Technical Manual
SAFETY
RECOGNIZE SAFETY INFORMATION
001-E01A-0001
SA-001
002-E01A-1223
SA-1
SAFETY
FOLLOW SAFETY INSTRUCTIONS
004-E01A-0437
SA-2
SAFETY
WEAR PROTECTIVE CLOTHING
005-E01A-0438
006-E01A-0434 SA-434
INSPECT MACHINE
S007-E01A-0435
SA-435
SA-3
SAFETY
USE HANDHOLDS AND STEPS
008-E01A-0439
009-E01A-0378
SA-4
SAFETY
FASTEN YOUR SEAT BELT
010-E01A-0237
011-E01A-0426
SA-5
SAFETY
OPERATE ONLY FROM OPERATOR'S
SEAT
012-E01B-0444
Starting fluid:
JUMP STARTING
S013-E01A-0032
SA-6
SAFETY
KEEP RIDERS OFF MACHINE
SA-379
014-E01B-0379
018-E01A-0481
SA-481
SA-7
SAFETY
DRIVE MACHINE SAFELY
SA-388
SA-441
SA-589
S019-E02B-0590
SA-8
SAFETY
AVOID INJURY FROM ROLLAWAY
ACCIDENTS
To avoid rollaways:
• Select level ground when possible to park
machine.
• Do not park the machine on a grade.
• Lower the bucket and/or other work tools to the
ground.
• Turn the auto-idle switch off. SA-391
• Run the engine at slow idle speed without load for
5 minutes to cool down the engine.
• Stop the engine and remove the key from the key
switch.
• Pull the pilot control shut-off lever to LOCK
position.
• Block both tracks and lower the bucket to the
ground. Thrust the bucket teeth into the ground if
you must park on a grade.
• Position the machine to prevent rolling.
• Park a reasonable distance from other machines.
020-E02A-0493 SA-392
SA-9
SAFETY
AVOID INJURY FROM BACK-OVER AND
SWING ACCIDENTS
S021-E01A-0494
SA-10
SAFETY
AVOID TIPPING
To avoid tipping:
• Be extra careful before operating on a grade.
S025-E02B-0495
SA-11
SAFETY
AVOID POWER LINES
029-E01A-0381
OBJECT HANDLING
032-E01A-0014
SA-12
SAFETY
PROTECT AGAINST FLYING DEBRIS
SA-432
031-E01A-0432
To avoid accidents:
• Park machine on a firm, level surface.
• Lower bucket to the ground.
• Turn auto-idle switch off.
• Run engine at slow idle speed without load for 5
minutes.
• Turn key switch to OFF to stop engine.
• Remove the key from the key switch.
• Pull the pilot control shut-off lever to the LOCK
position.
• Close windows, roof vent, and cab door. SA-390
• Lock all access doors and compartments.
033-E02B-0390
SA-13
SAFETY
HANDLE FLUIDS SAFELYҥ
ҥAVOID FIRES
034-E01A-0496 SA-019
SA-14
SAFETY
PRACTICE SAFE MAINTENANCE
To avoid accidents:
SA-15
SAFETY
WARN OTHERS OF SERVICE WORK
S501-E01A-0287
SA-287
519-E01A-0527
502-E01A-0026 SA-026
SA-16
SAFETY
PREVENT PARTS FROM FLYING
503-E01B-0344
SA-034
504-E01A-0034
SA-040
S522-E01A-0040
SA-17
SAFETY
PREVENT BURNS
• Engine oil, gear oil and hydraulic oil also become hot
during operation.
The engine, hoses, lines and other parts become hot
as well.
SA-225
505-E01B-0498
506-E01A-0019
SA-18
SAFETY
AVOID HIGH-PRESSURE FLUIDS
SA-292
507-E01A-0499 SA-044
SA-19
SAFETY
PREVENT FIRES
Clean up Flammables:
S508-E05B-0019
SA-20
SAFETY
Check Emergency Engine Stop Switch:
S518-E01A-0393
SA-21
SAFETY
BEWARE OF EXHAUST FUMES
509-E01A-0016 SA-016
510-E01B-0030
SA-22
SAFETY
REMOVE PAINT BEFORE WELDING OR
HEATING
511-E01A-0029
512-E01B-0032
SA-23
SAFETY
SERVICE AIR CONDITIONING SYSTEM
SAFELY
513-E01A-0405
SA-24
SAFETY
HANDLE CHEMICAL PRODUCTS SAFELY
• Check the MSDS before you start any job using a SA-309
hazardous chemical. That way you will know
exactly what the risks are and how to do the job
safely. Then follow procedures and use
recommended equipment.
S515-E01A-0309
S516-E01A-0226
SA-25
SAFETY
BEFORE RETURNING THE MACHINE TO
THE CUSTOMER
S517-E01A-0435 SA-435
SA-26
SECTION 1
GENERAL
—CONTENTS—
Group 1 Specification
Base Machine Dimensions ..........................T1-1-1
Working Range ............................................T1-1-2
144T-1-1
(Blank)
144T-1-2
GENERAL / Specifications
BASE MACHINE DIMENSIONS
M144-11-003
T1-1-1
GENERAL / Specifications
WORKING RANGE
Loading Shovel
M144-11-001
Items
A: Minimum Digging Reach 5510 mm (18 ft 1 in)
B: Minimum Level Crowding Reach 7610 mm (25 ft 0 in)
C: Level Crowding Distance 4820 mm (15 ft 10 in)
D: Maximum Digging Reach 13400 mm (44 ft 0 in)
E: Maximum Cutting Height ∗14540 mm (47 ft 9 in)
F : Maximum Dumping Height ∗10400 mm (34 ft 1 in)
G: Maximum Digging Depth ∗5930 mm (19 ft 6 in)
NOTE: ∗The dimensions include the height of the shoe lug.
T1-1-2
GENERAL / Specifications
Backhoe
M144-11-004
T1-1-3
GENERAL / Specifications
(Blank)
T1-1-4
GENERAL / Component Layout
MAIN COMPONENTS 4
Backhoe 3 6
2
7
1
6
Loading Shovel 7
8
M145-01-016
5
9
4 10
3 11
2
12
1 13
14
15
16
33
32
34 31
30
29 17
28
27
26
25
24 18
23 19
22 T144-01-02-001
21
20
1 - Bucket 10 - Lubricator 19 - Auxiliary Hydraulic Oil Tank 27 - Accumulator (For Pilot Circuit)
T1-2-1
GENERAL / Component Layout
ELECTRICAL SYSTEM COMPONENT
23
1
2
3
4
5
6
7
8
9
10
22
21
20
19
18
17
16
15
14
13
12
11 T144-01-02-002
T1-2-2
GENERAL / Component Layout
24
25
26
27
28
29
30
31
32
33
34
35
36
47
46
37
45
44 38
43 39 T144-01-02-002
42
41
40
24 - Air Cleaner Restriction 30 - Coolant Temperature 36 - Coolant Temperature 42 - Pump Room Light
Switch Sensor Sensor
25 - Ether Solenoid Valve 31 - Engine Room Light 37 - ∗Engine Oil Level Switch 43 - Engine Speed Sensor
26 - Coolant Level Switch 32 - Ether Solenoid Valve 38 - Travel Alarm 44 - Pump Transmission Oil
(For Indicator) Pressure Switch
27 - Thermo Guard Switch 33 - Coolant Level Switch 39 - Engine Speed Sensor 45 - Contamination Sensor
(For Ether Solenoid Valve) (For Indicator)
28 - Coolant Level Switch 34 - Thermo Guard Switch 40 - Pump Transmission Oil 46 - Engine Stop Switch
(For ECM) (For Ether Solenoid Valve) Pressure Switch
29 - Air Cleaner Restriction 35 - Coolant Level Switch 41 - Contamination Sensor 47 - EHC Valve
Switch (For ECM)
NOTE: ∗Engine oil level switch for the front engine is located in the same position.
T1-2-3
GENERAL / Component Layout
ELECTRICAL SYSTEM COMPONENT (In the cab)
4
1
5
M144-01-020
6 7
15
14
8
13 9
10
12
11
M144-01-005
M144-07-096
1 - Switch Panel 5 - Key Switch 9 - Data Link Connector 13 - Data Link Connector
(For Front Engine) (For Front Engine) (For Rear Engine)
2 - Monitor Panel 6 - Fuse Box 2 10 - Engine Diagnostic 14 - Engine Diagnostic
Switch B Switch A
(For Front Engine) (For Rear Engine)
3 - Emergency Engine Stop 7 - Power Source Terminal 11 - Transformer 15 - Buzzer
Switch (24 V to 12 V)
4 - Key Switch 8 - Engine Diagnostic 12 - Engine Diagnostic
(For Rear Engine) Switch A Switch B
(For Front Engine) (For Rear Engine)
T1-2-4
GENERAL / Component Layout
Monitor Panel 10 11 12 13 14
1 2 3 4 5 6 7 8 9
34
33
32
31
30
29
28
27 26 25 24 23 22 21 20 19 18 17 16 15 T144-01-02-006
Switch Panel 35 36 37 38 39 40 41
42
43
44
45
54 53 52 51 50 49 48 47 46
M144-01-017
1 - Engine Oil Level Indicator 16 - Alternator Indicator 29 - Air Cleaner Restriction Indi- 42 - Indicator Light Check
(For Front Engine) cator (For Rear Engine) Switch
2 - Coolant Level Indicator 17 - Pump Transmission Oil 30 - Pump Contamination 43 - Level Check Switch
(For Front Engine) Pressure Indicator Indicator
(For Front Engine)
3 - Hydraulic Oil Level Indicator 18 - Hydraulic Oil Level 31 - Engine Stop Indicator 44 - Buzzer Stop Switch
Indicator
4 - Slow Travel Mode Indicator 19 - Pump Transmission Oil 32 - Ladder Position Indicator 45 - Dimmer Switch
Pressure Indicator
(For Rear Engine)
5 - Auto Idle Indicator 20 - Fuel Level Indicator 33 - Engine Oil Level Indicator 46 - Engine Speed Control
(For Rear Engine) Lever
6 - Engine Room Light 21 - Auto-Lubrication Indicator 34 - Coolant Level Indicator 47 - Work Light Switch
Indicator (Option) (For Rear Engine)
7 - Entrance Light Indicator 22 - Engine Stop Indicator 35 - Washer Switch 48 - Dome Light Switch
(For Front Engine)
8 - Work Light Indicator 23 - Engine Warning Indicator 36 - Cigar Lighter 49 - Engine Room Light
(For Front Engine) Switch
9 - Fast Travel Mode Indicator 24 - Engine Protection Indicator 37 - Wiper Delay Selector 50 - Entrance Light Switch
(For Front Engine)
10 - Coolant Temperature Gauge 25 - Engine Protection Indicator 38 - Wiper Switch 51 - Travel Mode Switch
(For Rear Engine) (For Rear Engine)
11 - Hydraulic Oil 26 - Engine Warning Indicator 39 - Air Conditioner Control 52 - Auto Idle Switch
Temperature Gauge (For Rear Engine) Panel (For Rear)
12 - Tachometer 27 - Engine Stop Indicator 40 - Air Conditioner Control 53 - Ether (Starting Aid)
(For Rear Engine) (For Rear Engine) Panel (For Side) Switch
13 - Tachometer 28 - Air Cleaner Restriction Indi- 41 - Air Conditioner Control 54 - Auxiliary Switch
(For Front Engine) cator Panel (For Front)
14 - Coolant Temperature Gauge (For Front Engine)
(For Front Engine)
15 - Fuel Gauge
T1-2-5
GENERAL / Component Layout
PUMP
T144-03-01-001
1 - Main Pump 4 3 - Center Gear Pump 4- Main Pump 3 5- Triple Gear Pump
(For Front Engine) (For Front Engine)
Main Pump 2 Main Pump 1
(For Rear Engine) (For Rear Engine)
2 - Swing Pump 2
(For Front Engine)
Swing Pump 1
(For Rear Engine)
T1-2-6
GENERAL / Component Layout
ENGINE
1 2 3
7 6 5 T144-01-02-003
1 - Coolant Temperature 3 - Intake Manifold 5 - ECM (Electrical Control 7 - Engine Oil Pressure
Sensor (For ECM) Temperature Sensor Module) Sensor (For ECM)
(For ECM)
2 - Intake Manifold Pressure 4 - Engine Speed Sensor 6 - Air Pressure Sensor
Sensor (For ECM) (For ECM) (For ECM)
T1-2-7
GENERAL / Component Layout
ELECTRICAL EQUIPMENT BOX
1
2
3
28 4
5
25, 26, 27
6
7
24
8
21, 22, 23
9
10
20 11
12
19
13
18 14
15
16
17
T144-01-02-004
1 - Limit Switch 8 - Work Light Relay (On the left 15 - Auto-Lubrication Relay 22 - Side Air Conditioner
side of base machine) Controller (Middle Shelf)
2 - Lower Wiper Slow Relay 9 - Work Light Relay (On the right 16 - Auto-Lubrication 23 - Front Air Conditioner
side of base machine) Interval Switch Controller (Lower Shelf)
3 - Upper Wiper Fast Relay 10 - Work Light Relay 17 - Fuse Box 1 24 - Resister (R2:27 Ω)
(On the cab)
4 - Upper Wiper Slow Relay 11 - Slow Wiper Relay 18 - Ether Relay 25 - Contamination Amplifier
(For Rear Engine) (Upper Shelf)
5 - Upper Wiper Main Relay 12 - Hour Meter Relay 19 - Ether Relay 26 - MC (B) (Middle Shelf)
(For Front Engine)
6 - Lower Wiper Main Relay 13 - Swing Inter Lock Relay 20 - Resister (R3:5.6 Ω) 27 - MC (A) (Lower Shelf)
7 - Load Dump Relay 14 - Fluorescent 21 - Rear Air Conditioner 28 - Resister (R1:27 Ω)
Illumination Light Controller (Upper Shelf)
T1-2-8
GENERAL / Component Layout
29
30
31
45 32
33
44
34
35
43
36
42
37
38
41 39
40
T144-01-02-004
29 - Illumination Relay 34 - Engine Room Light 38 - Air Conditioner Relay 42 - Air Conditioner Relay
Relay (For Side) (For Front)
30 - Indicator Light Check 35 - Emergency Relay 39 - Air Conditioner Relay 43 - Fan Motor Relay
Relay (For Front Engine) (For Rear) (For Front)
31 - Washer Motor Relay 36 - Fan Motor Relay 40 - Lower Wiper Fast Relay 44 - Entrance Light Relay
(For Side)
32 - Travel Speed Change 37 - Fan Motor Relay 41 - Dome Light Relay 45 - Horn Relay
Relay (For Rear)
33 - Emergency Relay
(For Rear Engine)
T1-2-9
GENERAL / Component Layout
BATTERY COMPARTMENT
1 2 3
10
4
9 7
T144-01-02-005
T1-2-10
GENERAL / Component Specifications
COMPONENT SPECIFICATIONS
ENGINE
MAIN SPECIFICATIONS
Manufacture .................................................. CUMMINS ENGINE COMPANY, Inc.
Model............................................................. QSK19C
Type............................................................... Diesel, 4 cycle, vertical, 6-cylinder inline, water-cooled,
turbo charged, after cooled, direct injection type
Cyl. No.-bore × stroke ................................... 6-159 mm×159 mm (6.25 in×6.25 in)
3 3
Piston displacement ...................................... 18900 cm (1140 in )
Rated output (SAE J1995) (GROSS)............ 373 kW/1800 min−1 (507 PS/1800 rpm)
(NET) .................. 333 kW/1800 min−1 (452 PS/1800 rpm)
Dry weight ..................................................... 2150 kg (4740 lb)
Firing order .................................................... 1-5-3-6-2-4
Rotation direction .......................................... Clockwise (view from fan side)
COOLING SYSTEM
Cooling fan .................................................... Dia. 1219 mm (48 in), draw-in type
Fan pulley ratio.............................................. 0.7 : 1
Thermostat .................................................... Cracking temp. : 79°C (174°F)
(under atmospheric pressure) Full open temp. : 91°C (196°F)
Water pump................................................... Centrifugal type
LUBRICATION SYSTEM
Lubrication pump type ................................... Gear pump
Oil filter .......................................................... Paper element type (Spin on type)
Oil pan capacity............................................. 49 to 61 L (13 to 16 US gal)
Include filters : 55 to 67 L (14.5 to 18 US gal)
STARTING SYSTEM
Motor ............................................................. Delco Remy 50MT-400
VoltagexOutput .............................................. 24 Vx9.0 kW
ALTERNATOR
Type............................................................... Delco Remy 30Sl-400, AC generator
VoltagexOutput .............................................. 24 Vx75 A
FUEL SYSTEM
Injection pump............................................... Cummins HPI electronic control
Governor ....................................................... Electronic all speed control
PERFORMANCE
Fuel consumption ratio (NET) ....................... 234 g/kWxh (173 g/PSxh)
Max. output torque (GROSS) ................. 2235 Nxm (228 kgfxm, 1650 Ibfxft) @ 1400±100 min−1
(NET) ....................... 2108 Nxm (215 kgfxm, 1555 Ibfxft) @ 1400±100 min−1
Max. no load speed ....................................... 2000±50 min−1
Min. no load speed ........................................ 700±25 min−1
T1-3-1
GENERAL / Component Specifications
Engine Performance Curve
PEAK TORQUE
∗2237 (2107) Nxm
@1400±100 min−1
GROSS
TORQUE NET
(Nxm)
POWER
OUTPUT
(kW)
RATED
∗370 (333) kW
@1800 min−1
GROSS
NET
FUEL
CONSUMPTION
(g/kWĊh)
NET
GROSS
HIGH IDLE
2000±50 min−1
Engine Speed
T144-01-03-001
T1-3-2
GENERAL / Component Specifications
ENGINE ACCESSORIES
RADIATOR ASSEMBLY
Type............................................................... Radiator/Oil cooler tandem type assembly
Weight ........................................................... 900 kg (1985 lb)
T1-3-3
GENERAL / Component Specifications
HYDRAULIC DEVICE
PUMP DEVICE
Gear speed ratio ........................................... Main pump : 1.02
Swing pump : 0.82
Center gear pump :1
Triple gear pump : 1.02
MAIN PUMP
Model............................................................. K3V280SH102L-SK
Type............................................................... Variable displacement swash plate type plunger pump
3 3
Displacement ................................................ 280 cm (17 in ) /rev
SWING PUMP
Model............................................................. K3V280SH102L-1 P
Type............................................................... Variable displacement swash plate type plunger pump
3 3
Displacement ................................................ 280 cm (17 in ) /rev
CONTROL VALVE
Model............................................................. KSV1000
Type............................................................... Pilot pressure operated type
2
Main relief pressure type ............................... 29 MPa (300 kgf/cm , 4270 psi)
2
Overload relief pressure................................ 31 MPa (320 kgf/cm , 4550 psi)
2
17 MPa (170 kgf/cm , 2420 psi) (Bucket Open-Close)
SWING MOTOR
Model............................................................. MX750
Type............................................................... Swash plate type, fixed displacement plunger motor
3 3
Displacement ................................................ 750 cm (45.8 in ) /rev
2
Relief pressure .............................................. 29 MPa (300 kgf/cm , 4270 psi)
+0 +0 2 +0
Parking brake release pressure .................... 1.77 −0.4 MPa (18 −4 kgf/cm , 256 −57 psi)
T1-3-4
GENERAL / Component Specifications
TRAVEL REDUCTION DEVICE
Type............................................................... Two-stage planetary gear type
Gear ratio ...................................................... 106.6 : 1
TRAVEL MOTOR
Model............................................................. MB750
Type............................................................... Swash plate type, variable displacement plunger motor
3 3
Displacement (Slow speed) .......................... 737 cm (45 in ) /rev
3 3
(Fast speed) ........................... 554 cm (33.8 in ) /rev
2
Parking brake release pressure .................... 1.42 to 1.71 MPa (14.5 to 17.4 kgf/cm , 206 to 247 psi)
T1-3-5
GENERAL / Component Specifications
COMPRESSOR DRIVE MOTOR
Model............................................................. MSF-46
3 3
Displacement ................................................ 46.1 cm (2.8 in ) /rev
EHC VALVE
Type............................................................... Proportional type
Voltage .......................................................... 24 V
2
Control pressure............................................ 0.3 to 3.1 MPa (3 to 32 kgf/cm , 43 to 455 psi)
T1-3-6
GENERAL / Component Specifications
ELECTRICAL COMPONENT
BATTERY RELAY
VoltagexCurrent ............................................. 24 Vx100 A
STARTER RELAY
VoltagexCurrent ............................................. 24 Vx180 A
STARTER RELAY 2
VoltagexCurrent ............................................. 12 Vx15 A
BRAKER
Current .......................................................... 120 A
HORN
Specification .................................................. 24 Vx2 Ax121 dB/mx669 Hz
WORK LIGHT
Specification .................................................. Halogen 24 Vx70 W
OTHERS
LUBRICATION DEVICE
Manufacture .................................................. LINCOLN
Grease capacity ............................................ 200 kg (440 lb)
2
Max. grease pressure ................................... 24 MPa (245 kgf/cm , 3480 psi)
3 3
Displacement ................................................ 240 cm (15 in ) /min
AIR CONDITIONER
3
Cooling ability ................................................ 3500 kcal/h (14700×10 J)
3
Heating ability................................................ 3600 kcal/h (15100×10 J)
Rated voltage consumption........................... 200 W (24 V Hour)
3
Condenser heat dissipation capacity............. 8200 kcal/h±10 % (34300×10 J)
T1-3-7
GENERAL / Component Specifications
(Blank)
T1-3-8
SECTION 2
SYSTEM
—CONTENTS—
144T-2-1
(Blank)
144T-2-2
SYSTEM / Control System
OUTLINE
MC (Main Controller) (A), MC (Main Controller) (B), NOTE: The ECM is the control unit for the QUAN-
and ECM (Electronic Control Module) process signals TM
TUM Electronic Governor System.
from various sensors and switches, activating solenoid A ECM is provided for each engine. The
valves and relays, and controlling the engines, pumps, ECM monitors engine conditions using vari-
auto-lubrication system, wiper, and monitor system. ous sensors, such as coolant temperature,
coolant level, boost pressure, engine oil
pressure, engine speed, fuel pressure, and
timing pressure sensors. Upon receiving
signals from these sensors, the ECM con-
trols fuel injection volume/pressure, injec-
tion timing, engine torque, and engine
speed, and turns on the engine warning in-
dicator, engine stop indicator, and engine
protection indicator as required.
MC (A)
Input Source Output Control Device Control Function
Engine Speed Sensor (Front Engine) EHC Valve Increased Horsepower Pump Control
Auto-Lubrication Interval Switch Auto-Lubrication Solenoid Valve Relay Auto-Lubrication Control
Auto-Lubrication Switch
MC (B)
Input Source Output Control Device Control Function
Engine Speed Sensor (Rear Engine) EHC Valve Increased Horsepower Pump Control
Wiper Switch Wiper Relay (Slow Speed) Wiper Control
Interval Switch
Auto-Idle Pressure Switch Electronic Governor via ECM Engine Control (Auto-Idle Control)
Auto-Idle Switch
ECM
Input Source Output Control Device Control Function
Accelerator Sensor Electronic Governor Engine Speed Control
Auto-idle signal from MC (B) Electronic Governor Auto-Idle Control
Engine Diagnostic Switches A and B Engine Warning Indicator Engine Diagnosing Function
(Front Engine) Engine Stop Indicator
Engine Diagnostic Switches A and B Engine Protection Indicator
(Rear Engine)
T2-1-1
SYSTEM / Control System
ENGINE CONTROL
Engine Speed Control
Purpose:
To control the engine speed corresponding to the en-
gine speed control lever stroke.
Operation:
The accelerator sensor sends the ECM an electrical
signal corresponding to the engine speed control
lever stroke. Consequently, the ECM activates the
electronic governor to control the engine speed.
ECM
Accelerator Sensor Electronic
Governor
MC (B)
Accelerator Sensor
Rear Engine
T144-02-01-001
T2-1-2
SYSTEM / Control System
Auto-Idle Control
Purpose:
To save fuel and to lower noise by lowering engine
speed while all control levers are in neutral.
Operation:
Signals from the auto-idle switch and auto-idle pres- Approximately three seconds after receiving the sig-
sure switch are sent to the MC (B). nal, the ECM activates the electronic governor, low-
The auto-idle pressure switch is turned off when all ering the engine speed to the auto-idle setting.
control levers are returned to neutral. When control lever(s) are moved, the auto-idle pres-
With the auto-idle switch turned in the ON position, sure switch is turned ON. Consequently, the MC (B)
the MC (B) outputs a signal to the ECM after the stops sending a signal to the ECM. Then, the ECM
auto-idle pressure switch is turned off. raises the engine speed to the engine control lever
setting.
Front Engine
ECM
Electronic
Governor
Auto-Idle Switch
ECM
Electronic
Governor
Rear Engine
T144-02-01-002
T2-1-3
SYSTEM / Control System
Engine Diagnosing Function
Purpose: Operation:
To indicate fault code(s) for engine troubleshooting if After the engine is stopped, turn the key switch to the
the engine protection indicator, engine warning indi- ON position and hold the engine diagnostic switch A
cator, and/or engine stop indicator should come on, in the ON (upward) position. The ECM will then send
due to failure of engine or engine related components. an electrical signal to the monitor to indicate fault
Fault codes can be indicated on the monitor by press- code on the monitor.
ing the engine diagnostic switches A and B. If the engine diagnostic switch B is pressed upward or
downward while a fault code is indicated on the moni-
tor, an another electrical signal is sent from the ECM
to the monitor to indicate the next or previous fault
code. (Refer to the “Troubleshooting A” group in the
“TROUBLESHOOTING” section for the trou-
bleshooting procedure.)
Engine Protection
Indicator
Engine Warning
Indicator ECM
Engine Stop
Indicator
24 V
Engine Diagnostic Engine Diagnostic
Switch A Switch B
T144-02-01-004
T2-1-4
SYSTEM / Control System
PUMP CONTROL
Increased Horsepower Pump Control (Speed
Sensing)
Purpose:
To efficiently utilize engine horsepower by increasing
the pump delivery rate corresponding to the actual
engine speed when the engine runs faster than the
rated speed.
Operation:
The engine speed sensors input the MC (A) and (B) This increased horsepower pump control is kept ac-
the engine speeds as electric signals. tivated until the engine speed is reduced to 1700
As long as the engine is running at a speed between min−1. (Note that the engine speed decreases with
1700 min−1 and 2050 min−1, the MC (A)/(B) sends the this pump control because the load applied to the en-
EHC valve an signal corresponding to the engine gine increases due to the increased pump displace-
speed. ment angle.)
Consequently, the EHC valve sends the main pump
regulator port PZ pilot pressure corresponding to the
signal, increasing the pump displacement angle. As a
result, the pump delivery rate is increased, moving
the actuator(s) faster. (Refer to “Pump Device” group,
“COMPONENT OPERATION” section.)
MC (A)
Front Engine
EHC Valve
Flywheel Housing
Pilot Pump
MC (B)
Rear Engine
Flywheel Housing
T144-02-01-005
T2-1-5
SYSTEM / Control System
AUTO-LUBRICATION CONTROL
Purpose: Purpose:
To automatically lubricate at a specified interval. To lubricate manually with a grease gun.
Operation: Operation:
When the auto-lubrication mode switch is turned to When the auto-lubrication mode switch is turned to
the AUTO LUB. position, an electrical signal is sent to the MANUAL position, an electrical signal is sent to
the MC (A). When a time specified by the auto- the MC (A), turning on the auto-lubrication solenoid
lubrication interval switch lapses, turning on the auto- relay. The auto-lubrication solenoid relay is kept on
lubrication solenoid relay is turned ON. Consequently, without any intermission.
the auto-lubrication solenoid valve 1 and auto- Since the grease pump is operated continuously in
lubrication solenoid valve 2 (the cycle timer) are this mode even when the grease gun is not in use,
turned on. pressure in the lubrication line rises continuously. To
Auto-lubrication solenoid valve 1 routs the pilot pres- prevent this from occurring, a grease pressure switch
sure from the pilot pump to auto-lubrication solenoid for the manual lubrication operation is provided in the
valve 2. Auto-lubrication solenoid valve 2 is turned on lubrication line.
and off by its cycle timer at a specified interval. Con- This grease pressure switch is turned on when the
2
sequently, the hydraulic lines to and from the grease grease pressure reaches 23.5 MPa (240 kgf/cm ).
pump are alternately changed. As a result, the grease When this grease pressure switch is turned on, the
pump is operated, discharging grease into the lubrica- MC (A) turns off the auto-lubrication solenoid valve
tion line, at a specified interval. relay. As a result, auto-lubrication solenoid valve 1
A grease pressure switch for the auto-lubrication is and the cycle timer (auto-lubrication solenoid valve 2)
provided in the lubrication line. This grease pressure are turned off, stopping the grease pump operation.
switch is turned on when the grease pressure
2
reaches 17.7 MPa (180 kgf/cm ). When this grease
pressure switch is turned on, the MC (A) turns off the
auto-lubrication solenoid valve relay. As a result,
auto-lubrication solenoid valve 1 and the cycle timer
(auto-lubrication solenoid valve 2) are turned off,
stopping the grease pump operation.
When a time specified by the auto-lubrication interval
switch lapses, the MC (A) turns on the auto-
lubrication solenoid valve relay, operating the grease
pump again.
T2-1-6
SYSTEM / Control System
Auto-Lubrication Indicator
Cycle Timer
Grease Pressure
Switch for Manual Grease Pump
Lubrication
To the
Auto-Lubrication lubrication
Auto-Lubrication Solenoid Valve 2 line.
Solenoid Valve 1
Vent Valve
Pilot Pump
Orifice
T144-02-01-006
T2-1-7
SYSTEM / Control System
WIPER CONTROL
Purpose: Purpose:
To operate the wiper at an interval set by the wiper de- To spray windshield washer fluid and to operate the
lay selector. wiper a few turns at slow speed.
Operation: Operation:
An electrical signal is sent to the MC (B) when the When the washer switch is pressed, the washer mo-
wiper switch is turned to the INT position. Conse- tor relay is turned on and an electrical signal is sent to
quently, the MC (B) turns on the slow wiper relay for the MC (B). The washer motor operates as the
approximately one and half seconds at an interval set washer motor relay is turned on. At the same time,
by the wiper delay selector. the MC (B) turns on the slow wiper relay, operating
As the slow speed wiper relay is turned on, the upper the wiper at slow speed. The wiper is operated for
side and lower side slow speed wiper relays are approximately five seconds after the washer switch is
turned on, operating the upper and lower wiper mo- released.
tors for one wiper turn at the slow speed.
