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PC58UU-3

TROUBLESHOOTING

POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE

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

1.

Points to remember when handling electric
equipment

1) Handling wiring harnesses and connectors

Wiring harnesses consist of wiring connecting
one component to another component, connec-
tors used for connecting and disconnecting one
wire from another wire, and protectors or tubes
used for protecting the wiring.
Compared with other electrical components fit-
ted in boxes or cases, wiring harnesses are
more likely to be affected by the direct effects of
rain, water, heat, or vibration. Furthermore, dur-
ing 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 care-
ful 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 oxi-
dization of the contact surfaces.

(2) Defective crimping or soldering of connec-

tors
The pins of the male and female connectors
are in contact at the crimped terminal or sol-
dered portion, but if there is excessive force
brought to bear on the wiring, the plating at
the joint will peel and cause improper con-
nection or breakage.

POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE

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Содержание PC58UU-3

Страница 1: ...e in your area Please consult your local Komatsu distributor for those items you may require Materials and specifications are subject to change without notice PC58UU 3 mounts the 4D88E 3G and 4D88E 5X...

Страница 2: ...00 2 PC58UU 3 CONTENTS No of page 01 GENERAL 01 1 10 STRUCTURE FUNCTION AND MAINTENANCE STANDARD 10 1 20 TESTING AND ADJUSTING 20 1 30 DISASSEMBLY AND ASSEMBLY 30 1 90 OTHERS 90 1...

Страница 3: ...23 10 24 10 25 10 26 5 10 27 10 28 10 29 5 10 30 10 31 10 32 10 33 10 34 10 35 10 36 10 37 5 Mark Page Revision number 10 38 10 39 10 40 5 10 41 10 42 5 10 43 10 44 10 45 10 46 5 10 47 5 10 48 5 10 49...

Страница 4: ...309 6 20 310 1 20 311 1 20 312 6 20 312 1 6 20 313 1 20 314 1 20 315 1 20 316 6 20 317 6 20 318 6 20 319 6 20 320 6 20 321 6 20 322 6 20 323 6 20 324 6 20 325 6 20 326 6 20 327 6 20 328 6 20 329 6 20...

Страница 5: ...33 2 30 34 2 30 35 2 30 36 2 30 37 2 30 38 2 30 39 4 30 40 2 30 41 2 30 42 2 30 43 2 30 44 2 30 45 2 30 46 2 30 47 2 30 48 2 30 49 2 30 50 2 30 51 2 30 52 2 30 53 2 30 54 2 30 55 2 30 56 2 30 57 2 Ma...

Страница 6: ...pron 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 fel...

Страница 7: ...ring 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...

Страница 8: ...tion may contain hydraulic circuit diagrams electric circuit diagrams and mainte nance standards TESTING AND ADJUSTING This section explains checks to be made before and after performing repairs as we...

Страница 9: ...h item 3 Additional pages Additional pages are indicated by a hyphen and number after the page number File as in the example Example 10 4 10 4 1 10 4 2 10 5 REVISED EDITION MARK When a manual is revis...

Страница 10: ...load with one rope alone but sling with two or more ropes symmetrically wound onto the load k Slinging with one rope may cause turning of the load during hoisting untwisting of the rope or slipping o...

Страница 11: ...ressure 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 pu...

Страница 12: ...ght until sliding pre vention ring 1 contacts contact surface a of the hexagonal portion at the male end 2 Hold in the condition in Step 1 and push until cover 3 contacts contact surface a of the hexa...

Страница 13: ...Three bond 1735 790 129 9140 50 g Polyethylene container Quick hardening type adhesive Cure time within 5 sec to 3 min Used mainly for adhesion of metals rubbers plastics and woods Aron alpha 201 790...

Страница 14: ...an molybdenum di sulfide grease Since this grease is white it does not stand out against machine body Biogrease G2B G2 BT For high temperature and large load SYG2 400B SYGA 16CNB SYG2 400BT SYGA 16CNB...

Страница 15: ...4 7 27 34 59 74 98 123 153 190 1 2 1 5 2 8 3 5 6 7 5 10 12 5 15 5 19 5 16 18 20 22 24 24 27 30 32 36 235 285 320 400 455 565 610 765 785 980 23 5 29 5 33 41 46 5 58 62 5 78 80 100 27 30 33 36 39 41 46...

Страница 16: ...iameter Width across flat Tightening torque Nm kgm mm mm Range Target 02 03 04 05 06 10 12 14 14 20 24 33 42 Varies depending on type of connector 35 63 3 5 6 5 84 132 8 5 13 5 128 186 13 0 19 0 363 4...

Страница 17: ...tening torque mm Nm kgm 6 8 10 12 14 8 0 2 10 0 2 12 0 2 24 0 4 36 0 5 0 81 0 0 20 1 02 0 0 20 1 22 0 0 20 2 45 0 0 41 3 67 0 0 51 Thread diameter Tightening torque inch Nm kgm 1 16 1 8 1 4 3 8 1 2 3...

Страница 18: ...5 23 4 6 37 Charging and signal 15 84 0 45 13 36 7 0 59 Starting Glow plug 40 85 0 80 42 73 11 4 135 Starting 60 127 0 80 63 84 13 6 178 Starting 100 217 0 80 109 1 17 6 230 Starting Priori ty Circui...

Страница 19: ...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 mult...

Страница 20: ...3 819 0 315 0 709 1 102 1 496 1 890 2 283 2 677 3 071 3 465 3 858 0 354 0 748 1 142 1 536 1 929 2 323 2 717 3 110 3 504 3 898 0 1 2 3 4 5 6 7 8 9 0 10 20 30 40 50 60 70 80 90 0 22 05 44 09 66 14 88 1...

Страница 21: ...700 20 341 22 983 25 625 2 113 4 755 7 397 10 039 12 680 15 322 17 964 20 605 23 247 25 889 2 378 5 019 7 661 10 303 12 944 15 586 18 228 20 870 23 511 26 153 0 1 2 3 4 5 6 7 8 9 0 10 20 30 40 50 60 7...

Страница 22: ...62 0 1034 3 1106 6 1179 0 1251 3 1323 6 1396 0 28 9 101 3 173 6 245 9 318 3 390 6 462 9 535 2 607 6 679 9 752 2 824 6 896 9 969 2 1041 5 1113 9 1186 2 1258 5 1330 9 1403 2 36 2 108 5 180 8 253 2 325 5...

Страница 23: ...92 2034 2176 2318 2460 2603 2745 2887 3030 3172 3314 3456 56 9 199 1 341 4 483 6 625 8 768 1 910 3 1053 1195 1337 1479 1621 1764 1906 2048 2190 2333 2475 2617 2759 2901 3044 3186 3328 3470 71 1 213 4...

Страница 24: ...0 6 10 0 9 4 8 9 8 3 7 8 7 2 6 7 6 1 5 6 5 0 4 4 3 9 3 3 2 8 2 2 1 7 1 1 0 6 0 0 6 1 1 1 7 2 2 2 8 3 3 3 9 4 4 5 0 5 6 6 1 6 7 7 2 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33...

Страница 25: ...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 kP...

Страница 26: ...PC58UU 3 01 1 GENERAL ASSEMBLY DRAWING 01 2 WORK EQUIPMENT RANGE DRAWING 01 3 SPECIFICATIONS 01 4 WEIGHT TABLE 01 11 LIST OF LUBRICANTS AND COOLANT 01 13 01 GENERAL 5...

Страница 27: ...height Canopy spec mm 2 625 2 610 2 605 Cab spec mm 2 625 2 610 2 605 C Overall width mm 2 000 D Width of track shoe mm 400 E Tail swing radius mm 1 035 F Overall length of track 3 mm 2 470 2 460 2 43...

Страница 28: ...8UU 3 A Max digging reach 5 660 B Max digging depth 4 000 C Max digging height 6 330 D Max vertical wall depth 2 900 E Max dumping height 4 600 F Min swing radius of work equip ment when the offset is...

Страница 29: ...ow High km h 2 7 4 5 2 5 4 2 2 7 4 5 2 5 4 2 Gradeability deg 30 30 Ground Pressure kPa kg cm 30 4 0 31 31 4 0 32 30 4 0 31 31 4 0 32 Dimension Overall length for transport mm 5 335 5 335 Overall widt...

Страница 30: ...r roller 1 on each side Track roller 5 on each side Track shoe road liner shoe rubber shoe Assembly type road liner 38 pieces for one side Integrated rubber shoe Hydrualic system Hydraulic pump Type x...

Страница 31: ...ton rod mm 55 Stroke mm 650 Max distance between pins mm 845 Min distance between pins mm 195 Bucket cylinder Type Reciprocating piston Cylinder inside diameter mm 75 Diameter of piston rod mm 50 Stro...

Страница 32: ...2 7 4 5 2 5 4 2 2 7 4 5 2 5 4 2 Gradeability deg 30 30 Ground Pressure kPa kg cm2 30 4 0 31 31 4 0 32 30 4 0 31 31 4 0 32 Dimension Overall length for transport mm 5 335 5 335 Overall width mm 2 000...

Страница 33: ...ach side Track roller 5 on each side Track shoe road liner shoe Assembly type road liner 38 pieces for one side rubber shoe Integrated rubber shoe Hydraulic system Hydraulic pump Type x No Variable di...

Страница 34: ...de Track roller 4 on each side Track shoe road liner shoe Assembly type road liner 39 pieces for one side rubber shoe Integrated rubber shoe Hydraulic system Hydraulic pump Type x No Variable displace...

Страница 35: ...Stroke mm 650 Max distance between pins mm 845 Min distance between pins mm 195 Bucket cylinder Type Reciprocating piston Cylinder inside diameter mm 75 Diameter of piston rod mm 50 Stroke mm 580 Max...

Страница 36: ...95 195 Operator seat 26 26 Fuel tank without fuel 7 7 Hydraulic tank without hydraulic oil 50 50 Control valve 35 35 Counterweight 750 750 Swing motor with brake valve 15 15 Swing circle 66 66 Swing m...

Страница 37: ...el tank without fuel 7 Hydraulic tank without hydraulic oil 50 Control valve 35 Counterweight 750 Swing motor with brake valve 15 Swing circle 66 Swing machinery 35 Center swivel joint 18 Track frame...

Страница 38: ...boom 142 142 3rd bracket 95 95 Sub link 20 20 Arm assembly 104 104 Bucket link assembly 35 35 Bucket assembly with 680 mm with side cutter 133 133 Blade assembly 220 220 Boom cylinder assembly 54 54...

Страница 39: ...86 104 F 30 20 10 0 10 20 30 40 C Specified Refill Engine oil pan Engine oil 1 9 1 8 7 SAE 30 SAE 10 W SAE 10W 30 2 8 7 4 SAE 15W 30 Final drive case each 3 1 0 1 0 SAE 10W 4 0 8 0 8 Hydraulic system...

Страница 40: ...14 HYDRAULIC EQUIPMENT LAYOUT DRAWING 10 18 HYDRAULIC TANK AND FILTER 10 19 HYDRAULIC PUMP 10 20 CONTROL VALVE 10 29 CLSS 10 37 CENTER SWIVEL JOINT 10 61 TRAVEL MOTOR 10 62 SWING MOTOR 10 70 TRAVEL P...

Страница 41: ...STRUCTURE FUNCTION AND MAINTENANCE STANDARD PTO 10 2 PC58UU 3 PTO 1 Boss 2 Spring pin 3 Rubber 4 Cover 5 Hydraulic pump...

Страница 42: ...n guard 8 Radiator outlet hose 9 Oil cooler outlet 10 Oil cooler inlet 11 Drain valve SPECIFICATION Radiator Core type CF27 2 Fin pitch 4 0 2 mm Total heat dissipation surface 10 1 m Pressure valve cr...

Страница 43: ...1 Idler 2 Control valve 3 Swing motor 4 Travel motor 5 Engine 6 Hydraulic pump for travel and work equip ment 7 Hydraulic pump for swing and blade 8 Control pump for pilot control 9 Center swivel joi...

Страница 44: ...3 Greasing to swing circle pinion 4 Outer race 5 Inner race 6 Ball 7 Seal a Inner race soft zone position b Outer race soft zone position Specification Reduction ratio 90 10 9 0 Grease G2 LI ALBANIA E...

Страница 45: ...No 1 planetary gear number of teeth 32 4 No 2 sun gear number of teeth 22 5 Ring gear number of teeth 86 6 No 2 planetary gear number of teeth 32 7 Swing machinery case 8 Swing pinion number of teeth...

Страница 46: ...g gear 0 14 0 38 0 6 4 Backlash between No 1 planetary carrier and No 2 sun gear 0 10 0 26 5 Backlash between No 2 sun gear and No 2 planetary gear 0 12 0 28 0 6 6 Backlash between No 2 planetary gear...

Страница 47: ...10 8 PC58UU 3 STRUCTURE FUNCTION AND MAINTENANCE STANDARD TRACK FRAME IDLER CUSHION Serial No 20001 22300 TRACK FRAME IDLER CUSHION 7...

Страница 48: ...PC58UU 3 STRUCTURE FUNCTION AND MAINTENANCE STANDARD Serial No 22301 and up 7 TRACK FRAME IDLER CUSHION 10 8 1...

Страница 49: ...9 155 Rebuild or replace 3 Recoil spring Standard size Repair limit Replace Free length Installed length Installed load Free length Installed load Road liner steel shoe 302 238 2 26 9 kN 2 748 kg 294...

Страница 50: ...e between idler shaft and bushing Standard size Tolerance Standard clearance Clearance limit Replace Shaft Hole 35 0 025 0 064 0 142 0 080 0 105 0 260 1 5 7 Interference between idler and bushing Stan...

Страница 51: ...nce between shaft and bushing Standard size Tolerance Standard clearance Clearance limit Replace Shaft Hole 35 0 025 0 050 0 142 0 080 0 105 0 192 1 5 7 Interference between roller and bushing Standar...

Страница 52: ...Interference between shaft and bearing Standard size Tolerance Standard interference Interference limit Replace Shaft Hole 25 0 013 0 008 0 0 010 0 023 0 008 4 Interference between roller and bearing...

Страница 53: ...Criteria Remedy 1 Wear on tooth bottom diameter Standard size Tolerance Repair limit Rebuild or replace 380 37 1 0 2 0 368 2 Wear on addendum diameter 423 99 0 3 0 412 3 Wear on addendum width 26 24...

