607 Nm {50 – 62 kgm}

30-106

PC600-6

DISASSEMBLY AND ASSEMBLY

CARRIER ROLLER

DISASSEMBLY OF CARRIER ROLLER ASSEMBLY 1. Remove plug (1) to drain oil. 6 Carrier roller assembly: 135 – 165 cc

2. Secure carrier roller assembly with block 1. 3. Remove cover (2). 4. Remove cover (3). 5. Using push tool 2, push shaft assembly (4) out of roller (5) with press.

6. Remove floating seal (6) from support (7). 7. Secure support (7) with block 3. 8. Using push tool 4, push shaft (8) out of support (7) with press.

9. Remove floating seal (9) from roller (5). 10. Remove bushings (10) and (11).

PC600-6

30-107

DISASSEMBLY AND ASSEMBLY

CARRIER ROLLER

ASSEMBLY OF CARRIER ROLLER ASSEMBLY 1. Using tool 5, press fit bushing (10) to roller (5). fl Press fit bushing (11) similarly. 2. Using tool L5, press fit floating seal (9) to roller (5). fl When installing the floating seal, clean, degrease and completely dry the contact faces of the O-ring and floating seal (hatched parts in the figure at right). Take care that dirt does not stick to the contact face of the floating seal. fl After installing the floating seal, check that its angle is within 1 mm and its projection “a” is 9 – 11 mm.

3. Using push tool 4, press fit shaft (8) to support (7). 4. Using tool L5, press fit floating seal (6) to support (7). ﬂ For fitting procedure of the floating seal, see 2 above.

5. Using push tool 6, press fit shaft assembly (4) to roller (5) with press. 6. Install cover (3). 3 Mounting bolt: 44.12 – 53.93 Nm {4.5 – 5.5 kgm} 7. Install cover (2). 3 Mounting bolt: 44.12 – 53.93 Nm {4.5 – 5.5 kgm}

30-108

PC600-6

DISASSEMBLY AND ASSEMBLY

CARRIER ROLLER

8. Using tool L6, apply standard pressure to oil filler to check seal for air leakage. ﬂ Standard pressure: 0.1MPa {1kg/cm2} ﬂ Check method: Keep the standard pressure for 10 seconds, and check that the gauge reading does not drop.

9. Using tool L6, fill carrier roller assembly with oil, then tighten plug (1). 5

Carrier roller: 135 – 165 cc

3 Plug: 30.89 – 37.75 Nm {3.15 – 3.85 kgm}

PC600-6

30-109

DISASSEMBLY AND ASSEMBLY

HYDRAULIC TANK

REMOVAL OF HYDRAULIC TANK ASSEMBLY ﬂ Swing the upper structure so that the hydraulic tank will not be above the track shoe. ¤ Loosen the oil filler cap slowly to release the pressure inside the hydraulic tank. 1. Drain the oil from the hydraulic tank. 6 Hydraulic tank: 379 ¬ 2. Remove handrail and step (1). 3. Remove cover (2) between operator’s cab and hydraulic tank. 4. Disconnect three hoses (3) from inside of hydraulic tank. 5. Disconnect three hoses (4) from filter.

6. Disconnect wiring connectors (P09) (5) and (P13) (6) from rear side of hydraulic tank. 7. Disconnect nine hoses (7). 8. Disconnect pump suction hose (8).

9. Remove bracket (9).

30-110

PC600-6

DISASSEMBLY AND ASSEMBLY

10. Lift off hydraulic tank assembly (10).

HYDRAULIC TANK

4 Hydraulic tank assembly: 430 kg

INSTALLATION OF HYDRAULIC TANK ASSEMBLY •

Carry out installation in the reverse order to removal.

1 3 Hydraulic tank mounting bolt: 490 – 608 Nm {50 – 62 kgm} •

Refilling with oil Add oil through oil filler to the specified level. Run the engine to circulate the oil through the system. Then, check the oil level again. 5

•

Hydraulic tank: 379 ¬ (EO10-CD)

Bleeding air Bleed air from the hydraulic circuit. For details, see TESTING AND ADJUSTING, Bleeding air from each part.

PC600-6

30-111

DISASSEMBLY AND ASSEMBLY

MAIN RELIEF VALVE

DISASSEMBLY OF MAIN RELIEF VALVE ASSEMBLY 1. Loosen nut (2), and remove plug (1). ﬂ Before loosening the nut, measure protrusion dimension a of the plug from the end face of the nut. 2. Remove retainer (3). 3. Loosen nut (5), and remove holder (4). ﬂ Before loosening the nut, measure protrusion dimension b of the holder from the end face of the nut. 4. Remove spring (6) and poppet (7). 5. Remove sleeve (8), then remove seat (9), backup ring (10), spring (11), and valve (12). 6. Remove snap ring (14) from sleeve (13). 7. Remove backup ring (15) from sleeve (13).

30-112

PC600-6

DISASSEMBLY AND ASSEMBLY

MAIN RELIEF VALVE

ASSEMBLY OF MAIN RELIEF VALVE ASSEMBLY 1. Assemble backup ring (15) and O-ring in sleeve (13). 2. Install snap ring (14) to sleeve (13). 2 Plug threads: Thread tightener (Locktite No. 638 or equivalent) 3. Assemble backup ring (10) and O-ring to seat (9), then install valve (12), spring (11), seat (9), and sleeve (8) to sleeve (13). 4. Assemble poppet (7) and spring (6). 5. Assemble nut (5) and O-ring to holder (4), and install to sleeve (13). ﬂ Adjust so that protrusion dimension b of the holder from the end face of the nut is the same as when it was disassembled, then secure with the nut. 3 Nut: 93.2 – 122.6 Nm {9.5 – 12.5 kgm} 6. Assemble retainer (3). 7. Assemble nut (2) and O-ring to plug (1), and install to sleeve (13). ﬂ Adjust so that protrusion dimension a of the plug from the end face of the nut is the same as when it was disassembled, then secure with the nut. 3 Nut: 39.2 – 49.6 Nm {4 – 5 kgm}

PC600-6

30-113

DISASSEMBLY AND ASSEMBLY

MAIN CONTROL VALVE, SOLENOID VALVE

REMOVAL OF MAIN CONTROL VALVE, SOLENOID VALVE ASSEMBLY ¤ Lower the work equipment completely to the ground and stop the engine. Then, loosen the oil filler cap slowly to release the pressure inside the hydraulic tank. ¤ Release the pressure inside the hydraulic circuit. For details, see TESTING AND ADJUSTING, Releasing pressure inside hydraulic circuit. ¤ Disconnect the cable from the negative (–) terminal of the battery. ﬂ Before disconnecting the PPC circuit hoses, make match marks on them or attach tags to them. ﬂ Plug the disconnected tubes and hoses. 1. Remove main control valve assembly top cover (1) and step (2). 2. Disconnect following wiring connectors. • (3): (S08) (Swing switch) • (4): (C07) (R pump pressure sensor) • (5): (C08) (F pump pressure sensor) • (6): (S04) (Boom lowering switch) • (7): (S05) (Arm digging switch) • (8): (S02) (Boom raising switch) • (9): (S07) (Bucket dumping switch) • (10): (S06) (Bucket digging switch) • (11): (V08) Bucket HI cancel solenoid) • (12): (S08) (Swing switch) • (13): (V02) (CO cancel solenoid) • (14): (V05) (Main 2nd-stage relief valve solenoid) • (15): (V03) (Boom head 2nd-stage safety valve solenoid) • (16): (V06) (Travel gear speed selector solenoid) • (17): (V04) (Swing parking brake solenoid) 3. Disconnect hoses (18) and (19) between main control valve and swing motor and two suction hoses (20) of swing motor.

30-114

PC600-6

DISASSEMBLY AND ASSEMBLY

MAIN CONTROL VALVE, SOLENOID VALVE

4. Disconnect four hoses (21) between main control valve and arm/bucket cylinder. 5. Disconnect hose (22) between main control valve and return filter. 6. Disconnect two hoses (23) between line filter and main control valve. 7. Disconnect each tube (24) from main control valve side or opposite side. ﬂ Disconnect these tubes completly from chassis as needed. 8. Disconnect all PPC hoses (25) from front and rear sides of main control valve. 9. Disconnect all hoses (26) from each solenoid valve. 10. Lift off main control valve and solenoid valve assembly (27) together with bracket. 4 Main control valve, solenoid valve assembly: 330 kg

INSTALLATION OF MAIN CONTROL VALVE, SOLENOID VALVE ASSEMBLY •

Carry out installation in the reverse order to removal.

•

Refilling with oil Add oil through oil filler to the specified level. Run the engine to circulate the oil through the system. Then, check the oil level again.

•

Bleeding air Bleed air from the pump. For details, see TESTING AND ADJUSTING, Bleeding air from each part.

PC600-6

30-115

DISASSEMBLY AND ASSEMBLY

MAIN CONTROL VALVE

DISASSEMBLY OF MAIN CONTROL VALVE ASSEMBLY

30-116

PC600-6

DISASSEMBLY AND ASSEMBLY

ﬂ Since the set pressure of the safety valve cannot be adjusted without removing it from the machine, do not disassemble it. • The left main control valve is explained below as an example. 1. Main relief valve, jet sensor relief valve Remove main relief valve (1) and jet sensor relief valve (2). 2. Safety valves having suction ports Remove safety valves (3) and (5) having suction ports. 3. Check valve Remove plug (6), then remove spring (7) and check valve (8). 4. Left travel valve 1) Remove case (9). Remove retainer (10), shim (11), spring (12), retainer (13), spring (14), and retainer (15), then remove spool (16). 2) Remove case (17), then remove retainer (18), shim (19), spring (20), retainer (21), spring (22), and retainer (23). • Apply to the spools of the swing valve, right travel valve, boom HI valve (right control valve), and boom LO valve (left control valve). • Swing valve spool (Right control valve) i) Shim (11) and retainer (13) are not installed. ii) Shim (19) and retainer (21) are not installed. • Boom HI valve (Right control valve) i) Two shims (11) are installed. ii) Plates are installed instead of items (17) – (23) in 2) above. • Boom LO valve spool (Left control valve) i) Shim (11) is not installed. ii) Items (18) – (21) in 2) above are not installed.

MAIN CONTROL VALVE

6. Bucket valve 1) Remove case (28). Remove spring (29) and retainer (30), then pull out spool (31). 2) Remove case (32), then remove spring (33) and retainer (34). • Apply to the spools of the arm LO valve, service valve (right control valve) and arm HI valve (left control valve). • Arm LO valve (Right control valve) A retainer is installed between case (32) and spring (33). • Arm HI (Left control valve) Shim (35) is installed. 7. Straight travel valve 1) Remove plate (36), then remove spring (37). 2) Remove plug (38), then pull out spool (39).

5. Arm throttle valve 1) Remove plug (24) and spring (25). 2) Remove plate (26) and pull out spool (27). • Items (24), (25), and (26) of the swing priority valve (right control valve) in 1) and 2) above are installed reversely.

PC600-6

30-117

DISASSEMBLY AND ASSEMBLY

MAIN CONTROL VALVE

ASSEMBLY OF MAIN CONTROL VALVE ASSEMBLY

30-118

PC600-6

DISASSEMBLY AND ASSEMBLY

1. Straight travel valve 1) Install spool (39) and fit the O-ring, then install plug (38). 2) Install spring (37), then install plate (36). 2. Bucket valve 1) Install spool (31). Install retainer (34) and spring (33), then fit the O-ring and install case (32). 2) Install retainer (30) and spring (29), then fit the O-ring and install case (28). • Apply to the spools of the arm LO valve, service valve (right control valve), and arm HI valve (left control valve). • Arm LO valve (Right control valve) Install the retainer between case (32) and spring (33). • Arm HI valve (Left control valve) Install shim (35). 3. Arm throttle valve 1) Install spool (27) and fit the O-ring, then install plate (26). 2) Install spring (25) and fit the O-ring, then install plug (24). • Reversely reinstall items (24), (25), and (26) of the swing priority valve (right control valve) in 1) and 2) above.