Purpose:
To operate the wiper at slow speed.
Operation:
An electrical signal is sent to the MC (B) when the
wiper switch is turned to the LOW position. Conse-
quently, the MC (B) turns on the slow wiper relay. As
the slow wiper relay is turned on, the upper and lower
slow wiper relays are turned on, operating the upper
and lower wiper motors at the slow speed.
Purpose:
To operate the wiper at fast speed.
Operation:
When the wiper switch is turned to the HI position, the
upper and lower fast wiper relays and the upper and
lower main wiper relays are turned on, operating the
upper and lower wiper motors at fast speed.
T2-1-8
SYSTEM / Control System
Washer Motor
Washer
Motor Relay
MC (B)
Slow
Wiper Relay
Washer Switch
T144-02-01-007
T2-1-9
SYSTEM / Control System
MONITOR CONTROL
Purpose: Operation:
To display machine conditions on the monitor. Electrical signals from various sensors and switches
are sent to the MC (A) and MC (B). Upon receiving
these electrical signals, the MC (A) and MC (B) oper-
ate the gauges and indicators as required.
MC (A)
Input Source Output Control Device
Engine Speed Sensor (Front Engine) Tachometer (Front Engine)
Hydraulic Oil Level Switch 2 Hydraulic Oil Level Indicator (Warning)
Air Cleaner Restriction Switch (Front Engine) Air Cleaner Restriction Indicator (Front Engine)
Pump Transmission Oil Pressure Switch (Front Engine) Pump Transmission Oil Pressure Indicator (Front Engine)
Pump Transmission Oil Pressure Switch (Rear Engine) Pump Transmission Oil Pressure Indicator (Rear Engine)
Fuel Level Switch Fuel Level Indicator
Auto-Lubrication Mode Switch Auto-Lubrication Indicator
Pump Contamination Sensor Amplifier Pump Contamination Indicator
Starter Relay 2 (Front/Rear Engines) Alternator Indicator
MC (B)
Input Source Output Control Device
Engine Speed Sensor (Rear Engine) Tachometer (Rear Engine)
Hydraulic Oil Level Switch 1 Hydraulic Oil Level Indicator
Coolant Level Switch (Front Engine) Coolant Level Indicator (Front Engine)
Coolant Level Switch (Rear Engine) Coolant Level indicator (Rear Engine)
Engine Oil Level Switch (Front Engine) Engine Oil Level Indicator (Front Engine)
Engine Oil Level Switch (Rear Engine) Engine Oil Level Indicator (Rear Engine)
Air Cleaner Restriction Switch (Rear Engine) Air Cleaner Restriction Indicator (Rear Engine)
Auto-Idle Switch Auto-Idle Indicator
Emergency Engine Stop Switch (Located in the cab) Engine Stop Indicator
Engine Stop Switch (Located in the pump room)
Ladder Limit Switch Ladder Position Indicator
Others
Input Source Output Control Device
Coolant Temperature Sensor (Front Engine) Coolant Temperature Gauge (Front Engine)
Coolant Temperature Sensor (Rear Engine) Coolant Temperature Gauge (Rear Engine)
Hydraulic Oil Temperature Sensor Hydraulic Oil Temperature Gauge
Fuel Sensor Fuel Gauge
ECM (Front/Rear Engines) Engine Stop Indicators (Front/Rear Engines)
Engine Diagnostic Switch A (Front/Rear Engines) Engine Warning Indicators (Front/Rear Engines)
Engine Diagnostic Switch B (Front/Rear Engines) Engine Protection Indicators (Front/Rear Engines)
Travel Mode Switch→Travel Mode Relay Travel Mode Indicator (Slow Speed)
Travel Mode Indicator (Fast Speed)
Work Light Relay→Illumination Relay Panel Illumination
Engine Room Light Switch→Engine Room Light Relay Engine Room Light Indicator
Entrance Light Switch→Entrance Light Relay Entrance Light Indicator
T2-1-10
SYSTEM / Control System
OTHERS
Travel Mode Change Circuit
Operation:
When the travel switch is in the OFF (Slow Speed)
position, the travel mode relay is turned off. Conse-
quently, the travel mode change solenoid valve is
turned off, changing the travel mode to the slow
speed mode.
When the travel switch is in the ON (Fast Speed) po-
sition, the travel mode relay is turned on. Conse-
quently, the travel mode change solenoid valve is
turned on, changing the travel mode to the fast speed
mode. (Refer to the “Travel Device” group,
“COMPONENT OPERATION” section.)
Travel Switch
Power Source
Power Source
Power Source
T2-1-11
SYSTEM / Control System
Swing Interlock Control
Purpose:
To deactivate the swing function when the ladder is
lowered or when the emergency engine stop switch is
turned ON.
Operation:
The ladder limit switch is turned on while the ladder is As the swing stop solenoid valve is turned on, the
lowered. swing pilot pressure is blocked between the pilot
Consequently, the swing interlock relay is turned on, valve and control valve. For this reason, the swing
turning on the swing stop solenoid valve. function is interlocked.
When the emergency engine stop switch is turned
ON, the swing stop relay is turned ON, turning the
swing stop solenoid valve ON.
Power Source
Pilot Valve
Swing Spool
Swing Stop
Solenoid Valve
T144-02-01-009
T2-1-12
SYSTEM / Hydraulic System
OUTLINE
Main Circuit:
A hydraulic circuit that actuates cylinders and motors
by pressure oil delivered from the main pumps.
Pilot Circuit:
A hydraulic circuit that supplies pressure oil from the
pilot pump to the pilot operating circuit, travel speed
mode shift circuit, pump control circuit, auto lubrication
circuit, and swing parking brake release circuit.
T2-2-1
SYSTEM / Hydraulic System
HYDRAULIC CIRCUIT DIAGRAM
Loading shovel 1- Bucket Cylinder
2- Dump Cylinder
3- Arm Cylinder
4- Boom Cylinder
5- Level Cylinder
6- Bucket Close Pilot Valve
7- Bucket Open Pilot Valve
8- Travel Pilot Valve
9- Left Pilot Valve
10 - Right Pilot Valve
11 - Pilot Shut-Off Valve
12 - Accumulator
13 - Hydraulic Oil Tank
14 - Suction Strainer
15 - Full-Flow Filter
16 - Bypass Filter
17 - Air-Con. Comp. Motor
18 - Control Valve (Swing)
19 - Swing Motor
20 - Center Joint
21 - Grease Pump
22 - Drain Filter
23 - Pilot Filter
24 - Control Valve (Left Travel)
25 - Control Valve (Boom Raise/Bucket Tilt-in)
26 - Control Valve (Bucket Open and Close)
27 - Control Valve (Arm)
28 - Control Valve (Arm)
29 - Control Valve (Bucket)
30 - Control Valve (Boom)
31 - Control Valve (Right Travel)
32 - Fan Motor
33 - Relief Valve
34 - Fuel Cooler
35 - Hydraulic Oil Tank (Aux Tank)
36 - Engine
37 - Main Pump
38 - Swing Pump
39 - Air-Con. Comp. Pump
40 - Pilot Pump
41 - Fan Drive Pump
42 - Oil Pump (Transmission)
43 - Check Valve
44 - High Pressure Strainer
45 - Check Valve
46 - Radiator
Supply Line from Pumps
47 - Oil Cooler
Return Line
48 - Transmission Cooler
Suction Line
49 - Bypass Check Valve
Actuator Line
50 - Travel Motor
Drain and Pilot Line
51 - Brake Valve
M144-07-072
T2-2-2
SYSTEM / Hydraulic System
Backhoe
1- Bucket Cylinder
2- Arm Cylinder
3- Boom Cylinder
4- Travel Pilot Valve
5- Left Pilot Valve
6- Right Pilot Valve
7- Pilot Shut-Off Valve
8- Accumulator
9- Hydraulic Oil Tank
10 - Suction Strainer
11 - Full-Flow Filter
12 - Bypass Check Valve
13 - Air-Con. Comp. Motor
14 - Control Valve (Swing)
15 - Swing Motor
16 - Center Joint
17 - Grease Pump
18 - Drain Filter
19 - Pilot Filter
20 - Control Valve (Left Travel)
21 - Control Valve (Boom)
22 - Control Valve (Bucket)
23 - Control Valve (Arm)
24 - Control Valve (Arm)
25 - Control Valve (Bucket Roll-in)
26 - Control Valve (Boom)
27 - Control Valve (Right Travel)
28 - Fan Motor
29 - Relief Valve
30 - Fuel Cooler
31 - Hydraulic Oil Tank (Aux Tank)
32 - Engine
33 - Main Pump
34 - Swing Pump
35 - Air-Con. Comp. Pump
36 - Pilot Pump
37 - Fan Drive Pump
38 - Oil Pump (Transmission)
39 - Check Valve
40 - High Pressure Strainer
41 - Check Valve
42 - Radiator
43 - Oil Cooler
44 - Transmission Cooler
45 - Bypass Check Valve
Supply Line from Pumps 46 - Travel Motor
Return Line 47 - Brake Valve
Suction Line
Actuator Line
Drain and Pilot Line
M144-07-073
T2-2-3
SYSTEM / Hydraulic System
MAIN CIRCUIT
T2-2-4
SYSTEM / Hydraulic System
Right Swing
Left Swing
Swing Motor Control Valve
Control Valve
Swing Swing
Center Joint
Swing Pump 2
Main Pump 4
Main Pump 3
Swing Pump 1
Main Pump 2
Main Pump 1
Center Joint
Rear Engine
T144-02-02-014
T2-2-5
SYSTEM / Hydraulic System
Single Operation Circuit
• Boom Operation
T2-2-6
SYSTEM / Hydraulic System
Boom Cylinder
Boom Raise/
Bucket Tilt-In
Boom
Boom
Lower
From From
Main Pumps Main Pumps
1 and 4 2 and 3
Boom Boom
Raise Raise
T2-2-7
SYSTEM / Hydraulic System
• Arm Operation
T2-2-8
SYSTEM / Hydraulic System
Arm Circuit
Arm Cylinder
Arm Arm
From From
Main Pumps Main Pumps
1 and 4 2 and 3
Arm
Retract
Level
Cylinder
Extend
Extend Retract
Retract
Boom
Cylinder
T144-02-02-003
T2-2-9
SYSTEM / Hydraulic System
• Bucket Operation
T2-2-10
SYSTEM / Hydraulic System
Boom Raise/
Bucket Tilt-In Bucket
Bucket Bucket
Tilt-In Tilt-Out
From From
Main Pumps Main Pumps
1 and 4 2 and 3
Bucket
Tilt-In
T2-2-11
SYSTEM / Hydraulic System
• Bucket Open/Close Operation
(Loading Shovel Type Only)
Bucket Open
When the bucket open/close pedal is operated to
open the bucket, pressure oil from main pumps 1 and
4 flows into the rod side of the dump cylinder via the
bucket open/close section in the left control valve.
Bucket Close
When the bucket open/close pedal is operated to
close the bucket, pressure oil from main pumps 1 and
4 flows into the boom side of the dump cylinder via
the bucket open/close section in the left control valve.
Dump Cylinder
Bucket
Open
From
Main Pumps
1 and 4
Bucket
Close
T2-2-12
SYSTEM / Hydraulic System
• Travel Operation
When the travel levers are operated, pressure oil
from main pumps 1 and 4 flows into the left travel
motor via the left travel section of the left control
valve while pressure oil from main pumps 2 and 3
flows into the right travel motor via the right travel
section of the right control valve.
Center Joint
Right
Left Travel Travel
Reverse Reverse
From From
Main Pumps Main Pumps
1 and 4 2 and 3
Forward Forward
T2-2-13
SYSTEM / Hydraulic System
• Swing Operation
Pressure oil from swing pump 1 flows into the
swing motors via the left swing control valve while
pressure oil from swing pump 2 flows into the
swing motors via the right swing control valve.
Pressure oil flowing out of the left and right swing
control valves is combined before it is supplied
equally to both swing motors.
Swing Motor
Right Swing
Left Swing
From
Swing Pump 1
From
Swing Pump 2
Left Swing
Right Swing
Swing Motor
Left Swing Control Valve Right Swing Control Valve
T144-02-02-007
T2-2-14
SYSTEM / Hydraulic System
(Blank)
T2-2-15
SYSTEM / Hydraulic System
Combined Operation Circuit
Pilot Circuit
T144-02-02-015
T2-2-16
SYSTEM / Hydraulic System
Main Circuit
Center Joint
To Respective Cylinder
Bucket
Open/Close Right
Left Travel Travel
Arm Bucket Boom
From
Main Pumps From
1 and 4 Main Pumps
From Flow 2 and 3
Combiner
Valve
Shift Valve
T2-2-17
SYSTEM / Hydraulic System
• Bucket Tilt-In/Boom Raise Combined Operation
(Loading Shovel Type)
In bucket tilt-in and boom raise combined opera- Consequently, pressure oil from main pumps 1
tion, the bucket tilt-in pilot pressure shifts the and 4 is supplied to the left control valve to be
bucket priority shift valve. As the bucket priority used only for bucket tilt-in function, while pressure
shift valve is shifted, the boom raise pilot pressure oil from main pumps 2 and 3 is supplied to the
to the left control valve is blocked, shifting the right control valve to be used for both the boom
bucket tilt-in/boom raise spool in the left control raise and bucket tilt-in functions.
valve to the bucket tilt-in side.
Pilot Circuit
Boom Raise
Pilot Pressure
Bucket Tilt-In
Pilot Pressure
T2-2-18
SYSTEM / Hydraulic System
Main Circuit
Boom Raise/
Bucket Tilt-In
Bucket Boom
Bucket
Tilt-In
From From
Main Pumps Main Pumps
1 and 4 2 and 3
Tilt-In Raise
T144-02-02-009
T2-2-19
SYSTEM / Hydraulic System
• Arm Retract/Other Function Combined Operation
(Loading Shovel Type)
In arm retract (single) operation, the arm spool To prevent this from occurring, the pilot pressure
section in the right control valve is not used. shifts the shift valve 3 and arm retract shift valve
(Refer to “Arm Operation” on page T2-2-8.) in arm retract/other function combined operation.
Moreover, because a parallel passage is not pro- As the arm retract shift valve is shifted, the arm re-
vided in the arm section of the left control valve, tract pilot pressure is re-routed to the right control
arm retract and other function (left travel, boom valve from the left control valve.
raise, bucket tilt-in, or bucket close/open) com- Consequently, arm retract/other function com-
bined operation becomes inoperable. bined operation becomes operable.
Pilot Circuit
Shift Valve 3
Arm Retract Pilot Pressure Arm Retract
(To the right control valve) Shift Valve
T2-2-20
SYSTEM / Hydraulic System
Main Circuit
Arm Cylinder
From From
Main Pumps Main Pumps
1 and 4 2 and 3
T144-02-02-010
T2-2-21
SYSTEM / Hydraulic System
Hydraulic Oil Cooling Circuit
Most of the return oil from the left and right control When the hydraulic oil temperature is less than 30 °C
valves returns directly to the hydraulic oil tank. A part (86 °F), the swing Pi pressure control solenoid valve
of this return oil goes through the oil cooler due to is turned ON. In this case, Pi pressure is supplied to
back pressure applied by the bypass check valve. swing pumps 1 and 2 to increase swing pump deliv-
All return oil from the left and right swing control ery rate only when the control lever is operated.
valves goes through the oil cooler before returning to When the hydraulic oil temperature is more than 30
the hydraulic oil tank. In other words, most of the re- °C (86 °F), the swing Pi pressure control solenoid
turn oil from the front and travel functions returns to valve is turned OFF. In this case, Pi pressure is al-
the hydraulic oil tank without being cooled. To in- ways supplied to swing pumps 1 and 2, increasing
crease hydraulic circuit cooling efficiency, delivery swing pump delivery rate as long as the pilot control
rate of swing pumps 1 and 2 are set relatively high so shut-off lever is in the unlock position.
that a large volume of hydraulic oil passes through
the oil cooler.
Pilot Circuit
Pi Pressure
(To Swing Pumps 1 and 2)
T144-02-02-018
T2-2-22
SYSTEM / Hydraulic System
Main Circuit
Pi Pi
T144-02-02-019
T2-2-23
SYSTEM / Hydraulic System
PILOT CIRCUIT
Pressure oil from the pilot pump is supplied as operat- In addition, three accumulators are provided in the pilot
ing pressure to the pilot operating circuit, travel speed circuit to supply pressure oil into the pilot circuit for a
mode shift circuit (Refer to “Travel Device” group, limited period of time in case the engine stalls.
“COMPONENT OPERATION” section), pump control
circuit (Refer to “Pump Device” group, “COMPONENT
OPERATION” section), auto lubrication circuit (Refer to
“Control System” group, “SYSTEM” section), and
swing parking brake release circuit (Refer to “Swing
Device” group, “COMPONENT OPERATION” section).
Travel Speed Mode Pump Control Swing Parking Brake Release Circuit
Shift Valve Circuit
Pilot Pumps
T144-02-02-011
T2-2-24
SYSTEM / Hydraulic System
Pilot Operating Circuit
Accumulators
Bucket Boom/
Open/ Bucket
Close
T2-2-25
SYSTEM / Hydraulic System
Pump Control Circuit
Maximum Flow Rate Reducing Pressure Pic Maximum Flow Rate Reducing Pressure Pic
Main Pump 1: Main Pumps 1, 2, 3, and 4:
Supplied when the arm retract or travel function is Supplied when the travel function is operated.
operated.
Main Pumps 2, 3, and 4: Relief Oil Minimizing Control Override Pressure Pe
Supplied when the travel function is operated. Main Pumps 1, 2, 3, and 4:
Supplied when the travel function is operated.
Relief Oil Minimizing Control Override Pressure Pe
Main Pumps 1, 2, 3, and 4:
Supplied when the travel function is operated.
T2-2-26
SYSTEM / Hydraulic System
T144-02-02-020
T2-2-27
SYSTEM / Hydraulic System
PUMP TRANSMISSION OIL COOLING CIR-
CUIT
Pressure oil from the fuel cooler fan motor drive pump
drives the fuel cooler fan motor.
Because high fuel pressure is used for fuel injection
timing control, the quantity of returning fuel is relatively
large, requiring the returning fuel to be cooled. For this
reason, a fuel cooler is provided on the machine.
Pump Transmission
Fuel Cooler Fan Motors
Oil Cooler
Oil Cooler
T144-02-02-013
T2-2-28
SYSTEM / Electrical System
OUTLINE
• Main Circuit
• Power Supply Circuit
Power source for the whole electrical system.
• Accessory Circuit
Electrical components are activated with the key
switch in the ACC position.
• Starting Aid Circuit
Helps the engine to start using starting aid fluid
(ether) in cold weather.
• Engine Start Circuit
The starter is rotated to start the engine.
• Charging Circuit
Alternator generated electrical current is used to
charge the batteries and to actuate the electrical
components.
• Surge Voltage Prevention Circuit
Protects the electrical components, such as the
controllers, from surge voltage.
• Engine Stop Circuit (with Key Switch)
Stops the engine by turning the key switch to the
OFF position.
• Emergency Engine Stop Circuit
(with Emergency Engine Stop Switch)
Stops the engine with the emergency engine stop
switch.
• Engine Stop Circuit (with Engine Stop Switch)
Stops the engine with the engine stop switch. Also,
prevents the engine from being started with the
key switch.
• Control Circuit
A circuit pertinent to machine control, such as en-
gine and pump flow rate controls. (Refer to the
“Control System” group in this section.)
• Monitor Circuit
Indicates machine conditions. (Refer to the “Control
System” group in this section.)
T2-3-1
SYSTEM / Electrical System
POWER SUPPLY CIRCUIT
T2-3-2
SYSTEM / Electrical System
Fuse Box 2
Fuse Box 1
㈏㈓ 4 3 2 1
B G1 G2 ACC M ST B G1 G2 ACC M ST
H H
OFF OFF
ACC ACC
ON ON
START START
Key Switch (Rear Engine) Key Switch (Front Engine) Load Dump
Relay
To MC (B)
G Battery
T144-02-03-001
T2-3-3
SYSTEM / Electrical System
ACCESSORY CIRCUIT
T2-3-4
SYSTEM / Electrical System
2 3 4
Fuse Box 2
Fuse Box 1
㈏㈓
20 19
B G1 G2 ACC M ST B G1 G2 ACC M ST
H H
OFF OFF
ACC ACC
ON ON
START START
G Battery
T144-02-03-002
T2-3-5
SYSTEM / Electrical System
STARTING AID CIRCUIT
T2-3-6
SYSTEM / Electrical System
(Rear) (Rear)
Fuse Box 1
28 27 25 10 1
B G1 G2 ACC M ST B G1 G2 ACC M ST
H H
OFF OFF
ACC ACC
ON ON
START START
Key Switch (Rear Engine) Key Switch (Front Engine) Load Dump
Relay
To MC (B)
Battery Relay
G Battery
T144-02-03-003
T2-3-7
SYSTEM / Electrical System
ENGINE START CIRCUIT
T2-3-8
SYSTEM / Electrical System
Fuse Box 1
To MC (B)
30 28 26 24 6 5 1
B G1 G2 ACC M ST B G1 G2 ACC M ST
H H
OFF OFF
ACC ACC
ON ON
START START
Key Switch (Rear Engine) Key Switch (Front Engine) Load Dump
Relay
To MC (B)
(Front)
B S (Rear)
G (F) Battery
M
(Rear)
B S
G
M
Starter Starter Relay 2
(R)
T144-02-03-004
T2-3-9
SYSTEM / Electrical System
As the engine starts, the alternator starts generating
electrical current. Alternator generated electrical cur-
rent flows from alternator terminals R and B.
Electrical current from alternator terminal R energizes
starter relay 2. Consequently, starter relay 2 is deacti-
vated, interrupting the starter relay 1 ground line, thus
deenergizing starter relay 1.
For this reason, the starter does not rotate even when
the key switch is turned to the START position while
the engine is running, i.e. while the alternator is gener-
ating electrical current.
T2-3-10
SYSTEM / Electrical System
26 24
B G1 G2 ACC M ST B G1 G2 ACC M ST
H H
OFF OFF
ACC ACC
ON ON
START START
Starter
Relay 1
(Front)
(Front)
R
(Front) (Rear)
G B Battery
Alternator (Rear)
R
G
B
(Rear) Starter Relay 2
T144-02-03-005
T2-3-11
SYSTEM / Electrical System
CHARGING CIRCUIT
T2-3-12
SYSTEM / Electrical System
1 2 3 4 5
Fuse Box 2
Fuse Box 1
40 39 38 37 36 35 34 33 32 31 30 29 28 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
B G1 G2 ACC M ST B G1 G2 ACC M ST
H H
OFF OFF
ACC ACC
ON ON
START START
(Front)
R
(Front)
G B Battery
Alternator (Rear)
R Breaker
G B
(Rear) Starter Relay 2
T144-02-03-006
T2-3-13
SYSTEM / Electrical System
SURGE VOLTAGE PREVENTION CIRCUIT
T2-3-14
SYSTEM / Electrical System
To MC (B)
30
B G1 G2 ACC M ST B G1 G2 ACC M ST
H H
OFF OFF
ACC ACC
ON ON
START START
Key Switch (Rear Engine) Key Switch (Front Engine) Load Dump
Relay
To MC (B)
Battery Relay
R
(Front)
G
B
Battery
Alternator R
G
B
(Rear)
T144-02-03-007
T2-3-15
SYSTEM / Electrical System
ENGINE STOP CIRCUIT (WITH KEY
SWITCH)
T2-3-16
SYSTEM / Electrical System
Emergency Relay
ECM (Front)
ECM (Rear)
(Rear) (Front)
6 5
B G1 G2 ACC M ST B G1 G2 ACC M ST
H H
OFF OFF
ACC ACC
ON ON
START START
Battery
T144-02-03-008
T2-3-17
SYSTEM / Electrical System
EMERGENCY ENGINE STOP CIRCUIT
(WITH EMERGENCY ENGINE STOP
SWITCH)
T2-3-18
SYSTEM / Electrical System
Emergency En-
Emergency Relay gine Stop Switch
ECM (Front)
ECM (Rear)
(Rear) (Front)
6 5
B G1 G2 ACC M ST B G1 G2 ACC M ST
H H
OFF OFF
ACC ACC
ON ON
START START
To MC (B)
Starter Relay 2
Engine Stop Switch
(Front)
(Rear)
T144-02-03-009
T2-3-19
SYSTEM / Electrical System
(Blank)
T2-3-20
SECTION 3
COMPONENT OPERATION
—CONTENTS—
144T-3-1
(Blank)
144T-3-2
COMPONENT OPERATION / Pump Device
OUTLINE
The pump device consists of two transmissions, four The gear type center pump supplies pressure oil to the
main pumps, two swing pumps, gear type center pump air conditioner compressor drive motor.
and gear type triple pump. The gear type triple pump consists of the transmission
The transmissions distribute and transmit engine oil cooling pump, fuel cooler fan motor drive pump, and
power to the pumps in proportion to each pump’s gear the pilot pump, in that order from the end of the trans-
ratio. The gear ratios of the main pumps, swing pumps, mission.
center pump, and triple pump are 1.02, 0.82, 1, and
1.02, respectively.
(Gear Ratio=Pump Speed/Engine Speed)
The main pumps and swing pumps are variable dis-
placement, swash plate type, axial plunger pumps,
supplying high operating pressure into the main circuit.
T144-03-01-001
T3-1-1
COMPONENT OPERATION / Pump Device
MAIN PUMP
W142-02-03-010
T3-1-2
COMPONENT OPERATION / Pump Device
Delivery Rate Increase/Decrease Operation
Servo Piston
Shaft
Valve Plate
Cylinder Block
Plunger
Swash Plate
T142-02-01-001
T3-1-3
COMPONENT OPERATION / Pump Device
REGULATOR
The regulators are provided on the top of the main and • Reduced Horsepower Pump Control
swing pumps, controlling pump flow rate. Two type of (Main pump only)
the regulators are provided: one for the main pumps When the travel or swing function is operated, re-
and the other for the swing pumps. duced horsepower pump control pressure P2
from the reduced horsepower pump control valve
Various Regulator Functions acts on the regulator, decreasing the pump dis-
placement angle.
• Constant Torque Control
Monitoring the pump delivery pressure (P), the • Increased Horsepower Pump Control
regulator controls pump delivery rate to utilize en- (Main pump only)
–1
gine power to the best possible extent. This con- When the engine speed exceeds 1700 min , in-
stant torque control consists of two operations as creased horsepower pump control pressure Pz
follows: from the EHC valve acts on the regulator, increas-
(1) Overload Preventing Operation ing the pump displacement angle.
When the pump delivery pressure (P) in-
creases, the regulator decreases the pump • Relief Oil Minimizing Control (Main pump only)
displacement angle, decreasing pump deliv- When the pump delivery pressure (P) reaches the
ery rate. set relief oil minimizing pressure (a pressure
(2) Delivery Rate Increasing Operation slightly lower than the relief pressure), the pump
When the pump delivery pressure (P) de- displacement angle is decreased to the minimum.
creases, the regulator increases the pump
displacement angle, increasing pump deliv- • Relief Oil Minimizing Control Override Control
ery rate. (Main pump only)
When the travel function is operated, the relief oil
• Flow Rate Control minimizing control override pressure Pe acts on
(1) Main Pump Regulator the regulator to override the relief oil minimizing
When a control lever is operated, the pump control.
flow rate control pressure Pi acts on the regu-
lator via the shuttle valve, changing the pump • Maximum Flow Rate Reducing Control
displacement angle to control flow rate. (Main pump only)
(2) Swing Pump Regulator When the travel or arm retract functions are oper-
The flow rate control pressure Pi from the ated, the maximum flow rate reducing pressure
swing Pi pressure control solenoid valve acts Pic acts on the regulator to reduce the maximum
on the regulator, changing the pump dis- flow rate.
placement angle to control flow rate. (Refer
to “Hydraulic System” group, “SYSTEM” sec- • Preference Mechanism to Lowest Displacement
tion.) Angle (Flow Rate) Command
When a multiple number of pump control com-
mands exist at the same time, the lowest dis-
placement angle (flow rate) command is me-
chanically selected.
T3-1-4
COMPONENT OPERATION / Pump Device
Cross Section
A
C
B
A B C T117-02-01-005
1 2 3 4 5 6 7 8 9 10 11
Pic
Pi
17 16 15 14 13 12
T144-03-01-002
T3-1-5
COMPONENT OPERATION / Pump Device
Cross Section B-B (Horsepower Pump Control Section)
18 19 20 21 22 23 24 25 26
Pz
Pi
27
T144-03-01-003
28 29 30 31 32 33
T Pe
T144-03-01-014
18 - Piston 22 - Hole 26 - Piston 30 - Sleeve
19 - Compensating Piston 23 - Compensating Piston 27 - Pin 31 - Outer Spring
20 - Lever 2 24 - Outer Spring 28 - Piston 32 - Inner Spring
21 - Pin 25 - Inner Spring 29 - Spool 33 - Piston
T3-1-6
COMPONENT OPERATION / Pump Device
Link Mechanism
Movement of pilot piston (10) is transmitted to lever 1 For this reason, when lever 1 (7) or lever 2 (20) ro-
(7) via pin (9). Lever 1 (7) rotates around pin (4), tates, pin (5) comes into contact with the hole edge
which is fixed to the support plug. on the lever, and is moved further. As a result, feed-
Movement of compensating rod (23) is transmitted to back lever (12) rotates around pin (13) located on
lever 2 (20) via pin (27). Lever 2 (20) rotates around servo piston (14). On the other hand, when compen-
pin (21), which is fixed to the casing. sating rod (23) and pilot piston (10) are not moved, i.e.
Pin (5) is threaded through a hole on feedback lever levers 1 (7) and 2 (20) do not move, and when servo
(12), and the ends of pin (5) are inserted in a hole on piston (14) is moved, feedback lever (12) rotates
levers 1 (7) and 2 (20) respectively. (The hole is around pin (5).
larger than the pin (5) diameter.)