Страница 54: ...10 14 PC58UU 3 STRUCTURE FUNCTION AND MAINTENANCE STANDARD TRACK SHOE ROAD LINER AND TRIPLE GROUSER SHOE Serial No 20001 22300 1 Road liner shoe 2 Triple grouser shoe TRACK SHOE 7...

Страница 55: ...22 5 Hole 22 3 0 030 0 070 0 052 0 0 078 0 170 8 Clearance between regular pin and bushing Standard size Tolerance Standard clearance Clearance limit Shaft Hole Shaft 22 5 Hole 22 9 0 060 0 0 2 0 140...

Страница 56: ...PC58UU 3 STRUCTURE FUNCTION AND MAINTENANCE STANDARD Serial No 22301 and up 1 Triple grouser shoe 2 Road liner TRACK SHOE 7 10 15 1...

Страница 57: ...egu lar pin and link Shaft 22 5 Hole 22 3 0 060 0 030 0 052 0 030 0 148 0 260 8 Interference between mas ter pin and link Shaft 22 5 Hole 22 3 0 030 0 070 0 052 0 030 0 078 0 170 9 Clearance between r...

Страница 58: ...NTENANCE STANDARD TRIPLE GROUSER SHOE Unit mm No Check item Criteria Remedy 1 Grouser height Standard size Repair limit Rebuild or replace 14 10 2 Plate thickness 6 3 Grouser base length 17 4 13 5 Gro...

Страница 59: ...RUBBER SHOE Serial No 20001 22300 Unit mm No Check item Criteria Remedy 1 Wear of lug height Standard size Repair limit Replace 25 5 2 Wear of roller guard 38 49 3 Wear of sprocket meshing portion St...

Страница 60: ...RD Serial No 22301 and up Unit mm No Check item Criteria Remedy 1 Wear of lug height Standard size Repair limit Replace 25 5 2 Wear of roller guide 47 60 3 Wear of meshing parts of sprocket 2 3 4 Wear...

Страница 61: ...tank 4 Swing motor 5 Oil cooler 6 Hydraulic pump 7 Center swivel joint 8 R H work equipment PPC valve 9 L H work equipment PPC valve 10 Travel PPC valve 11 R H travel motor 12 Bucket cylinder 13 Arm c...

Страница 62: ...lic tank 3 Drain plug 4 Bypass valve 5 Filter element 6 Suction strainer 7 Oil filler cap Specification Tank capacity 56 l l l l Hydraulic oil amount in tank 38 l l l l Pressure valve cracking pressur...

Страница 63: ...p to control the pump absorption torque by sensing the engine speed and a tandem gear pump for swing and blade pilot P1 Pump discharge port P1L Pump pressure input port P2 Pump discharge port P1T Trav...

Страница 64: ...E FUNCTION AND MAINTENANCE STANDARD HYDRAULIC PUMP PC58UU 3 10 21 3 Case 4 Rocker cam 5 Shoe 6 Piston 7 Cylinder block 8 Valve plate 9 Spring in servo piston 10 Servo piston 11 Ball for rocker cam sup...

Страница 65: ...shoe 5 is punched tooth tip of the piston 6 with a concave ball so that the piston 6 and the shoe 5 form a spherical bearing The shoe 5 is always pressed to the plane A of the rocker cam 4 and slides...

Страница 66: ...7 come to change differently Then the pump absorbs and discharges the difference E F When the capacity in the E chamber con tracts as the cylinder block 7 rotates the pump discharges oil during the pr...

Страница 67: ...operates as a dou ble pump While the machine is not travelling the oils merge in the control valve and the pump functions as a single pump Merge mode While the machine is travelling the two discharge...

Страница 68: ...0 0 l l l l min 16 2 kW 22 0 PS 6 60 kW 9 0 PS 22 8 kW 31 0 PS Since the pump input horsepower is larger than the engine horsepower the PC control is started to prevent the engine from stalling Right...

Страница 69: ...ssure port GH Gear pump Hi signal port PDE EPC drain port GL Gear pump Lo signal port PAVE Pump average pressure port PE Control piston pressure point PEPC EPC main pressure input port 1 Lock nut 6 Pi...

Страница 70: ...ifferential pressure is set low automatically at low idling to lower the discharge The engine speed is detected by the GH and GL pressures before and after the fixed throttle metering throttle in the...

Страница 71: ...delivery Q The relationship between the PAVE pump average pressure When the double pump is employed the average of P1 and P2 is sensed and Q pump discharge is shown in the figure at right Usually the...

Страница 72: ...ffset cylinder head PA6 From R H offset PPC valve A7 To blade cylinder head PA8 From swing to left PPC valve A8 To swing motor MB PB1 From L H travel REVERSE PPC valve B1 To L H travel motor PB2 From...

Страница 73: ...STRUCTURE FUNCTION AND MAINTENANCE STANDARD CONTROL VALVE 10 30 PC58UU 3...

Страница 74: ...uction valve arm bottom 16 Spool L H travel 5 Suction valve bucket bottom 17 Spool R H travel 6 Safety valve with suction blade bottom 18 Unload valve 7 Safety valve 19 Spool boom 8 Safety valve with...

Страница 75: ...R R H travel 5 Pressure compensation valve F boom 18 Pressure compensation valve R L H travel 6 Pressure compensation valve F arm 19 Cooler bypass valve 7 Pressure compensation valve F bucket 20 Spoo...

Страница 76: ...ve 17 Suction valve 5 Pressure compensation valve R R H travel 18 Boom hydraulic drift prevention valve 6 Unload valve 19 Check valve 7 Check valve 20 Check valve 8 Main relief valve 21 Suction valve...

Страница 77: ...ssist valve 5 Suction valve 18 Spool blade 6 Pressure compensation valve R arm 19 Suction valve 7 Pressure compensation valve F bucket 20 Check valve 8 Spool bucket 21 Safety valve with suction 9 Suct...

Страница 78: ...STRUCTURE FUNCTION AND MAINTENANCE STANDARD CONTROL VALVE PC58UU 3 10 35 1 Spool swing 2 Swing relief valve for gear pump 3 Safety valve 4 Pressure bleeding plug...

Страница 79: ...kg F Pressure compensation valve spring 20 0 x 8 40 12 0 6 86 N 0 70 kg 5 49 N 0 56 kg G Pressure compensation valve spring 22 75 x 8 40 17 0 16 57 N 1 69 kg 13 24 N 1 35 kg H Pressure compensation v...

Страница 80: ...of load Controlability that allows digging even in the fine control mode Ease of compound operation in which the flow distribution performance depends on spool opening area during compound operation S...

Страница 81: ...oad pressure at the control valve outlet becomes constant LS differential pressure PLS Pump pressure PP LS pressure PLS When the LS differential pressure PLS reduces below the set pressure of the LS v...

Страница 82: ...e of the control valve In case of compound operation of the actuator with this valve the differential pressure P between the spool upstream inlet and the downstream outlet of each valve becomes consta...

Страница 83: ...STRUCTURE FUNCTION AND MAINTENANCE STANDARD CLSS 10 40 PC58UU 3 EACH FUNCTION AND OPERATION OF EACH VALVE Hydraulic circuit diagram and valve names 5...

Страница 84: ...Pa 295 kg cm 3 Main relief valve Set pressure 26 0 MPa 265 kg cm 4 Pump merge divider valve 5 Logic valve 6 Pressure compensation valve 7 Suction valve 8 Pilot pressure check valve 9 Check valve 10 Li...

Страница 85: ...o the left end face of the spool 1 and the LS pressure PLS1 and PLS2 are applied to the right end face Since the LS pressure PLS1 and PLS2 are 0 when the control valve is neutral the pump discharge pr...

Страница 86: ...fine control mode the LS pressure PLS1 PLS2 will occur and will be applied to the right end face of the spool 1 At the same time the dif ferential pressure between the LS pressure PLS1 PLS2 and the p...

Страница 87: ...e right end face of the spool 1 At the same time the differ ence between the LS pressure PLS1 PLS2 and the pump discharge pressure PP1 PP2 is small because the opening areas of the control valve spool...

Страница 88: ...he oil flow is controlled according to the opening ratio of the spool Operation If the travel control valve is operated singu larly it is set in the separate mode by the pump merge divider valve Accor...

Страница 89: ...om the flow control valve 2 and the spool notch a As the pressure reducing valve 3 moves to the right the pump discharge pressure PP3 is reduced due to pressure loss at notch c and is led to the LS ci...

Страница 90: ...S This plug slows the rising speed of the LS pressure PLS causes pressure losses at the spool and the throttle of the shuttle valve by the discarded throttled flow and reduces the effective LS differe...

Страница 91: ...e PLS of another actuator is applied to the spring chamber PLS and pushes the pressure reducing valve 1 and the flow control valve 2 to the left side The flow control valve 2 throttles the open ing ar...

Страница 92: ...the piston 3 S2 Area of the pressure reducing valve 1 area of the piston 3 Area ratio S1 S2 and compensation characteristics When the ratio is 1 00 The expression Pump discharge pressure PP Spool not...

Страница 93: ...t actuator become equal to the pump circuit pressure PP Relief pressure In this case the PLS2 spring chamber pres sure of the above actuator becomes equal to the PP pump circuit pressure because of ba...

Страница 94: ...e L H and R H travel motors will become the same during the straight travel and travel deviation will decrease The b damper is installed to relieve the tran sient characteristics of sudden opening and...

Страница 95: ...ight 1 is returned from the straight travel position to the neutral position to steer the machine a difference is made in the load pressure between both PA travel actuator circuits Left A Right A At t...

Страница 96: ......

Страница 97: ...MAINTENANCE STANDARD CLSS 10 54 PC58UU 3 SWING AND BLADE VALVE Structure The swing and blade sections are the open center valve of the gear pump The blade sec tion is arranged in tandem in the rear o...

Страница 98: ...PA8 port the spool moves to the right and oil flows in the A8 port The load check valve has A port and B port one each in its spool The relief valve 1 for the gear pump is installed to the swing sect...

Страница 99: ...ing both swing PPC pressures and arm IN PPC pressure as signals Operation Both swing PPC pressures and arm IN PPC pressure are output respectively through the check valve in the spring case to the BR...

Страница 100: ...he pump merge divider valve to set the pump in the sepa rate mode 2 In merge mode If the work equipment PPC pressure excluding the swing PPC pressure is applied to the a port the c output port of the...

Страница 101: ...ion When the travel valve is operated singularly the travel PPC pressure is applied through the logic valve spool to the right side of the pump merge divider valve spool 1 If the travel PPC pressure e...

Страница 102: ...ogic valve output pressure is drained and spool operating pressure of pump merge divider valve goes to zero So spool of merge divider valve is pressed to the R H end and PP1 PP2 and PP3 are merged PLS...

Страница 103: ...valve sends the oil from the gear pump circuit to the main pump circuit Operation If the boom is raised the boom raising PPC pressure is applied to the a port to move the boom assist valve to the left...

Страница 104: ...ontrol valve C1 To R H travel motor D From R H travel control valve D1 To R H travel motor E From travel 2nd speed selector solenoid E1 To travel 2nd speed selector valve F From Blade control valve F1...

Страница 105: ...CTURE FUNCTION AND MAINTENANCE STANDARD TRAVEL MOTOR 10 62 PC58UU 3 TRAVEL MOTOR A From travel control valve B From travel control valve D To hydraulic tank P From travel 2nd speed selector solenoid v...

Страница 106: ...hange pressure 1 96 4 41 MPa 20 45 kg cm Reduction ratio 57 9 1 Check valve 13 Shaft 2 Counterbalance valve 14 Cover 3 Regulator valve 15 Drain plug 4 Valve plate 16 Case 5 Brake piston 17 Regular pis...

Страница 107: ...58UU 3 OUTLINE The swash plate 1 has two planes x and y on the back and is supported with the pivot 2 To change the travel speed the pressurized oil in the control chamber a is sent to the reg ulator...

Страница 108: ...ssed the reg ulator valve 2 to the left side So the regulator valve 2 stops the main pressurized oil led from the control valve to the end cover 5 by pushing the check valve 6 The pressurized oil in t...

Страница 109: ...pump will flow in the Pi port and push the regulator valve 2 in the right direc tion Therefore the main pressurized oil from the control valve passes through the passage c of the regulator valve 2 fl...

Страница 110: ...for the engine speed pump delivery to prevent this danger Operation at oil supply When the travel lever is operated the pres surized oil from the control valve will be sup plied to the PA port push an...

Страница 111: ...A and MA ports are opened to prevent cavi tation Braking operation for travelling down slope If the machine starts running away while it is travelling down a slope the motor runs idle and the oil pres...

Страница 112: ...lt the pressing force of the spring 5 applied to the plate 3 and disc 4 is lost and the plate 3 and disc 4 are separated to release the brake When travel lever is set to neutral during travel If the t...

Страница 113: ...From control valve S From tank T To tank MA From control valve MB From control valve Specification Type LMF16 Theoretical delivery 16 1 cc rev Rated speed 2 100 rpm Rated flow capacity 33 8 min Safet...

Страница 114: ...lve 6 Valve plate 14 Check valve 7 Disc 15 Check valve spring 8 Plate 16 Hydraulic timer valve No Check item Criteria Remedy A Timer valve spring Standard size Repair limit Replace spring if any damag...

Страница 115: ...the piston 4 The pressurized oil sent to the 1 side of the cylinder block 5 presses the pistons 4 3 or 4 pieces and generates the F1 force F1 kg P kg cm x 4D cm This force is applied to the thrust pla...

Страница 116: ...pressure at the MB port will rise generate starting torque to the motor and start the motor rotating The oil from the motor outlet will return to the tank from the MA port through the control valve 2...

Страница 117: ...s pressed up by the brake spring 13 Accordingly the brake piston presses the disc 14 and plate 15 to apply the brake 2 When swing and arm levers are operated The pressurized oil from the PPC flows thr...

Страница 118: ...plied to the a chamber and the swing brake is released Under this condi tion if the PPC lever is set in neutral pressur ized oil is not supplied to the B port and the pressure in the a chamber lowers...

Страница 119: ...arply When the circuit pressure reaches P1 the oil pressure will push the spring 4 due to the area difference D1 D3 of the valve 3 Then the valve 3 will start opening At this time the oil pressure wil...