MAIN CONTROL VALVE

•

Boom LO valve spool (Left control valve) i) Shim (11) is not installed. ii) Items (18) – (21) in 2 above are not installed.

5. Check valve Install check valve (8) and spring (7), then fit the O-ring and install plug (6). 3 Plug: 177 – 216 Nm {18 – 22 kgm} 6. Safety valves having suction ports Fit the O-ring, then install safety valves (5) and (3) having suction ports. 3 Safety valve having suction port: 216 – 235 Nm {22 – 24 kgm} 7. Jet sensor relief valve and main relief valve Install jet sensor relief valve (2) and main relief valve (1). 3 Jet sensor relief valve: 49 – 58.8 Nm {5 – 6 kgm} 3 Main relief valve: 177 – 196 Nm {18 – 20 kgm}

4. Left control valve 1) Install spool (16), then install retainer (23), spring (22), retainer (21), spring (20), shim (19), and retainer (18). Fit the Oring and install case (17). 2) Install retainer (15), spring (14), retainer (13), spring (12), shim (11), and retainer (10), then fit the O-ring and install case (9). • Apply to the spools of the swing valve, right travel valve, boom HI valve (right control valve), and boom LO (left control valve). • Swing valve spool (Right control valve) i) Shim (11) and retainer (13) are not installed. ii) Shim (19) and retainer (21) are not installed. • Boom HI valve (Right control valve) i) Install two shims (11). ii) Install plates instead of items (17) – (23) in 2) above.

PC600-6

30-119

DISASSEMBLY AND ASSEMBLY

REMOVAL OF NO. 1 AND NO. 2 PUMP ASSEMBLY

NO. 1 AND NO. 2 PUMP

PC600, 600LC-6 Serial No.: 10001 – 11000

¤ Lower the work equipment completely to the ground and stop the engine. Then loosen the oil filler cap of the hydraulic tank slowly to release the pressure inside the hydraulic tank. ¤ Disconnect the cable from the negative (–) terminal of the battery. 1. Remove hydraulic tank strainer, and using tool S, stop the oil. ﬂ When not using tool S, remove the drain plug, and drain the oil from the hydraulic tank and inside the system.

PC600, 600LC-6 Serial No.: 11001 and up

6 Hydraulic tank: 379 ¬ 2. Open 2 pump side covers (1), then remove pump top cover (2) and cover (3) between pump and engine. 3. Disconnect air hose, then sling and remove air cleaner case (4). 4 Air cleaner case: 50 kg

4. Disconnect wiring connector (CO13)(5) from No. 1 pump assembly.

5. Disconnect pump discharge hoses (6). 6. Disconnect suction hoses (7). 7. Disconnect all hoses (8). ﬂ Before disconnecting, mark all the hoses with tags to prevent mistakes in the mounting position when installing.

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NO. 1 AND NO. 2 PUMP

8. Using eyebolts, lift off No. 1 pump assembly (9) and No. 2 pump assembly (10). 4 No. 1 pump assembly: 170 kg 4 No. 2 pump assembly: 160 kg

INSTALLATION OF NO. 1 AND NO. 2 PUMP ASSEMBLY •

Carry out installation in the reverse order to removal.

1 3 Air hose clamp: 8.3 – 9.3 Nm {0.85 – 0.95 kgm} 3 Air cleaner case band: 17.6 – 21.6 Nm {1.8 – 2.2 kgm} •

Refilling with oil (hydraulic tank) Add oil through the oil filler to the specified level. Run the engine to circulate the oil through the system. Then check the oil level again. 5

•

Hydraulic tank: 379 ¬ (EO10-CD)

Bleeding air Bleed the air from the hydraulic circuit. For details, see TESTING AND ADJUSTING, Bleeding air.

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HYDRAULIC PUMP

DISASSEMBLY OF HYDRAULIC PUMP ASSEMBLY HPV95+95 ﬂ The diagrams all show the No. 1 pump. With the No. 1 pump and No. 2 pump, the only differences are the shape of the servo valve, the position of port T and port P, and the direction of the servo piston. The procedure is basically the same. 1. Hydraulic pump assembly Set hydraulic pump assembly (1) to tool P1.

2. Servo valve assembly 1) Remove tube (2). fl Not installed to the No. 2 pump. 2) Remove front servo valve assembly (3). fl With the No. 1 pump and No. 2 pump, only the shape is different. 3) Remove rear servo valve assembly (4). fl With the No. 1 pump and No. 2 pump, only the shape is different.

3. Rear pump assembly [1] Remove 4 mounting nuts, then remove rear pump assembly (5).

4. Front end cap assembly 1) Remove 2 mounting bolts and 4 nuts, then remove front end cap assembly (6).

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2) Disassemble front end cap assembly as follows. i) Remove valve plate (7) from end cap (8). ﬂ The valve plate and cylinder block may be tightly fitted, so be careful when removing. ii) Remove ring (9).

iii) Remove needle bearing (10). ﬂ Push with a press from the notched portion on the inside of the end cap when removing the bearing.

iv) Remove flange (11). v) Remove 4 studs (12) and 4 studs (13).

5. Front cylinder block, piston assembly 1) Remove front cylinder block and piston assembly (14). ﬂ The piston is fitted tightly to the rocker cam, so check that the cylinder block and piston come off together as one unit.

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2) Disassemble front cylinder block and piston assembly as follows. i) Remove piston assembly (15) from cylinder block assembly (16). ﬂ Remove the piston and shoe retainer as one unit. ii) Remove retainer guide (17). iii) Remove 3 pins (18).

iv) Remove 9 pistons (19) from shoe retainer (20).

v) Set tool P2 to cylinder block assembly and compress spring. vi) Remove snap ring (21) from cylinder block (22). vii) Remove tool P2. viii)Remove seat (23), spring (24), and seat (25).

6. Front cradle, shaft, rocker cam assembly 1) Remove 12 mounting bolts (75).

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2) Using guide bolt 1, remove front cradle, shaft, and rocker cam assembly (26). ﬂ Be careful not to let the rocker cam separate from the cradle. 3) Remove joint from mating surface of pump case and cradle.

4) Disassemble front cradle, shaft, and rocker cam assembly as follows. i) Remove slider (27) and rocker cam (28) from cradle and shaft assembly (29).

ii) Hold cradle and shaft assembly (29) in a vice. iii) Remove housing (30). ﬂ If it is difficult to remove, use a forcing screw. ﬂ Shims are installed, so check the number and thickness of the shims, and keep in a safe place.

iv) Remove oil seal (31) from housing (30).

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v) Using press, remove shaft assembly (32) from cradle (33).

vi) Remove snap ring (34) and washer (35) from shaft (36). ﬂ The washer is a selected part, so check the thickness. vii) Using tool P3 and press, remove roller bearing (37).

7. Front servo piston 1) Remove cap (38). ﬂ Loosen the mounting bolts uniformly until the spring tension is released. ﬂ Shims are installed, so check the number and thickness of the shims, and keep in a safe place. 2) Remove spring (39).

3) Remove cap (40). ﬂ If it is difficult to remove, use a forcing screw. ﬂ Shims are installed, so check the number and thickness of the shims, and keep in a safe place. 4) Remove front servo piston (41).

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8. Front pump case 1) Remove plug (42). 2) Remove front pump case (43) from tool P1.

9. Rear pump assembly [2] Install rear pump assembly (5) to tool P1.

10. Impeller assembly 1) Remove mounting bolts (44), then remove impeller assembly (45).

2) Disassemble impeller assembly as follows. i) Remove shims (46). ﬂ Check the number and thickness of the shims, and keep in a safe place. ii) Remove 2 plates (47). iii) Using tool P4, remove 4 mounting bolts, then remove impeller (48) from coupling (49).

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11. Rear end cap assembly 1) Remove 4 mounting bolts, then remove rear end cap assembly (50).

2) Disassemble rear end cap assembly as follows. i) Remove valve plate (51) from end cap (52). ﬂ The valve plate and cylinder block may be tightly fitted, so be careful when removing. ii) Remove ring (53).

iii) Remove needle bearing (54). ﬂ Push with a press from the notched portion on the inside of the end cap when removing the bearing.

12. Rear cylinder block, piston assembly 1) Remove rear cylinder block and piston assembly (55). ﬂ The piston is fitted tightly to the rocker cam, so check that the cylinder block and piston come off together as one unit. 2) Disassemble rear cylinder block and piston assembly as follows. ﬂ For details, see 5. Front cylinder block, piston assembly.

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13. Rear cradle, shaft, rocker cam assembly 1) Remove 12 mounting bolts (56).

2) Using guide bolt 1, remove rear cradle, shaft, and rocker cam assembly (57). ﬂ Be careful not to let the rocker cam separate from the cradle. 3) Remove joint from mating surface of pump case and cradle.

4) Disassemble rear cradle, shaft, and rocker cam assembly as follows. i) Remove slider (58) and rocker cam (59) from cradle and shaft assembly (60).

ii) Hold cradle and shaft assembly (60) in a vice. iii) Remove cover (61). ﬂ If it is difficult to remove, use a forcing screw. ﬂ Shims are installed, so check the number and thickness of the shims, and keep in a safe place.

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iv) Using press, remove shaft assembly (62) from cradle (63).

v) Remove snap ring (64) and washer (65) from shaft (66). ﬂ The washer is a selected part, so check the thickness. vi) Using tool P3 and press, remove roller bearing (67).

vii) Using tool P4, remove mounting bolts, then remove stopper (68) from cradle (63).

14. Rear servo piston 1) Remove cap (69). ﬂ Loosen the mounting bolts uniformly until the spring tension is released. ﬂ Shims are installed, so check the number and thickness of the shims, and keep in a safe place. 2) Remove spring (70).

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3) Remove cap (71). ﬂ If it is difficult to remove, use a forcing screw. ﬂ Shims are installed, so check the number and thickness of the shims, and keep in a safe place. 4) Remove rear servo piston (72).

15. Rear pump case Remove plug (73).

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HYDRAULIC PUMP

ASSEMBLY OF HYDRAULIC PUMP ASSEMBLY HPV95+95 fl Clean all parts, remove all burrs, check for dirt or damage, and be particularly sure to clean the drill hole oil passage. fl Coat the rotating and sliding surfaces of all parts with engine oil (EO-10CD) before assembling. fl Always check the contact of the following parts before assembling. For details, see CHECKING CONTACT BETWEEN PARTS. 1) Cradle and rocker cam 2) Cylinder block and valve plate 3) Valve plate and end cap fl The diagrams all show the No. 1 pump. With the No. 1 pump and No. 2 pump, the only differences are the shape of the servo valve, the position of port T and port P, and the direction of the servo piston. The procedure is basically the same. 1. Rear pump case [1] Set rear pump case (74) to working stand. 2. Rear servo piston 1) Insert rear servo piston (72) in pump case (74). fl When the slider groove is set facing the bottom of the case, insert the servo piston so that the part receiving the servo valve lever faces the mounting surface of the servo valve. 2) Adjust minimum swash plate angle (MIN) of servo piston as follows. fl The minimum swash plate angle is at the end where no spring is installed. fl With the No. 1 pump and No. 2 pump, the position of adjustment is the opposite (left and right). i) Using tool P5, secure servo piston. fl As shown in the diagram on the right, fit the pin portion of tool P5 securely into the part receiving the lever of servo piston (74), and check that the servo piston is held in position.

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ii) Measure protrusion dimension a of cap (71). iii) Measure inset dimension b from end face of pump case (74) to end face of servo piston (72). iv) Calculate shim thickness c. • c = (a – b) ± 0.05 mm • Shim thickness: 0.1 mm, 0.2 mm, 0.5 mm

3) Adjust maximum swash plate angle (MAX) of servo piston as follows. ﬂ The maximum swash plate angle is at the end where the spring is installed. ﬂ With the No. 1 pump and No. 2 pump, the position of adjustment is the opposite (left and right). i) Using tool P6, secure servo piston.