6
5
7
8
4
3 9 Support Plug
13
10
14
T117-02-01-009
T3-1-7
COMPONENT OPERATION / Pump Device
Constant Torque Control
T3-1-8
COMPONENT OPERATION / Pump Device
1 2 3 19 5 20 21 22 23 24 25
Pressure
(P1→P2)
14 13 12 27
21
27 T144-03-01-005
Housing 20
22
12
23
14
13
T117-02-01-009
T3-1-9
COMPONENT OPERATION / Pump Device
• Delivery Rate Increasing Operation
T3-1-10
COMPONENT OPERATION / Pump Device
2 3 19 5 20 21 22 23 24 25
Pressure
(P1→P2)
Pressure
(P2→P1)
14 13 12 27
21 T144-03-01-006
27
Housing 20
22
12
23
14
13
T117-02-01-009
2- Sleeve 13 - Pin 21 - Pin 24 - Outer Spring
3- Spool 14 - Servo Piston 22 - Hole 25 - Inner Spring
5- Pin 19 - Compensating Piston 23 - Compensating Rod 27 - Pin
12 - Feedback Lever 20 - Lever 2
T3-1-11
COMPONENT OPERATION / Pump Device
Flow Rate Control
T3-1-12
COMPONENT OPERATION / Pump Device
17 16 15 2 3 4 5 7 8 9 10 11
Pi
14 13 12
T144-03-01-007
Housing
12
3 4
Support Plug
14
13
10
T117-02-01-009
2- Sleeve 7- Lever 1 11 - Spring 15 - Piston
3- Spool 8- Hole 12 - Feedback Lever 16 - Stopper
4- Pin 9- Pin 13 - Pin 17 - Piston
5- Pin 10 - Pilot Piston 14 - Servo Piston
T3-1-13
COMPONENT OPERATION / Pump Device
• Flow Rate Decreasing Operation
T3-1-14
COMPONENT OPERATION / Pump Device
17 15 2 3 4 5 7 8 9 10 11
Pi
14 13 12
T144-03-01-00
12
3 4
Support Plug
14
13
10
T117-02-01-009
T3-1-15
COMPONENT OPERATION / Pump Device
Reduced Horsepower Pump Control
T3-1-16
COMPONENT OPERATION / Pump Device
18 19 2 3 5 20 21 22 23 24 25
P2
14 13 12 27
21 T144-03-01-009
27
Housing 20
22
12
23
14
13
T117-02-01-009
T3-1-17
COMPONENT OPERATION / Pump Device
Increased Horsepower Pump Control
T3-1-18
COMPONENT OPERATION / Pump Device
2 3 19 5 20 21 22 23 24 Pz 25 26
14 13 12 27
21 T144-03-01-010
27
Housing 20
22
12
23
14
13
T117-02-01-009
T3-1-19
COMPONENT OPERATION / Pump Device
Relief Oil Minimizing Control
1. Pump delivery pressure P is acting on piston (28). 3. With the above operation, the pump displacement
When the pump pressure acting on piston (28) angle becomes the minimum pump delivery rate
rises to overcome the combined set force of outer when a function is relieving.
spring (31) and inner spring (32), which is slightly
lower than the system relief pressure, piston (28)
move spool (29) to the right.
28 29 30 31 32
T Pe
14
T142-02-01-010
Q
(Flow Rate)
T3-1-20
COMPONENT OPERATION / Pump Device
Relief Oil Minimizing Control Override Control
1. When the travel levers are operated, relief oil 3. Therefore, the Relief Oil Minimizing Control is
minimizing control override pressure Pe acts on overridden when the travel levers are operated.
piston (33), moving it to compress outer spring
(31) and inner spring (32), thus increasing the
spring set force.
28 29 30 31 32 33
T Pe
15
T142-02-01-011
Q
(Flow Rate)
14 - Servo Piston 31 - Outer Spring
28 - Piston 32 - Inner Spring
29 - Spool 33 - Piston
30 - Sleeve
T3-1-21
COMPONENT OPERATION / Pump Device
Maximum Flow Rate Reducing Control
1. When the travel or arm retract functions are 2. Since the rightward movable range of piston (15)
operated, maximum flow rate reducing pressure is decided by the position of stopper (16), the
Pit acts on stopper (16), moving stopper (16) to maximum flow rate in the flow rate control (T3-1-
the left until it comes into contact with stopper (17). 12) is reduced by the above operation, as
Moreover, as the left end staged part of stopper illustrated below.
(16) comes into contact with the neck part of
piston (15), piston (15) also moves to the left.
Pic
17 16 15
T144-03-01-011
Q
(Flow Rate)
15 - Piston 17 - Stopper
16 - Stopper
Pic
(Maximum Flow Rate Reducing Pressure)
T3-1-22
COMPONENT OPERATION / Pump Device
Preference Mechanism to Lower Displacement
Angle (Flow Rate) Command
T3-1-23
COMPONENT OPERATION / Pump Device
GEAR TYPE CENTER PUMP
Driven Gear
T137-02-03-005
T3-1-24
COMPONENT OPERATION / Pump Device
GEAR TYPE TRIPLE PUMP
The triple pump consists of pilot pump (A), fuel cooler In each pump, the drive gear rotates the driven gear as
fan motor drive pump (B) and transmission oil cooling the shaft rotates, drawing hydraulic oil. Hydraulic oil
pump (C). drawn from the inlet port into the pump is trapped
The engine power is transmitted to the shaft via the between the gear teeth and the pump housing wall,
transmission. Since three pumps are connected via and it is delivered to the outlet port as the gears rotate.
couplings, they operate simultaneously.
A B C
T144-03-01-013
A - Pilot Pump B - Fuel Cooler Fan Motor Drive Pump C - Transmission Oil Cooling Pump
T137-02-03-005
T3-1-25
COMPONENT OPERATION / Pump Device
(Blank)
T3-1-26
COMPONENT OPERATION / Swing Device
OUTLINE
The swing device consists of the valve unit, the motor, The reduction gear functions to reduce the speed of
and the reduction gear. the rotational force and to increase its torque before
The motor is driven by pressure oil from the pump and transmitting the rotational force to the pinion shaft.
transmits rotational force to the reduction gear. The valve unit functions to protect the swing circuit.
㈩ 144-03-02-001
T3-2-1
COMPONENT OPERATION / Swing Device
SWING MOTOR
The swing motor is a swash-plate-type axial plunger The spherical end of plunger (5) is installed in shoe (2)
motor. by a ball-and-socket joint. The shaft part of plunger (5)
The swing motor consists of shaft (4), swash plate (3), is inserted into rotor (6). Rotor (6) is installed onto shaft
shoes (2), plungers (5), rotor (6), valve plate (7), and (4) with a spline coupling.
housing (1). The parking brake is a wet-type multiple disc brake,
consisting of friction plates (8) and plates (9).
7 1
2
5
W117-02-04-005
T3-2-2
COMPONENT OPERATION / Swing Device
Principles of Motor Operation
Swing speed varies depending on the amount of oil The rotational force is then transmitted to the swing
delivered from the pump. reduction gear via the shaft. As the rotor is rotated,
When pressure oil is fed into the rotor bores via port the plungers are moved to port (B) side one by one,
(A), the plungers are pushed from the top dead returning oil to the hydraulic oil tank. When pressure
center to the bottom dead center causing the shoes oil is fed via port (B), the motor rotates in the opposite
to slide along the swash plate, developing rotational direction.
force.
Plunger
Shoe
T115-02-03-003
Shaft
T3-2-3
COMPONENT OPERATION / Swing Device
VALVE UNIT
Relief Valve
When starting or stopping swing operation, oil
pressure in the swing circuit becomes high. The relief
valve prevents the circuit pressure from rising higher
than the specified pressure.
If the pressure at port AV (BV) side rises higher than
the relief valve set pressure, the pressure at port AV
(BV) is routed to piston chamber (9) via orifice (3) in
main poppet (4), acting against pilot piston (7). As the
pressure overcomes spring (8) force, pilot poppet (7)
is moved to the right, reducing the pressure in piston
chamber (9). As a result, a pressure difference arises
between in front of and behind main poppet (4). As
the pressure difference increases, it overcomes
spring (5) force, opening main poppet (4) to route oil
from port AV (BV) to the hydraulic oil tank side.
As pilot piston (7) is moved to the stroke end, the
differential pressure between in front of and behind
orifice (3) in main poppet (4) disappears, closing main
poppet (4).
Make-Up Valve
When the swing lever is moved toward the neutral
position during swing operation, the control valve
spool moves to close the line to the swing motor,
decreasing oil supply to the swing oil supply line.
However, the swing motor continues to rotate
because of the inertia force of the upperstructure,
causing cavitation in the swing motor. To prevent this
from occurring, the make-up valve functions to draw
hydraulic oil from port M (return line) to compensate
for insufficient oil in the oil supply line.
If pressure at the port AV (BV) becomes lower than
that in the make-up circuit, poppet (10) opens to
supply oil to port AV (BV).
T3-2-4
COMPONENT OPERATION / Swing Device
Valve Unit
Port M Make-Up Circuit
Port M
T144-03-02-003
T117-02-02-003
Port AV (BV) To Hydraulic Oil Tank
Relief Valve 3 4 5 6 7
8
Port AV (BV)
T117-02-02-004
To Hydraulic Oil Tank 9
10 11
Make-UP Valve
Make-Up Circuit
T117-02-02-005
Port AV (BV)
T3-2-5
COMPONENT OPERATION / Swing Device
SWING PARKING BRAKE
The swing parking brake consists of coupling (4), When the pilot control shut-off lever is in the UN-LOCK
friction plates (5), plates (6), piston (2), and springs (1). position, the brake release pressure is routed into the
Coupling (4) is spline-connected to shaft (3). piston chamber, pushing piston (2) against springs (1).
Plates (6) are spline-connected to coupling (4). And, For this reason, friction plates (5) and plates (6) are
friction plates are spline-connected to casing (7). disengaged from each other so that shaft (3) can
When the pilot control shut-off lever is in the LOCK rotate.
position, as the brake release pressure does not exert
on the piston chamber, springs (1) push piston (2) to
lock friction plates (5) and plates (6) together so as to
lock shaft (3) rotation.
1 2 3 4
Piston Chamber
6 Brake Release
Pressure
5 (From the Pilot
Shut-Off Valve)
㈩ 144-03-02-002
T3-2-6
COMPONENT OPERATION / Swing Device
SWING REDUCTION GEAR
The swing reduction gear is of a two-stage planetary As the second speed reduction takes place between
gear type. second stage planetary gears (2) and second stage
Rotational force of the motor shaft is transmitted to first carriers (4), the rotational force of second stage sun
stage sun gear (7). gear (5) is then transmitted to output shaft (3).
The first speed reduction takes place between first
stage planetary gears (1) and first stage carriers (6),
turning second stage sun gear (5).
6
2
W114-02-06-022
1 - First Stage Planetary Gear 3 - Shaft 5 - Second Stage Sun Gear 7 - First Stage Sun Gear
2 - Second Stage Planetary 4 - Second Stage Carrier 6 - First Stage Carrier
Gear
T3-2-7
COMPONENT OPERATION / Swing Device
(Blank)
T3-2-8
COMPONENT OPERATION / Control Valve
OUTLINE
The control valve controls oil pressure, flow rate, and Main components of the control valves are main relief
flow direction in the hydraulic circuit. The machine is valves, overload relief valves, flow combiner valve,
equipped with two main control valves and two swing load check valves, make-up valve, and spools. The
control valves. spools are operated by hydraulic pilot pressure.
Overload Relief
Valve
Flow Combiner
Valve
Main Relief Valve
T144-03-03-004
T3-3-1
COMPONENT OPERATION / Control Valve
HYDRAULIC OIL CIRCUIT
T3-3-2
COMPONENT OPERATION / Control Valve
NOTE: The diagram shown below is of the loading
shovel type excavator.
Main Relief
Port P Valve
Port P
Parallel
Passage
Parallel
Passage
Main Relief
Valve Left Main Control Valve Right Main Control Valve
Front Engine
Swing Pump 2
Main Pump 4
Main Pump 3
Rear Engine
Swing Pump 1
Main Pump 2
Main Pump 1
T144-03-03-002
T3-3-3
COMPONENT OPERATION / Control Valve
FLOW COMBINER VALVE
Left Right
Travel Arm Bucket Boom Travel
Flow
Combiner
Valve
T3-3-4
COMPONENT OPERATION / Control Valve
MAIN RELIEF VALVE OVERLOAD RELIEF VALVE
The main relief valve protects the main circuit from The overload relief valve protects each actuator circuit
excessive pressure. from excessive pressure.
The pressure at port P acts on pilot poppet (7) via Principles of valve operation is the same as those of
orifice (2) of main poppet (1) and orifice (6) of sleeve the main relief valve.
(5). If the pressure at port P exceeds the specified
pressure (the pressure set by spring (8)), pilot poppet
(7) opens to route a small amount of oil from port P to
port T via the circumference of sleeve (9), decreasing
pressure at spring chamber (4).
Consequently, a pressure difference arises between
port P and spring chamber (4) due to orifice (2).
When this pressure difference, which acts as a
pushing force against main poppet (1), increases,
overcoming spring (3), main poppet (1) opens, routing
pressure oil at port P directly to port T.
As the pressure at port P decreases, main poppet (1)
is seated on port P by spring (3).
1 2 3 4 5 6 7 8
Port T T145-02-03-001
MAKE-UP VALVE
The make-up valve functions to supply oil from port T if If the actuator port pressure drops below the pressure
the pressure at the actuator circuit decreases lower at port T, poppet (10) opens to route oil at port T into
than pressure in the hydraulic tank. the actuator circuit via the actuator port.
The actuator port pressure acts on poppet (10). As As the pressure at the actuator port increases, poppet
long as the actuator port pressure is larger than (10) is closed by the combined force of spring (12) and
pressure at port T, poppet (10) is seated on sleeve (11) the pressure acting on poppet (10) (the actuator port
and oil in the actuator circuit does not flow into the port pressure).
T side.
10 11 12
10 - Poppet
Actuator Port 11 - Sleeve
12 - Spring
T145-02-03-002
Port T
T3-3-5
COMPONENT OPERATION / Control Valve
(Blank)
T3-3-6
COMPONENT OPERATION / Pilot Valve
OUTLINE
The pilot valve functions to control pilot pressure oil, The machine is equipped with the front/swing pilot
causing the control valve spools to move. When a valve, travel pilot valve, and bucket open/close pilot
control valve is operated, the pilot valve routes a pilot valve (the loading shovel only). Construction and
pressure, in proportion to the lever stroke, to the operation of all pilot valves are approximately the same
control valve to move the respective control valve as each other.
spool.
Travel Pilot Valve, Bucket Open/Close Pilot Valve
15 16 17 18 22 23 24
1 2 3 8 9 10
F F
21 20 19 26 25
R L R L T115-02-05-002
7 14
4 11
R R
6 5 13 12
T117-02-04-001
1 - Left Pilot Valve 8 - Right Pilot Valve 15 - Travel Pilot Valve 22 - Bucket Open/Close Pilot
Valve
2- Tank Port 9- Port P 16 - Left Travel Forward 23 - Bucket Open Port
3- Right Swing Port 10 - Boom Lower Port 17 - Port P 24 - Port P
4- Arm Roll-In Port 11 - Bucket Roll-In Port 18 - Left Travel Reverse 25 - Tank Port
5- Port P 12 - Tank Port 19 - Right Travel Reverse 26 - Bucket Close Port
6- Left Swing Port 13 - Boom Raise Port 20 - Tank Port
7- Arm Roll-Out Port 14 - Bucket Roll-Out Port 21 - Right Travel Forward
T3-4-1
COMPONENT OPERATION / Pilot Valve
CONSTRUCTION
Spool (7) is held upward by return spring (6) via spring With spool (7) in this position, the output port is
guide (4). Spring guide (4) cannot be lifted further as it connected to port T via a notch on spool (7).
is held by the lower neck of collar (3) that is making
contact with bushing (2) which is immovable.
Front/Swing Pilot Valve Travel Pilot Valve, Bucket Open/Close Pilot Valve
1
1 2
4
3
5 Port T
2 6
7
3
Port P
4
Port T 8
5
Output Port
T115-02-05-004
7
Notched Part
Port P
Output Port
T115-02-05-003
T3-4-2
COMPONENT OPERATION / Pilot Valve
FUNCTION
When a control lever is operated, oil pressure, in The return oil from the opposite-side of the spool
proportion to the lever stroke, is output to the control returns to the hydraulic oil tank via the other port of the
valve via the output port and a hydraulic pilot line, pilot valve.
moving the respective control valve spool to a position
where the combined force of the spring and the output
pressure balances against the opposite-side spring.
Pilot Valve
Actuator
Control Valve
Opposite-Side Spring
Spool
From Main Pump To Hydraulic Oil Tank
Output Port
Hydraulic Pilot Lines
T115-02-05-005
T3-4-3
COMPONENT OPERATION / Pilot Valve
OPERATION
In neutral
(Pusher stroke: A to B in the output diagram)
When the control lever is in the neutral position, spool
(7) completely blocks pressure oil from port P. Since
the output port is open to port T, pressure at the
output port equals that of the hydraulic oil tank.
When the control lever is slightly moved, pusher (1),
collar (3), and spring guide (4) move downward as a
unit against return spring (6) and balance spring (5).
As the neck of spool (7) is pulled downward and held
against spring guide (4) by balance spring (5), spool
(7) is also moved downward together with the above-
mentioned unit until clearance “a” of the spool notch
becomes zero.
Output Port
Operation Corresponding to the control lever Pressure E F
stroke (Pilot Pressure)
(Pusher stroke: C to D in the output diagram)
D
As the control lever is moved further, the lower notch
on spool (7) reaches port P, routing pressure oil from
port P to the output port, thus increasing pressure at
the output port. A part of the pressure oil at the output
port is routed inside spool (7) via a passage on spool
C
(7), acting against spool (7) from the inside, pushing it
upward, and also acting against piston (8). As long as
the force of balance spring (5) is larger than this
upward pressure, the output port pressure rises A B Pusher Stroke
continuously.
When the output port pressure overcomes balance Output Diagram
spring (5) force, spool (7) is moved upward,
compressing balance spring (5). As a result, the
lower notch is closed to block pressure oil from port P
to the output port, stopping pressure rise at the output
port.
If the control lever is further moved, spool (7) is
pushed downward again, opening the notch and in-
creasing the output port pressure. At this time,
balance spring (5) is compressed for the amount
equivalent to the movement of spool (7). For this
reason, the output pressure rises further until the
output pressure (pressure force to push spool (7)
upward) balances against balance spring (5) force.
T3-4-4
COMPONENT OPERATION / Pilot Valve
Pusher Stroke : A to B
1
2
3
4
Port T
5
6
7
a
a
Port P
T115-02-05-006
Output Port Output Port T115-02-05-007
5
3
7
7
Passage
Port P
Port P
T3-4-5
COMPONENT OPERATION / Pilot Valve
(Blank)
T3-4-6
COMPONENT OPERATION / Travel Device
OUTLINE
Front
Brake Valve
Travel Line
Travel Speed
Change Line
Drain Line
Travel Motor
T117-03-01-001
Rear
Travel Reduction Gear
Travel Reduction Gear
T3-5-1
COMPONENT OPERATION / Travel Device
TRAVEL MOTOR
Shaft
T115-03-02-002
Shoe Housing
T3-5-2
COMPONENT OPERATION / Travel Device
Operation Principles
Shaft
T117-03-01-003
Shoe Plunger
T3-5-3
COMPONENT OPERATION / Travel Device
TRAVEL SPEED CHANGE
Slow Speed
Reducing Valve
Travel Speed
Change
Solenoid
Travel Speed Valve
Switch
Center Joint
Pilot Pump
Travel Speed
Change Valve
Travel Speed
Change Valve
Tilt Piston
Tilt Piston
Parking Brake
Parking Brake
Left Travel Motor Right Travel Motor
T144-03-05-003
T3-5-4
COMPONENT OPERATION / Travel Device
Fast Speed
Reducing Valve
Travel Speed
Change Solenoid
Valve
Travel Speed
Switch
Center Joint
Pilot Pump
Travel Speed
Change Valve
Travel Speed
Change Valve
Tilt Piston
Tilt Piston
Parking Brake
Parking Brake
Left Travel Motor Right Travel Motor
T144-03-05-004
T3-5-5
COMPONENT OPERATION / Travel Device
BRAKE VALVE
The brake valve consists of counterbalance valve (10) Therefore, oil pressure in port AV and chamber (1)
and relief valve (11). decreases so that spool (5) returns to the left, block-
ing the return oil flow from port BM and braking motor
Traveling Flat or Up rotation. Once the return oil from port BM is blocked,
When the pressure oil from the control valve is routed the oil pressure in port AV again increases.
to port AV, the pressure oil further flows into port AM Thereby, spool (5) is moved to the right. The
after passing around spool (5) and opening check repetition of this blocking and easing of the return oil
valve (4). On the other hand, the return oil from port flow, which is called hydraulic braking, prevents the
BM is blocked by check valve (6) and spool (5) so that machine from running away while traveling down
the return oil cannot flow into port BV. Accordingly, slopes.
pressure at port AV increases gradually and is routed
into chamber (1) through orifice (3), causing spool (5) Circuit Protection
to move to the right. As a result, the return oil from If the circuit pressure exceeds the specified set
port BM can flow to port BV via a notch on spool (5), pressure, relief valves (11) open to relieve excessive
allowing the motor to rotate. high pressure to the low pressure side, protecting the
motor from overload. Also, relief valves (11) buffers
Traveling Down Slope shock pressure which occurrs due to the machine
While traveling down slope, the travel motor is forcibly inertial force when stopping. Moreover, check valve
driven by the machine weight, causing the motor to (4) or (6) opens (a make-up operation) to prevent
draw oil in port AM. cavitation from occurring in the motor circuit when the
motor begins to draw oil.
1 2 3 4 5 6 7 8 9
AV BV
10
AM BM
11
11
T144-03-05-002
T3-5-6
COMPONENT OPERATION / Travel Device
PARKING BRAKE
The parking brake consists of coupling (3), friction With the pilot control shut-off lever placed in the unlock
plate (1), plate (2), piston (4), and spring (5). Coupling position, the pilot pressure is routed to port (PB),
(3) is connected to the shaft with a spline coupling and pushing piston (4) against spring (5). Thus, friction
each plate (2) is connected to coupling (3) with a spline plates (1) and plates (2) are freed, allowing the shaft to
coupling. Each friction plate (1) is connected to casing rotate.
(6) with a spline coupling and installed between the
center plates. With the pilot control shut-off lever NOTE: The parking brake can be manually
placed in the lock position, the pilot pressure is not released in an emergency. .
routed to port (PB). For this reason, friction plates (1)
and plates (2) are pushed together by spring (5) via
piston (4), holding the shaft immovable.
1 2
4
Shaft
PB
T115-03-02-008
Pilot Pressure 6 5
T3-5-7
COMPONENT OPERATION / Travel Device
TRAVEL REDUCTION GEAR
The reduction gear consists of one stage spur gear The first stage sun gear rotation is transferred to the
and two stage planetary gear combination. The total second stage sun gear after the second stage
reduction gear ratio is 106.6 : 1. The travel motor shaft reduction takes place between the first stage planetary
rotates the spur gear via the pinion gear where the first gear and the first stage carrier. The second stage sun
speed reduction takes place. The spur gear rotation gear rotation drives the sprocket after the third stage
drives the first stage sun gear via the shaft. reduction takes place between the second stage
planetary gear and the second stage carrier.
Travel Motor
Spur Gear
T144-03-05-001
T3-5-8
COMPONENT OPERATION / Others (Upperstructure)
PILOT SHUT-OFF VALVE To Pilot Valve
From Pilot
Valve
From Pilot
Pump
T162-03-06-001
T162-03-06-002
From Pilot
T162-03-06-003
Pump
T3-6-1
COMPONENT OPERATION / Others (Upperstructure)
AIR-CONDITIONER
The air-conditioner system consists of a compressor Compressor drive motor (4) is driven by pressure oil
drive pump (mounted on the engine), compressor from the compressor drive pump when the engine is
drive motor (4), air-conditioner units (11, 12, and 13), running. When the air-conditioner is turned ON, the
condensers (8, 9, and 10), and receiver-dryers (5, 6, compressor clutch is engaged, activating the
and 7). compressor. When the heater system is activated, the
compressor clutch is disengaged, deactivating the
compressor.
1
2
3
13
12
11
10
7
6
5
4
T144-03-06-001
T3-6-2
COMPONENT OPERATION / Others (Upperstructure)
Cooling Operation
The cooling circuit consists of compressor (10), con- • Receiver-Dryer:
denser (1), receiver-dryer (9), expansion valve (3), Removes moisture from the refrigerant, then
evaporator (5), thermistor (6), thermo sensor tube (4), stores the refrigerant.
and blower fan (2). The system is charged with • Expansion Valve:
refrigerant. As the high-pressurized refrigerant (liquid) goes
Air via the fresh air inlet port or the circulation air port through a restriction in the expansion valve, the
is sent to the evaporator by blower fan (2). As refrigerant is atomized, becoming low-pressurized
evaporator (5) is cold, air cooled through the refrigerant.
evaporator is sent into the cab via the vents. • Thermo Sensor Tube:
Function of each component is as follows: Senses air temperature blowing through the
evaporator, and depending on the temperature
• Compressor: sensed, adjusts the restriction in the expansion
Suctions and compresses refrigerant from the low valve to adjust the refrigerant flow.
pressure line (the line between the evaporator and • Thermistor:
compressor), then sends it to the condenser. Deactivates the compressor when the
(Refrigerant generates heat when compressed.) temperature on the evaporator fin falls to 0 °C.
• Condenser: • Blower Fan:
Cools the heated refrigerant. Blows air through evaporator.
1 2 3 4 5 6
Fresh Air Inlet Port Vent
Air
Conditioner
T117-02-05-002
1 - Condenser 4 - Thermo Sensor Tube 7 - Heater 9 - Receiver-Dryer
2 - Blower Fan 5 - Evaporator 8 - Valve 10 - Compressor
3 - Expansion Valve 6 - Thermistor
T3-6-3
COMPONENT OPERATION / Others (Upperstructure)
AUTO-LUBRICATION SYSTEM
The auto-lubrication system automatically lubricates This system can be switched, into one of three modes
the front attachment joint pins, swing bearing, and using the auto-lubrication mode selection switch: auto-
center joint. The major components in this system are lubrication, off, and manual-lubrication.
the grease pump, the auto-lubrication solenoid valve 1, When the auto-lubrication mode is selected, greasing
the auto-lubrication solenoid valve 2, the pressure is automatically performed at the interval set by the
reducing valve, the vent valve, MC (A), the auto- auto-lubrication interval switch. When the switch is off,
lubrication interval switch, the auto-lubrication mode no lubrication is done. When the manual-lubrication
selection switch, and the grease pressure switch. mode is selected, auto-lubrication is not performed so
that greasing can be done using a grease gun.
Grease Pump
Vent Valve
T117-02-05-003
T3-6-4
COMPONENT OPERATION / Others (Upperstructure)
SOLENOID VALVE
The solenoid valves provided on this machine are the Travel Speed Change
travel speed change solenoid valve with the pressure Solenoid Valve
reducing valve, the swing stop solenoid valve, the
swing Pi pressure control solenoid valve, and the EHC
valve.
T144-05-02-007
T144-03-06-002
T144-03-06-003
• EHC Valve
This valve delivers oil pressure in proportion to the EHC Valve
electrical signals from the main controller (MC) to
the pump regulator.
T144-04-04-002
T3-6-5
COMPONENT OPERATION / Others (Upperstructure)
FUEL COOLER FAN MOTOR
Drive Disc
Rotor
T142-06-04-021
T3-6-6
COMPONENT OPERATION / Others (Upperstructure)
ACCUMULATOR
A
T105-02-10-003
1 - Poppet 4 - Holder
2 - Bladder 5 - Body
3 - Oil Port 6 - Gas Plug
T3-6-7
COMPONENT OPERATION / Others (Upperstructure)
(Blank)
T3-6-8
COMPONENT OPERATION / Others (Undercarriage)
SWING BEARING
Support Seal
Outer Race
Ball
Inner Race
T144-03-07-001
Support Seal
T3-7-1
COMPONENT OPERATION / Others (Undercarriage)
ADJUSTER CYLINDER
The adjuster cylinder comprises two single-acting In addition, the travel stop pilot valve is installed on the
cylinders, the rear cylinder is a cushion cylinder as a stroke end of the cushion cylinder. If the track tension
buffer and the front one is a track sag adjusting exceeds the specified limit and the cushion cylinder
cylinder. reaches the stroke end, the travel stop pilot valve is
The pressure from the right forward travel circuit is activated, causing the travel function to stop. (Refer to
routed to the cushion cylinder after reducing its the Hydraulic Circuit in the System Section.)
pressure at a reducing valve. When an external load is The adjuster cylinder adjusts the track sag depending
applied on the front idler, the cushion cylinder is moved on the grease amount supplied in the cylinder
back, causing the hydraulic oil in the cylinder chamber chamber.
to flow into the accumulator. As a result, the bladder in
the accumulator is contracted to absorb an impact
load.
Cushion Cylinder
Adjuster Cylinder
Hydraulic Oil
Signal Pressure
to Pilot Pressure
Switch Valve
Front Idler
Yoke
Rear Side
Front Side
Grease
T144-03-07-002
T3-7-2
COMPONENT OPERATION / Others (Undercarriage)
ACCUMULATOR
Oil Port
Assembly Shell Bladder Gas Valve
T115-03-03-003
T3-7-3
COMPONENT OPERATION / Others (Undercarriage)
CENTER JOINT
The center joint is a 360 ° rotating joint. It allows oil to Oil flows into travel motors via oil passages in spindle
flow to and from the travel motors without twisting (1) and body (2). Seals (3) are installed between
hoses when the upperstructure is rotated. spindle (1) and body (2), preventing oil leaks from oil
Spindle (1) is fastened to the upperstructure. Body (2) ports.
is fastened to the swing center of the undercarriage.
T145-03-02-001
T3-7-4
SECTION 4
OPERATIONAL
PERFORMANCE TEST
CONTENTS
144T-4-1
(Blank)
144T-4-2
OPERATIONAL PERFORMANCE TEST / Introduction
OPERATIONAL PERFORMANCE TESTS
1. To comprehensively evaluate each operational 1. To evaluate not only that the test data are correct,
function by comparing the performance test data but also in what range the test data are.
with the standard values.
2. Be sure to evaluate the test data based on the
2. According to the evaluation results, repair, adjust, machine operation hours, kinds and state of work
or replace parts or components as necessary to loads, and machine maintenance conditions.
restore the machine’s performance to the desired
standard. The machine performance does not always
deteriorate as the working hours increase. However,
3. To economically operate the machine under the machine performance is normally considered to
optimal conditions. reduce in proportion to the increase of the operation
hours.