Страница 120: ...STRUCTURE FUNCTION AND MAINTENANCE STANDARD TRAVEL PPC VALVE PC58UU 3 10 77 12 TRAVEL PPC VALVE P From main pump P1 L H reverse P2 L H forward P3 R H reverse P4 R H forward T To tank...

Страница 121: ...Repair limit Replace spring if any damages or deformations are found Free length x O D Installed length Installed load Free length Installed load 26 56 x 8 15 24 9 16 7 N 1 7 kg 13 7 N 1 40 kg B Cente...

Страница 122: ...e connection of the fine control hole f is switched from the pump pressure chamber PP to the drain chamber D thereby relieving P1 port pressure As a result the spool 1 moves up and down so that force...

Страница 123: ...re chamber PP and starts sup plying pump pressure This supply continues until P1 port pressure is reconverted to the level equivalent to the lever position When the operation valve spool returns oil i...

Страница 124: ...PC VALVE PC58UU 3 10 81 12 PPC VALVE FOR WORK EQUIPMENT AND SWING P From PPC lock valve P1 Left Arm OUT Right Boom LOWER P2 Left Arm IN Right Boom RAISE P3 Left Swing to left Right Bucket CURL P4 Left...

Страница 125: ...UCTURE FUNCTION AND MAINTENANCE STANDARD PPC VALVE 10 82 PC58UU 3 12 1 Spool 2 Metering spring 3 Centering spring 4 Piston 5 Disk 6 Nut for linking the lever 7 Joint 8 Plate 9 Retainer 10 Body 11 Filt...

Страница 126: ...tandard size Repair limit Replace spring if any damages or deformations are found Free length x O D Installed length Installed load Free length Installed load 38 7 x 15 5 34 0 9 8 N 1 0 kg 7 8 N 0 8 k...

Страница 127: ...hereby disconnecting the fine control hole f from the pump pressure chamber PP The disconnected spool 1 is in no time connected to the drain chamber D resulting in relieving pressure on port P1 Thus t...

Страница 128: ...p pressure chamber PP and starts supplying pump pressure This supply continues until the port P1 pressure has recovered to the level equivalent to the lever position When the operation valve returns o...

Страница 129: ...ANCE STANDARD PPC VALVE 10 86 PC58UU 3 12 FOR OFFSET FOR SERVICE 1 Spool 2 Metering spring 3 Centering spring 4 Piston 5 Lever 6 Plate 7 Retainer 8 Body 9 Filter P From main pump P1 To service valve P...

Страница 130: ...ia Remedy A Centering spring Standard size Repair limit Replace spring if any damages or deformations are found Free length x O D Installed length Installed load Free length Installed load 33 9 x 15 3...

Страница 131: ...is move connection of the fine control hole f is switched from the pump pressure chamber PP to the drain chamber D thereby relieving port P1 pressure As a result the spool 1 moves up and down so the f...

Страница 132: ...PP and starts supplying pump pressure This supply continues until the P1 port pressure recovers to the level equivalent to the lever position When the operation valve spool returns oil in the drain c...

Страница 133: ...STRUCTURE FUNCTION AND MAINTENANCE STANDARD HYDRAULIC CYLINDER 10 90 PC58UU 3 12 HYDRAULIC CYLINDER BOOM CYLINDER ARM CYLINDER BUCKET CYLINDER 5...

Страница 134: ...STRUCTURE FUNCTION AND MAINTENANCE STANDARD HYDRAULIC CYLINDER PC58UU 3 10 91 12 OFFSET CYLINDER BLADE CYLINDER 5...

Страница 135: ...6 1 0 Blade 55 0 030 0 076 0 174 0 100 0 130 0 250 1 0 3 Clearance between cylinder bottom support shaft and bushing Boom 50 0 147 0 209 0 142 0 080 0 025 0 351 1 0 Bucket 45 0 025 0 064 0 142 0 080 0...

Страница 136: ...STRUCTURE FUNCTION AND MAINTENANCE STANDARD SOLENOID VALVE PC58UU 3 10 93 12 SOLENOID VALVE...

Страница 137: ...e ARM IN B5 To control valve BOOM RAISE T To hydraulic oil tank 1 Boom RAISE stop EPC valve 2 Arm IN stop EPC valve 3 Offset left stop solenoid valve 4 2nd speed selector solenoid valve 5 PPC lock sol...

Страница 138: ...y this spool flow of pilot oil pressure to the actuator is blocked At the same time oil from the actuator is led from port B to port T then drained to the hydraulic oil tank When solenoid is magnetize...

Страница 139: ...hrough the spool 2 and port B up to the operation valve At the same time port T is closed thereby block ing oil flow to the tank When solenoid is demagnetized circuit is iso lated The solenoid 1 is de...

Страница 140: ...coil is mag netized and circuit pressure is at a reduced level If signal from the controller to the coil 1 is reduced the coil thrust is reduced in propor tion to the reduction in signal current thou...

Страница 141: ...ing flow of pressurized oil from the PPC valve to the operation valve At the same time oil from the operation valve is passed through ports B and T and finally drained to the tank Signal current 0 inc...

Страница 142: ...98 1 STRUCTURE FUNCTION AND MAINTENANCE STANDARD MULTI CONTROL VALVE 1 JIS pattern 2 J D pattern Operation pattern selection drawing The port names correspond to the symbols in the drawing 4 MULTI CO...

Страница 143: ...STRUCTURE FUNCTION AND MAINTENANCE STANDARD WORK EQUIPMENT PC58UU 3 10 99 12 WORK EQUIPMENT...

Страница 144: ...STRUCTURE FUNCTION AND MAINTENANCE STANDARD WORK EQUIPMENT 10 100 PC58UU 3 12...

Страница 145: ...pin and bushing 80 0 145 0 059 0 335 0 270 0 125 0 276 1 0 5 Clearance between 3rd bracket and sub link mounting pin and bushing 50 0 025 0 064 0 142 0 080 0 105 0 206 1 0 6 Clearance between 3rd brac...

Страница 146: ...STRUCTURE FUNCTION AND MAINTENANCE STANDARD WORK EQUIPMENT 10 102 PC58UU 3 12 DIMENSION OF WORK EQUIPMENT 1 Arm 5...

Страница 147: ...Cylinder head side 60 0 0 5 3 50 0 025 0 064 0 100 0 4 Boom side 186 0 5 1 0 Arm side 180 0 5 1 0 5 143 1 6 185 9 1 0 7 323 1 0 8 1 620 9 1 932 3 2 0 10 1 393 4 1 11 202 2 1 12 16 7 1 13 330 0 5 14 3...

Страница 148: ...STANDARD WORK EQUIPMENT 10 104 PC58UU 3 12 2 Bucket Unit mm No PC58UU 3 Measuring position Standard size Tolerance 1 246 9 0 5 2 5 7 0 5 3 736 3 4 55 5 55 6 30 7 30 8 13 5 9 170 2 0 10 60 11 42 12 258...

Страница 149: ...PC58UU 3 10 105 12 AIR CONDITIONING PIPING 1 Hot water take off piping 2 Hot water return piping 3 Refrigerant piping 4 Receiver dryer 5 Condenser 6 Air conditioner compressor 7 Air conditioner unit 8...

Страница 150: ...ock lever 6 PPC lock switch 7 Neutral engine start relay for starter circuit 8 Safety relay 9 Starter 10 Deceleration controller 11 Fuel adjust dial 12 Fuel adjust motor 13 One touch deceleration swit...

Страница 151: ...tch 2 is shifted to the START position with the safety lock lever 5 at the LOCK position the starting signal flows in the starter 9 and the engine starts If the safety lock lever 5 is at the FREE posi...

Страница 152: ...STRUCTURE FUNCTION AND MAINTENANCE STANDARD ELECTRICAL CONTROL SYSTEM 10 108 PC58UU 3 12 ELECTRICAL CONTROL SYSTEM OVERALL SYSTEM DIAGRAM 5...

Страница 153: ...uipment operation resistor 13 Monitor panel 14 Alarm buzzer 15 TVC EPC valve 16 2nd travel speed selector solenoid valve 17 PPC lock solenoid valve 18 Boom RAISE stop EPC valve 19 Arm IN stop EPC valv...

Страница 154: ...box 5 Emergency pump driving switch 6 Resistor 7 TVC EPC valve 8 Main pump 8a Servo valve 8b LS valve 8c PC valve 9 Engine speed sensor 10 Engine 11 Control valve 11a Work equipment control valve 11b...

Страница 155: ...torque When the engine speed goes low the controller reduces the pump absorbtion torque to prevent the engine from stopping A Pump obsorbtion torque B Engine torque P Engine rated flywheel horsepower...

Страница 156: ...l PPC oil pressure switch signal f Travel alarm actuation signal Function Travel speed selection Travel speed is switched according to changes in the motor capacity which is controlled by the travel a...

Страница 157: ...Travel PPC valve 12 Offset PPC valve 13 Engine 14 Main pump Input output signal a Controller power supply b Solenoid power supply c Solenoid valve driving signal Function The PPC lock switch is linked...

Страница 158: ......

Страница 159: ...and the Auto matic Boom Arm Stop System CONTROL FUNCTIONS Reduction function Stop alarm function Interference prevention system Emergency stop alarm function Cancelling function Reset function Depth f...

Страница 160: ...STRUCTURE FUNCTION AND MAINTENANCE STANDARD ELECTRICAL SYSTEM 10 116 PC58UU 3 12 SYSTEM DIAGRAM 5...

Страница 161: ...t terminal 20 Safety lock lever 21 PPC lock switch 22 Neutral engine start relay for PPC lock 23 PPC lock solenoid valve 24 Engine 25 Main pump 26 Control valve 26a Merged valve Input output signal a...

Страница 162: ...fering zones Drawing dimension A 200 250 mm B 150 200 mm This function ensures work safety and operating performance in the left offset area The controller constantly calculates X Y and Z coordinates...

Страница 163: ...tion in the diagram is somewhat modified from that in actual operations to facilitate descriptions of the system function A Interference B Emergency stop alarm point B1 50 mm B2 50 mm C Stop alarm poi...

Страница 164: ...the predeter mined stop point due to failures of the sole noid or EPC valves and enters the emergency stop zone the system stops action of work equipment swing travel and sounds the alarm buzzer When...

Страница 165: ...onic system caution lamp will also start flashing to notify the operator that the cancel function has been turned on If any failure is present in the electric system of the solenoid or EPC valves this...

Страница 166: ...ition cal culation or computer calculation error this function allows you to correct it in a single switch operation For the correction stop the bucket in the specified position then enter the auto ma...

Страница 167: ...This function will determine the differ ence calculation error between the actual depth A and the depth B calcu lated based upon the output voltage from respective potentiometers and stores it in mem...

Страница 168: ...round Level display func tion The depth C of the measurement level B from the ground level G L is kept displayed on the monitor panel depth indicator during the operation Setup procedure Turn the star...

Страница 169: ...ame position when the datum plane A is set and when the bucket is placed on the measurement level B Display method Depth below the datum plane A is indicated in 0 1 mm steps Fractions are rounded off...

Страница 170: ...e resulting shocks or impacts Note that this function is not usable for limit ing the bucket height Setup procedures Shift the mode select switch to the Height Lift the boom up to the height where you...

Страница 171: ...ximately 20 This function reduces move speed of the arm in this zone by reducing output pressure from the arm PPC valve to the arm operation valve RETRACT move at the EPC valve This arrangement helps...

Страница 172: ...s the counting to the con troller Remarks Number of ring gear teeth is 116 1 Connector 2 Sensor PPC OIL PRESSURE SWITCH 1 Plug 2 Switch 3 Connector Specifications Contact Normally open Turning ON pres...

Страница 173: ...g arm X O X Standard arm X counter weight O X O Long arm X counter weight X O O Slide arm X X X Multiple changer arm O O X Mode selection table CN G2 13P CN G2 3P Depth display 0 set X X Height setup...

Страница 174: ...utput 16 TVC solenoid valve Output 17 Swing and travel alarm Output 18 Governor motor relay for drive Output 19 Acceleration signal Input 20 NC Pin No Signal name I O signal 13 NC 14 Offset angle Inpu...

Страница 175: ...lled on each of the boom feet arm foot and second boom top to detect the angle of the boom arm and offset work equipment Using the resistance value of the variable resistor potentiometers send angle d...

Страница 176: ...the emergency work equipment operation switch or the emergency pump drive switch is turned ON Boom RAISE stop EPC valve Arm IN stop EPC valve Offset left stop solenoid valve PPC lock solenoid valve 2n...

Страница 177: ...TOR SYSTEM PC58UU 3 10 133 12 MONITOR SYSTEM This system monitors the machine status using sensors installed on various parts of the machine processes the monitoring data and displays the current mach...

Страница 178: ...ality in the monitor panel controller or wiring between the moni tor panel and controller the monitor does not display normally Input output signal AMP040 16P CN F27 Pin No Signal name I O signal 1 Po...

Страница 179: ...l is in lowest level Empty 6 Pilot Preheating When pre heater is turned on Lights up for about 18 seconds when starting switch is turned to HEAT position then goes off to show that preheat ing is fini...

Страница 180: ...the diaphragm 4 is below the specified level the switch is turned on and a signal is sent to the monitor panel COOLANT TEMPERATURE SENSOR 1 Connector 2 Plug 3 Thermistor Function The coolant temperatu...

Страница 181: ...SOR Function The fuel level sensor is installed to the fuel tank The float 1 moves up and down according to the fuel level The float 1 oper ates the variable resistor 4 through the arm 2 and sends a s...

Страница 182: ......

Страница 183: ...alue 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...

Страница 184: ...ressure SAE 30 oil Oil temperature 40 60 C MPa 3 43 0 1 0 28 0 1 engine speed 250 rpm kg cm 35 1 28 1 Blow by pressure SAE 30 oil Water temperature Operating range Pa mm H2O At high idling Oil pressur...

Страница 185: ...ession pressure SAE 30 oil Oil temperature 40 60 C MPa kg cm 3 43 0 1 0 28 0 1 engine speed 250 rpm 35 1 28 1 Blow by pressure SAE 30 oil Water temperature Operating range Pa mm H2O At high idling Oil...

Страница 186: ...valve 30 6 6 30 6 6 Bucket control valve Offset control valve Swing control valve L H travel control valve R H travel control valve Blade control valve 20 6 6 20 6 6 Travel of control lever Boom cont...