ﬂ As shown in the diagram on the right, fit the pin portion of tool P6 securely into the part receiving the lever of servo piston (72), and check that the servo piston is held in position.

ii) Measure protrusion dimension d of cap (69). iii) Measure inset dimension e from end face of pump case (74) to end face of servo piston (72). iv) Calculate shim thickness f. • f = (d – e) ± 0.05 mm • Shim thickness: 0.1 mm, 0.2 mm, 0.5 mm

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HYDRAULIC PUMP

4) Install selected shims, then fit O-ring and install cap (71). 3 Mounting bolt: 59 – 74 Nm {6 – 7.5 kgm}

5) Install spring (70). 6) Install selected shims, then fit O-ring and install cap (69). 3 Mounting bolt: 59 – 74 Nm {6 – 7.5 kgm}

3. Rear pump case [2] 1) Install rear pump case (74) to tool P1. 2) Fit O-ring and install plug (73). 3 Plug: 58.8 – 78.4 Nm {6.0 – 8.0 kgm}

4. Rear cradle, shaft, rocker cam assembly 1) Assemble rear cradle, shaft, and rocker cam assembly as follows. i) Using tool P7 and press, press fit roller bearing (67) to shaft (66). 2 Press-fitting surface of bearing: Grease (G2-LI) ﬂ The bearing is a split type, so be careful to install facing in the correct direction.

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ii) Select washer thickness as follows. Select each thickness of washer (65) and assemble temporarily. Measure dimension g from top surface of washer to top end of snap ring groove. Then select washer so that dimension is within range below. • g = 1.45 to 1.60 mm • Washer thickness: 2.8 mm, 2.9 mm, 3.0 mm, 3.1 mm

iii) Fit selected washer (64), and install snap ring (65).

iv) Fit stopper (68) to cradle (63), then using tool P4, tighten mounting bolts. 2 Mounting bolt: Loctite #648 3 Mounting bolt: 13.2 ± 1.5 Nm {1.35 ± 0.15 kgm}

v) Using tool P8 and press, press fit shaft assembly (62) to cradle (63). 2 Press-fitting surface of bearing: Grease (G2-LI)

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HYDRAULIC PUMP

2) Select shim thickness as follows. i) Measure protrusion dimension h of cover (61). ii) Measure inset dimension i from end face of cradle (63) to top face of outer race of bearing (67). iii) Calculate shim thickness j. • j = h – i + (0.05 to 0.15) mm • Shim thickness: 0.1 mm, 0.2 mm

3) Assemble rear cradle, shaft, and rocker cam assembly further as follows. i) Install selected shim, then fit O-ring and assemble cover (61) to cradle and shaft assembly (60) temporarily. ﬂ Tighten the mounting bolts fully after installing the impeller assembly.

ii) Install rocker cam (59) to cradle and shaft assembly (60). ﬂ Check that the sliding portion is fitted tightly. iii) Install slider (58). ﬂ Install so that the angled surface faces the rocker cam.

4) Install joint to mating surface of pump case and cradle. ﬂ Install the joint so that the hole with the small diameter is facing the cradle. 5) Using guide bolt 1, fit O-ring and insert rear cradle, shaft, and rocker cam assembly (57) in pump case. 2 Mating surface: Gasket sealant (LG-7 or LG-5)

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6) Tighten 12 mounting bolts (56). 3 Mounting bolt: 98 – 122.2 Nm {10 – 12.5 kgm} ﬂ After installing, check that the rocker cam is fitted securely in the cradle.

5. Rear cylinder block, piston assembly 1) Assemble rear cylinder block and piston assembly as follows. i) Assemble seat (25), spring (24), and seat (23) to cylinder block (22). ﬂ Assemble so that the chamfered inside diameter of the seat is facing the cylinder block. ii) Set tool P2 to cylinder block (24) and compress spring. iii) Install snap ring (21) and remove tool P2.

iv) Assemble 9 pistons (19) to shoe retainer (20).

v) Install 3 pins (18) to cylinder block assembly (16). vi) Install retainer guide (17). vii) Assemble piston assembly (15) to cylinder block assembly (16).

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2) Assemble rear cylinder block and piston assembly (55). ﬂ Check that the spline of the cylinder block and shaft is meshed and that the sliding portion of the rocker cam and piston shoe is tightly fitted.

6. Rear end cap assembly 1) Assemble rear end cap assembly as follows. i) Using press, press fit needle bearing (54) to end cap (52).

ii) Install ring (53) to end cap (52). ﬂ Install the ring so that the hole with the small diameter is facing the end cap. iii) Install valve plate (51). ﬂ Align the pin groove at the valve plate end and the pin at the end cap end, and check that the valve plate and end cap are tightly fitted.

2) Fit O-ring and install end cap assembly (50). 2 Mating surface: Gasket sealant (LG-7 or LG-5) 3 Mounting bolt: 59 – 74 Nm {6 – 7.5 kgm}

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HYDRAULIC PUMP

7. Impeller assembly 1) Assemble impeller assembly as follows. i) Install impeller (48) to coupling (49), then using tool P4, tighten mounting bolts. 2 Mounting bolt: Loctite #648 3 Mounting bolt: 4.4 – 5.4 Nm {0.45 – 0.55 kgm} ii) Install 2 plates (47) to groove of coupling.

2) Prevent rear shaft from rotating as follows. i) Remove cover (61). ii) Use guide bolt 2 and hexagonal wrench 3 to prevent rear shaft from rotating.

3) Select shim thickness as follows. i) Assemble each thickness of shims (46) temporarily, then fit impeller assembly (45) and tighten mounting bolts (44) temporarily. • Shim thickness: 0.10 mm, 0.15 mm, 0.20 mm, 0.50 mm ii) Measure protrusion dimension k from mounting surface of end cap (52) to tip of impeller assembly (45). iii) Select shim so that protrusion dimension k is within range below. • k = 8.66 ± 0.1 mm 4) Install selected shims (46), then install impeller assembly (45) and tighten mounting bolts (44). ﬂ Check that there is no interference between the impeller and rear end cap. 2 Mounting bolt: Loctite #648 3 Mounting bolt: 59 – 74 Nm {6 – 7.5 kgm}

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5) Remove hexagonal wrench 3 and guide bolt 2 used to prevent shaft from rotating. 6) Install shims and install cover (61). 3 Mounting bolt: 27.5 – 34.5 Nm {2.8 – 3.5 kgm}

8. Rear pump assembly [1] Remove rear pump assembly (5) from tool P1.

9. Front pump case 1) Set front pump case (43) to tool P1. 2) Fit O-rings and install plug (42). 3 Plug: 58.8 – 78.4 Nm {6.0 – 8.0 kgm}

10. Front servo piston 1) Insert front servo piston (41) in front pump case. fl When the slider groove is set facing the bottom of the case, insert the servo piston so that the part receiving the servo valve lever faces the mounting surface of the servo valve. 2) Adjust minimum swash plate angle (MIN) and maximum swash plate angle (MAX) of servo piston as follows. fl For details, see 2. Rear servo piston. fl With the front pump and rear pump, the position of adjustment is the opposite (left and right). 3) Insert selected shim, then fit O-ring and install cap (40). 3 Mounting bolt: 59 – 74 Nm {6 – 7.5 kgm}

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4) Install spring (39). 5) Insert selected shim, then fit O-ring and install cap (38). 3 Mounting bolt: 59 – 74 Nm {6 – 7.5 kgm}

11. Front cradle, shaft, rocker cam assembly 1) Assemble front cradle, shaft, and rocker cam assembly as follows. i) Using tool P7 and press, press fit roller bearing (37) to shaft (36). 2 Press-fitting surface of bearing: Grease (G2-LI) fl The bearing is a split type, so be careful to install facing in the correct direction. ii) Select washer thickness as follows. fl For details, see 4. Rear cradle, shaft, rocker cam assembly. iii) Fit selected washer (35), and install snap ring (34). iv) Using tool P8 and press, press fit shaft assembly (32) to cradle (33). 2 Press-fitting surface of bearing: Grease (G2-LI) v) Select shim thickness as follows. fl For details, see 4. Rear cradle, shaft, rocker cam assembly.

vi) Using tool P9, press fit oil seal (31) to housing (30).

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vii) Install selected shim, then fit O-ring and install housing (30) to cradle and shaft assembly (29). 2 Lip of oil seal: Grease (G2-LI) 3 Mounting bolt: 27.5 – 34.5 Nm {2.8 – 3.5 kgm}

viii)Install rocker cam (28) to cradle and shaft assembly (29). ﬂ Check that the sliding portion is fitted tightly. ix) Install slider (27). ﬂ Install so that the angled surface faces the rocker cam.

2) Install joint to front cradle, shaft, and rocker cam assembly. ﬂ Install the joint so that the hole with the small diameter is facing the cradle. 3) Using guide bolt 1, fit O-ring and insert front cradle, shaft, and rocker cam assembly (26) in pump case. 2 Mating surface: Gasket sealant (LG-7 or LG-5)

4) Tighten 12 mounting bolts (75). 3 Mounting bolt: 98 – 122.2 Nm {10 – 12.5 kgm} ﬂ After installing, check that the rocker cam is fitted securely in the cradle.

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HYDRAULIC PUMP

12. Front cylinder block, piston assembly 1) Assemble front cylinder block and piston assembly as follows. ﬂ For details, see 5. Rear cylinder block, piston assembly. 2) Assemble cylinder block and piston assembly (14) to pump case. ﬂ Check that the spline of the cylinder block and shaft is meshed and that the sliding portion of the rocker cam and piston shoe is tightly fitted.

13. Front end cap assembly 1) Assemble front end cap assembly as follows. i) Using press, press fit needle bearing (10) to end cap (8).

ii) Install 4 studs (13) and 4 studs (12). 3 Stud: 118 – 147 Nm {12 – 15 kgm} iii) Fit O-ring and install flange (11). 3 Mounting bolt: 27.4 – 34.3 Nm {2.8 – 3.5 kgm}

iv) Install ring (9) to end cap (8). ﬂ Install the ring so that the hole with the small diameter is facing the end cap. v) Install valve plate (7). ﬂ Align the pin groove at the valve plate end and the pin at the end cap end, and check that the valve plate and end cap are tightly fitted.

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HYDRAULIC PUMP

2) Fit O-ring, install front end cap assembly (6). 2 Mating surface: Gasket sealant (LG-7 or LG-5) 3 Mounting nut: 235 ± 20 Nm {24 ± 2 kgm} Mounting bolt: 59 – 74 Nm {6 – 7.5 kgm}

14. Rear pump assembly [2] Fit O-ring and install rear pump assembly (5). 2 Mating surface: Gasket sealant (LG-7 or LG-5) ﬂ If a gap is formed at the mating surface of the end cap, there is probably improper adjustment of the rear pump impeller shim, so carry out the adjustment again. 3 Mounting nut: 235 ± 20 Nm {24 ± 2 kgm}

15. Inspection of shaft rotating torque Using tool P10, measure rotating torque of input shaft. ﬂ Rotate shaft at a constant speed (3 – 5 sec/1 turn) and measure the rotating torque. • Rotating torque: Max. 49.0 Nm {max. 5.0 kgm} (Torque variation range: Max. 2.94 Nm {max. 0.3 kgm} ﬂ If the rotating torque is not normal, disassemble again and look for the cause.

16. Servo valve assembly 1) Fit O-ring and install rear servo valve assembly (4). 2 Mating surface: Gasket sealant (LG-7 or LG-5) ﬂ When inserting the arm of the servo valve into the servo piston, be careful not to cause any gouging.

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HYDRAULIC PUMP

fl Gradually tighten the mounting bolts on opposite sides in turn in the order shown in the diagram. 3 Mounting bolt: 27.5 – 34.3 Nm {2.8 – 3.5 kgm} fl With the No. 1 pump and No. 2 pump, only the shape is different. 2) Fit O-ring and install front servo valve assembly (3). 2 Mating surface: Gasket sealant (LG-7 or LG-5) fl When inserting the arm of the servo valve into the servo piston, be careful not to cause any gouging. fl Gradually tighten the mounting bolts on opposite sides in turn in the order shown in the diagram. 3 Mounting bolt: 27.5 – 34.3 Nm {2.8 – 3.5 kgm} fl With the No. 1 pump and No. 2 pump, only the shape is different. 3) Fit O-ring and install tube (2). 3 Eyebolt: 15.7 – 19.6 Nm {1.6 – 2.0 kgm} fl Not installed to the No. 2 pump.