Kinds of Tests Accordingly, restoring the machine performance by
repair, adjustment, or replacement shall consider the
1. Base machine performance test is to check the number of the machine’s working hours.
operational performance of each system such as
engine, travel, swing, and hydraulic cylinders. Definition of “Performance Standards”
2. Hydraulic component unit test is to check the 1. Operation speed values and dimensions of the
operational performance of each component such new machine.
as hydraulic pump, motor, and various kinds of
valves. 2. Operational performance of new components
adjusted to specification. Allowable errors will be
Performance Standards indicated as necessary.
T4-1-1
OPERATIONAL PERFORMANCE TEST / Introduction
PREPARATION FOR PERFORMANCE
TESTS
1. THE MACHINE
Repair any defects and damage found, such as oil
or water leaks, loose bolts, cracks and so on,
before starting to test.
2. TEST AREA
(1) Select a hard, flat surface.
(2) Secure enough space to allow the
machine to run straight more than 20 m
(65 ft 7 inch), and to make a full swing
with the front attachment extended.
(3) If required, rope off the test area and
provide signboards to keep unauthorized
personnel away.
3. PRECAUTIONS T105-06-01-003
T4-1-2
OPERATIONAL PERFORMANCE TEST / Engine Test
ENGINE SPEED
Preparation:
Measurement:
Evaluation:
T4-2-1
OPERATIONAL PERFORMANCE TEST / Engine Test
(Blank)
T4-2-2
OPERATIONAL PERFORMANCE TEST / Excavator Test
TRAVEL SPEED
Summary:
1. Check the overall operational performance of the
travel power system (between the hydraulic
pumps and travel motors) by measuring time re-
quired for the machine to travel the specified dis-
tance.
Preparation:
1. Equally adjust the track sag on both right and left Track Sag
undercarriages. 570 to 640 mm
2. Prepare a flat and firm travel test yard 20 m (65.5 (22 to 25 in)
ft) long with fringes 7 to 9 m (22.8 to 29.4 ft) on
both ends for machine acceleration and decelera- T145-05-03-001
tion.
3. Empty the bucket and roll in the arm.
4. Maintain the hydraulic oil temperature at 50±5 °C
(122±9 °F).
Measurement:
1. Measure travel time at both fast and slow travel
speeds.
2. Engine Speed Control Lever : Fast Idle Position
3. Start machine to travel from the rear end of the
acceleration zone by moving the travel levers full
stroke.
4. Measure the time required to travel the travel test
distance 20 m (65.5 ft).
5. After measuring the forward travel time, rotate the
machine upperstructure 180 °. Then, measure the
reverse travel time on the way back to the starting
position in the same method.
6. Repeat steps (4) and (5) three times and calculate
the average values.
Evaluation:
Refer to T4-5 Operational Performance Standard.
Remedy:
Refer to the T5-4 Troubleshooting B.
T4-3-1
OPERATIONAL PERFORMANCE TEST / Excavator Test
TRACK REVOLUTION SPEED
Summary:
1. Check the overall operational performance of the
travel power system (between the hydraulic
pumps and travel motors) by measuring the track
revolution cycle time.
Preparation:
1. Equally adjust the track sag on both right and left
undercarriages.
Track sag : 570 to 640 mm (22 to 25 in)
2. Mark one shoe with chalk or a piece of cloth on 90 to 110 °
the track to be measured.
3. Rotate the upperstructure 90° to the track and
lower the bucket to raise the track to be measured
off the ground. Keep the boom and arm angle be- T142-05-03-011
Measurement:
1. Measure the track rotation time at both fast and
slow travel speeds.
2. Engine Speed Control Lever : Fast Idle Position
3. Operate the travel control lever of the raised track
in full forward and reverse.
4. After the track revolution attains to constant speed,
measure the time required for the marked shoe to
rotate three times in both directions.
5. Raise the other side of the track and repeat the Forward
procedure.
6. Repeat steps (3) and (4) three times and calculate Reverse
the average values.
T145-05-03-001
Evaluation:
Refer to T4-5 Operational Performance Standard. Travel Device
Remedy:
Refer to T5-4 Troubleshooting B.
T4-3-2
OPERATIONAL PERFORMANCE TEST / Excavator Test
MISTRACK
Summary:
1. Check the equilibrium in operational performance
between the right and left travel power systems
(between the hydraulic pumps and travel motors)
by measuring the amount of mistrack found while
the machine travels for the specified distance.
Preparation:
1. Equally adjust the track sag on both right and left
undercarriages.
Track sag : 570 to 640 mm (22Ȁto 25 in) T145-05-03-005
2. Prepare a flat and firm travel test yard 20 m (65.5
ft) long with fringes 7 to 9 m (22.8 to 29.4 ft) on
both ends for machine acceleration and decelera-
tion.
3. Set the front attachment in the driving position.
4. Maintain the hydraulic oil temperature at 50±5 °C
(122±9 °F).
Measurement:
T145-05-03-006
1. Measure the amount of mistracking in both fast
and slow travel speeds.
2. Engine Speed Control Lever : Fast Idle Position Deceleration Zone
3. Start machine to travel from the rear end of the 7 to 9 m
acceleration zone by moving both travel levers full
stroke.
4. Draw a 20 m (65.5 ft) straight line along the rut
from the travel start point to the travel end point as Maximum Distance (A)
illustrated. Measure the maximum distance (A)
20 m
between the rut and the straight line.
5. Conduct the measurement in both forward and
reverse travel operation in the same method.
6. Repeat steps (4) and (5) three times and calculate
the average values. Acceleration Zone
7 to 9 m
Evaluation:
T115-07-03-005
Refer to T4-5 Operational Performance Standard.
Remedy:
Refer to T5-4 Troubleshooting B.
T4-3-3
OPERATIONAL PERFORMANCE TEST / Excavator Test
TRAVEL PARKING FUNCTION CHECK
Summary:
To measure the parking brake function on a specified
slope.
Preparation:
1. The surface of the test slope shall be even with a
gradient of 20 % (11.3 °).
2. Mark a white line on the travel device cover.
3. Hold the bucket 0.5 to 1.0 m (20 to 40 in) above
the ground with the arm and bucket fully rolled in.
4. Maintain the hydraulic oil temperature at 50±5 °C
(122±9 °F). 0.5 to 1.0 m
Measurement:
1. Measure in the fast travel mode.
2. Engine Speed Control Lever : Fast Idle Position
3. Measure the displacement (revolution angle) of T142-05-03-002
the travel device cover until the parking brake is
applied.
3-1. Climb the slope and place the travel levers in
Position where the machine
neutral. comes to a stop.
3-2. Pull the pilot control shut-off lever to the LOCK Position when the travel
position. levers are in neutral.
3-3. Measure the displacement from the mark posi- Displacement
(Revolution Angle)
tion on the travel device cover when the pilot
control shut-off lever to the LOCK position Mark
when the machine stops moving.
4. Measure the travel parking brake slip amount
while parked.
4-1. Climb the slope and place the travel levers in
neutral. T107-06-03-002
4-2. Pull the pilot control shut-off lever to the LOCK
position.
4-3. Stop the engine.
4-4. After the machine stops, put alignment marks
on a track link or shoe, and the track side
frame.
4-5. After 5 minutes, measure the distance between
the marks on the track link or shoe and the Alignment marks on the track side
track side frame. frame and shoe when the machine
comes to a stop.
Displacement measured after 5
Evaluation: minutes.
Refer to T4-5 Operational Performance Standard. T105-06-03-006
T4-3-4
OPERATIONAL PERFORMANCE TEST / Excavator Test
SWING SPEED
Summary:
1. Check the overall operational performance of the
swing power system (between the hydraulic
pumps and swing motors) by measuring time re-
quired for the machine upperstructure to make
three complete turns.
Preparation:
1. Confirm that the swing gears and bearing are suf-
ficiently greased.
2. Secure a space wide enough for the machine up-
perstructure to swing on a flat and firm surface.
Never attempt to perform this test on a slope.
3. Empty the bucket and roll out (extend) the arm. T145-05-03-007
4. Maintain the hydraulic oil temperature at 50±5 °C
(122±9 °F).
CAUTION: Prevent personal injury. Always
make sure that the area is clear and that co-
workers are out of the swing area before
starting the measurement.
T145-05-03-008
Measurement:
1. Engine Speed Control Lever : Fast Idle Position
2. Operate the swing control lever at full stroke.
3. After the swing attains to constant speed, meas- 3 Revolutions
ure the time required for the upperstructure to ro-
tate three times.
4. Measure in both directions (clockwise and coun-
terclockwise).
5. Repeat steps (3) and (4) three times and calculate
the average values.
Evaluation
Refer to T4-5 Operational Performance Standard.
Remedy:
Refer to T5-4 Troubleshooting B.
T145-05-03-009
T4-3-5
OPERATIONAL PERFORMANCE TEST / Excavator Test
SWING FUNCTION DRIFT
Summary:
1. Measure the swing drift on the circumference of
the swing-bearing outer race when stopping after
a 180 ° full-speed swing to evaluate the opera-
tional performance of the swing brake valve.
Preparation:
1. Confirm that the swing gears and bearing are suf-
ficiently greased.
2. Secure a space wide enough for the machine up-
T145-05-03-007
perstructure to swing on a flat and firm surface.
Never attempt to perform this test on a slope.
3. Empty the bucket and roll out (extend) the arm.
4. Put aligning marks on the outer circumference of
the swing bearing and the track frame.
5. Swing the upperstructure 180 °.
6. Maintain the hydraulic oil temperature at 50±5 °C
(122±9 °F).
CAUTION: Prevent personal injury. Always
make sure that the area is clear and that co-
workers are out of the swing area before
T145-05-03-008
starting the measurement.
Return the swing
control lever to the
Measurement: neutral position.
1. Engine Speed Control Lever : Fast Idle Position
2. Operate the swing control lever at full stroke and
rotate the upperstructure at full-speed back to the Drift
original position. Then, return the swing control Amount
lever to the neutral position when the upper-
structure rotates 180 °.
3. After the upperstructure stops, measure the dis-
tance between the two marks along the outer cir-
cumference of the swing bearing.
4. Align the marks again. Then, measure in the op-
posite direction. Rotate 180 °
5. Repeat steps (2) to (4) three times and calculate
the average values.
Evaluation:
Refer to T4-5 Operational Performance Standard.
Remedy:
Refer to the T5-4 Troubleshooting B.
. Start rotation T142-05-03-003
T4-3-6
OPERATIONAL PERFORMANCE TEST / Excavator Test
SWING MOTOR LEAKAGE
Summary:
Check for upperstructure drift while suspending a
load on a slope.
Preparation:
1. Check the lubrication of the swing gear and swing
bearing.
2. Park the machine on a smooth slope with a gradi-
ent of 26.8 % (15 °)
3. Bucket empty.
4. With the arm rolled out (extended), and bucket
rolled in, (tilted in) position the arm top pin height
to be level with the boom foot pin.
5. Swing the upperstructure to position it 90 ° to the T142-05-03-004
slope. Make aligning marks on the swing bearing
periphery and track frame using tape, as illus-
trated.
6. Maintain the hydraulic oil temperature at 50±5 °C
(122±9 °F).
Measurement:
1. Pull the pilot control shut-off lever to the LOCK
position.
2. Stop the engine. After five minutes, measure the
difference between the marks along the swing
bearing periphery and the track frame.
3. Perform the measurement in both right and left
swing directions.
4. Perform the measurement three times in each di-
rection and calculate the average values.
Evaluation:
Refer to T4-5 Operational Performance Standard. Measure Difference Between Marks
Remedy:
Refer to the T5-4 Troubleshooting B.
T105-06-03-010
T4-3-7
OPERATIONAL PERFORMANCE TEST / Excavator Test
MAXIMUM SWINGABLE SLANT ANGLE
Summary:
With the upperstructure swung 90 ° to the slope,
check the maximum slant angle on which the upper-
structure can swing to the uphill side.
Preparation:
1. Check that the swing gear and bearing are well
lubricated.
2. Load bucket fully. In lieu of loading the bucket,
weight (W:tons) of the following specification can
be used.
W=M×1.5
3
Where: M=bucket heaped capacity (CECE: m )
1.5=Soil specific gravity.
3. With the arm rolled out (retracted) and the bucket
rolled (tilted in), hold the arm top pin to the posi- T142-05-03-004
tion flush with the boom foot pin height.
4. Park the machine on a smooth slope with a gradi-
ent of 26.8 % (15 °).
5. Climb a slope and swing the upperstructure 90 °
to the slope.
6. Maintain the hydraulic oil temperature at 50±5 °C
(122±9 °F).
Measurement:
1. Engine Speed Control Lever : Fast Idle Position
2. Operate the swing lever to full stroke to swing the
upperstructure to the uphill side.
3. If the machine can swing, measure the cab floor
slant angle.
4. Increase the slope angle and repeat steps (2 and
3). Check both clockwise and counterclockwise.
5. Perform the measurement three times in each di-
rection and calculate the averageȀ Ȁvalues.
Evaluation:
Refer to T4-5 Operational Performance Standard.
Remedy:
Refer to the T5-4 Troubleshooting B.
T4-3-8
OPERATIONAL PERFORMANCE TEST / Excavator Test
SWING BEARING PLAY
Summary:
1. Measure the play between the outer and inner
races of the swing bearing to check wear on the
bearing races and balls.
Preparation:
1. Confirm that the swing bearing mounting bolts are
securely tightened.
2. Confirm that the swing bearing is well lubricated
and rotates smoothly with no noise.
3. Attach a dial gauge on the track frame using a
magnetic base. T105-06-03-015
Evaluation:
Refer to T4-5 Operational Performance Standard.
T145-05-03-023
Backhoe Front
Loader Front
Figure 1 Figure 2
T142-05-03-005
T4-3-9
OPERATIONAL PERFORMANCE TEST / Excavator Test
HYDRAULIC CYLINDER CYCLE TIME Backhoe
Summary:
Boom Cylinder
1. Check the overall operational performance of the
front attachment hydraulic system (between the
hydraulic pumps and each cylinder) by measuring
the cycle time of the boom, arm, bucket, and
bucket dump (open/close) cylinders with the
T145-05-03-012
bucket emptied.
Preparation:
1. Maintain the hydraulic oil temperature at 50±5 °C
(122±9 °F).
Measurement:
Arm Cylinder
1. Engine Speed Control Lever : Fast Idle Position
2. Position the front attachment as described in the
following. Then, measure the operating time until
T145-05-03-013
the cylinder reaches the stroke end by fully mov-
ing the control lever.
• Backhoe
Boom Cylinder:
With the bucket cylinder fully extended and the
arm cylinder fully retracted, lower the bucket to Bucket Cylinder
the ground.
Arm Cylinder: Loading Shovel T145-05-03-014
T4-3-10
OPERATIONAL PERFORMANCE TEST / Excavator Test
CYLINDER DRIFT
Summary:
1. Evaluate the internal oil leakage in the control
valve, boom, arm, and bucket cylinders by meas-
uring cylinder (dig function) drift with the bucket
loaded.
Preparation:
1. Load bucket fully. In lieu of loading the bucket,
weight (W:tons) of the following specification can
be used.
W=M×1.5
3
Where: M = bucket heaped capacity (CECE: m )
T145-05-03-021
1.5 = Soil specific gravity.
2. Position the arm and bucket cylinders with rods
approx. 50 mm (2 in) extended or retracted from
the stroke end as illustrated to the right.
3. Maintain the hydraulic oil temperature at 50±5 °C
(122±9 °F).
Evaluation:
Refer to T4-5 Operational Performance Standard. T110-06-03-002
Remedy:
Refer to the T5-4 Troubleshooting B.
Mark
T110-06-03-001
T4-3-11
OPERATIONAL PERFORMANCE TEST / Excavator Test
CONTROL LEVER OPERATING FORCE
Summary:
Use a spring scale to measure the maximum resis-
tance of each control lever as illustrated.
Preparation:
Maintain the hydraulic oil temperature at 50±5 °C
(122±9 °F).
Measurement:
1. Start the engine.
Evaluation:
Refer to T4-5 Operational Performance Standard.
T4-3-12
OPERATIONAL PERFORMANCE TEST / Excavator Test
CONTROL LEVER STROKE
Summary:
Measure each lever stroke at the lever top using a
ruler.
Preparation:
Maintain the hydraulic oil temperature at 50±5 °C
(122±9 °F).
Measurement:
1. Stop the engine. T107-06-03-005
2. Measure each lever stroke at the lever top from
neutral to the stroke end using a ruler.
3. Repeat step (2) three times and calculate the av-
erage values.
Evaluation:
Refer to T4-5 Operational Performance Standard.
T4-3-13
OPERATIONAL PERFORMANCE TEST / Excavator Test
COMBINED BOOM RAISE/SWING FUNC-
TIONS CHECK
Summary:
Check boom raise and swing movement and speeds
while operating both functions simultaneously.
Preparation:
1. Start the engine and run it at fast idle. Operate the T142-05-03-007
Measurement:
1. Engine Speed Control Lever : Fast Idle Position
2. Raise the boom and swing simultaneously, both at
full stroke.
3. When the upperstructure rotates 90 °, release the
control levers to stop both functions. Measure the
time required to swing 90 ° and the height (H) of
the bucket teeth.
4. Repeat steps (2) to (3) three times and calculate T142-05-03-009
Evaluation:
Refer to T4-5 Operational Performance Standard.
Remedy:
Refer to the T5-4 Troubleshooting B.
T142-05-03-010
T4-3-14
OPERATIONAL PERFORMANCE TEST / Component Test
PILOT PRIMARY PRESSURE
Preparation:
Plug
1. Stop the engine.
Measurement:
1. Select the following lever and switch positions:
Engine Speed Control Lever : Fast Idle Position
Auto-Idle Switch : OFF
Evaluation:
Refer to the Performance Standard Table in
Group T4-5.
Adjustment:
Pilot relief valve pressure setting is not adjust-
able.
T4-4-1
OPERATIONAL PERFORMANCE TEST / Component Test
PILOT SECONDARY PRESSURE
Measurement:
Preparation:
1. Select the following lever and switch positions:
1. Stop the engine.
Engine Speed Control Lever : Fast Idle Position
Auto-Idle Switch : OFF
CAUTION: The hydraulic oil tank cap may fly 2. Measure the pilot pressure with the correspond-
off if turned quickly due to internal pressure. ing control lever operated full stroke.
Turn it slowly to release internal pressure be- 3. Repeat the measurement three times and cal-
fore removing. culate the average values.
Do not remove the spool lock plates. Do not remove the spool lock plates.
T4-4-2
OPERATIONAL PERFORMANCE TEST / Component Test
SOLENOID VALVE SET PRESSURE
Travel Speed Change Solenoid Valve
Preparation:
1. Stop the engine. Output Port
Measurement:
1. Select the following switch positions:
Ȁ Auto-Idle Switch: OFF
Output Port
2. Measure each solenoid valve set pressure during
the following operations:
• Travel Speed Change Solenoid Valve
Measure travel mode change pressure while op- T144-04-04-002
Evaluation:
Refer to Performance Standard Table in Group
T4-5.
T4-4-3
OPERATIONAL PERFORMANCE TEST / Component Test
MAIN RELIEF PRESSURE
Summary:
Measure the main relief valve set pressure at the Pressure Gauge
main pump delivery port.
Preparation:
1. Stop the engine.
Measurement:
1. Select the following lever and switch positions:
Engine Speed Control Lever : Fast Idle Position
Auto-Idle Switch : OFF
2. Slowly operate the bucket, arm, and boom control
levers until each cylinder is fully extended or re-
tracted and the main relief valve relieves.
3. When checking swing relief pressure, make the
upperstructure immovable. Then, slowly operate
the swing lever to relieve the swing function.
4. When checking travel relief pressure, secure the
tracks against an immovable object. Then, slowly
operate the travel levers to relieve the travel func-
tion.
Evaluation:
Refer to Performance Standard Table in Group
T4-5.
Reference:
If the pressures for all measured functions are lower
than specifications, the probable cause is a decrease
in the main relief valve set pressure.
T4-4-4
OPERATIONAL PERFORMANCE TEST / Component Test
Main Relief Valve Set Pressure Adjustment
Lock Nut
Adjustment:
After loosening the lock nut, turn the adjusting screw
to adjust the set pressure.
W107-02-05-129
T4-4-5
OPERATIONAL PERFORMANCE TEST / Component Test
Swing Relief Valve Set Pressure Adjustment
Swing Relief Valve
Adjustment:
After loosening the lock nut, turn the adjusting screw
to adjust the set pressure.
T4-4-6
OPERATIONAL PERFORMANCE TEST / Component Test
Travel Relief Valve Set Pressure Adjustment
Adjustment:
After loosening the lock nut, turn the adjusting screw
to adjust the set pressure.
Adjusting
Screw
T145-05-04-004
W107-02-05-129
T4-4-7
OPERATIONAL PERFORMANCE TEST / Component Test
OVERLOAD RELIEF VALVE SET PRES-
SURE
Summary:
1. The circuit pressure must be increased by apply-
ing an external force while blocking the return cir-
cuit from the control valve. This measuring Pressure Gauge
method is hazardous and the results obtained with
this method are unreliable.
2. Loosen the hydraulic oil tank cap to release in- 3. Measure the relief pressure.
ternal pressure.
4. Measure the bucket, arm, and boom circuits one
3. Remove the plug from the test port located on the by one.
main pump delivery port. Install adapter (ST 6069),
hose (ST 6943), and pressure gauge (ST 6941). 5. Repeat the measurement three times and cal-
culate the average values.
4. Start the engine. Check that no oil leaks from the
pressure gauge connections. Evaluation:
Performance of each overload relief valve is con-
5. Maintain hydraulic oil temperature at 50±5 °C (122 sidered to be normal if the measured main relief
±9 °F). pressure for the bucket, arm, or boom function is
within the specifications.
T4-4-8
OPERATIONAL PERFORMANCE TEST / Component Test
Overload Relief Valve Set Pressure Adjustment
Adjustment:
After loosening the lock nut, turn the adjusting screw Lock Nut
to adjust the set pressure.
W107-02-05-129
T4-4-9
OPERATIONAL PERFORMANCE TEST / Component Test
MAIN PUMP FLOW RATE MEASURE-
MENT 7. Disconnect the engine speed sensor and connect
a pulse meter. Fully open the hydraulic tester load-
Summary: ing valve.
Connect a hydraulic tester to the main pump delivery
pipe. Measure the main pump flow rate to check the 8. Start the engine. Check line connections for any
pump performance. Use a pressure gauge at the oil leaks.
same time.
Measurement:
Preparation: 1. Maintain hydraulic oil temperature at 50±5 °C
(122±9 °F).
CAUTION: The hydraulic oil tank cap may fly 2. Select the following lever and switch positions:
off if turned quickly due to internal pressure. Engine Speed Control Lever : Fast Idle Position
Turn it slowly to release internal pressure be- Auto-Idle Switch : OFF
fore removing.
3. While slowly closing the hydraulic tester loading
1. Stop the engine. Loosen the hydraulic oil tank cap valve, measure the flow rate and engine speed at
to release internal pressure. Connect a vacuum each specified delivery pressure. (Refer to page
pump to the tank cap hole. T4-4-4.)
NOTE: Keep operating the vacuum pump during 4. Repeat the measurement three times and cal-
the work of connecting test circuit to the culate the average values.
main pump.
Evaluation:
2. Disconnect the delivery hose from the main pump. Convert the measured results to data for the
Connect pipe (ST 6139) to the main pump deliv- pump rated speed. Then, refer to the Perform-
ery port using the removed split flanges and bolts. ance Standard Table in Group T4-5.
T4-4-10
OPERATIONAL PERFORMANCE TEST / Component Test
Fig. A
Main
Pump
High Pres-
sure Strainer
Adapter
(ST 6146)
T144-04-04-005
Fig. B
2 1
T144-03-01-004
T4-4-11
OPERATIONAL PERFORMANCE TEST / Component Test
Adjustment:
Adjustment of Maximum and Minimum Flow Rate NOTE: Turn screw (1) clockwise to decrease the
maximum flow rate and counterclockwise to
The pump flow rate can be adjusted by changing the increase. Turning screw (1) one forth a turn
maximum stroke of the servo piston. changes approx. 9.4 L/min of flow rate.
When adjusting the maximum flow rate, loosen nut Turn screw (4) clockwise to increase the
(2) and turn screw (1) on the small chamber side of minimum flow rate and counterclockwise to
the servo piston. When adjusting the minimum flow decrease. Turning screw (4) one forth a
rate, loosen nut (3) and turn screw (4) on the large turn changes approx. 9.4 L/min of flow rate.
chamber side of the servo piston.
: screw (1): 13 mm
: nuts (2), (3): 30 mm
: screw (4): 10 mm
1 2 3 4
T144-03-01-004
Q Q
(Flow (Flow
Rate) Rate)
Pi Pi
(Flow Rate Control Pressure) (Flow Rate Control Pressure)
T4-4-12
OPERATIONAL PERFORMANCE TEST / Component Test
Constant Pump Drive Torque Adjustment
1 2 3 4
5 6
2
NOTE: 1 kgf/cm =0.09807 Mpa
1 kgfxm=9.807 Nxm T144-04-04-003
When adjusting the outer spring When adjusting the inner spring
Screw Turns 1/4 Screw Turns 1/4
Flow Rate 42.0 L/min Flow Rate 18.7 L/min
2 2
Pressure 19.2 kgf/cm Pressure 18.4 kgf/cm
Pump Drive Torque 6.2 kgfxm Pump Drive Torque 3.9 kgfxm
Q Q
(Flow (Flow
Rate) Rate)
Pd Pd
Delivery Pressure Delivery Pressure
T4-4-13
OPERATIONAL PERFORMANCE TEST / Component Test
Flow Rate Control Adjustment
The pump flow rate is controlled by flow rate control : nut (2): 13 mm
pressure (Pi). Therefore, the pump flow rate is ad- : screw (3) : 4 mm
justed by changing set force of spring (1).
When adjusting set force of spring (1), loosen nut (2)
and turn screw (3).
2 3
T144-04-04-004
When adjusting the outer spring
Screw Turns 1/4
Flow Rate 43.9 L/min 2
NOTE: 1 kgf/cm =0.09807 MPa
2
Pressure 2.7 kgf/cm
Q Q
(Flow (Flow Q
Rate) Rate) (Flow
Rate)
T4-4-14
OPERATIONAL PERFORMANCE TEST / Component Test
(Blank)
T4-4-15
OPERATIONAL PERFORMANCE TEST / Component Test
SWING MOTOR DRAINAGE
Summary:
Check the swing motor performance by measuring
the swing motor drain oil quantity while rotating the
upperstructure.
Preparation:
1. Maintain hydraulic oil temperature at 50±5 °C
(122±9 °F). Rotate the swing motor to warm the
inside of the swing motor.
T4-4-16
OPERATIONAL PERFORMANCE TEST / Component Test
Measurement:
Quantity of Drain Oil While Swinging
(1) With the bucket empty, position the front attach-
ment as follows:
Backhoe:
With the arm cylinder fully retracted, and the
bucket cylinder fully extended, raise the boom so
that the arm tip pin height is flush with the boom
foot pin height.
Loading Shovel:
With the arm cylinder and the bucket cylinder fully T145-05-03-007
extended, raise the boom so that the arm tip pin
height is flush with the boom foot pin height.
(2) Start the engine. Operate and hold the swing lever
full stroke. Begin to measure time and the drain oil
quantity from the drain hose using a container af-
ter the swing speed reaches a constant maximum
speed.
(3) Repeat the measurement at least three times in
both clockwise and counterclockwise directions,
and calculate the average values.
(4) The measuring time should be more than 20 sec-
onds. T145-05-03-008
Evaluation:
Refer to Performance Standard Table in Group
T4-5.
∆QȀȝȀȖȐȀ×ȀɑȀȏȀɔ
T4-4-17
OPERATIONAL PERFORMANCE TEST / Component Test
TRAVEL MOTOR DRAINAGE
Summary:
Check the travel motor performance by measuring
the travel motor drain oil quantity while rotating the
travel motor with the measuring side track raised off
the ground with the front attachment.
Preparation:
1. Maintain hydraulic oil temperature at 50±5 °C
(122±9 °F). Rotate the travel motor to warm the
inside of the travel motor.
CAUTION: The hydraulic oil tank cap may fly
off if turned quickly. Turn it slowly to release
internal pressure before removing. Drain Hose
T4-4-18
OPERATIONAL PERFORMANCE TEST / Component Test
Measurement:
Quantity of Drain Oil While Rotating the Travel Motor
(1) Start the engine. Raise the measuring side track
off the ground using the front attachment.
and the drain oil quantity from the drain hose us-
ing a container.
(3) Repeat the measurement at least three times in
both forward and reverse directions, and calculate
the average values.
(4) The measuring time should be more than 20 sec-
onds. 90 to
110ń
Evaluation:
T142-05-03-012
Refer to Performance Standard Table in Group
T4-5.