Страница 187: ...lic oil temperature 45 55 C All control levers at HOLD Engine at full throttle MPa kg cm 2 9 0 5 30 5 2 9 0 5 30 5 Boom Hydraulic oil temperature 45 55 C Relief pressure at engine full Relieve only ci...

Страница 188: ...g one turn and measure time taken to swing next 5 turns Sec 30 3 Max 36 Hydraulic drift of swing Posture when measuring Max reach bucket at rated load or full of soil rated load 3 53 kN 360 kg Engine...

Страница 189: ...re devia tion when traveling next 20 m on flat ground Use a hard horizontal surface Measure dimension x mm Max 300 At Hi or Lo Max 330 At Hi or Lo Hydraulic drift of travel Engine stopped Hydraulic oi...

Страница 190: ...retraction of cyl inder Max 15 Max 22 Blade hydraulic drift at tip of blade Engine stopped Hydraulic oil temperature 45 55 C Set blade at maximum lifting height and mea sure downward movement at edge...

Страница 191: ...1 9 Time lag Boom Engine at low idling Hydraulic oil temperature 45 55 C Fully retract arm and bucket cylinders then lower boom from maximum height and mea sure time taken from point where bucket con...

Страница 192: ...moving again after stopping at bottom Sec 0 Max 1 Blade Engine at low idling Hydraulic oil temperature 45 55 C Lower blade from maximum height and mea sure time taken from point where blade con tacts...

Страница 193: ...ar pump 2 9 MPa 30 kg cm STD mode Rated speed of pump 2 400 rpm Check point Test pump discharge pressure MPa kg cm Average pressure MPa kg cm Standard value for discharge amount l l l l min Judgement...

Страница 194: ...g switch ON Work equip ment selection Monitoring code 1 Measure voltage If the condition is within the range shown in the table below it is normal 1 Turn starting switch ON 2 Monitoring code 01 is dis...

Страница 195: ...e shown in the table below it is normal 1 Turn starting switch OFF 2 Disconnect connector Arm potentiometer W4 Measure resistance If the condition is within the range shown in the table below it is no...

Страница 196: ...he condition is within the range shown in the table below it is normal At normal temperature 25 C 1 Turn starting switch OFF 2 Disconnect connector Travel speed rais ing solenoid valve F8 Measure resi...

Страница 197: ...on section 1 Connect T adapter Monitor item Input connector Measurement condition Indication Sensor input signal Engine oil pressure F27 j Start engine Lamp ON Max 1V Lamp OFF 10 15V Charge level F27...

Страница 198: ...OFF 500 Disconnection Engine oil pressure sensor M5 Measure resistance If the condition is within the range shown in the table below it is normal 1 Start engine 2 Disconnect terminal Coolant tempera t...

Страница 199: ......

Страница 200: ...e in work equipment swing and travel circuits 20 112 Testing and adjusting LS differential pressure 20 114 Adjusting PC valve 20 115 Testing and adjusting hydraulic pressure in control pump circuit 20...

Страница 201: ...kg cm 5 799 401 2701 Differential pressure gauge Compression pressure D 1 795 502 1905 Compression gauge 0 6 9 MPa 0 70 kg cm 2 795 111 1110 Adapter 3 795 101 1571 Joint Valve clearance E Commerciall...

Страница 202: ...high idling speeds Measure the engine speed with the fuel con trol lever at the low idling and high idling positions 2 Measuring engine speed when pump is relieved Run the engine at full throttle and...

Страница 203: ...h you are measur ing For details see DISSASSEMBLY AND ASSEMBLY Removal of nozzle holder assem bly 4 Install adapter D2 to the nozzle holder mounting part and connect compression gauge D1 5 Disconnect...

Страница 204: ...inder No 1 is on the flywheel side 3 Bring cylinder No 1 to the compression top dead center and adjust it then rotate the crank shaft by 180 and adjust valve clearance a of each cylinder in firing ord...

Страница 205: ...ng mark 2 stamped on the flywheel is matched to the timing mark 3 on the flywheel housing a For the injection timing see the STANDARD VALUES ADJUSTING If the injection timing is out of standard adjust...

Страница 206: ...jection angle instead of measuring the injection timing 1 Befor romoving fuel injection pump 2 remove the cover in front of the timing gear case and make match marks on the meshing parts of pump drive...

Страница 207: ...of fuel injection pump 7 Read the injection angle difference calculated in step 5 above by the scale of the adjustment seal Minimum division 0 5 of cam angle and adjust the installed angle of the fuel...

Страница 208: ...e alternator outward to adjust the belt tension 4 Tighten adjustment bolt 2 and alternator mount ing bolt 1 in order Serial No 22001 and up TESTING 1 Remove covers 2 pieces on the rear of boom 2 Press...

Страница 209: ...the fuel control lever to the high idling position 3 Bring fuel injection pump governor lever 1 in contact with stopper 6 on the FULL side 4 Under this condition secure cable 2 to bracket 5 with nuts...

Страница 210: ...the exhaust pipe then tighten the clip to secure it to the exhaust pipe 2 Connect the probe hose accelerator switch plug and air hose to smoke meter F2 The pressure of the air supply should be less t...

Страница 211: ...front part of the upper structure lowers and the rear part rises 3 Set the dial gauge to the zero point 4 Set the arm at about right angles to the ground and lower the boom until the front part of the...

Страница 212: ...VAL OF TRACK SHOE ASSEMBLY 2 Align wear gauge M with the sprocket Align the datum line then align the wave shape of the wear gauge 3 Judge the sprocket wear If the wave shape of the sprocket is above...

Страница 213: ...e the machine slowly forward and in reverse 2 To check that the track shoe tension is nor mal run the engine at low idling and move the machine forward by the length of track on the ground and stop sl...

Страница 214: ...2 Adjust the yoke of cable 3 to dimension f Installation dimension f 132 8 mm 3 Adjust the yoke on the valve side of cable 3 to dimension g Installation dimension g 119 2 mm 4 Loosen and retract stopp...

Страница 215: ...stall oil pressure gauge C1 39 2 MPa 400 kg cm 2 Run the engine at full throttle and relieve each actuator and measure the oil pressure at this time 3 Measuring travel circuit relief pressure 1 Remove...

Страница 216: ...ircuit relief pressure 1 Remove oil pressure pickup plug 3 10 mm P 1 25 2 Install oil pressure gauge C1 39 2 MPa 400 kg cm 3 Run the engine at full throttle and relieve the swing circuit and blade cir...

Страница 217: ...ring digging operation of bucket with no load 1 57 0 1 MPa 16 1 kg cm 2 Measure with oil pressure gauge Since the differential pressure does not exceed 1 96 MPa 20 kg cm measure it with the same press...

Страница 218: ...eased the engine speed may lower or the engine speed may be nor mal and working speed may lower If this trou ble occurs and the pump discharge and LS differential pressure are normal adjust the pump P...

Страница 219: ...ral and measure the oil pres sure Adjusting If the control circuit pressure is abnormal adjust the control relief valve installed to the 5 spool solenoid valve assembly according to the following proc...

Страница 220: ...on the travel motor side If the output pressure is measured when the boom is raised or the arm is moved IN to the stroke end it is lower than the normal value The pressure in hose 3 can also be mea su...

Страница 221: ...er to the FREE position 2 Travel speed Hi solenoid valve Press the travel speed Hi pedal 3 Offset LEFT stop solenoid valve Perform the LEFT offset operation 4 Arm IN stop EPC valve Perform the arm IN...

Страница 222: ...e assembly For the hose to be disconnected see hydraulic circuit diagram on the next page 2 Install nipple C4 including the O ring and plug and C3 including O ring then install oil pres sure gauge C1...

Страница 223: ...TESTING AND ADJUSTING 20 120 PC58UU 3 b ADJUSTING PC VALVE MEASURING PPC VALVE OUTPUT PRESSURE PPC VALVE AND SWING HOLDING BRAKE CIRCUIT...

Страница 224: ...eliminated by the above adjustment TESTING SWING HOLDING BRAKE INLET PRESSURE 1 Disconnect hose 1 2 Install nipple C4 including O ring and plug and C3 including the O ring then install oil pres sure...

Страница 225: ...ravel posture When setting the machine in the travel posture extend the bucket and arm cyl inder rods fully and hold the boom at an angle of 45 2 Travel for 10m then measure dimension a for the next 2...

Страница 226: ...locknut 3 with the hexagonal wrench inserted Before adjusting mark the position of the locknut with paint Loosen the locknut with the hexagonal wrench in position Loosening angle of locknut Approx 90...

Страница 227: ...kage is below the standard value the cause of hydraulic drift is on the control valve side If the leakage is above the standard value the cause of hydraulic drift is on the cylinder side 1 Fully extra...

Страница 228: ...R 3 Run the engine at full throttle and apply relief pressure to the bottom side of the cylinder Boom cylinder RAISE operation Arm cylinder IN operation Bucket cylinder CURL operation Offset cylinder...

Страница 229: ...ine speed at middle range or below for about 1 hour Air bleeding procedures 1 2 3 4 5 6 7 Bleed air from pump Start engine Bleed air from cylinder Bleed air from swing motor Bleed air from travel moto...

Страница 230: ...each of the arm bucket off set swing and blade cylinders by perform ing above operations of 2 and 3 3 Bleeding air from swing motor 1 Run the engine at slow speed and swing to the left 3 times 2 Swin...

Страница 231: ...hydraulic tank gradually to release the residual pressure from the tank PRESSURIZING HYDRAULIC TANK If the oil filler cap of the hydraulic tank was removed pressurize the hydraulic tank accord ing to...

Страница 232: ...position depth display and side stop Flow chart of resetting of electric system The number in the square shows the number of the item for resetting procedure written on pages 20 130 to 20 140 1 Reset...

Страница 233: ...systemcaution lamp at center of 88 starts blinking at intervals of 0 8 seconds After 2 sec onds electric system cau tion lamp at center of 88 starts blinking at intervals of 0 8 seconds After 2 sec on...

Страница 234: ...female plug red wiring harness and the input reset terminal 2 is a male plug yellow white wiring harness with out tape 3 Check that the electric system caution lamp on the monitor panel starts blinki...

Страница 235: ...or more systems have error Codes other than ones marked The total of the first figures to the left is dis played For explanation of in the Repro duction column see Displayed method of monitor panel a...

Страница 236: ...iometer 2 and offset poten tiometer 3 i Set the work equipment in the position for resetting and check again to see if the error code is displayed Boom RAISE stroke end Arm IN stroke end Offset RIGHT...

Страница 237: ...tic stop and stopping distance in front direction Use the arm IN operation to check 1 Check automatic stop i Set the work equipment to the following posture Boom Rear face perpendicular Bucket Horizon...

Страница 238: ...et teeth and the cab to 260 300 mm Because of inertia when stopping the work equipment will move about 50 mm closer than the set position so allow a margin when setting 3 Turn the starting switch OFF...

Страница 239: ...teeth and the cab to 260 mm Because of inertia when stopping the work equipment will move about 50 mm closer than the set position so allow a margin when setting 3 Turn the starting switch OFF and st...

Страница 240: ...s any problem with normal operations carry out the resetting operation again from 1 Reset potentiometer input signal If an abnormality display appears during the resetting operation remove all the cau...

Страница 241: ...nal 2 is a male 1 pin con nector yellow white wiring harness without tape 4 Check that the electrical system caution lamp on the monitor panel starts to flash 2 seconds later in a 1 second cycle If ab...

Страница 242: ...In the above posture set the mode selection switch to DEPTH SET 0 and turn the setting switch to the SET posi tion Check that the depth display changes to 0 0 when this is done ii Lower the bucket to...

Страница 243: ...throttle and operate the lever fully to raise the boom and check that it stops at the original position iii Turn the setting switch to the CLEAR position to cancel the setting 11 Compensation resettin...

Страница 244: ...from 1 Reset potentiometer input signal 5 Disconnect terminals 1 and 3 then turn the starting switch OFF 6 When the starting switch is turned ON again the resetting operation is completed Run the eng...

Страница 245: ...uipment and install new ones Boom potentiometer 1 Arm potentiometer 2 Offset potentiometer 3 After replacing the potentiometers set the work equipment in the position for resetting and check to see if...

Страница 246: ...of the diode and the black end in contact with the cathode N There is a mark showing the direction of continuity on the surface of the diode 2 If a normal tester is switched to the diode range the vo...

Страница 247: ......

Страница 248: ...AM 20 216 CONNECTION TABLE FOR CONNECTOR PIN NUMBERS 20 219 T ADAPTER BOXES AND T ADAPTER TABLE 20 241 1 EXPLANATIONS OF CONTROL MECHANISM OF ELECTRICAL SYSTEM 20 242 METHOD OF USING JUDGEMENT TABLE 2...

Страница 249: ...failed part or a problem with the method of operation When operating the machine to re enact the symptoms do not perform any trouble shooting or measurement that may make matters worse 5 Troubleshooti...

Страница 250: ...PC58UU 3 20 203 TROUBLESHOOTING SEQUENCE OF EVENTS IN TROUBLESHOOTING SEQUENCE OF EVENTS IN TROUBLESHOOTING 6...

Страница 251: ...ted in boxes or cases wiring harnesses are more likely to be affected by the direct effects of rain water heat or vibration Furthermore dur ing inspection and repair operations they are frequently re...

Страница 252: ...efore if water should get into the connector the pins will be short cir cuited by the water so if any water gets in immediately dry the connector or take other appropriate action before passing electr...

Страница 253: ...ur thumb and pull the connectors apart Never pull with one hand When removing from clips When removing a connector from a clip pull the connector in a parallel direction to the clip If the connector i...

Страница 254: ...hen insert it securely For connectors with lock stopper push in the connector until the stopper clicks into posi tion Correct any protrusion of the boot and any misalignment of the wiring harness For...

Страница 255: ...act so re move all oil and water from the com pressed air before blowing with air Dry the inside of the connector with a dryer If water gets inside the connector use a dryer to dry the connector Hot a...

Страница 256: ...y disconnect all wiring harness connectors connected to the control box Fit an arc weld ing ground close to the welding point 2 Points to remember when troubleshooting electric circuits 1 Always turn...