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HYDRAULIC PUMP

CHECKING CONTACT BETWEEN PARTS ﬂ If either part of the following pairs of sliding parts has been repaired or replaced with a repair part (new part), check the contact as follows. There is no need for this check if both parts of the pair have been repaired or replaced with a repair part (new part). 1) Cradle and rocker cam 2) Cylinder block and valve plate 3) Valve plate and end cap

1. Cradle and rocker cam 1) Remove all oil and grease from the parts to be checked. fl Do not wipe with a cloth. 2) Paint the cradle with inspection paint, then put the rocker cam on top. fl Coat thinly with paint. fl Assemble in the direction shown in the diagram on the right. 3) Push the rocker cam with a force of 39.2 – 49.0 N {4 – 5 kg}, and move it from the position where it contacts the stopper to the maximum swash plate angle. Repeat this process 2 or 3 times. 4) Remove the rocker cam, transfer the contact surface to a tape, and check the contact surface. fl The standard for the contact is as given below. (1) Within 32 – 44 mm of center (center portion): Contact of more than 90% (2) Range from center portion (32 – 44 mm) to 60 mm: Contact of 50% – 90% (3) Not within width of 60 mm (outside): Contact of less than 50% • (It is not permitted to have contact only at the outside and no contact at the center.) fl If the contact is defective and lapping is carried out, it must always be carried out for both parts together.

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2. Cylinder block and valve plate 1) Make a centering tool for the cylinder block and valve plate. fl The tool can be made from plastic, bakelite or any other soft material. 2) Remove all oil and grease from the parts to be checked. fl Do not wipe with a cloth. 3) Paint the cylinder block with inspection paint, then put the tool and valve plate on top. fl Coat thinly with paint. 4) Push the valve plate with a force of 39.2 – 49.0 N {4 – 5 kg} against the cylinder block, turn the valve plate 90°, then turn it back to the original position. Repeat this process 2 or 3 times. 5) Remove the valve plate, transfer the contact surface to a tape, and check the contact surface. fl The standard for the contact is as given below. (1) Seal portion (range of φ 90.5 mm): Contact of more than 80% and no break around whole circumference (2) Land portion (range of φ 90.5 mm – φ 112 mm): Contact of more than 60% and no break around whole circumference

3. Valve plate and end cap 1) Remove all oil and grease from the parts to be checked. fl Do not wipe with a cloth. 2) Paint the end cap with inspection paint, then put the valve plate on top. fl Coat thinly with paint. 3) Push the valve plate with a force of 39.2 – 49.0 N {4 – 5 kg} against the end cap, turn the valve plate 90°, then turn it back to the original position. Repeat this process 2 or 3 times. 4) Remove the valve plate, transfer the contact surface to a tape, and check the contact surface. fl The contact of the mating surface of the valve plate and end cap must cover at least 80% without any variation. fl If the contact is defective, use a surface plate and correct by lapping.

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CONTROL, PTO LUBRICATION PUMP

REMOVAL OF CONTROL, PTO LUBRICATION PUMP ASSEMBLY ¤ Lower the work equipment completely to the ground and stop the engine. Then loosen the oil filler cap of the hydraulic tank slowly to release the pressure inside the hydraulic tank. ¤ Disconnect the cable from the negative (–) terminal of the battery. 1. Remove hydraulic tank strainer, and using tool S, stop the oil. ﬂ When not using tool S, remove the drain plug, and drain the oil from the hydraulic tank and inside the system. 6 Hydraulic tank: 379 ¬ 2. Open pump side cover. 3. Disconnect suction hoses (1) and (2). 4. Disconnect discharge hoses (3) and (4). 5. Disconnect hoses (5) and (6). 6. Remove control, PTO lubrication pump assembly (7).

INSTALLATION OF CONTROL, PTO LUBRICATION PUMP ASSEMBLY •

Carry out installation in the reverse order to removal.

•

Refilling with oil (hydraulic tank) Add oil through the oil filler to the specified level. Run the engine to circulate the oil through the system. Then check the oil level again. 5

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Hydraulic tank: 379 ¬ (EO10-CD)

PC600-6

DISASSEMBLY AND ASSEMBLY

CENTER SWIVEL JOINT

REMOVAL OF CENTER SWIVEL JOINT ASSEMBLY ¤ Lower the work equipment completely to the ground and stop the engine. Then loosen the oil filler cap of the hydraulic tank slowly to release the pressure inside the hydraulic tank. 1. Disconnect all hoses (1) at bottom of center swivel joint assembly. ﬂ Before disconnecting, mark all the hoses with tags to prevent mistakes in the mounting position when installing. 2. Remove elbow (2). 3. Disconnect all hoses (3) at top of swivel joint assembly. ﬂ Before disconnecting, mark all the hoses with tags to prevent mistakes in the mounting position when installing. 4. Pull out pin (4) and move link (5) towards frame. 5. Sling center swivel joint assembly (6), then remove 4 mounting bolts from bottom. 4 Center swivel joint assembly: 45 kg

INSTALLATION OF CENTER SWIVEL JOINT ASSEMBLY •

Carry out installation in the reverse order to removal.

•

Refilling with oil (hydraulic tank) Add oil through the oil filler to the specified level. Run the engine to circulate the oil through the system. Then check the oil level again.

•

Bleeding air Bleed the air from the travel motor. For details, see TESTING AND ADJUSTING, Bleeding air.

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30-149

DISASSEMBLY AND ASSEMBLY

CENTER SWIVEL JOINT

DISASSEMBLY OF CENTER SWIVEL JOINT ASSEMBLY 1 1. Remove cover (1). 2. Remove snap ring (2). 3. Using puller 1, pull out swivel rotor (4) and ring (3) from swivel shaft (5). 4. Remove O-ring (6) and slipper seal (7) from swivel rotor.

2 3

ASSEMBLY OF CENTER SWIVEL JOINT ASSEMBLY 5 1. Assemble slipper seal (7) and O-ring (6) to swivel rotor. CEP00381

2. Set swivel shaft (5) to block, then using push tool, tap swivel rotor (4) with a plastic hammer to install. 2 Contact surface of rotor, shaft: Grease (G2-LI) ﬂ When installing the rotor, be extremely careful not to damage the slipper seal and the O-ring. 3. Install ring (3) and secure with snap ring (2). 4. Fit O-ring and install cover (1). 3 Mounting bolt: 31.4 ± 2.9 Nm {3.2 ± 0.3 kgm}

30-150

CEP00382

PC600-6

DISASSEMBLY AND ASSEMBLY

WORK EQUIPMENT PPC VALVE

DISASSEMBLY OF WORK EQUIPMENT PPC VALVE ASSEMBLY

1. Remove nut (1), then remove disc (2) and boot (3).

2. Remove bolts, then remove plate (5). ﬂ Do not remove joint (4) unless it is to be replaced.

3. Remove seal (6) and collar (7).

4. Pull out piston (8), and remove retainer (9), springs (10) and (11), and shim (12). ﬂ Spring (10) consists of two springs each of two types with different installed loads, so check the mounting position (hydraulic port) and mark with tags to prevent mistakes when installing.

5 6 7

5. Pull out valve (13) from body (14).

8 9 10 11 12 13

CEP00424

PC600-6

30-151

DISASSEMBLY AND ASSEMBLY

WORK EQUIPMENT PPC VALVE

ASSEMBLY OF WORK EQUIPMENT PPC VALVE ASSEMBLY 1. Assemble valve (13) to body (14). 2. Assemble shim (12) and spring (11) to valve (13). ﬂ When assembling spring (11), set the end with the small coil diameter (inside diameter) at shim (12) end. 3. Assemble spring (10), retainer (9), and piston (8). ﬂ The number of loops in the coil for spring (10) is different for each of the hydraulic ports below, so be careful when installing.

4. 5.

Position of port

Free length of spring (mm)

P1, P2

44.4

P3, P4

42.4

fl The position of each port is marked at the bottom of the valve body. 2 Piston: Grease (G2-LI) fl When assembling piston (8), coat the outside of the piston and the inside of the hole in the body with grease. Fit O-ring to collar (7) and assemble in body (14), then install seal (6). Install plate (5). 3 Mounting bolt: 13.2 ± 1.5 Nm {1.35 ± 0.15 kgm} Install joint (4). 2 Sliding portion of joint: Grease (G2-LI) 2 Female thread of body: Thread tightener (LT-2) fl Coat two places on the female thread with one drop of thread tightener each as shown in the diagram on the right. 3 Joint: 44.1 ± 4.9 Nm {4.5 ± 0.5 kgm} fl Keep strictly to the tightening torque. Assemble boot (3) and disc (2), and tighten with nut (1). 3 Nut: 112.8 ± 14.7 Nm {11.5 ± 1.5 kgm} fl After assembling the disc, adjust the height of the disc. For details, see TESTING AND ADJUSTING, Adjusting PPC valve.

30-152

5〜7mm

CEP00425

PC600-6

DISASSEMBLY AND ASSEMBLY

TRAVEL PPC VALVE

DISASSEMBLY OF TRAVEL PPC VALVE ASSEMBLY 1. Remove screw (1), then remove lever (2). 2. Remove mounting bolts (3), then remove case and shaft assembly (4).

3. Remove mounting bolts (5), then remove plate (6) together with damper assembly (7). ﬂ Check the thickness and mounting position of washer (18).

4 2

4. Remove mounting bolts (8), then remove damper assembly (7) from plate (6).

5. Remove seal (9) and collar (10). 6. Pull out piston (11), and remove retainer (12), springs (13) and (14), and shims (15). ﬂ Check the number and thickness of shims (15) for each mounting position, and keep in a safe place.

18 1

6 9 10

7. Pull out valve (16) from body (17).

11 7

8 13 14 15 16

CEP00533

PC600-6

30-153

DISASSEMBLY AND ASSEMBLY

TRAVEL PPC VALVE

ASSEMBLY OF TRAVEL PPC VALVE ASSEMBLY 1. Assemble valve (16) in body (17). 2. Assemble shim (15) and spring (14) to valve (16). fl Assemble the same number and thickness of shim (15) as was removed during disassembly. Standard shim thickness: 0.3 mm fl Spring (14) is not symmetrical at the top and bottom, so assemble with the small coil diameter (inside diameter) at the shim end. 3. Assemble spring (13), retainer (12), and piston (11). 2 Outside circumference of piston, body hole: Grease (G2- LI) 4. Fit O-ring to collar (10) and assemble in body (17), then install seal (9). 5. Install damper assembly (7) to plate (6), then tighten mounting bolts (8). 2 Mounting bolt: Thread tightener (Locktite 262 or equivalent) 3 Mounting bolt: 3.9 – 4.9 Nm {0.4 – 0.5 kgm} 6. Install plate (6) and damper assembly (7) as one unit, then tighten mounting bolts (5). fl Temporarily assemble standard washer (1.6 mm) for washer (18). After completing the assembly, measure the difference in the angle when the left and right levers are operated fully. If the angle is greater than 0.7°, change the thickness of washer (18) to make the difference less than 0.7°. fl Washer thickness: 1.0, 1.3, 1.6 mm fl If the washer is thinner by 0.3 mm, the angle of the full stroke is 0.39° greater. 3 Mounting bolt: 27 – 34 Nm {2.8 – 3.5 kgm} 7. Install case and shaft assembly (4), then tighten mounting bolts (3). 2 Rocking portion of shaft, contact portion of lever and piston: Grease (G2-LI) 3 Mounting bolt: 25 – 31 Nm {2.8 – 3.5 kgm} 8. Install lever (2), then tighten screw (1). 2 Rocking portion of lever pin and plate: Grease (G2-LI) 3 Screw: 7.8 – 9.8 Nm {0.8 – 1.0 kgm}

30-154

4 2 5 18 1

6 9 10 11 7

8 13 14 15 16

CEP00533

PC600-6

DISASSEMBLY AND ASSEMBLY

BUCKET CYLINDER

REMOVAL OF BUCKET CYLINDER ASSEMBLY ¤ Extend the bucket cylinder piston rod to a point approx. 200 mm before the end of the DUMP stroke, lower the work equipment completely to the ground, then set the safety lock lever to the LOCK position. 1. Set block 1 under arm top, block 2 between link and arm, and block 3 between bucket cylinder and arm. 2. Remove head pin (1).