∆QȀȝȀȖȐȀ×ȀɑȀȏȀɔ
T4-4-19
OPERATIONAL PERFORMANCE TEST / Component Test
(Blank)
T4-4-20
SECTION 5
TROUBLESHOOTING
CONTENTS
Group 3 Troubleshooting A
Introduction ..................................................T5-3-1
How to Read CUMMINS Engine
Fault Codes ................................................T5-3-2
Cummins Engine Fault Code
Information .................................................T5-3-4
144T-5-1
Group 5 Troubleshooting C
Troubleshooting C Procedure ......................T5-5-1 Malfunction of Level Check Switch............ T5-5-29
Malfunction of Tachometer...........................T5-5-2 Malfunction of Indicator Light
Malfunction of Coolant Check Switch ........................................... T5-5-30
Temperature Gauge ...................................T5-5-4 Malfunction of Hour Meter ......................... T5-5-31
Malfunction of Hydraulic Oil Malfunction of Buzzer ................................ T5-5-32
Temperature Gauge ...................................T5-5-6 Troubleshooting Pump Contamination
Malfunction of Fuel Gauge ...........................T5-5-8 Indicators ................................................. T5-5-33
Malfunction of Hydraulic Oil Level
Indicator (Warning)...................................T5-5-10 Group 6 Electrical System Inspection
Malfunction of Fuel Level Precautions for Inspection and
Indicator....................................................T5-5-11 Maintenance .............................................. T5-6-1
Malfunction of Auto-lubrication Battery Voltage Check ................................. T5-6-3
Indicator....................................................T5-5-12 Fuse Continuity Check ................................ T5-6-4
Malfunction of Pump Transmission Slow Blow Fuse Inspection.......................... T5-6-6
Oil Pressure Indicator...............................T5-5-13 Alternator Check.......................................... T5-6-7
Malfunction of Pump Contamination Voltage Check ............................................. T5-6-8
Indicator....................................................T5-5-14 Continuity Check........................................ T5-6-10
Malfunction of Ladder Indicator..................T5-5-16 5 Volt Circuit............................................... T5-6-11
Malfunction of Air Filter Restriction Circuit Check with Lamp Harness ............. T5-6-12
Indicator....................................................T5-5-17
Malfunction of Engine Stop, Engine Warning,
or Engine Protection Indicator ..................T5-5-18
Malfunction of Hydraulic Oil Level
Indicator....................................................T5-5-19
Malfunction of Coolant Level
Indicator....................................................T5-5-20
Malfunction of Engine Oil Level
Indicator....................................................T5-5-21
Malfunction of Emergency Stop
Indicator....................................................T5-5-22
Malfunction of Entrance Light
Indicator....................................................T5-5-23
Malfunction of Engine Room Light
Indicator....................................................T5-5-24
Malfunction of Auto-idle
Indicator....................................................T5-5-25
Malfunction of Fast Speed Travel
Indicator....................................................T5-5-26
Malfunction of Slow Speed Travel
Indicator....................................................T5-5-27
Malfunction of Alternator
indicator....................................................T5-5-28
144T-5-2
TROUBLESHOOTING / Diagnosing Procedure
INTRODUCTION
T5-1-1
TROUBLESHOOTING / Diagnosing Procedure
DIAGNOSING PROCEDURE
T107-07-01-003
T5-1-2
TROUBLESHOOTING / Diagnosing Procedure
4. Operate the machine yourself
5. Perform troubleshooting
T107-07-01-004
T107-07-01-006
T107-07-01-007
T5-1-3
TROUBLESHOOTING / Diagnosing Procedure
(Blank)
T5-1-4
TROUBLESHOOTING / Component Layout
MAIN COMPONENTS 4
Backhoe 3 6
2
7
1
6
Loading Shovel 7
8
M145-01-016
5
9
4 10
3 11
2
12
1 13
14
15
16
33
32
34 31
30
29 17
28
27
26
25
24 18
23 19
22 T144-01-02-001
21
20
1 - Bucket 10 - Lubricator 19 - Auxiliary Hydraulic Oil Tank 27 - Accumulator (For Pilot Circuit)
2 - Bucket Cylinder 11 - Swing Control Valve 20 - Travel Device 28 - Adjuster Cylinder
3 - Arm 12 - Fuel Tank 21 - Travel Brake Valve 29 - Compressor Drive Motor,
Compressor (For Air Conditioner)
4- Arm Cylinder 13 - Main Hydraulic Oil Tank 22 - EHC Valve 30 - Travel Mode Shift Solenoid Valve
5- Level Cylinder 14 - Main Control Valve 23 - Center Joint 31 - Pilot Shut-Off Vale
6- Boom Cylinder 15 - Fuel Cooler 24 - Lower Roller 32 - Bucket Open-Close Pilot Valve
7- Boom 16 - Radiator, Oil Cooler 25 - Upper Roller 33 - Travel Pilot Valve
8- Front/Swing Pilot Valve 17 - Engine 26 - Accumulator (For Adjuster 34 - Dump Cylinder
Cylinder)
9 - Swing Device 18 - Pump Device
T5-2-1
TROUBLESHOOTING / Component Layout
ELECTRICAL SYSTEM COMPONENT
23
1
2
3
4
5
6
7
8
9
10
22
21
20
19
18
17
16
15
14
13
12
11 T144-01-02-002
T5-2-2
TROUBLESHOOTING / Component Layout
24
25
26
27
28
29
30
31
32
33
34
35
36
47
46
37
45
44 38
43 39 T144-01-02-002
42
41
40
24 - Air Cleaner Restriction 30 - Coolant Temperature 36 - Coolant Temperature 42 - Pump Room Light
Switch Sensor Sensor
25 - Ether Solenoid Valve 31 - Engine Room Light 37 - Engine Oil Level Switch* 43 - Engine Speed Sensor
26 - Coolant Level Switch 32 - Ether Solenoid Valve 38 - Travel Alarm 44 - Pump Transmission Oil
(For Indicator) Pressure Switch
27 - Thermo Guard Switch 33 - Coolant Level Switch 39 - Engine Speed Sensor 45 - Contamination Sensor
(For Ether Solenoid Valve) (For Indicator)
28 - Coolant Level Switch 34 - Thermo Guard Switch 40 - Pump Transmission Oil 46 - Engine Stop Switch
(For ECM) (For Ether Solenoid Valve) Pressure Switch
29 - Air Cleaner Restriction 35 - Coolant Level Switch (For 41 - Contamination Sensor 47 - EHC Valve
Switch ECM)
∗ Engine oil level switch for the front engine is located in the same position.
T5-2-3
TROUBLESHOOTING / Component Layout
ELECTRICAL SYSTEM COMPONENT (In the cab)
2
3
1 4
5
M144-01-020
6 7
15
14 8
13 9
10
12
11
M144-01-005 M144-07-096
1 - Switch Panel 5 - Key Switch 9 - Data Link Connector 13 - Data Link Connector
(For Front Engine) (For Front Engine) (For Rear Engine)
2 - Monitor Panel 6 - Fuse Box 2 10 - Engine Diagnostic Switch B 14 - Engine Diagnostic Switch A
(For Front Engine) (For Rear Engine)
3 - Emergency Engine Stop 7 - Power Source Terminal 11 - Transformer (24 V to 12 V) 15 - Buzzer
Switch
4 - Key Switch 8 - Engine Diagnostic Switch A 12 - Engine Diagnostic Switch B
(For Rear Engine) (For Front Engine) (For Rear Engine)
T5-2-4
TROUBLESHOOTING / Component Layout
Monitor Panel 10 11 12 13 14
1 2 3 4 5 6 7 8 9
34
33
32
31
30
29
28
27 26 25 24 23 22 21 20 19 18 17 16 15 T144-01-02-006
Switch Panel 35 36 37 38 39 40 41
42
43
44
45
54 53 52 51 50 49 48 47 46
M144-01-017
1 - Engine Oil Level Indicator 16 - Alternator Indicator 29 - Air Cleaner Restriction 42 - Indicator Light Check
(For Front Engine) Indicator (For Rear Engine) Switch
2 - Coolant Level Indicator 17 - Pump Transmission Oil 30 - Pump Contamination 43 - Level Check Switch
(For Front Engine) Pressure Indicator Indicator
(For Front Engine)
3 - Hydraulic Oil Level Indicator 18 - Hydraulic Oil Level 31 - Engine Stop Indicator 44 - Buzzer Stop Switch
Indicator
4 - Slow Travel Mode Indicator 19 - Pump Transmission Oil 32 - Ladder Position Indicator 45 - Dimmer Switch
Pressure Indicator
(For Rear Engine)
5 - Auto Idle Indicator 20 - Fuel Level Indicator 33 - Engine Oil Level Indicator 46 - Engine Speed Control
(For Rear Engine) Lever
6 - Engine Room Light 21 - Auto-Lubrication Indicator 34 - Coolant Level Indicator 47 - Work Light Switch
Indicator (Option) (For Rear Engine)
7 - Entrance Light Indicator 22 - Engine Stop Indicator 35 - Washer Switch 48 - Dome Light Switch
(For Front Engine)
8 - Work Light Indicator 23 - Engine Warning Indicator 36 - Cigar Lighter 49 - Engine Room Light
(For Front Engine) Switch
9 - Fast Travel Mode Indicator 24 - Engine Protection Indicator 37 - Wiper Delay Selector 50 - Entrance Light Switch
(For Front Engine)
10 - Coolant Temperature Gauge 25 - Engine Protection Indicator 38 - Wiper Switch 51 - Travel Mode Switch
(For Rear Engine) (For Rear Engine)
11 - Hydraulic Oil 26 - Engine Warning Indicator 39 - Air Conditioner Control 52 - Auto Idle Switch
Temperature Gauge (For Rear Engine) Panel (For Rear)
12 - Tachometer 27 - Engine Stop Indicator 40 - Air Conditioner Control 53 - Ether (Starting Aid)
(For Rear Engine) (For Rear Engine) Panel (For Side) Switch
13 - Tachometer 28 - Air Cleaner Restriction 41 - Air Conditioner Control 54 - Auxiliary Switch
(For Front Engine) Indicator Panel (For Front)
14 - Coolant Temperature Gauge (For Front Engine)
(For Front Engine)
15 - Fuel Gauge
T5-2-5
TROUBLESHOOTING / Component Layout
PUMP
T144-03-01-001
1 - Main Pump 4 3 - Center Gear Pump 4 - Main Pump 3 5 - Triple Gear Pump
(For Front Engine) (For Front Engine)
Main Pump 2 Main Pump 1
(For Rear Engine) (For Rear Engine)
2 - Swing Pump 2
(For Front Engine)
Swing Pump 1
(For Rear Engine)
T5-2-6
TROUBLESHOOTING / Component Layout
ENGINE
1 2 3
7 6 5 T144-01-02-003
1 - Coolant Temperature 3 - Intake Manifold 5 - ECM (Electrical Control 7 - Engine Oil Pressure
Sensor (For ECM) Temperature Sensor Module) Sensor (For ECM)
(For ECM)
2 - Intake Manifold Pressure 4 - Engine Speed Sensor 6 - Air Pressure Sensor
Sensor (For ECM) (For ECM) (For ECM)
T5-2-7
TROUBLESHOOTING / Component Layout
ELECTRICAL EQUIPMENT BOX
1
2
3
28 4
5
25, 26, 27
6
7
24
8
21, 22, 23 9
10
20 11
12
19
13
18 14
15
16
17
T144-01-02-004
1 - Limit Switch 8 - Work Light Relay (On the 15 - Auto-Lubrication Relay 22 - Side Air Conditioner
left side of base machine) Controller (Middle Shelf)
2 - Lower Wiper Slow Relay 9 - Work Light Relay (On the 16 - Auto-Lubrication Interval 23 - Front Air Conditioner
right side of base machine) Switch Controller (Lower Shelf)
3 - Upper Wiper Fast Relay 10 - Work Light Relay 17 - Fuse Box 1 24 - Resister (R2:27 Ω)
(On the cab)
4 - Upper Wiper Slow Relay 11 - Slow Wiper Relay 18 - Ether Relay 25 - Contamination Amplifier
(For Rear Engine) (Upper Shelf)
5 - Upper Wiper Main Relay 12 - Hour Meter Relay 19 - Ether Relay 26 - MC (B) (Middle Shelf)
(For Front Engine)
6 - Lower Wiper Main Relay 13 - Swing Inter Lock Relay 20 - Resister (R3:5.6 Ω) 27 - MC (A) (Lower Shelf)
7 - Load Dump Relay 14 - Fluorescent Illumination 21 - Rear Air Conditioner 28 - Resister (R1:27 Ω)
Light Controller (Upper Shelf)
T5-2-8
TROUBLESHOOTING / Component Layout
29
30
31
45 32
33
44
34
35
43
36
42
37
38
41 39
40
T144-01-02-004
29 - Illumination Relay 34 - Engine Room Light Relay 38 - Air Conditioner Relay 42 - Air Conditioner Relay
39 - (For Side) (For Front)
30 - Indicator Light Check Relay 35 - Emergency Relay 40 - Air Conditioner Relay 43 - Fan Motor Relay
(For Front Engine) (For Rear) (For Front)
31 - Washer Motor Relay 36 - Fan Motor Relay (For Side) 41 - Lower Wiper Fast Relay 44 - Entrance Light Relay
32 - Travel Speed Change 37 - Fan Motor Relay 42 - Dome Light Relay 45 - Horn Relay
Relay (For Rear)
33 - Emergency Relay
(For Rear Engine)
T5-2-9
TROUBLESHOOTING / Component Layout
BATTERY COMPARTMENT
1 2 3
10
4
9 7
T144-01-02-005
T5-2-10
TROUBLESHOOTING / Component Layout
PILOT PIPING
(LOADING SHOVEL) 1
2
3
4
5
6
22 7
8
21
20
19
18
17
16
23 24 25 26
15
14
13
12
11
10
9
29
T144-05-02-032
27
30
31
28
32
T144-05-02-034
1 - Left Pilot Valve 9 - Manifold 7 17 - Pilot Shut-Off Valve 25 - Pi Pressure Change Valve
2 - Right Pilot Valve 10 - Swing Pump 18 - Shuttle Valve 1 26 - Travel Speed Change
Solenoid Valve
3 - Manifold 4 11 - Manifold 6 19 - Travel Cut-Off Valve 27 - Manifold 2
4 - Swing Motor 12 - Swing Pump 20 - Manifold 1 28 - Manifold 3
5 - Swing Inter Lock Solenoid 13 - Manifold 5 21 - Bucket Open-Close Pilot 29 - Multi Shuttle Valve
Valve Valve
6 - Control Valve 14 - EHC Valve 22 - Travel Pilot Valve 30 - Shuttle Valve 2
7 - Main Pump 15 - Center Joint 23 - Swing Pi Pressure Control 31 - Shuttle Valve 3
Solenoid Valve
8 - Main Pump 16 - Swing Control Valve 24 - Flow Combiner Valve 32 - Shuttle Valve 4
Change Valve
T5-2-11
TROUBLESHOOTING / Component Layout
NOTE: Parenthesized numbers after component
names in the following table correspond to
the location shown with same number in
each component illustration.
1 2 3
Front
9 Right Left
4
Rear
8 7 6 5
T144-05-02-001
Left Pilot Valve
The valve controls the pilot pressure to the arm and
swing control valves.
No. Connecting point Remarks
1 Pilot shut-off valve(4) Return oil to hydraulic oil tank
2 Multi shuttle valve(5) Pilot pressure for right swing
3 Multi shuttle valve(14) Pilot pressure for arm retract
4 Pilot shut-off valve(3) Primary pilot pressure
5 Multi shuttle valve(6) Pilot pressure for left swing
6 Multi shuttle valve(15) Pilot pressure for arm extend
1 2
Front
6 3
Right Left
Rear
5 4
T144-05-02-002
T5-2-12
TROUBLESHOOTING / Component Layout
Right Pilot Valve
The valve controls the pilot pressure to the boom and
bucket control valves.
No. Connecting point Remarks
1 Pilot shut-off valve(1) Primary pilot pressure
2 Multi shuttle valve(17) Pilot pressure for boom raise
3 Multi shuttle valve(16) Pilot pressure for bucket roll-out
4 Pilot shut-off valve(9) Return oil to hydraulic oil tank
5 Multi shuttle valve(18) Pilot pressure for bucket boom lower
6 Multi shuttle valve(2) Pilot pressure for bucket roll-in
1 2 Front
6 3
Right Left
5 4 Rear
T144-05-02-002
Travel Pilot Valve
The valve controls the pilot pressure to the travel
control valves.
No. Connecting point Remarks
1 Travel cut-off valve(13) Pilot pressure for travel forward left
2 Manifold l(7), bucket open-close pilot valve(2) Primary pilot pressure
3 Travel cut-off valve(12) Pilot pressure for travel reverse left
4 Travel cut-off valve(11) Pilot pressure for travel reverse right
5 Manifold 1(1), bucket open-close pilot valve(3) Return oil to hydraulic oil tank
6 Travel cut-off valve(14) Pilot pressure for travel forward right
Front
1
6
5 2
Right Left
4 3
Rear
T117-06-02-004
Bucket Open-Close Pilot Valve
The valve controls the pilot pressure to the bucket
open-close control valves.
No. Connecting point Remarks
1 Multi shuttle valve(3) Pilot pressure for bucket close
2 Travel pilot valve(2) Primary pilot pressure
3 Travel pilot valve(5) Return oil to hydraulic oil tank
4 Multi shuttle valve(4) Pilot pressure for bucket open
1 Front
4
3 2 Left
Right
Rear
T117-06-02-004
T5-2-13
TROUBLESHOOTING / Component Layout
Multi Shuttle Valve
T5-2-14
TROUBLESHOOTING / Component Layout
1 2 3 4 5 6 7 8
21
9 Upper
20
10 Right Left
19
Lower
11
18 17 16 15 14 13 12
T144-05-02-003
22 23 24 25 26 27 28 29 30 31
Upper
Right Left
Lower
38 37 36 35 34 33 32
T144-05-02-003
T5-2-15
TROUBLESHOOTING / Component Layout
Travel Cut-Off Valve
When the traveling signal pressure from the adjuster
cylinder, the spool is shifted, blocking the travel pilot
pressure to stop machine movement.
6
5
4
3
2
1 Left Rear
Front Right
7
8
9
10
11
12
13
14
T144-05-02-004
Swing Inter Lock Solenoid Valve
This valve stops swing function while the ladder is lowered.
No. Connecting point Remarks
1 Manifold 4(4) Pilot pressure for right swing
2 Swing control valve: Right(7) Pilot pressure for left swing
3 Swing control valve: Right(9) Pilot pressure for right swing
4 Manifold 4(5) Pilot pressure for left swing
4
Upper
Right Left
Lower
1
2
3 T144-05-02-005
T5-2-16
TROUBLESHOOTING / Component Layout
Swing Pi Pressure Control Solenoid Valve, Flow
Combiner Valve Change Valve, Pi Pressure
Change Valve change valve regulates the flow combiner valve
Swing Pi pressure control solenoid valve regulates Pi control pressure. Pi pressure change valve regulates
pressure to the swing pump. Flow combiner valve PI pressure to the main pump.
1 2 3
Upper
5
Left Right
Lower
7 6
11 10 9 8
T144-05-02-006
Travel Speed Change Solenoid Valve
This valve controls the travel speed change pressure
in two stage.
No. Connecting point Remarks
1 Manifold 1(6) Primary pilot pressure
2 Manifold 4(10) Travel speed change pressure
3 Swing Pi pressure control solenoid valve, flow combiner Return oil to hydraulic oil tank
valve change valve, Pi pressure change valve(4)
4 Manifold 4(8) Swing parking brake release pressure
1 2
Upper
Left Right
4
3 Lower
T144-05-02-007
T5-2-17
TROUBLESHOOTING / Component Layout
Manifold 1
This manifold is connection block for travel pilot valve,
travel cut-off valve, travel speed change solenoid
valve, swing Pi pressure control solenoid valve.
No. Connecting point Remarks
1 Travel pilot valve(5) Return oil to hydraulic oil tank
2 Travel cut-off valve(2) Return oil to hydraulic oil tank
3 Pilot shut-off valve(8) Return oil to hydraulic oil tank
4 Pilot shut-off valve(2) Primary pilot pressure
5 Swing Pi pressure control solenoid valve(2) Primary pilot pressure
6 Travel speed change solenoid valve(1) Primary pilot pressure
7 Travel pilot valve(2) Primary pilot pressure
7
1
Front
6
Right Left
2
5 Rear
4
T144-05-02-008
Manifold 2
Manifold 2 functions as the drain oil junction block to the
hydraulic oil tank from each valve.
No. Connecting point Remarks
1 Multi shuttle valve(11) Return oil to hydraulic oil tank
2 Multi shuttle valve(7) Return oil to hydraulic oil tank
3 Swing Pi pressure control solenoid valve, flow combiner Return oil to hydraulic oil tank
valve change valve, Pi pressure change valve(5)
4 Pilot shut-off valve Return oil to hydraulic oil tank
5 Manifold 3(6) Return oil to hydraulic oil tank
3
2
Upper
1
4
Right Left
Lower
T144-05-02-009
T5-2-18
TROUBLESHOOTING / Component Layout
Manifold 3
Manifold 3 functions as the pump control pressure oil
junction block.
No. Connecting point Remarks
1 Multi shuttle valve(33) Travel pressure
2 Swing Pi pressure control solenoid valve(l0) Swing Pi pressure
3 Shuttle valve 4(2) Travel pressure, pilot pressure for arm retract
4 Shuttle valve 3(3) Boom, arm extend, bucket, bucket open-close pilot
pressure
5 Shuttle valve 2(3) Boom, arm, bucket, bucket open-close pilot pressure
6 Manifold 2(5) Return oil to hydraulic oil tank
7 Hydraulic oil tank Return oil to hydraulic oil tank
8 Multi shuttle valve(19) Return oil to hydraulic oil tank
9 Manifold 5(19) Pi pressure(Main pump 1,2 and 4)
10 Manifold 5(20) Pi pressure(Main pump 3)
11 Manifold 5(22) Pit pressure(Main pump 1)
12 Manifold 5(23) Swing Pi pressure(Swing pump 1 and 2)
13 Manifold 5(21) Pic pressure(Main pump 2,3 and 4)
Pe pressure(Main pump 1,2,3 and 4)
1 2 3 4 5 6
Upper
Right Left
7
Lower
8
13 12 11 10 9
T144-05-02-010
Manifold 4
This manifold is connection block for swing pilot
pressure, travel speed change pressure, traveling
stop signal pressure and swing parking brake release
pressure.
No. Connecting point Remarks
1 Center joint(2) Travel speed change pressure
2 Center joint(3) Traveling stop signal pressure
3 Swing motor: Front(5) Swing parking brake release pressure
4 Swing inter lock solenoid valve(1) Pilot pressure for right swing
5 Swing inter lock solenoid valve(4) Pilot pressure for left swing
6 Multi shuttle valve(31) Pilot pressure for left swing
7 Multi shuttle valve(30) Pilot pressure for right swing
8 Travel speed change solenoid valve(4) Swing parking brake release pressure
9 Travel cut-off valve(1) Traveling stop signal pressure
10 Travel speed change solenoid valve(2) Travel speed change pressure
5 6
Upper
7
4
3 8
Front Rear
2 9
1
10 Lower
T144-05-02-011
T5-2-19
TROUBLESHOOTING / Component Layout
Manifold 5
Manifold 5 functions as the pump control pressure oil
junction block.
No. Connecting point Remarks
1 Main pump 3(7) Pi pressure(Main pump 3)
2 Main pump 4(5) Pic pressure(Main pump 3 and 4)
3 Main pump 4(3) Psv pressure(Main pump 3 and 4)
4 Swing pump 2(1) Psv pressure(Swing pump 2)
5 Swing pump 2(2) Pi pressure(Swing pump 2)
6 Main pump 4(2) Pe pressure(Main pump 3 and 4)
7 Manifold 6(14) Psv pressure(Main pump 1 and 2, swing pump 1)
8 Manifold 6(15) Pi pressure(Swing pump 1)
9 Manifold 6(13) Pic pressure(Main pump 1)
10 Manifold 6(12) Pic pressure(Main pump 2)
Pe pressure(Main pump 1 and 2)
11 Manifold 6(11) P2 pressure(Main pump 1 and 2)
12 Manifold 6(10) Pi pressure(Main pump 1 and 2)
13 Manifold 6(9) Pz pressure(Main pump 1 and 2)
14 Main pump 4(4) P2 pressure(Main pump 3 and 4)
15 Main pump 4(1) Pz pressure(Main pump 3 and 4)
16 Main pump 4(6) Pi pressure(Main pump 4)
17 EHC valve (3) Pz pressure(Main pump 1 and 2)
18 EHC valve (2) Pz pressure(Main pump 3 and 4)
19 Manifold 3(9) Pi pressure(Main pump 1, 2 and 4)
20 Manifold 3(10) Pi pressure(Main pump 3)
21 Manifold 3(11) Pic pressure(Main pump 2, 3 and 4)
Pe pressure(Main pump 1, 2, 3 and 4)
22 Manifold 3(12) Pic pressure(Main pump 1)
23 Manifold 3(13) Swing Pi pressure(Swing pump 1 and 2)
24 EHC valve (5) Psv pressure(Main pump 1,2,3 and 4, swing pump 1 and 2)
1 2 3 4 5 6
24 7
23 8
9
22
Right
21 10
11
20 Front Rear
19 12
18 Left
13
17
14
16 15
T144-05-02-012
T5-2-20
TROUBLESHOOTING / Component Layout
Manifold 6
Manifold 6 functions as the pump control pressure oil
junction block.
No. Connecting point Remarks
1 Swing pump 1(4) Pi pressure(Swing pump 1)
2 Swing pump 1(5) Psv pressure(Swing pump 1)
3 Manifold 7(13) Psv pressure(Main pump 1 and 2)
4 Manifold 7(12) Pic pressure(Main pump 1)
5 Manifold 7(11) Pic pressure(Main pump 2)
6 Manifold 7(10) P2 pressure(Main pump 1 and 2
7 Manifold 7(9) Pi pressure(Main pump 1 and 2)
8 Manifold 7(8) Pz pressure(Main pump 1 and 2)
9 Manifold 5(13) Pz pressure(Main pump 1 and 2)
10 Manifold 5(12) Pi pressure(Main pump 1 and 2)
11 Manifold 5(11) P2 pressure(Main pump 1 and 2)
12 Manifold 5(10) Pic pressure(Main pump 2)
13 Manifold 5(9) Pic pressure(Main pump 1)
14 Manifold 5(7) Psv pressure(Main pump 1 and 2, swing pump 1)
15 Manifold 5(8) Pi pressure(Swing pump 1)
15
2
14 3
13 4 Right
12 5
Front Rear
11 6
10 7 Left
9 8
T144-05-02-013
T5-2-21
TROUBLESHOOTING / Component Layout
Manifold 7
Manifold 7 functions as the pump control pressure oil
junction block.
No. Connecting point Remarks
1 Main pump 1(12) Psv pressure(Main pump 1 and 2)
2 Main pump 1(11) Pic pressure(Main pump 1)
3 Main pump 2(8) Pic pressure(Main pump 2)
4 Main pump 1(13) Pe pressure(Main pump 1 and 2)
5 Main pump 1(9) P2 pressure(Main pump 1 and 2)
6 Main pump 1(10) Pi pressure(Main pump 1 and 2)
7 Main pump 1(14) Pz pressure(Main pump 1 and 2)
8 Manifold 6(8) Pz pressure(Main pump 1 and 2)
9 Manifold 6(7) Pi pressure(Main pump 1 and 2)
10 Manifold 6(6) P2 pressure(Main pump 1 and 2)
11 Manifold 6(5) Pic pressure(Main pump 2)
12 Manifold 6(4) Pic pressure(Main pump 1)
13 Manifold 6(3) Psv pressure(Main pump 1 and 2)
1 2 3 4 5 6 7
Right
Front Rear
Left
13 12 11 10 9 8
T144-05-02-014
T5-2-22
TROUBLESHOOTING / Component Layout
Shuttle Valve 1
During travel operations, shuttle valve 1 supplies the
travel pilot pressure to the multi-shuttle valve.
No. Connecting point Remarks
1 Travel cut-off valve(7) Pilot pressure for travel reverse right
2 Travel cut-off valve(8) Pilot pressure for travel reverse left
3 Travel cut-off valve(9) Pilot pressure for travel forward left
4 Travel cut-off valve(10) Pilot pressure for travel forward right
5 Multi shuttle valve(13) Travel pressure
1 2
3
4
Left Rear
Front Right
T144-05-02-015
Shuttle Valve 2
During operations other than swing, shuttle valve 2
supplies flow control pressure (Pi pressure) to main
pumps 1, 2, and 4.
No. Connecting point Remarks
1 Multi shuttle valve(12) Boom, arm, bucket, bucket open-close pilot pressure
2 Pi pressure change valve(7) Boom, arm, bucket, bucket open-close pilot pressure
3 Manifold 3(5) Boom, arm, bucket, bucket open-close pilot pressure
4 Shuttle valve 3(5) Travel pressure, boom raise pilot pressure
1
Upper
Right Left
Lower
4 3
T144-05-02-016
T5-2-23
TROUBLESHOOTING / Component Layout
Shuttle Valve 3
During operations other than swing and arm extend,
shuttle valve 3 supplies flow control pressure (Pi
pressure) to main pump 3.
No. Connecting point Remarks
1 Multi shuttle valve(38) Pilot pressure for bucket roll-in
2 Multi shuttle valve(37) Pilot pressure for boom raise
3 Manifold 3(4) Boom, arm extend, bucket, bucket open-close pilot
pressure
4 Multi shuttle valve(35) Travel pressure, pilot pressure for boom raise
5 Shuttle valve 2(4) Travel pressure, pilot pressure for boom raise
6 Multi shuttle valve(32) Travel pressure
7 Shuttle valve 4(3) Travel pressure
8 Pi pressure change valve(6) Boom, arm extend, bucket, bucket open-close pilot
pressure
1 2 3 4
Upper
Right Left
Lower
8 7 6 5
T144-05-02-017
Shuttle Valve 4
During travel and arm retract operations, shuttle valve
4 supplies maximum flow rate cut pressure (Pic
pressure) to main pump 1.
2 Upper
Right Left
Lower
T144-05-02-018
T5-2-24
TROUBLESHOOTING / Component Layout
EHC Valve
EHC valve supplies power increase control pressure
Pz to main pumps 1, 2, 3, and 4.