Страница 257: ...draulic equip ment should be carried out in a specially prepared dustproof workshop and the perfor mance should be confirmed with special test equipment 3 Sealing openings After any piping or equipmen...

Страница 258: ...f the hydraulic oil 6 Flushing operations After disassembling and assembling the equip ment or changing the oil use flushing oil to remove the contaminants sludge and old oil from the hydraulic circui...

Страница 259: ...k operation of instruments Repair or replace Hydraulic mechanical equipment 14 Check for abnormal noise smell Repair 15 Check for oil leakage Repair 16 Carry out air bleeding Bleed air 17 Check effect...

Страница 260: ......

Страница 261: ...PC S 5 F23 DT 2 T 7 D4 SWP 2 Diode Offset S 5 F24 DT 4 Attachment selection connector X 6 D5 SWP 2 Diode Arm T 1 F25 X 2 Emergency work equipment opera tion switch S 6 D6 SWP 2 Diode Boom V 1 F26 M 2...

Страница 262: ...rking lamp Right F 9 M15 X 4 Safety relay L 1 T1 X 2 Travel pressure switch I 2 M15 DT 3 Junction connector T2 DT 2 Travel alarm I 2 M16 KES1 4 Timer L 2 M31 DT 4 Junction connector J 2 M32 X 4 Juncti...

Страница 263: ...on connector X 6 D5 SWP 2 Diode Arm T 1 F25 X 2 Emergency work equipment operation switch S 6 D6 SWP 2 Diode Boom V 1 F26 M 2 Horn switch T 7 D7 SWP 2 Diode PPC T 1 F27 AMP040 16 Monitor panel U 7 D8...

Страница 264: ...1 R1 Yazaki 2 Engine stop solenoid relay K 3 R2 5 Neutral engine start relay For PPC lock circuit V 1 R3 5 Fuel governor motor relay For deceleration V 1 R3 Yazaki 1 Engine stop solenoid relay K 3 R4...

Страница 265: ...TROUBLESHOOTING CONNECTOR ARRANGEMENT DIAGRAM 20 216 PC58UU 3 CONNECTOR ARRANGEMENT DIAGRAM Serial No 20001 22000 6...

Страница 266: ...TROUBLESHOOTING CONNECTOR ARRANGEMENT DIAGRAM PC58UU 3 20 217 1...

Страница 267: ...TROUBLESHOOTING CONNECTOR ARRANGEMENT DIAGRAM 20 218 PC58UU 3 1...

Страница 268: ...20 218 2 PC58UU 3 TROUBLESHOOTING Serial No 22001 and up CONNECTOR ARRANGEMENT DIAGRAM 6...

Страница 269: ...PC58UU 3 20 218 3 TROUBLESHOOTING CONNECTOR ARRANGEMENT DIAGRAM 6...

Страница 270: ...20 218 4 PC58UU 3 TROUBLESHOOTING CONNECTOR ARRANGEMENT DIAGRAM 6...

Страница 271: ...No 1 Part No 08055 00181 Part no 08055 00191 799 601 7010 2 799 601 7020 Part No 08055 00282 Part No 08055 00292 3 799 601 7030 Part No 08055 00381 Part No 08055 00391 4 799 601 7040 Part No 08055 00...

Страница 272: ...connector Male female housing Female male housing T adapter Part No 6 799 601 7050 Part No 08055 10681 Part No Part No 08055 10691 8 799 601 7060 Part No 08055 10881 Part No 08055 10891 12 799 601 731...

Страница 273: ...sing T adapter Part No 16 799 601 7320 Part No 08055 11681 Part No 08055 11691 Terminal part no Electric wire size 0 85 Grommet black Quantity 20 Terminal part no Electric wire size 0 85 Grommet black...

Страница 274: ...dapter Part No 1 Part No 08056 00171 Part No 08056 00181 799 601 7080 2 799 601 7090 Part No 08056 00271 Part No 08056 00281 3 799 601 7110 Part No 08056 00371 Part No 08056 00381 4 799 601 7120 Part...

Страница 275: ...or Male female housing Female male housing T adapter Part No 8 799 601 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...

Страница 276: ...PIN NUMBERS 20 224 PC58UU 3 1 No of pins S type connector Male female housing Female male housing T adapter Part No 10 blue 12 blue 799 601 7160 Part No 08056 11272 Part No 08056 11282 16 blue 799 60...

Страница 277: ...A 222 2640 Qty 5 Housing part No 79A 222 2630 Qty 5 11 Housing part No 79A 222 2680 Qty 5 Housing part No 79A 222 2670 Qty 5 5 799 601 2710 Housing part No 79A 222 2620 Qty 5 Housing part No 79A 222 2...

Страница 278: ...or Male female housing Female male housing T adapter Part No 17 799 601 2730 Housing part No 79A 222 2730 Qty 2 Housing part No 79A 222 2720 Qty 2 21 799 601 2740 Housing part No 79A 222 2750 Qty 2 Ho...

Страница 279: ...emale housing Female male housing T adapter Part No 8 799 601 7180 Housing part No 79A 222 3430 Qty 5 12 799 601 7190 Housing part No 79A 222 3440 Qty 5 16 799 601 7210 Housing part No 79A 222 3450 Qt...

Страница 280: ...1 No of pins AMPO70 type connector Male female housing Female male housing T adapter Part No 10 799 601 7510 Part No 08195 10210 12 799 601 7520 Part No 08195 12210 14 799 601 7530 Part No 08195 1421...

Страница 281: ...of pins L type connector Male female housing Female male housing T adapter Part No 2 No of pins PA type connector Male female housing Female male housing T adapter Part No 9 No of pins Bendix MS conn...

Страница 282: ...art No 2 Part No 08027 10210 natural color 08027 10220 black Part No 08027 10260 natural color 08027 10270 black 3 Part No 08027 10310 Part No 08027 10360 4 Part No 08027 10410 natural color 08027 104...

Страница 283: ...NNECTOR PIN NUMBERS PC58UU 3 20 231 1 No of pins KES 1 Automobile connector Male female housing Female male housing T adapter Part No 8 Part No 08027 10810 natural color 08027 10820 black Part No 0802...

Страница 284: ...BLESHOOTING CONNECTION TABLE FOR CONNECTOR PIN NUMBERS 20 232 PC58UU 3 1 No of pins Connector for relay socket type Male female housing Female male housing T adapter Part No 5 799 601 7360 6 799 601 7...

Страница 285: ...TROUBLESHOOTING CONNECTION TABLE FOR CONNECTOR PIN NUMBERS PC58UU 3 20 233 1 No of pins F type connector Male female housing Female male housing T adapter Part No 4...

Страница 286: ...1 14102 08191 14105 08191 14106 Pin female terminal Pin male terminal Part No 08191 12201 08191 12202 08191 12205 08191 12206 Part No 08191 13101 08191 13102 08191 13105 08191 13106 18 14 2 Pin male t...

Страница 287: ...al 799 601 9230 Part No 08191 31201 08191 31202 Part No 08191 34101 08191 34102 Pin female terminal Pin male terminal Part No 08191 32201 08191 32202 Part No 08191 33101 08191 33102 18 21 4 Pin male t...

Страница 288: ...Part No 08191 54101 08191 54102 Pin female terminal Pin male terminal Part No 08191 52201 08191 52202 Part No 08191 53101 08191 53102 24 16 6 Pin male terminal Pin female terminal 799 601 9260 Part No...

Страница 289: ...l Pin male terminal Part No 08191 72201 08191 72202 08191 72205 08191 72206 Part No 08191 73101 08191 73102 08191 73105 08191 73106 24 22 8 Pin male terminal Pin female terminal 799 601 9280 Part No 0...

Страница 290: ...cle T adapter Part No 24 31 9 Pin male terminal Pin female terminal 799 601 9290 Part No 08191 91203 08191 91204 08191 91205 08191 91206 Part No 08191 94103 08191 94104 08191 94105 08191 94106 Pin fem...

Страница 291: ...100 normal type 08192 22100 fine wire type 3 799 601 9030 Part No 08192 13200 normal type 08192 23200 fine wire type Part No 08192 13100 normal type 08192 23100 fine wire type 4 799 601 9040 Part No 0...

Страница 292: ...601 9060 8B 799 601 9070 8G 799 601 9080 8Br 799 601 9080 Part No 08192 1820 normal type 08192 2820 fine wire type Part No 08192 1810 normal type 08192 2810 fine wire type 12 12Gr 799 601 9110 12B 799...

Страница 293: ...T adapter Part No 2 799 601 9010 Part No 08192 02200 Part No 08192 02100 No of pins DTHD series connector Body plug Body receptacle T adapter Part No 1 Part No 08192 31200 contact size 12 08192 41200...

Страница 294: ...3410 BENDIX MS 24P Q Q 799 601 3420 BENDIX MS 24P Q Q 799 601 3430 BENDIX MS 17P Q Q 799 601 3440 BENDIX MS 17P Q Q 799 601 3450 BENDIX MS 5P Q Q 799 601 3460 BENDIX MS 10P Q Q 799 601 3510 BENDIX MS...

Страница 295: ...8P Q 799 601 7190 AMP040 12P Q Q 799 601 7210 AMP040 16P Q Q Q Q 799 601 7220 AMP040 20P Q Q Q Q 799 601 7230 Short connector X 2 Q Q Q Q 799 601 7240 Case Q Q 799 601 7270 Case Q 799 601 7510 070 10...

Страница 296: ...601 9300 799 601 9240 HD30 18 21 Q Q 799 601 9250 HD24 24 9 Q Q 799 601 9260 HD30 24 16 Q Q 799 601 9270 HD30 24 21 Q Q 799 601 9280 HD30 24 23 Q Q 799 601 9290 HD30 24 31 Q Q 799 601 9310 Plate For H...

Страница 297: ...panel and controller It carries out various controls such as stopping the work equipment in the interference area setting the working area height depth offset displaying the depth and one touch decele...

Страница 298: ...inputs error code is not displayed Some input and output signals are checked with the monitoring function When work equipment solenoid valve systems E F G are troubled Error codes 5 5 4 Stops operati...

Страница 299: ...zer sounds at intervals of about 1 sec F Move bucket away from cab canopy Work equipment can be moved away from cab Arm DUMP RIGHT offset Buzzer sounds continuously until work equipment is moved away...

Страница 300: ...G PC58UU 3 20 245 1 EXPLANATIONS OF CONTROL MECHANISM OF ELECTRICAL SYSTEM POSITIONS OF WORK EQUIPMENT Operation steps E and F Front of operator s cab Operation steps E and F Side of operator s cab Op...

Страница 301: ...up in the height mode If the starting switch is turned OFF setting is cleared 3 Depth display section i Display of depth Normal display The depth from the ground level or from the datum plane is displ...

Страница 302: ...c system caution lamp and the alarm buzzer are not turned on In this case since communication between the controller and monitor is erroneous machine condition cannot be monitored For the displayed er...

Страница 303: ...ble ii If there is not a trouble record is dis played iii If the trouble is still being detected the HEIGHT indicator of the mode indicator lights up 3 While the code is displayed advance return to th...

Страница 304: ...y the method in 4 above If a trouble occurs in communication between the monitor panel and controller the monitor displays the error code of EE on itself Accordingly while communication is troubled ev...

Страница 305: ...on error code display sec tion After 2 5 seconds the data of each code are displayed While the code is displayed the central indi cator lamp keeps lighted up While the data are displayed the central a...

Страница 306: ...hen left indicator is turned on it denotes that number of thousands in rpm is 2 If 03 is dis played engine speed is 2 030 rpm 20 ON OFF input output 1 B See Bit map table 21 ON OFF input output 2 B 22...

Страница 307: ...connected Reset 2 When plug is connected 3 Deceleration LED When one touch deceleration is turned ON Monitor back light When lighting up 23 ON OFF input output 4 24 ON OFF input output 5 Motor drive r...

Страница 308: ...ay of code Accordingly you cannot check that they are working nor mally When they can change the display of data to the display of code however they are judged nor mal Attachment Attachment selection...

Страница 309: ...Single mutiple Method of repro duction Group Error code Troubled system Single mutiple Method of repro duction Reset 01 Front stop position reset trouble Single Reset 11 Boom angle reset trouble Singl...

Страница 310: ...sor system trouble Single 48 Traveling accelerator sole noid trouble Single 33 Boom angle sensor system Arm angle sensor system trouble 31 32 49 PPC lock solenoid Travel ing accelerator solenoid troub...

Страница 311: ...motor relay trouble Single 62 Source voltage trouble Single 72 Accelerator motor relay trouble Single 63 Valve open Source volt age trouble 61 62 73 Accelerator motor relay Accelerator motor relay tro...

Страница 312: ...tem works Automatic stop Sounds at intervals of 1 sec When emergency stop system works Error code 61 is dis played Blinks Blinks at intervals of 0 4 sec Sounds at intervals of 0 4 sec When reset switc...

Страница 313: ...g judgement table A mark is put at the places where the failure mode and self diagnostic display match so check if that abnormality display is being given and proceed as follows If the abnormality dia...

Страница 314: ...he are correct or the answer to the question inside the is YES follow the YES line if the judgement value is not correct or the answer to the question is NO follow the NO line Below the is given the p...

Страница 315: ...tive engine speed sensor Internal disconnec tion defective contact short circuit with chassis ground Replace Is resistance between M9 male b c normal No Yes Turn starting switch OFF Disconnect G2 2 10...

Страница 316: ...ator is displayed 20 329 E 15 Error code 74 Motor drive relay decelerator is displayed 20 330 E 16 Error code 78 Abnormality in motor stall system is displayed 20 331 E 17 Error code EE Fault in contr...

Страница 317: ...n solenoid 5 Contact of side of solenoid with wiring harness on ground side 6 Defective controller 51 Boom RAISE stop EPC solenoid system 1 Disconnection in solenoid 2 Short circuit in solenoid or sho...

Страница 318: ...age between G3 26 23 0 75 1 0 V In bucket safety area 1 Turns off output to boom RAISE stop solenoid arm IN stop solenoid and LEFT offset stop sole noid a Trouble is kept displayed even after troubled...

Страница 319: ...side of relay coil 3 Disconnection in relay coil or short circuit of it 4 Defective controller 78 Motor stall system When motor burn pre vention function operates 1 Fixing of motor or disconnection i...

Страница 320: ...to slow If accelerator decelerator or one touch decelerator operates continuously for 10 seconds Motor drive relay output Motor drive accelerator relay out put and Motor drive decelerator relay outpu...