3. Start engine, and retract piston rod, then tie piston rod with wire to prevent it from coming out. ¤ Release the remaining pressure in the hydraulic circuit. For details, see TESTING AND ADJUSTING, Releasing remaining pressure in hydraulic circuit. 4. Disconnect two hoses (2). 5. Sling bucket cylinder assembly (3) temporarily and remove pin (4) on bottom side, then remove bucket cylinder assembly. 2 ﬂ There are shims installed, so check the number and thickness, and keep in a safe place. 4 Pin: 25 kg 4 Bucket cylinder assembly: 470 kg

PC600-6

30-155

DISASSEMBLY AND ASSEMBLY

BUCKET CYLINDER

INSTALLATION OF BUCKET CYLINDER ASSEMBLY •

Carry out installation in the reverse order to removal.

1 2 Inside of bushing before fitting pin: Lubricant containing molybdenum disulfide (LM-P) 2 Lubrication after fitting pin: Lubricant containing molybdenum disulfide (LM-G) ¤ When aligning the position of the pin hole, never insert your fingers in the pin hole. ﬂ Adjust the shim so that gap a between links (5) and (6) will be 1 – 2 mm. • Standard shim thickness: 0.8 mm 2 2 Inside of bushing before fitting pin: Lubricant containing molybdenum disulfide (LM-P) 2 Lubrication after fitting pin: Lubricant containing molybdenum disulfide (LM-G) ¤ When aligning the position of the pin hole, never insert your fingers in the pin hole. ﬂ Adjust the shim so that gap b between bottom end of cylinder (3) and bracket (7) will be 1 mm maximum. • Thickness of shim: 1.0 mm •

Bleeding air Bleed the air. For details, see TESTING AND ADJUSTING, Bleeding air.

•

Refilling with oil (hydraulic tank) Add oil through the oil filler to the specified level. Run the engine to circulate the oil through the system. Then check the oil level again.

30-156

PC600-6

DISASSEMBLY AND ASSEMBLY

ARM CYLINDER

REMOVAL OF ARM CYLINDER ASSEMBLY 4

¤ Extend the arm cylinder piston rod to a point approx. 200 mm before the end of the IN stroke, lower the work equipment completely to the ground, then set the safety lock lever to the LOCK position.

1 2 3

1. Set block 1 between arm cylinder and boom. 2. Disconnect grease hose (1). CEP00522

3. Remove plate (2), and pull out head pin (3). 1 ﬂ If the pin does not come out, use tool V2 and remove the pin from the head end. 4 Pin (3): 35 kg 4. Start engine, and retract piston rod, then tie piston rod with wire to prevent it from coming out. ¤ Stop the engine and release the remaining pressure in the circuit. For details, see TESTING AND ADJUSTING, Releasing pressure in hydraulic circuit.

5. Disconnect hose (4) and grease hose (5). fl Fit blind plugs in the hoses to prevent dust or dirt from entering. 6. Sling arm cylinder assembly (6), then remove plate (7) and pull out bottom pin (8). 2 fl If the pin does not come out, use tool V2 and remove the pin from the bottom end. fl There are shims installed, so check the number, thickness, and position, and keep in a safe place.

6 CEP00523

4 Pin (8): 40 kg 7. Remove arm cylinder assembly (6).

4 Arm cylinder assembly: 800 kg

PC600-6

30-157

DISASSEMBLY AND ASSEMBLY

ARM CYLINDER

INSTALLATION OF ARM CYLINDER ASSEMBLY •

Carry out installation in the reverse order to removal.

1 2 Inside of bushing before fitting pin: Lubricant containing molybdenum disulfide (LM-P) 2 Lubrication after fitting pin: Lubricant containing molybdenum disulfide (LM-G) ¤ When aligning the position of the pin hole, never insert your fingers in the hole. 1 2 Inside of bushing before fitting pin: Lubricant containing molybdenum disulfide (LM-P) 2 Lubrication after fitting pin: Lubricant containing molybdenum disulfide (LM-G) ¤ When aligning the position of the pin hole, never insert your fingers in the hole. ﬂ Adjust with shims so that the clearance a between bracket (9) and the bottom end face of cylinder (6) is less than 1 mm. • Shim thickness: 0.8 mm •

Bleeding air Bleed the air. For details, see TESTING AND ADJUSTING, Bleeding air.

•

Refilling with oil (hydraulic tank) Add oil through oil filler to the specified level. Run the engine to circulate the oil through the system. Then check the oil level again.

30-158

PC600-6

DISASSEMBLY AND ASSEMBLY

BOOM CYLINDER

REMOVAL OF BOOM CYLINDER ASSEMBLY ¤ Retract the arm and bucket cylinder piston rods fully, lower the work equipment completely to the ground, then put the safety lock lever in the LOCK position. ﬂ Fit blind plugs in the hoses to prevent dust or dirt from entering. 1. Disconnect grease hose (1). 2. Sling boom cylinder assembly (2) temporarily, and remove lock bolt (8). 3. Remove plate (9). ﬂ Check the number, thickness, and positions of the shims. 4. Sling boom cylinder assembly (2) temporarily. 5. Using tool 1, pull out head pin (3), then disconnect piston rod from boom. 1 4 Pin (3): 110kg (1 piece) 6. Start engine, and retract piston rod, then tie piston rod with wire to prevent it from coming out. ¤ Stop the engine and release the remaining pressure in the circuit. For details, see TESTING AND ADJUSTING, Releasing pressure in hydraulic circuit. 7. Support boom cylinder assembly (2) with a stand, etc., and disconnect hose (4). 8. Disconnect grease hose (5). 9. Sling boom cylinder assembly and remove plate (6). 10. Using tool V1, pull out bottom pin (7).

4 Pin (7): 30 kg 11. Remove boom cylinder assembly. 4 Boom cylinder assembly: 650 kg (1 piece)

PC600-6

30-159

DISASSEMBLY AND ASSEMBLY

BOOM CYLINDER

INSTALLATION OF BOOM CYLINDER ASSEMBLY •

Carry out installation in the reverse order to removal.

1 2 Inside of bushing before fitting pin: Lubricant containing molybdenum disulfide (LM-P) 2 Lubrication after fitting pin: Lubricant containing molybdenum disulfide (LM-G) ¤ When aligning the position of the pin hole, never insert your fingers in the hole. ﬂ Adjust the shim so that gap a between rod end of cylinder (2) and plate (9) will be 1 mm maximum. • Thickness of shim: 0.5 mm 2 2 Inside of bushing before fitting pin: Lubricant containing molybdenum disulfide (LM-P) 2 Lubrication after fitting pin: Lubricant containing molybdenum disulfide (LM-G) ¤ When aligning the position of the pin hole, never insert your fingers in the hole. ﬂ Adjust with shims so that clearance b between bracket (11) and the bottom end face of boom cylinder (2) is less than 1 mm. • Shim thickness: 1.5 mm •

Bleeding air Bleed the air. For details, see TESTING AND ADJUSTING, Bleeding air.

•

Refilling with oil (hydraulic tank) Add oil through oil filler to the specified level. Run the engine to circulate the oil through the system. Then check the oil level again.

30-160

PC600-6

DISASSEMBLY AND ASSEMBLY

HYDRAULIC CYLINDER

DISASSEMBLY OF HYDRAULIC CYLINDER ASSEMBLY 1. Piston rod assembly 1) Remove piping from cylinder assembly. 2) Remove mounting bolts, and disconnect head assembly (1). 3) Pull out piston rod assembly (2). ﬂ Place a container under the cylinder to catch the oil.

4) Disassemble piston rod assembly as follows. i) Set piston rod assembly (2) to tool U1.

ii) Remove piston assembly stopper screw (3). Screw size: M12 x pitch 1.75: Boom, Arm, Bucket

ﬂ If screw (3) has been caulked strongly and cannot be removed, screw it in fully, then fit a tap to the thread and pull it out.

PC600-6

30-161

DISASSEMBLY AND ASSEMBLY

HYDRAULIC CYLINDER

iii) Using tool U6, remove piston assembly (4). • When not using tool U6, use the drill holes (φ10: 4 places) and loosen the piston assembly.

iv) Remove plunger (5). v) Remove collar (6). vi) Remove head assembly (7).

vii) Remove cap (8), and pull out 11 balls (9), then remove cushion plunger (10). • Arm cylinder only

2. Disassembly of piston assembly 1) Remove ring (11). 2) Remove wear ring (12). ﬂ Two pieces are installed to each of the bucket cylinder and boom cylinder, and four pieces to the arm cylinder. 3) Remove piston ring (13). 4) Remove O-ring and backup ring (14).

30-162

PC600-6

DISASSEMBLY AND ASSEMBLY

HYDRAULIC CYLINDER

3. Disassembly of cylinder head assembly 1) Remove O-ring and backup ring (15). 2) Remove snap ring (16), then remove dust seal (17). 3) Remove rod packing (18). 4) Remove buffer ring (19). 5) Remove bushing (20).

PC600-6

30-163

DISASSEMBLY AND ASSEMBLY

HYDRAULIC CYLINDER

ASSEMBLY OF HYDRAULIC CYLINDER ASSEMBLY ﬂ Be careful not to damage the packings, dust seals, and O-rings. ﬂ Do not try to force the backup ring into position. Warm it in warm water (50 – 60°C) before fitting it. 1. Assembly of cylinder head assembly 1) Using tool U4, press fit bushing (20). 2) Assemble buffer ring (19). 3) Assemble rod packing (18). 4) Using tool U5, install dust seal (17), and secure with snap ring (16). 5) Install backup ring and O-ring (15).

2. Assembly of piston assembly 1) Using tool U2, expand piston ring (13). ﬂ Set the piston ring on tool U2, and turn the handle 8 – 10 times to expand the ring. 2) Set tool U3 in position, and compress piston ring (13).

3) Install backup ring and O-ring (14). 4) Assemble wear ring (12). 5) Assemble ring (11). ﬂ Be careful not to open the end gap of the ring too wide. 2 Ring groove : Grease (G2-LI)

30-164

PC600-6

DISASSEMBLY AND ASSEMBLY

HYDRAULIC CYLINDER

3. Piston rod assembly 1) Set piston rod assembly (2) to tool U1.

2) Assemble head assembly (7). 3) Fit O-ring and backup ring to collar (6), then assemble. 4) Assemble plunger (5). ﬂ After tightening the piston, check that the plunger has a little play.

5) Set cushion plunger (10) to piston rod, then assemble 11 balls (9), and secure with cap (8). • Arm cylinder only ﬂ After installing, check that the cushion plunger end has a little play.

6) Assemble piston assembly (4) as follows. • When using rod and piston assembly (2) again ﬂ Wash thoroughly and remove all metal particles and dirt. i) Screw in piston assembly (4), then use tool U6 to tighten piston assembly so that position of screw thread hole matches. ﬂ Remove all burrs and flashes with a file.