No. Connecting point Remarks
1 Hydraulic oil tank Return oil to hydraulic oil tank
2 Manifold 5(18) Pz pressure(Main pump 3,4)
3 Manifold 5(17) Pz pressure(Main pump 1,2)
4 Pilot shut-off valve Primary pilot pressure
5 Manifold 5(24) Psv pressure(Main pump 1,2,3,4)
2 3 4
1
Upper
Left Right
5
Lower
T144-05-02-019
Upper
1 3
Front Rear
Lower
2
4
T144-05-02-020
T5-2-25
TROUBLESHOOTING / Component Layout
Main Pump
14
1
13
2
12
11
3
4 10
T144-05-02-021
5 6 7 8 9
Right
Front Rear
Left
T5-2-26
TROUBLESHOOTING / Component Layout
Swing Pump
No. Connecting point Remarks
1 Manifold 5(4) Psv pressure(Swing pump 2)
2 Manifold 5(5) Pi pressure(Swing pump 2)
3 Horsepower reducing valve (3) Main pressure
4 Manifold 6(1) Pi pressure(Swing pump 1)
5 Manifold 6(2) Psv pressure(Swing pump 1)
6 Horsepower reducing valve (4) Main pressure
1
4
3
6
T144-05-02-022
Upper
Front Rear
Lower
T5-2-27
TROUBLESHOOTING / Component Layout
Control Valve
No. Connecting point Remarks
1 Travel cut-off valve(4) Pilot pressure for travel forward right
2 Multi shuttle valve(25) Pilot pressure for boom raise
3 Multi shuttle valve(24) Pilot pressure for bucket roll-in
4 Multi shuttle valve(1) Pilot pressure for arm retract
5 Multi shuttle valve(21) Pilot pressure for arm retract
6 Multi shuttle valve(26) Pilot pressure for bucket close
7 Multi shuttle valve(20) Pilot pressure for boom raise
8 Travel cut-off valve(3) Pilot pressure for travel forward left
9 Hydraulic oil tank Return oil to hydraulic oil tank
10 Flow combiner valve change valve(3) Change pressure for flow combiner valve
11 Travel cut-off valve(5) Pilot pressure for travel reverse left
12 Multi shuttle valve(23) Pilot pressure for bucket roll-in
13 Multi shuttle valve(28) Pilot pressure for bucket open
14 Multi shuttle valve(29) Pilot pressure for arm extend
15 Right control valve(16) Pilot pressure for arm extend
16 Left control valve(15) Pilot pressure for arm extend
17 Multi shuttle valve(27) Pilot pressure for bucket roll-out
18 Multi shuttle valve(22) Pilot pressure for bucket boom lower
19 Travel cut-off valve(6) Pilot pressure for travel reverse right
1 2 3 4 5 6 7 8 9
10
19 18 17 16 15 14 13 12 11 T144-03-03-001
Upper
Right Left
Lower
T5-2-28
TROUBLESHOOTING / Component Layout
Swing Control Valve, Swing Motor, Center Joint
No. Connecting point Remarks
1 Swing control valve: Right(8) Pilot pressure for left swing
2 Manifold 4(1) Travel speed change pressure
3 Manifold 4(2) Traveling stop signal pressure
4 Swing control valve: Right(10) Pilot pressure for right swing
5 Manifold 4(3) Swing parking brake release pressure
6 Swing motor: Rear(11) Swing parking brake release pressure
7 Swing inter lock solenoid valve(2) Pilot pressure for left swing
8 Swing control valve: Left(1) Pilot pressure for left swing
9 Swing inter lock solenoid valve(3) Pilot pressure for right swing
10 Swing control valve: Left(4) Pilot pressure for right swing
11 Swing motor: Front(6) Swing parking brake release pressure
1 2 3 4 5
Center Joint
T144-05-02-023
11 10 9 8 7 6
Left
Rear Front
Right
T5-2-29
TROUBLESHOOTING / Component Layout
(Blank)
T5-2-30
TROUBLESHOOTING / Component Layout
PILOT PIPING
(BACKHOE) 1
2
3
4
5
6
22 7
8
20
19
18
17
23 16
24
26
15
14
13
12
11
10
9
29
T144-05-02-032
33 27
30
31
32
28
T144-05-02-033
T5-2-31
TROUBLESHOOTING / Component Layout
NOTE: Parenthesized numbers after component
names in the following table correspond to
the location shown with same number in
each component illustration.
1 2 3
Front
9 Right Left
4
Rear
8 7 6 5
T144-05-02-001
Left Pilot Valve
The valve controls the pilot pressure to the arm and
swing control valves.
No. Connecting point Remarks
1 Pilot shut-off valve(4) Return oil to hydraulic oil tank
2 Multi shuttle valve(4) Pilot pressure for right swing
3 Multi shuttle valve(13) Pilot pressure for arm roll-out
4 Pilot shut-off valve(3) Primary pilot pressure
5 Multi shuttle valve(5) Pilot pressure for left swing
6 Multi shuttle valve(14) Pilot pressure for arm roll-in
1 2
Front
6 3
Right Left
Rear
4
5
T144-05-02-002
T5-2-32
TROUBLESHOOTING / Component Layout
1 2 Front
6 3
Right Left
5 4 Rear
T144-05-02-002
1
6 Front
5 2
4 Right Left
3
Rear
T 117-06-02-004
T5-2-33
TROUBLESHOOTING / Component Layout
Multi Shuttle Valve
Multi-shuttle valve divides and / or combines pressure
oil from each pilot valve and supplies pressure oil to
the control valve pilot ports or the switch valve.
No. Connecting point Remarks
1 − Plug
2 Right control valve(6) Pilot pressure for bucket roll-in
3 Right pilot valve(3) Pilot pressure for bucket roll-out
4 Left pilot valve(2) Pilot pressure for right swing
5 Left pilot valve(5) Pilot pressure for left swing
6 Manifold 2(2) Return to hydraulic oil tank
7 Flow combiner valve change valve(1) Change pressure for flow combiner valve change valve
(Travel pilot pressure)
8 Flow combiner valve change valve(8) Change pressure for flow combiner valve (Boom, arm,
bucket pilot pressure)
9 Swing Pi pressure control solenoid valve(8) Swing Pi pressure
10 Manifold 2(1) Return to hydraulic oil tank
11 Shuttle Valve 2(1) Boom, arm, bucket pilot pressure
12 Shuttle Valve 1(5) Travel pilot pressure
13 Left pilot valve(3) Pilot pressure for arm roll-out
14 Left pilot valve(6) Pilot pressure for arm roll-in
15 Right pilot valve(2) Pilot pressure for boom raise
16 Right pilot valve(5) Pilot pressure for boom lower
17 Manifold 3(7) Return to hydraulic oil tank
18 Left control valve(11) Pilot pressure for boom raise (The pilot pressure is blocked
at the joint section at the control valve.)
19 Left control valve(8) Pilot pressure for arm roll-out (The pilot pressure is blocked
at the joint section at the control valve.)
20 Right control valve(22) Pilot pressure for boom lower
21 Right control valve(4) Pilot pressure for arm roll-in and bucket roll-in(During
operations other than arm roll-out combined operations, the
bucket roll-in pressure is routed.)
22 Right control valve(3) Pilot pressure for boom raise
23 Left control valve(9) Pilot pressure for bucket roll-in
24 Right control valve(21) Pilot pressure for arm roll-in
25 Left control valve(17) Pilot pressure for bucket roll-out
26 Right control valve(6) Pilot pressure for arm roll-in
27 Left control valve(18) Pilot pressure for arm roll-out
28 Manifold 4(7) Pilot pressure for right swing
29 Manifold 4(6) Pilot pressure for left swing
30 Shuttle Valve 3(6) Pilot pressure for travel
31 Shuttle Valve 3(4) Pilot pressure for travel and boom raise
32 Shuttle Valve 5(3) Pilot pressure for arm roll-in
33 Shuttle Valve 3(1) Pilot pressure for bucket roll-out
34 Shuttle Valve 4(3) Pilot pressure for arm roll-in
35 Shuttle Valve 5(1) Pilot pressure for bucket roll-in
36 Shuttle Valve 3(2) Pilot pressure for boom raise
37 Shuttle Valve 5(2) Pilot pressure for arm roll-in and bucket roll-in
38 Shuttle Valve 4(1) Pilot pressure for boom lower
T5-2-34
TROUBLESHOOTING / Component Layout
1 2 3 4 5 6 7
Upper
19
18 8 Right Left
9
17
Lower
10
16 15 14 13 12 11
T144-05-02-024
20 21 22 23 24 25 26 27 28 29
Upper
Right Left
Lower
38 37 36 35 34 33 32 31 30
T144-05-02-024
T5-2-35
TROUBLESHOOTING / Component Layout
Travel Cut-Off Valve
When the traveling signal pressure from the adjuster
cylinder, the spool is shifted, blocking the travel pilot
pressure to stop machine movement.
No. Connecting point Remarks
1 Manifold 4(9) Traveling stop signal pressure
2 Manifold 1(2) Return oil to hydraulic oil tank
3 Left control valve(12) Pilot pressure for travel forward left
4 Right control valve(1) Pilot pressure for travel forward right
5 Left control valve(15) Pilot pressure for travel reverse left
6 Right control valve(23) Pilot pressure for travel reverse right
7 Shuttle valve 1(1) Pilot pressure for travel reverse right
8 Shuttle valve 1(2) Pilot pressure for travel reverse left
9 Shuttle valve 1(3) Pilot pressure for travel forward right
10 Shuttle valve 1(4) Pilot pressure for travel forward left
11 Travel pilot valve(4) Pilot pressure for travel reverse right
12 Travel pilot valve(3) Pilot pressure for travel reverse left
13 Travel pilot valve(1) Pilot pressure for travel forward left
14 Travel pilot valve(6) Pilot pressure for travel forward right
6
5
4
3
2
1 Left Rear
Front Right
7
8
9
10
11
12
13
14
T144-05-02-004
Swing Inter Lock Solenoid Valve
This valve stops swing function while the ladder is lowered.
No. Connecting point Remarks
1 Manifold 4(4) Pilot pressure for right swing
2 Swing control valve: Right(7) Pilot pressure for left swing
3 Swing control valve: Right(9) Pilot pressure for right swing
4 Manifold 4(5) Pilot pressure for left swing
4
Upper
Right Left
Lower
2 1
3 T144-05-02-005
T5-2-36
TROUBLESHOOTING / Component Layout
Swing Pi Pressure Control Solenoid Valve, Flow
Combiner Valve Change Valve
Swing Pi pressure control solenoid valve regulates Pi
pressure to the swing pump. Flow combiner valve
change valve regulates the flow combiner valve
control pressure.
No. Connecting point Remarks
1 Multi shuttle valve(7) Change pressure for flow combiner valve change
valve(Travel pressure)
2 Manifold 1(5) Primary pilot pressure
3 Left control valve(14) Change pressure for flow combiner valve
4 Travel speed change solenoid valve(3) Return oil to hydraulic oil tank
5 Manifold 2(3) Return oil to hydraulic oil tank
6 Multi shuttle valve(8) Change pressure for flow combiner valve(Boom, arm,
bucket pilot pressure)
7 Manifold 3(2) Swing Pi pressure
8 Multi shuttle valve(9) Swing Pi pressure
2 3
1
Upper
Right Left
Lower
8 7 6
T144-05-02-025
Travel Speed Change Solenoid Valve
This valve controls the travel speed change pressure
in two stage.
No. Connecting point Remarks
1 Manifold 1(6) Primary pilot pressure
2 Manifold 4(10) Travel speed change pressure
3 Swing Pi pressure control solenoid valve, flow combiner Return oil to hydraulic oil tank
valve change valve(4)
4 Manifold 4(8) Swing parking brake release pressure
1 2
Upper
Right Left
3 Lower
T144-05-02-007
T5-2-37
TROUBLESHOOTING / Component Layout
Manifold 1
This manifold is connection block for travel pilot valve,
travel cut-off valve, travel speed change solenoid
valve, swing Pi pressure control solenoid valve.
No. Connecting point Remarks
1 Travel pilot valve(5) Return oil to hydraulic oil tank
2 Travel cut-off valve(2) Return oil to hydraulic oil tank
3 Pilot shut-off valve(8) Return oil to hydraulic oil tank
4 Pilot shut-off valve(2) Primary pilot pressure
5 Swing Pi pressure control solenoid valve(2) Primary pilot pressure
6 Travel speed change solenoid valve(1) Primary pilot pressure
7 Travel pilot valve(2) Primary pilot pressure
7
1
6 Front
Right Left
2
5 Rear
4 T144-05-02-008
Manifold 2
Manifold 2 functions as the drain oil junction block to the
hydraulic oil tank from each valve.
No. Connecting point Remarks
1 Multi shuttle valve(10) Return oil to hydraulic oil tank
2 Multi shuttle valve(6) Return oil to hydraulic oil tank
3 Swing Pi pressure control solenoid valve, flow combiner Return oil to hydraulic oil tank
valve change valve(5)
4 Pilot shut-off valve Return oil to hydraulic oil tank
5 Manifold 3(5) Return oil to hydraulic oil tank
3
2
1
4 Upper
Right Left
5
Lower
T144-05-02-009
T5-2-38
TROUBLESHOOTING / Component Layout
Manifold 3
Manifold 3 function as the pump control pressure oil
junction block.
No. Connecting point Remarks
1 Shuttle valve 3(7) Travel pressure
2 Swing Pi pressure control solenoid valve(7) Swing Pi pressure
3 Shuttle valve 3(3) Boom, arm roll-out, bucket pilot pressure
4 Shuttle valve 2(2) Boom, arm, bucket pilot pressure
5 Manifold 2(5) Return oil to hydraulic oil tank
6 Hydraulic oil tank Return oil to hydraulic oil tank
7 Multi shuttle valve(17) Return oil to hydraulic oil tank
8 Manifold 5(19) Pi pressure(Main pump 1,2 and 4)
9 Manifold 5(20) Pi pressure(Main pump 3)
10 Manifold 5(23) Swing Pi pressure(Swing pump 1 and 2)
11 Manifold 5(21) Pic pressure(Main pump 2,3 and 4)
Pe pressure(Main pump 1,2,3 and 4)
12 Manifold 5(22) Pic pressure(Main pump 1)
1 2 3 4 5
Upper
Right Left
Lower
12 7 6
11 10 9 8
T144-05-02-026
Manifold 4
This manifold is connection block for swing pilot
pressure, travel speed change pressure, traveling
stop signal pressure and swing parking brake release
pressure.
No. Connecting point Remarks
1 Center joint(2) Travel speed change pressure
2 Center joint(3) Traveling stop signal pressure
3 Swing motor: Front(5) Swing parking brake release pressure
4 Swing inter lock solenoid valve(1) Pilot pressure for right swing
5 Swing inter lock solenoid valve(4) Pilot pressure for left swing
6 Multi shuttle valve(29) Pilot pressure for left swing
7 Multi shuttle valve(28) Pilot pressure for right swing
8 Travel speed change solenoid valve(4) Swing parking brake release pressure
9 Travel cut-off valve(1) Traveling stop signal pressure
10 Travel speed change solenoid valve(2) Travel speed change pressure
5 6
7 Upper
4
3 8
Front Rear
2 9
1
10 Lower
T144-05-02-011
T5-2-39
TROUBLESHOOTING / Component Layout
Manifold 5
Manifold 5 functions as the pump control pressure oil
junction block.
No. Connecting point Remarks
1 Main pump 3(7) Pi pressure(Main pump 3)
2 Main pump 4(5) Pic pressure(Main pump 3 and 4)
3 Main pump 4(3) Psv pressure(Main pump 3 and 4)
4 Swing pump 2(1) Psv pressure(Swing pump 2)
5 Swing pump 2(2) Pi pressure(Swing pump 2)
6 Main pump 4(2) Pe pressure(Main pump 3 and 4)
7 Manifold 6(14) Psv pressure(Main pump 1 and 2, swing pump 1)
8 Manifold 6(15) Pi pressure(Swing pump 1)
9 Manifold 6(13) Pic pressure(Main pump 1)
10 Manifold 6(12) Pic pressure(Main pump 2)
Pe pressure(Main pump 1 and 2)
11 Manifold 6(11) P2 pressure(Main pump 1 and 2)
12 Manifold 6(10) Pi pressure(Main pump 1 and 2)
13 Manifold 6(9) Pz pressure(Main pump 1 and 2)
14 Main pump 4(4) P2 pressure(Main pump 3 and 4)
15 Main pump 4(1) Pz pressure(Main pump 3 and 4)
16 Main pump 4(6) Pi pressure(Main pump 4)
17 EHC valve (3) Pz pressure(Main pump 1 and 2)
18 EHC valve (2) Pz pressure(Main pump 3 and 4)
19 Manifold 3(8) Pi pressure(Main pump 1, 2 and 4)
20 Manifold 3(9) Pi pressure(Main pump 3)
21 Manifold 3(11) Pic pressure(Main pump 2, 3 and 4)
Pe pressure(Main pump 1, 2, 3 and 4)
22 Manifold 3(12) Pic pressure(Main pump 1)
23 Manifold 3(10) Swing Pi pressure(Swing pump 1 and 2)
24 EHC valve (5) Psv pressure(Main pump 1,2,3 and 4, swing pump 1 and 2)
1 2 3 4 5 6
24 7
23 8
9
22
Right
21 10
11
20 Front Rear
19 12
18 Left
13
17
14
16 15
T144-05-02-012
T5-2-40
TROUBLESHOOTING / Component Layout
Manifold 6
Manifold 6 functions as the pump control pressure oil
junction block.
No. Connecting point Remarks
1 Swing pump 1(4) Pi pressure(Swing pump 1)
2 Swing pump 1(5) Psv pressure(Swing pump 1)
3 Manifold 7(13) Psv pressure(Main pump 1 and 2)
4 Manifold 7(12) Pic pressure(Main pump 1)
5 Manifold 7(11) Pic pressure(Main pump 2)
6 Manifold 7(10) P2 pressure(Main pump 1 and 2)
7 Manifold 7(9) Pi pressure(Main pump 1 and 2)
8 Manifold 7(8) Pz pressure(Main pump 1 and 2)
9 Manifold 5(13) Pz pressure(Main pump 1 and 2)
10 Manifold 5(12) Pi pressure(Main pump 1 and 2)
11 Manifold 5(11) P2 pressure(Main pump 1 and 2)
12 Manifold 5(10) Pic pressure(Main pump 2)
13 Manifold 5(9) Pic pressure(Main pump 1)
14 Manifold 5(7) Psv pressure(Main pump 1 and 2, swing pump 1)
15 Manifold 5(8) Pi pressure(Swing pump 1)
15
2
14 3
13 4 Upper
12 5
Front Rear
11 6
10 7 Lower
9 8
T144-05-02-013
T5-2-41
TROUBLESHOOTING / Component Layout
Manifold 7
Manifold 7 functions as the pump control pressure oil
junction block.
No. Connecting point Remarks
1 Main pump 1(12) Psv pressure(Main pump 1 and 2)
2 Main pump 1(11) Pic pressure(Main pump 1)
3 Main pump 2(8) Pic pressure(Main pump 2)
4 Main pump 1(13) Pe pressure(Main pump 1 and 2)
5 Main pump 1(9) P2 pressure(Main pump 1 and 2)
6 Main pump 1(10) Pi pressure(Main pump 1 and 2)
7 Main pump 1(14) Pz pressure(Main pump 1 and 2)
8 Manifold 6(8) Pz pressure(Main pump 1 and 2)
9 Manifold 6(7) Pi pressure(Main pump 1 and 2)
10 Manifold 6(6) P2 pressure(Main pump 1 and 2)
11 Manifold 6(5) Pic pressure(Main pump 2)
12 Manifold 6(4) Pic pressure(Main pump 1)
13 Manifold 6(3) Psv pressure(Main pump 1 and 2)
1 2 3 4 5 6 7
Right
Front Rear
Left
13 12 11 10 9 8
T144-05-02-014
T5-2-42
TROUBLESHOOTING / Component Layout
Shuttle Valve ȑ
During travel operations, shuttle valve 1 supplies the
travel pilot pressure to the multi-shuttle valve.
No. Connecting point Remarks
1 Travel cut-off valve(7) Pilot pressure for travel reverse right
2 Travel cut-off valve(8) Pilot pressure for travel reverse left
3 Travel cut-off valve(9) Pilot pressure for travel forward left
4 Travel cut-off valve(10) Pilot pressure for travel forward right
5 Multi shuttle valve(12) Travel pressure
1 2
3
4
Left Rear
Front Right
T144-05-02-015
Shuttle Valve 2
During operations other than swing, shuttle valve 2
supplies flow control pressure (Pi pressure) to main
pumps 1, 2, and 4.
No. Connecting point Remarks
1 Multi shuttle valve(11) Boom, arm, bucket pilot pressure
2 Manifold 3(5) Boom, arm, bucket, travel pilot pressure
3 Shuttle valve 3(5) Travel pressure, boom raise pilot pressure
1
2
Upper
Right Left
Lower
T144-05-02-027
T5-2-43
TROUBLESHOOTING / Component Layout
Shuttle Valve 3
During operations other than swing and arm roll-out,
shuttle valve 3 supplies flow control pressure (Pi
pressure) to main pump 3.
No. Connecting point Remarks
1 Multi shuttle valve(33) Pilot pressure for bucket roll-out
2 Multi shuttle valve(36) Pilot pressure for boom raise
3 Manifold 3(3) Boom, arm roll-out, bucket pilot pressure
4 Multi shuttle valve(31) Pilot pressure for travel and boom raise
5 Shuttle valve 2(3) Pilot pressure for travel and boom raise
6 Multi shuttle valve(30) Travel pressure
7 Manifold 3(1) Travel pressure
8 Shuttle valve 4(2) Pilot pressure for boom lower and arm roll-in
1 2 3 4
Upper
Right Left
Lower
8 7 6 5
T144-05-02-028
Shuttle Valve 4
During operations other than boom lower and arm
roll-in, shuttle valve 4 supplies pilot pressure to shuttle
valve 3.
No. Connecting point Remarks
1 Multi shuttle valve(38) Pilot pressure for boom lower
2 Manifold 3(8) Pilot pressure for boom lower and arm roll-in
3 Multi shuttle valve(34) Pilot pressure for arm roll-in
4 Shuttle valve 5(4) Pilot pressure for arm roll-in
1
Upper
Right Left
3
Lower
4
T144-05-02-029
T5-2-44
TROUBLESHOOTING / Component Layout
Shuttle Valve 5
No. Connecting point Remarks
1 Multi shuttle valve(35) Pilot pressure for bucket roll-in
2 Multi shuttle valve(37) Pilot pressure for arm roll-in and bucket roll-in
3 Multi shuttle valve(32) Pilot pressure for arm roll-in
4 Shuttle valve 4(4) Pilot pressure for arm roll-in
1 2
Upper
Right Left
Lower
4 3
T144-05-02-030
T5-2-45
TROUBLESHOOTING / Component Layout
EHC Valve
EHC valve supplies power increase control pressure
Pz to main pumps 1, 2, 3, and 4.
No. Connecting point Remarks
1 Hydraulic oil tank Return oil to hydraulic oil tank
2 Manifold 5(18) Pz pressure(Main pump 3,4)
3 Manifold 5(17) Pz pressure(Main pump 1,2)
4 Pilot shut-off valve Primary pilot pressure
5 Manifold 5(24) Psv pressure(Main pump 1,2,3,4)
2 3 4
1
Upper
Left Right
5
Lower
T144-05-02-019
Upper
1 3
Front Rear
Lower
2
4
T144-05-02-020
T5-2-46
TROUBLESHOOTING / Component Layout
Main Pump
No. Connecting point Remarks
1 Manifold 5(15) Pz pressure(Main pump 3 and 4)
2 Manifold 5(6) Pe pressure(Main pump 3 and 4)
3 Manifold 5(3) Psv pressure(Main pump 3 and 4)
4 Manifold 5(14) P2 pressure(Main pump 3 and 4)
5 Manifold 5(2) Pic pressure(Main pump 3 and 4)
6 Manifold 5(16) Pi pressure(Main pump 4)
7 Manifold 5(1) Pi pressure(Main pump 3)
8 Manifold 7(3) Pic pressure(Main pump 2)
9 Manifold 7(5) P2 pressure(Main pump 2)
10 Manifold 7(6) Pi pressure(Main pump 1 and 2)
11 Manifold 7(2) Pic pressure(Main pump 1)
12 Manifold 7(1) Psv pressure(Main pump 1 and 2)
13 Manifold 7(4) Pe pressure(Main pump 1 and 2)
14 Manifold 7(7) Pz pressure(Main pump 1 and 2)
14
1
13
2
12
11
3
4 10
T144-05-02-021
5 6 7 8 9
Right
Front Rear
Left
T5-2-47
TROUBLESHOOTING / Component Layout
Swing Pump
No. Connecting point Remarks
1 Manifold 5(4) Psv pressure(Swing pump 2)
2 Manifold 5(5) Pi pressure(Swing pump 2)
3 Horsepower reducing valve (3) Main pressure
4 Manifold 6(1) Pi pressure(Swing pump 1)
5 Manifold 6(2) Psv pressure(Swing pump 1)
6 Horsepower reducing valve (4) Main pressure
1
4
3
6
T144-05-02-022
Upper
Front Rear
Lower
T5-2-48
TROUBLESHOOTING / Component Layout
Control Valve
(Serial Number from 000501 to 000547)
No. Connecting point Remarks
1 Travel cut-off valve(4) Pilot pressure for travel forward right
2 Left control valve(10) Pilot pressure for boom raise
3 Multi shuttle valve(22) Pilot pressure for boom raise
4 Multi shuttle valve(21) Pilot pressure for arm roll-in and bucket roll-in(During
operations other than arm roll-out combined operations, the
bucket roll-in pressure is routed.)
5 Left control valve(7) Pilot pressure for arm roll-in
6 Multi shuttle valve(26) Pilot pressure for arm roll-in
7 Right control valve(5) Pilot pressure for arm roll-in
8 Multi shuttle valve(19) Pilot pressure for arm roll-in(The pilot pressure is blocked at
the joint section at the control valve.)
9 Multi shuttle valve(23) Pilot pressure for bucket roll-in
10 Right control valve(2) Pilot pressure for boom raise
11 Multi shuttle valve(28) Pilot pressure for boom raise(The pilot pressure is blocked
at the joint section at the control valve.)
12 Travel cut-off valve(3) Pilot pressure for travel forward left
13 Hydraulic oil tank Return oil to hydraulic oil tank
14 Flow combiner valve change valve(5) Change pressure for flow combiner valve
15 Travel cut-off valve(5) Pilot pressure for travel reverse left
16 Hydraulic oil tank Return oil to hydraulic oil tank
17 Multi shuttle valve(25) Pilot pressure for bucket roll-out
18 Multi shuttle valve(27) Pilot pressure for arm roll-out
19 Right control valve(20) Pilot pressure for arm roll-out
20 Left control valve(19) Pilot pressure for arm roll-out
21 Multi shuttle valve(24) Pilot pressure for arm roll-in
22 Multi shuttle valve(20) Pilot pressure for boom lower
23 Travel cut-off valve(6) Pilot pressure for travel reverse right
13
14
23 22 21 20 19 18 17 16 15
Upper
T144-05-02-031
Right Left
Lower
T5-2-49
TROUBLESHOOTING / Component Layout
Control Valve
(Serial Number from 000548 and later)
No. Connecting point Remarks
1 Travel cut-off valve(4) Pilot pressure for travel forward right
2 Left control valve(10) Pilot pressure for boom raise
3 Multi shuttle valve(22) Pilot pressure for boom raise
4 Multi shuttle valve(21) Pilot pressure for arm roll-in and bucket roll-in(During
operations other than arm roll-out combined operations, the
bucket roll-in pressure is routed.)
5 Left control valve(7) Pilot pressure for arm roll-in
6 Multi shuttle valve(26) Pilot pressure for arm roll-in
7 Right control valve(5) Pilot pressure for arm roll-in
8 Multi shuttle valve(19) Pilot pressure for arm roll-in(The pilot pressure is blocked at
the joint section at the control valve.)
9 Multi shuttle valve(23) Pilot pressure for bucket roll-in
10 Right control valve(2) Pilot pressure for boom raise
11 Multi shuttle valve(28) Pilot pressure for boom raise(The pilot pressure is blocked
at the joint section at the control valve.)
12 Travel cut-off valve(3) Pilot pressure for travel forward left
13 Hydraulic oil tank Return oil to hydraulic oil tank
14 Flow combiner valve change valve(5) Change pressure for flow combiner valve
15 Travel cut-off valve(5) Pilot pressure for travel reverse left
16 Right control valve (23) Pilot pressure for boom lower
17 Multi shuttle valve(25) Pilot pressure for bucket roll-out
18 Multi shuttle valve(27) Pilot pressure for arm roll-out
19 Right control valve(20) Pilot pressure for arm roll-out
20 Left control valve(19) Pilot pressure for arm roll-out
21 Multi shuttle valve(24) Pilot pressure for arm roll-in
22 Multi shuttle valve(20) Pilot pressure for boom lower
23 Left control valve (16) Pilot pressure for boom lower
24 Travel cut-off valve(6) Pilot pressure for travel reverse right
13
14
24 23 22 21 20 19 18 17 16 A 15
Upper
T144-05-02-035
NOTE: Adapter with key No. (A) is used to interrupt Right Left
the circuit and has no hole
Lower
T5-2-50
TROUBLESHOOTING / Component Layout
Swing Control Valve, Swing Motor, Center Joint
No. Connecting point Remarks
1 Swing control valve: Right(8) Pilot pressure for left swing
2 Manifold 4(1) Travel speed change pressure
3 Manifold 4(2) Traveling stop signal pressure
4 Swing control valve: Right(10) Pilot pressure for right swing
5 Manifold 4(3) Swing parking brake release pressure
6 Swing motor: Rear(11) Swing parking brake release pressure
7 Swing inter lock solenoid valve(2) Pilot pressure for left swing
8 Swing control valve: Left(1) Pilot pressure for left swing
9 Swing inter lock solenoid valve(3) Pilot pressure for right swing
10 Swing control valve: Left(4) Pilot pressure for right swing
11 Swing motor: Front(6) Swing parking brake release pressure
1 2 3 4 5
Center Joint
T144-05-02-023
11 10 9 8 7 6
Left
Rear Front
Right
T5-2-51
TROUBLESHOOTING / Component Layout
(Blank)
T5-2-52
TROUBLESHOOTING / Troubleshooting A
INTRODUCTION
T5-3-1
TROUBLESHOOTING / Troubleshooting A
HOW TO READ CUMMINS ENGINE FAULT
CODES
1. Turn the key switch OFF. Turn the troubleshoot- 6. After approx. one second, the engine stop indica-
ing side key switch ON (with the engine stopped). tor starts to flash. This flashing number indicates
the third number.
In case the fault code is stored:
The engine warning indicator, engine stop indica- 7. Finally, the engine warning indicator flashes once.
tor, and engine protection indicator come ON in
consecutive order. Then, all indicators go OFF 8. The fault code is repeatedly displayed in the order
once. After that, the indicator corresponding to the of step 4 to 8 described above.
trouble continues flashing.
In case more than one fault codes are stored:
In case no fault code is stored: While a fault code is displayed as described above,
The engine warning indicator, engine stop indica- when the engine troubleshooting switch B is turned to
tor, and engine protection indicator come ON in the upper side once, the next fault code is displayed.
consecutive order. Then, all indicators go OFF. Turn the engine troubleshooting switch B to the lower
side to display the previous fault code.
2. When engine troubleshooting switch A is turned
ONȌȀthe engine warning indicator and engine stop NOTE: In case only one fault code is stored, the
indicator come ON in order. (when no fault code is displayed fault code does not change even
stored, the three indicators stay ON.) if the engine troubleshooting switch B is
operated.