Страница 321: ...etting during operation Work equipment overruns then stops Work equipment stops before set depth Height mode stop is abnormal after setting during operation Work equipment overruns then stops Work equ...

Страница 322: ...fset potentiometer system PPC hydraulic lock solenoid system LEFT offset stop solenoid system Boom RAISE stop solenoid system Arm IN stop solenoid system Valve open system 34 41 42 51 52 61 q q q q q...

Страница 323: ...q q Arm does not move q q q q q q q q Bucket does not move q q Offset boom does not move q q q q q q q q Hydraulic drift is large Time lag is large Engine speed is low Compound operation Part loaded...

Страница 324: ...relay decelerator Motor drive relay Motor stall system Decelerator switch Traveling accelerator Troubleshooting code when abnormal display is not given 52 54 61 71 72 74 78 UP Hi q H 1 q H 2 q H 3 H...

Страница 325: ...TROUBLESHOOTING E MODE 20 310 PC58UU 3 1 E MODE RELATED ELECTRICAL CIRCUIT DIAGRAM...

Страница 326: ...TROUBLESHOOTING E MODE PC58UU 3 20 311 1 PUMP CONTROLLER...

Страница 327: ...20 312 PC58UU 3 TROUBLESHOOTING ENGINE CONTROLLER Serial No 20001 22000 E MODE 6...

Страница 328: ...PC58UU 3 20 312 1 TROUBLESHOOTING Serial No 22001 and up E MODE 6...

Страница 329: ...ot perform the boom RAISE arm IN and LEFT offset operations An example of returning forward is shown in the figure The bucket is still in the interference area by about 50 100 mm If it is returned fur...

Страница 330: ...tion changes If the potentiometer input signal is reset according to TESTING AND ADJUSTING the automatic stop position becomes normal 6 When the interference prevention function or auto matic control...

Страница 331: ...t circuit in the solenoid or short circuit with the chassis ground in the wiring harness between the controller and solenoid if the emergency work equipment operation switch is turned on an overcurren...

Страница 332: ...nal disconnection defective contact short cir cuit with chassis ground Replace Is resistance between M9 male 1 2 normal NO YES Turn starting switch OFF Disconnect G2 2 100 2 500 z 2 Disconnection defe...

Страница 333: ...1 NO Defective boom RAISE potentiometer Replace YES Resistance of wiring harness Max 10 z Resistance between wiring harness and chassis ground Min 1 Mz Turn starting switch OFF Disconnect G1 and M14 4...

Страница 334: ...ble 1 NO Defective arm potentiometer Replace YES Resistance of wiring harness Max 10 z Resistance between wiring harness and chassis ground Min 1 Mz Turn starting switch OFF Disconnect G1 and W4 4 Dis...

Страница 335: ...able 1 NO Defective arm potentiometer Replace YES Resistance of wiring harness Max 10 z Resistance between wiring harness and chassis ground Min 1 Mz Turn starting switch OFF Disconnect G1 and W3 4 Di...

Страница 336: ...lated electrical circuit diagram Cause Remedy 5 25z Between F7 2 chassis ground Min 1 Mz Turn starting switch OFF Disconnect F7 1 Is resistance between F7 male 1 2 normal and is wiring harness insu la...

Страница 337: ...ltage changes there is continuity E 6 Related electrical circuit diagram Cause Remedy 5 25z Between F9 2 chassis ground Min 1 Mz Turn starting switch OFF Disconnect F9 1 Is resistance between F9 male...

Страница 338: ...tween F8 male 2 1 normal and is wiring harness insu lated from chassis ground NO Replace YES Turn starting switch OFF Between G3 27 chassis ground Min 1 Mz Turn starting switch OFF Disconnect G3 Short...

Страница 339: ...tive boom RAISE sole noid valve Replace YES Turn starting switch OFF Disconnect G3 and F11 Measure on G3 female side in diode range Note 2 Disconnection defective con tact or short circuit with chassi...

Страница 340: ...ctive arm IN solenoid valve Replace YES Turn starting switch OFF Disconnect G1 and F10 Measure on G1 female side in diode range Note 2 Disconnection defective con tact or short circuit with chassis gr...

Страница 341: ...2 Disconnection defective con tact or short circuit with chassis ground in wiring har ness between G3 female 18 M11 female 1 Is resistance between G3 female 18 M11 female 1 normal and is wiring harne...

Страница 342: ...is not blown E 11 Related electrical circuit diagram Cause Remedy 1 10 16 V Turn starting switch ON Is voltage between G3 2 12 22 and 23 and chassis ground normal NO Defective controller Replace YES...

Страница 343: ...tarting switch ON Is voltage between G1 22 21 nor mal NO YES Defective controller Replace 2 Disconnection or defective contact in wiring harness between G3 1 11 bat tery Disconnection or defective con...

Страница 344: ...witch OFF Disconnect G3 and R4 2 Disconnection or defective contact in wiring harness between G3 female 13 R4 female 2 Is resistance between G3 female 13 R4 female 2 normal NO Repair or replace YES Be...

Страница 345: ...switch OFF Disconnect G3 and R3 2 Disconnection or defective contact in wiring harness between G3 female 13 R3 female 2 Is resistance between G3 female 13 R3 female 2 normal NO Repair or replace YES B...

Страница 346: ...starting switch OFF Disconnect G3 and R5 2 Disconnection or defective contact in wiring harness between G3 female 18 R5 female 2 Is resistance between G3 female 18 R5 female 2 normal NO Repair or rep...

Страница 347: ...n in neutral 3 and 6 are connected to each other When dial is increased R5 and R4 3 5 are connected to each other When dial is decreased R5 and R3 3 5 are connected to each other 3 Do relays R5 R4 and...

Страница 348: ...20 332 PC58UU 3 TROUBLESHOOTING E 16 Related electrical circuit diagram E 16 6...

Страница 349: ...ower supply line Voltage between CN G3 1 11 chassis 10 16 V Ordinary power supply line Voltage between CN G3 2 12 22 chassis 10 16 V 1 Defective wiring harness Defective constant power supply line Dis...

Страница 350: ...itch ON Disconnect G2 Voltage between G2 9 18 19 chassis ground 6 10 V 1 Does controller output communication signals normally NO Defective controller Replace con troller YES Turn starting switch ON D...

Страница 351: ...e contact in wiring harness between R3 female 5 R4 female 5 R5 female 5 Max 1 z Turn starting switch OFF Disconnect R3 R4 and R5 Is resistance between R3 female 5 R4 female 5 R5 female 5 nor mal NO Re...

Страница 352: ...rt T adapter Between F22 3 chassis Accelerate engine 10 16V Turn starting switch ON Insert T adapter Decelerate engine Max 1 V Turn starting switch ON Insert T adapter Between F22 4 chassis Accelerate...

Страница 353: ...itch OFF Disconnect R3 R4 and R5 Is resistance between R3 female 5 R4 female 5 R5 female 5 nor mal NO Repair or replace YES Max 1 z Turn starting switch OFF Disconnect F22 R3 R4 and R5 6 Disconnection...

Страница 354: ...ness between fuse 3 F18 female 2 Is voltage between F18 female 2 chassis ground normal NO Repair or replace YES 10 15 V Turn starting switch ON Turn one touch decelerator switch ON Set fuel control di...

Страница 355: ...Defective PPC lock switch Replace YES 5 Disconnection or defective contact in wiring harness between F13 female 2 and chassis ground 10 15 V Turn starting switch ON Is voltage between F13 female 2 and...

Страница 356: ...y relay terminal B starting switch terminal B Repair or replace 12 Starting switch ON 10 15 V Is voltage between starting switch ter minal ACC and chassis ground normal NO Defective starting switch be...

Страница 357: ...PC58UU 3 20 341 TROUBLESHOOTING E 19 a Related electrical circuit diagram E 19 6...

Страница 358: ...5 Disconnection or defective contact in wiring harness between F13 female 2 and chassis ground 10 15 V Turn starting switch ON Is voltage between F13 female 2 and chassis ground normal NO Repair or r...

Страница 359: ...y relay terminal B starting switch terminal B Repair or replace 12 Starting switch ON 10 15 V Is voltage between starting switch ter minal ACC and chassis ground normal NO Defective starting switch be...

Страница 360: ...20 344 PC58UU 3 TROUBLESHOOTING E 19 a Related electrical circuit diagram E 19 6...

Страница 361: ...ble NO Repair or replace YES Disconnection or defective contact in wiring harness between fuse 1 M12 female 1 Repair or replace 5 Repair or replace Is voltage between R3 female and chassis ground as s...

Страница 362: ...6 female 3 chassis ground Max 1 z Disconnect M16 Turn starting switch OFF Is resistance between M16 female 3 and chassis ground normal NO Repair or replace YES 2 Is voltage between M16 1 2 as shown in...

Страница 363: ...onnect the cable from the negative terminal of the battery E 20 Related electrical circuit diagram Cause Remedy 1 Defective starting switch When starting switch is turned OFF 0 V Is voltage between M1...

Страница 364: ...erminal of the battery E 20 Related electrical circuit diagram Cause Remedy 1 Defective starting switch When starting switch is turned OFF 0 V Is voltage between M13 2 and chassis ground normal NO Rep...

Страница 365: ...nnect switch terminal 2 Defective traveling accelera tor switch Is continuity of traveling accelerator switch normal NO Replace YES Max 1 z Turn starting switch OFF Disconnect F19 3 Disconnection or d...

Страница 366: ...tor switch is turned OFF Approx 12 V 1 Is voltage between F19 2 and chassis ground normal NO YES Trouble in hydraulic system When switch is turned ON Max 1 z When switch is turned OFF Min 1 Mz Turn st...

Страница 367: ...defective contact in wiring harness between fuse 13 F13 female 2 Max 1z Turn starting switch OFF Disconnect F13 Is resistance between fuse 13 and F13 female 2 normal NO Replace YES 6 Disconnection or...

Страница 368: ...revious page Cause Remedy 1 Disconnection or defective contact in wiring harness between R2 female 5 F7 female 2 Max 1z Turn starting switch OFF Disconnect R2 and F7 Is resistance between R2 female 5...

Страница 369: ...onnect F7 Is resistance between F7 male 1 and 2 normal NO YES 3 Defective relay R2 for PPC lock circuit Replace Replace R2 with normal relay When R2 is replaced is condition nor mal NO YES Max 1 V Tur...

Страница 370: ...Disconnection defective con tact or short circuit with chassis ground in wiring har ness between G2 female 3 F29 female 2 G2 female 13 F29 female 1 4 G2 female 26 F31 or G2 female 36 F32 or disconnect...

Страница 371: ...PC58UU 3 20 355 TROUBLESHOOTING E 25 Related electrical circuit diagram E 25 6...

Страница 372: ...ayed as shown in Table 1 NO YES Defective controller Replace 2 Disconnection or short circuit with chassis ground in wiring harness between G2 female 2 F28 female 3 G2 female 3 F29 female 2 G2 female...

Страница 373: ...t display 26 2 One touch deceleration 20 402 F 2 Controller does not display 26 3 Traveling accelerator switch 20 403 a Before carrying out troubleshooting check that all the related connectors are pr...

Страница 374: ...between G3 9 chassis normal NO YES Defective controller Replace Turn one touch decelerator switch ON Max 1 z Turn one touch decelerator switch OFF Min 1 Mz Turn starting switch OFF Disconnect F18 2 Is...

Страница 375: ...tive controller Replace At HIGH Max 1 z At LOW Min 1 Mz Turn starting switch OFF Disconnect switch terminal 2 Is resistance of traveling accelerator switch normal NO Defective traveling accelera tor s...

Страница 376: ...ump 20 515 H 5 Fine controllability is poor or response is low 20 516 Two or more systems have poor fine controllability or low response simultaneously 20 516 H 6 Boom speed or power is low Other work...

Страница 377: ...ot swing in either direction 20 550 b Machine does not swing in both directions 20 550 H 30 Swing acceleration is low 20 551 a Swing acceleration is low in both directions 20 551 b Swing acceleration...

Страница 378: ......

Страница 379: ...ime lag Engine speed is low In compound operations work equipment with larger load is slow Travel Excessive travel deviation Travel speed is slow or lacks power Machine cannot be steered sharply or st...

Страница 380: ...ve Boom lock valve Boom assist valve Gear pump circuit relief valve Swing PPC circuit throttle Swing brake circuit check valve Blade safety valve Back pressure valve Control relief valve PPC main pres...

Страница 381: ...If the combination of the detected troubles is not in Table 1 carry out troubleshooting for the actuators of each system which has low speed or power H 6 H 9 Table 1 Normal Speed is slow or lacks powe...

Страница 382: ...pair or replace Cause Remedy Bucket IN 26 0 1 0 5 MPa 265 10 5 kg cm Run engine at full throttle 1 Is work equipment relief pressure normal No Yes 2 Is travel relief pressure normal No Go to related t...

Страница 383: ...e gear pump Repair or replace Yes Defective gear pump rota tion relief pressure Adjust or repair Cause Remedy 1 26 0 1 0 5 MPa 265 10 5 kg cm Run engine at full throttle Is travel relief pressure norm...

Страница 384: ...Pa 25 kg cm Run engine at full throttle Is all PPC pressure normal at PPC pressure inlet of control valve No Yes 2 1 57 0 1 MPa 16 1 kg cm Run engine at full throttle Is LS differential pressure norma...

Страница 385: ...Yes Carry out troubleshooting No 4 3 26 0 1 0 5 MPa 265 10 5 kg cm Run engine at full throttle Is bucket CURL relief pressure nor mal No Yes 4 21 6 1 5 0 5 MPa 220 15 5 kg cm Run engine at full thrott...

Страница 386: ...paired No Yes Defective PC valve Adjust or replace 12 When orifice of servo is cleaned is trouble repaired No Yes Clogged orifice 13 When EPC valve TVC is replaced is trouble repaired No Carry out tro...

Страница 387: ...equipment boom arm bucket and off set travel swing and blade systems do not move Work equipment Travel Swing Blade Troubleshooting item a Go to a b Go to a c Go to a d Go to a e Go to a f Go to a g Go...

Страница 388: ...ated troubleshoot ing in H 10 13 24 and 29 Cause Remedy 1 When engine is cranked does oil flow out of main pump No Defective main pump Repair or replace Yes 2 2 94 0 5 0 1 MPa 30 5 1 kg cm Run engine...