PC600-6

30-165

DISASSEMBLY AND ASSEMBLY

HYDRAULIC CYLINDER

ii)

•

Tighten screw (3). 3 Screw (3): 66.2 ± 7.35 Nm {6.75 ± 0.75 kgm} iii) Caulk thread at 2 places with punch. When using a new part for either or both of rod or piston assembly (2) ﬂ For the rod with bottom cushion, mark the cushion plug position on the end face of the rod. • Arm cylinder only

Screw in until piston assembly (4) contacts end face of rod, then use tool U6 to tighten. 3 Piston assembly (4): 294 ± 29.4 Nm {30 ± 3.0 kgm} ﬂ After tightening the piston, check that there is play in plunger (5).

ii)

Machine one hole used to install screw (3). ﬂ Apply the drill to the V-groove between piston (4) and threaded part of rod (2), and make a hole horizontally. ﬂ For the cylinder with bottom cushion (arm cylinder), avoid the cushion plug position when machining. • Screw machining dimension (mm)

Cylinder

Bottom Tap Drill diameter hole depth used

Tap depth

Bucket Boom

10.3

12×1.75

Arm

10.3

12×1.75

iii) After machining, wash thoroughly to remove all metal particles and dust. iv) Tighten screw (3). 2 Threaded part: Thread tightener (Locktite No. 262 or equivalent) 3 Screw: 58.9 – 73.6 Nm {6 – 7.5 kgm} v) Caulk thread at 2 places with punch.

30-166

PC600-6

DISASSEMBLY AND ASSEMBLY

HYDRAULIC CYLINDER

7) Assemble piston rod assembly (2). 2 Seal portion: Grease (G2-LI) ﬂ Set the end gap of the ring at the horizontal (side) position, align the axial center of shaft and cylinder tube, then insert. ﬂ After inserting, check that the ring is not broken and has not come out, then push in fully.

8) Tighten head assembly (1) with mounting bolts. 3 Mounting bolt : Cylinder

Tightening torque

Bucket Boom

892 ± 137 Nm {91.0 ± 14 kgm}

Arm

1.270 ± 200 Nm {130 ± 20 kgm}

9) Install piping.

PC600-6

30-167

DISASSEMBLY AND ASSEMBLY

BUCKET

REMOVAL OF BUCKET ASSEMBLY ¤ Set the back of the bucket facing down, lower the work equipment completely to the ground, then set the safety lock lever to the LOCK position. 1. Remove plate (1), then remove connecting pin (2) of the link and bucket. 1 ﬂ Check the number and thickness of the shims, and keep in a safe place. 4 Pin (2): 55 kg 2. Start engine, and retract piston rod, then tie link to arm with wire to prevent piston rod from coming out. ¤ Stop the engine and release the remaining pressure in the circuit. For details, see TESTING AND ADJUSTING, Releasing pressure in hydraulic circuit. 3. Remove plate (3), then remove connecting pin (4) of the arm and bucket. 2 ﬂ Check the number and thickness of the shims, and keep in a safe place. 4 Pin (4): 65 kg 4. Start engine and raise work equipment, swing work equipment, then remove bucket assembly. 4 Bucket assembly: 2,500 kg

30-168

PC600-6

DISASSEMBLY AND ASSEMBLY

BUCKET

INSTALLATION OF BUCKET ASSEMBLY •

Carry out installation in the reverse order to removal.

1 2 Inside of bushing before fitting pin: Lubricant containing molybdenum disulfide (LM-P) 2 Lubrication after fitting pin: Lubricant containing molybdenum disulfide (LM-G) ¤ When aligning the position of the pin hole, never insert your fingers in the hole. 2 2 Inside of bushing before fitting pin: Lubricant containing molybdenum disulfide (LM-P) 2 Lubrication after fitting pin: Lubricant containing molybdenum disulfide (LM-G) ¤ When aligning the position of the pin hole, never insert your fingers in the hole. fl Insert the O-ring at the end face of the bucket boss securely. fl Adjusting of bucket clearance 1) Measure gap a between arm (8) and bucket (5). fl It is easier to measure if the bucket is moved to one side so that all the play is in one place. 2) Adjust the shim so that gap a will be 1 – 2 mm. • Shim thickness: 1.0 mm

PC600-6

30-169

DISASSEMBLY AND ASSEMBLY

ARM

REMOVAL OF ARM ASSEMBLY 1. Remove bucket assembly. For detail, see REMOVAL OF BUCKET ASSEMBLY. 2. Secure link to arm with wire. ¤ Extend the arm cylinder piston rod to a point approx. 200 mm before the end of the IN stroke, then lower the arm on to block 1 and stand 2, and set the safety lock lever to the LOCK position. Then, stop the engine.

CEP00525

3. Set block between arm cylinder and boom. 4. Disconnect grease hose (1). 5. Remove plate (2), and pull out head pin (3) of arm cylinder. 1 ﬂ If the pin does not come out, use tool 1 and remove the pin from the head end. 4 Pin (3): 35 kg 6. Start engine, and retract piston rod, then tie piston rod with wire to prevent it from coming out. ¤ Stop the engine and release the remaining pressure in the circuit. For details, see TESTING AND ADJUSTING, Releasing pressure in hydraulic circuit. 7. Disconnect 2 bucket cylinder hoses (4). 8. Remove plate (5), then using tool 2, pull out boom top pin (6). 2 ﬂ There are shims installed, so check the number, thickness, and position, and keep in a safe place. 4 Pin (8): 80 kg

9. Start engine, then raise boom and remove arm assembly (7). 4 Arm assembly: 4,700 kg 7

CEP00526

30-170

PC600-6

DISASSEMBLY AND ASSEMBLY

ARM

INSTALLATION OF ARM ASSEMBLY •

Carry out installation in the reverse order to removal.

1 2 IInside of bushing before fitting pin: Lubricant containing molybdenum disulfide (LM-P) 2 Lubrication after fitting pin: Lubricant containing molybdenum disulfide (LM-G) ¤ When aligning the position of the pin hole, never insert your fingers in the hole. 1 2 Inside of bushing before fitting pin: Lubricant containing molybdenum disulfide (LM-P) 2 Lubrication after fitting pin: Lubricant containing molybdenum disulfide (LM-G) ¤ When aligning the position of the pin hole, never insert your fingers in the hole. ﬂ Adjust with shims so that clearance a between boom (8) and the bottom end face of arm (7) is less than 1 mm. • Shim thickness: 1.0 mm •

Bleeding air Bleed the air. For details, see TESTING AND ADJUSTING, Bleeding air.

•

Refilling with oil (hydraulic tank) Add oil through oil filler to the specified level. Run the engine to circulate the oil through the system. Then check the oil level again.

PC600-6

30-171

DISASSEMBLY AND ASSEMBLY

BOOM

REMOVAL OF BOOM ASSEMBLY 1. Remove arm assembly. For details, see REMOVAL OF ARM ASSEMBLY. ¤ Lower the boom assembly completely to the ground, then set the safety lock lever to LOCK position. 2. Disconnect boom cylinder assembly from boom. For details, see REMOVAL OF BOOM CYLINDER ASSEMBLY. 3. Disconnect front lamp wiring. 4. Disconnect bucket cylinder hoses (1) and arm cylinder hoses (2). 5. Sling boom assembly (10). 6. Using tool V1, remove boom foot pin (3), then remove boom assembly (10). 1 ﬂ There are shims installed, so check the number, thickness, and position, and keep in a safe place. 4 Boom foot pin: 150 kg 4 Boom assembly: 5,550 kg

10 CEP00299

30-172

PC600-6

DISASSEMBLY AND ASSEMBLY

BOOM

INSTALLATION OF BOOM ASSEMBLY •

Carry out installation in the reverse order to removal.

Bleeding air Bleed the air. For details, see TESTING AND ADJUSTING, Bleeding air.

•

Refilling with oil (hydraulic tank) Add oil through oil filler to the specified level. Run the engine to circulate the oil through the system. Then check the oil level again.

PC600-6

30-173

DISASSEMBLY AND ASSEMBLY

OPERATOR’S CAB

REMOVAL OF OPERATOR’S CAB ASSEMBLY ¤ Disconnect the cable from the negative (–) terminal of the battery.

1. Remove floor mat. 2. Remove operator’s seat (1). ﬂ Be careful not to damage the cover.

CEP00438

3. Remove knob (2).

4. Remove 4 bolts and 1 clip, then remove panels (3) and (4).

CEP00439

5. Disconnect hose (5) for window washer. 6

6. Remove plate (6), then remove left cover (7).

5 CEP00440

CEP00441

7. Disconnect hose (8) and speaker wiring connector, and remove right cover (9). ﬂ Lift up right cover (9) slightly before disconnecting the speaker wiring connector.

9 8

CEP00442

30-174

PC600-6

DISASSEMBLY AND ASSEMBLY

OPERATOR’S CAB

8. Remove cover (10) and duct (11). 9. Disconnect air conditioner cable (12).

10. Disconnect duct (13) at front. 11. Disconnect 11 connectors (14). fl Panel : CN-X07 (MIC17) fl Controller : CN-C01 (MIC13) : CN-C02 (MIC21) : CN-C03 (AMP040, 20) : CN-C16 (MIC17) : CN-C17 (AMP040, 16) fl For wiring harness intermediate : CN-H12 (S16) White : CN-H13 (S16) Blue : CN-H14 (M6) : CN-H15 (L2) : CN-M71 (1-pin) fl Speaker : CN-M13 (KES-2) : CN-M73 (KES-2) fl For air conditioner, heater: CN-M26 (M6) : CN-M12 (KES-3)

10 CEP00443

14 14 12

12. Disconnect engine controller wiring harness. • PC600, 600LC-6 Serial No.: 11001 and up

CEP00444

13. Remove nuts and mounting bolts, then lift off operator’s cab assembly (15). 4 Operator’s cab assembly: 330 kg

CEP00446

INSTALLATION OF OPERATOR’S CAB ASSEMBLY •

Carry out installation in the reverse order to removal.

PC600-6

30-175

DISASSEMBLY AND ASSEMBLY

COUNTERWEIGHT

REMOVAL OF COUNTERWEIGHT ASSEMBLY 1. Set sling bolt of counterweight assembly in position, and sling. 2. Remove mounting bolts. ﬂ Check the location of the shims. 3. Lift off counterweight assembly (1).

4 Counterweight assembly: 10,750 kg

INSTALLATION OF COUNTERWEIGHT ASSEMBLY •

Carry out installation in the reverse order to removal.

1 ﬂ Adjust the stepped difference (top and bottom clearance) from the bodywork with shims. ﬂ Install so that the clearance between the door and counterweight and the clearance between the revolving frame and the counterweight are a uniform 15 ± 5 mm. 3 Counterweight mounting bolt: 3,430 – 4,212 Nm {350 – 430 kgm}

30-176

PC600-6

40 MAINTENANCE STANDARD

Engine mount ............................................... 40- 2 PTO ................................................................ 40- 3 Swing machinery ......................................... 40- 4 Swing circle .................................................. 40- 6 Final drive ..................................................... 40- 8 Track frame and recoil spring ..................... 40-10 Idler ................................................................ 40-12 Carrier roller ................................................. 40-14 Track roller .................................................... 40-15 Track shoe ..................................................... 40-16 Hydraulic pump ............................................ 40-21 Control and PTO lubrication pump ............ 40-23 Control valve ................................................ 40-24 Swing motor ................................................. 40-31 Travel motor ................................................. 40-32 Work equipment swing PPC valve ............. 40-33 Travel PPC valve .......................................... 40-34 Service PPC valve ........................................ 40-35 Solenoid valve .............................................. 40-36 Center swivel joint ....................................... 40-37 Boom holding valve ..................................... 40-38 Boom lower regeneration valve ................. 40-39 Hydraulic cylinder ........................................ 40-40 Work equipment ........................................... 40-42 Dimensions of work equipment ................. 40-44

PC600-6

40-1

MAINTENANCE STANDARD

ENGINE MOUNT

Unit: mm

No.

Check item

Free height of rear mount rubber

Free height of front mount rubber

40-2

Criteria

Remedy

Standard size

Repair limit

126

—

134

—

Replace

PC600-6

MAINTENANCE STANDARD

PTO

Unit: mm

No.

Check item

Backlash between drive gear and driven gear

Backlash of SAL56 pump input shaft

0.273 – 0.374

—

Backlash between main shaft and plate

0.081 – 0.226

—

PC600-6

Criteria

Remedy

Standard clearance

Repair clearance

0.23 – 0.74

— Adjust

40-3

MAINTENANCE STANDARD

SWING MACHINERY

40-4

PC600-6

MAINTENANCE STANDARD

SWING MACHINERY

Unit: mm

No.