3. The engine warning indicator flashes once.
T5-3-2
TROUBLESHOOTING / Troubleshooting A
T144-05-03-001
Troubleshooting Switch A
Troubleshooting Switch A (Front Engine)
(Rear Engine)
Troubleshooting Switch B
(Front Engine)
Troubleshooting Switch B
(Rear Engine)
M144-07-096
ON
OFF
One second One second
T5-3-3
TROUBLESHOOTING / Troubleshooting A
CUMMINS ENGINE FAULT CODE INFOR-
MATION
FAULT
CODE REASON EFFECT (Only when fault code is active)
INDICATOR
111 Error internal to the ECM related to memory No action by the ECM taken.
Red hardware failures or internal processor
communication failures.
* 112 The error between estimated timing fueling and Depending on the calibration the engine will shut
Red desired timing fueling is outside of acceptable down or speed derate or no action by the ECM is
limits. taken.
* 113 High voltage detected at pin 20 of the engine No action by the ECM is taken. Actuator is open or
Yellow harness connector. closed, or partially closed. Engine power output
will vary. Fault code 112 will be logged.
116 More than 4.78 volts DC detected at the timing Depending on the calibration the engine will shut
Red pressure sensor signal pin No.33 of the engine down or speed derate or no action by the ECM is
harness. taken.
117 Less than 0.15 volts DC detected at the timing Depending on the calibration the engine will shut
Red pressure sensor signal pin No.33 of the engine down or speed derate or no action by the ECM is
harness. taken.
* 121 No engine speed signal detected at one pair of No action by the ECM is taken.
Yellow pins, either pins No.27, 28 or pins No.37, 38 of the
engine harness.
* 122 More than 4.72 volts DC detected at the intake Engine power derate to no-air setting.
Off manifold air pressure sensor signal pin No.35 of
the engine harness.
* 123 Less than 0.33 volts DC detected at the intake Engine power derate to no-air setting.
Off manifold air pressure sensor signal pin No.35 of
the engine harness.
131 More than 4.20 volts DC detected at the throttle Calibration dependent power and speed derate.
Red position signal pin No.29 of the OEM interface
harness.
132 Less than 0.13 volts DC detected at throttle Calibration dependent power and speed derate.
Red position signal pin No.29 of the OEM interface
harness.
135 More than 4.88 volts DC detected at oil pressure No engine protection for oil pressure.
Yellow sensor signal pin No.24 of the engine harness.
141 Less than 0.31 volts DC detected at the oil No engine protection for oil pressure.
Yellow pressure sensor signal pin No.24 of the engine
harness.
* 143 Low oil pressure has been detected. Voltage Calibration dependent progressive power derate
Engine signal at oil pressure signal pin No.24 of the and engine shutdown with increasing time after
Protection engine harness indicates oil pressure lower than alert.
-1
103 kPa [15 psi] at 600 min (rpm); 131 kPa [19
-1
psi] at 800 min (rpm); 165 kPa [24 psi] at 1500
-1
min (rpm); and 207 kPa [30 psi] above 2100
-1
min (rpm).
144 More than 4.95 volts DC detected at the coolant Possible white smoke. No engine protection for
Yellow temperature signal pin No.22 of the engine coolant temperature.
harness.
145 Less than 0.21 volts DC detected at the coolant Possible white smoke. No engine protection for
Yellow temperature signal pin No.22 of the engine coolant temperature.
harness.
TM
NOTE: * Can be detected by Echek only.
T5-3-4
TROUBLESHOOTING / Troubleshooting A
FAULT
CODE REASON EFFECT (Only when fault code is active)
INDICATOR
151 High coolant temperature has been detected. Calibration dependent progressive power and
Engine Voltage signal at coolant temperature signal pin speed derate and engine shut down as
Protection No.22 indicates coolant temperature above 100 temperature increases over thresholds.
°C [212 °F].
153 More than 4.88 volts DC detected at intake No engine protection for intake manifold air
Yellow manifold air temperature signal pin No.23 of the temperature.
engine harness.
154 Less than 0.08 volts DC detected at intake No engine protection for intake manifold air
Yellow manifold air temperature signal pin No.23 engine temperature.
harness.
* 155 High intake air manifold temperature has been Calibration dependent progressive power and
Engine detected. Voltage signal at intake manifold sir speed derate and engine shutdown as
Protection temperature signal pin No.23 indicates intake temperature increases over thresholds.
manifold air temperature above 104 °C [220 °F].
221 More than 4.78 volts DC detected at the ambient No action by the ECM is taken.
Yellow air temperature signal pin No.34 of the engine
harness.
* 234 Engine speed signals on No.27 and 28 and/or 37 Fuel shutoff valve de-energizes ( valve closes).
Red and 38 of engine harness indicate an engine Re-energizes (FSO valve opens) when engine
-1 -1
speed greater than 2650 min (rpm). speed falls below 2130 min (rpm).
235 Low coolant level has been detected. Voltage Calibration dependent progressive power and
Engine signal on the coolant level signal pin No.23 of the speed derate and engine shut down with
Protection OEM interface harness indicates low radiator increasing time after alert.
coolant level on the vehicle.
343 Microprocessor communication error internal to Variable; Performance will or will not be affected.
Yellow the ECM.
* 346 ECM Powerdown internal data store error. Powerdown data (which includes maintenance
Off monitoring, current ECM/engine delta times, past
fault data) are lost.
* 415 Very low oil pressure has been detected. Voltage Calibration dependent progressive power and
Engine signal at oil pressure signal pin 24 of the engine speed derate and engine shutdown with
Protection harness indicates oil pressure lower than 83 kPa increasing time after alert.
-1
[12 psi] at 600 min (rpm); 110 kPa [16 psi] at 800
-1 -1
min (rpm); 138 kPa [20 psi] at 1500 min (rpm);
-1
and 172 kPa [25 psi] above 2000 min (rpm).
422 Voltage detected simultaneously on both the No engine protection for coolant level.
Yellow coolant level high and low signal pin No.14 and 23
of the OEM interface harness - or - no voltage
detected on either pin.
* 441 Less than 12.0 volts DC battery voltage detected ECM voltage supply approaching level at which
Off at ECM. unpredictable operation will occur.
442 More than 38.0 volts DC battery voltage detected ECM damage will occur.
Yellow at ECM.
451 More than 4.78 volts DC detected at the rail Depending on the calibration the engine will
Red pressure sensor signal pin No.31 of the engine shutdown or power derate or no action by the ECM
harness. is taken.
TM
NOTE: * Can be detected by Echek only.
T5-3-5
TROUBLESHOOTING / Troubleshooting A
FAULT
CODE REASON EFFECT (Only when fault code is active)
INDICATOR
452 Less than 0.15 volts DC detected at the rail Depending on the calibration the engine signal will
Red pressure sensor signal pin No.31 of the engine shutdown or power derate or no action by the ECM
harness. is taken.
* 455 Rail Actuator circuit is open, or supply pin No.3 is No action by the ECM is taken. Actuator is closed,
Red shorted to battery voltage or ground, or return pin or partially closed. Engine will not run, or runs at
No.10 is shorted to battery voltage or ground in one speed. Fault code 514 will also be logged.
the engine harness.
* 514 The error between estimated rail fueling and Depending on the calibration the engine will speed
Red desired rail fueling is outside of acceptable limits. derate or no action by the ECM is taken. Engine
will overspeed, or run at one speed, or not run.
* 553 Fuel rail pressure exceeds a normal limit. Fuel shutoff valve de-energized (valve closes).
Red Reenergizes (FSO valve opens) when fuel rail
pressure falls below acceptable limit for current
engine speed.
554 More than 1.83 volts DC or less than 0.50 volts DC Engine power derate of 25 percent.
Yellow detected at the rail pressure signal pin No.31 of
the engine harness at engine key on.
TM
NOTE: * Can be detected by Echek only.
T5-3-6
TROUBLESHOOTING / Troubleshooting A
(Blank)
T5-3-7
TROUBLESHOOTING / Troubleshooting B
TROUBLESHOOTING B PROCEDURE
YES (OK)
(2)
ѕ (1) After checking or measuring item (1), select either YES (OK) or NO
(NOT OK) and proceed to item (2) or (3).
(3)
NO (NOT OK)
Special instructions or reference item are indicated in the spaces under the box. Incorrect
ѕ measuring or checking methods will render troubleshooting impossible, and may damage
components as well.
·Key switch: ON
ѕ Causes are stated in a thick-line box. Scanning through thick-lined boxes, possible causes
can be seen without going through the flow chart.
Open End
Side Harness End Connector
T158-05-03-001
T5-4-1
TROUBLESHOOTING / Troubleshooting B
CORRELATION BETWEEN TROUBLE
SYMPTOMS AND PART FAILURES
Engine System
Possible Causes Controller Engine Control System
MC (B) EMC Accel- Auto- Auto- Start- Start- Start- Ther-
erator Idle Idle ing ing ing mo
Sensor Switch Pres- Aid Aid Aid Guard
sure Sole- Relay Switch Switch
Switch noid
Malfunctions Valve
E-1 Engine Speed does not
change even if the engine
z z
speed control lever is
operated.
E-2 In auto-idle mode, engine
speed does not increase
z z
even if a control lever is
operated.
E-3 Engine speed does not
decrease even if the auto-idle z z z z
switch is pushed.
E-4 Starting aid mechanism does
z z z z
not work.
T5-4-2
TROUBLESHOOTING / Troubleshooting B
Swing System
Hydraulic
Pump Control Valve Swing Function System
Possible Causes Components
Pilot Valve Swing Spool Main Over- Swing Swing Swing Swing
Pump/ Relief load Motor Relief Reduc Inter
Regu- Valve Relief Valve -tion Lock
lator Valve Gear Sole-
Malfunctions noid
Valve
S-1 Swing function does not
operater or operates slowly,or z z z z z z z z
swing power is weak.
S-2 Swing function excessively
drifts after the control lever is z z z z z z z
returned to neutral.
Travel System
Hydraulic Control
Travel Function System
Possible Causes Components Valve
Center Joint Flow Travel Travel Travel Travel Travel Travel Travel
Combi- Motor/ Brake Reduc- Cut-off Speed Speed Speed
ner Parking Valve tion Valve Change Change Change
Valve Brake Gear Sole- Relay Switch
noid
Malfunctions Valve
T-1 Travel function does not
operate or operates slowly, or z z z
travel power is weak.
T-2 Travel mode does not shift to
z z z
the fast speed mode.
T-3 Travel mode does not shift to
z z z
the slow speed mode.
T-4 Machine mistracks z z z z z
Auto-Lubrication System
Cont- Hydraulic Travel Func-
Automatic Lubrication System
Possible Causes roller Components tion System
MC Pilot Pilot Travel Speed Grease Auto- Auto- Auto- Auto- Auto-
(A) Valve Relief Change Pump Lubri- Lubri- Lubri- Lubri- Lubri-
Valve Switch cation cation cation cation cation
Sole- Sole- Switch Relay Grease
noid noid Pressure
Malfunctions Valve 1 Valve 2 Switch
G-1 Grease pump does not
operate (both automatically z z z z z z z z
and manually)
G-2 Auto-lubrication switch does
z z z
not operated.
G-3 Indicator comes ON when
z
auto-lubrication is selected.
T5-4-3
TROUBLESHOOTING / Troubleshooting B
ENGINE SYSTEM TROUBLESHOOTING
E-1 Engine Speed does not change even if the
engine speed control lever is operated.
Checking Instructions
• If the engine stop indicator is ON, refer to Trou-
bleshooting A.
·Measurement harness
ȀFront : Parts Number 3046248 Faulty accelerator sensor
ȀRear : Parts Number 3046249
NO
Connectors (Harness end connector terminals seen from the open end side)
2 1
2
3 1
3
4
T5-4-4
TROUBLESHOOTING / Troubleshooting B
E-2 In auto-idle mode, engine speed does not in-
crease even if a control lever is operated.
Connectors
(Harness end connector terminals seen from the open end side)
1 2
MC (B) Connector A
66 65 64 63 62 61 60 59 58 57 46 45 44 43 42 41 40 39 38 37 26 25 24 23 22 21 20 19 18 17 8 7 6 5 4 3 2 1
76 75 74 73 72 71 70 69 68 67 56 55 54 53 52 51 50 49 48 47 36 35 34 33 32 31 30 29 28 27 16 15 14 13 12 11 10 9
T5-4-5
TROUBLESHOOTING / Troubleshooting B
E-3 Engine speed does not decrease even if the
auto-idle switch is pushed.
Connectors (Harness end connector terminals seen from the open end side)
d b a 20 31
21 8 30
e c 9 19
10 2 18
22 3 7 29
11 1 17
23 4 6 28
12 5 16
13 15
24 14 27
25 26
MC (B) Connector A
66 65 64 63 62 61 60 59 58 57 46 45 44 43 42 41 40 39 38 37 26 25 24 23 22 21 20 19 18 17 8 7 6 5 4 3 2 1
76 75 74 73 72 71 70 69 68 67 56 55 54 53 52 51 50 49 48 47 36 35 34 33 32 31 30 29 28 27 16 15 14 13 12 11 10 9
MC (B) Connector B
35 34 33 32 31 30 29 28 27 26 25 24 23 15 14 13 12 11 10 9 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 22 21 20 19 18 17 16 8 7 6 5
T5-4-6
TROUBLESHOOTING / Troubleshooting B
T5-4-7
TROUBLESHOOTING / Troubleshooting B
E-5 Starting Aid Mechanism does not work.
T5-4-8
TROUBLESHOOTING / Troubleshooting B
d b a
e c
T5-4-9
TROUBLESHOOTING / Troubleshooting B
ACTUATOR OPERATING SYSTEM TROU-
BLESHOOTING
A-1 All actuators are slow, or do not operate.
Checking Instructions
• The main hydraulic circuit is grouped into the front
attachment, travel, and swing systems. In case
both systems begin malfunctioning at the same
time, the pilot system or engine system may be
the cause.
• When a load is applied, if engine speed decrease
remarkably, the engine may be the cause.
Checking Instruction
• Seizure of pilot valve spool or control valve spool
may be the cause of the trouble.
T5-4-10
TROUBLESHOOTING / Troubleshooting B
FRONT ATTACHMENT SYSTEM TROU-
BLESHOOTING
F-1 One or more front cylinders move slowly.
YES Faulty relevant cyl-
inder.
Check if relevant
YES
cylinder has inter-
nal leakage.
Spool is stuck in
Check if relevant relevant control
YES NO
overload relief valve.
valve is normal.
·Refer to the OP- Faulty relevant
ERATIONAL PER- overload relief
Check if relevant pi- FORMANCE TEST NO valve.
lot secondary pres- section for the
sure is normal. measurement pro-
cedure. YES Faulty multi-shuttle
·Refer to the OPERA- valve
TIONAL PERFORM- Check if pilot sec-
ANCE TEST section for ondary pressure at
the measurement pro- multi-shuttle valve
cedure. NO inlet port (pilot
valve side) is nor- Faulty pilot valve.
mal. NO
T144-05-04-001
11 9 7 5 4 2
Loading Shovel:
1 - Swing Left 4 - Arm Retract 7 - Bucket Roll-Out 10 - Bucket Roll-In
2 - Travel (Pilot Pressure) 5 - Arm Extend 8 - Bucket Close 11 - Boom Lower
3 - Swing Right 6 - Bucket Open 9 - Boom Raise
Backhoe:
1 - Swing Left 4 - Arm Roll-Out 6 - Bucket Roll-Out 9 - Boom Raise
2 - Travel (Pilot Pressure) 5 - Arm Roll-In 8 - Bucket Roll-In 11 - Boom Lower
3 - Swing Right
T5-4-11
TROUBLESHOOTING / Troubleshooting B
F-2 Front attachment drifts excessively.
·Refer to the
OPERATIONAL Faulty relevant
PERFORMANCE overload relief
TEST section for NO valve.
the measurement
procedure.
T5-4-12
TROUBLESHOOTING / Troubleshooting B
F-3 Front attachment briefly drops, then begins
to move when the control lever is operated
T5-4-13
TROUBLESHOOTING / Troubleshooting B
F-4 Bucket digging force is weak in boom
raise/bucket digging combined operation
(Loading Shovel).
Checking Instruction
• In boom raise/bucket digging combined operation,
bucket priority valve is switched to move the boom
raise/ bucket digging spool, in the left control valve,
to the bucket digging side. (Refer to the Hydraulic
System group in the SYSTEM section.)
Checking Instruction
• In arm retraction/other functions (travel, boom
raise/bucket digging, or bucket open-close) com-
bined operation, the arm retraction switch valve is
switched. Thereby, the arm retraction pilot pres-
sure is guided from the left control valve to the
arm spool in the right control valve. (Refer to the
Hydraulic System group in the SYSTEM section.)
T5-4-14
TROUBLESHOOTING / Troubleshooting B
(Blank)
T5-4-15
TROUBLESHOOTING / Troubleshooting B
SWING SYSTEM TROUBLESHOOTING
Checking Instruction
• Be sure to check that the ladder indicator is OFF
(the ladder is raised.).
M16 Bolt: : 8 mm
Plug (1): PT 1/2
T117-06-04-002
T5-4-16
TROUBLESHOOTING / Troubleshooting B
T5-4-17
TROUBLESHOOTING / Troubleshooting B
S-2 Swing function excessively drifts after the
control lever is returned to neutral.
Checking instruction
• If the upperstructure jerks, the cause may be
valve related; without jerking, it may be spool re-
lated.
2
NOTE: 1 kgf/cm = 98.07 kPa
NO Failure of swing
motor or swing re-
Inspect if any ab- duction gear.
YES normalities are
found on control
valve swing spool. Swing spool fail-
Check if secondary ure. Replace swing
YES pilot pressure
2
is 0 ·Disassemble to spool or control
kgf/cm with swing inspect. YES valve.
control lever in
neutral position.
·Refer to the OP- Pilot valve failure.
ERATIONAL NO
PERFORMANCE
Check if swing re- TEST section for
lief pressure is the measurement
normal. procedure.
·Refer to the OP- Switch overload re- YES Swing relief valve
ERATIONAL lief valve on swing failure.
PERFORMANCE control valve with
TEST section for overload relief
the measurement valve on main con-
procedure. NO trol valve (except
bucket close sec- Swing overload re-
tion). Check if trou- NO lief valve failure.
ble still appears.
T5-4-18
TROUBLESHOOTING / Troubleshooting B
TRAVEL SYSTEM TROUBLESHOOTING
T-1 Travel function does not operate or operates
slowly, or travel power is weak.
Checking Instructions
• It is unlikely for both sides of the same function to
fail, such as the left and right travel pilot valves,
travel motors, and travel control valve spools, at
the same time.
• If both tracks do not move, the cause may be in
the pilot system which is used commonly for both
tracks. However, it should be noted that not only
the travel function but other functions should be
effected asȀ Ȁwell if the cause is primary pilot pres-
sure failure. The flow chart in this section is pro-
vided for failure of both tracks. If only one track
has failed, refer to the troubleshooting chart T-4.
M16 Bolt: : 8 mm
Plug (1): PT 1/2 1
T117-06-03-003
T5-4-19
TROUBLESHOOTING / Troubleshooting B
T-2 Travel mode does not shift to the fast speed
mode.
Checking instruction
• Check the fuse if other solenoid valves are not
l
working as well.
2
NOTE: 1 kg/cm =98.07 kPa
2 Failure of travel
37 kgf/cm or more motor displace-
ment control
mechanism.
Disconnect line
end from output
port of travel speed
change solenoid Faulty travel mode
valve. Install a Switch travel switch or breakage
speed change re- NO
pressure gauge on of harness be-
the port. Measure lay with a general tween travel mode
Disconnect travel purpose relay. switch and relay.
output pressure. speed change re- YES
Check if pressure
lay. Connect termi- reducing valve con-
·Travel mode nal No.3 and No.5
switch: ON trol pressure be- Faulty travel speed
on harness end comes 37 kgf/cm
2
change relay.
connector with a YES
or more.
2
28±2 kgf/cm clip. Check of
pressure reducing Faulty travel speed
valve control pres- change solenoid
sure becomes 37 valve or breakage
2
kgf/cm or more. of harness be-
NO tween travel speed
change solenoid
valve and relay.
1 2
3 5
T144-04-04-001
T5-4-20
TROUBLESHOOTING / Troubleshooting B
T-3 Travel mode does not shift to the slow speed
mode.
2
NOTE: 1 kg/cm =98.07 kPa
Output Port.
T144-04-04-001
T5-4-21
TROUBLESHOOTING / Troubleshooting B
T-4 Machine mistracks.
Checking instruction
• Main relief pressure should be normal.
T5-4-22
TROUBLESHOOTING / Troubleshooting B
T5-4-23
TROUBLESHOOTING / Troubleshooting B
AUTO-LUBRICATION SYSTEM TROUBLE-
SHOOTING
G-1 Grease pump does not operate (both auto-
matically and manually).
Checking Instruction
• The auto-lubrication switch should be placed in 2
NOTE: 1 kgf/cm =98.07 kPa
the AUTO LUB or MANUAL position.
Reconnect auto-
lubrication switch. YES MC (A) failure.
Disconnect con-
nector “B” from MC
NO (A). Check if
grease pump op-
erates when har- Switch auto-
Disconnect auto- ness end connec- lubrication solenoid
lubrication switch. tor terminal No.32 valve relay with
Check if grease is grounded to ve- NO dome light relay.
YES pump operates Check if grease
hicle.
when harness end pump operates.
connector terminal
NOTE: Check if dome
No.1 is grounded light comes on
to vehicle. before switching
relays.
Faulty auto-
Check if primary YES lubrication switch.
pilot pressure is
correct.
YES Faulty pilot relief
·Primary pilot pressure:
2 valve.
44±5 kgf/cm
Disassemble and
clean pilot relief
valve. Check if
NO pressure is cor-
rected. Faulty pilot pump.
NO
T5-4-24
TROUBLESHOOTING / Troubleshooting B
Connectors (Harness end connector terminals seen from the open end side)
A
1 2 3
4 5 6
B C
MC (A) Connector B
35 34 33 32 31 30 29 28 27 26 25 24 23 15 14 13 12 11 10 9 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 22 21 20 19 18 17 16 8 7 6 5
T5-4-25
TROUBLESHOOTING / Troubleshooting B
G-2 Auto-lubrication switch does not operate.
T5-4-26
TROUBLESHOOTING / Troubleshooting B
MC (A) failure.
No continuity
Connectors (Harness end connector terminals seen from the open end side)
Auto-Lubrication Switch.
1 2 3
4 5 6
MC (A) Connector A.
66 65 64 63 62 61 60 59 58 57 46 45 44 43 42 41 40 39 38 37 26 25 24 23 22 21 20 19 18 17 8 7 6 5 4 3 2 1
76 75 74 73 72 71 70 69 68 67 56 55 54 53 52 51 50 49 48 47 36 35 34 33 32 31 30 29 28 27 16 15 14 13 12 11 10 9
T5-4-27
TROUBLESHOOTING / Troubleshooting B
G-3 Indicator comes ON when auto-lubrication is
selected.
T5-4-28
TROUBLESHOOTING / Troubleshooting B
NO Refill grease.
NO Is grease remain-
YES Faulty injector or
ing sufficiently ?
grease piping.
Check if grease
leaks from any in-
jectors or grease Is pressure be- YES Clogged orifice.
YES
piping. tween vent valve
and orifice 0
2
kgf/cm while
NO grease pump is Faulty vent valve.
operating ?
NO
NO Faulty auto-
lubrication grease
pressure switch.
T5-4-29
TROUBLESHOOTING / Troubleshooting B
AIR-CONDITIONER SYSTEM TROUBLE-
SHOOTING
Cooling Circuit
Refrigerant pressure is Air bubbles can be seen through Oil is blurred on pipe joint or part Gas
lower than specifica- sight glass. detector reacts.
tion at both high and
lower pressure sides. No oil blur and no gas detector reac-
tion are recognized. Gas has been not
refilled for longer than one season.
No air bubbles can be seen
through sight glass.
Refrigerant pressure is
lower than specifica- Air bubbles can be seen through
sight glass. Low pressure is reduced.
tion at high pressure
side.
Condenser stains and/or is clogged.
Air bubbles are not formed even if condenser is splashed with water. Receiver
drier temperature is low.
Thermistor is cooled.
T5-4-30
TROUBLESHOOTING / Troubleshooting B
Gas is leaking from piping joint or part. Tighten further or replace parts.
Faulty contact of expansion valve thermistor. Improve contact. Replace thermistor stay.
Faulty adjustment of water cock wire. Faulty cock. Check and readjust. Replace.
Clogged high pressure circuit before receiver drier. Remove clog or replace parts.
Clean condenser.
Even if function and performance are normal, if air-conditioner is Sufficiently instruct operator with correct operation
operated for a long time with wind volume at middle or low while method. (Either cooling thermistor at low to middle
thermistor is excessively cooled, frost may occur. range or increasing wind volume.)
T5-4-31
TROUBLESHOOTING / Troubleshooting B
Refrigerant Circuit
Refrigerant flow sound (roaring Gas vibration sound (compressor intake and discharge gas
sound). sound).
Noisy Expansion valve relatives, piping Abnormal sound from expansion valve.
sound, refrigerant flow sound.
Faulty compressor.
Sound heard when compressor
operates.
Vibration due to loose v-belt tension and/or loose screws.
Unusual smell. Adsorption and accumulation of cigarette smoke, dust, and cab
inside smell on evaporator fins.
T5-4-32
TROUBLESHOOTING / Troubleshooting B
Repair or replace.
Replace expansion valve if piping sound is heard. Small refrigerant flow sound may normally be
heard.
Replace.
Replace.
Clean evaporator. Or, when humidity is high, run engine at 1500 min− for 10 minutes or more
1
with cab door opened to clean fins with condensed dew on fins.
T5-4-33
TROUBLESHOOTING / Troubleshooting B
Air Conditioner Electrical System
Clutch slips.
⑤ Measure clutch engagement coil voltage (24V).
T5-4-34
TROUBLESHOOTING / Troubleshooting B
Go to step ② and
③.
Short circuit in clutch/blower circuit. Repair.
(Inappropriate power source outlet)
Perform as in-
structed.
T5-4-35
TROUBLESHOOTING / Troubleshooting B
Electric Thermo System
Faulty thermo switch, or faulty Turn switch ON. Measure resistance of thermo vol-
thermo volume harness. ume (Continuity check).
T5-4-36
TROUBLESHOOTING / Troubleshooting B
Tester needle moves when thermo volume is tapped. Replace thermo volume.
Thermo volume is normal if tester needle does not move when thermo volume is tapped.
T5-4-37
TROUBLESHOOTING / Troubleshooting B
Compressor
Compressor
does not ro- Clutch terminal voltage: Normal (24 V)
tate.
Does not
cool suffi-
ciently.
Go to the cooling circuit
Compressor is normal. Trouble cause is other than com- troubleshooting flow
pressor. chart on page T5-4-30.
T5-4-38
TROUBLESHOOTING / Troubleshooting B
Go to the Air Conditioner Electrical System troubleshooting flow chart on page T5-4-34.
Refrigerant gas leaks from joint sections of front housing or cylinder block. Replace.
No leakage
(normal).
T5-4-39
TROUBLESHOOTING / Troubleshooting B
Compressor
Abnormally noisy.
T5-4-40
TROUBLESHOOTING / Troubleshooting B
Engine System.
Replace.
Damaged Valve.
Internal noise.
Go to the cooling circuit
troubleshooting flow chart
on page T5-4-30.
Vibration due to loose V belt.
T5-4-41
TROUBLESHOOTING / Troubleshooting B
(Blank)
T5-4-42
TROUBLESHOOTING / Troubleshooting C
TROUBLESHOOTING C (TROUBLE-
SHOOTING FOR MONITOR) PROCEDURE
YES (OK)
(2)
ѕ (1) After checking or measuring item (1), select either YES (OK) or NO
(NOT OK) and proceed to item (2) or (3).
(3)
NO (NOT OK)
Special instructions or reference item are indicated in the spaces under the box. Incorrect
ѕ measuring or checking methods will render troubleshooting impossible, and may damage
components as well.
·Key switch: ON
ѕ Causes are stated in a thick-line box. Scanning through thick-lined boxes, possible causes
can be seen without going through the flow chart.
T158-05-03-001
T5-5-1
TROUBLESHOOTING / Troubleshooting C
MALFUNCTION OF TACHOMETER
Checking Instruction:
• Check first that the circuit connections are all cor-
rect.
0V
Disconnect tachometer.
NO Measure voltage between
harness end connector termi-
nal #1 (black) and #3 (red and
Re-connect engine speed me-
blue).
ter. Swing front and rear ta-
chometer. Check if abnormal
·Key switch: ON
24 V indication is moved to the op-
Switch front and rear engine posite speed meter.
speed sensors. Check if ab-
normal indication is moved to
the opposite speed meter.
T5-5-2
TROUBLESHOOTING / Troubleshooting C
3
YES Faulty tachometer.
1 2
T5-5-3
TROUBLESHOOTING / Troubleshooting C
MALFUNCTION OF COOLANT TEMPERA-
TURE GAUGE
Checking Instructions:
• Check that other gauges operate normally.
• Check first that the circuit connections are all cor-
rect.
NO
T5-5-4
TROUBLESHOOTING / Troubleshooting C
T5-5-5
TROUBLESHOOTING / Troubleshooting C
MALFUNCTION OF HYDRAULIC OIL TEM-
PERATURE GAUGE
Checking Instructions:
• Check that other gauges operate normally.
• Check first that the circuit connections are all cor-
rect.
YES
·Key switch: ON
·Without disconnecting con-
nector, connect terminal from
the connector reverse side to
vehicle ground using a clip.
Gauge needle swings over scale.
YES
YES
T5-5-6
TROUBLESHOOTING / Troubleshooting C
T5-5-7
TROUBLESHOOTING / Troubleshooting C
MALFUNCTION OF FUEL GAUGE
Checking Instructions:
• Check that other gauges operate normally.
• Check first that the circuit connections are all cor-
rect.
YES
·Key switch: ON
·Without disconnecting con-
nector, connect terminal from
connector reverse side to
vehicle ground using a clip.
Gauge needle swings over scale.
YES
NO
YES
Disconnect harness plug re-
ceptacle (green and black)
from fuel sensor. Connect
harness end plug receptacle
to vehicle ground. Check if
needle swings to the right side
and stays stably.
·Key switch: ON NO
T5-5-8
TROUBLESHOOTING / Troubleshooting C
Fuel Gauge
Connectors
Fuel Gauge
T5-5-9
TROUBLESHOOTING / Troubleshooting C
MALFUNCTION OF HYDRAULIC OIL
LEVEL INDICATOR (WARNING)
Checking Instruction:
• Check first that the circuit connections are all cor-
rect.