Страница 389: ...n relief valve is adjusted or replaced is travel repaired No Yes Defective main relief valve Repair or replace 3 Does unload valve move smoothly No Defective unload valve Repair or replace Yes Defecti...

Страница 390: ...ulic oil level Yes Go to troubleshooting No 4 4 Foreign matter Cloth etc Is suction strainer clogged with for eign matter No Yes Clogging of suction strainer with foreign matter cloth etc Remove 5 Is...

Страница 391: ...neously Cause Remedy 1 See TESTING AND ADJUSTING Is LS differential pressure normal No Yes 2 Is orifice of unload valve clogged No Yes Clogging of orifice of unload valve Clean 3 Is orifice of piston...

Страница 392: ...pressure compensation valve move smoothly No Defective pressure compen sation valve Repair or replace Yes 5 26 5 1 0 0 5 MPa 265 10 5 kg cm Run engine at full throttle Is boom LOWER relief pressure n...

Страница 393: ...fective operation of con trol valve spool or EPC valve spool Repair or replace Yes 4 Do poppet and pilot piston of boom lock valve move smoothly and is ori fice free of clogging No Defective operation...

Страница 394: ...pensation valve move smoothly No Defective pressure compen sation valve Repair or replace Yes Defective arm cylinder pack ing Repair or replace 5 26 5 1 0 0 5 MPa 265 10 5 kg cm Run engine at full thr...

Страница 395: ...alve spool move smoothly No Defective operation of con trol valve spool Repair or replace Yes 4 Does pressure compensation valve move smoothly No Defective pressure compen sation valve Repair or repla...

Страница 396: ...rol valve No Yes 3 Does control valve spool move smoothly No Defective operation of con trol valve spool Repair or replace Yes 4 Does pressure compensation valve move smoothly No Defective pressure co...

Страница 397: ...ve spool move smoothly No Defective operation of con trol valve spool Repair or replace Yes 4 Does pressure compensation valve move smoothly No Defective pressure compen sation valve Repair or replace...

Страница 398: ...oothly No Defective operation of con trol valve spool Repair or replace Yes 4 Does pressure compensation valve move smoothly No Defective pressure compen sation valve Repair or replace Yes Defective o...

Страница 399: ...ve smoothly No Defective operation of con trol valve spool Repair or replace Yes 4 Does pressure compensation valve move smoothly No Defective pressure compen sation valve Repair or replace Yes Defect...

Страница 400: ...1 0 0 5 MPa 265 10 5 kg cm Run engine at full throttle When boom is RAISED is pump relief pressure normal No Yes Deformation of cylinder or work equipment It does not move from deformed point Repair...

Страница 401: ...s 3 26 5 1 0 0 5 MPa 265 10 5 kg cm Run engine at full throttle When boom is LOWERED is pump relief pressure normal No Yes Defective operation of lock valve Repair or replace 4 Does spool move smoothl...

Страница 402: ...t does not move from deformed point Repair or replace YES 4 Does spool move smoothly NO Defective arm IN operation of spool Repair or replace YES Defective pressure compensation valve Repair or replac...

Страница 403: ...full throttle When arm is moved out is pump relief pressure normal NO Deformation of cylin der or work equip ment It does not move from deformed point Repair or replace YES 4 Does spool move smoothly...

Страница 404: ...10 5 kg cm Run engine at full throttle When bucket curls is pump relief pressure normal NO Deformation of cylin der or work equip ment It does not move from deformed point Repair or replace YES 4 Doe...

Страница 405: ...ll throttle When bucket dumps is pump relief pressure normal NO Deformation of cylin der or work equip ment It does not move from deformed point Repair or replace YES 4 Does spool move smoothly NO Def...

Страница 406: ...a 265 10 5 kg cm Run engine at full throttle When offset boom is moved to the left is pump relief pressure normal NO Deformation of cylin der or work equip ment It does not move from deformed point Re...

Страница 407: ...hrottle When offset boom is moved to the right is pump relief pres sure normal NO Deformation of cylin der or work equip ment It does not move from deformed point Repair or replace YES 4 Does spool mo...

Страница 408: ...d NO Defective boom lock valve Repair or replace YES Defective centralized safety valve Replace Cause Remedy 1 Is leakage from hydraulic cylin der normal NO Defective cylinder piston packing Repair or...

Страница 409: ...ve Replace 3 If suction valve is replaced with blind plug is travel repaired NO Defective oiltight ness of control valve spool Repair or replace YES Defective suction valve Repair or replace Cause Rem...

Страница 410: ...ter load side 1 Boom RAISE Arm IN Boom RAISE Arm IN 2 Boom RAISE Arm OUT Arm OUT Boom RAISE 3 Boom RAISE Bucket CURL Arm OUT Bucket CURL 4 Arm OUT Bucket DUMP Arm OUT Bucket CURL 5 Boom LOWER Arm OUT...

Страница 411: ...replaced with each other does deviation direction change NO YES 5 When only travel section is operated Is pressure at PP oil pressure pickup port at top of control valve equal to pump pressure NO YES...

Страница 412: ...place YES Defective swivel joint Repair or replace 12 When both PPC hoses are replaced with each other does deviation direction change NO Defective PPC circuit check valve of control valve Repair or r...

Страница 413: ...t full throttle Is pump pressure normal during travel NO Large resistance of travel motor and under carriage Repair or replace YES Large leakage from travel motor or swivel joint Repair or replace 5 A...

Страница 414: ...pair or replace YES Defective operation of logic valve Repair or replace 4 Is drive pump pressure of inside motor normal When machine is steered along curve about 5 m in radius on flat con crete is in...

Страница 415: ...OFF 0 MPa 0 kg cm Run engine at full throttle Is output of traveling accelera tor solenoid valve normal NO Defective traveling accelerator solenoid valve or trouble in elec tric system caused by defec...

Страница 416: ...end Is PPC pressure normal at PPC pressure inlet of control valve NO YES 6 Note 1 Does travel spool move smoothly NO Defective operation of spool Repair or replace If engine runs at full throttle and...

Страница 417: ...merging valve from the travel PPC pressure If the checking function of check valves b e is lost the machine may not travel Example When checking function of b is lost Normal operations Left forward Le...

Страница 418: ...is replaced is trouble repaired NO YES Defective suction valve Repair or replace 4 When back pressure valve is replaced is trouble repaired NO YES Defective back pressure valve Repair or replace 5 Do...

Страница 419: ...Defective operation of merging valve Repair or replace YES Defective operation of logic valve Repair or replace 4 Does unload valve move smoothly and is drilled hole free of clogging NO Defective ope...

Страница 420: ...operation of swing brake Defective reset Repair or replace YES Clogging of throttle Clean 5 Does check valve in spool move smoothly NO Defective operation of check valve in spool Repair or replace YES...

Страница 421: ...air or replace YES Defective arm valve or check valve of swing brake circuit Replace 11 When safety valve of swing motor is adjusted or replaced is trouble repaired NO YES Defective safety valves Adju...

Страница 422: ...ely after checking 4 When both PPC hoses are replaced with each other does condition change NO YES 5 When swing PPC line throttle is cleaned is trouble repaired NO Defective PPC valve Repair or replac...

Страница 423: ...circle Check repair or replace 4 When throttle of swing brake reset line is cleaned is trouble repaired NO YES Clogging of throttle of swing brake reset line Clean 5 When throttle of swing brake rese...

Страница 424: ...of swing brake circuit Replace 11 Does swing motor rotate Check by sound NO YES Damage of motor shaft or swing machinery Adjust or replace 12 When safety valve of swing motor is adjusted or replaced...

Страница 425: ...C hoses are replaced with each other does condition change NO YES Go to troubleshooting No 4 4 When swing PPC line throttle is cleaned is trouble repaired NO Defective PPC valve Repair or replace YES...

Страница 426: ...leration is low in either direction H 30 Swing acceleration is low Cause Remedy 1 IWhen swing motor safety valve is replaced is trouble repaired NO Carry out troubleshoot ing in H 28 and H 35 YES Defe...

Страница 427: ...ol valve spool move smoothly NO Defective operation of control valve spool Repair or replace YES When swing motor suction valve is replaced is trouble repaired NO YES Defective swing motor suction val...

Страница 428: ...rouble repaired NO Defective swing motor safety valve Replace YES Defective PPC valve Repair or replace Cause Remedy When safety valve is replaced is trouble repaired NO YES Defective swing motor safe...

Страница 429: ...ective PPC valve Repair or replace 5 Defective motor motor unit safety valve check valve suction valve brake When spring case sub assembly on port B side of arm valve is replaced is trouble repaired N...

Страница 430: ...0 0 5MPa 210 10 5 kg cm Run engine at full throttle Is blade relief pressure normal No Go to troubleshooting No 5 Yes 3 Does pump pressure rise to relief pressure during operation No Yes 4 Is any hos...

Страница 431: ...r trou ble of linkage and cable Adjust repair or replace Yes 2 Is blade relief pressure normal No Yes 3 Is cylinder or work equipment deformed No Yes Deformed cylinder or work equipment Repair or repl...

Страница 432: ...ace Yes 3 Is cylinder or work equipment deformed No Yes Deformed cylinder or work equipment Repair or replace 4 Is any hose flattened or deformed No Defective operation of check valve in spool or clog...

Страница 433: ...plug is trouble repaired No Defective oiltightness of spool Repair or replace Yes Defective safety suction valve Repair or replace 5 Hydraulic drift of blade is excessive when it is used to lift up ma...

Страница 434: ...el displays error code 61 and boom RAISE arm IN and LEFT offset operations stop just before interference H 41 Machine does not stop boom RAISE arm IN and LEFT offset operations automatically but inter...

Страница 435: ......

Страница 436: ...yTemperature reaches red range while engine is not overheated 20 609 c Water temperature gauge goes off 20 609 M 10 Fuel level gauge indicates abnormally 20 610 a All segments of fuel level gauge go o...

Страница 437: ...TROUBLESHOOTING M MODE 20 602 PC58UU 3 Electric circuit diagram of machine monitor system Serial No 20001 22000 6...

Страница 438: ...PC58UU 3 20 602 1 TROUBLESHOOTING Serial No 22001 and up M MODE 6...

Страница 439: ...position all segments light up but do not go off after 3 seconds Cause Remedy 10 15 V Turn starting switch ON 1 Is voltage between F27 female 1 and 3 4 normal NO YES Defective monitor panel Replace 2...

Страница 440: ...some items do not light up for all segment light up period of 3 seconds Cause Remedy Defective monitor panel Replace 1 Cause Remedy Check bulb visually for breakage Is any wire in the lamp which does...

Страница 441: ...circuit diagram Serial No 20001 22000 Serial No 22001 and up Cause Remedy Start engine 13 5 14 5 V 1 Is voltage between F27 female 10 and 3 4 normal NO YES Defective monitor panel Replace 2 Start eng...

Страница 442: ...e Remedy Max 0 5 z Turn starting switch OFF Disconnect terminal T M5 of sensor 1 Is continuity between sensor terminal T M5 and chassis ground normal NO Defective engine oil pres sure switch Replace Y...

Страница 443: ...tch to HEAT position 10 15 V 1 Disconnection in wiring har ness between F27 female 13 starting switch R1 or defective starting switch Defective monitor panel Is voltage between F27 13 and 3 4 normal N...

Страница 444: ...between alternator terminal L and chas sis ground 13 5 14 5 V 1 Is voltage at alternator terminal L nor mal NO YES Defective generation by alter nator Replace 2 Contact with chassis ground in wiring h...

Страница 445: ...and chas sis ground 13 5 14 5 V 1 Is voltage at alternator terminal L nor mal NO YES Defective generation by alter nator Replace 2 Contact with chassis ground in wiring harness between F27 female alte...

Страница 446: ...auge rise 1 level by 1 and go off at last NO YES Defective coolant tempera ture sensor Replace 2 Disconnection or defective contact in wiring harness between F27 female 6 M10 female 1 or between M10 f...

Страница 447: ...sis ground normal NO Repair or replace wiring harness YES 2 Start engine Min 4 kz Disconnect M10 Is resistance between M10 male 1 and 2 normal NO Defective engine water tem perature sensor Replace YES...

Страница 448: ...s between F27 female 7 M1 female 1 or between M1 female 2 chassis ground Repair or replace Cause Remedy 1 Disconnection or defective contact in wiring harness between F27 female 3 4 chassis ground Sta...

Страница 449: ...istance between M1 male 1 and 2 F position Max 10 z Disconnect M1 1 Is resistance of fuel level sensor nor mal NO Defective fuel level sensor Replace YES 2 Disconnection or defective contact in wiring...

Страница 450: ...defective contact in wiring harness between fuse 2 F14 female 2 Disconnection or defective contact in wiring harness between F14 female 1 F27 female 15 or defec tive buzzer 10 15 V Turn starting swit...

Страница 451: ...G3 30 and chassis ground normal No YES 2 When normal 0 15 V When abnormal Max 1 V Turn starting switch ON Is voltage between G3 8 and chassis ground normal No Defective controller Replace YES Defecti...

Страница 452: ...F27 female 10 M6 female 1 Defective monitor panel Is voltage between F27 10 and 3 4 normal NO Repair or replace wiring harness YES Replace Cause Remedy Start engine Measure voltage between alternator...

Страница 453: ...fective monitor panel Is voltage between F27 10 and 3 4 normal NO Repair or replace wiring harness YES Replace Cause Remedy Start engine Measure voltage between alternator terminal L and chas sis grou...

Страница 454: ...4 a b Related electrical circuit diagram Cause Remedy Disconnect F27 Turn starting switch ON Turn light switch ON 10 15 V 1 Disconnection or defective contact in wiring harness between F27 female 16 F...

Страница 455: ...Cause Remedy Max 1 V Turn starting switch ON 1 Is voltage between F27 11 and 3 4 normal NO YES Defective monitor panel Replace 2 Disconnection or defective contact in wiring harness between F27 female...

Страница 456: ...ace YES Cause Remedy 1 Turn starting switch OFF Disconnect F15 Set heater switch to Lo Is there continuity between F15 male 3 and 4 NO Defective heater switch Replace YES 2 Disconnection or defective...