Check item

Backlash between swing motor shaft and No. 1 sun gear

Criteria

Remedy

Standard clearance

Clearance limit

0.15 – 0.49

—

Backlash between No. 1 sun gear and No. 1 planet gear

0.15 – 0.49

1.00

Backlash between No. 1 planet gear and ring gear

0.15 – 0.57

1.10

Backlash between No. 2 planet carrier and coupling

0.06 – 0.25

—

Backlash between No. 1 planet carrier and No. 2 sun gear

0.38 – 0.66

1.20

Backlash between No. 2 sun gear and No. 2 planet gear

0.15 – 0.49

0.90

Backlash between No. 2 planet gear and ring gear

0.17 – 0.57

1.00

Backlash between coupling and swing pinion

0.07 – 0.23

—

Backlash between swing pinion and swing circle

0 – 0.126

2.00

Clearance between plate 10 and coupling

0.38 – 0.82

—

Standard size

Repair limit

0 140.3 –0.100

—

11 Wear of swing pinion oil seal contact surface

PC600-6

Replace

Repair hard chrome plating replace

40-5

MAINTENANCE STANDARD

SWING CIRCLE

Unit: mm

No.

Check item Clearance of bearing in axial direction (when mounted on machine)

40-6

Criteria

Remedy

Standard clearance

Repair limit

0.10 – 0.25

3.2

Replace

PC600-6

MAINTENANCE STANDARD

FINAL DRIVE

40-8

PC600-6

MAINTENANCE STANDARD

FINAL DRIVE

Unit: mm

No.

Check item

Backlash between No. 1 sun gear and No. 1 planet gear

2 3

Criteria

Remedy

Standard clearance

Clearance limit

0.14 – 0.45

1.00

Backlash between No. 1 planet gear and No. 1 ring gear

0.18 – 0.63

1.10

Backlash between No. 2 planet carrier and motor

0.06 – 0.21

—

0.17 – 0.62

1.00

Backlash between No. 2 sun gear and No. 2 planet gear Backlash between No. 2 planet gear and No. 2 ring gear Backlash between No. 1 planet carrier and No. 2 sun gear

0.21 – 0.69

1.10

0.16 – 0.56

1.00

End play of sprocket shaft

0.10 – 0.15

—

Wear of sprocket teeth

4 5 6

Sprocket tooth width

PC600-6

Replace

Repair limit: 6 Standard size

Repair limit

104

101.5

Rebuild or replace

40-9

MAINTENANCE STANDARD

TRACK FRAME AND RECOIL SPRING

TRACK FRAME AND RECOIL SPRING ﬂ The diagram shows the PC600-6.

Unit: mm

No.

Check item

Criteria

Remedy

Standard size Tolerance 1

Top-to-bottom width of idler guide

Track frame

163.5

163.5 0

Idler support

161

161 0

159

Track frame

329

329 0

334

Idler support

324

—

322

Left-to-right width of idler guide

Standard size 3

Recoil spring

40-10

Repair limit

167.5

Rebuild or replace

Repair limit

Free length x OD

Installed length

Installed load

Free length

Installed load

859 x 301

715

292 kN {29,770 kg}

—

233.6 kN {23,816 kg}

Replace

PC600-6

MAINTENANCE STANDARD

IDLER

40-12

PC600-6

MAINTENANCE STANDARD

IDLER

Unit: mm

No.

Check item

Outside diameter of protruding part

Criteria

Remedy

Standard size

Repair limit

761

—

Outside diameter of tread surface

716

704

Depth of tread

22.5

—

Overall width

234

—

Width of tread

—

Clearance between shaft and bushing

Interference between idler and bushing

Standard size

Shaft

Hole

Standard clearance

Clearance limit

110

–0.120 –0.207

+0.480 +0.420

0.540 – 0.687

1.5

Standard size

Shaft

Hole

+0.067 +0.037

–0.036 –0.136

120

PC600-6

Tolerance

Rebuild or replace

Tolerance

Replace bushing

Standard Interference interference limit 0.073 – 0.203

—

40-13

MAINTENANCE STANDARD

CARRIER ROLLER

Unit: mm

No.

Check item Standard size

Repair limit

Outside diameter of flange

210

—

Outside diameter of tread

180

170

Width of tread

—

Thickness of tread

53.5

—

Width of flange

—

Clearance between shaft and bushing

Criteria

Standard size 68

Interference between roller and bushing

Standard size 73

Play of roller in axial direction

40-14

Tolerance

Remedy

Replace

Shaft

Hole

Standard clearance

Clearance limit

+0.09 +0.07

+0.43 +0.18

0.09 – 0.36

—

Tolerance Shaft

Hole

+0.38 +0.33

+0.24 +0.21

Standard Interference interference limit 0.09 – 0.17

Standard size

Clearance limit

0.62 – 0.93

—

PC600-6

MAINTENANCE STANDARD

TRACK ROLLER

Unit: mm

No.

Check item

Criteria

Remedy

Standard size

Repair limit

260

—

Outside diameter of flange

Outside diameter of tread surface

220

208

Thickness of tread

56.2

— Rebuile or replace

Overall width

325

—

Inside width

120

—

Width of tread

—

Width of flange

39.5

—

Clearance between shaft and bushing

Interference between roller and bushing

PC600-6

Tolerance

Standard size

Shaft

Hole

Standard clearance

Clearance limit

100

–0.140 –0.207

+0.390 +0.330

0.470 – 0.597

1.5

Tolerance

Standard size

Shaft

Hole

107.6

+0.067 +0.037

+0.020 –0.015

Replace bushing

Standard Interference interference limit 0.017 – 0.082

—

40-15

MAINTENANCE STANDARD

TRACK SHOE

ﬂ P Portion shows the link of bushing press fitting end.

40-16

PC600-6

MAINTENANCE STANDARD

TRACK SHOE

Unit: mm

No. 1

Check item

Criteria Standard size

Repair limit

228.6

233.6

Link pitch

Standard size 2

Remedy

Bushing outside diameter 72.5

Link height

Thickness of link metal (bushing press-fitting portion)

Reverse or replace

When turned Normal load

Impact load

62.5

—

Standard size

Repair limit

133

123

Repair or replace

33.75 219.8 Replace

Shoe bolt pitch

76.2

8 9

169

Link

Inside width

122.4

Overall width

61.4

Tread width

54.5

Protrusion of pin

3.7

Protrusion of regular bushing

9.6

Overall length of pin

290

Overall length of bushing

200.6

Thickness of bushing metal

14.7

Thickness of spacer

—

17 18

Press-fitting force

Bushing

127.4 – 274.4 kN {13 – 28 ton}

Regular pin

254.8 – 303.8 kN {26 – 31 ton}

Master

205.8 – 254.8 kN {21 – 26 ton}

Repair or replace

Adjust or replace

—

ª : Dry type track link

PC600-6

40-17

MAINTENANCE STANDARD

TRACK SHOE

Unit: mm

No.

Check item

a. Regular link

Criteria Tightening torque (Nm {kgm})

Additional tightening angle (deg.)

784.5±78.5 {80±8}

120±10 Retighten

Shoe bolt 20 b. Master link

Tightening torque (Nm {kgm})

Additional tightening Lower limit torque angle (deg.) (Nm {kgm})

—

No. of shoes (each side)

Interference between bushing and link Interference between regular pin and link Clearance between regular pin and bushing

Interference between master pin and link

Standard size

Clearance between master pin and bushing

—

Tolerance

Standard interference

Shaft

Hole

72.9

+0.050 0

–0.326 –0.400

0.326 – 0.450

48.8

+0.180 +0.080

–0.318 –0.380

0.318 – 0.480

Standard size

Standard size 48.8

—

49.6 ª

Remedy

Standard size 49.2

Tolerance Shaft

Hole

–0.62 –0.72

+0.6 0 Tolerance

Shaft

Hole

+0.030 0

–0.318 –0.380 Tolerance

Shaft

Hole

–0.65 –0.75

+0.60 0

Standard clearance 0.72 – 1.22

Adjust or replace

Standard interference 0.238 – 0.330 Standard clearance 0.65 – 1.35

ª : Dry type track link

40-18

PC600-6

MAINTENANCE STANDARD

TRACK SHOE

DOUBLE SHOE

Unit: mm

No.

Check item

Criteria

Remedy

Standard size

Repair limit

Height

Thickness

25 Replace

36.5 Length at bottom

36.5

26 Length at top

PC600-6

40-19

MAINTENANCE STANDARD

TRACK SHOE

TRIPLE GROUSER SHOE

Unit: mm

No.

Check item

Height

Thickness

Criteria Standard size

Repair limit

25 18 33

3 Length of bottom 4

25.5

Remedy

Length at tip

40-20

Rebuild or replace

17.5 23.5

PC600-6

MAINTENANCE STANDARD

HYDRAULIC PUMP

HYDRAULIC PUMP No. 1 main pump HPV95 + 95

PC600-6

40-21

MAINTENANCE STANDARD

HYDRAULIC PUMP

No. 2 main pump HPV95 + 95

40-22

PC600-6

MAINTENANCE STANDARD

CONTROL AND PTO LUBRICATION PUMP

CONTROL AND PTO LUBRICATION PUMP SAL56 + 8

Unit: mm No.

Check item

Clearance between gear case and side plate

Clearance between bearing inner dia. and gear shaft outer dia.

Criteria

Remedy

Model

Standard clearance

Clearance limit

SAL56

0.13 – 0.18

0.22

SAL8

0.10 – 0.15

0.19

SAL56

0.067 – 0.125

0.20 Replace

SAL8

0.067 – 0.125

0.20

Standard size

Tolerance

Repair limit

–0 –0.5

—

–0 –0.5

—

3 Pin insertion depth 4 5

—

Spline shaft rotation torque

Delivery Oil: EO10-CD Oil temp.: 45 – 55°C

(

— Delivery pressure (MPa {kg/cm2})

Standard delivery (¬ /min.)

Delivery limit (¬ /min.)

2,500

2.9 {30}

134

124

2,500

2.9 {30}

SAL56

) SAL8

PC600-6

Speed (rpm)

—

40-23

MAINTENANCE STANDARD

CONTROL VALVE

CONTROL VALVE 4-spool valve + 5-spool valve (with travel shuttle valve) (1/6)

40-24

PC600-6

MAINTENANCE STANDARD

CONTROL VALVE

(2/6)

Unit: mm

No.

Check item

Criteria Standard size

Remedy Repair limit

Free length x OD

Installed length

Installed load

Free length

Installed load

30.7 x 9.60

26.8

325 N {33.1 kg}

—

260 N {26.5 kg}

Main relief valve, main valve spring

30.4 x 11.3

25.0

45.1 N {4.60 kg}

—

36.3 N {3.70 kg}

Jet sensor relief valve, pilot poppet spring

26.3 x 8.0

26.1

3.82 N {0.39 kg}

—

3.04 N {0.31 kg}

Jet sensor relief valve, main valve spring

23.8 x 7.80

18.1

23.6 N {2.41 kg}

—

18.9 N {1.93 kg}

Spool return spring

87.6 x 21.2

54.5

192 N {19.6 kg}

—

154 N {15.7 kg}

Spool return spring

58.1 x 26.5

52.5

324 N {33.0 kg}

—

259 N {26.4 kg}

Main relief valve, pilot poppet spring

PC600-6

Replace spring if damaged or deformed

40-25

MAINTENANCE STANDARD

CONTROL VALVE

(3/6)

Unit: mm

No.

Check item

Criteria Standard size

Main relief valve, pilot poppet spring

Remedy Repair limit

Free length x OD

Installed length

Installed load

Free length

Installed load

30.7 x 9.60

26.8

325 N {33.1 kg}

—

260 N {26.5 kg}

Main relief valve, main valve spring

30.4 x 11.3

25.0

45.1 N {4.60 kg}

—

36.3 N {3.70 kg}

Jet sensor relief valve, pilot poppet spring

26.3 x 8.0

26.1

3.82 N {0.39 kg}

—

3.04 N {0.31 kg}

Jet sensor relief valve, main valve spring

23.8 x 7.80

18.1

23.6 N {2.41 kg}

—

18.9 N {1.93 kg}

Spool return spring

53.8 x 26.5

52.5

104 N {10.6 kg}

—

83.4 N {8.50 kg}

40-26

Replace spring if damaged or deformed

PC600-6

MAINTENANCE STANDARD

CONTROL VALVE

(4/6)

40-28

PC600-6

MAINTENANCE STANDARD

CONTROL VALVE

(5/6)

Unit: mm

No.