Reference:
Hydraulic Oil Level Switch Activation Level: 600 L (159
US gal) or lower
Connectors
Hydraulic Oil Level Switch 2
MC (B) Connector A
66 65 64 63 62 61 60 59 58 57 46 45 44 43 42 41 40 39 38 37 26 25 24 23 22 21 20 19 18 17 8 7 6 5 4 3 2 1
1 2
76 75 74 73 72 71 70 69 68 67 56 55 54 53 52 51 50 49 48 47 36 35 34 33 32 31 30 29 28 27 16 15 14 13 12 11 10 9
MC (B) Connector B
35 34 33 32 31 30 29 28 27 26 25 24 23 15 14 13 12 11 10 9 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 22 21 20 19 18 17 16 8 7 6 5
T5-5-10
TROUBLESHOOTING / Troubleshooting C
MALFUNCTION OF FUEL LEVEL INDICA-
TOR
Checking Instruction:
• Check first that the circuit connections are all cor-
rect.
Reference:
Fuel Level Switch Activation Level: 250 L (66 US gal)
or lower
Connectors
Fuel Level Switch
MC (A) Connector A
66 65 64 63 62 61 60 59 58 57 46 45 44 43 42 41 40 39 38 37 26 25 24 23 22 21 20 19 18 17 8 7 6 5 4 3 2 1
1 2
76 75 74 73 72 71 70 69 68 67 56 55 54 53 52 51 50 49 48 47 36 35 34 33 32 31 30 29 28 27 16 15 14 13 12 11 10 9
MC (A) Connector B
35 34 33 32 31 30 29 28 27 26 25 24 23 15 14 13 12 11 10 9 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 22 21 20 19 18 17 16 8 7 6 5
T5-5-11
TROUBLESHOOTING / Troubleshooting C
MALFUNCTION OF AUTO-LUBRICATION
INDICATOR
Checking Instruction:
• Check first that the circuit connections are all cor-
rect.
Connectors
MC (A) Connector B
35 34 33 32 31 30 29 28 27 26 25 24 23 15 14 13 12 11 10 9 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 22 21 20 19 18 17 16 8 7 6 5
T5-5-12
TROUBLESHOOTING / Troubleshooting C
MALFUNCTION OF PUMP TRANSMISSION
OIL PRESSURE INDICATOR
Checking Instruction:
• Check first that the circuit connections are all cor-
rect.
Reference:
Pump Transmission Oil Pressure Switch Activation
2
Pressure: 49±10 kPa (0.5±0.1 kgf/cm , 7±1 psi) or
lower
Indicator does not come ON when key switch is YES Faulty pump
turned ON. transmission oil
Disconnect har- pressure switch.
YES ness from pump
transmission oil Breakage of har-
pressure switch. Connect the following YES ness between MC
Connect harness terminals on MC (A) (A) and pump
end connector to connector A to vehicle transmission oil
vehicle ground. NO ground. Check if indi- pressure switch.
Check if indicator cator comes ON.
Turn indicator light comes ON. ·Front engine: #11 MC (A) failure.
check switch ON. Rear engine: #12 NO
·Key switch: ON
Check if indicator ·Key switch: ON
comes ON. ·Without disconnecting connec-
tor, connect terminal from con-
·Key switch: ON
nector reverse side to vehicle
Replace indicator
bulb with normal YES ground using a clip. Burned out indica-
one. Check if indi- tor light.
cator comes ON
NO when indicator light Check continuity Continuity MC (A) failure.
check switch is between the follow-
turned ON. ing terminals on
MC (A) connector Breakage of har-
·Key switch: ON NO ness between MC
B and vehicle
ground. (A) and pump
No con- transmission oil
·Front engine: #8, #15 tinuity pressure switch.
Rear engine: #20, #37
Indicator comes ON even if oil pressure is high.
YES Faulty pump transmission oil
pressure switch.
MC (A) Connector B
35 34 33 32 31 30 29 28 27 26 25 24 23 15 14 13 12 11 10 9 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 22 21 20 19 18 17 16 8 7 6 5
T5-5-13
TROUBLESHOOTING / Troubleshooting C
MALFUNCTION OF PUMP CONTAMINA-
TION INDICATOR
T5-5-14
TROUBLESHOOTING / Troubleshooting C
Faulty contamination
sensor.
Connectors
Sensor
3 2 1
12 13 14 15 16 17 18 19 20 21
1 2 3 4 5 6 7 8 9 10 11
Faulty contamination
No continuity sensor amplifier.
MC (A) Connector A
66 65 64 63 62 61 60 59 58 57 46 45 44 43 42 41 40 39 38 37 26 25 24 23 22 21 20 19 18 17 8 7 6 5 4 3 2 1
76 75 74 73 72 71 70 69 68 67 56 55 54 53 52 51 50 49 48 47 36 35 34 33 32 31 30 29 28 27 16 15 14 13 12 11 10 9
MC (A) Connector B
35 34 33 32 31 30 29 28 27 26 25 24 23 15 14 13 12 11 10 9 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 22 21 20 19 18 17 16 8 7 6 5
T5-5-15
TROUBLESHOOTING / Troubleshooting C
MALFUNCTION OF LADDER INDICATOR
Checking Instruction:
• Check first that the circuit connections are all cor-
rect.
Connectors
Ladder Limit Switch
MC (B) Connector A
66 65 64 63 62 61 60 59 58 57 46 45 44 43 42 41 40 39 38 37 26 25 24 23 22 21 20 19 18 17 8 7 6 5 4 3 2 1
1 2 3
76 75 74 73 72 71 70 69 68 67 56 55 54 53 52 51 50 49 48 47 36 35 34 33 32 31 30 29 28 27 16 15 14 13 12 11 10 9
MC (B) Connector B
35 34 33 32 31 30 29 28 27 26 25 24 23 15 14 13 12 11 10 9 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 22 21 20 19 18 17 16 8 7 6 5
T5-5-16
TROUBLESHOOTING / Troubleshooting C
MALFUNCTION OF AIR FILTER RESTRIC-
TION INDICATOR
Checking Instruction:
• Check first that the circuit connections are all cor-
rect.
• Check that the air cleaner is not damp.
Reference:
Air Filter Restriction Switch Activation Pressure:
6.2±0.6 kPa (635±58 mmH2O)
Although air cleaner is restricted, air filter restric- YES Faulty air filter re-
tion indicator does not come ON. striction switch.
MC (A) Connector B
35 34 33 32 31 30 29 28 27 26 25 24 23 15 14 13 12 11 10 9 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 22 21 20 19 18 17 16 8 7 6 5
T5-5-17
TROUBLESHOOTING / Troubleshooting C
MALFUNCTION OF ENGINE STOP, EN-
GINE WARNING, OR ENGINE PROTEC-
TION INDICATOR
Checking Instruction:
• Check first that the circuit connections are all cor-
rect.
·Key switch: ON
Short circuit of harness be-
NO tween ECM and indicator.
Connector
ECM
20 31
21 8 30
9 19
10 2 18
22 3 7 29
11 1 17
23 4 6 28
12 5 16
13 15
24 14 27
25 26
T5-5-18
TROUBLESHOOTING / Troubleshooting C
MALFUNCTION OF HYDRAULIC OIL
LEVEL INDICATOR
Checking Instruction:
• Check first that the circuit connections are all cor-
rect.
Reference:
Hydraulic Oil Level Switch Deactivation Level: when
hydraulic oil level is reduced 35 mm (1.38 in) lower
than the LOW mark on level gauge.
Connectors
Hydraulic Oil Level Switch 1
MC (B) Connector A
66 65 64 63 62 61 60 59 58 57 46 45 44 43 42 41 40 39 38 37 26 25 24 23 22 21 20 19 18 17 8 7 6 5 4 3 2 1
1 2
76 75 74 73 72 71 70 69 68 67 56 55 54 53 52 51 50 49 48 47 36 35 34 33 32 31 30 29 28 27 16 15 14 13 12 11 10 9
MC (B) Connector B
35 34 33 32 31 30 29 28 27 26 25 24 23 15 14 13 12 11 10 9 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 22 21 20 19 18 17 16 8 7 6 5
T5-5-19
TROUBLESHOOTING / Troubleshooting C
MALFUNCTION OF COOLANT LEVEL IN-
DICATOR
Checking Instruction:
• Check first that the circuit connections are all cor-
rect.
Reference:
Coolant Level Switch Deactivation Level: when coolant
level is reduced lower than the LOW mark on reservoir.
MC (B) Connector B
35 34 33 32 31 30 29 28 27 26 25 24 23 15 14 13 12 11 10 9 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 22 21 20 19 18 17 16 8 7 6 5
T5-5-20
TROUBLESHOOTING / Troubleshooting C
MALFUNCTION OF ENGINE OIL LEVEL
INDICATOR
Checking Instruction:
• Check first that the circuit connections are all cor-
rect.
MC (B) Connector B
35 34 33 32 31 30 29 28 27 26 25 24 23 15 14 13 12 11 10 9 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 22 21 20 19 18 17 16 8 7 6 5
T5-5-21
TROUBLESHOOTING / Troubleshooting C
MALFUNCTION OF EMERGENCY ENGINE
STOP INDICATOR
Checking Instruction:
• Check first that the circuit connections are all cor-
rect.
Connectors
Emergency Engine Stop Switch
MC (B) Connector A
1 2 66 65 64 63 62 61 60 59 58 57 46 45 44 43 42 41 40 39 38 37 26 25 24 23 22 21 20 19 18 17 8 7 6 5 4 3 2 1
3 4 76 75 74 73 72 71 70 69 68 67 56 55 54 53 52 51 50 49 48 47 36 35 34 33 32 31 30 29 28 27 16 15 14 13 12 11 10 9
MC (B) Connector B
35 34 33 32 31 30 29 28 27 26 25 24 23 15 14 13 12 11 10 9 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 22 21 20 19 18 17 16 8 7 6 5
T5-5-22
TROUBLESHOOTING / Troubleshooting C
MALFUNCTION OF ENTRANCE LIGHT IN-
DICATOR
Checking Instruction:
• Check first that the circuit connections are all cor-
rect.
Connector
d b a
e c
T5-5-23
TROUBLESHOOTING / Troubleshooting C
MALFUNCTION OF ENGINE ROOM LIGHT
INDICATOR
Checking Instruction:
• Check first that the circuit connections are all cor-
rect.
Connector
d b a
e c
T5-5-24
TROUBLESHOOTING / Troubleshooting C
MALFUNCTION OF AUTO-IDLE INDICA-
TOR
Checking Instruction:
• Check first that the circuit connections are all cor-
rect.
Reference:
Auto-Idle Pressure Switch Activation Pressure:
2
490 kPa (5 kgf/cm , 71 psi) or higher
Auto-Idle Pressure Switch Deactivation Pressure:
2
290 kPa (3 kgf/cm , 43 psi) or lower
Connector
Auto-Idle Switch
d b a
e c
T5-5-25
TROUBLESHOOTING / Troubleshooting C
MALFUNCTION OF FAST SPEED TRAVEL
INDICATOR
Checking Instruction:
• Check first that the circuit connections are all cor-
rect.
Connector
d b a
e c
T5-5-26
TROUBLESHOOTING / Troubleshooting C
MALFUNCTION OF SLOW SPEED TRAVEL
INDICATOR
Checking Instruction:
• Check first that the circuit connections are all cor-
rect.
Connector
1 2
3 5
T5-5-27
TROUBLESHOOTING / Troubleshooting C
MALFUNCTION OF ALTERNATOR INDICA-
TOR
Checking Instruction:
• Check first that the circuit connections are all cor-
rect.
Reference:
Starter Relay Deactivation Voltage: 7 V
Connectors
MC (A) Connector A
66 65 64 63 62 61 60 59 58 57 46 45 44 43 42 41 40 39 38 37 26 25 24 23 22 21 20 19 18 17 8 7 6 5 4 3 2 1
76 75 74 73 72 71 70 69 68 67 56 55 54 53 52 51 50 49 48 47 36 35 34 33 32 31 30 29 28 27 16 15 14 13 12 11 10 9
MC (A) Connector B
35 34 33 32 31 30 29 28 27 26 25 24 23 15 14 13 12 11 10 9 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 22 21 20 19 18 17 16 8 7 6 5
T5-5-28
TROUBLESHOOTING / Troubleshooting C
MALFUNCTION OF LEVEL CHECK
SWITCH
Checking Instruction:
• Check first that the circuit connections are all cor-
rect.
• Check that all liquid levels are correct prior to trou-
bleshooting.
Connector
MC (B) Connector A
66 65 64 63 62 61 60 59 58 57 46 45 44 43 42 41 40 39 38 37 26 25 24 23 22 21 20 19 18 17 8 7 6 5 4 3 2 1
76 75 74 73 72 71 70 69 68 67 56 55 54 53 52 51 50 49 48 47 36 35 34 33 32 31 30 29 28 27 16 15 14 13 12 11 10 9
T5-5-29
TROUBLESHOOTING / Troubleshooting C
MALFUNCTION OF INDICATOR LIGHT
CHECK SWITCH
Checking Instruction:
• Check first that the circuit connections are all cor-
rect.
T5-5-30
TROUBLESHOOTING / Troubleshooting C
MALFUNCTION OF HOUR METER
Checking Instruction:
• Check first that the circuit connections are all cor-
rect.
T5-5-31
TROUBLESHOOTING / Troubleshooting C
MULFUNCTION OF BUZZER
Checking Instructions
• Check first that the circuit connections are all cor-
rect.
MC (A) failure.
NO
24 V
Faulty buzzer.
Connectors
35 34 33 32 31 30 29 28 27 26 25 24 23 15 14 13 12 11 10 9 4 3 2 1
2 1 48 47 46 45 44 43 42 41 40 39 38 37 36 22 21 20 19 18 17 16 8 7 6 5
T5-5-32
TROUBLESHOOTING / Troubleshooting C
TROUBLESHOOTING PUMP CONTAMINA- Electrical
TION INDICATORS Equipment Box Cover
: 36 mm
: 118 N⋅m (12 kgf⋅m, 87 lbf⋅ft)
Connector
Drain
Hose
M144-07-089
T5-5-33
TROUBLESHOOTING / Troubleshooting C
(Blank)
T5-5-34
TRUBLESHOOTING / Electrical System Inspection
PRECAUTIONS FOR INSPECTION AND Ȁ
MAINTENANCE
Ȁ
1. Disconnect the power source. Ȁ
Be sure to remove the negative terminals from the Ȁ
batteries first when taking wire harnesses and
connectors off for repair or replacement work. Ȁ
Failure to do so can result in damage to the wire Ȁ
harnesses, fuses, and fusible links and, in some Ȁ
cases, cause fire due to short circuiting.
Codes Color Codes Color
2. Color coding of wire harnesses. R Red G Green
The color codes of the wire harnesses in the
L Light Blue Lg Light Green
electrical system are shown below.
In cases where two color codes are indicated for Or Orange B Black
one wire, the left initial stands for the base color, Y Yellow P Pink
while the right initial stands for the marking color.
Br Brown V Violet
Gr Gray Sb Sky blue
NOTE: 1) Initials “O” and “Or” both stand for the
color orange.. W White
2) Wires with longitudinal stripes printed on Ȁ
them are not color coded. Be sure not to
confuse them with color coded wires. Right Wrong
3) Color code BW stands for the harness
with white fine line marking on black
base color.
T5-6-1
TRUBLESHOOTING / Electrical System Inspection
4. Precautions for Using A Circuit Tester
1) Before using a circuit tester, refer to the Tester Probe
Wind a Piece of Wire
instructions in the circuit tester manual.
Then, set the circuit tester to meet the object
to be measured, voltage range and current
polarity.
Sharpen End of Wire
2) Before starting the connector test, always T107-07-06-003
T5-6-2
TRUBLESHOOTING / Electrical System Inspection
BATTERY VOLTAGE CHECK
Normal value: 24 V
Normal value: 26 to 28 V
T105-07-01-006
T5-6-3
TRUBLESHOOTING / Electrical System Inspection
FUSE CONTINUITY CHECK
1. Turn the key switch ON NOTE: 1. All the inside terminals of the fuses in the
In doing so, the battery relay is activated by the fuse box 1 are connected to the power
current from terminal M of the key switch, and source, while the outside terminals are
electric power is supplied to all circuits. connected to the accessory (down-
stream) side.
NOTE: When the key switch is in the START posi-
tion, electric power is supplied to terminals NOTE: 2. All the upper side terminals of the fuses
#24, #25, #26, #27 in fuse box 1. in the fuse box 2 are connected to the
power source, while the lower side ter-
2. Remove the fuse box cover and set the correct minals are connected to the accessory
voltage measurement range (0 to 30 V) of the (downstream) side.
tester.
Fuse Box 1
1 2 3 4 5 6 7 8 9 10 21 22 23 24 25 26 27 28 29 30
M117-07-072
11 12 13 14 15 16 17 18 19 20 31 32 33 34 35 36 37 38 39 40
T5-6-4
TRUBLESHOOTING / Electrical System Inspection
Fuse Box 2
Power Source
Side
Accessory
(Downstream)
Side
1 2 3 4 5 6
T117-06-06-001
Fuse Box 1 Connections
Fuse No. Designation Capacity Connected to Remarks
1 LOAD DUMP RELAY 5A Load Dump Relay, Limit Switch
2 MAIN C/U (B) 5A MC (B)
3 E.C.M. (FRONT) 5A ECM (Front Engine)
4 E.C.M. (REAR) 5A ECM (Rear Engine)
5 E.C.M. ON SIG. (FRONT) 5A Emergency Relay (Front Engine)
6 E.C.M. ON SIG. (REAR) 5A Emergency Relay (Rear Engine)
7 MOT. ALARM 5A Travel Alarm
8 DC/DC 15 A Transformer (24 to 12 V)
9 10 A Monitor, Hour Meter
10 ETHER SOL. 30 A Starting Aid Relay
11 ENTRANCE LIGHT 10 A Entrance Light Relay
12 WORK LIGHT (UPPER) 10 A Work Light Relay (On Cab)
13 WORK LIGHT (RIGHT) 10 A Work Light Relay (Right Side of Base Machine)
14 WORK LIGHT (LEFT) 10 A Work Light Relay (Left Side of Base Machine)
15 ENG. ROOM LIGHT 15 A Engine Room Light Relay
16 ILLUMINATE 10 A Illumination Relay
17 MAIN C/U (A) 10 A MC (A), MC (B)
18 CONTAMI AMP 5A Contamination Sensor
19 HORN 5A Horn Relay
20 CAB DOME LIGHT 5A Dome light Relay
21 WIPER MOT. (LOWER) 10 A Wiper Motor (Lower)
22 WIPER MOT. (UPPER) 10 A Wiper Motor (Upper)
23 SOL. VALVE 10 A Travel Speed Change Solenoid Valve, Travel Speed Change Relay, Hydraulic
Oil Temperature Sensor,
Auto-Lubrication Solenoid Valve Relay,
Swing inter lock solenoid valve
24 STARTER RELAY (FRONT) 5A Starter Relay (Front Engine)
25 ETHER RELAY (FRONT) 5A Starting Aid Relay (Front Engine)
26 STARTER RELAY (REAR) 5A Starter Relay (Rear Engine)
27 ETHER RELAY (REAR) 5A Starting Aid Relay (Rear Engine)
28 BATTERY RELAY 5A Battery Relay
29 METER 5A Indicator Light Check Relay, Hour Meter Relay, Monitor, Hour Meter
30 MAIN C/U ON SIG. 5A MC (A), MC (B)
31 A/C MAIN (FRONT) 15 A Air-Conditioner Relay (Front)
32 A/C MAIN (SIDE) 15 A Air-Conditioner Relay (Side)
33 A/C MAIN (REAR) 15 A Air-Conditioner Relay (Rear)
34 A/C ON SIG. (FRONT) 5A Air-Conditioner Relay (Front), Air-Conditioner Controller (Front)
35 A/C ON SIG. (SIDE) 5A Air-Conditioner Relay (Side), Air-Conditioner Controller (Side)
36 A/C ON SIG. (REAR) 5A Air-Conditioner Relay (Rear), Air-Conditioner Controller (Rear)
37 A/C BACK UP 5A Air-Conditioner Controller (Front, Side, and Rear)
38 A/C C. (FRONT) 30 A Condenser Fan Relay (Front)
39 A/C C. (SIDE) 30 A Condenser Fan Relay (Side)
40 A/C C. (REAR) 30 A Condenser Fan Relay (Rear)
T5-6-5
TRUBLESHOOTING / Electrical System Inspection
SLOW BLOW FUSE INSPECTION
1 2 3 4 5
Disconnect slow blow fuse. Inspect visually.
T144-05-06-002
T5-6-6
TRUBLESHOOTING / Electrical System Inspection
ALTERNATOR CHECK
Terminal B Terminal R
The alternator indicator should go off after the engine
is started.
If the alternator indicator stays (comes) on while the
engine is running, the alternator may be failed.
M117-07-077
T5-6-7
TRUBLESHOOTING / Electrical System Inspection
VOLTAGE CHECK
24 V Circuit
Charging Circuit
Running ON Between (17) and (Ground): Starter Relay 2 10 V
Running ON Between (18) and (Ground): Alternator Generating Voltage (R) 10 V
Running ON Between (19) and (Ground): Alternator Generating Voltage (B) 26 to 30 V
Running ON Between (20) and (Ground): Breaker 26 to 30 V
Surge Voltage
Prevention Circuit
Running ON Between (23) and (Ground): Load Dump Relay 26 to 30 V
T5-6-8
TRUBLESHOOTING / Electrical System Inspection
12 11 Starting Aid 6 7
Relay
8
9 10
Starting Aid Solenoid Valve
Fuse Box 1
23
5
Slow Blow
17 16 21 22 Fuse
Starter
Relay 2
15
Starter
Relay
18
13 17
4 3 2 1 20
Alternator
14 15 16
Starter Battery
19
T144-05-06-001
T5-6-9
TRUBLESHOOTING / Electrical System Inspection
CONTINUITY CHECK Harness
A a
Single-line continuity check
Disconnect both end connectors of the harness and
check continuity between both ends:
If the ohm-meter reading is: 0 Ω = Continuity
ҁ Ω = Discontinuity Ω
T5-6-10
TRUBLESHOOTING / Electrical System Inspection
5 VOLT CIRCUIT Signal or
Power Source Ground
Voltage between terminal No.1 and the vehicle 1 2
frame chassis (Ground)
With the key switch turned OFF, disconnect the
sensor connector. Two Polarities
Measure the voltage between terminal No.1 of the
harness side connector and the vehicle frame under
the following conditions. V
Evaluation:
If the measured voltage is within 5 ± 0.5 volts, the Three Polarities
circuit up to terminal No.1 is normal.
T107-07-05-007
1 2
Voltage between terminal No.1 and the ground Two Polarities
terminal
With the key switch turned OFF, disconnect the
sensor connector. V
Measure the voltage between terminal No.1 on the
harness side connector and the ground terminal
(terminal No.2 for two polarities, or terminal No.3 for
three polarities) under the following conditions.
T107-07-05-009
T5-6-11
TRUBLESHOOTING / Electrical System Inspection
CIRCUIT CHECK WITH LAMP HARNESS
T5-6-12
THE ATTACHED DIAGRAM LIST
3. EX1800-3 CONNECTOR
1
2
3
4
5
A
10
6
7
8
9
A
K
6 1
A K 7 2
8 3
9 4
10 5
6 1
7 2
8 3
9 4
1
2
3
4
5
10 5
10
6
7
8
9
K A
K A
EX1800-3 ELECTRICAL CIRCUIT 2/2
1
2
3
4
5
1
2
3
4
5
1
2
3
4
5
K
K
1
2
3
4
5
10
10
6
7
8
9
6
7
8
9
10
6
7
8
9
A
A
10
6
7
8
9
6 1
7 2
8 3
9 4
10 5
6 1
7 2
8 3
9 4
10 5
EX1800-3 CONNECTOR
Cab Harness (Monitor Etc.), Electrical Equipment Box (To Cab Harness) Air Conditioner Panel, Electrical Equipment Box Cab Harness (Wiper Etc.) Electrical Equipment Box Air Conditioner Unit (Front) Electrical Equipment Box
Engine Room Harness Electrical Equipment Box (To Engine Room Harness) Rear Engine Harness Rear Engine Harness Engine Harness Engine Harness
Engine Harness (Front) Engine Harness (Front)
Relay Panel Harness Electrical Equipment Box
Air Conditioner Unit (Rear) Electrical Equipment Box Air Conditioner Unit (Rear) Air Conditioner Unit (Rear) Thrmo Guard Switch ~2 ~2 Coolant Level Switch ~2 Cab Harness (Key Switch Etc.) Electrical Equipment Box To Cab Cab Harness Electrical Equipment Box Cab Harness Electrical Equipment Box Auto-Lubrication Solenoid Valve
Cab Harness Cab Harness ~2 To Cab Harness Cycle Timer ECM
Data Link ~2
ECM(F)
ECM(R)
Mc(A) Mc(A) Air conditioner Controller ~3 Air conditioner Controller ~3 Air conditioner Control Panel ~3 Contamination Sensor Amplifier ~2
Mc(B) Mc(B)
Idicator(Warning) ~3 Wiper Switch Switch ~8 Accelerator Sensor (F) Accelerator Sensor (R) Buzzer Fuel Gauge Tachometer ~2 Radio Speaker ~2 Diode ~10 Cab Harness ~2 Cab Harness ~2 Cab Harness ~2 ECM(F)
Idicator Wiper Delay Selector Hydraulic Oil Temperature Gauge Intake Unit ~3 Hour Mater Wiper Motor ~2 ECM(R)
Dimmer Switch Coolant Temperature Gauge Inc./Dec. Switch ~2 Starter Relay 1 ~2 Key Switch ~2
Auto-Lubrication Interval Switch Ether Relay ~2
Cab Harness ~2 Starter Relay 2 ~2 Emergency Engine Stop Switch Diode ~7 Slow Blow Fuse 75A ~4 Slow Blow Fuse Slow Blow Fuse Slow Blow Fuse Slow Blow Fuse Slow Blow Fuse Slow Blow Fuse Air Conditioner Unit ~3 Intake Unit ~3 Condenser Fan Motor ~6 Air Conditioner Pressure Switch ~3
Dome Light To Electrical Equipment Box ~2 To Electrical Equipment Box ~2 To Electrical Equipment Box ~2 To Electrical Equipment Box ~2 To Electrical Equipment Box ~2 To Electrical Equipment Box ~2
Relay ~30 Ether Relay ~2 ~2 Emergency Engine Stop Switch Pump Harness ~2 Auto-Lubrication Switch Relay Panel Harness Ladder Limit Switch Contamination Sensor ~6 Travel Speed Change
Solenoid Valve Fuel Level Switch Harness Fuel Level Switch Harness Ehc Valve ~2 Auto-Idle Pressure Switch Travel Alarm Dome Light Harness
Pump Harness ~2 Relay Panel Harness Relay Panel Harness Auto-Lubrication Switch Harness Auto-Lubrication Switch Harness Pump Control Solenoid Valve Engine Oil Level Switch ~2 Ladder Limit Switch Harness Pressure Switch (For Travel Alarm)
BOOM
LOWER
EX1800-3 PILOT HYDRAULIC CIRCUIT(Loading Shovel)
Hitachi Authorized Dealer Use Only
Main Hydraulic Oil Tank
Pilot Shut-Off
Valve
Auxiliary Hydraulic Oil Tank
Drain Filter
Pilot Filter
Horsepower Reducing Valve
EHC Valve
SWING PUMP
Servo Assist Open Bucket Tilt-Out
Rev.(L)
For.(R)
Auto-Idle
Press. SW
Adjuster
Raise Tilt-In Sw. Bk Release
Travel Speed Change
Swing (L)
Swing (R)
Close Open
Extend
Retract
Sw. (L)
Travel Press.
Sw. (R)
Left C/V
Swing Inter Lock Arm Retract
Solenoid Valve Travel + Boom Raise
Swing Motor (R) Swing Motor (F) Arm Extend
Bucket Open
Extend Swing C/V (R) Bucket Tilt-Out
Retract
Bucket Close
Boom Raise
Bucket Tilt-in
Tilt-Out
Tilt-In Boom Lower
Travel Alarm
Center Joint
Press. SW
Front + Travel
Pilot
Swing Pi
Travel Pi
Rev.(L)
For.(R)
Right C/V
Pilot Shut-Off
Valve
Auxiliary Hydraulic Oil Tank
Drain Filter
Pilot Filter
Horsepower Reducing Valve
Arm
Forward(L) Roll-In
EHC Valve
SWING PUMP
Servo Assist Bucket Tilt-Out
For.(R) Rev.(L)
Auto-Idle
Press. SW
Boom Adjuster
Raise Sw. Bk Release
Travel Speed Change
Swing (L)
Swing (R)
Bucket Bucket
Roll-In Roll-Out
Arm Roll-Out
Sw. (L)
Travel Press.
Sw. (R)
Left C/V
Swing Inter Lock Arm Roll-Out
Solenoid Valve Travel + Boom Raise
Swing Motor (R) Swing Motor (F) Arm Roll-In
Bucket Tilt-Out
Swing C/V (R)
Arm Roll-Out Arm Roll-In
Arm Roll-In
Bucket Tilt-In
Boom Raise
Arm Roll-In + Bucket Roll-In
Front + Travel
Pilot
Swing Pi
Travel Pi
Travel Pi
For.(R) Rev.(L)
Right C/V
Pilot Shut-Off
Valve
Auxiliary Hydraulic Oil Tank
Drain Filter
Pilot Filter
Horsepower Reducing Valve
Arm
Forward(L) Roll-In
EHC Valve
SWING PUMP
Servo Assist Bucket Tilt-Out
For.(R) Rev.(L)
Auto-Idle
Press. SW
Swing (L)
Swing (R)
Bucket Bucket
Roll-In Roll-Out
Arm Roll-Out
Sw. (L)
Travel Press.
Sw. (R)
Left C/V
Swing Inter Lock Arm Roll-Out
Solenoid Valve Travel + Boom Raise
Swing Motor (R) Swing Motor (F) Arm Roll-In
Bucket Tilt-Out
Swing C/V (R)
Arm Arm Roll-In
Arm Roll-In
Roll-Out Bucket Tilt-In
Boom Raise
Arm Roll-In + Bucket Roll-In
Front + Travel
Pilot
Swing Pi
Travel Pi
Travel Pi
For.(R) Rev.(L)
Right C/V