Страница 457: ...TROUBLESHOOTING M 16 20 618 PC58UU 3 1 M 16 Related electrical circuit diagram...

Страница 458: ...Disconnection or defective contact in wiring harness between T2 female 2 chassis ground Defective travel alarm Is voltage between T2 female 2 chassis ground normal NO Repair or replace YES Replace 10...

Страница 459: ...20 620 PC58UU 3 TROUBLESHOOTING M 17 Related electrical circuit diagram M 17 6...

Страница 460: ...ion 30 34 SWING CIRCLE ASSEMBLY Removal 30 38 Installation 30 38 RUBBER SHOE ASSEMBLY Removal 30 39 Installation 30 39 ROAD LINER IRON SHOE ASSEMBLY Removal 30 40 Installation 30 41 SWING MACHINERY AS...

Страница 461: ...ortant point to remember when removing XXXX 1 2 2 Indicates that a technique is listed for use during installation 3 assembly 3 Quantity of oil or water drained INSTALLATION OF OOOO ASSEMBLY Title of...

Страница 462: ...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...

Страница 463: ...h the system Then check the oil level again If the piping or hydraulic equipment have been removed for repair Always bleed the air from the sys tem after reassembling the parts For details see TESTING...

Страница 464: ...of the strike Stop approx 100 mm before the end of the stroke 2 Operate the steering bucket and lift arm cylinders 3 4 times to the end of the stroke then stop the engine and bleed the air from the p...

Страница 465: ......

Страница 466: ...1 3 790 101 5201 Push tool KIT B q 1 Press fitting of main bearing outer races 790 101 5311 Plate 1 790 101 5221 Grip 1 01010 51225 Bolt 1 4 796 465 1120 Push tool t 1 Press fit of main bearing inner...

Страница 467: ...draulic cylinder 790 101 1102 Unit repair stand t 1 2 790 330 1100 Wrench assembly t 1 Removal and installation of cylinder head 3 790 302 1280 Socket wrench t 1 55 mm Bucket offset and blade 790 302...

Страница 468: ...0 Screw 1 791 101 2420 Adapter 1 790 101 2540 Washer 1 791 112 1180 Nut 1 790 101 2102 Puller 30 ton 1 790 101 1102 Hydraulic pump 1 3 790 201 2840 Spacer t 1 Removal of arm cylinder trunnion pin Arm...

Страница 469: ...over 3 mounting bolt Loosen the fuel air bleed hose clamp inside the cover and remove the hose Remove the fuel tank cap and remove the cover 3 3 Attach the eyebolts to the auxiliary counter weight 4 T...

Страница 470: ...ure 6 Loosen the drain plug 9 on the lower surface of the hydraulic tank and drain the hydraulic oil in a container Loosen the drain plug 10 on the radiator lower tank and drain the coolant in a con t...

Страница 471: ...bolt and remove the guard Remove the fan 24 mounting bolt and remove the fan 11 Loosen the upper radiator hose 25 and the lower radiator hose 26 clamps from the radi ator on the engine side and disco...

Страница 472: ...he bracket 35 record the number between the rod side nuts and the mounting nuts 16 Remove the clamp and fuel hose 37 Discon nect the hose below the fuel pump 38 17 Remove the controller cover 39 behin...

Страница 473: ...22 Disconnect each harness from the starting motor 46 23 Disconnect each harness from the alternator 47 Loosen adjuster 48 and move the alter nator 47 toward the engine Remove the connector 50 from th...

Страница 474: ...t to the bracket and tighten the nut to the specified torque 3 Mounting nut 59 74 Nm 6 7 5 kgm 2 Connect the hose of the fuel pump 38 and the fuel filter hose 37 to the engine pump assembly and clamp...

Страница 475: ...y Install the fan 24 with the 4 bolts Be careful not to drop the spacers Connect the upper hose 25 to the engine pump assembly and tighten the clamp to the specified torque 9 Pull the alternator 47 to...

Страница 476: ...ht 14 Install the air cleaner brackets 55 and 56 and then install the air cleaner 54 to the engine pump assembly 15 Connect the air cleaner air intake hose 21 Install the air intake manifold 20 Clamp...

Страница 477: ...inimum turn ing position Stop the engine Remove the tank cap and tighten it again so that pres sure is applied inside the tank Start the engine Turn the work equip ment to the right Lower the bucket c...

Страница 478: ...5 Remove the fuel cap Place the left rear cover 3 onto the engine pump assembly Connect the air bleed hose inside the cover which is used when adding oil Install the clamp on the engine pump assembly...

Страница 479: ...c tank and release any pressure inside the tank 2 Disconnect the negative cable 2 from the battery 1 terminal 3 Remove the floor mat 3 Temporarily lift the right side of the canopy 4 with a sling remo...

Страница 480: ...e screws of the removed connectors 8 Disconnect 4 pilot hoses 16 from the PPC valve 15 traveling Disconnect the hose 17 from the solenoid valve on the travel valve side Disconnect the hose marked with...

Страница 481: ...the lever Loosen the cable lock nut on the bracket 26 and remove the clamp 27 Disconnect the cable from the engine side Remove the clamp on the hydraulic pump by pulling it out toward the operator s s...

Страница 482: ...36 and 37 from the travel motor and those on the opposite side as well 17 Disconnect the hose 38 and 7 other hoses one after the other from the top of the center swivel joint and remove the plate 39...

Страница 483: ...nnect the 4 hoses first 37 and 36 and then 34 and 35 between the travel motors from below the swivel joint 3 Connect the hoses 32 and 33 below the swivel joint 4 Tighten the mounting bolt of the plate...

Страница 484: ...and tighten the nut Install the turnbuckle 22 on the control lever and install the roll pin and the beta pin in the turnbuckle by inserting them 9 Open the left side cover 19 to access the control pat...

Страница 485: ...ctors 9 Install the diode box 11 13 Install the cover 28 on which the fuel oil filler port is provided Install the left handrail 29 with the cover 30 14 Install the front cover 7 under which the work...

Страница 486: ...t works Operate the work equipment bring it to the oil level measuring position and check the oil level If the oil level is low open the hydraulic tank cap 42 and add oil up to the specified level Bri...

Страница 487: ...Attach male or female plugs to the removed hoses and nipples 3 Remove 8 mounting bolts 6 from the swing machinery 5 4 Lift the swing motor and machinery assembly 7 temporarily and pull out the machin...

Страница 488: ...om entering the motor 2 Connect the five hoses including the hoses 4 from the swing motor 3 3 Attach the covers 2 and 1 behind the boom foot Start the engine to supply oil to the swing motor During lo...

Страница 489: ...left side of the operator s seat with the cover Temporarily lift the right side of the canopy 2 with a lifting strap Remove the 11 bolts and lift the canopy away 2 Remove the front cover 4 horn cover...

Страница 490: ...he cylinder can be placed level below the cylinder and lower the cylinder onto it Cut off the binding bands holding the electrical harness 17 Remove the harness from the bracket and move the harness t...

Страница 491: ...per 11 Lift the work equipment assembly tempo rarily install tool V1 to the boom foot pin 28 and pull out the pin 12 Lift the work equipment assembly 29 Remove it from the revolving frame and lower i...

Страница 492: ...move the nipple 35 16 Remove the right and left bolts from the mounting bracket 37 and remove the engine hood 36 17 Insert a pin in the boom foot mounting bracket of the revolving frame assembly 38 an...

Страница 493: ...lts on the revolving arm through swing circle outer race 39 and temporarily secure all bolts Tighten the bolts permanently when the machine can be moved 3 Install nipple 35 of oil hose 34 connected to...

Страница 494: ...sliding surface with LM P during reassembly Use hyper white grease and refill the grease until the dust seals at both ends are full Change the position of boom foot section and add the grease 8 Insta...

Страница 495: ...structured special bands 13 Install separation cover 14 at the side of bat tery and install the rubber seals Plug har ness connector 13 into its socket potentiometer sensor for the work equip ment 14...

Страница 496: ...e and drive it at a slow speed Sequentially operate all actuators by fine steering control When the operation is sta ble change the equipment position and check the oil level Then change the work equi...

Страница 497: ...NG CIRCLE ASSEMBLY 1 Lift the swing circle assembly align the inner ring soft zone position the S marking posi tion on the inner ring surface with S marking 2 which is 27 degrees shifted toward the le...

Страница 498: ...ection If the rubber shoe is raised from the idler by the steel pipes slide the shoe off sideways INSTALLATION OF RUBBER SHOE ASSEMBLY Perform installation in the reverse order of removal Adjust the t...

Страница 499: ...and release the tension of road liner shoe 3 3 Remove the master pin using the tool R Place a small block in front of the shoe and slightly run the machine on the block When the pin hole has enough cl...

Страница 500: ...ight approximately half of the idler Insert a crowbar into the master pin hole at the sprocket side and place the sprocket in front of the front shoe end Slightly move the machine forward while holdin...

Страница 501: ...2 Remove No 1 sun gear 2 and No 1 plane tary gear carrier assembly 3 Disassemble No 1 planetary gear carrier assem bly 3 3 Using snap ring pliers Remove 3 snaps 4 3 thrust washers 5 3 planetary gears...

Страница 502: ...ing gear 6 Disassemble No 2 planetary gear carrier assembly 10 Remove 3 snap rings 14 using snap ring pliers Then remove 3 thrust washers 15 3 needle bearings 3 thrust washers and thrust plate 17 7 Us...

Страница 503: ...EMBLY 30 44 PC58UU 3 2 12 10 Remove bearing inner race 22 from shaft 23 and remove seal 24 11 Remove bearing inner race 25 from case assembly 26 12 Remove bearing outer race 27 from case 28 13 Remove...

Страница 504: ...l seal 24 to shaft 23 When installing make lip side of seal face to upper side Press fit bearing inner race 22 to shaft 23 by using tool F4 Press fitting force 7 25 to 19 70 kN 0 74 to 2 01 tons 3 Ins...

Страница 505: ...rrier Install 3 shafts 18 on carrier 19 and use a hammer and insert the stopper pin into shaft 18 through the hole of carrier 19 After pin insertion crimp two outer edge positions of the carrier pin 7...

Страница 506: ...ate 7 on carrier 3 10 Install a thrust washer on each shaft total 3 washers and install a needle bearing on each thrust washer total 3 needle bearings Install 3 planetary gears 6 and 3 thrust washers...

Страница 507: ...from shaft 5 Also remove one similar plug from the head of shaft 5 4 Use tool T and pull out shaft 5 from rotor 7 5 Remove shaft 5 from rotor 7 and remove dust seal 8 Remove 15 nipples 9 from the rot...

Страница 508: ...rease on the contact surface of the dust seal lip the rotor and the shaft Use a plastic hammer or equivlent and slightly tap the shaft to insert it into the rotor Take care not to damage the O ring 3...

Страница 509: ...il you can loosen the nut Spring compression force 26 9 kN 274 8 kg 3 Gradually release the hydraulic pressure to expand the recoil spring and remove bracket 5 and spring 6 from cylinder 7 Spring free...

Страница 510: ...3 Slowly apply oil pressure using tool M and tighten the spring then attach nut 4 and tighten lock bolt 3 Assemble the cylinder so that the lock bolt is fastened from above ASSEMBLY OF IDLER CUSHION A...

Страница 511: ...t the piston rod until the grease comes out of c so that no air remains in the cylinder When the grease comes out tighten valve 1 After tightening the valve confirm that the grease fitting faces the o...

Страница 512: ...ure that there are no contaminants 4 Install the O ring on shaft 5 then install it in the support 6 Insert the lock bolt for the shaft and tighten it to the specified torque 5 Install the support shaf...

Страница 513: ...engine oil EO30 CD to the sliding surface of the floating seal making sure that there are no contaminants 3 Install floating seal 4 to collars 1 and 2 using tool L4 Clean the O ring and the contacting...

Страница 514: ...l L5 Fill the ball section of bearing 6 with grease Albania EP 2 or equivalent 2 Press fit dust seal 4 onto roller 6 using tool L6 Fill roller 7 with grease 3 Install shaft 3 into roller 5 Attach snap...

Страница 515: ...insert it 1 Press fit bushing 14 into the cylinder head using tool U4 2 Install dust seal 12 using tool U5 3 Secure dust seal 12 using snap ring 11 Install rod packing 13 then install O ring 10 and ba...

Страница 516: ...Thoroughly bleed air during the first oper ation after assembling the cylinder For the first 3 to 5 strokes do not relieve both extending and retracting sides of the cyl inder at the strokes end Pisto...

Страница 517: ...h as O rings or seals Also apply a small amount of clean grease to parts such as O rings 1 Tighten the guide valve on the valve assem bly to the specified torque 1 cover 2 swing valve 3 blade valve 4...

Страница 518: ...ng 71 seal 72 seat 73 piston 74 spring 75 poppet 76 seal 77 sleeve 78 O ring 79 ring 80 O ring 81 5 Suction valve details Sleeve 82 O ring 83 spring 84 seal 85 valve 86 6 Apply one drop approximately...

Страница 519: ...mounting bolts 87 on each spool of the retainer of the spool return spring with spool 88 in the valve chest 89 to avoid deformation 11 Apply one drop 0 02 g of Loctite before installing plug 91 on the...

Страница 520: ...Serial No 20001 20423 90 7 ELECTRICAL CIRCUIT DIAGRAM 2 2 Serial No 20001 20423 90 9 ELECTRICAL CIRCUIT DIAGRAM 1 2 Serial No 20424 22000 90 11 ELECTRICAL CIRCUIT DIAGRAM 2 2 Serial No 20424 22000 90...

Страница 521: ...PC58UU 3 90 3 HYDRAULIC CIRCUIT DIAGRAM 7 1 For Serial No 22001 and up...

Страница 522: ...3 88 5 8 5 8 7 5 0 7 21 77 0 17 5 8 7 RU 6HULDO 1R DQG XS...

Страница 523: ...3 88 75 5 8 7 5 0 6HULDO 1R...

Страница 524: ...3 88 75 5 8 7 5 0 6HULDO 1R...

Страница 525: ...3 88 75 5 8 7 5 0 6HULDO 1R...

Страница 526: ...3 88 75 5 8 7 5 0 6HULDO 1R...

Страница 527: ...3 88 75 5 8 7 5 0 6HULDO 1R DQG XS...

Страница 528: ...3 88 75 5 8 7 5 0 6HULDO 1R DQG XS...

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