Check item

Criteria Standard size

Check valve spring

Remedy Repair limit

Free length x OD

Installed length

Installed load

Free length

Installed load

31.1 x 12.2

19.5

13.0 N {1.33 kg}

—

10.4 N {1.06 kg}

Check valve spring

31.8 x 7.60

26.5

0.98 N {0.10 kg}

—

0.78 N {0.08 kg}

Spool return spring

30.7 x 32.5

26.5

255 N {26.0 kg}

—

204 N {20.8 kg}

Spool return spring

54.0 x 34.2

52.0

255 N {26.0 kg}

—

204 N {20.8 kg}

Spool return spring

54.8 x 34.0

53.5

125 N {12.7 kg}

—

100 N {10.2 kg}

Spool return spring

21.0 x 16.9

21.0

0N {0 kg}

20.0

—

Spool return spring

54.9 x 34.0

53.5

125 N {12.7 kg}

—

100 N {10.2 kg}

Check valve spring

55.9 x 30.2

29.0

7.85 N {0.80 kg}

—

6.28 N {0.64 kg}

PC600-6

Replace spring if damaged or deformed

40-29

MAINTENANCE STANDARD

CONTROL VALVE

(6/6)

Unit: mm

No.

Check item

Criteria Standard size

Spool return spring

Remedy Repair limit

Free length x OD

Installed length

Installed load

Free length

Installed load

54.8 x 34.0

53.5

125 N {12.7 kg}

—

100 N {10.2 kg}

30.7 x 32.5

26.5

255 N {26.0 kg}

—

204 N {20.8 kg}

Spool return spring

54.0 x 34.2

52.0

255 N {26.0 kg}

—

204 N {20.8 kg}

Spool return spring

54.9 x 34.0

53.5

125 N {12.7 kg}

—

100 N {10.2 kg}

Spool return spring

54.8 x 34.0

53.5

125 N {12.7 kg}

—

100 N {10.2 kg}

Check valve spring

55.9 x 30.2

29.0

7.85 N {0.80 kg}

—

6.28 N {0.64 kg}

40-30

Replace spring if damaged or deformed

PC600-6

MAINTENANCE STANDARD

SWING MOTOR

SWING MOTOR KMF90ABE-3

Unit: mm

No.

Check item

Criteria Standard size

Check valve spring

Shuttle valve spring

PC600-6

Free length x OD

Remedy Repair limit

Installed length

Installed load

Free length

Installed load

35.0

3.53 N {0.36 kg}

—

2.84 N {0.29 kg}

62.5 x 20.0 16.4 x 8.9

11.5

13.7 N {1.4 kg}

—

10.8 N {1.1 kg}

Replace spring if damaged or deformed

40-31

MAINTENANCE STANDARD

TRAVEL MOTOR

TRAVEL MOTOR KMV335ADT

Unit: mm

No.

Check item

Criteria Standard size

Spool return spring

Remedy Repair limit

Free length x OD

Installed length

Installed load

Free length

Installed load

58.4 x 30.0

42.0

427 N {43.5 kg}

—

341 N {34.8 kg}

Check valve spring

62.5 x 20.0

35.0

3.53 N {0.36 kg}

—

2.84 N {0.29 kg}

Regulator piston spring

55.0 x 9.0

50.0

98.1 N {10.0 kg}

—

78.5 N {8.0 kg}

40-32

Replace spring if there damaged or deformation

PC600-6

MAINTENANCE STANDARD

WORK EQUIPMENT • SWING PPC VALVE

Unit: mm

No.

Check item

Criteria Standard size

Centering spring (for P3, P4)

Remedy Repair limit

Free length x OD

Installed length

Installed load

Free length

Installed load

38.7 x 15.5

9.81 N {1.0 kg}

—

7.85 N {0.8 kg}

Centering spring (for P1, P2)

42.5 x 15.5

17.7 N {1.8 kg}

—

14.1 N {1.44 kg}

Metering spring

26.5 x 8.2

24.9

16.7 N {1.7 kg}

—

13.3 N {1.36 kg}

PC600-6

Replace spring if any damages or deformations are found.

40-33

MAINTENANCE STANDARD

TRAVEL PPC VALVE

Unit: mm

No.

Check item

Criteria Standard size

Metering spring

Centering spring

40-34

Free length x OD

Remedy Repair limit

Installed length

Installed load

Free length

Installed load

24.7

16.7 N {1.7 kg}

—

13.7 N {1.4 kg}

26.5 x 8.15 48.1 x 15.5

32.5

108 N {11 kg}

—

86.3 N {8.8 kg}

Replace spring if there is damage or deformations.

PC600-6

MAINTENANCE STANDARD

SERVICE PPC VALVE

Unit: mm

No.

Check item

Criteria Standard size

Centering spring

Metering spring

PC600-6

Remedy Repair limit

Free length x OD

Installed length

Installed load

Free length

Installed load

33.6 x 15.3

28.4

125 N {12.7 kg}

—

100 N {10.2 kg}

22.7 x 8.1

22.0

16.7 N {1.7 kg}

—

13.3 N {1.36 kg}

Replace spring if any damages or deformations are found.

40-35

MAINTENANCE STANDARD

SOLENOID VALVE

40-36

PC600-6

MAINTENANCE STANDARD

CENTER SWIVEL JOINT

SBP00439

Unit: mm

No.

Check item

Clearance between rotor and shaft

PC600-6

Criteria

Remedy

Standard size

Standard tolerance

Clearance limit

0.056 – 0.105

0.111

Replace

40-37

MAINTENANCE STANDARD

BOOM HOLDING VALVE

Unit: mm

No.

Check item

Criteria Standard size

Pilot valve spring

Check valve spring

40-38

Remedy Repair limit

Free length x OD

Installed length

Installed load

Free length

Installed load

26.5 x 11.2

25.0

4.7 N {0.48 kg}

—

3.7 N {0.38 kg}

37.2 x 16.2

30.0

35.3 N {3.6 kg}

—

28.4 N {2.9 kg}

Replace spring if there is damage or deformation.

PC600-6

MAINTENANCE STANDARD

BOOM LOWER REGENERATION VALVE

Unit: mm

No.

Check item

Criteria Standard size

Remedy Repair limit

Free length x OD

Installed length

Installed load

Free length

Installed load

83.5 x 25.5

29.4 N {3.0 kg}

—

23.5 N {2.4 kg}

Spool return spring (large) 49.4 x 25.7

207 N {21.1 kg}

—

166 N {16.9 kg}

Spool return spring (small) 41.1 x 9.6

58.8 N {6.0 kg}

—

47.1 N {4.8 kg}

Spring (check valve)

PC600-6

Replace spring if damaged or deformed.

40-39

MAINTENANCE STANDARD

HYDRAULIC CYLINDER

HYDRAULIC CYLINDER BOOM CYLINDER

ARM CYLINDER

BUCKET CYLINDER

40-40

PC600-6

MAINTENANCE STANDARD

HYDRAULIC CYLINDER

Unit: mm

No.

Check item

Clearance between piston rod and bushing

Clearance between piston rod support shaft and bushing

Clearance between cylinder bottom support shaft and bushing

PC600-6

Criteria

Name of cylinder

Standard size

Boom

120

Tolerance

Remedy

Shaft

Hole

Standard clearance

Clearance limit

–0.036 –0.090

+0.263 +0.048

0.084 – 0.353

0.453 Replace bushing

Arm

140

–0.043 –0.106

+0.256 +0.039

0.082 – 0.362

0.062

Bucket

120

–0.036 –0.090

+0.263 +0.048

0.084 – 0.353

0.453

Boom

125

–0.043 –0.106

+0.495 +0.395

0.438 – 0.601

1.5

Arm

125

–0.043 –0.106

+0.495 +0.395

0.438 – 0.601

1.5

Bucket

110

–0.036 –0.090

+0.457 +0.370

0.406 – 0.547

1.5

Boom

110

–0.036 –0.090

+0.151 +0.074

0.110 – 0.241

1.5

Arm

120

–0.036 –0.090

+0.457 +0.370

0.406 – 0.547

1.5

Bucket

110

–0.036 –0.090

+0.457 +0.370

0.406 – 0.547

1.5

Replace pin, bushing

40-41

MAINTENANCE STANDARD

WORK EQUIPMENT

40-42

PC600-6

MAINTENANCE STANDARD

WORK EQUIPMENT

Unit: mm

No.

Check item

Clearance between bushing and mounting pin of boom and revolving frame

2 3 4 5 6 7

Clearance between bushing and mounting pin of boom and arm Clearance between bushing and mounting pin of arm and link Clearance between bushing and mounting pin of arm and bucket Clearance between bushing and mounting pin of link and link Clearance between bushing and mounting pin of link and bucket Bucket clearance

PC600-6

Criteria Standard size

Tolerance

Remedy

Shaft

Hole

Standard clearance

Clearance limit

140

–0.043 –0.106

+0.148 +0.057

0.100 – 0.254

1.5

130

–0.043 –0.106

+0.407 +0.325

0.368 – 0.513

1.5

110

–0.036 –0.090

+0.360 +0.284

0.320 – 0.450

1.5

115

–0.036 –0.090

+0.326 +0.223

0.259 – 0.416

1.5

110

–0.036 –0.090

+0.354 +0.275

0.311 – 0.444

1.5

115

–0.036 –0.090

+0.382 +0.279

0.315 – 0.472

1.5

0.5 – 1.0

Replace

Adjust shims

40-43

MAINTENANCE STANDARD

DIMENSIONS OF WORK EQUPMENT

DIMENSIONS OF WORK EQUPMENT 1. ARM

40-44

PC600-6

MAINTENANCE STANDARD

DIMENSIONS OF WORK EQUPMENT

Unit: mm

Model No.

PC600-6 PC600LC-6

125

148

458

130

582

321.7

1,187.2

3,465.2

3,324.2

497.6

810

700

608

2,138

115

457 ± 1

115 0

Arm as individual part

448 –0.5

When press fitting bushing

464

18 Min.

2,152

Max.

3,577

PC600-6

40-45

MAINTENANCE STANDARD

DIMENSIONS OF WORK EQUPMENT

2. BUCKET

40-46

PC600-6

MAINTENANCE STANDARD

DIMENSIONS OF WORK EQUPMENT

Unit: mm

Model No.

PC600-6

PC600-6 PC600LC-6

605.2 ± 0.5

58.1 ± 0.5

95.5°

608

2,119.9

277.9

—

φ115

457 ± 1

80.5

84.5

626

—

φ260

123.9

202.4

φ240

φ208

488.5 ± 1

40-47

OTHERS

Hydraulic circuit diagram ............................ 90- 3 Electric circuit diagram (1/4) ....................... 90- 5 Electric circuit diagram (2/4) ....................... 90- 7 Electric circuit diagram (3/4) ....................... 90- 9 Electric circuit diagram (4/4) ....................... 90-11

PC600-6

90-1

OTHERS

HYDRAULIC CIRCUIT DIAGRAM

PC600-6

90-3

OTHERS

ELECTRIC CIRCUIT DIAGRAM

ELECTRIC CIRCUIT DIAGRAM (1/4)

PC600-6

90-5

OTHERS

ELECTRIC CIRCUIT DIAGRAM

ELECTRIC CIRCUIT DIAGRAM (2/4)

PC600-6

90-7

OTHERS

ELECTRIC CIRCUIT DIAGRAM

ELECTRIC CIRCUIT DIAGRAM (3/4)

PC600-6

90-9

OTHERS

ELECTRIC CIRCUIT DIAGRAM

ELECTRIC CIRCUIT DIAGRAM (4/4)

PC600-6

90-11